BW211-212-213D-40 Service Manual E 00891163.c08.pdf

Service - Manual

BW 211 / 212 / 213 D-40 BW 211 / 212 / 213 PD-40 S/N 101 582 42 . . . . S/N 101 582 43 . . . . S/N 101 582 44 . . . . S/N 861 583 00 . . . . S/N 101 583 02 . . . . S/N 101 583 03 . . . . S/N 101 582 55 . . . . S/N 101 582 47 . . . . S/N 101 582 48 . . . . S/N 101 582 49 . . . .

Single drum roller Catalogue number.

008 911 63

03/2008

Table of Contents

General

7 1.1 Introduction

8

1.2 Safety regulations

9

1.3 General repair instructions

14

1.4 Tightening torques

24

Maintenance

29 2.1 General notes on maintenance

30

2.2 Table of fuels and lubricants

32

2.3 Running-in instructions

33

2.4 Maintenance chart

34

Technical data

37 3.1 Technical data

38

Connection overview

47 4.1 Connection overview

Tests and adjustments

51 5.1 Special tools, tests and adjustments

52

5.2 Checking the rotation speeds

56

5.3 Checking / adjusting the neutral positions of the travel pump

58

5.4 Pressure tests in the travel circuit

60

5.5 Checking / adjusting the vibrator shaft speeds

62

5.6 Pressure measurements in the vibration circuit

63

5.7 Check the leakage rate of the vibration motor

64

5.8 Pressure test in steering circuit

65

Flushing and bleeding

67 6.1 Special tools for flushing

68

6.2 Flushing - general

73

6.3 Flushing schematic travel circuit (distribution travel pump)

75

6.4 Flushing the travel circuit (travel pump distribution)

77

6.5 Flushing schematic travel circuit (distribution axle motor)

83

6.6 Flushing the travel circuit (axle motor distribution)

88

6.7 Flushing schematic for vibration drive

93

6.8 Flushing the vibration circuit

94

6.9 Bleeding the travel circuit

98

6.10 Bleeding the vibration circuit Fundamental electrics

008 911 63

48

100 103

7.1 Understanding circuit diagrams

104

7.2 Terminal designations

109

7.3 Current and voltage

113

7.4 CAN-Bus

116

7.5 Resistance

118

7.6 Series / parallel connection

120

7.7 Ohm's law

122

7.8 Electrical energy

122

7.9 Formula diagram

123

7.10 Metrology

124

7.11 Diodes, relays, fuses

127

BOMAG

3

Table of Contents 7.12 Batteries

130

7.13 Three-phase generator

133

7.14 Electric starter

141

7.15 Telemecanique switch

144

7.16 Inductive proximity switches

147

7.17 Angle sensors

148

7.18 Plug connectors

150

7.19 Deutsch plug, series DT and DTM

150

7.20 Plugs and terminals in spring clamping technology

157

7.21 Electric modules

160

Special tools, electrics

161 8.1 Special tools, electrics

Electronic modules 9.1 BEM, BOMAG Evib-meter

173

9.2 Electric module K04

234

9.3 Heating/air conditioning control

238

Speedometer Module

245 10.1 Speedometer module

Service Training

246 249

11.1 Service Training

251

Engine

4

162 171

315 12.1 Diesel engine, general

316

12.2 Service side

317

12.3 Starter side

318

12.4 Lubrication oil circuit

319

12.5 Oil pressure switch and low oil pressure circuitry

321

12.6 Check the engine oil level

322

12.7 Changing engine oil and oil filter cartridges

323

12.8 Coolant circuit

325

12.9 Coolant temperature switch

327

12.10 Disassembling and assembling the coolant temperature switch

328

12.11 Replacing the thermostat

329

12.12 Checking the thermostat in disassembled state

330

12.13 Check the coolant level

331

12.14 Change the coolant

331

12.15 Checking the anti-freeze concentration

332

12.16 Clean the cooling fins on engine and hydraulic oil cooler

333


334

12.18 Fuel supply

336

12.19 Injection system

339

12.20 Injection pump replacement during service

340

12.21 Injection valve replacement during service

349

12.22 Checking / repairing injection valves

352

12.23 Fuel filter

357

12.24 Check, clean the water separator

359

12.25 Change the fuel pre-filter cartridge

359

12.26 Change the fuel filter cartridge

361

BOMAG

008 911 63

Table of Contents 12.27 Checking the compression

361

12.28 Check, adjust the valve clearance

362

12.29 Boost fuel solenoid valve

364

12.30 Engine shut-down solenoid

365

12.31 Air filter

366

12.32 Cleaning, changing the dry air filter cartridge

367

12.33 Heating flange on engine

369

12.34 Checking the heating flange control

372

12.35 Electric throttle control

373

12.36 Engine monitoring

375

12.37 Engine

378

12.38 Special tools, Deutz engine (BFM 2012)

380

Air conditioning system

393

13.1 Physical basics

394

13.2 Refrigerant R134a

397

13.3 Compressor oil / refrigeration oil

398

13.4 Working principle of the air conditioning system

399

13.5 Monitoring devices

399

13.6 Description of components

400

13.7 Checking the compressor oil level

406

13.8 Checking the magnetic clutch

407

13.9 Inspection and maintenance work

408

13.10 Checking, replacing the refrigerant compressor V-belt

408

13.11 Service the air conditioning

409

13.12 Drying and evacuation

412

13.13 Emptying in case of repair

412

13.14 Leak test

413

13.15 Filling instructions

414

13.16 Trouble shooting in refrigerant circuit, basic principles

417

13.17 Trouble shooting, refrigerant circuit diagram

421

13.18 Trouble shooting procedure

422

13.19 Steam table for R134a

432

Replacing the cab window panes

437

14.1 Assembly of window panes

438

14.2 Special tools

439

14.3 Auxiliary materials

440

14.4 Removing and installing the window pane

442

Drum

447 15.1 Special tools, drum, single drum rollers 15.2 Repair overview for drum

450

15.3 Removing and installing the drum

457

15.4 Repairing the drum

462

15.5 Disassembling and assembling the change-over weight

495

15.6 Changing the rubber buffers and adjusting the pretension Oscillating articulated joint

008 911 63

448

498 501

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

502

16.2 Repair overview oscillating articulated joint

504

BOMAG

5

Table of Contents 16.3 Removing and installing the oscillating articulated joint

508

16.4 Dismantling the oscillating articulated joint

510

16.5 Assembling the oscillating articulated joint

515

Suppliers documentation

525

17.1 Travel pump

527

17.2 Vibration pump

617

17.3 Drum drive

655

17.4 Vibration motor

705

17.5 Axle drive motor

729

17.6 Axle

811

Circuit diagrams

6

933 18.1 Hydraulic diagram 581 202 10

935

18.2 Hydraulic diagram 581 202 11

939

18.3 Wiring diagram 582 702 09

943


979


1013

BOMAG

008 911 63

1 General

008 911 63

BOMAG

7

1.1 1.1

Introduction

Introduction

This manual is intended to support expert mechanics in efficient repair and maintenance work. Whoever wants to do repair work himself should have been sufficiently trained and posses profound expert knowledge, he should limit his work only to those parts and components which will not affect the safety of the vehicle or the passengers. It is highly recommended to have repairs to critical systems, such as steering, brakes and travel drive, sole carried out by a BOMAG workshop. Untrained persons should NEVER UNTERTAKE SUCH REPAIR WORK.

* The applicable documents valid at the date of printing are part of this manual.

The repair instructions describe the removal or dismantling and assembly of components and assembly groups. The repair of disassembled assembly groups is described as far as this makes sense with respect to available tools and spare parts supply and as far as it can be understood by a skilled mechanic. Documentation For the BOMAG machines described in this training manual the following documentation is additionally available: 1

Operating and maintenance instructions

2

Spare parts catalogue

3

Wiring diagram*

4

Hydraulic diagram*

5

Service Information

You should only use genuine BOMAG spare parts. Spare parts needed for repairs can be taken from the spare parts catalogue for the machine. This manual is not subject of any updating service; we would therefore like to draw your attention to the additionally published "technical service information". In case of a new release all necessary changes will be included. In the course of technical development we reserve the right for technical modifications without prior notification. Information and illustrations in this manual must not be reproduced and distributed, nor must they be used for the purpose of competition. All rights according to the copyright law remain expressly reserved. Danger Please observe strictly the safety regulations in this manual, in the operating instructions as well as the applicable accident prevention regulations. !

BOMAG GmbH Printed in Germany Copyright by BOMAG

8

BOMAG

008 911 63

1.2

Safety regulations Important notes 1.2

These safety regulations must be read and applied by every person involved in the repair of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be additionally observed. Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG. Any suggestions, safety precautions and warnings in this section are intended as a mnemonic aid for well trained and experienced expert mechanics. This manual should not be considered a bible on workshop safety. Workshop equipment and facilities as well as the use and waste disposal of solvent, fluids, gases and chemicals are subject to legal regulations, which are intended to provide a minimum on safety. It is obviously your own responsibility to know and adhere to these regulations. This manual contain headers like "Note", "Attention", "Danger" and "Environment", which must be strictly complied with in order to avoid dangers for health and for the environment. Danger Paragraphs marked like this highlight possible dangers for persons. !

Caution Paragraphs marked like this highlight possible dangers for machines or parts of the machine. !

i

Note

Paragraphs marked like this contain technical information for the optimal economical use of the machine. Environment Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts. Observe the regulations for the protection of the environment.

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Before starting repair work stand the machine on level and solid ground. Always secure the machine against unintended rolling. Secure the engine reliably against unintentional starting.

008 911 63

On machines with articulated joint keep the articulated joint locked during work.

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Use protective clothes like hard hat, safety boots and gloves.

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Keep unauthorized persons away from the machine during repair work.

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Tools, lifting gear, lifting tackle, supports and other auxiliary equipment must be fully functional and in safe condition.

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Use only safe and approved lifting gear of sifficient load bearing capacity to remove and install parts or components from and to the machine.

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Be careful with cleansing agents. Do not use easily inflammable or harmful substances, such as gasoline or paint thinners for cleaning.

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Cleaning or repair work on the fuel tank is very dangerous. Do not smoke or allow any ignitable sparks or open fire in the vicinity when cleaning or repairing a tank. .

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When performing welding work strictly comply with the respective welding instructions.

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Precautions and codes of conduct for welding work Welding work should only be performed by specially instructed expert personnel. Danger Electric shock! !

Sparks, fire hazard, burning of skin! Infrared or ultraviolet radiation (arc), flashing of eyes! Health hazard caused by welding work on highly alloyed work pieces, metal coatings, paint coatings, plastic coatings, oil containing dirt deposits, grease or solvent residues, etc.! ●

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General ●

Mark a machine that is defective or being repaired by attaching a clearly visible warning tag to the steering wheel.

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Safety regulations

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Check welding equipment and cables for damage before use (also the validity of inspection stickers). Ensure good conductivity between earth cable and work piece. Start the extraction fan before starting work and guide with the progressing work as required. Always isolate the burner when laying it down (remove possible electrode residues). Protect cables from being damaged, use cables with insulated couplings. Ensure sufficient fire protection, keep a fire extinguisher at hand.

BOMAG

9

1.2 ●

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Safety regulations

In case of welding work in fire or explosion endangered environments, you should always ask for a welding permission.

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Name a fire watch during and after welding work.

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Do not clamp the welding rod holder and the inert gas welding gun under your arm and lay these parts only on an insulated top.

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Place the inert gas bottles in a safe place and secure them against falling over. Use a protective screen or an arcing shield with welding glass, wear welding gloves and clothes, this applies also for assisting persons. Switch the welding unit off before connecting welding cables.

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Check electrode holders and electric cables at regular intervals. In case of deficiencies switch off the welding unit and inform supervising persons. In case of an extractor fan failure or any other fault inform the supervising persons.

Maintenance; waste disposal ●

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Remove combustible parts from the vicinity or cover such parts.

Behaviour in case of faults ●

full face visor; a facility suitable for rinsing the eyes should also be available.

Replace damaged insulating jaws and welding rod holders immediately. Replace the welding wire reels only in deenergized state.

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Call first air helpers.

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Report the accident.

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In case of an electric accident: Interrupt the power supply and remove the injured person from the electric circuit. If breathing and heart have stopped apply reactivation measures and call for an emergency doctor.

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Old oils Prolonged and repetitive contact with mineral oils will remove the natural greases from the skin and causes dryness, irritation and dermatitis. Moreover, used engine oils contain potentially hazardous contaminants, which could cause skin cancer. Appropriate skin protection agents and washing facilities must therefore be provided. ●

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Wash with soap and water to ensure that all oil has been removed (a skin cleaning agent and a nail brush will help). Lanolin containing agents will replace natural skin oils that were lost. Do not use gasoline, kerosene, diesel, thinner or solvents to wash the skin. Do not put oil soaked cloths into your pockets. Avoid clothes, especially underpants, getting soiled by oil. Overalls must be washed at regular intervals. Clothes that cannot be washed, must be disposed of. If possible degrease components before handling.

Hydraulics ●

Keep calm.

Apply protective cream before starting work, so that oil can be easier removed from the skin.

Environment It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Entrust special companies with the waste disposal of old oil. If in doubt you should consult your local authorities.

What to do in case of accidents; First Aid ●

Avoid prolonged and repetitive contact with oil, especially with old oil. In case of open incisions and injuries seek medical advice immediately.

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Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. You should therefore relieve the pressure in the system before disconnecting any lines. Before applying pressure to the system make sure that all line connections and ports have been properly tightened and are in perfect condition. Hydraulic oil leaking out of a small opening can hardly be noticed, therefore please use a piece of cardboard or wood when checking for leaks. When being injured by hydraulic oil consult a physician immediately, as otherwise this may cause severe infections. Do not step in front of or behind the drums/wheels/ crawler tracks when performing adjustment work in the hydraulic system while the engine is running. Block drums and/or wheels / crawler tracks with wedges.

Wear protective clothes and safety gloves, if possible. If there is a risk of eye contact you should protect your eyes appropriately, e.g. chemistry goggles or

10

BOMAG

008 911 63

1.2

Safety regulations Reattach all guards and safety installations after all work has been completed. Environment It is strictly prohibited to drain off hydraulic oil into the soil, the sewer system or into natural waters. Entrust special companies with the waste disposal of old oil. If in doubt you should consult your local authorities.

Fuels

plastic material, a so-called fluoroelastomer. Under normal operating conditions this material is safe and does not impose any danger to health. However, if this material becomes damaged by fire or extreme heat, it may decompose and form highly caustic hydrofluoric acid, which can cause severe burns in contact with skin. If the material is in such a state it must only be touched with special protective gloves. These gloves must be disposed of directly after use.

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If the material has contacted the skin despite these measures, take off the soiled clothes and seek medical advice immediately. In the meantime wash the affected parts of the skin for 15 to 60 minutes with cold water or lime water.

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Danger Repair work on fuel systems must only be performed by appropriately trained personnel. !

The following notes refer to general safety precautions for danger free handling of fuel. These notes are only general instructions; in case of uncertainties you should consult the person responsible for fire protection. Fuel vapours not only are easily inflammable, but also highly explosive inside closed rooms and toxic; dilution with air creates an easily inflammable mixture. The vapours are heavier than air and therefore sink down to the ground. Inside a workshop they may easily become distributed by draft. Even the smallest portion of spilled fuel is therefore potentially dangerous. ●

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Fire extinguishers charged with FOAM, SCHAUM, CO2 GAS or POWDER must be available wherever fuel is stored, filled in, drained off, or where work on fuel systems is performed. The vehicle battery must always be disconnected, BEFORE work in the fuel system is started. While working on the fuel system you should not disconnect the battery, because this could generate sparks, which would ignite explosive fuel vapours. Wherever fuel is stored, filled, drained off or where work on fuel systems is carried out, all potential ignition sources must be extinguished or removed. Search lights must be fire proof and well protected against possible contact with running out fuel.

Poisonous substances Some of the fluids and substances used are toxic and must under no circumstances be consumed. Skin contact, especially with open wounds, should be strictly avoided. These fluids and substances are, amongst others, anti-freeze agents, hydraulic oils, washing additives, lubricants and various bonding agents.

Engine Danger Do not work on the fuel system while the engine is running - danger to life! !

After the engine has stopped wait until the pressure has dropped (on Commonm Rail engines approx. 5 minutes, other engines 1 minute), because the system is under high pressure - danger to life! Keep out of the danger zone during the initial test rung. Danger caused by high pressure in case of leaks - danger to life! When performing work on the fuel system make sure that the motor cannot be started unitentionally - danger to life! ●

Hot fuels Before draining fuel off the tank for repair work, you must strictly apply the following measures: ●

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Allow the fuel to cool down, to prevent any contact with a hot fluid. Vent the system, by removing the filler cap in a well ventilated area. Screw the filler cap back on, until the tank is finally emptied.

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Maintenance and cleaning work on the engine must onyl be performed with the engine stopped and cooled down. Make sure that the electric system has been switched off (ignition key pulled out). Observe the accident prevention regulations for electric systems (e.g. -VDE-0100/-0101/-0104/0105 Electric precautions against dangerous contact voltages). Cover all electric components properly before wet cleaning.

Synthetic rubber Many O-rings, hoses and similar parts, which are apparently made of natural rubber, are actually made of 008 911 63

BOMAG

11

1.2

Safety regulations from April 1989). Paragraph 10 of the pressure vessel directive demands that these pressure containers must be periodically inspected and tested by a specialist, according to paragraph 32. In this case periodically recurring inspections consist of external examinations, normally on containers in operation. The refrigerant container must be visually inspected two times per year, within the frame work of major inspections. Special attention must thereby be paid to signs of corrosion and mechanical damage. If the container is in no good condition, it should be replaced for safety reasons, in order to protect the operator or third parties against the dangers when handling or operating pressure vessels.

Air conditioning system Caution Lines in the air conditioning system must only be loosened by trained and explicitly instructed experts. !

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Wear safety goggles! Put on your safety goggles. This will protect your eyes against coming into contact with refrigerant, which could cause severe damage by freezing. Wear safety gloves and an apron! Refrigerant are excellent solvents for greases and oils. In contact with skin they will remove the protective grease film. However, degreased skin is very sensitive against cold temperatures and germs. Do not allow liquid refrigerants to come into contact with skin! Refrigerant takes the heat required for evaporation from the environment. Very low temperatures may be reached. The results may be local frost injuries (boiling point of R134a -26.5°C at ambient pressure). Do not inhale higher concentrations of refrigerant vapours! Escaping refrigerant vapours will mix with the ambient air and displace the oxygen required for breathing. Smoking is strictly prohibited! Refrigerants may be decomposed by a glowing cigarette. The resulting substances are highly toxic and must not be inhaled. Welding and soldering on refrigeration equipment! Before starting welding or soldering work on vehicles, (in the vicinity of air conditioning components) all refrigerant must be drawn out and the rests removed by blowing out the system with nitrogen. The decomposition products created from the refrigerant under the influence of heat not only are highly toxic, but also have a strong corrosive effect, so that pipes and system components may be attacked. The substance is mainly fluorohydrogen. Pungent smell! In case of a pungent smell the afore mentioned decomposition products have already been created. Extreme care must be exercised not to inhale these substances, as otherwise the respiratory system, the lungs and other organs may be harmed. When blowing out components with compressed air and nitrogen the gas mixture escaping from the components must be extracted via suitable exhaust facilities (workshop exhaust systems).

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12

Refrigerant bottles must never be placed near heating radiators. Higher temperatures will cause higher pressures, whereby the permissible pressure of the vessel may be exceeded. The pressure vessel directive therefore specifies that a pressure vessel should not be warmed up to temperatures above 50 °C. Do not heat up refrigerant bottles with an open flame. Excessive temperatures can damage the material and cause the decomposition of refrigerant. Do not overfill refrigerant bottles, since any temperature increase will cause enormous pressures.

Battery ● ●

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Since the fluid container is pressurized, the manufacture and testing of these pressure vessels is governed by the pressure vessel directive. (New edition

Do not throw pressure vessels. Pressure vessels may thereby be deformed to such an extent, that they will crack. The sudden evaporation and escape of refrigerant releases excessive forces. This applies also when snapping off valves on bottles. Bottles must therefore only be transported with the safety caps properly installed.

Environment In operation, during maintenance and repair work and when taking refrigeration systems our of service it is not permitted to let refrigerant escape into the atmosphere, which would contradict the current status of technology.

Handling pressure vessels ●

Secure pressure vessels against tipping over or rolling away.

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Wear goggles and face protection (acid). Wear suitable clothes to protect face, hands and body (acid). Work and store accumulators only well ventilated rooms. (Development of oxyhydrogen gas). Do not lean over the battery while it is under load, being charged or tested. (Danger of explosion). Burning cigarettes, flames or sparks can cause explosion of the accumulator Keep ignition sources away from the battery.

BOMAG

008 911 63

1.2

Safety regulations ● ●

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Always shield eyes and face towards the battery. Do not use battery chargers or jump leads without following the operating instructions.

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Keep the cell plugs closed. After an accident with acid flush the skin with water and seek medical advice.

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There is a danger of scalding when draining off engine or hydraulic oil at operating temperature. on machines with rubber tires a tire may busr if incorrectly assembled. This can cause severe injury. Do not exceed the specified highest permissible tire pressure.

Do not allow children access to batteries. When mixing battery fluid always pour acid into water, never vice-versa.

Special safety regulations ●

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Use only genuine BOMAG spare parts for repair purposes. Original parts and accessories have been specially designed for this machine. We wish to make explicitly clear that we have not tested or approved any parts or accessories not supplied by us. The installation and/or use of such products may therefore have an adverse effect on the specific characteristics of the machine and thereby impair the active and/or passive driving safety. The manufacturer explicitly excludes any liability for damage caused by the use of non-original parts or accessories. Unauthorized changes to the machine are prohibited for safety reasons. If tests on the articulated joint need to be performed with the engine running, do not stand in the articulation area of the machine, danger of injury! Do not perform cleaning work while the engine is running. If tests must be performed with the engine running do not touch rotating parts of the engine, danger of injury. Exhaust gases are highly dangerous. Always ensure an adequate supply of fresh air when starting the engine in closed rooms. Refuel only with the engine shut down. Ensure strict cleanliness and do not spill any fuel. Keep used filters in a separate waste container and dispose of environmentally. Dispose of oils and fuel environmentally when performing repair or maintenance work. Do not refuel in closed rooms. Do not heat up oil higher than 160 °C because it may ignite. Wipe off spilled oil and fuel. Do not smoke when refuelling or when checking the acid level in the battery. Do not check the acid level of the battery with a naked flame, danger of explosion! Old batteries contain lead and must be properly disposed of.

008 911 63

BOMAG

13

1.3

General repair instructions

General 1.3

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Electrics


Before removing or disassembling and parts, hoses or components mark these parts for easier assembly. Before assembly oil or grease all parts, as far as this is necessary.

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

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In approx. 10 % of the examined cases the problems were caused by control units. In approx. 15 % sensors and actuators were the cause of the problems.

By far the highest proportion of all faults could be traced back to wiring and connections (plugs, etc.). General: ●

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14

Before changing any expensive components, such as control units, you should run a systematic trouble shooting session to eliminate any other possible fault sources. Electric signals must be checked at the locations to which they are applied, i.e. on control unit or sensor technology. So, if the system had been diagnosed without unplugging the control unit and checking the wiring, one should be alerted. Check for good cable and ground contacts, therefore keep all mechanical transition points between electric conductors (terminals, plugs) free of oxide and dirt, as far as this is possible. Perform trouble shooting in a systematic way. Do not become confused by the high number and variety of electric cables, current can only flow in a closed circuit. You should first become acquainted with the function of the corresponding electric circuit by following the correct wiring diagram. Detected faults should be rectified immediately. If the system still does not work correctly after this measure, trouble shooting must be continued. Several faults very rarely occur at the same time, but it is not impossible. Do not disconnect or connect battery or generator while the engine is running. Do not operate the main battery switch under load.

BOMAG

008 911 63

1.3

General repair instructions ●

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Do not use jump leads after the battery has been removed.

Battery

Sensors and electric actuators on control units must never be connected individually or between external power sources for the purpose of testing, but only in connection with the control unit in question, as otherwise there may be a risk of destruction (damage)!

Even though it may be conveniently installed in the engine compartment, it should never be used as a rest for tools. When connecting the poles, e.g. by means of a spanner, the battery will become an "electric welder".

Disconnecting the control unit plug connectors with the control unit switched on, i.e. with the power supply (terminal 15 "On"), is not permitted. Switch the voltage supply "off" first - then pull out the plug.

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Even with an existing polarity reversal protection incorrect polarity must be strictly avoided. Incorrect polarity can cause damage to control units!

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Plug-in connectors on control units are only dust and water tight if the mating connector is plugged on! Control units must be protected against spray water, until the mating connector is finally plugged on!

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Rules for the handling of batteries

As a measure to avoid short circuits you should first disconnect the negative pole during disassembly and reconnect the negative pole last during assembly. Terminal clamps should be assembled with as little force as possible. Poles and terminal clamps should always be kept clean to avoid transition resistances during starting and the related development of heat. You should obviously also pay attention to secure fastening of the battery in the vehicle.

Unauthorized opening of the control electronics (micro controller MC) as well as changes or repairs on the wiring can lead to dangerous malfunctions.

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Do not use any radio equipment or mobile phones inside the driver's cab without an appropriate outside antenna or in the vicinity of the control electronics!

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Electrical system and welding work Surge voltages in the electric system must be strictly avoided:

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When performing welding work always fasten the earth clamp of the welding unit in the immediate vicinity of the welding location.

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Caution Switch off the main battery switch, doisconnect the generator and pull the plug out on the control unit before starting welding work. !

008 911 63

BOMAG

15

1.3


Hydraulic system

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Caution Do not open any hydraulic components if you have not been properly trained and without exact knowledge. !

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Please note Cleanliness is of utmost importance. Make sure that no dirt or other contaminating substances can enter into the system. ●

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Clean fittings, filler covers and the area around such parts before disassembly to avoid entering of dirt. Before disconnecting hoses, pipes or similar relieve the system pressure with the engine shut down. During repair work keep all openings closed with clean plastic plugs and caps.

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When cleaning hydraulic components take care not to damage any fine machine surfaces.

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Chemical and rubber soluble cleansing agents may only be used to clean metal parts. Do not let such substances come in contact with sealing material.

Avoid the formation of rust on fine machined caused by hand sweat. Grease must not used as a sliding agent for assembly work. Use hydraulic oil. Do not start the engine after the hydraulic oil has been drained off. Use only the specified pressure gauges. Risk of damaging the pressure gauges under too high pressure.

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After the completion of all tests perform a test run and then check all connections and fittings for leaks with the engine still stopped and the hydraulic system depressurized. After changing a component clean the hydraulic oil tank thoroughly. Fill the housings of hydraulic pumps and motors with hydraulic oil. Use only hydraulic oils according to the specification in the maintenance instructions. After changing a component clean the hydraulic system as described in the flushing instructions in order to prevent all other components from being damaged by abrasion and metal chips remaining in the system. Change the hydraulic oil filter.

Commissioning ●

Bleed the hydraulic circuits.

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Start up the system without load.

●

Check the hydraulic oil level in the tank, fill up oil if necessary.

After commissioning ●

Check system pressures and speeds.

●

Check fittings and flanges for leaks.

●

Clean ports and fittings before removal so that no dirt can enter into the hydraulic system. Check the hydraulic oil level before and after the work.

The operating pressure of the exciter shaft to a great extent depends on the base under the vibrating drum. If the soil is too hard place the drums on old rubber tires. Do not activate the vibration on a hard, concreted base, danger of bearing damage.

Before commissioning

Do not run pumps and motors without oil.

Rinse of cleaned parts thoroughly, dry them with compressed air and apply anti-corrosion oil immediately. Do not install parts that show traces of corrosion.

After changing a component perform a high and charge pressure test, if necessary check the speed of the exciter shaft.

●

After each repair check all adjustment data, rotational speeds and nominal values in the hydraulic system, adjust if necessary. Do not adjust pressure relief valves and control valves to values above their specified values.

Use only clean oil according to specification. Check the hydraulic system for leaks, find and rectify the cause. Fill new hydraulic units with hydraulic oil before starting operation. After changing a component thoroughly flush and bleed the entire hydraulic system. Perform measurements at operating temperature of the hydraulic oil (approx. 40 ¯C).

16

BOMAG

008 911 63

1.3


damp air is drawn into the component by the difference in temperatures.

Air conditioning system CFC - halon prohibition The CFC - halon prohibition from May 06, 1991 regulates the withdrawal from the use of CFC and the handling of these refrigerants. Contents: Since 1995 CFC (R12) is no longer permitted for use in new systems. In operation, during maintenance and repair work and when taking refrigeration systems our of service it is not permitted to let refrigerant escape into the atmosphere, which would contradict the current status of technology. Work on refrigeration systems must only be carried out by persons with well founded knowledge about such systems and who have the necessary technical equipment available.

●

●

●

●

●

●

The use of refrigerant must be documented. Old systems should be converted to refrigerants harmless to ozone (refrigerant substitutes). For this reason the Federal Environmental Agency at the end of 1995 published suitable replacement refrigerants for R 12. As a consequence old systems must no longer be filled with R12. As soon as such a system is opened for service, the system must be converted to a suitable replacement or service refrigerant. Old systems may still be used, as long as they are leak tight. R 134a was nominated as replacement for R 12. Inside the European Union the "EU-Directive 2037/ 2000 on substances causing decomposition of the ozone layer" regulates the production, use and availability of CFC and H-CFC. ●

●

●

●

●

In case of a repair on the refrigeration system you should first evacuate the air conditioning system for at least 45 minutes to remove any moisture from the system, before you start to refill. Moisture bonded in the compressor oil / refrigeration oil (PAG oil) can only be removed from the system by changing the oil. During repair work on refrigerant lines and components, these must be kept closed as far as possible, in order to prevent the invasion of air, moisture and dirt, because the operational reliability of the system can only be assured if all components in the refrigerant circuit are clean and dry from inside. Make sure that no dirt or foreign parts can enter into the compressor or the air conditioning system. The area around the refrigerant hoses should be cleaned with a gasoline free solvent. All parts to be reused should be cleaned with a gasoline free solvent and blow-dried with clean compressed air or dried with a lint-free cloth. Before opening all components should have warmed up to ambient temperature, to avoid that

008 911 63

●

●

●

●

●

●

●

● ●

●

●

●

Damaged or leaking parts of the air conditioning must not be repaired by welding or soldering, but must generally be replaced. Do not fill up refrigerant, but extract existing refrigerant and refill the system. Different types of refrigerant must not be mixed. Only the refrigerant specified for the corresponding air conditioning system must be used. Refrigerant circuits with refrigerant type R134a must only be operated with the compressor oil / refrigeration oil approved for the compressor. Used compressor oil / refrigeration oil must be disposed of as hazardous waste. Due to its chemical properties compressor oil / refrigeration oil must never be disposed of together with engine or transmission oil. Compressor oil / refrigeration oil is highly hydroscopic. Oil cans must strictly be kept closed until use. Oil rests should not be used, if the can had been opened over a longer period of time. All O-rings as well as pipe and hose fittings must be oiled with compressor/refrigeration oil beforeiassembly. When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil / refrigeration oil lost by exchanging the components, must be replaced with fresh oil. A too high compressor oil / refrigeration oil level adversely affects the cooling performance and a too low oil level has a negative effect on the lifetime of the compressor. If a air conditioning unit needs to be opened, the dryer must be replaced in any case. Always use new O-rings when reassembling the unit. Always use two spanners when connecting pipes or hoses, to prevent the pipe end from being damaged . Tighten screw fittings with the specified torque. Check the connections of pipes, fittings or components thoroughly; do not use if damaged. Do not leave the refrigerant circuit unnecessarily open to the atmosphere. Do not attempt to repair bent or burst pipes. Compressor valves must only be opened after the system has been properly sealed. The use of leak detection colouring matter is not permitted, because its chemical composition is unknown and its effect on compressor oil and rubber elements is not predictable. The use of leak detec-

BOMAG

17

1.3


tion colouring matter makes any warranty claims null and void. ●

●

●

●

●

Fuel hoses

Tools used on refrigeration circuits must be of excellent condition, thus to avoid the damage of any connections. The dryer is to be installed last, after all connections in the refrigerant circuit have been tightened. After completion of repair work screw locking caps (with seals) on all connections with valves and on the service connections. Start up of the air conditioning system. Observe the filling capacity. Before start up of the air conditioning system after a new filling: - Turn the compressor approx. 10 revolutions by hand using the clutch or V-belt pulley of the magnetic clutch. - Start the engine with the compressor/control valve switched off. - Once the idle speed of the engine has stabilized switch on the compressor and run it for at least 10 minutes at idle speed and maximum cooling power. Never operate the compressor over longer periods of time with high engine speeds without a sufficient amount of refrigerant in the system. This could probably cause overheating and internal damage.

18

Fig. 1

Caution All fuel hoses have two layers of material, a reinforced rubber coating outside and an internal Viton hose. If a fuel hose has come loose one must make absolutely sure that the internal Viton layer has not been separated from the reinforced outer layer. In case of a separation the hose needs to be replaced. !

BOMAG

008 911 63

1.3

General repair instructions Gaskets and mating surfaces Leaking or failing seals and gaskets can in most cases be tracked down to careless assembly, causing damage not only to the seal or gasket, but also to the mating surfaces. Careful assembly work is mandatory if good results are to be achieved.

threads or splines. If no assembly sleeve is available, you should use a plastic tube or adhesive tape to prevent the sealing lip from being damaged.

Before assembling replacement seals make sure that the running surface is free of pitting, flutes, corrosion or other damage.

●

Inappropriately stored or handled seals (e.g. hanging from hooks or nails) must under no circumstances be used.

●

Sealing compound should only be used if specially requested in the instructions. In all other cases these joints should be assembled in dry condition.

●

Sealing compound must be applied thin and evenly on the corresponding surfaces; take care that the compound does not enter into oil galleries or blind threaded bores.

●

Before assembly remove any residues of old sealing compound. Do not use any tools that could damage the sealing surfaces.

●

Examine the contact faces for scratches and burrs, remove these with a fine file or an oilstone; take care that no grinding dust and dirt enters into tapped bores or enclosed components.

●

Blow lines, ducts and gaps out with compressed air, replace any O-rings and seals that have been dislodged by the compressed air.

●

Assembly of radial seals

Fig. 3

Lubricate the outer rim 1 (Fig. 3) of the seal and press it flat on the housing seat.

●

i

Note

If possible, use a "bell" 1 (Fig. 3), to make sure that the seal will not skew. In some cases it may be advisable to assemble the seal into the housing first, before sliding it over the shaft. Under no circumstances should the full weight of the shaft rest on the seal. If you have no proper service tools at hand, use a suitable drift punch with a diameter which is about 0.4mm smaller than the outer diameter of the seal. Use VERY LIGHT blows with the hammer if no press is available. ●

Press or knock the seal into the housing, until it is flush with the housing surface.

Fig. 2

Lubricate sealing lips 1 (Fig. 2) with clean grease; in case of double seals fill the space between the sealing lips with a generous amount of grease.

●

Slide the seal over the shaft, with the lip facing towards the fluid to be sealed.

●

i

Note

If possible, use an assembly sleeve 1 (Fig. 2), to protect the lip from being damaged by sharp edges, 008 911 63

BOMAG

19

1.3


Feather keys and keyways

Ball and roller bearings

Caution Feather keys must only be reused if they show no differences to new feather keys, any notches must be considered as initial signs of wear.

Caution Ball and roller bearings must only be reinstalled after it has been assured that they are in perfect condition.

!

!

Fig. 4 ● ●

Clean and thoroughly examine the feather key. Debur and thoroughly clean the edges of the keyway with a fine file before reassembling.

Fig. 5 ●

●

●

●

●

20

Remove any lubricant residues from the bearing to be examined by washing it with gasoline or any other appropriate degreasing agent. Cleanliness is of utmost importance for all related work. Check balls or rollers, running surfaces, outer faces of outer races and inner faces of inner races for visible damage. If necessary replace the bearing with a new one, since these symptoms are first signs of wear. Hold the bearing with you thumb and the index finger by the inner race, rotate the outer race and make sure that it runs without friction. Hold the bearing by the outer race and repeat this test with the inner race. Move the outer race gently to and fro while holding it by the inner race; check for resistance while rotating and replace the bearing if it does not work correctly. Lubricate the bearing with an appropriate lubricant before reinstalling.

BOMAG

008 911 63

1.3

General repair instructions Check shaft and bearing housing for discolouration or other signs of movement between bearing and seats.

●

Make sure that shaft and housing are free of burrs before assembling the bearing.

●

If a bearing of a pair of bearings shows any defects, we highly recommend the replacement of both bearings.

●

On greased bearings (e.g. wheel bearings) fill the space between bearing and outer seal with the recommended type of grease before assembling the seal.

●

Always mark the individual parts of separable 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 bearing instead.

●

Screws and nuts Tightening torque Caution Always tighten nuts or screws to the specified tightening torque. Tightening torques deviating from the ones in the table are specially mentioned in the repair instructions. !

Damaged screws must under no circumstances be used any longer. Recutting threads with thread cutters or taps adversely affects the strength and leak tightness of the screw joint. Damaged or corroded thread pitches can cause incorrect torque value readings. Self-locking nuts must be generally renewed. The use of screws with too high strength can cause damage! ●

●

●

Fig. 6

●

Caution When assembling the bearing to the shaft load must only be applied to the inner race 1 (Fig. 6). !

Nut of a higher strength can generally be used instead of nuts of a lower strength classification. When checking or retightening screw joints to the specified tightening torque you should first relieve by a quarter turn and then tighten to the correct torque. Before tightening you should lightly oil the thread, in order to ensure low friction movement. The same applies for self-locking nuts. Make sure that no oil or grease will enter into tapped bores. The hydraulic power generated when turning in the screw could cause breakage of the effected part.

When fitting the bearing into the housing load must only be applied to the outer race (2).

008 911 63

BOMAG

21

1.3


Strength classes of metric screws

Strength classes of metric nuts

The strength classes (from 3.6 to 12.9) are specified for all strength classes from a nominal diameter of 5mm. The corresponding identification can be found where allowed for by the shape of the screw.

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. 8 Identification of nuts

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

Fig. 7 Identification of screws

Example: A screw is identified with 12.9. The first number corresponds with 1/100 of the nominal tensile strength (minimum tensile strength) in N/ mm2. The nominal tensile strength is 12 X 100N/mm2 = 1200 N/mm2.

●

The second number specifies 10-times the ration between 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 (plastic deformation). When exceeding the upper yield point the material will not restore its original shape after being relieved. The lower tensile strength is 9/10 X 1200 N/mm2 = 1080 N/mm2.

●

i

Strength class of nut 4 5

Strength class of associated screw 3.6, 4.6, 4.8 3.6, 4.6, 4.8

6 8 9 10 12

5.6, 5.8 6.8 8.8 9.8 10.8 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. 8) 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. 8), for which no load values can be specified, e.g. because of their shape and dimensions, but which can only be classified by their hardness. Nut height below 0,5 d (d = nominal dimension).

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

008 911 63

1.3

General repair instructions Identification in clock system

Fig. 9 Identification of nuts in clock system

For small nuts (Fig. 9) the clock system can be used for identification. ●

●

The 12 o'clock position is identified by a dot or the manufacturer's symbol. The strength class is identified by a dash (b).

008 911 63

BOMAG

23

1.4

Tightening torques

The values specified in the table apply for screws: 1.4

Tightening torques

●

black oiled

●

with surface protection A4C

●

with surface protection DACROMET

i

Note

DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance.

Tightening torques for screws with metric unified thread1 Screw dimension M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30

Tightening torques Nm 8.8 3 6 10 25 50 88 137 211 290 412 560 711 1050 1420

10.9 5 9 15 35 75 123 196 300 412 578 785 1000 1480 2010

12.9 5 10 18 45 83 147 235 358 490 696 942 1200 1774 2400

Coefficient of friction μ tot. = 0,14

1

Tightening torques for screws with metric unified fine thread1 Screw dimension M8 x 1 M10 x 1.25 M12 x 1,25 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2 M27 x2 M30 x 2 1

24

Tightening torques Nm 8.8 26 52 98 93 152 225 324 461 618 780 1147 1568

10.9 37 76 137 127 216 318 466 628 863 1098 1578 2254

12.9 48 88 126 152 255 383 554 775 1058 1294 1920 2695


BOMAG

008 911 63

1.4

Tightening torques Tightening torques for screws treated with anti-seizure paste OKS 2401 (copper paste) Screw dimension M16 M16 x 1.5 M18 M18 x 1.5 M20 M20 x 1.5 M22 M22 x 1.5 M24 M24 x 2 M27 M27 X 2 M30 M30 x 2 3/4“ - 10 UNC 3/4“ - 16 UNC 1

Tightening torques Nm 8.8 169 180 232 260 330 369 448 495 569 624 840 918 1136 1255 276 308

10.9 240 255 330 373 463 502 628 691 800 879 1184 1263 1608 1804 388 432

12.9 287 307 392 444 557 620 754 847 960 1036 1520 1536 1920 2156 464 520

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) 1 2 Tightening torques Nm

Thread diameter

10.9 100 150 300 - 350 400 - 500 500 - 600

M12x1.5 M14x1.5 M18x1.5 M20x1.5 M22x1.5 1 2

Coefficient of friction μ tot. = 0,14 These values result in a 90% utilization of the yield point

008 911 63

BOMAG

25

1.4

Tightening torques

The values specified in the table apply for screws: ●

black oiled

●

with surface protection A4C

●

with surface protection DACROMET

i

Note

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. DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance.

Tightening torques for screws with UNC thread, 1 UNC Unified Coarse Thread Series, American Unified Coarse Thread Screw dimension 1/4“ - 20 5/16“ - 18 3/8“ - 16 7/16“ - 14 1/2“ - 13 9/16“ - 12 5/8“ - 11 3/4“ - 10 7/8“ - 9 1“ - 8 1 1/8“ - 7 1 1/4“ - 7 1 3/8“ - 6 1 1/2“ - 6

Tightening torques Nm 8.8 11 23 39 62 96 140 195 345 560 850 1200 1700 2200 3000

10.9 15 32 55 87 135 200 275 485 770 1200 1700 2400 3100 4200

12.9 19 39 66 105 160 235 330 580 940 1450 2000 2900 3700 5100


1

Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American Unified Fine Thread Screw dimension 1/4“ - 28 5/16“ - 24 3/8“ - 24 7/16“ - 20 1/2“ - 20 9/16“ - 18 5/8“ - 18 3/4“ - 16 7/8“ -14

26

Tightening torques Nm 8.8 13 25 45 70 110 155 220 385 620

10.9 18 35 63 100 155 220 310 540 870

BOMAG

12.9 22 42 76 120 185 260 370 650 1050

008 911 63

1.4

Tightening torques

Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American Unified Fine Thread Screw dimension 1“ - 12 1 1/8“ - 12 1 1/4“ - 12 1 3/8“ - 12 1 1/2“ - 12 1

Tightening torques Nm 8.8 930 1350 1900 2600 3300

10.9 1300 1900 2700 3700 4600

12.9 1600 2300 3200 4400 5600


008 911 63

BOMAG

27

1.4

28

Tightening torques

BOMAG

008 911 63

2 Maintenance

008 911 63

BOMAG

29

2.1 2.1

General notes on maintenance

General notes on maintenance

When servicing the machine pay careful attention to all applicable safety instructions. Thorough maintenance of the machine ensures maximum reliability and prolongs the lifetime of important components. The necessary effort can by no means be compared with the problems and malfunctions that could occur if this is not observed. The terms left/right are always related to travel direction forward. ●

●

●

●

●

●

Clean machine and engine thoroughly before starting maintenance work. For maintenance work park the machine on level ground.

the engine's performance and temperature level as well as the quality of the exhaust gas. If your machine has to operate permanently in "thin air" (at high altitudes) and with full power, you should consult the after sales service of BOMAG or the service department of the engine manufacturer.

Notes on the hydraulic system During maintenance work in the hydraulic system cleanliness is of utmost importance. Make sure that no dirt or other impurities can enter into the system. Small particles can flute valves, cause pumps to seize and block restrictors and pilot bores, thereby causing costly repairs. If during the daily oil level check the oil level is found to have dropped, check all lines, hoses and components for leakages.

●

Maintenance work must generally be carried out with the engine shut down. Depressurize hydraulic lines before working on them.

●

Disconnect the battery and cover it with insulation material before starting to work on electrical components.

●

Always attach the articulation lock (transport lock) before starting to work in the articulation area of the machine.

Environment Catch running out oils, coolant and fuel and do not let them seep into the ground or into the sewage system. Dispose of oils, coolant and fuels environmentally.

Seal external leaks immediately. If necessary inform the responsible service department. Do not store drums with hydraulic oil outside, or at least keep them under a cover. During weather changes water may penetrate through the bunghole. Always fill the hydraulic system using the filling and filtering unit (BOMAG part-no. 007 610 01). This unit is equipped with a fine filter, which filters the hydraulic oil and prolongs the lifetime of the system filter.

●

Clean fittings, filler caps and their immediate surrounding area before removing them, so that no dirt can fall in.

●

Do not leave the tank opening unnecessarily open, cover it so that no dirt can fall in.

●

Notes on the fuel system The lifetime of the diesel engine is decisively depending on the cleanliness of the fuel. ●

● ●

●

●

●

Notes on the cooling system

Zinc lined drums are not suitable for storing fuel.

On water cooled engines the preparation and monitoring of the coolant is of utmost importance, as otherwise engine failures caused by corrosion, caviation and freezing may occur.

The fuel drum should rest for a longer period of time before drawing off fuel.

The coolant is a mixture of water and a cooling system protection agent.

Keep the engine free of dirt and water as this could damage the injection elements of the engine.

Do not let the suction hose disturb the sludge on the bottom of the drum. Do not draw off fuel from near the bottom of the fuel drum. Fuel left in the fuel drum is not suitable for the engine and should only be used for cleaning purposes.

The concentration of the cooling system protection agent can be checked with commercially available test instruments (glycomat). Danger Health hazard! !

Notes on the engine performance Combustion air and fuel injection rates of the diesel engine have been carefully adjusted and determine

30

The cooling system must be permanently monitored. Apart from the coolant level inspection this includes also the inspection of the concentration of cooling system protection agent.

BOMAG

008 911 63

2.1

General notes on maintenance The mixing of nitride based cooling system protection agents with amine based agents will cause the generation of highly toxic nitrosamines. Environment Cooling system protection agents must be disposed of environmentally.

008 911 63

BOMAG

31

2.2 2.2

Table of fuels and lubricants

Table of fuels and lubricants

Assembly

Fuel or lubricant Summer

Winter

Quantity approx. Attention Observe the level marks

Engine

Engine oil ACEA: E3-96/E5-02 or

approx. 8,5 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 Hydraulic system

Winter diesel fuel

Hydraulic oil (ISO), HV46, kinem. viscosity

approx. 150 litres approx. 60 litres

46 mm2/s at 40 °C Vibration bearings

Engine oil SAE 15W/40

approx. 0,8 litres

Drive axle

Gear oil SAE 90, API GL5

approx. 9,5 litres

Wheel hubs

Gear oil SAE 90, API GL5

approx. 1,9 per side

Air conditioning system Tires (only BW 213)

Engine cooling system

32

Refrigerant R134A Water

approx. 1400 g approx. 295 litres

Calcium chloride (CaCl2) or magnesium chloride (MgCl2)

approx. 100 kg

Cooling system protection agent

approx. 16 litres

BOMAG

008 911 63

2.3

Running-in instructions

2.3

Running-in instructions

The following maintenance work must be performed when running in new machines or overhauled engines: ! Caution Up to approx. 250 operating hours check the engine oil level twice every day.

Depending on the load the engine is subjected to, the oil consumption will drop to the normal level after approx. 100 to 250 operating hours. After a running-in time of 30 minutes ●

Retighten the V-belt

After 250 operating hours ●

● ●

Retighten bolted connections on intake and exhaust tubes, oil sump and engine mounts. Retighten the bolted connections on the machine. Retighten all wheel fastening screws with the specified tightening torque.

●

Changing engine oil and oil filter

●

1. Oil change vibration bearings

●

Oil change in drive axle

●

Oil change in wheel hubs

After 500 operating hours ●

008 911 63

2. Oil change vibration bearings

BOMAG

33

2.4

Dipstick mark

5.7

Check the water separator

X

5.8

Check the fuel level

X

5.9

Check the hydraulic oil level

5.10 Check the coolant level

X

Inspection glass

X

Inspection glass

X

5.11 Check the dust separator

X

5.12 Check the tire pressure

X

5.13 Clean the cooling fins on engine and hydraulic oil cooler

X

5.14 Check the oil level in the drive axle

X

5.15 Check the oil level in the wheel hubs

X

5.16 Check the oil level in the vibration bearings

X

5.17 Change engine oil and oil filter cartridge1

min. 1x per year

X

5.18 Drain the sludge from the fuel tank 5.19 Service the battery

X X

Pole grease

X

5.20 Check, replace the refrigerant compressor V-belt

X

5.21 Service the air conditioning

X

5.22 Check, adjust the valve clearance

as required

Check the engine oil level

every 3000 operating hours

5.6


Remark


Maintenance work


No.


every 10 operating hours, daily

Maintenance chart

Running-in instructions after 250 operating hours

2.4

Maintenance chart

Intake = 0,3 mm

X

Exhaust = 0,5 mm 5.23 Check, replace the ribbed V-belt

X

5.24 Change the fuel filter cartridge

X

5.25 Change the fuel pre-filter cartridge

X

5.26 Check the engine mounts

X

X

5.27 Oil change in drive axle

min. 1x per year

X

X

5.28 Oil change in wheel hubs

min. 1x per year

X

X

5.29 Oil change vibration bearings2

see foot note, min. X 1 x per year

X

5.30 Retighten the fastening of the axle on the frame 34

X

BOMAG

008 911 63

X

5.32 Check the ROPS

X X

5.33 Clean the oil bath air filter

min. 1x per year

X

5.34 Change hydraulic oil and breather filter at least every 2 years

X

5.35 Change the hydraulic oil filter***

at least every 2 years

X

5.36 Change the coolant

at least every 2 years

X

3

5.37 Check the injection valves 5.38 Service the combustion air filter





5.31 Tighten the wheel nuts


Remark

every 10 operating hours, daily

Maintenance work

Running-in instructions after 250 operating hours

No.

as required

2.4

Maintenance chart

X min. 1x per year, safety cartridge at least every 2 years

X

5.39 Adjusting the scrapers

X

5.40 Adjust the parking brake

X

5.41 Change the tires

X

5.42 Change the fresh air filter in the cabin

X

5.43 Tightening torques

X

5.44 Engine conservation

X

1 2 3

Oil change intervals depend on quality of oil and fuel (sulphur content) Oil change intervals after 250 h, after 500 h, after 1000 h, and then every 1000 h. Also in case of repair in the hydraulic system.

008 911 63

BOMAG

35

2.4

36

Maintenance chart

BOMAG

008 911 63

3 Technical data

008 911 63

BOMAG

37

3.1 3.1

Technical data Technical data

Fig. 10

Dimensions in mm

A

B

D

H

H2

K

L

O1

O2

S

W

BW 211 D-40

2960

2250

1500

2268

2972

490

5840

60

60

25

2130

BW 211 PD-40

2960

2250

1480

2268

2972

490

5840

60

60

25

2130

1

Weights Operating weight (CECE) with ROPS and cabin Axle load, drum (CECE) Rear axle load (CECE) Static linear load Travel characteristics Travel speed (1) Travel speed (2) Max. gradability (depending on soil) Engine Engine manufacturer Type Cooling Number of cylinders Rated power DIN ISO 3046 Rated speed Fuel Electrical equipment Drive system Driven axles

BW 211 D-40

BW 211 PD-40

kg

9500

10500

kg kg kg/cm

5750 3750 27

6750 3750 -

km/h km/h %

0 ... 6 0 ... 10 45

0 ... 6 0 ... 10 49

kW

Deutz BF4M 2012C Water 4 98


2300 Diesel 12 hydrostatic 2


hydrostatic hydr.-mech.

hydrostatic hydr.-mech.

1 rpm V

Brakes Service brake Parking brake 38

BOMAG

008 911 63

3.1

Technical data 1

BW 211 D-40

BW 211 PD-40

Steering Type of steering Steering operation

articulated hydrostatic


Vibration Vibrating drum Drive system Frequency Amplitude

Hz mm

1 hydrostatic 30/36 1,8/0,9

1 hydrostatic 30/36 1,64/0,82

Tires Tire size Air pressure

bar

23.1-26/12 PR TL C7 1,4

23.1-26/12TL R1 1,4

Litres Litres Litres Litres

10 250 60 16

10 250 60 16

Filling capacities Engine Fuel Hydraulic oil Coolant 1

The right for technical modifications remains reserved

008 911 63

BOMAG

39

3.1

Technical data

Fig. 11

Dimensions in mm

A

B

D

H

H2

K

L

O1

O2

S

W

BW 212 D-40

2960

2250

1500

2268

2972

490

5840

60

60

25

2130

BW 212 PD-40

2960

2250

1480

2268

2972

490

5840

60

60

25

2130

1


BW 212 D-40

BW 212 PD-40

kg

10900

11350

kg kg kg/cm

7150 3750 33,6

7600 3750 -

km/h km/h %

0 ... 6 0 ... 10 45

0 ... 6 0 ... 10 49

kW





hydrostatic

hydrostatic

1 rpm V

Brakes Service brake 40

BOMAG

008 911 63

3.1

Technical data 1

BW 212 D-40 hydr.-mech.

BW 212 PD-40 hydr.-mech.





Hz mm


1 hydrostatic 30/36 1,64/0,82


bar

23.1-26/12 PR TL C7 1,4

23.1-26/12TL R1 1,4


10 250 60 16

10 250 60 16

Parking brake



008 911 63

BOMAG

41

3.1

Technical data

Fig. 12

Dimensions in mm

A

B

D

H

H2

K

L

O1

O2

S

W

BW 213 D-40

2960

2250

1500

2268

2972

490

5840

60

60

35

2130

BW 213 PD-40

2960

2250

1480

2268

2972

490

5840

60

60

25

2130

1


BW 213 D-40

BW 213 PD-40

kg

12420

12870

kg kg kg/cm

7820 4600 36,7

8270 4600 -

km/h km/h %

0 ... 6 0 ... 10 45

0 ... 6 0 ... 10 49

kW





hydrostatic

hydrostatic

1 rpm V

Brakes Service brake 42

BOMAG

008 911 63

3.1

Technical data 1

BW 213 D-40 hydr.-mech.

BW 213 PD-40 hydr.-mech.





Hz mm


1 hydrostatic 30/36 1,64/0,82


bar

Parking brake


23.1-26/12 PR TL C7 23.1-26/12TL R1 1,4

1,4

10 250 60 16

10 250 60 16



008 911 63

BOMAG

43

3.1 Additional engine data Combustion principle Low idle speed High idle speed Specific fuel consumption Valve clearance intake Valve clearance exhaust Injection valves opening pressure Travel pump Manufacturer Type System Max. displacement Max. flow capacity High pressure limitation Charge pressure, high idle Drum drive motor Manufacturer Type System Displacement (stage 1) Perm. leak oil rate Axle drive motor Manufacturer Type System Max. displacement (stage 1) Min. displacement (stage 2) Perm. leak oil rate Flushing rate Flushing pressure limitation Vibration pump Manufacturer Type System Max. displacement Start up pressure Operating pressure (soil dependent) Vibration motor Type System Displacement Flushing rate Flushing pressure limitation Check steering/ Type System Displacement Max. steering pressure

44

Technical data

rpm rpm g/kWh mm mm bar

4-stroke diesel 900 ± 200 2430 ± 50 243 0,3 0,5 220

cm3/rev. l/min bar bar

Sauer 90R 075 Axial piston/swash plate 75 172,9 400 +26 26

cm3/rev. l/min

Poclain MSE 18 1 CX Radial piston 2800 2

cm3/rev. cm3/rev. l/min l/min bar

Sauer 51D 110 Axial piston – bent axle 110 69 2 16 16

cm3/rev. bar bar

Sauer 42R 041 Axial piston/swash plate 41 345 +26 approx. 100

cm3/rev. l/min bar

A10FM 45 Axial piston/swash plate 45 6 13

cm3/rev. bar

HY/ZFS11/16 Gear 16 175 +26

BOMAG

008 911 63

3.1

Technical data

Steering valve Manufacturer Type System Rear axle Manufacturer Type Differential Degree of locking Reduction ratio

008 911 63

Danfoss OSPC 500 ON Rotary spool valve

%

BOMAG

Dana CHC 192/51HD No-Spin 100 43,72

45

3.1

46

Technical data

BOMAG

008 911 63

4 Connection overview

008 911 63

BOMAG

47

4.1

Connection overview

Fig. 1 Travel pump

48

BOMAG

008 911 63

4.1

Connection overview 1

Control solenoid, high frequency

21 Connection D, charge pressure to filter

2

Control solenoid, low frequency

3

Multi-function valve 400 bar (boost check and pressure relief valve), travel system

22 Multi function valve 345 bar (boost check and pressure relief valve), vibration drive high frequency

4

Connection, charge pressure to brake solenoid valve, travel speed range selection and charge oil supply for vibration pump

5

Multi-function valve 400 bar (boost check and pressure relief valve), travel system

6

Setscrew, mechanical neutral position

7

Connection L, leak oil connection to vibration pump

8

Lever, travel control

9

Pilot pressure test port

10 High pressure port B, high pressure reverse 11 Charge pressure relief valve, 26 bar 12 Adjustment screw, low frequency 13 Connection L2, leak oil to tank 14 Pressure test port MB, high frequency 15 High pressure test port MA, low frequency 16 High pressure port A, low frequency 17 High pressure port B, high frequency 18 Charge pump, internal 19 Connection L2, to drum drive motor (flushing) 20 Adjustment screw, high frequency

008 911 63

23 Connection S, suction line charge pump from hydraulic oil tank 24 Multi function valve 345 bar (boost check and pressure relief valve), vibration drive low frequency 25 Charge pressure relief valve, vibration pump (blocked) 26 Connection E, charge oil from travel pump 27 Connection L1, leak oil connection to travel pump 28 Pressure test port MB, high pressure reverse 29 Charge oil from filter 30 Pressure test port MA, high pressure forward 31 High pressure port A, high pressure forward 32 Setscrew, mechanical neutral position, vibration 33 Leak oil connection D, leak oil from axle drive motor 34 Leak oil connection A, leak oil from travel pump 35 Leak oil connection G, leak oil from drum drive motor 36 Leak oil connection F, leak oil from vibration motor 37 Radiator inlet

BOMAG

49

4.1

50

Connection overview

BOMAG

008 911 63

5 Tests and adjustments

008 911 63

BOMAG

51

5.1

Special tools, tests and adjustments 5.1 Special tools, tests and adjustments 1. Vibration reed frequency meter 1000 - 4000 rpm 17 - 67 Hz BOMAG part-no.: 300 120 80

Fig. 1

2. Sirometer (frequency meter) 800 - 50.000 rpm 14 - 750 Hz BOMAG part-no.: 059 710 02

Fig. 2

3. Anti-freeze tester, quick and accurate measuring, sturdy plastic housing, automatic temperature correction, no after-dripping, instructions for use on unit, reading down to -40 °C. Material: Plastic, Temperature range: down to -40 °C BOMAG part-no.: 050 100 75

Fig. 3

4. Digital rpm-meter for petrol engines BOMAG part-no.: 079 948 99

Fig. 4

52

BOMAG

008 911 63

5.1

Special tools, tests and adjustments 5. Digital rpm-meter for petrol engines BOMAG part-no.: 059 711 12

Fig. 5

6. Digital rpm-meter, optical/mechanical, universal use BOMAG part-no.: 079 948 98

Fig. 6

7. Infrared manual thermometer, -18 to 275°C BOMAG part-no.: 057 668 06

Fig. 7

8. Hydraulic test case, large BOMAG part-no.: 007 610 03

i Note 4 X 600 bar pressure gauges 4 X 60 bar pressure gauges 8 pressure test hoses

Fig. 8

008 911 63

BOMAG

53

5.1

Special tools, tests and adjustments 9. Hydraulic test case, small BOMAG part-no.: 079 930 01

i Note 1X 25 bar pressure gauge 1X 150 bar pressure gauge 2X 400 bar pressure gauges 4 pressure test hoses

Fig. 9

10. Pressure test hoses 1000 mm BOMAG part-no.: 079 930 02 2500 mm BOMAG part-no.: 079 930 03

Fig. 10

11. Pressure gauge 60 bar BOMAG part-no.: 059 721 07 600 bar BOMAG part-no.: 059 721 04

Fig. 11

12. Adapter for pressure test hose BOMAG part-no.: 055 439 02

Fig. 12

54

BOMAG

008 911 63

5.1

Special tools, tests and adjustments 13. Gear pump testing device BOMAG part-no.: 007 610 05

Fig. 13

14. Vacuum pump for hydraulic oil tank BOMAG part-no.: 007 610 04 (12 Volt) BOMAG part-no.: 007 610 24 (24 Volt)

Fig. 14

008 911 63

BOMAG

55

5.2

Checking the rotation speeds 5.2 Checking the rotation speeds Special tools Vibration reed frequency meter, RPM-meter for diesel engines. Caution Perform measurements at operating temperature of the hydraulic oil (50 °C). !

1. Drive the machine with both drums on an elastic base (rubber buffers) (Fig. 1). 2. Block the wheels with suitable chocks.

Fig. 1

Check the engine speed

i Note If necessary, the engine speed may also be checked with the vibration Reed frequency meter. 1. Connect the RPM-meter to the injection line (Fig. 2). 2. Run the engine with maximum speed. 3. Apply the brake. 4. Measure the rotation speeds. Nominal value idle speed: Low idle speed, see technical data. High idle speed, see technical data. 5. Switch the vibration on . Nominal value nominal speed:

Fig. 2

See technical data. Evaluation of test If the nominal value is not reached, perform trouble shooting for the engine.

56

BOMAG

008 911 63

5.2

Checking the rotation speeds

Checking the exciter shaft speed 1. Switch the vibration on at max. engine speed. 2. Apply the brake. 3. Measure the speed of the vibrator shaft, rest the tester on your thumb (Fig. 3). Nominal value: See technical data. Evaluation of test If the nominal value is not reached, perform trouble shooting in the vibration circuit.

Fig. 3

008 911 63

BOMAG

57

5.3

Checking / adjusting the neutral positions of the travel pump 5.3 Checking / adjusting the neutral positions of the travel pump Special tools Hydraulic test case Caution Perform measurements at operating temperature of the hydraulic oil (50 °C). !

1. Block drums and wheels with suitable chocks (Fig. 1).

Fig. 1

2. Unhook the travel cable (Fig. 2) from the pump.

Fig. 2

3. Pull the plug (Fig. 3) off the brake solenoid valve to close the brake.

Fig. 3

58

BOMAG

008 911 63

Checking / adjusting the neutral positions of the travel pump

5.3

4. Connect 600 bar pressure gauges to high pressure test ports MA and MB (Fig. 4).

Fig. 4

5. Connect the control chamber ports X3 and X4 (Fig. 5) with a hose.

Fig. 5

6. Start the engine and run it with maximum speed. Nominal value Both pressure gauges (Fig. 6) must show equal pressure (charge pressure).

i

Note If necessary repeat the pressure test with 60 bar pressure gauges, for more accurate readings.

Fig. 6

Evaluation of test If pressure builds up on one side, adjust the mechanical neutral position (Fig. 7), until the pressures on both pressure gauges are identical.

Fig. 7

008 911 63

BOMAG

59

5.4

Pressure tests in the travel circuit 5.4 Pressure tests in the travel circuit Special tools Hydraulic test case Caution Perform measurements at operating temperature of the hydraulic oil (50 °C). !

1. Block drums and wheels with suitable chocks (Fig. 1).

Fig. 1

2. Pull the plug (Fig. 3) off the brake solenoid valve to close the brake.

Fig. 2

3. Connect 600 bar pressure gauges to the high pressure test ports for "forward travel" and "reverse travel" and a 60 bar pressure gauge to the charge pressure test port (Fig. 2). 4. Start the engine and run it with maximum speed. 5. Read charge and high pressure gauges. Nominal value see technical data of travel pump: Charge pressure gauge = charge pressure at high idle High pressure gauge = charge pressure at high idle

Fig. 3

Evaluation of test If the nominal value is not reached, check the steering/charge pump.

60

BOMAG

008 911 63

5.4

Pressure tests in the travel circuit

Measurement with quickly operated travel lever 6. Move the travel lever (Fig. 4) quickly forward, read the pressure gauge. Nominal value see technical data of travel pump: Charge pressure gauge = charge pressure at high idle High pressure gauge = pressure override Evaluation of test If the specified high pressure is not reached, check the travel pump.

Fig. 4

If the charge pressure drops considerably during the high pressure test, check the components individually.

008 911 63

BOMAG

61

5.5

Checking / adjusting the vibrator shaft speeds 5.5 Checking / adjusting the vibrator shaft speeds Special tools Vibration reed frequency meter Caution Perform measurements at operating temperature of the hydraulic oil (50 °C). !

1. Drive the machine on an elastic base (rubber buffers) (Fig. 1). 2. Apply the parking brake and block the wheels additionally with suitable chocks. 3. Start the engine and run it with maximum speed. 4. Switch on vibration high frequency / low amplitude or low frequency / high amplitude.

Fig. 1

5. Measure the speed (Fig. 2), rest the tester on your thumb. Nominal value high amplitude/ low frequency = see technical data low amplitude/ high frequency = see technical data Evaluation of test In case of deviations exceeding 10% determine the cause, perform trouble shooting for engine / vibration circuit and check vibration motor. Fig. 2

6. Adjust the speed on the corresponding adjustment screw (Fig. 2).

i Note Turning the adjustment screw in reduces the speed, turning the screw out increases the speed.

Fig. 3

62

BOMAG

008 911 63

5.6

Pressure measurements in the vibration circuit

5.6 Pressure measurements in the vibration circuit Special tools Hydraulic test case Caution Perform measurements at operating temperature of the hydraulic oil (50 °C). !

1. Drive the machine with both drums on an elastic base (rubber buffers) (Fig. 1). 2. Block the wheels with suitable chocks. 3. Apply the brake.

Fig. 1

4. Connect a 60 bar pressure gauge (Fig. 2) to the charge pressure test port. 5. Connect a 600 bar pressure gauge each to the high pressure test ports for "high amplitude" and "low amplitude". 6. Start the engine and run it with maximum speed. 7. Switch on vibration with high or low frequency. Nominal value Charge pressure = charge pressure at high idle (see technical data of travel pump). Start-up pressure = vibration pump start-up pressure (see technical data of vibration pump).

Fig. 2

Operating pressure = vibration pump operating pressure (see technical data of vibration pump). Evaluation of test If the charge pressure drops, check the components individually. If the starting pressure is not reached, check the vibration pump. If the starting pressure is only reached for one frequency, check the high pressure relief valves.

008 911 63

BOMAG

63

5.7

Check the leakage rate of the vibration motor 5.7 Check the leakage rate of the vibration motor Caution Perform measurements at operating temperature of the hydraulic oil (50 °C). !

1. Drive the drum of the machine on an elastic base (rubber buffers) (Fig. 1) and block the wheels additionally with suitable chocks. 2. Apply the brake.

Fig. 1

3. Block the flushing valve (Fig. 2) with washers.

Fig. 2

4. Disconnect the leak oil hose (Fig. 3), connect a measuring hose and hold it into a measuring beaker. 5. Start the engine and run it with maximum speed. 6. Switch the vibration on and measure the running out leak oil during one timed minute. Nominal value max. 1.5 litre/min Evaluation of test If the permissible leak oil rate is exceeded, replace the vibration motor.

Fig. 3

64

BOMAG

008 911 63

5.8

Pressure test in steering circuit 5.8 Pressure test in steering circuit Special tools

Hydraulic test case, gear pump testing equipment Caution Perform measurements at operating temperature of the hydraulic oil (approx. 50 °C). !

Measurement 1 1. Connect a 600 bar pressure gauge to the steering pressure test port (Fig. 1). 2. Start the engine and run it at idle speed. Danger Danger of crushing, do not access the articulation area of the machine! !

3. Turn the steering against an end stop. 4. Read the pressure gauge. Nominal value see technical data, max. steering pressure of steering/charge pump.

Fig. 1

Evaluation of test 1 If the nominal value is reached, check the steering cylinder. Measurement 2 5. Disconnect the hydraulic hoses from ports L and R (Fig. 2) (machines with one steering cylinder) on the steering cylinder and close them with plugs.

Fig. 2

6. Disconnect the hydraulic hoses from ports L and R (Fig. 3) (machines with two steering cylinder) on the steering cylinders and close them with plugs. 7. Start the engine and run it at idle speed. 8. Turn the steering wheel. 9. Read the pressure gauge. Nominal value see technical data for steering/charge pump.

Fig. 3

008 911 63

BOMAG

65

5.8

Pressure test in steering circuit Evaluation of test 2 If the nominal value is reached, replace the steering cylinder. If the nominal value is not reached, check the steering/charge pump. 10. Reconnect the hydraulic hoses to the steering cylinders. Measurement 3 11. Actuate the emergency stop switch.

Fig. 4

12. Close the pump outlet port (Fig. 5) with the gear pump test equipment. 13. Crank the engine with the starter Nominal value see technical data for steering/charge pump. Evaluation of test 3 If the nominal value is reached, replace the steering valve. If the nominal value is not reached, replace the steering/charge pump. Fig. 5

66

BOMAG

008 911 63

6 Flushing and bleeding

008 911 63

BOMAG

67

6.1

Special tools for flushing 6.1 Special tools for flushing 1. Filling and filtering unit with oil bag BOMAG part-no.: 007 610 01 2. Filter element BOMAG part-no.: 079 930 35

Fig. 1

3. Flushing filter (S connection) BOMAG part-no.: 007 000 01 4. Filter element 1μ BOMAG part-no.: 079 930 52 5. Flushing hose 20S - 25S (2 pieces) BOMAG part-no.: 055 509 19 6. Screw socket R1“ - 25S (2 pieces) BOMAG part-no.: 055 400 52 Fig. 2

7. Flushing filter (L connection) BOMAG part-no.: 079 390 29 8. Filter element BOMAG part-no.: 079 390 14 9. Flushing hose 15L (2 pieces) BOMAG part-no.: 055 510 09 10. Screw socket R3/4“ -- 15L (2 pieces) BOMAG part-no.: 055 400 89 Fig. 3

11. SAE-flange 1“ - 20S BOMAG part-no.: 058 142 60 12. O-ring BOMAG part-no. 062 203 30

Fig. 4

68

BOMAG

008 911 63

6.1

Special tools for flushing 13. Flanged plate 1“ - 25S BOMAG part-no.: 007 160 18 14. O-ring BOMAG part-no. 062 202 22

Fig. 5

15. Reducing fitting 18L - 15L BOMAG part-no.: 055 422 92

Fig. 6

16. Reducing fitting 25S - 20S BOMAG part-no.: 055 422 98

Fig. 7

17. Reducing fitting 20S - 16S BOMAG part-no.: 055 423 26

Fig. 8

008 911 63

BOMAG

69

6.1

Special tools for flushing 18. Connecting socket 15L BOMAG part-no.: 055 426 55

Fig. 9

19. Connecting socket 18L BOMAG part-no.: 055 426 06

Fig. 10

20. Connecting socket 16S BOMAG part-no.: 055 459 43

Fig. 11

21. Connecting fitting 20S BOMAG part-no.: 055 459 44

Fig. 12

70

BOMAG

008 911 63

6.1

Special tools for flushing 22. Connecting fitting 25S BOMAG part-no.: 055 459 45

Fig. 13

23. Angular fitting 18L BOMAG part-no.: 055 421 26

Fig. 14

24. Elbow fitting 16L BOMAG part-no.: 055 421 36

Fig. 15

25. Elbow 20S BOMAG part-no.: 055 421 37

Fig. 16

008 911 63

BOMAG

71

6.1

Special tools for flushing 26. Elbow 25S BOMAG part-no.: 055 421 38

Fig. 17

27. Pipe connection 16S - 16S BOMAG part-no.: 493 301 01

Fig. 18

28. Connecting hose 15L BOMAG part-no.: 055 510 09

Fig. 19

72

BOMAG

008 911 63

6.2

Flushing - general 6.2 Flushing - general

Clean the hydraulic tank

Caution Solid particles in the circuit will very quickly cause damage to machine components. !

Environment Environmental damage Catch running out hydraulic oil and dispose of environmentally.

Changing a component Fig. 2

Caution Always flush the complete oil circuit after you have replaced a component. !

Caution Change the oil in case of excessive contamination, oil discoloration or if the oil change interval is almost due. !

Chips (abrasion) in the oil ●

Open and clean all components in the oil circuit, replace if necessary.

●

Clean all high pressure hoses in the oil circuit, replace if necessary.

●

If abrasion is found in the travel circuit you should also flush the vibration circuit.

●

If abrasion is found in the vibration circuit you should also flush the travel circuit.

●

Filter the tank content with the filling and filtering unit and pump it into the oil bag.

●

Mark all hoses and disconnect them from the hydraulic oil tank.

●

Clean the oil tank thoroughly from inside, if necessary remove the complete tank cover.

●

Reconnect all hoses.

●

Fill the hydraulic oil tank again with the filling and filtering unit.

Before flushing

Bleeding

Change the filter element

Fig. 3

Fig. 1 ●

Change the hydraulic oil filter element (1).

008 911 63

BOMAG

●

Always bleed closed hydraulic circuits if lines had been removed or connected.

73

6.2

Flushing - general

Servicing the flushing filter kit

Fig. 4

74

●

Replace the filter element of the flushing filter when the red control pin of the contamination indicator is pressed out during the filtering process.

●

Clean hoses and connections and store the flushing kit in a clean and protected environment.

BOMAG

008 911 63

Flushing schematic travel circuit (distribution travel pump)

008 911 63

BOMAG

6.3

75

6.3

Flushing schematic travel circuit (distribution travel pump)

1

Elbow union (tool)

2

Connecting union (tool)

3

Drum drive motor

4

Axle motor

5

Screw socket R1 - 25S (tool)

6

Flushing hose 25S - 20S (tool)

7


8

Flushing filter with filter element 1μ (tool)

9

Elbow union (tool)

13 High pressure hose (A, drum drive motor forward) 14 High pressure hose (B, axle motor reverse) 15 High pressure hose (A, axle motor forward) 16 High pressure hose (B, axle motor reverse) 17 High pressure port (B, drum drive motor reverse) 18 Flushing hose 25S - 20S (tool) 19 Flushing hose 25S - 20S (tool)

10 Reducing fitting (tool) 11 Travel pump 12 High pressure hose (B, drum drive motor reverse)

76

BOMAG

008 911 63

Flushing the travel circuit (travel pump distribution)

6.4

6.4 Flushing the travel circuit (travel pump distribution) Flushing the drum drive Replacing the hydraulic oil filter element Cleaning the hydraulic oil tank

i Note Observe the chapter "Flushing - General" Installing the flushing filter Caution Before the installation of the filters check hoses and connections for cleanliness. !

The flushing filter must be installed in the low pressure side in the return flow to the pump, so that only cleaned oil will enter the travel pump in forward travel. With the connection shown in the illustration the travel pump must therefore be actuated to forward direction. Fig. 1

1. Disconnect the high pressure hose 12 (see chapter "Flushing schematic - travel circuit") from the travel pump (high pressure port 17) and connect it with the flushing hose (7) (flushing filter inlet "IN"). 2. Connect the flushing hose (6) (flushing filter outlet "OUT") to the (high pressure port 17) on the travel pump. Disconnect the drum drive motor 3. Take the drum drive motor out of the hydraulic circuit by joining the high pressure hoses (12 and 13) on the drum drive motor together.

Fig. 2

008 911 63

BOMAG

77

6.4

Flushing the travel circuit (travel pump distribution) Bleeding the travel circuit

i Note Bleeding the travel circuit, see chapter "Bleeding the travel circuit".

Fig. 3

Flushing the hoses 4. Block drums and wheels with suitable chocks.

Fig. 4

i Note Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.

Fig. 5

Caution Move the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction. !

5. Start the engine and shift the travel lever to travel direction forward. 6. Perform the flushing process at various engine speeds for approx. 10 minutes. 7. Shut down the engine. 8. Reconnect the hydraulic hoses (12 and 13) to the drum drive motor. Fig. 6

78

BOMAG

008 911 63


6.4

Flushing the drum drive motor Danger Danger of accident! !

The drum must rotate freely. 9. Jack up the front of the machine, so that the drum can rotate freely. 10. Secure the rear wheels with chocks. 11. Pre-select the slow speed range.

Fig. 7

i

Note Keep circulating the complete tank content with the filling and filtering unit throughout the entire flushing process.

Fig. 8


12. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward. 13. Run the flushing procedure for approx. 10 minutes. During this process keep changing the pump flow by shifting the travel lever several times between full and halve forward travel. 14. Shut down the engine. Fig. 9

008 911 63

15. Remove the flushing filter and reconnect the high pressure lines.

BOMAG

79

6.4

Flushing the travel circuit (travel pump distribution) Flushing the axle drive Installing the flushing filter 16. Disconnect the high pressure hose 14 (see chapter "Flushing schematic - travel circuit") from the travel pump (high pressure port 16) and connect it with the flushing hose (18) (flushing filter inlet "IN"). 17. Connect the flushing hose (19) (flushing filter outlet "OUT") to the (high pressure port 16) on the travel pump.

Fig. 10

Disconnecting the axle motor 18. Take the axle drive motor out of the hydraulic circuit by joining the high pressure hoses (14 and 15) on the axle drive motor together.

Fig. 11

Bleeding the travel circuit

i

Note Bleeding the travel circuit, see chapter "Bleeding the travel circuit".

Fig. 12

80

BOMAG

008 911 63


6.4


Fig. 13

i


Fig. 14


20. Start the engine and shift the travel lever to travel direction forward. 21. Perform the flushing process at various engine speeds for approx. 10 minutes. 22. Shut down the engine. 23. Reconnect the hydraulic hoses (14 and 15) to the axle drive motor. Fig. 15

Flushing the axle motor Danger Danger of accident! !

Both wheels must be off the ground. The wheels must be able to rotate freely. 24. Jack up the rear of the machine, so that the wheels can rotate freely. 25. Secure the drum with wheel chocks. 26. Pre-select the slow speed range. Fig. 16

008 911 63

BOMAG

81

6.4



Fig. 17



30. Remove the flushing filter and reconnect the high pressure lines. Bleeding the travel circuit 31. Bleed the travel circuit (see corresponding chapter). Keep circulating the tank content. 32. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes. Function test 33. Check the hydraulic oil level in the tank, fill up if necessary. 34. Check all connections for leaks with the engine running (visual inspection). 35. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting on a gradient. 36. Check all ports and connections for leak tightness (visual inspection).

Fig. 19

82

BOMAG

008 911 63

Flushing schematic travel circuit (distribution axle motor)

008 911 63

BOMAG

6.5

83

6.5

84


BOMAG

008 911 63


008 911 63

BOMAG

6.5

85

6.5

86


BOMAG

008 911 63


6.5

1

Elbow union (tool)

13 High pressure hose (drum drive motor forward)

2


14 High pressure hose (B, axle motor reverse)

3

Drum drive motor

15 High pressure hose (A, axle motor forward)

4

Axle motor

16 High pressure hose (B, axle motor reverse)

5


17 not used

6

not used

18 Flushing hose 25S - 20S (tool)

7

not used

19 Flushing hose 25S - 20S (tool)

8


9

not used

10 Reducing fitting (tool) 11 Travel pump 12 High pressure hose (drum drive motor reverse)

008 911 63

BOMAG

87

6.6

Flushing the travel circuit (axle motor distribution) 6.6 Flushing the travel circuit (axle motor distribution) Flushing the drum drive Replacing the hydraulic oil filter element Cleaning the hydraulic oil tank

i Note Observe the chapter "Flushing - General" Installing the flushing filter Caution Before the installation of the filters check hoses and connections for cleanliness. !

The flushing filter must be installed in the low pressure side in the return flow to the pump, so that only cleaned oil will enter the travel pump in forward travel. With the connection shown in the illustration the travel pump must therefore be actuated to forward direction. Fig. 1

1. Disconnect the high pressure hose 14 (see chapter "Flushing schematic - travel circuit") from the travel pump (high pressure port 16) and connect it with the flushing hose (19) (flushing filter inlet "IN"). 2. Connect the flushing hose (18) (flushing filter outlet "OUT") to the (high pressure port 16) on the travel pump. Disconnect the drum drive motor 3. Take the drum drive motor out of the hydraulic circuit by joining the high pressure hoses (12 and 13) on the drum drive motor together.

Fig. 2

88

BOMAG

008 911 63

Flushing the travel circuit (axle motor distribution)

6.6


i Note Bleeding the travel circuit, see chapter "Bleeding the travel circuit".

Fig. 3

Flushing the hoses


Fig. 4

4. Block drums and wheels with suitable chocks.

Fig. 5


5. Start the engine and shift the travel lever to travel direction forward. 6. Perform the flushing process at various engine speeds for approx. 10 minutes. 7. Shut down the engine. 8. Reconnect the hydraulic hoses (12 and 13) to the drum drive motor. Fig. 6

008 911 63

BOMAG

89

6.6

Flushing the travel circuit (axle motor distribution) Flushing the drum drive motor Danger Danger of accident! !

The drum must rotate freely. 9. Jack up the front of the machine, so that the drum can rotate freely. 10. Secure the rear wheels with chocks. 11. Pre-select the slow speed range.

Fig. 7

i


Fig. 8



90

BOMAG

008 911 63

Flushing the travel circuit (axle motor distribution)

6.6

Flushing the axle motor Danger Danger of accident! !

Both wheels must be off the ground. The wheels must be able to rotate freely. 15. Jack up the rear of the machine, so that the wheels can rotate freely. 16. Secure the drum with wheel chocks. 17. Pre-select the slow speed range.

Fig. 10


Fig. 11 ! Caution Move the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.


21. Remove the flushing filter and reconnect the high pressure lines. Bleeding the travel circuit 22. Bleed the travel circuit (see corresponding chapter). Keep circulating the tank content. 23. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.

008 911 63

BOMAG

91

6.6

Flushing the travel circuit (axle motor distribution) Function test 24. Check the hydraulic oil level in the tank, fill up if necessary. 25. Check all connections for leaks with the engine running (visual inspection). 26. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting on a gradient. 27. Check all ports and connections for leak tightness (visual inspection).

Fig. 13

92

BOMAG

008 911 63

6.7

Flushing schematic for vibration drive

1

Elbow union (tool)

7


2


8


3

Vibration motor

9

SAE flange (tool)

4

Vibration pump

10 High pressure hose (B, high frequency)

5


11 High pressure hose (A, low frequency)

6


008 911 63

BOMAG

93

6.8

Flushing the vibration circuit 6.8

Flushing the vibration circuit Replacing the hydraulic oil filter element Cleaning the hydraulic oil tank

i

Note Observe the chapter "Flushing - General"

Installing the flushing filter Caution Before the installation of the filters check hoses and connections for cleanliness. !

The flushing filter must be installed in the low pressure side in the return flow to the pump, so that only cleaned oil will enter the vibration pump in high frequency. For the connection schematic shown here the vibration must always be filtered with "high frequency / low amplitude". Fig. 1

1. Disconnect the high pressure hose 10 (see chapter "Flushing schematic - vibration circuit") from the vibration pump (4) and connect it with the flushing hose (7) (flushing filter inlet "IN"). 2. Connect the flushing hose (6) (flushing filter outlet "OUT") to the (high pressure port A) on the vibration pump. Disconnect the vibration motor 3. Take the vibration motor out of the hydraulic circuit by joining the high pressure hoses (10 and 11) on the vibration motor together.

Fig. 2

94

BOMAG

008 911 63

6.8

Flushing the vibration circuit Bleeding the vibration circuit

i Note Bleeding the vibration circuit, see chapter "Bleeding the vibration circuit".

Fig. 3


Fig. 4


Fig. 5

Caution Use only high frequency, as otherwise the flushing filter will be subjected to oil flow from the wrong direction. !

5. Switch on vibration with high frequency. 6. Start the engine and run it with maximum speed. 7. Flush the circuit for approx. 10 minutes, thereby switch the vibration on and off at intervals of approx. 30 seconds. 8. Shut down the engine. Fig. 6

008 911 63

9. Reconnect the hydraulic hoses (10 and 11) to the vibration motor.

BOMAG

95

6.8

Flushing the vibration circuit Flushing the vibration motor 10. Unscrew the fastening screws for the vibration motor and pull the motor out of the coupling.

Fig. 7

i


Fig. 8

Caution Use only high frequency, as otherwise the flushing filter will be subjected to oil flow from the wrong direction. !

11. Start the engine and run it with maximum speed. 12. Run the flushing procedure for approx. 10 minutes. Switch the vibration on and off at intervals of approx. 30 seconds. 13. Shut down the engine. 14. Remove the flushing filter and reinstall the vibration motor. Fig. 9

Bleeding the vibration circuit 15. Bleed the vibration circuit (see corresponding chapter). Keep circulating the tank content. 16. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.

96

BOMAG

008 911 63

6.8

Flushing the vibration circuit Function test

17. Check the hydraulic oil level in the tank, fill up if necessary. 18. Test drive. 19. Check all ports and connections for leak tightness (visual inspection).

Fig. 10

008 911 63

BOMAG

97

6.9

Bleeding the travel circuit 6.9 Bleeding the travel circuit

Environment Catch hydraulic oil and dispose of environmentally. 1. Install a pressure test hose to the charge pressure test port. 2. Install a pressure test hose each to the high pressure test ports. 3. Actuate the emergency stop switch. Danger The engine should not start. !

Fig. 1

4. Hold the open ends of the pressure test hoses (Fig. 2) into a container. 5. Operate the starter motor for approx. 30 seconds. Wait one minute and repeat this procedure, until oil starts to run out from the pressure test hoses. 6. Remove the pressure test hoses.

Fig. 2

7. Unlock the emergency stop switch

Fig. 3

98

BOMAG

008 911 63

6.9


8. Connect a 60 bar pressure gauge to the charge pressure test port (Fig. 4) and run the engine max. 15 seconds at idle speed. 9. Pause for approx. 30 seconds and keep repeating this procedure, until the gauge shows a constant charge pressure reading.

Fig. 4

Caution With the flushing filter installed shift the travel lever only to travel direction forward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction. !

Danger Run the engine with idle speed. !

10. Start the engine. 11. Shift the travel lever (Fig. 5) approx. 1/3 to forward direction. Fig. 5

12. After approx. 1 to 2 minutes shut down the engine for a minute.

i Note This waiting time is necessary to allow air bubbles to escape through the leak oil return line. 13. After a waiting time of approx. 1 minute keep repeating this procedure, until the indicated charge pressure drops directly to zero when shutting down the engine.

008 911 63

BOMAG

99

6.10

Bleeding the vibration circuit 6.10 Bleeding the vibration circuit

Environment Catch hydraulic oil and dispose of environmentally. 1. Install a pressure test hose to the charge pressure test port. 2. Install a pressure test hose each to the high pressure test ports. 3. Actuate the emergency stop switch.

Fig. 1

4. Hold the open ends of the pressure test hoses (Fig. 2) into a container. 5. Crank the engine approx. 10 seconds with the starter motor. Wait one minute and keep repeating this procedure, until oil starts to run out from the pressure test hoses. 6. Remove the pressure test hoses.

Fig. 2

7. Unlock the emergency stop switch

Fig. 3

100

BOMAG

008 911 63

6.10

Bleeding the vibration circuit

8. Connect a 60 bar pressure gauge to the charge pressure test port (Fig. 4) and run the engine max. 15 seconds at idle speed. 9. Wait for approx. 30 seconds and repeat the procedure, until the pressure gauge shows a constant charge pressure.

Fig. 4

Caution With the flushing filter installed use only high frequency, as otherwise the flushing filter will be subjected to oil flow from the wrong direction. !

10. For bleeding switch on vibration with high frequency (Fig. 5). 11. Start the engine. 12. After running the engine 1 to 2 minutes pause for approx. one minute.

i

Fig. 5

Note This waiting time is necessary to allow air bubbles to escape through the leak oil return line. 13. After a waiting time of approx. 1 minute keep repeating this procedure, until the indicated charge pressure drops directly to zero when shutting down the engine.

008 911 63

BOMAG

101

6.10

102

Bleeding the vibration circuit

BOMAG

008 911 63

7 Fundamental electrics

008 911 63

BOMAG

103

7.1 7.1

Understanding circuit diagrams


Wiring diagrams are graphical representations of circuitry conditions, related to the electrical system. They do not contain any information about the actual type of wiring, they only serve the purpose of visualizing the circuitry logics. The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system. This plan provides the following information: ●

Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, ...

●

The sequence in which current flows through the individual elements in the electric circuit.

●

Connections between the examined, faulty electric circuit and other circuits in the vehicle wiring system.

●

Pin assignment of plug-and-socket connections.

Structure ●

Table of contents

●

Function groups

●

List of components

Table of contents The table of contents lists all function groups.

Fig. 6 Table of contents

Example: Function group "Warning systems“, drawing number XXX XX can be found on page no. 8.

104

BOMAG

008 911 63

7.1

Understanding circuit diagrams 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: ●

From top (plus potential) to bottom (minus potential).

●

From left to right.

●

From function group to function group.

●

Via cross references for potentials and relays.

Fig. 7 Function groups

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

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

008 911 63

BOMAG

105

7.1


Current paths The pages of a circuit diagram are sub-divided into current paths (Fig. 1) (0 ..... 20).

Fig. 1 Current paths

106

BOMAG

008 911 63

7.1

Understanding circuit diagrams List of components

Here you find all components used in alphabetical order, related to the name of the component (A01, A02....).

Fig. 1 List of components

Component cross references Example: The warning horn "B 11" is located on page no. 8 in current path 3.

008 911 63

BOMAG

107

7.1


Graphic symbol Graphic symbols are standardized representations for electrical appliances. They serve the purpose of a simplified representation of complete systems, from which, however, the function can be clearly identified. This standardization is in compliance with the globally valid regulations of the IEC (International Electrical Commission). For Germany these symbols were included in the DIN-Standard. 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 graphic symbol only shows as much of the function, as is needed for easy recognition and for the avoidance of mistakes.

Fig. 2 Graphic symbol

1

Current source

2

Conductor

3

Switch

4

Ground

5

Filament lamp

6

Filament lamp with two luminous elements

7

Voltmeter

8

Amperemeter

9

Resistance

10 Backup 11 Line connection (fixed) 12 Line connection (separable)

Fig. 3 Graphic symbol

1

Diode

2

Transistor

3

NPN-Transistor

4

changeable resistance

5

Condenser

6

Working current relay

108

BOMAG

008 911 63

7.2

Terminal designations

7.2


For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a terminal designation. In Germany the designation of the individual connection terminals is determined by the standard DIN 72552. The following table represents a section with the most important terminals from this standard. Terminal designation 1 1a 1b

Meaning

2

Short circuit terminal (magneto ignition)

4 4a 4b

Ignition coil, ignition distributor high voltage Ignition distributor with 2 separate electric circuits, from ignition coil 1, terminal 4 Ignition distributor with 2 separate electric circuits, from ignition coil 2, terminal 4

15 15a

Switch plus (after battery) : Output of ignition-travel switch Output from dropping resistor to ignition coil and starter

17

Preheating starter switch, preheating

19

Preheating starter switch, starting

30 30a

Battery plus direct Battery changeover relay 12V / 24V, input from battery 2 plus

31 31a 31b 31c

Battery minus direct or ground Battery changeover relay 12V / 24V return line to battery 2 minus Return line to battery minus or ground via switch or relay (switched minus) Battery changeover relay 12V / 24V return line to battery 1 minus

32

Electric motors, return line

33 33a 33b 33f 33g 33h 33L 33R

Electric motors, main connection Electric motors, limit shut down Electric motors, shunt field Electric motors, for 2nd lower speed range Electric motors, for 3rd lower speed range Electric motors, for 4th lower speed range Electric motors, counter-clockwise rotation Electric motors, clockwise rotation

45 45a 45b

Starter, separate starter relay output; starter: Input (main current) 2-starter parallel operation, start relay for engagement current, output starter 1 2-starter parallel operation, start relay for engagement current, output starter 2

48

Terminal on starter and on start repeat relay, monitoring of starting process

49 49a 49b 49c

Input flasher relay Output flasher relay Flasher relay output 2nd flasher circuit Flasher relay output 3rd flasher circuit

50 50a 50b

Starter, starter control Battery changeover relay, output for starter control Starter control, parallel operation of 2 starters with sequence control

008 911 63

Ignition coil, ignition distributor low voltage Ignition distributor with 2 separate electric circuits, to ignition timer 1 Ignition distributor with 2 separate electric circuits, to ignition timer 2

BOMAG

109

7.2 Terminal designation 50c

Terminal designations Meaning Start relay for sequence control of engagement current in parallel operation of 2 starters, input in starter relay for starter 1

50d 50f 50g 50h

Start relay for sequence control of engagement current in parallel operation of 2 starters, input in starter relay for starter 2 Start locking relay, input Start locking relay, output Start repetition relay, input Start repetition relay, output

51 51a

A.C.-generator, direct voltage on rectifier A.C.-generator, direct voltage on rectifier with reactance coil for day travel

52

Trailer signals: further signals from trailer to towing vehicle

53 53a 53b 53c 53e 53i

Wiper motor input (+) Wiper motor (+) end limit shut down Wiper shunt winding Electric windscreen washer pump Wiper, braking effect Wiper motor with permanent magnet and 3rd brush for higher speed

54 54g

Trailer signals, trailer plug device and lamp combination, brake light Trailer signals, compressed air valve for permanent brake in trailer, electromagnetically operated

55

Fog light

56 56a 56b 56d

Head light Head light, travel light and travel light control Head lights, dimmed head light Head lights, flash light

57 57a 57L 57R

Parking light for motor cycles (abroad also for cars and trucks) Parking light Parking light left Parking light right

58 58b 58c 58d 58L 58R

Side lights, tail light, number plate light, dashboard light Tail light changeover for single axle trailers Trailer plug for single core wired and trailer fused tail light Adjustable dashboard light, tail light and side light Side light, left Side light, right

59 59a 59b 59c

A.C.-generator (magneto generator), alternating voltage output or rectifier input A.C.-generator, charging armature output A.C.-generator, tail light armature output A.C.-generator, brake light armature output

61

Generator control

71 71a 71b

Intermittent tone control unit, input Intermittent tone control unit, output to horn 1 + 2 (low) Intermittent tone control unit, output to horn 3 + 4 (high)

72

Alarm switch (flashing beacon)

110

BOMAG

008 911 63

7.2

Terminal designations Terminal designation 75

Radio, cigarette lighter

76

Loudspeaker

77

Door valve control

81 81a 81b

Switch (breaker and two-way contact), input Switch (breaker and two-way contact), output 1 Switch (breaker and two-way contact), output 2

82 82a 82b 82z 82y

Switch (maker), input Switch (maker), output 1 Switch (maker), output 2 Switch (maker), input 1 Switch (maker), input 2

83 83a 83b 83L 83R

Switch (multi-position switch), input Switch (multi-position switch), output position 1 Switch (multi-position switch), output position 2 Switch (multi-position switch), output position left Switch (multi-position switch), output position right

84 84a 84b

Current relay, input drive and relay contact Current relay, output drive Current relay, output relay contact

85

Switching relay, output drive winding end (minus or ground)

86 86a 86b

Switching relay, input drive winding start Switching relay, input drive winding start 1st winding Switching relay, input drive winding start 2nd winding

87 87a 87b 87c 87z 87y 87x

Relay contact on breaker and two-way contact, input Relay contact on breaker and two-way contact, output 1 (breaker side) Relay contact on breaker and two-way contact, output 2 Relay contact on breaker and two-way contact, output 3 Relay contact on breaker and two-way contact, input 1 Relay contact on breaker and two-way contact, input 2 Relay contact on breaker and two-way contact, input 3

88 88a 88b 88c 88z 88y 88x

Relay contact for maker Relay contact on maker and two-way contact, (maker side) output 1 Relay contact on maker and two-way contact, (maker side) output 2 Relay contact on maker and two-way contact, (maker side) output 3 Relay contact on maker, input 1 Relay contact on maker, input 2 Relay contact on maker, input 3

B+ BD+ DDF DF1

Battery Plus Battery Minus Dynamo Plus Dynamo Minus Dynamo field (generator excitation current) Dynamo field 1 (generator excitation current)

008 911 63

Meaning

BOMAG

111

7.2


Terminal designation DF2

Dynamo field 2 (generator excitation current)

U V W

Three-phase generator, three-phase terminal Three-phase generator, three-phase terminal Three-phase generator, three-phase terminal

C C0 C2 C3 L R

Travel direction indicator (flasher relay) control light 1 Main connection for control light separated from flasher relay Travel direction indicator (flasher relay) control light 2 Travel direction indicator (flasher relay) control light 3 (e.g. for 2 trailer operation) Indicator left Indicator right

112

Meaning

BOMAG

008 911 63

7.3

Current and voltage

7.3

Current and voltage

The following statements concerning electric voltage can be made ●

General If one wants to describe electric current, this can most simply be accomplished by means of a comparison: One simply compares electric current with water.

● ●

electric voltage is the pressure or force applied to free electrons. the electric voltage is the cause of electric current electric voltage is a result of the equalization attempt 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 discharge will take place, resulting in the flow of an electric current. Plus pole= lack of electrons Minus pole = excess of electrons

008 911 63

BOMAG

113

7.3

Current and voltage

Current

Types of current

Electric current generally describes the directed movement of charge carriers.

Direct current (D.C.)

The charge carriers may either be electrons or ions.

●

Electric current can only flow if there is a sufficient amount of free moving charge carriers.

●

The higher the number of electrons flowing through a conductor per second, the higher the amperage.

●

Current is measured with an ammeter. Unit, Ampere

Fig. 1 Direct current (D.C.)

The electric amperage (I) is measured in Ampere (A).

Direct current flows with steady voltage and amperage from the plus to the minus pole.

The technical flow direction is specified from PLUS to MINUS.

Pure D.C.-voltages are only delivered by accumulators or batteries.

i

Note

Current actually flows from minus to plus, because the current flow is made up of negatively charged electrons. But since this was only discovered after the poles of a current source had already been designated, the assumption that current flows from plus to minus was maintained for historic reasons.

The voltage in the vehicle wiring system is no pure D.C.-voltage. Even without the generator running, but the consumers switched on, the voltage is not constant, but drops gradually according to the battery charge condition. The internal resistance of the battery also causes permanent changes in the vehicle voltage, as soon as consumers are switched on or off. Alternating current (A.C.)

Circuit

Fig. 2 Alternating current (A.C.) Fig. 3 Circuit

A simple circuit consists of a current source 1 (Fig. 3), a consumer (3) and the connecting wiring.

Alternating current not only changes its direction, but also its amperage. Pulsating direct current

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).

Fig. 3 Pulsating direct current

Converting alternating current into a direct current signal by means of a rectifier results in an pulsating direct current. 114

BOMAG

008 911 63

7.3

Current and voltage Pulse width modulation (PWM)

Fig. 4 PWM

The PWM signal is in most cases generated by a control and can be used to trigger proportional valves. The signal (square wave signal) is changed in its pulse control factor, the period, however, remains unchanged. The following applies: ●

The signal voltage cannot be measured.

●

The current can be measured.

Caution Solenoid valves must not be interference suppressed with suppressor diodes. !

008 911 63

BOMAG

115

7.4 7.4

CAN-Bus

CAN-Bus

Controller Area Network created by Bosch at the end of the eighties for automobile applications. Development objectives: Real-time critical, robust and low price communication of control units, such as transmission and engine control, but also less time critical applications in the field of convenience electronics, such as air conditioning.

Fig. 1 CAN

Why CAN? ●

Networking of control units for the realization of complex functions.

●

Reduction of the extend of wiring and plug connections.

●

Better diagnostic possibilities (central diagnostics socket).

Characteristics of CAN It is a kind of serial data transmission. The individual bits are transmitted one after the other, only 2 lines are required. CAN lines are twisted together 30 to 40 times per metre. Electromagnetic interferences therefore always occur simultaneously in both lines, the software is thus able to filter out interfering signals more easily. Wire (+) = cable colour blue Wire (-) = cable colour yellow

Measuring signals Signals transmitted through the bus line can generally not be measured with simple measuring instruments. Testing is therefore quite complicated for the user. Correct connection of lines can only be checked by means

116

BOMAG

008 911 63

7.4

CAN-Bus

of a continuity test. BOMAG display modules are connected to the BUS to give engineers and user the possibility to detect faults or to receive information from the BUS.

008 911 63

BOMAG

117

7.5 7.5

Resistance

Resistance

● ●

Resistance and voltage drop While current flows through a conductor the current flow is more or less inhibited by the conductor, this inhibitation is referred to as Resistance.

The cleaner the contacts, the better the current. The quality of the ground cable is of the same importance as the supply line.

Unnecessary resistances Unnecessary resistances are frequently caused by mechanical connections, even clean ones, but mainly soiled and oxidizes terminals, too thin cables, material with poor conductivity or bent open cable lugs. Bad

Fig. 1 Various size resistors

Each conductor has its specific resistance, which is characteristic for the corresponding material. A good conductor has a low resistance, a poor conductor has a high resistance.

Fig. 1 Screw-type terminals

Copper wires are squashed and thus become faulty. Better

Fig. 2 Spring clamps

Connecting clamps for flexible conductors BOMAG No. 057 565 72 Ampacity up to 20 Amp. Cable cross-section 0.08 to 2.5 qmm Fig. 2 Potentiometer, infinitely adjustable resistor

The resistance can only be measured with a Multimeter. Symbol, R Unit, Ohm Ω The electric resistance (R) is measured in Ohm Ω. Rule of thumb: ●

●

The thicker the cable cross-section, the lower the voltage loss. The shorter the cable, the better the current.

118

BOMAG

008 911 63

7.5

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

008 911 63

BOMAG

119

7.6 7.6

Series / parallel connection

Series / parallel connection

●

Series connection In a series circuit the resistors (consumers) are lined up one after the other and the same current (I) passes through each of the consumers However, series connection of consumers is not suitable in practice, as each resistance causes a voltage drop. In the vehicle wiring system all consumers are designed for the same vehicle voltage (e.g. 12 Volt).

●

●

In series connection the plus pole of the first battery must be connected with the minus pole of the second battery. The sum of all individual voltages is applied to the free poles. The total capacity (Ah) is identical with the capacity of the individual battery.

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 batteries of the same type and capacity must be connected in series mode.

120

BOMAG

008 911 63

7.6

Series / parallel connection Parallel connection

●

In parallel connection all resistances (consumers) are connected between feed and return line. ●

●

All resistances (consumers) are supplied with the same voltage.

●

Each of the resistances (consumers) draws as much current as required.

●

In parallel connection the plus pole of the first battery is connected with the plus pole of the second battery and the minus pole of the first battery with the minus pole of the second battery. Plus and minus poles have the voltage of the single battery applied. The total capacity (Ah) is identical with the sum of all battery capacities.

The disadvantage of a parallel connection becomes apparent, by equalizing currents flowing between parallel 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, because the individual capacities add up to the total capacity.

008 911 63

BOMAG

121

7.7 7.7

Ohm's law

Ohm's law

7.8

Electrical energy

In a closed electric circuit voltage, current and resistance 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 generate energy. Fig. 1

According to this law a voltage of 1V is required to let 1A (ampere) flow through a conductor with a resistance of 1 (Ohm Ω). Advice By means of this triangle the formula can be easily rearranged, the value you are looking form must just be blanked off with a finger. Voltage U = I multiplied with R Resistance R = U divided by I Amperage I = U divided by R U = Voltage in Volt I = Current in Ampere

If a current of 1 Ampere flows at a voltage of 1 Volt, energy of 1 Watt is produced. Advice By means of this triangle the formula can be easily rearranged, the value you are looking form must just be blanked off with a finger. Energy P = I multiplied with U Amperage I = P divided by U Voltage U = P divided by I U = Voltage in Volt I = Current in Ampere P = Power in Watt

R = Resistance in OHM Ω

122

BOMAG

008 911 63

7.9

Formula diagram

7.9

Formula diagram

Description: ●

Select the desired value from the inner circle.

