Professional Documents
Culture Documents
l13
l13
BMP 8500
S/N 101 720 12 ....
Multi-purpose compactor
Catalogue number.
008 922 85 12/2013
Table of Contents
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 13
1.4 Tightening torques 23
Overall view of machine 27
2.1 Overall view of machine 29
BOMAG Multi-purpose compactor 31
3.1 BOMAG Multi-purpose compactor 32
Technical data 37
4.1 Technical data 38
Maintenance 43
5.1 General notes on maintenance 44
5.2 Fuels and lubricants 45
5.3 Table of fuels and lubricants 47
5.4 Running-in instructions 48
5.5 Maintenance table 49
Electrics 51
6.1 Overview 52
6.2 Service the battery, check the main battery switch 54
6.3 Main battery switch 55
6.4 Starting with jump wires 56
6.5 Generator repair 57
6.6 Repair of starter 62
6.7 Glow plugs 68
6.8 Engine governor rod positioning solenoid 69
6.9 Engine shut-down solenoid 71
6.10 Oil pressure and low oil pressure circuitry 74
6.11 Coolant temperature and power reduction 76
6.12 Wiring looms 78
6.13 BLM - Power/Logic Module 81
6.14 Checking the voltage supply for the control unit 83
6.15 Diagnostics concept 91
6.16 Description of indicators and control elements 94
6.17 Fuses 95
6.18 Fault indicator 96
6.19 Switching ECO-mode on and off 96
6.20 Entering the machine type code 97
6.21 Replacing, recharging the radio remote control power pack 98
6.22 BOSS safety system 101
6.23 Teaching the BOSS safety system transponder 103
6.24 BOSS Service Mode 103
6.25 Safety field measurement of the Boss safety system 104
6.26 Problems with radio remote control Hetronic in radio operation 105
6.27 Problems with remote control Hetronic with spiral cable 106
6.28 Faults in BOSS safety system 109
1.1 Introduction
Documentation
For the BOMAG machines described in this manual
the following documentation is additionally available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Service information
4 Fundamental electrics
! Danger
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.
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.
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!
!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.
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-
able, you should use a plastic tube or adhesive tape Feather keys and keyways
to prevent the sealing lip from being damaged.
l Lubricate the outer rim (arrow 3 (Fig. 2)) of the seal Caution
!
and press it flat on the housing seat.
Feather keys may only be reused if they are free of
damage.
Fig. 3
l
Press or knock the seal into the housing, until it is
flush with the housing surface.
i Note
Fig. 4
If possible, use a "bell" (1 (Fig. 3)), to make sure that
the seal will not skew. In some cases it may be ad-
l Clean and thoroughly examine the feather key.
visable to assemble the seal into the housing first, be- l Deburr and thoroughly clean the edges of the key-
fore sliding it over the shaft. Under no circumstances way with a fine file before reassembling.
should the full weight of the shaft rest on the seal.
If you have no proper service tools at hand, use a suit-
able drift punch with a diameter which is about 0,4 mm
smaller than the outer diameter of the seal. Use VERY
LIGHT blows with the hammer if no press is available.
Fig. 6
!Caution
When assembling the ball or roller bearing to the
shaft load must only be applied to the inner race 1
(Fig. 6).
When fitting the bearing into the housing load
must only be applied to the outer race (2).
Fig. 5
l If a ball or roller bearing of a bearing pair shows de-
fects, both ball or roller bearings need to be re-
placed.
l
Remove any lubricant residues from the ball or roll-
er bearing to be examined by washing it with gaso-
line or any other appropriate degreasing agent.
Ensure strict cleanliness.
l
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. Replace the ball or roller bearing if
necessary.
l
Check the ball or roller bearing for clearance and re-
sistance between the inner and outer races, replace
if necessary.
l
Lubricate the ball or roller bearing with the recom-
mended type of grease before assembly or reas-
sembly.
l
On greased bearings (e.g. wheel bearings) fill the
space between ball or roller bearing and outer seal
with the recommended type of grease before as-
sembling the seal.
i Note
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas-
tic deformation).
When exceeding the upper yield point the material will
not restore its original shape after being relieved.
l The lower tensile strength is 9/10 X 1200 N/mm2 =
1080 N/mm2.
i Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.
Fig. 11
In places where cotter pins are used, these must be
reassembled. Cotter pins must generally be renewed
after disassembly.
Cotter pins must be assembled as shown in the illus-
tration, unless specified differently.
Fig. 10
Screws
The screw head is marked with a stamped in, round
cavity 3 (Fig. 10).
Nuts
An uninterrupted series of stamped in circles parallel
to the axis of the nut on a hexagon area (2).
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 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 Nm
Screw dimension
8.8 10.9 12.9
M8 x 1 26 37 48
M10 x 1.25 52 76 88
M12 x 1,25 98 137 126
M12 x 1.5 93 127 152
M14 x 1.5 152 216 255
M16 x 1.5 225 318 383
M18 x 1.5 324 466 554
M20 x 1.5 461 628 775
M22 x 1.5 618 863 1058
M24 x 2 780 1098 1294
M27 x2 1147 1578 1920
M30 x 2 1568 2254 2695
* Coefficient of friction μ tot. = 0,14
Tightening torques for screws treated with anti-seizure paste OKS 240* (copper paste)
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M16 169 240 287
M16 x 1.5 180 255 307
M18 232 330 392
M18 x 1.5 260 373 444
M20 330 463 557
M20 x 1.5 369 502 620
M22 448 628 754
M22 x 1.5 495 691 847
M24 569 800 960
M24 x 2 624 879 1036
M27 840 1184 1520
M27 X 2 918 1263 1536
M30 1136 1608 1920
M30 x 2 1255 1804 2156
3/4“ - 10 UNC 276 388 464
3/4“ - 16 UNC 308 432 520
* Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to high temperatures and corrosive
effects. Prevents seizure and corrosion.
Tightening torques Nm
Thread diameter
10.9
M12x1.5 100
M14x1.5 150
M18x1.5 300 - 350
M20x1.5 400 - 500
M22x1.5 500 - 600
* Coefficient of friction μ tot. = 0,14
** These values result in a 90% utilization of the yield point
i Note
The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks,
as the metric ISO-thread, whereas Withworth has a flank of only 55°.
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with UNC thread, * UNC Unified Coarse Thread Series, American Unified
Coarse Thread
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1/4“ - 20 11 15 19
5/16“ - 18 23 32 39
3/8“ - 16 39 55 66
7/16“ - 14 62 87 105
1/2“ - 13 96 135 160
9/16“ - 12 140 200 235
5/8“ - 11 195 275 330
3/4“ - 10 345 485 580
7/8“ - 9 560 770 940
1“ - 8 850 1200 1450
1 1/8“ - 7 1200 1700 2000
1 1/4“ - 7 1700 2400 2900
1 3/8“ - 6 2200 3100 3700
1 1/2“ - 6 3000 4200 5100
* Coefficient of friction μ tot. = 0,14
Tightening torques for screws with UNF thread, * UNF Unified National Fine Thread Series, American
Unified Fine Thread
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1/4“ - 28 13 18 22
5/16“ - 24 25 35 42
3/8“ - 24 45 63 76
7/16“ - 20 70 100 120
1/2“ - 20 110 155 185
9/16“ - 18 155 220 260
5/8“ - 18 220 310 370
3/4“ - 16 385 540 650
7/8“ -14 620 870 1050
Tightening torques for screws with UNF thread, * UNF Unified National Fine Thread Series, American
Unified Fine Thread
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1“ - 12 930 1300 1600
1 1/8“ - 12 1350 1900 2300
1 1/4“ - 12 1900 2700 3200
1 3/8“ - 12 2600 3700 4400
1 1/2“ - 12 3300 4600 5600
* Coefficient of friction μ tot. = 0,14
Fig. 12
Fig. 13 Overview
Secure and clean working above all under confined conditions, on difficult soils and in tipping endan-
gered areas – no problem with the BOMAG Multi-Purpose Compactor BMP 8500. As it has been specially
designed for earth work, it is particularly suitable for the compaction of cohesive soils in trench con-
struction, for construction backfills, in sewer and pipeline construction, for railway and dam construc-
tion, on sanitary landfill sites as well as for sub-base and foundation work.
Fig. 14
l High reliability and versatility
l Excellent compaction and work power
l
Low running costs,
l
Simple service and easy maintenance
l
High operating comfort
l
High safety standards
Fig. 15
With the optionally available drum extensions the working width can be modified to 610 mm or 850 mm, simply
and quick, directly on the construction site. Particularly beneficial for a wide range of applications.
Fig. 16
Using the radio remote control not only enables the operator to keep an optimal distance to the trench compactor
or the danger zone, but the use of radio signals also provides maximum reliability. With conventional systems,
e.g. operated via infrared remote control, sudden insolation, an unfavourable position to the machine or even
smallest obstacles can adversely affect the reception and thus cause control problems or undesired standstill of
the machine. This does not apply for a radio remote control, with this technology the trench compactor always
remains under control and and achieves and optimal compaction quality. Result: disturbance free, speedy and
safe work – and work that protects your health. Because there is no hand-arm vibration at all.
Fig. 17
A diagnostics module with error code display and operating hour meter ensures quick and exact fault diagnos-
tics, in many cases the fault rectification can be performed directly on site. This considerably reduces service
times and saves the company time and money. Besides the protection against external influences offered by the
fully closed protection hood made of highly impact resistant composite material, the engine itself has a protection
feature to protect against insufficient maintenance or turning over. The engine shuts down if the oil level is too
low or if the lateral tipping angle exceeds a certain limit. High service, repair and spare parts costs are most ef-
fectively avoided.
Fig. 18
BMP 8500 A D H K L S W W1
Dimensions in 1000 520 1275 222 1897 25 850 610
mm
Dimensions in 39.4 20.5 50.2 8.7 74.7 1.0 33.5 24.0
inch
BMP 8500
Weights
Operating weight (CECE) 1595 kg 3516 lbs
Basic weight 1585 kg 3494 lbs
Mean axle load (CECE) 775 kg 1709 lbs
Drum extension (610/850 mm) + 48 kg + 106 lbs
Travel characteristics
Travel speed (1) forward/reverse 1.3 km/h 0.8 mph
Travel speed (2) forward/reverse 2.5 km/h 1.6 mph
Max. gradability without/with vibration (soil dependent) 55/45 % 55/45 %
Drive
Engine manufacturer Kubota Kubota
Type D 1005 D 1005
Exhaust classification U.S. EPA including CALIFORNIA Tier 4 final Tier 4 final
NONROAD CI ENGINES
Cooling Water Water
Number of cylinders 3 3
Rated power ISO 9249 14.5 KW 19.4 hp
Rated speed 2600 min-1 2600 rpm
Drive system hydrostatic hydrostatic
Driven drum front + rear front + rear
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydro-mechanical hydro-mechanical
Steering
Type of steering Articulated joint Articulated joint
Steering operation hydrostatic hydrostatic
Exciter system
Vibrating drum front + rear front + rear
Drive system hydrostatic hydrostatic
Frequency 42 Hz 2520 vpm
Amplitude 1/2 1.12/0.56 mm 0.04/0.02 in
Centrifugal force 1/2 72/36 kN 16186/8093 lbf
Filling capacities
Fuel (diesel) 24.0 l 6.3 gal us
Transmitter
Frequency band F-band F-band
Transmitting frequency range 868/916 MHz 868/916 MHz
Number of channels 1 1
Reach, depending on environment approx.. 30 m approx. 98.4 ft
Current draw approx. 10 mA approx. 10 mA
Weight approx. 1.6 kg approx. 3.5 lbs
BMP 8500
Receiver
Receiver frequency range 868/916 MHz 868/916 MHz
Current draw approx. 10 mA approx. 10 mA
Battery charger
Operating voltage 110/230 V (AC) 110/230 V (AC)
12 - 24 V (DC) 12 - 24 V (DC)
i Note
The right for technical modifications remains reserved
Travel pump
Type AZPFFB-12-8+5,5+4R
System Triple gear pump
Max. displacement cm3/rev. 5.5
High pressure limitation bar 250
Travel motors
Type 2000 Series
Quantity 2
System Geroller hydraulic motor
Displacement (stage 1) cm3/rev. 306.6
Steering/charge/vibration pump
Type AZPFFB-12-8+5,5+4R
System Triple gear pump
Max. displacement cm3/rev. 8
Starting pressure bar 250
Operating pressure (soil dependent) bar 80 - 150
Vibration motor
Steering valve
Type 90 SBV
System Control valve
were determined during conditions typical for this type of equipment and by application of harmonized
standards.
During operation these values may vary because of the existing operating conditions.
Noise value
Sound pressure level on the place of the operator:
LpA = 85 dB(A), determined acc. to ISO 11204 and EN 500
! Danger
Wear your personal noise protection means (ear defenders) before starting operation.
5.1 General notes on maintenance l The fuel drum must rest for a longer period of time
before drawing off fuel.
Always comply with the appropriate safety regulations l Fuel residues in the drum are not suitable for the en-
when performing maintenance work.
gine.
Thorough maintenance of the machine guarantees far
longer safe functioning of the machine and prolongs
Notes on the performance of the engine
the lifetime of important components. The effort need-
ed for this work is only little compared with the prob- On diesel engines both combustion air and fuel injec-
lems that may arise when not observing this rule. tion quantities are thoroughly adapted to each other
and determine power, temperature level and exhaust
The terms right/left correspond with travel direction
gas quality of the engine.
forward.
If your engine has to work permanently in "thin air" (at
l Always clean machine and engine thoroughly be- higher altitudes) and under full load, you should con-
fore starting maintenance work.
sult our customer service or the customer service of
l Do not touch hot engine parts. the engine manufacturer.
l For maintenance work stand the machine on level
ground. Notes on the cooling system
l Always remove the main battery switch for all main- Prepare and check coolant with highest care, since
tenance work. otherwise the engine may be damaged by corrosion,
cavitation and freezing.
l Perform maintenance work only with the engine
shut down. The coolant is prepared by mixing a cooling system
protection agent (ethylene glycol) into the coolant.
l
Relieve hydraulic pressures before working on hy-
draulic lines. Mixing with cooling system protection agent is neces-
sary in all climatic zones. It prevents corrosion, lowers
l
Before working on electric parts of the machine dis- the freezing point and raises the boiling point of the
connect the battery and cover it with insulation ma- coolant.
terial.
l
When working in the area of the articulated joint at- Notes on the hydraulic system
tach the articulation lock (transport lock).
During maintenance work on the hydraulic system
cleanliness is of major importance. Make sure that no
Environment dirt or other contaminating substances can enter into
During maintenance work catch all oils and fuels the system. Small particles can produce flutes in
and do not let them seep into the ground or into valves, cause pumps to seize, clog nozzles and pilot
the sewage system. Dispose of oils and fuels en- bores, thereby making expensive repairs inevitable.
vironmentally. l
If, during the daily inspection of the oil level the hy-
Keep used filters in a separate waste container draulic oil level is found to have dropped, check all
and dispose of environmentally. lines, hoses and components for leaks.
Coolant
Always use a mixture of anti-freeze agent and clean,
dehardened water with a mixing ratio of 1:1.
* American Petroleum Institute
Under particularly extreme temperature conditions When changing from mineral oil based hydraulic oil to
you should consult our customer service concerning an ester based biologically degradable oil, you should
the anti-freeze agent to be used. consult the lubrication oil service of the oil manufactur-
There are various types of anti-freeze agents availa- er for details.
ble. For this engine you should use ethylene glycol.
Before filling in the coolant mixed with anti-freeze ! Caution
agent the radiator must be flushed with clean water. Check the filter more frequently after this change.
This procedure should be repeated two to three times
to clean the inside of radiator and engine block. Perform regular oil analyses for content of water
and mineral oil.
Mixing the anti-freeze agent: Prepare a mixture of
50% anti-freeze agent and 50% low mineral, clean Replace the hydraulic oil filter element every 500
water. Stir well before filling it into the radiator. The operating hours.
method for mixing water and anti-freeze agent de-
pends on the brand of the anti-freeze agent. In this re-
spect see standard SAE J1034 and also the standard
SAE J814c.
Add anti-freeze agent: If the coolant level drops be-
cause of evaporation,only clean water is to be used
for topping up. In case of leakages you must always
fill in anti-freeze agents of the same brand and the
same mixing ratio.
! Caution
Do not mix different coolants and additives of any
other kind.
Do not use any radiator cleaning agent after the anti-
freeze agent has been mixed in. The anti-freeze agent
also contains a corrosion protection agent. If this mix-
es with cleaning agent it may cause the development
of sludge, which could damage the cooling system.
Anti-freeze concentration
50% = -37 °C (-35 °F)
Environment
Coolant must be disposed of environmentally.
Motor
- Engine oil Engine oil API: CF, CF-4, CG-4, CH-4 or CI-4 4.7 l (1.2 USgal)
SAE 30
(+5 °C to +30 °C)
(+41 °F to +86 °F)
i Note
The maintenance plan inside the engine hood of the
machine assists you when servicing the machine!
Caution
!
as required
5.6 Checking the engine oil level Dipstick mark X
5.7 Check the hydraulic oil level Inspection glass X
5.8 Check the fuel level X
5.9 Check the water separator X
5.10 Check the coolant level X
5.11 Check fuel lines and clamps X
5.12 Check the air intake hose X
5.13 Change engine oil and oil filter car- at least 1x per year X
tridge* see foot note
5.14 Checking the V-belt, tightening, if renew every 500 oper- X
necessary replacing the V-belt ating hours
5.15 Clean the cooling fins on engine X
and hydraulic oil cooler
5.16 Changing the oil for exciter shaft min. 1x per year X
bearings
5.17 Check the central screw of the see foot note X
drive hub**
5.18 Drain the fuel tank sludge X
5.19 Changing the fuel filter, bleeding X
the fuel system
5.20 Service the battery, check the pole grease X
main battery switch
5.21 Check the rubber buffers X
5.22 Check, adjust the valve clearance 0.145 ... 0.185 mm X
(0.006 ... 0.007 in)
5.23 Measuring the protection field of X
the
BOSS safety system
5.24 Change hydraulic oil and filter*** at least every 2 years X
5.25 Change the coolant X
as required
5.26 Replacing the fuel lines at least every 2 years X
5.27 Check the injection pressure only by authorized X
service personnel
5.28 Check the fuel injection pump only by authorized X
service personnel
5.29 Check, clean the air filter, replace if replace min. 1x per X
necessary year
5.30 Adjust the scrapers X
5.31 Tightening torques X
5.32 Engine conservation X
* Running-in instructions: Oil change after 50 and 250 operating hours, then every 250 operating hours When using fuels with a sul-
phur content higher than 0.5% the oil change intervals must be halved.
