BW24RH Taller Nuevo

Service - Manual
BW 24 RH
S/N 101 538 01 ....
Rubber tire roller
Catalogue number.
008 915 04 04/2009
Table of Contents
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 26
Technical data 31
2.1 Technical data 32
Maintenance 37
3.1 General notes on maintenance 38
3.2 Fuels and lubricants 39
3.3 Table of fuels and lubricants 42
3.4 Running-in instructions 43
3.5 Maintenance table 44
Electrics 47
4.1 Understanding circuit diagrams 48
4.2 Designation of components in the wiring diagram 53
4.3 Terminal designations in wiring diagram 54
4.4 Circuit symbols in the circuit diagram 56
4.5 Battery ground and analog ground 57
4.6 Current and voltage 57
4.7 Resistance 60
4.8 Series / parallel connection 62
4.9 Ohm's law 64
4.10 Electrical energy 64
4.11 Formula diagram 65
4.12 Metrology 66
4.13 Diodes, relays, fuses 70
4.14 Telemecanique switch 73
4.15 Plug connectors 76
4.16 Magnetic coil plug 77
4.17 Deutsch plug, series DT and DTM 79
4.18 Plugs and terminals in spring clamping technology 86
4.19 Inductive proximity switches 90
4.20 Level sensor in diesel tank (R03) 91
4.21 Differential pressure switches hydraulic oil filter, B21and B22 92
4.22 Brake oil temperature switch, B148 92
4.23 Brake pressure switches, B12 and B102 93
4.24 Float switch in water tank, B33 94
4.25 Oil pressure switch, B06 95
4.26 Coolant temperature switch, B152 96
4.27 Sensor (B124), water in fuel filter 97
4.28 Air filter vacuum switch, B03 98
4.29 Charge control light, operating hour meter 99
4.30 Fuel preheating, R79 100
4.31 Glow plugs 100
4.32 Engine solenoid to shit down the engine, Y13 101
008 915 04 BOMAG 3

Table of Contents
4.33 Boost fuel solenoid valve, Y01 103

4.34 Engine monitoring 104
4.35 Batteries 106
4.36 Battery maintenance 109
4.37 Generator 110
4.38 Replacing the voltage regulator 119
4.39 Electric starter 121
4.40 Overview of electric components 128
4.41 Modules 147
Special tools, electrics 149
5.1 Special tools, electrics 150
Electronic modules 159
6.1 Module description A04 161
6.2 Heating/air conditioning control 171
Module description A100 177
7.1 Steering column locking module, A100 178
Speedometer Module 181
8.1 Speedometer module 182
Front axle 185
9.1 Repair overview for front axle 186
9.2 Dismantling the front axle 187
9.3 Assembling the front axle 194
Service Training 217
10.1 Service Training 219
Air conditioning system 291
11.1 Physical basics 292
11.2 Refrigerant R134a 295
11.3 Compressor oil / refrigeration oil 296
11.4 Working principle of the air conditioning system 297
11.5 Monitoring devices 297
11.6 Description of components 298
11.7 Measuring the compressor oil level 304
11.8 Checking the magnetic clutch 304
11.9 Inspection and maintenance work 305
11.10 Checking, replacing the refrigerant compressor V-belt 306
11.11 Service the air conditioning 307
11.12 Drying and evacuation 309
11.13 Emptying in case of repair 310
11.14 Leak test 310
11.15 Filling instructions 311
11.16 Trouble shooting in refrigerant circuit, basic principles 314
11.17 Trouble shooting, refrigerant circuit diagram 318
11.18 Trouble shooting procedure 319
11.19 Steam table for R134a 329
Replacing the cab window panes 335
12.1 Assembly of window panes 336
12.2 Special tools 337
4 BOMAG 008 915 04

Table of Contents
12.3 Auxiliary materials 338

12.4 Removing and installing the window pane 340
Suppliers documentation 345
13.1 Travel pump 347
13.2 Travel motor 389
13.3 Travel gear 443
13.4 Steering valve 517
Circuit diagrams 551
14.1 Hydraulic diagram 538 110 00 553
14.2 Pneumatic diagram 538 120 00 557
14.3 Wiring diagram 538 100 03 561
008 915 04 BOMAG 5

Table of Contents
6 BOMAG 008 915 04

1 General
008 915 04 BOMAG 7

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

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

plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
* The applicable documents valid at the date of print-
ing are part of this manual.
8 BOMAG 008 915 04

Safety regulations 1.2
Important notes Block the articulated joint with the articulation lock.
1.2 Safety regulations
●
●
Use protective clothes like hard hat, safety boots
These safety regulations must be read and ap-
and gloves.
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident ● Keep unauthorized persons away from the machine
prevention instructions and the safety regulations during repair work.
in the operating and maintenance instructions ●
Tools, lifting gear, lifting tackle, supports and other
must be additionally observed.
auxiliary equipment must be fully functional and in
Repair work shall only performed by appropriately safe condition.
trained personnel or by the after sales service of ●
Use only safe and approved lifting gear of sufficient
BOMAG. load bearing capacity to remove and install parts or
components from and to the machine.
Workshop equipment and facilities as well as the
use and waste disposal of fuels and lubricants, ●
Do not use easily inflammable or harmful substanc-
cleaning agents and solvent as well as gases and es, such as gasoline or paint thinners for cleaning.
chemicals are subject to legal regulations, which ●
Do not smoke or use open fire and avoid sparks
are intended to provide a minimum on safety. It is when cleaning or repairing a tank.
obviously your own responsibility to know and
adhere to these regulations.
●
When performing welding work strictly comply with
the respective welding instructions.
This manual contains headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to inform about and avoid dan- Transport work with cranes and lifting
gers to persons, property and the environment. tackle
i Note i Note
Paragraphs marked like this contain technical infor- Cranes must only be operated by instructed persons
mation for the optimal economical use of the machine. who had been trained in handling cranes.
● Follow the operating instructions of the manufactur-
Caution
! er when working with cranes.
Paragraphs marked like this highlight possible ● Follow the operating instructions of the operator
dangers for machines or parts of the machine. when working with cranes.
●
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
● 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
● 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.!
●
Secure the engine reliably against unintentional
starting.
● Check welding equipment and cables for damage
before use (also the validity of inspection stickers).
●
Mark a defective machine and a machine under re-
pair by attaching a clearly visible warning label to
● Ensure good conductivity between ground cable
the dashboard. and workpiece, avoid joints and bearings.
008 915 04 BOMAG 9

●
Start the extraction fan before starting work and gine oils contain potentially hazardous contaminants,
guide with the progressing work as required. which could cause skin cancer. Appropriate skin pro-
● Always isolate the burner when laying it down (re- tection agents and washing facilities must therefore
move possible electrode residues). be provided.
● Wear protective clothes and safety gloves, if possi-
●
Protect cables from being damaged, use cables
ble.
with insulated couplings.
●
If there is a risk of eye contact you should protect
●
Ensure sufficient fire protection, keep a fire extin-
your eyes appropriately, e.g. chemistry goggles or
guisher at hand.
full face visor; a facility suitable for rinsing the eyes
●
Welding work in areas where there is a risk of fire or should also be available.
explosion, must only be carried out with welding
permission.
●
Avoid longer and repetitive contacts with oils. In
case of open incisions and injuries seek medical ad-
●
Remove any combustible materials from the weld- vice immediately.
ing area or cover such items appropriately. ●
Apply protective cream before starting work, so that
●
Name a fire watch during and after welding work. oil can be easier removed from the skin.
●
Place welding rod holders and inert gas welding ●
Wash affected skin areas with water and soap (skin
guns only on properly insulated bases. cleansers and nail brushes will help). Lanolin con-
●
Place the inert gas bottles in a safe place and se- taining agents will replace natural skin oils that were
cure them against falling over. lost.
● Use a protective screen or hand shield with welding
● Do not use gasoline, kerosene, diesel, thinner or
filter, wear welding gloves and clothes. solvents to wash the skin.
●
Switch the welding unit off before connecting weld-
●
Do not put oil soaked cloths into your pockets.
ing cables. ●
Avoid clothes getting soiled by oil.
●
Check electrode holders and electric cables at reg- ● Overalls must be washed at regular intervals. Dis-
ular intervals. pose of non-washable clothes environmentally.
Behaviour in case of faults ●
If possible degrease components before handling.
●
In case of faults on the welding unit switch of the
welding unit immediately and have it repaired by ex- Environment
pert personnel. It is strictly prohibited to drain off oil into the soil,
●
In case of failure of the extraction system switch the the sewer system or into natural waters. Old oil
system off and have it repaired by expert personnel. must be disposed of according to applicable envi-
ronmental regulations. If in doubt you should con-
Maintenance; waste disposal sult your local authorities.
●
Replace damaged insulating jaws and welding rod
holders immediately. Hydraulics
●
Replace the welding wire reels only in de-energized ●
Always relieve the pressure in the hydraulic system
state. before disconnecting any lines. Hydraulic oil escap-
ing under pressure can penetrate the skin and
What to do in case of accidents; First Aid
cause severe injury.
●
Keep calm. ● Always make sure that all screw fittings have been
●
Call first air helpers. tightened properly and that hoses and pipes are in
●
Report the accident. mint condition before pressurizing the system
again.
●
In case of an electric accident: Interrupt the power
supply and remove the injured person from the
●
Hydraulic oil leaking out of a small opening can
electric circuit. If breathing and heart have stopped hardly be noticed, therefore please use a piece of
apply reactivation measures and call for an emer- cardboard or wood when checking for leaks. When
gency doctor. injured by hydraulic oil escaping under pressure
consult a physician immediately, as otherwise this
may cause severe infections.
Old oils
●
Do not step in front of or behind the drums, wheels
Prolonged and repetitive contact with mineral oils will or crawler tracks when performing adjustment work
remove the natural greases from the skin and causes in the hydraulic system while the engine is running.
dryness, irritation and dermatitis. Moreover, used en- Block drums, wheels or crawler tracks with wedges.
10 BOMAG 008 915 04

Reattach all guards and safety installations after Synthetic rubber
all work has been completed.
Many O-rings, hoses, etc. are made of synthetic ma-
terial, a so-called fluorocarbon elastomer. Under nor-
Environment mal operating conditions this material is safe and does
It is strictly prohibited to drain off oil into the soil, not impose any danger to health.
the sewer system or into natural waters. Oil oil However, if this material becomes damaged by fire or
must be disposed of according to applicable envi- extreme heat, it may decompose and form highly
ronmental regulations. If in doubt you should con- caustic hydrofluoric acid, which can cause severe
sult your local authorities. burns in contact with skin.
●
If the material is in such a state it must only be
Fuels touched with special protective gloves. The protec-
tive gloves must be disposed of according to appli-
!Danger cable environmental regulations immediately after
use.
Repair work shall only performed by appropriately
trained personnel or by the after sales service of
●
If the material has contacted the skin despite these
BOMAG. measures, take off the soiled clothes and seek
medical advice immediately. In the meantime cool
Follow the valid accident prevention instructions when and wash the affected area of skin over a sufficient
handling fuels. time with cold water or lime water.
The following notes refer to general safety precau-
tions for danger free handling of fuel. Poisonous substances
Fuel vapours not only are easily inflammable, but also Some of the fluids and substances used are toxic and
highly explosive inside closed rooms and toxic; dilu- must under no circumstances be consumed.
tion with air creates an easily inflammable mixture.
The vapours are heavier than air and therefore sink Skin contact, especially with open wounds, must be
down to the ground. Inside a workshop they may eas- avoided.
ily become distributed by draft. Even the smallest por- These fluids and substances are, amongst others,
tion of spilled fuel is therefore potentially dangerous. anti-freeze agents, hydraulic oils, fuels, washing addi-
tives, refrigerants, lubricants and various bonding
●
Fire extinguishers charged with FOAM, CO2 GAS agents.
or POWDER must be available wherever fuel is
stored, filled in, drained off, or where work on fuel
systems is performed. Engine
●
The vehicle battery must always be disconnected,
BEFORE work in the fuel system is started. Do not Danger
!
disconnect the battery while working on the fuel Do not work on the fuel system while the engine is
system. Sparks could cause explosion of the fuel running. (Danger to life!)
fumes.
Once the engine has stopped wait approx. 1 min-
●
Wherever fuel is stored, filled, drained off or where utes for the system to depressurize. The systems
work on fuel systems is carried out, all potential ig- are under high pressure. (Danger to life!)
nition sources must be extinguished or removed.
Keep out of the danger zone during the initial test
Search lights must be fire proof and well protected
rung. Danger caused by high pressure in case of
against possible contact with running out fuel.
leaks. (Danger to life!)
When performing work on the fuel system make
Hot fuels sure that the engine cannot be started uninten-
Please apply the following measures before draining tionally during repair work. (Danger to life!)
of fuel to prepare for repair work: ●
Maintenance and cleaning work on the engine must
●
Allow the fuel to cool down, to prevent any contact only be performed with the engine stopped and
with a hot fluid. cooled down. Make sure that the electric system is
●
Vent the system, by removing the filler cap in a well switched off and sufficiently secured against being
ventilated area. Screw the filler cap back on, until switched on again (e.g. pull off ignition key, attach a
the tank is finally emptied. warning label).
●
Observe the accident prevention regulations for
electric systems (e.g. -VDE-0100/-0101/-0104/-
008 915 04 BOMAG 11

0105 Electric precautions against dangerous con- In combination with the inspection, the refrigerant
tact voltages). collector must be visually examined two times per
● Cover all electric components properly before wet year. Special attention must thereby be paid to
cleaning. signs of corrosion and mechanical damage. If the
container is in no good condition, it should be re-
placed for safety reasons, in order to protect the op-
Air conditioning system erator or third parties against the dangers when
handling or operating pressure vessels.
! Caution ● Secure pressure vessels against tipping over or roll-
Work on air conditioning systems must only be ing away.
carried out by persons who can provide sufficient ●
Do not throw pressure vessels! Pressure vessels
evidence of their ability (proof of professionalism) may thereby be deformed to such an extent, that
and only with the appropriate technical equip- they will crack. The sudden evaporation and escape
ment. of refrigerant releases excessive forces. This ap-
●
Always wear goggles and protective clothing when plies also when snapping off valves on bottles. Bot-
performing maintenance and repair work on air con- tles must therefore only be transported with the
ditioning systems. Refrigerant withdraws heat from safety caps properly installed.
the environment when evaporating, which can ●
Refrigerant bottles must never be placed near heat-
cause injury by freezing when in contact with skin ing radiators. Higher temperatures will cause higher
(boiling point of R134a -26,5 °C at normal pres- pressures, whereby the permissible pressure of the
sure). vessel may be exceeded.
●
Perform maintenance and repair work on air condi- ●
Do not heat up refrigerant bottles with an open
tioning systems only in well ventilated rooms! Es- flame. Excessive temperatures can damage the
caping refrigerant vapours will mix with the ambient material and cause the decomposition of refriger-
air and displace the oxygen required for breathing ant.
(danger of suffocating).
●
Do not overfill refrigerant bottles, since any temper-
●
Smoking is prohibited when performing mainte- ature increase will cause enormous pressures.
nance and repair work on air conditioning systems!
Toxic breakdown products may be generated if re-
frigerant comes into contact with heat. Environment
●
Refrigerant should always be extracted and re- It is strictly prohibited to release refrigerant into
moved by flushing with nitrogen before starting the atmosphere during operation, maintenance
welding or soldering work near components of the and repair work and when taking air conditioning
air conditioning system. The development of heat systems into or out of service.
may cause the refrigerant to develop toxic and high-
ly corrosive breakdown products. Battery
●
Pungent smell! The toxic substances, which are re- ●
Always wear goggles and protective clothing to
sponsible for the pungent smell, must not be in- service or clean batteries! Battery acid can cause
haled, since this may cause damage to the severe injury by cauterization when coming in con-
respiratory system, the lung and other organs. Ex- tact with skin.
tract toxic breakdown products with a suitable ex- ●
Work only well ventilated rooms (formation of oxy-
traction system (workshop extraction system). hydrogen gas).
● When blowing out components with compressed air ●
Do not lean over the battery while it is under load,
and when flushing with nitrogen the gas mixture es- being charged or tested (danger of explosion).
caping from the components must be extracted via ●
Keep ignition sources away from the battery. Burn-
suitable extraction facilities (workshop extraction ing cigarettes, flames or sparks can cause explo-
systems). sion of the battery
Handling pressure vessels
●
Use battery chargers etc. only in strict compliance
with the operating instructions.
●
Since the fluid container is pressurized, the manu- ●
After an accident with acid flush the skin with a suf-
facture and testing of these pressure vessels is gov-
ficient amount of water and seek medical advice.
erned by the pressure vessel directive. The
pressure vessels must be repetitively tested by an ●
Do not allow children access to batteries.
expert as specified in TRB 532 Inspection by Ex- ●
When mixing battery fluid always pour acid into wa-
perts, Repetitive Tests. In this case periodically re- ter, never vice-versa.
curring inspections consist of external
examinations, normally on containers in operation.
12 BOMAG 008 915 04

Special safety regulations
●
Use only genuine BOMAG spare parts for repair
and maintenance work. Genuine spare parts and
original accessories were specially developed, test-
ed and approved for the machine.
●
The installation and use of non-genuine spare parts
or non-genuine accessories may therefore have an
adverse effect on the specific characteristics of the
machine and thereby impair the active and/or pas-
sive driving safety. The manufacturer explicitly ex-
cludes any liability for damage caused by the use of
non-original parts or accessories.
●
Unauthorized changes to the machine are prohibit-
ed for safety reasons.
● Do not perform any cleaning work while the engine
is running.
●
If tests on the articulated joint need to be performed
with the engine running, do not stand in the articu-
lation area of the machine (danger of crushing!).
●
If tests must be performed with the engine running
do not touch rotating parts of the engine (danger of
injury!).
●
Always ensure an adequate supply of fresh air
when starting in closed rooms. Exhaust gases are
highly dangerous!
● Refuel only with the engine shut down. Ensure strict
cleanliness and do not spill any fuel.
●
Always ensure an adequate supply of fresh air
when refuelling in closed rooms.
●
Dispose of used filters in accordance with applica-
ble environmental regulations.
● When performing repair and maintenance work col-
lect oils and fuels in suitable containers and dispose
of in compliance with applicable environmental reg-
ulations.
●
Do not heat up oils higher than 160 °C because they
may ignite.
●
Wipe off spilled or overflown oil using suitable
cleaning means and dispose of in accordance with
applicable environmental regulations.
● Dispose of old batteries according to applicable en-
vironmental regulations.
●
There is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature! Allow
engine and hydraulic system to cool down to a suf-
ficient level.
●
Do not exceed the max. permissible tire pressure.
008 915 04 BOMAG 13

1.3 General repair instructions
General Electrics
●
Before removing or disassembling parts, assem- General
blies, components or hoses mark these parts for
Due to the fast technical development electric and
easier assembly.
electronic vehicle systems become more intelligent
●
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:
●
In approx. 10 % of the examined cases the prob-
lems were caused by control units.
●
In approx. 15 % sensors and actuators were the
cause of the problems.
By far the highest proportion of all faults could be
traced back to wiring and connections (plugs, etc.).
General:
●
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. 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.
●
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.
●
Always use the machine related wiring diagram for
testing. If one or more faults were detected, these
should be corrected immediately.
●
Do not disconnect or connect battery or generator
while the engine is running.
●
Do not operate the main battery switch under load.
●
Do not use jump leads after the battery has been re-
moved.
●
Sensors and electric actuators on control units must
never be connected individually or between exter-
nal power sources for the purpose of testing, but
only in connection with the control unit in question.
● 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.
●
Even with an existing polarity reversal protection in-
correct polarity must be strictly avoided. Incorrect
polarity can cause damage to control units!
14 BOMAG 008 915 04

General repair instructions 1.3
●
Plug-in connectors on control units are only dust Battery
and water tight if the mating connector is plugged
on! Control units must be protected against spray Rules for the handling of batteries
water, until the mating connector is finally plugged When removing a battery always disconnect the mi-
on! nus pole before the plus pole. When installing the bat-
●
Unauthorized opening of control electronics (Micro- tery connect the minus pole after the plus pole to avoid
controller MC), modifications or repairs in the wiring short circuits.
can cause severe malfunctions. Fasten the terminal clamps with a little force as possi-
●
Do not use any radio equipment or mobile phones ble.
in the vehicle cab without a proper aerial or in the vi- Always keep battery poles and terminal clams clean to
cinity of the control electronics! avoid high transition resistances when starting and
the related development of heat.
Electrics and welding
Make sure the battery is properly fastened in the vehi-
cle.
!Caution
Before starting welding work you should discon-
nect the negative battery pole or interrupt the
electric circuit with the main battery switch, dis-
connect the generator and pull the plugs off all
control units in order to protect the electrical sys-
tem of the machine.
● Disconnect the minus pole of the battery or interrupt
the electric circuit with the main battery switch.
● Isolate the generator and all control units from the
electric circuit.
● Always fasten the earth clamp of the welding unit in
the immediate vicinity of the welding location.
● When choosing the location for the earth clamp
make sure that the welding current will not pass
through joints or bearings.
008 915 04 BOMAG 15

Generator Starter motor

Before removing the generator you must disconnect So-called jump starting (using an additional external
the ground cable from the minus pole of the battery battery) without the battery connected is dangerous.
while the ignition is switched off. Do not disconnect When disconnecting the cables from the poles high in-
the generator while the engine is running, because ductivities (arcs, voltage peaks) may occur and de-
this may cause extremely high voltage peaks in the stroy the electrical installation.
vehicle wiring system ("Load Dump"), which could For purposes like e.g. purging the fuel systems, start-
possibly damage control units, radios or other elec- ers may be operated for maximum 1 minute without
tronic equipment. interruption. Then you should wait for at least 30 min-
When disassembling the battery cable, the B+-nut un- utes (cooling down) until trying again. During the 1
derneath on the generator side may also be loosened. minute starting period this process should not be inter-
This nut must in this case be retightened. rupted.
When connecting e.g. the battery cable to the terminal Starter motors must not be cleaned with high pressure
of the generator you must make sure that the polarity steam cleaning equipment.
is correct (generator B+ to the + pole of the battery). The contacts on starter terminals 30, 45, 50 must be
Mixing up the polarities by mistake causes short cir- protected against unintended shorting (jump protec-
cuit and damage to the rectifier elements - the gener- tion).
ator will be out of function.
When replacing the starter the ring gear on the engine
The generator can only be operated with the battery flywheel must be checked for damage and its number
connected. Under special conditions emergency op- of teeth - if necessary replace the ring gear.
eration without battery is permitted, the lifetime of the
generator is in such cases especially limited. Always disconnect the battery before starting assem-
bly work in the starter area of the engine or on the
Plus and minus cables must be disconnected during starter itself.
rapid charging of the battery or electric welding on the
vehicle.
When cleaning the generator with a steam or water jet
make sure not to direct the steam or water jet directly
on or into the generator openings or ball bearings. Af-
ter cleaning the generator should be operated for
about 1 - 2 minutes to remove any deposits of water
from the generator.
16 BOMAG 008 915 04

Hydraulic system ●
Perform measurements at operating temperature of
the hydraulic oil (approx. 40 ¯ C).
!Caution
● 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. ● 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. ●
After the completion of all tests perform a test run
and then check all connections and fittings for leaks
●
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.
●
Before loosening hoses, pipe lines etc. relieve all Before commissioning
pressure from the system. ●
Fill the housings of hydraulic pumps and motors
●
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.
● Never run pumps, motors and engines without oil or
● After changing a component flush the hydraulic sys-
hydraulic oil. tem as described in the flushing instructions.
●
When cleaning hydraulic components take care not Taking into operation
to damage any fine machine surfaces. ●
Bleed the hydraulic circuits.
● Chemical and rubber soluble cleansing agents may ●
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.
●
Check the hydraulic oil level in the tank, if neces-
sary top up with hydraulic oil as specified in the op-
● 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
●
Avoid the formation of rust on fine machined caused ● Check fittings and flanges for leaks.
by hand sweat. ●
After each repair check all adjustment data, system
● Use new O-rings or seal rings for reassembly. pressures, rotational speeds and nominal values in
● Use only hydraulic oil as sliding agent when reas- the hydraulic system, adjust if necessary.
sembling. Do not use any grease! ●
Do not adjust pressure relief valves and control
●
Use only the specified pressure gauges. Risk of valves to values above their specified values.
damaging the pressure gauges under too high pres-
sure.
●
Check the hydraulic oil level before and after the
work.
●
Fill in only clean oil as specified in the maintenance
instructions.
●
Check the hydraulic system for leaks, if necessary
find and rectify the cause.
●
Before taking new hydraulic components into oper-
ation fill these with hydraulic oil as specified in the
operating and maintenance instructions.
●
After changing a hydraulic component thoroughly
flush, refill and bleed the complete hydraulic sys-
tem.
008 915 04 BOMAG 17

Air conditioning system ●

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

●
If the air conditioning system had been opened for Fuel hoses
repair work, a new drier should be installed in the re-
frigerant circuit.
●
After completion of repair work screw locking caps
(with seals) on all valve connections service con-
nections.
●
Before start up of the air conditioning system after a
new filling: - Turn the compressor approx. 10 revo-
lutions by hand using the clutch or V-belt pulley of
the magnetic clutch. - Start the engine with the com-
pressor/control valve switched off. - Once the idle
speed of the engine has stabilized switch on the
compressor and run it for at least 10 minutes at idle Fig. 1
speed and maximum cooling power.
●
Never run the compressor with an insufficient ! Caution
amount of refrigerant. All fuel hoses have two layers of material, a rein-
forced rubber coating outside and an internal Vi-
ton hose. If a fuel hose has come loose one must
make absolutely sure that the internal Viton layer
has not been separated from the reinforced outer
layer. In case of a separation the hose needs to be
replaced.
008 915 04 BOMAG 19

Gaskets and mating surfaces able, you should use a plastic tube or adhesive tape
to prevent the sealing lip from being damaged.
Leaking sealing faces can mostly be traced back to in-
correct assembly of seals and gaskets. ●
Lubricate the outer rim (arrow 3 (Fig. 2)) of the seal
●
Before assembling a new seal or gasket make sure and press it flat on the housing seat.
that the sealing surface is free of pitting, flutes, cor-
rosion or other damage.
● Inappropriately stored or handled seals (e.g. hang-
ing from hooks or nails) must under no circumstanc-
es be used.
●
Assemble seals and gaskets only with sealing com-
pound, grease or oil, if this is specifically specified
in the repair instructions.
●
If necessary remove any old sealing compound be-
fore assembling. For this purpose do not use any
tools that could damage the sealing surfaces.
●
Sealing compound must be applied thin and evenly
on the corresponding surfaces; take care that the
compound does not enter into oil galleries or blind Fig. 3
threaded bores.
●
Press or knock the seal into the housing, until it is
●
Examine the contact faces for scratches and burrs, flush with the housing surface.
remove these with a fine file or an oilstone; take
care that no grinding dust and dirt enters into
tapped bores or enclosed components. i Note
If possible, use a "bell" (1 (Fig. 3)), to make sure that
●
Blow out lines, ducts and gaps with compressed air,
the seal will not skew. In some cases it may be ad-
replace any O-rings and seals that have been dis-
visable to assemble the seal into the housing first, be-
lodged by the compressed air.
fore sliding it over the shaft. Under no circumstances
Assembly of radial seals should the full weight of the shaft rest on the seal.
If you have no proper service tools at hand, use a suit-
able drift punch with a diameter which is about 0,4 mm
smaller than the outer diameter of the seal. Use VERY
LIGHT blows with the hammer if no press is available.
Fig. 2
●
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.
●
Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.
i Note
If possible, use an assembly sleeve (1 (Fig. 2)), to
protect the lip from being damaged by sharp edg-
es, threads or splines. If no assembly sleeve is avail-
20 BOMAG 008 915 04

Feather keys and keyways Ball and roller bearings
Caution
! !Caution
Feather keys may only be reused if they are free of Ball and roller bearings may only be reused if they
damage. are free of damage and do not show any signs of
wear.
Fig. 4
●
Clean and thoroughly examine the feather key.
●
Deburr and thoroughly clean the edges of the key-
way with a fine file before reassembling.
Fig. 5
●
If a ball or roller bearing of a bearing pair shows de-
fects, both ball or roller bearings need to be re-
placed.
● 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.
●
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.
●
Check the ball or roller bearing for clearance and re-
sistance between the inner and outer races, replace
if necessary.
●
Lubricate the ball or roller bearing with the recom-
mended type of grease before assembly or reas-
sembly.
● On greased bearings (e.g. wheel bearings) fill the
space between ball or roller bearing and outer seal
with the recommended type of grease before as-
sembling the seal.
008 915 04 BOMAG 21

●
Check shaft and bearing housing for discolouration Screws and nuts
or other signs of movement between ball or roller
bearing and seats. Tightening torque
●
Make sure that shaft and housing are free of burrs
before assembling the ball or roller bearing. !Caution
● Always mark the individual parts of separable ball or Tighten nuts or screws with the tightening tor-
roller bearings (e.g. taper roller bearings) to enable ques specified in the following tables of tighten-
correct reassembling. Never assemble the rollers to ing torques. Tightening torques deviating from
an outer race that has already been used, replace the ones in the table are specially mentioned in
the complete ball or roller bearing instead. the repair instructions.
Damaged screws must under no circumstances
be used any longer. Recutting threads with thread
cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or cor-
roded thread pitches can cause incorrect torque
value readings.
Self-locking nuts must generally be replaced after
disassembly.
The use of screws with too high strength can
cause damage!
● Nut of a higher strength can generally be used in-
Fig. 6
stead of nuts of a lower strength classification.
● When checking or retightening screw joints to the
!Caution
specified tightening torque you should first relieve
When assembling the ball or roller bearing to the by a quarter turn and then tighten to the correct
shaft load must only be applied to the inner race 1 torque.
(Fig. 6).
● Before tightening you should lightly oil the thread, in
When fitting the bearing into the housing load order to ensure low friction movement. The same
must only be applied to the outer race (2). applies for self-locking nuts.
● Make sure that no oil or grease will enter into blind
tapped bores. The hydraulic power generated when
turning in the screw could cause breakage of the ef-
fected part.
22 BOMAG 008 915 04

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

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

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

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

i Note
(11H, 14H, 17H, 22H)
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas- This standard contains strength classes (hardness
tic deformation). classes) for nuts 3 (Fig. 8), for which no load values
can be specified, e.g. because of their shape and di-
When exceeding the upper yield point the material will mensions, but which can only be classified by their
not restore its original shape after being relieved. hardness.
● The lower tensile strength is 9/10 X 1200 N/mm2 = Nut height below 0,5 d (d = nominal dimension).
1080 N/mm2.
i Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.
008 915 04 BOMAG 23

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

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

At the outmost end a short end of the component is re-
duced to its core diameter (1).
24 BOMAG 008 915 04

Cotter pins
Fig. 11
In places where cotter pins are used, these must be
reassembled. Cotter pins must generally be renewed
after disassembly.
Cotter pins must be assembled as shown in the illus-
tration, unless specified differently.
008 915 04 BOMAG 25

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

●
black oiled
●
with surface protection A4C
●
with surface protection DACROMET
i Note
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with metric unified thread1
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
1 Coefficient of friction µ tot. = 0,14
Tightening torques for screws with metric unified fine thread1
Screw dimension
8.8 10.9 12.9
M8 x 1 26 37 48
M10 x 1.25 52 76 88
M12 x 1,25 98 137 126
M12 x 1.5 93 127 152
M14 x 1.5 152 216 255
M16 x 1.5 225 318 383
M18 x 1.5 324 466 554
M20 x 1.5 461 628 775
M22 x 1.5 618 863 1058
M24 x 2 780 1098 1294
M27 x2 1147 1578 1920
M30 x 2 1568 2254 2695
26 BOMAG 008 915 04

Tightening torques 1.4
Tightening torques for screws treated with anti-seizure paste OKS 2401 (copper paste)
Screw dimension
8.8 10.9 12.9
M16 169 240 287
M16 x 1.5 180 255 307
M18 232 330 392
M18 x 1.5 260 373 444
M20 330 463 557
M20 x 1.5 369 502 620
M22 448 628 754
M22 x 1.5 495 691 847
M24 569 800 960
M24 x 2 624 879 1036
M27 840 1184 1520
M27 X 2 918 1263 1536
M30 1136 1608 1920
M30 x 2 1255 1804 2156
3/4“ - 10 UNC 276 388 464
3/4“ - 16 UNC 308 432 520
1 Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to high temperatures and corrosive
effects. Prevents seizure and corrosion.
Tightening torques for wheel nuts (fine thread) 1 2
Thread diameter
10.9
M12x1.5 100
M14x1.5 150
M18x1.5 300 - 350
M20x1.5 400 - 500
M22x1.5 500 - 600
2 These values result in a 90% utilization of the yield point
008 915 04 BOMAG 27

The values specified in the table apply for screws:

●
black oiled
● with surface protection A4C
● with surface protection DACROMET
i Note
The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60°flanks,
as the metric ISO-thread, whereas Withworth has a flank of only 55°.
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with UNC thread, 1 UNC Unified Coarse Thread Series, American Unified
Coarse Thread
Screw dimension
8.8 10.9 12.9
1/4“ - 20 11 15 19
5/16“ - 18 23 32 39
3/8“ - 16 39 55 66
7/16“ - 14 62 87 105
1/2“ - 13 96 135 160
9/16“ - 12 140 200 235
5/8“ - 11 195 275 330
3/4“ - 10 345 485 580
7/8“ - 9 560 770 940
1“ - 8 850 1200 1450
1 1/8“ - 7 1200 1700 2000
1 1/4“ - 7 1700 2400 2900
1 3/8“ - 6 2200 3100 3700
1 1/2“ - 6 3000 4200 5100
1
Tightening torques for screws with UNF thread, UNF Unified National Fine Thread Series, American
Unified Fine Thread
Screw dimension
8.8 10.9 12.9
1/4“ - 28 13 18 22
5/16“ - 24 25 35 42
3/8“ - 24 45 63 76
7/16“ - 20 70 100 120
1/2“ - 20 110 155 185
9/16“ - 18 155 220 260
5/8“ - 18 220 310 370
3/4“ - 16 385 540 650
7/8“ -14 620 870 1050
28 BOMAG 008 915 04

Tightening torques 1.4
1
Tightening torques for screws with UNF thread, UNF Unified National Fine Thread Series, American
Unified Fine Thread
Screw dimension
8.8 10.9 12.9
1“ - 12 930 1300 1600
1 1/8“ - 12 1350 1900 2300
1 1/4“ - 12 1900 2700 3200
1 3/8“ - 12 2600 3700 4400
1 1/2“ - 12 3300 4600 5600
008 915 04 BOMAG 29

30 BOMAG 008 915 04

2 Technical data
008 915 04 BOMAG 31

2.1 Technical data
2.1 Technical data
Fig. 12
Dimensions in A B H H2 K L W
mm
BW 24 RH 3700 2118 2360 3090 300 4985 2042
1 BW 24 RH
Weights
Operating weight (CECE) kg 8800
with ROPS-cabin
Operating weight (CECE) kg 8300
without ROPS-cabin
Max. operating weight kg 23700
Max. mean wheel load kg 3000
Travel characteristics
Travel speed (1) km/h 0 ... 7
Max. gradability % 30
Engine
Engine manufacturer Deutz
Type TCD 2012 L04 2V
Cooling Water
Number of cylinders 4
Rated power ISO 9249 kW 74,9
Rated speed rpm 2300
Fuel Diesel
Electrical equipment V 12
Drive system hydrostatic
Driven axles 1
Brake
Service brake pneum./hydr.
Parking brake Spring accumulator
hydr. released
32 BOMAG 008 915 04

Technical data 2.1
1
BW 24 RH
Steering
Type of steering 2-point pivot steering
Steering operation hydrostatic
Tires
Tire size 11.00-20, 18 PR smooth
Air pressure min./max. bar 2 ... 8,1
Tank contents
Water Litres 400
Fuel Litres 250
Engine oil Litres 15,5
Hydraulic oil Litres 60
Coolant Litres approx. 20
1 The right for technical modifications remains reserved
Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 900
High idle speed rpm 2300 - 2350
Spec. fuel consumption g/kWh 222
Valve clearance intake mm 0,4
Valve clearance exhaust mm 0,6
Travel pump
Manufacturer Bosch-Rexroth
Type A4VG 105 DA
System Axial piston/swash plate
Max. displacement cm3/rev. 105
Max. flow capacity l/min 241,5
High pressure limitation bar 480-20
Pressure override valve bar 430+10/-20
Charge pressure, high idle bar 30 ± 2
Absolute pressure at control start bar 50
Absolute pressure at control end bar 400
Travel motor
Manufacturer Bosch-Rexroth
Type A6VM 107 HA 2T
Quantity 2
System Axial piston – bent axle
Displacement (stage 1) cm3/rev. 107
Displacement (stage 2) cm3/rev. 36,5
Permissible leakage rate l/min 4
Control start change-over bar 215
Control end change-over bar 315
Perm. leak oil rate l/min 4
Check steering/
Type AZPF-22-016R
System Gear
Displacement cm3/rev. 16
Max. steering pressure bar 175 ± 10
008 915 04 BOMAG 33

2.1 Technical data
Travel gear
Manufacturer Bonfiglioli
Type 606Y
Quantity 2
Reduction ratio 32
Steering valve
Type OSPC 250 LS
System Rotary valve
Front axle
Toe-in mm 2±1
34 BOMAG 008 915 04

Technical data 2.1
The following noise and vibration data acc. to
- EC Machine Regulation edition 98/37/EC and
- the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC
- Vibration Protection Regulation 2002/44/EC

were determined during conditions typical for this type of equipment and by application of harmonized
standards.
During operation these values may vary because of the existing operating conditions.
Noise value
Sound pressure level on the place of the operator:
LpA = 77,5 dB(A), determined acc. to ISO 11204 and EN 500
Guaranteed sound power level:

LWA = 104 dB(A), determined acc. to ISO 3744 and EN 500
! Danger
Wear your personal noise protection means (ear defenders) before starting operation.
Vibration value
Vibration of the entire body (driver’s seat)
The weighted effective acceleration value determined in accordance with ISO 7096 is ≤ 0.5 m/sec 2.
Hand-arm vibration values

The weighted effective acceleration value determined in accordance with EN 500/ISO 5349 is ≤ 2.5 m/sec2.
008 915 04 BOMAG 35

2.1 Technical data
36 BOMAG 008 915 04

3 Maintenance
008 915 04 BOMAG 37

3.1 General notes on maintenance
3.1 General notes on maintenance sult the customer service of BOMAG or the customer
service of the engine manufacturer.
When performing maintenance work always comply
with the appropriate safety regulations. Notes on the hydraulic system
Thorough maintenance of the machine guarantees far During maintenance work on the hydraulic system
longer safe functioning of the machine and prolongs cleanliness is of major importance. Make sure that no
the lifetime of important components. The effort need- dirt or other contaminating substances can enter into
ed for this work is only little compared with the prob- the system. Small particles can produce flutes in
lems that may arise when not observing this rule. valves, cause pumps to seize, clog nozzles and pilot
The terms right/left correspond with travel direction bores, thereby making expensive repairs inevitable.
forward. ●
If, during the daily inspection of the oil level the hy-
●
Always clean machine and engine thoroughly be- draulic oil level is found to have dropped, check all
fore starting maintenance work. lines, hoses and components for leaks.
● For maintenance work stand the machine on level ●
Seal external leaks immediately. If necessary in-
ground. form the responsible customer service.
●
Perform maintenance work only with the engine ●
Do not store drums with hydraulic oil outdoors, or at
shut down. least under a cover. Water can be drawn in through
●
Relieve hydraulic pressures before working on hy- the bunghole when the weather changes.
draulic lines. ●
Always use the filling and filtering unit (BOMAG
●
Before working on electric parts of the machine dis- part-no. 007 610 01) to fill the hydraulic system.
connect the battery and cover it with insulation ma- This unit is fitted with a fine filter to clean the hydrau-
terial. lic oil, thereby prolonging the lifetime of the filter.
● Clean fittings, filler covers and the area around such
parts before disassembly to avoid entering of dirt.
Environment
During maintenance work catch all oils and fuels
●
Do not leave the tank opening unnecessarily open,
and do not let them seep into the ground or into but cover it so that nothing can fall in.
the sewage system. Dispose of oils, coolant and
fuels environmentally. Notes on the cooling system
Prepare and check coolant with highest care, since
Notes on the fuel system otherwise the engine may be damaged by corrosion,
The lifetime of the diesel engine depends to a great cavitation and freezing.
extent on the cleanliness of the fuel. The coolant is prepared by mixing a cooling system
●
Keep fuel free of contaminants and water, since this protection agent (Etylene Glycol / Propylene Glycol) to
will damage the injection elements of the engine. the cooling water.
Mixing with cooling system protection agent is neces-
●
Drums with inside zinc lining are not suitable to
sary in all climatic zones. It prevents corrosion, lowers
store fuel.
the freezing point and raises the boiling point of the
● The fuel drum must rest for a longer period of time coolant.
before drawing off fuel.
●
Do not let the hose stir up the slurry at the bottom of
the drum.
●
Do not draw off fuel from near the bottom of the
drum.
●
The rest in the drum is not suitable for the engine
and should only be used for cleaning purposes.
Notes on the performance of the engine

On diesel engines both combustion air and fuel injec-
tion quantities are thoroughly adapted to each other
and determine power, temperature level and exhaust
gas quality of the engine.
If your engine has to work permanently in "thin air" (at
higher altitudes) and under full load, you should con-
38 BOMAG 008 915 04

Fuels and lubricants 3.2
3.2 Fuels and lubricants
Engine oil
Quality
Lubrication oils are classified according to their per-
formance and quality class. Oils according to other
comparable specifications may be used.
Approved engine oils

Deutz DQC II-05 DQC II-05
ACEA E3/96/E5-02/ E4-99/E6-04
E7-04
API CG-4/CH-4/CI- -
4
DHD DHD-1 -
The exact assignment of the approved oil qualities

and oil change intervals can be taken from the follow-
ing section "Lubrication oil change intervals".
Consult your local service station if in doubt.
Oil viscosity
Multi-purpose oils should be generally used.
Since lubrication oil changes its viscosity with the tem-
perature, the ambient temperature at the operating lo- Fig. 13
cation of the engine is of utmost importance when With their better temperature and oxidation stability
choosing the viscosity class (SAE-class). synthetic lubrication oils offer quite a few benefits.
Optimal operating conditions can be achieved by us-
ing the opposite oil viscosity chart (Fig. 13) as a refer- Oil change intervals
ence. The longest permissible time a lubrication oil should
Occasionally falling short of the temperature limits will remain in an engine is 1 year. If the following oil
impair the cold starting ability, but will not cause any change intervals are not reached over a period of 1
engine damage. In order to keep the occurring wear year, the oil change should be performed at least once
as low as possible, occasional exceeding of the limits per year, irrespective of the operating hours reached.
should not happen over a longer period of time. ACEA1
E3-96/E5-02/E7-04/
E4-99/
E6-04 = 500 operating hours
API2
CG-4/CH-4/
CI-4 = 500 operating hours
!Caution
These intervals apply only when using a diesel
fuel with maximum 0.5 % sulphur by weight and
for ambient temperatures higher than -10 °C.
When using fuels with a sulphur content of more
than 0.5% to 1% or under ambient temperatures
below -10 °C the oil change intervals specified in
the table must be halved. For fuels with a sulphur
1 Association des Constructeurs European d’Automobiles

2 American Petroleum Institute
008 915 04 BOMAG 39

3.2 Fuels and lubricants
content of more than 1% you should consult the ●

Avoid longer periods of standstill (formation of resin,
responsible service agency. corrosion in injection system)
● RME-fuel can damage the paint finish of the ma-
Fuels chine.
Quality ●
Fuel dilution of engine oil, therefore shortening of oil
change intervals to half.
You should only use commercially available brand
diesel fuel with a sulphur content below 0.5% and en- ●
Rubber parts, such as leak fuel return lines, seats
sure strict cleanliness when filling in. A higher sulphur will be damaged in the long run and need to be re-
content has a negative effect on the oil change inter- placed on a regular basis or should be replaced by
vals. Use only winter-grade diesel fuel under low am- parts made of fluorinated rubber. However, fluori-
bient temperatures. The fuel level should always be nated rubber is not resistant against normal diesel
topped up in due time so that the fuel tank is never run fuel.
dry, as otherwise filter and injection lines need to be ●
If the fuel filter is clogged the filter change intervals
bled. must be shortened accordingly.
When using fuels with a Cetan number < 49 poor
starting and white smoke can be expected, in particu- Coolant, anti-freeze agent
lar in connection with low ambient temperatures.
The correct quality of water is highly important when
The following fuel specifications are permitted: DIN/ preparing coolant. Clear and clean water within the
EN 590; DIN 51 601; Nato Codes: F-54, F-75; BS boundaries of the following analysis values should
2869: A1 and A2; ASTM D 975-78: 1-D and 2-D. generally be used.
●
DIN/EN 590
●
BS 2869 Water quality
●
ASTM D 975-78: 1-D and 2-D. Analysis values min. max.
pH-value at 20 °C 6,5 8,5
●
Nato Codes: F-54, F-34, F44 and XF63 Chloride ion content [mg/dm3] - 100
Sulphate ion content [mg/dm3] - 100
Winter fuel
Total hardness*1 [°dGH] ] 3 12
Danger
! *1Proportion of carbonate hardness on the total hard-
ness min. 3 dGH
Fire hazard!
Information concerning the water quality can be ob-
Diesel fuels must never be mixed with gasoline. tained from the waterworks.
For winter operation use only winter diesel fuel, to A test case for checking the water quality can be or-
avoid clogging because of paraffin separation. At very dered from the engine manufacturer.
low temperatures disturbing paraffin separation can
also be expected when using winter diesel fuel. If the values of the analysis deviate, the water must be
treated accordingly.
In most cases a sufficient cold resistance can also be
achieved by adding flow enhancing fuel additives. ●
pH-value too low
Consult the engine manufacturer. Adding of caustic lye of soda or caustic potash so-
lution.
Operation with rape seed oil methyl ester (RME ●
Total hardness too high:
„Bio Diesel“)
Mixing with dehardened water.
Due to the extreme quality differences of RMEW-fuels
available on the market, which are caused by the non-
●
Total hardness or carbonate hardness too low:
existence of a standardization, BOMAG does general- Mixing with harder water.
ly not approve any RME-fuels. If this is neglected the ●
Chlorides and/or sulphates too high:
warranty will become null and void! Mixing with dehardened water.
However, if you still intend to operate the machine As a protection against frost, corrosion and boiling
with RME-fuels you should observe the following in- point anti-freeze agents must be used under any cli-
formation: matic conditions.
●
Reduced engine power (approx. 7%), higher fuel The proportion of cooling system protection agent
consumption. must be between min. 35% and max. 45% to the wa-
●
The quality of RME-fuel should be in compliance ter.
with DIN draft 51606.
40 BOMAG 008 915 04

Fuels and lubricants 3.2
! Caution
Do not mix different coolants and additives of any
other kind.
! Danger
Health hazard!
The mixing of nitrite based anti-freeze agents with
amine based agents results in the formation of
health affecting nitrosamines.
Environment
Cooling system protection agents must be dis-
posed of environmentally.
Hydraulic oil
The hydraulic system is operated with hydraulic oil HV
46 (ISO) with a kinematic viscosity of 46 mm2/s at
40°C. For topping up or for oil changes use only high-
quality hydraulic oil, type HVLP according to DIN
51524, part 3, or hydraulic oils type HV according to
ISO 6743/3. The viscosity index (VI) should be at least
150 (observe information of manufacturer).
Bio-degradable hydraulic oil

On request the hydraulic system can also be filled with
ester based biodegradable hydraulic oil (Panolin HLP
Synth. 46). The biologically quickly degradable hy-
draulic oil meets all demands of a mineral oil based
hydraulic oil according to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth. 46
always use the same oil to top up. When changing
from mineral oil based hydraulic oil to an ester based
biologically degradable oil, you should consult the lu-
brication oil service of the oil manufacturer for details.
Check the filter more frequently after this change.
! Caution
Oil change bio-degradable hydraulic oil:
Perform regular oil analyses for content of water
and mineral oil.
Replace the hydraulic oil filter element every 500
operating hours.
Oil for travel gears/wheel hubs

For the drive axle use only multi-purpose transmission
oil of API-class GL4/GL5 with viscosity class SAE
75W/90.
The additives in this oil ensure low wear lubrication
under all operating conditions.
Lubrication grease
For lubrication use only EP-high pressure grease, lith-
ium saponified (penetration 2).
008 915 04 BOMAG 41

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

Observe the level marks
Engine BW 24 RH Engine oil ACEA E3-96/E5-02 API: CG-4/CH-4 with oil filter change
Engine oil ACEA E4-99/E6-04 approx. 9,5 litres

SAE 15W/40
(-15 °C to +40 °C)
Fuel
Diesel Winter diesel fuel approx. 250 litres
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity 46 mm2/s at approx. 60 litres
40 °C
Travel gear/wheel hubs Gear oil SAE 75W/90, API GL4/GL5 approx. 7,5 litre per side
Cooling system Coolant approx. 20 litres
Sprinkler system Water approx. 400 litres
Ballast compartment Water approx. 3500 litres
Air conditioning system Refrigerant R134A approx. 1200 g
Lubrication points lithium saponified multi-purpose grease, penetration 2 as required
42 BOMAG 008 915 04

Running-in instructions 3.4
3.4 Running-in instructions
The following maintenance work must be per-
formed when running in new machines or over-
hauled engines:
! Caution
Up to approx. 250 operating hours check the en-
gine oil level twice every day.
Depending on the load the engine is subjected to,
the oil consumption will drop to the normal level
after approx. 100 to 250 operating hours.
After 50 operating hours
● Retighten the wheel studs

● Change the engine oil
●
1st oil change in drive gear/wheel hubs
● Retighten bolted connections on intake and exhaust
tubes, oil sump and engine mounts.
● Retighten the bolted connections on the machine.

●
2. oil change in drive gear
008 915 04 BOMAG 43

3.5 Maintenance table
every 10 operating hours, daily

after 250 operating hours
Running-in instructions
every 1000 oper. hours


No. Maintenance work Comment
as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the coolant level Inspection X
glass
5.9 Check the hydraulic oil level Inspection X
glass
5.10 Drain the air pressure vessel X
5.11 Check/fill up the water provision X
in the sprinkler system
5.12 Check/adjust the scrapers X
5.13 Check the fuel level X
5.14 Multi-disc brake, function test X
5.15 Clean the cooling fins on engine X
and hydraulic oil cooler
5.16 Check the oil level in the drive X
gear/wheel hub
5.17 Change engine oil and oil filter min. 1x per X X
cartridge1 year
5.18 Change the fuel pre-filter car- X
tridge
5.19 Replace the fuel filter cartridge X
5.20 Drain the fuel tank sludge X
5.21 Battery service pole grease X
5.22 Check, replace the refrigerant X
compressor V-belt
5.23 Service the air conditioning X
5.24 Check hydraulic, pneumatic min. 1x per X
hoses and electric cables year
5.25 Check, replace the ribbed V- X
belt
5.26 Check the engine mounts X X
44 BOMAG 008 915 04

Maintenance table 3.5



as required
5.27 Retighten the wheel studs X X
5.28 Check the ROPS X
5.29 Brake system air drier min. 1x per X
year
5.30 Check, adjust the valve clear- Inlet = 0,3 mm X
ance exhaust = 0,5
mm
5.31 Adjust the control piston play X
5.32 Travel gears/wheel hubs min. 1x per X X
year
5.33 Change hydraulic oil and at least every 2 X
breather filter2 years
5.34 Change the hydraulic oil filter3 at least every 2 X
years
5.35 Change the filter for steering at least every 2 X
and brake circuits*** years
5.36 Change the coolant at least every 2 X
years
5.37 Check the supply lines for the X
compressor
5.38 Replace the crankcase ventila- at least every 2 X
tion valve years
5.39 Electronic injector test EMR X
5.40 Service the combustion air filter min. 1x per X
year,
safety car-
tridge at least
every 2 years
5.41 Service the water sprinkling X
system
5.42 Maintenance in case of frost X
5.43 Fill the windscreen washer sys- X
tem
5.44 Changing the fresh air filter in X
the cabin
008 915 04 BOMAG 45




as required
5.45 Change the tires X
5.46 Check bolted connections for X
tight fit
5.47 Temporary taking out of service X
1 Oil change intervals depend on quality of oil and fuel (sulphur content)
2 Also in case of repair in the hydraulic system.
3 Also in case of repair in the hydraulic system.
46 BOMAG 008 915 04

4 Electrics
008 915 04 BOMAG 47

4.1 Understanding circuit diagrams

Wiring diagrams are graphical representations of circuitry conditions, related to the electrical system. They do
not contain any information about the actual type of wiring, they only serve the purpose of visualizing the circuitry
logics.
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system.
This plan provides the following information:
●
Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses,
switches, consumers, relays, ...
●
The sequence in which current flows through the individual elements in the electric circuit.
●
Connections between the examined, faulty electric circuit and other circuits in the vehicle wiring system.
●
Pin assignment of plug-and-socket connections.
Structure
●
Table of contents (Fig. 14)
● Function groups (Fig. 15)
● List of components (Fig. 17)
48 BOMAG 008 915 04

Understanding circuit diagrams 4.1
Table of contents (Fig. 14)
The table of contents lists all function groups.
Fig. 14 Table of contents
Example:
Function group "Warning systems“, drawing number XXX XX can be found on page no. 8.
008 915 04 BOMAG 49

Function groups (Fig. 15)

On the individual pages the electric circuits are combined to function groups.
Arrangement of current paths
The individual current paths must be read as follows:
●
From top (plus potential) to bottom (minus potential).
●
From left to right.
●
From function group to function group.
●
Via cross references for potentials and relays.
Fig. 15 Function groups
Potential cross references

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

Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing
contacts.
A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is
additionally attached to the bottom of each contactor coil.
Example:
The coil of relay (K99) is located on page no. 8 in current path "6".
The mimic diagram under the relay informs that a change-over switch with contact types 30, 87 and 87a is trig-
gered.
The changeover contact can be found on page no. 8 in current path "3".
50 BOMAG 008 915 04

Understanding circuit diagrams 4.1
Current paths
The pages of a circuit diagram are sub-divided into current paths (Fig. 16) (0 ..... 20).
Fig. 16 Current paths
008 915 04 BOMAG 51

List of components (Fig. 17)

Here you find all components used in alphabetical order, related to the name of the component (A01, A02....).
Fig. 17 List of components
Component cross references

Example:
The warning horn "B 11" is located on page no. 8 in current path 3.
52 BOMAG 008 915 04

Designation of components in the wiring diagram 4.2
4.2 Designation of components in the wiring diagram
The designation of components in the wiring diagram groups several electrical parts of the machine in one
group. The components can be identified by the following table.
Component designa- Meaning

tion
A Interval switch, indicator relay, modules, electronic component
B Pressure, pressure differential, temperature switches and sensors, transducers
C Capacitor
E Headlights, heater, air conditioning condenser
F Fuses
G Battery, generator
H Control lights, warning buzzer, warning light
K Relays
M Starter, pumps, motors
P Operating hour meter, general gauges
R Transducers, resistors
S Switches, momentary contact switches
V Diode
X Terminal
Y Solenoid valves
008 915 04 BOMAG 53

4.3 Terminal designations in wiring diagram
4.3 Terminal designations in wiring diagram

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

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

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

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

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

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

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

58b Tail light changeover for single axle trailers
58c Trailer plug for single core wired and trailer fused tail light
58d Adjustable dashboard light, tail light and side light
58L Side light, left
58R Side light, right
61 Generator control
75 Radio, cigarette lighter
76 Loudspeaker
87 Relay contact on breaker and two-way contact, input
54 BOMAG 008 915 04

Terminal designations in wiring diagram 4.3
Terminal designation Meaning
87a Relay contact on breaker and two-way contact, output 1 (breaker side)
87b Relay contact on breaker and two-way contact, output 2
87c Relay contact on breaker and two-way contact, output 3
87z Relay contact on breaker and two-way contact, input 1
87y Relay contact on breaker and two-way contact, input 2
87x Relay contact on breaker and two-way contact, input 3
88 Relay contact for maker

88a Relay contact on maker and two-way contact, (maker side) output 1
88b Relay contact on maker and two-way contact, (maker side) output 2
88c Relay contact on maker and two-way contact, (maker side) output 3
88z Relay contact on maker, input 1
88y Relay contact on maker, input 2
88x Relay contact on maker, input 3
B+ Battery positive
B- Battery minus
D+ Dynamo Plus
D- Dynamo Minus
DF Dynamo field (generator excitation current)
DF1 Dynamo field 1 (generator excitation current)
DF2 Dynamo field 2 (generator excitation current)
008 915 04 BOMAG 55

4.4 Circuit symbols in the circuit diagram
4.4 Circuit symbols in the circuit diagram

Circuit symbol
●
Circuit symbols are standardized representations for electrical appliances. They serve the purpose of a sim-
plified representation of complete systems, from which, however, the function can be clearly identified. This
standardization is in compliance with the globally valid regulations of the IEC (International Electrical Commis-
sion). The standardization serves the purpose of global understanding and fault free connection of appliances,
especially in automobile repairs. Since the wiring diagram is intended to show only the most essential aspects,
the circuit symbol only shows as much of the function, as is needed for easy recognition and for the avoidance
of mistakes.
Fig. 1 Example: Circuit symbol

1 Current source
2 Conductor
3 Switch
4 Ground
5 Filament lamp
6 Filament lamp with two luminous elements
7 Voltmeter
8 Amperemeter
9 Resistance
10 Backup
11 Line connection (fixed)
12 Line connection (separable)
56 BOMAG 008 915 04

Battery ground and analog ground 4.5
4.5 Battery ground and analog 4.6 Current and voltage
ground
General
GND, battery ground If one wants to describe electric current, this can most
simply be accomplished by means of a comparison:
The term "ground" (abbreviated GND) describes a
conductive body which is normally defined with the One simply compares electric current with water.
potential of "Zero" Volt and represents the reference
potential for operating voltages. Voltage
The positive pole of the supply voltage (symbol + ) and
all other electric voltages and electical signals in an
electrical circuitry refer to the ground potential.
On motor vehicles and also on motorbikes and bicy-
cles the ground potential is represented by the chas-
sis or the frame. As a conductive part, which covers
the entire vehicle, it also serves a return conductor for
the vehicle wiring system - the consumers only need
to be wired up.
Terminal designation for GND = terminale 31
AGND, analog ground

Apart from the "normal" battery ground there is also
the analog ground, which is solely reserved for sen-
sors.
Fig. 1
1 (Fig. 1) Charge
2 Voltage
3 Current
The equalization attempt between different electric
charges is referred to as electric voltage.
Voltage sources have two poles of different charge.
On the one side we have the plus pole with a lack of
electrons, on the opposite side the minus pole with a
surplus of electrons. This electric "pressure" is known
as electric voltage.
Fig. 2
If there is a connection between these two poles a dis-
charge will take place, resulting in the flow of an elec-
tric current.
Plus pole= lack of electrons
Minus pole = excess of electrons
008 915 04 BOMAG 57

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

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

The electric amperage (I) is measured in Ampere
(A).
The technical flow direction is specified from

PLUS to MINUS.
i Note
Current actually flows from minus to plus, because the
current flow is made up of negatively charged elec-
trons.
But since this was only discovered after the poles of a
current source had already been designated, the as-
sumption that current flows from plus to minus was
maintained for historic reasons.
Circuit
Fig. 3 Circuit
A simple circuit consists of a current source 1 (Fig. 3),
a consumer (3) and the connecting wiring.
When the circuit is closed, current can flow.
The circuit can be interrupted or closed with a switch
(2).
The system is protected by a fuse (4).
58 BOMAG 008 915 04

Current and voltage 4.6
Types of current Pulse width modulation (PWM)
Direct current (D.C.)
Fig. 1 Direct current (D.C.)

Direct current flows with steady voltage and amper-
age from the plus to the minus pole. Fig. 3 PWM
Pure D.C.-voltages are only delivered by accumula- The PWM signal is in most cases generated by a con-
tors or batteries. trol and can be used to trigger proportional valves.
The voltage in the vehicle wiring system is no pure The signal (square wave signal) is changed in its
D.C.-voltage. Even without the generator running, but pulse control factor, the period, however, remains un-
the consumers switched on, the voltage is not con- changed.
stant, but drops gradually according to the battery The following applies:
charge condition. ●
The signal voltage cannot be measured.
The internal resistance of the battery also causes per- ●
The current can be measured.
manent changes in the vehicle voltage, as soon as
consumers are switched on or off.
Caution
!
Alternating current (A.C.)
Solenoid valves must not be interference sup-
pressed with suppressor diodes.
Fig. 2 Alternating current (A.C.)