●

Determine the formula variables in the quarter circle

●

Calculate

Example: P = 150 Watt U = 24 Volt Sought for = Current in Ampere I = P : U = 150 W : 24 Volt = 6.25 Ampere

Fig. 1 Formula diagram

Resistance, R Ohm Ω Voltage, U Volt Current, I Ampere Power, P Watt

008 911 63

BOMAG

123

7.10

Metrology

7.10 Metrology

Multimeter

Test lamps

This tester is a multimeter and can be used to measure e.g. current, voltage and resistance. Depending on the design it may also be suitable for transistor and frequency.

Test lamp

Fig. 1 Multimeter

In order to avoid damage:

Fig. 1 Test lamp

●

Caution This type of tester must not be used for testing on electronic components. The high power consumption of the test lamp may destroy electronic components in the control units. !

Diode test lamp

●

● ●

●

This instrument is used for simple voltage measurements. The test lamp consists of two test points. The negative measuring cable is connected to ground and the positive measuring cable to the corresponding measuring location.

●

the range selector switch must be correctly set for the corresponding measurement. the test cable must be plugged into the correct socket. the voltage type (AC/DC) must be set. In case of direct voltage the correct polarity must be assured. the measuring range should be chosen higher at the beginning of the test. In order to avoid any influence on the circuitry to be measured, the internal resistance of the voltage tester should be as high as possible.

Resistance and continuity measurement with multimeter The continuity tester of the multimeter can be used to measure whether there is a connection between 2 measuring points. The following information should be observed when measuring resistance and continuity: ●

●

●

The component to be measured must not be connected to the power supply during the measurement. At least one side of the component to be measured must be disconnected from the circuitry, as otherwise the measuring result may be influenced by parallel components. Polarity is of no significance.

Fig. 2 Diode test lamp

If voltage is present, the corresponding light emitting diode will light up.

124

BOMAG

008 911 63

7.10

Metrology Voltage and voltage drop measurement with multimeter

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

Fig. 2 Voltage measurement ●

●

●

The meter is always connected parallel to consumer, component or power source. Measurement at the voltage source measures the currently available Voltage. A measurement at the consumer measures the voltage drop at this component.

Current measurement with the multimeter Fig. 1 Clip-on measuring instrument ●

For measuring current the individual conductor must be fully enclosed by the measuring tongs, the actual measurement takes place without contact.

Fig. 3 Current measurement ●

During the measurement the current must be able to flow through the meter, i.e. the electric circuit must be opened. The meter is connected in series with the consumer.

Advice If the electric circuit is difficult to access and the internal 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.

008 911 63

BOMAG

125

7.10

Metrology

Magnet tester

Power measurement The electric power of a module within a circuit can be indirectly determined (calculated) by separate measuring of current and voltage. However, there are also pure power meters with 4 connections available. The power meter has a electrodynamic measuring mechanism. The current circuit must be opened for measuring. Take care when performing 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.Cvoltage, D.C.-voltage and permanent magnets. ●

●

The component to be tested does not need to be removed. The magnetic coil can also be tested under a protective cap.

Fig. 2

126

BOMAG

008 911 63

7.11

Diodes, relays, fuses

7.11 Diodes, relays, fuses

Diode logics and free-wheeling diode

Diodes

Fig. 1

A diode consists of two different semi-conductors, which are connected by a separating layer. The max. conducting state current must not be exceeded. Plus-voltage on diode: ●

At 0.6 – 0.7 Volt (silicium diode) the diode becomes conductive.

Negative voltage on diode: ●

The diode does not allow current to pass through.

Fig. 2 Marking of the cathode

Diodes are used: ●

For rectifying A.C. voltage.

●

For absorbing voltage peaks (free-wheeling diode).

●

For construction of logical circuits.

Fig. 3 Diode circuitry ●

●

●

The solenoid valve Y48 (Fig. 3) is supplied with electric current when switch S34 is switched to position "1" or "2". Solenoid valve Y20 is supplied, if the switch is in position "1". Solenoid valve Y21 is supplied, if the switch is in position "2".

The three diodes V02 serve as free-wheeling diodes with the function of of eliminating voltage peaks.

008 911 63

BOMAG

127

7.11

Diodes, relays, fuses Relays

Light emitting diodes

Fig. 1 Relays

Relays are commonly used to realize switching processes.

Fig. 4 LED

The light emitting diode, also referred to as LED, is a semi-conductor diode, which generates (emits) light during operation in forward direction. A semi-conductor crystal thereby emits a light signal, which is converged or scattered by the lenticular shape of the head. Light emitting diodes are available in various colours, sizes and shapes. They are for this reason used as signal lamps. This component is constructed of different semi-conductor crystals, depending on its colour. It works like any other semi-conductor diode.

A free-wheeling diode prevents induction voltage from flowing back from the coil into the vehicle wiring system, which would cause interference with electronic components (control units). With the possibility of using breaker - maker contacts the effect of an information can be reversed.

Fig. 2 Relay circuitry

The windscreen wiper and washer motors can only be operated via switches S20 and S21, when relay K32 is supplied with electric current (Fig. 2). 86 = Positive supply for coil 128

BOMAG

008 911 63

7.11

Diodes, relays, fuses 85 = Ground supply for coil

Fuses

30 = Supply voltage 87 = Normally open contact 87a= Normally closed contact

Fig. 1

Fuses are used to protect lines and equipment against overloads and short circuit. If the fuse is overloaded the fusible wire heats up with increasing current, until it finally melts. Caution Fuses must not be repaired or bridged. !

The melting time at 23 °C is: ●

approx. 1 hour with 1.5 times the rated current

●

approx. 1 minute with 2.5 times the rated current.

A 5 Amp fuse loaded with 1.5 times the rated current (7.5 Amp) will finally melt after approx. 1.5 hours. Yellow = 5 A Brown = 7.5 A White = 8 A Red = 16 A Blue = 25 A

008 911 63

BOMAG

129

7.12

Batteries

7.12 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 final discharging voltage of 10.5 Volt, as otherwise there is a risk of sulphation, i.e. the generated lead sulphate forms increasingly coarser crystals, which will finally not react at all or only very sluggishly during a subsequent charging process.

Fig. 1

In vehicles batteries are used to start the engine. The ability to start the engine depends on the charge condition of the batteries. Lead collectors or accumulators are secondary elements, i.e they can be recharged after discharging electric current. The basic element of a lead accumulator is the cell. It contains the plate blocks consisting of positive and negative plates. These plates are separated from each other by separators. All positive plates are arranged parallel to the plus pole, the negative plates parallel to the minus pole of the cells.

In the worst case the accumulator can only be disposed of after such an exhaustive discharge. The following therefore applies for longer downtimes: Remove the battery and store it in a cool, dry and frost protected room.

●

Check the open circuit voltage on the battery at regular intervals (at least once every month).

●

Recharge immediately if the open circuit voltage has dropped to 12.25 Volt (no rapid charging).

●

i

Note

The open circuit voltage of batteries occurs approx. 10 h after the last charging or approx. 1 h after the last discharge. Battery test in general ●

●

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

Testing batteries with screw plugs Checking the acid density: ●

Fig. 2

All cells are filled with a conductive fluid, the electrolyte. For a 12 Volt battery 6 cells are connected in series. Capacity is a synonym for the amount of current taken up and discharged by a battery over a specified period of time. ●

130

The cells are filled with diluted sulphuric acid as electrolyte (approx. 25 Vol% sulphuric acid in distilled water), also referred to as accumulator acid, which has a density of 1.285 kg/dm3 at a temperature of +27° Celsius. This means that one litre of electrolyte has a weight of 1.285 kg. As the cell is being discharged lead sulphate (PbSO4) will form on both electrodes and the electrolyte will 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 measure for the charge condition. This characteristic is used to determine the charge condition of a lead

BOMAG

008 911 63

7.12

Batteries battery. The so-called acid tester (hydrometer) is used for this purpose. In a battery of good condition the acid density should be the same in all cells. Acid density at 27 °C in kg/dm3 1.25 -1.28, open-circuit voltage approx. 12.7 Volt. Battery is charged.

●

1.20 -1.24, open circuit voltage approx.12.4 to 12.5 Volt, is 50% discharged. Charging is necessary.

●

1.19 and less, open circuit voltage less than 12.3 Volt. Battery is insufficiently charged. Battery needs to be recharged immediately.

●

i

Fig. 4 Battery and generator tester

Note

If the current consumption during charging is not 1/20 of the nominal capacity (example 100 Ah battery: 100Ah x 1/20 = 5 A) or full charging of the battery results in a final acid density of only 1.24 kg/dm3 or less, the battery shows normal wear by aging. The battery was insufficient charging or exhaustive discharge.

The battery and generator tester comes with an 8-line LC display with background illumination and is able to print out test results via an (optional) integrated thermal printer.

i

Note

Before testing clean the poles and ensure good connection between clamps and poles. The test program calculates the text messages "good" or "replace" on the basis of the charge condition (derived from the battery voltage) and the currently available starting power of the battery. A battery with 45% starting power may thus be rated good and another one with 75% starting power as poor ("replace"). The starting power represents the ratio of detected cold testing current to the entered cold testing current of the battery. The starting power can exceed 100%. Fig. 3 Reading the acid level ●

Maximum permissible tolerance between highest and lowest measuring value of the 6 cells: 0.03 kg/ dm3.

Testing batteries without screw plugs On closed batteries the acid density cannot be measured, we therefore recommend testing with the following mobile tester:

008 911 63

BOMAG

131

7.12

Batteries

Charge condition with hydrometer

Fig. 5 Charge condition

Green = Charge condition >65% Dark = Charge condition <65% Light = Electrolyte level too low ! Danger Danger of explosion!!! If the electrolyte level is too low, the battery must no longer be charged.

132

BOMAG

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7.13

Three-phase generator


Design and function

General

In the generator the armature windings are located inside the stationary stator, whereas the exciter winding is arranged on the internally revolving rotor (Fig. 6).

The generator should be of light weight, have a high rate of efficiency and supply all consumers in the vehicle with electric current at a steady voltage already at idling speed. ! Caution Before removing the generator you must disconnect the ground cable from the minus pole of the battery while the ignition is switched off. Do not disconnect the generator while the engine is running, because this may cause extremely high voltage peaks in the vehicle wiring system ("Load Dump"), which could possibly damage control units, radios or other electronic equipment.

When disassembling the battery cable, the B+-nut underneath on the generator side may also be loosened. This nut must in this case be retightened.

Fig. 6 Rotor with claw poles

When connecting e.g. the battery cable to the terminal of the generator you must make sure that the polarity is correct (generator B+ to the + pole of the battery). Mixing up the polarities by mistake causes short circuit and damage to the rectifier elements - the generator will be out of function. The generator can only be operated with the battery connected. Under special conditions emergency operation without battery is permitted, the lifetime of the generator is in such cases especially limited. Plus and minus cables must be disconnected during 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. After cleaning the generator should be operated for about 1 - 2 minutes to remove any deposits of water from the generator. Fig. 7 Stator with 3 windings

The three stator windings (Fig. 7) are electrically offset to each other by 120°. The excitation of the magnetic field requires direct current, which is fed to the rotor via two carbon brushes and slip rings.

008 911 63

BOMAG

133

7.13

Three-phase generator This includes : ●

Electric motors Relays

●

Finally, a variety of important components solely require direct current. These will under no circumstances work with alternating or three-phase current. This includes : ●

Accumulators

●

Control units

●

All electronics

●

Communication equipment.

Charge control light

Fig. 8 3-phase current

The generator first of all produces three-phase voltage / three-phase current. The wiring diagram (Fig. 8) shows the 3 windings in Yconnection and the 6 associated rectifier diodes. The diodes D1, D2, D3 are also referred to as minus diodes, because they have B- as common connection (minus plate). The other diodes are the plus diodes. The rectifier diodes have the effect that the negative half-wave is suppressed and only the positive section of the wave is allowed to pass, resulting in a pulsating D.C. voltage. Reverse current protection The rectifier diodes also prevent discharging of the battery via the stator windings. The current can only flow from the generator to the battery. Why does three-phase current need to be rectified and how does this work? There are a few components for which can either be operated with alternating current or direct current, because they work independently from the current flow direction.

It has by no means the function to show whether the ignition is switched on or off. It has the function of indicating that the generator works correctly. Under normal operating conditions the generator should work and the charge control light should be off. The charge control lamp receives (+) from the battery at one pole. The other pole is connected to (D+), i.e. the (+) carbon of the generator. If the generator is working correctly, (+) is attached to both connections on the charge control lamp. Since there is no difference in voltage, no current can flow, the lamp does not light up. If the generator does not work, current flows via the (+) carbon through the armature winding, via the (-) carbon to ground and from there back to the battery. The electric circuit is closed, battery voltage is applied to the charge control lamp and the lamp lights up. Since the generator does not work when the engine is not running, the charge control lamp is not connected directly to the battery, but via the ignition switch. When the ignition is off, the charge control lamp is dead. Voltage regulator A generator without regulator would just work light a bicycle dynamo. The power output would increase with rising speed. The voltage output would fluctuate with the load. (In case of a bicycle dynamo the tail light bulb is overloaded when the head light does not consume any power). The function of the regulator is the provision of a uniform vehicle voltage, almost completely independent from speed and load of the generator.

This includes : ●

Incandescent lamps

●

Fluorescent lamps

●

Glow lamps

●

Electric heating elements.

There are also a few components that could be operated either with alternating current, direct current or three-phase current, if the components were designed accordingly. 134

BOMAG

008 911 63

7.13

Three-phase generator Checking the generator

First one must check whether the generator is actually defective. ●

●

This can be easily found out by checking whether the charge control light in the dashboard lights up. If the light does not go out, even at higher speeds, there must be a defect on the generator, the regulator, the wiring or the V-belt. When the engine is at rest, the charge control light must light up. If not, the lamp may probably be defective. Defects on generator or wiring are obviously also possible.

The following points allow to contain faults in the voltage supply within certain limits.

Fig. 9 Regulator with diode plate and rectifier diodes

In most cases voltage regulators (Fig. 9) with carbon brushes form a compact component. The voltage regulator is maintenance free and the wear of carbon brushes is only so little, that they hardly ever need to be replaced during the lifetime of a machine.

●

Cable connections on the generator OK?

●

V-belt OK?

●

Generator ground (engine ground) OK?

●

Pre-excitation from vehicle electronics OK?

Only if all criteria mentioned above are OK, the fault must be in the generator itself. In this case it must be replaced or the following trouble shooting procedure must be performed.

The regulator has the following function: ●

● ●

To maintain the vehicle voltage under any operating conditions below 14.4 V. To match the regulator voltage to the temperature. Smooth rising of generator current when switching loads (convenience function to avoid jerking of the engine).

008 911 63

BOMAG

135

7.13


Checking the pre-excitation circuit

Measuring the charge current

The most common reason for a 3-phase alternator not charging is a too low pre-excitation current. The preexcitation current through connection D+ depends on the connected consumer (resistance), e.g. charge control light or relay of a MD+ engine control.

●

The pre-excitation current should be approx. 250 mA at 12 Volt. This corresponds with a 3 Watt light bulb or an equivalent combination of light bulb + resistance or an LED + resistance. The total resistance of the disconnected dead supply line D+ max. should not exceed 48 Ohm.

● ●

All plug-and-socket connectors must be free of corrosion and intermittent contact. The generator ground connection must be OK. During the measurement switch on as many consumers as possible.

1 Attach the clip-on ammeter around the B+ line. 2 Gradually increase the engine speed. 3 The generator current must be at least as high as the total current of all consumers.

In case of faults like ●

charge control light stays on

●

no voltage increase, e.g. from 12 V to 14 V

one should check that the correct resistance is assured.

Fig. 10 Connections on the three-phase alternator (exemplary design)

If the charge control light or LED stays on when the engine is running, you should proceed as follows: ●

Temporarily bridge connections D+ and B+ on the three-phase alternator (Fig. 10). The bridging must be made using an insulated cable with a cross-section 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.

136

BOMAG

008 911 63

7.13

Three-phase generator Checking the stator

Checking the rotor

i

Note

The rotor coils can only be measured in disassembled state.

Fig. 11 Rotor ●

Remove the regulator with carbon brush.

●

Contact the rotor slip ring with the tester points.

●

The resistance should be between 3 and 6 OHM Ω.

●

The rotor coils should not have continuity to ground.

Fig. 12 Stator

i

The stator coils can only be measured in disassembled state. ● ●

008 911 63

Note

Measure the resistance of all three coils. The coils should not have contact among each other.

BOMAG

137

7.13


Checking the regulator voltage with the generator tester

Checking the regulator voltage with the multimeter

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. 14 ●

Fig. 13

●

The generator test assesses the regulator voltage and the ripple factor of the generator voltage. ●

● ●

All plug-and-socket connectors must be free of corrosion and intermittent contact. The generator ground connection must be OK. The battery should be in good condition – the idle speed voltage of the battery should be at least 12.6 Volt.

●

If possible switch off all consumers.

●

Perform the measurement at raised engine speed.

138

●

All plug-and-socket connectors must be free of corrosion and intermittent contact. The generator ground connection must be OK. The battery should be in good condition – the idle speed voltage of the battery should be at least 12.6 Volt.

●

If possible switch off all consumers.

●

Perform the measurement at raised engine speed.

●

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

BOMAG

008 911 63

7.13

Three-phase 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 disassembled. Unscrew the housing screws to do so. Pull rotor with drive bearing and V-belt pulley out of the stator. Unscrew the ends of the stator winding from the diode carrier and separate the stator from the collector ring bearing. Disassemble exciter diodes and brush holders and remove also the regulator.

i

Note

When testing the regulator one should be aware that there are 2 different types of regulators: ●

If the carbon brush is not connected to ground the regulator is a so-called minus controlled regulator. The exciter winding is positioned between D+ and DF, the regulator therefore regulates the exciter winding on the ground side. The other carbon brush is connected with the cathodes of the exciter diodes, terminal D+. This leaves one further terminal, this is DF.

D+ (vehicle wiring system)

Fig. 16

E.g minus controlled regulator One connects the regulator (Fig. 16) with D+ and D- to the power source, as shown in the illustration, and the lamp to both carbon brushes, instead of the exciter winding. When slowly increasing the voltage the lamp will first become brighter, because the regulator allows all lamp current (= exciter current) to flow at voltage values up to 14.4V. Once the regulator voltage is reached, the regulator switches the lamp current off. When returning the voltage back below the control voltage, the regulator will switch the lamp back on. With this test the major difficulty is the problem to remove the regulator an identify terminals D+, DF and D-.

D- (ground contact, mostly located on one of the fastening screws) DF (Dynamo Field)

Fig. 17

Fig. 18

Fig. 15 ●

If the carbon brush is connected to ground the regulator 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 illustrations (Fig. 17) and (Fig. 18) show two different regulator types.

The basic function of a disassembled regulator can be easily tested with a 12V lamp and an adjustable D.C. power supply unit (0V ... 20V).

008 911 63

BOMAG

139

7.13


Replacing carbon brushes ●

●

On a Bosch generator unscrew two fastening screws for the regulator and lift the regulator off. Pull out the carbon brushes from underneath. Their minimum length is 5 mm, shorter carbon brushes need to be replaced, unsolder both connection litz wires. Solder the litz wires of the new carbon brushes, insert these and fasten the regulator again. For this work the generator does not need to be removed. For replacing the carbon brushes in the DelcoRemy generator the generator needs to be disassembled and partly dismantled. The carbon brush holder is located inside the collector ring bearing.

140

BOMAG

008 911 63

7.14

Electric starter

7.14 Electric starter

●

The starter converts the electric energy stored in the battery into mechanical energy. The starter can only generate its power when a battery with appropriate capacity is available. Duties of the starter: to accelerate the combustion engine to start speed with lowest possible current consumption.

●

Fig. 1 Electric starter

1

Pinion

2

Roller free-wheeling

3

Steep thread

4

Guide ring

5

Spring winding

6

Armature

7

Pole shoe

8

Carbon brushes

9

Armature brake

to maintain this connection.

●

to switch on the starter current.

After starting the engine: ●

to return the starter pinion to initial position.

●

to switch off the starter current.

Starter motors must not be cleaned with high pressure steam cleaning equipment. The contacts on starter terminals 30, 45, 50 must be protected against unintended shorting (jump protection). When replacing the starter the ring gear on the engine flywheel must be checked for damage and its number of teeth - if necessary replace the ring gear.

11 Magnetic switch 12 Engagement lever Caution So-called jump starting (using an additional external battery) without the battery connected is dangerous. When disconnecting the cables from the poles high inductivities (arcs, voltage peaks) may occur and destroy the electrical installation.

008 911 63

●

For purposes like e.g. purging the fuel systems, starters may be operated for maximum 1 minute without interruption. Then you should wait for at least 30 minutes (cooling down) until trying again. During the 1 minute starting period this process should not be interrupted.

10 Collector

!

establish the gear connection between starter and combustion engine.

Always disconnect the battery before starting assembly work in the starter area of the engine or on the starter itself.

BOMAG

141

7.14

Electric starter

Function of pre-engaged-drive starting motor This type of starter uses a solenoid to engage the pinion with the ring gear. The engaging solenoid contains switching contacts for the starting current. When closing the starter switch, the relay holding winding is active and current flows also through the series connection of pick-up winding and electric motor. The engaging solenoid picks up and moves the freewheeling with the pinion forward via the engaging lever and the engaging spring. In case of a favourable position of the pinion to the ring gear a tooth of the pinion will directly engage in a tooth gap. In this case the pinion will engage over the entire length of the screw path, until the contact bridge in the engaging relay touches the relay contacts. The starter motor is no switched on. However, if the pinion does not directly find a tooth gap, the ring gear will block any further engaging movement. The engaging lever in this case compresses the engaging spring and the main contact closes, even though the pinion and the ring gear are not engaged. The electric motor keeps rotating the pinion in front of the ring gear face, until a pinion tooth gap matches a tooth on the ring gear and the preloaded engaging spring moves pinion and free-wheeling forward. When switching the relay winding off, the return spring forces the relay armature and the pinion with free-wheeling back to rest position. This disengagement is supported by the steep thread.

Fig. 2 Switching position during engagement

Magnetic switch The magnetic switch is normally arranged directly above the starter.

Fig. 3 Switching position during starting

With the starter switch switched on, both the pickup winding and the holding winding are energized and shift the iron core in axial direction. With a lever this iron core pulls the starter pinion towards the engine flywheel.

1

Ground

2

Battery

Once the gears are engaged the starter current is applied to the back through a large cross-section. At the same time the pickup winding is shorted via the starter current and thus switched off as a measure to reduce the load on the energy household.

3

Starter switch

4

Pull-in winding

5

Holding winding

6

Exciter winding

7

Restoring spring

8

Driver

9

Pinion

10 Flywheel

142

BOMAG

008 911 63

7.14

Electric starter Trouble shooting "Starter"

Testing and measuring the electric starter

The most frequent fault is definitely a fully discharged battery. If the starter rotates too slowly, either the brushes are partly worn off, or parts of the exciter or armature winding is shorted. In some cases oxidized electric contacts or a soiled ground connection causing extremely high voltage losses in the overall starter system 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.

i

The highest current flows when the starter is blocked! (Short circuit current in starter). This is the case when the pinion is engaged and the starter has the duty to accelerate the flywheel to starting speed. Function test with starter installed Initiate the starting process and measure the voltage on the pickup solenoid switch (50a). At least 10.8 Volt should be applied.

●

When operating the starter switch the magnetic switch must engage in the flywheel ring gear (noticeable clicking sound) and release the starting current to the starter. On most magnetic switches the voltage can be measured with the multimeter. If this does not happen even though voltage is applied, replace the magnetic switch.

●

Frequently a jammed return mechanism is the reason for a starter failure. Occasionally worn contacts are found on the magnetic return switch Defects on the actual starter motor including pinion and carbon brushes are very rare. With a trouble shooting chart the faults in the starter system can be narrowed down. The starter system can only work when many conditions are fulfilled at the same time.

Function tests with disassembled starter Caution Before removing the starter you must disconnect the ground cable from the minus pole of the battery while the ignition is switched off. !

●

●

Immobilizer deactivated?

●

Ignition switch OK?

●

Travel lever in correct position?

●

Emergency stop not actuated?

●

●

Battery sufficiently charged?

●

●

Battery poles OK?

●

Main battery fuse OK?

●

Main battery switch closed?

●

Main starter cable (terminal 30) OK?

●

●

●

Starter control cable (terminal 50) OK, voltage drop?

●

Ground cable OK?

●

Switching of magnetic switches OK?

Note

Check the wear on the carbon brushes and their contact pressure. Check the collector, it must not have electrical contact with the rotor shaft. Check the drive pinion for excessive wear. The return mechanism should not be tight, if necessary grease amply with silicon grease (Bosch PZ 2 V3) or a comparable grease. Measure the resistance of the magnetic switch main contact in disengaged condition. Maximum value 0.2 OHM Ω.

The sequence of these tests is generally of no significance. It mainly depends on: ● ●

the experience of the specialist the failure probability of the component to be tested and the testing effort for the respective part.

Only if all criteria mentioned above are OK, the fault must be in the starter itself. In this case it can be repaired or replaced.

008 911 63

BOMAG

143

7.15

Telemecanique switch

7.15 Telemecanique switch Example of terminal designations

Fig. 1 Terminal designations ●

Normally open contact 23 located on block 2

●


●

Normally closed contact 12 located on block 1

●

Normally closed contact 11 located on block 1

●


●


●


●


●


●


i

Note

If e.g. block 5 is not needed to design a switch, the numbering for blocks 1,2,3,4 and 6 remains unchanged.

144

BOMAG

008 911 63

7.15

Telemecanique switch Disassembly

Fig. 2 Disassembly ●

Lift up the interlock (5).

Fig. 4 Pulling out the front element ●

Fig. 3 Folding down the switch block ●

Fold down the switch block (4).

●

Loosen screw (1).

008 911 63

Lift up the interlock (2) and pull out the front element (3).

BOMAG

145

7.15

Telemecanique switch

Assembly

Fig. 5 Assembly

Insert the front element (3) into the bore in the control panel.

●

Fig. 7 Assemble the switch block

Clip on the switch block (4).

●

i

Fig. 6 Observe the marks.

Clip the fastening adapter (6) onto the front element (3).

●

i

Note

Hook in the switch block at the bottom first (Fig. 7).

Note

Watch the marls on front element (Fig. 6) and fastening flange. ●

Tighten the screw (1) with a tightening torque of 0.6 Nm.

146

BOMAG

008 911 63

7.16

Inductive proximity switches

7.16 Inductive proximity switches

NPN circuitry

General In all automated sequences the use of sensors as a source of information for the electronic control is indispensable. The sensors deliver the necessary signals about positions, end positions, filling levels or serve as pulse transducers for counting tasks or speed detection. In industrial applications inductive and capacitive proximity switches are today indispensable. Compared with mechanical switches, they offer almost ideal prerequisites: non-contact, wear free operation, high switching frequencies and switching accuracies, as well as high protection against vibration, dust and moisture. Inductive sensors detect all metals without contact, capacitive sensors detect almost all solid and liquid media, such as metal, glass, wood, plastic, water, oil, etc.

Fig. 10 NPN circuitry

On sensors with NPN-circuitry the output stage contains a NPN-transistor, which switches the load against the negative operating voltage. The load is connected between the output and the positive operating voltage. Breaking and making contacts

Working principle

Fig. 8

The working principle is based on the principle of the dampened LC-oscillator. The coil of the oscillation circuit forms a high-frequency magnetic stray field. This stray field leaks out from the active area of the proximity switch. If metal or non-ferrous metal enters into the response range energy is absorbed. The oscillator is thus dampened and the resulting change in current consumption is evaluated. PNP circuitry

Fig. 11

Proximity switches are used as breaking or making contacts. Depending on the design the switching distances are 2 or 4 mm. The maximum amperage is 300 mA. The LED (Fig. 11) lights up, when the initiator has detected metal in its stray field.

Fig. 9 PNP circuitry

On sensors with PNP-circuitry the output stage contains a PNP-transistor, which switches the load against the positive operating voltage. The load is connected between the output and the negative operating voltage. The switch is designed with a normally open contact, i.e. the contact closes when the initiator comes in "contact" with metal. 008 911 63

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7.17

Angle sensors

7.17 Angle sensors Sensor with current output

Fig. 1 Sensor

Fig. 12 Circuit diagram, making contact

The circuit diagram (Fig. 12) shows a proximity switch with normally open contact. Brown = voltage supply Blue = ground supply Black = switching output The initiator switches the relay (K05)

148

The the function of the angle sensor (Fig. 1) is based on the so-called "Hall-Effect". Named after the American physicist E.H. Hall. Due to the fact that moving electrons are deflected in a magnetic field, a voltage transverse to the flow direction of the primary current can be expected on a current conducting conductor in the magnetic field. Since the electrons are deflected in transverse direction by the magnetic field, they must enrich on the one side and reduce on the opposite side. If a very thin circuit board is now subjected to a current that is uniformly distributed across its cross section, no voltage will be measured between two points A and B, which have an identical distance to the current supply lines and are connected by a highly sensitive galvanometer. When generating a magnetic field vertical to the circuit board, voltage will be present between A and B and a current will flow through the galvanometer connected to these points. This is referred to as "Hall-Effect". The cause for this effect is the warping of the originally parallel electron orbits in the board by the magnetic field.

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7.17

Angle sensors Sensor with voltage output

The design is almost identical with the angle sensor on the new single drum rollers of generation -4 with electronic steering wheel, where a sensor with a voltage output of 0-8.5 V is mounted on the articulated joint. The potentiometer inside the sensor transmits a variable voltage potential to the control. Due to the short distance between articulated joint and central electrics it is in this case possible to use a voltage signal.

Fig. 2 Connection diagram

The angle sensor has 3 electric connections (Fig. 2). Ub, supply voltage (+ 8.5 Volt) Gnd, ground Out, output current 4-20 mA. ●

at -35° = 4 mA output current

●

at 0° = 12 mA output current

●

at +35° = 20 mA output current.

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7.18

Plug connectors

7.18 Plug connectors

7.19 Deutsch plug, series DT and DTM

Duties and requirements Electric plug connectors must provide a reliable connection 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.

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.

Examples for these loads are: ● ●

● ●

Vibration acceleration Temperature fluctuations, high and low temperatures Dampness Micro movements of the contact with resulting friction corrosion.

These loads may increase the transition resistances of the contacts, up to total interruption. Even the insulation resistances may drop and thus cause short circuits in neighbouring lines. Electric plug connectors must therefore have the following properties: ● ●

●

Low transition resistances of the conductive parts. High insulation strength between conductive parts with different voltage potentials. Excellent leak tightness against water and moisture.

Fig. 3 Crimp connections

Caution Do not crimp more than one lead per pin or per socket. !

Sockets and pins must not be soldered to leads, they may only be crimped (see special tools for electrics). When connecting sockets and plugs these must engage with a noticeable click when both halves interlock. The plug connection should not be separable (without loosening the interlock). Pulling test This pulling test ensures that the lead is perfectly crimped and the contact has correctly engaged in the housing. ●

150

Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties.

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7.19

Deutsch plug, series DT and DTM DT Series

Fig. 1 DT plug connection

Fig. 2 DT Series

Fig. 3 Sectional drawing

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Deutsch plug, series DT and DTM

Installing DT contacts

Fig. 4

Insert the contacts through the rubber grommet until they click into place.

●

Insert the orange wedge in direction of arrow.

●

Caution Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties. !

i

Note

Use the same method when assembling the socket.

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Deutsch plug, series DT and DTM Disassembling DT contacts

Fig. 5

Pull the orange wedge out with long nose pliers.

●

Slightly pull the lead and unlock the interlocking hook with a screw driver.

●

Pull the contact out of the socket.

●

i

Note

Use the same method when assembling the socket. In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.

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7.19


DTM Series

Fig. 1 DTM plug connection

Fig. 2 DTM Series

Fig. 3 Sectional drawing

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Deutsch plug, series DT and DTM Installing DTM contacts

Fig. 4

Insert the contacts through the rubber grommet until they click into place.

●

Insert the orange wedge, until it clicks into place.

●

Caution Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force of 45 N without any difficulties. !

i

Note

Use the same method when assembling the socket.

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7.19


Disassembling DTM contacts

Fig. 5

Pull the orange wedge (interlock) out with long nose pliers.

●

Slightly pull the lead and unlock the interlocking hook with a screw driver.

●

Pull the contact out of the socket.

●

i

Note

Use the same method when assembling the socket. In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.

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Plugs and terminals in spring clamping technology

7.20 Plugs and terminals in spring clamping technology

7.20

ventional copper conductors (single, multiple or fine stranded) with or without wire and ferrule. Caution The spring clamp technology is not suitable for extra fine conductors. Extra fine conductors can be easily pulled out of the spring clamp! !

General

Fig. 1

Spring clamp technology (Fig. 1) for quick, vibration resistant and maintenance-free connection of all con-

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. 3). That's how it works ●

Strip 9-10 mm of the lead.

●

Open the actuating lever and insert the strand.

●

Return the actuating lever to initial position.

Fig. 3 Connecting clamp

Caution Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties. !

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7.20

Plugs and terminals in spring clamping technology

Series clamp


That's how it works Insert a screw driver into the actuating opening until it bottoms.

●

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

●

Pull out the screw driver.

●


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. 5 Test adapter

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Plugs and terminals in spring clamping technology X-COM System The X-COM-SYSTEM, a synthesis of plug connector and series clamp, has grown up to a construction kit

7.20

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


Measuring signals

That's how it works Insert a screw driver into the actuating opening until it bottoms.

●

●

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

●

Pull out the screw driver.


Fig. 8 X-COM plug plugged onto the series clamp

Fig. 7 X-COM plug with measuring cable ●

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

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7.21

Electric modules

7.21 Electric modules In the latest generation of machines BOMAG uses machine programmable modules. A module mainly consists of a programmable microprocessor with additional circuitry for inpiuts and outputs. With theses modules it is possible to cover the requirements of the individual machines.

Fig. 1

The modules have control lights on inputs and outputs to monitor the applied signals.

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8 Special tools, electrics

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Special tools, electrics 8.1 Special tools, electrics Measuring equipment 14. Electric test case BOMAG part-no.: 057 505 70

Fig. 2

15. Multimeter BOMAG part-no.: 057 509 91

Fig. 3

16. Test prod black, with flexible insulated shaft and button operated gripper with 4 mm bushing, length 157 mm. BOMAG part-no.: 079 900 53 17. Test prod red, with flexible insulated shaft and button operated gripper with 4 mm bushing, length 157 mm. BOMAG part-no.: 079 900 54

Fig. 4

18. Test prod black, with elastic insulated shaft 4 mm bushing, length 97.5 mm. BOMAG part-no.: 079 900 51 19. Test prod red, with elastic insulated shaft 4 mm bushing, length 97.5 mm. BOMAG part-no.: 079 900 52

Fig. 5

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20. Measuring and connecting lines with 4mm plug, high flexible design, black, length 0.5 m. BOMAG part-no.: 079 900 58 21. Measuring and connecting lines with 4mm plug, high flexible design, black, length 1 m. BOMAG part-no.: 079 900 59 22. Measuring and connecting lines with 4mm plug, high flexible design, black, length 2 m. BOMAG part-no.: 079 900 60 Fig. 6

23. Measuring and connecting lines with 4mm plug, high flexible design, red, length 0.5 m. BOMAG part-no.: 079 900 55 24. Measuring and connecting lines with 4mm plug, high flexible design, red, length 1 m. BOMAG part-no.: 079 900 56 25. Measuring and connecting lines with 4mm plug, high flexible design, red, length 2 m. BOMAG part-no.: 079 900 57 26. Measuring and connecting lines with 2 mm plug and gold plated lamella plugs, high flexible design, black, length 300 mm. BOMAG part-no.: 079 900 63 27. Measuring and connecting lines with 2 mm plug and gold plated lamella plugs, high flexible design, black, length 600 mm. BOMAG part-no.: 079 900 64 28. Measuring and connecting lines with 2 mm plug and gold plated lamella plugs, high flexible design, red, length 300 mm.

Fig. 7

BOMAG part-no.: 079 900 61 29. Measuring and connecting lines with 2 mm plug and gold plated lamella plugs, high flexible design, red, length 600 mm. BOMAG part-no.: 079 900 62 30. Transition plug connector, with 4 mm plug on one side and 2 mm socket on the other, insulated design BOMAG part-no.: 079 900 65

Fig. 8

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Special tools, electrics 31. Magnetic coil tester BOMAG part-no.: 057 555 54

Fig. 9

32. Clip-on measuring instrument BOMAG part-no.: 079 900 50

Fig. 10

33. Battery - generator tester BOMAG part-no.: 079 900 91

Fig. 11

Spring clamps (Wago or Weidmüller) 34. Cranked screwdriver (Fig. 12) to open spring clamps (Fig. 13). BOMAG part-no.: 972 024 68

Fig. 12

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35. Testing adapter to measure the signals from the series spring clamps (Wago). BOMAG part-no.: 057 564 26

Fig. 13

Deutsch contacts 36. Tool to disassemble the interlocking on Deutsch plugs (series DT and DTM). BOMAG part-no.: 079 900 84

Fig. 14

37. Crimping pliers for Deutsch contacts of series DT and DTM, size AWG 20,16 and 12. AWG 20 = 0.5 mm2 cable cross-section AWG 16 = 1,5 mm2 cable cross-section AWG 12 = 4,0 mm2 cable cross-section BOMAG part-no.: 079 900 79

Fig. 15

38. Crimping pliers for Deutsch contacts of series HDT, size AWG 6 and 8. AWG 8 = 10,0 mm2 cable cross-section AWG 6 = 16,0 mm2 cable cross-section AWG 6 = 16,0 mm2 cable cross-section

BOMAG part-no.: 079 900 69

Fig. 16

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Special tools, electrics 39. Disassembly tool for Deutsch contacts of series HDP. AWG 20, BOMAG part-no.: 079 900 78 AWG 16, BOMAG part-no.: 079 900 71 AWG 12, BOMAG part-no.: 079 900 72 AWG 8, BOMAG part-no.: 079 900 73

Fig. 17

ITT contacts 40. Installation tool for ITT crimp contacts of series CA-COM, contact size 15S/16S/15/16. BOMAG part-no.: 079 900 80

Fig. 18

41. Disassembly tool for ITT male contacts of series CA-COM, contact size 15S/16S/15/16. BOMAG part-no.: 079 900 81

Fig. 19

42. Disassembly tool for ITT female contacts of series CA-COM, contact size 15S/16S/15/16. BOMAG part-no.: 079 900 82

Fig. 20

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8.1

Special tools, electrics Schaltbau contacts

43. Disassembly tool for Schaltbau contacts of series M1, M2. BOMAG part-no.: 057 509 95

Fig. 21

44. Crimping pliers for Schaltbau contacts of series M1, M2 with connecting cross-section 0.14 - 6.0 mm2. BOMAG part-no.: 057 509 94

Fig. 22

FCI Burndy contacts 45. Disassembly tool for FCI Burndy contacts of series TRIM TRIO BOMAG part-no.: 079 900 00

Fig. 23

AMP contacts 46. Crimping pliers for AMP-contacts of series FASTIN-FASTON with a connecting cross-section of 1.0 - 2.5 mm2 (18 -14 AWG). BOMAG part-no.: 079 900 35

Fig. 24

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Special tools, electrics 47. Crimping pliers for AMP-contacts of series SUPER-SEAL with connecting cross-section 0.75 1.25 mm2. BOMAG part-no.: 079 900 48

Fig. 25

48. Crimping pliers for AMP-contacts of series .070SERIES with a connecting cross-section of AWG 20 - 18 (0.5 - 0.9 mm2) and AWG 16 (1.25 - 1.5 mm2). BOMAG part-no.: 079 900 23

Fig. 26

49. Crimping pliers for AMP-contacts of series FASTON with connecting cross-section AWG 14 - 10. BOMAG part-no.: 079 900 88

Fig. 27

50. Crimping pliers for AMP-contacts of series FASTON with connecting cross-section AWG 16 - 14 and AWG 18. BOMAG part-no.: 079 900 89

Fig. 28

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51. Crimping tool for Powertimer contacts with individual strand sealing (example: ESX control) BOMAG part-no.: 079 900 25

Fig. 29

52. Crimping jaws for Crimping tool 079 900 25 BOMAG part-no.: 079 900 27

Fig. 30

53. Disassembly tool for AMP-contacts of series CIRCULAR-CONNECTOR. 1.5 mm2, BOMAG part-no.: 079 900 74 2,5 mm2, BOMAG part-no.: 079 900 75 Spare sleeve 1.5 mm2, BOMAG part-no.: 079 900 76 Spare sleeve 2,5 mm2, BOMAG part-no.: 079 900 77

Fig. 31

Universal tools 54. Universal pressing pliers with toggle lever transmission and adjustable end pressure for Crimping roller connector 0.14 - 1.0 mm2. BOMAG part-no.: 972 038 47

Fig. 32

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Special tools, electrics 55. Precision pressing pliers for non-insulated flat male and female connectors0.5 - 6,0 mm2. BOMAG part-no.: 079 900 70

Fig. 33

Measuring adapter 56. Current measurement adapter for Hirschmann plugs. BOMAG part-no.: 057 503 83

Fig. 34

57. Voltage measurement adapter for Deutsch plugs, 8-piece (2 to 12 pole). BOMAG part-no.: 079 900 68

Fig. 35

58. Current measurement adapter for Deutsch and AMP plugs, 2 pole. BOMAG part-no.: 079 900 83

Fig. 36

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9 Electronic modules

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BEM, BOMAG Evib-meter

BOMAG

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Bild 37

i

Hinweis

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

174

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Service Training Electrics MESX

008 097 05

Version 4.00

Status: Author:

05.06.2007 T.Löw / TE

Dateiname:

p:\schulung\elektrik\wz\mesx_bvc\englisch\schulung elektrik mesx_v4.00_gb.doc

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Service Training MESX

Table of contents 1 2 3 4 5

Document alteration list.....................................................................................................................3 Proof of software change MESX .......................................................................................................4 Proof of software change BOP..........................................................................................................6 Known faults......................................................................................................................................7 How to proceed when replacing components?.................................................................................8 5.1 How to proceed when replacing an ESX control? .....................................................................8 5.2 How to proceed when replacing a rear axle sensor? ................................................................8 5.3 Which components can be replaced without a subsequent adjustment procedure? ................8 5.4 List of machine types .................................................................................................................9 6 Possible adjustments on machines without BOP ...........................................................................12 6.1 Description of the Display Module ...........................................................................................12 6.2 Input of code numbers .............................................................................................................12 6.3 Changing the machine type (only via display module) ............................................................13 6.4 Inverting the direction signal (only via display module) ...........................................................14 6.5 Changing the bit rate (only with display module).....................................................................15 7 Adjustment/display possibilities on machines with BOP.................................................................16 7.1 Adjusting the machine type (BOP)...........................................................................................16 7.2 Inverting the direction signal via the BOP control terminal ......................................................18 7.3 Accessing the diagnostics menu .............................................................................................20 7.3.1 Extended diagnostics on machines with circular exciter (BTMplus, BTMprof) ................. 22 7.3.2 Extended diagnose BVC machines ......................................................................................... 23 7.4 Changing the printout language...............................................................................................24 7.5 Setting the machine serial number ..........................................................................................26 7.6 Teaching distance pulses ........................................................................................................28 7.7 Activating the amplitude limitation (only BVC machines) ........................................................30 7.8 Changing the display mode (metric/imperial) ..........................................................................32 7.9 Switching the GPS Receiver Voltage Supply Mode ................................................................34 8 Possible settings on the BCM05mobile ..........................................................................................36 8.1 Reading the software version ..................................................................................................36 8.2 Changing the language............................................................................................................36 8.3 Changing the unit system (metric/imperial) .............................................................................36 9 Block diagram BEM.........................................................................................................................37 10 Block diagram BTMplus / VARIOCONTROL...............................................................................38 11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile................................................39 12 Description of the signals on the ESX-control .............................................................................40 13 Fault codes of the ESX control ....................................................................................................45 13.1 Overview...............................................................................................................................45 13.2 Description of fault reactions ................................................................................................46 13.3 Detailed description of fault codes and their possible causes ............................................47 14 Input codes for ESX control (only via BEM display module) .......................................................51 14.1 Travel system .......................................................................................................................51 14.2 Vibration ...............................................................................................................................52 14.3 Light......................................................................................................................................52 14.4 Acceleration transducer........................................................................................................53 14.5 Diesel engine........................................................................................................................53 14.6 Setting the machine type......................................................................................................54 14.7 Parameter change................................................................................................................55 15 Terminology in connection with ESX...........................................................................................56

Status:05.06.2007 Author: T.Löw / TE

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1 Document alteration list Version Date 0.00 27.04.2004 1.00 05.05.2004

1.01 2.00

23.07.2004 31.08.04

3.00

15.10.2004

3.01

14.02.2005

4.00

01.05.2007

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


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Löw Löw Löw

Löw, Horch

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2 Proof of software change MESX Version 1.00 1.01

Date 25.03.2004 05.04.2004

1.02

13.04.2004

1.03

05.05.2004

1.04

16.04.2004

1.05

26.07.2004

2.00

31.08.2004

3.00

15.10.2004

3.01

16.11.2004

3.02

01.12.2004

3.03

14.02.2005

3.04

10.05.2005

3.05

19.05.2005

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

Löw

Löw

Löw

Löw

Löw Löw

Löw

Löw

Löw

Î Vibration detection for BW177DH/PDH and BW179DH/PDH Löw corrected Î Phase response correction acceleration transducer Löw activated Î "Flash Request" activated


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Service Training MESX Version 4.00

Date 01.05.2005

Description of changes resp. Î Languages Slovakian, Slovenian, Czech, Romanian added Löw Î Function "vCheckMMISoftwareVersion" corrected Î Teach mode for distance via BCM implemented Î Triggering of a relay for GPS receiver voltage supply implemented Î GPS mode changed: Off and ON now independent from engine run, Automatic depending on engine run! Î Setting of work number in serial number has been realized Î ATTENTION: Signal distribution for CAN message MMI_CONFIG_DATA_2 0x156 was changed!!! Î new machine types:211PD, 213PD, 216PD, 219PD + "low cost" designs: 177D40,1777DHC,177D_40,177DHC,177PDHC,177PDH_ 40,179DHC,179PDHC,211D_40,211PD_40,213D_40,213D HC,213PDHC,213PD_40,214DHC,214PDHC,216DHC,216 PDHC,212D_40,212PD_40 Î Pulse numbers changed to 10m for BW219D Î VM classes taken from V3.90, VM class is sent to BCM


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3 Proof of software change BOP Version 1.00

Date 25.03.2004

Description of changes first software version for series production

resp. Löw

1.01

13.04.2004

Revision of BVC diagnostics screen

Löw

1.02

23.04.2004

2-stage jump information (yellow and red)

Löw

3.00

15.10.2004

Î Realization of imperial display Î Simulation mode implemented on BOP Î New TN 582 701 92

Löw

3.01

24.1.2005

Löw

3.02 4.00

10.02.2005 01.05.2007

Î Part-No. changed to 58 701 93 Î Designation "ESX" replaced by "MESX" and "BOP" by "BOP" Î Amplitude bar graph in imperial display mode corrected Î Flags for all EU-languages and additionally Japan and China stored in OPUS Î Page for changing over GPS Receiver Mode implemented Î Triggering for fault LED in BVC diagnostics page 2 activated


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4 Known faults Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to detect all faults. The following list contains a selection of known fault reactions of the control, which mostly have a different cause to the one described in this documentation.

Behaviour of machine

Possible cause

During initial commissioning the display shows the Bit rate on bmfsa not set to 125 kbit reading "ct0" => see "Setting the bit rate"


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5 How to proceed when replacing components? Each machine is adjusted individually during initial commissioning. This is mainly accomplished by setting the correct machine type (see "5.4 List of machine types", or "7.1 Adjusting the machine type (BOP)"). The following chapter describes the necessary adjustments to the control when replacing individual components in the measuring system.

5.1 How to proceed when replacing an ESX control? Attention:

A machine must not be operated with a wrong type setting, because in such a case the correct function of the control cannot be assured! You should therefore set the machine type first! see "5.4 List of machine types, or "7.1 Adjusting the machine type (BOP)").

After setting the machine type check the following items: Check the direction signal, invert the signal if necessary, see 6.4, or 7.2. Set the machine serial number (only on machines with BOP), see: 7.5 Set the printer language (only machines with printer), see: 7.4

5.2 How to proceed when replacing a rear axle sensor? Check the direction signal, invert the signal if necessary, see 6.4, or 7.2.

5.3 Which components can be replaced without a subsequent adjustment procedure? BOP Acceleration transducer Valve block for exciter adjustment Printer Bmfsa display module All switches in the dashboard

Note:

A final function test of the complete machine is highly recommended.


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5.4 List of machine types Since the same control is used for all single drum rollers with the new measuring technology, it is necessary to adjust the machine type after installing a new control. This is necessary during first time commissioning as well as in case of a spare parts installation. This type adjustment is necessary, because the machines have e.g. different axle loads or different drum widths, which requires the calculation of measuring values to be adapted. The adjustment procedure is described under items "6.3 Changing the machine type (only via display module)" or "7.1 Adjusting the machine type (BOP)". The following machine types can be adjusted: Machine type 177 D 177 DH 177 PDH 177 BVC 179 DH 179 PDH 211 D

211 PD 213 D 213 DH 213 PD 213 PDH 213 BVC 213 BVC plates 213 BVC DI 214 DH 214 PDH 216 D 216 DH 216 PD 216 PDH 219 D 219 DH 219 PD 219 PDH

First serial number

Last serial number

Code

101 582 20 1001 101 582 21 1001 101 582 22 1001 101 582 23 1001 101 582 24 1001 101 582 25 1001 101 582 40 1001 101 582 41 1001 101 583 09 1001 101 582 45 1001 101 583 10 1001 101 582 50 1001 101 583 08 1001 101 582 51 1001 101 583 14 1001 101 582 46 1001 101 583 13 1001 101 582 52 1001 101 582 53 1001 101 583 16 1001 101 582 54 1001 101 583 06 1001 101 582 53 1001 101 583 16 1001 101 582 58 1001 101 583 19 1001 101 582 59 1001 101 583 20 1001 101 582 62 1001 101 583 23 1001 101 582 60 1001 101 582 64 1001 101 582 63 1001 101 583 24 1001 101 582 61 1001 101 582 65 1001 101 582 72 1001 101 582 10 1001 101 582 70 1001 101 582 77 1001 101 582 73 1001 101 582 11 1001 101 582 71 1001 101 582 78 1001

XXX XXX XX XXXX XXX XXX XX XXXX XXX XXX XX XXXX XXX XXX XX XXXX XXX XXX XX XXXX XXX XXX XX XXXX XXX XXX XX XXXX

7500 7501 7502 7503 7511 7512 7520

Available from version 1.00 1.00 3.03 1.00 3.03 3.03 1.03

XXX XXX XX XXXX

7529

4.00

XXX XXX XX XXXX

7530

1.03

XXX XXX XX XXXX

7531

1.03

XXX XXX XX XXXX

7539

4.00

XXX XXX XX XXXX XXX XXX XX XXXX

7532 7533

3.03 1.02

XXX XXX XX XXXX

7534

3.00

XXX XXX XX XXXX

7535

1.05

XXX XXX XX XXXX

7541

3.03

XXX XXX XX XXXX

7542

3.03

XXX XXX XX XXXX

7550

3.03

XXX XXX XX XXXX

7551

3.03

XXX XXX XX XXXX

7559

4.00

XXX XXX XX XXXX

7552

3.03

XXX XXX XX XXXX

7560

2.00

XXX XXX XX XXXX

7561

1.05

XXX XXX XX XXXX

7569

4.00

XXX XXX XX XXXX

7562

3.03


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Machine type 226 DH

226 PDH

226 BVC

226 BVC DI

226 BVC RC

Machine type VARIOCONTROL VARIOCONTROL+

Machine type 177 D-40 177 DH-40 177 DHC-4 177 PDHC-4 177 PDH-40 179 DHC-4 179 PDHC-4 211 D-40 211 PD-40 212 D-40 212 PD-40 213 D-40 213 DH-40 213 DHC-4 213 PDHC-4 213 PD-40 213 PDH-40 214 DHC-4 214 PDHC-4 216 DHC-4 216 PDHC-4

First serial number

Last serial number

Code

101 582 80 1001 101 582 83 1001 101 582 88 1001 101 582 81 1001 101 582 84 1001 101 582 89 1001 101 582 82 1001 101 582 85 1001 101 582 86 1001 101 582 82 1001 101 582 85 1001 101 582 86 1001 101 582 82 1001 101 582 85 1001 101 582 86 1001

XXX XXX XX XXXX

7571

Available from version 3.03

XXX XXX XX XXXX

7572

3.03

XXX XXX XX XXXX

7573

3.01

XXX XXX XX XXXX

7575

1.04

XXX XXX XX XXXX

7576

3.03

First serial number

Last serial number

Code

101 582 12 1001 101 582 13 1001

XXX XXX XX XXXX XXX XXX XX XXXX

7537 7538

Available from version 4.00 4.00

First serial number

Last serial number

Code

101 582 26 1001 101 582 27 1001 101 582 00 1001 101 582 01 1001 101 582 28 1001 101 582 02 1001 101 582 03 1001 101 583 02 1001 101 583 25 1001 101 583 03 1001 101 583 26 1001 101 582 43 1001 101 583 48 1001 101 582 44 1001 101 582 55 1001 101 583 07 1001 101 582 56 1001 101 582 04 1001 101 583 11 1001 101 582 05 1001 101 583 12 1001 101 582 49 1001 101 582 57 1001 101 582 06 1001 101 583 17 1001 101 582 07 1001 101 583 18 1001 101 582 08 1001 101 583 21 1001 101 582 09 1001

XXX XXX XX XXXX

7600

Available from version 4.00

XXX XXX XX XXXX XXX XXX XX XXXX XXX XXX XX XXXX XXX XXX XX XXXX XXX XXX XX XXXX XXX XXX XX XXXX

7601 7602 7609 7611 7612 7620

4.00 4.00 4.00 4.00 4.00 4.00

XXX XXX XX XXXX

7629

4.00

XXX XXX XX XXXX XXX XXX XX XXXX XXX XXX XX XXXX

7680 7689 7630

4.00 4.00 4.00

XXX XXX XX XXXX

7631

4.00

XXX XXX XX XXXX

7632

4.00

XXX XXX XX XXXX

7639

4.00

XXX XXX XX XXXX

7641

4.00

XXX XXX XX XXXX

7642

4.00

XXX XXX XX XXXX

7651

4.00

XXX XXX XX XXXX

7652

4.00


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Service Training MESX 101 583 22 1001


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6 Possible adjustments on machines without BOP 6.1 Description of the Display Module Note:

The display module described next is only used in machines without the Bomag Operation Panel (BOP). On machines with BOP the settings are made via the BOP! (See item 7 "Adjustment/display possibilities on machines with BOP")

The display module consists of a 4-digit display and two keys, F1 and F2. It is used for the output of fault codes and display values as well as for the input of code numbers. Faults and warnings are displayed by flashing. If several faults are detected, the displayed fault codes will change in a 3 second cycle.

057 667 72

15/54

sign

Display values are permanently displayed, whereby values from 0 0 0 0 …9 9 9 9 are possible. Higher values lead to the display "- - - - ", negative values are indicated by the "minus dot" lighting up (see illustration).

The following description describes the input of code numbers.

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

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BOMAG

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6.3 Changing the machine type (only via display module) For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the display module of the central electrics when switching the ignition on. It can also be checked at any time by entering code 7000.

Setting the machine type requires the following sequence:

Note:

Parameter adjustments can only be performed when the engine is not running!

Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type". The display module now permanently shows the code 7 0 1 0 . Select and enter the machine from the table above. The display module now permanently shows the entered code. (e.g. 7 5 3 3 ) Enter code number 7 0 1 1 . This code number confirms the entered machine type. After confirming the machine type the control initiates a restart, the display module shows the new machine type for approx. 3 seconds. Switch the ignition off and on again. After this the newly adjusted machine type will be displayed for approx. 3 seconds.

Attention:

A machine must not be operated with a wrong type setting, because in such a case the correct function of the control cannot be assured! New controls are delivered with the default machine type setting 7 5 0 0 .

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6.4 Inverting the direction signal (only via display module) Depending on the installation position, the axle sensor used delivers a 12 V output signal in forward and reverse. This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and printout for the the travel direction correspond with the actual travel direction. Note:


Enter code number 7 6 0 0 . This code number activates the function "Invert direction signal“. The display module now permanently shows the code 7 6 0 0 . Enter code number 7 6 0 1 . This code number inverts the direction signal. The display module now permanently shows the code 0 0 0 1 (signal inverted), or the code 0 0 0 0 (signal not inverted). In succession the code number 1 0 0 1 can be used to check whether the direction signal is correctly interpreted (see item 14 "Input codes for ESX control").

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

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7 Adjustment/display possibilities on machines with BOP 7.1 Adjusting the machine type (BOP) Setting the machine type requires the following sequence: Note:


Press key "?" to open the screen page "MENU". The following screen is displayed:

Press key "F2" to open the screen page "Adjust machine type". The following screen is displayed:

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

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7.2 Inverting the direction signal via the BOP control terminal Depending on the installation position, the axle sensor used delivers a 12V output signal in forward and reverse. This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and printout for the travel direction correspond with the actual travel direction.

Note:



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

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

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7.3 Accessing the diagnostics menu Press key "?" to open the screen page "MENU". The following screen is displayed:

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

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If an actual error is present the corresponding error code will be displayed in the field "Actual Errors". Press "ESC" to leave the page. By pressing key "A" you can change into a machine specific, more detailed diagnostics menu (see below).

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7.3.1 Extended diagnostics on machines with circular exciter (BTMplus, BTMprof)

4.23 V Ubv:

actual voltage front acceleration transducer

4.24 V Ubh:

actual voltage rear acceleration transducer

98 % Small Ampl:

Triggering of solenoid valve for low amplitude in percent

0 % Big Ampl:

Triggering of solenoid valve for high amplitude in percent

Direction:

Status MESX input travel direction (LED on = 12 V)

Lights:

Status MESX input light detection (LED on = 12 V)

MD+

Status MESX input MD+ (detection engine running) (LED on = 12 V)

Vibration:

Status of vibration detection in the MESX (LED on = Vibration ON)

+01234

Distance pulses detected by the MESX (10 cm steps). The actually detected travel direction can be recognized by the roller symbol above.

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Service Training MESX 7.3.2 Extended diagnose BVC machines

4.25 V Uexciter:

actual voltage of exciter position potentiometer

4.23 V Ubv:

actual voltage front acceleration transducer

4.24 V Ubh:

actual voltage rear acceleration transducer

98 % Ampl:

Triggering of solenoid valve for vibration valve in percent

Direction:

Status MESX input travel direction (LED on = 12 V)

Lights:

Status MESX input light detection (LED on = 12 V)

MD+

Status MESX input MD+ (detection engine running) (LED on = 12 V)

Vibration:

Status of vibration detection in the MESX (LED on = Vibration ON)

+01234

Distance pulses detected by the MESX (10 cm steps). The actually detected travel direction can be recognized by the roller symbol above.

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7.4 Changing the printout language Press key "?" to open the screen page "MENU". The following screen is displayed:

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

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The desired printout language can be selected by pressing the keys "F11" and "F12". After selecting the desired language press key "F14" to save the setting. The symbol (F14) lights green for a moment as a sign of confirmation. Press "ESC" to leave the page.

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7.5 Setting the machine serial number Press key "?" to open the screen page "MENU". The following screen is displayed:

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

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The desired printout language can be selected by pressing the keys "F11" and "F12". After the adjustment press key"F14" to save the setting. The symbol (F14) lights green for a moment as a sign of confirmation. Press "ESC" to leave the page.

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7.6 Teaching distance pulses The distance pulses for the different machine types are already set by default after adjusting the correct machine type. However, due to slippage on the rear axle the recorded distance measurement may deviate from the actually travelled distance. In this case the distances pulses can be adjusted accordingly. Note:

An adaptation of the distance pulses is only possible within a range of +/- 10% of the preset value.


Press key "F8" to open the screen page "Distance pulses". The following screen is displayed:

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Pressing the key "F5" starts the teach mode. The following symbol appears:

Drive a distance of 10 m length in forward and press the key "F6" at the end. The following symbol appears:

After the end of the measuring travel press key "F14" to save the adjustment. The following symbol appears:

Press "ESC" to leave the page. Note:

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If the following symbol is displayed after the end of the travel distance the measured distance pulses are not in the range of +/- 10% of the preset value. Saving is in this case not possible! The measurement must be repeated!

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7.7 Activating the amplitude limitation (only BVC machines) Press key "?" to open the screen page "MENU". The following screen is displayed:

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

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The limitation can now be activated or deactivated by pressing key "F5" ("Limit = 1" or "Limit = 0"). After the desired change press key "F14" to save the adjustment. The symbol lights green for a moment as a sign of confirmation. Press "ESC" to leave the page.

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7.8 Changing the display mode (metric/imperial) Press key "?" to open the screen page "MENU". The following screen is displayed:

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

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The imperial display (mph, °F, etc.) can now be activated or deactivated by pressing key "F5" ("Imperial = 1" or "Imperial = 0"). After the desired change press key "F14" to save the adjustment. The symbol lights green for a moment as a sign of confirmation. Press "ESC" to leave the page.

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7.9 Switching the GPS Receiver Voltage Supply Mode Press key "?" to open the screen page "MENU". The following screen is displayed:

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

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This function enables the GPS Receiver Power Supply to be controlled via MESX, so that the receiver can be switched on and off in a defined way.

The GPS Mode can now be changed over by pressing the "F5"-key: "0" "1" "2"

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OFF ON AUTO

GPS Receiver always switched off GPS Receiver switched on as soon as the ignition is switched on. GPS Receiver switched on as soon as the BCM transmits data to MESX

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8 Possible settings on the BCM05mobile Insert the BCM05mobile into the holder and close the clamp. Switch on the ignition and subsequently the BCM05mobile by holding the yellow switch on the right depressed for approx. 1-2 seconds; wait and confirm the time dialog. For functions beyond the following description, please refer to the BCM05 user manual.

8.1 Reading the software version Select "Configuration" at the right hand edge of the window. The software currently installed in the BCM05mobile is displayed at the top left under the name BOMAG.

8.2 Changing the language Note:

This function is only available from software version 1.37!

Select "Configuration" at the right hand edge of the window. Press the field "Language". A list with the available languages pops up. Choose the desired language and confirm with "Select".

8.3 Changing the unit system (metric/imperial) Open the service window: press the top switch of the three switches at the right hand edge of the touch screen "Configuration" for about 5 seconds, until a roller symbol appears under the software version number at the left hand side of the display. Release the "Configuration" switch and press the symbol within 3 seconds. The touch screens now shows 4 switches near the right hand edge and select the bottom switch "Service". Note:

After this setting the service window must be closed to avoid unauthorized access. Press "Close window" at the bottom right in the service window.

Shift the switch in the "Unit" field to the desired position.

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9 Block diagram BEM


Block diagram

Block diagram

commande

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BOMAG

211

212

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10 Block diagram BTMplus / VARIOCONTROL


Block diagram

Block diagram

BOMAG

commande

printer

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Block diagram

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BOMAG

Block diagram

USB CAN interface

commandes

Printer

BCM 05 (mobile device with card reader)

11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile


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213

214

Description of signals

BOMAG

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X44:9

X44:8

X44:7

X44:6

X44:5

X44:4

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Input exciter position front Analogue input / voltage input 0..8,5 V

Analogue input / voltage input 0..8,5 V

Input acceleration transducer VH20g/HR15g

Interface RS 232 TxD, used for printer control.

)

4,2..4,3 V


Position of front exciter (measured against AGND) Bottom stop ) approx. 2,2 V Neutral position ) approx. 4,25 V Top stop ) approx. 6,6 V

Open circuit voltage (vibration off):

Acceleration signal (measured against AGND)

Measurement not possible!


approx. 0..6 V

PWM signal (100Hz): )

X44:3

Output Evib Display PWM (max. 2.5 A) Interface RS 232 RxD, used for printer control.

Nominal values (voltage / current) approx. 0 V measured against ground (terminal 31)

ESX terminal Signal description X44:1 AGND = Analogue ground: Ground potential for sensors (steering joystick, speed range switch etc.) X44:2

Notes: 1. Wherever the value of 12 V is mentioned in the following text, it refers to the current battery voltage under due consideration of voltage drops in the lines.

12 Description of the signals on the ESX-control


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X44:24

X44:23

X44:22

X44:21

X44:20

X44:19

X44:18

X44:17

X44:16

X44:15

X44:14

X44:13

X44:12

X44:11

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) >6V )approx.0 V ) 12 V ) 2V ) 12 V ) 2V ) 12 V ) 2V ) 12 V ) 2V


Nominal voltage = 8,5 V Permissible range: approx. 7,65..9,35 V This voltage must be measured against AGND.

Vibration on: Vibration off: Button depressed: Button not depressed Button depressed: Button not depressed Button depressed: Button not depressed Button depressed: Button not depressed

Nominal values (voltage / current)


Output voltage supply for sensors This output supplies steering joystick, travel speed range switch, etc. Without this voltage the control cannot work correctly and will switch to override mode (emergency function).

Input vibration 1 On Digital input active high Input button START (option) Digital input active high Input button STOP (option) Digital input active high Input button PRINT (option) Digital input active high Input button CLEAR (option) Digital input active high

ESX terminal Signal description X44:10


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216

Input potential terminal 15 Digital input active high This signal must be present, so that the control can work. Input acceleration transducer VV/VL15g

X44:28

BOMAG

X44:31

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) )

)

)

)

4,2..4,3 V

4,2..4,3 V

4,2..4,3 V

12 V approx.2 V

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Transducer delivers square-wave pulses Frequency depends on machine type.









Input distance transducer

X44:35

Digital input active high

Interface CAN-Bus2 Wire -, is used to communicate with the BCM05.

X44:33 X44:34

X44:32

Analogue input / voltage input 0..8,5 V Input acceleration transducer VV20g/HR15g

X44:30

Analogue input / voltage input 0..8,5 V

Analogue input / voltage input 0..8,5 V Input acceleration transducer VH/VR15g

X44:29

Control switched on Control switched off



Interface CAN-Bus Wire -, is used to communicate with the BOP operating unit. Interface CAN-Bus Wire +, is used to communicate with the BOP operating unit.

X44:26

X44:27






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BOMAG

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X44:52

X44:51

X44:50

X44:49

X44:48

X44:47

X44:46

X44:45

X44:44

X44:43

X44:42

X44:41

X44:40

X44:39

X44:38

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Output valve 1 front PWM digital output (max. 4 A) Output valve 2 front PWM digital output (max. 4 A)

) ) ) )


permissible current range: approx. 0..1,5 A

permissible current range: approx. 0..1,5 A

Engine running / engine is started Engine stopped Vibration on: Vibration off:

X44:37

Input D+ generator Digital input active high Input vibration 2 On Digital input active high





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12 V 0V >6V approx.0 V


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218

Voltage supply for outputs



X44:57

X44:58

X44:59

BOMAG

Mouse port Baby Boards


X44:67

X44:68

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X44:66

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X44:65

X44:64

X44:63

X44:62

X44:61



X44:56

X44:60

approx. 12 V measured against ground

Ground connection electronics

X44:55


approx. 0 V

approx. 0 V

approx. 0 V

approx. 0 V





Nominal values (voltage / current) Measurement not possible! Emergency stop not actuated ) Emergency stop actuated ) 0 V measured against ground


ESX terminal Signal description X44:53 Interface CAN-Bus2 Wire +, is used to communicate with the BCM05. X44:54 Voltage supply for electronics


12 V 0V

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Service Training

Fault codes of the ESX control

13 Fault codes of the ESX control 13.1 Overview Fault code 4501 4540 4601 4620 8000 8250

Status: Author:

008 911 63

Fault description Position controller (exciter potentiometer, valves) Acceleration transducer Internal software errors

05.06.2007 T.Löw / TE

Fault codes of the ESX control

BOMAG

Page 45 of 59

219

220

BOMAG

Status: Author:

05.06.2007 T. Löw / TE

Fault Code Description ESX Control

Errors with error reaction 1 are only warning messages and are NOT stored in the error log!

Note:

5

4

3

2

Description of fault reaction Warning. Fault code is displayed. Signal light in BOP (option) lights in 5 second intervals. Function affected, the faulty function is replaced by an emergency function. Fault code is displayed. Signal light in BOP (option) lights in 5 second intervals. Partial function faulty, the partial function cannot be overridden by an emergency function. After the occurrence of the fault the machine is stopped, after returning the travel lever to neutral the machine can move again. The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible. Fault code is displayed. Signal light in BOP (option) lights in 5 second intervals. Partial function faulty, the partial function cannot be overridden by an emergency function. The machine is no longer able to drive, e.g. because parts of the travel system are defective ) the diesel engine is shut down. Fault code is displayed. Signal light in BOP (option) lights in 1 second intervals. Fatal fault. The function of the control can no longer be guaranteed. Control is switched off. Error code is displayed. Signal light in BOP (option) lights permanently.

Description of fault codes of the ESX control

Fault reaction 1

13.2 Description of fault reactions


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008 911 63

008 911 63


Fault description

Status: Author:

05.06.2007 T. Löw / TE

4 5 0 2 Input exciter potentiometer front The voltage applied to the input is above the specified range (see signal description).

4 5 0 1 Input exciter potentiometer front The voltage applied to the input is below the specified range (see signal description).

Fault code


) Wire breakage in current path ) Current path has short circuit to ground ) No voltage supply to potentiometer ) Fuse FM ? has tripped or wire breakage in voltage supply current path ) Potentiometer defective ) Current path has connection to +12 V / +8,5 V ) Potentiometer not connected to ground ) Potentiometer defective

Possible cause

13.3 Detailed description of fault codes and their possible causes


X44:09

X44:09

Terminal on ESX

Page 47 of 59

5

Input Fault code for reaction diagnose 5


9.1

BOMAG

221

222

BOMAG

) Current path has short circuit to voltage supply ) Current path has non-permitted connection to another current path ) Current path is interrupted ) Current path has short circuit to ground ) Current path has non-permitted connection to another current path ) Current path is interrupted ) Current path has impermissible connection to another current path / ground

4 5 2 6 Output proportional solenoid front Valve for exciter down Output current too low.

4 5 2 8 Output proportional solenoid front Valve for exciter down Fault when calibrating the valve

Status: Author:

05.06.2007 T. Löw / TE

4 5 2 7 Output proportional solenoid front Valve for exciter down Output current too high.


) Current path is interrupted ) Current path has impermissible connection to another current path / ground

4 5 2 2 Output proportional solenoid front Valve for exciter up Output current too high.

4 5 2 3 Output proportional solenoid front Valve for exciter up Fault when calibrating the valve

Possible cause

) Current path has short circuit to voltage supply ) Current path has non-permitted connection to another current path ) Current path is interrupted ) Current path has short circuit to ground ) Current path has non-permitted connection to another current path

Fault description


4 5 2 1 Output proportional solenoid front Valve for exciter up Output current too low.

Fault code


X44:47

X44:47

X44:47

X44:46

X44:46

X44:46

Terminal on ESX

Page 48 of 59

2

2

2

2

2



008 911 63

008 911 63

BOMAG

) Current path has no connection to +12 V / +8,5 V ) Current path connected to ground ) Transducer defective ) Current path has connection to +12 V / +8,5 V ) Current path not connected to ground ) Transducer defective

) Current path has no connection to +12 V / +8,5 V ) Current path connected to ground ) Transducer defective ) Current path has connection to +12 V / +8,5 V ) Current path not connected to ground ) Transducer defective


4 6 0 1 Input acceleration transducer 1 The voltage applied to the input is below the specified range (see signal description).

4 6 0 2 Input acceleration transducer 1 The voltage applied to the input is above the specified range (see signal description).

4 6 0 6 Input acceleration transducer 2 The voltage applied to the input is below the specified range (see signal description).

4 6 0 7 Input acceleration transducer 2 The voltage applied to the input is above the specified range (see signal description).

Status: Author:

05.06.2007 T. Löw / TE

) Supply and ground terminal on exciter potentiometer mixed up ) Valves for "Exciter up" and "Exciter down" mixed up ) MD+ input has 12 V potential, even though the engine is not running ) Air in hydraulic system, hydraulic pressure too low

4 5 3 2 Position controller negative limit reached The exciter does not move to the desired direction or does not move at all.

Possible cause

) Supply and ground terminal on exciter potentiometer mixed up ) Valves for "Exciter up" and "Exciter down" mixed up ) MD+ input has 12 V potential, even though the engine is not running ) Air in hydraulic system, hydraulic pressure too low

Fault description


4 5 3 1 Position controller positive limit reached The exciter does not move to the desired direction or does not move at all.

Fault code


X44:30, or X44:07

X44:30, or X44:07

X44:29, or X44:31

X44:29, or X44:31

X44:09 X44:37

X44:09 X44:37

Terminal on ESX

4606

4606

4601

4601

5000

Page 49 of 59

2

2

2

2

2

Input Fault code for reaction diagnose 5000 2


9.1

223

224

Fault description

BOMAG

Status: Author:

05.06.2007 T. Löw / TE

9 2 0 0 Fault message "Severe internal fault in control" The control has automatically switched off. This 9 9 9 9 fault cannot be rectified on the machine. The control must be immediately replaced. Ct0 Display module has no connection to ESXcontrol.

X44:26 X44:27

) Wire breakage in CAN bus lines ) Short circuit between CAN bus lines ) One or both CAN bus line(s) has (have) connection to 12V or ground ) Incorrect bit rate in display module (nominal value: 125 kBit)


-

X44:26 X44:27-

) Wire breakage in CAN bus lines ) Short circuit between CAN bus lines ) One or both CAN bus line(s) has (have) connection to 12V or ground

-

-

-

Terminal on ESX

-

Possible cause


8 0 0 0 Error message "Incorrect BOP Software version" The software version of the BOP is too old, i.e. various functions cannot be displayed. This fault cannot be repaired on the machine. The BOP needs to be replaced. 8 0 0 1 Fault message "severe software fault in control" This fault cannot be repaired on the machine. 8 9 9 9 The control must be immediately replaced. 9 0 0 0 Error message "Communication via CAN bus disturbed" 9 1 9 9 The modules controlled via the CAN bus cannot be addressed by the main control (ESX). The respective machine functions are not available

Fault code


-

-

-

-

Page 50 of 59

-

5

2

5



008 911 63

008 911 63

Description of Control Input Codes

BOMAG

Status: Author:

1011

1010

05.06.2007 T. Löw / TE

Display value = travel distance in 10 cm

Transducer for distance pulses The distances pulses summarized since starting the machine are displayed. If the machine has travel a longer distance in reverse than in forward, the value will be negative. Travel speed Shows the actual speed. Parameter "Show distance pulses per 10m" Eeprom Parameter is displayed Parameter "Invert travel direction" Eeprom Parameter is displayed

1002

1003

1000 ) 0000 ) 000I )

Travel direction Displays the travel direction derived by the control from the "transducer for travel direction".

1001


Depending on the selected machine type, e.g. 5896 for BW177 BVC 0000 ) Direction signal is not inverted 000I ) Direction signal is inverted

Display value = max. speed in km/h

Forward travel detected Neutral position Reverse travel detected

Display values 0000 ) 0V 0001 ) 12 V

Description of display function Transducer for travel direction Show status of transducer.

Input code 1000

14.1 Travel system

14 Input codes for ESX control (only via BEM display module)


Page 51 of 59


9.1

225

226

BOMAG

Status: Author:

Description of display function Input light switch The status of the lighting is displayed.


Display values 0000 ) Light OFF 0001 ) Light ON

Display values 0000 ) Vibration OFF 0001 ) Vibration ON 0000 ) Vibration OFF 0001 ) Vibration ON 0000 ) Vibration OFF 0001 ) Vibration ON


Description of display function Vibration status general The status of vibration is displayed. Vibrations status low amplitude The vibration status for low amplitude is displayed. Vibrations status high amplitude The vibration status for high amplitude is displayed.

05.06.2007 T. Löw / TE

Input code 3010

14.3 Light

3002

3001

Input code 3000

14.2 Vibration


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008 911 63

008 911 63

Description of display function Acceleration transducer 1 Shows the voltage of transducer 1. Acceleration transducer 2 Shows the voltage of transducer 2.

Status: Author:

Description of display function Input MD+ Show status of diesel engine.

05.06.2007 T. Löw / TE

Input code 5000

14.5 Diesel engine

4606

Input code 4601

14.4 Acceleration transducer



Display values 0000 ) Engine OFF 0001 ) Engine ON

Display value = voltage in V

Display values Display value = voltage in V


Page 53 of 59


9.1

BOMAG

227

228

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Display values


Description of display function Shows the adjusted machine type Switches on function „Set machine type“ Confirms entered machine type Pre-select machine type

05.06.2007 T. Löw / TE

Input code 7000 7010 7011 7500..7699

14.6 Setting the machine type


Page 54 of 59


BOMAG

008 911 63

008 911 63

Status: Author:


Display values Display value 7 6 0 0 see adjustment instructions


Description of display function Switch on function "Invert travel direction" Inverts the actually adjusted travel direction

05.06.2007 T. Löw / TE

Input code 7600 7601

14.7 Parameter change


Page 55 of 59


9.1

BOMAG

229

9.1



15 Terminology in connection with ESX Short circuit A direct, unwanted connection between two different cables or between machine and cables. Examples: Two lines rub against each other until the insulation has worn off. A conductive line rubs off the insulation at the vehicle ground.

Wire breakage This generally means that a connection is interrupted. Possible reasons may be: Line: torn (not necessarily visible from outside) chafed chafed mostly in connection with a short circuit to ground

Terminal, cable lug loosened, slipped off broken off, corroded, socket / plug faulty

Status: Author:

230

05.06.2007 T.Löw / TE

Terminology

BOMAG

Page 56 of 59

008 911 63

9.1


Service Training MESX Short circuit to ground Line, terminal has direct connection to vehicle ground, often in connection with wire breakage

Digital There are only two permissible states, e.g. switched on or off; lamp on / off; current flows / does not flow; valve open / closed (black-white valve)

Analogue In contrast to Digital many conditions are permitted within a certain range. For instance room temperature 0° to 40°; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 Ω to 300 Ω; valve 0% to 100% opened (proportional valve)

Status: Author:

008 911 63

01.04.2005 T.Löw / TE

General terminology

BOMAG

Page 57 of 59

231

9.1


Service Training MESX Control Controlling describes the process during which an input value influences a distance (the value to be controlled), following a fixed command. For this purpose all possible interfering factors (e.g. temperature, humidity ...) must be known.

disturbance variable (z) input (w)

Controll

a

distance

Output (y)

Closed loop control Closed loop control is a process during which a value, the closed loop control value (e.g. pressure), is continually measured and compared with a nominal value (guide value). The result of this comparison will affect the closed loop control value, thereby adapting the closed loop control value to the guide value. This sequence occurs in a closed circuit, the co-called closed loop control circuit. disturbance variable (z)

input (w)

+

e

u

Controll

distance

Output (y)

-

Marking Operating path:

Closed loop control closed (closed loop control circuit) Measurement and Value to be adjusted is comparison of value to measured and compared. be adjusted: Reaction to faults Counteracts to all faults (generally): targeting the system to be controlled. Technical expense: Low effort: Measurement of the value to be controlled, comparison of nominal and actual value, power amplification Performance in For unstable systems closed unstable systems loop controls must be used.

Status: Author:

232

05.06.2007 T.Löw / TE

Control open (control chain) Values to be controlled are not measured and compared. Does not respond to unknown faults High expense if many faults have to be considered, low expense if not faults occur. In unstable systems controls cannot be used.

Terminology

BOMAG

Page 58 of 59

008 911 63

9.1


Service Training MESX Current and voltage measurement

Ohm’s law: U = Voltage R = Resistance I = Current

U =R∗I U I= R U R= I

Plausibility check The control (ESX) runs a plausibility check on all inputs. This means the control checks permanently whether certain state combinations are permitted; e.g. travel lever position forward and reverse will cause an fault message, because this condition is normally not possible. Override / emergency operation In the event of a major fault the control will switch off and the override function will take over. This has the effect that the machine can still be moved and steered with reduced speed. Steering and dozer blade movements are only possible with a constant speed. (see also: page 34, "") GND - AGND Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional analogue ground, which is only to be used for sensors. (see description of the signals on the ESX-control) PWM – digital output Certain outputs on the ESX are designed as so-called PWM – digital outputs. This means that these outputs are special current outputs. Here it is possible to measure a current, but no voltage. These outputs are used to trigger proportional valves.

Status: Author:

008 911 63

01.04.2005 T.Löw / TE

General terminology

BOMAG

Page 59 of 59

233

9.2 9.2

234

Electric module K04

Electric module K04

BOMAG

008 911 63

008 911 63

BOMAG

235

9.2

236

Electric module K04

BOMAG

008 911 63

9.2

Electric module K04

008 911 63

BOMAG

237

9.3 9.3

238

Heating/air conditioning control


BOMAG

008 911 63

008 911 63

BOMAG

239

9.3

240


BOMAG

008 911 63

9.3


008 911 63

BOMAG

241

9.3

242


BOMAG

008 911 63

9.3


008 911 63

BOMAG

243

9.3

244


BOMAG

008 911 63

10 Speedometer Module

008 911 63

BOMAG

245

10.1

Speedometer module

10.1 Speedometer module

Fig. 1 Speedometer module

Description of function With the programmable module BM UPM the software realizes a speedometer function. To ensure that the tachometer function is not only realized for one special roller, there is a possibility to adapt the module to any machine with the help of a self-teaching mode. ●

●

●

Whenever the module is switched on the system runs a self-test by passing through the entire display range in both directions. The display self-test takes approx. 15 seconds. After this the module changes to measuring mode. The frequency of the travel pulses of the roller is detected and converted to a proportional output voltage that triggers the display. The output signal for the display is a PWM-signal.

Manual testing of the speedometer When the module is in learning mode a manual display test can be performed via the input "Test". For this purpose the input "IN" must be energized with 12 Volt, whereupon the speedometer is constantly triggered with 3 Volt.

246

BOMAG

008 911 63

10.1

Speedometer module

Pin-no. module

Pin name

Description

Test

E_ANZEIGENTEST

Input HIGH active: Activate manual display test

IN

E_WEGIMPULSE

Input: Path pulses

Learn

E_LERNMODUS

Input: HIGH active: Activate teach mode

OUT -

Display -

Output: Ground connection for speedometer

OUT +

Display +

Output: Output voltage for speedometer

GND (2X)

Ground

Input: Module ground connection

15/45 (2X)

15/54

Input: Module voltage supply

Teaching the module In self-teach mode the number of arriving path pulses is detected at the input (IN). The number of recorded pulses is referred to as pulse number per 10 or 18 m (machine dependent) travel distance of the roller. Connect the ground cable (-).

●

Connect the sensor signal (speed sensor) to frequency input (IN).

●

Install a cable bridge from terminal "15/54" to the connection "Teach".

●

Connect potential "Ignition / 15" to connection "15/ 54".

●

Switch on the ignition, start the engine and travel a distance of exactly 10 m.

●

Caution BW24RH, BW27RH, C550H and C560H = travel 18 meters. !

All other machines = travel 15 meters.

i

Note

If the module is in teach mode the LED on output "OUT +" will flash with the frequency of the path pulses arriving at input (IN). ●

●

Disconnect the cable bridge from "Teach" to "15/ 54“. Switch the ignition off and on again (Reset).

The module has now learned the pulses of the speed sensor. ●

Connect the speedometer (0 to 6 Volt) to "OUT +" and "OUT –“.

008 911 63

BOMAG

247

10.1

248

Speedometer module

BOMAG

008 911 63

11 Service Training

008 911 63

BOMAG

249

250

BOMAG

008 911 63


008 911 63

BOMAG

251

11.1

252

Service Training

BOMAG

008 911 63

11.1

Service Training

Service Training

Single Drum Rollers BW 211 / 212 / 213 D- 40

11/2005

008 911 63

BOMAG

253

11.1

Service Training

Service Training Table of contents Travel system

E1

Travel pump

E3

Control

E6

Charge pressure relief valve

E 11

High pressure relief valve

E 12

Pressure override

E 14

Axle drive motor

E 16

Drum drive motor

E 20

Test and adjustment points, travel system

E 25

Trouble shooting in travel system

E 29

BW 211 / 212 / 213 D-40

254

BOMAG

008 911 63

11.1

Service Training

Service Training Vibration

F1

Vibration pump

F3

High pressure relief valves

F6

Control

F7

Charge pump

F8

Vibration motor

F9

Drum

F 12

Test and adjustment points, vibration system

F 14

Trouble shooting in vibration system

F 16

Steering

G1

Steering pump(s)

G2

Steering valve

G4

Articulated joint

G6

Measuring and adjustment points

G8

Trouble shooting steering system

G9

BW 211 / 212 / 213 D-40

008 911 63

BOMAG

255

256

BW 211 / 212 / 213 D-40

BOMAG

25 bar

2

Charge pressure from hydraulic oil filter

Charge pressure to vibration pump

3

4

Travel pump Sauer 90 R 075

Servo control


1

2

3

6

5

4

5

M2

7

6

T3

M4

9

8

7

M3

from brake valve

Axle drive motor Sauer 51 D 110

Rear axle

Multi function valve

Fig. 1: Hydraulic diagram travel system BW 211 / 212 / 213 D-40

1

ø 0.81

ø 0.8

M4 M5

Travel circuit

ø 0.6

ø 0.6

B

A

9

Drum drive motor Poclain MSE 18 1C

Flushing valve

Speed range valve

8

L

from speed range valve


Service Training

-E1-

008 911 63

11.1

Service Training

Service Training The travel system of the single drum rollers is a closed hydraulic circuit and consists mainly of: • travel pump with control and safety elements, • Drum drive motor without brake, • axle drive motor, • rear axle with brake, • charge pump (also for vibration circuit), • hydraulic oil filter (in charge circuit), • hydraulic oil cooler with thermostat • hydraulic lines. Travel pump and vibration pump are connected to a tandem pump unit. The charge pump is an integral part of the vibration pump. The travel pump is the first pump section, flanged directly to the flywheel side of the diesel engine. The pump delivers the hydraulic oil to the travel motors for drum and axle drives. The multi-function valves in the pump limit the pressure in the closed circuit to (Δp = 400 bar between low and high pressure sides). A flushing valve in the axle drive motor (and in the Sauer drum drive motor 51 C 110) flushes a certain oil quantity out of the closed circuit when the machine is driving (Δp between the two sides of the closed circuit). Leakage in the individual components of the circuit are replaced by the charge circuit through the boost check valves in the travel pump. The charge pumps draw hydraulic oil out of the tank and deliver it through the hydraulic oil filter and the charge pressure relief valve to the boost check valves in travel and vibration pumps. The machine is fitted with two charge pumps. One pump is integrated in the vibration pump and the other pump is driven by the auxiliary output of the engine and serves primarily as steering pump. The charge circuit provides the oil for the charge system and the control functions in the closed circuits for travel and vibration drive, as well as to release the parking brakes and to change the travel speed ranges. The travel motor in the axle is desired with variable displacement. The operator can choose from two different travel speed ranges.

BW 211 / 212 / 213 D-40

008 911 63

-E2-

BOMAG

257

11.1

Service Training

Service Training Travel pump The travel pump is a swash plate operated axial piston pump with variable displacement, most suitable for applications in hydrostatic drives with closed circuit. M4

M5

2

A

25 bar

3

from/to Travel motor

4

1

from/to Travel motor

B Charge pressure to vibration pump Charge pressure from hydraulic oil filter

Fig. 2: Hydraulic diagram of travel pump 1

Pump drive

3


2

Servo control

4

Multi-function valves

BW 211 / 212 / 213 D-40

258

-E3-

BOMAG

008 911 63

11.1

Service Training

Service Training The travel pump delivers the hydraulic oil to the motors on rear axle and drum. The pump flow is proportional to the pump speed (output speed of diesel engine) and the actual displacement (swashing angle of swash plate) of the pump.

7

1

2 3

4

6

5

Fig. 3: Travel pump 1

Control lever

5

Cylinder block

2

Drive shaft

6

Valve plate

3

Swash plate bearing

7

Control piston

4

Pistons with slipper pads

With the servo control the swashing angle can be infinitely adjusted from neutral position (0) to both maximum displacement positions. When altering the swash plate position through the neutral position, the oil flow will be reversed and the machine will drive to the opposite direction. All valves as well as the safety and control elements needed for operation in a closed circuit, are integrated in the pump. Note: These machines are equipped with two charge pumps.

BW 211 / 212 / 213 D-40

008 911 63

-E4-

BOMAG

259

11.1

Service Training

Service Training Cross-sectional view of travel pump

2 4 5

1

3 6 7

9

10

8

11 Fig. 4: Cross-sectional view of travel pump 1

Retainer for swash plate

7

Swash plate bearing

2

Sliding block

8

Swash plate guide

3

Control piston

9

Swash plate

4

Servo arm

10

Swashing lever

5

Servo valve

11

Charge pump (only in vibration pump)

6

Feedback device

BW 211 / 212 / 213 D-40

260

-E5-

BOMAG

008 911 63

11.1

Service Training

Service Training View of the rotating group 1 2

5

4

3

Fig. 5: Travel pump, view of the rotating group 1

Working pistons

2

Slipper pad

3

Pre-tensioning spring

4

Cylinder block

5

Drive shaft

BW 211 / 212 / 213 D-40

008 911 63

-E6-

BOMAG

261

11.1

Service Training

Service Training Description of function

2

4

3

5

6

1

8

6

7

Fig. 6: Function of travel pump 1

Drive shaft

5

Cylinder block

2

Drive shaft bearing

6

Multi-function valves

3

Swash plate

7

Charge pump (only in vibration pump)

4

Pistons with slipper pads

8

Valve plate

The drive shaft (1) is directly driven by the diesel engine via an elastic coupling. the shaft turns the tightly connected cylinder block (5). With the rotation of the drive shaft (1) the cylinder block (5) moves the working pistons (4). The slipper pads of the working pistons abut against the swash plate (3).

BW 211 / 212 / 213 D-40

262

-E7-

BOMAG

008 911 63

11.1

Service Training

Service Training When moving the swash plate out of neutral position, the working pistons will perform a stroke movement with every rotation of the cylinder block. The slipper pads are hydrostatically balanced and are retained on the sliding face of the swashing cradle by a retaining device. During a full rotation of the cylinder block each working piston will move through the bottom and top dead centre back to the initial position. During this movement each piston performs a complete stroke. During the piston stroke each piston draws in a certain quantity of oil from the low pressure side of the hydraulic circuit and presses it out into the high pressure side.

BW 211 / 212 / 213 D-40

008 911 63

-E8-

BOMAG

263

11.1

Service Training

Service Training Tandem pump

BW 211 / 212 / 213 D-40

264

-E9-

BOMAG

008 911 63

11.1

Service Training

Service Training Tandem pump, connections and adjustment points

32

Thermostat housing

Fig. 7: Connections and adjustment points

BW 211 / 212 / 213 D-40

008 911 63

- E 10 -

BOMAG

265

11.1

Service Training

Service Training 1

Control solenoid, high frequency (vibration pump)

2

Control solenoid, low frequency (vibration pump)

3

Multi-function valve 400 bar (charging and pressure limitation), travel system

4

Charge pressure to solenoid valve for brakes and speed range selector, charging vibration

5

Multi-function valve 400 bar (charging and pressure limitation), travel system

6 7

Port L, leak oil to vibration pump

8

Travel lever

9

Pressure test port, pilot pressure

10

High pressure port B, high pressure reverse

11

Charge pressure relief valve, 26 bar

12

Adjustment screw, low frequency

13

Port L2, leak oil to tank

14

Pressure test port MB, high frequency

15

Pressure test port MA, low frequency

16

High pressure port A, low frequency

17

High pressure port B, high frequency

18

End plate with integrated charge pump (only in vibration pump)

19

Port L2

20

Adjustment screw, high frequency

21

Port D, charge pressure to filter

22

Multi-function valve 345 bar (charging and pressure limitation), vibration high frequency

23

Port S, suction line between hydraulic oil tank and charge pump

24

Multi-function valve 345 bar (charging and pressure limitation), vibration low frequency

25

Charge pressure relief valve, vibration pump (blocked)

26

Port E, charge oil from travel pump

27

Port L1, leak oil port to travel pump

28

Pressure test port MB, high pressure reverse

29

Charge oil from filter

30

Pressure test port MA, high pressure forward

31

High pressure port A, high pressure forward

32

Adjustment screw for mechanical neutral position, vibration

Thermostat housing: 33, 34, 35, 36 Leak oil port 37

cooler inlet

BW 211 / 212 / 213 D-40

266

- E 11 -

BOMAG

008 911 63

11.1

Service Training

Service Training servo control The servo control (mechanical – hydraulic displacement control) converts the mechanical input signal of the pump control lever into a position controlling output signal. This position controlling signal determines the swashing angle of the swash plate (the displacement of the pump), as well as the swashing direction (flow direction of the pressure fluid). The flow quantity delivered by the variable displacement pump is proportional to the value of the mechanical input signal. A mechanical feedback device ensures the fixed correlation between the mechanical input signal and the swashing angle of the swash plate (displacement of pump). Servo cylinder

Control piston

Sliding block

Servo arm

Fig. 8: Control piston A mechanical safety device (spring) makes sure that a too fast lever movement will not cause any damage to the servo control. The pump displacement can be adjusted by actuating the pump control lever via travel lever and travel control cable. This requires only very little manual forces and only a slight movement of the lever.

Since the control is spring centred, the swash plate will automatically return to neutral position under the following conditions, thereby interrupting the oil flow and braking the machine:

BW 211 / 212 / 213 D-40

008 911 63

- E 12 -

BOMAG

267

11.1

Service Training

Service Training • when shutting the engine down, • if the external control cable comes loose, • if the pressure in the charge circuit drops below a certain value.

BW 211 / 212 / 213 D-40

268

- E 13 -

BOMAG

008 911 63

11.1

Service Training

Service Training Multi-function valves High pressure limitation Pumps of series 90 are equipped with so-called multi-function valves, which activate a pressure override and a pressure relief valve, one after the other.

1

2

7 3 A

6

5

B 4 7

2 Fig. 9: Multi-function valves 1

to the control

6

Drive shaft

2

Multi-function valve

7

to the control piston

3

Charge pump

8

to the control piston

4


A

Port A

5

Pilot pressure relief valve

B

Port B

If the adjusted pressure is reached, the pressure override will move the swash plate quickly back towards neutral position, thereby limiting the system pressure. The average response time is less than 90 ms.

BW 211 / 212 / 213 D-40

008 911 63

- E 14 -

BOMAG

269

11.1

Service Training

Service Training In case of a very quick increase in pressure (pressure peaks) the system utilizes the function of the pressure relief valves as a protection for the hydraulic systems. In such a case the pressure override works as a pre-control unit for the control piston of the pressure relief valve. The pressure level of the high pressure relief valve is higher than the pressure level of the pressure override. The high pressure relief valves will only respond if the pressure override is not able to swash the pump back quick enough in case of sudden pressure peaks.

3

2

4

5

1

6 9

7 8

10 11

Fig. 10: Multi-function valve, details 1

Reducing fitting

7

Check valve

2

Hydraulic by-pass piston

8

Pressure limitation

3

Spring plate

9

Spring

4

Spring

10

By-pass housing

5

High pressure relief valve

10

By-pass sleeve

6

Valve seat

Pressure override and high pressure relief valve are both parts of the multi-function valve, which is screwed into the pump. With its possibility to swash the swash plate inside the pump back within a period of 90 ms, the pressure override makes sure that the high pressure relief valves will only respond in exceptional cases. This protects the hydraulic circuit against overheating and reduces the load on the diesel engine. Note: The multi function valves must be tightened with a torque of 89 Nm!

BW 211 / 212 / 213 D-40

270

- E 15 -

BOMAG

008 911 63

11.1

Service Training

Service Training Charge pressure relief valve The machines are equipped with two charge pumps, one driven by the auxiliary output of the engine (steering and charge pump) and the other pump is integrated in the vibration pump. The pressures of both pumps are limited by a charge pressure relief valve. The charge pressure relief valve is a direct acting valve with fixed adjustment and is part of the safety elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the adjusted value (26 bar). The charge circuit compensates leaks and flushing quantities in the closed travel and vibration circuits and provides the necessary pressure to control the travel and vibration pumps and to operate the multidisc brakes in the travel drives. Since feeding of cool and filtered oil is only possible in the low pressure side of the closed circuit, the pressure in the low pressure side is almost identical with the pressure in the charge circuit. When parking the machine on level ground with the engine running, the pressures in both sides of the closed circuit are identical (charge pressure).

BW 211 / 212 / 213 D-40

008 911 63

- E 16 -

BOMAG

271

11.1

Service Training

Service Training Flushing valve 2

1 Fig. 11Cross-section of flushing valve 1 Flushing spool 2 Flushing pressure relief valve The flushing valve is integrated in the axle drive motor. In case of a pressure increase in one of the two sides of the closed circuit the flushing valves have the function to flush a certain quantity of oil out of the low pressure side. The valve is operated by the pressure difference between the two sides of the closed circuit (A and B). If the pressure in one side is higher than in the other, this pressure will move the valve out of neutral position against the neutral setting spring. Oil can now flow out of the low pressure side. This oil flows through a thermostat valve back to the tank. The oil quantity flushed out of the closed circuit is immediately replaced by oil entering from the charge circuit through the corresponding boost check valve (part of the multi-function valve). In this way the closed travel circuit is permanently supplied with cool and filtered oil and the temperature household of the hydraulic system is maintained at a permissible level.

BW 211 / 212 / 213 D-40

272

- E 17 -

BOMAG

008 911 63

11.1

Service Training

Service Training Axle drive motor, The axle drive motor is a swash plate controlled axial piston motor of series 51 D 110 with variable displacement.

5

8

7

6 9

1

11 4

2

10

3 Fig. 12: Axle drive motor, 1

Control piston

7

Cylinder block

2

Flushing valve

8

Universal joint

3

Control

9

Output shaft

4

Spindle with ball

10

Output shaft bearing

5

Qmin-screw

11

Working piston

6

Valve plate

BW 211 / 212 / 213 D-40

008 911 63

- E 18 -

BOMAG

273

11.1

Service Training

Service Training The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle between cylinder block and output shaft. With a large angle position the motor works with maximum displacement, slow speed and high torque. When changing the swash plate position to minimal angle the motor works with minimum displacement, high speed and low torque. The displacement is changed by a control piston, which is tightly connected with the valve segment. Changing of the displacement is accomplished by pressurizing the corresponding control piston side with pressure oil from the charge circuit via a 4/2-way solenoid valve. Function The motor is connected with the travel pump via the high pressure ports A and B. The hydraulic oil flows under high pressure through the corresponding port to the back of the working pistons. Since the working pistons are arranged under an angle to the output shaft, the pressurized pistons will perform a stroke movement, thereby causing a rotation of the output shaft. Once the respective piston has passed its dead centre (max. extended position), it will change to the low pressure side. As the rotation progresses, the piston will move back into the cylinder bore. Oil is thereby displaced out of the cylinder chamber through the low pressure side back to the pump. The synchronizing shaft with roller surfaces ensures uniform rotation of output shaft and cylinder block. The ball joints of the pistons run in journal bearings, which are pressed into the outer shaft. For the connection between output shaft and pistons no other parts are required. The output shaft runs in two tapered roller bearings.

BW 211 / 212 / 213 D-40

274

- E 19 -

BOMAG

008 911 63

11.1

Service Training

Service Training Rear axle Releasing the axle drive brake manually (on both axle drive designs) For manual releasing of the brakes on the rear axle you should proceed as follows:

Fig. 13: Manual releasing of rear axle brakes • Slacken the counter nut (Fig. 14, Pos. 1) and back it off by approx. 8 mm. • Turn the brake releasing screw (2) in against the stop. • To release the brake tighten the screw for max. 1 complete turn. Attention! Turn the screws on both sides in uniformly (alternately by 1/4 of a turn) • Repeat this procedure on the opposite side of the axle.

BW 211 / 212 / 213 D-40

008 911 63

- E 20 -

BOMAG

275

11.1

Service Training

Service Training Front drum drive motor: Radial piston motor MSE 18 2 CX On single drum rollers of series D-40 the drum is driven by a hydraulic radial piston motor. These drum drive motors consist of three housing parts, the flat distributor, the cylinder block with the working pistons and the output shaft.

2

3 4

1

43090070

6

5

4

5

Fig. 14: Drum drive motor 1

Drive shaft with output flange

2

Piston with roller

3

Oil distributor

4

Cylinder block

5

Cam ring

6

Bearing plate

The housing consists of:

BW 211 / 212 / 213 D-40

276

- E 21 -

BOMAG

008 911 63

11.1

Service Training

Service Training • bearing section (drive shaft bearings), • torque section (cam race) and • oil distributor. Pressure oil flows through the flat distributor to the working pistons in the cylinder block. This pressure oil presses the working pistons with the rollers against the cam race of the torque section and forces the rollers to roll along the cam race. This transforms the axial movement of the pistons to a radial movement of the cylinder block. The cylinder block transfers this rotation via a splined connection to the output shaft. The output shaft runs in two tapered roller bearings. It transfers the rotary movement via the drive disc and the rubber elements to the drum. The function of the radial piston motor is described hereunder. The piston positions described in this explanation can be seen in the related illustration. The movement of a piston along the cam race must be examined in several phases during a full rotation: 5

1 4

2 3

Fig. 15: Function of the radial piston motor

BW 211 / 212 / 213 D-40

008 911 63

- E 22 -

BOMAG

277

11.1

Service Training

Service Training Piston position 1: The oil enters into the oil distributor under pressure, flows through the distributor and presses against the piston. The rotation starts at this point. The pressure applied to the back of the piston moves the roller along the cam and causes a rotation of the cylinder block. Piston position 2: At this point the opening cross-section for the oil flow to the piston has reached its maximum size. The piston continues his travel along the cam race towards the valley between two cams. As the movement continues the opening cross-section for the oil supply decreases. Piston position 3: Once the piston has reached the bottom of the valley, the oil flow to the piston is interrupted. The piston is no longer driven. It has reached its dead centre. Now another piston must be driven to move the first piston out of the dead centre. Piston position 4: Other driven pistons now move the first piston out of the dead centre. The oil behind the piston is now connected with the low pressure side and the reverse movement of the piston presses the oil back to the pump. Piston position 5: The pumping movement of the motor back to the pump comes to an end, the connecting bore between cylinder chamber and low pressure side closes again. The piston will now reach its second dead centre position. This point is the start of a new working cycle. Reversing the oil flow reverses also the rotation of the motor. The output shaft runs in two tapered roller bearings. It transmits the rotary movement via the drive disc and the rubber elements to the drum.

BW 211 / 212 / 213 D-40

278

- E 23 -

BOMAG

008 911 63

11.1

Service Training

Service Training Travel circuit:

Drum drive with radial piston motor

2 3

1

4

8

6

1

7 5

High pressure

Tr

e av

i ld

tio c e r

Low pressure Charge pressure

n 1 2 3 4 5 6 7 8

Travel pump Vibration pump Travel lever Hydraulic oil filter Rear axle Axle drive motor Drum drive motor Hydraulic oil tank

Leak oil (case pressure)

Fig. 16: Single drum rollers D-40, travel circuit, hose installation

BW 211 / 212 / 213 D-40

008 911 63

- E 24 -

BOMAG

279

11.1

Service Training

Service Training Brake control:

Travel motor in axle

Brake valve

Charge pressure Brake releasing pressure Leak oil

Fig. 17: Brake circuit

BW 211 / 212 / 213 D-40

280

- E 25 -

BOMAG

008 911 63

11.1

Service Training

Service Training Travel drive, components and test points Travel pump:

3

2 2 Pos.