** Running-in instructions: check tightening torque after 50 and 250 operating hours, then every 250 operating hours
*** Also in case of repair in the hydraulic system.
6.1 Overview
Fig. 1
Fig. 2
! 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!
For recharging remove the plugs from the battery
to avoid the accumulation of highly explosive gas-
es.
Environment
Dispose of the old batteries environmentally.
i Note
Maintenance free batteries also need care. Mainte-
nance free only means that the fluid level does not
need to be checked. Each battery suffers under self-
discharge, which may, in not checked occasionally,
even cause damage to the battery as a result of ex-
haustive discharge.
! Caution
Exhausted batteries (batteries with formation of
sulphate on the plates) are not covered under war-
ranty!
Open the maintenance flap and remove the battery
cover.
Fig. 3
i Note
If the power pack of the radio remote control is to be
charged, the main battery switch must remain
switched on when the engine is shut down.
Fig. 4
Fig. 6
Fig. 7
! Caution
A wrong connection will cause severe damage in
the electric system.
Bridge the machine only with a 12 Volt battery.
When starting with an external battery connect the
plus poles (Fig. 7) first and the minus poles (ground
cable) after.
Start the engine as described in the chapter “Start-
ing the engine”.
After starting disconnect the cable from the minus
poles (ground cable) first and from the plus poles
last.
Fold the control box back in and close the hood.
Fig. 1
Dismantling
Remove the V-belt pulley (1).
Remove the rear covering (12).
Disassemble the brush holder (11).
Disassemble the IC-regulator (10).
Unscrew the four stator cable fastening screws.
Take off the rectifier (9).
Take off the rear bearing plate (8).
Press the rotor (6) out of the drive bearing plate (2).
Bearing Stator
Fig. 2 Fig. 3
Check whether the bearing rotates without obstruc- Use the resistance range of the continuity tester to
tion. measure the resistance between the individual lines
Replace the bearing if it does not rotate properly. of the stator winding.
If the measuring value does not comply with the fac-
tory specification, replace the stator.
Use the resistance range of the continuity tester to
check the continuity between the individual stator
windings and the core.
Replace the stator if no infinite value is indicated.
i Note
Factory specification for resistance: Less than 1 OHM.
Fig. 4 Fig. 5
Measure the resistance between the sliprings. Check the slipring for score marks.
If the resistance does not comply with the factory If score marks are found rework the slipring with
specification, replace the rotor. emery cloth or on a lathe.
Use the resistance range of the continuity tester to Measure the outer diameter of the slipring with a
check the continuity between slipring and core. vernier caliper.
Replace the rotor if no infinite value is indicated. Replace if the measuring value is below the permis-
sible limit.
i Note
Factory specification for resistance: 2.9 OHM. i Note
Outer slipring diameter: 14.4 mm.
Permissible limit: 14.0 mm.
Fig. 6 Fig. 7
Measure the brush length with a vernier caliper. Use the resistance range of the continuity tester to
Replace if the measuring value is below the permis- check the continuity between the individual rectifier
sible limit. diodes.
Make sure that the brush is light moving. The rectifier is in good working order when the rec-
tifier diode conducts to one direction and block in
A defective carbon brush must be replaced.
the other direction.
i Note
Brush: 10.0 mm.
Permissible limit: 8.4 mm.
Fig. 8
Fig. 9
Use the resistance range of the continuity tester to
check the continuity between terminal B (2) and ter-
minal F (1) on the IC-regulator.
The IC-regulator is in good working order when it
conducts current to one direction, but not in the oth-
er direction.
Fig. 1
1 Through bolt Separate the armature (5) from the starter frame
2 Brush (4).
3 Terminal nut C Disassemble the housing (13).
4 Starter frame Disassemble intermediate gear (7) and freewheel
(6).
5 Armature
Remove the magnetic switch cover (9).
6 Freewheel
Disassemble the piston (11).
7 Intermediate gear
8 Housing cover
! Caution
9 Brush holder
Do not damage carbon bushes or collector.
10 Magnetic switch cover
11 Piston Assembly
12 Terminal nut B Apply some grease to intermediate gear and free-
13 Housing wheel. Tightening torque for terminal nut (12): 5.88
to 11.8 Nm
Dismantling
Unscrew the terminal nut (3) and take off the con-
necting cable.
Disassemble the two through bolts (1).
Take off the motor.
Disassemble the housing cover (8).
Compress the spring and take the carbon brush off
the brush holder.
Disassemble the brush holder (9).
Fig. 2
Check the pinion, replace the complete freewheel if Fig. 3
signs of wear or damage are found. Check the contact surface of the collector for wear
Make sure that the pinion rotates freely in the free- and rework it with sanding paper if it is slightly worn.
wheeling direction and does not slip in starting di-
rection.
If the pinion slips or does not rotate to both direc-
tions, replace the freewheel assembly.
i Note
Do not wash the grease in the freewheel out with
chemicals or oils.
Fig. 4
Measure the outer diameter of the collector at sev-
eral points with an outside micrometer.
If the smallest outside diameter is below the permis-
sible limit, the rotor must be replaced.
i Note
Factory specification, collector outside diameter:
30.0 mm.
Permissible limit: 29.0 mm.
Fig. 5
If the difference between the outer diameter meas-
uring values exceeds the permissible limit have the
i Note
Factory specification, difference of outer diameter
measurements: Less than 0.02 mm.
Permissible limit: 0.05 mm.
Fig. 7
If the contact area of the carbon brush is dirty or
dusty, clean it with emery cloth.
Measure the brush length (A) with a vernier caliper.
If the length is shorter than the permissible limit, the
brush holder must be replaced.
Fig. 6
1 Segment i Note
2 Counterdraft Factory specification, brush length: 16.0 mm.
3 Collector Permissible limit: 10.5 mm.
a) correct
b) not correct
Measure the counterdraft on the collector.
If the counterdraft falls short of the lower limit value,
correct it with a saw blade and bevel the segment
edges.
i Note
Factory specification, collector counterdraft: 0.5 to 0.8
mm
Permissible limit: 0.2 mm.
Fig. 9
Fig. 8 Use the resistance range of the continuity tester to
Use a continuity tester to check the continuity be- check the continuity between collector and arma-
tween brush holder and holder carrier. ture coil.
If continuity is found replace the brush holder. If continuity is found replace the armature.
Fig. 10
Use the resistance range of the continuity tester to
check the continuity between the collector seg-
ments.
If no continuity is found replace the armature.
i Note
The most frequent fault is definitely a fully discharged
battery.
If the starter rotates too slowly, either the brushes
are partly worn off, or parts of the exciter or armature
winding is shorted. In some cases oxidized electric
contacts or a soiled ground connection causing ex-
tremely high voltage losses in the overall starter sys-
tem are the cause of problems.
If the starter only emits a clicking sound,- either
Fig. 11 the magnetic switch is defect / soiled (dismantle and
1 Replace the clean))- the main contacts on the magnetic switch are
worn off / soiled (scrape off carefully with a file and
2 Brush
clean)- the starter motor is defective / soiled (remove
3 Stator armature and clean), cover cleaned, moveable parts
Use the continuity tester to check the continuity be- with grease.
tween line (1) and brush (2). Frequently a jammed return mechanism is the reason
If no continuity is found replace the stator frame. for a starter failure.
Occasionally worn contacts are found on the magnetic
return switch
Defects on the actual starter motor including pinion
and carbon brushes are very rare.
With a trouble shooting chart the faults in the starter
system can be narrowed down. The starter system
can only work when many conditions are fulfilled at
the same time.
Immobilizer deactivated?
Ignition switch OK?
Travel lever in correct position?
Fig. 12
Emergency stop not actuated?
Use the continuity tester to check the continuity be-
Battery sufficiently charged?
tween brush (2) and stator (3).
Battery poles OK?
If continuity is found replace the stator frame.
Main battery fuse OK?
Main battery switch closed?
Main starter cable (terminal 30) OK?
Starter control cable (terminal 50) OK, voltage
drop?
Ground cable OK?
Switching of magnetic switches OK?
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
the experience of the specialist
the failure probability of the component to be tested
and the testing effort for the respective part.
Only if all criteria mentioned above are OK, the fault
must be in the starter itself. In this case it can be re-
paired or replaced.
! Caution
Fasten the starter to make sure that it will not
come loose during the test.
Fig. 15
Use a continuity tester to check for continuity be-
tween terminal (1) and terminal (29 while holding
the pin depressed.
Replace the magnetic switch if no continuity is de-
tected.
Fig. 13
Connect a jumper lead between start terminal (1)
and battery plus (2).
Connect a jumper cable instantaneously between
starter housing and battery minus (3).
i Note
If the motor does not start, the starter is defective. Re-
pair or replace the starter.
Fig. 14
Connect a jumper lead between start terminal (1)
and battery plus (2).
Connect a jumper cable instantaneously between
starter housing and battery minus (3).
i Note
If the pinion does not disengage, the magnetic switch
is defective. Repair or replace the starter.
Fig. 1
Switch on the ignition and check the voltage (within
10 seconds) between cable terminal and engine
block with a line tester.
i Note
If the voltage deviates from the battery voltage you
should measure the voltage on terminal X3:38 (BLM
power module) under the same conditions.
If battery voltage is present on terminal X3:38, either
the wiring loom or the relay K14 is defective.
If battery voltage is not present on terminal X3:38, the
BLM module must be faulty.
Continuity test
Fig. 2
Disassemble the glow plug.
Use a continuity tester to measure the resistance
between glow plug connection and glow plug body.
If the measured value does not correspond with the
factory specification, the glow plug is defective.
(terminal X3:4) evaluates this signal for monitoring Adjusting the positioning solenoid
purposes.
i Note
If the "aux" signal is not correct despite the switched
on control solenoid, the positioning solenoid will be
de-energized (down to idle speed) by the BML-mod-
ule via relay K97.
Fig. 3
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. 4
i Note
Adjustments must only be made on the clevis head
(3).
! Caution
The gap should be min. 0.1 mm and max. 0.5 mm.
If the gap is too small, the limit switch in the sole-
noid may not be able to operate and the "aux" sig-
nal will report this condition to the BLM-module
(A70).
In case of a too wide gap the engine will not reach
its maximum speed.
Fig. 1
Fig. 2 (2) back to initial position and the governor rod (3) is
1 Engine shut-down solenoid Y13 blocked in position "No fuel injection".
2 Armature
3 Governor rod
The battery voltage has the effect that the shut-down
solenoid (1) engages the armature (2) to the left, so
that the governor rod can move freely. When switch-
ing off the battery current a spring will pul the armature
Fig. 3
1 Injection pump
2 Engine shut-down solenoid
3 Starter
4 BLM-module
5 Starter battery
i Note
P: Terminal for pick-up winding, resistance approx.
0.38Ω
H: Terminal for holding winding, resistance approx.
16Ω
Disassemble the shut-down solenoid.
Connect bridging cables between terminal P of the
pick-up winding and switch (4), as well as between
Fig. 5 switch (4) and battery plus.
Connect bridging cables between terminal H of the
Danger
! holding winding and switch (3), as well as between
Danger of burning! switch (3) and battery plus.
Connect a bridging cable between the housing of
The shut-down solenoid gets very hot during the the shut-off solenoid and battery minus (ground
stating process. supply).
Remove the shut-down solenoid, leave the plug on Switch the switch (4) on and off.
the solenoid.
Connect the housing of the solenoid to engine
ground (ground supply). i Note
Start the engine for a moment. When switching the switch (4) on the pin is retracted
and it moves out again when the switch (4) is switched
off.
i Note
Switch the switch (3) on first and switch (4) after -the
During the starting process the pin is retracted and it pin is retracted into the body of the solenoid and re-
extends again when the ignition is switched off. mains in this position when switch (4) is switched
Testing the shut-off solenoid off.
Fig. 6
1 Plug
2 Battery
3 Switch for holding winding (H)
4 Switch for pick-up winding (P)
Fig. 1
The oil pressure switch is mounted on the cylinder block and is connected to the lubrication oil channel.
If the oil pressure drops below a specific value for longer than 8 seconds
the warning buzzer will sound
the engine will be shut down
a fault code is emitted
Fig. 2
1 Terminal
2 Insulator
3 Spring
4 Diaphragm
5 Contact rivet
6 Contact
7 Oil switch housing
8 BLM-module (A70)
9 Holding winding for engine shut-down solenoid (Y13)
10 Display module (P18)
11 Warning buzzer (H11)
The pressure building up after starting the engine will press the diaphragm (4) up. This lifts the contact rivet (5)
and interrupts the electric circuit between BLM-module (A70) and engine ground.
Fig. 1
The temperature switch (B53) is arranged in the coolant circuit of the engine in such a way, that its tip is sur-
rounded by coolant.
If the temperature rises over a specific value for longer than 8 seconds
the warning buzzer will sound
vibration is shut down
the travel speed is limited to travel range 1
a fault code is emitted
Parameters
Normally open contact: Closes at 105 °C and opens at 98 °C.
Fig. 1
H07, Warning buzzer
B53, Coolant temperature switch
Y03, Solenoid valve 2nd speed
Y57, Vibration high amplitude
Y56, Vibration low amplitude
Fig. 1
Control units (ECU = electronic control unit or ECM = electronic control module) are electronic modules which
are mainly installed in places where something needs to be controlled or regulated. Control units are used in
almost any electronic sector in the automotive industry, but also to control machines, plants and other technical
processes.
Control units generally work according to the IPO-principle. IPO stands for Input-Processing-Output. Sensors
are available for input. These determine a physical parameter like e.g. speed, pressure, temperature etc. This
value is then compared with a calculated or fixed nominal value that had been entered into the control unit. If
the measured value does not match the stored value, the control unit regulates the physical process by means
of actors, so that the measured actual values match the setpoint again. This means that the actors correctively
interfere with the ongoing process.
In current vehicles control units are linked via various system buses (CAN, LIN, MOST, Flexray). The units ex-
change information about operating states and other relevant data in vehicle across the system. Furthermore,
the on-board diagnostic or the diagnostic system of the vehicle is connected via such busses (and possible K-
lines). Furthermore, external diagnostic 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.
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. 2
Why CAN?
Networking of control units for the realization of
complex functions.
Reduction of the extend of wiring and plug connec-
tions.
Better diagnostic possibilities (central diagnostics
socket).
Characteristics of CAN
It is a kind of serial data transmission. The individual
bits are transmitted one after the other, only 2 lines are
required.
CAN lines are twisted together 30 to 40 times per me-
tre. Electromagnetic interferences therefore always
occur simultaneously in both lines, the software is
thus able to filter out interfering signals more easily.
Wire (+) = cable colour blue
Wire (-) = cable colour yellow
i Note
(Fig. 3) 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.
Test steps
1. Switch off the ignition.
! 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.
Setpoint
The voltage drop UV should not exceed 0.5 V => USetpoint ≤ 0.5 V.
Setpoint
The voltage drop UV should not exceed 0.5 V => USetpoint ≤ 0.5 V.
Connection example to check the plus line between battery and plug pin 28
Fig. 7
X = Unplug the control unit from the wiring loom.
P = Multimeter
E = Setpoint : E is bright. UV max. 0.5 Volt
Fig. 8
P = Multimeter
X = Unplug the control unit from the wiring loom.
S30 = Main battery switch closed
E = Setpoint : E is bright. 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 14, 28 and 42 the voltage drop is too high. There are two possible reasons. Either
all contacts are corroded, or the supply line between battery and fuse F67 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.
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.
Description of fault,
Questioning of customer
Visual inspection,
possible test drive
(1)
Fault memorized in
error log
(2)
No fault memorized in
error log
Fig. 9
(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.
Localizing faults
Line or component?
Fig. 10
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.
Checking the voltage supply for the control unit
Checking the sensor lines
Checking the actor lines
Fault found
Replace component or
repair the connecting line
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. 11
Fig. 12
1 S101 Toggle switch for cable remote control/radio remote control
2 P18 Display module
3 S30 Main battery switch
4 S137 Steering control lever
5 S132 Toggle switch, vibration automatic/manual
6 S133 Toggle switch, travel ranges
7 S134 Toggle switch, engine speed
8 S138 Travel direction control lever
9 S36 Toggle switch for vibration high/low amplitude
10 S102 Emergency stop switch
11 H77 Control light data transfer/power pack radio remote control
! Danger
Fire hazard!
Do not use fuses with higher ampere ratings and do not bridge fuses.
Fuse box
Fig. 13
Main fuse
Fig. 14
! Caution
The code can only be entered when the engine is
shut down.
Fig. 15
Faults are displayed in the display module h (Fig. 15)
in form of flashing fault codes. If several faults occur
at the same time, these will be indicated by flashing
codes, one after the other.
Fig. 16
h
F1 F2
720163
Fig. 17
i Note
Whenever switching the ignition on the machine type
will appear in the display module for 3 seconds.
6.21 Replacing, recharging the ra- Charging the power pack in the machine
dio remote control power pack
i Note
As standard the power pack is recharged in the ma-
chine through the spiral cable. A separate battery
charger is available as an option. The recharging time
is approx. 6 hours.
! Danger
Operate the battery charger only in dry rooms at
temperatures of min. 0 °C to max. 40 °C (32 °F to
max. 104 °F)!
Fig. 19
A charged power pack is a concentrated energy
source! Do not store charged power packs in a Switch off the transmitter (Fig. 19) with the ignition
tool box or similar, because metal parts may key.
cause a short circuit. Short circuits may also be Plug the spiral cable into the transmitter
caused by keys etc. in a trouser pocket.
