Service Manual BF600C

Service - Manual
BF 600 C - HCE/HCG
BF 600 C - HSG/HSE
BF 600 C - E/G
S/N 821 837 45 .... 821 837 46 ....
S/N 821 837 47 .... 821 837 48 ....
S/N 821 837 53 .... 821 837 61 ....
Road Finisher
Catalogue number.
008 916 41 04/2011
Table of Contents
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 13
1.4 Tightening torques 25
Technical data 29
2.1 Technical data 30
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 chart 44
Fundamental electrics 47
4.1 Understanding wiring diagrams 48
4.2 Circuit symbols in the circuit diagram 53
4.3 Battery ground and analog ground 54
4.4 Processor signals 54
4.5 Current and voltage 55
4.6 Pulse width modulation, PWM 57
4.7 Resistance 59
4.8 Series / parallel connection 61
4.9 Ohm's law 63
4.10 Electrical energy 63
4.11 Formula diagram 64
4.12 Metrology 65
4.13 Diodes, relays, fuses 69
4.14 Inductive proximity switches 72
4.15 Plug connectors 73
4.16 Magnetic coil plug 74
4.17 Deutsch plug, series DT and DTM 76
4.18 Plugs and terminals in spring clamping technology 82
4.19 Batteries 86
4.20 Battery maintenance 90
4.21 Starting with jump wires 91
4.22 Main battery switch 91
4.23 Fuses 92
4.24 Replace heating elements 95
4.25 Failure codes, SAUER controller 98
Engine electrics 99
5.1 Installation location for engine control unit 100
5.2 EMR3 system components 101
5.3 Pin assignment of engine control EDC16 / EMR3 106
5.4 Camshaft speed sensor 111
5.5 Crankshaft speed sensor 112
5.6 Rail pressure sensor 115
008 916 41 BOMAG 3

Table of Contents
5.7 Fuel pressure sensor 117

5.8 Fuel control unit FCU 118
5.9 Injectors 120
5.10 Oil pressure sensor 121
5.11 Charge air temperature - charge air pressure sensor 122
5.12 EMR coolant temperature sensor 124
5.13 Glow plugs 126
5.14 Sensor, water in fuel, C39 127
5.15 Air filter vacuum switch, C40 127
5.16 Level probe coolant tank, C38 128
5.17 Diagnostics interface 128
5.18 Diagnose with CAN-bus 130
5.19 Diagnose with SERDIA 131
5.20 Fault code indication, diesel engine 134
5.21 EMR3 List of fault codes 135
5.22 Generator 208
5.23 Electric starter 217
Engine 225
6.1 Diesel engine 226
6.2 Engine description TCD 2013, 4 and 6 cylinder 227
6.3 Lubrication oil circuit TCD 2012 / 2013 231
6.4 Coolant circuit TCD 2012 / 2013 232
6.5 Fuel system TCD 2012 / 2013 233
6.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 235
6.7 Exhaust gas recirculation TCD 2012 / 2013 239
6.8 Wastegate - charge pressure controller on TCD-engines 240
6.9 Engine problems 242
6.10 Check the engine oil level 245
6.11 Changing engine oil and oil filter cartridge 245
6.12 Change the fuel pre-filter cartridge 247
6.13 Change the fuel filter cartridge 248
6.14 Check, clean the water separator 249
6.15 Check the coolant level 249
6.16 Change the coolant 250
6.17 Combustion air filter service 250
6.18 Adjusting the valve clearance 252
6.19 Adjusting the control piston play 254
6.20 Clean the cooling fins on engine and hydraulic oil cooler 255
6.21 Check the engine mounts 256
6.22 Replacing the crank case ventilation valve 257
6.23 Electronic injector test EMR 257
6.24 Engine conservation 258
6.25 Checking/replacing the heating generator toothed belt 258
6.26 Check, tension, replace the V-belt 259
6.27 Special tools, Deutz engine (TCD 2013 2V) 261
Service Training Hydraulics 281
7.1 General 282
7.2 Travel system 284
4 BOMAG 008 916 41

Table of Contents
7.3 Actuator drive 313

7.4 Scraper chain drive 326
7.5 Vibration and tamper drive 337
7.6 Fan drive 353
Tests and adjustments 361
8.1 Check and adjust 362
8.2 Checking and adjusting the tamping pressure limitation 366
8.3 Checking and adjusting charge pressurerelief/high pressure relief and pressure
override travel pump 370
8.4 Checking and adjusting the adjusting times and pressure limitations for mobile sc-
reeds 374
8.5 Measuring the max. fan motor speed 379
Central lubrication system 383
9.1 BF 600C with HC screed, 32 lubrication points 384
9.2 BF 600C with HC screed, 34 lubrication points 386
9.3 Filling the lubricant container 388
9.4 Electric pump 389
9.5 Integrated electronic control 393
9.6 Progressive distributor 397
9.7 Fault - Cause - Remedy 403
9.8 Repair of a blocked distributor 405
Suppliers documentation 407
10.1 Travel pump 409
10.2 Travel motor 563
10.3 Conveyor screws - scraper belt motor 657
10.4 Travel gear 675
Circuit diagrams 711
11.1 Hydraulic diagram 2542306 713
11.2 Wiring diagram DE006002 717
008 916 41 BOMAG 5

Table of Contents
6 BOMAG 008 916 41

1 General
008 916 41 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 008 916 41

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

These safety regulations must be read and ap-
and gloves.
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident l Keep unauthorized persons away from the machine
prevention instructions and the safety regulations during repair work.
in the operating and maintenance instructions l Tools, lifting gear, lifting tackle, supports and other
must be additionally observed.
auxiliary equipment must be fully functional and in
Repair work shall only performed by appropriately safe condition.
trained personnel or by the after sales service of l Use only safe and approved lifting gear of sufficient
BOMAG. load bearing capacity to remove and install parts or
components from and to the machine.
Workshop equipment and facilities as well as the
use and waste disposal of fuels and lubricants, l Do not use easily inflammable or harmful substanc-
cleaning agents and solvent as well as gases and es, such as gasoline or paint thinners for cleaning.
chemicals are subject to legal regulations, which l Do not smoke or use open fire and avoid sparks
are intended to provide a minimum on safety. It is when cleaning or repairing a tank.
obviously your own responsibility to know and
adhere to these regulations.
l When performing welding work strictly comply with
the respective welding instructions.
This manual contains headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to inform about and avoid dan- Transport work with cranes and lifting
gers to persons, property and the environment. tackle
i Note i Note
Paragraphs marked like this contain technical infor- Cranes must only be operated by instructed persons
mation for the optimal economical use of the machine. who had been trained in handling cranes.
l Follow the operating instructions of the manufactur-
Caution
! er when working with cranes.
Paragraphs marked like this highlight possible l Follow the operating instructions of the operator
dangers for machines or parts of the machine. when working with cranes.
l Always comply with the applicable accident preven-
Danger
!
tion instructions when working with cranes and lift-
ing tackle.
Paragraphs marked like this highlight possible
dangers for persons.
Precautions and codes of conduct for
welding work
Environment
Welding work must only be carried out by properly
Paragraphs marked like this point out practices
trained personnel.
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Danger
!
Observe the regulations for the protection of the
environment. Electric shock!
Sparks, fire hazard, burning of skin!
General Infrared or ultraviolet radiation (arc), flashing of
l
For repair and maintenance work move the ma- eyes!
chine on a firm base and shut it down. Health hazard caused by welding work on highly
l
Always secure the machine against unintended roll- alloyed work pieces, metal coatings, paint coat-
ing. ings, plastic coatings, oil containing dirt deposits,
grease or solvent residues, etc.!
l Secure the engine reliably against unintentional
starting.
l Check welding equipment and cables for damage
before use (also the validity of inspection stickers).
l Mark a defective machine and a machine under re-
pair by attaching a clearly visible warning label to
l Ensure good conductivity between ground cable
the dashboard. and workpiece, avoid joints and bearings.
008 916 41 BOMAG 9

l 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-
tection agents and washing facilities must therefore
l Always isolate the burner when laying it down (re-
be provided.
move possible electrode residues).
l Wear protective clothes and safety gloves, if possi-
l Protect cables from being damaged, use cables
with insulated couplings. ble.
l If there is a risk of eye contact you should protect
l 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
l 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.
l Avoid longer and repetitive contacts with oils. In
case of open incisions and injuries seek medical ad-
l Remove any combustible materials from the weld- vice immediately.
ing area or cover such items appropriately. l Apply protective cream before starting work, so that
l Name a fire watch during and after welding work. oil can be easier removed from the skin.
l Place welding rod holders and inert gas welding l Wash affected skin areas with water and soap (skin
guns only on properly insulated bases. cleansers and nail brushes will help). Lanolin con-
l 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.
l
Use a protective screen or hand shield with welding
l
Do not use gasoline, kerosene, diesel, thinner or
filter, wear welding gloves and clothes. solvents to wash the skin.
l
Switch the welding unit off before connecting weld-
l
Do not put oil soaked cloths into your pockets.
ing cables. l
Avoid clothes getting soiled by oil.
l
Check electrode holders and electric cables at reg- l
Overalls must be washed at regular intervals. Dis-
ular intervals. pose of non-washable clothes environmentally.
Behaviour in case of faults l
If possible degrease components before handling.
l
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,
l
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.
l
Replace damaged insulating jaws and welding rod
holders immediately. Hydraulics
l
Replace the welding wire reels only in de-energized l 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.
l
Keep calm. l
Always make sure that all screw fittings have been
l Call first air helpers. tightened properly and that hoses and pipes are in
l
Report the accident. mint condition before pressurizing the system
again.
l
In case of an electric accident: Interrupt the power
supply and remove the injured person from the
l 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
l 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 008 916 41

Safety regulations 1.2
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.
l 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
l 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
l 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
l
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. 5 min-
l 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: l Maintenance and cleaning work on the engine must
l 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
l
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).
l
Observe the accident prevention regulations for
electric systems (e.g. -VDE-0100/-0101/-0104/-
008 916 41 BOMAG 11

0105 Electric precautions against dangerous con- l Always ensure an adequate supply of fresh air
tact voltages). when refuelling in closed rooms.
l Cover all electric components properly before wet l Dispose of used filters in accordance with applica-
cleaning. ble environmental regulations.
l When performing repair and maintenance work col-
Battery lect oils and fuels in suitable containers and dispose
l Always wear goggles and protective clothing to of in compliance with applicable environmental reg-
service or clean batteries! Battery acid can cause ulations.
severe injury by cauterization when coming in con- l Do not heat up oils higher than 160 °C because they
tact with skin. may ignite.
l
Work only well ventilated rooms (formation of oxy- l Wipe off spilled or overflown oil using suitable
hydrogen gas). cleaning means and dispose of in accordance with
l Do not lean over the battery while it is under load, applicable environmental regulations.
being charged or tested (danger of explosion). l Dispose of old batteries according to applicable en-
l Keep ignition sources away from the battery. Burn- vironmental regulations.
ing cigarettes, flames or sparks can cause explo-
sion of the battery
l There is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature! Allow
l Use battery chargers etc. only in strict compliance engine and hydraulic system to cool down to a suf-
with the operating instructions.
ficient level.
l
After an accident with acid flush the skin with a suf- l
Do not exceed the max. permissible tire pressure.
ficient amount of water and seek medical advice.
l
Do not allow children access to batteries.
l
When mixing battery fluid always pour acid into wa-
ter, never vice-versa.
Special safety regulations

l
Use only genuine BOMAG spare parts for repair
and maintenance work. Genuine spare parts and
original accessories were specially developed, test-
ed and approved for the machine.
l
The installation and use of non-genuine spare parts
or non-genuine accessories may therefore have an
adverse effect on the specific characteristics of the
machine and thereby impair the active and/or pas-
sive driving safety. The manufacturer explicitly ex-
cludes any liability for damage caused by the use of
non-original parts or accessories.
l
Unauthorized changes to the machine are prohibit-
ed for safety reasons.
l Do not perform any cleaning work while the engine
is running.
l
If tests on the articulated joint need to be performed
with the engine running, do not stand in the articu-
lation area of the machine (danger of crushing!).
l
If tests must be performed with the engine running
do not touch rotating parts of the engine (danger of
injury!).
l
Always ensure an adequate supply of fresh air
when starting in closed rooms. Exhaust gases are
highly dangerous!
l Refuel only with the engine shut down. Ensure strict
cleanliness and do not spill any fuel.
12 BOMAG 008 916 41

General repair instructions 1.3
General Electrics
1.3 General repair instructions
l
Before removing or disassembling parts, assem- General
blies, components or hoses mark these parts for
easier assembly. Due to the fast technical development electric and
electronic vehicle systems become more intelligent
l Before assembling and installing parts, assemblies and more comprehensive day by day, and can hardly
or components oil or grease all movable parts or be dispensed with in hydraulic and mechanical vehicle
surfaces as required and in compliance with the systems.
compatibility of materials.
Diagnostics according to plan
Well structured trouble shooting procedures can save
time and money.
Random tests have revealed that purely electronic
components or control units only very rarely are the
actual cause of failures:
l In approx. 10 % of the examined cases the prob-
lems were caused by control units.
l In approx. 15 % sensors and actuators were the
cause of the problems.
By far the highest proportion of all faults could be
traced back to wiring and connections (plugs, etc.).
General:
l
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Knowledge in basic electrics is re-
quired for this purpose. If a fault was diagnosed
without having pulled the plug of the control unit or
inspected the wiring, this should be done before
changing any parts.
l
Check for good cable and ground contacts, there-
fore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
l
Always use the machine related wiring diagram for
testing. If one or more faults were detected, these
should be corrected immediately.
l
Do not disconnect or connect battery or generator
while the engine is running.
l
Do not operate the main battery switch under load.
l
Do not use jump leads after the battery has been re-
moved.
l Sensors and electric actuators on control units must
never be connected individually or between exter-
nal power sources for the purpose of testing, but
only in connection with the control unit in question.
l
It is not permitted to pull plugs off while the voltage
supply is switched on (terminal 15 "ON")! Switch the
voltage supply "OFF" first and pull out the plug.
l Even with an existing polarity reversal protection in-
correct polarity must be strictly avoided. Incorrect
polarity can cause damage to control units!
008 916 41 BOMAG 13

l Plug-in connectors on control units are only dust Battery

and water tight if the mating connector is plugged
on! Control units must be protected against spray Rules for the handling of batteries
water, until the mating connector is finally plugged When removing a battery always disconnect the mi-
on! nus pole before the plus pole. When installing the bat-
l Unauthorized opening of control electronics (Micro- tery connect the minus pole after the plus pole to avoid
controller MC), modifications or repairs in the wiring short circuits.
can cause severe malfunctions. Fasten the terminal clamps with a little force as possi-
l
Do not use any radio equipment or mobile phones ble.
in the vehicle cab without a proper aerial or in the vi- Always keep battery poles and terminal clams clean to
cinity of the control electronics! avoid high transition resistances when starting and
the related development of heat.
Electrics and welding
Make sure the battery is properly fastened in the vehi-
cle.
!Caution
Before starting welding work you should discon-
nect the negative battery pole or interrupt the
electric circuit with the main battery switch, dis-
connect the generator and pull the plugs off all
control units in order to protect the electrical sys-
tem of the machine.
l Disconnect the minus pole of the battery or interrupt
the electric circuit with the main battery switch.
l Isolate the generator and all control units from the
electric circuit.
l Always fasten the earth clamp of the welding unit in
the immediate vicinity of the welding location.
l When choosing the location for the earth clamp
make sure that the welding current will not pass
through joints or bearings.
14 BOMAG 008 916 41

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.
008 916 41 BOMAG 15

Hydraulic system l Perform measurements at operating temperature of

the hydraulic oil (approx. 40 ¯C).
!Caution
l After changing a component perform a high and
charge pressure test, if necessary check the speed
Repair work on hydraulic elements shall only per-
of the exciter shaft.
formed by appropriately trained personnel or by
the after sales service of BOMAG. l The operating pressure of the exciter shaft to a
great extent depends on the base under the vibrat-
Please note ing drum. On hard ground place the drums on a suit-
able base and check the drum pressure. Do not
i Note activate the vibration on a hard, concreted base,
danger of bearing damage.
Cleanliness is of utmost importance. Dirt and other
contaminations must strictly be kept out of the system. l After the completion of all tests perform a test run
and then check all connections and fittings for leaks
l Connections and screw fittings, filler neck covers
with the engine still stopped and the hydraulic sys-
and their immediate surrounding areas must be
tem depressurized.
cleaned before removal.
l Before loosening hoses, pipe lines etc. relieve all Before commissioning
pressure from the system. l Fill the housings of hydraulic pumps and motors
l During repair work keep all openings closed with with hydraulic oil. Use only hydraulic oils according
clean plastic plugs and caps. to the specification in the maintenance instructions.
l Never run pumps, motors and engines without oil or
l
After changing a component flush the hydraulic sys-
hydraulic oil. tem as described in the flushing instructions.
l When cleaning hydraulic components take care not Taking into operation
to damage any fine machine surfaces. l
Bleed the hydraulic circuits.
l Chemical and rubber soluble cleansing agents may l
Start up the hydraulic system without load.
only be used to clean metal parts. Do not let such
substances come in contact with rubber parts.
l
Check the hydraulic oil level in the tank, if neces-
sary top up with hydraulic oil as specified in the op-
l Rinse of cleaned parts thoroughly, dry them with erating and maintenance instructions or drain oil off
compressed air and apply anti-corrosion oil immedi- into a suitable container.
ately. Do not install parts that show traces of corro-
sion. After taking into operation
l Avoid the formation of rust on fine machined caused l
Check fittings and flanges for leaks.
by hand sweat. l
After each repair check all adjustment data, system
l Use new O-rings or seal rings for reassembly. pressures, rotational speeds and nominal values in
l Use only hydraulic oil as sliding agent when reas- the hydraulic system, adjust if necessary.
sembling. Do not use any grease! l
Do not adjust pressure relief valves and control
l Use only the specified pressure gauges. Risk of valves to values above their specified values.
damaging the pressure gauges under too high pres-
sure.
l Check the hydraulic oil level before and after the
work.
l Fill in only clean oil as specified in the maintenance
instructions.
l Check the hydraulic system for leaks, if necessary
find and rectify the cause.
l Before taking new hydraulic components into oper-
ation fill these with hydraulic oil as specified in the
operating and maintenance instructions.
l After changing a hydraulic component thoroughly
flush, refill and bleed the complete hydraulic sys-
tem.
16 BOMAG 008 916 41

Notes on cleanliness for Common Rail l Blow drying with compressed air is only permitted
engines while the fuel system is still closed.
Special requirements with respect to cleanliness in

l When using steam cleaning equipment cover con-
the fuel system do apply for commissioning, mainte- trol unit, cable plugs, all other electrical connections
nance and repair work, particularly for TEIRIII engines and the generator beforehand and do not expose
with the DEUTZ Common Rail System. Contamina- these items to the direct steam jet.
tion like dirt, welding residues or similar can lead to the l Electrical plug connections must be plugged in dur-
failure of individual components and adversely affect ing jet cleaning.
engine operation. l Remove loose parts (e.g. paint scales that may
have come off during assembly work) with an indus-
trial vacuum cleaner or any means of extraction.
l Vacuum cleaning equipment must generally be
used for cleaning when the fuel system is open.
l Perform work on the fuel system only in a clean en-
vironment (no dust, no grinding or welding work).
Avoid draughts (dust). The workshop floor must be
cleaned at regular intervals. No brake or power test
stand should be present or operated in the same
room.
l
Air movements, which could swirl up dust, such as
brake repairs or starting of engines, must be strictly
avoided.
l
For work, such as disassembly and assembly of de-
fective hydraulic components in the Common Rail
System, it is strongly recommended to set up a sep-
arate workshop area, i.e. an area which is spatially
separated from all other areas (general vehicle re-
pairs, brake repairs).
l
No general machine tools should be operated in this
room.
l
Periodic cleaning of this workshop area is obligato-
Fig. 1 ry, draughts, ventilation system and heating blow-
l
Spare parts should be left in their original packaging ers must be minimized.
as long as possible and should only be unpacked l
Engine compartment area where dirt particles could
just before use. come loose, should be covered with new, clean foil.
l
When parts are unpacked any connections must be l
Working means and tools must be cleaned before
closed with suitable plugs or caps, in order to pre- being used for work. Use only tools without dam-
vent (Fig. 1) contamination of hose connections. If aged chromium coating, or tools without chromium
e.g. fuel hoses are connected to one side, while the coating.
second side cannot yet be connected, there is a
danger of dirt entering into the system. The free Notes and measures to be applied during work in
connection must in this case also be appropriately the fuel system
closed. l
Wear clean working clothes.
Notes and measures to be applied before starting l Use only lint-free cleaning cloths for work in the fuel
work in the fuel system system.
l
The fuel system must be closed. Visual examination l
Remove loose parts (e.g. paint scales that may
for leaks / damage in the fuel system. have come off during assembly work) with an indus-
l
Before starting work in the fuel system clean the
Vacuum cleaning equipment must generally be
complete engine and the engine compartment with
used for cleaning when the fuel system is open.
the system still closed.
l Working means and tools must be cleaned before
l
The engine should be dry before work is started in
being used for work. Use only tools without dam-
the fuel system.
aged chromium coating, or tools without chromium
coating.
008 916 41 BOMAG 17

l Do not use any previously used cleaning or testing l Remove loose parts (e.g. paint scales that may
fluids for cleaning. have come off during assembly work) with an indus-
l Compressed air should never be used for cleaning
when the fuel system is open. l Working means and tools must be cleaned before
being used for work. Use only tools without dam-
l Work on disassembled components must only be
carried out at a specially furnished work place. aged chromium coating, or tools without chromium
coating.
l When disassembling or assembling components
you should not use any materials from which parti-
cles or fibres could flake off (cardboard, wood, tow-
els).
l Dismantled parts must only be wiped off with clean,
lint-free cloths if required. No dirt particles must be
wiped into the components.
l Close openings on components and engine imme-
diately with suitable plugs/caps.
l Plugs/caps must only be removed just before the in-
stallation.
l Keep plugs/caps in their original packaging, where
they are protected against dust and dirt, dispose of
after one time use.
l
Take new parts out of their original packaging just
before installation.
l
Disassembled components must be stored in new,
sealable bags or – if available – in the packaging
material of the new components.
l
Always use the original packaging material of the
new part to return the disassembled old component.
Notes and measures concerning the workshop

area
l
For work, such as disassembly and assembly of de-
fective hydraulic components in the Common Rail
System, it is strongly recommended to set up a sep-
arate workshop area, i.e. an area which is spatially
separated from all other areas (general vehicle re-
pairs, brake repairs).
l The workshop floor must be sealed or tiled.
l
No welding equipment, grinding machines, general
machine tools, brake or power test benches must
be operated in this room.
l
Periodic cleaning of this workshop area is obligato-
ry, draughts, ventilation system and heating blow-
ers must be minimized.
Notes and measures for work place and tools in

the workshop
l
A special work place must be set up for work on dis-
assembled components.
l Clean disassembly and assembly tools at regular
intervals and keep these in a closed tool cabinet.
18 BOMAG 008 916 41

Fuel hoses Gaskets and mating surfaces
Leaking sealing faces can mostly be traced back to in-
correct assembly of seals and gaskets.
l Before assembling a new seal or gasket make sure
that the sealing surface is free of pitting, flutes, cor-
rosion or other damage.
l Inappropriately stored or handled seals (e.g. hang-
ing from hooks or nails) must under no circumstanc-
es be used.
l Assemble seals and gaskets only with sealing com-
pound, grease or oil, if this is specifically specified
Fig. 2 in the repair instructions.
l If necessary remove any old sealing compound be-
! Caution fore assembling. For this purpose do not use any
tools that could damage the sealing surfaces.
All fuel hoses have two layers of material, a rein-
forced rubber coating outside and an internal Vi- l Sealing compound must be applied thin and evenly
ton hose. If a fuel hose has come loose one must on the corresponding surfaces; take care that the
make absolutely sure that the internal Viton layer compound does not enter into oil galleries or blind
has not been separated from the reinforced outer threaded bores.
layer. In case of a separation the hose needs to be l
Examine the contact faces for scratches and burrs,
replaced. remove these with a fine file or an oilstone; take
care that no grinding dust and dirt enters into
tapped bores or enclosed components.
l
Blow out lines, ducts and gaps with compressed air,
replace any O-rings and seals that have been dis-
lodged by the compressed air.
Assembly of radial seals
Fig. 3
l
Lubricate the sealing lips (2) (Fig. 3) with clean
grease; in case of double seals fill the space be-
tween the sealing lips with a generous amount of
grease.
l
Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.
i Note
If possible, use an assembly sleeve (1 (Fig. 3)), to
protect the lip from being damaged by sharp edg-
es, threads or splines. If no assembly sleeve is avail-
008 916 41 BOMAG 19

able, you should use a plastic tube or adhesive tape Feather keys and keyways
to prevent the sealing lip from being damaged.
l Lubricate the outer rim (arrow 3 (Fig. 3)) of the seal Caution
!
and press it flat on the housing seat.
Feather keys may only be reused if they are free of
damage.
Fig. 4
l
Press or knock the seal into the housing, until it is
flush with the housing surface.
i Note
Fig. 5
If possible, use a "bell" (1 (Fig. 4)), to make sure that
the seal will not skew. In some cases it may be ad-
l Clean and thoroughly examine the feather key.
visable to assemble the seal into the housing first, be- l Deburr and thoroughly clean the edges of the key-
fore sliding it over the shaft. Under no circumstances way with a fine file before reassembling.
should the full weight of the shaft rest on the seal.
If you have no proper service tools at hand, use a suit-
able drift punch with a diameter which is about 0,4 mm
smaller than the outer diameter of the seal. Use VERY
LIGHT blows with the hammer if no press is available.
20 BOMAG 008 916 41

Ball and roller bearings l Check shaft and bearing housing for discolouration
or other signs of movement between ball or roller
bearing and seats.
!Caution
l Make sure that shaft and housing are free of burrs
Ball and roller bearings may only be reused if they
before assembling the ball or roller bearing.
are free of damage and do not show any signs of
wear. l Always mark the individual parts of separable ball or
roller bearings (e.g. taper roller bearings) to enable
correct reassembling. Never assemble the rollers to
an outer race that has already been used, replace
the complete ball or roller bearing instead.
Fig. 7
!Caution
When assembling the ball or roller bearing to the
shaft load must only be applied to the inner race 1
(Fig. 7).
When fitting the bearing into the housing load
must only be applied to the outer race (2).
Fig. 6
l If a ball or roller bearing of a bearing pair shows de-
fects, both ball or roller bearings need to be re-
placed.
l
Remove any lubricant residues from the ball or roll-
er bearing to be examined by washing it with gaso-
line or any other appropriate degreasing agent.
Ensure strict cleanliness.
l
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. Replace the ball or roller bearing if
necessary.
l
Check the ball or roller bearing for clearance and re-
sistance between the inner and outer races, replace
if necessary.
l
Lubricate the ball or roller bearing with the recom-
mended type of grease before assembly or reas-
sembly.
l
On greased bearings (e.g. wheel bearings) fill the
space between ball or roller bearing and outer seal
with the recommended type of grease before as-
sembling the seal.
008 916 41 BOMAG 21

Screws and nuts Strength classes, metric screws

The strength classes (from 3.6 to 12.9) are specified
Tightening torque
for all strength classes from a nominal diameter of
5mm. The corresponding identification can be found
!Caution where allowed for by the shape of the screw.
Tighten nuts or screws with the tightening tor-
ques specified in the following tables of tighten-
ing torques. Tightening torques deviating from
the ones in the table are specially mentioned in
the repair instructions.
Damaged screws must under no circumstances
be used any longer. Recutting threads with thread
cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or cor-
roded thread pitches can cause incorrect torque
value readings.
Self-locking nuts must generally be replaced after
disassembly.
The use of screws with too high strength can
cause damage!
l Nut of a higher strength can generally be used in-
stead of nuts of a lower strength classification.
l When checking or retightening screw joints to the
specified tightening torque you should first relieve
Fig. 8 Identification of screws
by a quarter turn and then tighten to the correct
torque. Example: A screw is identified with 12.9.
l Before tightening you should lightly oil the thread, in The first number corresponds with 1/100 of the nomi-
order to ensure low friction movement. The same nal tensile strength (minimum tensile strength) in N/
applies for self-locking nuts. mm2.
l Make sure that no oil or grease will enter into blind l
The nominal tensile strength is 12 X 100 N/mm2 =
tapped bores. The hydraulic power generated when
1200 N/mm2.
turning in the screw could cause breakage of the ef-
fected part. The second number specifies 10-times the ration be-
tween lower yield point and nominal tensile strength
(yield point ratio).
i Note
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas-
tic deformation).
When exceeding the upper yield point the material will
not restore its original shape after being relieved.
l The lower tensile strength is 9/10 X 1200 N/mm2 =
1080 N/mm2.
i Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.
22 BOMAG 008 916 41

Strength classes of metric nuts Identification in clock system
Nuts are differentiated by three load groups. Each
load group has a special designation system for the
strength class assigned, so that the load group can be
clearly identified.
Nuts for screw joints with full load capability (4, 5,

6, 8, 10, 12)
Fig. 10 Identification of nuts in clock system

For small nuts (Fig. 10) the clock system can be used
for identification.
l The 12 o'clock position is identified by a dot or the
manufacturer's symbol.
Fig. 9 Identification of nuts l
The strength class is identified by a dash (b).
In a connection with a screw, these nuts 1 (Fig. 9)
must be able to bear the full pre-load at the yield point.
Nut height above 0.8 d (d = nominal dimension).
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
6 6.8
8 8.8
9 9.8
10 10.8
12 12.8
Nuts for screw joints with limited load factor (04,

05)
The preceding "0" indicates that, due to their low
height, nuts 2 (Fig. 9) in this group are only able to
withstand the force of a screw to a limited extent.
Nut height below 0,8 d (d = nominal dimension).
Nuts for screw joints without specified load factor

(11H, 14H, 17H, 22H)
This standard contains strength classes (hardness
classes) for nuts 3 (Fig. 9), for which no load values
can be specified, e.g. because of their shape and di-
mensions, but which can only be classified by their
hardness.
Nut height below 0,5 d (d = nominal dimension).
008 916 41 BOMAG 23

Identification of UNF-threads Cotter pins
Fig. 12
In places where cotter pins are used, these must be
reassembled. Cotter pins must generally be renewed
after disassembly.
Cotter pins must be assembled as shown in the illus-
tration, unless specified differently.
Fig. 11
Screws
The screw head is marked with a stamped in, round
cavity 3 (Fig. 11).
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 008 916 41

Tightening torques 1.4
The values specified in the table apply for screws:
1.4 Tightening torques
l black oiled
l with surface protection A4C
l with surface protection DACROMET
i Note
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with metric unified thread*
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M4 3 5 5
M5 6 9 10
M6 10 15 18
M8 25 35 45
M10 50 75 83
M12 88 123 147
M14 137 196 235
M16 211 300 358
M18 290 412 490
M20 412 578 696
M22 560 785 942
M24 711 1000 1200
M27 1050 1480 1774
M30 1420 2010 2400
* Coefficient of friction  tot. = 0,14
Tightening torques for screws with metric unified fine thread*
Screw dimension
8.8 10.9 12.9
M8 x 1 26 37 48
M10 x 1.25 52 76 88
M12 x 1,25 98 137 126
M12 x 1.5 93 127 152
M14 x 1.5 152 216 255
M16 x 1.5 225 318 383
M18 x 1.5 324 466 554
M20 x 1.5 461 628 775
M22 x 1.5 618 863 1058
M24 x 2 780 1098 1294
M27 x2 1147 1578 1920
M30 x 2 1568 2254 2695
008 916 41 BOMAG 25

Tightening torques for screws treated with anti-seizure paste OKS 240* (copper paste)
Screw dimension
8.8 10.9 12.9
M16 169 240 287
M16 x 1.5 180 255 307
M18 232 330 392
M18 x 1.5 260 373 444
M20 330 463 557
M20 x 1.5 369 502 620
M22 448 628 754
M22 x 1.5 495 691 847
M24 569 800 960
M24 x 2 624 879 1036
M27 840 1184 1520
M27 X 2 918 1263 1536
M30 1136 1608 1920
M30 x 2 1255 1804 2156
3/4“ - 10 UNC 276 388 464
3/4“ - 16 UNC 308 432 520
* Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to high temperatures and corrosive
effects. Prevents seizure and corrosion.
Tightening torques for wheel nuts (fine thread) * **
Thread diameter
10.9
M12x1.5 100
M14x1.5 150
M18x1.5 300 - 350
M20x1.5 400 - 500
M22x1.5 500 - 600
** These values result in a 90% utilization of the yield point
26 BOMAG 008 916 41

Tightening torques 1.4
The values specified in the table apply for screws:
l black oiled
l with surface protection A4C
l with surface protection DACROMET
i Note
The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks,
as the metric ISO-thread, whereas Withworth has a flank of only 55°.
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with UNC thread, * UNC Unified Coarse Thread Series, American Unified
Coarse Thread
Screw dimension
8.8 10.9 12.9
1/4“ - 20 11 15 19
5/16“ - 18 23 32 39
3/8“ - 16 39 55 66
7/16“ - 14 62 87 105
1/2“ - 13 96 135 160
9/16“ - 12 140 200 235
5/8“ - 11 195 275 330
3/4“ - 10 345 485 580
7/8“ - 9 560 770 940
1“ - 8 850 1200 1450
1 1/8“ - 7 1200 1700 2000
1 1/4“ - 7 1700 2400 2900
1 3/8“ - 6 2200 3100 3700
1 1/2“ - 6 3000 4200 5100
Tightening torques for screws with UNF thread, * UNF Unified National Fine Thread Series, American
Unified Fine Thread
Screw dimension
8.8 10.9 12.9
1/4“ - 28 13 18 22
5/16“ - 24 25 35 42
3/8“ - 24 45 63 76
7/16“ - 20 70 100 120
1/2“ - 20 110 155 185
9/16“ - 18 155 220 260
5/8“ - 18 220 310 370
3/4“ - 16 385 540 650
7/8“ -14 620 870 1050
008 916 41 BOMAG 27

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
28 BOMAG 008 916 41

2 Technical data
008 916 41 BOMAG 29

2.1 Technical data
2.1 Technical data
Fig. 13
Dimensions in A B C D E F G H I
mm
BF 600 C 875 2700 300 755 4330 440 3360 3635 1800
L M N O P Q R S Z
560 2100 2655 180 2550 1960 2830 180 1645
* BF 600 C -HSE/HSG
Weights
Operating weight (CECE) kg 17840
Weight of basic screed kg 4200
Screed
Basic mat width mm 2550
Max. mat width without extension mm 5000
Max. mat width with extension mm 7500
Min. mat width (standard) mm 1900
Min. mat width with optional re- mm 1300
ducing plates
Mat height mm 5 ... 300
Tamper frequency Hz/ min-1 0 ... 29 / 0 ... 1740
Vibration frequency Hz/ min-1 20 ... 58 / 1200 ... 3500
Heating Gas/electric
Travel characteristics
Working speed m/min 0 - 24
Transport speed km/h 0 - 4.8
Max perm. inclination (ramp) ° 15
Max. theoretical inclination % 70
(working/transport speed)
Drive
Engine manufacturer Deutz
Type TCD 2013 L04 2V
Cooling Water
Number of cylinders 4
Rated power ISO 3046 kW(HP) 120 (160)
30 BOMAG 008 916 41

Technical data 2.1
*
BF 600 C -HSE/HSG
Rated speed rpm 2300
Fuel Diesel
Track
Crawler tracks (WxL mm 300x2700
Electric system
Voltage V 24
Batteries (2) Ah 2x100
Generator diesel engine A 55
Generator for electric heating KW 25
Conveyor system
Conveyor belt width mm 2x440
Hopper capacity m2 7.1
Filling capacities
Diesel fuel l 215
Coolant l 20
Hydraulic oil l 160
Engine oil l 15
* The right for technical modifications remains reserved
008 916 41 BOMAG 31

2.1 Technical data
Fig. 14
Dimensions in A B C D E F G H I
mm
BF 600 C 875 2700 300 755 4330 440 3360 3635 1800
L M N O P Q R S Z
560 2100 2655 180 2550 1960 2830 180 1445
*
BF 600 C -HCE/HCG
Weights
Operating weight (CECE) kg 16740
Weight of basic screed kg 3300
Screed
Basic mat width HCE/HCG mm 2500
Max. mat width without/with ex- mm 4750/7550
tension HCE/HCG
ducing plates
Basic mat width HCE/HCG mm 2550
ducing plates
Max. mat thickness mm 5 ... 300
Tamper frequency Hz/ min-1 0 ... 29 / 0 ... 1740
Vibration frequency Hz/ min-1 20 ... 58 / 1200 ... 3480
Heating Gas/electric
Travel characteristics
Working speed m/min 0 - 24
Transport speed km/h 0 - 4.8
Max perm. inclination (ramp) ° 15
Max. theoretical inclination % 70
(working/transport speed)
Drive
Engine manufacturer Deutz
32 BOMAG 008 916 41

Technical data 2.1
*
BF 600 C -HCE/HCG
Type TCD 2013 L04 2V
Cooling Water
Number of cylinders 4
Rated power ISO 3046 kW(HP) 120 (160)
Rated speed rpm 2300
Fuel Diesel
Track
Crawler tracks (WxL mm 300x2700
Electric system
Voltage V 24
Batteries (2) Ah 2x100
Generator diesel engine A 55
Generator for electric heating KW 25
Conveyor system
Conveyor belt width mm 2x440
Hopper capacity m2 7.1
Filling capacities
Diesel fuel l 215
Coolant l 20
Hydraulic oil l 160
Engine oil l 15
* The right for technical modifications remains reserved
008 916 41 BOMAG 33

2.1 Technical data
Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 700 - 800
High idle speed rpm 2200 - 2250
Valve clearance intake mm 90° (0.4 mm)
Valve clearance exhaust mm 150° (0.6 mm)
Spec. fuel consumption g/kWh 222
Travel pump
Manufacturer Sauer Danfoss
Type 90R042-KA-57
System Axial piston - swash plate
Max. displacement cm3/rev. 42
Max. flow capacity l/min 176
High pressure limitation bar 450
Travel motor
Type 51C060
System Axial piston – swash plate
Quantity 2
Max. displacement. cm3/rev. 60
Travel gear
Manufacturer Bonfiglioli
Type 707 C3B
System Transmission
Quantity 2
Vibration pump
Type PRRR 26/26 S SC47
System Gear pump
Quantity 1
Max. displacement cm3/rev. 26.2
Max. flow capacity l/min 78.6
Vibration motor screed,

Vibration motor Extension left/right
Type BF 8 with HS 500
System Gear motor
Quantity 4
Max. displacement. cm3/rev. 8.4
Tamper motor screed,

Tamper motor Extension left/right
Type SNM2/17 SC02
System Gear motor
Quantity 4
Max. displacement. cm3/rev. 16.8
Tamper pump
TYPE PRRR 26/26 S SC47
34 BOMAG 008 916 41

Technical data 2.1
System Gear pump
MAX. Displacement cm3/rev. 26.2
Scraper belt pump

System Gear pump
Quantity 1
High pressure limitation bar 270
Scraper belt motor

Type OMT 400
System Orbital motor
Quantity 2
Conveyor screw pump

System Gear pump
Quantity 1
Conveyor screw motor

Type OMT 500
System Orbital motor
Quantity 2
Service pump
Type PRRR 38/33 S SC 47
System Gear pump
Quantity 1
Max. displacement cm3/rev. 33.1
Fan motor
System Gear motor
Quantity 1
Displacement 1. step cm3/rev. 14.4
008 916 41 BOMAG 35

2.1 Technical data
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 operator’s stand:
LpA = 83 dB(A), determined acc. to ISO 11204 and EN 500
Guaranteed sound power level:

LWA = 107 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.
36 BOMAG 008 916 41

3 Maintenance
008 916 41 BOMAG 37

3.1 General notes on maintenance
3.1 General notes on maintenance and determine power, temperature level and exhaust
gas quality of the engine.
Maintenance work must only be carried out by If your engine has to work permanently in "thin air" (at
qualified and appropriately trained personnel. higher altitudes) and under full load, you should con-
When performing maintenance work always comply sult the customer service of BOMAG or the customer
with the appropriate safety regulations. service of the engine manufacturer.
Thorough maintenance of the machine guarantees far
longer safe functioning of the machine and prolongs Notes on the hydraulic system
the lifetime of important components. The effort need- During maintenance work on the hydraulic system
ed for this work is only little compared with the prob- cleanliness is of major importance. Make sure that no
lems that may arise when not observing this rule. dirt or other contaminating substances can enter into
The terms right/left correspond with travel direction the system. Small particles can produce flutes in
forward. valves, cause pumps to seize, clog nozzles and pilot
bores, thereby making expensive repairs inevitable.
l Always clean machine and engine thoroughly be-
fore starting maintenance work. l If, during the daily inspection of the oil level the hy-
draulic oil level is found to have dropped, check all
l For maintenance work stand the machine on level
lines, hoses and components for leaks.
ground.
l Seal external leaks immediately. If necessary in-
l Perform maintenance work only with the motor
form the responsible customer service.
switched off.
l
Do not store drums with hydraulic oil outdoors, or at
l
Relieve hydraulic pressures before working on hy-
least under a cover. Water can be drawn in through
draulic lines.
the bunghole when the weather changes.
l
Before working on electric parts of the machine dis- l
Always use the filling and filtering unit (BOMAG
connect the battery and cover it with insulation ma-
part-no. 007 610 01) to fill the hydraulic system.
terial.
This unit is fitted with a fine filter to clean the hydrau-
l
When working in the area of the articulated joint at- lic oil, thereby prolonging the lifetime of the filter.
tach the articulation lock (transport lock). l
Clean fittings, filler covers and the area around such
parts before disassembly to avoid entering of dirt.
Environment l
Do not leave the tank opening unnecessarily open,
During maintenance work catch all oils and fuels but cover it so that nothing can fall in.
and do not let them seep into the ground or into
the sewage system. Dispose of oils, coolant and
Notes on the cooling system
fuels environmentally.
For water-cooled engines the preparation and inspec-
tion of the coolant is of greatest importance, as other-
Notes on the fuel system
wise 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
l Keep fuel free of contaminants and water, since this protection agent into the coolant.
will damage the injection elements of the engine. The cooling system must be permanently monitored.
l
Drums with inside zinc lining are not suitable to Besides the inspection of the coolant level this in-
store fuel. cludes also the inspection of the concentration of cool-
ing system protection agent.
l The fuel drum must rest for a longer period of time
before drawing off fuel. The concentration of cooling system protection agent
can be checked by means of commercial testers (gly-
l Do not let the hose stir up the slurry at the bottom of
comat).
the drum.
l Do not draw off fuel from near the bottom of the
drum. Danger
!
Health hazard!
l The rest in the drum is not suitable for the engine
and should only be used for cleaning purposes. The mixing of nitrite based anti-freeze agents with
amine based agents results in the formation of
Notes on the performance of the engine health affecting nitrosamines.
On diesel engines both combustion air and fuel injec-

tion quantities are thoroughly adapted to each other
38 BOMAG 008 916 41

Fuels and lubricants 3.2
Environment 3.2 Fuels and lubricants
Cooling system protection agents must be dis-
posed of environmentally. 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 DQC III
ACAE E3/96/E5-02 E4-99
API CH-4/CG-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-
cation of the engine is of utmost importance when
choosing the viscosity class (SAE-class) .
Optimal operating conditions can be achieved by us-
ing the opposite oil viscosity chart (Fig. 15) as a refer-
ence.
Occasionally falling short of the temperature limits will
impair the cold starting ability, but will not cause any
engine damage. In order to keep the occurring wear
as low as possible, occasional exceeding of the limits
should not happen over a longer period of time.
008 916 41 BOMAG 39

3.2 Fuels and lubricants
Coolant, anti-freeze agent

Use only soft tap water (drinking water) to prepare the
coolant mix.
As a protection against frost, corrosion and boiling
point anti-freeze agents must be used under any cli-
matic conditions.
The proportion of cooling system protection agent
must be between min. 35% and max. 45% to the wa-
ter.
Caution
!
Do not mix different coolants and additives of any

other kind.
Environment
Cooling system protection agents must be dis-
posed of environmentally.
Fuels
Quality
You should only use commercially available brand
diesel fuel with a sulphur content below 0.5% and en-
sure strict cleanliness when filling in. A higher sulphur
Fig. 15 content has a negative effect on the oil change inter-
With their better temperature and oxidation stability vals. Use only winter-grade diesel fuel under low am-
synthetic lubrication oils offer quite a few benefits. bient temperatures. The fuel level should always be
topped up in due time so that the fuel tank is never run
Oil change intervals dry, as otherwise filter and injection lines need to be
The longest permissible time a lubrication oil should bled.
remain in an engine is 1 year. If the following oil When using fuels with a Cetan number < 49 poor
change intervals are not reached over a period of 1 starting and white smoke can be expected, in particu-
year, the oil change should be performed at least once lar in connection with low ambient temperatures.
per year, irrespective of the operating hours reached.
The following fuel specifications are permitted: DIN/
ACEA* EN 590; DIN 51 601; Nato Codes: F-54, F-75; BS
2869: A1 and A2; ASTM D 975-78: 1-D and 2-D.
E3-96/E5-02
E4-99 = 250 operating hours l DIN/EN 590
API**
l BS 2869
CG-4/CH-4 = 250 operating hours l ASTM D 975-78: 1-D and 2-D.
l Nato Codes: F-54, F-34, F44 and XF63
! Caution Winter fuel
These intervals apply only when using a diesel
fuel with maximum 0.5 % sulphur by weight and
! Danger
for ambient temperatures higher than -10 °C.
Fire hazard!
When using fuels with a sulphur content of more
than 0.5% to 1% or under ambient temperatures Diesel fuels must never be mixed with gasoline.
below -10 °C the oil change intervals specified in For winter operation use only winter diesel fuel, to
the table must be halved. For fuels with a sulphur avoid clogging because of paraffin separation. At very
content of more than 1% you should consult the low temperatures disturbing paraffin separation can
responsible service agency. also be expected when using winter diesel fuel.
In most cases a sufficient cold resistance can also be
achieved by adding flow enhancing fuel additives.
* European Engine Oil Sequences
** American Petroleum Institute Consult the engine manufacturer.
40 BOMAG 008 916 41

Fuels and lubricants 3.2
Hydraulic oil
The hydraulic system is operated with hydraulic oil
HLP-D 46 (ISO VG 46) with a kinematic viscosity of 46
mm2/s at 40°C. Use only high quality hydraulic oil,
type HLP, when filling up or changing oil.
Oil for crawler track drive gear

For the gearbox use only multi-purpose transmission
oil of API-class GL5 with viscosity class SAE 80W/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 (NLGI 3).
008 916 41 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
Motor Engine oil ACEA: E3-96/E5-02 or approx. 15 litres without

oil filter
API: CG-4/CH-4
SAE 10W/40
(-20 °C to +40 °C)
SAE 15W/40
(-15 °C to +40 °C)
Fuel
Diesel Winter diesel fuel approx. 215 litres
Engine cooling system Cooling system protection agent approx. 20 litres
Hydraulic system Hydraulic oil (ISO VG 46), HLP-D 46, approx. 160 litres
kinem. viscosity 46 mm2/s at 40 °C
Crawler track drive gear Gear oil SAE 80W/90, API GL5 2 x approx. 3,2 litres
Lubrication points, general lithium saponified multi-purpose grease, NLGI 3 as required
42 BOMAG 008 916 41

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

l Retighten the V-belt
After 50 operating hours

l Track pads for tight fit
After 250 operating hours

l Retighten bolted connections on intake and exhaust
tubes, oil sump and engine mounts.
l Retighten the bolted connections on the machine.
l Oil change diesel engine and engine oil filter
l Track drive wheel hubs, oil change
008 916 41 BOMAG 43

3.5 Maintenance chart
3.5 Maintenance chart
every 10 operating hours, daily
every 1000 operating hours


after 250 operating hours
Running-in instructions
No. Maintenance work Remark
as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Check the coolant level Inspection glass X
5.11 Lubricate the machine X
5.12 Change engine oil and oil filter car- min. 1x per year X
tridge*
5.13 Change the fuel filter cartridge X
5.14 Checking / adjusting the conveyor X
belt chain tension
5.15 Grease the conveyor belt chain X
5.16 Check the tension/adjustment of X
the conveyor belt drive chain
5.17 Check the tension/adjustment of X
the auger drive chain
5.18 Grease the sliding surfaces of the X
auger height adjustment
5.19 Grease the conveyor belt drive X
chain
5.20 Lubricate the machine X
5.21 Grease the screed extension slid- X
ing surface
5.22 Clean the cooling fins on engine X
and hydraulic oil cooler
5.23 Checking the oil level in the chain X
drive wheel hubs
5.24 Battery maintenance Pole grease X
5.25 Checking/replacing the heating X
generator tooth belt
5.26 Check, tension, replace the V-belt X
44 BOMAG 008 916 41

Maintenance chart 3.5


No. Maintenance work Remark
as required
5.27 Drain the sludge from the fuel tank X
5.28 Change the fuel pre-filter cartridge X
5.29 Check the state of the conveyor belt X
chain
5.30 Check the state of the conveyor belt X
surface
5.31 Check the state of the auger X
5.32 Auger, check state of bearing guard X
5.33 Check, adjust tamper bar and floor X
plates
5.34 Checking the track drive X
5.35 Check, adjust the valve clearance Intake = 90° (0,4 X
mm)
Exhaust = 150°
(0,6 mm)
5.36 Adjust the control piston play X
5.37 Check the engine mounts X
5.38 Change the coolant at least every 2 X
years
5.39 Change hydraulic oil and hydraulic at least every 2 X
oil filter** years
5.40 Track drive wheel hubs, oil change min. 1x per year X X
5.41 Grease the auger drive chain X
5.42 Hopper, check scrapers and rubber X
apron
5.43 Replace the crank case ventilation X
valve
5.44 Electronic injector test EMR X
5.45 Combustion air filter service min. 1x per year,  X
safety cartridge at
least every 2
years
5.46 Replace heating elements X
008 916 41 BOMAG 45

46
No.
3.5

Maintenance work
5.48 Engine conservation
** Also in case of repair in the hydraulic system.

Remark
* Oil change intervals depend on quality of oil and fuel (sulphur content)
BOMAG

X
X
as required
008 916 41
Maintenance chart
4 Fundamental electrics
008 916 41 BOMAG 47

4.1 Understanding wiring diagrams

Electric circuit diagrams are graphic presentations of control logical conditions in the electric system. They do
not contain any information on the type of wiring, their purpose is solely the clarification of control logics.
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system.
This plan provides the following information:
l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses,
switches, consumers, relays, ...
l The sequence in which current flows through the individual elements in the electric circuit.
l Connections between the examined, faulty electric circuit and other circuits in the vehicle wiring system.
l Pin assignment of plug-and-socket connections.
Structure
l Table of contents (Fig. 16)
l Current paths (Fig. 17)
l Function groups (Fig. 18)
l Potential cross references (Fig. 18)
l Relay cross references (Fig. 19)
l List of components (Fig. 20)
48 BOMAG 008 916 41

Understanding wiring diagrams 4.1
Table of contents (Fig. 16)
The table of contents lists all function groups.
Fig. 16 Table of contents
Example:
The function group "ENGINE SENSORS/MOTORE SENSORI" can be found on sheet no. 10.1 (PAGINA/
PAGE).
Current paths (Fig. 17)

The pages of a circuit diagram are sub-divided into current paths (Fig. 17) (0 ..... 9).
Fig. 17 Current paths
008 916 41 BOMAG 49

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

The individual current paths must be read as follows:
l From top (plus potential) to bottom (minus potential),
l from left to right,
l From function group to function group and
l via cross references for potentials and relays.
Potential cross references (Fig. 18)

Potential cross references serve the purpose of tracking signals, which are transmitted from one function group
to another.
Example:
Potential "GEN-ON /80.4.2" on sheet no. 80.3 is continued on sheet no. 80.4 in current path "2" (see arrow).
Fig. 18 Potential cross reference
Relay cross references (Fig. 19)

Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing
contacts.
Apart from this there is a contact plan under each contactor coil providing information about the contact types of
a relay and where these appear in the wiring diagram.
Example:
The coil of relay (E1) is located on page no. 7 in current path "8".
50 BOMAG 008 916 41

Understanding wiring diagrams 4.1
The contact pictogram under coil (E1) that a normally open contact with terminals 30 and 87 in current path 8 is
triggered.
Fig. 19 Relay cross-reference
008 916 41 BOMAG 51

List of components (Fig. 20)

This list contains all components used in alphabetical order, related to their component abbreviation (NAME)
(AD, AS, BJ,...).
Fig. 20 List of components
Component cross references

Example:
In the circuit diagram the battery (BATTERIA 12V) "LC1-C1" is located on sheet no. 5 in current path 4.
52 BOMAG 008 916 41

Circuit symbols in the circuit diagram 4.2
4.2 Circuit symbols in the circuit diagram
Circuit symbol
l Circuit symbols are standardized representations for electrical appliances. They serve the purpose of a sim-
plified representation of complete systems, from which, however, the function can be clearly identified. This
standardization is in compliance with the globally valid regulations of the IEC (International Electrical Commis-
sion). The standardization serves the purpose of global understanding and fault free connection of appliances,
especially in automobile repairs. Since the wiring diagram is intended to show only the most essential aspects,
the circuit symbol only shows as much of the function, as is needed for easy recognition and for the avoidance
of mistakes.
Fig. 1 Example: Circuit symbol

1 Current source
2 Conductor
3 Switch
4 Ground
5 Filament lamp
6 Filament lamp with two luminous elements
7 Voltmeter
8 Amperemeter
9 Resistance
10 Backup
11 Line connection (fixed)
12 Line connection (separable)
008 916 41 BOMAG 53

4.3 Battery ground and analog ground
4.3 Battery ground and analog 4.4 Processor signals

ground
Signals
GND, battery ground Analog signals
The term "ground" (abbreviated GND) describes a Process states are continuous (analog) when they
conductive body which is normally defined with the can be mapped by means of a real number, e.g. tem-
potential of "Zero" Volt and represents the reference perature = 65.5 °C. The sensor converts a continuous
potential for operating voltages. process status into an analog signal. If the control unit
The positive pole of the supply voltage (symbol + ) and needs the numerical value of the analog signal, an an-
all other electric voltages and electical signals in an alog-digital conversion is required.
electrical circuitry refer to the ground potential. Analog signals are needed to control, display or mon-
On motor vehicles and also on motorbikes and bicy- itor limit values. Checking the limit values of physical
cles the ground potential is represented by the chas- quantities leads to the binary information: Limit value
sis or the frame. As a conductive part, which covers reached/not reached.
the entire vehicle, it also serves a return conductor for
the vehicle wiring system - the consumers only need Binary signals
to be wired up. Process states are bivalent (binary) if they have only
2 possible states of truth, such as e.g. button pressed/
Terminal designation for GND = terminale 31 not pressed, object present/not present. The two
states of truth are mapped by means of defined states
AGND, analog ground of an information carrier, e.g. not-
pressed'equals0V,'pressed'equals24V.Thesestate-
Apart from the "normal" battery ground there is also
the analog ground, which is solely reserved for sen- saredescribedwith{0,1}or{false,true}'
sors.
54 BOMAG 008 916 41

Current and voltage 4.5
4.5 Current and voltage The following statements concerning electric volt-
age can be made
l electric voltage is the pressure or force applied to
General
free electrons.
If one wants to describe electric current, this can most l the electric voltage is the cause of electric current
simply be accomplished by means of a comparison:
l electric voltage is a result of the equalization at-
One simply compares electric current with water. tempt of electric charges.
Voltage is measured with a Voltmeter.
Voltage
Unit, Volt
The electric voltage (U) is measured in Volt (V).
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
008 916 41 BOMAG 55

4.5 Current and voltage
Current Types of current

Electric current generally describes the directed Direct current (D.C.)
movement of charge carriers.
l The charge carriers may either be electrons or ions.
l Electric current can only flow if there is a sufficient
amount of free moving charge carriers.
l The higher the number of electrons flowing through
a conductor per second, the higher the amperage.
Current is measured with an ammeter.
Unit, Ampere Fig. 1 Direct current (D.C.)
The electric amperage (I) is measured in Ampere Direct current flows with steady voltage and amper-
(A). age from the plus to the minus pole.
Pure D.C.-voltages are only delivered by accumula-
The technical flow direction is specified from
tors or batteries.
PLUS to MINUS.
The voltage in the vehicle wiring system is no pure
D.C.-voltage. Even without the generator running, but
i Note the consumers switched on, the voltage is not con-
Current actually flows from minus to plus, because the stant, but drops gradually according to the battery
current flow is made up of negatively charged elec- charge condition.
trons.
The internal resistance of the battery also causes per-
But since this was only discovered after the poles of a manent changes in the vehicle voltage, as soon as
current source had already been designated, the as- consumers are switched on or off.
sumption that current flows from plus to minus was
maintained for historic reasons. Alternating current (A.C.)
Circuit
Fig. 2 Alternating current (A.C.)
Fig. 3 Circuit Alternating current not only changes its direction, but
also its amperage.
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).
56 BOMAG 008 916 41

Pulse width modulation, PWM 4.6
4.6 Pulse width modulation, PWM ! Caution
PWM-valves must not be interference suppressed
Pulse - Width - Modulation, PWM
with suppressor diodes.
PWM is the abbreviation for Pulse Width Modulation,
frequently also referred to as "Pulse-Pause-Modula- What does a PWM-output do?
tion" (PPM). It is used in controls for mobile and Digital outputs normally deliver a fixed output voltage,
heavy-duty applications, mainly to control proportional as soon as they are switched on. The value of the out-
valves (PWM-valves). put voltage can in this case not be changed. In con-
The following applies: trast to this, PWM-outputs divide the voltage into a
l The signal voltage cannot be measured. very fast sequence of many square pulses. The ration
of pulse duration "switched on" to pulse duration
l The current can be measured. "switched off" determines the effective value of the de-
sired output voltage. One refers to the duty cycle (in
percent)
Fig. 1
(Fig. 1)Course of PWM-voltage U abd coil current I at
10% duty cycle: The effective coil current Ieff also is
10%
Fig. 1
(Fig. 1) Course of PWM-voltage U abd coil current I at
50%
008 916 41 BOMAG 57

4.6 Pulse width modulation, PWM
Fig. 1
(Fig. 1) Course of PWM-voltage U abd coil current I at
100%
What is a Dither?
When triggering a proportional hydraulic valve the pis-
ton will not move instantaneously and at the beginning
not proportionally to the coil current. Due to this "Slip-
Stick effect" - some kind of "breakaway torque" - the
valve at the beginning requires a slightly higher cur-
rent to be able to supply the force that is required to
move the piston out of its resting position. The same
occurs whenever changing any other position of the
valve. This effect becomes apparent in form of a jerky
movement, particularly with very low actuating
speeds.
Engineering tackles this problem by subjecting the
valve piston permanently to very small shuttle move-
ments (the dither). The piston permanently vibrates to
either side and cannot "stick". Even minor position
changes now take place without delay, i.e. like a "fly-
ing start".
Advantage: A hydraulic cylinder controlled this way,
can be operated more sensitively.
Disadvantage: With the dither the valve becomes
measurably hotter, because the valve coil is perma-
nently in action.
58 BOMAG 008 916 41

Resistance 4.7
4.7 Resistance l The cleaner the contacts, the better the current.
l The quality of the ground cable is of the same im-
portance as the supply line.
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 
The electric resistance (R) is measured in Ohm .

Rule of thumb:
l
The thicker the cable cross-section, the lower the
voltage loss.
l
The shorter the cable, the better the current.
008 916 41 BOMAG 59

4.7 Resistance
Sometimes the flanks of flat plugs bend open. If these

are closed again with the help of pliers the flanks will
be excessively strained at the bend and will definitely
break sooner or later. It is better to place a small nail
under the bottom of the cable lug before bending.
Fig. 3
In many cases it is better to replace the contact. Soiled
or oxidized contacts should be cleaned with Ballistol
(Fig. 4) and subsequently wetted with copper paste.
Copper paste is a heat resistant grease, which has
been mixed with copper powder. The paste protects
electric contacts against oxidation. Copper paste
keeps water away.
Fig. 5
Hint for practice:
A tool you cannot buy. The pliers were converted, the
nail is permanently present.
Fig. 4 Balistol oil
60 BOMAG 008 916 41

Series / parallel connection 4.8
4.8 Series / parallel connection l 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 l 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- l 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.
008 916 41 BOMAG 61

4.8 Series / parallel connection
Parallel connection l 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.
l All resistances (consumers) are supplied with the
same voltage.
l Plus and minus poles have the voltage of the single
battery applied.
l Each of the resistances (consumers) draws as
much current as required.
l The total capacity (Ah) is identical with the sum of
all battery capacities.
The disadvantage of a parallel connection becomes
apparent, by equalizing currents flowing between par-
allel batteries, if the batteries have different states of
charging.
Fig. 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.
62 BOMAG 008 916 41

Ohm's law 4.9
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 ).
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 
008 916 41 BOMAG 63

4.11 Formula diagram
4.11 Formula diagram

Description:
l Select the desired value from the inner circle.
l Determine the formula variables in the quarter circle
l Calculate
Example:
P = 150 Watt
U = 24 Volt
Sought for = Current in Ampere
I = P : U = 150 W : 24 Volt = 6.25 Ampere
Fig. 1 Formula diagram
Resistance, R Ohm 
Voltage, U Volt
Current, I Ampere
Power, P Watt
64 BOMAG 008 916 41

Metrology 4.12
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
l
the range selector switch must be correctly set for
the corresponding measurement.
! Caution l
the test cable must be plugged into the correct
This type of tester must not be used for testing on socket.
electronic components. The high power con- l
the voltage type (AC/DC) must be set.
sumption of the test lamp may destroy electronic l
In case of direct voltage the correct polarity must be
components in the control units.
assured.
Diode test lamp l
the measuring range should be chosen higher at
This instrument is used for simple voltage measure- the beginning of the test.
ments. The test lamp consists of two test points. The l In order to avoid any influence on the circuitry to be
negative measuring cable is connected to ground and measured, the internal resistance of the voltage
the positive measuring cable to the corresponding tester should be as high as possible.
measuring location.
Fig. 2 Diode test lamp

If voltage is present, the corresponding light emitting
diode will light up.
008 916 41 BOMAG 65

4.12 Metrology
Resistance and continuity measurement with mul- Voltage and voltage drop measurement with mul-
timeter timeter
Fig. 2
The continuity tester of the multimeter can be used to Fig. 4 Measuring voltage
measure whether there is a connection between 2 l Measurement at the voltage source measures the
measuring points. currently available Voltage.
l The meter is always connected parallel to consum-
er, component or power source.
Fig. 3
The following information should be observed when
measuring resistance and continuity: Fig. 5 Voltage measurement
l The component to be measured must not be con- l
A measurement at the consumer measures the volt-
nected to the power supply during the measure- age drop at this component.
ment.
l At least one side of the component to be measured
must be disconnected from the circuitry, as other-
wise the measuring result may be influenced by
parallel components.
l Polarity is of no significance.
66 BOMAG 008 916 41

Metrology 4.12
Current measurement with the multimeter Clip-on measuring instrument
The clip-on measuring instrument can be used to
measure current, voltage and resistance.
Fig. 6 Measuring current

l The meter is connected in series with the consum-
er. Fig. 1 Clip-on measuring instrument
l During the measurement the current must be able
to flow through the meter, i.e. the electric circuit
must be opened.
Fig. 2
l
For measuring current the individual conductor
must be fully enclosed by the measuring tongs, the
actual measurement takes place without contact.
Fig. 7 Current measurement
Advice
If the electric circuit is difficult to access and the inter-
nal resistance of the consumer is known, the voltage
may also be measured at the consumer.
The current value can then be calculated with the help
of Ohm's law.
008 916 41 BOMAG 67

4.12 Metrology
Magnet tester Power measurement

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

The magnet tester is used to test solenoid valves and
magnetic coils.
The test lamp responds to the magnetic fields of A.C-
voltage, D.C.-voltage and permanent magnets.
l
The component to be tested does not need to be re-
moved.
l The magnetic coil can also be tested under a pro-
tective cap.
Fig. 2
68 BOMAG 008 916 41

Diodes, relays, fuses 4.13
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:
l At 0.6 – 0.7 Volt (silicium diode) the diode becomes
conductive.
Negative voltage on diode:
l The diode does not allow current to pass through.
Fig. 2 Marking of the cathode

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

l The solenoid valve Y48 (Fig. 3) is supplied with
electric current when switch S34 is switched to po-
sition "1" or "2".
l Solenoid valve Y20 is supplied, if the switch is in po-
sition "1".
l Solenoid valve Y21 is supplied, if the switch is in po-
sition "2".
The three diodes V02 serve as free-wheeling diodes
with the function of of eliminating voltage peaks.
008 916 41 BOMAG 69

4.13 Diodes, relays, fuses
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
70 BOMAG 008 916 41

Diodes, relays, fuses 4.13
85 = Ground supply for coil Fuses
30 = Supply voltage
87 = Normally open contact
87a= Normally closed contact
Fig. 1
Fuses are used to protect lines and equipment against
overloads and short circuit. If the fuse is overloaded
the fusible wire heats up with increasing current, until
it finally melts.
Caution
!
Fuses must not be repaired or bridged.

The melting time at 23 °C is:
l
approx. 1 hour with 1.5 times the rated current
l
approx. 1 minute with 2.5 times the rated current.
A 5 Amp fuse loaded with 1.5 times the rated current
(7.5 Amp) will finally melt after approx. 1.5 hours.
Yellow = 5 A
Brown = 7.5 A
White = 8 A
Red = 16 A
Blue = 25 A
008 916 41 BOMAG 71

4.14 Inductive proximity switches
4.14 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. 4 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. 2
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. 5
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. 5) lights up, when the initiator has de-
tected metal in its stray field.
PNP circuitry
Fig. 3 PNP circuitry

On sensors with PNP-circuitry the output stage con-
tains a PNP-transistor, which switches the load
against the positive operating voltage. The load is
connected between the output and the negative oper-
ating voltage. The switch is designed with a normally
open contact, i.e. the contact closes when the initiator
comes in "contact" with metal.
72 BOMAG 008 916 41

Plug connectors 4.15
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:
l Vibration acceleration
l
Temperature fluctuations, high and low tempera-
tures
l Dampness
l Micro movements of the contact with resulting fric-
tion corrosion.
These loads may increase the transition resistances
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:
l
Low transition resistances of the conductive parts.
l
High insulation strength between conductive parts
Fig. 6 Circuit diagram, making contact
with different voltage potentials.
The circuit diagram (Fig. 6) shows a proximity switch
l
Excellent leak tightness against water and mois-
with normally open contact. ture.
Brown = voltage supply
Blue = ground supply
Black = switching output
The initiator switches the relay (K05)
008 916 41 BOMAG 73

4.16 Magnetic coil plug
4.16 Magnetic coil plug Assembly of magnetic coil plugs

These instructions are intended to explain the correct
Magnetic coil plug with LED and suppres- installation of the magnetic coil plug. The objective of
sor diode the instructions is the correct installation of the plug
and to avoid malfunctions in the field caused by mois-
The plug is equipped with a polarized function display ture and any related corrosion damage.
and a suppressor diode as protection against over-
voltages.
Fig. 7
The plug is reverse polarity protected, it does not mat-
ter whether Pin1 or Pin 2 is supplied with current, Pin
3 is not used. The LED lights if voltage is applied to the Fig. 10 Solenoid valve plug with pointed cable
solenoid valve.
Fig. 8
Fig. 11
l Connect the plug with the coil connection and press
it firmly onto the connecting housing.
Fig. 9 Switching symbol in circuit diagram
Magnetic coil plug without LED and with-

out supressor diode
The plug has no LED and no suppressor diode as pro-
tection against overvoltages.
74 BOMAG 008 916 41

Magnetic coil plug 4.16
Fig. 12 Fig. 15
l
Fasten the screw with a suitable screwdriver.
! Caution
There should be no gap between plug and sole-
noid coil!
Fig. 13
l
Press the plug firmly on again.
Fig. 16 Correctly installed plug without gap
Fig. 14
l Retighten the screw.
008 916 41 BOMAG 75

4.17 Deutsch plug, series DT and DTM
4.17 Deutsch plug, series DT and DT Series

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. 1 DT plug connection
Fig. 17 Crimp connections
Fig. 2 DT Series
Caution
!
Do not crimp more than one lead per pin or per

socket.
Sockets and pins must not be soldered to leads,
they may only be crimped (see special tools for
electrics).
When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).
Fig. 3 Sectional drawing
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
l
Perform a pull test on each lead, each of the termi-
nals and connections must withstand a pulling force
of 45 N without any difficulties.
76 BOMAG 008 916 41

Deutsch plug, series DT and DTM 4.17
Installing DT contacts
Fig. 4
l Insert the contacts through the rubber grommet until
they click into place.
l Insert the orange wedge in direction of arrow.
Caution
!

nals and connections must withstand a pulling
force of 45 N without any difficulties.
i Note
Use the same method when assembling the socket.
008 916 41 BOMAG 77

Disassembling DT contacts
Fig. 5
l Pull the orange wedge out with long nose pliers.
l
Slightly pull the lead and unlock the interlocking
hook with a screw driver.
l Pull the contact out of the socket.
i Note
In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.
78 BOMAG 008 916 41

DTM Series
Fig. 1 DTM plug connection
Fig. 2 DTM Series
Fig. 3 Sectional drawing
008 916 41 BOMAG 79

Installing DTM contacts
Fig. 4
l
Insert the contacts through the rubber grommet until
they click into place.
l
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
80 BOMAG 008 916 41

Disassembling DTM contacts
Fig. 5
i Note
l 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
l Slightly pull the lead and unlock the interlocking tools for electrics) serves as an aid to remove the
hook with a screw driver. wedges.
l Pull the contact out of the socket.
008 916 41 BOMAG 81

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

l Strip 9-10 mm of the lead.
l
Open the actuating lever and insert the strand.
l Return the actuating lever to initial position.
! Caution
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without
any difficulties.
82 BOMAG 008 916 41

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

l Insert a screw driver into the actuating opening until it bottoms.
l Strip 9-10 mm of the lead and insert it into the clamp.
l Pull out the screw driver.
Caution
!
any difficulties.
Measuring signals
On these terminal blocks the bridge slot is most suitable for tapping off and measuring signals. Here you may
directly insert a 4 mm test adapter (see special tools for electrics) for connecting a measuring lead. This test
adapter is standard in the central electrics of heavy equipment machines.
Fig. 4 Test adapter
008 916 41 BOMAG 83

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

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

l The most reliable measurements on the plug can be made when using the measuring and connecting cable
with 2mm plug (see special tools for electrics).
84 BOMAG 008 916 41

Plugs and terminals in spring clamping technology 4.18
Measuring signals
Fig. 7 X-COM plug plugged onto the series clamp
008 916 41 BOMAG 85

4.19 Batteries
4.19 Batteries Battery maintenance
Battery – accumulator
i Note
Maintenance free batteries are gaining more and
more significance, this freedom from maintenance,
however, is only limited to the fact that no water needs
to be added.
If the battery is not charged and discharged over a
longer period of time, the battery will slowly discharge
by itself.
The accumulator may only be discharged down to a fi-
nal discharging voltage of 10.5 Volt, as otherwise
there is a risk of sulphation, i.e. the generated lead
sulphate forms increasingly coarser crystals, which
will finally not react at all or only very sluggishly during
Fig. 1 a subsequent charging process.
In vehicles batteries are used to start the engine. The In the worst case the accumulator can only be dis-
ability to start the engine depends on the charge con- posed of after such an exhaustive discharge.
dition of the batteries. The following therefore applies for longer downtimes:
Lead collectors or accumulators are secondary ele- l Remove the battery and store it in a cool, dry and
ments, i.e they can be recharged after discharging frost protected room.
electric current. l Check the open circuit voltage on the battery at reg-
The basic element of a lead accumulator is the cell. It ular intervals (at least once every month).
contains the plate blocks consisting of positive and l Recharge immediately if the open circuit voltage
negative plates. These plates are separated from has dropped to 12.25 Volt (no rapid charging).
each other by separators.
All positive plates are arranged parallel to the plus
pole, the negative plates parallel to the minus pole of i Note
the cells. The open circuit voltage of batteries occurs approx. 10
h after the last charging or approx. 1 h after the last
discharge.
Battery test in general

l
Is the battery leaking? Can traces of impact, shock
or compression be found in the leaking area?
l
Check for e.g. incorrect fastening, foreign bodies on
the battery mounting surface and similar.
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.
86 BOMAG 008 916 41

Batteries 4.19
Batteries with screw plugs Checking the electrolyte density
Checking the electrolyte level
Fig. 4
Fig. 3 The cells are filled with diluted sulphuric acid as elec-
1 Upper filling level mark trolyte (approx. 25 Vol% sulphuric acid in distilled wa-
ter), also referred to as accumulator acid, which has a
2 Lower filling level mark
density of 1.285 kg/dm3 at a temperature of +27° Cel-
l If the electrolyte level only reaches up to the lower sius. This means that one litre of electrolyte has a
filling level mark (2), fill distilled water into the corre- weight of 1.285 kg. As the cell is being discharged
sponding cells. lead sulphate (PbSO4) will form on both electrodes
and the electrolyte will increasingly change to water.
Since water has a lower specific weight than diluted
sulphuric acid, the density of the electrolyte will also
drop during the discharge and with a fully discharged
cell and a temperature of 27°C it will only be 1.18 kg/
dm3.
With a lead cell the acid density is therefore a meas-
ure for the charge condition. This characteristic is
used to determine the charge condition of a lead bat-
tery. The so-called electrolyte tester (densimeter) is
used for this purpose.
Fig. 5 Checking the electrolyte density:

1) correct
2) poor
3) poor
i Note
(Hold the pipe of the electrolyte tester vertically, with-
out taking it out of the electrolyte.
008 916 41 BOMAG 87

4.19 Batteries
Do not draw too much electrolyte into the pipe. Testing batteries without screw plugs
Make sure that the float is not obstructed in its move- On closed batteries the acid density cannot be meas-
ment and hold the electrolyte tester at eye level. ured, we therefore recommend testing with the follow-
The electrolyte tester must be read at the highest ing mobile tester:
electrolyte level.
l If the electrolyte temperature deviates from the
electrolyte tester calibration temperature, the indi-
cated value for the specific electrolyte weight must
be corrected acc. to the formula (reference) below.
Reference
The specific weight varies slightly with temperature.
To be exact, the specific weight drops by 0.0007 per 1
°C temperature increase (by 0.0004 per 1 °F) and in-
creases by 0,0007 per 1 °C temperature reduction (by
0,0004 per 1 °F) . If e.g. a temperature of 20 °C (68 °F)
is used as reference, the indicated value of the specif-
ic weight must be corrected acc. to the following for- Fig. 6 Battery and generator tester
mula.
The battery and generator tester comes with an 8-line
l Specific weight at 20 °C = measuring value + LC display with background illumination and is able to
0,0007 × (electrolyte temperature: 20 °C) print out test results via an (optional) integrated ther-
l
Specific weight at 68 °F = measuring value + 0,0004 mal printer.
× (electrolyte temperature: 68 °F)
Acid density at 27 °C in kg/dm3 i Note

l
1.25 -1.28, open-circuit voltage approx. 12.7 Volt. Before testing clean the poles and ensure good con-
Battery is charged. nection between clamps and poles.
l
1.20 -1.24, open circuit voltage approx.12.4 to 12.5 The test program calculates the text messages "good"
Volt, is 50% discharged. Charging is necessary. or "replace" on the basis of the charge condition (de-
l
1.19 and less, open circuit voltage less than 12.3 rived from the battery voltage) and the currently avail-
Volt. Battery is insufficiently charged. The battery able starting power of the battery. A battery with 45%
needs to be recharged immediately. starting power may thus be rated good and another
l
If there is a deviation of the specific weight of more one with 75% starting power as poor ("replace").
than 0.05 between any of the cells, the battery The starting power represents the ratio of detected
needs to be replaced. cold testing current to the entered cold testing current
l
If the current consumption during charging is not 1/ of the battery.
20 of the nominal capacity (example 100 Ah battery: The starting power can exceed 100%.
100Ah x 1/20 = 5 A) or full recharging of the battery
results in a final electrolyte density of only 1.24 kg/
dm3 or less, the battery shows normal wear by ag-
ing. The battery was insufficient charging or ex-
haustive discharge.
88 BOMAG 008 916 41

Batteries 4.19
Charge condition with hydrometer
Fig. 7 Charge condition

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

low, the battery must no longer be charged.
008 916 41 BOMAG 89

4.20 Battery maintenance
4.20 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. 8
Environment l Remove the battery (Fig. 8) and clean the battery
Dispose of the old battery environmentally. compartment.
l Clean the outside of the battery.
i Note l Clean battery poles and pole clamps and grease
Maintenance free batteries also need care. Mainte- them with pole grease (Vaseline).
nance free only means that the fluid level does not
need to be checked. Each battery suffers under self-
l Check the fastening of the battery.
discharge, which may, in not checked occasionally, l On serviceable batteries check the acid level, if nec-
even cause damage to the battery as a result of ex- essary top up to the filling mark with distilled water.
haustive discharge.
Charging voltage recommendation
The following therefore applies for the service life:
l
Switch off all consumers (e.g. ignition, light, inside
light, radio).
l
Check open-circuit voltage of the battery at regular
intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V =
50% discharged.
l Recharge the battery immediately after an open-cir-
cuit voltage of 12.25 V or less is reached. Do not
perform boost charging.
The open-circuit voltage of the battery occurs approx.
10 hours after the last charging process or one hour
after the last discharge. Fig. 9
l
After each charging process allow the battery to rest
for one hour before taking it into service.
l
For resting periods of more than one month you
should always disconnect the battery. Do not forget
to perform regular open-circuit voltage measure-
ments.
Caution
!
Exhausted batteries (batteries with formation of

sulphate on the plates are not covered under war-
ranty!
l
Open the cover.
90 BOMAG 008 916 41

Starting with jump wires 4.21
4.21 Starting with jump wires 4.22 Main battery switch
! Caution
When using external starting aid two external bat-
teries (24 V system) are required, one for each on-
board battery.
A wrong connection will cause severe damage in
the electric system.
Fig. 11
No. 1 = Main battery switch
Position "I" = Normal position, operation
Position "II" = Separates batteries from the on-
board electrics in case of cable fire
and fire in the engine compart-
ment as well as protection against
unauthorized use.
Fig. 10
l
First connect the plus poles with the jump lead.
l
Then connect the ground cable first to the minus
pole of the current supplying auxiliary battery and
then to engine or chassis ground, as far away from
the battery as possible (Fig. 10).
l
Start as described under "Starting the engine".
l
Once the engine is running switch on a powerful
consumer (working light, etc.).
!Caution
If no powerful consumer is switched on voltage
peaks may occur when separating the connecting
cables between the batteries, which could dam-
age electrical components.
l
After starting disconnect the negative poles (ground
cable) first and the positive poles after.
l
Switch off the consumer.
008 916 41 BOMAG 91

4.23 Fuses
Fuses, relays and diodes in the dashboard (Fig. 1)

4.23 Fuses
Fig. 1 Dashboard
Fig. 2 BF 600C
92 BOMAG 008 916 41

Fuses 4.23
Fig. 3 BF 600P E10 = Brake, PLC

(D) diodes, (E) relays, (F) fuses E13 = 2. gear
E14 = L.C.S.
! Danger E15 = Screw, right
Fire hazard! E16 = Screw, left
Do not use fuses with higher ampere ratings and E17 = Main switch hydraulics
do not bridge fuses. E18 = Automatic functions, bucket screed ex-
D1 = Dashboard light tension
D2 = Dashboard light E19 = Transport mode
D3 = Main switch hydraulics F1 = 25A- Water pump
D4 = Main switch hydraulics F2 = 10A- Flashing beacon
D5 = Warning buzzer F3 = 10A- Pressure switch brake, warning
buzzer
D6 = Display elements
F4 = 10A- Horn, lateral operator stand
D7 = Automatic functions, travel direction for-
ward F5 = 10A- Working lights
D9 = Loading functions F6 = 25A- Washing pump
D10 = Automatic conveyor belt F7 = 10A- Emergency stop
E1 = Ignition F8 = 10A- ECO mode
E2 = Warning buzzer F9 = 10A- Travel, transport mode
E3 = Horn F10 = 10A- Voltage converter 24V/12V
E4 = Rear working light F11 = 10A- Fan
E5 = Working lights, front F13 = 15A- EMR
E6 = Emergency stop F14 = 25A- Warning horn, dashboard
E7 = Main switch hydraulics F17 = 15A- Working lights, front
E8 = EMR F18 = 15A- Working lights, rear
E9 = Automatic screw, conveyor belt F19 = 10A- Dashboard illumination
008 916 41 BOMAG 93

4.23 Fuses
F20 = 10A- Temperature control, heating F38 = 10A- Conveyor belt, left
F21 = 10A- Levelling, right F39 = 25A- Main switch, hydraulics
F22 = 10A- Transport mode F40 = 7,5A- Preheating system
F25 = 3A- Brake, PLC F41 = 10A- Screw
F26 = 10A- 2. gear F42 = 10A- Conveyor belt
F27 = 10A- Screed extension, right F43 = 10A- L.C.S. Type 2*
F28 = 10A- Screed up F44 = 10A- Tamper, vibration
F29 = 10A- Compaction control display F45 = 10A- Water spray box
F30 = 15A- Automatic functions F46 = 10A- L.C.S. Type 1
F31 = 10A- Levelling, left F47 = 10A- Automatic functions, travel direc-
F32 = 10A- Screed extension, left tion forward
F33 = 10A- Screw up/down F48 = 5A- Travel, reverse
F34 = 10A- Hopper wings Fuses under operator's stand, left side (battery
F35 = 10A- Screw, right box) (Fig. 4)
F36 = 10A- Screw, left

F37 = 10A- Conveyor belt, right * Optional equipment
Fig. 4 Battery box JF 4 = 20A- Heating control, screed

JF 5 = 100A- Pre-heating system
! Danger JF 7 = 15A- Lights, front
Fire hazard! JF 8 = 15A- Lights, rear
Do not use fuses with higher ampere ratings and
do not bridge fuses.
JF 1 = 20A- Brake, PLC
JF 2 = 60A- General, ignition
JF 3 = 20A- Xenon light**
** Optional equipment
94 BOMAG 008 916 41

Replace heating elements 4.24
Control cabinet for electric heater (Fig. 5) 4.24 Replace heating elements
On left side of vehicle.
! Danger
Life hazard!
High voltage 400 Volt
Work on the electric heating system must only be
performed by skilled personnel.
i Note
Defective heating elements are indicated by means of
LEDs on the terminal box (Fig. 7).
Replacing the heating elements for the base plate
Fig. 5
a = Ground fault circuit interrupter for electric
screed heating
b = Fuses for electric screed heating
Fig. 6
l Unscrew fastening screws a (Fig. 6) and remove
the protection cover.
Fig. 7
l Pull the plug off the junction box (Fig. 7) and remove
the cover.
l Disconnect the cable for the defective heating ele-
ment.
008 916 41 BOMAG 95

4.24 Replace heating elements
Fig. 8
l Unscrew the plug (Fig. 8) and loosen the clamping
screws underneath.
l Pull the heating element out to the side.
! Caution
Do not overtighten the clamping screws for the
heating elements, this may damage the heating el-
ements.
l
Push in a new heating element, tighten the clamp-
ing screw lightly.
l
Connect the heating element.
l
Close the junction box, screw in the plug and reas-
semble the guard.
96 BOMAG 008 916 41

Replace heating elements 4.24
Replacing the heating element for the tamper
Fig. 9
l Unscrew the fastening screws b (Fig. 9) and take off
the holding block.
l Remove the protection plate (c).
l Disconnect the cable inside the terminal box (Fig.
7).
Fig. 10
l Loosen the fastening screws 1 (Fig. 10) for the ter-
minal strip (2) and pull out the heating element.
l
Slide in, fasten and connect a new heating element.
008 916 41 BOMAG 97

4.25 Failure codes, SAUER controller
The failure code will repeated all 10 seconds

Failure code number
4.25 Failure codes, SAUER controller
Failure code number 8 = 8 flashing with 8 x 0,5sec. LED on

1 = unique flashing all 10 seconds and 8 x 0,5 sec LED off followed
Failure code number from 2 sec. interruption before the
8 = 8 flashing all 10 seconds flashing code starts again.
One flash takes 0,5 seconds

Failure code number
1 = 0,5 seconds flashing and 9,5 sec-
onds with switched off LED.
Fig. 1
The flashing code will be visualise on this both steering display LED’s
Fig. 2
Amount of Which kind of failure which LED is flashing

flashings
1 Failure on the speed sensor (motor left) only left
1 Failure on the speed sensor (motor rigt) only right
2 Failure on the potentiometer foot pedal left & right
3 Failure on the potentiometer for the driving speed left & right
4 Failure on the potentiometer for the steering left & right
5 Failure on the EDC driving pump left only left
5 Failure on the EDC driving pump right only right
6 Failure on the CAN BUS or EMR for the engine left & right
7 Calibration of the potentiometer for the driving speed left & right
7 Calibration of the potentiometer for the food pedal left & right
7 Calibration of the potentiometer for steering left & right
8 Calibration for the EDC driving pump left & right
98 BOMAG 008 916 41

5 Engine electrics
008 916 41 BOMAG 99

5.1 Installation location for engine control unit
5.1 Installation location for engine control unit
Fig. 1
Installation location under the operator's stand on right hand side.
i Note
Slide the operator's stand to the left and open the floor flap on the right hand side.
100 BOMAG 008 916 41

EMR3 system components 5.2
5.2 EMR3 system components i Note
The Deutz part-number specified on the EMR-control
Engine control unit unit is the part number without software specific for
the engine. The correct part number can be found in
the spare parts catalogue.
! Caution
It is not permitted to interchange control units Replacing the EMR or DCR components
from one manufacturing series or against another l
On TCD-engines with Common Rail technology the
engine number. In this case the warranty will be- system pressure is so high, that in case of leaks or
come null and void. repair all parts need to be replaced. When replacing
Sensors and actuators must not be connected to sensors or other electric components, the new parts
external power sources for the purpose of testing, must be calibrated with the EMR control unit. This
but must only be operated on the EMR3. Other- calibration must be performed with SERDIA (Level
wise components may be permanently damaged. IIIa). (see also SERDIA manual).
Pulling off the plug connectors of the control unit

l
Any other EMR components (sensors etc) must un-
while the control unit is working (i.e. with the powder no circumstances be repaired, but must be re-
er supply to terminal 15switched on) is not permit- placed if they are defective.
ted. Correct procedure: Switch off the electric
power supply (normally with the ignition key), wait
until the main relay has switched off (with a delay
of up to 15 seconds, listen for clicking sound),
then pull off the plugs from the control unit.
The engine control unit is the central component of the
EMR3-system. It has the function of ensuring optimal
performance of the engine with the following goals
l excellent exhaust gas characteristics,
l low fuel consumption,
l smooth running of engine,
l long lifetime of engine,
l efficient servicing
under all operating conditions. For this purpose the
engine control unit uses the recorded measuring val-
ues and the parameters stored in its data memory to
run a number of calculations, which form the basis or
all the available functions. The most important func-
tions include:
l
exact control of the injection process (among others
the number, start and duration of injections),
l idle speed regulation,
l regulation of exhaust gas recirculation,
l
optimization of smooth running (by means of injec-
tion quantity correction),
l engine monitoring,
l system diagnose.
Replacing the control unit

Each control unit is clearly designated to the engine,
in accordance with the respective application. In case
of a replacement the control unit therefore needs to be
completed with the engine specific data set. When or-
dering a new control unit you must not only specify the
part-number, but also the engine serial number (see
sticker on EMR-control unit).
008 916 41 BOMAG 101

5.2 EMR3 system components
Fig. 2
The EMR3-S (TCD 2012 and TCD 2013) (Fig. 2) en-
gine control unit is fitted with two sockets on the front
side of the housing:
l
socket D2.1 to connect the engine wiring loom,
l socket D2.2 to connect the vehicle wiring loom.
Fig. 3
The EMR3-E (TCD 2015) (Fig. 3) engine control unit
is fitted with three sockets on the upper side of the
housing:
l socket D2.1 to connect the vehicle wiring loom,
l socket D2.2 to connect the engine wiring loom for
sensors and actuators,
l socket D2.3 to connect the engine wiring loom for
fuel metering unit and injection valves.
102 BOMAG 008 916 41

EMR-3 system in connection with injec-
tion system and electrics
Fig. 1 19 Pressure relief valve

1 Fuel tank 20 Battery terminal 31 and 30
2 Pre-filter 21 Connecting line control unit-engine
3 Fuel lift pump 22 Wiring loom connecting cable
4 Fuel filter 23 Engine wiring harness
5 High pressure fuel pump 24 Sensor, water in fuel
6 Fuel control unit FCU
7 Control unit
8 High pressure accumulator, Rail
9 Injector
10 Rail pressure sensor
11 Exhaust gas turbocharger
12 Engine transfer plug
13 Exhaust gas recirculation, option
14 Engine sensors
15 Diagnostics lamp
16 Ignition switch
17 Pedal
18 Diagnostics button
008 916 41 BOMAG 103

5.2 EMR3 system components
Sensors TCD 2012/2013 Sensors TCD 2015
Fig. 1 Fig. 1
1 Fuel control unit FCU 1 Oil pressure sensor
2 Coolant temperature sensor 2 Fuel temperature sensor
3 Sensor for charge air temperature and charge air 3 Sensor for charge air temperature and charge air
pressure pressure
4 Wiring loom connecting cable 4 Engine control unit
5 Engine control unit 5 Coolant temperature sensor
6 Crankshaft speed sensor 6 Oil level sensor, option
7 Rail pressure sensor 7 Central plug
8 Oil level sensor, option 8 Crankshaft speed sensor
9 Oil pressure sensor 9 Camshaft speed sensor
10 Fuel pressure sensor 10 Wiring loom connecting cable
11 Camshaft speed sensor
12 Central plug
104 BOMAG 008 916 41

Shut down the engine.
When shutting down the engine, the ignition switch
isolates the electronic system from terminal 15. The
injectors are closed immediately, the Rail pressure is
discharged in an orderly manner and the counter
readings are saved in the non-volatile memory. During
this time the system must not be disconnected from
terminal 30 (+Ubatt). Once the time has expired the
main relay switches off and the control unit is no de-
energized..
The main relay serves the purpose of releasing the
vehicle energy supply for the EMR3 system.
l The EMR3 engine control unit requires an external
main relay (relay K41, in single drum rollers and
tandem rollers), (relay E8 in road finishers), see ma-
chine related circuit diagram.
l The EMR3-E engine control unit has an internal
electronic main relay.
The following applies for both control units: when ter-
minal 15 is no longer connected to battery (+) (i.e. af-
ter the ignition has been switched off), the main relay
is switched off after approx. 10 seconds.
The main relay thereby disconnects the control unit
from terminal 30 battery (+), whereby it becomes de-
energized.
On the EMR3-S the fault state of the main relay can
be examined directly on Pin72, on the EMR3-E on
Pin13.
008 916 41 BOMAG 105

5.3 Pin assignment of engine control EDC16 / EMR3
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Camshaft speed sensor 5.4
5.4 Camshaft speed sensor
Speed sensor
l Inductive sensor
l Determination of TDC
l Limp-home function in case of crankshaft sensor
failure
Fig. 4
Fig. 2 l
Unscrew the screw (Fig. 4).
Disassemble the speed sensor l
Remove the speed sensor.
Assemble the speed sensor
Fig. 5
l Clean the sealing surfaces on speed sensor and
wheel housing cover.
l Assemble the new O-ring (Fig. 5) (arrow).
l
Cover the O-ring slightly with oil.
Fig. 3
l Remove the cable strap (Fig. 3).
l Disconnect the cable plug.
008 916 41 BOMAG 111

5.5 Crankshaft speed sensor
Speed sensor
l Inductive sensor
l Exact determination of engine speed
l Limp-home function in case of camshaft sensor fail-
ure
RPM-meter
The rotary speed is detected by the EMR control and
passed on to the multi-function display (Fig. 8) via the
CAN-bus connection.
Fig. 6
l
Assemble the speed sensor (Fig. 6).
l
Tighten the screw.
i Note
Install the screws with screw retention agent.
Fig. 8
p = Engine rpm-meter
In case of a fault a fault code is transmitted via the
CAN-bus connection to the multi-function display (see
chapter "Fault code display engine").
Fig. 7
l Push on the cable plug (Fig. 7).
l Install the cables.
l Fasten the cables with cable straps.
112 BOMAG 008 916 41

Crankshaft speed sensor 5.5
Disassemble the speed sensor
Fig. 11
l Unscrew the screw (Fig. 11).
l Pull the speed sensor out of the bracket
Install the speed sensor
Fig. 9
l
Disconnect the cable plug (Fig. 9).
Fig. 12
l Press the speed sensor into the bracket (Fig. 12).
i Note
Clean threads on screw and in bore. Assemble the
screws with screw retention agent.
l
Tighten the screw with 9 Nm.
Fig. 10
l
Unscrew both screws (Fig. 10).
l
Remove the bracket with the speed sensor
Fig. 13
l
Attach the bracket with the speed sensor (Fig. 13).
008 916 41 BOMAG 113

Check the gap measurement

i Note
Assemble the screws with screw retention agent and
check the gap, adjust if necessary.
Fig. 15
l
Check the gap measurement with a feeler gauge
(Fig. 15).
Fig. 14
l Push on the cable plug (Fig. 14). Nominal value: 0,6 ± 0,1mm
i Note
The feeler gauge must fit with only little resistance
through the gap between toothed disc and speed sen-
sor (crankshaft).
Adjusting the gap measurement
Fig. 16
l Unscrew both screws (Fig. 16).
i Note
Install the screws with screw retention agent.
114 BOMAG 008 916 41

Rail pressure sensor 5.6
Caution
! 5.6 Rail pressure sensor
Observe the different screw lengths.
Pressure sensor
l Pressure sensor
l Monitoring the injection pressure
Fig. 18
Fig. 17
l
Slide the feeler gauge through the gap between
Disassembling the pressure sensor
toothed disc and speed sensor.
l
Press the speed sensor slightly against the feeler
! Danger
gauge and tighten the screws.
After shutting down the engine wait another 30
seconds before starting work in the fuel system.
i Note
Tightening torque: 20Nm
!Caution
Ensure absolute cleanliness when working in the
fuel system.
Thoroughly clean the area around the affected
component. Dry off wet locations with com-
pressed air.
No foreign objects should enter into the Rail.
Ensure strict cleanliness. Especially on thread
and sealing surface of Rail.
Follow the safety regulations and country specific
regulations concerning the handling of fuel.
Immediately close all connections and openings
with new and clean plugs/caps.
Only remove plugs/caps just before assembling.
Do not touch the contact pins of the Rail pressure
sensor with bare hands to avoid electrostatic dis-
charging.
Environment
Catch running out fuel and dispose of environ-
mentally.
008 916 41 BOMAG 115

5.6 Rail pressure sensor
Assembling the pressure sensor
Fig. 19
l Unlock and pull out the cable plug (Fig. 19).
Fig. 21
l
Unscrew the Rail pressure sensor with a socket
spanner.
Caution
!
Ensure strict cleanliness. Especially on thread

and sealing surface of Rail.
l Slightly grease thread and sealing edge on Rail
pressure sensor with assembly grease.
l Turn in and tighten the Rail pressure sensor (2)
(Fig. 21).
i Note
Tightening torque: 40 + 5Nm
l Plug in the cable plug.
Fig. 20
l Check thread and sealing edge (arrows) (Fig. 20)
on the Rail pressure sensor visually.
116 BOMAG 008 916 41

Fuel pressure sensor 5.7
5.7 Fuel pressure sensor
Pressure sensor
l Pressure sensor
l Monitoring the inlet pressure
The fuel low pressure sensor is located after the fuel
filter and the pressure is normally between 5 and 7
bar.
Fig. 23
l Unscrew the locking ring (Fig. 23).
l
Pull off the cable plug.
l
Unscrew the fuel pressure sensor with a socket
Fig. 22
spanner.
Disassembling the pressure sensor Installing the pressure sensor
! Caution
fuel system.
component. Dry off wet locations with com-
pressed air.
Follow the safety regulations and country specific
regulations concerning the handling of fuel.
Immediately close all connections and openings
with new and clean plugs/caps.
Only remove plugs/caps just before assembling.
Environment
mentally.
Fig. 24
l
Insert the fuel pressure sensor with a new seal ring
and tighten (Fig. 24).
i Note
Tightening torque: 30 ± 5 Nm
008 916 41 BOMAG 117

5.8 Fuel control unit FCU
5.8 Fuel control unit FCU
Fuel control unit (FCU)
Fig. 25
l Push the cable plug back onto the fuel pressure
sensor (Fig. 25).
l
Turn in the locking ring until it engages.
Fig. 26
i Note
Make sure the contacts are matching. Function
Here the fuel flowing into the pump elements is me-
Spulenkörpered the fuel system with the fuel hand
tered by an infinitely controllable solenoid valve (also
pump on the fuel pre-cleaner.
referred to as "fuel control unit").
This valve is mounted to the FCU control block and
adapts the fuel quantity supplied to the Rail to the sys-
tem requirements. The solenoid valve is controlled by
a pulse width modulated (PWM) signal. When control-
ling the valve, the piston is operated by magnetic
force. It opens a flow cross-section that corresponds
to its position. This quantity regulation reduces the
power requirement of the high pressure pump, it will
only deliver as much fuel as is needed by the mapped
Rail pressure.
118 BOMAG 008 916 41

Fuel control unit FCU 5.8
Fig. 28
1 max. flow capacity
2 max. flow capacity
Fig. 27
1 Plug with electric interface
2 Solenoid housing
3 Bearing
4 Anchor with plunger
5 Winding with coil core
6 Bowl
7 Residual air gap disc
8 Magnetic core
9 O-ring
10Piston with control slots
11Spring
12Locking elements
008 916 41 BOMAG 119

5.9 Injectors
5.9 Injectors
Injectors
Fig. 29
Function
Fig. 30
The injectors are installed in the cylinder head. They 
have the same functions as nozzöe and nozzle holder 
in conventional injection systems. The injectors are
connected with the pressure accumulator (Rail) by
high pressure lines (Fig. 30).
In the injector the beginning and end of injection of the
nozzle are determined by a valve. The operating forc-
es for opening and closing the valve are generated by
a solenoid. The injectors work with approx. 50 to 70
Volt, instead of the 12 Volt vehicle voltage, which
causes undelayed opening of the injectors. This high
voltage is generated by capacitors in the control unit.
The solenoid valves are then held in position by cy- Fig. 31
cled 12 Volt.
The forces required to open and close the nozzle nee-
dle cannot be generated by a solenoid valve on its
own. The nozzle needle is therefore indirectly control-
led via an hydraulic booster system in the injector (Fig.
31).
120 BOMAG 008 916 41

Oil pressure sensor 5.10
5.10 Oil pressure sensor Disassembling the pressure sensor
Pressure sensor !Caution

Oil pressure monitoring lubrication oil system.
The operator is warned if
l the oil pressure falls short of the warning limit and/or component. Dry off wet locations with com-
l
the power is reduced by the EMR after a pre-warn- pressed air.
ing time, or Immediately close all connections and openings
l the oil pressure falls short of the shut-down limit and with new and clean plugs/caps.
the engine is shut down after a pre-warning time. Only remove plugs/caps just before assembling.
Environment
Catch engine oil and dispose of environmentally.
Fig. 32 Oil pressure sensor

In case of a fault a fault code is transmitted via the
CAN-bus connection to the multi-function display (see
chapter "Fault code display engine").
Fig. 33
l
Unscrew the coolant temperature sensor.
008 916 41 BOMAG 121

5.11 Charge air temperature - charge air pressure sensor
Installing the pressure sensor 5.11 Charge air temperature -

charge air pressure sensor
Sensor
Combined charge air pressure / temperature sen-
sor
Fig. 34
l
Insert the oil pressure sensor with a new seal ring
and tighten.
i Note
Tightening torque: 20Nm Fig. 35
This sensor unites two functions in one housing. The
one function measures the charge air pressure in the
and adapts the injection quantity in dependence on
the measured pressure. On the other hand the EMR
now detects the temperature of the passing air flow.
This is used for the smoke limitation.
i Note
With a faulty pressure sensor the engine continues to
run with charge pressure simulation.
With a defective temperature sensor the engine also
carries on running.
Charge air temperature monitoring

l
the temperature exceeds the warning limit and/or
l
the power is reduced by the EMR 3 after a pre-
warning time, or
l
the temperature exceeds the shut-down limit and
the engine is shut down after a pre-warning time.
122 BOMAG 008 916 41

Charge air temperature - charge air pressure sensor 5.11
Disassembling the sensor Installing the sensor
Fig. 38
l
Assemble a new O-ring (Fig. 38).
Fig. 36 l
Slightly cover the O-ring with grease.
l
Unscrew screw 1 (Fig. 36).
l
Remove the cover plate.
Fig. 39
l Carefully insert the pressure/temperature sensor
Fig. 37 (Fig. 39).
l
Unlock and pull out the cable plug (Fig. 37). l Plug on the cable plug and engage the lock.
l Remove the pressure/temperature sensor.
008 916 41 BOMAG 123

5.12 EMR coolant temperature sensor
5.12 EMR coolant temperature sen-

sor
Temperature sensor
The coolant temperature has an effect on the calculat-
ed injection quantity and the preheating behaviour of
the glow plugs.
Coolant temperature monitoring

l the temperature exceeds the warning limit and/or
l the power is reduced by the EMR after a pre-warn-
ing time, or
l the temperature exceeds the shut-down limit and
the engine is shut down after a pre-warning time.
Fig. 40
l Attach the cover platel (Fig. 40).
l
Tighten the screw (1).
Fig. 41 Coolant temperature sensor
Warning light engine overheating

The coolant temperature is detected by the EMR con-
trol. In case of a fault a message is transmitted via the
CAN-bus connection to the multi-function display (Fig.
42).
Fig. 42
h = lights if engine overheats. Warning buzz-
er sounds.
o = Display of operating hours and engine
fault codes
124 BOMAG 008 916 41

EMR coolant temperature sensor 5.12
Coolant temperature gauge Disassembling the temperature sensor
n = Gauge, coolant temperature.
Environment
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. 43
Fig. 44
l Unscrew the coolant temperature sensor (Fig. 44).
i Note
Counter the adapter piece.
008 916 41 BOMAG 125

5.13 Glow plugs
Installing the temperature sensor 5.13 Glow plugs
i Note
The circuitry is shown in the circuit diagram on page
10.2.
The engines are equipped with glow plugs for cold
starting as standard. 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).
During cold starting the EMR-control switches (Pin24
Ground, Pin34 Plus) (Fig. 48) and the coil of relay JE1
(Fig. 48) is excited. The glow plugs are supplied with
battery current via the switch contact of relay (EJ1)
and fuse JF5 (Fig. 47).
Fig. 45
l Tighten the coolant temperature sensor (Fig. 45).
i Note
Make sure that the seal rings are present .
Tightening torque: 22±2 Nm.
Fig. 47 Fuses in battery compartment
! Danger
Fire hazard!
Do not use fuses with higher ampere ratings and
do not bridge fuses.
JF 5 = 100A- Pre-heating system
Fig. 46
l Push on the cable plug (Fig. 46).
Fig. 48 Relay JE1
126 BOMAG 008 916 41

Sensor, water in fuel, C39 5.14
5.14 Sensor, water in fuel, C39 5.15 Air filter vacuum switch, C40
i Note i Note
The circuitry is shown in the circuit diagram on page The circuitry is shown in the circuit diagram on page
10.1. 10.1.
Fig. 1
The vacuum switch operates at a vacuum of > 50
mbar.
Fig. 1 Fault message
1 Sensor for water separator The switch is electronically monitored by the EMR-
Fault message control. In case of a fault a fault code is transmitted via
the CAN-bus connection to the multi-function display
The analog sensor is electronically monitored by the (see chapter "Fault code display").
EMR-control. In case of a fault a fault code is transmit-
ted via the CAN-bus connection to the multi-function
display (see chapter "Fault code display").
008 916 41 BOMAG 127

5.16 Level probe coolant tank, C38
5.16 Level probe coolant tank, C38 5.17 Diagnostics interface
i Note
The circuitry is shown in the circuit diagram on page
10.1.
Fig. 1 Diagnostic link

Fig. 1
A = Battery plus (+)
The level probe works according to the capacitive
principle. The capacity change, that is generated B = Battery minus (-)
when an air surrounded, insulated electrode is sub- F = CAN2 low
merged in a liquid medium, is detected. This capacity
G = CAN1 low
change on the sensor electrode excites an oscillator.
H = CAN1 high
These level probes have a short circuit proof switching
output. Since they do not contain any moveable parts, K = K-Line
their function can neither be impaired by dirt particles, M = CAN2 high
nor by other influences.
Fault message
The probe is electronically monitored by the EMR-
control. In case of a fault a fault code is transmitted via
the CAN-bus connection to the multi-function display
(see chapter "Fault code display engine").
Fig. 2 Diagnostics plug
128 BOMAG 008 916 41

Diagnostics interface 5.17
SERDIA connection CAN-bus display connection
Operation of the display is described in a separate op-
eration manual.
Fig. 4
Display for EMR control (Fig. 4).
Fig. 3
The KWP-protocol with encrypted dataflow is used via
the K-line. For this purpose the PC or laptop (Fig. 3) is
connected to the diagnostic interface by means of a Fig. 5
special interface cable. The display is connected to the diagnostic interface by
Operation of SERDIA is described in a separate oper- means of a special cable.
ation manual. Wiring loom for display (Fig. 5)
008 916 41 BOMAG 129

5.18 Diagnose with CAN-bus
5.18 Diagnose with CAN-bus

The CAN-bus is used to transfer standard messages
of the SAE J 1939.
The display is a compact, robust and integratable
modules which enables the user to invoke engine data
and to display these in the following formats:
l Analog display
l
Digital data
l Multi data (a combination of analog and digital data)
l Alarm messages currently present
The different diagnostic screens enable detailed ex-
amination of the engine data flow
Fig. 1
Display for EMR control (Fig. 1).
130 BOMAG 008 916 41

Diagnose with SERDIA 5.19
5.19 Diagnose with SERDIA
SERDIA
With the diagnostics tool SERDIA and a hardware interface one can read out / delete and save the error log of
the control unit.
EDC16
EMR3
Fig. 1 Service-Software TCD 2012 / 2013

The SERDIA software is first choice for any diagnostics task.
SERDIA is a software program from Deutz which can be used in connection with a laptop computer to perform
more detailed fault analyses, especially reading out of the error log.
This displays information on
l
Location of fault (e.g. ’coolant temperature sensor’)
l Nature of fault (e.g. ’fallen short of bottom limit value’, ’sporadic fault’)
l Environmental data / operating data (speed and operating hours at the time of the last fault occurrence)
l Number of fault locations and frequency of fault
l Fault status (active – fault present / passive- fault no longer present)
l Fault messages for non-present / rectified faults can be deleted with SERDIA.
Function test
The control outputs can be activated with the engine shut down.
Assignment of inputs/outputs
Display of the current input and output assignment of the EMR-control.
008 916 41 BOMAG 131

5.19 Diagnose with SERDIA
Representation of measuring values
Fig. 2
There is a vast variety of measuring values available for selection which can even be used if no EMR-fault is
present (start behaviour, engine sawing, lack of power).
132 BOMAG 008 916 41

Diagnose with SERDIA 5.19
Representation of fault log
Fig. 3
When looking for the cause of a fault in the EMR3-system examining the fault log of the engine control unit usu-
ally provides useful information.
008 916 41 BOMAG 133

5.20 Fault code indication, diesel engine
5.20 Fault code indication, diesel engine
Fig. 1 Display
a = lights, water in fuel filter
g = lights, if the fuel filter is blocked
h = lights if the engine overheats
i = lights if the engine oil pressure is too low
j = lights if the coolant level is too low
k = lights if the battery is not being charged
I = lights in case of a fault
o = Display of operating hours and engine fault codes (hexa-decimal code).
l When the warning buzzer sounds and the fault indicator (I) lights up, read out the hexa-decimal code in the
window (o).
i Note
Hexa-decimal codes are explained in the following fault code list, column "SPN (hex)".
! Caution
A detailed reading out of fault codes for the diesel engine is only possible with Deutz-Serdia
134 BOMAG 008 916 41

5.21
ID Error Error SPN SPN FMI Blink Description Self-

code code (dec) (hex) code curing1
008 916 41
EMR3 List of fault codes
(dec) (hex)
AirFltSysReac 11 0B 107 0000006B 1, 11 1-3-6 Air filter: pressure loss above target range with system reaction yes
APP1 12 0C 91 0000005B 2, 3, 4, 11 2-2-6 Accelerator pedal: cable break or short circuit, implausible compared to no
signal of idle sensor
APPPwm 14 0E 91 0000005B 2, 8 2-2-2 PWM accelerator pedal: bad signal (range or frequency), cable break or yes
short circuit
APPPwmPer 15 0F 91 0000005B 8, 11 2-2-2 PWM accelerator pedal: bad pulse-width repetition rate yes
APSCD 16 10 108 0000006C 2, 3, 4, 11 2-9-2 ECU internal error: ambient pressure sensor defective yes
ArHt1 17 11 729 000002D9 3, 4, 5, 11 2-6-3 Air heater relay: cable break or short circuit yes
ArHt2 18 12 730 000002DA 3, 4, 5, 11 2-6-3 Air heater magnetic valve: cable break or short circuit yes
ArHtCD_NoLd 19 13 676 000002A4 4, 11 2-6-3 Air heater relay: cable break or wrong connection no
ArHtCD_RlyErr 20 14 676 000002A4 2, 5, 11 2-6-3 Air heater relay: inoperable during shut-off no
BattCD 22 16 168 000000A8 0, 1, 11 3-1-8 Battery input (voltage 0-5V): outside target range yes
BattCDSysReac 23 17 168 000000A8 2, 11 3-1-8 Battery voltage: above target range with system reaction yes
BIPCyl1 24 18 3561 00000DE9 2 5-3-1 Begin of injection period in cylinder 1: outside target range or missing yes
BIPCyl2 25 19 3562 00000DEA 2 5-3-2 Begin of injection period in cylinder 2: outside target range or missing yes
BIPCyl3 Begin of injection period in cylinder 3: outside target range or missing yes
BOMAG
26 1A 3563 00000DEB 2 5-3-3
BIPCyl4 27 1B 3564 00000DEC 2 5-3-4 Begin of injection period in cylinder 4: outside target range or missing yes
BIPCyl5 28 1C 3565 00000DED 2 5-3-5 Begin of injection period in cylinder 5: outside target range or missing yes
BIPCyl6 29 1D 3566 00000DEE 2 5-3-6 Begin of injection period in cylinder 6: outside target range or missing yes
BIPCyl7 30 1E 3567 00000DEF 2 5-3-7 Begin of injection period in cylinder 7: outside target range or missing yes
BIPCyl8 31 1F 3568 00000DF0 2 5-3-8 Begin of injection period in cylinder 8: outside target range or missing yes
BPSCD 32 20 102 00000066 2, 3, 4 2-2-3 Charge air pressure sensor: cable break or short circuit yes
BPSCDSysReac 33 21 102 00000066 2, 11 2-2-3 Charge air pressure: outside target range yes
CLSCDSysReac 37 25 111 0000006F 1, 11 2-3-5 Coolant level: outside target range no
CmbChbMisfire1 38 26 1323 0000052B 11, 12 2-4-1 Misfire detected in cylinder 1 no
CmbChbMisfire2 39 27 1324 0000052C 11, 12 2-4-1 Misfire detected in cylinder 2 no
CmbChbMisfire3 40 28 1325 0000052D 11, 12 2-4-1 Misfire detected in cylinder 3 no
CmbChbMisfire4 41 29 1326 0000052E 11, 12 2-4-1 Misfire detected in cylinder 4 no
5.21
135
136
5.21

(dec) (hex)
CmbChbMisfire5 42 2A 1327 0000052F 11, 12 2-4-1 Misfire detected in cylinder 5 no
CmbChbMisfire6 43 2B 1328 00000530 11, 12 2-4-1 Misfire detected in cylinder 6 no
CmbChbMisfire7 44 2C 1450 000005AA 11, 12 2-4-1 Misfire detected in cylinder 7 no
CmbChbMisfire8 45 2D 1451 000005AB 11, 12 2-4-1 Misfire detected in cylinder 8 no
CmbChbMisfireMul 46 2E 1322 0000052A 11, 12 2-4-1 Misfire detected in multiple cylinders no
CmbChbSysReac 47 2F 1346 00000542 0, 11 2-4-1 Misfire detected with system reaction no
CoEngShOffDemIgr 48 30 1109 00000455 2, 11 3-4-1 Shut-off request ignored no
CRERCD 52 34 1072 00000430 3, 4, 5, 11 5-2-8 Internal engine brake: cable break or short circuit no
CSLpCD 53 35 1081 00000439 2, 3, 4, 5 3-2-8 Preheating signal lamp: cable break or short circuit no
CTLpCD 54 36 704 000002C0 11 1-2-3 Coolant temp. warning lamp: cable break or short circuit no
CTSCD 55 37 110 0000006E 2, 3, 4 2-2-5 Coolant temp. sensor: cable break or short circuit yes
CTSCDSysReac 56 38 110 0000006E 0, 11 2-3-2 Coolant temp.: outside target range with system reaction yes
Dummy1CD_Max 57 39 701 000002BD 11 - Reserve output 1: short circuit to Ubatt no
Dummy1CD_Min 58 3A 701 000002BD 11 - Reserve output 1: short circuit to ground no
Dummy1CD_SigNpl Reserve output 1: cable break or ECU internal error no
BOMAG
59 3B 701 000002BD 11 -
Dummy2CD_Max 60 3C 702 000002BE 11 - Reserve output 2: short circuit to Ubatt no
Dummy2CD_Min 61 3D 702 000002BE 11 - Reserve output 2: short circuit to ground no
Dummy2CD_SigNpl 62 3E 702 000002BE 11 - Reserve output 2: cable break or ECU internal error no
EGRCD_Max 69 45 2791 00000AE7 3, 11 4-1-4 EGR actuator (external): short circuit to Ubatt no
EGRCD_Min 70 46 2791 00000AE7 4, 11 4-1-4 EGR actuator (external): short circuit to ground no
EGRCD_SigNpl 71 47 2791 00000AE7 2, 5, 11 4-1-5 EGR actuator (external): cable break or ECU internal error no
EGRCDIntEGR 72 48 2791 00000AE7 2, 3, 4, 5 4-1-6 EGR actuator (internal): cable break or short circuit no
EngCDTrqCalcOut 74 4A 923 0000039B 2, 3, 4, 5 5-5-5 "Engine Power" output: cable break or short circuit no
EngMBackUp 75 4B 190 000000BE 11, 12 2-1-2 Running with cam-shaft speed signal only yes
EngMCaS1 76 4C 190 000000BE 8, 11, 12 2-1-2 Speed signal from cam-shaft: bad or missing yes
EngMCrS1 77 4D 190 000000BE 8, 11, 12 2-1-2 Speed signal from crank-shaft: bad or missing yes
EngMOfsCaSCrS 78 4E 190 000000BE 2, 11 2-1-3 Speed signals of crank-shaft and cam-shaft: phase-shifted no
EngPrtSysReacFOC 79 4F 190 000000BE 0, 11 2-1-4 Engine overspeed with system reaction no
EngPrtSysReacORC 80 50 190 000000BE 11, 14 2-1-4 Overrun conditions with system reaction yes
DEUTZ S i I f i S 2/
008 916 41
008 916 41
(dec) (hex)
ESLpCD 81 51 703 000002BF 2, 3, 4, 5 1-4-2 Engine operating signal lamp: cable break or ECU internal error no
ExFlCD 82 52 1074 00000432 3, 4, 5, 11 2-1-9 Engine brake flap actuator: cable break or short circuit no
FanCD 83 53 975 000003CF 2, 3, 4, 5 2-3-8 Fan actuator: cable break or short circuit no
FanCDSysReac 86 56 523602 0007FD52 2, 11 2-3-8 Fan speed: above target range with system reaction yes
FlFCD 87 57 97 00000061 3, 4, 11 2-2-8 Fuel filter / water separator sensor: cable break or short circuit yes
FlFCD_WtLvl 89 59 97 00000061 11, 12 2-2-8 Water level in fuel filter: above target range no
FlPSCD 90 5A 94 0000005E 3, 4, 11 2-1-6 Fuel low pressure sensor: cable break or short circuit yes
FlPSCDSysReac 91 5B 94 0000005E 2, 11 2-1-6 Fuel low pressure: below target range with system reaction yes
FrmMngDecV1 94 5E 523239 0007FBE7 2, 12 5-2-6 CAN message "DecV1" (pseudo pedal): missing or above target range. yes
FrmMngFunModCtl 95 5F 523240 0007FBE8 11, 12 5-2-7 CAN message "FunModCtl" (function mode control): missing yes
FrmMngTOEngPrt 106 6A 523212 0007FBCC 11, 12 3-3-3 CAN message "EngPrt" (engine protection): missing yes
FrmMngTOPrHtEnCmd 110 6E 523216 0007FBD0 11, 12 3-3-7 CAN message "PrHtEnCmd" (preheat and engine command): missing yes
FrmMngTORxCCVS 112 70 523218 0007FBD2 11, 12 1-1-1 CAN message "RxCCVS" (cruise control): missing yes
FrmMngTORxEngTemp 113 71 523604 0007FD54 11, 12 1-1-2 CAN message "RxEngTemp" (enigne temperature): missing yes
FrmMngTOSwtOut 117 75 523238 0007FBE6 11, 12 1-1-5 CAN message "SwtOut" (switch outputs): missing yes
BOMAG
FrmMngTOTCO1 118 76 523222 0007FBD6 11, 12 1-1-6 CAN message "TCO1" (speedo signal): missing yes
FrmMngTOTSC1AE 120 78 523605 0007FD55 11, 12 1-1-8 CAN message "TSC1-AE": missing no
FrmMngTOTSC1AR 121 79 523606 0007FD56 11, 12 1-1-9 CAN message "TSC1-AR": missing no
FrmMngTOTSC1DE 122 7A 523607 0007FD57 11, 12 1-1-8 CAN message "TSC1-DE": missing no
FrmMngTOTSC1DR 123 7B 523608 0007FD58 11, 12 1-1-9 CAN message "TSC1-DR": missing no
FrmMngTOTSC1PE 124 7C 523609 0007FD59 11, 12 1-1-8 CAN message "TSC1-PE": missing no
FrmMngTOTSC1TE 125 7D 898 00000382 11, 12 1-1-8 CAN message "TSC1-TE": missing no
FrmMngTOTSC1TR 126 7E 520 00000208 11, 12 1-1-9 CAN message "TSC1-TR": missing no
FrmMngTOTSC1VE 127 7F 523610 0007FD5A 11, 12 1-1-8 CAN message "TSC1-VE": missing no
FrmMngTOTSC1VR 128 80 523611 0007FD5B 11, 12 1-1-9 CAN message "TSC1-VR": missing no
FrmMngTxTO 131 83 523500 0007FCEC 11, 12 2-7-1 CAN bus: time out of at least one sended message yes
FTSCD 133 85 174 000000AE 3, 4, 11 2-2-7 Fuel temp. sensor: cable break or short circuit yes
FTSCDSysReac 134 86 174 000000AE 0, 11 2-3-7 Fuel temp.: above target range with system reaction yes
5.21
137
138
5.21
(dec) (hex)
GOTSCD 136 88 - - 2, 3, 4, 11 1-3-3 Customer-specific sensor 1: cable break or short circuit yes
GOTSCDSysReac 137 89 - - 2, 11 1-3-3 Customer-specific temp. 1: outside target range with system reaction yes
HdThrt 138 8A 29 0000001D 2, 3, 4, 11 1-2-6 Hand throttle: cable break or short circuit, implausible compared to no
signal of idle sensor
HOTSCD 139 8B 1638 00000666 3, 4, 11, 12 3-1-4 Customer-specific sensor 2: cable break or short circuit yes
HOTSCDSysReac 140 8C 1638 00000666 2, 11 3-1-4 Customer-specific temp. 2: outside target range with system reaction yes
HWEMonCom 141 8D 523617 0007FD61 11, 12 5-5-5 ECU internal error: communication with chip CJ 940 disturbed no
HWEMonEEPROM 142 8E 630 00000276 11, 12 2-8-1 ECU internal error: EEPROM memory access no
HWEMonRcyLocked 143 8F 523612 0007FD5C 11, 14 5-5-5 ECU internal hardware monitoring: a recovery occurred which is stored no
as protected
HWEMonRcySuppressed 144 90 523612 0007FD5C 11, 14 5-5-5 ECU internal hardware monitoring: a recovery occurred which is not no
stored
HWEMonRcyVisible 145 91 523612 0007FD5C 11, 14 5-5-5 ECU internal hardware monitoring: a recovery occurred which is visible no
in the error memory
HWEMonUMaxSupply 146 92 523612 0007FD5C 3, 11 5-5-5 ECU internal hardware monitoring: overvoltage no
HWEMonUMinSupply 147 93 523612 0007FD5C 4, 11 5-5-5 ECU internal hardware monitoring: undervoltage no
BOMAG
IATSCD 149 95 105 00000069 2, 3, 4, 11 1-2-8 Charge air temp. sensor: cable break or short circuit yes
IATSCDSysReac 150 96 105 00000069 0, 11 2-3-3 Charge air temp.: above target range with system reaction yes
InjVlvBnk1A 153 99 523350 0007FC56 3, 4, 11, 13 1-5-1 Injectors of cylinder bank 1: short circuit no
InjVlvBnk1B 154 9A 523351 0007FC57 5, 13 1-5-1 Injectors of cylinder bank 1: cable break no
InjVlvBnk2A 155 9B 523352 0007FC58 3, 4, 11, 13 1-5-2 Injectors of cylinder bank 2: short circuit no
InjVlvBnk2B 156 9C 523353 0007FC59 5, 13 1-5-2 Injectors of cylinder bank 2: cable break no
InjVlvChipA 157 9D 523354 0007FC5A 2, 3, 12, 14 1-5-3 ECU internal error: injector power stage A no
InjVlvChipB 158 9E 523355 0007FC5B 12 1-5-3 ECU internal error: injector power stage B no
InjVlvCyl1A 159 9F 651 0000028B 3, 4, 11, 13 1-5-4 Injector 1: short circuit no
InjVlvCyl1B 160 A0 651 0000028B 5, 13 1-5-4 Injector 1: cable break yes
InjVlvCyl2A 161 A1 652 0000028C 3, 4, 11, 13 1-5-5 Injector 2: short circuit no
InjVlvCyl2B 162 A2 652 0000028C 5, 13 1-5-5 Injector 2: cable break yes
InjVlvCyl3A 163 A3 653 0000028D 3, 4, 11, 13 1-5-6 Injector 3: short circuit no
InjVlvCyl3B 164 A4 653 0000028D 5, 13 1-5-6 Injector 3: cable break yes
008 916 41
008 916 41
(dec) (hex)
InjVlvCyl4A 165 A5 654 0000028E 3, 4, 11, 13 1-6-1 Injector 4: short circuit no
InjVlvCyl4B 166 A6 654 0000028E 5, 13 1-6-1 Injector 4: cable break yes
InjVlvCyl5A 167 A7 655 0000028F 3, 4, 11, 13 1-6-2 Injector 5: short circuit no
InjVlvCyl5B 168 A8 655 0000028F 5, 13 1-6-2 Injector 5: cable break yes
InjVlvCyl6A 169 A9 656 00000290 3, 4, 11, 13 1-6-3 Injector 6: short circuit no
InjVlvCyl6B 170 AA 656 00000290 5, 13 1-6-3 Injector 6: cable break yes
InjVlvCyl7A 171 AB 1419 0000058B 3, 4, 11, 13 1-6-4 Injector 7: short circuit no