Designation

1 2 3

Test port, forward High pressure port, forward Charge pressure port

1 Pos. in wiring diagram

BW 211 / 212 / 213 D-40

008 911 63

1 Pos. in hydraulic diagram

Measuring values

10, MD 10, A 7, MA

max. 426 bar 26 bar

- E 26 -

BOMAG

281

11.1

Service Training

Service Training Travel pump: right hand side

3 2

1 Pos.

Designation

1 2 3

Test port, reverse High pressure port, reverse Travel control (travel control cable)

Pos. in wiring diagram

BW 211 / 212 / 213 D-40

282

3

Pos. in hydraulic diagram

Measuring values

10, MC 10, B

max. 426 bar

- E 27 -

BOMAG

008 911 63

11.1

Service Training

Service Training Front travel motor, without brake (radial piston motor)

1

2 2

1 45

3 4

6 3

Pos.

Designation

1 2 3 4

High pressure port, forward High pressure port, reverse Cross-flushing of travel pump T1 Leak oil port


Measuring values

12, L 12, R 12 12, 1

BW 211 / 212 / 213 D-40

008 911 63


- E 28 -

BOMAG

283

11.1

Service Training

Service Training Rear travel motor: Axle motor

1 4 2

3

6

5

7

Pos.

Designation



Measuring values

1

Solenoid for speed range selector valve

Y31

14

Motor Qmax--depressurized, Motor Qmin--26 bar

2 3

Flushing valve High pressure port, drum drive motor forward High pressure port, drum drive motor reverse High pressure from travel pump forward High pressure from travel pump reverse Qmin- setscrew

4 5 6 7

14 14, A 14, B 14, A 14, B 14

BW 211 / 212 / 213 D-40

284

- E 29 -

BOMAG

008 911 63

11.1

Service Training

Service Training Brake valve

11

Pos.

Designation



Measuring values

1

Brake valve

Y 04

08,

open, 12V closed, de-energized

BW 211 / 212 / 213 D-40

008 911 63

- E 30 -

BOMAG

285

11.1

Service Training

Service Training Travel lever console

BW 211 / 212 / 213 D-40

286

- E 31 -

BOMAG

008 911 63

11.1

Service Training

Service Training Travel lever

1

2

Pos.

Designation


1

Initiator for backup alarm

B14

2

Initiator for brake

B13

BW 211 / 212 / 213 D-40

008 911 63


Measuring values

0 / 12V, normally closed Normally closed, opened in braking position 0/12V

- E 32 -

BOMAG

287

11.1

Service Training

Service Training Trouble shooting The following trouble shooting chart contains a small selection of possible faults, which may occur during operation of the machine. The fault list is by no means complete, however, the fault table is based on the experience of the central service department, i.e. the list covers almost all faults that have occurred in the past. Procedure: The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.

SYMPTOMS

TROUBLE SHOOTING TRAVEL SYSTEM BW 211 / 212 / 213 D-40

Machine does not drive (forw. and reverse) Machine drives to one direction only Machine travels with travel lever in 'Neutral' Max. travel speed not reached Hydraulic oil overheating

The numerical values specified in the table indicate the probability of the fault cause and thereby the recommended trouble shooting sequence, based on our latest field experience.

POSSIBLE CAUSES Brake valve (electric/mechanical/hydraulic) Brake in axle-drive motor (mechanical/hydraulic) Travel speed range switch position /defective/wiring Charge pump / charge pressure relief valve(s) dirty/defective Pump control (servo control) Pressure override/ travel pump high pressure limitation dirty/out of adjustment/defective Adjustment of travel cable Travel pump mechanical neutral Travel pump(s) defective Axle drive motor control valve (electric / mechanical / hydraulic) Flushing valve axle drive motor seized Travel motor(s) defective Hydraulic oil cooler soiled (internally/externally) Thermostat (hydraulics) soiled/jammed/defective Clutch- Dieselmotor-Pumpe Dieselmotor

1 2

2 3 1 2

3

2 1 2 3 3 2

3 3 1 2 3 3 3 2 1 2

3 3 3

3 1 2

2 1

BW 211 / 212 / 213 D-40

288

BOMAG

008 911 63

11.1

Service Training

Service Training Vibration system The vibration system of the single drum rollers of generation D-40 works with two frequencies and two amplitudes. This enables perfect adaptation of the machine to various types of soil and different applications. The vibration drive is a closed hydraulic circuit. The circuit consists of: • the vibration pump, • the vibration motor and • the pressure resistant connecting hoses to release the brake

from charge pump via Travel pump D

L2

M3

E

Charge oil Vibration pump

N

Block A

M1 M2 S B

1

2

M4

M5

Fig. 1: Vibration circuit 1 2

Vibration pump Vibration motor

BW 211 / 212 / 213 D-40

008 911 63

-F1-

BOMAG

289

11.1

Service Training

Service Training Vibration pump and travel pump are joined together to a tandem pump unit. This tandem unit is directly driven by the diesel engine. When operating a 4/3-way solenoid valve on the pump control the pump is actuated out of neutral position to one of the two possible displacement positions, pilot oil from the charge circuit is guided to one of the two control piston sides. The swash plate inside the pump will swash to the corresponding side and the pump will deliver oil to the vibration motor. The vibration motor starts and rotates the vibrator shaft inside the drum. When altering the position of the swash plate through the neutral position to the opposite side, the oil flow will change its direction and the vibration motor will change its sense of rotation. Since the end stops for the swash plate are set to different swashing angles to both directions, the angle for the piston stroke is also different to both sides. This angle influences the length of the piston stroke and thereby the actual displacement of the pump. • Large angle = high displacement = high vibrator shaft speed (frequency) • Small angle = low displacement = slow vibrator shaft speed (frequency) The eccentric weights on the vibrator shaft are fitted with additional change-over weights. Depending on the sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic weights. This results in the following constellations: • Basic weight + change-over weight = high amplitude • Basic weight - change-over weight = low amplitude In order to achieve effective compaction results the vibration system is designed in such a way, that high amplitude is coupled with low frequency and low amplitude with high frequency.

Fig. 2:

BW 211 / 212 / 213 D-40

290

-F2-

BOMAG

008 911 63

11.1

Service Training

Service Training Vibration pump Similar to the travel pump the vibration pump is also a swash plate operated axial piston pump with variable displacement for operation in a closed circuit. The displacement of the pump is proportional to the engine speed and the chosen displacement. When actuating the swash plate out of neutral position the flow quantity to the chosen direction will increase from ”0” to the maximum value. When altering the position of the swash plate through the neutral position to the opposite side, the oil flow will change its direction and the vibration motor will change its sense of rotation. All valves and safety elements for operation in a closed circuit are integrated in the pump. Releasing the brake

from charge pump via Travel pump

Charge oil Vibration pump D

L2

M3

E

1 Vibration pump 2 Charge pump

N

3 High pressure limitation

Block

4 4/3-way solenoid valve A M1 M2

S

B

M4 M5

Fig. 3: Hydraulic diagram vibration pump

BW 211 / 212 / 213 D-40

008 911 63

-F3-

BOMAG

291

11.1

Service Training

Service Training Function

1

2

6

4

5

3

Fig. 4Cross-section of vibration pump 1

Servo piston

2

Working pistons

3

Charge pump

4

Valve plate

5

Roller bearing

6

Swash plate

BW 211 / 212 / 213 D-40

292

-F4-

BOMAG

008 911 63

11.1

Service Training

Service Training 1 2 5

3

4

Fig. 5 Cross-section of vibration pump 1

Control

2

Servo piston

3

Friction free swash plate bearing

4

Attachment plate

5

Spool valve

The engine drives the drive shaft with the cylinder block. The cylinder block carries the working pistons. The slipper pads rest against the sliding surface of the swash plate and are at the same time held on the sliding surface by a retaining device. During each rotation the piston pass through their upper and lower dead centre back to their initial position. Between both dead centres each piston performs a full working stroke. During this stroke movement oil is drawn in from the low pressure side of the closed circuit and pressed out through the slots in the valve plate into the high pressure side. The oil quantity depends on the piston area and the length of the working stroke.

BW 211 / 212 / 213 D-40

008 911 63

-F5-

BOMAG

293

11.1

Service Training

Service Training During the suction stroke the oil is drawn into the piston chamber, i.e. the charge pressure forces it into the piston chamber. On the opposite side the piston presses the oil out into the high pressure side of he closed circuit.

Control The electro-hydraulic displacement control (remote control) converts the electric input signal to a load controlling output signal. Since the pump is not equipped with a proportional control, but a 12 Volt solenoid valve, the pump is always actuated to one of the two end stop positions.

Charge pumps These machines are equipped with two charge pumps. One of the pumps is an external gear pump, which is directly driven by the auxiliary output of the engine and serves also as steering pump. The second pump is an internal gear pump and is located in the end cover of the vibration pump. The oil flow generated by the charge pumps is joined together with the return flow from the steering valve before the hydraulic oil filter and flows through the filter to the charge ports on travel pump and vibration pump.

BW 211 / 212 / 213 D-40

294

-F6-

BOMAG

008 911 63

11.1

Service Training

Service Training High pressure relief valves As a measure to protect the closed vibration circuit against to high pressures the vibration pump is fitted with pressure relief valves.

1 2

3

Fig. 6Pressure relief valve 1

From the charge pump

2

Closed circuit

3

High pressure relief valve with integrated boost check valve

Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this phase. The high pressure relief valve reduces these pressure peaks to a value of max. 371 bar (pressure difference between high and low pressure side = 345 bar + charge pressure = 26 bar). The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the closed vibration circuit. The function of these valves has already been described in the chapter "travel system".

BW 211 / 212 / 213 D-40

008 911 63

-F7-

BOMAG

295

11.1

Service Training

Service Training Vibration motor The vibration motor is a Bosch-Rexroth (Hydromatik) axial piston motor of series A10FM 45 with fixed displacement in bent axle design. Since the motor can be subjected to pressure from both sides, it is most suitable for the use in closed hydraulic circuits. The output speed of the motor depends on the oil quantity supplied by the vibration pump.

2

3

4

5

1

6

10

9

8

7

Fig. 7Cross-section of vibration motor 1 2

Flushing valve block Flushing valve

3

Working pistons with slipper pads

4

Roller bearing for output shaft

5

Radial seal

6

Output shaft

7

swash plate

8

Retaining plate

9

Pre-tensioning spring

10

Flushing pressure relief valve

BW 211 / 212 / 213 D-40

296

-F8-

BOMAG

008 911 63

11.1

Service Training

Service Training The output torque raises with increasing pressure difference between low and high pressure side in the closed circuit. Changing the flow direction of the oil will also change the sense of rotation of the vibration motor. When switching the vibration on the motor must first start to move the resting vibration shaft. This resistance causes a hydraulic starting pressure, which is limited to 345 bar by the corresponding high pressure relief valve. Once the vibrator shaft has reached its final speed, the pressure will drop to a value between 100 and 150 bar (operating pressure). The value of the operating pressure mainly depends on the condition of the ground (degree of compaction, material etc.). • Hard ground = High operating pressure • Loose ground = Low operating pressure

MA

A 2

3

1

MB

B

Fig. 8Circuit diagram of vibration motor 1

Vibration motor

2

Flushing valve

3

Flushing pressure relief valve

BW 211 / 212 / 213 D-40

008 911 63

-F9-

BOMAG

297

11.1

Service Training

Service Training The vibration motor is equipped with an integrated flushing valve. When switching the vibration on a pressure difference will appear between the two sides of the closed circuit. The higher pressure moves the valve spool of the flushing valve against the neutral setting spring, so that oil can flow out of the low pressure side.

1

A

2

B

Fig. 9 Flushing valve 1 2

Flushing spool Flushing pressure limitation valve

The flushing valve is fitted with a downstream 13 bar pressure relief valve. This valve ensures that only a certain quantity of hydraulic oil is flushed out of the low pressure side. This oil flows via a thermostat valve back to the hydraulic tank. The flushed out oil is immediately replaced with fresh and filtered oil through the corresponding boost check valve.

BW 211 / 212 / 213 D-40

298

- F 10 -

BOMAG

008 911 63

11.1

Service Training

Service Training Drum

4

14

5

9

2

6

13

7 10

3

8

11

12

1 Fig. 10Cross-section of drum 1

Drum shell

8

Change-over weight

2

Vibration bearing

9

Coupling vibr.-motor – vibrator shaft

3

Basic weight

10

Travel bearing

4

Vibrator housing

11

Travel bearing housing

5

Cooling fan

12

Rubber buffer

6

Vibrator shaft

13

Vibration motor

7

Elastic coupling between shafts

14

Flanged bearing housing

BW 211 / 212 / 213 D-40

008 911 63

- F 11 -

BOMAG

299

11.1

Service Training

Service Training Vibration system: Components and test ports Vibration pump

11

2

3 2 5

6

3 6 5 4

4 Pos.

Designation

1 2

Pressure test port, charge pressure Hydraulic oil filter (charge circuit) with visual pressure differential indicator High pressure port, low amplitude High pressure port, high amplitude Solenoid valve, low amplitude Solenoid valve, high amplitude

3 4 5 6


Measuring values

MA 07

26 bar

MF ME Y08 Y07

BW 211 / 212 / 213 D-40

300


12V / 3,33A 12V / 3,33A

- F 12 -

BOMAG

008 911 63

11.1

Service Training

Service Training Vibration pump

1

2

Pos.

Designation

1

Pressure test port, vibration pressure low amplitude Pressure test port, vibration pressure high amplitude

2


low amplitude

Measuring values

MF

max. 371 bar

ME

max. 371 bar

high amplitude

BW 211 / 212 / 213 D-40

008 911 63


- F 13 -

BOMAG

301

11.1

Service Training

Service Training Vibration motor

1 2

3 4

5

Pos.

Designation


1 2 3

High pressure port, high amplitude High pressure port, low amplitude Leak oil and flushing oil port

16 16 16

4 5

Flushing spool Flushing valve

16 16

BW 211 / 212 / 213 D-40

302


Measuring values

approx. 7 l/min, incl. flushing quantity 13 bar

- F 14 -

BOMAG

008 911 63

11.1

Service Training

Service Training Trouble shooting The following trouble shooting chart contains a small selection of possible faults, which may occur during operation of the machine. The fault list is by no means complete, however, the fault table is based on the experience of the central service department, i.e. the list covers almost all faults that have occurred in the past. Procedure: The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.

SYMPTOMS

TROUBLE SHOOTING VIBRATION BW 211 / 212 / 213 D-40

No vibration (charge pressure OK) Vibration only with one amplitude Exciter shaft speed too low

The numerical values specified in the table indicate the probability of the fault cause and thereby the recommended trouble shooting sequence, based on our latest field experience.

POSSIBLE CAUSES Vibration switch (amplitude pre-selection) Vibration push button (on/off) Electrics defective / wiring Pump control (electrical / hydraulic) Pressure override / high pressure relief valves in vibration pump soiled/out of adjustment/ defective Charge pump / charge pressure relief valve soiled/ defective Vibration pump frequency adjustment Vibration pump defective Coupling between diesel engine and travel pump defective Exciter shaft bearings defective Vibration motor coupling defective Vibration motor defective Diesel engine

1 1 1 2 2 1 1 2 2 2

2 2 3

2 2

1 1

BW 211 / 212 / 213 D-40

008 911 63

BOMAG

303

11.1

Service Training

Service Training Steering Single drum rollers of series BW 211 / 212 / 213 D-40 are equipped with a hydrostatically operated articulated steering system. The steering system mainly consists of steering pump, steering valve, steering cylinders and pressure resistant connecting hoses.

to charge system 1 7

6 5

3 2 4 from steering pump

Fig. 1Steering hydraulics 1

Rating pump

2

Distributor valve

3

Steering pressure relief valve (Δp =175 bar)

4

Check valve (pre-loaded to 0.5 bar)

5

Anti-cavitation valve

6

Shock valves (240 bar)

7

Steering cylinders

The steering pump draws the hydraulic oil out of the hydraulic oil tank and delivers it to the steering valve and the connected steering unit under the operator's platform of the machine. If the steering is not operated, the complete oil supply will flow through the fine filter to the charge system for the closed travel circuits. When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod side of the steering cylinder. A rating pump inside the steering unit measures the exact oil quantity corresponding with the turning angle of the steering wheel and delivers the oil to the steering cylinders. The steering cylinders retract or extend and steer the machine. The steering unit is equipped with a pressure relief valve. This valve limits the steering pressure to 175 bar. The charge pressure must, however, be added to this value, because the oil leaving the steering system enters the charge circuit. The actual steering pressure is therefore approx. 200 bar.

BW 211 / 212 / 213 D-40

304

-G1-

BOMAG

008 911 63

11.1

Service Training

Service Training Steering pump The steering pump is a gear pump with fixed displacement. It is driven by the auxiliary drive of the diesel engine, draws the hydraulic oil out of the hydraulic oil tank and pumps it through the steering valve to the steering cylinders or to the boost check valves for travel and vibration circuits.

9

9

6

1

7

9

3 8 2

4

5

Fig. 2Steering pump 1

Housing

2

Flange

3

Shaft

4

Bearing plate

5

Bearing plate

6

Cover

7

Gear (driving)

8

Gear (driven)

9

Seals

BW 211 / 212 / 213 D-40

008 911 63

-G2-

BOMAG

305

11.1

Service Training

Service Training Working principle of the gear pumps The drive gear of the steering pump is connected with the auxiliary drive of the diesel engine via a coupling. Drive gear and driven gear are positioned by a bearing plate in such a way, that the teeth of both gears mesh with minimum clearance when rotating. The displacement chambers are created between the tooth flanks, the inside wall of the housing and the faces of the bearing plates. When the pump is running the chambers transport hydraulic oil from the suction side to the pressure side. This causes a vacuum in the suction line by which the hydraulic oil is drawn out of the tank. The tooth chambers transport the fluid to the outlet of the pump from where it is pressed to the consumers. To ensure a safe function of the pump the tooth chambers must be so tightly sealed that the hydraulic fluid can be transported from the suction side to the pressure side without any losses. For this purpose external gear pumps are fitted with gap seals. This causes pressure dependent fluid losses from the pressure side to the suction side. As a measure to ensure that these losses are reduced to a minimum, the bearing plate on the cover side is pressed against the faces of the gears by an axial pressure field. This pressure field is always under the actual system pressure.

BW 211 / 212 / 213 D-40

306

-G3-

BOMAG

008 911 63

11.1

Service Training

Service Training Steering valve The steering valve block consists mainly of distributor valve, measuring pump, pressure relief valve and shock valves.

1 9

2

3 4

5 8

6 7

Fig. 3Cross-sectional view of steering valve 1

Neutral setting springs

2

Housing

3

Inner spool

4

Outer spool

5

Universal shaft

6

Ring gear

7

Gear

8

Check valve

9

Pressure relief valve

When turning the steering wheel the distributor valve guides the oil flow from the pump to the rating pump. The rating pump guides the oil flow through the distributor valve to the corresponding sides of the steering cylinders. The rating pump measures the exact oil quantity in accordance with the rotation angle of the steering wheel. This oil flow to the steering cylinders articulates the machine and causes a steering movement.

BW 211 / 212 / 213 D-40

008 911 63

-G4-

BOMAG

307

11.1

Service Training

Service Training

240 bar

Δp = 175 bar 240 bar

0,5 bar

Fig. 4Steering valve, hydraulic diagram The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar. The charge pressure value must be added to this pressure, because the oil leaving the steering system is fed into the charge circuit for the closed travel circuits. The steering unit is fitted with so-called shock valves in each supply line to the steering cylinder. These valves are adjusted to an opening pressure of 240 bar. The valves compensate extreme pressure peaks which may occur, e.g. when driving over obstructions, and protect the system against overloads. Each of these shock valves is fitted with an additional anti-cavitation valve. If the shock valves respond these anti-cavitation valves protect the system against cavitation damage. A check valve at the inlet of the steering unit makes sure that no oil will flow back to the pump in case of pressure peaks caused by sudden steering movements. In such a case the steering cylinders would act as pumps and press the oil back to the pump.

BW 211 / 212 / 213 D-40

308

-G5-

BOMAG

008 911 63

11.1

Service Training

Service Training Articulated joint Front and rear frames of the single drum rollers are connected by an oscillating articulated joint. This ensures that drum and wheels are at all times in contact with the ground, even when driving extreme curves.

Fig. 5Articulated joint

BW 211 / 212 / 213 D-40

008 911 63

-G6-

BOMAG

309

11.1

Service Training

Service Training The rear console is tightly bolted to the rear frame. The front console is fastened with screws to the rear cross-member of the front frame. The use of rocker bearings between front and rear frame ensures that both frames can oscillate to each other for +/- 12°. This gives drum and wheels excellent ground contact, even under extremely severe conditions. The front console is connected with the rear console by two vertical bolts. The vertical bolts are mounted in friction bearings. The steering cylinder anchor point is welded to the front console. When turning the steering wheel the steering cylinder will extend or retract. The piston rod swivels the front console around the vertical bolts. This articulates the machine and results in a steering movement. All bearings on the articulated joint are maintenance free and do not require any lubrication.

Notes on assembly: When assembling or repairing the articulated joint the correct pretension of the centre pin is of highest importance. Please follow the instructions in the repair manual for the articulated joint.

BW 211 / 212 / 213 D-40

310

-G7-

BOMAG

008 911 63

11.1

Service Training

Service Training Steering: Components and test ports Steering pump

1

2

Pos.

Designation

1 2

Steering pump (and charge pump) Steering pressure test port


09 MB

BW 211 / 212 / 213 D-40

008 911 63


Measuring values

max. 175+26 bar

-G8-

BOMAG

311

11.1

Service Training

Service Training Vibration and noise damper

The damper is located in the steering/charge circuit directly after the steering and charge pump. It is subjected to hydraulic oil flow and has the function of eliminating any vibrations and noises. The damper is mounted to the front plate of the rear frame, between both steering cylinders.

BW 211 / 212 / 213 D-40

312

-G9-

BOMAG

008 911 63

11.1

Service Training

Service Training Steering valve

The steering valve is located under the operator's stand

BW 211 / 212 / 213 D-40

008 911 63

- G 10 -

BOMAG

313

11.1

Service Training

Service Training Trouble shooting The following trouble shooting chart contains a small selection of possible faults, which may occur during operation of the machine. The fault list is by no means complete, however, the fault table is based on the experience of the central service department, i.e. the list covers almost all faults that have occurred in the past. Procedure: The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults. The numerical values specified in the table indicate the probability of the fault cause and thereby the recommended trouble shooting sequence, based on our latest field experience.

No steering function End stops are not reached Steering hard to move

SYMPTOMS

TROUBLE SHOOTING STEERING SYSTEM BW 211 / 212 / 213 D-40

POSSIBLE CAUSES Steering orbitrol valve Steering/charge pump Steering cylinder Articulated joint

2 1 3 3

2 1 3 3

1 2 3 2

BW 211 / 212 / 213 D-40

314

BOMAG

008 911 63

12 Engine

008 911 63

BOMAG

315

12.1

Diesel engine, general

12.1 Diesel engine, general

Fig. 1 Engine compartment

Single drum rollers of series BW211/213 D/PD-4 and BW213/214 DHC/PDHC-4 are powered by Deutz diesel engines type BF4M 2012 C with intercooling. The intercooler reduces the thermal load on the engine, the exhaust temperature and the fuel consumption and thus enables a higher power output. The engines are characterized by the following positive features: ●

short and compact design

●

low noise level

●

almost vibration free operation

●

low fuel consumption

●

low exhaust emissions (EPA II)

●

high power reserves and

●

excellent access to all service locations.

The pistons are made of aluminium alloy. The side walls of the slightly externally arranged combustion trough are inclined towards the inside by 10°. All pistons are fitted with three piston rings and a cast iron ring carrier for the first ring. The pistons are oil mist lubricated. The forged crankshaft is designed with integrated counter weights. The block-type cylinder head is made of cast steel. Each of the cylinders has an inlet and an outlet valve. The valve guides are shrunk into the cylinders. The valve seat rings are made of high quality steel and also shrunk fit.

Crankcase and cylinders on this engine are made of alloyed cast iron. This provides rigidness and high wear resistance. The forged steel conrods are designed with balancing weights in the area of the conrod bearing seats. These weights compensate manufacturing tolerances with respect to weight and position of the centre of gravity.

316

BOMAG

008 911 63

12.2

Service side

12.2 Service side

Fig. 1 Service side

1

Oil filler neck

2

Lubrication oil cooler

3

Engine solenoid

4

Oil pressure switch (B06)

5

Radiator fan

6

Fuel pump

7

V-belt pulley

8

Main fuel filter

9

Lubrication oil filter

10 Oil sump 11 Oil dipstick 12 Compressor (only BW24/27 RH 13 Plug-in injection pumps 14 Generator 15 Heating flange (R19, option) 16 Hydraulic pump 17 Tensioning roller with torsion spring 18 Crankcase ventilation valve

008 911 63

BOMAG

317

12.3

Starter side

12.3 Starter side

Fig. 1 Starter side

1

Exhaust manifold

2

Exhaust turbo charger

3

Oil filling (optional)

4

Engine mounts

5

Oil return line from turbo charger

6

Relay (starter)

7

Ribbed V-belt

8

Coolant inlet

9

Coolant outlet

10 Coolant pump 11 Connection of compensation line

318

BOMAG

008 911 63

12.4

Lubrication oil circuit

12.4 Lubrication oil circuit

Fig. 1 Lubrication oil circuit

1

Oil sump

2

Return flow from turbo charger to crankcase

3

Turbo charger

4

Oil line to turbo charger

5

Line to mass balancing gear (2 x)

6

Oil pressure sensor

7

Valve with pulse lubrication

8

Push rod, oil supply to rocker arms

9

Line to spray nozzles

18 Leak oil return line 19 Oil filter 20 Suction line 21 Crankshaft bearings 22 Conrod bearings

10 Rocker arm 11 Return flow to oil sump 12 Nozzle for piston cooling 13 Camshaft bearings 14 Main oil channel 15 Lubrication oil cooler 16 Oil pump 17 Pressure relief valve

008 911 63

BOMAG

319

12.4

Lubrication oil circuit

General The oil inside the combustion engine has the function of lubricating and cooling all drive components, removing impurities and neutralizing chemically effective combustion products, transferring forces and damping vibrations.. The oil is only able to fulfil this function, if sufficient quantities are transported to the critical points in the engine and if its properties are adapted to the prevailing requirements by corresponding manufacturing processes and refining (additives). Figure (1) shows pressure circulation lubrication in combination with splash and oil mist lubrication. Here oil is transported under pressure to all bearing locations by the oil pump (16), while sliding surfaces are splash or oil mist lubricated. After flowing through the bearing locations and along sliding surfaces the oil is collected in the oil sump (1) under the drive, where the oil is cooled, defoamed by calming and stored. The oil filter (19) removes solid foreign particles from the engine oil (combustion residues, metal abrasion, dust) and thus maintains the function of the lubrication oil during the maintenance intervals.

320

BOMAG

008 911 63

12.5

Oil pressure switch and low oil pressure circuitry

12.5 Oil pressure switch and low oil pressure circuitry

Fig. 1

1

Oil pressure switch

Pos. 1

008 911 63

Designation in circuit diagram B06

Designation

Technical data

Oil pressure switch

Below 0.8 bar the contact switches to engine ground, closed without pressure. Tightening torque 20 ± 2 Nm with copper ring.

BOMAG

321

12.6

Check the engine oil level

12.6 Check the engine oil level ! Danger Danger of injury!

Support the engine hood for all maintenance and repair work.

i

Note

The machine must be parked horizontally with the engine shut down.

Fig. 2 Oil pressure switch

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

Fig. 3

Pull the dipstick (Fig. 3) out, wipe it off with a lintfree, clean cloth and reinsert it until it bottoms.

●

●

Pull the dipstick back out again.

●

If the oil level is below the "MAX" mark fill in oil. If the oil level is above the “Max” mark determine the cause and drain the oil off.

●

Caution Before longer work periods you should always top the oil up to the "MAX"-mark. !

For quality and quantity of oil refer to the table of fuels and lubricants.

322

BOMAG

008 911 63

12.7

Changing engine oil and oil filter cartridges

12.7 Changing engine oil and oil filter cartridges Caution The oil change at 500 operating hours refers to the use of oils of oil quality class API CG-4/CH-4 or ACAE E3-96/E5-02 respectively. !

Refer also to the chapter 5.2, fuels and lubricants. Drain the engine oil only when the engine is warm. Danger Danger of scalding! !

Fig. 5

Thoroughly clean the outside of both filter cartridges (Fig. 5).

●

When draining off hot oil. By hot oil when unscrewing the engine oil filter. Environment Catch running out oil and dispose of environmentally together with the engine oil filter cartridge.

Unscrew both filter cartridges using an appropriate filter wrench.

●

i

Note

The filter cartridges are fitted with a valve that prevents engine oil from running out during removal and installation. ●

●

Clean the sealing face on the filter carrier from any dirt. Slightly oil the rubber seal on the new filter cartridges.

Fig. 4 ●

●

Unscrew the drain plug (Fig. 4) and catch running out oil. Turn the drain plug tightly back in.

Fig. 6 ●

●

008 911 63

Turn the new filter cartridges (Fig. 6) on by hand, until the seal contacts. Tighten the filter cartridges for another half turn.

BOMAG

323

12.7

Changing engine oil and oil filter cartridges

Fig. 7 ●

Fill in new engine oil (Fig. 7).

For quality and quantity of oil refer to the table of fuels and lubricants. ●

Tighten the oil filler cap properly.

! Caution Before starting crank the engine with the starter motor until the oil pressure warning light goes out. ●

●

●

●

After a short test run check the oil level on the dipstick, if necessary top up to the top dipstick mark. Check filter cartridge and drain plug for leaks after a short test run. Shut the engine down and wait for about 15 minutes, so that all oil can flow back into the oil sump. Check the oil level again, if necessary fill up to the Max.-mark.

324

BOMAG

008 911 63

12.8

Coolant circuit

12.8 Coolant circuit

Fig. 1 Coolant circuit

1

Radiator

2

To radiator

3

From radiator

4

Coolant pump

5


6

Cylinder cooling

7

Cylinder head cooling

8

Ventilation connection from cylinder head to heat exchanger

9

Fan

008 911 63

BOMAG

325

12.8

Coolant circuit

General In order to avoid thermal overloads, burning of lubrication oil on piston sliding surfaces and uncontrolled burns caused by high component temperatures, the components surrounding the combustion chamber, like cylinders, cylinder head, valves and possibly also the pistons, must be cooled intensively. Brief description The coolant pump ("water pump") draws coolant through the hose lines directly out of the radiator and forces it first of all through the lubrication oil cooler, which is integrated in the engine. The coolant then enters into the engine, flows up along the cylinders into the cylinder head and to the thermostat at the coolant outlet. Form their the coolant is returned through the corresponding lines to the radiator inlet. When the engine is cold the coolant is pumped in a short circuit through the engine, until the response temperature of the thermostat (start of opening) is reached. The water pump draws cold coolant out of the radiator, as required to replenish the hot out flowing coolant.

Fig. 2 Direct heating

1

Thermostat

2

Coolant pump

3


4

Heat exchanger

The coolant is a mixture of water and anti-freeze agent. The anti-freeze agent increases the boiling temperature of the mixture and thus enables temperatures of up to 120° C at an overpressure of up to 1.4 bar. The coolant compensation tank enables reliable gas separation, thus avoiding cavitation in the cooling system, which mainly occurs in the suction side of the pump. The air volume inside the compensation must be so high, that quick build-up of pressure in case of heating and expansion of coolant is assured and any escape of coolant during after-boiling is avoided. The radiator (1) dissipates the waste heat generated in the engine into the into the environment. Part of the combustion heat is transferred to the lubrication oil. The lubrication oil cooler (5) serves the function of cooling the lubrication oil. Heating Water-cooled DEUTZ diesel engines utilize the coolant to heat the driver's cab. For this purpose the engine coolant is guided directly to the heat exchanger and the heat is directly dissipated into the environment (direct heating).

326

BOMAG

008 911 63

12.9

Coolant temperature switch

12.9 Coolant temperature switch

Fig. 1 Coolant temperature switch

Pos.

008 911 63

Designation in circuit diagram B152

Designation

Technical data

Coolant temperature switch

Contact switches at approx. 110° C to engine ground

BOMAG

327

12.10

Disassembling and assembling the coolant temperature switch

12.10Disassembling and assembling the coolant temperature switch Removal ●

●

Installation Clean thread and seat for switch.

●

Install the temperature switch with Loctite 577 and a new seal, tightening torque 20 Nm.

●

Push the plug back on (plug interlock clicks into place).

●

Turn the battery disconnecting switch to position "OFF".

Check the plug interlock by lightly pulling on the wiring loom.

●

Open the lid on the coolant reservoir.

! Danger Danger of scalding!

Do not remove the cap from the compensation tank when the engine is still hot.

●

Fill in coolant up to the “MAX” mark .

●

Run the engine up to operating temperature.

i

Note

Check the area around the coolant temperature sensor for leaks. ●

Let the engine cool down and check the coolant level again, top up if necessary.

Fig. 2 Temperature switch ●

●

Press in the locking wire and disconnect the plug (Fig. 2). Lay a cloth around the temperature switch and catch running out coolant.

Environment Dispose of escaping coolant environmentally ●

Unscrew the temperature switch.

Fig. 3 Coolant temperature switch ●

Remove and dispose of the seal (Fig. 3).

328

BOMAG

008 911 63

12.11

Replacing the thermostat

12.11Replacing the thermostat Open the lid on the coolant reservoir.

●

Danger Danger of scalding! !

Do not remove the cap from the compensation tank when the engine is still hot. Drain the coolant from the engine and catch it.

●

Environment Catch running out coolant and dispose of environmentally.

Fig. 6 ●

Assemble the outlet socket (Fig. 6).

●

Tightening torque: 30 Nm.

●

Install the coolant hose again.

●

Fill in coolant up to the “MAX” mark .

●

Run the engine up to operating temperature.

i

Note

Check for leaks around the thermostat. ●

Let the engine cool down and check the coolant level again, top up if necessary.

Fig. 4 ●

Disconnect the coolant hose.

●

Remove the outlet socket (Fig. 4).

●

Remove the thermostat.

Fig. 5 ●

Fit a new seal to the thermostat.

●

Insert the new thermostat with the seal ring (Fig. 5).

i

Note

Mind the installation position. The arrow (ventilation groove) points up.

008 911 63

BOMAG

329

12.12

Checking the thermostat in disassembled state

12.12Checking the thermostat in disassembled state

The temperature increase should not exceed 1°C/ min, as otherwise the start of opening will be delayed accordingly.

The thermostat serves the optimal temperature control of the coolant, in order to promote efficient combustion and to bring the engine quickly to operating temperature after starting. At temperatures below approx. 83°C the thermostat is closed. Once the coolant temperature has reached about 83°C, the thermostat will start to open, at about 95° C it is fully open. In this condition the full coolant flow is guided through the radiator.

Fig. 3

Measure and write down the measurement "b" on the thermostat . (Fig. 3).

●

Calculate the stroke.

●

Stroke = b - a

i Fig. 1

Measure and write down the measurement "a" on the thermostat (Fig. 4).

●

i

Note

The stroke at the given temperature (T2) should be min. 8 mm.

Note

"a" = beginning of stroke at approx. 83 ± 2°C (T1) "b" = end of stroke at approx. 95 °C (T2)

Fig. 2

Warm up the thermostat in a water bath (Fig. 2).

●

i

Note

In order to determine the exact start of opening the temperature should be measured as close to the thermostat as possible, but without touching it. The water must thereby be stirred continuously, to ensure even temperature distribution.

330

BOMAG

008 911 63

12.13

Check the coolant level

12.13Check the coolant level

12.14Change the coolant



Fill up coolant only when the engine is cold.

Change the coolant only when the engine is cold. Environment Catch running out coolant and dispose of environmentally.

Fig. 4

Check the coolant level (Fig. 4).

●

Caution If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks. !

●

Fig. 5 ●

Set the cock valve for the cabin heater to position "warm".

To top up unscrew the filler cap and fill in coolant up to the MAX-mark.

For quality of coolant refer to the chapter 5.2, fuels and lubricants.

Fig. 6 ●

●

008 911 63

Unscrew the plug, let the coolant run out and catch it. Screw the plug back in once all coolant has run out.

BOMAG

331

12.15

Checking the anti-freeze concentration

12.15Checking the anti-freeze concentration Caution In order to avoid damage to the engine e.g. by corrosion, cavitation and freezing, particular attention must be paid to the inspection of the coolant. !

Danger Danger of scalding! !

Fig. 7 ●

Unscrew the cap and fill in coolant up to the MAXmark.

For quality of coolant refer to the chapter 5.2, fuels and lubricants. ●

●

Start the diesel engine and run it warm to operating temperature. Let the engine cool down and check the coolant level again, top up if necessary.

Check the anti-freeze concentration only when the engine is cold. ●

●

Perform the inspection with conventional test equipment. The anti-freeze concentration (additive) must be at least 35 Vol% and maximum 45 Vol%.

! Danger Health hazard!

The mixing of nitrite based anti-freeze agents with amine based agents results in the formation of health affecting nitrosamines. Environment Catch all anti-freeze agent and dispose of environmentally.

332

BOMAG

008 911 63

Clean the cooling fins on engine and hydraulic oil cooler

12.16

12.16Clean the cooling fins on engine and hydraulic oil cooler Danger Danger of injury! !

Perform cleaning work only after the engine has cooled down and with the engine stopped. Caution Do not damage any cooling fins on the cooler core when cleaning. !

i

Note

Dirt on fan blades and oil cooler reduce the cooling effect. Dirt deposits in these areas are substantially supported by oil and fuel on these surfaces. For this reason you should always seal any oil or fuel leaks in the vicinity of the cooling fan or the oil cooler and clean the cooling surfaces after.

Cleaning with compressed air

Fig. 8

i

Note

Start to blow out from the exhaust side. Blow the cooler (Fig. 8) out with compressed air.

●

Cleaning with cold cleansing agent Caution Protect electrical equipment such as generator, regulator and starter against the direct water jet. !

●

●

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. Run the engine warm for a while to avoid corrosion.

008 911 63

BOMAG

333

12.17


12.17Three-phase generator

Fig. 1

1

Generator (G02)

Pos. B+ D+ W

334

Designation in circuit diagram B+ D+ W

Designation

Technical data

Battery Plus Dynamo Plus Rotational speed signal

14.4 Volt, 90 Amp. 14.4 Volt, maximum load 0.2 Amp. pulsing D.C. voltage to determine the engine speed

BOMAG

008 911 63

12.17

Three-phase generator General The generator should be of light weight, have a high rate of efficiency and supply all consumers in the vehicle with electric current at a steady voltage already at idling speed.

i

Note

The generator is maintenance free. Function tests and repair work must only be performed in authorized workshops. ! Caution Before removing the generator you must disconnect the ground cable from the minus pole of the battery while the ignition is switched off. Do not disconnect the generator while the engine is running, because this may cause extremely high voltage peaks in the vehicle wiring system ("Load Dump"), which could possibly damage control units, radios or other electronic equipment.

When disassembling the battery cable, the B+-nut underneath on the generator side may also be loosened. This nut must in this case be retightened. When connecting e.g. the battery cable to the terminal of the generator you must make sure that the polarity is correct (generator B+ to the + pole of the battery). Mixing up the polarities by mistake causes short circuit and damage to the rectifier elements - the generator will be out of function. The generator can only be operated with the battery connected. Under special conditions emergency operation without battery is permitted, the lifetime of the generator is in such cases especially limited. Plus and minus cables must be disconnected during 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. After cleaning the generator should be operated for about 1 - 2 minutes to remove any deposits of water from the generator.

008 911 63

BOMAG

335

12.18

Fuel supply

12.18Fuel supply

11 Pressure retaining valve - 5 bar

Fig. 1 Fuel supply

1

Water separator sensor connection

2

Flow to fuel lift pump

3

Fuel lift pump

4

Connecting line between fuel lift pump and main filter (fuel pre-pressure up to 10 bar)

5

Main fuel filter (pressure proof)

6

Connecting line between main filter and flow to injection pumps

7

Single-cylinder injection pump

8

High pressure line

9

Injection nozzle

12 Return flow to tank 13 Fuel tank 14 Manual fuel pump 15 Fuel pre-filter 16 Water separator 17 Fuel pre-heating connection (option) 18 Fuel pre-heating (R79) 200 Watt (option) 19 Water separator sensor (B124)

10 Leak oil line 336

BOMAG

008 911 63

12.18

Fuel supply Work in the low pressure system Service and repair work in the low pressure system, including main fuel filter changes, are only permitted under absolutely clean environmental conditions, because even smallest dirt particles entering into the high pressure fuel system will cause considerable damage. Air pollution, like dirt, dust, moisture etc. must be strictly avoided. Before starting work in the fuel system (including filter changes) the engine must be thoroughly cleaned and dried (steam cleaning equipment). Engine compartments in which dirt deposits may come loose, must be covered with new and clean foil. When working in the open you may need to apply protective measures against dust entering because of wind. Danger For diesel fuel the ignition temperature, i.e. the temperature at which fuel will ignite when coming into contact with air, is approx. 220°C, but may deviate strongly because of impurities. !

Fuel conducting components and lines therefore are a source of danger inside the engine compartment, because leaks may lead to fire resulting in considerably damage to material and persons.

008 911 63

BOMAG

337

12.18

Fuel supply

Check valve

Fig. 1 ●

According to our experience, it is not always assured that only clean fuel will be used. Fuel tanks are frequently filled without suitable precautions against contamination or fuel filters are inappropriately serviced. Many damage analyses on injection pumps and injection valves have revealed that most of these components had failed due to premature wear. Wear on injection pump plunger and injection valve needle seat is caused by contaminated fuel. Modern exhaust optimized diesel engines with high pressure injection systems strictly require clean fuel to be able to work reliably over their entire lifetime. If the throttle resistances of pre-cleaner/main filter caused by contaminated fuel are so high that the fuel pump is no longer able to ensure a sufficient fuel supply, the injection pumps will draw the required fuel through the leak fuiel return line from the tank without filtration. The engine is no longer able to provide its full power, operation of construction equipment or other machines, however, may still be possible to a limited extent. After short time operation under such conditions the injection system components may already be pre-damaged.

338

Fig. 2 Observe the direction of flow

i

Note

From August 2006 the check valve (Fig. 2) is used by BOMAG in series machines. Caution This valve must strictly be installed into the fuel return line by our customers. !

BOMAG

008 911 63

12.19

Injection system

12.19Injection system The injection system serves the fuel supply for the diesel engine. The low pressure side of an injection system includes fuel tank, fuel filter and fuel lines. In the high pressure side the injection pump generates the pressure required for injection. The fuel is pumped through the pressure line to the injection pump, from where it is injected into the combustion chamber. Load and speed of the diesel engine are adjusted via the fuel quantity without throttling the intake air. With a sufficient injection quantity the speed of an unloaded diesel engine may therefore rise up to the point of self destruction. A governor for engine speed limitation is therefore required.

Single cylinder plug-in injection pumps Deutz diesel engines series 2012/1013 are equipped with Bosch cylinder plug-in injection pumps series PF 33. The concept of plug-in injection pumps enables the realization of high injection pressures, combined with short injection lines, which is necessary to ensure a high hydraulic stiffness of the injection system. This, in turn, creates the prerequisite for maintaining low exhaust emission values (soot) in combination with low fuel consumption values. The start of injection is influenced by: ● ● ●

the fuel consumption the power the exhaust emission

Fig. 3 Single cylinder plug-in injection pump

The drive cams 2 (Fig. 3) for the single PF-injection pumps are located on the camshaft (1) for engine valve control. Permissible manufacturing tolerances for the components: ●

Cylinder crankcase

●

Camshaft

●

Roller-type plunger

●

Plug-in injection pump

are determined and eliminated by the adjustment of the start of injection.

of the engine. The term "start of injection" refers to the start of the injection pump delivering fuel.

However, in cases of interest for BOMAG field engineers engines are not completely overhauled, but individual injection pumps are replaced. Crankcase, camshaft and roller-type plunger remain unchanged. This results in a certain installation measurement for the drive, which is specified on the engine type plate. It is stamped as "CODE" in the column "EP" for each cylinder.

008 911 63

BOMAG

339

12.20

Injection pump replacement during service

12.20Injection pump replacement during service

Injection valves Injection valves have the following functions: ●

Preparation of fuel

●

Forming of the injection sequence

●

Sealing against the combustion chamber

Disassembly

The peak injection pressure of the diesel fuel is up to 1000 bar. Under these conditions the fuel no longer behaves like a rigid fluid, but it is compressible. During the short injection period (1ms) the injection system is "blown up" and, depending on the nozzle size, more or less fuel will enter into the combustion chamber.

Caution Ensure strict cleanliness when working on the injection system.

Fig. 4 Design of injection valve

Fig. 1

1

Tensioning nut

2

Nozzle

3

Intermediate piece

4

Pressure bolt

5

Pressure spring

6

Shim

i

!

●

●

●

Disassemble pressure control valve and cylinder head cover (Fig. 1). Disconnect the cable plugs from shut-down solenoid, governor and temperature sensor. Swing the holding plate to the side.

Note

A thicker shim 6 (Fig. 4) increases the opening pressure. Caution When replacing an injection pump and/or an injection valve, you must also replace the high pressure line between pump and valve. !

Fig. 2 ●

340

Remove the engine shut-down assy (Fig. 2).

BOMAG

008 911 63

12.20


Fig. 3

Fig. 5

Use the shut-down lever to push the governor rod to stop position (Fig. 3).

●

Set the cylinder of the injection pump to be disassembled to top dead centre (TDC) for ignition (valves overlapping) (Fig. 5).

●

Insert and fasten the pressing device 100 830.

●

Turn the crankshaft for approx. 120° against the sense of rotation.

●

i

Note

Illustration shows view on flywheel.

Fig. 4

Use the knurled fastening screw to force the governor rod to stop position (Fig. 4).

●

i

Note

Tighten the knurled fastening screw by hand.

Fig. 6

Remove the injection line (Fig. 6).

●

i

Note

Close the connections with protection caps.

008 911 63

BOMAG

341

12.20


Fig. 7 ●

Carefully remove the shim with a rod-type magneto (Fig. 7).

342

BOMAG

008 911 63

12.20

Injection pump replacement during service Determining the start of injection

Fig. 8 Injection pump code BFM 2012

i

Note

Old injection pump and shim are not required for this purpose. Example: The injection pump for cylinder 3 is to be replaced on an engine BF6M 2012. Procedure: Read the EP-code for cylinder 3 in the column "EP" on the type plate (table) (Fig. 8), e.g. 295.

●

i

Note

Sequence of reading: Line 1 = cyl.1, line 2 = cyl.2, etc. ●

Take the corrected injection pump installation measurement (EK) matching the EP-code from the table (Fig. 11), e.g. 120.875 mm.

Fig. 10 Injection pump length "A" and Lo

i

Note

Measurement "A" (Fig. 3) determines by how many 1/ 100 of a mm the distance between cylinder crankcase contact surface and plunger foot is longer than the basic measurement Lo. Basic measurement of injection pump (Lo) = 117.5 mm. ●

Determine the theoretical thickness of the shim (TS).

TS = EK - (Lo + A/100) TS = 120.875 mm - (117.5 mm + 42/100 mm) TS = 2.955 mm Fig. 9 Length of injection pump (A) ●

●

Read the coefficient for the injection pump length (A) (Fig. 9) on the new injection pump, e.g. 42.

008 911 63

Choose the shim thickness (SS) from the table.

BOMAG

343

12.20


TS 2.955 mm = SS 3.0 mm Theor. thickness "TS" (mm) 0.95 - 1.049 1.05 - 1.149 1.15 - 1.249 1.25 - 1.349 1.35 - 1.449 1.45 - 1.549

Shim thickness "SS" (mm) 1.0 1.1 1.2 1.3 1.4 1.5

1.55 - 1.649 1.65 - 1.749 1.75 - 1.849 1.85 - 1.949 1.95 - 2.049 2.05 - 2.149 2.15 - 2.249 2.25 - 2.349 2.35 - 2.449

1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4

344

Theor. thickness "TS" (mm) 2.45 - 2.549 2.55 - 2.649 2.65 - 2.749 2.75 - 2.849 2.85 - 2.949 2.95 - 3.049 3.05 - 3.149 3.15 - 3.249 3.25 - 3.349 3.35 - 3.449 3.45 - 3.549 3.55 - 3.649 3.65 - 3.749 3.75 - 3.849

BOMAG

Shim thickness "SS" (mm) 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8

008 911 63


12.20

Fig. 11 Table of injection pump codes BFM 2012

008 911 63

BOMAG

345

12.20


Assembly

Fig. 15

Slightly oil the receiving bore in the crankcase and the O-rings on the injection pump.

●

Fig. 12

Carefully insert the injection pump control lever into the governor rod. (Fig. 15).

●

Caution The roller plunger for the corresponding injection pump must be positioned on the base circle of camshaft. !

Fig. 13 ●

Lay the newly determined shim on roller plungers (Fig. 12) and (Fig. 13).

Fig. 16 ●

Attach the flange (Fig. 16).

! Caution The chamfer must face towards the injection pump body.

Fig. 14 ●

Turn the injection pump control lever approx. to middle position (Fig. 14).

346

BOMAG

008 911 63

12.20


Fig. 20

Fig. 17 ●

Slightly oil the screws and tighten with a torque of 5 Nm (Fig. 17).

Turn the screws in again for 60°, then tighten in steps to a torque of 7 Nm, 10 Nm and 30 Nm. (Fig. 20).

●

i

Note

Always start with the outer screw furthest away from the flywheel.

Fig. 18 ●

Loosen the screws again for 60° (Fig. 18).

Fig. 21 ●

Turn the knurled fastening screw back (Fig. 21).

●

Remove the pressing device.

Caution Check whether the governor rod is light moving between stop and start position. !

Operate the shut-down lever to do so. Fig. 19 ●

Carefully turn the injection pump with an open end spanner anti-clockwise against the noticeable end stop (Fig. 19).

008 911 63

BOMAG

347

12.20


Fig. 22 Fig. 24

Assemble a new O-ring (Fig. 22).

●

i

Caution Take care that the sealing cones match exactly when assembling the injection line. Subsequent bending is not permitted. The injection line must never be used twice. !

Note

Cover the O-ring slightly with oil.

●

●

●

Install the new injection line with the sealing rubber (Fig. 24). Pre-tension the injection line cap nuts on injection pump and injection valve with a torque of approx. 5 Nm (use claw spanner 8018). Tighten the cap nut with 25 ± 3.5 Nm.

Fig. 23 ●

Use the shut-down lever to push the governor rod to stop position and hold it (Fig. 23).

●

Assemble the engine shut-down assy.

●

Tighten the screws with 21 Nm.

●

Plug the cable plug onto the shut-down magneto.

Fig. 25 ●

348

Install the gasket (Fig. 25).

BOMAG

008 911 63

12.21

Injection valve replacement during service

12.21Injection valve replacement during service

i

Note

Injection valves may wear mechanically over the course of time. Spray pattern and injection pressure should be tested on an injection valve test bench ("hydrostesting"). The nozzles must be disassembled for this purpose. In case of excessive deposits on the nozzles these may be cleaned in an ultrasonic bath with gasoline. The injection pressure can be corrected by means of shims. Fig. 26

Assemble cylinder head cover and holding plate (Fig. 26).

●


●

i

Note

Removal

Ensure the sealing rubber is fitted correctly. ●

●

Caution Ensure strict cleanliness when working on the injection system. Use only clean testing oil acc. to ISO 4113 or clean diesel fuel to test the injection valves. !

If necessary assemble the pressure control valve with a new seal. Tighten the screws with 8.5 Nm.

Fig. 1 ●

●

●

008 911 63

Disassemble pressure control valve and cylinder head cover (Fig. 4). Disconnect the cable plugs from shut-down solenoid, governor and temperature sensor. Swing the holding plate to the side.

BOMAG

349

12.21

Injection valve replacement during service Installation

Fig. 2

Disassemble the injection lines (Fig. 2).

●

Fig. 1

Slide the new seal rings with some grease over the injection valves and insert the injection valves (Fig. 1).

●

i

Note

Close connections on injection valves and injection pumps with protective caps.

Caution The chamfer on the injection valves must point away from the claws. !

Fig. 3

Disassemble the claws and take out the injection valves (Fig. 3).

●

Fig. 2

i

Note

●

In case of tight fit use the extracting device 150 800 with puller 110 030.

Attach the claws and turn the screws in loosely (Fig. 2).

Pull out the seal ring with the extracting device 120 680.

350

BOMAG

008 911 63

12.21

Injection valve replacement during service

Fig. 3

Fig. 5

Pre-tension the injection line cap nuts on injection pumps and injection valves with a torque of approx. 5 Nm (Fig. 5).

●

Caution Take care that the sealing cones match exactly when assembling the injection line. Subsequent bending is not permitted. The injection line must never be used twice. !

●

●

Install the new injection lines with the sealing rubbers (Fig. 3).

Tighten the cap nuts with 25 + 3.5 Nm.

●

i

Note

Use a claw spanner 8018.

Tighten the cap nuts finger tight.

Fig. 6 ●

Fig. 4 ●

Install the gasket (Fig. 25).

Tighten the screws for the claws with 16 + 5 Nm (Fig. 4).

008 911 63

BOMAG

351

12.22

Checking / repairing injection valves

12.22Checking / repairing injection valves Special tools: Nozzle tester 8008 Holder for Injection valve 110 110 Long socket 8012 Caution Ensure strict cleanliness when working on the injection system. Use only clean testing oil acc. to ISO 4113 or clean diesel fuel to test the injection valves. !

Fig. 7

Assemble cylinder head cover and holding plate (Fig. 26).

●

Check the injection valves


●

i

i

Note

Ensure the sealing rubber is fitted correctly. ●

●

If necessary assemble the pressure control valve with a new seal. Tighten the screws with 8.5 Nm.

Note

The injection valves are leak fuel free. Fuel cannot flow off and will accumulate above the nozzle needle in the spring chamber of the nozzle holder. Operation of the nozzle tester hand leever is in this case no longer possible. In order to eliminate the pressure inside the spring chamber the clamping nut must be slackened and retightened again before each test.

Fig. 1

Loosen the clamping screw by approx. 180° and tighten it again (Fig. 1).

●

Tightening instructions: 30 - 40 Nm

i

Note

Use injection valve holder 110 110.

352

BOMAG

008 911 63

12.22


Adjusting tze opening pressure on the injection valve

i

Note

If the opening pressure needs toi be corrected: Detach the injection valve from the nozzle tester 8008. Unscrew the clamping nut and remove all parts. Use injection valve holder 110 110.

Fig. 2

Mount the injection valve to the nozzle tester (Fig. 2).

●

! Danger Keep your hands away from the nozzle spray jet. Fuel will penetrate deeply into the flesh and may cause blood poisoning.

Fig. 4 ●

Unscrew the clamping nut and remove all parts (Fig. 4).

Fig. 3

Slowly press the lever of the nozzle tester 8008 down with the pressure gauge connected (Fig. 3).

●

Fig. 5

Sequence of disassembly (Fig. 5):

Opening pressure: 220 bar

1

Tensioning nut

2

Injection nozzle

The opening pressure is reached, when the pointer stops or suddenly drops.

3

Intermediate piece

4

Pressure bolt

The pressure inside the spring chamber will have build up again after approx. 3 - 4 strokes. In order to repeat the test the clamping nut needs to be slackened and retightened again, as specified.

5

Pressure spring

6

Shim

i

Note

Once identical values are measured during 3 tests, the values can be considered valid.

008 911 63

●

Clean all parts with clean diesel fuel and blow off with compressed air.

BOMAG

353

12.22


Fig. 6

Fig. 8

Assemble the shim (Fig. 8).

●

Caution Nozzle needle and nozzle body have been fitted by lapping and must never be mixed up by mistake or replaced individually. Do not touch the nozzle needle with your fingers. With the nozzle body in vertical position, the nozzle needle must smoothly slide on its seat just by its own weight (Fig. 6). !

i

i

Note

Adjust the opening pressure by choosing the required shim. A thicker shim increases the opening pressure.

Note

If the needle slides down jerkily, wash out the nozzle body with diesel fuel again, replace if necessary. Clean the new injection nozzle also in clean diesel fuel.

Fig. 9 ●

Assemble the pressure spring.

Fig. 7 ●

Check the seat areas of the intermediate piece for signs of wear. Make sure that the centring pins are present (Fig. 7).

Fig. 10 ●

354

Install the pressure bolt with the centring collar towards the pressure spring (Fig. 10).

BOMAG

008 911 63

12.22


Fig. 11

Fig. 13

Insert the centring pins of the intermediate piece into the bores of the nozzle holder (Fig. 11).

●

i

Screw on the clamping nut.

●

Note

The chamfer points towards the pressure bolt.

Fig. 14

Tighten the clamping nut.

●

i

Fig. 12

Attach the centring bores of the injection nozzle to the centring pins of the intermediate piece (Fig. 12).

●

i

Note

Use the injection valve holder 110 110 and a long socket 8012. Tightening torque: 30 to 40 Nm

Note

The nozzle needle must not drop out of the nozzle body.

008 911 63

BOMAG

355

12.22


Leak test

Rattle and spray pattern test

Fig. 1

Fig. 1

Dry nozzle and nozzle holder - blow dry with compressed air.

●

Press the hand klever of the tester slowly down, to a point about 20 bar before the previously indicated opening pressure (Fig. 1).

●

Switch off the pressure gauge on the tester.

●

i

Note

The rattle test enables audible testing of the nozzle needle movement inside the nozzle body. In comparison with used injection valves, new ones have a different rattling behaviour. It becomes worse as the wear in the needle seat area progresses. Caution A used injection valve must audibly rattle and spray off well atomized fuel when operating the lever quickly. The spray pattern may be noticeably different from the one produced by a new injection valve. !

If an injection nozzle does not rattle despite of cleaning, it nees to be replaced by a new one! Fig. 2

i

Note

The nozzle is leak tight, if no drop drips off within a period of 10 seconds. Caution If a drop drips off (Fig. 2), the injection valve must be dismantled and the leak must be eliminated by thorough cleaning. If this does not lead to a success, replace the injection nozzle. !

Rework is not permitted!

356

BOMAG

008 911 63

12.23

Fuel filter

12.23Fuel filter

Fig. 1 Fuel pre-filter

1

Hand pump

2

Bleeding valve

3

Filter element

4

Water and dirt collecting bowl

5

Drain valve

6

Water separator sensor connection (B124)

7

Fuel pre-heating connection (R79) 200 Watt (option)

008 911 63

BOMAG

357

12.23

Fuel filter

General The quality of the fuel filter and the compliance with the specified service intervals are decisive for the lifetime of the fuel injection system. The heart of the fuel filter is made of hydrophobic special paper, which is spirally wound in form of a bag in order to offer the largest possible filtering area under the prevailing spatial conditions and thus to achieve a high lifetime in combination with a high dirt retaining capacity. The fuel pre-filter / water separator mainly consists of: ●

the dirt / water collecting bowl

●

and the filter element

Open the drain valve and drain off approx. 0.5 l of fuel. The fuel above the filter element presses through the filter element and frees the underside from dirt.

●

Function The fuel lift pump draws the fuel through this filter. Any water contained in the fuel deposits on the dirt side of the filter paper and separates from the fuel in form of large drops on the clean side of the filter (coalescence effect).

Close the drain valve again.

●

Perform A power drop or poor starting of the engine is mainly caused by leaks in the fuel system. If you suspect a filter problem, you should check whether bleeding screw and drain valve are tightly closed and the filter element is flush with the sight glass. Check the filter connections for leaks and the lines for clogging or porous points.

Main fuel filter

Water is heavier than diesel fuel, it settles as a different colour fluid on the bottom. Once the water level reaches the height of the warning connections (sensor B124), the warning lamp (H70) in the monitoring board (A15) will come on.

Fuel pre-heating (option) In diesel engines the pre-heating of the fuel prevents malfunctions caused by the formation of jelly (paraffin separation) in the fuel under low temperatures. The integrated heating is a starting aid for cold weather applications. The heating is delivered with an automatic thermostat to start the heating when the fuel temperature drops below 7°C. The generated heat works directly under the filter element and melts the wax crystals that have formed, so that the fuel can flow through the filter element without restriction. The heating automatically shuts down at a fuel temperature of 24°C. The 200W heating is supplied with 12V D.C-current. The heater is activated when operating the ignition switch; this should take place at least 5 minutes before starting the engine. A normal On/Off switch may be installed to operate the relay. This can be used to e.g. interrupt the current flow to the relay in the summer season.

Fig. 2 Main fuel filter

Caution The main fuel filter is subjected to the approx. 10 bar fuel pre-pressure from the fuel lift pump. This pressure value is considerably higher than on other engines. You should therefore only use original filter elements (Fig. 2) at this point. Similar looking filters with identical dimensions are not necessarily pressure proof! !

A filter, with insufficient pressure resistance, will be destroyed and disintegrate by this high pressure This will cause severe damage in the injection system!

Draining off water or fuel Should the filter element be clogged prematurely (noticeable e.g. by a drop in power), operation of the machine can be continued with the following procedure: ●

Open the bleeding screw (this applies atmospheric pressure to the filter element and loosens larger dirt particles from the underside of the filter, which will then drop down).

358

BOMAG

008 911 63

12.24

Check, clean the water separator

12.24Check, clean the water separator

12.25Change the fuel pre-filter cartridge

Danger Danger of injury!

Danger Fire hazard!

Support the engine hood for all maintenance and repair work.

When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.

!

i

!

Catch running out fuel, do not let it seep into the ground.

Note

The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should therefore check the water separator every day for signs of water.

Do not inhale any fuel fumes.

If a to high quantity is drained off, the filter must be refilled with fuel. See chapter "maintenance as required", bleeding the fuel system. Environment Catch running out fuel and dispose of environmentally. Fig. 4 ●

Close the shut-off cock (Fig. 4) again

Fig. 3 ●

●

Slacken the drain plug (Fig. 3) for a few turns and catch running out fuel / water. Tighten the drain plug again and check for leaks, if necessary replace the seal ring.

Fig. 5 ●

●

008 911 63

Unscrew the fuel filter cartridge (Fig. 5) using an appropriate filter wrench. Clean the sealing face on the filter carrier from any dirt.

BOMAG

359

12.25

Change the fuel pre-filter cartridge

Fig. 6

Fig. 8

Unscrew the water separator from the filter cartridge (Fig. 6).

●

●

●

●

Slacken the bleeding screw (Fig. 8) on the fuel prefilter for 2 to 3 turns. Operate the hand pump manually, until fuel flows out of the slackened bleeding screw (Fig. 8) without air bubbles. Then tighten the bleeding screw while pumping.

Fig. 7

Apply a thin coat of oil to the rubber seal of the water separator 1 (Fig. 7).

●

Screw the water separator on by hand (2), until the seal contacts.

●

●

Tighten the water separator for another half turn (3).

●

Fill the filter cartridge with clean diesel fuel (4). Apply some oil to the rubber seal of the filter element (5) and screw it on by hand, until the seal contacts.

●

●

Tighten the filter element for another half turn (6).

●

Open the shut-off cock (Fig. 4) again. Check the filter cartridge for leaks after a short test run.

●

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.

360

BOMAG

008 911 63

12.26

Change the fuel filter cartridge

12.26Change the fuel filter cartridge Danger Fire hazard! !

12.27Checking the compression ●

Adjust the valves.

●

Disassemble the injection valves.

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. 1 ●

Insert the connecting piece 100 110 with seal ring (Fig. 4).

Fig. 9 ●

●

Loosen and unscrew the fuel filter cartridge (Fig. 9) using an appropriate filter wrench. Clean the sealing face on the filter carrier from any dirt.

Fig. 2 ●

Attach the claws (Fig. 2).

●

Tighten the screw.

Fig. 10 ●

● ●

● ●

Slightly oil the rubber seal (Fig. 10) on the new filter cartridge. Fill the filter cartridge with clean diesel fuel. Turn the new filter cartridge on by hand, until the seal contacts. Tighten the filter element for another half turn. Check the filter cartridge for leaks after a short test run. Fig. 3 ●

008 911 63

Screw on the adapter for connecting piece 100 110 (Fig. 3).

BOMAG

361

12.28

Check, adjust the valve clearance

12.28Check, adjust the valve clearance Caution 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.

Valve adjustment schematic Fig. 4 ●

Connect the compression tester 8005 (Fig. 4).

●

Crank the engine with the starter.

i

Note

Check the compression on each of the cylinders. Compression: 30 - 38 bar The measured compression depends on the starter speed during the measuring process and the altitude of the engine location. Limit values can therefore not be specified exactly. It is recommended to use the compression measurement to compare the cylinders of an engine among each other. Should a deviation of more than 15% be measured, the affected cylinders should be dismantled to examine the cause. ●

●

Fig. 5

Valve 1 (Fig. 5) white = not adjustable Valve (2) black = adjustable

Remove the compression tester 8005 and the connecting piece 100 110. Install the injection valves.

Fig. 6

Crankshaft position 1 (Fig. 6) (4 cylinder engine) ●

Crank the engine with the starter or a spanner by the V-belt pulley until both valves on cylinder 1 are “overlapping”.

Overlapping means: Exhaust valve not yet closed, intake valve starts to open. ●

●

362

Perform the adjustment of the valve by following the adjustment diagram "crankshaft position 1", black mark. For control purposes mark the respective rocker arm with while chalk once the corresponding valve is adjusted.

BOMAG

008 911 63

12.28

Check, adjust the valve clearance

Fig. 7

Fig. 9

Crankshaft position 2 (Fig. 7) (4 cylinder engine) ● ●

Turn the crankshaft one revolution (360°) further. Perform the adjustment of the valve by following the adjustment diagram "crankshaft position 2", black mark.

●

Intake valve

The feeler gauge must fit with little resistance. ●

Loosen the crankcase ventilation valve and swing it to the side.

Fig. 8 ● ●

If the gap is too narrow or too wide for the feeler gauge, the valve must be adjusted.

Adjusting the valve clearance

Fig. 10

Remove the valve cover (Fig. 8).

●

Crankshaft position as per "valve adjustment schematic". ●

●

● ●

●

008 911 63

= 0,3 mm

Exhaust valve = 0,5 mm

Checking the valve clearance ●

Check valve clearance 2 (Fig. 9) between rocker arm (1) and valve (3) with a feeler gauge.

Slightly slacken the counter nut. Adjust setscrew 7 (Fig. 10) with a screwdriver, until the feeler gauge (6) can be inserted and pulled out with little resistance after retightening the counter nut. Perform tests and adjustments on all other adjustable valves. Check the gasket of the valve cover, replace it if necessary. Reassemble the cylinder head cover. Swivel the ventilation valve back to correct position and fasten it. Fasten the air filter again and ensure correct fit of combustion air hoses and clamps.

BOMAG

363

12.29

Boost fuel solenoid valve

12.29Boost fuel solenoid valve During the starting process the solenoid valve is supplied with 12 Volt.

for rising the engine torque during the acceleration phase after starting. For this compensation and to assure starting of the cold engine additional fuel needs to be injected at the time of starting and accelerating.

This injection adaptation serves the purpose of compensating for condensation and leakage losses and

Fig. 11

1


Pos. 1

364

Designation in circuit diagram Y01

Designation

Technical data


12 Volt, approx. 3,5 Amp.

BOMAG

008 911 63

12.30

Engine shut-down solenoid

12.30Engine shut-down solenoid

Fig. 1

1

Engine shut-down solenoid

Pos. 1

Designation in circuit diagram Y13

Designation

Technical data

Engine solenoid

12 Volt, approx. 4 Amp.

General When switching the ignition on, the engine solenoid is supplied with 12 Volt. Interrupting this power supply shuts down the engine. The engine shut-down can be triggered through the ignition switch (S00), the emergency stop button (S01) or the monitoring board in case of too low oil pressure.

008 911 63

BOMAG

365

12.31

Air filter

12.31Air filter The air filter retains the dust contained in the intake air and keeps it away from the engine in order to avoid engine wear. On paved roads the dust content in the air is 1 mg/m3 on average, on sealed roads or construction sites the dust content can rise up to 40 mg/m3.

gine speed and inclination) and thus enable long lasting and low wear engine operation. The air filter has the additional function of damping the air intake noise. This damping is achieved by the design of the air filter in from of a reflection silencer based on the principle of a Helmholz resonator, damping the intake noise by its resonance frequency.

Dry air filters with integrated dust separator are characterized by a good filtering effect (irrespective of en-

Fig. 2

Pos.

Designation in circuit diagram

Designation

Technical data

Visual differential pressure indicator Caution Combustion air lines between filter and engine ("clean air lines") must be absolutely leak tight !

366

and withstand mechanical loads caused by engine vibrations and pressure pulsation.

BOMAG

008 911 63

12.32

Cleaning, changing the dry air filter cartridge

12.32Cleaning, changing the dry air filter cartridge Caution Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element. !

Fig. 5

Pull the main filter element (Fig. 5) with light turning movements.

●

Cleaning the main filter element Caution If necessary, the main filter element may be cleaned up to five times. It must be renewed at the latest after a maximum utilization period of two years. !

Fig. 3

Servicing of the dry air filter is necessary when the yellow piston (Fig. 3) has reached the inscription "Service" in front of a red background, but at the latest after 2 years. After completion of the filter service reset the indicator back to "Zero" by pressing the button.

Removing the main filter element ●

Fully open the engine hood.

The number of cleaning intervals of the main filter element can be marked on the safety element with a ball pen or a felt pen. Cleaning does not make sense if the main filter element is covered with a sooty deposit. Use a new filter cartridge. Incorrectly handled inserts may be ineffective because of damage (e.g. cracks) and cause damage to the engine. Replace the safety cartridge if the main filter element is defective! Additional cleaning intervals between two filter services signalized by the fault monitoring board are not necessary.

Fig. 4 ●

Unclip three clamps on the housing cover and take off the cover (Fig. 4).

008 911 63

BOMAG

367

12.32

Cleaning, changing the dry air filter cartridge Caution When assembling the inner part make sure that the notch in the cover engages in the opening of the inner part. !

Installing the main filter element Slide the main filter element carefully into the housing.

●

When closing the housing cover the main filter element is automatically forced in the correct position. Reinstall the service covers.

●

Fig. 6

Changing the safety filter element

i

Note

For cleaning purposes fit a tube to the compressed air gun (Fig. 6), the end of which should be bent for approx. 90°. The length should reach down to the bottom of the cartridge. Blow the cartridge out with compressed air (max. 5 bar) from inside to outside by moving the tube up and down inside the cartridge, until it if free of dust.

●

Examine the filter cartridge with a torch for cracks and holes in the paper bellows.

●

Caution Do not continue to run the machine with a damaged main filter element. If in doubt use a new main filter element. !

Caution The safety filter element must not be cleaned and should not be used again after it has been removed. !

Break the seal only to replace the safety filter element. 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. ●

Remove the housing cover and pull the main filter element off.

Cleaning the dust bowl

Fig. 8 ●

Fig. 7 ●

●

Pull the internal part (Fig. 7) out and remove the dust from the cover.

●

Reinsert the inner part.

368

Perforate the seal of the safety filter element from inside to outside using a suitable tool (Fig. 8) and pull both latches up. Grip the safety element by both latches and pull it out with slight turning movements.

●

Push in a new safety filter element.

●

Reassemble main filter element and cover.

BOMAG

008 911 63

12.33

Heating flange on engine Caution Make sure that the cover locks engage correctly. !

12.33Heating flange on engine

Fig. 1 Heating flange

The heating flange is a component with an electrically operated heating wire and high energy density used to heat up the intake air in case of very low ambient temperatures. The heating power is approx. 2000 Watt. The heating power improves the cold starting characteristics and the exhaust emissions (white smoke) of the diesel engine. A differentiation is made between preheating, to assure the cold start ability of the engine, and subsequent heating.

i

Note

Pre-heating is triggered by switching on the ignition (12 Volt on control unit A13, terminals 15(7) and S(2)). With a coolant temperature of -30°C the preheating time will be max. 52 seconds, with +5°C the minimum time will be 38 seconds. During the preheating period the control light in the monitoring board is permanently on. In case of a fault the lamp will flash. After-heating is triggered by the starting process (12 Volt on control unit A13, terminal 50(5)). With a coolant temperature of -30°C the subsequent heating time will be max. 180 seconds, with +25°C the minimum time will be 35 seconds. This after-heating time is not indicated by the control light. Caution Multiple activation of the heater control in short term operation (low generator running time) discharges the starter battery. !

If the engine does not start properly in case of automatic starting of the heating flange because the starter does not get energized due to a fault and does not crank the engine, the starting process must be completely aborted (ignition key to OFF, voltage supply to heating flange interrupted). In order to avoid damage to heating flange or charge air hoses caused by overheating, another start of

008 911 63

BOMAG

369

12.33

Heating flange on engine

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

Fig. 3

1

Heating control unit (A13)

2

Heating relay (K14)

Fig. 2 Heating flange (R19) with hose socket BF4M 2012 C

Fig. 4 Coolant temperature sensor

370

1

Temperature sensor (B113) for heating flange control (A13)

2

Coolant temperature switch (B30)

BOMAG

008 911 63

12.33

Heating flange on engine

Pos.

Designation in circuit diagram R19

Designation

Technical data

Heating flange

With a coolant temperature of -30°C the preheating time will be max. 52 seconds, with +5°C the minimum time will be 38 seconds.

(Fig. 2)

With a coolant temperature of -30°C the after-heating time will be max. 180 seconds, with +25°C the minimum time will be 35 seconds. 12 Volt approx. 2000 Watt approx. 167 A approx. 0.07 Ohm 2 (Fig. 3)) 3 (Fig. 3)

A13 K14

Heating control unit Heating relay

12 Volt 12 Volt

1 (Fig. 4)

B113

approx. 2 Ohm at 20°C

2 (Fig. 4)

B30

Temperature sensor for heating flange control (A13) Coolant temperature switch

Contact switches at approx. 110° C to ground

Fig. 5 Heating flange function diagram

1

Heating start

2

Signal lamp

3

Start

4

Switching relay

5

Condition

6

Terminal 15/S

7

Terminal L

8

Terminal 50

9

Terminal R

10 Start process 11 Ready for starting: 0 sec.

008 911 63

BOMAG

371

12.34

Checking the heating flange control

12.34Checking the heating flange control

perature sensor is pulled off (simulated sensor failure), a coolant temperature of 0° C is assumed. Start the heating process.

●

Depending on the coolant temperature the control light (K)(Fig. 1) will light between 30s and 50s, the heating flange relay is energized. Place a tong-test ammeter over the heating flange connecting line.

●

Rated current: 165 Amp +- 10 Amp.

i

Note

The relay must remain energized for another approx. 15 seconds, after the control light has gone out. After the engine has started the after heating time must continue for 35 to 180 seconds. This after-heating time is not indicated by the control light.

Fig. 1 Monitoring module, old design (A15)

Fig. 2 Monitoring module, new design (A15)

i

Note

During the preheating period the control light K (Fig. 1), c (Fig. 2) is permanently on. In case of a fault the lamp will flash. The lamp flashes with a frequency of 1 Hz during the pre-heating phase.

●

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

●

Heating flange failure: Either short circuit or cable breakage at the output of the control unit (A13), terminal R(6)

i

Note

The heating flange only becomes active at a coolant temperature below 25°C. When the plug of the tem-

372

BOMAG

008 911 63

12.35

Electric throttle control

12.35Electric throttle control

Fig. 1 Engine solenoid

Throttle control switch

Fig. 2 Throttle control switch

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

008 911 63

BOMAG

373

12.35

Electric throttle control

Throttle control solenoid Y120

i

Note

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

Fig. 3 Electric circuit of solenoid

The throttle control solenoid 5 (Fig. 3)) is equipped with a pick-up winding (4) and a holding winding (3), both switched in series. The holding winding has a much higher resistance than the pick-up winding. The "aux"-connection is connected between the two windings. The engine solenoid is equipped with a limit switch (2), which is mechanically connected with the governor rod (1) on the diesel engine. This switch bridges the holding winding until the end position of the governor rod is reached (high engine speed) This bridging has the effect, that the "aux"-terminal has the same potential as the "+"-terminal. If the bridge is open, the "aux"-terminal has almost the same potential as the "-" terminal, because of the low resistance of the pick-up winding and the high resistance of the holding winding.

Fig. 5 ●

Measure the gap between stop screw 1 (Fig. 5) and throttle lever (2).

! Caution The gap should be min. 0.1 mm and max. 0.5 mm.

If the gap is too small, the limit switch in the solenoid may not be able to operate. In case of a too wide gap the engine will not reach its maximum speed.

Adjusting the solenoid

Fig. 4 ●

Switch on the ignition.

●

Turn the rotary switch (Fig. 4) to position "MAX".

374

BOMAG

008 911 63

12.36

Engine monitoring

12.36Engine monitoring

Tank gauge, Pin 2: (0Ω ⇒tank fuel, 65Ω ⇒tank empty, 26Ω ⇒tank ½. If no level switch is connected or the cable is broken, the gauge will go out.

Fig. 1 Monitoring module, old design

Output warning buzzer, Pin 1: +UB switching. Output engine shut down, Pin 9: +UB switching.

Pos.

Designation

Control light

Water separator, Pin 3 and 4: Resistance <500kΩ .

Warning buzzer

Engine Engine Remedy shut-down shut-down time time 10 sec.

a

b c d i k

Control light, overheating of engine

red, flashing

Engine oil pressure control light

red, flashing

Control light for engine air filter

not used

X

2 min. X

Low-active

X

X

Low-active

Low-active Charge control light yellow, lights Control light, water in diesel filter Control light, preheating monitoring

High-active yellow, lights

Check V-belt, if necessary repair the generator X

X


X

X

Change the hydraulic oil filter

yellow, lights

j

Coolant provision

Low-active not used

e

Hydraulic oil filter

Low-active yellow, lights Low-active

008 911 63

Switch off vibration, run engine with idle speed or shut down engine if necessary, clean engine oil cooler and radiator, if necessary repair engine. Check the engine oil level, if necessary repair the engine.

BOMAG

375

12.36

Engine monitoring

Tank gauge, Pin 1: (0Ω ⇒tank fuel, 65Ω ⇒tank empty, 26Ω ⇒tank ½. If no level switch is connected or the cable is broken, the gauge will go out.

Fig. 2 Monitoring module, new design

Output warning buzzer, Pin 23: +UB switching. Output engine shut down, Pin 24: +UB switching.

Water separator, Pin 21 and 22: Resistance <500kΩ .

Pos.

Designation

Control light

Warning buzzer

g

Control light, overheating of engine

red, flashing

X

Engine oil pressure control light

red, flashing

h

Control light for engine air filter

not used

f

Charge control light

Engine Engine Remedy shut-down shut-down time time 10 sec.

d

a b

Low-active

X

X

Low-active Low-active yellow, lights

High-active Control light, water in yellow, lights diesel filter Low-active Control light, preheat- yellow, lights ing monitoring Low-active

e

Coolant provision

not used

i

Hydraulic oil filter

Low-active yellow, lights

Switch off vibration, run engine with idle speed or shut down engine if necessary, clean engine oil cooler and radiator, if necessary repair engine. Check the engine oil level, if necessary repair the engine.

Check V-belt, if necessary repair the generator X

X


X

X

Change the hydraulic oil filter

Low-active

376

2 min. X

BOMAG

008 911 63

12.36

Engine monitoring Water separator

Push the plug back on, the plug interlock clicks into place.

●


●

Engine overheating

Fig. 3 Sensor water separator

Press the plug interlock and disconnect the plug (Deutsch plug).

●

Bridge both contacts on the plug of the wiring loom.

●

Fig. 5 Coolant temperature switch

i

Note

Control light i (Fig. 1) a (Fig. 2) lights up. An audible warning will sound and the engine is shut down after 2 minutes. Push the plug back together, the plug interlock clicks into place.

●


●

Press on the locking wire (Fig. 5) and pull off the plug.

●

Engine oil pressure

Bridge both contacts on the plug of the wiring loom.

●

i

Note

Control light a (Fig. 1) g (Fig. 2) flashes. An audible warning will sound and the engine is shut down after 2 minutes. ●

●

Push the plug back on, the plug interlock clicks into place. Check the plug interlock by lightly pulling on the wiring loom.

Emergency stop switch

Fig. 4 Oil pressure switch

Press on the locking wire and pull off the plug 1 (Fig. 4).

●

Apply the contact to engine ground.

●

Fig. 6 Emergency stop switch ●

i

Note

Press the emergency stop switch (Fig. 6). The engine should stop immediately.

The control light b (Fig. 1) d (Fig. 2) flashes. An audible warning will sound and the engine is shut down after 10 seconds. 008 911 63

BOMAG

377

12.37

Engine

12.37Engine Faults

Possible cause

Remedy

The engine does not start

Starter defective or pinion not engaging

Have examined by a specialist

Fuel tank empty

Fill and bleed the tank

Temperature below starting limit

Use winter fuel and engine oil acc. to the ambient temperature.

Fuel filter clogged, in winter due to paraffin separation.

Change the filter. use winter fuel

Fuel lines leaking

Check all line connections for leakages and tighten the fittings.

Battery discharged or not connected

Tighten the pole clamps, check the cable connections

Injection valves or injection pump defective


Battery power too low, battery clamps loose or oxidized, causing the starter to turn too slowly

Have the battery checked, clean the terminal clamps, tighten them and cover them with acid free grease

Especially during winter: the use of too viscous engine oil

Use engine oil suitable for the ambient temperature

Fuel supply restricted, in winter fuel system clogged due to paraffin separation

Change the fuel filter. Check the line connections for leaks and tighten the fittings. Use winter fuel in the cold season.

Incorrect valve clearance

Adjust the valve clearance

Injection valve defective


Injection lines leaking

Check the lines for leakages

Turbo charger defective


Dry air filter dirty

clean, replace if necessary

Excessive play in the throttle cable

Adjust the throttle cable, change it if necessary

Engine oil level too high

Drain the oil to the upper dipstick mark


clean, replace if necessary

Exhaust gas turbo-charger defective


Poor compression due to burned or broken compression rings or incorrect valve clearance

Have compression rings and pistons examined by a specialist, adjust the valve clearance



The engine starts poorly and works irregularly with poor power

Excessive exhaust smoke

378

BOMAG

008 911 63

12.37

Engine

Faults

Possible cause

Remedy

Engine overheats, shut down immediately!

Cooling fins on radiator extremely soiled (the warning light "engine oil temperature" lights)

Clean the cooling fins



Engine oil level too low

Top up engine oil to the upper dipstick mark

Filling capacity of the injection pump not correctly adjusted

Have adjusted by a specialist

Cooling air flow restricted

Clean the cooling air duct

V-belt loos or broken

Tension or replace the V-belt

Engine oil level too high

Drain the engine oil down to the upper dipstick mark


clean, change if necessary

Exhaust gas turbo-charger defective


Charge air hose leaking

Check fastening and connections





Engine oil level too low (control light "engine oil pressure" lights, the warning buzzer sounds)

Top up oil

Leakages in the lubrication system

Shut the engine down immediately, check fittings on oil lines, lubrication oil filter and oil cooler for leaks, if necessary tighten the fittings.

Generator speed too low

Check the V-belt tension, replace the Vbelt if necessary

The generator does not charge the battery, because generator or regulator is defective

Have examined by a specialis

Poor engine power

Engine oil pressure too low

The charge control light lights during operation, the warning buzzer sounds

008 911 63

BOMAG

379

12.38

Special tools, Deutz engine (BFM 2012)

12.38Special tools, Deutz engine (BFM 2012)

Deutsch English Français Español

No.

Druckpumpe für Kühlmitteldichtheitsprüfung

8002

057 250 66 Pressure pump for coolant leakage test. Pompe refoulante pour contrôle de l’étanchéité du liquide refroidisseur Bomba de presión para pruebas de estanqueidad sistema de líquido refrigerante

35409 ©

Kompressionsdruckprüfer

8005

057 250 67 Compression tester Compressiomètre Compresímetro

35410 ©

Düsenprüfgerät

8008

Nozzle tester Pompe d’essai d’injecteurs Comprobador para inyectores

35411 ©

Stecknuss SW 15, lange Ausführung für Einspritzventil. (Überwurfmutter)

8012

Socket a/flats 15, long version for injector (cap nut) Douille de 15, version longue pour injecteur (écrou-raccord). Llave de vaso de 15, versión larga, para inyector (tuerca de unión) 35412 ©

380

BOMAG

008 911 63

12.38


008 911 63

BOMAG

381

12.38


057 250 78

382

BOMAG

008 911 63

12.38



No.

Anschlußstück für Kompressionsdruckprüfer

100 110

Connector for compression tester Raccord pour compressiomètre Pieza de empalme para el compresímetro

35421 ©

Durchdrehvorrichtung

100 320

057 250 80

Turning gear Dispositif vireur Dispositivo de viraje

35422 ©

Durchdrehvorrichtung

100 330

079 947 19 Turning gear Dispositif vireur Dispositivo de viraje

35423 ©

Messuhr M2T mit Feststellring.

100 400

057 250 81

Dial gauge M2T with locking ring Comparateur M2T avec bague d’immobilisation Comparador M2T con anillo exterior de bloqueo

35424 ©

008 911 63

BOMAG

383

12.38


No.


100 750

Messbalken mit Abstandsblättchen zum Messen des OT und des Kolbenüberstandes.

057 250 83

Measuring bar with spacers for gauging TDC and piston projection Barre de mesure avec plaquettes d’écartement pour mesurer le PMH et la cote de dépassement du piston Barra de medición con plaquitas distanciadoras para la medición del PMS y saliente de pistón

35425 ©

100 800

Messgerät zum Messen und Blockieren der Regelstange. Measuring device for measuring and locking control rod Appareil de mesure et de blocage de la crémaillère. Equipo de medición y de bloqueo de la cremallera

35426 ©

100 810

Einstellbolzen für MAG-Wellen. Adjusting pin for mass balancing shafts Pige de calage pour arbres à masses d’équilibrage (MAG) Pernos de ajuste para ejes equilibradores de masa „MAG".

35427 ©

100 830

Andrückvorrichtung für Regelstange Press-on device for control rod Dispositif de montage de cremaillère Dispositivo de presión para la cremallera

35428 ©

384

BOMAG

008 911 63

12.38



No.

Messvorrichtung für Grundkreismessung „Einspritzpumpe und Förderbeginn“.

100 890

Measuring device for base circle measurement Dispositif de mesure du cercle de base Dispositivo de medición del círculo base “bomba de inyección y comienzo de alimentación“

35429 ©

Gradscheibe 360° mit Befestigung an der Schwungscheibe für OT und FB Einstellung.

101 020

Graduated disc 360° with device for fastening to flywheel for TDC and COD setting Disque gradué 360° avec fixation sur volant moteur pour réglage du PMH et point de calage du début d’injection Disco graduado 360° con fijación en el volante, para ajuste del PMS y comienzo de alimentación

Adapter für Gradscheibe.

35430 ©

101 030

Adapter for graduated disc Adaptateur pour disque gradué Adaptador para el disco graduado

35431 ©

Zeiger für Gradscheibe.

101 300

Pointer for graduated disc Index pour disque gradué Indicador para el disco graduado

35432 ©

008 911 63

BOMAG

385

12.38

386


BOMAG

008 911 63

12.38



No.

Spezialschlüssel für Einspritzleitung

110 500

057 250 86

Special wrench for injection line Clé spéciale pour conduite d’injection Llave especial para tubería de inyección

35436 ©

Ausziehvorrichtung für den Dichtring unter dem Einspritzventil.

120 680

Extractor for sealing ring beneath injector Outil d’extraction pour le joint de l’injecteur Dispositivo de extracción para el anillo de junta del inyector

35437 ©

Aufspannbock für Zylinderkopf.

120 900

057 250 90

Clamping stand for cylinder head Chevalet d’ablocage pour culasse Caballete de sujeción para culata

35438 ©

Aufspannplatte für 120 900.

120 910

057 250 91

Clamping plate for 120 900 Plaque d’ablocage pour 120 900 Placa de sujeción para 120 900

35439 ©

008 911 63

BOMAG

387

12.38


No.


121 410

Montagewerkzeug für Ventilschaftabdichtung Sleeve for fitting valve stem seal Outil de montage pour joint de tige de soupape Util de montaje para juntas de vástago de válvula

35440 ©

130 300

Kolbenring-Auflegezange Piston ring pliers Pince à monter les segments de piston Alicates para colocar aros de pistón

35441 ©

130 440

Trapeznut-Verschleißlehre Trapezoidal groove wear gauge Jauge d’usure pour gorge trapézoïdale Calibre de desgaste para ranura trapezoidal

35442 ©

057 250 97

130 660

Kolbenringspannband Ø 98 mm Piston ring compressor Collier à segments de piston de Ø 98 mm Compresor de aros de pistón, Ø 98 mm

35443 ©

388

BOMAG

008 911 63

12.38



No.

Kolbenringspannband Ø 101 mm

130 670

057 250 98

Piston ring compressor Collier à segments de piston de Ø 101 mm Compresor de aros de pistón, Ø 101 mm

35443 ©

Montagewerkzeug für Kurbelwellendichtring vorn.

142 670

Assembly tool for front crankshaft seal

079 947 26

Outil de montage de bague d’étanchéité de vilebrequin AV Herramienta de montaje para el retén delantero del cigüeñal

35445 ©

Montagewerkzeug für Kurbelwellendichtring hinten.

142 830

079 947 27

Assembly tool for rear crankshaft seal Outil de montage de bague d’étanchéité de vilebrequin AR Herramienta de montaje para el retén trasero del cigüeñal

35446 ©

Montagewerkzeug für MAG-Buchsen.

143 780

Assembly tool for engine balancer bushes Outil de montage de douilles d’arbres à masses d’équilibrage Herramienta de montaje para casquillos de ejes equilibradores

35447 ©

008 911 63

BOMAG

389

12.38


057 250 99

079 947 18

390

BOMAG

008 911 63

12.38



No.

Maul-Steckaufsatz für Drehmomentschlüssel (mit großem Vierkant 14 x 18 mm) für Lüfter (Ein- / Ausbau) - Zentralmutter

160 340

Open jawed wrench socket for torque wrench (large square wrench 14 x 18 mm) for fan (assembly and removal) – center nut Embout à mâchoire pour clé dynamométrique (à grand quatre-pans 14 x 18 mm) pour ventilateur (démontage/remontage) – écrou central Boca enchufable para llave dinamométrica (con macho cuadrado grande 14 x 18 mm) para (montaje/desmontaje) tuerca central del ventilador

Gegenhalter für Zahnrad Luftpresser

35455 ©

170 630

Dolly for air compressor gear Dispositif de maintien pour pignon de compresseur d’air Dispositivo de retención para rueda dentada compresor de aire

35450 ©

Motormontagebock für doppelseitige Aufspannung

6066

Engine assembly stand for double-sided chucking Chevalet de montage moteur avec double ablocage

079 947 30

Caballete de montaje para sujeción bilateral del motor

35451 ©

1 Satz Aufspannwinkel für doppelseitige Auf spannung.

6066/158

1 Set of angled clamping plates for double-sided chucking 1 jeu d’équerre de fixation pour double ablocage

079 947 31

1 juego de angulares para sujeción bilateral

35452 ©

008 911 63

BOMAG

391

12.38

392


BOMAG

008 911 63

13 Air conditioning system

008 911 63

BOMAG

393

13.1

Physical basics

13.1 Physical basics

A - heat absorption

In order to understand the working principle of an air conditioning system one must first become familiar with the physical basics of such a system.

B- Heat dissipation

The four well known physical conditions of water apply also for the refrigerant in the air conditioning system. 1. gaseous (invisible) 2. vaporous 3. liquid 4. solid

Fig. 2

Heat always flows from the warmer to the colder matter. Any matter consists of a mass of moving molecules. The rapidly moving molecules or a warmer matter dissipate part of their energy to the slower moving molecules with less heat. The movement of the molecules in the warmer matter becomes slower and the molecules in the cooler matter are accelerated. This process continued, until all molecules in the two matters move with identical speed. The matters have then reached an identical temperature and the transfer of heat stops.

Fig. 1

If the water in a container is heated up (absorption of heat), the rising steam is visible. If the steam is heated up further, due to the absorption of heat, the visible steam will turn into invisible gas. This process is reversible. When withdrawing the heat contained in gaseous water, the gas will turn into steam, then into water and finally into ice.

394

BOMAG

008 911 63

13.1

Physical basics Pressure and boiling point The boiling point is the temperature at which fluid changes to gaseous state. Changing the pressure above a fluid also changes the boiling point. It is a well known fact, that e.g. the lower the pressure applied to water, the lower the boiling point. When looking at water, the following values do apply: ●

Atmospheric pressure, boiling point 100°C

●

Overpressure 0.4 bar, boiling point 126°C

●

Vacuum -0.6 bar, boiling point 71°C

4. If a fluid evaporates it requires a lot of heat, i.e. the fluid thereby cools down the surrounding environment (e.g. alcohol on skin)

i

Note

At absolute pressure 0 bar correspond with an absolute vacuum. The normal ambient pressure (overpressure) corresponds with 1 bar absolute pressure. On the scales of most pressure gauges 0 bar corresponds with an absolute pressure of 1 bar (indicated by the statement -1 bar below the 0).

For an optimal exchange of heat, liquid refrigerants must have a low boiling point, so that they can absorb and dissipate heat quickly.

Fig. 4 Pressure - Temperature Diagram

In the pressure - temperature diagram for the refrigerant the drawn in closed curve shows the cycle of the refrigerant. This cycle permanently continues in direction of the arrow. The characters A, B, C, D stand for: Fig. 3 Steam pressure curve

A - compression

Steam pressure curve for refrigerant R134a

B- condensation

The steam pressure curve is a means for explaining the operation principle of an air conditioning system.

C- relaxation D- evaporation.

A- liquid B- gaseous The diagram shows the evaporation curve of R134a. The diagram for example shows, that R134a is liquid at 0°C and a pressure of 5 bar, but becomes gaseous at 40°C and 5 bar. For better understanding one must also be aware of the following: 1. A gas heats up when being compressed (e.g. air pump, turbo charger, ...). 2. When relieving gas it will cool down (e.g. white frost forms on the valve when relieving air pressure from a car tire). 3. Condensing gas dissipates a lot of heat energy. 008 911 63

BOMAG

395

13.1

Physical basics

Excerpt from the wet steam table 1 R134a 1

This table is used for the determination of evaporation and condensation temperature.

Saturation temperature -20 -10 0 10 20

396

Overpressure (pressure gauge reading Pe in bar) 0,33 1,01 1,93 3,15 4,72

BOMAG

Absolute pressure (pamb = 1 bar P in bar) 1,33 2,01 2,93 4,15 5,72

008 911 63

13.2

Refrigerant R134a

13.2 Refrigerant R134a

Characteristics of the refrigerant R134a:

General The evaporation and condensation process is the method commonly used in mobile air conditioning systems. The system in this case works with a substance that boils at low temperature, a substance referred to a refrigerant. The refrigerant used is tetrafluoroethane R134a, which boils at a temperature of -26.5°C and under a steam pressure of 1 bar. Although the refrigerant circuit is a hermetically closed loop, the system loses approx. 100g of refrigerant over the course of 1 year by diffusion through hoses, pipes and seals, even though the system is free of leaks. If too much refrigerant is lost the cooling power of the system will drop. Physical data of the refrigerant R134a

Refrigerant R134a is currently available under the following trade marks. H-FKW 134a SUVA 134a KLEA 134a

Colour: Refrigerant in form of vapour or liquid is colourless as water. The gas is invisible. Only the bordering layer between gas and liquid is visible. (Fluid level in rising pipe of filling cylinder or bubbles in inspection glass). In the inspection glass the liquid refrigerant R134a may appear coloured (milky). This turbidity results from partially dissolved refrigeration oil and is no indicator for a fault.

Steam pressure:

Chemical formula:

In an incompletely filled, closed container, vaporous refrigerant will volatilize from the surface in the same quantity that will turn liquid in combination with steam particles. This state of equilibrium occurs under pressure and is frequently referred to as steam pressure. The steam pressure is independent from the temperature.

CH2F-CF3 or CF3-CH2F

Chemical designation: Tetrafluoroethane

Boiling point at 1 bar: Physical properties of R134a:

- 26.5 °C

The steam pressure curves of R134a and other refrigerants are partly very similar, making a clear differentiation solely by pressure impossible. With R 134a the compressor is lubricated by special synthetic refrigeration oils, e.g. PAG-oils (polyalkylene glycol oils).

Solidification point: -101.6 °C

Critical temperature:

Behaviour with metals:

100,6 °C

In pure condition refrigerant R134a is chemically stable and does not attack iron and aluminium. However, contamination of the refrigerant, e.g. with chlorine compounds, leads to aggressiveness against certain metals and plastics. This can cause clogging, leaks or deposits on the pistons of the compressor.

Critical pressure: 40.56 bar (absolute)

Critical point: Critical point (critical temperature and critical pressure) means that above this point there is no separating interface between liquid and gas. Above its critical point any substance is gaseous. At temperatures below the critical point all refrigerant types in pressure containers have a liquid and a gaseous phase, i.e. a gas cushion is above the liquid. As long as gas is in the container, besides the liquid, the pressure depends on the ambient temperature.

Critical temperature / critical pressure: Up to a gas pressure of 39.5 bar overpressure (this corresponds with a temperature of 101 °C) the refrigerant R134a remains chemically stable, above this temperature the refrigerant decomposes (see combustibility).

Water content: In liquid refrigerant water can only be dissolved in very low quantities. In contrast to this refrigerant steam mixes with water steam at any ratio. If the dryer in the

008 911 63

BOMAG

397

13.3

Compressor oil / refrigeration oil

liquid container has absorbed approx. 8 gr. of water, the refrigerant circuit transports possibly existing water in form of droplets. This water flows to the nozzle of the expansion valve and turns to ice. The air conditioning system stops cooling. Water destroys the air conditioning system, because under high pressures and temperatures and in connection with other contaminants it forms acids.

Inflammability: Refrigerant is not inflammable. On the contrary, it has fire inhibiting or fire extinguishing properties. Refrigerant is decomposed by flames or glowing surfaces. Ultraviolet light also cracks refrigerant (caused by electric welding). This results in toxic fission products, these must not be inhaled. However, irritation of the mucous membranes is an early and in-time warning.

Filling factor: In a container there must be a steam space above the liquid space. The liquid expands with increasing temperature. The steam filled space becomes smaller. From a certain time on the container will be filled with just liquid. After this only a minor temperature increase is enough to generate very high pressures in the container, because the liquid would like to expand, but there is no more room. The related forces are high enough to cause the container to burst. In order to avoid overfilling of a container the pressure gas directive clearly specifies how many kilograms of refrigerant may be filled into the container per litre volume. Multiplied with the internal volume this "filling factor" determines the permissible filling capacity For refrigerants used in motor vehicles it is 1.15 kg/l.

Environmental aspects The contribution of R134a to the greenhouse effect is by factor 10 smaller than the contribution of R12.

13.3 Compressor oil / refrigeration oil The compressor oil lubricates the movable parts in the compressor, seals e.g. the gap between piston and cylinder inside the compressor to prevent refrigerant loss and prevents other seals in the system from drying up. Part of the compressor oil dissolves in the refrigerant until saturation is reached, so that a gas mixture of refrigerant, water steam, compressor oil and contrast agent circulates through the system. Compressor oil (the oil quantity should be 10 % of the refrigerant weight) mixes with the refrigerant and circulates permanently through the system. In connection with R134a- air conditioning systems special synthetic compressor oils, e.g. polyalkylene glycol (PAG) oils, are used. This is necessary, because e.g. mineral oil does not mix with R134a. Apart from this, the materials in the R134a air conditioning system may be attacked when the mixture is flowing through the refrigerant circuit under high pressure and at high temperatures or if the lubrication film in the compressor tears off. The use of non-permitted oils can cause damage to the air conditioning system, you should therefore only used the approved oils.

Properties of compressor oil / refrigeration oil: The most important properties are high solvency in connection with refrigerants, good lubrication characteristics, that they are free of acids and their low water content. For this purpose only certain oils can be used. PAG-oils suitable for use with refrigerant R134a are highly hygroscopic and will not mix with other oil. As a protection against the invasion of moisture drums must immediately be closed again after they had been opened. Compressor oil ages under the effect of moisture and acids, becomes dark, viscous and aggressive against metals.

Since approx. 1992 the air conditioning systems for newly produced construction equipment were successively converted to refrigerant R134a. This refrigerant does not contain any chlorine and is thus harmless for the ozone layer. Until approx. 1992 air conditioning systems were filled with refrigerant R12. Due to its chlorine atoms this CFC has a high ozone decomposition potential and also a potential to amplify the greenhouse effect. Conversion programs for existing old systems with the ozone damaging R12 are in effect. For reasons of protecting the environment refrigerant must not be discharged into the atmosphere.

398

BOMAG

008 911 63

Working principle of the air conditioning system

13.4 Working principle of the air conditioning system

13.4

13.5 Monitoring devices

All air conditioning systems are based on the same principle. They extract heat from the surrounding environment. Everybody knows the effect: if a sweating body is exposed to wind it will cool down, because heat is extracted. For this purpose a refrigerant circulates in a closed circuit inside the vehicle. This refrigerant thereby continuously changes its physical state between liquid and gaseous.

Fig. 1 Principle sketch of an air conditioning system

An engine driven compressor (1) draws in gaseous refrigerant from the evaporator (5) and compresses it. During this process the temperature of the refrigerant increases tremendously. The refrigerant vapour is then pumped to the condenser (2). This condenser is arranged directly in front of the vehicle radiator, so that a sufficient air flow is assured. In the condenser (2) the gas is cooled down and consequently liquefied. In the dryer / liquid container (3) the refrigerant is then collected and freed of moisture and contaminants. The expansion valve (4) regulates the flow rate from the dryer / liquid container (3) back to the evaporator (5) and the circuit starts again.

Pressure switch The pressure switch (8) is used as monitoring feature for too high and too low pressures. The switching contacts (4 and 5) effect the magnetic clutch of the compressor via a relay (6). If the system pressure increases excessively, e.g. because of a excessively soiled condenser, a failed fan or a defective expansion valve, the high pressure contact (5) will cut off the electric power supply to the magnetic clutch when the set pressure is reached. When the system pressure drops below the cut-off pressure by the set differential pressure, the magnetic clutch of the compressor is switched on again. The low pressure contact (4) interrupts the electric power supply to the magnetic clutch when the set pressure is fallen short of (possible causes: lack of refrigerant, defective expansion valve, too low heat load, defective evaporator fan, ...). Since the refrigerant R134a has an evaporation temperature of 0 °C at an overpressure of 2 bar, the low pressure contact (4) is set to approx. 1.5 bar to avoid icing. The switch on pressure is 0.5 to 2 bar higher than the shut-off pressure (depending on system, see description of components.) Thermostat A frost protection thermostat (3) protects the evaporator against icing. Similar to the pressure switch, the thermostat activates or deactivates the magnetic clutch for the compressor. Depending on the design, the feeler of the temperature control is mounted between the fins of the evaporator or attached to the evaporator outlet (suction side). With fixed temperature controls the control switches the compressor off at about 1 °C and back on again at about 2.5°C to 5.5 °C (depending on system, see description of components.) With adjustable temperature regulators the switching point can be changed so that the compressor is already shut down at higher temperatures. This enables regulation of the air temperature.

008 911 63

BOMAG

399

13.6 Monitoring chain

Description of components

13.6 Description of components Compressor

Fig. 2 Monitoring chain consisting of: ●

1 Switch

●

2 Fuse

●

3 Thermostat

●

4 Low pressure switch contact

●

5 High pressure switch contact

●

6 Relay

●

7 Connection for magnetic clutch

●

8 Pressure switch

Fig. 1

The compressor is mounted to the engine and has the duty to build up the refrigerant pressure required for the function of the system. Coupling and decoupling is accomplished by an electromagnetically controlled mechanical clutch, which is integrated in the V-belt pulley of the compressor. Compressor data Displacement: 155 cm² Weight: 6,9 kg max. rpm: 6000 Sense of rotation: cw Refrigerant: R134a Oil quantity (scope of delivery): 207 gr Oil: PAG SP-20 (H14-003-404) Caution The compressor oil level must be checked after replacing a system component or if a leak in the system is suspected. Use only refrigeration oil PAG SP-20 (H14-003-404). !