! Caution
Change the power pack only when the sender is
switched off.
Before connecting the battery charger make sure
that the mains voltage is in accordance with the
specifications mentioned on the battery charger.
Strictly follow the operating instructions for the
battery charger.
i Note
Ageing of the power pack reduces the discharging ca- Fig. 20
pacity and therefore the operating time of the sender.
The main battery switch (Fig. 20) must be switched
The full discharging capacity is only reached after sev- on (position "Vertical").
eral charging cycles.
i Note
i Note The power pack recharging time is approx. 6 hours.
As the charging of the power pack succeeds, the
charging current drops, so that overcharging of the
power pack is almost impossible. However, if the con-
trol is switched off for a couple of days (holidays, bad
weather) you should also disconnect the charging unit
from the mains supply or switch off the main battery
switch.
Fig. 24
Fig. 22
Press the power pack forward and lift it out of the Fig. 25
housing (Fig. 22).
Insert the power pack into the battery charger (Fig.
25).
Fig. 23
Push lock (1) (Fig. 23) on the mains unit of the bat- Fig. 26
tery charger forward and pull plug (2) upward out of
Connect the battery charger to a power source (Fig.
the mains unit.
26).
The two light emitting diodes on battery charger and
mains unit must light up.
i Note
The power pack recharging time is approx. 6 hours.
When charging is completed the green LED on the
charger will start to flash.
Antenna 2
Antenna 1
Function
The machine is equipped with a protection field control, whereby each of the two protection field antennas emits
a spherical electro-magnetic field. This creates a spherical protection field around the machine (Fig. 1).
Remote control
Radio signal
Transmitter
868 MHz / 916
Transponder Radio transmitter
Radio receiver
Display /
Control unit
Spiral cables
Radio signal
Transponder CAN BUS
868 MHz / 916
Machine control
reverse
Antenna 1
Feedback
Monitoring
Feedback valve
forward
forward
Antenna 2 reverse
valve
reverse
Fig. 3
Fig. 4
!Danger
Danger of injury!
The safety field of the machine must be measured
at a height fo one meter, also after maintenance/
repair work on the safety system.
A safety field length < 1.20 m is not permitted.
Fig. 5
Nominal value:
>1.20 m
!Danger
Danger of injury!
If the safety distance is fallen short of stop the ma-
chine and have the safety system repaired. It is
not permitted to continue operation.
Repeat this inspection in front of the machine.
i Note
Assumed that the function is correct when using the spiral cable.
Steel ropes or metal attachments on the frame can disturb the radio connection.
Machine does not re- Incorrect or defective aerial Replace the aerial (observe the frequency
spond of the aerial)
Check the plug connection between aerial
and receiver
The receiver is electrically not or Check the plug connection between re-
not correctly connected ceiver and machine
Ignition on, display mod- Power pack empty or defective Charge or replace the power pack
ule on, but starting not
possible
Engine stops without Power pack empty or defective Charge or replace the power pack
any reason
Disturbance caused by other radio Check whether the problem arises when
systems other radio signals are transmitted nearby
(airport, construction crane, etc.)
If necessary continue in cable operation
Emergency stop push button Switch operated? Display off, pull button
out
Switch defective? replace
Engine stops without Engine oil pressure too low or en- Check engine oil level or oil pressure
any reason gine oil pressure switch defective switch
(does the oil pressure controol
lamp light up while the engine is
running?)
Emergency stop push button Switch operated? Display off, pull button
out
Switch defective? replace
Fuses F 54, F 67, F 103 defective Replace the fuses (may be damaged by
vibration)
Toggle switch cable/radio S101 Check plug connections, bridge switch for
testing
Ignition on, display mod- Travel lever not in "0"-position Actuate the travel lever and return it to "0"-
ule on, but starting not position
possible Check with input code 2500 and 2501
After starting still no Not waited for horn signal before Press the horn button or wait fro the horn
function starting signal before starting
Emergency stop push button Switch operated? Display off, pull button
out
Switch defective? Replace
Display module shows Spiral cables Check the continuity of the individual ca-
CTO when ignition is on bles
Check the cables for short circuit to the
housing
Replace the cables
Engine not running at Toggle switch for speed S 134 Toggle switch in position "Max“ ?
max. speed, otherwise Check with input code 2505
OK
If necessary replace the toggle switch
no travel move- The operator is inside the safety field Leave the safety field
ments, steering
is still possible
Transponder (in transmitter) has not see chapter Safety equipment, teaching
been taught the BOSS safety system transponder
Safety antenna front / rear Replace the antenna, check plug connec-
defective or not plugged in tion
Safety field control defective or not Replace the safety field control or
plugged in check the plug connection
Wiring loom for safety field antennas Replace the wiring loom for safety field
antennas
! Danger
Danger of injury!
After maintenance and/or repair work on the safety system the safety field length must be checked
again, see corresponding chapter.
Overview
9000 - 9998 External IO nodes, joysticks, data collectors (CAN communication and hardware de-
fects )
9999 Unknown fault, displayed value higher than +/- 10000, automatic output by the BMFSA
1032 Output is switched Output valve travel- Wire breakage in cur- X3:22 1030
off, function no long- ling forward, Y 16 rent path 1031
er possible No or too low current Current path con- 1032
flow out of this output nected to +12V
1033 Engine is shut down Output valve travel- Current path con- X3:22 1030
ling forward, Y 16 nected to +12V 1031
Although the output is 1032
switched off, voltage is
present
1042 Output is switched Output valve travel- Wire breakage in cur- X3:24 1040
off, function no long- ling reverse, Y 17 rent path 1041
er possible No or too low current Current path con- 1042
flow out of this output nected to +12V
1043 Engine is shut down Output valve travel- Current path con- X3:24 1040
ling reverse, Y 17 nected to +12V 1041
Although the output is 1042
switched off, voltage is
present
1052 Output is switched Output valve 2. gear, Wire breakage in cur- X3:11 1050
off, function no long- Y 03 rent path 1051
er possible No or too low current Current path con- 1052
flow out of this output nected to +12V
1053 Output is switched Output valve 2. gear, Current path con- X3:11 1050
off, engine runs only Y 03 nected to +12V 1051
with idle speed Although the output is 1052
switched off, voltage is
present
1062 Output is switched Output brake valve, Y Wire breakage in cur- X3:40 1060
off, function no long- 04 rent path 1061
er possible No or too low current Current path con- 1062
flow out of this output nected to +12V
1063 Output is switched Output brake valve, Y Current path con- X3:40 1060
off, engine runs only 04 nected to +12V 1061
with idle speed Although the output is 1062
switched off, voltage is
present
1307 Output is switched Output valve vibra- Wire breakage in cur- X3:12 1305
off, function no long- tion low ampl., Y 56 rent path 1306
er possible No or too low current Current path con- 1307
flow out of this output nected to +12V
1308 Output is switched Output valve vibra- Current path con- X3:12 1305
off, engine runs only tion low ampl., Y 56 nected to +12V 1306
with idle speed 2nd Although the output is
gear is inhibited 1307
switched off, voltage is
present
1312 Output is switched Output valve vibra- Wire breakage in cur- X3:13 1310
off, function no long- tion high ampl., Y 57 rent path 1311
er possible No or too low current Current path con- 1312
flow out of this output nected to +12V
1313 Output is switched Output valve vibra- Current path con- X3:13 1310
off, engine runs only tion high ampl., Y 57 nected to +12V 1311
with idle speed 2nd Although the output is
gear is inhibited 1312
switched off, voltage is
present
2010 Output is switched Output valve steer- Excessive current X3:19 1010
off, function no long- ing right, Y 237 flow in current path,
er possible Too high current flow probably because of
out of this output Out- a defective coil or a
put was switched off! short circuit to
ground
2012 Output is switched Output valve steer- Wire breakage in cur- X3:19 1010
off, function no long- ing right, Y 237 rent path 1011
er possible No or too low current Current path con- 1012
flow out of this output nected to +12V
2013 Engine is shut down Output valve steer- Current path con- X3:19 1010
ing right, Y 237 nected to +12V 1011
Although the output is 1012
switched off, voltage is
present
2022 Output is switched Output valve steer- Wire breakage in cur- X3:21 1020
off, function no long- ing left, Y 238 rent path 1021
er possible No or too low current Current path con- 1022
flow out of this output nected to +12V
2023 Engine is shut down Output valve steer- Current path con- X3:21 1020
ing left, Y 238 nected to +12V 1021
Although the output is 1022
switched off, voltage is
present
2500 Engine is stopped, all func- Operation of two remote A remote control with cable
tions are locked, horn control system at the same and a wireless remote con-
sounds time trol are operated at the same
time.
2600 Engine stopped, emergency Remote control emergen- Emergency stop on remote
stop relay in the control is cy stop control operated
switched off, all outputs on
control are switched off
2601 Engine stopped, emergency Fault in data transfer be- Battery empty
stop relay in the control is tween remote control Radio signal transmission is
switched off, all outputs on sender and receiver disturbed
control are switched off
Distance between sender an
machine too big
2605* Engine stopped, emergency Receive signal too weak Radio signal transmission is
stop relay in the control is disturbed
switched off, all outputs on Distance between sender an
control are switched off machine too big
5015 Only warning, horn Potential 15 miss- Fuse F 103 defective X3:20 not
sounds, ing Relay K11 defective possible
display module is Control has switched Cable breakage in
dark, relay K11, no voltage wiring loom
5016 Output is switched Battery voltage too Battery acid level too 0561
off, function low low
no longer possible Battery voltage al- Battery defective
ready below 11 Volt Battery discharged
when switching on
5020 Only warning, horn Input engine oil The oil pressure X3:03 5020
sounds pressure, B 06 switch has measured
Oil pressure switch a too low oil pres-
delivers the signal sure. The engine
"no engine oil pres- may be shut down.
sure" Should this message
be displayed even
though the engine is
not running, the fol-
lowing faults should
be examined:
Current path has
short circuit to
ground
Engine oil level not
correct
Engine oil pump de-
fective
Pressure relief valve
after engine oil filter
soiled
Oil pressure switch
defective
5021 Engine shut down by Input engine oil see fault code 5 0 2 0 X3:03 5020
too low oil pressure pressure, B 06
Fault 5 0 2 0 present
longer than 8 sec-
onds
Engine is shut down
5043 Output is switched Output HW-shut- Current path con- X3:10 5040
off, engine stops down solenoid, Y nected to +12V
5041
13
5042
Although the output
is switched off, volt-
age is present
5053 Output is switched Output relay K 114, Current path con- X3:09 5050
off, engine runs only engine speed sole- nected to +12V
5051
with idle speed noid
5052
Although the output
is switched off, volt-
age is present
5060 Output switched off, Output relay K 11, Excessive current X3:07 -
no potential 15 on changeover of po- flow in current path,
machine, control is tential 15 probably because of
working, engine is a defective coil or a
Too high current flow
stopped or cannot be short circuit to
out of this output
started ground
Output was switched
off!
5061 Output switched off, Output relay K 11, Short circuit to X3:07 -
no potential 15 on changeover of po- ground in the current
machine, control is tential 15 path
working, engine is Lines rubbed
Short-circuit current through
stopped or cannot be flow out of this output
started
Output was switched
off!
5062 Output switched off, Output relay K 11, Wire breakage in X3:07 5060
no potential 15 on changeover of po- current path
5061
machine, control is tential 15 Current path con-
working, engine is nected to +12V 5062
No or too low current
stopped or cannot be flow out of this output
started
5063 Output switched off, Output relay K 11, Current path con- X3:07 5060
no potential 15 on changeover of po- nected to +12V
5061
machine, control is tential 15
working, engine is 5062
Although the output
stopped or cannot be is switched off, volt-
started age is present
5070 Output switched off, Output relay K 39, Excessive current X3:06 -
engine cannot be starter flow in current path,
started probably because of
Too high current flow a defective coil or a
out of this output short circuit to
Output was switched ground
off!
5071 Output switched off, Output relay K 39, Wire breakage in X3:06 -
engine cannot be starter current path
started Current path con-
Short-circuit current
nected to +12V
flow out of this output
Lines rubbed
Output was switched through
off!
5072 Output switched off, Output relay K 39, Wire breakage in X3:06 5070
engine cannot be starter current path
5071
started Current path con-
No or too low current 5072
nected to +12V
flow out of this output
5073 All outputs switched Output relay K 39, Current path con- X3:06 5070
off, engine stopped, starter nected to +12V
5071
safety relay switched Although the output
off 5072
is switched off, volt-
age is present
5082 Output switched off, Output horn, H 07 Wire breakage in X3:08 5080
horn cannot sound current path
5087 No or too low current X3:36 5081
Current path con-
flow out of this output 5082
nected to +12V
5083 Horn may sound Output horn, H 07 Current path con- X3:08 5080
5088 continuously Although the output nected to +12V X3:36 5081
is switched off, volt- 5082
age is present
5090 Machine does not Input inclination Wire breakage in X3:23 1405
start switch B56 current path
Switch defective
The machine cannot
The switch is in actu-
be started, because
ated state (incorrect
the input does not re-
installation position)
ceive a signal from
the inclination switch
5091 Shut down of diesel Input inclination Wire breakage in X3:23 1405
engine switch B56 current path
Switch defective
The diesel engine is
shut down because The switch is in actu-
the input on the con- ated state (machine
trol does not receive has turned over) The
a signal from the in- machine must first
clination sensor be shut down after it
has been placed in
correct position.
5092 Shut down of diesel Input inclination The switch is in actu- X3:23 1405
engine switch B56 ated state (machine
The diesel engine is has turned over)
shut down because + Start lock activated
the input on the con- Wire breakage in
trol does not receive current path
a signal from the in- Switch defective
clination sensor
+ Start lock activated
5100 Warning horn Input coolant tem- Lack of coolant X3:05 5100
sounds, only warn- perature sensor, Radiator defective
ing! B53 Sensor defective
Coolant temperature
too high
5101 Vibration and 2. gear Input coolant tem- Lack of coolant X3:05 5100
switched off perature sensor, Radiator defective
B53 Sensor defective
Coolant temperature
too high over a long-
er period of time
6001 Machine travels for 15min. Warning that service mode is Service mode activated via in-
without activated BOSS safe- active put code
ty system. Attention: Only for
servicing purposes!
6010 Travel movement not possi- Fault of front safety field an- Wire breakage in current
ble, only steering tenna (W12) path, front safety field anten-
na defective
6011 Travel movement not possi- Fault of rear safety field an- Wire breakage in current
ble, only steering tenna (W13) path, rear safety field antenna
defective
6012 Travel movement not possi- Transponder fault (no feed- Fault in radio link of safety
ble, only steering back) system, transponder of re-
mote control defective
6013 Travel movement not possi- Transponder fault Internal fault in transponder of
ble, only steering remote control
6014 Travel movement not possi- Fault in safety field control Internal fault in safety field
ble, only steering (A115) control
6015 Travel movement not possi- Fault in bus communication Wire breakage in current path
ble, only steering between safety field control
and transponder
Faults in parameterization
7010 Machine cannot be No machine type set Module is new, pa- 0725
started, module is rameters were
not completely initial- deleted
ized
1010 Output valve steering right, Y 237 Display value = output voltage in Volt
Voltage at output
1011 Output valve steering right, Y 237 Display value = output current in Amperè
Current at output
1012 Output valve steering right, Y 237 0000 = Output not triggered
Logic level of control 0001 = Output triggered
1020 Output valve steering left, Y 238 Display value = output voltage in Volt
Voltage at output
1021 Output valve steering left, Y 238 Display value = output current in Amperè
Current at output
1022 Output valve steering left, Y 238 0000 = Output not triggered
Logic level of control 0001 = Output triggered
1030 Output valve travelling forward, Y 16 Display value = output voltage in Volt
Voltage at output
1031 Output valve travelling forward, Y 16 Display value = output current in Amperè
Current at output
1040 Output valve travelling reverse, Y 17 Display value = output voltage in Volt
Voltage at output
1041 Output valve travelling reverse, Y 17 Display value = output current in Amperè
Current at output
1305 Output valve vibration low amplitude, Y 56 Display value = output voltage in Volt
Voltage at output
1306 Output valve vibration low amplitude, Y 56 Display value = output current in Amperè
Current at output
1307 Output valve vibration low amplitude, Y 56 0000 = Output not triggered
Logic level of control 0001 = Output triggered
1310 Output valve vibration high amplitude, Y Display value = output voltage in Volt
57
Voltage at output
1311 Output valve vibration high amplitude, Y Display value = output current in Amperè
57
Current at output
1312 Output valve vibration high amplitude, Y 0000 = Output not triggered
57 0001 = Output triggered
Logic level of control
1402 Input limit switch engine speed solenoid, 12 V > Solenoid retracted
Aux 0V Ground > Solenoid not in end position
1409 Activation input, cable remote control, S 12 V > Operating mode cable remote con-
101 trol
1410 Activation input, radio remote control, S 12 V > Operating mode wireless
101
5040 Output bia winding of shut-down solenoid, Display value = output voltage in Volt
Y 13
Voltage at output
5041 Output bia winding of shut-down solenoid, Display value = output current in Amperè
Y 13
Current at output
5042 Output bia winding of shut-down solenoid, 0000 = Output not triggered
Y 13 0001 = Output triggered
Logic level of control
5050 Output relay K 114, engine speed solenoid Display value = output voltage in Volt
Voltage at output
5051 Output relay K 114, engine speed solenoid Display value = output current in Amperè
Current at output
5052 Output relay K 114, engine speed solenoid 0000 = Output not triggered
Logic level of control 0001 = Output triggered
5056 Confirm parameter change ECO-mode Subsequently switch off the ignition!
5060 Output relay K 11, potential changeover Display value = output voltage in Volt
Voltage at output
5061 Output relay K 11, potential changeover Display value = output current in Amperè
Current at output
5062 Output relay K 11, potential changeover 0000 = Output not triggered
Logic level of control 0001 = Output triggered
5070 Output relay K 39, starter Display value = output voltage in Volt
Voltage at output
5071 Output relay K 39, starter Display value = output current in Amperè
Current at output
2500 Actuation of travel lever on remote control, 0100 = Travel lever shifted forward
S 138 0010 = Travel lever not moved
0001 = Travel lever shifted backward
2501 Actuation of steering joystick on remote 0100 = Joystick actuated to the left
control, S 137 0010 = Joystick not moved
0001 = Joystick actuated to the right
2502 Position of switch for vibration, S 36 0100 = Switch operated to forward, vibra-
tion high amplitude
0010 = Switch not operated
0001 = Switch operated to reversed, vibra-
tion low amplitude
2503 Position of switch for type of vibration, S 0100 = Switch operated to forward, auto-
132 matic operation
0010 = Switch not operated, manual oper-
ation
2504 Position of switch for fast speed, S 133 0100 = Switch operated to forward, fast
speed selected
0010 = Switch not operated, fast speed
disabled
2505 Position of switch for engine speed, S 134 0100 = Switch operated to forward, high
engine speed
0010 = Switch not operated, idle speed
i Note
With the input codes listed above it is possible to check the transfer of the individual switching signals from the
remote controls to the central control unit.