InjVlvCyl7B 172 AC 1419 0000058B 5, 13 1-6-4 Injector 7: cable break yes
InjVlvCyl8A 173 AD 1420 0000058C 3, 4, 11, 13 1-6-5 Injector 8: short circuit no
InjVlvCyl8B 174 AE 1420 0000058C 5, 13 1-6-5 Injector 8: cable break yes
InjVlvErrDet 175 AF 523370 0007FC6A 11, 14 5-5-5 Compression test active: rail-pressure monitoring is going to be
disabled
MeUnCD_ADC 176 B0 523615 0007FD5F 3, 4, 11 1-3-5 Metering unit valve: flow rate outside target range no
MeUnCDNoLoad 177 B1 523615 0007FD5F 5, 11, 12 1-3-5 Metering unit valve: not connected or output disabled no
MeUnCDSCBat 178 B2 523615 0007FD5F 11, 12 1-3-5 Metering unit valve: short circuit to Ubatt no
BOMAG
MeUnCDSCGnd 179 B3 523615 0007FD5F 11, 12 1-3-5 Metering unit valve: short circuit to ground no
MnRly1_SCB 182 B6 2634 00000A4A 3, 11 1-3-7 Main relay 1: short circuit to Ubatt no
MnRly1_SCG 183 B7 2634 00000A4A 4, 11 1-3-8 Main relay 1: short circuit to ground no
Montr 184 B8 523420 0007FC9C 11, 14 1-3-9 ECU internal error: watchdog counter exceeds maximum no
MRlyCD 186 BA 2634 00000A4A 7, 11, 12 2-6-1 Main relay 2: short circuit to ground or emergency shut-off no
MRlyCDMnRly2 187 BB 563 00000233 7, 11, 12 2-6-1 Main relay 3: short circuit to ground or emergency shut-off (EDC16 only) no
MRlyCDMnRly3 188 BC 2634 00000A4A 7, 11, 12 2-6-1 Main relay 3: short circuit to ground or emergency shut-off (EDC7 only) no
MSSCD1 189 BD 523450 0007FCBA 2, 3, 4, 11 1-4-3 Multi state switch 1: cable break or short circuit, input voltage outside yes
target range
MSSCD2 190 BE 523451 0007FCBB 2, 3, 4, 11 1-4-3 Multi state switch 2: cable break or short circuit, input voltage outside yes
target range
MSSCD3 191 BF 523452 0007FCBC 2, 3, 4, 11 1-4-3 Multi state switch 3: cable break or short circuit, input voltage outside yes
target range
NetMngCANAOff 192 C0 639 0000027F 11, 14 2-7-1 CAN bus A: cable break or short circuit, off-state yes
NetMngCANBOff 193 C1 1231 000004CF 11, 14 2-7-1 CAN bus B: cable break or short circuit, off-state yes
5.21
139
140
5.21
(dec) (hex)
NetMngCANCOff 194 C2 1235 000004D3
11, 14 2-7-1 CAN bus C: cable break or short circuit, off-state yes
OPLpCD 195 C3 705 000002C1
2, 3, 4, 5 1-3-5 Oil pressure warning lamp: cable break or short circuit no
OPSCD 196 C4 100 00000064
0, 2, 3, 4 2-2-4 Charge air pressure sensor: cable break or short circuit yes
OPSCD1 197 C5 100 00000064
1, 11 2-3-1 Oil pressure: value implausible low yes
OPSCDSysReacHi 198 C6 100 00000064
0, 11 2-3-1 Oil pressure: above target range yes
OPSCDSysReacLo 199 C7 100 00000064
1, 11 2-3-1 Oil pressure: below target range yes
OSwCD 200 C8 1237 000004D5
2, 11 1-4-5 Override switch hangs yes
OTSCD 201 C9 175 000000AF
2, 3, 4 1-4-4 Oil temperature sensor: cable break or short circuit yes
OTSCDSysReac 203 CB 175 000000AF
0, 11 1-4-4 Oil temperature: below target range with system reaction yes
PRVMon 208 D0 523470 0007FCCE
2, 11, 12, 1-4-6 Rail pressure limiting valve: opening failure no
14
RailCD 209 D1 157 0000009D 3, 4, 11 1-4-7 Rail pressure sensor: cable break or short circuit no
RailCDOfsTst 210 D2 157 0000009D 0, 1, 11 1-4-7 Rail pressure sensor: low quality signal (deviation of signal during start yes
or after-run above target range)
RailMeUn0 211 D3 523613 0007FD5D 0, 11 1-3-4 Rail pressure: positive deviation (speed dependent) outside target yes
range
BOMAG
RailMeUn1 212 D4 523613 0007FD5D 0, 11 1-3-4 Rail pressure: positive deviation (flow dependent) outside target range yes
RailMeUn2 213 D5 523613 0007FD5D 0, 11 1-3-4 Rail pressure: negative deviation (flow dependent) outside target range yes
RailMeUn3 214 D6 523613 0007FD5D 1, 11 1-3-4 Rail pressure: negative deviation (speed dependent) outside target yes
range
RailMeUn4 215 D7 523613 0007FD5D 0, 11 1-3-4 Rail pressure: above target range yes
RailMeUn7 216 D8 523613 0007FD5D 2, 11 1-3-4 Rail pressure: implausible (leakage, injector needle blocked in open no
position, wastage of injectors or high pressure pumps, high pressure
pumps defective)
SOPTst 218 DA 523490 0007FCE2 3, 4, 11, 12 1-4-9 ECU internal error: redundant shut-off conditions detected no
SSpMon1 219 DB 1079 00000437 3, 4, 11 2-8-2 ECU internal error: wrong voltage of internal 5V reference source 1 yes
SSpMon2 221 DD 1080 00000438 3, 4, 11 2-8-2 ECU internal error: wrong voltage of internal 5V reference source 2 yes
SSpMon3 222 DE 523601 0007FD51 3, 4, 11 2-8-2 ECU internal error: wrong voltage of internal 5V reference source 3 yes
StrtCDHS 223 DF 677 000002A5 3, 4, 11 5-1-2 Start relay (high side): short circuit no
StrtCDLS 224 E0 677 000002A5 3, 4, 5, 11 5-1-2 Start relay (low side): cable break or short circuit, disabled by ECU no
008 916 41
008 916 41
(dec) (hex)
SysLamp 225 E1 624 00000270 2, 3, 4, 5 5-1-3 Diagnostic lamp: cable break or short circuit, disabled by ECU no
T15CD 226 E2 158 0000009E 11, 12 5-1-4 Terminal 15: ignition ON not detected no
T50CD 227 E3 523550 0007FD1E 11, 12 5-1-5 Terminal 50: engine start switch hangs no
TPUMon 228 E4 523550 0007FD1E 2, 11 5-5-5 ECU internal error: time processing unit (TPU) defective no
VSSCD1 232 E8 5-2-1 Vehicle speed: above target range, signal missing or implausible yes
84 00000054 0, 8, 12, 14
WdCom 235 EB 523600 0007FD50 11, 12 5-5-5 ECU internal error: serial communication interface defective no
1
Non-self-curing errors remain active up to the next ECU reset.
Table 2: FMI codes

FMI Description FMI Description
0 Data valid but above normal operational range 8 Abnormal frequency, pulse width,or period
1 Data valid but below normal operational range 9 Abnormal update rated
2 Data erratic, intermittent, or incorrect 10 Abnormal rate of change
BOMAG
3 Voltage above normal or shorted high 11 Failure mode not identifiable
4 Voltage below normal or shorted low 12 Bad intelligent device or component
5 Current below normal or open circuit 13 Out of Calibration
6 Current above normal or grounded circuit 14 Special Instructions
7 Mechanical system not responding properly 15 Reserved
5.21
141
142
referrenced ECU-Software
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
Deutz-Code / SPN / Fehlername ...............................Seite Deutz-Code / SPN / Fehlername............................... Seite Deutz-Code / SPN / Fehlername...............................Seite
11 / 107 / AirFltSysReac.................................................... 3 56 / 110 / CTSCDSysReac ..............................................15 122 / 523607 / FrmMngTOTSC1DE................................ 27
12 / 91 / APP1.................................................................... 3 57 / 701 / Dummy1CD_Max.............................................15 123 / 523608 / FrmMngTOTSC1DR................................ 28
14 / 91 / APPPwm.............................................................. 3 58 / 701 / Dummy1CD_Min..............................................16 124 / 523609 / FrmMngTOTSC1PE ................................ 28
15 / 91 / APPPwmPer........................................................ 4 59 / 701 / Dummy1CD_SigNpl.........................................16 125 / 898 / FrmMngTOTSC1TE ...................................... 28
16 / 108 / APSCD .............................................................. 4 60 / 702 / Dummy2CD_Max.............................................16 126 / 520 / FrmMngTOTSC1TR ...................................... 29
17 / 729 / ArHt1.................................................................. 4 61 / 702 / Dummy2CD_Min..............................................17 127 / 523610 / FrmMngTOTSC1VE ................................ 29
18 / 730 / ArHt2.................................................................. 5 62 / 702 / Dummy2CD_SigNpl.........................................17 128 / 523611 / FrmMngTOTSC1VR................................ 29
19 / 676 / ArHtCD_NoLd.................................................... 5 69 / 2791 / EGRCD_Max .................................................17 131 / 523500 / FrmMngTxTO .......................................... 30
20 / 676 / ArHtCD_RlyErr .................................................. 5 70 / 2791 / EGRCD_Min ..................................................18 133 / 174 / FTSCD........................................................... 30
22 / 168 / BattCD ............................................................... 6 71 / 2791 / EGRCD_SigNpl..............................................18 134 / 174 / FTSCDSysReac ............................................ 30
23 / 168 / BattCDSysReac................................................. 6 72 / 2791 / EGRCDIntEGR ..............................................18 136 / 523618 / GOTSCD ................................................. 31
24 / 523561 / BIPCyl1........................................................ 6 74 / 923 / EngCDTrqCalcOut ...........................................19 137 / 523619 / GOTSCDSysReac................................... 31
25 / 523562 / BIPCyl2........................................................ 7 75 / 190 / EngMBackUp ...................................................19 138 / 29 / HdThrt ............................................................. 31
26 / 523563 / BIPCyl3........................................................ 7 76 / 190 / EngMCaS1.......................................................19 139 / 1638 / HOTSCD ..................................................... 32
27 / 523564 / BIPCyl4........................................................ 7 77 / 190 / EngMCrS1........................................................20 140 / 1638 / HOTSCDSysReac....................................... 32
28 / 523565 / BIPCyl5........................................................ 8 78 / 190 / EngMOfsCaSCrS.............................................20 141 / 523617 / HWEMonCom.......................................... 32
29 / 523566 / BIPCyl6........................................................ 8 79 / 190 / EngPrtSysReacFOC ........................................20 142 / 630 / HWEMonEEPROM........................................ 33
30 / 523567 / BIPCyl7........................................................ 8 80 / 190 / EngPrtSysReacORC........................................21 143 / 523612 / HWEMonRcyLocked ............................... 33
31 / 523568 / BIPCyl8........................................................ 9 81 / 703 / ESLpCD ...........................................................21 144 / 523612 / HWEMonRcySuppressed........................ 33
BOMAG
32 / 102 / BPSCD .............................................................. 9 82 / 1074 / ExFlCD...........................................................21 145 / 523612 / HWEMonRcyVisible ................................ 34
33 / 102 / BPSCDSysReac................................................ 9 83 / 975 / FanCD..............................................................22 146 / 523612 / HWEMonUMaxSupply............................. 34
37 / 111 / CLSCDSysReac .............................................. 10 85 / 1639 / FanCDEval.....................................................22 147 / 523612 / HWEMonUMinSupply.............................. 34
38 / 1323 / CmbChbMisfire1............................................ 10 86 / 523602 / FanCDSysReac .........................................22 149 / 105 / IATSCD ......................................................... 35
39 / 1324 / CmbChbMisfire2............................................ 10 87 / 97 / FlFCD.................................................................23 150 / 105 / IATSCDSysReac........................................... 35
40 / 1325 / CmbChbMisfire3............................................ 11 89 / 97 / FlFCD_WtLvl......................................................23 153 / 523350 / InjVlvBnk1A ............................................. 35
41 / 1326 / CmbChbMisfire4............................................ 11 90 / 94 / FlPSCD ..............................................................23 154 / 523351 / InjVlvBnk1B ............................................. 36
42 / 1327 / CmbChbMisfire5............................................ 11 91 / 94 / FlPSCDSysReac................................................24 155 / 523352 / InjVlvBnk2A ............................................. 36
43 / 1328 / CmbChbMisfire6............................................ 12 94 / 523239 / FrmMngDecV1...........................................24 156 / 523353 / InjVlvBnk2B ............................................. 36
44 / 1450 / CmbChbMisfire7............................................ 12 95 / 523240 / FrmMngFunModCtl ....................................24 157 / 523354 / InjVlvChipA.............................................. 37
45 / 1451 / CmbChbMisfire8............................................ 12 106 / 523212 / FrmMngTOEngPrt....................................25 158 / 523355 / InjVlvChipB.............................................. 37
46 / 1322 / CmbChbMisfireMul ........................................ 13 110 / 523216 / FrmMngTOPrHtEnCmd............................25 159 / 651 / InjVlvCyl1A .................................................... 37
47 / 1346 / CmbChbSysReac .......................................... 13 112 / 523218 / FrmMngTORxCCVS ................................25 160 / 651 / InjVlvCyl1B .................................................... 38
48 / 1109 / CoEngShOffDemIgr....................................... 13 113 / 523604 / FrmMngTORxEngTemp...........................26 161 / 652 / InjVlvCyl2A .................................................... 38
52 / 1072 / CRERCD ....................................................... 14 117 / 523238 / FrmMngTOSwtOut...................................26 162 / 652 / InjVlvCyl2B .................................................... 38
53 / 1081 / CSLpCD......................................................... 14 118 / 523222 / FrmMngTOTCO1 .....................................26 163 / 653 / InjVlvCyl3A .................................................... 39
54 / 704 / CTLpCD........................................................... 14 120 / 523605 / FrmMngTOTSC1AE.................................27 164 / 653 / InjVlvCyl3B .................................................... 39
55 / 110 / CTSCD ............................................................ 15 121 / 523606 / FrmMngTOTSC1AR.................................27 165 / 654 / InjVlvCyl4A .................................................... 39
DEUTZ AG, TE-CE, Fi Seite 1 Rev. 2.1, 22.10.2008
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300
008 916 41
Diagnosis- and Errorcodes
Deutz-Code / SPN / Fehlername ...............................Seite Deutz-Code / SPN / Fehlername............................... Seite Deutz-Code / SPN / Fehlername...............................Seite
166 / 654 / InjVlvCyl4B .................................................... 40 211 / 523613 / RailMeUn0 ...............................................52 255 / 523659 / FrmMngRapeOilVlv1 ............................... 64
167 / 655 / InjVlvCyl5A .................................................... 40 212 / 523613 / RailMeUn1 ...............................................52 256 / 523660 / FrmMngRapeOilVlv2 ............................... 65
169 / 656 / InjVlvCyl6A .................................................... 41 214 / 523613 / RailMeUn3 ...............................................53 258 / 523662 / FrmMngRapeOilVlv4 ............................... 65
171 / 657 / InjVlvCyl7A .................................................... 41 216 / 523613 / RailMeUn7 ...............................................54 260 / 523664 / FrmMngSTIN1RX.................................... 66
172 / 657 / InjVlvCyl7B .................................................... 42 218 / 523490 / SOPTst.....................................................54

173 / 658 / InjVlvCyl8A .................................................... 42 219 / 1079 / SSpMon1 .....................................................54
174 / 658 / InjVlvCyl8B .................................................... 42 221 / 1080 / SSpMon2 .....................................................55
175 / 523370 / InjVlvErrDet.............................................. 43 222 / 523601 / SSpMon3 .................................................55
176 / 523615 / MeUnCD_ADC ........................................ 43 223 / 677 / StrtCDHS .......................................................55
177 / 523615 / MeUnCDNoLoad ..................................... 43 224 / 677 / StrtCDLS........................................................56
178 / 523615 / MeUnCDSCBat........................................ 44 225 / 624 / SysLamp ........................................................56
179 / 523615 / MeUnCDSCGnd ...................................... 44 226 / 158 / T15CD............................................................56
182 / 2634 / MnRly1_SCB ............................................... 44 227 / 523550 / T50CD......................................................57
183 / 2634 / MnRly1_SCG............................................... 45 228 / 523550 / TPUMon...................................................57
184 / 523420 / Montr........................................................ 45 232 / 84 / VSSCD1...........................................................57
186 / 2634 / MRlyCD ....................................................... 45 235 / 523600 / WdCom ....................................................58
187 / 563 / MRlyCDMnRly2 ............................................. 46 236 / 523470 / PRVMonSysReac ....................................58
BOMAG
188 / 2634 / MRlyCDMnRly3 ........................................... 46 237 / 523006 / APPCDSwtnSel........................................58
189 / 523450 / MSSCD1.................................................. 46 238 / 523007 / FrmMng_TORxEngPress.........................59
190 / 523451 / MSSCD2.................................................. 47 239 / 523008 / MplCtl.......................................................59
191 / 523452 / MSSCD3.................................................. 47 240 / 98 / OLSCD.............................................................59
192 / 639 / NetMngCANAOff ........................................... 47 241 / 98 / OLSCDSysReacHi...........................................60
193 / 1231 / NetMngCANBOff ......................................... 48 242 / 107 / ADPSCDAna..................................................60
194 / 1235 / NetMngCANCOff ......................................... 48 243 / 98 / OLSCDSysReacLo ..........................................60
195 / 705 / OPLpCD ........................................................ 48 244 / 523009 / PrvMonWear ............................................61
196 / 100 / OPSCD.......................................................... 49 245 / 523010 / RailMeUn8 ...............................................61
197 / 100 / OPSCD1........................................................ 49 246 / 523650 / FlSys_FLPFMSysReac............................61
198 / 100 / OPSCDSysReacHi ........................................ 49 247 / 523651 / FlSys_FTSFMSysReac............................62
199 / 100 / OPSCDSysReacLo........................................ 50 248 / 523652 / FlSys_FlushStateEngineOff.....................62
200 / 1237 / OSwCD........................................................ 50 249 / 523653 / FlSys_RapeOilHeatEx .............................62
201 / 175 / OTSCD .......................................................... 50 250 / 523654 / FrmMngDieselLvl .....................................63
203 / 175 / OTSCDSysReac............................................ 51 251 / 523655 / FrmMngFuelTemp....................................63
208 / 523470 / PRVMon .................................................. 51 252 / 523656 / FrmMngLowPressureDiesel.....................63
209 / 157 / RailCD ........................................................... 51 253 / 523657 / FrmMngRapeOilIn....................................64
210 / 157 / RailCDOfsTst................................................. 52 254 / 523658 / FrmMngRapeOilLvl ..................................64

5.21
143
144
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

11 / 107 / AirFltSysReac 12 / 91 / APP1 14 / 91 / APPPwm

Error description AIR FILTER COND. Error description THROTTLE 1 Error description THROTTLE 1
Air filter differential pressure: the pressure difference of the intake Analog accelerator pedal sensor 1 or double accelerator pedal Digital accelerator pedal sensor (PWM): the signal received by
air between the filter inlet and outlet calculated by ECU is above sensor: the voltage measured by ECU is out of the target range ECU is defective or implausible or the pulse-duty factor is out of
the target range and the ECU activates a system reaction or the calculated pedal position is implausible compared with the the target range
Error codes position of the second pedal Error codes
DEUTZ-Errorcode: 11 Error codes DEUTZ-Errorcode: 14
BlinkCode (short-long-short): 1 - 3 - 6 DEUTZ-Errorcode: 12 BlinkCode (short-long-short): 2 - 2 - 2
SPN: 107 BlinkCode (short-long-short): 2 - 2 - 6 SPN: 91
possible FMI: SPN: 91 possible FMI:
0: data valid, but above normal working area possible FMI: 8: unusual frequency, pulse or period.
12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt 8: unusual frequency, pulse or period.
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 2: data stream is defective
12. Errormode not identifiable 12. Errormode not identifiable 8: unusual frequency, pulse or period.
Errordetection 2: data stream is defective Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errordetection Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
Pressure loss above target range with system reaction, air filter Possible reason for error Duty cycle outside target range, signal erroneous or implausible
clogged or defective, sensor not working, connection cable Voltage outside target range, signal implausible compared to (pedal 1), sensor defective, onnection cable demaged
demaged signal of redundant pedal (analog pedal 1), sensor defective, Take actions for error repair
BOMAG
Take actions for error repair connection cable demaged Check cabling, check accelator pedal sensor and if necessary
Check airfilter and if necessary clean or renew it, check cabling, Take actions for error repair replace it, check connection cable and if necessary repair or
check air filter and if necessary replace the filter component, Check cabling, check accelator pedal sensor and if necessary replace it
check sensor and if necessary replace it, check connection cable replace it, check connection cable and if necessary repair or other error properties
and if necessary repair or replace it replace it System reaction: Warning, switching to substitute value
other error properties other error properties correspond to Priority-Chain or Limp Home
System reaction: Warning or Warning and power reduction System reaction: Warning, switching to substitute value Behaviour error lamp: permanent light
Behaviour error lamp: permanent light correspond to Priority-Chain or Limp Home Selfhealing: yes
Selfhealing: yes Behaviour error lamp: permanent light Signal Priority: 4
Signal Priority: 2 Selfhealing: no Measurement @ errortime: actual value
Measurement @ errortime: actual value Signal Priority: 4
Measurement @ errortime: actual value
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
15 / 91 / APPPwmPer 16 / 108 / APSCD 17 / 729 / ArHt1

Error description THROTTLE 1 Error description BAROMETRIC PRESS. Error description AIR HEATER RELAY
digital accelerator pedal sensor (PWM): the frequence of the Ambient air pressure sensor (in ECU): the voltage measured by Air heater relay: the current drain measured by ECU is out of the
signal received by ECU is out of the target range ECU is out of the target range or the calculated ambient air target range
Error codes pressure is implausible compared with the charge air pressure Error codes

8: unusual frequency, pulse or period. possible FMI: 3: Voltage to high or short circuit to +Ubatt
8: unusual frequency, pulse or period. 3: Voltage to high or short circuit to +Ubatt 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection 2: data stream is defective Errordetection
Pulse frequency outside target range (pedal 1), sensor defective, Possible reason for error Cable break or short circuit at EDC output, relay defective,
connection cable demaged Ambient air pressure sensor defective, ECU defective connection cable demaged
Take actions for error repair Take actions for error repair Take actions for error repair
Check cabling, check accelator pedal sensor and if necessary Change ECU Check cabling, if sensor not working, check relay and if
BOMAG
replace it, check connection cable and if necessary repair or other error properties necessary replace it, check connection cable and if necessary
replace it System reaction: Warning, substitute value (0,85bar) repair or replace it
other error properties Behaviour error lamp: permanent light other error properties
System reaction: Warning, switching to substitute value Selfhealing: yes System reaction: Warning, shutoff output
correspond to Priority-Chain or Limp Home Signal Priority: 4 Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Measurement @ errortime: default value Selfhealing: yes
Selfhealing: yes Signal Priority: 2
Signal Priority: 4 Measurement @ errortime: shut off value

5.21
145
146
DTC-List P490_: 220, 310, 501 P492_: 213
5.21
18 / 730 / ArHt2 19 / 676 / ArHtCD_NoLd 20 / 676 / ArHtCD_RlyErr

Error description AIR HEATER VALVE Error description AIR HEATER Error description AIR HEATER
Air heater magnet valve: the current drain measured by ECU is Air heater relay: the ECU detects no switching operation at the Air heater relay: the ECU detects an implausible signal at the
out of the target range input of a readback process input of a readback process
Error codes Error codes Error codes
DEUTZ-Errorcode: 18 DEUTZ-Errorcode: 19 DEUTZ-Errorcode: 20
BlinkCode (short-long-short): 2 - 6 - 3 BlinkCode (short-long-short): 2 - 6 - 3 BlinkCode (short-long-short): 2 - 6 - 3
SPN: 730 SPN: 676 SPN: 676
possible FMI: possible FMI: possible FMI:
3: Voltage to high or short circuit to +Ubatt 12. Errormode not identifiable 5: current to low or broken wire
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 2: data stream is defective
5: current to low or broken wire 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Cable break or short circuit, valve defective, connection cable Relay energized, but no feedback on sense line, relay defective Relay not energized, but working voltage on sense line, relay
demaged or wrong wired, preheat component defective, connection cable defective (can not disconnect or switch off), preheat component
Take actions for error repair demaged defective, connection cable demaged
Check valve and if necessary replace it, check connection cable Take actions for error repair Take actions for error repair
BOMAG
and if necessary repair or replace it Check cabling of preheat component, if relay not working,check Check cabling of preheat component, if relay not working,check
other error properties relay and if necessary replace it, check preheat component and if relay and if necessary replace it, check preheat component and if
System reaction: necessary replace it, check connection cable and if necessary necessary replace it, check connection cable and if necessary
Behaviour error lamp: permanent light repair or replace it repair or replace it
Selfhealing: yes other error properties other error properties
Signal Priority: 2 System reaction: Warning System reaction: Warning
Measurement @ errortime: shut off value Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: no Selfhealing: no
Signal Priority: 3 Signal Priority: 3
Measurement @ errortime: setpoint for output status Measurement @ errortime: setpoint for output status
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
22 / 168 / BattCD 23 / 168 / BattCDSysReac 24 / 523561 / BIPCyl1

Error description BATTERY VOLTAGE Error description BATTERY VOLTAGE Error description INJECT. PERIOD ZYL.1
Battery voltage: the voltage measured by ECU is out of the target Battery voltage: the voltage measured by ECU is out of the target Begin of injection of cylinder 1: the ECU can not identify the
range range; the ECU activates a system reaction magnet valve or the injection pump with the measured value of
Error codes Error codes current drain at the begin of the injection
DEUTZ-Errorcode: 22 DEUTZ-Errorcode: 23 Error codes
BlinkCode (short-long-short): 3 - 1 - 8 BlinkCode (short-long-short): 3 - 1 - 8 DEUTZ-Errorcode: 24

SPN: 168 SPN: 168 BlinkCode (short-long-short): 5 - 3 - 1
possible FMI: possible FMI: SPN: 523561
0: data valid, but above normal working area 2: data stream is defective possible FMI:
1: data valid, but below normal working area 2: data stream is defective 2: data stream is defective
12. Errormode not identifiable 12. Errormode not identifiable 2: data stream is defective
Errordetection Errordetection 2: data stream is defective
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errordetection
Possible reason for error Possible reason for error Errorlamp shows permanent light. Entry in errormemory.
Voltage below target range, battery defective, too high power Above target range with system reaction, too high power supply Possible reason for error
supply voltage, too high contact resistance, wiring demaged, voltage, parametering inaccurate, ECU defective Value outside target range or missing (cylinder 1), magnet valve
energie system overloaded, parametering inaccurate, ECU Take actions for error repair or injection pump defective
defective Check dataset of calibration of working voltage for application, Take actions for error repair
BOMAG
Take actions for error repair check LIMA? Check voltage of generator, check the parameters Check magnetic valve or injection pump and if
Check LIMA?, ECU, cabling, contact resistance, safety fuses, too and if necessary correct them, replace ECU necessary change them
high load in energy system, check battery and if necessary other error properties other error properties
replace it, check battery pole and if necessary clean it, check System reaction: Warning System reaction: No function at the moment/ Allocation check
connection cable and if necessary repair or replace it, check volta Behaviour error lamp: permanent light cylinder!
other error properties Selfhealing: yes Behaviour error lamp: permanent light
System reaction: Warning, substitute value, dependent upon Signal Priority: 4 Selfhealing: yes
supply voltage (12V, 24V) Measurement @ errortime: actual value Signal Priority: 3
Behaviour error lamp: permanent light Measurement @ errortime: actual value
Selfhealing: yes
Signal Priority: 3

5.21
147
148
DTC-List P490_: 220, 310, 501 P492_: 213
5.21
25 / 523562 / BIPCyl2 26 / 523563 / BIPCyl3 27 / 523564 / BIPCyl4

Error description INJECT. PERIOD ZYL.2 Error description INJECT. PERIOD ZYL.3 Error description INJECT. PERIOD ZYL.4
Begin of injection of cylinder 2: the ECU can not identify the Begin of injection of cylinder 3: the ECU can not identify the Begin of injection of cylinder 4: the ECU can not identify the
magnet valve or the injection pump with the measured value of magnet valve or the injection pump with the measured value of magnet valve or the injection pump with the measured value of
current drain at the begin of the injection current drain at the begin of the injection current drain at the begin of the injection
SPN: 523562 SPN: 523563 SPN: 523564
2: data stream is defective 2: data stream is defective 2: data stream is defective
Value outside target range or missing (cylinder 2), magnet valve Value outside target range or missing (cylinder 3), magnet valve Value outside target range or missing (cylinder 4), magnet valve
or injection pump defective or injection pump defective or injection pump defective
BOMAG
Check magnetic valve or injection pump and if Check magnetic valve or injection pump and if d
necessary change them necessary change them other error properties
other error properties other error properties System reaction: No function at the moment/ Allocation check
System reaction: No function at the moment/ Allocation check System reaction: No function at the moment/ Allocation check cylinder!
cylinder! cylinder! Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Selfhealing: yes
Selfhealing: yes Selfhealing: yes Signal Priority: 3
Signal Priority: 3 Signal Priority: 3 Measurement @ errortime: actual value
Measurement @ errortime: actual value Measurement @ errortime: actual value
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
28 / 523565 / BIPCyl5 29 / 523566 / BIPCyl6 30 / 523567 / BIPCyl7

Error description INJECT. PERIOD ZYL.5 Error description INJECT. PERIOD ZYL.6 Error description INJECT. PERIOD ZYL.7
Begin of injection of cylinder 5: the ECU can not identify the Begin of injection of cylinder 6: the ECU can not identify the Begin of injection of cylinder 7: the ECU can not identify the
magnet valve or the injection pump with the measured value of magnet valve or the injection pump with the measured value of magnet valve or the injection pump with the measured value of
current drain at the begin of the injection current drain at the begin of the injection current drain at the begin of the injection

SPN: 523565 SPN: 523566 SPN: 523567
Value outside target range or missing (cylinder 5), magnet valve Value outside target range or missing (cylinder 6), magnet valve Value outside target range or missing (cylinder 7), magnet valve
or injection pump defective or injection pump defective or injection pump defective
BOMAG
Check magnetic valve or injection pump and if Check magnetic valve or injection pump and if Check magnetic valve or injection pump and if
necessary change them necessary change them necessary change them
other error properties other error properties other error properties
System reaction: No function at the moment/ Allocation check System reaction: No function at the moment/ Allocation check System reaction: No function at the moment/ Allocation check
cylinder! cylinder! cylinder!
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: yes Selfhealing: yes Selfhealing: yes
Signal Priority: 3 Signal Priority: 3 Signal Priority: 3
Measurement @ errortime: actual value Measurement @ errortime: actual value Measurement @ errortime: actual value

5.21
149
150
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

31 / 523568 / BIPCyl8 32 / 102 / BPSCD 33 / 102 / BPSCDSysReac

Error description INJECT. PERIOD ZYL.8 Error description CHARGE AIR PRESS. Error description CHARGE AIR PRESS.
Begin of injection of cylinder 8: the ECU can not identify the Charge air pressure sensor: the measured voltage of sensor by Charge air pressure: the charge air pressure calculated by ECU
magnet valve or the injection pump with the measured value of ECU is out of the target range; the calculated charge air pressure is above the target range; the ECU activates a system reaction
current drain at the begin of the injection is implausible or the received value via CAN is defective Error codes
Error codes Error codes DEUTZ-Errorcode: 33
DEUTZ-Errorcode: 31 DEUTZ-Errorcode: 32 BlinkCode (short-long-short): 2 - 2 - 3
BlinkCode (short-long-short): 5 - 3 - 8 BlinkCode (short-long-short): 2 - 2 - 3 SPN: 102
SPN: 523568 SPN: 102 possible FMI:
possible FMI: possible FMI: 2: data stream is defective
2: data stream is defective 3: Voltage to high or short circuit to +Ubatt 2: data stream is defective
2: data stream is defective 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
2: data stream is defective 2: data stream is defective 12. Errormode not identifiable
2: data stream is defective 2: data stream is defective Errordetection
Errordetection Errordetection Errorlamp shows permanent light
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. oder
Possible reason for error Possible reason for error blinking. Entry in errormemory.
Value outside target range or missing (cylinder 8), magnet valve Cable break or short circuit, sensor defective, onnection cable Possible reason for error
or injection pump defective demaged Outside target range with system reaction, air system demaged,
Take actions for error repair Take actions for error repair sensor defective, onnection cable demaged
BOMAG
Check magnetic valve or injection pump and if Check cabling, if LDF6T sensor not working, check sensor and if Take actions for error repair
necessary change them necessary replace it, check connection cable and if necessary Check air system, inspect air system and if necessary repair it,
other error properties repair or replace it check sensor and if necessary replace it, check connection cable
System reaction: No function at the moment/ Allocation check other error properties and if necessary repair or replace it
cylinder! System reaction: Warning, substitute value other error properties
Behaviour error lamp: permanent light Behaviour error lamp: permanent light System reaction: Advice: BPSCD_stSysReacReq
Selfhealing: yes Selfhealing: yes Behaviour error lamp: permanent light
Signal Priority: 3 Signal Priority: 4 oder
Measurement @ errortime: actual value Measurement @ errortime: default value blinking
Selfhealing: yes
Signal Priority: 4
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
37 / 111 / CLSCDSysReac 38 / 1323 / CmbChbMisfire1 39 / 1324 / CmbChbMisfire2

Error description ENG COOLANT LEVEL Error description MISFIRE CYL. 1 Error description MISFIRE CYL. 2
Coolant level: the coolant level calculated by ECU is underneath Misfire at cylinder 1: the number of the misfire detected by ECU Misfire at cylinder 2: the number of the misfire detected by ECU
the allowed minimum is out of the allowed limit value is out of the allowed limit value

SPN: 111 SPN: 1323 SPN: 1324
1: data valid, but below normal working area 12: Defective component 12: Defective component
1: data valid, but below normal working area 12. Errormode not identifiable 12. Errormode not identifiable
Errorlamp shows permanent light Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
oder Possible reason for error Possible reason for error
blinking. Entry in errormemory. Misfire detected (cylinder 1), magnet valve or injection pump Misfire detected (cylinder 2), magnet valve or injection pump
Possible reason for error defective, fuel system defective, motor engineering demaged defective, fuel system defective, motor engineering demaged
Outside target range with system reaction, cooling system Take actions for error repair Take actions for error repair
untight, sensor defective, onnection cable demaged Check magnetic valve or injection pump and if necessary replace Check magnetic valve or injection pump and if necessary replace
BOMAG
Take actions for error repair them, check fuel system and if necessary repair it, check motor them, check fuel system and if necessary repair it, check motor
Check coolant level, check cabling, inspect cooling system and if engineering and if necessary repair it engineering and if necessary repair it
necessary repair it, check sensor and if necessary replace it, other error properties other error properties
check connection cable and if necessary repair or replace it System reaction: System reaction:
other error properties Behaviour error lamp: permanent light Behaviour error lamp: permanent light
System reaction: Advice: CLSCD_stSysReacReq Selfhealing: no Selfhealing: no
Behaviour error lamp: permanent light Signal Priority: 0 Signal Priority: 0
oder Measurement @ errortime: actual value Measurement @ errortime: actual value
blinking
Selfhealing: no
Signal Priority: 3

5.21
151
152
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

40 / 1325 / CmbChbMisfire3 41 / 1326 / CmbChbMisfire4 42 / 1327 / CmbChbMisfire5

Error description MISFIRE CYL. 3 Error description MISFIRE CYL. 4 Error description MISFIRE CYL. 5
Misfire at cylinder 3: the number of the misfire detected by ECU Misfire at cylinder 4: the number of the misfire detected by ECU Misfire at cylinder 5: the number of the misfire detected by ECU
is out of the allowed limit value is out of the allowed limit value is out of the allowed limit value
SPN: 1325 SPN: 1326 SPN: 1327
12: Defective component 12: Defective component 12: Defective component
Misfire detected (cylinder 3), magnet valve or injection pump Misfire detected (cylinder 4), magnet valve or injection pump Misfire detected (cylinder 5), magnet valve or injection pump
defective, fuel system defective, motor engineering demaged defective, fuel system defective, motor engineering demaged defective, fuel system defective, motor engineering demaged
Check magnetic valve or injection pump and if necessary replace Check magnetic valve or injection pump and if necessary replace Check magnetic valve or injection pump and if necessary replace
BOMAG
them, check fuel system and if necessary repair it, check motor them, check fuel system and if necessary repair it, check motor them, check fuel system and if necessary repair it, check motor
engineering and if necessary repair it engineering and if necessary repair it engineering and if necessary repair it
System reaction: System reaction: System reaction:
Selfhealing: no Selfhealing: no Selfhealing: no
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
43 / 1328 / CmbChbMisfire6 44 / 1450 / CmbChbMisfire7 45 / 1451 / CmbChbMisfire8

Error description MISFIRE CYL. 6 Error description MISFIRE CYL. 7 Error description MISFIRE CYL. 8
Misfire at cylinder 6: the number of the misfire detected by ECU Misfire at cylinder 7: the number of the misfire detected by ECU Misfire at cylinder 8: the number of the misfire detected by ECU
is out of the allowed limit value is out of the allowed limit value is out of the allowed limit value

SPN: 1328 SPN: 1450 SPN: 1451
Misfire detected (cylinder 6), magnet valve or injection pump Misfire detected (cylinder 7), magnet valve or injection pump Misfire detected (cylinder 8), magnet valve or injection pump
defective, fuel system defective, motor engineering demaged defective, fuel system defective, motor engineering demaged defective, fuel system defective, motor engineering demaged
Check magnetic valve or injection pump and if necessary replace Check magnetic valve or injection pump and if necessary replace Check magnetic valve or injection pump and if necessary replace
BOMAG
them, check fuel system and if necessary repair it, check motor them, check fuel system and if necessary repair it, check motor them, check fuel system and if necessary repair it, check motor
engineering and if necessary repair it engineering and if necessary repair it engineering and if necessary repair it

5.21
153
154
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

46 / 1322 / CmbChbMisfireMul 47 / 1346 / CmbChbSysReac 48 / 1109 / CoEngShOffDemIgr

Error description MULTIPL. CYL. MISFIRE Error description MISFIRE SYST. REACT Error description SHUT OFF REQUEST
Misfire at more cylinders: the number of the misfire detected by Misfire at more cylinders: the number of the misfire detected by Request of engine off: the operator ignors the engine off request
ECU is out of the allowed limit value ECU is out of the allowed limit value; the ECU activates a system within an allowed period.
Error codes reaction Error codes
12: Defective component possible FMI: 2: data stream is defective
12. Errormode not identifiable 0: data valid, but above normal working area 12. Errormode not identifiable
Errordetection 12. Errormode not identifiable Errordetection
Misfire detected, magnet valve or injection pump defective, fuel Possible reason for error Shut-off request ignored by operator
system defective, motor engineering demaged Misfire detected with system reaction, magnet valve or injection Take actions for error repair
Take actions for error repair pump defective, fuel system defective, motor engineering Warranty relevant
Check magnetic valve or injection pump and if necessary replace demaged other error properties
BOMAG
them, check fuel system and if necessary repair it, check motor Take actions for error repair System reaction: Warning
engineering and if necessary repair it Check magnetic valve or injection pump and if necessary replace Behaviour error lamp: permanent light
other error properties them, check fuel system and if necessary repair it, check motor Selfhealing: no
System reaction: engineering and if necessary repair it Signal Priority: 4
Behaviour error lamp: permanent light other error properties Measurement @ errortime: actual value
Selfhealing: no System reaction:
Signal Priority: 0 Behaviour error lamp: permanent light
Measurement @ errortime: actual value Selfhealing: no
Signal Priority: 0
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300
008 916 41
52 / 1072 / CRERCD 53 / 1081 / CSLpCD 54 / 704 / CTLpCD

Error description ENGINE BRAKE INT. Error description PREHEAT LAMP Error description TEMP. LAMP
Engine brake actuator (internal): the current drain measured by Indicator lamp of air heater relay: the current drain measured by Warning lamp for coolant temperature: the current drain
ECU is out of the target range or the maximum permissble ECU is out of the target range or the maximum permissble measured by ECU is out of the target range or the maximum
temperature of the ECU component for power supply of the temperature of the ECU component for power supply of the lamp temperature of the ECU component for power supply of the lamp
actuator is exceeded. is exceeded is exceeded

SPN: 1072 SPN: 1081 SPN: 704
3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt 12. Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
5: current to low or broken wire 5: current to low or broken wire 12. Errormode not identifiable
12. Errormode not identifiable 2: data stream is defective 12. Errormode not identifiable
cable break or short circuit, sensor defective, connection cable Cable break or short circuit, lamp defective, connection cable Cable break or short circuit, lamp defective, connection cable
demaged demaged demaged
BOMAG
Check actuator and if necessary replace it, check connection Check cabling and load, check lamp and if necessary replace it, Check cabling and load, check lamp and if necessary replace it,
cable and if necessary repaire or replace it check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it
System reaction: Warning, shutoff output, capacity reduction via System reaction: Warning, shutoff output System reaction: Warning, shutoff output
second topcurve? Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Selfhealing: no Selfhealing: no
Selfhealing: no Signal Priority: 1 Signal Priority: 1
Signal Priority: 2 Measurement @ errortime: setpoint for output status Measurement @ errortime: setpoint for output status
Measurement @ errortime: setpoint for output status

5.21
155
156
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

55 / 110 / CTSCD 56 / 110 / CTSCDSysReac 57 / 701 / Dummy1CD_Max

Error description ENG COOLANT TEMP. Error description ENG COOLANT TEMP. Error description RESERVE 2
Coolant temperature sensor: the voltage of the sensor measured Coolant temperature: the coolant temperature calculated by ECU Reserve output 1: the ECU detects a short circuit to battery
by ECU is out of the target range; the coolant temperature is above the target range; the ECU activates a system reaction Error codes
calculated by ECU is implausible compared with the oil Error codes DEUTZ-Errorcode: 57
temperature or the received value via CAN is defective DEUTZ-Errorcode: 56 BlinkCode (short-long-short): 1 - 0 - 0
Error codes BlinkCode (short-long-short): 2 - 3 - 2 SPN: 701
DEUTZ-Errorcode: 55 SPN: 110 possible FMI:
BlinkCode (short-long-short): 2 - 2 - 5 possible FMI: 12. Errormode not identifiable
SPN: 110 0: data valid, but above normal working area 12. Errormode not identifiable
possible FMI: 0: data valid, but above normal working area 12. Errormode not identifiable
3: Voltage to high or short circuit to +Ubatt 12. Errormode not identifiable 12. Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable Errordetection
2: data stream is defective Errordetection Errorlamp shows permanent light. Entry in errormemory.
2: data stream is defective Errorlamp shows permanent light Possible reason for error
Errordetection oder Short circuit to Ubatt (output 1), connection cable demaged
Errorlamp shows permanent light. Entry in errormemory. blinking. Entry in errormemory. Take actions for error repair
Possible reason for error Possible reason for error Check connection cable and if necessary repair or replace it
Cable break or short circuit, lamp defective, connection cable Outside target range with system reaction, cooling system not other error properties
demaged enough to be filled, clogged or demaged, cooling compressor System reaction: Warning, shutoff output
BOMAG
Take actions for error repair dropped out, sensor defective, onnection cable demaged Behaviour error lamp: permanent light
Check cabling, sensor defect, check sensor and if necessary Take actions for error repair Selfhealing: no
replace it, check connection cable and if necessary repair or Check cycle cooling system and compressor, inspect cooling Signal Priority: 1
replace it system and if necessary repair it, check cooling compressor and Measurement @ errortime: shut off value
other error properties if necessary replace it, check sensor and if necessary replace it,
System reaction: Warning, substitute value check connection cable and if necessary repair or replace it
Behaviour error lamp: permanent light other error properties
Selfhealing: yes System reaction: Advice: CTSCD_stSysReacReq
Measurement @ errortime: default value oder
blinking
Selfhealing: yes
Signal Priority: 4
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
58 / 701 / Dummy1CD_Min 59 / 701 / Dummy1CD_SigNpl 60 / 702 / Dummy2CD_Max

Error description RESERVE 2 Error description RESERVE 2 Error description THRUST MODE
Reserve output 1: the ECU detects a short circuit to ground Reserve output 1: the ECU detects no load or excess Reserve output 2: the ECU detects a short circuit to battery
Error codes temperature of the ECU component for power supply of the Error codes
DEUTZ-Errorcode: 58 connected components DEUTZ-Errorcode: 60
BlinkCode (short-long-short): 1 - 0 - 0 Error codes BlinkCode (short-long-short): 1 - 0 - 0
SPN: 701 DEUTZ-Errorcode: 59 SPN: 702

possible FMI: BlinkCode (short-long-short): 1 - 0 - 0 possible FMI:
12. Errormode not identifiable SPN: 701 12. Errormode not identifiable
12. Errormode not identifiable possible FMI: 12. Errormode not identifiable
Errordetection 12. Errormode not identifiable Errordetection
Errorlamp shows permanent light. Entry in errormemory. 12. Errormode not identifiable Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Errordetection Possible reason for error
Short circuit to ground (output 1), connection cable demaged Errorlamp shows permanent light. Entry in errormemory. Short circuit to Ubatt (output 2), onnection cable demaged
Take actions for error repair Possible reason for error Take actions for error repair
Check connection cable and if necessary repair or replace it Cable break or ECU internal error (output 1), connection cable Check connection cable and if necessary repair or replace it
other error properties demaged, connected components defective, parametering of the other error properties
System reaction: Warning, shutoff output output inaccurate, ECU defective System reaction: Warning, shutoff output
BOMAG
Behaviour error lamp: permanent light Take actions for error repair Behaviour error lamp: permanent light
Selfhealing: no Check connection cable and if necessary repair or replace it, Selfhealing: no
Signal Priority: 1 check parameters and if necessary correct it, replace ECU Signal Priority: 1
Measurement @ errortime: shut off value other error properties Measurement @ errortime: shut off value
System reaction: Warning, shutoff output
Behaviour error lamp: permanent light
Selfhealing: no
Signal Priority: 1
Measurement @ errortime: shut off value

5.21
157
158
DTC-List P490_: 220, 310, 501 P492_: 213
5.21
61 / 702 / Dummy2CD_Min 62 / 702 / Dummy2CD_SigNpl 69 / 2791 / EGRCD_Max

Error description THRUST MODE Error description THRUST MODE Error description EGR ACTUATOR
Reserve output 2: the ECU detects a short circuit to ground Reserve output 2: the ECU detects no load or excess Actuator of the external EGR valve: the ECU detects a short
Error codes temperature of the ECU component for power supply of the circuit to battery
DEUTZ-Errorcode: 61 connected components Error codes
BlinkCode (short-long-short): 1 - 0 - 0 Error codes DEUTZ-Errorcode: 69
SPN: 702 DEUTZ-Errorcode: 62 BlinkCode (short-long-short): 4 - 1 - 4
possible FMI: BlinkCode (short-long-short): 1 - 0 - 0 SPN: 2791
12. Errormode not identifiable SPN: 702 possible FMI:
12. Errormode not identifiable possible FMI: 3: Voltage to high or short circuit to +Ubatt
Errordetection 12. Errormode not identifiable 12. Errormode not identifiable
Errorlamp shows permanent light. Entry in errormemory. 12. Errormode not identifiable Errordetection
Possible reason for error Errordetection Errorlamp shows permanent light. Entry in errormemory.
Short circuit to ground (output 2), connection cable demaged Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
Take actions for error repair Possible reason for error Short circuit to Ubatt, connection cable demaged
Check connection cable and if necessary repair or replace it Cable break or ECU internal error (output 2), connection cable Take actions for error repair
other error properties demaged, connected components defective, parametering of the Check cabling, sensor defect, check sensor and if necessary
System reaction: Warning, shutoff output output inaccurate, ECU defective replace it, check connection cable and if necessary repair or
BOMAG
Behaviour error lamp: permanent light Take actions for error repair replace it
Selfhealing: no Check connection cable and if necessary repair or replace it, other error properties
Signal Priority: 1 check parameters and if necessary correct it, replace ECU System reaction: Warning, shutoff output, power reduction via
Measurement @ errortime: shut off value other error properties second topcurve?
System reaction: Warning, shutoff output Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Selfhealing: no
Selfhealing: no Signal Priority: 3
Signal Priority: 1 Measurement @ errortime: shut off value
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
70 / 2791 / EGRCD_Min 71 / 2791 / EGRCD_SigNpl 72 / 2791 / EGRCDIntEGR

Error description EGR ACTUATOR Error description EGR ACTUATOR Error description EGR ACTUATOR
Actuator of the external EGR valve: the ECU detects a short Actuator of the external EGR valve: the ECU detects no load or Actuator of the internal EGR valve: the ECU detects no load or
circuit to ground excess temperature of the ECU component for power supply of excess temperature of the ECU component for power supply of
Error codes the connected components the actuator
DEUTZ-Errorcode: 70 Error codes Error codes
BlinkCode (short-long-short): 4 - 1 - 4 DEUTZ-Errorcode: 71 DEUTZ-Errorcode: 72

SPN: 2791 BlinkCode (short-long-short): 4 - 1 - 5 BlinkCode (short-long-short): 4 - 1 - 6
possible FMI: SPN: 2791 SPN: 2791
12. Errormode not identifiable possible FMI: possible FMI:
4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt
12. Errormode not identifiable 12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 5: current to low or broken wire 5: current to low or broken wire
Errordetection 2: data stream is defective 2: data stream is defective
Errorlamp shows permanent light. Entry in errormemory. Errordetection Errordetection
Possible reason for error Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Short circuit to ground, connection cable demaged Possible reason for error Possible reason for error
Take actions for error repair Cable break or excess temperature, sensor defective, connection Cable break, short circuit or excess temperature, sensor
Check cabling, sensor defect, check sensor and if necessary cable demaged defective, connection cable demaged
replace it, check connection cable and if necessary repair or Take actions for error repair Take actions for error repair
BOMAG
replace it Check cabling, sensor defect, check sensor and if necessary Check cabling, sensor defect, check sensor and if necessary
other error properties replace it, check connection cable and if necessary repair or replace it, check connection cable and if necessary repair or
System reaction: Warning, shutoff output, power reduction via replace it replace it
second topcurve? other error properties other error properties
Behaviour error lamp: permanent light System reaction: Warning, shutoff output, power reduction via System reaction: Warning, shutoff output, power reduction via
Selfhealing: no second topcurve? second topcurve?
Signal Priority: 3 Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Measurement @ errortime: shut off value Selfhealing: no Selfhealing: no
Measurement @ errortime: shut off value Measurement @ errortime: shut off value

5.21
159
160
DTC-List P490_: 220, 310, 501 P492_: 213
5.21
74 / 923 / EngCDTrqCalcOut 75 / 190 / EngMBackUp 76 / 190 / EngMCaS1

Error description ENGINE POWER OUT Error description ENGINE SPEED Error description ENGINE SPEED
Output with PWM signal of the engine power: the current drain Crankschaft speed sensor: the ECU receives no signal and uses Camschaft speed sensor: the ECU receives no signal or the
measured by ECU is out of the target range or the maximum the signal from camschaft speed sensor as alternative to signal is defective
permissible temperature of the ECU component to control the calculate the engine speed Error codes
output is exceeded Error codes DEUTZ-Errorcode: 76
Error codes DEUTZ-Errorcode: 75 BlinkCode (short-long-short): 2 - 1 - 2
DEUTZ-Errorcode: 74 BlinkCode (short-long-short): 2 - 1 - 2 SPN: 190
BlinkCode (short-long-short): 5 - 5 - 5 SPN: 190 possible FMI:
SPN: 923 possible FMI: 12: Defective component
possible FMI: 12. Errormode not identifiable 8: unusual frequency, pulse or period.
3: Voltage to high or short circuit to +Ubatt 12: Defective component 12. Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable 12. Errormode not identifiable
5: current to low or broken wire 12. Errormode not identifiable Errordetection
2: data stream is defective Errordetection Errorlamp shows permanent light. Entry in errormemory.
Errordetection Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
Errorlamp shows permanent light. Entry in errormemory. Possible reason for error Speed signal from cam-shaft defectiveiv or missing, transmitter
Possible reason for error Engine running only with cam-shaft speed signal, transmitter defective, connection cable demaged, parametering of the sensor
Engine Power output: cable break or short circuit, output defective, connection cable demaged wheel inaccurate
defective, connection cable demaged Take actions for error repair Take actions for error repair
BOMAG
Take actions for error repair Check cabling of crankschaft sensor, check crankschaft sensor Check cabling, check camschaft sensor and if necessary replace
Check cabling, sensor defect, check sensor and if necessary and if necessary replace it, check connection cable and if it, check configuration of sensor wheel, check connection cable
replace it, check connection cable and if necessary repair or necessary repair or replace it and if necessary repair or replace it, check parameters and if
replace it other error properties necessary correct them
other error properties System reaction: Warning, calculation of injektion initation point other error properties
System reaction: Warning, shutoff output will be incorrect System reaction: Warning, difficult start
Selfhealing: no Selfhealing: yes Selfhealing: yes
Measurement @ errortime: shut off value Measurement @ errortime: - Measurement @ errortime: 0
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300
008 916 41
77 / 190 / EngMCrS1 78 / 190 / EngMOfsCaSCrS 79 / 190 / EngPrtSysReacFOC

Error description ENGINE SPEED Error description ENGINE SPEED Error description ENGINE SPEED
Crankschaft speed sensor: the ECU receives no signal or the Speed sensor of crankschaft and camschaft: the received signals Engine speed: the engine speed calculated by ECU is above the
signal is defective are out of phase target range; the ECU activates a system reaction

SPN: 190 SPN: 190 SPN: 190
12: Defective component 2: data stream is defective 0: data valid, but above normal working area
8: unusual frequency, pulse or period. 12. Errormode not identifiable 12. Errormode not identifiable
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows blinking. Entry in errormemory.
Speed signal from crankshaft defectiveiv or missing, transmitter Speed signals of crank-shaft and cam-shaft are phase-shifted, Engine overspeed detected with system reaction, maximum
defective, connection cable demaged, sensor wheel installed sensor wheel installed in wrong position, sensor wrong wired engine speed exceeded
inaccurately Take actions for error repair Take actions for error repair
Take actions for error repair Check position from crankschaft sensor wheel to camschaft other error properties
BOMAG
Check cabling, check camschaft sensor and if necessary replace sensor wheel, polarisation crankschaft or camschaft sensor, System reaction:
it, check configuration of sensor wheel, check connection cable check position of sensor wheel and if necessary correct it, check Behaviour error lamp: blinking
and if necessary repair or replace it, check the position of sensor cabling and if necessary correct it Selfhealing: no
wheel and if necessary correct it other error properties Signal Priority: 5
other error properties System reaction: Warning, not possible to start engine Measurement @ errortime: actual value
System reaction: Warning, power reduction via second topcurve Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Selfhealing: no
Signal Priority: 4 Measurement @ errortime: -
Measurement @ errortime: 0

5.21
161
162
DTC-List P490_: 220, 310, 501 P492_: 213
5.21
80 / 190 / EngPrtSysReacORC 81 / 703 / ESLpCD 82 / 1074 / ExFlCD

Error description ENGINE SPEED Error description ENG. RUNNING LAMP Error description BRAKE FLAP ACTUATOR
Engine speed: under overrun conditions, the engine speed Indicator lamp for engine running: the current drain measured by Engine brake flap actuator: the current drain measured by ECU is
calculated by ECU is above the target range; the ECU activates a ECU is out of the target range or the maximum permissible out of the target range or the maximum permissible temperature
system reaction temperature of the ECU component for power supply of the lamp of the ECU component for power supply of the actuator is
Error codes is exceeded exceeded
14: Special Instructions possible FMI: possible FMI:
12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 5: current to low or broken wire 5: current to low or broken wire
Errordetection 2: data stream is defective 12. Errormode not identifiable
Overrun conditions detected with system reaction, maximum Possible reason for error Possible reason for error
engine speed exceeded Cable break or internal ECU error, lamp defective, connection Engine brake flap actuator: cable break or short circuit, sensor
Take actions for error repair cable demaged defective, connection cable demaged
BOMAG
other error properties Take actions for error repair Take actions for error repair
System reaction: Check cabling and load, check lamp and if necessary replace it, Check cabling, sensor defect, check sensor and if necessary
Behaviour error lamp: permanent light check connection cable and if necessary repair or replace it replace it, check connection cable and if necessary repair or
Selfhealing: yes other error properties replace it
Signal Priority: 4 System reaction: Warning, shutoff output other error properties
Measurement @ errortime: actual value Behaviour error lamp: permanent light System reaction: Warning, shutoff output
Selfhealing: no Behaviour error lamp: permanent light
Signal Priority: 1 Selfhealing: no
Measurement @ errortime: shut off value Signal Priority: 2
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
83 / 975 / FanCD 85 / 1639 / FanCDEval 86 / 523602 / FanCDSysReac

Error description FAN ACTUATOR Error description Error description FAN SPEED
Fan power stage: the current drain measured by ECU is out of Fan speed sensor: the current drain measured by ECU is out of Fan speed: the fan speed calculated by ECU is above the target
the target range or the maximum permissible temperature of the the target range range; the ECU activates a system reaction
ECU component for power supply of the actuator is exceeded Error codes Error codes
Error codes DEUTZ-Errorcode: 85 DEUTZ-Errorcode: 86
DEUTZ-Errorcode: 83 BlinkCode (short-long-short): 2 - 3 - 8 BlinkCode (short-long-short): 2 - 3 - 8

BlinkCode (short-long-short): 2 - 3 - 8 SPN: 1639 SPN: 523602
SPN: 975 possible FMI: possible FMI:
possible FMI: 3: Voltage to high or short circuit to +Ubatt 2: data stream is defective
3: Voltage to high or short circuit to +Ubatt 4: Voltage to low or short circuit to -Ubatt 2: data stream is defective
4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable 12. Errormode not identifiable
5: current to low or broken wire 12. Errormode not identifiable 12. Errormode not identifiable
2: data stream is defective Errordetection Errordetection
Errordetection Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Errorlamp shows permanent light. Entry in errormemory. Possible reason for error Possible reason for error
Possible reason for error Sensor defective, connection cable demaged, fan speed outside Above target range with system reaction
cable break or short circuit, sensor defective, connection cable the target range Take actions for error repair
demaged Take actions for error repair other error properties
Take actions for error repair Check sensor and if necessary replace it, check connectionn System reaction:
BOMAG
Check cabling, sensor defect, check sensor and if necessary cable and if necessary repair or replace it, check fan Behaviour error lamp: permanent light
replace it, check connection cable and if necessary repair or other error properties Selfhealing: yes
replace it System reaction: Signal Priority: 3
other error properties Behaviour error lamp: permanent light Measurement @ errortime: actual value
System reaction: Warning, shutoff output Selfhealing: yes
Behaviour error lamp: permanent light Signal Priority: 2
Selfhealing: no Measurement @ errortime: actual value
Signal Priority: 2
Measurement @ errortime: Sollwert

5.21
163
164
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

87 / 97 / FlFCD 89 / 97 / FlFCD_WtLvl 90 / 94 / FlPSCD

Error description WATER IN FUEL Error description WATER IN FUEL Error description FUEL PRE PRESS.
Fuel filter water level sensor: the voltage of sensor measured by Water in fuel: the water level calculated by ECU is above the Low fuel pressure sensor: the voltage of sensor measured by
ECU is out of the target range allowed limit value ECU is out of the target range
SPN: 97 SPN: 97 SPN: 94
3: Voltage to high or short circuit to +Ubatt 12: Defective component 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
cable break or short circuit, sensor defective, connection cable Above target range, excess of maximum permissible water level cable break or short circuit, sensor defective, connection cable
demaged in fuel filter demaged
Check cabling, if sensor not working, check sensor and if flush water seperator Check cabling, if sensor not working, check sensor and if
BOMAG
necessary replace it, check connection cable and if necessary other error properties necessary replace it, check connection cable and if necessary
repair or replace it System reaction: Warning repair or replace it
other error properties Behaviour error lamp: permanent light other error properties
System reaction: Warning, substitute value Selfhealing: no System reaction: Warning, substitute value
Behaviour error lamp: permanent light Signal Priority: 3 Behaviour error lamp: permanent light
Selfhealing: yes Measurement @ errortime: actual value Selfhealing: yes
Measurement @ errortime: default value Measurement @ errortime: default value
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
91 / 94 / FlPSCDSysReac 94 / 523239 / FrmMngDecV1 95 / 523240 / FrmMngFunModCtl

Error description FUEL PRE PRESS. Error description CAN ERROR DEC-V1 Error description CAN ERROR FUNMODCTL
Low fuel pressure: the low fuel pressure calculated by ECU is CAN message DecV1 (Pseudo Pedal): the message can not be CAN message FunModCtl (Function Mode Control): the message
underneath the target range; the ECU activates a system received by ECU or the received value is above the target range can not be received by ECU
reaction Error codes Error codes
Error codes DEUTZ-Errorcode: 94 DEUTZ-Errorcode: 95
DEUTZ-Errorcode: 91 BlinkCode (short-long-short): 5 - 2 - 6 BlinkCode (short-long-short): 5 - 2 - 7

BlinkCode (short-long-short): 2 - 1 - 6 SPN: 523239 SPN: 523240
SPN: 94 possible FMI: possible FMI:
possible FMI: 12: Defective component 12: Defective component
2: data stream is defective 12: Defective component 12. Errormode not identifiable
2: data stream is defective 12: Defective component 12. Errormode not identifiable
12. Errormode not identifiable 2: data stream is defective 12. Errormode not identifiable
12. Errormode not identifiable Errordetection Errordetection
Errordetection Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Errorlamp shows permanent light. Entry in errormemory. Possible reason for error Possible reason for error
Possible reason for error Missing or value above target range (message "DecV1" = pseudo Missing message "FunModCtl" = function mode control, CAN bus
Below target range with system reaction, interruption in cycling pedal), CAN bus wrong cabled, wiring is demaged, receiver wrong cabled, wiring is demaged, receiver (sender of the
process of low fuel pressure (for example, fuel pump defective), (sender of the message) work inaccurately, parametering message) work inaccurately, parametering inaccurate
sensor defective, connection cable demaged inaccurate Take actions for error repair
BOMAG
Take actions for error repair Take actions for error repair Check CAN Bus cabling (Bus sheduling, polarity, short circuit,
Check low fuel pressure loop system, Check fuel pump, inspect Check CAN Bus cabling (Bus sheduling, polarity, short circuit, power interrupt), test protocol of receiver, check CAN functional
fuel system and if necessary repair it, check sensor and if power interrupt), test protocol of receiver, check CAN functional range
necessary replace it, check connection cable and if necessary range other error properties
repair or replace it other error properties System reaction: Warning, changing to substitute values
other error properties System reaction: Warning, changing to substitute values according to customers configuration.
System reaction: Advice: FLPSCD_stSysReacReq according to customers configuration. Behaviour error lamp: permanent light
Signal Priority: 3 Signal Priority: 1 Measurement @ errortime: default valuee
Measurement @ errortime: actual value Measurement @ errortime: default value

5.21
165
166
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

106 / 523212 / FrmMngTOEngPrt 110 / 523216 / FrmMngTOPrHtEnCmd 112 / 523218 / FrmMngTORxCCVS

Error description CAN ERROR ENGPRT Error description CAN ERROR PRHTENCMD Error description CAN ERROR RXCCVS
CAN message EngPrt (Engine Protection): the message can not CAN message PrHtEnCmd (Preheat and Engine Command): the CAN message RxCCVS (Cruise Control): the message can not
be received by ECU message received can not be received by ECU be received by ECU
SPN: 523212 SPN: 523216 SPN: 523218
12: Defective component 12. Errormode not identifiable 12. Errormode not identifiable
Missing message "EngPrt" = engine protection, CAN bus wrong Missing message "PrHtEnCmd" = preheat and engine command; Missing message "RxCCVS" = cruise control; CAN bus wrong
cabled, wiring is demaged, receiver (sender of the message) CAN bus wrong cabled, wiring is demaged, receiver (sender of cabled, wiring is demaged, receiver (sender of the message)
work inaccurately, parametering inaccurate the message) work inaccurately, parametering inaccurate work inaccurately, parametering inaccurate
BOMAG
Check CAN Bus cabling (Bus sheduling, polarity, short circuit, Check CAN Bus cabling (Bus sheduling, polarity, short circuit, Check CAN Bus cabling (Bus sheduling, polarity, short circuit,
power interrupt), test protocol of receiver, check CAN functional power interrupt), test protocol of receiver, check CAN functional power interrupt), test protocol of receiver, check CAN functional
range range range
System reaction: Warning. Hold last value. System reaction: Warning, changing to substitute values System reaction:
Behaviour error lamp: permanent light according to customers configuration. Behaviour error lamp: permanent light
Selfhealing: yes Behaviour error lamp: permanent light Selfhealing: yes
Signal Priority: 1 Selfhealing: yes Signal Priority: 1
Measurement @ errortime: default value Signal Priority: 1 Measurement @ errortime: default valuee
Measurement @ errortime: default valuee
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
113 / 523604 / FrmMngTORxEngTemp 117 / 523238 / FrmMngTOSwtOut 118 / 523222 / FrmMngTOTCO1

Error description CAN ERROR RxEngTemp Error description CAN ERROR SWTOUT Error description CAN ERROR TCO1
CAN message RxEngTemp (Engine Temperature): the message CAN message SwtOut (Switching Output): the message can not CAN message "TCO1" (Speedo Signal): the message can not be
can not be received by ECU be received by ECU received by ECU

SPN: 523604 SPN: 523238 SPN: 523222
12: Defective component 12: Defective component 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12: Defective component
Missing message "RxEngTemp" = engine temperature, CAN bus Missing message "SwtOut" = switch outputs, CAN bus wrong Missing message "TCO1" = speedo signal, CAN bus wrong
wrong cabled, wiring is demaged, receiver (sender of the cabled, wiring is demaged, receiver (sender of the message) cabled, wiring is demaged, receiver (sender of the message)
message) work inaccurately, parametering inaccurate work inaccurately, parametering inaccurate work inaccurately, parametering inaccurate
BOMAG
range range range
Measurement @ errortime: default value Measurement @ errortime: default valuee Measurement @ errortime: default value

5.21
167
168
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

120 / 523605 / FrmMngTOTSC1AE 121 / 523606 / FrmMngTOTSC1AR 122 / 523607 / FrmMngTOTSC1DE

Error description CAN ERROR TSC1-AE Error description CAN ERROR TSC1-AR Error description CAN ERROR TSC1-DE
CAN message TSC1-AE (Torque/Speed Control #1 from CAN message TSC1-AR (Torque/Speed Control #1 from CAN message TSC1-DE (Torque/Speed Control #1 from
Automatic Traction Control to Engine): the message can not be Automatic Traction Control to Retarder): the message can not be Driveline to Engine): the message can not be received by ECU
received by ECU received by ECU Error codes
possible FMI: possible FMI: 12: Defective component
12. Errormode not identifiable 12. Errormode not identifiable Errordetection
Errordetection Errordetection Errorlamp shows permanent light. Entry in errormemory.
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
Possible reason for error Possible reason for error Missing message "TSC1-DE", CAN bus wrong cabled, wiring is
Missing message "TSC1-AE", CAN bus wrong cabled, wiring is Missing message "TSC1-AR", CAN bus wrong cabled, wiring is demaged, receiver (sender of the message) work inaccurately,
demaged, receiver (sender of the message) work inaccurately, demaged, receiver (sender of the message) work inaccurately, parametering inaccurate
parametering inaccurate parametering inaccurate Take actions for error repair
BOMAG
Take actions for error repair Take actions for error repair Check CAN Bus cabling (Bus sheduling, polarity, short circuit,
Check CAN Bus cabling (Bus sheduling, polarity, short circuit, Check CAN Bus cabling (Bus sheduling, polarity, short circuit, power interrupt), test protocol of receiver, check CAN functional
power interrupt), test protocol of receiver, check CAN functional power interrupt), test protocol of receiver, check CAN functional range
range range other error properties
other error properties other error properties System reaction: Warning, changing to substitute values
System reaction: Warning, changing to substitute values System reaction: Warning, changing to substitute values according to priority chain.
according to priority chain. according to priority chain. Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Selfhealing: no
Selfhealing: no Selfhealing: no Signal Priority: 1
Signal Priority: 1 Signal Priority: 1 Measurement @ errortime: default value
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
123 / 523608 / FrmMngTOTSC1DR 124 / 523609 / FrmMngTOTSC1PE 125 / 898 / FrmMngTOTSC1TE

Error description CAN ERROR TSC1-DR Error description CAN ERROR TSC1-PE Error description CAN ERROR TSC1-TE
CAN message TSC1-DR (Torque/Speed Control #1 from CAN message TSC1-PE (Torque/Speed Control #1 from Power CAN message TSC1-TE (Torque/Speed Control #1 from Traction
Driveline to Retarder): the message can not be received by ECU Take Off to Engine): the message can not be received by ECU Control to Engine): the message can not be received by ECU

SPN: 523608 SPN: 523609 SPN: 898
Missing message "TSC1-DR", CAN bus wrong cabled, wiring is Missing message "TSC1-PE", CAN bus wrong cabled, wiring is Missing message "TSC1-TE", CAN bus wrong cabled, wiring is
demaged, receiver (sender of the message) work inaccurately, demaged, receiver (sender of the message) work inaccurately, demaged, receiver (sender of the message) work inaccurately,
parametering inaccurate parametering inaccurate parametering inaccurate
BOMAG
range range range
System reaction: Warning, changing to substitute values System reaction: Warning, changing to substitute values System reaction: Warning, changing to substitute values
according to priority chain. according to priority chain. according to priority chain.
Measurement @ errortime: default value Measurement @ errortime: default value Measurement @ errortime: default value

5.21
169
170
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

126 / 520 / FrmMngTOTSC1TR 127 / 523610 / FrmMngTOTSC1VE 128 / 523611 / FrmMngTOTSC1VR

Error description CAN ERROR TSC1-TR Error description CAN ERROR TSC1-VE Error description CAN ERROR TSC1-VR
CAN message TSC1-TR (Torque/Speed Control #1 from Traction CAN message TSC1-VE (Torque/Speed Control #1 from Vehicle CAN message TSC1-VR (Torque/Speed Control #1 from Vehicle
Control to Retarder): the message can not be received by ECU Control to Engine): the message can not be received by ECU Control to Retarder): the message can not be received by ECU
SPN: 520 SPN: 523610 SPN: 523611
Missing message "TSC1-TR", CAN bus wrong cabled, wiring is Missing message "TSC1-VE", CAN bus wrong cabled, wiring is Missing message "TSC1-VR", CAN bus wrong cabled, wiring is
demaged, receiver (sender of the message) work inaccurately, demaged, receiver (sender of the message) work inaccurately, demaged, receiver (sender of the message) work inaccurately,
parametering inaccurate parametering inaccurate parametering inaccurate
BOMAG
range range range
System reaction: Warning, changing to substitute values System reaction: Warning, changing to substitute values System reaction: Warning, changing to substitute values
according to priority chain. according to priority chain. according to priority chain.
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
131 / 523500 / FrmMngTxTO 133 / 174 / FTSCD 134 / 174 / FTSCDSysReac

Error description CAN MESS. TIMEOUT Error description FUEL TEMP. SENSOR Error description FUEL TEMP. SENSOR
CAN message: the ECU detects a timeout for one or more Fuel temperature sensor: the voltage measured by ECU is out of Fuel temperature: the fuel temperature calculated by ECU is
posted message the target range above the target range; the ECU activates a system reaction

SPN: 523500 SPN: 174 SPN: 174
12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt 0: data valid, but above normal working area
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 0: data valid, but above normal working area
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light
Possible reason for error Possible reason for error oder
Timeout for sent messages Fuel temp. sensor: cable break or short circuit, sendor defective, blinking. Entry in errormemory.
Take actions for error repair connection cable demaged Possible reason for error
other error properties Take actions for error repair Above target range with system reaction, interruption of fuel loop
System reaction: Check cabling, if sensor not working, check sensor and if (for example, rail pressure relief valve defective), sensor
BOMAG
Behaviour error lamp: permanent light necessary replace it, check connection cable and if necessary defective, connection cable demaged
Selfhealing: yes repair or replace it Take actions for error repair
Signal Priority: 1 other error properties Check fuel system and if necessary repair it, check sensor and if
Measurement @ errortime: - System reaction: Warning, substitute value necessary replace it, check connection cable and if necessary
Behaviour error lamp: permanent light repair or replace it
Selfhealing: yes other error properties
Signal Priority: 4 System reaction: Advice: FTSCD_stSysReacReq
Measurement @ errortime: default value Behaviour error lamp: permanent light
oder
blinking
Selfhealing: yes
Signal Priority: 4

5.21
171
172
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

136 / 523618 / GOTSCD 137 / 523619 / GOTSCDSysReac 138 / 29 / HdThrt

Error description CUSTOMER TEMPSENS 1 Error description Error description THROTTLE 2
Customer specific temperature sensor 1: the voltage of sensor Customer specific temperature 1: the temperature calculated by Hand throttle pedal sensor: the voltage measured by ECU is out
measured by ECU is out of the target range or the received value ECU is above the target range; the ECU activates a system of the target range or the calculated pedal position is implausible
of temperature via CAN is defective reaction compared with the position of accelerator pedal 1
SPN: 523618 SPN: 523619 SPN: 29
3: Voltage to high or short circuit to +Ubatt 2: data stream is defective 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 2: data stream is defective 4: Voltage to low or short circuit to -Ubatt
2: data stream is defective 12. Errormode not identifiable 12. Errormode not identifiable
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error oder Possible reason for error
Cable break or short circuit (sensor 1), sensor defective, blinking. Entry in errormemory. Cable break or short circuit, signal implausible compared to
connection cable demaged, CAN bus wrong cabled, wiring Possible reason for error signal of idle sensor, transmitter defective, connection cable
demaged, receiver (sender of the message) work inaccurately, Outside target range with system reaction (temperature 1), demaged
BOMAG
parametering inaccurate dependant on the application Take actions for error repair
Take actions for error repair Take actions for error repair Check cabling, check sensor and if necessary replace it, check
Customer specific bugfixing, check sensor and if necessary Customer specific bugfixing, denpendant on application connection cable and if necessary repair or replace it
replace it, check connection cable and if necessary repair or other error properties other error properties
replace it, Check CAN Bus cabling (Bus sheduling, polarity, short System reaction: Advice: GOTSCD_stSysReacReq System reaction: Warning, changing to substitute values
circuit, power interrupt), test protocol of receiver, check CAN fun Behaviour error lamp: permanent light according to priority chain or limp home
other error properties oder Behaviour error lamp: permanent light
System reaction: Warning, substitute value (customer specific) blinking Selfhealing: no
Behaviour error lamp: permanent light Selfhealing: yes Signal Priority: 4
Selfhealing: yes Signal Priority: 3 Measurement @ errortime: actual value
Signal Priority: 2 Measurement @ errortime: actual value
Measurement @ errortime: default value
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
139 / 1638 / HOTSCD 140 / 1638 / HOTSCDSysReac 141 / 523617 / HWEMonCom

Error description CUSTOMER TEMPSENS 2 Error description CUSTOMER TEMPSENS 2 Error description INTERNAL COMM. ERROR
Customer specific temperature sensor 2: the voltage of sensor Customer specific temperature 2: the temperature calculated by Internal hardware monitoring: the ECU detects a communication
measured by ECU is out of the target range or the received value ECU is above the target range; the ECU activates a system distrubance
of temperature via CAN is defective reaction Error codes

possible FMI: possible FMI: 12: Defective component
3: Voltage to high or short circuit to +Ubatt 2: data stream is defective 12. Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 2: data stream is defective 12. Errormode not identifiable
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light Possible reason for error
Possible reason for error oder Communication with chip CJ 940 disturbed, ECU defective
Cable break or short circuit (sensor 2), sensor defective, blinking. Entry in errormemory. Take actions for error repair
connection cable demaged, CAN bus wrong cabled, wiring Possible reason for error If cannot delete the error, change ECU
demaged, receiver (sender of the message) work inaccurately, Outside target range with system reaction (temperature 2), other error properties
BOMAG
parametering inaccurate dependant on the application System reaction: Warning
Take actions for error repair Take actions for error repair Behaviour error lamp: permanent light
Customer specific bugfixing, check sensor and if necessary Customer specific bugfixing, denpendant on application Selfhealing: no
replace it, check connection cable and if necessary repair or other error properties Signal Priority: 4
replace it, Check CAN Bus cabling (Bus sheduling, polarity, short System reaction: Advice: HOTSCD_stSysReacReq Measurement @ errortime: -
circuit, power interrupt), test protocol of receiver, check CAN fun Behaviour error lamp: permanent light
other error properties oder
System reaction: Warning, substitute value (customer specific) blinking
Behaviour error lamp: permanent light Selfhealing: yes

5.21
173
174
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

142 / 630 / HWEMonEEPROM 143 / 523612 / HWEMonRcyLocked 144 / 523612 / HWEMonRcySuppressed

Error description EEPROM MEM. ACCESS Error description INT. RECOVERY Error description INT. RECOVERY
Internal hardware monitoring: the ECU finds an error during the Internal hardware monitoring: the CPU of the ECU is reset and Internal hardware monitoring: the CPU of the ECU is reset and
access to ist EEPROM memory or works with an alternative the cause is logged internally; no item will be created in error the cause is logged internally; no item will be created in error
value memory memory
SPN: 630 SPN: 523612 SPN: 523612
12: Defective component 14: Special Instructions 14: Special Instructions
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows blinking. Entry in errormemory. Errorlamp shows blinking. Entry in errormemory.
Error during EEPROM memory access or EEPROM works with A recovery occurred which is stored as protected A recovery occurred which is not stored
substitute value, programming error, ECU defective Take actions for error repair Take actions for error repair
Take actions for error repair Recoverey occured which is stored as protected Recoverey occured which is stored as protected
BOMAG
If not programmed, EEPROM is defect --> ECU is defect, With parameter HWEMon_numRexxxxxxx the recovery nummer With parameter HWEMon_numRexxxxxxx the recovery nummer
reprogram ECU and if necessary replace it and the subsequent position can be identified. See especially and the subsequent position can be identified. See especially
other error properties SW-Doku _rcy_auto.pdf SW-Doku _rcy_auto.pdf
System reaction: Warning other error properties other error properties
Behaviour error lamp: permanent light System reaction: Recovery of ECU System reaction: Warning, shown at error path
Selfhealing: no Behaviour error lamp: blinking Behaviour error lamp: blinking
Signal Priority: 4 Selfhealing: no Selfhealing: no
Measurement @ errortime: - Signal Priority: 5 Signal Priority: 5
Measurement @ errortime: - Measurement @ errortime: -
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
145 / 523612 / HWEMonRcyVisible 146 / 523612 / HWEMonUMaxSupply 147 / 523612 / HWEMonUMinSupply

Error description INT. RECOVERY Error description INT. RECOVERY Error description INT. RECOVERY
Internal hardware monitoring: the CPU of the ECU is reset and Internal hardware monitoring: the ECU detects an excess of the Internal hardware monitoring: the ECU detects an undershooting
an item will be created in error memory target range for the power supply of ist communication module of the target range for the power supply of ist communication
Error codes Error codes module

12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt possible FMI:
14: Special Instructions 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection 12. Errormode not identifiable
Errorlamp shows blinking. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errordetection
A recovery occurred which is visible in the error memory Overvoltage at CJ940, power supply voltage too high, ECU Possible reason for error
Take actions for error repair defective Undervoltage at CJ940, power supply voltage too low, ECU
Recoverey occured which is stored as protected Take actions for error repair defective
With parameter HWEMon_numRexxxxxxx the recovery nummer Check working voltage and if necessary correct it, Check ECU Take actions for error repair
BOMAG
and the subsequent position can be identified. See especially and if necessary replace it Check working voltage and if necessary correct it, Check ECU
SW-Doku _rcy_auto.pdf other error properties and if necessary replace it
other error properties System reaction: Power stage shut off other error properties
System reaction: Recovery of ECU Behaviour error lamp: permanent light System reaction: Power stage shut off
Behaviour error lamp: blinking Selfhealing: no Behaviour error lamp: permanent light
Selfhealing: no Signal Priority: 4 Selfhealing: no
Signal Priority: 5 Measurement @ errortime: - Signal Priority: 4
Measurement @ errortime: - Measurement @ errortime: -

5.21
175
176
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

149 / 105 / IATSCD 150 / 105 / IATSCDSysReac 153 / 523350 / InjVlvBnk1A

Error description CHARGE AIR TEMP. Error description CHARGE AIR TEMP. Error description INJECTOR BANK A
Charge air temperature sensor: the voltage of sensor measured Charge air temperature: die charge air temperature calculated by Injector cylinder bank 1: the current drain measured by ECU is
by ECU is out of the target range or the received value of ECU is above the target range; the ECU activates a system above the target range
temperature via CAN is defective reaction Error codes
possible FMI: possible FMI: 3: Voltage to high or short circuit to +Ubatt
3: Voltage to high or short circuit to +Ubatt 0: data valid, but above normal working area 4: Voltage to low or short circuit to -Ubatt
4: Voltage to low or short circuit to -Ubatt 0: data valid, but above normal working area 13: out of calibrated range
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light Possible reason for error
Possible reason for error oder Short circuit (cylinder bank 1), injector defective, connection
Cable break or short circuit, sensor defective, connection cable blinking. Entry in errormemory. cable demaged
demaged, CAN bus wrong cabled, wiring demaged, receiver Possible reason for error Take actions for error repair
(sender of the message) work inaccurately, parametering Above target range with system reaction, air system demaged, Check cabling, check injectors and if necessary replace them,
BOMAG
inaccurate sensor defective, connection cable demaged check connection cable and if necessary repair or replace it
Take actions for error repair Take actions for error repair other error properties
Check cabling, LDF6T-sensor not working, check sensor and if Check construction of LDF6T , check suction parts, check air System reaction: Warning, cylinder shut off
necessary replace it, check connection cable and if necessary system and if necessary repair it, check sensor and if necessary Behaviour error lamp: permanent light
repair or replace it, Check CAN Bus cabling (Bus sheduling, replace it, check connection cable and if necessary repair or Selfhealing: yes
polarity, short circuit, power interrupt), test protocol of receiver, c replace it Signal Priority: 4
other error properties other error properties Measurement @ errortime: actual value
System reaction: Warning, substitute value System reaction: Advice: IATSCD_stSysReacReq
Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: yes oder
Signal Priority: 4 blinking
Measurement @ errortime: default value Selfhealing: yes
Signal Priority: 4
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
154 / 523351 / InjVlvBnk1B 155 / 523352 / InjVlvBnk2A 156 / 523353 / InjVlvBnk2B

Error description INJECTOR BANK A Error description INJECTOR BANK B Error description INJECTOR BANK B
Injector cylinder bank 1: the current drain measured by ECU is Injector cylinder bank 2: the current drain measured by ECU is Injector cylinder bank 2: the current drain measured by ECU is
underneath the target range above the target range underneath the target range

SPN: 523351 SPN: 523352 SPN: 523353
13: out of calibrated range 3: Voltage to high or short circuit to +Ubatt 13: out of calibrated range
13: out of calibrated range 4: Voltage to low or short circuit to -Ubatt 13: out of calibrated range
5: current to low or broken wire 13: out of calibrated range 5: current to low or broken wire
13: out of calibrated range 12. Errormode not identifiable 13: out of calibrated range
Cable break (cylinder bank 1), injector defective, connection Short circuit (cylinder bank 2), injector defective, connection Cable break (cylinder bank 2), injector defective, connection
cable demaged cable demaged cable demaged
Check cabling, check injectors and if necessary replace them, Check cabling, check injectors and if necessary replace them, Check cabling, check injectors and if necessary replace them,
BOMAG
check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it
System reaction: Warning, cylinder shut off System reaction: Warning, cylinder shut off System reaction: Warning, cylinder shut off

5.21
177
178
DTC-List P490_: 220, 310, 501 P492_: 213
5.21
157 / 523354 / InjVlvChipA 158 / 523355 / InjVlvChipB 159 / 651 / InjVlvCyl1A

Error description PWR. INJ. BANK B Error description PWR. INJ. BANK B Error description INJECTOR 1
Internal hardware monitoring: the ECU detects an error of ist Internal hardware monitoring: the ECU detects a disturbance in Injector 1: the current drain measured by ECU is above the target
injector high current output its injector high current output range
SPN: 523354 SPN: 523355 SPN: 651
3: Voltage to high or short circuit to +Ubatt 12: Defective component 3: Voltage to high or short circuit to +Ubatt
2: data stream is defective 12: Defective component 13: out of calibrated range
14: Special Instructions 12: Defective component 4: Voltage to low or short circuit to -Ubatt
Errorlamp shows blinking. Entry in errormemory. Errorlamp shows blinking. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
High power stage Injector A, ECU defective High power stage Injector B, ECU defective Short circuit (cylinder 1), injector defective, connection cable
Take actions for error repair Take actions for error repair demaged
If error is not removable, change ECU If error is not removable, change ECU Take actions for error repair
other error properties other error properties Check cabling, check injectors and if necessary replace them,
BOMAG
System reaction: Warninig, outputs shut off System reaction: Warninig, outputs shut off check connection cable and if necessary repair or replace it
Behaviour error lamp: blinking Behaviour error lamp: blinking other error properties
Selfhealing: no Selfhealing: no System reaction: Warning, fuel injection failed, shut off wenn the
Signal Priority: 5 Signal Priority: 5 number of active cylinders below minimum
Measurement @ errortime: actual value Measurement @ errortime: actual value Behaviour error lamp: permanent light
Selfhealing: yes
Signal Priority: 4
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
160 / 651 / InjVlvCyl1B 161 / 652 / InjVlvCyl2A 162 / 652 / InjVlvCyl2B

Error description INJECTOR 1 Error description INJECTOR 2 Error description INJECTOR 2
Injector 1: the current drain measured by ECU is underneath the Injector 2: the current drain measured by ECU is above the target Injector 2: the current drain measured by ECU is underneath the
target range range target range

SPN: 651 SPN: 652 SPN: 652
13: out of calibrated range 13: out of calibrated range 13: out of calibrated range
5: current to low or broken wire 4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire
Cable break (cylinder 1), injector defective, connection cable Short circuit (cylinder 2), injector defective, connection cable Cable break (cylinder 2), injector defective, connection cable
BOMAG
System reaction: Warning, fuel injection failed, shut off wenn the System reaction: Warning, fuel injection failed, shut off wenn the System reaction: Warning, fuel injection failed, shut off wenn the
number of active cylinders below minimum number of active cylinders below minimum number of active cylinders below minimum

5.21
179
180
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

163 / 653 / InjVlvCyl3A 164 / 653 / InjVlvCyl3B 165 / 654 / InjVlvCyl4A

Injector 3: the current drain measured by ECU is above the target Injector 3: the current drain measured by ECU is underneath the Injector 4: the current drain measured by ECU is above the target
range target range range
SPN: 653 SPN: 653 SPN: 654
3: Voltage to high or short circuit to +Ubatt 13: out of calibrated range 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 13: out of calibrated range 12. Errormode not identifiable
Short circuit (cylinder 3), injector defective, connection cable Cable break (cylinder 3), injector defective, connection cable Short circuit (cylinder 4), injector defective, connection cable
BOMAG
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41


SPN: 654 SPN: 655 SPN: 655
BOMAG

5.21
181
182
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

169 / 656 / InjVlvCyl6A 170 / 656 / InjVlvCyl6B 171 / 657 / InjVlvCyl7A

Injector 6: the current drain measured by ECU is above the target Injector 6: the current drain measured by ECU is underneath the Injector 7: the current drain measured by ECU is above the target
range target range range
SPN: 656 SPN: 656 SPN: 657
3: Voltage to high or short circuit to +Ubatt 13: out of calibrated range 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 13: out of calibrated range 12. Errormode not identifiable
Short circuit (cylinder 6), injector defective, connection cable Cable break (cylinder 6), injector defective, connection cable Short circuit (cylinder 7), injector defective, connection cable
BOMAG
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41


SPN: 657 SPN: 658 SPN: 658
BOMAG

5.21
183
184
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

175 / 523370 / InjVlvErrDet 176 / 523615 / MeUnCD_ADC 177 / 523615 / MeUnCDNoLoad

Error description RAIL PRESS. MON. DISABLED Error description METERING UNIT Error description METERING UNIT
Rail pressure monitoring: the monitoring of the rail pressure will Fuel volume flow rate: the fuel volume rate calculated by ECU at Valve at outlet of the fuel metering unit: the ECU detects no load
be deactivated by ECU because of the activation of the function outlet of the fuel metering unit is out of the target range or temperature excess of the ECU component for power supply
"compression test" by user Error codes of the valve
Error codes DEUTZ-Errorcode: 176 Error codes
DEUTZ-Errorcode: 175 BlinkCode (short-long-short): 1 - 3 - 5 DEUTZ-Errorcode: 177
BlinkCode (short-long-short): 5 - 5 - 5 SPN: 523615 BlinkCode (short-long-short): 1 - 3 - 5
SPN: 523370 possible FMI: SPN: 523615
possible FMI: 3: Voltage to high or short circuit to +Ubatt possible FMI:
14: Special Instructions 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 5: current to low or broken wire
12. Errormode not identifiable Errordetection 12: Defective component
Errordetection Errorlamp shows permanent light. Entry in errormemory. Errordetection
Errorlamp shows . Entry in errormemory. Possible reason for error Errorlamp shows permanent light, 15s before shut off. Entry in
Possible reason for error Flow rate outside target range errormemory.
Compression test active: rail-pressure monitoring is going to be Take actions for error repair Possible reason for error
disabled other error properties wiring error or ECU output is switched off because of
Take actions for error repair System reaction: overtemperature, fuel metering unit defective, connection cable
BOMAG
not correct Behaviour error lamp: permanent light demaged
other error properties Selfhealing: no Take actions for error repair
System reaction: Rail pressure monitoring disabled Signal Priority: 4 Check cabling , if necessary check FCU, check fuel metering unit
Behaviour error lamp: Measurement @ errortime: actual value and if necessary replace it, check connection cable and if
Selfhealing: - necessary repair or replace it
Signal Priority: 1 other error properties
Measurement @ errortime: System reaction: Warning, max.extraction of FCU --> open rail
pressure relief valve --> shut the engine off in about 5 minutes
Behaviour error lamp: permanent light, 15s before shut off
Selfhealing: no
Signal Priority: 4
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
178 / 523615 / MeUnCDSCBat 179 / 523615 / MeUnCDSCGnd 182 / 2634 / MnRly1_SCB

Error description METERING UNIT Error description METERING UNIT Error description MAIN RELAY
Valve at outlet of the fuel metering unit: the current drain Valve at outlet of the fuel metering unit: the current drain Main relay 1: the current drains measured by ECU is above the
measured by ECU is above the target range measured by ECU is above the target range target range

SPN: 523615 SPN: 523615 SPN: 2634
12: Defective component 12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt
12. Errormode not identifiable 12: Defective component 12. Errormode not identifiable
Errorlamp shows permanent light, 15s before shut off. Entry in Errorlamp shows permanent light, 15s before shut off. Entry in Errorlamp shows permanent light. Entry in errormemory.
errormemory. errormemory. Possible reason for error
Possible reason for error Possible reason for error Short circuit to Ubatt (relay 1), relay defective, connection cable
Short circuit to Ubatt, fuel metering unit defective, connection Short circuit to ground, fuel metering unit defective, connection demaged
cable demaged cable demaged Take actions for error repair
Take actions for error repair Take actions for error repair Check cabling, check ECU, check relay and if necessary replace
BOMAG
Check cabling , if necessary check FCU, check fuel metering unit Check cabling , if necessary check FCU, check fuel metering unit it, check connection cable and if necessary repair or replace it
and if necessary replace it, check connection cable and if and if necessary replace it, check connection cable and if other error properties
necessary repair or replace it necessary repair or replace it System reaction: Warning, shutoff the outputs MPROP
other error properties other error properties Behaviour error lamp: permanent light
System reaction: Warning, rail pressure relief valve will open System reaction: Warning, rail pressure relief valve will open Selfhealing: no
Behaviour error lamp: permanent light, 15s before shut off Behaviour error lamp: permanent light, 15s before shut off Signal Priority: 3
Selfhealing: no Selfhealing: no Measurement @ errortime: actual value

5.21
185
186
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

183 / 2634 / MnRly1_SCG 184 / 523420 / Montr 186 / 2634 / MRlyCD

Error description MAIN RELAY Error description WATCHDOG COUNTER Error description MAIN RELAY
Main relay 1: the current drains measured by ECU is above the Internal hardware monitoring: the ECU detects an disturbance in Main relay: during the switching off, main relay does not switch
target range ist monitoring module (Wachtdog) on within an allowed time
SPN: 2634 SPN: 523420 SPN: 2634
12. Errormode not identifiable 12. Errormode not identifiable 7: Mechanical system not OK
4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable 12: Defective component
12. Errormode not identifiable 14: Special Instructions 12. Errormode not identifiable
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows blinking. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Short circuit to ground (relay 1), relay defective, connection cable Watchdog counter exceeds maximum, ECU defective EDC16: main relay not open in allowed time or main relay open
demaged Take actions for error repair too early; EDC7: main relay not open in allowed time or short
Take actions for error repair If error is not removable, change ECU circuit of main relay to ground; EDC16: main relay defective,
Check cabling, check ECU, check relay and if necessary replace other error properties connection cable demaged; generally: rapid shut-off of the ECU
BOMAG
it, check connection cable and if necessary repair or replace it System reaction: Recovery of ECU (witho
other error properties Behaviour error lamp: blinking Take actions for error repair
System reaction: Warning, shutoff the outputs MPROP Selfhealing: no EDC16: check external main relay, check cabling
Behaviour error lamp: permanent light Signal Priority: 5 EDC7: if error is not removable, change ECU, EDC16: Check
Selfhealing: no Measurement @ errortime: - main relay and if necessary replace it, check connection cable
Signal Priority: 3 and if necessary repair or replace it; both: if error is not
Measurement @ errortime: actual value removable, change ECU
other error properties
System reaction: Warning
Selfhealing: no
Signal Priority: 3
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
187 / 563 / MRlyCDMnRly2 188 / 2634 / MRlyCDMnRly3 189 / 523450 / MSSCD1

Error description MAIN RELAY 2 Error description MAIN RELAY Error description MULTISTATE SWITCH 1
Main relay 2 (in ECU): during the switching off, main relay does Main relay 3 (in ECU): during the switching off, main relay does Multi state switch 1: the voltage measured by ECU is out of the
not switch on within an allowed time not switch on within an allowed time target range or the swith setting is not plausible

SPN: 563 SPN: 2634 SPN: 523450
7: Mechanical system not OK 7: Mechanical system not OK 3: Voltage to high or short circuit to +Ubatt
12: Defective component 12: Defective component 4: Voltage to low or short circuit to -Ubatt
rapid shut-off of the ECU (without waiting till the end of the Short circuit to ground or emergency shut-off (relay 3 internal), Cable break or short circuit, input voltage outside target range
afterrun), ECU defective rapid shut-off of the ECU (without waiting till the end of the (switch 1), switch defective, connection cable demaged
Take actions for error repair afterrun), ECU defective Take actions for error repair
If error not removable, change ECU Take actions for error repair Check cabling and sensor, check switch and if necessary replace
BOMAG
other error properties Check cabling, check ECU, if error not removable, change ECU it, check connection cable and if necessary repair or replace it
System reaction: other error properties other error properties
Behaviour error lamp: permanent light System reaction: Warning, shutoff the outputs MPROP (see System reaction: Warning, substitute value
Selfhealing: no BOSCH-Electricity operating plan) Behaviour error lamp: permanent light
Signal Priority: 3 Behaviour error lamp: permanent light Selfhealing: yes
Measurement @ errortime: actual value Selfhealing: no Signal Priority: 2
Signal Priority: 3 Measurement @ errortime: default value

5.21
187
188
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

190 / 523451 / MSSCD2 191 / 523452 / MSSCD3 192 / 639 / NetMngCANAOff

Error description MULTISTATE SWITCH 2 Error description MULTISTATE SWITCH 3 Error description CAN A BUS OFF
Multi state switch 2: the voltage measured by ECU is out of the Multi state switch 3: the voltage measured by ECU is out of the CAN bus A: the ECU is not allowed to send messages, because
target range or the swith setting is not plausible target range or the swith setting is not plausible the status "BusOff" is detected
SPN: 523451 SPN: 523452 SPN: 639
3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt 14: Special Instructions
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
Cable break or short circuit, input voltage outside target range Cable break or short circuit, input voltage outside target range Cable break or short circuit, off-state (CAN bus A), CAN bus
(switch 2), switch defective, connection cable demaged (switch 3), switch defective, connection cable demaged deactivated, connection cable demaged
Check cabling and sensor, check switch and if necessary replace Check cabling and sensor, check switch and if necessary replace Check cabling of CAN bus and if necessary repair it, check
BOMAG
it, check connection cable and if necessary repair or replace it it, check connection cable and if necessary repair or replace it connection cable and if necessary repair or replace it
System reaction: Warning, substitute value System reaction: Warning, substitute value System reaction:
Measurement @ errortime: default value Measurement @ errortime: default value Measurement @ errortime:
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
193 / 1231 / NetMngCANBOff 194 / 1235 / NetMngCANCOff 195 / 705 / OPLpCD

Error description CAN B BUS OFF Error description CAN C BUS OFF Error description OIL PRESS LAMP
CAN bus B: the ECU is not allowed to send messages, because CAN bus C: the ECU is not allowed to send messages, because Warning lamp for oil level: the current drain measured by ECU is
the status "BusOff" is detected the status "BusOff" is detected out of the target range or the maximum temperature of the ECU
Error codes Error codes component for power supply of the lamp is exceeded

14: Special Instructions 14: Special Instructions possible FMI:
12. Errormode not identifiable 12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt
12. Errormode not identifiable 12. Errormode not identifiable 5: current to low or broken wire
Errordetection Errordetection 2: data stream is defective
Cable break or short circuit, off-state (CAN bus B), CAN bus Cable break or short circuit, off-state (CAN bus C), CAN bus Possible reason for error
deactivated, connection cable demaged deactivated, connection cable demaged Cable break or short circuit, lamp defective, connection cable
Check cabling of CAN bus and if necessary repair it, check Check cabling of CAN bus and if necessary repair it, check Take actions for error repair
BOMAG
connection cable and if necessary repair or replace it connection cable and if necessary repair or replace it Check cabling and load, check lamp and if necessary replace it,
other error properties other error properties check connection cable and if necessary repair or replace it
System reaction: System reaction: other error properties
Behaviour error lamp: permanent light Behaviour error lamp: permanent light System reaction: Warning, shutoff output
Selfhealing: yes Selfhealing: yes Behaviour error lamp: permanent light
Signal Priority: 2 Signal Priority: 2 Selfhealing: no
Measurement @ errortime: Measurement @ errortime: Signal Priority: 1

5.21
189
190
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

196 / 100 / OPSCD 197 / 100 / OPSCD1 198 / 100 / OPSCDSysReacHi

Error description ENG OIL PRESS. Error description ENG OIL PRESS. Error description ENG OIL PRESS.
Oil pressure sensor: the voltage of sensor measured by ECU is Oil pressure: the oil pressure calculated by ECU is implausibly Oil pressure: the oil pressure calculated by ECU is above the
out of the target range or the received value of oil pressure via low target range; the ECU activates a system reaction
CAN is implausible (Oil pressure is above the target range with Error codes Error codes
higher oil temperature at the same time) DEUTZ-Errorcode: 197 DEUTZ-Errorcode: 198
Error codes BlinkCode (short-long-short): 2 - 3 - 1 BlinkCode (short-long-short): 2 - 3 - 1
DEUTZ-Errorcode: 196 SPN: 100 SPN: 100
BlinkCode (short-long-short): 2 - 2 - 4 possible FMI: possible FMI:
SPN: 100 12. Errormode not identifiable 0: data valid, but above normal working area
possible FMI: 12. Errormode not identifiable 0: data valid, but above normal working area
3: Voltage to high or short circuit to +Ubatt 12. Errormode not identifiable 12. Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 1: data valid, but below normal working area 12. Errormode not identifiable
2: data stream is defective Errordetection Errordetection
0: data valid, but above normal working area Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light
Errordetection Possible reason for error oder
Errorlamp shows permanent light. Entry in errormemory. Oil pressure implausible low, sensor defective, connection cable blinking. Entry in errormemory.
Possible reason for error demaged Possible reason for error
Cable break or short circuit, sensor defective, connection cable Take actions for error repair Above target range, oil volume too large, sensor defective, oil
demaged, CAN bus wrong cabled, wiring demaged, receiver Check cabling, if sensor not working, check sensor and if pump defective, connection cable demaged
BOMAG
(sender of the message) work inaccurately, parametering necessary replace it, check connection cable and if necessary Take actions for error repair
inaccurate repair or replace it Check oil level and if necessary correct it, check oil pump and if
Take actions for error repair other error properties necessary replace it, check sensor and if necessary replace it,
Check cabling, if sensor not working, check sensor and if System reaction: Warning, substitute value check connection cable and if necessary repair or replace it
necessary replace it, check connection cable and if necessary Behaviour error lamp: permanent light other error properties
repair or replace it, Check CAN Bus cabling (Bus sheduling, Selfhealing: yes System reaction: Advice: OPSCD_stSysReacReqHi
polarity, short circuit, power interrupt), test protocol of receiver, Signal Priority: 2 Behaviour error lamp: permanent light
chec Measurement @ errortime: actual value oder
other error properties blinking
System reaction: Warning, substitute value Selfhealing: yes
Behaviour error lamp: permanent light Signal Priority: 4
Selfhealing: yes Measurement @ errortime: actual value
Signal Priority: 4
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
P491_: 220, 310, 400, 501 P513_: 214, 300
008 916 41
199 / 100 / OPSCDSysReacLo 200 / 1237 / OSwCD 201 / 175 / OTSCD

Error description ENG OIL PRESS. Error description OVERRIDE SWITCH Error description OIL TEMP. SENSOR
Oil pressure: the oil pressure calculated by ECU is underneath Bridgeover switch: the ECU receives a permanent signal Oil temperature sensor: the voltage of sensor measured by ECU
the target range; the ECU activates a system reaction Error codes is out of the target range; the oil temperature calculated by ECU
Error codes DEUTZ-Errorcode: 200 is implausible compared with coolant temperature or the received
DEUTZ-Errorcode: 199 BlinkCode (short-long-short): 1 - 4 - 5 value via CAN is defective
BlinkCode (short-long-short): 2 - 3 - 1 SPN: 1237 Error codes

SPN: 100 possible FMI: DEUTZ-Errorcode: 201
possible FMI: 12. Errormode not identifiable BlinkCode (short-long-short): 1 - 4 - 4
1: data valid, but below normal working area 12. Errormode not identifiable SPN: 175
1: data valid, but below normal working area 12. Errormode not identifiable possible FMI:
12. Errormode not identifiable 2: data stream is defective 3: Voltage to high or short circuit to +Ubatt
12. Errormode not identifiable Errordetection 4: Voltage to low or short circuit to -Ubatt
Errordetection Errorlamp shows permanent light. Entry in errormemory. 2: data stream is defective
Errorlamp shows permanent light Possible reason for error 2: data stream is defective
oder Switch is blocked, taster locked, connection cable demaged Errordetection
blinking. Entry in errormemory. Take actions for error repair Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Check cabling, if sensor not working, check switch and if Possible reason for error
Below target range, oil volume too small, sensor defective, oil necessary replace it, check connection cable and if necessary Cable break or short circuit, sensor defective, connection cable
pump defective, connection cable demaged repair or replace it demaged
BOMAG
Take actions for error repair other error properties Take actions for error repair
Check oil level and if necessary correct it, check oil pump and if System reaction: Warning Check cabling, if sensor not working, check switch and if
necessary replace it, check sensor and if necessary replace it, Behaviour error lamp: permanent light necessary replace it, check connection cable and if necessary
check connection cable and if necessary repair or replace it Selfhealing: yes repair or replace it
other error properties Signal Priority: 2 other error properties
System reaction: Advice: OPSCD_stSysReacReqLo Measurement @ errortime: actual value System reaction: Warning, substitute value
Behaviour error lamp: permanent light Behaviour error lamp: permanent light
oder Selfhealing: yes
blinking Signal Priority: 4
Selfhealing: yes Measurement @ errortime: default value
Signal Priority: 4

5.21
191
192
DTC-List P490_: 220, 310, 501 P492_: 213
5.21
203 / 175 / OTSCDSysReac 208 / 523470 / PRVMon 209 / 157 / RailCD

Error description OIL TEMP. SENSOR Error description RAIL PRESS. LIM. VALVE Error description RAIL PRESS. SENSOR
Oil temperature: the oil temperature calculated by ECU is above Rail pressure relief valve: is open, will be forced to open, the Rail pressure sensor: the voltage of sensor measured by ECU is
the target range; the ECU activates a system reaction forced-open failed out of the target range
SPN: 175 SPN: 523470 SPN: 157
0: data valid, but above normal working area 14: Special Instructions 3: Voltage to high or short circuit to +Ubatt
0: data valid, but above normal working area 2: data stream is defective 4: Voltage to low or short circuit to -Ubatt
Errorlamp shows permanent light Errorlamp shows permanent light, 15s before shut off. Entry in Errorlamp shows permanent light, 15s before shut off. Entry in
oder errormemory. errormemory.
blinking. Entry in errormemory. Possible reason for error Possible reason for error
Possible reason for error Rail pressure relief valve open or forced open abortive Cable break or short circuit, sensor defective, connection cable
Above target range with system reaction, oil volume too small, oil (interpretation of the rail pressure gradient), operating voltage too demaged
loop disturbed, sensor defective, connection cable demaged low, rail pressure sensor defective, fuel metering unit defective, Take actions for error repair
BOMAG
Take actions for error repair rail pressure relief valve defective, air in fuel system Check cabling, check rail pressure sensor and if necessary
Check cycle cooling system and compressor, check oil level and Take actions for error repair replace it, check connection cable and if necessary repair or
if necessary correct it, check sensor and if necessary replace it, Check working voltage and if necessary correct it, check rail- replace it
check oil loop and if necessary repair it, check connection cable pressure sensor and if necessary replace it, check FCU and if other error properties
and if necessary repair or replace it necessary replace it, check rail pressure relief valve and if System reaction: Warning, max.extraction of FCU --> open rail
other error properties necessary replace it, bleed the fuel-system pressure relief valve --> shut the engine off in about 5 minutes
System reaction: Advice: OTSCD_stSysReacReq other error properties Behaviour error lamp: permanent light, 15s before shut off
Behaviour error lamp: permanent light System reaction: Warning, shut the engine off in about 5 minutes Selfhealing: no
oder Behaviour error lamp: permanent light, 15s before shut off Signal Priority: 4
blinking Selfhealing: no Measurement @ errortime: default value
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
210 / 157 / RailCDOfsTst 211 / 523613 / RailMeUn0 212 / 523613 / RailMeUn1

Error description RAIL PRESS. SENSOR Error description RAIL PRESSURE Error description RAIL PRESSURE
Rail pressure sensor: the change of the voltage measured by Rail pressure: the fuel pressure in rail calculated by ECU is Rail pressure: the fuel pressure in rail calculated by ECU is
ECU during the engine start or the after-run is out of the target above the target range which is dependant on the engine speed above the target range which is dependant on the volume flow
range Error codes rate
Error codes DEUTZ-Errorcode: 211 Error codes
DEUTZ-Errorcode: 210 BlinkCode (short-long-short): 1 - 3 - 4 DEUTZ-Errorcode: 212

BlinkCode (short-long-short): 1 - 4 - 7 SPN: 523613 BlinkCode (short-long-short): 1 - 3 - 4
SPN: 157 possible FMI: SPN: 523613
possible FMI: 0: data valid, but above normal working area possible FMI:
0: data valid, but above normal working area 12. Errormode not identifiable 0: data valid, but above normal working area
1: data valid, but below normal working area 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable Errordetection 12. Errormode not identifiable
Errordetection Errorlamp shows permanent light Errordetection
Errorlamp shows permanent light. Entry in errormemory. oder Errorlamp shows permanent light
Possible reason for error blinking. Entry in errormemory. oder
Deviation of signal during start or after-run above target range, Possible reason for error blinking. Entry in errormemory.
sensor defective 1) Leakage in high pressure system (external) , Possible reason for error
Take actions for error repair 2) Leakage at rail pressure relief valve (internal), 1) Leakage in high pressure system (external) ,
BOMAG
Replace sensor 3) Needle clampt in open position, 2) Leakage at rail pressure relief valve (internal),
other error properties 4) Abrasion at injector, 3) Needle clampt in open position,
System reaction: Warning 5) Abrasion at high pressure pump, 4) Abrasion at injector,
Behaviour error lamp: permanent light 6) Too low primary pressure on low pressure side, sensor d 5) Abrasion at high pressure pump,
Selfhealing: yes Take actions for error repair 6) Too low primary pressure on low pressure side, sensor d
Signal Priority: 2 (A) Check for leakage Take actions for error repair
Measurement @ errortime: actual value (B) Chek fuel-primary pressure (A) Check for leakage
(C) Change components, check sensor and if necessary replace (B) Chek fuel-primary pressure
it, check fuel system and if necessary repair it (C) Change components, check sensor and if necessary replace
other error properties it, check fuel system and if necessary repair it
System reaction: Warning or Warning and power reduction other error properties
Behaviour error lamp: permanent light System reaction: Warning or Warning and power reduction
oder Behaviour error lamp: permanent light
blinking oder
Selfhealing: yes blinking
Signal Priority: 4 Selfhealing: yes
Measurement @ errortime: actual value Signal Priority: 4

5.21
193
194
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

213 / 523613 / RailMeUn2 214 / 523613 / RailMeUn3 215 / 523613 / RailMeUn4

Error description RAIL PRESSURE Error description RAIL PRESSURE Error description RAIL PRESSURE
Rail pressure: the fuel pressure in rail calculated by ECU is Rail pressure: the fuel pressure in rail calculated by ECU is Rail pressure: the fuel pressure in rail calculated by ECU is
underneath the target range which is dependant on the engine underneath the target range which is dependant on the volume above the absolute target range
speed flow rate Error codes
possible FMI: possible FMI: 0: data valid, but above normal working area
0: data valid, but above normal working area 1: data valid, but below normal working area 12. Errormode not identifiable
Errordetection Errordetection Errorlamp shows permanent light
Errorlamp shows permanent light Errorlamp shows permanent light oder
oder oder blinking. Entry in errormemory.
blinking. Entry in errormemory. blinking. Entry in errormemory. Possible reason for error
Possible reason for error Possible reason for error 1) No power supply in FCU,
1) No power supply in FCU, 1) Leakage in high pressure system (external) , 2) ZME clamped in open position,
BOMAG
2) ZME clamped in open position, 2) Leakage at rail pressure relief valve (internal), 3) Too high pressure nach Nullförderdrossel (FCU),
3) Too high pressure nach Nullförderdrossel (FCU), 3) Needle clampt in open position, 4) Nullförderdrossel clogged,
4) Nullförderdrossel clogged, 4) Abrasion at injector, 5) Too high primary pressure on low pressure side, sensor
5) Too high primary pressure on low pressure side, sensor 5) Abrasion at high pressure pump, defective, fuel system disturbed
defective, fuel system disturbed 6) Too low primary pressure on low pressure side, sensor d Take actions for error repair
Take actions for error repair Take actions for error repair (A) Check return-pressure FCU
(A) Check return-pressure FCU (A) Check for leakage (B) Check flow-pressure
(B) Check flow-pressure (B) Chek fuel-primary pressure (C) Change FCU, check sensor and if necessary replace it, check
(C) Change FCU, check sensor and if necessary replace it, check (C) Change components, check sensor and if necessary replace fuel system and if necessary repair it
fuel system and if necessary repair it it, check fuel system and if necessary repair it other error properties
other error properties other error properties System reaction: Warning or Warning and power reduction
System reaction: Warning or Warning and power reduction System reaction: Warning or Warning and power reduction Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Behaviour error lamp: permanent light oder
oder oder blinking
blinking blinking Selfhealing: yes
Signal Priority: 4 Signal Priority: 4 Measurement @ errortime: actual value
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
216 / 523613 / RailMeUn7 218 / 523490 / SOPTst 219 / 1079 / SSpMon1

Error description RAIL PRESSURE Error description REDUNDANT SHUT OFF DET. Error description 5V SUPPLY 1 FAIL.
Rail pressure: the fuel pressure in rail calculated by ECU is Internal hardware monitoring: the ECU finds an disturbance in the Internal hardware monitoring: the ECU detects a deviation of the
implausible compared with the setpoint setting of the fuel redundant switch off path through a test during the ramp up target range of the power supply voltage of sensor 1
metering unit phase Error codes

possible FMI: possible FMI: 3: Voltage to high or short circuit to +Ubatt
2: data stream is defective 12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt 12. Errormode not identifiable
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt Errordetection
Errorlamp shows permanent light Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
oder Possible reason for error 5V sensor supply voltage 1 outside target range, operating
blinking. Entry in errormemory. Test of redundant shut-off paths voltage too high or to low, connection cable demaged, ECU
Possible reason for error Take actions for error repair defective
1) Leakage in high pressure system (external) , Could be triggered by over/undervoltage or external Watchdog Take actions for error repair
BOMAG
2) Leakage at rail pressure relief valve (internal), other error properties If error not removable, change ECU, check cabling of external
3) Needle clampt in open position, System reaction: Test will only be executed with ECU components, check working voltage and if necessary correct it,
4) Abrasion at injector, Initialisation. Warning, dependent upon application. check connection cable and if necessary repair or replace it
5) Abrasion at high pressure pump, Behaviour error lamp: permanent light other error properties
6) Too low primary pressure on low pressure side, sensor d Selfhealing: no System reaction: Warning
Take actions for error repair Signal Priority: 4 Behaviour error lamp: permanent light
(A) Check for leakage Measurement @ errortime: - Selfhealing: yes
(B) Chek fuel-primary pressure Signal Priority: 3
(C) Change components, check sensor and if necessary replace Measurement @ errortime: actual value
it, check fuel system and if necessary repair it
System reaction: Warning or Warning and power reduction
oder
blinking
Selfhealing: yes
Signal Priority: 4

5.21
195
196
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

221 / 1080 / SSpMon2 222 / 523601 / SSpMon3 223 / 677 / StrtCDHS

Error description 5V SUPPLY 2 FAIL. Error description 5V SUPPLY 3 FAIL. Error description START RELAY
Internal hardware monitoring: the ECU detects a deviation of the Internal hardware monitoring: the ECU detects a deviation of the Start relay (high side power stage): the current drain measured
target range of the power supply voltage of sensor 2 target range of the power supply voltage of sensor 3 by ECU is above the target range
SPN: 1080 SPN: 523601 SPN: 677
3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt
5V sensor supply voltage 2 outside target range, operating Wrong voltage of internal 5V reference source 3, operating Start relay (high side): short circuit, relay defective, conncection
voltage too high or to low, connection cable demaged, ECU voltage too high or too low, connection cable demaged, ECU cable defective
defective defective Take actions for error repair
Take actions for error repair Take actions for error repair Check cabling and start relay and if necessary replace it, check
BOMAG
If error not removable, change ECU, check cabling of external If error not removable, change ECU, check cabling of external connection cable and if necessary repair or replace it
components, check working voltage and if necessary correct it, components, check working voltage and if necessary correct it, other error properties
check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it System reaction: Warning, shutoff output
other error properties other error properties Behaviour error lamp: permanent light
System reaction: Warning System reaction: Warning Selfhealing: no
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Signal Priority: 1
Selfhealing: yes Selfhealing: yes Measurement @ errortime: default value
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
224 / 677 / StrtCDLS 225 / 624 / SysLamp 226 / 158 / T15CD

Error description START RELAY Error description DIAGNOSTIC LAMP Error description TERMINAL 15
start relay (low side power stage): the current drain measured by Error lamp (diagnositic lamp): the current drain measured by Terminal 15: ECU receives no signal
ECU is out of the target range ECU is out of the target range or the maximum permissble Error codes
Error codes temperature of the ECU component for power supply of the lamp DEUTZ-Errorcode: 226
DEUTZ-Errorcode: 224 is exceeded BlinkCode (short-long-short): 5 - 1 - 4
BlinkCode (short-long-short): 5 - 1 - 2 Error codes SPN: 158

SPN: 677 DEUTZ-Errorcode: 225 possible FMI:
possible FMI: BlinkCode (short-long-short): 5 - 1 - 3 12. Errormode not identifiable
3: Voltage to high or short circuit to +Ubatt SPN: 624 12. Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt possible FMI: 12: Defective component
5: current to low or broken wire 3: Voltage to high or short circuit to +Ubatt 12. Errormode not identifiable
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt Errordetection
Errordetection 5: current to low or broken wire Errorlamp shows permanent light. Entry in errormemory.
Errorlamp shows permanent light. Entry in errormemory. 2: data stream is defective Possible reason for error
Possible reason for error Errordetection Ignition ON not detected, ignition switch defective, connection
Start relay (low side): cable break or short circuit, disabled by Errorlamp shows -. Entry in errormemory. cable demaged
ECU, relay defective, connection cable demaged Possible reason for error Take actions for error repair
Take actions for error repair Cable break or short circuit, disabled by ECU, lamp defective, Check cabling, if sensor not working, check ignition switch and if
Check cabling and start relay and if necessary replace it, check connection cable demaged necessary replace it, check connection cable and if necessary
BOMAG
connection cable and if necessary repair or replace it Take actions for error repair repair or replace it
other error properties Check cabling and load, check lamp and if necessary replace it, other error properties
System reaction: Warning, shutoff output check connection cable and if necessary repair or replace it System reaction: Warning, engine can not start
Behaviour error lamp: permanent light other error properties Behaviour error lamp: permanent light
Selfhealing: no System reaction: only error memory item Selfhealing: no
Signal Priority: 1 Behaviour error lamp: - Signal Priority: 2
Measurement @ errortime: default value Selfhealing: no Measurement @ errortime: actual value
Signal Priority: 2
Measurement @ errortime: setpoint Diagnosticlamp

5.21
197
198
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

227 / 523550 / T50CD 228 / 523550 / TPUMon 232 / 84 / VSSCD1

Error description TERMINAL 50 Error description TERMINAL 50 Error description VEHICLE SPEED
Terminal 50: ECU receives a permanent signal Internal hardware monitoring: ECU detects a deviation between Vehicle speed: over the maximum, signal invalid or implausible
Error codes the signal of time module and the system time compared with the injection quantity and the engine speed, offset
DEUTZ-Errorcode: 227 Error codes factors unlearned
BlinkCode (short-long-short): 5 - 1 - 5 DEUTZ-Errorcode: 228 Error codes
SPN: 523550 BlinkCode (short-long-short): 5 - 5 - 5 DEUTZ-Errorcode: 232
possible FMI: SPN: 523550 BlinkCode (short-long-short): 5 - 2 - 1
12: Defective component possible FMI: SPN: 84
12. Errormode not identifiable 12. Errormode not identifiable possible FMI:
12. Errormode not identifiable 12. Errormode not identifiable 0: data valid, but above normal working area
Errordetection 2: data stream is defective 8: unusual frequency, pulse or period.
Errorlamp shows permanent light. Entry in errormemory. Errordetection 14: Special Instructions
Possible reason for error Errorlamp shows blinking. Entry in errormemory. Errordetection
Engine start switch stuck, start switch clamped, connection cable Possible reason for error Errorlamp shows permanent light. Entry in errormemory.
demaged Time processing unit (TPU) defective, ECU defective Possible reason for error
Take actions for error repair Take actions for error repair Speed above target range, signal invalid or implausible compared
Check cabling, if sensor not working, check start switch and if If error not removable, change ECU to injection volume and engine speed, distance factor not
necessary replace it, check connection cable and if necessary other error properties learned, sensor defective, connection cable demaged
BOMAG
repair or replace it System reaction: Recovery of ECU Take actions for error repair
other error properties Behaviour error lamp: blinking Check cabling, if sensor not working, check sensor and if
System reaction: Warning Selfhealing: no necessary replace it, check connection cable and if necessary
Behaviour error lamp: permanent light Signal Priority: 5 repair or replace it
Selfhealing: no Measurement @ errortime: - other error properties
Signal Priority: 1 System reaction: Warning
Measurement @ errortime: actual value Behaviour error lamp: permanent light
Selfhealing: yes
Signal Priority: 3
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
235 / 523600 / WdCom 236 / 523470 / PRVMonSysReac 237 / 523006 / APPCDSwtnSel

Error description SERIAL INTERFACE DEF. Error description RAIL PRESS. LIM. VALVE Error description CONTR. MODE SWITCH
Internal hardware monitoring: the ECU detects a disturbance in Rail pressure relief valve: is open, will be forced to open, the Controller mode switch: the signal received by ECU is defective
internal communication forced-open failed; the ECU activates a system reaction or implausible.