Alternating current not only changes its direction, but
also its amperage.
008 915 04 BOMAG 59

4.7 Resistance
4.7 Resistance ●
The cleaner the contacts, the better the current.
●
The quality of the ground cable is of the same im-
portance as the supply line.
Resistance and voltage drop
While current flows through a conductor the current
Unnecessary resistances
flow is more or less inhibited by the conductor, this in-
hibitation is referred to as Resistance. Unnecessary resistances are frequently caused by
mechanical connections, even clean ones, but mainly
soiled and oxidizes terminals, too thin cables, material
with poor conductivity or bent open cable lugs.
Bad
Fig. 1 Various size resistors

Fig. 1 Screw-type terminals
Each conductor has its specific resistance, which is
characteristic for the corresponding material. A good Copper wires are squashed and thus become faulty.
conductor has a low resistance, a poor conductor has
Better
a high resistance.
Fig. 2 Spring clamps

Connecting clamps for flexible conductors
BOMAG No. 057 565 72
Ampacity up to 20 Amp.
Cable cross-section 0.08 to 2.5 qmm
Fig. 2 Potentiometer, infinitely adjustable resistor
The resistance can only be measured with a Multime-
ter.
Symbol, R
Unit, Ohm Ω
The electric resistance (R) is measured in Ohm Ω.

Rule of thumb:
●
The thicker the cable cross-section, the lower the
voltage loss.
●
The shorter the cable, the better the current.
60 BOMAG 008 915 04

Resistance 4.7
Sometimes the flanks of flat plugs bend open. If these
are closed again with the help of pliers the flanks will
be excessively strained at the bend and will definitely
break sooner or later. It is better to place a small nail
under the bottom of the cable lug before bending.
Fig. 3
In many cases it is better to replace the contact. Soiled
or oxidized contacts should be cleaned with Ballistol
(Fig. 4) and subsequently wetted with copper paste.
Copper paste is a heat resistant grease, which has
been mixed with copper powder. The paste protects
electric contacts against oxidation. Copper paste
keeps water away.
Fig. 5
Hint for practice:
A tool you cannot buy. The pliers were converted, the
nail is permanently present.
Fig. 4 Balistol oil
008 915 04 BOMAG 61

4.8 Series / parallel connection
4.8 Series / parallel connection ●

In series connection the plus pole of the first battery
must be connected with the minus pole of the sec-
Series connection ond battery.
In a series circuit the resistors (consumers) are lined ●
The sum of all individual voltages is applied to the
up one after the other and the same current (I) passes free poles.
through each of the consumers However, series con- ●
The total capacity (Ah) is identical with the capacity
nection of consumers is not suitable in practice, as of the individual battery.
each resistance causes a voltage drop. In the vehicle
wiring system all consumers are designed for the
same vehicle voltage (e.g. 12 Volt).
Fig. 1 Series connection
Current
In series connection the current is identical at every
point.
Itotal = I1 = I2 = I3
Voltage
The sum of all partial voltages is identical with the total
voltage.
Utotal = U1 + U2 + U3
Resistance
The sum of all partial resistances is identical with the
total resistance.
Rtotal = R1 + R2 + R3
Series connection of batteries
Fig. 2
In order to achieve a vehicle voltage of 24 V two bat-
teries of the same type and capacity must be connect-
ed in series mode.
62 BOMAG 008 915 04

Series / parallel connection 4.8
Parallel connection ●
In parallel connection the plus pole of the first bat-
In parallel connection all resistances (consumers) are tery is connected with the plus pole of the second
connected between feed and return line. battery and the minus pole of the first battery with
the minus pole of the second battery.
●
All resistances (consumers) are supplied with the
same voltage.
●
Plus and minus poles have the voltage of the single
battery applied.
● Each of the resistances (consumers) draws as
much current as required.
●
The total capacity (Ah) is identical with the sum of
all battery capacities.
The disadvantage of a parallel connection becomes
apparent, by equalizing currents flowing between par-
allel batteries, if the batteries have different states of
charging.
Fig. 3 Parallel connection
Current
The total current is the sum of all currents.
Itotal = I1 + I2 + I3
Voltage
The voltage values are identical at every resistance
(consumer).
Utotal = U1 = U2 = U3
Resistance
The total resistance is less than the lowest individual
resistance.
Parallel connection of batteries
Fig. 4
By connecting 2 batteries of same type and capacity
in parallel mode the capacity can be doubled, be-
cause the individual capacities add up to the total ca-
pacity.
008 915 04 BOMAG 63

4.9 Ohm's law
4.9 Ohm's law 4.10 Electrical energy

In a closed electric circuit voltage, current and resist-
ance must always be considered in close relation.
This relation is represented by Ohm's Law.
Fig. 1
In a closed electric circuit current and voltage gener-
ate energy.
Fig. 1 If a current of 1 Ampere flows at a voltage of 1 Volt,
According to this law a voltage of 1V is required to let energy of 1 Watt is produced.
1A (ampere) flow through a conductor with a resist-
Advice
ance of 1 (Ohm Ω).
By means of this triangle the formula can be easily re-
Advice arranged, the value you are looking form must just be
By means of this triangle the formula can be easily re- blanked off with a finger.
arranged, the value you are looking form must just be
Energy P = I multiplied with U
blanked off with a finger.
Amperage I = P divided by U
Voltage U = I multiplied with R
Voltage U = P divided by I
Resistance R = U divided by I
U = Voltage in Volt
Amperage I = U divided by R
I = Current in Ampere
U = Voltage in Volt
P = Power in Watt
I = Current in Ampere
R = Resistance in OHM Ω
64 BOMAG 008 915 04

Formula diagram 4.11
4.11 Formula diagram
Description:
● Select the desired value from the inner circle.
● Determine the formula variables in the quarter circle
●
Calculate
Example:
P = 150 Watt
U = 24 Volt
Sought for = Current in Ampere
I = P : U = 150 W : 24 Volt = 6.25 Ampere
Fig. 1 Formula diagram
Resistance, R Ohm Ω
Voltage, U Volt
Current, I Ampere
Power, P Watt
008 915 04 BOMAG 65

4.12 Metrology
4.12 Metrology Multimeter

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

If voltage is present, the corresponding light emitting
diode will light up.
66 BOMAG 008 915 04

Metrology 4.12
Resistance and continuity measurement with mul- Voltage and voltage drop measurement with mul-
timeter timeter
Fig. 2
The continuity tester of the multimeter can be used to Fig. 4 Measuring voltage
measure whether there is a connection between 2 ●
Measurement at the voltage source measures the
measuring points. currently available Voltage.
●
The meter is always connected parallel to consum-
er, component or power source.
Fig. 3
The following information should be observed when
measuring resistance and continuity: Fig. 5 Voltage measurement
● The component to be measured must not be con- ●
A measurement at the consumer measures the volt-
nected to the power supply during the measure- age drop at this component.
ment.
●
At least one side of the component to be measured
must be disconnected from the circuitry, as other-
wise the measuring result may be influenced by
parallel components.
●
Polarity is of no significance.
008 915 04 BOMAG 67

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

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

●
The meter is connected in series with the consum-
er. Fig. 1 Clip-on measuring instrument
●
During the measurement the current must be able
to flow through the meter, i.e. the electric circuit
must be opened.
Fig. 2
●
For measuring current the individual conductor
must be fully enclosed by the measuring tongs, the
actual measurement takes place without contact.
Fig. 7 Current measurement
Advice
If the electric circuit is difficult to access and the inter-
nal resistance of the consumer is known, the voltage
may also be measured at the consumer.
The current value can then be calculated with the help
of Ohm's law.
68 BOMAG 008 915 04

Metrology 4.12
Magnet tester Power measurement
The electric power of a module within a circuit can be
indirectly determined (calculated) by separate meas-
uring of current and voltage.
However, there are also pure power meters with 4
connections available. The power meter has a electro-
dynamic measuring mechanism. The current circuit
must be opened for measuring. Take care when per-
forming power measurements: Voltage or current path
may already be overloaded during the measurement,
even though the end stop in the meter has not yet
been reached.
Fig. 1 Magnet tester

The magnet tester is used to test solenoid valves and
magnetic coils.
The test lamp responds to the magnetic fields of A.C-
voltage, D.C.-voltage and permanent magnets.
●
The component to be tested does not need to be re-
moved.
●
The magnetic coil can also be tested under a pro-
tective cap.
Fig. 2
008 915 04 BOMAG 69

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

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

●
The solenoid valve Y48 (Fig. 3) is supplied with
electric current when switch S34 is switched to po-
sition "1" or "2".
●
Solenoid valve Y20 is supplied, if the switch is in po-
sition "1".
●
Solenoid valve Y21 is supplied, if the switch is in po-
sition "2".
The three diodes V02 serve as free-wheeling diodes
with the function of of eliminating voltage peaks.
70 BOMAG 008 915 04

Diodes, relays, fuses 4.13
Light emitting diodes Relays
Fig. 1 Relays
Relays are commonly used to realize switching proc-
esses.
Fig. 4 LED
A free-wheeling diode prevents induction voltage from
The light emitting diode, also referred to as LED, is a
flowing back from the coil into the vehicle wiring sys-
semi-conductor diode, which generates (emits) light
tem, which would cause interference with electronic
during operation in forward direction. A semi-conduc-
components (control units).
tor crystal thereby emits a light signal, which is con-
verged or scattered by the lenticular shape of the With the possibility of using breaker - maker contacts
head. Light emitting diodes are available in various the effect of an information can be reversed.
colours, sizes and shapes. They are for this reason
used as signal lamps. This component is constructed
of different semi-conductor crystals, depending on its
colour. It works like any other semi-conductor diode.
Fig. 2 Relay circuitry

The windscreen wiper and washer motors can only be
operated via switches S20 and S21, when relay K32
is supplied with electric current (Fig. 2).
86 = Positive supply for coil
008 915 04 BOMAG 71

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

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

The melting time at 23 °C is:
●
approx. 1 hour with 1.5 times the rated current
●
approx. 1 minute with 2.5 times the rated current.
A 5 Amp fuse loaded with 1.5 times the rated current
(7.5 Amp) will finally melt after approx. 1.5 hours.
Yellow = 5 A
Brown = 7.5 A
White = 8 A
Red = 16 A
Blue = 25 A
72 BOMAG 008 915 04

Telemecanique switch 4.14
4.14 Telemecanique switch
Example of terminal designations
Fig. 1 Terminal designations

●
Normally open contact 23 located on block 2
●
●
Normally closed contact 12 located on block 1
●
Normally closed contact 11 located on block 1
●
● Normally open contact 33 located on block 3
●
●
● Normally open contact 43 located on block 4
●
i Note
If e.g. block 5 is not needed to design a switch, the
numbering for blocks 1,2,3,4 and 6 remains un-
changed.
008 915 04 BOMAG 73

4.14 Telemecanique switch
Disassembly
Fig. 2 Disassembly
● Lift up the interlock (5).
Fig. 4 Pulling out the front element

●
Lift up the interlock (2) and pull out the front element
(3).
Fig. 3 Folding down the switch block
●
Fold down the switch block (4).
●
Loosen screw (1).
74 BOMAG 008 915 04

Telemecanique switch 4.14
Assembly
Fig. 5 Assembly
●
Insert the front element (3) into the bore in the con-
trol panel.
Fig. 7 Assemble the switch block

●
Clip on the switch block (4).
Fig. 6 Observe the marks.

i Note
Hook in the switch block at the bottom first (Fig. 7).
●
Clip the fastening adapter (6) onto the front element
(3).
i Note
Watch the marls on front element (Fig. 6) and fasten-
ing flange.
●
Tighten the screw (1) with a tightening torque of 0.6
Nm.
008 915 04 BOMAG 75

4.15 Plug connectors
4.15 Plug connectors

Duties and requirements
Electric plug connectors must provide a reliable con-
nection between different system components and
thus ensure the safe function of the systems under
any operating condition. There design ensures that
they will withstand the applied loads throughout the
lifetime of the machine.
Examples for these loads are:
● Vibration acceleration
● Temperature fluctuations, high and low tempera-
tures
●
Dampness
● Micro movements of the contact with resulting fric-
tion corrosion.
These loads may increase the transition resistances
of the contacts, up to total interruption. Even the insu-
lation resistances may drop and thus cause short cir-
cuits in neighbouring lines. Electric plug connectors
must therefore have the following properties:
●
Low transition resistances of the conductive parts.
●
High insulation strength between conductive parts
with different voltage potentials.
●
Excellent leak tightness against water and mois-
ture.
76 BOMAG 008 915 04

Magnetic coil plug 4.16
Magnetic coil plug with LED and suppres-
4.16 Magnetic coil plug
sor diode
The plug is equipped with a polarized function display
and a suppressor diode as protection against over-
voltages.
Fig. 8 Magnetic coil plug without LED and with-

The plug is polarized, it does not matter whether Pin1 out supressor diode
or Pin 2 is supplied with current, Pin 3 is not used. The
The plug has no LED and no suppressor diode as pro-
LED lights if voltage is applied to the solenoid valve.
tection against overvoltages.
Fig. 9
Fig. 10 Switching symbol in circuit diagram
008 915 04 BOMAG 77

4.16 Magnetic coil plug
Assembly of magnetic coil plugs

These instructions are intended to explain the correct
installation of the magnetic coil plug. The objective of
the instructions is the correct installation of the plug
and to avoid malfunctions in the field caused by mois-
ture and any related corrosion damage.
Fig. 13
●
Fasten the screw with a suitable screwdriver.
Fig. 11 Solenoid valve plug with pointed cable
Fig. 14
●
Press the plug firmly on again.
Fig. 12
●
Connect the plug with the coil connection and press
it firmly onto the connecting housing.
Fig. 15
●
Retighten the screw.
78 BOMAG 008 915 04

Deutsch plug, series DT and DTM 4.17
4.17 Deutsch plug, series DT and
DTM
General
Plug connectors DT and DTM have a wedge to hold
the pins and sockets in their position. This wedge can
be removed and replaced, without having to cut any
leads.
Fig. 16
! Caution
There should be no gap between plug and sole-
noid coil!
Fig. 18 Crimp connections
Caution
!
Do not crimp more than one lead per pin or per

socket.
Sockets and pins must not be soldered to leads,
they may only be crimped (see special tools for
electrics).
Fig. 17 Correctly installed plug without gap When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
●
Perform a pull test on each lead, each of the termi-
nals and connections must withstand a pulling force
of 45 N without any difficulties.
008 915 04 BOMAG 79

4.17 Deutsch plug, series DT and DTM
DT Series
Fig. 1 DT plug connection
Fig. 2 DT Series
Fig. 3 Sectional drawing
80 BOMAG 008 915 04

Installing DT contacts
Fig. 4
●
Insert the contacts through the rubber grommet until
they click into place.
● Insert the orange wedge in direction of arrow.
Caution
!

nals and connections must withstand a pulling
force of 45 N without any difficulties.
i Note
Use the same method when assembling the socket.
008 915 04 BOMAG 81

Disassembling DT contacts
Fig. 5
● Pull the orange wedge out with long nose pliers.
● Slightly pull the lead and unlock the interlocking
hook with a screw driver.
●
Pull the contact out of the socket.
i Note
In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.
82 BOMAG 008 915 04

DTM Series
Fig. 1 DTM plug connection
Fig. 2 DTM Series
Fig. 3 Sectional drawing
008 915 04 BOMAG 83

Installing DTM contacts
Fig. 4
● Insert the contacts through the rubber grommet until
they click into place.
●
Insert the orange wedge, until it clicks into place.
Caution
!

nals and connections must withstand a pulling
force of 45 N without any difficulties.
i Note
84 BOMAG 008 915 04

Disassembling DTM contacts
Fig. 5
i Note
●
Pull the orange wedge (interlock) out with long nose Use the same method when assembling the socket.
pliers.
In this case the interlock disassembly tool (see special
●
Slightly pull the lead and unlock the interlocking tools for electrics) serves as an aid to remove the
hook with a screw driver. wedges.
●
Pull the contact out of the socket.
008 915 04 BOMAG 85

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

The connecting clamp clamps up to 3 or 5 stripped fine conductors of 0.08 mm2 to 4 mm2, single or multiple
strand up to 2.5 mm2. And this even without tools (Fig. 2).
That's how it works
● Strip 9-10 mm of the lead.
●
Open the actuating lever and insert the strand.
●
Return the actuating lever to initial position.
! Caution
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without
any difficulties.
86 BOMAG 008 915 04

Plugs and terminals in spring clamping technology 4.18
Series clamp
That's how it works

● Insert a screw driver into the actuating opening until it bottoms.
●
Strip 9-10 mm of the lead and insert it into the clamp.
●
Pull out the screw driver.
Caution
!
any difficulties.
Measuring signals
On these terminal blocks the bridge slot is most suitable for tapping off and measuring signals. Here you may
directly insert a 4 mm test adapter (see special tools for electrics) for connecting a measuring lead. This test
adapter is standard in the central electrics of heavy equipment machines.
Fig. 4 Test adapter
008 915 04 BOMAG 87

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

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

●
The most reliable measurements on the plug can be made when using the measuring and connecting cable
with 2mm plug (see special tools for electrics).
88 BOMAG 008 915 04

Plugs and terminals in spring clamping technology 4.18
Measuring signals
Fig. 7 X-COM plug plugged onto the series clamp
008 915 04 BOMAG 89

4.19 Inductive proximity switches
4.19 Inductive proximity switches NPN circuitry
General
In all automated sequences the use of sensors as a
source of information for the electronic control is indis-
pensable. The sensors deliver the necessary signals
about positions, end positions, filling levels or serve as
pulse transducers for counting tasks or speed detec-
tion. In industrial applications inductive and capacitive Fig. 10 NPN circuitry
proximity switches are today indispensable. Com-
pared with mechanical switches, they offer almost ide- On sensors with NPN-circuitry the output stage con-
al prerequisites: non-contact, wear free operation, tains a NPN-transistor, which switches the load
high switching frequencies and switching accuracies, against the negative operating voltage. The load is
as well as high protection against vibration, dust and connected between the output and the positive oper-
moisture. Inductive sensors detect all metals without ating voltage.
contact, capacitive sensors detect almost all solid and Breaking and making contacts
liquid media, such as metal, glass, wood, plastic, wa-
ter, oil, etc.
Working principle
Fig. 8
The working principle is based on the principle of the
dampened LC-oscillator. The coil of the oscillation cir-
cuit forms a high-frequency magnetic stray field. Fig. 11
This stray field leaks out from the active area of the Proximity switches are used as breaking or making
proximity switch. If metal or non-ferrous metal enters contacts. Depending on the design the switching dis-
into the response range energy is absorbed. The os- tances are 2 or 4 mm. The maximum amperage is 300
cillator is thus dampened and the resulting change in mA.
current consumption is evaluated. The LED (Fig. 11) lights up, when the initiator has de-
tected metal in its stray field.
PNP circuitry
Fig. 9 PNP circuitry

On sensors with PNP-circuitry the output stage con-
tains a PNP-transistor, which switches the load
against the positive operating voltage. The load is
connected between the output and the negative oper-
ating voltage. The switch is designed with a normally
open contact, i.e. the contact closes when the initiator
comes in "contact" with metal.
90 BOMAG 008 915 04

Level sensor in diesel tank (R03) 4.20
4.20 Level sensor in diesel tank
(R03)
Fig. 1
●
The analog level switch is a variable resistance to
ground.
Fig. 12 Circuit diagram, making contact

The circuit diagram (Fig. 12) shows a proximity switch
with normally open contact.
Brown = voltage supply
Blue = ground supply
Black = switching output
The initiator switches the relay (K05)
Fig. 2
n = Fuel level gauge (P01)
008 915 04 BOMAG 91

4.21 Differential pressure switches hydraulic oil filter, B21and B22
4.21 Differential pressure switches 4.22 Brake oil temperature switch,

hydraulic oil filter, B21and B22 B148
Fig. 1 Fig. 1
1 B21, differential pressure switch hydraulic oil filter 1 B21, differential pressure switch hydraulic oil filter
(brake oil) (brake oil)
2 B22, differential pressure switch hydraulic oil filter 2 B22, differential pressure switch hydraulic oil filter
(charge circuit) (charge circuit)
3 B148, brake oil temperature switch 3 B148, brake oil temperature switch
●
The differential pressure switches (Fig. 1) switch to ●
The temperature switch switches to ground at a
ground at a pressure differential of ∆ 3.6 bar. temperature above 120°C.
Switching of one of the pressure switches connects If the brake oil temperature exceeds 120°C, the mon-
the monitoring board (A15, Pin17) to ground. The itoring board (A15, Pin20) is connected to ground.
warning light j (Fig. 2) lights. Warning lamp l (Fig. 2) flashes.
Fig. 2 Monitoring board, A15 Fig. 2 Monitoring board, A15

j yellow = lights when the hydraulic oil filter is con- l red = flashes when the brake oil temperature
taminated. Check the hydraulic system, exceeds 120°C. The warning buzzer
change the hydraulic oil filter. sounds.
i Note
The warning buzzer is activated by the monitoring
board (Pin23).
92 BOMAG 008 915 04

Brake pressure switches, B12 and B102 4.23
4.23 Brake pressure switches, B12 Pressure switch (B102)
and B102 ●
At a pressure of 5 bar the pressure switch will
switch to ground.
When the pressure switch (B102) switches, relay
(K36) will switch on the brake lights (E33) and (E34).
Fig. 1
1 B12, brake pressure switch (normally closed)
2 B102, brake light pressure switch (normally open)
Pressure switch (B12)

●
The pressure switch opens at a pressure higher
than 5.6±0.6 bar.
The monitoring board (A15, pin 18) remains connect-
ed to ground, as long as the pressure is below this
switching point. The warning light a (Fig. 2) lights.
Fig. 2 Monitoring board, A15

a red = lights in case of too low pressure in the
brake accumulator. The warning buzzer
sounds. Stop the machine and wait with
the engine running, until the warning light
goes out.
i Note
board (Pin23).
008 915 04 BOMAG 93

4.24 Float switch in water tank, B33
4.24 Float switch in water tank, B33

d yellow = Waning light for water tank filling level.
Lights if the water level in the tank is too
low.
Fig. 1 Float switch (normally closed)

In case of a too low water level the float switch will
switch to ground.
With the sprinkling system switched on (relay K104
switched) and a lack of water, the monitoring board
(A15, Pin19) is connected to ground. The water tank
filling level warning light d (Fig. 2) lights.
94 BOMAG 008 915 04

Oil pressure switch, B06 4.25
4.25 Oil pressure switch, B06 Immediately close all connections and openings
with new and clean plugs/caps.
Oil pressure monitoring Only remove plugs/caps just before assembling.
Environment
Catch engine oil and dispose of environmentally.
Fig. 3 Oil pressure switch (normally closed)
Warning light, engine oil pressure

With a too low engine oil pressure the monitoring
board (A15, Pin17) is connected to ground. Warning
lamp e (Fig. 4)flashes.
Fig. 5
●
Unlock and pull out the cable plug (Fig. 5).
● Unscrew the oil pressure switch.
Assembling the pressure switch

e red = Warning light, engine oil pressure
Flashes when the engine oil level is too
low, the warning buzzer sounds, the en-
gine is shut down after 10 seconds.
Fig. 6
i Note ●
Insert the oil pressure switch with a new seal ring
The warning buzzer is activated by the monitoring and tighten.
board (Pin23).
The engine is shut down by the monitoring board i Note
(Pin24) via relay (K22). Tightening torque: 40 Nm
Disassembling the pressure switch

●
Push on the cable plug.
! Caution
Ensure absolute cleanliness when working in the
lubrication oil system.
Thoroughly clean the area around the affected
component. Dry off wet locations with com-
pressed air.
008 915 04 BOMAG 95

4.26 Coolant temperature switch, B152
4.26 Coolant temperature switch, Disassembling the temperature switch

B152
Environment
Coolant temperature monitoring Catch running out fluids in a suitable vessel and
dispose of environmentally.
i Note
Follow the corresponding documentation in the oper-
ating instructions to drain and fill the cooling system.
Fig. 7 Coolant temperature switch (normally open)
Warning light, overheating of engine

With a too high coolant temperature the monitoring
board (A15, Pin17) is connected to ground. Warning
lamp i (Fig. 8)flashes.
Fig. 9
●
Unlock and pull out the cable plug (Fig. 9).

i red = Warning lamp, overheating of engine
flashes if the engine overheats, warning
buzzer sounds.
i Note
board (Pin23). Fig. 10
● Unscrew the temperature switch (Fig. 10).
96 BOMAG 008 915 04

Sensor (B124), water in fuel filter 4.27
Installing the temperature switch 4.27 Sensor (B124), water in fuel fil-
ter
2
2
2
Fig. 11
● Screw in the temperature switch (Fig. 11).
1 1
i Note
Make sure that the seal rings are present .
Tightening torque: 24 Nm. 4
Fig. 12
● Push on the cable plug (Fig. 12). Fig. 13
Warning light water in fuel filter

With water in the filter the sensor will switch to ground.
The water in fuel warning light b (Fig. 14) lights up.
008 915 04 BOMAG 97

4.28 Air filter vacuum switch, B03
4.28 Air filter vacuum switch, B03

b yellow = Water in fuel warning light.
Lights when the water content in the fuel
pre-cleaner reaches the sensor contacts.
The warning buzzer sounds.
Fig. 15 Vacuum switch (normally open)
i Note
Air filter warning light
board (Pin23). The vacuum switch 1 (Fig. 15) operates at a vacuum
of > 50 mbar.
The switch contact connects the monitoring board
(A15, Pin16) to ground. The air filter warning light h
(Fig. 16) lights.

h yellow = Air filter warning light.
Lights when the combustion air filter is
contaminated.
Clean or replace, as necessary.
98 BOMAG 008 915 04

Charge control light, operating hour meter 4.29
4.29 Charge control light, operat- RPM-meter1
ing hour meter Terminal "W" on the generator delivers a pulsating di-
rect voltage, which can be utilized to determine the ro-
tary speed of the engine.
Fig. 1 Generator
1 Terminal W
2 Terminal D+
3 Terminal B+
Charge control light, H08

If the battery is not being charged, a ground signal is
applied to D+ terminal 2 (Fig. 1). Current flows from
the monitoring board (A15) through the charge control
light and through (Pin10) to the D+ terminal. The
charge control light g (Fig. 1) lights up.

g yellow = Charge control light.
Lights if the battery is not being charged.
Operating hour meter, P00

When battery voltage is applied to the D+ terminal, the
operating hour meter will count the operating hours.
p = Operating hour meter.
Counts the operating hours while the
generator is rotating.
1 Option
008 915 04 BOMAG 99

4.30 Fuel preheating, R79
4.30 Fuel preheating, R79 4.31 Glow plugs
R81 to R84
The engines are optionally fitted with glow plugs as
cold starting aids. Preheating the glow plugs in the
combustion chamber of the diesel engine ensures
perfect cold starting and post-heating of the glow
plugs has a positive effect on the emissions from the
still "cold running" diesel engine (e.g. avoidance of
white smoke, noise reduction).
Fig. 1
1 Water separator sensor connection (B124)
2 Fuel pre-heating connection 1 (R79)
In diesel engines the pre-heating of the fuel prevents
malfunctions caused by the formation of jelly (paraffin
separation) in the fuel under low temperatures.
Operating the ignition switch activates the heater, this
should take place at least 5 minutes before starting
the engine. Fig. 1
The generated heat works directly under the filter ele-
ment and melts the wax crystals that have formed, so Triggering of glow plugs
that the fuel can flow through the filter element without ●
When the preheating control unit (K14) is energized
restriction. The 200W heating is supplied with 12V via terminal (17 and 50a) on the ignition switch, it
D.C-current. supplies the glow plugs with battery current and the
control light in the monitoring board (A15, Pin3) with
ground via relay (K86).
i Note
Relay (K14) and glow plug fuse (F48) are mounted on
the battery (G03).
1 Option
100 BOMAG 008 915 04

Engine solenoid to shit down the engine, Y13 4.32
Pre-heating control light 4.32 Engine solenoid to shit down
the engine, Y13
General
When switching the ignition on, the engine solenoid is
supplied with 12 Volt.
Interrupting this power supply shuts down the engine.
The engine shut-down can be triggered through the
ignition switch (S00), the emergency stop button
(S01) or the monitoring board (A15) in case of too low
oil pressure (terminal X6:24).
Technical data: 12 Volt, 4 Ampere

c yellow = Pre-heating control light.
Lights when the ignition switch is in posi-
tion "Preheating or Start".
Fig. 1
Disassembling the engine solenoid

● Pull the cable of the engine shut-down facility.
Fig. 2
●
Unscrew fastening screws 1 (Fig. 2).
●
Remove the engine shut-down assembly.
●
Check the components visually.
008 915 04 BOMAG 101

4.32 Engine solenoid to shit down the engine, Y13
Assembling the engine solenoid
Fig. 5
● Force the governor rod to stop position and hold it
(Fig. 5).
Fig. 3
●
Assemble a new O-ring (Fig. 3).
●
Cover the O-ring slightly with oil.
Fig. 6
●
Assemble the engine shut-down assembly (Fig. 6).
●
Tighten the screws. Tightening torque 21Nm.
Fig. 4
●
Push the cable plug back onto the engine shut-
down assembly.
Caution
!
Check the governor rod for light movement.

●
Actuate the governor rod between start and stop
position (Fig. 4).
102 BOMAG 008 915 04

Boost fuel solenoid valve, Y01 4.33
4.33 Boost fuel solenoid valve, Y01
General
Technical data: 12 Volt, 3.5 Ampere
During the starting process the solenoid valve is sup-
plied with 12 Volt.
This injection adaptation serves the purpose of com-
pensating for condensation and leakage losses and
for rising the engine torque during the acceleration
phase after starting. For this compensation and to as-
sure starting of the cold engine additional fuel needs
to be injected at the time of starting and accelerating.
Fig. 1
008 915 04 BOMAG 103

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

buzzer shut-down shut-down
time time
10 sec. 2 min.
i H49, control light en- red, flashing X X Run the engine with idle
gine overheating Low-active speed or shut it down if
necessary, clean engine
oil cooler and radiator, if
necessary repair engine.
e H09, engine oil pres- red, flashing X X Check the engine oil lev-
sure control light Low-active el, if necessary repair the
engine.
h H15, engine air filter not used
control light Low-active
g H08, charge control yellow, lights Check V-belt, if neces-
light High-active sary repair the generator
b H70, control light, wa- yellow, lights Check, clean the water
ter in diesel filter separator
c H52, pre-heating con- yellow, lights see chapter "Check heat-
trol light yellow, flashing flange control"
es in case of
fault
Low-active
f Option red, flashing X Option Fill up coolant
H73, coolant level Low-active
104 BOMAG 008 915 04

Engine monitoring 4.34
Checking the engine monitoring system ●
Push the plug back together, the plug interlock
clicks into place.
The following control lights and shut-down functions
can be checked with the engine running: ● Check the plug interlock by lightly pulling on the wir-
ing loom.
Air filter
Engine oil pressure
Fig. 2 Pressure differential switch

Fig. 4 Oil pressure switch
● Press on the locking wire and pull the plug off the
differential pressure switch 1 (Fig. 2). ●
Press on the locking wire and pull off the plug (Fig.
4).
● Bridge both contacts on the plug of the wiring loom.
●
Apply the contact to engine ground.
i Note
Control light h (Fig. 1) lights up. No audible will sound i Note
and the engine will not be shut down. Control light e (Fig. 1) flashes. An audible warning will
sound and the engine is shut down after 10 seconds.
●
Push the plug back on, the plug interlock clicks into
place. ●
place.
●
Check the plug interlock by lightly pulling on the wir-
ing loom. ●
ing loom.
Water separator
Engine overheating
Fig. 3 Sensor plug on water separator

Fig. 5 Coolant temperature switch
●
Press the plug interlock and disconnect the plug
(Deutsch plug) (Fig. 3).
●
Press on the locking wire (Fig. 5) and pull off the
plug.
●
Bridge both contacts on the plug of the wiring loom.
●
Bridge both contacts on the plug of the wiring loom.
i Note
Control light b (Fig. 1) lights up.
008 915 04 BOMAG 105

4.35 Batteries
i Note 4.35 Batteries

Control light i (Fig. 1) flashes. An audible warning will
Battery – accumulator
sound and the engine is shut down after 2 minutes.
●
place.
●
ing loom.
Emergency stop switch
Fig. 1
In vehicles batteries are used to start the engine. The
ability to start the engine depends on the charge con-
dition of the batteries.
Lead collectors or accumulators are secondary ele-
ments, i.e they can be recharged after discharging
electric current.
Fig. 6 Emergency stop switch The basic element of a lead accumulator is the cell. It
contains the plate blocks consisting of positive and
●
Press the emergency stop switch (Fig. 6). The en-
negative plates. These plates are separated from
gine should stop immediately.
each other by separators.
All positive plates are arranged parallel to the plus
pole, the negative plates parallel to the minus pole of
the cells.
Fig. 2
All cells are filled with a conductive fluid, the electro-
lyte. For a 12 Volt battery 6 cells are connected in se-
ries.
Capacity
is a synonym for the amount of current taken up and
discharged by a battery over a specified period of
time.
106 BOMAG 008 915 04

Batteries 4.35
Battery maintenance Testing batteries without screw plugs
On closed batteries the acid density cannot be meas-
i Note ured, we therefore recommend testing with the follow-
Maintenance free batteries are gaining more and ing mobile tester:
more significance, this freedom from maintenance,
however, is only limited to the fact that no water needs
to be added.
If the battery is not charged and discharged over a
longer period of time, the battery will slowly discharge
by itself.
The accumulator may only be discharged down to a fi-
nal discharging voltage of 10.5 Volt, as otherwise
there is a risk of sulphation, i.e. the generated lead
sulphate forms increasingly coarser crystals, which
will finally not react at all or only very sluggishly during
a subsequent charging process.
In the worst case the accumulator can only be dis- Fig. 3 Battery and generator tester
posed of after such an exhaustive discharge.
The battery and generator tester comes with an 8-line
The following therefore applies for longer downtimes: LC display with background illumination and is able to
● Remove the battery and store it in a cool, dry and print out test results via an (optional) integrated ther-
frost protected room. mal printer.
●
Check the open circuit voltage on the battery at reg-
ular intervals (at least once every month).
i Note
●
Recharge immediately if the open circuit voltage Before testing clean the poles and ensure good con-
has dropped to 12.25 Volt (no rapid charging). nection between clamps and poles.
The test program calculates the text messages "good"
i Note or "replace" on the basis of the charge condition (de-
The open circuit voltage of batteries occurs approx. 10 rived from the battery voltage) and the currently avail-
h after the last charging or approx. 1 h after the last able starting power of the battery. A battery with 45%
discharge. starting power may thus be rated good and another
one with 75% starting power as poor ("replace").
Battery test in general
The starting power represents the ratio of detected
●
Is the battery leaking? Can traces of impact, shock
cold testing current to the entered cold testing current
or compression be found in the leaking area?
of the battery.
●
Check for e.g. incorrect fastening, foreign bodies on
the battery mounting surface and similar. The starting power can exceed 100%.
008 915 04 BOMAG 107

4.35 Batteries
Charge condition with hydrometer
Fig. 4 Charge condition

Green = Charge condition >65%
Dark = Charge condition <65%
Light = Electrolyte level too low
! Danger
Danger of explosion!!! If the electrolyte level is too

low, the battery must no longer be charged.
108 BOMAG 008 915 04

Battery maintenance 4.36
4.36 Battery maintenance
! Danger
Danger of cauterisation ! Danger of explosion!

When working on the battery do not use open fire,
do not smoke!
The battery contains acid. Do not let acid come in
contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
Fig. 5
Environment ●
Remove the battery (Fig. 5) and clean the battery
Dispose of the old battery environmentally. compartment.
●
Clean the outside of the battery.
i Note ●
Clean battery poles and pole clamps and grease
Maintenance free batteries also need care. Mainte- them with pole grease (Vaseline).
nance free only means that the fluid level does not
need to be checked. Each battery suffers under self-
●
Check the fastening of the battery.
discharge, which may, in not checked occasionally, ● On serviceable batteries check the acid level, if nec-
even cause damage to the battery as a result of ex- essary top up to the filling mark with distilled water.
haustive discharge.
Function "Magic Eye"
The following therefore applies for the service life:
green = O.K.
●
Switch off all consumers (e.g. ignition, light, inside bright = Charge battery
light, radio).
black = defective, replace battery, do not re-
●
Check open-circuit voltage of the battery at regular charge
intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V = Charging voltage recommendation
50% discharged.
●
Recharge the battery immediately after an open-cir-
cuit voltage of 12.25 V or less is reached. Do not
perform boost charging.
The open-circuit voltage of the battery occurs approx.
10 hours after the last charging process or one hour
after the last discharge.
●
After each charging process allow the battery to rest
for one hour before taking it into service.
●
For resting periods of more than one month you
should always disconnect the battery. Do not forget
to perform regular open-circuit voltage measure-
ments.
Fig. 6
Caution
!
Exhausted batteries (batteries with formation of

sulphate on the plates are not covered under war-
ranty!
●
Open the engine hood and remove the covering
008 915 04 BOMAG 109

4.37 Generator
4.37 Generator Three-phase generator

The AC-generator first of all produces AC-voltage /
General
AC-current.
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve- Why does AC-current need to be rectified?
hicle with electric current at a steady voltage already There are a few components for which can either be
at idling speed. operated with alternating current or direct current, be-
cause they work independently from the current flow
Terminal designations
direction.
●
B61, L = charge control This includes :
●
B+, B = battery plus, also with the designation "30" ●
Incandescent lamps
●
B- = battery minus, also with the designation "31" ●
Fluorescent lamps
●
D+ = dynamo plus corresponds with terminal "61" ●
Glow lamps
and "L" ●
Electric heating elements.
●
D- = dynamo minus (this designation is only found There are also a few components that could be oper-
on D.C. generators or A.C. generators with regula- ated either with alternating current, direct current or
tor removed) three-phase current, if the components were designed
accordingly.
●
DF = dynamo field (this designation is only found on
D.C. generators or A.C. generators with regulator This includes :
removed). Note: The designation DF is also found ● Electric motors
on older alternators with externally arranged regula- ●
Relays.
tor on the connection of the exciting coil to the reg-
ulator or on the regulator itself Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc-
●
DF1 = dynamo field 1 es work with alternating or three-phase current.
●
DF2 = dynamo field 2 This includes :
●
IG = "15" ignition switch ●
Accumulators
●
Control units
●
All electronics
●
Communication equipment.
Design and function
Fig. 7
1 Fan
2 Holding plate
3 Stator core
4 Stator winding
5 Brush
110 BOMAG 008 915 04

Generator 4.37
6 Brush holder
7 Rectifier
8 Bearing cover
9 Rotor winding
10Rotor
11V-belt pulley
Fig. 10 3-phase current
Fig. 8 Rotor with claw poles The wiring diagram (Fig. 10) shows the 3 windings in
Y-connection and the 6 associated rectifier diodes (D1
In the generator the armature windings are located in-
to D6).
side the stationary stator (Fig. 9), whereas the exciter
winding is arranged on the internally revolving rotor The diodes D1, D2, D3 are also referred to as minus
(Fig. 1). diodes, because they have B- as common connection
(minus plate). The other diodes are the plus diodes.
The rectifier diodes have the effect that the negative
half-wave is suppressed and only the positive section
of the wave is allowed to pass, resulting in a pulsating
D.C. voltage.
Fig. 9 Stator
The three stator windings (Fig. 9) are electrically offset
to each other by 120°. The excitation of the magnetic
field requires direct current, which is fed to the rotor
via two carbon brushes and slip rings.
008 915 04 BOMAG 111

4.37 Generator
Charge control light Any other behaviour would indicate a defect on the
The charge control light has two duties: generator (rectifier, carbon brushes, regulator) or a
defect on the lamp, presumed the on-board battery is
●
Indication of the correct generator function not discharged.
●
External excitation of the generator during the start- A far more important function of the lamp is the transi-
ing phase tion and provision of field current. At standstill there is
no magnetic field in the de-energized generator. Since
this is necessary for the generation of electric current,
the rotor must be supplied with current, so that a weak
field can build up.
The current flows from the ignition switch via the
charge control light through the generator winding
against ground (terminal 31) and is limited to approx.
300 mA by the light bulb (4 W) (without the lamp the
current flow would be 2 to 5 A). While the rotor is ro-
tating current is induced into the stator winding,
whereby a small part (2–5 A, depending on speed)
flows through the charge regulator into the field wind-
ing of the rotor and the major part flows to the output
terminals (B+), where it can be tapped as useful cur-
rent. If the charge control light is defective or no bat-
Fig. 11 plus controlled charging regulator tery is available or the battery is discharged, external
(Fig. 11) shows the current flow with the ignition excitation is no longer possible at standstill and no
switched on, engine stopped. voltage will be generated, even when the generator is
running.
With used, older generators a weak permanent mag-
netic field may have developed over the lifetime,
which does even exist when no voltage is applied.
This type of machines can even start without charge
control light and produce current during operation.
However, this is an unintended effect and you should
not presume that a generator without charge control
light or external excitation can be started up.
Fig. 12 plus controlled charging regulator

(Fig. 12) shows the current flow with the ignition
switched on, engine running.
1 Battery
2 Charge controller
3 Ignition switch
4 Charge control light
5 Rectifier
6 Rotor
7 Sliprings / carbon brush
8 Auxiliary rectifier
Normally the charge control light lights with the engine
stopped and the ignition switched on and goes out at
low engine speed, but at the latest after a single,
short-term increase in engine speed from idle speed,
because there is no longer a voltage difference on the
lamp.
112 BOMAG 008 915 04

Generator 4.37
Charge controller
The charge controller has the following functions
●
To regulate the voltage generated by the generator
●
To protect against overloads caused by too high
output current
●
Protection against reverse current
If the output voltage or the output current of the gen-
erator exceeds the determined maximum values, the
field current and thus the electric power is reduced.
Electronic charge regulator
Fig. 14 plus controlled regulator
Fig. 13
In AC-generators the electrically generated exciter
field of the generator rotor is influenced by an at-
tached electronic charge regulator. Together with the Fig. 15 minus controlled regulator
holder for the carbon brushes this regulator forms a
unit, which transfers the field current to the sliprings of
the rotor.
The regulator compares the rectified actual current of
the generator with the a stable reference voltage in
the regulator and matches the strength of the exciter
field (field current) by increasing or reducing the cur-
rent flow (PWM, switching controller) in such a way,
that the actual voltage of the generator remains con-
stant, irrespective of load and speed. The generator
voltage is thereby regulated, the generator current,
however, is not measured, but limited by the construc-
tion dependent internal resistance of the stator coils or
thermal monitoring.
008 915 04 BOMAG 113

4.37 Generator
Checking the generator Checking the pre-exciter circuit, D+ generator

First one must check whether the generator is actually The most common reason for a 3-phase alternator not
defective. charging is a too low pre-excitation current. The pre-
excitation current through connection D+ depends on
●
This can be easily found out by checking whether
the connected consumer (resistance), e.g. charge
the charge control light in the dashboard lights up. If
control light or relay of a MD+ engine control.
the light does not go out, even at higher speeds,
there must be a defect on the generator, the regula- The pre-excitation current should be approx. 250 mA
tor, the wiring or the V-belt. at 12 Volt. This corresponds with a 3 Watt light bulb or
●
When the engine is at rest, the charge control light an equivalent combination of light bulb + resistance or
must light up. If not, the lamp may probably be de- an LED + resistance.
fective. Defects on generator or wiring are obviously The total resistance of the disconnected dead supply
also possible. line D+ max. should not exceed 48 Ohm.
The following points allow to contain faults in the volt- In case of faults like
age supply within certain limits. ●
charge control light stays on
●
Cable connections on the generator OK? ●
no voltage increase, e.g. from 12 V to 14 V
●
V-belt OK?
one should check that the correct resistance is as-
●
Generator ground (engine ground) OK?
sured.
●
Pre-excitation from vehicle electronics OK?
Only if all criteria mentioned above are OK, the fault
must be in the generator itself. In this case it must be
replaced or the following trouble shooting procedure
must be performed.
Fig. 16 Connections on the three-phase alternator (exemplary de-

sign)
If the charge control light or LED stays on when the
engine is running, you should proceed as follows:
●
Temporarily bridge connections D+ and B+ on the
three-phase alternator (Fig. 16). The bridging must
be made using an insulated cable with a cross-sec-
tion of approx. 1.0 mm, which is stripped for approx.
5 mm on either end. This cable must be fitted with a
consumer (X), e.g. a light bulb of 21 W, 12 V, in
case of a 12 V system.
If this measure does not clear the fault, the alternator
must be defective.
114 BOMAG 008 915 04

Generator 4.37
Checking the rotor
Measuring the charge current
●
All plug-and-socket connectors must be free of cor-
rosion and intermittent contact. i Note
The rotor coils can only be measured in disassembled
●
The generator ground connection must be OK.
state.
●
During the measurement switch on as many con-
sumers as possible.
1 Attach the clip-on ammeter around the B+ line.
2 Gradually increase the engine speed.
3 The generator current must be at least as high as
the total current of all switched on consumers.
Fig. 17
●
Measure the resistance between the sliprings.
● If the resistance does not comply with the factory
specification, replace the rotor.
●
Use the resistance range of the continuity tester to
check the continuity between slipring and core.
● Replace the rotor if no infinite value is indicated.
i Note
Factory specification for resistance: 2.8 to 5 Ω.
008 915 04 BOMAG 115

4.37 Generator
Checking the stator Checking the bearings
i Note
The stator coils can only be measured in disassem-
bled state.
Fig. 19
●
Check whether the bearing rotates without obstruc-
tion.
●
Replace the bearing if it does not rotate properly.
Fig. 18
●
measure the resistance between the individual lines
of the stator winding.
● If the measuring value does not comply with the fac-
tory specification, replace the stator.
●
check the continuity between the individual stator
windings and the core.
●
Replace the stator if no infinite value is indicated.
i Note
Factory specification for resistance: Less than 1Ω.
116 BOMAG 008 915 04

Generator 4.37
Checking the regulator voltage with the generator Checking the regulator voltage with the multime-
tester ter
The battery and generator tester comes with an 8-line
LC display with background illumination and is able to
print out test results via an (optional) thermal printer.
Fig. 21
● All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
Fig. 20 ●
The generator ground connection must be OK.
The generator test assesses the regulator voltage and ● The battery should be in good condition – the idle
the ripple factor of the generator voltage. voltage of the battery should be at least 12.6 Volt.
●
All plug-and-socket connectors must be free of cor- ●
If possible switch off all consumers.
rosion and intermittent contact. ●
Perform the measurement at raised engine speed.
●
The generator ground connection must be OK. ●
The voltage (B+) should adjust itself at 13 to 14 Volt.
●
The battery should be in good condition – the idle
voltage of the battery should be at least 12.6 Volt.
●
If possible switch off all consumers.
●
Perform the measurement at raised engine speed.
008 915 04 BOMAG 117

4.37 Generator
Checking the regulator in disassembled state

On a Bosch generator unscrew two fastening screws
for the regulator and lift the regulator off. For this work
the generator does not need to be removed.
The Delco-Remy generator needs to be removed
and partly dismantled, if the regulator needs to be dis-
assembled. Unscrew the housing screws to do so.
Pull rotor with drive bearing and V-belt pulley out of
the stator. Unscrew the ends of the stator winding
from the diode carrier and separate the stator from the
collector ring bearing. Disassemble exciter diodes and
brush holders and remove also the regulator. Fig. 23
E.g minus controlled regulator
i Note One connects the regulator (Fig. 23) with D+ and D- to
When testing the regulator one should be aware that the power source, as shown in the illustration, and the
there are 2 different types of regulators: lamp to both carbon brushes, instead of the exciter
winding. When slowly increasing the voltage the lamp
●
If the carbon brush is not connected to ground the will first become brighter, because the regulator al-
regulator is a so-called minus controlled regulator. lows all lamp current (= exciter current) to flow at volt-
The exciter winding is positioned between D+ and age values up to 14.4V. Once the regulator voltage is
DF, the regulator therefore regulates the exciter reached, the regulator switches the lamp current off.
winding on the ground side. The other carbon brush When returning the voltage back below the control
is connected with the cathodes of the exciter di- voltage, the regulator will switch the lamp back on.
odes, terminal D+. This leaves one further terminal,
With this test the major difficulty is the problem to re-
this is DF.
move the regulator an identify terminals D+, DF and
D+ (vehicle wiring system) D-.
D- (ground contact, mostly located on one of the fas-
tening screws)
DF (Dynamo Field)
Fig. 24
Fig. 25
Fig. 22
The illustrations (Fig. 24) and (Fig. 25) show two dif-
●
If the carbon brush is connected to ground the reg-
ferent regulator types.
ulator is a so-called plus controlled regulator. The
exciter winding is positioned between DF and D-,
the regulator therefore regulates the exciter winding
on the plus side. The other carbon brush is then
connected with terminal DF. This leaves one further
terminal, this is D+.
The basic function of a disassembled regulator can be
easily tested with a 12V lamp and an adjustable D.C.
power supply unit (0V ... 20V).
118 BOMAG 008 915 04

Replacing the voltage regulator 4.38
Replacing carbon brushes 4.38 Replacing the voltage regula-
●
On a Bosch generator unscrew two fastening tor
screws for the regulator and lift the regulator off.
Pull out the carbon brushes from underneath. Their
minimum length is 5 mm, shorter carbon brushes Disassembling the regulator
need to be replaced, unsolder both connection litz
wires. Solder the litz wires of the new carbon brush-
es, insert these and fasten the regulator again. For
this work the generator does not need to be re-
moved.
●
For replacing the carbon brushes in the Delco-
Remy generator the generator needs to be disas-
sembled and partly dismantled. The carbon brush
holder is located inside the collector ring bearing.
Fig. 1
●
Loosen the hexagon nuts M5 (Fig. 1).
● Take off hexagon nuts and washers.
●
Remove the plastic cover.
i Note
Optional:
Unscrew the hexagon nut M5 from terminal W, take
off washer and flat plug connector.
Fig. 2
●
Check whether washers are present. Take off the
washers (3x) (Fig. 2), to prevent these from falling
into the generator.
008 915 04 BOMAG 119

4.38 Replacing the voltage regulator
Fig. 3
● Slacken the screws M3 (A) (Fig. 3). Fig. 2
● Loosen the hexagon nuts M5 (B). ● Check whether the rubber seal is present on the
brush holder (Fig. 2).
● Remove screw and hexagon nuts.
●
Take off the voltage regulator.
Assembling the voltage regulator
Fig. 3
●
Attach the voltage regulator (Fig. 3).
●
Tighten the screw M3 (A).- Tightening torque 0.7-
1.0 Nm.
Fig. 1 ●
Tighten the screw M5 (B).- Tightening torque 3.5-
●
Check for correct fit of sealing ring on protective 4.5 Nm.
cover (Fig. 1).
Fig. 4
●
Install the washers (Fig. 4).
120 BOMAG 008 915 04

Electric starter 4.39
4.39 Electric starter
General
Combustion engines need to be started by means of
a special device, because they are not able to start by
themselves. Considerable resistances caused by
compression and friction must thereby be overcome.
The starter converts the electric energy stored in the
battery into mechanical energy. The starter can only
generate its power when a battery with appropriate
capacity is available.
Duties of the starter:
Fig. 5 ●
to accelerate the combustion engine to start speed
with lowest possible current consumption.
● Assemble the cover (Fig. 5).
●
establish the gear connection between starter and
● Install the washers. combustion engine.
●
Fasten the protective cover with the hexagon nuts.- ● to maintain this connection.
Tightening torque for hexagon nut M5 2.1-3.1 Nm. ●
to switch on the starter current.
After starting the engine:
i Note ●
to return the starter pinion to initial position.
Optional: ●
to switch off the starter current.
Assemble flat plug connector, washer and hexagon
nut M5 to connection W.
Tightening torque for hexagon nut 2.7-3.8 Nm.
008 915 04 BOMAG 121

Directly acting electric starter 5 Ignition switch

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

With the ignition switch (5) in "START" position cur-
rent flows from the battery (10) through the holding
winding (2) and the pick-up winding (3).
The armature (1) is magnetically picked up and forces
the pinion (8) with the actuating lever (6) to engage
with the ring gear (7).
1 Armature
2 Holding winding
3 Pick-up winding
4 Magnetic switch
122 BOMAG 008 915 04

Engine running 4 Resetting spring
5 Magnetic switch
6 Ignition switch
7 Pinion
8 Ring gear
9 Battery
Fig. 9
Once the engine is running and drives the pinion (1)
via the ring gear (2), the freewheeling clutch (3) will
open and prevent the armature (4) from being driven
by the engine.
1 Pinion
2 (Ring gear
3 Freewheeling clutch
4 Armature
Ignition switch released
Fig. 10
When releasing the ignition switch (6) it will return
from position "START" to "ON" and interrupt the start-
er current circuit. Current will now flow from the bat-
tery (9) through the contact plate in the pick-up
winding (3) and the holding winding (2). Since both
coils generate opposed magnetic fields, the magnetic
field will collapse and the resetting spring (4) takes the
armature (1) back to its initial position.
This opens the current circuit on the contact plate and
the pinion (7) is pulled back from the ring gear (8) and
stops.
1 Armature
2 Holding winding
3 Pick-up winding
008 915 04 BOMAG 123

Magnetic switch Freewheeling clutch
Fig. 1 Direct acting electric motor Fig. 1 Freewheeling clutch

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

Armature (4), contact plate (3) and armature guide (6)
form a closed unit. When the ignition switch is turned
to "START", the armature is picked up and causes the
pinion of the clutch to disengage.
This causes the pinion and the ring gear to mesh,
while the contact plate establishes a connection be-
tween the contacts, which enable the main current to
flow into the armature. Once the ignition switch is
opened, the resetting spring (5) will pull the armature
back to initial position.
1 Holding winding
2 Pick-up winding
3 Contact plate
4 Armature
5 Resetting spring
6 Armature guide
124 BOMAG 008 915 04

Trouble shooting "Starter" Testing and measuring the starter
i Note i Note
The most frequent fault is definitely a fully discharged The highest current flows when the starter is blocked!
battery. (Short circuit current in starter). This is the case when
the pinion is engaged and the starter has the duty to
If the starter rotates too slowly, either the brushes
accelerate the flywheel to starting speed.
are partly worn off, or parts of the exciter or armature
winding is shorted. In some cases oxidized electric Function control with the starter installed
contacts or a soiled ground connection causing ex- ●
Initiate the starting process and measure the volt-
tremely high voltage losses in the overall starter sys- age on the pickup solenoid switch (50a). At least
tem are the cause of problems. 10.8 Volt should be applied.
If the starter only emits a clicking sound,- either ●
When operating the starter switch the magnetic
the magnetic switch is defect / soiled (dismantle and switch must engage in the flywheel ring gear (no-
clean))- the main contacts on the magnetic switch are ticeable clicking sound) and release the starting
worn off / soiled (scrape off carefully with a file and current to the starter. On most magnetic switches
clean)- the starter motor is defective / soiled (remove the voltage can be measured with the multimeter. If
armature and clean), cover cleaned, moveable parts this does not happen even though voltage is ap-
with grease. plied, replace the magnetic switch.
Frequently a jammed return mechanism is the reason
for a starter failure.
Occasionally worn contacts are found on the magnetic
return switch
Defects on the actual starter motor including pinion
and carbon brushes are very rare.
With a trouble shooting chart the faults in the starter
system can be narrowed down. The starter system
can only work when many conditions are fulfilled at
the same time.
●
Immobilizer deactivated?
●
Ignition switch OK?
● Travel lever in correct position?
● Emergency stop not actuated?
● Battery sufficiently charged?
●
Battery poles OK?
●
Main battery fuse OK?
●
Main battery switch closed?
●
Main starter cable (terminal 30) OK?
● Starter control cable (terminal 50) OK, voltage
drop?
● Ground cable OK?
● Switching of magnetic switches OK?
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
●
the experience of the specialist
●
the failure probability of the component to be tested
and the testing effort for the respective part.
Only if all criteria mentioned above are OK, the fault
must be in the starter itself. In this case it can be re-
paired or replaced.
008 915 04 BOMAG 125

Testing and measuring the starter Continuity test for the magnetic switch
Function control with the starter removed
Caution
!
Fasten the starter to make sure that it will not

come loose during the test.
Fig. 4
●
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. 2
●
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.
Checking the magnetic switch
Fig. 3
● 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.
126 BOMAG 008 915 04

Disassembling and assembling the start- Assembling the starter
er
Disassembling the starter
Fig. 5
●
Switch the main battery switch (Fig. 5) to position
“left”. Fig. 7
● Put the starter into place.
● Tighten the screws (arrows) (Fig. 7), tightening
torque 60 Nm.
● Screw on the cable connections (terminal 30 and
50).
Caution
!
To prevent the starter terminals or components

from being damaged you should make sure that
the cable connections are tightened with the fol-
lowing torque values.
Terminal 30, 24±4 Nm
Terminal 50, 1 - 1,3 Nm
Excessively tightened nuts can cause damage to
starter components (e.g. cracks in the cover of the
solenoid switch). Penetrating dampness can
cause short circuit - or even burning of cables.
Fig. 6
Insufficiently tightened nuts can cause loosening
●
Unscrew the cable connections (terminal 30 and of cable connections and thus short circuit - or
50). even fire.
●
Unscrew screws (arrows) (Fig. 6).
●
Remove the starter.
008 915 04 BOMAG 127

4.40 Overview of electric components
1) Wiring loom cabin, flap
128 BOMAG 008 915 04

Overview of electric components 4.40
2) Wiring loom cabin, internal
008 915 04 BOMAG 129

1) Wiring loom cabin, power supply
130 BOMAG 008 915 04

1) Wiring loom wiper blades

2) Wiring loom cabin - battery
3) Wiring loom air conditioning
4) Wiring loom, ground air conditioning compressor
008 915 04 BOMAG 131

1) Wiring loom instruments
132 BOMAG 008 915 04

1) Wiring loom central electrics
Pos. Designation in circuit diagram Designation in circuit diagram

X1 X1:1.... Terminal strip X1
X2 X2:1.... Terminal strip X2
a V41... V48 Diode module, diodes (A1 ....A8)
b A100 Module steering column switch, travel direction
c A04 Module sprinkling system
d R09 Dropping resistor, generator excitation
e K05 ... K149 Relays
f A05 Speedometer electronics
008 915 04 BOMAG 133

1) Wiring loom engine
134 BOMAG 008 915 04

5) Wiring loom front lighting

6) Wiring loom front frame
008 915 04 BOMAG 135

1) Wiring loom, battery (-)

2) Wiring loom rear lighting
3) Wiring loom, battery (+)
4) Wiring loom main battery switch - engine
5) Wiring loom engine - central electrics (-)
136 BOMAG 008 915 04

1) Wiring loom speed transducer - central electrics

2) Wiring loom speed transducer
3) Wiring loom tachograph, cabin - central electrics
008 915 04 BOMAG 137

5) Wiring loom speed transducer - central electrics

6) Wiring loom speed transducer
138 BOMAG 008 915 04

1) Wiring loom, battery (+)

2) Wiring loom, battery (-)
4) Wiring winter package
5) Wiring fuel heating
6) Wiring loom glow plugs
7) Wiring central electrics
008 915 04 BOMAG 139

1) Wiring loom ROPS - battery (+)

2) Wiring loom E1-working lights
140 BOMAG 008 915 04

5) Cable set for loudspeakers

6) Cable set for radio
7) Cable set
008 915 04 BOMAG 141

13) Wiring loom solenoid valve for edge cutter

14) Wiring loom dash board for edge cutter
142 BOMAG 008 915 04

Fig. 8 18 S37 Rotary switch for direction indicators left / right

1 S31 / S184 Travel lever 19 S15 Rotary switch for light system (StVZO)
2 Steering wheel 20 S26 Rotary switch for working lights
3 not used 21 S119 Throttle pedal
4 Tire pressure gauge 22 S00 Ignition switch
5 S01 Emergency stop push button 23 Brake pedal
6 S14 Rotary switch for hazard light system 24 Rotary switch for tire inflation
7 A15 Instrument cluster 25 Rotary switch to relieve tire pressure
8 P04 / E04 Speedometer1 26 XS Utility socket 12 V
9 H04 EMR Deutz engine (only BW27RH) 27 Rotary switch for cabin heater
10 not used 28 Rotary switch for cabin fan
11 S02 Rotary switch for travel ranges 29 Rotary switch for air conditioning *
12 S185 Rotary switch, dashboard illumination
13 S05 Rotary switch for pressure sprinkler system
14 not used
15 not used
16 S111 Rotary switch for parking brake
17 S03 Push button for warning horn
1 Optional equipment
008 915 04 BOMAG 143

Fig. 9 Monitoring board A15
Pos. Designation in circuit diagram Designation in circuit diagram

a H43 Brake pressure control light
b H70 Control light, water in diesel filter
c H52 Control light, preheating monitoring
d H79 Remaining water quantity, sprinkling system
e H09 Engine oil pressure control light
f H73, option Control light, coolant provision
g H08 Charge control light
h H15 Control light for engine air filter
i H49 Control light, overheating of engine
j H23 Hydraulic oil filter control light
k H05 Indicator control light
l H86 Brake oil temperature control light
m H01 Brake control light
n P01 Fuel level gauge
o no function Tank gauge for sprinkling system
p P00 Operating hour meter
144 BOMAG 008 915 04

Fig. 10
Fig. 12
a = S38, toggle switch for flashing beacon
f = fuse box in cabin
b = S20, toggle switch for front windscreen wiper/
washer
! Danger
c = S21, toggle switch for rear windscreen wiper/ Fire hazard!
washer
Do not use fuses with higher ampere ratings and
d = S53, toggle switch for working headlights do not bridge fuses.
e = S163, toggle switch for rear windscreen heat- (1), 15A = (F41) Flashing beacon
ing (2), 15A = (F27) Wiper/washer, front
(3), 15A = (F28) Wiper/washer, rear
(4), 25A = (F31) Cabin fan
(5), 25A = (F110) Working head lights, front/rear
(6), 5A = (F90) Cabin heater
(7), 10A = (F68) Potential 30
(8), 20A = (F40) Cabin heater
Fig. 11
g = E29, reading and dashboard light
h = S158, toggle switch for reading and dashboard

light
i = S45, toggle switch for cabin lamp
j = E70, cabin lamp

Fig. 13
No. 1 = Fuse box ROPS*
! Danger
Fire hazard!
do not bridge fuses.
(1) 25A = Working head lights
008 915 04 BOMAG 145

Fig. 14 Fig. 15
No. 2 = Fuses in electric installation box No. 3 = Main fuse for battery
F01, 30A = Main fuse 125A = (F00)
F05, 15A = Socket
F37, 20A = Sprinkling pump
F93, 20A = Control
F119, 7,5A = Diesel engine
F07, 15A = Hazard light
F129, 15A = MD+
F04, 5A = Instruments
F14, 10A = Engine solenoid
F22, 15A = Working head lights, rear1*
F23, 10A = Warning horn
F25, 10A = Solenoid valve brake/travel
F26, 10A = Solenoid valve for speed range
selection
F70, 10A = Direction indicators
F77, 10A = Driving
F120, 15A = Brake light
F124, 25A = Winter package
F09, 10A = Parking and tail light, left hand
side
F10, 10A = Parking and tail light, right hand
side
F11, 10A = Headlights, left
F12, 10A = Headlights, right
F06, 10A = Water sprinkler system
F156, 20A = StVZO
Danger
!
Fire hazard!
do not bridge fuses.
146 BOMAG 008 915 04

Modules 4.41
4.41 Modules Signals
In the latest generation of machines BOMAG uses Analog signals
machine programmable modules. A module mainly Process states are continuous (analog) when they
consists of a programmable microprocessor with ad- can be mapped by means of a real number, e.g. tem-
ditional circuitry for inputs and outputs. perature = 65.5 °C. The sensor converts a continuous
process status into an analog signal. If the control unit
needs the numerical value of the analog signal, an an-
alog-digital conversion is required.
Analog signals are needed to control, display or mon-
itor limit values. Checking the limit values of physical
quantities leads to the binary information: limit value
reached/not reached.
Binary signals
Process states are bivalent (binary) if they have only
2 possible states of truth, such as e.g. button pressed/
not pressed, object present/not present. The two
states of truth are mapped by means of defined states
of an information carrier, e.g. 'not pressed' equals 0 V,
'pressed' equals 24 V. These states are described
with {0,1} or {false, true}
Fig. 1 Module
The modules have control lights on inputs and outputs
to monitor the applied signals.
008 915 04 BOMAG 147

4.41 Modules
148 BOMAG 008 915 04

5 Special tools, electrics
008 915 04 BOMAG 149

5.1 Special tools, electrics

Measuring equipment
48. Electric test case
Fig. 2
49. Multimeter
Fig. 3
50. Test prod black, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.