When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil / refrigeration oil lost by exchanging the components, must be replaced with fresh oil. The actual quantity depends on the amount of oil that may have been lost in connection with the possible replacement of other components. Environment Used compressor oil / refrigeration oil must be disposed of as hazardous waste. The following table shows how much compressor oil / refrigeration oil will be lost in connection with various types of work on the air conditioning system. 400

BOMAG

008 911 63

13.6

Description of components Condenser

Reason of oil loss Amount of oil lost Loss when emptying approx. 15 gr Defective A/C hose approx. 30 gr Hose change approx. 15 gr Replacement of condens- approx. 30 gr er Replacement of evapora- approx. 30 gr tor Replacement of liquid con- approx. 30 gr tainer Replacement of expan- approx. 15 gr sion valve Caution Please bear in mind, that the new compressor is delivered with a filling of 207 gr. compressor oil. To avoid excessive oil in the A/C-system and thus a poor cooling effect, the oil level in the A/C-system must be adjusted accordingly. !

The quantity depends on the amount of oil that may have been lost in connection with the possible replacement of other components. The compressor oil quantity must be 10% of the refrigerant quantity in the complete system. With a refrigerant filling of 1100 gr. the system requires a compressor oil / refrigerant oil filling of 100 gr. Procedure: Drain and measure the compressor oil from the old compressor.

Fig. 1

The condenser is located in front of the the radiator for the machine. It emits heat energy from the system into the surrounding air and liquefies the gaseous refrigerant.

i

Note

The fins must be free of dirt and damage. Caution When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil lost by exchanging the components, must be replaced with fresh oil. !

Drain the compressor oil from the new compressor and only fill in the exact quantity that had been drained out of the old compressor. The compressor oil from the new compressor can be used for this purpose.

i

Note

Topping up compressor oil / refrigeration oil is possible on a pressureless compressor directly into the oil pan, in a pressureless refrigeration system directly into the pressure side, but it is also possible to draw it into the pressure side of the refrigeration system during the evacuation process.

008 911 63

BOMAG

401

13.6


Dryer / filter / fluid container / inspection glass

Safety valve

Fig. 2

The fluid container is equipped with a safety valve.

Fig. 1

Response pressure 32 +/- 4 bar

Dryer / filter The fluid container collects the fluid drops and passes these then as a constant flow to the expansion valve. Moisture that has entered during assembly of the refrigerant circuit is absorbed by a dryer in the fluid container.

Tightening torque 10 - 15 Nm Inspection glass

At evaporation temperatures below zero the refrigerant will deposit previously absorbed moisture on the expansion valve, where this water turns into ice and thus adversely affects the controllability of the expansion valve. Moreover, moisture in the refrigerant circuit causes corrosion, forms acids and enters into chemical compositions. Inside the refrigerant container the heavy liquid refrigerant collects in the lower part of the container, flows through a rising pipe to the outlet marked "A" and thus ensures bubble free operation of the expansion valve. Fig. 3

i

Note

Since the absorbing capacity of this filter/dryer is limited, it must be changed within certain service intervals. We recommend to replace it 1 x per years, before the start of the season. Caution The filter/dryer must generally be replaced whenever opening the refrigerant circuit, because moisture will enter in such a case. !

This requires emptying the air conditioning system! Installation position: The arrow marks on the filter/dryer must point in flow direction, i.e. towards the expansion valve. Filter/dryer cannot be treated for further use!

402

During operation the refrigerant must flow through the inspection glass without air bubbles. In most cases the presence of air bubbles is a sign for a too low refrigerant level in the system. Apart from this, the refrigerant may not sufficiently condense as a result of a soiled evaporator or a defective condenser fan and the fluid level in the refrigerant container may drop down to a level, at which gaseous refrigerant could flow through the rising tube to the inspection glass. This results in abnormally high temperatures in and on the fluid lines (between refrigerant container and expansion valve), as well as very high pressures in the pressure side. However, incorrect evacuation or filling may also be the reason for air entering into the system and since air cannot be condensed, one will not be able to get rid of these bubbles by topping up refrigerant. In this case the air conditioning system needs to be evacuated and refilled.

BOMAG

008 911 63

13.6


i

Expansion valve

Note

Air in the system is characterized by high pressures and temperatures. On R134a refrigeration systems from KONVEKTA the inspection glasses are equipped with moisture indicators. In addition to the float, the dryer/collector/inspection glass combination has an indicator pearl integrated in the inspection glass, which changes its colour when absorbing moisture. The refrigerant level should be inside the inspection glass and should only be checked after approx. 5 minutes continuous operation, because the refrigerant must first evenly distribute all over the system. ! Danger In case of mechanical damage or corrosion on this pressure container this collector unit must be replaced, to avoid bursting and further damage.

Fig. 1

The expansion valve is mounted inside the HKL-module in the cabin. The expansion valve always allows a small amount of the high pressure liquefied refrigerant to flow into the evaporator, which has a much lower pressure. This lower pressure causes these liquid refrigerant to expand and to evaporate to gaseous state. The heat required for this evaporation process is taken from the ambient air through the lamellas and supplied to the refrigerant. This is the so-called cooling effect. The thermostatic expansion valve operates with an external pressure compensation. This type of expansion valve works with high accuracy, because it uses pressure and temperature at the evaporator outlet and adjusts and overheating of approx. 7 K. The already installed expansion valves and the ones delivered as spare parts have this overheating value pre-set. In order to prevent a loss in performance or compressor damage you should only use original expansion valves, because adjusting expansion valves takes a lot of time and care.

i

Note

In case of dirt in the refrigerant system you should also check or clean the screen at the expansion valve inlet.+

008 911 63

BOMAG

403

13.6


Evaporator

Defroster thermostat

Fig. 1

Fig. 1

The evaporator is mounted inside the HKL-module in the cabin. It consists of a heat exchanger (inside air refrigerant), with refrigerant flowing to a pipe system with cooling flanges. As with the condenser, correct operation of all fans and cleanliness of the fins must be assured. Air conditioning systems have a circulation air filter mounted in the air flow in front of the evaporator, which should be cleaned or changed by the operator after each third trip, depending on the amount of dirt. A condensation water filter is mounted in the air flow after the evaporator. This filter has the function to collect the water that has condensed from the air in the evaporator block and to discharge this water into the water pan With a defective condensation water filter condensation water may flow into the inside of the vehicle.

The feeler of a defroster thermostat to switch off the magnetic clutch in case of icing up or to switch the clutch back on after defrosting, is mounted on the evaporator. The correct adjustment of the defroster thermostat as well as the correct feeler assembly should be checked during maintenance. Switching point on: + 1°C (± 1°C) Switching point off: + 5,5°C (± 1°C)

i

Note

It is very important that the feeler is mounted downstream of the evaporator, but before the pressure sensor, in countercurrent direction, with full length and insulated against the outside temperature.

Caution When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil lost by exchanging the components, must be replaced with fresh oil. !

404

BOMAG

008 911 63

13.6

Description of components Pressure switch

Pipes and hoses Pipes and hoses in air conditioning systems must meet very high requirements with respect to resistance against heat and pressure. The requirements concerning leak tightness and, in case of hoses, against diffusion, i.e. seepage of refrigerant through the hose material, are very high. Pipes and hoses to be used must therefore be specially made for air conditioning purposes. For this reason the hoses have an inside lining of butyl rubber and an outside coating of EDPM rubber. Hose sections exposed to heat are provided with a special heat insulation.

Fig. 1

After a minimum pressure is reached in the low pressure side or a maximum pressure in the high pressure side, the pressure switch will switch of the magnetic clutch of the compressor, thus to avoid destruction of system components by excessive pressure or drawing in external gases and foreign matter as a result of too low pressure. Working pressure: Low pressure off: 1,5 ±0,5 bar Low pressure on: 3.5 bar Overpressure off: 25,0 ±1,5 bar Overpressure on: 18,0 ±1,5 bar

O-rings are made of a special type of chloroprene rubber (neoprene). Before assembly of the air conditioning system these O-rings must be lubricated with compressor oil / refrigeration oil. The O-rings must always be replaced when assembling A/C-components. Recommended tightening torques for O-ring sealed fittings Thread 5/8“ 3/4“ 7/8“ 1 1/16“ M30X2 M36X2

Bending radii for air conditioning hoses Hose type GH 134 GH 134 GH 134 GH 134 GH 494 GH 494 GH 494

008 911 63

Spanner width Torque 17 or 19 13,6 - 20,3 Nm 32,5 - 39,3 Nm 27 35,3 - 42,0 Nm 32 40,7 - 47,5 Nm 36 105,0 - 115,0 Nm 41 165,0 - 175,0 Nm

BOMAG

Nominal width NW8 NW10 NW12 NW16 NW20 NW25 NW32

Bending radius min. 50 mm min. 65 mm min. 75 mm min. 100 mm min. 160 mm min. 194 mm min. 225 mm

405

13.7

Checking the compressor oil level

13.7 Checking the compressor oil level Checking the compressor oil level / refrigeration oil level Caution The compressor oil level must be checked after replacing a system component or if a leak in the system is suspected. Use only compressor oil / refrigeration oil PAG SP-20 (H14-003-404). !

●

●

Run the compressor for 10 minutes at engine idle speed. In order to avoid any compressor oil losses you should slowly drain all refrigerant from the air conditioning system.

Fig. 2

Turn the nut that hold the armature clockwise with a socket wrench, until the counterweight is correctly positioned.

●

i

Note

2 o'clock position with inclination to the right (Fig. 2). 10 o'clock position with inclination to the left ● ●

●

Insert the oil dipstick. Pull out the dipstick and count the notches covered by oil. Drain off oil or fill up as specified in the table.

Environment Used compressor oil / refrigeration oil must be disposed of as hazardous waste. Fig. 1 ●

●

Measure the fastening angle (Fig. 1) of the compressor (oil plug at top) Remove the oil filler plug.

Fastening angle (degree) 0 10 20 30 40 50 60 90 ●

Oil dipstick in increments 5-7 6-8 7-9 8-10 9-11 10-12 11-13 16-18

Screw the oil filler plug back in.

! Caution The contact area must be clean and should be free of damage.

Use a new O-ring. Tightening torque 15 to 25 Nm ●

406

Refill the air conditioning system.

BOMAG

008 911 63

13.8

Checking the magnetic clutch

13.8 Checking the magnetic clutch

Take off the drive V-belt and rotate the V-belt pulley by hand while the magnetic clutch is disengaged.

●

i

Note

The gap should be 0.4 to 0.8 mm.

Measure the voltage.

●

i

Note

Nominal value = vehicle voltage ●

Check the magnetic coil locking ring for secure fit.

●

Check the current consumption.

i

Note

In case of excessive flatness faults or deviations the magnetic clutch needs to be replaced.

Cross-section of magnetic clutch Fig. 3 shows a cross-section of the magnetic clutch. If the coil (7) is not supplied with operating voltage, there is no contact between the front plate of the clutch (1) and the V-belt pulley (2). A spring presses the front plate away from the belt pulley. The V-belt pulley rotates with the bearing (3) in idle speed, the compressor does not work. When the coil is supplied with operating voltage (12 or 24 V), a magnetic field is generated and pulls the front plate of the clutch. Both front plate and compressor shaft (8) are then driven by the V-belt pulley, the compressor works.

Fig. 1

i

Note

at 12 Volt vehicle voltage approx. 3.5 Amp. at 24 Volt vehicle voltage approx. 1.75 Amp. Overcurrent indicates a short circuit inside the magnetic coil. No current indicates an interrupted electric circuit.

Fig. 3 Cross-section of magnetic clutch

Fig. 2 Measuring the air gap ●

Measure the air gap on the magnetic clutch between V-belt pulley (2) and thrust plate (1).

008 911 63

BOMAG

407

13.9

Inspection and maintenance work

13.9 Inspection and maintenance work ●

●

●

●

●

Visual inspection of the complete system for damage. Check the compressor mounting bracket on the vehicle engine for tight fit and damage. Check the condition, alignment and tightness of the V-belt. Check the routing of refrigerant hoses and cables in the area of the vehicle engine and transmission, as well as on the chassis for chafing and rectify any detected faults. Ensure sufficient clearance to hot parts, such as the exhaust; install a protective shield, if necessary.

Check all hose and screw fittings for leaks.

●

Check the fastening of the condenser unit.

● ●

●

●

●

●

●

Danger Danger of injury! !

Work on the V-belt must only be performed with the engine shut down. Wear safety goggles.

Check the V-belt

Check the routing of hoses and hoses on the attachment box or in the cabin.

●

●

13.10Checking, replacing the refrigerant compressor V-belt1

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

Fig. 4

Check the electric control panel. If discolorations on conductors are found, these should be replaced and possibly also the corresponding relays.

●

Switch on the cooling system and check the refrigerant level.

●

Filter/dryer and filter/dryer/fluid container combinations must always be replaced after opening the refrigerant circuit. If these are in service for more than 1 year, there is a risk that they may be clogged by excessive absorption of moisture! The filter/dryer should be replaced in regular intervals.

Inspect the entire circumference of the V-belt (Fig. 4) visually for damage and cracks. Replace damaged or cracked V-belts. Check with thumb pressure whether the V-belt can be depressed more than 10 to 15 mm (0.4 – 0.6 inches) between the V-belt pulleys, retighten if necessary.

Tighten the V-belt.

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

Fig. 5 ●

Slightly slacken fastening screws 1, 2 and 3 (Fig. 5).

1

408

BOMAG

Optional equipment

008 911 63

13.11

Service the air conditioning Press the compressor in direction of arrow, until the correct V-belt tension is reached.

●

Retighten all fastening screws.

●

13.11Service the air conditioning1 Cleaning the condenser

Changing the V-belt Slightly slacken the fastening screws 1, 2 and 3.

●

Press the compressor against the direction of arrow completely against the engine.

●

●

Take the old V-belt off.

●

Fit the new V-belt to the V-belt pulleys.

●

Tension the V-belt as previously described.

Caution Check the V-belt tension after a running time of 30 minutes. !

! Caution A soiled condenser results in a considerable reduction of air conditioning power.

Under extremely dusty conditions it may be necessary to clean the condenser several times per day. If, during operation of the air conditioning system, the warning buzzer sounds switch the air conditioning off and clean the condenser. In case of formation of foam have the air conditioning system inspected by the service department. Danger Danger of accident! !

Do not clean with a hot water jet. Heat will cause extreme overpressure, which could cause damage or explosion of the system. Use access steps and grips to mount and dismount the machine.

Fig. 6 ●

●

Unscrew the condenser fastening screws (Fig. 6) and fold the condenser forward. Clean the condenser fins on front and back with compressed air or cold water .

Checking the refrigerant level

008 911 63

●

Start the engine.

1

Optional equipment

BOMAG

409

13.11

Service the air conditioning

Fig. 7

Fig. 9

Switch the air conditioning (Fig. 7) on.

●

Check whether the white float (Fig. 9) inside the inspection glass of the drier/collector unit floats right at the top.

●

i

Note

The refrigerant level is correct.

Fig. 8

Choose a cooling temperature with the rotary switch for cabin heater (Fig. 8) in the blue section.

●

Open the air outlet nozzles.

●

Check, whether the outflowing air is noticeably cooler.

●

Fig. 10

If the white float (Fig. 10) inside the inspection glass of the drier/collector unit floats at the bottom, inform the service department.

●

i

Note

The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on. ●

Open the hood.

i

The refrigerant level is not correct. ●

410

Note Refrigerant must be filled up, if necessary check the air conditioning system for leaks.

BOMAG

008 911 63

13.11

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

Fig. 12 ●

Fig. 11

Check the drier/collector unit (Fig. 12) for mechanical damage or rust.

Check the moisture indication pearl (Fig. 11) inside the inspection glass of the drier/collector unit.

●

orange

= drying agent o.k.

colorless = moisture level of drying agent too high. Inform the service department. Replace drier/collector unit, check air conditioning system.

●

Caution Have the drier/collector unit replaced by the service department every year before the operating season. !

Checking the condition of the drier/collector unit Caution According to the regulation for pressure reservoirs all pressure reservoirs must be repeatedly inspected by a specialist. In this sense repeated inspections are external examinations, normally on pressure reservoirs in operation. In connection with this inspection the drier/collector unit must be visually examined twice every year. During these inspections special attention must be paid to corrosion and mechanical damage. If the reservoir is not in proper condition it must be replaced for safety reasons, as a precaution to protect operators and third parties against any danger arising from the handling and operation of pressure reservoirs. !

! Danger Danger of injury!

In case of mechanical damage or corrosion on this drier/collector unit this unit must be replaced, to avoid bursting and further damage.

008 911 63

BOMAG

411

13.12

Drying and evacuation

13.12Drying and evacuation

13.13Emptying in case of repair

Evacuation of air conditioning systems using R-type refrigerants not only has the purpose of emptying the system of all air before filling in refrigerant, but also to verify the leak tightness over a longer lifetime in the achieved vacuum. However, the most important factor in this work step is the drying of the system.

For repair work the air conditioning systems must very often be emptied of all refrigerant.

Any water residues in the refrigerant circuit will combine with the refrigerant, which will lead to the previously described consequential damage. Vacuum pumps with a capacity of more than 100 l/min and a final pressure of less than 30 micron, i.e. 0.039 mbar should be used to evacuate the refrigeration system. The refrigerant compressor is not suitable for the purpose of evacuation, because it is not able to achieve a sufficient final vacuum and, apart from this, may be mechanically damaged because of a lack of lubrication when running empty during evacuation. It is common practice to evacuate the refrigeration system to a final vacuum of 1 Torr, i.e. 1.33 mbar. An exact time for evacuation and drying cannot be predicted. It can only be determined by means of a vacuum meter. However, if there is no vacuum meter at hand it is generally better to evacuate 1 hour longer than 1 hour too less. Function drying: Under normal ambient pressure (1.013 mbar) evaporates absolute at 100° C. If the pressure is reduced, water will already evaporate, e.g. under a pressure of 10 mbar, at an ambient temperature of almost 7°C, but the water will not evaporate all at once. Since it is very difficult to separate the steam from the vacuum in the system, the evacuation process is supported by the co-called vacuum breaking (filling the circuit with dried nitrogen). With vacuum breaking the filled in dried nitrogen absorbs the moisture in the refrigerant circuit, which can then be easily discharged together with the nitrogen.

412

Especially with expensive refrigerants and larger amounts of oil it may be necessary to keep the refrigerant for later use. For later use these refrigerants must be drawn out with suitable equipment and intermediately stored in collecting containers. Environment Contaminated refrigerant must be disposed of environmentally Releasing refrigerant into the atmosphere is prohibited (see restrictive injunction concerning CFC, day of enforcement 01. 08. 1991, § 8) Danger For draining refrigeration systems you should not simply use any delivery containers, but only appropriate pressure bottles, which must be specially marked and should comply with the pressure gas directive. !

When transferring refrigerant you must make sure that the bottle does not contain more than the permitted amount of refrigerant in litres and has sufficient gas space for expansion (filling factor: 0,7). In order to reduce the evacuation period in case of short repairs, you may fill the refrigerant circuit with approx. 0.5 bar nitrogen when opening. This ensures that nitrogen will flow out of the refrigerant circuit while it is open and no air or moisture can enter. However, the necessity for vacuum generation and a dryer change remains.

BOMAG

008 911 63

13.14

Leak test

13.14Leak test ! Caution The use of leak detection colouring matter is not permitted, because its chemical composition is unknown and its effect on compressor oil and rubber elements is not predictable. The use of leak detection colouring matter makes any warranty claims null and void.

Before starting the evacuation process, the refrigerant circuit is filled with nitrogen through a pressure reducer valve (approx. 22 bar). After this all connections in the air conditioning system are checked with the help of a suitable leak detection spray. A leak is thereby indicated by means of foam bubbles. A leak test is required if a pressure drop is noticed. The leak test must be repeated after filling the air conditioning system with refrigerant. Leak test with electronic leak tester

Fig. 1 Electronic leak tester

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

Fig. 2 Soap bubble test

Points susceptible for leakage are sprayed with a soapy solution. Bubbles indicate the leak. The detection limit for R 134a is 250 g/year. 008 911 63

BOMAG

413

13.15

Filling instructions

13.15Filling instructions Filling of refrigerant into the dried, vented and oil filed machines takes place under various conditions. In most large series production facilities highly complicated equipment is available for this purpose, whereas individual machines at the place of installation must be filled directly from the refrigerant container. Liquid refrigerant is only used to pre-fill the pressure side of the evacuated refrigeration system (protective filling). After switching the refrigeration system on and watching the inspection glass, gaseous refrigerant can be filled into the system while the engine is running, if the refrigerant level is found to be too low (gas bubbles in the inspection glass). ! Caution Liquid refrigerant in the suction side of the compressor should generally be avoided during filling and operation of the refrigeration system, since this could damage the compressor..

When filling the air conditioning system directly from the refrigerant bottle care must be taken not to overfill the system. As an additional control and for statistical purposes, e.g. for refilling, it is important to write down the weight of the filled in refrigerant. With correct operation of the air conditioning the refrigerant container should be about 1/3 filled with liquid refrigerant, the evaporator should be maximally filled at the calculated evaporation temperature, i.e. the suction line should only be a few degrees warmer than the evaporation temperature indicated by the pressure gauge.

i

Note

White frost on the suction line is no measure for assessing the filling.

414

BOMAG

008 911 63

13.15


Fig. 1

10 Filter dryer

1

High pressure - gaseous

2

High pressure - liquid

3

Low pressure - gaseous

4

Compressor

5

Compressor pressure switch (not used)

14 Pressure switch with high and low pressure contacts

6

not used

15 Defroster thermostat

7

Evaporator

16 Vacuum meter

8

Expansion valve

17 Low pressure gauge

9

Inspection glass

18 High pressure gauge

008 911 63

11 Fluid container 12 Condenser 13 Manual shut-off valve (not used)

BOMAG

415

13.15


19 Pressure reducing valve

16 Switch off the vacuum pump, watch the pressure gauges to see whether the vacuum is maintained.

20 Vacuum pump


17 Open the valve on the refrigerant bottle and open the black and red hand wheels on the pressure gauge bar. Fill refrigerant into the system, until a pressure equilibrium between suction and pressure side is reached (reading of pressure gauges).

1

Connect the service adapter with the blue hand wheel in the suction side.

18 Close the red hand wheel.

2

Connect the service adapter with the red hand wheel in the pressure side (the hand wheels on the service adapters must be fully backed out - left hand stop)

21 Nitrogen bottle 22 Refrigerant bottle 23 Pressure gauge bar

3

Connect the blue suction hose below the blue hand wheel on the pressure gauge bar to the blue service adapter.

4

Connect the red pressure hose below the red hand wheel on the pressure gauge bar to the red service adapter.

5

Connect the yellow hose below the yellow hand wheel on the manometer bar to the 2-stage vacuum pump.

6

Connect the last hose below the black hand wheel on the nitrogen bottle via the pressure reducing valve.

7

Check on the pressure gauge bar that all hand wheels are closed.

8

Turn the hand wheels on both service adapter clockwise. This opens the valves (right hand stop).

9

Open the valve on the nitrogen bottle (only via pressure reducer); pressure approx. 20 bar.

10 Open the black and red hand wheels on the pressure gauge bar and fill nitrogen into the system, until a pressure of approx. 3.5 to 5.0 bar is indicated on the suction side. 11 Then open the blue hand wheel and raise the pressure in the suction side (max. 10 bar). Check for leaks with a leak detection fluid or soapsuds.

19 Perform a leak test with the electronic leak detector. 20 Start the engine and switch on the system. 21 Open the blue hand wheel and continue filling in refrigerant until the inspection glass is free or air bubbles (in fluid container/dryer combinations the white pearl should float in the upper third of the inspection glass). Then close the refrigerant bottle. 22 Close the blue hand wheel on the pressure gauge bar. 23 Preparing the test run: -Close windows and doors -Fan on full speed stage -Mount measuring feelers to air discharge and air intake. 24 Run the system for approx. 20 minutes with medium engine speed. 25 The temperature difference between air discharge and air intake should be (depending on type of air condition) 8-10°C. The ambient temperature thereby is approx. 20°C. (These data are only reference values, which may be influenced by possible insolation) 26 Switch off system and engine and check for leaks again. 27 Turn out (left hand stop) and remove the hand wheels on both service adapters. 28 Fit all valves with dust caps. 29 Perform a leak test. 30 Mark the system with the corresponding type plates and information decals, such as type of oil and refrigerant.

12 If the system is leak tight, release the nitrogen from the system. For this purpose disconnect the hose from the nitrogen bottle and open the red, blue and black hand wheels on the pressure gauge bar. 13 Then connect the hose to the refrigerant bottle. 14 Switch on the vacuum pump and open all hand wheels on the pressure gauge bar. In case of a leak no or only an insufficient vacuum will be reached. In this case proceed as described under point 9-12. Once the leak is sealed continue with point 14. 15 Once a sufficient vacuum is reached, both pressure gauges show -1, close all hand wheels on the pressure gauge bar.

416

BOMAG

008 911 63

Trouble shooting in refrigerant circuit, basic principles

13.16

13.16Trouble shooting in refrigerant circuit, basic principles Basic principles Requirements For trouble shooting two requirements must be fulfilled: ●

Expert knowledge

●

technical equipment

Technical equipment The most important aids for trouble shooting are pressure gauges and thermometer. The refrigerant conditions, like overheating and excessive cooling provide important Information when searching for faults. Even your own senses are important aids for trouble shooting. Bubbles in the sight glass, dirt and white frost can be visibly perceived. If the compressor draws in wet steam, this can be noticed by the suction line and it may also be audibly detectable. An overloaded compressor can even be smelled. The following tools and auxiliary materials should be available for trouble shooting: ●

Service station

●

Pressure gauge

●

Thermometer

●

dry nitrogen

●

Refrigerant bottle for new refrigerant

●

Container for old oil

●

Vacuum pump

●

Hoses

●

Scales

●

Suction station

●

Leak detector

Fig. 2 Pressure gauge

Example: A totally empty air conditioning system holds an atmospheric pressure of approx. Pamp = 1 bar. Filling the system with refrigerant causes an excess pressure of Pe = 3 bar. Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar Evacuating the system down to Pe = -0.6 bar, creates a "vacuum" (negative excess pressure). Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar

The measuring equipment must be checked at regular intervals. Calibration can only be made by an approved testing authority. Pressure gauge Most pressure gauges used in practice are (for cost reasons) excess pressure gauges. These pressure gauges measure the excess pressure in relation to the ambient pressure (air pressure). In order to achieve the absolute (actual) pressure the ambient pressure must be added to the pressure gauge reading. The absolute pressure is needed for the calculation and determination of material data. Pabs = Pamb + Pe Pabs = absolute pressure Pamb = atmospheric air pressure (ambient pressure) Pe = excess pressure (pressure gauge reading)

008 911 63

BOMAG

417

13.16


Pressure gauge with saturation temperature scale

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

Fig. 3 Absolute pressure gauge

Temperature scales on the pressure gauges always refer to the absolute pressures Pabs. Please note that it is not possible to measure a temperature directly with a pressure gauge. The indicated temperatures are just reference values. Only the saturation temperature is assigned to the measured pressure. If the refrigerant is fluid, the temperature is below the saturation temperature.

The optimal overheating value is approx. 5 - 8 Kelvin. With this overheating the maximum system power is reached. However, the thermostatic expansion valve is unable to regulate this value exactly. Depending on design and operating conditions overheating fluctuates within a range between 4 and 12 Kelvin. The influence of the ambient air on the suction line causes an additional overheating effect. Overheating is calculated as follows: Δ to2h = to2h - to Δ to2h, overheating at evaporator outlet in K

If the refrigerant is gaseous, the temperature is above the saturation temperature.

to2h, temperature at evaporator outlet in °C

Pressure gauges must indicate 0 bar when not connected to the system.

„h“ represents "overheated"

Low pressure gauges have a blue, high pressure gauges a red border.

Supercooling

Thermometer

It is the function of the expansion valve to reduce the refrigerant to a lower pressure level (evaporation pressure) after it has been liquefied. For an optimal function of the valve pure fluid must be applied to its inlet port.

Normally digital thermometers with surface or contact feelers are used. Especially for high temperature differences excellent heat insulation of the measuring location is of utmost importance. The sparing use of a heat conducting paste is highly recommended. If the measuring location is soiled, it needs to be cleaned and probably treated with a fine emery cloth. Only the temperature of the feeler is measured. Due to missing heat insulation and insulating oxide layers on the line, temperature differences of a few degrees Kelvin between the measured and the actual values may arise.

Overheating Due to its design a refrigerant compressor can only deliver gaseous or vaporous substances. Fluids are not compressible and must therefore not enter into the compression chamber of the compressor. 418

to, evaporation temperature in °C

The refrigerant must "squeeze" (literally speaking) through a throttle gap inside the expansion valve. When comparing a certain mass of refrigerant in fluid and in vaporous state (with constant pressure), the vaporous refrigerant requires a much higher volume. That's why the vaporous refrigerant needs a much longer time to "squeeze" through the throttle gap. Vaporous refrigerant in front of the expansion valve reduces the flow rate and results in an undersupply of the evaporator with refrigerant. Evaporation pressure and evaporator power will drop. If the refrigeration system is operated with the "expansion valve inlet" condition directly on the boiling curve, slightest fluctuations in operating condition may cause

BOMAG

008 911 63


13.16

a formation of bubbles in front of the expansion element. For this reason one shifts the condition "Expansion Valve Inlet" away from the boiling curve into the fluid area and refers to this condition as Supercooling. This supercooling ensures a fluid supply in front of the expansion valve. Common supercooling values In systems with fluid container the supercooling at the fluid container outlet is approx. Zero "0" Kelvin (assumed that the system is filled with the correct refrigerant quantity). In this case the fluid container provides the required fluid supply. Supercooling is calculated as follows: Δ tc2u = tc - tc2u Δ tc2u, supercooling at evaporator outlet in K tc2u, temperature at evaporator outlet in °C tc, evaporation temperature in °C „u“ represents "supercooled"

008 911 63

BOMAG

419

13.16


Fig. 1 Refrigerant circuit with t, h- diagram

1

Hot gas line (overheated steam)

2

Deheating (overheated steam)

3

Condenser / liquefier

4

Condensation (wet steam)

5

Fluid line (supercooled fluid)

6

Expansion valve

7

Injection line (wet steam)

8

Evaporation (wet steam)

9

Evaporator

10 Overheating (overheated steam) 11 Suction steam line (overheated steam) 12 Compressor 13 Supercooling (fluid) 14 Compression 15 Expansion

420

BOMAG

008 911 63

Trouble shooting, refrigerant circuit diagram

13.17

13.17Trouble shooting, refrigerant circuit diagram

13 Compressor

Fig. 1 Refrigerant circuit diagram

1

Cold air

2

Evaporator

3

Thermostat

4

Warm air

5

Fan

6

Inspection glass

7

Expansion valve

14 Condenser 15 Cooling air 16 Pressure gauge, low pressure

8

Pressure gauge, high pressure

9

Pressure switch with high and low pressure contacts

10 Dryer 11 Fluid container 12 Hot air 008 911 63

BOMAG

421

13.18

Trouble shooting procedure

13.18Trouble shooting procedure

●

●

Procedure Knowledge Trouble shooting is not possible with exact knowledge about the system design, the installed components and their function in the system trouble shooting is not possible:

● ●

Evaporator and heating (with highest fresh air fan speed) do not draw leak air. The fresh air fan runs when the engine is running and the air conditioning system is set to max. cooling power. Ambient temperature above 15 °C. The thermostat is correctly installed and the switching temperatures are correct.

Visual inspection With the appropriate experience some faults can be visually detected or felt. Frequently occurring condenser soiling or formation of steam bubbles in the inspection glass can be quickly detected. In case of unusual formation of hoarfrost on the evaporator the hoarfrost pattern provides useful information. Hoarfrost only occurring at the inlet side is a clear indication of insufficient refrigerant feed, which in turn indicates an incorrectly working expansion valve or a lack of refrigerant.. Complete hoarfrost covering indicates load problems, i.e. no or insufficient air flow. Even overheating can sometimes be detected with the naked eye. At the end of the evaporator there should be an area which is dry or at least drier at evaporator temperatures above -2 °C. The fluid line in the refrigeration system is warm. If a local cooling can be felt or if condensation develops, this is a clear indicator for an extreme pressure drop in the line. Similar phenomena can be noticed in case of blocked filters. Unusually cold pressure lines indicate "wet" intake of the compressor. The oil level in the compressor sight glass provides information about the oil quantity and the oil recirculation in the system. However, the oil level may also be considerably influenced by condensing refrigerant. Discoloration informs about the state of the oil. Water in the system can simply be detected through the inspection glass with moisture indicator.

i

Note

The dangerous part of common rules is that they apply in most, but not in all cases. The refrigerant states in the individual piping sections or components must therefore be exactly determined by means of pressure and temperature measurements. Test prerequisites ●

●

●

●

Cooler and condenser are clean, clean if necessary. The ribbed belt for compressor and generator is correctly tightened. All air ducts, covers and seals are OK and correctly fitted. Flaps reach their end positions. The engine has operating temperature.

422

BOMAG

008 911 63

13.18

Trouble shooting procedure Measuring points and measurements

to assess the filling quantity. In systems with fluid container the inspection glass is most suitable to check the minimum filling quantity. Supercooling is in this case the between indicator for overfilling.

Fig. 2 Flow diagram with measuring points ●

C, condenser measuring points

●

E, expansion valve measuring points

●

O, evaporator measuring points

●

V, compressor measuring points

The flow diagram contains "Minimum Requirements" which must be fulfilled to be able to check the system or perform trouble shooting. Temperature and pressure at the evaporator outlet can be used to derive the overheating of the evaporator. Overheating is a clear indicator for the evaporator filling level. In case of excessive overheating the refrigerant quantity fed into the evaporator is too low, in case of insufficient overheating it is too high. In individual cases one must then check if this situation is caused by the expansion element or by insufficient filling. A differentiation is only possible if there is a clear indicator for the refrigerant filling quantity. Pressure and temperature at the condenser outlet can be used to derive the supercooling. This can be used 008 911 63

The hot gas temperature can be used to check whether the compressor runs in the permissible operating range. Example: Measurement of overheating ●

a) Which measuring equipment is required ?

●

b) Where to measure with which size ?

●

● ●

●

c) A pressure gauge connected to the evaporator indicates "Peo2 = 1.7 bar". How high is the evaporator pressure "Po" ? d) How high is the evaporator temperature "to" ? e) A thermal sensor attached to the evaporator outlet measures the temperature "to2h = +3 °C". How high is the overheating „Δto2h“ ? f) Evaluation of the measured overheating.

BOMAG

423

13.18

Trouble shooting procedure be a defect in the expansion valve or problems in the oil recirculation.

Solution: ● ●

●

●

●

●

a) Pressure gauge, thermometer, steam table b) Evaporation pressure "Peo2" and temperature "to2h" are measured at the same point on the evaporator outlet.

The following list contains pressure values in a system, that can be expected at various ambient temperatures (measured at medium speeds).

c) Po = Peo2 + Pamb, "Evaporation pressure = pressure on evaporator + atmospheric pressure" = 1.7 bar + 1 bar = 2.7 bar.

Suction pressure (low pressure gauge)

d) "Pc" = 2,7 bar can then be used to derive an condensing temperature "to" of -2,2 °C from the steam table for R134a. e) Δto2h = to2h - to, „Overheating at evaporator outlet = evaporator outlet temperature - evaporation temperature" = 3 °C - (-2.2 °C) = 5.2 Kelvin. f) The determined overheating is within the usual range of 4 - 12 Kelvin.

Ambient temperature in °C 25 30 35

Excess pressure in bar approx. 2,0 approx. 2,5 approx. 3

High pressure (high pressure gauge) Ambient temperature in °C 25 35 40 45

Excess pressure in bar approx. 8,0 approx. 13 approx. 16 approx. 18

Example: Measuring supercooling ●

a) Which measuring equipment is required ?

●

b) Where to measure with which size ?

●

● ●

●

c) A pressure gauge connected to the condenser indicates "Pec2 = 15 bar". How high is the condensing pressure "Pc" ? d) How high is the condensing temperature "tc" ? e) A thermal sensor attached to the condenser outlet measures the temperature "tc2u = 58 °C". How high is the supercooling "Δtc2u" ? f) Evaluation of the measured supercooling.

Solution: ● ●

●

●

●

●

a) Pressure gauge, thermometer, steam table b) Condensing pressure "Pec2" and temperature "tc2u" are measured at the same point on the condenser. c) Pc = Pec2 + Pamb, "Evaporation pressure = pressure on evaporator + atmospheric pressure" = 15 bar + 1 bar = 16 bar. d) "Pcc = 16 bar can then be used to derive an condensing temperature "tc" of 57.9 °C from the steam table for R134a. e) Δtc2u = tc - tc2u, "Supercooling at condenser outlet = condensing temperature - condenser outlet temperature" = 57.9°C - 58 °C) = -0.1 Kelvin. f) The determined overheating is within the usual range of approx. "0" Zero Kelvin.

Typical faults and possible causes Most faults in the refrigerant side of the system can be clearly assigned with the help a checklist. r Occurring faults frequently have a similar appearance, but An evaporator showing hoarfrost different causes. may be quite normal. However, there may also

424

BOMAG

008 911 63

13.18


tions, it is mandatory to know these dependencies. The following table contains some of these dependencies.

Values effecting the operating pressures

Since the pressures occurring in a refrigeration system are highly dependent on environmental condiMeasuring value Suction pressure increases drops increases Compressor speed X drops X increases

Vehicle interior temperature

drops

Ambient temperature

increases

X

increases

X X

X X

X X

X X

drops

008 911 63

X X

drops Humidity

High pressure increases drops X

X

BOMAG

X

425

13.18

Trouble shooting procedure Suction pressure too low (1), high pressure too low to normal (2)

Fig. 3

Cause Lack of refrigerant

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

426

BOMAG

008 911 63

13.18


Suction pressure normal (1), high pressure too high (2)

Fig. 4

Cause Condenser dirty

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

008 911 63

BOMAG

427

13.18

Trouble shooting procedure Suction pressure too high (1), high pressure too low to normal (2)

Fig. 5

Cause Compressor defective

428

Possible effect Cooling power too low

BOMAG

Remedy Replace the compressor

008 911 63

13.18


Suction pressure too high (1), high pressure too high (2)

Fig. 6

Cause Expansion valve defective

008 911 63

Possible effect Remedy overheating too low, wet operation Replace the valve of compressor

BOMAG

429

13.18

Trouble shooting procedure Other faults

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

Possible cause Remedy V-belt slips and generates noise Retention or renew the V-belt Magnetic clutch runs until high pres- Repair or replace the magnetic sure builds up, then the clutch starts clutch to slip Mounting bracket is loose, internal Repair the mounting bracket, reparts worn, low oil level in compres- place the compressor, renew the resor frigeration oil Replace the fan motor

Fan is loud, fan motor excessively worn Whistling and rattling noise in opera- V-belt pulley and bearing worn tion, noticeable unevenness when turning by hand Rattling noise or vibration of high System overfilled pressure line, knocking noise in compressor, ball in inspection glass floating at the top Expansion valve loud excessive moisture in system Hissing noise in evaporator housing, refrigerant level in system too low on expansion valve, turbidity in inspection glass or ball does not float

430

BOMAG

Replace the bearing, check V-belt pulley for wear Draw out refrigerant

Replace the dryer Perform a leak test, fill up the system

008 911 63

13.18

Trouble shooting procedure Inspection glass Faults Steam bubbles in inspection glass

Discolouration of inspection glass (black from inside) Moisture indicator changes to pink Ball floats at bottom

Possible cause No supercooling before expansion valve, lack of refrigerant in system, pressure loss in system, supercooling caused by excessively soiled filter dryer Lubricant destroyed by excessive operating temperatures Moisture level of drying agent too high lack of refrigerant

Remedy Fill up the system, replace the filter dryer, perform a leak test

Replace the refrigeration oil, examine the temperature increase Replace the filter dryer Fill the system

Monitoring devices Faults The high pressure contact has switched off the magnetic clutch

Possible cause Remedy System pressure exceeded, conClean the condenser, replace the denser excessively soiled, condens- expansion valve, check the coner fan defective, expansion valve denser fan defective System pressure fallen short of, re- Clean the evaporator, replace the The low pressure contact has frigerant level too low, expansion expansion valve, check the evaporaswitched off the magnetic clutch valve defective, evaporator fan de- tor fan fective, heat load too low, ambient temperature below 1.5 °C The thermostat has switched off the Ambient temperature below 1°C, Check the thermostat switching magnetic clutch expansion valve defective, thermo- point, replace the expansion valve, stat defective, air flow volume too clean the evaporator, check the low evaporator fan

008 911 63

BOMAG

431

13.19 Tempera- Presture sure

Steam table for R134a

Density of the fluid

432

of the steam

spec. volume

spec. enthalpy

of the fluid of the steam

of the fluid of the steam

BOMAG

Evaporation heat

008 911 63

13.19


008 911 63

BOMAG

433

13.19

434


BOMAG

008 911 63

13.19


008 911 63

BOMAG

435

13.19

436


BOMAG

008 911 63

14 Replacing the cab window panes

008 911 63

BOMAG

437

14.1

Assembly of window panes

Fig. 1

1

Glass panes

2

Fastening element

3

Fixing washer and spacer

4

Washer

5

Hexagon nut, self locking

6

Protective cap

438

BOMAG

008 911 63

14.2

Special tools 14.2 Special tools 1. Locking handle for fastening element BOMAG part-no.: 055 705 84

Fig. 1

2. Suction lifter commercial

Fig. 2

008 911 63

BOMAG

439

14.3

Auxiliary materials 14.3 Auxiliary materials Safety gloves 3. Cutter Commercial

Fig. 1

4. Window glass bonding agent BOMAG part-no.: 009 780 34

Fig. 2

5. Activator BOMAG part-no.: 009 780 33

Fig. 3

440

BOMAG

008 911 63

14.3

Auxiliary materials 6. Silicone sealant BOMAG part-no.: 009 700 36

Fig. 4

008 911 63

BOMAG

441

14.4

Removing and installing the window pane 14.4 Removing and installing the window pane Environment Environmental damage Dispose of glass splinters fro0m machine and cabin or inside cabin in an environmentally friendly way. ! Danger Danger of cutting

Wear safety gloves. 1. Pull large glass rests off the bonding strip (Fig. 1). Fig. 1

2. Clean the sealing surfaces from any adhesive material (Fig. 2). 3. Use a cutter to remove adhesive residues with glass rests. 4. Cover places without adhesive residues with an activator.

Fig. 2

5. Insert the fastening element with washer into the bore in the glass pane (Fig. 3).

Fig. 3

442

BOMAG

008 911 63

14.4

Removing and installing the window pane

6. Turn the fixing and spacer washer hand-tight onto the thread of the fastening element (Fig. 4).

i Note Do not overtighten the thread.

Fig. 4

7. Lay an approx. 1 cm high triangular bead of glass pane bonding agent on the inside of the pane, approx. 1.5 cm away from the edge (Fig. 5).

i Note Apply window pane bonding agent only to the sides (sealing areas) which have contact with the cabin.

Fig. 5

8. Attach the suction lifter to the outside of the pane (Fig. 6). 9. Install the window pane so that the fastening elements fit into the bores of the fastening bars. 10. Press the glass pane against the sealing surface.

Fig. 6

11. Assemble the washer and the self-locking hexagon nut. 12. Fasten the window pane to the fastening bar using a locking handle and a ring spanner (Fig. 7).

i Note Only use the locking handle to counter. 13. Press the protective cap onto the hexagon nut.

Fig. 7

008 911 63

BOMAG

443

14.4

Removing and installing the window pane 14. Remove the suction lifter (Fig. 8).

Fig. 8

15. Clean the joining edges on the window pane (Fig. 9).

i Note The joint flanks must be solid, dry and free of dirt, dust, grease, oil and other foreign substances. 16. Mask the upper and lower contact areas to the cabin.

Fig. 9

17. Apply silicone sealant evenly and under pressure first to the inside joint edge (Fig. 10).

Fig. 10

18. Then apply silicone sealant evenly and under pressure to the outside joint edge (Fig. 11).

Fig. 11

444

BOMAG

008 911 63

14.4


19. Then spray the joints from inside and outside with water containing washing up liquid (Fig. 12).

Fig. 12

20. Treat the inside joint (Fig. 13)

Fig. 13

21. and the outside joint (Fig. 14) with a scraper or a spattle.

i

Note Once the silicone sealing agent has cured it can only be removed mechanically.

Fig. 14

008 911 63

BOMAG

445

14.4

446


BOMAG

008 911 63

15 Drum

008 911 63

BOMAG

447

15.1

Special tools, drum, single drum rollers 15.1 Special tools, drum, single drum rollers 1. Disassembly device for side plate BOMAG part-no.: 007 211 55

Fig. 1

2. Assembly device for side plate BOMAG part-no.: 971 079 21

Fig. 2

3. Assembly device for coupling hub and flanged hub

Fig. 3

448

BOMAG

008 911 63

15.1

Special tools, drum, single drum rollers

4. Pressing plate for cylinder roller bearing

Fig. 4

5. Pressing plate for travel bearing

Fig. 5

6. Pressing bushing for radial seal

Fig. 6

7. Lifting device for exciter unit BOMAG part-no.: 007 215 08

Fig. 7

008 911 63

BOMAG

449

15.2

450

Repair overview for drum

BOMAG

008 911 63

15.2

Repair overview for drum 1

Drum

13 Flanged hub

2

Cylinder roller bearing

14 Vibrator shaft

3

Coupling

15 Coupling

4

Vibration motor

16 Vibrator shaft

5

Cover

17 Change-over weight

6

Grooved ball bearing

18 Cylinder roller bearing

7

Spacer block

19 Basic weight

8

Rectangular rubber buffer

20 Flanged housing

9

Side plate

21 Flange

10 Spacer ring

22 Cylinder roller bearing

11 Grooved ball bearing

23 Cover

12 Mechanical seal

008 911 63

BOMAG

451

15.2

452


BOMAG

008 911 63

15.2


008 911 63

BOMAG

453

15.2

454


BOMAG

008 911 63

15.2


008 911 63

BOMAG

455

15.2

456


BOMAG

008 911 63

15.3

Removing and installing the drum

15.3 Removing and installing the drum

i Note After disassembling the side plate (vibration motor side) the drum can be lifted sideways out of the frame (Fig. 1).

Fig. 1

i Note However, the drum can also be removed without having to disassemble the side plate, if it is lifted up and out of the frame (Fig. 2).

Fig. 2

Removing the drum

i Note The following section describes the procedure for lifting the frame sideways out of the drum. Environment Environmental damage Catch running out hydraulic oil and dispose of environmentally. 1. Mark the hydraulic hoses (Fig. 3)on the travel motor and disconnect them from the ports. 2. Close all hydraulic hoses and motor ports with suitable plugs.

Fig. 3

008 911 63

BOMAG

457

15.3

Removing and installing the drum 3. Mark the hydraulic hoses on the vibration motor (Fig. 4) and disconnect them from the ports. 4. Close all hydraulic hoses and motor ports with suitable plugs.

Fig. 4

5. Unscrew screws 1 (Fig. 5) from holding plate (2) for hydraulic hoses from both sides.

Fig. 5

6. Unscrew screws (Fig. 6) from the spacer piece on vibration and travel motors.

Fig. 6

7. Fasten the lifting gear to the side plate on the vibration side. 8. Support the front cross-member safely with suitable trestles or wooden blocks (Fig. 7). 9. Unscrew plugs (1) and screws (2).

Fig. 7

458

BOMAG

008 911 63

15.3


10. Support the rear cross-member safely with suitable trestles or wooden blocks (Fig. 8). 11. Unscrew plugs (1) and screws (2). ! Danger Danger of squashing! Do not stand or step under loads being loaded.

12. Take off the side plate.

Fig. 8

13. Fasten the lifting tackle to the drum and lift the drum carefully sideways out of the front frame (Fig. 9). ! Danger Danger of squashing! Do not stand or step under loads being loaded.

Fig. 9

14. Check all rubber buffers (Fig. 10), replace if necessary (see corresponding chapter).

Fig. 10

15. Check rectangular rubber buffers (Fig. 11), replace if necessary.

Fig. 11

008 911 63

BOMAG

459

15.3

Removing and installing the drum Installing the drum Danger Danger of squashing! !

Do not stand or step under loads being loaded. 1. Place the drum into the frame and align it parallel to the frame (Fig. 12).

Fig. 12

2. Attach the side plate, insert screws 2 (Fig. 13) into the rear cross-member, slide on washers, turn on and tighten the nuts.

i Note Apply sliding lacquer OKS 240 to threads and screw head contact face to ease assembly. 3. Close the screw holes with plugs (1).

Fig. 13

4. Attach the side plate, insert screws 2 (Fig. 14) into the rear cross-member, slide on washers, turn on and tighten the nuts.

i Note Apply sliding lacquer OKS 240 to threads and screw head contact face to ease assembly. 5. Close the screw holes with plugs (1).

Fig. 14

6. Fasten the spacer pieces with screws (Fig. 15) and nuts to the side plate.

Fig. 15

460

BOMAG

008 911 63

15.3


Adjust the pretension of the rubber buffers. 7.

Measure distance „X“ between spacer piece 1 (Fig. 16) and side plate.

8. Calculate the thickness of the compensation plates. Nominal value: Distance "X" + 2 mm 9. Turn one screw (3) into the welded nut (2) at top and bottom and open a sufficient gap to insert the compensation plates. Fig. 16

10. Insert the compensation plates (Fig. 17). Insert screws (1), slide on washers (3), turn on and tighten nuts (2). 11. Unscrew the screws from the welded nuts.

Fig. 17

12. Connect hydraulic hoses to the connections on travel motor and vibration motor according to the marking.

Fig. 18

13. Fasten holding plate 2 (Fig. 19) for hydraulic hoses with screws (1). Caution After connecting the hydraulic components and before starting operation bleed the hydraulic system, check the function and inspect the system for leaks. !

Fig. 19

008 911 63

BOMAG

461

15.4

Repairing the drum 15.4 Repairing the drum Removing the travel motor Danger Danger of squashing! !

Do not stand or step under suspended loads. 1. Attach the lifting tackle to the travel motor. 2. Unscrew all nuts (Fig. 3) from the rubber buffers. 3. Take the drive disc with the travel motor off the rubber buffers.

Fig. 1

4. Unscrew the nuts, pull out the screws and remove the support legs (Fig. 4).

Fig. 2

5. Attach the lifting tackle to the travel motor (Fig. 3). Danger Danger of squashing! !

Do not stand or step under suspended loads.

Fig. 3

462

BOMAG

008 911 63

15.4

Repairing the drum

6. Unscrew the bolts (Fig. 4) and separate the travel motor from the drive disc. Caution Flush the hydraulic system if dirt or chips are found in the travel motor. !

Fig. 4

Disassembling the exciter unit (travel motor side) 1. Unscrew both socket head cap screws from the flange (Fig. 5).

Fig. 5

2. Mount bracket 1 (Fig. 8) for the lifting device to the flange. 3. Unscrew screws (2) from the flange.

i Note Do not unscrew the thin drawn screws.

Fig. 6

008 911 63

BOMAG

463

15.4

Repairing the drum 4. Slide the lifting device over the bracket. 5. Force the exciter unit off with two forcing screws (Fig. 7).

Fig. 7

Danger Danger of squashing! !

Do not stand or step under suspended loads. 6. Pull the exciter unit out of the drum (Fig. 8). 7. Take the coupling element off the coupling half.

Fig. 8

Disassembling the exciter unit (travel motor side) 1. Unscrew fastening screws 1 (Fig. 9) for the fan. 2. Loosen clamping screw (2). 3. Pull the coupling hub off the shaft.

Fig. 9

464

BOMAG

008 911 63

15.4

Repairing the drum

4. Unscrew all other fastening screws 1 (Fig. 10) from the flange. 5. Press the flange off the flanged housing with forcing screws (2).

Fig. 10

Environment Environmental damage! Catch running out oil and dispose of environmentally. 6. Lift the flange off the flanged housing (Fig. 11). 7. Take the O-ring out of the groove in the flanged housing.

Fig. 11

8. Unclip the circlip from the groove in the flange (Fig. 12).

Fig. 12

9. Press the cylinder roller bearing with forcing screws out of the flange (Fig. 13).

Fig. 13

008 911 63

BOMAG

465

15.4

Repairing the drum 10. Take the exciter unit (Fig. 14) out of the flanged housing.

Fig. 14

11. Knock the radial seal (Fig. 15) out of the flanged housing.

Fig. 15

12. Unclip the circlip from the groove in the flanged housing (Fig. 16).

Fig. 16

13. Press the cylinder roller bearing with forcing screws out of the flanged housing (Fig. 17).

Fig. 17

466

BOMAG

008 911 63

15.4

Repairing the drum 14.

Extract inner ring 1 (Fig. 18) for the radial seal and inner bearing races (2). Danger Danger of burning! !

Wear safety gloves.

i

Note If the rings are very tight, heat them up with a torch. Fig. 18

15. Unclip the circlip from the basic weight (Fig. 19).

Fig. 19

16. To change shaft 1 (Fig. 20) knock out dowel pins (2 and 3) and press the shaft out of the basic weight.

i

Note If necessary disassemble, assemble the changeover weight (see corresponding chapter).

Fig. 20

008 911 63

BOMAG

467

15.4

Repairing the drum Disassembling the exciter unit (vibration motor side) 1. Unscrew fastening screw 1 (Fig. 21). 2. Take rectangular rubber buffer (2) with spacer block (3) off the side plate.

i Note Remove both rectangular rubber buffers.

Fig. 21

3. Unscrew fastening screws 1 (Fig. 22). 4. Force cover (2) together with the attached vibration motor off the side plate with forcing screws.

Fig. 22

5. To change the vibration motor loosen clamping screw 1 (Fig. 23) and pull off coupling half (2).

Fig. 23

468

BOMAG

008 911 63

15.4

Repairing the drum

6. Unscrew nut 1 (Fig. 24), take off conical socket (2) and conical disc (3). 7. Take the vibration motor off the cover.

Fig. 24

8. Remove the coupling element (Fig. 25).

Fig. 25

9. Fasten the lifting device. 10. Unscrew fastening screws 1 (Fig. 26). Caution The four short fastening screws (2) must remain screwed in (the two others are not visible). !

Fig. 26

11. Press the exciter unit out of the drum with forcing screws (Fig. 27).

i Note The second forcing screw is covered by the side plate.

Fig. 27

008 911 63

BOMAG

469

15.4

Repairing the drum ! Caution Danger of squashing!

Do not stand or step under suspended loads. 12. Pull the exciter unit out of the drum (Fig. 28).

Fig. 28

Removing, dismantling the side plate 1. Take off V-ring 1 (Fig. 29). 2. Unclip circlip (2).

Fig. 29

3. Attach the disassembly device to the side plate (Fig. 30) and force off the side plate.

Fig. 30

4. Lift the side plate of the flanged hub (Fig. 31).

Fig. 31

470

BOMAG

008 911 63

15.4

Repairing the drum

5. Knock the grooved roller bearing out of the side plate (Fig. 32) and take out the spacer ring.

Fig. 32

6. Unclip the circlip from the side plate (Fig. 33).

Fig. 33

7. Take the mechanical seal off the flanged hub (Fig. 34).

Fig. 34

008 911 63

BOMAG

471

15.4

Repairing the drum Dismantling the exciter unit (vibration motor side) 1. Unscrew the fastening from the coupling hub. 2. Pull coupling hub (2) off the shaft using a pulling device (Fig. 35).

Fig. 35

3. Loosen hose clamp 1 (Fig. 36). 4. Pull coupling hub (2) off the shaft.

Fig. 36

5. Unscrew all other fastening screws 1 (Fig. 37) and press the flanged hub off the flanged housing with forcing screws (2). 6. Take off the flanged hub. 7. Take the O-ring out of the groove in the flanged housing.

Fig. 37

472

BOMAG

008 911 63

15.4

Repairing the drum

8. Unclip the circlip from the groove in the flanged hub (Fig. 38).

Fig. 38

9. Knock the cylinder roller bearing out of the flanged hub (Fig. 39).

Fig. 39

Environment Environmental damage! Catch running out oil and dispose of environmentally. 10. Lift the exciter unit out of the flanged housing (Fig. 40).

Fig. 40

11. Knock the radial seal (Fig. 41) out of the flanged housing.

Fig. 41

008 911 63

BOMAG

473

15.4

Repairing the drum 12. Unclip the circlip from the groove in the flanged housing (Fig. 42).

Fig. 42

13. Press the cylinder roller bearing with forcing screws out of the flanged housing (Fig. 43).

Fig. 43

14. Extract inner rings 1 (Fig. 44) for the radial seals and inner bearing races (2) from the shaft. Danger Danger of burning! !

Wear protective gloves.

i Note If the rings are very tight, heat them up with a torch. Fig. 44

15. Unclip the circlip from the basic weight and remove the cover (Fig. 45).

i Note The shafts cannot be pressed out. If damaged they must be replaced with basic weight and cover. If necessary disassemble, assemble the changeover weight (see corresponding chapter).

Fig. 45

474

BOMAG

008 911 63

15.4

Repairing the drum

Assembling the exciter unit (vibration motor side) ! Caution Ensure strict cleanliness.

i

Note If the shafts are damaged they must be inserted into the basic weight or the cover as follows. Danger When working with liquid nitrogen protect your face and wear gloves. !

Do not place any unintended parts into liquid nitrogen.

Fig. 46

Observe the safety instructions for the handling of liquid nitrogen. Caution Close the bores on the short shaft with a screw. !

1. Cool the shaft down in liquid nitrogen. 2. Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig. 46). 3. Secure shaft 1 (Fig. 47) with dowel pins (2 and 3). Caution Assemble the dowel pins with the grooves offset by 180° to each other, but in line with the axis of the shaft. !

i

Note Unscrew the screw from the shaft.

Fig. 47

Caution Close the bores on the short shaft with a screw. !

4. Cool the shaft down in liquid nitrogen. 5. Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig. 48).

Fig. 48

008 911 63

BOMAG

475

15.4

Repairing the drum 6. Secure shaft 2 (Fig. 49) with dowel pins (1 and 3). Caution Assemble the dowel pins with the grooves offset by 180° to each other, but in line with the axis of the shaft. !

i Note Unscrew the screw from the shaft.

Fig. 49

7. Insert the fitting key into the keyway in the respective shaft (Fig. 50).

Fig. 50

8.

Insert the circlip into the groove in the basic weight and on the cover (Fig. 51).

Fig. 51

Danger Danger of burning! !

Wear safety gloves. 9. Heat the inner bearing race up to approx. 100° C and press it onto the basic weight against the shoulder with the larger outer diameter forward (Fig. 52).

Fig. 52

476

BOMAG

008 911 63

15.4

Repairing the drum ! Danger Danger of burning!

Wear safety gloves. 10. Heat the inner ring up to approx. 50° C and slide it onto the short shaft against the shoulder with the wider chamfer facing towards the outside (Fig. 53).

Fig. 53


Wear safety gloves. 11. Heat the inner bearing race up to approx. 100° C and press it onto the cover against the shoulder with the larger outer diameter forward (Fig. 54).

Fig. 54


Wear safety gloves. 12. Heat the inner ring up to approx. 50° C and slide it onto the longer shaft against the shoulder with the wider chamfer facing towards the outside (Fig. 55).

Fig. 55

13. Press cylinder roller bearing 1 (Fig. 56) with pressing plate (2) into the flanged housing until it bottoms.

Fig. 56

008 911 63

BOMAG

477

15.4

Repairing the drum 14. Insert the circlip into the groove in the flanged housing (Fig. 57).

Fig. 57

15. Fit the new radial seal with some grease into the groove in the flanged housing (Fig. 58). 16. Fill approx. 1.2 l oil SAE-15W/40 into the flanged housing.

Fig. 58

Caution Danger of squashing! !

Do not stand or step under suspended loads. 17. Insert the exciter unit with the longer shaft forward into the flanged housing (Fig. 59).

Fig. 59

18. Press cylinder roller bearing 1 (Fig. 60) with pressing plate (2) into the flanged hub until it bottoms.

Fig. 60

478

BOMAG

008 911 63

15.4

Repairing the drum

19. Insert the circlip into the groove in the flanged hub (Fig. 61).

Fig. 61

20. Attach the flanged hub to the flanged housing (Fig. 62). ! Caution Fitting and contact surfaces must be absolutely dry and free of grease, paint and conserving agents.

21. Unscrew eye bolts (1) and replace them with short screws. 22. Turn short screws (2) into the tapped bores in the flanged housing (four screws) and tighten them. Fig. 62

23. Apply some grease to the sealing lip of radial seal 1 (Fig. 63). 24. Insert the radial seal into the flanged hub with the sealing lip facing down and press it down against the stop with pressing bushing (2).

Fig. 63


Wear protective gloves. 25. Heat the coupling hub up to approx. 80 °C and slide it onto the shaft against the stop (Fig. 64).

Fig. 64

008 911 63

BOMAG

479

15.4

Repairing the drum 26. Apply some grease to the sealing lip of radial seal 1 (Fig. 65). 27. Slide the radial seal with the sealing lip forward over the shaft and drive it completely into the flanged housing, using a suitable tube (2).

Fig. 65

28. Cover the thread of screw 1 (Fig. 66) with a screw retention agent (e.g. Loctite CVX strong, blue, 582). 29. Slide on the new U-seal ring (2), turn in and tighten the screws.

Fig. 66

! Danger Danger of burning!

Wear safety gloves. 30. Heat coupling hub 1 (Fig. 67) with marking letter “L“ up t approx. 80° C and slide it over the shaft against the shoulder. 31. Turn in and tighten clamping screw (2).

Fig. 67

480

BOMAG

008 911 63

15.4

Repairing the drum

Assembling and installing the side plate 1. Fill grooved ball bearing 1 (Fig. 68) on both sides with grease. 2. Press the grooved ball bearing completely in using pressing plate (2).

Fig. 68

3. Insert the circlip into the groove in the side plate (Fig. 69).

Fig. 69

4. Apply a thick coat of grease to the spacer ring on both sides and insert it into the side plate (Fig. 70).

Fig. 70

008 911 63

BOMAG

481

15.4

Repairing the drum 5. Fill grooved ball bearing 1 (Fig. 71) on one sides with grease. 6. Insert the grooved ball bearing with the grease side forward and press it completely in with pressing plate (2).

i Note Grease the other side after installing the exciter unit.

Fig. 71

7. Insert the oiled loop-ring into the mechanical seal (Fig. 72). 8. Clean the sliding surfaces of the mechanical seal and cover them with oil.

Fig. 72

9. Lay one half of the radial seal on the flanged hub with the sliding surface pointing up (Fig. 73).

Fig. 73

10. Lay the second half of the mechanical seal down with the sliding face pointing down (Fig. 74).

Fig. 74

482

BOMAG

008 911 63

15.4

Repairing the drum

11. Bolt the threaded section of the assembly device to the flanged hub (Fig. 75).

Fig. 75

Caution Danger of squashing! Do not stand or step under suspended loads. !

12. Lay the side plate on the flanged hub (Fig. 76).

Fig. 76

13. Attach bushing 2 (Fig. 77) of the assembly device and turn on nut (1).

Fig. 77

14. Pull the side plate with the assembly device onto the flanged hub. Caution During assembly make sure that the mechanical seal slides correctly into the side plate and the loop rings are not damaged (Fig. 78). !

Fig. 78

008 911 63

BOMAG

483

15.4

Repairing the drum 15. Remove the assembly device. 16. Insert the circlip into the groove in the flanged hub (Fig. 79).

Fig. 79

Assembling the exciter unit (travel motor side) Danger When working with liquid nitrogen protect your face and wear gloves. !

Do not place any unintended parts into liquid nitrogen. Observe the safety instructions for the handling of liquid nitrogen. ! Caution Ensure strict cleanliness.

1. Cool the shaft down in liquid nitrogen. Fig. 80

2. Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig. 80). 3. Secure shaft 1 (Fig. 81) with dowel pins (2 and 3). ! Caution Assemble the dowel pins with the grooves offset by 180° to each other, but in line with the axis of the shaft.

Fig. 81

484

BOMAG

008 911 63

15.4

Repairing the drum

4. Insert the circlip into the groove in the basic weight and on the cover (Fig. 82).

Fig. 82


Wear safety gloves. 5. Heat the inner bearing race up to approx. 100° C and press it onto the basic weight against the shoulder with the larger outer diameter forward (Fig. 83).

Fig. 83


Wear safety gloves. 6. Heat the inner ring up to approx. 50° C and slide it onto the shaft against the shoulder with the wider chamfer facing towards the outside (Fig. 84).

Fig. 84


Wear safety gloves. 7. Heat the inner bearing race up to approx. 100° C and press it onto the cover against the shoulder with the larger outer diameter forward (Fig. 85).

Fig. 85

008 911 63

BOMAG

485

15.4

Repairing the drum 8. Press cylinder roller bearing 1 (Fig. 86) with pressing plate (2) into the flanged housing until it bottoms.

Fig. 86

9. Insert the circlip into the groove in the flanged housing (Fig. 87).

Fig. 87

10. Fit the new radial seal with some grease into the groove in the flanged housing (Fig. 88). 11. Fill approx. 1.2 l oil SAE-15W/40 into the flanged housing.

Fig. 88

Caution Danger of squashing! Do not stand or step under suspended loads. !

12. Insert the exciter unit into the flanged housing (Fig. 89).

Fig. 89

486

BOMAG

008 911 63

15.4

Repairing the drum

13. Press cylinder roller bearing 1 (Fig. 90) with pressing plate (2) into the flange until it bottoms.

Fig. 90

14. Insert the circlip into the groove in the flange (Fig. 91).

Fig. 91

15. Lift the flange onto the flanged housing and align it the bores (Fig. 92). Caution Fitting and contact surfaces must be absolutely dry and free of grease, paint and conserving agents. !

Fig. 92

16. Turn the screws into the tapped bores of the flanged housing and tighten them (Fig. 93).

Fig. 93

008 911 63

BOMAG

487

15.4

Repairing the drum 17. Apply some grease to the sealing lip of radial seal 1 (Fig. 94). 18. Slide the radial seal with the sealing lip forward over the shaft and drive it completely into the flanged housing, using a suitable tube (2).

Fig. 94

19. Cover the thread of screw 1 (Fig. 95) with a screw retention agent (e.g. Loctite CVX strong, blue, 582). 20. Slide on the new U-seal ring (2), turn in and tighten the screws.

Fig. 95

21. Insert the fitting key into the keyway of the shaft (Fig. 96).

Fig. 96


Wear safety gloves. 22. Slide the fan with assembly disc over the shaft. 23. Heat coupling hub 1 (Fig. 97) with marking letter “R“ up to approx. 80° C and slide it over the shaft against the shoulder. 24. Turn in and tighten clamping screw (2). 25. Assemble the fan to the coupling hub.

Fig. 97

488

BOMAG

008 911 63

15.4

Repairing the drum

Assembling the exciter unit (travel motor side) 1. Check coupling elements, replace if necessary. 2. Insert the coupling element into the coupling hub (Fig. 98). ! Caution Fitting and contact surface of the connection between exciter unit and drum must be absolutely dry and free of grease, oil, paint and conserving agent.

3. Fasten the lifting device to the exciter unit. Caution Danger of squashing! Do not stand or step under suspended loads. !

Fig. 98

4. Insert the vibrator unit into the drum (Fig. 99).

Fig. 99

i Note Insert the exciter unit so that oil filler plug 1 (Fig. 100) is in line with bore (2) in the drum.

Fig. 100

008 911 63

BOMAG

489

15.4

Repairing the drum 5. Turn in and tighten screws 2 (Fig. 101). 6. Remove bracket (1) for the lifting device.

Fig. 101

7. Cover the thread of screws (Fig. 102) with a screw retention agent (e.g. Loctite green 270). 8. Slide on the new U-seal ring, turn in and tighten the screws.

Fig. 102

Installing the travel motor ! Danger Danger of squashing!

Do not stand or step under suspended loads. 1. Fasten the lifting tackle to the travel motor and attach the motor to the drive disc (Fig. 103).

Fig. 103

2. Turn in and tighten the fastening screws (Fig. 104).

Fig. 104

490

BOMAG

008 911 63

15.4

Repairing the drum

3. Mount the support leg to the travel motor, insert the screws, turn on and tighten the nuts (Fig. 105).

Fig. 105

Danger Danger of squashing! !

Do not stand or step under suspended loads. 4. Attach the drive disc with the assembled travel motor to the rubber buffers. Turn on and tighten the nuts (Fig. 106).

Fig. 106

Installing the exciter unit (vibration motor side) Caution Fitting and contact surface of the connection between exciter unit and drum must be absolutely dry and free of grease, oil, paint and conserving agent. !

Danger Danger of squashing! Do not stand or step under suspended loads. !

1. Fasten the lifting gear to the exciter unit and insert it into the drum (Fig. 107).

Fig. 107

008 911 63

BOMAG

491

15.4

Repairing the drum ! Caution Ensure correct engagement of coupling and alignment of shaft (Fig. 108).

If the shafts are not correctly in line determine the cause, if necessary measure the drum.

Fig. 108

2. Turn in and tighten screws 1 (Fig. 109). 3. Remove the lifting gear. 4. Fit cover (2) to the drum.

Fig. 109

5. Check the end float of the exciter shafts (Fig. 110). Nominal value: 0.6...1.8 mm

Fig. 110

6. Attach disc 1 (Fig. 111), turn in and tighten the fastening screws (2).

Fig. 111

492

BOMAG

008 911 63

15.4

Repairing the drum

7. Lay a new V-ring over the journal of the flanged hub (Fig. 112). 8. Fill the grooved ball bearing with grease.

Fig. 112

9. Check coupling element, replace if necessary. 10. Insert the coupling element into the coupling hub (Fig. 113).

Fig. 113

11. Fasten the vibration motor to the cover so that sockets 1 (Fig. 114) and ventilation bore (2) are opposite each other.

Fig. 114

12. Slide on coupling half 2 (Fig. 115) and secure with clamping screw (1).

Fig. 115

008 911 63

BOMAG

493

15.4

Repairing the drum 13. Attach the cover with the installed vibration motor, turn in and tighten the screws (Fig. 116).

Fig. 116

14. Install rectangular rubber buffers 2 (Fig. 117) with attached spacer block (3) and screws (1) to the side plate.

i Note Assemble both rectangular rubber buffers.

Fig. 117

494

BOMAG

008 911 63

Disassembling and assembling the change-over weight

15.5

15.5 Disassembling and assembling the change-over weight Dismantling the change-over weight 1. Unscrew all screws (Fig. 3).

Fig. 1

2. Force the cover with forcing screws (Fig. 4) off the basic weight. Environment Environmental hazard! Catch running out oil and dispose of environmentally.

Fig. 2

3. Take the change-over weight out of the basic weight (Fig. 5).

Fig. 3

008 911 63

BOMAG

495

15.5

Disassembling and assembling the change-over weight 4. Take the O-rings 1 and 2 (Fig. 4) out of the grooves.

Fig. 4

Assembling the change-over weight 1. Insert the new O-rings 1 and 2 (Fig. 5) with grease.

Fig. 5

2. Place the change-over weight into the basic weight (Fig. 6).

Fig. 6

3. Fill aprox 2,5 litres of silicone oil 47 V 1000 cst (up to the upper edge of the change-over weight) into the basic weight (Fig. 10).

Fig. 7

496

BOMAG

008 911 63

Disassembling and assembling the change-over weight

15.5

4. Lay the cover on (Fig. 11), so that the raised areas are in line. 5. Screw the screws in with screw locking agent (e.g. Loctite green 270) and tighten them with 120 Nm. 6. Check the axial clearance of the shaft.

i

Note The shaft must have clearance.

Fig. 8

008 911 63

BOMAG

497

15.6

Changing the rubber buffers and adjusting the pretension 15.6 Changing the rubber buffers and adjusting the pretension Relieve the rubber buffers 1. Lift the frame up by both sides, until rubber buffers and rectangular buffers are relieved of any load (Fig. 1). 2. Loosen all fastening screws.

Fig. 1

3. Turn one screw each into the welded nuts (Fig. 2) on the spacer blocks.

Fig. 2

4.

Remove the compensation shims 1 (Fig. 3).

Fig. 3

498

BOMAG

008 911 63

Changing the rubber buffers and adjusting the pretension

15.6

5. Unscrew the screws (Fig. 4) from the welded nuts.

Fig. 4

Changing the rubber buffers 6. Unscrew nut 1 (Fig. 3) and remove the washer. 7. Unscrew screws (2). 8. Take off rubber buffer (3). 9. Attach the new rubber buffer to the drive disc and align the bores to the tapped bores in the drum. 10. Turn in and tighten the fastening screws. 11. Assemble the washer, turn on and tighten the nut.

Fig. 5

Adjusting the pre-load 12. Measure distance „X“ between spacer piece and side plate (Fig. 6). 13. Calculate the thickness of the compensation plates. Nominal value: Distance „X“ + 2 mm

Fig. 6

14. Turn in screws into each welded nut and provide sufficient space to insert the compensation plates (Fig. 7).

Fig. 7

008 911 63

BOMAG

499

15.6

Changing the rubber buffers and adjusting the pretension 15. Insert the compensation shims 1 (Fig. 8).

Fig. 8

16. Unscrew the screws (Fig. 9) from the welded nuts.

Fig. 9

17. Tighten the fastening screws (Fig. 10). 18. Lower the frame again.

Fig. 10

500

BOMAG

008 911 63

16 Oscillating articulated joint

008 911 63

BOMAG

501

16.1

Special tools, oscillating articulated joint (BW177 to BW 216) 16.1 Special tools, oscillating articulated joint (BW177 to BW 216) 1. Pressing device for rocker bearings

Fig. 1

2. Pressing bushing for outer rocker bearing race

Fig. 2

3. Pressing bushing for inner rocker bearing race

Fig. 3

502

BOMAG

008 911 63

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

16.1

4. Guide pin

Fig. 4

5. Clamping device

Fig. 5

6. Disassembly device

Fig. 6

008 911 63

BOMAG

503

16.2

504

Repair overview oscillating articulated joint

BOMAG

008 911 63

16.2


1

Housing

12 Cover

2

Seal ring

13 Cover

3

Cover

14 Intermediate ring

4

Self-aligning bearing

15 Self-aligning bearing

5

Bolt

16 Intermediate ring

6

Shim/supporting disc

17 Self-aligning bearing

7

Belleville springs

18 Carrier

8

Self-aligning bearing

19 Friction bearing

9

Console

20 V-ring

10 Belleville springs

21 Seal ring

11 Shim/supporting disc

008 911 63

BOMAG

505

16.2

506


BOMAG

008 911 63


008 911 63

BOMAG

16.2

507

16.3

Removing and installing the oscillating articulated joint 16.3 Removing and installing the oscillating articulated joint 1. Jack up the frame (Fig. 1) at the back and secure it with trestles or wooden blocks.

Fig. 1

2. Support the rear frame near the oscillating articulated joint (Fig. 2) on both sides safely with trestles or wooden blocks.

Fig. 2

3. Fasten the lifting tackle to the front frame near the oscillating articulated joint (Fig. 3).

Fig. 3

508

BOMAG

008 911 63

Removing and installing the oscillating articulated joint

16.3

4. Unscrew fastening screws 1 (Fig. 4) and take off axle holder (2). 5. Knock out bearing bolt (3). 6. Retract steering cylinder (4).

Fig. 4

Danger Danger of accident! !

7. Support the oscillating articulated joint in the middle with a suitable jack or a similar device. 8. Unscrew fastening screws 1 (Fig. 5) and take off with disc (2).

Fig. 5

9. Unscrew nuts 3 (Fig. 6) and take off the clamping washers (2). 10. Pull out the fastening screws (1). 11. Slightly raise the front frame and lower the oscillating articulated joint to the ground. 12. Pull out the oscillating articulated joint.

Fig. 6

Note on assembly 13. Insert the bolt for the steering cylinder so that groove (2) is in line with tapped bores (1).

Fig. 7

008 911 63

BOMAG

509

16.4

Dismantling the oscillating articulated joint 16.4 Dismantling the oscillating articulated joint 1. Unscrew the nuts from hexagon screw 1 (Fig. 1) and pull out the hexagon screw. 2. Unscrew the screws (2) for the cover.

Fig. 1

3. Take off the cover with Belleville springs, shim and backing disc (Fig. 2). 4. Disassemble also the cover from the opposite side.

i Note No Belleville springs, shim and backing disc are under this cover.

Fig. 2

5. Drive the console with a plastic hammer to one side against the end stop (Fig. 3).

i Note The outer race of the rocker bearing is thereby stripped off.

Fig. 3

510

BOMAG

008 911 63

16.4

Dismantling the oscillating articulated joint

6. Force inner race 1 (Fig. 4) of the rocker bearing off the bolt. 7. Take of supporting disc (2). 8. Drive the console to the opposite side and remove the rocker bearing in the same way.

Fig. 4

9. Unscrew fastening screws 1 (Fig. 5). 10. Press bolt (3) out of the console with forcing screws (2).

i

Note Remove the bolt on the opposite side in the same way.

Fig. 5

11. Lift console 1 (Fig. 6) off housing (2).

Fig. 6

12. Take the seal rings out of the console (Fig. 7).

Fig. 7

008 911 63

BOMAG

511

16.4

Dismantling the oscillating articulated joint 13. Remove the cover from the housing. 14. Take off shims 1 (Fig. 8), backing disc (2) and Belleville springs (3).

Fig. 8

15. Unscrew bolts 1 (Fig. 9) and take off cover (2).

Fig. 9

16. Take the intermediate ring out of the housing (Fig. 10).

Fig. 10

17. Place the plate 1 (Fig. 11) on the beam. 18. Attach the puller (2) to the housing (3) and separate the carrier from the rocker bearings.

Fig. 11

512

BOMAG

008 911 63

16.4

Dismantling the oscillating articulated joint 19. Pull the housing off the beam (Fig. 12).

Fig. 12

20. Drive the outer race of the friction bearing out of the housing (Fig. 13).

Fig. 13

21. Drive the friction bearing out of the housing (Fig. 14).

Fig. 14

22. Take seal ring 1 (Fig. 15) and V-ring (2) off the beam.

Fig. 15

008 911 63

BOMAG

513

16.4

Dismantling the oscillating articulated joint 23. Check rocker bearings, if necessary press out of the housing (Fig. 16).

Fig. 16

514

BOMAG

008 911 63

16.5

Assembling the oscillating articulated joint

16.5 Assembling the oscillating articulated joint 1. If previously disassembled, press the rocker bearing fully into the housing with a pressing mandrel (Fig. 1).

i Note Apply sliding lacquer OKS 571 to mating surfaces to ease assembly Caution Do not use any grease. !

Fig. 1

2. Slide the new V-ring on the beam against the stop with the lip facing up (Fig. 2).

Fig. 2

3. Lay the seal ring into the beam (Fig. 3). 4. Fill the space between V-ring and seal ring with multi-purpose grease.

Fig. 3

008 911 63

BOMAG

515

16.5

Assembling the oscillating articulated joint 5. Press the friction bearing fully into the housing with the chamfered side pointing towards the outside (Fig. 4).

Fig. 4

6. Slide the housing over the beam (Fig. 5).

i Note The journal on the housing must be centrally in the recess of the beam.

Fig. 5

7. Press the seal ring carefully towards the inside, until it sits in the recess of the housing (Fig. 6).

Fig. 6

8. Spray the sliding surface of the outer rocker bearing race with sliding agent OKS 571. Caution Do not use any grease. !

9. Press the outer rocker bearing race 1 (Fig. 7) in until it bottoms with the wider outer rim forward using pressing sleeve (2).

Fig. 7

516

BOMAG

008 911 63

16.5


10. Press inner rocker bearing race 1 (Fig. 8) in until it bottoms, using pressing sleeve (2).

Fig. 8

11. Insert the intermediate ring (Fig. 9).

Fig. 9

12. Press inner rocker bearing race 1 (Fig. 10) in until it bottoms, using pressing sleeve (2).

Fig. 10

i Note Apply sliding lacquer OKS 571 to mating surfaces to ease assembly ! Caution Do not use any grease.

13. Press the outer rocker bearing race 1 (Fig. 11) in until it bottoms with the wider outer rim pointing up, using pressing sleeve (2).

Fig. 11

008 911 63

BOMAG

517

16.5

Assembling the oscillating articulated joint 14. Press in intermediate ring 1 (Fig. 12) until it bottoms. 15. Attach cover (2) with the machined edge forward. 16. Turn in screws (3) and tighten crosswise.

Fig. 12

Determining the shim thickness 17. Determine the shim thickness, for this purpose stand the cross-member on a wooden board with an ∅ 18 mm bore. Caution Check the measurement with an axial preload of 40kN. With threaded rod M12-8.8 tightening torque 77Nm. With threaded rod M168.8 tightening torque 90Nm. !

Fig. 13

18. Slide the rod of the tensioning device in from underneath, attach the plate, screw on the nut and tighten. 19. Measure the distance from housing edge to intermediate ring (Fig. 13) and write it down, e.g. 4,7 mm.

i Note From this measured value of 4.7 mm subtract the fixed value of 4.0 mm to determine the shim thickness. Calculation example: 4,7 mm - 4,0 mm = 0,7 mm measured value: 4,7 mm fixed value: 4,0 mm Shim thickness: 0,7 mm 20. Remove the tensioning device.

518

BOMAG

008 911 63

16.5


21. Insert shim 2 (Fig. 14) of appropriate thickness and backing disc (1) into the cover.

Fig. 14

22. Lay the Belleville springs into the cover with the curvature pointing down (Fig. 15).

Fig. 15

23. Assemble cover 2 (Fig. 16) with Belleville springs, shim and backing disc. 24. Turn in screws (1) and tighten crosswise.

Fig. 16

25. Press the new sealing rings into the respective groove in the console (Fig. 17).

Fig. 17

008 911 63

BOMAG

519

16.5

Assembling the oscillating articulated joint 26. Lift console 1 (Fig. 18) over the housing (2).

Fig. 18

27. Turn four guide pins into the housing bores (Fig. 19).

Fig. 19

i Note Perform the following eight work steps on both sides. 28. Slide the bolt over the guide pins (Fig. 20) and drive in until it bottoms.

Fig. 20

Caution When driving in the bolt make sure that the seal ring is not pressed out through the back of the console (Fig. 21). !

Fig. 21

520

BOMAG

008 911 63

16.5

Assembling the oscillating articulated joint 29. Unscrew the guide pins .

30. Turn in the screws and tighten with 75 Nm (Fig. 22).

Fig. 22

31. Slide the backing discs over the bolt (Fig. 23).

Fig. 23

32. Drive the inner rocker bearing race on against the end stop with the wider outer rim forward (Fig. 24).

Fig. 24

33. Spray the sliding surface of the outer rocker bearing race with sliding agent OKS 571. Caution Do not use any grease. !

34. Attach the outer rocker bearing race with the wider outer rim facing towards the outside (Fig. 25) and drive it in until it bottoms.

Fig. 25

008 911 63

BOMAG

521

16.5

Assembling the oscillating articulated joint 35. Attach cover 1 (Fig. 26) to the bottom side of the console. 36. Turn in and tighten screws (2).

Fig. 26

Determining the shim thickness 37. Determine the shim thickness, for this purpose insert rod 1 (Fig. 27) of the tensioning device from underneath. Attach plate (2), screw on nut (3) and tighten. Caution Check the measurement with an axial preload of 40kN. With threaded rod M12-8.8 tightening torque 77Nm. With threaded rod M168.8 tightening torque 90Nm. !

Fig. 27

38. Measure the distance from outer rocker bearing race to console surface (Fig. 28) and write it down, e.g. 3.4 mm.

i

Note From this measured value of 3.4 mm subtract the fixed value of 2.2 mm to determine the shim thickness. Calculation example: 3.4 mm - 2.2 mm = 1.2 mm measured value: 3,4 mm fixed value: 2,2 mm

Fig. 28

Shim thickness: 1.2 mm 39. Remove the tensioning device.

522

BOMAG

008 911 63

16.5


40. Insert shims 2 (Fig. 29) of appropriate thickness and backing disc (1) into the cover.

Fig. 29

41. Lay the Belleville springs into the cover with the curvature pointing down (Fig. 30).

Fig. 30

42. Assemble cover 1 (Fig. 31) with Belleville springs, shims and supporting discs. 43. Turn in screws (2) and tighten crosswise.

Fig. 31

44. Insert hexagon screw 1 (Fig. 32) so that the screw head rests on the upper side of the console.

Fig. 32

008 911 63

BOMAG

523

16.5

Assembling the oscillating articulated joint 45. Assemble the washer, turn on and tighten the nut with 120 Nm (Fig. 33).

Fig. 33

524

BOMAG

008 911 63

17 Suppliers documentation

008 911 63

BOMAG

525

526

BOMAG

008 911 63

17.1 Travel pump

008 911 63

BOMAG

527

17.1

Travel pump

Bild 34

528

BOMAG

008 911 63

17.1

Travel pump

Series 90

Axial Piston Pumps and Motors Service Manual

008 911 63

BOMAG

529

17.1

Travel pump

Series 90

Introduction

Introduction Use of this Manual This manual includes information for the normal operation, maintenance, and servicing of the Series 90 family of hydrostatic pumps and motors. The manual also includes the description of the units and their individual components, troubleshooting information, adjustment instructions, and minor repair procedures. Unit warranty obligations should not be affected if maintenance, adjustment, and minor repairs are performed according to the procedures described in this manual. Many service and adjustment activities can be performed without removing the unit from the vehicle or machine. However, adequate access to the unit must be available, and the unit must be thoroughly cleaned before beginning maintenance, adjustment, or repair activities.

Since dirt and contamination are the greatest enemies of any type of hydraulic equipment, cleanliness requirements must be strictly adhered to. This is especially important when changing the system filter and during adjustment and repair activities. For further information refer to Series 90 Technical Information. For information about fluid requirements refer to SAUER-SUNDSTRAND BLN 9887 or SDF (Id No. 697581). A worldwide network of SAUER-SUNDSTRAND Authorized Service Centers is available should repairs be needed. Contact any SAUER-SUNDSTRAND Authorized Service Center for details. A list of all Service Centers can be found in bulletin BLN-2-400527, or in brochure SAW (Ident. No. 698266).

Safety Precautions Observe the following safety precautions when using and servicing hydrostatic products.

Loss of Hydrostatic Braking Ability

Fluid under High Pressure

WARNING The loss of hydrostatic drive line power in any mode of operation (e.g., forward, reverse, or "neutral" mode) may cause the loss of hydrostatic braking capacity. A braking system, redundant to the hydrostatic transmission must, therefore, be provided which is adequate to stop and hold the system should the condition develop.

WARNING Use caution when dealing with hydraulic fluid under pressure. Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury. This fluid may also be hot enough to burn. Serious infection or reactions can develop if proper medical treatment is not administered immediately.

S000 001E

S000 003E

Disable Work Function

Flammable Cleaning Solvents

WARNING Certain service procedures may require the vehicle/machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing them in order to prevent injury to the technician and bystanders.

WARNING Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area where a source of ignition may be present. S000 004E

S000 005E

Copyright 1987-1998, SAUER-SUNDSTRAND GmbH & Co. All rights reserved. Contents subject to change.

S90MVCTCD S90PVMFCD

2

530

BOMAG

008 911 63

17.1

Travel pump

Series 90

Contents

Contents Introduction ......................................................................................................................................................................... 2 Use of this Manual ........................................................................................................................................................................................ 2 Safety Precautions ........................................................................................................................................................................................ 2

Functional Description ....................................................................................................................................................... 5 General Description and Cross Sectional Views ......................................................................................................................................... 5 Variable Displacement Pumps ................................................................................................................................................................ 5 Fixed Displacement Motor ..................................................................................................................................................................... 5 Variable Displacement Motor .................................................................................................................................................................. 6 The System Circuit ....................................................................................................................................................................................... 7 The Basic Closed Circuit ........................................................................................................................................................................ 7 Case Drain and Heat Exchanger ........................................................................................................................................................... 7 Common Features of Pumps and Motors .................................................................................................................................................... 8 End Caps and Shafts ............................................................................................................................................................................. 8 Speed Sensors ....................................................................................................................................................................................... 8 Pump Features ............................................................................................................................................................................................. 9 Charge Pump .......................................................................................................................................................................................... 9 Charge Relief Valve ................................................................................................................................................................................. 9 Multi-Function Valves .............................................................................................................................................................................. 9 Pressure Limiter and High Pressure Relief Valves ....................................................................................................................... 10 System Check Valves .................................................................................................................................................................... 10 Bypass Valves ................................................................................................................................................................................ 10 Displacement Limiters .......................................................................................................................................................................... 11 Auxiliary Mounting Pads ....................................................................................................................................................................... 11 Filtration Options ................................................................................................................................................................................... 11 Pressure Override (POR) - 180 Frame Size Only ............................................................................................................................. 12 Pump Control Options .......................................................................................................................................................................... 13 Manual Displacement Control (MDC) ........................................................................................................................................... 13 Hydraulic Displacement Control (HDC) ........................................................................................................................................ 13 Electric Displacement Control (EDC) ............................................................................................................................................ 14 Automotive Control (FBA II B) ....................................................................................................................................................... 14 3-Position (FNR) Electric Control .................................................................................................................................................. 14 Motor Features ........................................................................................................................................................................................... 15 Motor Loop Flushing Valve and Charge Relief Valve ........................................................................................................................... 15 Variable Motor Displacement Limiters .................................................................................................................................................. 15 Variable Motor Controls ........................................................................................................................................................................ 16 Hydraulic 2-Position Control .......................................................................................................................................................... 16 Electric 2-Position Control .............................................................................................................................................................. 16

Technical Specifications .................................................................................................................................................. 17 General Specifications ................................................................................................................................................................................ 17 Circuit Diagrams ......................................................................................................................................................................................... 17 Hydraulic Parameters ................................................................................................................................................................................. 18 Size Specific Data ....................................................................................................................................................................................... 19

Pressure Measurement ................................................................................................................................................... 20 Required Tools ............................................................................................................................................................................................ 20 Port Locations and Pressure Gauge Installation ....................................................................................................................................... 20 Variable Pump ....................................................................................................................................................................................... 20 Fixed Motor ........................................................................................................................................................................................... 23 Variable Motor ....................................................................................................................................................................................... 24

Initial Start-Up Procedure ................................................................................................................................................ 25 Fluid and Filter Maintenance ........................................................................................................................................... 26 Troubleshooting ................................................................................................................................................................ 27 "NEUTRAL" Difficult or Impossible to Find ................................................................................................................................................. 27 System Operating Hot ................................................................................................................................................................................ 27 Transmission Operates Normally in One Direction Only .......................................................................................................................... 28 System Will Not Operate in Either Direction .............................................................................................................................................. 28 Low Motor Output Torque ........................................................................................................................................................................... 29 Improper Motor Output Speed .................................................................................................................................................................... 29 Excessive Noise and/or Vibration .............................................................................................................................................................. 30 System Response is Sluggish .................................................................................................................................................................... 30

3

008 911 63

BOMAG

531

17.1

Travel pump

Series 90

Contents

Inspections and Adjustments ......................................................................................................................................... 31 Pump Adjustments ...................................................................................................................................................................................... 31 Charge Pressure Relief Valve Adjustment ........................................................................................................................................... 31 Multi-Function Valve Pressure Adjustment .......................................................................................................................................... 33 Engaging the Bypass Function ............................................................................................................................................................ 35 Pressure Override (POR) Valve Pressure Adjustment (Option for 180 Frame Size) ....................................................................... 36 Displacement Limiter Adjustment ......................................................................................................................................................... 37 Pump Control Adjustments ......................................................................................................................................................................... 38 Standard Manual Displacement Control (MDC) Adjustment .............................................................................................................. 38 Non-Linear Manual Displacement Control (MDC) .............................................................................................................................. 39 MDC Neutral Start Switch (NSS) Adjustments .................................................................................................................................... 40 Hydraulic Displacement Control (HDC) and Electric Displacement Control (EDC) Adjustment ....................................................... 46 Motor Adjustments ...................................................................................................................................................................................... 48 Charge Relief Valve Adjustment ........................................................................................................................................................... 48 Displacement Limiter Adjustment (MV) ................................................................................................................................................ 49 Displacement Control Adjustments ...................................................................................................................................................... 49 Speed Sensor Adjustment .......................................................................................................................................................................... 50

Minor Repair Instructions ................................................................................................................................................ 51 Pump and Motor Minor Repair .................................................................................................................................................................... 53 Pump / Fitting Torques .......................................................................................................................................................................... 53 Shaft Seal and Shaft Replacement ...................................................................................................................................................... 54 Pump Minor Repairs ................................................................................................................................................................................... 56 Multi-Function Valve Cartridges ........................................................................................................................................................... 56 Pressure Override Valve (Option for 180 Frame Size) ....................................................................................................................... 57 Charge Relief Valve ............................................................................................................................................................................... 57 Charge Pump - Remove ...................................................................................................................................................................... 58 Installing the Charge Pump .................................................................................................................................................................. 60 Auxiliary Pad Installation ....................................................................................................................................................................... 62 Auxiliary Pad Conversion ..................................................................................................................................................................... 63 Filtration Options ................................................................................................................................................................................... 64 Pump controls ....................................................................................................................................................................................... 65 Cover Plate ..................................................................................................................................................................................... 65 Manual Displacement Control (MDC) ........................................................................................................................................... 66 Solenoid Override Valve for MDC .................................................................................................................................................. 67 Solenoid Override Valve for MDC with Pressure Released Brake .............................................................................................. 67 Hydraulic and Electric Displacement Controls ............................................................................................................................. 68 Pressure Control Pilot (PCP) for Electric Displacement Control .................................................................................................. 68 3-Position (FNR) Electric Control .................................................................................................................................................. 69 Displacement Control Components ............................................................................................................................................... 69 Minor Repair - Motor ................................................................................................................................................................................... 71 Loop Flushing and Charge Relief Valves ............................................................................................................................................. 71 Variable Motor Displacement Limiters .................................................................................................................................................. 73 Variable Motor Controls ............................................................................................................................................................................... 74 Electrohydraulic 2-Position Control (Types NA, NB, NC, and ND) ..................................................................................................... 74 Hydraulic 2-Position Control (Type PT) ............................................................................................................................................... 74 Control Plugs ........................................................................................................................................................................................ 74 Variable Motor Control Orifices ............................................................................................................................................................ 75 Speed Sensor .............................................................................................................................................................................................. 77

Exploded View Parts Drawings / Parts Lists .................................................................................................................. 78 Variable Pumps ........................................................................................................................................................................................... 78 Minor Repair Parts ................................................................................................................................................................................ 78 Parts List ............................................................................................................................................................................................... 79 Variable Pump Controls ........................................................................................................................................................................ 80 Control Parts List .................................................................................................................................................................................. 81 Filter and Options ................................................................................................................................................................................. 82 Parts List Filter and Options ................................................................................................................................................................. 83 Name Plates ......................................................................................................................................................................................... 83 Fixed Motor ................................................................................................................................................................................................. 84 Minor Repair Parts ................................................................................................................................................................................ 84 Parts List ............................................................................................................................................................................................... 85 Name Plates ......................................................................................................................................................................................... 85 Variable Motor .............................................................................................................................................................................................. 86 Minor Repair Parts ................................................................................................................................................................................ 86 Parts List ............................................................................................................................................................................................... 87 Name Plate ............................................................................................................................................................................................ 87

4

532

BOMAG

008 911 63

17.1

Travel pump

Series 90

Functional Description

Functional Description This section describes the operation of pumps, motors, and their various serviceable features. It is a useful reference for readers unfamiliar with the functioning of a specific system.

General Description and Cross Sectional Views Variable Displacement Pumps The Variable Displacement Pump (PV) is designed to convert an input torque into hydraulic power. The input shaft turns the pump cylinder which contains a ring of pistons. The pistons run against a tilted plate, called the swashplate. This causes the pistons to compress the hydraulic fluid which imparts the input energy into the hydraulic fluid. The high pressure fluid is then ported out to provide power to a remote function. The swashplate angle can be varied by the control piston. Altering the swashplate angle varies the displacement of fluid in a given revolution of the input shaft. F000 539

Series 90 Variable Displacement Pump (PV) Slider Block Servo Arm Servo Valve Cradle Hold Down

Servo Piston Feed Back

Cradle Bearing

Cradle Leveler Charge Pump

Cradle Cradle Guide

P001 413E

Series 90 PV Cross Section

Fixed Displacement Motor The Fixed Displacement Motor (MF) is designed to convert an input of hydraulic power into an output torque. It operates in the reverse manner of the pump. The high pressure hydraulic fluid enters through the input port. The fluid pressure builds behind the pistons causing them to move down the swashplate (the path of least resistance). As the piston returns up the swashplate again, the fluid is allowed to exit through the exit port. The spinning pistons are housed in a cylinder which is connected to the output shaft. The output torque can be applied to a mechanical function. 90000347

Series 90 Fixed Displacement Motor (MF)

5

008 911 63

BOMAG

533

17.1

Travel pump

Series 90

Functional Description In the Fixed Displacement Motor the "swashplate" is fixed, so any variation in motor speed and torque must be made by the input mechanism, i.e. the pump.

Loop Flushing Valve Valve Plate

Piston Roller Bearing

Output Shaft

Fixed Swashplate End Cap

Cylinder Block 90000190E

Series 90 MF Cross Section

Variable Displacement Motor The Variable Displacement Motor (MV) operates in the same manner as the fixed motor. However, its swashplate is not fixed; it can be switched between minimum and maximum angle to amplify torque or speed like the Variable Displacement Pump.

90000348

Series 90 Variable Displacement Motor (MV) Minimum Angle Control Piston

Valve Plate Piston End Cap Roller Bearing

Cradle Swashplate

Output Shaft

"A"

Partial Section "A-A" Cradle Swashplate in Full Displacement Position

"A"

Cradle Swashplate Cylinder Block Maximum Angle Control Piston

Electric 2-Position Control (optional)

90000234E

Series 90 MV Cross Section

6

534

BOMAG

008 911 63

17.1

Travel pump

Series 90


The System Circuit

System loop (low pressure) Control Handle

Displacement Control Valve

Case drain fluid Heat Exchanger Bypass Valve

System loop (high pressure) Reservoir

Orificed Check Valve

Control fluid Vacuum Gauge

Suction line Heat Exchanger

Servo Control Cylinder

Variable Displacement Pump

Multi-Function Valve

Purge Relief Valve

Charge Pressure Relief Valve

Fixed Displacement Motor

to Pump Case Servo Pres. Relief Valve Charge Pump Input Shaft

Output Shaft Multi-Function Valve

Pump Swashplate

Servo Control Cylinder

Motor Swashplate Loop Flushing Valve

Pump

Fixed Motor 90000800E

Circuit Diagram for Series 90 PV and 90 MF

The Basic Closed Circuit The main ports of the pump are connected by hydraulic lines to the main ports of the motor. Fluid flows, in either direction, from the pump to the motor then back to the pump in this closed circuit. Either of the hydraulic lines can be under high pressure. In pumping mode the position of the pump swashplate determines which line is high pressure as well as the direction of fluid flow.

Case Drain and Heat Exchanger The pump and motor require case drain lines to remove hot fluid from the system. The motor should be drained from its topmost drain port to ensure the case remains full of fluid. The motor case drain can then be connected to the lower drain port on the pump housing and out the top most port. A heat exchanger, with a bypass valve, is required to cool the case drain fluid before it returns to the reservoir.

Reservoir Input

PV

MF

Output

Flow (Bi-directional)

Case Drain Line 90000803E

Basic Closed Circuit

7

008 911 63

BOMAG

535

17.1

Travel pump

Series 90


Common Features of Pumps and Motors End Caps and Shafts Series 90 pumps and motors can be supplied with a variety of end caps and shafts to allow for almost any configuration. For pumps, end caps are available with system ports on either side ("side ports") or both ports on one side ("twin ports"). Motors have end caps with ports on the face of the end cap ("axial ports") or both ports on one side ("twin ports"). See the Series 90 Technical Information manuals (BLN-10029 and BLN-10030) or the Series 90 Price Book (BLN-2-40588) for information on available options. Removing the end cap will void the warranty on a Series 90 pump or motor.

Speed Sensors An optional speed sensor can be installed on Series 90 pumps and motors to provide unit speed information. The sensor reads a magnetic ring wrapped about the unit's cylinder. See the corresponding Section to locate, install and adjust the sensor.

90000810

Speed Sensor

8

536

BOMAG

008 911 63

17.1

Travel pump

Series 90


Pump Features Charge Pump The charge pump is necessary to supply cool fluid to the system, to maintain positive pressure in the main system loop, to provide pressure to operate the control system, and to make up for internal leakage. Charge pressure must be at its specified pressure under all conditions of driving and braking to prevent damage to the transmission. The charge pump is a fixed-displacement, gerotor type pump installed in the variable displacement pump and driven off the main pump shaft. Charge pressure is limited by a relief valve. The standard charge pump will be satisfactory for most applications. However, if the charge pump sizes available for the given main pump size are not adequate, a gear pump may be mounted to the auxiliary mounting pad and supply the required additional charge flow.

90000243

PV with Charge Pump Case Drain Line

Charge Relief Valve System Check Valves

Charge Relief Valve The charge relief valve on the pump serves to maintain charge pressure at a designated level. A direct-acting poppet valve relieves charge pressure whenever it surpasses a certain level. This level is nominally set referencing case pressure at 1500 rpm. This nominal setting assumes the pump is in neutral (zero flow); in forward or reverse charge pressure will be lower. The charge relief valve setting is specified on the model code of the pump.

Input

PV

PF Charge Pump

Inlet Filter Tank 90000804E

Pump Charge System

Multi-Function Valves The multi-function valve incorporates the system check valve, the pressure limiter valve, the high pressure relief valve and the bypass valve in a replaceable cartridge. These functions are described separately. There are two multi-function valve cartridges in each Series 90 pump to handle functions in either direction. See corresponding Sections for adjustments and repairs. NOTE: Some multi-function valves do not include a pressure limiter valve.

90000243


9

008 911 63

BOMAG

537

17.1

Travel pump

Series 90

Functional Description Pressure Limiter and High Pressure Relief Valves

Pressure Limiter Housing Pressure Limiter Lock Nut

High Pressure Relief / check Valve Poppet

Check Valve Poppet

Pressure Limiter Adjustment Screw

Bypass Actuator

Pressure Limiter Valve Poppet

Bypass

Series 90 pumps are designed with a sequenced pressure limiting system and high pressure relief valves. When the preset pressure is reached, the pressure limiter system acts to rapidly destroke the pump so as to limit the system pressure. For unusually rapid load application, the high pressure relief valve acts to immediately limit system pressure by cross-porting system flow to the low pressure side of the loop. The pressure limiter valve acts as the pilot for the high pressure relief valve spool. The high pressure relief valve is sequenced to operate at approximately 35 bar (500 psi) above the level that initiates the pressure limiter valve. Both the pressure limiter sensing valves and relief valves are built into the multi-function valves (see above).

90000806E

Cross Section of Multi-Function Valve

NOTE: For 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 The system check valves allow pressurized flow from the charge pump to enter the low pressure side of the loop whenever system pressure dips below a certain level. This is needed as the pump will generally lose system pressure due to leakage and other factors. Since the pump can operate in either direction, two system check valves are used to direct the charge supply into the low pressure lines. The system check valves are poppet valves located in the multi-function valve assembly.

To Control


Bypass Adjustment

Servo Piston Port "A"

Bypass Valves

Servo Pres. Relief Valve Port "B" Servo Piston Charge Pressure Relief Valve

The bypass valves ("tow") can be operated when it is desired to move the vehicle or mechanical function when the pump is not running. The valve is opened by manually resetting the valve position. The bypass valves are built into the multi-function valves.

Multi-Function Valve 90000801E

Circuit Diagram showing Pressure Control Mechanism

10

538

BOMAG

008 911 63

17.1

Travel pump

Series 90


Displacement Limiters All Series 90 pumps are designed for optional mechanical displacement (stroke) limiters. The maximum displacement of the pump can be limited in either direction. The setting can be set as low as 0° in either direction. For instructions on adjustment see corresponding Section.

90000244

Auxiliary Mounting Pads

PV with Displacement Limiters

Auxiliary mounting pads are available on all Series 90 pumps. SAE A through E mounts are available (availability varies by pump size). This pad is used for mounting auxiliary hydraulic pumps and for mounting additional Series 90 pumps to make tandem pumps. The pads allow for full through-torque capability.