SPN: 523600 SPN: 523470 SPN: 523006
12. Errormode not identifiable 12: Defective component 3: Voltage to high or short circuit to +Ubatt
12. Errormode not identifiable 12: Defective component 4: Voltage to low or short circuit to -Ubatt
Errorlamp shows blinking. Entry in errormemory. Errorlamp shows permanent light, 15s before shut off. Entry in Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error errormemory. Possible reason for error
Communication disturbed, ECU defective Possible reason for error Cable break, signal implausible, switch defective, connection
Take actions for error repair Rail pressure relief valve open or forced open abortive cable demaged
If error not to removable, change ECU (interpretation of the rail pressure gradient), power supply voltage Take actions for error repair
other error properties too low, rail pressure sensor defective, fuel metering unit Check switch and if necessary replace it, check connection cable
BOMAG
System reaction: Recovery of ECU defective, rail pressure relief valve defective, air in fuel system and if necessary repair or replace it
Behaviour error lamp: blinking Take actions for error repair other error properties
Selfhealing: no Check working voltage and if necessary correct it, check rail- System reaction:
Signal Priority: 5 pressure sensor and if necessary replace it, check FCU and if Behaviour error lamp: permanent light
Measurement @ errortime: - necessary replace it, check rail pressure relief valve and if Selfhealing: yes
necessary replace it, bleed the fuel-system Signal Priority: 2
other error properties Measurement @ errortime: actual value
System reaction: Warning, shut the engine off in about 5 minutes
Behaviour error lamp: permanent light, 15s before shut off
Selfhealing: no
Signal Priority: 4

5.21
199
200
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

238 / 523007 / FrmMng_TORxEngPress 239 / 523008 / MplCtl 240 / 98 / OLSCD

Error description CAN ERROR RxEngPress. Error description MANIPULATION CONTROL Error description OIL LEVEL SWITCH
Error codes Data monitoring: the torque curve does not match the Oil level sensor: the voltage of sensor measured by ECU is out of
DEUTZ-Errorcode: 238 specification the target range or the received value of oil level via CAN is
BlinkCode (short-long-short): 2 - 1 - 5 Error codes defective or the signal value is implausible
SPN: 523007 DEUTZ-Errorcode: 239 Error codes
possible FMI: BlinkCode (short-long-short): 4 - 2 - 4 DEUTZ-Errorcode: 240
12: Defective component SPN: 523008 BlinkCode (short-long-short): 2 - 1 - 1
12. Errormode not identifiable possible FMI: SPN: 98
12. Errormode not identifiable 1: data valid, but below normal working area possible FMI:
12. Errormode not identifiable 2: data stream is defective 3: Voltage to high or short circuit to +Ubatt
Errordetection 12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
Errorlamp shows permanent light. Entry in errormemory. 12. Errormode not identifiable 2: data stream is defective
Possible reason for error Errordetection 2: data stream is defective
Take actions for error repair Errorlamp shows . Entry in errormemory. Errordetection
other error properties Possible reason for error Errorlamp shows permanent light. Entry in errormemory.
System reaction: Manipulation of Topcurve detected, data manipulation, too slow Possible reason for error
Behaviour error lamp: permanent light changed curve Voltage outside target range, CAN signal error, signal
Selfhealing: yes Take actions for error repair implausible, sensor defective, connection cable demaged, CAN
Signal Priority: 1 other error properties bus wrong cabled, wiring demaged, receiver (sender of the
BOMAG
Measurement @ errortime: default value System reaction: message) work inaccurately, parametering inaccurate
Behaviour error lamp: Take actions for error repair
Selfhealing: - Check cabling, if sensor not working, check sensor and if
Signal Priority: 3 necessary replace it, check connection cable and if necessary
Measurement @ errortime: repair or replace it, Check CAN Bus cabling (Bus sheduling,
polarity, short circuit, power interrupt), test protocol of receiver,
chec
System reaction: Warning, substitute value
Selfhealing: yes
Signal Priority: 3
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
241 / 98 / OLSCDSysReacHi 242 / 107 / ADPSCDAna 243 / 98 / OLSCDSysReacLo

Error description OIL LEVEL SWITCH Error description AIR FILTER COND. Error description OIL LEVEL SWITCH
Oil level: the oil level calculated by ECU is above the target Air filter differential pressure sensor: the voltage of sensor Oil level: the oil level calculated by ECU is underneath the target
range; the ECU activates a system reaction measured by ECU is out of the target range range; the ECU activates a system reaction

SPN: 98 SPN: 107 SPN: 98
0: data valid, but above normal working area 3: Voltage to high or short circuit to +Ubatt 1: data valid, but below normal working area
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
Oil level too high with system reaction, oil volume too large, Voltage outside target range, sensor defective, connection cable Oil level too low with system reaction, oil volume too small,
sensor defective, connection cable demaged, CAN data error demaged sensor defective, connection cable demaged, CAN data error
Check oil level and if necessary correct it, check sensor and if Check cable harness, check sensor and if necessary replace it, Check oil level and if necessary correct it, check sensor and if
BOMAG
necessary replace it, check connection cable and if necessary check connection cable and if necessary repair or replace it necessary replace it, check connection cable and if necessary
repair or replace it other error properties repair or replace it
other error properties System reaction: Warning, substitute value other error properties
System reaction: Advice: OLSCD_stSysReacReq Behaviour error lamp: permanent light System reaction: Advice: OLSCD_stSysReacReq
Behaviour error lamp: permanent light Selfhealing: yes Behaviour error lamp: permanent light
Selfhealing: yes Signal Priority: 3 Selfhealing: yes
Signal Priority: 4 Measurement @ errortime: default value Signal Priority: 4

5.21
201
202
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

244 / 523009 / PrvMonWear 245 / 523010 / RailMeUn8 246 / 523650 / FlSys_FLPFMSysReac

Error description REPL. RAIL PRESS. VALVE Error description LEAKAGE DETECTION Error description
Rail pressure relief valve: is open more frequently or for a longer Wenn the engine is in idle running, the metering unit compares its Low fuel pressure Diesel: the low fuel pressure calculated by
time than what the technical specification allows output and rail pressure with the default value (Parameter) and ECU is underneath the target range; the ECU activates a system
Error codes calculates a correction factor-it calibrates itself then reaction
9: Abnormal update rated possible FMI: possible FMI:
10: Abnormal rate of change 0: data valid, but above normal working area 2: data stream is defective
14: Special Instructions 12. Errormode not identifiable 2: data stream is defective
Errordetection 12. Errormode not identifiable 12. Errormode not identifiable
Rail pressure relief valve open more frequently than the technical Possible reason for error Possible reason for error
specification allowed, rail pressure relief valve open longer than Take actions for error repair Diesel fuel pressure below target range with system reaction,
the technical specification allowed, rail pressure relief valve other error properties interruption in cycling process of low fuel pressure (for example,
defective System reaction: fuel pump defective), sensor defective, connection cable
BOMAG
Take actions for error repair Behaviour error lamp: permanent light demaged
Change rail pressure relief valve and remove the error through Selfhealing: no Take actions for error repair
Serdia command Signal Priority: 3 Check Diesel low fuel pressure loop system, Check electrical fuel
other error properties Measurement @ errortime: actual value pump, inspect fuel system and if necessary repair it, check
System reaction: permanent error message, unerasable by sensor and if necessary replace it, check connection cable and if
"Clear EM" necessary repair or replace it
Behaviour error lamp: permanent light other error properties
Selfhealing: no System reaction: Warning
Measurement @ errortime: actual value Selfhealing: yes
Signal Priority: 4
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
247 / 523651 / FlSys_FTSFMSysReac 248 / 523652 / FlSys_FlushStateEngineOff 249 / 523653 / FlSys_RapeOilHeatEx

Error description Error description Error description RAPEOILSYSTEM
Rape Oil Fuel temperature: the fuel temperature calculated by Engine shut off without flushing or flushing was not already Awaited temperatur rise with opened heat exchanger valve did
ECU is above the target range; the ECU activates a system completed. ECU stores every shutoff with uncompleted or not occur. Error in fuel heating system.
reaction missing flushing process Error codes

possible FMI: possible FMI: 2: data stream is defective
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
Possible reason for error Possible reason for error Fuel heating system (heat exchanger) not working correctly
Rape oil fuel temperature above target range with system Engine shut off without flushing of the fuel system in Diesel Take actions for error repair
reaction, interruption of rape oil fuel loop (for example, heat operation mode, Shutoff before flushing in Diesel operation mode Check Heat exchanger and heat exchanger valve, check cooling
exchanger not working properly), sensor defective, connection was finished system going to the heat exchanger, check rape oil system going
BOMAG
cable demaged Take actions for error repair to the heat exchanger
Take actions for error repair Awaiting complete flushing of the fuel system everytime before other error properties
Check rape oil fuel system as well as heat exchanger and heat engine shut off System reaction: Warning
exchanger valve, if necessary repair it, check sensor and if other error properties Behaviour error lamp: permanent light
necessary replace it, check connection cable and if necessary System reaction: Warning Selfhealing: yes
repair or replace it Behaviour error lamp: permanent light Signal Priority: 3
other error properties Selfhealing: yes Measurement @ errortime: -
System reaction: Warning and switchover to Diesel operation Signal Priority: 3
mode Measurement @ errortime: -
Selfhealing: yes
Signal Priority: 3

5.21
203
204
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

250 / 523654 / FrmMngDieselLvl 251 / 523655 / FrmMngFuelTemp 252 / 523656 / FrmMngLowPressureDiesel

Error description RAPEOILSYSTEM Error description RAPEOILSYSTEM Error description RAPEOILSYSTEM
Status DieselLvl (Diesel tank level): the voltage of the sensor Status FuelTemp (Fuel Temperature): the voltage of the sensor Status LowPressureDiesel (Low fuel pressure diesel): the voltage
measured by ECU is out of the target range measured by ECU is out of the target range of the sensor measured by ECU is out of the target range
SPN: 523654 SPN: 523655 SPN: 523656
3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt
Cable break or short circuit, sensor defective, connection cable Cable break or short circuit, lamp defective, connection cable Cable break or short circuit, lamp defective, connection cable
Check cabling, if sensor not working, check sensor and if Check cabling, if sensor not working, check sensor and if Check cabling, if sensor not working, check sensor and if
BOMAG
necessary replace it, check connection cable and if necessary necessary replace it, check connection cable and if necessary necessary replace it, check connection cable and if necessary
repair or replace it repair or replace it repair or replace it
System reaction: Warning, substitute value System reaction: Warning, substitute value System reaction: Warning, substitute value
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
253 / 523657 / FrmMngRapeOilIn 254 / 523658 / FrmMngRapeOilLvl 255 / 523659 / FrmMngRapeOilVlv1

CAN messageRapeOilln (Rape oil input): the message can not Status RapeOilLvl (Rape oil tank level): the voltage of the sensor Status RapeOilVlv1 (Valve 1): the current drain measured by
be received by ECU measured by ECU is out of the target range ECU is out of the target range or the maximum permissible
Error codes Error codes temperature of the ECU component is exceeded

12: Defective component 3: Voltage to high or short circuit to +Ubatt possible FMI:
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
Errordetection Errordetection 12. Errormode not identifiable
CAN bus wrong cabled, wiring is demaged, receiver (sender of Cable break or short circuit, lamp defective, connection cable Possible reason for error
the message) work inaccurately, parametering inaccurate demaged Cable break or short circuit, valve defective, connection cable
Check CAN Bus cabling (Bus sheduling, polarity, short circuit, Check cabling, if sensor not working, check sensor and if Take actions for error repair
BOMAG
power interrupt), test protocol of receiver, check CAN functional necessary replace it, check connection cable and if necessary Check cabling, if valve not working, check valve and if necessary
range repair or replace it replace it, check connection cable and if necessary repair or
other error properties other error properties replace it
System reaction: Warning, substitute values System reaction: Warning, substitute value other error properties
Behaviour error lamp: permanent light Behaviour error lamp: permanent light System reaction: Warning and switchover to Diesel operation
Selfhealing: yes Selfhealing: yes mode
Signal Priority: 3 Signal Priority: 3 Behaviour error lamp: permanent light
Measurement @ errortime: default value Measurement @ errortime: default value Selfhealing: yes
Signal Priority: 3

5.21
205
206
5.21
DTC-List P490_: 220, 310, 501 P492_: 213

256 / 523660 / FrmMngRapeOilVlv2 257 / 523661 / FrmMngRapeOilVlv3 258 / 523662 / FrmMngRapeOilVlv4

Status RapeOilVlv2 (Valve 2): the current drain measured by Status RapeOilVlv3 (Valve 3): the current drain measured by Status RapeOilVlv4 (Valve 4): the current drain measured by
ECU is out of the target range or the maximum permissible ECU is out of the target range or the maximum permissible ECU is out of the target range or the maximum permissible
temperature of the ECU component is exceeded temperature of the ECU component is exceeded temperature of the ECU component is exceeded
SPN: 523660 SPN: 523661 SPN: 523662
Cable break or short circuit, valve defective, connection cable Cable break or short circuit, valve defective, connection cable Cable break or short circuit, valve defective, connection cable
BOMAG
Check cabling, if valve not working, check valve and if necessary Check cabling, if valve not working, check valve and if necessary Check cabling, if valve not working, check valve and if necessary
replace it, check connection cable and if necessary repair or replace it, check connection cable and if necessary repair or replace it, check connection cable and if necessary repair or
replace it replace it replace it
System reaction: Warning and switchover to Diesel operation System reaction: Warning and switchover to Diesel operation System reaction: Warning
mode mode Behaviour error lamp: permanent light
Signal Priority: 3 Signal Priority: 3 Measurement @ errortime: default value
008 916 41
DTC-List P490_: 220, 310, 501 P492_: 213
008 916 41
259 / 523663 / FrmMngRapeOilVlv5 260 / 523664 / FrmMngSTIN1RX

Error description RAPEOILSYSTEM Error description RAPEOILSYSTEM
Status RapeOilVlv5 (Valve 5): the current drain measured by CAN message STIN1 (State Inputs 1): the message can not be
ECU is out of the target range or the maximum permissible received by ECU
temperature of the ECU component is exceeded Error codes
Error codes DEUTZ-Errorcode: 260
DEUTZ-Errorcode: 259 BlinkCode (short-long-short): 5 - 6 - 8

BlinkCode (short-long-short): 5 - 6 - 7 SPN: 523664
SPN: 523663 possible FMI:
possible FMI: 12: Defective component
12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12: Defective component
12: Defective component 12. Errormode not identifiable
12. Errormode not identifiable Errordetection
Errordetection Errorlamp shows permanent light. Entry in errormemory.
Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
Possible reason for error CAN bus wrong cabled, wiring is demaged, receiver (sender of
Cable break or short circuit, valve defective, connection cable the message) work inaccurately, parametering inaccurate
demaged Take actions for error repair
Take actions for error repair Check CAN Bus cabling (Bus sheduling, polarity, short circuit,
BOMAG
Check cabling, if valve not working, check valve and if necessary power interrupt), test protocol of receiver, check CAN functional
replace it, check connection cable and if necessary repair or range
replace it other error properties
other error properties System reaction: Warning, substitute values
System reaction: Warning Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Selfhealing: yes
Signal Priority: 3 Measurement @ errortime: default value

5.21
207
5.22 Generator
5.22 Generator Three-phase generator

The AC-generator first of all produces AC-voltage /
General
AC-current.
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve- Why does AC-current need to be rectified?
hicle with electric current at a steady voltage already There are a few components for which can either be
at idling speed. operated with alternating current or direct current, be-
cause they work independently from the current flow
Terminal designations
direction.
l B61, L = charge control This includes :
l B+, B = battery plus, also with the designation "30" l
Incandescent lamps
l
B- = battery minus, also with the designation "31" l
Fluorescent lamps
l D+ = dynamo plus corresponds with terminal "61" l Glow lamps
and "L" l Electric heating elements.
l D- = dynamo minus (this designation is only found There are also a few components that could be oper-
on D.C. generators or A.C. generators with regula- ated either with alternating current, direct current or
tor removed) three-phase current, if the components were designed
accordingly.
l DF = dynamo field (this designation is only found on
D.C. generators or A.C. generators with regulator This includes :
removed). Note: The designation DF is also found l
Electric motors
on older alternators with externally arranged regula- l
Relays.
tor on the connection of the exciting coil to the reg-
ulator or on the regulator itself Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc-
l
DF1 = dynamo field 1 es work with alternating or three-phase current.
l
DF2 = dynamo field 2 This includes :
l
IG = "15" ignition switch l
Accumulators
l
Control units
l
All electronics
l
Communication equipment.
Design and function
Fig. 2
1 Fan
2 Holding plate
3 Stator core
4 Stator winding
5 Brush
208 BOMAG 008 916 41

Generator 5.22
6 Brush holder
7 Rectifier
8 Bearing cover
9 Rotor winding
10Rotor
11V-belt pulley
Fig. 5 3-phase current
Fig. 3 Rotor with claw poles The wiring diagram (Fig. 5) 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. 4), whereas the exciter
winding is arranged on the internally revolving rotor The diodes D1, D2, D3 are also referred to as minus
(Fig. 3). 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. 4 Stator
The three stator windings (Fig. 4) 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.
008 916 41 BOMAG 209

5.22 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
l Indication of the correct generator function not discharged.
l External excitation of the generator during the start- A far more important function of the lamp is the transi-
ing phase tion and provision of field current. At standstill there is
no magnetic field in the de-energized generator. Since
this is necessary for the generation of electric current,
the rotor must be supplied with current, so that a weak
field can build up.
The current flows from the ignition switch via the
charge control light through the generator winding
against ground (terminal 31) and is limited to approx.
300 mA by the light bulb (4 W) (without the lamp the
current flow would be 2 to 5 A). While the rotor is ro-
tating current is induced into the stator winding,
whereby a small part (2–5 A, depending on speed)
flows through the charge regulator into the field wind-
ing of the rotor and the major part flows to the output
terminals (B+), where it can be tapped as useful cur-
rent. If the charge control light is defective or no bat-
Fig. 6 plus controlled charging regulator tery is available or the battery is discharged, external
(Fig. 6) 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. 7 plus controlled charging regulator

(Fig. 7) 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.
210 BOMAG 008 916 41

Generator 5.22
Charge controller
The charge controller has the following functions
l To regulate the voltage generated by the generator
l To protect against overloads caused by too high
output current
l Protection against reverse current
If the output voltage or the output current of the gen-
erator exceeds the determined maximum values, the
field current and thus the electric power is reduced.
Electronic charge regulator
Fig. 9 plus controlled regulator
Fig. 8
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. 10 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.
008 916 41 BOMAG 211

5.22 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
l This can be easily found out by checking whether
the connected consumer (resistance), e.g. charge
the charge control light in the dashboard lights up. If
control light or relay of a MD+ engine control.
the light does not go out, even at higher speeds,
there must be a defect on the generator, the regula- The pre-excitation current should be approx. 250 mA
tor, the wiring or the V-belt. at 12 Volt. This corresponds with a 3 Watt light bulb or
l When the engine is at rest, the charge control light an equivalent combination of light bulb + resistance or
must light up. If not, the lamp may probably be de- an LED + resistance.
fective. Defects on generator or wiring are obviously The total resistance of the disconnected dead supply
also possible. line D+ max. should not exceed 48 Ohm.
The following points allow to contain faults in the volt- In case of faults like
age supply within certain limits. l charge control light stays on
l Cable connections on the generator OK? l no voltage increase, e.g. from 12 V to 14 V
l V-belt OK?
one should check that the correct resistance is as-
l Generator ground (engine ground) OK?
sured.
l Pre-excitation from vehicle electronics OK?
Only if all criteria mentioned above are OK, the fault
must be in the generator itself. In this case it must be
replaced or the following trouble shooting procedure
must be performed.
Fig. 11 Connections on the three-phase alternator (exemplary de-

sign)
If the charge control light or LED stays on when the
engine is running, you should proceed as follows:
l Temporarily bridge connections D+ and B+ on the
three-phase alternator (Fig. 11). 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.
212 BOMAG 008 916 41

Generator 5.22
Checking the rotor
Measuring the charge current
l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact. i Note
The rotor coils can only be measured in disassembled
l The generator ground connection must be OK.
state.
l During the measurement switch on as many con-
sumers as possible.
1 Attach the clip-on ammeter around the B+ line.
2 Gradually increase the engine speed.
3 The generator current must be at least as high as
the total current of all switched on consumers.
Fig. 12
l Measure the resistance between the sliprings.
l If the resistance does not comply with the factory
specification, replace the rotor.
l Use the resistance range of the continuity tester to
check the continuity between slipring and core.
l Replace the rotor if no infinite value is indicated.
i Note
Factory specification for resistance: 2.8 to 5 OHM.
008 916 41 BOMAG 213

5.22 Generator
Checking the stator Checking the bearings
i Note
The stator coils can only be measured in disassem-
bled state.
Fig. 14
l Check whether the bearing rotates without obstruc-
tion.
l Replace the bearing if it does not rotate properly.
Fig. 13
measure the resistance between the individual lines
of the stator winding.
l If the measuring value does not comply with the fac-
tory specification, replace the stator.
check the continuity between the individual stator
windings and the core.
l Replace the stator if no infinite value is indicated.
i Note
Factory specification for resistance: Less than 1 OHM.
214 BOMAG 008 916 41

Generator 5.22
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. 16
l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
Fig. 15 l The generator ground connection must be OK.
The generator test assesses the regulator voltage and l
The battery should be in good condition – the idle
the ripple factor of the generator voltage. voltage of the battery should be at least 12.6 Volt.
l
All plug-and-socket connectors must be free of cor- l
If possible switch off all consumers.
rosion and intermittent contact. l
Perform the measurement at raised engine speed.
l
The generator ground connection must be OK. l
The voltage (B+) should adjust itself at 13 to 14 Volt.
l
The battery should be in good condition – the idle
voltage of the battery should be at least 12.6 Volt.
l
If possible switch off all consumers.
l
Perform the measurement at raised engine speed.
008 916 41 BOMAG 215

5.22 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. 18
E.g minus controlled regulator
i Note One connects the regulator (Fig. 18) with D+ and D- to
When testing the regulator one should be aware that the power source, as shown in the illustration, and the
there are 2 different types of regulators: lamp to both carbon brushes, instead of the exciter
winding. When slowly increasing the voltage the lamp
l If the carbon brush is not connected to ground the will first become brighter, because the regulator al-
regulator is a so-called minus controlled regulator. lows all lamp current (= exciter current) to flow at volt-
The exciter winding is positioned between D+ and age values up to 14.4V. Once the regulator voltage is
DF, the regulator therefore regulates the exciter reached, the regulator switches the lamp current off.
winding on the ground side. The other carbon brush When returning the voltage back below the control
is connected with the cathodes of the exciter di- voltage, the regulator will switch the lamp back on.
odes, terminal D+. This leaves one further terminal,
With this test the major difficulty is the problem to re-
this is DF.
move the regulator an identify terminals D+, DF and
D+ (vehicle wiring system) D-.
D- (ground contact, mostly located on one of the fas-
tening screws)
DF (Dynamo Field)
Fig. 19
Fig. 20
Fig. 17
The illustrations (Fig. 19) and (Fig. 20) show two dif-
l If the carbon brush is connected to ground the reg-
ferent regulator types.
ulator is a so-called plus controlled regulator. The
exciter winding is positioned between DF and D-,
the regulator therefore regulates the exciter winding
on the plus side. The other carbon brush is then
connected with terminal DF. This leaves one further
terminal, this is D+.
The basic function of a disassembled regulator can be
easily tested with a 12V lamp and an adjustable D.C.
power supply unit (0V ... 20V).
216 BOMAG 008 916 41

Electric starter 5.23
Replacing carbon brushes 5.23 Electric starter
l On a Bosch generator unscrew two fastening
screws for the regulator and lift the regulator off. General
Pull out the carbon brushes from underneath. Their Combustion engines need to be started by means of
minimum length is 5 mm, shorter carbon brushes a special device, because they are not able to start by
need to be replaced, unsolder both connection litz themselves. Considerable resistances caused by
wires. Solder the litz wires of the new carbon brush- compression and friction must thereby be overcome.
es, insert these and fasten the regulator again. For The starter converts the electric energy stored in the
this work the generator does not need to be re- battery into mechanical energy. The starter can only
moved. generate its power when a battery with appropriate
l
For replacing the carbon brushes in the Delco- capacity is available.
Remy generator the generator needs to be disas- Duties of the starter:
sembled and partly dismantled. The carbon brush l to accelerate the combustion engine to start speed
holder is located inside the collector ring bearing.
with lowest possible current consumption.
l establish the gear connection between starter and
combustion engine.
l to maintain this connection.
l to switch on the starter current.
After starting the engine:
l
to return the starter pinion to initial position.
l
to switch off the starter current.
008 916 41 BOMAG 217

5.23 Electric starter
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. 21
1 Magnetic switch
2 Armature
3 Actuating lever
4 Freewheeling clutch Fig. 23 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. 22 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
218 BOMAG 008 916 41

Engine running 4 Resetting spring
5 Magnetic switch
6 Ignition switch
7 Pinion
8 Ring gear
9 Battery
Fig. 24
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. 25
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
008 916 41 BOMAG 219

Magnetic switch Freewheeling clutch
Fig. 26 Direct acting electric motor Fig. 28 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. 27 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
220 BOMAG 008 916 41

Trouble shooting "Starter" Testing and measuring the starter
Function control with the starter removed
i Note
The most frequent fault is definitely a fully discharged
Caution
!
battery.
Fasten the starter to make sure that it will not
If the starter rotates too slowly, either the brushes come loose during the test.
are partly worn off, or parts of the exciter or armature
winding is shorted. In some cases oxidized electric
contacts or a soiled ground connection causing ex-
tremely high voltage losses in the overall starter sys-
tem are the cause of problems.
If the starter only emits a clicking sound,- either
the magnetic switch is defect / soiled (dismantle and
clean))- the main contacts on the magnetic switch are
worn off / soiled (scrape off carefully with a file and
clean)- the starter motor is defective / soiled (remove
armature and clean), cover cleaned, moveable parts
with grease.
Frequently a jammed return mechanism is the reason
for a starter failure. Fig. 29
Occasionally worn contacts are found on the magnetic l
Connect a jumper lead between start terminal (1)
return switch and battery plus (2).
Defects on the actual starter motor including pinion l
Connect a jumper cable instantaneously between
and carbon brushes are very rare. starter housing and battery minus (3).
With a trouble shooting chart the faults in the starter
system can be narrowed down. The starter system i Note
can only work when many conditions are fulfilled at
If the motor does not start, the starter is defective. Re-
the same time.
pair or replace the starter.
l Immobilizer deactivated?
l Ignition switch OK? Checking the magnetic switch
l Travel lever in correct position?
l Emergency stop not actuated?
l Battery sufficiently charged?
l Battery poles OK?
l Main battery fuse OK?
l Main battery switch closed?
l Main starter cable (terminal 30) OK?
l Starter control cable (terminal 50) OK, voltage
drop?
l Ground cable OK?
l Switching of magnetic switches OK?
Fig. 30
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
l
Connect a jumper lead between start terminal (1)
and battery plus (2).
l the experience of the specialist
l
Connect a jumper cable instantaneously between
l the failure probability of the component to be tested
starter housing and battery minus (3).
and the testing effort for the respective part.
Only if all criteria mentioned above are OK, the fault
must be in the starter itself. In this case it can be re- i Note
paired or replaced. If the pinion does not disengage, the magnetic switch
is defective. Repair or replace the starter.
008 916 41 BOMAG 221

Continuity test for the magnetic switch Removing and assembling the starter
Removing the starter
Fig. 31
l
Use a continuity tester to check for continuity be-
Fig. 32
tween terminal (1) and terminal (29 while holding
the pin depressed. l Switch the main battery switch to position "0" (Fig.
l Replace the magnetic switch if no continuity is de- 32).
tected.
Fig. 33
l
Disconnect the cable connections (terminal 30 and
50).
l
Unscrew the screws (arrows) (Fig. 33).
l
Take off the starter.
222 BOMAG 008 916 41

Assembling the starter
Fig. 34
l Insert the starter.
l Tighten the screws (arrows) (Fig. 34), tightening
torque 60 Nm.
l Connect the cables (terminal 30 and 50).
Caution
!
Please comply with the following tightening tor-

ques when tightening the cable connections, in
order to avoid damage to the starter terminals or
other components.
Terminal 30, 24±4 Nm
Terminal 50, 1 - 1,3 Nm
To tightly tightened nuts can cause damage to
starter components (e.g. cracks in the cover of the
magnetic switch). Moisture entering into the start-
er can cause short circuit - or even cable fire.
Insufficiently tightened nuts can cause cable con-
nections to come loose and thus short circuit - or
even cable fire.
008 916 41 BOMAG 223

224 BOMAG 008 916 41

6 Engine
008 916 41 BOMAG 225

6.1 Diesel engine
6.1 Diesel engine l compact design

l low noise level
The road finishers of type BF600 are powered by a 4-
cylinder Deutz diesel engine type TCD 2013.
l almost vibration free operation
l low fuel consumption
The engines are water cooled in-line engines with
EMR3 electronics.
l low exhaust emission EPA/COM IIl
The engines are mainly designed in two-valve tech-
l high power density
nology with turbo charging and intercooler. They are l good access to all service points.
highly compact and come with a Deutz-Common-Rail l high reliability
injection system, called DCR in short. l low running costs,
All engines are designed with exhaust gas recircula- l long lifetime
tion and thus reach emission values complying with
EPA/ COM/ Tier/ stage lll
These engines are characterized by the following pos-
itive features:
Fig. 1 Deutz diesel engine TCD 2012 and 2013
226 BOMAG 008 916 41

Engine description TCD 2013, 4 and 6 cylinder 6.2
6.2 Engine description TCD 2013,
4 and 6 cylinder
Fig. 1 Deutz diesel engine TCD 2013 L04 2V, right hand side 14 Fuel control unit
15 High pressure pump
1 Combustion air inlet (possibility to install a heating 16 Crankcase ventilation valve
flange, optionally) 17 Injector
2 Connection cabin heater ort compensation line 18 Lubrication oil filling neck
3 Fan
4 Generator
5 Belt pulley on crankshaft
6 V-belt
7 Fuel lift pump drive
8 Fuel filter
9 Replaceable lubrication oil filter
10 Lubrication oil cooler
11 Possible installation of hydraulic pump or com-
pressor (optional)
12 Lubrication oil return line crankcase ventilation
13 Central plug (for engine control)
008 916 41 BOMAG 227

6.2 Engine description TCD 2013, 4 and 6 cylinder
Fig. 2 Deutz diesel engine TCD 2013 L04 V2, left hand side
1 Lubrication oil filling neck (optional)

2 Transmission connection (SAE)
3 Engine mounts
4 Lubrication oil drain plug
5 Lubrication oil sump
6 Starter motor
7 Lubrication oil return line from exhaust gas turbo
charger
8 Exhaust turbo charger
9 Coolant inlet
10 Charge air connection to intercooler
11 Coolant outlet
12 Exhaust manifold
13 Charge air line
14 Transport device
228 BOMAG 008 916 41

Engine description TCD 2013, 4 and 6 cylinder 6.2
Fig. 3 Deutz diesel engine TCD 2013 L06 2V, right hand side 17 Crankcase ventilation valve
18 Injector
1 Combustion air inlet
2 Lubrication oil filling neck
3 Transport device
4 Fan hub
5 Generator
7 Fuel filter
8 Lubrication oil sump
9 Oil dipstick
10 Lubrication oil drain plug
11 Oil return line crankcase ventilation
12 Engine mounts
13 Transmission connection (SAE)
14 Central plug (for engine control)
16 Rail
008 916 41 BOMAG 229

6.2 Engine description TCD 2013, 4 and 6 cylinder
Fig. 4 Deutz diesel engine TCD 2013 L06 2V, left hand side

2 Exhaust manifold
3 Starter motor
4 Lubrication oil flow to exhaust turbo charger
5 Coolant drain plug
6 Coolant inlet
7 Ribbed V-belt
8 Fan hub
9 Idler pulley
10 Connection cabin heater ort compensation line
11 Ventilation line to compensation tank
12 Coolant line from engine to radiator
230 BOMAG 008 916 41

Lubrication oil circuit TCD 2012 / 2013 6.3
6.3 Lubrication oil circuit TCD
2012 / 2013
25 26 23 22 18 12
12
123 19 20 21 17 15 11
12
8 7 6
5
24
27 1
1
1 14 13 16 10 9 4 2 3
Fig. 1 Lubrication oil diagram 17 Piston cooling nozzle with pressure maintaining
valve
1 Lubrication oil sump 18 Plunger with rocker arm pulse lubrication
2 Lubrication oil suction pipe 19 Push rod, lubrication oil supply for rocker arm lu-
brication
3 Lubrication oil pump
20 Rocker arm
4 Pressure relief valve
21 Return line to lubrication oil sump
22 Lubrication oil flow to exhaust turbo charger
6 Return flow check valve (only on 2012)
7 By-pass valve
24 Return line from compressor / hydraulic pump to
8 By-pass valve lubrication oil filter
crankcase
9 Pressure control valve
25 Compressor or hydraulic pump
26 Lubrication oil line to crankshaft and camshaft,
11 Main lubrication oil lines compressor / hydraulic pump
12 Internally switched exhaust gas recirculation 27 Return flow from exhaust turbo charger
13 Crankshaft bearings
14 Conrod bearings
15 Camshaft bearings
16 Line to spray nozzle
008 916 41 BOMAG 231

6.4 Coolant circuit TCD 2012 / 2013
6.4 Coolant circuit TCD 2012 /

2013
Fig. 1 Fuel diagram
1 Coolant outlet on radiator

2 Thermostat
3 Coolant - supply to water pump
4 Coolant pump
6 Cylinder cooling
7 Cylinder liner / head cooling
8 Coolant flow to heater
9 Cabin heater (optional)
10 Coolant to thermostat
11 Connection for cabin heater
12 Compensation line
13 Ventilation line to compensation tank
14 Coolant outlet to radiator
15 Compensation tank
16 Compensation line to heat exchanger
232 BOMAG 008 916 41

Fuel system TCD 2012 / 2013 6.5
6.5 Fuel system TCD 2012 / 2013
Fig. 1 Coolant diagram 12 Fuel return flow on cylinder head

13 Fuel return line to fuel tank
1 Fuel tank A= minimum distance 500 mm 14 Fuel lines from fuel control unit to high pressure
2 Fuel pre-filter with pre-pressure pumping possibil- pumps and Rail
ity to fill the low pressure section (provided by cus- 15 Fuel lift pump 2013
tomer)
3 Line to fuel lift pump
4 Fuel lift pump
5 Fuel filter
6 Fuel supply line to fuel control unit
7 Rail
9 Fuel supply line to injector
10 Injector
11 FCU (Fuel Control Unit)
008 916 41 BOMAG 233

6.5 Fuel system TCD 2012 / 2013
Fuel pre-cleaner
Fig. 2 Fuel pre-cleaner
1 Fuel supply to pump

2 Fuel return flow from FCU (Fuel Control Unit)
3 Manual fuel pump with bayonet lock to lock and
unlock
4 Thermostat valve with shut-down lever
5 Filter cartridge
6 Possibility to connect an electric water level sen-
sor
7 Drain tap
8 Water collecting bowl
9 Fuel inlet from fuel tank
10 Fuel return flow to fuel tank
A Electric water level sensor
234 BOMAG 008 916 41

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 6.6
6.6 Deutz Common Rail (DCR) in- tion solely controlled by mapping is only possible un-
der this condition. Injection timing and injection
jection system for TCD 2012 / quantity are controlled by the engine electronics. The
2013 electric signals control an electrically operated valve
per cylinder, which is integrated in the injection noz-
The diesel engines type TCD 2012 and 2013 are zle. The short distances between valve and injection
equipped with a "Deutz Common Rail" injection sys- nozzle result in short pressure rise times, which has a
tem, DCR in short. positive effect on the combustion process and its con-
The English term "Common Rail" indicates that the trol. Various types of injection van be realized, e.g.
system is based on a common Rail. It describes the pre-injection, main injection and post-injection. These
use of a common high pressure fuel line with corre- are freely controllable, in dependence on the control
sponding branches to supply all cylinders with fuel. unit.
The "Common Rail" injection is an injection system for The electric control is accomplished by the electronic
combustion engines, in which a high pressure pump control unit (EDC16) with EMR3, in dependence on
pressurizes the fuel to a high pressure level. The pres- the operating parameters. The system is capable of
surized fuel fills a piping system, which is permanently providing a wide range of limp-home functions, should
under pressure while the engine is running. any of the sensors fail. This ensures a reliable and
safe completion of travel and work.
The general idea is the total isolation of the pressure
generation from the actual injection process. An injec-
Overview of electronic diesel fuel control
Sensors Control unit (EMR3) Actuators

Injector
Rail
Pump
Fig. 1 TCD 2012 and 2013
008 916 41 BOMAG 235

6.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013
10
8
7
5
11
9
4 1
12
Fig. 2 Schematic of the Deutz Common Rail System "DCR" Under normal conditions the Rail pressure is be-
tween 300 and 1350 bar
1 Fuel filter high pressure The PRV is set to 1600 bar
2 Fuel low pressure sensor (5-7bar)
If the PRV is defective or always open, the pres-
3 High pressure pumps
sure in the Rail will only build up to max. 700 bar.
4 Fuel lift pump
5 Rail (high pressure pipe up to 1600 bar) The Rail pressure must be at least 1.5 bar to start
the diesel engine
6 PRV (max. Rail pressure limitation 1600bar)
7 Rail pressure sensor The fuel low pressure sensor is located after the
fuel filter and the pressure is normally between 5
8 Injectors
and 7 bar.
9 FCU Fuel Control Unit
10 Engine control EDC16 - EMR3 The solenoid valve of the Fuel Control Unit (FCU)
is dead, open towards the tank.
11 Fuel pre-filter with water separator
12 Hand pump The voltage applied to the injectors is normally
approx. 40 V.
236 BOMAG 008 916 41

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 6.6
FCU Fuel Control Unit
electric connection
Fig. 3 Fuel Control Unit FCU
Two high pressure pumps
High pressure
Low
pressure
High pressu
pumps
Fig. 4 High pressure pump
008 916 41 BOMAG 237

6.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013
Injector)
electr. connections
Return flow
Armature group
Nozzle
Supply
Fig. 5 Injector
238 BOMAG 008 916 41

Exhaust gas recirculation TCD 2012 / 2013 6.7
6.7 Exhaust gas recirculation TCD 2012 / 2013
In order to be able to meet the exhaust gas standards EC and stage/Tier3, all engines are designed with
exhaust gas recirculation.
On 4-cylinder 2-valve engines TCD 2012/2013 the exhaust gas recirculation has been realized internally
through the intake valves, on 6-cylinder 2-valve engines through the exhaust valves. For this purpose
the camshaft has been manufactured with an additional cam for short-term opening of the intake valve
or exhaust valve respectively.
Fig. 1 Exhaust/intake valve control TCD 2012 / 2013
008 916 41 BOMAG 239

6.8 Wastegate - charge pressure controller on TCD-engines
6.8 Wastegate - charge pressure controller on TCD-engines

The Wastegate is a exhaust gas bypass valve and is located on or in the exhaust turbocharger
The Wastegate (exhaust gas bypass valve) is used to control the charge pressure
The charge pressure control takes place by means of a charge pressure triggered pressure valve in connection
with the exhaust gas bypass valve. Depending on this bypass valve hot exhaust gases flow past the exhaust
gas turbine into the exhaust without the available energy being utilized
The bypass valve is normally closed
Control line
Pressure contro
Bypass valve
closed
Fig. 1 Exhaust gas turbocharger with Wastegate
Wastegate active, charge pressure control, i.e. bypass valve open
Bypass valve
open
240 BOMAG 008 916 41

Wastegate - charge pressure controller on TCD-engines 6.8
Wastegate on TCD 2013
008 916 41 BOMAG 241

6.9 Engine problems
6.9 Engine problems
Fault Possible cause Remedy
Engine does not Temperature below starting limit Check

start or starts Oil level too low Fill up lubrication oil
poorly
Lubrication oil level too high Check the lubrication oil level, drain off
Lubrication oil cooler defective if necessary
Check
Exhaust gas counter pressure too high Check
V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose
Engine oil with wrong SAE viscosity class Change the lubrication oil
Fuel quality not as specified in the operating Change the fuel

instructions
Air in the fuel system Bleed the fuel system
Battery defective or not charged Check the battery
Cable to starter loose or oxidized Check cable connection
Starter defective or pinion does not engage Check starter
Engine does not Engine electronics prevent starting Check fault by fault code, repair as nec-
start and diag- essary
nostic lamp
flashing
Engine starts, V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose
but runs irregu-
larly or misfires Incorrect valve clearance Adjust
Injector defective Replace
Injection valve defective Check / replace the injection valve
Glow plug defective Replace
Air in the fuel system Bleed the fuel system
Fuel pre-cleaner soiled Clean/replace

instructions
Injection line leaking Check the injection line
Speed changes Engine electronics detected a system fault Check fault by fault code, repair as nec-
are possible and and activates a substitute speed essary
diagnostic lamp
lights
242 BOMAG 008 916 41

Engine problems 6.9
Engine over- Bleeding line clogged Clean ventilation line

heating, temper-
ature warning Injector defective Replace
system re- Coolant heat exchanger soiled Clean
sponds
Coolant pump defective (V-belt torn or check, whether torn or loose
loose)
Lack of coolant Fill up
Charge air pipe leaking Check the charge air pipe
V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose
Lubrication oil filter soiled Replace
Lubrication oil level too low Fill up lubrication oil
Lubrication oil level too high Check the lubrication oil level, drain off
if necessary
Air filter clogged / exhaust turbocharger de- Check/replace

fective
Fan defective / V-belt torn or loose Check fan / V-belt, replace if necessary
Short circuit of heat in cooling system Check the cooling system
Resistance in cooling system too high / flow Check the cooling system
quantity too low
Engine has to Lubrication oil level too low Fill up lubrication oil
low or no oil
pressure Engine oil with wrong SAE viscosity class Change the lubrication oil
Insufficient en- Engine oil level too high Drain the engine oil down to the top dip-
gine power stick mark

instructions
Air filter clogged / exhaust turbocharger de- Check/replace

fective
Charge air pipe leaking Check the charge air pipe
Intercooler soiled Clean
Injection line leaking Check the injection line
Injection valve defective Check the injection valve
Insufficient en- Engine electronics reduces the power Check fault by fault code, repair as nec-
gine power and essary
diagnostic lamp
lights
Engine does not Injection line leaking Check the injection line
work with all cyl-
inders Injection valve defective Check / replace the injection valve
008 916 41 BOMAG 243

6.9 Engine problems
Engine has ex- Lubrication oil level too high Check the lubrication oil level, drain off
cessive oil con- if necessary
sumption
Blue engine ex- Lubrication oil level too high Check the lubrication oil level, drain off
haust smoke if necessary
White engine Temperature below starting limit Check

exhaust smoke
instructions
Injection valve defective Check/replace
Black engine ex- Air filter clogged / exhaust turbocharger de- Check/replace
haust smoke fective
Charge air pipe leaking Check charge air line
Injection valve defective Check / replace the injection valve
244 BOMAG 008 916 41

Check the engine oil level 6.10
6.10 Check the engine oil level 6.11 Changing engine oil and oil fil-
ter cartridge
! Danger
Danger of injury! !Caution

Support the engine hood for all maintenance and The oil change at 250 operating hours refers to
repair work. the use of oils of oil quality class API CG-4/CH-4 or
ACAE E3-96/E5-02 respectively.
i Note Refer also to the chapter 5.2, fuels and lubricants.

The machine must be parked horizontally with the en- Drain the engine oil only when the engine is warm.
gine shut down.
l Open the engine hood. Danger
!
Danger of scalding!
When draining off hot oil.
By hot oil when unscrewing the engine oil filter.
Environment
Catch running out oil and dispose of environmen-
tally together with the engine oil filter cartridge.
Fig. 3
l Pull the dipstick (Fig. 3) out, wipe it off with a lint-
free, clean cloth and reinsert it until it bottoms.
l Pull the dipstick back out again.
l If the oil level is below the "MAX" mark fill in oil.
l If the oil level is above the “MAX” mark, determine
the cause and drain off oil.
Fig. 4
!Caution l Unscrew the drain hose (Fig. 4) and catch running
Before longer work periods you should always top out oil.
the oil up to the "MAX"-mark. l
Reassemble the drain hose.
For quality and quantity of oil refer to the table of
fuels and lubricants
008 916 41 BOMAG 245

6.11 Changing engine oil and oil filter cartridge
For quality and quantity of oil refer to the table of

fuels and lubricants.
l Tighten the oil filler cap properly.
! Caution
Before starting crank the engine with the starter
motor until the oil pressure warning light goes
out.
l After a short test run check the oil level on the dip-
stick, if necessary top up to the top dipstick mark.
l Check filter cartridge and drain hose for leaks after
Fig. 5 a short test run.
l Thoroughly clean the outside of the filter cartridge l Shut the engine down and wait for about 15 min-
(Fig. 5). utes, so that all oil can flow back into the oil sump.
l Unscrew the filter cartridge using an appropriate fil- l Check the oil level again , if necessary fill up to the
ter wrench. Max.-mark.
l Clean the sealing face on the filter carrier from any
dirt.
l Slightly oil the rubber seal on the new filter car-
tridge.
Fig. 6
l
Turn the new filter cartridge (Fig. 6) on by hand, until
the seal contacts.
l Tighten the filter element for another half turn.
Fig. 7
l Fill in new engine oil (Fig. 7).
246 BOMAG 008 916 41

Change the fuel pre-filter cartridge 6.12
6.12 Change the fuel pre-filter car-
tridge
Danger
!
Fire hazard!
When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground.
Do not inhale any fuel fumes.
Fig. 10
l Unscrew the water separator from the filter car-
tridge (Fig. 10).
Fig. 8
l
Slacken the bleeding screw (Fig. 8) on the fuel pre-
filter for 2 to 3 turns.
Fig. 11
l Apply a thin coat of oil to the rubber seal of the water
separator 1 (Fig. 11).
l Screw the water separator on by hand (2), until the
seal contacts.
l
Tighten the water separator for another half turn (3).
l
Fill the filter cartridge with clean diesel fuel (4).
l Apply some oil to the rubber seal of the filter ele-
ment (5) and screw it on by hand, until the seal con-
tacts.
l Tighten the filter element for another half turn (6).
Fig. 9 l
Plug the water sensor cable back on.
l Pull the cable off the water separator and unscrew l Check the filter cartridge for leaks after a short test
the fuel filter cartridge (Fig. 9) using an appropriate run.
filter wrench.
l Clean the sealing face on the filter carrier from any
dirt.
i Note
Air in the fuel system causes irregular running of the
engine, a drop in engine power, stalls the engine and
makes starting impossible.
Therefore bleed the fuel system after changing the
fuel pre-filter.
008 916 41 BOMAG 247

6.13 Change the fuel filter cartridge
Environment 6.13 Change the fuel filter cartridge

mentally. ! Danger
Fire hazard!
When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground.
Do not inhale any fuel fumes.
l Open and secure the floor flap in the operator's
stand.
Fig. 12
l With the bleeding pump loosened operate the hand
pump manually, until fuel flows out of the slackened
bleeding screw (Fig. 12) without air bubbles.
l
Then tighten the bleeding screw while pumping.
Fig. 13
l
Loosen and unscrew fuel filter cartridges 1 and 2
(Fig. 13) using an appropriate filter wrench.
l
Clean the sealing face on the filter carrier from any
dirt.
l
Slightly oil the rubber seal on the new filter car-
tridge.
l Fill the filter cartridge with clean diesel fuel.
Fig. 14
l Turn the new filter cartridges (Fig. 14) on by hand,
until the seal contacts.
l Tighten the filter cartridges for another half turn.
l
Check the filter cartridge for leaks after a short test
run.
248 BOMAG 008 916 41

Check, clean the water separator 6.14
6.14 Check, clean the water separa- 6.15 Check the coolant level
tor
! Danger
Danger
! Danger of scalding!
Danger of injury! Fill up coolant only when the engine is cold.
Support the engine hood for all maintenance and
repair work. ! Caution
If, during the daily inspection the coolant level is
i Note found to have dropped, check all lines, hoses and
The service intervals for the water separator depend engine for leaks.
on the water content in the fuel and can therefore not l Open the engine flap and secure it.
be determined precisely. After taking the engine into
operation you should therefore check the water sepa-
rator every day for signs of water.
If a to high quantity is drained off, the filter must be re-
filled with fuel. See chapter "maintenance as re-
quired", bleeding the fuel system.
Environment
mentally.
l
Open the access door on the right side of the vehi-
cle.
Fig. 16
l
Check the coolant level (Fig. 16).
l
Top up coolant, if necessary.
For quality of coolant refer to the chapter 5.2, fuels

and lubricants.
Fig. 15
l Slacken the drain plug (Fig. 15) for a few turns and
catch running out fuel / water.
l Tighten the drain plug again and check for leaks, if
necessary replace the seal ring.
008 916 41 BOMAG 249

6.16 Change the coolant
6.16 Change the coolant 6.17 Combustion air filter service
! Danger ! Caution
Danger of scalding! Perform cleaning, maintenance and repair work
only with the engine shut down. Do not start the
Change the coolant only when the engine is cold.
engine after removing the filter element.
Environment
Catch running out coolant and dispose of environ-
mentally.
Fig. 19
Maintenance of the dry air filter is due when control
light g (Fig. 19) lights permanently when the engine is
running.
Fig. 17
However, the filter cartridge must be replaced at the
l
Unscrew the drain plug (Fig. 17) and drain off all latest after two years.
coolant. After completion of the filter service reset the indicator
l
Turn the drain plug tightly back in. piston back to "Zero" by pressing the button.
l
Open the engine hood completely and secure it.
Removing the main filter element
Fig. 18
l Open the radiator cap (Fig. 18) and fill in coolant.
For quality of coolant refer to the chapter 5.2, fuels

Fig. 20
and lubricants.
l Loosen the strap (Fig. 20) on the combustion air fil-
l Start the diesel engine and run it warm to operating
ter.
temperature.
l Loosen both snap hooks on the housing cover and
l Let the engine cool down and check the coolant lev-
take the cover off.
el again, top up if necessary.
250 BOMAG 008 916 41

Combustion air filter service 6.17
gun up and down inside the cartridge, until it if free
of dust.
Fig. 21
l Pull the main filter element (Fig. 21) with light turn-
ing movements.
Fig. 23
l Examine the filter cartridge with a torch for cracks
Cleaning the main filter element
and holes in the paper bellows (Fig. 23).
!Caution
Caution
!
If necessary, the main filter element may be
Do not continue to run the machine with a dam-
cleaned up to five times. It must be renewed at the
aged main filter element. If in doubt use a new
latest after a maximum utilization period of two
main filter element.
years.
The number of cleaning intervals of the main filter Installing the main filter element
element can be marked on the safety element with
a ball pen or a felt pen.
l
Slide the main filter element carefully into the hous-
ing.
Cleaning does not make sense if the main filter el-
ement is covered with a sooty deposit. Use a new When closing the housing cover the main filter ele-
filter cartridge. ment is automatically forced in the correct position.
Incorrectly handled inserts may be ineffective be-
cause of damage (e.g. cracks) and cause damage Changing the safety filter element
to the engine.
Replace the safety cartridge if the main filter ele- Caution
!
ment is defective! The safety filter element must not be cleaned and
Additional cleaning intervals between two filter should not be used again after it has been re-
services signalized by the fault monitoring board moved.
are not necessary.
Break the seal only to replace the safety filter ele-
ment.
The safety filter element must be replaced:
If the main filter element is defective.
after five service intervals of the filter cartridge,
at the latest after 2 years,
if the warning light comes on again after servicing
the main filter cartridge.
l
Remove the housing cover and pull the main filter
element off.
Fig. 22
l
Blow the cartridge (Fig. 22) out with compressed air
(max. 5 bar) from inside to outside by moving the air
008 916 41 BOMAG 251

6.18 Adjusting the valve clearance
6.18 Adjusting the valve clearance
! Caution
We recommend to have this work carried out by
trained personnel or our after sales service.
Before checking the valve clearance let the engine
cool down for at least 30 minutes. The engine oil
temperature must be less than 80 °C.
After a short test run check the engine for leaks.
l Attach the cranking device over the V-belt pulley
fastening screws.
Fig. 24
l Remove the valve covers.
l Pull the safety element (Fig. 24) out by turning it
lightly.
l Crank the engine, until the valves on cylinder 1
overlap.
l Push in a new safety filter element.
l The individual cylinder positions can be taken from
l Reassemble main filter element and cover. the section "valve adjustment schematic".
Caution
! Adjusting the valve clearance
Make sure that the cover locks engage correctly.
Fig. 25
l Loosen counter nut 1 (Fig. 25).
252 BOMAG 008 916 41

Adjusting the valve clearance 6.18
Intake valve clearance adjustment in case
of exhaust gas recirculation
Fig. 26
Fig. 28
l Loosen counter nut 6 (Fig. 28).
Fig. 27
l Attach the rotation angle disc 3 (Fig. 27) and the
spanner socket (4) to the valve adjustment screw 2
(Fig. 26).
l Fix the magnet (5) of the rotation angle disc. Fig. 29
l Turn the rotation angle disc clockwise against the

stop (rocker arm no clearance) and set the scale to
zero.
l
Turn the rotation angle disc counterclockwise, until
the specified angle is reached.
Intake valve IN = 90° (0,4 mm)
Exhaust valves EX= 150° (0,6 mm)
l
Hold the rotation angle disc tight, so that it does not
turn, and tighten counter nut 1 (Fig. 25).
l Repeat this adjustment procedure an all other cylin-
ders, after cranking the crankshaft accordingly.
l Assemble the cylinder head cover with a new gas-
ket. Fig. 30
l Attach the rotation angle disc 3 (Fig. 29) with the
special spanner (8) to the valve setscrew 7 (Fig. 30)
on the intake valve.
l Fix the magnet 5 (Fig. 29) of the rotation angle disc.
l Turn the rotation angle disc 3 (Fig. 29) clockwise
against the stop (rocker arm no clearance) and set
the scale to zero.
008 916 41 BOMAG 253

6.19 Adjusting the control piston play
l Turn the rotation angle disc 3 (Fig. 29) anti-clock- 6.19 Adjusting the control piston
wise, until the specified angle is reached (90°).
play
l Hold the rotation angle disc tight, so that it does not
Caution
!
l Repeat the adjustment procedure on each intake
valve. This work must be performed after adjusting the
valve clearance.
Valve adjustment schematic l Crank the engine, until the valves on cylinder 1
overlap.
l
Firing order 1-3-4-2
l The cylinders to be adjusted can be taken from the
section "Adjustment Schematic".
Valves Cylinder
overlapping 1 3 4 2 Adjusting the control piston play
adjustment 4 2 1 3
Overlapping of valves:
Exhaust valve not yet closed,
intake valve starts to open.
! Caution
With the intake valve opened, the exhaust valve
will temporarily open for about 2 mm.
This is no valve overlap condition!
Fig. 31
l
Loosen counter nut 1 (Fig. 31).
Fig. 32
l Plug rotation angle disc and socket onto the set-
screw 2 (Fig. 32).
l Fix the magnet of the rotation angle disc.
l Turn the rotation angle disc clockwise against the
stop (rocker arm no clearance) and set the scale to
zero.
l
Turn the rotation angle disc anti-clockwise, until the
specified angle is reached.
254 BOMAG 008 916 41

Clean the cooling fins on engine and hydraulic oil cooler 6.20
l Hold the rotation angle disc tight, so that it does not 6.20 Clean the cooling fins on en-
gine and hydraulic oil cooler
l Repeat this adjustmennt procedure on each control
piston according to the crankshaft position.
Danger
!
l Assemble the cylinder head cover with a new gas-
ket. Danger of injury!
Perform cleaning work only after the engine has
Adjustment schematic cooled down and with the engine stopped.
l
Firing order 1-3-4-2
Caution
!
Do not damage any cooling fins on the cooler core

Valves Cylinder
when cleaning.
overlapping 1 3 4 2
adjustment 4 2 1 3
i Note
Overlapping of valves: Dirt on fan blades and oil cooler reduce the cooling ef-
fect. Dirt deposits in these areas are substantially sup-
Exhaust valve not yet closed,
ported by oil and fuel on these surfaces. For this
intake valve starts to open. reason you should always seal any oil or fuel leaks in
the vicinity of the cooling fan or the oil cooler and clean
! Caution the cooling surfaces after.
With the intake valve opened, the exhaust valve
will temporarily open for about 2 mm. Cleaning with compressed air
This is no valve overlap condition!
Fig. 33
i Note
Start to blow out from the exhaust side.
l Blow radiator and hydraulic oil cooler (Fig. 33) out
with compressed air.
008 916 41 BOMAG 255

6.21 Check the engine mounts
6.21 Check the engine mounts
Fig. 34
i Note Fig. 35
Start to blow out from the exhaust side. l Tighten fastenings of intake and exhaust manifolds
(Fig. 35) on the cylinder heads.
l
Blow the intercooler (Fig. 34) out with compressed
air. l Check sockets and clamps between air filter, ex-
haust turbocharger and charge air line as well as
Cleaning with cold cleansing agent the lubrication air line for tight fit and leaks.
l Retighten the fastening screws for oil sump and en-
gine mounts.
Caution
!
Protect electrical equipment such as generator,

regulator and starter against the direct water jet.
l Spray the engine with a suitable cleansing agent,
e.g. cold cleanser, let it soak in for a while and spray
it off with a strong water jet.
l Run the engine warm for a while to avoid corrosion.
256 BOMAG 008 916 41

Replacing the crank case ventilation valve 6.22
6.22 Replacing the crank case ven- 6.23 Electronic injector test EMR
tilation valve
i Note
This work must only be performed by authorized serv-
ice personnel.
Fig. 36
l Replace the crank case ventilation valve (Fig. 35).
008 916 41 BOMAG 257

6.24 Engine conservation
6.24 Engine conservation 6.25 Checking/replacing the heat-

If the engine is to be shut down for a longer period of ing generator toothed belt*
time (e.g. over winter), please consult the service de-
partment of the engine manufacturer for further de-
tails. Danger
!
Danger of injury!
Work on the toothed belt must only be performed
with the engine shut down.
Checking the toothed belt
Fig. 37
l Inspect the entire circumference of the toothed belt
(Fig. 37) visually for damage and cracks. Replace
damaged or cracked toothed belts.
l Check with thumb pressure whether the toothed
belt can be depressed between the toothed belt pul-
leys, retighten if necessary.
Tensioning the toothed belt
Fig. 38
l
Loosen the counter nut on spindle 3 (Fig. 38).
l
Turn the spindle to adjust the toothed belt tension.
Replacing the toothed belt

l Turn spindle 3 (Fig. 38) to lower the generator car-
rier.
* only with electric screed heating
258 BOMAG 008 916 41

Check, tension, replace the V-belt 6.26
l Unscrew the fastening screws (1) from the pump 6.26 Check, tension, replace the V-
flange.
belt
l Loosen the clamping screws of the bracket (2) on
both sides.
Danger
!
l Pull the pump flange away from the engine housing
to a distance of approx. 50-60 mm. Danger of accident!
l Take off the old toothed belt. Perform this work only with the engine shut down!
l Fit the new toothed belt to the toothed belt pulleys.
Check the V-belt
l
Carefully reassemble pump flange and bracket and
tighten the fastening screws with the specified
l Remove the guard.
torque.
l Tension the toothed belt as described above.
Caution
!
Check the toothed belt tension after a running

time of 30 minutes.
Fig. 39
l
Check the entire circumference of the V-belts (Fig.
39) for damage and cracks. Replace damaged or
cracked V-belts.
l
Check with thumb pressure whether the V-belt can
be depressed more than 10 to 15 mm between the
V-belt pulleys, retighten if necessary.
Tensioning the generator V-belt
Fig. 40
l Slightly slacken fastening screws 1, 2 and 3(Fig.
40).
l Turn the tensioning screw (4), until the correct V-
belt tension is achieved.
l Retighten all fastening screws.
008 916 41 BOMAG 259

6.26 Check, tension, replace the V-belt
Replacing the generator V-belt

l
Slightly slacken the fastening screws 1, 2 and 3.
l Screw in the tensioning screw (4).
l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
l Tension the V-belt as previously described.
Caution
!
Check the V-belt tension after a running time of 30

minutes.
Tightening the V-belt, coolant/fuel pump
Fig. 41
l
Slacken the fastening screws 1 and 2(Fig. 41)
slightly.
l
Press the idler pulley in direction of arrow, until the
correct V-belt tension is reached.
l
Retighten all fastening screws.
Replacing the V-belt, coolant/fuel pump

l
Take of the fan generator V-belt, see following sec-
tion.
l
Slightly slacken fastening screws 1 and 2.
l
Press the idler pulley in opposite direction to the ar-
row completely against the engine.
l
Take the old V-belt off.
l
Fit the new V-belt to the V-belt pulleys.
l
Tension the V-belt as previously described.
l
Reassemble the generator V-belt.
Caution
!
Check the V-belt tension after a running time of 30

minutes.
260 BOMAG 008 916 41

Special tools, Deutz engine (TCD 2013 2V) 6.27
6.27 Special tools, Deutz engine (TCD 2013 2V)

TCD 2013 2V Standard tools
8002
Pressure pump
Checking cooling system for leak-tightness
057 250 66
© 35409-2
8005
Compression pressure tester
for diesel engines
10 - 40 bar
057 250 67
© 35410-3
8011
Hose clip pliers
e. g. fuel return pipe
© 39426-1
008 916 41 BOMAG 261

Standard tools TCD 2013 2V
8024
Assembly pliers
Removing valve stem gaskets
057 250 68
© 37509-2
8035
Socket wrench insert
reinforced, size 22
removing and installing main bearing
© 37504-2
8113
Torx - E 14
057 250 69
© 43022-0
262 BOMAG 008 916 41


8114
Torx - E 20
© 35415-1
8115
V-belt tension measuring device
150 to 600 N 079 947 09
for checking the V-belt tension
079 947 09
© 35416-3
8189
Torx tool set
Contents of case:
079 947 01
- Double-ended ring spanner E6/E8
- Double-ended ring spanner E10/E12
Socket wrench insert E8 and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E18 (1/2 inch)
079 947 01
© 39432-1
008 916 41 BOMAG 263

8190
Rotation angle disc
with magnet
Setting valve clearance
057 250 72
© 43528-0
8191
Screwdriver insert
for slotted screw
Valve clearance setting
057 250 74
© 43060-0
8192
Bowl wrench
Fuel pre-filter (type: Racor)
057 250 73
© 43193-1
264 BOMAG 008 916 41


8193
Screwdriver insert
with pressed in hexagonal pin (5 mm),
1/2 inch, long version
(in conjunction with rotation angle disc 8190)
057 250 59
© 43183-0
8194
Screwdriver insert
with hexagon socket (size 4 mm),
1/2 inch, long version
(in conjunction with rotation angle disc 8190)
057 250 75
© 43183-0
8195
Multi-toothed screwdriver set
260 mm long
remove and install air compressor
© 43195-0
008 916 41 BOMAG 265

8196
Open end wrench adapter
Size 13,
for torque wrench
Tightening of lock nut of the valve clearance setting
screw
057 250 71
© 43019-0
8198
Pricker
Removing rotary shaft lip seal
057 250 76
© 43206-0
8199
Crowfoot wrench
Size 15
3/4 inch
(in connection with rotation angle disc 8190)
057 250 77
© 44309-0
266 BOMAG 008 916 41


9017
Assembly lever
Example: Removing and installing the valves
057 250 78
© 37511-2
9090
Spring band pliers
320 mm
tighten spring band clamp
© 35420-3
008 916 41 BOMAG 267


TCD 2013 2V Special tools
100 190
Connector
(in conjunction with compression pressure tester 8005)
057 250 79
© 42524-1
100 320
Turning gear
flywheel side
057 250 80
© 35422-1
100 330
Turning gear
V-belt pulley
Turning crankshaft on torsional vibration damper
079 947 19
© 35423-1
268 BOMAG 008 916 41

Special tools TCD 2013 2V
100 400
Dial gauge with fixing wheel
Measuring range 0 - 10 mm / 0.01 mm
057 250 81
© 35424-1
100 410
Digital gauge
Measuring range 0 - 30 mm / 0.01 mm
057 250 82
© 43205-0
100 750
Measuring device
Measuring bar with two shims
(in conjunction with 100400 and 100410)
Checking valve lag dimension
Checking piston projection
057 250 83
© 39402-1
008 916 41 BOMAG 269


103 050
Size 15
for valve clearance setting with removed exhaust return
module
(in connection with 8190)
057 250 84
© 43023-0
103 220
Special pliers
for removing the roller tappet
057 250 85
© 43010-0
110 500
Special wrench
Size 17
Removing and installing high-pressure lines
057 250 86
© 35436-1
270 BOMAG 008 916 41

110 640
Lever tool
Remove injector
© 43941-0
110 700
long
Installing and removing pressure sensors
(rail pressure, oil pressure, fuel pressure)
057 250 87
© 43198-2
110 900
Assembly case
Case for O-rings, complete with:
Disassembly tool 110 901 and three
assembly sleeves with guide:
- High pressure pump (Ø 36), 110 902
- Injector, 2V motor (Ø 16), 110 903
- Injector, 4V motor (Ø 23), 110 904
Removing and installing O-rings
057 250 88
© 43208-0
008 916 41 BOMAG 271


120 430
Assembly tool
Removing and installing the glow plugs
057 250 89
© 43020-0
120 680
Puller
(in conjunction with slide hammer 150 800)
Removing fixed injector sealing ring
© 35437-1
120 900
Support bracket
pivoting
Clamping cylinder head
057 250 90
© 35438-3
272 BOMAG 008 916 41

120 910
Base plate
(in conjunction with support bracket 120 900 if support
bracket is not screwed tightly)
057 250 91
© 35439-3
121 330
Assembly lever
Removing and installing the valves
© 43185-0
121 420
Assembly sleeves
Set of assembly sleeves for valve stem gasket
057 250 93
© 43210-0
008 916 41 BOMAG 273


130 300
Universal piston ring pliers
Removing and installing the piston rings
057 250 94
© 43021-0
130 420
Trapezoidal groove wear gauge
Piston diameter 108 mm
© 36461-2
130 640
Piston ring compressor
Piston diameter 108 mm
© 39408-1
274 BOMAG 008 916 41

142 810
Assembly tool
Installing crankshaft sealing ring
(flywheel side)
© 35446-1
142 820
Assembly tool
Installing crankshaft sealing ring
(opposite side to flywheel)
© 35445-1
150 170
Puller, universal
Comprising traverse, support and threaded rod
(in conjunction with disc 150 171)
Removing cylinder liner
© 43207-0
008 916 41 BOMAG 275


150 171
Plate
(in conjunction with puller 150 170)
for liner diameter: 108 mm
Removing cylinder liner
© 43204-0
150 180
Liner holder
(Set comprises 7 holders)
Turning crankshaft with cylinder head removed
© 43181-0
150 190
Assembly lever
Lever with bolts
(in conjunction with disc 150 191)
Installing cylinder liner
© 43209-2
276 BOMAG 008 916 41

150 191
Washer
(in conjunction with assembly tool 150 190)
for liner diameter: 108 mm
Installing cylinder liner
© 43203-2
079 947 18
150 800
Slide hammer
(in conjunction with puller 120 680)
Removing injector sealing ring
079 947 18
© 35449-2
170 050
Special wrench
Unscrewing the filter cartridges
079 947 28
© 37629-2
008 916 41 BOMAG 277


170 160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system
079 947 29
© 43663-0
6066
Assembly block
Engine clamping, double-sided
079 947 30
© 35451-2
6066/158
Clamping bracket
consisting of:
1 holder 6066/158-1 rear right,
1 holder 6066/158-2 rear left,
1 holder 6066/158-3 front right,
1 holder 6066/158-4 front left
(in connection with assembly block 6066)
Clamping of the engine, double-sided
079 947 31
© 35452-1
278 BOMAG 008 916 41

6068
Engine lifting device
Version for commercial vehicles with worm gear, ulti-
mate load (2t), 3-point suspension, spindle clamp,
traverse, chains and hooks
© 43184-0
6692
Slotted nut wrench
Cable plug
© 43199-0
008 916 41 BOMAG 279

280 BOMAG 008 916 41

7 Service Training Hydraulics
008 916 41 BOMAG 281

7.1 General
Foreword
7.1 General
These training documents were prepared for the road finisher series BF 600 C. It shall help the service engineer
to perform trouble shooting in the most effective way and to carry out any necessary repairs and adjustment
work.
The road finisher BF 600 C is especially characterized by its simple operation, power, reliability and efficiency.
Its robust design, the high material throughput, the variable paving width and its maximum tractive power make
this machine first choice for large construction projects.
This documentation is by no means complete. Technical data and machine details that may have changed since
the date of issue of the documentation must be updated by the corresponding trained while preparing the training
course.
The chapter “Documentation” contains notes on further documents, which are additionally available for this ma-
chine.
Documentation
For the BOMAG machine described in this manual the following documentation is additionally available:
Caution
!
The currently valid part numbers for the documents can be taken from the Doclist or the Customer Serv-
ice page in the BOMAG Intranet or Extranet (BOMAG Secured Area) in accordance with the serial
number of the machine.
l Operating and maintenance instructions
l Spare parts catalogue
l Wiring diagram
l Hydraulic diagram
l Service Manual
l Service Information
General
The road finisher BF 600 C is a heavy-duty machine for applications in asphalt construction.
The BOMAG road finishers "BF" of this series 600 C are powered by water cooled Deutz diesel engines of series
TCD 2013 L04 V2 Tier 3.
The travel, conveyor screw and gear pumps, which are directly driven by the engine, transfer the output power
of the engine via hydrostatic circuits to travel drive, vibration motors for tampers and screeds, conveyor screw
and scraper chain motors, fan motor and various adjusting units. This type of drive ensures lowest possible pow-
er losses and high efficiency and reliability of the machine. The drives for tamping, vibration, scraper chain ad-
justment and fan motor are solely supplied by gear pumps.
The machines are equipped with a crawler track assembly, which is driven by two axial piston drive motors with
drive gear. The track tension is controlled by two hydraulic cylinders, which are supplied by the scraper chain
pump with constant pressure and controlled in parallel mode.
When the engine is started and the brake releasing valve is actuated, the spring loaded multi-disc holding brakes
in the travel gears are release by the hydraulic oil pressure generated by the scraper chain pump. With the brake
releasing valve not actuated and when the engine is shut down, the spring loaded multi-disc holding brakes will
be automatically closed by the decreasing hydraulic oil pressure and the integrated spring loaded discs.
The functions of the hopper side wall adjustment, the screed lock and the screw height adjustment have been
realized in form of a series connection with a gear pump and integrated control valve. The valves for drawing
point adjustment and screed up/down as well as load control system for screed (L.S.C.) and crown adjustment
are also driven by gear pumps.
Lifting/lowering the screed is accomplished by two hydraulic cylinders connected in parallel mode at the rear
ends of both side arms. These control cylinders lift/lower or release the screed. In order to be able to adjust the
draw point of the screed, hydraulic cylinders are mounted to the front ends of both side arms. These can be con-
trolled individually, so that the screed setting can be adapted individually to each paving application.
For transporting the machine, the screed is equipped with a hydraulically controllable interlock, which ensures
mechanical locking of the screed. 
282 BOMAG 008 916 41

General 7.1
The hopper side walls are opened and closed by two independently controlled hydraulic cylinders. These are
fastened in the middle of each outer hopper side wall, so that torsional distorting forces are voided. The two
scraper belts installed in longitudinal direction of the vehicle as well as the two conveyor screws at the rear end
of the vehicle are independently driven each by an hydraulic motor and chain drive. By construction these chain
drives are separated from the paving material to avoid excessive wear by dirt.
In order to be able to guarantee uniform distribution of paving material in front of the screed, both conveyor
screws can be adjusted in height.
Both mobile screeds are hydraulically adjusted via the gear pump for the left hand scraper chain drive.
The vibration and tamper motors of screed/mobile screeds are both driven in parallel by a gear pump, whereby
the vibration and tamper motors of the screed are additionally connected by a universal shaft. This ensures syn-
chronous amplitudes and prevents uncontrolled resonance vibrations of the screed.
The fan motors are driven by engine mounted gear pumps. The gear pump also has the function of a hydraulic
oil circulation pump, which pumps the hot hydraulic oil to the oil cooler and subsequently to the hydraulic oil fil-
ters.
The function and design of travel, adjustment, vibration, conveyor screw, scraper chain and fan drive are de-
scribed in the corresponding following chapters in detail.
008 916 41 BOMAG 283

7.2 Travel system
Travel system
7.2 Travel system
On the machine described in this documentation the travel system works with a closed hydraulic circuit, i.e. the
hydraulic oil remains in the pressure lines and circulates permanently between travel pump and travel motor.
The system is driven by a diesel engine, the output of which is transferred to the attached pumps (e.g. travel
pumps and gear pumps)(Fig. 42).
The most essential components of the travel system are

the two travel pumps with integrated safety elements,
a brake releasing valve,
the gear pumps to release the brakes and to tension the crawler tracks,
the travel motors with integrated safety elements,
and
the travel gears with integrated brakes.
284 BOMAG 008 916 41

Travel system 7.2
Fig. 42 Travel drive - excerpt from hydraulic diagram
008 916 41 BOMAG 285

7.2 Travel system
1 Brake releasing valve 7 Travel motor, right

2 Travel pumps 8 Electric-hydraulic two-point control, travel motor
right
3 Diesel engine 9 Electric-hydraulic two-point control, travel motor
left
4 10 Travel motor, left
5 11 Travel gear, left
6 Travel gear, right 12 Valve block crawler track tensioning
The travel pumps, which are linked to a tandem unit, have the function of supplying the complete travel drive
with hydraulic oil.
The hydraulic oil is filtered by a charge pressure filter, which is fitted with an electric blockage monitoring facility
and is hydraulically installed direftly after the charge pumps for the charge oil circuit. The charge circuit also sup-
plies the closed circuits with cool and filtered hydraulic oil to compensate for leakage and flushing quantities.
The gear pump at the auxiliary output of the engine is used for the brake releasing valve to release the hydrau-
lically released spring accumulator multi-disc brakes and for the valve block for tensioning the crawler tracks.
The two travel motors are both flanged to a travel gear and can be switched between a fast speed range (low
torque) and a slow speed range (high torque). Moreover, the travel motors are each hydraulically connected with
an independently controllable travel pump and can thereby initiate travel movements and direction changes.
Brake circuit and valve block for crawler track tensioning

When the travel/working speed is returned towards neutral position or the travel direction is changed, the dis-
placement of both or one travel pump is adjusted towards zero accordingly and the machine is hydraulically
braked.
To avoid creeping movements of the machine, the machine is additionally equipped with spring accumulator
multi-disc parking brakes in the travel gears. These close in neutral position of the travel lever and when the
machine is stopped.
The spring accumulator multi-disc parking brake and the valve block for tensioning the crawler tracks are con-
trolled via an electrically actuated 4/2-way solenoid valve (see section "Brake circuit"). In de-energized state the
hydraulic oil supply from the gear pump to the brake pistons and to the valve block for crawler track tensioning
is interrupted, so that the oil flows through the 4/2-way solenoid valve directly back into the hydraulic oil tank.
With the 4/2--way solenoid valve operated the spring accumulator multi-disc parking brake is released yb the
applied hydraulic pressure and travel movements are possible. The hydraulic oil (brake releasing pressure) is
also guided to the valve block for crawler track tensioning, which ensures automatic tensioning of the crawler
track, while the integrated shock valves protect the hydraulic system against overloads.
Travel pumps
Both rotor pumps are linked to a tandem unit.
Two swash plate operated axial piston pumps with variable displacement from Sauer Danfoss , type 90R42-
KA57 serve as travel pumps.
The pumps are equipped with all control and safety elements needed for operation in a closed hydraulic circuit.
These are:
l Charge pressure relief valve (2/(Fig. 43)),
l servo control with electric control via 4/3-way proportional valve (3),
l variable displacement pump with control cylinder (5),
l
charge pump (6),
l
multi-function valves (7)
and a
l charge pressure filter (1).
286 BOMAG 008 916 41

Travel system 7.2
Fig. 43 Travel pumps - excerpt from hydraulic diagram
1 Charge pressure filter 5 Variable displacement pump

2 Charge pressure relief valve 6 Charge pump
3 Servo control (4/3-way proportional valve) 7 Multi-function valves
4 Diesel engine
008 916 41 BOMAG 287

7.2 Travel system
Fig. 44 Sectional view of travel pump (vertical)
1 High pressure port 10 Lateral swash plate guidance

2 Swashing lever hold-down 11 Lateral swash plate guidance
3 Sliding block 12 Swash plate
4 Control piston 13 Swash plate reset
5 Swashing lever 14 Cylinder block
6 Slipper pad 15 Working pistons
7 Servo valve (4/3-way proportional valve) 16 End housing
8 Recirculation 17 Charge pump
9 Swash plate bearing
288 BOMAG 008 916 41

Travel system 7.2
Travel pump control unit
The travel pump control unit is an integral part of the pump housing and consists mainly of:
l Electro-hydraulic servo valve (7/(Fig. 44)) or (1/(Fig. 45)) with 4/3-proportional solenoid valve.
l swashing lever (5/ (Fig. 44))
l control piston (4)
l swash plate (12)
l swash plate bearing (9)
l
swash plate reset (13).
Fig. 45 Cross-sectional drawing of travel pump control
1 Servo valve (4/3-way proportional valve) 2 Pilot control valve
Function and design

The pilot valve (2/(Fig. 45)) of the travel pump converts the electric input signal of the travel control into a hy-
draulic signal and thus controls the servo valve (4/3-way proportional valve) (1) accordingly. In compliance with
the input signal the servo valve opens or closes the charge circuit to one side of the double-acting control piston
(4/(Fig. 44)), which then moves due to the pressure application on one side.
The resulting displacement of the swash plate (12/(Fig. 44)) or (5/(Fig. 46)) triggers the movement of the working
pistons (15/(Fig. 44)) or (3/(Fig. 46)) inside the cylinder block (14/(Fig. 44)) or (2/(Fig. 46)). During this axial
movements hydraulic oil is drawn in from the low pressure side through the valve plate, pressurized by the up-
wards movement of the piston inside the closed cylinder and discharged into the high pressure side through the
high pressure port (1/(Fig. 44)) to the travel motors.
Once the control piston has reached the position that is determined by the input signal, the travel pump displace-
ment will remain at a constant level. If the input signal is changed, e.g. by reversing the travel direction, the con-
trol elements will be repositioned through the neutral position, whereby the flow direction of the hydraulic oil will
change.
The hydraulic oil from the opposite control chamber flows directly back into the hydraulic oil tank, together with
the leakage oil.
Since the travel pump control is spring centred, the swash plate will automatically return to neutral position when
the engine is shut down or in case of a pressure drop in the charge circuit.
As a measure to prevent metal to metal contact between the slipper pads (6/(Fig. 44)) or (4/(Fig. 46)) and the
swash plate, all working pistons are bored through their entire length. The hydraulic oil flowing through these
bore holes generates a hydrostatically balanced field on which the slipper pads can glide without having metal
to metal contact with the swash plate.
008 916 41 BOMAG 289

7.2 Travel system
When operating the travel lever pressure builds up in the hydraulic lines between travel pump outlet and travel
motor inlet, which is dependent on the load applied to the travel motors. This pressure keeps the boost check
valve inside the multi-function valve (1 or 8/(Fig. 46)) in closed position.
In order to be able to operate and control the travel system at all, the travel pump is equipped with a pump shaft
driven charge pump (17/(Fig. 44)) or (10/(Fig. 46)). The hydraulic oil supplied by the charge pump serves the
positive pressure supply of the travel circuit, the control of the travel pump, the supply of cool and filtered hy-
draulic oil and the compensation of leakages and flushing quantities. Due to the system design these leakages
and flushing quantities can be replenished in the low pressure side of the closed hydraulic system, through the
boost check valve, which is part of the multi-function valve.
The multi-function valve limits possibly occurring extreme pressure peaks to the setting of the valve. When these
valves react, hydraulic oil flows out of the high pressure side and re-enters into the low pressure side.
Since the cross-sections of these valves are very small and the hydraulic oil enters the low pressure side already
inside the travel pump, the system would very quickly overheat if the pressure in the system would be perma-
nently relieved via the multi-function valves. For this reason the travel pump is equipped with an additional pres-
sure override valve, which cuts off the control oil flow to the control piston. This regulates the displacement of
the travel pump to the value determined by the pressure override.
If the pressure drops again, the pressure override valve will open and the travel pump can swash back to the
previously chosen position. This design prevents overheating of the multi-function valves and thus of the entire
hydraulic system as well as overloading of the engine.
The bypass function (4) in the multi-function valve enables free circulation of the hydraulic oil, which may be
needed when having to tow the machine. Opening of the bypass valve thereby causes a closed hydraulic circuit
which bypasses the travel pump, but directly connects both pressure lines.
Fig. 46 Sectional view of travel pump (horizontal)
1 Multi-function valve 6 Drive shaft

2 Cylinder block 7 Valve plate
3 Working pistons 8 Multi-function valve
4 Slipper pad 9 End housing
5 Swash plate 10 Charge pump
290 BOMAG 008 916 41

Travel system 7.2
Charge pump
The charge pump (1/(Fig. 47)), which is integrated in the travel pump case, is a fixed displacement pump, which
always delivers the same oil volume per revolution.
Fig. 47 Charge pump - detail from hydraulic diagram
1 Charge pump
The pump is driven by the engine via coupler gear and pump shaft of the corresponding travel pump.
The charge pump supplies the servo control of the variable displacement pump with the required amount of hy-
draulic oil through the charge pressure relief valve (see section "Charge pressure relief valve") and the charge
pressure filter (see section "Charge pressure filter").
Furthermore, the hydraulic arrangement of the multi-function valves (see section "Multi-function valve") makes
sure that the travel circuit is supplied with cool and filtered hydraulic oil.
The boost check valves open to the low pressure side and let cool and filtered oil flow from the charge oil circuit
into the closed hydraulic circuit, in order to compensate leaks and flushing quantities.
Charge pressure relief valve

The charge pressure relief valve (1/(Fig. 48)) is a direct acting pressure relief valve with a fixed setting.
008 916 41 BOMAG 291

7.2 Travel system
Fig. 48 Charge pressure relief valve - excerpt from hydraulic diagram
1 Charge pressure relief valve
It has the function of limiting the fed flow volume to the value set by the valve and to direct any excess oil to the
hydraulic oil tank.
In order to be able to compensate for leak oil and flushing quantities in the closed hydraulic circuit, the hydraulic
pressure in the low pressure side is identical with the charge pressure.
Charge pressure filter

The charge pressure filter (1/(Fig. 49)) is mounted to the engine with a vibration dampened angle bracket. It has
the function to clean the charge oil for the auger pump from contamination.
Fig. 49 Charge pressure filter - detail from hydraulic diagram
1 Charge pressure filter 3 Filter element

2 Bypass valve
Function and design

Due to the pressure drop in the hydraulic circuit caused by filtration, the charge pressure filter is installed as close
as possible after the pump.
For safety reasons the charge pressure filter is equipped with a bypass valve (2), so that all machine functions
can be maintained using unfiltered charge oil, if the filter is blocked. In this case the higher charge pressure will
open the bypass valve against spring pressure, allowing the oil to flow past the filter element (3).
The condition of the charge pressure filter is electrically monitored by a sensor on the filter housing. In case of
blockage the display and control elements on the
operatorsstandwillindicatethatthechargepressurefilterneedstobecheckedandreplaced.'
292 BOMAG 008 916 41

Travel system 7.2
Multi-function valve
The travel pump is protected by two multi-function valves (1/(Fig. 50)) each with an integrated zero-flow control
(2), high pressure relief valve (3), boost check valve (4) and a bypass function (5).
Fig. 50 Multi-function valve - detail from hydraulic diagram
1 Multi-function valve 4 Boost check valve

2 Zero-flow control 5 bypass
3 High pressure relief valve
Once the maximum system pressure in the travel circuit set by the multi-function valve (1/(Fig. 51)) is reached,
the zero-flow control (5) overrides the signal of the displacement control, so that the returning swash plate limits
the system pressure accordingly (see section "Travel pumps").
In case of a exceptionally rapid pressure increase in the travel circuit the integrated high pressure relief valve
(2) will immediately limit the system pressure by connecting the high pressure side to the low pressure side of
the travel circuit. Cutting off the hydraulic pressure protects the hydraulic system, the engine and all other com-
ponents of the machine against overloads.
The boost check valve (3) in the corresponding low pressure side compensates for leak oil and oil quantities
flushed out of the travel circuit. The boost check valve connects the charge circuit with the low pressure side,
because the hydraulic pressures in low pressure side and charge circuit are identical, so that hydraulic oil can
flow into the closed travel circuit.
The bypass valve (4), which is also integrated in the multi-function valve, enables free circulation of the hydraulic
oil, which is required, e.g. when towing the machine. Opening the bypass valve directly connects both pressure
lines, making sure that the oil flow bypasses the travel pump and only circulates to the consumer.
008 916 41 BOMAG 293

7.2 Travel system
Fig. 51 Cross-sectional view Multi-function valve
1 Multi-function valve 4 bypass

2 High pressure relief valve 5 Zero-flow control
3 Boost check valve
Travel motors
Unit of travel motor and travel gear
The travel motors (6 and 11/(Fig. 52)) are variable displacement axial piston motors from Sauer Danfoss, type
51C60, which are each flange-mounted to a travel gear.
294 BOMAG 008 916 41

Travel system 7.2
from the
Gear pump
for crawler track tensioning
Fig. 52 Travel motors - excerpt from hydraulic diagram
1 Brake releasing valve 8 Electric-hydraulic two-point control, right

2 Pressure relief valve 9 Electric-hydraulic two-point control, left
3 Travel gear, right 10 Charge pressure relief valve, left
4 Variable displacement motor, right 11 Travel motor, left
5 Control piston, right 12 Control piston, left
6 Travel motor, right 13 Variable displacement motor, left
7 Charge pressure relief valve, right 14 Travel gear, left
Function and design

The travel motor is connected with the corresponding travel pump via the high pressure ports A and B (see sec-
tion "Travel pumps"). Hydraulic oil flows under high pressure through the adjustable valve segment (2/(Fig. 53))
and the bearing plate (3) to the back of the working pistons (10), which are moving away from dead centre po-
sition. The inflowing hydraulic oil moves the working piston in the cylinder block (14) towards the upper dead
centre and thus converts the stoke movement (axial movement) into a rotary movement of the drive shaft (8).
Since the angle of the cylinder block to the drive shaft can be changed via the electric hydraulic two-point control
(8 or 9) to two different positions, the piston strokes of the working pistons are of different length, depending on
the angle. With a large angle (as shown in (Fig. 53)) the motor works with maximum stroke length (max. dis-
placement), which in turn results in a slow rotary speed but with a high torque. With a smaller angle the motor
works with a shorter stroke length (min. displacement), which in turn results in a fast rotary speed but with a low
torque.
Once the respective working piston (4) has reached its lower dead centre, the slot in the valve plate takes it over
to the low pressure side . The pressurized working pistons on the high pressure side now move this particular
working piston back to its top dead centre. This stroke pumps the hydraulic oil out of the cylinder room back to
the travel pump.
008 916 41 BOMAG 295

7.2 Travel system
The synchronizing shaft (5) ensures uniform rotation of output shaft and cylinder block. The ball joints of the
working pistons run in journal bearings, which are pressed into the outer shaft by two tapered roller bearings (7).
The flushing pressure relief valve (12) flushes hydraulic oil out of the low pressure side into the motor housing
to cool the high pressure circuit and to remove contaminants from the circuit. The flushing pressure relief valve
limits the flushing pressure to 16 bar, so that it does not fall below the charge pressure of 16 bar.
Fig. 53 Sectional view of travel motor
1 Setting of swashing angle 8 Output shaft

2 Valve segment 9 RPM-sensor
3 Bearing plate 10 Working piston (moving towards the top dead
centre)
4 Working piston (moving towards the bottom 11 Electric-hydraulic two-point control
dead centre)
5 Synchronizing joint 12 Flushing pressure relief valve
6 Magnetic ring for rotary speed detection 13 Control piston
7 Taper roller bearing 14 Cylinder block
296 BOMAG 008 916 41

Travel system 7.2
Flushing pressure relief valve
The flushing pressure relief valve (1/(Fig. 54)) is integrated into the housing of the travel motor. In case of a pres-
sure increase in one of the two sides of the closed circuit the flushing valve has the function to flush a certain
quantity of oil out of the low pressure side.
Fig. 54 Flushing pressure relief valves - detail from hydraulic diagram
1 Flushing pressure relief valve 3 3/3-way valve (spring centred)

Function and design

The flushing pressure relief valve (1/(Fig. 55)) is operated by the pressure differential between high and low
pressure side. The generated hydraulic pressure firces the 3/3-way valve (3/(Fig. 54)) out of neutral position
against the neutral setting spring and thereby opens the low pressure side.
Hydraulic oil now flows from the low pressure side through the pressure relief valve (2) back to the tank. The oil
quantity flushed out of the closed circuit is immediately replaced by oil entering from the charge circuit through
the corresponding boost check valve (see section "Multi-function valve").
In this way the closed travel circuit is permanently supplied with cool and filtered oil and the temperature house-
hold of the hydraulic system is maintained at a permissible level.
008 916 41 BOMAG 297

7.2 Travel system
Fig. 55 Flushing pressure relief valve - sectional drawing
1 Flushing pressure relief valve 2 Flushing spool
Travel gear
The travel gears are planetary gears for mobile equipment made by Bonfiglioli, type 707 C3B, which are each
driven by a flange mounted travel motor (see section "Travel motors").
Function and design

The housing side of the travel gear is rigidly connected with the crawler track drive via a flange. The travel motor
is also flanged with its housing side to the travel gear and meshes directly with the drive shaft.
A second flange on the bearing axle side carries a gear, which engages in the crawler track.
The drive shaft transfers the travel motor torque via an external gearing to the spur wheel of the planet gear set.
The rotation is transferred from the spur wheel via the sun gear to the planet gears, which are rotably mounted
in tapered roller bearings on the bearing axle. The hollow wheel, which is fixed on the housing, transfers the
rotation of the planet gears to the crawler track gear with a fixed ratio.
The drive shaft also carries the hydraulically released spring accumulator multi-disc parking brake, which is sup-
plied with pressurized hydraulic oil from the gear pump, when the brake releasing valve is operated. This hy-
draulic oil pressure works against the discs of the parking brake and releases the drive shaft for travel
movements. When the brake releasing valve returns to idle position, the dropping hydraulic oil pressure and the
spring force will automatically close the spring accumulator multi-disc parking brake, so that no travel move-
ments of the travel motors and no undesired creeping movements of the machine are possible.
298 BOMAG 008 916 41

Travel system 7.2
Fig. 56 Travel gear, left hand side
Brake circuit
The brake circuit mainly consists of a brake releasing valve (1/(Fig. 57)) and a parallel connected pressure relief
valve (3), which controls the function of the spring accumulator multi-disc parking brakes in both travel gears.
008 916 41 BOMAG 299

7.2 Travel system
from the
gear pump
40
Brake and
Chain tension Brake
Fig. 57 Brake circuit - excerpt from hydraulic diagram
1 Pressure switch 4 Hydraulic oil tank

2 Pressure gauge 5 4/2-way solenoid valve (brake releasing valve)
Function and design

With the 4/2-way solenoid valve (5) not actuated and when the engine is shut down, the parking brakes (see
section "Travel gears") are automatically closed by the spring loaded disc packages, so that the machine is no
longer able to drive or to creep. In this case the hydraulic oil supplied by the scraper chain pump (see section
"Scraper chain drive") is guided through the 4/2-way solenoid valve back to the hydraulic oil tank (4), together
with the hydraulic oil from the spring accumulator multi-disc brakes.
With the 4/2-way solenoid valve actuated the spring force of the parking brake is overcome by the hydraulic oil
pressure generated by the scraper chain pump, so that the brake discs are forced apart against the spring pres-
sure, releasing the drive shaft for travel movements (see section "Travel motors"). The pressure relief valve (3)
upstream of the 4/2-way solenoid valve limits the permissible hydraulic oil pressure by discharging excess hy-
draulic oil through the travel motor housing back into the hydraulic oil tank when the adjusted value is exceeded.
This makes sure that both the entire brake system and the connected hydraulic system for track tensioning (see
section "Valve block track tensioner") are limited to a constant hydraulic pressure.
The pressure switch (1), which is also installed after the 4/2-way solenoid valve, is actuated by hydraulic oil pres-
sure and transmits the corresponding switching state to the vehicle control in form of an electric signal.
300 BOMAG 008 916 41

Travel system 7.2
Brake valve and solenoid valve for crawler tracks
Fig. 58 Detail from hydraulic diagram
5
4
Fig. 59 Brake valve and solenoid valve for crawler tracks
1 Valve block for crawler tracks 4 Brake valve

2 Pressure test port, crawler track right 5 Pressure switch
008 916 41 BOMAG 301

7.2 Travel system
Brake pressure gauge
Fig. 60 Pressure gauge
Valve block for track tensioning
302 BOMAG 008 916 41

Travel system 7.2
Fig. 61 Valve block for track tensioning - detail from hydraulic diagram
1 Tensioning cylinder
2 Check valves
3 Pressure relief valves
Function and design

The valve block for track tensioning is controlled via a 4/2-way solenoid valve (brake releasing valve, see section
"Brake circuit"). Only by operating the 4/2-way solenoid valve, the valve block for track tensioning is supplied
with hydraulic oil from the scraper chain pump.
Due to the function of the two fixed pressure relief valves (3/(Fig. 61)) the valve block keeps the tracks under a
constant pressure level via one tensioning cylinder (1) per track drive, and thus provides a track tensioning fa-
cility with automatic readjustment.
The so-called "Shock limitation" prevents sudden pressure shocks in the hydraulic oil circuit, which may be
caused by external influences. In this case the two check valves (2) prevent hydraulic oil from being forced back
into the hydraulic circuit, but direct it through the pressure relief valves back into the hydraulic oil tank. Moreover,
the two check valves have the additional effect that the track tension is maintained after the machine has been
switched off.
008 916 41 BOMAG 303

7.2 Travel system
Test and adjustment points

Travel pump, tandem unit with gear pump on through-drive side
Diesel engine
Fig. 62 Travel pump, excerpt from hydraulic diagram
2
1
Fig. 63 Travel pump, tandem pump bottom view
Pos Designation Position in hy- Position in wir- Measuring values

draulic diagram ing diagram and switching points
1 Travel pump for travel drive, right hand side 3
2 Travel pump for travel drive, left hand side 4
304 BOMAG 008 916 41

Travel system 7.2
Pressure test ports, travel pump for travel drive right hand side
2
Fig. 64 Pressure test port high pressure, travel pump for travel lever right hand side
Pressure test ports, travel pump for travel lever left hand side
Fig. 65 Pressure test port high pressure, travel pump for travel drive left hand side

1 Pressure test port, high pressure - right hand 3- M1 Pressure override
side, forward-reverse 410bar, HP 440bar
2 Pressure test port, high pressure - right hand 3- M2 Pressure override
3 Pressure test port, high pressure - left hand 4- M1 Pressure override
4 Pressure test port, high pressure - left hand 4- M2 Pressure override
008 916 41 BOMAG 305

7.2 Travel system
Charge pressure test port on travel pump
Fig. 66 Travel pump, excerpt from hydraulic diagram
Fig. 67 Charge pressure test port on travel pump

1 Pressure test port, charge pressure 4- M3 25 bar
306 BOMAG 008 916 41

Travel system 7.2
Travel pump control control, proportional valve
Fig. 68 Proportional control
Fig. 69 Travel drive - excerpt from wiring diagram
008 916 41 BOMAG 307

7.2 Travel system
Charge pressure filter and travel pump
Fig. 70 Pressure test port M2 - excerpt from hydraulic diagram

1 Cahreg pressure filter 25
2 Different.pressure switch - charge pressure fil- 25 C15, C22,
ter Page 20
308 BOMAG 008 916 41

Travel system 7.2
Pressure gauge for brake releasing valve
Fig. 71 Pressure gauge for brake releasing valve - excerpt from hydraulic diagram
Fig. 72 Pressure gauge - brake releasing valve
1 Pressure relief valve 4 4/2-way brake solenoid valve

2 Brake pressure gauge (160 bar)High pressure 3 Floor flap, operator's stand
gauge (160 bar)
008 916 41 BOMAG 309

7.2 Travel system
Valve block for crawler tracks
5
4
Fig. 74 Valve block for crawler tracks
1 Valve block for crawler tracks 4 Brake valve

2 Pressure test port, crawler track right 5 Pressure switch
310 BOMAG 008 916 41

Travel system 7.2
Brake pressure gauge
Fig. 75 Pressure gauge
008 916 41 BOMAG 311

7.2 Travel system
Adjustment points on travel pumps
Fig. 76 Adjustment points on travel pumps - excerpt from hydraulic diagram
1 Pressure test port for control pressure (M4 and 6 Adjusting screw for mechanical neutral position
M5), travel pump right of travel pump, right
2 Pressure test port for control pressure (M4 and 7 Charge pressure relief valve, travel pump right
M5), travel pump left
3 Multifunction valve (B), travel pump, left 8 Adjusting screw for mechanical neutral position
of travel pump, left
4 Multifunction valve (A), travel pump, left 9 Multifunction valve (A), travel pump, right
5 Multifunction valve (B), travel pump, right 10 Charge pressure relief valve, travel pump left
312 BOMAG 008 916 41

Actuator drive 7.3
Actuator drive
7.3 Actuator drive
Unlike the travel drive, the actuator drive is an open hydraulic circuit, i.e. the gear pump (10) draws hydraulic oil
from the hydraulic oil tank, delivers it to the consumers and subsequently through the cooler back to the tank.
The essential components are gear pump (10/(Fig. 77)), service block (12), levelling block (14), load control sys-
tem for the screed (L.C.S.) (1), crown adjustment, option (13), screed up/down (2), draw point adjustment
screed right (3) and left (4), hopper side wall adjustment right (6) and left (5), screed interlock (7) and screw
height adjustment (8).
10
9
12
11
Fig. 77 Actuation - excerpt from hydraulic diagram
008 916 41 BOMAG 313

7.3 Actuator drive
1 Load control system screed (L.S.C.) 8 Screw height adjustment

2 Screed up/down 9 Diesel engine
3 Draw point adjustment screed right 10 Gear pump
4 Draw point adjustment screed left 11 Volume flow distribution
5 Hopper side wall adjustment, left 12 Service block
6 Hopper side wall adjustment, right 13 Crown adjustment
7 Screed interlock 14 Levelling block
The outer gear pump of the tandem pump unit serves the hydraulic oil supply for the actuator circuit with service
and levelling blocks.
A flow divider at the inlet of the service block divides the volume flow and thus enables parallel operation of serv-
ice and levelling block.
A pressure relief valve with fixed setting protects the service block against overpressure. The functions of hopper
side wall, right and left, screed interlock as well as screw height adjustment can be electrically controlled via a
4/3-way solenoid valve. Both the screed interlock and the screw height adjustment are equipped with an addi-
tional locking valve in the hydraulic supply and return lines, whereby the screed and the screws can be held in
fixed position.
A flow divider in the levelling block in turn divides the hydraulic oil flow for load control system screed (L.C.S.),
screed up/down as well as draw point and crown adjustment. The functions for screed up/down, draw point ad-
justment right and left as well as the crown adjustment can be electrically controlled via a 4/3-way solenoid valve.
To be able to hold the set position for height and draw point adjustment as well as crown adjustment, the supply
and return lines are equipped with unlockable locking valves.
Lifting/lowering the screed is accomplished by two hydraulic cylinders at the rear ends of both side arms. These
control cylinders lift/lower or release the screed by means of the screed load control system (L.C.S.) intervening
in the hydraulic circuit. This combination enables floating operation when paving asphalt, with the machine
stopped during asphalt application as well as relieving or locking the screed to avoid flatness faults caused by
uncontrolled lowering.
The draw point adjustment for the screed is accomplished by two independently adjustable adjusting cylinders
mounted to the front ends of both side arms. These adjusting cylinders control the floating behaviour of the
screed or the thickness of the paved material.
The crown adjustment enables individual adjustment of the screed with respect to the mobile screeds as re-
quired for the "transverse profile" of the finished road. By well directed adjustment of the screed and changing
the lateral inclination angle of the mobile screeds you can e.g. adjust a W-profile or a lateral inclination of the
carriageway.
Service block
Control with solenoid valves in an open circuit
The service block (18/(Fig. 78)) is a valve block made up of five 4/3-way solenoid valves in series connection in
an open hydraulic circuit..
314 BOMAG 008 916 41

Actuator drive 7.3
to the
levelling block
7
Fig. 78 Service block - excerpt from hydraulic diagram
1 Diesel engine 48 Check valves, unlockable (locking block)

7 Gear pump 18 Service block
37 Adjusting cylinders for screw height adjustment 19 Volume flow and pressure relief valve
and
33
40 Adjusting cylinder hopper wall adjustment, right 26 Pressure relief valve, retraction of screed
and left
55 4/3-way solenoid valve, adjusting cylinder for 62 Screed adjustment, extension/retraction
screw height adjustment and
63
Service block
The service block is hydraulically installed between gear pump and the downstream levelling block. The con-
sumers are the adjusting cylinders for hopper side wall adjustment (4), the screed control (62 and 63) and the
screw height adjustment.
008 916 41 BOMAG 315

7.3 Actuator drive
Solenoid valve
Function and design

The 4/3-way solenoid valves mounted to the service block are solenoid operated spool valves to control the start,
stop and direction of the volume flow to the connected consumers. The spool valves mainly consist of the hosing
(2/(Fig. 79)), two magnets (5), the control piston (3) and two resetting springs (6).
If not operated the control piston (3) is retained in middle or initial position by the resetting springs (4) and thus
blocks both the high and low pressure lines.. Operation of the control piston is indicated by a lighting diode on
the corresponding connecting plug.
When the magnet is excited, the plunger (1) applies a force to the control piston, pushes it out of its resting po-
sition to the corresponding end position. The flow direction is released and the the oil volume flows into the ad-
justing cylinder and adjusts the related component.
Once the magnet is de-energized the resetting springs return the control piston back to its resting position,
whereby the volume flow is interrupted and the adjusting cylinder remains in its last position.
Besides the actual spool valve the 4/3-way solenoid valve of the screw height adjustment contains additional
unlockable check valves (48/(Fig. 78)) in high and low pressure lines. With this feature both the screed and the
screws can be permanently held in a fixed position.
Fig. 79 4/3-way solenoid valve - sectional view
1 Plunger 4 Emergency control facility

2 Housing 5 Replace the
3 Control piston 6 Resetting spring
316 BOMAG 008 916 41

Actuator drive 7.3
Service block
Fig. 80 Service block, excerpt from hydraulic diagram
008 916 41 BOMAG 317

7.3 Actuator drive
Pump for service block (7)
Fig. 81 Tandem gear pump, in hydraulic diagram no.: 7
Service block (18)
Fig. 82 Valves underneath the floor plate
318 BOMAG 008 916 41

Actuator drive 7.3
Service block
4
3
2
1
6 7
Fig. 83 Service block

1 Solenoid valve, conveyor screws, up/down 18 / 55 A19 / B19, 0 / 24 V
Page 100.2
2 Solenoid valve, screed extend/retract left 18 A16 / B16, 0 / 24 V
Page 150
3 Solenoid valve, screed extend/retract right 18 B14 / A14, 0 / 24 V
Page 150.1
4 Solenoid valve, hopper open/close right 18 A2 / B21, Page 0 / 24 V
120
5 Solenoid valve, hopper open/close left 18 A22 / B22, 0 / 24 V
Page 120
6 Pressure test port, pressure service block 18 / M1 Pressure relief valve
140 bar
7 Pressure test port, screed up 18 / M2 Pressure relief valve
180 bar
008 916 41 BOMAG 319

7.3 Actuator drive
Levelling block
Valve block
The levelling block (17/(Fig. 84)) is a valve block made up of three 4/3-way solenoid valves.
Option
Fig. 84 Levelling block - excerpt from hydraulic diagram
1 Load control system screed (L.S.C.) 9 Flow divider

2 Levelling block (17) 10 Pressure relief valve draw point adjustment
3 Adjusting cylinder for screed height 11 4/3-way solenoid valve, adjusting cylinder draw
point left
4 Check valves, adjusting cylinder draw point left 12 Pressure relief valve screed up/down
5 Adjusting cylinder draw point, left 13 Option, crown control valve
6 Adjusting cylinder draw point, right 14 4/3-way solenoid valve, adjusting cylinder
screed height
7 Check valves, adjusting cylinder draw point, 15 One-way restrictor
right
8 4/3-way solenoid valve, adjusting cylinder draw
point, right
Function and design
320 BOMAG 008 916 41

Actuator drive 7.3
The levelling block is hydraulically arranged between service block (see section "Service block") and the con-
sumers connected in series. The consumers are the screed load control system (L.C.S.), the control cylinders
for screed up/down (3), the control cylinders for the draw point adjustment (5) and (6) and the crown adjustment
(13).
The high and low pressure lines of the service block are internally connected and combined as central ports.
The 4/3-way solenoid valves (8, 11 and 14) mounted to the service block are solenoid operated spool valves to
control the start, stop and direction of the volume flow to the connected consumers. The spool valves mainly
consist of the hosing (2/(Fig. 85)), two magnets (5), the control piston (3) and two resetting springs (6).
If not operated the control piston (3) is retained in middle or initial position by the resetting springs (4) and thus
blocks both the high and low pressure lines..
Operation of the control piston is indicated by a lighting diode on the corresponding connecting plug.
When the magnet is excited, the plunger (1) applies a force to the control piston, pushes it out of its resting po-
sition to the corresponding end position. The direction of volume flow is released and the adjusting cylinder ad-
justs the element to be adjusted.
Once the magnet is de-energized the resetting springs return the control piston back to its resting position,
whereby the volume flow is interrupted and the adjusting cylinder remains in its last position.
The complete screed levelling is accomplished via one flow divider, which is installed upstream of the 4/3-way
solenoid valves. This flow divider divides the volume flows for screed up/down, screed draw point adjustment,
screed load control system (L.C.S.) and crown adjustment to allow synchronous adjustments.
Two pressure relief valves (10 and 12) are installed in the high pressure lines of the service block, downstream
from the flow divider. These cut off the hydraulic oil pressure at the value set by the valve by opening a connec-
tion to the charge circuit of the conveyor screw pump. Depending on the operating status of the crown adjusting
valve (13) the cut-off hydraulic oil is returned into the charge circuit of the conveyor screw pump, or it is further
used for crown adjustment.
With the 4/3-way solenoid valve (crown adjustment) operated, the same piston sides of both cylinders are sup-
plied with pressure through the locking valve in the high pressure side. The increasing hydraulic oil pressure
level in the high pressure line also opens the connected multi-disc brakes and thus enables adjustment of the
screed. The hydraulic oil displaced by the piston movement flows through the locking valve in the low pressure
side, which has been unlocked by the locking valve in the high pressure side, back into the charge circuit of the
conveyor screw pump. When the 4/3-way solenoid valve is returned to idle condition, the hydraulic pressure in
the high pressure line of the crown adjusting valve will drop, so that both locking valves and the multi-disc brake
will close. Both adjusting cylinders are thereby held in their current position and the screed is once again me-
chanically locked by the multi disc brake.
The load control system (L.S.C.) consists of two 2/2-way solenoid valves, each with a downstream installed
pressure relief valve with different, freely adjustable pressure ranges. The pressure reduction of one of these
pressure relief valves in "floating position" (position for aspahlt paving) a pressure level is built up in the adjusting
cylinder for screed up/down, which fully or partly compensates the basic weight of the screed.
The adjusting cylinders for screed up/down are equipped with a one-way restrictor (15) integrated in the high
pressure line of the 4/3-way solenoid valve. The throttle restricts the hydraulic oil flow to a pre-set volume, to
accommodate sensitive adjustment of the screed. The check valve has the function of permanently holding the
current position.
The 4/3-way solenoid valve of the screed draw point adjustment is additionally equipped with unlockable locking
valves (4 and 7) in high and low pressure lines. With this the adjusting cylinders for draw point can be perma-
nently held in position.
008 916 41 BOMAG 321

7.3 Actuator drive
Fig. 85 4/3-way solenoid valve - sectional view
1 Plunger 4 Emergency control facility

2 Housing 5 Replace the
3 Control piston 6 Resetting spring
322 BOMAG 008 916 41

Actuator drive 7.3
Levelling block
M1
M2
Fig. 86 Levelling block - excerpt from hydraulic diagram
008 916 41 BOMAG 323

7.3 Actuator drive
M1
M2
1 2
3
5
Fig. 88 Levelling block

1 Solenoid valve, screed height adjustment, up/ 17 / 39 A13 / B13, 0 / 24 V
down Page 170
2 Solenoid valve, screed draw point adjustment 17 / 38 A17 / B17, 0 / 24 V
left, up/down Page 150
3 Solenoid valve, screed draw point adjustment 17 / 38 B15 / A15, 0 / 24 V
right, up/down Page 160.1
4 Pressure test port, screed height adjustment 17 / M1 Pressure relief valve
175 bar
5 Pressure test port, draw point adjustment 17 / M2 Pressure relief valve
120 bar
Design and function of a gear pump

The driven gear of the actuator pump is connected with the drive shaft of the flanged on vibration and tamper
pump via the drive shaft (7). The drive force of the engine is transferred to the pump drive shafts via the coupling
gear.
The tooth flank spaces between inside wall of the pump housing and bearing plate faces form the displacement
chambers (5) for the hydraulic oil to be delivered. When the pump is running the displacement chambers trans-
port hydraulic oil from the suction side "S" to the pressure side "P". The resulting vacuum in the suction side
constantly draws in hydraulic oil from the hydraulic oil tank and the gear pump displaces it to the consumers.
The bearing plates (9 and 10/(Fig. 89)) hold both the driven and the driving gear (6) in position, so that they mesh
with the smallest possible clearance.
324 BOMAG 008 916 41

Actuator drive 7.3
The hydraulic oil in between the tooth flanks is discharged from the tooth gaps by the meshing gears, before the
rotation would transport it back to the suction side (see arrows).
Due to this displacement and the bearing plate (1) on the pressure side it is assured that the hydraulic oil is trans-
ported from the suction to the pressure side, almost without any losses. The system pressure loaded pressure
fields press the bearing plates against the axial faces of the gears and thus seal both pressure sides.
Fig. 89 Sectional drawing of gear pump
1 Cover 6 Gear
2 Seals and gaskets 7 Drive shaft
3 Housing 8 Flange
4 Gear (driven) 9 Bearing plate
5 Displacement chamber 10 Bearing plate
008 916 41 BOMAG 325

7.4 Scraper chain drive
Scraper chain and conveyor screw drive

The scraper chain and conveyor screw drives on right and left hand sides are two open hydraulic circuits.
The essential components of these circuits are the two gear pumps (5 and 7), a valve block (14) consisting of 4/
3-way solenoid valves and the hydraulic motors for scraper chain right/left (43) and conveyor screw right/left
(44).(Fig. 90)
Travel pumps
Fig. 90 Scraper chain and conveyor screw drive - excerpt from hydraulic diagram
1 Diesel engine 14 Valve block, scraper chain and conveyor screw

5 Gear pump, scraper chain and conveyor screw, 43 Scraper chain motor, right and left
right hand side
7 Gear pump, scraper chain and conveyor screw, 44 Scraper chain motor, right and left
left hand side
326 BOMAG 008 916 41

Scraper chain drive 7.4
The scraper chain and conveyor screw pump for the right hand side (7) is located at the front face of the diesel
engine. It is the first gear pump on the tandem unit.
The gear pump for the left hand side (5) is located on the travel pump through-drive side.
The pump deliver oil to the valve block (14).
The hydraulic oil supply for the conveyor screw motor, right or left, is accomplishes via a separately controllable
4/3-way proportional valve in the valve block, right or left. It enables individual speeds of right or left hand motor,
depending on the prevailing application condition. With the proportional valve not actuated the pumped hydraulic
oil is discharged through a pressure maintaining valve integrated in the corresponding valve block. With the pro-
portional valves open, this pressure maintaining valve is closed by the increasing pressure in the pilot line, so
that the full hydraulic oil volume is available for driving the motors.
The right or left valve block is protected against overpressure by a directly controlled presure relief valve with
adjustable value.
For the right or left scraper chain drives 4/3-way control valves are used instead of the 4/3-way proportional
valves.
Valve arrangement
008 916 41 BOMAG 327

Valve block for scraper chain and conveyor screw
8
7
1 2
5
6
3
4
Fig. 92 Valve block

1 Proportional valve, conveyor screw left 14 A/B 24, Prop.
Page 100
2 Proportional valve, conveyor screw right 14 A/B 23, Prop.
Page 100.1
3 Solenoid valve, scraper chain left 14 A/B 26, 0 /24 V
Page 90
4 Solenoid valve, scraper chain right 14 A/B 25, 0 /24 V
Page 90.1
5 Pressure test port, conveyor screw left 14 / MA4 A/B 24, PRV, 260 bar
6 Pressure test port, conveyor screw right 14 / MA1 A/B 23, PRV, 260 bar
7 Pressure test port, scraper chain left 14 / MA2 A/B 26, PRV, 190 bar
8 Pressure test port, scraper chain right 14 / MA3 A/B 25, PRV, 190 bar
328 BOMAG 008 916 41

Gear pumps assigned fro left and right hand sides
Fig. 93 Scraper chain and conveyor screw pump, left hand side
Fig. 94 Scraper chain and conveyor screw pump, right hand side
008 916 41 BOMAG 329

Scraper chain motors

The scraper chain motors (1/(Fig. 95)) are two orbital motors from Danfoss, typeOMSS 160, which are each
flange mounted to a reduction gear from Bonfiglioli, type 301H . One motor each drives a scraper chain via the
reduction gear by means of a drive chain.
Fig. 95 Scraper chain motors - excerpt from hydraulic diagram
1 Scraper chain motor with reduction gear 3 Leakage line

2 Check valve
Function and design

The working principle of the orbital motor is based on an internal gear, which consists of a displacement ring (1/
(Fig. 96)) with internal gearing (7 rollers) mounted in the housing and a meshing rotor (3) (6 teeth).
The pressurizing (example: Pos. 6) of the working chambers (example: Pos. 4) controlled by the distributor valve
(7) causes a planetary movement of the rotor, whereby one tooth of the rotor is moved from one tooth gap in the
displacement ring to the next. This working movement is executed by a complete filling and emptying of the
working chambers in a sequence determined by the distributor valve (plate valve).
Both the distributor valve and the reduction gear are synchronously driven by the output torque or output speed
transmitted by the rotor to the universal shaft (valve drive shaft) and the axle shaft.
Fig. 96 Operational principle (pressurizing of working chamber - control slot)
1 Displacement ring 5 Pressurizing of working chamber - control slot

2 Working chamber (low pressure side) 6 Control slot (high pressure side)
3 Rotor 7 Distributor valve (plate valve)
4 Working chamber (high pressure side) 8 Control slot (low pressure side)
A balancing plate equalizes the hydraulic forces around the distributor valve and thus ensures high efficiency of
the motor.
330 BOMAG 008 916 41

Due to the 3-chamber design of the orbital motor, high pressure has no direct connection to the inside of the
housing or the radial seal, which enables an external leak oil connection and operation with very high return flow
pressures.
The orbital motor is equipped with two additional check valves, which make sure that the pressure acting on the
radial seal does not exceed the pressure in the low pressure line.
Due to the movement of the drive shaft in the housing no seals can be fitted at the shaft outlet, so that the leak
oil from the orbital motor flows into the reduction gear, from where it is returned to the hydraulic oil tank.
008 916 41 BOMAG 331


Scraper chain motor right
Fig. 98 Pressure test port M - valve block scraper chain motor, right
1 Hydraulic test case [BOMAG Part-No.: 079 930 4 Scraper chain motor, right
01]
2 High pressure gauge (600 bar) 5 Service door side, right
332 BOMAG 008 916 41

Scraper chain motor left
Fig. 99 Pressure test port - excerpt from hydraulic diagram
Fig. 100 Scraper chain motor, left
1 Hydraulic test case [BOMAG Part-No.: 079 930

01]
2 High pressure gauge (600 bar) 4 Scraper chain motor, left
008 916 41 BOMAG 333

Conveyor screw motor

The conveyor screw motors (1/(Fig. 101)) are two orbital motors from Danfoss, typeOMSS 200, which are each
flange mounted to a reduction gear from Bonfiglioli, type 303H . One motor each drives a conveyor screw via
the reduction gear by means of a drive chain.
Fig. 101 Conveyor screw motor - excerpt from hydraulic diagram
1 Leakage line 3 Check valve

2 Conveyor screw motor with reduction gear;
3-way flow divider (pressure compensated)

The flow divider installed between variable displacement pump and adjusting drive (see section "Adjusting
drive") (6/(Fig. 102)) is a 3-way flow divider with integrated control and pressure relief valve.
Fig. 102 3-way flow divider (pressure compensated) - section from hydraulic diagram
1 Pressure relief valve 5 Bypass filter

2 Control valve, adjustable 6 Flow divider
3 Bypass (pressure relief valve) 7 Main flow
4 Supply 8 Measuring connection
Function and design

The constant and pressure compensated volumetric flow required for the main flow (7) is generated by the con-
trol valve (2), which is integrated in the supply (4), after a minimum pressure differential exists between feed and
main flow.
The excess part of the flow volume in the supply is discharged through the "bypass" (pressure relief valve) into
the bypass flow (5). The thus generated main flow is directed to the adjusting drive and supplies this drive with
hydraulic oil. The bypass flow serves the purpose of supplying the charge system for the conveyor screwpump
(see section "Conveyor screw pump").
A pressure relief valve (1) downstream of the control valve protects the main flow to the adjusting drive against
pressure peaks. If the pressure of the main flow rises above the setting of the pressure relief valve, the pressure
relief valve of the "bypass" is closed through the pilot line and the pressure relief valve opens to the by pass.
The hydraulic pressure of the main flow is thereby limited to the max. pressure determined by the pressure lim-
itation plus charge pressure for the conveyor screw pump.
334 BOMAG 008 916 41

This hydraulic oil discharged into the bypass also serves the charge pressure supply for the conveyor screw
pump (see section "Conveyor screw drive").
Fig. 103 Sectional view 3-way flow divider (pressure compensated)
1 Control valve, adjustable 3 Pressure relief valve

2 Bypass (pressure relief valve)
The tooth flank spaces between inside wall of the motor housing and bearing plate faces form the displacement
chambers (5) for the hydraulic oil. With the motor driven the hydraulic oil from the high pressure side "P1" is
forced through the displacement chambers to the low pressure side "P2" and causes rotation of both gears (4
and 6) (see arrows). The drive shaft connected with the driving gear (7) transfers the generated torque to the
attached consumer.
The bearing plates (9 and 10((Fig. 104)) hold both the driven and the driving gear (4 and 6) in position, so that
they mesh with the smallest possible clearance. The meshing gears discharge the hydraulic oil from the spaces
between the teeth into the low pressure side, before it can re-enter the high pressure side.
008 916 41 BOMAG 335

Fig. 104 Sectional drawing - gear motor
1 Cover 6 Gear (driven)

3 Housing 8 Flange
4 Gear (driving) 9 Bearing plate
336 BOMAG 008 916 41

Vibration and tamper drive 7.5
Vibration and tamper drive
7.5 Vibration and tamper drive
Similar to the scraper chain drive, the vibration and tamper drive is also an open hydraulic circuit.
The essential components are the vibration (4) and tamper pumps (5) flanged to the auxiliary output of the en-
gine (7/(Fig. 105)), the valve block for vibration drive (1) with the 2 vibration motors (10 and 13) for the screed,
the 2 vibration motors (9 and 14) of the mobile screeds and the valve block for tamper operation (2) with the 2
tamper motors (11 and 12) for the screed and the 2 tamper motors (8 and 15) for the mobile screeds.
Fig. 105 Vibration and tamper drive - excerpt from hydraulic diagram
1 Valve block for vibration drive 9 Vibration motor, mobile screed right
2 Valve block for tamper operation 10 Vibration motor, screed right
3 11 Tamper motor, screed right
4 Vibration pump 12 Tamper motor, screed left
5 Tamper pump 13 Vibration motor, screed right
6 Tandem pump 14 Vibration motor, mobile screed left
7 Diesel engine 15 Tamper motor, mobile screed left
8 Tamper motor, mobile screed right
The vibration and tamper pumps are joined together to a tandem gear pump and are driven by the auxiliary out-
put of the diesel engine (7). The vibration and tamper pumps (4 and 5) supply the corresponding hydraulic cir-
cuits for vibration and tamping with a constant oil flow.
This hydraulic oil supply runs through separate valve blocks for vibration drive (1) and tamper drive (2). For pres-
sure limitation these are equipped with a pressure relief valve with fixed setting for pressure override and one
proportionally adjustable 3-way flow divider, which enables and individually adjustable frequency (speed) of the
driven vibration (9, 10, 13, 14) or tamper motors (8, 11, 12, 15) to match the actual paving situation.
The tamper motors of screed and mobile screeds each drive a drive shaft which are connected with the corre-
sponding tamper plate by eccentrically mounted connecting rods. These eccentrically mounted connecting rods
cause an up and down movement of the connected tamper plates, which are positioned directly in front of the
008 916 41 BOMAG 337

screed plates. This up and down movement serves the purpose of pre-compacting the material to be laid, before
it is further compacted by the screed plates.
The vibration motors each engage directly into a flanged on exciter housing with exciter shaft (eccentric shaft).
The eccentric arrangement of the weight of the exciter shaft causes a radial vibration, which works directly on
the screed plates of screed and mobile screeds The generated vibration of the screed plates serves the com-
paction and levelling of the paved material.
The vibration and tamper motors of the screed are additionally linked by a universal shaft, to ensure synchroni-
zation of amplitudes in vibration and tamping. This makes ure that there will be no undesired resonance vibra-
tions or mutual elimination of amplitudes during operation.
Valve blocks
The two valve blocks (1 and 6/(Fig. 106)) are blocks from Atos, each consisting of a pressure relief valve (3 and
5) and a proportionally adjustable 3-way flow divider (2 and 4).
Fig. 106 Valve blocks - excerpt from hydraulic diagram
1 Valve block for vibration 5 Pressure relief valve

2 3-way flow divider, proportionally adjustable 6 Valve block for tamping
3 Pressure relief valve 7 Tamper motor (screed and mobile screeds)
4 3-way flow divider, proportionally adjustable 8 Vibration motors (screed and mobile screeds)
Function and design

The corresponding valve block is hydraulically installed between the pumps (see section "Vibration and tamper
pump" and the correspondingly controlled motors for screed and mobile screeds (7 and 8) (see section "Vibra-
tion and tamper motors").
The high and low pressure lines of the valve block are internally connected and combined as central ports.
The directly controlled pressure relief valve (6/(Fig. 107)) in the high pressure line limits the hydraulic oil pressure
to the value set by the valve for the motors 7 or 8/(Fig. 106)) by opening the hydraulic circuit via port "T" to the
338 BOMAG 008 916 41

low pressure side to reduce the overpressure. Just like the bypass (3) of the proportionally adjustable 3-way flow
divider (1 or 4/(Fig. 106)), the port "T" is directly connected with the low pressure lines (5/(Fig. 107)), which re-
turns to the hydraulic oil tank.
Fig. 107 3-way flow divider - excerpt from hydraulic diagram
1 Proportional solenoid 4 High pressure line

2 Throttle, adjustable 5 Low pressure line
3 Bypass 6 High pressure relief valve
The oil volume flowing in through port "A" is subsequently regulated by the adjustable throttle of the 3-way flow
divider, which is controlled by the proprtional solenoid (1/(Fig. 106)) or completely returned to the hydraulic oil
tank via the bypass "P" (3). With this hydraulic oil volume, which can be adjusted proportionally to the input sig-
nal, the drive motors can be operated with constant displacements for vibration or tamping within a fixed fre-
quency range, or to disconnect them completely from the hydraulic oil circuit (no vibration or tamper drive). Also
here the excess hydraulic oil is returned to the hydraulic oil tank via bypass (3) and low pressure line (5) in the
valve block.
Vibration and tamper motors

The vibration and tamper motors on screed and both mobile screeds are gear motors from Sauer Danfoss, type
SNM2.
The vibration motors (1, 3, 6 and 15/(Fig. 108)) are tightly connected with the screed plates via an exciter unit,
whereas the tampers are connected to the tamper motors via eccentrically mounted connecting rods and a drive
shaft. The vibration and tamper motors of the screed are additionally interconnected by a universal shaft (2 and
10), to ensure synchronization of the generated amplitudes.
008 916 41 BOMAG 339

Fig. 108 Vibration and tamper motors - excerpt from hydraulic diagram
1 Tamper motor, screed left 10 Universal shaft, vibration motors

2 Universal shaft, tamper motors 11 Pressure relief valve, vibration motors left
3 Tamper motor, screed right 12 Vibration motor, mobile screed left
4 High pressure line, tamper motors 13 Low pressure line, vibration motors
5 Pressure relief valve, tamper motors right 14 Vibration motor, screed right
6 Tamper motor, mobile screed right 15 Tamper motor, mobile screed left
7 Vibration motor, screed right 16 Pressure relief valve, tamper motors left
8 Vibration motor, mobile screed right 17 High pressure line, vibration motors
9 Pressure relief valve, vibration motor right 18 Low pressure line, tamper motors
Function and design

The hydraulic oil delivered by the respective pump flows through the upstream valve block into the high pressure
side "P1" of the vibration or tamper motor.
The tooth flank spaces between inside wall of the motor housing and bearing plate faces form the displacement
chambers (5) for the hydraulic oil. With the motor driven the hydraulic oil from the high pressure side "P1" is
forced through the displacement chambers to the low pressure side "P2" and causes rotation of both gears (4
and 6) (see arrows). The drive shaft connected with the driving gear (7) transfers the generated torque to the
attached consumer.
The bearing plates (9 and 10((Fig. 104)) hold both the driven and the driving gear (4 and 6) in position, so that
they mesh with the smallest possible clearance. The meshing gears discharge the hydraulic oil from the spaces
between the teeth into the low pressure side, before it can re-enter the high pressure side.
340 BOMAG 008 916 41

Fig. 109 Sectional drawing - gear motor
1 Cover 6 Gear (driven)

3 Housing 8 Flange
4 Gear (driving) 9 Bearing plate
008 916 41 BOMAG 341


Valve block vibration and tamper operation
Fig. 110 Vibration and tamper operation - excerpt from hydraulic diagram
342 BOMAG 008 916 41

Valve block vibration and tamper
M1
Fig. 111 Valve block, vibration and tamper

1 Proportional valve, tamper 15 A8, Page 200 Prop.
2 Proportional valve, vibration 15 A7, Page 200 Prop.
3 Pressure test port, tamper 15 / M1 Pressure relief valve
200 bar
4 Pressure test port, vibration 15 / M Pressure relief valve
180 bar
008 916 41 BOMAG 343

Pressure test port M1 - vibration motor screed, right
Fig. 113 Pressure test port M1 - vibration motor screed, right
1 Vibration motor screed, right 4 High pressure gauge (600 bar)

2 Screed, right 5 Pressure test port M1
3 Hydraulic test case [BOMAG Part-No.: 079 930
01]
344 BOMAG 008 916 41

Pressure test port M1 - vibration motor screed, left
Fig. 115 Pressure test port M1 - vibration motor screed, left
1 Screed, left 4 High pressure gauge (600 bar)

2 Vibration motor screed, left 5 Hydraulic test case [BOMAG Part-No.: 079 930
01]
3 Pressure test port M1
008 916 41 BOMAG 345

Pressure test port M1 - tamper motor mobile screed, right
Fig. 117 Pressure test port M1 - tamper motor mobile screed, right
1 Screed 4 Mobile screed, right

2 Tamper motor mobile screed, right 5 High pressure gauge (600 bar)
3 Pressure test port M1 6 Hydraulic test case [BOMAG Part-No.: 079 930
01]
346 BOMAG 008 916 41

Pressure test port M1 - tamper motor mobile screed, left
Fig. 119 Pressure test port M1 - tamper motor mobile screed, left
1 Tamper motor mobile screed, left 4 High pressure gauge (600 bar)
2 Pressure test port M1 5 Hydraulic test case [BOMAG Part-No.: 079 930
01]
3 Screed 6 Mobile screed, left
008 916 41 BOMAG 347

Adjustment points valve block vibration and valve block tamping
Fig. 120 Adjustment point valve block vibration and valve block tamping - excerpt from hydraulic diagram
Fig. 121 Adjustment points valve block vibration and valve block tamping
1 Pressure relief valve vibration (shown) and 4 Valve block for vibration
tamping (not shown)
2 Solenoid valve tamping (control symbol no.: A8) 5 Solenoid valve vibration (control symbol no.:
A7)
3 Valve block for tamping 6 Opening, maintenance flap driver's stand
348 BOMAG 008 916 41

Adjustment point for vibration drive mobile screed, right
Fig. 122 Adjustment point for vibration drive mobile screed, right - excerpt from hydraulic diagram
Fig. 123 Adjustment point for vibration drive mobile screed, right
1 Vibration motor, mobile screed right 3 Exciter housing

2 Pressure relief valve 4 Mobile screed, right
008 916 41 BOMAG 349

Adjustment point for vibration drive mobile screed, left
Fig. 124 Adjustment point for vibration drive mobile screed, left - excerpt from hydraulic diagram
Fig. 125 Adjustment point for vibration drive mobile screed, left
1 Pressure relief valve 3 Exciter housing

2 Vibration motor 4 Mobile screed, left
350 BOMAG 008 916 41

Adjustment point for tamper drive mobile screed, right
Fig. 126 Adjustment point for tamper drive mobile screed, right - excerpt from hydraulic diagram
Fig. 127 Adjustment point for tamper drive mobile screed, right
1 Tamper motor, mobile screed right 3 Pressure relief valve

2 Mobile screed, right
008 916 41 BOMAG 351

Adjustment point for tamper drive mobile screed, left
Fig. 128 Adjustment point for tamper drive mobile screed, left - excerpt from hydraulic diagram
Fig. 129 Adjustment point for tamper drive mobile screed, left
1 Mobile screed, left 3 Pressure relief valve

2 Tamper motor, mobile screed left
352 BOMAG 008 916 41

Fan drive 7.6
Fan drive
7.6 Fan drive
The fan drive also is an open hydraulic circuit.