For this purpose start the machine and subsequently press the horn button to bring the remote control sender
in operating mode for this function test.
For testing the spiral cable switch the operating mode switch to cable operation, connect the spiral cable to the
sender and start the machine.
If the engine starts, the spiral cable is OK.
System information
0661 confirms the entered remote control type See adjustment instructions
0662 Preselect radio remote control, default set- See adjustment instructions
ting
Fault log
0701 Switch off function "Show stored faults" See adjustment instructions
6001 Service mode active, machine travels for 6001 = service mode active
15min. without activated BOSS safety sys-
tem.
Attention: Only for servicing purposes!
7500 Display of hours, operating hour meter The full hours are displayed
7501 Display of minutes, operating hour meter The minute digits of the operating hour me-
ter are displayed
7103 Preselect machine type BMP 8500 with See adjustment instructions
protection bow
7104 Preselect machine type BMP 8500 without See adjustment instructions
protection bow
Documentation
BMP 8500
with
Safety System BOSS
008 097 xx
Author: VK
Status: 20.07.2012
Table of contents
4 FAULT CODES AND WARNING MESSAGES OF THE BMP 8500 CONTROL 11
4.1 Overview ..................................................................................................................................... 11
4.2 Fault codes of travel functions .................................................................................................... 12
4.3 Fault codes of work functions ..................................................................................................... 14
4.4 Fault codes steering ................................................................................................................... 15
4.5 Fault codes of remote control ..................................................................................................... 16
4.6 General fault codes diesel engine, machine .............................................................................. 18
4.7 Fault codes safety system BOSS ............................................................................................... 23
4.8 Faults in parameterization .......................................................................................................... 24
Page 2 /30
132 BOMAG 008 922 85
with safety field control 7.1
Confirmation of changes
1 Confirmation of changes
No. Date Description of changes resp.
1 19.06.2002 Creation of version 1.00 Ch. Fondel
2 09.10.2002 Revision of version 1.00 Ch. Fondel
3 31.05.2005 Version 1.03 from software version 1.11 Ch. Fondel
4 07.12.2006 Version 1.04 from software version 1.21 Ch. Fondel
5 11.01.2010 BMP 8500 with safety bars J.Kob
6 15.09.2010 BMP 8500 with BOSS Version 2.0, P/N 724 002 33 J.Kob
7 20.07.2012 BMP 8500 mit BOSS Version 2.02, P/N 724 002 33 J.Kob
Page 3 /30
008 922 85 BOMAG 133
7.1 with safety field control
Functions of the BLM control
F1 F2
1. Press both keys (F1 and F2) on the display module for 2 seconds.
) The value 0 0 0 0 will be displayed, with the 1st digit 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.
NOTE: To verify work- and driving funktion with codes, the horn button needs to be pushed
once.
Page 4 /30
134 BOMAG 008 922 85
with safety field control 7.1
Functions of the BLM control
Note: Apart from the stored faults the current faults are also displayed.
Note: The stored faults can only be deleted when the engine is not running.
If the PDFKLQH has tipped over and has been put back on the wheels, it is important to make sure that
there is no oil in front of the pistons of the Diesel engine. Otherwise the conrods and tappets can be
bent.
To make sure that the operator cannot start the engine now without checking this, you can preselect a
start blocking function before the machine is delivered to the site. If the start lock mode was selected
before delivery and the machine tips over now while the engine is running, the display shows codes
5092, 5091 one after the other. Now the operator can restart the engine only after he put in three
particular input codes.
The input codes are not listed in the operators manual, so the operator has to contact the
workshop now.
Now the work shop can make sure that the oil in the combustion chamber is removed, can type in the
input codes and after that he can restart the engine.
Note: The start lock is activated only, if the machine tipped over with the engine running.
(Every time when the machine fell over, you can start the engine only if it is standing upright and the
release code has been entered)
Page 5 /30
008 922 85 BOMAG 135
7.1 with safety field control
Functions of the BLM control
Page 6 / 30
Since this control is used on two machines with CAN - Bus remote control it is necessary to adjust the
central control to the corresponding machine type or remote control when switching it on for the first
time. On new machine this adjustment is made during production. This adjustment is only required
when replacing a central control unit in the field.
The machine type can be checked by entering the code 7010. If no machine type is adjusted the fault
code 7010 will be displayed when switching on the first time.
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 entered code. (e.g. 7 1 0 4 )
• Enter code number 7 0 1 1 . This code number confirms the entered machine type.
After confirming the machine type the control switches off and back on again. The machine type is
thereby displayed for 3 seconds (e.g. 7 1 0 4 ). Hereafter the machine type is always displayed for 3
seconds when switching on the ignition.
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!
On new controls the machine type is not adjusted. The warning 7010 appears in the display.
Page 7 /30
008 922 85 BOMAG 137
7.1 with safety field control
Functions of the BLM control
Since this machine may be equipped with two different types of wireless remote controls the machine
control needs to be informed about the control type presently used
The remote control type can be checked by entering the code 0665.
Note: Parameter adjustments can only be performed when the engine is not running!
• Enter code number 0660. This code number activates the function "Adjusting remote control type“.
• select and enter the remote control type from the table above.
The display module now permanently shows the entered code. (e.g. 0662)
• Enter code number 0 6 6 1 . This code number confirms the entered remote control type.
After confirming the remote control type the control switches off. The control automatically switches on
again is now ready for starting.
Attention: A machine must not be operated with a wrong type adjustment, because in such
a case the correct function of the control cannot be assured!
On new controls the remote control type 0662 (radio remote control) is set as default.
After entering code 0 5 0 0 the brake will not be opened any more. When moving a travel lever
forward or reverse, the travel motors will be activated and the machine drives against the brake. At the
same time the display shows code 0500 and the warning buzzer is activated.
To desactivate this function and to open the brake again you have to enter code 0501 or shutt off the
ignition once.
Note: This function can only be activated / desactivated when the travel lever is in
neutral position.
Page 8 /30
138 BOMAG 008 922 85
with safety field control 7.1
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.
Page 9 / 30
Page 10 / 30
Page 11 / 30
Page 12 / 30
Page 13 / 30
Page 14 / 30
Page 15 / 30
2 6 0 0 Engine stopped, emergency stop Remote control emergency stop ) Emergency stop on remote control
relay in the control is switched off, all operated
outputs on control are switched off
2 6 0 1 Engine stopped, emergency stop Fault in data transfer between remote ) Battery empty
relay in the control is switched off, all control sender and receiver ) Radio transmission disturbed
outputs on control are switched off ) Distance between sender an machine
too big
2 6 0 5 Engine stopped, emergency stop Receive signal too weak ) Radio transmission disturbed
relay in the control is switched off, all ) Distance between sender an machine
outputs on control are switched off too big
2 6 1 1 Engine is stopped. Communication error between BLM modul ) Plug connector of spiral cable on one
and cable control box. end defective or loose
) Spiral cable broken
) BLM-modul defektive
) Cable control defektive
2 6 1 2 Engine is stopped. Communication error between BLM modul ) Plug connector at radio receiver
and radio remote control. defective or loose
) Radio receiver defective
) BLM-modul defektive
2 6 1 3 Engine is stopped. Communication error between BLM modul ) Plug connector at infrared receiver
and infra red control. defective or loose
) IR receiver defective
) BLM-modul defektive
Page 16 / 30
Output of error code 2605 only with software version older than 1.11!
Page 17 / 30
Page 18 / 30
Page 19 / 30
5 0 6 3 Output switched off, no potential 15 Output relay K 11, changeover of ) Current path connected to +12V X3:07 5060
on machine, control is working, engine potential 15 5061
is stopped or cannot be started Although the output is switched off, voltage 5062
is present
5070 Output switched off, engine cannot be Output relay K 39, starter ) Excessive current flow in current path, X3:06 -
started The current flow from this output is too high probably because of a defective coil or
output ) was switched off! a short circuit to ground
5 0 7 1 Output switched off, engine cannot be Output relay K 39, starter ) Wire breakage in current path X3:06 -
started Short circuit current flowing from this output ) Current path connected to +12V
) output was switched off ! ) Lines rubbed through
5 0 7 2 Output switched off, engine cannot be Output relay K 39, starter ) Wire breakage in current path X3:06 5070
started No or too low current flow out of this output ) Current path connected to +12V 5071
5072
5 0 7 3 All outputs switched off, engine Output relay K 39, starter ) Current path connected to +12V X3:06 5070
stopped, safety relay switched off Although the output is switched off, voltage 5071
is present 5072
No display for fault codes 5060 to 5063, because the display module is not supplied with voltage. The horn sounds if these faults occur. These faults are only
stored and serve only for internal processing in the control.
Page 20 / 30
5 0 8 3 Horn may sound continuously Output horn, H 07 ) Current path connected to +12V X3:08 5085
5088 Although the output is switched off, voltage X3:36 5086
is present 5087
5 0 9 0 Machine does not start Input inclination switch B56 ) Wire breakage in current path X3:23 1405
The machine cannot be started, because ) Switch defective
) The switch is in actuated state
the input does not receive a signal from the
inclination switch (incorrect installation position)
5 0 9 1 Shut down of diesel engine Input inclination switch B 56 ) Wire breakage in current path X3:23 1405
The diesel engine is shut down because the ) Switch defective
input on the control does not receive a ) The switch is in actuated state
signal from the inclination sensor (machine has turned over) The
machine must first be shut down after it
has been placed in correct position.
5 0 9 2 Shut down of diesel engine Input inclination switch B 56 ) The switch is in actuated state X3:23 1405
The diesel engine is shut down because the (machine has turned over)
input on the control does not receive a
signal from the inclination sensor + start blocking function active
5 1 0 0 Horn sounds, just warning Input cooling water temperature B 53 ) deficit of cooling water X3:05 5100
Cooling water temperature is too high ) cooler broken
) sensor broken
Page 21 / 30
Due to the higher operating current two outputs are switched parallel for operation of the horn.
Page 22 / 30
Page 23 / 30
When reading out the error log this error is usually present.
Page 24 / 30
Page 25 / 30
Page 26 / 30
Page 27 / 30
Page 29 / 30
Due to the higher operating current two outputs are switched parallel for operation of the horn.
Page 30 / 30
With the input codes listed above it is possible to check the transfer of the individual switching signals from the remote controls to the central control unit. For this
purpose start the machine or press the horn button to bring the remote control sender in operating mode for this function test.
For testing the spiral cable switch the operating mode switch to cable operation, connect the spiral cable to the sender and start the machine. If the engine starts,
the spiral cable is OK!
Page 31 / 30
Page 32 / 30
Page 33 / 30
Old: New:
Up to S/N 101720111929 :
Up to S/N 101720111929 the BMP 8500 shows code 5091 in the display, when the
machine tipped over with the engine running. However, after putting the machine back
on the wheels you can restart the engine directly.
If the start lock mode was selected before delivery and the machine tips over now while
the engine is running, the display shows codes 5092, 5091 one after the other. Now the
operator can restart the engine only after he put in three particular input codes.
The input codes are not listed in the operators manual, so the operator has to
contact the workshop now.
Now the work shop can make sure that the oil in the combustion chamber is removed,
can type in the input codes and after that he can restart the engine.
Note: The start lock is activated only, if the machine tipped over with the engine
running.
-1-
If a machine with preselected start lock mode is tipping over, the display is showing
codes 5092, 5091 one after the other, and you cannot restart the engine.
-2-
2. Then type in the input codes 5035, 5034, 5036 (see below)
By this the start lock is opened again.
-3-
F1 F2 F1 F2
-4-
LOGIC Hetronic control with BLM modul (A 70) for BMP 8500
008 922 85
For (see below) The following is necessary (see below)
1
2 Ignition on (K11) Power supply X3:14, X3:28, X3:42
3 Ground on X3:1, X3:15
4 Aktivation signal X3:39 or X3:37 (12 V from transmitter)
5
6 Display on Ground on monitoring module (P18 : 6)
7 Voltage on monitoring module (P18 : 7)
8 Communication between A 70 and P18 through Can - and Can + o.k. [digital>>no constant voltage]
9
10 Display shows CTO Ground on monitoring module (P18 -)
11 Voltage on monitoring module (P18 + )
12 No communication between A 70 and P18 through Can - and Can + [digital>>no constant voltage]
13
14 Engine start Power supply X3:14, X3:28, X3:42
BOMAG
15 Ground on X3:1, X3:15
16 Aktivation signal X3:39 or X3:37 (12 V from transmitter)
17 Initializing program finished ( 2sec after Aktivation signal X3:39 or X3:37 (constantly 12 V)) >> Horn
18 Travel levers in neutral
19 Slope sensor signal 12 V (X3:23)
20 First starting after ignition on (start repeat lock)
Engine not turning >> at least two of the following signals must have the mentioned status >> X3:2
21 [L] on ground, X3:41 [W] lower than 100 Hz, X3:3 [p] on ground
22 Key switch start signal through Can - and Can + [digital>>no constant voltage]
23 code for machine type needs to be adjusted
24
Holding coil of shutt
off solenoid Y13
energized before
25 starting Power supply X3:14, X3:28, X3:42
26 Ground on X3:1, X3:15
7.3
173
174
7.3
Kob, 12.01.2010
LOGIC Hetronic control with BLM modul (A 70) for BMP 8500
BOMAG
37
38 Travel forward Power supply X3:14, X3:28, X3:42
39 Ground on X3:1, X3:15
40 Aktivation signal X3:39 or X3:37 (12 V from transmitter)
Starter switch must have been turned to start position or horn button pushed at least once after
41 ignition on and initializing phase >>> horn
42 Travel lever S 138 in forward position (signal through Can - and Can + [digital>>no constant voltage])
43 proximity switch safety bar in front 12 V (X3: 34)
44
45 Travel revers Power supply X3:14, X3:28, X3:42
46 Ground on X3:1, X3:15
47 Aktivation signal X3:39 or X3:37 (12 V from transmitter)
Starter switch must have been turned to start position or horn button pushed at least once after
48 ignition on and initializing phase >>> horn
49 Proximity switch revers protection bow 12 V (X3:27)
Logic
008 922 85
Kob, 12.01.2010
Logic
LOGIC Hetronic control with BLM modul (A 70) for BMP 8500
008 922 85
For (see below) The following is necessary (see below)
50 Travel lever S138 in revers position (signal through Can - and Can + [digital>>no constant voltage])
51
52
53
54
55
56 high engine rpm Power supply X3:14, X3:28, X3:42
57 Ground on X3:1, X3:15
58 Aktivation signal X3:39 or X3:37 (12 V from transmitter)
Starter switch must have been turned to start position or horn button pushed at least once after
59 ignition on and initializing phase >>> horn
60 Switch S 134 on (signal through Can - and Can + [digital>>no constant voltage])
61 code 0500 must not be activated
During starting of the engine the engine rpm solenoid is generally activated (K114) as long as the
62 NOTE >>> starter is activated.
BOMAG
If there is no signal to travel, vibration or steering for more than 20 seconds, the rpm
63 NOTE >>> falls down (ECO mode)
64
65 2nd speed travel Power supply X3:14, X3:28, X3:42
66 Ground on X3:1, X3:15
67 Activation signal X3:39 or X3:37 (12 V from transmitter)
Starter switch must have been turned to start position or horn button pushed at least once after
68 ignition on and initializing phase >>> horn
69 Switch S 133 on 2nd speed (signal through Can - and Can + [digital>>no constant voltage])
70 code 0500 must not be activated
71 cooling water temperature sensor must not be connected to ground.
72 Note >>>> 2 sec delay
73
74 steering right power supply X3:14, X3: 28, X3: 42
75 Ground on X3:1, X3:15
76 Activation signal X3:39 or X3:37 (12 V from transmitter)
7.3
175
176
7.3
Kob, 12.01.2010
LOGIC Hetronic control with BLM modul (A 70) for BMP 8500
BOMAG
86 amplitude power supply X3:14, X3: 28, X3: 42
87 Ground on X3:1, X3:15
88 Activation signal X3:39 or X3:37 (12 V from transmitter)
Starter switch must have been turned to start position or horn button pushed at least once after
89 ignition on and initializing phase >>> horn
90 cooling water temperature sensor must not be connected to ground.
91 toggle switch S36 switched to low amplitude
92
Vibration high
93 amplitude power supply X3:14, X3: 28, X3: 42
94 Ground on X3:1, X3:15
95 Activation signal X3:39 or X3:37 (12 V from transmitter)
Starter switch must have been turned to start position or horn button pushed at least once after
96 ignition on and initializing phase >>> horn
97 cooling water temperature sensor must not be connected to ground.
98 toggle switch S36 switched to high amplitude
99
Logic
008 922 85
Kob, 12.01.2010
Logic
LOGIC Hetronic control with BLM modul (A 70) for BMP 8500
008 922 85
For (see below) The following is necessary (see below)
100
101
BOMAG
7.3
177
7.3 Logic
8.1 Overview
Fig. 6
Fig. 7
The machine is equipped with four drums. For enhanced traction the drums are provided with padfeet.
In contrast to the previous model this machine is now equipped with
Articulated joint
two amplitudes
and two travel motors
.