51. Test prod red, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.
Fig. 4
52. Test prod black, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.

53. Test prod red, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.
Fig. 5
150 BOMAG 008 915 04

Special tools, electrics 5.1
54. Measuring and connecting lines with 4mm plug,
high flexible design, black, length 0.5 m.
high flexible design, black, length 1 m.

high flexible design, black, length 2 m.

Fig. 6 high flexible design, red, length 0.5 m.
high flexible design, red, length 1 m.

high flexible design, red, length 2 m.

60. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, black, length 300 mm.

sign, black, length 600 mm.

sign, red, length 300 mm.
Fig. 7
sign, red, length 600 mm.
64. Transition plug connector, with 4 mm plug on one
side and 2 mm socket on the other, insulated de-
sign
Fig. 8
008 915 04 BOMAG 151

65. Magnetic coil tester

Fig. 9
66. Clip-on measuring instrument
Fig. 10
67. Battery - generator tester
Fig. 11
Spring clamps (Wago or Weidmüller)
68. Cranked screwdriver (Fig. 12) to open spring
clamps (Fig. 13).
Fig. 12
152 BOMAG 008 915 04

69. Testing adapter to measure the signals from the
series spring clamps (Wago).
Fig. 13
Deutsch contacts
70. Tool to disassemble the interlocking on Deutsch
plugs (series DT and DTM).
Fig. 14
71. Crimping pliers for Deutsch contacts of series DT
and DTM, size AWG 20,16 and 12.
AWG 20 = 0.5 mm2 cable cross-section
AWG 16 = 1,5 mm2 cable cross-section
Fig. 15
72. Crimping pliers for Deutsch contacts of series
HDT, size AWG 6 and 8.
Fig. 16
008 915 04 BOMAG 153

73. Disassembly tool for Deutsch contacts of series

HDP.
AWG 20, BOMAG part-no.: 079 900 78
Fig. 17
ITT contacts
74. Installation tool for ITT crimp contacts of series
CA-COM, contact size 15S/16S/15/16.
Fig. 18
75. Disassembly tool for ITT male contacts of series
CA-COM, contact size 15S/16S/15/16.
Fig. 19
76. Disassembly tool for ITT female contacts of se-
ries CA-COM, contact size 15S/16S/15/16.
Fig. 20
154 BOMAG 008 915 04

Schaltbau contacts
77. Disassembly tool for Schaltbau contacts of series
M1, M2.
Fig. 21
78. Crimping pliers for Schaltbau contacts of series
M1, M2 with connecting cross-section 0.14 - 6.0
mm2.
Fig. 22
FCI Burndy contacts
79. Disassembly tool for FCI Burndy contacts of se-
ries TRIM TRIO
Fig. 23
AMP contacts
80. Crimping pliers for AMP-contacts of series FAS-
TIN-FASTON with a connecting cross-section of
1.0 - 2.5 mm2 (18 -14 AWG).
Fig. 24
008 915 04 BOMAG 155

81. Crimping pliers for AMP-contacts of series SU-

PER-SEAL with connecting cross-section 0.75 -
1.25 mm2.
Fig. 25
82. Crimping pliers for AMP-contacts of series .070-
SERIES with a connecting cross-section of AWG
20 - 18 (0.5 - 0.9 mm2) and AWG 16 (1.25 - 1.5
mm2).
Fig. 26
TON with connecting cross-section AWG 14 - 10.
Fig. 27
TON with connecting cross-section AWG 16 - 14
and AWG 18.
Fig. 28
156 BOMAG 008 915 04

85. Crimping tool for Powertimer contacts with indi-
vidual strand sealing (example: ESX control)
Fig. 29
86. Crimping jaws for Crimping tool 079 900 25
Fig. 30
87. Disassembly tool for AMP-contacts of series CIR-
CULAR-CONNECTOR.
1.5 mm2, BOMAG part-no.: 079 900 74
2,5 mm2, BOMAG part-no.: 079 900 75
Spare sleeve 1.5 mm2, BOMAG part-no.: 079
900 76
Spare sleeve 2,5 mm2, BOMAG part-no.: 079
900 77
Fig. 31
Universal tools
88. Universal pressing pliers with toggle lever trans-
mission and adjustable end pressure for Crimp-
ing roller connector 0.14 - 1.0 mm2.
Fig. 32
008 915 04 BOMAG 157

89. Precision pressing pliers for non-insulated flat

male and female connectors0.5 - 6,0 mm2.
Fig. 33
Measuring adapter
90. Current measurement adapter for Hirschmann
plugs.
Fig. 34
91. Voltage measurement adapter for Deutsch plugs,
8-piece (2 to 12 pole).
Fig. 35
92. Current measurement adapter for Deutsch and
AMP plugs, 2 pole.
Fig. 36
158 BOMAG 008 915 04

6 Electronic modules
008 915 04 BOMAG 159

160 BOMAG 008 915 04
6.1 Module description A04
008 915 04 BOMAG 161

162 BOMAG 008 915 04

Module description A04 6.1
Description UPM1
Sprinkling module 27R
- 538 380 02 -
RS 232
LED 2
LED 3
LED 1
LED 4
LED 5
+ - 6 4 3 2 13
30
Version 1.0 from 29.06.2004
A. Hehner Page 1 from 29.06.2004

008 915 04 BOMAG 163
Table of Contents
1. Version history................................................................................................ 3
2. Description of hardware ................................................................................. 4
2.1. Pin assignment for digital inputs......................................................................................... 4
2.2. Pin assignment for analog inputs........................................................................................ 4
2.3. Pin assignment for outputs .................................................................................................. 4
3. Description of function................................................................................... 6
3.1. Total overview of sprinkling cycle ....................................................................................... 6
4. Software version history ................................................................................ 7

164 BOMAG 008 915 04
1. Version history
No. Version Date Description of version Resp.

1 1.0 29.06.04 1. version created Hehner

008 915 04 BOMAG 165
2. Description of hardware
The inputs were changed in such a way, that the following table applies:
Input Behaviour Remark

Input PIN13 LOW-active LED lights when applying ground potential!
Input PIN3 HIGH-active LED lights when applying positive voltage!
2.1. Pin assignment for digital inputs

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

pin
Not used + / -
2.3. Pin assignment for outputs

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

166 BOMAG 008 915 04
The hardware is available under BOMAG part-no. 057 644 39.
PIN Signal Description

13 IN (Active LOW) Emulsion switch
RS 232 2 IN (Active LOW) Optional (ground bridge)
LED 2
3 IN (Active HIGH) not used

4 IN (Active HIGH) not used
LED 3
LED 1
LED 4
LED 5
6 OUT (BTS) OUT 15/54, 4A

OUT - PWM -
OUT + PWM +
30 Relay - Contact IN 12V, 15 A
+ - 6 4 3 2 13
87
87a
Relay - Contact Normally open
Relay - Contact Normally closed
15/45 Supply voltage 10-39 V
30 Ground
!
Figure 1: Module
The complete module (including the specific software) is available under

BOMAG part-number 538 380 02.
The following applies when measuring the signal level:
PIN Potential with LED on Potential with LED off

digit. inputs (HIGH active) Operating voltage Voltage < 1V
digit. input (LOW active) Ground Input open

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

008 915 04 BOMAG 167
3. Description of function
The following sequences were realized in the UPM2 Software for realization of sprinkling cycles.
3.1. Total overview of sprinkling cycle
In order to realize a switching interval for the emulsion sprinkling system, the input (PIN 13) and
the output (PIN 6), as well as the relay of the module are used. The emulsion sprinkling system
is activated by the ground signal on input PIN13. If an additional ground signal (bridge) is
applied to input (PIN 2), the interval time is changed to the following values:
Impulse time Pause time
With ground bridge on PIN 2 6 seconds 6 seconds

Without ground bridge on PIN 2 6 seconds 12 seconds
As long as the emulsion sprinkling system is ACTIVE (ground signal on PIN 13), output PIN 6
(LED 5) and relay (LED 6) are cyclically set in intervals for 6 (6) seconds to ON or 12 (6)
seconds to OFF.
During an OFF-pause the emulsion sprinkling system can be triggered by switching input PIN13
short-term to Active LOW, the ON-phase at the output will start immediately from the beginning
for 6 (6) seconds. Triggering is not possible during an ON-phase.
If the emulsion sprinkling system is switched off during an ON-phase, the ON-phase will
continue to the end (6 seconds). An ON-phase cannot be interrupted (or only by switching off
the module).

168 BOMAG 008 915 04
4. Software version history
Version management: BOMAG Sprinkling Module 538 380 02

Module: BM UPM1
Controller: PIC16F84a
Version 1.00 from 29.06.2004:

----------------------------
Checksum: ba02
1. version created.

008 915 04 BOMAG 169
170 BOMAG 008 915 04

6.2 Heating/air conditioning control
008 915 04 BOMAG 171

172 BOMAG 008 915 04

Heating/air conditioning control 6.2
008 915 04 BOMAG 173

174 BOMAG 008 915 04

Heating/air conditioning control 6.2
008 915 04 BOMAG 175

176 BOMAG 008 915 04

7 Module description A100
008 915 04 BOMAG 177

7.1 Steering column locking module, A100
Description UPM03
BW24/27RH
538 380 06 Version 1.0 dated 17.07.06
538 380 12 Version 1.0 dated 09.06.08
Fig. 37
Description of hardware
The module consists of the modified UPM2 module. The inputs were designed in such a way, that the following
table applies:
Input Performance Comment

178 BOMAG 008 915 04

Steering column locking module, A100 7.1
Pin assignment digital inputs
Signal Name Module Pin Signal on input

Steering column switch left/ 11 Active-HIGH left forward LED on
reverse LOW = left not reverse LED off
Steering column switch left/ 12 Active-HIGH = left forward LED on
forward LOW = left not forward LED off
Parking brake 13 Active-LOW = Parking brake released LED on
HIGH = Parking brake closed LED off
Steering column switch right/ 14 Active-HIGH = right reverse LED on
reverse LOW = right not reverse LED off
Steering column switch right/ 15 Active-HIGH = right forward LED on
forward LOW = right not forward LED off
Pin assignment outputs
Signal Name Module Pin Signal on input

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

digital inputs (HIGH-active) Operating voltage (UB) Voltage < 1V
digital inputs (LOW-active) Ground Input open
digital outputs (HIGH-active) Operating voltage (UB -0.7V) <1V
digital outputs (LOW-active) Ground Operating voltage (UB -0.7V)
Emergency operation
If a bridge is inserted between PIN2 and PIN3, the outputs PIN4 and PIN5 are at HIGH potential and the cor-
responding LED, as well as the red LED on PIN3, will light.
i Note
This function can be used in emergencies (defect), to be able to move the machine for a short time.
Description of function
Switching on
If operating voltage is applied to the module, the Stay-Alive LED will flash in intervals of one second.
Fault signal
If both steering column switches are actuated at the same time, a fault signal is emitted by output PIN 6. This
fault is deactivated by returning both steering column switches to neutral position.
If one steering column switch is actuated while the parking brake is closed, PIN 6 will also emit a fault signal.
Travel direction
When shifting the steering column switch forward (Pin12 or Pin15), output Pin5 will switch.
008 915 04 BOMAG 179

When shifting the steering column switch backward (Pin11 or Pin14), output Pin7 will switch.
Outputs PIN5 and PIN7 will only emit a signal when the parking brake is open (Pin13 active-LOW).
Changing the steering column switch, module 538 380 06, old version
Replacing the steering column switch is only permitted when both travel levers are in neutral position. When the
left hand steering column switch is actuated, the right hand steering column switch is locked (and vice-versa).
Any changes to the locked steering column switch are ineffective).
Changing the steering column switch, module 538 380 12, old version
Replacing the steering column switch is only permitted when both travel levers are in neutral position. When both
steering column switches are actuated, both outputs (Pin5 and Pin7) will switch off and a fault signal will appear
on output Pin6 (LED lights). This fault signal remains present, until both travel levers have been returned to neu-
tral position.
Control of travel direction switchover

When actuating the steering column switch forward, output Pin4 is switched on with a delay of 0.8 seconds.
When actuating the steering column switch backward, output Pin4 is switched off with a delay of 0.8 seconds.
Start release
If no steering column switch is actuated, a signal is submitted through the start release output Pin 8.
180 BOMAG 008 915 04

8 Speedometer Module
008 915 04 BOMAG 181

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

When the module is in learning mode a manual dis-
play test can be performed via the input "Test". For
this purpose the input "IN" must be energized with 12
Volt, whereupon the speedometer is constantly trig-
gered with 3 Volt.
182 BOMAG 008 915 04

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

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

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

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

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

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

speed sensor.
●
Connect the speedometer (0 to 6 Volt) to "OUT +"
and "OUT –“.
008 915 04 BOMAG 183

184 BOMAG 008 915 04

9 Front axle
008 915 04 BOMAG 185

9.1 Repair overview for front axle
9.1 Repair overview for front axle
Fig. 1 6 Tie rods

1 Joint carrier 7 Rotation joint
2 Body bolster 8 Steering axle
3 Steering leg 9 Joint bolt with bearing
4 Wheel bearing 10 Wheel discs
5 Steering cylinder 11 Bearing bushes for steering axle
186 BOMAG 008 915 04

Dismantling the front axle 9.2
9.2 Dismantling the front axle
! Danger
Danger of squashing!
Do not stand or work under suspended loads!
1. Disassemble the front axle.
2. Attach the lifting tackle to the front axle (Fig. 1).
Fig. 1
3. Place the front axle with the top side down safely
on a assembly trestle (Fig. 2).
Fig. 2
4. Remove the locking plates from the steering arms
(Fig. 3).
5. Drive bolt (1) out with a suitable drift punch and
pull out the tie rods (2).
Fig. 3
Disassembly of wheel bearing units
6. Remove the wheel discs (Fig. 4).
Fig. 4
008 915 04 BOMAG 187

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

8. Disassemble the front bearing cover with Bel-
leville springs, shims and backing discs.
Fig. 5
9. Attach the lifting tackle to the wheel bearing unit.
10. Turn impact puller 1 (Fig. 6) into the thread (M24)
and extract the bearing bolt with the bearing.
iNote
Remove also the joint bolt from the opposite side.
Fig. 6
11. Lift the bearing unit out of the body bolster (Fig.
7).
Fig. 7
12. Bend the lug if the locking plate open and un-
screw the grooved nut 1 (Fig. 8).
Fig. 8
188 BOMAG 008 915 04

13. Take off the locking plate (Fig. 9).
Fig. 9
14. Take off the shim (Fig. 10).
15. Extract the wheel bearing using a suitable puller.
Fig. 10
Disassembling the steering arm
16. Disassemble the left hand holding plate (Fig. 11).
17. Disassemble the right hand holding plate .
18. Attach the lifting tackle to the body bolster.
Fig. 11
19. Lift both steering arms out of the steering axles
(Fig. 12).
20. Unscrew the steering cylinder fastening screws
and disassemble the steering cylinder (1).
Fig. 12
008 915 04 BOMAG 189

21. Lay the steering arms on the workbench (Fig. 13).
Fig. 13
22. Knock out the bearing bushings 1 (Fig. 14).
Fig. 14
Disassembling the body bolster
23. Attach the lifting tackle to the body bolster.
24. Remove the rear bearing cover (Fig. 15).
25. Disassemble the front bearing cover with Bel-
leville springs, shims and backing discs.
Fig. 15
26. Press the body bolster against the joint recepta-
cle to the stop (Fig. 16).
i Note
The outer race (1) of the rocker bearing is thereby
stripped off.
If the outer race is not stripped off completely, it
may need to be destroyed.
It may be helpful to weld a flat steel bar to the out-
er race so that it can be pulled off with a puller.
Fig. 16
190 BOMAG 008 915 04

27. Force inner race 1 (Fig. 17) of the rocker bearing
off the bolt.
i Note
If the inner race cannot be levered off, it may
need to be destroyed.
It may be helpful to weld a flat steel bar to the in-
ner race so that it can be pulled out with a puller.
28. Remove backing disc (2).
Fig. 17
29. Unscrew the socket head cap screws (Fig. 18).
Fig. 18
30. Turn in the forcing screws and force the joint bolt
out of the body bolster (Fig. 19).
Fig. 19
31. Take the joint bolts out of the body bolster (Fig.
20).
Fig. 20
008 915 04 BOMAG 191

32. Press the body bolster against the joint recepta-

cle to the stop (Fig. 21).
i Note
The outer race (1) of the rocker bearing is thereby
stripped off.
If the outer race is not stripped off completely, it
may need to be destroyed.
It may be helpful to weld a flat steel bar to the out-
er race so that it can be pulled off with a puller.
Fig. 21
33. Force inner race 1 (Fig. 22) of the rocker bearing
off the bolt.
i Note
If the inner race cannot be levered off, it may
need to be destroyed.
It may be helpful to weld a flat steel bar to the in-
ner race so that it can be pulled out with a puller.
34. Remove backing disc (2).
Fig. 22
35. Unscrew the socket head cap screws (Fig. 23).
Fig. 23
36. Turn in the forcing screws and force the joint bolt
out of the body bolster (Fig. 24).
Fig. 24
192 BOMAG 008 915 04

37. Take the joint bolts out of the body bolster (Fig.
25).
Fig. 25
38. Take the joint receptacle out of the body bolster
and lay it safely to the side (Fig. 26).
Fig. 26
Disassembling the steering axles
i Note
The steering axles 1 (Fig. 27) cannot be disas-
sembled without being destroyed.
The steering axles were assembled with the help
of liquid oxygen at -20°C.
Fig. 27
008 915 04 BOMAG 193

9.3 Assembling the front axle
! Caution
Ensure strict cleanliness.
! Danger
Danger of squashing!
Do not stand or work under suspended loads!
1. Lay the body bolster with the top side down on the
assembly trestle (Fig. 1).
Fig. 1
Assembling the steering axles
2. Spray the receiving bores with sliding lacquer
OKS 571 to ease assembly (Fig. 2).
Fig. 2
! Danger
Persons handling liquid oxygen must learn

the following safety instructions:
Safety instructions, handling low temperature
liquid gases
Safety instructions, lack of oxygen.
Safety instructions, oxygen enrichment.
Safety instructions, frost bites and congela-
tion.
3. Cool the steering axles down to at least -20°C
with liquid oxygen.
Fig. 3 4. Press the steering axles 1 (Fig. 3) into the body
bolster until they bottom.
i Note
The steering axles must slide into the body bol-
ster.
194 BOMAG 008 915 04

Assembling the front axle 9.3
Assembling the joint receptacle
5. Lay the joint receptacle 1 (Fig. 4) on the assembly
trestle.
! Caution
Do not apply any load to the steering axles be-
fore the bottom section is free of ice.
6. Attach lifting tackle to steering axles with body
bolster (2).
Fig. 4
7. Assemble new seal rings (Fig. 5).
8. Oil the seal rings.
Fig. 5
9. Oil the receiving bores for the joint bolts (Fig. 6).
Fig. 6
10. Insert the body bolster into the joint receptacle
(Fig. 7).
Fig. 7
008 915 04 BOMAG 195

Assembling the joint bolts

11. Screw in the front guide pins (M10) (Fig. 8).
12. Screw in the rear guide pins (M10) .
Fig. 8
13. Oil and attach the front and rear joints bolts (Fig.
9).
! Caution
Avoid skewing of the joint bolts.
14. Attach the assembly tool (1).
Fig. 9
15. Pull both joint bolts in against the stop (Fig. 10).
16. Remove the assembly tool.
Fig. 10
17. Remove the guide pins (Fig. 11).
Fig. 11
196 BOMAG 008 915 04

18. Screw in the socket head cap screws from both
sides (Fig. 12) and........
Fig. 12
19. ..... tighten (Fig. 13).
Fig. 13
Assembling the rocker bearings
20. Assemble the front backing disc (Fig. 14).
21. Assemble the rear backing disc.
Fig. 14
22. Spray the bearing seats and the inner bearing
races with sliding lacquer OKS 571 to ease as-
sembly (Fig. 15).
! Caution
Do not use any grease.
Fig. 15
008 915 04 BOMAG 197

23. Attach the inner rocker bearing races with the

wide outer rim forward (Fig. 16) and.....
! Caution
Do not skew.
Fig. 16
24. .... drive in with a suitable mandrel (Fig. 17)
Fig. 17
25. Spray the bearing seats and the outer bearing
sembly (Fig. 18).
! Caution
Fig. 18
26. Attach the outer bearing races with the wide outer
rim facing outside and drive them in with a plastic
hammer (Fig. 19).
! Caution
Do not skew.
Fig. 19
198 BOMAG 008 915 04

27. Assemble the rear bearing cover.
28. Tighten the hexagon screws (Fig. 20) cross-wise.
Fig. 20
Adjusting the bearing preload
! Caution
The bearings must be fully pressed in!
29. Insert backing disc 1 (Fig. 21) and Belleville
springs (2) into the front cover.
i Note
Lay the Belleville springs into the cover with the
curvature pointing down.
Fig. 21
30. Attach the front bearing cover with backing disc
and Belleville springs and locate the assembly
with two fastening screws (Fig. 22).
! Caution
Adjust the bearing preload with an axial
preload of 40KN.
With threaded rod M12-8.8 = 77 Nm tightening
torque
torque.
31. Push the threaded rod through joint receptacle
Fig. 22
and body bolster.
32. Tighten the threaded rod with the specified torque
(Fig. 23).
Fig. 23
008 915 04 BOMAG 199

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

cover and joint receptacle with a feeler gauge
(Fig. 24).
i Note
Shim thickness "S" = 3.4 mm - "Y"
34. Remove the cover again.
Fig. 24
35. Insert shim 2 (Fig. 25) of appropriate thickness
and backing disc (1) into the cover.
Fig. 25
36. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 26).
Fig. 26
37. Assemble the cover (Fig. 27) with Belleville
springs, shims and backing disc.
38. Turn in and tighten the fastening screws.
Fig. 27
200 BOMAG 008 915 04

39. Turn in protection plug 1 (Fig. 28).
Assembling the steering cylinders
40. Insert the steering cylinder with fastening clamps
into the grooves (2) in the body bolster.
41. Turn in and tighten the screws.
Fig. 28
Steering arm
i Note
The work steps (Fig. 29) to (Fig. 45) apply for both
body bolsters.
42. Lay the steering arm on the workbench (Fig. 29).
Fig. 29
43. Attach the bottom bearing bushing (Fig. 30).
Fig. 30
44. Attach the top bearing bushing (Fig. 31).
Fig. 31
008 915 04 BOMAG 201

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

46. Pull both bearing bushings fully in with the as-
sembly tool.
Fig. 32
47. Assemble new seals and apply a thin coat of oil
(Fig. 33).
Fig. 33
48. Apply some grease to the friction disc contact
surface (Fig. 34).
Fig. 34
49. Assemble the friction disc (Fig. 35).
Fig. 35
202 BOMAG 008 915 04

50. Apply some grease to the friction disc seal ring
(Fig. 36).
Fig. 36
51. Assemble and grease the seal (Fig. 37).
Fig. 37
52. Clean the steering axle (Fig. 38).
Fig. 38
53. Spray the steering axle with sliding agent OKS
571 (Fig. 39).
Fig. 39
008 915 04 BOMAG 203

54. Apply some grease to the body bolster contact

surface (Fig. 40).
Fig. 40
55. Attach the lifting tackle to the body bolster (Fig.
41).
Fig. 41
56. Fit body bolster and steering axle together (Fig.
42).
Fig. 42
57. Assemble the holding plate (Fig. 43).
Fig. 43
204 BOMAG 008 915 04

58. Tighten the screw (Fig. 44).
Fig. 44
59. Oil the receiving bores for the bearing bolts (Fig.
45).
Fig. 45
Assembling the wheel bearings
i Note
bearing shafts.
60. Attach lifting tackle to the bearing shaft (Fig. 46)
and..........
Fig. 46
61. ......... stand the shaft in a hydraulic press (Fig.
47).
62. Assemble spacer (1).
63. Spray the bearing mounting surfaces with sliding
agent OKS 571 .
Fig. 47
008 915 04 BOMAG 205

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

48).
Fig. 48
65. Turn the bearing shaft by 180° (Fig. 49).
66. Assemble spacer (1).
67. Spray the bearing mounting surfaces with sliding
agent OKS 571 .
Fig. 49
68. Press the wheel bearing in until it bottoms (Fig.
50).
Fig. 50
69. Attach shim and locking plate (Fig. 51).
Fig. 51
206 BOMAG 008 915 04

70. Attach the grooved nut with the bevelled side
down and tighten it hand tight with a sickle span-
ner (Fig. 52).
Fig. 52
71. If necessary loosen the grooved nut again, until a
lug of the locking plate matches a groove in the
grooved nut (Fig. 53).
72. Bend the lug down.
73. Perform the work steps (Fig. 51), (Fig. 52) and
(Fig. 53) on both sides of the wheel bearing unit.
Fig. 53
Assembling the wheel bearing units
i Note
bearing units.
74. Attach the lifting tackle to the wheel bearing unit
(Fig. 54).
75. Oil the receiving bores for the bearing bolts.
Fig. 54
76. Fit wheel bearing unit and body bolster together
(Fig. 55).
Fig. 55
008 915 04 BOMAG 207

77. Oil and attach the front and rear joints bolts (Fig.
56).
! Caution
Avoid skewing of the joint bolts.
78. Attach the assembly tool (1).
Fig. 56
79. Pull both joint bolts in against the stop (Fig. 57).
80. Remove the assembly tool.
Fig. 57
81. Assemble the backing discs on both sides (Fig.
58).
Fig. 58
82. Spray the bearing seats and the inner bearing
sembly (Fig. 59).
! Caution
Fig. 59
208 BOMAG 008 915 04

83. Attach the inner rocker bearing races with the
wide outer rim forward (Fig. 60) and.....
! Caution
Do not skew.
84. ...... drive in with a suitable mandrel.
Fig. 60
85. Spray the bearing seats and the outer bearing
sembly (Fig. 61).
! Caution
Fig. 61
86. Attach the outer bearing races with the wide outer
rim facing outside and drive them in with a plastic
hammer (Fig. 62).
! Caution
Do not skew.
Fig. 62
87. Assemble the rear bearing cover (Fig. 63).
88. Tighten the hexagon screws cross-wise.
Fig. 63
008 915 04 BOMAG 209

Adjusting the bearing preload
! Caution
Bearings and bearing bolts must be fully
pressed in!
89. Insert backing disc 1 (Fig. 64) and Belleville
springs (2) into the front cover.
i Note
Lay the Belleville springs into the cover with the
curvature pointing down.
Fig. 64
90. Attach the front bearing cover with backing disc
and Belleville springs and locate the assembly
with two fastening screws (Fig. 65).
91. Push the threaded rod through joint receptacle
and body bolster.
! Caution
Adjust the bearing preload with an axial
preload of 40KN.
torque
Fig. 65
torque.
92. Tighten the threaded rod with the specified
torque.
93. Measure the gap (measurement „Y“) between
cover and joint receptacle with a feeler gauge
(Fig. 66).
i Note
Shim thickness "S" = 3,2 mm - "Y"
94. Remove the cover again.
Fig. 66
210 BOMAG 008 915 04

95. Insert shim 2 (Fig. 67) of appropriate thickness
and backing disc (1) into the cover.
Fig. 67
96. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 68).
Fig. 68
97. Assemble the cover (Fig. 69) with Belleville
springs, shims and backing disc.
98. Turn in and tighten the fastening screws.
99. Press in the protection plug (1).
Fig. 69
100. Assemble the wheel discs (Fig. 70).
Fig. 70
008 915 04 BOMAG 211

Assembling the tie rods
i Note
Perform work steps (Fig. 71) to (Fig. 74) on the
left and right hand steering arms.
101. Spray the mating surfaces with sliding lacquer
OKS 571 to ease assembly (Fig. 71).
102. Drive the bearing into the tie rod with a suitable
drift punch.
Fig. 71
103. Apply both tie rod seals 2 (Fig. 72).
104. Slide tie rod (1) and seals (2) into the receptacle
on the steering arm.
Fig. 72
105. Spray the bolts with sliding lacquer OKS 571 to
ease assembly (Fig. 73).
i Note
Insert the bolt so that groove (2) is in line with
tapped bores (1).
106. Knock the bolt in with a plastic hammer.
Fig. 73
107. Fasten the locking plate (Fig. 74).
Fig. 74
212 BOMAG 008 915 04

Adjusting the toe-in
i Note
Toe-in occurs when the front ends of the wheels
are closer together than the rear ends. With toe-
in the right hand wheel steers slightly to the left,
while the left hand wheel steers slightly to the
right (Fig. 75).
Fig. 75
108. Align both steering arms to each other (Fig. 76).
Fig. 76
109. Apply both tie rod seals 4 (Fig. 77).
110. Slide both tie rods (1) with seals (4) into the fork
heads (2) of the steering cylinder (5).
111. Insert a special tool (3, bolt with undersize) into
the fork heads of the cylinder.
Fig. 77
112. Measure the distance of the outer wheel discs at
the front (Fig. 78).
113. Measure the distance of the outer wheel discs at
the rear.
i Note
Nominal value for toe-in: 2 +/- 1 mm.
Fig. 78
008 915 04 BOMAG 213

i Note
The toe-in is adjusted by turning the fork head (2)
accordingly. Adjust the left and right hand fork
heads as uniformly as possible.
114. Remove the special tool 3 (Fig. 79).
115. Pull the tie rods (1) out of the fork heads (2).
116. Turn the fork heads (2) into or out of the cylinder
(5).
i Note
Turning the for heads out reduces the toe-in.
Fig. 79
117. Slide both tie rods (1) with seals (4) into the fork
heads (2) of the steering cylinder (5) again.
118. Assemble the special tool (3) again.
119. Repeat the measurement (Fig. 80).
i Note
Repeat work steps (Fig. 79) and (Fig. 80), until
the toe-in is correctly adjusted.
Fig. 80
Assembling the steering bolts
120. Remove the special tool (Fig. 81).
Fig. 81
214 BOMAG 008 915 04

i Note
Perform work steps (Fig. 82) to (Fig. 84) on the
left and right hand fork heads.
121. Spray the bolts with sliding lacquer OKS 571 to
ease assembly.
i Note
Insert the bolt so that groove (2) is in line with
tapped bores (1).
122. Drive the bolts (2) in with a plastic hammer.
Fig. 82
123. Fasten the locking plate 2 (Fig. 83).
124. Push the screws 1 through the fork head and turn
on the nuts.
Fig. 83
125. Tighten the fork head (Fig. 84).
Fig. 84
Turning the front axle around
126. Attach the lifting tackle to the front axle (Fig. 85).
Fig. 85
008 915 04 BOMAG 215

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

(Fig. 86).
128. Assemble the front axle.
Fig. 86
216 BOMAG 008 915 04

10 Service Training
008 915 04 BOMAG 217

218 BOMAG 008 915 04
10.1 Service Training
008 915 04 BOMAG 219

220 BOMAG 008 915 04

Service Training 10.1
Service Training
Hydraulics and Pneumatics
Rubber Tire Rollers

BW 24 RH
BW 27 RH
12/2006
008 915 04 BOMAG 221

Service Training
Table of contents
Hydraulic system D
Travel drive D
Travel pump E
Travel motors F
Travel gear G
Brake system H
Pneumatic system J
Compressed air brake J
Tire inflation system J
Steering K
BW 24/27 RH
222 BOMAG 008 915 04

Service Training
General
The rubber tire rollers of series BW 24/27 RH are high performance machines for the extremely difficult
use in asphalt compaction and earth work.
Due to their kneading and fulling effect these rubber tire rollers achieve an excellent surface sealing
effect.
The machines of this series are powered by engine oil cooled Deutz diesel engines of series BF4M 2012
and 2012 C.
The new rubber tired rollers from BOMAG have modern HYDROSTATIC DRIVES.
The hydrostatic drive works with a travel pump (DA-controlled) and two compact travel systems
consisting of bent axle variable displacement motors and travel gear units on the rear axle. Apart from
extreme inclinations or declines these rubber tire rollers can comfortably work in one speed range.
The rubber tire rollers are designed with three travel speed ranges.
The new rubber tire rollers from BOMAG are designed with a HYDRO-DYNAMIC SERVICE BRAKE
with so-called wet discs. The new brake system is maintenance free and offers higher safety reserves,
than conventional drum brakes.. The brake is pneumatically supported.
By standard the rubber tire rollers are equipped with pressure sprinkling system and lighting according
to STVZO.
The pneumatic system is supplied by a diesel engine driven compressor.

The air pressure in the pneumatic system supports the brake system and is also used for the tire inflation
system.
BW 24/27 RH -A3-
008 915 04 BOMAG 223

Service Training
Hydraulic system
Travel system and steering on the new rubber tire rollers from BOMAG work with hydraulically drives.
This enables low loss transmission of engine output power to all drives.
The pumps for the respective drives are driven by the engine and convert the mechanical energy
provided by the engine into hydraulic energy.
Since the medium oil is used for this power transfer the appearing power losses are only minimal.
Hydraulic oil filters protect the hydraulic circuits against contamination.
Temperature control valve and and hydraulic oil cooler ensure optimal temperature in the hydraulic
system.
Safety elements in pumps and hydraulic control elements protect the hydraulic system and the engine
against overloads and other damage.
Special features of the new BOMAG rubber tire rollers are:

the hydrostatic travel drive and
the hydrodynamic service brake
BW 24/27 RH -D1-
224 BOMAG 008 915 04

Service Training
Travel system
The new rubber tire rollers all have hydrostatic travel drives.
The speed dependent drive regulation (DA) is a purely hydro-mechanical regulation for travel drives in
closed hydraulic systems.
The travel drive regulation enables travel comfort similar to motor vehicles with automatic gearbox: The
more the throttle pedal is kicked down, the bigger the swashing angle and the flow volume from the
travel pump and the higher the travel speed.
With any occurring overload the maximum load control will reduce the flow volume from the pump to a
value that prevents the diesel engine from being extremely overloaded.
The DA-control also makes sure that the DA-pump will adapt the power take-off to the power provided
by the diesel engine.
The travel drive is a closed hydraulic circuit. One talks about a closed hydraulic system, when the
hydraulic oil flows from the consumer directly back to the pump. The closed circuit consists of a high
and a low pressure side, depending on the load direction (take-off moment on the consumer).
The fluid remains in the closed circuit, only the leakages in pump and motor must be replenished.
The hydrostatic travel system primarily consists of:
a travel pump (DA-control pump)
two travel motors (bent axle variable displacement motors)
and two travel gears with brakes (reduction gear)
BW 24/27 RH -D2-
008 915 04 BOMAG 225

Service Training
Travel drive schematics
Brake pedal Travel direction

Throttle pedal Travel speed range selector switch
switch
back forw.
Signal
Inching valve forward
Engine Travel pump 2 travel motors

Diesel engine DA-pump parallel 2 travel gears
with brake
BW 24/27 RH -D3-
226 BOMAG 008 915 04

Service Training
Operator’s stand
1 1
3 2
3
2
1) Travel direction switch (electrically forward-reverse)
2) Throttle pedal and travel speed via control cable
3) Brake pedal via compressed air
BW 24/27 RH -D4-
008 915 04 BOMAG 227

Service Training
Travel pump
The DA-control uses a variable displacement pump which is controlled by means of a speed dependent
hydraulic control. This pump is referred to as DA-pump.
The DA-pump is operated hydraulically in dependence on the rotational speed. For this purpose the
system is equipped with a charge pump and a DA-control valve to generate the pilot pressure in
dependence on the speed of the diesel engine.
4
1
4 5
8
Fig. 1 Hydraulic diagram Bosch/Rexroth travel pump A4VG105DA
1 Charge pump
2 4/3-way valve (control unit for travel direction)
3 Inching valve
4 High pressure relief valve with boost check valve
5 Charge pressure relief valve
6 DA-control valve
7 Charge pressure filter
8 Pressure override
BW 24/27 RH -E1-
228 BOMAG 008 915 04

Service Training
9 Travel pump
The pump flow is determined by the displacement and the actual rotary speed of the pump. It is
proportional to the drive speed and the displacement. Due to the possibility of an infinite adjustment of
the swash plate the pump flow rate and therefore the travel speed can also be infinitely changed within
the pre-selected travel speed range.
The pump is equipped with all control and safety elements needed for operation in a closed hydraulic
circuit.
Inching valve
/ control
Fig. 2 Side view of pump
BW 24/27 RH -E2-
008 915 04 BOMAG 229

Service Training
Pressure override
DA-control valve / DA-control cartridge
High pressure relief valves
Charge pressure relief valve
Fig. 3 Connecting plate
Inching valve
with inching valve
Fig. 4 Control
BW 24/27 RH -E3-
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Service Training
Pump control
Fig. 5 Travel pump control
1 DA-control cartridge 5 4/3-way valve (travel direction)

2 Charge pressure relief valve 6 Discharge orifice
3 Pressure override 7 Supply orifice (8mm)
4 Control 8 Charge pump
A High pressure port B High pressure port
BW 24/27 RH -E4-
008 915 04 BOMAG 231

Service Training
Fig. 6 DA-control valve
1 Charge pump 12 Circlip

2 Circlip 13 Threaded pin
3 Control tube 14 Control screw
4 Stepped piston 15 Locking nut
5 Ring 16 Charge pressure relief valve
6 Circlip 17 Housing channel
7 Nut 18 Pilot pressure channel
8 Washer 19 Control edge
9 Pressure spring 20 Control edge
10 O-ring 21 Measuring orifice (8mm)
11 Spring plate 22 Bore
BW 24/27 RH -E5-
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Service Training
Pilot pressure is used to control the pump is infinitely from neutral position to the desired direction of oil
flow and to the desired displacement.
The necessary pilot pressure for the pump is supplied by the charge pump (auxiliary pump) and flows
through the DA-control valve cartridge to the control.
At an engine speed between low idle speed and control start (approx. 1100 rpm), the pump flow rate
of the charge pump is so low, that almost all of the oil can pass through the inside of the control valve
and flow to the charge ports in the travel pump. The static pressure in front of the orifice (ø 8 mm) in the
control valve cartridge is not yet high enough to move the inside spool against the spring.
When accelerating the engine to a speed higher than the control start (1100 rpm or HD=50bar), the
flow rate from the charge pump will increase accordingly. This higher oil flow rate causes a higher
pressure drop across the orifice and pushes the inside spool against the spring. This opens four bores,
which are arranged in a ring around the circumference of the spool and provides a connection to the
proportional 4/3-way solenoid valve on the pump control. The opening cross-section of these bores
around the circumference depends on the pressure drop across the inlet orifice of the control valve
cartridge and therefore on the speed of the diesel engine. It enlarges with increasing engine speed or
with increasing pump flow rate respectively.
At the control end these bores are fully open.
Since the bores have a considerable restricting effect, even when they are fully open, the pilot pressure
may be a lot lower than the charge pressure.
At control start (bores start to open) the pilot pressure is approx. 6 bar.
If the solenoid valve has been switched to a certain travel direction, the available pilot pressure is high
enough to actuate the pump slowly out of neutral position. The pump starts to deliver hydraulic oil to the
corresponding travel motors.
Raising the diesel engine speed also increases the pump flow rate of the charge pump, opens the bores
(orifice) around the circumference of the control valve spool and the pilot pressure increases gradually.
The pump changes to a higher displacement and delivers a higher amount of oil per unit of time to the
motors. The machine drives faster.
The rest of the oil flow passes through the DA-control valve cartridge to the charge pressure relief valves
in the travel pump.
Control start of the travel pump should be at an engine speed of 1100 rpm and a high pressure
(travel pump) of approx. 50 bar!
BW 24/27 RH -E6-
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Service Training
Fig. 7 Valve arrangement
1 DA-control cartridge 7 Supply orifice (8mm)

2 Charge pressure relief valve 8 Charge pump
3 High pressure relief valve 9 Travel pump
4 Pressure override A High pressure port
5 Travel direction valve B High pressure port
6 High pressure relief valve
The charge circuit is needed for the compensation of leaks and flushing quantities in a closed hydraulic
circuit and to accommodate controlling of the pump.
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Service Training
Pressure override
in function
Fig. 8 Pressure override
1 Valve piston 8 Pressure spring

2 Bore 9 Adjustment screw
3 Valve seat 10 Pilot pressure channel
4 Piston 11 Housing channel
5 Valve bush 12 High pressure circuit
6 Control piston 13 High pressure circuit
7 Spring cup 14 Valve seat
BW 24/27 RH -E8-
008 915 04 BOMAG 235

Service Training
High pressure relief valves with bypass to tow the machine
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Service Training
Inching valve
The inching valve is attached to the travel pump between control unit and pump housing.
The inching valve works in connection with the service brake.
The inching function supports the service brake.
In case of soft braking (up to 20 bar braking pressure) only the hydrostatic drive will brake using the
inching function.
When applying high braking pressure, both the hydraulic system and the service brake will work
simultaneously. The pump control unit is in this case directly linked with the service brake circuit.
Increasing pressure in the brake system causes a reduction in pilot pressure and thus a reduction of the
travel pump swashing angle.
Compressed air Travel

direction Travel speed range selecto
Throttle (pneumatic)
pedal Brake pedal
Brake
cylinder
to the
Brake
inching valve
BW 24/27 RH - E 10 -
008 915 04 BOMAG 237

Service Training
Components and test ports
2
3
Travel pump
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values

diagram
1 Travel pump 9
2 High pressure port, forward 9 max. 455 bar
3 High pressure port, reverse 9 max. 455 bar
4 Pressure test port - charge pressure 9 25 bar
5 Suction connection for internal 9 Q=25.1ccm
charge pump
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Service Training
Travel pump
1 4
3
2
5 6 7

diagram
1 Pressure test port, travel pressure 9 max. 455 bar
reverse
2 Charge pressure relief valve 9 25 bar
3 DA-control valve 9
4 Pressure test port, travel pressure 9 max. 455 bar
forward
5 Pressure reducing valve 15 Setting 21 bar
6 Brake valve Y 04, sheet 003 14 12 V brake open
7 Brake releasing valve 12
BW 24/27 RH - E 12 -
008 915 04 BOMAG 239

Service Training
Travel pump control

diagram
1 Travel direction solenoid, reverse Y17, sheet 009 9 switched 12 V
2 Travel direction solenoid, reverse Y16, sheet 009 9 switched 12 V
3 Pressure override 9 Setting 430 bar
BW 24/27 RH - E 13 -
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Service Training
inching valve

diagram
1 inching valve 9
2 Ventilation 9
3 Connection - inching pressure from 9 0 - 81 bar
brake cylinder
BW 24/27 RH - E 14 -
008 915 04 BOMAG 241

Service Training
Filter
3 1

diagram
1 charge oil filter 7
2 Pressure differential switch B21, sheet 004 7 Switching point at
a pressure
differential of 3.5
bar
3 Return flow filter from brake housing 19
cross-flushing
BW 24/27 RH - E 15 -
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Service Training
Travel motors
The rubber tire rollers are equipped with two drive axles which drive one wheel pair each. The drive
axles consists of two travel motors and two travel gears with brake and are located in the rear area of
the machine.
The motors are Bosch/Rexroth bent axle motors with variable displacement A6VM 107 HA2R.
With a solenoid valve the motors can be electrically controlled from minimum displacement Qmin (high
speed and low torque) to maximum displacement Qmax (low speed and high torque). Whereby the
motor automatically changes from Qmin towards Qmax when an operating pressure (high pressure) of
approx. 215 bar is reached. The motors can thus be operated in different travel speed ranges, as
desired.
The machines are designed with 3 speed ranges.
1. Travel speed range

Both motors are switched and remain in Qmax position (low speed and high torque).

In this cased only one motor is switched to Qmax. In this case only the right hand motor in travel
direction will be at Qmax.

Both motors are not switched and remain in Qmin position (high speed and low torque), until an
operating pressure (high pressure in travel circuit) of approx..215 bar is reached. Then the motors swing
automatically towards Qmax.
The pressure range and the speed with which the motors swing from Qmin to Qmax is determined by
the internal pressure increase spring.
The control start of the motor is the point at which the motor starts to swing from Qmin to Qmax.
The control end of the motor is reached when the motor has reached Qmax position.
In zero position or without pressure the motor is

always in Vgmin or Qmin position
Important motor adjustment data

The control start of the travel motors is 125 bar.
The value of the pressure increase spring is 100 bar.
The control end of the motors is approx. 315 bar
All pressures are operating pressures (high pressure), measured in the travel circuit and related to a
charge pressure of 25 bar.
These values are factory default values and should not be changed.
BW 24/27 RH -F1-
008 915 04 BOMAG 243

Service Training
Cross-section of bent axle motor A6VM HA2R with flushing valve
Port M
Pilot pressure Flushing valve
Qmin
Stop screw
Drive shaft
Valve plate
Piston
Qmax
Stop screw
Port G
High pressure
Ho Control start
Setscrew
Qmax
solenoid
Travel direction
solenoid
BW 24/27 RH -F2-
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Service Training
Variable displacement motor A6VM 107 HA2R
Working principle:
High pressure oil is fed through the inlet port. The pistons perform an axial stroke movement, which is
then transferred to the drive shaft by the piston joints, whereby the axial movement is converted to a
rotary movement of the shaft. The cylinder is driven by the pistons. The out flowing hydraulic oil flows
back to the pump.
When the volume flow rises to high pressure, the axial piston movement will become faster. This
increases also the output speed.
In a variable displacement motor this angle can be infinitely adjusted within certain limits. The change
in swashing angle causes a difference in stroke length and thus a change in displacement. The output
speed is proportional to the supplied fluid volume and the swashing angle. The available motor torque
increases with the pressure drop between high and low pressure side.
The swashing angle is hydraulically changed by the control piston. The hydraulic section with the valve
plate is thereby displaced and hydraulically held in position.
An increasing angle results in higher displacement and torque, but in a lower output speed. Reducing
the swashing angle reduces also displacement and torque, but increases the output speed. In
combination with the DA-control in the pump the variable displacement motor A6VM can be used. This
motor can be regulated in various ways.
In combination with DA-pumps the high pressure dependent control HA is of relevance for the variable
displacement motor.
In speed range 3 the displacement changes in dependence on the operating pressure (high pressure).
The control unit measures the internal operating pressure at port A or B on the hydraulic motor (no pilot
line required) and swashes from minimum displacement (Vg min to maximum displacement Vg max
when the nominal pressure (pressure increase spring) set on the controller is reached.
With the high pressure dependent control the control start takes place at Vg min (min. torque, max.
speed) and the control end at Vg max. (max. torque, min. speed).
Vgmin or Qmin is 36.5 qcm per revolution.
Vgmax or Qmax is 107 qcm per revolution.
In zero position or without pressure the motor always

is in position Vgmin or Qmin
BW 24/27 RH -F3-
008 915 04 BOMAG 245

Service Training
Travel direction solenoid valve
The travel direction valve ensures that, when changing the high pressure side
(e.g. travel drive when driving downhill), the pre-selected pressure side of the motor will always regulate
the swashing angle and an undesired swashing of the variable displacement motor (travel motor) to
higher displacement is avoided.
On the rubber tire rollers the travel direction valve is always energized (12V) in forward travel.
Qmax solenoid valve (1st speed range)
The high pressure dependent control of the travel motor is overridden by an electrical signal applied to
the switching solenoid (Qmax solenoid). This causes the variable displacement motor (travel motor) to
swash to maximum swashing angle (Qmax) and speed range 1 is activated.
Flushing valve
The flushing and flushing pressure relief valve has the function of dissipating heat from the closed circuit
and flushing the housing.
Hot pressure fluid is discharged from the corresponding low pressure side into the motor housing. This
fluid is returned to the tank, together with the leak oil.
Any pressure fluid removed from the closed circuit must be replaced by cool oil from the charge pump.
The valve is flanged to the variable displacement motor.
Various flushing quantities can be adjusted by means of orifices.
The flushing pressure relief valve is a safety valve. It has the function of limiting the flushing pressure,
so that the charge pressure is maintained.
BW 24/27 RH -F4-
246 BOMAG 008 915 04

Service Training
Description and testing the motor control start
Control start from Vgmin to Vgmax
BW 24/27 RH -F5-
008 915 04 BOMAG 247

Service Training
Hydraulic diagram travel motor driving to the right
1 2
Qmax
Qmin 4

diagram
11 Travel motor right 11
1 Travel direction valve Y 164, sheet 009 11 switched 12 V
Y 163 left motor
2 Qmax valve (1st speed range) Y 130, sheet 009 11 switched 12 V
Y 03 left motor
3 Flushing valve with flushing 11 16 bar
limitation valve
4 Control 11 Zero position
Qmin
BW 24/27 RH -F6-
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Service Training
5
1 4
Travel motor left

diagram
1 Travel motor left 10
2 High pressure ports forw./rev. 10 max. 455 bar
3 Travel direction solenoid valve Y 163, sheet 009 10 switched 12 V
(Y164 right motor)
4 Speed range solenoid, Qmax. Y 03, sheet 009 10 switched 12 V
(Y130 right motor)
5 Flushing valve 10
6 Pressure test port M1, pilot pressure 10 approx. 1/2 high
pressure
BW 24/27 RH -F7-
008 915 04 BOMAG 249

Service Training
Travel motor left
2
3
1
4
5

diagram
1 Travel motor left 10
2 High pressure ports forw./rev. 10 max. 455 bar
3 Travel direction solenoid valve Y 163, sheet 009 10 switched 12 V
(Y164 right motor)
4 Speed range solenoid, Qmax. Y 03, sheet 009 10 switched 12 V
(Y130 right motor)
5 Leak oil port 10
BW 24/27 RH -F8-
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Service Training
Travel gear with brake
The travel gear in the rubber tire roller is a reduction gear from Bonfiglioli with a transmission ratio of
i=32,2.
The gearbox inlet carries the travel motor and the hydro-dynamic multi-disc brake.
This brake is statically released and applied via the brake valve.
Another brake port serves the purpose of hydro-dynamic braking. This brake pressure is applied by a
brake cylinder and closes the brake with the brake valve opening pressure of 21 bar.
The brake housing is cross-flushed in order to avoid premature wear of brake discs.
These two ports are also located on the brake housing.
The two rubber wheels are mounted to the power take-off of the gearbox.
BW 24/27 RH -G1-
008 915 04 BOMAG 251

Service Training
Travel gear with brake
T1
T2
P1
Hydraulic diagram of travel gear
P1) Brake releasing pressure from brake valve

P2) Brake pressure from brake cylinder
T1) Cross-flushing brake housing inlet
T2) Cross-flushing of brake housing outlet
BW 24/27 RH -G2-
252 BOMAG 008 915 04

Service Training
Gearbox inlet
Gearbox outlet
BW 24/27 RH -G3-
008 915 04 BOMAG 253

Service Training
Travel gear unit with travel motor
BW 24/27 RH -G4-
254 BOMAG 008 915 04

Service Training
BW 24/27 RH -G5-
008 915 04 BOMAG 255

Service Training
Brake system
The new rubber tire rollers are equipped with two brake systems.
A conventional static multi-disc brake, also referred to as parking brake, which is released via a brake
valve with charge pressure (pressure reducing valve 21 bar) and is closed when no pressure is
available.
The second brake is the hydro-dynamic multi-disc brake, which is pneumatically operates a
compressed air brake pedal with a brake cylinder which then acts on the brake piston with boosted
hydraulic pressure (1:10) and closes the brake.
At a brake pressure of up to 20 bar an inching valve only reduces the swashing angle in the travel pump.
If the brake pressure increases over 21 bar, the brake will close immediately, even if it is opened by
charge pressure (pressure reducing valve 21 bar).
The brake pressure from the brake valve can be up to 80 bar.
BW 24/27 RH -H1-
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Service Training
The brake housing is cross-flushed to avoid premature wear of the brake discs. Cross-flushing is
accomplished by the steering pump and it is described in detail in the corresponding chapter.
from / to Flushing of brake housing

Brake valve
Hydraulic diagram
Brake
housing
Oil supply
from
Hydraulic oil tank
from brake pedal

Brake cylinder
Return flow to filter and tank
BW 24/27 RH -H2-
008 915 04 BOMAG 257

Service Training
BW 24/27 RH -H3-
258 BOMAG 008 915 04

Service Training
BW 24/27 RH -H4-
008 915 04 BOMAG 259

Service Training
Cross-section of brake housing
BW 24/27 RH -H5-
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Service Training
Compressed air port

from brake pedal
The hydraulic brake pressure is 10 times higher than the pneumatic pilot pressure
i.e. the pneumatic pilot pressure = max. 8 bar, hydraulic brake pressure = max. 80 bar
BW 24/27 RH -H6-
008 915 04 BOMAG 261

Service Training
BW 24/27 RH -H7-
262 BOMAG 008 915 04

Service Training
BW 24/27 RH -H8-
008 915 04 BOMAG 263

Service Training
BW 24/27 RH -H9-
264 BOMAG 008 915 04

Service Training
BW 24/27 RH - H 10 -
008 915 04 BOMAG 265

Service Training
Ventilation
Important:
The brake system must be thoroughly bled after any work in the hydraulic system of the
machine.
Ventilation
Brake cylinder
Ventilation
inching valve
BW 24/27 RH - H 11 -
266 BOMAG 008 915 04

Service Training
Ventilation
Brake housing
BW 24/27 RH - H 12 -
008 915 04 BOMAG 267

Service Training
Pneumatic system
The rubber tire rollers are equipped with a compressed air system.
This compressed air system serves two on-board systems.
1. The compressed air brake system
2. The tire inflation system (option)
The compressor is directly mounted to the engine and takes in air through the air filter.
After the compressor this hot pressurized air is supplied through a cooling spiral to the air drier,
regeneration tank and air tank..
The system pressure is 8.1 bar
At an air pressure under 5.7 bar the pressure switch (B12, sheet 4, electric wiring diagram) will
switch, the control light (brake system) will light up and the warning buzzer will sound.
Pressure to the brake system always has priority.
At a system pressure lower than 6.5 bar no air pressure will be available for the tire inflation system.
Each of the eight rubber wheels is fitted with a pressure retaining valve. This valve is set to a residual
pressure of 2 bar and thus prevents exhaustive emptying of the tires.
BW 24/27 RH -J1-
268 BOMAG 008 915 04

Service Training
BW 24/27 RH -J2-
008 915 04 BOMAG 269

Service Training
BW 24/27 RH -J3-
270 BOMAG 008 915 04

Service Training
BW 24/27 RH -J4-
008 915 04 BOMAG 271

Service Training
BW 24/27 RH -J5-
272 BOMAG 008 915 04

Service Training
Compressor and regeneration tank
1 5 4
Pos. Designation Pos. in wiring diagram Pos. in pneumatic Measuring values

diagram
1 Compressor 1
2 Air intake 1
3 Pressure line 1
4 Cooler - cooling spiral 4
5 Regeneration tank 19
BW 24/27 RH -J6-
008 915 04 BOMAG 273

Service Training
Air drier
3 2

diagram
1 Air drier 5
2 DBV pneumatic system 5 Setting 8,1 bar
3 Input 5
4 output 5
BW 24/27 RH -J7-
274 BOMAG 008 915 04

Service Training
Air tank
3
1

diagram
1 Air tank 6
2 Pressure switch B12, Page 004 7 Switching pnt. 5.7
bar
3 Output, brake pedal 6
4 Tire inflation system 6
5 Overflow valve 11 Setting 6.3 bar
6 Pressure test port, pneumatic 6 max. 8.1 bar
system
BW 24/27 RH -J8-
008 915 04 BOMAG 275

Service Training
diagram
7 Brake cylinder input, pressure from 18 max. 8.1 bar
brake pedal
BW 24/27 RH -J9-
276 BOMAG 008 915 04

Service Training
Brake pedal

diagram
1 Brake pedal 8 and 9
2 Compressed air inlet 8 and 9
3 Output to brake cylinder 8 and 9
BW 24/27 RH - J 10 -
008 915 04 BOMAG 277

Service Training
Tire inflation system
Air-ON Air-OFF
BW 24/27 RH - J 11 -
278 BOMAG 008 915 04

Service Training
Tire pressure retaining valve
1
2

diagram
1 Pressure retaining valve 16 Setting 2 bar
2 Rotary joint 17
BW 24/27 RH - J 12 -
008 915 04 BOMAG 279

Service Training
Steering
The new rubber tire rollers from BOMAG are equipped with a hydraulically operated steering system.
30
30
Hydraulic diagram steering system

1 Steering/flushing pump 8 Safety check valve
3 Steering valve 19 Return flow filter with pressure switch B22
5 Steering cylinder 20 Temperature switch B148
6 Priority valve 30 Gearbox brake housing right and left
BW 24/27 RH -K1-
280 BOMAG 008 915 04

Service Training
The steering system consists mainly of:
• the steering pump,
• the priority valve,
• the steering valve,
• the steering cylinder and
• the pressure resistant connecting hoses
Since the steering pump besides its function of supplying the steering system also serves the purpose
of cross-flushing the brake, the system is equipped with a priority valve. The priority valve ensures that
the steering will always be prioritized under any condition. The priority valve is triggered by the steering
valve through the LS-line. This valve restricts the oil flow to the brake housing whenever oil is needed
for the steering. The gear pump delivers the hydraulic oil out of the hydraulic oil tank to the priority valve.
When the steering is not operated, the complete oil flow will flow to both brake housings for cross-
flushing. After the brake housings the oil flows are united and passed through a filter back into the tank.
This cross-flushing is protected by a 6 bar check valve.
When operating the steering the steering valve will generate a load signal "LS", informing the priority
valve that more oil should be directed to the steering.
When turning the steering wheel the distributor valve guides the oil flow to the corresponding steering
cylinder sides.
The steering cylinder displaces the front steering bolster (steering axle) of the machine.
The steering valve contains also a pressure relief valve. This valve limits the steering pressure to 170
bar.
Suddenly occurring pressure peaks, which may be caused by e.g. external influences like driving
against a curb stone, are compensated by two shock valves (setting 235 bar), which are integrated in
the steering valve.
Note
This steering system is a dynamic steering system, i.e. a small quantity of oil (approx. 1 - 2 l/min)
will always flow via the LS-line.
BW 24/27 RH -K2-
008 915 04 BOMAG 281

Service Training
Steering pump
The steering/charge pump is a tandem gear pump with fixed displacement. The pump is designed with
a displacement of 16 ccm/rev. and supplies steering and brake housing.
The pump is driven by the diesel engine and draws the hydraulic oil directly out of the oil tank. The oil
then flows to the priority valve and from there to the steering valve or the brake housings.
9 9 6 1 7
3
8
2
4 5
Steering pump
1 Housing 4, 5 Bearing plates 9 Seals
2 Flange 6 Cover
3 Shaft 7, 8 Pinions
Function of the gear pump
The drive pinion of the steering pump is driven by the auxiliary drive of the engine. Drive gear and driven
gear are positioned by a bearing plate in such a way, that the teeth of both gears mesh with minimum
clearance when rotating.
The displacement chambers are formed between the tooth flanks, the inside wall of the housing and the
faces of the bearing plates. The chambers transport the hydraulic oil from the suction side to the
pressure side. This generates a vacuum in the suction line, which draws the hydraulic oil out of the tank.
These tooth chambers transport the hydraulic oil along the inside wall of the housing from the suction
side to the pressure side, from where it is pressed to the consumers. To ensure a safe function of the
pump the tooth chambers must be so tightly sealed that the hydraulic fluid can be transported from the
suction side to the pressure side without any losses.
Outer gear pumps are fitted with gap seals. This results in pressure level dependent fluid losses from
the pressure side to the suction side. An axial pressure field presses the bearing plate on the cover side
against the front face of the gears, making sure that only a very little quantity of oil will leak from the
pressure side to the suction side when the pressure increases during operation.
The pressure field is always under system pressure.
BW 24/27 RH -K3-
282 BOMAG 008 915 04

Service Training
Priority valve
Since the pressure oil from the steering pump is also needed for cross-flushing the brake housings, the
machine is fitted with a priority valve. This valve ensures that the steering will always be prioritized under
any condition. The priority valve guides the oil to the following consumers:
• to the steering valve (port CF)
• to the brake housings (port EF)
Priority valve
Distribution of the oil is determined by the switching position of the valve spool.
This position depends on the following values:
• the requirements caused by the steering load (LS-signal) arriving from the steering valve
• the load (pressure) in the steering system (max. 176 bar)
The load signal (LS) from the steering valve controls the position of the valve spool in such a way, that
the oil flow is at any time determined by the steering speed.
Note
BW 24/27 RH -K4-
008 915 04 BOMAG 283

Service Training
Steering valve
The steering valve consists mainly of:
• the distributor valve,
• the rating pump,
• the steering pressure relief valve and
• the shock valves.