The most essential components are the tandem pumo (8) flanged to the auxiliary output of the engine (1), the
two fan motors (77 and 78), the check valve (27) and three temeprature switches (33, 35, 36) with control valve
(29).(Fig. 130)
32
Fig. 130 Fan drive - excerpt from hydraulic diagram
1 Diesel engine 36 Temperature switch hydraulic oil cooler

8 Tandem gear pump 70 Combination cooler colamnt/hydraulic oil
27 Check valve 71 Intercooler
29 Control valve 77 Fan motor - intercooler
32 Temperature switch intercooler 78 Fan motor - combination cooler
35 Coolant temperature switch
008 916 41 BOMAG 353

7.6 Fan drive
The tandem pump (8), which is directly drive by an auxiliary drive of the diesel engine (1), supplies both fan cir-
cuits with hydraulic oil. The fan motors (77 and 78) are connected in series and always run at the same time.
Under normal conditions only the oil from the first pump flows to the fan motors (77 and 78), because the control
valve (29) is energized in cold condition and thus directs the oil from the second pump directly back into the hy-
draulic oil tank.
If one of the three temperature switches (32, 35, 36) responds, the control valve (29) is de-energized and the
second pump delivers its oil also to the fan circuit, to both fan motors (77and 78).
This means if one pump is used, the control valve (29) is energized (24V) and the fan speed is approx. 900 rpm.
If both pumps are used, the control valve (29) is de-energized and the fan speed is approx. 2100 rpm.
A pressure relief valve in the fan motor housing (78) protects the entire fan drive against overpressure, by limiting
the hydraulic pressure to the value set by the valve.
354 BOMAG 008 916 41

Fan drive 7.6
The fan motors work with two different speeds, which are realized by the second gear pump being
switched on or off. The signal for the control valve to switch on the second pump is submitted by the
three temperature switches.

Fan circuit
Components
Fig. 131 Tandem gear pump
008 916 41 BOMAG 355

7.6 Fan drive
Fig. 132 Fan motor fr intercooler
Test port for fan pressure
Fig. 133 Fan motor for combined coolant/hydraulic oil cooler
356 BOMAG 008 916 41

Fan drive 7.6
Fig. 134 PRV fan circuit on fan motor for combined coolant/hydraulic oil cooler
Control valve (29) and check valve (27)
Fig. 135 Control valve
008 916 41 BOMAG 357

7.6 Fan drive
Fig. 136 Check valve
Temperature switch
Fig. 137 Temperature switch on coolers
358 BOMAG 008 916 41

Fan drive 7.6
Fig. 138 Excerpt from the wiring diagram
008 916 41 BOMAG 359

7.6 Fan drive
360 BOMAG 008 916 41

8 Tests and adjustments
008 916 41 BOMAG 361

8.1 Check and adjust
Checking and adjusting the vibration
Special tools
Hydraulic test case [BOMAG Part-No.: 079 930
01]
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).
Pressure test vibration drive, mobile

screed right and left
1. Extend right and left hand screed (1) completely.
2. If necessary raise and lock the screed (2/(Fig. 1)).
Fig. 1
i Note
Perform work steps 3 to 14 on vibration motor for
left mobile screed accordingly.
3. Disconnect the hydraulic line (1) from the right vi-
bration motor, screed (3) and close the hydraulic
line/port with a plug.
4. Connect a high pressure gauge (600 bar) (2) to
pressure test port M1 (4/(Fig. 2)) on the vibration
motor, screed.
Fig. 2
362 BOMAG 008 916 41

Check and adjust 8.1
5. Start the engine, set switch (Fig. 3) to position
"MAX".
Fig. 3
6. Activate the hydraulic system (Fig. 4).
Fig. 4
7. Select "Work"-mode (Fig. 5).
Fig. 5
! Caution
Run the following pressure test only for max.
5 seconds.
8. Switch on vibration with switch (b/(Fig. 6)).
Fig. 6
008 916 41 BOMAG 363

9. Read the hydraulic pressure on the high pressure

gauge (600 bar) (2/(Fig. 7)).
Fig. 7
10. Switch off vibration with switch (b/(Fig. 8)).
Nominal value
See chapter "Technical data", "Pressure limita-
tion, vibration motor mobile screed left/right".
Evaluation of test
If the nominal value of the pressure limitation is
not reached, adjust the pressure relief valve (1/
(Fig. 7)) on the vibration motor for the right mobile
screed accordingly.
i Note
Fig. 8 Repeat testing and adjustment as specified in
steps 8 to 10, until the nominal value is reached.
11. Deactivate the hydraulic system (Fig. 9).
Fig. 9
12. Turn the switch (Fig. 10) to position "MIN", shut
down the engine.
Fig. 10
364 BOMAG 008 916 41

Check and adjust 8.1
13. Disconnect the high pressure gauge (600 bar)
from test port M1 (4) on the right vibration motor
for screed (3).
14. Unscrew the plugs and connect the hydraulic line
(1/(Fig. 11)) to the right hand vibration motor for
the screed.
Fig. 11
008 916 41 BOMAG 365

8.2 Checking and adjusting the tamping pressure limitation
8.2 Checking and adjusting the tamping

pressure limitation
Special tools
01]
! Caution
Pressure test tamper drive, mobile

screed right and left
1. Extend right and left hand screed (1) completely.
2. If necessary raise and lock the screed (2/(Fig. 1)).
Fig. 1
i Note
Perform work steps 3 to 14 on tamper motor for
left mobile screed accordingly.
3. Disconnect the hydraulic line (5) from the right
tamper motor for the right mobile screed (2) and
close the hydraulic line/port with a plug.
pressure test port M1 (1/(Fig. 2)) on the tamper
motor for right mobile screed.
Fig. 2
"MAX".
Fig. 3
366 BOMAG 008 916 41

Checking and adjusting the tamping pressure limitation 8.2
Fig. 4
Fig. 5
! Caution
5 seconds.
8. Switch on the tamper with switch (a/(Fig. 6)).
Fig. 6
gauge (600 bar) (4/(Fig. 7)).
Fig. 7
008 916 41 BOMAG 367

8.2 Checking and adjusting the tamping pressure limitation
10. Switch off the tamper with switch (a/(Fig. 8)).
Nominal value
See chapter "Technical data", "Pressure limita-
tion, tamper motor mobile screed left/right".
Evaluation of test
not reached, adjust the pressure relief valve (3/
(Fig. 7)) on the tamper motor for the right mobile
screed accordingly.
i Note
Fig. 8 Repeat testing and adjustment as specified in
Fig. 9
down the engine.
Fig. 10
13. Disconnect the high pressure gauge (600 bar) (4)
from pressure test port M1 (1) on the tamper mo-
tor for right mobile screed.
14. Unscrew the plugs and connect the hydraulic line
(5/(Fig. 11)) to the right hand tamper motor for the
right hand mobile screed.
Fig. 11
368 BOMAG 008 916 41

Checking and adjusting the tamping pressure limitation 8.2
Pressure measurement tamper drive,
tamper system valve block.
1. Block the universal shaft (1) of the tamper mo-
tors, screed (2/(Fig. 12)) with a suitable object.
Fig. 12
pressure test port M1 (2) on the tamper system
valve block (3/(Fig. 13)).
Fig. 13
"MAX".
Fig. 14
008 916 41 BOMAG 369

8.3 Checking and adjusting charge pressurerelief/high pressure re-
8.3 Checking and adjusting charge pres-

surerelief/high pressure relief and
pressure override travel pump
Special tools
01]
! Caution
! Caution
For the following pressure tests the brakes on
both tracks must be applied.
i Note
The multi-function valve (pressure relief valve
and zero-flow control valve [pressure override])
are adjusted at the same time. The value of the
pressure relief valve is automatically higher than
the setting of the zero-flow control valve by a fixed
ratio.
Pressure test high pressure side "A"
travel pump, left
1. Block the left and right hand tracks by ´disco-
nnecting the electrical connection (1) on the
brake valve (2/(Fig. 1)).
Fig. 1
! Caution
5 seconds.
pressure test port M1 (2) on the travel pump (1/
(Fig. 2)).
Fig. 2
370 BOMAG 008 916 41

Checking and adjusting charge pressurerelief/high pressure re- 8.3
"MAX".
Fig. 3
Fig. 4
Fig. 5
6. Slightly actuate the potentiometer for speed (Fig.
6).
Fig. 6
008 916 41 BOMAG 371

8.3 Checking and adjusting charge pressurerelief/high pressure re-
7. Shift the travel lever (Fig. 7) to travel direction

"forward".
gauge (600 bar) (3/(Fig. 8)).
9. Shift the travel lever (Fig. 7) to position "Neutral" .
Nominal value
See chapter "Technical data", "Travel pump".
Fig. 7
Evaluation of test
If the nominal values for pressure relief and pres-

sure override are not correct, adjust the multi-
function valve (4) on travel pump, left (1).
i Note
Repeat testing and adjustment as specified in
Turn the adjusting screw clockwise = increase
pressure relief and pressure override settings.
Turn the adjusting screw counter-clockwise = re-
Fig. 8
duce pressure relief and pressure override set-
tings.
from pressure test port M1 (2/(Fig. 8)) on travel
pump, left.
Fig. 9
372 BOMAG 008 916 41

Checking and adjusting charge pressurerelief/high pressure re- 8.3
down the engine.
Fig. 10
i Note
For proper operation the brakes on both track
drives must be returned to good working order!
13. Connect the electrical supply (1) to the brake
valve (2/(Fig. 11)).
Fig. 11
008 916 41 BOMAG 373

8.4 Checking and adjusting the adjusting times and pressure limi-
8.4 Checking and adjusting the adjusting

times and pressure limitations for mo-
bile screeds
Special tools
01]
! Caution
Time measurement for extension and

retraction of mobile screeds
"MAX".
Fig. 1
Fig. 2
Fig. 3
374 BOMAG 008 916 41

Checking and adjusting the adjusting times and pressure limi- 8.4
4. If necessary raise and lock the screed (2).
5. If neceary retract the right and left hand mobile
screed (1/(Fig. 4)) completely (c and d/(Fig. 5)).
Fig. 4
6. Measure the time for complete and synchronous
extension of right and left mobile screeds (c and
d).
Nominal value
See chapter "Technical data", "Mobile screeds,
extension time".
7. Measure the time for complete and synchronous
retraction of right and left mobile screeds (c and
d/(Fig. 5)).
Nominal value
See chapter "Technical data", "Mobile screeds,
Fig. 5 retraction time".
Evaluation of test
If the nominal values for extension and retraction

of the mobile screeds are not reached, adjust the
volume flow divider for scraper chain/mobile
screeds (2) on the distributor block for scraper
chain/mobile screeds (1/(Fig. 6)).
i Note
Increase flow volume = shorter time for extension
and retraction
Fig. 6 Rediuce volume flow = longer time for extension
and retraction
i Note
Changing the volume flow on the flow divider for
scraper chain/mobile screeds also influences the
max. rotary speed of the scraper chain drive.
008 916 41 BOMAG 375

Fig. 7
down the engine.
Fig. 8
Pressure limitation mobile screeds

pressure test port M (2) on the valve block for mo-
bile screed adjusting cylinders (3/(Fig. 9)).
Fig. 9
"MAX".
Fig. 10
376 BOMAG 008 916 41

Checking and adjusting the adjusting times and pressure limi- 8.4
Fig. 11
4. Extend right and left hand screeds (c and d) com-
pletely.
! Caution
For the following pressure test drive the mo-
bile screeds max. 5 seconds against block.
5. Retract the mobile screeds completely and syn-
chronously against block (c and d/(Fig. 12)), read
the hydraulic oil pressure in the high pressure
gauge (600 bar) (2/(Fig. 13)).
Nominal value
Fig. 12 See chapter "Technical data", "Mobile screeds".
Evaluation of test

not reached, adjust the pressure relief valve (1)
on the valve block for mobile screed adjusting cyl-
inders (3/(Fig. 13)).
i Note
Fig. 13
to pressure test port M (2) on the valve block for
mobile screed adjusting cylinders (3/(Fig. 14)).
7. Retract right and left hand screeds completely.
Fig. 14
008 916 41 BOMAG 377

Fig. 15
down the engine.
Fig. 16
378 BOMAG 008 916 41

Measuring the max. fan motor speed 8.5
8.5 Measuring the max. fan motor speed
Special tools
Digital RPM-meter [BOMAG Part-No.: 059 711
12]
Digital RPM-meter, optical/mechanical [BOMAG
Part-No.: 079 948 98]
! Caution
! Caution
The max. speed of the fan motor in 2nd speed
range should not exceed 2100 rpm.
Engine speed measurement
1. Connect the RPM-meter (Fig. 1) to the injection
line on the engine.
Fig. 1
"MAX".
3. Measure the rotation speeds.
Nominal value high idle speed

See chapter "Technical data", "Engine at high
idle".
Evaluation of test
If the nominal value is not reached, adjust the en-
gine speed or perform trouble shooting on the en-
gine.
Fig. 2
008 916 41 BOMAG 379

Fig. 3
6. Switch on all consumers, e.g. vibration, tampers
and scraper chains.
7. Measure the rotation speeds.
Setpoint nominal speed

See chapter "Technical data", "Engine at nominal
speed".
Evaluation of test
If the nominal value is not reached, adjust the en-
gine speed or perform trouble shooting on the en-
gine.
Fig. 4
down the engine.
Fig. 5
9. Disconnect the RPM-meter (Fig. 6) from the in-
jection line on the engine.
Fig. 6
380 BOMAG 008 916 41

Measuring the max. fan motor speed 8.5
Rotary speed of fan motor
i Note
The speed is realized by a fixed ratio restrictor in-
side the fan motor.
This restrictor cannot be used to adjust the rotary
speed.
1. Bridge the solenoid valve (1) of the fan motor by
pulling off the jumper (3/(Fig. 7)).
Fig. 7
"MAX".
Fig. 8
Fig. 9
008 916 41 BOMAG 381

4. Measure the speed of the fan/fan motor optically/

mechanically (Fig. 10) with the digital RPM-me-
ter.
Nominal value
See chapter "Technical data", "Fan motor 2nd
speed range".
Fig. 10
Evaluation of test
If the nominal rotary speed is not reached, adjust

the pressure relief valve (1) for the fan motor (2/
(Fig. 11)) accordingly.
i Note
step 4, until the nominal value is reached.
Fig. 11
Fig. 12
down the engine.
Fig. 13
382 BOMAG 008 916 41

9 Central lubrication system
008 916 41 BOMAG 383

9.1 BF 600C with HC screed, 32 lubrication points
384 BOMAG 008 916 41

BF 600C with HC screed, 32 lubrication points 9.1
After a running-in phase of 100 hours and after inspection of all lubrication points the lubrication intervals can be
extended or reduced, as required.
! Caution
The cycle time must not be changed.
Lubrication time
Cycle time
Fig. 14
Pump revolutions:= 60
Cycle time = 0.5 hours
Grease = lithium saponified multi-purpose grease, NLGI3
008 916 41 BOMAG 385

386 BOMAG 008 916 41

BF 600C with HC screed, 34 lubrication points 9.2
After a running-in phase of 100 hours and after inspection of all lubrication points the lubrication intervals can be
extended or reduced, as required.
! Caution
Lubrication time
Cycle time
Fig. 15
Pump revolutions:= 60
Cycle time = 0.5 hours
Grease = lithium saponified multi-purpose grease, NLGI3
008 916 41 BOMAG 387

9.3 Filling the lubricant container
9.3 Filling the lubricant container
Fig. 1 Filler coupling

(Fig. 1) Through filler coupling.
Fig. 2 Grease gun

(Fig. 2) With grease gun
Fig. 3 Grease nipple

(Fig. 3) Through grease nipple with hand-operated or pneumatic grease gun
388 BOMAG 008 916 41

Electric pump 9.4
9.4 Electric pump Technical dada
Motor:
Electric pump EP-1 Operating voltage= 12/24 V DC
The central lubrication grease pump is electrically Rated speed = 15 rpm
driven. With a working pressure of max. 280 bar (set-
Power consumption
ting of high pressure relief valve) this pump is suitable
at idle speed = 0.4 A
for pumping conventional greases up to NLGI-Kl. 2.
Power consumption
at full load speed= 1.1 A
Fuse = 3A
Pump:
Max. operating pres-
sure = 280 bar
Permissible operat-
ing temperature= -35°C to +80°C
Container capacity= 1.9 kg, 2.5 kg, 4 kg or 8 kg
Rotation of agitator =counter-clockwise
Installation position= Container vertically upright
Protection class= IP5K9K acc. to DIN 40050
Fig. 4 EP-1 with 4 kg container and integrated electronic control
008 916 41 BOMAG 389

9.4 Electric pump
Working principle
Fig. 5
A DC-motor 10 (Fig. 5) continuously drives the eccen-
tric (5) with thrust ring (6). This eccentricity causes the
suction and pressure stroke of the pump piston (7),
whereby the integrated check valve (8) prevents the
pumped medium from being sucked back in from the
main line.
The agitator (2) forces the lubricant out of the provi-
sion container (1) through a screen plate (4 to the suc-
Fig. 6 Pump element drawing in grease
tion area in the pump housing (3), whereby air
bubbles are eliminated A scraper on the agitator (2)
enables visual inspection of the still available grease
quantity inside the transparent provision container (1).
The pressure relief valve (9) is factory set to 280 bar.
Fig. 7 Pump element pumping
390 BOMAG 008 916 41

Electric pump 9.4
Pump element PE-120V
Max. flow capacity
l Pump element factory set to full stroke
l max. flow capacity 0.12 cm with full stroke
l Reduction of 0.013 cm per detent = 1/2 revolution
Flow capacity regulation:

l Unscrew the plug 2 (Fig. 8)) with an Allen key (SW
5)
l
The setscrew (3) is then regulated with a screwdriv-
er
l Turning clockwise reduces the flow capacity
l Turn anti-clockwise increases the flow capacity
l Max. stroke of setscrew is 2.4 mm = 6 detents.
l 1 turn of the setscrew is 0.8 mm = 2 detents
Fig. 8
l Tighten the plug (2) with the seal ring.
Technical data: Max. flow capacity

F
Max. flow capacity= 0.04 to 0.12 cm3 / stroke

Flow capacity regula-
tion = 6 detents per 1/2 turn
Reduction = 0.013 cm3 per detent
Piston return = forced
Detents
Revolutions
Fig. 9
008 916 41 BOMAG 391

9.4 Electric pump
Installation of pump element

l Installation and removal only with the pump
stopped.
l Assembly of the pump element with the piston (4)
partly pulled out, insert upwards under a slanted an-
gle into the housing bore (Fig. 10)).
l Once the piston head touches the pressing ring -
move the element to horizontal position (Fig. 11).
l The piston head must run in the groove of the guide
ring.
l
Tighten the pump element.
l Disassemble in reverse order.
i Note
When disassembling the pump element make sure
that the piston (4) does not remain in the pump hous-
Fig. 10
ing.
Fig. 11
392 BOMAG 008 916 41

Integrated electronic control 9.5
9.5 Integrated electronic control 2 Green LED to indicate function
3 Red LED to indicate faults
The control unit is equipped with a data memory which
logs the following values: Technical data:
l Control type Supply voltage = 10 to 60 V DC
l Version of control serial number Current load max.= 6.0 A
l Manufacturing date Fuse (not contained
in the unit) = 6.3 A
l
Type of operation (time or speed control)
Output for signal
l Settings (setting ranges). lamp = 0.4 A
Temperature range= -35°C to +75°C
Functional sequence
Protection class= IP 65
After switching on the ignition the green and red LEDs
light up for 1.5 seconds to indicate readiness for oper-
ation (switch-on control), irrespective of the set pro-
gram.
Each initial connection of the control triggers a lubrica-
tion process, the green LED 2 (Fig. 12) in the control
bowl light during the entire lubrication process.
The integrated electronic control unit BEKA-troniX1 is
equipped with a data log. This, among other, serves
the purpose of logging expired times. If the ignition is
interrupted during a lubrication process or within a
pause period, this time is stopped and logged. After
switching the ignition back on the still remaining lubri-
cation or pause times are read out of the log and the
function will be resumed at exactly the point where it
was interrupted.
With the ignition switched on intermediate lubrication
can be triggered at any time by pressing the push but-
ton (1) on the side of the motor housing, this function
also serve the purpose of function testing. The pump
in this case immediately starts a lubrication cycle, the
accumulated or logged lubrication or cycle time is re-
set and starts anew.
Fig. 12
1 Push button to trigger intermediate lubrication
008 916 41 BOMAG 393

9.5 Integrated electronic control
Modes of operation Setting parameters

A) Timer control The cycle or lubrication times can be set with the help
of maintained-contact switches in the inspection win-
With time dependent control of a central lubrication dow of the control.
system both the cycle time and the lubrication time
can be adjusted. Cycle time means the time span be-
tween beginning of a lubrication process to the begin-
ning of the next lubrication process.
Lubrication time
Cycle time
Fig. 13
B) RPM-control
With the integrated electronic control unit one can,
e.g. in case of speed fluctuations caused by low tem- Fig. 14
peratures or high torques, also determine the lubrica- For setting the time disassemble the red frame from
tion period on the basis of the number of revolutions the motor protection housing of the pump using a flat
of the pump motor. screwdriver (Fig. 14), loosen four cross-recessed
A sliding contact connects the pump motor with the screws and remove the transparent protection cover.
control. Each pump revolution sends a signal to the The cycle or lubrication time can be set with a flat
control, which in turn counts the number of arriving screwdriver.
signals.
If no signals are received from the pump motor over ! Caution
an adjustable monitoring time (standard 30 sec.) after
the beginning of the lubrication process, the control
will indicate a fault. In case of improper closing of the cover water will
The red LED in the inspection window in the bottom seep into the control and cause damage. In this
motor shell of the pump or an externally installed sig- case any warranty will become null and void.
nal lamp (option) will start to flash.
Fig. 15
1 Connection of system diagnose
2 Maintained-contact switch to set the lubrication time
3 Maintained-contact switch to set the cycle time
394 BOMAG 008 916 41

Integrated electronic control 9.5
Lubrication times: a) Functional readiness
1 to 16 min. (16 contacts for 1 min. each)
Functionally ready: 1.5 sec.
2 to 32 min. (16 contacts for 2 min. each)
LED red
2 to 32 sec. (16 contacts for 2 sec. each)
LED green
Cycle times:
0.5 to 8 h (16 contacts for 0.5 h each) Fig. 2 Indication of functional readiness
2 to 32 min. (16 contacts for 2 min. each) b) Lubrication active

2 to 32 h (16 contacts for 2 h each)
LED red
Pump revolutions:
Over the entire lubrication period
1 to 16 revolutions (16 contacts for 1 revolution each)
10 to 160 revolutions (16 contacts for 10 revolution LED green
each)
Fig. 3 Lubrication sequence
170 to 320 revolutions (16 contacts for 10 revolution
each) c) Rotary speed fault
Summary of signal displays

LED red
Two control LEDs (green/red) in the inspection win-
dow of the motor shell show the functions of the pump, LED green
whereby the red LED always indicates a fault in the
program sequence. Fig. 4 Rotary speed fault on pump motor
d) Fault CPU/memory
LED red
LED green
Fig. 5 Fault CPU/memory

Fig. 1 Indication of functional readiness
e) Test lubrication (permanent lubrication)
1 Red LED to indicate faults
2 Green LED to indicate function
LED red
LED green
Fig. 6 Test lubrication
i Note
In order to be able to trigger permanent lubrication for
service purposes in "Timer controlled" mode, the lubri-
cation time must be set to a value that is higher than
the cycle time.
008 916 41 BOMAG 395

9.5 Integrated electronic control
Terminal diagram
Signal lamp green

green (no. 1)
red (no. 2)
Signal lamp red
External signal lamps
orange (no. 4)
Push button
Ignition, terminal 15 black (no. 3)
Ground, terminal 31 brown (ye/gr)
Fig. 7
i Note
(No. ...) = Cable no. for mono-colour cable
396 BOMAG 008 916 41

Progressive distributor 9.6
9.6 Progressive distributor
The progressive distributor can be employed as main
or a secondary distributor.
Progressive piston distributors are distributor units
with a hydraulic sequence control the pistons of which
are controlled by the fed lubricant in such a way that
the lubricant is forced successively to the individual
outlets. In case of disturbances in the sequence of lu-
bricant flow, e.g. blockage of lubrication lines or lubri-
cation points, the distributors will block. This blockage
is used as an aid to monitor the distributors. With au-
tomatic pumps, such as e.g. the electric pump EP-1,
the lubricant emerges from the pressure relief valve.
The progressive distributors are manufactured in a
variable disc design. This has the advantage that the
distributor can be extended or shortened, depending
on the number of lubrication points. This disc design
also provides the possibility to customize individual
distributor discs with different displacements per pis-
ton stroke to one overall progressive distributor.
The different displacements per piston stroke are
achieved by different piston diameters.
For correct functioning a progressive distributor re-
quires at least three pistons, i.e. at lest three pumping
elements.
Technical data:
Operating pressure
at inlet = max. 300 bar Fig. 8 Example: 4 piston elements and 8 outlets
Temperature range= -35°C to + 80°C In detail the progressive distributor consists of a start
element (without piston), a middle element ME and an
Number of ele-
end element EE, which are held together as distributor
ments = Min. 3 piston elements, Max. 12
blocks by tie rods (socket head cap screws) with ser-
piston elements
rated washers. The individual elements are sealed by
O-rings.
Element Max. flow capacity Piston

designation per outlet per ele- 
ment
3
MX- F25 25 mm 50 mm3 3 mm
3
MX- F45 45 mm 90 mm3 4 mm
3
MX- F75 75 mm 150 mm3 5 mm
3
MX- F105 105 mm 210 mm3 6 mm
008 916 41 BOMAG 397

Description of function
Lubricant flows into the distributor inlet port through all
distributor discs to piston I (Fig. 1). Piston (I) is dis-
placed to the left and the lubricant from the left pres-
sure chamber of the pumping piston is pressed to
outlet 1 (Fig. 2).
Then the metering pistons (II) and (III) are displaced in
succession and lubricant is delivered to outlets 2 and
3. After displacing piston (III) lubricant is delivered to
the left side of pumping piston (I) (Fig. 3) and dis-
placed out of the right pressure chamber of the pump-
ing piston to outlet 4.
Then the metering pistons (II) and (III) are displaced in
succession and lubricant is pressed to outlets 5 and 6.
After the displacement of pumping piston (III) the lubri-
cant is once again guided to the right side of the
pumping piston (Fig. 1) and a new cycle of the pro-
gressive piston distributor is started. The function de-
scribed above is repeated, as long as the progressive
distributor is supplied with grease.
Fig. 2
Pressure chamber
Fig. 3
Fig. 1
398 BOMAG 008 916 41

Connection of 2 outlets Connection of several outlets
For large lubrication points it may be necessary to join Connection of outlets with bridging pipes without
two or more outlets on the progressive distributor to- outlet
gether.
Should the total metering quantity exceed the capacity
The individual discs of the progressive distributor of the outlets connected in one disc of the progressive
have two outlets. distributor, e.g. for extremely big lubrication points or
When connecting two outlets on the progressive dis- for main distributors, there is a possibility to join the
tributor, both outlets of one disc are joined together. outlets of several distributor discs with bridging pipes
For this purpose the sealing screw, which separates (Fig. 6).
both sides, is removed and a plug is screwed into the
side to be closed. The metered quantity of the closed
side no emerges from the other side, i.e. the metered
quantity on the open side is doubled.
2 outlets per distributor element (Fig. 4)
single
Fig. 6 Bridging pipe
3 outlets joined together (Fig. 7)

Fig. 4 2 outlets In this case two distributor discs are connected with a
bridging pipe or a distributor bridge without outlet, as
1 Sealing screw
described hereunder. Depending on the element from
1 outlet per distributor element (Fig. 5) which the sealing screw 1 (Fig. 7) had been removed,
three outlets are joined together this way. The me-
tered quantities of the closed outlets then emerge
from one common outlet.
double
The metered quantity is calculated on the basis of the
metering parameters for all joined piston sides.
tripe
Fig. 5 1 outlet
1 Plug
For connecting outlets, plugs are required. single
Fig. 7 3 outlets
1 Sealing screw

With the help of a bridging pipe or a distributor bridge
without outlet you can even join four outlets. For this
purpose the sealing screws must be removed from
both distributor discs and one of the two outlets oppo-
site the bridging pipe or the distributor bridge must be
closed with a plug.
008 916 41 BOMAG 399

Distributor bridge without outlet

Distributor bridge without check valve (Fig. 9)
quadruple
Fig. 8 4 outlets
Fig. 9 without check valve
Distributor bridge with integrated check valve

In order to ensure proper functioning of a progressive
distributor with three delivering elements but only two
outlets (Fig. 10), you must use a distributor bridge
without outlet, but with integrated check valve (Fig.
11).
Fig. 10
Fig. 11 with check valve
400 BOMAG 008 916 41

Connection of outlets with distributor lets in this case emerges from the outlet in the distrib-
bridges with outlet utor disc.
quadruple
Fig. 15 4 outlets
Fig. 12 Distributor bridge with outlet

If two outlets (on different, adjacent distributor discs)
are to be joined together, the sealing screws must not
be unscrewed from any of the affected distributor
discs. The delivery from both outlets in this case
emerges from the outlet on the distributor bridge.
single
double
single
Fig. 13 2 outlets

If three outlets are to be joined together, the sealing
screw must be unscrewed from one of the two affect-
ed distributor discs and a plug must be screwed into
the free outlet on this distributor disc. The delivery
from all three outlets in this case emerges from the
outlet in the distributor disc.
tripe
single
Fig. 14 3 outlets

If four outlets are to be joined together, the sealing
screws must be unscrewed from both distributor discs
the plugs must be screwed into the outlets opposite
the distribuitor bridge. The delivery from all four out-
008 916 41 BOMAG 401

Check valves
The check valves are used in combination with high
pressure hoses, e.g. on lubrication points with high
counter pressure or in main distributors.
There are two versions of check valves available, on
which the pipe socket is screwed in.
Check valve for main distributor (Fig. 16)
Fig. 16
1 Cap screw
2 Duplex ring
Check valve for secondary distributor (Fig. 17)
Fig. 17
1 Cap nut and cutting ring
402 BOMAG 008 916 41

Fault - Cause - Remedy 9.7
9.7 Fault - Cause - Remedy
Fault Cause Remedy

Pump does not work Integrated electronic control defec-
Replace the lower part of the motor
tive protection housing
Electric line interrupted Replace the electric line
Pump defective Replace the pump
Pump works, but does not deliver Air cushion in pumping piston Vent the pump
Min. filling level fallen short of
Fill up the provision container
Pump element defective Replace the pump element
No grease collar at the lubrication Pump does not work See "Pump does not work"
points Pause time too long or lubrication
Reduce pause time or extend lubri-
period too short cation time
System blocked See "Grease emerging from pres-
sure relief valve"
No grease collars at various lubrica- Supply line to secondary distributor Replace the line
tion points burst or leaking
Screw fittings leaking Retighten or replace screw fitting
No grease collar on one lubrication Corresponding grease line burst or Replace the line
point leaking
Screw fitting leaking Retighten or replace screw fitting
Pump speed too low High system pressure or low ambi- Check system / bearing point
ent temperature No damage (perform 1 or 2 interme-
diate lubrication cycles)
Grease emerging from pressure re- System pressure too high Check system
lief valve Progressive distributor blocked Replace the distributor
System blocked Repair blocked / seized bearing
points
Valve spring defective Replace the pressure relief valve
LED-display The LED of the control flashes or is See "Summary of signal displays"
permanently on
Cause for a blockage in the system

l
A crushed or blocked lubricant line
l
A bearing overfilled with lubricant or blocked
l
An unsuitable lubricant for central lubrication systems
l A blocked distributor outlet
l A blocked distributor
Indication of a blockage
l
Grease emerging from pressure relief valve
008 916 41 BOMAG 403

9.7 Fault - Cause - Remedy
Identify the location of the blockage
!Caution
All repair work must be carried out with utmost cleanliness.
Fig. 18
l 1.) Unscrew the main line from the main distributor, operate the pump and check whether lubricant is delivered
properly.
l
2.) Unscrew the cap screws on the distributor one after the other and operate the pump each time a cap screw
is removed. The line (cap screw) at which the pressure drops, is the blocked line or lubrication point.
l 3.) Follow the same principle when checking the associated secondary distributor all the way to the lubrication
point.
Fig. 19 KIT to check central lubrication systems
404 BOMAG 008 916 41

Repair of a blocked distributor 9.8
Repair of a blocked distributor
9.8 Repair of a blocked distributor
Caution
!
All repair work must be carried out with utmost cleanliness.
Fig. 20 Example
Remove the distributor from the system. .
l
Note the sequence of distributor discs.
l
Remove the draw bars 1(Fig. 20)
l Take off the distributor disc(s).
Caution
!
Pistons are not exchangeable among each other .

If piston and bores in the distributor disc show deposits of hardened grease, these deposits must be
removed by washing or blowing out. The bores in the distributor disc must be free of grease residues.
i Note
Grease getting hard indicates that the grease is not suitable for central lubrication systems.
l Unscrew the plugs from the piston bores (2) and slide the pistons from side to side (do not push out).
l Screw the plugs back in.
l Check the next distributor disc, until the blocked piston is found.
l
the piston of the blocked distributor disc out and check the bore in the distributor disc and the surface of the
piston for scratches and damage.
Caution
!
In case of severe damage replace the distributor disc.

l Once all distributor discs have been checked reassemble the distributor in the recorded sequence.
l To prevent jamming of the pistons tighten the draw bars with 12 Nm.
l
Check function of the distributor.
008 916 41 BOMAG 405

9.8 Repair of a blocked distributor
406 BOMAG 008 916 41

10 Suppliers documentation
008 916 41 BOMAG 407

408 BOMAG 008 916 41
10.1 Travel pump
008 916 41 BOMAG 409

10.1 Travel pump
410 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Service Manual
008 916 41 BOMAG 411

10.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
2EVISIONS
HISTORY OF REVISIONS Table of Revisions

Date Page Changed Rev.
!PRIL 70 4ORQUE FOR ' ' ' ' " " " " CHANGED !"
TO .M ; LBFsFT=
3EPTEMBER - &IRST PRINTING REPLACES ",. !!
¹ 3AUER $ANFOSS !LL RIGHTS RESERVED
3AUER $ANFOSS ACCEPTS NO RESPONSIBILITY FOR POSSIBLE ERRORS IN CATALOGS BROCHURES AND OTHER PRINTED MATERIAL
3AUER $ANFOSS RESERVES THE RIGHT TO ALTER ITS PRODUCTS WITHOUT PRIOR NOTICE4HIS ALSO APPLIES TO PRODUCTS
ALREADY ORDERED PROVIDED THAT SUCH ALTERATIONS ARENT IN CONmICT WITH AGREED SPECIlCATIONS !LL TRADEMARKS IN
THIS MATERIAL ARE PROPERTIES OF THEIR RESPECTIVE OWNERS 3AUER $ANFOSS AND THE 3AUER $ANFOSS LOGOTYPE ARE
TRADEMARKS OF THE 3AUER $ANFOSS 'ROUP
&RONT COVER ILLUSTRATIONS & & &
2 520L0818 s 2EV !" s !PRIL 2008
412 BOMAG 008 916 41

Travel pump 10.1
Service Manual
#ONTENTS
INTRODUCTION /VERVIEW

7ARRANTY
'ENERAL INSTRUCTIONS
3AFETY PRECAUTIONS 7
5NINTENDED MACHINE MOVEMENT 7
&LAMMABLE CLEANING SOLVENTS 7
&LUID UNDER PRESSURE 7
0ERSONAL SAFETY 7
3YMBOLS USED IN 3AUER $ANFOSS LITERATURE 8
$ESIGN 9
4HE SYSTEM CIRCUIT0
OPERATION #HARGE PUMP2

#HARGE RELIEF VALVE2
-ULTI FUNCTION VALVES 2
0RESSURE LIMITER AND HIGH PRESSURE RELIEF VALVES
3YSTEM CHECK VALVES
"YPASS VALVES
3PEED SENSORS
&ILTRATION OPTIONS
0RESSURE OVERRIDE 0/2 n FRAME SIZE ONLY
-ANUAL DISPLACEMENT CONTROL -$#
.ON LINEAR -$#
3OLENOID OVERRIDE VALVE FOR -$#
.EUTRAL START SWITCH .33
(YDRAULIC DISPLACEMENT CONTROL ($#
%LECTRIC DISPLACEMENT CONTROL %$#
!UTOMOTIVE CONTROL &"! )) "
0OSITION &.2 ELECTRIC CONTROL
OPERATING /VERVIEW

PARAMETERS )NPUT SPEED
3YSTEM PRESSURE
#HARGE PRESSURE7
#HARGE INLET PRESSURE7
#ASE PRESSURE7
4EMPERATURE AND VISCOSITY8
4EMPERATURE 8
6ISCOSITY8
&LUID AND lLTER RECOMMENDATIONS9
TECHNICAL /VERVIEW 20

SPECIFICATIONS &EATURES AND OPTIONS 20
/PERATING PARAMETERS 20
&LUID SPECIlCATIONS 20
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Service Manual
#ONTENTS
INITIAL STARTUP 'ENERAL 2

PROCEDURES 3TART UP PROCEDURE 2
PRESSURE 2EQUIRED TOOLS 2

MEASUREMENTS 0ORT LOCATIONS AND GAUGE INSTALLATION2
TROUBLESHOOTING /VERVIEW 2

.EUTRAL DIFlCULT OR IMPOSSIBLE TO lND2
3YSTEM OPERATING HOT 2
4RANSMISSION OPERATES NORMALLY IN ONE DIRECTION ONLY 27
3YSTEM WILL NOT OPERATE IN EITHER DIRECTION27
,OW MOTOR OUTPUT TORQUE 28
)MPROPER MOTOR OUTPUT SPEED28
3YSTEM NOISE OR VIBRATION28
3YSTEM RESPONSE IS SLUGGISH29
ADJUSTMENTS 3TANDARD PROCEDURES INSPECTIONS AND ADJUSTMENTS 0

!DJUSTMENTS
#HARGE PRESSURE RELIEF VALVE ADJUSTMENT
-ULTI FUNCTION VALVE PRESSURE ADJUSTMENT
%NGAGING THE BYPASS FUNCTION
0RESSURE OVERRIDE 0/2 VALVE PRESSURE ADJUSTMENT OPTION FOR FRAME SIZE
$ISPLACEMENT LIMITER ADJUSTMENT7
3TANDARD MANUAL DISPLACEMENT CONTROL -$# ADJUSTMENT7
.ON LINEAR MANUAL DISPLACEMENT CONTROL -$# 8
-$# NEUTRAL START SWITCH .33 ADJUSTMENTS 9
.EUTRAL START SWITCH ECCENTRIC PLUG ADJUSTMENT CONDITION I
.33 DEADBAND ADJUSTMENT CONDITIONS II III 2
#HECKING SWITCH CONTINUITY
(YDRAULIC DISPLACEMENT CONTROL ($# AND ELECTRIC DISPLACEMENT CONTROL %$#
ADJUSTMENT
3PEED SENSOR ADJUSTMENT
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Service Manual
#ONTENTS
MINOR REPAIR 3TANDARD PROCEDURES 7

3HAFT SEAL AND SHAFT REPLACEMENT8
-ULTI FUNCTION VALVE CARTRIDGES0
-ULTI FUNCTION VALVE CARTRIDGES PRE 2
0RESSURE OVERRIDE VALVE OPTION FOR FRAME SIZE
#HARGE PRESSURE RELIEF VALVE
!UXILIARY PAD
#HARGE PUMP
!DDING AN !UXILIARY PAD TO A PUMP PREVIOUSLY WITHOUT ONE8
)NTEGRAL CHARGE PRESSURE lLTER REPLACEMENT 9
0UMP CONTROL COVER PLATE0
$ISPLACEMENT CONTROL ORIlCES
$ISPLACEMENT CONTROL ORIlCE CHECK VALVE
$ISPLACEMENT CONTROL ADAPTER PLATE EARLY PRODUCTION PUMPS ONLY
-ANUAL DISPLACEMENT CONTROL -$# 2
3OLENOID OVERRIDE VALVE FOR -$# WITH PRESSURE RELEASED BRAKE
(YDRAULIC AND ELECTRIC DISPLACEMENT CONTROLS
0RESSURE CONTROL PILOT 0#0 FOR ELECTRIC DISPLACEMENT CONTROL %$#
0OSITION &.2 ELECTRIC CONTROL 7
$ISPLACEMENT CONTROL lLTER SCREENS8
3PEED SENSOR8
TORQUE CHART &ASTENER SIZE AND TORQUE CHART 9

0LUG SIZE AND TORQUE CHART 70
&ASTENERS AND PLUGS70
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Service Manual
)NTRODUCTION
OVERVIEW 4HIS MANUAL INCLUDES INFORMATION FOR THE INSTALLATION MAINTENANCE AND MINOR REPAIR OF
3ERIES AXIAL PISTON CLOSED CIRCUIT PUMPS )T INCLUDES A DESCRIPTION OF THE UNIT AND ITS
INDIVIDUAL COMPONENTS TROUBLESHOOTING INFORMATION AND MINOR REPAIR PROCEDURES
0ERFORMING MINOR REPAIRS REQUIRES YOU REMOVE THE UNIT FROM THE VEHICLEMACHINE
4HOROUGHLY CLEAN THE UNIT BEFORE BEGINNING MAINTENANCE OR REPAIR ACTIVITIES 3INCE DIRT
AND CONTAMINATION ARE THE GREATEST ENEMIES OF ANY TYPE OF HYDRAULIC EQUIPMENT FOLLOW
CLEANLINESS REQUIREMENTS STRICTLY4HIS IS ESPECIALLY IMPORTANT WHEN CHANGING THE SYSTEM
lLTER AND WHEN REMOVING HOSES OR PLUMBING
! WORLDWIDE NETWORK OF 3AUER $ANFOSS 'LOBAL 3ERVICE 0ARTNERS '30S IS AVAILABLE FOR
MAJOR REPAIRS 3AUER $ANFOSS TRAINS '30S AND CERTIlES THEIR FACILITIES ON A REGULAR BASIS
9OU CAN LOCATE YOUR NEAREST !3# USING THE DISTRIBUTOR LOCATOR AT WWWSAUER DANFOSSCOM
#LICK ON THE Sales and Service LINK
WARRANTY 0ERFORMING INSTALLATION MAINTENANCE AND MINOR REPAIRS ACCORDING TO THE PROCEDURES IN
THIS MANUAL WILL NOT AFFECT YOUR WARRANTY -AJOR REPAIRS REQUIRING THE REMOVAL OF A UNITS
REAR OR SIDE COVER VOIDS THE WARRANTY UNLESS DONE BY A 3AUER $ANFOSS !UTHORIZED 3ERVICE
#ENTER
GENERAL INSTRUCTIONS &OLLOW THESE GENERAL PROCEDURES WHEN REPAIRING 3ERIES VARIABLE DISPLACEMENT CLOSED
CIRCUIT PUMPS
w Remove the unit

0RIOR TO PERFORMING MAJOR REPAIRS REMOVE THE UNIT FROM THE VEHICLEMACHINE #HOCK
THE WHEELS ON THE VEHICLE OR LOCK THE MECHANISM TO INHIBIT MOVEMENT "E AWARE THAT
HYDRAULIC mUID MAY BE UNDER HIGH PRESSURE ANDOR HOT )NSPECT THE OUTSIDE OF THE PUMP
AND lTTINGS FOR DAMAGE #AP HOSES AFTER REMOVAL TO PREVENT CONTAMINATION
e Keep it clean
#LEANLINESS IS A PRIMARY MEANS OF ASSURING SATISFACTORY PUMP LIFE ON EITHER NEW OR
REPAIRED UNITS #LEAN THE OUTSIDE OF THE PUMP THOROUGHLY BEFORE DISASSEMBLY4AKE CARE
TO AVOID CONTAMINATION OF THE SYSTEM PORTS #LEANING PARTS BY USING A CLEAN SOLVENT WASH
AND AIR DRYING IS USUALLY ADEQUATE
!S WITH ANY PRECISION EQUIPMENT KEEP ALL PARTS FREE OF FOREIGN MATERIALS AND CHEMICALS
0ROTECT ALL EXPOSED SEALING SURFACES AND OPEN CAVITIES FROM DAMAGE AND FOREIGN MATERIAL
)F LEFT UNATTENDED COVER THE PUMP WITH A PROTECTIVE LAYER OF PLASTIC
d Replace all O-rings and gaskets

5SE NEW / RINGS AND GASKETS DURING REASSEMBLY ,IGHTLY LUBRICATE ALL / RINGS WITH CLEAN
PETROLEUM JELLY PRIOR TO ASSEMBLY
t Secure the unit

&OR REPAIR PLACE THE UNIT IN A STABLE POSITION WITH THE SHAFT POINTING DOWNWARD )T WILL BE
NECESSARY TO SECURE THE PUMP WHILE REMOVING AND TORQUING END COVERS CONTROLS AND
VALVES
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Service Manual
)NTRODUCTION
SAFETY PRECAUTIONS !LWAYS CONSIDER SAFETY PRECAUTIONS BEFORE BEGINNING A SERVICE PROCEDURE 0ROTECT
YOURSELF AND OTHERS FROM INJURY4AKE THE FOLLOWING GENERAL PRECAUTIONS WHENEVER SERVICING A
HYDRAULIC SYSTEM
Unintended machine movement

W Warning
5NINTENDED MOVEMENT OF THE MACHINE OR MECHANISM MAY CAUSE INJURY TO THE TECHNICIAN
OR BYSTANDERS4O PROTECT AGAINST UNINTENDED MOVEMENT SECURE THE MACHINE OR DISABLE
DISCONNECT THE MECHANISM WHILE SERVICING
Flammable cleaning solvents

W Warning
3OME CLEANING SOLVENTS ARE mAMMABLE4O AVOID POSSIBLE lRE DO NOT USE CLEANING
SOLVENTS IN AN AREA WHERE A SOURCE OF IGNITION MAY BE PRESENT
Fluid under pressure

W Warning
%SCAPING HYDRAULIC mUID UNDER PRESSURE CAN HAVE SUFlCIENT FORCE TO PENETRATE YOUR SKIN
CAUSING SERIOUS INJURY ANDOR INFECTION4HIS mUID MAY ALSO BE HOT ENOUGH TO CAUSE BURNS
5SE CAUTION WHEN DEALING WITH HYDRAULIC mUID UNDER PRESSURE 2ELIEVE PRESSURE IN THE
SYSTEM BEFORE REMOVING HOSES lTTINGS GAUGES OR COMPONENTS .EVER USE YOUR HAND
OR ANY OTHER BODY PART TO CHECK FOR LEAKS IN A PRESSURIZED LINE 3EEK MEDICAL ATTENTION
IMMEDIATELY IF YOU ARE CUT BY HYDRAULIC mUID
Personal safety
W Warning
0ROTECT YOURSELF FROM INJURY 5SE PROPER SAFETY EQUIPMENT INCLUDING SAFETY GLASSES AT ALL
TIMES
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Service Manual
)NTRODUCTION
SYMBOLS USED IN  7!2.).' MAY RESULT IN INJURY  4IP HELPFUL SUGGESTION

SAUER-DANFOSS
LITERATURE  #!54)/. MAY RESULT IN DAMAGE TO  ,UBRICATE WITH CLEAN HYDRAULIC mUID
PRODUCT OR PROPERTY
 !PPLY GREASEPETROLEUM JELLY
 2EUSABLE PART
 !PPLY LOCKING COMPOUND
 .ON REUSABLE PART USE A NEW PART
 )NSPECT FOR WEAR OR DAMAGE
 .ON REMOVABLE ITEM
 #LEAN AREA OR PART
 /PTION n EITHER PART MAY EXIST
 "E CAREFUL NOT TO SCRATCH OR DAMAGE
 3UPERSEDED n PARTS ARE NOT
INTERCHANGEABLE  .OTE CORRECT ORIENTATION
 -EASUREMENT REQUIRED  -ARK ORIENTATION FOR REINSTALLATION
 &LATNESS SPECIlCATION  4ORQUE SPECIlCATION
 0ARALLELISM SPECIlCATION  0RESS IN n PRESS lT
 %XTERNAL HEX HEAD  0ULL OUT WITH TOOL n PRESS lT
 )NTERNAL HEX HEAD  #OVER SPLINES WITH INSTALLATION

sleeve
 4ORX HEAD
 0RESSURE MEASUREMENTGAUGE
 / RING BOSS PORT LOCATION OR SPECIlCATION
4HE SYMBOLS ABOVE APPEAR IN THE ILLUSTRATIONS AND TEXT OF THIS MANUAL4HEY ARE INTENDED
TO COMMUNICATE HELPFUL INFORMATION AT THE POINT WHERE IT IS MOST USEFUL TO THE READER
)N MOST INSTANCES THE APPEARANCE OF THE SYMBOL ITSELF DENOTES ITS MEANING4HE LEGEND
ABOVE DElNES EACH SYMBOL AND EXPLAINS ITS PURPOSE
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Travel pump 10.1
Service Manual
)NTRODUCTION
DESIGN 3AUER $ANFOSS 3ERIES CLOSED CIRCUIT PISTON PUMPS CONVERT INPUT TORQUE INTO HYDRAULIC
POWER4HE INPUT SHAFT TRANSMITS ROTATIONAL FORCE TO THE CYLINDER BLOCK "EARINGS SUPPORT
THE INPUT SHAFT AT THE FRONT AND REAR OF THE PUMP4HE SHAFT IS SPLINED INTO THE CYLINDER
BLOCK ! LIP SEAL AT THE FRONT END OF THE PUMP PREVENTS LEAKAGE WHERE THE SHAFT EXITS
THE PUMP HOUSING4HE SPINNING CYLINDER BLOCK CONTAINS NINE RECIPROCATING PISTONS !
BALL JOINT AT ONE END CONNECTS EACH PISTON TO A BRASS SLIPPER &IXED CLEARANCE HOLD DOWN
BRACKETS KEEP THE SLIPPERS IN CONTACT WITH THE SWASHPLATE4HE RECIPROCATING MOVEMENT
OF THE PISTONS OCCURS AS THE SLIPPERS SLIDE AGAINST THE INCLINED SWASHPLATE DURING ROTATION
4HE VALVE PLATE CONNECTS ONE HALF OF THE CYLINDER BLOCK TO LOW PRESSURE AND THE OTHER
HALF TO HIGH PRESSURE !S EACH PISTON CYCLES IN AND OUT OF ITS BORE mUID IS DRAWN FROM THE
INLET AND DISPLACED TO THE OUTLET THEREBY IMPARTING HYDRAULIC POWER INTO THE SYSTEM !
SMALL AMOUNT OF mUID mOWS FROM THE CYLINDER BLOCKVALVE PLATE AND SLIPPERSWASHPLATE
INTERFACES FOR LUBRICATION AND COOLING #ASE DRAIN PORTS RETURN THIS mUID TO THE RESERVOIR
4HE ANGLE OF THE SWASHPLATE CONTROLS THE VOLUME OF mUID DISPLACED INTO THE SYSTEM4HE
SERVO PISTON FORCES THE SWASHPLATE INTO AN INCLINED POSITION4HE PUMP CONTROL ACTING
ON INPUT FROM THE OPERATOR BY MODULATING PRESSURE BALANCE ACROSS THE SERVO PISTON SETS
DISPLACEMENT IN THE SYSTEM CIRCUIT
Cross section
Piston
Slipper
Displacement control
Slider block Servo arm
Servo piston
Feedback linkage
Cradle bearing
Bushing
Cylinder block Roller bearing
Shaft
Valve plate seal
Rear
bushing
Input shaft
Charge pump Swashplate Cradle guide P106 648E
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Service Manual
)NTRODUCTION
THE SYSTEM CIRCUIT The basic closed circuit Basic closed circuit diagram
(YDRAULIC LINES CONNECT THE MAIN PORTS
OF THE PUMP TO THE MAIN PORTS OF THE
MOTOR &LUID mOWS IN EITHER DIRECTION
FROM THE PUMP TO THE MOTOR THEN BACK
Reservoir
TO THE PUMP IN THIS CLOSED CIRCUIT %ITHER
OF THE HYDRAULIC LINES CAN BE UNDER HIGH Input PV MF Output
PRESSURE )N PUMPING MODE THE POSITION
OF THE PUMP SWASHPLATE DETERMINES
WHICH LINE IS HIGH PRESSURE AS WELL AS THE
DIRECTION OF mUID mOW
Flow (Bi-directional)
Case drain line
P104 120E
Case drain and heat exchanger

4HE PUMP AND MOTOR REQUIRE CASE DRAIN LINES TO REMOVE HOT mUID FROM THE SYSTEM
4HE TOPMOST PORT DRAINS THE MOTOR TO ENSURE THE CASE REMAINS FULL OF mUID &LUID ROUTES
THROUGH THE LOWER DRAIN PORT ON THE PUMP AND OUT THE TOPMOST PORT TO THE RESERVOIR
! HEAT EXCHANGER WITH A BYPASS VALVE COOLS THE CASE DRAIN mUID BEFORE IT RETURNS TO THE
RESERVOIR
System circuit diagram
Control handle Displacement control valve
Heat exchanger bypass valve
Reservoir
Orificed check
valve Vacuum gauge
Heat exchanger
Purge relief valve
Charge pressure relief valve P102 000
Reversible variable Servo control cylinder Multi-function valve Fixed displacement motor
displacement pump
To
pump
case
Servo
pressure
relief valves
Charge pump
Input shaft Output shaft
Multi-function valve Motor swashplate
Pump swashplate
Servo control cylinder Loop flushing valve
Pump Motor
Working loop (high pressure) Working loop (low pressure) Suction line Control fluid Case drain fluid
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Travel pump 10.1
Service Manual
)NTRODUCTION
THE SYSTEM CIRCUIT

(continued)
Pump schematic
M3
X5
A
M1
M5
M4
M2
L1 S L2
P104 126E
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Service Manual
/PERATION
CHARGE PUMP 4HE CHARGE PUMP IS NECESSARY TO SUPPLY Pump charge system
COOL mUID TO THE SYSTEM TO MAINTAIN
Case
POSITIVE PRESSURE IN THE MAIN SYSTEM drain Charge relief valve
line
LOOP TO PROVIDE PRESSURE TO OPERATE System
check
THE CONTROL SYSTEM AND TO MAKE UP FOR valves
INTERNAL LEAKAGE #HARGE PRESSURE MUST Input PV PF
BE AT ITS SPECIlED PRESSURE UNDER ALL Charge
pump
CONDITIONS TO PREVENT DAMAGE TO THE
TRANSMISSION
4HE CHARGE PUMP IS A lXED
DISPLACEMENT GEROTOR TYPE PUMP DRIVEN Inlet filter
OFF THE MAIN PUMP SHAFT4HE CHARGE Tank P104 121E
RELIEF VALVE LIMITS CHARGE PRESSURE
CHARGE RELIEF VALVE 4HE CHARGE RELIEF VALVE ON THE PUMP Charge pressure relief valve
MAINTAINS CHARGE PRESSURE AT A
DESIGNATED LEVEL ! DIRECT ACTING
POPPET VALVE RELIEVES mUID WHEN CHARGE
PRESSURE REACHES A CERTAIN LEVEL4HIS
LEVEL IS NOMINALLY SET REFERENCING CASE
PRESSURE AT RPM4HIS NOMINAL
SETTING ASSUMES THE PUMP IS IN NEUTRAL
ZERO mOW )N FORWARD OR REVERSE CHARGE
PRESSURE IS LOWER4HE PUMP MODEL CODE
SPECIlES THE CHARGE RELIEF VALVE SETTING
Charge pressure P106 157E
MULTI-FUNCTION VALVES 4HE MULTI FUNCTION VALVE INCORPORATES Multi-function valve

THE SYSTEM CHECK VALVE THE PRESSURE
LIMITER VALVE THE HIGH PRESSURE RELIEF High pressure
Pressure limiter housing relief / check Check valve
VALVE AND THE BYPASS VALVE IN A Pressure limiter valve poppet poppet
REPLACEABLE CARTRIDGE4HESE FUNCTIONS lock nut
ARE DESCRIBED SEPARATELY4HERE ARE TWO Pressure limiter

MULTI FUNCTION VALVE CARTRIDGES IN EACH adjustment screw
3ERIES PUMP TO HANDLE FUNCTIONS

Bypass
IN EITHER DIRECTION 3EE CORRESPONDING actuator Pressure limiter
Bypass
P104 122E
SECTIONS FOR ADJUSTMENTS AND REPAIRS valve poppet
3OME MULTI FUNCTION VALVES DO NOT INCLUDE A PRESSURE LIMITER VALVE
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Travel pump 10.1
Service Manual
/PERATION
PRESSURE LIMITER AND 3ERIES PUMPS HAVE A SEQUENCED Circuit diagram showing pressure
HIGH PRESSURE RELIEF PRESSURE LIMITING SYSTEM AND HIGH control mechanism
VALVES PRESSURE RELIEF VALVES7HEN THE SYSTEM
To control
PRESSURE REACHES THE PRESET THE PRESSURE
LIMITER SYSTEM RAPIDLY DE STROKES THE Multi-function valve
PUMP TO LIMIT SYSTEM PRESSURE &OR
UNUSUALLY RAPID LOAD APPLICATION THE Servo piston Bypass
adjustment
HIGH PRESSURE RELIEF VALVE IMMEDIATELY Port "A"
LIMITS SYSTEM PRESSURE BY CROSS PORTING Servo Pres.
Relief Valve
SYSTEM mOW4HE PRESSURE LIMITER VALVE
Port "B"
ACTS AS THE PILOT FOR THE HIGH PRESSURE
Servo piston Charge
RELIEF VALVE SPOOL4HE HIGH PRESSURE pressure
RELIEF VALVE IS SEQUENCED TO OPERATE AT relief valve
APPROXIMATELY BAR PSI ABOVE THE Multi-function valve
LEVEL THAT INITIATES THE PRESSURE LIMITER P104 123E
VALVE
&OR SOME APPLICATIONS SUCH AS DUAL PATH VEHICLES THE PRESSURE LIMITER FUNCTION MAY BE
DEFEATED SO THAT ONLY THE HIGH PRESSURE RELIEF VALVE FUNCTION REMAINS
SYSTEM CHECK VALVES 4HE SYSTEM CHECK VALVES ALLOW PRESSURIZED mOW FROM THE CHARGE PUMP TO ENTER THE LOW
PRESSURE SIDE OF THE LOOP4HIS IS NEEDED AS THE PUMP GENERALLY LOSES SYSTEM PRESSURE
DUE TO LUBRICATIONCOOLING mOW AND OTHER FACTORS 3INCE THE PUMP OPERATES IN EITHER
DIRECTION THE SYSTEM USES TWO CHECK VALVES TO DIRECT THE CHARGE SUPPLY INTO THE LOW
PRESSURE LINES4HE SYSTEM CHECK VALVES ARE PART OF THE MULTI FUNCTION VALVE ASSEMBLY
BYPASS VALVES 9OU CAN OPERATE THE BYPASS VALVES TO MOVE THE VEHICLE OR MECHANICAL FUNCTION WHEN THE
PUMP IS NOT RUNNING -ANUALLY RESETTING THE VALVE POSITION OPENS THE VALVE4HE BYPASS
VALVES ARE BUILT INTO THE MULTI FUNCTION VALVES
SPEED SENSORS !N OPTIONAL SPEED SENSOR CAN PROVIDE UNIT SPEED INFORMATION4HE SENSOR READS A
MAGNETIC RING ON THE UNITS CYLINDER BLOCK 3EE THE CORRESPONDING SECTION TO LOCATE
INSTALL AND ADJUST THE SPEED SENSOR
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Service Manual
/PERATION
FILTRATION OPTIONS 3ERIES PUMPS MAY HAVE EITHER SUCTION Suction filtration
OR CHARGE PRESSURE lLTRATION TO lLTER THE # !
mUID ENTERING THE CIRCUIT

Suction filtration – option S

4HE SUCTION lLTER IS IN THE CIRCUIT BETWEEN
THE RESERVOIR AND THE INLET TO THE CHARGE
" !!
PUMP AS SHOWN BELOW4HE USE OF A lLTER

CONTAMINATION MONITOR IS RECOMMENDED
Charge pressure filtration – option R, Charge pressure filtration

T, P, and L Screen
4HE PRESSURE lLTER CAN BE MOUNTED
ON THE PUMP OR REMOTELY FOR EASE OF Hydraulic fluid reservoir
Adjustable
SERVICING9OU WILL TYPICALLY lND A charge pressure
relief valve
M MESH SCREEN IN THE RESERVOIR OR
Charge pump
THE CHARGE INLET4HIS SYSTEM REQUIRES A
lLTER CAPABLE OF WITHSTANDING CHARGE Filter
To low To pump case
PRESSURE REFERENCE TO ATMOSPHERE ADD pressure
CASE PRESSURE side and
P102 004E
control
PRESSURE OVERRIDE 4HE 0RESSURE /VER2IDE VALVE 0/2 POR-Valve (180 frame size only)
(POR) – 180 FRAME SIZE MODULATES CONTROL PRESSURE TO MAINTAIN To control
ONLY A PUMP DISPLACEMENT WHICH PRODUCES A
SYSTEM PRESSURE LEVEL LESS THAN OR EQUAL
TO THE 0/2 SETTING &OR UNUSUALLY RAPID Multi-function valve
LOAD APPLICATION THE HIGH PRESSURE RELIEF Pressure

Bypass
VALVE FUNCTION OF THE MULTI FUNCTION override control valve
adjustment
VALVES IS AVAILABLE TO ALSO LIMIT THE Port "A"
PRESSURE LEVEL Shuttle

valve
Port "B"
4HE PRESSURE OVERRIDE CONSISTS OF A THREE

WAY NORMALLY OPEN VALVE WHICH OPERATES
IN SERIES WITH THE PUMP DISPLACEMENT Multi-function valve
Charge pressure
CONTROL #ONTROL SUPPLY PRESSURE NORMALLY relief valve
PORTS THROUGH THE 0/2 VALVE TO THE P104 124E
DISPLACEMENT CONTROL VALVE )F THE SYSTEM
DEMANDS A PRESSURE ABOVE THE OVERRIDE
SETTING THE 0/2 VALVE OVERRIDES THE
CONTROL BY REDUCING THE PRESSURE TO THE DISPLACEMENT CONTROL !S THE CONTROL PRESSURE
REDUCES THE INTERNAL FORCES ROTATING THE SWASHPLATE OVERCOME THE FORCE OF THE SERVO
PISTONS AND DECREASES THE PUMPS DISPLACEMENT
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Service Manual
/PERATION
MANUAL DISPLACEMENT 4HE MANUAL DISPLACEMENT CONTROL CONVERTS A MECHANICAL INPUT SIGNAL TO A HYDRAULIC
CONTROL (MDC) SIGNAL USING A SPRING CENTERED FOUR WAY SERVO VALVE4HIS VALVE PORTS HYDRAULIC PRESSURE
TO EITHER SIDE OF A DUAL ACTING SERVO PISTON4HE SERVO PISTON ROTATES THE CRADLE
SWASHPLATE THROUGH AN ANGULAR ROTATION OF ¼² VARYING THE PUMPS DISPLACEMENT FROM
FULL IN ONE DIRECTION TO FULL IN THE OPPOSITE DIRECTION4HE ANGULAR POSITION OF THE PUMP
SWASHPLATE IS PROPORTIONAL TO THE ROTATION OF THE CONTROL INPUT SHAFT
NON-LINEAR MDC 4HE NON LINEAR MANUAL DISPLACEMENT CONTROL OPERATES IN THE SAME MANNER EXCEPT THAT IT
IS DESIGNED SO THE CHANGE IN THE ANGULAR POSITION OF THE PUMP SWASHPLATE PROGRESSIVELY
INCREASES AS THE CONTROL INPUT SHAFT IS ROTATED TOWARD ITS MAXIMUM DISPLACEMENT POSITION
SOLENOID OVERRIDE ! SOLENOID OVERRIDE VALVE OPTION IS AVAILABLE FOR THE -$#4HIS SAFETY FEATURE RETURNS THE
VALVE FOR MDC SWASHPLATE TO ZERO DISPLACEMENT )T IS AVAILABLE IN NORMALLY OPEN ACTIVATE TO ALLOW OR
NORMALLY CLOSED ACTIVATE TO DISALLOW OPTIONS
NEUTRAL START SWITCH 4HE NEUTRAL START SWITCH IS AN OPTIONAL FEATURE AVAILABLE WITH THE -$#7HEN CONNECTED
(NSS) PROPERLY WITH THE VEHICLES ELECTRICAL SYSTEM THE NEUTRAL START SWITCH ENSURES THAT THE
PRIME MOVER CAN START ONLY WHEN THE CONTROL IS IN NEUTRAL POSITION
HYDRAULIC 4HE HYDRAULIC DISPLACEMENT CONTROL USES A HYDRAULIC INPUT SIGNAL TO OPERATE A SPRING
DISPLACEMENT CENTERED FOUR WAY SERVO VALVE4HIS VALVE PORTS HYDRAULIC PRESSURE TO EITHER SIDE OF A
CONTROL (HDC) DUAL ACTING SERVO PISTON4HE SERVO PISTON ROTATES THE CRADLE SWASHPLATE THROUGH AN
ANGULAR ROTATION OF ¼² THUS VARYING THE PUMPS DISPLACEMENT FROM FULL DISPLACEMENT IN
ONE DIRECTION TO FULL DISPLACEMENT IN THE OPPOSITE DIRECTION4HE ANGULAR POSITION OF THE
PUMP SWASHPLATE IS PROPORTIONAL TO INPUT PRESSURE
ELECTRIC DISPLACEMENT 4HE ELECTRIC DISPLACEMENT CONTROL USES A 0RESSURE #ONTROL 0ILOT 0#0 VALVE TO MODULATE
CONTROL (EDC) PRESSURE BALANCE ACROSS THE SPRING CENTERED FOUR WAY SERVO VALVE4HE 0#0 VALVE
CONVERTS A $# ELECTRICAL INPUT SIGNAL TO A HYDRAULIC SIGNAL4HE SERVO VALVE PORTS HYDRAULIC
PRESSURE TO EITHER SIDE OF A DUAL ACTING SERVO PISTON4HE SERVO PISTON ROTATES THE
SWASHPLATE THROUGH AN ANGULAR ROTATION OF ¼² VARYING THE PUMPS DISPLACEMENT4HE
ANGULAR POSITION OF THE SWASHPLATE IS PROPORTIONAL TO THE %$# INPUT
AUTOMOTIVE CONTROL 4HE AUTOMOTIVE CONTROL ALLOWS THE OPERATOR TO DRIVE A VEHICLE SIMILAR TO AN AUTOMOBILE
(FBA II B) WITH AN AUTOMATIC TRANSMISSION4HE AUTOMOTIVE CONTROL INCLUDES A THREE POSITION
ELECTRIC CONTROL TO PROVIDE DIRECTION CONTROL
3-POSITION (FNR) 4HIS CONTROL UTILIZES A OR 6DC ELECTRICALLY OPERATED SPOOL VALVE TO PORT PRESSURE TO
ELECTRIC CONTROL EITHER SIDE OF THE PUMP SERVO PISTON %NERGIZING ONE OF THE SOLENOIDS CAUSES THE PUMP
TO GO TO ITS MAXIMUM DISPLACEMENT IN THE CORRESPONDING DIRECTION !LL FUNCTIONS OF THE
THREE POSITION &.2 ELECTRIC CONTROL ARE PRESET AT THE FACTORY
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Service Manual
/PERATING PARAMETERS
OVERVIEW 4HIS SECTION DElNES THE OPERATING PARAMETERS AND LIMITATIONS FOR 3ERIES PUMPS WITH
REGARD TO INPUT SPEEDS AND PRESSURES &OR ACTUAL PARAMETERS REFER TO THE OPERATING
PARAMETERS FOR EACH DISPLACEMENT
INPUT SPEED Minimum speed IS THE LOWEST INPUT SPEED RECOMMENDED DURING ENGINE IDLE CONDITION
/PERATING BELOW MINIMUM SPEED LIMITS THE PUMPS ABILITY TO MAINTAIN ADEQUATE mOW FOR
LUBRICATION AND POWER TRANSMISSION
Continuous speed IS THE HIGHEST INPUT SPEED RECOMMENDED AT FULL POWER CONDITION
/PERATING AT OR BELOW THIS SPEED SHOULD YIELD SATISFACTORY PRODUCT LIFE
Maximum speed IS THE HIGHEST OPERATING SPEED PERMITTED %XCEEDING MAXIMUM SPEED
REDUCES PRODUCT LIFE AND CAN CAUSE LOSS OF HYDROSTATIC POWER AND BRAKING CAPACITY .EVER
EXCEED THE MAXIMUM SPEED LIMIT UNDER ANY OPERATING CONDITIONS
7HEN DETERMINING SPEED LIMITS FOR A PARTICULAR APPLICATION SEE 3AUER $ANFOSS
PUBLICATION BLN-9884 Pressure and speed limits
W7ARNING
Unintended vehicle or machine movement hazard
%XCEEDING MAXIMUM SPEED MAY CAUSE A LOSS OF HYDROSTATIC DRIVE LINE POWER AND BRAKING
CAPACITY9OU MUST PROVIDE A BRAKING SYSTEM REDUNDANT TO THE HYDROSTATIC TRANSMISSION
SUFlCIENT TO STOP AND HOLD THE VEHICLE OR MACHINE IN THE EVENT OF HYDROSTATIC DRIVE POWER
LOSS
SYSTEM PRESSURE System pressure IS THE DIFFERENTIAL PRESSURE BETWEEN SYSTEM PORTS ! AND " )T IS THE
DOMINANT OPERATING VARIABLE AFFECTING HYDRAULIC UNIT LIFE (IGH SYSTEM PRESSURE WHICH
RESULTS FROM HIGH LOAD REDUCES EXPECTED LIFE 3YSTEM PRESSURE MUST REMAIN AT OR BELOW
CONTINUOUS PRESSURE DURING NORMAL OPERATION TO ACHIEVE EXPECTED LIFE
Continuous pressure IS THE AVERAGE REGULARLY OCCURRING OPERATING PRESSURE /PERATING

AT OR BELOW THIS PRESSURE SHOULD YIELD SATISFACTORY PRODUCT LIFE
Maximum pressure IS THE HIGHEST INTERMITTENT PRESSURE ALLOWED -AXIMUM MACHINE

LOAD SHOULD NEVER EXCEED THIS PRESSURE &OR ALL APPLICATIONS THE LOAD SHOULD MOVE BELOW
THIS PRESSURE
!LL PRESSURE LIMITS ARE DIFFERENTIAL PRESSURES REFERENCED TO LOW LOOP CHARGE PRESSURE
3UBTRACT LOW LOOP PRESSURE FROM GAUGE READINGS TO COMPUTE THE DIFFERENTIAL
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Travel pump 10.1
Service Manual
CHARGE PRESSURE !N INTERNAL CHARGE RELIEF VALVE REGULATES CHARGE PRESSURE4HE CHARGE PUMP SUPPLIES THE
CONTROL WITH PRESSURE TO OPERATE THE SWASHPLATE AND TO MAINTAIN A MINIMUM PRESSURE IN
THE LOW SIDE OF THE TRANSMISSION LOOP
Minimum charge pressure IS THE LOWEST PRESSURE ALLOWED TO MAINTAIN A SAFE WORKING
CONDITION IN THE LOW SIDE OF THE LOOP -INIMUM CONTROL PRESSURE REQUIREMENTS ARE A
FUNCTION OF SPEED PRESSURE AND SWASHPLATE ANGLE AND MAY BE HIGHER THAN THE MINIMUM
CHARGE PRESSURE SHOWN IN THE OPERATING PARAMETERS TABLE
Maximum charge pressure IS THE HIGHEST CHARGE PRESSURE ALLOWED BY THE CHARGE RELIEF
ADJUSTMENT AND PROVIDES NORMAL COMPONENT LIFE9OU CAN USE ELEVATED CHARGE PRESSURE
AS A SECONDARY MEANS TO REDUCE THE SWASHPLATE RESPONSE TIME
4HE CHARGE PRESSURE SETTING IN THE ORDER CODE IS THE SET PRESSURE OF THE CHARGE RELIEF
VALVE WITH THE PUMP IN NEUTRAL OPERATING AT MIN RPM AND WITH A mUID VISCOSITY
OF MM2SEC 353 4HE CHARGE PRESSURE SETTING IS REFERENCED TO CASE PRESSURE
#HARGE PRESSURE IS THE DIFFERENTIAL PRESSURE ABOVE CASE PRESSURE
CHARGE INLET PRESSURE !T NORMAL OPERATING TEMPERATURE CHARGE INLET PRESSURE MUST NOT FALL BELOW rated charge
inlet pressure
Minimum charge inlet pressure IS ONLY ALLOWED AT COLD START CONDITIONS )N SOME
APPLICATIONS IT MAY BE NECESSARY TO WARM UP THE mUID BY RUNNING THE ENGINE AT LIMITED
SPEED UNTIL THE SYSTEM mUID TEMPERATURE REACHES AN ACCEPTABLE LEVEL
5NDER NORMAL OPERATING CONDITIONS DO NOT EXCEED THE rated case pressure $URING COLD
CASE PRESSURE START MAINTAIN THE CASE PRESSURE BELOW MAXIMUM INTERMITTENT CASE PRESSURE
C#AUTION
Possible component damage or leakage
/PERATION WITH CASE PRESSURE IN EXCESS OF STATED LIMITS MAY DAMAGE SEALS GASKETS ANDOR
HOUSINGS CAUSING EXTERNAL LEAKAGE 0ERFORMANCE MAY ALSO BE AFFECTED SINCE CHARGE AND
SYSTEM PRESSURE ARE ADDITIVE TO CASE PRESSURE
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10.1 Travel pump
Service Manual
TEMPERATURE AND Temperature

VISCOSITY 4HE HIGH TEMPERATURE LIMITS APPLY AT THE HOTTEST POINT IN THE TRANSMISSION LOOP WHICH
IS NORMALLY THE MOTOR CASE DRAIN -AINTAIN SYSTEM TEMPERATURE BELOW THE QUOTED rated
temperature
.EVER EXCEED THE maximum intermittent temperature
#OLD OIL WILL GENERALLY NOT AFFECT THE DURABILITY OF THE TRANSMISSION COMPONENTS BUT IT
MAY AFFECT THE ABILITY OF OIL TO mOW AND TRANSMIT POWER THEREFORE TEMPERATURES SHOULD
REMAIN ²# ; ²&= ABOVE THE POUR POINT OF THE HYDRAULIC mUID
4HE minimum temperature RELATES TO THE PHYSICAL PROPERTIES OF COMPONENT MATERIALS
3IZE HEAT EXCHANGERS TO KEEP THE mUID WITHIN THESE LIMITS4EST HEAT EXCHANGERS TO VERIFY
THAT THESE TEMPERATURE LIMITS ARE NOT EXCEEDED
Viscosity
&OR MAXIMUM EFlCIENCY AND BEARING LIFE ENSURE THE mUID VISCOSITY REMAINS IN THE
recommended range
Minimum viscosity SHOULD BE ENCOUNTERED ONLY DURING BRIEF OCCASIONS OF MAXIMUM

AMBIENT TEMPERATURE AND SEVERE DUTY CYCLE OPERATION
Maximum viscosity SHOULD BE ENCOUNTERED ONLY AT COLD START
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Travel pump 10.1
Service Manual
FLUID AND FILTER 4O ENSURE OPTIMUM PUMP LIFE PERFORM REGULAR MAINTENANCE OF THE mUID AND lLTER
RECOMMENDATIONS #ONTAMINATED mUID IS THE MAIN CAUSE OF UNIT FAILURE -AINTAIN mUID CLEANLINESS WHEN
SERVICING
#HECK THE RESERVOIR DAILY FOR PROPER mUID LEVEL THE PRESENCE OF WATER AND RANCID mUID
ODOR &LUID CONTAMINATED BY WATER MAY APPEAR CLOUDY OR MILKY OR FREE WATER MAY
SETTLE IN THE BOTTOM OF THE RESERVOIR 2ANCID ODOR INDICATES THE mUID HAS BEEN EXPOSED
TO EXCESSIVE HEAT #HANGE THE mUID IMMEDIATELY IF THESE CONDITIONS OCCUR #ORRECT THE
PROBLEM IMMEDIATELY
)NSPECT VEHICLE FOR LEAKS DAILY

Fluid and filter change interval
#HANGE THE mUID AND lLTER PER THE Reservoir type Max oil change interval
VEHICLEMACHINE MANUFACTURERS 3EALED HOURS
RECOMMENDATIONS OR AT THE INTERVALS "REATHER HOURS
SHOWN IN THE TABLE #HANGE mUID AFTER
lRST HOURS
C#AUTION
(IGH TEMPERATURES AND PRESSURES RESULT IN ACCELERATED mUID AGING #HANGE mUID MORE
FREQUENTLY IF OPERATING UNDER EXTREME CONDITIONS
#HANGE THE mUID MORE FREQUENTLY IF IT BECOMES CONTAMINATED WITH FOREIGN MATTER DIRT
WATER GREASE ETC OR IF THE mUID IS SUBJECTED TO TEMPERATURE LEVELS GREATER THAN THE
RECOMMENDED MAXIMUM
$ISPOSE OF USED HYDRAULIC mUID PROPERLY .EVER REUSE HYDRAULIC mUID
#HANGE lLTERS WHENEVER THE mUID IS CHANGED OR WHEN THE lLTER INDICATOR INDICATES A lLTER
CHANGE 2EPLACE ALL mUID LOST DURING lLTER CHANGE
&OR DETAILED lLTRATION INFORMATION SEE 3AUER $ANFOSS PUBLICATION 520L0463 Fluids
and Filtration &OR INFORMATION ON BIODEGRADABLE mUIDS SEE 3AUER $ANFOSS PUBLICATION
520L0465 Biodegradable Hydraulic Fluids
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10.1 Travel pump
Service Manual
4ECHNICAL SPECIlCATIONS
OVERVIEW 3PECIlCATIONS AND OPERATING PARAMETERS FOR PUMPS APPEAR HERE FOR REFERENCE
FEATURES AND OPTIONS Model Series 90 Pumps

Mount 3!% " 3!% # AND % 3!% *
Pump type !XIAL PISTON TYPE
Rotation "IDIRECTIONAL
Installation position $ISCRETIONARY (OUSING MUST ALWAYS BE lLLED WITH HYDRAULIC mUID $O NOT INSTALL WITH
CONTROL ON BOTTOM
Input shafts 3PLINED
Control options -$# WITH OPTIONS %$# ($# &.2
OPERATING Parameter Unit Pressure

PARAMETERS 2ATED ;=
BAR
3YSTEM PRESSURE -AXIMUM ;=
;PSI=
-INIMUM LOW LOOP ;=
Minimum BAR ;=
#HARGE PRESSURE
-AXIMUM ;PSI= ;=
2ATED BAR ABSOLUTE ;=
#HARGE INLET PRESSURE
-INIMUM COLD START ;IN (G VACUUM= ;=
2ATED BAR ;=
#ASE PRESSURE
-AXIMUM ;PSI= ;=
Frame size
Parameter Unit
042 055 075 100 130 180 250
Displacement cm³
MAXIMUM ;INÃ= ;= ;= ;= ;= ;= ;= ;=
Minimum speed min-1 RPM
Rated speed min-1 RPM
Maximum speed min-1 RPM
Maximum attainable speed at
min-1 RPM
maximum displacement
.sMBAR
Theoretical torque at maximum
;LBFsIN
displacement ;= ;= ;= ;= ;= ;= ;=
PSI=
kg 88
Weight BASE UNIT ONLY
;LB= ;= ;= ;= ;= ;= ;= ;=
FLUID SPECIFICATIONS Parameter Unit Minimum Continuous Maximum

6ISCOSITY mm2SEC C3T 7
;353= ;= ; = ;=
2ATINGS AND DATA ARE BASED 4EMPERATURE ²# ;²&= ; = ;= ;=
ON OPERATION WITH PREMIUM #LEANLINESS )3/ #LASS OR BETTER
PETROLEUM BASED HYDRAULIC &ILTRATION EFlCIENCY SUCTION lLTRATION β β≥
mUIDS CONTAINING OXIDATION CHARGE lLTRATION β β≥
AND FOAM INHIBITORS
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Travel pump 10.1
Service Manual
)NITIAL START UP PROCEDURE
GENERAL &OLLOW THIS PROCEDURE WHEN STARTING UP A NEW PUMP INSTALLATION OR WHEN RESTARTING AN
INSTALLATION IN WHICH THE PUMP WAS REMOVED
W 7ARNING
0RIOR TO INSTALLING THE PUMP INSPECT FOR SHIPPING DAMAGE
START-UP PROCEDURE %NSURE THAT THE HYDRAULIC mUID AND SYSTEM COMPONENTS RESERVOIR HOSES VALVES
lTTINGS AND HEAT EXCHANGER ARE CLEAN AND FREE OF CONTAMINATION
)NSTALL NEW SYSTEM lLTER ELEMENTS IF NECESSARY #HECK THAT INLET LINE lTTINGS ARE
PROPERLY TIGHTENED AND THERE ARE NO AIR LEAKS
)NSTALL THE PUMP )NSTALL A BAR ; PSI= GAUGE IN THE CHARGE PRESSURE GAUGE PORT
-
&ILL THE HOUSING BY ADDING lLTERED mUID IN THE UPPER CASE DRAIN PORT /PEN THE CASE
PLUG IN THE TOP OF THE CONTROL TO ASSIST WITH AIR BLEED
&ILL THE RESERVOIR WITH HYDRAULIC mUID OF THE RECOMMENDED TYPE AND VISCOSITY 5SE A
MICRON lLLER lLTER &ILL INLET LINE FROM RESERVOIR TO PUMP
$ISCONNECT THE PUMP CONTROL INPUT SIGNAL
!FTER START UP THE mUID LEVEL IN THE RESERVOIR MAY DROP DUE TO lLLING OF THE SYSTEM
COMPONENTS #HECK THE LEVEL IN THE RESERVOIR TO MAINTAIN A FULL mUID LEVEL THROUGHOUT THE
START UP PROCEDURE
C #AUTION
$AMAGE TO HYDRAULIC COMPONENTS MAY OCCUR FROM FAILURE TO MAINTAIN mUID SUPPLY
5SE A COMMON METHOD TO DISABLE THE ENGINE TO PREVENT THE ENGINE FROM STARTING
#RANK THE STARTER FOR SEVERAL SECONDS $O NOT TO EXCEED THE ENGINE MANUFACTURERS
RECOMMENDATION7AIT SECONDS AND THEN CRANK THE ENGINE A SECOND TIME
4HIS OPERATION HELPS REMOVE AIR FROM THE SYSTEM LINES 2ElLL THE RESERVOIR TO
RECOMMENDED FULL mUID LEVEL
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10.1 Travel pump
Service Manual
)NITIAL START UP PROCEDURE
START-UP PROCEDURE 7HEN CHARGE PRESSURE REACHES BAR ; PSI= ENABLE AND START ENGINE ,ET THE
(continued) ENGINE RUN FOR A MINIMUM OF SECONDS AT LOW IDLE TO ALLOW THE AIR TO WORK ITSELF OUT
OF THE SYSTEM #HECK FOR LEAKS AT ALL LINE CONNECTIONS AND LISTEN FOR CAVITATION #HECK
FOR PROPER mUID LEVEL IN RESERVOIR
C#AUTION
!IR ENTRAPMENT IN mUID UNDER HIGH PRESSURE MAY DAMAGE HYDRAULIC COMPONENTS
C#AUTION
$O NOT RUN AT MAXIMUM PRESSURE UNTIL SYSTEM IS FREE OF AIR AND mUID HAS BEEN THOROUGHLY
lLTERED
7HEN ADEQUATE CHARGE PRESSURE IS ESTABLISHED AS SHOWN IN MODEL CODE INCREASE
ENGINE SPEED TO NORMAL OPERATING RPM TO FURTHER PURGE RESIDUAL AIR FROM THE SYSTEM
3HUT OFF THE ENGINE #ONNECT THE PUMP CONTROL SIGNAL 3TART THE ENGINE CHECKING TO
BE CERTAIN THE PUMP REMAINS IN NEUTRAL 2UN THE ENGINE AT NORMAL OPERATING SPEED
AND CAREFULLY CHECK FOR FORWARD AND REVERSE CONTROL OPERATION
#ONTINUE TO CYCLE BETWEEN FORWARD AND REVERSE FOR AT LEAST lVE MINUTES TO BLEED ALL
AIR AND mUSH SYSTEM CONTAMINANTS OUT OF LOOP
.ORMAL CHARGE PRESSURE mUCTUATION MAY OCCUR DURING FORWARD AND REVERSE OPERATION
#HECK THAT THE RESERVOIR IS FULL 2EMOVE CHARGE PRESSURE GAUGE4HE PUMP IS NOW
READY FOR OPERATION
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Travel pump 10.1
Service Manual
0RESSURE MEASUREMENT
REQUIRED TOOLS 9OU CAN PERFORM THE SERVICE PROCEDURES DESCRIBED IN THIS MANUAL USING COMMON
MECHANICS TOOLS 3PECIAL TOOLS IF REQUIRED ARE SHOWN 5SE CALIBRATED PRESSURE GAUGES TO
ENSURE ACCURACY 5SE SNUBBERS TO PROTECT PRESSURE GAUGES
PORT LOCATIONS AND 4HE FOLLOWING SECTIONS LIST THE PORTS FOR EACH TYPE OF HYDRAULIC UNIT4HE lTTING SIZE AND
GAUGE INSTALLATION RECOMMENDED PRESSURE GAUGE ARE ALSO SPECIlED
4HE FOLLOWING TABLE AND DRAWINGS SHOW THE PORT LOCATIONS AND GAUGE SIZES NEEDED
Port information
Port identifier Pressure obtained Gauge size Port size
M1, M2 3YSTEM PRESSURE BAR ; PSI=
M3 (M6) #HARGE PRESSURE BAR ; PSI=
M4, M5 3ERVO PRESSURE BAR ; PSI=
L1, L2 #ASE PRESSURE BAR ; PSI=

X1, X2 ($#%$# CONTROL PRESSURE BAR ; PSI= OR
X3 %XTERNAL CONTROL PRESSURE BAR ; PSI=
S #HARGE PUMP INLET 6ACUUM GAUGE
4EE INTO INLET LINE

3!% SPLIT mANGE
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10.1 Travel pump
Service Manual
PORT LOCATIONS AND

GAUGE INSTALLATION
(continued)
Pump with side port end cap and manual displacement control
Case drain Servo / displacement

port L1 cylinder pressure
gauge port M4
Servo / displacement
System pressure cylinder pressure
port B gauge port M5
External control pressure
System pressure supply port X3
gauge port M2
Speed sensor
Charge inlet pressure

(vacuum)
System pressure
gauge port M1
Carge pump
inlet port S System pressure
port A Case drain port L2 Charge pressure
gauge port M3 P106 158E
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Travel pump 10.1
Service Manual
PORT LOCATIONS AND

GAUGE INSTALLATION
(continued)
Pump with twin port end cap and manual displacement control
cylinder pressure
gauge port M4
Case drain
port L1
cylinder pressure
gauge port M5
System pressure
gauge port M2
System pressure
port B
Charge pump inlet

port S
System pressure
port A
System pressure
gauge port M1
Case drain port L2
P106 160E
Pump with side port end cap and remote pressure filtration Pump with side port end cap and integral pressure
filtration
Charge pressure
gauge port M6 Port E
(before the filter) (from filter)
Port D
(to filter)
Charge pressure
gauge port M3
Charge pressure (back side-after
gauge port M3 the filter)
(after the filter)
P106 163E
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008 916 41 BOMAG 435
10.1 Travel pump
Service Manual
4ROUBLESHOOTING
OVERVIEW 4HIS SECTION PROVIDES GENERAL STEPS TO FOLLOW IF CERTAIN UNDESIRABLE SYSTEM CONDITIONS
OCCUR &OLLOW THE STEPS IN A SECTION UNTIL YOU SOLVE THE PROBLEM 3OME OF THE ITEMS
ARE SYSTEM SPECIlC &OR AREAS COVERED IN THIS MANUAL WE REFERENCE THE SECTION !LWAYS
OBSERVE THE SAFETY PRECAUTIONS LISTED IN THE Introduction SECTION PAGE AND THOSE
RELATING TO YOUR SPECIlC EQUIPMENT
NEUTRAL DIFFICULT OR
IMPOSSIBLE TO FIND
Item Description Action

)NPUT TO PUMP CONTROL )NPUT TO CONTROL MODULE IS OPERATING IMPROPERLY #HECK CONTROL INPUT AND REPAIR OR REPLACE AS NECESSARY
0UMP DISPLACEMENT CONTROL #ONTROL LINAGES ARE NOT SECURE CONTROL ORIlCES ARE !DJUST REPAIR OR REPLACE CONTROL MODULE AS NECESSARY
BLOCKED
-ULTIFUNCTION VALVE -ULTIFUNCTION VALVE IS LEAKING 3WAP MULTIFUNCTION VALVES )F SYSTEM CHANGES DIRECTION
REPLACE DEFECTIVE VALVE
SYSTEM OPERATING HOT

/IL LEVEL IN RESERVOIR )NSUFlCIENT HYDRAULIC mUID WILL NOT MEET COOLING &ILL RESERVOIR TO PROPER LEVEL
DEMANDS OF SYSTEM
(EAT EXCHANGER (EAT EXCHANGER IS NOT SUFlCIENTLY COOLING THE #HECK AIR mOW AND INPUT AIR TEMPERATURE FOR HEAT
SYSTEM EXCHANGER #LEAN REPAIR OR REPLACE HEAT EXCHANGER
#HARGE PRESSURE ,OW CHARGE PRESSURE WILL OVERWORK SYSTEM -EASURE CHARGE PRESSURE )NSPECT AND ADJUST OR REPLACE
CHARGE RELIEF VALVE OR REPAIR LEAKY CHARGE PUMP
#HARGE PUMP INLET VACUUM (IGH INLET VACUUM WILL OVERWORK SYSTEM ! DIRTY #HECK CHARGE INLET VACUUM )F HIGH INSPECT INLET lLTER AND
lLTER WILL INCREASE THE INLET VACUUM )NADEQUATE LINE REPLACE AS NECESSARY #HECK FOR ADEQUATE LINE SIZE LENGTH
SIZE WILL RESTRICT mOW OR OTHER RESTRICTIONS
3YSTEM RELIEF PRESSURE SETTINGS )F THE SYSTEM RELIEF SETTINGS ARE TOO LOW THE RELIEF 6ERIFY SETTINGS OF PRESSURE LIMITERS AND HIGH PRESSURE
VALVES WILL BE OVERWORKED RELIEF VALVES AND ADJUST OR REPLACE MULTI FUNCTION VALVES
AS NECESSARY
&OR INTERNAL LEAKAGE IN MOTOR ,EAKAGE WILL REDUCE LOW SIDE SYSTEM PRESSURE AND -ONITOR MOTOR CASE mOW WITHOUT LOOP mUSHING IN THE
OVERWORK THE SYSTEM CIRCUIT USE DEFEAT SPOOL )F mOW IS EXCESSIVE REPLACE
MOTOR
3YSTEM PRESSURE (IGH SYSTEM PRESSURE WILL OVERHEAT SYSTEM -EASURE SYSTEM PRESSURE )F PRESSURE IS HIGH REDUCE LOADS
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Travel pump 10.1
Service Manual
4ROUBLESHOOTING
TRANSMISSION
OPERATES NORMALLY IN
ONE DIRECTION ONLY

)NPUT TO PUMP CONTROL )NPUT TO CONTROL MODULE IS OPERATING IMPROPERLY #HECK CONTROL INPUT AND REPAIR OR REPLACE AS NECESSARY
0UMP DISPLACEMENT CONTROL #ONTROL LINKAGES ARE NOT SECURE CONTROL ORIlCES ARE 2EPAIR OR REPLACE CONTROL MODULE AS NECESSARY
BLOCKED
3YSTEM PRESSURE LIMITERS HIGH )NTERCHANGING THE MULTI FUNCTION VALVES WILL SHOW )NTERCHANGE MULTI FUNCTION VALVES )F THE PROBLEM
PRESSURE RELIEF VALVES OR SYSTEM IF THE PROBLEM IS RELATED TO THE VALVE FUNCTIONS CHANGES DIRECTION REPAIR OR REPLACE THE VALVE ON THE SIDE
CHECK VALVES CONTAINED IN THE MULTI FUNCTION VALVES THAT DOES NOT OPERATE
#HARGE PRESSURE )F CHARGE PRESSURE DECAYS IN ONE DIRECTION THE LOOP -EASURE CHARGE PRESSURE IN FORWARD AND REVERSE )F
mUSHING VALVE MAY BE STICKING IN ONE DIRECTION PRESSURE DECAYS IN ONE DIRECTION INSPECT AND REPAIR THE
MOTOR LOOP mUSHING VALVE
SYSTEM WILL NOT

OPERATE IN EITHER
DIRECTION

/IL LEVEL IN RESERVOIR )NSUFlCIENT HYDRAULIC mUID TO SUPPLY SYSTEM LOOP &ILL RESERVOIR TO PROPER LEVEL
)NPUT TO PUMP CONTROL )NPUT TO CONTROL MODULE IS OPERATING IMPROPERLY #HECK CONTROL INPUT AND REPAIR REPLACE AS NECESSARY
0UMP DISPLACEMENT CONTROL #ONTROL LINKAGE IS NOT SECURE CONTROL ORIlCES ARE 2EPAIR OR REPLACE CONTROL MODULE AS NECESSARY
BLOCKED ETC
"YPASS VALVES OPEN )F BYPASS VALVES ARE OPEN THE SYSTEM LOOP WILL BE #LOSE BYPASS VALVES 2EPLACE MULTI FUNCTION VALVE IF
DEPRESSURIZED DEFECTIVE
#HARGE PRESSURE WITH PUMP IN ,OW CHARGE PRESSURE IS INSUFlCIENT TO RECHARGE -EASURE CHARGE PRESSURE WITH THE PUMP IN NEUTRAL )F
NEUTRAL SYSTEM LOOP PRESSURE IS LOW GO TO Pump charge relief valve OTHERWISE
CONTINUE WITH Charge pressure with pump in stroke.
#HARGE PRESSURE WITH PUMP IN ,OW CHARGE PRESSURE WITH THE PUMP IN STROKE -EASURE CHARGE PRESSURE WITH PUMP IN STROKE )F PRESSURE
STROKE INDICATES A MOTOR CHARGE RELIEF VALVE OR SYSTEM IS LOW ADJUST OR REPLACE MOTOR CHARGE RELIEF VALVE
PRESSURE RELIEF VALVE MAY BE IMPROPERLY SET OTHERWISE GO TO Charge pumps.
0UMP CHARGE RELIEF VALVE ! PUMP CHARGE RELIEF VALVE THAT IS LEAKY OR SET TOO LOW !DJUST OR REPLACE PUMP CHARGE RELIEF VALVE AS NECESSARY
WILL DEPRESSURIZE THE SYSTEM
#HARGE PUMP INLET lLTER ! CLOGGED lLTER WILL UNDER SUPPLY SYSTEM LOOP )NSPECT lLTER AND REPLACE IF NECESSARY
#HARGE PUMPS ! MALFUNCTIONING CHARGE PUMP WILL PROVIDE 2EPAIR OR REPLACE THE CHARGE PUMP
INSUFlCIENT CHARGE mOW
0UMP DISPLACEMENT CONTROL #ONTROL LINKAGES ARE NOT SECURE CONTROL ORIlCES ARE 2EPAIR OR REPLACE CONTROL MODULE AS NECESSARY
BLOCKED
3YSTEM PRESSURE ,OW SYSTEM PRESSURE WILL NOT PROVIDE POWER -EASURE SYSTEM PRESSURE #ONTINUE TO NEXT STEP
NECESSARY TO MOVE LOAD
3YSTEM MULTI FUNCTION VALVES $EFECTIVE MULTI FUNCTION VALVES WILL CAUSE SYSTEM TO 2EPAIR OR REPLACE MULTI FUNCTION VALVES
PRESSURE TO BE LOW
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008 916 41 BOMAG 437
10.1 Travel pump
Service Manual
4ROUBLESHOOTING
LOW MOTOR OUTPUT

TORQUE

3YSTEM PRESSURE AT MOTOR ,OW SYSTEM PRESSURE AT THE MOTOR WILL REDUCE TORQUE -EASURE SYSTEM PRESSURE AT MOTOR )F PRESSURE LIMITER
SETTING IS LOW INCREASE SETTING
6ARIABLE MOTOR STUCK AT -INIMUM MOTOR DISPLACEMENT YIELDS LOW OUTPUT #HECK CONTROL SUPPLY PRESSURE OR REPAIR DISPLACEMENT
MINIMUM DISPLACEMENT TORQUE CONTROL #HECK MOTOR CONTROL ORIlCES
)NTERNAL LEAKAGE )NTERNAL LEAKAGE WILL REDUCE SYSTEM PRESSURE #HECK FOR LEAKING / RINGS GASKETS AND OTHER lTTINGS
2EPAIR UNIT AS REQUIRED OR REPLACE LEAKING UNIT
IMPROPER MOTOR
OUTPUT SPEED

/IL LEVEL IN RESERVOIR )NSUFlCIENT HYDRAULIC mUID WILL REDUCE MOTOR SPEED &ILL OIL TO PROPER LEVEL
0UMP OUTPUT mOW )NCORRECT OUTmOW WILL AFFECT OUTPUT SPEED )NCORRECT -EASURE PUMP OUTPUT AND CHECK FOR PROPER PUMP SPEED
OUTPUT mOW INDICATES THE SWASHPLATE IS OUT OF %NSURE THE PUMP IS IN FULL STROKE
POSITION
6ARIABLE MOTOR DISPLACEMENT )F VARIABLE MOTOR DISPLACEMENT CONTROL IS NOT 3EE IF VARIABLE MOTOR DISPLACEMENT CONTROL IS RESPONDING
CONTROL FUNCTIONING CORRECTLY VARIABLE MOTOR SWASHPLATE MAY )F NOT REPAIR OR REPLACE CONTROL
BE IN WRONG POSITION
)NTERNAL LEAKAGE )NTERNAL LEAKAGE WILL REDUCE SYSTEM PRESSURE #HECK FOR LEAKING / RINGS GASKETS AND OTHER lTTINGS
2EPAIR UNIT AS REQUIRED OR REPLACE LEAKY UNIT
SYSTEM NOISE OR
VIBRATION

/IL IN RESERVOIR )NSUFlCIENT HYDRAULIC mUID WILL LEAD TO CAVITATION &ILL RESERVOIR TO PROPER LEVEL
!IR IN SYSTEM !IR BUBBLES WILL LEAD TO CAVITATION ,OOK FOR FOAM IN RESERVOIR #HECK FOR LEAKS ON INLET SIDE
SYSTEM LOOP AND REPAIR !FTERWARDS LET RESERVOIR SETTLE
UNTIL FOAM DISSIPATES 2UN SYSTEM AT LOW SPEED TO MOVE
SYSTEM mUID TO RESERVOIR 2EPEAT
0UMP INLET VACUUM (IGH INLET VACUUM CAUSES NOISE ! DIRTY lLTER WILL )NSPECT AND REPLACE lLTER AS NECESSARY #HECK FOR PROPER
INCREASE THE INLET VACUUM SUCTION LINE SIZE
3HAFT COUPLINGS ! LOOSE SHAFT COUPLING WILL CAUSE EXCESSIVE NOISE 2EPLACE LOOSE SHAFT COUPLING OR REPLACE PUMP OR MOTOR
3HAFT ALIGNMENT -ISALIGNED SHAFTS CAUSE NOISE !LIGN SHAFTS
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Service Manual
4ROUBLESHOOTING
SYSTEM RESPONSE IS
SLUGGISH

/IL LEVEL IN RESERVOIR )NSUFlCIENT HYDRAULIC mUID CAUSES SLUGGISH RESPONSE &ILL RESERVOIR TO PROPER LEVEL
-ULTI FUNCTION VALVES PRESSURE )NCORRECT PRESSURE SETTINGS AFFECTS SYSTEM REACTION !DJUST OR REPLACE MULTI FUNCTION VALVES
SETTINGS TIME
0UMP INLET VACUUM (IGH PUMP INLET VACUUM REDUCES SYSTEM PRESSURE -EASURE CHARGE INLET VACUUM )F HIGH REPLACE INLET lLTER
0RIME MOVER SPEED ,OW ENGINE SPEED REDUCES SYSTEM PERFORMANCE !DJUST ENGINE SPEED
#HARGE AND CONTROL PRESSURES )NCORRECT CHARGE OR CONTROL PRESSURES AFFECTS SYSTEM -EASURE CHARGE AND CONTROL PRESSURES AND CORRECT IF
PERFORMANCE NECESSARY
3YSTEM INTERNAL LEAKAGE )NTERNAL LEAKAGE REDUCES SYSTEM PRESSURE #HECK FOR LEAKAGE IN / RINGS GASKETS AND OTHER lTTINGS
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008 916 41 BOMAG 439
10.1 Travel pump
Service Manual
!DJUSTMENTS
STANDARD
PROCEDURES, "EFORE WORKING ON THE PUMP CLEAN THE OUTSIDE OF THE PUMP
INSPECTIONS, AND
ADJUSTMENTS
CCaution
#ONTAMINATION CAN DAMAGE INTERNAL COMPONENTS AND VOID YOUR WARRANTY4AKE
PRECAUTIONS TO ENSURE SYSTEM CLEANLINESS WHEN REMOVING AND REINSTALLING SYSTEM LINES
7ITH THE PRIME MOVER OFF THOROUGHLY CLEAN THE OUTSIDE OF THE PUMP
)F REMOVING THE PUMP TAG EACH HYDRAULIC LINE CONNECTED TO THE PUMP )F HYDRAULIC
LINES ARE DISCONNECTED PLUG EACH OPEN PORT WITH A CLEAN PLUG TO ENSURE THAT DIRT AND
CONTAMINATION DO NOT GET INTO THE PUMP
%NSURE THE SURROUNDING AREAS ARE CLEAN AND FREE OF CONTAMINANTS
)NSPECT THE SYSTEM FOR CONTAMINATION
6ISUALLY INSPECT THE HYDRAULIC mUID FOR SIGNS OF SYSTEM CONTAMINATION mUID
DISCOLORATION FOAM IN THE mUID SLUDGE OR SMALL METAL PARTICLES
)F THERE ARE SIGNS OF CONTAMINATION IN THE HYDRAULIC mUID REPLACE ALL lLTERS DRAIN AND
mUSH THE HYDRAULIC SYSTEM AND lLL WITH THE CORRECT lLTERED HYDRAULIC mUID
&LUSH THE LINES BEFORE REPLACING THE HYDRAULIC mUID
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Travel pump 10.1
Service Manual
!DJUSTMENTS
ADJUSTMENTS 4HIS SECTION OFFERS INSTRUCTION ON INSPECTION AND ADJUSTMENT OF PUMP COMPONENTS 2EAD
THROUGH THE ENTIRE RELATED SECTION BEFORE BEGINNING A SERVICE ACTIVITY 2EFER TO Pressure
measurements PAGES AND FOR LOCATION OF GAUGE PORTS AND SUGGESTED GAUGE
SIZES
CHARGE PRESSURE 4HE FOLLOWING PROCEDURE EXPLAINS HOW TO CHECK AND ADJUST THE CHARGE PRESSURE RELIEF
RELIEF VALVE VALVE
ADJUSTMENT
)NSTALL A BAR ; PSI= PRESSURE GAUGE IN THE PUMP CHARGE PRESSURE GAUGE PORT
W Warning - )NSTALL A BAR ; PSI= GAUGE TO MEASURE CASE PRESSURE TEE INTO , OR , OR
4HE FOLLOWING PROCEDURE USE SERVO GAUGE PORT - OR - /PERATE THE SYSTEM WITH THE PUMP IN NEUTRAL ZERO
MAY REQUIRE THE VEHICLE DISPLACEMENT WHEN MEASURING PUMP CHARGE PRESSURE
MACHINE TO BE DISABLED
WHEELS RAISED OFF THE 4HE TABLE SHOWS THE ACCEPTABLE PUMP CHARGE PRESSURE RANGE FOR SOME CHARGE RELIEF
GROUND WORK FUNCTION VALVE SETTINGS4HESE PRESSURES ASSUME MINÂ RPM AND A RESERVOIR TEMPERATURE
DISCONNECTED ETC IN ORDER OF ²# ;²&= AND ARE REFERENCED TO CASE PRESSURE
TO PREVENT INJURY TO THE
TECHNICIAN AND BYSTANDERS
4AKE NECESSARY SAFETY Charge pressure relief valve
#ASE DRAIN PORT ,
PRECAUTIONS BEFORE MOVING
THE VEHICLEMACHINE - G BAR ; PSI=
K90 B
!DJUSTING SCREW t .sM ; LBFsFT=
+ -
,OCK NUT
.sM ; LBFsFT=
#HARGE PRESSURE GAUGE PORT -

G BAR ; PSI=
B
t .sM ; LBFsFT=
3EE APPROPRIATE TABLE 0 %
,ISTED PRESSURES ASSUME A PUMP SPEED Charge pressure ranges

OF MIN RPM !T HIGHER PUMP Model code Measured charge pressure*
INPUT SPEEDS WITH HIGHER CHARGE mOWS n BAR
20
THE CHARGE PRESSURE WILL RISE OVER THE ; n PSI=
RATED SETTING n BAR

; n PSI=
n BAR
28
; n PSI=
4HIS IS THE ACTUAL CHARGE PRESSURE PORT GAUGE
READING MINUS THE CASE PRESSURE PORT GAUGE
READING
520L0818 s 2EV !" s !PRIL 2008 31

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10.1 Travel pump
Service Manual
!DJUSTMENTS
CHARGE PRESSURE %ARLIER PRODUCTION 3ERIES PUMPS HAVE A SHIM ADJUSTABLE CHARGE PRESSURE RELIEF
RELIEF VALVE VALVE 3HIM KITS ARE AVAILABLE FROM 3AUER $ANFOSS 2EMOVE THE PLUG USING A IN HEX
ADJUSTMENT WRENCH AND EXCHANGE SHIMS BEHIND THE SPRING TO ADJUST CHARGE PRESSURE4ORQUE
(continued) PLUG TO .sM ; LBFsFT=
,ATER PRODUCTION 3ERIES PUMPS HAVE AN EXTERNAL SCREW ADJUSTABLE CHARGE

PRESSURE RELIEF VALVE ,OOSEN LOCKNUT + AND TURN THE ADJUSTING SCREW + USING A
SCREWDRIVER OR IN HEX WRENCH TO ADJUST CHARGE PRESSURE SETTING
Lock nut wrench size

Frame size Wrench size
n INCH
n INCH
#LOCKWISE ROTATION OF THE PLUG INCREASES THE SETTING AND COUNTERCLOCKWISE ROTATION
DECREASES THE SETTING AT A RATE OF APPROXIMATELY BAR ; PSI= PER TURN 4ORQUE
LOCK NUT TO .sM ; LBFsFT=
/NCE YOU ACHIEVE THE DESIRED CHARGE PRESSURE SETTING REMOVE THE GAUGES AND PLUG
THE PORTS
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Service Manual
!DJUSTMENTS
MULTI-FUNCTION VALVE 9OU ACCOMPLISH ADJUSTMENT OF THE PRESSURE LIMITER SETTING AND THE HIGH PRESSURE RELIEF
PRESSURE ADJUSTMENT VALVE (026 SETTING SIMULTANEOUSLY4HE (026 SETTING IS AUTOMATICALLY SET APPROXIMATELY
BAR ; PSI= ABOVE THE PRESSURE LIMITER SETTING
W7ARNING ,OCK THE MOTOR OUTPUT SHAFT BY LOCKING THE VEHICLES BRAKES OR RIGIDLY lXING THE WORK
4AKE NECESSARY PRECAUTIONS FUNCTION SO IT CANNOT ROTATE OR CAP THE SYSTEM PORTS W
THAT THE MOTOR SHAFT
REMAINS STATIONARY DURING
THE ADJUSTMENT PROCEDURE
Multi-function valve adjustment
#HARGE PRESSURE GAUGE PORT -

G BAR ; PSI=
B
t .sM ; LBFsFT=
I !DJUSTING SCREW
h ,OCK NUT SMALLER HEX NUT
t,OCK NUT TORQUE 3EE APPROPRIATE TABLE
3YSTEM PRESSURE GAUGE PORT M2

G BAR ; PSI=
B
t .sM ; LBFsFT=
3YSTEM PRESSURE GAUGE PORT -
G BAR ; PSI=
B
t .sM ; LBFsFT=
0 %
)NSTALL TWO BAR OR PSI PRESSURE GAUGES IN THE HIGH PRESSURE GAUGE
PORTS - AND - )NSTALL A BAR OR PSI PRESSURE GAUGE IN THE PUMP CHARGE
PRESSURE GAUGE PORT -
3TART THE PRIME MOVER AND OPERATE AT NORMAL SPEED
,OOSEN LOCKING NUT
)NSERT AN INTERNAL HEX WRENCH INTO THE PRESSURE ADJUSTING SCREW
! PLASTIC DUST PLUG IS INSTALLED IN THE ADJUSTING SCREW
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10.1 Travel pump
Service Manual
!DJUSTMENTS
MULTI-FUNCTION VALVE 4HE MODEL CODE SHOWS THE FACTORY PRESET PRESSURE LIMITER SETTING )T IS REFERENCED TO
PRESSURE ADJUSTMENT CHARGE PRESSURE SO THE PRESSURE LIMITER SETTING IS THE DIFFERENCE BETWEEN THE HIGH
(continued) AND LOW PRESSURE SIDES OF THE SYSTEM LOOP !CTIVATE OR MOVE THE CONTROL INPUT SO
THAT PRESSURE INCREASES IN THE HIGH PRESSURE SIDE OF THE CLOSED CIRCUIT TO THE PRESSURE
LIMITER PRESSURE SETTING4HE PRESSURE LIMITER SETTING IS REACHED WHEN THE PRESSURE
STOPS INCREASING AND REMAINS STEADY AT A GIVEN PRESSURE LEVEL AS SHOWN ON THE
GAUGES
2ETURN THE PUMP TO ITS NEUTRAL ZERO mOW POSITION AND ADJUST THE PRESSURE LIMITER
SETTING BY ROTATING THE PRESSURE ADJUSTING SCREW WITH AN INTERNAL HEX WRENCH
#LOCKWISE ROTATION OF THE PRESSURE ADJUSTMENT SCREW INCREASES THE PRESSURE SETTING
AND COUNTERCLOCKWISE ROTATION DECREASES THE PRESSURE SETTING %ACH COMPLETE
ROTATION OF THE PRESSURE ADJUSTING SCREW CHANGES THE PRESSURE AS SHOWN IN THE
FOLLOWING TABLE
Pressure limiter adjustment data

Frame size Lock nut wrench size and torque Adjusting Approximate pressure change
screw size per revolution of adjusting screw
EARLY MM .sM ; LBFsIN= MM BAR ; PSI=
MM .sM ; LBFsFT= MM BAR ; PSI=
EARLY MM .sM ; LBFsFT= MM BAR ; PSI=
MM .sM ; LBFsFT= 8 mm BAR ; PSI=
4O VERIFY THE ACTUAL PRESSURE SETTING ACTUATE OR MOVE THE CONTROL INPUT SO THAT THE
PUMP AGAIN DEVELOPS PRESSURE IN THE HIGH PRESSURE CIRCUIT TO THE NEWLY ADJUSTED
PRESSURE LIMITER PRESSURE SETTING THEN READ THE HIGH PRESSURE GAUGE !LLOW THE PUMP
TO RETURN TO ITS NEUTRAL POSITION4HE PRESSURE IN THE HIGH PRESSURE CIRCUIT SHOULD
RETURN TO THE CHARGE PRESSURE SETTING
7HILE HOLDING THE PRESSURE ADJUSTING SCREW STATIONARY TIGHTEN THE PRESSURE ADJUSTING
SCREW LOCK NUT4ORQUE AS SHOWN IN THE TABLE
$O NOT OVERTORQUE
3HUT DOWN THE PRIME MOVER REMOVE THE GAUGES AND INSTALL THE GAUGE PORT PLUGS
2EPLACE THE PLASTIC DUST PLUGS IF USED
5SE THE SAME PROCEDURE FOR SETTING THE PRESSURE LIMIT OF THE OTHER MULTI FUNCTION VALVE
-OVE OR ACTIVATE THE CONTROL INPUT SIGNAL IN THE OPPOSITE DIRECTION SO THAT HIGH PRESSURE
DEVELOPS IN THE OPPOSITE SIDE OF THE CLOSED CIRCUIT
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Service Manual
!DJUSTMENTS
ENGAGING THE BYPASS 4HE MULTI FUNCTION VALVE CARTRIDGES PERFORM THE BYPASS FUNCTION 3HUT DOWN THE PRIME
FUNCTION MOVER WHEN ENGAGING THE BYPASS FUNCTION /PEN BOTH THE BYPASS VALVES TO ENGAGE THE
BYPASS FUNCTION
C#AUTION LOOSEN THE BYPASS ACTUATOR THREE Bypass actuator wrench size
$AMAGE TO THE PUMP AND TURNS 2EFER TO TABLE FOR WRENCH SIZE Frame size Wrench size
MOTOR CAN RESULT FROM NEWER n INCH
ROTATING THESE COMPONENTS $O NOT ROTATE MORE THAN n INCH
WITHOUT CHARGE mOW FOR REVOLUTIONS AS ADDITIONAL ROTATION WILL
LUBRICATION "YPASS VALVES PERMIT EXTERNAL LEAKAGE Multi-Function Valve with Bypass
ARE INTENDED FOR MOVING Function Engaged
A MACHINE OR VEHICLE FOR &OR UNITS WITH AN -$# TYPE CONTROL Opening bypass valve
allows flow to circuit
VERY SHORT DISTANCES AT VERY PRIOR TO MOVING THE VEHICLE OR Bypass through multi-function valves
SLOW SPEEDS4HEY ARE NOT OTHERWISE CAUSING THE MOTOR SHAFT actuator
TOW VALVES TO TURN MOVE THE CONTROL HANDLE OF

THE MANUAL DISPLACEMENT CONTROL
ON THE PUMP TO THE MAXIMUM FULL
FORWARD POSITION (OLD THE HANDLE
IN THIS POSITION DURING BYPASS VALVE
OPERATION
P104 144E
4O CLOSE THE BYPASS VALVE TIGHTEN THE

BYPASS ACTUATOR 3EE TABLE PROVIDED Bypass actuator torque
FOR PROPER TORQUE Frame size Torque
NEWER n .sM ; LBFsFT=
n .sM ; LBFsFT=
520L0818 s 2EV !" s !PRIL 2008 35

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10.1 Travel pump
Service Manual
!DJUSTMENTS
PRESSURE OVERRIDE 0RESSURE OVERRIDE VALVE OPERATION IS Pressure override valve for 180 frame size
(POR) VALVE PRESSURE EXPLAINED IN THE Operation section
ADJUSTMENT (OPTION PAGE Pressure override valve Adjusting screw
FOR 180 FRAME SIZE) Lock nut
)NSTALL TWO BAR ; PSI=
PRESSURE GAUGES IN THE HIGH PRESSURE
GAUGE PORTS - AND - )NSTALL A
BAR ; PSI= PRESSURE GAUGE IN
W Warning THE PUMP CHARGE PRESSURE GAUGE
5NINTENDED MOVEMENT OF PORT -
THE MACHINE OR MECHANISM
MAY CAUSE INJURY TO THE 3TART THE PRIME MOVER AND OPERATE AT
TECHNICIAN OR BYSTANDERS NORMAL SPEED
4O PROTECT AGAINST P104 145E
UNINTENDED MOVEMENT 7ITH THE PUMP OPERATING AT