90000242

Filtration Options

PV with Auxillary Mounting Pad

All Series 90 pumps are available with provisions for either suction or charge pressure filtration (integral or remote mounted) to filter the fluid entering the charge circuit. Suction Filtration The suction filter is placed in the circuit between the reservoir and the inlet to the charge pump. When suction filtration is used, a reducer fitting is placed in the charge pressure gauge port (M3). Filtration devices of this type are provided by the user. 90000243

PV with Suction Filtration (No filtration device attached)

Charge Pressure Filtration The pressure filter may be integrally mounted directly on the pump or a filter may be remotely mounted for ease of servicing. A 125 m screen, located in the reservoir or the charge inlet line, is recommended when using this filtration option.

90000246

PV with Integral Charge Pump

90000247

PV with Remote Charge Pump

11

008 911 63

BOMAG

539

17.1

Travel pump

Series 90

Functional Description Pressure Override (POR) - 180 Frame Size Only

To Control


Pressure Override Control Valve

Bypass Adjustment

The pressure override valve (POR) modulates the control pressure to the displacement control to maintain a pump displacement which will produce a system pressure level less than or equal to the POR setting. For unusually rapid load application, the high pressure relief valve function of the multifunction valves is available to also limit the pressure level.

Port "A" Shuttle Valve Port "B"


Charge Pressure Relief Valve

90000802E

POR-Valve (180 Frame Size only)

The pressure override consists of a three-way normally open valve which operates in series with the pump displacement control. Control supply pressure is normally ported through the pressure override valve to the displacement control valve for controlling the pump's displacement. If the system demands a pressure above the override setting, the POR valve will override the control by reducing the control pressure supplied to the displacement control. As the control pressure reduces, the internal forces tending to rotate the swashplate overcome the force of the servo pistons and allow the pump's displacement to decrease.

12

540

BOMAG

008 911 63

17.1

Travel pump

Series 90


Pump Control Options Manual Displacement Control (MDC) The manual displacement control converts a mechanical input signal to a hydraulic signal using a spring- centered fourway servo valve. This valve ports hydraulic pressure to either side of a dual-acting servo piston. The servo piston rotates the cradle swashplate through an angular rotation of ±17°, thus varying the pump’s displacement from full displacement in one direction to full displacement in the opposite direction. The MDC is designed so the angular position of the pump swashplate is proportional to the rotation of the control input shaft.

Non-Linear MDC The non-linear manual displacement control operates in the same manner as the regular MDC except that it is designed so the change in the angular position of the pump swashplate progressively increases as the control input shaft is rotated toward its maximum displacement position. Solenoid Override Valve for MDC A solenoid override valve option (not shown here) is available for MDC. This safety feature will return the swashplate to zero displacement position when activated. The valve may be set in either a normally open or normally closed mode.

90000237

PV with Manual Displacement Control

Neutral Start Switch (NSS) The neutral start switch is an optional feature available with MDC. When connected properly with the vehicle’s electrical system, the neutral start switch ensures that the prime mover can be started only when the control is in a neutral position.

90000239

PV with Manual Displacement Control and Neutral Start Switch

Hydraulic Displacement Control (HDC) The hydraulic displacement control uses a hydraulic input signal to operate a spring-centered four-way servo valve. This valve ports hydraulic pressure to either side of a dual-acting servo piston. The servo piston rotates the cradle swashplate through an angular rotation of ±17°, thus varying the pump’s displacement from full displacement in one direction to full displacement in the opposite direction. The HDC is designed so the angular position of the pump swashplate is proportional to input pressure.

90000240

PV with Hydraulic Displacement Control

13

008 911 63

BOMAG

541

17.1

Travel pump

Series 90

Functional Description Electric Displacement Control (EDC)

90000241

PV with Electric Displacement Control

The electric displacement control is similar to the hydraulic displacement control with the input signal pressure controlled by a pressure control pilot (PCP) valve. The PCP valve converts a DC electrical input signal to a hydraulic signal which operates a spring- centered fourway servo valve. This valve ports hydraulic pressure to either side of a dual-acting servo piston. The servo piston rotates the cradle swashplate through an angular rotation of ±17°, thus varying the pump’s displacement from full displacement in one direction to full displacement in the opposite direction. The control is designed so the angular position of the swashplate is proportional to the EDC input. Automotive Control (FBA II B) Automotive Control allows a vehicle to be driven in a manner similar to an automobile with an automatic transmission. The Automotive Control includes a three-position electric control to provide direction control.

3-Position (FNR) Electric Control This control utilizes a 12 or 24 VDC electrically operated spool valve to port pressure to either side of the pump displacement control piston. Energizing one of the solenoids will cause the pump to go to its maximum displacement in the corresponding direction. All functions of the three-position (FNR) electric control are preset at the factory.

90000354

PV with 3-Position (FNR) Electric Control

14

542

BOMAG

008 911 63

17.1

Travel pump

Series 90


Motor Features Motor Loop Flushing Valve and Charge Relief Valve All Series 90 motors are designed to accommodate a loop flushing valve. The loop flushing valve is used in installations which require additional fluid to be removed from the main hydraulic circuit because of transmission cooling requirements, or unusual circuits requiring additional loop flushing to remove excessive contamination in the high pressure circuit.

90000248

Loop Flushing Valve (MF)

A shuttle valve and charge relief valve are installed in the motor end cap to provide the loop flushing function. The shuttle valve provides a circuit between the low pressure side of the closed loop and the charge relief valve in the motor end cap. The motor charge relief valve regulates the charge pressure level only when there is a pressure differential in the main loop. The shuttle valve is spring centered to the closed position so that no high pressure fluid is lost from the circuit when reversing pressures.

Top of Motor

Charge Relief Valve

For charge relief valve adjustment see corresponding Section.

Loop Flushing Shuttle Valve

End Cap

90000238E

Motor Charge Relief Valve and Loop Flushing Shuttle Valve

Variable Motor Displacement Limiters All Series 90 variable motors include mechanical displacement (stroke) limiters. Both the maximum and minimum displacement of the motor can be limited. The range of the settings is as follows:

Minimum Displacement Maximum Displacement

055 MV

075 MV

19 - 40 cm3 1.2 - 2.4 in3

26 - 54 cm3 1.6 - 3.3 in3

65 - 100 %

65 - 100 %

90000352

MV Maximum Displacement Limiter (Minimum Displacement Limiters on opposite side)

T002 251E

15

008 911 63

BOMAG

543

17.1

Travel pump

Series 90


Variable Motor Controls

Hydraulic 2-Position Control This control utilizes a hydraulically operated three-way hydraulic valve to port system pressure to either of the motor displacement control pistons. The motor is normally held at its maximum displacement. Supplying pilot hydraulic pressure to the valve will cause the motor to go to its minimum displacement.

90000350

MV with Hydraulic 2-Position Control

Electric 2-Position Control This control utilizes an electric solenoid operated threeway hydraulic valve to port system pressure to either of the motor displacement control pistons. The motor is normally held at its maximum displacement. Energizing the solenoid will cause the motor to go to its minimum displacement.

90000351

MV with Electric 2-Position Control

16

544

BOMAG

008 911 63

17.1

Travel pump

Series 90

Technical Specifications

Technical Specifications General Specifications Design

Port Connections (for details see chapter "Pressure Measurement")

Variable Pumps and Motors: Axial piston pump of variable displacement, cradle swashplate design.

Main pressure ports: SAE flange, Code 62, Remaining ports: SAE straight thread O-ring boss.

Fixed Motors: Axial piston motor with fixed displacement, fixed swashplate design.

Direction of Rotation

Type of Mounting (per SAE J744)

Clockwise or counterclockwise (motors are bi-directional)

SAE flange, Size "B", 2 bolts, SAE flange, Size "C and E", 4 bolts.

Recommended Installation Position Pump installation recommended with control position on the top or side. Consult SAUER-SUNDSTRAND for nonconformance guidelines. The housing must always be filled with hydraulic fluid.

Cartridge flange, 2 bolts (for motor only).

Circuit Diagrams

L2

M3 M1

A

M3 X5

Vg max

A M1

M5 M4

M2

B L1

M2 B L1

S

MV with Electrohydraulic 2-Position Control

L2

PV with Charge Pump and Manual Displacement Control

L2

M3

A

M1

B

M2

L1

MF

90000811 90000812 90000813

17

008 911 63

BOMAG

545

17.1

Travel pump

Series 90


Hydraulic Parameters System Pressure Range

bar

psi

Rated Pressure

420

6000

Maximum Pressure

480

6960

Temperature Range1) Minimum Rated Maximum

°C -40 104 115

[°F] [-40] [220] [240]

intermittent, cold start intermittent T002 006E

T002 252E

Charge Pump Inlet Vacuum (on pumps only)

bar abs

1)

At the hottest point, normally the case drain port.

Viscosity

in Hg

Minimum Vacuum (continuous)

0.7

10

Minimum Recommended operating range

Minimum Vacuum during Cold Start (Intermittent)

0.2

25

Maximum

mm2/s 7

[SUS] [49]

12-60

[70-278]

1600

[7500]

intermittent

intermittent, cold start T002 010E

T002 253E

Case Pressure

bar

psi

Maximum (Continuous)

3

44

Maximum during Cold Start (Intermittent)

5

73 T002 254E

Cleanliness Level and β x-Ratio Required fluid cleanliness level Recommended βx-ratio for suction filtration Recommended βx-ratio for charge pressure filtration Recommended inlet screen size for charge pressure filtration

ISO 4406 Class 18/13 β35-45=75

(β10≥2)

β15-20=75

(β10≥10)

100

m-125

m

T002 007E

Hydraulic Fluid

Cleanliness

Refer to SAUER-SUNDSTRAND BLN 9887 or SDF (Id No. 697581). Also refer to publication ATI-E 9101 for information relating to biogradable fluids.

Refer to SAUER-SUNDSTRAND Publications BLN 9887 or SDF (NO. 697581) and ATI-E 9201.

Refer to Series 90 technical information for definitions.

18

546

BOMAG

008 911 63

17.1

Travel pump

Series 90


Size Specific Data Variable Displacement Pumps Dimension

030 PV

042 PV

055 PV

075 PV

100 PV

130 PV

180 PV

250 PV

cm in3

30 1.83

42 2.56

55 3.35

75 4.57

100 6.10

130 7.93

180 10.98

250 15.25

Minimum Speed

min-1 (rpm)

500

500

500

500

500

500

500

500

Rated Speed

min-1 (rpm)

4200

4200

3900

3600

3300

3100

2600

2300

Maximum Speed

min-1 (rpm)

4600

4600

4250

3950

3650

3400

2850

2500

Maximum attainable Speed at max. Displacement

min-1 (rpm)

5000

5000

4700

4300

4000

3700

3150

2750

Nm/bar lbf in/1000 psi

0.48 290

0.67 380

0.88 530

1.19 730

1.59 870

2.07 1260

2.87 1750

3.97 2433

kg lb

28 62

34 75

40 88

49 108

68 150

88 195

136 300

154 340

Displacement (maximum)

Theoretical Torque at max. Displacement Weight (only base unit)

3

T002 257E

Fixed and Variable Displacement Motors Einheit 3

030 MF

042 MF

055 MF

075 MF

100 MF

130 MF

055 MV

075 MV

Displacement (maximum)

cm in3

30 1.83

42 2.56

55 3.35

75 4.57

100 6.10

130 7.93

55 3.35

75 4.57

Displacement (minimum)

cm3 in3

--

--

--

--

--

--

19

26

at maximum displacement

min-1 (rpm)

4200

4200

3900

3600

3300

3100

3900

3600

at minimum displacement

min-1 (rpm)

--

--

--

--

--

--

4600

4250

at maximum displacement

min-1 (rpm)

4600

4600

4250

3950

3650

3400

4250

3950

at minimum displacement

min-1 (rpm)

--

--

--

--

--

--

5100

4700

min-1 (rpm)

5000

5000

4700

4300

4000

3700

4700

4300

Nm/bar lbf in/1000 psi

0.48 290

0.67 380

0.88 530

1.19 730

1.59 970

2.07 1260

0.88 530

1.19 730

l/min gal/min

138 36.5

193 51

234 62

296 78

365 96

442 117

234 62

296 78

Max. corner power

kW hp

111 149

155 208

187 251

237 318

292 392

354 475

224 300

282 378

Weight SAE-Flange

kg lb

11 24

15 34

22 49

26 57

34 74

45 99

39 86

44 98

Weight Cartridge Motor

kg lb

--

21 46

26 57

33 72

--

--

40 88

46 101

Rated speed

Maximum speed

Max. attainable speed at max. displacement Theoretical torque at max. displacement Maximum flow ar max. displacement

T002 258E

Refer to Series 90 technical information for definitions.

19

008 911 63

BOMAG

547

17.1

Travel pump

Series 90

Pressure Measurement

Pressure Measurement Required Tools The service procedures described in this manual for Series 90 pumps and motors can be performed using common mechanic's tools. Special tools, if required are shown.

Pressure gauges should be calibrated frequently to ensure accuracy. Snubbers are recommended to protect pressure gauges.

Port Locations and Pressure Gauge Installation The following sections list the ports for each type of hydraulic unit. The recommended pressure gauge and fitting are also specified.

Outline drawings showing port locations follow the tables below.

Variable Pump

Port

Function

Gauge Size and Fitting

M1

System Pressure Port "A"

1000 bar or 10 000 psi 9/16-18 O-ring

M2

System Pressure Port "B"

1000 bar or 10 000 psi 9/16-18 O-ring fitting

Charge Pressure

50 bar or 1000 psi 9/16-18 O-ring

Servo Pressure

50 bar or 1000 psi 9/16-18 O-ring

M3 (M6) M4 M5

Port

Function

L1 L2

Case Pressure

T002 259E

Gauge Size and Fitting 10 bar or 100 psi 030 042

7/8-14 O-ring

055 075 100

1-1/16-12 O-ring

130

1-5/16-12 O-ring

180 250

1-5/8-12 O-ring

X1 X2

HDC / EDC Control Pressure

50 bar or 1000 psi 7/16-20 O-ring or 9/16-18 O-ring

X3

External Control Pressure

50 bar or 1000 psi 9/16-18 O-ring

S

Charge Pump Inlet

Vacuum Gauge, Tee into Inlet Line 030 042

1-1/16-12 O-ring

055 075

1-5/16-12 O-ring

100 130 180

1-5/8-12 O-ring

250

1-1/2 SAE-Split Flange T002 260E

20

548

BOMAG

008 911 63

17.1

Travel pump

Series 90


Servo / Displacement Cylinder Pressure Gauge Port M4 Case Drain Port L1 System Pressure Port B

Servo / Displacement Cylinder Pressure Gauge Port M5 Top View

90000814E

System Pressure Gauge Port M2

System Pressure Port B

External Control Pressure Supply Port X3 Speed Sensor

Charge Inlet Pressure


Carge Pump Inlet Port S

System Pressure Port A

Case Drain Port L2

Left Side View

Charge Pressure Gauge Port M3 Right Side View

90000815E 90000816E

PV with Side Port End Cap and Manual Displacement Control

21

008 911 63

BOMAG

549

17.1

Travel pump

Series 90



Case Drain Port L1

Servo / Displacement Cylinder Pressure Gauge Port M4

System Pressure Port B Charge Pump Inlet Port S System Pressure Port A System Pressure Gauge Port M1

Servo / Displacement Cylinder Pressure Gauge Port M5 Top View

Case Drain Port L2 Left Side View

90000819E 90000820E

PV with Twin Port End Cap and Manual Displacement Control

Charge Pressure Gauge Port M6 (before the filter)

Port E (from filter) Port D (to filter)

Charge Pressure Gauge Port M3 (after the filter)

Charge Pressure Gauge Port M3 (after the filter)

Rear View

Rear View

90000817E 90000818E

PV with Side Port End Cap and Remote Pressure Filtration

PV with Side Port End Cap and Integral Pressure Filtration

22

550

BOMAG

008 911 63

17.1

Travel pump

Series 90


Fixed Motor


Port

Function


Port

Function

M1

System Pressure Port "A"

1000 bar or 10 000 psi 9/16-18 O-ring

L1 L2

Case Pressure)

M2

System Pressure Port "B"

1000 bar or 10 000 psi 9/16-18 O-ring

Charge Pressure

50 bar or 1000 psi 9/16-18 O-ring

M3

10 bar or 500 psi

T002 261E

030 042 055

7/8-14 O-ring

075 100 130

1-1/16-12 O-ring T002 262E

System Pressure Gauge Port M1 System Pressure Gauge Port M2

Charge Pressure Gauge Port M3

Case Drain Port L1

System Pressure Port B Case Drain Port L2 System Pressure Port A

Speed Sensor

Left Side View

Rear View MF with SAE Flange

System Pressure Gauge Port M1 System Pressure Gauge Port M2

Charge Pressure Gauge Port M3

Case Drain Port L1

Speed Sensor System Pressure Port B System Pressure Port A Rear View

Case Drain Port L2 Left Side View 90000821E

MF with Cartridge Flange

23

008 911 63

BOMAG

551

17.1

Travel pump

Series 90


Variable Motor

Port

Function


M1

Systempressure Port "A"

1000 bar or 10 000 psi 9/16-18 O-ring

M2

Systempressure Port "B"

1000 bar or 10 000 psi 9/16-18 O-ring

Charge Pressure

50 bar or 1000 psi 9/16-18 O-ring

M3

T002 263E

Port

Function


M4

Control Cylinbder Pressure "Minimum Displacement"

1000 bar or 10 000 psi 7/16-20 O-ring

M5

Control Cylinbder Pressure"Maximum Displacement"

1000 bar or 10 000 psi 7/16-20 O-ring

L1 L2

Case Pressure

10 bar or 500 psi 1-1/16-12 O-ring T002 264E

Displacement Control Cylinder Pressure Gauge Port M4 Min. Displacement


Displacement Control Cylinder Pressure Gauge Port M5 Max. Displacement (Earlier Production Not available as gauge port with servo orifices)

Control Pressure Port X1 (Hydraulic 2-Position Control)


Displacement Control Cylinder Pressure Gauge Port M5 Max. Displacement (Newer Production) Left Side View

MV with Cartridge Flange and Hydraulic 2-Position Control (SAE Flange Version Similar)

Case Drain Port L1

System Pressure Gauge Port M1 charge Pressure Gauge Port M3 (Same position as in MF)

Speed Sensor System Pressure Port A Case Drain Port L2 Right Side View

90000823E

MV with SAE Flange (Cartridge Flange Version Similar)

24

552

BOMAG

008 911 63

17.1

Travel pump

Series 90

Initial Start-Up Procedure

Initial Start-Up Procedure

The following start-up procedure should always be followed when starting-up a new Series 90 installation or when restarting an installation in which either the pump or motor had been removed.

connections for EDC) be disconnected at the pump control until after initial start-up. This will ensure that the pump remains in its neutral position.

WARNING The following procedure may require the vehicle/ machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. Take necessary safety precautions before moving the vehicle/machine.

WARNING Do not start prime mover unless pump is in neutral position (0° swashplate angle). Take precautions to prevent machine movement in case pump is actuated during initial start up. S000 008E

S000 007E

Prior to installing the pump and/or motor, inspect the units for damage incurred during shipping and handling. Make certain all system components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean prior to filling with fluid. Fill the reservoir with recommended hydraulic fluid. This fluid should be passed through a 10 micron (nominal, no bypass) filter prior to entering the reservoir. The use of contaminated fluid will cause damage to the components, which may result in unexpected vehicle/machine movement. See the publications BLN-9887 and SDF 697581 for further related information. The inlet line leading from the reservoir to the pump must be filled prior to start-up. Check inlet line for properly tightened fittings and make sure it is free of restrictions and air leaks. Be certain to fill the pump and/or motor housing with clean hydraulic fluid prior to start up. Fill the housing by pouring filtered oil into the upper case drain port. Install a 50 bar (or 1000 psi) pressure gauge in the charge pressure gauge port to monitor the charge pressure during start-up. It is recommended that the external control input signal (linkage for MDC, hydraulic lines for HDC, or electrical

“Jog” or slowly rotate prime mover until charge pressure starts to rise. Start the prime mover and run at the lowest possible RPM until charge pressure has been established. Excess air may be bled from the high pressure lines through the high pressure system gauge port. Once charge pressure has been established, increase speed to normal operating RPM. Charge pressure should be as indicated in the pump model code. If charge pressure is inadequate, shut down and determine cause for improper pressure. Refer to Troubleshooting.

WARNING Take necessary precautions that the motor shaft remains stationary during the adjustment procedure. S000 010E

Shut down the prime mover and connect the external control input signal. Also reconnect the machine function if disconnected earlier. Start the prime mover, checking to be certain the pump remains in neutral. With the prime mover at normal operating speed, slowly check for forward and reverse machine operation. Charge pressure may slightly decrease during forward or reverse operation. Continue to cycle slowly between forward and reverse for at least five minutes. Shut down prime mover, remove gauges, and plug ports. Check reservoir level and add filtered fluid if needed. The transmission is now ready for operation.

25

008 911 63

BOMAG

553

17.1

Travel pump

Series 90

Fluid and Filter Maintenance

Fluid and Filter Maintenance To ensure optimum service life of Series 90 products, regular maintenance of the fluid and filter must be performed. Contaminated fluid is the main cause of unit failure. Care should be taken to maintain fluid cleanliness while performing any service procedure.

ManoVacuummeter

Check the reservoir daily for proper fluid level, the presence of water (noted by a cloudy to milky appearance, or free water in bottom of reservoir), and rancid fluid odor (indicating excessive heat). If either of these conditions occur, change the fluid and filter immediately.

Hydraulic fluid reservoir Filter Charge pump

It is recommended that the fluid and filter be changed per the vehicle/machine manufacturer’s recommendations or at the following intervals:

Adjustable Charge pressure relief valve

to low pressure side and control

First change

To pump case

500 operating hours after start up second and subsequent changes P000 797E

every 2000 operating hours or once a year.

Suction Filtration Schematic

This recommendation applies for the most applications. High temperatures and pressures will result in accelerated fluid aging and an earlier fluid change may be required. At lower fluid loads longer change intervalls are possible. Therefore we suggest to check the fluid with the manufacturer for suitability. This should be done at latest half way between fluid changes.

Screen

Hydraulic fluid reservoir Adjustable Charge pressure relief valve

It may be necessary to change the fluid more frequently than the above intervals if the fluid becomes contaminated with foreign matter (dirt, water, grease, etc.) or if the fluid has been subjected to temperature levels greater than the recommended maximum. Never reuse fluid.

Charge pump

to low pressure side and control

To pump case

The filter should be changed whenever the fluid is changed or whenever the filter indicator shows that it is necessary to change the filter.

Filter Cleanliness Level and β x-Ratio P000 798E

Charge Pressure Filtration Schematic (Partial flow)

Required fluid cleanliness level Recommended βx-ratio for suction filtration Recommended βx-ratio for charge pressure filtration Recommended inlet screen size for charge pressure filtration

ISO 4406 Class 18/13 β35-45=75

(β10≥2)

β15-20=75

(β10≥10)

100

m-125

m

T002 007E

26

554

BOMAG

008 911 63

17.1

Travel pump

Series 90

Toubleshooting

Troubleshooting This section provides general steps to follow if certain undesirable system conditions are observed. Follow the steps in a section until the problem is solved. Some of the items will be system specific. For areas covered in this manual, a section is referenced. Always observe the safety precautions listed in the section "Introduction" and related to your specific equipment.

"NEUTRAL" Difficult or Impossible to Find Check

Description

Action

1. Input to pump control.

Input to control module is operating improperly.

Check control input and repair or replace as necessary.

2. Pump displacement control.

Control linkages are not secure, control orifices are blocked, etc.

Adjust, repair, or replace control module as necessary.

If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center.

System Operating Hot Check

Description

Action

1. Oil level in reservoir.

Insufficient hydraulic fluid will not meet cooling demands of system.

Fill reservoir to proper level.

2. Heat exchanger.

Heat exchanger not sufficiently cooling the system.

Check air flow and input air temperature for heat exchanger. Clean, repair or replace heat exchanger.

3. Charge pressure.

Low charge pressure will overwork system.

Measure charge pressure. Inspect and adjust or replace charge relief valve. Or repair leaky charge pump.

4. Charge pump inlet vacuum.

High inlet vacuum will overwork system. A dirty filter will increase the inlet vacuum. Inadequate line size will restrict flow.

Check charge inlet vacuum. If high, inspect inlet filter and replace as necessary. Check for adequate line size, length or other restrictions.

5. System relief pressure settings.

If the system relief settings are too low, the relief valves will be overworked.

Verify settings of pressure limiters and high pressure relief valves and adjust or replace multi-function valves as necessary.

Leakage will reduce low side system pressure and overwork the system.

Monitor motor case flow without loop flushing in the circuit (use defeat spool). If flow is excessive, replace motor.

High system pressure will overheat system.

Measure system pressure. If pressure is high reduce loads.

6. For internal leakage in motor.

7. System pressure.


27

008 911 63

BOMAG

555

17.1

Travel pump

Series 90

Toubleshooting

Transmission Operates Normally in One Direction Only Check

Description

Action






Repair or replace control module as necessary.

3. Interchange system pressure limiters, high pressure relief valves, and system check valves.

Interchanging the multi-function valves will show if the problem is related to the valve functions contained in the multifunction valves.

Interchange multi-function valves. If the problem changes direction, repair or replace the valve on the side that does not operate.

4. Charge pressure.

If charge pressure decays in one direction the loop flushing valve may be “sticking” in one direction.

Measure charge pressure in forward and reverse. If pressure decays in one direction, inspect and repair the motor loop flushing valve.


System Will Not Operate in Either Direction Check

Description

Action


Insufficient hydraulic fluid to supply system loop.








4. Ensure bypass valve(s) are closed.

If bypass valve(s) is open, the system loop will be depressurized.

Close bypass valves. Replace multifunction valve if defective.

5. Charge pressure with pump in neutral.

Low charge pressure insufficient to recharge system loop.

Measure charge pressure with the pump in neutral. If pressure is low, go to step 6; otherwise continue with step 5.

6. Charge pressure with pump in stroke.

Low charge pressure with the pump in stroke indicates a motor charge relief valve or system pressure relief valve may be improperly set.

Measure charge pressure with pump in stroke. If pressure is low, adjust or replace motor charge relief valve, otherwise go to step 9.

7. Pump charge relief valve.

A pump charge relief valve that is leaky or set too low will depressurize the system.

Adjust or replace pump charge relief valve as necessary.

8. Charge pump inlet filter.

A clogged filter will undersupply system loop.

Inspect filter and replace if necessary.

9. Charge pump.

A malfunctioning charge pump will provide insufficient charge flow.

Repair or replace the charge pump. If OK go to last step.

28

556

BOMAG

008 911 63

17.1

Travel pump

Series 90

Toubleshooting




11. System pressure.

Low system pressure will not provide power necessary to move load.

Measure system pressure. Continue with next step.

12. System multi-function valves.

Defective multi-function valves will cause system pressure to be low.

Repair or replace multi-function valve(s).


Low Motor Output Torque Check

Description

Action

1. System pressure at motor.

Low system pressure at the motor will reduce torque.

Measure system pressure at motor. If pressure limiter setting is low, increase setting.

2. Variable motor stuck at minimum displacement.

Minimum motor displacement yields low output torque.

Check control supply pressure or repair displacement control. Check motor control orifices.

3. For internal leakage.

Internal leakage will reduce system pressure.

Check for leakage in O-rings, gaskets, and other fittings. Repair unit as required, or replace leaky unit.


Improper Motor Output Speed Check

Description

Action


Insufficient hydraulic fluid will reduce motor speed.

Fill oil to proper level.

2. Pump output flow.

Incorrect outflow will affect output speed. Incorrect output flow indicates the swashplate is out of position.

Measure pump output and check for proper pump speed and see that the pump is in full stroke.

3. Variable motor displacement control.

If variable motor displacement control is not functioning correctly, variable motor swashplate may be in wrong position.

See if variable motor displacement control is responding. If not, repair or replace control.

4. For internal leakage.


Check for leakage in O-rings, gaskets, and other fittings. Repair unit as required, or replace leaky unit.


29

008 911 63

BOMAG

557

17.1

Travel pump

Series 90

Toubleshooting

Excessive Noise and/or Vibration Check

Description

Action

1. Oil in reservoir.

Insufficient hydraulic fluid will lead to cavitation.


2. Air in system.

Air bubbles will lead to cavitation.

Look for foam in reservoir. Check for leaks on inlet side of system loop. Afterwards, let reservoir settle until bubbles are gone. Run system at low speed to move system fluid to reservoir. Repeat.

3. Pump inlet vacuum.

High inlet vacuum will create noise. A dirty filter will increase the inlet vacuum.

Inspect and replace filter as necessary. Check for proper suction line size.

4. Shaft couplings.

A loose shaft coupling will cause excessive noise.

Replace loose shaft coupling in charge pump or replace pump or motor.

5. Shaft alignment.

Unaligned shafts will create excessive frictional noise.

Align shafts.


System Response is Sluggish Check

Description

Action


Insufficient hydraulic fluid will reduce output pressure.


2. Multi-function valves’ pressure settings.

Incorrect pressure settings will affect system reaction time.

Adjust or replace multi-function valves.

3. Pump inlet vacuum.

High pump inlet vacuum will reduce system pressure.

Measure charge inlet vacuum. If high replace inlet filter.

4. Prime mover speed.

Low engine speed will reduce system performance.

Adjust engine speed.

5. Charge and control pressures.

Incorrect charge or control pressures will affect system performance.

Measure charge and control pressures and correct if necessary.

6. System internal leakage.


Check for leakage in O-rings, gaskets, and other fittings.


30

558

BOMAG

008 911 63

17.1

Travel pump

Series 90

Inspections and Adjustments

Inspections and Adjustments This section offers instruction on how to perform inspections and adjustments on pump and motor components. Read through the entire related section before beginning a service activity. Refer to the corresponding section for location of gauge ports and suggested gauge size.

Pump Adjustments Charge Pressure Relief Valve Adjustment The following procedure explains how to check and adjust the charge pressure relief valve. WARNING The following procedure may require the vehicle/ machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. Take necessary safety precautions before moving the vehicle/machine. S000 007E

90000243

Charge Pressure Gauge Port (Reducer fitting shown - if filtration device attached)

1.

2.

To measure pump charge pressure, install a pressure gauge in the pump charge pressure gauge port (M3). Also install a gauge to measure case pressure (tee into L1 or L2 or use servo gauge port). Operate the system with the pump in “neutral” (zero displacement) when measuring pump charge pressure.

90L055 EA 1 N 6 S 3 C6 C 03 HNN 35 35 24

The table shows the acceptable pump charge pressure range for some nominal charge relief valve settings (see sample model code at right). These pressures assume 1500 pump rpm and a reservoir temperature of 50°C (120°F ), and are referenced to case pressure (see footnote on next page). Smaller displacement charge pumps will produce charge pressure readings in the lower portion of the range, while larger displacement charge pumps will produce readings in the higher portion of the range.

Nominal Charge Pressure

Model Code on Unit Name Plate (“24 bar”)

Model Code

Measured Charge Pressure *

20

18.1 bis 21.7 bar (262 to 315 psi)

24

22.0 bis 26.9 bar (319 to 390 psi)

28

25.8 bis 30.7 bar (374 to 445 psi) T002 266E

* This is the actual charge pressure port gauge reading minus the case pressure port gauge reading.

Note:

These pressures assume a pump speed of 1450 - 1500 rpm. At higher pump input speeds (with higher charge flows) the charge pressure will rise over the rated setting.

* This is the actual charge pressure port gauge reading minus the case pressure port gauge reading.

31

008 911 63

BOMAG

559

17.1

Travel pump

Series 90


3.

90000262

Shim Adjustable Charge Pressure Relief Valve (Pump)

Earlier production Series 90 pumps are equipped with a shim adjustable charge pressure relief valve. Shim kits are available from SAUER-SUNDSTRAND. Adjustment of charge pressure is accomplished by removing the plug [1 inch Hex] and changing the shim thickness behind the spring. The plug for this type of charge relief valve should be torqued to 68 Nm (50 lbf ft). Later production Series 90 pumps are equipped with an external screw adjustable charge pressure relief valve. Adjustment of the charge pressure is accomplished by loosening the lock nut -

90000264

Screw Adjustable Charge Pressure Relief Valve (Pump)

Frame Size 030 - 100 130 - 250

Wrench Size 1-1/16 inch 1-5/8 inch T002 267E

and turning the adjustment plug with a large screwdriver or a 1/2 inch hex wrench. Clockwise rotation of the plug increases the setting, and counterclockwise rotation decreases the setting (at a rate of approximately 3.9 bar (50 psi) per turn). The lock nut for this type of charge relief valve should be torqued to 52 Nm (39 lbf ft). 4.

Once the desired charge pressure setting is achieved, remove the gauges.

32

560

BOMAG

008 911 63

17.1

Travel pump

Series 90


Multi-Function Valve Pressure Adjustment Adjustment of the pressure limiter setting and the high pressure relief valve setting is accomplished simultaneously. The latter is automatically set approximately 35 bar (500 psi) above the former. In order to adjust the pressure limiter setting, the motor output shaft must be locked so it does not rotate. This may be accomplished by locking the vehicle’s brakes or rigidly fixing the work function so it cannot rotate.

WARNING Take necessary precautions that the motor shaft remains stationary during the adjustment procedure. S000 010E 90000258

Multi-Function Valves on PV

1.

Install two 1000 bar (or 10 000 psi) pressure gauges in the high pressure gauge ports (M1 and M2). Install a 50 bar (or 1000 psi) pressure gauge in the pump charge pressure gauge port (M3).

2.

Start the prime mover and operate at normal speed.

3.

Loosen locking nut. Frame Size early 042 - 100 newer 030 - 100 early 130 130 - 250

Wrench Size 10 mm 19 mm 13 mm 24 mm T002 268E

4.

Insert a internal hex wrench into the pressure adjusting screw. Frame Size early 042 - 100 newer 030 - 100 early 130 130 - 250

Internal Hex Wrench Size 90000259

3 mm

Loosen Pressure Adjusting Screw Lock Nut

5 mm 4 mm 8 mm T002 269E

Note:

A plastic dust plug is installed in the adjusting screw on 030 and late 042 through 250 units.

33

008 911 63

BOMAG

561

17.1

Travel pump

Series 90


90L055 EA 1 N 6 S 3 C6 C 03 HNN 35 35 24

5.

The factory preset pressure limiter setting is shown on the model code as at right. It is referenced to charge pressure, so the pressure limiter setting is the difference between the high and low pressure sides of the system loop. Activate or move the control input so that pressure increases in the high pressure side of the closed circuit to the pressure limiter pressure setting. The pressure limiter setting is reached when the pressure stops increasing and remains steady at a given pressure level (as shown on the gauges).

6.

Return the pump to its “neutral” (zero flow) position and adjust the pressure limiter setting by rotating the pressure adjusting screw with the internal hex wrench.

Pressure Limiter Setting Ports A and B (differential pressure in 10s of bars, e.g. “35” = 350 bar)

Clockwise rotation of the pressure adjustment screw will increase the pressure setting, and counterclockwise rotation will decrease the pressure setting. Each complete rotation of the pressure adjusting screw changes the pressure as shown in the following table. Frame Size early 042 - 100 newer 030 - 100 130 - 250

90000260

Approx Change per Rev of the Adjusting Screw 80 bar (1157 psi) per Rev 90 bar (1300 psi) per Rev 80 bar (1157 psi) per Rev T002 270E

Rotate Pressure Adjusting Screw

7.

To verify the actual pressure setting, actuate or move the control input so that the pump again develops pressure in the high pressure circuit to the newly adjusted pressure limiter pressure setting, and read the high pressure gauge. Then allow the pump to return to its “neutral” position. The pressure in the high pressure circuit should return to the charge pressure setting.

8.

While holding the pressure adjusting screw stationary, tighten the pressure adjusting screw lock. Frame Size early 042 - 100 newer 030 - 100 130 - 250

Torque 3 Nm (26 lbf in) 20 Nm (15 lbf ft) 40 Nm (30 lbf ft) T002 271E

Do not overtorque. 90000261

9.

Tighten Lock Nut

Shut down the prime mover, remove the gauges and install the gauge port plugs. Replace the plastic dust plugs (if used).

The same procedure is used for setting the pressure limit of the other multi-function valve, but the control input signal must be activated or moved in the opposite direction so that high pressure develops in the opposite side of the closed circuit.

34

562

BOMAG

008 911 63

17.1

Travel pump

Series 90


Engaging the Bypass Function The bypass function is performed by the multi-function valve cartridges. The prime mover should be shut down when opening or closing the bypass valves. The bypass valves on both of the multi-function valves must be opened to engaged the bypass function. 1.

Using a Frame Size newer 030 - 100 130 - 250


wrench on the middle sized hex of the multi-function valve cartridge, and a Frame Size newer 030 - 100 130 - 250

Wrench Size

90000266

Loosening and Rotating Bypass Hex on Multi-Function Valve

1-1/4 inch 1-5/8 inch T002 273E

Bypass Actuator

Opening Bypass Valve allows flow to circuit through Multi-Function Valves

wrench on the large hex to prevent rotation of the cartridge assembly, rotate the middle hex three revolutions counterclockwise to open the bypass valve. Do not rotate more than 3-1/2 revolutions, as additional rotation will permit external leakage. 2.

For units with an MDC-type control, prior to moving the vehicle or otherwise causing the motor shaft to turn, move the control handle of the manual displacement control on the pump to the maximum full forward position. Hold the handle in this position during bypass valve operation.

90000827E

Multi-Function Valve with Bypass Function Engaged

Caution "Tow" at extremely low speeds and for short distances only. S000 011E

3.

To close the bypass valve, rotate the middle hex clockwise until it is seated. Then torque the middle hex. Frame Size newer 030 - 100 130 - 250

Torque 41 Nm (30 lbf ft) 100 Nm (75 lbf ft) T002 274E

35

008 911 63

BOMAG

563

17.1

Travel pump

Series 90

Inspections and Adjustments Pressure Override (POR) Valve Pressure Adjustment (Option for 180 Frame Size) The Pressure Override Valve is explained in the corresponding section.

Pressure Override Valve

1.

Install two 1000 bar (or 10 000 psi) pressure gauges in the high pressure gauge ports (M1 and M2). Install a 50 bar (or 1000 psi) pressure gauge in the pump charge pressure gauge port (M3).

2.

Start the prime mover and operate at normal speed.

3.

With the pump operating at approximately 20% displacement, load the work function and note the pressure as the POR valve operates (pump displacement reduces to “zero”).

4.

Adjustment of the pressure override setting is made by loosening the lock nut with a 9/16 inch hex wrench and turning the adjustment screw with a 3/16 inch internal hex wrench. The POR setting should be at least 50 bar (750 psi) below the high pressure relief valve setting of the multi-function valves for proper operation.

5.

Following the adjustment, torque the lock nut to 43 Nm (32 lbf ft).

6.

Shut down the prime mover and remove the gauges and install the gauge port plugs.

Adjusting Screw Lock Nut

Right Side View 90000828E

Pressure Override Valve for 180 Frame Size

36

564

BOMAG

008 911 63

17.1

Travel pump

Series 90


Displacement Limiter Adjustment The maximum displacement can be limited in either direction. 1.

Loosen the seal lock nut retaining the displacement limiter adjusting screw. Frame Size 030 - 100 130 180 - 250

Wrench Size 13 mm 17 mm 19 mm T002 275E

2.

Rotate the adjusting screw. Frame Size 030 - 100 130 180 - 250

Internal Hex Wrench Size 4 mm 5 mm 6 mm

90000267

Loosen Displacement Limiter Lock Nut

T002 276E

Rotating the adjusting screw clockwise will decrease the maximum displacement of the pump while rotating the adjusting screw counterclockwise will increase the maximum displacement. Caution Care should be taken in adjusting displacement limiters to avoid undesirable flow or speed conditions. The seal lock nut must be retorqued after every adjustment to prevent an unexpected change in operating conditions and to prevent external leakage during unit operation. S000 012E 90000268

3.

After establishing the desired maximum displacement setting, tighten the lock nut on the adjusting screw as follows. Frame Size 030 - 100 130 180 - 250

Rotate Adjusting Screw

Torque 24 Nm (18 lbf ft) 48 Nm (35 lbf ft) 125 Nm (92 lbf ft) T002 278E

4.

One turn of the adjusting screw will change the maximum displacement approximately as follows.

Frame Size 030 042 055 075 100 130 180 250

Approx Change in Disp per Rev of Adjusting Screw 2.8 cm3 / Rev (0.17 in3 / Rev) 3.5 cm3 / Rev (0.21 in3 / Rev) 4.2 cm3 / Rev (0.26 in3 / Rev) 5.1 cm3 / Rev (0.31 in3 / Rev) 6.2 cm3 / Rev (0.38 in3 / Rev) 8.8 cm3 / Rev (0.53 in3 / Rev) 12.5 cm3 / Rev (0.76 in3 / Rev) 17.3 cm3 / Rev (1.06 in3 / Rev)

90000269

Tighten Lock Nut

T002 277E

37

008 911 63

BOMAG

565

17.1

Travel pump

Series 90


Pump Control Adjustments Standard Manual Displacement Control (MDC) Adjustment There are no adjustable elements in the manual displacement control. The control spool is held in its “neutral” position by centering springs and washers on each end of the spool. Since there is no centering spring on the control input shaft, the shaft will automatically assume the appropriate position when the control is installed on the pump.

90000237

Variable Displacement Pump with Standard Manual Displacement Control

38

566

BOMAG

008 911 63

17.1

Travel pump

Series 90


Non-Linear Manual Displacement Control (MDC) A centering spring, located on the control input shaft, locates the control shaft in its “neutral” position. A bias spring on the control spool maintains a force on the spool and the control linkage to eliminate looseness (“freeplay”) in the linkage. The “neutral” adjustment is the only adjustment that can be made on the nonlinear manual displacement control. All other functions are preset at the factory. This adjustment must be made on a test stand or on the vehicle/machine with the prime mover operating.

90000829

Variable Displacement Pump with Non-Linear Manual Displacement Control

WARNING The following procedure may require the vehicle/ machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. Take necessary safety precautions before moving the vehicle/machine. S000 007E

1.

Install two 50 bar (or 1000 psi) gauges in each of the displacement control cylinder gauge ports (M4 and M5). Disconnect the external control linkage from the control handle and make certain the control shaft is in its “neutral” position. Start the prime mover and operate at normal speed.

2.

Loosen the lock nut on the neutral adjusting screw with a 13 mm hex wrench.

3.

Using a 4 mm internal hex wrench, rotate the neutral adjusting screw clockwise until the pressure increases on one of the pressure gauges. Note the angular position of the wrench.

4.

Rotate the adjusting screw counterclockwise until the pressure increases by an equal amount on the other gauge. Note the angular position of the wrench.

5.

Rotate the adjusting screw clockwise half the distance between the locations noted above. The gauges should read the same pressure (case pressure), indicating that the control is in its “neutral” position.

6.

Hold the adjusting screw stationary and tighten the lock nut to 13.5 Nm (10 lbf ft). Do not overtorque the nut.

7.

Once the neutral position is set, stop the prime mover, remove the gauges, and install the gauge port plugs. Reconnect the external control linkage.

90000357

Rotate Neutral Adjusting Screw

90000358

Tighten Neutral Adjusting Screw Lock Nut

39

008 911 63

BOMAG

567

17.1

Travel pump

Series 90

Inspections and Adjustments MDC Neutral Start Switch (NSS) Adjustments

A

The neutral start switch (NSS) provides a means to prevent the system prime mover from starting while the pump control handle and control input shaft are in a position which would command the pump to go “instroke” in either the “forward” or “reverse” direction.

A Control Shaft

Switch Cam

When the control input shaft is in its “neutral” position, the inner end of the switch pin moves into a slot on the eccentric cam attached to the control shaft. This allows the spring loaded NSS to close, completing the electrical starting circuit for the prime mover.

Switch Lock Nut Neutral Start Switch Eccentric Plug Switch Pin Special Lock Nut for Eccentric Plug

When the control input shaft is NOT in its “neutral” position, the eccentric cam moves the switch pin out of the slot. This forces the NSS to open, breaking the electrical starting circuit for the prime mover.

MDC with Neutral Start switch

The neutral start switch is threaded into the special lock nut for the eccentric plug. Turning the NSS clockwise (CW) into the special nut will move the NSS closer to the switch cam on the control shaft, and will narrow the NSS deadband. Turning the NSS counterclockwise (CCW) out of the special nut will move the NSS farther from the switch cam on the control shaft, and will widen the NSS deadband.

Orifice Check Valve Seat Control Spool Assembly Control Link Assembly View at Section A-A

90000830E

Components of the Standard Manual Displacement Control with Neutral Start Switch

The switch pin is located in an eccentric plug which is turned to move the center of the NSS deadband. (continued)

40

568

BOMAG

008 911 63

17.1

Travel pump

Series 90


The NSS must be adjusted to meet the following three requirements: i.

The distance the control handle can be turned without opening the NSS is called the “NSS Deadband.” The distance the control handle can be moved without moving the control spool enough to port hydraulic fluid to the pump displacement control cylinders is called the “Control Deadband.” These deadbands must be centered in relation to each other. Since the position of the control deadband cannot be adjusted, the position of the NSS deadband must be adjusted to match it.

ii.

NSS Deadband (Switch closed, "ON")

Control Shaft ("Free-Play")

Control Deadband ("Neutral")

Total Control Shaft Rotation

Control Shaft

The NSS deadband must be wide enough so the NSS will not open within the loose area of control handle movement caused by normal operating clearances in the control linkage (control shaft “free-play”). By setting the NSS to open outside this area, the control spool springs or control shaft centering spring can always act to return the handle to “neutral” and re-close the NSS.

iii. The NSS deadband must be narrow enough so the NSS will open before the unit builds 7 bar (100 psi) differential system pressure in either direction. 90000831E

Neutral Start Switch Adjustment Requirements

(continued)

41

008 911 63

BOMAG

569

17.1

Travel pump

Series 90

Inspections and Adjustments NSS Deadband Adjustment (Conditions ii & iii) The NSS deadband must be wide enough so the NSS will not open within the control shaft “free-play” area, and it must be narrow enough so the NSS will open before the unit builds 7 bar (100 psi) differential system pressure in either direction. 1.

Install two 1000 bar (10 000 psi) pressure gauges in the system pressure gauge ports M1 and M2.

2.

Using two 1-1/8 inch wrenches, hold the neutral start switch from turning and loosen the locknut.

3.

Disconnect the external control linkage and make certain the control shaft is in its “neutral” position.

4.

Attach a continuity checker to the terminals of the switch. With the control shaft in its “neutral” position, turn the switch clockwise (CW) until electrical continuity is broken, then turn the switch counterclockwise (CCW) until electrical continuity is obtained. Turn the switch counterclockwise (CCW) an additional 1/4 turn (90°) after continuity has been obtained.

5.

Hold the switch in place and tighten the locknut to 27 Nm (20 lbf ft) torque.

6.

With the continuity checker attached to the switch, rotate the control handle (or the control shaft) in each direction to assure continuity is broken when the control is not in the “neutral” position.

7.

If continuity is obtained in “neutral” and satisfactorily interrupted in each direction, proceed to check the switch with the prime mover running. The switch must open before the unit builds 7 bar (100 psi) differential system pressure in either direction.

90000253

Loosening the NSS Lock Nut

Control Shaft

Switch Lock Nut Switch Cam

Switch Pin

Neutral Start Switch

1-1/8 in. hex wrench Torque: 27 Nm (20 lbf ft)

If the switch opens after the unit builds system pressure in either direction, loosen the switch lock nut and turn the switch clockwise (CW) 1/12 turn (30°). Tighten the switch lock nut and recheck the switch operation. Repeat this procedure if necessary.

90000832E

NSS

8.

If continuity is not interrupted 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.

9.

If neutral start switch operation is satisfactory, turn off the prime mover, remove the pressure gauges, and reconnect the external control linkage.

90000870

Checking Continuity of NSS (System Pressure Gauges installed on far side)

42

570

BOMAG

008 911 63

17.1

Travel pump

Series 90


Neutral Start Switch Eccentric Plug Adjustment (Condition i)

9.14 (0.36)

12.7 (0.5)

The NSS deadband and the control deadband must be centered in relation to each other. Since the position of the control deadband cannot be adjusted, the position of the NSS deadband must be adjusted to match it. The switch pin is located in an eccentric plug which is turned to move the center of the NSS deadband. The MDC should be installed on the pump and be in its “neutral” position when adjusting the neutral start switch eccentric plug.

3.175 (0.125)

1.52 (0.06)

25.4+ (1.0) 90000834E

Eccentric Plug Adjustment Tool

The accompanying drawing provides dimensions for an Eccentric Plug Adjustment Tool. 1.

Hold the switch and eccentric plug from turning and use two 1-1/8 inch wrenches to loosen the locknut. Remove the neutral start switch.

WARNING Do not start the prime mover while the neutral start switch is removed from the control. Case pressure will force the pin out of the eccentric plug, causing oil loss.

Switch Lock Nut Eccentric Plug

X

Switch Pin Special Lock Nut for Eccentric Plug

Neutral Start Switch

S000 032E

MDC with Neutral Start Switch Special Lock Nut for Eccentric Plug Eccentric Plug

Control Mounting Surface

Switch Pin View in Direction X (Switch and lock nut removed) 90000833E

NSS with Eccentric Plug

2.

Note the slots on the eccentric plug for the adjustment tool. Hold the eccentric plug in place with the adjustment tool, and loosen the lock nut with a 1-1/8 inch wrench.

(continued)

90000256

Loosen Eccentric Lock Nut

90000257

NSS Removed

43

008 911 63

BOMAG

571

17.1

Travel pump

Series 90


Switch Pin

3.

Position the eccentric plug so the switch pin is offset toward the control mounting surface. This will provide the best contact between the pin and the cam on the control shaft.

4.

Hold the control shaft in its “neutral” position (in the center of the control shaft “free-play” area). Locate the switch pin in the slot of the switch cam by turning the eccentric plug while checking the pin position (depth) in the plug. When the pin engages the cam slot, the pin will be at its maximum depth in the plug. Hand tighten the plug lock nut to hold the eccentric plug in position.

5.

Turn the control shaft an equal amount in either direction from “neutral.” The switch pin should move out of the eccentric plug an equal distance when the control shaft is turned. Turn the eccentric plug to center the switch pin with the cam slot. Only a small amount of adjustment in either direction should be needed to center the pin.

6.

While holding the eccentric plug in place, tighten the eccentric plug lock nut to 27 Nm (20 lbf ft). Reinstall and adjust the switch as outlined in the previous section.

Eccentric Plug

90˚

Control Mounting Surface

90˚ Eccentric Plug Adjustment Range

90000835E

Eccentric Plug Adjustment

Note:

The eccentric plug normally requires between 5-1/2 and 6-1/2 turns to install into the control housing .

90000256

Adjust the Eccentric Plug

Caution Do not turn the eccentric plug into or out of the housing beyond specifications. S000 014E

7.

Once the switch is correctly adjusted, hold the switch in place and tighten the locknut to 27 Nm (20 lbf ft) torque.

(continued)

44

572

BOMAG

008 911 63

17.1

Travel pump

Series 90


Checking Switch Continuity Recheck switch continuity to determine whether additional adjustment of the eccentric plug is necessary. WARNING The following procedure may require the vehicle/ machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. Take necessary safety precautions before moving the vehicle/machine. S000 007E

1.

Install two 50 bar (or 1000 psi) gauges in each of the displacement control cylinder gauge ports (M4 and M5). Attach a continuity checker to the terminals of the neutral start switch.

2.

Energize the starter circuit, and start the prime mover.

3.

While operating at normal speed and with the pump in its “neutral” (zero flow) position, note the pressure reading on the gauges. This reading should be noted as the base pressure.

4.

Slowly move the control handle in one direction while observing the pressure gauges and the continuity checker. Continuity must be broken before the pressure on either gauge increases more than 1 bar (12 psi) from the base pressure obtained at “neutral.”

5.

Slowly move the control handle in the opposite direction. Again, continuity must be broken before the gauge pressure increases more than 1 bar (12 psi) from base pressure.

6.

Continuity must again be verified when the control is returned to neutral.

7.

If continuity is not broken at base pressure plus 0 to 1 bar (0 to 12 psi) in either direction, stop the prime mover and readjust the eccentric plug as described in the previous section. If the pressure difference is equal in each direction but greater than 1 bar (12 psi), loosen the switch locknut and turn the switch clockwise 1/12 turn (30°) to increase the sensitivity. Retighten the locknut and recheck pressure differences and continuity.

8.

After verifying proper control and switch operation, stop the prime mover. Remove the continuity checker and pressure gauges. Reinstall the servo pressure port plugs and reconnect the electrical leads from the machine starter circuit to the neutral start switch. Install and adjust, if necessary, the external control linkage.

90000255

Checking Continuity of NSS (Gauges installed in Servo Gauge Ports)

45

008 911 63

BOMAG

573

17.1

Travel pump

Series 90

Inspections and Adjustments Hydraulic Displacement Control (HDC) and Electric Displacement Control (EDC) Adjustment The “neutral” adjustment is the only adjustment that can be made on hydraulic and electric displacement controls. All other functions are preset at the factory. This adjustment must be made on a test stand or on the vehicle/machine with the prime mover operating.

90000240

PV with Hydraulic Displacement Control

The neutral adjustment is performed by adjusting a neutral adjusting shaft (earlier production EDCs) or a neutral adjusting screw (HDCs and current production EDCs).

WARNING The following procedure may require the vehicle/ machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. Take necessary safety precautions before moving the vehicle/machine. S000 007E

90000241

PV with Electric Displacement Control

1.

Install two 50 bar (or 1000 psi) gauges in each of the two displacement control cylinder gauge ports (M4 and M5). Disconnect the external control input (hydraulic or electronic) from the control. Start the prime mover and operate at normal speed.

2.

Loosen the lock nut with a 17 mm hex wrench for the neutral adjusting shaft or with a 10 mm or 13 mm hex wrench for the neutral adjusting screw.

90000249

Install Gauges in Displacement Control Cylinder Gauge Ports

46

574

BOMAG

008 911 63

17.1

Travel pump

Series 90


3.

Using a 5 mm internal hex wrench for the neutral adjusting shaft or a 3 mm or 4 mm internal hex wrench for the neutral adjusting screw, rotate clockwise until the pressure increases in one of the pressure gauges. Note the angular position of the wrench. Then rotate the neutral adjusting shaft or screw counterclockwise until the pressure increases by an equal amount on the other gauge. Again note the angular position of the wrench.

4.

Rotate the neutral shaft or adjusting screw clockwise half the distance between the locations noted above. The gauges should read the same pressure (case pressure), indicating that the control is in its “neutral” position.

5.

Hold the neutral adjusting shaft or screw stationary. Tighten the neutral shaft lock nut (early production controls) to 22 Nm (195 lbf in.). Tighten the neutral adjusting screw lock nut (later production controls) to 7 Nm (62 lbf in.) for the 6 mm screw or 13.5 Nm (120 lbf in.) for the 8 mm screw. Do not overtorque the nut.

6.

Once the neutral position is set, stop the prime mover, remove the gauges, and install the gauge port plugs. Reconnect the external control input.

90000250

Rotate Neutral Adjusting Shaft (Early production)

90000251

Rotate Neutral Adjusting Screw (Later production)

90000355

Rotate Neutral Adjusting Shaft (Current production HDC)

90000252

Tighten Neutral Adjusting Shaft Lock Nut (Early production)

90000318

Tighten Neutral Adjusting Screw Lock Nut (Later production)

90000356

Tighten Neutral Adjusting Shaft Lock Nut (Current production HDC)

47

008 911 63

BOMAG

575

17.1

Travel pump

Series 90


Motor Adjustments Charge Relief Valve Adjustment

90000248

1.

To measure motor charge pressure, install a 50 bar (or 1000 psi) pressure gauge in the motor charge pressure gauge port (M3). Size 30 and 42 don’t have the M3 gauge port. Install pressure gauge in the motor system pressure gauge port. For this kind of measurement add 1 bar (14.5 psi) to the nominal values shown in the table. Also install a gauge to measure case pressure. Operate the system with the pump in stroke (forward or reverse) when measuring motor charge pressure.

2.

The following table shows acceptable motor charge pressures for some nominal charge relief valve settings (see model code at right). These pressures assume a reservoir temperature of 50°C (120°F). They are referenced to case pressure and assume a one pump/one motor system.

3.

Earlier production Series 90 motors are equipped with a shim adjustable charge relief valve. Shim kits are available as service items. Adjustment of the charge pressure is accomplished by removing the plug (7/8 inch hex) and changing the shim thickness behind the spring. The plug for this type charge relief port should be torqued to 68 Nm (50 lbf ft).

Charge Pressure Gauge Port (MF)

90M055 NC 0 N 8 N 0 C6 W 00 NNN 00 00 24

Nominal charge Pressure Setting

Model Code

Motor Charge Pressure (±1.4 bar [±20 psi])

10

8.1 bar (117 psi)

18

16.1 bar (233 psi)

20

18.1 bar (262 psi)

24

22.1 bar (320 psi)

28

26.1 bar (378 psi)

30

30.0 bar (435 psi)

Later production Series 90 motors are equipped with an external screw adjustable charge relief valve. Adjustment of charge pressure is accomplished by loosening the lock nut, Frame Size 030 - 130

T002 279E

Wrench Size 1-1/16 inch T002 293E

Model Code at the Name Plate (24 bar)

and turning the adjustment plug with a large screwdriver or a 1/2 inch hex wrench. Clockwise rotation of the plug increases the setting, and counterclockwise rotation decreases the setting (at a rate of approximately 5.4 bar [78 psi] per turn). The lock nut for this type charge relief valve should be torqued to 52 Nm (38 lbf ft). 4.

90000263

Shim Adjustable Charge Pressure Relief Valve (Motor)

Once the desired charge pressure setting is achieved, remove the gauges.

90000343

Screw Adjustable Charge Pressure Relief Valve (Motor)

48

576

BOMAG

008 911 63

17.1

Travel pump

Series 90


Displacement Limiter Adjustment (MV) Both the maximum and minimum displacement may be limited. 1.

Remove the tamper resistant cap from the displacement limiter screw. Loosen the seal lock nut retaining the displacement limiter adjusting screw with a 19 mm wrench.

Tamper-Resistant Cap Seal Lock Nut Maximum Displacement Limiter Screw

Caution The displacement limiters act as travel stops for the swashplate. Do not turn the limiter screws counterclockwise beyond the point of contact with the swashplate for either the maximum or minimum displacement position. S000 015E

2.

All adjustments can only be done when the motor is running and the pump is in neutral position. Steer the respective displacement limiter by the control. Rotate the adjusting screw with a 6 mm internal hex wrench. Rotating the maximum displacement adjusting screw clockwise will decrease the maximum displacement of the motor. Rotating the minimum displacement adjusting screw clockwise will increase the minimum displacement of the motor.

Minimum Displacement Limiter Screw Seal Lock Nut Tamper-Resistant Cap SAE Flange Version shown (Cartridge Version similar) 90000837E

MV Displacement Limiters

Caution Care should be taken in adjusting displacement limiters to avoid undesirable flow or speed conditions. See corresponding section for speed and pressure limits. The seal lock nut must be retorqued after every adjustment to prevent an unexpected change in operating conditions and to prevent external leakage during unit operation. S000 016E

3.

After establishing the desired displacement setting, tighten the lock nut on the adjusting screw to 54 Nm (40 lbf ft). Install a new tamper resistant cap.

4.

One turn of the adjusting screw will change the maximum or minimum displacement according to the following chart. Frame Size 055 075

90000359

Rotate Adjusting Screw for Minimum Displacement Limiter

90000360

Tighten Lock Nut for Minimum Displacement Limiter

Approx Change in Disp per Rev of Adjusting Screw 5.6 cm3 / Rev (0.34 in3 / Rev) 7.1 cm3 / Rev (0.43 in3 / Rev) T002 280E

Displacement Control Adjustments All variable motor displacement control settings do not require adjusting.

90000352

Maximum Displacement Limiter

49

008 911 63

BOMAG

577

17.1

Travel pump

Series 90


Speed Sensor Adjustment When installing or adjusting the speed sensor on a pump or motor, it must be set at a specific distance from the speed ring on the unit’s cylinder. To locate the position of the speed sensor on the unit or description see the corresponding section.

Gap

Speed Sensor Magnetic Speed Ring 90000838E

Cross Section View of Speed Sensor in Variable Pump

1.

Loosen the sensor lock nut with an 1-1/16 inch hex wrench.

2.

Turn the sensor clockwise (CW) by hand until it contacts the speed ring.

3.

Turn the sensor counterclockwise (CCW) 1/2 turn (180°) to establish the nominal gap of 0.71 mm (0.028 inch).

4.

Then turn the sensor clockwise (CW) until the wrench flats on sensor body are positioned at a 22° angle to the pump shaft center line.

Gap

Magnetic Speed Ring Speed Sensor 90000839E

Note:

Cross Section View of Speed Sensor in fixed Motor

Many adjustable wrenches have a 22° handle offset.

5.

The final sensor position should be between 1/2 (180°) and 1/4 turn (90°) counterclockwise (CCW) from the point where the sensor contacts the speed ring.

6.

Hold sensor in position with a 1/2 inch hex wrench while tightening the lock nut to 13 Nm (10 lbf ft).

Gap

Speed Sensor Magnetic Speed Ring 90000840E

Cross Section View of Speed Sensor in Variable Motor

Shaft Centerline 1/2 in. Wrench Flats

22˚

22˚

Speed Sensor with Packard Connector

Speed Sensor with Turck Connector Shaft Centerline

1/2 in. Wrench Flats

22˚

22˚ Speed Sensor with Packard Connector

Speed Sensor with Turck Connector 90000841E

Positioning Speed Sensor relative to Pump or Motor Shaft

50

578

BOMAG

008 911 63

17.1

Travel pump

Series 90

Minor Repair Instructions Minor Repair Instructions

Minor repairs may be performed, following the procedures in this section, without voiding the unit warranty. Although specific models are shown, these procedures apply to all series and types of units in the Series 90 Family.

items must be kept free of foreign materials and chemicals.

Cleanliness is a primary means of ensuring satisfactory transmission life, on either new or repaired units. Cleaning parts by using a solvent wash and air drying is adequate, providing clean solvent is used. As with any precision equipment, the internal mechanism and related

It is recommended that all gaskets and O-rings be replaced when servicing. All gasket sealing surfaces must be cleaned prior to installing new gaskets. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly.

Protect all exposed sealing surfaces and open cavities from damage and foreign material.

51

008 911 63

BOMAG

579

17.1

Travel pump

Series 90

Minor Repair Instructions Hydrostatic Unit Outlines for Minor Repair Reference

Charge Pressure Relief Valve Filtration Options

Control Control Orifice Charge Pump

Shaft Seal

Main Shaft

(Auxiliary Pad)

Speed Sensor

Right Side View

Left Side View

90000843E

SAE-Flange PV Charge Pressure Relief Valve

Charge Pressure Relief Valve Loop Flushing Valve

Loop Flushing Valve

Shaft Seal

Shaft Seal

(Speed Sensor)

(Speed Sensor) Left Side View

Left Side View

90000844E

SAE Flange MF

Control Orifices Charge Pressure Relief Valve

Cartridge Flange MF

Maximum Angle Displacement Limiter

Loop Flushing Valve Shaft Seal

Control Orifices Charge Pressure Relief Valve Loop Flushing Valve

Maximum Angle Displacement Limiter Shaft Seal

Control

Control

Minimum Angle Displacement Limiter

Minimum Angle Displacement Limiter

Left Side View

Left Side View

90000845E

Cartridge Flange MV

SAE Flange MV

52

580

BOMAG

008 911 63

17.1

Travel pump

Series 90

Minor Repair Instructions

Pump and Motor Minor Repair Pump / Fitting Torques If any plugs or fittings are removed from the pump or motor during servicing, they should be torqued as indicated in the accompanying table. Always install new O-rings before reinstalling the plugs or fittings.

Caution Plugs or fittings installed into aluminum housings should always be torqued to the lower values specified for internal hex plugs of the same size. S000 017E

Description

Torque

7/16-20 O-ring 9/16 inch Hex Wrench

20 Nm (15 lbf ft)

7/16-20 O-ring 3/16 inch Internal Hex Wrench

12 Nm (9 lbf ft)


37 Nm (27 lbf ft)


23 Nm (17 lbf ft)


68 Nm (50 lbf ft)


68 Nm (50 lbf ft)

7/8-14 O-ring 1 inch Hex Wrench

95 Nm (70 lbf ft)


68 Nm (50 lbf ft)

1-1/16-12 O-ring 1 1/4 inch Hex Wrench

163 Nm (120 lbf ft)

1-1/16-12 O-ring 9/16 inch Internal Hex Wrench

115 Nm (85 lbf ft)

1-5/16-12 O-ring 1-1/2 inch Hex Wrench

190 Nm (140 lbf ft)

1-5/16-12 O-ring 5/8 inch Internal Hex Wrench

129 Nm (95 lbf ft)

1-5/8-12 O-ring 1-7/8 inch Hex Wrench

224 Nm (165 lbf ft) T002 281E

53

008 911 63

BOMAG

581

17.1

Travel pump

Series 90


Shaft Seal and Shaft Replacement Lip type shaft seals are used on Series 90 pumps and motors. These seals and/or the shafts can be replaced without major disassembly of the unit. However, replacement usually requires removal of the pump or motor from the machine. 1.

Position the pump with the shaft facing up.

Note:

2.

90000270

90000271

Remove Screws Holding Retainer Plate and Seal Carrier

Remove Seal Carrier

Remove the three or four screws holding the retainer plate and seal carrier to the housing, using a 10 mm hex wrench (030 and 042 units), a 5 mm internal hex wrench (055 through 100 units), or a 6 mm internal hex wrench (130 through 250 units). Remove the retainer plate.

Note:

90000272

Press Out Old Seal

After removing the screws, the spring force on the shaft may move the seal carrier out of its bore by approximately 5 mm (1/4 inch). If the seal carrier does not move from its bore after removing the screws, pry it from its bore as shown and/or lightly tap the end of the shaft with a soft mallet.

4.

Remove the O-ring from the seal carrier.

5.

Place seal carrier and seal in an arbor press and press out old seal.

6.

Inspect the seal carrier, the new seal and the O-ring for any damage or nicks.

7.

Using the arbor press, press the new seal into seal carrier. Be careful not to damage the seal.

New Seal Installed in Carrier

Screw

Seal Seal Carrier (One Piece)

Certain earlier production units use a one piece retainer plate and seal carrier.

3.

90000273

Retaining Plate Seal Carrier

If the unit is positioned horizontally when the shaft is removed, the cylinder block could move out of place, making shaft installation difficult.

Screw

Note:

Seal O-ring

The outside diameter of the seal may be lightly coated with a sealant (such as Loctite High Performance Sealant #59231) prior to installation. This aids in preventing leaks caused by damage to the seal bore in the seal carrier.

90000846E

Series 90 Shaft Seal Components

54

582

BOMAG

008 911 63

17.1

Travel pump

Series 90 8.

Minor Repair Instructions Roller Bearing Assembly Retaining Ring

Inspect the sealing area on the shaft for rust, wear, or contamination. If the shaft is not being replaced proceed to step 12.

Splined Shaft

Tapered Shaft OR

Roller Bearing

OR

9.

Remove shaft and roller bearing assembly from pump or motor. The bearing assembly can be transferred to the new shaft.

10. Remove the retaining ring that secures roller bearing assembly with a snap ring pliers. Remove the roller bearing assembly. 11. Place roller bearing assembly on new shaft and secure with the retaining ring. 12. Wrap spline or key end of shaft with plastic film to prevent damage to the sealing lip on the seal during installation.

OR

Straight Key Shaft 90000866E

Fixed Motor Shaft Configuration Roller Bearing Assembly Splined Shaft

Retaining Ring OR

Rollen Bearing Tapered Shaft

OR

OR

13. Prior to assembly, lubricate the O-ring on the O.D. of the seal carrier and the I.D. of the seal with clean petroleum jelly. 14. Assemble the seal carrier and seal over the shaft and into the housing bore. Install the retainer plate (if used).

Straigt Key Shaft 90000867E

Variable Pump Shaft Configuration Roller Bearing Assembly

15. Install the screws and torque like the tables. Splined Shaft

Pumps Frame Size 030 - 042 055 - 100 130 - 250

Retaining Ring

Torque Pumps 12 Nm (9 lbf ft) 16 Nm (12 lbf ft) 32 Nm (24 lbf ft)

OR

T002 282E

Tapered Shaft 90000868E

Variable Motor Shaft Configuration

Motors Frame Size 030 - 100 130

Torque Motors 9.5 Nm (7 lbf ft) 22.5 Nm (16.6 lbf ft) T002 283E

Note:

Torque the screws in a sequenced pattern then recheck.

90000274

Install Seal Carrier

90000275

Torque Retainer Screw

55

008 911 63

BOMAG

583

17.1

Travel pump

Series 90


Pump Minor Repairs Multi-Function Valve Cartridges 1.

The multi-function valve cartridge is removed with a hex wrench on the largest hex on the cartridge. Frame Size 030 - 100 130 - 250


2. 90000276

Remove Multi-Function Valve Cartridge

Inspect cartridge for damage to parts and O-rings. The multi-function valve cartridge may be disassembled for cleaning. However, if the pressure limiter housing assembly is disassembled, the pressure settings must be readjusted. Usually, if there is contamination problem, it will be in the valve seat assembly. If it is not necessary to clean the interior of the cartridge, proceed to step 7.

90000277

Install and Torque Cartridge

Note:

Multi-function valve components are not sold separately as service parts (except O-rings).

90000278

Multi-Function Valve Cartridge Components (Earlier production)

3.

On early versions of the multi-function valves, the valve seat assembly is held by a retaining ring. Remove retaining ring with a snap ring pliers. On late versions, the valve seat section is pressed over a lip. Place the cartridge in a vise and pry the lower section off with an appropriate tool. Maintain sufficient control to prevent the contents from flying loose.

90000279

Multi-Function Valve Cartridge Components (Later production)

High Pressure Pressure Limiter Pressure Limiter Relief/Check Valve Spring Lock Nut Valve Poppet Pressure Limiter Spring Seat Housing Check Valve

4.

Remove pressure limiter lock nut and bypass actuator.

5.

Unscrew the pressure limiter adjustment screw from the bypass actuator. Clean and inspect all disassembled parts.

6.

Reassemble with new, lightly lubricated O-rings by reversing the above procedure. For early versions assemble with the retaining ring. For late versions, place the cartridge in a vise and press on lower assembly.

Poppet

Valve Seat Pressure Limiter Spring Valve Poppet Pressure Limiter Pressure Limiter Adjustment Screw Valve Poppet Bypass

Caution The pressure settings must be readjusted after disassembling the pressure limiter housing of the multi-function valve cartridge. S000 018E

7.

Install cartridge in multi-function valve cavity and torque. Frame Size 030 - 100 130 - 250

Actuator 90000869E

Multi-Function Valve Cartridge Sectional View

Torque 89 Nm (66 lbf ft) 210 Nm (155 lbf ft) T002 285E

Do not overtorque the multi-function valve cartridge.

56

584

BOMAG

008 911 63

17.1

Travel pump

Series 90

Minor Repair Instructions Screws

Pressure Override Valve (Option for 180 Frame Size) 1.

Pressure Override Valve

Remove the four screws attaching the pressure override valve to the pump end cap with a 5 mm internal hex wrench. Remove the O-rings.

2.

Inspect valve for damage to parts.

3.

Install new O-rings. Install the valve onto the pump end cap and torque the screws to 16 Nm (12 lbf ft).

O-rings

Charge Relief Valve The pump charge relief valve may be shim adjustable (early models) or screw adjustable (late models). 1.

90000870E

Remove the shim adjustable charge relief valve plug with a 1 inch hex wrench.

Pressure Override Valve Components

Before removing the screw adjustable relief valve plug, mark the plug, lock nut, and housing so as to approximately maintain the original adjustment when assembling. Remove the screw adjustable charge relief valve plug by loosening the lock nut with a wrench. Frame Size 030 - 100 130 - 250


Unscrew the plug with a large screwdriver or 1/2 inch hex wrench. 2.

Remove the spring and relief valve poppet.

3.

Inspect the poppet and mating seat in the end cap for damage or foreign material.

90000280

Remove Charge Relief Valve (Shim adjustable)

90000262

Shim Adjustable Charge Relief Valve

When inspecting shim adjustable valves, do not alter the shims or interchange parts with another valve. 4.

Install the poppet and spring. For shim adjustable valves, install the plug and torque to 68 Nm (50 lbf ft). For screw adjustable valves, install the plug with its lock nut, aligning the marks made at disassembly, and torque the lock nut to 52 Nm (38 lbf ft). 90000264

Check the charge pressure and adjust, if necessary.

Remove Charge Relief Valve (Screw adjustable)

90000265

Screw Adjustable Charge Relief Valve

57

008 911 63

BOMAG

585

17.1

Travel pump

Series 90

Minor Repair Instructions Charge Pump - Remove The following procedure shows how to remove and install a charge pump. 1.

For pumps with an auxiliary mounting pad, remove the four screws holding the pad to the end cap and remove the pad. Refer to the Auxiliary Mounting Pad Installation instructions (next section) for details.

Note:

At earlier production frame size 75 pumps with twin ports secure the end cap to the pump housing with a clamp to avoid gasket damage.

90000303

90000281

Remove Auxiliary Pad Adapter

Remove Auxiliary Pad Adapter Screws

Caution Do not allow the force of the cylinder block spring and swashplate leveler springs to separate the end cap from the pump housing. Gasket damage and external leakage may result. S000 019E

2.

90000282

Remove Retainer Screws

Remove the six screws holding the charge pump cover retainer. Frame Size 030 - 100 130 - 250

90000284

Remove Charge Pump Cover

Wrench Size 10 mm 13 mm T002 287E

3.

Remove the retainer and the charge pump cover. For pumps with an auxiliary mounting pad, remove the auxiliary drive coupling. Note the orientation of the gerotor.

4.

Remove the charge pump shaft and charge pump drive key.

5.

Remove the spacer plate(s), if present (intermediate production pumps only).

90000297

Remove Drive Coupling

Discharge

Remove the charge pump outer port plate, if present (early and intermediate production pumps).

Gerotor Assembly

Remove the charge pump gerotor assembly.

Discharge

Alignment Pin

Inlet

Inlet

6.

Remove the outer eccentric ring and alignment pin.

7.

Remove the inner port plate.

8.

Inspect all parts for abnormal wear or damage.

Alignment Pin Gerotor Assembly Left Hand Rotation (Outside looking into pump)

Right Hand Rotation (Outside looking into pump)

90000871E

Orienting Alignment Pin

58

586

BOMAG

008 911 63

17.1

Travel pump

Series 90 Note:


If a different displacement charge pump is being installed, the gerotor assembly, gerotor outer eccentric ring, and inner port plate (early and late production pumps) or outer spacer plate(s) (intermediate production pumps) must be replaced together. If different thickness port plates are used in an early production charge pump assembly, the thicker plate is the inner port plate (installed next to the pump end cap).

Standard End Cap Screws Alignment Pin Charge Pump Assembly Thin Port Plate Key

Thick Port Plate

Shaft

Eccentric Ring Gerotor Assembly

O-ring Cover

Each charge pump assembly includes a different quantity / types of port plates and spacer plates.

Journal Bearing Cover Retainer Retainer Screw

The charge pump kit "No Charge Pump" includes a spacer.

90000872E

Charge Pump Components (Early Production) Standard End Cap Screw Alignment Pin Thin Port Plate Charge Pump Assembly

Eccentric Ring

Key

Gerotor Assembly

Shaft

Thin Port Plate

O-ring

Spacer Plate(s)

Cover Journal Bearing Cover Retainer Retainer Screw

90000873E

Charge Pump Components (Intermediate Production)

Standard End Cap Screw Alignment Pin Charge Pump Assembly Key Shaft

Port Plate

O-ring

Eccentric Ring Gerotor Assembly

Cover

Journal Bearing Cover Retainer Retainer Screw

90000874E

Charge Pump Components (Late Production) Standard End Cap Screw Spacer Shaft O-ring Cover Plug Journal Bearing Cover Retainer Retainer Screw

90000875E

"No Charge Pump" Components

59

008 911 63

BOMAG

587

17.1

Travel pump

Series 90 Discharge

Minor Repair Instructions Gerotor Assembly

Installing the Charge Pump

Discharge

Be sure to install the charge pump in the proper orientation. If unsure of charge pump rotation, refer to the model code.

Alignment Pin

Inlet

Inlet

Note:

Alignment Pin Gerotor Assembly Left Hand Rotation (Outside looking into pump)

Right Hand Rotation (Outside looking into pump)

Do not mix charge pump piece parts from different production periods. Always install as a complete assembly.

90000871E

Orienting Alignment Pin

90000285

Install Inner Port Plate

90000287

Install Alignment Pin

90000289

Install Outer Port Plate (Early and intermediate production only)

90000286

The charge pump rotation is determined by the orientation of the gerotor assembly outer eccentric ring and the location of the alignment pin in the end cap.

1.

Install the inner port plate and the gerotor assembly outer ring.

2.

Install the alignment pin to properly orient the port plates and outer eccentric ring for corresponding pump rotation.

3.

Prior to installation, apply a small quantity of petroleum jelly to the I.D., O.D., and side faces of the gerotor assembly to provide initial lubrication.

4.

Install the gerotor assembly.

5.

Install the outer port plate (early production and intermediate production pumps only).

6.

Install the spacer plate, if present (intermediate production pumps).

7.

Install the charge pump drive key into the charge pump shaft and retain with petroleum jelly.

Install Gerotor Assembly Outer Ring

90000288

Install Gerotor Assembly

90000290

Install Spacer Plate (Intermediate production only)

60

588

BOMAG

008 911 63

17.1

Travel pump

Series 90 Note:

8.

Intermediate production 75 cc and 100 cc pumps use the same charge pump drive shaft. Two keyways are provided in the drive shaft for the charge pumps used in these units. The rear keyway (with identifier groove) is used in 75 cc pumps. The front keyway (closest to the internally splined end of the shaft) is used in 100 cc pumps.

100 cc

75 cc

Install the charge pump shaft. The internally splined end of the shaft must engage the main pump shaft.

Note:

9.


The outside diameter of the internally splined end of some early production charge pump shafts was chamfered. Early production end caps may not be machined to accept a nonchamfered shaft. Always use a chamfered charge pump shaft in pumps with the early end cap.

90000291

Keyways in Charge Pump Shaft (Intermediate Production 075 and 100)

90000292

Install Charge Pump Shaft

For pumps with an auxiliary mounting pad, install the auxiliary drive coupling.

10. Install a new O-ring onto the non-auxiliary pad charge pump cover. (If an auxiliary pad is installed, an O-ring is not used on the cover.) 11. Carefully remove the alignment pin from the charge pump parts. Install the pin in its hole in the charge pump cover (see previous page for correct orientation) and retain with petroleum jelly. Install the cover (with alignment pin) into the end cap and aligned charge pump parts. (Take care not to damage the cover O-ring, if used.)

Caution In order to avoid loss of charge pressure in pumps with an auxiliary mounting pad, always install the charge pump cover with the pad drain hole located on the same side of the end cap as the charge inlet port. Refer to the section Auxiliary Pad Installation“ for details. S000 020E

90000293

Alignment Pin Installed in Cover

90000294

Install Charge Pump Cover

12. Install the charge pump cover retainer and the six hex screws and torque the screws. Frame Size 030 - 100 130 - 250

Torque 13.5 Nm (10 lbf ft) 32 Nm (24 lbf ft) T002 288E

13. For pumps with auxiliary mounting pads, install the O-ring and auxiliary mounting pad adaptor onto the end cap. Refer to the corresponding section for instructions on auxiliary pad installation.

90000283

Install Cover Retainer

90000295

Torque Retainer Screws

61

008 911 63

BOMAG

589

17.1

Travel pump

Series 90

Minor Repair Instructions Auxiliary Pad Installation 1.

Remove the six screws holding the charge pump cover retainer. Remove the retainer. Frame Size 030 - 100 130 - 250

Wrench Size 10 mm 13 mm T002 287E

2.

Remove the charge pump cover and its O-ring.

Note: 90000282

The original charge pump cover will not be used when installing the auxiliary pad.

90000284

Remove Screws and Retainer

Remove Charge Pump Cover

3.

Remove the four large screws which fasten the end cap to the pump housing. Frame Size 030 early 042 late 042 055 075 - 100 100 - 130 180 - 250

Wrench Sizes Internal Hex External Hex 8 mm 10 mm 19 mm 24 mm 14 mm 17 mm T002 289E

Note: 90000296

Remove Large End Cap Screws

At earlier production frame size 75 pumps with twin ports secure the end cap to the pump housing with a clamp to avoid gasket damage.

Charge Pump Parts

Cover Assembly Special Washer End Cap Screw

Caution Do not allow the force of the cylinder block spring and swashplate leveler springs to separate the end cap from the pump housing. Gasket damage and external leakage may result.

Coupling (Typical) Journal Bearing O-ring

S000 019E

auxiliary Pad (Typical) O-ring Pad Cover

Auxiliary Pad Kit

Cover Retainer Retainer Screw

4.

Take care to assure the surfaces are clean and free of any foreign material or paint prior to installing the auxiliary pad.

5.

Install the auxiliary drive coupling onto the pump drive shaft spline (auxiliary drive spline must be toward the rear of the pump).

Screw

90000876E

Auxiliary Pad Components (Typical)

62

590

BOMAG

008 911 63

17.1

Travel pump

Series 90 6.


Carefully remove the alignment pin from the charge pump parts. Install the pin in its hole in the new charge pump cover (with hole for the auxiliary coupling) and retain with petroleum jelly. Install the new charge pump cover with alignment pin into the end cap and the aligned charge pump parts.

Caution In order to avoid loss of charge pressure in pumps with an auxiliary mounting pad, always install the charge pump cover with the pad drain hole located on the same side of the end cap as the charge inlet port. Refer to the section "Auxiliary Pad Installation" for details. S000 020E

90000297

Install Drive Coupling

7.

90000298

Install Alignment Pin in Cover (CCW rotation shown)

Install the charge pump cover retainer and the six hex screws and torque the screws. Frame Size 030 - 100 130 - 250

Torque 13.5 Nm (10 lbf ft) 32 Nm (24 lbf ft) T002 288E

8.

Install O-ring on end cap pilot.

9.

Install the auxiliary mounting pad adapter on external pilot on rear of end cap. 90000299

10. Install four new large screws and washers through the mounting pad and end cap into the housing. Torque per the accompanying table. Frame Size 030 early 042 late 042 055 075 - 100 100 - 130 180 - 250

Install New Charge Pump Cover

90000300

Install Screws and Cover Retainer

Torque 58 Nm (43 lbf ft) 122 Nm (90 lbf ft) 122 Nm (90 lbf ft) 256 Nm (189 lbf ft) 298 Nm (220 lbf ft) 580 Nm (429 lbf ft) T002 290E 90000302

Install O-ring on End Cap Pilot

11. Install the O-ring and flange cover or auxiliary pump.

90000303

Install Auxiliary Pad Adapter

Auxiliary Pad Conversion To convert an auxiliary mounting pad to a different size mounting pad, use the above procedure with the following additions: After removing the charge pump cover (step 2), remove the old auxiliary drive coupling. After removing the four end cap retaining screws, remove the old auxiliary mounting pad adapter. 90000281

Install Auxiliary Pad Adapter Screws

90000305

Torque Pad Adapter Screws

63

008 911 63

BOMAG

591

17.1

Travel pump

Series 90

Minor Repair Filtration Options Suction Filtration Installation 1.

Install the hydraulic fitting to connect the external suction filter to the charge pump inlet port.

2.

The reducer fitting (placed on the charge pressure gauge port) is installed as follows. Frame Size 030 - 042 055 - 130 180 - 250

Wrench Size 1-1/4 inch 1-1/2 inch 1-1/2 inch


90000310

Charge Pump Inlet

90000243

The gauge port plug takes a 1/4 inch internal hex wrench and is torqued to 27 Nm (20 lbf ft).

Reducer Fitting and Gauge Port Plug

Remote Charge Pressure Filtration or Integral Charge Pressure Filtration Install either of these two filtration devices as follows.

90000311

remote Pressure Filter Manifold

90000312

Install Remote Pressure Filter Manifold

1.

Remove the reducer fitting, located at charge pressure gauge port, from pump end cap (this part will not be used).

2.

Install the filter manifold or filter head into the port. The hydraulic tube should enter its mating bore in the pump end cap with a low force.

3.

After rotating the filter manifold or filter head clockwise so that the threads engage with the threads in the end cap, continue to rotate it clockwise between 6 and 7 revolutions. Face manifold or head to the desired position.

90000314

Integral Pressure Filter Head

90000315

Install Integral Pressure Filter Head

Caution Failure to install the filter manifold or filter head to a sufficient depth in the end cap will result in insufficient engagement of the tube in the end cap bore. This may allow unfiltered oil to bypass the filter and enter the charge system. S000 021E

4.

While holding the filter manifold or filter head in the desired position, tighten the swivel lock nut. Frame Size 030 - 042 055 - 130 180 - 250

Wrench Size 1-3/8 inch 1-5/8 inch 1-5/8 inch


90000313

Tighten Remote Pressure Filter Manifold Lock Nut

90000316

Tighten Integral Pressure Filter Head Lock Nut

5.

After installing the integral pressure filter head assembly, install the filter canister per the instructions on the filter canister.

64

592

BOMAG

008 911 63

17.1

Travel pump

Series 90

Minor Repair

Pump controls Cover Plate 1.

Thoroughly clean external surfaces prior to removal of cover plate.

2.

Using a 5 mm internal hex wrench, remove the eight cover plate mounting screws. Remove the cover plate and gasket from housing.

Caution Protect exposed surfaces and cavities from damage and foreign material. S000 022E

3.

90000361

Pump with Cover Plate

In preparation for installing the cover plate, place a new gasket on the housing. Place the cover plate into position and install the screws. Torque the screws to 16 Nm (12 lbf ft).

NOTE A sealing washer must be installed under the head of any mounting screws that are installed into "thru" holes in the housing. S000 023E

65

008 911 63

BOMAG

593

17.1

Travel pump

Series 90

Minor Repair Manual Displacement Control (MDC) 1.

Thoroughly clean external surfaces prior to removal of control.

2.

Using a 5 mm internal hex wrench, remove the eight control mounting screws. Remove the control (with orifice check valve and spring) and control gasket from housing.

Caution Protect exposed surfaces and cavities from damage and foreign material. S000 022E 90000319

Remove Mounting Screws

90000321

Inner Face of Control

90000320

Remove Control

3.

In preparation for installing the control, place a new gasket on the housing. Inspect to assure that the control orifice check valve and spring are in their proper position in the control.

4.

While setting the control into position, engage the pin on the control linkage into the mating hole in the link attached to the swashplate.

5.

With the control in position, move control lever both directions to check proper engagement of control linkage pin. Proper engagement will be indicated by centering torque as the lever is moved from center. Non-engagement of control linkage pin is indicated by lack of centering torque as the lever is moved. In case of non-engagement remove the control and repeat the above procedure.

6.

Align the control gasket and install the screws. Torque the screws to 16 Nm (12 lbf ft).

90000322

Assemble Control to Linkage

NOTE A sealing washer must be installed under the head of any mounting screws that are installed into "thru" holes in the housing. S000 023E

90000323

Assemble Control to Pump

90000324

Torque Mounting Screws

7.

If the control is equipped with a neutral start switch, refer to the "MDC Neutral Start Switch Adjustment" instructions.

WARNING The neutral start switch "neutral" must be readjusted after reassembling the MDC module. S000 024E

66

594

BOMAG

008 911 63

17.1

Travel pump

Series 90

Minor Repair

Solenoid Override Valve for MDC 1.

Thoroughly clean external surfaces prior to removal of valve.

2.

Using a 5 mm internal hex wrench, remove the two screws and remove solenoid manifold from housing. Remove the old gasket.

3.

The solenoid may be removed from the valve by removing the nut with a 3/4 inch hex wrench. The solenoid valve may be removed from the manifold with a 7/8 inch hex wrench.

4.

When installing the solenoid valve into the manifold, the valve should be torqued to 24 ± 2.4 Nm (17.7 ± 1.8 lbf ft). When installing the solenoid onto the valve, torque the nut to 6 Nm (53 ± 12 lbf in).

5.

90000363

Components of Solenoid Override for MDC

In preparation for installing the solenoid manifold, place a new gasket on the control housing. Install the manifold onto the control housing, align the gasket, and install the screws. Torque the screws to 13.5 Nm (10 lbf ft).

Solenoid Override Valve for MDC with Pressure Released Brake 1.

Thoroughly clean external surfaces prior to removal of valve.

2.

Using a 4 mm internal hex wrench, remove the four solenoid valve mounting screws. Remove the solenoid valve (with O-rings) from the adapter plate.

3.

Using a 4 mm internal hex wrench, remove the four adapter plate mounting screws. Remove the adapter plate and O-rings from the control housing.

4.

Remove the check valve seat and O-ring from the control side of the adapter plate. Remove the check ball and spring.

5.

Install a new O-ring on the check valve seat and reassemble the check valve spring, ball, and seat into the adapter plate.

6.

Install new O-rings on the adapter plate. Place the adapter plate into position and install the screws. Torque the screws to 5.4 Nm (48 lbf in).

7.

90000364

Components of Solenoid Override with Brake Pressure Defeat for MDC

Install new O-rings onto the solenoid valve assembly and install the solenoid valve onto the adapter plate. Install the screws and torque to 5.4 Nm (48 lbf in).

67

008 911 63

BOMAG

595

17.1

Travel pump

Series 90

Minor Repair Hydraulic and Electric Displacement Controls 1.


2.

Using a 5 mm internal hex wrench, remove the eight control mounting screws. Remove the control (with orifice check valve and spring) and control gasket from housing.

Caution Protect exposed surfaces and cavities from damage and foreign material. S000 022E

90000325

Remove Mounting Screws

90000327

Inner Face of Control

90000326

3.

In preparation for installing the control, place a new gasket on the housing. Inspect to ensure that the control orifice check valve and spring are in their proper position in the control.

4.

While setting the control into position, engage the pin on the control linkage into the mating hole in the link attached to the swashplate.

5.

With the control in position, move control assembly left and right to check engagement of pin in the link. Proper engagement will be indicated by an increasing resistance as the control is moved away from center position. Non-engagement of pin will be indicated by lack of spring force. In case of non-engagement, remove control and repeat the above procedure.

6.

Align the control gasket and install the screws. Torque the screws to 16 Nm (12 lbf ft).

Remove Control

90000328

Assemble Control to Linkage

Caution A sealing washer must be installed under the head of any mounting screws that are installed into "thru" holes in the housing. S000 023E

90000329

Install Mounting Screws

90000332

PCP Components

90000330

Pressure Control Pilot (PCP) for Electric Displacement Control

Torque Mounting Screws

90000334

1.

Thoroughly clean external surfaces of control.

2.

Using a 4 mm internal hex wrench, remove the four screws and remove the PCP.

3.

Check surfaces for nicks or damage. Clean internal screens.

4.

Install new O-rings in PCP Housing. Place PCP against EDC housing and install the screws. Torque to 5.4 Nm (48 lbf in).

Note:

Torque PCP Valve Screws

Do not remove black plastic cover from the aluminum plate. This is not a serviceable item and will void the product warranty.

68

596

BOMAG

008 911 63

17.1

Travel pump

Series 90

Minor Repair

3-Position (FNR) Electric Control 1.


2.

Using a 4 mm internal hex wrench, remove the four solenoid valve mounting screws. Remove the solenoid valve (with O-rings and orifice) from the adapter plate.

3.

Using a 5 mm internal hex wrench, remove the eight adapter plate mounting screws. Remove the adapter plate and gasket from housing.

Caution Protect exposed surfaces and cavities from damage and foreign material.

90000362

3-Position Electric Control Components

S000 022E

4.

Inspect the orifice installed between the valve and adapter plate. This orifice MUST be installed in the case drain passage for proper pressure limiter operation.

5.

In preparation for installing the adapter plate, place a new gasket on the housing. Place the adapter plate into position and install the screws. Torque the screws to 16 Nm (12 lbf ft).

NOTE A sealing washer must be installed under the head of any mounting screws that are installed into thru“ holes in the housing. S000 023E

6.

Install new O-rings and the orifice onto the solenoid valve assembly and install the solenoid valve onto the adapter plate. Install the screws and torque to 5.4 Nm (48 lbf in).

Displacement Control Components Displacement Control Orifices 1.

Remove the control assembly as described in the instructions for the specific displacement control.

2.

Orifice plugs may be located in the control assembly, at the pump housing face surface. Remove the orifice plugs with a 4 mm internal hex wrench. Note the location of each plug, do not interchange plugs. Torque the orifice plugs to 3 Nm (26 lbf in).

3.

Assemble the control onto the pump. Refer to the instructions for the specific control.

A B TA

P TB

Orifice Plugs Orifice Check Valve 90000849E

Underside of an HDC/EDC Module Showing Orifice Locations

69

008 911 63

BOMAG

597

17.1

Travel pump

Series 90

Minor Repair Displacement Control Orifice Check Valve

B

TA A

1.

Remove the control assembly as described in the instructions for the specific displacement control.

2.

The orifice check valve is located in the control assembly, at the surface of the pump housing face. Remove the spring retainer and spring from the orifice check valve cavity and then remove the orifice check valve.

3.

Install the desired orifice check valve in the cavity and then install the spring and spring retainer to hold the orifice check valve in position.

4.

Assemble the control onto the pump. Refer to the instructions for the specific control.

TB

P

Orifice Plugs

Orifice check Valve 90000848E

Underside of an MDC Module Showing Orifice Locations

Displacement Control Adapter Plate (Early production 130 Pumps only) The screws fastening the control adapter plate to the housing have retaining compound on the threads. They are removed with a 6 mm internal hex wrench. When installing the adapter plate, ensure the O-rings are in the proper position and torque the screws to 32 Nm (24 lbf ft).

Displacement Control Filter Screens If the pump is equipped with control filter screens in the pump housing (late production), they should be pressed into position (with the rounded edge of the filter screens facing the control until they are flush to 2.0 mm (0.08 inch) below the surface of the housing.

90000847

Displacement Control Adapter Plate (Early production 130cc Pumps only)

70

598

BOMAG

008 911 63

17.1

Travel pump

Series 90

Minor Repair

Minor Repair - Motor Loop Flushing and Charge Relief Valves Loop Flushing Valve 1.

Using an 1-1/16 inch wrench, remove the hex plugs and O-rings from both sides of the valve. Remove the springs, shoulder washers, and flushing valve shuttle spool. Note orientation of the washers. Remove the flushing valve spool.

2.

Inspect parts for damage or foreign material.

Note:

3.

Early production motors used a small diameter shuttle valve spool. Late production motors use a larger diameter spool.

90000338

Remove Plugs Springs

90000339

Remove Flushing Shuttle Spool

Install flushing valve spool in end cap, then install the shoulder washers (with shoulders facing “out”) and springs on each end of the spool. Install the hex plugs with O-rings, and torque to 41 Nm (30 lbf ft) on 030 through 100 motors or 68 Nm (50 lbf ft) on 130 motors.

Motor Charge Relief Valve 1.

Remove the shim adjustable charge relief valve plug with a 7/8 inch hex wrench.

90000340

Install Flushing Shuttle Spool

Before removing the screw adjustable relief valve plug, mark the plug, lock nut, and housing so as to be able to maintain the original adjustment when assembling. Remove the screw adjustable charge relief valve plug by loosening the lock nut with a 1-1/16 inch hex wrench for 030 through 100 units, or a 1-5/8 inch hex wrench for 130 units, and unscrewing the plug with a large screwdriver or 1/2 inch hex wrench. 2.

Remove the spring and valve poppet.

3.

Inspect the poppet and mating seat in the end cap for damage or foreign material. When inspecting shim adjustable valves, do not alter the shims or interchange parts with another valve.

90000342

90000341

Torque Plugs

90000343

Remove Shim Charge Relief Remove Screw Charge Relief Valve Valve

71

008 911 63

BOMAG

599

17.1

Travel pump

Series 90

Minor Repair

90000344

Shim Adjustable Charge Relief Valve

4.

Install the poppet and spring. For shim adjustable valves, install the plug and torque to 68 Nm (50 lbf ft). For screw adjustable valves, install the plug with its lock nut, aligning the marks made at disassembly, and torque the lock nut to 52 Nm (38 lbf ft).

5.

Check and adjust the charge pressure.

90000345

Screw Adjustable Charge Relief Valve

Defeating the Loop Flushing Valve Lock Nut Plug Plug O-ring

O-ring

1.

Remove loop flushing valve components (these parts will not be used).

2.

Install defeating spool into spool bore in end cap.

3.

Install hex plugs provided and torque to 41 Nm (30 lbf ft).

4.

Remove charge relief valve components (these parts are not necessary).

5.

Replace with the hex plug provided and torque to 41 Nm (30 lbf ft).

Shims

Spring

Spring

Poppet

Poppet Plug with O-ring (defeat)

Plug with O-ring (defeat)

Plug Spool (defeat)

O-ring Spring

Plug with O-ring (defeat)

Shoulder Washer

Note orientation of washers! Shoulder OUT (toward spring).

Spool Shoulder Washer Spring O-ring Plug

90000850E

Motor charge Relief Valve and Loop Flushing Valve Parts

72

600

BOMAG

008 911 63

17.1

Travel pump

Series 90

Minor Repair

Variable Motor Displacement Limiters 1.

Remove the tamper-resistant cap from the displacement limiter. Measure and note the length of the adjustment screw up to the seal lock nut. Using a 19 mm hex wrench, loosen the seal lock nut and remove the nut. Remove the limiter screw from the motor housing with a 6 mm internal hex wrench.

2.

Install the limiter screw with the noted length between adjustment screw and the seal lock nut. Do not install a new tamper-resistant cap until the limiter has been adjusted.

3.

Final adjustment of the displacement limiters should be performed on a test stand.

Tamper-Resistant Cap Seal Lock Nut Maximum Displacement Limiter Screw

Do not turn the limiter screws counterclockwise beyond their initial adjustment positions. Caution Care should be taken in adjusting displacement limiters to avoid undesirable speed conditions. The seal lock nut must be retorqued after every adjustment to prevent an unexpected change in operating conditions and to prevent external leakage during unit operation.

Minimum Displacement Limiter Screw Seal Lock Nut Tamper-Resistant Cap SAE Flange Version shown (cartridge Version similar)

S000 026E 90000851E

One full turn of the displacement limiter adjustment screw will change the displacement as follows: Frame Size 055 075

MV Displacement Limiters

Approx Change in Disp per Rev of Adjusting Screw 5.6 cm3 / Rev (0.34 in3 / Rev) 7.1 cm3 / Rev (0.43 in3 / Rev) T002 295E

4.

Following the final adjustment, install new tamper resistant caps.

73

008 911 63

BOMAG

601

17.1

Travel pump

Series 90

Minor Repair

Variable Motor Controls Electrohydraulic 2-Position Control (Types NA, NB, NC, and ND)

Note: Remove BEFORE removing control. Install AFTER installing control. Refer to "Control Orifices" Section

Hydraulic 2-Position Control Valve

Electric 2-Position Control Valve

1.

Thoroughly clean external surfaces prior to removal of the control.

2.

Disconnect the external electrical signal connection.

3.

Remove the hex nut and solenoid from the control valve.

4.

Remove the orifice check valve for the maximum angle control cylinder, if equipped.

5.

Remove the control valve from the motor housing.

6.

Remove O-rings from the valve.

7.

Install new O-rings on the control valve.

8.

Install the valve into the motor housing and torque to 47 Nm (35 lbf ft). Do not overtorque the control valve. Over-torquing may result in the valve spool sticking.

9.

Install the solenoid onto the valve and torque the hex nut to 5 Nm (44 lbf in). Do not overtorque the nut.

90000852E

MV Control components

10. If previously removed, reinstall the orifice check valve. Reconnect the external signal connection.

Hydraulic 2-Position Control (Type PT) Follow the steps above, except that in step 2 a hydraulic signal line will be disconnected, and steps 3 and 9 are not applicable. 1/8 in. int. hex wrench Torque: 5.4 Nm (48 lbf in)

Control Plugs Remove the control plugs from the housings of earlier production motors, if necessary. Install new O-rings, reinstall, and torque.

9/16 in. hex wrench Torque: 34 Nm (25 lbf ft)

7/8 in. hex wrench Torque: 68 Nm (50 lbf ft)

90000853E

MV Control Plugs

74

602

BOMAG

008 911 63

17.1

Travel pump

Series 90

Minor Repair

Variable Motor Control Orifices Control Suply Orifice

Control Supply Orifice 1.

Screen (pressed in)

Remove the control supply orifice from the motor housing with an 1-1/16 inch hex wrench.

O-ring Backup Washer

2.

3.

Remove the O-rings and the backup washers. Check that the filter screen is secure in the orifice body and that the screen and the orifice are not plugged. Install new backup washers and O-rings onto the orifice body. Install the orifice into the motor housing and torque to 37 Nm (27 lbf ft).

Caution Do not interchange the control supply orifice with the minimum displacement orifice (next section).



Backup Washer

Screen (pressed in) Orifice Body

S000 027E

O-ring

Cross-section View of Control Supply Orifice Assembly

90000854E

MV Control Supply Orifice

Minimum Displacement Cylinder Orifice or Orifice Check Valve Orifice / Check Valve Assembly

Orifice

1.

Remove the minimum displacement cylinder drain orifice or the orifice check valve from the motor housing with an 1-1/16 inch hex wrench.


2.

3.

Remove the O-rings and the backup washers. Check that the orifice is not plugged. Check that the check valve seat is secure in the body and that the check ball is free.


Install new backup washers and O-rings onto the orifice body. Install the orifice into the motor housing and torque to 37 Nm (27 lbf ft). O-ring

O-ring

Caution Do not interchange the control supply orifice (previous section) with the minimum displacement orifice. S000 028E

Orifice Body

Orifice Body Backup Washer

Spring Pin


Backup Washer O-ring

Kugel

Backup Washer Orifice Seat (Spot welded)

Cross-Section View of Orifice Assembly

Cross-Section View of Orifice / Check Valve Assembly

90000855E

MV Minimum Displacement Orifice

75

008 911 63

BOMAG

603

17.1

Travel pump

Series 90

Minor Repair Maximum Displacement Cylinder Orifice Check Valve 1.

Remove the seal lock nut with a 3/4 inch hex wrench. Remove the maximum displacement cylinder orifice check valve from the motor housing with a 1/4 inch end wrench. Remove the O-ring. The check ball in the valve must be free.

2.

Reinstall the check valve and torque to 15 Nm (11 lbf ft). Install a new O-ring. Install the seal lock nut with the seal toward the motor housing.

Housing Plug Seal Lock Nut (seal toward housing)

O-ring Orifice / Check Valve Assembly

Seal Lock Nut (seal toward housing)

Hold the check valve from turning while torquing the seal lock nut to 34 Nm (25 lbf•ft).

O-ring

3. Orifice Body Check Ball

If no orifice check valve is installed, the housing plug may be removed with a 9/16 inch hex wrench. Always install a new O-ring. Reinstall the plug and torque to 20 Nm (15 lbf ft).

Spring Pin Cross-Section View of Orifice / Check Valve Assembly

90000856E

MV Maximum Displacement Orifice

76

604

BOMAG

008 911 63

17.1

Travel pump

Series 90

Minor Repair

Speed Sensor 1.

Remove the speed sensor by disconnecting the electrical connector, loosening the lock nut, and unscrewing the speed sensor from the pump or motor housing.

Speed Sensor

2.

Always install a new O-ring before installing the sensor.

1-1/16 in. hex wrench Torque: 13 Nm (10 lbf ft) After adjustment!

3.

Reinstall the speed sensor (with lock nut and O-ring) into the housing. Adjust the gap between the sensor and the magnetic speed ring as instructed in Section "Speed Sensor Adjustment" and torque the sensor lock nut.

4.

If a speed sensor is not installed, the housing plug should be torqued as indicated in the accompanying figure.