1
1
2
9
3
8
6
Steering unit
1 Neutral setting springs 6 Ring gear
2 Housing 7 Gear
3 Inner spool 8 Check valve
4 Outer spool 9 Pressure relief valve
5 Universal shaft
BW 24/27 RH -K5-
284 BOMAG 008 915 04

Service Training
When turning the steering wheel the oil flow from the pump is guided through the distributor valve to the
rating pump and from there to the respective sides of the steering cylinders.
The rating pump determines the exact oil quantity in dependence on the turning angle of the steering
wheel.
The high pressure relief valve in the steering unit limits the pressure in the steering system to 170 bar.
The steering unit is equipped with so-called shock valves. These valves are adjusted to 235 bar. They
compensate extreme pressure peaks, which can be introduced from outside, e.g. when driving over
obstacles. The system is thereby protected against overloads.
Each of these shock valves is fitted with an additional anti-cavitation valve. These anti-cavitation valves
protect the system against cavitation which could be caused by the reaction of the shock valves.
A check valve inside the steering unit makes sure that the hydraulic oil cannot flow to the steering pump
if forces are introduced from outside. In such a case the steering cylinders would act as pumps and
press the oil back to the pump.
Note
BW 24/27 RH -K6-
008 915 04 BOMAG 285

Service Training
4
5
1
1
3 2 2
Steering pump and return flow filter

diagram
1 Steering pump 16ccm 1
2 Steering pressure test port 1 max.170 + 6 bar
3 Return flow filter - flushing of brake 19
housings
4 Pressure differential switch B22, Page 004 19 ∆p 3,5 bar
5 Temperature switch B148, Page 004 20 Switching point
120°C
BW 24/27 RH -K7-
286 BOMAG 008 915 04

Service Training
Steering valve
3 2
9
5
6
4 3
4 2 1
5

diagram
1 Steering valve 3 Pressure relief
valve setting 170
bar
2 LS-port to priority valve 3
3 L-port to steering valve 3
4 R-port to steering cylinder 3
5 Port P from priority valve 3
6 Port T to charge system 3
BW 24/27 RH -K8-
008 915 04 BOMAG 287

Service Training
Priority valve
2 1
Priority valve
BW 24/27 RH -K9-
288 BOMAG 008 915 04

Service Training
Check valve in hydraulic tank inlet
BW 24/27 RH K 10 -
008 915 04 BOMAG 289

290 BOMAG 008 915 04

11 Air conditioning system
008 915 04 BOMAG 291

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

conditioning system one must first become familiar
with the physical basics of such a system.
The four well known physical conditions of water apply
also for the refrigerant in the air conditioning system.
1. gaseous (invisible)
2. vaporous
3. liquid
4. solid
Fig. 2
Heat always flows from the warmer to the colder mat-
ter. Any matter consists of a mass of moving mole-
cules. The rapidly moving molecules or a warmer
matter dissipate part of their energy to the slower
moving molecules with less heat. The movement of
the molecules in the warmer matter becomes slower
and the molecules in the cooler matter are accelerat-
ed. This process continued, until all molecules in the
two matters move with identical speed. The matters
have then reached an identical temperature and the
transfer of heat stops.
Fig. 1
If the water in a container is heated up (absorption of
heat), the rising steam is visible. If the steam is heated
up further, due to the absorption of heat, the visible
steam will turn into invisible gas. This process is re-
versible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into
water and finally into ice.
292 BOMAG 008 915 04

Physical basics 11.1
Pressure and boiling point 4. If a fluid evaporates it requires a lot of heat, i.e. the
fluid thereby cools down the surrounding environment
The boiling point is the temperature at which fluid
(e.g. alcohol on skin)
changes to gaseous state.
Changing the pressure above a fluid also changes the
boiling point. It is a well known fact, that e.g. the lower i Note
the pressure applied to water, the lower the boiling At absolute pressure 0 bar correspond with an abso-
point. lute vacuum. The normal ambient pressure (overpres-
sure) corresponds with 1 bar absolute pressure. On
When looking at water, the following values do apply:
the scales of most pressure gauges 0 bar corre-
●
Atmospheric pressure, boiling point 100°C sponds with an absolute pressure of 1 bar (indicated
●
Overpressure 0.4 bar, boiling point 126°C by the statement -1 bar below the 0).
●
Vacuum -0.6 bar, boiling point 71°C
For an optimal exchange of heat, liquid refrigerants
must have a low boiling point, so that they can absorb
and dissipate heat quickly.
Fig. 4 Pressure - Temperature Diagram

In the pressure - temperature diagram for the refriger-
ant the drawn in closed curve shows the cycle of the
refrigerant. This cycle permanently continues in direc-
tion of the arrow.
The characters A, B, C, D stand for:
Fig. 3 Steam pressure curve A - compression
Steam pressure curve for refrigerant R134a B- condensation
The steam pressure curve is a means for explaining C- relaxation
the operation principle of an air conditioning system. D- evaporation.
A- liquid
B- gaseous
The diagram shows the evaporation curve of R134a.
The diagram for example shows, that R134a is liquid
at 0°C and a pressure of 5 bar, but becomes gaseous
at 40°C and 5 bar.
For better understanding one must also be aware of
the following:
1. A gas heats up when being compressed (e.g. air
pump, turbo charger, ...).
2. When relieving gas it will cool down (e.g. white frost
forms on the valve when relieving air pressure from a
car tire).
3. Condensing gas dissipates a lot of heat energy.
008 915 04 BOMAG 293

11.1 Physical basics
Excerpt from the wet steam table 1 R134a

1 This table is used for the determination of evaporation and con-
densation temperature.
Saturation temperature Overpressure (pressure gauge Absolute pressure (pamb = 1 bar
reading Pe in bar) P in bar)
-20 0,33 1,33
-10 1,01 2,01
0 1,93 2,93
10 3,15 4,15
20 4,72 5,72
294 BOMAG 008 915 04

Refrigerant R134a 11.2
11.2 Refrigerant R134a Characteristics of the refrigerant R134a:
Refrigerant R134a is currently available under the fol-
General lowing trade marks.
The evaporation and condensation process is the H-FKW 134a
method commonly used in mobile air conditioning sys- SUVA 134a
tems. The system in this case works with a substance KLEA 134a
that boils at low temperature, a substance referred to
a refrigerant. The refrigerant used is tetrafluoroethane
R134a, which boils at a temperature of -26.5°C and Colour:
under a steam pressure of 1 bar. Refrigerant in form of vapour or liquid is colourless as
Although the refrigerant circuit is a hermetically closed water. The gas is invisible. Only the bordering layer
loop, the system loses approx. 100g of refrigerant between gas and liquid is visible. (Fluid level in rising
over the course of 1 year by diffusion through hoses, pipe of filling cylinder or bubbles in inspection glass).
pipes and seals, even though the system is free of In the inspection glass the liquid refrigerant R134a
leaks. If too much refrigerant is lost the cooling power may appear coloured (milky). This turbidity results
of the system will drop. from partially dissolved refrigeration oil and is no indi-
cator for a fault.
Physical data of the refrigerant R134a
Steam pressure:
Chemical formula:
In an incompletely filled, closed container, vaporous
CH2F-CF3 or CF3-CH2F refrigerant will volatilize from the surface in the same
quantity that will turn liquid in combination with steam
particles. This state of equilibrium occurs under pres-
Chemical designation: sure and is frequently referred to as steam pressure.
Tetrafluoroethane The steam pressure is independent from the temper-
ature.
Boiling point at 1 bar:

- 26.5 °C Physical properties of R134a:
The steam pressure curves of R134a and other refrig-
erants are partly very similar, making a clear differen-
Solidification point: tiation solely by pressure impossible. With R 134a the
compressor is lubricated by special synthetic refriger-
-101.6 °C
ation oils, e.g. PAG-oils (polyalkylene glycol oils).
Critical temperature:
Behaviour with metals:
100,6 °C
In pure condition refrigerant R134a is chemically sta-
ble and does not attack iron and aluminium. However,
contamination of the refrigerant, e.g. with chlorine
Critical pressure:
compounds, leads to aggressiveness against certain
40.56 bar (absolute) metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.
Critical point:
Critical point (critical temperature and critical pres- Critical temperature / critical pressure:
sure) means that above this point there is no separat- Up to a gas pressure of 39.5 bar overpressure (this
ing interface between liquid and gas. Above its critical corresponds with a temperature of 101 °C) the refrig-
point any substance is gaseous. At temperatures be- erant R134a remains chemically stable, above this
low the critical point all refrigerant types in pressure temperature the refrigerant decomposes (see com-
containers have a liquid and a gaseous phase, i.e. a bustibility).
gas cushion is above the liquid. As long as gas is in
the container, besides the liquid, the pressure de-
pends on the ambient temperature. Water content:
In liquid refrigerant water can only be dissolved in very
low quantities. In contrast to this refrigerant steam
mixes with water steam at any ratio. If the dryer in the
008 915 04 BOMAG 295

11.3 Compressor oil / refrigeration oil
liquid container has absorbed approx. 8 gr. of water, 11.3 Compressor oil / refrigeration
the refrigerant circuit transports possibly existing wa-
ter in form of droplets. This water flows to the nozzle oil
of the expansion valve and turns to ice. The air condi- The compressor oil lubricates the movable parts in the
tioning system stops cooling. Water destroys the air compressor, seals e.g. the gap between piston and
conditioning system, because under high pressures cylinder inside the compressor to prevent refrigerant
and temperatures and in connection with other con- loss and prevents other seals in the system from dry-
taminants it forms acids. ing up.
Part of the compressor oil dissolves in the refrigerant
Inflammability: until saturation is reached, so that a gas mixture of re-
frigerant, water steam, compressor oil and contrast
Refrigerant is not inflammable. On the contrary, it has agent circulates through the system.
fire inhibiting or fire extinguishing properties. Refriger-
ant is decomposed by flames or glowing surfaces. Ul- Compressor oil (the oil quantity should be 10 % of the
traviolet light also cracks refrigerant (caused by refrigerant weight) mixes with the refrigerant and cir-
electric welding). This results in toxic fission products, culates permanently through the system.
these must not be inhaled. However, irritation of the In connection with R134a- air conditioning systems
mucous membranes is an early and in-time warning. special synthetic compressor oils, e.g. polyalkylene
glycol (PAG) oils, are used. This is necessary, be-
cause e.g. mineral oil does not mix with R134a. Apart
Filling factor: from this, the materials in the R134a air conditioning
In a container there must be a steam space above the system may be attacked when the mixture is flowing
liquid space. The liquid expands with increasing tem- through the refrigerant circuit under high pressure and
perature. The steam filled space becomes smaller. at high temperatures or if the lubrication film in the
From a certain time on the container will be filled with compressor tears off. The use of non-permitted oils
just liquid. After this only a minor temperature in- can cause damage to the air conditioning system, you
crease is enough to generate very high pressures in should therefore only used the approved oils.
the container, because the liquid would like to expand,
but there is no more room. The related forces are high
enough to cause the container to burst. In order to Properties of compressor oil / refrigeration oil:
avoid overfilling of a container the pressure gas direc- The most important properties are high solvency in
tive clearly specifies how many kilograms of refriger- connection with refrigerants, good lubrication charac-
ant may be filled into the container per litre volume. teristics, that they are free of acids and their low water
Multiplied with the internal volume this "filling factor" content. For this purpose only certain oils can be
determines the permissible filling capacity For refrig- used. PAG-oils suitable for use with refrigerant R134a
erants used in motor vehicles it is 1.15 kg/l. are highly hygroscopic and will not mix with other oil.
As a protection against the invasion of moisture drums
must immediately be closed again after they had been
opened. Compressor oil ages under the effect of
Environmental aspects moisture and acids, becomes dark, viscous and ag-
The contribution of R134a to the greenhouse effect is gressive against metals.
by factor 10 smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for
newly produced construction equipment were succes-
sively converted to refrigerant R134a. This refrigerant
does not contain any chlorine and is thus harmless for
the ozone layer. Until approx. 1992 air conditioning
systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decompo-
sition potential and also a potential to amplify the
greenhouse effect. Conversion programs for existing
old systems with the ozone damaging R12 are in ef-
fect. For reasons of protecting the environment refrig-
erant must not be discharged into the atmosphere.
296 BOMAG 008 915 04

Working principle of the air conditioning system 11.4
11.4 Working principle of the air 11.5 Monitoring devices
conditioning system
All air conditioning systems are based on the same
principle. They extract heat from the surrounding en- Pressure switch
vironment. Everybody knows the effect: if a sweating
The pressure switch (8) is used as monitoring feature
body is exposed to wind it will cool down, because
for too high and too low pressures. The switching con-
heat is extracted. For this purpose a refrigerant circu-
tacts (4 and 5) effect the magnetic clutch of the com-
lates in a closed circuit inside the vehicle. This refrig-
pressor via a relay (6).
erant thereby continuously changes its physical state
between liquid and gaseous. If the system pressure increases excessively, e.g. be-
cause of a excessively soiled condenser, a failed fan
or a defective expansion valve, the high pressure con-
tact (5) will cut off the electric power supply to the
magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off
pressure by the set differential pressure, the magnetic
clutch of the compressor is switched on again.
The low pressure contact (4) interrupts the electric
power supply to the magnetic clutch when the set
pressure is fallen short of (possible causes: lack of re-
frigerant, defective expansion valve, too low heat
load, defective evaporator fan, ...). Since the refriger-
ant R134a has an evaporation temperature of 0 °C at
an overpressure of 2 bar, the low pressure contact (4)
Fig. 1 Principle sketch of an air conditioning system
is set to approx. 1.5 bar to avoid icing. The switch on
An engine driven compressor (1) draws in gaseous re- pressure is 0.5 to 2 bar higher than the shut-off pres-
frigerant from the evaporator (5) and compresses it. sure (depending on system, see description of com-
During this process the temperature of the refrigerant ponents.)
increases tremendously.
Thermostat
The refrigerant vapour is then pumped to the con-
denser (2). This condenser is arranged directly in front A frost protection thermostat (3) protects the evapora-
of the vehicle radiator, so that a sufficient air flow is as- tor against icing. Similar to the pressure switch, the
sured. In the condenser (2) the gas is cooled down thermostat activates or deactivates the magnetic
and consequently liquefied. clutch for the compressor. Depending on the design,
the feeler of the temperature control is mounted be-
In the dryer / liquid container (3) the refrigerant is then
tween the fins of the evaporator or attached to the
collected and freed of moisture and contaminants.
evaporator outlet (suction side). With fixed tempera-
The expansion valve (4) regulates the flow rate from ture controls the control switches the compressor off
the dryer / liquid container (3) back to the evaporator at about 1 °C and back on again at about 2.5°C to 5.5
(5) and the circuit starts again. °C (depending on system, see description of compo-
nents.)
With adjustable temperature regulators the switching
point can be changed so that the compressor is al-
ready shut down at higher temperatures. This enables
regulation of the air temperature.
008 915 04 BOMAG 297

11.6 Description of components
Monitoring chain 11.6 Description of components
Compressor
Fig. 2 Monitoring chain consisting of:

● 1 Switch
● 2 Fuse
●
3 Thermostat
●
4 Low pressure switch contact Fig. 1
●
5 High pressure switch contact The compressor is mounted to the engine and has the
duty to build up the refrigerant pressure required for
●
6 Relay
the function of the system. Coupling and decoupling is
● 7 Connection for magnetic clutch accomplished by an electromagnetically controlled
● 8 Pressure switch mechanical clutch, which is integrated in the V-belt
pulley of the compressor.
Compressor data
Displacement: 155 cm²
Weight: 6,9 kg
max. rpm: 6000
Sense of rotation: cw
Refrigerant: R134a
Oil quantity (scope of delivery): 207 gr
Oil: PAG SP-20 (H14-003-404)
! Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only refrigeration oil
PAG SP-20 (H14-003-404).
or condenser, any compressor oil / refrigeration
oil lost by exchanging the components, must be
replaced with fresh oil.
The actual quantity depends on the amount of oil
that may have been lost in connection with the
possible replacement of other components.
Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
The following table shows how much compressor oil /
refrigeration oil will be lost in connection with various
types of work on the air conditioning system.
298 BOMAG 008 915 04

Description of components 11.6
Reason of oil loss Amount of oil lost Condenser
Loss when emptying approx. 15 gr
Defective A/C hose approx. 30 gr
Hose change approx. 15 gr
Replacement of condens- approx. 30 gr
er
Replacement of evapora- approx. 30 gr
tor
Replacement of liquid con- approx. 30 gr
tainer
Replacement of expan- approx. 15 gr
sion valve
! Caution
Please bear in mind, that the new compressor is
delivered with a filling of 207 gr. compressor oil. Fig. 1
To avoid excessive oil in the A/C-system and thus The condenser is located in front of the the radiator for
a poor cooling effect, the oil level in the A/C-sys- the machine. It emits heat energy from the system into
tem must be adjusted accordingly. the surrounding air and liquefies the gaseous refriger-
ant.
The quantity depends on the amount of oil that
may have been lost in connection with the possi-
ble replacement of other components. i Note
The compressor oil quantity must be 10% of the The fins must be free of dirt and damage.
refrigerant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system re- ! Caution
quires a compressor oil / refrigerant oil filling of When replacing a heat exchanger, e.g. evaporator
100 gr. or condenser, any compressor oil lost by ex-
Procedure: changing the components, must be replaced with
Drain and measure the compressor oil from the fresh oil.
old compressor.
Drain the compressor oil from the new compres-
sor and only fill in the exact quantity that had been
drained out of the old compressor. The compres-
sor oil from the new compressor can be used for
this purpose.
i Note
Topping up compressor oil / refrigeration oil is possi-
ble on a pressureless compressor directly into the oil
pan, in a pressureless refrigeration system directly
into the pressure side, but it is also possible to draw it
into the pressure side of the refrigeration system dur-
ing the evacuation process.
008 915 04 BOMAG 299

Dryer / filter / fluid container / inspection Safety valve

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

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

the reason for air entering into the system and since
The arrow marks on the filter/dryer must point in air cannot be condensed, one will not be able to get
flow direction, i.e. towards the expansion valve. rid of these bubbles by topping up refrigerant. In this
Filter/dryer cannot be treated for further use! case the air conditioning system needs to be evacuat-
ed and refilled.
300 BOMAG 008 915 04

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

this pressure container this collector unit must be
replaced, to avoid bursting and further damage. Fig. 1
The expansion valve is mounted inside the HKL-mod-
ule in the cabin. The expansion valve always allows a
small amount of the high pressure liquefied refrigerant
to flow into the evaporator, which has a much lower
pressure. This lower pressure causes these liquid re-
frigerant to expand and to evaporate to gaseous state.
The heat required for this evaporation process is tak-
en from the ambient air through the lamellas and sup-
plied to the refrigerant. This is the so-called cooling
effect.
The thermostatic expansion valve operates with an
external pressure compensation. This type of expan-
sion valve works with high accuracy, because it uses
pressure and temperature at the evaporator outlet and
adjusts and overheating of approx. 7 K. The already
installed expansion valves and the ones delivered as
spare parts have this overheating value pre-set. In or-
der to prevent a loss in performance or compressor
damage you should only use original expansion
valves, because adjusting expansion valves takes a
lot of time and care.
i Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in-
let.+
008 915 04 BOMAG 301

Evaporator Defroster thermostat
Fig. 1 Fig. 1
The evaporator is mounted inside the HKL-module in The feeler of a defroster thermostat to switch off the
the cabin. It consists of a heat exchanger (inside air - magnetic clutch in case of icing up or to switch the
refrigerant), with refrigerant flowing to a pipe system clutch back on after defrosting, is mounted on the
with cooling flanges. evaporator. The correct adjustment of the defroster
thermostat as well as the correct feeler assembly
As with the condenser, correct operation of all fans
should be checked during maintenance.
and cleanliness of the fins must be assured.
Switching point on: + 1°C (+/- 1°C)
Air conditioning systems have a circulation air filter
mounted in the air flow in front of the evaporator, Switching point off: + 5.5°C (+/- 1°C)
which should be cleaned or changed by the operator
after each third trip, depending on the amount of dirt. i Note
A condensation water filter is mounted in the air flow It is very important that the feeler is mounted down-
after the evaporator. This filter has the function to col- stream of the evaporator, but before the pressure sen-
lect the water that has condensed from the air in the sor, in countercurrent direction, with full length and
evaporator block and to discharge this water into the insulated against the outside temperature.
water pan With a defective condensation water filter
condensation water may flow into the inside of the ve-
hicle.
! Caution
or condenser, any compressor oil lost by ex-
changing the components, must be replaced with
fresh oil.
302 BOMAG 008 915 04

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

GH 134 NW8 min. 50 mm
GH 134 NW16 min. 100 mm
GH 494 NW20 min. 160 mm
GH 494 NW25 min. 194 mm
GH 494 NW32 min. 225 mm
008 915 04 BOMAG 303

11.7 Measuring the compressor oil level
11.7 Measuring the compressor oil 11.8 Checking the magnetic clutch
level ●
Measure the voltage.
!Caution i Note
The compressor oil level must be checked after Nominal value = vehicle voltage
replacing a system component or if a leak in the ●
Check the magnetic coil locking ring for secure fit.
system is suspected. Use only compressor oil / re-
frigeration oil PAG SP-20 (H14-003-404). ●
Check the current consumption.
● Run the compressor for 10 minutes at engine idle
speed.
●
remove the refrigerant from the air conditioning sys-
tem.
Fig. 1
Fig. 1 i Note
●
Turn the compressor, as shown in (Fig. 1), if neces- at 12 Volt vehicle voltage approx. 3.5 Amp.
sary remove V-belt and hoses.
at 24 Volt vehicle voltage approx. 1.75 Amp.
●
Remove the oil plug.
Overcurrent indicates a short circuit inside the mag-
netic coil.
i Note No current indicates an interrupted electric circuit.
The oil level must reach the bottom edge of the bore,
top up or drain off oil if necessary.
● Close the oil plug again.
!Caution
The contact area must be clean and should be free
of damage.
Tightening torque 15 to 25 Nm
●
Refill the air conditioning system.
Fig. 2 Measuring the air gap

●
Measure the air gap on the magnetic clutch be-
tween V-belt pulley (2) and thrust plate (1).
304 BOMAG 008 915 04

Inspection and maintenance work 11.9
i Note 11.9 Inspection and maintenance
The gap should be 0.4 to 0.8 mm. work
●
Take off the drive V-belt and rotate the V-belt pulley ● Visual inspection of the complete system for dam-
by hand while the magnetic clutch is disengaged. age.
●
Check the compressor mounting bracket on the ve-
i Note hicle engine for tight fit and damage.
In case of excessive flatness faults or deviations the ●
Check the condition, alignment and tightness of the
magnetic clutch needs to be replaced. V-belt.
● Check the routing of refrigerant hoses and cables in
Cross-section of magnetic clutch
the area of the vehicle engine and transmission, as
Fig. 3 shows a cross-section of the magnetic clutch. If well as on the chassis for chafing and rectify any de-
the coil (7) is not supplied with operating voltage, tected faults. Ensure sufficient clearance to hot
there is no contact between the front plate of the parts, such as the exhaust; install a protective
clutch (1) and the V-belt pulley (2). A spring presses shield, if necessary.
the front plate away from the belt pulley. The V-belt ●
Check the routing of hoses and hoses on the at-
pulley rotates with the bearing (3) in idle speed, the
tachment box or in the cabin.
compressor does not work. When the coil is supplied
with operating voltage (12 or 24 V), a magnetic field is ●
Check all hose and screw fittings for leaks.
generated and pulls the front plate of the clutch. Both ●
Check the fastening of the condenser unit.
front plate and compressor shaft (8) are then driven by
the V-belt pulley, the compressor works. ●
Clean the condenser fins, replace the condenser
block if damaged fins are found.
●
Check the fastening of the evaporator unit.
●
Check the function of evaporator and condenser
fans.
● Check the electric control panel. If discolorations on
conductors are found, these should be replaced
and possibly also the corresponding relays.
●
Switch on the cooling system and check the refrig-
erant level.
●
Filter/dryer and filter/dryer/fluid container combina-
tions must always be replaced after opening the re-
frigerant circuit. If these are in service for more than
1 year, there is a risk that they may be clogged by
excessive absorption of moisture! The filter/dryer
should be replaced in regular intervals.
● Measure the temperature on the evaporator: Meas-
ure the intake air temperature - Measure the blow
Fig. 3 Cross-section of magnetic clutch out air temperature - The temperature difference
should be at least 8-10 K.
●
Measuring the pressure in the refrigerant circuit
008 915 04 BOMAG 305

11.10 Checking, replacing the refrigerant compressor V-belt
11.10Checking, replacing the refrig- ●

Press the compressor in direction of arrow, until the
correct V-belt tension is reached.
erant compressor V-belt1 ● Retighten all fastening screws.
Danger
! Changing the V-belt
Danger of injury! ●
Slightly slacken the fastening screws 1, 2 and 3.
Work on the V-belt must only be performed with ●
Press the compressor against the direction of arrow
the engine shut down. completely against the engine.
Wear safety goggles. ●
Take the old V-belt off.
●
Fit the new V-belt to the V-belt pulleys.
Check the V-belt
●
Tension the V-belt as previously described.
Caution
!
Check the V-belt tension after a running time of 30

minutes.
Fig. 4
●
Inspect the entire circumference of the V-belt (Fig.
4) visually for damage and cracks. Replace dam-
aged or cracked V-belts.
●
Check with thumb pressure whether the V-belt can
be depressed more than 10 to 15 mm (0.4 – 0.6
inches) between the V-belt pulleys, retighten if nec-
essary.
Tighten the V-belt.
Fig. 5
●
Slightly slacken fastening screws 1, 2 and 3 (Fig.
5).
306 BOMAG 008 915 04

Service the air conditioning 11.11
11.11Service the air conditioning1
Cleaning the condenser
! Caution
A soiled condenser results in a considerable re-
duction of air conditioning power.
Under extremely dusty conditions it may be nec-
essary to clean the condenser several times per
day.
If, during operation of the air conditioning system,
Fig. 7
the warning buzzer sounds switch the air condi-
tioning off and clean the condenser. ●
Switch the air conditioning (Fig. 7) on.
In case of formation of foam have the air condi-
tioning system inspected by the service depart-
ment.
! Danger
Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
age or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.
Fig. 8
●
Choose a cooling temperature with the rotary switch
for cabin heater (Fig. 8) in the blue section.
●
Open the air outlet nozzles.
●
Check, whether the outflowing air is noticeably cool-
er.
i Note
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on.
Fig. 6 ●
Open the hood.
● Clean the condenser fins with compressed air or
cold water (Fig. 6).
Checking the refrigerant level

●
Start the engine.
008 915 04 BOMAG 307

11.11 Service the air conditioning
Checking the moisture level of the drying

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

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

lector unit
Fig. 10 !Caution
●
If the white float (Fig. 10) inside the inspection glass According to the regulation for pressure reser-
of the drier/collector unit floats at the bottom, inform voirs all pressure reservoirs must be repeatedly
the service department. inspected by a specialist. In this sense repeated
inspections are external examinations, normally
on pressure reservoirs in operation. In connection
i Note
with this inspection the drier/collector unit must
The refrigerant level is not correct.
be visually examined twice every year. During
●
Refrigerant must be filled up, if necessary check the these inspections special attention must be paid
air conditioning system for leaks. to corrosion and mechanical damage. If the reser-
voir is not in proper condition it must be replaced
for safety reasons, as a precaution to protect op-
erators and third parties against any danger aris-
ing from the handling and operation of pressure
reservoirs.
! Danger
Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be replaced,
to avoid bursting and further damage.
308 BOMAG 008 915 04

Drying and evacuation 11.12
11.12Drying and evacuation
Evacuation of air conditioning systems using R-type
refrigerants not only has the purpose of emptying the
system of all air before filling in refrigerant, but also to
verify the leak tightness over a longer lifetime in the
achieved vacuum. However, the most important factor
in this work step is the drying of the system.
Any water residues in the refrigerant circuit will com-
bine with the refrigerant, which will lead to the previ-
ously described consequential damage.
Vacuum pumps with a capacity of more than 100 l/min
and a final pressure of less than 30 micron, i.e. 0.039
Fig. 12 mbar should be used to evacuate the refrigeration
●
Check the drier/collector unit (Fig. 12) for mechani- system.
cal damage or rust. The refrigerant compressor is not suitable for the pur-
pose of evacuation, because it is not able to achieve
a sufficient final vacuum and, apart from this, may be
mechanically damaged because of a lack of lubrica-
tion when running empty during evacuation.
It is common practice to evacuate the refrigeration
system to a final vacuum of 1 Torr, i.e. 1.33 mbar.
An exact time for evacuation and drying cannot be
predicted. It can only be determined by means of a
vacuum meter. However, if there is no vacuum meter
at hand it is generally better to evacuate 1 hour longer
than 1 hour too less.
Function drying:
Under normal ambient pressure (1.013 mbar) evapo-
rates absolute at 100° C. If the pressure is reduced,
water will already evaporate, e.g. under a pressure of
10 mbar, at an ambient temperature of almost 7°C,
but the water will not evaporate all at once. Since it is
very difficult to separate the steam from the vacuum in
the system, the evacuation process is supported by
the co-called vacuum breaking (filling the circuit with
dried nitrogen). With vacuum breaking the filled in
dried nitrogen absorbs the moisture in the refrigerant
circuit, which can then be easily discharged together
with the nitrogen.
008 915 04 BOMAG 309

11.13 Emptying in case of repair
11.13Emptying in case of repair 11.14Leak test

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

Points susceptible for leakage are sprayed with a
soapy solution. Bubbles indicate the leak. The detec-
tion limit for R 134a is 250 g/year.
310 BOMAG 008 915 04

Filling instructions 11.15
11.15Filling instructions
Filling of refrigerant into the dried, vented and oil filed

machines takes place under various conditions.
In most large series production facilities highly compli-
cated equipment is available for this purpose, where-
as individual machines at the place of installation must
be filled directly from the refrigerant container.
Liquid refrigerant is only used to pre-fill the pressure
side of the evacuated refrigeration system (protective
filling).
After switching the refrigeration system on and watch-
ing the inspection glass, gaseous refrigerant can be
filled into the system while the engine is running, if the
refrigerant level is found to be too low (gas bubbles in
the inspection glass).
! Caution
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
When filling the air conditioning system directly from
the refrigerant bottle care must be taken not to overfill
the system. As an additional control and for statistical
purposes, e.g. for refilling, it is important to write down
the weight of the filled in refrigerant.
With correct operation of the air conditioning the re-
frigerant container should be about 1/3 filled with liq-
uid refrigerant, the evaporator should be maximally
filled at the calculated evaporation temperature, i.e.
the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the
pressure gauge.
i Note
White frost on the suction line is no measure for as-
sessing the filling.
008 915 04 BOMAG 311

11.15 Filling instructions
Fig. 1 10 Filter dryer

1 High pressure - gaseous 11 Fluid container
2 High pressure - liquid 12 Condenser
3 Low pressure - gaseous 13 Manual shut-off valve (not used)
4 Compressor 14 Pressure switch with high and low pressure con-
5 Compressor pressure switch (not used) tacts
6 not used 15 Defroster thermostat
7 Evaporator 16 Vacuum meter
8 Expansion valve 17 Low pressure gauge
9 Inspection glass 18 High pressure gauge
312 BOMAG 008 915 04

Filling instructions 11.15
19 Pressure reducing valve 16 Switch off the vacuum pump, watch the pressure
20 Vacuum pump gauges to see whether the vacuum is maintained.
21 Nitrogen bottle 17 Open the valve on the refrigerant bottle and open
the black and red hand wheels on the pressure
22 Refrigerant bottle
gauge bar. Fill refrigerant into the system, until a
23 Pressure gauge bar pressure equilibrium between suction and pres-
sure side is reached (reading of pressure gaug-
Filling instructions es).
1 Connect the service adapter with the blue hand 18 Close the red hand wheel.
wheel in the suction side. 19 Perform a leak test with the electronic leak detec-
2 Connect the service adapter with the red hand tor.
wheel in the pressure side (the hand wheels on 20 Start the engine and switch on the system.
the service adapters must be fully backed out - left 21 Open the blue hand wheel and continue filling in
hand stop) refrigerant until the inspection glass is free or air
3 Connect the blue suction hose below the blue bubbles (in fluid container/dryer combinations the
hand wheel on the pressure gauge bar to the blue white pearl should float in the upper third of the in-
service adapter. spection glass). Then close the refrigerant bottle.
4 Connect the red pressure hose below the red 22 Close the blue hand wheel on the pressure gauge
hand wheel on the pressure gauge bar to the red bar.
service adapter. 23 Preparing the test run: -Close windows and doors
5 Connect the yellow hose below the yellow hand -Fan on full speed stage -Mount measuring feel-
wheel on the manometer bar to the 2-stage vacu- ers to air discharge and air intake.
um pump. 24 Run the system for approx. 20 minutes with medi-
6 Connect the last hose below the black hand wheel um engine speed.
on the nitrogen bottle via the pressure reducing 25 The temperature difference between air discharge
valve. and air intake should be (depending on type of air
7 Check on the pressure gauge bar that all hand condition) 8-10°C. The ambient temperature
wheels are closed. thereby is approx. 20°C. (These data are only ref-
8 Turn the hand wheels on both service adapter erence values, which may be influenced by possi-
clockwise. This opens the valves (right hand ble insolation)
stop). 26 Switch off system and engine and check for leaks
9 Open the valve on the nitrogen bottle (only via again.
pressure reducer); pressure approx. 20 bar. 27 Turn out (left hand stop) and remove the hand
10 Open the black and red hand wheels on the pres- wheels on both service adapters.
sure gauge bar and fill nitrogen into the system, 28 Fit all valves with dust caps.
until a pressure of approx. 3.5 to 5.0 bar is indicat- 29 Perform a leak test.
ed on the suction side.
30 Mark the system with the corresponding type
11 Then open the blue hand wheel and raise the plates and information decals, such as type of oil
pressure in the suction side (max. 10 bar). Check and refrigerant.
for leaks with a leak detection fluid or soapsuds.
12 If the system is leak tight, release the nitrogen
from the system. For this purpose disconnect the
hose from the nitrogen bottle and open the red,
blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand
wheels on the pressure gauge bar. In case of a
leak no or only an insufficient vacuum will be
reached. In this case proceed as described under
point 9-12. Once the leak is sealed continue with
point 14.
15 Once a sufficient vacuum is reached, both pres-
sure gauges show -1, close all hand wheels on the
pressure gauge bar.
008 915 04 BOMAG 313

11.16 Trouble shooting in refrigerant circuit, basic principles
11.16Trouble shooting in refriger-

ant circuit, basic principles
Basic principles
Requirements
For trouble shooting two requirements must be ful-
filled:
●
Expert knowledge
●
technical equipment
Technical equipment
The most important aids for trouble shooting are pres-
sure gauges and thermometer. The refrigerant condi-
tions, like overheating and excessive cooling provide
important Information when searching for faults. Even
your own senses are important aids for trouble shoot-
ing. Bubbles in the sight glass, dirt and white frost can
be visibly perceived. If the compressor draws in wet
steam, this can be noticed by the suction line and it
may also be audibly detectable. An overloaded com- Fig. 2 Pressure gauge
pressor can even be smelled.
Example:
The following tools and auxiliary materials should be
A totally empty air conditioning system holds an at-
available for trouble shooting:
mospheric pressure of approx. Pamp = 1 bar.
●
Service station
Filling the system with refrigerant causes an excess
● Pressure gauge pressure of Pe = 3 bar.
● Thermometer
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
●
dry nitrogen
Evacuating the system down to Pe = -0.6 bar, creates
●
Refrigerant bottle for new refrigerant
a "vacuum" (negative excess pressure).
● Container for old oil
● Vacuum pump Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
●
Hoses
●
Scales
●
Suction station
●
Leak detector
The measuring equipment must be checked at regular
intervals. Calibration can only be made by an ap-
proved testing authority.
Pressure gauge
Most pressure gauges used in practice are (for cost
reasons) excess pressure gauges. These pressure
gauges measure the excess pressure in relation to the
ambient pressure (air pressure). In order to achieve
the absolute (actual) pressure the ambient pressure
must be added to the pressure gauge reading. The
absolute pressure is needed for the calculation and
determination of material data.
Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = excess pressure (pressure gauge reading)
314 BOMAG 008 915 04

Trouble shooting in refrigerant circuit, basic principles 11.16
Pressure gauge with saturation temperature scale If the suction condition of the compressor is directly on
the dew line, an e.g. incorrect evaporator load can
cause "wet suction". This can lead to two processes,
which are destructive for the compressor. The liquid
refrigerant washes off the lubricating film between pis-
ton and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in
the cylinder causes a direct energy transfer from pis-
ton to cylinder cover during compression. The valve
plate may then be damaged by so-called fluid strokes.
Apart from protecting the compressor against fluid,
overheating has further advantages. Since the fluid
proportions in the drawn in steam reduces the flow
rate of the compressor, it may be increased by a over-
heating. Overheating also improves the oil recircula-
tion.
Common overheating values

The optimal overheating value is approx. 5 - 8 Kelvin.
With this overheating the maximum system power is
reached. However, the thermostatic expansion valve
Fig. 3 Absolute pressure gauge is unable to regulate this value exactly. Depending on
design and operating conditions overheating fluctu-
Temperature scales on the pressure gauges always
ates within a range between 4 and 12 Kelvin. The in-
refer to the absolute pressures Pabs. Please note that
fluence of the ambient air on the suction line causes
it is not possible to measure a temperature directly
an additional overheating effect.
with a pressure gauge. The indicated temperatures
are just reference values. Only the saturation temper- Overheating is calculated as follows:
ature is assigned to the measured pressure.
∆ to2h = to2h - to
If the refrigerant is fluid, the temperature is below the
saturation temperature. ∆ to2h, overheating at evaporator outlet in K
If the refrigerant is gaseous, the temperature is above to2h, temperature at evaporator outlet in °C
the saturation temperature. to, evaporation temperature in °C
Pressure gauges must indicate 0 bar when not con- „h“ represents "overheated"
nected to the system.
Low pressure gauges have a blue, high pressure Supercooling
gauges a red border.
Thermometer
It is the function of the expansion valve to reduce the
Normally digital thermometers with surface or contact refrigerant to a lower pressure level (evaporation
feelers are used. Especially for high temperature dif- pressure) after it has been liquefied. For an optimal
ferences excellent heat insulation of the measuring lo- function of the valve pure fluid must be applied to its
cation is of utmost importance. The sparing use of a inlet port.
heat conducting paste is highly recommended. If the
The refrigerant must "squeeze" (literally speaking)
measuring location is soiled, it needs to be cleaned
through a throttle gap inside the expansion valve.
and probably treated with a fine emery cloth. Only the
When comparing a certain mass of refrigerant in fluid
temperature of the feeler is measured. Due to missing
and in vaporous state (with constant pressure), the
heat insulation and insulating oxide layers on the line,
vaporous refrigerant requires a much higher volume.
temperature differences of a few degrees Kelvin be-
That's why the vaporous refrigerant needs a much
tween the measured and the actual values may arise.
longer time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve
Overheating
reduces the flow rate and results in an undersupply of
the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.
Due to its design a refrigerant compressor can only
deliver gaseous or vaporous substances. Fluids are If the refrigeration system is operated with the "expan-
not compressible and must therefore not enter into the sion valve inlet" condition directly on the boiling curve,
compression chamber of the compressor. slightest fluctuations in operating condition may cause
008 915 04 BOMAG 315

11.16 Trouble shooting in refrigerant circuit, basic principles
a formation of bubbles in front of the expansion ele-

ment.
For this reason one shifts the condition "Expansion
Valve Inlet" away from the boiling curve into the fluid
area and refers to this condition as Supercooling. This
supercooling ensures a fluid supply in front of the ex-
pansion valve.
Common supercooling values

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

∆ tc2u = tc - tc2u
∆ tc2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in °C
tc, evaporation temperature in °C
„u“ represents "supercooled"
316 BOMAG 008 915 04

Trouble shooting in refrigerant circuit, basic principles 11.16
Fig. 1 Refrigerant circuit with t, h- diagram

1 Hot gas line (overheated steam)
2 Deheating (overheated steam)
3 Condenser / liquefier
4 Condensation (wet steam)
5 Fluid line (supercooled fluid)
6 Expansion valve
7 Injection line (wet steam)
8 Evaporation (wet steam)
9 Evaporator
10 Overheating (overheated steam)
11 Suction steam line (overheated steam)
12 Compressor
13 Supercooling (fluid)
14 Compression
15 Expansion
008 915 04 BOMAG 317

11.17 Trouble shooting, refrigerant circuit diagram
11.17Trouble shooting, refrigerant

circuit diagram
Fig. 1 Refrigerant circuit diagram 13 Compressor

1 Cold air 14 Condenser
2 Evaporator 15 Cooling air
3 Thermostat 16 Pressure gauge, low pressure
4 Warm air
5 Fan
6 Inspection glass
7 Expansion valve
8 Pressure gauge, high pressure
9 Pressure switch with high and low pressure con-
tacts
10 Dryer
11 Fluid container
12 Hot air
318 BOMAG 008 915 04

Trouble shooting procedure 11.18
11.18Trouble shooting procedure ●
Evaporator and heating (with highest fresh air fan
speed) do not draw leak air.
●
The fresh air fan runs when the engine is running
Procedure
and the air conditioning system is set to max. cool-
Knowledge ing power.
Trouble shooting is not possible with exact knowledge
●
Ambient temperature above 15 °C.
about the system design, the installed components ●
The thermostat is correctly installed and the switch-
and their function in the system trouble shooting is not ing temperatures are correct.
possible:
Visual inspection
With the appropriate experience some faults can be
visually detected or felt. Frequently occurring con-
denser soiling or formation of steam bubbles in the in-
spection glass can be quickly detected.
In case of unusual formation of hoarfrost on the evap-
orator the hoarfrost pattern provides useful informa-
tion. Hoarfrost only occurring at the inlet side is a clear
indication of insufficient refrigerant feed, which in turn
indicates an incorrectly working expansion valve or a
lack of refrigerant.. Complete hoarfrost covering indi-
cates load problems, i.e. no or insufficient air flow.
Even overheating can sometimes be detected with the
naked eye. At the end of the evaporator there should
be an area which is dry or at least drier at evaporator
temperatures above -2 °C.
The fluid line in the refrigeration system is warm. If a
local cooling can be felt or if condensation develops,
this is a clear indicator for an extreme pressure drop
in the line. Similar phenomena can be noticed in case
of blocked filters.
Unusually cold pressure lines indicate "wet" intake of
the compressor.
The oil level in the compressor sight glass provides in-
formation about the oil quantity and the oil recircula-
tion in the system. However, the oil level may also be
considerably influenced by condensing refrigerant.
Discoloration informs about the state of the oil.
Water in the system can simply be detected through
the inspection glass with moisture indicator.
i Note
The dangerous part of common rules is that they ap-
ply in most, but not in all cases. The refrigerant states
in the individual piping sections or components must
therefore be exactly determined by means of pressure
and temperature measurements.
Test prerequisites
● Cooler and condenser are clean, clean if neces-
sary.
●
The ribbed belt for compressor and generator is
correctly tightened.
●
All air ducts, covers and seals are OK and correctly
fitted. Flaps reach their end positions.
●
The engine has operating temperature.
008 915 04 BOMAG 319

11.18 Trouble shooting procedure
Measuring points and measurements
Fig. 2 Flow diagram with measuring points to assess the filling quantity. In systems with fluid con-
●
C, condenser measuring points tainer the inspection glass is most suitable to check
●
E, expansion valve measuring points the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
●
O, evaporator measuring points
The hot gas temperature can be used to check wheth-
●
V, compressor measuring points
er the compressor runs in the permissible operating
The flow diagram contains "Minimum Requirements" range.
which must be fulfilled to be able to check the system
or perform trouble shooting. Example: Measurement of overheating
Temperature and pressure at the evaporator outlet
● a) Which measuring equipment is required?
can be used to derive the overheating of the evapora- ● b) Where to measure with which size?
tor. Overheating is a clear indicator for the evaporator ●
c) A pressure gauge connected to the evaporator
filling level. In case of excessive overheating the re- indicates "Peo2 = 1.7 bar". How high is the evapora-
frigerant quantity fed into the evaporator is too low, in tor pressure "Po" ?
case of insufficient overheating it is too high. In indi-
vidual cases one must then check if this situation is ●
d) How high is the evaporator temperature "to" ?
caused by the expansion element or by insufficient fill- ●
e) A thermal sensor attached to the evaporator out-
ing. A differentiation is only possible if there is a clear let measures the temperature "to2h = +3 °C". How
indicator for the refrigerant filling quantity. high is the overheating „∆to2h“ ?
Pressure and temperature at the condenser outlet can ●
f) Evaluation of the measured overheating.
be used to derive the supercooling. This can be used
320 BOMAG 008 915 04

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

Most faults in the refrigerant side of the system can be
clearly assigned with the help a checklist. r Occur-
ring faults frequently have a similar appearance, but
different causes. An evaporator showing hoarfrost
may be quite normal. However, there may also
008 915 04 BOMAG 321

Values effecting the operating pressures tions, it is mandatory to know these dependencies.
Since the pressures occurring in a refrigeration sys- The following table contains some of these dependen-
tem are highly dependent on environmental condi- cies.
Measuring value Suction pressure High pressure
increases drops increases drops
Compressor speed increases X X
drops X X
Vehicle interior tempera- increases X X
ture drops X X
Ambient temperature increases X X
drops X X
Humidity increases X X
drops X X
322 BOMAG 008 915 04

Suction pressure too low (1), high pressure too
low to normal (2)
Fig. 3
Cause Possible effect Remedy

Lack of refrigerant no supercooling, bubbles in inspec- Check for leaks, refill
tion glass, high overheating, hoar-
frost on evaporator
Evaporator fins or air filter soiled Cooling power too low clean
Evaporator fan failed Low pressure shut off Repair the fan
Expansion valve defective Suction pressure gauge shows vac- Replace the valve
uum, because the valve has closed
Screen or nozzle in expansion valve high overheating clean
clogged
Filter dryer clogged Bubbles in inspection glass, high Change filter dryer
overheating, filter dryer cold
Heat power too low Frequent low pressure shut off, Check the control
thawing thermostat / rotary thermo-
stat switching too frequently
008 915 04 BOMAG 323

Suction pressure normal (1), high pressure too

high (2)
Fig. 4

Condenser dirty high hot gas temperature, low cool- clean
ing power
Condenser fan failed high hot gas temperature, high pres- repair
sure shut down
overfilled high hot gas temperature, low su- Correct the filling capacity
percooling, low cooling power
Leak gas (air) high hot gas temperature, low renew filling
measured supercooling, low cooling
power
Restriction between compressor and high hot gas temperature, low cool- Check lines and valves
condenser ing power
324 BOMAG 008 915 04

Suction pressure too high (1), high pressure too
low to normal (2)
Fig. 5

Compressor defective Cooling power too low Replace the compressor
008 915 04 BOMAG 325

Suction pressure too high (1), high pressure too

high (2)
Fig. 6

Expansion valve defective overheating too low, wet operation Replace the valve
of compressor
326 BOMAG 008 915 04

Other faults
Symptom Cause Possible effect Remedy

Hot gas temperature too Lack of refrigeration oil increased compressor Refill refrigeration oil
high, the hot gas line be- wear
comes so hot that it cannot
be touched long with a
hand
Compressor does not start Pressure switch or any oth- System stopped Check the control units,
er safety feature has trig- check cause for switching
gered, electrical fault, and rectify
cylinder filled with liquid re-
frigerant
Compressor switches con- Switching difference too Cycling of compressor, in- Check the control units,
tinuously small, triggering of a creased wear, too low cool- check cause for switching
switching element (over- ing power and rectify
pressure switch, low pres-
sure switch), lack of
refrigerant, fan defective,
overfilled
Excessive overheating Expansion valve deadjust- low cooling power, hot gas Replace the expansion
ed or screen blocked, lack temperatures too high valve, clean the screen, fill
of refrigerant in refrigerant, leak test
Hoarfrost on inlet side of incorrectly working expan- too low infeed of refrigerant Check the expansion
evaporator sion valve, lack of refriger- into the evaporator valve, check the refrigerant
ant filling
Evaporator fully covered Load problem, too low air low cooling power of sys- Clean the evaporator,
with hoarfrost flow volume tem check the evaporator fan
Fluid line is warm and Pressure drop in fluid line, low cooling power Eliminate the pressure
shows condensation filter dryer clogged drop, replace the filter dryer
Exceptionally cold pres- "Wet intake" of the com- low cooling power, exces- Clean the compressor, re-
sure lines pressor due to insufficient sive wear of compressor place if necessary, replace
overheating of evaporator the expansion valve if nec-
essary
Noise in system
Faults Possible cause Remedy
V-belt loose or excessively worn V-belt slips and generates noise Retention or renew the V-belt
Magnetic clutch loud Magnetic clutch runs until high pres- Repair or replace the magnetic
sure builds up, then the clutch starts clutch
to slip
Refrigerant compressor is loud Mounting bracket is loose, internal Repair the mounting bracket, re-
parts worn, low oil level in compres- place the compressor, renew the re-
sor frigeration oil
Fan is loud, fan motor excessively Replace the fan motor
worn
Whistling and rattling noise in opera- V-belt pulley and bearing worn Replace the bearing, check V-belt
tion, noticeable unevenness when pulley for wear
turning by hand
Rattling noise or vibration of high System overfilled Draw out refrigerant
pressure line, knocking noise in
compressor, ball in inspection glass
floating at the top
Expansion valve loud excessive moisture in system Replace the dryer
Hissing noise in evaporator housing, refrigerant level in system too low Perform a leak test, fill up the system
on expansion valve, turbidity in in-
spection glass or ball does not float
008 915 04 BOMAG 327

Inspection glass
Steam bubbles in inspection glass No supercooling before expansion Fill up the system, replace the filter
valve, lack of refrigerant in system, dryer, perform a leak test
pressure loss in system, supercool-
ing caused by excessively soiled fil-
ter dryer
Discolouration of inspection glass Lubricant destroyed by excessive Replace the refrigeration oil, exam-
(black from inside) operating temperatures ine the temperature increase
Moisture indicator changes to pink Moisture level of drying agent too Replace the filter dryer
high
Ball floats at bottom lack of refrigerant Fill the system
Monitoring devices
The high pressure contact has System pressure exceeded, con- Clean the condenser, replace the
switched off the magnetic clutch denser excessively soiled, condens- expansion valve, check the con-
er fan defective, expansion valve denser fan
defective
The low pressure contact has System pressure fallen short of, re- Clean the evaporator, replace the
switched off the magnetic clutch frigerant level too low, expansion expansion valve, check the evapora-
valve defective, evaporator fan de- tor fan
fective, heat load too low, ambient
temperature below 1.5 °C
The thermostat has switched off the Ambient temperature below 1°C, Check the thermostat switching
magnetic clutch expansion valve defective, thermo- point, replace the expansion valve,
stat defective, air flow volume too clean the evaporator, check the
low evaporator fan
328 BOMAG 008 915 04

Steam table for R134a 11.19
Tempera- Pres- Density spec. volume spec. enthalpy Evapora-

ture sure tion heat
of the fluid of the of the fluid of the of the fluid of the
steam steam steam
008 915 04 BOMAG 329

11.19 Steam table for R134a
330 BOMAG 008 915 04

008 915 04 BOMAG 331

332 BOMAG 008 915 04

008 915 04 BOMAG 333

334 BOMAG 008 915 04

12 Replacing the cab window panes
008 915 04 BOMAG 335

12.1 Assembly of window panes
Fig. 1
1 Glass panes
2 Fastening element
3 Fixing washer and spacer
4 Washer
5 Hexagon nut, self locking
6 Protective cap
336 BOMAG 008 915 04

Special tools 12.2
12.2 Special tools
1. Locking handle for fastening element
Fig. 1
2. Suction lifter
commercial
Fig. 2
008 915 04 BOMAG 337

12.3 Auxiliary materials
12.3 Auxiliary materials

Safety gloves
3. Cutter
Commercial
Fig. 1
4. Window glass bonding agent
Fig. 2
5. Activator
Fig. 3
338 BOMAG 008 915 04

Auxiliary materials 12.3
6. Silicone sealant
Fig. 4
008 915 04 BOMAG 339

12.4 Removing and installing the window pane
12.4 Removing and installing the window

pane
Environment
Environmental damage
Dispose of glass splinters fro0m machine and
cabin or inside cabin in an environmentally
friendly way.
! Danger
Danger of cutting
Wear safety gloves.
1. Pull large glass rests off the bonding strip (Fig. 1).
Fig. 1
2. Clean the sealing surfaces from any adhesive
material (Fig. 2).
3. Use a cutter to remove adhesive residues with
glass rests.
4. Cover places without adhesive residues with an
activator.
Fig. 2
5. Insert the fastening element with washer into the
bore in the glass pane (Fig. 3).
Fig. 3
340 BOMAG 008 915 04

Removing and installing the window pane 12.4
6. Turn the fixing and spacer washer hand-tight onto
the thread of the fastening element (Fig. 4).
i Note
Do not overtighten the thread.
Fig. 4
7. Lay an approx. 1 cm high triangular bead of glass
pane bonding agent on the inside of the pane, ap-
prox. 1.5 cm away from the edge (Fig. 5).
i Note
Apply window pane bonding agent only to the
sides (sealing areas) which have contact with the
cabin.
Fig. 5
8. Attach the suction lifter to the outside of the pane
(Fig. 6).
9. Install the window pane so that the fastening ele-
ments fit into the bores of the fastening bars.
10. Press the glass pane against the sealing surface.
Fig. 6
11. Assemble the washer and the self-locking hexa-
gon nut.
12. Fasten the window pane to the fastening bar us-
ing a locking handle and a ring spanner (Fig. 7).
i Note
Only use the locking handle to counter.
13. Press the protective cap onto the hexagon nut.
Fig. 7
008 915 04 BOMAG 341

14. Remove the suction lifter (Fig. 8).
Fig. 8
15. Clean the joining edges on the window pane (Fig.
9).
i Note
The joint flanks must be solid, dry and free of dirt,
dust, grease, oil and other foreign substances.
16. Mask the upper and lower contact areas to the
cabin.
Fig. 9
17. Apply silicone sealant evenly and under pressure
first to the inside joint edge (Fig. 10).
Fig. 10
18. Then apply silicone sealant evenly and under
pressure to the outside joint edge (Fig. 11).
Fig. 11
342 BOMAG 008 915 04

Removing and installing the window pane 12.4
19. Then spray the joints from inside and outside with
water containing washing up liquid (Fig. 12).
Fig. 12
20. Treat the inside joint (Fig. 13)
Fig. 13
21. and the outside joint (Fig. 14) with a scraper or a
spattle.
i Note
Once the silicone sealing agent has cured it can
only be removed mechanically.
Fig. 14
008 915 04 BOMAG 343

344 BOMAG 008 915 04

13 Suppliers documentation
008 915 04 BOMAG 345

346 BOMAG 008 915 04
13.1 Travel pump
008 915 04 BOMAG 347

13.1 Travel pump
348 BOMAG 008 915 04

Travel pump
Electric Drives Linear Motion and
13.1
and Controls Hydraulics Assembly Technologies Pneumatics Service
Verstellpumpe A4VG 71–180 RDE 92 003-21-R/01.06
Variable Pump A4VG 71–180

Baureihe/Series 32
Reparaturanleitung / Repair Manual

Baugruppen / Assembly Groups
008 915 04 BOMAG 349

2/40
13.1
Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump
Vermeidung von Gefahren Avoiding Dangers

Für einen sicheren Betrieb und um Schäden bei der Reparatur To ensure safe operations and avoid damages during repairs,
zu vermeiden, lesen Sie diese Reparaturanleitung sorgfältig read this complete repair manual carefully and attentively.
und aufmerksam durch!
Für Personen- oder Maschinenschäden, die durch Nichtbe- Bosch Rexroth AG accepts no responsibility for personal
achtung dieser Reparaturanleitung entstehen, verfällt jegliche injuries or damages to the machine that arise from disregarding
Gewährleistung von Bosch Rexroth AG. this repair manual.
1 Zu dieser Anleitung 1 About this Manual