SECURE THE MACHINE APPROXIMATELY DISPLACEMENT
OR DISABLEDISCONNECT LOAD THE WORK FUNCTION AND NOTE THE PRESSURE AS THE 0/2 VALVE OPERATES PUMP
THE MECHANISM WHILE DISPLACEMENT REDUCES TO ZERO
SERVICING
!DJUST THE PRESSURE OVERRIDE SETTING BY LOOSENING THE LOCK NUT WITH A INCH HEX
WRENCH AND TURNING THE ADJUSTMENT SCREW WITH A INCH INTERNAL HEX WRENCH
3ET THE 0/2 SETTING TO AT LEAST BAR ; PSI= BELOW THE HIGH PRESSURE RELIEF VALVE
SETTING OF THE MULTI FUNCTION VALVES
4ORQUE THE LOCK NUT TO .sM ; LBFsFT=
3HUT DOWN THE PRIME MOVER AND REMOVE THE GAUGES AND INSTALL THE GAUGE PORT
PLUGS
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Service Manual
!DJUSTMENTS
DISPLACEMENT LIMITER 9OU CAN LIMIT THE MAXIMUM DISPLACEMENT IN EITHER DIRECTION
ADJUSTMENT
,OOSEN THE LOCK NUT & WHILE Displacement limiter adjustment
HOLDING THE ADJUSTING SCREW &
STEADY
2OTATE THE ADJUSTING SCREW SOME

C#AUTION AMOUNT USING INFORMATION IN THE
4AKE CARE IN ADJUSTING FOLLOWING TABLE C2OTATING THE
DISPLACEMENT LIMITERS TO ADJUSTING SCREW CLOCKWISE DECREASES
AVOID UNDESIRABLE mOW OR THE MAXIMUM DISPLACEMENT OF THE
SPEED CONDITIONS 2E PUMP WHILE ROTATING THE ADJUSTING
TORQUE LOCK NUT & SCREW COUNTERCLOCKWISE INCREASES
AFTER EVERY ADJUSTMENT TO THE MAXIMUM DISPLACEMENT
PREVENT AN UNEXPECTED
&
CHANGE IN OPERATING /NE TURN OF THE ADJUSTING SCREW I!DJUSTING SCREW
CONDITIONS AND TO PREVENT CHANGES THE MAXIMUM DISPLACEMENT
EXTERNAL LEAKAGE DURING AS SHOWN IN TABLE BELOW &
,OCK NUT
UNIT OPERATION
,OCK NUT TORQUE
!FTER ESTABLISHING THE DESIRED
MAXIMUM DISPLACEMENT SETTING
TORQUE THE LOCK NUT TO THE TORQUE 0 %
SHOWN IN TABLE BELOW
Frame size Lock nut wrench size and torque Adjusting Approximate displacement change
screw size per revolution of adjusting screw
MM .sM ; LBFsFT= MM CMÃREV ; INÃREV=
STANDARD MANUAL 4HERE ARE NO ADJUSTABLE ELEMENTS IN THE MANUAL DISPLACEMENT CONTROL #ENTERING SPRINGS
DISPLACEMENT AND WASHERS ON EACH END OF THE CONTROL SPOOL HOLD IT IN ITS NEUTRAL POSITION 3INCE THERE
CONTROL (MDC) IS NO CENTERING SPRING ON THE CONTROL INPUT SHAFT THE SHAFT AUTOMATICALLY ASSUMES THE
ADJUSTMENT APPROPRIATE POSITION WHEN THE CONTROL IS INSTALLED ON THE PUMP
520L0818 s 2EV !" s !PRIL 2008 37

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10.1 Travel pump
Service Manual
!DJUSTMENTS
NON-LINEAR MANUAL ! CENTERING SPRING LOCATED ON THE CONTROL INPUT SHAFT LOCATES THE CONTROL SHAFT IN ITS
DISPLACEMENT NEUTRAL POSITION ! BIAS SPRING ON THE CONTROL SPOOL MAINTAINS A FORCE ON THE SPOOL AND
CONTROL (MDC) THE CONTROL LINKAGE TO ELIMINATE FREE PLAY IN THE LINKAGE
.EUTRAL ADJUSTMENT IS THE ONLY ADJUSTMENT THAT CAN BE MADE ON THE NONLINEAR MANUAL
DISPLACEMENT CONTROL !LL OTHER FUNCTIONS ARE PRESET AT THE FACTORY 0ERFORM NEUTRAL
ADJUSTMENT ON A TEST STAND OR ON THE VEHICLEMACHINE WITH THE PRIME MOVER OPERATING
W Warning
MDC neutral adjustment

SerVO PRESSURE GAUGE PORT -
BAR ; PSI=
ServO PRESSURE GAUGE PORT - 8
.sM ; LBFsFT=
G BAR ; PSI=
B 8 M72
t .sM ; LBFsFT= I MM
M90
MM
.sM ; LBFsFT=
0 %
)NSTALL A BAR ; PSI= GAUGE IN EACH OF THE TWO SERVO CYLINDER GAUGE PORTS -
AND - $ISCONNECT THE EXTERNAL CONTROL LINKAGE FROM THE CONTROL HANDLE AND MAKE
CERTAIN THE CONTROL SHAFT IS IN ITS NEUTRAL POSITION 3TART THE PRIME MOVER AND OPERATE
AT NORMAL SPEED
,OOSEN THE LOCK NUT - ON THE NEUTRAL ADJUSTING SCREW - WITH A MM HEX
WRENCH
5SING A MM INTERNAL HEX WRENCH ROTATE THE NEUTRAL ADJUSTING SCREW CLOCKWISE UNTIL
THE PRESSURE INCREASES ON ONE OF THE PRESSURE GAUGES .OTE THE ANGULAR POSITION OF
THE WRENCH4HEN ROTATE THE ADJUSTING SCREW COUNTERCLOCKWISE UNTIL THE PRESSURE
INCREASES BY AN EQUAL AMOUNT ON THE OTHER GAUGE .OTE THE ANGULAR POSITION OF THE
WRENCH
2OTATE THE ADJUSTING SCREW CLOCKWISE HALF THE DISTANCE BETWEEN THE LOCATIONS NOTED
ABOVE4HE GAUGES SHOULD READ THE SAME PRESSURE INDICATING THAT THE CONTROL IS IN ITS
NEUTRAL POSITION
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Travel pump 10.1
Service Manual
!DJUSTMENTS
NON-LINEAR MANUAL (OLD THE ADJUSTING SCREW STATIONARY AND TIGHTEN THE LOCK NUT TO .sM ; LBFsFT=
DISPLACEMENT $O NOT OVERTORQUE THE NUT
CONTROL (MDC)
(continued) /NCE THE NEUTRAL POSITION IS SET STOP THE PRIME MOVER REMOVE THE GAUGES AND INSTALL
THE GAUGE PORT PLUGS 2ECONNECT THE EXTERNAL CONTROL LINKAGE
MDC NEUTRAL 4HE .EUTRAL 3TART 3WITCH .33 PROVIDES MDC with neutral start switch
START SWITCH (NSS) A MEANS TO PREVENT THE SYSTEM PRIME
A A
ADJUSTMENTS MOVER FROM STARTING WHILE THE PUMP
CONTROL HANDLE IS IN STROKE7HEN THE
Control shaft Switch cam
CONTROL INPUT SHAFT IS IN ITS NEUTRAL
POSITION THE SWITCH PIN ENGAGES A SLOT ON
THE ECCENTRIC CAM ATTACHED TO THE CONTROL Switch lock nut
SHAFT4HIS ALLOWS THE SPRING LOADED Neutral start switch
.33 TO CLOSE COMPLETING THE ELECTRICAL
Eccentric plug
STARTING CIRCUIT FOR THE PRIME MOVER
Switch pin
7HEN THE CONTROL INPUT SHAFT IS NOT IN ITS
Special lock nut
NEUTRAL POSITION THE ECCENTRIC CAM OPENS for eccentric plug
THE .33 SWITCH
4HE NEUTRAL START SWITCH IS THREADED INTO View at section A-A

THE SPECIAL LOCK NUT FOR THE ECCENTRIC
PLUG4URNING THE .33 CLOCKWISE #7
MOVES THE .33 CLOSER TO THE SWITCH
CAM ON THE CONTROL SHAFT AND NARROWS
THE .33 DEADBAND4URNING THE .33
Orifice check valve seat
COUNTERCLOCKWISE ##7 MOVES THE Control spool assembly
.33 FARTHER FROM THE SWITCH CAM ON Control link assembly
THE CONTROL SHAFT WIDENING THE .33 View A-A P104 146E
DEADBAND4HE SWITCH PIN IS LOCATED IN AN
ECCENTRIC PLUG WHICH IS TURNED TO MOVE
THE CENTER OF THE .33 DEADBAND
520L0818 s 2EV !" s !PRIL 2008 39

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Service Manual
!DJUSTMENTS
MDC NEUTRAL !DJUST THE .EUTRAL 3TART 3WITCH TO MEET Neutral start switch adjustment
START SWITCH (NSS) THE FOLLOWING THREE REQUIREMENTS requirements
ADJUSTMENTS NSS deadband Control shaft
(continued) I 4HE DISTANCE YOU CAN MOVE THE (switch closed, ON) (free-play)
CONTROL HANDLE WITHOUT OPENING Control deadband
(neutral)
THE .33 IS THE NSS deadband4HE
DISTANCE YOU CAN MOVE THE CONTROL Total control
HANDLE WITHOUT MOVING THE CONTROL shaft rotation
SPOOL ENOUGH TO PORT HYDRAULIC

mUID TO THE PUMP DISPLACEMENT Control shaft
CONTROL CYLINDERS IS THE control

deadband4HESE DEADBANDS MUST
BE CONCENTRIC
3INCE YOU CANNOT ADJUST THE POSITION

OF THE CONTROL DEADBAND YOU MUST
ADJUST THE POSITION OF THE .33
DEADBAND TO MATCH IT
II 4HE .33 DEADBAND MUST BE WIDE

ENOUGH SO THE .33 WILL NOT OPEN
WITHIN THE LOOSE AREA OF CONTROL
HANDLE MOVEMENT CAUSED BY NORMAL P104 147E
OPERATING CLEARANCES IN THE CONTROL
LINKAGE CONTROL SHAFT FREE PLAY
"Y SETTING THE .33 TO OPEN OUTSIDE THIS AREA THE CONTROL SPOOL SPRINGS OR CONTROL
SHAFT CENTERING SPRING CAN ALWAYS RETURN THE HANDLE TO NEUTRAL AND RE CLOSE THE .33
III 4HE .33 DEADBAND MUST BE NARROW ENOUGH SO THE .33 WILL OPEN BEFORE THE UNIT
BUILDS BAR ; PSI= DIFFERENTIAL SYSTEM PRESSURE IN EITHER DIRECTION
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Travel pump 10.1
Service Manual
!DJUSTMENTS
MDC NEUTRAL Neutral start switch eccentric plug Eccentric plug adjustment tool
START SWITCH (NSS) adjustment (condition i)
12.7 9.14
ADJUSTMENTS #ENTER THE .33 DEADBAND AND THE [0.5] [0.36]
(continued) CONTROL DEADBAND IN RELATION TO EACH
OTHER 3INCE YOU CANNOT ADJUST THE
POSITION OF THE CONTROL DEADBAND YOU
MUST ADJUST THE POSITION OF THE .33 3.175 1.52
[0.125] [0.06]
DEADBAND TO MATCH IT4HE SWITCH PIN 25.4
IS LOCATED IN AN ECCENTRIC PLUG WHICH [1.0]
YOU TURN TO MOVE THE CENTER OF THE .33

P104 149E
DEADBAND %NSURE THE -$# IS INSTALLED
ON THE PUMP AND IN ITS NEUTRAL POSITION
WHEN ADJUSTING THE NEUTRAL START SWITCH NSS with eccentric plug
ECCENTRIC PLUG4HE ACCOMPANYING
DRAWING PROVIDES DIMENSIONS FOR AN
ECCENTRIC PLUG ADJUSTMENT TOOL
(OLD THE SWITCH AND ECCENTRIC PLUG

FROM TURNING AND USE A INCH
WRENCH TO LOOSEN THE LOCK NUT B
W 7ARNING 2EMOVE THE NEUTRAL START SWITCH W Switch

Eccentric plug lock nut
$O NOT START THE PRIME Switch pin
B
MOVER WHILE THE NEUTRAL .OTE THE SLOTS ON THE ECCENTRIC PLUG Special lock nut
START SWITCH IS REMOVED FOR THE ADJUSTMENT TOOL (OLD THE for eccentric plug Neutral start switch
FROM THE CONTROL #ASE ECCENTRIC PLUG IN PLACE WITH THE

PRESSURE WILL FORCE THE PIN ADJUSTMENT TOOL AND LOOSEN THE LOCK Special lock nut
for eccentric plug
OUT OF THE ECCENTRIC PLUG NUT WITH A INCH WRENCH
Eccentric plug
CAUSING OIL LOSS Control
mounting
0OSITION THE ECCENTRIC PLUG SO THE surface Switch pin
SWITCH PIN IS OFFSET TOWARD THE
View B-B
CONTROL MOUNTING SURFACE4HIS WILL (switch and lock nut removed)
PROVIDE THE BEST CONTACT BETWEEN P104 150E
THE PIN AND THE CAM ON THE CONTROL

SHAFT
520L0818 s 2EV !" s !PRIL 2008 41

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10.1 Travel pump
Service Manual
!DJUSTMENTS
MDC NEUTRAL (OLD THE CONTROL SHAFT IN ITS NEUTRAL Eccentric plug adjustment
START SWITCH (NSS) POSITION IN THE CENTER OF THE CONTROL Switch pin Eccentric plug
ADJUSTMENTS SHAFT FREE PLAY AREA ,OCATE THE
(continued) SWITCH PIN IN THE SLOT OF THE SWITCH
CAM BY TURNING THE ECCENTRIC PLUG
WHILE CHECKING THE PIN POSITION
DEPTH IN THE PLUG7HEN THE PIN 90° 90°
ENGAGES THE CAM SLOT THE PIN WILL BE

AT ITS MAXIMUM DEPTH IN THE PLUG Control mounting Eccentric plug
adjustment range
(AND TIGHTEN THE PLUG LOCK NUT TO surface
P104 151E
HOLD THE ECCENTRIC PLUG IN POSITION
4URN THE CONTROL SHAFT AN EQUAL

AMOUNT IN EITHER DIRECTION FROM
NEUTRAL4HE SWITCH PIN SHOULD MOVE OUT OF THE ECCENTRIC PLUG AN EQUAL DISTANCE
WHEN THE CONTROL SHAFT IS TURNED4URN THE ECCENTRIC PLUG TO CENTER THE SWITCH PIN
WITH THE CAM SLOT /NLY A SMALL AMOUNT OF ADJUSTMENT IN EITHER DIRECTION IS NEEDED TO
CENTER THE PIN
7HILE HOLDING THE ECCENTRIC PLUG IN PLACE TIGHTEN THE ECCENTRIC PLUG LOCK NUT TO
.sM ; LBFsFT= 2EINSTALL AND ADJUST THE SWITCH AS OUTLINED IN THE PREVIOUS SECTION
4HE ECCENTRIC PLUG NORMALLY REQUIRES BETWEEN AND TURNS TO INSTALL INTO THE
CONTROL HOUSING
C#AUTION
$O NOT TURN THE ECCENTRIC PLUG INTO OR OUT OF THE HOUSING BEYOND SPECIlCATIONS
/NCE THE SWITCH IS CORRECTLY ADJUSTED HOLD THE SWITCH IN PLACE AND TIGHTEN THE LOCK
NUT TO .sM ; LBFsFT= TORQUE
NSS deadband adjustment (conditions ii & iii)

4HE .33 DEADBAND MUST BE WIDE ENOUGH SO THE .33 WILL NOT OPEN WITHIN THE CONTROL
SHAFT FREE PLAY AREA AND IT MUST BE NARROW ENOUGH SO THE .33 WILL OPEN BEFORE THE UNIT
BUILDS BAR PSI DIFFERENTIAL SYSTEM PRESSURE IN EITHER DIRECTION
)NSTALL TWO BAR ; PSI= PRESSURE GAUGES IN THE SYSTEM PRESSURE GAUGE PORTS
- AND -
5SING TWO INCH WRENCHES HOLD THE NEUTRAL START SWITCH FROM TURNING AND
LOOSEN THE LOCK NUT
$ISCONNECT THE EXTERNAL CONTROL LINKAGE AND MAKE CERTAIN THE CONTROL SHAFT IS IN ITS
NEUTRAL POSITION
!TTACH A CONTINUITY CHECKER TO THE TERMINALS OF THE SWITCH7ITH THE CONTROL SHAFT IN
ITS NEUTRAL POSITION TURN THE SWITCH CLOCKWISE #7 UNTIL THE SWITCH OPENS THEN TURN
THE SWITCH COUNTERCLOCKWISE ##7 UNTIL IT CLOSES4URN THE SWITCH COUNTERCLOCKWISE
##7 AN ADDITIONAL TURN ² AFTER THE SWITCH CLOSES
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Travel pump 10.1
Service Manual
!DJUSTMENTS
MDC NEUTRAL (OLD THE SWITCH IN PLACE AND TIGHTEN Neutral start switch
START SWITCH (NSS) THE LOCK NUT TO .sM LBFsFT
ADJUSTMENTS TORQUE
(continued)
7ITH THE CONTINUITY CHECKER ATTACHED
TO THE SWITCH ROTATE THE CONTROL Control shaft
HANDLE OR THE CONTROL SHAFT IN EACH

DIRECTION TO ASSURE THE SWITCH OPENS
WHEN THE CONTROL IS NOT IN THE NEUTRAL Switch lock nut
POSITION Neutral start switch

Switch cam
)F THE SWITCH CLOSES IN NEUTRAL AND
SATISFACTORILY OPENS IN EACH DIRECTION Switch pin 1-1/8 in
PROCEED TO CHECK THE SWITCH WITH ##t)
THE PRIME MOVER RUNNING4HE SWITCH P104 148E
MUST OPEN BEFORE THE UNIT BUILDS

BAR ; PSI= DIFFERENTIAL SYSTEM
PRESSURE IN EITHER DIRECTION
)F THE SWITCH OPENS AFTER THE UNIT BUILDS SYSTEM PRESSURE IN EITHER DIRECTION LOOSEN
THE SWITCH LOCK NUT AND TURN THE SWITCH CLOCKWISE #7 TURN ² 4IGHTEN THE
SWITCH LOCK NUT AND RECHECK THE SWITCH OPERATION 2EPEAT THIS PROCEDURE IF NECESSARY
)F THE SWITCH DOES NOT OPEN WITH AN EQUAL MOVEMENT OF THE CONTROL HANDLE IN EACH
DIRECTION TURN OFF PRIME MOVER REMOVE THE PRESSURE GAUGES AND CONTINUE WITH THE
NEXT SECTION
)F NEUTRAL START SWITCH OPERATION IS SATISFACTORY TURN OFF THE PRIME MOVER REMOVE THE
PRESSURE GAUGES AND RECONNECT THE EXTERNAL CONTROL LINKAGE
520L0818 s 2EV !" s !PRIL 2008 43

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Service Manual
!DJUSTMENTS
CHECKING SWITCH 2ECHECK SWITCH CONTINUITY TO DETERMINE WHETHER ADDITIONAL ADJUSTMENT OF THE ECCENTRIC
CONTINUITY PLUG IS NECESSARY W
W 7ARNING )NSTALL A BAR ; PSI= GAUGE IN EACH OF THE TWO SERVO CYLINDER GAUGE PORTS -
4HE FOLLOWING PROCEDURE AND - !TTACH A CONTINUITY CHECKER TO THE TERMINALS OF THE NEUTRAL START SWITCH
MAY REQUIRE THE VEHICLE
WHEELS RAISED OFF THE Checking switch continuity
GROUND WORK FUNCTION
DISCONNECTED ETC WHILE
PERFORMING THE PROCEDURE G BAR ; PSI=
IN ORDER TO PREVENT INJURY
ServO PRESSURE GAUGE PORT - B 8
TO THE TECHNICIAN AND G BAR ; PSI= t .sM ; LBFsFT=
BYSTANDERS4AKE NECESSARY B 8
SAFETY PRECAUTIONS BEFORE t .sM ; LBFsFT=
MOVING THE VEHICLE
MACHINE
0 %
%NERGIZE THE STARTER CIRCUIT AND START THE PRIME MOVER
7HILE OPERATING AT NORMAL SPEED AND WITH THE PUMP IN ITS NEUTRAL ZERO mOW
POSITION NOTE THE PRESSURE READING ON THE GAUGES .OTE THIS READING AS THE BASE
PRESSURE
3LOWLY MOVE THE CONTROL HANDLE IN ONE DIRECTION WHILE OBSERVING THE PRESSURE
GAUGES AND THE CONTINUITY CHECKER4HE SWITCH MUST OPEN BEFORE THE PRESSURE ON
EITHER GAUGE INCREASES MORE THAN BAR ; PSI= FROM THE BASE PRESSURE OBTAINED AT
NEUTRAL
3LOWLY MOVE THE CONTROL HANDLE IN THE OPPOSITE DIRECTION !GAIN 4HE SWITCH MUST
OPEN BEFORE THE GAUGE PRESSURE INCREASES MORE THAN BAR ; PSI= FROM BASE
PRESSURE
6ERIFY CONTINUITY AGAIN WHEN THE CONTROL IS RETURNED TO NEUTRAL
)F THE SWITCH DOES NOT OPEN AT BASE PRESSURE PLUS TO BAR ; TO PSI= IN EITHER
DIRECTION STOP THE PRIME MOVER AND READJUST THE ECCENTRIC PLUG AS DESCRIBED IN THE
PREVIOUS SECTION )F THE PRESSURE DIFFERENCE IS EQUAL IN EACH DIRECTION BUT GREATER
THAN BAR ; PSI= LOOSEN THE SWITCH LOCK NUT AND TURN THE SWITCH CLOCKWISE
TURN ² TO INCREASE THE SENSITIVITY 2ETIGHTEN THE LOCK NUT AND RECHECK PRESSURE
DIFFERENCES AND CONTINUITY
!FTER VERIFYING PROPER CONTROL AND SWITCH OPERATION STOP THE PRIME MOVER 2EMOVE
THE CONTINUITY CHECKER AND PRESSURE GAUGES 2EINSTALL THE SERVO PRESSURE PORT PLUGS
AND RECONNECT THE ELECTRICAL LEADS FROM THE MACHINE STARTER CIRCUIT TO THE .33 )NSTALL
AND ADJUST THE EXTERNAL CONTROL LINKAGE IF NECESSARY
44 520L0818 s 2EV !" s !PRIL 2008
454 BOMAG 008 916 41

Travel pump 10.1
Service Manual
!DJUSTMENTS
HYDRAULIC 4HE NEUTRAL ADJUSTMENT IS THE ONLY ADJUSTMENT THAT CAN BE MADE ON HYDRAULIC AND
DISPLACEMENT ELECTRIC DISPLACEMENT CONTROLS !LL OTHER FUNCTIONS ARE PRESET AT THE FACTORY
CONTROL (HDC) AND
ELECTRIC DISPLACEMENT -AKE THIS ADJUSTMENT ON A TEST STAND OR ON THE VEHICLEMACHINE WITH THE PRIME MOVER
CONTROL (EDC) OPERATING W
ADJUSTMENT
HDC and EDC neutral adjustment

W 7ARNING
4HE FOLLOWING PROCEDURE
MAY REQUIRE THE VEHICLE G BAR ; PSI=
ServO PRESSURE GAUGE PORT - B
WHEELS RAISED OFF THE G BAR ; PSI= t .sM ; LBFsFT=
GROUND WORK FUNCTION B M72
DISCONNECTED ETC WHILE t .sM ; LBFsFT= I OR MM
PERFORMING THE PROCEDURE
IN ORDER TO PREVENT INJURY
TO THE TECHNICIAN AND
BYSTANDERS4AKE NECESSARY
SAFETY PRECAUTIONS BEFORE
MOVING THE VEHICLE
MACHINE M90
h OR MM
t .sM ; LBFsFT= OR
.sM ; LBFsFT=
0 %
)NSTALL A BAR ; PSI= GAUGE IN EACH OF THE TWO DISPLACEMENT CONTROL CYLINDER
GAUGE PORTS - AND - $ISCONNECT THE EXTERNAL CONTROL INPUT HYDRAULIC OR
ELECTRONIC FROM THE CONTROL 3TART THE PRIME MOVER AND OPERATE AT NORMAL SPEED
,OOSEN THE LOCK NUT - WITH A MM OR MM HEX WRENCH
5SING A MM OR MM INTERNAL HEX WRENCH ROTATE THE ADJUSTING SCREW -

CLOCKWISE UNTIL THE PRESSURE INCREASES IN ONE OF THE PRESSURE GAUGES .OTE THE
ANGULAR POSITION OF THE WRENCH 2OTATE THE NEUTRAL ADJUSTING SCREW COUNTERCLOCKWISE
UNTIL THE PRESSURE INCREASES BY AN EQUAL AMOUNT ON THE OTHER GAUGE !GAIN NOTE THE
ANGULAR POSITION OF THE WRENCH
2OTATE THE ADJUSTING SCREW CLOCKWISE HALF THE DISTANCE BETWEEN THE LOCATIONS NOTED
ABOVE4HE GAUGES SHOULD READ THE SAME PRESSURE CASE PRESSURE INDICATING THAT THE
CONTROL IS IN ITS NEUTRAL POSITION
(OLD THE NEUTRAL ADJUSTING SCREW STATIONARY4IGHTEN THE NEUTRAL ADJUSTING SCREW
LOCK NUT TO .sM ; LBFsIN= FOR THE MM SCREW OR .sM ; LBFsIN= FOR THE MM
SCREW $O NOT OVERTORQUE THE NUT
/NCE THE NEUTRAL POSITION IS SET STOP THE PRIME MOVER REMOVE THE GAUGES AND INSTALL
THE GAUGE PORT PLUGS 2ECONNECT THE EXTERNAL CONTROL INPUT
520L0818 s 2EV !" s !PRIL 2008 45

008 916 41 BOMAG 455
10.1 Travel pump
Service Manual
!DJUSTMENTS
SPEED SENSOR 7HEN INSTALLING OR ADJUSTING THE SPEED SENSOR ON A PUMP IT MUST BE SET AT A SPECIlC
ADJUSTMENT DISTANCE FROM THE SPEED RING ON THE UNITS CYLINDER4O LOCATE THE POSITION OF THE SPEED
SENSOR ON THE UNIT OR DESCRIPTION SEE THE CORRESPONDING SECTION
,OOSEN THE SENSOR LOCK NUT WITH AN Cross section view of speed sensor in
INCH HEX WRENCH variable pump
4URN THE SENSOR CLOCKWISE #7 BY

HAND UNTIL IT CONTACTS THE SPEED RING
Gap
4URN THE SENSOR COUNTERCLOCKWISE

##7 TURN ² TO ESTABLISH THE
Speed sensor
NOMINAL GAP OF MM ; INCH= Magnetic speed ring
Cylinder block
4HEN TURN THE SENSOR CLOCKWISE #7 P104 152E
UNTIL THE WRENCH mATS ON SENSOR BODY

ARE POSITIONED AT A ² ANGLE TO THE Positioning speed sensor relative to
PUMP SHAFT CENTER LINE pump shaft
Shaft centerline
1/2 inch wrench flats
-OST OPEN END WRENCHES HAVE A ²
HANDLE OFFSET 22° 22°
4HE lNAL SENSOR POSITION SHOULD BE Speed sensor with Speed sensor with
BETWEEN ² AND TURN ² packard connector turck connector
COUNTERCLOCKWISE ##7 FROM THE Shaft centerline

1/2 inch wrench flats
POINT WHERE THE SENSOR CONTACTS THE
SPEED RING
22° 22°
(OLD SENSOR IN POSITION WITH A
Speed sensor with Speed sensor with
INCH HEX WRENCH WHILE TIGHTENING packard connector turck connector
THE LOCK NUT TO .sM ; LBFsFT=
P104 155E
46 520L0818 s 2EV !" s !PRIL 2008
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Travel pump 10.1
Service Manual
-INOR REPAIR
STANDARD PROCEDURES Removing the pump

"EFORE WORKING ON THE PUMP CLEAN THE OUTSIDE OF THE PUMP )F THE PUMP HAS AN AUXILIARY
PUMP ATTACHED REMOVE BOTH PUMPS AS A SINGLE UNIT4AG AND CAP ALL HYDRAULIC LINES AS
THEY ARE DISCONNECTED AND PLUG ALL OPEN PORTS TO ENSURE THAT CONTAMINATION DOES NOT
ENTER THE SYSTEM
CCaution
#ONTAMINATION CAN DAMAGE INTERNAL COMPONENTS AND VOID YOUR WARRANTY4AKE
PRECAUTIONS TO ENSURE SYSTEM CLEANLINESS WHEN REMOVING AND REINSTALLING SYSTEM LINES
Disassembly
7ITH THE PRIME MOVER OFF THOROUGHLY CLEAN THE OUTSIDE OF THE PUMP
4AG CAP AND DISCONNECT EACH HYDRAULIC LINE CONNECTED TO THE PUMP !S HYDRAULIC
LINES ARE DISCONNECTED PLUG EACH OPEN PORT TO ENSURE THAT DIRT AND CONTAMINATION
DO NOT ENTER THE SYSTEM
2EMOVE THE PUMP AND ITS AUXILIARY PUMP IF APPLICABLE AS A SINGLE UNIT
Inspection
%NSURE THE WORK SURFACE AND SURROUNDING AREA ARE CLEAN AND FREE OF CONTAMINANTS
)NSPECT THE SYSTEM FOR CONTAMINATION
,OOK AT THE HYDRAULIC mUID FOR SIGNS OF SYSTEM CONTAMINATION mUID DISCOLORATION
FOAM SLUDGE OR SMALL METAL PARTICLES
Reassembly
"EFORE REPLACING THE PUMP ON THE MACHINE REPLACE ALL lLTERS AND DRAIN AND lLL THE
HYDRAULIC SYSTEM WITH THE CORRECT HYDRAULIC mUID
&LUSH THE LINES BEFORE REPLACING THE HYDRAULIC mUID
520L0818 s 2EV !" s !PRIL 2008 47

008 916 41 BOMAG 457
10.1 Travel pump
Service Manual
-INOR REPAIR
SHAFT SEAL AND SHAFT 9OU CAN REPLACE THE SHAFT AND SEAL WITHOUT MAJOR DISASSEMBLY OF THE UNIT #LEAN PUMP
REPLACEMENT AND SURROUNDING AREA THOROUGHLY $ISCONNECT AND REMOVE THE PUMP FROM THE UNIT AND
CLEAN IT THOROUGHLY BEFORE STARTING REPAIRS -ARK ALL CONNECTIONS FOR LATER REASSEMBLY
Shaft removal
0OSITION THE PUMP WITH THE SHAFT FACING UP
)F THE UNIT IS POSITIONED HORIZONTALLY OR MOVED OR JARRED WHILE THE SHAFT IS OUT THE CYLINDER
BLOCK COULD MOVE OUT OF PLACE MAKING SHAFT INSTALLATION DIFlCULT
2EMOVE THE THREE OR FOUR SCREWS , HOLDING THE RETAINER PLATE , AND SEAL
CARRIER , TO THE HOUSING USING A MM HEX WRENCH UNIT A MM INTERNAL
HEX WRENCH THROUGH UNITS OR A MM INTERNAL HEX WRENCH THROUGH
UNITS 2EMOVE THE RETAINER PLATE
#ERTAIN EARLIER PRODUCTION UNITS USE A Shaft assembly

ONE PIECE RETAINER PLATE AND SEAL CARRIER
L70
!FTER REMOVING THE SCREWS THE

L60
SPRING FORCE ON THE SHAFT MAY MOVE
THE SEAL CARRIER OUT OF ITS BORE BY
L30
APPROXIMATELY MM ; INCH= )F
THE SEAL CARRIER DOES NOT MOVE FROM L40
ITS BORE PRY IT FROM ITS BORE ANDOR
LIGHTLY TAP THE END OF THE SHAFT WITH A L50
SOFT MALLET L20
2EMOVE THE / RING , FROM THE

SEAL CARRIER AND DISCARD L10
0LACE SEAL CARRIER AND SEAL IN AN ARBOR

L100
PRESS AND PRESS OUT THE SEAL ,
2EMOVE SHAFT , AND ROLLER

BEARING ASSEMBLY , FROM
PUMP9OU CAN TRANSFER THE BEARING
ASSEMBLY TO THE NEW SHAFT
5SING SNAP RING PLIERS REMOVE THE

RETAINING RING , THAT SECURES THE
ROLLER BEARING ASSEMBLY 2EMOVE THE
ROLLER BEARING ASSEMBLY
P106 181E
48 520L0818 s 2EV !" s !PRIL 2008
458 BOMAG 008 916 41

Travel pump 10.1
Service Manual
-INOR REPAIR
SHAFT SEAL AND SHAFT Inspection

REPLACEMENT )NSPECT THE SEAL CARRIER THE NEW SEAL AND THE / RING FOR ANY DAMAGE OR NICKS
(continued)
)NSPECT THE SHAFT AND BEARING FOR RUST WEAR OR CONTAMINATION 3PIN THE BEARING IN
YOUR HAND FEELING FOR ROUGHNESS 2EPLACE IF NECESSARY
Reassembly
5SING THE ARBOR PRESS PRESS THE NEW SEAL , INTO SEAL CARRIER , "E CAREFUL NOT TO
DAMAGE THE SEAL
)F THE SHAFT IS NOT BEING REPLACED PROCEED TO STEP
0LACE ROLLER BEARING ASSEMBLY ON NEW SHAFT AND SECURE WITH THE RETAINING RING
)NSTALL AN INSTALLATION SLEEVE OR WRAP SPLINE OR KEYED END OF SHAFT WITH PLASTIC lLM TO
PREVENT DAMAGE TO THE SEALING LIP ON THE SEAL DURING INSTALLATION
,UBRICATE AND INSTALL A NEW / RING , ON THE SEAL CARRIER ,UBRICATE THE SEAL WITH
CLEAN PETROLEUM JELLY
!SSEMBLE THE SEAL CARRIER AND SEAL OVER THE SHAFT AND INTO THE HOUSING BORE )NSTALL
THE RETAINER PLATE IF USED
)NSTALL THE SCREWS AND TORQUE TO THE Shaft retainer screw torque
APPROPRIATE VALUE IN THE TABLE TO THE Frame size Torque
RIGHT n .sM ; LBFsFT=
n .sM ; LBFsFT=
4ORQUE THE SCREWS IN A SEQUENCED n .sM ; LBFsFT=
PATTERN THEN RECHECK
520L0818 s 2EV !" s !PRIL 2008 49

008 916 41 BOMAG 459
10.1 Travel pump
Service Manual
-INOR REPAIR
MULTI-FUNCTION VALVE Multi-function valve removal / installation

CARTRIDGES
/LDER MULTIFUNCTION
VALVES PRE CONTAIN
DIFFERENT COMPONENTS
See multifunction valves P2B1
- Pre 1988 PAGE FOR
DISASSEMBLY INSTRUCTIONS
P13
P06
P2A1
P106 180E
Removal Multi-function valve wrench size

2EMOVE MULTI FUNCTION VALVES 0! Frame size Wrench size
AND 0" USING HEX WRENCH LISTED IN n INCH
TABLE n INCH
2EMOVE AND DISCARD / RINGS 0 AND 0
2ELIEVE SPRING PRESSURE BY REMOVING BYPASS ACTUATOR 0 USING A WRENCH4O
RETAIN PRESSURE SETTING DO NOT SEPARATE ADJUSTING SCREW 0 AND LOCKNUT 0 FROM
BYPASS ACTUATOR 0
2EMOVE AND DISCARD / RING 0
-ULTI FUNCTION VALVES ARE SOLD AS COMPLETE UNITS ONLY9OU MAY PURCHASE / RINGS
SEPARATELY
4HE POPPET SEAT SECTION IS PRESSED OVER A LIP 0LACE THE CARTRIDGE IN A VISE AND PRY THE
POPPET SEAT 0 OFF WITH AN APPROPRIATE TOOL -AINTAIN SUFlCIENT CONTROL TO PREVENT
THE INTERNAL COMPONENTS FROM mYING LOOSE $O NOT DAMAGE PARTS DURING DISASSEMBLY
2EMOVE INTERNAL PARTS 0 0 0 0 0 0 0 AND 0
50 520L0818 s 2EV !" s !PRIL 2008
460 BOMAG 008 916 41

Travel pump 10.1
Service Manual
-INOR REPAIR
MULTI-FUNCTION VALVE Multi-function valve

CARTRIDGES
(continued) P04
P03
P01
P02
P05
P06
P07
P08
P17
P16
P15
P14
P09
P11
P13
P12
E101 531E
Inspection
#LEAN AND INSPECT ALL DISASSEMBLED PARTS
Reassembly
,UBRICATE AND INSTALL INTERNAL COMPONENTS 0 0 0 0 0 0 0 0 AND
0
0LACE THE CARTRIDGE IN A VISE AND PRESS ON THE POPPET SEAT 0
,UBRICATE AND INSTALL NEW / RINGS 0 0 0
)NSTALL BYPASS ACTUATOR 0 WITH PRESSURE LIMITER VALVE 0 4ORQUE TO .sM
; LBFsFT=
C#AUTION
)F PRESSURE LIMITER 0 WAS REMOVED FROM BYPASS ACTUATOR 0 ADJUST PRESSURE LIMITER
TO MODEL CODE SPECIlCATIONS
C#AUTION )NSTALL CARTRIDGES AND TORQUE AS SHOWN IN THE TABLE C

$O NOT OVERTORQUE THE
MULTI FUNCTION VALVE
CARTRIDGES Multi-function valve torque
Frame size Torque
n .sM ; LBFsFT=
n .sM ; LBFsFT=
520L0818 s 2EV !" s !PRIL 2008 51

008 916 41 BOMAG 461
10.1 Travel pump
Service Manual
-INOR REPAIR
MULTI-FUNCTION VALVE Removal Multi-function valve wrench size

CARTRIDGES - PRE 1988 2EMOVE MULTI FUNCTION VALVES USING Frame size Wrench size
HEX WRENCH LISTED IN TABLE n INCH
n INCH
)T IS NOT NECESSARY TO REMOVE THE BYPASS FUNCTION 0 EXCEPT FOR CLEANING7RENCH
SIZE IS
-ULTI FUNCTION VALVES ARE SOLD AS COMPLETE UNITS ONLY / RINGS MAY BE PURCHASED
SEPARATELY
4O RETAIN PRESSURE SETTING DO NOT DISASSEMBLE BYPASS FUNCTION 0
2EMOVE RETAINING RING 0 WITH A SNAP RING PLIERS
2EMOVE POPPET SEAT 0
2EMOVE INTERNAL PARTS 0 0 0 0 AND 0
Inspection
#LEAN AND INSPECT ALL DISASSEMBLED PARTS
Multi-function valve - pre 1988
P14
P19
P12
P06
P21
P15
P14
P09
P11
P13 P22
P1
E101 532E
52 520L0818 s 2EV !" s !PRIL 2008
462 BOMAG 008 916 41

Travel pump 10.1
Service Manual
-INOR REPAIR
MULTI-FUNCTION VALVE Reassembly

CARTRIDGES - PRE 1988 ,UBRICATE AND INSTALL INTERNAL COMPONENTS 0 0 0 0 0 AND 0
(continued)
)NSTALL POPPET SEAT 0
)NSTALL RETAINING RING 0
)F PREVIOUSLY REMOVED LUBRICATE AND INSTALL / RING 0
)F PREVIOUSLY REMOVED REASSEMBLE AND INSTALL BYPASS ACTUATOR 0 4ORQUE TO
.sM ; LBFsFT=
,UBRICATE AND INSTALL NEW / RINGS 0 0
C#AUTION
)F PRESSURE LIMITER WAS REMOVED FROM BYPASS ACTUATOR 0 ADJUST PRESSURE LIMITER TO
MODEL CODE SPECIlCATIONS
C#AUTION )NSTALL CARTRIDGES AND TORQUE AS SHOWN IN THE TABLE BELOW C
$O NOT OVERTORQUE THE
CARTRIDGES Multi-function valve torque
Frame size Torque
n .sM ; LBFsFT=
n .sM ; LBFsFT=
PRESSURE OVERRIDE Removal Pressure override valve components

VALVE (OPTION FOR 180 2EMOVE THE FOUR SCREWS ATTACHING
FRAME SIZE) THE PRESSURE OVERRIDE VALVE TO THE
Screws
PUMP END CAP WITH A MM INTERNAL
HEX WRENCH 2EMOVE AND DISCARD THE Pressure override
/ RINGS valve
Inspection
O-rings
#LEAN AND INSPECT VALVE FOR DAMAGE
TO PARTS
Reassembly
)NSTALL NEW / RINGS )NSTALL THE VALVE
ONTO THE PUMP END CAP AND TORQUE
THE SCREWS TO .sM ; LBFsFT=
E101 079E
520L0818 s 2EV !" s !PRIL 2008 53

008 916 41 BOMAG 463
10.1 Travel pump
Service Manual
-INOR REPAIR
CHARGE PRESSURE 4HE CHARGE PRESSURE RELIEF VALVE IS SHIM ADJUSTABLE EARLY MODELS OR SCREW ADJUSTABLE
RELIEF VALVE LATE MODELS 3CREW ADJUSTABLE CHARGE RELIEF VALVE IS SHOWN
Removal
2EMOVE THE SHIM ADJUSTABLE CHARGE RELIEF VALVE PLUG WITH A INCH HEX WRENCH
"EFORE REMOVING THE SCREW ADJUSTABLE RELIEF VALVE PLUG MARK THE PLUG + LOCK NUT
+ AND HOUSING TO APPROXIMATELY MAINTAIN THE ORIGINAL ADJUSTMENT WHEN ASSEM
BLING 2EMOVE THE SCREW ADJUSTABLE CHARGE RELIEF VALVE PLUG BY LOOSENING THE LOCK
NUT WITH A HEX WRENCH CORRESPONDING TO THE TABLE
5NSCREW THE PLUG USING A LARGE Lock nut wrench size

SCREWDRIVER OR INCH HEX WRENCH Frame size Wrench size
2EMOVE AND DISCARD THE / RING + n INCH
n INCH
2EMOVE THE SPRING + AND RELIEF
VALVE POPPET +
Inspection
)NSPECT THE POPPET + AND MATING
K90
SEAT IN THE ENDCAP FOR DAMAGE OR h ,OCK NUT
FOREIGN MATERIAL t ,OCK NUT TORQUE
7HEN INSPECTING SHIM ADJUSTABLE +

VALVES DO NOT ALTER THE SHIMS OR h IN
INTERCHANGE PARTS d+ K
Reassembly K70
)NSTALL THE POPPET + AND SPRING
K80
+ &OR SHIM ADJUSTABLE VALVES
INSTALL THE SHIMS AND PLUG TORQUE
TO .sM ; LBFsFT= &OR SCREW
ADJUSTABLE VALVES INSTALL THE PLUG 3EE APPROPRIATE TABLE
WITH ITS LOCK NUT ALIGNING THE MARKS
MADE AT DISASSEMBLY AND TORQUE THE
LOCK NUT TO .sM ; LBFsFT=
#HECK THE CHARGE PRESSURE AND

ADJUST IF NECESSARY 2EFER TO Charge
pressure adjustments PAGE
0 %
54 520L0818 s 2EV !" s !PRIL 2008
464 BOMAG 008 916 41

Travel pump 10.1
Service Manual
-INOR REPAIR
AUXILIARY PAD Removal

2EMOVE THE FOUR END CAP SCREWS * 2EMOVE AND DISCARD SPECIAL WASHERS *
C#AUTION Aux. pad screw wrench size

/N EARLIER PRODUCTION FRAME SIZE Frame size Wrench sizes
PUMPS WITH TWIN PORTS SECURE THE END n EARLY MM INTERNAL HEX
CAP TO THE PUMP HOUSING WITH A CLAMP TO LATE MM INTERNAL HEX
AVOID GASKET DAMAGE MM HEX
n MM HEX
2EMOVE THE AUXILIARY PAD * AND n MM INTERNAL HEX
DISCARD THE / RINGS * AND * n MM INTERNAL HEX
Inspection
)NSPECT THE AUXILIARY PAD FOR DAMAGE AND REPLACE IF NECESSARY
4AKE CARE TO ASSURE THE SURFACES ARE CLEAN AND FREE OF ANY FOREIGN MATERIAL OR PAINT
PRIOR TO INSTALLING THE AUXILIARY PAD
C#AUTION
$O NOT ALLOW THE FORCE OF THE CYLINDER BLOCK SPRING AND SWASHPLATE LEVELER SPRINGS TO
SEPARATE THE END CAP FROM THE PUMP HOUSING 'ASKET DAMAGE AND EXTERNAL LEAKAGE MAY
RESULT
Auxiliary pad components (typical)
J50
J80
Endcap screw J70
Screw torque
J60
See appropriate table for wrench size and torque
E101 084E
Inspection
)NSPECT THE AUXILIARY PAD COMPONENTS FOR WEAR OR DAMAGE AND REPLACE IF ANY IS
FOUND
4AKE CARE TO ENSURE THE SURFACES ARE CLEAN AND FREE OF ANY FOREIGN MATERIAL OR PAINT
PRIOR TO INSTALLING THE AUXILIARY PAD
Reassembly
,UBRICATE AND INSTALL / RING * ON END CAP PILOT
)NSTALL THE AUXILIARY MOUNTING PAD End cap screw torque

* ON REAR OF ENDCAP Frame size Torque
.sM ; LBFsFT=
)NSTALL FOUR LARGE SCREWS * .sM ; LBFsFT=
4ORQUE ENDCAP SCREWS IN A AND NEW WASHERS * THROUGH .sM ; LBFsFT=
CRISS CROSS PATTERN THE MOUNTING PAD AND END CAP n .sM ; LBFsFT=
INTO THE HOUSING4ORQUE PER THE n .sM ; LBFsFT=
ACCOMPANYING TABLE
520L0818 s 2EV !" s !PRIL 2008 55
008 916 41 BOMAG 465
10.1 Travel pump
Service Manual
-INOR REPAIR
CHARGE PUMP 4HE FOLLOWING PROCEDURE SHOWS HOW TO REMOVE AND INSTALL A CHARGE PUMP
Removal
&OR PUMPS WITH AN AUXILIARY MOUNTING PAD REFER TO THE Auxiliary Pad INSTRUCTIONS
PAGE
C#AUTION
/N EARLIER PRODUCTION FRAME SIZE PUMPS WITH TWIN PORTS SECURE THE ENDCAP TO THE
PUMP HOUSING WITH A CLAMP TO AVOID GASKET DAMAGE
2EMOVE THE SIX SCREWS ( HOLDING THE CHARGE PUMP COVER RETAINER (
2EMOVE THE RETAINER ( AND THE Retainer screw wrench size
CHARGE PUMP COVER * 2EMOVE Frame size Wrench size
AND DISCARD / RING * .OTE THE n MM
ORIENTATION OF THE GEROTOR ASSEMBLY n MM
(
Current charge pump configuration
H40
H05
H60
H50
H31
J50
J15
J30
H70
E101 082E
H80
2EFER TO APPROPRIATE Sauer-Danfoss Series 90 service parts manual FOR EARLIER CHARGE PUMP
CONlGURATIONS
2EMOVE THE CHARGE PUMP COUPLING ( AND CHARGE PUMP DRIVE KEY (
2EMOVE THE CHARGE PUMP GEROTOR ASSEMBLY (
56 520L0818 s 2EV !" s !PRIL 2008
466 BOMAG 008 916 41

Travel pump 10.1
Service Manual
-INOR REPAIR
CHARGE PUMP 2EMOVE THE ALIGNMENT PIN (

(continued)
2EMOVE THE INNER PORT PLATE (
Inspection
)NSPECT ALL PARTS FOR ABNORMAL WEAR OR DAMAGE AND REPLACE IF NECESSARY
)F INSTALLING A DIFFERENT DISPLACEMENT CHARGE PUMP THE GEROTOR ASSEMBLY GEROTOR OUTER
ECCENTRIC RING AND INNER PORT PLATE EARLY AND LATE PRODUCTION PUMPS OR OUTER SPACER
PLATES INTERMEDIATE PRODUCTION PUMPS MUST BE REPLACED TOGETHER )F DIFFERENT
THICKNESS PORT PLATES ARE USED IN AN EARLY PRODUCTION CHARGE PUMP ASSEMBLY THE THICKER
PLATE IS THE INNER PORT PLATE INSTALLED NEXT TO THE PUMP END CAP
$IFFERENT PRODUCTION CHARGE PUMP ASSEMBLIES INCLUDE A DIFFERENT QUANTITY TYPE OF PORT
PLATES AND SPACER PLATES
Reassembly
"E SURE TO INSTALL THE CHARGE PUMP IN THE Orienting alignment pin
PROPER ORIENTATION )F UNSURE OF CHARGE
Discharge Gerotor Discharge
PUMP ROTATION REFER TO THE MODEL CODE assembly
Alignment pin
4HE ORIENTATION OF THE GEROTOR ASSEMBLY

Inlet Inlet
OUTER ECCENTRIC RING AND THE LOCATION
Alignment pin
OF THE ALIGNMENT PIN IN THE END CAP
Gerotor assembly
DETERMINE THE CHARGE PUMP ROTATION
Left hand rotation Right hand rotation
(outside looking into pump) (outside looking into pump)
$O NOT MIX CHARGE PUMP PARTS FROM P104 160E
DIFFERENT PRODUCTION PERIODS !LWAYS
INSTALL AS A COMPLETE ASSEMBLY
)NSTALL THE INNER PORT PLATE ( AND THE GEROTOR ASSEMBLY OUTER RING
)NSTALL THE ALIGNMENT PIN ( TO PROPERLY ORIENT THE PORT PLATES AND OUTER ECCENTRIC
RING FOR CORRESPONDING PUMP ROTATION
0RIOR TO INSTALLATION LUBRICATE THE )$ /$ AND SIDE FACES OF THE GEROTOR ASSEMBLY
)NSTALL THE GEROTOR ASSEMBLY (
)NSTALL THE OUTER PORT PLATE EARLY PRODUCTION AND INTERMEDIATE PRODUCTION PUMPS
ONLY
)NSTALL THE SPACER PLATE IF PRESENT INTERMEDIATE PRODUCTION PUMPS
)NSTALL THE CHARGE PUMP DRIVE KEY ( INTO THE CHARGE PUMP COUPLING ( AND
RETAIN WITH PETROLEUM JELLY
520L0818 s 2EV !" s !PRIL 2008 57

008 916 41 BOMAG 467
10.1 Travel pump
Service Manual
-INOR REPAIR
CHARGE PUMP )NTERMEDIATE PRODUCTION CMÃ AND CMÃ PUMPS USE THE SAME CHARGE PUMP
(continued) COUPLING4WO KEYWAYS ARE PROVIDED IN THE COUPLING FOR THE CHARGE PUMPS USED IN THESE
UNITS4HE REAR KEYWAY WITH IDENTIlER GROOVE IS USED IN CMÃ PUMPS4HE FRONT KEYWAY
CLOSEST TO THE INTERNALLY SPLINED END OF THE SHAFT IS USED IN CMÃ PUMPS
)NSTALL THE CHARGE PUMP COUPLING4HE INTERNALLY SPLINED END OF THE COUPLING MUST
ENGAGE THE MAIN PUMP SHAFT
4HE OUTSIDE DIAMETER OF THE INTERNALLY SPLINED END OF SOME EARLY PRODUCTION CHARGE
PUMP COUPLINGS WERE CHAMFERED %ARLY PRODUCTION END CAPS MAY NOT BE MACHINED TO
ACCEPT A NON CHAMFERED COUPLING !LWAYS USE A CHAMFERED CHARGE PUMP COUPLING IN
PUMPS WITH THE EARLY ENDCAP
&OR PUMPS WITH AN AUXILIARY MOUNTING PAD INSTALL THE AUXILIARY DRIVE COUPLING
&OR PUMPS WITH NO AUXILIARY PAD INSTALL A NEW / RING * ONTO CHARGE PUMP COVER
)F AN AUXILIARY PAD IS INSTALLED AN / RING IS NOT USED ON THE COVER
#AREFULLY REMOVE THE ALIGNMENT PIN FROM THE CHARGE PUMP PARTS )NSTALL THE PIN IN ITS
HOLE IN THE CHARGE PUMP COVER * SEE PREVIOUS PAGE FOR CORRECT ORIENTATION AND
RETAIN WITH PETROLEUM JELLY )NSTALL THE COVER WITH ALIGNMENT PIN INTO THE END CAP
AND ALIGNED CHARGE PUMP PARTS 4AKE CARE NOT TO DAMAGE THE COVER / RING IF USED
C#AUTION
)N ORDER TO AVOID LOSS OF CHARGE PRESSURE IN PUMPS WITH AN AUXILIARY MOUNTING PAD
ALWAYS INSTALL THE CHARGE PUMP COVER WITH THE PAD DRAIN HOLE LOCATED ON THE SAME SIDE
OF THE END CAP AS THE CHARGE INLET PORT 2EFER TO THE SECTION “Auxiliary Pad Installation” FOR
DETAILS
)NSTALL THE CHARGE PUMP COVER Retainer screw torque

RETAINER ( AND THE SIX INTERNAL Frame size Torque
HEX SCREWS ( 4ORQUE THE SCREWS n .sM ; LBFsFT=
PER THE TABLE AT THE RIGHT n .sM ; LBFsFT=
&OR PUMPS WITH AUXILIARY MOUNTING PADS INSTALL THE / RING AND AUXILIARY MOUNTING
PAD ADAPTOR ONTO THE END CAP 2EFER TO THE CORRESPONDING SECTION FOR INSTRUCTIONS ON
AUXILIARY PAD INSTALLATION
ADDING AN AUXILIARY )F INSTALLING AN AUXILIARY PAD KIT ON A PUMP THAT WAS PREVIOUSLY WITHOUT ONE CAREFULLY
PAD TO A PUMP REMOVE THE ALIGNMENT PIN FROM THE CHARGE PUMP PARTS
PREVIOUSLY WITHOUT
ONE )NSTALL THE PIN IN ITS HOLE IN THE NEW CHARGE PUMP COVER WITH HOLE FOR THE AUXILIARY
COUPLING AND RETAIN WITH PETROLEUM JELLY
)NSTALL THE NEW CHARGE PUMP COVER WITH ALIGNMENT PIN INTO THE END CAP AND THE
ALIGNED CHARGE PUMP PARTS
,UBRICATE AND INSTALL / RING )NSTALL AUXILIARY PAD 2EFER TO PREVIOUS SECTIONS Auxiliary
pad PAGE AND Charge pump PAGE FOR INSTRUCTIONS
58 520L0818 s 2EV !" s !PRIL 2008
468 BOMAG 008 916 41

Travel pump 10.1
Service Manual
-INOR REPAIR
INTEGRAL CHARGE Removal Lock nut wrench size and torque

PRESSURE FILTER 2EMOVE THE lLTER CANISTER . FROM Frame size Wrench size Torque
REPLACEMENT THE lLTER HEAD . AS DESCRIBED ON n INCH .sM ; LBFsFT=
THE CANISTER n INCH .sM ; LBFsFT=
n INCH .sM ; LBFsFT=
(OLD THE lLTER HEAD IN PLACE AND
LOOSEN THE LOCK NUT . USING THE WRENCH SIZE CORRESPONDING TO PUMP FRAME SIZE
2OTATE THE lLTER HEAD COUNTERCLOCKWISE TO REMOVE IT FROM THE HOUSING 2EMOVE AND
DISCARD THE / RING .
2EMOVE THE HYDRAULIC TUBE . FROM ITS BORE IN THE ENDCAP
Inspection
)NSPECT THE lLTER HEAD AND LOCK NUT SEALING SURFACES )F YOU lND ANY NICKS OR SCRATCHES
REPLACE THE DAMAGED COMPONENTS
Reassembly
)NSTALL THE HYDRAULIC TUBE . INTO ITS BORE IN THE ENDCAP )NSTALL THE lLTER HEAD .
INTO THE PORT USING A NEW / RING . 4HE HYDRAULIC TUBE SHOULD GO IN WITH LOW FORCE
!FTER ROTATING THE lLTER HEAD CLOCKWISE SO THAT THE THREADS ENGAGE WITH THE THREADS
C#AUTION IN THE ENDCAP CONTINUE TO ROTATE IT CLOCKWISE BETWEEN AND REVOLUTIONS 0OSITION
&AILURE TO INSTALL THE lLTER HEAD AS DESIRED C
MANIFOLD OR lLTER HEAD
TO A SUFlCIENT DEPTH IN 7HILE HOLDING THE lLTER HEAD IN THE DESIRED POSITION TIGHTEN THE SWIVEL LOCK NUT
THE END CAP WILL RESULT IN . AND TORQUE AS SHOWN IN TABLE
INSUFlCIENT ENGAGEMENT
OF THE TUBE IN THE END )NSTALL A NEW lLTER CANISTER . PER THE INSTRUCTIONS ON THE lLTER CANISTER
CAP BORE4HIS MAY ALLOW
UNlLTERED OIL TO BYPASS THE
lLTER AND ENTER THE CHARGE Integral charge pressure filter
SYSTEM
N25 N20
N15 Fi"!#"
#""! #
N36A
N36
11/16 in
$ $t]
N40
N10
N35A
N35
11/16 in
$ $t] P106 182E
520L0818 s 2EV !" s !PRIL 2008 59

008 916 41 BOMAG 469
10.1 Travel pump
Service Manual
-INOR REPAIR
PUMP CONTROL COVER Removal

PLATE 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF COVER PLATE
5SING A MM INTERNAL HEX WRENCH REMOVE THE SIX COVER PLATE MOUNTING SCREWS
- 2EMOVE THE COVER PLATE - AND GASKET - FROM HOUSING $ISCARD THE
GASKET
C#AUTION
0ROTECT EXPOSED SURFACES AND CAVITIES FROM DAMAGE AND FOREIGN MATERIAL
Reassembly
)NSTALL A NEW GASKET ON THE HOUSING )NSTALL THE COVER PLATE AND INSTALL THE SCREWS
4ORQUE THE SCREWS TO .sM ; LBFsFT=
)NSTALL A SEALING WASHER UNDER THE HEAD OF ANY MOUNTING SCREWS THAT ARE INSTALLED INTO
THROUGH HOLES IN THE HOUSING
Pump controls cover plate
M90 X
h MM
.sM ; LBFsFT=
-
3EAL WASHER
LOCATION CC
-
d
0 %
60 520L0818 s 2EV !" s !PRIL 2008
470 BOMAG 008 916 41

Travel pump 10.1
Service Manual
-INOR REPAIR
DISPLACEMENT 2EMOVE THE CONTROL ASSEMBLY AS Underside of an HDC/EDC module showing

CONTROL ORIFICES DESCRIBED IN THE INSTRUCTIONS FOR THE orifice locations
SPECIlC DISPLACEMENT CONTROL A
B
TA P
/RIlCE PLUGS MAY BE LOCATED IN TB
THE CONTROL ASSEMBLY AT THE PUMP
HOUSING FACE 2EMOVE THE ORIlCE
PLUGS ONE AT A TIME TO AVOID MIXING
THEM UP WITH A MM INTERNAL HEX
WRENCH .OTE THE LOCATION OF EACH Orifice plugs
PLUG DO NOT INTERCHANGE PLUGS Orifice check valve
#LEAN REINSTALL AND TORQUE THE ORIlCE E101 085E
PLUGS TO .sM ; LBFsFT=
!SSEMBLE THE CONTROL ONTO THE PUMP 2EFER TO THE INSTRUCTIONS FOR THE SPECIlC CONTROL
DISPLACEMENT 2EMOVE THE CONTROL ASSEMBLY AS Underside of an MDC module showing

CONTROL ORIFICE DESCRIBED IN THE INSTRUCTIONS FOR THE orifice locations
CHECK VALVE SPECIlC DISPLACEMENT CONTROL
TA A B TB
4HE ORIlCE CHECK VALVE IS LOCATED IN P
THE CONTROL ASSEMBLY AT THE SURFACE

OF THE PUMP HOUSING FACE 2EMOVE
THE SPRING RETAINER AND SPRING FROM
Orifice plugs
THE ORIlCE CHECK VALVE CAVITY AND
THEN REMOVE THE ORIlCE CHECK VALVE
Orifice check valve
#LEAN AND INSTALL THE ORIlCE CHECK E101 086E
VALVE IN THE CAVITY AND THEN INSTALL

THE SPRING AND SPRING RETAINER TO HOLD THE ORIlCE CHECK VALVE IN POSITION
!SSEMBLE THE CONTROL ONTO THE PUMP 2EFER TO THE INSTRUCTIONS FOR THE SPECIlC CONTROL
DISPLACEMENT $O NOT REMOVE THE ADAPTER PLATE UNLESS Displacement control adapter plate (early
CONTROL ADAPTER LEAKAGE IS EVIDENT4HE MOUNTING SCREWS production 130 cm³ pumps only)
PLATE (EARLY WITH SEALING COMPOUND ARE DIFlCULT TO Adapter plate
screws
PRODUCTION 130 REMOVE
PUMPS ONLY) 6 mm
4HE SCREWS FASTENING THE CONTROL ADAPTER

PLATE TO THE HOUSING HAVE SEALING

COMPOUND ON THE THREADS9OU MAY O-rings Adapter plate
REMOVE THEM WITH A MM INTERNAL HEX
WRENCH IF NECESSARY 2EMOVE AND DISCARD
THE / RINGS AND SEALS Seal
7HEN INSTALLING THE ADAPTER PLATE

REPLACE SCREWS WITH SEALING COMPOUND
AND ENSURE THE NEW / RINGS AND SEAL ARE
E101 087E
IN THE PROPER POSITION4ORQUE THE SCREWS
TO .sM ; LBFsFT=
520L0818 s 2EV !" s !PRIL 2008 61
008 916 41 BOMAG 471
10.1 Travel pump
Service Manual
-INOR REPAIR
MANUAL DISPLACEMENT Removal

CONTROL (MDC) 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF CONTROL
5SING A MM INTERNAL HEX WRENCH REMOVE THE SIX CONTROL MOUNTING SCREWS -
2EMOVE THE CONTROL - WITH ORIlCE CHECK VALVE 4 AND SPRING 4 AND CONTROL
GASKET - FROM THE HOUSING $ISCARD THE GASKET
)F NECESSARY REMOVE THE CONTROL HANDLE - BY REMOVING THE LOCKING NUT - AND
WASHER -
C#AUTION
Reassembly
)NSTALL A NEW GASKET - )NSPECT CONTROL TO ASSURE THAT THE CONTROL ORIlCE CHECK
VALVE AND SPRING ARE IN THEIR PROPER POSITION IN THE CONTROL
)NSTALL THE CONTROL %NGAGE THE PIN ON THE CONTROL LINKAGE INTO THE MATING HOLE IN THE
LINK ATTACHED TO THE SWASHPLATE
7ITH THE CONTROL IN POSITION MOVE CONTROL LEVER BOTH DIRECTIONS TO CHECK PROPER
ENGAGEMENT OF CONTROL LINKAGE PIN )F PROPERLY ASSEMBLED LEVER WILL RETURN TO
CENTER )F LEVER DOES NOT RETURN TO CENTER REMOVE THE CONTROL AND REPEAT THE ABOVE
PROCEDURE
MDC removal/installation
M72
3 - h 8 mm
h IN M70 .sM ; LBFsFT=
.sM ; LBFsFT=
- X
I MM
.sM ; LBFsFT=
-
3EAL WASHER d
LOCATION CC
4
4 4
0 %
62 520L0818 s 2EV !" s !PRIL 2008
472 BOMAG 008 916 41

Travel pump 10.1
Service Manual
-INOR REPAIR
MANUAL DISPLACEMENT )F REMOVED INSTALL THE CONTROL HANDLE - AND LOCKING NUT - WITH WASHER -
CONTROL (MDC) (OLD THE POSITION OF THE HANDLE AND TORQUE THE LOCKING NUT TO .sM ; LBFsFT= USING
(continued) AN MM HEX WRENCH
!LIGN THE CONTROL GASKET AND INSTALL THE SCREWS4ORQUE THE SCREWS TO .sM
; LBFsFT=
W 7ARNING )NSTALL A SEALING WASHER UNDER THE HEAD OF MOUNTING SCREWS THAT ARE INSTALLED INTO
4HE NEUTRAL START SWITCH THROUGH HOLES IN THE HOUSING
NEUTRAL MUST BE READJUSTED
AFTER REASSEMBLING THE
-$# MODULE )F THE CONTROL IS EQUIPPED WITH A NEUTRAL START SWITCH REFER TO MDC Neutral start switch
adjustment INSTRUCTIONS PAGE
SOLENOID OVERRIDE Removal

VALVE FOR MDC 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF VALVE
2EMOVE THE SOLENOID FROM THE VALVE BY REMOVING THE NUT WITH A INCH HEX
WRENCH 2EMOVE THE SOLENOID VALVE - FROM THE MANIFOLD - WITH A INCH
HEX WRENCH
5SING A MM INTERNAL HEX WRENCH REMOVE THE TWO SCREWS - AND REMOVE
SOLENOID MANIFOLD - FROM HOUSING 2EMOVE AND DISCARD THE GASKET -
Reassembly
4ORQUE VALVE - TO .sM ; LBFsFT=4ORQUE SOLENOID NUT TO .sM ; LBFsFT=
$O NOT OVERTORQUE THE SOLENOID NUT
)NSTALL A NEW GASKET ON THE CONTROL HOUSING )NSTALL THE MANIFOLD ONTO THE CONTROL
HOUSING ALIGN THE GASKET AND INSTALL THE SCREWS4ORQUE THE SCREWS TO .sM
; LBFsFT=
Solenoid override valve removal/installation
M90 (x6)
5 mm M77
] M76A
M76C
M76B
M76
M78 (x2)
5 mm
M75
]
P106 186E
520L0818 s 2EV !" s !PRIL 2008 63

008 916 41 BOMAG 473
10.1 Travel pump
Service Manual
-INOR REPAIR

VALVE FOR MDC WITH 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF VALVE
PRESSURE RELEASED
BRAKE 5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR SOLENOID VALVE MOUNTING SCREWS
- 2EMOVE THE SOLENOID VALVE - WITH / RINGS FROM THE ADAPTER PLATE $ISCARD
THE / RINGS
5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR ADAPTER PLATE MOUNTING SCREWS
- 2EMOVE THE ADAPTER PLATE AND / RINGS - - AND - FROM THE CONTROL
HOUSING $ISCARD THE / RINGS
Reassembly
5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS - - - ON THE
ADAPTER PLATE 0LACE THE ADAPTER PLATE INTO POSITION AND INSTALL THE SCREWS -
4ORQUE THE SCREWS TO .sM ; LBFsFT=
5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS ONTO THE SOLENOID VALVE
ASSEMBLY - AND INSTALL THE SOLENOID VALVE ONTO THE ADAPTER PLATE )NSTALL THE
SCREWS - AND TORQUE TO .sM ; LBFsFT=
M98 (x4)
4 mm
M9
t]
M95
M96
M97 M92 (x4)
4 mm
t]
P106 192E
64 520L0818 s 2EV !" s !PRIL 2008
474 BOMAG 008 916 41

Travel pump 10.1
Service Manual
-INOR REPAIR
HYDRAULIC AND Removal

ELECTRIC DISPLACEMENT 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF CONTROL
CONTROLS
5SING A MM INTERNAL HEX WRENCH REMOVE THE SIX CONTROL MOUNTING SCREWS -
GASKET - FROM HOUSING $ISCARD THE GASKET
C#AUTION
Reassembly
)NSTALL A NEW GASKET - 6ERIFY THE CONTROL ORIlCE CHECK VALVE AND SPRING 4 ARE IN
THEIR PROPER POSITION IN THE CONTROL
0OSITION THE CONTROL ON THE HOUSING )NSERT THE CONTROL LINKAGE PIN INTO THE
SWASHPLATE LINK
Hydraulic/Electric displacement control

M90 X
I MM
.sM ; LBFsFT=
-
-
d
4
4
0 %
520L0818 s 2EV !" s !PRIL 2008 65

008 916 41 BOMAG 475
10.1 Travel pump
Service Manual
-INOR REPAIR
7ITH THE CONTROL IN POSITION MOVE CONTROL ASSEMBLY LEFT AND RIGHT TO CHECK
ENGAGEMENT OF PIN IN THE LINK 0ROPER ENGAGEMENT IS INDICATED BY AN INCREASING
RESISTANCE AS THE CONTROL IS MOVED AWAY FROM CENTER POSITION .ON ENGAGEMENT OF
PIN IS INDICATED BY LACK OF SPRING FORCE )N CASE OF NON ENGAGEMENT REMOVE CONTROL
AND REPEAT THE ABOVE PROCEDURE
; LBFsFT=
PRESSURE CONTROL Removal

PILOT (PCP) FOR 4HOROUGHLY CLEAN EXTERNAL SURFACES OF CONTROL
ELECTRIC DISPLACEMENT
5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR SCREWS - AND REMOVE THE
0#0 -
Inspection
#HECK SURFACES FOR NICKS OR DAMAGE #LEAN INTERNAL SCREENS
Reassembly
)NSTALL NEW / RINGS - AND - IN 0#0 (OUSING 0LACE 0#0 AGAINST %$# HOUSING
AND INSTALL THE SCREWS - 4ORQUE TO .sM ; LBFsFT=
$O NOT REMOVE BLACK PLASTIC COVER FROM THE ALUMINUM PLATE4HIS IS NOT A SERVICEABLE ITEM
AND WILL VOID THE PRODUCT WARRANTY
PCP removal/installation M90 (x6)

5 mm
''$]
Seal washer
location
(42, 180, 250 cc)
M97
M96 (x3)
M98 (x4)
M9
4 mm
' 't] P106 194E
66 520L0818 s 2EV !" s !PRIL 2008
476 BOMAG 008 916 41

Travel pump 10.1
Service Manual
-INOR REPAIR
3-POSITION (FNR) Removal

ELECTRIC CONTROL 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF CONTROL
5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR SOLENOID VALVE MOUNTING SCREWS
7 2EMOVE THE SOLENOID VALVE 7 WITH / RINGS 7! AND ORIlCE FROM
THE ADAPTER PLATE
5SING A MM INTERNAL HEX WRENCH REMOVE THE SIX ADAPTER PLATE MOUNTING SCREWS
C#AUTION - 2EMOVE THE ADAPTER PLATE AND GASKET - FROM THE HOUSING $ISCARD THE
0ROTECT EXPOSED SURFACES GASKET C
AND CAVITIES FROM DAMAGE
AND FOREIGN MATERIAL Inspection
)NSPECT THE ORIlCE INSTALLED BETWEEN THE VALVE AND ADAPTER PLATE4HIS ORIlCE must BE
INSTALLED IN THE CASE DRAIN PASSAGE FOR PROPER PRESSURE LIMITER OPERATION
Reassembly
)NSTALL A SEALING WASHER )NSTALL A NEW GASKET - ON THE HOUSING 0LACE THE ADAPTER PLATE INTO POSITION AND
UNDER THE HEAD OF ANY INSTALL THE SCREWS - C4ORQUE THE SCREWS TO .sM ; LBFsFT=
MOUNTING SCREWS THAT
ARE INSTALLED INTO THROUGH )NSTALL NEW / RINGS 7! AND THE ORIlCE ONTO THE SOLENOID VALVE ASSEMBLY AND
HOLES IN THE HOUSING INSTALL THE SOLENOID VALVE ONTO THE ADAPTER PLATE )NSTALL SCREWS 7 4ORQUE TO
.sM ; LBFsFT=
FNR removal/installation
7 X
I MM
.sM ; LBFsFT=
7!
- X d
I MM
.sM ; LBFsFT= 4
4
4 M900
-
3EAL WASHER
LOCATION CC
4
- 4
4
d
0 %
520L0818 s 2EV !" s !PRIL 2008 67

008 916 41 BOMAG 477
10.1 Travel pump
Service Manual
-INOR REPAIR
DISPLACEMENT )F THE PUMP IS EQUIPPED WITH CONTROL Filter screen installation

CONTROL FILTER lLTER SCREENS IN THE PUMP HOUSING LATE B90
SCREENS PRODUCTION PRESS THEM INTO POSITION
WITH THE ROUNDED EDGE OF THE lLTER P106 690E
SCREENS FACING THE CONTROL UNTIL THEY ARE

mUSH TO MM ; INCH= BELOW THE
SURFACE OF THE HOUSING
SPEED SENSOR Removal

,OOSEN THE LOCK NUT USING A IN HEX WRENCH
5NSCREW THE SPEED SENSOR " FROM THE PUMP HOUSING 2EMOVE AND DISCARD THE
/ RING "!
Reassembly
)NSTALL A NEW / RING BEFORE REINSTALLING THE SENSOR
2EINSTALL THE SPEED SENSOR WITH LOCK NUT AND / RING INTO THE HOUSING !DJUST THE
GAP BETWEEN THE SENSOR AND THE MAGNETIC SPEED RING AS INSTRUCTED IN Speed sensor
adjustment PAGE AND TORQUE THE SENSOR LOCK NUT TO .sM ; LBFsFT=
)F A SPEED SENSOR IS NOT INSTALLED USE A IN INTERNAL HEX WRENCH TO TORQUE THE
HOUSING PLUG " TO .sM ; LBFsFT=
Typical location of speed sensor

B83 O-ring plug
]
B83A
B83 B83A
]
E101 095E
68 520L0818 s 2EV !" s !PRIL 2008
478 BOMAG 008 916 41

Travel pump 10.1
Service Manual
4ORQUE CHART
FASTENER SIZE AND Item Fastener Frame size Wrench size Torque
TORQUE CHART B83 3PEED SENSOR LOCK NUT IN HEX .sM ; LBFsFT=
E60 3IDE COVER SCREW MM HEX .sM ; LBFsFT=
"LIND HOLES MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
4HRU HOLES MM HEX .sM ; LBFsFT=
& 3ERVO CYLINDER SCREW MM HEX .sM ; LBFsFT=
F211 MM HEX .sM ; LBFsFT=
' %ND CAP SCREW MM INTERNAL HEX .sM ; LBFsFT=
G97 MM INTERNAL HEX .sM ; LBFsFT=
H80 #HARGE PUMP RETAINING SCREW MM HEX .sM ; LBFsFT=
J80 %ND CAP SCREW MM INTERNAL HEX .sM ; LBFsFT=
EARLY MM INTERNAL HEX .sM ; LBFsFT=
LATE MM INTERNAL HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
K10 #HARGE PRESSURE VALVE PLUG IN HEX .!
K90 #HARGE PRESSURE LOCK NUT IN HEX .sM ; LBFsFT=
IN HEX .sM ; LBFsFT=
L70 3HAFT RETAINING SCREW MM HEX .sM ; LBFsFT=
M72 -$# HANDLE NUT 8 mm .sM ; LBFsFT=
M78 $E STROKE VALVE MANIFOLD SCREW MM INTERNAL HEX .sM ; LBFsFT=
M85 %CCENTRIC PLUG LOCK NUT IN HEX .sM ; LBFsFT=
M88 .EUTRAL START SWITCH LOCK NUT IN HEX .sM ; LBFsFT=
M90 #ONTROL MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
M92 3OLENOID VALVE MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
M98 0#0 MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
N10 &ILTER REDUCER ASSEMBLY IN HEX .sM ; LBFsFT=
N37 &ILTER PLUG ASSEMBLY IN INTERNAL HEX .sM ; LBFsFT=
0" -ULTI FUNCTION VALVE IN HEX .sM ; LBFsFT=
P2A1 IN HEX .sM ; LBFsFT=
520L0818 s 2EV !" s !PRIL 2008 69

008 916 41 BOMAG 479
10.1 Travel pump
Service Manual
4ORQUE CHART
PLUG SIZE AND TORQUE )F ANY PLUGS OR lTTINGS ARE REMOVED FROM THE PUMP DURING SERVICING INSTALL AND TORQUE AS
CHART INDICATED IN THE ACCOMPANYING TABLEC
!LWAYS INSTALL NEW / RINGS BEFORE REINSTALLING THE PLUGS OR lTTINGS

C#AUTION
4ORQUE PLUGS OR lTTINGS Item O-ring plug Wrench size Torque
INSTALLED INTO ALUMINUM B70, B72 INTERNAL HEX WRENCH .sM ; LBFsFT=
HOUSINGS TO THE LOWER B71 INTERNAL HEX WRENCH .sM ; LBFsFT=
VALUES SPECIlED FOR B80 INTERNAL HEX WRENCH .sM ; LBFsFT=
INTERNAL HEX PLUGS OF THE B82, B83 INTERNAL HEX WRENCH .sM ; LBFsFT=
SAME SIZE G18 INTERNAL HEX WRENCH .sM ; LBFsFT=
G45-G50 INCH HEX WRENCH .sM ; LBFsFT=
G52-G54 INTERNAL HEX WRENCH .sM ; LBFsFT=
H90 (not shown) INTERNAL HEX WRENCH .sM ; LBFsFT=
N35, N36 (not shown) INCH HEX WRENCH .sM ; LBFsFT=
N37 INTERNAL HEX WRENCH .sM ; LBFsFT=
FASTENERS AND PLUGS
Fastener and plug locations

B70, B72 O-ring plug
9/16-18
J80 Auxilliary pad / G90 End cap screw
end cap screw M90 Control bolt
H80 Charge pump

retaining screw L70 Shaft seal
retaining screw
G53, G54 O-ring plug

9/16-18
K10 Charge pressure

relief valve plug M88 Neutral start switch
lock nut
M85 Eccentric plug
K90 Charge pressure lock nut
relief valve lock nut
B80 O-ring plug
1-1/16-12 P2B1 Multi-function valve
G97 End cap screw B71 O-ring plug

B82 O-ring plug
9/16-18
9/16-18
B83 Speed sensor /
G50 O-ring plug O-ring plug
9/16-18 9/16-18
G49 O-ring plug

9/16-18
G48 O-ring plug

9/16-18
N37 Filter plug assembly

F111 / F211 Servo cylinder screw E60 Side cover screw N10 Filter reducer assembly
P106 189E
P2A1 Multi-function valve
70 520L0818 s 2EV !" s !PRIL 2008
480 BOMAG 008 916 41

Travel pump 10.1
Service Manual
.OTES
520L0818 s 2EV !" s !PRIL 2008 71

008 916 41 BOMAG 481
10.1 Travel pump
OUR PRODUCTS Sauer-Danfoss Mobile Power and Control Systems

– Market Leaders Worldwide
(YDROSTATIC TRANSMISSIONS
3AUER $ANFOSS IS A COMPREHENSIVE SUPPLIER PROVIDING COMPLETE
(YDRAULIC POWER STEERING
SYSTEMS TO THE GLOBAL MOBILE MARKET
%LECTRIC POWER STEERING
3AUER $ANFOSS SERVES MARKETS SUCH AS AGRICULTURE CONSTRUCTION ROAD
%LECTROHYDRAULIC POWER STEERING
BUILDING MATERIAL HANDLING MUNICIPAL FORESTRY TURF CARE AND MANY
#LOSED AND OPEN CIRCUIT AXIAL PISTON OTHERS
PUMPS AND MOTORS
'EAR PUMPS AND MOTORS 7E OFFER OUR CUSTOMERS OPTIMUM SOLUTIONS FOR THEIR NEEDS AND
DEVELOP NEW PRODUCTS AND SYSTEMS IN CLOSE COOPERATION AND
"ENT AXIS MOTORS PARTNERSHIP WITH THEM
/RBITAL MOTORS
3AUER $ANFOSS SPECIALIZES IN INTEGRATING A FULL RANGE OF SYSTEM
4RANSIT MIXER DRIVES COMPONENTS TO PROVIDE VEHICLE DESIGNERS WITH THE MOST ADVANCED
0LANETARY COMPACT GEARS TOTAL SYSTEM DESIGN
0ROPORTIONAL VALVES 3AUER $ANFOSS PROVIDES COMPREHENSIVE WORLDWIDE SERVICE FOR ITS
$IRECTIONAL SPOOL VALVES PRODUCTS THROUGH AN EXTENSIVE NETWORK OF 'LOBAL 3ERVICE 0ARTNERS
STRATEGICALLY LOCATED IN ALL PARTS OF THE WORLD
#ARTRIDGE VALVES
(YDRAULIC INTEGRATED CIRCUITS
,OCAL ADDRESS
(YDROSTATIC TRANSAXLES
)NTEGRATED SYSTEMS
&AN DRIVE SYSTEMS
%LECTROHYDRAULICS
-ICROCONTROLLERS AND SOFTWARE
%LECTRIC MOTORS AND INVERTERS
*OYSTICKS AND CONTROL HANDLES 3AUER $ANFOSS 53 #OMPANY 3AUER $ANFOSS !P3
$ISPLAYS %AST TH 3TREET $+ .ORDBORG $ENMARK
!MES )! 53! 0HONE
3ENSORS 0HONE &AX
&AX
3AUER $ANFOSS 'MB( #O /(' 3AUER $ANFOSS $AIKIN ,4$
0OSTFACH $ .EUMüNSTER 3ANNOMIYA 'RAND "LDG &
+ROKAMP $ .EUMüNSTER 'ERMANY )SOGAMI DORI #HUO KU
0HONE +OBE (YOGO *APAN
&AX 0HONE
&AX
WWWSAUER DANFOSSCOM
520L0818 s 2EV !" s !PRIL 2008
482 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
008 916 41 BOMAG 483

10.1 Travel pump
Series 90 Pumps
Repair Instructions
2EVISIONS

!PRIL 79 4ORQUE FOR ' ' ' ' " " " " CHANGED !"
TO .M ; LBFsFT=
$EC &IRST PRINTING !!
&RONT COVER ILLUSTRATIONS & & &
2 11019577 s 2EV !" s !PRIL
484 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
Contents
INTRODUCTION /VERVIEW

'ENERAL INSTRUCTIONS
3AFETY PRECAUTIONS
5NINTENDED MACHINE MOVEMENT
&LAMMABLE CLEANING SOLVENTS
&LUID UNDER PRESSURE
0ERSONAL SAFETY
3YMBOLS USED IN 3AUER $ANFOSS LITERATURE 7
DISASSEMBLY 3HAFT

-ULTI FUNCTION VALVE CARTRIDGES 9
-ULTI FUNCTION VALVE CARTRIDGES PRE
!UXILIARY PAD
#HARGE PUMP
)NTEGRAL CHARGE PRESSURE lLTER REPLACEMENT
0UMP CONTROL COVER PLATE
3OLENOID OVERRIDE VALVE FOR -$# WITH PRESSURE RELEASED BRAKE 9
(YDRAULIC AND ELECTRIC DISPLACEMENT CONTROLS 0
0RESSURE CONTROL PILOT 0#0 FOR ELECTRIC DISPLACEMENT CONTROL %$#
0OSITION &.2 ELECTRIC CONTROL
$ISPLACEMENT CONTROL ORIlCES %$#($# CONTROL
$ISPLACEMENT CONTROL ORIlCE CHECK VALVE -$# CONTROL
$ISPLACEMENT CONTROL ADAPTER PLATE EARLY PRODUCTION PUMPS ONLY
$ISPLACEMENT CONTROL lLTER SCREENS
3PEED SENSOR
3ERVO RELIEF VALVES
%NDCAP9
6ALVEPLATE0
3IDECOVER0
3IDECOVER DISASSEMBLY
#YLINDER BLOCK
#YLINDER BLOCK
3ERVO CYLINDERS
3WASHPLATE
0ISTON ASSEMBLY
3WASHPLATE
INSPECTION /VERVIEW 7

3HAFT ASSEMBLY 7
0ISTONS AND SLIPPERS7
#YLINDER BLOCK
%NDCAP JOURNAL BEARING
6ALVEPLATE
#HARGE PRESSURE RELIEF VALVE 0
#HARGE PUMP0
11019577 s 2EV !" s !PRIL 3
008 916 41 BOMAG 485
10.1 Travel pump
Series 90 Pumps
Repair Instructions
Contents
INSPECTION (YDRAULIC AND ELECTRIC DISPLACEMENT CONTROLS

(CONTINUED) )NTEGRAL CHARGE PRESSURE lLTER
3WASHPLATE
3ERVO PISTON
#YLINDER BLOCK
ASSEMBLY #YLINDER BLOCK

3ERVO PISTON 2INGS
3ERVO ARM
3WASHPLATE GUIDE
2OLL PIN AND mAT WASHER
0ISTON ASSEMBLY 7
&IXED CLEARANCE HOLD DOWN BEARING
"EARING CAGE 0
(OUSING
3ERVO CYLINDER SCREWS
$ISPLACEMENT LIMITER
"EARING CAGE LOCATOR LINK
6ERIFY PROPER ASSEMBLY
3WASHPLATE LEVELER
)NSTALLING LEVELER AND SIDE COVER
3ETTING LEVELER NEUTRAL POSITION
#YLINDER BLOCK INSTALLATION7
0OSITIONING THE SIDE COVER 7
%ND CAP INSTALLATION
0REPARING FOR END CAP INSTALLATION
%ND CAP PARTS9
%ND CAP INSTALLATION9
3PEED SENSOR0
-ULTI FUNCTION VALVE CARTRIDGES PRE
#HARGE PUMP
!UXILIARY PAD
$ISPLACEMENT CONTROL lLTER SCREENS
)NTEGRAL CHARGE PRESSURE lLTER REPLACEMENT
0UMP CONTROL COVER PLATE7
$ISPLACEMENT CONTROL ADAPTER PLATE EARLY PRODUCTION PUMPS ONLY 7
(YDRAULIC AND ELECTRIC DISPLACEMENT CONTROLS
3OLENOID OVERRIDE VALVE FOR -$#70
3OLENOID OVERRIDE VALVE FOR -$# WITH PRESSURE RELEASED BRAKE 7
0RESSURE CONTROL PILOT 0#0 FOR ELECTRIC DISPLACEMENT CONTROL %$# 7
0OSITION &.2 ELECTRIC CONTROL 7
)NSTALLING SHAFT AND BEARING7
&INAL ASSEMBLY AND TESTING 77
&ASTENER SIZE AND TORQUE CHART 7
0LUG SIZE AND TORQUE CHART 79
&ASTENERS AND PLUGS79
4 11019577 s 2EV !" s !PRIL
486 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
)NTRODUCTION
OVERVIEW 4HIS MANUAL DETAILS MAJOR REPAIR PROCEDURES FOR 3ERIES PUMPS4HESE INCLUDE THE
COMPLETE DISASSEMBLY INSPECTION AND REASSEMBLY OF THE UNIT7HERE REWORK OF WORN
OR DAMAGED COMPONENTS IS POSSIBLE SPECIlCATIONS APPEAR TO ENSURE THESE PARTS MEET
FACTORY TOLERANCES /NLY 3AUER $ANFOSS 'LOBAL 3ERVICE 0ARTNERS '30S ARE AUTHORIZED TO
PERFORM MAJOR REPAIRS 3AUER $ANFOSS TRAINS 'LOBAL 3ERVICE 0ARTNERS AND CERTIlES THEIR
FACILITIES ON A REGULAR BASIS
W 7ARNING
5SE OF COMPONENTS THAT DO NOT COMPLY WITH REWORK SPECIlCATIONS MAY RESULT IN LOSS OF
PERFORMANCE WHICH MAY CONSTITUTE A SAFETY HAZARD $O NOT REUSE COMPONENTS THAT DONT
COMPLY TO GIVEN SPECIlCATIONS REPLACE WITH GENUINE 3AUER $ANFOSS SERVICE PARTS
-INOR REPAIR PROCEDURES ADJUSTMENTS AND TROUBLESHOOTING INFORMATION APPEAR IN THE

Series 90 Pumps Service Manual 520L0818 -INOR REPAIRS INCLUDE SERVICE OPERATIONS YOU
CAN PERFORM WITHOUT REMOVING THE UNITS ENDCAP 2EMOVAL OF THE ENDCAP VOIDS YOUR
WARRANTY
&OLLOW THESE GENERAL PROCEDURES WHEN REPAIRING 3ERIES PUMPS

GENERAL INSTRUCTIONS
w Remove the unit
HYDRAULIC mUID MAY BE UNDER HIGH PRESSURE ANDOR HOT )NSPECT THE OUTSIDE OF THE
PUMP AND lTTINGS FOR DAMAGE #AP HOSES AND PLUG PORTS AFTER REMOVAL TO PREVENT
CONTAMINATION
e Keep it clean
TO AVOID CONTAMINATION OF THE SYSTEM PORTS #LEANING PARTS IN A CLEAN SOLVENT WASH AND
AIR DRYING IS USUALLY ADEQUATE
)F LEFT UNATTENDED COVER THE PUMP WITH A PROTECTIVE LAYER OF PLASTIC
l Lubricate moving parts

$URING ASSEMBLY COAT ALL MOVING PARTS WITH CLEAN HYDRAULIC mUID4HIS ASSURES THAT THESE
PARTS ARE LUBRICATED DURING START UP

3AUER $ANFOSS RECOMMENDS THAT YOU REPLACE ALL / RINGS SEALS AND GASKETS ,IGHTLY
LUBRICATE ALL / RINGS WITH CLEAN PETROLEUM JELLY PRIOR TO ASSEMBLY
t Secure the unit

&OR MAJOR REPAIR PLACE THE UNIT IN A STABLE POSITION WITH THE SHAFT POINTING DOWNWARD )T
IS NECESSARY TO SECURE THE PUMP WHILE REMOVING AND TORQUING THE ENDCAP BOLTS
11019577 s 2EV !" s !PRIL 5

008 916 41 BOMAG 487
10.1 Travel pump
Series 90 Pumps
Repair Instructions
)NTRODUCTION
HYDRAULIC SYSTEM

W Warning
OR BYSTANDERS4O PROTECT AGAINST UNINTENDED MOVEMENT SECURE THE MACHINE OR
DISABLEDISCONNECT THE MECHANISM WHILE SERVICING

W Warning

W Warning
Personal safety
W Warning
TIMES
6 11019577 s 2EV !" s !PRIL
488 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
)NTRODUCTION

SAUER-DANFOSS
LITERATURE  #!54)/. MAY RESULT IN DAMAGE TO  ,UBRICATE WITH HYDRAULIC mUID
PRODUCT OR PROPERTY
 2EUSABLE PART

SLEEVE
 4ORX HEAD
11019577 s 2EV !" s !PRIL 7

008 916 41 BOMAG 489
10.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SHAFT Shaft and bearing Removing the shaft and bearing assembly
0OSITION PUMP WITH THE SHAFT
POINTING UP L70
.UMBER OF SCREWS AND WRENCH SIZE VARIES L60

BY MODEL
L30
2EMOVE THE THREE OR FOUR SCREWS
L40
, HOLDING THE RETAINER PLATE ,
AND SEAL CARRIER , TO THE HOUSING L50
USING A MM HEX WRENCH
L20
UNIT A MM INTERNAL HEX WRENCH
THROUGH UNITS OR A MM
INTERNAL HEX WRENCH THROUGH L10
UNITS 2EMOVE THE RETAINER PLATE
0RY THE SEAL CARRIER , FROM ITS L100

BORE9OU MAY TAP LIGHTLY ON THE END
OF THE SHAFT WITH A SOFT MALLET TO
FACILITATE REMOVAL
2EMOVE THE / RING , FROM THE

SEAL CARRIER AND DISCARD
0LACE SEAL CARRIER IN AN ARBOR PRESS

AND PRESS OUT THE SEAL , $ISCARD
SEAL
P106 181E
,IFT THE SHAFT AND BEARING ASSEMBLY

OUT OF THE PUMP
2EMOVE THE SNAP RING ,
2EMOVE THE BEARING WASHER AND

ROLLER ASSEMBLY ,
0RESS THE INNER BEARING RACE OFF THE

SHAFT ,
8 11019577 s 2EV !" s !PRIL
490 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
MULTI-FUNCTION VALVE Multi-function valve removal

CARTRIDGES
/LDER MULTIFUNCTION
VALVES PRE CONTAIN
DIFFERENT COMPONENTS P2B1
See multifunction valves
- Pre 1988 PAGE 0 FOR
DISASSEMBLY INSTRUCTIONS
P13
P06
P2A1
E101 537E
Removal Multi-function valve wrench size

2EMOVE MULTI FUNCTION VALVES 0! AND Frame size Wrench size
0" USING HEX WRENCH LISTED IN TABLE n INCH
n INCH
11019577 s 2EV !" s !PRIL 9

008 916 41 BOMAG 491
10.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
MULTI-FUNCTION VALVE Disassembly

CARTRIDGE (continued) 2EMOVE AND DISCARD / RINGS 0 AND 0
2ELIEVE SPRING PRESSURE BY REMOVING BYPASS ACTUATOR 0 USING A WRENCH4O
RETAIN PRESSURE SETTING DO NOT SEPARATE ADJUSTING SCREW 0 AND LOCKNUT 0 FROM
BYPASS ACTUATOR 0
2EMOVE AND DISCARD / RING 0
-ULTI FUNCTION VALVES ARE SOLD AS COMPLETE UNITS ONLY9OU MAY PURCHASE / RINGS
SEPARATELY
4HE POPPET SEAT SECTION IS PRESSED OVER A LIP 0LACE THE CARTRIDGE IN A VISE AND PRY THE
POPPET SEAT 0 OFF WITH AN APPROPRIATE TOOL -AINTAIN SUFlCIENT CONTROL TO PREVENT
THE INTERNAL COMPONENTS FROM mYING LOOSE $O NOT DAMAGE PARTS DURING DISASSEMBLY
2EMOVE INTERNAL PARTS 0 0 0 0 0 0 0 AND 0
P04
P03
P01
P02
P05
P06
P07
P08
P17
P16
P15
P14
P09
P11
P13
P12
E101 531E
10 11019577 s 2EV !" s !PRIL
492 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
MULTI-FUNCTION VALVE Removal Multi-function valve wrench size

CARTRIDGES - PRE 1988 2EMOVE MULTI FUNCTION VALVES USING HEX Frame size Wrench size
WRENCH LISTED IN TABLE n INCH
n INCH
Disassembly
)T IS NOT NECESSARY TO REMOVE THE BYPASS ACTUATOR 0 EXCEPT FOR CLEANING7RENCH
SIZE IS
-ULTI FUNCTION VALVES ARE SOLD AS COMPLETE UNITS ONLY / RINGS MAY BE PURCHASED
SEPARATELY
4O RETAIN PRESSURE SETTING DO NOT DISASSEMBLE BYPASS ACTUATOR 0
2EMOVE RETAINING RING 0 WITH A SNAP RING PLIERS
2EMOVE POPPET SEAT 0
2EMOVE INTERNAL PARTS 0 0 0 0 AND 0
P14
P19
P12
P06
P21
P15
P14
P11 P22
P09
P1
P13
E101 532E
11019577 s 2EV !" s !PRIL 11

008 916 41 BOMAG 493
10.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
CHARGE PRESSURE 4HE CHARGE PRESSURE RELIEF VALVE IS Charge pressure relief valve
RELIEF VALVE SHIM ADJUSTABLE EARLY MODELS OR
SCREW ADJUSTABLE LATE MODELS 3CREW +
h ,OCK NUT
ADJUSTABLE CHARGE RELIEF VALVE IS SHOWN
Removal +
2EMOVE THE SHIM ADJUSTABLE CHARGE h IN
RELIEF VALVE PLUG WITH A INCH HEX d+ +
WRENCH 2ETAIN SHIMS
+
"EFORE REMOVING THE SCREW
ADJUSTABLE RELIEF VALVE PLUG MARK +
THE PLUG + LOCK NUT + AND
HOUSING TO APPROXIMATELY MAINTAIN
THE ORIGINAL ADJUSTMENT WHEN ASSEM
3EE TABLE FOr
BLING 2EMOVE THE SCREW ADJUSTABLE WRENCH SIZe
CHARGE RELIEF VALVE PLUG BY LOOSENING
THE LOCK NUT WITH A HEX WRENCH
CORRESPONDING TO THE TABLE
5NSCREW THE PLUG USING A LARGE

SCREWDRIVER OR INCH HEX WRENCH
2EMOVE AND DISCARD THE / RING +
2EMOVE THE SPRING + AND RELIEF

VALVE POPPET +
Lock nut wrench size

n INCH % %
n INCH
PRESSURE OVERRIDE Removal Pressure override valve components

VALVE (OPTION FOR 180 2EMOVE FOUR SCREWS ATTACHING
Screws
FRAME SIZE) THE PRESSURE OVERRIDE VALVE TO THE
END CAP WITH A MM INTERNAL HEX Pressure override
WRENCH valve
2EMOVE AND DISCARD THE / RINGS

O-rings
E101 079E
12 11019577 s 2EV !" s !PRIL
494 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
AUXILIARY PAD Removal

2EMOVE FOUR END CAP SCREWS * 2EMOVE AND DISCARD SEAL WASHERS *
2EMOVE THE AUXILIARY PAD * AND DISCARD THE / RING *
Auxiliary pad components (typical)
J50
J80
Endcap screw J70
J60
See table for wrench size and torque
E101 084E
Auxiliary pad screw wrench size

Frame size Wrench sizes
n EARLY MM INTERNAL HEX
LATE MM INTERNAL HEX
MM HEX
n MM HEX
n MM INTERNAL HEX
n MM INTERNAL HEX
11019577 s 2EV !" s !PRIL 13

008 916 41 BOMAG 495
10.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
CHARGE PUMP Removal

&OR PUMPS WITH AN AUXILIARY MOUNTING PAD REFER TO THE Auxiliary Pad instructions
PAGE
2EMOVE AND DISCARD SIX SCREWS ( FROM THE CHARGE PUMP COVER RETAINER (
2EMOVE RETAINER ( AND THE Retainer screw wrench size

CHARGE PUMP COVER * 2EMOVE Frame size Wrench size
AND DISCARD / RING * .OTE THE n MM
ORIENTATION OF THE GEROTOR ASSEMBLY n MM
(
Current charge pump configuration
H40
H05
H60
H50
H31
J15
J50
J30
H70
E101 539E
H80
2EFER TO APPROPRIATE Sauer-Danfoss Series 90 service parts manual FOR EARLIER CHARGE PUMP
CONlGURATIONS
2EMOVE CHARGE PUMP COUPLING ( AND CHARGE PUMP DRIVE KEY (
2EMOVE THE CHARGE PUMP GEROTOR ASSEMBLY (
2EMOVE THE ALIGNMENT PIN (
2EMOVE THE VALVE PLATE (
14 11019577 s 2EV !" s !PRIL
496 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
INTEGRAL CHARGE Removal Lock nut wrench size and torque

PRESSURE FILTER 2EMOVE lLTER CANISTER . FROM THE Frame size Wrench size Torque
REPLACEMENT lLTER HEAD . AS DESCRIBED ON THE n INCH .sM ; LBFsFT=
CANISTER n INCH .sM ; LBFsFT=
(OLD lLTER HEAD IN PLACE AND LOOSEN THE LOCK NUT . USING THE WRENCH SIZE IN THE
TABLE
2OTATE lLTER HEAD COUNTERCLOCKWISE TO REMOVE IT FROM THE HOUSING 2EMOVE AND
DISCARD THE / RING .
2EMOVE HYDRAULIC TUBE . FROM ITS BORE IN THE ENDCAP
Integral charge pressure filter
N25 N20
N15 Filter manifold lock nut
N36A
N36
11/16 in
N40
N10
N35A
N35
11/16 in
P106 182E
11019577 s 2EV !" s !PRIL 15

008 916 41 BOMAG 497
10.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
PUMP CONTROL COVER Removal

PLATE 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVING COVER PLATE
5SING A MM INTERNAL HEX WRENCH REMOVE SIX COVER PLATE MOUNTING SCREWS -
2EMOVE THE COVER PLATE - AND GASKET - FROM HOUSING $ISCARD THE GASKET
CCaution
Pump controls cover plate

M90 X
MM
t .sM ; LBFsFT=
-
3EAL WASHER
LOCATION CC
-
d
0 %
16 11019577 s 2EV !" s !PRIL
498 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
MANUAL DISPLACEMENT Removal

CONTROL (MDC) 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVING CONTROL
5SING A MM INTERNAL HEX WRENCH REMOVE SIX CONTROL MOUNTING SCREWS -
GASKET - FROM THE HOUSING $ISCARD THE GASKET
)F NECESSARY REMOVE THE CONTROL HANDLE - BY REMOVING THE LOCKING NUT - AND
WASHER -
CCaution
MDC removal/installation
-
3 - h MM
h IN M70
- X
I MM
-
3EAL WASHER d
LOCATION CC
4
4 4
0 %
11019577 s 2EV !" s !PRIL 17

008 916 41 BOMAG 499
10.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

VALVE FOR MDC 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVING VALVE
2EMOVE THE SOLENOID FROM THE VALVE BY REMOVING THE COIL NUT WITH A INCH HEX
WRENCH 2EMOVE THE SOLENOID VALVE - FROM THE MANIFOLD - WITH A INCH
HEX WRENCH 2EMOVE THE / RINGS -! " AND BACKUP RING -# DISCARD
5SING A MM INTERNAL HEX WRENCH REMOVE TWO SCREWS - AND REMOVE SOLENOID
MANIFOLD - FROM HOUSING 2EMOVE AND DISCARD THE GASKET -
Seal washer
location
(42, 180, 250 cc)
M77
M76A
M76C
M76B
M76
M78 (x2)
5 mm
M75
P106 186E
18 11019577 s 2EV !" s !PRIL
500 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

VALVE FOR MDC WITH 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVING VALVE
PRESSURE RELEASED
BRAKE 5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR SOLENOID VALVE MOUNTING SCREWS
- 2EMOVE THE SOLENOID VALVE - WITH / RINGS FROM THE ADAPTER PLATE $ISCARD
THE / RINGS
5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR ADAPTER PLATE MOUNTING SCREWS
- 2EMOVE THE ADAPTER PLATE AND / RINGS - - AND - FROM THE CONTROL
HOUSING $ISCARD THE / RINGS
M98 (x4)
4 mm
M9
M95
M96
M97 M92 (x4)
4 mm
P106 192E
11019577 s 2EV !" s !PRIL 19

008 916 41 BOMAG 501
10.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
HYDRAULIC AND Removal

ELECTRIC DISPLACEMENT 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVING CONTROL
CONTROLS
5SING A MM INTERNAL HEX WRENCH REMOVE SIX CONTROL MOUNTING SCREWS -
$ISCARD SEAL WASHER IF PRESENT 2EMOVE CONTROL - WITH ORIlCE CHECK VALVE 4
AND SPRING 4 AND CONTROL GASKET - FROM HOUSING $ISCARD THE GASKET
CCaution

- X
I MM
-
-
d
4
4
0 %
20 11019577 s 2EV !" s !PRIL
502 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
PRESSURE CONTROL Removal

PILOT (PCP) FOR 4HOROUGHLY CLEAN EXTERNAL SURFACES OF CONTROL
ELECTRIC DISPLACEMENT
CONTROL (EDC) 5SING A MM INTERNAL HEX WRENCH REMOVE FOUR SCREWS - AND REMOVE THE 0#0
- 2EMOVE AND DISCARD THE / RINGS - -
$O NOT DISASSEMBLE THE

0#0 - )T IS AVAILABLE PCP removal/installation
ONLY AS A COMPLETE UNIT
M97
M96 (x3)
M98 (x4)
M9
4 mm
P106 194E
11019577 s 2EV !" s !PRIL 21

008 916 41 BOMAG 503
10.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
3-POSITION (FNR) Removal

ELECTRIC CONTROL 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF CONTROL
5SING A MM INTERNAL HEX WRENCH REMOVE FOUR SOLENOID VALVE MOUNTING SCREWS
7 2EMOVE THE SOLENOID VALVE 7 WITH / RINGS 7! AND ORIlCE FROM
THE ADAPTER PLATE
5SING A MM INTERNAL HEX WRENCH REMOVE THE SIX ADAPTER PLATE MOUNTING SCREWS
CCaution - 2EMOVE THE ADAPTER PLATE AND GASKET - FROM THE HOUSING $ISCARD THE
0ROTECT EXPOSED SURFACES GASKET C
AND CAVITIES FROM DAMAGE
AND FOREIGN MATERIAL )F NECESSARY REMOVE AND CLEAN THE THREE ORIlCES 4 4 4 USING A MM
INTERNAL HEX WRENCH AND A MM INTERNAL HEX WRENCH
$O NOT DISASSEMBLE THE FNR removal/installation

&.2 CONTROL )T IS AVAILABLE 7 X
I MM
AS A COMPLETE UNIT ONLY
7!
- X d
I MM
4
4
4
-
3EAL WASHER
LOCATION CC
4
- 4
4
d
0 %
22 11019577 s 2EV !" s !PRIL
504 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
DISPLACEMENT 2EMOVE THE CONTROL ASSEMBLY AS Underside of an HDC/EDC module showing

CONTROL ORIFICES DESCRIBED IN THE INSTRUCTIONS FOR THE orifice locations
(EDC/HDC CONTROL) SPECIlC DISPLACEMENT CONTROL A
B
TA P
9OU MAY lND ORIlCE PLUGS IN THE TB
CONTROL ASSEMBLY AT THE PUMP
HOUSING FACE4O AVOID MIXING THEM
UP REMOVE CLEAN AND REPLACE
ORIlCE PLUGS INDIVIDUALLY 5SE A MM
INTERNAL HEX WRENCH TO REMOVE THE Orifice plugs
PLUGS .OTE THE LOCATION OF EACH PLUG Orifice check valve
DO NOT INTERCHANGE PLUGS #LEAN E101 085E
REINSTALL AND TORQUE THE ORIlCE PLUGS

TO .sM ; LBFsFT=
DISPLACEMENT 2EMOVE THE CONTROL ASSEMBLY AS Underside of an MDC module showing

CONTROL ORIFICE DESCRIBED IN THE INSTRUCTIONS FOR THE orifice locations
CHECK VALVE (MDC SPECIlC DISPLACEMENT CONTROL
CONTROL) TA A B TB
4HE ORIlCE CHECK VALVE IS IN THE P
CONTROL ASSEMBLY AT THE SURFACE OF

THE PUMP HOUSING FACE 2EMOVE THE
SPRING RETAINER AND SPRING FROM THE
Orifice plugs
ORIlCE CHECK VALVE CAVITY AND THEN
REMOVE THE ORIlCE CHECK VALVE
Orifice check valve
#LEAN AND INSTALL THE ORIlCE CHECK E101 086E
VALVE IN THE CAVITY AND THEN INSTALL

THE SPRING AND SPRING RETAINER
TO HOLD THE ORIlCE CHECK VALVE IN
POSITION
DISPLACEMENT $O NOT REMOVE THE ADAPTER PLATE UNLESS Displacement control adapter plate (early
CONTROL ADAPTER LEAKAGE IS EVIDENT4HE MOUNTING SCREWS production 130 cm³ pumps only)
PLATE (EARLY WITH SEALING COMPOUND ARE DIFlCULT TO Adapter plate
PRODUCTION 130 REMOVE screws
PUMPS ONLY)
4HE SCREWS FASTENING THE CONTROL ADAPTER 6 mm
PLATE TO THE HOUSING HAVE SEALING
t]
COMPOUND ON THE THREADS9OU MAY O-rings
REMOVE THEM WITH A MM INTERNAL HEX Adapter plate
WRENCH IF NECESSARY 2EMOVE AND DISCARD
THE / RINGS AND SEALS Seal
E101 087E
11019577 s 2EV !" s !PRIL 23

008 916 41 BOMAG 505
10.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
DISPLACEMENT )F YOU REMOVE THE SCREENS REPLACE WITH Filter screen installation
CONTROL FILTER NEW SCREENS 0RESS THEM INTO POSITION B90
SCREENS WITH THE ROUNDED EDGE OF THE SCREEN
FACING THE CONTROL UNTIL THEY ARE mUSH TO P106 690E
MM ; INCH= BELOW THE SURFACE OF

THE HOUSING
SPEED SENSOR Removal

,OOSEN THE LOCK NUT USING AN IN HEX WRENCH
5NSCREW SPEED SENSOR " FROM THE PUMP HOUSING 2EMOVE AND DISCARD THE / RING
"!
Typical location of speed sensor

B83 O-ring plug
ft]
B83A
B83 B83A

t]
E101 095E
24 11019577 s 2EV !" s !PRIL
506 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SERVO RELIEF VALVES #ERTAIN FRAME SIZE PUMPS WITH TWIN PORT END CAPS MAY HAVE THE SERVO RELIEF VALVES AND
ROTATION PLUGS IN A REMOVABLE ROTATION BLOCK
5SING A MM INTERNAL HEX WRENCH REMOVE THE ROTATION BLOCK SCREWS
2EMOVE THE BLOCK
2EMOVE THE GASKET
3OME PUMPS HAVE A PRESSURE LIMITER FUNCTION
2EMOVE THE SERVO RELIEF VALVES FROM THE END CAP OR ROTATION BLOCK 5SE A
SCREWDRIVER
Servo relief valve removal
Veiw 'C'
View 'C'
View 'C'
P80
P802
P70
P702
With Pressure Limiters Without Pressure Limiters
P106 729E
Servo relief passage plugs
3OME PUMPS HAVE PRESSURE LIMITER VALVES ANDOR RELIEF VALVES
.OTE THE POSITION OF THE ROTATION PIPE PLUGS
5SING A INCH INTERNAL HEX WRENCH REMOVE THE SERVO RELIEF PASSAGE PLUGS FROM THE
END CAP OR ROTATION BLOCK
5SING A INCH INTERNAL HEX WRENCH REMOVE THE PIPE PLUGS FROM THE END CAP OR
ROTATION BLOCK
#LEAN PASSAGES WITH A SUITABLE SOLVENT
3EE THE ILLUSTRATIONS ON THE FOLLOWING PAGES FOR PROPER PLUG AND VALVE LOCATIONS ON
VARIOUS PUMPS
11019577 s 2EV !" s !PRIL 25

008 916 41 BOMAG 507
10.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SERVO RELIEF VALVES Installing servo relief valves

(continued) )NSTALL SERVO RELIEF VALVES OR RELIEF VALVE PASSAGE PLUGS INTO THE END CAP OR ROTATION
BLOCK
)NSTALL SERVO RELIEF VALVES IN THE END CAP OR ROTATION BLOCK OF PUMPS WITH PRESSURE
LIMITER FUNCTIONS OR RELIEF VALVES
)NSTALL THE ROTATION PIPE PLUGS INTO THE END CAP OR ROTATION BLOCK W
W 7ARNING
-AKE SURE THE PRESSURE LIMITER LOGIC PLUGS ARE IN THE CORRECT PORTS FOR PUMP ROTATION
5NCONTROLLABLE MACHINE MOVEMENT RESULTS FROM IMPROPER PLUG INSTALLATION6ERIFY CORRECT
PRESSURE LIMITER FUNCTION4EST THE PUMP BEFORE INSTALLING IN MACHINE !LSO TEST IT BEFORE
RELEASING THE MACHINE FROM REPAIR
4ORQUE THE SERVO RELIEF VALVES OR RELIEF VALVE PASSAGE PLUGS TO .sM ; LBFsFT=
4ORQUE THE ROTATION PIPE PLUGS TO .sM ; LBFsFT=
)NSTALL ROTATION BLOCK GASKET AND SCREWS IF USED
4ORQUE THE ROTATION BLOCK SCREWS TO .sM ; LBFsFT=
Specifications
Pressure limiter Pump rotation Holes with Holes with servo Holes with Open holes
Port A Port B pipe plugs relief valves O-ring plugs
9ES 9ES 2IGHT #7 .ONE
9ES 9ES ,EFT ##7 .ONE
.O .O %ITHER .ONE
9ES .O 2IGHT #7 .ONE
9ES .O ,EFT ##7 .ONE
9ES 9ES 2IGHT #7 WITH .ONE
AUTOMOTIVE CONTROL
9ES 9ES ,EFT ##7 WITH .ONE
AUTOMOTIVE CONTROL
030 twin ported end cap (early units) 030 Twin ported end cap
3 4
7 6
5 6
5
3 4
7
1 1
2
2
0 0
26 11019577 s 2EV !" s !PRIL
508 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SERVO RELIEF VALVES 042 twin ported end cap (early units) 042 twin ported end cap
(continued)
6 3 6
2 2
3
5
5 1 4 1
7 4 7
0
0
055 side ported end cap 055 twin ported end cap
6 6
2 2
4 5 4
1 1
7 7
5 3 3
0 0
075 side and twin ported end cap 075 twin ported end cap rotation block
6 1 2
4 2
1
5 4 3
5
7 3
0
6 7
0
11019577 s 2EV !" s !PRIL 27

008 916 41 BOMAG 509
10.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SERVO RELIEF VALVES 100 side ported end cap 100 twin ported end cap
(continued)
6 6 2
2
4 7 1 5 7
3
3
1
5 4
0
0
130 twin ported end cap 180 twin ported end cap rotation block
4 3
1 2
5
5 4
3
6 1 2 6
7
0
0
250 twin port end cap
5 4
3 6
7
2 1
0
28 11019577 s 2EV !" s !PRIL
510 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
ENDCAP 0LACE THE PUMP ON THE WORK SURFACE WITH ENDCAP ' FACING UP
.UMBER OF SCREWS AND WRENCH SIZE VARIES BY MODEL
5SING A OR MM INTERNAL HEX WRENCH OR A MM HEX WRENCH REMOVE THE OR

SCREWS '' FASTENING THE END CAP TO THE PUMP HOUSING
4HE SCREW ' RETAINS A SPACER ' A (J80) Screw removal

LIFTING BRACKET ' AND A WASHER ' Pump size Wrench size
CC MM INTERNAL HEX
2EMOVE SCREWS * IF PRESENT CC MM HEX
2EFER TO THE TABLE Screw removal FOR CC AND CC MM HEX
WRENCH SIZES CC MM INTERNAL HEX
CC AND CC MM INTERNAL HEX
2EMOVE END CAP ' FROM HOUSING
4HE ALIGNMENT PINS AND VALVE PLATE WILL USUALLY REMAIN WITH THE HOUSING
2EMOVE AND DISCARD END CAP GASKET '
2EMOVE THE HARDENED SHIMS % FROM THE END CAP POCKETS
Removing the end cap and gasket

G97
G95
G94
J80
G93
G90
G04
E24
E101 101
11019577 s 2EV !" s !PRIL 29

008 916 41 BOMAG 511
10.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
VALVEPLATE Valveplate and springs Removing internal parts

2EMOVE VALVE PLATE # NOTING
DIRECTION OF ARROWS ON VALVE PLATE
2EMOVE THE LONG SPRINGS % FROM

THE SWASHPLATE LEVELER D95
3OME UNITS HAVE DUAL SWASHPLATE LEVELER B50 (2X)

SPRINGS AN INNER SPRING NESTED INSIDE
EACH OF THE STANDARD SPRINGS
B10
2EMOVE THE SHORT SWASHPLATE HOLD
DOWN SPRING $ IF PRESENT E82
E101 102
Arrows C80
2EMOVE THE TWO ALIGNMENT PINS
"
SIDECOVER -ARK THE ORIENTATION OF THE SIDE Removing the side cover
COVER % TO THE HOUSING
3TRAIGHTEN THE LOCKING TABS USED ON

EARLIER PRODUCTION UNITS
2EMOVE THE SIDE COVER SCREWS

% 2EFER TO TABLE BELOW FOR WRENCH
SIZES
2EMOVE SIDE COVER ASSEMBLY FROM

PUMP HOUSING
Side cover screw removal

B10
Pump size Wrench size
CC MM HEX
CC THROUGH CC MM HEX
CC THROUGH CC MM HEX
E101 103
E60
30 11019577 s 2EV !" s !PRIL
512 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SIDECOVER Side cover components Leveler disassembly

DISASSEMBLY 2EMOVE SPACER WASHERS IF USED ON
E30
THE LEVELER SPRING SEATS %
E30
3OME UNITS WITH DUAL SWASHPLATE LEVELER

SPRINGS HAVE SPACER WASHERS ON THE
LEVELER SPRING SEATS
E22
2EMOVE SPRING SEATS % FROM
SWASHPLATE LEVELER %
3OME LEVELERS DO NOT HAVE REMOVABLE

Spacer
SPRING SEATS Washer
2EMOVE THE SEALING NUTS % AND

GUIDE POSTS % HOLDING THE LEVELER
% TO THE SIDE COVER % 2EFER TO
TABLE BELOW FOR WRENCH SIZES E90
Sealing nut removal

Pump size Wrench sizes
CC AND CC MM OPEN END
MM HEX

CC THROUGH CC INCH OPEN END
MM HEX
CC THROUGH CC MM OPEN END
MM HEX
E101 104
.OTE THE ORIENTATIONS OF THE LEVELER
% AND SIDE COVER % E40
2EMOVE LEVELER % FROM SIDE COVER

% Cylinder block removal
2EMOVE THE INSERT ASSEMBLY %
2EMOVE AND DISCARD SIDE COVER / C12

RING %
CYLINDER BLOCK 2EMOVE THE CYLINDER BLOCK # FROM

THE HOUSING
4HE SWASHPLATE AND PISTON ASSEMBLY

REMAINS IN THE HOUSING C4AKE CARE TO
PREVENT PISTONS FROM BEING SCRATCHED
WHILE THE CYLINDER BLOCK IS OUT OF THE
HOUSING 4HE PISTONS ARE NOT SELECTIVELY
lTTED HOWEVER UNITS WITH HIGH HOURLY
USAGE MAY DEVELOP WEAR PATTERNS
.UMBER THE PISTONS AND BORES FOR RE E101 131
ASSEMBLY IF THEY ARE TO BE REUSED
11019577 s 2EV !" s !PRIL 31

008 916 41 BOMAG 513
10.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
CYLINDER BLOCK -OST REPAIRS DO NOT REQUIRE BLOCK SPRING Cylinder block disassembly
REMOVAL 0ERFORM THIS PROCEDURE ONLY
IF YOU SUSPECT PROBLEMS WITH THE BLOCK
SPRING C16
W 7ARNING
2ISK OF PERSONAL INJURY
C15
#OMPRESSING THE BLOCK 5SING A PRESS APPLY PRESSURE ON
SPRING REQUIRES TO THE BLOCK SPRING WASHER # TO
. ; TO LBF = 5SE A COMPRESS THE BLOCK SPRING #
PRESS SUFlCIENT TO MAINTAIN #OMPRESS THE SPRING ENOUGH TO C14
THIS FORCE WITH REASONABLE SAFELY REMOVE THE SPIRAL RETAINING
EFFORT %NSURE THE SPRING IS RING # 7HILE MAINTAINING
SECURE BEFORE ATTEMPTING PRESSURE UNWIND THE SPIRAL RETAINING
TO REMOVE THE SPIRAL RING #AREFULLY RELEASE THE PRESSURE C13
RETAINING RING 2ELEASE THE AND REMOVE THE OUTER BLOCK SPRING
PRESSURE SLOWLY AFTER THE WASHER BLOCK SPRING AND INNER
RETAINING RING IS REMOVED BLOCK SPRING WASHER # FROM THE
CYLINDER BLOCK W
C12
E101-113
32 11019577 s 2EV !" s !PRIL
514 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SERVO CYLINDERS -ARK THE SERVO CYLINDERS && AND HOUSING " 4HIS HELPS TO IDENTIFY EACH
SERVO CYLINDER && WITH ITS RESPECTIVE SIDE OF THE HOUSING "
.UMBER OF SCREWS AND WRENCH SIZE VARIES BY MODEL
5SING A MM OR MM HEX WRENCH REMOVE THE OR SCREWS &&

RETAINING EACH SERVO CYLINDER && TO THE HOUSING "
A &OR EARLY PRODUCTION UNITS CAREFULLY PRY EACH CYLINDER && FROM THE
HOUSING " BY USING A SCREWDRIVER IN THE NOTCHES IN THE CYLINDER
4HE SERVO PISTON WILL
REMAIN IN THE HOUSING B &OR LATER PRODUCTION UNITS INSTALL AN MM OR MM SCREW IN THE THREADED
&OR LATER PRODUCTION UNITS HOLE IN THE CENTER OF EACH CYLINDER && AND PULL THE CYLINDERS FROM THE
WITH DISPLACEMENT LIMITERS HOUSING "
REMOVE THE NUT
&& AND LIMITER
SCREW && FROM Servo cylinder removal
EACH SERVO CYLINDER
F112 F113
&& AND INSTALL AN
MM OR MM SCREW IN
ITS PLACE AS A PULLER SCREW F40
F50
F40
F50
B10
F40
F50
F40
F50
F212
F213 E101 105E
11019577 s 2EV !" s !PRIL 33

008 916 41 BOMAG 515
10.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SWASHPLATE 2EMOVE THE SWASHPLATE BEARING CAGE LINK PIN $ FROM THE HOUSING THROUGH THE
CONTROL OPENING
CMÃ DISPLACEMENT 2EMOVE THE BEARING CAGE LOCATOR LINK $ FROM THE SWASHPLATE THROUGH THE CONTROL
PUMPS USE A SCREW AS THE OPENING
LINK PIN 2EMOVE IT WITH A
MM INTERNAL HEX WRENCH IF CC AND CC PUMPS HAVE SCREW TYPE LINK PINS /NE IS AT THE CONTROL OPENING4HE
NECESSARY OTHER IS AT THE SIDE COVER OPENING
2EMOVE THE SWASHPLATE $ AND PISTON ASSEMBLY # THROUGH THE HOUSING SIDE
COVER OPENING
5NITS WITH AN AUTOMOTIVE
CONTROL HAVE A THREADED $ISENGAGE THE SERVO ARM $ FROM THE SLIDER BLOCK & IN THE SERVO PISTON AS YOU
HOLE IN ONE END OF THE REMOVE THE ASSEMBLY
SERVO PISTON4HIS IS FOR THE
CENTERING ASSIST SPRING 2EMOVE THE SERVO PISTON AND SLIDER BLOCK & FROM HOUSING
ASSEMBLY &OR THESE UNITS
NOTE THE ORIENTATION OF 2EMOVE THE CRADLE BEARING CAGE AND RACES WITH LOCATING PINS
THE SERVO PISTON IN THE
HOUSING 4HE BEARING RACE LOCATING PINS ARE A LOOSE lT
Disassembling the swashplate

Locating Pin
Servo piston
F20
D10
D95 D85 Bearing race
D80 Bearing cage

C20
D10
D50
D80
D85
C20
D50 E101 106E
34 11019577 s 2EV !" s !PRIL
516 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
PISTON ASSEMBLY 5SING A MM OR MM HEX WRENCH REMOVE THE SCREWS C70 AND SPACERS #
HOLDING THE TWO SLIPPER GUIDE HOLD DOWN BEARINGS # TO THE SWASHPLATE $
$ISCARD SCREWS # 2EPLACE WITH NEW SCREWS WHEN PUMP IS ASSEMBLED
2EMOVE THE HOLD DOWN BEARINGS # AND SPACERS #
2EMOVE THE SLIPPER GUIDE # AND PISTONS # FROM THE SWASHPLATE $
2EMOVE THE PISTON ASSEMBLIES # FROM THE SLIPPER GUIDE #
Removing the piston/slipper assembly
C20
C30
C50
D50
C40
C20
C30
C50
D50
C40
E101 107E
11019577 s 2EV !" s !PRIL 35