Housing Plug 1/4 in. int. hex wrench Torque: 23 Nm (17 lbf ft)

or

90000857E

Typical Location of Speed Sensor - PV


or

Housing Plug 1/4 in. int. hex wrench Torque: 23 Nm (17 lbf ft)

Speed Sensor

90000858E

Typical Location of Speed Sensor - MF


or Speed Sensor Housing Plug 1-1/16 in. hex wrench Torque: 37 Nm (27 lbf ft)

90000859E

Typical Location of Speed Sensor - MV

77

008 911 63

BOMAG

605

17.1

Travel pump

Series 90

Exploded View Parts Drawings / Parts Lists Exploded View Parts Drawings / Parts Lists

Variable Pumps Minor Repair Parts

K90 B83 OR B83

K10

B70 G532 G536

K50 K70

G542 G546 B82

L35 (Early Production 075 Frame Size)

K018 bis K042

(L70)

(L40)

K80

L60

(B80)

(B90)

L30

P2B_ (B70) P30

L70

L40

B90

P06 P13

L50

P30 B71 P2A_

P06 P13

G512 G516 G502 G506 G522 G526

G172 G176

B80 (G502 G506)

(G502 G506)

(G63) G63 (CODE 61 OPTION)

(G64)

G64 (CODE 61 OPTION) BOTH SIDES

(K018 THRU K042)

G531 G538

G501 G508 G511 G518

OR G541 G548

G63 (CODE 61 OPTION)

G521 G528 (G501 G508) (G501 G508)

(G63) (G64)

G64 (CODE 61 OPTION)

90000860E

78

606

BOMAG

008 911 63

17.1

Travel pump

Series 90

Exploded View Parts Drawings / Parts Lists

Parts List

Item

Description

Qty

B70 ............... Plug ......................................................... 2 B71 ............... Plug ......................................................... 1 B80 ............... Plug ......................................................... 1 B82 ............... Plug ......................................................... 1 B90 ............... Filter screen ............................................ 3 G63 .............. Split flange clamp .................................... 4 G64 .............. Plug ......................................................... 4 G172 ............ Plug ......................................................... 1 G176 ............ O-ring ...................................................... 1 G501 ............ Plug ......................................................... 3 G502 ............ Plug ......................................................... 3 G506 ............ O-ring ...................................................... 3 G508 ............ O-ring ...................................................... 3 G511 ............ Plug ......................................................... 1 G512 ............ Plug ......................................................... 1 G516 ............ O-ring ...................................................... 1 G518 ............ O-ring ...................................................... 1 G521 ............ Plug ......................................................... 1 G522 ............ Plug ......................................................... 1 G526 ............ O-ring ...................................................... 1 G528 ............ O-ring ...................................................... 1 G531 ............ Plug ......................................................... 1

Item

Description

Qty

G532 ............ Plug ......................................................... 1 G536 ............ O-ring ...................................................... 1 G538 ............ O-ring ...................................................... 1 G541 ............ Plug ......................................................... 1 G542 ............ Plug ......................................................... 1 G546 ............ O-ring ...................................................... 1 G548 ............ O-ring ...................................................... 1 K10 ............... Plug assembly ......................................... 1 K50 ............... O-ring ...................................................... 1 K70 ............... Spring ...................................................... 1 K80 ............... Poppet ..................................................... 1 K90 ............... Nut ........................................................... 1 L30 ............... Seal carrier .............................................. 1 L35 ............... Seal carrier .............................................. 1 L40 ............... Lip seal .................................................... 1 L50 ............... O-ring ...................................................... 1 L60 ............... Retainer ................................................... 1 L70 ............... Screw ...................................................... 3 L8 ................. Key .......................................................... 1 L9 ................. Slotted nut ............................................... 1

79

008 911 63

BOMAG

607

17.1

Travel pump

Series 90


Variable Pump Controls

M1DC M1DD

M90D

M0DC M0DD OR

M11D

M9ME

M0MA M0ME M0MB M0MF M0MC M0MG M0MD M0M9 M74M M78M

M76M

M0CA M1CA M11C

M92M M97M

T001 THRU T009, T022 T050

M77M M98M

M95M M96M

M75M S40 M90M M1MA M880 M1MB M1MC M1MD M1ME M1MF M1MG

T201 THRU T209, T222 T250 T301 THRU T309, T322 T350

M90C M87C

T401 THRU T409, T422 T450

M72M M71M OR

M7MA M7MB M7MC M7MD M7ME M7MF M7MG

M0EA M0EF M0EP

M91E

M87M M11M M90E M1EA M880 M1EF M1EP

M870 M860

M98E

M95E M97E M96E

M11E

M850 M840 M840 REF M830

M9EA M9EP

M87E M810 M840 REF

M820

(Early Production 130 cc Frame Size) OR

OR

M1HA, M1HC M1HF, M1HG M1HH, M1HJ M1HK, M1HL M1HM, M1HN M11H

M90H M880 M87H M0HA, M0HC M0HF, M0HG M0HH, M0HJ M0HK, M0HL M0HM, M0HN

90000861E

80

608

BOMAG

008 911 63

17.1

Travel pump

Series 90


Control Parts List

Item

Description

Qty

Item

Description

Qty

M0CA ........... Cover plate kit ......................................... 1 M1CA ........... Cover plate .............................................. 1 M11C ........... Control gasket ......................................... 1 M11D ........... Control gasket ......................................... 1 M87C ........... Washer, seal (042) ................................. 1 M90C ........... Screw ...................................................... 6

M71M ........... Washer .................................................... 1 M72M ........... Nut ........................................................... 1 M80 .............. Control gasket ......................................... 1 M87M ........... Washer, seal (042) ................................. 1 M90M ........... Screw ...................................................... 6 S40 ............... Neutral start switch kit ............................. 1

M0DC ........... Control kit, 3-position FNR 12V .............. 1 M0DD ........... Control kit, 3-position FNR 24V .............. 1 M1DC ........... Control, 3-position FNR 12V ................... 1 M1DD ........... Control, 3-position FNR 24V ................... 1 M80 .............. Control gasket ......................................... 1 M87D ........... Washer, seal (042) ................................. 1 M90D ........... Screw ...................................................... 6

M0MC .......... Control MDC w/ sol. valve ...................... 1 M7M ............. Control handle ......................................... 1 M71M ........... Washer .................................................... 1 M72M ........... Nut ........................................................... 1 M74M ........... Solenoid valve ......................................... 1 M75M ........... Control manifold ...................................... 1 M77M ........... Manifold gasket ....................................... 1 M78M ........... Screw ...................................................... 2 M80 .............. Control gasket ......................................... 1 M87M ........... Washer, seal (042) ................................. 1 M90M ........... Screw ...................................................... 6

M0EA ........... Control kit, EDC with MS connector .......................................... 1 M0EP ........... Control kit, EDC with Packard connector .................................. 1 M1EA ........... Control, EDC with MS-connector .......................................... 1 M1EP ........... Control, EDC with Packard-connector .................................. 1 M9EA ........... PCP type 3 oil filled (MS) ........................ 1 M9EA ........... PCP type 3 oil filled (Packard) ................ 1 M80 .............. Control gasket ......................................... 1 M87E ............ Washer, seal (042) ................................. 1 M90E ............ Screw ...................................................... 6 M91E ............ Plastic cap (MS) ...................................... 1 M95E ............ O-ring ...................................................... 2 M96E ............ O-ring ...................................................... 1 M97E ............ O-ring ...................................................... 1 M98E ............ Screw ...................................................... 4 M1MA ........... Servovalve kit .......................................... 1 M0HA ........... Control kit, hydraulic, HDC ..................... 1 M0HC ........... Control kit, hydraulic, HDC ..................... 1 M1HA ........... Control, hydraulic, HDC .......................... 1 M1HC ........... Control, hydraulic, HDC .......................... 1 M11H ........... Control gasket ......................................... 1 M80 .............. Control gasket ......................................... 1 M87H ........... Washer, seal (042) ................................. 1 M90H ........... Screw ...................................................... 6 M0MA ........... Control MDC w/o neutral start switch ........................... 1 M7M ............. Control handle ......................................... 1 M71M ........... Washer .................................................... 1 M72M ........... Nut ........................................................... 1 M80 .............. Control gasket ......................................... 1 M87M ........... Washer, seal (042) ................................. 1 M90M ........... Screw ...................................................... 6

M0MD .......... Control MDC w/ sol. valve and neutral start switch .................................. 1 M7M ............. Control handle ......................................... 1 M71M ........... Washer .................................................... 1 M72M ........... Nut ........................................................... 1 M75M ........... Control manifold ...................................... 1 M76M ........... Solenoid valve ......................................... 1 M77M ........... Manifold gasket ....................................... 1 M78M ........... Screw ...................................................... 2 M80 .............. Control gasket ......................................... 1 M87M ........... Washer, seal (042) ................................. 1 M90M ........... Screw ...................................................... 6 S40 ............... Neutral start switch ................................. 1 M810 ............ Adapter plate - Control (130 cc) ............. 1 M820 ............ O-ring (130 cc) ........................................ 1 M830 ............ O-ring (130 cc) ........................................ 1 M840 ............ O-ring (130 cc) ........................................ 2 M850 ............ Plug (130 cc) ........................................... 1 M860 ............ Screw (130 cc) ........................................ 6 M870 ............ Plug (130 cc) ........................................... 1 M9ME ........... 4/2 Way valve ......................................... 1 M92M ........... Screw ...................................................... 4 M95M ........... O-ring ...................................................... 1 M96M ........... O-ring ...................................................... 1 M97M ........... O-ring ...................................................... 1 M98M ........... Screw ...................................................... 4 T001-9 .......... Control orifice kit ..................................... 1 T201-9 .......... Orificed check valve ................................ 1 T301-9 .......... Spring ...................................................... 1 T401-9 .......... Spring retainer ......................................... 1

M0MB ........... Control MDC w/ neutral start switch ............................. 1 M7M ............. Control handle ......................................... 1

81

008 911 63

BOMAG

609

17.1

Travel pump

Series 90


Filter and Options

N40P

N40L

N00M N00S N35M REF

N35S N10S Or

N10M N30R

N35M

N00R

N25M

N20M N15M N31R

N10R

N20R N15R N25R

N35R

OR

90000862E

H50L

H50 H40 H05

OR H30 H60 H50

H40 OR H05

H30

(H30) J80N

H40 H05

H60 H50

OR H60 H50 H90L

J40N J15N H70

J15_ J10_

J30 J30

J70_

H80

H70

OR

J80_

J50_

J60_ J90_

H80 J00_

J92_

J95_

90000863E

82

610

BOMAG

008 911 63

17.1

Travel pump

Series 90


Parts List Filter and Options

Item

Description

Qty

H05B-H ........ Kit - Charge pump ................................... 1 H50L ............ Spacer (No charge pump) ...................... 1 H30 .............. Port plate ................................................. 2 H40 .............. Pin ........................................................... 1 H50 .............. Charge pump shaft ................................. 1 H60 .............. Key .......................................................... 1 H70 .............. Retaining plate ........................................ 1 H80 .............. Screw ...................................................... 6 H90L ............ Plug ......................................................... 1 J00A ............. Aux. mtg. SAE A flange .......................... 1 J00B ............. Aux. mtg. SAE B flange .......................... 1 J00C ............. Aux. mtg. SAE C flange .......................... 1 J00D ............. Aux. mtg. SAE D flange .......................... 1 J00T ............. Aux. mtg. SAE A flange (11 T) ............... 1 J00V ............. Aux. mtg. SAE B-B flange ....................... 1 J00N ............. Aux. mtg. flange - none .......................... 1 J10A-V ......... Coupling .................................................. 1 J15 ............... Charge pump cover assembly ................ 1 J15N ............. Charge pump cover assembly ................ 1 J30 ............... Bushing ................................................... 1 J50A-V ......... O-ring ...................................................... 1 J60A/T .......... Flange adaptor SAE A ............................ 1 J60B/V ......... Flange adaptor SAE B ............................ 1 J60C ............. Flange adaptor SAE C ............................ 1 J60D ............. Flange adaptor SAE D ............................ 1 J70A-V ......... Washer .................................................... 4

Item

Description

Qty

J80A-V ......... Screw ...................................................... 4 J80N ............. Screw ...................................................... 4 J90A-V ......... O-ring ...................................................... 1 J92A-V ......... Cover plate .............................................. 1 J95A-V ......... Screw ................................................... 2/4 N00M ........... Filtration manifold kit (Int) ....................... 1 N10M ........... Manifold ................................................... 1 N15M ........... O-ring ...................................................... 2 N20M ........... Nut ........................................................... 1 N25M ........... Tube ........................................................ 1 N35M ........... Plug ......................................................... 2 N40L ............ Filter ........................................................ 1 N40P ............ Filter ........................................................ 1 N00R ............ Filtration manifold kit (Rmt) ..................... 1 N10R ............ Manifold ................................................... 1 N15R ............ O-ring ...................................................... 1 N20R ............ Nut ........................................................... 1 N25R ............ Tube ........................................................ 1 N30R ............ Plastic plug .............................................. 2 N35R ............ Plug ......................................................... 1 N00S ............ Filtration kit (Suction Flt) ......................... 1 N10S ............ Reducer fitting (Suction Flt) .................... 1 N35S ............ Plug ......................................................... 1

Name Plates

Ames, Iowa, U.S.A. Model Code

Neumünster, Germany Typ

90L055 EA 1 N 6 S 3 C6 C 03 Model No.

Model Number

Ident Nr

94 – 2029


Model Code Model Number


90L055 EA 1 N 6 S 3 C6 C 03 Model No.

Model Code

Ident Nr

687459

Serial Number

Serial Number Serial No. Fabr Nr MADE IN U.S.A.

Serial No. Fabr Nr MADE IN GERMANY

Place of Manufacture


Name Plate (German Production)

Name Plate (U.S.A. Production)

83

008 911 63

BOMAG

611

17.1

Travel pump

Series 90


Fixed Motor Minor Repair Parts

H68W L35 (Early Production 075 Frame Size)

H60W H62W H64W

(L70)

(L40)

H66W

L60

H60N L40

(B80)

(H50N)

L70

L30

(G50) (H50W)

(H30W)

L50

(H40W) (H20W) G50 G70 H10N

(B80) H50N

H20W

(G63)

B80

H10W

G63 (CODE 61 OPTION) (G64)

H40W

H30W H50W

G64 (CODE 61 OPTION) B83

OR

B83

B80 G63 (CODE 61 OPTION) (G63) G64 (CODE 61 OPTION)

(G64)

(B83)

(B83)

90000864E

84

612

BOMAG

008 911 63

17.1

Travel pump

Series 90


Parts List

Item

Description

Qty

B80 ............... Plug ......................................................... 2 B83 ............... Plug ......................................................... 1 B83 ............... Speed sensor .......................................... 1 G50 G70 G63 G64

.............. Plug ......................................................... 2 .............. Plug ......................................................... 1 .............. Split flange screw .................................... 4 .............. Screw - Shipping Cover .......................... 4

H10N ............ Loop flushing spool - defeat .................... 1 H50N ............ Plug ......................................................... 2 H10W ........... Shuttle valve spool .................................. 1 H20W ........... Spring guide ............................................ 2 H30W ........... Spring ...................................................... 2 H40W ........... O-ring ...................................................... 2

Item

Description

Qty

H50W ........... Plug ......................................................... 2 H60W ........... Charge relief valve plug .......................... 1 H62W ........... O-ring ...................................................... 1 H64W ........... Spring ...................................................... 1 H66W ........... Charge relief poppet ............................... 1 H68W ........... Lock nut ................................................... 1 L30 ............... Seal carrier .............................................. 1 L35 ............... Seal carrier .............................................. 1 L40 ............... Lip seal .................................................... 1 L50 ............... O-ring ...................................................... 1 L60 ............... Retainer ................................................... 1 L70 ............... Screw ...................................................... 3 L8 ................. Key .......................................................... 1 L9 ................. Slotted nut ............................................... 1

Name Plates



90M055 NC 0 N 8 N 0 C6 W 00 NNN 00 00 24 Model No.

Model Number

Model Code

Ident Nr

94 – 2029 A – 91 – 26 – 67890

Serial Number


90M055 NC 0 N 8 N 0 C6 W 00 NNN 00 00 24 Model No.

Model Number Serial Number

Serial No. Fabr Nr MADE IN U.S.A.


Model Code

Ident Nr

312918 N – 91 – 26 – 67890 Serial No. Fabr Nr MADE IN GERMANY



Name Plate (German Production)

Name Plate (U.S.A. Production)

85

008 911 63

BOMAG

613

17.1

Travel pump

Series 90


Variable Motor Minor Repair Parts

Y100 Y101

Y102

Y40

E15

E35

E26

Y50 Y60 (Y50)

L35 (Early Production 075 Frame Size)

(L70) L60

(L40)

L70

L30 L40

B83

(B74) B80

B83

L50 B76 T100 T101 T30 T40 T50 T60 (T50)

H68W H60W (B74)

H62W H64W M1PT

H66W

Y80

M1NA, M1NB M1NC, M1ND

(G50)

P700 P702

G50

(H50N)

(B80)

(H50W)

E25

(B74)

(H40W)

E35

(H30W) (H20W)

Y71 Y72

B74

H60N

H10N E15

G70

H50N

P601 P603 (P400) (P401) (P402) (P403)

Y70 (P400) (P401) (P402) (P403) P600 P602

H10W H20W (G63)

(G64)

H30W H40W

H50W

G63 (CODE 61 OPTION) G64 (CODE 61 OPTION)

P800

90000865E

86

614

BOMAG

008 911 63

17.1

Travel pump

Series 90


Parts List

Item

Description

Qty

B74 ............... Plug ......................................................... 4 B76 ............... Plug ......................................................... 1 B80 ............... Plug ......................................................... 2 B83 ............... Plug ......................................................... 1 B83 ............... Speed sensor .......................................... 1 E15 ............... Cap .......................................................... 1 E25 ............... Set screw ................................................ 1 E35 ............... Nut - Seal Lock ....................................... 1 G50 .............. Plug ......................................................... 2 G63 .............. Split flange clamp .................................... 4 G64 .............. Shipping cover screw .............................. 4 G70 .............. Plug ......................................................... 1 H10N ............ Loop flushing spool - defeat .................... 1 H50N ............ Plug ......................................................... 2 H60N ............ Plug ......................................................... 1 H10W ........... Shuttle valve spool .................................. 1 H20W ........... Spring guide ............................................ 2 H30W ........... Spring ...................................................... 2 H40W ........... O-ring ...................................................... 2 H50W ........... Plug ......................................................... 2 H60W ........... Charge relief valve plug .......................... 1 H62W ........... O-ring ...................................................... 1 H64W ........... Spring ...................................................... 1 H66W ........... Charge relief poppet ............................... 1 H68W ........... Lock nut ................................................... 1

Item

Description

Qty

L30 ............... Seal carrier .............................................. 1 L35 ............... Seal carrier .............................................. 1 L40 ............... Lip seal .................................................... 1 L50 ............... O-ring ...................................................... 1 L60 ............... Retainer ................................................... 1 L70 ............... Screw ...................................................... 3 M1N ............. Control valve - electric ............................ 1 M1P .............. Control valve - hydraulic ......................... 1 P400 ............. Plug ......................................................... 2 P600 ............. Plug ......................................................... 1 P601 ............. PCOR-Valve ............................................ 1 P700 ............. Special plug ............................................. 1 P800 ............. O-ring ...................................................... 1 T30 ............... Filter screen ............................................ 1 T40 ............... O-ring ...................................................... 1 T50 ............... Backup ring ............................................. 2 T60 ............... O-ring ...................................................... 1 T100 ............. Orifice plug .............................................. 1 Y40 ............... O-ring ...................................................... 1 Y50 ............... Backup ring ............................................. 2 Y60 ............... O-ring ...................................................... 1 Y70 ............... Orifice check valve .................................. 1 Y71 ............... Nut - Seal Lock ....................................... 1 Y72 ............... O-ring ...................................................... 1 Y80 ............... Plug ......................................................... 1 Y100 ............. Orifice plug .............................................. 1 Y102 ............. Orifice check valve .................................. 1

L8 ................. Key .......................................................... 1 L9 ................. Slotted nut ............................................... 1

Name Plate



90S055 NB 2 0 8 N 4 S1 W 01 NNN 01 00 24 Model No.

Model Number Serial Number

Model Code

Ident Nr

94 – 4002 A – 91 – 26 – 67890 Serial No. Fabr Nr MADE IN U.S.A.


Name Plate (U.S.A. Production) 87

008 911 63

BOMAG

615

17.1

Travel pump

Hydraulic Power Systems SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide SAUER-SUNDSTRAND is a world leader in the design and manufacture of Hydraulic Power Systems. Research and development resources in both North America and Europe enable SAUER-SUNDSTRAND to offer a wide range of design solutions utilizing hydraulic power system technology.

SAUER-SUNDSTRAND specializes in integrating a full range of system components to provide vehicle designers with the most advanced total-design system. SAUER-SUNDSTRAND is Your World Source for Controlled Hydraulic Power Systems F000 691

F000 692

Heavy Duty Axial Piston Pumps and Motors

Heavy Duty Bent Axis Variable Motors

Cartridge Motors/ Compact Wheel Drives

F000 685 F000 688

Medium Duty Axial Piston Pumps and Motors

F000 686

F000 690

Microcontrollers and Electrohydraulic Controls F000 717

F000 684

Hydrostatc Transmission Packages F000 693

F000 687

Open Circuit Axial Piston Pumps

Gear Pumps and Motors

Genuine Service Parts

Worldwide Service Support SAUER-SUNDSTRAND provides comprehensive worldwide service for its produkts through an extensive network of Authorized Service Centers strategically located in all parts of the world. Look to SAUER-SUNDSTRAND for the best in WORLDWIDE SERVICE.

Original Ersatzteile Genuine Parts

http://www.sauer-danfoss.com

SAUER-SUNDSTRAND COMPANY 2800 East 13th Street Ames IA 50010 U.S.A. Phone: (515) 239-6000 Fax: (515) 239-6618

SAUER-SUNDSTRAND GMBH & CO. Postfach 2460 D-24531 Neumünster Krokamp 35 D-24539 Neumünster Germany Phone: (04321) 871-0 Fax: (04321) 871 122

SM-SPV/SMF/SMV90-E • 10/98 • 300047G

616

BOMAG

008 911 63

17.2 Vibration pump

008 911 63

BOMAG

617

17.2

618

Vibration pump

BOMAG

008 911 63

17.2

Vibration pump

Series 42

Axial Piston Pumps Service Instructions

008 911 63

BOMAG

619

17.2

Vibration pump

Series 42

Introduction

1. Introduction 1.1

Using This Manual

The Adjustment and Minor Repair procedures detailed herein may be performed by trained personnel without voiding the unit warranty.

placed. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly. All gasket sealing surfaces must be cleaned prior to installing new gaskets.

Cleanliness is a primary means of assuring satisfactory transmission life. Cleaning parts by using a clean solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign materials and chemicals. When performing service activities, protect all exposed sealing surfaces and open cavities from damage and foreign material.

All exploded view drawings depict the 28cc frame size. For variances in the 41cc frame size, see the outline drawings in section 3. Differences in wrench size and torquing for the two frame sizes are noted in the text. Note that exterior housing screws are mostly Torx-type T30 or T45. These symbols are used within drawings: Apply petroleum jelly.

Whenever removing a service component, it is recommended that any gaskets and O-rings be re-

1.2

Lubricate with clean hydraulic oil.

Safety Precautions

Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury. The following general precautions should be taken into consideration whenever servicing a hydrostatic system.

Loss of Hydrostatic Braking Ability WARNING When Series 42 units are used in vehicular hydrostatic drive systems, the loss of hydrostatic drive line power in any mode of operation (e.g. acceleration, deceleration or “neutral” mode) may cause a loss of hydrostatic braking capacity. A braking system which is independent of the hydrostatic transmission must, therefore, be provided which is adequate to stop and hold the system should the condition develop.

Disable Work Function WARNING Certain service procedures may require the vehicle/machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing them in order to prevent injury to the technician and bystanders.

F000719

Fluid Under High Pressure WARNING Use caution when dealing with hydraulic fluid under pressure. Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury. This fluid may also be hot enough to burn. Serious infection or reactions can develop if proper medical treatment is not administered immediately.

Flammable Cleaning Solvents WARNING Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area where a source of ignition may be present.

Copyright 1996-1998, Sauer-Sundstrand GmbH & Co. All rights reserved. Contents subject to change. Printed in Germany.

2

620

BOMAG

008 911 63

17.2

Vibration pump

Series 42

Introduction

Contents 1. Introduction ................................................................................................................................ 2 1.1

Using This Manual................................................................................................................................. 2

1.2

Safety Precautions ................................................................................................................................ 2

2. Model Code ................................................................................................................................. 4 3. Component and Port Locations ............................................................................................... 5 3.1

Component Locations ........................................................................................................................... 5

3.2

Ports and Pressure Gauges .................................................................................................................. 6

4. Adjustment and Minor Repair Instructions ............................................................................. 8 4.1

Size and Torque for Plugs and Fittings .................................................................................................. 8

4.2

Pump “Neutral” Adjustment ................................................................................................................... 9

4.3

Control “Neutral” Adjustment for MDC/EDC Controls .......................................................................... 10

4.4

MDC Control Module ............................................................................................................................ 11

4.5

EDC Control Module ........................................................................................................................... 12

4.6

MDC/EDC Control Spool, Control Linkage, and Control Neutral Adjustment Screw ........................... 13

4.7

MDC Neutral Start/Backup Alarm Switch ............................................................................................ 14

4.8

MDC Solenoid Override Valve ............................................................................................................. 16

4.9

FNR, NFPE, and NFPH Controls ........................................................................................................ 17

4.10 System Check Relief Valves (High Pressure Relief, Charge Check, & Bypass Valves) ...................... 18 4.11 Charge Relief Valve ............................................................................................................................. 19 4.12 Loop Flushing Valve ............................................................................................................................ 21 4.13 Shaft Seal and Shaft Replacement ..................................................................................................... 22 4.14 Auxiliary Mounting Pads ...................................................................................................................... 24 4.15 Charge Pump ...................................................................................................................................... 25 4.16 Filtration .............................................................................................................................................. 28 4.17 Servo Piston Covers ........................................................................................................................... 29 4.18 Displacement Limiter Adjustment ........................................................................................................ 30

5. Exploded View Parts Drawings............................................................................................... 31 5.1

Shaft Options ...................................................................................................................................... 31

5.2

Filtration, Charge Relief, System Relief, and Loop Flushing ............................................................... 32

5.3

Charge Pump, Auxiliary Pads, and Servo Covers ............................................................................... 33

5.4

Control Options ................................................................................................................................... 34

3

008 911 63

BOMAG

621

17.2

Vibration pump

Series 42

Model Code

2. Model Code Refer to the model code exhibited on the unit's name plate for information regarding the configuration of the unit.

Ames, Iowa, U.S.A. Neumünster, Model Code Germany Typ 42L28 - C - ANN1 - 01

Note: Some options listed here may not currently be available. Some options on your unit may not be listed here. This is not an order code. See the Series 42 Price Book for up-to-date ordering information.

Model Code

ANA - 2CNB - NN - NN - N N - N - NNN - NNN Model No.

Ident Nr

428 2051 A 93 23 67890

Serial No.

Serial No.

Fabr Nr

X

XX

XX

XXXXX

Location

Year

Week

Sequence No. T000 022E

MADE IN U.S.A.

A

B

C

1 2 A B

D 1234

Series 1 Rotation 2 Displacement

C

D

E

F

G

123

12 34 E

L = CCW R = CW

F

28 = 28 cm3 (1.71 in3) 41 = 41 cm3 (2.50 in3)

1 Control Type

N A C E F G

= None = MDC, Linear, Low Force = MDC, Non-Linear, Low Force = EDC (Electric Displacmt Contrl) = FNR (3-Pos Forwrd-Neut-Revrs) = NFP (Non-Feedback Proport'l)

NSS for MDC or PCP for EDC 2 or Connector for FNR or Style for NFP

N = None or Not Applicable 1 = NSS / Weatherpack for MDC, or PCP Style for EDC or 12V Electric for NFP 2 = 12 V DIN for FNR 3 = NSS+BAS / CW Handle Rot. / Weatherpack for MDC or Hydraulic for NFP 5 = NSS+BAS / CCW Handle Rot. / Weatherpack for MDC

Handle for MDC 4 or Connector for EDC or Connector for NFP

K

L

N = None or Not Applicable A = 12V Override / Weather Pack, or EDC Input = 14-85 mA or 400 - 1200 mA or 5-20 bar for NFP E = 12V Override / Brake Port N = None or Not Applicable 1,6 = Standard Handle fpr MDC or M/S Connector for EDC or Amp Connector for NFP 2,5 = Clevis Handle for MDC or Weather Pack for EDC

Control Response Time 1 Port Style 2 Loop Flushing/Cooling

= 13T 16/32P Spline = 15T 16/32P Spline = 19T 16/32P Spline = 1.000 in. O.D. Straight Keyed = 1.000 in. O.D. Tapered (1.5 in/ft)

Solenoid Override with MDC 3 or EDC Input or Inching/Braking for NFP

J

42

C D E G K

Input Shaft Configurations

H

G

M

N

P

x1 = Fast x2 = Medium x3 = Slow A,J,P = SAE Threaded O-Ring Boss N = None 2,3 = Loop Flushing/Cooling Shuttle

3 Filtration

N A C G

1 Charge Pump

N = None 2 = 11 cm3/rev (0.67 in3/rev)

2 Charge Relief Setting

C = 14 bar (205 psi) F = 20 bar (280 psi)

3 Special Drive Features

N = None 1 = NFP

4 Rear Auxilliary Mounting Pad

N A B T

H

High Pressure Relief Setting Port "A"

J

High Pressure Relief Setting Port "B"

K

Loop Bypass Valve

L

Displacement Limiters - Side 1

M

Displacement Limiters - Side 2

NN 14 17 19 21 23 25 28 30 34 00

= None (Ext. Charge Supply) = Suction (No Adapter Plate) = Remote Pressure (Partial Flow) = Suction (Adapter Plate)

= None = SAE-A, 9 Tooth = SAE-B, 13 Tooth = SAE-A Special, 11 Tooth = Check Valve only, No HPRV = 140 bar (2030 psi) = 175 bar (2450 psi) = 190 bar (2755 psi) = 210 bar (3045 psi) = 230 bar (3330 psi) = 250 bar (3625 psi) = 280 bar (4060 psi) = 300 bar (4350 psi) = 345 bar (5000 psi) = No HPRV, No Check Valves

N = None B = Yes N, 0 = None A, 1 = Yes, Set at Max Disp

N

Special Hardware Features

NNN = None

P

Special Non-Hardware Features

NNN = None

4

622

BOMAG

008 911 63

17.2

Vibration pump

Series 42

Component and Port Locations

3. Component and Port Locations 3.1 Component Locations A pump with a manual displacement control (MDC) and no filtration adapter is shown. With non-feedback and automotive controls, the positions of the case drains vary (shown in gray). With a filtration adapter, the porting in the "Filtration Options" area varies (see section 4.16).

Control Neutral Adjustment (MDC/EDC)

Control Module (MDC Shown)

Pump Neutral Adjustment

Servo Piston Covers System Check Relief Valves

Displacement Limiters Charge Pump

Shaft Seal

Filtration Options (No Filtration Adapter Shown Here)

Auxiliary Mounting Pad

Charge Relief Valve

(Loop Flushing Valve) Left Side View (Side "2")

Right Side View (Side "1") P100101 E

Series 42 28cc Variable Pump Control Neutral Adjustment (MDC/EDC)

Control Module (MDC Shown)

Pump Neutral Adjustment

Servo Piston Covers Displacement Limiters

Charge Pump

Auxiliary Mounting Pad

System Check Relief Valves

Shaft Seal

Charge Relief Valve

(Loop Flushing Valve) Left Side View (Side "2")

Filtration Options (No Filtration Adapter Shown Here)


Series 42 41cc Variable Pump

5

008 911 63

BOMAG

623

17.2

Vibration pump

Series 42 3.2


Ports and Pressure Gauges

Proper servicing of pumps and motors requires that pressure be measured and monitored at various points in the hydraulic circuit. The Series 42 pump has several locations at which to take these measure-

Gauge Port Name

Pressure Measured

ments. The following outlines show the locations of the various gauge ports. The tables show the recommended gauge size and the fitting size for each port. Refer to this page when installing pressure gauges.

Fitting

Recommended Gauge Size

028

041

System Pressure for Ports A and B

600 bar or 10 000 psi

9/16-18 O-Ring Fitting


Charge Pressure

60 bar or 1000 psi



M4 & M5

Servo Pressure

60 bar or 1000 psi



L1 & L2

Case Pressure

35 bar or 500 psi

1-1/16-12 O-Ring Fitting


Charge Pump Inlet Vacuum

1 bar, absolute or 30 in Hg Vacuum



M1 & M2 M3

S

T000 025E


Servo Pressure Gauge Port M5 Servo Pressure Gauge Port M4


Charge Pressure Gauge Port M3 (Charge Pressure Supply For No Charge Pump Option)

Case Drain Port L2 (Non-Feedback Controls)

System Pressure Port A

Case Drain Port L1 Case Drain Port L1 (Non-Feedback Controls)

Charge Pump Inlet Port S

Case Drain Port L2

System Pressure Gauge Port M1 Left Side View (Side "2")


28cc Base Unit with MDC and No Filtration Adapter

6

624

BOMAG

008 911 63

17.2

Vibration pump

Series 42


Servo Pressure Gauge Port M5 Servo Pressure Gauge Port M4



Charge Pressure Gauge Port M3 (Charge Pressure Supply For No Charge Pump Option)

Case Drain Port L2

System Pressure Port A Charge Pump Inlet Port S

Case Drain Port L1 System Pressure Gauge Port M1 Left Side View (Side "2")

Right Side View (Side "1")

P100104 E

41cc Base Unit with MDC and No Filtration Adapter

To Filter, Port D (Pressure Filtration)

Charge Pressure Gauge Port M3 (Full Flow Pressure Filtration)

From Filter, Port E (Pressure Filtration) Charge Pressure Gauge Port M3 (Partial Flow Pressure Filtration)

Charge Pressure Gauge Port M3 (Suction Filtration) P100105 E

Filtration Adapter (28cc and 41cc Models)

7

008 911 63

BOMAG

625

17.2

Vibration pump

Series 42

Adjustments and Minor Repairs

4. Adjustment and Minor Repair Instructions 4.1

Size and Torque for Plugs and Fittings

Plug and fitting sizes are given here. Place a fresh O-ring, lightly lubricated with petroleum jelly, whenever a plug is removed. Each should be torqued as indicated. A 28cc unit with manual displacement control (MDC) is shown.

Servo Gage Port M4

11/16 in Hex 27-47 Nm (20-35 ft lbf)

28cc: 9/16 in Int. Hex 95-135 Nm (70-100 ft lbf) 41cc: 5/8 in Int. Hex 125-250 Nm (90-190 ft lbf)

Case Drain Port L1 Charge Pressure Gage Port M3 (Position Varies, Refer to Filtration Options)

Charge Pump Inlet Port S Torque: 115 Nm (85 ft lbf)

Case Drain Port L2 Port N (Unused)

11/16 in Hex 27-47 Nm (20-35 ft lbf) Servo Gage Port M5

System Gage Ports M1 and M2

11/16 in Hex 27-47 Nm (20-35 ft lbf) 28cc: 9/16 in Int. Hex 95-135 Nm (70-100 ft lbf) 41cc: 5/8 in Int. Hex 125-250 Nm (90-190 ft lbf)

System Ports A and B 115 Nm (85 ft lbf)

11/16 in Hex 27-47 Nm (20-35 ft lbf) E100001 E

8

626

BOMAG

008 911 63

17.2

Vibration pump

Series 42 4.2


Pump “Neutral” Adjustment

The pump neutral adjustment sets the position of the servo piston and pump swashplate relative to the controlling mechanism. WARNING The following procedure requires the vehicle / machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. 1. Disconnect machine function. 2. Connect a hose between gauge ports M4 and M5 to equalize the pressures on both ends of the pump servo piston.

Pump "Neutral" Adjustment Screw

Pump "Neutral" Adjustment Seal Lock Nut

3. Install pressure gauges in gauge ports M1 and M2 to measure system pressure. 4. Start the prime mover and operate at normal speed. 5. Loosen the pump "neutral" adjustment seal lock nut [28cc 13 mm Hex; 41cc 17 mm Hex]. Turn the pump "neutral" adjustment screw [28cc 5 mm Hex; 41cc 7 mm Hex] until the system pressure gauge readings are equal.

E100002 E

Pump Neutral Adjustment Screw (MDC Control Shown)

6. Turn the adjustment screw clockwise until one of the gauges registers an increase in system pressure. Note the position of the adjustment screw. Turn the screw counterclockwise until the other gauge registers an increase in system pressure. Note the position of the adjustment screw. 7. Turn the adjustment screw clockwise to a position halfway between the positions noted above. The system pressure gauges should indicate equal pressures. 8. While holding the adjustment screw in position, torque the seal lock nut [28cc 20-26 Nm (15-19 ft lbf); 41cc 28-51 Nm (21-37 ft lbf)] . 9. Stop the prime mover and remove the hose between gauge ports M4 and M5. Remove the pressure gauges installed in gauge ports M1 and M2. Reinstall the plugs in the gauge ports. 10. Reconnect work function. IMPORTANT If the pump is equipped with an MDC or EDC, the CONTROL "neutral" adjustment MUST also be performed before putting the pump into service (see next section). 9

008 911 63

BOMAG

627

17.2

Vibration pump

Series 42 4.3


Control “Neutral” Adjustment for MDC/EDC Controls

The control neutral adjustment aligns the pump swashplate and the control spool so that a zero angle control setting provides a zero degree swashplate setting. This adjustment should be performed whenever any part of the control or swashplate mechanisms is adjusted or removed or after the pump neutral setting (previous section) is adjusted.

MDC / EDC Control "Neutral" Adjustment Screw

WARNING The following procedure requires the vehicle / machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. 1. Disconnect the work function. Disconnect the external control linkage (for MDC) or control signal input (for EDC) from the pump. 2. Install pressure gauges in gauge ports M4 and M5 to measure pressure on the pump servo piston. 3. Start the prime mover and operate at normal speed.

MDC / EDC Control "Neutral" Adjustment Seal Lock Nut E100003 E

Control Neutral Adjustment Screw (EDC Control Shown)

4. Loosen the CONTROL "neutral" adjustment seal lock nut (see drawing) [17 mm Hex] . Turn the control "neutral" adjustment screw [5 mm Int. Hex] until the servo piston pressure gauge readings are as close to equal as possible. 5. Turn the adjustment screw clockwise until one of the gauges registers an increase in pressure on the servo piston. Note the position of the adjustment screw. Turn the screw counterclockwise until the other gauge registers an increase in pressure on the servo piston. Note the position of the adjustment screw. 6. Turn the adjustment screw clockwise to a position halfway between the positions noted above. The servo piston pressure gauges should indicate nearly equal pressures. 7. While holding the adjustment screw in position, torque the seal lock nut [14-24 Nm (10-18 ft lbf)]. 8. Stop the prime mover and remove the pressure gauges installed in gauge ports M4 and M5. Reinstall the plugs in the gauge ports. 9. Reconnect the external control linkage (for MDC) or control signal input (for EDC) to the pump. Reconnect the work function. 10

628

BOMAG

008 911 63

17.2

Vibration pump

Series 42 4.4


MDC Control Module

The manual displacement control (MDC) module provides control of the pump servo piston through a connection to the summing link pin within the pump housing. The following procedure shows how to remove and install the control housing. Section 4.6 explains how to remove and install the control spool and linkage. 1. Clean the external surfaces of the pump. If necessary, remove the MDC handle. 2. Remove the seven (7) control retaining screws [Torx T30] that secure the control to the pump housing. Remove the control and control gasket from the pump.

Plug for Visual Inspection

Nut Lock Washer MDC Handle

Control Retaining Screws Control Gasket Hold summing link (and control spool) in position

Note: See section 4.6 for instructions on removing/installing the control spool and linkage. 3. Clean the sealing surfaces of the control and the pump housing. Place a new gasket in position on the housing. CAUTION The control orifices are part of the control gasket. Refer to the appropriate Service Parts List to determine the correct gasket. 4. Hold the summing link pin in position while installing the control. (The spring on the control spool will tend to push the link to an extreme position.) The link pin MUST engage the slot in the control cam. A plug is provided on the MDC housing to permit visual inspection of linkage pin engagement. Note: It may be easiest to lay the servo piston side of the control down first, then watch the link pin engage from the charge pump side of the pump.

E100004 E

MDC Control Module Assembly

Summing link pin MUST enter the slot in the control cam! E100005 E

Link Pin Into Cam Slot

5. Install and torque the control screws [15-17 Nm (11-13 ft lbf)]. Perform Control Neutral Adjustment (Section 4.3). WARNING Failure to properly engage the link pin with the control cam will result in incorrect control operation, which may lead to loss of control of the vehicle / machine.

Link Pin Into Cam Slot

F100201

11

008 911 63

BOMAG

629

17.2

Vibration pump

Series 42 4.5


EDC Control Module

The Electric Displacement Control (EDC) provides a control function through connections to the summing link pin within the pump housing. The following procedure shows how to remove and install the control housings. The next section explains how to remove and install the control spool and linkage. 1. Clean the external surfaces of the pump. If necessary, remove control input signal.

EDC Control Pressure Gauge Port X1

2. Remove the seven (7) control retaining screws [Torx T30] that secure the control to the pump housing. Note the position of the different length screws. Remove the control and control gasket from the pump. Note: See next section for instructions on removing/installing the control spool and linkage.

EDC Control Pressure Gauge Port X2

3. Clean the sealing surfaces of the control and the pump housing. Place a new gasket in position on the housing.

P100106 E

EDC Module Showing Port Locations

CAUTION The control orifices are part of the control gasket. Refer to the appropriate Service Parts List to determine the correct gasket.

Control Retaining Screws (note different sizes)

4. Hold the summing link pin in position while installing the control. (The spring on the control spool will tend to push the link to an extreme position.) The link pin MUST engage the hole in the control piston fork. Note: It may be easiest to lay the servo piston side of the control down first, then watch the link pin engage from the charge pump side of the pump. 5. Install and torque the control screws [15-17 Nm (11-13 ft lbf)]. Perform Control Neutral Adjustment (Section 4.3).

Control Gasket Hold summing link (and control spool) in position

WARNING Failure to properly engage the link pin with control piston fork will result in incorrect control operation, which may lead to loss of control of the vehicle / machine.

Summing link pin MUST enter the hole in the control piston fork!

E100006 E

EDC Control Module Assembly

12

630

BOMAG

008 911 63

17.2

Vibration pump

Series 42 4.6


MDC/EDC Control Spool, Control Linkage, and Control Neutral Adjustment Screw

The control spool, control linkage, and control neutral adjustment screw can be removed for cleaning and to change the O-rings or the seal lock nut.

Summing Link Linkage Pivot Screw

Removal of Spool, Linkage, and Adjustment Screw 1. Clean the external surfaces of the pump.

Neutral Adjustment Link

2. Remove the MDC or EDC module and the control gasket from the pump housing (see previous two sections).

Feedback Link

Control Neutral Adjust Screw

Opposite Bore Plug Seal Lock Nut Control Spool and Spring Note orientation!

3. Remove the summing link. 4. Remove the control spool bore plug [5/16 in Int. Hex] or screws [Torx T30], cover, and gasket. Remove the opposite bore plug [5/16 in Int. Hex], and remove the control spool and spring.

Housing without Filtration Adapter

5. Remove the linkage pivot screw [4 mm Int. Hex], feedback link, and neutral adjustment link.

Control Spool Bore Plug

6. Remove the seal lock nut [17 mm Hex] and the control neutral adjustment screw [5 mm Int. Hex]. Installation of Spool, Linkage, and Adjustment Screw 1. Install the control neutral adjustment screw and seal lock nut. Do not tighten the nut.

Housing with Filtration Adapter

Gasket

2. Assemble the "neutral" adjustment link and feedback link, and install as shown. Install and torque the linkage pivot screw [8-15 Nm (6-11 ft lbf)].

Control Spool Bore Cover

3. Lubricate and install the control spool and spring assembly noting proper orientation. WARNING The control spool and spring assembly MUST be oriented in the housing as shown for proper control operation. 4. Install and torque the control spool bore plug [4194 Nm (30-70 ft lbf)]. Or install the control spool cover (with a new gasket) or plug, and torque the screws [15-17 Nm (11-13 ft lbf)]. 5. Install the summing link. Hold the control spool in position while engaging the fork on the summing link with the flats on the spool. If necessary, rotate the spool to engage the summing link.

E100007 E

MDC/EDC Control Spool and Linkage

Feedback link must enter slot in servo piston Pivot screw

Slot in "neutral" adjust link must engage groove in adjusting screw

Fork on summing link must engage flats on control spool E100008 E

Servo Piston Linkage and Control Spool (Internal Parts Shown with Housing Removed)

6. Install a new control gasket. Hold the summing link and control spool in position while reinstalling the MDC or EDC (see section 4.4 or 4.5). Perform Control Neutral Adjustment (section 4.3). 13

008 911 63

BOMAG

631

17.2

Vibration pump

Series 42 4.7


MDC Neutral Start/Backup Alarm Switch

The Neutral Start Switch (NSS) prevents the engine and pump from being started when the pump is out of neutral. The NSS should be wired in series with the engine starting circuit. The switch contact is closed at the control handle's neutral position and opens when the control handle is rotated 1.5 to 2° from neutral.

NSS Cover NSS Control Nut NSS Cam

The Backup Alarm Switch (BUA) outputs an electronic signal when the control handle is in a reverse position. This switch is normally wired in series with an audio output. The switch contact is open until the control handle is rotated 2.6 to 3.75° in the reverse direction.

NSS Cavity

NSS with Weatherpack

CAUTION The control handle's neutral position must agree with the pump's neutral position for the NSS/BUA to work effectively (see section 4.3).

NSS with Screw Terminals E100009 E

The Neutral Start / Backup Alarm Switch assembly can be configured for three different settings. i.

NSS Assembly on MDC

A Neutral Start Switch only.

ii. A Neutral Start Switch with Backup Alarm for units where clockwise (CW) handle rotation results in "reverse" motion. iii. A Neutral Start Switch with Backup Alarm for units where counterclockwise (CCW) handle rotation results in "reverse" motion. The setting must be in accordance with the configuration of the unit. See the model code (section 2) if uncertain of the type of NSS you have. Alignment of the NSS requires a special alignment tool. Dimensions are given at right.

Control Cam

Yolk

NSS only

NSS with BUA (CW = Reverse)

NSS with BUA (CCW = Reverse) P100107 E

Top View of NSS Showing Cam Positions

(continued)

9/16 -18UNF 2A THD .04 x 45 Chamfer

R.125

ø .236–.030 Knurl

35.0 1.250 .306

.354 2.000 Material: .75 DIA x 3 ETD150 (All Dimensions in inches)

P100108 E

Alignment Tool

14

632

BOMAG

008 911 63

17.2

Vibration pump

Series 42


Adjustment is performed by setting the cam position within the NSS assembly. 1. The MDC module must be removed from the pump housing. Refer to section 4.4.

NSS Cover

NSS

NSS Control Nut

2. Remove NSS [7/8 in Hex].

NSS Cam

3. Remove the NSS cover by inserting a screwdriver into the NSS cavity and popping off the cover with a hammer. Be careful not to damage the internal hardware. P100109 E

Side View of NSS and NSS Cavity

4. Remove the control nut [8 mm Hex]. 5. Use a screwdriver to pop off the cam. 6. Set cam in proper orientation according to the unit's configuration (i, ii, or iii above). 7. Screw special alignment tool in NSS cavity to hold cam in place. 8. On the underside of the MDC module, clamp a pair of locking pliers around the spring contacts of the control cam. The pliers should hold the nub on the control cam to the pin underneath. This will hold the control cam in neutral position. 9. Screw control nut on cam [4.1-6.8 Nm (3-5 ft lbf)]. 10. Press new cover on top of cam cavity. This requires either an arbor press or a full-sized punch (punch depth = 1.06 mm (0.0417 in), punch width = 23.3 mm (0.916 in)).

F100202

11. Remove the alignment tool and the locking pliers.

Underside of MDC Module Showing Where to Clamp Locking Pliers

12. Place a new lubricated O-ring on NSS. 13. Reconnect the NSS [25-29 Nm (18-22 ft lbf)] to the MDC. 14. Reinstall MDC module onto pump housing (refer to section 4.4).

15

008 911 63

BOMAG

633

17.2

Vibration pump

Series 42 4.8


MDC Solenoid Override Valve

The solenoid override valve is a safety feature that connects both ends of the servo control piston together when the solenoid is de-energized. Thus the pump can be put into stroke only when the solenoid is energized.

Port L4 Port X7

The solenoid override with brake release includes hydraulic control of a safety brake. When de-energized, a spring-applied, hydraulically-released brake is drained through port X7. For conditions where case back-pressure on the spring-applied brake is critical, an external drain to the reservoir can be connected through port L4. The solenoid override valve can be removed to inspect and remove foreign matter. Removal 1. Remove retaining nut [9/16 in Hex].

Solenoid Override Valve Assembly

E100010 E

Solenoid Override Valve Assembly

2. Remove solenoid housing. 3. Remove retaining ring at base of solenoid.

Retaining Nut

4. Remove solenoid. This should be connected to internal spool.

Solenoid Housing

Installation 1. Replace O-ring.

Washer Retaining Ring

2. Place spring and plunger inside of solenoid.

Solenoid

3. Attach spool (male notch) to plunger (female notch). 4. Insert solenoid/spool assembly in solenoid override bore.

O-Ring Spring Plunger

5. Snap retaining ring over base of solenoid. Spool

6. Place washer at base of solenoid. 7. Install housing and retaining nut [2-4 Nm (1.5-3.5 ft lbf)].

E100011 E

Exploded View of Solenoid Override Assembly

16

634

BOMAG

008 911 63

17.2

Vibration pump

Series 42 4.9


FNR, NFPE, and NFPH Controls

The 3-position FNR control and the electric and hydraulic non-feedback proportional (NFPE and NFPH) controls are non-feedback type controls. The FNR and NFPE controls consist of modules mounted on the pump housing. The hydraulic input for NFPH is received through ports on the top of the pump [9/16–18 SAE O-ring fitting].

NFPH Ports (Ports X1 and X2)

The non-feedback controls are set at the factory. The control modules can be removed to clean the ports and change the O-rings. The orifice plugs for the FNR and NFPE are located inside the servo piston covers. The orifice plugs for the NFPH are located in the NFPH ports. Orifice plugs may be cleaned or replaced.

E100012 E

Position of NFPH Ports

Note: Future models may contain orifice plate between module and pump housing.

Control Solenoid Control Module

Removal and Installation of FNR and NFPE Modules 1. Clean pump and module housings. 2. Remove four (4) screws retaining module to housing [4 mm Int. Hex], and remove module from pump housing.

Control Ports Locator Pin

3. Remove O-rings from the control ports. Examine ports for cleanliness. 4. Clean sealing surfaces. 5. Replace locator pin. 6. Install new O-rings. 7. Replace screws [4.7-6.1 Nm (3.5-4.5 ft lbf]. E100013 E

Removal and Installation of FNR and NFPE Control Orifices Note: Future models may contain an orifice plate between module and pump housing. This will take the place of the orifice plugs beneath the servo piston cover.

NFPE Assembly (FNR Similar) Non-Feedback Control Orifice

1. Remove servo piston cover (see section 4.17). 2. Remove orifice plug [1/8 in Int. Hex]. 3. Examine orifice and port for cleanliness. 4. Install orifice plug [2.0-3.4 Nm (1.5-2.5 ft lbf)].

E100014 E

Location of Non-Feedback Control Orifice

17

008 911 63

BOMAG

635

17.2

Vibration pump

Series 42


4.10 System Check Relief Valves (High Pressure Relief, Charge Check, & Bypass Valves) The charge check, high pressure relief, and the loop bypass functions are all contained within the system check relief (SCR) valve assembly. This assembly may be removed for cleaning and installation of fresh O-rings. The model code specifies whether high pressure relief valves, combination charge check/ high pressure relief valves, and/or loop bypass valves are present or not.

With Bypass Without Bypass Valve Seat Plug

1. Remove the valve seat plugs [9 mm Int. Hex] or valve seat/bypass plugs [1 in Hex] from the pump housing.

Outer O-Ring Backup Ring

2. Remove the check poppet or relief valve assemblies from the pump housing. The smaller end of each conical spring is crimped to retain it on the check poppet or relief valve. Do not remove.

Inner O-Ring

Valve Seat Retaining Ring Standard Bypass Plunger O-Ring Valve Seat Plug Outer O-Ring Backup Ring Inner O-Ring

3. Inspect the valves and mating seats in the special plugs for damage or foreign material. CAUTION The relief valves are factory set and should not be tampered with, except for replacing the entire valve. 4. The O-ring on the standard bypass plunger may be replaced by removing the retaining ring and removing the plunger from the special valve seat plug. Remove the O-ring from the plunger and install a new O-ring. Reinstall the plunger and retaining ring.

Check Poppet or High Pressure Relief Valve Conical Spring

5. Install a new outer O-ring, new backup ring, and new inner O-ring on each valve seat plug. 6. Check that the conical springs are properly retained on the check poppets or relief valves. Install the check poppet or high pressure relief valve assemblies into the pump housing . CAUTION The conical springs MUST be correctly positioned on the check poppets or relief valves after installation for proper pump operation.

E100015 E

System Check Relief Valve Components

7. Install the valve seat plugs or valve seat/bypass plugs into the pump housing and torque [40-95 Nm (30-70 ft lbf)].

18

636

BOMAG

008 911 63

17.2

Vibration pump

Series 42


4.11 Charge Relief Valve The charge relief valve may be removed for cleaning and installation of fresh O-rings. The pressure setting may be changed. However, note that the setting will vary for different charge flows which depends on charge pump size and pump speed. The factory setting is set relative to case pressure at 1800 rpm. The actual charge pressure will vary at different speeds. Shim Adjustable Style 1. Remove the shim adjustable charge relief valve plug [1 in Hex] from the pump housing. Remove the O-ring from the plug.

Shim Adjustable Charge Relief Valve Plug O-Ring Shims

2. Remove the spring and poppet from the housing.

Spring Poppet

3. Do not alter the shims which may be installed between the spring and valve plug, or interchange parts with another valve. Inspect the poppet and mating seat in the housing for damage or foreign material. 4. If desired, the charge relief valve setting can be changed. An approximate rule of thumb is 4 bar / 1.25 mm (58 psi / 0.050 in). The effective setting will vary. To confirm the charge relief valve setting, measure charge pressure (port M3) with the pump in stroke. The charge pressure should level off when the relief setting is reached. 5. Install a new O-ring on the valve plug. Reinstall the poppet, spring, and plug (with shims and Oring) into the pump housing [55-135 Nm (40-100 ft lbf)].

E100016 E

Shim Adjustable Charge Relief Valve Components

Approximate Relief Setting vs Shim Thickness 4 bar / 1.25 mm

(58 psi / 0.050 in) T000 023E

(continued)

19

008 911 63

BOMAG

637

17.2

Vibration pump

Series 42


Screw Adjustable Style

Charge Relief Lock Nut

1. Before removing the screw adjustable relief valve plug, mark the plug, lock nut, and housing so as to approximately maintain the original adjustment when assembling, Remove the screw adjustable charge relief valve plug by loosening the lock nut [1-1/16 in Hex] and unscrewing the plug [8 mm Int. Hex]. Remove the O-ring from the plug.

O-Ring Screw Adjustable Charge Relief Valve Plug Spring Poppet

2. Remove the spring and poppet from the housing. 3. Inspect the poppet and mating seat in the housing for damage or foreign material. 4. Install a new O-ring on the valve plug. Reinstall the poppet and spring. Reinstall the plug with its lock nut [47-57 Nm (34-42 ft lbf)], aligning the marks made at disassembly.

E100017 E

Screw Adjustable Charge Relief Valve Components

5. Check and adjust, if necessary, the charge pressure. For screw adjustable "anti-stall" charge relief valves, an approximate rule of thumb is 2.8 bar / quarter turn (40 psi / quarter turn). To confirm the charge relief valve setting, measure charge pressure (port M3) with the pump in stroke. The charge pressure should level off when the relief setting is reached.

Approximate Relief Setting vs Screw Revolution 2.8 bar / 1⁄4 turn

(40 psi / 1⁄4 turn) T000 024E

20

638

BOMAG

008 911 63

17.2

Vibration pump

Series 42


4.12 Loop Flushing Valve The loop flushing function consists of the loop flushing shuttle valve and the loop flushing relief valve. The assemblies may be removed for cleaning and installation of new O-rings. The relief valve poppet may be exchanged for one with a different flow rating, but the relief valve shims should not be changed out unless specifically instructed so by Sauer-Sundstrand. The function also can be defeated.

Loop Flushing Relief Plug Loop Flushing Relief Plug (Defeat) O-Ring

O-Ring Shims Spring Poppet

Loop Flushing Valve 1. Remove the loop flushing valve plug from the pump housing [11/16 in Hex]. Remove the O-ring from the plug. 2. Remove the loop flushing valve spool assembly from the housing. 3. Inspect the parts for damage or foreign material. The centering spring must be securely retained to the spool by the washer.

Loop Flushing Plug (Defeat) O-Ring Defeat Spool

Loop Flushing Plug O-Ring Loop Flushing Spool Assembly

4. Install the loop flushing valve spool assembly into its bore. Install a new O-ring on the loop flushing plug and install [27-47 Nm (20-35 ft lbf)]. Loop Flushing Relief Valve 1. Remove the loop flushing relief valve internal hex plug [5/8 in Hex] from the pump housing. Remove the O-ring from the plug. 2. Remove the spring and poppet from the housing. 3. Do not alter the shims which are installed between the spring and valve plug, or interchange parts with another valve. Inspect the poppet and mating seat in the housing for damage or foreign material. Inspect the orifice in the valve poppet. 4. Install a new O-ring on the valve plug. Reinstall the poppet, spring, shims, and plug (with O-ring) into the pump housing [15-34 Nm (15-25 ft lbf)].

E100018 E

Loop Flushing Valve and Loop Flushing Defeat Components

Defeating Loop Flushing 1. Remove the loop flushing valve from the pump housing. 2. Install the defeat spool into the spool bore in the housing. Install the plain plug with O-ring into the housing [11/16 in Hex], and torque [27-47 Nm (20-35 ft lbf)]. 3. Remove the charge relief valve (these parts are not necessary). 4. Install the plain hex plug with O-ring into the end cap [5/8 in Hex], and torque [15-34 Nm (15-25 ft lbf)]. 21

008 911 63

BOMAG

639

17.2

Vibration pump

Series 42


4.13 Shaft Seal and Shaft Replacement A lip type shaft seal is used in Series 42 pumps. This seal and/or the shaft can be replaced without major disassembly of the unit. Replacement generally requires removal of the pump from the machine.

Retaining Ring Seal Carrier Assembly

1. Position the pump with the shaft facing up. NOTE: If the unit is positioned horizontally when the shaft is removed, the cylinder block could move out of place, making shaft installation difficult. 2. Remove the retaining ring from the housing. 3. Pull out seal carrier assembly. 4. Remove the O-ring from the seal carrier. To install a new shaft only, proceed to step 8. 5. Place the seal carrier in an arbor press with the shaft bearing side down, and press out the old seal. An appropriately sized pipe spacer or socket wrench can be used as a press tool. Once removed, the seal is not reusable. 6. Inspect the seal carrier and the new seal for damage. Inspect the sealing area on the shaft for rust, wear, or contamination. Polish the sealing area on the shaft if necessary. 7. Press the new seal into the shaft bearing side of the seal carrier. The seal lip must face the outside of the pump. Be careful not to damage the seal. The outside diameter of the seal may be coated with a sealant (e.g. Loctite High Performance Sealant #59231) prior to installation. This aids in preventing leaks caused by damage to the seal bore in the seal carrier.

E100019 E

Shaft Seal Components

O-Ring

Seal

Sealant may be used on outside diameter

Seal Carrier

Inside Lip (face down)

(continued)

Press Seal to bottom of Seal Carrier E100020 E

Installation of Shaft Seal

22

640

BOMAG

008 911 63

17.2

Vibration pump

Series 42


If the shaft is not being replaced proceed to step 11.

Retaining Ring

8. Remove the shaft and roller bearing assembly from the pump or motor. The bearing assembly can be transferred to the new shaft (steps 9 and 10).

Roller Bearing

9. Remove the retaining ring that secures roller bearing assembly with a snap ring plier. Remove the roller bearing assembly. 10. Place roller bearing assembly on new shaft and secure with the retaining ring.

Key

Shaft OR

Shaft Assembly OR

11. Wrap the spline or key end of shaft with thin plastic to prevent damage to the seal lip during installation. Lubricate the inside diameter of the shaft seal with petroleum jelly. 12. Place the O-ring onto the shaft bearing and lubricate with petroleum jelly. 13. Slide the seal carrier assembly over the shaft and into the housing bore. Press against O-ring. Hold inward pressure against the shaft to compress the cylinder block spring while pressing the seal carrier into place. 14. Install the retaining ring.

E100021 E

Shaft Components

23

008 911 63

BOMAG

641

17.2

Vibration pump

Series 42


4.14 Auxiliary Mounting Pads The following procedure can be used to remove and install a new auxiliary mounting pad or to install a fresh O-ring for the current auxiliary mounting pad. Several auxiliary mounting pads are available. Auxiliary mounting pads are integrated into the charge pump cover. When nothing is mounted on the pads, a flange cover is attached to protect the mounting flange. This cover is removed when mounting a pump. Removal of Auxiliary Mounting Pad 1. Remove the auxiliary pump or remove the two screws retaining the flange cover ["A" Pad 9/16 in Hex; "B" Pad 3/4 in Hex]. Remove the O-ring.

Pad Cover Screws Charge Pump Cover

Aux Mount Pad Cover Retaining Screws O-Ring

2. Orient pump so that charge pump cover (auxiliary pad) is facing up.

OR

3. Remove the charge pump cover. The auxiliary pad is integrated into the charge pump cover. Use a Torx T45 male driver to remove the screws. Note: If a different auxiliary pad is being installed, then a new drive coupling must be installed. To do this follow the instructions in the section on removing and installing the charge pump (next section). Note: If the charge pump components come out with the charge pump cover refer to section 4.15 on how to properly reinstall them. 4. Install a new charge pump cover gasket.

OR

Auxiliary Mounting Pad "A" Gasket

Auxiliary Mounting Pad "B" No Charge Pump Defeat

Locating Pin 1 Charge Pump Components

5. Install the charge pump cover (auxiliary pump mounting pad is integrated in cover). NOTE: The threaded screw holes in the auxiliary pump mounting pad used on very early production pumps with the SAE "A" pad option are drilled through into the area between the gerotor cover and charge pump cover. Any of these holes which are not used to attach the flange cover or auxiliary pump should be plugged with internal hex set screws installed hand tight to prevent the entrance of water or dirt into this area.

Locating Pin 2

E100022 E

Auxiliary Pad Options and Components

6. Attach the auxiliary pump. If no pump is to be attached on an auxiliary mounting pad, the pad should be protected with a flange cover and Oring to prevent leakage.

24

642

BOMAG

008 911 63

17.2

Vibration pump

Series 42


4.15 Charge Pump

(Screw used with "No Pad" and "A Pad" Only) Cover Retaining Screws

1. Remove auxiliary pump, if necessary.

Charge Pump Cover or Auxiliary Pad

Note: For units without integral charge pumps see the last page of this section for additional information.

2. Remove the screws retaining the charge pump cover to the pump housing [Torx T45] (seven (7) screws are used with the "no pad" or SAE "A" auxiliary mounting pad charge pump cover, while six (6) screws are used with the SAE "B" auxiliary mounting pad charge pump cover). Remove the charge pump cover, gasket, and the cover locating pins. 3. Remove the gerotor cover assembly from the charge pump cover or the back of the pump housing. Remove the gerotor cover O-rings. Two (2) O-rings are used on the gerotor cover of all pumps. (An additional O-ring was used on the gerotor cover of very early production pumps with the SAE "A" pad option.)

Gasket O-Rings

Geroter Cover

4. Remove the gerotor assembly from the gerotor cover or pump housing. 5. Remove the gerotor drive pin and drive coupling. Remove the gerotor cover locating pin from the pump housing. 6. Each part should be inspected separately if they are to be reused. If either of the gerotor assembly parts needs to be replaced, they must both be replaced. Always replace the O-rings and charge pump cover gasket. Inspect the journal bearing in the gerotor cover for excessive wear.

Geroter Assembly Drive Coupling Geroter Cover Locating Pin Charge Pump Cover Locating Pin

Geroter Drive Pin Charge Pump Cover Locating Pin

Charge Pump Components

The charge pump may be disassembled to inspect and clean, or to change the auxiliary shaft drive coupling.

7. Prior to assembly, lubricate the gerotor assembly with clean hydraulic oil. 8. Install the gerotor drive pin into the hole in the drive coupling, and retain with grease or petroleum jelly. 9. Install the drive coupling onto the pump shaft with the smaller outside diameter oriented away from the pump shaft. Different couplings are used with the different auxiliary pad options.

E100023 E

Charge Pump Components

10. Install the gerotor assembly onto the coupling. (continued)

25

008 911 63

BOMAG

643

17.2

Vibration pump

Series 42


11. Install the gerotor cover locating pin into the pump housing. Install the gerotor cover assembly over the gerotor. The locating pin must engage the slot in the gerotor cover. NOTE: The charge pump rotation is determined by the location of the gerotor recess and pressure balance hole in the gerotor cover. Different gerotor covers are used for clockwise and counterclockwise rotation pumps. 12. Install new pressure balance O-rings onto the gerotor cover and retain with petroleum jelly or grease. (An additional O-ring was used on the gerotor cover of very early production pumps with the SAE "A" pad option.) 13. Install the charge pump cover locating pins and a new charge pump cover gasket. 14. Install the charge pump cover. The cover must engage the gerotor cover and the locating pins. Install the charge pump cover screws and torque evenly [36-43 Nm (26-32 ft lbf)]. 15. If necessary, reinstall auxiliary pump.

CW

CCW P100110 E

Determining Charge Pump Orientation Looking Inside of Gerotor Pump Cover

For units without an integral charge pump see the next section. (continued)

26

644

BOMAG

008 911 63

17.2

Vibration pump

Series 42


Units without Integral Charge Pump Variable Pumps without an integral charge pump do not have a gerotor assembly, gerotor drive pin, or gerotor cover locating pin installed. The charge pump inlet port is plugged with an O-ring plug.

Cover Retaining Screws

For these units that are equipped with housings without filtration adapters, the gerotor cavity outlet is plugged with a special plug installed in a housing passage. The 3/4—16 charge inlet fitting should be torqued to 68 Nm (50 ft lbf). For these units that are equipped with housings that include filtration adapters, the gerotor cavity outlet is plugged with an O-ring plug installed in the "To Filter" port of a "Full Filter Flow" (charge relief valve after filter) filter adapter. The 7/8—14 charge inlet fitting should be torqued to 95 Nm (70 ft lbf).

Gasket

Charge Pump Cover or Auxiliary Pad

(Screw used with "No Pad" and "A Pad" Only)

CAUTION A "Partial Filter Flow" (charge relief valve before filter) adapter must not be used on variable pumps without an integral charge pump. If this design adapter is used, the charge relief valve will be defeated.

Geroter Cover Drive Coupling Charge Pump Cover Locating Pin 2

Geroter Cavity Outlet Plug (Charge Pump Defeat)

Charge Pump Cover Locating Pin 1

"No Charge Pump" Components

O-Rings

Charge Inlet

Charge Pump Inlet Plug

Charge Pump Inlet Plug

Charge Inlet (For Wrench Sizes and Torquing See Filtration Section) E100024 E

No Charge Pump Option Components (Housing with Filtration Adapter)

No Charge Pump Option Components (Housing without Filtration Adapter)

27

008 911 63

BOMAG

645

17.2

Vibration pump

Series 42


4.16 Filtration Filtration of foreign matter from the hydraulic fluid is of primary importance. Dirt and foreign fluids within the hydraulic circuit will greatly reduce the life of the hydraulic equipment.

M3 Gauge Port Plug

Filtration Plate Retaining Screws

Filter-Related Pump Hardware Filtration mechanisms for the Series 42 pump may be before (suction filtration) or after (charge pressure filtration) the charge pump. Sauer-Sundstrand provides a filtration adapter to provide for each type of filtration configuration. If filtration is provided for elsewhere in the hydraulic circuit, the pump will not have a filtration adapter.

Partial Flow Pressure Filtration

Full Flow Pressure Filtration

Suction Filtration

Pumps equipped with housings without filtration adapters have an additional construction bore next to the charge relief valve which is unused and plugged [5/8 in Hex, 21-33 Nm (15-25 ft lbf)]. When these pumps are equipped with suction filtration, the external charge inlet is plugged [5/16 in Int. Hex, 41-94 Nm (30-70 ft lbf)]. Pumps equipped with housings that include filtration adapters have the appropriate adapter and gasket fastened to the housing with screws [Torx T30, 16 Nm (12 ft lbf)]. The position of the M3 gauge port [11/ 16 in Hex, 11-13 Nm (8-10 ft lbf)] will vary depending on filtration type.

Housing with Filtration Adapter

Filter Specifications The selection of a filter depends on a number of factors including the contaminant ingression rate, the generation of contaminants in the system, the required fluid cleanliness, and the desired maintenance interval. A filter capable of controlling the fluid cleanliness to ISO 4406 Class 18/13 or better is recommended and may be located either on the inlet (suction filtration) or discharge (charge pressure filtration) side of the charge pump.

Charge Inlet Plug Construction Bore Plug

E100025 E

Housing without Filtration Adapter (Suction Filtration Only)

Filter capacity depends on desired maintenance levels. As a rough guide, a capacity in grams equal to twice the charge flow in gpm or 1/2 charge flow in l/min has been found to be satisfactory for many closed circuit systems.

Filtration Type Closed Circuit Suction Filtration or Open Circuit Return Line Filtration Systems Sharing a Reservoir with Other Gears, Clutches, or Cylinders Charge Pressure Filtration

Filter efficiency as measured by a "Beta" (β) ratio* should be as in the table at right. See Sauer-Sundstrand publication BLN-9887 or 697581 and ATI-E 9201 for more information on filtration.

Plug

β-ratio β10 ≥ 2 β10 ≥ 10 β10 ≥ 10

* Filter ßx-ratio is a measure of filter efficiency defined by ISO 4572. It is defined as the ratio of the number of particles greater than a given size (x) upstream of the filter to number of particles greater than the same size downstream of the filter. The ßx-ratio applies to a specific particle size, measured in microns.

28

646

BOMAG

008 911 63

17.2

Vibration pump

Series 42


4.17 Servo Piston Covers The servo piston cover can be removed to change the gasket or to inspect/change the control orifices for NFP or FNR controls (section 4.9).

Pump Neutral Ajustment Seal Lock Nut

1. On the right side (side “1”) of the pump, remove the pump “neutral” adjustment seal lock nut [13 mm Hex]. (Not necessary on side "2") 2. Remove the servo piston cover screws [Torx T30].

Servo Piston Cover Screw

Servo Piston Cover

Servo Piston Cover (Non-Feedback and Automotive controls only)

3. The left side (side "2") servo cover can be removed directly.

Pump "Neutral" Adjustment Screw

On the right side (side “1”) of the pump, the cover should be pushed away from the pump housing. It is then necessary to turn the “neutral” adjustment screw [5 mm Hex] clockwise (inward) far enough for the servo cover to clear the nearby drain port. Then pull the cover away from the housing and turn the cover counterclockwise to disengage it from the adjustment screw.

Servo Piston Cover – Right Side (Side "1")

4. Remove the gasket. Note: FNR and NFPE control orifice plugs are located here, see section 4.9 for more information. 5. Install new gasket. 6. On the right side (side "1"), screw the servo piston cover on the neutral adjustment screw. Then, while holding the cover, turn the neutral adjustment screw CCW to engage the cover to the screw threads.

Servo Piston Cover Screws Servo Piston Cover

7. Install servo piston cover screws (15-17 Nm (1113 ft lbf)]. 8. On the right side (side "1"), loosely install neutral adjustment seal lock nut. Perform pump neutral adjustment (section 4.2).

Servo Piston Cover – Left Side (Side "2") E100026 E

Servo Piston Cover Components

WARNING After installing the servo piston cover on right side (side “1”) of the pump, the pump “neutral” adjustment and control neutral adjustment MUST be performed before the vehicle / machine is put back into service. CAUTION Performance of the above procedure may adjust the position of the displacement limiter somewhat.

29

008 911 63

BOMAG

647

17.2

Vibration pump

Series 42


4.18 Displacement Limiter Adjustment Displacement limiters can limit the maximum swashplate position. For Series 42 pumps, displacement limiters are available on one or both sides of the servo piston.

Displacement Limiter Seal Lock Nut Displacement Limiter Servo Piston Cover

Adjustment of the displacement limiters should be performed on a test stand. WARNING Care should be taken in adjusting displacement limiters to avoid undesirable speed conditions. The limiter screw must have full thread engagement in the servo piston cover, and the seal lock nut must be retorqued after every adjustment to prevent unexpected changes in operating conditions and external leakage during unit operation.

Displacement Limiter – Right Side (Side "1") (Exploded View, No Need to Remove Limiter or Nut)

1. Mount pump on test stand. 2. Loosen displacement limiter seal lock nut [13 mm Hex]. Do not remove.

Displacement Limiter Seal Lock Nut

3. Adjust displacement limiter [4 mm Int. Hex]. Tighten the seal lock nut every time the pump is to be tested [20-26 Nm (15-19 ft lbf)]. One full turn of the displacement limiter adjustment screw will change the displacement of the pump approximately as follows. 28 cc

3.6 cc/rev

0.22 in3/rev

41 cc

5.0 cc/rev

0.31 in3/rev

Displacement Limiter Servo Piston Cover

T000 026E

4. After reaching proper displacement tighten the seal lock nut [20-26 Nm (15-19 ft lbf)]. If necessary, repeat procedure for displacement limiter on other side.

Displacement Limiter – Left Side (Side "2") (Exploded View, No Need to Remove Limiter or Nut) E100027 E

Displacement Limiters

30

648

BOMAG

008 911 63

17.2

Vibration pump

Series 42

Exploded View Parts Drawings

5. Exploded View Parts Drawings 5.1

Shaft Options

F096 C020 C017 C018 C015

C005 C002 C003 C001 C015

F001 OR

C001

OR C001

E100028

31

008 911 63

BOMAG

649

17.2

Vibration pump

Series 42 5.2


Filtration, Charge Relief, System Relief, and Loop Flushing

(F086) (F086A) (F043) (F043A) (F040) (F042)

(F040) (F042)

(F043) (F043A) OR

F043 F043A OR

F040 F042

OR

K001

K001 K005 F091 F091A

G040 G040A G041

G043 G042

K001A K001B F030 K001C F030A

K006 K007

F041 K008 K009 K010

G043 G042 G041 G040A G040 OR 045A G045

K002

J005 J002 J003

F062 F061 F063 F060A F060

(F060A) (F060)

F051

OR

F0511

F0512 F0513 F0514 F0515 F050A F050 OR

(F051) (F050A) (F050)

H005 H002 H003

(F091A)

F093

(F091)

F093A F093 F093A N002A N002

E100029

32

650

BOMAG

008 911 63

17.2

Vibration pump

Series 42 5.3


Charge Pump, Auxiliary Pads, and Servo Covers

L010 L010A

F020 F020A

G005

(G075)

G010 G015

G002

G020 (G021) G022

G065

G075

G030 F009

G023

G001

M001 OR (M001)

OR (G001) M005 M010A (M005) (M010A)

G036

M010 OR (G080)

(M010) M020 M025 (G001)

(G036)

G085

G090

(G090) (G036)

(G080) (G085)

E100030

33

008 911 63

BOMAG

651

17.2

Vibration pump

Series 42 5.4


Control Options D039

D038 D037

D081

D003 D003A (D017)

D080

D082

D019 D016

D002

OR

OR D017

D056 D040 D010 D012

F035

E001

F035A

D070 OR

OR D011 D013 F036

D004

F035 F034

D081

D081 OR

D060

(F010)

F010

D090 D014 D015

D032A E100031

D032

34

652

BOMAG

008 911 63

17.2

Vibration pump

Series 42


Notes

35

008 911 63

BOMAG

653

17.2

Vibration pump

Hydraulic Power Systems SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide SAUER-SUNDSTRAND is a world leader in the design and manufacture of Hydraulic Power Systems. Research and development resources in both North America and Europe enable SAUER-SUNDSTRAND to offer a wide range of design solutions utilizing hydraulic power system technology.

SAUER-SUNDSTRAND specializes in integrating a full range of system components to provide vehicle designers with the most advanced total-design system. SAUER-SUNDSTRAND is Your World Source for Controlled Hydraulic Power Systems.


Heavy Duty Bent Axis Variable Motors

Cartridge Motors/ Compact Wheel Drives


Mikrocontrollers and Electrohydraulic Controls

Hydrostatic Transmissions Packages




Worldwide Service Support SAUER-SUNDSTRAND provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world. Look to SAUER-SUNDSTRAND for the best in WORLDWIDE SERVICE.

http://www.sauer-danfoss.com

SAUER-SUNDSTRAND COMPANY 2800 East 13th Street Ames, IA 50010 U.S.A. Phone: (515) 239-6000 Fax: (515) 239-6618

SAUER-SUNDSTRAND GMBH & CO. Postfach 2460 D-24531 Neumünster Krokamp 35 D-24539 Neumünster Germany Phone: (04321) 871-0 Fax: (04321) 871 465

SI-SPV42-E • 11/98 • 300 093B

654

BOMAG

008 911 63

17.3 Drum drive

008 911 63

BOMAG

655

17.3

656

Drum drive

BOMAG

008 911 63

17.3

Drum drive

Hydraulikmotoren Hydraulic motors

MS Reparaturen Repairs

02

05

08

11

18

MS MSE

Störungsbeseitigung Trouble Shooting

Wartungsarbeiten Maintenance

Reparaturen Repairs 5767

Ersatzteile Spare Parts

0549

5766

5763

0545

5764 0550

Ref : 800378128J REPAR MS2-18 D/GB Rev : A - Avr - 00

008 911 63

POCLAIN HYDRAULICS Industrie B.P. 106 60411 VERBERIE CEDEX - FRANCE Tel.: 33 3 44 40 77 77 Fax: 33 3 44 40 77 99 www.poclain-hydraulics.com

BOMAG

5765

0547

POCLAIN HYDRAULICS Certifié ISO 9001

657

17.3

Drum drive

POCLAIN HYDRAULICS Dieses Dokument richtet sich an die Hersteller von Maschinen und Systemen, die Produkte von POCLAIN-HYDRAULICS einbauen, deren Artikelnummer auf der Titelseite genannt sind. Es beschreibt die Installationsangaben und den Inbetriebnahmevorgang, damit ihre optimale Funktionsweise gewährleistet wird. Es wird empfohlen, daß sämtliche Arbeiten von Monteuren mit einer angemessene Ausbildung durchgeführt werden. Sie müssen die Informationen in diesem Dokument gelesen und verstanden haben und vom Hersteller der Maschine bevollmächtigt sein. Selbstverständlich müssen die Monteure die Richtlinien zur Sicherheit und zur Unfallverhütung beachten.

This document is provided to machine manufacturers integrating POCLAIN-HYDRAULICS products.. It suggests processes that manufacturers may utilize to repair products after the warranty period.

Dieses Dokument enthält wichtige Hinweise zur Sicherheit. Sie werden auf folgende Weise gekennzeichnet:

This document includes major safety warnings announced in this way:

!

It is recommended that all operations be performed by technicians trained accordingly. The technicians should read and understand the information given in this document and be authorized by the machine manufacturer. It is essential that the technicians comply with safety instructions to prevent injury.

!

Sicherheitshinweis.

Dieses Dokument enthält weiterhin wesentliche Anweisungen zum Betrieb des Produkts sowie allgemeine Informationen. Sie werden auf folgende Weise gekennzeichnet:

Safety warning.

Additionally, this document includes instructions essential to product function as well as those providing general information. Both are announced similar to the following examples:

Essential instruction.

Wesentliche Anweisung.

General information.

Allgemeine Information. POCLAIN HYDRAULICS kann nicht für Vorfälle haftbar gemacht werden, die auf die Anwendung der in diesem Dokument empfohlenen Verfahren zurückgehen. POCLAIN HYDRAULICS ist nicht verantwortlich für die Konstruktion und die Betriebsbedingungen der Maschinen und Systeme, die mit PHProdukten ausgestattet sind. Ebenso ist POCLAIN HYDRAULICS weder für die Folgen eines falschen Einbaus der Produkte noch für ein falsches Parametrieren einstellbarer Werte, noch für ungültige oder unvollständige Gebrauchs- und Wartungsanweisungen, die den Endverbrauchern von den Maschinenherstellern zur Verfügung gestellt worden sind, verantwortlich. Jegliche Änderung einstellbarer Parameter der PH Produkte kann eine Neuzulassung der Maschinen erforderlich machen. Mit dem Ziel, den besten Service zu bieten, empfiehlt POCLAIN HYDRAULICS seinen Kunden, jede Anwendung von POCLAIN HYDRAULICS prüfen und freigeben zu lassen. Das Öffnen der Produkte führt zum Garantieverlust. Verwenden Sie nur Original-Ersatzteile von POCLAIN HYDRAULICS. Die Montage von Teilen anderen Ursprungs könnte den Betrieb des Bauteils und des Systems sowie die Sicherheit beeinträchtigen.

POCLAIN HYDRAULICS designs products that are integrated by its customers in the machines they design.

Stets um die Verbesserung seiner Erzeugnisse bemüht, behält sich POCLAIN HYDRAULICS das Recht vor, ohne vorherige Ankündigung alle Änderungen vorzunehmen, die als nützlich für die in diesem Dokument beschriebenen Produkte bewertet werden. Dieses Dokument enthält Abschnitte auf deutsch und kursiv gedruckte Abschnitte, die Übersetzung in englischer Sprache darstellen. Im Zweifelsfall ist die französische Version ausschlaggebend. Die Maße sind in metrischen Einheiten angegeben. Die Entsprechungen in anderen Meßsystemen (vor allem angelsächsisch) werden zur Unterrichtung angegeben. Die Abbildungen haben unverbindlichen Charakter.

In accordance with its policy of continuous improvement, POCLAIN HYDRAULICS reserves the right to modify the specifications of all products described herein without prior notice.

© POCLAIN HYDRAULICS Industrie 1998. Die Handelsmarke POCLAIN HYDRAULICS ist das Eigentum von POCLAIN HYDRAULICS SA. Dieses Dokument ist das Eigentum von POCLAIN HYDRAULICS Industrie. Es ist streng vertraulich. Es darf ohne unseres vorheriges schriftliches Einverständnis weder gesamt noch teilweise verwendet, vervielfältigt, kopiert oder an Dritte weitergegeben werden. FACOM ist ein eingetragenes Warenzeichen der FACOM SA. LOCTITE ist ein eingetragenes Warenzeichen der LOCTITE SA. AUTO-TOP ist ein eingetragenes Warenzeichen der AGIP SPA.

© POCLAIN HYDRAULICS Industrie 1998. The trademark POCLAIN HYDRAULICS is the property of POCLAIN HYDRAULICS S.A. This document is the property of POCLAIN HYDRAULICS Industrie. It is strictly confidential. It must not be used, duplicated, copied or disclosed to a third party in full or in part without our prior written consent. FACOM is FACOM SA registered trademark. LOCTITE is LOCTITE SA registered trademark. AUTO-TOP is AGIP SPA registered trademark.

2

Subsequently POCLAIN HYDRAULICS disclaims liability for consequences of improper integration of its products and of improper set-up of adjustable devices. In the same way, POCLAIN HYDRAULICS may not be liable for incomplete or improper operating and maintenance instructions provided to the end user by the machine manufacturer nor for failures resulting from operations performed by any person using these suggested procedures. A re-certification of the machine may be required for every change in set-up of adjustable devices. In order to offer the best quality service, POCLAIN HYDRAULICS recommends to its customers to have applications approved by POCLAIN HYDRAULICS. Opening of products voids the warranty contract. Use only POCLAIN HYDRAULICS genuine spare parts. Using parts from different sources could reduce the performance of the product and pose a safety hazard..

This document contains sections written in German and sections printed in italics composing the English translation of the French sections. The French sections will be the reference in case of dispute. All measures are expressed in metric units. Converted values to other systems (notably US and UK) are given for reference only. The illustrations for information only.

REPAR MS2-18 D/GB

658

BOMAG

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS

Inhaltsverzeichnis

Contents

INHALTSVERZEICHNIS ............................................. 3

CONTENTS................................................................. 3

SICHERHEIT UND QUALITÄT ................................... 4

SAFETY AND QUALITY ............................................. 4

VOR DEN W ARTUNGSARBEITEN ....................................... 4 W ÄHREND DER W ARTUNGSARBEITEN............................... 4 NACH DEN W ARTUNGSARBEITEN ..................................... 4 IDENTIFIZIERUNG DES BAUTEILS ....................................... 5

BEFORE SERVICING ........................................................ 4 DURING SERVICING ......................................................... 4 AFTER SERVICING ........................................................... 4 IDENTIFICATION OF THE COMPONENT................................. 5

STÖRUNGSBESEITIGUNG........................................ 6

TROUBLE SHOOTING ............................................... 7

WARTUNGSARBEITEN.............................................. 8

MAINTENANCE .......................................................... 8

AUSTAUSCHEN DES MOTORS........................................... 8 Ausbau..................................................................... 8 Einbau...................................................................... 8 MECHANISCHE BREMSLÖSUNG ........................................ 9 KONTROLLE DER STATISCHE HALTEBREMSE. ................... 10

REPLACING THE MOTOR .................................................. 8 Removal................................................................... 8 Installation................................................................ 8 MECHANICAL BRAKE RELEASE .......................................... 9 CHECKING THE PARKING BRAKE EFFICIENCY..................... 10

REPARATUREN. ...................................................... 11

REPAIRS. ................................................................. 11

AUSWECHSELN DER BREMSKOLBENDICHTUNG................. 11 Demontage ............................................................ 11 Wiedereinbau......................................................... 13 AUSWECHSELN DES LAGERTEILES (070)......................... 16 Demontage ............................................................ 16 Wiedereinbau......................................................... 18 AUSWECHSELN DER BREMSBACKEN ............................... 20 Demontage ............................................................ 20 Wiedereinbau......................................................... 23 AUSWECHSELN DES NOCKENRINGS (026)....................... 27 Demontage ............................................................ 27 Wiedereinbau......................................................... 27 AUSWECHSELN DES KOMPLETTEN ZYLINDERBLOCKS (010) 28 Demontage ............................................................ 28 Wiedereinbau......................................................... 28 AUSWECHSELN DES VERTEILERS (047). ......................... 29 Demontage ............................................................ 29 Wiedereinbau......................................................... 29 AUSWECHSELN DER DECKELDICHTUNG (045).................. 32 Demontage ............................................................ 32 Wiedereinbau......................................................... 33 AUSWECHSELN DES DREHZAHLSENSORS (OPTION).......... 34 Demontage ............................................................ 34 Wiedereinbau......................................................... 35

REPLACEMENT OF THE O-RING OF THE BRAKE PISTON....... 11 Disassembly........................................................... 11 Reassembly. .......................................................... 13 REPLACEMENT OF THE BEARING SUPPORT (070).............. 16 Disassembly........................................................... 16 Reassembly ........................................................... 18 REPLACING THE BRAKE SHOES....................................... 20 Disassembly........................................................... 20 Reassembly ........................................................... 23 REPLACEMENT OF THE CAM (026) .................................. 27 Disassembly........................................................... 27 Reassembly ........................................................... 27 REPLACEMENT OF THE CYLINDERS BLOCK ASSEMBLY (010)28 Disassembly........................................................... 28 Reassembly ........................................................... 28 REPLACEMENT OF THE VALVING (047). ........................... 29 Disassembly........................................................... 29 Reassembly ........................................................... 29 REPLACEMENT OF THE O-RING (045) OF THE END COVER . 32 Disassembly........................................................... 32 Reassembly ........................................................... 33 REPLACING THE SENSOR (OPTIONAL) .............................. 34 Disassembly........................................................... 34 Reassembly ........................................................... 35

WERKZEUG-LISTE .................................................. 36

TOOLING INVENTORY............................................. 36

Standard Werkzeug................................................ 36 Spezialwerkzeuge .................................................. 37 ANZIEHDREHMOMENTE NM ± 10%........................... 38 ERSATZTEILE.......................................................... 39 MOTOREN MIT KONSTANTEM HUBVOLUMEN MS, MSE 0205-08-11-18. .............................................................. 42 MOTOREN MIT UMSCHALTBAREM HUBVOLUMEN MS, MSE 02-05-08-11-18. ......................................................... 44

800378128J

008 911 63

Standard tools ........................................................ 36 Special tools........................................................... 37 TIGHTENING TORQUES IN [LBF.FT] ± 10% .......... 38 SPARE PARTS LIST ................................................ 39 SINGLE DISPLACEMENT MOTORS MS, MSE 02-05-08-1118. ............................................................................. 42 DUAL DISPLACEMENT MOTORS MS, MSE 02-05-08-11-18.44

REPAR MS2-18 D/GB

BOMAG

3

659

17.3

Drum drive

POCLAIN HYDRAULICS

Sicherheit und Qualität

Safety and Quality

Vor den Wartungsarbeiten

Before servicing

• Alle notwendigen Sicherheitsvorkehrungen treffen (Menschen und Material) und die geltenden Sicherheitsvorschriften beachten. • Parkbremse betätigen und Maschine mit Keilen festsetzen. • Energieerzeugung (Motor) des Hydrauliksystems abstellen und die Stromversorgung ausschalten. • Gegebenenfalls eine Sicherheitszone einrichten.

• Be extremely careful to prevent personal injury and to avoid damage to material. Comply with all safety regulations.

• Die Außenflächen der Bauteile reinigen, um Schmutz und Fett restlos zu entfernen. • Warten, bis das Hydrauliksystem vollständig abgekühlt und druckentlastet ist (die Speicher entlasten).

• Wash dirt and grease from exterior of the components.

Das heiße oder unter Druck stehende Öl kann zu schweren Verbrennungen mit Entzündung führen. Bei einem Unfall einen Arzt hinzuziehen.

Hot or pressurized hydraulic fluid may cause serious burns & infections to the human body. Consult a physician in case of accident.

!

• Apply the parking brake and prevent the machine from rolling with tire blocks. • Stop the hydraulic system power source (engine) and disconnect the battery. • If necessary, block off the safety area.

• Await the complete cooling down and depressurization of the hydraulic system (accumulators must be purged).

!

Während der Wartungsarbeiten

During servicing

• Bestimmte Bauteile sind sehr schwer. Sie müssen bei der Abnahme vom Rahmen mit einer angemessen ausgelegten Hebevorrichtung gehalten werden. • Die Sauberkeit ist wesentlich beim Betrieb der Hydraulikbauteile. Die meisten Teile können mit einem sauberen Lösungsmittel gereinigt werden. • Während der Handhabung alle empfindlichen Oberflächen gegen Stöße schützen (Zentrierungen, gleitende Teile, Auflagen, Dichtungs- und Lagerauflagen usw.).

• Some hydraulic components are very heavy. Secure them with a lifting device of adequate capacity when removing from the machine frame.

•

Diese Flächen vor dem Wiederzusammenbau reinigen. • Systematisch die demontierten Dichtungen beim Wiederzusammenbau durch neue ersetzen. Wir empfehlen, vor der Montage alle Dichtungen zu fetten.

•

• Alle gleitenden Flächen durch Aufbringen eines Films sauberer Hydraulikflüssigkeit ölen, der eine korrekte Schmierung beim ersten Neustart gewährleistet.

• Lubricate all surfaces which have relative motion between parts by coating them with a film of clean hydraulic fluid to assure lubrication at first start.

• Niemals die Hydraulikflüssigkeit, die sich bei hohen Temperaturen entzünden kann, erwärmen. Einige Lösungsmittel sind ebenfalls entzündlich.

• Never heat hydraulic fluid, as it may flame at high temperature. Some solvents are also flammable.

Während der Arbeiten nicht rauchen.

Do not smoke during servicing.

Nach den Wartungsarbeiten

After servicing

Die Bauteile wieder einbauen und das Hydrauliksystem gemäß den Anweisungen in den folgenden Dokumenten wieder in Betrieb nehmen: • INSTALLATION MS D/GB (ref: 800078173V) • INSTALLATION CIRCUITS D/GB (ref. 677777853U)

Reinstall the components and restart the hydraulic system according to instructions defined in the following documents: • INSTALLATION MS F/GB (ref. 677777844K)

! 4

• Cleanliness is essential to functioning of the hydraulic components. Most of the parts may be cleaned with a clean solvent. • During handling, protect all sensitive surfaces from shocks (piloting and interface surfaces, thrust & bearings surfaces, seal races, etc...) Clean up these surfaces before reassembling.

• Always install new O-rings, seals & gaskets discarding the old ones. We recommend lubricating all seals prior to assembly.

• INSTALLATION CIRCUITS F/GB (ref. 677777831V)

Die Einstellung der Sicherheitsventile nicht erhöhen.

!

REPAR MS2-18 D/GB

660

BOMAG

Do not overset relief valves.

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS

Identification of the component

Identifizierung des Bauteils

A

MS18-2-D11-F19-2A10-K000 B

D 000143896J C

40712

001

0349

A : Handelsbezeichnung: Ex : MSE18-2-D11-F19-2A10-K000

A: Commercial description: E.g : MSE18-2-D11-F19-2A10-K000

B : Code : Artikelnr.: Ex : 000143896J

B: Code: Part number. E.g : 000143896J

C : Serie : Herstellungsnummer Ex : 001

C: Series: Manufacturing batch number. E.g : 001

D : Num : Chronologische Ordnungsnummer Ex : 40712

D: Num: Chronological serial number. E.g : 40712

Bei sämtlichen Ersatzteilbestellungen müssen die Artikelnummer und die chronologische Ordnungsnummer angegeben werden.

800378128J

008 911 63

The part number and the chronological serial number must be specified to order spare parts.

REPAR MS2-18 D/GB

BOMAG

5

661

17.3

Drum drive

POCLAIN HYDRAULICS

Störungsbeseitigung BECHÄDIGUNG → ABRIEB → ERKENNUNG DURCH FILTER → VORBEUGUNG……

Störung

Ursachen Ohne Last

LAUTE GERÄUSCHE DES MOTORS Unter Last

MOTOR DREHT SICH NICHT

DER MOTOR DREHT SICH NICHT MIT NORMALER LASTDREHZAHL

DER MOTOR DREHT SICH UNREGELMÄSSIG

ÄUSSERE ÖLUNDICHTIGKEITEN

6

Regelmäßiges Brummen

Lagerteil verschlissen

Lagerteil ersetzen

Vibrationen

Lockere Befestigungen und / oder Anschlüsse

Mit entsprechendem Drehmoment anziehen

Klappern

Speisedruck zu niedrig

Speise- und Austauschdruckventil kontrollieren.

Kavitation

Interne Lecks zu groß

Zylinderblock und Ölverteiler ersetzen

Der Motor wird nicht versorgt

Den Antrieb der Pumpe und ihre Versorgung überprüfen

Kein Druckanstieg im Kreis

Hochdruck-Begrenzungsventile kontrollieren (Regler)


Zylinderblock und Ölverteiler ersetzen

Die Bremse bleibt angezogen

Den Steuerkreis der Bremse kontrollieren

Der Fördermenge der Pumpe ist unzureichend

Die Antriebsdrehzahl und den Zustand der Pumpe kontrollieren


Den Zustand des Zylinderblocks und des Ölverteilers überprüfen

Der Betriebsdruck ist zu niedrig

Den Zustand des Sicherheitsventils kontrollieren (Regler)

Die Fördermenge der Pumpe schwankt

Steuerdruck und Fördermenge der Pumpe kontrollieren


Den Zustand des Zylinderblocks und des Ölverteilers überprüfen.

Gehäusedruck zu groß

Den Leckagekreis und den Zustand des Filters überprüfen

Dichtungen beschädigt

Die Dichtungen ersetzen

Fehlerhafte Montage

Das Anziehmoment der Montageschrauben, der Entlüftungsschrauben und der Anschlüsse kontrollieren

REPAR MS2-18 D/GB

662

Abhilfe

BOMAG

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS

Trouble shooting DAMAGE → IRON PARTICLES → DETECTION BY FILTERS → PREVENTION……

Troubles

Causes Without load

Regular rumbling

Worm bearing support

Replace the bearing support

Vibrations

Mountings and/or hydraulic piping becoming loose

Tighten to torque

Clattering

Boost pressure too low

Check the setting and condition of counter-pressure valve

Cavitation

Excessive internal leaks

Replace the cylindersblock and distribution valve assembly

No supply to the motor

Check pump drive and pump inlet

The circuit does not reach working pressure

Check condition of safety valve (regulator)


Replace the cylinders block and distribution valve assembly

The brake stays engaged

Check the brake pilot circuit

Pump flow is too low

Check drive speed and condition of the pump


Check condition of cylindersblock and distribution valve assembly

Working pressure is too low

Check safety valve setting pressure (regulator)

Irregular flow

Check the pump flow

Excessive leaks

Check condition of cylindersblock and distribution valve assembly

Too high casing pressure

Check the leakage circuit and filter condition

Seals damaged

Replace seals

Incorrect assembling

Check tightening of mounting screws, bleed screws and unions

NOISY MOTOR Under load

THE MOTOR DOES NOT REVOLVE

THE MOTOR DOES NOT REVOLVE AT ITS NORMAL SPEED UNDER LOAD

THE MOTOR REVOLVES IRREGULARLY

EXTERNAL OIL LEAKS

800378128J

008 911 63

Remedies

REPAR MS2-18 D/GB

BOMAG

7

663

17.3

Drum drive

POCLAIN HYDRAULICS

Wartungsarbeiten

Maintenance

Austauschen des Motors

Replacing the motor

Ausbau

Removal

• •

• •

• • • •

Druck im Arbeitskreis abbauen. Leckageleitung am Tank abschrauben, um ein Leerlaufen zu verhindern. Die Rohre oder Schläuche, die am Motor angeschlossen sind, abklemmen. Drehzahlsensor abklemmen. Die Befestigungsschrauben demontieren und den Motor ausbauen. Das Motorgehäuse entleeren.

Einbau Die zum Ausbau angegebenen Arbeitsgänge in umgekehrter Reihenfolge ausführen. Für weitere Informationen beziehen Sie sich bitte auf folgende Dokumente: • INSTALLATION MS D/GB (ref: 800078173V) • INSTALLATION CIRCUITS D/GB (ref: 677777853U)

8

• • • •

Release the pressure in the supply circuit. Disconnect the drain line at the tank level to avoid its siphoning. Disconnect and plug the pipes or hoses which are connected to the motor. Disconnect the speed sensor. Disconnect the mounting screws, and remove the motor. Drain the casing.

Installation Execute the removal operations in the reverse order. Please refer to the following documentation brochures: • •

INSTALLATION MS F/GB (ref: 677777844K) INSTALLATION CIRCUITS F/GB (ref: . 677777831V)

REPAR MS2-18 D/GB

664

BOMAG

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS

Mechanische Bremslösung

Mechanical brake release

Bei bestimmten Reparaturfällen oder zum Abschleppen der Maschine muß die integrierte Parkbremse gelöst werden.

In certain service situations, it may be necessary to release the motor brake.

• Stopfen (142) aus der Schutzkappe (141) herausziehen.

• Extract and release the plug (142) from the brake cover (141).

142

6499

•

Schraube im Kolben festziehen

•

Tighten the screw in the piston

6556

• Mutter so weit anziehen, bis die Welle frei dreht.

• And tighten the nut until the motor shaft turns freely.

6555

Force [lbf]

F02-F04

18000

[4.000]

42

[30.9]

M12

F05-F07

20000

[4.500]

47

[34.6]

M12

F08

34000

[7.600]

110

[81.1]

M16

F11

45000

[10.000]

140

[103]

M16

F12

45000

[10.000]

140

[103]

M16

F19

45000

[10.000]

140

[103]

M16

!

Brakes

Entsprechendes Drehmoment Nm

Kraft N

Bremsen

Nach Bremslösung, einen neuen Stopfen (142) einbauen.

800378128J

008 911 63

!

Equivalent torque [lbf.ft]

Mutter Nut

After brake release, mount a new plug (142).

REPAR MS2-18 D/GB

BOMAG

9

665

17.3

Drum drive

POCLAIN HYDRAULICS

Checking the parking brake efficiency.

Kontrolle der statische Haltebremse.

!

Bei fahrbaren Maschinen den Test auf ebenem Grund durchführen.

Bremssteuerdruck:

!

For a rolling machine, make the test on a horizontal ground.

Pilot brake pressure : minimum 12 bar [174 PSI] Maximum 30 bar [435 PSI]

mini 12 bar Maxi 30 bar.

• Sich vergewissern, daß der Bremsversorgungsdruck gleich Null ist, • Die Bremse über die höchstgelegene Schraube (112) entlüften, • Den Motor mit Maximaldruck beaufschlagen,

Make sure that the brake supply pressure is zero,

• Die Motorwelle darf sich nicht drehen, da andernfalls die Bremse ausgetauscht werden muß :

• The motor shaft must not turn, otherwise it is necessary to replace the brake :

!

10

• Purge the brake using the screw (112) located at the highest level, • Supply the motor up to the setting pressure.

Mehrscheibenbremsen nicht einfahren.

!

REPAR MS2-18 D/GB

666

BOMAG

Do not run multidisc brakes in.

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS

Repairs.

Reparaturen. Auswechseln der kolbendichtung

Brems-

Replacement of the O-ring of the brake piston.

Demontage

Disassembly

• •

• Remove the motor. • Place the motor on the bearing support.

Den Motor ausbauen. Motor auf das Lagerteil stellen.

Muttern zum Schutz der Gewindebolzen wieder aufsetzen

!

• Schutzkappe (141) abnehmen und beseitigen.

!

Protect the studs by reinstalling the nuts

• Remove and discard the brake cover.(141)

141

6500

• O-Ring (143) herausziehen und beseitigen.

• Extract and discard the O-ring (143).

143

6501

• Tellerfeder (108) zusammendrücken:

•

Compress the washer (108).

• Mit Hilfe des Dorns und Abziehers (siehe Werkzeug Seite 36) (fig 6502) • Mit Hilfe des Dorns und einer Schraube Klasse 12.9 (siehe Werkzeug Seite 36) • Mit Hilfe des Dorns und einer Presse (fig 6503). Die Kraft F beibehalten (siehe Schaubild Seite 9)

• Using a mandrel and an extractor (see tools page 36) (fig 6502) • Using a mandrel and a screw class 12.9 (see tools page 36) • Using a mandrel and a press (fig 6503). Respect the force F (see table page 9)

Einsatzrichtung des Sicherungsrings markieren.

Mark the mounting direction of the snap ring.

6502

6503

800378128J

008 911 63

REPAR MS2-18 D/GB

BOMAG

11

667

17.3 POCLAIN HYDRAULICS • Sicherungsring (109) mit Hilfe einer Zange für Innenringe herausnehmen (siehe Werkzeuge Seite 36)

Drum drive • Remove the snap ring (109) using internal snap ring pliers. (see tools page 36) • Extractor and pliers (fig 6504 and 6505) • Press and pliers (fig 6506 and 6507)

• Abzieher und Zange (fig 6504 und 6505) • Presse und Zange (fig 6506 und 6507)

! •

Bei Verwendung der Presse das Lagerteil nicht auf den Gewindebolzen abstützen.

Tellerfeder (108) herausziehen.

! •

6504

6505

6506

6507

If you use the press do not place the bearing support on the studs.

Extract the washer (108).

108

6508

• Bremskolben (107) herausziehen.

•

Extract the brake piston (107)

6513

•

O-Ring (106) beseitigen.

•

Discard the O-ring (106). 106

6511

12

REPAR MS2-18 D/GB

668

BOMAG

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS Wiedereinbau. Vor dem Wiedereinbau ist unbedingt sicherzustellen, daß alle Teile, Nuten und Dichtungs-Auflageflächen sauber sind.

!

Reassembly. Before reassembling, it is necessary to ensure that all parts, the surface condition of the piston seal contact surface and the grooves are clean.