Diese Anleitung unterstützt Sie bei der Reparatur, den Über- This manual supports you in the repair, adjustment and recom-
prüfungen und der Wiederinbetriebnahme von Rexroth A4VG missioning of Rexroth A4VG variable pumps, sizes 71–180.
Verstellpumpen, NG 71–180. Diese Anleitung umfasst die The manual is structured as follows:
folgenden Kapitel:
! „Sicherheit“ auf Seite 7 !" “Safety” on page 7
Hier erhalten Sie grundsätzliche Hinweise zum sicheren This chapter provides you with basic hints and tips regarding
Umgang mit Verstellpumpen und zu deren Betrieb. working with and operating variable pumps.
Lesen Sie dieses Kapitel bevor Sie anfangen zu arbeiten. Read this chapter before you start working.
!" „Produktbeschreibung“ auf Seite 11 !" “Product Description” on page 11
Hier erfahren Sie, wie Sie den Typ einer Verstellpumpe This chapter explains how you identify the variable pump.
feststellen. Ferner finden Sie hier eine Übersicht über die Addtionally, it provides you an overview of the how the vari-
Funktionsweise und Informationen zur bestimmungsgemäßen able pump and information regarding the correct usage.
Verwendung der Verstellpumpe. Read this chapter to refresh your knowledge of the variable
Lesen Sie dieses Kapitel, um Ihr Grundwissen über die pumps.
Verstellpumpe aufzufrischen.
!" „Austausch externer Baugruppen“ auf Seite 15 !" “Exchanging Extermnal Assembly Groups” on page 15
Dieses Kapitel erklärt Ihnen, wie Sie Baugruppen einer Ver- Rexroth provides various replacement parts for repairs. This
stellpumpe austauschen. section provides you an overview of the available spare parts
subassemblies.
!" „Überprüfungen“ auf Seite 33 !" “Checking” on page 33
Dieses Kapitel erklärt Ihnen, wie Sie die Einstellarbeiten an Read this chapter to be able to restore the settings on an
einer Verstellpumpe vornehmen. variable pump after a repair.
350 BOMAG 008 915 04

RDE 92 003-21-R/01.06
Travel pump Reparaturanleitung/Repair Manual A4VG 71–180
13.13/40
Bosch Rexroth AG
1.1 Inhaltsverzeichnis 1.1 Contents
1. Zu dieser Anleitung 2 1. About this Manual 2

1.1 Inhaltsverzeichnis 3 1.1 Contents 3
1.2 Gültigkeitsbereich dieser Anleitung 4 1.2 Validity of this Manual 4
1.3 Wichtige Unterlagen 5 1.3 Important Documents 5
1.4 Gefahrenkennzeichnungen und Pictogramme 6 1.4 Danger Labels and Pictograms 6
2. Sicherheit 7 2. Safety 7
2.1 Grundlegende Sicherheitshinweise 7 2.1 Basic Safety Information 7
2.2 Anforderungen an das Personal 10 2.2 Requirements on the Personnel 10
3. Produktbeschreibung 11 3. Product Description 11
3.1 Typschild 11 3.1 Name Plate 11
3.2 Funktionsbeschreibung 11 3.2 Functional Description 11
3.3 Technische Daten 14 3.3 Technical Data 14
4. Austausch externer Baugruppen 15 4. Exchanging External Assembly Groups 15
4.1 Wellendichtring austauschen 16 4.1 Exchanging the Shaft Seal 16
4.2 Dichtungen austauschen 18 4.2 Exchanging Seals 18
4.3 Hilfspumpe austauschen 24 4.3 Exchanging the Backing Pump 24
4.4 Steuergerät austauschen 26 4.4 Exchanging the Control Unit 26
5. Überprüfungen 33 5. Checking 33
5.1 Niederdruck (Speisedruck) überprüfen 34 5.1 Checking Low Pressure (Charge Pressure) 34
5.2 Hochdruck überprüfen 34 5.2 Checking High Pressure 34
5.3 Mechanische Nulllage überprüfen 35 5.3 Checking the Mechanical Zero Stroke 35
5.4 Hydraulische Nulllage überprüfen 36 5.4 Checking the Hydraulic Zero Stroke 36
008 915 04 BOMAG 351

4/40
13.1
Travel pump
1.2 Gültigkeitsbereich dieser 1.2 Validity of this Manual

Anleitung
Diese Reparaturanleitung gilt für die Axialkolben-Verstellpumpe This manual is valid for the Bosch Rexroth axial piston variable
A4VG NG 71–180 der Bosch Rexroth AG. Informationen zu pump A4VG NG 71–180. Refer to the system manufacturer for
zugelassenen Druckflüssigkeiten entnehmen Sie den Angaben information about the allowed hydraulic fluids.
des Anlagenherstellers.
Diese Reparaturanleitung richtet sich an: This repair manual is directed at:
!" Anlagenbetreiber, ! the system operator
!" den autorisierten Fachbetrieb bzw. Händler, ! authorized dealers
!" den Anlagenhersteller. ! the system manufacturer
Für den Anlagenhersteller sind zusätzlich auch die jeweilige For the system manufacturer, the installation drawing, the
Einbauzeichnung, das technische Datenblatt, die Betriebsan- catalog sheet, the manual, and the confirmation of order from
leitung und die Auftragsbestätigung der Bosch Rexroth AG the Bosch Rexroth AG are also obligatory.
verbindlich.
352 BOMAG 008 915 04

RDE 92 003-21-R/01.06
Travel pump Reparaturanleitung/Repair Manual A4VG 71–180 Bosch Rexroth AG
13.15/40
1.3 Wichtige Unterlagen 1.3 Important Documents

Bevor Sie mit den in dieser Anleitung beschriebenen Arbeiten Before you start any of the procedures described in this manu-
anfangen, stellen Sie sicher, dass Sie folgende Unterlagen al, make sure you have the following documents:
griffbereit haben:
!" Auftragsbestätigung !" Confirmation of order
Die Auftragsbestätigung enthält die voreingestellten techni- The confirmation of order contains the values set during the
schen Daten. Die Axialkolbenmaschine darf nur unter den in commissioning by Rexroth. Before you can recommission the
der Auftragsbestätigung angegebenen Werten und Bedin- axial piston unit after a repair, you have to restore the values
gungen betrieben werden. originally set by Rexroth.
!" Einbauzeichnung !" Installation drawing
Die Einbauzeichnung der Axialkolbenmaschine enthält die The installation drawing of the axial piston unit contains the
Außenabmessungen, sämtliche Anschlüsse und den Schalt- sizes of all connections.
plan.
!" Technisches Datenblatt !" Technical data sheet
Das technische Datenblatt RD 92 003 enthält u.a. die zuläs- The technical data sheet RE 92 003 contains the maximum
sigen technischen Daten für die Axialkolbenmaschine. allowed performance data.
!" Gesamtschaltplan der Maschine bzw. Anlage !" Hydraulic diagram"#"Wiring diagram
Der Hydraulikschaltplan und der elektrische Schaltplan der The hydraulic diagram and the wiring diagram of the unit
Maschine bzw. Anlage enthalten die Informationen zu den or system contain the information related to the respective
hydraulischen bzw. elektrischen Anschlüssen. Diese Daten machine.You need this data to work with the axial piston as
brauchen Sie, um mit der Axialkolbenmaschine als Teil der part of the machine or system. You can get this information
Maschine bzw. Anlage zu arbeiten. Die Unterlagen erhalten from the unit or system manufacturer.
Sie vom Maschinen- bzw. Anlagenhersteller.
!" RD 90 300-B: Allgemeine Betriebsanleitung für Axialkol- !" RE 90 300-B: General Manual for Axial Piston Units
benmaschinen The general manual supports you during the installation,
Die allgemeine Betriebsanleitung unterstützt Sie bei Installa- initiation, and operation of Rexroth axial piston units.
tion, Inbetriebnahme und Betrieb von Rexroth-Axialkolbenma-
schinen.
!" Produktspezifische Betriebsanleitung !" Product Specific Manual
Die produktspezifische Betriebsanleitung enthält spezielle, The product-specific manual contains information specially
für die Axialkolbenmaschine gültige Informationen. Informie- designed for the axial piston unit. Get in touch with Rexroth
ren Sie sich bei Rexroth, ob es zu Ihrer Axialkolbenmaschine to find out if there is any product-specific information on your
eine produktspezifische Betriebsanleitung gibt. specific axial piston unit.
Folgende Rexroth-Druckschriften geben Ihnen weitere Informa- The following Rexroth publications provide additional informati-
tionen zu Installation und Betrieb der Axialkolbenmaschine: on to the installation and operation of axial piston units:
! RD 90 220: Druckflüssigkeiten auf Mineralölbasis !" RE 90 220: Mineral-oil Based Pressure Fluids
Beschreibt die Anforderungen an eine Druckflüssigkeit auf This publication describes the requirements on a hydraulic
Mineralölbasis für den Betrieb mit Rexroth-Axialkolbenma- fluid for operation in an axial piston unit and supports you in
schinen und unterstützt Sie bei der Wahl einer Druckflüssig- the selection of a hydraulic fluid for your installation.
keit für Ihre Anlage.
! RD 90 221: Umweltfreundliche Druckflüssigkeiten HEES, !" RE 90 221: Environmentally Acceptable Hydraulic Fluids
HEPG, HETG für Axialkolbenmaschinen HEES, HEPG, HETG for Axial Piston Units
Beschreibt die Anforderungen an eine umweltfreundliche Describes the demands on environmentally compatible, rea-
Druckflüssigkeit für den Betrieb mit Rexroth-Axialkolbenma- dily biodegradeable hydraulic fluids HEPG, HEES that can
schinen und unterstützt Sie bei der Wahl einer Druckflüssig- be used in Rexroth axial piston units and supports you by the
keit für Ihre Anlage. choice of a hydraulic fluid for your system.
! RD 90 223: Axialkolbenmaschinen für den Betrieb mit !" RE 90 223: Axial Piston Units for Use with HF Fluids
HF-Druckflüssigkeiten Provides additional information for the use of Rexroth axial
Enthält zusätzliche Informationen zum Einsatz von Rexroth- piston units with HF hydraulic fluids.
Axialkolbenmaschinen mit HF-Druckflüssigkeiten.
! RD 90 300-03-B: Hinweise zum Einsatz von hydrauli- !" RE 90 300-03-B: Instructions on the Use of Hydrostatic
schen Antrieben bei tiefen Temperaturen Drives at Low Temperatures
Enthält zusätzliche Informationen zum Einsatz von Rexroth- Provides additional information for the use of Rexroth axial
Axialkolbenmaschinen bei tiefen Temperaturen. piston units for low temperatures.
008 915 04 BOMAG 353

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13.1
Travel pump
1.4 Gefahrenkennzeichnungen 1.4 Danger Labels and Pictograms

und Piktogramme
Diese Anleitung unterscheidet zwischen Kategorien von Gefah- This manual differentiates between the following categories of
ren gemäß ISO Guide 37: danger according to ISO Guide 37:
! GEFAHR ! DANGER
Weist auf hohes Risiko und die Gefahr von Tod oder schwe- Indicates high risk, mortal danger and serious injuries.
ren Verletzungen hin.
! WARNUNG ! WARNING
Weist auf mittleres Risiko und die Gefahr von Verletzungen Indicates middle risk, injuries or serious material damage.
und schweren Sachschäden hin.
! VORSICHT ! CAUTION
Weist auf geringes Risiko und Sachschäden hin. Indicates low risk or material damage.
Hinweis Note
Kennzeichnet Informationen, die zum besseren Verständnis Indicates information that contributes to a better understan-
der Maschinenabläufe beitragen oder weist auf einen beson- ding of the machine processes or indicates important informa-
deren bzw. wichtigen Sachverhalt hin. tion.
Tipp Tip
Kennzeichnet Informationen, die zum effizienteren Arbeiten Indicates information that contributes to more efficient work.
beitragen.
354 BOMAG 008 915 04

RDE 92 003-21-R/01.06
13.17/40
2 Sicherheit 2 Safety
Lesen Sie dieses Kapitel sorgfältig durch, bevor Sie mit Arbei- Read through this chapter carefully before you start any work
ten an der Verstellpumpe beginnen. on the variable pump.
Die Rexroth-Verstellpumpen sind im Sinne der Maschinenricht- The Rexroth variable pump are in the sense of the machine gui-
linie 98/37/EG Komponenten, die zum Einbau in eine Anlage deline 98/37/EG components of a larger machine or system.
bestimmt sind. Die Sicherheitsrichtlinien in dieser Anleitung be- The safety guidelines in this manual only cover the variable
ziehen sich nur auf die Verstellpumpe. Beachten Sie zusätzlich pump. You must additionally follow the system manufacturer’s
die Sicherheitsrichtlinien des Anlagenherstellers. safety guidelines.
Informieren Sie sich an Hand der allgemeinen Betriebsanlei- Read the general manual for axial piston units to get more infor-
tung für Axialkolbenmaschinen über die bestimmungsgemäße mation on the designated use and the operator‘s obligation to
Verwendung und die Sorgfaltspflicht des Betreibers und exercise dilligence.
Bedieners.
2.1 Grundlegende 2.1 Basic Safety Information

Sicherheitshinweise
Befolgen Sie die folgenden Sicherheitshinweise und die des Pay exact attention to the following safety information and that
Anlagenherstellers genau, um Verletzungen und Gesundheits- of the system manufacturer to eliminate injuries and health
schäden sowie Sach- und Umweltschäden auszuschließen. damages as well as damages to material or the environment.
! GEFAHR ! DANGER
Lebensgefahr Danger to Life

Das Arbeiten an nicht stillgelegten Maschinen bzw. Anlagen Working on systems that have not been shut down is life-thre-
stellt eine Gefahr für Leib und Leben dar. atening.
Die in diesem Dokument beschriebenen Arbeiten dürfen nur The work described in this document can only be carried out
an stillgelegten Maschinen bzw. Anlagen vorgenommen on a shut down system. Before you start any of the tasks:
werden. Bevor Sie mit den Arbeiten beginnen:
!" Stellen Sie sicher, dass der Antriebsmotor nicht eingeschal- !" Make sure that the engine / motor cannot be switched on.
tet werden kann.
!" Stellen Sie sicher, dass sämtliche kraftübertragenden Kom- !" Make sure that all components and connections that carry
ponenten und Anschlüsse (elektrisch, pneumatisch, hydrau- energy (electrical, pneumatic, hydraulic) have been shut
lisch) gemäß den Herstellerangaben ausgeschaltet sind und down according to the manufacturer’s instructions and
nicht eingeschaltet werden können. Falls möglich, entfernen cannot be switched on. If possible, disable the main fuse.
Sie die Hauptsicherung der Maschine bzw. Anlage.
!" Stellen Sie sicher, dass die Maschine bzw. Anlage komplett !" Make sure that the system is completely unloaded. Follow
hydraulisch entlastet ist (drucklos). Folgen Sie hierzu den the instructions of the the system manufacturer.
Angaben des Maschinen- bzw. Anlagenherstellers.
! WARNUNG ! WARNING
Verletzungsgefahr Danger of injuries

Um Verletzungen zu vermeiden, beachten Sie bitte folgende To avoid injuries, pay attention to the following regarding
Empfehlungen betreffend Sicherheitskleidung: safety clothing.
!" Tragen Sie bei Arbeiten an Maschine bzw. Anlage Sicher- !" When working on the system, wear steel-toed safety shoes.
heitsschuhe mit Stahlkappen.
!" Tragen Sie bei Arbeiten mit gefährlichen Stoffen (beispiels- !" When working with dangerous substances (for example,
weise Druckflüssigkeiten) Schutzhandschuhe und Schutz- certain hydraulic fluids), wear protective gloves and protec-
brille. tive glasses.
008 915 04 BOMAG 355

13.1
8/40 Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump
! GEFAHR ! DANGER
Vergiftungs- und Verletzungsgefahr Danger of poisoing or injuries

Der Kontakt mit Drückflüssigkeiten ruft Gesundheitsschäden Contact with hydraulic fluids can cause health damage (eye
hervor (z.B. Augenverletzungen, Haut- und Gewebeschädi- injuries, skin damage, poisoning due to inhalation).
gungen, Vergiftungen beim Einatmen).
! Überprüfen Sie vor jeder Inbetriebnahme die Leitungen auf ! Always check the hydraulic lines for wear and damage prior
Verschleiß bzw. Beschädigungen. to putting the unit into operation.
! Tragen Sie dabei Schutzhandschuhe und Schutzbrille. ! Always wear protective gloves and safety glasses.
! Wenn dennoch Druckflüssigkeit in die Augen gelangt oder ! Should pressure fluid come into contact with your eyes or
in die Haut eindringt, konsultieren Sie unmittelbar einen skin: Get medical help immediately!
Arzt.
! Beachten Sie beim Umgang mit Druckflüssigkeiten unbe- ! When handling hydraulic fluids, pay exact attention to the
dingt die Sicherheitsangaben des Druckflüssigkeitsherstel- manaufacturer’s safety instructions.
lers.
! WARNUNG ! WARNING
Verbrennungsgefahr Danger of burns

Die Axialkolbenmaschine erwärmt sich während des Betriebs. The variable pump heats up during operation. The unit’s sole-
Auch die Magnete an der Axialkolbenmaschine werden im noids get hot during operation. Touching the variable pump or
laufenden Betrieb heiß. Bei Berührung der Axialkolbenma- solenoids can lead to severe injuries.
schine oder der Magnete können schwere Brandverletzungen
entstehen.
! Lassen Sie die Axialkolbenmaschine vor jedem Kontakt ! Let the variable pump cool down prior to any contact.
abkühlen.
! Schützen Sie sich mit hitzebeständigen Handschuhen und ! Protect yourself from burns by wearing safety gloves and
Schutzkleidung. protective clothing.
! GEFAHR ! DANGER
Vergiftungs- und Verletzungsgefahr Danger of poisoning

Beim Suchen nach Leckstellen kann entweichende Druckflüs- When looking for leaks, escaping hydraulic fluid can break
sigkeit in die Haut eindringen und schwerste Vergiftungen und into the skin and cause serious poisoning.
Verletzungen hervorrufen.
! Suchen Sie nur bei abgestellter und druckloser Maschine ! Always use a piece of cardboard or paper to look for leaks.
nach Leckstellen.
! WARNUNG ! WARNING
Verletzungs- und Beschädigungsgefahr Danger of injuries or damage

Durch falsch angeschlossene Komponenten können erhebli- Incorrectly connected components can considerably impair
che Fehlfunktionen entstehen. the functionality of a hydraulic system.
! Achten Sie auf korrekte Verrohrung gemäß Schaltplan. ! Make sure that the hydraulic lines are connected properly.
! Führen Sie komponentenorientierte Funktionstests durch. ! Check the correct functioning of all components.
356 BOMAG 008 915 04

RDE 92 003-21-R/01.06
13.19/40
Bosch Rexroth AG
! GEFAHR ! DANGER
Feuergefahr Danger of fire

Hydraulische Druckflüssigkeit ist brennbar. Hydraulic fluid is inflammable.
! Halten Sie offenes Feuer von der Verstellpumpe fern. ! Keep open fires away from the variable pump.
! WARNUNG ! WARNING
Gehörschäden Danger of hearing loss

Die Geräuschemission von Axialkolbenmaschinen ist u.a. von The noise emission produced by axial piston units depends
Drehzahl, Betriebsdruck und Einbauverhältnissen abhängig. on speed, operating pressure, and installation. During normal
Es ist damit zu rechnen, dass der Schalldruckpegel bei nor- application conditions, over 70 dBA can be anticipated. This
malen Einsatzbedingungen über 70 dBA steigt. Dies kann zu can lead to hearing damage.
Gehörschäden führen.
! Schützen Sie sich stets mit Gehörschutz bei Arbeiten in ! Always wear hearing protection when working in the vicinity
der Nähe der Axialkolbenmaschine während des laufenden of the variable pump during operation.
Betriebs.
! WARNUNG ! WARNING
Umweltschäden Risk of damage to the environment

Druckflüssigkeiten sind wassergefährdende Flüssigkeiten. Hydraulic fluid leakage leads to contamination of the ground
Das Austreten von Druckflüssigkeiten kann zu Grundwasser- and ground water.
vergiftung und Bodenverseuchung führen.
! Bringen Sie unter der Axialkolbenmaschine eine Auffang- ! A basin for catching any hydraulic fluid must be placed
wanne an. under the variable pump.
! Beseitigen Sie Leckstellen unverzüglich. ! Leaks must be cleaned up immediately.
! Es sind stets die nationalen Gesetze und Vorschriften zu ! In Europe, hydraulic systems are considered “Systems
beachten. In Deutschland sind hydraulische Maschinen bzw. using water-threatening substances” in the sense of the
Anlagen „Anlagen zum Umgang mit wassergefährdenden Water Management Law (WHG).Therefore, pay special
Stoffen im Sinne des Wasserhaushaltsgesetzes (WHG)“. attention to §1 and §19 WHG( §19g, 19i, 19l). Additionally
Beachten Sie in diesem Zusammenhang besonders §1 und pay attention to any national regulations and norms.
§19 WHG (§19g, 19i, 19l).
! Weitere Informationen zum richtigen Umgang mit Rexroth- ! For further information regarding the correct use of Bosch
Hydraulikprodukten finden Sie in unseren Druckschriften Rexroth hydraulic products, see the publications RE 90 220
„Allgemeine Produktinformationen für Hydraulikprodukte“, “Mineral-oil Based Pressure Fluids” and RE 90 221 “En-
RD 90 220 und „Umweltschonende, biologisch schnell vironmentally Acceptable Hydraulic Fluids HEES, HEPG,
abbaubare Druckflüssigkeiten HEPG, HEES für Axialkol- HETG for Axial Piston Units“, RD 90 221.
benmaschinen“, RD 90 221.
008 915 04 BOMAG 357

13.1
10/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump
2.2 Anforderungen an das Personal 2.2 Requirements on the Personnel

Diese Reparaturanleitung richtet sich an Fachkräfte mit This repair manual is directed at qualified personnel with
Hydraulik-Fachwissen, die an einer Service-Schulung bei specialized hydraulics know-how who have taken part at a
Rexroth teilgenommen haben. service training at Rexroth.
Als Fachkraft gilt, wer aufgrund seiner fachlichen Ausbildung Qualified personnel is defined as persons who have sufficient
und Erfahrung ausreichende Kenntnisse hat, sowie mit den knowledge on the basis of specialized training and experience,
einschlägigen Bestimmungen so weit vertraut ist, dass er and are familiar with the relevant regulations, so that they are
able to
!" die ihm übertragenene Arbeiten beurteilen kann, !" judge the delegated tasks,
!" mögliche Gefahren erkennen kann, !" recognize possible dangers,
!" die notwendigen Maßnahmen zur Beseitigung von Gefahren !" take the necessary measures for the elimination of dangers,
ergreifen kann,
! Kenntnisse über die möglichen Gesundheitsgefahren von !" judge the possible health risks from hydraulic fluids,
Druckflüssigkeiten hat
!" und die erforderlichen Reparatur- und Montagekenntnisse !" and have the required repair and installation know-how.
hat.
Hydraulik-Fachwissen bedeutet, das Personal muss, Specialized hydraulics know-how means that these persons
must:
!" in der Lage sein, die Hydraulikpläne zu lesen und vollständig !" be able to read and completely understand hydraulic plans,
zu verstehen,
!" insbesondere die Zusammenhänge bezüglich der eingebau- !" especially understand the connections regarding the in-
ten Sicherheitseinrichtungen vollständig verstehen stalled safety equipment,
!" und Kenntnisse über Funktion und Aufbau von hydraulischen !" and are familiar with the function and structure of hydraulic
Bauteilen haben. components.
358 BOMAG 008 915 04

RDE 92 003-21-R/01.06
13.111/40
Bosch Rexroth AG
3 Produktbeschreibung 3 Product Description

Dieses Kapitel gibt Ihnen einen allgemeinen Überblick über die This chapter provides a general overview of the functionality of
Funktionalität der Rexroth A4VG Verstellpumpe. the A4VG variable pump.
Machen Sie sich mit den Inhalten dieses Kapitels vertraut, You should be familiar with the contents of this chapter before
bevor Sie mit Arbeiten an einer Verstellpumpe beginnen. starting any work on the variable pump.
3.1 Typschild 3.1 Name Plate

Die Verstellpumpe ist am Typschild zu identifizieren: The variable pump can be identified on its name plate:
1 3FYSPUI
D-89275 Elchingen
2 TYP: A4VG90DA2D2/32R-NZF02F001SP 7
3 MNR: R90XXXXXXX
7202 8
4 SN: 12345678
5 FD: 05W28 Rotation:
-1 9
6 n = XXXX min P = XXX kW
Made in Germany 10
Folgende Informationen finden Sie auf dem Typschild: The following information can be found on the name plate:
1 Hersteller 1 Manufacturer
2 Typschlüssel 2 Ordering code
3 Materialnummer der Axialkolbenmaschine 3 Material number of the axial piston unit
4 Seriennummer 4 Serial number
5 Fertigungsdatum 5 Date of manufacturing
6 Drehzahl 6 Speed
7 interne Werksbezeichnung 7 Internal manufacturing code
8 Drehrichtung (bei Blick auf die Welle; hier: rechts) 8 Direction of rotation (when facing the shaft; here: clockwi-
se)
9 vorgesehener Platz für Prüfstempel 9 Designated space for certification stamp
10 Leistung 10 Power
Stellen Sie sicher, dass Typ und Nenngröße der zu reparieren- Ensure that the variable pump to be repaired is of the type and
den Verstellpumpe mit dieser Anleitung übereinstimmen. size covered by this manual.
3.2 Funktionsbeschreibung 3.2 Functional Description

Damit Sie in der Lage sind, Probleme an der Verstellpumpe To make sure that you are able to identify problems with a vari-
zu identifizieren und gezielt Reparaturen durchzuführen, sind able pump and to carry out specific repairs, familiarity with how
Kenntnisse der Funktionsweise und des Aufbaus erforderlich. the unit functions and its assembly are required. This section
Dieser Abschnitt gibt Ihnen eine grobe Übersicht. provides you with a rough overview.
Die A4VG Verstellpumpe ist eine Axialkolben-Verstellpum- The variable displacement axial piston pump type A4VG in
pe in Schrägscheibenbauart für hydrostatische Antriebe im swashplate design is designed for closed circuit hydrostatic
geschlossenen Kreislauf. Der Volumenstrom ist proportional zu drives. The flow is proportional to the input drive speed and
der Antriebsdrehzahl und dem Verdrängungsvolumen. Durch displacement. By adjusting the swashplate, it is possible to
die Verstellung der Schrägscheibe ist eine stufenlose Volumen- infinitely vary the flow.
stromänderung möglich.
008 915 04 BOMAG 359

13.1
Travel pump
3.2.1 Schnittzeichnung 3.2.1 Sectional Drawing

Die folgenden Schnittzeichnungen zeigen das Zusammenspiel The following drawings show the interrelation of the compon-
der Komponenten der A4VG Verstellpumpe. ents of the A4VG variable pump.
Seitenansicht / Side View Steuergerät (siehe unten) /

Control unit (see below)
Schwenkwiege /
Cradle
Antriebswelle /
Drive Shaft
Anschlussplatte
mit Hilfspumpe /
Port Plate with
Auxiliary Pump
Wellendichtring /
Shaft Seal Ring
Triebwerk /
Rotary Group
Draufsicht Verstellungen/
Top View with Controllers
Steuergerät
HWD Control unit DAD
Antriebswelle
Antriebswelle Drive Shaft
Drive Shaft
Verstellkolben
Control Piston
EPD HDD
Antriebswelle
Drive Shaft
Antriebswelle
Drive Shaft
Steuergerät
Control unit
360 BOMAG 008 915 04

RDE 92 003-21-R/01.06
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Bosch Rexroth AG
Ansicht Anschlussplatte /
View Port Plate
HWD / EPD / HDD
DAD
008 915 04 BOMAG 361

13.1
Travel pump
3.3 Technische Daten 3.3 Technical Data

Die technischen Daten der Verstellpumpe finden Sie in der Auf- You can find the technical data for the variable pump in the
tragbestätigung. Ergänzend dazu ist das jeweilige technische Confirmation of Order. This is supplemented by the unit‘s data
Datenblatt. Für die A4VG Verstellpumpe gilt das technische sheet. For the A4VG variable pump, the valid data sheet is
Datenblatt RD 92 003. RE 92 003.
362 BOMAG 008 915 04

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4 Austausch externer 4 Exchanging External
Baugruppen Assembly Groups
Dieses Kapitel beschreibt den Austausch von extern zugängli- This chapter describes the replacement of the externally acces-
chen Baugruppen der Verstellpumpe A4VG. sible assembly groups of the variable pump A4VG.
Der Austausch folgender Baugruppen wird beschrieben: The exchange of the following assembly groups is described:
!" Wellendichtring !" Shaft seal
!" Dichtungen !" Seals
!" Hilfspumpe !" Auxiliary pump
!" Steuergerät !" Control unit
Hinweis Note
Alle in nachfolgenden Zeichnungen dargestellten Steuergerä- All the following illustrations are only examples and do not
te sind nur stellvertretend und müssen nicht der Konfiguration have to completely correspond with the configrations of your
Ihrer Axialkolbenmaschine entsprechen. axial piston unit.
! WARNUNG ! WARNING
Gefahr von Verschleiß und Funktionsstörungen Danger of wear and malfunction

Die Sauberkeit der Druckflüssigkeit und die Lebensdauer der The durability of the hydraulic unit depends to a great extent
Hydraulikanlage stehen in unmittelbarem Zusammenhang. on how clean the unit is kept. Dirt in the hydraulic fluid can
Verschmutzung der Druckflüssigkeit führt zu Verschleiß und lead to malfunctions. Especially hard foreign matter in the
Funktionsstörungen. Insbesondere harte Fremdkörper in den hydraulic conduits, for example, welding beads and cuttings,
Hydraulikleitungen, wie z.B. Schweißperlen und Metallspäne, can damage the axial piston unit.
können die Axialkolbenmaschine beschädigen.
Beachten Sie daher unbedingt folgende Hinweise: Therefore you should observe the following instructions:
!" Achten Sie auf äußerste Sauberkeit. Die Axialkolbenmaschi- !" Make sure everything is kept extremely clean. The axial pis-
ne muss schmutzfrei eingebaut werden. Verunreinigungen ton unit must be installed in a dirt-free environment. Conta-
in der Druckflüssigkeit können die Funktion und Lebensdau- mination of the hydraulic fluid can lead to considerable wear
er der Axialkolbenmaschine erheblich beeinträchtigen. and malfunctions of the axial piston unit.
!" Achten Sie besonders bei der Installation darauf, dass !" Espacially during the istallation, you should make sure that
Anschlüsse, Hydraulikleitungen und Anbauteile (z.B. Mess- ports, hydraulic conduits, and mounting components (for
geräte) sauber sind. Reinigen Sie diese gründlich, bevor example, gauges) are clean. Clean these thoroughly before
Sie Anschlüsse öffnen. Stellen Sie sicher, dass auch beim you open connections. After that, when sealing the ports,
nachfolgenden Verschließen der Anschlüsse keine Verunrei- make sure that contaminating elements cannot enter the
nigungen eindringen. system.
!" Verwenden Sie für die Beseitigung von Schmiermitteln und !" When removing grease and other dirt you should use ap-
anderen starken Verschmutzungen geeignete flüssige Reini- propriate liquid cleaning agents. Cleaning agents must not
gungsmittel. Es darf kein Reinigungsmittel in das Hydraulik- enter the hydraulic system.
system eindringen.
!" Verwenden Sie zur Reinigung keine Putzwolle oder fasern- !" Do not use cotton waste or rags which lose threads.
de Putzlappen.
!" Verwenden Sie als Dichtungsmittel keinesfalls Hanf oder !" Never use hemp or putty as a sealant.
Kitt.
008 915 04 BOMAG 363

13.1
Travel pump
4.1 Wellendichtring austauschen 4.1 Exchanging the Shaft Seal

Dieser Abschnitt erklärt, wie Sie den Wellendichtring austau- This section explains how you can replace the shaft seal.
schen.
Benötigtes Sonderwerkzeug: Required Special Tools:
!" Montagehülse !" Mounting sleeve
Die Materialnummern sind je nach Pumpenmodell verschie- The material number depends on the pump model.
den:
– A4VG71: Mat.-nr. R909877509 – A4VG71: Mat. no. R909877509
NG 71, 90, 125
NG 180
b
a
a: Sicherungsring Circlip
b: Wellendichtring Shaft Seal
c: Triebwelle Drive Shaft
Um den Wellendichtring auszutauschen: To exchange the shaft seal:

1 Kleben Sie die Triebwelle (c) ab, um Beschädigungen am 1 Mask the drive shaft (c) for protection against damage of the
Wellendichtring (b) zu vermeiden. shaft seal (b).
2 Entfernen Sie den Sicherungsring (a). 2 Remove the safety ring (a).
364 BOMAG 008 915 04

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3 Drehen Sie Blechschrauben in die mit Gummi gefüllten 3 Screw the tapping screw into the rubber lined holes of the
Löcher des Wellendichtrings (b) und ziehen Sie den Wellen- shaft seal (b), and use pliers to pull the shaft seal out.
dichtring mit einer Zange heraus.
4 Fetten Sie den Wellendichtring zwischen Dicht- und Staub- 4 Grease the shaft seal between the seal and dust lip to avoid
lippe leicht ein, um Trockenlauf zu vermeiden. a dry run.
5 Pressen Sie den Wellendichtring mit Hilfe der Montagehülse 5 Using the mounting sleeve (special tool), press the shaft seal
(Sonderwerkzeug) auf Anschlag ein. until it is in stop position.
6 Führen Sie den Sicherungsring so ein, dass er in die dafür 6 Place the safety ring so that it locks into place in the respec-
vorgesehene Nut einrastet. tive slot.
7 Entfernen Sie die Abklebung an der Triebwelle. 7 Remove the mask on the drive shaft.
008 915 04 BOMAG 365

13.1
18/40 Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump
4.2 Dichtungen austauschen 4.2 Exchanging Seals

Die Baugruppe „Dichtungssatz komplett“ enthält Dichtungen The assembly group "complete seal set" contains seals for the
für folgende Komponenten: following components:
!" Stellkolbendeckel !" Positioning piston covers
!" Ventile !" Valves
!" Druckabschneidung !" Pressure cut-off
!" Hilfspumpe (siehe „Hilfspumpe austauschen“) !" Auxiliary pump (refer to "Exchanging the Auxiliary Pump")
!" Steuerung (siehe „Steuergerät austauschen“) !" Control unit (refer to "Exchanging the Control Unit")
Benötigtes Sonderwerkzeug: Keines Required Special Tools: none
Dichtung an den Stellkolbendeckeln austauschen Exchanging the valve positioning piston covers
Die beiden Seiten des Stellkolbens sind mit zwei unterschiedli- Both sides of the positioning piston have their own different
chen Deckeln abgedeckt. Die nötigen Schritte zum Austausch covers. The required steps to exchange the covers are threre-
der Deckeldichtungen unterscheiden sich daher. fore different.
a
c
d
c c
b
e
f
a: Linker Deckel Left cover
b: Rechter Deckel Right cover
c: O-Ring O-ring
d: Stellschraube Adjustment screw
e: Kontermutter Counter nut
f: Befestigungsschrauben Fastening screw
Um die Dichtung an den Stellkolbendeckeln auszutauschen: To exchange the valves of the positioning pistons:
1 Kennzeichnen Sie die Lage des linken Deckels (a) und ent- 1 Mark the position of the left cover (a) and remove the faste-
fernen Sie die Befestigungsschrauben (f). ning screws (f).
2 Verdrehen Sie den Deckel (a) und lösen Sie ihn vorsichtig 2 Twist the cover (a) and carefully loosen it by tapping it with a
mit leichten Hammerschlägen (Gummihammer). (rubber) hammer.
366 BOMAG 008 915 04

RDE 92 003-21-R/01.06
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3 Entfernen Sie den alten O-Ring (c). Kontrollieren Sie die 3 Remove the old o-ring (c). Check the slot (h) and the
Nut (h) und das Gehäuse (g) auf Verschleiß und Verunreini- housing (g) for wear and dirt.
gungen.
c
h g
4 Setzen Sie einen neuen O-Ring ein und schrauben Sie den 4 Install a new o-ring and screw the cover shut.
linken Deckel fest.
5 Markieren Sie die Lage des rechten Deckels (b), damit Sie 5 Mark the position of the right cover (b) so that you can set it
ihn nach dem Abdichten wieder lagerichtig aufsetzen kön- back to its original position after sealing.
nen.
Messen und notieren Sie das Maß X der Kontermutter (e) für Measure and write down the dimension X of the counter
die spätere Montage. nut (e). You need this for the subsequent assembly.
Entfernen Sie die Kontermutter (e). Halten Sie dazu die Remove the counter nut (e). To do so, grip the positioning
Stellschraube (d) fest. screw (d).
b
e
X
d
X
6 Schrauben Sie den Deckel von der Stellschraube durch 6 Unscrew the cover from the positioning screw.
Drehen ab.
7 Entfernen Sie die beiden O-Ringe (c). Kontrollieren Sie die 7 Remove the two o-rings (c). Check the slots (h) and housing
Nuten (h) und das Gehäuse (g) auf Verschleiß und Verunrei- (g) for wear and dirt.
nigungen.
c
g h
h
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8 Kleben Sie das Gewinde ab, um Beschädigungen des O- 8 Mask the screw thread to avoid damaging the o-ring, and
Rings zu vermeiden, und schieben Sie den kleinen O-Ring push the smaller o-ring up to the designated slot.
bis zur vorgesehenen Nut auf.
9 Setzen Sie den großen O-Ring ein, entfernen Sie die Abkle- 9 Insert the larger o-ring, remove the masking and screw the
bung und schrauben Sie den Deckel fest. cover back on.
10 Schrauben Sie die Kontermutter (e) per Hand ein. Blockie- 10 Screw in the counter nut (e) manually. Block the adjusting
ren Sie die Stellschraube (d) während Sie die Kontermutter- screw (d) while you tighten the counter nut.
festziehen.
Kontrollieren Sie das Maß X nach der Montage. Check the dimension X after assembly.
b
e
X
d
X
Hinweis Note
Nach dem Einbau im Gerät bzw. Prüfstand muss die korrekte After the installation of the unit or the test rig, the correct
mechanische Nulllagen-Einstellung erfolgen, siehe „Überprü- mechnical zero stroke must be adjusted, refer to "Checking",
fungen“ auf Seite 29. page 29.
368 BOMAG 008 915 04

RDE 92 003-21-R/01.06
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Ventildichtungen austauschen Exchanging the valve seals
Hinweis Note
Möglicherweise sind nicht alle in den Zeichnungen gezeigten It is possible that the valves displayed in these illustrations are
Ventile an Ihrer Einheit vorhanden. not all present in your unit.
Hochdruckventil /
High-pressure valve
Niederdruckventil
Low-pressure valve
Um die Ventildichtungen auszutauschen: To exchange the valve seals:

1 Schrauben Sie das Niederdruckventil heraus. 1 Unscrew the low pressure valve.
2 Kleben Sie die Gewinde der Niederdruckventile ab, um 2 Mask the screw thread to avoid damage to the o-rings.
Beschädigungen der O-Ringe zu vermeiden.
3 Setzen Sie die neuen O-Ringe ein, entfernen Sie die Abkle- 3 Insert the new o-rings, remove the masking from the screw
bungen an den Gewinden und schrauben Sie das Nieder- thread, and screw the low pressure valve back in.
druckventil wieder ein.
Ziehen Sie es mit einem Drehmoment von 70 Nm fest. Tighten it with a torque of 70 Nm.
4 Schrauben Sie die Hochdruckventile heraus. 4 Unscrew the high-pressure valves.
Beachten Sie: Bei NG 71–90 gibt es zwei O-Ringe und Note: NG 71–90 have two o-rings and one There are two
einen Stützring, bei NG 125 und 180 nur einen O-Ring. types of this valve: with or without bypass function.
Sicherungskappe / Tamper prof cap
O-Ring
O-Ring
Stützring /
Support ring
O-Ring
NG 71–90 NG 125, 180
008 915 04 BOMAG 369

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5 Entfernen Sie die O-Ringe und den Stützring (NG 71–90) 5 Remove the o-rings and the supprot ring (NG 71–90) and
und kontrollieren Sie das Gehäuse auf Verschleiß und Verun- check the housing for wear and dirt.
reinigungen.
6 Bauen Sie das Hochdruck-Ventil ein und ziehen Sie es mit 6 Install the high-pressure valve and tighten it with a torque of
einem Drehmoment von 150 Nm (NG 71–90) bzw. 200 Nm 150 Nm (NG 71–90) or 200 Nm (NG 125, 180).
(NG 125, 180) fest.
Hinweis Hinweis
Nach dem Einbau muss eine Überprüfung des Hochdrucks Nach dem Einbau muss eine Überprüfung des Hochdrucks
erfolgen, siehe „Überprüfungen“ auf Seite 29. erfolgen, siehe „Überprüfungen“ auf Seite 29.
Dichtung der Druckabschneidung austauschen Exchanging the seals of the pressure cut-off
Um die Dichtung der Druckabschneidung auszutauschen: To exchange the seal of the pressure cut-off:
1 Notieren Sie das Einstellmaß X der Dichtmutter für die späte- 1 Write down the sealing nut's setting dimension X for the
re Montage. subsequent assembly.
2 Bauen Sie die Dichtmutter (a) und die Verschlussschraube 2 Extract the sealing nut (a) and the locking screw (b).
(b) aus.
Entfernen Sie den O-Ring (c). Remove the o-ring (c).
a
b X
3 Setzen Sie einen neuen O-RIng (c) ein. 3 Install a new o-ring (c).
4 Setzen Sie die Verschlussschraube (b) ein und ziehen Sie 4 Install the locking screw (b) and tighten it with a torque of 35
sie mit einem Drehmoment von 35 Nm fest. Nm.
5 Bauen Sie eine neue Dichtmutter (a) ein und stellen Sie das 5 Install the new sealing nut (a) and adjust to the setting
notierte Einstellmaß X ein. measure X that you wrote down previously.
Ziehen Sie die Dichtmutter mit 25 Nm fest. Tighten it with a torque of 25 Nm.
370 BOMAG 008 915 04

RDE 92 003-21-R/01.06
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Bosch Rexroth AG
Dichtung des Regelventils austauschen Exchanging the control valve
b
a
a: Regelventil Control valve

b: O-Ring O-ring
Um die Dichtung am Regelventil auszutauschen: To exchange the control valve:

1 Schrauben Sie das Regelventil (a) aus. 1 Unscrew the control valve (a).
2 Kleben Sie das Gewinde zur Vermeidung von Beschädigun- 2 Mask the screw thread to avoid damaging the o-ring.
gen des O-Rings ab.
3 Schieben Sie den neuen O-Ring auf. 3 Slide the new o-ring on.
4 Entfernen Sie die Abklebung und schrauben Sie das Regel- 4 Remove the masking and screw the control valve back on.
ventil ein.
Ziehen Sie sie mit einem Drehmoment von 50 Nm fest. Tighten them with a torque of 50 Nm.
008 915 04 BOMAG 371

13.1
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4.3 Hilfspumpe austauschen 4.3 Exchanging the Auxiliary Pump

Die nachfolgenden Schritte gelten sowohl für den Austausch The following steps apply to the exchange of an auxiliary pump
einer Hilfspumpe als auch für den Austausch eines O-Rings. as well as to the exchange of an o-ring.
Benötigtes Sonderwerkzeug: Keines Required Special Tools: none
Um die Hilfspumpe auszutauschen: To exchange the auxiliary pump:
1 Markieren Sie die Lage des Deckels (a), damit Sie ihn nach 1 Mark the position of the cover (a), so that you can replace it
dem Abdichten wieder lagerichtig aufsetzen können. in its original position after the sealing.
2 Entfernen Sie die vier Befestigungsschrauben (b). 2 Remove the four fastening screws (b).
3 Drücken Sie den Deckel wie gezeigt ab. 3 Press the cover off as illustrated.
4 Entfernen Sie die Hilfspumpe und untersuchen Sie die Teile 4 Remove the auxiliary punp and check the part for wear and
der Hilfspumpe auf Verschleiß und Verunreinigungen. dirt.
Markieren Sie vorher die Lage der Hilfspumpe, damit Sie sie Mark the position of the auxiliary pump beforehand, so that
später wieder lagerichtig einbauen können (sofern Sie die you can return it to its original position afterwards (if you
alte Hilfspumpe weiter verwenden). keep the old auxiliary pump in use).
Hinweis Note
Die Hilfspumpe kann nur komplett ausgetauscht werden. The auxiliary pump can only be exchanged as a whole.
5 Setzen Sie zwei neue O-Ringe (c) ein. 5 Install two new o-rings (c).
372 BOMAG 008 915 04

RDE 92 003-21-R/01.06
13.125/40
Bosch Rexroth AG
6 Setzen Sie die (neue) Hilfspumpe ein. 6 Install the (new) auxiliary pump.
Achten Sie darauf, dass die angefaste „Seite“ (d) zum De- Pay attention that the chamfered "side" (d) is assembled
ckel (a) montiert wird. facing the cover (a).
d a
d
Hinweis Note
Die Hilfspumpe wird mit Haltestopfen (e) geliefert. Diese wer- The auxiliary pump is delivered with fixing plugs (e). These are
den bei der Montage auf die Anschlussplatte in die entspre- pressed into the bore of the port plate during assembly.
chenden Bohrungen eingepresst.
7 Schrauben Sie den Deckel (a) fest. Beachten Sie dabei die 7 Screw the cover (a) back on. Pay attention to the marking
vorher angebrachte Markierung. made previously.
008 915 04 BOMAG 373

13.1
Travel pump
4.4 Steuergerät austauschen 4.4 Exchanging the Control Unit

Die nachfolgenden Schritte gelten sowohl für den Austausch The following steps apply to the exchange of the whole control
des ganzen Steuergeräts als auch für den Austausch eines O- unit as well as to the exchange of an o-ring.
Rings am Steuergerät.
Benötigtes Sonderwerkzeug: Required Special Tools:
!" NG 71: Keines !" NG 71: none
!" NG 90–180: 2 Hilfsschrauben (Mat.-nr. R02774871) !" NG 90–180: 2 auxiliary screws (Mat. no. R02774871)
Hinweis Note
Es gibt eine Vielzahl von Steuergeräten (siehe Abbildung). There exists a multitude of control units (as illustrated).
Bitte beachten Sie, dass hier exemplarisch nur der Austausch Please pay attention to the fact that only the example of an
eines HW Steuergeräts gezeigt wird. HW controller is described here.
alt / old
DA
neu / new alt / old
HD
neu / new
EP
HW alt / old
neu / new
Polrohr
Anziehmoment 19 Nm /
Pole tube
Tightening torque 19 Nm
Anziehmoment 5+1 Nm
Steckschlüssel SW 26 /
Tightening torque 5+1 Nm
26 A/F socket spanner
374 BOMAG 008 915 04

RDE 92 003-21-R/01.06
13.127/40
Austausch des Steuergeräts bei NG 71 Exchanging the Control Unit with NG 71
Um das Steuergerät bei NG 71 auszutauschen: To exchange the control unit:
1 Entfernen Sie die fünf Befestigungsschrauben (a). 1 Remove all five fastening screws (a).
2 Drücken Sie das Steuergerät (b) wie gezeigt ab. 2 Press the control unit (b) off as illustrated.
3 Entfernen Sie den O-Ring (c) und die Flachdichtung (e). 3 Remove the o-ring (c) and the gasket (e). Check the sealing
Kontrollieren Sie die Dichtflächen (d) auf Beschädigungen surfaces (d) for wear and dirt.
und Verunreinigungen.
Tauschen Sie das Steuergerät bei Bedarf aus. Exchange the control unit if required.
Hinweis Note
Das Steuergerät kann nur komplett ausgetauscht werden. The control unit can only be exchanged as a whole.
d
e
e
d
4 Setzen Sie einen neuen O-Ring (c) und eine neue Flachdich- 4 Insert the new o-ring (c) and the new gasket (e).
tung (e) ein.
008 915 04 BOMAG 375

13.1
Travel pump
5 Setzen Sie das (neue) Steuergerät ein. 5 Insert the new control unit.
6 Zentrieren Sie die Dichtung (e) mit zwei Befestigungsschrau- 6 Center the seal (e) with two fastening screws (a) and install
ben (a) und bauen Sie das Steuergerät ein. the control unit.
Ziehen Sie alle vier Befestigungsschrauben mit halbem Screw all four fastening screws tight with half the torque.
Drehmoment an.
a
a: Befestigungsschraube Fixing screw

b: Steuergerät Control unit
e: Dichtung Seal
7 Setzen Sie die fünfte Schraube (f) ein und ziehen Sie sie mit 7 Insert the fifth screw (f) and tighten it with a torque of
einem Drehmoment von 10,4 Nm fest. 10.4 Nm.
Ziehen Sie die anderen vier Schrauben (a) nach Drehmo- Tighten the other four screws (a) crosswise and according
ment über Kreuz fest. to torque.
Hinweis Note
Nach der Montage des Steuergeräts muss die hydraulische After installing the control unit, the hydraulic zero stroke must
Nulllage neu eingestellt werden (gilt nicht für DA-Regelung), be re-established. This does not apply to DA-control. Please
siehe „Überprüfungen“ auf Seite 33. refer to "Checking", page 33.
376 BOMAG 008 915 04

RDE 92 003-21-R/01.06
13.129/40
Austausch des Steuergeräts bei NG 90–180 Exchanging the Control Unit with NG 90–180
Hinweis Note
Die folgende Handlungsanweisung behandelt exemplarisch The following instructions show how to exchange an HD
den Austausch eines HD-Steuergeräts. control unit, exemplarily.
Um das HD-Steuergerät bei NG 90–180 auszutauschen: To exchange the HD control unit with NG 90–180:
1 Entfernen Sie die vier Befestigungsschrauben (a). 1 Remove all four fastening screws (a).
Entfernen Sie den Deckel (g) und die Flachdichtung (d). Remove the cover (g) and the gasket (d).
g
d
a
2 Entfernen Sie die zwei Zylinderschrauben (f). 2 Remove the two assembly screws (f).
f
3 Drücken Sie das Steuergerät (b) wie gezeigt ab. 3 Press the control unit (b) off as illustrated.
008 915 04 BOMAG 377

13.1
Travel pump
4 Entfernen Sie die O-Ringe (c). Kontrollieren Sie die Dichtflä- 4 Remove the o-rings (c). Check the sealing surfaces for wear
chen auf Beschädigungen und Verunreinigungen. and dirt.
Tauschen Sie Steuergerät bei Bedarf aus. Exchange the control unit if required.
Hinweis Note
Das Steuergerät kann nur komplett ausgetauscht werden. The control unit can only be exchanged as a whole.
c
d
5 Setzen Sie neue O-Ringe (c) und eine neue Flachdichtung 5 Insert the new o-rings (c) and the new gasket (d).
(d) ein.
6 Setzen Sie das (neue) Steuergerät (b) ohne Deckel auf. 6 Insert the (new) control unit (b) without cover.
Schrauben Sie das Steuergerät diagonal mit zwei Hilfs- Tighten the control unit with two auxiliary screws (e) (special
schrauben (e) (Sonderwerkzeug) an (mit 7 Nm). tools) diagonally (with a torque of 7 Nm).
Schrauben Sie es mit zwei Zylinderschrauben (f) an (mit Fix it with two assembly screws (f) (with a torque of
10,4 Nm). 10,4 Nm).
f e
7 Entfernen Sie die Hilfsschrauben (e) wieder. 7 Remove the auxiliary screws (e).
8 Kontrollieren Sie, ob die Zugfedern richtig in den Kerben des 8 Make sure that both spring catches are hooked to the pair of
Hebelpaares eingehängt sind. leavers.
378 BOMAG 008 915 04

RDE 92 003-21-R/01.06
13.131/40
9 Setzen Sie den Deckel (g) mit der Dichtung (d) auf und 9 Put on the cover (g) with the gasket (d) and fix it with the
schrauben Sie ihn mit den vier Befestigungsschrauben fest. four fastening screws.
Ziehen Sie die schrauben mit 10,4 Nm fest. Tighten the screws with a torque of 10,4 Nm.
a
g
d
Hinweis Note
Nach der Montage des Steuergeräts muss die hydraulische After installing the control unit, the hydraulic zero stroke must
Nulllage neu eingestellt werden (gilt nicht für DA-Regelung), be re-established. This does not apply to DA-control. Please
siehe „Überprüfungen“ auf Seite 33. refer to "Checking", page 33.
008 915 04 BOMAG 379

13.1
Travel pump
380 BOMAG 008 915 04

RDE 92 003-21-R/01.06
13.133/40
5 Überprüfungen 5 Checking
Bei der ersten Inbetriebnahme nach einer Reparatur müssen When starting up for the first time after a repair, you must
Sie die ursprünglichen Einstellungen der Verstellpumpe kontrol- check the original settings of the variable pump. This chapter
lieren. Dieses Kapitel erklärt folgende Überprüfungen: describes the following checkings:
• Niederdruck • Low pressure
• Hochdruck • High pressure
• Mechanische Nulllage • Mechanical zero stroke
• Hydraulische Nulllage • Hydraulic zero stroke
Hinweis Note
Führen Sie alle Überprüfungen bei Betriebstemperatur durch. Carry out checkings at operating temperature.
Hinweis Note
Wenn die überprüften Werte von den ursprünglichen Einstel- If the checked values differ from the original settings, please
lungen abweichen, setzen Sie sich bezüglich der Einstellung contact Rexroth in terms of adjusting the settings.
bitte mit dem Rexroth-Service in Verbindung.
! WARNUNG ! WARNING

Arbeiten an der Verstellpumpe bei Betriebstemperatur sind Working on the variable pump at operating temperature is
gefährlich. dangerous.
! Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“ ! Pay exact attention to the safety advice (refer to "Safety",
auf Seite 7). page 7).
! WARNUNG ! WARNING
Gefahr von Verschleiß und Funktionsstörungen Danger of wear and malfunction

Die Sauberkeit der Druckflüssigkeit und die Lebensdauer der The durability of the hydraulic unit depends to a great extent
Hydraulikanlage stehen in unmittelbarem Zusammenhang. on how clean the unit is kept.
! Achten Sie bei Überprüfungen darauf, dass Messanschlüs- ! When checking settings, you should make sure that gauge
se, Schläuche und Messgeräte sauber sind. Reinigen Sie ports, hydraulic conduits, and und gauges are clean. Clean
diese gründlich bevor Sie die Messpunkte öffnen und mit these thoroughly before you open gauge ports and begin
den Einstellarbeiten beginnen. adjusting settings.
! Stellen Sie sicher, dass auch beim nachfolgenden Verschlie- ! After that, when sealing the ports, make sure that contami-
ßen der Messpunkte keine Verunreinigungen eindringen. nating elements cannot enter the system.
008 915 04 BOMAG 381

34/40
13.1
Travel pump
5.1 Niederdruck (Speisedruck) überprüfen 5.1 Checking Low Pressure (Charge Pressure)
Dieser Abschnitt erklärt, wie Sie ND-Ventile überprüfen. This section describes how to check the low pressure valves.
Um den Niederdruck zu überprüfen: To check the low pressure:
1 Schließen Sie wie gezeigt ein Manometer an Anschluss G 1 Connect a manometer to connection G as displayed.
an.
bei DA-
Ausführung /
with DA
version
2 Überprüfen Sie den Niederdruck (G). 2 Check the low pressure (G):
Hinweis Note
Die genauen Einstelldaten entnehmen Sie dem Technischen Refer to the catalog sheet RE 92 003 and your specification
Datenblatt RD 92 003 und Ihrer Spezifikation. for the detailed setting data.
5.2 Hochdruck überprüfen 5.2 Checking the High Pressure

Die Begrenzung des Hochdrucks erfolgt über die Druckab- The limitation of the operating pressure is performed by a high
schneidung. Zusätzlich ist ein Hochdruckbegrenzungsventil pressure relief valve. Additionally, a high pressure relief valve
(Sicherheitsventil) überlagert. Der Druckwert der Druckab- (safety valve) is in superposition. The pressure value of the
schneidung liegt ca. 10 % unter dem Wert des Hochdruckbe- pressure cut-off is 10 % below that of the high pressure relief
grenzungsventils. valve.
Es kann also nur der Druckwert der Druckabschneidung über- Therefore, only the pressure value of the pressure cut-off can
prüft werden. be measured.
Hinweis Note
Die genauen Einstelldaten entnehmen Sie Ihrer Spezifikation. Refer to your specification for the detailed setting data.
382 BOMAG 008 915 04

RDE 92 003-21-R/01.06
13.135/40
5.3 Mechanische Nulllage überprüfen 5.3 Checking the Mechanical Zero Stroke
Dieser Abschnitt erklärt, wie Sie die mechanische Nulllage bei This section describes how to check the mechanical zero stro-
HW-, HD-, EP- und DA-Steuergeräten überprüfen. ke for HW, HD, EP, and DA controllers.
HW HD EP DA
! WARNUNG ! WARNING

Die im Folgenden beschriebenen Arbeiten an der Verstellpum- The following procedures carried out on the variable pump are
pe sind gefährlich. dangerous.
! Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“ ! Please pay attention to the safety advice (refer to "Safety",
auf Seite 7). page 7).
! Blockieren Sie das Fahrzeug bzw. entlasten Sie die Anlage ! Block the machinery or unit before you carry out the installa-
bevor Sie die Einstellarbeiten durchführen. tion.
mind. / at least
Nennweite 6 / Nominal Width 6
MA
Messbereich/
Metering range
0 ... 600 bar
MB
Um die mechanische Nulllage zu überprüfen: To check the mechanical zero stroke:

1 Verbinden Sie beide Stellkammern über einen Schlauch mit 1 Connect the two position chambers with a hose (with at
mindestens Nennweite NW6. least nominal width NW6).
Dadurch stellen Sie sicher, dass ein Restsignal aus dem Thus, you ensure that a residual signal from the controller
Steuergerät keine Auswirkung auf die Einstellung der me- has no influence on the setting of the hydraulic zero stroke.
chanischen Nullage hat.
2 Schließen Sie an die Messanschlüsse MA und M B Manome- 2 Connect manometers to the measuring ports MA and M B.
ter an.
3 Überprüfen Sie, ob bei blockiertem Antrieb beide Manometer 3 Check if both manometers show the same pressure value
den gleichen Druckwert anzeigen. when the unit is blocked.
008 915 04 BOMAG 383

13.1
Travel pump
5.4 Hydraulische Nulllage überprüfen 5.4 Checking the Hydraulic Zero Stroke
Dieser Abschnitt erklärt, wie Sie die hydraulische Nulllage bei This section describes how to check the hydraulic zero stroke
HW-, HD- und EP-Steuergeräten überprüfen. for HW, HD, and EP controllers.
! WARNUNG ! WARNING

Die folgenden Arbeiten an der Verstellpumpe sind gefährlich. The following procedures carried out on the variable pump are
dangerous.
! Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“
auf Seite 7). ! Pay attention to the safety advice (refer to "Safety",
page 7).
! Blockieren Sie das Fahrzeug bzw. entlasten Sie die Anlage ! Block the machinery or unload the unit before you procede
bevor Sie die Einstellarbeiten durchführen. with the installation.
HW HD EP
Messbereich/
Metering range
0 ... 60 bar
X1
X2
Um die hydraulische Nulllage zu überprüfen: To check the hydraulic zero stroke:

1 Schließen Sie an die Anschlüsse X1 und X2 Manometer an. 1 Connect manometers to the ports X1 und X2.
2 Überprüfen Sie, ob bei blockiertem Antrieb beide Manometer 2 Check if both manometers show the same pressure value
den gleichen Druckwert anzeigen. when the unit is blocked
Hinweis Note
Verdrehen Sie die Exzenterjustierung (a) am Steuergerät nicht Never turn the eccentric calibration (a) of the controller over
über ±90°. ±90 degrees.
384 BOMAG 008 915 04

RDE 92 003-21-R/01.06
13.137/40
Bosch Rexroth AG
008 915 04 BOMAG 385

13.1
Travel pump
386 BOMAG 008 915 04

RDE 92 003-21-R/01.06
13.139/40
Bosch Rexroth AG
008 915 04 BOMAG 387

13.1 Travel pump
Bosch Rexroth AG
Hydraulics
Produktsegment
Axialkolbenmaschinen
Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72-74
info.brm-ak@boschrexroth.de
www.boschrexroth.com/brm
© This document, as well as the data, © Alle Rechte bei Bosch Rexroth AG,
specifications and other information auch für den Fall von Schutzrechtsan-
set forth in it, are the exclusive proper- meldungen. Jede Verfügungsbefugnis,
ty of Bosch Rexroth AG. It may not be wie Kopier- und Weitergaberecht,
reproduced or given to third parties bei uns.
without its consent.
Die angegebenen Daten dienen
The data specified above only serve to allein der Produktbeschreibung.
describe the product. No statements Eine Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
information given does not release werden. Die Angaben entbinden
the user from the obligation of own den Verwender nicht von eigenen
judgment and verification. It must be Beurteilungen und Prüfungen. Es ist
remembered that our products are
zu beachten, dass unsere Produkte
subject to a natural process of wear
einem natürlichen Verschleiß- und
and aging.
Alterungsprozess unterliegen.
Subject to change. Änderungen vorbehalten.
Printed in Germany
RDE 92 003-21-R/01.06
388 BOMAG 008 915 04

13.2 Travel motor
008 915 04 BOMAG 389

13.2 Travel motor
390 BOMAG 008 915 04

Travel motor 13.2
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics
RDE 91 604-01-R/03.03
Verstellmotor A6VM 28...200 ersetzt/replaces 08.01
Variable Displ. Motor A6VM 28...200
Reparaturanleitung / Repair Instructions
008 915 04 BOMAG 391

13.2 Bosch Rexroth AG | Mobile Hydraulics
2 A6VM | RDE 91 604-01-R/03.03
Travel motor
Typschlüssel
Typschlüssel A6V M / 6 3 W
Axialkolbenmaschine
Schrägachsenbauart, verstellbar A6V
Betriebsart
Motor (Einschubmotor A6VE siehe RD 91606) M
Nenngröße
≅ Schluckvolumen Vg max (cm3) 28 55 80 107 140 160 200
NG 28...200: Fertigung Werk Elchingen
Regel- und Verstelleinrichtung 28 55 80 107 140 160 200
Hydraulische Verstellung Steuerdruckanstieg 10 bar HD1 HD1 *
steuerdruckabhängig 25 bar HD2 HD2 *
35 bar HD3 – – – – – – – HD3 *
Hydraulische Zweipunktverstellung HZ – – – – – – – HZ .
HZ1 – – – HZ1 *
HZ3 – – – – HZ3
Elektrische Verstellung, Steuerspannung 12 V EP1 EP1 *
mit Proportionalmagnet 24 V EP2 EP2 *
Elektrische Steuerspannung 12 V EZ1 – – – EZ1 *
Zweipunktverstellung, 24 V EZ2 – – – EZ2 *
mit Schaltmagnet 12 V EZ3 – – – – EZ3
24 V EZ4 – – – – EZ4
Automatische Verstellung, ohne Druckanstieg HA1 HA1 *
hochdruckabhängig mit Druckanstieg ∆p = 100 bar HA2 HA2 *
Hydraulische Verstellung, drehzahlabhängig DA – – – – – – – DA *
pSt/pHD = 5/100, hydraulisches Fahrtrichtungsventil DA1 DA1 *
elektrisches Fahrtrichtungsventil 12 V DA2 DA2 *
+ elektrische Vg max-Schaltung 24 V DA3 DA3 *
pSt/pHD = 8/100, hydraulisches Fahrtrichtungsventil DA4 DA4 *
elektrisches Fahrtrichtungsventil 12 V DA5 DA5 *
+ elektrische Vg max-Schaltung 24 V DA6 DA6 *
Druckregelung (nur für HD, EP) 28 55 80 107 140 160 200
ohne Druckregelung (kein Zeichen)
Druckregelung, direktgesteuert D
direktgesteuert, mit 2. Druckeinstellung E
fernsteuerbar – – – – – – – G
Übersteuerung der HA-Verstellung (nur für HA1, HA2)
ohne Übersteuerung (kein Zeichen)
hydraulische Übersteuerung T
elektrische Übersteuerung Steuerspannung 12 V U1
24 V U2
elektrische Übersteuerung Steuerspannung 12 V R1
+ elektrisches Fahrtrichtungsventil 24 V R2
* Differentialkolben Gleichgangkolben
392 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.23
Type code
Type code A6V M / 6 3 W
Axial piston unit
Bent axis design, variable displacement A6V
Mode of operation
Motor (plug-in motor A6VE see RE 91606) M
Size
≅ Displacement Vg max (cm3) 28 55 80 107 140 160 200
Sizes 28...200: production plant Elchingen
Control device 28 55 80 107 140 160 200
Hydraulic control pilot pressure increase 10 bar HD1 HD1 *
pilot pressure related 25 bar HD2 HD2 *
35 bar HD3 – – – – – – – HD3 *
Hydraulic two-position control HZ – – – – – – – HZ .
HZ1 – – – HZ1 *
HZ3 – – – – HZ3
Electrical control, control voltage 12 V EP1 EP1 *
with proportional solenoid 24 V EP2 EP2 *
Electrical control voltage 12 V EZ1 – – – EZ1 *
two-position control, 24 V EZ2 – – – EZ2 *
with switching solenoid 12 V EZ3 – – – – EZ3
24 V EZ4 – – – – EZ4
Automatic control, without pressure increase HA1 HA1 *
high pressure related with pressure increase ∆p = 100 bar HA2 HA2 *
Hydraulic control, speed related DA – – – – – – – DA *
pSt/pHD = 5/100, hydraulic valve for travel direction DA1 DA1 *
electrical valve for travel direction 12 V DA2 DA2 *
+ electrical Vg max-switch 24 V DA3 DA3 *
pSt/pHD = 8/100, hydraulic valve for travel direction DA4 DA4 *
electrical valve for travel direction 12 V DA5 DA5 *
+ electrical Vg max-switch 24 V DA6 DA6 *
Pressure control (only for HD, EP) 28 55 80 107 140 160 200
without pressure control (no code)
Pressure control, direct control D
direct control, with 2nd pressure setting E
remote control – – – – – – – G
Override of HA-control (only for HA1, HA2)
without override (no code)
Hydraulic override T
Electrical override control voltage 12 V U1
24 V U2
Electrical override control voltage 12 V R1
+ el. valve for travel direction 24 V R2
* Differential piston Synchronizing piston
008 915 04 BOMAG 393

13.2 Travel motor
394 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Schnittbild
Sectional drawing
A6VM 55-107 HZ3
A B
max. min.
X T
A6VM 55-107 EZ3

A B
max. min.
A6VM 55-107 HA3

A B
max. min.
A6VM 55-107 HA3U

A B
max. min.
008 915 04 BOMAG 395

6 A6VM | RDE 91 604-01-R/03.03
Travel motor
Schnittbild
Sectional drawing
A6VM 28-200 HD
A B
max min
X
G
M1 T(T1)
A6VM 28-200 HD
mit Spülventil / with flushing valve
A B
max min
M1 T(T1)
A6VM 28-200 HD1D

mit Druckregelventil / with pressure
control valve
A B
max min
X
G
M1 T(T1)
396 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Schnittbild
Sectional drawing
A6VM 28-200 EP
A B
max min
M1 T(T1)
A6VM 28-200 EP./..A
A B
max min
T(T1) M1
A6VM 28-200 EP./..A
A B
max min
Sa
T(T1) M1
008 915 04 BOMAG 397

8 A6VM | RDE 91 604-01-R/03.03
Travel motor
Schnittbild
Sectional drawing
A6VM ... DA1
A B X1 X2
max min
G
X3
M1 T(T1)
A6VM ... DA3 A B
X1
X3
max min
G
M1 T(T1)
398 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Schnittbild
Sectional drawing
A6VM 28-200 HA2U

mit Bremsventil / with braking valve
A
S
max min
T(T1) M1
A6VM 28-200 HA1R

A B
max min
T(T1) M1
A6VM ... HA1U

A B
max min
T(T1) M1
008 915 04 BOMAG 399

10 A6VM | RDE 91 604-01-R/03.03
Travel motor
Allgemeine Reparaturhinweise
General repair instructions
Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!
Attention!
Observe the following notices when carrying out
repair work at hydraulic aggregates!
Alle Öffnungen der Hydraulikaggregate

verschließen.
Close all ports of the hydraulic aggregates.
Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.
Replace all seals.