008 916 41 BOMAG 517
10.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SWASHPLATE 2EMOVE GUIDE $ AND FEEDBACK LINK - BY REMOVING SPECIAL LOCKING SCREW $
$ISCARD LOCKING SCREW 3EE TABLE Swashplate components BELOW FOR WRENCH SIZES
2EMOVE SERVO ARM $ FROM SWASHPLATE $ BY REMOVING LOCKING SCREW $
$ISCARD LOCKING SCREW 3EE TABLE Swashplate components BELOW FOR WRENCH SIZES
#LEAN THE THREADED HOLES FOR THE HOLD DOWN SCREWS IN SWASHPLATE $ OF ALL OLD
LOCKING COMPOUND 5SE A - 8 OR - 8 THREAD TAP FOR THIS PROCEDURE
#LEAN THE THREADED HOLES FOR THE LOCKING SCREWS $ $ IN SWASHPLATE $ OF ALL
OLD LOCKING COMPOUND 5SE A THREAD TAP GIVEN IN THE TABLE BELOW FOR THIS PROCEDURE
Swashplate components
Pump size D55 wrench size D55 thread size D65 wrench size D65 thread size
CC AND CC MM HEX - MM INTERNAL HEX -
Removing the swashplate guide and servo arm
M14
M14
D10
D10
D50 D50
E101 191E
36 11019577 s 2EV !" s !PRIL
518 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
Inspection
OVERVIEW #LEAN ALL PARTS IN A SUITABLE SOLVENT 2EPLACE / RINGS GASKETS SHAFT SEAL )NSPECT ALL PARTS
FOR DAMAGE NICKS OR UNUSUAL WEAR PATTERNS 2EPLACE ALL PARTS WITH UNUSUAL OR EXCESSIVE
WEAR OR DISCOLORATION WHICH INDICATES EXCESSIVE HEAT
SHAFT ASSEMBLY Inspection

)NSPECT THE SEAL CARRIER FOR ANY DAMAGE OR NICKS )NSPECT THE SHAFT AND BEARING FOR RUST
WEAR OR CONTAMINATION 3PIN THE BEARING IN YOUR HAND FEELING FOR ROUGHNESS 2EPLACE IF
NECESSARY
Shaft assembly
Shaft
Bearing
Seal Carrier
E101 541E
PISTONS AND SLIPPERS )NSPECT THE PISTONS FOR DAMAGE AND Inspect pistons
DISCOLORATION $ISCOLORED PISTONS MAY
INDICATE EXCESSIVE HEAT DO NOT REUSE
Slipper
)NSPECT THE RUNNING SURFACE OF THE
SLIPPERS 2EPLACE ANY PISTON ASSEMBLIES
WITH SCORED OR ROUNDED SLIPPER EDGES
-EASURE THE SLIPPER FOOT THICKNESS
2EPLACE ANY PISTON ASSEMBLIES WITH P104 109E
WORN SLIPPERS #HECK THE SLIPPER AXIAL
END PLAY 2EPLACE ANY PISTON ASSEMBLIES
WITH EXCESSIVE END PLAY 2EFER TO 2EWORK
3PECIlCATIONS , FOR COMPONENT
REWORK GUIDELINES
11019577 s 2EV !" s !PRIL 37

008 916 41 BOMAG 519
10.1 Travel pump
Series 90 Pumps
Repair Instructions
Inspection
CYLINDER BLOCK %XAMINE THE RUNNING FACE OF THE CYLINDER Inspect cylinder block
BLOCK 4HE SURFACE SHOULD BE SMOOTH AND
FREE OF NICKS AND BURRS 2EMOVE ANY BURRS
%NSURE THAT NO SCRATCHES OR GROOVES EXIST
Cylinder
THESE MAY DRASTICALLY REDUCE OUTPUT block
mOW AND LIFE OF PUMP 2EFER TO 2EWORK
3PECIlCATIONS , FOR COMPONENT A
REWORK GUIDELINES
flat to 0.0026 mm check for burrs

[0.000100 in]
P106 692E
ENDCAP JOURNAL )NSPECT THE ENDCAP VALVE PLATE AND End cap and journal bearing
BEARING SEALING SURFACES FOR NICKS AND SCRATCHES
#HECK SURFACE mATNESS 2EFER TO 2EWORK
3PECIlCATIONS , FOR COMPONENT
REWORK GUIDELINES )F ANY OF THE BASE
W 7ARNING METAL IS VISIBLE THROUGH THE PLASTIC
$O NOT DAMAGE THE VALVE BEARING MATERIAL REPLACE THE END CAP
PLATE SURFACE OF THE END JOURNAL BEARING ' 5SE A SUITABLE
CAP WHEN REMOVING THE PULLER TO REMOVE THE BEARING W0RESS THE
BEARING JOURNAL BEARING INTO THE END CAP '
USING A PRESS PIN -AKE SURE BEARING IS
mUSH TO MM ; INCHES= BELOW
THE VALVE PLATE SURFACE OF THE END CAP
'
2EPLACE ENDCAP )F JOURNAL BEARING SPINS

IN THE ENDCAP
E101 108
VALVEPLATE )NSPECT VALVE PLATE FOR WEAR AND SCRATCHES 3CRATCHES DEEP ENOUGH FOR YOU TO FEEL WITH
YOUR lNGERNAIL OR A PENCIL TIP ARE NOT ACCEPTABLE $O NOT ATTEMPT TO REWORK 3ERIES
VALVE PLATES REPLACE IF DAMAGED
38 11019577 s 2EV !" s !PRIL
520 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
Inspection
MULTI-FUNCTION VALVE Inspection

CARTRIDGES #LEAN AND INSPECT ALL PARTS #ARTRIDGE IS AVAILABLE AS COMPLETE UNIT ONLY
/ RINGS ARE AVAILABLE SEPARATELY
P04
P03
P01
P02
P05
P06
P07
P08
P17
P16
P15
P14
P09
P11
P13
P12
E101 531E

P14
P19
P12
P06
P21
P15
P14
P11 P22
P09
P1
P13
E101 532E
11019577 s 2EV !" s !PRIL 39

008 916 41 BOMAG 521
10.1 Travel pump
Series 90 Pumps
Repair Instructions
Inspection
CHARGE PRESSURE Inspection

RELIEF VALVE )NSPECT THE POPPET + AND MATING SEAT IN THE ENDCAP FOR DAMAGE OR FOREIGN MATERIAL
7HEN INSPECTING SHIM ADJUSTABLE VALVES DO NOT ALTER THE SHIMS OR INTERCHANGE PARTS
,OCK NUt
"ODY
/ RING
3PRING
Seat
% %
CHARGE PUMP Inspection

)NSPECT ALL PARTS FOR WEAR OR DAMAGE AND REPLACE IF NECESSARY #HECK GEROTOR ASSEMBLY
AND VALVE PLATE FOR PITTING FROM CAVITATION
Charge pump
H40
H05
H60
H50
H31
J50
J15
J30
H70
E101 542E
H80
40 11019577 s 2EV !" s !PRIL
522 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
Inspection
INTEGRAL CHARGE Inspection

PRESSURE FILTER )NSPECT THE lLTER HEAD AND LOCK NUT SEALING SURFACES )F YOU lND ANY NICKS OR SCRATCHES
REPLACE DAMAGED COMPONENTS
Integral charge pressure filter manifold
N25 N20
N15
N36A
N36
N10
N35A
N35
11/16 in
E101 543E
HYDRAULIC AND Inspection

ELECTRIC DISPLACEMENT )NSPECT MACHINED SURFACES ON CONTROL AND PUMP FOR NICKS AND SCRATCHES 2EPLACE CONTROL
CONTROLS IF YOU lND DAMAGE TO MACHINED SURFACES
Hydraulic/Electric displacement controls
% %
11019577 s 2EV !" s !PRIL 41

008 916 41 BOMAG 523
10.1 Travel pump
Series 90 Pumps
Repair Instructions
Inspection
SWASHPLATE )NSPECT RUNNING SURFACE FOR WEAR OR SCRATCHES )NSPECT HOLD DOWN SCREW HOLES FOR
DAMAGE )F SCREW HOLES ARE DAMAGED REPLACE SWASHPLATE )NSPECT FOR WEAR IN LEVELER PAD
AREAS EXCESSIVE WEAR MAY AFFECT PUMP NEUTRAL )F YOU lND DAMAGE REPLACE SWASHPLATE
)NSPECT SWASHPLATE GUIDE $ FOR WEAR 2EPLACE IF NECESSARY 2EFER TO 2EWORK
3PECIlCATIONS , FOR COMPONENT REWORK GUIDELINES
Swashplate and guide inspection
D50
Hold down
screw holes
Running surface
Leveler pad areas E101 548E
42 11019577 s 2EV !" s !PRIL
524 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
Inspection
SERVO PISTON )NSPECT THE SERVO PISTON FOR WEAR 2EMOVE AND DISCARD SEAL RINGS & AND EXPANDER
/ RINGS & 2EPLACE SERVO PISTON IF NECESSARY 2EPLACE / RINGS AND SEAL RINGS BEFORE
REASSEMBLY
Servo piston inspection
Servo piston
E101 112E
CYLINDER BLOCK 6ISUALLY INSPECT THE CYLINDER BLOCK Cylinder block inspection
SPRING AND WASHERS FOR INDICATIONS OF
WEAR OR DAMAGE 2EPLACE IF WEAR CRACKS C16
OR OTHER DAMAGE IS PRESENT
C15
C14
C13
C12
E101-113
11019577 s 2EV !" s !PRIL 43

008 916 41 BOMAG 525
10.1 Travel pump
Series 90 Pumps
Repair Instructions
Inspection
CYLINDER BLOCK #OAT ALL PARTS WITH CLEAN HYDRAULIC Cylinder block assembly
mUID PRIOR TO REASSEMBLY
W 7ARNING C16
2ISK OF PERSONAL INJURY )NSTALL THE INNER BLOCK SPRING WASHER
#OMPRESSING THE BLOCK # BLOCK SPRING # AND OUTER
SPRING REQUIRES TO WASHER # INTO THE CYLINDER C15
. ; TO LBF = 5SE A BLOCK 5SING A PRESS COMPRESS THE
PRESS SUFlCIENT TO MAINTAIN BLOCK SPRING ENOUGH TO EXPOSE THE
THIS FORCE WITH REASONABLE RETAINING RING GROOVE7IND THE SPIRAL
C14
EFFORT %NSURE THE SPRING IS RETAINING RING # INTO THE GROOVE
SECURE BEFORE ATTEMPTING IN THE CYLINDER BLOCK W
TO REMOVE THE SPIRAL
RETAINING RING 2ELEASE THE 2ELEASE PRESSURE ON SPRING6ISUALLY C13
PRESSURE SLOWLY AFTER THE CHECK THAT SPIRAL RETAINING RING IS
RETAINING RING IS REMOVED PROPERLY POSITIONED IN ITS GROOVE
C12
E101-113
SERVO PISTON RINGS )NSTALL NEW EXPANDER / RINGS & INTO THE SEAL GROOVES IN THE SERVO PISTON )NSTALL
THE SEAL RINGS & IN THE GROOVES OVER THE EXPANDER / RINGS & C
C Caution !LLOW THE ASSEMBLY TO SET FOR AT LEAST MINUTES4HIS ALLOWS THE SEAL RINGS & TO
$O NOT STRETCH THE RETURN TO THEIR ORIGINAL UNSTRETCHED SIZE
SEAL RINGS ANY MORE
THAN NECESSARY DURING Servo piston assembly
INSTALLATION
Servo piston
P106 730E
44 11019577 s 2EV !" s !PRIL
526 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
SERVO ARM )NSTALL THE SERVO ARM $
!LIGN PRESS lT DESIGN SERVO ARMS WITH THE SWASHPLATES SLOT AND THREADED HOLES WHILE
INSTALLING 0RESS COMPLETELY INTO THE SWASHPLATE SLOT
)NSTALL NEW LOCKING SCREW $ WITH PRE APPLIED LOCKING COMPOUND INTO SWASHPLATE
4ORQUE LOCKING SCREW $ 3EE TABLE BELOW FOR WRENCH SIZES AND TORQUES
Servo arm specifications

Pump size Wrench size (for D55) 4ORQUE .sM ;LBFsFT=
CC THROUGH CC MM HEX ;=
CC MM HEX ;=
CC MM HEX ;=
CC CC MM HEX ;=
Servo arm installation
D10 D10
D50 D50
E101 110
11019577 s 2EV !" s !PRIL 45

008 916 41 BOMAG 527
10.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
SWASHPLATE GUIDE !SSEMBLE THE SWASHPLATE GUIDE $ AND FEEDBACK LINK - TO THE SWASHPLATE
)NSTALL NEW LOCKING SCREW $ WITH PRE APPLIED LOCKING COMPOUND USING AN INTERNAL
HEX WRENCH
4ORQUE THE SCREW TO SPECIlCATIONS IN THE TABLE BELOW
7HEN INSTALLING THE GUIDE ONTO THE CC SWASHPLATE HOLD THE STRAIGHT SIDES OF THE
GUIDE PERPENDICULAR TO THE SLIPPER SURFACE OF THE SWASHPLATE $ WHILE TIGHTENING
SCREW
Special locking screw specifications
Pump size D65 wrench sizes 4ORQUE .sM ;LBFsFT=
CC AND CC MM INTERNAL HEX ;=
CC THROUGH CC MM INTERNAL HEX ;=
CC MM INTERNAL HEX ;=
CC AND CC MM INTERNAL HEX ;=
Attaching swashplate guide

D65
M14
M14
D60
D50
D50
E101 111
Roll pin and flat washer

)NSTALL THE HEADED ROLL PIN $ AND mAT WASHER $ IF REMOVED &OR PROPER DISTANCE
( BETWEEN THE WASHER $ AND THE SIDE OF THE SWASHPLATE FOLLOW THE TABLES Roll pin
specifications (A) AND (B) BELOW
Roll pin specifications (A) Pin and washer positions

Pump frame size Distance, H: + 0.1, -0.25 mm
; INCHES=
CC MM ; INCHES= Swashplate
NO WASHER D75
Roll pin specifications (B)

D70
Pump frame size Distance, H: ± 0.25 mm
;¼ INCHES=
Distance H
CC MM ; INCHES= P104 188E
CC THROUGH CC MM ; INCHES=
CC MM ; INCHES=
CC AND CC ;=
;=
0IN AT SIDE COVER POSITION
0IN AT CONTROL POSITION
46 11019577 s 2EV !" s !PRIL
528 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
PISTON ASSEMBLY Piston assembly

!SSEMBLE THE PISTON ASSEMBLIES # INTO THE SLIPPER GUIDE #
C Caution ,UBRICATE THE SLIPPER AND SWASHPLATE RUNNING SURFACES

-OST PARTS HAVE CRITICAL
HIGH TOLERANCE SURFACES #ENTER THE PISTONS # AND GUIDE # ON THE SWASHPLATE
4AKE CARE NOT TO DAMAGE
THESE SURFACES DURING
ASSEMBLY 0ROTECT EXPOSED Piston assembly
SURFACES OPENINGS AND
PORTS FROM DAMAGE AND
FOREIGN MATERIAL
D10
C20
D50
C20
D50
E101 114
11019577 s 2EV !" s !PRIL 47

008 916 41 BOMAG 529
10.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
PISTON ASSEMBLY Fixed-clearance hold-down bearing

(continued)
3OME EARLY PRODUCTION PUMPS USE A SPRING LOADED HOLD DOWN MECHANISM 3ERVICE PARTS
FOR THE SPRING LOADED HOLD DOWN MECHANISM ARE NO LONGER AVAILABLE4HE lXED CLEARANCE
HOLD DOWN BEARING MUST BE INSTALLED IF HOLD DOWN PARTS REQUIRE REPLACEMENT ON THESE
EARLY PUMPS 2EFER TO THE APPROPRIATE Service Parts Manual FOR MORE INFORMATION
!SSEMBLE ONE HALF OF THE lXED CLEARANCE SLIPPER GUIDE HOLD DOWN BEARINGS #
0OSITION SPACERS # OVER THE THREADED HOLES IN THE SWASHPLATE $
C Caution )NSTALL ONE SLIPPER GUIDE HOLD DOWN BEARING # AND SPACERS # C
0OSITION THE SPLIT BETWEEN
THE # SLIPPER GUIDE )NSTALL NEW SCREWS C70 THROUGH THE SLIPPER GUIDE HOLD DOWN BEARING # AND
BEARING PLATES IN LINE WITH SPACERS # C
THE $ SWASHPLATE ARM
,OCATE THE BEARING SURFACE C Caution
OF THE # BEARING PLATES !LWAYS USE NEW SCREWS WITH PROPER LOCKING COMPOUND
NEXT TO THE # SLIPPER
GUIDE 3TART THE SCREWS C70 INTO THE SWASHPLATE $ DO NOT TORQUE
0OSITION SLIPPER GUIDE WITH PISTONS UNDER lRST HOLD DOWN BEARING
!SSEMBLE SECOND SLIPPER GUIDE HOLD DOWN BEARING WITH SCREWS AND SPACERS ONTO THE
SWASHPLATE 3TART THE SCREWS DO NOT TORQUE
,UBRICATE SLIPPER GUIDE AND HOLD DOWN BEARINGS
Hold-down bearing installation

D50
D10
C30
C20
C40
C50
E101 115
48 11019577 s 2EV !" s !PRIL
530 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
PISTON ASSEMBLY Alternate hold-down bearing installation

(continued) D50
D10
C30
C20
C40
D50
C50
P106 542E
4ORQUE THE SLIPPER GUIDE HOLD DOWN Torque settings

SCREWS C70 TO THE SPECIlCATIONS IN Pump size 4ORQUE .sM ;LBFsFT=
Torque settings CC THROUGH CC ;=
CC THROUGH CC ;=
%NSURE THE SLIPPER GUIDE # AND PISTON SLIPPERS # SLIDE FREELY ON THE SWASHPLATE
AFTER ALL BOLTS ARE TORQUED
11019577 s 2EV !" s !PRIL 49

008 916 41 BOMAG 531
10.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
BEARING CAGE .EW PARTS HAVE LOCKING PIN " INTEGRAL TO BEARING RACE &OR OLDER PUMPS LOCKING PINS
ARE SEPARATE FROM RACES4HE LOCATING PINS ASSURE PROPER ASSEMBLY
2ETAIN THE RACES IN POSITION WITH PETROLEUM JELLY
)NSTALL THE BEARING RACES INTO THE HOUSING POSITIONING THE RACES ON THE LOCATING PINS
"
!SSEMBLE AND LUBRICATE THE BEARING CAGE
)NSTALL THE BEARING CAGE ON THE BEARING RACES
Bearing assembly
Bearing race
New parts have locking pin (B20) integral

to bearing race. For older pumps, locking
pins are separate from races. B20
B20
P106 513E
50 11019577 s 2EV !" s !PRIL
532 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
HOUSING 2EFER TO THE ILLUSTRATION Housing installations, NEXT PAGE FOR THE NEXT STEPS
0OSITION THE SERVO PISTON & IN THE HOUSING
&OR UNITS WITH AN ,UBRICATE AND INSTALL THE BRONZE SLIDER BLOCK & ONTO THE SERVO PISTON
AUTOMOTIVE CONTROL
THE SERVO PISTON HAS A #AREFULLY LOWER THE SWASHPLATE ASSEMBLY INTO THE HOUSING THROUGH THE END CAP
THREADED HOLE ON ITS OPENING 0ROTECT THE PISTONS FROM BEING SCRATCHED
MACHINED END 0UT THIS END
ON THE SIDE OF THE HOUSING (OLD THE SWASHPLATE ASSEMBLY APPROXIMATELY MM ;³ INCH= ABOVE THE CRADLE
WHERE THE CENTERING ASSIST BEARINGS
SPRING SLEEVE IS LOCATED
0OSITION THE FEEDBACK LINK $ IN THE CONTROL OPENING
,OWER THE SWASHPLATE ASSEMBLY ONTO THE CRADLE BEARINGS
C Caution 0OSITION THE SERVO PISTON ON THE SLIDER BLOCK & 4HE PARTS SHOULD SLIDE FREELY
"E SURE TO ASSEMBLE THE
CORRECT SERVO CYLINDER ON ,UBRICATE INSIDE THE SERVO CYLINDERS (OLD THE SERVO PISTON IN PLACE AND INSTALL THE
EACH SIDE OF THE HOUSING SERVO CYLINDERS C
&OR UNITS WITH AN AUTOMOTIVE CONTROL THERE IS A SPECIAL SERVO CYLINDER ON THE CENTERING
ASSIST SPRING SIDE OF THE HOUSING
)F PREVIOUSLY REMOVED INSTALL NEW SCREENS " 5SE PROPER INSTALLATION TOOL
11019577 s 2EV !" s !PRIL 51

008 916 41 BOMAG 533
10.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
HOUSING (continued) Servo cylinder screws

)NSTALL THE SERVO CYLINDERS & COMPLETELY INTO THE HOUSING BORES
C Caution .UMBER OF SCREWS AND WRENCH SIZES VARY BY MODEL

)F THE SERVO CYLINDERS ARE
NOT SEATED COMPLETELY INTO )NSTALL THE OR SCREWS && Servo cylinder screw torques
THE BORES TIGHTENING OF IN EACH SERVO CYLINDER C Pump size F111/F211
THE SCREWS CAN DAMAGE THE .sM ;LBFsFT=
/ RINGS 4ORQUE TO SPECIlCATIONS IN Servo CC ;=
cylinder screw torques CC ;=
CC ;=
&OR UNITS WITH AN AUTOMOTIVE CONTROL CC ;=
INSTALL THE SERVO CYLINDER SCREWS ON TO THE CC ;=
HOUSINGS CENTERING ASSIST SPRING SIDE CC ;=
CC AND CC ;=
)F PREVIOUSLY REMOVED REPLACE
SCREENS " WITH NEW SCREENS
Housing installations
F20
F10
F111
Swashplate assembly F112

O
D14
F111 F113
F213 B60
O
F212
F211
F211 E101 118E
52 11019577 s 2EV !" s !PRIL
534 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
HOUSING (continued) Displacement limiter.

)NSTALL DISPLACMENT LIMITERS & & INTO SERVO CYLINDERS TO LOCATION MARKED
DURRING DISASSEMBLY7RENCH SIZES ARE SHOWN IN TABLE BELOW
)NSTALL NEW SEAL LOCK NUTS & & ONTO DISPLACEMENT LIMITERS4ORQUE SEAL
LOCK NUTS WHILE HOLDING DISPLACEMENT LIMITER7RENCH SIZES AND TORQUE VALUES ARE
SHOWN IN TABLE BELOW 2EFER TO THE Series 90 Pumps Service Manual 520L0818 FOR
DISPLACEMENT LIMITER ADJUSTMENT INFORMATION
Displacment limiter and seal lock nut wrench sizes and torques
Pump size F113 F213 F112/F212 F112/F212
wrench size wrench 4ORQUE .sM ;LBFsFT=
CC CC MM MM ;=
CC MM MM ;=
CC AND CC MM MM ;=
Housing installations
F20
Servo piston
F111
Swashplate assembly F112

O
D14
F113
F111
F213
B60
O
F211
F212
F211
E101 118E
11019577 s 2EV !" s !PRIL 53

008 916 41 BOMAG 535
10.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
BEARING CAGE LOCATOR !LIGN THE SWASHPLATES BEARING CAGE SLOT WITH THE HEADED SPRING PIN !LIGN WITH THE
LINK HOUSINGS PIN HOLE 3EE ILLUSTRATION Locator link position FOR CORRECT ORIENTATION
(OOK THE CAGE LOCATOR LINK $ OVER THE SPRING PIN BETWEEN THE WASHER AND THE
SWASHPLATE
2OTATE THE LINK $ INTO THE BEARING CAGE SLOT
FRAME SIZE PUMPS DO NOT HAVE A WASHER ON THE SPRING PIN
!LIGN THE LOCATOR LINK $ HOLE WITH THE HOUSING HOLE
)NSTALL THE LINK PIN $ THROUGH THE LOCATOR LINK $ AND INTO THE HOUSING
AND PUMPS USE A mAT HEAD SCREW AS THE LINK PIN 3TEPS AND REFER TO THESE
C Caution PUMPS
!LWAYS USE A NEW SCREW
WITH PROPER LOCKING )NSTALL A NEW SCREW WITH LOCKING COMPOUND THROUGH THE LOCATOR LINK $ AND INTO
COMPOUND THE HOUSING C
C Caution 4IGHTEN THE SCREW INTO THE HOUSING $O THIS UNTIL THE HEAD OF THE SCREW IS AT A HEIGHT OF
$O ./4 TORQUE THIS SCREW TO MM ; TO INCHES= FROM THE PUMP HOUSINGS MACHINED SURFACE C
AGAINST THE $ LOCATOR
LINK4HE LINK MUST ROTATE Locator link position
FREELY Finished Assembly
Housing pin hole
D80
D85
Bearing cage slot

Headed spring
pin washer
E101 120E
54 11019577 s 2EV !" s !PRIL
536 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
VERIFY PROPER 0USH THE SWASHPLATE ASSEMBLY TOWARD THE CONTROL SIDE OF THE HOUSING UNTIL THE
ASSEMBLY SWASHPLATE GUIDE CONTACTS THE BEARING RACE
#HECK FOR CLEARANCE BETWEEN THE SERVO ARM AND THE SLIDER BLOCK
%NSURE SWASHPLATE ASSEMBLY MOVES FREELY ON BEARINGS
2OTATE SWASHPLATE ON BEARINGS TO CHECK FOR CONTROL LINK MOVEMENT AND PROPER
LOCATOR LINK POSITION
SWASHPLATE LEVELER 0LACE INSERTS % ONTO SIDE COVER Attach leveler to side cover
%
E30
0OSITION THE SWASHPLATE LEVELER %

ON THE SIDE COVER INSERTS %
.OTE THE ORIENTATION OF THE LEVELER

% AND THE SIDE COVER %
)NSTALL THE GUIDE POSTS %

E22
AND SEALING NUTS % 3EE Guide
post/sealing nut installation TABLE
FOR WRENCH SIZES AND TORQUE
SPECIlCATIONS E90
)NSTALL THE LEVELER SPRING SEATS % IF

NECESSARY
3OME PUMPS DO NOT HAVE REMOVABLE

SWASHPLATE LEVELER SPRING SEATS %
E40
E101 121
Guide post/sealing nut installation

Pump size Wrench sizes 4ORQUE .sM ;LBFsFT=
CC AND CC MM OPEN END ;=
MM HEX
CC THROUGH CC
INCH OPEN END ;=
MM HEX
CC THROUGH CC MM OPEN END ;=
MM HEX
11019577 s 2EV !" s !PRIL 55

008 916 41 BOMAG 537
10.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
INSTALLING LEVELER ,UBRICATE AND INSTALL A NEW SIDE COVER / RING %
AND SIDE COVER
)NSTALL THE SIDE COVER ASSEMBLY C
C Caution )NSTALL SIDE COVER SCREWS % WITHOUT LOCKING COMPOUND AT OCLOCK AND
3LIDE SWASHPLATE LEVELER OCLOCK LOCATIONS4IGHTEN ONLY TO HALF TORQUE
% TOWARD THE CASE DRAIN
PORT4HIS ALLOWS THE LEVELER 4HIS HOLDS THE % COVER WHILE CHECKING THE ZERO ANGLE POSITION OF THE SWASHPLATE
% TO CLEAR THE SIDE OF
THE SWASHPLATE DURING SIDE Setting leveler - neutral position
COVER INSTALLATION )F REUSING ORIGINAL PARTS ROTATE THE SIDE COVER % TO ALIGN THE MARKS ON THE COVER
AND HOUSING ADDED DURING DISASSEMBLY )F USING NEW SWASHPLATE LEVELER PARTS
ALIGNMENT MARKS MAY NOT BE ACCURATE
!PPLY A FORCE OF TO . ; TO LBF = TO THE SWASHPLATE LEVELER % 4HIS ENSURES

BOTH ARMS ARE IN CONTACT WITH THE SWASHPLATE #LAMP A mAT PLAT ONTO THE PUMP
HOUSING AS SHOWN IN Leveling swashplate DRAWING BELOW
%NSURE THE SWASHPLATE IS ON ITS BEARINGS
-EASURE WITH A DEPTH MICROMETER TO lND THE DISTANCE FROM THE END CAP FACE OF THE
HOUSING TO THE OUTER EDGE OF THE SWASHPLATE SURFACE
W 7ARNING
4HESE MEASUREMENTS MUST 4AKE A SECOND MEASUREMENT AT A POINT ² FROM THE lRST POINT OF MEASUREMENT AT
NOT VARY BY MORE THAN THE OPPOSITE EDGE OF SWASHPLATE SURFACE W
MM ; INCHES=
Side cover and O-ring installations

Slide towards this end
Blind housing screw when installing
torques and Through
8 AND 9 ARE MEASUREMENTS housing screw torques
Case drain
FROM THE TOP OF THE port
SWASHPLATE TO THE END OF
THE HOUSING $IFFERENCE
BETWEEN 8 AND 9 MUST BE E20
LESS THAN
MM ; IN=
Leveling swashplate E10

22-44 N [5-10 lb]
Y X
B10
E101 122E
P106 516E
56 11019577 s 2EV !" s !PRIL
538 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
INSTALLING LEVELER Positioning the side cover

AND SIDE COVER 2OTATE THE SIDE COVER % WHICH WILL ALSO ROTATE THE LEVELER AND SWASHPLATE UNTIL
(continued) THE MEASURED DEPTH ON EACH SIDE OF THE SWASHPLATE IS WITHIN MM ; IN=
)NSTALL THE REMAINING SCREWS % WITH PRE APPLIED LOCKING COMPOUND
W 7ARNING
4HESE MEASUREMENTS MUST 4ORQUE THESE SCREWS TO THE SPECIlCATIONS IN Blind housing screw torques AND Through
NOT VARY BY MORE THAN housing screw torques.
MM ; INCHES=
2EPLACE THE SCREWS % USED INITIALLY TO HOLD THE SIDE COVER ON WHILE SETTING
NEUTRAL WITH NEW SCREWS THAT HAVE LOCKING COMPOUND
4ORQUE THESE SCREWS TO THE SPECIlCATIONS IN Blind housing screw torques.
Through housing screw torques Blind housing screw torques

Pump size 4ORQUE .sM ;LBFsFT= Pump size 4ORQUE .sM ;LBFsFT=
CC AND CC ;= CC AND CC ;=
CC THROUGH CC ;= CC THROUGH CC ;=
CC THROUGH CC ;= CC THROUGH CC ;=
CYLINDER BLOCK 0OSITION PISTONS USING A TWISTING Installing cylinder block

INSTALLATION MOTION SO THAT THEY ALL LEAN IN A
Turn cylinder block
CLOCKWISE DIRECTION counterclockwise when
placing on pistons.
3ET CYLINDER BLOCK # ONTO PISTONS O
SO EACH BLOCK BORE SITS ON TOP OF A
PISTON
C12
0REVENT THE PISTONSSLIPPERS FROM
TURNING BY CAREFULLY PLACING a
SCREWDRIVER BETWEEN THE SLIPPER
RETAINER AND SWASHPLATE $O NOT
SCRATCH SWASHPLATE OR SLIPPERS
Lean pistons clockwise.
4URN THE CYLINDER BLOCK
COUNTERCLOCKWISE
4HIS MAKES THE PISTONS STAND UP STRAIGHT O

AND lT INTO THE BLOCK BORES
,OWER THE BLOCK ONTO THE PISTONS
2ELUBRICATE PISTON BORES AND CYLINDER

BLOCK
E101 130E
11019577 s 2EV !" s !PRIL 57

008 916 41 BOMAG 539
10.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
END CAP INSTALLATION Preparing for end cap installation Installing the valve plate
)NSTALL THE END CAP ALIGNMENT PINS
" INTO THE HOUSING
,UBRICATE THE RUNNING SURFACE OF THE B50

CYLINDER BLOCK
B50
)NSTALL THE VALVE PLATE # ON THE

ALIGNMENT PINS
.OTE THE DIRECTION OF THE ARROW CUT

OUTS IN THE VALVE PLATE
7HEN VIEWING FROM THE END CAP SIDE E101 123E
OF VALVE PLATE THE ARROWS MUST POINT IN

THE OPPOSITE DIRECTION OF PUMP ROTATION Installing the springs
&OR EXAMPLE A RIGHT HAND CLOCKWISE
ROTATION PUMP MUST HAVE THE ARROWS
POINTING IN THE COUNTERCLOCKWISE
DIRECTION E80
D95
)NSTALL THE LONG SPRINGS %
WITH INNER SPRINGS IF USED ON THE
SWASHPLATE LEVELER SPRING SEATS
)F USED INSTALL THE SHORT SPRING $

ON THE SERVO ARM BRACKET
3OME MODELS ARE BUILT WITH AN ALTERNATE

SERVO ARM WHICH DOES NOT REQUIRE SPRING
$
E101 124
0LACE NEW END CAP GASKET ' Installing the gasket

C Caution ON THE HOUSING IN THE ORIENTATION
$O NOT BEND OR DAMAGE SHOWN LOCATED BY THE ALIGNMENT
THE END CAP GASKET DURING PINS C
INSTALLATION
G30 C
E101 125E
58 11019577 s 2EV !" s !PRIL
540 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
END CAP INSTALLATION End cap parts Installations into end cap
(continued) ,UBRICATE THE END CAP JOURNAL
BEARING ' 0RESS BEARING INTO
HOUSING IF NECESSARY
)NSTALL THE HARDENED SHIMS %

IN THE END CAP POCKETS FOR THE
SWASHPLATE LEVELER SPRINGS
2ETAIN THE SHIMS USING PETROLEUM JELLY End cap
4HE SHIM POCKETS ARE DIFFERENT DEPTH IN

ENDCAP
E24
E101 126E
End cap installation Fastening end cap to housing

,OWER THE END CAP ONTO HOUSING
WHILE POSITIONING THE SPRINGS IN THEIR
END CAP POCKETS
G95
)NSTALL THE LARGE END CAP SCREWS G94
* G93
7HEN PROPERLY INSTALLED
THE END CAP ENGAGES 4IGHTEN THE LARGE END CAP SCREWS
THE ALIGNMENT PINS4HE * EVENLY 3EE Large end cap screw
SPRINGS HOLD THE END CAP torques
TO MM ; TO INCH=
AWAY FROM THE HOUSING .UMBER OF SCREWS AND WRENCH SIZE VARIES
BY MODEL
E101 127E
)NSTALL THE OR SMALLER SCREWS
'' HOLDING THE END CAP TO Torque 6 mm internal hex
THE HOUSING #"'#$)t]
Torque 8 mm internal hex
#"'#$ )t]
4HERE IS A LIFTING BRACKET ' SPACER
' AND WASHER ' ON THE END CAP See Large endcap screw
SCREW ' torques for appropriate J80
torque values.
4ORQUE THE MM INTERNAL HEX SCREWS

' ' TO .sM ; LBFsFT= Large end cap screw torques
Pump size 4ORQUE .sM ;LBFsFT=
4ORQUE THE MM INTERNAL HEX SCREWS CC ;=
' ' TO .sM ; LBFsFT= CC ;=
CC ;=
CC ;=
CC ;=
CC ;=
CC AND CC ;=
11019577 s 2EV !" s !PRIL 59

008 916 41 BOMAG 541
10.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
SPEED SENSOR Assembly

)NSTALL A NEW / RING "! ONTO THE SENSOR "
5SING AN WRENCH INSTALL THE SPEED SENSOR WITH LOCK NUT AND / RING INTO
THE HOUSING !DJUST THE GAP BETWEEN THE SENSOR AND THE MAGNETIC SPEED RING AS
INSTRUCTED IN Speed sensor adjustment in Series 90 Pumps Service Manual 520L0818
!FTER ADJUSTMENT TORQUE THE SENSOR LOCK NUT TO .sM ; LBFsFT=
)F A SPEED SENSOR IS NOT INSTALLED USE A IN INTERNAL HEX WRENCH TO TORQUE THE
HOUSING PLUG " TO .sM ; LBFsFT=
Speed sensor
B83 O-ring plug
ft]
B83A
B83 B83A

t]
E101 095E
60 11019577 s 2EV !" s !PRIL
542 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
MULTI-FUNCTION VALVE Multi-function valve - pre 1988

CARTRIDGES - PRE 1988
P14
P19
P12
P06
P21
P15
P14
P11 P22
P09
P1
P13
E101 532E
Assembly
,UBRICATE AND INSTALL INTERNAL COMPONENTS 0 0 0 0 0 AND 0
)NSTALL POPPET SEAT 0
)NSTALL RETAINING RING 0
,UBRICATE AND INSTALL / RING 0
)F PREVIOUSLY REMOVED REASSEMBLE AND INSTALL BYPASS ACTUATOR 0 4ORQUE TO

.sM ; LBFsFT=
,UBRICATE AND INSTALL NEW / RINGS 0 0
CCaution
)F PRESSURE LIMITER WAS REMOVED FROM BYPASS ACTUATOR 0 ADJUST PRESSURE LIMITER TO
MODEL CODE SPECIlCATIONS
)NSTALL CARTRIDGES AND TORQUE AS SHOWN IN THE TABLE BELOW C
Multi-function valve wrench size Multi-function valve torque

Frame size Wrench size Frame size Torque
n INCH n .sM ; LBFsFT=
11019577 s 2EV !" s !PRIL 61

008 916 41 BOMAG 543
10.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
PRESSURE OVERRIDE Assembly Pressure override valve components

VALVE (OPTION FOR 180 )NSTALL NEW / RINGS
FRAME SIZE)
Screws
)NSTALL THE VALVE ONTO THE PUMP END
CAP AND TORQUE THE SCREWS TO .sM Pressure override
; LBFsFT= valve
O-rings
E101 079E
CHARGE PRESSURE Assembly Lock nut wrench size

RELIEF VALVE )NSTALL THE POPPET + AND SPRING Frame size Wrench size
+ n INCH
n INCH
&OR SHIM ADJUSTABLE VALVES INSTALL
THE SHIMS AND PLUG TORQUE TO
.sM ; LBFsFT= &OR SCREW ADJUSTABLE Charge pressure relief valve
VALVES INSTALL THE PLUG WITH ITS LOCK
NUT ALIGNING THE MARKS MADE AT
+
DISASSEMBLY AND TORQUE THE LOCK NUT h ,OCK NUT
TO .sM ; LBFsFT= t ,OCK NUT TORQUE
#HECK THE CHARGE PRESSURE AND +

ADJUST IF NECESSARY h IN
d+ +
+
+
3EE APPROPRIATE TABLE
62 11019577 s 2EV !" s !PRIL
544 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
CHARGE PUMP Current charge pump configuration
H40
H05
H60
H50
H31
J50
J15
J30
H70
E101 082E
H80
Retainer screw wrench size

n MM
n MM
Assembly
"E SURE TO INSTALL THE CHARGE PUMP IN THE PROPER ORIENTATION )F UNSURE OF CHARGE PUMP
ROTATION REFER TO THE MODEL CODE
4HE ORIENTATION OF THE GEROTOR ASSEMBLY OUTER ECCENTRIC RING AND THE LOCATION OF THE
ALIGNMENT PIN IN THE END CAP DETERMINE THE CHARGE PUMP ROTATION $O NOT MIX CHARGE
PUMP PARTS FROM DIFFERENT PRODUCTION PERIODS !LWAYS INSTALL AS A COMPLETE ASSEMBLY
)NSTALL THE VALVE PLATE ( AND THE GEROTOR ASSEMBLY OUTER RING
)NSTALL THE ALIGNMENT PIN ( TO PROPERLY ORIENT THE VALVE PLATE AND OUTER ECCENTRIC
RING FOR CORRESPONDING PUMP ROTATION
0RIOR TO INSTALLATION LUBRICATE THE )$ /$ AND SIDE FACES OF THE GEROTOR ASSEMBLY
)NSTALL THE GEROTOR ASSEMBLY (
)NSTALL THE OUTER PLATE EARLY PRODUCTION AND INTERMEDIATE PRODUCTION PUMPS ONLY
NOT SHOWN
11019577 s 2EV !" s !PRIL 63

008 916 41 BOMAG 545
10.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
CHARGE PUMP )NTERMEDIATE PRODUCTION CMÃ AND CMÃ PUMPS USE THE SAME CHARGE PUMP
(continued) COUPLING4WO KEYWAYS ARE PROVIDED IN THE COUPLING FOR THE CHARGE PUMPS USED IN THESE
UNITS4HE REAR KEYWAY WITH IDENTIlER GROOVE IS USED IN CMÃ PUMPS4HE FRONT KEYWAY
CLOSEST TO THE INTERNALLY SPLINED END OF THE SHAFT IS USED IN CMÃ PUMPS
)NSTALL THE CHARGE PUMP COUPLING4HE INTERNALLY SPLINED END OF THE COUPLING MUST
ENGAGE THE MAIN PUMP SHAFT &OR PUMPS WITH AN AUXILIARY MOUNTING PAD INSTALL THE
AUXILIARY DRIVE COUPLING INSTEAD
4HE OUTSIDE DIAMETER OF THE INTERNALLY SPLINED END OF SOME EARLY PRODUCTION CHARGE
PUMP COUPLINGS WAS CHAMFERED %ARLY PRODUCTION END CAPS MAY NOT BE MACHINED TO
ACCEPT A NON CHAMFERED COUPLING !LWAYS USE A CHAMFERED CHARGE PUMP COUPLING IN
PUMPS WITH THE EARLY ENDCAP
&OR PUMPS WITH NO AUXILIARY PAD INSTALL A NEW / RING * ONTO CHARGE PUMP COVER
)F AN AUXILIARY PAD IS INSTALLED AN / RING IS NOT USED ON THE COVER
#AREFULLY REMOVE THE ALIGNMENT PIN FROM THE CHARGE PUMP PARTS )NSTALL THE PIN IN ITS
HOLE IN THE CHARGE PUMP COVER * SEE PREVIOUS PAGE FOR CORRECT ORIENTATION AND
RETAIN WITH PETROLEUM JELLY )NSTALL THE COVER WITH ALIGNMENT PIN INTO THE END CAP
AND ALIGNED CHARGE PUMP PARTS 4AKE CARE NOT TO DAMAGE THE COVER / RING IF USED
CCaution
)N ORDER TO AVOID LOSS OF CHARGE PRESSURE IN PUMPS WITH AN AUXILIARY MOUNTING PAD
ALWAYS INSTALL THE CHARGE PUMP COVER SO THE PAD DRAIN HOLE IS LOCATED ON THE SAME SIDE OF
THE END CAP AS THE CHARGE INLET PORT
)NSTALL THE CHARGE PUMP COVER Retainer screw torque

RETAINER ( AND THE SIX INTERNAL Frame size Torque
HEX SCREWS ( 4ORQUE THE SCREWS n .sM ; LBFsFT=
PER THE TABLE AT THE RIGHT n .sM ; LBFsFT=
&OR PUMPS WITH AUXILIARY MOUNTING PADS INSTALL THE / RING AND AUXILIARY MOUNTING
PAD ADAPTOR ONTO THE END CAP
64 11019577 s 2EV !" s !PRIL
546 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
AUXILIARY PAD Auxiliary pad components (typical)
J50
J80
Endcap screw J70
J60
See table for wrench size and torque
E101 084E
Assembly
,UBRICATE AND INSTALL / RING * ON END CAP PILOT
)NSTALL THE AUXILIARY MOUNTING PAD * ON REAR OF ENDCAP
4ORQUE AUX PAD SCREWS IN A )NSTALL FOUR LARGE SCREWS * AND NEW WASHERS * THROUGH THE MOUNTING PAD AND
CRISS CROSS PATTERN END CAP INTO THE HOUSING4ORQUE PER THE ACCOMPANYING TABLE
Aux. pad screw wrench size Aux pad screw torque

Frame size Wrench sizes Frame size Torque
n EARLY MM INTERNAL HEX .sM ; LBFsFT=
n MM HEX n .sM ; LBFsFT=
n MM INTERNAL HEX n .sM ; LBFsFT=
n MM INTERNAL HEX
DISPLACEMENT )F THE PUMP IS EQUIPPED WITH CONTROL Filter screen installation

CONTROL FILTER lLTER SCREENS IN THE PUMP HOUSING LATE B90
SCREENS PRODUCTION PRESS THEM INTO POSITION
WITH THE ROUNDED EDGE OF THE lLTER P106 690E
SCREENS FACING THE CONTROL UNTIL THEY ARE

mUSH TO MM ; INCH= BELOW THE
SURFACE OF THE HOUSING
11019577 s 2EV !" s !PRIL 65

008 916 41 BOMAG 547
10.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
INTEGRAL CHARGE Assembly

PRESSURE FILTER )NSTALL THE HYDRAULIC TUBE . INTO ITS BORE IN THE ENDCAP )NSTALL THE lLTER HEAD .
REPLACEMENT INTO THE PORT USING A NEW / RING . 4HE HYDRAULIC TUBE SHOULD GO IN WITH LOW FORCE
!FTER ROTATING THE lLTER HEAD CLOCKWISE SO THAT THE THREADS ENGAGE WITH THE THREADS
CCaution IN THE ENDCAP CONTINUE TO ROTATE IT CLOCKWISE BETWEEN AND REVOLUTIONS 0OSITION
&AILURE TO INSTALL THE lLTER HEAD AS DESIRED C
MANIFOLD OR lLTER HEAD
TO A SUFlCIENT DEPTH IN 7HILE HOLDING THE lLTER HEAD IN THE DESIRED POSITION TIGHTEN THE SWIVEL LOCK NUT
THE END CAP WILL RESULT IN . AND TORQUE AS SHOWN IN TABLE
INSUFlCIENT ENGAGEMENT
OF THE TUBE IN THE END )NSTALL A NEW lLTER CANISTER . PER THE INSTRUCTIONS ON THE lLTER CANISTER
CAP BORE4HIS MAY ALLOW
UNlLTERED OIL TO BYPASS THE
lLTER AND ENTER THE CHARGE Integral charge pressure filter
SYSTEM
N25 N20
N15 Filter manifold lock nut
N36A
N36
11/16 in
N40
N10
N35A
N35
11/16 in
P106 182E
Lock nut wrench size and torque

Frame size Wrench size Torque
66 11019577 s 2EV !" s !PRIL
548 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
PUMP CONTROL COVER Assembly

PLATE )NSTALL A NEW GASKET ON THE HOUSING )NSTALL THE COVER PLATE
)NSTALL SCREWS - USING A MM INTERNAL HEX WRENCH4ORQUE THE SCREWS TO .sM
; LBFsFT=
Pump controls cover plate M90 X

MM
t .sM ; LBFsFT=
-
3EAL WASHER
LOCATION CC
-
d
0 %
DISPLACEMENT )NSTALL NEW / RINGS USING PETROLEUM Displacement control adapter plate (early
CONTROL ADAPTER JELLY TO RETAIN THEM production 130 cm³ pumps only)
PLATE (EARLY Adapter plate
PRODUCTION 130 )NSTALL ADAPTER PLATE screws
PUMPS ONLY)
)NSTALL SCREWS USING A MM INTERNAL 6 mm
HEX WRENCH4ORQUE TO .sM
; LBFsFT= t]
O-rings
Adapter plate
Seal
E101 087E
11019577 s 2EV !" s !PRIL 67

008 916 41 BOMAG 549
10.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
HYDRAULIC AND Assembly

ELECTRIC DISPLACEMENT )NSTALL A NEW GASKET - 6ERIFY THE CONTROL ORIlCE CHECK VALVE AND SPRING 4 ARE IN
CONTROLS THEIR PROPER POSITION IN THE CONTROL
0OSITION THE CONTROL - ON THE HOUSING )NSERT THE CONTROL LINKAGE PIN INTO THE
SWASHPLATE LINK

- X
I MM
-
-
d
4
4
0 %
68 11019577 s 2EV !" s !PRIL
550 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
MANUAL DISPLACEMENT Assembly

CONTROL (MDC) )NSTALL A NEW GASKET - )NSPECT CONTROL TO ASSURE THAT THE CONTROL ORIlCE CHECK
VALVE AND SPRING ARE IN THEIR PROPER POSITION IN THE CONTROL
)NSTALL THE CONTROL %NGAGE THE PIN ON THE CONTROL LINKAGE INTO THE MATING HOLE IN THE
LINK ATTACHED TO THE SWASHPLATE
)F REMOVED INSTALL THE CONTROL HANDLE - AND LOCKING NUT - WITH WASHER -
(OLD THE POSITION OF THE HANDLE AND TORQUE THE LOCKING NUT TO .sM ; LBFsFT=
USING AN MM HEX WRENCH
MDC installation -

3 - h MM
h IN M70
- X
I MM
-
3EAL WASHER d
LOCATION CC
4
4 4
0 %
7ITH THE CONTROL IN POSITION MOVE CONTROL LEVER BOTH DIRECTIONS TO CHECK PROPER
ENGAGEMENT OF CONTROL LINKAGE PIN )F PROPERLY ASSEMBLED LEVER WILL RETURN TO
CENTER )F LEVER DOES NOT RETURN TO CENTER REMOVE THE CONTROL AND REPEAT THE ABOVE
PROCEDURE
; LBFsFT=
W 7ARNING
2ISK OF IMPROPER MACHINE )NSTALL A SEALING WASHER UNDER THE HEAD OF MOUNTING SCREWS IN THE LOCATION SHOWN
START UP )F EQUIPPED WITH
.EUTRAL 3TART 3WITCH .33 )F THE CONTROL IS EQUIPPED WITH A NEUTRAL START SWITCH REFER TO MDC Neutral start switch
PERFORM .33 ADJUSTMENT adjustment INSTRUCTIONS IN THE Series 90 Pumps Service Manual 520L0818
PROCEDURE IN SERVICE
11019577 s 2EV !" s !PRIL 69

008 916 41 BOMAG 551
10.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
SOLENOID OVERRIDE Solenoid override valve installationSeal washer

VALVE FOR MDC location
(42, 180, 250 cc)
M77
M76A
M76C
M76B
M76
M78 (x2)
5 mm
M75
P106 186E
Assembly
)NSTALL A NEW GASKET - ON THE CONTROL HOUSING )NSTALL THE MANIFOLD - ONTO
THE CONTROL HOUSING ALIGN THE GASKET AND INSTALL THE SCREWS - 4ORQUE THE SCREWS
TO .sM ; LBFsFT=
5SING A MM WRENCH TORQUE VALVE - TO .sM ; LBFsFT= )F SOLENOID WAS
REMOVED TORQUE SOLENOID NUT TO .sM ; LBFsFT= $O NOT OVERTORQUE THE SOLENOID
NUT
70 11019577 s 2EV !" s !PRIL
552 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
SOLENOID OVERRIDE Assembly

VALVE FOR MDC WITH 5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS - - - ON THE
PRESSURE RELEASED ADAPTER PLATE 0LACE THE ADAPTER PLATE INTO POSITION AND USING A MM INTERNAL HEX
BRAKE INSTALL THE SCREWS - 4ORQUE THE SCREWS TO .sM ; LBFsFT=
5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS ONTO THE SOLENOID VALVE
ASSEMBLY - AND INSTALL THE SOLENOID VALVE ONTO THE ADAPTER PLATE 5SING A MM
INTERNAL HEX INSTALL THE SCREWS - AND TORQUE TO .sM ; LBFsFT=
Solenoid override valve installation
M98 (x4)
4 mm
M9
M95
M96
M97 M92 (x4)
4 mm
P106 192E
11019577 s 2EV !" s !PRIL 71

008 916 41 BOMAG 553
10.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
PRESSURE CONTROL Assembly

PILOT (PCP) FOR 5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS - AND - IN 0#0
ELECTRIC DISPLACEMENT (OUSING
CONTROL (EDC)
0LACE 0#0 AGAINST %$# HOUSING AND USING A MM INTERNAL HEX INSTALL THE SCREWS
- 4ORQUE TO .sM ; LBFsFT=
$O NOT REMOVE BLACK PLASTIC COVER FROM THE ALUMINUM PLATE4HIS IS NOT A SERVICEABLE ITEM
AND REMOVAL VOIDS THE PRODUCT WARRANTY
PCP installation
M97
M96 (x3)
M98 (x4)
M9
4 mm
P106 194E
72 11019577 s 2EV !" s !PRIL
554 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
3-POSITION (FNR) Assembly

ELECTRIC CONTROL )NSTALL A NEW GASKET - ON THE HOUSING 0LACE THE ADAPTER PLATE INTO POSITION AND
USING A MM INTERNAL HEX INSTALL THE SCREWS - )NSTALL A SEALING WASHER UNDER THE
HEAD OF MOUNTING SCREWS THAT ARE INSTALLED INTO THROUGH HOLES IN THE HOUSING4ORQUE
THE SCREWS TO .sM ; LBFsFT=
)NSTALL ORIlCES 4 AND 4 INTO ADAPTER PLATE USING A OR MM
INTERNAL HEX WRENCH )NSTALL ORIlCE 4 INTO ADAPTER PLATE USING A OR MM
INTERNAL HEX WRENCH4ORQUE - THREADS TO .sM ; LBSsLFT= - THREADS TO .sM
; LBSsLFT= AND - THREADS TO .sM ; LBSsLFT=
5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS 7! ONTO THE SOLENOID
VALVE ASSEMBLY AND INSTALL THE SOLENOID VALVE ONTO THE ADAPTER PLATE 5SING A MM
INTERNAL HEX INSTALL SCREWS 7 4ORQUE TO .sM ; LBFsFT=
FNR installation
7 X
I MM
7!
- X d
I MM
4
4
4
-
3EAL WASHER
LOCATION CC
4
- 4
4
d
0 %
11019577 s 2EV !" s !PRIL 73

008 916 41 BOMAG 555
10.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
MULTI-FUNCTION VALVE Multi-function valve installation

CARTRIDGES
P2B1
P13
P06
P2A1
P106 180E
P04
P03
P01
P02
P05
P06
P07
P08
P17
P16
P15
P14
P09
P11
P13
P12
E101 531E
74 11019577 s 2EV !" s !PRIL
556 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
Assembly
,UBRICATE AND INSTALL INTERNAL COMPONENTS 0 0 0 0 0 0 0 0 AND
0
0LACE THE CARTRIDGE IN A VISE AND PRESS ON THE POPPET SEAT 0
,UBRICATE AND INSTALL NEW / RINGS 0 0 0
)NSTALL BYPASS ACTUATOR 0 WITH PRESSURE LIMITER VALVE 0 4ORQUE TO .sM
; LBFsFT=
CCaution
)F PRESSURE LIMITER 0 WAS REMOVED FROM BYPASS ACTUATOR 0 ADJUST PRESSURE LIMITER
TO MODEL CODE SPECIlCATIONS
CCaution
$O NOT OVERTORQUE THE )NSTALL CARTRIDGES AND TORQUE AS SHOWN IN THE TABLE C
CARTRIDGES Multi-function valve wrench size Multi-function valve torque
Frame size Wrench size Frame size Torque
11019577 s 2EV !" s !PRIL 75

008 916 41 BOMAG 557
10.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
INSTALLING SHAFT AND Shaft and bearing installation

BEARING 0OSITION THE PUMP ON ITS END CAP
0RESS THE ROLLER BEARING , ONTO THE INPUT SHAFT , &OR UNITS WITH A PIECE
BEARING PRESS THE INNER RACE ONTO THE SHAFT THEN INSTALL THE OUTER RACECAGE ASSEMBLY
AND SPECIAL WASHER C
5SING SUITABLE RETAINING RING PLIERS INSTALL THE BEARING RETAINING RING ,
C Caution
$O NOT DAMAGE THE SEALING SURFACE IN THE HOUSING DURING SHAFTBEARING INSTALLATION
,UBRICATE AND INSTALL SHAFT AND BEARING ASSEMBLY THROUGH FRONT OF HOUSING ALIGNING
THE SHAFT SPLINE WITH THE CYLINDER BLOCK SPLINE )F PUMP IS EQUIPPED WITH AUXILIARY
PAD ALIGN CHARGE PUMP SHAFT WITH AUXILIARY PAD COUPLING
#ONTINUE TO LOWER THE SHAFT INTO THE UNIT WHILE ALIGNING THE END OF THE SHAFT WITH END
CAP JOURNAL BEARING
)F NECESSARY COAT THE ,UBRICATE AND PRESS SEAL , IN Installing the shaft and bearing assembly
OUTSIDE DIAMETER OF THE CARRIER ,
L70
SEAL LIGHTLY WITH A SEALANT (see table)
SUCH AS ,OCTITE4- (IGH ,UBRICATE AND INSTALL / RING , IN
0ERFORMANCE 3EALANT CARRIER , L60
PRIOR TO INSTALLA
TION4HIS AIDS IN PREVENTING ,UBRICATE AND PRESS SEAL CARRIER INTO L30
LEAKS CAUSED BY DAMAGE ITS BORE IN THE HOUSING
L40
TO THE SEAL BORE IN THE SEAL
CARRIER )NSTALL RETAINER PLATE , AND BOLTS L50
, 7RENCH SIZES AND TORQUE VALUES
L20
FOR RETAINER PLATE BOLTS ARE SHOWN IN
TABLE BELOW
L10
L70 wrench sizes and torques

Pump size Wrench size 4ORQUE .sM ;LBFsFT= L100
CC MM HEX .sM ; LBFsFT=
CC MM .sM ; LBFsFT=
INTERNAL HEX
CC MM .sM ; LBFsFT=
INTERNAL HEX
E101 534E
76 11019577 s 2EV !" s !PRIL
558 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
FINAL ASSEMBLY AND Final assembly and testing procedures

TESTING 2OTATE THE PUMP SHAFT WITH A TORQUE WRENCH TO ASSURE CORRECT ASSEMBLY4HE TABLE Torque
to turn shaft at 0° (with seal assembly installed) shows TORQUES NECESSARY TO TURN THE
SHAFT AFTER BREAK AWAY
Torque to turn shaft at 0° (with seal assembly installed)

Pump size -INIMUM TORQUE .sM ;LBFsFT= -AXIMUM TORQUE .sM ;LBFsFT=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
W 7ARNING
4EST THE PUMP BEFORE PUTTING IT INTO SERVICE6ERIFY CORRECT PRESSURE LIMITER AND CONTROL
FUNCTION )MPROPER FUNCTION OF THESE SYSTEMS CAN RESULT IN UNCONTROLLABLE MOVEMENT OF
THE VEHICLEMACHINE
11019577 s 2EV !" s !PRIL 77

008 916 41 BOMAG 559
10.1 Travel pump
Series 90 Pumps
Repair Instructions
4ORQUE #HART
FASTENER SIZE AND Item Fastener Frame size Wrench size Torque
TORQUE CHART B83 3PEED SENSOR LOCK NUT IN HEX .sM ; LBFsFT=
"LIND HOLES MM HEX .sM ; LBFsFT=
4HRU HOLES MM HEX .sM ; LBFsFT=
F111/ 3ERVO CYLINDER SCREW MM HEX .sM ; LBFsFT=
F211 MM HEX .sM ; LBFsFT=
G90/ %ND CAP SCREW MM INTERNAL HEX .sM ; LBFsFT=
G97 MM INTERNAL HEX .sM ; LBFsFT=
H80 #HARGE PUMP RETAINING SCREW MM HEX .sM ; LBFsFT=
J80 %ND CAP SCREW MM INTERNAL HEX .sM ; LBFsFT=
EARLY MM INTERNAL HEX .sM ; LBFsFT=
K10 #HARGE PRESSURE VALVE PLUG IN HEX .!
K90 #HARGE PRESSURE LOCK NUT IN HEX .sM ; LBFsFT=
L70 3HAFT RETAINING SCREW MM HEX .sM ; LBFsFT=
M72 -$# HANDLE NUT MM .sM ; LBFsFT=
M78 $E STROKE VALVE MANIFOLD SCREW MM INTERNAL HEX .sM ; LBFsFT=
M85 %CCENTRIC PLUG LOCK NUT IN HEX .sM ; LBFsFT=
M88 .EUTRAL START SWITCH LOCK NUT IN HEX .sM ; LBFsFT=
M90 #ONTROL MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
M92 3OLENOID VALVE MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
M98 0#0 MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
N10 &ILTER REDUCER ASSEMBLY IN HEX .sM ; LBFsFT=
N37 &ILTER PLUG ASSEMBLY IN INTERNAL HEX .sM ; LBFsFT=
P2B1/ -ULTI FUNCTION VALVE IN HEX .sM ; LBFsFT=
P2A1 IN HEX .sM ; LBFsFT=
78 11019577 s 2EV !" s !PRIL
560 BOMAG 008 916 41

Travel pump 10.1
Series 90 Pumps
Repair Instructions
4ORQUE #HART
PLUG SIZE AND TORQUE )F ANY PLUGS OR lTTINGS ARE REMOVED FROM THE PUMP DURING SERVICING INSTALL AND TORQUE AS
CHART INDICATED IN THE ACCOMPANYING TABLEC
!LWAYS INSTALL NEW / RINGS BEFORE REINSTALLING THE PLUGS OR lTTINGS

CCaution
4ORQUE PLUGS OR lTTINGS Item O-ring plug Wrench size Torque
INSTALLED INTO ALUMINUM B70, B72 INTERNAL HEX WRENCH .sM ; LBFsFT=
HOUSINGS TO THE LOWER B71 INTERNAL HEX WRENCH .sM ; LBFsFT=
VALUES SPECIlED FOR B80 INTERNAL HEX WRENCH .sM ; LBFsFT=
INTERNAL HEX PLUGS OF THE B82, B83 INTERNAL HEX WRENCH .sM ; LBFsFT=
SAME SIZE G18 INTERNAL HEX WRENCH .sM ; LBFsFT=
G45-G50 INCH HEX WRENCH .sM ; LBFsFT=
G52-G54 INTERNAL HEX WRENCH .sM ; LBFsFT=
H90 (not shown) INTERNAL HEX WRENCH .sM ; LBFsFT=
N35, N36 (not shown) INCH HEX WRENCH .sM ; LBFsFT=
N37 INTERNAL HEX WRENCH .sM ; LBFsFT=
FASTENERS AND PLUGS
Fastener and plug locations
B70, B72 O-ring plug

9/16-18
J80 Auxilliary pad / G90 End cap screw
end cap screw M90 Control bolt
H80 Charge pump

retaining screw L70 Shaft seal
retaining screw
G53, G54 O-ring plug

9/16-18
K10 Charge pressure

relief valve plug M88 Neutral start switch
lock nut
M85 Eccentric plug
K90 Charge pressure lock nut
relief valve lock nut
B80 O-ring plug
1-1/16-12 P2B1 Multi-function valve
G97 End cap screw B71 O-ring plug

B82 O-ring plug
9/16-18
9/16-18
B83 Speed sensor /
G50 O-ring plug O-ring plug
9/16-18 9/16-18
G49 O-ring plug

9/16-18
G48 O-ring plug

9/16-18
N37 Filter plug assembly

F111 / F211 Servo cylinder screw E60 Side cover screw N10 Filter reducer assembly
P106 189E
P2A1 Multi-function valve
11019577 s 2EV !" s !PRIL 79

008 916 41 BOMAG 561
10.1 Travel pump

PUMPS AND MOTORS
/RBITAL MOTORS
#ARTRIDGE VALVES
,OCAL ADDRESS
)NTEGRATED SYSTEMS
&AN DRIVE SYSTEMS
%LECTROHYDRAULICS
$ISPLAYS %AST TH 3TREET $+ .ORDBORG $ENMARK
!MES )! 53! 0HONE
Sensors 0HONE &AX
&AX
0OSTFACH $ .EUMünster 3ANNOMIYA 'RAND "LDG &
&AX 0HONE
&AX
WWWSAUER DANFOSSCOM
11019577 s 2EV !" s !PRIL
562 BOMAG 008 916 41

10.2 Travel motor
008 916 41 BOMAG 563

10.2 Travel motor
564 BOMAG 008 916 41

Travel motor 10.2
Series 51 and 51-1

Bent Axis Motors
Service Manual
008 916 41 BOMAG 565

10.2 Travel motor
Series 51 and 51-1 Motors
Service Manual
2EVISIONS

November 2009 14 correction to defeated loop flushing information AE

November 2009 19 11009442 is correct number for Series 51 two position AD
controls manual
April 2009 5 remove list of manuals AC
&EBRUARY 34 &RAME SIZE -INIMUM DISPLACEMENT RANGE TO CCM AB
$ECEMBER - First edition AA
3AUER $ANFOSS ACCEPTS NO RESPONSIBILITY FOR POSSIBLE ERRORS IN CATALOGS BROCHURES AND
OTHER PRINTED MATERIAL 3AUER $ANFOSS RESERVES THE RIGHT TO ALTER ITS PRODUCTS WITHOUT
PRIOR NOTICE4HIS ALSO APPLIES TO PRODUCTS ALREADY ORDERED PROVIDED THAT SUCH ALTERATIONS
CAN BE MADE WITHOUT AFFECTING AGREED SPECIlCATIONS !LL TRADEMARKS IN THIS MATERIAL
ARE PROPERTIES OF THEIR RESPECTIVE OWNERS 3AUER $ANFOSS THE 3AUER $ANFOSS LOGOTYPE
THE 3AUER $ANFOSS 3 ICON 0,53 » 7HAT REALLY MATTERS IS INSIDE¸ AND +NOW (OW IN
-OTION» ARE TRADEMARKS OF THE 3AUER $ANFOSS 'ROUP
2 11008567 s 2EV !% s .OVEMBER
566 BOMAG 008 916 41

Travel motor 10.2
Service Manual
Contents
INTRODUCTION /VERVIEW 5

/RDERING REPLACEMENT PARTS AND SERVICE 5
3AFETY PRECAUTIONS
5NINTENDED MACHINE MOVEMENT
&LAMMABLE CLEANING SOLVENTS
&LUID UNDER PRESSURE
0ERSONAL SAFETY
(AZARDOUS MATERIAL
3YMBOLS USED IN 3AUER $ANFOSS LITERATURE
'ENERAL INSTRUCTIONS 8
+EEP IT CLEAN 8
)NSPECT FOR SYSTEM CONTAMINATION 8
2EPLACE THE / RINGS AND GASKETS 8
,UBRICATE ALL MOVING PARTS 8
4ORQUING PROCEDURE 8
6ARIABLE DISPLACEMENT MOTORS
3ERIES MOTORS 1
Closed circuit 11
/PEN CIRCUIT11
3HAFTS 1
OPERATION ,OOP mUSHING13

$ISPLACEMENT LIMITERS15
-OUNTING CONlGURATIONS 1
3PEED SENSORS1
Controls18
4WO POSITION CONTROLS18
/VERVIEW18
0RESSURE COMPENSATOR CONTROLS 1
0ROPORTIONAL CONTROLS
TECHNICAL 'ENERAL SPECIlCATIONS 1

SPECIFICATIONS 4ECHNICAL DATA1
&LUID SPECIlCATIONS
PRESSURE 2EQUIRED TOOLS 3

MEASUREMENTS 0ORT LOCATIONS AND GAUGE INSTALLATION3
FLUID AND FILTER &LUID AND lLTER RECOMMENDATIONS5

MAINTENANCE (AZARDOUS MATERIAL 5
INITIAL STARTUP 0ROCEDURE

PROCEDURES
11008567 s 2EV !% s .OVEMBER 3

008 916 41 BOMAG 567
10.2 Travel motor
Service Manual
Contents
TROUBLESHOOTING 3LUGGISH SYSTEM 8

3YSTEM OPERATING HOT 8
%XCESSIVE NOISE OR VIBRATION
-OTOR OPERATES NORMALLY IN ONE DIRECTION ONLY
)MPROPER OUTPUT SPEED
,OW OUTPUT TORQUE3
ADJUSTMENTS /VERVIEW 31

#HARGE PRESSURE RELIEF VALVE31
-EASURING CHARGE PRESSURE31
!DJUSTING CHARGE PRESSURE3
-INIMUM DISPLACEMENT LIMITER33
!DJUSTING MINIMUM DISPLACEMENT33
-AXIMUM DISPLACEMENT LIMITER35
3ERIES MOTORS 35
3ERIES MOTORS 35
MINOR REPAIR )NSTALLATION AND ADJUSTMENT 3

$). AND 3!% mANGE UNITS 3
#ARTRIDGE UNITS 38
3HAFT SEAL REPLACEMENT3
3!% AND $). mANGED MOTORS 3
#ARTRIDGE mANGED MOTORS 41
,OOP mUSHING SHUTTLE VALVE 4
#HARGE RELIEF VALVE44
/VERVIEW44
0OPPET STYLE OLDER PRODUCTION 44
/RIlCED STYLE45
$EFEAT PLUG 4
-AXIMUM ANGLE STOP 3ERIES MOTORS 4
-AXIMUM ANGLE STOP 3ERIES MOTORS 48
-INIMUM ANGLE ADJUSTMENT SCREW5
7AY VALVE AND THRESHOLD SPRINGS5
4HRESHOLD ADJUSTMENT SCREW AND SPRINGS DISASSEMBLY 54
REPAIR PARTS (OUSING PLUGS AND SPEED SENSORS

&LANGE AND SHAFT SEAL 1
%NDCAP
3ERIES RAMP AND THRESHOLD4
3ERIES %NDCAP
4 11008567 s 2EV !% s .OVEMBER
568 BOMAG 008 916 41

Travel motor 10.2
Service Manual
Introduction
OVERVIEW 4HE COMPLETE SERVICE AND REPAIR INFORMATION FOR 3ERIES AND 3ERIES MOTORS IS
IN A MODULAR FORMAT 3ERVICE INFORMATION MODULES ARE AVAILABLE FOR THE BASIC MOTOR
COMPONENTS FOR EACH FAMILY OF MOTOR CONTROLS AND FOR MAJOR REPAIR PROCEDURES %ACH
MODULE CONTAINS INFORMATION ON THE FUNCTION ADJUSTMENT AND REPAIR OF EACH GROUP
OF COMPONENTS OR CONTROLS4HE REPAIR INSTRUCTIONS MODULE FOCUSES ON MAJOR REPAIR
PROCEDURES
&UNCTIONAL DESCRIPTION TECHNICAL SPECIlCATIONS ADJUSTMENT PROCEDURES MINOR REPAIR

PROCEDURES AND EXPLODED VIEW COMMON PARTS DRAWINGS FOR THE BASIC 3ERIES AND
3ERIES MOTOR COMPONENTS COMPRISE THIS MANUAL )T DISCUSSES THOSE MINOR REPAIRS
YOU CAN PERFORM WITHOUT REMOVING THE MOTORS END CAP4HESE REPAIRS WILL NOT AFFECT THE
UNITS WARRANTY
-AJOR REPAIRS REQUIRE REMOVING THE MOTORS END CAP4HIS MANUAL DOES NOT DESCRIBE
-AJOR REPAIRS PERFORMED THEM /NLY 3AUER $ANFOSS !UTHORIZED 3ERVICE #ENTERS AND OR ORIGINAL EQUIPMENT
BY PERSONS OTHER THAN A MANUFACTURERS TRAINED BY 3AUER $ANFOSS SHOULD PERFORM THESE REPAIRS
3AUER $ANFOSS !UTHORIZED
Service Center or trained &OR INFORMATION ON CONTROL TYPES SEE PAGES
/%- PERSONNEL MAY VOID
THE UNITS WARRANTY
ORDERING /RDER GENUINE 3AUER $ANFOSS REPLACEMENT PARTS TO ENSURE THE BEST PERFORMANCE &OR
REPLACEMENT PARTS lists of available service parts and service kits for Series 51 units SEE 520L0765 THROUGH
AND SERVICE 520L0770
3AUER $ANFOSS PROVIDES A COMPLETE REPAIR AND PARTS SERVICE FOR ALL PRODUCTS #ONTACT ANY
3AUER $ANFOSS !UTHORIZED 3ERVICE #ENTER FOR DETAILS #HECK OUR WEB SITE AT HTTPWWW
SAUER DANFOSSCOM TO SEE A LIST OF 3AUER $ANFOSS !UTHORIZED 3ERVICE #ENTER LOCATIONS
11008567 s 2EV !% s .OVEMBER 5

008 916 41 BOMAG 569
10.2 Travel motor
Service Manual
Introduction
HYDRAULIC SYSTEM

W Warning

W Warning

W Warning
Personal safety
W Warning
TIMES
Hazardous material
W Warning
(YDRAULIC mUID CONTAINS HAZARDOUS MATERIAL !VOID PROLONGED CONTACT WITH HYDRAULIC
mUID !LWAYS DISPOSE OF USED HYDRAULIC mUID ACMÃORDING TO STATE AND FEDERAL
ENVIRONMENTAL REGULATIONS
6 11008567 s 2EV !% s .OVEMBER
570 BOMAG 008 916 41

Travel motor 10.2
Service Manual
Introduction

SAUER-DANFOSS
PRODUCT OR PROPERTY
 2EUSABLE PART

sleeve
 4ORX HEAD
11008567 s 2EV !% s .OVEMBER 7

008 916 41 BOMAG 571
10.2 Travel motor
Service Manual
Introduction
GENERAL INSTRUCTIONS Keep it clean

 9OU CAN COMPLETE MANY REPAIRS OR ADJUSTMENTS WITHOUT REMOVING THE UNIT FROM THE
MACHINE if THE UNIT IS ACCESSIBLE AND YOU CAN THOROUGHLY CLEAN IT BEFORE BEGINNING ANY
PROCEDURES
#LEANLINESS IS A PRIMARY MEANS OF ASSURING SATISFACTORY MOTOR LIFE ON EITHER NEW OR

REPAIRED UNITS Clean the outside of the motor thoroughly before disassembly. 4AKE CARE TO
AVOID CONTAMINATION OF THE SYSTEM PORTS #LEANING PARTS WITH A CLEAN SOLVENT WASH AND
AIR DRYING IS USUALLY ADEQUATE
#AP ALL HOSES AFTER REMOVAL AND PLUG ALL OPEN PORTS #OVER ANY UNATTENDED PARTS WITH A
PROTECTIVE LAYER OF PLASTIC
Inspect for system contamination

 )NSPECT THE MOTOR FOR SIGNS OF SYSTEM CONTAMINATION )F YOU lND CONTAMINATION FULLY
DISASSEMBLE CLEAN AND INSPECT ALL COMPONENTS OF THE MOTOR
Replace the O-rings and gaskets

  2EPLACE ALL / RINGS AND GASKETS $ISCARD THEM ONLY AFTER YOU MAKE CERTAIN
THAT YOU HAVE THE CORRECT REPLACEMENT PARTS ,IGHTLY LUBRICATE ALL / RINGS WITH CLEAN
PETROLEUM JELLY BEFORE ASSEMBLY
Lubricate all moving parts

 $URING REASSEMBLY COAT ALL MOVING PARTS WITH A lLM OF CLEAN HYDRAULIC OIL4HIS HELPS
LUBRICATE THE SURFACES DURING START UP
&OR mUID QUALITY REQUIREMENTS REFER TO 520L0463 Hydraulic Fluids and Lubricants,
Technical Information
Torque procedure
 $URING REASSEMBLY CROSS TORQUE ALL RETAINING SCREWS TO THE GIVEN VALUE $O NOT
OVERTORQUE
8 11008567 s 2EV !% s .OVEMBER
572 BOMAG 008 916 41

Travel motor 10.2
Service Manual
Introduction
VARIABLE 3ERIES AND 3ERIES VARIABLE DISPLACEMENT MOTORS FEATURE A BENT AXIS ROTATING
DISPLACEMENT MOTORS GROUP THAT PROVIDES HIGH STARTING TORQUE AND HIGH SPEED4HE BALL END OF EACH PISTON
RUNS IN A BUSHING PRESSED INTO THE DRIVE SHAFT4HIS PERMITS THE TRANSFER OF HYDRAULIC
POWER DIRECTLY INTO ROTARY MOTION AT THE DRIVE SHAFT4HE PRESSURE BALANCED SPHERICAL
PISTON RINGS MAINTAIN CONTACT WITH THE CYLINDER BLOCK BORES PROVIDING HIGH VOLUMETRIC
EFlCIENCY AND LOW FRICTION ! CONSTANT VELOCITY JOINT SYNCHRONIZING SHAFT KEEPS THE
ROTATION OF THE CYLINDER BLOCK SYNCHRONIZED WITH THE MOTOR OUTPUT SHAFT
! SERVO PISTON CHANGES THE ANGLE OF THE ROTATING GROUP AND VARYS THE DISPLACEMENT OF
THE MOTOR $ECREASING DISPLACEMENT INCREASES SPEED )NCREASING DISPLACEMENT DECREASES
SPEED
3EVERAL HYDRAULIC AND ELECTROHYDRAULIC CONTROLS ARE AVAILABLE
4HE WAY SPOOL VALVE SHIFTS THE SERVO SUPPLY PRESSURE TO CHANGE THE MOTOR
DISPLACEMENT4HE SERVO SUPPLY PRESSURE CAN BE EXTERNAL OR INTERNAL
Series 51 motor cross section

-INIMUM DISPLACEMENt ValvE SEGMENt
liter 3PEED PICKUP RING
"EARING
(YDRAULIC PROPORtional PLATE
control 4APERED ROLLER BEARINGS
WAY
valve
3!% &LANGE
3PEED SENSOR 3YNCHRONIZING SHAFt

0ISTON
Servo
PISTON #HARGE PRESSURE RELIEF Valve 0 %
11008567 s 2EV !% s .OVEMBER 9

008 916 41 BOMAG 573
10.2 Travel motor
Service Manual
Introduction
SERIES 51-1 MOTORS 3ERIES MOTORS FEATURE SIMPLIlED END CAP AND CONTROL COMPONENTS4HE SERVO PISTON
IN THE 3ERIES HAS A DIFFERENTIAL AREA OF TO 4HE CONNECTING JOINT IS DESIGNED TO
DECREASE THE OVERALL LENGTH OF THE MOTOR
4HE 3ERIES CONTROL FEEDS SERVO PRESSURE DIRECTLY TO THE SERVO PISTON ,OW SYSTEM
LOOP PRESSURE FOR TWO POSITION CONTROLS AND HIGH SYSTEM LOOP PRESSURE FOR PRESSURE
COMPENSATING CONTROLS ACTUATES THE SERVO PISTON
2OTATING HARDWARE AND HOUSING COMPONENTS ARE COMMON BETWEEN 3ERIES AND 3ERIES

Series 51-1 motor cross section

-INIMUM ValvE SEGMENt
DISPLACEMENT LIMITER
"EARING PLATE 3PEED PICKUP RING
4APERED ROLLER BEARINGS
$). FLANGE
3YNCHRONIZING SHAFt
3PEED SENSOR
ServO PISTON
0ISTON
%LECTROHYDRAULIC TWO POSITION CONTROl

#HARGE PRESSURE RELIEF Valve 0 %
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Service Manual
Introduction
CLOSED CIRCUIT )N A CLOSED CIRCUIT HYDRAULIC LINES CONNECT THE MAIN PORTS OF THE PUMP TO THE MAIN PORTS
OF THE MOTOR &LUID mOWS IN EITHER DIRECTION FROM THE PUMP TO THE MOTOR AND BACK TO THE
PUMP %ITHER OF THE HYDRAULIC LINES CAN BE UNDER HIGH PRESSURE
Case
drain
line
/UTPUT
)NPUT 06 MV
2ESERvoir FlOW "I DIRECTIONAL

0 %
4HE DIRECTION AND SPEED OF THE mUID mOW AND MOTOR OUTPUT SHAFT ROTATION DEPENDS
ON THE POSITION OF THE PUMP SWASH PLATE4HE PUMP mOW AND MOTOR DISPLACEMENT
DETERMINES MOTOR OUTPUT SHAFT SPEED4HE MACHINE LOAD DETERMINES THE SYSTEM
PRESSURE
OPEN CIRCUIT ! HYDRAULIC LINE CONNECTS THE OUTLET PORT OF THE PUMP TO A DIRECTIONAL VALVE IN AN OPEN
CIRCUIT4HE MAIN PORTS OF THE MOTOR CONNECT TO THE WORKING PORTS OF THIS VALVE7HEN THE
DIRECTIONAL VALVE IS ACTUATED mUID mOWS lRST FROM THE PUMP TO THE VALVE4HE DIRECTIONAL
VALVE THEN DIRECTS THE mUID TO THE MOTOR IN EITHER DIRECTION
FlOW FlOW
5NIDIRECTIONAL "I DIRECTIONAL
$)2%#4)/.!, VA,6%
)NPUT 05-0 MV /UTPUT
Case
drain
line
2ESERvoir
0 %
4HE DIRECTION OF mUID mOW AND MOTOR OUTPUT SHAFT ROTATION DEPENDS ON THE POSITION
OF THE DIRECTIONAL VALVE4HE MOTOR OUTPUT SPEED DEPENDS ON PUMP OUTPUT VOLUME
THE RESTRICTION OF THE VALVE OPENING AND MOTOR DISPLACEMENT4HE MACHINE LOAD
DETERMINES THE SYSTEM PRESSURE4HE DIRECTIONAL VALVE ROUTES mUID RETURNING FROM THE
MOTOR TO THE RESERVOIR !DDITIONAL COMPONENTS MAY BE NECESSARY TO PROVIDE DYNAMIC
BREAKING AND TO DEAL WITH OVERRUNNING LOADS
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Service Manual
Introduction
SHAFTS -ANY SHAFT CONlGURATIONS ARE AVAILABLE ON 3ERIES AND 3ERIES MOTORS4HESE TABLES
SHOW SHAFTS THAT MAY BE ON EACH MOTOR mANGE CONlGURATION
Series 51-1 shaft options

Frame size 60 80 110
Order Cart/ Cart/ Cart/
Shaft description Flange SAE SAE SAE
code DIN DIN DIN
S1 TOOTH PITCH 34$ — 34$ — — —
# TOOTH PITCH /04 — — — — —
# TOOTH PITCH — — /04 — — —
C8 TOOTH PITCH — — — — — —
F1 TOOTH PITCH — — — — 34$ —
D1 7XXXXG PER $). — 34$ — — /04
$ 7XXXXG PER $). — /04 — 34$ — —
D3 7XXXXG PER $). — — — /04 — 34$
D4 7XXXXG PER $). — — — — — /04
Series 51 shaft options
Frame size 80 110 160 250

Order Shaft Cart/ Cart/ Cart/
Flange SAE SAE SAE SAE
code description DIN DIN DIN
S1 TOOTH PITCH 34$ — — — — — —
# TOOTH PITCH /04 — — — — — —
C8 TOOTH PITCH — — /04 — /04 — —
F1 TOOTH PITCH — — 34$ — 34$ — —
& TOOTH PITCH — — — — — — 34$
$ 7XXXXG PER $). — 34$ — — — — —
D3 7XXXXG PER $). — /04 — — — — —
D4 7XXXXG PER $). — — — 34$ — — —
D5 7XXXXG PER $). — — — — — 34$ —
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Service Manual
/PERATION
LOOP FLUSHING 3ERIES AND MOTORS ARE DESIGNED TO ACCOMMODATE A LOOP mUSHING FUNCTION
)NSTALLATIONS THAT REQUIRE ADDITIONAL mUID REMOVAL FROM THE MAIN HYDRAULIC CIRCUIT BECAUSE
OF TRANSMISSION COOLING REQUIREMENTS USE A LOOP mUSHING FUNCTION4HE LOOP mUSHING
FUNCTION CONSISTS OF A SHUTTLE VALVE AND A POPPET STYLE RELIEF VALVE OR AN ORIlCED RELIEF
VALVE CARTRIDGE
4HE shuttle valve ACTS AS A RESOLVER DIRECTING mUID ONLY FROM THE LOW PRESSURE SIDE OF THE
LOOP TO THE MOTOR RELIEF VALVE4HE SHUTTLE VALVE IS SPRING CENTERED TO THE CLOSED POSITION
TO PREVENT HIGH PRESSURE mUID LOSS FROM THE CIRCUIT WHEN REVERSING DIRECTIONS
Loop flushing cross-section showing orificed relief valve
/RIFICED
RELIEF Valve 3HUTTLE Valve
0 %
4HE poppet style relief valve REGULATES THE CHARGE PRESSURE LEVEL IN THE SYSTEM CIRCUIT
WHEN THERE IS A PRESSURE DIFFERENTIAL IN THE MAIN LOOP7HEN YOU USE THIS VALVE THE
PRESSURE SETTING OF THE MOTOR MUST BE LESS THAN THE PUMPS CHARGE PRESSURE SETTING4HE
PRESSURE SETTING OF THIS VALVE IS CRITICAL TO ACHIEVING THE PROPER LOOP mUSHING mOW RATE
Loop flushing cross-section showing poppet style relief valve

0OPPET STYLE
RELIEF VALVe
3HUTTLE Valve
0 %
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10.2 Travel motor
Service Manual
/PERATION
LOOP FLUSHING 4HE orificed relief cartridge CONTROLS mUSHING mOW UNDER MOST CONDITIONS !
(continued) COMBINATION OF ORIlCE SIZE AND CHARGE PRESSURE WILL PRODUCE A SPECIlC mUSHING mOW9OU
MAY EXCHANGE THE ORIlCED RELIEF CARTRIDGE FOR ONE WITH A DIFFERENT mOW RATING
Loop flushing cross-section showing defeated relief valve

/RIFICED
RELIEF
valve
3HUTTLE
valve
0
! PLUG IS INSTALLED IN THE RELIEF VALVE CAVITY TO DEFEAT THE LOOP mUSHING FUNCTION
Defeated loop flushing
Defeat
plug
Shuttle spool
P101 265E
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Service Manual
/PERATION
DISPLACEMENT LIMITERS 3ERIES AND 3ERIES MOTORS INCORPORATE MECHANICAL DISPLACEMENT LIMITERS9OU CAN
SET A SPECIlC DISPLACEMENT RANGE BY LIMITING THE TRAVEL OF THE VALVE SEGMENTROTATING
GROUP
Displacement limiters Series 51

4AMPER RESISTANT
caP
WAY
valve MINIMUM
DISPLACEMENT
LIMITER
ValvE SEGMENt
3PACER
ServO PISTON
-AXIMUM
DISPLACEMENT
LIMITER 0 %
4HE maximum displacement OF THE MOTOR IS SET BY A SCREW AND SPACERS INSTALLED ON
THE END OF THE SERVO PISTON4HE minimum displacement OF THE MOTOR IS SET BY AN
ADJUSTABLE STOP IN THE MOTOR HOUSING
Displacement limiters Series 51-1

4AMPER
resistant caP
MINIMUM
DISPLACEMENT LIMITER
ValvE SEGMENt
Servo
PISTON
-AXIMUM DISPLACEMENT
3PACER
0 %
See Adjustments, PAGES FOR AVAILABLE SETTING RANGES

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10.2 Travel motor
Service Manual
/PERATION
MOUNTING 3ERIES AND 3ERIES MOTORS ARE AVAILABLE IN THREE MOUNTING CONlGURATIONS4HEY
CONFIGURATIONS ARE DESIGNATED BY THE LETTERS 6 # OR $ FOLLOWING THE NUMBER IN THE MODEL CODE4HE
DESIGNATIONS REPRESENT
• 6 3!% # $ OR % MOUNTING mANGE
• # #ARTRIDGE STYLE MOUNTING
• $ $). )3/ MOUNTING mANGE
SAE configuration
P101 197
Cartridge configuration
P101 198
DIN configuration
P101 199
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Service Manual
/PERATION
SPEED SENSORS 3ERIES AND 3ERIES MOTORS ARE AVAILABLE WITH AN OPTIONAL SPEED SENSOR FOR DIRECT
MEASUREMENT OF MOTOR OUTPUT SPEED4HE SENSOR MAY ALSO BE USED TO SENSE THE DIRECTION
OF MOTOR ROTATION
Speed sensor with Packard connector

0ACKARD WEATHER PACK
PIN TOWER CONNECtor
2Ed
A
3UPPLY VOLTAGE
7HITe
B SPEED SIGNAL
BlacK
C GROUND COMMON
'REEn
D direction
$EUTZ CONNECtor
0 %
! SPECIAL MAGNETIC SPEED RING IS PRESSED ON TO THE OUTSIDE DIAMETER OF THE SHAFT ! (ALL
EFFECT SENSOR IS INSTALLED IN THE MOTOR HOUSING4HE SENSOR ACMÃEPTS SUPPLY VOLTAGE AND
OUTPUTS A DIGITAL PULSE SIGNAL IN RESPONSE TO THE SPEED OF THE RING
Speed sensor location cartridge motors
3PEED
sensor Conical end
0ISTON
"EARING
-AGNETIC RING
0 % PRESSED ONTO THE SHAFT
4HE OUTPUT CHANGES ITS HIGHLOW STATE AS THE NORTH AND SOUTH POLES OF THE PERMANENTLY
MAGNETIZED SPEED RING PASS BY THE FACE OF THE SENSOR4HE DIGITAL SIGNAL IS GENERATED AT
FREQUENCIES SUITABLE FOR MICROPROCESSOR BASED CONTROLS
Speed sensor location SAE / DIN flange motors
4HE 3!% AND $). mANGE MOTORS USE A

mAT END SPEED SENSOR #ARTRIDGE mANGE
0ISTON MOTORS USE A CONICAL END SPEED SENSOR
-AGNETIC RING
3PEED SENSOR
0 %
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10.2 Travel motor
Service Manual
/PERATION
CONTROLS Overview
4HERE ARE THREE BASIC CATEGORIES OF CONTROLS AVAILABLE FOR 3ERIES AND 3ERIES
• 4WO POSITION CONTROLS
• 0RESSURE COMPENSATOR CONTROLS
• 0ROPORTIONAL CONTROLS 3ERIES ONLY
TWO-POSITION 4WO POSITION CONTROLS SHIFT THE MOTOR TO Two-position control

CONTROLS ONLY TWO DISCRETE POSITIONS
• MAXIMUM DISPLACEMENT
• MINIMUM DISPLACEMENT
#ONTROL INPUT MAY BE EITHER BY HYDRAULIC

OR ELECTRICAL SIGNAL4O CHANGE MOTOR
DISPLACEMENT THE CONTROL ROUTES PILOT
G36
PRESSURE TO ONE END OF THE SERVO PISTON
G42
WHILE DRAINING THE OTHER 3ERIES G38
CONTROLS MAY DIRECT PILOT PRESSURE TO
G42
BOTH ENDS OF THE SERVO SIMULTANEOUSLY G38
ALLOWING THE DIFFERENTIAL AREA OF THE M16
PISTON TO STROKE THE MOTOR TO MINIMUM M16A
ANGLE
M18
M18A
3OME TWO POSITION CONTROLS ARE AVAILABLE M18 M10
WITH A Pressure COMPENSATOR OverRide M18A M12
PCOR FEATURE M1
4HE 0#/2 FEATURE ALLOWS NORMAL

M18
POSITION CONTROL WHILE CAUSING THE M18A M16A
MOTOR TO INCREASE DISPLACEMENT WHEN M16
SYSTEM PRESSURE REACHES A SET LEVEL M22
DUE TO LOAD4HE PRESSURE COMPENSATOR P101 268
PORTION OF THE CONTROL OVERRIDES THE

MINIMUM DISPLACEMENT POSITION COMMANDED BY THE CONTROL INPUT SIGNAL 0#/2 CONTROLS
ARE AVAILABLE WITH BRAKE PRESSURE DEFEAT TO PREVENT THE PRESSURE COMPENSATOR FROM
OPERATING DURING DYNAMIC BRAKING
#OMPLETE FUNCTIONAL DESCRIPTION MAINTENANCE AND REPAIR PROCEDURES FOR POSITION

CONTROLS ARE COVERED IN DETAIL IN THESE SUPPLEMENTS TO THIS MANUAL
• Series 51 Hydraulic and Electrohydraulic Two-position Controls

4YPES . (: % % & & ' ' 3
• Series 51-1 Controls Service Instructions

4YPES . % % % " " " 4 4 4 4! 4(
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Travel motor 10.2
Service Manual
/PERATION
PRESSURE- 0RESSURE COMPENSATOR 0# CONTROLS

COMPENSATOR ALLOW THE MOTOR TO MATCH ITS
CONTROLS DISPLACEMENT TO THE SYSTEM LOAD 5SUALLY
THIS MEANS THAT THE MOTOR DEFAULTS TO
MINIMUM DISPLACEMENT WHILE ALLOWING
THE MOTOR TO INCREASE DISPLACEMENT
WHEN SYSTEM PRESSURE REACHES A SET LEVEL
DUE TO LOAD4HIS PERMITS THE MOTOR TO
REGULATE SYSTEM PRESSURE BY MODULATING
THE DISPLACEMENT ANGLE OF THE ROTATING
GROUP !S DISPLACEMENT INCREASES SO
DOES AVAILABLE TORQUE WHILE OUTPUT
SPEED DECREASES AND SYSTEM PRESSURE
REMAINS NEARLY CONSTANT AT THE 0# SETTING
0# CONTROLS ARE AVAILABLE WITH A BRAKE 0 %

Pressure DEFEAT BPD FEATURE4HE "0$
FEATURE DEFEATS THE OPERATION OF THE 0#
DURING DYNAMIC BREAKING WHEN THE
MOTOR IS RUNNING AS A PUMP
! SHUTTLE SPOOL UPSTREAM OF THE 0# VALVE DIRECTS ONLY ACMÃELERATION SYSTEM PRESSURE TO
THE 0# $URING DYNAMIC DECELERATION THE DYNAMIC BREAKING PRESSURE IS BLOCKED FROM
THE 0#4HE MOTOR REMAINS AT MINIMUM DISPLACEMENT LIMITING RAPID AND UNCONTROLLED
PRESSURES OR ENGINE OVER SPEEDING WHILE THE VEHICLEMACHINE IS SLOWING DOWN (YDRAULIC
OR ELECTRIC ACTUATION IS AVAILABLE 0# ON ONE SYSTEM PRESSURE SIDE IS ALSO AN OPTION
#OMPLETE FUNCTIONAL DESCRIPTION MAINTENANCE AND REPAIR PROCEDURES FOR PRESSURE

COMPENSATOR CONTROLS ARE COVERED IN DETAIL IN THE SUPPLEMENT TO THIS MANUAL
• Series 51 Two Position Controls Service Manual

4YPES4 4 4( 4! 0# 0$
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008 916 41 BOMAG 583
10.2 Travel motor
Service Manual
/PERATION
PROPORTIONAL Proportional control 0ROPORTIONAL CONTROLS ALLOW THE MOTOR

CONTROLS TO OPERATE IN AN INlNITELY VARIABLE
DISPLACEMENT POSITION BASED ON A
HYDRAULIC OR ELECTRICAL INPUT SIGNAL
0ROPORTIONAL CONTROLS ARE AVAILABLE ON

3ERIES MOTORS 3ERIES MOTORS ARE
TWO POSITION ONLY 0ROPORTIONAL CONTROLS
ARE ALSO AVAILABLE WITH A 0#/2 FEATURE
4HE 0#/2 FEATURE ALLOWS NORMAL

PROPORTIONAL CONTROL WHILE CAUSING THE
MOTOR TO INCREASE DISPLACEMENT WHEN
SYSTEM PRESSURE REACHES A SET LEVEL
DUE TO LOAD4HE PRESSURE COMPENSATOR
PORTION OF THE CONTROL overrides ANY
POSITION LESS THAN MAXIMUM AS
COMMANDED BY THE CONTROL INPUT SIGNAL
0#/2 CONTROLS ARE AVAILABLE WITH "0$

TO PREVENT THE PRESSURE COMPENSATOR
FROM OPERATING DURING DYNAMIC BRAKING
3UPPLEMENTS TO THIS MANUAL DETAIL
FUNCTIONAL DESCRIPTION MAINTENANCE
AND REPAIR PROCEDURES FOR PROPORTIONAL
P001826
CONTROLS 3UPPLEMENTS INCLUDE
• Series 51 Single Input Hydraulic Proportional Controls

4YPES (: (! (" (% (3 (( * * * ++
• Series 51 Dual Input Hydraulic Proportional Controls

4YPES (0 (# *!
• Series 51 Electrohydraulic Proportional Controls

4YPES %0 %1 %2 %3 , , , ! $ $
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Travel motor 10.2
Service Manual
GENERAL -OST SPECIlCATIONS FOR 3ERIES AND MOTORS ARE LISTED ON THESE PAGES &OR
SPECIFICATIONS DElNITIONS OF THE VARIOUS SPECIlCATIONS SEE 520L0440 Series 51 Technical Information
Manual
.OT ALL HARDWARE OPTIONS ARE AVAILABLE FOR ALL CONlGURATIONS #ONSULT THE Series 51 Model
Code Supplement or price book FOR MORE INFORMATION
"ASIC REQUIREMENTS
• -OTOR TYPE !XIAL PISTON MOTOR WITH VARIABLE DISPLACEMENT BENT
AXIS DESIGN
• $IRECTION OF ROTATION #LOCKWISE AND COUNTER CLOCKWISE BI DIRECTIONAL
• )NSTALLATION POSITION $ISCRETIONARY THE HOUSING MUST ALWAYS BE lLLED WITH

HYDRAULIC mUID
• /THER SYSTEM REQUIREMENTS )NDEPENDENT BRAKING SYSTEM CIRCUIT OVERPRESSURE

PROTECTION SUITABLE RESERVOIR
4ECHNICAL DATA INCLUDES DIMENSION AND FRAME SIZE FOR DISPLACEMENT CASE AND SYSTEM
PRESSURE SPEED AND TORQUE4HESE TABLES ILLUSTRATE EACH FACET
TECHNICAL DATA
Frame size
Dimension 60 80 110 160 250
3
-AXIMUM DISPLACEMENT 6GMAX CM
[in3] ;= ;= ;= ;= ;=
-INIMUM DISPLACEMENT 6GMIN CM3
[in3] ;= ;= ;= ;= ;=
2ATED mOW 1 LMIN
;GALMIN= ;= ;= [81] ;= [145]
-AXIMUM CORNER POWER 0 CORNER K7
MAX ;HP= ;= ;= ;= ;= ;=
7EIGHT WITH CONTROL (Z M KG 44
LB ;= ;= ;= ;= ;
-ASS MOMENT OF INERTIA OF THE INTERNAL KGsM
ROTATING PARTS SLUGsFT ;= ;= ;= ;= ;=
4YPE OF MOUNTING &OUR BOLT mANGE 3!% OR $). mANGE CONlGURATION
4WO BOLT mANGE CARTRIDGE MOTOR CONlGURATION
0IPE CONNECTIONS -AIN PRESSURE PORTS 3!% mANGE
2EMAINING PORTS 3!% STRAIGHT THREAD / RING BOSS
Controls 4WO POSITION PROPORTIONAL 3ERIES HYDRAULIC OR ELECTRIC PRESSURE COMPENSATOR WWO OVERRIDE
WWO BRAKE PRESSURE DEFEAT
$ISPLACEMENT LIMITER !LL 3ERIES MOTORS INCORPORATE MECHANICAL MINIMUM AND MAXIMUM DISPLACEMENT LIMITERS
3HAFT CONlGURATION 3PLINED !.3) OR $). SHAFT
11008567 s 2EV !% s .OVEMBER 21

008 916 41 BOMAG 585
10.2 Travel motor
Service Manual
TECHNICAL DATA Case pressure System pressure range

(continued)
bar psi bar psi
2ATED PRESSURE 3 44 -AXIMUM DELTA PRESSURE
-AXIMUM PRESSURE COLD START 5 -INIMUM LOW PRESSURE SIDE 145
-INIMUM PRESSURE 1 15
Speed limits
Frame size
-1
Speed min [rpm] 060 080 110 160 250
AT MAXIMUM DISPLACEMENT
2ATED SPEED
AT MINIMUM DISPLACEMENT
AT MAXIMUM DISPLACEMENT
-AXIMUM SPEED1
AT MINIMUM DISPLACEMENT
1
#ONTACT YOUR 3AUER $ANFOSS REPRESENTATIVE FOR MAXIMUM SPEED AT DISPLACEMENTS BETWEEN MAXIMUM AND
MINIMUM DISPLACEMENT
Theoretical torque
Frame size
Displacement condition 060 080 110 160 250
AT MAXIMUM .sMBAR
DISPLACEMENT ;LBFsIN PSI= 583
AT MINIMUM .sMBAR
DISPLACEMENT ;LBFsIN PSI= 313
FLUID SPECIFICATIONS Temperature range1 Viscosity

Calefaction °C °F mm2/s SUS
)NTERMITTENT COLD START -INIMUM INTERMITTENT
Continuous 2ECOMMENDED OPERATING
RANGE
)NTERMITTENT 115
1 -AXIMUM COLD START
!T THE HOTTEST POINT USUALLY THE CASE DRAIN PORT
Fluid cleanliness
Cleanliness level and βx-ratio
2EQUIRED mUID CLEANLINESS LEVEL )3/ #LASS
2ECOMMENDED βx RATIO FOR SUCTION lLTRATION B35-45 "≥
2ECOMMENDED βx RATIO FOR CHARGE PRESSURE lLTRATION B "≥
2ECOMMENDED INLET SCREEN SIZE FOR CHARGE PRESSURE lLTRATION μM μM
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Travel motor 10.2
Service Manual
0RESSURE MEASUREMENTS
REQUIRED TOOLS 9OU CAN PERFORM SERVICE PROCEDURES DESCRIBED IN THIS MANUAL USING COMMON MECHANICS
HAND TOOLS 3PECIAL TOOLS IF REQUIRED ARE SHOWN #ALIBRATE PRESSURE GAUGES FREQUENTLY TO
ENSURE ACMÃURACY 5SE SNUBBERS TO PROTECT PRESSURE GAUGES
PORT LOCATIONS AND Series 51 motors

GAUGE INSTALLATION
Servo pressure supply Side port
for minimum angle or servo Y
pressure minimum angle
Guage port M3
System pressure B
M3
Main ports A+B Gauge port M2
Case drain L1
Y
side port
W
M1
Servo supply
M5
pressure
Guage port M5
System pressure A
Alternate position Gauge port M1
case drain L2 Control pressure
Guage port M7
Gauge information W
Servo pressure supply for
3YSTEM PRESSURE BAR ; PSI=
M1 maximum angle or
PORT A / RING lTTING servo pressure maximum angle
Guage port M4
-
PORT B / RING lTTING
0 %A
3ERVO PRESSURE BAR ; PSI=

M3
MINIMUM ANGLE / RING lTTING
3ERVO SUPPLY BAR ; PSI=
M4 PRESSURE
MAXIMUM ANGLE / RING lTTING
3ERVO SUPPLY BAR ; PSI= Axial port Y

M5
PRESSURE / RING lTTING
System pressure A+B
Guage port M1+M2 Main
port B
M3
Axial port W
M4
M5
Main
port A P107 757E
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008 916 41 BOMAG 587
10.2 Travel motor
Service Manual
0RESSURE MEASUREMENTS
PORT LOCATIONS AND Series 51-1 motors

GAUGE INSTALLATION
Y
(continued)
3IDE POrt
,OOP FLUSHING
SHUTTLE Valve
X
#HARGE PRESSURe
RELIEF Valve
7
M4
#ASE DRAIN ,
3YSEM PRESSURE B
Y B A 'AUGE POrt -
-AIN PORTS ! "
3YSTEM PRESSURE A 7
'UAGE POrt M1
Alternate
POSITION
CASE DRAIN ,
Gauge information 'UAGE POrt M4

ServO PRESSURe
3YSTEM PRESSURE BAR ; PSI= 0 % MAXIMUM ANGLE
M1
PORT A / RING lTTING

-
PORT B / RING lTTING
BAR ; PSI=
3ERVO PRESSURE BAR ; PSI=
M3 MINIMUM ANGLE GAUGE FOR POSITION
ON CONTROL control
/ RING lTTING
BAR ; PSI=
BAR ; PSI= Y
3ERVO SUPPLY !XIAL POrt
M4 PRESSURE GAUGE FOR POSITION
MAXIMUM ANGLE control
/ RING lTTING
7
X
M4
B A
Main
POrt B
-AIN POrt A
3YSTEM PRESSURE ! "
'UAGE POrt - - 0 %
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Travel motor 10.2
Service Manual
&LUID AND lLTER MAINTENANCE
FLUID AND FILTER 4O ENSURE OPTIMUM LIFE PERFORM REGULAR MAINTENANCE OF THE mUID AND lLTER
RECOMMENDATIONS #ONTAMINATED mUID IS THE MAIN CAUSE OF UNIT FAILURE4AKE CARE TO MAINTAIN mUID
CLEANLINESS WHEN SERVICING )NSPECT VEHICLE FOR LEAKS DAILY
#HECK THE RESERVOIR DAILY FOR PROPER mUID LEVEL THE PRESENCE OF WATER AND RANCID mUID
ODOR &LUID CONTAMINATED BY WATER MAY APPEAR CLOUDY OR MILKY OR FREE WATER MAY SETTLE
IN THE BOTTOM OF THE RESERVOIR 2ANCID ODOR INDICATES EXCESSIVE HEAT #HANGE THE mUID
IMMEDIATELY IF THESE CONDITIONS OCMÃUR #ORRECT THE PROBLEM IMMEDIATELY
#HANGE THE mUID AND lLTER PER THE Fluid and filter change interval
VEHICLEMACHINE MANUFACTURERS Reservoir type Max. oil change interval
RECOMMENDATIONS OR AT THESE INTERVALS Sealed HOURS
&IRST mUID CHANGE RECOMMENDED AT "REATHER HOURS
HOURS
(IGH TEMPERATURES AND PRESSURES RESULT IN ACMÃELERATED mUID AGING -ORE FREQUENT mUID
CHANGES MAY BE REQUIRED
#HANGE THE mUID MORE FREQUENTLY IF IT BECOMES CONTAMINATED WITH FOREIGN MATTER DIRT
WATER GREASE ETC OR IF THE mUID IS SUBJECTED TO TEMPERATURE LEVELS GREATER THAT THE
RECOMMENDED MAXIMUM $ISPOSE OF USED HYDRAULIC mUID PROPERLY .EVER REUSE HYDRAULIC
mUID
#HANGE lLTERS WHENEVER THE mUID IS CHANGED OR WHEN THE lLTER INDICATOR SHOWS THAT IT IS
NECESSARY TO CHANGE THE lLTER 2EPLACE ALL mUID LOST DURING lLTER CHANGE
Hazardous material
W Warning
(YDRAULIC mUID CONTAINS HAZARDOUS MATERIAL !VOID CONTACT WITH HYDRAULIC mUID !LWAYS
DISPOSE OF USED HYDRAULIC mUID ACMÃORDING TO STATE AND FEDERAL ENVIRONMENTAL
REGULATIONS
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008 916 41 BOMAG 589
10.2 Travel motor
Service Manual
)NITIAL STARTUP PROCEDURES
PROCEDURE !LWAYS FOLLOW THIS PROCEDURE WHEN STARTING UP A NEW 3ERIES OR 3ERIES INSTALLATION
OR WHEN RESTARTING AN INSTALLATION IN WHICH EITHER THE PUMP OR MOTOR HAS BEEN REMOVED
 7!2.).' "EFORE INSTALLING THE MOTOR ANDOR PUMP INSPECT THE UNITS FOR DAMAGE INCURRED
4HIS SERVICE PROCEDURE DURING SHIPPING AND HANDLING
MAY REQUIRE DISABLING
THE VEHICLE MACHINE -AKE CERTAIN ALL SYSTEM COMPONENTS RESERVOIR HOSES VALVES lTTINGS HEAT EXCHANGER
RAISING THE WHEELS OFF THE AND SO FORTH ARE CLEAN BEFORE lLLING WITH mUID
GROUND DISCONNECTING
WORK FUNCTION AND SO &ILL THE RESERVOIR WITH RECOMMENDED HYDRAULIC mUID &ILTER USING A MICRON
FORTH WHILE PERFORMING NOMINAL NO BYPASS lLTER INTO THE RESERVOIR 5SING CONTAMINATED mUID MAY DAMAGE
TO PREVENT INJURY TO THE COMPONENTS WHICH MAY RESULT IN UNEXPECTED VEHICLEMACHINE MOVEMENT
TECHNICIAN AND BYSTANDERS
4AKE THE NECESSARY SAFETY &ILL THE INLET LINE LEADING FROM THE RESERVOIR TO THE PUMP
PRECAUTIONS
#HECK INLET LINE FOR PROPERLY TIGHTENED lTTINGS
-AKE SURE THE INLET LINE IS FREE OF RESTRICTIONS AND AIR LEAKS
&ILL THE MOTOR ANDOR PUMP HOUSING WITH CLEAN HYDRAULIC mUID BEFORE START UP &ILL BY
POURING lLTERED OIL INTO THE UPPER CASE DRAIN PORT
 Caution
.EVER START THE PRIME MOVER UNLESS THE MOTOR AND PUMP ARE filled completely WITH
CLEAN HYDRAULIC mUID
)NSTALL A BAR ; PSI= PRESSURE GAUGE IN THE CHARGE PRESSURE GAUGE PORT OF
THE PUMP TO MONITOR THE CHARGE PRESSURE DURING START UP
$ISCONNECT ANY EXTERNAL CONTROL INPUT SIGNAL LINKAGE FOR -$# HYDRAULIC LINES FOR
($# OR ELECTRICAL CONNECTIONS FOR %$# FROM THE PUMP CONTROL UNTIL AFTER INITIAL START
UP4HIS ENSURES THAT THE PUMP REMAINS IN ITS NEUTRAL POSITION
5SE A COMMON METHOD TO DISABLE THE PRIME MOVER *OG SLOWLY ROTATE PRIME MOVER
UNTIL CHARGE PRESSURE STARTS TO RISE
 7!2.).' %NABLE PRIME MOVER 3TART THE PRIME MOVER AND RUN AT THE LOWEST POSSIBLE SPEED
$O NOT START THE PRIME UNTIL CHARGE PRESSURE IS ESTABLISHED
MOVER UNLESS THE PUMP IS
IN NEUTRAL POSITION SWASH )F NECESSARY BLEED EXCESS AIR FROM THE HIGH PRESSURE LINES THROUGH THE HIGH PRESSURE
PLATE AT ² ANGLE 4AKE SYSTEM GAUGE PORT
NECESSARY PRECAUTIONS
TO PREVENT MACHINE /NCE CHARGE PRESSURE IS ESTABLISHED INCREASE SPEED TO NORMAL OPERATING SPEED
MOVEMENT IN CASE PUMP IS
ACTUATED IN STROKE DURING #HARGE PRESSURE SHOULD BE AS INDICATED IN THE PUMP MODEL CODE )F CHARGE PRESSURE IS
INITIAL START UP LOW SHUT DOWN AND DETERMINE CAUSE 3EE Troubleshooting PAGES
 Caution
,OW CHARGE PRESSURE MAY AFFECT THE OPERATORS ABILITY TO CONTROL THE MACHINE
26 11008567 s 2EV !% s .OVEMBER
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Travel motor 10.2
Service Manual
)NITIAL STARTUP PROCEDURES
PROCEDURE (continued) 3HUT DOWN THE PRIME MOVER
#ONNECT THE EXTERNAL CONTROL INPUT SIGNAL
2ECONNECT THE MACHINE FUNCTION IF DISCONNECTED EARLIER
3TART THE PRIME MOVER CHECKING TO ENSURE THE PUMP REMAINS IN NEUTRAL
#HECK FOR FORWARD AND REVERSE MACHINE OPERATION WITH THE PRIME MOVER AT NORMAL
OPERATING SPEED
#HARGE PRESSURE MAY DECREASE SLIGHTLY DURING FORWARD OR REVERSE OPERATION
#ONTINUE TO CYCLE SLOWLY BETWEEN FORWARD AND REVERSE FOR AT LEAST lVE MINUTES
3HUT DOWN PRIME MOVER
2EMOVE GAUGES
0LUG THE GAUGE PORTS
#HECK RESERVOIR LEVEL
!DD lLTERED mUID TO THE RESERVOIR IF NEEDED
4HE MOTOR TRANSMISSION IS NOW READY FOR OPERATION
11008567 s 2EV !% s .OVEMBER 27

008 916 41 BOMAG 591
10.2 Travel motor
Service Manual
4ROUBLESHOOTING
SLUGGISH SYSTEM
Check Cause Corrective action

#ONTROL ORIlCES "LOCKED OR RESTRICTED ORIlCE WILL CAUSE SLUGGISH 2EMOVE INSPECT AND CLEAN ALL ORIlCES %NSURE THE
RESPONSE /RIlCES INSTALLED TO THE WRONG APPROPRIATE ORIlCES ARE INSTALLED
LOCATIONS WILL CAUSE 0#/2 CONTROL TO BE SLUGGISH
4HRESHOLD SETTING PROPORTIONAL )NAPPROPRIATELY HIGH THRESHOLD SETTING WILL SHIFT #HECK THRESHOLD SETTING !DJUST IF NECESSARY
CONTROLS THE MOTOR AT THE WRONG TIME
#ONTROL SPOOL OR PISTON ! STICKY WAY SPOOL OR CONTROL PISTON WILL CAUSE #LEAN AND INSPECT THE WAY VALVE SPOOL AND CONTROL
SLUGGISH RESPONSE PISTON 2EPLACE IF NECESSARY
0RESSURE COMPENSATOR SETTING )NAPPROPRIATELY LOW PRESSURE COMPENSATING #HECK PRESSURE COMPENSATOR SETTING !DJUST IF
SETTING WILL SHIFT MOTOR TO MAXIMUM NECESSARY
DISPLACEMENT AT LOWER PRESSURE
#ONTROL INPUT SIGNAL !N IMPROPER OR ERRATIC INPUT SIGNAL TO THE CONTROL #HECK INPUT SIGNAL OR ELECTRIC CURRENT AND CORRECT IF
MAY CAUSE SLUGGISH RESPONSE NECESSARY
#HARGE PRESSURE )NAPPROPRIATELY LOW PRESSURE SETTING AT LOOP -EASURE CHANGE PRESSURE IN FORWARD AND REVERSE
mUSHING RELIEF VALVE MAY CAUSE IMPROPER SUPPLY !DJUST LOOP mUSHING RELIEF VALVE IF NECESSARY
PRESSURE TO MOTOR CONTROL
3YSTEM PRESSURE )NAPPROPRIATELY LOW SYSTEM PRESSURE SETTING MAY -EASURE SYSTEM PRESSURE !DJUST PUMP PRESSURE
CAUSE SLUGGISH RESPONSE LIMITER OR SYSTEM RELIEF VALVE IF NECESSARY
)NTERNAL LEAKAGE %XCESSIVE LEAKAGE WILL CAUSE LOWER CHARGE )NSTALL LOOP mUSHING DEFEAT OPTION AND MONITOR CASE
PRESSURE AND AFFECT PERFORMANCE mOW )F CASE mOW IS EXCESSIVE MOTOR MAY REQUIRE
MAJOR REPAIR #ONTACT YOUR 3AUER $ANFOSS SERVICE
PROVIDER
SYSTEM OPERATING HOT

Oil level )NSUFlCIENT HYDRAULIC mUID WILL CAUSE OVERHEATING &ILL RESERVOIR TO PROPER LEVEL
(EAT EXCHANGER "LOCKED HEAT EXCHANGER OR LOW AIR mOW WILL NOT #HECK TEMPERATURE UPSTREAM AND DOWNSTREAM
SUFlCIENTLY COOL THE SYSTEM OF HEAT EXCHANGER #LEAN REPAIR OR REPLACE HEAT
EXCHANGER IF NECESSARY
,OOP mUSHING CHARGE PRESSURE )NAPPROPRIATELY HIGH LOOP mUSHING RELIEF VALVE -ONITOR CASE DRAIN mOW )F LOW ADJUST LOOP mUSHING
SETTING WILL REDUCE OR PREVENT LOOP mUSHING mOW RELIEF VALVE SETTING OR REPLACE WITH ORIlCED TYPE
)MPROPER ORIlCE SIZE WILL NOT GIVE PROPER mOW FOR RELIEF
COOLING PURPOSES
3YSTEM PRESSURE )F SYSTEM RELIEF VALVE SETTINGS ARE TOO LOW EXCESS !DJUST SYSTEM RELIEF VALVE SETTINGS
HEAT WILL BE GENERATED
!IR IN SYSTEM %NTRAINED AIR GENERATES HEAT UNDER PRESSURE AND ,OOK FOR FOAM OR BUBBLES IN RESERVOIR #HECK FOR
causes cavitation LEAKS ON INLET SIDE OF CHARGE PUMP
)NTERNAL LEAKAGE %XCESSIVE INTERNAL LEAKAGE WILL OVERHEAT THE )NSTALL LOOP mUSHING DEFEAT OPTION AND MONITOR CASE
SYSTEM mOW )F CASE mOW IS EXCESSIVE MOTOR MAY REQUIRE
MAJOR REPAIR #ONTACT YOUR 3AUER $ANFOSS SERVICE
PROVIDER
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Travel motor 10.2
Service Manual
4ROUBLESHOOTING
EXCESSIVE NOISE OR
VIBRATION
Oil level in reservoir )NSUFlCIENT HYDRAULIC mUID WILL CAUSE CAVITATION &ILL RESERVOIR TO PROPER LEVEL
!IR IN SYSTEM !IR BUBBLES MAY LEAD TO CAVITATION ,OOK FOR FOAM OR BUBBLES IN RESERVOIR #HECK FOR
LEAKS ON INLET SIDE OF CHARGE PUMP
3HAFT COUPLING ,OOSE SHAFT COUPLING CREATES EXCESS NOISE 2EPLACE LOOSE SHAFT COUPLING 2EPLACE OR REPAIR
MOTOR IF SHAFT SPLINES ARE WORN EXCESSIVELY
3HAFT ALIGNMENT -ISALIGNED SHAFTS CREATE EXCESSIVE NOISE AND #ORRECT SHAFT MISALIGNMENT
DAMAGE MOTOR
MOTOR OPERATES
NORMALLY IN ONE
DIRECTION ONLY
#HARGE PRESSURE )F CHARGE PRESSURE IS LOW IN ONE DIRECTION THE -EASURE CHARGE PRESSURE IN FORWARD AND REVERSE )F
LOOP mUSHING SHUTTLE SPOOL MAY BE STICKING TO PRESSURE DROPS IN ONE DIRECTION INSPECT AND REPAIR
ONE SIDE LOOP mUSHING SHUTTLE SPOOL
Motor control )F CONTROL SHIFTS MOTOR TO MINIMUM DISPLACEMENT -EASURE MAXIMUM AND MINIMUM SERVO PRESSURES
IN ONE DIRECTION MOTOR MAY NOT HAVE ENOUGH TO CHECK CONTROL OPERATION 2EPAIR CONTROL OR CORRECT
TORQUE TO OPERATE INPUT SIGNAL IF NECESSARY
0RESSURE COMPENSATOR CONTROL )F PRESSURE COMPENSATOR OPERATES IN ONE #HECK BRAKE PRESSURE DEFEAT SPOOL )T MAY BE
DIRECTION ONLY THE MOTOR WILL STAY AT MINIMUM STICKING OR RECEIVING AN IMPROPER SIGNAL 2EPAIR
DISPLACEMENT IN THE OTHER DIRECTION SPOOL OR CORRECT INPUT SIGNAL
IMPROPER OUTPUT
SPEED
Oil level in reservoir )NSUFlCIENT HYDRAULIC mUID WILL REDUCE SYSTEM &ILL RESERVOIR TO PROPER LEVEL
EFlCIENCY
4HRESHOLD SETTING )MPROPER THRESHOLD SETTING WILL CAUSE MOTOR TO #HECK THRESHOLD SETTING 2EFER TO CONTROL SERVICE
HAVE WRONG DISPLACEMENT FOR GIVEN SIGNAL MANUAL FOR ADJUSTMENT PROCEDURE
0RESSURE COMPENSATOR SETTING )MPROPER PRESSURE COMPENSATOR SETTING SHIFTS #HECK PRESSURE COMPENSATOR SETTING !DJUST IF
MOTOR DISPLACEMENT AT WRONG PRESSURE NECESSARY
#ONTROL SPOOL OR PISTON 0RESSURE COMPENSATOR PISTON OR SPOOL STICKING #HECK PRESSURE COMPENSATOR PISTON OR SPOOL 2EPAIR
HOLDS MOTOR AT WRONG DISPLACEMENT OR REPLACE IF NEEDED
#ONTROL ORIlCES "LOCKED OR RESTRICTED ORIlCE CAUSES MOTOR TO SHIFT 2EMOVE INSPECT AND CLEAN ALL ORIlCES
IMPROPERLY
#ONTROL PISTON 3TICKY CONTROL PISTON CAUSES MOTOR TO SHIFT #HECK CONTROL PISTON FOR PROPER OPERATION 2EPAIR IF
IMPROPERLY NECESSARY
#ONTROL INPUT SIGNAL )MPROPER INPUT SIGNAL CAUSES MOTOR TO SHIFT #ORRECT CONTROL INPUT SIGNAL
IMPROPERLY
)NTERNAL LEAKAGE %XCESS INTERNAL LEAKAGE CAUSES LOWER CHARGE )NSTALL LOOP mUSHING DEFEAT OPTION AND MONITOR CASE
PRESSURE AND AFFECTS SYSTEM PERFORMANCE mOW )F CASE mOW IS EXCESSIVE MOTOR MAY REQUIRE
INCLUDING OUTPUT SPEED MAJOR REPAIR #ONTACT YOUR 3AUER $ANFOSS 3ERVICE
0ROVIDER
11008567 s 2EV !% s .OVEMBER 29

008 916 41 BOMAG 593
10.2 Travel motor
Service Manual
4ROUBLESHOOTING
LOW OUTPUT TORQUE

3YSTEM PRESSURE ,OW SYSTEM PRESSURE AT MOTOR REDUCES OUTPUT -EASURE SYSTEM PRESSURE AT THE MOTOR )F THE
TORQUE PRESSURE LIMITER OR RELIEF VALVE SETTING IS LOW
INCREASE SETTING TO THE PROPER LEVEL
#HARGE PRESSURE ,OW LOOP mUSHING RELIEF VALVE SETTING MAY CAUSE -EASURE CHARGE PRESSURE IN FORWARD AND REVERSE
IMPROPER SUPPLY PRESSURE TO MOTOR CONTROL !DJUST LOOP mUSHING RELIEF VALVE SETTING IF NECESSARY
0RESSURE COMPENSATOR SETTING (IGH PRESSURE COMPENSATOR SETTING CAUSES #HECK AND ADJUST PRESSURE COMPENSATOR SETTING
IMPROPER MOTOR DISPLACEMENT FOR TORQUE
REQUIRED
#ONTROL ORIlCES "LOCKED OR RESTRICTED ORIlCE CAUSES MOTOR TO SHIFT 2EMOVE INSPECT AND CLEAN ALL ORIlCES
IMPROPERLY
0RESSURE COMPENSATOR PISTON OR 3TICKING PRESSURE COMPENSATOR PISTON OR SPOOL 2EMOVE AND INSPECT CONTROL SPOOL AND SENSING
SPOOL CAUSES CONTROL TO HOLD MOTOR AT MINIMUM PISTON 2EPAIR OR REPLACE IF NECESSARY
DISPLACEMENT
#ONTROL SPOOL OR PISTON 3TICKING WAY SPOOL OR CONTROL PISTON CAUSES 2EMOVE AND INSPECT WAY SPOOL AND CONTROL
MOTOR TO SHIFT IMPROPERLY PISTON 2EPAIR OR REPLACE IF NECESSARY
4WO POSITION SOLENOID 4WO POSITION CONTROL NOT SHIFTING MOTOR TO )NSPECT SOLENOID VALVE FOR BENT STEM OR BAD COIL
MAXIMUM DISPLACEMENT 2EPAIR OR REPLACE IF NECESSARY
#ONTROL INPUT SIGNAL )MPROPER CONTROL INPUT SIGNAL CAUSES MOTOR TO #ORRECT CONTROL INPUT SIGNAL
STAY AT MINIMUM DISPLACEMENT
4HRESHOLD SETTING )MPROPER THRESHOLD SETTING CAUSES IMPROPER #HECK AND ADJUST THRESHOLD SETTING
MOTOR DISPLACEMENT FOR TORQUE REQUIRED
)NTERNAL LEAKAGE %XCESS INTERNAL LEAKAGE CAUSES CHARGE PRESSURE )NSTALL LOOP mUSHING DEFEAT OPTION AND MONITOR CASE
TO DECAY REDUCING OUTPUT TORQUE mOW )F CASE mOW IS EXCESSIVE MOTOR MAY REQUIRE
MAJOR REPAIR #ONTACT YOUR 3AUER $ANFOSS 3ERVICE
0ROVIDER
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Travel motor 10.2
Service Manual
!DJUSTMENTS
OVERVIEW !DJUST COMPONENTS OF THE 3ERIES AND 3ERIES MOTORS PER FOLLOWING PROCEDURES
WHERE NECESSARY REFER TO Pressure Measurement PAGES 4 FOR GAUGE PORT LOCATIONS
AND SIZES