Es dürfen keine Rost-, Schmutz- oder Wasserspuren vorhanden sein

Mit Korrosionsschutzfett (siehe Werkzeug Seite 36) einschmieren: die Nut, die obere Fläche des Bremskolbens, die Tellerfeder, den Sicherungsring und die Auflagefläche der Kolbendichtung im Bremsgehäuse.

!

All traces of rust, mud, water must be removed.

• Neuen O-Ring (106) auf den Kolben (107) montieren.

Coat with anti-oxidizing grease (see tools page 36), the grooves, the top of the brake piston, the spring washer, the snap ring and the piston seal contact surface in the brake body. • Install a new O-ring (106) on the piston (107).

Der Ring muß fest an den Kolben gepreßt und nicht verdreht werden.

The ring should be tight on the piston and not twisted.

!

!

106

6512

•

Bremskolben (107) einsetzen.

!

Achtung, wenn die Dichtung über die Nut des Sicherungsrings geführt wird.

•

Install the brake piston (107).

!

Take care when passing the seal over the snap ring groove.

107

6509

•

Tellerfeder

(108)

einlegen.

Install the spring washer (108).

108

6513

800378128J

008 911 63

REPAR MS2-18 D/GB

BOMAG

13

669

17.3 POCLAIN HYDRAULICS • Tellerfeder (108) zusammendrücken:

Drum drive • Compress (108).

the spring washer

• Mit Hilfe des Dorns und Abziehers (siehe Werkzeug Seite 36) (fig 6502) • Mit Hilfe des Dorns und einer Presse (fig 6503). Die Kraft F einbehalten (siehe Schaubild Seite 9)

• Using a mandrel and an extractor (see tools page 36) (fig 6502) • Using a mandrel and a press (fig 6503). Respect the force F (see table page 9)

Bei Verwendung der Presse das Lagerteil nicht auf den Gewindebolzen abstützen.

If you use the press do not place the bearing support on the studs.

!

!

6502

6503

• Sicherungsring (109) mit Hilfe einer Zange für Innenringe gemäß der bei der Demontage angebrachten Kennzeichnung montieren: (siehe Werkzeuge Seite 36) • Abzieher und Zange (fig 6504 und 6505) • Presse und Zange (fig 6506 und 6507)

• Install the snap ring (109) using internal snap ring pliers in line with the mark made during disassembly . (see tools page 36) 6504

6506

• Neuen, mit Korrosionsschutzfett eingeschmierten O-Ring (143) in die Nut einsetzen (siehe Werkzeuge Seite 36).

6505

• Extractor and pliers (fig 6504 and 6505) • Press and pliers (fig 6506 and 6507)

• Install a new O-ring (143) coated with anti-oxidizing grease in its groove. (see tools page 36)

6507

143

6515

• Neue Schutzkappe (141) auf den Anschnitt legen.

• Place the new cover (141) on the entry chamfer .

141

6516

14

REPAR MS2-18 D/GB

670

BOMAG

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS • Schutzkappe mit Hilfe des Dorns einrasten lassen (siehe Werkzeug Seite 36).

• Click the cover into place using the right mandrel. (see tools page 36).

Sich vergewissern, daß der Außenrand des Schutzkappe in die Nut eingreift ist.

Make sure that the outer edge of the cover is engaged in the groove.

!

!

6517

•

Neuen Stopfen (142) einsetzen.

!

•

Sich vergewissern, daß zwischen Schutzkappe und Stopfenrille einwandfreier Kontakt besteht.

Install a new plug (142).

!

Make sure about the contact between the cover and the plug groove.

142

6518

•

Motor wieder einsetzen.

800378128J

008 911 63

•

Install the motor.

REPAR MS2-18 D/GB

BOMAG

15

671

17.3

Drum drive

POCLAIN HYDRAULICS

Auswechseln teiles (070)

des

Lager-

Replacement of the bearing support (070)

Demontage

Disassembly

Motor herausnehmen. Motor auf der Bremse oder Verschlussplatte abstützen (Motor ohne Bremse).

Remove the motor. Place the motor on the brake or on the end cover (motor without brake).

• Position des Lagerteiles (070) in Bezug auf Nockenring (026) und Verteilerdeckel (040) kennzeichnen.

• Mark the position of the bearing support (070) in relation to the cam (026) and to the valving cover (040).

070 025

040

• Schrauben nehmen.

(042)

heraus-

•

6519

Remove the screws (042).

042 6520

• Lagerteil (070) herausnehmen.

• Remove the bearing support (070). 070

6521

• Nockenring nehmen.

(026)

heraus-

•

Remove the cam (026). 026

6524

16

REPAR MS2-18 D/GB

672

BOMAG

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS • O-Ring (027) vom Verteilerdeckel (041) entfernen.

• Discard the O-ring (027) from the valving cover (041).

027

041

6525

• O-Ring (027) vom Lagerteil (071) entfernen.

• Discard the O-ring (027) from the bearing support (071)

027

071

6522

800378128J

008 911 63

REPAR MS2-18 D/GB

BOMAG

17

673

17.3

Drum drive

POCLAIN HYDRAULICS Wiedereinbau

Reassembly

Vor dem Wiedereinbau ist unbedingt sicherzustellen, daß die Nut sauber ist

Before reassembling it is necessary to ensure that the groove is clean

Es dürfen keine Rost-, Schmutz- oder Wasserspuren vorhanden sein.

All traces of rust, mud, water must be removed

!

• Neuen, mit Korrosionsschutzfett eingeschmierten O-Ring (027) in die Nut des Lagerteiles (071) einsetzen (siehe Werkzeuge Seite 36) .

!

• Install a new O-ring (027) coated with anti-oxidizing grease (see tools page 36) in the groove of the bearing support (071).

027

071 6523

• Neuen, mit Korrosionsschutzfett eingeschmierten O-Ring (027) in die Nut des Verteilerdekkels (041) einsetzen (siehe Werkzeuge Seite 36) .

• Install a new O-ring (027) coated with anti-oxidizing grease (see tools page 36) in the groove of the valving cover (041)

041

6525

• Nockenring (026) gemäß der bei der Demontage markierten Kennzeichnung montieren.

!

Große Ansenkungen in Richtung Lagerteil

Den Nockenring anhand von zwei einander gegenüberliegenden Schrauben (042) zentrieren.

18

• Install the cam (026) in line with the marks made during disassembling.

!

The big chamfers oriented towards bearing support

Center the cam using two screws (042) diametrically opposite.

REPAR MS2-18 D/GB

674

026

BOMAG

6526

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS •

•

Lagerteil montieren

!

Bei Wellenmotoren müssen die Anschlüsse quer zur Einbauachse des Motors liegen. (Abb. 6521)

!

Install the bearing support For shaft motors the ports must be perpendicular to the mounting axis of the motor. (Fig 6521) 6521 A

A

6527

• Befestigungsschrauben (042) einsetzen und mit dem angegebenen Drehmoment anziehen. (siehe Schaubild Seite 38).

• Install and tighten the mounting screws (042) to the right torque. (see table page 38).

042

6520

•

Motor wieder einsetzen.

800378128J

008 911 63

•

Install the motor.

REPAR MS2-18 D/GB

BOMAG

19

675

17.3

Drum drive

POCLAIN HYDRAULICS

Auswechseln der backen

Brems-

Vor der Demontage kann man die Abnutzung der Bremsbeläge durch die Inspektionsöffnungen kontrollieren.

Replacing the brake shoes.

Before disassembling it is possible to make a visual checking of the brake pads wear via the inspection ports.

2055

Demontage

!

Disassembly

Das Auswechseln des Bremsbacken und das Schleifen der Trommeln muß auf allen Motoren der gleichen Achse vorgenommen werden.

!

The same repairs should be made on each motor of the same axle when replacing shoes and brake drums.

• Befestigungsmuttern der Felge lösen. • Maschine auf der Höhe der auszubauenden Felge hochheben. • Rad abnehmen (Reifen). • Mechanische Bremse lösen.

• Loosen the wheel rim retaining nuts. • Raise the machine on the side of the wheel rim to be removed. • Remove the wheel rim (tyre). • Release the mechanical brake.

•

•

Trommel (096) abziehen.

!

20

Reibfläche der Trommel überprüfen, die weder tiefe Rillen (tiefer als 0,2 mm) noch abnormale Abnutzungserscheinungen aufweisen darf, sonst muß sie geschliffen werden. (Ra 1,6 bis 3,2)

Extract the drum (096).

!

Check the friction surface condition of the drum which should show no deep scratches (deeper than 0,2 mm [0.0078 in]) nor abnormal wear. Otherwise, the brake drum should be replaced. (Ra 1.6 to 3.2)

REPAR MS2-18 D/GB

676

BOMAG

096 6528

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS •

Rückholfeder (154.a) abbauen.

• Remove (154.a).

the

return

spring

154.a

6529

6530

• Halterungsfedern (154.b) abbauen.

• Remove the retention springs (154.b).

1

154.b

2 6531

• Bremsbacken aus der Betätigungsvorrichtung lösen.

• Release the brake shoes from the regulating mechanism.

6532

• Rückholfedern (154.c) abbauen.

• Remove (154.c).

the

return

springs

154.c

6533

800378128J

008 911 63

REPAR MS2-18 D/GB

BOMAG

21

677

17.3 POCLAIN HYDRAULICS • Bremsbacke (154.1) abbauen.

Drum drive •

Remove the brake shoe (154.1)

154.1 6534

• Den mechanischen Bremshebel vom Bremsseil lösen und Bremsbacke (154.2) entfernen

• Releasing the mechanical brake control lever from its cable, remove the brake shoe (154.2) 154.2

6535

6536

22

REPAR MS2-18 D/GB

678

BOMAG

800378128J

008 911 63

17.3

Drum drive


!

Vorrichtung entstauben, sich vergewissern, daß der Radzylinder dicht ist.

Reassembly

!

Remove all dust from the whole assembly. Make sure there are no leaks at the wheel cylinder.

Reibfläche der Trommel überprüfen, die weder tiefe Rillen (tiefer als 0,2 mm) noch abnormale Abnutzungserscheinungen aufweisen darf, sonst muß sie geschliffen werden.

Check the friction surface condition of the drum which should show no deep scratches (deeper than 0.2 mm) [0.0078in] nor abnormal wear. Otherwise, the brake drum should be replaced.

• Den Bremshebel am Bremsseil (098) befestigen und Bremsbacke (154.2) einbauen

• Attaching the control lever on the brake cable (098), install the brake shoe (154.2)

6549

098

154.2

6536

6535

800378128J

008 911 63

REPAR MS2-18 D/GB

BOMAG

23

679

17.3 POCLAIN HYDRAULICS • Rückholplatte an die Bremsbacke (154.2) montieren.

Drum drive • Mount the return plate on the brake shoe (154.2)

6537

6538

•

Bremsbacke (154.1) einsetzen.

•

Install the brake shoe (154.1)

6539

• Bremsbacken auf der Betätigungseinrichtung positionieren.

• Position the brake shoes on the regulating mechanism.

6532

• Rückholfedern (154.c) einsetzen.

Install the return springs (154.c)

154.c

6533

24

REPAR MS2-18 D/GB

680

BOMAG

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS • Bremsbacken in die Betätigungseinrichtung einbauen.

• Install the brake shoes in the regulating mechanism

6532

• Halterungsfedern (154.b) einsetzen.

• Install (154.b).

the

retention

springs 1

154.b

2 • Rückholfedern (154.a) einsetzen.

•

6531

Install the return spring (154.a).

154.a 6530

• Reibungsdurchmesser D der Trommel und der eingesetzten Backen messen.

• Measure the brake drum friction diameter D and that of the brake shoes, which have been installed.

Durchmesser D diameter 6529

800378128J

008 911 63

REPAR MS2-18 D/GB

BOMAG

25

681

17.3

Drum drive

POCLAIN HYDRAULICS • Backendurchmesser anpassen, um bei Bremsen mit mechanischer Einstellvorrichtung mit Hilfe des einen Zahnrads (156.1), oder bei Bremsen mit automatischer Bremsennachstellung mit Hilfe der zwei Zahnräder (156.2 und 156.3), das nötige Spiel zwischen Belag und Trommel zu erzielen. In diesem Fall muß die Wirkung auf die Zahnräder symmetrisch (a) sein. Den Hebel (156.4) muss zu diesem Zweck freigängig sein.

Bremsen Brake 250 x 60

• Adjust the brake shoes diameter to obtain correct clearance between the brake padding and the drum using the adjusting wheel (156.1) for brakes equipped with mechanical adjustment system or two adjusting wheels (156.2 and 156.3) for brakes equipped with automatic clearance adjustment. In this case, the adjusting wheels should be adjusted symmetrically (a). Release the lever slightly (156.4) to enable this operation to take place.

Trommeldurchmesser (mm) Drum diameter [in] nominal maximum 250 [9.84] 252 [9.92]

325 x 80

270 [10.63] 325 [12.79]

272 [10.70] 327 [12.87]

350 x 60

350 [13.78]

352 [13.85]

270 x 60

• Trommel aufsetzen und überprüfen, ob sie frei dreht.

1 5 6 .4 1 5 6 .2

a

1 5 6 .3

a

6540

Total Spiel (mm) Total clearance [in] 0.55 [0.02] 0.80 [0.03] 0.80 [0.03] 0.80 [0.03]

• Install the drum, check that it can turn freely.

6528

• Wenn nötig, den Radzylinder entlüften. • Felge montieren. Siehe Dokument INSTALLATION MS D/GB (ref: 800078173V)

26

• Bleed the wheel cylinder, if necessary. • Install the wheel rim. See documentation INSTALLATION MS F/GB (ref 677777844K )

REPAR MS2-18 D/GB

682

BOMAG

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS

Auswechseln des Nockenrings (026)

Replacement of the cam (026)

Demontage Dazu die im Kapitel « Auswechseln des Lagerteils » unter « Demontage » beschriebenen Arbeiten ausführen, Seite 16 Wiedereinbau Dazu die im Kapitel « Auswechseln des Lagerteils » unter " Wiedereinbau " beschriebenen Arbeiten ausführen, Seite 18. Allerdings muß bei Motoren mit 2 Schluckvolumen mit einem Schluckvolumenverhältnis über oder unter 2 die Winkelposition berücksichtigt werden. Beispiel: Motor MS18, Schluckvolumen 1747-1049-698 3 Kleines Schluckvolumen: 698 cm Buchstabe P 3 Mittleres Schluckvolumen: 1 049 cm Buchstabe M Die Buchstaben P oder M müssen sich in der Achse befinden und in Richtung des Schiebers für das Wechseln des Schluckvolumens zeigen, auf der der Nockenring auf dem Lagerteil befestigt ist.

Disassembly Do operations described in chapter "replacement of the bearing support" section "disassembly" page 16 Reassembly Do operations described in chapter "replacement of the bearing support" section "reassembly" page 18. The angular position of the cam must be respected on dual displacement motors with a displacement ratio different from 2. Example : Motor MS18 with displacement 1747-1049-698. 3 Small displacement : 698 cm [42.59 cu.in] letter P 3 Medium displacement : 1049 cm [64.01 cu.in] letter M. The letter P or M must be located in the axis and towards the displacement change spool, with the blind hole towards the fixing of the cam on the bearing support.

P

M M

P

MS08 MSE08 A

R A

R

MS18 MSE18

MS11 MSE11

P

M

M

P

R A

A

P

800378128J

008 911 63

M

2035

REPAR MS2-18 D/GB

BOMAG

27

683

17.3

Drum drive

POCLAIN HYDRAULICS

Auswechseln des kompletten Zylinderblocks (010)

Replacement of the cylinders block assembly (010)

Demontage

Disassembly

Dazu die im Kapitel « Auswechseln des Lagerteils » unter « Demontage » beschriebenen Arbeiten ausführen, Seite 16

Do operations described in chapter "replacement of the bearing support" section "disassembly" page 16

• Nach Demontage des Nockenrings den Zylinderblock ausbauen.

• After removing the cam, remove the cylinders block.

6541

Wiedereinbau

Reassembly

•

•

Neuen O-Ring (027) einsetzen.

Install a new O-ring (027).

6542

• Kompletten Zylinderblock (010) einsetzen.

• Install the cylinders block assembly (010).

6541

• Dazu die im Kapitel « Auswechseln des Lagerteils » unter "Wiedereinbau" beschriebenen Arbeiten ausführen, Seite 18

28

• Do operations described in chapter "replacement of the bearing support" section "reassembly" page 18

REPAR MS2-18 D/GB

684

BOMAG

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS

Auswechseln des Verteilers (047).

Replacement of the valving (047).

Demontage

Disassembly

• Dazu die im Kapitel « Auswechseln des kompletten Zylinderblocks (010)» unter « Demontage » beschriebenen Arbeiten ausführen, Seite 28.

• Do operations described in chapter "replacement of the cylinders bloc assembly (010)" section "disassembly" page 28.

Position des Verteilers (047) in Bezug auf Verteilerdeckel (041) kennzeichnen. (Motor mit 2 Hubvolumen).

Mark location to the valving (047) in relation to the valving cover (041) (Dual displacement motor).

!

• Den Verteiler (047) durch Anheben an den Ausrichtungszapfen oder am Flansch vom Verteilerdekkel (041) abmontieren.

!

• Separate the valving (047) from the cover (041) by levering at the indexing pins or at the flange. 2031

!

Den Verteiler vor Staub schützen.

!

Protect the valving from dusts.

• Federn (052) ausbauen. • Dichtungen und Gegendichtungen (048) vom Verteilerdeckel (041) herausziehen und beseitigen.

• Remove the springs (052). • Remove and discard the seals and back-up rings (048) from the cover (041).

Wiedereinbau

Reassembly

!

Es dürfen keine Rost-, Schmutz- oder Wasserspuren vorhanden sein.

• Neue Dichtungen und Gegendichtungen (048) ölen und einsetzen; dabei die Gegendichtungen so wenig wie möglich verformen.

!

All traces of rust, mud, water must be removed.

• Lubricate and install new seals and back-up rings (048), ensuring the back up rings are twisted as little as possible.

1135

• Die Federn (052) in ihr zuvor mit Fett gefülltes Gehäuse einsetzen. • Die Dichtungsauflageflächen des Verteilers (047) fetten. • Den Verteiler(047) in den Verteilerdeckel (041) drücken 800378128J

008 911 63

• Place the springs (052) in their housings, previously filled with grease. • Lubricate the faces of the seals of the valving (047). • Press the valving (047) into the cover (041).

REPAR MS2-18 D/GB

BOMAG

29

685

17.3

Drum drive

POCLAIN HYDRAULICS

!

Die Einbaurichtung des Verteilers (047) in bezug auf den Verteilerdeckel (041) beachten).

!

Den Einsatz des Verteilers (047) in den Verteilerdeckel (041) nicht forcieren.

!

Respect the assembly sense of the valving (047) in relation to the cover (041).

!

Do not force when installing the valving (047) into the cover (041).

Montage der Verteilerausführung 1C (konstanter Hubvolumen).

Valving assembly type single displacement motor.

• Keine besondere Montagerichtung.

•

No particular assembly sense.

041 047

Montage der Verteilerausführung 2C (umschaltbarer Hubvolumen).

Valving assembly type Dual displacement motor.

• Den gewählten Buchstaben, der die Drehrichtung anzeigt, gegenüber dem Steuerkolben (053) anordnen.

• Write the chosen letter indicate the rotation sense in front of the displacement change spool (053).

POSITIONIERUNG DES VERTEILERS G/L Links

VALVING POSITIONING

2031

G/L Left

041 R

047 L

053 6758 R

053

A

3 2 2 7

30

REPAR MS2-18 D/GB

686

BOMAG

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS D/R Right

D/R Rechts

047 R

041 L

6757 R A

053

3 2 2 8

• Falls kein Buchstabe vorhanden ist, die Ausrichtung anhand der beim Ausbau festgelegten Markierungen vornehmen.

• If there is no letter, do the indexing according to the marks made during disassembly.

• Dazu die im Kapitel « Auswechseln des kompletten Zylinderblocks (010)» unter « Wiedereinbau » beschriebenen Arbeiten ausführen, Seite 28.

• Do operations described in chapter "replacement of the cylinders block" section "reassembly" page 28.

Motoren SE02 und S05

Situation of SE02 and S05 motors

SE02 Motor : SE02 motor :

D/R Rechts D/R Right

G/L Links G/L Left

6959 6 9 5 9

S05 Motor : S05 motor G/L Links G/L Left

D/R Rechts D/R Right 053

6 9 4 8

6948 800378128J

008 911 63

REPAR MS2-18 D/GB

BOMAG

31

687

17.3

Drum drive

POCLAIN HYDRAULICS

Auswechseln der Deckeldichtung (045)

Replacement of the O-ring (045) of the end cover

Demontage

Disassembly

• Motor auf Lagerteil stellen (Muttern sind zum Schutz der Gewindebolzen aufgesetzt) • Schrauben (066) herausnehmen.

• • Place the motor on the bearing support (fitted with nuts for studs protection) • Remove the screws (066)

066

6543

•

Verschlussplatte abnehmen.

•

Remove the end cover

6544

•

O-Ring (045) entfernen.

•

Discard the O-ring (045) 045 057

6545

• Wenn Motor mit 2 Hubvolumen, O-Ring (057) entfernen

• Discard the O-ring (057) if the motor has 2-displacement

6546

32

REPAR MS2-18 D/GB

688

BOMAG

800378128J

008 911 63

17.3

Drum drive


Reassembly

•

Install

Neuen O-Ring (045) einsetzen.

a

new

O-ring

(045).

6547

• Wenn Motor mit 2 Hubvolumen, neuen O-Ring (057) einsetzen, andernfalls zum nächsten Schritt übergehen

• Install a new O-ring (057) if the motor has 2-displacement. If not go to the next section

6548

•

Verschlussplatte montieren.

•

Install the end cover

6544

• Schrauben (066) einsetzen und mit entsprechendem Drehmoment anziehen (siehe Schaubild Seite 38)

• Install and tighten the screws (066) to the right torque (see table page 38)

6543

800378128J

008 911 63

REPAR MS2-18 D/GB

BOMAG

33

689

17.3

Drum drive

POCLAIN HYDRAULICS

Auswechseln des Drehzahlsensors (Option)

Replacing the sensor (optional)

Demontage

Disassembly

•

• Disconnect (161.3)

Stecker (161.3) abziehen

the

connector

6550

• Schraube (165) aufschrauben und ausbauen

• Unscrew and remove the screw (165)

165

6551

• Sensor (161) mit dem Träger (166) abziehen

• Extract the sensor (161) with its support (166)

166

161

6552

34

REPAR MS2-18 D/GB

690

BOMAG

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS Reassembly

Wiedereinbau

!

Der Dichtung (164) auf Sauberkeit der Auflagefläche dem Verteilerdeckel (041) prüfen.

!

Make sure that the seal mounting surface (164) on the valving cover (041) is clean.

• Neuen Haltering (163) und neue Dichtung (164) auf den Sensor (161) mit seiner Distanzscheibe (167) schieben.

• Install the new brake washer (163) and the new seal (164) on the sensor (161) fitted with its adjusting sticker (167).

• Den Sensor in die Halterung (166) stecken, so daß die Dichtung (164) korrekt in ihrer Aufnahme sitzt.

• Push the sensor assembly into the support (166) until the seal (164) is in its housing.

6552

• Sensor (041) in die Bohrung des Verteilerdeckels bis zum Kontakt mit dem Zylinderblock (011) schieben.

• Push the sensor into the valving cover (041) until it comes in contact with the cylinders block (011),

2064

Die Kerbe im Steckeranschluss des Sensors muss radial zur Mitte des Motors (Richtung Welle) zeigen.

the notch of the sensor should be oriented towards the center of the motor.

1 5 ° m a x i 1 5 ° m a x i 6558

• Schrauben (165) einsetzen und mit entsprechendem Drehmoment anziehen (siehe Schaubild Seite 38)

• Install and tighten the screw (165) to the right torque (see table page 38)

6551

• Stecker schließen.

(161.3)

wieder

an-

• Reconnect (161.3).

the

connector

6550

800378128J

008 911 63

REPAR MS2-18 D/GB

BOMAG

35

691

17.3

Drum drive

POCLAIN HYDRAULICS

Tooling inventory

Werkzeug-Liste

Standard tools

Standard Werkzeug • Innensechskant-Schlüssel • Ring-/Maulschlüssel für Sechskantschraube

Hollow head wrench

5 6 8 10 12 14

Hex head wrench

13 17 19 22 24

• Drehmoment-Schlüssel

FACOM J 250 A


FACOM S 250 A Torque wrench

50 bis 240 N.m [35 to 175 lbf.ft]


FACOM K 250 A Torque wrench

160 bis 800 N.m [120 à 600 lbf.ft]

• Korrosionsschutzfett

Auto-top 2000 Anti-oxidizing grease origine AGIP

Leuchtend grüne Farbe / fluorescent green color

•

Zange für Innenringe

•

Abzieher

FACOM 499.32

FACOM U 20 B

Torque wrench

6 bis 30 N.m [4.4 to 22.1 lbf.ft]

Internal snap ring pliers

Extractor

6553

• Sechskantschlüssel für Innensechskantschraube

Hex head wrench

13 17 19 22 24

•

Drehmoment-Schlüssel

FACOM J 250 A

•


FACOM S 250 A Torque wrench

50 à 240 N.m [35 to 175 lbf.ft]

•


FACOM K 250 A Torque wrench

160 à 800 N.m [120 à 600 lbf.ft]

36

Torque wrench

REPAR MS2-18 D/GB

692

BOMAG

6 à 30 N.m [4.4 to 22.1 lbf.ft]

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS

Special tools

Spezialwerkzeuge

Ø

A

G

• Mandrel for reassembling the brake cover or to compress the spring washer.

E

• Montagewerkzeug zum Anheben der Schutzkappe oder zum Komprimieren der Tellerfeder.

B

F

Ø

Ø

C Ø

D 0759

ØA

F02

ØB

mm

[inch]

mm

[inch]

110

[4.3]

100

[4.0]

ØC

ØD

mm [inch] 125

[4.9]

mm 135

[inch]

E

F

[inch]

mm

G

mm

[inch]

mm

[inch]

[5.3]

F03 F04

M12

F05

125

[4.92]

115

[4.52] 151 [5.94]

159

[6.25]

125

[4.92]

115

[4.52] 151 [5.94]

159

[6.25]

50

[1.96]

10

[0.39]

20

[0.78]

50

[1.96]

10

[0.39]

20

[0.78]

50

[1.96]

20

[0.78]

30

[1.18]

F07 F08 F09 F11 F12

M16

F18

190

[7.48]

180

[7.08] 205 [8.07]

215

[8.46] [2.75]

70

F19

[0.39]

10

• Rohr zum Festsetzen des Motors

Tube to immobilize the motor

Ø

Ø 2 5 [0 .9 8 " d ia ]

F21

1 6

[0 .6 2 " d ia ] 5 5 [2 .1 6 " ] 7 0 0 [2 7 .5 5 " ]

M 1 2 H

x 1 2 0

M 1 6 x 1 2 0 c l. 1 0 .9

M 1 2

H M 1 6

Z 1 2 N

• Werkzeuge zur mechanischen Bremslösung.

800378128J

008 911 63

Tools for mechanical brake release

REPAR MS2-18 D/GB

BOMAG

A = 2 0 0

A = 2 8 0

F 0 2 F 0 3 F 0 4 F 0 5 F 0 7 F 0 8 F 0 9

F 1 1 F 1 2 F 1 8 F 1 9 F 2 1

A

Ø

6 0 x 3 0

1 6 .5 [0 .6 4 ] 5 0 x 5

37

693

17.3

Drum drive

POCLAIN HYDRAULICS

Anziehdrehmomente Nm ± 10%

Tightening torques in [lbf.ft] ± 10%

(Gemäß Norm DIN 912)

(According to the standard DIN 912)

Größe Size

8.8

10.9

12.9

8.8

10.9

12.9

M6 M8 M10 M12 M14 M16 M18 M20

10 25 49 86 135 210 290 410

14 35 69 120 190 295 405 580

17 41 83 145 230 355 485 690

7.5 18.4 36 63.4 100 155 214 302

10 26 51 88.4 140 218 299 428

12.5 30 61 107 170 262 358 509

38

REPAR MS2-18 D/GB

694

BOMAG

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS

Ersatzteile

Spare parts list Item Description 010 Cylinders-block assembly 012 Piston Cl 0 assembly 013 Piston Cl 1 assembly 015 Repair kit

Nummer Bezeichnung 010 Kompletter Zylinderblock 012 Kompletter Kolben Cl. 0 013 Kompletter Kolben Cl. 1 015 Reparatursatz 026

040 041 042 043 044 045 047 048 050 051 052 053 054 055 056 057 059 065

026

Kompletter Nockenring 027 O-Ring

040

Komplettes Verteilerdeckel Verteilerdeckel Schraube Dichtungsring Schraube O-Ring Verteiler Dichtungssatz Stopfen O-Ring Feder Umschaltkolben Scheibe Sicherungsring Feder O-Ring Stift

041 042 043 044 045 047 048 050 051 052 053 054 055 056 057 059

Kompletter Verschlussplatte 066 Schraube 067 Dichtring

065

Komplettes Lagerteil Lagerteil Innerer Lippendichtring Rollenlager Rollenlager Scheibensatz Stützring Sicherungsring Äußerer Dichtring Abweiser Dichtungsträger Passfeder Welle Radbolzensatz Bremstrommel Schraube Bremsseil Sicherungsring Komplette Bremsbacke Kompletter Radzylinder Gegenhalter

070

070 071 072 073 074 075 076 077 078 079 081 087 090 091 096 097 098 099 154 155 156

800378128J

008 911 63

Cam assembly 027 O-ring

End cover assembly 066 Screw 067 Sealing ring

071 072 073 074 075 076 077 078 079 081 087 090 091 096 097 098 099 154 155 156

REPAR MS2-18 D/GB

BOMAG

Valving cover assembly Valving cover part Screw Seal washer Screw O-ring Valving Seal kit Plug O-ring Spring Valve spool Washer Snap ring Spring O-ring Pin

Bearing support assembly Bearing support part Radial lip seal Roller bearing Roller bearing Set of shims Thrust ring Snap ring Lip seal Deflector Seal support Key Shaft Set of studs Drum brake Screw Brake cable Snap ring Brake shoe sub-assembly Brake cylinder sub-assembly Brake adjustment

39

695

17.3

Drum drive

POCLAIN HYDRAULICS Nummer 100 101 102 106 107 108 109 110 111 112 113 135 141 142 143 150

Item 100

Bezeichnung Komplette Bremse Bremsgehäuse Schraube O-Ring Kolben Tellerfeder Sicherungsring Welle Dichtsatz Bremswelle Schraube Dichtungsring Satz Bremslamellen Schutzkappe Stopfen O-Ring

101 102 106 107 108 109 110 111 112 113 135 141 142 143 150

Drehzahlsensor-Vorbereitung 152 Scheibe 153 Scheibe

160 161 162 163 164

161 162 163 164

REPAR MS2-18 D/GB

696

Speed sensor assembly Speed sensor part Nut Washer Seal

Sub-assembly sold assembled

Als Satz lieferbare Baugruppe

40

Speed sensor predisposition 152 Washer 153 Washer

160

Kompletter Sensor Sensor Mutter Scheibe Dichtung

Description Brake assembly Brake body Screw O-ring Brake piston Spring washer Snap ring Brake shaft Seal Screw Seal washer Brake kit Cover Plug O-ring

BOMAG

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS

800378128J

008 911 63

REPAR MS2-18 D/GB

BOMAG

41

697

17.3

Drum drive

POCLAIN HYDRAULICS

Motoren mit konstantem Hubvolumen MS, MSE 02-05-08-11-18. Single displacement motors MS, MSE 02-05-08-11-18.

0987

42

REPAR MS2-18 D/GB

698

BOMAG

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS

Dichtungssatz Seal kit

800378128J

008 911 63

REPAR MS2-18 D/GB

BOMAG

0988

43

699

17.3

Drum drive

POCLAIN HYDRAULICS

Motoren mit umschaltbarem Hubvolumen MS, MSE 02-05-08-11-18. Dual displacement motors MS, MSE 02-05-08-11-18.

0990

44

REPAR MS2-18 D/GB

700

BOMAG

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS

Dichtungssatz Seal kit

800378128J

008 911 63

REPAR MS2-18 D/GB

BOMAG

0989

45

701

17.3

Drum drive

POCLAIN HYDRAULICS

46

REPAR MS2-18 D/GB

702

BOMAG

800378128J

008 911 63

17.3

Drum drive

POCLAIN HYDRAULICS

800378128J

008 911 63

REPAR MS2-18 D/GB

BOMAG

47

703

17.3

Drum drive

China

España & Portugal

POCLAIN HYDRAULICS BEIJING rep. office Unit A0808, Hui Bin Officies No.8 Beichendong St. BEIJING 100101 CHINA Tel.: 86 10 6499 3988 Fax: 86 10 6499 3979 e-mail: [email protected]

POCLAIN HYDRAULICS SPAIN S.L. Gran Via Carlos III no84 – 1o 3a 08028 BARCELONA ESPAÑA Tel.: 349 3 409 54 54 Fax: 349 3 490 21 79 e-mail: [email protected]

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POCLAIN HYDRAULICS France SAS B.P. 106 60411 VERBERIE CEDEX FRANCE Tel.: 33 3 44 40 77 77 Fax: 33 3 44 40 77 91 e-mail: [email protected]

Deutschland

Japan

POCLAIN HYDRAULICS GMBH Bergstrasse 106 64319 PFUNGSTADT DEUTSCHLAND Tel.: 49 6157 9474 0 Fax: 49 6157 9474 74 e-mail: [email protected]

POCLAIN HYDRAULICS KK 5-4-6 Kugenumashinme FUJISAWA 251 JAPAN Tel: 81 466 50 4400 Fax: 81 466 50 4422 e-mail: [email protected]

Italia

United Kingdom

POCLAIN HYDRAULICS SRL Via Svizzera 4/A 41012 CARPI (MODENA) ITALIA Tel.: 390 59 64 22 44 Fax: 390 59 64 20 44 e-mail: [email protected]

POCLAIN HYDRAULICS LTD Nene Valley Business Park Oundle PETERBOROUGH, Cambs PE8 4HN ENGLAND Tel.: 44 1832 273773 Fax: 44 1832 274990 e-mail: [email protected]

Nederland

USA

POCLAIN HYDRAULICS BENELUX BV Penningweg 32C 4879 AM ETTEN-LEUR NEDERLAND

POCLAIN HYDRAULICS INC. 7900 Durand Avenue P.O. BOX 801 STURTEVANT, WI 53177 USA Tel.: 1 262 554 6739 Fax: 1 262 554 4860 e-mail: [email protected]

Tel.: 31 76 5021152 Fax: 31 76 5012279 e-mail: [email protected]

POCLAIN HYDRAULICS INDUSTRIE B.P. 106 60411 VERBERIE CEDEX - France Tel.: 33 3 44 40 77 77 Fax: 33 3 44 40 77 99 e-mail: [email protected] www.poclain-hydraulics.com

704

S.A.S. au capital de 85 124 000 Francs Siège social: Route de Saint Sauveur VERBERIE (OISE) R.C.S. Senlis B 414 781 823 Siret 414 781 823 00011

BOMAG

008 911 63

17.4 Vibration motor

008 911 63

BOMAG

705

17.4

706

Vibration motor

BOMAG

008 911 63

17.4

Vibration motor

A10FM

A10FE

RDE92172-01-R/08.01 ersetzt / replaces 06.99

Reparaturanleitung - A10FM 28 - 60 Repair instructions -

008 911 63

BOMAG

A10FE28 - 60 A10FM 28 - 60 A10FE28 - 60

Baureihe 5 Baureihe 5 Series 5 Series 5

707

RDE 92172-01-R/08.01

17.4

Vibration motor

Hinweis / Inhalt

Reparaturanleitung A10FM / A10FE

Notice / Contents

Repair Instructions A10FM / A10FE

HINWEIS Bezeichnungen, Beschreibungen und Darstellungen entsprechen dem Informationsstand zum Zeitpunkt der Drucklegung dieser Unterlage. Änderungen können den Service am Produkt beeinflussen, Verpflichtungen entstehen uns daraus nicht. Methoden und Vorrichtungen sind Empfehlungen, für deren Resultat wir keine Haftung übernehmen können. BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Fabrik-Nr. bestellt, sind die Basis guter Reparaturen. Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf dem Teststand vorzunehmen. Schutz von Personen und Eigentum ist durch Vorkehrungen sicherzustellen. Sachkenntnis, die Voraussetzung für jede Service-arbeit, vermitteln wir in unseren Schulungskursen.

NOTICE Specifications, descriptions and illustrative material shown herein were as accurate as known at the time this publication was approved for printing. BRUENINGHAUS HYDROMATIK reserves the right to discontinue models or options at any time or to change specifications, materials, or design without notice and without incurring obligation. Optional equipment and accessories may add cost to the basic unit, and some options are available only in combination with certain models or other options. For the available combinations refer to the relevant data sheet for the basic unit and the desired option. Adjustment and tests have to be carried out on the test bench under operating temperatures. Protection of personnel and property has to be guaranteed by appropriate measures. Expert knowledge, the precondition of any service work, can be obtained in our training courses.

INHALT

CONTENTS

Seite/ Page

A10FM / A10FE Schnittbild Allgemeine Reparaturhinweise Triebwelle abdichten Motor demontieren Überprüfungshinweise Motor montieren Spülventil demontieren Abstimmung- Lagerung / Hinweise Werkzeuge / Hilfswerkzeuge / Anziehdrehmomente

2

Brueninghaus Hydromatik

708

A10FM / A10FE 3 4 5-7 8-14 15 16-19 20 21 27

Sectional view General repair guidelines Sealing the drive shaft Disassemble the motor Inspection hints Motor assembly Disassembly of the flushing valve Bearing adjustment / Note Tools / auxiliary tools / tightening torques

BOMAG

008 911 63

RDE 92172-01-R/08.01

17.4

Vibration motor

Schnittbild

Reparaturanleitung A10FM / A10 FE

Sectional view


A10FM

A10FE

Optional

Option

Ausführung mit Spülventil

Unit with flushing valve

für geschlossenen Kreislauf

for closed circuit application

008 911 63

BOMAG

Brueninghaus Hydromatik 709

3

RDE 92172-01-R/08.01

17.4

Vibration motor

Allgemeine Reparaturhinweise


General repair guidelines


Achtung! Nachfolgend Hinweise bei allen Reparaturarbeiten an Hydraulikaggregaten beachten! Attention! Observe the following guidelines when carrying out repairs on hydraulic units!

Alle Öffnungen der Hydraulikaggregate verschließen. Close off all openings of the hydraulic unit.

Alle Dichtungen erneuern. Nur original BRUENINGHAUS HYDROMATIK Ersatzteile verwenden. Replace all of the seals. Use only original BRUENINGHAUS HYDROMATIK spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen. Achtung: Nacharbeiten an Dichtflächen z.B. durch Schleifpapier kann die Oberfläche beschädigen. Check all sealing and sliding surfaces for wear. Attention: Re-work of the sliding surfaces by using, for example abrasive paper, can damage the surface.

Hydraulikaggregate vor Inbetriebnahme mit Hydrauliköl befüllen. Fill the hydraulic unit with hydraulic oil before commissioning.

4


710

BOMAG

008 911 63

RDE 92172-01-R/08.01

17.4

Vibration motor


Triebwelle abdichten


Sealing the drive shaft

2 1

1 2

1. Sicherungsring, 2. Wellendichtring

1 1. Circlip, 2. Shaft seal

2

3

(Paßfeder ausbauen bei Ausführung Paßfeder)) Triebwelle abkleben. Sicherungsring ausbauen. (Remove key, version with keyway) Protect the drive shaft. Remove the circlip.

008 911 63

BOMAG


5

RDE 92172-01-R/08.01

17.4

Vibration motor





4

Nach der Demontage des gelaufenen Wellendichtringes, einfetten des neuen WDR.(Kontrolle der Laufflächen, Welle, Gehäuse). Change the shaft seal and check its sliding surface (drive shaft) and housing, grease the sealing ring.

5

Welle mit Schutzhülse oder Klebeband versehen. Use installation tool or plastic strip for assembling seal.

6

Mit geeignetem Rohr den WDR nur so tief montieren, daß der Sicherungsring montierbar ist (zu tiefes Montieren führt zum Ausfall: Berührung mit dem Wellenlager! ). Use a suitable pipe to mount the shaft seal ring, but don't push it too deap. If the shaft ring touches the bearing ring you will damage the seal ring.

7

Sicherungsring einsetzen. Assemble the snap ring.

8

Sicherungsring ganz einrasten. Assemble the snap ring in the correct position.

6


712

BOMAG

008 911 63

RDE 92172-01-R/08.01

17.4

Vibration motor





Hinweis!

Note!

Die hier beschriebene Möglichkeit zum Wechsel der Antriebswellen - Abdichtung stellt nicht die serienmäßige Montage dar. Für sicheres Dichtungsverhalten ist eine Montage des Dichtringes zusammen mit dem Kegelrollenlager von innen her durch das Montagegehäuse durchzuführen. Soll aus Gründen der Vereinfachung im Reparaturfall die vorgehend beschriebene Vorgehensweise durchgeführt werden, so ist beim Ausbau der Dichtung besonders darauf zu achten, daß die Antriebswelle nicht beschädigt wird.

This discription showes how th change the drive shaft sealing ring but it isn't the way of serial assembly. The sealing ring is assembled together with the taper roller bearing from inside the motor housing normally to get a secure sealing condition. If you decide to repair the motor in the shown way be very careful while handling so that the drive shaft wouldn't be damaged during disassembly of the shaft sealing ring.

008 911 63

BOMAG


7

RDE 92172-01-R/08.01

17.4

Vibration motor

Motor demontieren


Disassemble the motor


A10FM

9

8


714

BOMAG

008 911 63

RDE 92172-01-R/08.01

17.4

Vibration motor

Motor demontieren




A10FE

10

008 911 63

BOMAG


9

RDE 92172-01-R/08.01

17.4

Vibration motor

Motor demontieren




11

Demontageposition Lage der Anschlußplatte zum Gehäuse kennzeichnen. Disassembly position Mark the location of the connection plate on the housing.

12

Anschlußplattenbefestigung über Kreuz lösen. Remove the connection plate fixing bolts crosswise.

13

Anschlußplatte abheben. Verteilerplatte kann herunterfallen - festhalten. Verteilerplatte abheben. Remove the connection plate. Distributor plate can drop down - hold tight. Remove distributor plate.

10


716

BOMAG

008 911 63

RDE 92172-01-R/08.01

17.4

Vibration motor

Motor demontieren




14

Verteilerplatte abheben. Remove control plate.

15

Lageraußenring mit Abziehvorrichtung ausbauen. Dichtfläche Verteilerplatte nicht beschädigen. Remove bearing outer ring with withdrawal tool. Do not damage the sealing surface.

16

Abheben des Kegelrollenlagers (anschlußplattenseitig). Entfernen der Abstimmscheibe. Disassemble the taper roller bearing (near by port plate) Remove the adjustment shim.

008 911 63

BOMAG

Brueninghaus Hydromatik 717 11

RDE 92172-01-R/08.01

17.4

Vibration motor

Motor demontieren




17

Triebwerk in horizontaler Lage herausziehen. Remove the rotary group in a horizontal position.

18

Welle nach hinten herausziehen. Remove the drive shaft to rear side.

19

Hubscheibe mit Sonderwerkzeug ausbauen (siehe Bild 20). Remove swash plate with special tool (see picture 20).

20

Der Ausbau der Hubscheibe erfolgt mit einer Schleuder, ein kleiner Haken - aus Rundmaterial Durchmesser 6 mm greift dabei unter die Hubscheibe. Loosen the swash plate with a slide hammer ( a small hook - diameter 6 mm - catches the end of the swash plate at the bottom).

21

Lager mit Presse abziehen. Press down bearing.

12


718

BOMAG

008 911 63

RDE 92172-01-R/08.01

17.4

Vibration motor


Motor demontieren



22

Abziehen des Lageraußenringes im Pumpengehäuse. Zweckmäßige Unterlage benutzen, zur Vermeidung von Gehäusebeschädigungen (s. a. Hinweis Abb.xx). The external front bearing ring is pulled out of the pump housing (tool and surface infos see picture xx, too).

23

Sicherungsring entfernen. Disassemblecirclip and shaft seal.

24

Wellendichtring und Fixierscheibe entnehmen Remove shaft seal ring and shim.

008 911 63

BOMAG


RDE 92172-01-R/08.01

17.4

Vibration motor

Motor demontieren




25

Feder mit Vorrichtung vorspannen. Pre-tension the spring using a suitable device.

26

Sicherungsring demontieren. Feder und Druckstifte ausbauen. Remove circlip. Remove spring and pressure pins.

27

14


720

BOMAG

008 911 63

RDE 92172-01-R/08.01

17.4

Vibration motor


Überprüfungshinweise


Inspection hints

28

Kontrolle! Lauffläche (1) keine Kratzer, keine Metalleinlagerungen, kein Axialspiel (2), (Kolben nur satzweise tauschen). Check! Check to see that there are no scratches or metal deposits on the sliding surface (1), and that there is no axial play (2), (pistons must only be replaced as a set).

29

Kontrolle! Zylinderbohrungen (1), Verzahnungen (2). Check! Cylinder bores (1), splines (2).

30

Riefenfrei, keine Einlaufspuren Free of grooves, no signs of wear.

31

Kontrolle! Zylindergleitfläche riefenfrei, nicht eingelaufen, keine Einlagerungen, Steuerplatte nicht riefig (nur satzweise austauschen). Check! Cylinder sliding surface free of grooves, no wear, no embedded foreign particles. That there are no scratches on the control plate. (Only replace them as a set).

32

Kontrolle! Auflagefläche - Steuerplatte ohne Beschädigung. Check! Mounting surface - control plate undamaged

008 911 63

BOMAG


RDE 92172-01-R/08.01

17.4

Vibration motor

Motor montieren


Motor assembly


33

Sicherungsring ins Gehäuse montieren. Fit the circlip into the housing.

34

Wellendichtring und Fixierscheibe gegen Sicherungsring einsetzen. Assemble shaft seal ring and shim against circlip.

35

3 1

Montage des Wellendichtringes 1 gegen den Sicherungsring 2, anschließend Fixierscheibe 3 einlegen. Assembly of the shaft seal 1 against the safety ring 2, back up the shim 3 down to the seal ring.

2 36

Lageraußenring ins Gehäuse pressen. Welle mit Lager vormontiert ins Gehäuse einstecken. Wellendichtring nicht beschädigen. Wellenverzahnung mit Klebeband umwickeln.

Press outer bearing ring into housing. Shaft seal with pre-assembled bearing into housing. Protect splines of the shaft with plastic strip against damage of the seal lip.

16


722

BOMAG

008 911 63

RDE 92172-01-R/08.01

17.4

Vibration motor


Motor montieren


Motor assembly

37

Hubscheibe montieren. Assemble swash plate.

38

Mit Vorrichtung Druckstifte montieren. Fit pressure pins using an assembly aid.

39

Feder mit Vorrichtung vorspannen. Pre-tension the spring using a suitable device.

40 41

Kolben mit Rückzugeinrichtung montieren. Hinweis: Kolben, Gleitschuhe einölen. Assemble piston with retaining plate. Note: Oil piston and slipper pad.

008 911 63

BOMAG


RDE 92172-01-R/08.01

17.4

Vibration motor

Motor montieren


Motor assembly


42

Rotationsgruppe montieren! Montagehilfe: Mit O-Ring Kolben festhalten.

Fit rotary group! Assembly aid: Hold the pistons by using an O-ring.

43 4

3

Lager (1) in Anschlußplatte montieren. Zylinderstift (2) einsetzen. O-Ring (3) einsetzen. Verteilerplatte (4) aufsetzen. Montagehilfe: Teile mit Fett fixieren.

1 2

Fit bearing (1) in connection plate. Fit cyilindrical pin (2). Fit O-ring (3). Fit distributor plate (4). Assembly: Hold the components in place with grease.

18


724

BOMAG

008 911 63

RDE 92172-01-R/08.01

17.4

Vibration motor


Motor montieren


Motor assembly

44

Verteilerplatte montieren. Montagehilfe: Fett Fit distributor plate. Assembly aid: Grease

45

Anschlußplatte aufsetzen und mit Schrauben über Kreuz anziehen. Fit the connection plate and fix it with the screws crosswise.

A10FM

A10FE

46

008 911 63

BOMAG


RDE 92172-01-R/08.01

17.4

Vibration motor

Spülventil demontieren


Disassembly of the flushing valve


47

Beidseitig Schrauben 1 lösen und Federn mit Scheiben 2 entnehmen. Loosen screws 1, take out springs and shims 2.

1

2

2 1

48

Spülschieber 3 vorsichtig zu einer Seite heausdrücken. Take out spool carefully.

3

49

Verschlußschraube Speisedruckventil 4 lösen, Feder und Einsatz entnehmen. Loosen the screw of the boost valve and take out the spring and the cartridge.

Montage in umgekehrter Reihenfolge! Assembling by opposite steps!

20


726

BOMAG

008 911 63

RDE 92172-01-R/08.01

17.4

Vibration motor

Abstimmung- Lagerung / Hinweise


Bearing adjustment / Note


(Kegelrollenlager) / Taper roller bearing initial tension

Montage - Abstimmung

AA10FM Baureihe 50 AA10FM Series 50 0 .... 0,05 mm

Pos. 12

Abstimmung der Triebwerkslagerung

Adjustment of stopper min displacement

Die Vorspannung der Triebwerkslagerung muß im Gußgehäuse von 0 bis 0,05 mm durch Abschleifen der

Cast iron housing must have initial tension of bearings: 0 ...... 0,05 mm , grind Pos. 12 if necessary.

Abstimmscheibe Pos. 12 hergestellt werden. Adjustment: Qmin- stopper Einstellhinweis: Qmin-Anschlag Bei gegebenem Zusatzstrom wird bei drucklosem Umlauf der Anschlag Qmin so eingestellt, daß die gemessene Drehzahl des Motors einem Schluckvolumen von 12 cm3 entspricht (vgmin). Eine kontinuierliche Verstellung bis vgmax = 45 cm3 ist möglich - Volumenänderung pro Gewindestiftumdrehung ca. 3,1 cm3 (s. a. Seite 3). Schluckvolumen vgmin =

Increase of adjustment is possible to vgmax = 45 cm3 Differential volume is appr. 3,1 cm3 (see page 3). Displacement vgmin =

Q inflow x 1000 Measurement speed

Q Zulauf x 1000 Meßdrehzahl

Achtung: Falsch eingestellte Qmin Anschläge können zu überhöhten Drehzahlen bis hin zum Ausfall der Bauteile führen.

008 911 63

With a given inflow and pressureless circulation adjust the stopper Qmin displacement so that the measured speed of the motors results in a displacement of 12 cm3 (vgmin).

BOMAG

Attention: Wrong adjustments of stopper Qmin displacement increases the speed of the motor up to a possible failure of parts of the unit.


RDE 92172-01-R/08.01

17.4

Vibration motor

Werkzeuge / Hilfswerkzeuge / Anziehdrehmomente


Tools / auxiliary tools / tightening torques


49

Plastikhammer Soft hammer

50

Schleuder ...

Anziehdrehmomente / Tightening torques Festigkeitsklassen Bolt tensile strength grade:

Ma

10,9; 12,9

M4

M5

M6

M8

M10

M12

M14

M16

M18

M20

M24

M30

8,8

2,3

5,0

8,5

21

41

72

115

176

240

350

600

1220

10,9

3,2

7,2

12

29

58

100

165

250

350

490

840

1670

12,9

4,1

8,5

14,5

35

70

121

195

300

410

590

990

2000

Ma (Nm) = max. Anziehdrehmoments (geölte Schrauben μ = 0,125) Ma (Nm) = max. tightening torques (lubricated screws μ = 0,125)

22

8,8;


728

BOMAG

51

008 911 63


008 911 63

BOMAG

729

17.5

730

Axle drive motor

BOMAG

008 911 63

17.5

Axle drive motor

saue Series 51

Bent Axis Variable Motors Service Manual

008 911 63

BOMAG

731

17.5

Axle drive motor

saue Bent Axis Variable Displacement Motors

Series 51

General Description Series 51 Variable Displacement Motors are bent axis design units, incorporating spherical pistons. These motors are designed primarily to be combined with other products in closed circuit systems to transfer and control hydraulic power. Series 51 Motors have a large maximum / minimum displacement ratio (5 to 1) and high output speed capabilities. SAE flange and cartridge motor configurations are available.

A complete family of controls and regulators is available to fulfill the requirements of a wide range of applications.

Motors equipped with controls normally start at maximum displacement. This provides maximum starting torque (high acceleration). The controls may utilize externally or internally supplied servo pressure. They may be overridden by a pressure compensator which functions when the motor is operating in motor and pump modes. A defeat option is available to disable the pressure compensator override when the motor is running in pump mode. The pressure compensator option features a low pressure rise (short ramp) to provide optimal power utilization throughout the entire displacement range of the motor. The pressure compensator is also available as a stand-alone regulator.

●

The Series 51 - Advanced Technology Today

●

The Most Technically Advanced Hydraulic Units in the Industry

●

SAE Flange and Cartridge Motors

●

Cartridge Motors designed for Direct Installation in Compact Planetary Drives

●

Large Displacement Ratio (5:1)

●

Complete Family of Control Systems

●

Proven Reliability and Performance

●

Optimum Product Configurations

●

Compact, Lightweight

Front page: Option - hydraulic two-position control Copyright 1992-1997, Sauer-Sundstrand Company. All rights reserved. Contents subject to change. Printed in U.S.A. 0992H 2

732

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Contents Introduction ......................................................................................................................................................4 Basic Hydraulic Circuits ...................................................................................................................................4 General Description of the Series 51 Variable Displacement Motors ..............................................................5 Functional Description ......................................................................................................................................6 Technical Specifications and Data - Variable Displacement Motors .............................................................. 20 Safety Precautions .........................................................................................................................................21 Gauge Installation ..........................................................................................................................................23 Start-Up Procedure and Maintenance ............................................................................................................25 Component Inspection and Adjustment .........................................................................................................27 Troubleshooting ............................................................................................................................................. 37 Exploded View of the Series 51 Variable Motor .............................................................................................41 Minor Repair and Replacement - Variable Motor ........................................................................................... 51 General .....................................................................................................................................................51 Shaft Seal (SAE Flange Configuration) ....................................................................................................52 Shaft Seal (Cartridge Configuration) .........................................................................................................53 Loop Flushing Shuttle Valve (Option)........................................................................................................54 Charge Pressure Relief Valve ...................................................................................................................55 Minimum Angle Servo Cover .................................................................................................................... 55 Hydraulic 2-Position Control (Type N2) .....................................................................................................56 Electrohydraulic 2-Position Controls (Types E1•E2 and F1•F2) ...............................................................57 Electric 2-Position Controls (Type S1) ......................................................................................................58 Hydraulic Proportional Control (Type HZ) .................................................................................................59 Hydraulic Proportional Control (Type HS) .................................................................................................60 Hydraulic Proportional Control with Maximum Angle Over-ride (Types H1•H2 or K1•K2) ........................61 Two Connection Hydraulic Proportional Control (Type HP) ......................................................................62 Two Connection Hydraulic Proportional Control for “Dual Path” Vehicles (Type HC) ...............................64 Electrohydraulic Proportional Control (Types EP and EQ)........................................................................68 Pressure Control Pilot (PCP) Valve for Electrohydraulic Proportional Control (Types EP and EQ) .......... 70 Multi-function Block ...................................................................................................................................71 Pressure Compensator Regulator (Type PC) ........................................................................................... 76 Control Orifices .........................................................................................................................................77 Plug / Fitting Torques ................................................................................................................................77

0-1

008 911 63

3

BOMAG

733

17.5

Axle drive motor


Series 51

Introduction The purpose of this manual is to provide information necessary for the normal servicing of the Series 51 family of variable displacement hydrostatic motors. This manual includes unit and component description, troubleshooting, adjustments, and minor repair procedures. By following the procedures in this manual, inspections and minor repairs may be performed without affecting the unit warranty. A Series 51 motor does occasionally require servicing, and these units are designed to meet this requirement. Many repairs or adjustments can be completed without removing the unit from the vehicle or machine, provided the unit is accessible and can be thoroughly cleaned before beginning any procedures.

Dirt or contamination is the greatest enemy of any type of hydraulic equipment. The greatest possible cleanliness is necessary when starting up the system, changing filters, or performing any other service procedure. For Technical Information on Series 51 motors, refer to publication BLN-10042 or 368753. For Fluid Quality Requirements, refer to publication BLN-9987 or 697581. Sauer-Sundstrand provides a complete repair service for its products. Contact any Sauer-Sundstrand Authorized Service Center for details. Sauer-Sundstrand Authorized Service Center locations are listed in publication BLN-2-40527 or 698266.

Basic Hydraulic Circuits Closed Circuit

CASE DRAIN LINE

INPUT

OUTPUT

MV

PV

The main ports of the pump are connected by hydraulic lines to the main ports of the motor. Fluid flows in either direction from the pump to the motor then back to the pump in this closed circuit. Either of the hydraulic lines can be under high pressure. The direction and speed of fluid flow (and the motor output shaft rotation) depends on the position of the pump swashplate. The system pressure is determined by the machine load.

Open Circuit

FLOW (BI-DIRECTIONAL) RESERVOIR 51000001

Fig. 0-1 - Basic Closed Circuit FLOW (BI-DIRECTIONAL)

INPUT

PUMP

CONTROL VALVE

FLOW (UNI-DIRECTIONAL)

MV

RESERVOIR

Fig. 0-2 - Basic Open Circuit

OUTPUT

CASE DRAIN LINE 51000002

The outlet port of the pump is connected by a hydraulic line to a directional control valve. The working ports of this valve are connected to the main ports of the motor. When the valve is actuated, fluid flows first from the pump to the valve. The valve then directs the fluid to the motor in either direction. The direction of fluid flow (and motor output shaft rotation) depends on the direction the control valve is shifted. The speed of fluid flow (and motor output shaft speed) depends on pump output volume and the distance the control valve is shifted. The system pressure is determined by the machine load. Fluid returning from the motor is routed through the control valve to the reservoir. Additional components may be necessary to provide dynamic braking and to deal with over-running loads.

0-2

4

734

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

General Description of the Series 51 Variable Displacement Motors The Series 51 variable displacement hydraulic motors use spherical pistons and piston rings. The angle between the cylinder block and the output shaft can be set between 32° and 6°, providing a 5 to 1 maximum to minimum displacement ratio.

Various hydraulic and electrohydraulic controls may be mounted on the motor end cap to control the servo piston and the motor displacement. Servo pressure oil may either be supplied internally from the motor, or externally.

At maximum displacement, the motor will provide a certain maximum output shaft torque and minimum speed corresponding to the pressure and flow supplied to the motor. Under the same input conditions but at minimum displacement, the shaft speed will be approximately five (5) times faster while the available output torque will decrease to approximately one-fifth (1/5) the full displacement value. The displacement is changed by a servo piston which is connected to the valve segment.

For all controls except the N2 and PC, servo pressure oil is supplied to a four (4) way spool valve in the motor end cap. When a combination of pilot pressure (or force) from an external control assembly and internal spring force shifts this valve, servo pressure is routed to move the servo piston and change the motor’s displacement. A synchronizing shaft, with spherical rollers, synchronizes the rotation of the output shaft and the cylinder block. The ball end of each piston runs in a socket bushing, pressed into the output shaft. There are no other parts used to connect the pistons to the shaft. Two tapered roller bearings support the output shaft.

Minimum Displacement Limiter

Control Pressure Port

Hydraulic Pressure Compensator Proportional Override Control

Valve Segment Bearing Plate Tapered Roller Bearings

Piston

Synchronizing Shaft

Servo Piston Cylinder

Charge Pressure Relief Valve P001 196

Fig. 10-1 - Sectional view of Series 51 variable displacement motor (SAE Flange Configuration) with Hydraulic Proportional Control 10 - 1

008 911 63

5

BOMAG

735

17.5

Axle drive motor


Series 51

Functional Description Loop Flushing

51000003

Fig. 10-2 - Loop Flushing Components

51000004

Fig. 10-3 - Loop Flushing Defeat Components

Series 51 motors used in closed circuit applications incorporate an integral loop flushing valve as standard equipment. Installations that require additional fluid to be removed from the main hydraulic circuit because of fluid cooling requirements, or circuits requiring the removal of excessive contamination from the high pressure circuit, can benefit from loop flushing. Series 51 motors used in open circuit applications may have the optional loop flushing defeat components installed. Series 51 motors equipped with an integral loop flushing valve also include a charge pressure relief valve. The setting of the motor charge relief valve affects the function of the flushing circuit. Higher motor charge relief settings reduce the loop flushing flow and increase the flow over the pump charge pressure relief valve when the circuit is operating. Lower motor charge relief settings increase the loop flushing flow and may increase the motor case pressure when the circuit is operating. An appropriate combination of pump and motor charge pressure settings should be maintained to insure the proper function of the loop flushing circuit. Correct charge pressure must be maintained under all conditions of operation to maintain pump control performance in closed loop systems. NOTE: An optional orifice may be installed between the motor charge relief and the motor case to limit the maximum flushing oil flow.

10 - 2

6

736

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Functional Description (Continued) Displacement Limiters All Series 51 motors incorporate mechanical displacement limiters. The minimum displacement of the motor can be limited within the standard range by a set screw in the motor housing. The maximum displacement can be limited with spacers installed on the servo piston.

51000005

Fig. 10-4 - Minimum Displacement Limiter with Tamper Resistant Cap (Cartridge Motor Configuration Shown)

51000006

Fig. 10-5 - Maximum Displacement Limiter Screw Controls - General A wide range of control options is available for the Series 51 motors. These include pilot operated Electrohydraulic 2-Position Controls, Hydraulic Proportional Controls (single or two [2] connection), and Electrohydraulic Proportional Controls. A directly operated Hydraulic 2-Position Control and a Pressure Compensator regulator are also available. The Series 51 variable motor servo piston (except when equipped with N2 control or the PC regulator) may be operated either by servo pressure oil supplied internally from the main ports of the motor, or by servo pressure oil supplied from an external source. (The N2 control uses servo pressure supplied by an external control valve. The PC regulator obtains servo pressure from the main ports of the motor.) Orifice plugs are installed in the control spool sleeve in the end cap to regulate the flow of oil from the servo piston to the motor housing. Orifice plugs may be installed in the end cap to regulate the flow of servo pressure supply oil to the control valve, and to regulate the flow of oil from the control valve to the servo piston.

5100007

Fig. 10-6 - Internal Servo Pressure Supply Screen with Multi-function Block and/or Control Removed (Plug for External Supply)

51000008

Fig. 10-7 - External Servo Pressure Supply Fitting (Plug for Internal Supply)

10 - 3

008 911 63

7

BOMAG

737

17.5

Axle drive motor


Series 51

Functional Description (Continued) Hydraulic 2-Position Control (Type N2) This is a two (2) position (maximum - minimum displacement) control, consisting of a cover plate mounted on the end cap. An external control valve supplies servo pressure from an external source directly to the servo piston. PCOR is not available with the N2 control. 51000009

Fig. 10-8 - Series 51 Motor with N2 Control

When servo pressure is supplied to port “Y1,” the setting piston moves to the maximum motor displacement position. When servo pressure is supplied to port “Y2,” the setting piston moves to the minimum motor displacement position. Orifices may be installed in the external control valve or its connections to regulate the speed of servo piston movement.

51000010

Fig. 10-9 - N2 Control Components

L2

M6

(M4) Y1 Y2 (M3)

A

M1

max. disp.

U4 (opt.)

B

M2

L1 51000011

Fig. 10-10 - N2 Control Schematic

10 - 4

8

738

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Functional Description (Continued) Electrohydraulic 2-Position Control (Types E1•E2 and F1•F2) A 12 or 24 VDC solenoid valve, mounted on the multifunction block, connects the end of the control valve spool in the end cap with pilot pressure (provided by the shuttle spool in the multi-function block) or with the motor case. The control valve in the end cap is biased by a threshold spring, and controls oil flow to the ends of the servo piston. Servo pressure may be supplied from an external source or internally by the shuttle spool in the multi-function block. PCOR is available with these controls.

51000012

Fig. 10-11 - Series 51 Motor with E1•E2 or F1•F2 Control

With the E1 and E2 controls, energizing the solenoid will cause the motor to shift to minimum displacement. When the solenoid is not energized, the motor is held at maximum displacement. With the F1 and F2 controls, energizing the solenoid causes the motor to shift to maximum displacement. When the solenoid is not energized, the motor is held at minimum displacement. 51000013

Fig. 10-12 - E1•E2 and F1•F2 Control Components L2 M6

M4 M3

A

M1

A1 max. disp.

U4 (opt.)

T3 T2

E1•E2

B1 U5 (plug for ext. servo press.)

T7, T8 T1

Servo B Pressure internal L1 M8

M9 X3 (M5) Servo press, external M2

M7 F1•F2

51000014

Fig. 10-13 - E1•E2 and F1•F2 Control Schematic

10 - 5

008 911 63

9

BOMAG

739

17.5

Axle drive motor


Series 51

Functional Description (Continued) Electric 2-Position Control (Type S1) A 12 VDC solenoid valve, mounted on the multifunction block, directly operates the control valve spool in the end cap. The control valve in the end cap is biased by a threshold spring, and controls oil flow to the ends of the servo piston. Servo pressure may be supplied from an external source or internally by the shuttle spool in the multi-function block. PCOR is available with this control. 51000162

Fig. 10-14 - Series 51 Motor with S1 Control

With the S1 control, energizing the solenoid causes the motor to shift to maximum displacement. When the solenoid is not energized, the motor is held at minimum displacement.

51000163

Fig. 10-15 - S1 Control Components

L2 M6

M4 M3

A

M1

A1 max. disp.

U4 (opt.)

T3 T2

S1


T7, T8 T1

Servo B Pressure internal L1


51000085

Fig. 10-16 - S1 Control Schematic

10 - 6

10

740

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Functional Description (Continued) Hydraulic Proportional Control (Type HZ) The HZ control consists of a cover plate mounted directly on the end cap. A ball type shuttle valve provides internal servo pressure supply to the control valve in the end cap. PCOR is not available with the HZ control. Feedback springs (single spring for 060, 080 and 110) and a threshold spring are installed in the end cap. The feedback springs and threshold spring provide a force on the end of the control spool. The force of the threshold spring is externally adjustable with an adjusting screw. The feedback spring is positioned between the control spool and a feedback lug attached to the servo piston. The force of the feedback spring increases as the motor’s displacement decreases. Pilot oil pressure from an external source is applied to the end of the control spool opposite the feedback and threshold springs. An increase in pilot pressure (above the threshold pressure and within the modulating pressure range) will result in a decrease in motor displacement, while a decrease in pilot pressure will result in an increase in motor displacement.

51000015

Fig. 10-17 - Series 51 Motor with HZ Control

51000016

Fig. 10-18 - HZ Control Components

L2

M6

M4 M3

A

M1

max. disp.

U4 (opt.)

T3 T2

T7, T8

U5 (plug for ext. servo press.)

T1

B Servo Pressure internal L1 X1


M7 51000017

Fig. 10-19 - HZ Control Schematic

10 - 7

008 911 63

11

BOMAG

741

17.5

Axle drive motor


Series 51

Functional Description (Continued) Hydraulic Proportional Control (Type HS) The HS control consists of a cover plate (with a hydraulic port) mounted on the multi-function block. Servo pressure may be supplied from an external source or internally by the shuttle spool in the multifunction block. PCOR is available with this control. The function of the HS control is identical to the function of the HZ control. 51000018

Fig. 10-20 - Series 51 Motor with HS Control

51000019

Fig. 10-21 - HS Control Components L2

M6

M4 M3

A

M1

A1 max. disp.

U4 (opt.)

T3 T2

B1 T7, T8

U5 (plug for ext. servo press.)


T1


X1

M7

X1

M7

X1

HS

H1•H2

K1•K2 51000022

Fig. 10-22 - HS, H1•H2, and K1•K2 Control Schematic 10 - 8

12

742

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Functional Description (Continued) Hydraulic Proportional Control with Electric Override (Types H1•H2 and K1•K2) The function of the H1•H2 and K1•K2 controls is similar to the function of the HS control. A 12 or 24 VDC solenoid valve is installed between the external pilot pressure source and the control spool. With the H1•H2 controls, energizing the solenoid allows the control to function as an HS control. When the solenoid is not energized, pilot pressure is blocked and the end of the control spool is drained to the motor case, causing the motor to shift to maximum displacement.

51000020

Fig. 10-23 - Series 51 Motor with H1•H2 Control

With the K1•K2 controls, energizing the solenoid blocks pilot pressure and drains the end of the control spool to the motor case, causing the motor to shift to maximum displacement. When the solenoid is not energized, the control functions as an HS control.

51000167

Fig. 10-24 - Series 51 Motor with K1•K2 Control

51000021

Fig. 10-25 - H1•H2 and K1•K2 Control Components

10 - 9

008 911 63

13

BOMAG

743

17.5

Axle drive motor


Series 51

Functional Description (Continued) Two Line Hydraulic Proportional Control (Type HP)

51000023

Fig. 10-26 - Series 51 Motor with HP Control

This control consists of a valve block with two (2) hydraulic ports mounted on the multi-function block. The valve block incorporates a shuttle spool and a pilot piston with centering springs. A pin transmits force from the pilot piston to the control spool in the end cap. Feedback springs (single spring for 060, 080, and 110) and a threshold spring are installed in the end cap. These springs function similar to the HS control. Servo pressure may be supplied from an external source or internally by the shuttle spool in the multi-function block. PCOR is available with this control. Two pilot pressures are provided to the control. The shuttle spool directs the higher pilot pressure to the end of the pilot piston opposite the feedback spring, and the lower pressure to the opposite side of the pilot piston. The rod transmits a force, proportional to the difference of the pilot pressures, to the control spool.

51000024

Fig. 10-27 - HP Control Components

L2

M6

An increase in the difference between the pilot pressures will result in a decrease in motor displacement, while a decrease will result in an increase in displacement.

M4 M3

A

M1

A1 max. disp.

U4 (opt.)

T3 T2


T7, T8 T1

Servo B Press, internal L1


X2 X1

Fig. 10-28 - HP Control Schematic

51000025

10 - 10

14

744

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Functional Description (Continued) Two Line Hydraulic Proportional Control for “Dual-Path” Vehicles (Type HC) The HC control operates in a similar manner to the HP control, however the HC control is optimized for use in “dual-path” drive vehicles. This control consists of a valve block with two (2) hydraulic ports mounted on the end cap. The valve block incorporates a shuttle spool and a pilot piston with centering springs. A pin transmits force from the pilot piston to the control spool in the end cap. A bleed valve is provided to eliminate any air which might become trapped in the pilot piston oil passages.

51000158

Fig. 10-29 - Series 51 Motor with HC Control

Feedback springs are installed in the end cap. Servo pressure is supplied internally by a ball type shuttle valve in the control housing. PCOR is not available with this control. Two pilot pressures are provided to the control. The shuttle spool directs the higher pilot pressure to the end of the pilot piston opposite the feedback springs, and the lower pressure to the opposite side of the pilot piston. The pin transmits a force, proportional to the difference of the pilot pressures, to the control spool. An increase in the difference between the pilot pressures will result in a decrease in motor displacement, while a decrease will result in an increase in displacement. The feedback springs in the end cap have differing spring rates and operate in parallel (060, 080, and 110) or series (160 or 250) to provide a linear relationship between motor displacement and pilot pressure differential.

51000111

Fig. 10-30 - HC Control Components L2

M6

M4 M3

A

M1

max. disp.

U4 (opt.)

T3 T2

T7, T8 T1

M9 M5 M2

B L1 X2 X1

Fig. 10-31 - HC Control Schematic

10 - 11

008 911 63

51000160

15

BOMAG

745

17.5

Axle drive motor


Series 51

Functional Description (Continued) Electrohydraulic Proportional Control (Types EP and EQ)

51000026

Fig. 10-32 - Series 51 Motor with EP Control (EQ Similar)

This control consists of a valve block and PCP (Pressure Control Pilot) valve mounted on the multi-function block. The valve block incorporates a pilot piston with centering springs. A pin transmits force from the pilot piston to the control spool in the end cap. Feedback springs (single spring for 060, 080, and 110) and a threshold spring are installed in the end cap. These springs function similar to the HS control. Servo pressure may be supplied from an external source or internally by the shuttle spool in the multifunction block. PCOR is available with this control. An external pilot pressure source is connected to the inlet of the PCP valve, which produces differential pilot pressures proportional to the current through it. These pressures are applied to the pilot piston. The operation of this control is similar to that of the HP Control, with the motor displacement being proportional to the current through the PCP valve. An increase in current (above the threshold current) will result in a decrease in motor displacement, while a decrease will result in an increase in displacement.

51000027

Fig. 10-33- EQ Control Components (EP Similar)

L2

M6

M4 M3

A

M1

A1 max. disp.

U4 (opt.)

T3 T2


T7, T8 T1


X1


M8 51000028

Fig. 10-34 - EP and EQ Control Schematic

10 - 12

16

746

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Functional Description (Continued) Multi-function Block Components The Multi-function Valve Block includes a shuttle valve which provides internally supplied servo pressure, and an optional Pressure Compensator OverRide (PCOR) function with optional brake pressure defeat.

51000029

Fig. 10-35 - Multi-function Block (Without Control) Servo Pressure Supply For internal supply, the multi-function block incorporates a shuttle spool with internal check ball valve that routes oil from the main circuit ports of the motor to the control valve in the end cap. “High side” pressure is provided to the servo control valve in the end cap. For external supply, the connection between the shuttle spool and the servo control valve is blocked in the end cap. The external pressure supply to the servo control valve connects to a port (“M5”) on the end cap.

51000030

Fig. 10-36 - Multi-function Block with Servo Pressure Supply Shuttle Spool

Pressure Compensator Over-Ride (PCOR) The Pressure Compensator Over-Ride (PCOR) system includes a spool valve located in the PCOR block which is attached to the multi-function block. This system increases the motor displacement at system pressures above the PCOR valve setting. (Pressure Compensator Over-Ride is not available with the N2 and HZ controls, or the PC regulator.) For bi-directional PCOR operation, the shuttle valve in the multi-function block routes system high pressure to the PCOR spool valve. For single direction PCOR operation, the PCOR spool valve is connected to one (1) side of the closed loop through passages in the multi-function block

51000031

Fig. 10-37 - Multi-function Block with PCOR Block and Spool Valve (K1•K2 Control Shown)

When system pressure exceeds the PCOR setting, the spool valve moves to connect the displacement reducing end of the servo piston to the motor case, and the displacement increasing end of the servo piston to system pressure. This increases the motor displacement, which reduces the motor output speed. When the PCOR valve closes, control of the servo piston returns to the control spool in the motor end cap.

10 - 13

008 911 63

17

BOMAG

747

17.5

Axle drive motor


Series 51

Functional Description (Continued)

51000032

Fig. 10-38 - Multi-function Block with PCOR Defeat Spool Components Shuttle Valve

Shuttle Valve A1

Defeat Spool

T4

An optional “brake pressure defeat” spool may be installed in the multi-function block. When used with the PCOR, this spool assures that the PCOR does not cause the motor displacement to increase during deceleration (which could cause pump overspeed). Pressure from a source such as the pump servos or an external valve, shifts the defeat spool to block the high pressure supply to the PCOR valve from the “deceleration” side of the closed loop. Either bidirectional or single direction PCOR operation can be specified when PCOR defeat is installed.

PCOR Brake Pressure Defeat Operation A1

Rotation

High pressure port

Control pressure on port

CW

A

XB

CCW

B

XA

T5

U7

U6

PCOR Valve

U7

B1

T6

U6

B1

PCOR Valve XA XB

Standard with Defeat Pressure Compensator Override 51000033

Fig. 10-39 - PCOR and PCOR with Defeat Schematic

10 - 14

18

748

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Functional Description (Continued) Pressure Compensator Regulator (Type PC) In this regulator, the Pressure Compensator system in the multi-function block assembly controls the motor displacement. At system pressures below the compensator setting, the servo piston is maintained in the minimum motor displacement position. When system pressure exceeds the POR setting, hydraulic pressure acts on the servo piston to increase the motor displacement. With the Pressure Compensator regulator, an increase in system pressure (above the setting pressure) will result in an increase in motor displacement and output torque, and a decrease in motor shaft speed.

51000034

Fig. 10-40 - Series 51 Motor with PC Regulator

51000035

Fig. 10-41 - PC Regulator Components

L2

M6

M4 M3

A

M1

max. disp. T5 U7 U4 (opt.)

U6

T7 T1

M9 M5

B

M2

L1 51000036

Fig. 10-42 - PC Regulator Schematic

10 - 15

008 911 63

19

BOMAG

749

17.5

Axle drive motor


Series 51

Technical Specifications and Data - Variable Displacement Motors Design

Hydraulic Fluid

Piston motor with variable displacement, bent axis construction.

Refer to Sauer-Sundstrand publication BLN-9887 or 697581.

Type of Mounting

Temperature

SAE four (4) bolt flange – SAE Flange Configuration. Two (2) bolt flange – Cartridge Motor Configuration.

ϑ min ϑ nominal ϑ max

Pipe Connections

1)

= -40°C (-40°F), intermittent, cold start = 104°C (220°F), continuous = 115°C (240°F), intermittent

1)

Main pressure ports: Remaining ports:

at the hottest point, normally the case drain line. Hydraulic fluid viscosity must be as shown below.

SAE flange SAE O-ring thread

Fluid Viscosity Limits

Direction of Rotation Clockwise and counter-clockwise.

Installation Position Installation position discretionary. The housing must always be filled with hydraulic fluid.

System Pressure Range, Input Max: Min:

ν min ν min ν min ν max ν max

= 5 mm2/s (42 SUS) = 6.4 mm2/s (47 SUS) = 13 mm2/s (70 SUS) = 110 mm2/s (510 SUS) = 1600 mm2/s (7400 SUS)

intermittent min. continuous optimum max. continuous intermittent, cold start

Filtration Acceptable contamination level: ISO Code 18/13 or better. Refer to Sauer-Sundstrand publication BLN-9887 or 697581.

480 bar (6960 psi) 10 bar (145 psi)

Case Pressure Max. Continuous: 3 bar (44 psi) Intermittent (Cold start): 5 bar (73 psi) Frame Size Dimension

060

080

110

160

250

maximum

cm3 in3

60.0 3.66

80.7 4.92

109.9 6.71

160.9 9.82

250.0 15.26

minimum

cm3 in3

12.0 0.73

16.1 0.98

22.0 1.34

32.2 1.96

50.0 3.05

Continuous speed

at max disp at min disp

min-1 (rpm) min-1 (rpm)

3600 5600

3100 5000

2800 4500

2500 4000

2200 3400

Max. speed

at max disp at min disp

min-1 (rpm) min-1 (rpm)

4400 7000

4000 6250

3600 5600

3200 5000

2700 4250

Theoretical torque

at max disp

Nm / bar lbf•in / 1000 psi

0.95 583

1.28 784

1.75 1067

2.56 1563

3.98 2428

at min disp

Nm / bar lbf•in / 1000 psi

0.19 117

0.26 156

0.35 214

0.51 313

0.80 486

Q max

L / min gal / min

216 57

250 66

308 81

402 106

550 145

Pcorner max

kW hp

336 450

403 540

492 660

644 864

850 1140

Mass moment of inertia

J

kg • m2 lbf • ft2

0.0046 0.1092

0.0071 0.1685

0.0128 0.3037

0.0234 0.5553

0.0480 1.1580

Weight (with control N2)

m

kg lb

28 62

32 71

44 97

56 123

86 190

Displacement

Max. continuous flow Max. corner power

10 - 16

20

750

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Safety Precautions ● When Series 51 units are used in vehicular hydrostatic drive systems, the loss of hydrostatic drive line power in any mode of operation may cause a loss of hydrostatic braking capacity. A braking system, redundant to the hydrostatic transmission must, therefore, be provided which is adequate to stop and hold the system should the condition develop. ● Certain service procedures may require the vehicle/machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing them in order to prevent injury to the technician and bystanders.

20 - 1

008 911 63

● Use caution when dealing with hydraulic fluid under pressure. Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury. This fluid may also be hot enough to burn. Serious infection or reactions can develop if proper medical treatment is not administered immediately. ● Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area where a source of ignition may be present.

21

BOMAG

751

17.5

Axle drive motor


Series 51

Notes

20 - 2

22

752

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Gauge Installation Various pressure gauge readings can be a great asset in troubleshooting problems with the Series 51 motor or support system.

Snubbers are recommended to protect pressure gauges. Frequent gauge calibration is necessary to insure accuracy.

Fig. 30-1 - Gauge Ports, Motor with N2 Control Port "L1"

Port Y2: Servo press., external (N2 Control Only) "X" Gauge port M3; Servo pressure min. displacement

Gauge port M6: Charge pressure 9/16 — 18 UNF-2B Gauge port M2: Port "B" system pressure

A

B

Gauge port M1: Port "A" system pressure

M1 Port Y1: Servo press., external (N2 Control Only) Gauge port M4: Servo pressure max. displacement

Port "L2"

M2

Side Port End Cap Axial Port End Cap View in Direction "X"

Right Side View

51000037

Fig. 30-2- Gauge Ports, Motor with E1•E2, F1•F2, H1•H2, and K1•K2 Controls Port X3: servo press., external Gauge port M5: servo press., internal Control • E1/E2•F1/F2 Gauge port M8 Control • H1/H2 Control pressure port X1

Control • E1/E2 • F1/F2 Control • H1/H2 • K1/K2 Gauge port M7 control pressure

XA

View"T"

Control • K1/K2 Control pressure port X1

XA XB

XB

"T"

51000038

Fig. 30-3 - Gauge Ports, Motor with HS and HZ Controls Port X3: servo press., ext. Gauge port M5: servo press., int.

Gauge port M7: Control pressure

XA

Gauge port M7: Control pressure View"U" (HS)

XB

XA

Control pressure port X1

XB "U"

Control pressure port X1 51000039

30 - 1

008 911 63

View"U" (HZ)

23

BOMAG

753

17.5

Axle drive motor


Series 51

Gauge Installation (Continued) Fig. 30-4 - Gauge Ports, Motor with HP Control Port X3: servo press., ext. Gauge port M5: servo press., int.

XA

View"V"

XB

XA XB

X1 X2 Ports X1, X2: Control pressure 9/16 — 18 UNF-2B "V"

51000040

Fig. 30-5 - Gauge Ports, Motor with EP•EQ Control Port X3: servo press., ext. Gauge port M5: servo press., int.

XA

View"W"

XB

XA XB

MS-Connector (MS3102C) 7/8 — 20 UNEF

Manual override "W"

Port X1: External PCP supply pressure

Packard Connector

51000041

Gauge Information System Pressure Port “A” System M2 Pressure Port “B” Servo M3 Pressure (Min. Angle) Servo M4 Pressure (Max. Angle) Servo M5 Supply (M9) Pressure

600 bar or 10,000 psi Gauge

M1

M6 9/16 — 18 O-Ring Fitting 600 bar or 10,000 psi Gauge 9/16 — 18 O-Ring Fitting 600 bar or 10,000 psi Gauge

M7 M8 L1 L2

9/16 — 18 O-Ring Fitting 600 bar or 10,000 psi Gauge 9/16 — 18 O-Ring Fitting 600 bar or 10,000 psi Gauge 9/16 — 18 O-Ring Fitting or Tee into Control Pressure Line

X1 X2 X3 XA XB

Control Pressure Defeat Pressure

60 bar or 1000 psi Gauge 9/16 — 18 O-Ring Fitting 60 bar or 1000 psi Gauge 9/16 — 18 O-Ring Fitting 60 bar or 1000 psi Gauge 060, 080, 110: 1-1/16 — 12 O-Ring Fitting 160, 250: 1-5/16 — 12 O-Ring Fitting 60 bar or 1000 psi Gauge 9/16 — 18 O-Ring Fitting 60 bar or 1000 psi Gauge Tee into Defeat Pressure Line(s) 30 - 2

24

754

Motor Charge Pressure Control Test Port Case Pressure

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Start-Up Procedure and Maintenance Start-Up Precautions Cleanliness Ensure that all system components, including fittings, pipes, and hoses, are completely clean. If cloths are used for cleaning components, they must be made of lint-free materials. Follow the guidelines presented in Sauer-Sundstrand publication BLN-9887 or 697581 for required fluid cleanliness levels at machine start-up. Reservoir and Fluid Level The reservoir should be designed to accommodate maximum volume changes during all system operating modes, and to promote de-aeration of the fluid as it passes through the tank. The reservoir outlet (charge pump inlet) and the reservoir inlet (fluid return) must always be below the normal fluid level. A sight glass is the preferred method for checking fluid level. The reservoir inlet (fluid return) should be positioned so that flow to the reservoir is directed into the interior of the reservoir for maximum dwell and efficient deaeration. A baffle (or baffles) between the reservoir inlet and outlet ports will promote de-aeration and reduce surging of the fluid. No funnel-shaped eddying at the reservoir outlet (charge pump inlet) or formation of foam at the reservoir inlet (fluid return) is permitted.

Start-Up Procedure The following start-up procedure should always be followed when starting-up a new Series 51 installation or when restarting an installation in which either the pump or motor has been removed from the system. WARNING The following procedure may require the vehicle/machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. Take necessary safety precautions before operating the vehicle/machine. Prior to installing the motor, inspect the unit for damage incurred during shipping and handling. Make certain all system components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean prior to filling with fluid.

Fill the reservoir with recommended hydraulic fluid, which should be passed through a 10 micron (nominal, no bypass) filter prior to entering the reservoir. The use of contaminated fluid will cause damage to the components, which may result in unexpected vehicle/machine movement. The inlet line leading from the reservoir to the pump must be filled prior to start up. Check inlet line for properly tightened fittings and make sure it is free of restrictions and air leaks. Be certain to fill the pump and motor housing with clean hydraulic fluid prior to start up. Fill the housing by pouring filtered oil into the upper case drain port. Install a 0 to 60 bar or 0 to 1000 psi pressure gauge in the charge pressure gauge port to monitor the charge pressure during start-up. The external control input signal should be disconnected at the pump control during initial start-up. This will allow the pump to remain in its neutral position. “Jog” or slowly rotate prime mover until charge pressure starts to rise. Start the prime mover and run at the lowest possible RPM until charge pressure is established. Excess air may be bled from the high pressure lines through the high pressure gauge ports. Once charge pressure is established, increase speed to normal operating RPM. Note the charge pressure. If charge pressure is incorrect, shut down and determine cause for improper pressure. Shut down prime mover and connect external control input signal. Start prime mover, checking to be certain pump remains in neutral. With prime mover at normal operating speed, slowly check for forward and reverse machine operation. Charge pressure should be maintained during forward or reverse operation. Continue to cycle slowly between forward and reverse for at least five (5) minutes. Shut down prime mover, remove gauges, and plug ports. Check reservoir level and add fluid if necessary. The transmission is now ready for operation.

30 - 3

008 911 63

25

BOMAG

755

17.5

Axle drive motor


Series 51

Start-Up Procedure and Maintenance (Continued) Maintenance

Changing the Fluid and Filter

Cleanliness The reservoir breather air filter (if equipped) must be kept clean. Clean the area around the filler cap before opening the reservoir. The hydraulic fluid should be filtered before it enters the reservoir. Follow the guidelines presented in Sauer-Sundstrand publication BLN-9887 or 697581 for required fluid cleanliness levels during machine operation.

To insure optimum service life on Series 51 products, regular maintenance of the fluid and filter must be performed. The fluid and filter must be changed per the vehicle/ machine manufacturer’s recommendations. In the absence of such recommendations, the following intervals may be used:

Recommended Fluids

• System with a sealed type reservoir - 2000 hrs. • System with a breathing type reservoir - 500 hrs.

Hydraulic fluids used with Sauer-Sundstrand products should be carefully selected with assistance from a reputable supplier, following the guidelines presented in Sauer-Sundstrand publication BLN-9887 or 697581.

It may be necessary to change the fluid more frequently if the fluid becomes contaminated with foreign matter (dirt, water, grease, etc.) or if the fluid has been operating at temperature levels greater than the maximum recommended. Never reuse fluid.

Checking for Leaks

The filter should be changed when changing the fluid, or whenever the filter indicator shows that it is necessary to change the filter.

Check the system components for leakage at regular intervals. Tighten any leaking connections while the system is not under pressure. Replace any defective seals and gaskets. Check hydraulic hoses for damage or aging. When installing replacements, be certain that the hoses are clean and connected properly. Checking the Fluid Level Check the reservoir daily for proper fluid level, the presence of water (noted by a cloudy or milky appearance, or free water in bottom of reservoir), and rancid fluid odor (indicating excessive heat).

30 - 4

26

756

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Component Inspection and Adjustment WARNING The following procedures may require the vehicle/machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the adjustments to prevent injury to the technician and bystanders.

Charge Pressure Relief Valve Adjustment An appropriate combination of pump and motor charge pressure settings should be maintained to insure the proper function of the loop flushing circuit. Correct charge pressure must be maintained under all conditions of operation to maintain pump control performance in closed loop systems. To measure motor charge pressure, install a 0 to 60 bar or 0 to 500 psi pressure gauge in the motor charge pressure gauge port. Install a gauge to measure case pressure. Operate the system with the prime mover at normal operating speed and the pump at half stroke (forward or reverse) when measuring motor charge pressure.

51000042

Fig. 30-6 - Adjusting Charge Pressure Relief Valve

In most applications, the motor charge relief valve is set 2 to 4 bar (29 to 58 psi) below the setting of the pump charge relief valve (measured with the pump in its “neutral” or zero-angle position). This setting assumes a reservoir temperature of 50° C (122° F), and is referenced to case pressure. Series 51 motors are equipped with an external screw adjustable charge pressure relief valve. To adjust the charge pressure, loosen the lock nut (with a 1-1/16" hex wrench) and turn the adjustment plug with a large screwdriver. Clockwise rotation of the plug increases the setting, and counter-clockwise rotation decreases the setting (at a rate of approximately 3.4 bar [50 psi] per turn). The lock nut should be torqued to 52 Nm (38 ft•lbsf).

51000043

Fig. 30-7 - Tighten Charge Pressure Relief Valve Lock Nut

Once the desired charge pressure setting is achieved, remove the gauges and reinstall the port plugs.

30 - 5

008 911 63

27

BOMAG

757

17.5

Axle drive motor


Series 51

Component Adjustment (Continued) Minimum Displacement Limiter Adjustment The minimum displacement is set at the factory, and the adjustment screw is covered with a tamperresistant cap WARNING

510000434

Fig. 30-8 - Loosen Minimum Displacement Limiter Lock Nut

Care should be taken in adjusting displacement limiters to avoid undesirable speed conditions. The sealing lock nut must be retorqued after every adjustment to prevent an unexpected change in operating conditions and to prevent external leakage during unit operation. NOTE: Changes in motor displacement can be detected by providing a constant flow of fluid to the motor, while maintaining the motor at minimum displacement and monitoring the motor output shaft speed. An increase in displacement will result in a decrease in shaft speed, while a decrease in displacement will result in an increase in shaft speed.

51000045

Fig. 30-9 - Rotate Minimum Displacement Adjusting Screw

Frame Size 060 080 110 180 250 Frame Size 060 080 110 160 250

Approximate Change in Minimum Displacement Per Revolution of Adjusting Screw 1.5 cc/Rev (.09 in3/Rev) 2.1 cc/Rev (.13 in3/Rev) 3.1 cc/Rev (.19 in3/Rev) 4.0 cc/Rev (.24 in3/Rev) 6.2 cc/Rev (.38 in3/Rev)

Min. Displacement Range cc/Rev (in /Rev) 12 to 29 (.73 to 1.77) 30 to 40 (1.83 to 2.44) 16 to 35 (.98 to 2.14) 36 to 54 (2.20 to 3.20) 22 to 46 (1.34 to 2.81 ) 47 to 74 (2.87 to 4.52) 32 to 72 (1.95 to 4.39) 73 to 107 (4.45 to 6.53) 50 to 90 (3.05 to 5.49) 91 to 130 (5.55 to 7.93) 131 to 167 (7.99 to 10.19) 3

To adjust the minimum displacement, first remove and discard the cap covering the adjusting screw. Using a 17 mm hex wrench for 060 and 080 frame size motors or a 19 mm hex wrench for 110 through 250 frame size motors, loosen the lock nut retaining the minimum displacement limiter adjusting screw. Using a 5 mm internal hex wrench for 060 and 080 frame size motors or a 6 mm internal hex wrench for 110 through 250 frame size motors, rotate the adjusting screw to limit the minimum displacement of the motor.

Screw Size and Length mm (in) M10x65 (2.56) M10x80 (3.15) M10x65 (2.56) M10x80 (3.15) M12x70 (2.76) M12x80 (3.15) M12x75 (2.95) M12x90 (3.54) M12x75 (2.95) M12x90 (3.54) M12x100 (3.94)

Rotating the adjusting screw clockwise will increase the minimum displacement of the motor, while rotating the adjusting screw counter-clockwise will decrease the minimum displacement. For each full revolution, of the adjusting screw, the displacement will change according to the accompanying chart. Different minimum displacements may require different length adjusting screws. The various lengths are shown in the accompanying chart. After establishing the desired minimum displacement setting, tighten the lock nut on the adjusting screw to 51 Nm (38 ft•lbsf) for 060 and 080 frame size motors or 86 Nm (63 ft•lbsf) for 110 through 250 frame size motors. Install a new tamper-resistant cap on the adjusting screw.

30 - 6

28

758

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Component Adjustment (Continued) Maximum Displacement Limiter Adjustment The maximum displacement of the Series 51 motors can be limited by limiting the stroke of the setting piston, and the resulting movement of the valve segment. A displacement stop screw is installed on the setting piston (under the minimum angle servo cover) to limit the stroke of the piston. Spacers may be installed on the displacement stop screw to limit the stroke. A longer or shorter screw must be used to retain a thicker or thinner spacer. WARNING Care should be taken in adjusting displacement limiters to avoid undesirable speed conditions. The stop screw must be retorqued after adjustment to prevent an unexpected change in operating conditions. NOTE: Changes in motor displacement can be detected by providing a constant flow of fluid to the motor, while maintaining the motor at maximum displacement and monitoring the motor output shaft speed. An increase in displacement will result in a decrease in shaft speed, while a decrease in displacement will result in an increase in shaft speed.

51000046

Fig. 30-10 - Remove Minimum Angle Servo Cover Screws

Frame Size

To adjust the maximum displacement, first remove the screws retaining the minimum angle servo cover to the end cap with an 8 mm internal hex wrench (060, 080, 110, and 160 units), or a 10 mm internal hex wrench (250 units). Remove the minimum angle servo cover and O-rings. Remove the displacement limiter screw with an 8 mm internal hex wrench.

060 080 110 160 250

Installing a thicker spacer on the end of the setting piston will reduce the maximum displacement of the motor. Installing a thinner spacer will increase the maximum displacement. The displacement will change according to the accompanying chart.

Approximate Change in Maximum Displacement with Change in Spacer Thickness cc/mm (in3/.1 in) 0.98 (.15) 1.14 (.18) 1.48 (.23) 1.93 (.30) 2.63 (.41)

Torque the displacement limiter screw to 54 Nm (40 ft•lbsf). Install the minimum angle servo cover and its O-rings. Install the cover screws and torque to 78 Nm (58 ft•lbsf) for 060, 080, 110, and 160 motors, or 110 Nm (81 ft•lbsf) for 250 motors. 51000070

Fig. 30-11 - Torque Maximum Displacement Limiter Screw 30 - 7

008 911 63

29

BOMAG

759

17.5

Axle drive motor


Series 51

Component Adjustment (Continued) Displacement Control Adjustments NOTE: A change in motor displacement can be detected by providing a constant flow of fluid to the motor and monitoring the motor output shaft speed while adjusting the control. An increase in displacement will result in a decrease in shaft speed, while a decrease in displacement will result in an increase in shaft speed.

Hydraulic 2-Position Control (Type N2) No adjustments are provided for the N2 control. A minimum of 25 bar (360 psi) servo pressure is required to change the motor displacement with the motor shaft turning. A minimum of 70 bar (1015 psi) servo pressure is required to change the motor displacement with the motor shaft locked. 50000009

Fig. 30-12 - Hydraulic 2-Position Control, Type N2) Electrohydraulic 2-Position Control (Types E1•E2 and F1•F2) and Electric 2-Position Control (Type S1) These controls do not require adjustment. CAUTION Do not tamper with the adjusting screw in the end cap (opposite the control). 50000012

Fig. 30-13 - Electrohydraulic 2-Position Control, Types E1•E2 and F1•F2

Pilot pressure for the E1•E2 or F1•F2 electric solenoid valve is internally supplied. When the solenoid is energized, motor charge pressure should be present at test ports M7 and M8. When the solenoid is not energized, test port M8 should drop to case pressure. The S1 control utilizes a direct acting solenoid to operate the control valve spool in the end cap.

50000162

Fig. 30-14 - Electric 2-Position Control, Type S1

Servo pressure supply oil is usually provided internally from the main system ports of the motor. If external servo pressure supply is utilized, a minimum of 25 bar (360 psi) is required to change the motor displacement with the motor shaft turning, and a minimum of 70 bar (1015 psi) is required with the motor shaft locked. 30 - 8

30

760

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Component Adjustment (Continued) Hydraulic Proportional Control (Types HZ, HS, H1•H2, and K1•K2) The control start pressure for these controls may be adjusted with the adjusting screw on the end cap (opposite the control block). Control start is that pilot pressure at which the motor displacement starts to decrease. To check the control start setting, install a gauge to monitor the pilot pressure (connect to port M7 or tee into the pilot line connected to port X1), and the minimum angle servo pressure (port M3). If adjusting an H1 or H2 control, the override solenoid must be energized. If adjusting a K1 or K2 control, the solenoid must not be energized.

51000015

Fig. 30-15 - Hydraulic Proportional Control, Type HZ

NOTE: The pilot signal may be determined by prime mover speed, other shaft speeds, or other control pressures, depending upon the design of the vehicle / machine control circuit. Increase the pilot signal to the required control start pressure. An increase in minimum angle servo pressure will be noted as the motor displacement starts to decrease. To adjust the control start pressure, loosen the lock nut using a 10 mm hex wrench and turn the adjusting screw with a 4 mm internal hex wrench. Turning the screw clockwise increases the control start pressure. Torque the lock nut to 9 Nm (6.6 ft•lbsf) after adjusting.

51000018

Fig. 30-16 - Hydraulic Proportional Control, Type HS

For the H1•H2 controls, the pilot signal pressure supplied to port X1 should also be present at test port M7 when the solenoid is energized. When the solenoid is not energized, test port M7 should drop to case pressure. 51000020

For the K1•K2 controls, the pilot signal pressure supplied to port X1 should also be present at test port M7 when the solenoid is not energized. When the solenoid is energized, test port M7 should drop to case pressure.

Fig. 30-17 - Hydraulic Proportional Control with Electric Override, Type H1•H2 (K1•K2 Similar)

Shut down the prime mover. Remove the gauges and install the gauge port plugs. Return the pump and motor controls to their normal operation. Servo pressure supply oil is usually provided internally from the main system ports of the motor. If external servo pressure supply is utilized, a minimum of 25 bar (360 psi) is required to change the motor displacement with the motor shaft turning, and a minimum of 70 bar (1015 psi) is required with the motor shaft locked.

51000047

Fig. 30-18 - Adjusting Control Threshold, Types HS, HZ, H1•H2, and K1•K2

30 - 9

008 911 63

31

BOMAG

761

17.5

Axle drive motor


Series 51

Component Adjustment (Continued) Two Line Hydraulic Proportional Control (Type HP) The differential control start pressure for this control may be adjusted with the adjusting screw on the end cap (opposite the control block). Control start is that differential pilot pressure at which the motor displacement starts to decrease. 51000023

Fig. 30-19 - Two Line Hydraulic Proportional Control, Type HP

To check the control start setting, install gauges to monitor the pilot pressures (tee into the pilot lines connected to ports X1 and X2), and the minimum angle servo pressure (port M3). NOTE: The pilot signals may be determined by prime mover speed, other shaft speeds, or other control pressures, depending upon the design of the vehicle / machine control circuit. Increase the pilot signal differential to the required control start pressure. An increase in minimum angle servo pressure will be noted as the motor displacement starts to decrease.

51000047

Fig. 30-20 - Adjusting Control Threshold (Type HP)

The differential control start pressure should be the same no matter which pilot pressure is higher. Differences in control operation when the pilot pressure differential is reversed indicate a problem with the shuttle spool in the control block. To adjust the control start differential pressure, loosen the lock nut using a 10 mm hex wrench and turn the adjusting screw with a 4 mm internal hex wrench. Turning the screw clockwise increases the control start pressure. Torque the lock nut to 9 Nm (6.6 ft•lbsf) after adjusting. Shut down the prime mover. Remove the gauges and install the gauge port plugs. Return the pump and motor controls to their normal operation. Servo pressure supply oil is usually provided internally from the main system ports of the motor. If external servo pressure supply is utilized, a minimum of 25 bar (360 psi) is required to change the motor displacement with the motor shaft turning, and a minimum of 70 bar (1015 psi) is required with the motor shaft locked.

30 - 10

32

762

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Component Adjustment (Continued) Two Line Hydraulic Proportional Control for “Dual Path” Vehicles (Type HC) The differential control start pressure for this control may be adjusted with the adjusting screw on the control housing. Control start is that differential pilot pressure at which the motor displacement starts to decrease. To check the control start setting, install gauges to monitor the pilot pressures (tee into the pilot lines connected to ports X1 and X2), and the minimum angle servo pressure (port M3).

51000158

Fig. 30-21 - Two Line Hydraulic Proportional Control, Type HC

NOTE: The pilot signals may be determined by prime mover speed, other shaft speeds, or other control pressures, depending upon the design of the vehicle / machine control circuit. Increase the pilot signal differential to the required control start pressure. An increase in minimum angle servo pressure will be noted as the motor displacement starts to decrease. The differential control start pressure should be the same no matter which pilot pressure is higher. Differences in control operation when the pilot pressure differential is reversed indicate a problem with the shuttle spool in the control block.

51000159

Fig. 30-22 - Adjusting Control Threshold (Type HC)

To adjust the control start differential pressure, loosen the lock nut using a 10 mm hex wrench and turn the adjusting screw with a 4 mm internal hex wrench. Turning the screw counter-clockwise (CCW) increases the control start pressure. Torque the lock nut to 9 Nm (6.6 ft•lbsf) after adjusting. Shut down the prime mover. Remove the gauges and install the gauge port plugs. Return the pump and motor controls to their normal operation. Servo pressure supply oil is provided internally from the main system ports of the motor.

30 - 11

008 911 63

33

BOMAG

763

17.5

Axle drive motor


Series 51

Component Adjustment (Continued) Electrohydraulic Proportional Control (Types EP and EQ) The control start current for the EP and EQ controls may be adjusted with the adjusting screw on the end cap (opposite the control block). Control start is that current supplied to the PCP (Pressure Control Pilot) valve at which the motor displacement starts to decrease. 51000026

Fig. 30-23 - Electrohydraulic Proportional Control, Type EP (EQ Similar)

To check the threshold setting, install instruments to monitor the PCP current, and the minimum angle servo pressure (port M3). NOTE: The current supplied to the PCP may be determined by prime mover speed, other shaft speeds, control pressures, or other electrical signals, depending upon the design of the vehicle / machine control circuit. Increase the PCP current to the required control start current. An increase in minimum angle servo pressure will be noted as the motor displacement starts to decrease.

51000047

Fig. 30-24 - Adjusting Control Threshold (Type EP•EP)

To adjust the control start current, loosen the lock nut using a 10 mm hex wrench and turn the adjusting screw with a 4 mm internal hex wrench. Turning the screw clockwise increases the control start current. Torque the lock nut to 9 Nm (6.6 ft•lbsf) after adjusting. PCP supply pressure oil is provided externally. PCP supply pressure must be a minimum of 20 bar (290 psi) and no more than 70 bar (1015 psi). Shut down the prime mover. Remove the gauges and install the gauge port plugs. Return the pump and motor controls to their normal operation. Servo pressure supply oil is usually provided internally from the main system ports of the motor. If external servo pressure supply is utilized, a minimum of 25 bar (360 psi) is required to change the motor displacement with the motor shaft turning, and a minimum of 70 bar (1015 psi) is required with the motor shaft locked.