Use only OR IG I NAL B R U E N I NG HAUS
HYDROMATIK spare parts.
Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.
Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.
Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befüllen.
Fill up hydraulic aggregates with medium

before start- up.
400 BOMAG 008 915 04

RDE 91 604-01-R/03.03
11
Dichtsätze und Baugruppen

Seal kits and sub assembly groups
Dichtsatz für Triebwelle.
Seal kit for drive shaft.
Äußerer Dichtsatz.
External seal kit.
Gehäuse
Housing
Triebwerk komplett
Hinweis: Pos. 1 - Für Anschlußplatte mit
Pos. 2 Differentialkolben
Pos. 2 - Für Anschlußplatte mit
Gleichgangkolben
Complete rotary group

Note: Pos. 1 - For port plate with differential
piston
Pos. 2 - For port plate with
synchronizing piston
Pos. 1
Pos. 1 Pos. 2 Anschlußplatte mit Stellkolben

Hinweis: Pos. 1 - Für Anschlußplatte mit
Differentialkolben
Pos. 2 - Für Anschlußplatte mit
Gleichgangkolben
Port plate with control piston

Note: Pos. 1 - For port plate with differential
piston
Pos. 2 - For port plate with
synchronizing piston
008 915 04 BOMAG 401

12 A6VM | RDE 91 604-01-R/03.03
Travel motor
Dichtsätze und Baugruppen

Seal kits and sub assembly groups
Schaltmagnet / Proportionalmagnet
Solenoid
Deckel mit * Drosselstift.

* Drosselstift "Auftragsbezogen".
* Cover with * throttle pin.
* Throttle pin "as to order requirement".
*
*
*
*
Deckel mit Spül- und Speisedruckventil
* und * Drosselstift
* Drosselstift "Auftragsbezogen".
Cover with flushing and boost pressure valve
and * throttle pin.
* Throttle pin "as to order requirement".
402 BOMAG 008 915 04

RDE 91 604-01-R/03.03
13
Baugruppen / Steuerteile
Component groups / Control components
z. B. HA EP
HA2
Auftrags-
bezogen *
"as to order
DA
requirement".
HD
008 915 04 BOMAG 403

14 A6VM | RDE 91 604-01-R/03.03
Travel motor
Baugruppen / Steuerteile
Component groups / Control components
z. B. HZ3 / EZ3
HA3 / HA3U
404 BOMAG 008 915 04

RDE 91 604-01-R/03.03
15
Dichtmutter austauschen
Replace seal nut
Dichtmutter austauschen.
Zuerst Maß X messen und festhalten.
Replace seal nut.

First measure and record setting height.
Maß X
Beim Anziehen Einstellschraube gegenhalten,

anschließend Einstellhöhe kontrollieren.
When tightening, counterhold setting screw, then

check setting height.
008 915 04 BOMAG 405

16 A6VM | RDE 91 604-01-R/03.03
Travel motor
Triebwelle abdichten
Sealing of the drive shaft
Triebwelle abkleben.
Sicherungsring und Scheibe ausbauen.
Protecting the drive shaft.

Remove retaining ring and shim.
Blechschraube in die mit Gummi gefüllten

Löcher eindrehen.
Mit Zange WDR herausziehen.
Screw in sheet metal screw into the holes

fitted with rubber.
Pull out seal with pliers.
Wellendichtring und Scheibe mit Montagehülse

einpressen.
Zwischen Dicht- und Staublippe, Wellendichtring
* leicht einfetten
Einpresstiefe beachten! * Marke für Einpresstiefe.
Sicherungsring einbauen.
Press in shaft seal ring and shim with bush to stop.

Take note of press-in depth!
Lightly grease the seal, dust lips and shaft seal ring.
Install * mark for press-in depth of safety ring.
406 BOMAG 008 915 04

RDE 91 604-01-R/03.03
17
Steuerteile abdichten
Sealing of the control parts
Achtung!
Federvorspannung
1 Attention!
Spring load
1. Deckel / Cover
2. Steuerteil / Control part
1
Kontrolle
Bohrung im Gehäuse, O-Ring, Nut.
Inspect
Drilling in housing, O-ring, groove.
Einstellschraube nicht ausbauen.

2 Kontrolle
O-Ring, O-Ring-Nut, Gehäuse
Do not remove adjustment screw.

Inspect
O-ring, O-ring groove, housing
Montagehilfe
Stift mit Fett einkleben.
2 Assembly aid
Insert pin with grease.
008 915 04 BOMAG 407

18 A6VM | RDE 91 604-01-R/03.03
Travel motor
Verstellung abdichten
Sealing the hydraulic control
Beispiel: A6VM ... HD Verstellung

Demontageposition:
Deckel Pos. 1 abbauen.
Example: A6VM ... HD control

Pos.1 Disassembly position:
Remove cover pos. 1
1
1. O-Ring
2
2. Stellölzulauf
3. Drosselstift
Einbaulage je nach Steuerteil verschieden.
1. O-ring
2. Input flow of oil control
3. Throttle pin
Installation position differs according to the
3 control components
1
5
1. Stellölzulauf / Input flow of oil control
2 3 2. Hochdruck bzw. Niederdruck / High pressure /
low pressure
3. Hochdruck bzw. Niederdruck / High pressure /
low pressure
4. Lecköl / Leckage oil
4 5. Stellkolben / Control piston
408 BOMAG 008 915 04

RDE 91 604-01-R/03.03
19
Verstellung abdichten
Sealing the hydraulic control
Pos. 2
Beispiel: A6VM ... Verstellung - Differentialkolben

Demontageposition: Deckel Pos. 2 abbauen.
Achtung! Federvorspannung.
Maß x: Maß festhalten (Regelbeginn).
x
Example: A6VM... control - differential piston
Disassembly position: Remove cover pos. 2.
Attention! Spring load.
Dimension x: Note dimension (begin of regulation).
1. O-Ring Kontrolle
1. Check of O-ring
1
2 1. Hochdruck - kleine Stellkolbenseite
* 2. Stelldruck
3. Hochdruck - Rückschlagventil
4. Hochdruck - Rückschlagventil
* siehe Serviceinfo
1. High pressure - small control piston side

2. Control pressure
3
4 3. High pressure - check valve
4. High pressure - check valve
* see serviceinfo
008 915 04 BOMAG 409

20 A6VM | RDE 91 604-01-R/03.03
Travel motor
Abschlußplatte demontieren
Disassembly of the port plate
x Differentialkolben:
Maß X festhalten.
Differential piston:
Note dimension x
Bei "Demontage" der Anschlußplatte

"Triebwerk" immer auf Null schwenken.
Kolbenringe hängen aus der Zylinder-
bohrung aus.
For disassembly of the port plate, swivel

always rotary group to zero position.
Piston rings to hang out of the cylinder
boring.
Qmin-Schraube
Qmin-screw
Qmin-Schraube ausbauen.
Triebwerk auf 0o schwenken.
Remove Qmin-screw.
Swivel rotary group to 0o.
410 BOMAG 008 915 04

RDE 91 604-01-R/03.03
21
x Gleichgangkolben:
Maß X festhalten.
Synchronizing piston:
Note dimension x.
Bei "Demontage" der Anschlußplatte "Triebwerk"

immer auf Null schwenken.
* Kolbenringe hängen sonst aus der Zylinder-
bohrung aus.
Qmin-Schraube
For disassembly of the port plate, swivel always
Qmin-screw
rotary group to zero position.
* Piston rings to hang out of the cylinder boring.
Qmin-Schraube und Verschlußschraube ausbauen.
Remove Qmin-screw and plug.
Mit Schraube Qmin Triebwerk auf 0o schwenken.
Swivel rotary group to zero position with screw Qmin

.
008 915 04 BOMAG 411

22 A6VM | RDE 91 604-01-R/03.03
Travel motor
Anschlußplatte
Lage markieren. Schrauben lösen.
Abbauen
Port plate
Mark position. Loosen screws.
Removal
O-Ring austauschen.
Neuer O-Ring mit etwas Fett einkleben.
Triebwerk nicht ausschwenken.
Kolbenringe hängen aus der Zylinderbohrung aus.
Check O-ring.
Stick new O-ring with some grease.
Do not swivel rotary group.
Piston rings to hang out from the cylinder boring.
Steuerlinse in Gleitbahn mit Fett einkleben.

Fertigmontage in umgekehrter Reihenfolge.
Anschlußplatte aufsetzen.
Triebwerk senkrecht.
Stick control lens in sliding surface with grease.

Assembly in reversal order.
Mount port plate.
Rotary group vertical.
412 BOMAG 008 915 04

Travel motor 13.2
008 915 04 BOMAG 413

13.2 Travel motor
414 BOMAG 008 915 04

RDE 91 604-01-R/03.03
25
Triebwerk ausbauen
Remove rotary group
Gewindestift in Mittelzapfen einschrauben,

mit Schutzscheibe und Mutter Zylinder befestigen.
Qmax - Anschlagschraube ausbauen.
Screw in threaded pin into center pin.

Fix the cylinder with disc and locknut.
Remove Qmax -stop screw.
Nenngröße / Size 28 : M4 x 60 mm
55 : M5 x 80 mm
80 : M6 x 90 mm
107 : M6 x 100 mm
140 : M8 x 110 mm
160 : M8 x 110 mm
200 : M8 x 110 mm
Triebwerk auspressen!
Bei Wiederverwendung der Lager nicht schlagen.
Press out rotary group!

If the bearings are used again do not hit on the drive
shaft.
008 915 04 BOMAG 415

26 A6VM | RDE 91 604-01-R/03.03
Travel motor
Triebwerk ausbauen
Remove rotary group
Oder mit Abziehvorrichtung ausdrücken.
Or press-out with extraction device.
416 BOMAG 008 915 04

RDE 91 604-01-R/03.03
27
Triebwerk austauschen
Exchanging of the rotary group
eingepresst
pressed in
Triebwerk komplett
Abstimmung hydraulischer
Teil notwendig.
Complete rotary group

Setting of hydraulic part
necessary.
Triebwerk Baugruppe
1.Mechanischer Teil: Triebwelle mit Lager abgestimmt.
2.Hydraulischer Teil: Abstimmung notwendig *.
Rotary group
1. Mechanical part: Adjust drive shaft with bearing.
2. Hydraulic part: Adjustment necessary *.
Triebwerk: Alle Bauteile

* Abstimmung
Abstimmwerte, Drehmomente siehe Serviceinfo.
Rotary group: All parts

* Setting
Setting value, torque see service information.
008 915 04 BOMAG 417

28 A6VM | RDE 91 604-01-R/03.03
Travel motor
Triebwerk austauschen
Exchanging of the rotary group
Befestigungsschraube (Zylinder) ausbauen.

Zylinder abheben.
Remove fixing screw (cylinder).

Remove cylinder.
Rückzugplatte demontieren.
Schrauben sind eingeklebt. Nach Erwärmen auf
max 120o C mit Torx-Werkzeug demontieren.
Disassemble retaining plate.

Screws are glued. Warm it up to max. 120o C
and remove with Torx-tools.
418 BOMAG 008 915 04

RDE 91 604-01-R/03.03
29
Überprüfungshinweise
Inspection notes
Kein Passungsrost, nicht ausgeschlagen.
Free of corrosion, erosion or fretting;

no damage to splines or keyways.
Kolben
Riefenfrei und keine Pittings.
Pistons
No scoring and no pittings.
1 2
Mittelzapfen
Riefenfrei und keine Pittings.
Center pin
No scoring and no pittings.
Rückzugplatte
Riefenfrei und keine Ausbrüche.
Retaining plate
No scoring and no evidence of wear
Zylinder / Steuerlinse
1 Bohrungen riefenfrei, nicht ausgelaufen.
2 Gleichmäßiges Tragbild, riß- und riefenfrei.
Cylinder block / control lens

1 Bores free of scoring, no evidence of wear.
2 Faces smooth and even, free of cracks
and scoring.
008 915 04 BOMAG 419

30 A6VM | RDE 91 604-01-R/03.03
Travel motor
Überprüfungshinweise
Inspection notes
Reglergehäuse
Gleitbahn und Seitenführung riefenfrei,
nicht ausgelaufen.
Control housing
Sliding surface and side guides free of scoring
and no wear.
Sichtkontrolle:
Im Lagerbereich riefenfrei und keine Einlaufspuren.
Visual check:
Bearing areas free of scoring and no evidence
of wear.
420 BOMAG 008 915 04

RDE 91 604-01-R/03.03
31
Triebwerk montieren / siehe Serviceinformation

Rotary group assembly / see service information
Triebwelle: mechanischer Teil

Rotary group: mechanical part
1 Abstimmung Maß * und Lagerdrehmomente

siehe Serviceinfo.
2
* Adjustment dimension * and bearing torque
see service infoprmation.
Lager aufpressen.
Beim Aufpressen Lagerdrehmoment nicht
überschreiten.
Press on bearing.
Do not exeed bearing torque during press-on.
BOJH
GG
DRTT
GHE
000
000
BOJH
GG
DRTT
GHE
Lager mit Montagehülse vorspannen und laufende Drehmomentenkontrolle.
Preload bearing with assembly sleeve and steady control of the torque.
008 915 04 BOMAG 421

32 A6VM | RDE 91 604-01-R/03.03
Travel motor
Triebwerk montieren
Rotary group assembly
Sicherungsring 1 montieren.
Maß * für Abstimmscheibe mit Endmaß ermitteln
(überkreuz).
Abstimmscheibe einbauen.
Sicherungsring montieren.
1 Assemble safety ring.

Determine dimension * for adjustment disc with fi-
* nal dimensions (crossover)
Install adjustment shim.
Assemble safety ring.
Triebwelle einbaufertig.
Drive shaft ready for assembly.
422 BOMAG 008 915 04

RDE 91 604-01-R/03.03
33
Triebwerk montieren
Rückzugplatte mit Kolben und Mittelzapfen

einsetzen.
Schrauben mit Precote-Beschichtung verwenden.
(Anziehdremoment siehe Seite 42).
Insert retaining plate with piston and center pin.

Use screw with Precote-coating.
(Tightening torque see page 42).
Auf richtige Schichtung aller Teile achten.
Make sure all parts are fitted in correctly.
Triebwerk auf Null schwenken und Zylinder mit

Gewindestift befestigen. (siehe Seite 25)
Swivel cylinder block to zero position and fix the

cylinder with a threaded pin (see page 25)
008 915 04 BOMAG 423

34 A6VM | RDE 91 604-01-R/03.03
Travel motor
Triebwerk montieren
Triebwerk komplett zum Einbau fertig.
Rotary group completely assembled ready

for assembly.
Montagehülse montieren.
Place assembly sleeve.
Gehäuse auf 80oC erwärmen.
Warm up housing to 80oC.
424 BOMAG 008 915 04

RDE 91 604-01-R/03.03
35
Triebwerk montieren
Triebwerk ins Gehäuse auf Anschlag einsetzen.
Insert rotary group into housing to seat position.
Nach Einbau des Triebwerks im Gehäuse ist die

Triebwelle bis auf Anschlag nach vorne zu ziehen.
Pull the drive shaft after rotary groupassembly into

housing to seat position.
2 1
Zylinder in Nullposition
ausrichten.
1. Zylinderbefestigungsschraube
demontieren.
2. O-Ring einsetzen.
Fix zero position of cylinder

with Qmax-screw.
1. Disassemble cylinder
fixing screw.
2. Insert O-ring.
008 915 04 BOMAG 425

36 A6VM | RDE 91 604-01-R/03.03
Travel motor
Triebwerksabstimmung (siehe Serviceinfo)

Rotary group adjustment (see service information)
Mit Schraube Zylinderausschwenkung

vermitteln.
Determine cylinder swivel range to

max. angle with screw.
* * Scheibe
* Disc
Zentrierscheibe aufsetzen.
Place centering disc.
Meßvorrichtung aufbauen.
Mount measuring device.
Maß X überprüfen.
Check dimension X.
426 BOMAG 008 915 04

RDE 91 604-01-R/03.03
37
Abschlußplatte montieren
Assembly of the port plate
1. Anschlußplatte mit Differential-

* kolben montieren.
Montageausführung beachten!
Befestigungsschrauben mit
Drehmoment anziehen.
2. Triebwerk in "Ausgangsstellung"
schwenken.
3. Qmin -Schraube auf
Maß * einstellen.
4. Verschlußschraube einbauen.
5. Montagehülse demontieren.
1. Assemble port plate with

differential piston.
Take care of assembly design!
Tighten fixing screws
with torque.
2. Swivel rotary group to "starting
position".
3. Set Qmin -screw to
dimension*.
4. Assemble plug.
5. Remove assembly sleeve.
Deckel montieren.
Assemble cover.
Steuerteil montieren.
x
Assemble control components.
008 915 04 BOMAG 427

38 A6VM | RDE 91 604-01-R/03.03
Travel motor
Anschlußplatte montieren
Assembly of the port plate
1. Anschlußplatte mit Gleichgang-

kolben montieren.
Montageausführung beachten!
Befestigungsschrauben mit
* Drehmoment anziehen.
2. Triebwerk in "Ausgangsstellung"
schwenken.
3. Qmin -Schraube auf Maß * einstellen.
4. Verschlußschraube einbauen.
5. Montagehülse demontieren.
1. Assemble port plate with

synchronizing piston.
Take care of assembly design!
Tighten fixing screws
with torque.
2. Swivel rotary group to "starting
position".
3. Set Qmin -screw to dimension*.
4. Assemble plug.
5. Remove assembly sleeve.
Wellendichtring, Scheiben und Sicherungsring

montieren.
Mit Montagehülse einpressen.
Dicht- und Staublippe, Wellendichtring leicht
einfetten.
Einpresstiefe beachten!
Assemble shaft seal, disc and safety ring.

Press-in with assembly sleeve.
Lightly grease the seal, dust lips and shaft seal ring.
Take care of press-in depth.
428 BOMAG 008 915 04

RDE 91 604-01-R/03.03
39
Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques
1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)
Die Werte gelten für Schaftschrauben mit metrischen The values stated are valid for bolts with metric ISO threads
ISO-Gewinde nach DIN 13 Teil 13, sowie Kopfauflage- to DIN 13 part 13, as well as head areas to DIN 912 socked
maßen nach DIN 912 Zylinderschrauben, DIN 931 head cap screws, DIN 931 hexagon bolt or
Sechskantschrauben mit Schaft bzw. DIN 933 hexagon bolts with threads up to the head.
DIN 933 Sechskantschrauben mit Gewinde bis Kopf.
Festigkeitsklassen / Tensile strength class

Gewinde / Thread 8.8 10.9 12.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 1,1 1,6 1,9
M4 3,1 4,5 5,3
M5 6,1 8,9 10,4
M6 10,4 15,5 18
M8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240
008 915 04 BOMAG 429

40 A6VM | RDE 91 604-01-R/03.03
Travel motor

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).
G
EOLASTIC-
Dichtung / Seal
Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1,5 20 G 3/8 A 35
M14 x 1,5 30 G 1/2 A 60
M16 x 1,5 35 G 3/4 A 90
M18 x 1,5 40 G1 A 140
M20 x 1,5 50 G 1 1/4 A 240
M22 x 1,5 60 G 1 1/2 A 300
M26 x 1,5 70
M27 x 2 90
M30 x 1,5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300
430 BOMAG 008 915 04

RDE 91 604-01-R/03.03
41

5. Verschlußschrauben mit Innensechskant, 5. Plugs with internal hexagon, O-ring and UNF-,
O-Ring und UNF-, UN-Gewinde nach SAE J 514 UN- threads to SAE J 514 (nach N 02.106)
(nach N 02.106)
G
O-Ring / O-ring seal
Dichtung / Thread
Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
7/16 - 20 UNF 15 M12 x 1,5 20
1/2 - 20 UNF 20 M14 x 1,5 30
9/16 - 18 UNF 25 M27 x 1,5 90
3/4 - 16 UNF 72
7/8 - 14 UN 127
1 1/16 -12 UN 147
1 3/16 -12 UN 173
1 5/16 -12 UN 198
1 5/8 -12 UN 320
1 7/8 -12 UN 390
008 915 04 BOMAG 431

42 A6VM | RDE 91 604-01-R/03.03
Travel motor

6. Linsenschrauben mit Innen-TORX, Gewindevor- 6. Oval head screw with inner TORX, thread precoated with
beschichtung mit "precote" "precote"
precote 80 - Rot / Red

Standard / Standard
precote 86 - Blau / Blue

Variante / Variant
* * mit Unterkopfbeschichtung - farblos
Ι 2602493 M5 x 16
Ι 2602395 M6 x 20
* with head bottom coating - colorless
siehe Stückliste / as to parts list
Festigkeitsklassen / Tensile strength class

Gewinde / Thread 10.9
Anziehdrehmoment / Tightening torque MA in Nm
M3 2,1
M4 4,7
M5 9,1
M6 15,8
M8 37,7
7. SEAL-LOCK-Dichtmuttern (nach N 02.100) 7. SEAL-LOCK - sealing nuts (to N 02.100)
Gewinde / Anziehdrehmoment MA in Nm
Thread Tightening torque MA in Nm
M6 10
M6 x 0,5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1,5 72
M14 110
M14 x 1,5 120
M16 170
M16 x 1,5 180
432 BOMAG 008 915 04

RDE 91 604-01-R/03.03
43

A6V - Stellkolben / positioning piston

für / for A6V / A7V / A7F / A8V)
Anziehdrehmoment MA für Gewindestift (1) / Anziehdrehmoment MA für Schraube (2) /

Tightening torque MA for threaded pin (1) Tightening torque MA for shaft bolts (2)
(Verbindung: Stellkolben und Stellzapfen / (Verbindung: Stellkolben und Stellzapfen für A6V
Connection: Positioning piston and positioning trunnion Connection: Positioning piston and piston for A6V
M6 : 8,5 Nm M14 x 1,5 : 120 Nm

M8 : 14,0 Nm
M10 : 30,0 Nm
M12 : 52,0 Nm
008 915 04 BOMAG 433

44 A6VM | RDE 91 604-01-R/03.03
Travel motor
Sicherheitsbestimmungen
Safety regulations
Allgemein General advice
● Machen Sie sich mit der Ausstattung der Maschine ● Make yourself familiar with the equipment of the
vertraut. machine.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den ● Only operate the machine if your are completely familiar with
Bedien- und Steuerelementen sowie der Arbeitsweise der the operating and control elements as well as the functioning
Maschine vertraut gemacht haben. of the machine.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, ● Use your safety equipment like helmet, safety shoes and
Sicherheitsschuhe und Gehörschutz. hearing protection.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ● Make yourself familiar with your working field.
● Benutzen Sie die Maschine nur für den ihr zugedachten ● Only operate the machine for its intended purpose.
Zweck.
Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.
Vor dem Start Before starting
● Beachten Sie die Bedienungshinweise vor dem Starten. ● Observe the operating instructions before starting.
● Prüfen Sie die Maschine auf auffällige Fehler. ● Check the machine for remarkable faults.
● Fahren Sie die Maschine nicht mit defekten Instrumenten, ● Do not operate the machine with defective instruments,
Kontrolleuchten oder Steuerorganen. warning lights or control elements.
● Alle Schutzvorrichtungen müssen fest auf ihrem Platz sein. ● All safety devices must be in a secure position.
● Nehmen Sie keine losen Gegenstände mit bzw. befestigen ● Do not carry with you movable objects or secure them to the
Sie diese an der Maschine. machine.
● Halten Sie die Maschine von öligem und zündfähigem ● Keep oily and inflammable material away from the machine.
Material frei. ● Before entering thc driver’s cabin, check if personsor
● Prüfen Sie vor dem Besteigen der Maschine, ob sich obstacles are beside or beneath the machine.
Personen oder Hindernisse neben oder unter der Maschine ● Be careful when entering the driver’s cabin, use stairs and
befinden. handles.
● Vorsicht beim Besteigen der Maschine, benützen Sie ● Adjust your seat before starting.
Treppen und Griffe.
● Stellen Sie vor dem Start Ihren Sitz ein.
434 BOMAG 008 915 04

RDE 91 604-01-R/03.03
45
Sicherheitsbestimmungen
Safety regulations
Starten Start
● Beim Starten müssen alle Bedienhebel in “Neutralstellung” ● When starting all operating levers must be in “neutral position”.
stehen. ● Only start the machine from the driver’s seat.
● Die Maschine nur vom Fahrersitz aus Starten. ● Check the indicating instruments after start to assure that all
● Prüfen Sie die Anzeigeinstrumente nach dem Start, um functions are in order.
sicher zu gehen, daß alles ordnungsgemäß funktioniert. ● Do not leave the machine unobserved when the motor is
● Lassen Sie die Maschine nicht unbewacht, während running.
der Motor läuft. ● When starting with battery connection cables connect plus
● Beim Start mit Batterieverbindungskabeln verbinden Sie Plus with plus and minus with minus. Always connect mass cable
mit Plus und Minus mit Minus. Massekabel (Minus) immer (minus) at last and cut off at first.
zuletzt anschliesen und zuerst abtrennen.
Vorsicht Attention
● Auspuffgase sind lebensgefährlich. Bei Start in ● Exhaust gas is dangerous. Assure sufficient fresh air when
geschlossenen Räumen für ausreichende Luftzufuhr starting in closed rooms!
sorgen!
Hydraulikanlage Hydraulic equipment

1. Hydraulikanlage steht unter hohem Druck! 1. Hydraulic equipment is standing under high pressure.
Unter hohem Druck austretende Hochdruck- Flüssig- High pressure fluids (fuel, hydraulic oil) which escape
keiten (Kraftstoff, Hydrauliköl) können die Haut durch- under high pressure can penetrate the skin and cause
dringen und schwere Verletzungen verursachen. Daher heavy injuries. Therefore immediately consult a doctor as
sofort einen Arzt aufsuchen, da anderenfalls schwere otherwise heavy infections can be caused.
Infektionen entstehen können! 2. When searching leakages use appropriate auxiliary devices
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr because of the danger of accidents.
geeignete Hilfsmittel verwenden! 3. Before working at the hydraulic equipment, lower pressure
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt to zero and lower working arms of the rnachine.
drucklos machen und angebaute Geräte absenken! 4. When working at the hydraulic equipment, absolutely stop
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor motor and secure tractor against rolling away (parking brake,
abstellen und Traktor gegen Wegrollen sichern shim)!
(Feststellbremse, Unterlegkeil)! 5. When connecting hydraulic cylinders and motor pay attention
5. Beim Anschließen von Hydraulikzylindern und -motoren ist to correct connection of hydraulic flexible hoses.
auf vorgeschriebenen Anschluß der Hydraulikschläuche zu 6. In case of exchanging the ports, the tunctions are vice versa
achten! (f. ex. lift-up/lower) - danger of accidents!
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen 7. Check hydraulic flexible hoses regularly and replace them in
(z.B. Heben/Senken) - Unfallgefahr! case of dammage or wear! The new hose pipes must comply
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und bei with the technical requirements of the machine manufacturer!
Beschädigung und Alterung austauschen! Die Austausch-
schlauchleitungen müssen den technischen Anforderungen Orderly disposal or recycling of oil, fuel and
des Geräteherstellers entsprechen! filters!
Öle, Kraftstoffe und Filter ordnungsgemäß

entsorgen!
008 915 04 BOMAG 435

46 A6VM | RDE 91 604-01-R/03.03
Travel motor
Inbetriebnahme
Operating instruction
Einstellüberprüfung Setting test

(Regelbeginn von Vg max - Vg min ) (Begin of regulation of Vg max - Vg min )
z.Beispiel HD e.g HD
X - 10 bar
Einstellschraube - Regelbeginn / P
Set screw - begin of control
Vg min
G
X
Betriebsdruck /
Operating
pressure
~ P/2
1:2
M1
Stelldruck /
Control pressure
Sicherheitsbestimmungen beachten! Observe safety regulations!
Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake).
A6VM - HD Vg max - Vg min A6VM - HD Vg max - Vg min
● Manometer "G" = 600 bar ● Pressure gauge "G" = 600 bar

● Manometer "M1" = 600 bar ● Pressure gauge "M1" = 600 bar
● Manometer "X" = 60 bar ● Pressure gauge "X" = 60 bar
Regelbeginn / Einstellung Begin of regulation / Setting
Beispiel: 10 bar Steuerdruck an X Example: 10 bar pilot pressure at X
Manometer an M1 beachten! Observe pressure gauge at M1!

Druckwert an X erhöhen bis an M1 die Hälfte Increase pressure value at X till half the pressure is generated
des Druckes von G ansteht ♦ Regelbeginn from G ♦ Begin of regulation
Einstellschraube im Uhrzeigersinn ♦ Regelbeginn Setscrew turned clockwise ♦ Begin of regulation earlier

früher
Setscrew turned anti-clockwise ♦ Begin of regulation later
Einstellschraube gegen Uhrzeigersinn ♦ Regelbeginn
später
436 BOMAG 008 915 04

RDE 91 604-01-R/03.03
47
Inbetriebnahme

(Regelbeginn von Vg max - Vg min ) (Begin of regulation of Vg max - Vg min )
z.Beispiel EP e.g EP
Einstellschraube - Regelbeginn /
Set screw - Begin of control
P
Vg min
Betriebsdruck /
Operating pressure
~ P/2
1:2
M1
Stelldruck /
Control pressure

Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake).
A6VM - EP Vg max - Vg min A6VM - HD Vg max - Vg min
● Manometer "G" = 600 bar ● Pressure gauge "G" = 600 bar

● Manometer "M1" = 600 bar ● Pressure gauge "M1" = 600 bar
● Magnet = Multimessgerät ● Solenoid = multi measuring device
Regelbeginn / Einstellung Begin of regulation / Setting
Beispiel: 200/400 mA Example: 200/400 mA
Manometer an M1 beachten! Observe pressure gauge at M1!

Strom erhöhen bis an M1 die Hälfte Increase current till half the pressure is generated
des Druckes von G ansteht ♦ Regelbeginn from G ♦ Begin of regulation
Einstellschraube im Uhrzeigersinn ♦ Regelbeginn Setscrew turned clockwise ♦ Begin of regulation earlier

früher
Setscrew turned anti-clockwise ♦ Begin of regulation later
Einstellschraube gegen Uhrzeigersinn ♦ Regelbeginn
später
008 915 04 BOMAG 437

48 A6VM | RDE 91 604-01-R/03.03
Travel motor
Inbetriebnahme

(Regelbeginn von Vg min - Vg max ) (Begin of regulation of Vg min - Vg max )
z.Beispiel HA z.Beispiel HA
Vg min X M1
Stelldruck /
Control
pressure
1:2
Einstellschraube - Regelbeginn / G
Set screw - Begin of control Betriebsdruck /
Operating
pressure
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake)
Manometer 600 bar an G und M1 anschließen. Connect pressure gauge 600 bar at G and M1
Beispiel 1: Example 1:
Regelbeginn 200 bar, Begin of regulation 200 bar
Betriebsdruck langsam erhöhen bis Manometer an G 200 bar Increase service pressure slowly till pressure gauge at
Stelldruck Manometer M1 G = 200 bar
1 /2 des Betriebsdruckes = ca. 100 bar Positioning pressure gauge M1
♦ Regelbeginn 1/2 of the sevice pressure = approx. 100 bar.
Nachjustierung des Stelldruckes an ♦ Begin of control
Einstellschraube - Regelbeginn Readjust positioning pressure at set screw - start of control
Hinweis: Note:
Drehen im Uhrzeigersinn - Regelbeginn früher. Clockwise turning - begin of regulation earlier
Drehen gegen Uhrzeigersinn - Regelbeginn später. Anti-clockwise turning - begin of regulation later
Beispiel 2: Example 2:
Bei Anlagen mit zwei oder mehr Motoren z. B. Raupenfahrzeuge In systems with two or more motors, e.g. tracked vehicles,
kann folgende Einstellung zusätzlich erfolgen. the following setting may be carried out additionally.
Kontermutter von Einstellschraube Vgmin lösen - Remove safety cap from the setscrew Vg min - do not disturb
Einstellschraube nicht verdrehen. Maß X festhalten. setscrew.
Betriebsdruck langsam erhöhen bis Manometer an G 200 bar Increase service pressure slowly till pressure gauge is indicating
anzeigt. 200 bar at G.
Kontrolle: Einstellschraube Vg min "fest" (Steuerlinse wird gegen Verification: Vg min "fixed" (lens plate is pressed against setscrew).
die Einstellschraube gedrückt). Up from 200 bar service pressure the screw is becoming
Ab 200 bar Betriebsdruck wird die Schraube "lose" "movable".
(Steuerlinse schwenkt Richtung Vg max). (lens plate is stroking to direction Vg max).
♦ Regelbeginn ♦ Begin of control
Achtung! Attention
Einstellwert Vg min -Schraube nicht verändern. Do not modify setting data of Vg min screw.
Hinweis: Nachjustierung an Einstellschraube- Regelbeginn Note: Readjustment at the set screw - begin of regulation
438 BOMAG 008 915 04

RDE 91 604-01-R/03.03
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Inbetriebnahme
Einstellüberprüfung (Regelbeginn) G1
DA1/4, DA2,3,4,5,6 X3 Einstellschraube - Regelbeginn
Vg min
5/8
100
1:2
M1
DA1, DA2, DA3 = PST / PHD 5 / 100
DA4, DA5, DA6 = PST / PHD 8 / 100 Stelldruck
Beispiel: Betriebsdaten nach Geräteblatt

Verstellbeginn Vg min - Vg max bei 20 bar Steuerdruck X3
und 220 bar Betriebsdruck
● Manometer G = 600 bar Betriebsdruck

● Manometer X3 = 60 bar Steuerdruck
● Manometer M1 = 600 bar Stelldruck G
Fahrzeug beladen, Straßengang, Fahren (max. Geschwindigkeit
= max. Steuerdruck)
Manometer M1 beobachten, anbremsen für Druckaufbau an
"G", ab 220 bar Betriebsdruck baut sich Druck an M1 ab.
♦ Regelbeginn P/2.
DA1, DA2, DA3 PSt / PSt 5/100
X3 G M1 = 1/2 Betriebsdruck (Regelbeginn)

20 bar 200 bar 200 bar = Vg min
20 bar 220 bar 110 bar = Regelbeginn Vg min ♦ Vg max
20 bar 240 bar 0-50 bar = Vg max
* Einstellschraube - Regelbeginn - Drehen im Uhrzeigersinn - Regelbeginn später
nur 1/8 Umdrehung verstellen ♦ kontrollieren

X3 G M1
20 bar 207,5 bar 207,5 bar = Vg min M1
20 bar 220 bar 110 bar = Vg min ® Vg max
20 bar 225 bar 0 bar = Vg max Stelldruck
008 915 04 BOMAG 439

50 A6VM | RDE 91 604-01-R/03.03
Travel motor
Inbetriebnahme
Setting test (Begin of Regulation) G1

DA1/4, DA2,3,4,5,6 X3
Setscrew - Begin of control
Vg min
5/8
100
1:2
M1
DA1, DA2, DA3 = PST / PHD 5 / 100
DA4, DA5, DA6 = PST / PHD 8 / 100 Control
pressure
X3
Example: Operation data as to machine specification sheet
Begin of regulation Vg min - Vg max at 20 bar pilot pressure
and 220 bar service pressure
G
● Pressure gauge G = 600 bar service pressure
● Pressure gauge X3 = 60 bar pilot pressure
● Pressure gauge M1 = 600 bar positioning pressure
Load vehicle, travel mode, travel (max. speed = max. pilot pressure
Observe pressure gauge M1, declarate at "G" for pressure generation,
up from 220 bar service pressure pressure at M1 is dropping.
♦ begin of regulation P/2.

X3 G M1 = 1/2 service pressure (begin of regulation)
20 bar 200 bar 200 bar = Vg min
20 bar 220 bar 110 bar = begin of regulation Vg min ♦ Vg max
20 bar 240 bar 0-50 bar = Vg max
* Setscrew - begin of regulation - turn clockwise - begin of regulation later
displace by 1/8 turn only ♦ verification

X3 G M1
20 bar 207,5 bar 207,5 bar = Vg min M1
20 bar 220 bar 110 bar = Vg min ♦ Vg max
20 bar 225 bar 0 bar = Vg max Control
pressure
440 BOMAG 008 915 04

RDE 91 604-01-R/03.03
51
008 915 04 BOMAG 441

13.2 Travel motor
Brueninghaus Hydromatik GmbH

Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
info.brm@boschrexroth.de
www.boschrexroth.com/brm
© 2003 by Brueninghaus Hydromatik © 2003 by Brueninghaus Hydromatik

GmbH, 89275 Elchingen GmbH, 89275 Elchingen
All rights reserved. No part of this Alle Rechte vorbehalten. Kein Teil des
document may be reproduced or Werkes darf in irgendeiner Form ohne
stored, processed, duplicated or vorherige schriftliche Zustimmung der
circulated using electronic systems, in Brueninghaus Hydromatik GmbH
any form or by any means, without the reproduziert oder unter Verwendung
prior written authorization of Bosch elektronischer Systeme gespeichert,
Rexroth AG. In the event of verarbeitet, vervielfältigt oder verbreitet
contravention of the above provisions, werden. Zuwiderhandlungen
the contravening party is obliged to verpflichten zu Schadensersatz.
pay compensation. Die angegebenen Daten dienen allein
The data specified above only serve to der Produktbeschreibung. Eine
describe the product. No statements Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
given information does not release the werden. Die Angaben entbinden den
user from the obligation of own Verwender nicht von eigenen
judgement and verification. It must be Beurteilungen und Prüfungen. Es ist zu
remembered that our products are beachten, dass unsere Produkte einem
subject to a natural process of wear natürlichen Verschleiß- und
and aging. Alterungsprozess unterliegen.
Printed in Germany
RDE 91 604-01-R/03.03
442 BOMAG 008 915 04

13.3 Travel gear
008 915 04 BOMAG 443

13.3 Travel gear
444 BOMAG 008 915 04

Travel gear 13.3
RIDUTTORE PER COMANDO RUOTA

WHEEL DRIVE
6 06 Y 3 LB S011 B 32 I3 5EW90-S02 VAM
CODICE
CODE 2T255608241A
Manuale di installazione, uso

e manutenzione
Installation, operation and maintenance

manual
Emissione:
02/2007
Issue:
Aggiornamento - data:
Revision - date: 0.0 - 14/02/2007
Compilatore:
Ufficio tecnico commerciale: Prepared by: .............................................................
Technical and commercial dept: Approvato da:
Approved by: ............................................................
008 915 04 BOMAG 445

13.3 Travel gear
-2-
446 BOMAG 008 915 04
Travel gear 13.3
INDICE INDEX
1. INFORMAZIONI GENERALI 1. GENERAL INFORMATIONS

1.1. Scopo del manuale ........................................... 2 1.1. Manual aim ...................................................... 2
1.2. Identificazione del prodotto ............................... 3 1.2. Product identification........................................ 3
1.3. Modalità di richiesta assistenza ........................ 3 1.3. Requesting assistance ..................................... 3
1.4. Informazioni sulla sicurezza.............................. 4 1.4. Informations on safety...................................... 4
1.5. Modalità di consegna ........................................ 5 1.5. Delivery methods ............................................. 5
1.6. Modalità di imballaggio ..................................... 5 1.6. Packaging methods ......................................... 5
1.7. Sollevamento e movimentazione ...................... 6 1.7. Lifting and handling ......................................... 6
1.8. Modalità di magazzinaggio ............................... 7 1.8. Storage methods.............................................. 7
2. INFORMAZIONI TECNICHE 2. TECHNICAL INFORMATIONS

2.1. Descrizione del prodotto ................................... 8 2.1. Product description .......................................... 8
3. INFORMAZIONI SULL’INSTALLAZIONE 3. INSTALLATION INFORMATIONS

3.1. Procedure per l’installazione........................... 11 3.1. Installation procedure..................................... 11
3.2. Installazione del motore idraulico.................... 12 3.2. Hydraulic motor installation ............................ 12
3.3. Installazione del motoriduttore 3.3. Installation of the wheel drive
sulla macchina 13 on the machine ............................................... 13
3.4. Fissaggio ruota al motoriduttore ..................... 13 3.4. Fixing of the wheel to the gearmotor.............. 13
3.5. Collegamento del freno................................... 14 3.5. Connecting the brake..................................... 14
3.6. Caratteristiche olio lubrificazione 3.6. Characteristics of oil forced
forzata freno 15 brake lubrication 15
3.7. Riempimento olio lubrificante del riduttore...... 16 3.7. Filling-up the gearbox with lubricating oil ....... 16
3.8. Prima messa in esercizio e rodaggio .............. 18 3.8. First start up and running in ........................... 18
4. INFORMAZIONI SULLA MANUTENZIONE 4. MAINTENANCE INFORMATIONS

4.1. Manutenzione periodica.................................. 19 4.1. Periodic maintenance .................................... 19
4.2. Sostituzione dell'olio lubrificante ..................... 20 4.2. Changing the lubricating oil............................ 20
4.3. Ricerca guasti ................................................. 21 4.3. Troubleshooting ............................................. 21
4.4. Smontaggio del motoriduttore......................... 22 4.4. Motorgearbox disassembly ............................ 22
4.5. Fasi di smontaggio.......................................... 25 4.5. Disassembling method................................... 25
4.6. Fasi di smontaggio riduttore............................ 25 4.6. Gearbox disassembly method ....................... 25
4.7. Fasi di smontaggio gruppo riduttore ............... 29 4.7. Gearbox kit disassembly method ................... 29
4.8. Fasi di smontaggio gruppo freno .................... 36 4.8. Brake kit disassembly method ....................... 36
4.9. Valutazione dei pezzi da sostituire.................. 41 4.9. Evaluating that pieces to replace ................... 41
4.10.Fasi di rimontaggio gruppo freno .................... 42 4.10.Brake kit reassembling method...................... 42
4.11.Fasi di rimontaggio gruppo riduttore ............... 48 4.11.Gearbox kit reassembling method ................. 48
4.12.Fasi di rimontaggio riduttore ........................... 57 4.12.Gearbox reassembling method ...................... 57
4.13.Controllo finale e reinstallazione ..................... 64 4.13.Final test and reinstallation ............................ 64
4.14.Dismissione e rottamazione del prodotto........ 65 4.14.Dismantling and destroying the product......... 65
INDICE -1- INDEX

008 915 04 BOMAG 447
13.3 Travel gear
1. INFORMAZIONI GENERALI 1. GENERAL INFORMATIONS
1.1. Scopo del manuale 1.1. Manual aim
Questo manuale è stato realizzato dal costruttore per This manual has been realized by the manufacturer to
fornire le informazioni necessarie a coloro che sono give necessary information to those authorised to work
autorizzati ad interagire con il prodotto: dai progettisti, on this product for example the design engineers,
agli installatori, manutentori e riparatori. installers, repair and maintenance technicians.
Oltre ad adottare le regole della buona tecnica di Besides helping one understand the rules of good
costruzione, le informazioni devono essere lette manufacturing techniques used, the information given
attentamente ed applicate in modo rigoroso. must be read attentively and strictly put into action.
La non osservanza di dette informazioni può essere Failure to observe this information may lead to health
causa di rischi per la salute e la sicurezza delle and safety risks to persons as well as economic loss.
persone e danni economici.
This information was compiled by the Italian
Queste informazioni sono state realizzate dal manufacturer in his original language (Italian) and can
costruttore nella propria lingua originale (italiano) e be translated into other languages to satisfy
possono essere tradotte in altre lingue per soddisfare commercial and/or legal needs.
le esigenze commerciali e/o legislative.
Informazioni Information
La completa e costante osservanza delle indicazioni A strict and consistent compliance with the
contenute nel presente manuale tecnico garantisce specifications of this technical manual ensure the
la migliore economia di esercizio ed una più lunga minimum operating costs and a longer unit life.
durata di funzionamento del motoriduttore.
La documentazione fotografica ed i disegni sono forniti Photographic documentation and drawings are
a scopo esplicativo, in modo da descrivere supplied for educational purposes, so as to safely and
esaurientemente le operazioni da eseguire sul riduttore. properly carry out maintenance operations.
Anche se il riduttore in vostro possesso si discostasse Minor deviations from pictures of this manual may
in parte dalle illustrazioni contenute in questo manuale appear on the actual gearbox. However, these
tecnico, le caratteristiche e la sequenza delle operazioni discrepancies are not relevant to the main parameters,
descritte sono sempre garantite. or maintenance functions.
INFORMAZIONI GENERALI -2- GENERAL INFORMATIONS

448 BOMAG 008 915 04
Travel gear 13.3
1.2. Identificazione del prodotto 1.2. Product identification
I dati per l'identificazione del prodotto sono riportati in The data to identify the product are shown on the
una targhetta applicata su di esso. identification plate attached to it.
Per la richiesta di informazioni, ricambi, For all enquiries regarding general information on
assistenza, ect, fornire sempre i dati identificativi. the product, spare parts, assistance etc, always
give the identification data stamped on the ID
plate.
La targhetta va mantenuta integra per tutta la vita del The plate must not be removed or damaged during the
prodotto. L'illustrazione evidenzia la disposizione dei life of the product. The following illustration shows how
dati. the data is set out.
Identificazione del Costruttore Codice del montatore

Manufacturer’s identification Assembler code
Designazione del prodotto: Rapporto di riduzione

composizione alfanumerica che Reduction ratio
consente di identificare il prodotto.
Product designation: Data di produzione
alphanumeric composition which Date of production
allows identification of the product.
Codice prodotto Codice del prodotto cliente

Trasmital Bonfiglioli Customer product code
Trasmital Bonfiglioli
product code Numero di matricola
Serial number
Codice a barre (tipo 39)
Bar code (type 39)
IDM-15220100300.tif
1.3. Modalità di richiesta assistenza 1.3. Requesting assistance
Per qualsiasi richiesta di assistenza rivolgersi For all requests for assistance please contact the
direttamente alla rete di vendita del costruttore manufacturers’ sales network, directly.

008 915 04 BOMAG 449
13.3 Travel gear
1.4. Informazioni sulla sicurezza 1.4. Informations on safety
Leggere attentamente le istruzioni riportate in questo Carefully read the instructions given in this instruction
manuale e eventualmente quelle applicate manual as well as the ones attached to the product and
direttamente sul prodotto, in particolare rispettare make sure to follow the information concerning safety.
quelle riguardanti la sicurezza.
Personnel, which perform any type of work on the
Il personale che effettua qualsiasi tipo di intervento in product during its life span, must possess precise
tutto l’arco di vita del prodotto, deve possedere precise technical qualifications as well as recognised skills and
competenze tecniche, particolari capacità ed experience gained in the specific sector. Failure to do
esperienze acquisite e riconosciute nel settore so may lead to health and safety risks to persons.
specifico. La mancanza di questi requisiti può causare
It is recommended that when handling the product
danni alla sicurezza e alla salute delle persone.
attention is paid to the information given in this manual
Eseguire la movimentazione del prodotto rispettando and particularly in the sections: “Packaging Methods”
le informazioni riportate in questo manuale nei and “Lifting and handling” or simply follow the
paragrafi "Modalità di imballaggio" e "Sollevamento e instructions given on the packaging (if present).
movimentazione" oppure applicate direttamente
Utilise the product only for the use specified by the
sull’imballo (se presenti).
manufacturer. Improper use of the product could lead
Utilizzare il prodotto solo per gli usi previsti dal to health and safety risks to persons as well as
fabbricante. L’impiego del prodotto per usi impropri economic loss and furthermore will invalidate the
può recare rischi per la sicurezza e la salute delle guarantee given by the manufacturer.
persone e danni economici, nonché il decadere della
Keep the product in perfect working order by following
garanzia da parte del costruttore.
the scheduled maintenance procedure set out by the
Mantenere il prodotto in condizioni di massima manufacturer. Good maintenance will ensure the best
efficienza effettuando le operazioni di manutenzione performances, a longer period of operation and a
programmata previste dal costruttore. Una buona constant safeguard towards security requirements.
manutenzione consentirà di ottenere le migliori
To undertake maintenance procedures in areas which
prestazioni, una più lunga durata di esercizio e un
are hard to reach or otherwise dangerous it is
mantenimento costante dei requisiti di sicurezza.
important to follow adequate safety conditions for one
Per eseguire interventi di manutenzione in zone non self and for others in compliance with the rules and
facilmente accessibili o pericolose, predisporre regulations that govern safety in the workplace.
adeguate condizioni di sicurezza per sé stessi e per gli
When replacing worn parts, use original spare parts.
altri rispondenti alle leggi vigenti in materia di
Use oils and greases recommended by the
sicurezza sul lavoro.
manufacturer. Doing this, will ensure that the product
Sostituire i particolari usurati utilizzando i ricambi works properly and that the safety level is
originali. Usare gli oli e i grassi consigliati dal “acceptable”.
costruttore. Tutto questo potrà assicurare la
funzionalità del prodotto ed un livello di “sicurezza
accettabile”.

450 BOMAG 008 915 04
Travel gear 13.3
1.5. Modalità di consegna 1.5. Delivery methods
I riduttori vengono forniti dalla BONFIGLIOLI Gearboxes are supplied by BONFIGLIOLI

TRASMITAL nelle seguenti condizioni standard: TRASMITAL at the following standard conditions:
– Già predisposti per essere installati nella posizione – Ready for installation in the mounting position
di montaggio come definito in fase d’ordine. specified when ordering.
– Le parti interne, per garantirne l’integrità, sono – To guarantee their reliability, the internal parts are
preventivamente lubrificate con un velo d’olio usato properly lubricated with a layer of oil, the same as
per il collaudo finale del riduttore. Non viene the one used in the final test of the gearbox.
eseguito il riempimento dell’olio lubrificante Lubricating oil has not been added (as shown on
(come segnalato da cartellino). the card).
– Le parti grezze e le superfici di accoppiamento – All unmachined parts and surfaces to be coupled
vengono opportunamente trattate con antiossidanti. are appropriately treated with antioxidants.
– Le superfici esterne sono protette con smalto di – External surfaces are protected with an antioxidant
fondo antiossidante all'acqua di colore grigio e water resistant grey color and painted with a grey
successivamente finite con smalto di colore grigio (i sinthetic finish coat (painting data are shown on the
dati di verniciatura sono riportati nel disegno di installation drawing). Machined surfaces are not
installazione). Le superfici di accoppiamento non painted. The breather plug must not be painted, if
sono verniciate. Il tappo di sfiato se presente, non available.
deve essere verniciato. – Tested to in-house specifications.
– Collaudati secondo specifiche interne. – Appropriately packaged to facilitate handling,
– Appositamente imballati per agevolarne la transport and storage.
movimentazione, il trasporto e lo stoccaggio.
IMBALLO SU PALLET CON TERMORETRAIBILE IMBALLO CON CASSA

PACKAGED ON A PALLET WITH PACKAGED IN A CASE
THERMOSHRINKING FILM
Cartellino che informa

“privo di lubrificante”
Card which states: “does not
contain lubricating oil”
IDM-15220600100.tif
1.6. Modalità di imballaggio 1.6. Packaging methods
Le illustrazioni raffigurano i tipi di imballo più frequenti. The illustrations show the more common types of
packaging.
Al ricevimento del prodotto, accertarsi che When the product arrives, ensure that it meets the
corrisponda alle specifiche di acquisto e che non information contained in the purchase agreement
presenti danni o anomalie. Per qualsiasi and that there are no damages or irregularities. If
inconveniente rivolgersi direttamente alla rete di there are any problems contact the manufacturers’
vendita del costruttore. sales network directly.

008 915 04 BOMAG 451
13.3 Travel gear
1.7. Sollevamento e movimentazione 1.7. Lifting and handling
Se la movimentazione avviene quando il prodotto è If the handling occurs when the product is still
imballato, è sufficiente attenersi alle indicazioni packaged, simply follow the instructions given on the
applicate direttamente sull'imballo e/o comunque packaging and/or use normal hoisting means.
utilizzando i normali mezzi di sollevamento.
Cautela - Precauzione Caution

Considerando che la massa e la forma del prodotto Considering that the size and form of the product
non ne consentono lo spostamento a mano, in does not allow manual shifting, in particular
particolari movimentazioni (es: installazione), è handlings, (e.g. installation) it is necessary to use
necessario utilizzare accessori che consentono di accessories that guarantee human safety and
garantire la sicurezza delle persone ed evitare which also avoid damages to the product.
danni al prodotto.
Per sollevare e movimentare il prodotto, dopo aver To lift and handle the product, after having opened the
aperto l'imballo, attenersi alle seguenti indicazioni: packaging, follow the information given below:
1. Avvitare n° 2 golfari M20 UNI ISO 3266 nei fori 1. Tighten nos. 2 eyebolts M20 UNI ISO 3266 into the
filettati del corpo angolare. thread holes of the right angle housing.
2. Servendosi di un paranco sollevare e movimentare 2. By using a tackle lift and handle with care avoiding
con la massima cautela evitando gli urti. impacts.
Golfare M20 UNI

ISO 3266
Eyebolt M20 UNI
ISO 3266
IDM-15220600200.tif

452 BOMAG 008 915 04
Travel gear 13.3
1.8. Modalità di magazzinaggio 1.8. Storage methods
In fase di magazzinaggio del prodotto adottare le In the storage process of the product follow the safety
precauzioni di seguito indicate. measures given below.
1. Evitare ambienti con eccessiva umidità ed esposti 1. Avoid environments with excessive humidity and
ad intemperie ed escludere aree all'aperto. exposed to changing weather conditions and make
sure that open areas are excluded.
2. Evitare il contatto diretto del prodotto con il suolo.
2. Make sure that the product does not lie directly on
3. Disporre il prodotto in modo che abbia una base di
the ground.
appoggio stabile e verificare che non sussistano
rischi di spostamenti imprevisti. 3. Make sure that the product is placed on a stable
base thereby avoiding that the product moves
4. Accatastare il prodotto imballato (se consentito)
about unexpectedly.
seguendo le indicazioni riportate sull'imballo stesso.
4. Stack the packaged product (if allowed) following
Per periodi di magazzinaggio previsti superiori a 6
the indications given on the packaging itself.
mesi, verificare ed eventualmente eseguire le seguenti
operazioni. For storing periods that go beyond 6 months, check
and consult the following procedures.
5. Per evitare ossidazioni, ricoprire tutte le parti
esterne lavorate con grasso. 5. To avoid oxidation, cover all the worked external
parts with grease.
6. Riempire completamente i riduttori di olio
lubrificante. 6. Fill completely the gearboxes with lubricant oil.
I riduttori, prima del loro utilizzo, dovranno essere Before use, the gearboxes should be filled with the
riempiti con la corretta quantità e tipo di proper amount of lubricant of the recommended
lubrificante previsto. type.