3ET THE CHARGE PRESSURE RELIEF VALVE TO THE MODEL ORDER CODE SPECIlCATIONS )N MOST
 7!2.).' APPLICATIONS THE MOTOR CHARGE RELIEF VALVE IS SET TO BAR ; TO PSI= below the setting
4HIS SERVICE PROCEDURE of the pump charge relief valve MEASURED WITH THE PUMP IN ITS NEUTRAL OR ZERO ANGLE
MAY REQUIRE DISABLING THE POSITION 4HIS SETTING ASSUMES A RESERVOIR TEMPERATURE OF ² # ;² &= #HARGE PRESSURE
VEHICLE MACHINE RAISING IS REFERENCED ADDITIVE TO CASE PRESSURE
THE WHEELS OFF THE GROUND
DISCONNECTING THE WORK Measuring charge pressure
FUNCTION AND SO FORTH )NSTALL A TO BAR ; TO PSI= Series 51 charge pressure relief valve
WHILE PERFORMING IN ORDER PRESSURE GAUGE IN PORT - OR - Adjustment
TO PREVENT INJURY TO THE USE WHICH EVER IS AT low LOOP plug
TECHNICIAN AND BYSTANDERS PRESSURE 1
1 /16
4AKE THE NECESSARY SAFETY lock nut
PRECAUTIONS )NSTALL A TO BAR ; TO PSI=
GAUGE IN PORT , OR , TO MEASURE
CASE PRESSURE
/PERATE THE SYSTEM WITH THE PRIME

MOVER AT NORMAL OPERATING SPEED
P101 208E
AND THE PUMP AT HALF STROKE FORWARD
OR REVERSE
/LDER 3ERIES AND 3ERIES MOTORS MAY BE EQUIPPED WITH AN EXTERNAL SCREW
ADJUSTABLE CHARGE PRESSURE RELIEF VALVE NOT SHOWN
11008567 s 2EV !% s .OVEMBER 31

008 916 41 BOMAG 595
10.2 Travel motor
Service Manual
!DJUSTMENTS
OVERVIEW (continued) Adjusting charge pressure

,OOSEN THE LOCK NUT USING A 1 HEX WRENCH
4URN THE ADJUSTMENT PLUG WITH A LARGE SCREWDRIVER OR MM HEX WRENCH
 7!2.).'
)NCORRECT CHARGE PRESSURE #LOCKWISE ROTATION OF THE PLUG INCREASES THE SETTING AND COUNTERCLOCKWISE ROTATION
SETTINGS MAY RESULT IN THE DECREASES THE SETTING4HE CHARGE PRESSURE SETTING WILL BE REDUCED OR INCREASED AT A RATE
INABILITY TO BUILD REQUIRED OF APPROXIMATELY BAR ; PSI= PER TURN
SYSTEM PRESSURE AND OR
INADEQUATE LOOP mUSHING !FTER ADJUSTING THE PLUG TORQUE THE LOCKNUT TO .sM ; LBFsFT= $O NOT OVERTORQUE
mOWS9OU MUST MAINTAIN
THE CORRECT CHARGE PRESSURE 2EMOVE THE GAUGES
UNDER ALL OPERATION
CONDITIONS TO MAINTAIN 2EINSTALL THE PORT PLUGS
PUMP PERFORMANCE
-OTORS WITH LOOP mUSHING DEFEATED OR EQUIPPED WITH AN ORIlCED CHARGE PRESSURE RELIEF
valve SEE charge relief valve, orificed style ON PAGE DO NOT REQUIRE ADJUSTMENT
Series 51-1 charge pressure relief valve

11/16 inch
t]
Adjustment plug
0 %
32 11008567 s 2EV !% s .OVEMBER
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Travel motor 10.2
Service Manual
!DJUSTMENTS
MINIMUM 4HE FACTORY SETS MINIMUM DISPLACEMENT ! TAMPER RESISTANT CAP COVERS THE ADJUSTMENT
DISPLACEMENT LIMITER SCREW
 Caution
4O AVOID UNEXPECTED CHANGES IN OPERATING CONDITIONS AND TO PREVENT EXTERNAL LEAKAGE
TORQUE THE LOCK NUT 9 AFTER every ADJUSTMENT
$ETECT CHANGES IN MOTOR DISPLACEMENT BY PROVIDING A CONSTANT mOW OF mUID TO THE

MOTOR WHILE MAINTAINING THE MOTOR AT MINIMUM DISPLACEMENT AND MONITORING THE
MOTOR OUTPUT SHAFT SPEED !N INCREASE IN DISPLACEMENT WILL RESULT IN A DECREASE IN SHAFT
SPEED WHILE A DECREASE IN DISPLACEMENT WILL RESULT IN AN INCREASE IN SHAFT SPEED
 7!2.).' Adjusting minimum displacement

!DJUSTMENT OF THE 2EMOVE THE TAMPER RESISTANT CAP 1 FROM THE ADJUSTING SCREW 9 2EMOVING
MINIMUM DISPLACEMENT THE TAMPER RESISTANT CAP DESTROYS THE LOCKING DEVICE
LIMITER CAN RESULT IN
UNDESIRABLE OR UNSAFE $ISCARD THE CAP 1 AFTER COMPARING IT WITH A NEW ONE TO MAKE SURE THE NEW ONE
SPEED CONDITIONS lTS
#ONSULT WITH THE /RIGINAL
%QUIPMENT -ANUFACTURER Minimum displacement limiter
OR YOUR 3AUER $ANFOSS Q120
REPRESENTATIVE BEFORE Tamper
CHANGING THE MINIMUM resistant
Y20
cap
DISPLACEMENT SETTING
!FTER ADJUSTMENT VERIFY Y10
SETTING BY USING AN
APPROPRIATE TEST APPARATUS
P101216E
(OLD ADJUSTING SCREW 9 USING A MM OR MM INTERNAL HEX WRENCH
,OOSEN THE SEALING LOCK NUT 9 USING A

• MM HEX WRENCH FOR CMÃ AND CMÃ FRAME SIZE MOTORS
or
• MM HEX WRENCH FOR CMÃ CMÃ AND CMÃ FRAME SIZE MOTORS
11008567 s 2EV !% s .OVEMBER 33

008 916 41 BOMAG 597
10.2 Travel motor
Service Manual
!DJUSTMENTS
MINIMUM 4URN THE ADJUSTMENT SCREW 9 FOR THE DESIRED DISPLACEMENT FOLLOWING THE TABLE
DISPLACEMENT LIMITER WITH A
(continued) • MM HEX WRENCH FOR CMÃ AND CMÃ FRAME SIZE MOTORS
or
• MM HEX WRENCH FOR CMÃ CMÃ AND CMÃ FRAME SIZE MOTORS
2OTATING THE ADJUSTMENT SCREW CLOCKWISE INCREASES THE MINIMUM DISPLACEMENT OF THE
MOTOR ROTATING THE ADJUSTMENT SCREW COUNTERCLOCKWISE DECREASES IT
4HE MINIMUM DISPLACEMENT SETTING CHANGES SEE CHART FOR EACH FULL REVOLUTION OF THE
ADJUSTMENT SCREW -AJOR CHANGES IN MINIMUM DISPLACEMENT SETTING MAY REQUIRE A
DIFFERENT SIZE ADJUSTMENT SCREW
Adjustment screw and displacement

Approximate change in minimum
Frame Minimum displacement Screw size and length displacement per revolution of
size range cm³ [in3] mm [in] adjusting screw
cm³/rev [in3/rev]
; = - X ;=
;=
; = - X ;=
; = - X ;=
;=
; = - X ;=
; = - X ;=
;=
; = - X ;=
; = - X ;=
;=
; = - X ;=
; = - X ;=
; = - X ;= ;=
; = - X ;=
C #AUTION !FTER ADJUSTMENT TORQUE THE LOCK NUT ON THE ADJUSTMENT SCREW TO
$O NOT OVERTORQUE LOCKNUT • .sM ; LBFsFT= FOR CMÃ AND CMÃ MOTORS
or
• .sM ; LBFsFT= FOR CMÃ CMÃ AND CMÃ MOTORS
)NSTALL A NEW TAMPER RESISTANT CAP
34 11008567 s 2EV !% s .OVEMBER
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Travel motor 10.2
Service Manual
!DJUSTMENTS
MAXIMUM ,IMIT THE MAXIMUM DISPLACEMENT BY SETTING THE STROKE OF THE SERVO PISTON ! STOP SCREW
DISPLACEMENT LIMITER AND SPACER IS ON THE SERVO PISTON TO LIMIT THE MAXIMUM DISPLACEMENT OF THE MOTOR TO
LESS THAN 3PACERS ARE AVAILABLE IN INCREMENTS
 7!2.).' ,IMIT THE DISPLACEMENT BY USING SPACERS ON THE DISPLACEMENT STOP SCREW7HEN
!DJUSTING THE MAXIMUM CHANGING THE MAXIMUM DISPLACEMENT YOU MAY NEED A DIFFERENT LENGTH SCREW TO
DISPLACEMENT LIMITER CAN ACCOMMODATE THE ALTERNATE SPACERS
RESULT IN UNDESIRABLE OR
UNSAFE SPEED CONDITIONS $ETECT CHANGES IN MOTOR DISPLACEMENT BY PROVIDING A CONSTANT mOW OF mUID TO THE
#ONSULT WITH THE /RIGINAL MOTOR WHILE MAINTAINING THE MOTOR AT MAXIMUM DISPLACEMENT AND MONITORING THE
%QUIPMENT -ANUFACTURER MOTOR OUTPUT SHAFT SPEED
OR YOUR 3AUER $ANFOSS
REPRESENTATIVE BEFORE !N INCREASE IN DISPLACEMENT RESULTS IN A DECREASE IN SHAFT SPEED ! DECREASE IN
CHANGING THE MAXIMUM DISPLACEMENT RESULTS IN AN INCREASE IN SHAFT SPEED
DISPLACEMENT SETTING
Series 51 motors Series 51 Maximum displacement limiter

2EMOVE THE SCREWS ' RETAINING G24 G24
THE SERVO COVER ' USING F10* G24
• AN MM HEX WRENCH CMÃ
CMÃ CMÃ AND CMÃ F20* G24
G260
MOTORS
OR G36
• A MM HEX WRENCH CMÃ
G100
MOTORS
2EMOVE THE SERVO COVER ' AND

/ RINGS ' AND '
P101 223E
2EMOVE THE DISPLACEMENT LIMITER
SCREW & AND SPACER & IF USED
WITH A MM HEX WRENCH FOR CMÃ CMÃ CMÃ CMÃ AND CMÃ MOTORS
3AVE ORIGINAL SPACER REPLACING EACH WITH THE APPROPRIATE SPACER AND SCREW TO
ACHIEVE THE DESIRED MAXIMUM DISPLACEMENT 3EE THE chart on the next page
Series 51-1 Maximum displacement limiter Series 51-1 motors

M16 2EMOVE THE SCREWS -
RETAINING THE CONTROL ASSEMBLY USING
F10* M16 AN MM HEX WRENCH
F20*
2EMOVE THE CONTROL ASSEMBLY
Control
G36 2EMOVE INTERFACE ' AND / RINGS
' OR SEAL PLATE
or
G42
!DD APPROPRIATE SPACER &
AND SCREW TO ACHIEVE THE DESIRED
DISPLACEMENT SEE chart below
P101 222E
11008567 s 2EV !% s .OVEMBER 35

008 916 41 BOMAG 599
10.2 Travel motor
Service Manual
!DJUSTMENTS
MAXIMUM 5SING A LONGER SPACER DECREASES THE MAXIMUM DISPLACEMENT 5SING A SHORTER SPACER
DISPLACEMENT LIMITER INCREASES MAXIMUM DISPLACEMENT
(continued)
4ORQUE DISPLACEMENT LIMITER SCREW & TO
• .sM ; LBFsFT= FOR THE CMÃ AND CMÃ MOTORS
• .sM ; LBFsFT= FOR THE CMÃ MOTOR
 Caution
$O NOT OVERTORQUE SCREWS
Maximum displacement screw (F10) and spacer (F20)

% of full F10=screw
60 cm³ 80cm³ 110cm³ 160cm³ 250cm³
disp. F20=spacer
&. - X - X - X - X - X
&! & X - X - X - X - X

&! MM MM MM MM MM
&" - X - X - X - X - X

&" MM MM MM MM MM
&# - X - X - X - X - X
85
&# MM MM MM MM MM
&$ - X - X - X - X - X

&$ MM MM MM MM MM
&% M8 x 35 - X - X - X - X

&% MM MM MM MM MM
&& - X - X - X - X - X

&& MM MM MM MM MM
&' - X - X - X - X - X

&' MM MM MM MM MM
2EPLACE ALL / RINGS OR SEAL PLATE $O NOT DISCARD ANY / RING UNTIL YOU ARE CERTAIN THAT
YOU HAVE THE CORRECT REPLACEMENT
)NSTALL THE 3ERIES MINIMUM ANGLE SERVO COVER OR 3ERIES CONTROL
)NSTALL THE SERVO COVER ' OR CONTROL SCREWS -
4ORQUE THE SERVO COVER CONTROL SCREWS - TO

• .sM ; LBFsFT= FOR CMÃ CMÃ CMÃ AND CMÃ MOTORS USING AN MM
HEX WRENCH
• .sM ; LBFsFT= FOR CMÃ MOTOR USING A MM HEX WRENCH
 Caution
36 11008567 s 2EV !% s .OVEMBER
600 BOMAG 008 916 41

Travel motor 10.2
Service Manual
!DJUSTMENTS
SPEED SENSOR DIN and SAE flange units

INSTALLATION AND ,OOSEN LOCKNUT
ADJUSTMENT
+EEP ALL OLD PARTS UNTIL YOU RECEIVE AND INVENTORY NEW PARTS
Speed sensor installation

Speed sensor
4 pin turck
Air gap to be 1.52 [0.060] max.
(Approx. 1/2-1 turn of thread)
M12x1D6G thread
Keyway ref. Pin 1

16.2 power +
Pin 2
[0.64]
50.8 direction
[2.00]
61.2 Pin 4
[2.41]
Pin 3
Speed speed ground
ring
P101334E
12.7 [0.50]
flats
0USH THE / RING TOWARD CONNECTOR END OF SENSOR UNIT SO THAT THE / RING DOES NOT
CONTACT MOTOR HOUSING DURING STEP
Speed sensor with Turck connector Speed sensor with Packard connector
Shaft
centerline
1/2 inch
wrench flats
22°
22°
P101332Erev
Shaft
centerline 1/2 inch
wrench flats
22°
22°
11008567 s 2EV !% s .OVEMBER 37

008 916 41 BOMAG 601
10.2 Travel motor
Service Manual
!DJUSTMENTS
INSTALLATION 4HREAD SENSOR #7 INTO MOTOR HOUSING BY HAND UNTIL BOTTOM END TOUCHES THE
AND ADJUSTMENT SPEED RING
(continued)
"ACK OUT ##7 TURN
#ONTINUE BACKING OUT UNTIL THE mATS ARE ² EITHER SIDE OF THE MOTOR SHAFT CENTER LINE
² TO ² IS ACMÃEPTABLE
(OLD SENSOR WITH A INCH WRENCH TORQUE THE LOCKNUT USING AN INCH WRENCH
TO .sM ; LBFsFT=
 Caution
$O NOT OVERTORQUE LOCKNUT
Cartridge units
,OOSEN LOCKNUT
0USH / RING TOWARD CONNECTOR END OF SENSOR UNIT SO THAT THE / RING DOES NOT CONTACT
MOTOR HOUSING DURING STEP
4HREAD SENSOR #7 INTO MOTOR HOUSING BY HAND UNTIL BOTTOM END TOUCHES THE SPEED
RING
"ACK OUT ##7 TURNS
4URN IN OR OUT WHICHEVER IS CLOSEST UNTIL THE ORIENTATION NOTCH IS ² AWAY FROM
HOUSING
(OLD SENSOR WITH A INCH WRENCH TORQUE THE LOCKNUT USING AN INCH WRENCH
TO .sM ; LBFsFT=
 Caution
Cartridge model speed sensor
Orientation
NOTCH IN
;=
;=
FLATS
5.& ! THREAD

3PEED RING
Orientation !IR GAP TO BE
NOTCH MM ; IN=
MAX APPROXIMATE
3PEED SENSOR TURN OF THREAD 0 %
38 11008567 s 2EV !% s .OVEMBER
602 BOMAG 008 916 41

Travel motor 10.2
Service Manual
-INOR REPAIR
SHAFT SEAL SAE and DIN flanged motors

REPLACEMENT Disassembly
4HOROUGHLY CLEAN ALL EXTERNAL SURFACES BEFORE DISASSEMBLY
Internal parts of the shaft seal

L70
L35
L40
L50
0
2EMOVE THE SCREWS , RETAINING THE mANGE TO THE MOTOR HOUSING USING A
• MM HEX WRENCH FOR CMÃ AND CMÃ MOTORS
• MM HEX WRENCH FOR CMÃ MOTORS
2EMOVE THE mANGE , FROM THE MOTOR HOUSING USING AN APPROPRIATE PULLER
0RESS OUT THE SHAFT SEAL , FROM THE mANGE FRONT SIDE
Inspection
)NSPECT THE SHAFT SEAL CAVITY IN THE mANGE
)NSPECT THE SEALING AREA ON THE SHAFT FOR WEAR
Reassembly
/RIENT THE NEW SHAFT SEAL , WITH THE CUPPED SIDE FACING TOWARDS THE MOTOR SHAFT
BEARINGS
0RESS THE SHAFT SEAL , INTO THE mANGE FROM THE REAR SIDE 0RESS UNTIL THE SHAFT SEAL
BOTTOMS OUT IN THE CAVITY
2EMOVE THE / RING ,
$ISCARD THE / RING AFTER MAKING CERTAIN THAT YOU HAVE A CORRECT REPLACEMENT
11008567 s 2EV !% s .OVEMBER 39

008 916 41 BOMAG 603
10.2 Travel motor
Service Manual
-INOR REPAIR
SHAFT SEAL ,UBRICATE WITH PETROLEUM JELLY AND INSTALL NEW / RING , TO THE GROOVE IN THE
REPLACEMENT mANGE
(continued)
)NSTALL THE mANGE , TO THE HOUSING USING A SEAL PROTECTION SLEEVE ON THE SHAFT
)NSTALL THE SOCKET HEAD CAPSCREWS ,
4IGHTEN THE SOCKET HEAD CAPSCREWS , SLOWLY IN A CRISSCROSS PATTERN UNTIL THE
mANGE IS PULLED FULLY DOWN ONTO THE HOUSING
4ORQUE THE CAPSCREWS USING A CRISSCROSS PATTERN TO

• .sM ; LBFsFT= FOR CMÃ AND CMÃ MOTORS USING AN MM WRENCH
• .sM ; LBFsFT= FOR CMÃ MOTORS USING A MM WRENCH
 Caution
$O NOT OVERTORQUE CAPSCREWS
2EMOVE THE SHAFT PROTECTION SLEEVE
40 11008567 s 2EV !% s .OVEMBER
604 BOMAG 008 916 41

Travel motor 10.2
Service Manual
-INOR REPAIR
SHAFT SEAL Cartridge flanged motors

REPLACEMENT Disassembly
(continued) 4HOROUGHLY CLEAN ALL EXTERNAL SURFACES BEFORE DISASSEMBLY
2EMOVE THE SEAL CARRIER SNAP RING , FROM THE MOTOR HOUSING USING APPROPRIATE
SNAP RING PLIERS
#AREFULLY PULL THE SEAL CARRIER , FROM THE HOUSING
 Caution
$O NOT DAMAGE THE HOUSING BORE OR SHAFT
2EMOVE THE / RING ,# FROM THE HOUSING BORE
$ISCARD THE / RING ,# AFTER INSPECTING THE NEW ONE TO MAKE CERTAIN THAT IT lTS
#AREFULLY PRESS THE SHAFT SEAL , FROM THE SEAL CARRIER
$ISCARD THE SHAFT SEAL , FROM THE SEAL CARRIER , AFTER MAKING CERTAIN THAT THE
NEW ONE lTS
 Caution
$O NOT DAMAGE THE SEAL CARRIER DURING REMOVAL
Inspection
)NSPECT THE SEAL CARRIER , AND HOUSING BORE FOR DAMAGE
)NSPECT THE SEALING AREA ON THE SHAFT FOR WEAR
Common parts of a cartridge flanged motor L80
L75
L40
L50
L40
Shaft seal
L75 Seal carrier
P101225
11008567 s 2EV !% s .OVEMBER 41

008 916 41 BOMAG 605
10.2 Travel motor
Service Manual
-INOR REPAIR
SHAFT SEAL Reassembl;y

REPLACEMENT /RIENT THE NEW SHAFT SEAL , SO THE CUPPED SIDE FACES INWARD
(continued)
0RESS NEW SHAFT SEAL , INTO THE SEAL CARRIER ,
0RESS UNTIL THE SHAFT SEAL BOTTOMS OUT IN THE CAVITY
5SING PETROLEUM JELLY TO LUBRICATE INSTALL NEW / RING , TO THE GROOVE IN THE
HOUSING BORE
5SING A SEAL PROTECTION SLEEVE ON THE SHAFT PUSH THE SEAL CARRIER , INTO THE
HOUSING BORE UNTIL IT CLEARS THE SNAP RING GROOVE
)NSTALL SNAP RING , INTO THE GROVE IN THE HOUSING BORE USING THE APPROPRIATE SNAP
RING PLIERS
2EMOVE THE SHAFT SEAL PROTECTION SLEEVE
LOOP FLUSHING Disassembly

SHUTTLE VALVE 4HOROUGHLY CLEAN ALL EXTERNAL SURFACES BEFORE DISASSEMBLY
5SING AN INCH HEX WRENCH REMOVE THE TWO HEX PLUGS ' FROM THE ENDCAP
2EMOVE THE / RINGS '! FROM THE HEX PLUGS
Common parts of loop flushing shuttle valve
G20
G20A
K14
K16
K18
K16
G20A
G20
K14
P101226
Legend for G20

h USE AN INCH WRENCH
t .sM ; LBFsFT=
42 11008567 s 2EV !% s .OVEMBER
606 BOMAG 008 916 41

Travel motor 10.2
Service Manual
-INOR REPAIR
LOOP FLUSHING $ISCARD THE / RINGS '! AFTER INSPECTING THE NEW ONES TO MAKE CERTAIN THEY lT
SHUTTLE VALVE
(continued) 2EMOVE THE SPRINGS + AND SEATS + OR SPRING SEAT ASSEMBLY FROM THE CAVITY
2EMOVE THE SPOOL + FROM THE CAVITY
Inspection
)NSPECT THE SPOOL + AND CAVITY FOR WEAR OR DAMAGE
#LEAN THE SPOOL AND CAVITY
Reassembly
!AFTER MAKING CERTAIN THAT YOU HAVE THE EXACT REPLACEMENT PARTS REPLACE PARTS AS
NECESSARY
)NSTALL THE SPRING SEAT + OR SPRINGSEAT ASSEMBLY TO ONE END OF THE SPOOL
,UBRICATE THE SPOOL WITH CLEAN HYDRAULIC OIL
3LIDE THE LUBRICATED SPOOL INTO THE CAVITY
)NSTALL THE OTHER SPRING SEAT + OR SPRINGSEAT ASSEMBLY TO THE SPOOL FROM THE
OPPOSITE END
)NSTALL NEW / RINGS '! TO THE HEX PLUGS '
0LACE THE + SPRINGS IN TO THE HEX PLUGS
)NSTALL THE HEX PLUGS
4ORQUE THE HEX PLUGS TO .sM ; LBFsFT= USING AN HEX WRENCH
 Caution
$O NOT OVERTORQUE HEX PLUGS
11008567 s 2EV !% s .OVEMBER 43

008 916 41 BOMAG 607
10.2 Travel motor
Service Manual
-INOR REPAIR
CHARGE RELIEF VALVE Overview

9OU MAY USE ONE OF TWO CHARGE RELIEF VALVES ON 3ERIES AND 3ERIES MOTORS EITHER
POPPET OR ORIlCED !LTERNATIVELY A DEFEAT PLUG MAY BLOCK THE CHARGE RELIEF VALVE CAVITY
Poppet style (older production)

Disassembly
,OOSEN THE LOCKNUT + USING A 1 HEX WRENCH
5NSCREW THE ADJUSTMENT SCREW + FROM THE CAVITY IN THE ENDCAP USING A STANDARD
SCREWDRIVER OR A MM WRENCH
2EMOVE THE / RING + FROM THE ADJUSTMENT SCREW
$ISCARD THE / RING + AFTER INSPECTING THE NEW ONE TO MAKE CERTAIN THAT IT lTS
2EMOVE THE SPRING + AND POPPET + FROM THE CAVITY
Inspection
)NSPECT THE PARTS AND CAVITY FOR WEAR OR DAMAGE
#LEAN THE CAVITY
Reassembly
2EPLACE ANY DAMAGED OR WORN PART MAKING CERTAIN THAT YOU HAVE THE EXACT
REPLACEMENT PARTS BEFORE DISCARDING THE WORN PARTS
)NSTALL THE POPPET + TO THE CAVITY

Poppet charge relief valve
)NSTALL THE SPRING + TO THE POPPET K90
)NSTALL A NEW / RING + TO THE K10

ADJUSTMENT SCREW +
K70
)NSTALL THE ADJUSTMENT SCREW IN THE K80
CAVITY
K50
(AND TIGHTEN THE LOCKNUT +
#HECK AND ADJUST THE CHARGE RELIEF

VALVE TO THE PROPER SETTING
P101 227
44 11008567 s 2EV !% s .OVEMBER
608 BOMAG 008 916 41

Travel motor 10.2
Service Manual
-INOR REPAIR
CHARGE RELIEF VALVE Orificed style

(continued) Disassembly
2EMOVE CARTRIDGE + FROM THE CAVITY IN THE ENDCAP USING A INCH HEX WRENCH
2EMOVE / RING + FROM THE CARTRIDGE
$ISCARD / RING AFTER INSPECTING THE NEW ONE TO MAKE CERTAIN THAT IT lTS
$ISASSEMBLE CARTRIDGE + USING INCH AND INCH HEX WRENCHES
2EMOVE PLUG +
2EMOVE / RING +! Orificed charge relief valve

K95
$ISCARD THE / RING AFTER INSPECTING
THE NEW ONE TO MAKE CERTAIN THAT IT K95A
lTS K70
K000
K80
2EMOVE SPRING + K10
2EMOVE POPPET +

K50
Inspection
)NSPECT THE CAVITY AND PARTS FOR WEAR
OR DAMAGE
P101 227
#LEAN THE CAVITY AND PARTS
Reassembly
2EPLACE PARTS AS NECESSARY AFTER INSPECTING THE NEW ONE TO MAKE CERTAIN THAT EACH
lTS
$ISCARD REPLACED PARTS
)NSTALL / RINGS + +! TO PLUGS + +
2EASSEMBLE THE CARTRIDGE
4ORQUE PLUG + TO .sM ; LBFsFT= USING AN HEX WRENCH
)NSTALL CARTRIDGE INTO THE CAVITY
4ORQUE CARTRIDGE TO .sM ; LBFsFT= USING A INCH HEX WRENCH
 Caution
$O NOT OVERTORQUE CARTRIDGE
11008567 s 2EV !% s .OVEMBER 45

008 916 41 BOMAG 609
10.2 Travel motor
Service Manual
-INOR REPAIR
CHARGE RELIEF VALVE Defeat plug

(continued) Disassembly
2EMOVE PLUG + FROM THE CAVITY IN THE ENDCAP USING A INCH WRENCH
2EMOVE / RING +! FROM THE PLUG
$ISCARD / RING +! AFTER INSPECTING THE NEW ONE TO MAKE CERTAIN THAT IT lTS
Inspection
#LEAN AND INSPECT THE CAVITY
Defeat plug
)NSPECT THE PLUG + K90
#LEAN OR REPLACE THE PLUG IF K90A

NECESSARY
Reassembly
)NSTALL A NEW / RING TO THE PLUG
)NSTALL THE PLUG INTO THE CAVITY

P101 227
4ORQUE PLUG + TO .sM ; LBFsFT= USING A INCH WRENCH
 Caution
$O NOT OVERTORQUE PLUG
46 11008567 s 2EV !% s .OVEMBER
610 BOMAG 008 916 41

Travel motor 10.2
Service Manual
-INOR REPAIR
MAXIMUM ANGLE Disassembly

STOP - SERIES 51 4HOROUGHLY CLEAN ALL EXTERNAL SURFACES BEFORE DISASSEMBLY
MOTORS
2EMOVE THE SCREWS ' RETAINING THE MINIMUM ANGLE SERVO COVER TO THE ENDCAP
USING
• AN MM HEX WRENCH FOR CMÃ CMÃ CMÃ AND CMÃ MOTORS
• A MM HEX WRENCH FOR CMÃ MOTOR
2EMOVE THE / RINGS ' AND '
$ISCARD THE / RINGS AFTER INSPECTING THE NEW ONES TO MAKE CERTAIN THAT THEY lT
2EMOVE THE MAXIMUM ANGLE STOP SCREW & FROM THE SERVO PISTON END USING
• AN MM INTERNAL HEX WRENCH FOR CMÃ MOTORS
• A MM INTERNAL HEX WRENCH FOR CMÃ CMÃ CMÃ AND CMÃ MOTORS
)F EQUIPPED REMOVE THE SPACER & FROM THE SERVO PISTON END
Inspection
)NSPECT ALL PARTS FOR WEAR OR DAMAGE 2EPLACE WORN OR DAMAGED PARTS
Legend
' for G24
I USE AN MM INTERNAL HEX WRENCH
t .sM ; LBFsFT= FOR CMÃ CMÃ CMÃ MOTORS
' for G24

I USE A MM INTERNAL HEX WRENCH
' t .sM ; LBFsFT= FOR CMÃ MOTORS

'
for F10
I USE AN MM INTERNAL HEX WRENCH
&
t .sM ; LBFsFT= FOR CMÃ MOTORS
& for F10
I USE A MM INTERNAL HEX WRENCH
t .sM ; LBFsFT= FOR CMÃ CMÃ CMÃ CMÃ
' MOTORS
0
Reassembly
)NSTALL THE STOP SCREW AND SPACER IF SO EQUIPPED TO THE SERVO PISTON END
4ORQUE THE STOP SCREW & TO

• .sM ; LBFsFT= FOR A CMÃ MOTOR USING AN MM INTERNAL HEX WRENCH
• .sM ; LBFsFT= FOR CMÃ CMÃ CMÃ AND CMÃ MOTORS USING A
MM INTERNAL HEX WRENCH
11008567 s 2EV !% s .OVEMBER 47

008 916 41 BOMAG 611
10.2 Travel motor
Service Manual
-INOR REPAIR
MAXIMUM ANGLE STOP - 5SING PETROLEUM JELLY TO RETAIN THEM INSTALL A NEW / RING ' AND ' TO THE END
SERIES 51 MOTORS CAP
(continued)
)NSTALL SERVO COVER TO ' THE ENDCAP
)NSTALL THE SCREWS ITEMS '
4ORQUE THE SCREWS ' TO

• .sM ; LBFsFT= FOR CMÃ CMÃ CMÃ AND CMÃ MOTORS USING AN MM
INTERNAL HEX WRENCH
• .sM ; LBFsFT= FOR CMÃ MOTORS USING A MM INTERNAL HEX WRENCH
 Caution
MAXIMUM ANGLE STOP - Disassembly

SERIES 51-1 MOTORS 2EMOVE THE SCREWS - RETAINING THE CONTROL ASSEMBLY USING AN MM INTERNAL
HEX WRENCH
2EMOVE THE CONTROL ASSEMBLY
Series 51-1 maximum displacement limiter

M16 Legend
&
F10* I USING AN MM INTERNAL HEX WRENCH
M16 t .sM ; LBFsFT= FOR CMÃ MOTORS
F20* &
I USING A MM INTERNAL HEX WRENCH
Control t .sM ; LBFsFT= FOR CMÃ AND CMÃ MOTORS
G36
&
or I USING A MM INTERNAL HEX WRENCH
G42 t .sM ; LBFsFT= FOR CMÃ CMÃ AND CMÃ
MOTORS
P101 222E
2EMOVE INTERFACE ' AND / RINGS ' OR SEAL PLATE
2EMOVE THE SCREW & AND SPACER & IF PRESENT USING

s AN MM INTERNAL HEX WRENCH FOR CMÃ MOTORS AND
s A MM INTERNAL HEX WRENCH FOR CMÃ AND CMÃ MOTORS
48 11008567 s 2EV !% s .OVEMBER
612 BOMAG 008 916 41

Travel motor 10.2
Service Manual
-INOR REPAIR
MAXIMUM ANGLE STOP - Inspection

SERIES 51-1 MOTORS )NSPECT FOR ANY CONTAMINANTS
(continued)
Reassembly
#LEAN THE ENDCAP AND SERVO PISTON AREA
2EPLACE THE SCREW & AND SPACER & IF THEY WERE PRESENT
4ORQUE DISPLACEMENT LIMITER SCREW & TO

• .sM ; LBFsFT= FOR THE CMÃ AND CMÃ MOTORS USING A MM HEX WRENCH
• .sM ; LBFsFT= FOR THE CMÃ MOTOR USING AN MM HEX WRENCH
 Caution
$O NOT OVERTORQUE SCREW
2EPLACE ALL / RINGS
$ISCARD ALL PREVIOUSLY USED / RINGS $O NOT DISCARD ANY / RINGS UNTIL YOU ARE CERTAIN
THAT YOU HAVE THE CORRECT REPLACEMENT
)NSTALL THE CONTROL
)NSTALL THE CONTROL SCREWS '
4ORQUE THE CONTROL SCREWS - TO .sM ; LBFsFT= USING AN MM HEX WRENCH
 Caution
$O NOT OVERTORQUE SCREW
11008567 s 2EV !% s .OVEMBER 49

008 916 41 BOMAG 613
10.2 Travel motor
Service Manual
-INOR REPAIR
MINIMUM ANGLE Disassembly

ADJUSTMENT SCREW 4HOROUGHLY CLEAN ALL EXTERNAL SURFACES BEFORE DISASSEMBLY
2EMOVE THE TAMPER RESISTANT CAP 1 COVERING THE ADJUSTMENT SCREW
$ISCARD THE CAP 2EMOVING THE CAP DESTROYS THE LOCKING DEVICE
 7!2.).' -EASURE THE LENGTH OF THE SCREW 9 TO ASSURE CORRECT REINSTALLATION
)MPROPER ADJUSTMENT
OF THE MINIMUM Minimum displacement limiter
DISPLACEMENT LIMITER CAN Q120
Tamper
RESULT IN UNDESIRABLE OR resistant
UNSAFE SPEED CONDITIONS Y20
cap
#ONSULT WITH THE ORIGINAL
Y10
EQUIPMENT MANUFACTURER
OR YOUR 3AUER $ANFOSS
REPRESENTATIVE BEFORE
CHANGING THE MINIMUM
DISPLACEMENT SETTING !FTER
ADJUSTMENT VERIFY THE
SETTING BY TESTING USING AN
APPROPRIATE TEST APPARATUS
P101216E
,OOSEN THE LOCKNUT 9 ON THE MINIMUM ANGLE ADJUSTMENT SCREW USING
• A MM HEX WRENCH FOR CMÃ AND CMÃ MOTORS
OR
• MM HEX WRENCH FOR CMÃ CMÃ AND CMÃ MOTORS
2EMOVE THE ADJUSTMENT SCREW 9

• USING A MM HEX WRENCH FOR CMÃ AND CMÃ FRAME SIZE MOTORS
OR
• MM HEX WRENCH FOR CMÃ CMÃ AND CMÃ MOTORS
Inspection
)NSPECT THE ADJUSTMENT SCREW
Reassembly
)NSTALL THE ADJUSTMENT SCREW TO THE MOTOR HOUSING
4URN THE ADJUSTMENT SCREW THE APPROPRIATE NUMBER OF REVOLUTIONS TO SET THE
APPROXIMATE DISPLACEMENT LIMIT OR PROPER LENGTH
50 11008567 s 2EV !% s .OVEMBER
614 BOMAG 008 916 41

Travel motor 10.2
Service Manual
-INOR REPAIR
MINIMUM ANGLE #HECK THE MINIMUM DISPLACEMENT AND RESET AS REQUIRED

ADJUSTMENT SCREW
(continued) 6ERIFY MINIMUM DISPLACEMENT SETTING BY TESTING EITHER ON AN APPROPRIATE TEST
APPARATUS OR IN THE VEHICLE
See Adjustments, ON PAGES 4
7HILE HOLDING THE ADJUSTMENT SCREW TORQUE THE SEAL LOCKNUT 9 TO
• .sM ; LBFsFT= FOR CMÃ AND CMÃ MOTORS USING A MM HEX WRENCH
OR
• .sM ; LBFsFT= FOR CMÃ CMÃ AND CMÃ MOTORS USING A MM HEX
WRENCH
 Caution
11008567 s 2EV !% s .OVEMBER 51

008 916 41 BOMAG 615
10.2 Travel motor
Service Manual
-INOR REPAIR
4-WAY VALVE AND 4-way valve disassembly

THRESHOLD SPRINGS 2EMOVE SCREWS - FROM THE CONTROL USING
• MM HEX WRENCH FOR CMÃ CMÃ CMÃ MOTORS
4-way valve and threshold springs expanded view

G110
U8**
(250)
T1** G110
T3**
G12 G30
T2**
G30 G36
U5**
G42
S10* S10 G90
(160, 250)
S20
S10*
G38
(060, 080
110) G38
G42
J30
M22
J10*
J20/S70
T7**
T8**
F32
F324
P101 240
52 11008567 s 2EV !% s .OVEMBER
616 BOMAG 008 916 41

Travel motor 10.2
Service Manual
-INOR REPAIR
4-WAY VALVE AND 2EMOVE THE CONTROL VALVE FROM THE ENDCAP
THRESHOLD SPRINGS
(continued) 2EMOVE THE INTERFACE / RINGS ' ' AND ' OR SEAL PLATE
$ISCARD THE / RINGS ONLY AFTER MAKING CERTAIN YOU HAVE THE CORRECT REPLACEMENTS
2EMOVE THE PLUGS ' AND ' COVERING ORIlCES 4 4 AND 4 USING A
• © INCH HEX WRENCH FOR ' PLUGS
• 18 INCH HEX WRENCH FOR ' PLUGS
2EMOVE THE / RINGS '! AND '! FROM PLUGS
$ISCARD THE / RINGS AFTER INSPECTING THE NEW ONE TO MAKE CERTAIN THAT IT lTS
2EMOVE THE ORIlCES 4 4 AND 4 USING A MM HEX WRENCH
4AG TO EACH ORIlCE RECORDING ITS LOCATION FOR REASSEMBLY
2EMOVE THE FOUR WAY SPOOL & FROM THE WAY VALVE SLEEVE
Inspection
)NSPECT ALL PARTS FOR WEAR OR DAMAGE 2EPLACE WORN OR DAMAGED PARTS
Reassembly
)NSTALL A MM SCREW INTO ONE OF THE THREADED HOLES IN THE SLEEVE
5SE THE SCREW TO PULL THE SLEEVE OUT OF THE CAVITY
2EMOVE THE / RINGS & FROM THE SLEEVE &
$ISCARD THE / RINGS & AFTER INSPECTING THE NEW ONES TO MAKE CERTAIN THAT THEY
lT
2EMOVE ORIlCES 4 AND 4 FROM THE SLEEVE & USING A MM INTERNAL HEX
WRENCH
11008567 s 2EV !% s .OVEMBER 53

008 916 41 BOMAG 617
10.2 Travel motor
Service Manual
-INOR REPAIR
4-WAY VALVE AND Threshold adjustment screw and springs disassembly

THRESHOLD SPRINGS 2EMOVE THRESHOLD SPRING GUIDE * FROM THE CAVITY
(continued)
2EMOVE THE THRESHOLD SPRINGS 3
2EMOVE THE THRESHOLD SPRING GUIDE *
Threshold springs
G12
G12A G30
G30A
T1 T3
T2
G30A
S10*
(160, 250)
S20
G30
J30
S10*
(060, 080
110)
J20
T7**
T8**
F32
F324
P101 240 0E!
)F PRESENT REMOVE THE RAMP SPRINGS 3
4HERE ARE RAMP SPRINGS AND INTERMEDIATE SPRING GUIDES IN CMÃ AND CMÃ MOTORS
2EMOVE THE INTERMEDIATE RAMP SPRING GUIDE 3 IF PRESENT 2EMOVE THE OTHER
SPRING IF PRESENT
2EMOVE THE BOTTOM SPRING GUIDE 3

54 11008567 s 2EV !% s .OVEMBER
618 BOMAG 008 916 41

Travel motor 10.2
Service Manual
-INOR REPAIR
4-WAY VALVE AND 4URN THE MOTOR OVER TO ACCESS THE THRESHOLD ADJUSTMENT SCREW *
THRESHOLD SPRINGS
(continued) ,OOSEN LOCKNUT * Adjustment screws and springs
Exploded view — common parts
,OOSEN THE MOUNTING SLEEVE *
J70
HOLDING THE THRESHOLD ADJUSTMENT
J60
SCREW * USING A MM WRENCH J50
5NSCREW THE THRESHOLD ADJUSTMENT J90

SCREW ASSEMBLY
J40
2EMOVE THE / RING * FROM
THRESHOLD ADJUSTMENT SCREW
$ISCARD THE / RING AFTER INSPECTING

THE NEW ONE TO MAKE CERTAIN THAT IT
lTS N1U5
U5**
Inspection G90
#LEAN ALL PARTS
S10* S10
S20
)NSPECT ALL PARTS S20
JS10*
2EPLACE ANY PART AS NECESSARY
DISCARDING OLD OR WORN PARTS ONLY
AFTER MAKING CERTAIN YOU HAVE THE J30
CORRECT REPLACEMENTS J10*
J20/S70
Reassembly
T7**
)NSTALL NEW / RING * ON THRESHOLD
T8**
ADJUSTMENT SCREW
)NSTALL THE MOUNTING SLEEVE *

WITH THE THRESHOLD ADJUSTMENT SCREW
F324
F32
3LIDE SCREW * THROUGH THE HOLE IN THE
P101 231
FEEDBACK FORK
4ORQUE THE MOUNTING SLEEVE TO

.sM ; LBFsFT= USING A MM
WRENCH
4URN THE MOTOR OVER TO ACCESS THE WAY VALVE CAVITY
5SING A MAGNETIC PROBE CAREFULLY INSTALL THE RAMP SPRING GUIDE 3 IF PRESENT INTO
THE CAVITY
3LIDE GUIDE 3 INTO THE END OF THE THRESHOLD ADJUSTING SCREW
11008567 s 2EV !% s .OVEMBER 55

008 916 41 BOMAG 619
10.2 Travel motor
Service Manual
-INOR REPAIR
4-WAY VALVE AND )NSTALL THE RAMP SPRING 3 INTO THE CAVITY SITTING IT PROPERLY ON THE SPRING GUIDE
THRESHOLD SPRINGS 3 )NSTALL THE INTERMEDIATE SPRING GUIDE AND SECOND RAMP SPRING 3 INTO THE
(continued) CMÃ AND CMÃ UNITS
Ramp spring guide location
#AREFULLY INSTALL THE THRESHOLD SPRING J70
GUIDE * ON TO THE END OF THE J60
THRESHOLD ADJUSTING SCREW * USING J50
A MAGNETIC PROBE
J90
4HE GUIDE MUST SIT IN THE HOLE IN THE
THRESHOLD ADJUSTING SCREW * J40
)NSTALL THE THRESHOLD SPRING * ON

TO THE SPRING GUIDE *
)NSTALL THE REMAINING SPRING GUIDE S10* S10

* ON TO THE END OF THE RAMP
THRESHOLD SPRING 3 USING A S20
MAGNETIC PROBE S10*
J30
S10*
J20 P101 231
56 11008567 s 2EV !% s .OVEMBER
620 BOMAG 008 916 41

Travel motor 10.2
Service Manual
-INOR REPAIR
4-WAY VALVE AND Assembling the 4-way valve

THRESHOLD SPRINGS 5SING THE DIAGRAM OF ORIENTATION THAT YOU PREPARED WHEN DISASSEMBLING REASSEMBLE THE
(continued) WAY VALVE ACCORDINGLY PUTTING THE PARTS IN THE MARKED PLACES ON THE WAY VALVE IN
THAT ORDER
)NSTALL ORIlCES 4 AND 4 IN APPROPRIATE CAVITIES IN THE WAY VALVE SLEEVE USING A
MM HEX WRENCH
 Caution 4ORQUE THE ORIlCES TO .sM ; LBFsFT=

$O NOT OVERTORQUE ORIlCES
Assembly orientation
' '
'!
'!
4
4
4
5
3 3 '!

'

' '
3 '
3

* '
'
*
'
*3
4 -
4
&
&
0
Legend for T7/T8
I USE A MM HEX
WRENCH
FOR CMÃ CMÃ CMÃ CMÃ CMÃ MOTORS
t
t .sM ; LBFsFT=
11008567 s 2EV !% s .OVEMBER 57

008 916 41 BOMAG 621
10.2 Travel motor
Service Manual
-INOR REPAIR
4-WAY VALVE AND Assembling the 4-way valve (continued)

THRESHOLD SPRINGS )NSTALL NEW / RINGS & ON TO THE WAY VALVE SLEEVE &
(continued)
,UBRICATE THE SLEEVE AND / RINGS WITH CLEAN HYDRAULIC OIL
Assembly orientation
' '
'!
'!
4
4
4
5
3 3 '!

'

' '
3 '
3

* '
'
*
'
*3
4 -
Legend for T1, T2, T3
4 I USE A MM HEX WRENCH
FOR CMÃ CMÃ CMÃ CMÃ
t CMÃ MOTORS
t
t .sM ; LBFsFT=
&
&
0
0USH THE SLEEVE & INTO THE CAVITY
,UBRICATE THE WAY SPOOL WITH CLEAN HYDRAULIC OIL
)NSTALL THE WAY SPOOL IN THE CAVITY OF THE SLEEVE
)NSTALL ORIlCES 4 4 AND 4 IN THE APPROPRIATE CAVITIES
58 11008567 s 2EV !% s .OVEMBER
622 BOMAG 008 916 41

Travel motor 10.2
Service Manual
-INOR REPAIR
4-WAY VALVE AND Assembling the 4-way valve (continued)

THRESHOLD SPRINGS 4ORQUE THE 4 4 AND 4 ORIlCES TO .sM ; LBFsFT= USING A MM HEX WRENCH
(continued)
)NSTALL NEW RINGS '! AND '! ON THE CAVITY PLUGS ' AND '
)NSTALL THE CAVITY PLUGS IN THE ORIlCE CAVITIES
4ORQUE THE CAVITY PLUGS ' TO .sM ; LBFsFT= USING A © INCH HEX WRENCH
4ORQUE THE CAVITY PLUGS ' TO .sM ; LBFsFT= USING A 18 INCH WRENCH
5SING PETROLEUM JELLY TO RETAIN IT INSTALL A NEW INTERFACE / RING '
5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW INTERFACE / RINGS ' AND '
)NSTALL THE MOTOR CONTROL ANDOR MULTIFUNCTION BLOCK
)NSTALL THE SCREWS -
4ORQUE THE SCREWS

• .sM ; LBFsFT= USING A MM INTERNAL HEX WRENCH FOR CMÃ CMÃ
CMÃ MOTORS
• .sM ; LBFsFT= USING A MM INTERNAL HEX WRENCH FOR CMÃ AND CMÃ
MOTORS
 Caution
11008567 s 2EV !% s .OVEMBER 59

008 916 41 BOMAG 623
10.2 Travel motor
Our Products Sauer-Danfoss Mobile Power and Control Systems

/PEN CIRCUIT AXIAL PISTON PUMPS
'EAR PUMPS AND MOTORS SYSTEMS TO THE GLOBAL MOBILE MARKET
&AN DRIVE SYSTEMS
#LOSED CIRCUIT AXIAL PISTON PUMPS BUILDING MATERIAL HANDLING MUNICIPAL FORESTRY TURF CARE AND MANY
AND MOTORS OTHERS
"ENT AXIS MOTORS
7E OFFER OUR CUSTOMERS OPTIMUM SOLUTIONS FOR THEIR NEEDS AND
(YDROSTATIC TRANSMISSIONS DEVELOP NEW PRODUCTS AND SYSTEMS IN CLOSE COOPERATION AND
PARTNERSHIP WITH THEM
4RANSIT MIXER DRIVES
(YDROSTATIC TRANSAXLES 3AUER $ANFOSS SPECIALIZES IN INTEGRATING A FULL RANGE OF SYSTEM
COMPONENTS TO PROVIDE VEHICLE DESIGNERS WITH THE MOST ADVANCED
%LECTROHYDRAULICS
TOTAL SYSTEM DESIGN
)NTEGRATED SYSTEMS
3AUER $ANFOSS PROVIDES COMPREHENSIVE WORLDWIDE SERVICE FOR ITS
PRODUCTS THROUGH AN EXTENSIVE NETWORK OF 'LOBAL 3ERVICE 0ARTNERS
0,53 » '5)$% STRATEGICALLY LOCATED IN ALL PARTS OF THE WORLD
$ISPLAYS
*OYSTICKS AND CONTROL HANDLES ,OCAL ADDRESS
Sensors
/RBITAL MOTORS
Inverters
(YDRAULIC INTEGRATED CIRCUITS ()# 3AUER $ANFOSS 53 #OMPANY 3AUER $ANFOSS !P3
%AST TH 3TREET $+ .ORDBORG $ENMARK
#ARTRIDGE VALVES !MES )! 53! 0HONE
$IRECTIONAL SPOOL VALVES 0HONE &AX
&AX
0ROPORTIONAL VALVES 3AUER $ANFOSS 'MB( #O /('
3AUER $ANFOSS $AIKIN ,4$
3HIN /SAKA 4%2!3!+) RD "LDG&
0OSTFACH $ .EUMünster .ISHIMIYAHARA 9ODOGAWA KU
+ROKAMP $ .EUMüNSTER 'ERMANY /SAKA *APAN
0HONE 0HONE
&AX &AX
WWWSAUER DANFOSSCOM
11008567 s 2EV !% s .OVEMBER
624 BOMAG 008 916 41

Travel motor 10.2
Series 51 and 51-1

Bent Axis Motors
Repair Instructions
008 916 41 BOMAG 625

10.2 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
2EVISIONS

*ANUARY - First edition AA
&RONT COVER ILLUSTRATIONS & 0%
2 11009449 s 2EV !! s *ANUARY
626 BOMAG 008 916 41

Travel motor 10.2
Repair Instructions
Contents
INTRODUCTION /VERVIEW 4

'ENERAL INSTRUCTIONS 4
3AFETY PRECAUTIONS 5
5NINTENDED MACHINE MOVEMENT 5
&LAMMABLE CLEANING SOLVENTS 5
&LUID UNDER PRESSURE 5
0ERSONAL SAFETY 5
3YMBOLS USED IN 3AUER $ANFOSS LITERATURE
3ECTION DIAGRAM 7
DISASSEMBLY %NDCAP
2OTATING COMPONENTS 9
3HAFT REMOVAL 3!% OR $). 1
3HAFT REMOVAL #ARTRIDGE 11
%NDCAP DISASSEMBLY1
FRAME1
FRAME1
FRAME1
!LL FRAME SIZES1
%NDCAP 14
INSPECTION 3HAFT ASSEMBLY 15

0ISTON RINGS1
"EARING PLATE VALVE SEGMENT AND CYLINDER BLOCK 17
ASSEMBLY %NDCAP ASSEMBLY1

!LL FRAME SIZES1
FRAME1
FRAME1
FRAMES
!LL FRAME SIZES1
3HAFT AND MOUNTING mANGE ASSEMBLY
3!%$). mANGE
#ARTRIDGE mANGE
#YLINDER BLOCK AND SYNCHRONIZING SHAFT5
3YNCHRONIZING SHAFT AND ROLLERS 5
#YLINDER BLOCK 7
"EARING PLATE AND VALVE SEGMENT9
"EARING PLATE 9
%NDCAP INSTALLATION
11009449 s 2EV !! s *ANUARY 3

008 916 41 BOMAG 627
10.2 Travel motor
Repair Instructions
Introduction
OVERVIEW 4HIS MANUAL DETAILS REPAIR PROCEDURES FOR 3ERIES BENT AXIS MOTORS4HESE INCLUDE THE
COMPLETE DISASSEMBLY INSPECTION AND REASSEMBLY OF THE UNIT7HERE REWORK OF WORN OR
DAMAGED COMPONENTS IS POSSIBLE SPECIlCATIONS ARE GIVEN TO ENSURE THESE PARTS MEET
FACTORY TOLERANCES /NLY 3AUER $ANFOSS 'LOBAL 3ERVICE 0ARTNERS MAY PERFORM MAJOR
REPAIRS 3AUER $ANFOSS TRAINS 'LOBAL 3ERVICE 0ARTNERS TO PERFORM MAJOR REPAIRS AND
CERTIlES THEIR FACILITIES ON A REGULAR BASIS
W 7ARNING
5SE OF COMPONENTS THAT DO NOT COMPLY WITH REWORK SPECIlCATIONS MAY RESULT IN LOSS OF
PERFORMANCE WHICH MAY CONSTITUTE A SAFETY HAZARD $O NOT REUSE COMPONENTS THAT DONT
COMPLY TO GIVEN SPECIlCATIONS REPLACE WITH GENUINE 3AUER $ANFOSS SERVICE PARTS
-INOR REPAIR PROCEDURES ADJUSTMENTS AND TROUBLESHOOTING INFORMATION ARE GIVEN IN THE
Series 51 and 51-1 Service Manual 11008567 -INOR REPAIRS INCLUDE SERVICE OPERATIONS
YOU CAN PERFORM WITHOUT REMOVING THE UNITS ENDCAP 2EMOVAL OF THE ENDCAP VOIDS YOUR
WARRANTY
GENERAL INSTRUCTIONS &OLLOW THESE GENERAL PROCEDURES WHEN REPAIRING 3ERIES BENT AXIS VARIABLE
DISPLACEMENT CLOSED CIRCUIT MOTORS
w Remove the unit

HYDRAULIC mUID MAY BE UNDER HIGH PRESSURE ANDOR HOT )NSPECT THE OUTSIDE OF THE PUMP
AND lTTINGS FOR DAMAGE #AP HOSES AFTER REMOVAL TO PREVENT CONTAMINATION
e Keep it clean
TO AVOID CONTAMINATION OF THE SYSTEM PORTS #LEANING PARTS WITH A CLEAN SOLVENT WASH
AND AIR DRYING IS USUALLY ADEQUATE
!S WITH ANY PRECISION EQUIPMENT YOU MUST KEEP ALL PARTS FREE OF FOREIGN MATERIALS AND
CHEMICALS 0ROTECT ALL EXPOSED SEALING SURFACES AND OPEN CAVITIES FROM DAMAGE AND
FOREIGN MATERIAL )F LEFT UNATTENDED COVER THE PUMP WITH A PROTECTIVE LAYER OF PLASTIC
l Lubricate moving parts

$URING ASSEMBLY COAT ALL MOVING PARTS WITH CLEAN HYDRAULIC OIL4HIS ASSURES THAT THESE
PARTS ARE LUBRICATED DURING START UP

3AUER $ANFOSS RECOMMENDS YOU REPLACE ALL / RINGS GASKETS AND SEALS ,UBRICATE / RINGS
WITH CLEAN PETROLEUM JELLY PRIOR TO ASSEMBLY 'REASE MUST BE SOLUBLE IN HYDRAULIC mUID
t Secure the unit

&OR MAJOR REPAIR PLACE THE UNIT IN A STABLE POSITION WITH THE SHAFT POINTING DOWNWARD
3ECURE THE PUMP WHILE REMOVING AND TORQUING THE ENDCAP BOLTS
4 11009449 s 2EV !! s *ANUARY
628 BOMAG 008 916 41

Travel motor 10.2
Repair Instructions
Introduction
YOURSELF AND OTHERS FROM INJURY 4AKE THE FOLLOWING GENERAL PRECAUTIONS WHENEVER SERVICING
A HYDRAULIC SYSTEM

W Warning
OR BYSTANDERS 4O PROTECT AGAINST UNINTENDED MOVEMENT SECURE THE MACHINE OR DISABLE

W Warning

W Warning
Personal safety
W Warning
TIMES
11009449 s 2EV !! s *ANUARY 5

008 916 41 BOMAG 629
10.2 Travel motor
Repair Instructions
Introduction

SAUER-DANFOSS
PRODUCT OR PROPERTY
 !PPLY GREASE PETROLEUM JELLY
 2EUSABLE PART
 Superseded – parts are not

SLEEVE
 4ORX HEAD
 0RESSURE MEASUREMENT GAUGE
6 11009449 s 2EV !! s *ANUARY
630 BOMAG 008 916 41

Travel motor 10.2
Repair Instructions
Introduction
SECTION DIAGRAM Series 51 bent axis variable motor
Multi-function
Pressure compensator Minimum displacement
block
override limiter
Control Valve segment

(hydraulic proportional) Motor output shaft
Bearing plate
Tapered roller bearings
4-way valve
and sleeve
Control
springs
Synchronizing
Piston
shaft and rollers
End cap Housing
Servo piston
Charge pressure
relief valve
Minimum angle
servo cover P104 085
11009449 s 2EV !! s *ANUARY 7

008 916 41 BOMAG 631
10.2 Travel motor
Repair Instructions
$ISASSEMBLY
ENDCAP &OLLOWING PROCEDURES IN THE Series 51 and 51-1 Service Manual 11008567 2EMOVE THE
CONTROL AND MULTI FUNCTION BLOCK IF INSTALLED 2EMOVE THE WAY VALVE SPOOL AND SLEEVE
IF INSTALLED 2EMOVE THE THRESHOLD SPRINGS AND GUIDES 2EMOVE THE CONTROL SPRINGS IF
INSTALLED 2EMOVE THE RAMP SPRINGS AND GUIDES IF INSTALLED 2EMOVE THE MINIMUM ANGLE
SERVO COVER FROM THE MOTOR 2EMOVE THE LOOP mUSHING VALVE AND CHARGE RELIEF VALVE
2EMOVE THE SCREWS ' AND ' RETAINING THE END CAP ASSEMBLY TO THE MOTOR
HOUSING
2EMOVE THE END CAP ASSEMBLY
2EMOVE THE GASKET ' DISCARD
2EMOVE THE ALIGNMENT PINS "
Endcap and rotating components

B05
C10
Note orientation of segment with end cap and housing
Note orientation of pins

C20
Note orientation of rollers with synchronizing shaft (recess faces the centerline of the shaft)
(later version rollers do not have recess and can be installed either way), and synchronizing
shaft with cylinder block and output shaft, small end into shaft and big end into block.
Note locations of longer and
C05 G32
shorter screws
060 and 080: 8mm

G34
110 and 160: 10mm
250: 12mm
End cap assembly

Q20
(side port configuration shown)
B50
G60
B50
P104 086
SAE flange version Cartridge version
8 11009449 s 2EV !! s *ANUARY
632 BOMAG 008 916 41

Travel motor 10.2
Repair Instructions
$ISASSEMBLY
ROTATING COMPONENTS 2EMOVE THE VALVE SEGMENT " AND SET ASIDE
2EMOVE THE BEARING PLATE # AND ALIGNMENT PINS #
2EMOVE THE CYLINDER BLOCK # AND SET ASIDE "E CAREFUL NOT TO SCRATCH THE RUNNING
SURFACE OF THE BLOCK
2EMOVE THE SYNCHRONIZING SHAFT ASSEMBLY # WITH ROLLERS AND PINS
Endcap and rotating components
B05
C10
Note orientation of segment with end cap and housing
Note orientation of pins

C20
Note orientation of rollers with synchronizing shaft (recess faces the centerline of the shaft)
(later version rollers do not have recess and can be installed either way), and synchronizing
shaft with cylinder block and output shaft, small end into shaft and big end into block.
Note locations of longer and
C05 G32
shorter screws
060 and 080: 8mm

G34
110 and 160: 10mm
250: 12mm
End cap assembly

Q20
(side port configuration shown)
B50
G60
B50
P104 086
SAE flange version Cartridge version
11009449 s 2EV !! s *ANUARY 9

008 916 41 BOMAG 633
10.2 Travel motor
Repair Instructions
$ISASSEMBLY
SHAFT REMOVAL (SAE OR Shaft assembly SAE or DIN flange version 2EMOVE SCREWS , RETAINING THE
DIN) MOUNTING mANGE , TO THE MAIN
HOUSING "
2EMOVE THE MOUNTING mANGE USING A

B10 SUITABLE PULLER
2EMOVE THE / RING , DISCARD
2EMOVE THE SHAFT SEAL , FROM THE

mANGE DISCARD
0RESS SHAFT ASSEMBLY OUT OF MAIN

HOUSING TAKING CARE NOT TO DAMAGE
THE SHAFT AND SPEED SENSOR RING IF
INSTALLED
Shaft assembly
C Caution
$O NOT DAMAGE PISTON SOCKETS
L50
L40
P104 087
L35
L70
060 and 080: 6mm
110: 8mm
160: 10mm
250: 12mm
10 11009449 s 2EV !! s *ANUARY
634 BOMAG 008 916 41

Travel motor 10.2
Repair Instructions
$ISASSEMBLY
SHAFT REMOVAL 2EMOVE RETAINING RING ,

(CARTRIDGE)
2EMOVE SEAL CARRIER ,
2EMOVE SHAFT SEAL , DISCARD
2EMOVE RETAINING RING , FOR THE SHAFT SEAL CARRIER , FROM THE BEARING
HOUSING ,
2EMOVE THE SCREWS , RETAINING THE BEARING HOUSING , TO THE MAIN HOUSING
"
3EPARATE THE BEARING HOUSING FROM THE MAIN HOUSING "
2EMOVE THE RETAINING RING , IF PRESENT
2EMOVE SPACER RING ,
2EMOVE / RINGS , AND , OR GASKET , DISCARD
0RESS SHAFT ASSEMBLY OUT OF BEARING HOUSING TAKING CARE TO NOT DAMAGE THE SHAFT
PISTON SOCKETS AND SPEED SENSOR RING IF INSTALLED
Shaft assembly, cartridge version

Prior to
N94-42
L80
L35
N94-42
L85 thru L40
L90 N98-32 L50
L95 L80
B80
L35 L750
L95
L81
L70
L82
L35 060 and 080: 6mm

N98-33 110: 8mm
and beyond 160: 10mm
250: 12mm
L95
L81
L90
L85 P104 088

B10
11009449 s 2EV !! s *ANUARY 11

008 916 41 BOMAG 635
10.2 Travel motor
Repair Instructions
$ISASSEMBLY
ENDCAP DISASSEMBLY 060 frame

2EMOVE END CAP PLUG ' 2EMOVE / RING '! FROM PLUG DISCARD
2EMOVE LOCK SCREWS & FROM SERVO PISTON &
2EMOVE CONE POINT SET SCREWS & FROM SERVO PISTON
2EMOVE FEEDBACK FORK & THROUGH THE HOLE IN THE END CAP
2EMOVE THE SETTING LUG & FROM INSIDE OF END CAP
End cap components
3 mm (060)
3 mm (060)
F30
F28 (060)
F26 F10
F11 F12
060: 3/8 inch
G80 080: 9/16 inch
G80A
F26
G10
F24 F28
(060)
F24
(080)
F10 F12
F11
End cap
(typical for 060 and 080 frame sizes)
F26 axial port style shown
F28
P104 089
5 mm (080)
080 frame
2EMOVE END CAP PLUG '
2EMOVE LOCK SCREW &
2EMOVE CONE POINT SET SCREW &
2EMOVE FEEDBACK FORK SETTING LUG & THROUGH HOLE IN END CAP
12 11009449 s 2EV !! s *ANUARY
636 BOMAG 008 916 41

Travel motor 10.2
Repair Instructions
$ISASSEMBLY
ENDCAP DISASSEMBLY 110 - 250 frame

(continued) 2EMOVE LOCK SCREW &
2EMOVE CONE POINT SET SCREW &
2EMOVE FEEDBACK FORK SETTING LUG & FROM INSIDE OF END CAP
Disassembling the end cap
F10 F12
5 mm (110, 160, 250)
F11
F26
G10
F28
F24
(110, 160, 250)
P104 090
End cap
(typical for 110, 160, and 250 frame sizes)
side port style shown
All frame sizes

2EMOVE SERVO PISTON & FROM END CAP & GLIDE RING END lRST
)NSPECT GLIDE RING & FOR DAMAGE OR WEAR
2EMOVE GLIDE RING & FROM SERVO PISTON IF YOU NEED TO REPLACE IT
2EMOVE / RING & FROM SERVO PISTON DISCARD
)NSPECT SERVO PISTON BORE IN END CAP FOR DAMAGE OR WEAR
11009449 s 2EV !! s *ANUARY 13

008 916 41 BOMAG 637
10.2 Travel motor
Repair Instructions
$ISASSEMBLY
ENDCAP DISASSEMBLY 51-1 Endcap

(continued) 2EMOVE SERVO PISTON & FROM END CAP ' GLIDE RING END lRST
)NSPECT GLIDE RING & FOR DAMAGE OR WEAR
2EMOVE GLIDE RING & FROM SERVO PISTON IF YOU NEED TO REPLACE IT
2EMOVE / RING & FROM SERVO PISTON DISCARD
)NSPECT SERVO PISTON BORE IN END CAP FOR DAMAGE OR WEAR
Disassembling the end cap
F11
F10
F12 Servo piston
G10 End cap assembly
P106 541E
14 11009449 s 2EV !! s *ANUARY
638 BOMAG 008 916 41

Travel motor 10.2
Repair Instructions
Inspection
SHAFT ASSEMBLY #HECK THE SEAL AREA OF THE SHAFT , Shaft assembly
FOR DAMAGE OR WEAR
C Caution
4HE OPTIONAL MAGNETIC #HECK THE OUTPUT SPLINES FOR DAMAGE
SPEED SENSOR RING IS OR WEAR
PRESSED ONTO A MACHINED
SURFACE OF THE SHAFT4AKE )NSPECT SYNCHRONIZING SHAFT RACEWAYS
CARE NOT TO DAMAGE THE FOR WEAR
SENSOR RING
)NSPECT SHAFT BEARINGS FOR WEAR AND L1
ROUGHNESS
#HECK THAT THE BEARING RETAINING NUT

IS lRMLY STAKED TO THE OUTPUT SHAFT
AND THAT NO NOTICEABLE LOOSENESS IS P104 091
PRESENT IN THE BEARINGS
#HECK THE PISTON ASSEMBLIES , FOR DAMAGE OR WEAR
"EARINGS AND PISTONS ARE NOT INDIVIDUALLY SERVICEABLE 2EPLACE THE ENTIRE SHAFT ASSEMBLY IF
ANY COMPONENTS ARE DAMAGED OR WORN
11009449 s 2EV !! s *ANUARY 15

008 916 41 BOMAG 639
10.2 Travel motor
Repair Instructions
Inspection
PISTON RINGS 5SE A SMALL PAIR OF RETAINING RING PLIERS TO SPREAD AND REMOVE THE PISTON RINGS ,
FROM THE PISTONS $ISCARD THE RINGS
)NSTALL NEW PISTON RINGS , %NSURE THE SPHERICAL SURFACE CONFORMS TO THE SHAPE OF
THE PISTON ! RADIAL IDENTIlCATION MARK APPEARS ON THE OUTER SIDE OF THE PISTON RINGS
$O NOT LET THE ENDS OF EACH PISTON RING OVERLAP EACH OTHER
Spherical piston rings

L230
Split line
Radial identification mark located

on this side of piston ring
The spherical surface of the piston ring must

conform to the spherical shape of the piston
P104 092
16 11009449 s 2EV !! s *ANUARY
640 BOMAG 008 916 41

Travel motor 10.2
Repair Instructions
Inspection
BEARING PLATE, )NSPECT THE BRONZE SURFACE OF THE BEARING PLATE # FOR DAMAGE AND EXCESSIVE WEAR
VALVE SEGMENT, AND 3EALING SURFACE MUST BE FREE FROM SCRATCHES AND NICKS4HE LOCATING PIN HOLES MUST
CYLINDER BLOCK NOT BE WORN 2EPLACE IF NECESSARY
Bearing plate Valve segment

C10 B05
P104 093
P106 350E
)NSPECT THE VALVE SEGMENT " FOR DAMAGE OR WEAR ON THE SEALING SURFACES
)NSPECT THE SPINDLE FOR WEAR
%NSURE THE SPINDLE IS LOCATED CORRECTLY IN THE VALVE SEGMENT BY MEASURING DISTANCE
A )F THIS DIMENSION IS NOT WITHIN THE RANGE SHOWN IN THE TABLE IT INDICATES THAT THE
SPINDLE HAS MOVED IN THE VALVE SEGMENT 2EPLACE IT
Valve segment Spindle location distance

Frame size Distance A MM ;IN=
A
¼ ; ¼ =
¼ ; ¼ =
P104 094
¼ ; ¼ =
¼ ; ¼ =
¼ ; ¼ =
$O NOT LAP THE VALVE SEGMENT TO REMOVE SCRATCHES4HE HARD TREATED SURFACE IS THIN AND
LAPPING MAY REMOVE THIS SURFACE 2EMOVING THE SPINDLE LOOSENS ITS TIGHT PRESS lT AND
ALLOWS IT TO MOVE
)NSPECT CYLINDER BLOCK ASSEMBLY FOR Cylinder block bearing

WEAR OR DAMAGE )F BEARING IS WORN
OR DAMAGED REPLACE THE COMPLETE Bearing
BLOCK ASSEMBLY4HE BEARING IS NOT
AVAILABLE AS A SEPARATE PART
4HE PISTON BORES MUST BE SMOOTH

4HE BEARING PLATE SURFACE MUST BE
FREE FROM SCRATCHES OR NICKS4HE P104 095
HOLES FOR THE BEARING PLATE LOCATING
PINS MUST BE FREE FROM WEAR4HE
RACES FOR THE SYNCHRONIZING SHAFT
ROLLERS MUST ALSO BE FREE FROM WEAR
11009449 s 2EV !! s *ANUARY 17

008 916 41 BOMAG 641
10.2 Travel motor
Repair Instructions
!SSEMBLY
ENDCAP ASSEMBLY All frame sizes

#AREFULLY INSTALL A NEW / RING & AND GLIDE RING & ON THE SERVO PISTON &
,UBRICATE THE GLIDE RING
)NSTALL THE SERVO PISTON INTO THE END CAP '
4HE END OF THE SERVO PISTON WITH THE GLIDE RING IS OPPOSITE THE MULTI FUNCTION BLOCK
CONTROL MOUNTING SURFACE OF THE END CAP
060 frame
)NSTALL THE SETTING LUG & INTO THE SERVO PISTON & FROM INSIDE OF END CAP
5SING A MM INTERNAL HEX WRENCH INSTALL THE CONE POINT SET SCREW & SO THAT ITS
POINT ENTERS THE GROOVE IN THE SETTING LUG AND TORQUE TO .sM ; LBFsIN=
)NSTALL THE LOCK SCREW &
5SING A MM HEX WRENCH TORQUE THE LOCK SCREW & TO .sM ; LBFsIN=
)NSTALL THE FEEDBACK FORK & INTO THE SERVO PISTON THROUGH THE HOLE IN THE END CAP
4HE CONTACT PADS ON THE FORK MUST FACE TOWARD THE MULTI FUNCTION BLOCKCONTROL END OF
THE END CAP
5SING A MM INTERNAL HEX WRENCH INSTALL THE OTHER CONE POINT SET SCREW & SO THAT
ITS POINT ENTERS THE GROOVE IN THE FEEDBACK FORK & $O NOT TIGHTEN THE SET SCREW
YET 3EE PAGE FOR lNAL ASSEMBLY INSTRUCTIONS
,UBRICATE AND INSTALL A NEW / RING '! ON THE END CAP PLUG ' )NSTALL THE PLUG
5SING A IN INTERNAL HEX WRENCH TORQUE THE END CAP PLUG TO .sM ; LBFsFT=
080 frame
)NSTALL FEEDBACK FORK SETTING LUG & INTO THE SERVO PISTON THROUGH THE HOLE IN THE
END CAP
4HE OFFSET OF THE FORK MUST BE FACING AWAY FROM THE MULTI FUNCTION BLOCK CONTROL END OF
THE END CAP
)NSTALL THE CONE POINT SET SCREW & SO THAT ITS POINT ENTERS THE GROOVE IN THE
FEEDBACK FORK & SETTING LUG & $O NOT TIGHTEN THE SET SCREW YET 3EE PAGE
FOR lNAL ASSEMBLY INSTRUCTIONS
)NSTALL THE END CAP PLUG '
5SING A IN INTERNAL HEX WRENCH TORQUE THE END CAP PLUG ' TO .sM
; LBFsFT=
18 11009449 s 2EV !! s *ANUARY
642 BOMAG 008 916 41

Travel motor 10.2
Repair Instructions
!SSEMBLY
ENDCAP ASSEMBLY
(continued) Setting lugs
$$ +(!*-!* /(+#!#+! $$

F11 0$ #0!%
F30
F26 (060) 0$ #0!%
F10
F12
!%h
+#*!+%*!&%
Groove #&"&%*(&# 0$
#)0* G80
F24 F26
G80A
(060)
F28 G10
End cap (axial port style shown)
F24
+(!*-!* /(+#!#+! (080)
+#*!+%*!&%
#&"&%*(&#
Groove
F10
F11 F12
F26
$$
P104 096
11009449 s 2EV !! s *ANUARY 19

008 916 41 BOMAG 643
10.2 Travel motor
Repair Instructions
!SSEMBLY
ENDCAP ASSEMBLY 110-250 frames

(continued) )NSTALL FEEDBACK FORK & SETTING LUG INTO THE SERVO PISTON FROM INSIDE OF THE
ENDCAP
4HE OFFSET OF THE FORK MUST BE AWAY FROM THE MULTI FUNCTION BLOCK CONTROL END OF THE
END CAP
)NSTALL THE CONE POINT SET SCREW & SO THAT ITS POINT ENTERS THE GROOVE IN THE
FEEDBACK FORK & SETTING LUG $O NOT TIGHTEN THE SET SCREW YET 3EE PAGE FOR
lNAL ASSEMBLY INSTRUCTIONS
Cone-point screw and feedback fork
Lubricate with hydraulic fluid
F10
F11 F12
Multi-function
Groove block/control
F26
G10
F24
(110, 160, 250)
End cap (side port style shown)

typical for 110, 160, and 250 frame sizes P104 097
20 11009449 s 2EV !! s *ANUARY
644 BOMAG 008 916 41

Travel motor 10.2
Repair Instructions
!SSEMBLY
ENDCAP ASSEMBLY All frame sizes

(continued) 0OSITION FEEDBACK FORK & CC OR FEEDBACK FORKSETTING LUG CC CC
PERPENDICULAR TO THE SETTING PISTON FOR PROPER CONTROL SPRING OPERATION
)NSERT A MM ; IN= DIAMETER ROD WITH THE END MACHINED PERPENDICULAR TO ITS
AXIS INTO THE VALVE SLEEVE BORE IN THE END CAP !LIGN THE FORK WHILE TIGHTENING THE
CONE POINT SET SCREW &
5SING A OR MM INTERNAL HEX WRENCH TORQUE THE CONE POINT SET SCREW TO .sM
; LBFsIN=
)NSTALL AND TORQUE THE LOCK SCREW & TO

• .sM ; LBFsIN= USING A MM INTERNAL HEX WRENCH FOR A CC MOTOR
• .sM ; LBFsFT= USING A MM INTERNAL HEX WRENCH FOR THE CC THROUGH CC
MOTORS
Cone-point set screws

3 mm
]
F28
F26
3 mm

060 frame size
F28
6 mm

]
F26
6 mm

080, 110, 160, 250, frame sizes
11009449 s 2EV !! s *ANUARY 21

008 916 41 BOMAG 645
10.2 Travel motor
Repair Instructions
!SSEMBLY
SHAFT AND MOUNTING SAE/DIN flange

FLANGE ASSEMBLY 3UPPORT THE MAIN HOUSING " SO THE BEARING BORE IS VERTICAL
0RESS SHAFT ASSEMBLY , INTO MAIN HOUSING
)NSTALL NEW / RING , ON MOUNTING mANGE ,
)NSTALL NEW SEAL , IN mANGE
#OVER THE SHAFT SPLINES WITH AN INSTALLATION SLEEVE TO PROTECT THE SEAL DURING
ASSEMBLY )NSTALL mANGE ASSEMBLY ,
)NSTALL SCREWS ,
4ORQUE SCREWS , TO VALUE SHOWN IN THE DIAGRAM
SAE/DIN Flange version bearing bore and housing

# "" L70 ," !,(]
"" ," !,(]
"" ,"!,(]
"" ,"!,(]

)& ('!! %+ (&'
L35
L50
L1
B10
B10
19°
$)' #')%%$&( #%&''

' * +

22 11009449 s 2EV !! s *ANUARY
646 BOMAG 008 916 41

Travel motor 10.2
Repair Instructions
!SSEMBLY
SHAFT AND MOUNTING Cartridge flange

FLANGE ASSEMBLY )NSTALL THE INNER RETAINING RING , FOR THE SHAFT SEAL CARRIER IN THE BEARING HOUSING
(continued)
0RESS SHAFT ASSEMBLY INTO BEARING HOUSING ,
C Caution )NSTALL SPACER RING , C

$O NOT DAMAGE THE PISTON
SOCKETS OR SHAFT SEAL )NSTALL THE END OF THE SPACER WITH THE LARGER INSIDE DIAMETER NEXT TO THE INNER SHAFT
SURFACE BEARING CUP
)NSTALL RETAINING RING ,
!LIGN ENDS OF THE RETAINING RING BETWEEN THE TWO BOLT HOLES TO ALLOW CLEARANCE FOR
SPEED SENSOR
Speed sensors
speed sensor
Notch
Locking nut
Spacer ring
Sensor
Axial notch on speed sensor
Retaining-ring (L81)
P104 100
11009449 s 2EV !! s *ANUARY 23

008 916 41 BOMAG 647
10.2 Travel motor
Repair Instructions
!SSEMBLY
SHAFT AND MOUNTING )NSTALL / RINGS , AND , OR GASKET ,
FLANGE ASSEMBLY
(continued) )NSTALL MAIN HOUSING " %NSURE SNAP RING , ENDS ALIGN WITH SPEED SENSOR PORT
)NSTALL SCREWS ,
4ORQUE SCREWS

• .sM ; LBFsFT= FOR CC AND CC
• .sM ; LBFsFT= FOR CC
• .sM ; LBFsFT= FOR CC
Cartridge version bearing bore and housing
Before N94-42
N94-42
through L80
L35
N98-32
L85
O
L40
L90 L50
L95 L80
B80
L35 L750
L95
O
L81
N98-33
and beyond
L70
L82
060 and 080: 6mm
110: 8mm
L35 160: 10mm
250: 12mm
L95
P104 101
L81
L90
B10 L85
24 11009449 s 2EV !! s *ANUARY
648 BOMAG 008 916 41

Travel motor 10.2
Repair Instructions
!SSEMBLY
CYLINDER BLOCK AND Synchronizing shaft and rollers

SYNCHRONIZING SHAFT 5SING PETROLEUM JELLY TO RETAIN IT INSTALL THE lRST SYNCHRONIZING SHAFT SUPPORT PIN
# INTO THE RECESS IN THE CYLINDER BLOCK
5SING PETROLEUM JELLY TO RETAIN THEM INSTALL THE SYNCHRONIZING SHAFT ROLLERS # ON
THE JOURNALS OF THE SYNCHRONIZING SHAFT #
0OSITION THE RECESS ON EACH ROLLER TO FACE THE CENTER LINE OF THE SYNCHRONIZING SHAFT
-OTORS BUILT AFTER SERIAL NUMBER . 88888 HAVE SYMMETRICAL ROLLERS
3EE SERVICE BULLETIN SB-2001-015
0OSITION EACH ROLLER WITH ITS OUTSIDE EDGE mUSH WITH THE END OF THE SYNCHRONIZING
SHAFT JOURNAL
Cylinder block and sync-shaft
Cylinder
block
C40
C50
C60
Q20
C60 C50
C40
P104 102
11009449 s 2EV !! s *ANUARY 25

008 916 41 BOMAG 649
10.2 Travel motor
Repair Instructions
!SSEMBLY
MOTOR ASSEMBLY Synchronizing shaft and rollers (continued)

(continued) )NSTALL THE SECOND # SYNCHRONIZING SHAFT SUPPORT PIN INTO THE MOTOR SHAFT
ASSEMBLY
)NSTALL THE SYNCHRONIZING SHAFT AND ROLLERS INTO THE MOTOR SHAFT
4HE CYLINDER BLOCK END OF THE SHAFT IS A LARGER DIAMETER THAN THE MOTOR SHAFT END ON ALL
FRAME SIZES4HE ROLLERS MUST ENTER THE RACES IN THE MOTOR SHAFT AND THE RECESS IN THE END
OF THE SYNCHRONIZING SHAFT MUST ENGAGE THE SUPPORT PIN
4IP AND ROTATE THE SYNCHRONIZING SHAFT IN ALL DIRECTIONS TO CHECK FOR BINDING4HE
SYNCHRONIZING SHAFT ROLLERS MUST MOVE FREELY IN THE RACES IN THE MOTOR SHAFT
Cylinder block and sync-shaft
Cylinder
block
C40
C50
C60
Q20
C60 C50
C40
P104 102
26 11009449 s 2EV !! s *ANUARY
650 BOMAG 008 916 41

Travel motor 10.2
Repair Instructions
!SSEMBLY
CYLINDER BLOCK AND Cylinder block Pistons

SYNCHRONIZING SHAFT ,UBRICATE THE PISTONS AND SYNC SHAFT Position the motor shaft
(continued) AND ROLLERS WITH CLEAN HYDRAULIC OIL as shown prior to installing
the cylinder block
AND ROTATE THE SHAFT TO THE POSITION
SHOWN IN THE ILLUSTRATION
4IP THE PISTONS CLOSEST TO THE

MINIMUM ANGLE STOP OUT TOWARD THE
HOUSING
4IP THE REMAINING PISTONS FORWARD

TOWARD THE LOWEST PART OF THE END
CAP MOUNTING SURFACE
4IP THE SYNCHRONIZING SHAFT FORWARD

TOWARD THE LOWEST PART OF THE END
CAP MOUNTING SURFACE
P104 103
0OSITION THE CYLINDER BLOCK SO ONE (Cylinder block not installed)
SYNCHRONIZING SHAFT ROLLER RACEWAY IS
ALIGNED BETWEEN TWO PISTONS
)NSTALL THE CYLINDER BLOCK AND ITS SUPPORT PIN # ON TO THE PISTONS AND
SYNCHRONIZING SHAFT
4HE SYNCHRONIZING SHAFT ROLLERS # ENTER THEIR RACES IN THE BLOCK WHILE EACH PISTON
ENTERS ITS CORRESPONDING BORE IN THE BLOCK
)NSERT A BRASS ROD THROUGH THE CYLINDER BLOCK KIDNEYS TO GUIDE THE PISTONS INTO
POSITION
3TART WITH THE FOUR PISTONS CLOSEST TO THE LOWEST PART OF THE END CAP MOUNTING
SURFACE
!FTER THE PISTONS ENTER THEIR BORES TILT THE CYLINDER BLOCK SO THE SYNCHRONIZING SHAFT
ROLLERS # ENTER THEIR RACES IN THE CYLINDER BLOCK AND THE NEXT TWO PISTONS ENTER
THEIR BORE
4HE SUPPORT PIN # ENTERS ITS RECESS IN THE SYNCHRONIZING SHAFT #
,IFT THE CYLINDER BLOCK SLIGHTLY
'UIDE THE REMAINING PISTONS INTO THEIR BORES
!FTER THE LAST PISTON IS IN POSITION CHECK THE POSITION OF THE ROLLERS CLOSEST TO THE
MINIMUM ANGLE STOP
-AINTAIN AN INWARD FORCE ON THE CYLINDER BLOCK
#AREFULLY PUSH IT TOWARD THE HIGHEST PART OF THE END CAP MOUNTING SURFACE
11009449 s 2EV !! s *ANUARY 27

008 916 41 BOMAG 651
10.2 Travel motor
Repair Instructions
!SSEMBLY
CYLINDER BLOCK AND #HECK THAT ALL OF THE SYNCHRONIZING SHAFT ROLLERS ARE IN POSITION
SYNCHRONIZING SHAFT
(continued) )F THE CYLINDER BLOCK IS PROPERLY INSTALLED THERE WILL BE VERY LITTLE ROTATIONAL FREE PLAY
BETWEEN THE CYLINDER BLOCK AND THE MOTOR SHAFT
Lubricate the pistons and cylinder

Cylinder block block bores with hydraulic oil
Cylinder block
Pistons
P104 104
SAE flange version shown
cartridge version similar
28 11009449 s 2EV !! s *ANUARY
652 BOMAG 008 916 41

Travel motor 10.2
Repair Instructions
!SSEMBLY
BEARING PLATE AND Bearing plate

VALVE SEGMENT )NSTALL THE BEARING PLATE LOCATING PINS # INTO THE CYLINDER BLOCK
)NSTALL THE LONGER END OF EACH SHOULDERED PIN INTO THE BLOCK
)NSTALL THE BEARING PLATE # ON THE CYLINDER BLOCK WITH STEEL SIDE FACING THE BLOCK
,UBRICATE THE BRONZE SIDE OF THE PLATE WITH HYDRAULIC OIL
)NSTALL THE END CAP ALIGNMENT PINS " )NSTALL A NEW GASKET '
,OCATE THE CYLINDER BLOCK IN THE APPROXIMATE CENTER OF THE HOUSING OPENING
4IP THE HOUSING UNTIL THE ENDCAP MOUNTING SURFACE IS LEVEL TO HELP KEEP THE BLOCK
CENTERED $O NOT ALLOW PISTONS OR SYNCHRONIZING SHAFT ROLLERS TO FALL OUT OF POSITION
5SING PETROLEUM JELLY INSTALL THE VALVE SEGMENT " INTO THE END CAP SO THE
SEGMENT SPINDLE ENGAGES THE SETTING LUG IN THE SERVO PISTON
/RIENT THE VALVE SEGMENT SO THE HOLE AT THE EDGE IS ALIGNED WITH THE LOOP mUSHING
VALVE DRAIN HOLE IN THE END CAP
,OCATE THE VALVE SEGMENT AND SERVO PISTON IN THE APPROXIMATE CENTER OF THEIR TRAVEL
G32
Bearing plate and valve segment
see page 30
G34
End cap
(typical side port
configuration shown)
B50 B05
C10
C20 G60
B50

P104 105
(cartridge version similar)
11009449 s 2EV !! s *ANUARY 29

008 916 41 BOMAG 653
10.2 Travel motor
Repair Instructions
!SSEMBLY
ENDCAP INSTALLATION 2OTATE THE MOTOR SHAFT AND CHECK FOR PLAY BETWEEN THE SHAFT AND CYLINDER BLOCK !NY
PLAY INDICATES THAT THE SYNCHRONIZING SHAFT ROLLERS ARE NOT INSTALLED CORRECTLY
C Caution
$O NOT ALLOW THE PISTONS OR )NSTALL THE END CAP ASSEMBLY AND VALVE SEGMENT SO THE SPINDLE ENGAGES THE BEARING
SYNCHRONIZING SHAFT ROLLERS IN THE CYLINDER BLOCK C
TO FALL OUT OF POSITION
)NSTALL SCREWS ' AND ' TO RETAIN THE END CAP ASSEMBLY TO THE MOTOR
)NSTALL THE SCREWS IN THEIR PROPER LOCATIONS TO ENSURE ADEQUATE THREAD ENGAGEMENT4HE
INTERNAL SPRING IN THE MOTOR SHAFT WILL HOLD THE END CAP AWAY FROM THE HOUSING A SHORT
DISTANCE
C Caution 4IGHTEN THE SCREWS BY HAND IN A Endcap screw torque

$O NOT FORCE THE END DOUBLE 8 PATTERN WHILE ROTATING Frame size Wrench size 4ORQUE .sM
CAP INTO POSITION ON THE THE MOTOR SHAFT TO ENSURE PROPER ;LBFsFT=
HOUSING )F NECESSARY POSITIONING OF THE SYNCHRONIZING MM ;=
REASSEMBLE THE SHAFT ROLLERS
MM ;=
COMPONENTS TO ENSURE
PROPER ALIGNMENT 7HEN THE END CAP IS IN POSITION MM ;=
TORQUE THE SCREWS IN A DOUBLE 8 MM ;
PATTERN AS SHOWN IN THE TABLE C MM ;=
2ECHECK THE END CAP SCREW TORQUE
2EINSTALL THE MINIMUM ANGLE SERVO COVER CONTROL SPRINGS IF USED WAY VALVE SPOOL
AND SLEEVE IF USED AND CONTROL AND MULTIFUNCTION BLOCK IF USED 2EFER TO Series 51
and 51-1 Service Manual, 11008567 FOR INSTRUCTIONS
Torquing pattern
G34 see table

Endcap assembly 2/10
3/11 5/13
with valve segment G32 7/15
6/14 8/16
1/9 4/12
Double-X pattern torquing sequence
(110 frame size with side port end cap shown)

cartridge version similar
P104 106
30 11009449 s 2EV !! s *ANUARY
654 BOMAG 008 916 41

Travel motor 10.2
Repair Instructions
!SSEMBLY
ENDCAP INSTALLATION &OLLOWING PROCEDURES IN THE Series 51 and 51-1 Service Manual 11008567 )NSTALL THE
(continued) CONTROL AND MULTI FUNCTION BLOCK IF INSTALLED )NSTALL THE WAY VALVE SPOOL AND SLEEVE IF
INSTALLED )NSTALL THE THRESHOLD SPRINGS AND GUIDES )NSTALL THE CONTROL SPRINGS IF INSTALLED
)NSTALL THE RAMP SPRINGS AND GUIDES IF INSTALLED )NSTALL THE MINIMUM ANGLE SERVO COVER
FROM THE MOTOR )NSTALL THE LOOP mUSHING VALVE AND CHARGE RELIEF VALVE
!FTER ASSEMBLY TEST AND ADJUST THE MOTOR AS NECESSARY BEFORE PLACING THE UNIT BACK IN
SERVICE 2EFER TO Series 51 and 51-1 Service Manual 11008567 FOR ADJUSTMENT PROCEDURES
11009449 s 2EV !! s *ANUARY 31

008 916 41 BOMAG 655
10.2 Travel motor

PUMPS AND MOTORS
/RBITAL MOTORS
#ARTRIDGE VALVES
,OCAL ADDRESS
)NTEGRATED SYSTEMS
&AN DRIVE SYSTEMS
%LECTROHYDRAULICS
%AST TH 3TREET $+ .ORDBORG $E.sMARK
$ISPLAYS !MES )! 53! 0HONE
Sensors 0HONE &AX
&AX
0OSTFACH $ .EUMünster 3ANNOMIYA 'RAND "LDG &
&AX 0HONE
&AX
WWWSAUER DANFOSSCOM
11009449 s 2EV !! s *ANUARY
656 BOMAG 008 916 41

10.3 Conveyor screws - scraper belt motor
008 916 41 BOMAG 657

658 BOMAG 008 916 41

Conveyor screws - scraper belt motor 10.3
008 916 41 BOMAG 659

660 BOMAG 008 916 41

008 916 41 BOMAG 661

662 BOMAG 008 916 41

008 916 41 BOMAG 663

664 BOMAG 008 916 41

008 916 41 BOMAG 665

666 BOMAG 008 916 41

008 916 41 BOMAG 667

668 BOMAG 008 916 41

008 916 41 BOMAG 669

670 BOMAG 008 916 41

008 916 41 BOMAG 671

672 BOMAG 008 916 41

008 916 41 BOMAG 673

674 BOMAG 008 916 41

10.4 Travel gear
008 916 41 BOMAG 675

10.4 Travel gear
676 BOMAG 008 916 41

Travel gear
BONFIGLIOLI RIDUTTORI S.p.A.
DIVISIONE: Bonfiglioli Group 10.4
Bonfiglioli / Trasmital / Components / Silectron
New Power S olutions
Indice Index
DISEGNO ESPLOSO EXPLODED VIEW
DISEGNO DI INSTALLAZIONE INSTALLATION DRAWING
INFORMAZIONI GENERALI .................... 1.0 GENERAL INFORMATIONS.................... 2.0

G Scopo del manuale ......................................... 1.1 G Manual aim...................................................... 1.1
G Informazioni sulla sicurezza............................ 1.2 G Information on safety....................................... 1.2
TARGHETTA IDENTIFICATIVA.............. 2.0 NAME PLATE ............................................... 2.0
NOTE ............................................................... 3.0 NOTES ............................................................. 3.0

G Condizioni di fornitura ..................................... 3.1 G Delivery conditions .......................................... 3.1
G Trasporto ........................................................ 3.2 G Handling / Transport........................................ 3.2
G Stoccaggio ...................................................... 3.3 G Storage............................................................ 3.3
G Sollevamento e movimentazione.................... 3.4 G Lifting and handling ......................................... 3.4
INSTALLAZIONE ......................................... 4.0 INSTALLATION ............................................ 4.0

G Installazione del motore idraulico.................... 4.1 G Hydraulic motor Installation............................. 4.1
G Installazione del riduttore sulla macchina ....... 4.2 G Installation of the gearbox to the machine ...... 4.2
G Collegamento del freno................................... 4.3 G Connection of the brake pipe .......................... 4.3
LUBRIFICAZIONE ....................................... 5.0 LUBRICATION .............................................. 5.0

G Lubrificazione riduttore.................................... 5.1 G Gearbox lubrication ......................................... 5.1
G Riempimento olio ............................................ 5.2 G Oil filling........................................................... 5.2
G Scarico olio e sostituzione olio........................ 5.3 G Oil draining and replacement .......................... 5.3
MESSA IN ESERCIZIO .............................. 6.0 START UP ...................................................... 6.0
MANUTENZIONE......................................... 7.0 MAINTENANCE............................................ 7.0
SMONTAGGIO ............................................. 8.0 DISASSEMBLY ............................................ 8.0

G Controllo tenute frontali................................... 8.1 G Lifetime seal check.......................................... 8.1
RIMONTAGGIO ............................................ 9.0 REASSEMBLY ............................................. 9.0

G Note importanti prima del rimontaggio............ 9.1 G Important notes before reassembly ................ 9.1
G Istruzioni per rimontaggio tenuta frontale ....... 9.2 G Instructions for installation of the lifetime seal. 9.2
G Controllo freno ................................................ 9.3 G Brake check .................................................... 9.3
DISEGNI ATTREZZATURE .................... 10.0 FIXTURE DRAWINGS ..............................10.0
Man_2T261300732_sm.doc Pag.2 05/2001
008 916 41 BOMAG 677

10.4
DIVISIONE:
TravelGroup
Bonfiglioli gear
Man_2T261300732_sm.doc Pag.3 05/2001
678 BOMAG 008 916 41

Travel gear
1.0 INFORMAZIONI GENERALI 1.0 GENERAL INFORMATION

1.1 SCOPO DEL MANUALE 1.1 MANUAL AIM
Questo manuale è stato realizzato dal costruttore per This manual has been devised by the manufacturer to
fornire le informazioni necessarie a coloro che sono give necessary information to those authorised to
autorizzati ad interagire con il prodotto: dai progettisti, work on this product for example the design
agli installatori, manutentori e riparatori. engineers, in-stallers, repair and maintenance
Oltre ad adottare le regole della buona tecnica di technicians.
costruzione, le informazioni devono essere lette Besides helping one understand the rules of good
attentamente ed applicate in modo rigoroso. manufacturing techniques used, the information given
La non osservanza di dette informazioni può essere must be read attentively and strictly put into action.
causa di rischi per la salute e la sicurezza delle Failure to observe this information may lead to health
persone e danni economici. and safety risks to persons as well as economic loss.
Anche se le descrizioni non corrispondono Even though the descriptions may not correspond ex-
esattamente al prodotto in Vs possesso, ciò non actly to the product in possession, this does not have
pregiudica la loro validità. any bearing on their validity.
1.2 INFORMAZIONI SULLA SICUREZZA 1.2 INFORMATION 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
direttamente sul prodotto, in particolare rispettare and make sure to follow the information concerning
quelle riguardanti la sicurezza. safety.
Il personale che effettua qualsiasi tipo di intervento in Personnel, which perform any type of work on the
tutto larco di vita del prodotto, deve possedere product during its life span, must possess precise
precise competenze tecniche, particolari capacità ed tech-nical qualifications as well as recognised skills
esperienze acquisite e riconosciute nel settore and ex-perience gained in the specific sector. Failure
specifico. La mancanza di questi requisiti può to do so may lead to health and safety risks to
causare danni alla si-curezza e alla salute delle persons.
persone. It is recommended that when handling the product
Eseguire la movimentazione del prodotto rispettando attention is paid to the information given in this
le informazioni riportate in questo manuale oppure manual or simply follow the instructions given on the
applicate direttamente sullimballo (se presenti). packaging (if present).
Utilizzare il prodotto solo per gli usi previsti dal Utilise the product only for the use specified by the
fabbricante. Limpiego del prodotto per usi impropri manufacturer. Improper use of the product could lead
può recare rischi per la sicurezza e la salute delle to health and safety risks to persons as well as
persone e danni economici, nonchè il decadere della economic loss and furthermore will invalidate the
garanzia da parte del costruttore. guarantee given by the manufacturer.
Mantenere il prodotto in condizioni di massima effi- Keep the product in perfect working order by following
cienza effettuando le operazioni di manutenzione pro- the scheduled maintenance procedure set out by the
grammata previste dal costruttore. Una buona manufacturer. Good maintenance will ensure the best
manutenzione consentirà di ottenere le migliori performances, a longer period of operation and a
presta-zioni, una più lunga durata di esercizio e un con-stant safeguard towards security requirements.
manteni-mento costante dei requisiti di sicurezza.
To undertake maintenance procedures in areas which
Per eseguire interventi di manutenzione in zone non are hard to reach or otherwise dangerous it is
facilmente accessibili o pericolose, predisporre ade- important to follow adequate safety conditions for one
guate condizioni di sicurezza per sé stessi e per gli self and for others in compliance with the rules and
altri rispondenti alle leggi vigenti in materia di regulations that govern safety in the workplace.
sicurezza sul lavoro.
When replacing worn parts, use original spare parts.
Sostituire i particolari usurati utilizzando i ricambi Use oils and greases recommended by the manufac-
originali. Usare gli oli e i grassi consigliati dal turer. Doing this, will ensure that the product works
costruttore. Tutto questo potrà assicurare la properly and that the safety level is acceptable.
funzionalità del pro-dotto ed un livello di sicurezza
accettabile.
Man_2T261300732_sm.doc Pag.5 05/2001
008 916 41 BOMAG 679

10.4
DIVISIONE:
TravelGroup
Bonfiglioli gear
2.0 TARGHETTA IDENTIFICATIVA 2.0 NAME PLATE

I dati per lidentificazione del prodotto sono riportati in The data to identify the product are shown on the iden-
una targhetta applicata su di esso. tification plate attached to it.
Nel caso di un motoriduttore vi sono due targhette; una The gearmotor has two plates, one gives data on the
riporta i dati del riduttore, laltra quelli del motore gearbox and the other data on the hydraulic motor. The
idraulico. Lillustrazione evidenzia la disposizione dei following illustration shows how the data is set out.
dati.
TRASMITAL BONFIGLIOLI
DIVISIONE della BONFIGLIOLI RIDUTTORI S.p.A.
TYPE
❶ 7 07 C 3 B 24 C 53 H1 LQ
RATIO 1/ ❷ SERIAL N°
❺
DRWG.N°
❸ DATE
❻
COD.N° ❹ MADE IN ITALY
Ref. Dati / Data Descrizione / Description Note / Notes

❶ TYPE Designazione riduttore / Gearbox Designation 7 07 C 3 B 24 C 53 H1 LQ
❷ RATIO 1: Rapporto di riduzione / Reduction ratio 1:53
❸ DRWG.N° Disegno di installazione / Installation drawing 5.613.108.2
❹ COD.N° Codice Prodotto / Product code 2T261300732
❺ SERIAL N° N° di serie prodotto / Product serial number
❻ DATE Data di costruzione / Manufacturing date
Attenzione La targhetta deve essere sempre W a r n in g The informations stamped on the

conservata leggibile in tutti gli elementi in essa name plate must always be readable. Use the
contenuti. Usare i dati identificativi (almeno il numero identification data (at least serial number) for spare part
di serie) per i rapporti con il costruttore, come per enquiries, information and service, etc.
esempio: richiesta di ricambi, informazioni, assistenza. A strict and consistent compliance with the
La completa e costante osservanza delle indicazioni specifications of this technical manual ensure the
contenute nel presente manuale tecnico garantisce la minimum operating costs and a longer unit life.
migliore economia di esercizio ed una piu' lunga durata Photographic documentation and drawings are supplied
di funzionamento del riduttore. for educational purposes, so as to safely and properly
La documentazione fotografica ed i disegni sono forniti carry out maintenance operations.
a scopo esplicativo, in modo da descrivere Minor deviations from pictures of this manual may
esaurientemente le operazioni da eseguire sul riduttore. appear on the actual gearbox. However, these
Anche se il riduttore in vostro possesso si discostasse discrepancies are not relevant to the main parameters,
in parte dalle illustrazioni contenute in questo manuale or maintenance functions.
tecnico, le caratteristiche e la sequenza delle operazioni
descritte sono sempre garantite.
Man_2T261300732_sm.doc Pag.6 05/2001
680 BOMAG 008 916 41

Travel gear
3.0 NOTE 3.0 NOTES

3.1 CONDIZIONI DI FORNITURA 3.1 DELIVERY CONDITIONS
I riduttori vengono forniti dalla TRASMITAL Gearboxes are supplied by TRASMITAL
BONFIGLIOLI nelle seguenti condizioni standard: BONFIGLIOLI 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 di 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 e compatibile con the one used in the final test of the gearbox and
gli olii raccomandati (Tab.1). Non viene eseguito il compatible with the recommended oils (section 5.1).
riempimento dell'olio lubrificante (come Lubricating oil has not been added (as shown on
segnalato da cartellino). the card).
• Verniciati con una vernice di fondo antiossidante • Externally painted with an antioxidant grey-coloured
all'acqua di colore grigio, sopra verniciabile. Le water paint suitable for finish painting.
superfici di accoppiamento non sono verniciate. La Machined surfaces are not painted.
verniciatura finale è a cura del cliente. Finish coat to be applied by the customer.
• Collaudati. • 100% factory tested.
• Appositamente imballati. • Suitably packed.
i Informazioni Al ricevimento del prodotto, i Information When the product arrives, ensure
accertarsi che corrisponda alle specifiche di that it meets the information contained in the
acquisto e che non presenti danni o anomalie. Per purchase agreement and that there are no damages
qualsiasi inconveniente rivolgersi direttamente alla or irregularities. If there are any problems contact
rete di vendita del costruttore. the manufacturers sales network directly.
3.2 TRASPORTO 3.2 TRANSPORT

Durante il trasporto è norma trattare i riduttori come We recommend that the box containing gearboxes is
merce delicata per evitare danni. handled carefully in order to avoid damages during
Durante i trasporti interni dei riduttori senza imballo, transport. When removing gearboxes from their
evitare che questi prendano urti per non danneggiare packaging, extra caution should be taken to avoid
le parti delicate. impacts, which may damage sensitive parts.
3.3 STOCCAGGIO 3.3 STORAGE

Per il corretto stoccaggio del prodotto, osservare le Observe the following instructions to ensure correct
seguenti raccomandazioni: storage of delivered products:
• Escludere aree all'aperto, zone esposte alle • Do not store outdoors, in areas exposed to weather
intemperie o con eccessiva umidità. or with excessive humidity.
• Interporre sempre tra il pavimento ed i prodotti, • Always place boards of wood or other material
pianali lignei o di altra natura, atti ad impedire il between floor and products, to avoid direct contact
diretto contatto col suolo. with the floor.
• Per periodi di stoccaggio superiori ai 60 giorni, le • For storage periods of over 60 days, all machined
superfici interessate agli accoppiamenti quali flange, surfaces such as flanges, shafts and couplings must
alberi e giunti, devono essere protette con idoneo be protected with a suitable anti-oxidation product
prodotto antiossidante (SHELL ENSIS FLUID SDC (SHELL ENSIS FLUID SDC or equivalent
od equivalente). product).
Per periodi di stoccaggio previsti superiori ai 6 mesi, i The following measures must be taken for products
prodotti devono essere oggetto delle seguenti attività: which expected storage period exceeds 6 months:
• Ricoprire le parti lavorate esterne e quelle di accop- • Cover outer machined parts and mating parts with
piamento con grasso atto ad evitare ossidazioni. grease to avoid oxidation.
• Posizionare i riduttori con il tappo di sfiato nella • Position the gearboxes with the breather plug up
posizione più alta e riempirli di olio. and fill them with oil.
I riduttori, prima del loro utilizzo, dovranno essere Before use, the gearboxes should be filled with
riempiti con la corretta quantità e tipo di the proper amount of lubricant of the
lubrificante previsto. recommended type.
Man_2T261300732_sm.doc Pag.7 05/2001
008 916 41 BOMAG 681

10.4
DIVISIONE:
TravelGroup
Bonfiglioli gear
3.4 SOLLEVAMENTO E MOVIMENTAZIONE 3.4 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.
Attenzione
Considerando che la massa e la Warning Considering that the size and
forma del prodotto non ne consentono lo form of the product do not allow manual shifting,
spostamento a mano, in particolari in particular handlings, (e.g. installation) it is
movimentazioni (es: installazione), è necessario necessary to use accessories that guarantee
utilizzare accessori che consentono di garantire human safety and which also avoid damages to
la sicurezza delle persone ed evitare danni al the product.
prodotto.
i Informazioni Non togliere in nessun caso il
i Information Under no circumstance remove
coperchio in plastica delle porte di alimentazione the plastic lid from the power supply ports of the
del motore idraulico, in modo da evitare hydraulic motor; this will help avoid the
l'introduzione accidentale di corpi estranei, sino accidental introduction of foreign bodies into the
al momento del collegamento dei tubi flessibili. motor, until the hoses are assembled.
Man_2T261300732_sm.doc Pag.8 05/2001
682 BOMAG 008 916 41

Travel gear
4.0 INSTALLAZIONE 4.0 INSTALLATION

4.1 INSTALLAZIONE DEL MOTORE IDRAULICO 4.1 HYDRAULIC MOTOR INSTALLATION.
Assicurarsi che le superfici di accoppiamento ed il The mating areas and the pilot diameter of the
centraggio dove va inserito il motore idraulico siano gearbox where the motor is to be mounted must be
pulite ed esenti da bave. clean and without burrs.
i Informazioni Prima di montare il motore i Informazioni Before assembling the hydraulic
idraulico, verificare, con un calibro per interni, il motor, verify by a depth slide gauge the correct
corretto assemblaggio del riduttore controllando assembly of the unit checking the axial distance
la quota assiale indicata nello schema in basso: as shown in the scheme below:
Quota assiale = 93,2-94,0 mm. Axial dimension = 93,2-94,0 mm.
Montare la guarnizione O-ring (36), fornita con il Fit the O-ring (36), supplied with the gearbox, in its
riduttore, nella propria sede nel motore idraulico ed seat in the hydraulic motor, and assemble it to the
assemblare quest'ultimo al riduttore facendo gearbox being careful not to damage the seal already
attenzione a non danneggiare la guarnizione fitted.
precedentemente montata.
Serrare le n°2 viti TE M16x40, classe di resistenza Tighten the nos.2 hexagonal head screws M16x40,
8.8 (37), con una chiave dinamometrica alla coppia di grade 8.8 (37), by a torque wrench at 215 Nm torque.
215 Nm.
4.2 INSTALLAZIONE DEL RIDUTTORE 4.2 INSTALLATION OF THE GEARBOX
SULLA MACCHINA TO THE MACHINE
a) Pulire le zone di accoppiamento da protettivi o a) Clean the mating surfaces from oils or paint and fit
vernice ed installare il riduttore sul sottocarro. the gearbox to the undercarriage.
b) Fissare il riduttore al telaio con n°20 viti M20 classe b) Fix the gearbox to the frame with nos.20 screws
minima di resistenza 8.8, serrate con una chiave M20 minimum grade 8.8, tightened by a torque
dinamometrica alla coppia di 415 Nm. wrench at 415 Nm torque.
c) Pulire la zona di accoppiamento alla ruota motrice. c) Clean the area which mates to the driven wheel.
Per il fissaggio della ruota usare n°20 viti M16 To fit the sprocket use nos.20 screws M16, grade
classe di resistenza 8.8, serrate con una chiave 8.8, tightened by a torque wrench at 215 Nm
dinamometrica alla coppia di 215 Nm. torque.
Telaio macchina
Machine frame M16 N°20
M20x2,5 N°20
M16x40 N°2
93,2-94,0
Schema di installazione Installation scheme
Man_2T261300732_sm.doc Pag.9 05/2001
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10.4
DIVISIONE:
TravelGroup
Bonfiglioli gear
4.3 COLLEGAMENTO DEL FRENO 4.3 CONNECTION OF THE BRAKE PIPE

Il riduttore e' provvisto di un freno negativo a dischi The gearbox is supplied with a safety negative
multipli di sicurezza a comando idraulico (freno di multidisc brake hydraulically driven (parking brake).
stazionamento).
Per l'apertura del freno collegare il tubo di comando For brake releasing, connect the oil pipe to the
al foro filettato situato sul mozzo flangiato (filettatura threaded hole placed on the flanged hub
1/4"G - BSP 19 filetti per pollice) (1/4"G - BSP thread, 19 T.P.I).
DATI TECNICI FRENO / BRAKE TECHNICAL DATA

N° dischi acciaio / Nos. of steel discs [qty.] 5
N° dischi sinterizzati / Nos. of sintered discs [qty.] 6
N° molle / Nos. of springs [qty.] 18
Pressione minima di completa apertura / minimum brake release pressure (bar) 14±10%
Pressione massima di comando freno / Maximum operating pressure brake (bar) 50
Coppia frenante / Braking torque (Nm) 400±10%
5.0 LUBRIFICAZIONE 5.0 LUBRICATION

5.1 LUBRIFICAZIONE RIDUTTORE 5.1 GEARBOX LUBRICATION
La lubrificazione è separata fra motore e riduttore. The motor and the gearbox have separate lubrication.
La lubrificazione del riduttore e' a sbattimento in The gearbox is lubricated by oil splashing.
bagno d'olio.
L'olio consigliato e' del tipo per trasmissioni ad The recommended type of oil is SAE 80W/90 or
ingranaggi, con viscosita' SAE 80W/90 oppure SAE 85W/140 with EP features complying with
SAE 85W/140 con caratteristiche EP rispondente a: MIL-L-2105 C & API GL5, according to Tab.1
MIL-L-2105 C & API GL 5, secondo le indicazioni di
Tab.1
iInformazioni Durante l'esercizio e solo per i Information During operation the oil
brevi momenti l'olio può raggiungere, ma non temperature must not exceed 85-90°C
superare, la temperatura di 85-90°C intermittente. intermittent.
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
-10°C / +30°C +20°C / +45°C
Ambient temperature
Viscosità olio / Oil viscosity SAE 80W/90 SAE 85W/140
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 LUBRICANTE UNIVERSAL GEAR LUBRICANTE
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
Tab.1 Elenco olii consigliati / Lubricant oils suggested
Man_2T261300732_sm.doc Pag.10 05/2001
684 BOMAG 008 916 41

Travel gear
5.2 RIEMPIMENTO OLIO 5.2 OIL FILLING

Attenzione Il riduttore viene fornito privo di Warning The gearbox is supplied without
olio ma predisposto con tappi di carico, scarico e oil; anyway it has filling, draining and oil level
livello. Prima della messa in funzione occorre fare plugs. Before putting the gearbox into operation,
il riempimento. it is necessary to fill it with oil.
1. Con l'asse del riduttore in orizzontale, ruotare il 1. Check that the gearbox axis is horizontal. Rotate
corpo riduttore fino a che il tappo (2) si trovi the gearbox housing until the plug (2) is on the
sullasse orizzontale del coperchio. horizontal axis of the cover.
2. Svitare i tappi (1-2) 2. Unscrew the two plugs (1-2).
3. Riempire dal foro superiore (1) fino a che l'olio 3. Fill from the upper hole (1) until the lubricant oil
lubrificante (caratteristiche indicate in Tab.1) non (characteristics given in Tab.1) flows out from the
fuoriesca dal foro (2). hole (2).
4. Avvitare i tappi (1-2) e mettere in funzione il 4. Tighten the filling oil plug (1-2) and let the gearbox
riduttore; attendere qualche istante, poi verificare run. After a few minutes, stop and check the oil
nuovamente il livello dell'olio. level.
5. Aggiungere olio lubrificante se necessario. 5. If necessary, refill with lubricant oil.
Quantita' olio indicativa = 2,5 litri ±10%. Approximate oil capacity = 2,5 liters ±10%.
5.3 SCARICO E SOSTITUZIONE OLIO 5.3 OIL DRAINING AND REPLACEMENT
1. Con l'asse del riduttore in orizzontale, ruotare il 1. Check that the gearbox axis is horizontal. Rotate
corpo riduttore fino a che il tappo (2) si trovi in the gearbox housing until the plug (2) is on the
basso sull'asse verticale del coperchio. bottom of the vertical axis of the cover.
2. Svitare i tappi (1-2) e fare defluire l'olio; per 2. Unscrew the plugs (1-2) and let the oil flow; in
agevolare l'operazione di scarico e' bene operare order to facilitate the draining must be oil still
con olio caldo. warm.
3. Effettuare il riempimento dell'olio seguendo le 3. Proceed with the oil fill-up following the
modalità predefinite (vedi paragrafo 5.2). procedures given (see Section 5.2).
Attenzione Si raccomanda di non miscelare Warning Never mix mineral oils with
olii a base minerale con olii a base sintetica e synthetic oils and vice versa.
viceversa.
Warning Do not dispose of the oil in the
Attenzione
Non disperdere l olio nell natural environment but be careful to eliminate it
ambiente ma smaltirlo rispettando le leggi vigenti in compliance with the relative rules and
in materia. regulations that govern locally.
Asse orizzontale
Horizontal axis
Schema di carico, scarico e livello olio - Filling, draining and oil level scheme
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10.4
DIVISIONE:
TravelGroup
Bonfiglioli gear
6.0 MESSA IN ESERCIZIO 6.0 START UP

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. Avviare il motoriduttore dopo aver riempito il corpo 1. Start the gearmotor after having filled the motor
del motore con olio idraulico fino al foro di housing with hydraulic oil up to drain hole. Add more
drenaggio. Eliminare eventuale aria residua dal oil if necessary, after having eliminated any residual
circuito idraulico e aggiungere olio se necessario. air that may have been in the hydraulic circuit.
i Informazioni La presenza di aria residua nel i Information The presence of residual air in the
circuito idraulico si manifesta con la presenza di hydraulic circuit will manifest itself with the
schiuma nel serbatoio e causa un funzionamento a presence of foam in the tank and will lead to a
strappi del motore ed un eccessiva rumorosità del jerking of the motor as well as excessive noise
motore e delle valvole. coming from the motor and the 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.
i Informazioni Non arrivare alla massima i Information Do not reach maximum pressure
pressione sino a quando tutto limpianto non sia unless the entire system has been filtered to
stato filtrato per l'eliminazione di eventuali eliminate any particles of dirt that may be present.
particelle di impurità.
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. Check the correct revolution and direction of
rotazione siano corretti. rotation.
4. Controllare che il funzionamento sia regolare ed in 4. Make sure that the functioning is regular and with-
assenza di rumore eccessivo e vibrazioni. out any excessive noises and vibrations.
5. Controllare che la temperatura dellolio non superi i 5. Make sure that the oil temperature does not exceed
90°. 90°.
6. Controllare che non vi siano altri problemi. 6. Make sure there are no other problems in general.
Al termine di questo primo rodaggio eseguire le opera- After having terminated this first running-in follow the
zioni di seguito indicate. steps given below.
6. Controllare che non vi siano perdite 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 dellolio lubrificante del 7. Check the level of lubricating oil in the gearmotor
motoriduttore
8. Durante il primo avviamento, causa leventuale 8. It could happen that due to the presence of air,
presenza di aria, lapertura del freno potrebbe during the first start up, the opening action of the
risultare ritardata. Ripetere alcune volte il comando brake could be slowed down. It is advised to repeat
di apertura e chiusura del freno. the opening and closing function of the brake.
9. Controllare che non vi siano altri problemi. 9. Check that there are no other problems in general.
Man_2T261300732_sm.doc Pag.12 05/2001
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Travel gear
7.0 MANUTENZIONE 7.0 MAINTENANCE

In caso di normale funzionamento il motoriduttore non Under normal operating circumstances, no routine
necessita di alcuna manutenzione ad eccezione del maintenance is required, except routine oil checks and
controllo e cambio olio. Sono necessari interventi di oil changes. As recommended in this manual, unusual
assistenza solo in seguito ad anomalie di operating characteristics, such as noise or overheat,
funzionamento. should indicate further investigation.
Eseguire i controlli ed attività secondo la tabella For a proper maintenance of the gearbox, the following
seguente: checks and operations have to be done.
Controllo / Inspection Frequenza / Frequency Azione / Action

Serraggio viti Dopo le prime 50 ore di lavoro del riduttore Verificare serraggio viti
Tightening screws After the first 50 operating hours of the gearbox Screws tightening torque check
Livello olio Ogni 100 ore di lavoro del riduttore Aggiungere olio
Oil level Every 100 operating hours of the gearbox Refill oil
Primo cambio olio A 150 ore di lavoro del riduttore Sostituire olio
st
1 oil change At 150 operating hours of the gearbox Oil replacement
Cambi olio successivi Ogni 1000 ore di lavoro del riduttore o 1 volta lanno Sostituire olio
Next oil change Every 1000 operating hours or at least one a year Oil replacement
i Informazioni In caso di manutenzioni importanti i Information In case of important and complex

e complesse, fare riferimento ai Disegni Esplosi e maintenance operations, make reference to The
Liste Ricambi fornibili su richiesta ed alle Spare Part Lists Exploded View which can be
prescrizioni contenute nel presente manuale supplied under request or the suggestions of this
tecnico. manual.
Se sono necessarie istruzioni supplementari o se Do not hesitate to contatct the gearbox distributor or
dovessero nascere problemi particolari, non esitate a manufacturer if further instructions are necessary or in
contattare il distributore o direttamente il nostro servizio case of particular problems.
tecnico.
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10.4
DIVISIONE:
TravelGroup
Bonfiglioli gear
8.0 SMONTAGGIO 8.0 DISASSEMBLY

Per le prime verifiche degli ingranaggi, del freno e del Initial inspection of the gears, of the brake and of the
motore idraulico, è possibile intervenire senza hydraulic motor, can be made without disassembling
smontare la ruota e il riduttore dalla macchina. the wheel and the gearbox from the machine.
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 5.3. Svitare e sfilare le 2 section 5.3. Unscrew and remove the 2 hexagonal
viti TE M16x40 (37), classe di resistenza 8.8 e togliere il head screws M16x40 (37), grade 8.8, and remove the
motore idraulico e la guarnizione O-ring (36). hydraulic motor and the O-ring seal (36).
1.
Montare lattrezzatura (AT709C.03) sul mozzo (18) ed agire sulla
vite fino a contrastare la forza delle molle (33).
Install the equipment (AT709C.03) on the flanged hub (18) and turn
the screw until it contrasts the force of the spring (33).
2.
Con l'ausilio di pinze sfilare l'anello elastico (35) e smontare
lattrezzatura.
Using pliers remove the circlip (35) and take away the equipment.
3.
Sfilare il disco spingimolle (34).
Remove springs retainer (34).
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Travel gear

4.
Sfilare le molle (33) dalle proprie sedi nel pistone freno (32).
i Informazioni Contrassegnare la posizione delle molle allo
scopo di avere un riferimento per il rimontaggio.
Remove the springs (33) from their seats in the brake piston (32).
i Information Mark the position of the springs as a reference
for the reassembling step.
5.
Inserire un estrattore per interni nel foro dell'albero freno (21),
espandere l'estremità inferiore dell'estrattore nello scarico interno
dell'albero freno e sfilare contemporaneamente quest'ultimo e il
pistone freno (32).
Insert an inside puller into the hole of the brake shaft (21), expand
the lower end of the puller into the internal release of the brake
shaft and remove contemporary it and the brake piston (32).
6.
Sfilare il distanziale (25).
Remove the spacer (25).
7.
Togliere le guarnizioni O-ring (27-28) e gli anelli antiestrusione (26-
29) dalle proprie sedi nel distanziale (25).
Remove the O-Ring seals (27-28) and the backup rings (26-29)
from their seat in the spacer (25).
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10.4
DIVISIONE:
TravelGroup
Bonfiglioli gear

8.
Sfilare il pacco dei dischi freno (23-24).
Remove brake discs pack (23-24).
9.
Togliere la guarnizione O-ring (30) e lanello antiestrusione (31)
dalle proprie sedi situate nel mozzo flangiato (18).
Remove the O-ring seal (30) and the backup ring (31) from their
seats in the flanged hub (18).
10.
Svitare le n°3 viti TSPEI M10x25 (22), classe di resistenza 10.9,
che fissano l'anello ritegno (20) al mozzo flangiato (18).
Unscrew the nos.3 flathead screws M10x25 (22) grade 10.9, which
fix the cover (20) to the flanged hub (18).
11.
Sfilare l'anello ritegno (20).
Remove the cover (20).
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Travel gear