Fig. 9
The steering system is hydraulically operated. The steering angle is set by extending a hydraulic cylinder (2) .
Fig. 10 Vibration
The vibration system works with two exciter units (14) (Fig. 9) and (Fig. 10). One exciter unit per axle. Both
exciters are hydraulically driven by means of a common gear pump (13) and one gear motor (5) (Fig. 10) each.
With a tumbler switch the operator can choose between low and high amplitude. The tumbler switch is linked
with a 4/3-way valve, which reverses the sense of rotation of the hydraulic motor. In combination with change-
over weights, two amplitudes are realized this way.
Open circuit
Filter
Cooler (option)
Axial seal Outer pressure field Inner pressure field Radial seal
Sealing zone
Cover Flange Compensation forces
Fig. 1 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. 2
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.
Fig. 3
Vibration pump
The vibration pump is a directly driven gear pump. The vibration pump is the first pump section, viewed from the
drive side.
The vibration pump transports the hydraulic oil from the tank through the control valve block to the vibration mo-
tor and from there back to the tank.
Travel pump
The travel pump is a directly driven gear pump, which is connected with the vibration pump via a coupling.
The travel pumps deliver the hydraulic oil from the tank through the control valve block to the travel motors and
back to the tank.
Steering pump
The steering pump also is a directly driven gear pump, which is connected with the travel pump via a coupling.
Travel pump
Vibration pump Steering pump
Fig. 4
The vibration motors are reversible gear motors. Both vibration motors are connected to the corresponding ex-
citer shaft in the two centre frames via curved tooth couplings and drive the exciter shafts with output speed.
When the gear motor is supplied with pressure oil, a torque can be taken off the protruding output shaft. A dif-
ferentiation is thereby made between motors for one direction of rotation and reversible motors.
Output shaft
for one
direction of rotation
reversible
Fig. 6
The drums are the BMP 8500 are driven by two Eaton Geroller hydraulic motors. Geroller motors are slow run-
ning hydraulic motors with high torque. The series 2000 enables torques of up to 845 Nm, the approved design
is reliable and suitable for a long service life.
With a given oil flow and a given pressure the displacement of the motor (nominal size of motor) determines both
the speed and the torque.
This means:
a) that the speed is determined by the supplied oil flow and
b) the torque depends on the available pressure.
Fig. 1
The plate or distributor valve is arranged on the side of the drive set. The distributor valve is driven synchronous-
ly with the gear set, so that filling and emptying of the individual chambers takes place precisely and without
losses. This valve is separated from the drive shaft and is separately driven by a short universal shaft.
Displacement:
75 l/min. continuous
115 l/min. intermittent
Speed up to 1042 rpm.
Pressure difference:
200 bar continuous
300 bar intermittent
Torque:
845 Nm continuous
930 Nm intermittent
Fig. 2
The drive sets of the hydraulic motors consist of a housing section with internal gearing and a gear wheel, the
centre of which during rotation orbits around the centre of the ring gear.
Geroller hydraulic motors are characterized by a very robust and compact design.
Applications are mainly found in areas where high torques with relatively low rotary speeds are required.
The housing contains a fixed, integrated ring gear.
Long service life.
Highly power output.
Excellent volumetric and mechanical rate of efficiency due to the fixed integrated ORBITAL unit.
Suitable for short-term operation with medium pressure.
Excellently suitable for permanentb operation at medium pressure.
When starting the engine with all control valves set to initial position, hydraulic oil will flow from the travel pump
to the travel direction valve and from there back to the tank.
When switching the travel speed range selector valve to high travel speed, the pump flow from the vibration
pump is also fed to both travel motors. However, in this case the machine cannot be operated with vibration. The
line between the 4/2-way valve and the travel direction valve is fitted with a check valve. This valve prevents oil
flowing out of the travel circuit into the vibration circuit.
With the engine shut down no pressure is applied to the brake cylinder. Due to the internal springs the brake
cylinder is in this case extended and thus prevents rolling of the machine. When the engine is started the steering
pump will direct a hydraulic oil flow through Y04 to the brake cylinder and open the brake.
1.1 Pressure relief valve for travel circuit (250 bar) L2 Leak oil vibration
1.3.1 Retardation brake valve, rear A1 to rear travel motor port A1
1.3.2 Retardation brake valve, front B1 to front travel motor port B1
1.2 4/3 way solenoid valve travel direction valve, A2 to rear vibration motor port A2
(Y16 & Y17)
2.1 Pressure relief valve for vibration circuit B2 to front vibration motor port B2
2.2 4/3-way solenoid valve 2nd gear (Y03) A3 to steering cylinder port A3
2.3 4/3-way solenoid valve vibration (Y56 & Y57)- B3 to steering cylinder port B3
Magnetventil Vibration, Y56 & Y57)
2.4 Pre-loaded check valve BR to port on brake cylinder BR
3.1 Pressure relief valve for steering P1 Connection travel pump P2
3.2 Pressure relief valve for brake P2 Connection vibration pump P1
3.3 3/2-way solenoid valve for brake, Y04 P3 Connection steering pump P3
3.5 4/3-way solenoid valve steering, Y237 & Y238 T1 Return flow to tank via oil cooler
3.6 Pre-loaded check valve T2 Return flow to tank, direct
L1 Leak oil travel control
8.7 Hoses
EDU
% EDU
P
6 6 6
% 7
$ % $ % $ %
EDU
EDU
%HOIWXQJVILOWHU P
&RQWUROEORFN
EDU
0
%5
9HQWLODWLRQILOWHU P
EDU
EDU
EDU EDU 7
3 0 3 0 3 0 / / 7
.KOHU
+HDWH[FKDQJHU
DOOH'UFNHJHPHVVHQEHLHLQHUgOWHPSHUDWXUYRQFD&9HUEUHQQXQJVPRWRULPKRKHQ/HHUODXI
DOOSUHVVXUHPHDVXUHPHQWDWRLOWHPSHUDWXUH&FRPEXVWLRQHQJLQHDWKLJKLGOH
E D <
%UHPVH
< < < EUDNH
7UDQVSRUWJHVFKZLQGLJNHLW
WUDQVSRUWVSHHG
EDU
EDU EDU 7
BOMAG
3 0 3 0 3 0 / / 7
3 3 3
$
EDU
3
6 6 6
P
P
EDU
EDU
% EDU
P
% 7
008 922 85
Travel system
Travel system 8.8
Fig. 3
The travel motor 1 (Fig. 3) is hydraulically driven. The pinion (6) is directly connected with the travel motor and
drives the gear (4). This gear is fitted to the drive shaft (3) by means of a feather key. Both ends of the drive shaft
rest in cylinder roller bearings (2) in the cover of the centre frame.
8.9 Vibration
1 Gear 5 Eccentric
2 Cylinder roller bearing 6 Vibration motor
3 Coupling, vibration motor 7 Exciter unit
4 Change-over weight
The vibration system of the machine is hydraulically driven. The vibration system consists of:
Vibration control
The vibration control elements are integrated in the same valve block as the control elements for the travel sys-
tem. The vibration control is linked with the travel system control as follows:
If the machine is driven with high travel speed, a 2/4-way solenoid valve will cut off the oil flow to the vibration
motor and directs it additionally to the travel circuit.
When the vibration is switched on, the oil flow from the vibration pump must first start rotation of the resting ex-
citer shaft. The pressure (starting pressure) caused by this high starting resistance of the resting exciter shaft is
limited to max. 250 bar by a pressure relief valve inside the control valve block.
Once the final speed of the exciter shafts is reached, the resistance of the exciter shafts becomes lower and the
pressure drops down to a value (operating pressure) which is influenced by external effects (degree of compac-
tion, soil condition, etc.).
The sense of rotation of the vibration motors can be reversed by actuation of a 4/3-way valve. This way the am-
plitude adjustment is realized.
! Caution
If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped, check
all lines, hoses and components for leaks.
In hydraulic systems filled with Panolin HLP
Synth. 46 use only the same oil to top up. With oth-
er ester based oils consult the lubrication oil serv-
ice of the respective oil manufacturer.
For quality of oil refer to the "table of fuels and lu-
bricants".
Fig. 4
i Note
See also the notes on the hydraulic system in the
chapter "General notes on maintenance".
! Danger
Danger of scalding!
When draining off hot hydraulic oil!
! Caution Fig. 5
The hydraulic oil must also be changed after ma-
Unscrew the plug (Fig. 5) and drain off all hydraulic
jor repairs in the hydraulic system.
oil.
Perform the oil change when the hydraulic oil is Turn the plug tightly back in.
warm.
Replace the hydraulic oil filter element with every
hydraulic oil change.
Clean the area round hydraulic oil tank, filler
opening and breather filter.
Do not start the engine after draining the hydraulic
oil.
Do not use any detergents to clean the system.
For quality and quantity of oil refer to the "table of
fuels and lubricants".
When changing from mineral oil based hydraulic
oil to an ester based biologically degradable oil,
you should consult the lubrication oil service of
Fig. 6
the oil manufacturer for details.
Unscrew the filter cover 1 (Fig. 6) and take out the
filter element.
Environment
Catch running out oil and dispose of environmen-
tally. i Note
We recommend to use the BOMAG filling and filtering
Drive the machine, until the hydraulic oil has unit with fine filter to fill the system. This ensures finest
reached operating temperature. filtration of the hydraulic oil, prolongs the lifetime of the
Shut down the engine. hydraulic oil filter and protects the hydraulic system.
Fill in new hydraulic oil.
Insert a new filter and reassemble the filter cover.
Replace the breather filter (2).
Perform a test run and check the system for leaks.
Fig. 7
9.1 Overview
Fig. 8
Fig. 9
Fig. 2
Fig. 1
The special ECO mode additionally protects the en-
gine and ensures a longer service life. If the remote
control does not send a control signal for a few sec-
onds when in travel mode, the engine will automatical-
ly change to idle speed. If an activation signal is
received again, the engine speed is increased again
within fractions of a second, in contrast to convention-
al trench compactors. This results in lower fuel con-
sumption while protecting the environment and being
immediately ready for operation.
Fig. 3
1 Intake manifold
2 Speed control lever
3 (Engine shut-down lever
4 Injection pump
5 Fuel pump
6 Fan
7 V-belt pulley
8 Oil filter element
9 Water drain tap
10 (Cover of the oil filler opening
11 Exhaust manifold
12 Generator
13 Starter
Fig. 6
1 Valve cover
2 Ventilation hose
3 Bleeding valve
4 Oil separator
5 Rubber seal
Fig. 4
The engines are equipped with a closed crankcase
The cylinder sequence is No. 1, No. 2 and No. 3, start-
ventilation to prevent blow-by gases from escaping
ing from the timing gear side.
into the atmosphere. Once the oil vapours have been
separated by the oil separator (4) in the valve cover,
Engine block the blow-by gas is fed through the ventilation valve (3)
into the intake manifold to be combusted again.
Semi-floating valve cover
Fig. 7
Fig. 5
1 Valve cover
2 Rubber seal
A installed rubber seal ensures a distance of approx.
0.5 mm (0.02 inch) between valve cover and cylinder
head. This reduces the development of noise on the
cylinder head.
9.3 Check the engine oil level 9.4 Changing engine oil and oil fil-
ter cartridge
! Caution
The machine must be in horizontal position. When !Danger
the engine is warm, shut it down and check the oil
Danger of scalding!
level after five minutes. With a cold engine the oil
level can be checked immediately. When draining off hot oil.
For quality of oil refer to the "table of fuels and lu- By hot oil when unscrewing the engine oil filter.
bricants".
! Caution
The oil change at 250 operating hours refers to the
use of fuels with a sulphur content of less than
0.5%. When using fuels with a high sulphur con-
tent of 0.5 to 1.0 %, the oil change intervals must
be halved.
Drain the engine oil only when the engine is warm.
For quality and quantity of oil refer to the "table of
fuels and lubricants".
Environment
Catch running out oil and dispose of environmen-
Fig. 8 tally together with the oil filter cartridge.
Pull the dipstick (Fig. 8) out, wipe it off with a lint-
free, clean cloth and reinsert it until it bottoms.
Pull the dipstick back out.
The oil level must always be between the "MIN"- and
"MAX"-marks.
If the oil level is too low top up oil immediately.
If the oil level is too high, determine the cause and
drain the oil off.
Fig. 9
Fig. 10 Fig. 13
Unscrew the filter cartridge (1) (Fig. 10) using an After a short test run check the oil level once again
appropriate filter wrench. (Fig. 13), if necessary top up to the top mark (MAX).
Clean the sealing face on the filter carrier from any
dirt.
Fig. 11
Fig. 12
! Danger ! Danger
Environment
Catch running out coolant and dispose of environ-
mentally.
Fig. 14
Fig. 15
Fig. 16 Fig. 19
Unscrew the drain valve (Fig. 16) from the radiator. Fill in coolant up to the MAX mark (Fig. 19).
Drain the coolant completely off and collect it. Reattach the radiator cap and the cap of the com-
pensation tank.
Screw the drain valve back in.
Start the diesel engine and run it warm to operating
Check the condition of radiator hoses, if necessary temperature.
replace all radiator hoses.
Let the engine cool down and check the coolant lev-
el again, if necessary top up in the compensation
tank.
Fig. 17
Fig. 18
!Danger
Danger of accident!
Perform this work only with the engine shut down.
! Caution
Replace a damaged or cracked V-belt.
Replace the V-belt at the latest after 500 operating
hours.
Fig. 21
Fig. 20
! Caution
Check the V-belt tension again after a running
time of 30 minutes.
i Note
Dirt on fan blades and radiator reduce the cooling ef-
fect. Dirt deposits in these areas are substantially sup-
ported by oil and fuel on these surfaces. For this
reason you should always seal any oil or fuel leaks in
the vicinity of the cooling fan or the radiator and clean
the cooling surfaces after.
!Danger
Danger of injury!
Always wear protective clothes (goggles, gloves)
when working with compressed air.
i Note
Start to blow out from the exhaust side.
Fig. 23
9.9 Changing the fuel filter, bleed- Pull the fuel filter out of the hoses.
ing the fuel system Install the new fuel pre-filter and observe the flow di-
rection (arrow).
Fasten the hose clamps.
! Danger
Fire hazard! Fold the central electrics down again and fasten it.
!Danger
Health hazard!
Do not inhale any fuel fumes.
Environment
Catch running out fuel, do not let it seep into the
ground.
Dispose of the used fuel filter environmentally.
Fig. 26
Replacing the fuel pre-filter.
Loosen and unscrew the fuel filter (Fig. 26) using an
appropriate filter wrench.
Cleaning the sealing face on the filter head.
Fig. 24
Fig. 25
! Danger
Fire hazard!
When working on the fuel system do not use open
fire, do not smoke, do not spill any fuel.
Shut down the engine.
! Danger
Health hazard!
Do not inhale any fuel fumes.
Fig. 28
i Note
Open the bleeding screw on the fuel filter (Fig. 28) The service intervals for the water separator depend
and crank the engine with the starter, until fuel runs on the water content in the fuel and can therefore not
out without air bubbles. be determined precisely. After taking the engine into
Retighten the bleeding screw. operation you should therefore check the water sepa-
rator every day for signs of water.
Environment
Any fuel must be caught and disposed of in an en-
vironmentally friendly manner.
Fig. 29
9.11 Checking fuel lines and 9.12 Check, clean the air filter, re-
clamps place if necessary
! Danger ! Caution
Danger of burning! Do not start the engine after having removed the
air filter.
Perform inspection work only after the engine has
cooled down and with the engine stopped. If necessary, the air filter may be cleaned up to
three times. The air filter must be replaced at the
latest after one year.
! Caution
Cleaning does not make sense if the air filter ele-
If fuel lines or hose clamps are found to be dam-
ment is covered with a sooty deposit.
aged, the corresponding parts must be immedi-
ately repaired or replaced. Do not use gasoline or hot fluids to clean the filter
element.
Removed or new fuel lines must be closed with
clean cloths on both ends, to make sure that no After cleaning the air filter must be inspected for
dirt will enter into the fuel system. Dirt particles damage using a torch.
can destroy the injection pump. Do not continue to use a damaged air filter ele-
Check the condition and tight fit of all fuel lines and ment. If in doubt use a new air filter.
hose clamps. Incorrectly handled air filters may become ineffec-
tive because of damage (e.g. cracks) and cause
damage to the engine.
Fig. 31
Servicing of the air filter is necessary when the yellow
piston (Fig. 31) of the air filter service indicator has
reached the red underlaid inscription "Service".
! Caution
After completion of the filter service reset the indi-
cator back to "Zero" by pressing the button.
Fig. 32
! Caution
Air filters with damaged filter element or seal ring
must be replaced in any case.
Fig. 33
Pull out the main filter element (Fig. 33) with light
turning movements.
Fig. 36
Fig. 34
!Danger
Danger of injury!
Fig. 37
Slide the air filter carefully into the housing (Fig. 37).
Fig. 38
Fig. 1
i Note
Fig. 1
An oil pressure below the permissible limit may have
one of the following causes: Measure and write down the measurement "a" on
the thermostat (Fig. 1).
Engine oil level too low
Oil pump defective
i Note
Oil strainer clogged "a" = beginning of stroke at approx. 69.5°C to 72.5°C
Oil filter cartridge clogged (T1)
Oil gallery clogged "b" = end of stroke at approx. 85 °C (T2)
Excessive oil gap in crankshaft bearings
Foreign bodies in pressure relief valve
Tightening torque:
15 to 19 Nm
Fig. 2
i Note
In order to determine the exact start of opening the
temperature should be measured as close to the ther-
mostat as possible, but without touching it.
The water must thereby be stirred continuously, to en-
sure even temperature distribution.
The temperature increase should not exceed 1°C/ 9.16 Check the injection valves
min, as otherwise the start of opening will be delayed
accordingly.
! Caution
Ensure strict cleanliness when working on the in-
jection system. Use only clean testing oil acc. to
ISO 4113 or clean diesel fuel to test the injection
valves.
!Danger
Keep your hands away from the nozzle spray jet.