008 915 04 BOMAG 453
13.3 Travel gear
2. INFORMAZIONI TECNICHE 2. TECHNICAL INFORMATIONS
2.1. Descrizione del prodotto 2.1. Product description
I riduttori BONFIGLIOLI TRASMITAL della serie The BONFIGLIOLI TRASMITAL gearboxes of the
descritta in questo manuale sono stati progettati e series described in this manual are designed and built
costruiti per essere applicati su rulli gommati per il for wheel drive of pneumatic tyred roller machines.
comando ruota.
An important piece of advice given is “to perfectly”
Una importante raccomandazione è di progettare “a design the main hydraulic system.
regola d’arte” l’impianto idraulico di comando.
The illustrations show the parts and the main functions
L’illustrazione mostra le parti e le principali funzioni di of the gearbox.
un riduttore.
Gruppo riduttore
Gearbox kit
Gruppo riduzioni
Reduction kit
Gruppo riduzione angolare

Right angle reduction kit
Gruppo riduzioni
Reduction kit
Gruppo freno
Brake kit
IDM-15220600600.tif
INFORMAZIONI TECNICHE -8- TECHNICAL INFORMATIONS

454 BOMAG 008 915 04
Travel gear 13.3
Gruppo riduzioni
Reduction kit
IDM-15220600700.tif
Gruppo freno
Brake kit
IDM-15220600800.tif
INFORMAZIONI TECNICHE -9- TECHNICAL INFORMATIONS

008 915 04 BOMAG 455
13.3 Travel gear
Posizione dei tappi olio sul riduttore/ Oil plugs position on the gearbox
IDM-15220600900.tif
Legenda: Legend:
1 1
M18x1,5 ......................................... Tappo carico olio M18x1,5 .............................................. Oil filling plug
2 2
M14x1,5 ......................................... Tappo livello olio M14x1,5 ............................................... Oil level plug
3 3
M18x1,5 ....................................... Tappo scarico olio M18x1,5 ......................................... Oil draining plug
4 4
M14x1,5 .............................................. Tappo chiuso M14x1,5 ................................................ Closed plug
5 5
G 1/4” (n° 2) ..................................... Comando freno G 1/4” (nos. 2) ............................. Brake release port
6 6
G 1/4” (n° 2) ........................ Comando azionamento G 1/4” (nos. 2) ............................. Dynamic operated
dinamico del freno brake port
7 7
G 3/4” .......... Entrata olio lubrificazione forzata freno G 3/4” ............. Forced oil brake lubrication inlet port
8 8
G 3/4” ............ Uscita olio lubrificazione forzata freno G 3/4” ........... Forced oil brake lubrication outlet port
9 9
G 3/8” .................................. Tappo scarico olio freno G 3/8” ................................... Oil brake draining plug
INFORMAZIONI TECNICHE - 10 - TECHNICAL INFORMATIONS

456 BOMAG 008 915 04
Travel gear 13.3
3. INFORMAZIONI SULL’INSTALLAZIONE 3. INSTALLATION INFORMATIONS
3.1. Procedure per l’installazione 3.1. Installation procedure
Prima dell'installazione eseguire le seguenti operazioni. Before proceeding with installation, follow the
instructions given below.
1. Pulire accuratamente il prodotto dai residui
dell'imballaggio e di protezione. 1. Properly clean the product removing packaging
and all remains of protection padding.
2. Predisporre le parti di accoppiamento facendo
riferimento al disegno di installazione. 2. Prepare the parts to be coupled using the
installation drawing as a guide.
Le fasi principali di installazione sono di seguito
elencate. Nei paragrafi successivi sono indicate, in The main installation processes are given below. In the
dettaglio, le operazioni da eseguire. following sections, the procedures to follow are given
– Installazione del motore idraulico (paragrafo 3.2.) in detail.
– Installazione del prodotto sulla macchina – Hydraulic motor installation (section 3.2.)
(paragrafo 3.3.) – Mounting the product to the machine (section 3.3.)
– Fissaggio ruota al motoriduttore (paragrafo 3.4.) – Fixing of the wheel to the gearmotor (section 3.4.)
– Collegamento del freno (paragrafo 3.5.) – Connecting the brake (section 3.5.)
– Riempimento e livello dell'olio lubrificante riduttore – Filling-up the gearmotor with lubricating oil and level
(paragrafo 3.7.). of oil to maintain in the gearbox (section 3.7.).
INFORMAZIONI SULL’INSTALLAZIONE - 11 - INSTALLATION INFORMATIONS

008 915 04 BOMAG 457
13.3 Travel gear
3.2. Installazione del motore idraulico 3.2. Hydraulic motor installation
Assicurarsi che le superfici di accoppiamento ed il The mating areas and the pilot diameter of the gearbox
centraggio dove va inserito il motore idraulico siano where the motor is to be mounted must be clean and
pulite ed esenti da bave. without burrs.
Prima di montare il motore idraulico, verificare, Before assembling the hydraulic motor, verify by a
con un calibro per interni, il corretto assemblaggio depth slide gauge the correct assembly of the unit
del riduttore controllando la quota assiale indicata checking the axial distance as shown in the
nello schema seguente. scheme below.
1. Montare la guarnizione O-ring (A) nella propria 1. Fit the O-ring seal (A) in its seat in the hydraulic
sede nel motore idraulico ed assemblare motor, and assemble it to the gearbox being
quest'ultimo al riduttore facendo attenzione a non careful not to damage the seal already fitted.
danneggiare la guarnizione precedentemente
2. Tighten the nos. 4 screws M16 (B), grade 8,8, by a
montata.
torque wrench at 215 Nm torque.
2. Serrare le n° 4 viti M16 (B), classe di resistenza
8,8, con una chiave dinamometrica alla coppia di
215 Nm.
Togliere i tappi in plastica a protezione degli Only when it is necessary to attach pipes, remove
attacchi solamente al momento del collegamento the plastic caps protecting the connections, this
dei tubi, per evitare l’immissione di qualsiasi corpo will ensure that no foreign body goes inside the
estraneo all’interno del motore idraulico. hydraulic motor.
B A
IDM-15220601000.tif
Legenda: Legend:
B B
n° 4 viti ...............................M16 classe 8,8 - 215 Nm n° 4 screws......................... M16 grade 8,8 - 215 Nm

458 BOMAG 008 915 04
Travel gear 13.3
3.3. Installazione del motoriduttore sulla macchina 3.3. Installation of the wheel drive on the machine
1. Spostare il motoriduttore nella zona di 1. Move the wheel drive in the mounting area
installazione sollevandolo come indicato nel applying lifting methods shown in section 1.7.
paragrafo 1.7.
2. Clean the mating surfaces from oils or paint and fit
2. Pulire le zone di accoppiamento da protettivi o the wheel drive on the machine frame (for the
vernice ed installare il motoriduttore sul telaio correct orientation refer to the installation drawing).
macchina (per il corretto orientamento fare 3. Fix the wheel drive to the machine frame by using
riferimento al disegno di installazione). nos. 8 screws M20 (C), grade 10,9, tightened by a
3. Fissare il motoriduttore al telaio macchina con n° 8 torque wrench at 585 Nm.
viti M20 (C), classe di resistenza 10,9, serrate con
una chiave dinamometrica alla coppia di 585 Nm.
3.4. Fissaggio ruota al motoriduttore 3.4. Fixing of the wheel to the gearmotor
1. Pulire le zone di accoppiamento da protettivi o 1. Clean the mating surfaces from oils or paint and
vernice ed assemblare la ruota al motoriduttore. assemble the wheel to the gearmotor.
2. Fissare le ruote al motoriduttore con n° 20 viti 2. Fix the wheels to the wheel drive by using nos. 20
M20x1,5 (D), classe minima di resistenza 10,9, screws M20x1,5 (D), grade 10,9, tightened by a
serrate con una chiave dinamometrica alla coppia torque wrench at 635 Nm.
di 635 Nm.
Telaio macchina
Machine frame
D
Ruota
C Wheel
IDM-15220601100.tif
Legenda: Legend:
C C
n° 8 viti .............................M20 classe 10,9 - 585 Nm n° 8 screws ...................... M20 grade 10,9 - 585 Nm
D D
n° 20 viti ....................M20x1,5 classe 10,9 - 635 Nm n° 20 screws ............. M20x1,5 grade 10,9 - 635 Nm

008 915 04 BOMAG 459
13.3 Travel gear
3.5. Collegamento del freno 3.5. Connecting the brake
Il riduttore è provvisto di un freno negativo a dischi The gearbox is fitted with a negative multi disk safety
multipli di sicurezza con sblocco a comando idraulico brake with hydraulic control release (parking brake).
(freno di stazionamento). For information regarding the characteristics of the
Per informazioni riguardanti le caratteristiche del freno, brake refer to the installation drawing.
fare riferimento al disegno di installazione.
DATI FRENO / BRAKE TECHNICAL DATA
Pressione minima di completa apertura/minimum brake release pressure (bar) 19
Pressione massima di comando freno/ Maximum operating pressure brake (bar) 50
Coppia frenante/ Braking torque (Nm) 900 ± 10%
Togliere i tappi in plastica a protezione degli Only when it is necessary to attach pipes, remove
attacchi solamente al momento del collegamento the plastic caps protecting the connections, this
dei tubi, per evitare l'immissione di qualsiasi corpo will ensure that no foreign body goes inside the
estraneo all'interno del motore idraulico. hydraulic motor.
1. Effettuare i seguenti collegamenti al freno (per 1. Pipe the brake as shown below (for hose sizes and
dimensione e tipo, fare riferimento al disegno di dimensions refer to the installation drawing).
installazione).
– Comando apertura freno; porte “5”. – Brake release ports: “5”.
– Comando azionamento dinamico freno; porte “6”. – Dynamic operated brake ports: “6”.
– Entrata olio lubrificazione forzata freno; porta “7”. – Forced oil brake lubrication inlet port: “7”.
– Uscita olio lubrificazione forzata freno; porta “8”. – Forced oil brake lubrication outlet port: “8”.
IDM-15220601200.tif
Caratteristiche olio lubrificazione forzata freno / Forced oil brake lubrication characteristics
Portata olio nominale / Nominal oil flow (l/1') 23
Portata olio max intermittente / Max intermittent oil flow (l/1') 33
Contropressione massima intermittente alla porta "9"

(bar) 6
Intermittent max back pressure at drain port "9"
Temperatura max olio in uscita porta "8"

(°C) 100
Max oil output temperature port "8"

460 BOMAG 008 915 04
Travel gear 13.3
3.6. Caratteristiche olio lubrificazione forzata freno 3.6. Characteristics of oil forced brake lubrication
L’olio deve rispondere alle caratteristiche ISO VG 46. Lubrication must reflect the ISO VG 46 characteristics.
L’olio deve essere filtrato con grado massimo di It must be filtered with a maximum grade of 50 µm.
50 µm.
It is advised not to mix together oils with different
È opportuno non mescolare fra loro olii con proprietà properties.
differenti.
It is advised to use a filter with a led indicator that can
È consigliato usare un filtro con indicatore visivo be seen externally, with a flow control valve that blocks
d’intasamento visibile dall’esterno, con una valvola the flow of oil when the filter is clogged.
limitatrice che blocchi il flusso dell’olio quando il filtro
If it is necessary to work in low temperatures (artic
sia intasato.
climates) it is essential to use specific guidelines
Qualora si dovesse lavorare a basse temperature (contact the manufacturer).
(climi artici) sono necessarie norme specifiche
Checking the temperature of the hydraulic oil is one of
(contattare il costruttore).
the most critical aspects of the hydraulic system.
Il controllo della temperatura dell’olio idraulico è una
High operational temperatures will cause a
delle costanti più critiche nel sistema idraulico.
degradation of the oxidation resistance level and will
Alte temperature di esercizio, causano un degrado accelerate the deterioration process of the hydraulic
della resistenza all’ossidazione ed accelerano il oil.
deterioramento dell’olio idraulico.

008 915 04 BOMAG 461
13.3 Travel gear
3.7. Riempimento olio lubrificante del riduttore 3.7. Filling-up the gearbox with lubricating oil
La lubrificazione è separata fra motore e riduttore. The motor and the gearbox have separate lubrication.
La lubrificazione del riduttore è a sbattimento in The gearbox is lubricated by oil splashing.
bagno d'olio. L'olio consigliato è del tipo per The recommended type of oil is SAE 80W/90 or
trasmissioni ad ingranaggi, con viscosità SAE 85W/140 with EP features complying with
SAE 80W/90 oppure SAE 85W/140 con MIL-L-2105 C & API GL5.
caratteristiche EP rispondente a: MIL-L-2105 C & In following table the most common brands of lubricant
API GL 5. and the types recommended are shown.
Nella tabella seguente sono riportate le marche più
diffuse di lubrificanti con i tipi di olio consigliati.
Durante l'esercizio e solo per brevi momenti l'olio During operation the oil temperature must not
può raggiungere, ma non superare, la temperatura exceed 85-90°C intermittent.
di 85-90°C intermittente.
Elenco olii consigliati a Norme SAE 80W/90 e SAE 85W/140 con caratteristiche API GL5
Lubricant oils suggested according SAE 80W/90 and SAE 85W/140 API GL5 grade
Temperatura ambiente
-20°C / +30°C +10°C / +45°C
Ambient temperature
SAE 80W/90 SAE 85W/140
Viscosità olio / Oil viscosity
Produttori / Manufacturers Tipo olio / Oil Brand
SHELL SPIRAX HD SPIRAX HD
AGIP ROTRA MP ROTRA MP
ARAL GETRIEBEOL HYP GETRIEBEOL HYP
BP-MACH HYPOGEAR EP HYPOGEAR EP
CASTROL HYPOY HYPOY
CHEVRON UNIVERSAL GEAR LUBRICANT UNIVERSAL GEAR LUBRICANT
ELF TRANSELF B TRANSELF B
ESSO GEAR OIL GX PONTONIC MP GEAR OIL GX PONTONIC MP
I.P. PONTIAX HD PONTIAX HD
MOBIL MOBILUBE HD MOBILUBE HD
TOTAL TRASMISSION TM TRASMISSION TM
In caso di lubrificazione con olii sintetici, è consigliato In case of lubrication with syntetic oils, is
utilizzare solo quelli a base Polialfaolefine (PAO). recommended to use only oils with PAO base.
Non mescolare olii di marca o caratteristiche diverse. Do not mix together oils of different brands or
characteristics.

462 BOMAG 008 915 04
Travel gear 13.3
Il riduttore viene fornito privo di olio ma The gearbox is supplied without oil; anyway it has
predisposto con tappi di carico, scarico e livello. filling, draining and oil level plugs. Before putting
Prima della messa in funzione occorre eseguire il the gearbox into operation, it is necessary to fill it
riempimento. with oil.
Eseguire questa operazione come di seguito indicato. This procedure is undertaken following the indications
given below.
1. Con l'asse del riduttore in orizzontale, ruotare il 1. Check that the gearbox axis is horizontal. Rotate
corpo fino a che il tappo di scarico (3) si trovi in the gearbox housing until the drain plug (3) is on
basso sull'asse verticale del coperchio di chiusura. the bottom of the vertical axis of the end cover.
2. Svitare i tappi di carico e livello olio (1-2). 2. Unscrew the fill and level oil plugs (1-2).
3. Riempire dal foro (1) fino a che l'olio lubrificante 3. Fill from the hole (1) until the lubricant oil flows out
non fuoriesca dal foro (2). from the hole (2).
4. Avvitare i tappi di carico e livello olio (1-2) e 4. Tighten the fill and level oil plugs (1-2) and let the
mettere in funzione il riduttore; attendere qualche gearbox run. After a few minutes, stop and check
istante, poi verificare nuovamente il livello dell'olio. the oil level.
5. Aggiungere olio lubrificante se necessario. 5. If necessary, refill with lubricant oil.
IDM-15220601600.tif

008 915 04 BOMAG 463
13.3 Travel gear
3.8. Prima messa in esercizio e rodaggio 3.8. First start up and running in
In questa prima fase, si raccomanda di adottare alcune In this first stage it is advised to follow the measures
precauzioni come di seguito indicato. given below.
1. Eliminare eventuale aria residua dal circuito 1. Bleed air from every part of the hydraulic circuit
idraulico e aggiungere olio nel serbatoio se and add oil in the tank if necessary.
necessario.
La presenza di aria residua nel circuito idraulico si The presence of residual air in the hydraulic circuit
manifesta con la presenza di schiuma nel will manifest itself with the presence of foam in the
serbatoio e causa un funzionamento a strappi del tank and will lead to a jerking of the motor as well
motore ed un eccessiva rumorosità del motore e as excessive noise coming from the motor and the
delle valvole. valves.
2. Avviare il motoriduttore a bassa velocità ed 2. Start the gearmotor at a low speed and gradually
incrementare gradualmente, dopo avere verificato increase it after having verified that it is functioning
che il funzionamento sia corretto, in assenza di correctly without any noises or vibrations.
rumore e vibrazioni.
Non arrivare alla massima pressione sino a Do not reach maximum pressure unless the entire
quando tutto l'impianto non sia stato filtrato per system has been filtered to eliminate any particles
l'eliminazione di eventuali particelle di impurità. of dirt that may be present.
Durante il rodaggio eseguire le operazioni di seguito During the running-in stage follow the steps given
indicate. below.
3. Controllare che il numero dei giri ed il senso di 3. Make sure that the speed and direction of rotation
rotazione siano corretti. are correct.
4. Controllare che il funzionamento sia regolare ed in 4. Make sure that the functioning is regular and
assenza di rumore eccessivo e vibrazioni. without any excessive noises and vibrations.
5. Controllare che la temperatura dell’olio non superi 5. Make sure that the oil temperature does not
i 90°C. exceed 90°C.
Al termine di questo primo rodaggio eseguire le After having terminated this first running-in follow the
operazioni di seguito indicate. steps given below.
6. Controllare che non vi siano perdite d’olio. In caso 6. Check that there are no oil leakages. If present,
contrario provvedere alla loro eliminazione proceed to remove them.
7. Controllare il livello dell’olio lubrificante del 7. Check the level of lubricating oil in the gearmotor.
motoriduttore. 8. It could happen that due to the presence of air,
8. Durante il primo avviamento, causa l’eventuale during the first start up, the opening action of the
presenza di aria, l’apertura del freno potrebbe brake could be slowed down. It is advised to repeat
risultare ritardata. Ripetere alcune volte il the opening and closing function of the brake.
comando di apertura e chiusura del freno. 9. Check that there are no other problems in general.
9. Controllare che non vi siano altri problemi.

464 BOMAG 008 915 04
Travel gear 13.3
4. INFORMAZIONI SULLA MANUTENZIONE 4. MAINTENANCE INFORMATIONS
4.1. Manutenzione periodica 4.1. Periodic maintenance
Il riduttore necessita solamente delle operazioni di The gearbox only requires the scheduled maintenance
manutenzione programmata prevista dal costruttore procedures set out by the manufacturer (see Table
(vedi tabella). below).
Una buona manutenzione consentirà la continuità di Good maintenance will ensure an on going functioning
funzionamento nel tempo con la massima affidabilità. in time as well as maximum reliability.
Nel caso in cui insorgano anomalie di funzionamento Should irregularities in function arise, it will be
sarà necessario consultare la check-list della ricerca necessary to consult the troubleshooting checklist to
guasti per trovare una soluzione adeguata. find the most adequate solution.
In caso contrario potrebbe essere necessario If unsuccessful, it may be necessary to disassemble a

effettuare lo smontaggio parziale o completo del partially or completely the motorgearbox (see
motoriduttore (vedi paragrafo 4.4.) section 4.4.)
Controllo / Inspection Frequenza / Frequency Azione / Action
Serraggio viti Dopo le prime 50 ore Verifica serraggio viti

Tightening screws After the first 50 hours Screws tighening torque check
Livello olio Ogni 100 ore Rabboccare l’olio

Oil level Every 100 hours Refill oil
Primo cambio olio A 150 ore Sostituire olio

1st oil change At 150 hours Oil replacement
Cambi olio successivi Ogni 1000 ore o 1 anno Sostituire olio

Following oil changes Every 1000 hours or 1 year Oil replacement
INFORMAZIONI SULLA MANUTENZIONE - 19 - MAINTENANCE INFORMATIONS

008 915 04 BOMAG 465
13.3 Travel gear
4.2. Sostituzione dell'olio lubrificante 4.2. Changing the lubricating oil
1. Con l'asse del riduttore in orizzontale, ruotare il 1. Check that the gearbox axis is horizontal. Rotate
corpo fino a che il tappo di scarico (3) si trovi in the gearbox housing until the drain plug (3) is on
basso sull'asse verticale del coperchio di chiusura. the bottom of the vertical axis of the end cover.
2. Svitare i tappi (1-3) e fare defluire l'olio in un 2. Unscrew the plugs (1-3) and let the oil flow in a
recipiente sufficientemente capiente; per large enough container; in order to facilitate the
agevolare l'operazione di scarico è bene operare draining must be oil still warm.
con olio caldo.
3. Wait a few minutes until all the oil is drained and
3. Attendere qualche minuto affinché tutto l'olio sia then proceed to screw on the plugs (1-3).
uscito, quindi avvitare i tappi (1-3).
4. Proceed with the oil fill-up following the procedures
4. Effettuare il riempimento dell'olio seguendo le given (see section 3.7.).
modalità predefinite (vedi paragrafo 3.7.).
Si raccomanda di non miscelare oli a base Never mix mineral oils with synthetic oils and vice
minerale con oli a base sintetica e viceversa. versa.
Cautela - Precauzione Caution

Non disperdere l'olio nell'ambiente ma smaltirlo Do not dispose of the oil in the natural
rispettando le leggi vigenti in materia. environment but be careful to eliminate it in
compliance with the relative rules and regulations
that govern locally.
IDM-15220601700.tif

466 BOMAG 008 915 04
Travel gear 13.3
4.3. Ricerca guasti 4.3. Troubleshooting
La seguente tabella è stata realizzata per una The following table is realized to localize troubles in the
individuazione dei guasti nei riduttori per traslazione. gearbox.
Anomalie / Anomalies Cause / Causes Rimedi / Remedies

Perdita olio esterna / External oil leakage:
Dalla tenuta frontale a)Tenuta frontale danneggiata a)Sostituzione tenuta frontale
From the lifetime seal Lifetime damaged Replace lifetime seal
Dal coperchio a)Guarnizione O-ring danneggiata a)Sostituzione guarnizioni O-ring

From the end cover O-ring seal damaged Replace O-ring seals
a)Guarnizione tappo danneggiata a)Sostituzione guarnizione tappo

Plug seal damaged Replace plug seal
Dai tappi
From the plugs
b)Tappi o viti allentate b)Serrare tappi/viti
Plugs or screws loose Tighten the plugs/screws
Eccessiva rumorosità / Too much noise:
Rumore idraulico (in fase a)Impianto idraulico a)Verificare l'impianto idraulico
di rallentamento malfunzionante
velocità motore) Hydraulic circuit malfunctioning Verify hydraulic circuit
Hydraulic noise (during the
slowing down of the motor
speed)
Interno al riduttore (zona a)Danneggiamento interno a)Verificare riduttore

ingranaggi) Internal damage Check the gearbox
Inside the gearmotor
(reductions)
Altro / Other:
a)Livello olio scarso a)Verificare livello olio e aggiungerne
se necessario
Insufficient oil level Check the oil level and refill if
necessary
Surriscaldamento
Overheating b)Olio idraulico troppo caldo b)Verificare circuito idraulico
Hydraulic oil too warm Check the hydraulic circuit
c)Incompleta apertura freno c)Verificare pressione apertura freno

Brake not fully released Check brake release pressure
Malfunzionamento freno di stazionamento

Parking brake malfunctioning
Coppia frenante
a)Dischi freno usurati a)Sostituzione dischi freno
insufficiente
Brake discs worm Replace brake disc pack
Insufficient braking torque
b)Parti danneggiate b)Verifica componenti freno
Damaged parts Check brake components
a)Freno bloccato a)Verifica completa apertura freno

Parking brake locked Check the complete brake release
Rotazione ruota bloccata
b)Componenti meccanici b)Sostituzione parti danneggiate
Wheel locked
danneggiati
Mechanical components Replace damaged parts
damaged

008 915 04 BOMAG 467
13.3 Travel gear
4.4. Smontaggio del motoriduttore 4.4. Motorgearbox disassembly
Nel caso in cui sia necessario effettuare una revisione In the case that it was necessary to undergo a (partial
(parziale o totale) è necessario smontare il riduttore or total) revision, it will be necessary to dismount the
dalla macchina. Considerando che questo è un gearbox from the machine. As this is known as an out
intervento di manutenzione straordinaria, è opportuno of the ordinary maintenance procedure, it is important
che venga realizzato da personale con competenze that only personnel with specific skills and experience
specifiche e capacità acquisite. undertake it.
E' altresì importante che tale intervento sia effettuato in It is also important that this procedure is undertaken in
una officina opportunamente attrezzata. Oltre ai a workshop that is adequately tooled. As well as normal
normali attrezzi, è necessario disporre delle workshop tools it will be necessary to use special tools
attrezzature speciali che possono essere costruite that can be made (see special tools attachment) or may
(vedi allegati attrezzature speciali) oppure richieste be requested from the manufacturer.
direttamente al costruttore.
Attrezzature speciali Special Tools

Anello montaggio Tool for lifetime seal
tenuta frontale .......................... Codice/: 6689960610 assembly ...................................... Code/: 6689960610
Moltiplicatore di coppia............ Codice/: ATZ.09.003.1 Torque multiplier......................... Code/: ATZ.09.003.1
Per la realizzazione di queste attrezzature vedi disegni To be able to produce these equipments refer to the
costruttivi in fondo al manuale. production drawings at the end of this manual.

468 BOMAG 008 915 04
Travel gear 13.3
Nelle pagine seguenti vengono riportate tutte le fasi di In the following pages all the procedures for
smontaggio e rimontaggio del riduttore: rispettarle disassembling and reassembling the gearbox are
scrupolosamente. given, it is important to strictly adhere to them.
Eseguire questi interventi adottando tutte le Proceed with these operations using all the necessary
necessarie precauzioni, come ad esempio: safety measures, like for example:
1. chiudere tutti gli attacchi all'impianto oleodinamico 1. Plug all the Hydraulic ports on the gearbox to avoid
sul riduttore per evitare l'introduzione accidentale the introduction of any foreign particles in the
di corpi estranei nel circuito e nel riduttore. circuit and the gearbox.
2. fare attenzione che le superfici di accoppiamento 2. Making sure that the coupling surfaces are not
non vengano danneggiate. damaged.
3. eseguire la movimentazione in modo che non crei 3. Following the handling so as to be sure that there
pericoli per la sicurezza delle persone e garantisca are no risks for human safety and to guarantee the
l'integrità del riduttore. reliability of the gearbox.
4. predisporre la zona di lavoro al fine di rispettare le 4. Making available a work area that is in line with
leggi in materia di sicurezza e salute nei posti di work and health safety in the workplace guidelines.
lavoro.
NOTA: di seguito sono indicate tutte le fasi per NOTE: Below are all the steps to follow during these
eseguire questi interventi. I numeri fra parentesi nel operations. Numbers in brackets in the text correspond
testo, corrispondono ai riferimenti riportati nel to the references in the exploded view.
seguente disegno esploso.
Gruppo riduttore
Gearbox kit A1
A2
A3
A4
A5
A4
A3
A11 A2
A1
A6
A7
A8
A9
A10
A12
A7
A13
A14
A15
IDM-15220600300.tif

008 915 04 BOMAG 469
13.3 Travel gear
Gruppo riduzioni
Reduction kit
B1
B2
B3
B4
B5
B6
B16
B13
B17
B14 B15
B18
B7
B8
B9
B10
B11
B12
IDM-15220600400.tif
Gruppo freno
Brake kit
C7
C8
C11 C1
C12 C2
C13 C3
C14 C4
C5
C6
C9
C15 C10
C16
C17
C18
C19
C20
C7
C8
C21
C22
C23
IDM-15220600500.tif

470 BOMAG 008 915 04
Travel gear 13.3
4.5. Fasi di smontaggio 4.5. Disassembling method
Per eseguire lo smontaggio del riduttore occorre For starting the gearbox disassembly it is now
smontarlo dalla macchina e recarsi in un'officina necessary to remove it from the machine and
opportunamente attrezzata. move it to a properly equipped workshop.
Per dare inizio alla fase di smontaggio, fare defluire Before wheel drive disassembling, make sure that the
completamente l'olio lubrificante dal riduttore secondo oil is discharged according to instructions specified in
quanto descritto al paragrafo 4.2. section 4.2.
Svitare e sfilare le n° 4 viti M16, classe di resistenza Unscrew and remove the nos. 4 screws M16, grade
8,8, e togliere il motore idraulico e la propria 8,8, and remove the hydraulic motor and its O-ring
guarnizione O-ring. seal.
4.6. Fasi di smontaggio riduttore 4.6. Gearbox disassembly method
1. Svitare le n° 16 viti M12x40 (A3), classe di

resistenza 12,9, dal 1° gruppo riduttore (A2).
Unscrew the nos. 16 screws M12X40 (A3), grade

12,9, from the 1st gearbox kit (A2).
2. Servendosi di un paranco sfilare il 1° gruppo

riduttore (A2).
Informazioni
Fare attenzione a non daneggiare il tubo (A6)
durante questa fase.
By using a tackle remove the 1st gearbox kit (A2).
Information
Taking care not to damage the tube (A6) during
this step.
3. Sfilare il tubo (A6).
Remove the tube (A6).

008 915 04 BOMAG 471
13.3 Travel gear

resistenza 12,9, dal 2° gruppo riduttore (A2).

12,9, from the 2nd gearbox kit (A2).
5. Servendosi di un paranco sfilare il 2° gruppo

riduttore (A2).
By using a tackle remove the 2nd gearbox kit (A2).

resistenza 8,8, dal gruppo freno (A15).

8,8, from the brake kit (A15).
7. Sfilare il gruppo freno (A15).
Remove the brake kit (A15).

472 BOMAG 008 915 04
Travel gear 13.3
8. Sfilare l’albero scanalato (A13) dal gruppo

freno (A15).
Remove the splined shaft (A13) from the brake

kit (A15).
9. Togliere le guarnizioni O-ring (A14) dalle proprie

sedi nell’albero scanalato (A13).
Remove the O-ring seals (A14) from their seats in

the splined shaft (A13).

resistenza 8,8, dalla riduzione angolare (A5).

8,8, from the right angle reduction (A5).
11. Sfilare la flangia di collegamento (A10).
Remove the connecting flange (A10).

008 915 04 BOMAG 473
13.3 Travel gear
12. Togliere le guarnizioni O-ring (A7) dalle proprie

sedi nella flangia di collegamento (A10).
Remove the O-ring seals (A7) from their seats in

the connecting flange (A10).
13. Sfilare il giunto di collegamento (A8).
Remove the coupling (A8).
14. Servendosi di pinze sfilare l'anello elastico (A9)

dalla propria sede nel giunto di collegamento (A8).
By using pliers remove the circlip (A9) from its seat

in the coupling (A8).

474 BOMAG 008 915 04
Travel gear 13.3
4.7. Fasi di smontaggio gruppo riduttore 4.7. Gearbox kit disassembly method
15. Sfilare il solare di 1° riduzione (B1).
Remove the 1st stage sun gear (B1).
16. Estrarre, contemporaneamente, la 1°

riduzione (B2) e il solare di 2° riduzione (B10).
Remove, at the same time, the 1st reduction

assembly (B2) and the 2nd stage sun gear (B10).
17. Sfilare il solare di 2° riduzione (B10).
Remove the 2nd stage sun gear (B10).
18. Togliere la guarnizione O-ring (A4) dalla propria

sede nel mozzo flangiato (B3).
Remove the O-ring seal (A4) from its seat in the

flanged hub (B3).

008 915 04 BOMAG 475
13.3 Travel gear
19. Capovolgere il riduttore e svitare il tappo di livello

olio (B17) con chiave esagonale maschio.
Turn the gearbox upside down and unscrew the

level oil plug (B17) by a male hex head wrench.
20. Svitare i tappi di carico-scarico olio (B16) con

chiave esagonale maschio.
Unscrew the draining-filling oil plugs (B16) by a

male hex head wrench.
21. Svitare le n° 10 viti M10x20 (A1-B12), classe di

resistenza 8,8, dal coperchio di chiusura (B15).
Unscrew the nos. 10 screws M10x20 (A1-B12),

grade 8,8, from the end cover (B15).
22. Sfilare il coperchio di chiusura (B15).
Remove the end cover (B15).

476 BOMAG 008 915 04
Travel gear 13.3
23. Togliere la guarnizione "X-ring" (B14) dalla propria

sede nel coperchio di chiusura (B15).
Remove the "X-ring" seal (B14) from its seat in the

end cover (B15).
24. Togliere la guarnizione O-ring (B11) dalla propria

sede nel corpo riduttore (B6).
Remove the O-ring seal (B11) from its seat in the

gearbox housing (B6).
25. Servendosi di pinze sfilare gli anelli elastici (B9)

dalle proprie sedi situate nei perni del mozzo
flangiato (B3).
By using pliers remove the circlips (B9) from their

seats in the flanged hub’s pins (B3).
26. Servendosi di un estrattore sfilare i gruppi planetari

di 2° riduzione (B8).
By using a puller remove the planet assemblies of

the 2nd reduction (B8).

008 915 04 BOMAG 477
13.3 Travel gear
27. Servendosi di un trapano eliminare le cianfrinature

presenti sulla ghiera (B7).
By using a drill remove the calkings on the ring

nut (B7).
28. Posizionare il moltiplicatore di coppia

(ATZ.09.003.1) sulla ghiera (B7). Servendosi del
moltiplicatore di coppia svitare la ghiera (B7).
ATZ.09.003.1
Place the torque multiplier (ATZ.09.003.1) on the
ring nut (B7). By using the torque multiplier loosen
the ring nut (B7).
29. Rimuovere la ghiera (B7).
Take out the ring nut (B7).
30. Servendosi di una pressa e di un tampone

metallico, sfilare il mozzo flangiato (B3) dal corpo
riduttore (B6).
By using a press and a metal stopper, remove the

flanged hub (B3) from the gearbox housing (B6).

478 BOMAG 008 915 04
Travel gear 13.3
31. Servendosi di un paranco sfilare il mozzo

flangiato (B3) dal corpo riduttore (B6).
By using a tackle remove the flanged hub (B3)

from the gearbox housing (B6).
Può essere necessario in caso di perdite olio, In case of oil leakages, it might be necessary to
dover provvedere al controllo ed alla eventuale check and eventually replace the lifetime
sostituzione della tenuta frontale (B4), cioè di seal (B4), which means both the metal rings parts
entrambe le parti metalliche e delle guarnizioni and the O-ring seals.
O-ring.
32. Sfilare la 1° semitenuta frontale (B4) dal mozzo

flangiato (B3).
Remove the 1st half-seal (B4) from the flanged

hub (B3).
33. Sfilare la 2° semitenuta frontale (B4) dal corpo

riduttore (B6).
Remove the 2nd half-seal (B4) from the gearbox

housing (B6).

008 915 04 BOMAG 479
13.3 Travel gear
34. Servendosi di un estrattore e di un tampone

metallico, smontare l’anello interno del cuscinetto
dal mozzo flangiato (B3).
By using a puller and a metal stopper, remove the

bearing inner raceway from the flanged hub (B3).
35. Sfilare l'anello interno del cuscinetto dal mozzo

flangiato (B3).
Remove the bearing inner raceway from the

flanged hub (B3).
36. Servendosi di pinze estrarre l’anello di

spallamento (B5) dal corpo riduttore (B6).
By using pliers remove the elastic ring (B5) from

the gearbox housing (B6).
37. Sfilare i supporti in plastica e le sfere dal corpo

riduttore (B6).
Remove the plastic supports and the balls from the


480 BOMAG 008 915 04
Travel gear 13.3
38. Sfilare l'anello interno del cuscinetto dal corpo

riduttore (B6).
Remove the bearing inner raceway from the

Per lo smontaggio del secondo gruppo For the 2nd gearbox kit (A2) disassembly follow
riduttore (A2) seguire le stesse fasi descritte nel the same steps shown in section 4.7.
paragrafo 4.7.

008 915 04 BOMAG 481
13.3 Travel gear
4.8. Fasi di smontaggio gruppo freno 4.8. Brake kit disassembly method
39. Posizionare il gruppo freno (A15) su di un

distanziale.
Place the brake kit (A15) on a spacer.
40. Svitare le n° 8 viti M10x60 (C23), classe di

resistenza 8,8, dalla flangia predisposizione
motore (C22).
Unscrew the nos. 8 screws M10x60 (C23), grade

8,8, from the motor adaptor flange (C22).
Pericolo - Attenzione Danger - Warning

Svitare gradualmente le n° 8 viti (C23) in egual Loose the nos. 8 screws (C23) gradually by equal
misura in modo da bilanciare il carico delle molle amount each to balance the springs load on the
sulla flangia predisposizione motore (C22). motor adaptor flange (C22).
41. Sfilare la flangia predisposizione motore (C22).
Remove the motor adaptor flange (C22).

482 BOMAG 008 915 04
Travel gear 13.3
42. Togliere la guarnizione O-ring (C21) dalla propria

sede nella flangia predisposizione motore (C22).
Remove the O-ring (C21) from its seat in the motor

adaptor flange (C22).
43. Contrassegnare la posizione delle molle (C20) allo

scopo di avere un riferimento per il rimontaggio.
Mark the position of the springs (C20) as a

reference for the reassembling step.
44. Sfilare le molle (C20) dalle proprie sedi nel pistone

freno (C19).
Remove the springs (C20) from their seats in the

brake piston (C19).
45. Avvitare nei fori filettati di estrazione del pistone

freno (C19) n° 2 viti M5 e sollevarlo.
Tighten nos. 2 screws M5 in the extraction thread

holes of the brake piston (C19) and lift it.

008 915 04 BOMAG 483
13.3 Travel gear
46. Sfilare il pistone freno (C19).
Remove the brake piston (C19).

sede nel corpo freno (C6).
Remove the O-ring seal (C14) from its seat in the

brake housing (C6).
48. Sfilare il distanziale (C17).
Remove the spacer (C17).

sede nel distanziale (C17).

spacer (C17).

484 BOMAG 008 915 04
Travel gear 13.3
50. Togliere le guarnizioni O-ring (C13) dalle proprie

sedi nel corpo freno (C6).
Remove the O-ring seals (C13) from their seats in

the brake housing (C6).
51. Sfilare, contemporaneamente, l’albero

freno (C16), il pacco dei dischi freno (C11-C12) e
il cuscinetto (C4).
Remove, at the same time, the brake shaft (C16),

the brake discs pack (C11-C12) and the
bearing (C4).
52. Sfilare il pacco dei dischi freno (C11-C12).
Remove brake discs pack (C11-C12).
53. Servendosi di un estrattore e di un tampone

metallico, sfilare il cuscinetto (C4) dall’albero
freno (C16).
By using a puller and a metal stopper, remove the

bearing (C4) from the brake shaft (C16).

008 915 04 BOMAG 485
13.3 Travel gear
54. Servendosi di pinze sfilare l'anello elastico (C15)

dalla propria sede nell’albero freno (C16).
By using pliers remove the circlip (C15) from its

seat in the brake shaft (C16).
55. Servendosi di pinze sfilare l'anello elastico (C1)

dalla propria sede nel corpo freno (C6).
By using pliers remove the circlip (C1) from its seat

in the brake housing (C6).
56. Sfilare il disco spingimolle (C2).
Remove the spring retainer disc (C2).


brake housing (C6).

486 BOMAG 008 915 04
Travel gear 13.3
4.8. Valutazione
4.9. Fasi di smontaggio
dei pezzigruppo freno
da sostituire 4.8. Evaluating
4.9. Brake kit disassembly method
that pieces to replace
58. Togliere l’anello di tennuta (C3) dalla propria sede

nel disco spingimolle (C2).
Informazioni
Eseguire questa fase solo in caso di sostituzione.
Remove the seal ring (C3) from its seat in the

spring retainer disc (C2).
Information
Carry out this step only in case of replacement.
Lo smontaggio del riduttore termina con The gearbox disassembly ends with the above
quest'ultima operazione: tutti i particolari sono ora operation. All items are now available for the
a disposizione per le verifiche necessarie. necessary inspections.
4.9. Valutazione dei pezzi da sostituire 4.9. Evaluating that pieces to replace
I componenti soggetti ad usura sono i seguenti. The pieces that are subject to general wear and tear
– Ingranaggi. are the following:
– Cuscinetti. – Gears.
– Tutte le guarnizioni. – Bearings.
– All the seals
Sostituire i componenti usurati o guasti rispettando le Replace the used or irregular parts respecting the
seguenti indicazioni: following steps:
1. Rimuovere accuratamente lo sporco, in particolare 1. Accurately remove dirt, and in particular properly
pulire le sedi delle guarnizioni, dei cuscinetti e degli clean the seals, bearings and locking rings
anelli di bloccaggio. seating.
2. Lubrificare i componenti prima di montarli. 2. Lubricate the parts before connecting them.
3. In caso di ingranaggi danneggiati, esempio un 3. In the case of damaged gears, for example a
planetario, non sostituire il singolo ingranaggio ma planetary, do not proceed to replace the individual
tutta la riduzione. gear but the entire reduction assembly.
4. Sostituire sempre tutte le guarnizioni interessate 4. When reconnecting a part always replace all the
alla parte da rimontare. Aggiungere uno strato di seals involved. Add some grease on the seats and
grasso sulle sedi di montaggio e sulle guarnizioni on the new seals to make easier the reassembly.
nuove per facilitarne il montaggio.
5. Replace all the damaged parts with original spare
5. Sostituire le parti danneggiate con ricambi originali parts and doing so follow all the steps given by the
e rispettando le indicazioni fornite dal costruttore manufacturer in Section 4.10.
nel paragrafo 4.10.

008 915 04 BOMAG 487
13.3 Travel gear
4.10.Fasi di rimontaggio gruppo freno 4.10.Brake kit reassembling method
1. Montare l’anello di tenuta (C3) nella propria sede

nel disco spingimolle (C2).
Assemble the seal ring (C3) into its seat in the

spring retainer disc (C2).
2. Servendosi di un martello in gomma e di un

tampone metallico, spingere l’anello di tenuta (C3)
in battuta nella propria sede.
By using a rubber hammer and a metallic stopper,

push the seal ring (C3) against the seat shoulder.
3. Montare la guarnizione O-ring (C5) nella propria

Assemble the O-ring seal (C5) into its seat in the

brake housing (C6).
4. Inserire il disco spingimolle (C2).
Insert the spring retainer disc (C2).

488 BOMAG 008 915 04
Travel gear 13.3
4.10. Fasi di rimontaggio gruppo freno 4.10. Brake kit reassembling method
5. Servendosi di un martello in gomma spingere il

disco spingimolle (C2) in battuta nella propria
sede.
By using a rubber hammer push the spring retainer

disc (C2) against the seat shoulder.
6. Servendosi di pinze, montare l’anello elastico (C1)

nella propria sede nel corpo freno (C6).
By using pliers, assemble the circlip (C1) into its

seat in the brake housing (C6).
7. Servendosi di pinze, montare l’anello

elastico (C15) nella propria sede nell’albero
freno (C16).
By using pliers, assemble the circlip (C15) into its

seat in the brake shaft (C16).
8. Inserire il cuscinetto (C4) sull’albero freno (C16).
Insert the bearing (C4) on the brake shaft (C16).

008 915 04 BOMAG 489
13.3 Travel gear

tampone metallico, spingere il cuscinetto (C4) in
battuta nella propria sede.
By using a rubber hammer and a metal stopper,

push the bearing (C4) against the seat shoulder.
10. Montare l'albero freno (C16) all'interno del corpo

freno (C6).
Assemble the brake shaft (C16) inside the brake

housing (C6).
11. Montare il pacco dei dischi freno secondo il

seguente ordine: inserire per primo un disco in
bronzo sinterizzato (C11) a dentatura esterna.
Assemble the brake discs package according to

the following order: firstly, insert one sintered
bronze disc (C11) with external teeth.
12. Inserire successivamente un disco in acciaio (C12)

a dentatura interna. Ripetere l'operazione sino ad
ottenere una successione di n° 9 dischi in bronzo
sinterizzato e n° 8 in acciaio.
Then insert, an internally toothed steel disc (C12).

Repeat the operation until all nos. 9 sintered
bronze discs and nos. 8 steel discs have been
assembled.

490 BOMAG 008 915 04
Travel gear 13.3
13. Lubrificare la sede della guarnizione all'interno del

distanziale (C17) e montare la guarnizione
O-ring (C18).
Lube the seal seat into the spacer (C17) and

assemble the O-ring seal (C18).
14. Lubrificare le sedi delle guarnizioni all'interno del

corpo freno (C6) e montare le guarnizioni
O-ring (C13).
Lube the seal seats into the brake housing (C6)

and assemble the O-ring seals (C13).
15. Montare il distanziale (C17) all'interno del corpo

freno (C6), facendo attenzione a non danneggiare
le guarnizioni precedentemente montate.
Assemble the spacer (C17) inside the brake

housing (C6), paying attention not to damage the
seals already fitted.
16. Lubrificare la sede della guarnizione all'interno del

corpo freno (C6) e montare la guarnizione
O-ring (C14).
Lube the seal seat into the brake housing (C6) and
assemble the O-ring seal (C14).

008 915 04 BOMAG 491
13.3 Travel gear
17. Inserire il pistone freno (C19) all'interno del corpo

freno (C6), facendo attenzione a non danneggiare
le guarnizioni precedentemente montate.
Insert the brake piston (C19) inside the brake

housing (C6), paying attention not to damage the
seals already fitted.
18. Inserire le molle (C20) nelle sedi del pistone

freno (C19) rispettando le posizioni segnate in
precedenza.
Insert the springs (C20) into the holes in the brake

piston (C19) marked previously.
19. Montare la guarnizione O-ring (C21) nella propria

sede nella flangia predisposizione motore (C22).
Assemble the O-ring seal (C21) into its seat in the

motor adaptor flange (C22).
20. Posizionare la flangia predisposizione

motore (C22) sul corpo freno (C6).
Place the motor adaptor flange (C22) on the brake

housing (C6).

492 BOMAG 008 915 04
Travel gear 13.3
21. Serrare le n° 8 viti M10x60 (C23), classe di

resistenza 8,8, con una chiave dinamometrica alla
coppia di 50 Nm.
Tighten the nos. 8 socket head screws

M10x60 (C23),grade 8,8, by a torque wrench at
50 Nm torque.
50 Nm
Pericolo - Attenzione Danger - Warning

Avvitare gradualmente le n° 8 viti (C23) in egual Tighten the nos. 8 screws (C23) gradually by equal
misura in modo da bilanciare il carico delle molle amount each to balance the springs load on the
sulla flangia predisposizione motore (C22). motor adaptor flange (C22).

008 915 04 BOMAG 493
13.3 Travel gear
4.11.Fasi di rimontaggio gruppo riduttore 4.11.Gearbox kit reassembling method
22. Montare l’anello interno del cuscinetto nel corpo

riduttore (B6).
Assemble the bearing inner raceway in the

23. Assemblare il primo giro di sfere al corpo

riduttore (B6).
Assemble the 1st ball row to the gearbox

housing (B6).
24. Assemblare il supporto in plastica al primo giro di

sfere.
Assemble the plastic support to the 1st ball row.
25. Servendosi di un paranco posizionare il corpo

riduttore (B6) su di un distanziale.
By using a tackle place the gearbox housing (B6)

on a spacer.

494 BOMAG 008 915 04
Travel gear 13.3
4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method
26. Montare il 2° supporto in plastica nel corpo

riduttore (B6).
Assemble the 2nd plastic support in the gearbox

housing (B6).
27. Assemblare il secondo giro di sfere al supporto in

plastica.
Assemble the 2nd ball row to the plastic support.
28. Montare l’anello interno del cuscinetto nel corpo

riduttore (B6).
Assemble the bearing inner raceway in the

29. Servendosi di pinze, montare l’anello di

spallamento (B5) nella propria sede nel corpo
riduttore (B6).
By using pliers, assemble the elastic ring (B5) into

its seat in the gearbox housing (B6).

008 915 04 BOMAG 495
13.3 Travel gear
Preparazione della tenuta frontale: Make ready of the lifetime seal:

1. Effettuare una accurata pulizia degli 1. Carefully clean the seats (A and B) using, if
alloggiamenti (A e B) facendo uso, se necessary, metallic brushes or solvent (surfaces in
necessario, di spazzole metalliche o solventi (le contact with or (C) must be perfectly clean and
superfici a contatto con gli anelli di gomma (C) dry).
devono essere perfettamente pulite ed asciutte). 2. Make sure that sealing surfaces (D) of metal
2. Assicurarsi che le superfici di tenuta (D) degli rings (E) are free from scratches, dinges or foreign
anelli (E) siano esenti da qualsiasi rigatura, substances; metallic ring surfaces must be
ammaccatura o corpi estranei e che le perfectly clean and dry. We suggest to dip the
superfici (F) degli stessi anelli siano metallic rings in volatile solvent or industrial
perfettamente pulite ed asciutte. Si raccomanda degreasing alcohol.
l'immersione degli anelli metallici in solvente 3. Carefully clean the lapped surface (D) of metal
volatile o alcool bianco. rings (E) and remove dust or fingerprints. Then
3. Togliere dalle superfici lappate (D) degli lubrificate them with a thin oil film, taking care not
anelli (E) ogni traccia di polvere o impronte digitali to oil the other components.
e umettarle poi con un leggero strato di olio,
avendo cura di non ungere le rimanenti parti.
D D
A B
F F
C C
E E
IDM-1521530040
30. Montare la 1° semitenuta frontale (B4) sull'attrezzo

(6689960610).
6689960610 Assemble the 1st half seal (B4) on the tool

(6689960610).

496 BOMAG 008 915 04
Travel gear 13.3
31. Eseguire il montaggio della 1° semitenuta

frontale (B4) sul corpo riduttore (B6).
Assemble the 1st half seal (B4) on the gearbox

housing (B6).
32. Montare la 2° semitenuta frontale (B4) sull'attrezzo

(6689960610).
6689960610
Eseguire il montaggio della 2° semitenuta
frontale (B4) sul mozzo flangiato (B3).
Assemble the 2nd half seal (B4) on the tool

(6689960610).
Assemble the 2nd half seal (B4) on the flanged
hub (B3).
B4
Informazioni
Controllo corretto assemblaggio tenuta
frontale (B4).
B3
Information
Correct lifetime seal assembly check (B4).
B4
B6
IDM-15220601500.tif

008 915 04 BOMAG 497
13.3 Travel gear
33. Pulire accuratamente le superfici metalliche della tenuta

frontale (B4).
Cautela - Precauzione
Applicare un leggero strato di olio su una o entrambe le
superfici metalliche facendo attenzione a non ungere le
altre parti della tenuta frontale.
Clean carefully the seal faces (B4).
Caution
Apply a thin oil film on the entire metallic face of one or
both seals. Oil must not contact surfaces other than the
sealing faces.
34. Posizionare il mozzo flangiato (B3) all'interno del

corpo riduttore (B6).
Place the flanged hub (B3) inside the gearbox

housing (B6).
35. Servendosi di una pressa e di un tampone

metallico, spingere il mozzo flangiato (B3) in
battuta nel corpo riduttore (B6) fino ad ottenere il
completo assemblaggio del gruppo.
By using a press and a metallic stopper, push the

flanged hub (B3) against the shoulder in the
gearbox housing (B6) until assembling of the unit
is complete.
Cautela - Precauzione
Avvitare parzialmente la ghiera (B7) per evitare la
fuoriuscita del mozzo flangiato (B3) dal corpo
riduttore (B6) durante le fasi successive.
Caution
Screw the nut (B7) partially in order to avoid the
out coming of the flanged hub (B3) from the
gearbox housing (B6) during the following steps.

498 BOMAG 008 915 04
Travel gear 13.3
36. Posizionare il moltiplicatore di coppia (ATZ.09.003.1)

sulla ghiera (B7). Servendosi del moltiplicatore di
coppia, serrare la ghiera (B7) con una chiave
dinamometrica con coppia in ingresso al moltiplicatore
ATZ.09.003.1 di 113,5±3,5 Nm, corrispondente ad una coppia in
uscita dal moltiplicatore di 3500±100 Nm.
Place the multiplier (ATZ.09.003.1) on the ring

nut (B7). By using the multiplier, tighten the ring
nut (B7), by a torque wrench with an input
multiplier torque of 113,5±3,5 Nm corresponding to
an output multiplier torque of 3500±100 Nm.
3500±100 Nm
37. Cianfrinare la ghiera (B7) in corrispondenza dei 2

incavi del mozzo flangiato (B3).
Stake the ring nut (B7) near 2 seats of the flanged

hub (B3).
Informazioni
Cianfrinare Ø 4÷5 mm (profondità 1÷1,5 mm).
Information
Stake Ø 4÷5 mm (depth 1÷1,5 mm).
IDM-15217301600.tif
38. Posizionare i 4 gruppi planetari di 2° riduzione (B8)

nei perni del mozzo flangiato (B3).
Place the 4 planet assemblies of the 2nd

reduction (B8) in the flanged hub’s pins (B3).

008 915 04 BOMAG 499
13.3 Travel gear

tampone metallico, spingere i gruppi planetari di 2°
riduzione (B8) in battuta fino ad ottenere il
completo assemblaggio.
By using a rubber hammer and a metal stopper

push the planet assemblies of the 2nd
reduction (B8) against the shoulder until assembly
is complete.
40. Servendosi di pinze montare gli anelli elastici nelle

sedi dei perni del mozzo flangiato (B3).
By using pliers assemble the circlips in the flanged

hub pin seats (B3).
41. Montare la guarnizione O-ring (B11) nella propria

Assemble the O-ring seal (B11) into its seat in the

end cover (B15).
42. Applicare uno strato di grasso RETINAX HD-2 o

prodotto similare sulla guarnizione "X-ring" (B14).
Inserire la guarnizione "X-ring" (B14) nella propria
Apply a coat of grease RETINAX HD-2 or similar

product on the "X-ring" seal (B14).
Insert the "X-ring" seal (B14) in its seat in the end
cover (B15).

500 BOMAG 008 915 04
Travel gear 13.3
43. Posizionare il coperchio di chiusura (B15) sul

corpo riduttore (B6).
Place the end cover (B15) on the gearbox

housing (B6).
44. Serrare le n° 10 viti M10x20 (A1-B12), classe di

coppia di 50 Nm.

M10x20 (A1-B12), grade 8,8, by a torque wrench
at 50 Nm torque.
50 Nm
45. Capovolgere il riduttore e montare la guarnizione

O-ring (A4) nella propria sede nel mozzo
flangiato (B3).
Turn the gearbox upside down and assemble the

O-ring seal (A4) into its seat in the flanged
hub (B3).
46. Inserire il solare di 2° riduzione (B10) nel mozzo

flangiato (B3).
Insert the 2nd stage sun gear (B10) in the flanged

hub (B3).

008 915 04 BOMAG 501
13.3 Travel gear
47. Montare la 1° riduzione (B2).
Assemble the 1st reduction assembly (B2).
Per per il rimontaggio del secondo gruppo For the 2nd gearbox kit (A2) reassembly follow the
riduttore (A2) seguire le stesse fasi descritte nel same steps shown in section 4.11.
paragrafo 4.11.

502 BOMAG 008 915 04
Travel gear 13.3
4.12.Fasi di rimontaggio riduttore 4.12.Gearbox reassembling method
48. Inserire il solare di 1° riduzione (B1) nella riduzione

angolare (A5).
Insert the 1st stage sun gear (B1) in the right angle
reduction (A5).
49. Servendosi di un paranco montare il 1° gruppo

riduttore (A2).
By using a tackle assemble the 1st gearbox

kit (A2).
50. Applicare LOCTITE tipo 243 sulla filettatura delle

n° 16 viti M12x40 (A3), classe di resistenza 8.8.
Apply LOCTITE type 243 on the thread of the

nos. 16 screws M12x40 (A3), grade 8.8.
51. Serrare le n° 16 viti M12x40 (A3), classe di

resistenza 12,9, con una chiave dinamometrica
alla coppia di 145 Nm.

M12x40 (A3), grade 12,9, by a torque wrench at
145 Nm torque.
145 Nm

008 915 04 BOMAG 503
13.3 Travel gear
4.12. Fasi di rimontaggio riduttore 4.12. Gearbox reassembling method
52. Smontare il coperchio di chiusura (B15) del 2°

gruppo riduttore (A2) e, servendosi di un paranco,
montare il 2° gruppo riduttore (A2).
Remove the end cover (B15) of the 2nd gearbox

kit (A2) and, by using a tackle, assemble the 2nd
gearbox kit (A2).



resistenza 12,9, con una chiave dinamometrica
alla coppia di 145 Nm.

145 Nm torque.
145 Nm
55. Inserire il tubo (A6) nel 2° gruppo riduttore (A2).
Insert the tube (A6) in the the 2nd gearbox kit (A2).

504 BOMAG 008 915 04
Travel gear 13.3
56. Montare la guarnizione O-ring (B11) nella propria

Assemble the O-ring seal (B11) into its seat in the

end cover (B15).
57. Applicare uno strato di grasso RETINAX HD-2 o

prodotto similare sulla guarnizione "X-ring" (B14).
Inserire la guarnizione "X-ring" (B14) nella propria
Apply a coat of grease RETINAX HD-2 or similar

product on the "X-ring" seal (B14).
Insert the "X-ring" seal (B14) in its seat in the end
cover (B15).
58. Posizionare il coperchio di chiusura (B15) sul 2°

gruppo riduttore (A2).
Place the end cover (B15) on the 2nd gearbox

kit (A2).
59. Serrare le n° 10 viti M10x20 (A1-B12), classe di

coppia di 50 Nm.

M10x20 (A1-B12), grade 8,8, by a torque wrench
at 50 Nm torque.
50 Nm

008 915 04 BOMAG 505
13.3 Travel gear
60. Inserire i tappi (B16) nei fori di carico e scarico olio

del coperchio di chiusura (B15). Serrare i tappi con
una chiave dinamometrica alla coppia di 25±5 Nm.
Insert the plugs (B16) into the oil draing-filling

holes of the end cover (B15).Tighten the plugs by
a torque wrench at 25±5 Nm torque.
25±5 Nm
61. Inserire il tappo (B17) nel foro di livello olio del

coperchio di chiusura (B15). Serrare il tappo con
una chiave dinamometrica alla coppia di 10±2 Nm.
Insert the plug (B17) into the oil level hole of the
end cover (B15).Tighten the plug by a torque
wrench at 10±2 Nm torque.
10±2 Nm
62. Servendosi di pinze montare l’anello elastico (A9)

nella propria sede nel giunto di collegamento (A8).
By using pliers assemble the circlip (A9) into its

seat in the coupling (A8).
63. Montare il giunto di collegamento (A8) sulla

riduzione angolare (A5).
Assemble the coupling (A8) on the right angle

reduction (A5).

506 BOMAG 008 915 04
Travel gear 13.3
64. Montare la guarnizione O-ring (A7) nella propria

sede nella flangia di collegamento (A10).
Assemble the O-ring seal (A7) into its seat in the

connecting flange (A10).
65. Montare la flangia di collegamento (A10) sulla

riduzione angolare (A5).
Assemble the connecting flange (A10) on the right

angle reduction (A5).



coppia di 50 Nm.