12.
Togliere la guarnizione O-ring (19) dalla propria sede nel mozzo
flangiato (18).
Remove the O-ring seal (19) from its seat in flanged hub (18).
8.1 CONTROLLO TENUTA FRONTALE 8.1 LIFETIME SEAL CHECK

i Informazioni Puo' essere necessario in caso di i Information In case of oil leakages, it might be
perdite olio, dover provvedere al controllo ed alla necessary to check and eventually replace the
eventuale sostituzione della tenuta frontale (16), cioe' lifetime seal (16), which means both the steel rings
di entrambi gli anelli metallici e delle guarnizioni and the O-rings.
O-rings.
13.
Con l'aiuto di un cacciavite smontare la 1°semitenuta frontale (16)
dall'anello di ritegno (20).
st
Use a screwdriver to remove the 1 half-seal (16) from the cover
(20).
14.
Con l'aiuto di un cacciavite smontare la 2°semitenuta frontale (16)
dal mozzo flangiato (18).
nd
Use a screwdriver to remove the 2 half-seal (16) from the flanged
hub (18).
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10.4
DIVISIONE:
TravelGroup
Bonfiglioli gear

15.
Capovolgere il riduttore e svitare le n°10 viti TCEI M10x25 (1),
classe di resistenza 12.9, che fissano il coperchio di chiusura (2) al
corpo riduttore (15) con chiave esagonale maschio.
Turn the gearbox upside down and unscrew the nos.10 socket
head screws M10x25 (1) grade 12.9, which fix the end cover (2) to
the gearbox housing (15) by using a male hex head wrench.
16.
Sfilare il coperchio di chiusura (2) con l'ausilio di n°2 viti M18x1,5
avvitate nei fori dei tappi olio.
Remove the end cover (2) by using nos.2 screw M18x1,5 screwed
to the oil plugs holes.
17.
Togliere la guarnizione O-ring (5) dal coperchio di chiusura (2).
Remove the O-ring seal (5) from the end cover (2).
18.
Sfilare il solare di 1°riduzione (7).
st
Take out 1 stage sun gear (7).
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Travel gear

19.
Estrarre la 1°riduzione (8).
st
Remove the 1 reduction assembly (8).
20.
nd
Remove the 2 stage sun gear (9).
21.
Estrarre la 2°riduzione (10).
nd
Remove the 2 reduction assembly (10).
22.
rd
Remove the 3 stage sun gear (11).
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10.4
DIVISIONE:
TravelGroup
Bonfiglioli gear
OFFICINA
WORKSHOP
iInformazioni Per proseguire nello smontaggio i

Information In order to proceed with the
del riduttore, occorre a questo punto smontarlo gearbox disassembly, it is now necessary to
dalla macchina e recarsi in una officina remove it from the machine and bring it to a
opportunamente attrezzata. properly equipped workshop.
23.
Svitare le n°4 viti TCEI M16x100 (12), classe di resistenza 10.9,
che fissano la 3°riduzione (13) al mozzo flangiato (18) con chiave
esagonale maschio.
Unscrew the nos.4 socket head screws M16x100 (12), grade 10.9,
rd
which fix the 3 reduction assembly (13) to the flanged hub (18), by
using a male hex head wrench.
24.
Servendosi di un estrattore, sfilare il portaplanetario di 3° riduzione
(13) dal mozzo flangiato (18).
rd
By using a puller, remove the 3 reduction planet carrier (13) from
the flanged hub (18).
25.
Utilizzando l'attrezzatura (ATZ.05.006), sfilare le n°4 boccole (14)
dal mozzo flangiato (18) o dal portaplanetari di 3°riduzione (13).
Using the equipment (ATZ.05.006), remove the nos.4 bushes (14)
rd
from the flanged hub (18) or from the 3 reduction planet carrier
(13).
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Travel gear

26.
Utilizzando l'attrezzatura (ATZ.05.006), sfilare i n°4 gruppi planetari
di 3°riduzione (13).
By using the equipment (ATZ.05.006) remove the nos.4 planet
rd
assemblies of the 3 reduction (13).
27.
Sfilare l'anello spingidischi (17) dal mozzo flangiato (18).
Remove the discs retainer (17) from the flanged hub (18).
28.
Sollevare il corpo riduttore (15) posizionandolo su 2 distanziali.
Servendosi di una pressa e di un tampone metallico, sfilare il
mozzo flangiato (18) dal corpo riduttore (15) facendo attenzione
all'eventuale caduta delle sfere.
Lift the gearbox housing (15) positioning it on 2 spacers.
By using a press and a metal stopper, remove the flanged hub (18)
from the gearbox housing (15) paying attention to the eventual
falling down of the main bearing's balls.
29.
Servendosi di un estrattore, sfilare l'anello interno del cuscinetto
rimasto sul mozzo flangiato (18).
Use a puller to remove the bearing inner race remaining on the
flanged hub (18).
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10.4
DIVISIONE:
TravelGroup
Bonfiglioli gear
i Informazioni Lo smontaggio del riduttore i Information The gearbox disassembly ends

termina con quest'ultima operazione: tutti i with the above operation. All the parts are now
particolari sono ora a disposizione per le available for the necessary inspections.
verifiche necessarie.
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Travel gear
9.0 RIMONTAGGIO 9.0 REASSEMBLY

9.1 NOTE IMPORTANTI PRIMA DEL 9.1 IMPORTANT NOTES BEFORE
RIMONTAGGIO REASSEMBLY
When proceeding with the gearbox reassembly, it is
Quando si procede al rimontaggio del riduttore
necessary to follow the rules listed below:
occorre attenersi ad alcune regole fondamentali:
1. In case of damaged gears, for example a planet,
1. Nel caso di ingranaggi danneggiati, esempio un
do not replace the single gear, but the whole
planetario, non sostituire il singolo ingranaggio ma reduction stage.
tutta la riduzione.
2. Replace always the O-rings and seal rings of
2. Sostituire sempre le guarnizioni O-ring ed gli the part to be reassembled after having carefully
anelli di tenuta interessati alla parte da cleaned the seats and having buttered some
rimontare dopo aver pulito con attenzione le sedi grease on the seats themselves and on the O-
di montaggio ed aver aggiunto un film di grasso rings to make easier the reassembly.
sulle sedi stesse e sulle guarnizioni per facilitarne
3. always replace all the components that seems
il montaggio.
to be damaged or with excessive wear, with
3. sostituire sempre le parti che risultano original spare parts.
danneggiate o usurate, con ricambi originali.
f
d
e
c
105
b a
20
Ø220
b a
Ø230
Ø260
Ø290
30. 31.
Montare sul corpo riduttore (15) il giro di sfere inferiore Sfilare il distanziale (b).
(d), sostenendo l'anello interno (c) tramite i distanziali Montare il giro di sfere superiore (e).
(a-b). Inserire l'anello interno del cuscinetto (f).
Fit the lower ball row (d), into the gearbox housing (15) Remove the spacer (b).
holding the inner raceway (c) with spacers (a-b). Drop the upper ball row (e)
Assemble the inner raceway (f).
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10.4
DIVISIONE:
TravelGroup
Bonfiglioli gear

32.
Supportare il corpo riduttore (15) con il distanziale a (vedi schema
precedente).
Posizionare il mozzo flangiato (18) all'interno del corpo riduttore
(15) e servendosi di una pressa e di un tampone metallico,
spingere questultimo in battuta fino ad ottenere il completo
assemblaggio del gruppo.
Support the gearbox housing (15) by using the spacer a (shown in
the sketch above)
Place the flanged hub (18) inside the gearbox housing (15) and by
using a press and a metallic stopper, push it against the shoulder
until assembly of the unit is complete.
33.
Avvitare la boccola di sicurezza (ATZ.07.005) in uno dei quattro fori
filettati M16 presenti nel mozzo flangiato (18) usando la vite TCEI
M16x100 (12), classe di resistenza 10.9 e capovolgere l'unità
mozzo flangiato-corpo riduttore (18-15).
Al termine dell'operazione su indicata, smontare la boccola di
sicurezza.
Screw the safety bush (ATZ.07.005) in one of the four holes M16 in
ATZ.07.005 the flanged hub (18) by using the socket head screw M16x100 (12),
grade 10.9 and turn the gearbox housing flanged hub group (15-18)
upside down.
9
At the end of above step disassemble the safety bush.
34.
Montare correttamente l'anello spingi-dischi (17) nel mozzo
flangiato (18).
Assemble correctly the discs retainer (17) in the flanged hub (18).
35.
Posizionare le n°4 boccole (14) nelle proprie sedi nel mozzo
flangiato (18) e con la pressa spingerle in battuta fino ad ottenere il
completo assemblaggio.
Place the nos.4 bushes (14) into their seats on the flanged hub (18)
and by using a press, push them against the shoulder inside their
seats until assembling is complete.
Man_2T261300732_rm.doc Pag.24 05/2001
698 BOMAG 008 916 41

Travel gear

36.
Posizionare i n°4 gruppi planetari di 3°riduzione (13) nelle proprie
sedi nel mozzo flangiato (18), e con una pressa spingerli in battuta
fino ad ottenere il completo assemblaggio.
rd
Place the nos.4 planet assemblies of the 3 reduction (13) into their
seats on the flanged hub (18), and use a press to push them
against the shoulder until assembling is complete.
37.
Posizionare il portaplanetari di 3°riduzione (13) sul mozzo flangiato
(18), e con la pressa spingere quest'ultimo in battuta fino ad
ottenere il completo assemblaggio.
rd
Place the 3 reduction planet carrier (13) on the flanged hub (18)
and by using a press push it against the shoulder until assembling
is complete.
38.
Applicare LOCTITE 243 sulle n°4 viti TCEI M16x100 (12), classe di
resistenza 10.9, ed inserirle nei rispettivi fori nel mozzo flangiato
(18).
Apply LOCTITE 243 on the nos.4 socket head screws M16x100
(12), grade 10.9, and insert them in the thread holes in the flanged
hub (18).
Loctite
39.
Serrare le n°4 viti TCEI M16x100 (12), classe di resistenza 10.9
con chiave dinamometrica esagonale maschio alla coppia di 290
Nm.
Tighten the nos.4 socket head screws M16x100 (12), grade 10.9,
by a male hex head torque wrench at 290 Nm torque.
Nm
Man_2T261300732_rm.doc Pag.25 05/2001
008 916 41 BOMAG 699

10.4
DIVISIONE:
TravelGroup
Bonfiglioli gear

40.
Inserire il solare di 3°riduzione (11).
rd
Insert the 3 stage sun gear (11).
41.
Montare la 2° riduzione (10).
nd
Assemble the 2 reduction assembly (10).
42.
nd
43.
Montare la 1° riduzione (8).
st
Assemble the 1 reduction assembly (8).
Man_2T261300732_rm.doc Pag.26 05/2001
700 BOMAG 008 916 41

Travel gear

44.
st
45.
Montare la guarnizione O-ring (5) nella propria sede nel coperchio
di chiusura (2).
Assemble the O-ring seal (5) into its seat in the end cover (2).
46.
Fissare il coperchio di chiusura (2) al corpo riduttore (15) con n°10
viti TCEI M10x25 (1), classe di resistenza 12.9, serrate con una
chiave dinamometrica alla coppia di 75 Nm.
Fix the cover (2) to the gearbox housing (15) by using nos.10
socket head screws M10x25 (1) grade 12.9, tightened by a torque
wrench at 75 Nm torque.
Nm
47.
Capovologere il riduttore e assemblare le guarnizioni O-ring (30) e
lanello antiestrusione (31) come descritto nello schema seguente.
Turn the gearbox upside down and assemble the O-ring seal (30)
and the backup ring (31) as shown in the following scheme.
Man_2T261300732_rm.doc Pag.27 05/2001
008 916 41 BOMAG 701

10.4
DIVISIONE:
TravelGroup
Bonfiglioli gear
Entrata olio in pressione

Pressurized oil inlet
Guarnizione O-ring
O-ring seal
Anello Antiestrusore
Backup ring
Schema di montaggio guarnizioni freno - Brake seals installation scheme
i Informazioni i Information
Inserire nella sede un anello O-ring e un anello An O-ring and a backup ring must be fitted in the seat
antiestrusione in modo che quest'ultimo si trovi a valle paying attention that the backup ring must always be
dell'anello O-ring rispetto all'olio in pressione. beyond the O-ring seal against the oil flow.
48.
Montare un pacco nuovo di dischi freno secondo il seguente
ordine:
inserire per primo un disco in bronzo sinterizzato (24) a dentatura
esterna. Inserire successivamente un disco in acciaio (23) a
dentatura interna. Ripetere l'operazione sino ad ottenere una
successione di n°6 dischi in bronzo sinterizzato e n°5 in acciaio.
Assemble a new brake discs package according to the following
order: firstly insert an external toothed sintered bronze disc (24).
Then insert, an internal toothed steel disc (23). Repete the
operation untill reaching the number of 6 sintered bronze and 5
steel discs.
49.
Montare l'albero freno (21).
Assemble the brake shaft (21).
Man_2T261300732_rm.doc Pag.28 05/2001
702 BOMAG 008 916 41

Travel gear

50.
Montare le guarnizioni O-ring (27-28) e gli anelli antiestrusione (26-
29) nelle proprie sedi nel distanziale (25).
Fit the O-ring seals (27-28) and the backup rings (26-29) into their
seats in the spacer (25).
51.
Assemblare il distanziale (25) al pistone freno (32), facendo
attenzione a non danneggiare le guarnizioni precedentemente
montate.
Assemble the spacer (25) to the brake piston (32), paying attention
not to damage the seals already fitted.
52.
Inserire il gruppo pistone freno-distanziale pistone (32-25) all'
interno del mozzo flangiato (18), facendo attenzione a non
danneggiare le guarnizioni precedentemente montate.
Insert the brake piston-spacer group (32-25) inside the flanged hub
(18), paying attention not to damage the seals already fitted.
53.
i Informazioni Inserire le molle (33) nel proprio alloggiamento

rispettando le posizioni contrassegnate in precedenza.
i Information Insert the springs (33) in their seats respecting

the markings set out previously.
Man_2T261300732_rm.doc Pag.29 05/2001
008 916 41 BOMAG 703

10.4
DIVISIONE:
TravelGroup
Bonfiglioli gear

54.
Inserire il disco spingimolla (34).
Assemble the spring retainer disc (34).
55.
Montare lattrezzatura (AT.709C03) sul mozzo flangiato (18) ed
agire sulla vite fino a contrastare la forza delle molle.
Put the equipment (AT.709C03) in the flanged hub (18) and turn
the screw until it contrasts the force of the spring.
56.
Con l'aiuto di pinze, montare l'anello elastico (35) nella propria
sede.
Using pliers, assemble the circlip (35) into its seat.
57.
Attenzione 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.
W a r n in g 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 scheme.
93,2-94,0
Man_2T261300732_rm.doc Pag.30 05/2001
704 BOMAG 008 916 41

Travel gear

9.2 ISTRUZIONI PER IL MONTAGGIO DELLA 9.2 INSTRUCTIONS FOR THE INSTALLATION
TENUTA FRONTALE OF THE LIFETIME SEAL.
1 2
6 6
3 3
5 5
4 4
Particolare di tenuta frontale - Lifetime seal detail
Preparazione della tenuta frontale Makeready of the lifetime seal

Per ottenere una perfetta tenuta, e' necessario To follow these instructions at the time of fitting, in
procedere al montaggio degli anelli nel seguente order to obtain the correct seal:
modo:
1. Effettuare una accurata pulizia degli alloggiamenti 1. Carefully clean the seats "1" and "2" using, if
"1" e "2" facendo uso, se necessario, di spazzole necessary, metal brushes or solvent (surfaces in
metalliche o solventi (le superfici a contatto con gli contact with or "3" must be perfectly clean and
anelli di gomma "3" devono essere perfettamente dry).
pulite ed asciutte).
2. Assicurarsi che le superfici di tenuta "4" degli 2. Make sure that sealing surfaces "4" of metal rings
anelli "5" siano esenti da qualsiasi rigatura, "5" are free from scratches, dinges or foreign
ammaccatura o corpi estranei e che le superfici substances; metal ring surfaces must be perfectly
"6" degli stessi anelli siano perfettamente pulite ed clean and dry.
asciutte.
3. Togliere dalle superfici lappate "4" degli anelli "5" 3. Carefully clean the lapped surface "4" of metal
ogni traccia di polvere o impronte digitali e rings "5" and remove dust or fingerprints. Then
umettarle poi con un leggero strato di olio, avendo lubrificate them with a thin oil film, taking care not
cura di non ungere le rimanenti parti. to oil the other components.
58.
Montare una semitenuta frontale (16) sull' attrezzo (ATZ.04.003).
Assemble an half seal (16) on the tool (ATZ.04.003).
Man_2T261300732_rm.doc Pag.31 05/2001
008 916 41 BOMAG 705

10.4
DIVISIONE:
TravelGroup
Bonfiglioli gear

59.
Eseguire il montaggio della 1° semitenuta frontale (16) sul mozzo
flangiato (18).
Assemble the 1st half seal (16) on the flanged hub (18).
60.
Pulire le parti metalliche della tenuta frontale (16) da eventuali
residui o polvere, e applicare sulla loro superficie un leggero strato
di olio.
Clean carefully the metallic faces of the lifetime seal (16), and lube
them with a thin oil film.
O IL
61.
Montare la guarnizione O-ring (19) nella propria sede nel mozzo
flangiato (18).
Assemble the O-ring (19) in its seat in the flanged hub (18).
62.
Montare, sempre con lo stesso attrezzo (ATZ.04.003), la
semitenuta frontale (16) sull'anello ritegno (20).
Pulire le parti metalliche delle semitenute frontali da eventuali
residui o polvere.
Assemble, by using the same tool (ATZ.04.003), the half seal (16)
on the cover (20).
Clean carefully the metal faces of the half-seals.
Man_2T261300732_rm.doc Pag.32 05/2001
706 BOMAG 008 916 41

Travel gear

63.
Montare l'anello di ritegno (20) sul mozzo flangiato (18).
Assemble the cover (20) on the flanged hub (18).
64.
Fissare lanello ritegno (20) al mozzo flangiato (18) con n°3 viti
TSPEI M10x25 (22), classe di resistenza 10.9, serrate con chiave
dinamometrica esagonale maschio alla coppia di 50 Nm.
Fix the cover (20) to the flanged hub (18) by using nos.3 flathead
screws M10x25 (22) grade 10.9, tightened by a male hex head
torque wrench at 50 Nm torque.
Nm
Man_2T261300732_rm.doc Pag.33 05/2001
008 916 41 BOMAG 707

10.4
DIVISIONE:
TravelGroup
Bonfiglioli gear

9.3 CONTROLLO FRENO 9.3 BRAKE CHECK
Qualora si sia eseguito un intervento sul freno, è If the brake has been disassembled then a check of
necessario controllare che non ci siano perdite di olio. the brake function is needed before putting it into
Procedere come segue: operation.
1. Collegare al foro comando freno un manometro e Proceed as follow:
la relativa valvola di comando afflusso olio 1. Connect the pressure pilot line with the
2. Aprire la valvola di comando afflusso olio e manometer to the brake release port. The flow
sbloccare il freno, raggiungendo la pressione di valve is closed.
150 bar 2. Open the flow valve and release the brake with the
3. Chiudere la valvola di comando afflusso olio e pilot pressure of 150 bar
mantenere la pressione nel freno per un periodo 3. Close the flow valve and keep the brake released
di 3 minuti. 3 minutes long.
4. Verificare con il manometro che la pressione 4. Check that no pressure drop has occured
rimanga costante.
Attenzione Se la pressione diminuisce significa W a r n in g If the pressure drops down, the
che il rimontaggio non è stato eseguito in modo gearbox reassembly is not correct, or the seals are
corretto; oppure che le guarnizioni del freno non damaged: in this case the seals have to be repalced.
fanno tenuta: in tal caso si dovrà procedere alla loro
sostituzione.
Entrata olio in pressione

Oil pilot pressure
150
0 300
bar
Man_2T261300732_rm.doc Pag.34 05/2001
708 BOMAG 008 916 41

Travel gear

i Informazioni Al termine delle operazioni rimontare i I n f o rm a t i o n After having reassembled the
il motore idraulico completo della sua guarnizione O- gearbox, fit the hydraulic motor, being careful to include
ring (36), fissandolo al riduttore con n°2 viti TE M16x40 the O-ring (36), with nos.2 hexagonal head fixing
(37), classe di resistenza 8.8, serrate ad una coppia di screws M16x40 (37), grade 8.8, tightened at 215 Nm
215 Nm. torque.
Effettuare il riempimento olio come illustrato al
paragrafo 5.2 Fill the gearbox with the lubricant oil as shown in
section 5.2.
Nm
10.0 DISEGNI ATTREZZATURE 10.0 FIXTURE DRAWINGS
I disegni costruttivi delle attrezzature speciali utilizzate Special drawings of the tools used in the disassembly
per le fasi di smontaggio e rimontaggio del riduttore and reassembly steps of the gearbox are shown below:
sono riportati di seguito:
AT709C.03 Attrezzo smontaggio-rimontaggio freno AT709C.03: Tool for brake disassembly-reassembly
ATZ.05.006: Estrattore smontaggio riduzione ATZ.05.006: Puller for reduction disassembly
ATZ.07.005: Boccola di sicurezza ATZ.07.005: Safety bush
ATZ.04.003: Anello montaggio tenuta frontale ATZ.04.003: Tool for lifetime seal assembly
AT707C.08: Schema montaggio kit corpo AT707C.08: Scheme for kit housing assembly
AT707C.06: Ricambio kit corpo AT707C.06: Kit housing spare part
AT707C.09: Tubo per montaggio kit corpo AT707C.09: Tube for kit housing assembly
AT707C.07: Attrezzo per montaggio kit corpo AT707C.07: Tool for kit housing assembly
INDICE DELLE REVISIONI REVISIONS INDEX Par. Rev. Date

INSERIMENTI-MODIFICHE ADDITIONS-MODIFICATIONS
Questa pubblicazione annulla e sostituisce ogni precedente edizione This publication replaces and supersseds any previous issue and
o revisione. La TRASMITAL BONFIGLIOLI S.P.A. si riserva il diritto revision. TRASMITAL BONFIGLIOLI S.P.A. reserves the right to
di apportare modifiche senza preavviso. E' vietata la riproduzione implement modifications without notice. This manual cannot be
anche parziale senza specifica autorizzazione. reproduced, even partially, without prior written consent.
Man_2T261300732_rm.doc Pag.35 05/2001
008 916 41 BOMAG 709

10.4 Travel gear
710 BOMAG 008 916 41

11 Circuit diagrams
008 916 41 BOMAG 711

712 BOMAG 008 916 41
11.1 Hydraulic diagram 2542306
008 916 41 BOMAG 713

714 BOMAG 008 916 41

Hydraulic diagram 2542306 11.1
008 916 41 BOMAG 715

716 BOMAG 008 916 41

11.2 Wiring diagram DE006002
008 916 41 BOMAG 717

11.2 Wiring diagram DE006002
718 BOMAG 008 916 41

0 1 2 3 4 5 6 7 8 9
008 916 41
Industriegebiet Hellerwald
D-56154 Boppard
Wiring diagram DE006002
BF600C
DEUTZ TIER3
BOMAG
ELECTRIC DRAWING
CX17C
Drawing: DE006002
Created: 07.Lug.2006
Last update: 23.Lug.2007
Total Pages: 62
1.1
11.2
719
Design.: Zuccarino Luca
BF600C FRONT PAGE D: DE006002 pag. 1
date: 28.Apr.2008 PRIMA PAGINA
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9
720
PAGINA DESCRIZIONE COMMENTI PAGINA DESCRIZIONE COMMENTI
11.2
PAGE DESCRIPTION COMMENTS PAGE DESCRIPTION COMMENTS
1 FRONT PAGE 30 HORN

PRIMA PAGINA CLAXON
1.1 TABLE OF CONTENTS 40 DASHBOARD LIGHTS

INDICE LUCI CRUSCOTTO
1.2 TABLE OF CONTENTS 40.1 WORKING LIGHTS

INDICE FARI DI LAVORO
1.3 TABLE OF CONTENTS 45 ROOF

INDICE TETTOIA
5 BATTERY COMPARTMENT 50 BEACON

VANO BATTERIA GIROFARO
7 STARTING KEY 60 WASHING PUMP

CHIAVE AVVIAMENTO POMPA LAVAGGIO
10 ENGINE STARTER 70 EMERGENCY PUSH BUTTONS
BOMAG
AVVIAMENTO MOTORE PULSANTI EMERGENZA
10.1 ENGINE SENSORS 75 GENERAL ON

MOTORE SENSORI
10.2 ENGINE PRE-HEAT 80 TRAVELLING

MOTORE PRERISCALDO AVANZAMENTO
10.3 ENGINE EMR 80.1 TRAVELLING

MOTORE EMR AVANZAMENTO
10.4 ENGINE RPM 80.2 TRAVELLING

MOTORE RPM AVANZAMENTO
15 FAN 80.3 TRAVELLING

VENTOLA AVANZAMENTO
20 ALARMS 80.4 HYDRAULIC GEAR

ALLARMI CAMBIO IDRAULICO
008 916 41
1 1.2

BF600C TABLE OF CONTENTS D: DE006002 pag. 1.1
date: 28.Apr.2008 INDICE
0 1 2 3 4 5 6 7 8 9

008 916 41
80.5 BRAKE 155 DIODES CARD
FRENO SCHEDA DIODI
85 STEERING 160 LEFT LEVELLING

STERZATURA LIVELLO SINISTRO
90 LEFT CONVEYOR 160.1 RIGHT LEVELLING

NASTRO SINISTRO LIVELLO DESTRO
90.1 RIGHT CONVEYOR 160.2 LEVELLING SENSORS

NASTRO DESTRO SENSORI DI LIVELLAZIONE
100 LEFT AUGER 170 SCREED LIFTING

COCLEA SINISTRA SOLLEVAMENTO FERRO DA STIRO
100.1 RIGHT AUGER 170.1 SCREED LIFTING

COCLEA DESTRA SOLLEVAMENTO FERRO DA STIRO
100.2 AUGER BOX LIFTING 170.2 SCREED LIFTING

SOLLEVAMENTO CASSA COCLEE SOLLEVAMENTO FERRO DA STIRO
BOMAG
110 LOADING MATERIAL 180 SCREED HEATING
CARICAMENTO MATERIALE RISCALDAMENTO FERRO DA STIRO
120 HOPPERS 190 WATER SPRAYING

TRAMOGGE SPRUZZATURA ACQUA
130 SAFETY LOCK BOLTS 200 TAMPER AND VIBRATOR

CATENACCI DI SICUREZZA TAMPER E VIBRANTE
140 FUME EXHAUSTER 200.1 TAMPER AND VIBRATOR

ASPIRATORE FUMI TAMPER E VIBRANTE
150 LEFT SCREED EXTENSION 200.2 TAMPER AND VIBRATOR

ALLARGATORE SINISTRO TAMPER E VIBRANTE
150.1 RIGHT SCREED EXTENSION 200.3 TAMPER AND VIBRATOR

ALLARGATORE DESTRO TAMPER E VIBRANTE
1.1 1.3
11.2
721
0 1 2 3 4 5 6 7 8 9
722
11.2
250 ELECTRONIC UNIT

CENTRALINA
250.1 ELECTRONIC UNIT

CENTRALINA
301 COLORS
COLORI
1000 BILL OF MATERIALS

DISTINTA BASE

DISTINTA BASE

DISTINTA BASE
BOMAG
DISTINTA BASE

DISTINTA BASE

DISTINTA BASE

DISTINTA BASE
008 916 41
1.2 5

0 1 2 3 4 5 6 7 8 9
LC1 G-4-CENT
BATTERY
COMPARTMENT ELECTRONIC /80.5.1
R-16 UNIT
PREHEAT /10.2.5
R-10
BAT-KEY /7.0
008 916 41
A-4
POWER /180.2
HEATING
U-4
XENON /40.1.1
GR-2.5 LIGHTS
ON-2.5
30 30
JF1 JF5 JF2 JF4 JF3 JF7 JF8 JE3 JE2
.6 .6
20A 15A 87 87
20A 100A 60A 20A 15A REAR FRONT
ELECTRONIC PREHEAT KEY POWER XENON ROOF ROOF ROOF
ROOF BO-1.5-*456*
UNIT HEATING LIGHTS FRONT REAR
LIGHTING LIGHTING FRONT /45.0
ROOF
B-4
B-10
B-4
B-4
B-2.5
B-2.5
PO-1.5-*457*
REAR /45.0
ROOF
B-10
R-16 R-70 R-70
STARTER /10.3
ON-1
BOMAG
C3 C32 /40.1.2
MANUAL
SWITCH
GP-1-/668/
C28 /40.1.4
R-70
86 86
+
JE2 JE3
85 REAR 85
FRONT
ROOF ROOF
N-1
N-1
C2
BATTERY
-
GND GND
N-70
+
C1
BATTERY
-
N-4-CENT N-4-CENT
BAT-GND /250.2
N-70
GND
30 87 .7 30 87 .6
1.3 7
11.2
723
BF600C BATTERY COMPARTMENT D: DE006002 pag. 5
date: 28.Apr.2008 VANO BATTERIA
0 1 2 3 4 5 6 7 8 9
724
LC2
10.2.2
11.2
10.3.0 R-6 R-6

10.4.0 BATTERY /10.3.1
15.3
20.0
30.1 R-2.5
40.2
R-4
40.1.0
50.3
60.2
70.1 XKEY 1
75.0
80.0
80.1.2 C8 30 30 30 30 30 C7 30
80.2.0 C8 C8 C8 C8 E1
80.3.0 .2 SOCKET
80.4.1 .4 .2 .2 .2 .2 12V .2
58 15/54 19 17 50a 87
80.5.1 .3 IGNITION IGNITION IGNITION IGNITION KEY
85.0 .4 KEY KEY KEY KEY
90.0 IGNITION
90.1.0 KEY
100.0 NC NC NC
V-1.5 V-4
100.1.0
100.2.2 KEY /10.2.2
110.2 XKEY 5 XKEY 7
R-10
120.1
130.2
N-1.5
140.3
U-1.5-671
150.4 D-1
150.1.4
F10
GEN-ON /75.6
RN-1
155.0
10A
PO-2.5
160.0
160.1.0 24V/12V
160.2.2 TRANSFORMER
170.0 86 30 86
170.1.0 E17
170.2.4 E1 E17
.8
180.2 KEY 85 87a GEN-ON 85
190.0 GEN-ON
200.0
200.1.1
N-1
N-1
200.2.2 N-1.5
200.3.2
250.1
BOMAG
A-1.5-670
A-1.5-670
250.1.0
GND GND GND
DASH
BOARD WF 2 3 1
P-2.5-+50
GREEN
BLACK
RED
C10
24V/12V +12V GND +24V
TRANSFORMER
GND
N-6
Y 1 Y 3 R A1 R C2
F10 /45.0
R-10
N-6
P-14(AWG)-+50
5.8/ BAT-KEY GND START /10.3
ENGINE
008 916 41
30 87 .8 30 87a .4
5 10

BF600C STARTING KEY D: DE006002 pag. 7
date: 28.Apr.2008 CHIAVE AVVIAMENTO
0 1 2 3 4 5 6 7 8 9
008 916 41
LC3
10.1.2
20.1
ENGINE
COMPARTMENT
R-70 R-8(AWG)
5.8/ STARTER
30
B+
50 D+ B-18(AWG)-D+
C4 M
D+ /20.3
STARTER G
C5 3 W
GENERATOR NC
31 B-
GND GND
BOMAG
P-14(AWG)-+50
7.6/ START
ENGINE
7 10.1
11.2
725
BF600C ENGINE STARTER D: DE006002 pag. 10
date: 28.Apr.2008 AVVIAMENTO MOTORE
0 1 2 3 4 5 6 7 8 9
726
C150
10.3.2
10.4.1
11.2
EMR
ENGINE
COOLANT
LEVEL
ENGINE
FUEL
FILTER
ENGINE
FUEL
FILTER
AIR
FILTER
TIER3
XD 79 64 63 77
M-0.5
P-0.5-**
D-0.5
G-0.5-//
10.3.7
XC A7 B5 B4 C6
F3
M-1.5-"405"
M-1-XD79
P-1-*XD64*
D-1-XD63
G-1-/XD77/
Z A1 Z A2 Z A4 Z A3 Z A5
P:A3 /70.6
BOMAG
LC3
10.1
ENGINE
COMPARTMENT
GND
M-18(AWG)-"405"
N-18(AWG)
M-18(AWG)-XD79
P-1-*XD64*
D-1-XD63
G-1-/XD77/
O-1-XD28
WA 1 2 3 WB 2 WB 1
+ -
1 1
C39 C40 P
C38 ENGINE 2 ENGINE 2
ENGINE FUEL AIR FILTER
COOLANT FILTER
LEVEL S
008 916 41
10 10.2

BF600C ENGINE SENSORS D: DE006002 pag. 10.1
date: 28.Apr.2008 MOTORE SENSORI
0 1 2 3 4 5 6 7 8 9
LC2
7.0
V-4 V-4
DASH
BOARD 7.8/ KEY KEY /10.4.7
008 916 41
V-1
F40
7.5A
PREHEAT
5.8/ PREHEAT
R-16
XJE1 2
85 50i
BOMAG
JE1
JE1
.4
PREHEAT 50 30
PREHEAT
OR-1
R-16
XJE1 1
U-1-141
B-1-142
G-1.5-143
C9
PRE-HEATING
PLUG
XA 8 XA 3 XA 2 XA 5
XA8 XA3 XA2 XA5
30 50i .5
10.1 10.3
11.2
727
BF600C ENGINE PRE-HEAT D: DE006002 pag. 10.2
date: 28.Apr.2008 MOTORE PRERISCALDO
0 1 2 3 4 5 6 7 8 9
LC2
728
7.0
DASH
DIAGNOSTIC
BOARD
11.2
R-6
7.8/ BATTERY BATTERY /30.1
CANL
CANH
DIAGNOSTIC
CANH2
CANL2
GND
+VCC
E D C J L
R-2.5
XE E D G H K M F B C J L A
F13
NC NC NC NC NC
N-1
10A
POWER
EMR
M-1-"405"
GND
P-2.5
P-2.5 M-1.5-"405" M-1-"405"
10.1.3/ F3 F3 /20.1
85 30
E8
E8 P-1-XD62
.1
POWER 86 87 CAN H2 /20.7
EMR POWER
EMR XD:28 /70.4
R-2.5-XD1 U-1-XD61
CAN L2 /20.8
TWISTED TWISTED
BOMAG
TWISTED TWISTED
GND
A-1-XD72
R-1-XD1
R-1-XD3
R-1-XD5
O-1-XD28
N-1
N-1
N-1
B-1-XD60
G-1-XD82
V-1-XD25
P-1-XD62
U-1-XD61
XC A2 A1 B1 C1 A3 A8 B8 C8 A4 A5 A6 B2 B3
A-0.5
R-1
R-0.5
R-0.5
O-0.5
N-1
N-1
N-1
B-0.5
G-0.5
V-0.5
P-0.5
U-0.5
C150
10.1.3 XD 72 1 3 5 28 2 4 6 60 82 25 62 61
EMR
TIER3
GND
KEY
GND
GND
GND
+VCC
CANL
CANH
POWER
POWER
POWER
CANH2
CANL2
DIAGNOSTIC
008 916 41
30 87 .2
10.2 10.4

BF600C ENGINE EMR D: DE006002 pag. 10.3
date: 28.Apr.2008 MOTORE EMR
0 1 2 3 4 5 6 7 8 9
LC2 V-4
7.0
10.2.4/ KEY KEY /15.4
DASH C152
BOARD
ECO
SYSTEM
V-1.5
008 916 41
GND
RPM
GND
HEATING
MAX
ECO
TRAVELLING
AUGERS
CONVEYORS
F8
10A
ENGINE
XG 7 XG 8 XG 6 XG 2 XG 5 XG 4 XG 3 XG 1 RPM
MP-1.5
N-1.5
O-1.5-*533*
DIODES /155.1
GND CARD
*AN-1
TRAVELLING /80.7 13 23
C41 C41
.8
14 .7 24
U-1-/XD14/
B-1-/XD15/
PO-1.5
ECO
RPM MAX
RPM
PN-1.5
PR-1.5
BOMAG
Z A6
PO-1.5
Z:A6 /180.2
XC C4 XC C5
U-0.5//
B-0.5//
C150
10.1.3 XD 14 XD 15
EMR
TIER3
GND
RPM
10.3 15
11.2
729
BF600C ENGINE RPM D: DE006002 pag. 10.4
date: 28.Apr.2008 MOTORE RPM
0 1 2 3 4 5 6 7 8 9
730
LC2
7.0
11.2
V-4
DASH
BOARD 10.4.8/ KEY KEY /20.1
V-2.5
F11
10A
FAN
A-1.5-"610"
R A7
A-1.5-''610''
BOMAG
VA 1
VA
INTERCOOLER
FAN
THERMIC
SWITCH
VA 2
+
A1
FAN -
G-1.5-''603''
N-1.5
U-1.5-''601''
GND
A4 A2
WATER OIL
FAN FAN
THERMIC THERMIC
SWITCH SWITCH
B-1.5-''602''
008 916 41
10.4 20

BF600C FAN D: DE006002 pag. 15
date: 28.Apr.2008 VENTOLA
0 1 2 3 4 5 6 7 8 9
LC2
7.0 C151
V-4 V-4
DASH DISPLAY
BOARD 15.5/ KEY KEY /30.3
+24
D+
HYDR.
OIL
LEVEL
GND
HYDR.
OIL
FILTER
LIGHTS
HORN
HYDR.
OIL
TEMP.
HYDR.
OIL
THERM.
FUEL
LEVEL
CANH
CANL
V-2.5
008 916 41
JM 2 3 16 1 27 18 35 8 31 20 19 28
F3
N-1
10A
ALARMS TWISTED
G-1
DN-1
GND
JM18 JM35
M-2.5-"405"
40.3 30.3
M-1-"405"
B-1-D+
BO-1
GN-1
P-1-XD62
U-1-XD61
M-1.5-"405" M-1-"405"
10.3.9/ F3
+
S1 C20
3W -
C11 120OHM
NEGATIVE 100OHM DISPLAY
BRAKE DISPLAY
BR-1
GP-1
UO-1
UB-1
U-1-591
U-1-XD61
C12
BUZZER +
CAN L2 /250.1.1
P-1-XD62
D6
*GN-1
BOMAG
CAN L2
10.3.7
D5
CAN H2 /250.1.1
BR-1
OR-1-MC40
MC:40 /80.5.7
B-1-D+
CAN H2
10.3.7
R A4 R A3 R A5 R A6 R B2 R B3 R B4
B-18(AWG)-D+
10.7/ D+
BR-1
BO-1
GN-1
GP-1
UO-1
UB-1
LC3
10.1
ENGINE
COMPARTMENT 1 1 +
C13 P C6 C15 P C22 P C17 C18 C19
NEGATIVE HYDR. HYDR. 3 HYDR. 3 HYDR. HYDR. FUEL -
BRAKE OIL OIL OIL OIL OIL LEVEL
PRESSURE LEVEL FILTER FILTER TEMP. THERM.
SWITCH TRACTION TRACTION
N-1
N-1
N-1
N-1
N-1
N-1
N-1
GND GND GND GND GND GND GND
15 30
11.2
731
BF600C ALARMS D: DE006002 pag. 20
date: 28.Apr.2008 ALLARMI
0 1 2 3 4 5 6 7 8 9
LC2
732
7.0
R-6 R-6
DASH
BOARD 10.3.2/ BATTERY BATTERY /40.1.4
11.2
V-4 V-4
20.2/ KEY KEY /40.1.1
R-2.5
V-2.5
F14 F4
10A
25A HORN
HORN
O-1.5
A-2.5-300
A-2.5-300
O-2.5
A-1-300
A-1-300
A-1-300
30 86 30 13
E2 E3
E3 C21
.5 .4
87 HORN 85 87 HORN 14
HORN HORN
DN-1 B-1-*322*
20.6/ JM35
85
MN-2.5
E2
HORN 86
BOMAG
N-1
B-1-*322*
A-1.-300
GND
R B1 R C3 R B6 R B5
O-1.5 A-1.-300 A-1.-300

F14 /45.0
MN-2.5 B-1-*322* B-1-*322*
AS 1 AD 1 G A4 G A2 N A4 N A2
+ +
U 4 U 3 V 4 V 3
C25 C26
HORN - HORN -
PS A4 PS A2 PD A4 PD A2
AS 6 AD 6
LC4 LC5
70.2 70.6
90.4 13 90.1.4 13
100.0 100.1.0
N-2.5
N-2.5
150.2
C24 150.1.2 C23
160.0 HORN 14 160.1.0 HORN 14
LEFT RIGHT
SWITCHES SWITCHES
GND GND BOX
BOX
008 916 41
30 87 .5 30 87 .2
20 40

BF600C HORN D: DE006002 pag. 30
date: 28.Apr.2008 CLAXON
0 1 2 3 4 5 6 7 8 9
008 916 41
LC2
7.0
DASH
BOARD D1
DN-1.5 G-1.5
E5 /40.1.5
F19
10A D2
DASH
BOARD RN-1.5
LIGHTS E4 /40.1.8
G-1
G-1
20.5/ JM18
+ + +
L1 L2 L3
DASH - DASH - DASH -
BOARD BOARD BOARD
N-1
N-1
N-1
BOMAG
GND GND GND
30 40.1
11.2
733
BF600C DASHBOARD LIGHTS D: DE006002 pag. 40
date: 28.Apr.2008 LUCI CRUSCOTTO
0 1 2 3 4 5 6 7 8 9
LC2
734
V-4 R-6 R-2.5
7.0
30.5/ KEY KEY /50.3 30.5/ BATTERY
DASH
BOARD
11.2
V-2.5
F5
R-2.5
R-2.5
10A
WORKING
LIGHTS
F17 F18
B-1
15A 15A
B-1 FRONT REAR
WORKING WORKING
LIGHTS LIGHTS
GN-2.5
RN-2.5
N-1 N-1
C28
C32 C28
13 C32 X1 .5 13 X1
.2 .4
.1 GND REAR GND E5 30 30
FRONT WORKING E4
WORKING 14 X2 LIGHTS 14 X2 .1 .4
LIGHTS FRONT 87 REAR 87
WORKING WORKING
ON-1 GP-1-/668/ LIGHTS LIGHTS
86 86
E5 E4
G-2.5
RN-2.5
FRONT REAR
85 WORKING 85 G-1.5 RN-1.5
WORKING
LIGHTS LIGHTS 40.6/ E5 40.6/ E4
N-1
N-1
GND GND
G-2.5
G-2.5
RN-2.5
RN-2.5
BOMAG
M B7 M C7 M B1 M A1 M B8 M A8
ON-1 GP-1-/668/
5.8/ C32 5.8/ C28
G-2.5
G-2.5
RN-2.5
RN-2.5
5.8/ XENON
G-1.5
G-1.5
G-1.5
G-1.5
RN-1.5
RN-1.5
LIGHTS
GND AS 4 AS 5 AD 5 AD 4 SS 3 SD 3
U-4
N-4
L23 L14 L13
1 2
L20 L15 L17 REAR
FX FX + + + FRONT + + REAR +
FRONT FRONT FRONT LEFT
LEFT RIGHT RIGHT RIGHT
LEFT WORKING
WORKING WORKING WORKING WORKING
FX:1 FX:2 WORKING LIGHTS
- LIGHTS - LIGHTS - LIGHTS - - LIGHTS -
LIGHTS
AS 3 AS 2 AD 2 AD 3 SS 4 SD 4
N-1.5
N-1.5
N-1.5
N-1.5
N-1.5
N-1.5
GND GND GND GND GND GND
008 916 41
30 87 .6 30 87 .8
40 45

BF600C WORKING LIGHTS D: DE006002 pag. 40.1
date: 28.Apr.2008 FARI DI LAVORO
0 1 2 3 4 5 6 7 8 9
A-1.5-670
008 916 41
7.7/ F10
O-1.5
30.3/ F14
PO-1.5-*457*
5.8/ REAR BEACON /50.3
ROOF
BO-1.5-*456*
5.8/ FRONT
ROOF N-1
N-1
GND GND
TK 2 TK 3 TK 7 TK 8 TK 5 TK 6 TK 9 TK 4 TK 10
LC12
ROOF
BOMAG
+ + + +
L6 L7 L4 L5
FRONT - FRONT - REAR - -
REAR
LEFT RIGHT LEFT RIGHT
WORKING WORKING WORKING WORKING
LIGHTS LIGHTS LIGHT GT 2 GT 1 TR 1 TR 3 TR 2
LIGHT
BEACON WINDSCREEN WIPER

GIROFARO TERGICRISTALLO
GT:2 GT:1 TR:1 TR:3 TR:2
40.1 50
11.2
735
BF600C ROOF D: DE006002 pag. 45
date: 28.Apr.2008 TETTOIA
0 1 2 3 4 5 6 7 8 9
736
11.2
LC2
7.0
DASH
BOARD V-4 V-4
40.1.2/ KEY KEY /60.3
V-1.5
F2
10A
BEACON
DG-1.5
R A2
DG-1.5
45.6/ BEACON
BOMAG
DG-1.5
GR 1
+
L24
BEACON -
GR 2
N-1.5
GND
008 916 41
45 60

BF600C BEACON D: DE006002 pag. 50
date: 28.Apr.2008 GIROFARO
0 1 2 3 4 5 6 7 8 9
LC2
7.0
V-4 V-4
DASH
008 916 41
V-2.5
F6
25A
WASHING
PUMP
M-2.5
P A1
M-2.5
F6 /180.2
GND
M-2.5
N-2.5
TP 1 TP 2
RED
BLACK
LC6 RED
WASING
PUMP
BOX
K1 A1
BOMAG
TIMER 1 2
S1
WASHING A2
PUMP
RED
BLACK
XWP 1 2
LC7
WASHING
PUMP S1
PRESSURE
SWITCH +
M1 M
WASHING
PUMP
TP
-
50 70
11.2
737
BF600C WASHING PUMP D: DE006002 pag. 60
date: 28.Apr.2008 POMPA LAVAGGIO
0 1 2 3 4 5 6 7 8 9
LC2
738
7.0
V-4
DASH
11.2
V-1.5
N-1
F7
GND
10A
EMERGENCY 86 30
E6
E6
.5
EMERGENCY 85 87
EMERGENCY
VO-1.5
MN-1
11 EMERGENCY /75.1
C33
EMERGENCY
PUSH 12
BUTTON
O-1.5-XD28
O-1-XD28 O-1.5-XD28
10.3.4/ XD:28
R-1.5-*327*
P A2 P A3
O-1-XD28
10.1.7/ P:A3
G-1.5-454
BOMAG
G A8 G B1 N A8 N B1
R-1.5-*327*
O-1.5-454
O-1.5-454
O-1.5-XD28
U 2 U 13 V 2 V 13
R-1.5-*B-1.5*
O-1.5-*B-1.5*
R-1.5-*B-1.5*
O-1.5-*B-1.5*
LC4 LC5
30.6 PS A8 PS B1 30.8 PD A8 PD B1
LEFT RIGHT
SWITCHES 11 SWITCHES 11
BOX BOX
C34 C35
EMERGENCY 12 EMERGENCY 12
PUSH PUSH
BUTTON BUTTON
008 916 41
30 87 .6
60 75

BF600C EMERGENCY PUSH BUTTONS D: DE006002 pag. 70
date: 28.Apr.2008 PULSANTI EMERGENZA
0 1 2 3 4 5 6 7 8 9
008 916 41
LC2
7.0
V-4
DASH
D4
V-4
UR-1 MP-1
N-1
F39
86 13 -
GND 25A
C36 C36 GEN-ON
E7
.5 .4
GEN-ON 85 14 +
O-4
GEN-ON GEN-OFF
UR-1
MN-1 O-1-*562* 30 30
70.7/ EMERGENCY NEUTRAL /80.5
E7 E7
.2 .2
87a 87
GEN-ON GEN-ON
D-4
D3
D-1
BOMAG
D-1 D-4
7.8/ GEN-ON GEN-ON /80.3.4
30 87a .6
70 80
30 87 .7
11.2
739
BF600C GENERAL ON D: DE006002 pag. 75
date: 28.Apr.2008
0 1 2 3 4 5 6 7 8 9
LC2
740
7.0
V-4 V-2.5
DASH
BOARD 75.8/ KEY KEY /190.2 C47
TRAVELLING
11.2
JOYSTICK
V1
V-1.5
F9
V2
10A
TRAVELLING S1 S2
BACKWARD FORWARD
P-1.5
XJ + GND K F J R
C47 1 5 8 7 6 2
P-1.5
N-1
O-1
*ON-1
GND FORWARD
*AN-1
80.3.1
F48
O-1-MC8
5A
BACKWARD
O-1-*562* O-1-*562*
75.4/ NEUTRAL NEUTRAL /160.2
BOMAG
PO-1-MC3
250.1 250.1 250.1 250.1 250.1 250.1

MC:6 MC:10 MC:7 MC:26 MC:11 MC:27 10.4.6/ TRAVELLING MC:3 /250.1
Z C6 Z C7 Z C4 Z B2 Z B3 Z B7 Z C5
PO-1-MC3
U-1-*MC6*
B-1-*MC10*
D-1-*MC7*
A-1-*MC26*
V-1-*MC11*
G-1-*MC27*
SR 1
+
C48
C53 A B C D C49 A B C D BACKWARD -
TRAVELLING
C53 C49
LEFT RIGHT SR 2
TRACTION TRACTION
PUMP PUMP
N-1
GND
008 916 41
75 80.1

BF600C TRAVELLING D: DE006002 pag. 80
date: 28.Apr.2008 AVANZAMENTO
0 1 2 3 4 5 6 7 8 9
LC2
7.0
DASH C56 C55
BOARD DASH FOOT
POTI PEDAL
008 916 41
TRAVELLING TRAVELLING
WC 3 WC 2 WC 1 PE 1 PE 2 PE 3
DG-1
UP-1
B-1-//MC35//
O-1-MC1
U-1-//MC36//
M-1-//MC14//
MC:35 MC:36
250.1.1 250.1.1
MC:14 /80.2.1 MC:1 /80.2.2
C27 1 C27 2
C27
BOMAG
RESISTORS
KIT
R1 R2
680 680
OHM OHM
C27 4 C27 3
80 80.2
11.2
741
BF600C TRAVELLING D: DE006002 pag. 80.1
0 1 2 3 4 5 6 7 8 9
742
11.2
LC2
7.0
DASH
BOARD M-1-//MC14//
80.1.3/ MC:14 MC:14 /85.1
MC:16 /200.3.3 MC:17 /200.3.3
O-1-MC1 O-1-MC1
80.1.5/ MC:1 MC:1 /80.2.6 80.2.3/ MC:1 MC:1 /85.3
M-1-//MC14//
M-1-//MC14//
P-1-MC16
P-1-*MC17*
GND GND
P A5 P A4 P A6 P B3 P B2 P B4
BOMAG
GND GND
BROWN
WHITE
GREEN
BROWN
WHITE
GREEN
PK 1 PK 3 PK 2 PC 1 PC 3 PC 2
BROWN
WHITE
GREEN
BROWN
WHITE
GREEN
1 4 1 4
C66 C65
PICK-UP PICK-UP
LEFT RIGHT
CRAWLER 3 CRAWLER 3
008 916 41
80.1 80.3

0 1 2 3 4 5 6 7 8 9
LC2
7.0
DASH
BOARD O-1 D-4
80.6/ FORWARD 75.7/ GEN-ON GEN-ON /80.4.2
008 916 41
D-1.5
D-2.5
F22 F30
10A 15A
TRANSPORT AUTOMATIC
O-1
PN-1
13 43 21
BR-2.5-524
C45
14 C45 44 22 BR-2.5-524
.4 C45
.2 .1 .1
WORK TRANSPORT TRANSPORT
TRAVELLING TRAVELLING TRAVELLING
30 30 30
M-1-MC2
PO-1
86
E19 E9 E18
A-1-*MC4*
.2 .7 .5
E19 87 87 87
TIMER AUGER AUTOMATIC
TIMER 85 TRAVELLING CONVEYOR SERVICES D10 D9
TRAVELLING AUTO
N-1
G-1
MC:2 MC:4
250.8 250.1
V-1
BOMAG
GND 86 86
E18 E9
AUTOMATIC 85 AUGER 85
SERVICES CONVEYOR
U-2.5
AUTO
N-1
UN-2.5-590
N-1
GND GND
BG-1-/557/
AUGER AUTOMATIC LOADING

CONVEYOR SERVICES 110.3
AUTO 170.7
90.1
30 87 .5 30 87 .7 30 87 .6
80.2 80.4
11.2
743
0 1 2 3 4 5 6 7 8 9
LC2
744
7.0
D-4
DASH
BOARD 80.3.6/ GEN-ON GEN-ON /80.5.5
11.2
D-1.5
F26
10A
HYDRAULIC
GEARS
DB-1.5
GO-1-MC41
MC:41 /250.1.1
C57: C57 A2
E13 30 E13 86
A3->B6 HYDRAULIC
GEARS .7 SECOND
A1->B4 A1 A3 SECOND 87 HYDRAULIC 85
HYDRAULIC GEAR
GEAR
N-1
GND
*UN-1
AB-1-MC32
AB-1-MC32
BO-1.5-560
S6 + S7 +
SECOND FIRST
BOMAG
HYDRAULIC HYDRAULIC
GEAR - MC:32 -
GEAR
250.1
N-1
N-1
GND GND
Z B5
BO-1.5-560
BO-1.5-560
+ +
A5 B5
LEFT RIGHT
- -
TRACK TRACK
SECOND SECOND
N-1
N-1
HYDRAULIC HYDRAULIC
GEAR GEAR
GND GND
008 916 41
30 87 .5
80.3 80.5

BF600C HYDRAULIC GEAR D: DE006002 pag. 80.4
date: 28.Apr.2008 CAMBIO IDRAULICO
0 1 2 3 4 5 6 7 8 9
LC2
7.0
OR-1-MC40 OR-1.5-MC40
DASH
BOARD 20.2/ MC:40 MC:40 /250.1.1
F25
008 916 41
3A D-4
POWER 80.4.4/ GEN-ON GEN-ON /90.7
U-2.5
D-1
30 E10 86
E10
POWER
.5
87 85
POWER
N-1
GND
R-2.5-MC28
R-1-MC28
MC:28 /85.8
R-1-MC28
G-4-CENT
11
C50
DASH 12
BOMAG
BRAKE
OR-1.5-MC40
B-1-MC5
MC:5 /250.1
Y 2 Z B4
G-4-CENT
5.8/ ELECTRONIC
OR-1.5-MC40
UNIT
+
A3
NEGATIVE -
BRAKE
N-1.5
GND
30 87 .3
80.4 85
11.2
745
BF600C BRAKE D: DE006002 pag. 80.5
date: 28.Apr.2008 FRENO
0 1 2 3 4 5 6 7 8 9
746
11.2
LC2
7.0
DASH C67
BOARD STEERING
MO-1-MC22 R-1.5-MC28
MC:22 /250.1.1 80.5.4/ MC:28 MC:28 /250.1
PO-1-MC24
ST A ST B ST C MC:24 /250.1.1
S3 + S2 +
R-1-MC28
LEFT RIGHT A2
STEERING STEERING
- -
B-1-MC34
C58
SPIN A1
O-1-MC1
N-1
N-1
MC:34
M-1-//MC14//
250.1.1
PR-1-MC31
GND GND
80.2.7/ MC:14 MC:14 /250.1 80.2.7/ MC:1 MC:1 /250.1 S8 +

SPIN
-
PR-1-MC31
N-1
MC:31
BOMAG
GND 250.1
008 916 41
80.5 90

BF600C STEERING D: DE006002 pag. 85
date: 28.Apr.2008 STERZATURA
0 1 2 3 4 5 6 7 8 9
LC2
7.0
U-2.5 D-4
DASH
BOARD 80.3.6/ AUGER AUGER /100.1 80.5.6/ GEN-ON GEN-ON /90.1.6
CONVEYOR CONVEYOR
AUTO AUTO
F38
D-1.5
008 916 41
10A
LEFT
U-2.5
CONVEYOR
G-1-*323*
C126
F42 AP-1.5 AN-1
A B A1 A3
10A
AUTO
CONVEYORS C124
A2
AUTO-MAN
LEFT
CONVEYOR
G-1.5-*323*
A2
U-1-*321* U-1.5-*321* C123
C124 /155.1 90.1.7

REVERSE A1 A3
+ CONVEYORS
S12 AO-1.5
ON - C123-A3 /155.1
LEFT
N-1
CONVEYOR
ON-1.5
OR-1.5
U-1.5-*321*
GND
AO-1.5
T A6 T A5 T A4 T A3 T A2
U-1-*321* G-1-*323*
ON-1.5
G B2 G A6
BOMAG
AO-1.5
ON-1.5
OR-1.5
U-1.5-*321*
+ +
F42 B26 A26
90.1.1 - -
ON REVERSE
U-1-*321*
G-1-*323*
LEFT LEFT
CONVEYOR CONVEYOR
U 6 U 5
N-1.5
N-1.5
N-1.5
ZS 3 ZS 1 ZS 2 GND GND U-1

GND
G-1
LC4
30.6 PS B2 PS A6
LEFT
ON-1.5
OR-1.5
N-1.5
SWITCHES
BOX
LC8
NC
160.1
LEFT
U-1-*321*
G-1-*323*
SCREW
PLATE C132 A B D C
C131 A2
ON
+ - LEFT A1
CONVEYOR
SIGNAL
SIGNAL
85 90.1
11.2
747
BF600C LEFT CONVEYOR D: DE006002 pag. 90
date: 28.Apr.2008 NASTRO SINISTRO
0 1 2 3 4 5 6 7 8 9
LC2
748
7.0
D-4
DASH
BOARD 90.8/ GEN-ON GEN-ON /100.7
11.2
C125 F37
D-1.5
AB-1.5 AP-1 10A
A B A1 A3
RIGHT
CONVEYOR
C122 G-1-/473/
A2
AUTO-MAN
RIGHT
CONVEYOR
G-1.5-/473/
U-1-/471/ U-1.5-/471/ B5
C122 /155.1 C123
+ 90.7
REVERSE
S11 CONVEYORS B4 B6
ON -
RIGHT
CONVEYOR BO-1.5
C123-B6 /155.1
N-1
U-1.5-/471/
BG-1.5
GND
BO-1.5
T B4 T B3 T B2 T A7
U-1-/471/ G-1-/473/
BOMAG
N B2 N A6
90.1
BO-1.5
F42
U-1.5-/471/
+ +
B25 A25
ON - REVERSE -
U-1-/471/
G-1-/473/
RIGHT RIGHT
ON-1.5
BG-1.5
CONVEYOR CONVEYOR
V 6 V 5
N-1.5
N-1.5
N-1.5
ZD 3 ZD 1 ZD 2 GND GND GND
U-1
G-1
LC5
30.8 PD B2 PD A6
RIGHT
ON-1.5
BG-1.5
N-1.5
SWITCHES
BOX
LC9
NC
160.1.1
RIGHT
U-1-*321*
G-1-/473/
SCREW
PLATE C128 A B D C
C127 A2
ON
+ - RIGHT A1
CONVEYOR
SIGNAL
SIGNAL
008 916 41
90 100

BF600C RIGHT CONVEYOR D: DE006002 pag. 90.1
date: 28.Apr.2008 NASTRO DESTRO
0 1 2 3 4 5 6 7 8 9
LC2 D-4
7.0
90.1.8/ GEN-ON GEN-ON /100.1.6
DASH
BOARD
F36
D-1.5
10A
008 916 41
C117 LEFT
AUGER
A B BR-1.5 A1 A3 M-1.5-*325* M-1-*325*
C116
A2
AUTO-MAN
90.2 LEFT
AUGER AUGER
CONVEYOR AUTO
M-1.5-*325*
BN-1.5 BN-1 BN-1.5

C116 /155.1 C115 A2
REVERSE
LEFT
30 + A1
U-2.5
AUGER
E16 S10 D-1-*326*

F41 .7 87a ON - C115 /155.1
ON LEFT
10A 86
N-1
LEFT AUGER
AUTO AUGER
AUGERS E16
ON 85
GND LEFT
N-1
AUGER
D-1-*326*
GND
O-1.5-*324*
A-1.5-*320*
P-1-*328*
T C2 T C3 T B7 T B6 T B5
A-1.5-*320*
BOMAG
G C3 G A3 G C1 G B6 G B4
+ +
F41 B24 A24
100.1.2 - -
ON REVERSE
LEFT LEFT
O-1.5-*324*
A-1.5-*320*
N-1
P-1-*328*
D-1-*326*
M-1-*325*
N-1
AUGER AUGER
U 10 U 15 U 9 U 8 U 7
GND GND
O-1
A-1
P-1
D-1
M-1
LC4
30.6 PS C3 PS A3 C99 PS C1 PS B6 PS B4
C99 1 R1 C99 4 GR-1
LEFT
SWITCHES M-1-*325*
BOX
C99 3 V1 C99 2
C118
P-1-*328*
D-1-*326*
M-1-*325*
VO-1 ON
LEFT
AUGER A2
O-1.5-*324*
A-1.5-*320*
N-1
C119 D A B C A B C A1 A3
C100
GND
C100
+
-
LEFT
AUGERS
POTI
SIGNAL
SIGNAL
30 87a .3
90.1 100.1
11.2
749
BF600C LEFT AUGER D: DE006002 pag. 100
date: 28.Apr.2008 COCLEA SINISTRA
0 1 2 3 4 5 6 7 8 9
LC2
750
D-4
7.0
100.8/ GEN-ON GEN-ON /100.2.3
DASH
BOARD
11.2
F35
D-1.5
10A
C110 RIGHT
AUGER
A B GN-1.5 A1 A3 M-1.5-/475/ M-1.5-/475/
F35 /110.3
C109
A2
AUTO-MAN
RIGHT
AUGER
BP-1.5 BP-1 BP-1.5

C109 /155.1
M-1.5-/475/
C108 A2
30 + REVERSE
E15 RIGHT
S9 AUGER A1
.6
87a ON - D-1.5-/476/
ON RIGHT
RIGHT C108 /155.1
N-1
AUGER
AUGER
86
E15
GND ON 85
RIGHT
O-1.5-/474/
N-1
AUGER
P-1.5-/478/
D-1.5-/476/
M-1-/475/
GND
T C7 T C6 T C5 T C4
A-1.5-*320*
BOMAG
+ +
B23 A23
N C3 N A3 ON - N C1 N B6 N B4 REVERSE -
RIGHT RIGHT
N-1
N-1
AUGER AUGER
GND
F41 GND
O-1.5-/474/
A-1.5-*320*
P-1-/478/
D-1-/476/
M-1-/475/
100.2
V 10 V 15 V 9 V 8 V 7
M-1-/475/
O-1
A-1
P-1
D-1
M-1
LC5
30.8 C101
PD C3 PD A3 R1 PD C1 PD B6 PD B4
C101 1 C101 4 GR-1
RIGHT
SWITCHES
BOX
C101 3 V1 C101 2
VO-1
C111
P-1-/478/
D-1-/476/
M-1-/475/
ON
RIGHT
A2
O-1-/474/
A-1-*320*
N-1 AUGER
C112 D A B C C102 A B C
GND A1 A3
+ -
C102
RIGHT
AUGERS
POTI
008 916 41
SIGNAL
SIGNAL
30 87a .2
100 100.2

BF600C RIGHT AUGER D: DE006002 pag. 100.1
date: 28.Apr.2008 COCLEA DESTRA
0 1 2 3 4 5 6 7 8 9
LC2
7.0
D-4
DASH
BOARD 100.1.7/ GEN-ON GEN-ON /120.2
008 916 41
D-1.5
F33
10A
AUGERS
LIFTING
MN-1.5
F33 /130.4
OPTIONAL
KIT
C103
MN-1.5
AUGER
BOX A2
A1 A3
UR-1.5
UP-1.5
M B4 M B5
BOMAG
UR-1.5
UP-1.5
OPTIONAL
KIT CC 1 CC 2
+ +
A19 B19
UP - DOWN -
AUGER AUGER
LIFTING LIFTING
N-1.5
N-1.5
CC 3
GND
100.1 110
11.2
751
BF600C AUGER BOX LIFTING D: DE006002 pag. 100.2
date: 28.Apr.2008 SOLLEVAMENTO CASSA COCLEE
0 1 2 3 4 5 6 7 8 9
752
LC2
11.2
7.0
DASH
BOARD
M-1.5-/475/
100.1.8/ F35
C107 A2
LOADING
A1
BG-1-/557/
BG-1-/557/ BG-1-/557/
80.3.8/ LOADING LOADING /155.1
BOMAG
008 916 41
100.2 120

BF600C LOADING MATERIAL D: DE006002 pag. 110
date: 28.Apr.2008 CARICAMENTO MATERIALE
0 1 2 3 4 5 6 7 8 9
LC2
7.0
DASH
BOARD D-4
100.2.5/ GEN-ON GEN-ON /150.6
008 916 41
D-1.5
F34
10A
HOPPERS
MU-1.5
MU-1.5
C106 C105
LEFT A2 RIGHT A2
HOPPER HOPPER
A1 A3 A1 A3
GR-1.5
GP-1.5
UO-1.5
UB-1.5
C106-A1 /155.1 C106-A3 /155.1 C105-A1 /155.1 C105-A3 /155.1
BOMAG
M A4 M A5 M A6 M A7
GR-1.5
GP-1.5
UO-1.5
UB-1.5
+ + + +
A22 B22 A21 B21
UP - DOWN - UP - DOWN -
LEFT LEFT RIGHT RIGHT
HOPPER HOPPER HOPPER HOPPER
N-1.5
N-1.5
N-1.5
N-1.5
GND GND GND GND
110 130
11.2
753
BF600C HOPPERS D: DE006002 pag. 120
date: 28.Apr.2008 TRAMOGGE
0 1 2 3 4 5 6 7 8 9
754
LC2
11.2
7.0
DASH
BOARD MN-1.5
100.2.5/ F33 F33 /140.4
MN-1.5
OPIONAL
KIT C104
SAFETY
LOCK
BOLT A2
A1 A3
UG-1.5
UN-1.5
M B2 M B3
BOMAG
UG-1.5
UN-1.5
OPIONAL
KIT
CT 1 CT 2
+ +
A20 B20
ENGAGE - DISENGAGE -
LOCK LOCK
BOLTS BOLTS
N-1.5
N-1.5
CT 3
GND
008 916 41
120 140

BF600C SAFETY LOCK BOLTS D: DE006002 pag. 130
date: 28.Apr.2008 CATENACCI DI SICUREZZA
0 1 2 3 4 5 6 7 8 9
008 916 41
LC2
7.0
DASH
BOARD MN-1.5
130.6/ F33
OPTIONAL
KIT
A2
C71
ON A1
FUME
EXHAUSTER
MO-1.5
M B6
BOMAG
MO-1.5
OPTIONAL
KIT AF 1
+
A27
ON -
FUME
EXHAUSTER
N-1.5
AF 2
GND
130 150
11.2
755
BF600C FUME EXHAUSTER D: DE006002 pag. 140
date: 28.Apr.2008 ASPIRATORE FUMI
0 1 2 3 4 5 6 7 8 9
LC2
756
7.0
D-4
DASH
BOARD 120.3/ GEN-ON GEN-ON /150.1.6
11.2
D-1.5
R-1 F32
10A
LEFT
C91 SCREED
EXTENS
LEFT
A2
A-1
SCREED
EXTENS.
A2
A1 A3
C90
LEFT A1 A3
SCREED
EXTENS.
B-1-452
V-1-459
R-1-457
C91-A1 /155.1 C91-A3 /155.1
Q A4 Q A3 Q A2
BOMAG
G A5 G C7 G C5
B-1-452
V-1-459
R-1-457
U 16 U 12 U 11
B-1
V-1
R-1
B-1-452
V-1-459
LC4
30.6 C93 PS A5 PS C7 PS C5
LEFT DIODES
V1
SWITCHES CARD
BOX
+ +
R-1-457
B16 A16 - C92

CLOSE - OPEN -
LEFT LEFT LEFT
V2 A2
V-1-459
SCREED SCREED SCREED

EXTENS EXTENS EXTENS.
GND
N-1
N-1
A1 A3
B-1-452
BO-1
GND GND + +
C94 L21
- -
N-1.5
GND-LB /160.4
008 916 41
140 150.1

BF600C LEFT SCREED EXTENSION D: DE006002 pag. 150
date: 28.Apr.2008 ALLARGATORE SINISTRO
0 1 2 3 4 5 6 7 8 9
LC2
7.0
D-4
DASH
BOARD 150.8/ GEN-ON GEN-ON /160.6
D-1
008 916 41
*ON-1 F27
10A
RIGHT
C81 SCREED
EXTENS
RIGHT
A2
*PN-1
SCREED
EXTENS.
A2
A1 A3
C80
RIGHT A1 A3
SCREED
EXTENS.
B-1-302
V-1-309
R-1-307
C81-A1 /155.1 C81-A3 /155.1
Q C5 Q C6 Q C7
N A5 N C7 N C5
BOMAG
B-1-302
V-1-309
R-1-307
V 16 V 12 V 11
B-1
V-1
R-1
B-1-302
V-1-309
LC5
30.8 C83 PD A5 PD C7 PD C5
RIGHT DIODES
V1
SWITCHES CARD
BOX
+ +
R-1-307
A14 B14 - C82

CLOSE - OPEN -
RIGHT RIGHT RIGHT
V2 A2
V-1-309
SCREED SCREED SCREED

EXTENS EXTENS EXTENS.
GND
N-1
N-1
A1 A3
B-1-302
BO-1
GND GND + +
C84 L22
- -
N-1.5
GND-RB /160.1.4
150 155
11.2
757
BF600C RIGHT SCREED EXTENSION D: DE006002 pag. 150.1
date: 28.Apr.2008 ALLARGATORE DESTRO
0 1 2 3 4 5 6 7 8 9
LC2
758
7.0
DASH C14
BOARD
DIODES
11.2
BOARD
C14
V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11 V12 V13 V14 V15 V16

V17
C14 A2 A3 A4 A5 A6 B2 B3 B4 B5 B6 C2 C3 C4 C5 C6 B1 A8 C7 A7 A1
BG-1-/557/
110.5/ LOADING
BP-1.5
100.1.5/ C109
D-1.5-/476/
100.1.7/ C108
BN-1.5
100.6/ C116
D-1-*326*
100.8/ C115
U-1.5-/471/
90.1.4/ C122
U-1.5-*321*
90.4/ C124
AO-1.5
90.8/ C123-A3
BO-1.5
90.1.7/ C123-B6
BOMAG
UB-1.5
120.7/ C105-A3
UO-1.5
120.6/ C105-A1
GP-1.5
120.4/ C106-A3
GR-1.5
120.2/ C106-A1
B-1-452
150.4/ C91-A1
V-1-459
150.6/ C91-A3
B-1-302
150.1.4/ C81-A1
O-1.5-*533*
10.4.6/ DIODES CARD
V-1-309
150.1.6/ C81-A3
008 916 41
150.1 160

BF600C DIODES CARD D: DE006002 pag. 155
date: 28.Apr.2008 SCHEDA DIODI
0 1 2 3 4 5 6 7 8 9
LC2 D-4
7.0 C89 150.1.8/ GEN-ON GEN-ON /160.1.6
DASH 160.1.0
BOARD
LIVELLING D2
SYSTEM
D3 GND GND F31
D-1.5
10A
008 916 41
LEFT
LIVELLING
D1
N-1.5
D4 K2 K1
K1 K2
.3 .2
X:3 /160.1.2
XL 6 3 GND GND 4 14 12 11 13 5 GND
N-1
C95
.7
V-1-469
LEFT
O-1-*562* A2 C95 B5
LEVEL
N-1.5
.6 B4 B6 C95-C98:
LEFT
LEVEL A3->B6
A1 A3
P-1-458
D-1-456
M-1-455
AB-1
GND A1->B4
G-1-453
U-1-451
80.6/ NEUTRAL
V-1.5-469
Q B4 Q B3 Q B2 Q A6 Q A5 Q A7
V-1.5-469
M-1-455
D-1-456
G C6 G C2 G B7 G B5 G B8 G A7 G B3 G A1
GND
N-1
N-1
N-2.5
N-2.5
N-1.5
BOMAG
P-1-458
G-1-453
U-1-451
ZS 5 ZS 4 ZS 7 ZS 6
GND GND U 21 U 20 U 19 U 1 GND U 14 U 17 U 18 GND GND
LC8
90.1 C96 B A D C
LEFT
SCREW
+
-
PLATE
UP
DOWN
P-1-A-SIZE1
D-1-A-SIZE1
M-1-A-SIZE1
N-1.5-*B-1.5*
V-1.5-*B-1.5
G-1-A-SIZE1
U-1-A-SIZE1
U-1-451
G-1-453
LC4
30.6 PS C2 PS B7 PS B5 PS A1 PS B8 PS A7 PS B3
+
DOWN
UP
-
LEFT
V-1-469
V-1-469
SWITCHES
BOX GND
C97 B A D C
N-1
D-1-456
C98
+ +
P-1-458
M-1-455
N-1.5
G-1-453
U-1-451
C98 .5
.6 LEFT B17 A17
LEFT LEVEL
A2 B5 DOWN - UP -
LEVEL
LEFT LEFT
B4 B6 LEVEL LEVEL
150.4/ GND-LB
A1 A3
V-1-469
.4 .4
155 160.1
11.2
759
BF600C LEFT LEVELLING D: DE006002 pag. 160
date: 28.Apr.2008 LIVELLO SINISTRO
0 1 2 3 4 5 6 7 8 9
LC2
760
D-4
7.0 C89 160.6/ GEN-ON GEN-ON /170.1
DASH 160.0
BOARD
LIVELLING D6
SYSTEM
11.2
D7 GND F21
D-1.5
10A
RIGHT
LIVELLING
D5
D8 K4 K3
K3 K4
.3 .3
XL 2 160.1/ X:3 GND GND 10 8 7 9 1 GND
N-1
C85
.7
V-1-319
RIGHT
A2 C85 B5
LEVEL
.6 B4 B6 C85-C88:
RIGHT
LEVEL A3->B6
A1 A3
P-1-308
D-1-306
M-1-305
AO-1
A1->B4
G-1-303
U-1-301
V-1.5-319
Q B5 Q B6 Q B7 Q C3 Q C4 Q C2
V-1.5-319
M-1-305
D-1-306
N C6 N C2 N B7 N B5 N B8 N A7 N B3 N A1
BOMAG
GND
N-1
N-1
N-2.5
N-2.5
N-1.5
P-1-308
G-1-303
U-1-301
ZD 5 ZD 4 ZD 7 ZD 6
GND GND V 21 V 20 V 19 V 1 GND V 14 V 17 V 18 GND GND
LC9
90.1.0 C86 B A D C
RIGHT
SCREW
+
-
PLATE
UP
DOWN
P-1-A-SIZE1
D-1-A-SIZE1
M-1-A-SIZE1
N-1.5-*B-1.5*
V-1.5-*B-1.5
G-1-A-SIZE1
U-1-A-SIZE1
U-1-301
G-1-303
LC5
30.8 PD C2 PD B7 PD B5 PD A1 PD B8 PD A7 PD B3
+
DOWN
UP
-
RIGHT
V-1-319
V-1-319
SWITCHES
BOX GND
C87 B A D C
N-1
D-1-306
C88 + +
P-1-308
M-1-305
N-1.5
G-1-303
U-1-301
C88
RIGHT A15 B15
RIGHT LEVEL
A2 B5 DOWN - UP -
LEVEL RIGHT RIGHT
B4 B6 LEVEL LEVEL
150.1.4/ GND-RB
A1 A3
V-1-319
008 916 41
.4 .4
160 160.2

BF600C RIGHT LEVELLING D: DE006002 pag. 160.1
date: 28.Apr.2008 LIVELLO DESTRO
0 1 2 3 4 5 6 7 8 9
LC2
7.0
008 916 41
DASH
BOARD P-1
BJ:11 /200.2.3
U-1
BJ:13 /200.2.3
GO-1
BJ:12 /200.2.3
*MN-1
BJ:8 /200.2.3
*RN-1
BJ:10 /200.2.3
*VN-1
BJ:9 /200.2.3
P A8 P B1 P B8 P B5 P B6 P B7
P-1
U-1
GO-1
*MN-1
*RN-1
*VN-1
BOMAG
WE 1 WE 2 WE 3 WE 4 WE 5 WE 6
OPTIONAL
KIT
P-1
U-1
GO-1
*MN-1
*RN-1
*VN-1
A B C A B C
C60 C61
LEFT RIGHT
WIRE WIRE
SENSOR SENSOR
160.1 170
11.2
761
BF600C LEVELLING SENSORS D: DE006002 pag. 160.2
date: 28.Apr.2008 SENSORI DI LIVELLAZIONE
0 1 2 3 4 5 6 7 8 9
LC2
762
D-4 D-2.5 UN-2.5-590
7.0
160.1.6/ GEN-ON GEN-ON /180.4 80.3.7/ AUTOMATIC AUTOMATIC /170.1.1
DASH
BOARD SERVICES SERVICES
11.2
D-1.5
F28
UN-1.5-590
10A
SCREED
F46
10A
L.C.S.
C70
AP-1.5-*538*
SCREED A2
BR-1.5-*453* AO-1.5-540
A1 A3
30 30 86
E14 E14
E14
.7 .7
87a 87 L.C.S. 85
L.C.S. L.C.S.
N-1
GND
BG-1.5-*452*
BR-1.5-*453*
GO-1.5-*548*
GR-1.5-*549*
M C3 M C4 M C5 M C6
BOMAG
LC10
170.1.1
170.2.1
180.2
REAR
PANEL
NC
BR-1.5-*453*
GO-1.5-*548*
GR-1.5-*549*
B4 B6 A1 A3
C72:
C72 C72
A3->B6(STOP)
.6 B5 .5 A2
BG-1.5-*452*
BR-1.5-*453*
L.C.S. L.C.S. A1->B4(WORK)
VO-1.5-*552*
VG-1.5-*553*
+ +
+ + A10 B11
A13 B13 DOWN - UP -
LCS LCS
UP - DOWN -
SCREED SCREED
N-1.5
N-1.5
N-1.5
N-1.5
GND GND
008 916 41
GND GND 30 87a .5

160.2 170.1
30 87 .6

BF600C SCREED LIFTING D: DE006002 pag. 170
date: 28.Apr.2008 SOLLEVAMENTO FERRO DA STIRO
0 1 2 3 4 5 6 7 8 9
LC2 UN-2.5-590
7.0
170.8/ AUTOMATIC AUTOMATIC /170.2.5
DASH
008 916 41
UN-1.5-590
F43
10A
L.C.S.2
MG-1.5
Z C1
MG-1.5
F43 /180.2
MG-1.5
MG-1.5
OPTIONAL
KIT LC10
L.C.S.2 170.4 1 2
DC DC
REAR C74
PANEL 5KOHM
OR-1.5
C73
A2
L.C.S.2
VO-1.5
*MN-1
*DG-1
*MP-1
BOMAG
A1 A3
C74 1 2 3
VN-1.5
N-1.5
A-1.5
R-0.5
O-0.5
P-0.5
C75 1 4 3 2
C75
TIMER
CARD 85 30
K1
VN-1.5
K1
.4
86 87
DC 3
+
A12
-
N-1.5
GND
30 87 .5
170 170.2
11.2
763
BF600C SCREED LIFTING D: DE006002 pag. 170.1
0 1 2 3 4 5 6 7 8 9
LC2
764
UN-2.5-590
7.0
170.1.3/ AUTOMATIC AUTOMATIC /190.6
DASH
11.2
UN-1.5-590
F43
10A
L.C.S.2
MG-1.5
Z C1
MG-1.5
MG-1.5
OPTIONAL
KIT
LOCK LC10
CYLINDER
170.4 DC 1 DC 2
REAR C74
PANEL 5KOHM
BOMAG
VO-1.5
A-1.5
*MN-1
*DG-1
*MP-1
C74 1 2 3
VN-1.5
N-1.5
R-0.5
O-0.5
P-0.5
C75 1 4 3 2
C75
TIMER
CARD 85 30
K2
VN-1.5
K2
.5
86 87
DC 3
+
A12
-
N-1.5
GND
008 916 41
30 87 .5
170.1 180

BF600C SCREED LIFTING D: DE006002 pag. 170.2
0 1 2 3 4 5 6 7 8 9
LC2
7.0
D-2.5 D-2.5
DASH
BOARD 170.3/ GEN-ON GEN-ON /200.2.3
008 916 41
D-2.5
*AB-1
F20 CANH /200.2.3
10A *AO-1
HEATING CANL /200.2.3
TWISTED
BO-2.5
Z A8 M A3 M A2
5.8/ POWER
HEATING
10.4.3/ Z:A6
60.5/ F6
HEATING
OPTIONAL
HEATING
OPTIONAL
HEATING
OPTIONAL
170.1.2/ F43
TWISTED
BOMAG
GND GND
N-1.5
MG-1.5
M-2.5
PO-1.5
A-4
BO-2.5
*AB-1
*AO-1
G-1.5-533
U-1.5-532
D-1.5-531
N-1
LC10
170.4
REAR
PANEL
GND
+24
KEY
ECO
+24
GND
CANH
CANL
GEN-ON
BATTERY
HEATING
HEATING
HEATING
OPTIONAL
OPTIONAL
OPTIONAL
AUTOMATIC
170.2 190
11.2
765
BF600C SCREED HEATING D: DE006002 pag. 180
date: 28.Apr.2008 RISCALDAMENTO FERRO DA STIRO
0 1 2 3 4 5 6 7 8 9
LC2
766
7.0
V-2.5 UN-1.5-590
DASH
BOARD 80.2/ KEY 170.2.7/ AUTOMATIC AUTOMATIC /200.1
SERVICES SERVICES
11.2
GND
F1
N-2.5
F45
25A
WATER 10A
SPRAY AUTO
WATER
SPRAY
OPIONAL A2
KIT
WATER
C135
SPRAY WATER A1
SPRAY
OR-2.5
PR-2.5
O-1.5-''404''
M C1 M C8 M C2
GND
OR-2.5
PR-2.5
PR-2.5
O-1.5-''404''
N-2.5
C136 1 C136 2 WH 1 WH 2 WH 3
OPIONAL
BOMAG
KIT
WATER
SPRAY
LC11
WATER
SPRAY A1 A3
BOX
+
S1
A2
WATER
SPRAY
C136
WATER M
SPRAY
15 A1
- K1
K1
.6
18 TIMER A2
WATER WATER
SPRAY SPRAY
+
A30
-
GND
008 916 41
15 18 .6
180 200

BF600C WATER SPRAYING D: DE006002 pag. 190
date: 28.Apr.2008 SPRUZZATURA ACQUA
0 1 2 3 4 5 6 7 8 9
LC2
7.0
UN-2.5-590
DASH
BOARD 190.7/ AUTOMATIC AUTOMATIC /250.7
SERVICES SERVICES
008 916 41
F44
10A
TAMPER
AND
VIBRATOR
M-1.5
M-1.5
A2 A2
C69 C68
ON A1 ON A1
TAMPER VIBRATOR
BO-1-*528* G-1.5-663
RJ:6 /200.3.3 RJ:14 /200.3.3
OR-1-*530* O-1.5-664
RJ:5 /200.3.3 RJ:15 /200.3.3
P A7 P C1
BOMAG
G-1.5-663
O-1.5-664
+ +
A8 A7
ON - ON -
TAMPER VIBRATOR
N-1.5
N-1.5
GND GND
190 200.1
11.2
767
BF600C TAMPER AND VIBRATOR D: DE006002 pag. 200
date: 28.Apr.2008 TAMPER E VIBRANTE
0 1 2 3 4 5 6 7 8 9
768
LC2
11.2
7.0
DASH
BOARD
PR-1-555 PR-1-555
BJ:1 /200.2.3
GND M-1-665
GND D-1-666
RJ:3 /200.3.3 RJ:4 /200.3.3
N-1
PR-1-555
N-1
P C2 C4 C3 P C7 C5 C6
N-1
N-1
PR-1-555
M-1-665
PR-1-555
D-1-666
BOMAG
PB 1 3 2 PA 1 3 2
OPTIONAL
KIT
N-1
N-1
PR-1-555
M-1-665
PR-1-555
D-1-666
1 4 1 4
C64 C63
PICK-UP PICK-UP
TAMPER VIBRATOR
3 3
008 916 41
200 200.2

BF600C TAMPER AND VIBRATOR D: DE006002 pag. 200.1
0 1 2 3 4 5 6 7 8 9
LC2
7.0
DASH C153
BOARD D-2.5
008 916 41
200.3.4
180.5/ GEN-ON
TAMPER
+
+
GND
CANH
CANL
RIGHT
LEVEL
RIGHT
LEVEL
RIGHT
LEVEL
LEFT
LEVEL
LEFT
LEVEL
LEFT
LEVEL
VIBRATOR
CONTROLLER
F29
BJ 1 2 3 6 7 8 9 10 11 12 13
10A
AUTEC
DISPLAY
N-1.5
GND
PR-1.5-555
PR-1.5-555
PR-2.5-555
TWISTED
PR-1.5-555
200.1.7/ BJ:1
*AB-1
180.6/ CANH
*AO-1
180.6/ CANL
BOMAG
*MN-1
160.2.6/ BJ:8
*VN-1
160.2.6/ BJ:9
*RN-1
160.2.6/ BJ:10
P-1
160.2.6/ BJ:11
GO-1
160.2.6/ BJ:12
U-1
160.2.6/ BJ:13
200.1 200.3
11.2
769
0 1 2 3 4 5 6 7 8 9
770
11.2
LC2
7.0
DASH C153
BOARD
200.2.4
TAMPER
VIBRATOR
CONTROLLER
PICK-UP
TAMPER
PICK-UP
VIBRAT.
TAMPER
INPUT
VIBRAT.
INPUT
OUTPUT
TAMPER
OUTPUT
VIBRAT.
LEFT
CRAWLER
RIGHT
CRAWLER
RJ 3 4 5 6 14 15 2 1
M-1-665
200.1.3/ RJ:3
D-1-666
200.1.7/ RJ:4
OR-1-*530*
200.4/ RJ:5
BOMAG
BO-1-*528*
200.4/ RJ:6
G-1.5-663
200.8/ RJ:14
O-1.5-664
200.8/ RJ:15
P-1-MC16 P-1-MC16
80.2.4/ MC:16 MC:16 /250.1.1
P-1-*MC17* P-1-*MC17*
80.2.8/ MC:17 MC:17 /250.1.1
008 916 41
200.2 250

0 1 2 3 4 5 6 7 8 9
LC2
7.0
DASH C170
BOARD
250.1.3
ELECTRONIC
UNIT
008 916 41
GND SENSORS
BACKWARD
TRANPORT
DASH BRAKE
FORW.
LEFT CRAWLER
BACKW.
LEFT CRAWLER
FEEDBACK
EDC LEFT
FEEDBACK
EDC RIGHT
+5V
FORW.
RIGHT CRAWLER
BACKW.
RIGHT CRAWLER
+24V
SPIN ON
SECOND GEAR
BATTERY GND
BATTERY GND
FORWARD
MC 1 3 4 5 6 7 10 11 14 26 27 28 31 32 15 29 2
O-1-MC1
85.3/ MC:1
N-4-CENT
N-4-CENT
PO-1-MC3 M-1-MC2
80.9/ MC:3
A-1-*MC4*
80.3.4/ MC:4
B-1-MC5
80.5.4/ MC:5 D7
U-1-*MC6*
80.1/ MC:6
D-1-*MC7* MC:2
80.3.1
80.3/ MC:7
B-1-*MC10*
80.2/ MC:10
A-1-310
V-1-*MC11*
80.4/ MC:11
BOMAG
M-1-//MC14//
85.1/ MC:14 F47
A-1-*MC26* 10A
80.4/ MC:26 FORWARD
G-1-*MC27*
80.5/ MC:27
R-2.5-MC28
85.8/ MC:28
UN-1-590
PR-1-MC31
85.8/ MC:31
AB-1-MC32
80.4.3/ MC:32
AUTOMATIC
SERVICES
200.3
Y 4
N-4-CENT
5.8/ BAT-GND
200.3 250.1
11.2
771
BF600C ELECTRONIC UNIT D: DE006002 pag. 250
date: 28.Apr.2008 CENTRALINA
0 1 2 3 4 5 6 7 8 9
LC2
772
7.0 C170
DASH 250.2
BOARD
ELECTRONIC
11.2
UNIT
C62
RS232 GND
RS232 TX
RS232 RX
PPU LEFT
CRAWLER
PPU RIGHT
CRAWLER
LEFT STEER
LAMP
RIGHT STEER
LAMP
STEERING
POTI
DASHBOARD
POTI
FOOT PEDAL
POTI
NEGATIVE
BRAKE
SECOND GEAR
CAN H2
CAN L2
3 2 5
ELECTRONIC
UNIT
SOCKET
C62 3 2 5 MC 13 20 21 16 17 22 24 34 35 36 40 41 37 38
BP-1-MC13
TWISTED
BG-1-MC20
BR-1-MC21
P-1-MC16
200.3.7/ MC:16
P-1-*MC17*
200.3.7/ MC:17
MO-1-MC22
85.6/ MC:22
PO-1-MC24
85.6/ MC:24
B-1-MC34
85.2/ MC:34
B-1-//MC35//
80.1.4/ MC:35
BOMAG
U-1-//MC36//
80.1.6/ MC:36
OR-1.5-MC40
80.5.8/ MC:40
GO-1-MC41
80.4.8/ MC:41
P-1-XD62
20.8/ CAN H2
U-1-XD61
20.8/ CAN L2
008 916 41
250 301

BF600C ELECTRONIC UNIT D: DE006002 pag. 250.1
date: 28.Apr.2008 CENTRALINA
0 1 2 3 4 5 6 7 8 9
A=ORANGE/ARANCIONE
B=BLUE/BLU
008 916 41
O=WHITE/BIANCO
G=YELLOW/GIALLO
U=GREY/GRIGIO
M=BROWN/MARRONE
N=BLACK/NERO
D=PINK/ROSA
R=RED/ROSSO
P=GREEN/VERDE
V=VIOLET/VIOLA
BOMAG
250.1 1000
11.2
773
BF600C COLORS D: DE006002 pag. 301
date: 28.Apr.2008 COLORI
0 1 2 3 4 5 6 7 8 9
774
DISTMACC2.SKO
11.2
NOME QUANTITA' CODICE DESCRIZIONE PAGINA/COLONNA TESTO FUNZIONALE

NAME AMOUNT ARTICLE NUMBER DESCIPTION PAGE/COLUMN FUNCTION TEXT
AD 1 74005 2568 CONN.FEM. 14P SICMA COMPL. 30. 2 FRONT RIGHT LIGHTING
AD 1 74005 2570 CONN.MASCHIO 14P SICMA COMPL. 30. 2 FRONT RIGHT LIGHTING
AS 1 74005 2568 CONN.FEM. 14P SICMA COMPL. 30. 1 FRONT LEFT LIGHTING
AS 1 74005 2570 CONN.MASCHIO 14P SICMA COMPL. 30. 1 FRONT LEFT LIGHTING
BJ 1 429053124 CONNETTORI PER CONTROLLO TAMPER E VIBRANTE 200.2. 4 TAMPER AND VIBRATOR CONTROLLER
C25 1 434022342 CLAXON 30. 1 HORN
C26 1 434022342 CLAXON 30. 2 HORN
C48 1 59222588 SIRENA RETROMARCIA 80. 8 BACKWARD TRAVELLING
C75-K1 1 434022413 RELE' 24V 170.1. 4
C75-K2 1 434022413 RELE' 24V 170.2. 5
C86 1 434022446 SPINA FISSA 10 POLI 160.1. 2 RIGHT LEVELLING
C87 1 434022446 SPINA FISSA 10 POLI 160.1. 2 RIGHT LEVELLING
C96 1 434022446 SPINA FISSA 10 POLI 160. 2 LEFT LEVELLING
C97 1 434022446 SPINA FISSA 10 POLI 160. 2 LEFT LEVELLING
C112 1 434022393 SPINA FIX 4P VITE 100.1. 0 RIGHT AUGER
C119 1 434022393 SPINA FIX 4P VITE 100. 0 LEFT AUGER
C128 1 434022393 SPINA FIX 4P VITE 90.1. 1 RIGHT CONVEYOR
C132 1 434022393 SPINA FIX 4P VITE 90. 1 LEFT CONVEYOR
BOMAG
DC 2 434022507 CONN. FEMM. SUPERSEAL 3POLI 170.1. 2 L.C.S. 2
DC 2 434022515 CONN. MASCHIO SUPERSEAL 3POLI 170.1. 2 L.C.S. 2
G 1 74005 2569 CONN.FEM. 24P SICMA COMPL. 30. 7 HARNESS
G 1 74005 2567 CONN.MASCHIO 24P SICMA COMPL. 30. 7 HARNESS
L24 1 434022781 GIREVOLE 50. 4 BEACON
LC1-C1 1 408020011 BATTERIA 12V 5. 3 BATTERY
LC1-C2 1 408020011 BATTERIA 12V 5. 3 BATTERY
LC1-C3 1 434022340 STACCABATTERIE MANUALE 5. 3 MANUAL SWITCH
LC1-JE2 1 434022413 RELE' 24V 5. 6 FRONT ROOF
LC1-JE3 1 434022413 RELE' 24V 5. 6 REAR ROOF
LC1-JF1 1 434022828 MAXI FUSE LAMELLARE 20A 5. 1 ELECTRONIC UNIT
LC1-JF2 1 434022341 MAXI FUSE LAMELLARE 60A 5. 3 KEY
LC1-JF3 1 434022828 MAXI FUSE LAMELLARE 20A 5. 4 XENON LIGHTS
LC1-JF4 1 434022828 MAXI FUSE LAMELLARE 20A 5. 3 POWER HEATING
LC1-JF5 1 434022695 MAXI FUSE LAMELLARE 100A 5. 2 PREHEAT
LC1-JF7 1 434022346 FUSIBILE LAMELLARE 15A 5. 5 ROOF FRONT LIGHTING
LC1-JF8 1 434022346 FUSIBILE LAMELLARE 15A 5. 5 ROOF REAR LIGHTING
LC2-C7 1 434022851 PRESA 12V + COPERCHIO 7. 5 SOCKET 12V
LC2-C8 1 057 668 13 CONTATTO CHIAVE 7. 2 IGNITION KEY
LC2-C8 1 057 668 85 PROTEZIONE CONTATTO CHIAVE 7. 2 IGNITION KEY
LC2-C10 1 05710968 REG.TENSIONE 24->12VCC 7. 5 TRANSFORMER
LC2-C11 1 434022807 RESISTENZA 100 OHM 25W 20. 3 DISPLAY
008 916 41
301 1001

BF600C BILL OF MATERIALS D: DE006002 pag. 1000
date: 28.Apr.2008 DISTINTA BASE
0 1 2 3 4 5 6 7 8 9
DISTMACC2.SKO
008 916 41
LC2-C12 1 434022386 BUZZER 20. 2 BUZZER

LC2-C14 1 434022825 BOX DIODI 155. 1 DIODES BOARD
LC2-C20 1 434022965 RESISTENZA 120 OHM + CONNETTORE 20. 8 DISPLAY
LC2-C21 1 434022808 PULS.CLAXON 30. 6 HORN
LC2-C27 1 434022849 KIT RESISTENZE 2X680 OHM PER PEDALE 80.1. 2 RESISTORS KIT
LC2-C28 1 434022812 SEL. 2 POS.STAB 40.1. 4 REAR WORKING LIGHTS
LC2-C32 1 434022812 SEL. 2 POS.STAB 40.1. 1 FRONT WORKING LIGHTS
LC2-C33 1 434022823 FUNGO EMERGENZA 70. 3 EMERGENCY PUSH BUTTON
LC2-C36 1 434022881 PULSANTE LUMINOSO ROSSO 75. 4 GEN-ON

LC2-C41 1 434022813 SEL. 3 POS.STAB+UN CONT. NO E UN CONT. NC 10.4. 7 RPM
LC2-C45 1 434022850 SEL. 2 POS.STAB+1 CONT.NO E 1 NC 80.3. 1 TRAVELLING
LC2-C47 1 434022826 MANIPOLATORE 80. 3 TRAVELLING JOYSTICK
LC2-C50 1 434022766 PULSANTE GIALLO FRENO NEGATIVO 80.5. 3 DASH BRAKE
LC2-C55 1 434022885 PEDALE TRASFERIMENTO PER CINGOLATE (GRIGIO) 80.1. 6 FOOT PEDAL TRAVELLING
LC2-C56 1 434022866 POTENZIOMETRO AVANZAMENTO CINGOLATE 80.1. 3 DASH POTI TRAVELLING
LC2-C57 1 434022563 DEVIATORE ON-OFF 80.4. 3 HYDRAULIC GEARS
LC2-C58 1 434022536 INTER. OFF-MOM 85. 8 SPIN
LC2-C67 1 434022416 STERZO ELETTRICO 85. 2 STEERING
LC2-C68 1 434022318 INTER. ON-OFF 200. 3 VIBRATOR
BOMAG
LC2-C69 1 434022318 INTER. ON-OFF 200. 2 TAMPER
LC2-C70 1 434022535 INTER. ON-OFF-MOM 170. 2 SCREED
LC2-C71 1 434022318 INTER. ON-OFF 140. 5 FUME EXHAUSTER
LC2-C80 1 434022563 DEVIATORE ON-OFF 150.1. 7 SCREED EXTENS.
LC2-C81 1 434022317 INTER. MOM-OFF-MOM 150.1. 5 SCREED EXTENS.
LC2-C85 1 434022537 INTER. DOPPIO MOM-OFF-MOM 160.1. 6 RIGHT LEVEL
LC2-C89 1 434022839 SCHEDA LIVELLAZIONE 160. 0 LIVELLING SYSTEM
LC2-C90 1 434022563 DEVIATORE ON-OFF 150. 7 SCREED EXTENS.
LC2-C91 1 434022317 INTER. MOM-OFF-MOM 150. 5 SCREED EXTENS.
LC2-C95 1 434022537 INTER. DOPPIO MOM-OFF-MOM 160. 6 LEFT LEVEL
LC2-C103 1 434022317 INTER. MOM-OFF-MOM 100.2. 4 AUGER BOX
LC2-C104 1 434022317 INTER. MOM-OFF-MOM 130. 4 SAFETY LOCK BOLT
LC2-C105 1 434022317 INTER. MOM-OFF-MOM 120. 6 HOPPER
LC2-C106 1 434022317 INTER. MOM-OFF-MOM 120. 2 HOPPER
LC2-C107 1 434022536 INTER. OFF-MOM 110. 4 LOADING
LC2-C108 1 434022536 INTER. OFF-MOM 100.1. 7 RIGHT AUGER
LC2-C109 1 434022535 INTER. ON-OFF-MOM 100.1. 4 RIGHT AUGER
LC2-C110 1 434022369 DIODO 2.5A 100.1. 3
LC2-C115 1 434022536 INTER. OFF-MOM 100. 8 LEFT AUGER
LC2-C116 1 434022535 INTER. ON-OFF-MOM 100. 5 LEFT AUGER
LC2-C117 1 434022369 DIODO 2.5A 100. 4
1000 1002
11.2
775
0 1 2 3 4 5 6 7 8 9
776
DISTMACC2.SKO
11.2

LC2-C122 1 434022535 INTER. ON-OFF-MOM 90.1. 3 RIGHT CONVEYOR

LC2-C123 1 434022534 INT. DOPPIO OFF-MOM 90. 7 CONVEYORS
LC2-C124 1 434022535 INTER. ON-OFF-MOM 90. 3 LEFT CONVEYOR
LC2-C125 1 434022369 DIODO 2.5A 90.1. 2
LC2-C126 1 434022369 DIODO 2.5A 90. 2
LC2-C135 1 434022318 INTER. ON-OFF 190. 1 WATER SPRAY
LC2-C151 1 424030240 CRUSCOTTO CAN-BUS 5LCD 12P 20. 3 DISPLAY
LC2-C152 1 431050557 SCHEDA ECO-MODE 10.4. 1 ECO SYSTEM
LC2-C153 1 74005 2721 CONTROLLO TAMPER E VIBRANTE 200.2. 4 TAMPER VIBRATOR CONTROLLER
LC2-C170 1 74005 2618 CENTRALINA SAUER PER BF600C 250. 2 ELECTRONIC UNIT
LC2-D1 1 434022739 DIODO LAMELLARE 40. 6
LC2-D9 1 434022739 DIODO LAMELLARE 80.3. 8
BOMAG
LC2-D10 1 434022739 DIODO LAMELLARE 80.3. 7
LC2-E1 1 434022413 RELE' 24V 7. 2 KEY
LC2-E2 1 434022413 RELE' 24V 30. 5 HORN
LC2-E3 1 434022413 RELE' 24V 30. 4 HORN
LC2-E4 1 434022413 RELE' 24V 40.1. 4 REAR WORKING LIGHTS
LC2-E5 1 434022413 RELE' 24V 40.1. 1 FRONT WORKING LIGHTS
LC2-E6 1 434022413 RELE' 24V 70. 5 EMERGENCY
LC2-E7 1 434022413 RELE' 24V 75. 2 GEN-ON
LC2-E8 1 434022413 RELE' 24V 10.3. 1 POWER EMR
LC2-E9 1 434022413 RELE' 24V 80.3. 7 AUGER CONVEYOR AUTO
LC2-E10 1 434022413 RELE' 24V 80.5. 5 POWER
LC2-E13 1 434022413 RELE' 24V 80.4. 7 HYDRAULIC GEAR
LC2-E14 1 434022413 RELE' 24V 170. 7 L.C.S.
LC2-E15 1 434022413 RELE' 24V 100.1. 6 RIGHT AUGER
LC2-E16 1 434022413 RELE' 24V 100. 7 LEFT AUGER
LC2-E17 1 434022413 RELE' 24V 7. 8 GEN-ON
LC2-E18 1 434022413 RELE' 24V 80.3. 5 AUTOMATIC SERVICES
LC2-E19 1 421033056 TEMPORIZZATORE 80.3. 2 TRAVELLING
LC2-F1 1 434022415 FUSIBILE LAMELLARE 25A 190. 3 WATER SPRAY
LC2-F2 1 434022578 FUSIBILE LAMELLARE 10A 50. 4 BEACON
LC2-F3 1 434022578 FUSIBILE LAMELLARE 10A 20. 1 ALARMS
LC2-F4 1 434022578 FUSIBILE LAMELLARE 10A 30. 4 HORN
008 916 41
1001 1003

0 1 2 3 4 5 6 7 8 9
DISTMACC2.SKO
008 916 41
LC2-F5 1 434022578 FUSIBILE LAMELLARE 10A 40.1. 1 WORKING LIGHTS

LC2-F6 1 434022415 FUSIBILE LAMELLARE 25A 60. 4 WASHING PUMP
LC2-F7 1 434022578 FUSIBILE LAMELLARE 10A 70. 3 EMERGENCY
LC2-F8 1 434022578 FUSIBILE LAMELLARE 10A 10.4. 7 ENGINE RPM
LC2-F9 1 434022578 FUSIBILE LAMELLARE 10A 80. 1 TRAVELLING
LC2-F10 1 434022578 FUSIBILE LAMELLARE 10A 7. 6 TRANSFORMER
LC2-F11 1 434022578 FUSIBILE LAMELLARE 10A 15. 4 FAN
LC2-F13 1 434022578 FUSIBILE LAMELLARE 10A 10.3. 1 POWER EMR
LC2-F14 1 434022415 FUSIBILE LAMELLARE 25A 30. 2 HORN

LC2-F17 1 434022346 FUSIBILE LAMELLARE 15A 40.1. 6 FRONT WORKING LIGHTS
LC2-F18 1 434022346 FUSIBILE LAMELLARE 15A 40.1. 8 REAR WORKING LIGHTS
LC2-F19 1 434022578 FUSIBILE LAMELLARE 10A 40. 4 DASH BOARD LIGHTS
LC2-F20 1 434022578 FUSIBILE LAMELLARE 10A 180. 4 HEATING
LC2-F21 1 434022578 FUSIBILE LAMELLARE 10A 160.1. 6 RIGHT LIVELLING
LC2-F22 1 434022578 FUSIBILE LAMELLARE 10A 80.3. 4 TRANSPORT
LC2-F25 1 434022627 FUSIBILE LAMELLARE 3A 80.5. 3 POWER
LC2-F26 1 434022578 FUSIBILE LAMELLARE 10A 80.4. 3 HYDRAULIC GEARS
LC2-F27 1 434022578 FUSIBILE LAMELLARE 10A 150.1. 7 RIGHT SCREED EXTENS
LC2-F28 1 434022578 FUSIBILE LAMELLARE 10A 170. 2 SCREED
BOMAG
LC2-F29 1 434022578 FUSIBILE LAMELLARE 10A 200.2. 3 AUTEC DISPLAY
LC2-F30 1 434022346 FUSIBILE LAMELLARE 15A 80.3. 5 AUTOMATIC
LC2-F31 1 434022578 FUSIBILE LAMELLARE 10A 160. 6 LEFT LIVELLING
LC2-F32 1 434022578 FUSIBILE LAMELLARE 10A 150. 7 LEFT SCREED EXTENS
LC2-F33 1 434022578 FUSIBILE LAMELLARE 10A 100.2. 4 AUGERS LIFTING
LC2-F34 1 434022578 FUSIBILE LAMELLARE 10A 120. 2 HOPPERS
LC2-F35 1 434022578 FUSIBILE LAMELLARE 10A 100.1. 7 RIGHT AUGER
LC2-F36 1 434022578 FUSIBILE LAMELLARE 10A 100. 8 LEFT AUGER
LC2-F37 1 434022578 FUSIBILE LAMELLARE 10A 90.1. 7 RIGHT CONVEYOR
LC2-F38 1 434022578 FUSIBILE LAMELLARE 10A 90. 7 LEFT CONVEYOR
LC2-F39 1 434022415 FUSIBILE LAMELLARE 25A 75. 7 GEN-ON
LC2-F40 1 434022829 MAXI FUSE LAMELLARE 7.5A 10.2. 3 PREHEAT
LC2-F41 1 434022578 FUSIBILE LAMELLARE 10A 100. 1 AUGERS
LC2-F42 1 434022578 FUSIBILE LAMELLARE 10A 90. 1 CONVEYORS
LC2-F43 1 434022578 FUSIBILE LAMELLARE 10A 170.1. 2 L.C.S.2
LC2-F43 1 434022578 FUSIBILE LAMELLARE 10A 170.2. 5 L.C.S.2
LC2-F44 1 434022578 FUSIBILE LAMELLARE 10A 200. 2 TAMPER AND VIBRATOR
LC2-F45 1 434022578 FUSIBILE LAMELLARE 10A 190. 7 WATER SPRAY
LC2-F46 1 434022578 FUSIBILE LAMELLARE 10A 170. 7 L.C.S.
LC2-F47 1 434022578 FUSIBILE LAMELLARE 10A 250. 7 FORWARD
LC2-F48 1 434022433 FUSIBILE LAMELLARE 5A 80. 8 BACKWARD
1002 1004
11.2
777
0 1 2 3 4 5 6 7 8 9
778
DISTMACC2.SKO
11.2

LC2-L1 1 434022830 OSIRIS 40. 3 DASH BOARD

LC2-S1 1 434022337 LAMPADA 3W 20. 1 NEGATIVE BRAKE
LC2-S1 1 434022674 SPIA FRENO 20. 1 NEGATIVE BRAKE
LC2-S2 1 434022672 SPIA STERZATURA A DX 85. 5 RIGHT STEERING
LC2-S2 1 434022337 LAMPADA 3W 85. 5 RIGHT STEERING
LC2-S3 1 434022673 SPIA STERZATURA A SX 85. 4 LEFT STEERING
LC2-S3 1 434022337 LAMPADA 3W 85. 4 LEFT STEERING
LC2-S6 1 434022683 SPIA MARCIA 2 80.4. 2 HYDRAULIC GEAR
LC2-S6 1 434022337 LAMPADA 3W 80.4. 2 HYDRAULIC GEAR
LC2-S7 1 434022690 SPIA MARCIA 1 80.4. 4 HYDRAULIC GEAR
LC2-S7 1 434022337 LAMPADA 3W 80.4. 4 HYDRAULIC GEAR
LC2-S8 1 434022689 SPIA CONTROROTAZIONE 85. 7 SPIN
LC2-S8 1 434022337 LAMPADA 3W 85. 7 SPIN
LC2-S9 1 434022681 SPIA COCLEA 100.1. 3 RIGHT AUGER
LC2-S9 1 434022337 LAMPADA 3W 100.1. 3 RIGHT AUGER
LC2-S10 1 434022681 SPIA COCLEA 100. 4 LEFT AUGER
BOMAG
LC2-S10 1 434022337 LAMPADA 3W 100. 4 LEFT AUGER
LC2-S11 1 434022680 SPIA NASTRO 90.1. 2 RIGHT CONVEYOR
LC2-S11 1 434022337 LAMPADA 3W 90.1. 2 RIGHT CONVEYOR
LC2-S12 1 434022680 SPIA NASTRO 90. 3 LEFT CONVEYOR
LC2-S12 1 434022337 LAMPADA 3W 90. 3 LEFT CONVEYOR
LC3-C13 1 434022362 PRESSOSTATO FRENO NEGATIVO 20. 1 NEGATIVE BRAKE PRESSURE SWITCH
LC3-C19 1 434022629 GALLEGGIANTE LIV.GASOLIO 20. 7 FUEL LEVEL
LC3-C38 1 332098747 LIVELLOSTATO ACQUA MOTORE 10.1. 3 ENGINE COOLANT LEVEL
LC4-C92 1 434022317 INTER. MOM-OFF-MOM 150. 7 SCREED EXTENS.
LC4-C93 1 434022838 SCHEDA DIODI PULSANTIERE 150. 3 DIODES CARD
LC4-C94 1 434022386 BUZZER 150. 3
LC4-C98 1 434022537 INTER. DOPPIO MOM-OFF-MOM 160. 5 LEFT LEVEL
LC4-C99 1 434022875 REGOLATORE PER CONTROLLO ULTRASUONO 100. 2
LC4-C100 1 434022876 POTENZIOMETRO PER REMOTO 100. 3 LEFT AUGERS POTI
LC4-C118 1 434022317 INTER. MOM-OFF-MOM 100. 5 LEFT AUGER
LC4-C131 1 434022317 INTER. MOM-OFF-MOM 90. 5 LEFT CONVEYOR
LC4-L21 1 434022432 LAMPADA 5W T5 150. 3
LC4-L21 1 434022565 LAMPEGGIATORE 150. 3
008 916 41
1003 1005

0 1 2 3 4 5 6 7 8 9
DISTMACC2.SKO
008 916 41
LC5-C82 1 434022317 INTER. MOM-OFF-MOM 150.1. 7 SCREED EXTENS.

LC5-C83 1 434022838 SCHEDA DIODI PULSANTIERE 150.1. 3 DIODES CARD
LC5-C84 1 434022386 BUZZER 150.1. 3
LC5-C88 1 434022537 INTER. DOPPIO MOM-OFF-MOM 160.1. 5 RIGHT LEVEL
LC5-C101 1 434022875 REGOLATORE PER CONTROLLO ULTRASUONO 100.1. 2
LC5-C102 1 434022876 POTENZIOMETRO PER REMOTO 100.1. 3 RIGHT AUGERS POTI
LC5-C111 1 434022317 INTER. MOM-OFF-MOM 100.1. 5 RIGHT AUGER
LC5-C127 1 434022536 INTER. OFF-MOM 90.1. 5 RIGHT CONVEYOR
LC5-L22 1 434022432 LAMPADA 5W T5 150.1. 3

LC5-L22 1 434022565 LAMPEGGIATORE 150.1. 3
LC10-C72 1 434022538 INTER. DOPPIO ON-OFF-ON 170. 5 L.C.S.
LC10-C73 1 434022321 INTER. ON-OFF-ON 170.1. 2 L.C.S.2
N 1 74005 2569 CONN.FEM. 24P SICMA COMPL. 30. 9 HARNESS
N 1 74005 2567 CONN.MASCHIO 24P SICMA COMPL. 30. 9 HARNESS
OPIONALKIT 1 74005 3301 KIT SPRUZZATURA RUOTE 190. 1 WATER SPRAY
OPTIONALKIT 1 74005 3039 KIT L.C.S.2 170.1. 0 L.C.S.2
OPTIONALKIT 1 74005 3039 KIT L.C.S.2 170.2. 0 LOCK CYLINDER
P 1 74005 2569 CONN.FEM. 24P SICMA COMPL. 60. 4 HARNESS
P 1 74005 2567 CONN.MASCHIO 24P SICMA COMPL. 60. 4 HARNESS
BOMAG
PA 1 434022515 CONN. MASCHIO SUPERSEAL 3POLI 200.1. 5 PICK-UP VIBRATOR
PA 1 434022507 CONN. FEMM. SUPERSEAL 3POLI 200.1. 5 PICK-UP VIBRATOR
PB 1 434022515 CONN. MASCHIO SUPERSEAL 3POLI 200.1. 2 PICK-UP TAMPER
PB 1 434022507 CONN. FEMM. SUPERSEAL 3POLI 200.1. 2 PICK-UP TAMPER
PC 1 434022515 CONN. MASCHIO SUPERSEAL 3POLI 80.2. 5 PICK-UP RIGHT CRAWLER
PC 1 434022507 CONN. FEMM. SUPERSEAL 3POLI 80.2. 5 PICK-UP RIGHT CRAWLER
PE 1 434022508 CONN. FEMM. SUPERSEAL 4POLI 80.1. 6 FOOT PEDAL TRAVELLING
PE 1 434022516 CONN. MASCHIO SUPERSEAL 4POLI 80.1. 6 FOOT PEDAL TRAVELLING
PK 1 434022515 CONN. MASCHIO SUPERSEAL 3POLI 80.2. 1 PICK-UP LEFT CRAWLER
PK 1 434022507 CONN. FEMM. SUPERSEAL 3POLI 80.2. 1 PICK-UP LEFT CRAWLER
Q 2 74005 2569 CONN.FEM. 24P SICMA COMPL. 150. 4 HARNESS
Q 2 74005 2567 CONN.MASCHIO 24P SICMA COMPL. 150. 4 HARNESS
R 3 74005 2569 CONN.FEM. 24P SICMA COMPL. 7. 4 HARNESS
R 3 74005 2567 CONN.MASCHIO 24P SICMA COMPL. 7. 4 HARNESS
RJ 1 429053124 CONNETTORI PER CONTROLLO TAMPER E VIBRANTE 200.3. 4 TAMPER AND VIBRATOR CONTROLLER
T 1 74005 2569 CONN.FEM. 24P SICMA COMPL. 90. 1 HARNESS
T 1 74005 2567 CONN.MASCHIO 24P SICMA COMPL. 90. 1 HARNESS
VA 1 434022514 CONN. MASCHIO SUPERSEAL 2POLI 15. 4 FAN
VA 1 434022506 CONN. FEMM. SUPERSEAL 2POLI 15. 4 FAN
WA 1 434022515 CONN. MASCHIO SUPERSEAL 3POLI 10.1. 3 ENGINE COOLANT LEVEL
WA 1 434022507 CONN. FEMM. SUPERSEAL 3POLI 10.1. 3 ENGINE COOLANT LEVEL
1004 1006
11.2
779
0 1 2 3 4 5 6 7 8 9
780
DISTMACC2.SKO
11.2

WB 1 434022514 CONN. MASCHIO SUPERSEAL 2POLI 10.1. 4 ENGINE FUEL FILTER

WB 1 434022506 CONN. FEMM. SUPERSEAL 2POLI 10.1. 4 ENGINE FUEL FILTER
WE 1 434022510 CONN. FEMM. SUPERSEAL 6POLI 160.2. 3 LEVELLING WIRE SENSORS
WE 1 434022518 CONN. MASCHIO SUPERSEAL 6POLI 160.2. 3 LEVELLING WIRE SENSORS
WH 1 434022515 CONN. MASCHIO SUPERSEAL 3POLI 190. 6 WATER SPRAYING
WH 1 434022507 CONN. FEMM. SUPERSEAL 3POLI 190. 6 WATER SPRAYING
XC 1 74005 2569 CONN.FEM. 24P SICMA COMPL. 10.1. 4 EMR
XC 1 74005 2567 CONN.MASCHIO 24P SICMA COMPL. 10.1. 4 EMR
XJE1 1 434022506 CONN. FEMM. SUPERSEAL 2POLI 10.2. 4 PRE-HEAT
XKEY 1 057 555 46 PROTEZIONE 4P CONTATTO CHIAVE 7. 2 STARTING KEY
XKEY 1 057 555 47 PROTEZIONE 6P CONTATTO CHIAVE 7. 2 STARTING KEY
Z 1 74005 2569 CONN.FEM. 24P SICMA COMPL. 10.1. 3 HARNESS
Z 1 74005 2567 CONN.MASCHIO 24P SICMA COMPL. 10.1. 3 HARNESS
BOMAG
008 916 41
1005

Head Office/Hauptsitz
BOMAG
Hellerwald
D-56154 Boppard
Germany
Telefon: +49 6742 100-0
Fax: +49 6742 3090
E-Mail: info@bomag.com
BOMAG BOMAG BOMAG

Niederlassung Berlin Niederlassung Boppard Niederlassung Chemnitz
Gewerbestraße 3 Hellerwald Querstraße 6
15366 Hoppegarten 56154 Boppard 09247 Chemnitz
GERMANY GERMANY GERMANY
Tel.: +49 3342 369410 Tel.: +49 6742 100360 Tel.: +49 3722 51590
Fax: +49 3342 369436 Fax: +49 6742 100392 Fax: +49 3722 515951
e-mail: nlberlin@bomag.com.de e-mail: nlboppard@bomag.com e-mail: nlchemnitz@bomag.com
BOMAG BOMAG BOMAG

Niederlassung Hannover Niederlassung München Niederlassung Stuttgart
Dieselstraße 44 Otto-Hahn-Ring 3 Uferstraße 22
30827 Garbsen-Berenbostel 85301 Schweitenkirchen 73630 Remshalden-Grunbach
GERMANY GERMANY GERMANY
Tel.: +49 5131 70060 Tel.: +49 8444 91840 Tel.: +49 7151 986293
e-mail: nlhannover@bomag.de e-mail: nlmuenchen@bomag.de e-mail: nlstuttgart@bomag.de
BOMAG (China) Construction BOMAG France S.A.S. BOMAG (GREAT BRITAIN), LTD
Machinery Co. , Ltd 2, avenue du Général de Gaulle Sheldon Way, Larkfield
No. 2808, west Huancheng Road, 91170 VIRY-CHATILLON Aylesford
Shanghai Comprehensive Industrial FRANCE Kent ME20 6SE
Zone Fengxian Shanghai 201401 GREAT BRITAIN
CHINA
Tel.: +86 21 3365 5566 Tel.: +33 1 69578600 Tel.: +44 1622 716611
Fax: +86 21 3365 5508 Fax: +33 1 69962660 Fax: +44 1622 710233
e-mail: china@bomag.com e-mail: france@bomag.com e-mail: gb@bomag.com
BOMAG Italia Srl. BOMAG (CANADA), INC. BOMAG Maschinenhandelsgesellschaft

Z.I. Via Mella, 6 3455 Semenyk Court m.b.H.
25015 Desenzano del Garda (BS) Missisauga, Ontario Porschestraße 9
ITALY CANADA 1230 Wien
Tel.: +39 030 9127263 Tel.: +1 905 361 9961 Tel.: +43 1 69040-0
Fax: +39 030 9127278 Fax: +1 905 361 9962 Fax: austria@bomag.com
e-mail: italy@bomag.com e-mail: canada@bomag.com e-mail: austria@bomag.com
FAYAT BOMAG Polska Sp. z.o.o. FAYAT BOMAG Rus OOO BOMAG GmbH, Singapore
Ul. Szyszkowa 52 Klyazma block, h 1-g 300, Beach Road
02-285 Warzawa 141400 Khimki, Moscow region, RF The Concourse, ‚ 18-06
POLAND RUSSIA Singapore 199555
SINGAPORE
Tel.: +48 22 4820400 Tel.: +7 (495) 2879290 Tel.: +65 294 1277
Fax: +48 22 4820401 Fax: +7 (495) 2879291 Fax: +65 294 1377
e-mail: poland@bomag.com e-mail: russia@bomag.com e-mail: singapore@bomag.com
BOMA Equipment Hong Kong LTD BOMAG Americas, Inc.

Room 1003, 10/F Charm Centre 2000 Kentville Road
700, Castle Peak Road Kewanee, Illinois 61443
Kowloon, U.S.A.
HONG KONG
Tel.: +852 2721 6363 Tel.: +1 309 8533571
Fax: +852 2721 3212 Fax: +1 309 8520350
e-mail: bomahk@bomag.com e-mail: usa@bomag.com
Printed in Germany

Service Manual BF600C

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Service Manual BF600C

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Service - Manual

008 916 41 BOMAG 3

5.7 Fuel pressure sensor 117

4 BOMAG 008 916 41

7.3 Actuator drive 313

008 916 41 BOMAG 5

6 BOMAG 008 916 41

008 916 41 BOMAG 7

Use only genuine BOMAG spare parts.

These safety regulations must be read and ap-

8 BOMAG 008 916 41

l Use protective clothes like hard hat, safety boots

008 916 41 BOMAG 9

10 BOMAG 008 916 41

008 916 41 BOMAG 11

Special safety regulations

12 BOMAG 008 916 41

008 916 41 BOMAG 13

l Plug-in connectors on control units are only dust Battery

14 BOMAG 008 916 41

008 916 41 BOMAG 15

Hydraulic system l Perform measurements at operating temperature of

16 BOMAG 008 916 41

Special requirements with respect to cleanliness in

008 916 41 BOMAG 17

Notes and measures concerning the workshop

Notes and measures for work place and tools in

18 BOMAG 008 916 41

Assembly of radial seals

008 916 41 BOMAG 19

20 BOMAG 008 916 41

008 916 41 BOMAG 21

Screws and nuts Strength classes, metric screws

22 BOMAG 008 916 41

Nuts for screw joints with full load capability (4, 5,

Fig. 10 Identification of nuts in clock system

Strength class of Strength class of associated

Nuts for screw joints with limited load factor (04,

Nuts for screw joints without specified load factor

008 916 41 BOMAG 23

Identification of UNF-threads Cotter pins

Studs and brake rods

24 BOMAG 008 916 41

Tightening torques for screws with metric unified thread*

Tightening torques for screws with metric unified fine thread*

008 916 41 BOMAG 25

Tightening torques for wheel nuts (fine thread) * **

26 BOMAG 008 916 41

008 916 41 BOMAG 27

28 BOMAG 008 916 41

008 916 41 BOMAG 29

2.1 Technical data

30 BOMAG 008 916 41

008 916 41 BOMAG 31

32 BOMAG 008 916 41

008 916 41 BOMAG 33

Additional engine data

Vibration motor screed,

Tamper motor screed,

34 BOMAG 008 916 41

Scraper belt pump

Scraper belt motor

Conveyor screw pump