Fuel will penetrate deeply into the flesh and may
cause blood poisoning.
Fig. 3
Stroke = b - a
i Note
Stroke:
BMP8500 and BW80 to BW100-5, at the given tem-
perature (T2) approx. 8 mm.
BW100 to BW138-5, at the given temperature (T2) ap-
prox. 6 mm.
If the measured value is not within the factory specifi-
cation, the thermostat needs to be replaced.
Fig. 1
b) Not correct
Mount the injection nozzle to a nozzle tester and
check the nozzle spray pattern.
i Note
If the spray pattern is not ok, replace the nozzle ele-
ment.
Fig. 2 Fig. 4
Mount the injection valve to the nozzle tester (Fig. Mount the injection valve to the nozzle tester (Fig.
2). 4).
Slowly operate the testing lever to measure the Increase the fuel pressure and hold it 130.0 bar
pressure at which fuel starts to emerge from the over a period of 10 seconds.
nozzle.
If this measurement is not compliant with the factory i Note
specifications replace the adjusting shim (1) in the If a fuel leakage is detected, replace the nozzle ele-
nozzle holder in order to adjust the nozzle pressure. ment.
Nominal value: 140.0 to 150.0 bar
Fig. 3
i Note
0.01 mm (0.0004 inch) difference in the adjusting shim
thickness 1 (Fig. 3) results in a opening pressure dif-
ference of approx. 2.35 bar.
Fig. 1
Fig. 2
1 Mark for start of commencement
2 Alignment mark
Fig. 1
Fig. 2
Install an injection nozzle (2) (Fig. 2) set according Remove the injection nozzles.
to factory specifications to the second port of the in- Install a compression tester with nozzle adapter in-
jection pump pressure tester (1). stead of the injection nozzle.
Operate the starter to increase the pressure. Measurement with glow plug adapter
Switch off the starter when fuel emerges from the
injection nozzle. Subsequently turn the flywheel by
hand and increase the pressure to approx. 140.0
bar.
Turn the flywheel back by approx. half a turn and
hold it in this position.
Measure the time by which the pressure has
dropped from 140.0 to 130.0 bar.
i Note
If the measured pressure is below the permissible lim-
iting value replace the pump or have it repaired in a Fig. 4
workshop approved by BOMAG.
Remove the glow plugs.
Factory specification: 140.0 to 130.0 bar, 10 sec-
Install a compression tester with glow plug adapter
onds.
instead of the glow plug.
Permissible limit: 140.0 to 130.0 bar, 5 seconds.
Measurement
1) Once you made sure that the stop lever is in stop
position (no injection) crank the engine with the starter
and measure the compression pressure.
2) Repeat step 1) for each cylinder.
3) If the measured value is below the permissible limit
apply some oil to the cylinder wall through the nozzle
or glow plug bore and measure the compression pres-
sure again.
4) If the compression pressure is still below the per-
missible limit, check the upper clearance, the valve
clearance and the cylinder head.
5) If the compression pressure increases after oil has
been injected, check piston wall and piston rings.
Fig. 5
Crankshaft position 1
IN = Intake valve
EX = Exhaust valve
Crank the engine until both valves on cylinder 1 are
“overlapping”.
Perform the adjustment of the valve by following the
adjustment diagram 1"(Fig. 5), black mark.
Fig. 6
Fig. 7
Crankshaft position 2
IN = Intake valve
EX = Exhaust valve
Turn the crankshaft one revolution (360 °) further.
Perform the adjustment of the valve by following the
adjustment diagram 2"(Fig. 7), black mark.
Assemble the cylinder head cover with a new gas-
ket.
i Note
After a short test run check the engine for leaks.
Fuel lines leaking Check all line connections for leaks and
tighten the fittings
Battery not charged or not connected Charge the battery, check the pole
clamps
Fuel supply too low, fuel system clogged Change the fuel filter. Check the line con-
by paraffin separation during winter nections for leaks and tighten the fittings.
Use winter fuel under cold conditions
The specified valve clearance is not cor- Adjust the valve clearance
rect
Engine looses Engine oil level too high Drain the oil down to the top dipstick mark
power and
speed, exces- Air filter dirty clean, if necessary use a new one
sive exhaust Poor compression due to burned or bro- Have piston rings and pistons examined
smoke ken piston rings or incorrect valve clear- by a specialist, adjust the valve clearance
ance
Engine over- Cooling fins heavily soiled Clean the cooling fins
heating, engine
must be shut Injection valve defective Have examined by a specialist
down immedi- Engine oil level too high Drain the oil down to the top dipstick mark
ately!
Injection pump displacement not correctly Have corrected by a specialist
adjusted
Lack of cooling air Remove any clogging from the cooling air
duct
Engine has too Leaks in the lubrication system, oil level Check fittings on oil lines and lubrication
low oil pressure, too low oil filter for leaks, if necessary tighten all
engine must be fittings Fill up engine oil up to the mark on
immediately the dipstick
shut down!
Engine oil with wrong SAE viscosity class Change the engine oil
Charge control The generator does not charge the bat- Have examined by a specialist
light lights up tery, because of defect on generator or
during operation regular
Fig. 1
Fig. 1
2. Puller
Fig. 2
Environment
Catch running out oil and dispose of environ-
mentally.
! Danger
Danger of injury!
Do not step under suspended loads.
1. Enter input code 500 (see chapter 7) and drive
the machine, until the brake engages.
Dismantling
2. Lift the machine up and support it safely.
3. Unscrew the fastening screws and remove the
drums on both sides.
Fig. 1
4. Unscrew fastening screw 1 (Fig. 2) and replace it
with a grub screw.
Fig. 2
5. Remove backing ring 1 (Fig. 3) and seal (2).
Fig. 3
i Note
At the rear always remove the left hand hub,
when viewed in travel direction.
At the front always remove the right hand hub,
when viewed in travel direction.
Fig. 4
i Note
Disassemble drum and cover on the opposite
machine side as described under 1. - 6.
7. Unscrew the fastening screw 1 (Fig. 5) from the
cover.
8. Turn the fastening screws into the bores (2) and
force off the cover.
Fig. 5
9. Check the Nilos ring 1 (Fig. 6) for damage, re-
place if necessary.
Fig. 6
10. Pull out the drive shaft 1 (Fig. 7).
Fig. 7
Fig. 8
12. Remove circlip 1 (Fig. 9).
13. Pull the bearing (2) out of the cover.
14. Take out the Nilos ring (3).
Fig. 9
15. Remove circlip 3 (Fig. 10) dfrom the drive shaft.
16. Pull off the gear (4) and remove the feather key
(2) from the keyway.
Fig. 10
Assembly
1. Assemble pinion 1 (Fig. 1) with copper paste to
the travel motor.
2. Turn in the threaded socket.
Fig. 1
3. Install the travel motor 1 (Fig. 2) and connect the
hydraulic hoses.
Fig. 2
4. Place the Nilos ring 1 (Fig. 3) into the cover.
5. Knock in the bearing (2).
6. Assemble circlip (3).
Fig. 3
7. Fill the bearing with grease (Fig. 4).
Fig. 4
Fig. 5
9. Fill the radial seal with grease (Fig. 6).
Fig. 6
10. Place the radial seal 1 (Fig. 7) into the cover.
Fig. 7
11. Assemble hub 1 (Fig. 8).
! Caution
Clean the hub thoroughly.
The inner ring must be free of grease!
Fig. 8
Fig. 9
14. Insert the drive shaft into the hub.
15. Apply some grease to the gear (Fig. 10).
Fig. 10
16. Turn in fastening screw 3 (Fig. 11) with washer
(1) and spring washer (2).
Fig. 11
17. Clean the sealing face and apply a coat of OMNI-
FIT FD10 (P/N 009 700 16) and assemble the
new O-ring.
18. Assemble cover and drive shaft and insert a new
sealing ring (Fig. 12).
Fig. 12
Fig. 13
21. Assemble the backing ring 1 (Fig. 14) with a new
seal (2).
Fig. 14
Assembly
Fig. 15
Removal
l Unscrew the fastening screws and take off
the drum extensions.
l Turn the fastening screws back into the
drum and fasten.
Fig. 1
2. Puller
Fig. 2
Danger of injury!
Do not step under suspended loads.
1. Enter input code 500 (see chapter 7) and drive
the machine, until the brake engages.
Dismantling
2. Lift the machine up and support it safely.
3. Unscrew the fastening screws and remove the
drums on both sides.
Fig. 1
4. Unscrew fastening screw 1 (Fig. 2) and replace it
with a grub screw.
Fig. 2
5. Remove backing ring 1 (Fig. 3) and seal (2).
Fig. 3
i
At the rear always remove the left hand hub,
when viewed in travel direction.
At the front always remove the right hand hub,
when viewed in travel direction.
Fig. 4
i
Disassemble drum and cover on the opposite
machine side as described under 1. - 6.
7. Unscrew the fastening screw 1 (Fig. 5) from the
cover.
8. Turn the fastening screws into the bores (2) and
force off the cover.
Fig. 5
9. Check the Nilos ring 1 (Fig. 6) for damage, re-
place if necessary.
Fig. 6
10. Pull out the drive shaft 1 (Fig. 7).
Fig. 7
Fig. 8
12. Unscrew the locking cap 1 (Fig. 9) from the centre
frame.
Fig. 9
13. Unscrew the fastening screws 1 (Fig. 10) from the
cover.
14. Turn the fastening screws into the bores (2) and
force off the cover.
15. Also disassemble the cover from the opposite
side.
Fig. 10
16. Pull the exciter shafts out of the housing.
Fig. 11
Fig. 12
18. Pull the bearing 1 (Fig. 13) out of the flange.
Fig. 13
Fig. 1
2. Assemble the circlip 1 (Fig. 2).
i
Repeat steps 1. - 2. on the opposite side of the
centre frame.
Fig. 2
3. Assemble gear 3 (Fig. 3) with feather key (2) to
the exciter shaft.
4. Pull the bearing shell (1) over the shaft end.
Fig. 3
5. Fasten coupling 1 (Fig. 4) with fastening screws
(2) to the exciter shaft on the motor side.
Fig. 4
Fig. 5
8. Insert the exciter shaft without coupling.
Fig. 6
9. Fill 1.7 l of engine oil into the exciter housing.
Fig. 7
Danger of squashing!
10. Guide the exciter shaft 1 (Fig. 8) on the motor
side into the exciter housing using a suitable tube
(2).
Fig. 8
Fig. 9
12. Press bearing 1 (Fig. 10) into the flange.
13. Assemble the new O-ring (2).
14. Clean the sealing face (3) and apply a coat of
OMNIFIT FD10 (P/N 009 700 16).
Fig. 10
15. Assemble the flange and tighten the fastening
screws 1 (Fig. 11).
i
repeat steps 12. - 16. with the second flange.
Fig. 11
16. Knock the locking cap 1 (Fig. 12) into the housing.
Fig. 12
17. Insert the circlip 2 (Fig. 13) into the curved tooth
coupling.
Fig. 13
18. Plug the curved tooth coupling (Fig. 14) on the vi-
bration motor.
19. Assemble the new O-ring.
20. Clean the sealing face and apply a coat of OMNI-
FIT FD10 (P/N 009 700 16).
Fig. 14
21. Install the vibration motor 1 (Fig. 15).
Fig. 15
23. Clean the sealing face and apply a coat of OMNI-
FIT FD10 (P/N 009 700 16) and assemble the
new O-ring.
24. Assemble cover and drive shaft and insert a new
sealing ring (Fig. 16).
Fig. 16
Fig. 17
27. Assemble the backing ring 1 (Fig. 18) with a new
seal (2).
Fig. 18
Fig. 22
Fig. 20
Fig. 24
Fig. 25
® No. 7-124
Char-Lynn July, 1999
Hydraulic Motor
Repair Information
2000 Series
Disc Valve Geroler Motor 006
Valve
Plate
Seal
Splined Geroler
Drive
Shaft
Face Seal Seal
Wear
Bearing and Plate
Shaft
Shaft
Seal
Assembly
Key
Bearing Back-up
Housing Washer Valve
Drive O-ring/
Seal Plug S/A
Valve
Exclusion Housing Tie
Dash Pot
Seal Spring Bolt
Outer Spring
Face Seal
Poppet
Balance
Seal Piston
Ring
Valve Poppet
Spring
Dash Pot
O-ring/ O-ring/
Pin
Plug S/A Plug S/A
Inner
Face Seal Shuttle Vave Option
Disassembly
Cleanliness is extremely important when repairing a hydraulic motor. 2 Remove 4 bolts from motor.
Work in a clean area. Before disconnecting the lines, clean the port
area of the motor thoroughly. Use a wire brush to remove foreign
material and debris from around the exterior joints of the motor.
Check the shaft and key slot, remove all nicks, burrs or sharp edges
that might damage the bearing housing seals when installing the shaft
and bearing assembly. Before starting the disassembly procedures,
drain the oil from inside the motor.
Figure 3
3 Lift valve housing straight up. If done carefully the pins, springs,
balance ring assembly, and valve will remain on the valve plate.
Figure 1
1 Place the motor in a vise with the output shaft down. Clamp
across the mounting flange of the motor not the housing. Excessive
clamping pressure will cause distortion. When clamping, use some
protective device on the vise, such as special soft jaws, pieces of hard
rubber or board.
Although not all drawings show the motor in a vise, we recommend Seal Seal Case Drain Plug
that you keep the motor in the vise during disassembly and reas-
sembly. Follow the clamping procedures explained throughout the Figure 4
manual.
Tie Bolts
Figure 2
Disassembly
Figure 5 Figure 8
Shaft and
Bearing
Assembly
Seal Valve Plate
Figure 9
Figure 6
19 You may need a press to remove shaft and bearing assembly from
bearing housing. (Key must be removed before removing shaft.)
10 Remove the valve plate.
11 Remove the 76,0 [3.00] diameter seal from valve plate.
12 Remove the valve drive. Bearing Housing Shaft Seal
Exclusion
Seal
Seal
Back-up Washer
Seal Geroler
Figure 10
Figure 7 20 Use a small screwdriver to remove shaft seal, back-up washer and
exclusion seal from bearing housing, see Figure 10. Do not damage
13 Remove the Geroler. Be sure to retain the rollers in the outer ring bore of housing.
if they are loose. Note: Individual parts of shaft and bearing assembly are not sold
14 Remove the drive. separately. Replace as a unit.
Reassembly
Check all mating surfaces. Replace any parts that have scratches or 26 Alignment studs can be very helpful in reassembly of the motor.
burrs that could cause leakage. Clean all metal parts in clean solvent. See special tool listing page 2. If you use studs, install 2 studs
Blow dry with air. Do not wipe dry with cloth or paper towel because diagonally opposed in the bearing housing.
lint or other matter can get in the hydraulic system and cause damage. 27 Install the shaft face seal in the wear plate as shown in Figure 11.
Do not use a coarse grit or try to file or grind these parts. Check Do not distort seal.
around the keyway and chamfered area of the shaft for burrs, nicks or
sharp edges that can damage the seals when reassembling the bearing 28 Install the wear plate, see Figure 11.
housing. 29 Apply a light film of petroleum jelly to the 76,0 [3.00] diameter seal
Note: Lubricate all seals (prior to installation) with petroleum jelly such and install seal in the wear plate.
as Vaseline. Use new seals when reassembling this motor. Refer to 30 Install the drive into the output shaft.
parts list (6-129) for proper seal kit number.
31 Align the notch on the outside of the Geroler with the notch on the
21 Use a press to install exclusion seal in outer bore of bearing wear plate. Install the Geroler against the wear plate. Be sure to retain
housing. Lip of seal must face outward. See Figure 11. If a press is the rollers in the outer ring if they are loose.
not available use a plastic or rubber hammer, being careful not to
damage or cock seal in the bore. 32 Install the valve drive in the Geroler.
Note: Installation at this time involves 3 steps in the timing of the
motor. Timing determines the direction of rotation of the output shaft.
Timing parts include:
Shaft Face
1. Geroler
Shaft Seal Shaft Face 2. Valve Drive
Seal 3. Valve Plate
4. Valve
Wear Plate
Back-up
Washer
Exclusion Seal
Seal
Geroler Valve Plate Valve
Valve
Shaft and Drive Drive Rotate
Bearing Valve
Assembly Clockwise
1/2 tooth max.
to Engage Spline
Figure 11
Anyone of
22 Place back-up washer into seal bore. Place shaft seal onto Largest Alignment 6 Ports Open
installation tool (600496) and press seal into seal bore of the Open Pocket Ref. Only to Ouside of Vave
housing.
23 Clamp housing in vise, see Figure 1. Figure 12 Timing Alignment
24 Place protective bullet (see note below) over shaft. Apply
petroleum jelly to inside diameter of dust and shaft seal. You may
need a press to install shaft and bearing assembly. Do not distort
Timing Step # 1 — Locate the largest open pocket in the Geroler and
shaft seal. Damage to this seal will cause leakage.
mark it on the outside edge of the Geroler.
Note: Bullet (600465), for 1inch dia. shafts, available— by special
33 Apply a light film of petroleum jelly to the 76,0 [3.00] diameter
order. Use tape over other shafts to prevent cutting the seals.
seal. Install seal in groove of valve plate.
25 Apply petroleum jelly to the 76,0 [3.00] diameter seal. Install
seal into the bearing housing.
Reassembly
34 Align the notch on the outside of the valve plate with the notch on
the Geroler as shown in Figure 12.
Important: Install face seals in the positions shown in Figure 15, or the
Timing Step # 2 — Locate the slot opening in the valve plate which is motor will not operate properly. Do not force or bend the face seals.
in line with the largest open pocket of the Geroler. Any damage to these seals will affect the operation of the motor.
Timing Step # 3 — Locate any one of the side openings of the valve
and align this opening with the open slot of the valve plate that is in Outer Seal Inner Seal Pin Notch
line with the largest open pocket of the Geroler. Install the valve by
rotating it clockwise until the spine teeth engage (1/2 spine tooth
max.). This will provide the proper rotation when pressurized as
shown in Figure 13.
Balance Ring
Figure 15
38 Align pin notches in balance ring with pins in bore of valve housing.
Install balance ring assembly in valve housing.