50 Nm torque.
50 Nm

008 915 04 BOMAG 507
13.3 Travel gear
68. Montare le guarnizioni O-ring (A14) nelle proprie

sedi nell’albero scanalato (A13).
Assemble the O-ring seals (A14) into their seats in

the splined shaft (A13).
69. Inserire l’albero scanalato (A13) nel giunto di

collegamento (A8).
Insert the splined shaft (A13) in the coupling (A8).
70. Montare la guarnizione O-ring (A7) nella propria

sede nella flangia di collegamento (A10).
Assemble the O-ring seal (A7) into its seat in the

connecting flange (A10).
71. Montare il gruppo freno (A15) sulla flangia di

collegamento (A10).
Assemble the brake kit (A15) on the connecting

flange (A10).

508 BOMAG 008 915 04
Travel gear 13.3



coppia di 50 Nm.

50 Nm torque.
50 Nm
Informazioni
Prima di montare il motore idraulico, verificare,
con un calibro per interni, il corretto assemblaggio
del riduttore controllando la quota assiale indicata
nel disegno a fianco.
Information
Before assembling the hydraulic motor, verify by a
depth slide gauge the correct assembly of the unit
checking the axial distance as shown in the
IDM-15220601300.tif
scheme.

008 915 04 BOMAG 509
13.3 Travel gear
4.13.Controllo finale e reinstallazione 4.13.Final test and reinstallation
Verificare il prodotto reinstallandolo sulla macchina. Check the product by remounting it to the machine.
Verificare la funzionalità della trasmissione eseguendo Check the function of the transmission following all the
tutti i controlli indicati nel paragrafo 3.8. checks shown in section 3.8.
Qualora si sia eseguito un intervento sul freno, è If work on the brake was undertaken, it is important to
necessario controllare che non ci siano perdite d’olio. check that there are no oil leakages. Follow the
Procedere come segue: procedure below:
1. Collegare al foro comando freno (porta 5) un 1. Connect the pressure pilot line with the manometer
manometro (con fondo scala a 100 bar) e la (with a base scale of 100 bars) to the brake release
relativa valvola di comando afflusso olio. port (port 5).
2. Aprire la valvola di comando afflusso olio e 2. Open the flow valve and release the brake with the
sbloccare il freno, raggiungendo la pressione di pilot pressure of 50 bar.
50 bar.
3. Close the flow valve and keep the brake released
3. Chiudere la valvola di comando afflusso olio e 3 minutes or longer.
mantenere la pressione nel freno per un periodo di
4. Using the manometer, check that the pressure
almeno 3 minuti.
remains constant.
4. Verificare con il manometro che la pressione
5. Follow the same steps (1-2-3-4) for the dinamic
rimanga costante.
operated brake port (port 6).
5. Ripetere le stesse operazioni (1-2-3-4) per il
comando di azionamento dinamico del freno
(porta 6).
Se la pressione diminuisce significa che le If the pressure drops it may mean that the brake
guarnizioni del freno non fanno tenuta, in tal caso si seals are not tight and consequently they must be
dovrà procedere alla loro sostituzione, oppure che il replaced or it may mean that the reassembling was
rimontaggio non è stato eseguito in modo corretto. not completed properly.
IDM-15220601400.tif

510 BOMAG 008 915 04
Travel gear 13.3
6. Al termine delle operazioni rimontare il motore 6. After having reassembled the gearbox, fit the
idraulico come indicato nel paragrafo 3.2. hydraulic motor, as shown in section 3.2.
7. Effettuare il riempimento dell'olio lubrificante come 7. Fill the gearmotor with the lubricant oil as shown in
illustrato al paragrafo 3.7. section 3.7.
4.14.Dismissione e rottamazione del prodotto 4.14.Dismantling and destroying the product
La dismissione del riduttore va effettuata rispettando le When dismantling the gearbox follow the indications
seguenti indicazioni: given below:
1. Smontare il riduttore dalla sua sede e svuotare 1. Dismount the gearbox from its seating and empty
l'olio lubrificante. the lubricating oil.
2. Smontare completamente il riduttore e rimuovere 2. Completely dismount the gearbox and remove all
l'olio e il grasso dai componenti. oil and grease from its parts.
3. Avviare i materiali pericolosi e/o inquinanti ai 3. Send all dangerous and/or polluted parts to the
rispettivi centri di smaltimento, come richiesto dalle authorised demolishing centres whilst keeping in
leggi vigenti in materia. line with respective local rules and regulations.

008 915 04 BOMAG 511
13.3 Travel gear

512 BOMAG 008 915 04
Travel gear 13.3
008 915 04 BOMAG 513

13.3 Travel gear
514 BOMAG 008 915 04

Travel gear 13.3
Data / Date
Revisioni manuale
Manual revisions
Rev. 01 02 03 04 05 06 07 08 09 10
- Paragrafo / Paragraph
- Fase / Step
- Disegno / Drawing
sostituito dal
replaced by
Questa pubblicazione annulla e sostituisce ogni precedente edizione This publication replaces and supersseds any previous issue and
o revisione. la BONFIGLIOLI TRASMITAL si riserva il diritto di revision. BONFIGLIOLI TRASMITAL reserves the right to implement
apportare modifiche senza preavviso. E' vietata la riproduzione modifications without notice. This manual cannot be reproduced,
anche parziale senza specifica autorizzazione. even partially, without prior written consent.
008 915 04 BOMAG 515

13.3 Travel gear
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BONFIGLIOLI HELLAS S.A. BONFIGLIOLI USA INC
O.T. 48A T.O. 230 - C.P. 570 22, Industrial Area - Thessaloniki 1000 Worldwide Boulevard - Hebron, KY 41048
Tel. (+30) 2310 796456 - Fax (+30) 2310 795903 Tel.: (+1) 859 334 3333 - Fax: (+1) 859 334 8888
www.bonfiglioli.gr - bonfigr@otenet.gr www.bonfiglioliusa.com
industrialsales@bonfiglioliusa.com
mobilesales@bonfiglioliusa.com
HOLLAND VENEZUELA
ELSTO AANDRIJFTECHNIEK MAQUINARIA Y ACCESSORIOS IND.-C.A.
Loosterweg, 7 - 2215 TL Voorhout Calle 3B - Edif. Comindu - Planta Baja - Local B
Tel. (+31) 252 219 123 - Fax (+31) 252 231 660 La Urbina - Caracas 1070
www.elsto.nl - imfo@elsto.nl Tel. 0058.212.2413570 / 2425268 / 2418263
Fax 0058.212.2424552 - Tlx 24780 Maica V
www.maica-ve.com - maica@telcel.net.ve
516 BOMAG 008 915 04

13.4 Steering valve
008 915 04 BOMAG 517

13.4 Steering valve
518 BOMAG 008 915 04

Steering valve 13.4
Hydrostatic
Steering Unit Type
OSPB, OSPC and
OSPF
Service Manual
008 915 04 BOMAG 519

13.4 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
Table of Contens
Table of contens฀
฀ ฀ B฀ 3
฀ ฀ ฀฀ F฀ 4
Tools฀
g฀
฀ ฀ ฀ ฀ ฀ ฀ C฀
g฀
฀ ฀ ฀ ฀ g฀
฀ ฀ ฀ ฀฀ ฀ d฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ C฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ s฀
฀ ฀ ฀฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
2 520L0066฀ ฀ ฀ ฀฀ ฀
520 BOMAG 008 915 04

Steering valve 13.4
Service Manual
฀ ฀
฀ ฀ ฀
฀ ฀ ฀ ฀ ฀
฀ ฀฀ ฀ ฀ ฀
฀ ฀
฀ ฀฀ ฀ ฀ ฀
฀ ฀
฀ ฀ ฀ ฀
฀ ฀ ฀ ฀
฀ ฀ ฀ ฀฀ ฀ ฀ ฀ ฀ ฀฀ ฀ ฀ ฀฀ ฀
฀ ฀฀ ฀ ฀ ฀
฀ ฀ ฀ ฀฀฀ ฀ ฀ ฀฀ ฀฀ ฀ ฀ ฀฀ ฀฀ ฀
฀ ฀ ฀฀฀ ฀ ฀
฀ ฀฀฀ ฀
฀ ฀ ฀฀ ฀ ฀฀฀ ฀ ฀
฀ ฀฀ ฀ ฀฀฀ ฀
520L0066฀ ฀ ฀ ฀฀ ฀ 3
008 915 04 BOMAG 521
13.4 Steering valve
Service Manual
฀ ฀ ฀฀
฀ ฀฀฀฀฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀฀ ฀ ฀ ฀ ฀ ฀ ฀ 33 Ball 3 in
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
4 520L0066฀ ฀ ฀ ฀฀ ฀
522 BOMAG 008 915 04

Steering valve 13.4
Service Manual
Tools
Tools Holding tool

฀ ฀ ฀
฀
฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀
฀ ฀ ฀
฀ ฀ ฀
฀ ฀ ฀ ฀
฀ ฀ ฀
520L0066฀ ฀ ฀ ฀฀ ฀ 5
008 915 04 BOMAG 523
13.4 Steering valve
Service Manual
Tools
Tools ฀ ฀ ฀ ฀
฀ ฀ ฀
฀ ฀ ฀ ฀
฀ ฀ ฀
฀ ฀฀ ฀ ฀ ฀
฀ ฀ ฀
฀ ฀ ฀ ฀
฀ ฀
฀ ฀ ฀ ฀
฀ ฀
฀ ฀ ฀ ฀ ฀
฀
฀ ฀ ฀ ฀ ฀ ฀
6 520L0066฀ ฀ ฀ ฀฀ ฀
524 BOMAG 008 915 04

Steering valve 13.4
Service Manual
Dismantling ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀
฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀
520L0066฀ ฀ ฀ ฀฀ ฀ 7
008 915 04 BOMAG 525
13.4 Steering valve
Service Manual
Dismantling ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀
฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀฀฀฀฀฀฀฀฀฀฀฀
฀ ฀ ฀ ฀ ฀ ฀
8 520L0066฀ ฀ ฀ ฀฀ ฀
526 BOMAG 008 915 04

Steering valve 13.4
Service Manual
Dismantling ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀
฀ ฀ ฀ ฀
OSPF
฀ ฀ ฀฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ m
฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀
520L0066฀ ฀ ฀ ฀฀ ฀ 9
008 915 04 BOMAG 527
13.4 Steering valve
Service Manual
Dismantling ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀฀
฀฀ ฀
฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀I ฀ ฀
spanner
10 520L0066฀ ฀ ฀ ฀฀ ฀
528 BOMAG 008 915 04

Steering valve 13.4
Service Manual
Dismantling ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀I฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀
฀ ฀ ฀ ฀ ฀
520L0066฀ ฀ ฀ ฀฀ ฀ 11
008 915 04 BOMAG 529
13.4 Steering valve
Service Manual
฀ ฀ ฀ ฀ ฀ ฀
Dismantling ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀I ฀ ฀ ฀
฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀I ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
12 520L0066฀ ฀ ฀ ฀฀ ฀
530 BOMAG 008 915 04

Steering valve 13.4
Service Manual
฀ ฀ ฀ ฀ ฀
Dismantling the Pressure ฀ ฀ ฀ ฀ ฀ ฀

Relief Valve (Cartridge) ฀ ฀ ฀ ฀I ฀ ฀
for OSPC LS / OSPC LSR ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀
520L0066฀ ฀ ฀ ฀฀ ฀ 13
008 915 04 BOMAG 531
13.4 Steering valve
Service Manual
฀ ฀ ฀ ฀ ฀
Dismantling the Pressure ฀ ฀ ฀ ฀ ฀ ฀

Relief Valve (Cartridge) ฀
for OSPC LS / OSPC LSR ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀
฀ ฀ ฀ ฀ ฀ ฀
Cleaning Lubrication
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀
Inspection and replacement

฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀
14 520L0066฀ ฀ ฀ ฀฀ ฀
532 BOMAG 008 915 04

Steering valve 13.4
Service Manual
Assembling
฀
฀ ฀ ฀ ฀ ฀
฀ ฀ ฀
฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
OSPF are placed correctly in relation
฀ ฀ ฀ ฀ ฀
520L0066฀ ฀ ฀ ฀฀ ฀ 15
008 915 04 BOMAG 533
13.4 Steering valve
Service Manual
Assembling ฀ ฀ ฀
OSPB LS, OSPBX LS, OSPC LS, OSPC

LSR and OSPF
฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀฀ ฀ ฀ ฀
฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀
OSPB CN and OSPC CN

฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀
฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
16 520L0066฀ ฀ ฀ ฀฀ ฀
534 BOMAG 008 915 04

Steering valve 13.4
Service Manual
Assembling ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
Fit bearing races and needle bearings

฀ ฀ ฀ ฀ ฀ ฀
520L0066฀ ฀ ฀ ฀฀ ฀ 17
008 915 04 BOMAG 535
13.4 Steering valve
Service Manual
฀ ฀ ฀ ฀
Assembling for Assembly pattern for standard bearing

Standard Bearing
฀ ฀ ฀
฀
3 Inner bearing race
4 Spool
฀
Assembly pattern for double bearing
฀ ฀ ฀ ฀
฀ ฀
3 Outer bearing race
4 Spool
฀
฀ ฀
฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
18 520L0066฀ ฀ ฀ ฀฀ ฀
536 BOMAG 008 915 04

Steering valve 13.4
Service Manual
฀ ฀ ฀ ฀฀ ฀฀ ฀
Installation ฀ ฀ ฀ ฀ ฀ ฀ ฀
Instructions for ฀ ฀ ฀ ฀ ฀ ฀ ฀
O-ring / Kin-ring ฀ ฀ ฀ ฀ ฀ ฀ ฀
Roto glyd ฀
฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀
520L0066฀ ฀ ฀ ฀฀ ฀ 19
008 915 04 BOMAG 537
13.4 Steering valve
Service Manual
฀ ฀ ฀ ฀฀ ฀฀ ฀
O-ring / Kin-ring / ฀ ฀ ฀ ฀ ฀ ฀ ฀
Roto Glyd ฀ ฀ ฀ ฀
20 520L0066฀ ฀ ฀ ฀฀ ฀
538 BOMAG 008 915 04

Steering valve 13.4
Service Manual
฀ ฀ ฀ ฀
Installation ฀ ฀ ฀ ฀ ฀ ฀
Lip Seal
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀
฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
520L0066฀ ฀ ฀ ฀฀ ฀ 21
008 915 04 BOMAG 539
13.4 Steering valve
Service Manual
฀ ฀ ฀ ฀
Instructions for ฀ ฀ ฀ ฀ ฀
Lip Seal ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀
22 520L0066฀ ฀ ฀ ฀฀ ฀
540 BOMAG 008 915 04

Steering valve 13.4
Service Manual
฀ ฀ ฀ ฀
Installation ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
Instructions for
Lip Seal
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀
฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
520L0066฀ ฀ ฀ ฀฀ ฀ 23
008 915 04 BOMAG 541
13.4 Steering valve
Service Manual
฀ ฀ ฀ ฀
Instructions for ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
Lip Seal ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
Caution
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀
24 520L0066฀ ฀ ฀ ฀฀ ฀
542 BOMAG 008 915 04

Steering valve 13.4
Service Manual
฀ ฀ ฀ ฀
Installation ฀ ฀ ฀ ฀
Instructions for
Lip Seal
฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀
฀ ฀ ฀฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀฀
฀ ฀ ฀ ฀ ฀ ฀฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀
520L0066฀ ฀ ฀ ฀฀ ฀ 25
008 915 04 BOMAG 543
13.4 Steering valve
Service Manual
฀ ฀ ฀ ฀ ฀ ฀ ฀
Assembly of the Pressure ฀ ฀

Relief Valve for OSPC
฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀I ฀
฀
฀ ฀ ฀ ฀
฀ ฀ ฀
26 520L0066฀ ฀ ฀ ฀฀ ฀
544 BOMAG 008 915 04

Steering valve 13.4
Service Manual
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
Assambly of the Shock ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀

Valves for OSPC/OSPC LS/ ฀ ฀
OSPC LSR
Place springs and valve cones over

฀ ฀
฀฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
untreated spring applies to setting
฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀I ฀ ฀ ฀
฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀I ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀
520L0066฀ ฀ ฀ ฀฀ ฀ 27
008 915 04 BOMAG 545
13.4 Steering valve
Service Manual
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
Assambly of the Shock ฀ ฀ ฀ ฀

฀ ฀ ฀
Valves for OSPC/OSPC LS/ ฀ ฀ ฀ ฀ ฀ ฀ ฀
OSPC LSR ฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀
฀ ฀ ฀ ฀ ฀
฀
฀ ฀ ฀ ฀ ฀ ฀
฀ ฀
฀ ฀ ฀ ฀
28 520L0066฀ ฀ ฀ ฀฀ ฀
546 BOMAG 008 915 04

Steering valve 13.4
Service Manual
฀ ฀ ฀ ฀ ฀
Max. Tightening Torque ฀ ฀

and Hydraulic Connec-
tions ฀ ฀ ฀
฀ ฀
Max. tightening torque N.m [lbf.in]
Screwed With cooper With aluminium

With cutting edge With O-ring
connection washer washer
฀ 4 ฀ ฀฀ ฀
3
฀ ฀ ฀ ฀
฀ ฀ ฀ ฀
฀฀ ฀ ฀
34 ฀ ฀
฀ ฀฀ ฀ ฀ ฀ ฀
฀฀ ฀ ฀ ฀ ฀
฀฀ ฀ ฀ ฀ ฀
520L0066฀ ฀ ฀ ฀฀ ฀ 29
008 915 04 BOMAG 547
13.4 Steering valve
Service Manual
30 520L0066฀ ฀ ฀ ฀฀ ฀
548 BOMAG 008 915 04

Steering valve 13.4
Service Manual
520L0066฀ ฀ ฀ ฀฀ ฀ 31
008 915 04 BOMAG 549
13.4 Steering valve
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550 BOMAG 008 915 04
14 Circuit diagrams
008 915 04 BOMAG 551

552 BOMAG 008 915 04
14.1 Hydraulic diagram 538 110 00
008 915 04 BOMAG 553

554 BOMAG 008 915 04

Hydraulic diagram 538 110 00 14.1
008 915 04 BOMAG 555

556 BOMAG 008 915 04

14.2 Pneumatic diagram 538 120 00
008 915 04 BOMAG 557

558 BOMAG 008 915 04

Pneumatic diagram 538 120 00 14.2
008 915 04 BOMAG 559

560 BOMAG 008 915 04

14.3 Wiring diagram 538 100 03
008 915 04 BOMAG 561

562 BOMAG 008 915 04

Inhaltsverzeichnis: BW 24 RH TIER 3
008 915 04
table of contents: BW 24 RH TIER 3
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing ! no.
001 538 100 03 Stromlaufplan Circuit Diagram
002 538 100 03 Versorgung, Starten, Steckdose supply, starting unit, socket
003 538 100 03 Bremse, Not!Aus, Warnsummer brake, emergency off, warning buzzer
004 538 100 03 Überwachung monitoring unit
005 538 100 03 Berieselung, Signalhorn sprinkler system, warning horn
Wiring diagram 538 100 03
007 538 100 03 Blinkbegrenzung, Arbeitsbeleuchtung (StVZO) illumination, working light (StVZO)
009 538 100 03 Fahrtricht., Fahrstufenumschalt., Rückfahrwarnsum. traveling directon, speed selection, warning buzzer,
012 538 100 03 Tachograph, Geschwindigkeitsanzeige tachograph, speedometer
013 538 100 03 Heizung, Klimaanlage heating, air conditioning
014 538 100 03 Kabine cab
015 538 100 03 Arbeitsscheinwerfer ROPS worklamp RORS
016 538 100 03 Diebstahlschutz System anti ! theft system
017 538 100 03 Kantenschneidgerät edge cutter
101 538 100 03 Bauteilliste component listing
BOMAG
18.4.2008
Nallin 001 001 538 100 03
Stromlaufplan
18.4.2008
14.3
563
circuit diagram 001
Seis
564
X2:3!1
X2:1!2 X2:1!1
X2:2!1
14.3
F01
X2:4!1 F37
5:2 30A
Sicherung F05
fuse
X2:2!2 Sicherung
fuse
15A
X2:5!1 30
7:5 30 X2:3!2
30 X13:A K11
P0123
P01 2:18
S00
X89:B
X89:A
87 87a
Zündstartschalter
K32 14:1 ignition switch 15 54 58 19 17
50a
X1:13
F124 X13:B X13:C

7:2 15 3:1 K11 3:6
X2:6!1
2 ZA/option Sicherung F119
F00
X2:24!1 fuse 7,5A
125A Sicherung Battrie
fuse, battery Sicherung F124 X2:6!2 F119
1 F119 2:15 2:12 F119 14:6
25A
X1:17
X2:24!2 1 ZA/option X1:129
(6) V46
X2:26!1
1 2 Meldeleuchte Ladekontrolle
Sicherung indicator light, charge control Sicherung F195
X1:163 30
fuse 5A X6:+
G01+ 2:8 F48 86 1 X6:+ 2:16 K05 X6:+
125A 9:13 X2:26!2
B+ 2 K62 R09 H08 2:12 4:6
2:8 87 87a
X6:14 H52
BOMAG
(8) 30 85 2
2
+ G01 102AH X1:106
K14 2:13 X6:3
X1:23
+ G03 P00
W D+ X14:A X14:B
! Batterie (9) 87 G02 Betriebsstundenzähler X1:21
battery
! 2.Batterie Generator operating hour meter
2.battery generator X6:!
4:18 3:5
B! B+ X1:166 X1:165
2:5 M! 2:7 2
ZA/option
R81
R82
R83
R84
S30 G01+ K11
Batterietrennschalter Glühstifkerzen 1!4 2:1 4 3 86 + XS
switch battery disconnect pen. type glow plug 1!4 B+ K14
2:1 2 Y01 12V
2 1 5 85 !
30 50
X51:C br X63:3 V01 X1:167
R79 87a 87
M01 1
X91:B K31 1 86
13:1 K86 K86 2:15 K! 3:9
! X1:28
M! 2:7 2:7 M! M! 3:3 85 30
X1:164 X1:168 X1:168 X1:125 31 3:1
4:1 Startmehrmenge 2:5 2:17 2:15 Steckdose

start boost fuel
socket
Kraftstoffvorheizung
fuel, pre!heating Starter Relais/Steuergerät Glühstiftkerzen Kontrollampe Glühüberwachung
starter
relay/controll unit, glow plugs indicator light, glow plug
29.04.2008
1 1
008 915 04
Nallin Versorgung, Starten, Steckdose 538 100 03

18.06.2008
Seis supply, starting unit, socket 002
2:12 15 15 4:1
2:19 K11 K11 5:1
X2:7!1 F14
Sicherung 10A
fuse F25 X2:13!1
Sicherung 10A
X2:7!2 fuse
008 915 04
X2:13!2
X1:8
S111 9:12
X1:1
B0T 12 21 31
S111
B0
Bremsschalter
switch brake A15
11 22 32
X1:9
K22 30
3:17
X6:24 X6:23
87 87a
X1:44 X1:46
3:3
9:7
X1:144
11 21 31
X1:145 S01 12 22 32 A100:6

9:2
K112 30 Not!Aus!Schalter
21 switch, emergency off
BOMAG
S01 3:9
X1:14
Not!Aus!Schalter 87 87a
switch, emergency off 3:12
22 X1:97
X30:1
86
K22 +
X1:15
X1:98 H07
X1:48 !
X1:47 86 Relais Motor Stop 85
K112
X6:12 X6:11 relay, engine stop
2 Y13 1 + H20 + H01 Y04 1 2
! ! 85
V41 1 2 X30:2
(1) 2 V42 1
2:12 M! M! 3:11 2:12 X6:! X6:! 4:18 3:4 M! M! 4:11 (2)
2:19 K! K! 3:17 3:10 K! K! 9:6
X1:49
31 X1:49 X1:49 X1:49
2:20 31 4:1
Hubmagnet Motor 3:7 Bremsventil 3:3 Warnsummer
shut off solenoid, engine solenoid valve, brake warning buzzer
Meldeleuchte Bremskontrolle
indicator light, brake Meldeleuchte Bremse Überwachungsmodul
indicator light brake monitoring module
22.04.2008
1 1 538 100 03
Nallin Bremse, Not!Aus, Warnsummer
18.06.2008
14.3
565
Seis brake, emergency off, warning buzzer 003
566
3:20 15 15
X2:9!1
F129
X2:8!1 F04 5A
14.3
15A
Sicherung Sicherung
fuse
fuse
X2:8!2 X2:9!2
F04 F04 7:13
X1:51
F120
7:19
X6:26
Bremsdruck Meldeleuchte Motoröl
brake pressure indicator light, engine oil pressure
Bremsöltemp. Meldeleuchte Motorüberhitzung

brake oil, temp. idicator ligh, engine overheating
Wasserrestmenge Meldeleuchte Luftfilter
water reserve indicator light, air cleaner
Kühlmittelvorrat Motor Differenzdruck Hy.
X6:+ indicator light, eng. coolant res. idicator ligh, hydr.oil filter X6:+
2:17
H86 H79 H73 H09 H49 H15 H23
H43
R20
X6:15 X6:11 X6:8 X6:16 X6:17

X6:18 X6:20 X6:19
X1:45 X1:25 X1:26 X1:24 X1:22
X1:108 X1:109 X1:107 X1:105
X1:155
R21
R22
H70
Tankanzeige
X1:157 level gauge
X1:156
X6:21 X6:22 P01
X1:142 Q
BOMAG
X1:20 X1:19
X1:153
30 86 X1:103 X1:102 X6:1
K36 30 X98:1 B22 1
K62 K104 X1:42
5:5
2:8
X1:126
87 87a 85 3 B55 p 2 1
87 87a
B124 X10:2 X10:1
X1:151 X1:91 X1:128 4
X27:1 2
geplant B03 31 B21
B102 3 Fußbremse B12 1 B148 1 X98:2 projected 1 B06 3 B152
foot brake 1 B33
P R03
P P P P _t
42 p
5 BAR 4 2 120_GC 2 2 4
2
M! M!
MD+ 5:1 X27:2 2:11 X6:! X6:25
3:12 7:1 X10:3
X1:158 X1:125 X1:154 X1:49 X1:159
31
5.7+/!0.6BAR
3:20 31 5:1
Meldeleuchte Wasser im Diesel
7:19 indicator light, water in fuel
Geber Kraftstofftank
sender, level gauge
29.04.2008
1 1
008 915 04
Nallin Überwachung 538 100 03

18.06.2008
Seis monitoring unit 004
3:20 K11 K11 7:1
4:2 MD+
F37 X2:22!1
2:5 Sicherung
fuse F06
008 915 04
10A
X2:12!1
X2:22!2
Sicherung F37
fuse 20A
Sicherung
F23 fuse
10A
X2:4!2
86
K104
X2:12!2
85
Berieselung
sprinkler system
23 13
1 0 2
S05 10
24 14 X1:52
13
X1:12 S03
13
Taster Signalhorn
15/54 14
BOMAG
A04 switch warning horn
30 Modul Berieselung
modul, sprinkler system
87
X1:43
X1:132
X17:1
+ X1:127
M02 2
+
11A V02
! B11
1
X17:2 !
Signalhorn
X1:133 X1:111 X1:49 warning horn
31 X1:125 31
4:20 7:1
4:9
Berieselungspumpe
sprinkler pump
20.07.2006
1 1 538 100 03
Nallin Berieselung, Signalhorn
04.08.2006
14.3
567
Werner sprinkler system, warning horn 005
568
5:20 K11 K11 9:1
30 X2:15!1 4:20 F04 F04 12:1 X2:23!1 X2:17!1
X2:11!1 2:5 F70 F120
2:7 F124 F07 F156
Sicherung 20A Sicherung
14.3
Sicherung 15A 15A 15A

F22 Sicherung fuse fuse 1 fuse
15A S185
fuse X2:5!2 X2:15!2 X2:23!2 X2:17!2
X2:11!2 X1:41 Überwachungsmodul X1:4
X1:146 monitoring module Schalter Beleuchtung
13 23 2 F120
L0R A15 switch head lights 11 23 4:3
S37 X6:8 012
13
S26 Schalter Nachtbeleuchtung
Schalter Blinker 14 24 switch, night lamp
switch indicator S15 12 24
14 X1:6 X1:7 X1:2 X1:3
X1:147
E61 49L 49R
+ 30 X2:18!1 X2:19!1
Blinkgeber X2:20!1 X2:21!1
flasher F09 Sicherung Sicherung F10
A02 10A fuse fuse 10A
X1:93
! 31 Sicherung F12 Sicherung
fuse fuse
E04 X2:18!2 X2:19!2 10A
F11 10A
+ 82
X2:20!2 X2:21!2
switch, working head lights

X1:54 A42
L R 14:6
!
Schalter Arbeitsbeleuchtung
X6:19
30
X6:18 X1:31 X1:121 X1:122 X1:32 X1:130 X1:131 K36
13 4:3
01 23 X1:55 X1:123 X95:2!2
X1:33 X1:124 X95:1!2 87 87a
X1:34 V12
S14
X95:1!2
X95:2!3
X1:50
+ + + +
E12 E14 E16 E17
X96:1!2
X96:2!7
14 24 V13
! ! ! X1:94
+ ! +
X95:1!1
X96:1!1
X95:2!1
X96:2!1
X96:1!3
E13 E15
BOMAG
H05 ZA
X96:2!3 2 1 ! option
X97:1 X97:1 !
1 1
1 1 H(!)
H06 7:7 E41 E43
X95:1!6
X95:2!6
56b 56b
X96:1!7
X96:7!7
E08 E10
E18 E19 1 1 2 2 1 1
switch, hazard light

2 2
Schalter Warnblinker
31 31 E09 E11 E33 E34
X97:2 X97:2
X95:1!4 2 2 2 2
X96:1!5
X96:2!5
X95:2!4 X95:1!5 X95:2!5
links/left
X96:1!6 X96:1!4 X96:2!4
rechts/right
X96:2!6 X6:7
H06 MV 7:13 7:8 MV MV 7:17 7:16 MV
4:16 M! M! 7:8 H(!) 7:11 7:3 M! M! 9:8

31
X1:49
X1:111
5:20 X1:125 31 9:1
X1:49
Arbeitsscheinwerfer Meldeleuchte Blinker Scheinwerfer links
indicator light, indicators Parkleuchte links
working head light Meldeleuchte Warnblinker Blinkleuchte VL Blinkleuchte VR head light LH
Bel. Reifendruckanz. indicator light, hazard light indicator front,lh. indicator front,rh. parking light lh.
illum. wheel pressure Schlußleuchte links Parkleuchte rechts Scheinwerfer rechts
Bel. Geschwindigkeitsanz.. Blinkleuchte HL tail light,lh parking light rh. head light RH
indicator rear,lh
illum. speedometer Blinkleuchte HR Schlußleuchte rechts Bremsleuchte links
indicator rear,rh. tail light,rh brake light lh
Bremsleuchte rechts
brake light rh
18.04.2008
1 1
008 915 04
Nallin Blinkbegrenzung, Arbeitsbeleuchtung (StVZO) 538 100 03

18.06.2008
Seis illumination, working light (StVZO) 007
Meldeleuchte Warnblinker
7:20 K11 K11 17:1
F77 X2:16!1 X2:14!1

Sicherung 10A F26 10A
fuse Sicherung
X2:16!2 fuse X2:14!2
008 915 04
X1:143
31 X1:53
S01 Schalter, NOT AUS
3:12 switch, emergency off
32
X1:5
K42
9:9
+ br/brn X1:81 + br/brn

X11:1 X12:1
r0v r0v 13 21
S31 S184
123 S02
123
Fahrtrichtungsschalter R V Fahrtrichtungsschalter
bl/blu
sw/blk
rt/red
switch, travel direction R V switch, travel direction Fahrstufenschalter
rt/red
sw/blk
bl/blu
X11:2 X11:3 X11:4 X12:4 X12:3 X12:2 14 22 speed range selector
X1:82 X1:83 2 3 X1:148 X1:149 1

11 12 15/54 14 15 15/54 X1:16 X1:27
A100 (!) X1:99 X1:110
6 7 5 4 Modul Lenkstocker Fahrtrichtung 9 13 10 8
A100:6 modul, lever switch, travel direction
3:20
BOMAG
K42
86 9:6 Beide Fahrhebel in 0!Stellung:
K42 S111
Out K05 high = Startfreigabe
3:14
30
K42
X1:95 X1:96 85 9:7
87 87a
Y16
X3:1 1 Y03 1 Y130 1
X1:92
+ 85
Y17 2 2
H14 1 2 2
! Y163 1 Y164 1 V45
X3:2 1 K05
2 2 2 86
3:18 K! M!
X1:133 7:20 M! 13:6
X1:49 X1:111 X1:111
7:20 31 31 12:1
Warnsummer Rückfahrwarneinrichtung 9:10 Mag.!ventile Fahrtri 2:13 Mag.ventil Fahrstufe, links

warning buzzer back up alarm solenoid valves travel dir. switch over sol.valve speed range, l.h.
Mag.vent. Fahren, vorw. Mag.ventil Fahrstufe, rechts

sol.valve speed range, r.h.
solenoid valve traveling, forw.
Relais Startstrom
Mag.vent. Fahren, rückw. relay starting current
solenoid valve traveling, backw.
17.04.2008
1 1 538 100 03
Nallin Fahrtricht., Fahrstufenumschalt., Rückfahrwarnsum.
18.06.2008
14.3
569
Seis traveling directon, speed selection, warning buzzer, 009
570
7:15 F04 F04 16:1
14.3
Lernmodus
to learn
Anzeigetest
diagnose
Tachographenmodul
B15.1
module, tachograph Lern Test
15/54
15/54
12:12
X1:61
5 A16 4 A05
IN
2 1 6 3 7.8.9
12:12
OUT+ 1
OUT!
X1:10 + X1:11
B15.1
P04
P09.A2
14:6
P09.A1 !
14:6
X1:73 X1:71 ZA
option
B4 B3 A2 A3 A1
BOMAG
X24:4
P09 C3
SW/BK X24:3
BR/BR X24:1
Anzeige
indicator
A5 A6
B15
X24:2
BL/BU
Rexroth
G02 X1:72
14:8
31 X1:111
9:20 31 13:12
Aufnehmer Geschwindigkeit Geschwindigkeitsanzeige
transducer speed
speedometer
ZA
option
09.01.2007
1 1
008 915 04
Nallin Tachograph, Geschwindigkeitsanzeige 538 100 03

09.01.2007
Werner tachograph, speedometer 012
F31
14:2
D
F31 F68:G
Box 1 G 14:2
4 F68 H F F15 14:2
008 915 04
B Box 1
F40 F15
0123 Schalter Kabinenlüfter 7 F68:7 14:6
BOX 1 BOX 1
switch, cabin ventilator Schalter Kabinenheizung
8 switch, cab heating 6
3
S44
L M H C 4 5
A72 2 A72:2
14:6
Steuergerät
low
mid
high
control unit
S28
1
6 11 12 6 2 1 3
ZA
X65:3
X65:2
X65:4
30 option
K85 X63:7 X63:4 X63:6 X53:6

14:19
X52:1 15 1 4 7 6
87 87a 1
Diagnose
B103 X49:1 diagnostics
Thermofühler Klimaanlage _t
temperature sensor 2
X52:2
X40:1
X40:3
X50:1 1 P18
X40:2
E30
X43:1 _t B131 Heizung
4 2 heater timer
Thermofühler Heizung
temperature sensor, heating
B104 P
Überwachung Kühlmitteldruck LP HP X49:2
3
monitoring coolant pressure
BOMAG
X43:3 X43:4 5 8 10
X53:3
X53:5
X43:2
X45:3
X42:3
X45:2
X42:2
X45:4
X42:4
ge rt or ge rt or X55:1 X54:1
X21:1 Y15 1 E30 13:18 13:14 E30
M09 M09
2 1 1 Y14
br br V09 Y138 2
V10
1 2 2
X42:1 X45:1 X54:2
9:10 M! Magnetventil Heizung 12:20 31 31 16:1
solenoid valve, heating unit
X40:4 X55:2
2:4 K31 K31 14:1
Kabinenlüfter
cab ventilator indicator light, air conditioning Kraftstoffpumpe
fuel pump heating unit
Klimakompressor
air conditioning compr.
ZA ZA
option option
12.01.2007
1 1 538 100 03
Nallin Heizung, Klimaanlage
14.3
571
12.01.2007
Werner heating, air conditioning 013
572
K32 X91:A
2:6 K32 15:1
X51:B
14.3
F68:G 7:14 A42 A42

13:19 15:7
30
K32 2:19 F119 X51:A
14:16 X63:8 14:1 E72+ F143 14:17 14:15 F143

A72:2
87 13:11
Wischer vorne Wischer hinten 15A

F143
windscreen wiper, front windscreen wiper, rear Inline!Fuse
13:19 F15
E A B C
13:19 F31 13:11 F68:7 F27 F28 X63:5
F110 F41
25A Box 1 15A Box 1
Box 1 Box 1 P09.A1 X67:A X67:A 15A S163 5
15A 12:5
5 1 2 3
option Tachograph K141 30
E72+ X67:B
14:11 P09.A2
12:5 14:18 1
X67:B 87 87a
S20 7 S21 7
1 1 1
0 2 2 0 2 2
1 1 1 1 X66:1 X67:B X67:A 01 S53
01
E72
S53 2 2 2 2 1 +
S45 5 4 5 4
30 S38 A12 Radio R80 1 5
K118 E71 1
S20 S21 S38 radio
switch, worklamp
14:20
Schalter Arbeitsscheinwerfer
5 15 30
87 87a X64:4 + 2
indicator
S158 2 X64:2
Kontrolleuchte
X63:1
X62:1
X63:2
X62:2
E72!
X64:5
X64:3
X64:6
X64:8
14:7 B51 31 B51
Auffindbeleuchtung option X61:C X61:A
BOMAG
X64:7
E70
+
! X67:C
X46:31b
X46:53
X44:31b
X44:53
X46:53a
X44:53a
E32 ! G02
12:5
+ + X67:C X46 +
53
53a
31b
53
53a
31b
Abfallverzögert
3 min
E29 +
E23 E25 XS option X44
+ X67:C 86 K32 86 K118
53a
+ + 12V ! Tachograph I 15 86 K85

! ! M04 M06 M05 M07
53a
E28 E27 K141
31b 53
31
! 2,5A
31 ! 31 ! 31 85
! ! 85 85
31b 53
31
E72! X61:B X61:B
14:1 14:15 14:13
X64:1 X44:31 X46:31 X61:B
13:19 K31 K31 15:1

Arbeitsscheinwerfer vorne Steckdose Heizung Heckscheibe
working lights, front socket Wascher vorn heating rear screen
washer motor,front
Arbeitsscheinwerfer hinten Kennleuchte Nachtbeleuchtung Wischermotor vorn Wischermotor hinten 14:4 14:17 13:2 14:4
working lights, rear
rotary beacon night lamp wiper motor front wiper motor rear
Wascher hinten
Kabinenleuchte washer motor,rear
cabin inside light
20.07.2006
1 1
008 915 04
Nallin Kabine 538 100 03

04.08.2006
Werner cab 014
14:20 K32
008 915 04
14:20 A42
13 A
S53
F108
1
14
30
K135
15:14
87 87a
BOMAG
+ +
E23 E25
! !
86
K135
+ +
E28 E27
85 ! !
14:20 K31
Arbeitsscheinwerfer vorne
working head lights, front
15:16 Arbeitsscheinwerfer hinten Arbeitsscheinwerfer hinten

working head lights, rear working head lights, rear
ZA
option
20.07.2006
1 1 538 100 03
Nallin Arbeitsscheinwerfer ROPS
04.08.2006
14.3
573
Werner worklamp RORS 015
574
14.3
A67 1 2 3
Keyboard
keyboard
4 5 6
7 8 9
* 0
X22:1
X22:2
A66
Steuereinheit
control unit
BOMAG
13:15 31 31 17:1
ZA
option
20.07.2006
1 1
008 915 04
Nallin Diebstahlschutz System 538 100 03

04.08.2006
Werner anti ! theft system 016
9:20 K11 K11
X2:25!1
1
F45 10A
Sicherung
008 915 04
2
X2:25!2
X1:181
0 13 23
S34 0
14 24
X1:182 X1:183
X1:185 X1:186
BOMAG
1 1
Y20
Y21
2
2
X1:184 31
16:12 31
Mag.ventil/solenoid valve
Kantenschneidgerät ab
edge cutter down
Mag.ventil/solenoid valve
Kantenschneidgerät hoch
edge cutter up
07.04.2008
Nallin Kantenschneidgerät 538 100 03
07.04.2008
14.3
575
Seis 0558 edge cutter 017
Name Bl. Pf. Benennung title TYP
14.3 A02
A04
A05
007
005
012
9
7
15
Blinkgeber
Modul Berieselung
Elektronik Geschwindigkeitsanzeige
Flasher
modul sprinkler system
Electronic system, speedometer
4X21WATT
A12 014 9 Radio Radio
A15 003 18 Ueberwachungsmodul monitoring module
A15 007 10 Ueberwachungsmodul monitoring module
A16 012 6 Elektronik Tachograph Electronic system, tachograph
A66 016 9 Elektronik Steuereinheit Electronic control unit
A67 016 15 Eingabeeinheit Keyboard
A72 013 7 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A100 009 8 Modul, Lenkstockschalter Fahrrichtung modul, lever switch, travel direction
B03 004 15 Unterdruckschalter Luftfilter neu Vacuum switch, air cleaner new
B06 004 12 Druckschalter Motoroel Pressure switch, engine oil
29.4.08
Nallin
29. 4. 8
B11 005 16 Signalhorn Warning horn

B12 004 6 Druckschalter Bremse Pressure switch, brake 5.7+/!0.6BAR
B15 012 10 Aufnehmer Geschwindigkeit Transducer, speed
B21 004 15 Differenzdruckschalter Hydr.!Oelfilter Pressure diff. switch, hydr. oil filter
B22 004 16 Differenzdruckschalter Hydr.!Oelfilter Pressure diff. switch, hydr. oil filter
B33 004 9 Sensor Wassertankrestmenge Sensor, water tank residual quantity
B51 014 9 Lautsprecher Radio Speaker radio
B51 014 10 Lautsprecher Radio Speaker radio
B55 004 10 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B102 004 3 Druckschalter Bremsleuchten Pressure switch, brake lights 5 BAR
B103 013 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning 4_GC
B104 013 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B124 004 17 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B131 013 9 Temperaturschalter Heizung Temperature switch, heating 110_GC
B148 004 8 Temperaturschalter Bremsoel Temperature switch, brake oil 120_GC
B152 004 13 Temperaturgeber Kuehlmittel temperature switch, collant
E04 007 4 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer 2W

E08 007 8 Blinkleuchte vorne links Indicator, front, lh. 21W
E09 007 9 Blinkleuchte hinten links Indicator, rear, lh. 21W
E10 007 9 Blinkleuchte vorne rechts Indicator, front, rh. 21W
E11 007 10 Blinkleuchte hinten rechts Indicator, rear, rh. 21W
E12 007 14 Parkleuchte links Parking light, lh. 5W
E13 007 13 Schlussleuchte links Tail light, lh. 5W
E14 007 15 Parkleuchte rechts Parking light, rh. 5W
E15 007 17 Schlussleuchte rechts Tail light, rh. 5W
E16 007 17 Scheinwerfer links Head light, lh. 55 W
E17 007 18 Scheinwerfer rechts Head light, rh. 55 W
E18 007 1 Arbeitsscheinwerfer links Working head light, lh. 55W
component listing
E19 007 2 Arbeitsscheinwerfer rechts Working head light, rh. 55 WATT

E23 014 2 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55W
Bauteilliste
E23 015 17 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55 WATT
E25 014 3 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
E25 015 18 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55 WATT
E27 014 3 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55W
E27 015 19 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55 WATT
E28 014 1 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55W
E28 015 16 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55 WATT
E29 014 7 Innenleuchte Kabine Inside light, cabin 21W
E30 013 13 Heizgeraet Heating unit
E32 014 5 Kennleuchte Warning light 55W
E33 007 19 Bremsleuchte links Brake light, lh. 21W
E34 007 20 Bremsleuche rechts Brake light, rh. 21W
E41 007 13 Umrissleuchte vorne links Contour illumination front, lh. 5W
E43 007 16 Umrissleuchte vorne rechts Contour illumination front, rh. E43
E61 007 3 Beleuchtung Reifendruckanzeige Illumination 2W
E70 014 7 Nachtleuchte Night lamp 5W
E71 014 17 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 2W
E72 014 1 Beleuchtung Bedienschalter illum. Switches 2W, 24V
F00 002 1 Hauptsicherung Batterie Fuse, main, battery 125A

F01 002 12 Hauptsicherung Fuse, main 30A
F04 004 18 Sicherung Instrumente Fuse, gauges 5A
F05 002 20 Sicherung Steckdose Fuse, socket 15A
F06 005 5 Sicherung Berieselung Fuse, sprinkler system 10A
F07 007 6 Sicherung Warnblinker Fuse, hazard light 15A
F09 007 13 Sicherung Park! u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 007 16 Sicherung Park! u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
F11 007 17 Sicherung Scheinwerfer links Fuse, head light, lh. 10A
F12 007 18 Sicherung Scheinwerfer rechts Fuse, head light, rh. 10A
F14 003 3 Sicherung Hubmagnet Motor Fuse, shut off solenoid, engine 10A
F15 013 17 Sicherung Heizgeraet Fuse, heating unit 5A
F22 007 2 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 15A
F23 005 16 Sicherung Signalhorn Fuse, warning horn 10A
F25 003 9 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 10A
1
F26 009 17 Sicherung Magnetv. Fahrstufenumsch. Fuse, sol. valve, speed range sel. 10A
F27 014 12 Sicherung Wischer u. Wascher vorne Fuse, windscr. wiper and washer, fr. 15A
F28 014 14 Sicherung Wischer u. Wascher hinten Fuse, windscr. wiper and washer, re. 15A
F31 013 1 Sicherung Kabinenluefter Fuse, cabin ventilator 25A
F37 005 2 Sicherung Berieselungspumpe Fuse, sprinkler pump 20A
6
F40 013 14 Sicherung Kabinenheizung Fuse, heating unit cab 20A

F41 014 5 Sicherung Rundumkennleuchte Fuse, rotary beacon 15A
F45 017 7 Sicherung Kantenschneidgeraet Fuse, edgecutter 10A
F48 002 5 Sicherung Gluehanlage Fuse, glow plug system 125A
538 100 03
F68 013 9 Sicherung Potential 30 Fuse, potential 30 10A

F70 007 9 Sicherung Blinker Fuse, indicators 15A
F77 009 7 Sicherung Fahren Fuse, traveling 10A
F108 015 16 Sicherung Scheinwerfer mitte Fuse, head lights middle 25A
F110 014 4 Sicherung Scheinwerfer aussen Fuse, head lights outside 25A
101
F119 002 12 Sicherung Motor Fuse, motor 7,5A

F120 007 19 Sicherung Bremsleuchte Fuse, brake light 15A
576 F124 002 6 Sicherung Kraftstoffvorwaermung BOMAG
Fuse, fuel pre!heating 25A 008 915 04
F129
F156
004
F143 014
007
1
17
17
Sicherung, MD+
Sicherung Heckscheibenheizung
Sicherung StvzO
Fuse, MD+
fuse rear screen heating unit
Fuse, StvzO
15A
15A
20A
14.3
F195 002 15 Sicherung Steuergeraet Vorgluehen Fuse, glow plug control 5A
G01 002 1 Batterie Battery 102AH

G02 002 7 Generator Generator 90A
G03 002 3 Batterie Battery 102AH
H01 003 7 Meldeleuchte Bremse Indicator light, brake LED IN A15

H05 007 11 Meldeleuchte Blinker Indicator light, indicators LED IN A15
H06 007 6 Meldeleuchte Warnblinker Indicator light, hazard light LED IN A15
H06 007 6 Meldeleuchte Warnblinker Indicator light, hazard light LED S14, 18MA
H07 003 18 Warnsummer Betriebsstoerung Warning buzzer, breakdown 9!30V CA70MA
29.4.08
Nallin
29. 4. 8
H08 002 11 Meldeleuchte Ladekontrolle Indicator light, charge control LED IN A15
H09 004 12 Meldeleuchte Oeldruck Motor Indicator light, engine oil pressure LED IN A15
H14 009 2 Warnsummer Rueckwaertsfahrt Back!up alarm buzzer 8!15V CA0,3A
H15 004 15 Meldeleuchte Motorluftfilter Indicator light, engine air filter LED IN A15
H20 003 6 Meldeleuchte Sitzkontaktschalter Indicator light, drivers seat contact LED IN A15
H23 004 16 Meldeleuchte Hydraulikoelfilter Indicator light, hydr.oil filter LED IN A15
H43 004 6 Meldeleuchte Bremsdruck Indicator light, brake pressure LED IN A15
H49 004 13 Meldeleuchte Motorueberhitzung Indicator light, engine overheating LED IN A15
H52 002 17 Anzeige Gluehueberwachung Glow plug indicator LED IN A15
H70 004 18 Anzeige Wasser im Diesel Indicator water in fuel
H73 004 10 Meldeleuchte Kuehlmittelvorrat Indicator light, eng. coolant res. LED IN A15
H79 004 9 Meldeleuchte Wasserrestmenge Indicator light, Water res. LED IN A15
H86 004 8 Meldeleuchte Bremsöltemperatur Indicator light, brake oil temperature LED IN A15
K05 009 13 Relais Startstrom Relay, starting current BOSCHW

K11 002 18 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHW
K14 002 13 Relais Vorgluehen Relay, glow plug system BOSCHL
K22 003 17 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
K32 014 16 Relais Kabine Relay, cabin BOSCHL
K36 004 3 Relais Bremskontrolle Relay, brake control BOSCHW
K42 009 7 Umschaltrelais Relay, switch over BOSCHW
K62 002 8 Relais D+ Relay, D+ BOSCHW
K104 005 5 Relais, Stoermeldungen Relay, failure indication BOSCHW
K112 003 9 Relais, Meldeleuchte Bremse Relay, indicator light brake BOSCHW
K118 014 20 Relais Arbeisscheinwerfer Relay, working lights BOSCHW
K135 015 14 Relais Arbeisscheinwerfer Relay, working lights BOSCHW
K141 014 18 Relais Heckscheibenheizung relay, heating rear screen BOSCHW
component listing
M01 002 8 Starter Starter

Bauteilliste
M02 005 6 D*Berieselungspumpe E*Sprinkler pump 11A

M04 014 11 Scheibenwischermotor vorne Windscreen wiper motor, front 7,9A
M05 014 14 Scheibenwischermotor hinten Windscreen wiper motor, rear 7,9A
M06 014 13 Scheibenwaschermotor vorne Windscreen washer motor, front 2,5A
M07 014 15 Scheibenwaschermotor hinten Windscreen washer motor, rear 2,5A
M09 013 1 Kabinenluefter Cabin ventilator MAX.11A
M09 013 3 Kabinenluefter Cabin ventilator MAX.11A
P00 002 11 Betriebsstundenzaehler Operating hour meter

P01 004 18 Tankanzeige Level gauge IN A15
P04 012 15 Geschwindigkeitsanzeige Speedometer
P09 012 5 Frequenz! und Geschwindigkeitsanzeige Frequency! and Speedometer
P18 013 18 Diagnose Diagnostics
R03 004 19 Geber Tankanzeige Sender, level gauge

R03 004 20 Geber Tankanzeige Sender, level gauge
R09 002 9 Vorwiderstand Dropping resistor 82 OHM
R20 004 18 Widerstand Resistor
R79 002 6 Kraftstoffvorwärmung fuel pre!heater 200W
R80 014 17 Heizung Heckscheibe heating rear screen MAX. 13A
R81 002 4 Gluehstiftkerze 1 glow plug 1
S00 002 12 Startschalter Starter switch

S01 003 12 Schalter NOT AUS Switch, emergency off
S02 009 18 Fahrstufenschalter Switch, speed range selector
S03 005 16 Taster Signalhorn Push button, warning horn
S05 005 6 Berieselungsschalter Switch, sprinkler system
S14 007 6 Warnblinkschalter Switch, hazard light
S15 007 17 Beleuchtungsschalter StVZO Switch, lighting StVZO
S20 014 12 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 014 14 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S26 007 2 Schalter Arbeitsbeleuchtung hinten Switch, working head lights, rear
2
S28 013 17 Schalter Kabinenheizung Switch, cabin heating

S30 002 1 Batterietrennschalter Switch, battery disconnect
S31 009 4 Schalter Fahrtrichtung Switch, travel direction
S34 017 7 Schalter Kantenschneidgeraet Switch, edge cutter
S37 007 9 Schalter Blinker Switch, indicator
6
S38 014 5 Schalter Kennleuchte Switch, warning light

S44 013 1 Schalter Kabinenluefter Switch, cabin ventilator
S45 014 7 Schalter Kabineninnenleuchte Switch, cabin inside light
S53 014 20 Schalter Arbeitsbeleuchtung Switch, working lights
538 100 03
S53 015 14 Schalter Arbeitsbeleuchtung Switch, working lights

S111 003 11 Schalter Feststellbremse Switch, parking brake
S158 014 7 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 014 18 Schalter Heckscheibenheizung switch rear screen heating unit
S184 009 10 Schalter Fahrtrichtung switch, travel direction
102
S185 007 13 Schalter Nachtbeleuchtung Modul switch, night illumination module
008 915
V01 04 002 9 Diode BOMAG
Diode MR756, KABEL 577
14.3 V02
V09
V10
005
013
013
18
6
10
Diode
Diode
Diode
Diode
Diode
Diode
FE5B, KABEL
FE5B
STECKER Y138
V12 007 11 Diode Diode IN A15
V13 007 11 Diode Diode IN A15
V41 003 2 Diode (A1) Diode (A1) DIODENMODUL
V42 003 13 Diode (A2) Diode (A2) Diodenmodul
X1:1 003 12 Wago Zentralelektrik Wago e!box

29.4.08
Nallin
29. 4. 8

X1:17 002 15 WAGO ZENTRALELEKTRIK WAGO E!BOX
component listing

Bauteilliste

3

6

538 100 03

103

578 X1:125 002 18 Wago Zentralelektrik BOMAG
Wago e!box 008 915 04
X1:125
X1:125
004
X1:125 005
007
9
16
8
Wago Zentralelektrik
Wago e!box
Wago e!box
Wago e!box
14.3
29.4.08
Nallin
29. 4. 8

X2:1!1 002 4 Wago Zentralelektrik Wago e!box
component listing

Bauteilliste

4

6

538 100 03
X3:1 009 2 WARNSUMMER H14 Warning buzer H14

X3:2 009 2 WARNSUMMER H14 Warning buzer H14
X6:1 004 19 ARMATURENPULT Instrument board
104

008 915
X6:11 04 003 7 ARMATURENPULT BOMAG
Instrument board 579
14.3 X6:11
X6:12
X6:14
004
003
002
12
6
10
ARMATURENPULT
ARMATURENPULT
ARMATURENPULT
Instrument board
Instrument board
Instrument board
29.4.08
Nallin
29. 4. 8

XS 002 20 Steckdose Socket
XS 014 6 Steckdose Socket 15A
X10:1 004 20 KRAFTSTOFFTANK Fuel tank
X11:1 009 6 FAHRTRICHTUNGSSCHALTE switch, travel direction
X12:2 009 10 FAHRTRICHTUNGSCHALTER switch, travel direction
X13:A 002 12 FAHRERSTAND Operators platform
X13:B 002 12 FAHRERSTAND Operators platform
X13:C 002 13 FAHRERSTAND Operators platform
X17:1 005 6 BERIESELUNGSPUMPE Sprinkler pump
X17:2 005 6 BERIESELUNGSPUMPE Sprinkler pump
X19:1 016 5 KEYBOARD Keyboard
component listing

Bauteilliste

X21:1 013 7 KLIMAKOMPRESSOR Air conditioning compr.
X24:1 012 10 B15 B15
X24:2 012 10 B15 B15
X24:3 012 10 B15 B15
X24:4 012 9 B15 B15
X27:1 004 9 WASSERTANK Water tank
X27:2 004 9 WASSERTANK Water tank
X30:1 003 18 H82 H82
X30:2 003 18 H82 H82
X40:1 013 1 Kabine cabin
X43:1 013 7 FAHRERSTAND Operators platform
X44:31b 014 12 Kabine cabin
X44:53a 014 12 Kabine cabin
X46:31b 014 14 Kabine cabin
5
X46:53a 014 14 Kabine cabin

6

X51:C 002 2 FAHRERSTAND Operators platform
538 100 03

X54:1 013 13 Kraftstoffpumpe fuel pump heating unit
X54:2 013 13 Kraftstoffpumpe fuel pump heating unit
105

580 X61:A 014 15 Kabine BOMAG
cabin 008 915 04
X61:B
X62:1
014
X61:C 014
014
15
13
14
Kabine
Kabine
Kabine
cabin
cabin
cabin
14.3
X63:3 002 2 KABINE Cabin
29.4.08
Nallin
29. 4. 8

X67:A 014 8 Kabine cabin
X67:B 014 8 Kabine cabin
X67:C 014 9 Kabine cabin
X91:A 014 2 MOTORRAUM Engine room
X91:B 002 3 MOTORRAUM Engine room
X95:1!1 007 8 Blende vorn Srceen front
component listing

Bauteilliste

X96:1!2 007 13 Blende hinten Screen rear
X97:1 007 13 ZA, Umrissleuchte Option, Contour illumination
X98:1 004 10 DEUTSCH 2POL. Deutsch 2pol.
X98:2 004 10 DEUTSCH 2POL. Deutsch 2pol.
Y01 002 11 Magnetventil Startmehrmenge Solenoid valve, start boost fuel 3,5A
Y03 009 17 Magnetventil Fahrstufenumschaltung Solenoid valve, speed range selector KABEL+STECKER
Y04 003 12 Magnetventil Bremse Solenoid valve, brake 2,41A HYTOS
Y13 003 3 Hubmagnet Motor Shut off solenoid, engine 4A
Y14 013 13 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit 2A
Y15 013 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 49W 4A
Y16 009 5 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 26,2W
Y17 009 4 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 26,2W
Y20 017 8 Magnetventil Kantenschneidgeraet Solenoid valve, edge cutter 30W
Y21 017 6 Magnetventil Kantenschneidgeraet Solenoid valve, edge cutter 30W
Y130 009 19 Magnetventil Fahrstufenumschaltung Solenoid valve, speed range selector KABEL+STECKER
Y138 013 9 Magnetveentil Heizung Solenoid valve, heating unit 3,5A
6
Y163 009 9 Magnetventil Fahrtrichtung solenoid valve, travel direction

Y164 009 10 Magnetventil Fahrtrichtung solenoid valve, travel direction
6
538 100 03
106
008 915 04 BOMAG 581

582 BOMAG 008 915 04

BW24RH Taller Nuevo

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BW24RH Taller Nuevo

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Service - Manual

Rubber tire roller

008 915 04 BOMAG 3

4.33 Boost fuel solenoid valve, Y01 103

4 BOMAG 008 915 04

12.3 Auxiliary materials 338

008 915 04 BOMAG 5

6 BOMAG 008 915 04

008 915 04 BOMAG 7

Use only genuine BOMAG spare parts.

These safety regulations must be read and ap-

8 BOMAG 008 915 04

008 915 04 BOMAG 9

10 BOMAG 008 915 04

008 915 04 BOMAG 11

12 BOMAG 008 915 04

008 915 04 BOMAG 13

14 BOMAG 008 915 04

008 915 04 BOMAG 15

Generator Starter motor

16 BOMAG 008 915 04

008 915 04 BOMAG 17

Air conditioning system ●

18 BOMAG 008 915 04

008 915 04 BOMAG 19

20 BOMAG 008 915 04

008 915 04 BOMAG 21

22 BOMAG 008 915 04

Nuts for screw joints with full load capability (4, 5,

Fig. 8 Identification of nuts

Strength class of Strength class of associated

Nuts for screw joints without specified load factor

008 915 04 BOMAG 23

Identification in clock system Identification of UNF-threads

Fig. 9 Identification of nuts in clock system

Studs and brake rods

24 BOMAG 008 915 04

008 915 04 BOMAG 25

The values specified in the table apply for screws:

Tightening torques for screws with metric unified thread1

Tightening torques for screws with metric unified fine thread1

26 BOMAG 008 915 04

Tightening torques for wheel nuts (fine thread) 1 2

008 915 04 BOMAG 27

The values specified in the table apply for screws:

28 BOMAG 008 915 04

008 915 04 BOMAG 29

30 BOMAG 008 915 04

008 915 04 BOMAG 31

2.1 Technical data

32 BOMAG 008 915 04

Additional engine data

008 915 04 BOMAG 33

34 BOMAG 008 915 04

- the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC

- Vibration Protection Regulation 2002/44/EC

Guaranteed sound power level:

Hand-arm vibration values

008 915 04 BOMAG 35

36 BOMAG 008 915 04

008 915 04 BOMAG 37

Notes on the performance of the engine

38 BOMAG 008 915 04