Clockwise
Rotation
Balance
Counter Ring
Clockwise
Rotation
Figure 13 Valve
Housing
Figure 16
Alignment
Valve
Studs
Seal Housing
Figure 14 Valve
Plate
35 Install 2 springs and 2 pins in the holes located in the bore of the
valve housing, as shown in Figure 14. Figure 17
36 Apply a light film of petroleum jelly to the 76,0 [3.00] diameter
seal. Install seal in the valve housing.
37 Apply petroleum jelly to inner and outer face seals. Install seals 39 Insert your finger through port of valve housing. Apply pressure
on balance ring as shown in Figure 15. to side of balance ring as shown in Figure 16. Hold ring in position
until valve housing is in place against valve plate (see Figure 17).
Note: After installing the valve housing on the valve plate check for
proper placement. Push down on the valve housing. You should
get a slight spring action.
Reassembly
40 Install tie bolts. If you use alignment Studs, install 2 bolts opposite
the studs. Finger tighten the bolts. Remove the alignment studs and Tie Bolts
replace with the two remaining bolts. Torque all four bolts alternately
to 50 Nm [450 lb-in].
41 Install seal on case drain plug then install in valve housing. Torque Case Drain Plug with Seal
to 6 Nm [50 lb-in.]
Figure 18
Bearing Housing
Back-up Washer
Seal
Exclusion Seal
Figure 19
Exclusion Seal
Seal Guard
Wheel Motor
with Seal Guard 4,40[.177]
Installation of Seal Guard:
After completing assembly of the shaft and bearing assembly into the
bearing housing, press the seal guard onto the shaft with a tool that
will provide an even push over the seal. This tool must bottom out
against the bearing housing and provide a 4,5 mm [.177 inch] stop for
the seal guard.
Reassembly —
Speed Sensor
Alignment Notchs
haft
Perpendicular to
l w ith otor S
Centerline of Motor lle fM
Alignment Notch Para erline o
en t
C
Alignment Nut
Figure 24 Figure 25 9/16 inch
90° Hex Head
Back out
Lock Nut
11/16 inch
Hex Head Alignment Notch
Product Identification
For Additional Literature Contact Eaton Corp. Hydraulics Char-Lynn ® Date Code
Division 15151 Highway 5 Eden Prairie, MN 55344. Product number 00 00
Specifications and performance data, Catalog No. 11-878
Week of Last
Replacement part numbers and kit information — Parts Eaton Corp. Hydraulics Div. Year 01 Number(s)
Eden Prairie, MN 55344
Information No. 6-129 Thru 52 of Year
Product Number
How to Order Replacement Parts 000 0000 000
Each Order Must Include the Following: Product Line Product Engineering
1. Product Number 4. Part Number Identification Identification Change
2. Date Code 5. Quantity of Parts Number Number Code
3. Part Name
Product Numbers—2000 Series Use digit prefix —104-, 105-, or 106- plus four digit number from charts 104-1007
for complete product number—Example 106-1039.
Displacement cm3/r [ in3/r ] and Product Number
80 100 130 160 195 245 305 395 490
Mounting Shaft Ports [ 4.9] [ 6.2] [ 8.0] [ 9.6] [11.9] [14.9] [18.7] [24.0] [29.8]
7/8-14 O-ring Staggered 104-1001 -1002 -1003 -1004 -1005 -1006 -1007 -1143 —
1 inch Straight
1-1/16—12 O-ring 180° Apart 104-1037 -1038 -1039 -1040 -1041 -1042 -1043 -1044 —
2 Bolt 7/8-14 O-ring Staggered 104-1022 -1023 -1024 -1025 -1026 -1027 -1028 -1228 -1420
SAE A 1-1/4 Inch Straight
Flange 1-1/16—12 O-ring 180° Apart 104-1061 -1062 -1063 -1064 -1065 -1066 -1067 -1068 -1421
1-1/4 Inch 7/8-14 O-ring Staggered 104-1029 -1030 -1031 -1032 -1033 -1034 -1035 -1229 -1422
14 T Splined 1-1/16—12 O-ring 180° Apart 104-1087 -1088 -1089 -1090 -1091 -1092 -1093 -1094 -1423
1-1/4 Inch Straight 7/8-14 O-ring Staggered 104-1200 -1201 -1202 -1203 -1204 -1205 -1206 -1207 —
2 Bolt
SAE B 1-1/4 In. Involute SAE C Splined 7/8-14 O-ring Staggered 104-1208 -1209 -1210 -1211 -1212 -1213 -1214 -1215 —
Flange 1 Inch SAE 6B Splined 7/8-14 O-ring Staggered 104-1193 -1194 -1195 -1196 -1197 -1198 -1199 — —
7/8 Inch SAE B Splined 7/8-14 O-ring Staggered 104-1216 -1217 -1218 -1219 -1220 — — — —
Standard 32 mm Straight G 1/2 (BSP) 104-1384 -1385 -1386 -1387 -1388 -1389 -1390 -1391 —
with 4 Bolt
Square 1-1/4 Inch
Flange G 1/2 (BSP) 104-1376 -1377 -1378 -1379 -1380 -1381 -1382 -1383 —
14 T Splined
7/8-14 O-ring Staggered 105- — — — — — — — — -1148
1-1/4 Inch Straight
1-1/16—12 O-ring 180° Apart 105- — — — — — — — — -1149
32 mm Straight G 1/2 (BSP) 105-1134 -1135 -1136 -1137 -1138 -1139 -1140 -1141 —
Wheel
Motor 1-1/4 Inch 7/8-14 O-ring Staggered 105-1001 -1002 -1003 -1004 -1005 -1006 -1007 -1060 -1152
Tapered
1-1/16—12 O-ring 180° Apart 105-1071 -1072 -1073 -1074 -1075 -1076 -1077 -1078 —
1-1/4 Inch 7/8-14 O-ring Staggered 105-1029 -1030 -1031 -1032 -1033 -1034 -1035 -1096 —
14 T Splined 1-1/16—12 O-ring 180° Apart 105-1079 -1080 -1081 -1082 -1083 -1084 -1085 -1086 —
7/8-14 O-ring Staggered 106-1008 -1009 -1010 -1011 -1012 -1013 -1014 -1015 -1047
Bearingless
G 1/2 (BSP) 106-1038 -1039 -1040 -1041 -1042 -1043 -1044 -1045 —
10
Notes:
11
Eaton Corporation Eaton Ltd. Eaton B.V. Sumitomo Eaton Hydraulic Co.
Hydraulics Division Hydraulics Division Boeing Avenue 11 8 Temasek Blvd.
15151 Hwy. 5 Glenrothes, Fife 1119 PC Schiphol-Rijk 42-01 Suntec Tower Three
Eden Prairie, MN 55344 Scotland, KY7 4NW The Netherlands Singapore 03988
Telephone: 612/937-7254 Telephone: [+44] (0)1592-771-771 Telephone: [+31] (0)20-655 6776 Telephone: [+65] 832-7727 ACCREDITED BY
THE DUTCH COUNCIL
Fax: 612/937-7130 Fax: [+44] (0)1592-773-184 Fax: [+31] (0)20-655 6800 Fax: [+65] 832-7733 FOR CERTIFICATION
Reg. No. 24
Hydraulic Company Ltd. 7th Floor, Woo Duk Building 388 Aidu Road, Waigaogiao FTZ 6 Ji Da Road
Qualitiy System Certified
Ooi-Cho Kameoka-Shi 832-2 Yeoksam-Dong, Kangnam-Ku Pudong New Area Jining City Products in this catalog are manufactured
621-0017 Kyoto Soeul 135-750 Shanghai 200137 Shandong Province 272131 in an ISO-9001-certified site.
Japan Korea Peoples Republic of China Peoples Republic of China
Telephone: [+81] 771-22-9601 Telephone: [+82] 2-557-0595 Telephone: [+86] 21-5046 0758 Telephone: [+86] 537-2221288
Fax: [+81] 771-29-2020 Fax: [+82] 2-557-1634 Fax: [+86] 21-5046 0767 Fax: [+86] 537-2221557
www.eatonhydraulics.com
Copyright Eaton Corporation, 1985, 1988, 1994, 1996, 1997 and 1999
All Rights Reserved
Form No. 7-124 Printed in USA
280
%RPDJ*PE+
14.1
+HOOHUZDOG +\GUDXOLNVFKDOWSODQ
%RSSDUG
+\GUDXOLFVFKHPDWLF
3URMHNWEHVFKUHLEXQJ %03
3URMHFWGHVFULSWLRQ
=HLFKQXQJVQXPPHU
'UDZLQJQXPEHU
7\S
BOMAG
7\SH
0DVFKLQHQKRFKQXPPHU
0DFKLQHLQGH[
(UVWHOOWDP
&UHDWHGRQ
YRQ.U]HO
%HDUEHLWHWDP KDJHQ
(GLWGDWH E\VKRUWQDPH
Hydraulic diagram 248
008 922 85
=HLFKQXQJVQXPPHU
%HDUE GUDZLQJQXPEHU
%ODWW
(GE\ %03 'HFNEODWW 3DJH
'RNXPHQWDUW
*HSU ,+DJHQ FRYHUVKHHW GRFXPHQWW\SH
%ODWW
$SSU 3DJH
6SDOWH;HLQHDXWRPDWLVFKHU]HXJWH6HLWHZXUGHPDQXHOOQDFKEHDUEHLWHW
,QKDOWVYHU]HLFKQLV 7DEOHRIFRQWHQWV &ROXPQ;$QDXWRPDWLFDOO\JHQHUDWHGSDJHZDVHGLWHG )B
%HDUEHLWHU
6HLWH 3DJH 6HLWHQEHVFKUHLEXQJ 3DJHGHVFULSWLRQ 'DWXP 'DWH (GLWHGE\
;
'HFNEODWW FRYHUVKHHW +$*(1 ;
,QKDOWVYHU]HLFKQLV 7DEOHRIFRQWHQWV KDJHQ
hEHUVLFKW 2YHUYLHZ KDJHQ
008 922 85
+\GUDXOLNVFKDOWSODQ +\GUDXOLFVFKHPDWLF KDJHQ
%HWULHEVPLWWHOOLVWH 'HYLFHWDJOLVW KDJHQ
Hydraulic diagram 248
BOMAG
14.1
281
=HLFKQXQJVQXPPHU
%HDUE GUDZLQJQXPEHU
%ODWW
(GE\ %03 ,QKDOWVYHU]HLFKQLV 3DJH
'RNXPHQWDUW
*HSU ,+DJHQ 7DEOHRIFRQWHQWV GRFXPHQWW\SH
%ODWW
$SSU 3DJH
282
14.1
BOMAG
Hydraulic diagram 248
008 922 85
=HLFKQXQJVQXPPHU
%HDUE GUDZLQJQXPEHU
%ODWW
(GE\ %03 hEHUVLFKW 3DJH
'RNXPHQWDUW
*HSU ,+DJHQ 2YHUYLHZ GRFXPHQWW\SH
%ODWW
$SSU 3DJH
KLQWHQ YRUQH KLQWHQ YRUQH
UHDU IURQW UHDU IURQW
008 922 85
$ % $ % $ %
NOHLQH9LEUDWLRQ JURH9LEUDWLRQ
VPDOOYLEUDWLRQ ODUJHYLEUDWLRQ
EDU EDU
E D D E
< < < <
OHQNHQUHFKWV OHQNHQOLQNV
VWHHUULJKW VWHHUOHIW
Hydraulic diagram 248
EDU %5
IDKUHQYRUZlUWV IDKUHQUFNZlUWV
WRGULYHIRUZDUG
WRGULYHEDFNZDUG
E D <
%UHPVH
< < < EUDNH
7UDQVSRUWJHVFKZLQGLJNHLW
WUDQVSRUWVSHHG
EDU
EDU EDU 7
3 3 3 / / 7
BOMAG
3 3 3
$
EDU
3
6 6 6
P
P
EDU
EDU
% EDU
P
% 7
14.1
283
=HLFKQXQJVQXPPHU
%HDUE GUDZLQJQXPEHU
%ODWW
(GE\ %03 +\GUDXOLNVFKDOWSODQ 3DJH
'RNXPHQWDUW
*HSU ,+DJHQ +\GUDXOLFVFKHPDWLF GRFXPHQWW\SH
%ODWW
$SSU 3DJH
%HWULHEVPLWWHOOLVWH'HYLFHWDJOLVW )B
7HFKQLVFKH'DWHQ 7HFKQLVFKH'DWHQ
284
%HWULHEVPLWWHONHQQ]HLFKHQ )XQNWLRQVWH[W 49: WHFKQLFDOGDWD 6\PERO %HWULHEVPLWWHONHQQ]HLFKHQ )XQNWLRQVWH[W 49: WHFKQLFDOGDWD 6\PERO
'HYLFHWDJ )XQFWLRQWH[W ;5HI 0HVVZHUW 6\PERO 'HYLFHWDJ )XQFWLRQWH[W ;5HI 0HVVZHUW 6\PERO
0HWHUHGYDOXH 0HWHUHGYDOXH
14.1
$
3 3 3
EDU
3
'UHLIDFKSXPSH FPñFPñFPñ 5FNODXIVDXJILOWHU PP
P
7ULSOH[SXPS 5HWXUQVXFWLRQILOWHU
EDU
% EDU
P
6 6 6 % 7
$ % $ % $ %
EDU EDU
6WHXHUEORFN %HOIWXQJVILOWHU P
EDU %5 P
&RQWUROEORFN 9HQWLODWLRQILOWHU
EDU
EDU
EDU EDU 7
3 3 3 / / 7
BOMAG
9LEUDWLRQVPRWRUYRUQH FPñ
9LEUDWLRQPRWRUIURQW
.KOHU
+HDWH[FKDQJHU
DOOH'UFNHJHPHVVHQEHLHLQHUgOWHPSHUDWXUYRQFD&9HUEUHQQXQJVPRWRULPKRKHQ/HHUODXI
Hydraulic diagram 248
008 922 85
DOOSUHVVXUHPHDVXUHPHQWDWRLOWHPSHUDWXUH&FRPEXVWLRQHQJLQHDWKLJKLGOH
=HLFKQXQJVQXPPHU
%HDUE GUDZLQJQXPEHU
%ODWW
(GE\ %03 %HWULHEVPLWWHOOLVWH 3DJH
'RNXPHQWDUW
*HSU ,+DJHQ 'HYLFHWDJOLVW GRFXPHQWW\SH
%ODWW
$SSU 3DJH
14.2 Wiring diagram 73
%RPDJ*PE+
,QGXVWULHJHELHW+HOOHUZDOG
'%RSSDUG
BOMAG
Wiring diagram 73
008 922 85
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW &RYHUVKHHW
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
'HFNEODWW (LQEDXRUW (3(
7DEOHRIFRQWHQWV
008 922 85
,QKDOWVYHU]HLFKQLV
3DJH +LJKHUOHYHOIXQFWLRQ )XQFWLRQ
%ODWW $QODJH )XQNWLRQ 'HVFULSWLRQ %HVFKUHLEXQJ
&RYHUVKHHW 'HFNEODWW
7DEOHRIFRQWHQWV ,QKDOWVYHU]HLFKQLV
Wiring diagram 73
VXSSO\HQJLQHVWRS530SUHKHDWLQJ 9HUVRUJXQJ0RWRU6WRS'UHK]DKO9RUJOKHQ
0RGXO%/0VROHQRLGYDOYHV 0RGXO%/00DJQHWYHQWLOH
0RGXO%/0GLDJQFRQQHFWRUUHOD\V 0RGXO%/0'LDJQ6WHFNHU5HODLV
0RGXO%/0VORSHVHQVRUVDIHW\GHYLFHZDUQLQJKRUQ 0RGXO%/01HLJXQJVVHQVRU6LFKHUKHLWVHLQU+XSH
6DIHW\GHYLFHEXUJODU\SURWHFWGLDJQPRGXOH 6LFKHUKHLWVHLQU'LHEVWDKOVFKXW]'LDJQRVH0RGXOH
5HPRWHFRQWUROUHFHLYHUDQWHQQD )HUQVWHXHUXQJ(PSIlQJHU$QWHQQH
'HYLFHWDJOLVW %HWULHEVPLWWHOOLVWH
'HYLFHWDJOLVW %HWULHEVPLWWHOOLVWH
3LQRYHUYLHZ$ 3LQhEHUVLFKW$
3OXJRYHUYLHZ 6WHFNHUEHUVLFKW
3OXJRYHUYLHZ 6WHFNHUEHUVLFKW
2YHUYLHZHQJLQHOK hEHUVLFKW0RWRUOLQNH6HLWH
2YHUYLHZHQJLQHUK hEHUVLFKW0RWRUUHFKWH6HLWH
2YHUYLHZ&HQWUDO(OHFWULF hEHUVLFKW=HQWUDOHOHNWULN
2YHUYLHZIURQWUHDUIUDPH hEHUVLFKW5DKPHQYRUQKLQWHQ
BOMAG
14.2
287
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 7DEOHRIFRQWHQWV
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
,QKDOWVYHU]HLFKQLV (LQEDXRUW (3(
288
14.2
%
/
9 ) &
$
%R[$
5
RKP . )
D $
'
%R[$
; ;
; ;
$ & *
,* / ) ) )
$ $ $
* %R[$ %R[$ %R[$
*
*HQHUDWRU
*HQHUDWRU % % :
*URXQG&HQWUDO(OHFWULF . . .
( 0DVVH=HQWUDOHOHNWULN
D D D
) ;
$
%R[$
;
BOMAG
$ $ %/0
$ $
0DFKLQHFRQWUROOHU 0DFKLQHFRQWUROOHU 6$ 6(
%/0 %/0 ; ;
[$
=
*URXQG&HQWUDO(OHFWULF (QJLQHUSP $OWHUQDWRUFKDUJH
0DVVH=HQWUDOHOHNWULN
0RWRUGUHK]DKO /LFKWPDVFKLQH'
; ; 5 5 5
*ORZSOXJ
*OKNHU]H
) $: +:
$ DX[ $:+:
)XVH0DLQ
+DXSWVLFKHUXQJ % 67 9 9
<
+:$ <
0 $:$ +:$
* $:$ *;
9$K$K(1 6WDUWHU
EDWWHU\
%DWWHULH 6WDUWHU B ;
0
6 =
'LVFRQQHFWVZLWFKEDWWHU\
%DWWHULHWUHQQVFKDOWHU ; %
6ROHQRLGPRWRU
+XEPDJQHW0RWRU 6ROHQRLGYDOYH5SP(QJLQH
+XEPDJQHW0RWRUGUHK]DKO
= =
*URXQG)UDPH *URXQG&HQWUDO(OHFWULF
0DVVH5DKPHQ 0DVVH=HQWUDOHOHNWULN
Wiring diagram 73
008 922 85
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW VXSSO\HQJLQHVWRS530SUHKHDWLQJ
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
9HUVRUJXQJ0RWRU6WRS'UHK]DKO9RUJOKHQ (LQEDXRUW (3(
&$1
&$1
008 922 85
&DFWLY
5DFWLY
)
UHVLVWRU
) 5 :LGHUVWDQG
$
%R[$
2KP
'
Wiring diagram 73
$ UHVLVWRU
%20$*PRGXOH%/0 5 :LGHUVWDQG
%20$*/HLVWXQJVPRGXO
P$PD[$ 2KP
; ; ; ; ; ; ; ;
; ; ; ; ; ; ; ;
6( 8% 8% 8% 6($NW 6($NW &+ &/
$ $ $ $ $ $ $ $
*URXQG *URXQG 7UDYHOGLUHFWLRQIRUZDUG 7UDYHOGLUHFWLRQEDFNZDUGV %UDNH 9LEUDWLRQORZ 9LEUDWLRQKLJK 7UDYHOGLUHFWLRQOK 7UDYHOGLUHFWLRQUK QGVSHHGUDQJH
0DVVH 0DVVH )DKUWULFKWXQJYRUZlUWV )DKUWULFKWXQJ5FNZlUWV %UHPVH 9LEUDWLRQNOHLQ 9LEUDWLRQJUR )DKUWULFKWXQJOLQNV )DKUWULFKWXQJUHFKWV *DQJ
%/0 %/0 %/0 %/0 %/0 %/0 %/0 %/0 %/0 %/0
0DFKLQHFRQWUROOHU 0DFKLQHFRQWUROOHU 0DFKLQHFRQWUROOHU 0DFKLQHFRQWUROOHU 0DFKLQHFRQWUROOHU 0DFKLQHFRQWUROOHU 0DFKLQHFRQWUROOHU 0DFKLQHFRQWUROOHU 0DFKLQHFRQWUROOHU 0DFKLQHFRQWUROOHU
$ $ $ $ $ $ $ $ $ $
'* '* 6$ 6$ 6$ 6$ 6$ 6$ 6$ 6$
; ; ; ; ; ; ; ; ; ;
BOMAG
; ; ; ; ; ; ; ; ; ;
[
[ [ [ [ [ [ < [
< < < < < < $
<
$ $ $ $ $ $ [ $
[ [ [ [ [ [ [
*;
; ;
289
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 0RGXO%/0VROHQRLGYDOYHV
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
0RGXO%/00DJQHWYHQWLOH (LQEDXRUW (3(
290
14.2
; ; ; ;
%6/ '* 5;' 7;'
$ $ $ $
BOMAG
$ $ $ $
6$ 6$ 6$ 6$
; ; ; ;
. . . .
008 922 85
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 0RGXO%/0GLDJQFRQQHFWRUUHOD\V
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
0RGXO%/0'LDJQ6WHFNHU5HODLV (LQEDXRUW (3(
008 922 85
.
%
6ORSH
VHQVRU
1HLJXQJVVFKDOWHU
Nj& .
Wiring diagram 73
;
;
6(
(QJLQHRLOSUHVVXUH 7HPSHUDWXUHVZLWFKFROODQW :DUQLQJKRUQ :DUQLQJKRUQ
0RWRU|OGUXFN 7HPSHUDWXUVFKDOWHU.KOZDVVHU $ 6LJQDOKRUQ 6LJQDOKRUQ
%/0 %/0 %/0 %/0
0DFKLQHFRQWUROOHU 0DFKLQHFRQWUROOHU 0DFKLQHFRQWUROOHU 0DFKLQHFRQWUROOHU 0DFKLQHFRQWUROOHU
%/0 %/0
$ $ 6ORSHVHQVRU $ $
BOMAG
6( 6( 1HLJXQJVVFKDOWHU 6$ 6$
; ; ; ;
; ;
;
[
+ 9
[
% 3 %
*;
0
= =
291
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 0RGXO%/0VORSHVHQVRUVDIHW\GHYLFHZDUQLQJKRUQ
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
0RGXO%/01HLJXQJVVHQVRU6LFKHUKHLWVHLQU+XSH (LQEDXRUW (3(
292
14.2
$ 3
.H\ERDUG ZKW JUQ \HO GLDJQRVLV
7DVWDWXU 'LDJQRVH
71&
$
0RGXORSHUDWRUSURWHFWLRQ 71&
0RGXO%HGLHQHUVFKXW]
EUQ
; ;
RXW RXW
;
: :
$QWHQQD5),'/)UHDU $QWHQQD5),'/)IURQW
$QWHQQH5),'/)KLQWHQ $QWHQQH5),'/)YRUQH
2SWLRQEXUJODU\SURWHFWLRQ
=$'LHEVWDKOVFKXW]
; ;
BOMAG
DWWKHPRPHQWXQGHUZD\
]XU=HLWLQ(QWZLFNOXQJ
KLQWHQ IURQW
UHDU YRUQH
$
$
$
$
008 922 85
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 6DIHW\GHYLFHEXUJODU\SURWHFWGLDJQPRGXOH
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
6LFKHUKHLWVHLQU'LHEVWDKOVFKXW]'LDJQRVH0RGXOH (LQEDXRUW (3(
&$1
&$1
5DFWLY
008 922 85
/
&DFWLY
&
6
6ZLWFKFDEOHUDGLRFRQWUROO
8PVFKDOWHU.DEHO)XQNIHUQVWHXHUXQJ
;
Wiring diagram 73
:
$QWHQQD
$QWHQQH
:
5HPRWHFRQWURO
)HUQEHWlWLJXQJ ; ) ' % $ & (
IRUZDUGEDFNZDUGV :
OKUK
YRUZlUWVUFNZlUWV 5HFHLYHUUDGLR 71&
OLQNVUHFKWV (PSIlQJHU)XQN
6 6
7UDYHOGLUHFWLRQ 7UDYHOOHYHU
)DKUWULFKWXQJ )DKUKHEHO
BOMAG
EDWWHU\9UHFKDUJHDEOH
$NNX9
6
(PHUJHQF\VWRS
1RW$XV
+
:DUQEX]]HU
:DUQVXPPHU +
6 /(' 6 6
/HXFKWGLRGH 9LEUDWLRQORZKLJK 6
6LJQDOKRUQ (QJLQHVWDUW .H\VZLWFK
9 9LEUDWLRQNOHLQJUR
6LJQDOKRUQ 0RWRUVWDUW 6FKOVVHOVFKDOWHU
=
14.2
293
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 5HPRWHFRQWUROUHFHLYHUDQWHQQD
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
)HUQVWHXHUXQJ(PSIlQJHU$QWHQQH (LQEDXRUW (3(
294
14.2
'HYLFHWDJOLVW
%HWULHEVPLWWHOOLVWH
+LJKHUOHYHO
'HYLFHWDJ 3DJH 3DWK 0RXQWLQJORFDWLRQ IXQFWLRQ FKDUDFWHULVWLFV
%0. %ODWW 3IDG (LQEDXRUW
)XQFWLRQWH[W )XQNWLRQVWH[W 7HFKQ.HQQJU|HQ
$QODJH
BOMAG
* EDWWHU\ %DWWHULH 9$K$K(1
* *HQHUDWRU *HQHUDWRU $
+ :DUQLQJEX]]HUEUHDNGRZQ :DUQVXPPHU%HWULHEVVW|UXQJ $
. 5HOD\SRWHQWLDORQ 5HODLV3RWHQWLDODXI :12$1&$
. 5HOD\JORZSOXJV\VWHP 5HODLV9RUJOKHQ :12$1&$
. 5HOD\VWDUWHU 5HODLV$QODVVHU :12$1&$
. 5HOD\HQJLQHUSP 5HODLV0RWRUGUHK]DKO :12$1&$
0 6WDUWHU 6WDUWHU N:
3 GLDJQRVLV 'LDJQRVH P$SOXVRXW[$
5 *ORZSOXJ *OKNHU]H [$DIWHUV[$
5 'URSSLQJ5HVLVWRU 9RUZLGHUVWDQG RKP
5 UHVLVWRU :LGHUVWDQG 2KP
5 2KP
6 'LVFRQQHFWVZLWFKEDWWHU\ %DWWHULHWUHQQVFKDOWHU
6 6ZLWFKFDEOHUDGLRFRQWUROO 8PVFKDOWHU.DEHO)XQNIHUQVWHXHUXQJ
9 'LRGH 'LRGH 05
9 )(%
9 )(%
9 )(%
: 5HFHLYHUUDGLR (PSIlQJHU)XQN
:71& $QWHQQDVRFNHW $QWHQQHQDQVFKOX
Wiring diagram 73
008 922 85
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 'HYLFHWDJOLVW
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
%HWULHEVPLWWHOOLVWH (LQEDXRUW (3(
'HYLFHWDJOLVW
%HWULHEVPLWWHOOLVWH
008 922 85
+LJKHUOHYHO
'HYLFHWDJ 3DJH 3DWK 0RXQWLQJORFDWLRQ IXQFWLRQ FKDUDFWHULVWLFV
%0. %ODWW 3IDG (LQEDXRUW
)XQFWLRQWH[W )XQNWLRQVWH[W 7HFKQ.HQQJU|HQ
$QODJH
BOMAG
14.2
295
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 'HYLFHWDJOLVW
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
%HWULHEVPLWWHOOLVWH (LQEDXRUW (3(
296
14.2
3LQRYHUYLHZ
3LQhEHUVLFKW
%20$*PRGXOH%/0
$ %20$*/HLVWXQJVPRGXO
3LQ 3DJH 3DWK 'HVFULSWLRQ
6LJQDO 6LJQDO
.RQWDNW %ODWW 3IDG %HVFKUHLEXQJ
%20$*PRGXOH%/0 %20$*/HLVWXQJVPRGXO
; '* *URXQG 0DVVH
; 6( $OWHUQDWRUFKDUJH /LFKWPDVFKLQH'
; 6( (QJLQHRLOSUHVVXUH 0RWRU|OGUXFN
; 6( (QJLQHVSHHG 0RWRUGUHK]DKO
; 6( 7HPSHUDWXUHVZLWFKFROODQW 7HPSHUDWXUVFKDOWHU.KOZDVVHU
; 6$ 6WDUW 6WDUW
; 6$ 3RWHQWLDO 3RWHQWLDO
; 6$ :DUQLQJKRUQ 6LJQDOKRUQ
; 6$ (QJLQHUSP 0RWRUGUHK]DKO
; 6$ (QJLQHVWRS 0RWRU6WRS
; 6$ QGVSHHGUDQJH *DQJ
; 6$ 9LEUDWLRQORZ 9LEUDWLRQNOHLQ
; 6$ 9LEUDWLRQKLJK 9LEUDWLRQJUR
; 8% 3RZHUVXSSO\ $QVFKOXVVYHUVRUJXQJ
BOMAG
; '* *URXQG 0DVVH
; 5;' GLDJQRVLV 'LDJQRVH
; 7;'
; 6$ 7UDYHOGLUHFWLRQUK )DKUWULFKWXQJUHFKWV
; 6( &RQWUROOSRW .RQWUROOH3RW
; 6$ 7UDYHOGLUHFWLRQOK )DKUWULFKWXQJOLQNV
; 6$ 7UDYHOGLUHFWLRQIRUZDUG )DKUWULFKWXQJYRUZlUWV
; 6( 6ORSHVHQVRU 1HLJXQJVVFKDOWHU
; 6$ 7UDYHOGLUHFWLRQEDFNZDUGV )DKUWULFKWXQJ5FNZlUWV
; 8% 3RZHUVXSSO\ 6SDQQXQJVYHUVRUJXQJ
; '* GLDJQRVLV 'LDJQRVH
; &/ &$1ORZ &$1
; &+ &$1KLJK &$1
; %6/ GLDJQRVLV 'LDJQRVH
; 6$ :DUQLQJKRUQ 6LJQDOKRUQ
; 6($NW &DEOHDFWLYDWLRQ .DEHO$NWLYLHUXQJ
; 6$ 3UHKHDWLQJ 9RUJOKHQ
; 6($NW 5DGLRDFWLYDWLRQ )XQN$NWLYLHUXQJ
; 6$ %UDNH %UHPVH
; 6()4 (QJLQHUSP 0RWRUGUHK]DKO
; 8% 3RZHUVXSSO\ 6SDQQXQJVYHUVRUJXQJ
Wiring diagram 73
008 922 85
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 3LQRYHUYLHZ$
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
3LQhEHUVLFKW$ (LQEDXRUW (3(
3OXJRYHUYLHZ
6WHFNHUEHUVLFKW
008 922 85
'HVLJQDWLRQ 0RXQWLQJORFDWLRQ )XQFWLRQWH[W 'HVLJQDWLRQ 0RXQWLQJORFDWLRQ )XQFWLRQWH[W
%H]HLFKQXQJ (LQEDXRUW )XQNWLRQVWH[W %H]HLFKQXQJ (LQEDXRUW )XQNWLRQVWH[W
5HPRWHFRQWURO VSLUDOFDEOHUHPRWHFRQWURO &HQWUDOHOHFWULF PRGXO%/0
; )HUQEHWlWLJXQJ 6SLUDONDEHO)HUQVWHXHUXQJ ; =HQWUDOHOHNWULN 0RGXO%/0
&RQWDFW 3DJH 3DWK 7\SH &RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S &$66% .RQWDNW %ODWW 3IDG 7\S -37*3$03
Wiring diagram 73
$
%
& 5HDUIUDPHFHQWUDOHOHFWULF (QJLQH
; +LQWHUUDKPHQ=HQWUDOHOHNWULN 0RWRU
' &RQWDFW 3DJH 3DWK 7\SH
( .RQWDNW %ODWW 3IDG 7\S '73
)
&HQWUDOHOHFWULF PRGXO%/0
; =HQWUDOHOHNWULN 0RGXO%/0
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S -37*3$03
5HDUIUDPHFHQWUDOHOHFWULF 6ROHQRLGYDOYHV
; +LQWHUUDKPHQ=HQWUDOHOHNWULN 0DJQHWYHQWLOH
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '703
BOMAG
5HDUIUDPHFHQWUDOHOHFWULF 6XSSO\
; +LQWHUUDKPHQ=HQWUDOHOHNWULN 9HUVRUJXQJ
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S 07$0
$
%
*HQHUDWRU *HQHUDWRU
; *HQHUDWRU *HQHUDWRU
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S 6,0*)
14.2
297
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 3OXJRYHUYLHZ
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
6WHFNHUEHUVLFKW (LQEDXRUW (3(
298
3OXJRYHUYLHZ
14.2
6WHFNHUEHUVLFKW
'HVLJQDWLRQ 0RXQWLQJORFDWLRQ )XQFWLRQWH[W 'HVLJQDWLRQ 0RXQWLQJORFDWLRQ )XQFWLRQWH[W
%H]HLFKQXQJ (LQEDXRUW )XQNWLRQVWH[W %H]HLFKQXQJ (LQEDXRUW )XQNWLRQVWH[W
5HDUIUDPHFHQWUDOHOHFWULF HQJLQH<SUHKHDWLQJ
; +LQWHUUDKPHQ=HQWUDOHOHNWULN 0RWRU<9RUJOKHQ
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '73
5HDUIUDPH VSLUDOFDEOHPDFKLQHVRFNHW
; +LQWHUUDKPHQ 6SLUDONDEHO6WHFNDQVFKOX0DVFKLQH
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '73
&HQWUDOHOHFWULF GLDJQRVLV
; =HQWUDOHOHNWULN 'LDJQRVH
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '76
BOMAG
&HQWUDOHOHFWULF EXUJODU\SURWHFWLRQ
; =HQWUDOHOHNWULN 'LHEVWDKOVFKXW]
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '76
;
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S
)URQWIUDPH 6DIHW\GHYLFHIURQW
; 9RUGHUUDKPHQ 6FKXW]HLQULFKWXQJYRUQ
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '706
Wiring diagram 73
008 922 85
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 3OXJRYHUYLHZ
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
6WHFNHUEHUVLFKW (LQEDXRUW (3(
008 922 85
+ 5 5 5
Wiring diagram 73
<
BOMAG
<
14.2
299
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 2YHUYLHZHQJLQHOK
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
hEHUVLFKW0RWRUOLQNH6HLWH (LQEDXRUW (3(
300
14.2
%
*%
;
;
BOMAG
%
%
0
0
0
Wiring diagram 73
008 922 85
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 2YHUYLHZHQJLQHUK
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
hEHUVLFKW0RWRUUHFKWH6HLWH (LQEDXRUW (3(
008 922 85
:
6 .
6
Wiring diagram 73
3 .
.
5 .
;
$
:
%
$ $
BOMAG
:
;
;
;
6
14.2
301
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 2YHUYLHZ&HQWUDO(OHFWULF
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
hEHUVLFKW=HQWUDOHOHNWULN (LQEDXRUW (3(
302
14.2
6
F00
)
W13
BOMAG
X22
:
;
;
X116
:
W12
<<
<
<<
<<
<
;
Wiring diagram 73
008 922 85
+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG '1DOOLQ $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 2YHUYLHZIURQWUHDUIUDPH
)XQNWLRQ
&KHFNHG 75DX %03 0RXQWLQJORFDWLRQ
*HSUIW
hEHUVLFKW5DKPHQYRUQKLQWHQ (LQEDXRUW (3(