30 - 12

34

764

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Component Adjustment (Continued) Pressure Compensator Over-Ride (PCOR) and Pressure Compensator Regulator (Type PC) Adjustment The PCOR or PC regulator valve setting may be adjusted with the adjusting screw on the PCOR/PC valve block attached to the multi-function block. The regulator start pressure is that system pressure at which the PCOR or PC regulator starts to increase the motor displacement. In order to measure the regulator start pressure setting of the PCOR or the PC regulator, the motor output shaft must be loaded to increase the system working pressure. This can accomplished by applying the vehicle’s brakes or by loading the work function.

51000031

Fig. 30-25 - PCOR Block on Multi-Function Block (K1•K2 Control Shown)

WARNING The following procedures may require the vehicle/machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the adjustment to prevent injury to the technician and bystanders. Install gauges to monitor system pressure (connect to ports M1 and M2), the minimum angle servo pressure (port M3), and the maximum angle servo pressure (port M4). Start the prime mover and operate at normal speed. Provide a signal to the pump control to provide a constant flow of hydraulic fluid to the motor. Provide a signal to the motor control to maintain the motor at its minimum displacement.

51000034

Fig. 30-26 - Pressure Compensator Regulator (Type PC)

Increase the load on the motor to increase the system pressure to the required regulator start pressure. The maximum angle servo pressure (M4) will increase and the minimum displacement servo pressure (M3) will decrease as the PCOR or PC regulator operates. The servo pressures will equalize, and the maximum angle servo pressure continue to increase, as the motor displacement starts to increase. During the transition from minimum to maximum displacement, an additional 10 bar (145 psi) increase in system pressure may be noted.

51000048

Fig. 30-27 - System Pressure Gauge Ports (Side Port End Cap)

Once the motor is at maximum displacement, further increases in load will result in increasing system pressure until the maximum system pressure (determined by the system relief valve or pump pressure limiter) is reached.

30 - 13

008 911 63

35

BOMAG

765

17.5

Axle drive motor


Series 51

Component Adjustment (Continued) Allow the pump to return to its neutral position. Repeat the procedure for the other side of the closed circuit if so configured. The PCOR or PC regulator must operate at the same start pressure as noted previously. Any noticeable difference in operation from side to side may indicate a problem with the pressure supply shuttle spool or brake pressure defeat spool in the multi-function block. NOTE: Some motors may be configured for the PCOR or PC regulator to function on only one (1) side of the closed loop. Refer to the nomenclature on the motor nameplate. In order for the PCOR or PC regulator to function properly on motors equipped with a brake pressure defeat spool, the defeat spool must be positioned correctly. The control pressure for the defeat spool should be applied to the appropriate port (XA or XB) as shown in the following table to shift the defeat spool and permit PCOR or PC regulator operation. Maximum pressure across the brake pressure defeat ports XA and XB is 50 bar (725 psi). 51000049

Fig. 30-28 - Loosen PCOR/PC Lock Nut

Pressure Compensator Override Defeat Operation Rotation

High system pressure port

Control pressure on port

CW

A

XB

CCW

B

XA

The PCOR or PC regulator valve is screw adjustable. To adjust, loosen the locknut with a 1-1/16" hex wrench. Turn the adjusting screw with a large screwdriver until the desired pressure setting is established. Clockwise rotation of the adjustment screw will increase the pressure setting at a rate of approximately 70 bar (1000 psi) per turn. 51000050

Fig. 30-29 - Rotate PCOR/PC Adjusting Screw

CAUTION A stop pin is installed in the adjusting screw to prevent “overtravel” of the PCOR/PC valve spool. The stop pin must protrude (distance “X”) 19 mm (.75 in.) from the spring seat for settings of 270 to 370 bar (3900 to 5350 psi), or 24 mm (.94 in.) for settings of 110 to 260 bar (1600 to 3750 psi). Refer to the appropriate Service Parts Manual for further information.

"X"

While holding the adjusting screw from turning, torque the lock nut to 52 Nm (38 ft•lbsf). Recheck the PCOR or PC regulator setting. 51000051

Fig. 30-30 - PCOR/PC Adjusting Screw Stop Pin

Shut down the prime mover. Remove the gauges and install the gauge port plugs. Return the pump and motor controls to their normal operation. 30 - 14

36

766

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Troubleshooting Fault-Logic Diagrams • Closed Circuit

Check Oil Level OK in Reservoir

Check System OK Relief Valve Pressure Settings

Low

Low

Defective

Fill to Proper Level

Replace Transmission (Pump and Motor)

Low

OK

Check Charge and Control Pressures

High

Incorrect

Repair as Required

Repair as Required

Check Pump OK Inlet Pressure

Air in System OK

OK

Adjust

Check System Internal Leakage

OK

SYSTEM RESPONSE IS SLUGGISH

OK

Low

Inspect Inlet Filter and Replace if Necessary

Adjust or Replace

Check Oil Level in Reservoir

Check Prime Mover Speed

Check Pump OK Inlet Pressure

Inspect Shaft OK Couplings

Inspect Shaft Alignment

Loose Fitting

Low

Defective

Defective

Purge Air and Tighten Fittings


Repair or Replace

Align Shafts


EXCESSIVE NOISE AND/OR VIBRATION Check Oil Level OK in Reservoir

Inspect Heat OK Exchanger

Check Pump Inlet Pressure

Check Charge OK Pressure

Low

Defective

Incorrect

Low


Clean, Repair or Replace

Repair as Required



OK

Check System Pressure

High Reduce Load on Transmission

Check for Internal

OK System Leakage High

Repair as Required

OK

Check System Relief

OK Pressure Settings Low Adjust or Replace

SYSTEM OPERATING HOT 30 - 15

008 911 63

37

BOMAG

767

17.5

Axle drive motor


Series 51

Troubleshooting (Continued) Fault-Logic Diagrams • Closed Circuit (Continued) Check Charge Pressure

OK

Decays in One Direction (Forward or Reverse) Only Inspect and Repair Loop Flushing Valve

Check Pump Control System OK

Interchange System Relief Valves and/or OK Charge Check Valves

Defective


Problem Changes Direction Repair or Replace

Repair or Replace Appropriate Valve

MOTOR OPERATES NORMALLY IN ONE DIRECTION ONLY Check Inlet Pressure at Motor

OK

Check Outlet Pressure at Motor

OK

Motor at Incorrect (Minimum) Displacement OK

Low

High / Low

Incorrect

Correct System

Correct System

Check Control Supply Pressure and/or Repair Displacement Control

LOW MOTOR OUTPUT TORQUE Check Oil Level in Reservoir

OK

Check Charge Pressure OK

Check Pump Output Flow

OK

Repair or Replace Motor

Check Motor Displacement

Low

Incorrect

Improper

Incorrect


Repair Charge System

Repair Pump Control and/or Pump

Check and Repair Control System and Displacement Controls (Pump and Motor) Repair or Replace Motor

IMPROPER MOTOR OUTPUT SPEED

30 - 16

38

768

OK

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Notes

30 - 17

008 911 63

39

BOMAG

769

17.5

Axle drive motor


Series 51

Notes

30 - 18

40

770

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Exploded View of the Series 51 Variable Motor The following information is for general parts identification ONLY. Refer to the applicable Service Parts List when ordering service parts.

Base Unit

L35

OPTION WNNT

W10 W50

L40 L50 B71

W25

B71A

B80

B80 L70

L80

L75 L40 L50 B70 B70A

B70A Y10 B70

Y20

W25

Y30

Y20 W50

Y10

W10 OPTION WNNS

Y10

B70A

Y20 B70 Y30

Name Plate

saue Ames, Iowa, U.S.A. Model Code


51V160 RF1N E1A2 ANE1 NNN 050AA210322 Model Number Serial Number

Model No.

Model Code

Ident Nr

516-40104 786673 N 91 25 67890 Serial No. Fabr Nr MADE IN GERMANY


Name Plate (German Production) 40 - 1

008 911 63

41

BOMAG

771

17.5

Axle drive motor


Series 51

Exploded View of the Series 51 Variable Motor (Continued) End Cap G30

(....) = Applies to the indicated frame size(s).

G24

G30A J70 J60

G26

G38 G36

J50

F10N, F10A–G

M18/M98

F20A–G

M16/M96

K90 K50 J40

K10

OR K16 (250)

G20

OR

K70

K90N

G20A

K80

Q40

K90A

K14 K16 (060—160)

G12

G50 G50A

G12

G30 G30A (250) (250)

G12A

K18N

G80 (060, 080)

G12A G80A (060, 080)

G30 (250) G30A (250)

K18

G30 G30A

OR K16 (060—160) K16 (250) K14 G20A

M11/T3A1-A9 T3B0-B6 T3C2-C7

G12

G20 S20

G12A M11/T1A1-A9 T1B0-B6 T1C2-C7

G12

G12A

S10 (060, 080, 110) OR

G30A (250)

G18 G90

G30 G12A G12 (250) T8A1-A9 T8B0-B6 T8C2-C7

Y40 N1U5 Y50 G30A G30

J30 J10A-D J20/S70

G44 G38 G38

F33

G42

G38

F32

40 - 2

42

772

S10 (160, 250)

T7A1-A9 T7B0-B6 T7C2-C7

G42 G36 M11/T2A1-A9 T2B0-B6 T2C2-C7

OR

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Exploded View of the Series 51 Variable Motor (Continued) Multi-Function Valve Q50

N28

N84

N28A N84A

OR

N52

N34

N32 N34A

N72 N66 N66A

N46/T5

N52/T4

N72A

N34 N34A N34 N34A N52/T6

N30

N34A

N84 OR N84A

N34

N34

N34A

N1A1-A6

N28 N28A

OR

N90A

N66A N90

N66

OR

N26A

N26 N34A

N34

N58 N24 N82 N11

N29

Z10 & Z20 N82

N22 & N20

N24

U7 U6

N11 & N21 N14 N16 N18

N27A N27

N29

N23

N27A N23A

N27

Q60

40 - 3

008 911 63

43

BOMAG

773

17.5

Axle drive motor


Series 51

Exploded View of the Series 51 Variable Motor (Continued) Controls

M28 M30

M24

M38 M36 M10

M30 M18 M28 M32A M32

M26

M14

M32 M26

M24 M28

M30

M1HS M16

M1HP

M18 M16

M1EP•EQ

M20 M14

M18

M12

M16

EP•EQ

M16

M14

M12

HS

M10

M22

M18 M10

M36

HP

M16

M1S1

M10

M1E1•E2•E5 M1F1•F2 M1H1•H2 M1K1•K2

M14

M20

M22 M22A

S1 M18A

M14 M18 M2E5

E1•E2•E5 / F1•F2 / H1•H2 / K1•K2

40 - 4

44

774

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Exploded View of the Series 51 Variable Motor (Continued) Controls (Continued) (....) = Applies to the indicated frame size(s). S50 S30

S20

S40 S60

S11T (060, 080, 110) OR

M10 M12

S10 (060, 080, 110)

S11T (160, 250) S10 (160, 250)

S10T (060, 080, 110)

S10T (160, 250)

S70

M32

M44 M34 M34A M14 M1N2

M1HC

M40 M16 M16A

M47 M46

M38

M14

N2 M18 M18A

M50A M50

M34A M34

M10

M18

M12

M18A M18A M18

M11 (060, 080, 110)

M26

M48

M34A M22

M10 M16A M16

M1HZ

M48A

M34

J10 M25

HZ

M24 M22 M20 M14 M12 M28

M18 M16

HC 40 - 5

008 911 63

45

BOMAG

775

17.5

Axle drive motor


Series 51

Exploded View of the Series 51 Variable Motor (Continued) PC Regulator

T7

F33 F32 M84

M28

M84A

M28A

M52 M34 M34A

M72 M66

M72A

M66A

T5

T4 M34 M34A M34 M34A

M30

M84

T6 M34A

M84A

M34

M34

M34A

M28 M28A

M10 M90A M28A

M90 M26A

M34

M28

M26

M34A

M58 Z10 & Z20 M24 U7 U6

M82

M22 & M20

M1PC & M21 M14

M18

M27A M27

M16 M29

M23

M27A M23A M27

Q60

40 - 6

46

776

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Exploded View of the Series 51 Variable Motor (Continued) Item

Description

Quantity

B000 B80 L35 L40 L50 L70

COMMON PARTS GROUP (SAE FLNG) O-RING FLANGE- SAE SEAL- SHAFT O-RING SCREW- SOC HD

C000 L40 L50 L75 L80

COMMON PARTS GROUP (CARTRIDGE) SEAL- SHAFT 1 O-RING 1 COVER- SEAL 1 RING- RETAINING 1

F••• F10 F20

MAXIMUM DISPLACEMENT SPACER- MAX DISPL LMTR SCREW-SOC HD - MAX DISPL LMTR

1 1

G00A G00B G00R G00S G12 G14 G16 G18 G20 G20N G24 G26 G30 G36 G38 G42 G44 G50 G70 G90 K10 K14 K16 K16 K18 K18N K50 K70 K80 K90 K90N

END CAP-AXIAL (160-250) END CAP-AXIAL, CODE 61 (160-250) END CAP-SIDE, LOOP FL END CAP-SIDE, LOOP FL, CODE 61 PLUG-STR THD HEX PLUG-EXP PLUG-MANDREL SCREW-SET, FLAT PT PLUG- SPECIAL PLUG- STR THD HEX SCREW-SOC HD COVER-SERVO PISTON PLUG-STR THD HEX O-RING O-RING O-RING O-RING PLUG-ST THD HEX COVER-PORT CONTROL SCREEN FILTER ADJ PLUG ASSY-CHG RLF SPRING-HELICAL COMP GUIDE-SPRING (060 — 160) GUIDE-SPRING (250) SHUTTLE VALVE SPOOL LOOP FLUSH SPOOL- DEFEAT O-RING SPRING-HELICAL COMPRESSION POPPET-CHG RELIEF NUT-HEX LOCK PLUG- ST THD HEX

7 1 2 2 2 2 4 1 3 2 4 2 1 2 2 1 1 2 2 2 1 1 1 1 1 1 1

1 1 1 1 8

40 - 7

008 911 63

Item

Description

Quantity

J00A-K J10A-K J20 J30 J40 J50 J60 J70

CONTROL START SETTING SPRING-HEL COMP- CONT START SEAT-SPRING SEAT-SPRING SCREW-ADJUSTING O-RING NUT-ADJUSTING SCREW NUT-LOCK

J00N

CONT START N/A (FOR 2 POS CONT)

M0EP M0EQ F32 M1EP M1EQ M10 M12 M14 M16 M18 M24 M26 M28 M30 M32 M34 M36 M38 M40 M42 M44 N90

CONTROL- ELHYD PRP, PACKARD CONTROL- ELHYD PRP, MS BUSHING- VALVE ASSY PCP VALVE, PACKARD CONN PCP VALVE, MS CONN HOUSING- CONTROL SCREW- SOC HD COVER GASKET SCREW- SOC HD PISTON- SHUTTLE, DELTA P SPRING- HEL COMPRESSION PIN O-RING PLUG-SOC HD PLUG-MANDREL O-RING O-RING CONTROL SCREEN FILTER PLUG-SOC HD PLUG-PLASTIC PLUG-STR THD HEX

1 1 1 1 4 1 1 4 1 1 1 1 2 6 1 1 1 1 1 1

M0E1/E2 M0F1/F2 F32 M1E1 M1E2 M10 M10 M12 M14 M16 M18 M20 M22 N90

CONTROL- ELHYD 2 POS CONTROL- ELHYD 2 POS, MAX ANG BUSHING- VALVE ASSY VALVE ASSY- SOLENOID,12V VALVE ASSY- SOLENOID,24V HOUSING-CONT, ELHYD, 2 POS (E) HOUSING-CONT, ELHYD, 2 POS (F) PLUG-EXP SCREW-SOC HD O-RING PLUG-STR THD HEX O-RING PLUG-STR THD HEX PLUG-STR THD HEX

1 1 1 1 1 7 4 2 1 1 1 1

1 1 1 1 1 1 1

47

BOMAG

777

17.5

Axle drive motor


Series 51


Description

Quantity

M0HC F32 M1HC M10 M11 M12 M14 M16 M18 M20 M22 M24 M25 M26 M28 M32 M34 M38 M40 M44 M46 M47 M48 M50

CONTROL- HYD PRPNL 2LN, DUAL PATH BUSHING- VALVE ASSY 1 HOUSING- HYD PRPNL (2LN),DUAL 1 SCREW-SOC HD 4 WASHER, FLAT (060, 080, 110) 4 COVER 1 GASKET 1 NUT-SEAL LOCK 1 SCREW-SET, FL PT 1 GUIDE- SPRING 1 SPRING-HELICAL COMPRESSION 1 PISTON- DELTA P 1 SEAT- SPRING 1 PIN 1 SCREW-SOC HD 4 CONTROL SCREEN FILTER 2 PLUG-SOC HD 4 VALVE- BLEED 1 NUT- SEAL LOCK 1 VALVE, SHUTTLE- DELTA P 1 SEAT- BALL CHECK 1 BALL- SHUTTLE 1 PLUG-STR THD HEX 1 PLUG-STR THD HEX 1

M0HP F32 M1HP M10 M12 M14 M16 M18 M24 M26 M28 M30 M32 M34 M36 N90

CONTROL- HYD PRPNL 2LN, W/BLD BUSHING- VALVE ASSY HOUSING- HYD PRPNL (2LN),W/BLD COVER GASKET PISTON-SHUTTLE, DELTA P SPRING-HELICAL COMPRESSION PIN O-RING VALVE SHUTTLE,DELTA P PLUG-SEALING O-RING PLUG-SEALING PLUG-EXP SCREW-SOC HD PLUG-STR THD HEX

1 1 1 1 1 1 1 1 1 1 2 1 6 4 1

Item

Quantity

M0HS F32 M1HS M10 M12 M14 M16 N90

CONTROL- HYD PRP, 1 LN BUSHING-VALVE ASSY HOUSING- VALVE, HYD PRPRNL 1 LN SCREW-SOC HD O-RING PLUG-STR THD HEX PLUG-PLASTIC PLUG-STR THD HEX

M0HZ F32 M1HZ M10 M12 M14 M16 M18

CONTROL- HYD PRP, 1 LN, CMPCT BUSHING- VALVE ASSY 1 HOUSING- VALVE, HYD PRP, 1 LN, CPT 1 VALVE ASSY- DBL CHECK 1 SCREW- SOC- DRILLED 1 CONTROL SCREEN FILTER 2 PLUG-STR THD HEX 2 PLUG-STR THD HEX 3

M0H1/H2 M0K1/K2 F32 M1H1 M1H2 M10 M12 M14 M16 M18 M20 M22 N90

CONTROL- HYD PRP, 1 LN, MAX ANG CONTROL- HYD PRP, 1 LN, MIN ANG BUSHING-VALVE ASSY VALVE ASSY-SOLENOID,12V VALVE ASSY-SOLENOID,12V HSG-CONT,ELHYD, 2 POS PLUG-EXP SCREW-SOC HD O-RING PLUG-STR THD HEX O-RING PLUG-PLASTIC PLUG-STR THD,SOC HD

1 1 1 1 8 4 2 1 1 1 1

M0N2 M1N2 M10 M11 M12 M14 M16 M18

CON-HYD, 2 POS, DIRECT COVER PLUG SCREW- SET,FLT PT O-RING SCREW-SOC GASKET PLUG

1 1 3 1 4 1 1

1 1 4 1 1 1 1

40 - 8

48

778

Description

BOMAG

008 911 63

17.5

Axle drive motor


Series 51


Description

Quantity

M0PC F32 F33 M1PC M10 M14 M16 M18 M20 M21 M22 M23 M26 M27 M28 M29 M30 M34 M36 M38 M50 M52 M54 M58 M62 M66 M72 M82 M84 M86 M90 M96 M98 N24

REGULATOR- PRESS COMP PLUG- VALVE BUSHING BORE O-RING HOUSING- VALVE HOUSING- MULTI FUNCTION BLOCK NUT-HEX LOCK O-RING SPRING-HELICAL COMPRESSION SEAT-SPRING, PC BUSHING-VALVE SPOOL-PC VALVE PLUG-STR THD HEX PLUG-SOC HD PLUG-STR THD HEX PLUG-STR THD HEX SCREW-SOC SPOOL, BI-DIRECTIONAL CHECK PLUG-STR THD HEX SCREW-SET,FLT PT PLUG-EXP PLUG-EXP CONTROL SCREEN FILTER PLUG-EXP SCREW-SOC HD PLUG-EXP PLUG-STR THD HEX PLUG-STR THD,SOC HD O-RING PLUG-STR THD HEX SCREW-FL PT PLUG-STR THD HEX GASKET PLUG O-RING

M0S1 F32 M1S1 M10 M14 M16 M18 M20 M22 N90

CONTROL- ELECTRIC 2 POS, DIRECT BUSHING- VALVE ASSY SOLENOID,12V ADAPTER PLATE- SOLENOID SCREW-SOC HD O-RING O-RING PIN O-RING PLUG-STR THD HEX

1 1 1 1 1 1 1 1 1 1 1 1 10 4 4 1 10 5 11 8 2 1 4 1 2 1 1 2 1 1 1 1 5

1 1 1 4 1 1 1 1 1

40 - 9

008 911 63

Item

Description

Quantity

N0A1-6 N1A1-6 N11 N14 N16 N18 N20 N21 N22 N23 N24 N26 N26 N27 N28 N28 N29 N30 N32 N34 N36 N38 N50 N52 N54 N58 N62 N66 N66 N72 N74 N82 N84 N84 N86 U5 U6 U7

SVO PRS SPLY, PCOR, DFT HOUSING-MULTI FUNCTION BLOCK HOUSING-VALVE NUT-HEX LOCK O-RING SPRING-HELICAL COMPRESSION SEAT-SPRING, PCOR BUSHING-VALVE SPOOL-PCOR VALVE PLUG-STR THD HEX O-RING PLUG-SOC HD (W/PCOR) PLUG-STR THD HEX (WO/PCOR) PLUG-STR THD HEX PLUG-PLASTIC (W/DFT) PLUG-STR THD HEX (WO/DFT) SCREW-SOC SPOOL, BI-DIRECTIONAL CHECK PISTON PLUG-STR THD HEX SCREW-SET,FLT PT PLUG-EXP (060 - 110 ONLY) PLUG-EXP (060 - 110 ONLY) CONTROL SCREEN FILTER PLUG-EXP SCREW-SOC HD PLUG-EXP PLUG-STR THD HEX (060-110) PLUG-STR THD HEX (160-250) PLUG-STR THD,SOC HD SCREW-SET, FL PT O-RING PLUG, SPECIAL PLUG-STR THD HEX SCREW-SET PLUG- SOC (EXT SUPPLY) ORIFICE, PCOR DAMPING ORIFICE, PCOR DAMPING

N0NN

SERVO PRESS SPLY- NONE

P0AA

SYS PRESS PROTECT- NONE

1 1 1 1 1 1 1 1 1 5 1 1 17 2 2 4 1 1 10 5 11 6 2 1 4 1 2 1 1 3 1 2 2 1 1 1 1

49

BOMAG

779

17.5

Axle drive motor


Series 51


Description

Quantity

S00D-G S10 S10D-G S10D-G S20 S70

CONTROL RAMP- HP, HS, H1/H2, K1/K2 GUIDE-SPRING (160-250) CONT RAMP SPRING (060-110) CONT RAMP SPRING ASSY (160-250) GUIDE-SPRING SEAT-SPRING

S00N

CONTROL RAMP-NONE

S00T S10 S10T S11T S20 S30 S40 S50 S60 S70

CONTROL RAMP- HC GUIDE-SPRING CONT RAMP SPRING CONT RAMP SPRING GUIDE-SPRING NUT- ADJUSTING SCREW O-RING NUT- LOCK SCREW- ADJUSTING SEAT-SPRING

1 1 1 1 1 1 1 1 1

S00U-Z S10 S10U-Z S10U-Z

CONTROL RAMP- EP/EQ GUIDE-SPRING (160-250) CONT RAMP SPRING (060-110) CONT RAMP SPRING ASSY (160-250)

1 1 1

T0A0

CON ORIFICE (A0)- NONE

T0A1 T1 T2 T3 T4 T5 T6 T7 T8 U3

CON ORIFICE (A1) ORIFICE ORIFICE ORIFICE SCREW ORIFICE SCREW ORIFICE ORIFICE SCREW-FL PT

1 2 1 2 1 1 2 1 1

T0A2 T1 T2 T3 T4 T5 T6 T7 T8

CON ORIFICE (A2) ORIFICE ORIFICE ORIFICE ORIFICE SCREW ORIFICE ORIFICE ORIFICE

1 2 1 2 1 1 2 1

WNNN A10 B70 B71

SPCL HDW-NONE SPEED SENSOR 51V PLUG-SOC HD PLUG-PLASTIC

0 1 1

1 1 2 1 1

Item

MINIMUM DISPLACEMENT SCREW- SET, FLT PT NUT- HEX, SEAL LOCK TAMPER RESISTANT CAP

Z000

PRS COMP SET- NONE

Z0•• Z10 Z20

PCOR / PRESS COMP SETTING ADJUSTER- THREADED PIN-STRAIGHT

Quantity 1 1 1

1 1

40 - 10

50

780

Description

Y••• Y10 Y20 Y30

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor Charge Pressure Relief Valve Loop Flushing Valve

Shaft Seal

Control Orifices Multi-function Block

Control Minimum Displacement Limiter

51000052

Variable Displacement Motor (SAE Flange Configuration) Fig. 50-1 - Minor Repairs

Minor Repairs may be performed, following the procedures in this section, without voiding the unit warranty. Although specific products are illustrated, these procedures apply to all units in the Series 51 family.

General

Protect all exposed sealing surfaces and open cavities from damage and foreign material. It is recommended that all gaskets and O-rings be replaced. All gasket sealing surfaces must be cleaned prior to installing new gasket. Lightly lubricate all Orings with clean petroleum jelly prior to assembly.

Cleanliness is a primary means of insuring satisfactory transmission life, on either new or repaired units. Cleaning parts by using a solvent wash and air drying is adequate, providing clean solvent is used. As with any precision equipment, the internal mechanism and related items must be kept free of foreign materials and chemicals.

50 - 1

008 911 63

51

BOMAG

781

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Shaft Seal (SAE Flange Configuration) Lip type shaft seals are used on the Series 51 motors. Replacement of the shaft seal usually requires removal of the motor from the machine. Remove the screws holding the flange to the housing, using a 6 mm internal hex wrench (060 and 080 units), an 8 mm internal hex wrench (110 units), a 10 mm internal hex wrench (160 units), or a 12 mm internal hex wrench (250 units). Remove the flange from the housing using a suitable puller. Care must be taken so as to not damage the housing bore or shaft. 51000178

Fig. 50-2 - Remove Screws Holding Flange to Housing (SAE)

CAUTION

51000179

Fig. 50-3 - Remove Flange (SAE)

Do not allow the output shaft to move out of the housing while removing the flange. After the flange is removed, do not attempt to remove the shaft from the housing. If the output shaft moves out of the housing, the synchronizing shaft and rollers could fall out of position, requiring major disassembly of the unit.

Remove the old seal from the flange. Once removed, the seal is not reusable. Inspect the flange and the new seal for any damage or nicks. Using an arbor press, press the new seal into the flange. Be careful not to damage seal. 51000053

51000054

Fig. 50-4 - Remove Fig. 50-5 - New Seal Old Seal from Flange Installed in Flange (SAE) (SAE)

NOTE: The outside diameter of the seal may be lightly coated with a sealant (such as Loctite High Performance Sealant #59231) prior to installation. This will aid in preventing leaks caused by damage to the seal bore in the flange. Inspect the sealing area on the shaft for rust, wear, or contamination.

50 - 2

52

782

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Install a new O-ring on the flange. Prior to assembly, lubricate the flange O-ring and the I.D. of the seal with petroleum jelly. Protect the seal lip from damage during installation by wrapping the spline or key end of shaft with plastic film, or by using a seal installation tool. Assemble the flange and seal over the shaft and into the housing bore. Install four (4) of the flange screws, and tighten them evenly to pull the flange into position. Take care to not damage the O-ring or seal lip during installation.

51000055

51000056

Fig. 50-6 - Install Fig. 50-7 - Torque Flange onto Housing Flange Screws (SAE) (SAE)

Install the flange screws and torque evenly to 32 Nm (24 ft•lbsf) for 060 and 080 motors, 63 Nm (46 ft•lbsf) for 110 motors, 110 Nm (81 ft•lbsf) for 160 motors, and 174 Nm (128 ft•lbsf) for 250 motors.

Shaft Seal (Cartridge Configuration) Lip type shaft seals are used on the Series 51 motors. These seals can be replaced without major disassembly of the unit. However, replacement of the shaft seal requires removal of the motor from the wheel drive or track drive gearbox. Remove the seal carrier retaining ring from the housing. Carefully pull the seal cover out of the housing. Care must be taken so as not to damage the housing bore or shaft. Remove the O-ring from the housing. Remove the old seal from the carrier. Once removed, the seal is not reusable. Inspect the carrier and the new seal for any damage or nicks.

51000057

Fig. 50-8 - Remove Carrier Retaining Ring (Cartridge)

51000058

Fig. 50-9 - Remove Seal Carrier (Cartridge)

Using an arbor press, press the new seal into the carrier. Be careful not to damage seal. NOTE: The outside diameter of the seal may be lightly coated with a sealant (such as Loctite High Performance Sealant #59231) prior to installation. This will aid in preventing leaks caused by damage to the seal bore in the seal carrier. Inspect the sealing area on the shaft for rust, wear, or contamination.

51000059

Fig. 50-10 - Seal Carrier Removed (Cartridge)

50 - 3

008 911 63

51000060

Fig. 50-11 - Seal Installed in Carrier (Cartridge) 53

BOMAG

783

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Install the carrier O-ring into the groove in the housing. Prior to assembly, lubricate the carrier O-ring and the I.D. of the seal with petroleum jelly. Protect the seal lip from damage during installation by wrapping the spline or key end of shaft with plastic film, or by using a seal installation tool.

51000061

Fig. 50-12 - Install Seal Carrier (Cartridge)

51000057

Fig. 50-13 - Install Carrier Retaining Ring (Cartridge)

Assemble the carrier and seal over the shaft and into the housing bore. Take care to not damage the O-ring or seal lip during installation. Install the seal carrier retaining ring.

Loop Flushing Shuttle Valve (Option) Using an 11/16" wrench, remove the hex plugs from both sides of end cap. Remove springs and spring seat washers. Note the orientation of the washers. NOTE The 250 frame size motors use thicker spring seat washers. 51000062

Fig. 50-14 - Remove Shuttle Valve Plugs

51000063

Remove flushing valve spool.

Fig. 50-15 - Remove Valve Spool Inspect parts for damage or foreign material.

51000066

Fig. 50-16 - Loop Flushing Shuttle Valve Components Install flushing valve spool in end cap, then install the spring seat washers (thick washers on 250 frame size motors) on each end of the spool. The step on the spring seat washers should face out, toward the springs. Install the spool springs and hex plugs. Torque the plugs to 41 Nm (30 ft•lbsf).

51000064

Fig. 50-17 - Install Valve Spool and Washers

51000065

Fig. 50-18 - Install Plugs and Springs 50 - 4

54

784

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Charge Pressure Relief Valve Before removing the screw adjustable relief valve plug, mark the plug, lock nut, and end cap to allow maintaining the original adjustment when assembling. Remove the screw adjustable charge relief valve plug by loosening the lock nut (with a 1-1/16" hex wrench), and unscrewing the plug with a large screwdriver. Remove the spring and relief valve poppet.

51000067

Inspect the poppet and mating seat in the end cap for damage or foreign material.

Fig. 50-19 - Remove Charge Relief Valve Plug

51000068

Fig. 50-20 - Remove Charge Relief Valve

Install the poppet and spring. Install the plug with its lock nut, aligning the marks made at disassembly, and torque the lock nut to 52 Nm (38 ft•lbsf). Check and adjust, if necessary, the charge pressure.

51000069

Fig. 50-21 - Charge Relief Valve Components Minimum Angle Servo Cover Thoroughly clean external surfaces prior to removal of cover. Remove the four (4) screws retaining the cover to the end cap with an 8 mm internal hex wrench (060, 080, 110, and 160 units) or a 10 mm internal hex wrench (250 units). Remove the cover. Remove the O-rings between the cover and end cap. 51000046

Install new O-rings on the end cap and retain with petroleum jelly. Install the cover onto the end cap and install the screws. Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080, or 110 units, or 110 Nm (81 ft•lbsf) for 160 or 250 units.

51000006

Fig. 50-22 - Remove Fig. 50-23 - Install Servo Cover Screws Servo Cover

The plug in the cover may be removed with a 7/16" hex wrench. Torque this plug to 9 Nm (7 ft•lbsf).

50 - 5

008 911 63

55

BOMAG

785

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Hydraulic 2-Position Control (Type N2) Thoroughly clean external surfaces prior to removal of cover plate. Remove the four (4) screws retaining the cover plate to the end cap with an 8 mm internal hex wrench (060, 080, and 110 units) or a 10 mm internal hex wrench (160 and 250 units). Remove the cover plate. 51000071

Fig. 50-24 - Remove Cover Plate Screws

51000072

Fig. 50-25 - Remove Cover Plate

Remove the solid plug from the valve sleeve bore in the end cap. (An 8 mm threaded hole is provided in the plug for a puller screw.) Remove the O-ring from the plug. Remove the O-rings from the end cap. Install new O-rings on the end cap and retain with petroleum jelly. Install a new O-ring on the solid plug and install the solid plug into the end cap.

51000168

Fig. 50-26 - Remove Valve Sleeve Bore Plug

Install the cover plate onto the end cap and install the screws. Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080, or 110 units, or to 110 Nm (81 ft•lbsf) for 160 or 250 units.

51000010

Fig. 50-27 - N2 Control Components

Set screws are installed in control orifice holes in the end cap to plug the valve sleeve bore passages. To gain access to the screw plugs, remove the outer plugs from the end cap with a 7/16" or 11/16" hex wrench. Remove the screw plugs with a 3 mm internal hex wrench. When installing, torque the screw plugs to 4 Nm (35 in•lbsf). Torque the 5/16" outer plugs to 9 Nm (7 ft•lbsf), and the 9/16" outer plugs to 37 Nm (27 ft•lbsf). Refer to the “Control Orifices” topic for additional information. The special plug and seal washer on the end cap opposite the control may be removed with a 13 mm hex wrench. When installing, torque this plug to 20 Nm (15 ft•lbsf).

51000073

Fig. 50-28 - Torque Cover Plate Screws

51000074

Fig. 50-29 - Torque Plug in End Cap 50 - 6

56

786

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Electrohydraulic 2-Position Controls (Types E1•E2 and F1•F2) Thoroughly clean external surfaces prior to removing the control. The solenoid may be removed from the valve by removing the nut with a 3/4" hex wrench. The solenoid valve may be removed from the control valve housing with a 7/8" hex wrench. 51000075

Fig. 50-30 - Remove E1•E2 or F1•F2 Control Solenoid

51000076

Fig. 50-31 - Remove Solenoid Valve

Remove the screws retaining the valve housing to the multi-function block with a 4 mm internal hex wrench. Remove the valve housing. The plugs on the control housing may be removed with an 11/16" hex wrench. When reinstalling, torque the plugs to 37 Nm (27 ft•lbsf).

51000013

Fig. 50-32 - E1•E2 and F1•F2 Control Components Install new O-rings onto the valve housing. Install the valve housing onto the multi-function block, and install the screws. Torque the screws to 6.4 Nm (4.7 ft•lbsf).

51000077

Fig. 50-33 - Install E1•E2 or F1•F2 Control Valve Housing When installing the solenoid valve into the valve housing, the valve should be torqued to 20 Nm (15 ft•lbsf). When installing the solenoid onto the valve, torque the nut to 15 Nm (11 ft•lbsf.).

51000078

Fig. 50-34 - Install Solenoid Valve 50 - 7

008 911 63

51000079

Fig. 50-35 - Install Solenoid 57

BOMAG

787

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Electric 2-Position Controls (Type S1) Thoroughly clean external surfaces prior to removing the control. Remove the screws retaining the solenoid and solenoid adapter plate to the multi-function block with a 4 mm internal hex wrench. Remove the solenoid and the solenoid adapter plate from the multi-function block. 51000164

Fig. 50-36 - Remove S1 Control Screws

51000165

Fig. 50-37 - Remove Adapter Plate and Solenoid

Remove the solenoid pin from the multi-function block. Install new O-rings onto the adapter plate and the solenoid.

51000163

Fig. 50-38 - S1 Control Components

Install the solenoid pin into the hole in the multifunction block.

51000086

Fig. 50-39 - Install S1 Control Solenoid Pin

Install the adapter plate with O-rings onto the multifunction block. Install the solenoid with O-ring onto the adapter plate. Install the screws and torque to 6.4 Nm (4.7 ft•lbsf).

51000165

Fig. 50-40 - Install Adapter Plate and Solenoid

51000166

Fig. 50-41 - Torque Control Solenoid Screws 50 - 8

58

788

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Hydraulic Proportional Control (Type HZ) Thoroughly clean external surfaces prior to removal of control. Remove the four (4) screws retaining the valve housing to the end cap with an 8 mm internal hex wrench (060, 080, and 110 units) or a 10 mm internal hex wrench (160 and 250 units). Remove the valve housing. Remove the O-rings between the valve housing and end cap, and the O-ring on the valve spool sleeve. The plugs on the control housing may be removed

51000080

Fig. 50-42 - Remove HZ Control Housing Screws

51000081

Fig. 50-43 - Remove HZ Control Housing

with a 7/16" or 11/16" hex wrench. When reinstalling, torque the 5/16" plugs to 9 Nm (7 ft•lbsf), and the 9/16" plugs to 37 Nm (27 ft•lbsf) The valve housing is equipped with filter screens in

51000016

Fig. 50-44 - HZ Control Components

the passages between the housing and the end cap. Units with internal servo pressure supply have a filter screen installed in the end cap passage leading to the valve spool sleeve. These screens should be pressed into position (with the rounded edge of the filter screens facing “out”) until they are flush to 2.0 mm (0.08 in.) below the machined surface of the valve housing or end cap. Units with external servo pressure supply have a plug installed in the end cap passage leading to the valve spool sleeve. This plug may be removed with a 2.5 mm internal hex wrench. When installing this plug, torque to 2 Nm (18 in•lbsf).

51000082

Fig. 50-45 - HZ Control Housing Screens

51000083

Fig. 50-46 - End Cap O-Rings Installed

Install a new O-ring onto the valve spool sleeve in the end cap. Install new O-rings onto the end cap. Install the valve housing onto the multi-function block, and install the screws. Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080, or 110 units, or to 110 Nm (81 ft•lbsf) for 160 or 250 units.

51000081

51000084

Fig. 50-47 - Install HZ Fig. 50-48 - Torque HZ Control Valve Control Housing Housing Screws 50 - 9

008 911 63

59

BOMAG

789

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Hydraulic Proportional Control (Type HS) Thoroughly clean external surfaces prior to removal of control. Remove the screws retaining the valve housing to the multi-function block with a 4 mm internal hex wrench. Remove the valve housing.

51000087

Fig. 50-49 - Remove HS Control Housing Screws The plug on the control housing may be removed with an 11/16" hex wrench. When reinstalling, torque the plug to 37 Nm (27 ft•lbsf). Install a new O-ring onto the valve housing.

51000019

Fig. 50-50 - HS Control Components

Install the valve housing onto the multi-function block, and install the screws. Torque the screws to 6.4 Nm (4.7 ft•lbsf).

51000088

Fig. 50-51 - Torque HS Control Housing Screws

50 - 10

60

790

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Hydraulic Proportional Control with Maximum Angle Over-ride (Types H1•H2 or K1•K2) Thoroughly clean external surfaces prior to removing the control. The solenoid may be removed from the valve by removing the nut with a 3/4" hex wrench. 51000089

Fig. 50-52 - Remove H1•H2 or K1•K2 Control Solenoid

51000090

Fig. 50-53 - Remove Solenoid Valve

The solenoid valve may be removed from the control valve housing with a 7/8" hex wrench. Remove the screws retaining the valve housing to the multi-function block with a 4 mm internal hex wrench. Remove the valve housing. The plugs on the control housing may be removed with an 11/16" hex wrench. When reinstalling, torque the plugs to 37 Nm (27 ft•lbsf). 51000091

Fig. 50-54 - Remove Control Housing Screws Install new O-rings onto the valve housing. Install the valve housing onto the multi-function block, and install the screws. Torque the screws to 6.4 Nm (4.7 ft•lbsf).

51000021

Fig. 50-55 - H1•H2 and K1•K2 Control Components When installing the solenoid valve into the valve housing, the valve should be torqued to 20 Nm (15 ft•lbsf). When installing the solenoid onto the valve, torque the nut to 15 Nm (11 ft•lbsf.).

51000092

Fig. 50-56 - Install Solenoid Valve 50 - 11

008 911 63

51000093

Fig. 50-57 - Install Solenoid 61

BOMAG

791

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Two Connection Hydraulic Proportional Control (Type HP) Thoroughly clean external surfaces prior to removal of control.

51000094

Fig. 50-58 - Remove HP Control Housing Screws

51000095

Fig. 50-59 - Remove Control Housing

Hold the control housing in position, and remove the screws retaining the cover and control housing to the multi-function block with a 4 mm internal hex wrench. Remove the housing cover and gasket. Remove the valve housing with shuttle valve assembly and pilot piston from the multi-function block. Remove the O-rings from the valve housing. Remove the pilot piston and spring from the valve housing. Remove the pilot piston pin from the multi-function block.

51000096

Fig. 50-60 - Remove Shuttle Spool Plug

51000086

Fig. 50-61 - Remove Pilot Piston Pin

Remove the inner shuttle spool plug from the valve housing. (A 5 mm threaded hole is provided in the inner plug for a puller screw.) Remove the shuttle spool from the valve housing. Remove the outer shuttle spool plug. Remove the O-rings from the plugs.

Install new O-rings on the shuttle spool plugs. Install new O-rings on the valve housing and retain with petroleum jelly.

51000024

Fig. 50-62 - HP Control Components

50 - 12

62

792

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Install the pilot piston pin in the multi-function block. Install the outer (thin) shuttle piston plug with the large chamfer toward the shuttle valve bore. Install the shuttle spool into its bore and install the inner (thick) plug with the large chamfer toward the shuttle valve bore.

51000097

Fig. 50-63 - Pilot Piston Pin Installed

51000098

Fig. 50-64 - Install Shuttle Spool and Plugs

Position the valve housing (with O-ring) on the multifunction block. Install the pilot piston into the housing and over the pin. The end of the piston with the cross drilled hole should engage the pin.

51000099

Fig. 50-65 - Install Control Housing

51000100

Fig. 50-66 - Install Pilot Piston

Install the small spring in the outer end of the pilot piston. Install the control cover and gasket. Align the control assembly with the multi-function block and install the four (4) screws. Torque the control screws to 6.4 Nm (4.7 ft•lbsf). 51000101

Fig. 50-67 - Install Spring

50 - 13

008 911 63

51000102

Fig. 50-68 - Install Cover, Gasket, and Screws

63

BOMAG

793

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Two Connection Hydraulic Proportional Control for “Dual Path” Vehicles (Type HC) Bleed Valve Loosen the seal lock nut on the bleed valve with a 10 mm hex wrench, and remove the valve with a 4 mm internal hex wrench. Install the bleed valve and torque to 3 Nm (27 in•lbsf). 51000103

Fig. 50-69 - Remove HC Control Bleed Valve

51000175

Fig. 50-70 - Install HC Control Bleed Valve Install the seal lock nut and torque to 19 Nm (14 ft•lbsf). Servo Pressure Shuttle Valve Remove the servo pressure shuttle plug with an 11⁄16" hex wrench. Remove the shuttle ball seat with a 5 mm internal hex wrench and remove the ball.

51000176

Fig. 50-71 - Install HC Control Bleed Valve Seal Nut

51000104

Fig. 50-72 - Remove Servo Pressure Ball Shuttle Valve Install the servo pressure shuttle ball. Install the shuttle ball seat and torque to 11 Nm (8 ft•lbsf). Install the shuttle passage plug and torque to 37 Nm (27 ft•lbsf).

51000123

Fig. 50-73 - Install Servo Pressure Shuttle Ball Valve

51000174

Fig. 50-74 - Torque Servo Pressure Shuttle Ball Seat Control Pressure Shuttle Valve Remove the shuttle spool plugs with a 1/4" internal hex wrench. Remove the control pressure shuttle spool. Install the control pressure shuttle spool. Install the shuttle spool plugs and torque to 20 Nm (15 ft•lbsf).

51000105

Fig. 50-75 - Install Control Pressure Shuttle Spool

51000122

Fig. 50-76 - Torque Shuttle Spool Plugs 50 - 14

64

794

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Pilot Piston and Control Housing Thoroughly clean external surfaces prior to disassembly of control. Remove the four (4) screws retaining the cover to the control housing with a 4 mm internal hex wrench. Remove the housing cover and gasket (with the adjusting screw and seal lock nut). 51000177

51000106

Fig. 50-77 - Remove Fig. 50-78 - Remove HC Control Housing HC Control Housing Cover Screws Cover Remove the control start adjustor spring seat and spring from the pilot piston. Remove the pilot piston from the control housing. Remove the pilot piston pin seat and pin from the control housing (or pilot piston). Remove the control start spring from the control housing. 51000107

Fig. 50-79 - Remove Adjustment Spring and Pilot Piston

51000108

Fig. 50-80 - Remove Pilot Piston Pin and Control Start Spring

Remove the four (4) screws (and washers for 060, 080, and 110 units) retaining the control housing to the end cap with an 8 mm internal hex wrench (060, 080, and 110 units) or a 10 mm internal hex wrench (160 and 250 units). Remove the control housing from the end cap. Remove the O-rings between the control housing and the end cap, and the O-ring on the valve spool sleeve. 51000109

Fig. 50-81 - Remove HC Control Housing Screws

50 - 15

008 911 63

51000110

Fig. 50-82 - Remove HC Control Housing

65

BOMAG

795

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) The plugs on the control housing may be removed with a 7/16" hex wrench or a 1/4" internal hex wrench. When reinstalling, torque the 5/16" plugs to 9 Nm (7 ft•lbsf), and the 9/16" plugs to 20 Nm (15 ft•lbsf).

51000111

Fig. 50-83 - HC Control Components

The control housing is equipped with filter screens in the passages between the housing and the end cap. Units with internal servo pressure supply have a filter screen installed in the end cap passage leading to the valve spool sleeve. These screens should be pressed into position (with the rounded edge of the filter screens facing “out”) until they are flush to 2.0 mm (0.08 in.) below the machined surface of the valve housing or end cap. 51000112

Fig. 50-84 - HC Control Housing Screens

51000113

Fig. 50-85 - End Cap O-Rings Installed for HC Control

Install a new O-ring onto the valve spool sleeve in the end cap. Install new O-rings onto the end cap.

Install the valve housing onto the end cap, and install the screws (with flat washers on 060, 080, and 110 units). Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080, and 110 units, or to 110 Nm (81 ft•lbsf) for 160 and 250 units.

51000110

51000114

Fig. 50-86 - Install Fig. 50-87 - Torque HC Control Housing HC Control Housing Screws 50 - 16

66

796

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Install the control start spring into the control housing. Install the pilot piston pin. The end of the pin must engage the recess in the end of the control valve spool.

51000115

Fig. 50-88 - Install HC Control Start Spring

51000116

Fig. 50-89 - Install Pilot Piston Pin

Install the pilot piston pin seat. Install the pilot piston into the housing and over the spring and spring seat. The end of the piston with the deeper bore and the cross drilled hole should engage the start spring and pin seat.

51000117

51000118

Fig. 50-90 - Install Fig. 50-91 - Install Pilot Piston Pin Seat HC Control Pilot Piston Install the adjustor spring in the outer end of the pilot piston. Install the adjustor spring seat.

51000119

Fig. 50-92 - Install HC Control Start Adjuster Spring

51000120

Fig. 50-93 - Install HC Control Start Adjuster Spring Seat

Install the control cover and gasket (with adjusting screw and seal lock nut). Torque the control cover screws to 6.4 Nm (4.7 ft•lbsf).

51000106

Fig. 50-94 - Install HC Control Cover and Gasket 50 - 17

008 911 63

51000121

Fig. 50-95 - Torque Control Cover Screws 67

BOMAG

797

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Electrohydraulic Proportional Control (Types EP and EQ) Thoroughly clean external surfaces prior to removal of control. The Pressure Control Pilot (PCP) valve may be removed from the control valve housing, as described under the following heading. 51000124

Fig. 50-96 - Remove PCP Valve

51000125

Fig. 50-97 - Remove EP•EQ Control Housing Screws

Remove the screws retaining the control housing cover and control valve housing to the multi-function block with a 4 mm internal hex wrench. Remove the housing cover and gasket. Remove the valve housing with the pilot piston from the multi-function block. Remove the O-rings from the valve housing. Remove the pilot piston and spring from the valve housing. Remove the pilot piston pin from the multi-function block.

51000126

Fig. 50-98 - Remove EP•EQ Control Housing

51000086

Fig. 50-99 - Remove Pilot Piston Pin Install new O-rings on the valve housing and retain with petroleum jelly. The plugs on the control housing may be removed with a 1/4" internal hex wrench. When reinstalling, torque the 9/16" plugs to 20 Nm (15 ft•lbsf).

51000027

Fig. 50-100 - EQ Control Components (EP Similar)

50 - 18

68

798

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Install the pilot piston pin in the multi-function block. Position the valve housing (with O-rings) on the multifunction block.

51000097

Fig. 50-101 - Pilot Piston Pin Installed

51000127

Fig. 50-102 - Install Control Housing

Install the pilot piston into the housing and over the pin. The end of the piston with the cross drilled hole should engage the pin. Install the small spring in the outer end of the pilot piston.

51000128

Fig. 50-103 - Install Pilot Piston

51000129

Fig. 50-104 - Install Spring

Install the control cover and gasket. Align the control assembly with the multi-function block and install the four (4) screws. Torque the control screws to 6.4 Nm (4.7 ft•lbsf). Reinstall the PCP valve, if removed.

51000130

Fig. 50-105 - Torque Cover, Gasket, and Screws

50 - 19

008 911 63

51000131

Fig. 50-106 - Install PCP Valve

69

BOMAG

799

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Pressure Control Pilot (PCP) Valve for Electrohydraulic Proportional Control (Types EP and EQ) Thoroughly clean external surfaces of control. Using a 4 mm internal hex wrench, remove the four (4) screws and remove the PCP valve.

51000132

51000133

Fig. 50-107 - Remove Fig. 50-108 - PCP PCP Valve Screws Valve Components

Check surfaces for nicks or damage. Clean internal screens.

Install new O-rings on the PCP housing and retain with petroleum jelly. Position the PCP on the control valve housing and install the screws. Torque the screws to 5.4 Nm (48 in•lbsf).

51000124

Fig. 50-109 - Install PCP onto Control

51000131

Fig. 50-110 - Torque PCP Valve Screws

50 - 20

70

800

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Multi-function Block Removal and Installation Remove the external control assembly as described in the instructions for the specific control. Remove the four (4) screws (and washers for 060, 080, and 110 units) retaining the multi-function block to the end cap with an 8 mm internal hex wrench (060, 080, and 110 units) or a 10 mm internal hex wrench (160 and 250 units). Remove the multi-function block from the end cap. Remove the O-rings between the multi-function block and the end cap, and the O-ring on the valve spool sleeve. The multi-function block is equipped with filter screens in the passages between the block and the end cap. Units with internal servo pressure supply have a filter screen installed in the end cap passage leading to the valve spool sleeve. These screens should be pressed into position (with the rounded edge of the filter screens facing “out”) until they are flush to 2.0 mm (0.08 in.) below the machined surface of the multifunction block or end cap. Units with external servo pressure supply have a plug installed in the end cap passage leading to the valve spool sleeve. This plug may be removed with a 2.5 mm internal hex wrench. When installing this plug, torque to 2 Nm (18 in•lbsf).

51000087

51000134

Fig. 50-111 - Remove Fig. 50-112 - Remove External Control (HS Multi-function Block Shown) Screws

51000135

51000136

Fig. 50-113 - Remove Fig. 50-114 - MultiMulti-function Block function Block Screens

Install a new O-ring onto the valve spool sleeve in the end cap. Install new O-rings onto the end cap. Install the multi-function block onto the end cap, and install the screws. Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080, or 110 units, or to 110 Nm (81 ft•lbsf) for 160 or 250 units.

51000083

Fig. 50-115 - End Cap O-Rings Installed

51000135

Fig. 50-116 - Install Multi-function Block

Reinstall the external control assembly as described in the instructions for the specific control.

51000137

51000088

Fig. 50-117 - Torque Fig. 50-118 - Install Multi-function Block External Control (HS Screws Shown) 50 - 21

008 911 63

71

BOMAG

801

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Servo Pressure Supply Shuttle Spool Remove the servo pressure supply shuttle spool plug from the multi-function valve with a 9/16" hex wrench.

51000138

51000139

Fig. 50-119 - Remove Fig. 50-120 - Remove Servo Pressure Servo Pressure Supply Spool Plug Supply Shuttle Spool

NOTE: If a pressure compensator valve block is installed, the opposite end of the shuttle spool bore in the multi-function valve is plugged with an internal hex head plug located under the valve block. If a pressure compensator valve block is not installed, the opposite end of the shuttle spool bore is plugged with a hex head plug. Remove the servo pressure supply shuttle spool from the multi-function valve block. Inspect the shuttle spool for burrs or scoring. The spool must slide free in its bore. The shuttle ball in the spool must be free to move.

51000030

Fig. 50-121 - Multi-function Block with Servo Pressure Supply Shuttle Spool Install the shuttle spool into the multi-function block. Install the hex head plug into the multi-function valve and torque to 37 Nm (27 ft•lbsf). NOTE: If an internal hex head plug was removed from the opposite end of the shuttle spool bore, torque it to 20 Nm (15 ft•lbsf). 51000139

51000140

Fig. 50-122 - Install Fig. 50-123 - Torque Servo Pressure Servo Pressure Supply Shuttle Spool Supply Spool Plug

50 - 22

72

802

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Blocking Plate for Multi-function Block Without PCOR The blocking plate may be removed by removing the four (4) screws with a 5 mm internal hex wrench. Remove the O-rings from the plate. Install new O-rings on the blocking plate and retain with petroleum jelly. Install the plate on the multifunction block and install the screws. Torque the screws to 11 Nm (8 ft•lbsf).

51000170

51000171

Fig. 50-124 - Remove Fig. 50-125 - Torque Blocking Plate (Less Blocking Plate PCOR) Screws (Less PCOR)

Pressure Compensator Valve for Pressure Compensator Over-Ride (PCOR) and Pressure Compensator Regulator (Type PC) Loosen the adjusting screw lock nut with a 1-1/16" hex wrench. Remove the adjusting screw from the valve block with a large screwdriver. Remove the pressure compensator valve spring and the spool assembly from the block. 51000142

51000143

Fig. 50-126 - Remove Fig. 50-127 - Remove PCOR•PC Adjustor PCOR•PC Spring and Spool Valve Remove the valve block plug with a 1" hex wrench. Remove the four (4) screws retaining the valve block to the multi-function block with a 5 mm internal hex wrench. Remove the valve block and O-rings.

51000144

51000145

Fig. 50-128 - Remove Fig. 50-129 - Remove PCOR•PC Plug PCOR•PC Valve Block Install new O-rings on the pressure compensator valve block and retain with petroleum jelly. Install a new O-ring on the adjusting screw. The plugs on the valve block may be removed with a 7⁄16" hex wrench. When reinstalling, torque the 5⁄16" plugs to 9 Nm (7 ft•lbsf).

51000146

Fig. 50-130 - Pressure Compensator Valve Block Components 50 - 23

008 911 63

73

BOMAG

803

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Install the valve block on the multi-function block and install the screws. Torque the screws to 11 Nm (8 ft•lbsf). Install the valve block plug and torque to 54 Nm (40 ft•lbsf).

51000147

Fig. 50-131 - Install PCOR•PC Valve Block

51000148

Fig. 50-132 - Install PCOR•PC Valve Plug Install the pressure compensator spool assembly and the valve spring. Install the adjusting screw and lock nut. Perform the PCOR or PC regulator pressure adjustment as described under “Component Adjustment."

51000143

Fig. 50-133 - Install PCOR•PC Spring and Spool Valve

51000142

Fig. 50-134 - Install PCOR•PC Adjusting Screw PCOR and PC Regulator Orifices To gain access to the PCOR or PC regulator orifices, remove the three (3) plugs located between the defeat spool stop plugs on the multi-function block, using a 7/16" hex wrench. Remove the PCOR brake pressure defeat spool (if installed). Remove the orifice plug(s) and plain plug(s) with a 2.5 mm internal hex wrench. 51000149

Fig. 50-135 - PCOR and PC Regulator Orifices

Refer to the appropriate Service Parts Manual for information on orifice locations and sizes. Install the orifice plug(s) and plain plug(s), and torque to 4 Nm (35 in•lbsf). Install the outer plugs and torque to 6 Nm (4 ft•lbsf). Reinstall the PCOR defeat spool (if removed). Additional orifices are installed in the passages under the pressure compensator valve block.

51000172

Fig. 50-136 - PCOR and PC Regulator Orifices 50 - 24

74

804

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) PCOR Brake Pressure Defeat Spool Remove the PCOR defeat spool bore plugs or fittings with a hex wrench. Remove the PCOR defeat spool stop plugs with a 7⁄16" hex wrench. Remove the defeat spool. NOTE: The defeat spool may be removed from either end of its bore in the multi-function block. 51000150

51000151

Fig. 50-137 - Remove Fig. 50-138 - Remove PCOR Defeat Spool PCOR Defeat Spool Plug or Fitting Stop Plug Inspect the defeat spool for burrs or roughness. The spool must slide freely in its bore. Inspect the pins in the stop plugs for damage.

51000032

Fig. 50-139 - Multi-function Block With PCOR Defeat Spool Components Install the PCOR defeat spool into its bore in the multifunction block. Install the spool stop plugs into the multi-function block. Torque the stop plugs to 6 Nm (4 ft•lbsf). Install the defeat spool bore plugs or fittings and torque to 27 Nm (20 ft•lbsf). 51000152

Fig. 50-140 - Install PCOR Defeat Spool

50 - 25

008 911 63

51000153

Fig. 50-141 - Install PCOR Defeat Spool Stop Plug

75

BOMAG

805

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Pressure Compensator Regulator (Type PC) The PC regulator utilizes the multi-function block and pressure compensator valve to control the motor displacement. Service procedures for these components are included in the “Multi-function Block” section of this manual. 51000035

Fig. 50-142 - PC Regulator Components

A valve sleeve bore plug is installed in the motor end cap in place of the valve spool sleeve. Remove the plug from the valve sleeve bore in the end cap. (An 8 mm threaded hole is provided in the plug for a puller screw.) Remove the O-ring from the plug.

51000169

51000173

Fig. 50-143 - Remove Fig. 50-144 - Servo Valve Sleeve Bore Drain Orifice (T7) Plug

A single servo drain orifice is installed in the valve sleeve bore plug. This orifice limits oil flow from the maximum displacement end of the servo piston to the motor case. Install a new O-ring on the valve sleeve bore plug. Install the bore plug into the end cap. The special plug and seal washer on the end cap opposite the multi-function block may be removed with a 13 mm hex wrench. When installing, torque this plug to 20 Nm (15 ft•lbsf).

50 - 26

76

806

BOMAG

008 911 63

17.5

Axle drive motor


Series 51

Minor Repair and Replacement - Variable Motor (Continued) Control Orifices Orifices are installed in the motor end cap to regulate oil flow to the servo control valve and the servo piston. To gain access to these orifice plugs, remove the three (3) plugs located on the motor end cap nearest the multi-function block or control, using a 7⁄16" or 9⁄16" hex wrench. Remove the orifice plugs (plain plugs for N2 control) with a 3 mm internal hex wrench. 51000154

Install the orifice plugs, and torque to 4 Nm (35 in•lbsf). Torque the 5⁄16" outer plugs to 9 Nm (7 ft•lbsf), and the 9⁄16" outer plug to 37 Nm (27 ft•lbsf).

Fig. 50-145 - Servo Pressure Supply Orifice (T1)

51000155

Fig. 50-146 - Servo Orifice for Maximum Displacement (T2)

Orifices are also installed in the servo control valve sleeve to control oil flow from the servo piston to the motor case.

51000156

Fig. 50-147 - Servo Orifice for Minimum Displacement (T3)

51000157

Fig. 50-148 - Servo Drain Orifices (T7 and T8)

Plug / Fitting Torques If any plugs or fittings are removed from the unit during servicing, they should be torqued as indicated in the accompanying table. Item Pressure Gauge Ports (9/16—18 O-Ring Hex) Construction Plugs (9/16—18 O-Ring Int. Hex) Construction Plugs (5/16—24 O-Ring) Screw Plugs (M6 Int. Hex)

Torque 37 Nm (27 ft•lbsf) 20 Nm (15 ft•lbsf) 9 Nm (7 ft•lbsf) 4 Nm (35 in•lbsf)

50 - 27

008 911 63

77

BOMAG

807

808

J60

J40

BOMAG

J50

T2

Items T1, T2, and T3: 3 mm internal hex wrench; Torque to 5 Nm (44 lbsf•in)

For Proportional Controls [Except HC] (060 — 110 Frame Sizes)

10 mm hex wrench Torque to 9 Nm (6.6 lbsf•ft) after adjustment FOR 2-POSITION CONTROLS, DO NOT DISTURB ADJUSTMENT!

T7

J30 J10 S70

F32 F33

J30 J10

5 mm threaded holes for puller screws Install O-rings on valve sleeve

Items T7 and T8: 2.5 mm int. hex wrench Torque to 2 Nm (18 lbsf•in)

T8

S10

S10

S70


For 2-Position Controls [Except N2]

S20

S20

For Proportional Controls [Except HC] (160 — 250 Frame Sizes)

saue

13 mm hex wrench Torque to 20 Nm (15 lbsf•ft)

Remove Item T1 BEFORE removing Item F32! Install Item T1 AFTER installing Item F32! J30 Install O-ring J10 on adjustor screw J20

T1 T3

4 mm internal hex wrench

J70

DO NOT REMOVE UNTIL CONTROL VALVE AND SPRINGS ARE REMOVED! Remove as an assembly to preserve adjustment. INSTALL BEFORE INSTALLING SPRINGS AND CONTROL VALVE!


a

Series 51 MV Sheet 1 of 2

Minor Repair Instructions 4-Way Valve and Feedback Springs

78

008 911 63

008 911 63

S60

BOMAG

S40

T2

Items T1, T2, and T3: 3 mm internal hex wrench; Torque to 5 Nm (44 lbsf•in)

10 mm hex wrench Torque to 9 Nm (6.6 lbsf•ft) after adjustment.

T7

S10

S10 S10T S70

S11T

S10T

F33

5 mm threaded holes for puller screws Install O-rings on valve sleeve

F32

S70


T8 Items T7 and T8: 2.5 mm int. hex wrench Torque to 2 Nm (18 lbsf•in)

S11T

S20

For 160 — 250 Frame Sizes

saue

13 mm hex wrench Torque to 20 Nm (15 lbsf•ft)

S20

For 060 — 110 Frame Sizes

Remove Item T1 BEFORE removing Item F32! Install Item T1 AFTER installing Item F32! Install O-ring on adjustor screw

T1 T3

4 mm internal hex wrench

S50 S30

DO NOT REMOVE UNTIL CONTROL VALVE AND SPRINGS ARE REMOVED! Remove as an assembly to preserve adjustment (060 — 110). INSTALL BEFORE INSTALLING SPRINGS AND CONTROL VALVE!

Axle drive motor

17.5

a

Series 51 MV Sheet 2

Minor Repair Instructions 4-Way Valve and Feedback Springs - HC Control

79

809

17.5

Axle drive motor

saue Hydraulic Power Systems SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide SAUER-SUNDSTRAND is a world leader in the design and manufacture of Hydraulic Power Systems. Research and development resources in both North America and Europe enable SAUER-SUNDSTRAND to offer a wide range of design solutions utilizing hydraulic power system technology.

SAUER-SUNDSTRAND specializes in integrating a full range of system components to provide vehicle designers with the most advanced total-design system. SAUER-SUNDSTRAND is Your World Source for Controlled Hydraulic Power Systems. F000 691

F000 692


Heavy Duty Bent Axis Variable Motors F000 685 F000 688


Cartridge Motors/ Compact Wheel Drives F000 690

Microcontrollers and Electrohydraulic Controls F000 689


F000 686

F000 684

Hydrostatic Transmission Packages F000 687


F000 693


Worldwide Service Support SAUER-SUNDSTRAND provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world. Look to SAUER-SUNDSTRAND for the best in WORLDWIDE SERVICE.

saue

SAUER-SUNDSTRAND COMPANY 2800 East 13th Street • Ames IA 50010 • U.S.A. Phone: (515) 239-6000 • FAX: (515) 239-6618 TWX: 9105201150

SAUER-SUNDSTRAND GMBH & CO. Postfach 2460 • D-24531 Neumünster Krokamp 35 • D-24539 Neumünster • Germany Phone: (04321) 871-0 • FAX: (04321) 871 122

SM-VMV51E • 11/97 • 300 043A BLN-10043 • November 1997

810

BOMAG

008 911 63

17.6 Axle

008 911 63

BOMAG

811

17.6

Axle

Bild 35

812

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

813

17.6

814

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

815

17.6

816

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

817

17.6

818

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

819

17.6

820

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

821

17.6

822

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

823

17.6

824

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

825

17.6

826

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

827

17.6

828

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

829

17.6

830

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

831

17.6

832

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

833

17.6

834

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

835

17.6

836

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

837

17.6

838

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

839

17.6

840

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

841

17.6

842

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

843

17.6

844

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

845

17.6

846

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

847

17.6

848

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

849

17.6

850

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

851

17.6

852

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

853

17.6

854

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

855

17.6

856

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

857

17.6

858

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

859

17.6

860

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

861

17.6

862

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

863

17.6

864

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

865

17.6

866

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

867

17.6

868

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

869

17.6

870

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

871

17.6

872

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

873

17.6

874

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

875

17.6

876

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

877

17.6

878

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

879

17.6

880

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

881

17.6

882

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

883

17.6

884

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

885

17.6

886

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

887

17.6

888

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

889

17.6

890

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

891

17.6

892

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

893

17.6

894

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

895

17.6

896

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

897

17.6

898

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

899

17.6

900

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

901

17.6

902

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

903

17.6

904

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

905

17.6

906

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

907

17.6

908

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

909

17.6

910

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

911

17.6

912

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

913

17.6

914

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

915

17.6

916

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

917

17.6

918

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

919

17.6

920

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

921

17.6

922

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

923

17.6

924

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

925

17.6

926

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

927

17.6

928

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

929

17.6

930

Axle

BOMAG

008 911 63

17.6

Axle

008 911 63

BOMAG

931

17.6

932

Axle

BOMAG

008 911 63

18 Circuit diagrams

008 911 63

BOMAG

933

934

BOMAG

008 911 63

18.1 Hydraulic diagram 581 202 10 58120210

008 911 63

BOMAG

935

18.1

936

Hydraulic diagram 581 202 10

BOMAG

008 911 63

18.1


008 911 63

BOMAG

937

18.1

938


BOMAG

008 911 63

18.2 Hydraulic diagram 581 202 11 58120210

008 911 63

BOMAG

939

18.2

940


BOMAG

008 911 63

18.2


008 911 63

BOMAG

941

18.2

942


BOMAG

008 911 63


008 911 63

BOMAG

943

18.3

Wiring diagram 582 702 09

Wiring diagram 582 702 09 Design status: December 2006 to June 2007

944

BOMAG

008 911 63

008 911 63

001 002 003 004 005 006 007 008 009 010 101

Blatt Nr.: sheet no.:

582 702 09 582 702 09 582 702 09 582 702 09 582 702 09 582 702 09 582 702 09 582 702 09 582 702 09 582 702 09 582 702 09

16.11.2005 Vogt 16.11.2005 Seis

Stromlaufplan circuit diagram

Stromlaufplan Versorgung, Starten, Motordrehzahl Motor−Heizflansch, Signalhorn, Geschwindigkeit−Anz. Bremse, Rückfahrwarneinr., Anzeige Fahrstufen, Sitzkontaktsch., Vibration ZA Messtechnik BOMAG Compaction Management BCM ZA Beleuchtung und StvZO ZA Kabine, Beleuchtung, Radio, Tachograph ZA Kabinenheizung, Klimaanlage, Zusatzheizung Bauteilliste

Funktionsgruppe

BW 177..219 D−4/D−40 BW 177..219 D−4/D−40

Zeichnungsnummer drawing − no.

Inhaltsverzeichnis: table of contents:

001

001

BOMAG

001

582 702 09

Circuit Diagram supply, starting unit, engine−speed engine heating−flange cont., warning horn, speedometer brake, back up alarm, indicator speed−ranges, seat−switch, vibr. option measurement equipm. BOMAG Compaction Management BCM opt. illumination and StvZO opt. cabin, headlights, radio, tachograph opt. cabin−heater, air conditioning, add. heater component listing

function unit


18.3

945

2

1

87(4)

Sicherung Heizflansch

F48

1

2

1

−

G03 +

S30

heating−flange

2

−

G01 +

1

F00 2

X36:A

Option option

Trennschalter Batterie break switch battery Heizflansch Batterie heating−flange battery

31

R19

3:5

167A

K14

125A

30(3)

125A

K36

4:4

W

K61

6:2

85

86

87a

30

K09

X1:168

10:7

85

86

4:13

R10 2:5 82 OHM 87

K61/85

2

1

D+ MESX

X1:66

W

D+

65

1

Generator generator

X1

X1

85

86

X1

3:2

85

86 M01

B+ 2:5

K11:86

X1:4

79

−

Starter starter

M

50

X38:A

K05/87

S120

Startmehrmenge start boost fuel

1

12

X1

80

87

2:16

K114

11

X1

30

3:2

87a

K35 2:16

Y01 2

X1:53

87a

30

50a

X1 X1 7 8

4:3 87

K05

X37:B

19 17

30

54 58 15:54 2:13

30

Versorgung, Starten, Motordrehzahl supply, starting unit, engine−speed

2:18

2

1

15

X1:55

K11

X1:3

Startschalter starting switch

X37:A

X1:15A

30A

F13

15:54

1

85

−

AW + HW

2x2.5qmm

X1 X1 58 59

87

S01

X1

17A

2

1

17E

K11 2:10 87

Hubmagnet Drehzahl sol. engine speed

62 63

X1 X1

70A/1A

Y120

V47

2

X1:60

K35

30

86

87a

K114 2:14

2:13

X1:56

85

86

81

24

23

X1

20A

F105

X1

4qmm

X1:10

X36:B

16.05.2005 Vogt 16.05.2005 Seis

Batterie battery

2:8

B−

G02

B+

125mA

K61

2

1

2:11

V01

B+

S00

nur bei Klimaanlage only acc.to air conditioning

2:10

1

X1 55

87a

30

54 1 2

1

12

11

15A

32

31

31

?

?

S01:21

F14:2

K32:86

X1:30A

2

1 F39

X1:30E

3:1

5:9

5:9

9:2

K11/87 3:1

30 6:1

008 911 63

002

582 702 09

X1:152

22

21

27A

2

1

27E

87a

30

Kraftstoffabschaltug fuel shut off

Y13

X1

87

4:9

K22

NOT−AUS Emerg.−Stop

X1:151

X1

15A

F14

nur ohne Sitzkontaktschalter without switch seat−contact

X1:15E

125mA

9:2

Schalter Motordrehzl switch engine speed 3.9A

X1:9

Hauptsicherung main fuse

31−1

BOMAG 50A / 10A

4:5

K30

AUX

6:5

946 3.8A


nur bei BW 219D−4 und D−40 USA Version, sonst Option only at BW 219 D−4 and D−40 USA version, otherwise option

2:20

2:13

31

Modul Heizflanschsteuerung modul heating−flange−control

K05/87

K11:86

X1

3

5

52

2

4

BOMAG

64

X1 99

4.2A

100

nicht bei D−40/BW211D−4 ohne SN1 not at D−40/BW211D−4 ohne SN1

−

+

X1:172

speed

dir. X1:173

Sensor Achse sender axle

X1:174

B60

X1:171

Lern

−

A05

Test

SPEED TAC

1

9:6

SPEED MESX 6:2

DIR MESX 6:2

4:10

Modul Geschw. modul speedometer

F24:2

nur bei ZA Messtechnik, Geschw.−Anzeige und Tachograph only at opt. measurement−equ., speedometer and tachograph

Signalhorn warning horn

X1

2

B11 1

1

Motor−Heizflansch, Signalhorn, Geschwindigkeit−Anz. engine heating−flange cont., warning horn, speedometer


2

B11 1

V22

16.11.2005 Vogt 16.11.2005 Seis

2

24

14 X1 97 98 X1 X1 101 102

X1

23

13

X1:155

28A

2

1

28E

1

X1

Anbau im Motorbereich assembled in engine−area

K14

1

S03

X1

10A

F23

X1

V21

57

6

1

75

78

2

2

1

7

X1

X1

2

Kühlmitteltemperatur collant temperature

A13

X1

GLÜH

4:19

Taster Signalhorn push but. warning horn

2:10

B113

15/54 in


K11/87

Relais Heizflansch relais heating−flange

OUT+

P04

X1

X1

93

−

+

92

K11/87 4:1

1

003

582 702 09

31 4:1

ZA Geschwindigkeitsanzeige option speedometer

OUT−

008 911 63 4.2A

Geschwindigkeitsanz. speedometer

2:20


18.3

947

Nur bei BW 219 D−4 und D−40 USA Version, sonst Option only at BW 219 D−4 and D−40 USA version, otherwise option

geöffnet in 0

BR/BN

X12

X1:156

1

29A

3:20 31

X1:149

4:3

K48

K48 4:2 87a

2:11

85

86

K05

X1:148

X12 3 X12 2

BL/BU SW/BK

B13

Position (Bremse ein)

2

Initiator Farhebel"0 proximity switch travel lever "0"−position

X1

87

85

86

87

X1:147 11

X1:117

2

1

1

X1

4:8

129

K26

X1

H14+ − X9

X9

K26/87A

87

30

X1:117

2

1

114

K26 4:6 87a

5:9

X1

+

X1

X1

P

89

BEL

Bel.

OUT1

OUT2

15/54

X1:82

X10

R03

X10

X1

X1

Resist. buzzer

X1 69

14

5 4 3 2 1

X1

X1

X1:117

P

B21

87

4

3

106

110

13

X1:57

P

B03

X1

X1

4

3

67

71

15

2

B30

_t

1

P

Motoröldruck

X1

X1

B06

X1:74

X1:77

17

2

1

73

76

16

5:9 Q

B55

B06:1

5

Sitz

X21:2

X21:1

X1:68

GLÜH

−

+

1 X8

X8

B124

X1 107 108 X1

31 5:1

2

X1 111 112

1

1

5:9

8:17

8:17

8:16

3:5

X1

A68/6

BL−L

BL−R

BL−W

nicht bei D−40/BW177 D−4 not at D−40/BW177 D−4

Blinker links

Blinker rechts

Warnbl.

Vorglühen

X1:72

3

4

12

18

19

7

6

K11/87 5:1

008 911 63

004

582 702 09

Luftfilter Sensor Wasserabschei Motoröldruck sens. water separator air cleaner engine oil pressure Hydraulikölfilter Öltemperatur Kühlmittelstand coolant stock level hydraulik oil cleaner oil temperature

nicht bei D−40 not at D−40

K48:87A 4:3

X1

11

201918 1716151413 121110

9 8 7 6

HOURS

2:6

X1:117

3

bl

2 or

105

109

2

FUEL

X5:1−20

Tankgeber sender fuel

10

8

1

9

20

SITZWARN. 5:9

8:5

86

F24:2

Sammelanzeige monitoring module A15 3:15

Warnsummer Störung buzzer failure

85

86

90

X1:31A

2

1

Bremse, Rückfahrwarneinr., Anzeige brake, back up alarm, indicator

K22

5:2

2:18

F25:2

Rückfahrwarnsummer buzzer back up alarm

85

86

X1:153

X13 3 X13 2

6:2 BRAKE MESX

X1:150

12

BR/BN

BL/BU SW/BK

B14

Magnetventil Bremse solenoid valve brake

Y04

X1:113

5:9

S01 2:18

4:13

30

16.11.2005 Vogt 16.11.2005 Seis

K48/86

K48:87A

K36 2:7 87a

30

X13

Initiator Vorw. und Null proximity switch forwards and "0"−position

10A

GND

F24

5:9 D+

10A

D+

K61/85

Bremse

X1:31E

Hydraulikölfilter

29E 1

125mA

Luftfilter

F25

125mA

Tankanzeige

Zentralstecker Sammelanzeige (Ansicht von hinten) mainplug monitoring module (view from backside)

Öltemperatur

X1

125mA

X1:61

K11/87

Kühlmittelfüllstand

3:20

2.5A

300mA

BOMAG

Sensor

Wasserabscheider

948 H07


4:20

31

X1:124

2

Y31

V03 1 2

1.23A

V05

SITZWARN. 4:10

4:19

A68/6

V09

4

1

13

D+

Fahren

14

X1 88

6

S58

X14 A

4

3

X11

X14 S13

X1:157

B

11

X1:158

9

Sitzschalter/Vibration A68 Modul module seatswitch/vibration

12

Öldruck

Fahrstufen, Sitzkontaktsch., Vibration speed−ranges, seat−switch, vibr.

X1:124

2

1

X1:141

X1:143

Stufenumschaltung hinten switching axle

X1:124

2

1

1

X1:162

F14:2

K48/86

B06:1

S01:21 2:20 K26/87A 4:8

2:20

4:3

4:17

1

16.11.2005 Vogt 16.11.2005 Vogt

V02

X1:142

2

1 5 7 3

Stufenumschaltung vorn switching drum


nur BW216+219D−4 only BW216+219D−4

X1:138

2

1

X1:137

2

X1:144

Fahrstufensch. switch speed ranges

S42

1234

Y30

1

X1:141

X1:143

14

13

Standard D−Maschinen/D−40 USA Standard D−maschines/D−40 USA

Y31

S42

Stufenumsch. hinten switching axle

Schalter Fahrstufen switch speed ranges

nur D−40/BW177D−4 only D−40/BW177D−4

1.23A

F25:2 4:8

1.23A

4:13

X1:149

D+

X11

Taster Vibration pushbutton vibration

K11/87

Sitzkontaktschalter switch seat−contact X1:154

BOMAG X1:149

2 2

X6

Y07

X1:116 X6

S35 13

14

1

15

a X7

Y08

X1:115 X7

2

1

b

X1:160

14

13

9:7 KA Vibration vorne groß vibration big ampl. Vibration vorne klein vibration small ampl.

Schalter Vibration klein/groß switch vibration small/big ampl.

2

1

X1:161

24

23

X1:159

5

Nur mit Sitzkontaktschalter only with switch seat−contact

3.33A

2 X1:118

1

3.33A

008 911 63 6:2

S

30

2

1

1

1

KA MESX 6:2

GA MESX

K04

X1:32A

15A

F03

X1:32E

56b

31

56

X1:149

4:20

K11/87 8:1

Modul Vibration modul vibration Nur ohne Sitzkontaktschalter without switch seat−contact 005

582 702 09

31 6:1


18.3

949

9:6 GA

5:17

5:20

8:4

2:6

4:5

3:16 3:16

5:17

F148:2

15A

7:15

X1:35A

BEL MESX 31

BRAKE MESX D+ MESX

PITCH MESX

KA MESX SPEED MESX DIR MESX

2

X44:57

16.11.2005 Vogt 16.11.2005 Seis

A83 Messtechnik−Rechner measurement calc. unit

X44:28

GA MESX

Pot. 15

X2:57

2

Leistung

10A

X1:34A

10A

F84

X1:34E

X1:146

X44:58

X44:38

X1:33A

X44:59

X44:15

F146

Elektronik

F148

X44:56

S01 2:18

2

1

32

31

X44:54

1

X44:14

X1:35E

X2:54

X48:3

X48:2

X2:56

X44:37

X2:55

X48:4

15g/bl

−/gg

B62

X48:1

X2:53

20g/br Aufn. vorne 20g

1

Aufn. vorne 15g

+/sw X44:31

X1:33E

X44:41

X2:49

X2:58

X49:3

X49:2

X2:60

ZA Messtechnik option measurement equipm.

X2:59

X49:4

15g/bl

−/gg

B62

X49:1

X2:57

20g/br Aufn. hinten 20g

Pot 15

Aufn. hinten 15g

+/sw X44:7

X1:145

X44:60

X44:35

X44:29 X44:38

GND

X2:52

X44:1

X2:71

X2:63

AGND MESX

X44:55

K11/87

X44:30 GND

nur bei BTM prof only at BTM prof X44:65

8:20

GND

RxD

X2:64

X2:66

TxD

X2:65

X74:2 X4:B

X4:A

X2:70

X74:1

P11

X2:66

X44:67

Pot 30

X44:66

X4:C X74:3 X44:4

X4:E

X4:D X74:5

P16

−

nur bei BEM only at BEM

+

CAN+

F1

CAN3+

1

CAN−

X2:50

F2

−

Anzeige BMFSA Display BMFSA

EVIB−Meter EVIB−meter

X1:82

+ P07 E VIB

X1:85

X44:5

30

X44:3

2:20

EVIB

nur bei BEM only at BEM CAN1+

X44:27

Drucker printer

X42:2 X42:3 X46:A X46:E

X42:1 X46:B

1

CAN3+

31 7:1

008 911 63

006

582 702 09

7:15

CAN3− 7:15

CAN3−

X2:51

X42:5

X42:4

R20 1 2 60OHM

X46:F

X46:D

P33

X2:48 X2:49

X2:47

30 8:1

Display Messtechnik BOP display measurem. BOP

X44:33

X74:4

X44:68

BOMAG

X44:53

CAN1−

Beschleunigungssensoren acc. sensor rear

nur bei BTM+/BTM prof only at BTM+/BTM prof

950 X44:26

Beschleunigungssensoren acc. sensor front


X44:36

X44:32

008 911 63

6:20

31

16.11.2005 Vogt 16.11.2005 Seis

BOMAG Compaction Management BCM BOMAG Compaction Management BCM

CAN3−

F148:2

BOMAG

P15

1 R242

BCM 05

X75:2

R25 1 2 120 OHM

120 OHM

nur bei BCM only at BCM

A87 USB−CAN Schnittst. USB−CAN Interface BCM

X75:7

X4:N

X2:61

CAN3+

6:18 CAN3+

6:18

6:2

X4:M

X2:62

CAN3−

1

X76:2

X76:1

1

X2:63

X4:F

X4:G

X2:70

007

582 702 09

31 8:1


18.3

951

87a

31

2

2

E16 1 E17 1

4,6A

Scheinwerfer rechts head light RH

Scheinwerfer links head light LH

7:20

87

8:9

K16 30

S15

13

32

31

8:10

85

X1:301

24

12

connection working head lights without StvZO

Anschluß Arbeitsschein− werfer ohne StvZO

4:11

X1:23A

X1:24A

15A

F10

F09

15A

X1:24E

X1:23E

BEL

23

11

6:2 BEL MESX

16.11.2005 Vogt 16.11.2005 Seis

K06

86

S53 14

X1:84

012

2

2

2

2

E13 1 E12 1 E14 1 E15 1

8:2

K16

Schlußleuchte rechts tail light, RH

Schlußleuchte links tail light, LH Parkleuchte links parking light, LH Parkleuchte rechts parking light, RH

Anschluß Arbeitsschein− werfer ohne StvZO connection working head lights without StvZO

Schalter StvZO switch, StvZO

X1:319

X60:3

X1:323 X60:4

X58:5 X1:309

X1:315 X58:6

X1:26A X1:83

X1:315 X58:6

X1:310

86

X1:22E 4

E25 1 2

E23 1 2

2

2

Connection head lights acc.to ROPS/SD

Anschluß Arbeitsscheinwerfer bei ROPS/SD Aufbau

X3:1

01

01

H06

14

13

X1:19A

−

+

24

23

4:19

BL−W

4:19 4:19

L0R 24

14

49L

23

13

A02

X1:96

X1:91

31 82

30

L0R

X1:25A X1:305

15A

F08

X1:25E

E09 1 2

E08 1 2

BL−R

BL−L

S37

Bel. Warnbinkschalter illumination, switch hazard light

Warnblinkschalter switch, hazard light

S14

Anschluß Arbeitsscheinwerfer D bei Kabine Connection head lights with cabin STV1 9:17 STV2 9:17

E28 1

X3:5

X1:22A

15A

F19

E27 1

X3:4

87a

ZA Beleuchtung und StvZO opt. illumination and StvZO

85

5

X1:21A E

15A

F22

X1:21E

87

K06 8:4

30

X1:19E

X1:304

X1:18A

Schalter Arbeitsbeleuchtung switch, working head lights

15A

0,42A

10A

0,42A

X59:5

X1:316 X59:6

X1:311 X58:3

X1:312 X59:3 X1:316 X59:6

0,125A

X1:303 0,125A

F07

0,42A

Arbeitsscheinwerfer hinten links working head lights, rear lh. 4,6A

X1:302

X1:2

4,6A

X1:308

15A

4,6A

Arbeitsscheinwerfer hinten rechts working head lights, rear rh.

F18

0,42A

Arbeitsscheinwerfer vorne links working head lights, front lh. 4,6A

X61:3 X1:320 X1:324 X61:4

Arbeitsscheinwerfer vorne rechts working head lights, front rh. 4,6A

X1:313 X58:2

L

1

R

49R

Schalter Blinker switch indicator

2 2

1

008 911 63

008

582 702 09

Blinkleuchte VR indicator front, RH

Blinkleuchte HR indicator rear, RH

31

E11 1

9:1

K11/87 6:2 30

E10 1

Blinkleuchte VL indicator front, LH Blinkleuchte HL indicator rear, LH

X58:6

X1:26E

1,75A

X1:315

X1:307

F11

1,75A

X1:306

X60:1 X1:321 X60:2 X1:323

X1:314 X59:2 X59:6

K11/87 6:19 30 X1:18E

1,75A

X1:316

X61:1 X1:322

BOMAG

X61:2

5:20

1,75A

952 X1:324


12V

XS

Steckdose Fahrerst.

9:6

8:20

Nur bei Geländer/Rops/SD only at hand−rail/Rops/sun−roof

X3:3

R80

85

86

2

1

9:16 87

K141

31

Relais Kabine relais cabin

K32

−

+

socket operator platform

15A

S45

E29

10A

F42

TK

2

1

8

H

−

+

+

−

A12

− −

B51 + +

16.11.2005 Vogt 16.11.2005 Seis

Türkontaktschalter door switch

S86

A01

2

E71 1

87a

30

7

G

Kontrolleuchte indicator

F143

Schalter Innenleuche switches interior lights

87a

3

4 A51 2

5

7,8,9

Frequenzmodul module, frequency

1

5

3 A5+A6

P09

A2+A3

15A

F43

S21

01W 7 01

F42 10:8 F130 9:14

X55:2

M05

M

5

2

1

A

3,8A

Wischer hinten windscreen wiper, rear

Wascher hinten washer rear

− M07

M

+

4

X55:1

15A

F44

X56:2

M04

M

5

2

2

B

+

4

9:9

E70

F130

10A

F130

S158

4

3

2

1

3

C

K141

I

Wascher vorn washer front

9:2

8:13 8:13

2

1 E28

E72

E27

2

1

F130 10:7

STV1

STV2

1

2

+

1

XS

−

12V

10:18

−

+

009

582 702 09

Rundumkennleuchte rotary beacon

31 10:1

KABINE 31

2

1

1

5

15A

S38

F144 6

F

10:2

10:13

10A

5

E

K32:87

F41:5

F41

ZA option

E32

1 E25

4,6A

Arbeitsscheinwerfer vorn working head lights, front

2

1 E23

4,6A

Arbeitsscheinwerfer hinten working head lights, rear

Schalterbel. switch illum.

15 31

1

S163 5

Schalter Nachtleuchte switch, night illumination

− M06

M

3,8A

Wischer vorne windscreen wiper, rear

S20

01W 7 01

ZA Kabine, Beleuchtung, Radio, Tachograph opt. cabin, headlights, radio, tachograph

Tachograph tachograph

C3

B4

B3

1 2

A1

6

Tachographenmodul module, tachograph

Radio radio

− −

15 + + B51

87

X3:17 4 3:16 SPEED TAC A16

31

30

K32

9:2

X55:3

X3:8

2,9A

2:20

X56:4

30

X56:3

X3:7

4,7A

2:11

X56:1

K32:86

Heizung Heckscheibe heating rear screen

1,75A

Innenleuchte inside light, cabin

0,83A

Nachtleuchte night illumination

10:13

3 min

4,6A

F42:H

4,6A

X3:6

X3:16 GA X3:15 5:17

KA 5:16

X55:4 X3:1

Abfallverzögert

BOMAG X3:2

5A

008 911 63 Steckdose Kabine socket cabin

2:11 K30


18.3

953

9:20

31

Schalter Kabinenlüfter switch blower cabin

ge

M09

rt

or

X3:12

ge

Bedienteil Kabinenheizung/Klimaanlage

Vogt Seis 16.11.2005 Seis

Kabinenlüfter cab ventilator

br

rt

M

or

2

V04 1

2

X18:2

_t

B131

X18:1

X1:167

X3:14

X54:11

1 2

2

Y138 1

X1:168

X54:12

1

2

X54:2

Magnetventil Heizung solenoid valve, heating unit

V06

X54:3

3 A72 Steuergerät control unit 6 11 12

4

X54:4

X54:1

2.5qmm

1

1

A

2

3

BOX2

2

1

9

8

7

4

15

Anlaufstrom beim Start = 8,3A

Power Stufe = 2,8A

große Stufe = 1.9A

mittleter Stufe = 1,0A

Kleine Stufe = 0,67A

Regel aus = 0,4A

12 11 13 14 16

10 6

Kraftstoffpumpe fuel pump heating unit

X77:2

Y14

X77:1

5

E30 Zusatzheizung add. heater

20A

F40

9:19 F41:5 F42:H 9:4

ZA Kabinenheizung, Klimaanlage, Zusatzheizung opt. cabin−heater, air conditioning, add. heater

Klimakompressor air conditioning compr.

1

HP

2

1

87a

30

Y15

X20:2

X1:170

B104 4 P LP 3

X19:2 X20:1

_t

B103

X19:1

X1:169

87

2:8

K09

X3:13

X54:6

Potential 30 aus Kabine

9:17 F130 F42 Potential 15 aus Kabine 9:9

control−unit cab−heater /air conditioning

X1:164

X17:4

M09 M Kabinenlüfter br

X53:L

X3:9

X17:1 X1:163

0123

X53:C

X53:M

X3:10

X17:2 X1:165

S44

4

D

X53:H

X3:11

X17:3 X1:166

X53:B

20A

F31

Thermofühler Klimaanlage temperature sensor air conditioning


X20:3 Überwachung Kühlmitteldruck monitoring coolant pressure

K32:87

1A

BOMAG X20:4

Thermofühler Heizung temperature sensor heating unit

9:20

2.5qmm

954 3,5A

Schaltuhr Heizung heater timer 1

9:19

2

B BOX2

KABINE 31

1

2 6 8 9 4 12

S28

5 7 11 3 10 1

5A

F15

008 911 63

010

582 702 09

31


18.3

Wiring diagram 582 702 09 Name

Bl. Pf. Benennung 005 4

title

TYP MAX. 1,67A

16.11.2005 Vogt 16.11.2005 Seis

Bauteilliste component listing 1 6 101

582 702 09

A02 A05 A12 A13 A15 A16 A51 A68 A72 A83 A87

008 003 009 003 004 009 009 005 010 006 007

17 17 5 3 16 7 6 10 11 6 15

Blinkrelais Elektronik Geschwindigkeitsanzeige Radio Steuergeraet Heizung Ueberwachungsmodul Elektronik Tachograph Platine Frequenzanzeige Modul Sitzkontakt Steuergeraet Klimaanlage, Heizung Elektronik Messtechnik USB−CAN Schnittstelle BCM

indicator relay Electronic system, speedometer Radio Control unit, heating monitoring module Electronic system, tachograph Circuit board,frequenzy meter Modul seat contact Control unit,air conditioning,heating electronic measurement−equipment USB−CAN Interface BCM

B03 B06 B11 B11 B13 B14 B21 B30 B51 B51 B55 B60 B61 B62 B62 B103 B104 B113 B124 B131

004 004 003 003 004 004 004 004 009 009 004 003 006 006 006 010 010 003 004 010

15 17 9 11 2 6 14 16 5 6 17 14 12 8 10 7 7 3 19 10

Unterdruckschalter Luftfilter Druckschalter Motoroel Signalhorn Signalhorn Naeherungsinitiator Fahrhebel links Naeherungsinitiator Fahrhebel rechts Differenzdruckschalter Hydr.−Oelfilter Temperaturschalter Motoroel Lautsprecher Radio Lautsprecher Radio Kuehlmittelstand Ausgleichsbehaelter Aufnehmer Achsgeschwindigkeit Aufnehmer Verstellzylinder Beschleunigungsaufnehmer Beschleunigungsaufnehmer Temperaturschalter Klimaanlage Druckschalter Klimaanlage EMR Temperaturgeber Kuehlmittel Geber Wasserstandsabscheider Diesel Temperaturschalter Heizung

Vacuum switch, air cleaner Pressure switch, engine oil Warning horn Warning horn Proximity switch, travel lever, lh. Proximity switch, travel lever, rh. Pressure diff. switch, hydr. oil filter Temperature switch, engine oil Speaker radio Speaker radio Coolant charge expansion tank Sensor, axle speed Sensor, ajustable zylinder Acceleration sensor Acceleration sensor Temperature switch, air conditioning Pressure switch, air conditioning EMR Temperature switch, collant Sender, water separator fuel Temperature switch, heating

E08 E09 E10 E11 E12 E13 E14 E15 E16 E17 E23 E23 E25 E25 E27 E27 E28 E28 E29 E30 E32 E70 E71 E72

008 008 008 008 008 008 008 008 008 008 008 009 008 009 008 009 008 009 009 010 009 009 009 009

17 18 19 19 7 6 7 8 2 2 11 18 12 19 10 17 11 17 4 13 19 15 3 16

Blinkleuchte vorne links Blinkleuchte hinten links Blinkleuchte vorne rechts Blinkleuchte hinten rechts Parkleuchte links Schlussleuchte links Parkleuchte rechts Schlussleuchte rechts Scheinwerfer links Scheinwerfer rechts Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer hinten links Arbeitsscheinwerfer hinten links Arbeitsscheinwerfer hinten rechts Arbeitsscheinwerfer hinten rechts Innenleuchte Kabine Heizgeraet Kennleuchte Nachtleuchte Kontrolleuchte Schalter Heckscheibenheizung Beleuchtung Bedienschalter

Indicator, front, lh. Indicator, rear, lh. Indicator, front, rh. Indicator, rear, rh. Parking light, lh. Tail light, lh. Parking light, rh. Tail light, rh. Head light, lh. Head light, rh. Working head light, front, lh. Working head light, front, lh. Working head light, front, rh. Working head light, front, rh. Working head light, rear, lh. Working head light, rear, lh. Working head light, rear, rh. Working head light, rear, rh. Inside light, cabin Heating unit Warning light Night lamp indicator light switch rear screen illum. Switches

MAX. 1,75A MAX. 1,75A MAX. 1,75A MAX. 1,75A MAX. 0,42A MAX. 0,42A MAX. 0,42A MAX. 0,42A MAX. 4,6A MAX. 4,6A MAX. 4,6A 4,6A MAX. 4,6A 4,6A MAX. 4,6A 4,6A MAX. 4,6A 4,6A 1,75A

F00 F03 F07 F08 F09 F10 F11 F13 F14 F15 F18 F19 F22 F23 F24 F25 F31 F39 F40 F41 F42 F43 F44 F48 F84 FM4 F105 F130 F143 F144 F146 F148

002 005 008 008 008 008 008 002 002 010 008 008 008 003 004 004 010 002 010 009 009 009 009 002 006 006 002 009 009 009 006 006

4 18 15 18 6 8 2 10 18 18 5 12 10 9 10 2 3 19 13 19 4 10 13 3 5 11 16 15 2 20 4 2

Hauptsicherung Batterie Sicherung Vibration Sicherung Warnblinker Sicherung Blinker u. Arbeitsscheinw. Sicherung Park− u. Schlussl. links Sicherung Park− u. Schlussl. rechts Sicherung Scheinwerfer links Sicherung Startschalter Sicherung Hubmagnet Motor Sicherung Heizgeraet Vorsicherung Arbeitsscheinw. vorne Sicherung Arbeitsscheinw. vorne li. Sicherung Arbeitsscheinwerfer hinten Sicherung Signalhorn Sicherung Ueberwachungsmodul Sicherung Magnetv. Fahren u. Bremse Sicherung Kabinenluefter Hauptsicherung Kabine Sicherung Kabinenheizung Sicherung Rundumkennleuchte Sicherung Kabineninnenleuchte Sicherung Wischermotor hinten Sicherung Wischermotor vorn Sicherung Gluehanlage Sicherung Steuerung (Klemme 54) Platinensicherung Sicherung Motordrehzahl Sicherung Nachtleuchte Sicherung Heckscheibenheizung Sicherung Kabinensteckdose Sicherung Steuerung MESX (Potential 30) Sicherung Steuerung MESX (Potential 15)

Fuse, main, battery Fuse, vibration Fuse, hazard light Fuse, indicators a. work. head light Fuse, parking and tail light, lh. Fuse, parking and tail light, rh. Fuse, head light, lh. Fuse, starter switch Fuse, shut off solenoid, engine Fuse, heating unit Primary fuse, work. head light, fr. Fuse, working head light, front, lh. Fuse, working head lights, rear Fuse, warning horn Fuse, monitoring module Fuse, sol. valve, travel and brake Fuse, cabin ventilator Main fuse, cab Fuse, heating unit cab Fuse, rotary beacon Fuse, inside light cab Fuse, wipermotor rear Fuse, wipermotor front Fuse, glow plug system Fuse, controller (Pin 54) Multifuse Fuse, motor speed Fuse, night lamp fuse rear screen heating unit Fuse cabin−socket Fuse Controller (Pot. 30) Fuse Controller (Pot. 15)

125A MAX. 1,23A 15A 15A 10A 10A 15A 30A 15A BOX2 30A 30A 30A 10A 10A 10A

G01 G02 G03

002 4 002 5 002 3

Batterie Generator Batterie

Battery Generator Battery

103A

H06 H07

008 15 004 10

Meldeleuchte Warnblinker Warnsummer Betriebsstoerung

Indicator light, hazard light Warning buzzer, breakdown

MAX. 0,12A

008 911 63

BOMAG

MODUL

MAX. 0,12A

MAX.5A MAX.5A

5A 0,83A 1,75A

15A BOX2

125A 10A 20A

103A

955

18.3 Name

16.11.2005 Vogt 16.11.2005 Seis


582 702 09

956


H14

Bl. Pf. Benennung 004 8 Warnsummer Rueckwaertsfahrt

Back−up alarm buzzer

title

MAX. 0,12A

K04 K05 K06 K09 K11 K14 K16 K22 K26 K32 K35 K36 K48 K61 K114 K141

005 004 008 002 002 003 008 004 004 009 002 002 004 002 002 009

18 3 4 8 10 5 9 9 6 2 16 7 2 5 14 16

Schrittrelais Vibration Relais Startstrom Relais Scheinwerfer hinten Relais Klimageraet Relais Klemme 30 auf 15 Relais Vorgluehen Relais Scheinwerfer vorne Relais Hubmagnet Motor Relais Rueckfahrwarneinrichtung Relais Kabine Relais Selbsthaltung Relais Bremskontrolle Relais Fahrhebel 0−Stellung Relais Ladekontrolle Relais Motordrehzahl Relais Heckscheibenheizung

Toggle relay, vibration Relay, starting current Relay, head lights, rear Relay, air conditioning Relay, terminal 30 to 15 Relay, glow plug system Relay, head lights, front Relay, shut off solenoid, engine Relay, back up alarm Relay, cabin Relay, holding contact Relay, brake control Relay, travel lever 0−position Relay, charge control Relay, engine rpm relay, heating rear screen

MAX. 1,23A BOSCHW BOSCHW BOSCHW BOSCHW BOSCHL BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW

M01 M04 M05 M06 M07 M09 M09

002 009 009 009 009 010 010

11 13 10 14 11 3 4

Starter Scheibenwischermotor vorne Scheibenwischermotor hinten Scheibenwaschermotor vorne Scheibenwaschermotor hinten Kabinenluefter Kabinenluefter

Starter Windscreen wiper motor, front Windscreen wiper motor, rear Windscreen washer motor, front Windscreen washer motor, rear Cabin ventilator Cabin ventilator

2.3 KW 4,7A 2,9A MAX. 3,8A MAX. 3,8A

P04 P07 P09 P11 P15 P16 P33

003 006 009 006 007 006 006

19 15 8 14 16 16 18

Geschwindigkeitsanzeige Omegameter Frequenz− und Geschwindigkeitsanzeige Drucker BCM 03 Bildschirm Diagnose, Variomatic Opus 21

Speedometer Omegameter Frequency− and Speedometer Printer BCM 03 terminal Diagnostics, varimatic Opus 21

R03 R10 R19 R20 R24 R25 R80

004 002 002 006 007 007 009

12 6 2 17 15 15 2

Geber Tankanzeige Parallelwiderstand Heizflansch Widerstand Widerstand Widerstand Heizung Heckscheibe

Sender, level gauge Parallel resistor heater flange Resistor Resistor Resistor heating rear screen

S00 S01 S03 S13 S14 S15 S20 S21 S28 S30 S35 S37 S38 S42 S42 S44 S45 S53 S58 S86 S120 S158 S163

002 002 003 005 008 008 009 009 010 002 005 008 009 005 005 010 009 008 005 009 002 009 009

10 18 9 13 15 4 13 10 17 3 15 18 19 3 7 3 4 4 13 4 14 15 16

Startschalter Schalter NOT AUS Taster Signalhorn Vibrationsschalter Fahrhebel rechts Warnblinkschalter Beleuchtungsschalter StVZO Schalter Scheibenwischer vorne Schalter Scheibenwischer hinten Schalter Kabinenheizung Batterietrennschalter Vibrationsschalter klein/gross Schalter Blinker Schalter Kennleuchte Stufenumschalter schnell−langsam Stufenumschalter schnell−langsam Schalter Kabinenluefter Schalter Kabineninnenleuchte Schalter Arbeitsbeleuchtung Schalter Aetherstartanlage Schalter Tuer, links Schalter Motordrehzahl Schalter Nachtbeleuchtung Schalter Heckscheibenheizung

Starter switch Switch, emergency off Push button, warning horn Switch, vibration, travel lever, rh. Switch, hazard light Switch, lighting StVZO Switch, windscreen wiper, front Switch, windscreen wiper, rear Switch, cabin heating Switch, battery disconnect Switch, vibration low/high Switch, indicator Switch, warning light Speed range selector, fast−slow Speed range selector, fast−slow Switch, cabin ventilator Switch, cabin inside light Switch, working lights Push button, ether starting unit Switch door, lh. Switch, engine speed Switch, cabin night lamp switch rear screen heating unit

V01 V02 V03 V04 V05 V06 V09 V21 V22 V47

002 005 005 010 005 010 005 003 003 002

6 6 7 8 10 9 10 10 11 15

Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode (A7)


X1:1 X1:2 X1:3 X1:4 X1:7 X1:8 X1:9 X1:10 X1:52 X1:53 X1:54 X1:55 X1:55 X1:56 X1:57 X1:57 X1:58 X1:59 X1:60 X1:61 X1:62

002 008 002 002 002 002 002 002 003 002 002 002 002 002 003 004 002 002 002 004 002

5 10 9 10 11 11 4 4 2 12 18 10 18 15 3 15 16 16 16 15 16

WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten

WAGO,E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX

BOMAG

TYP

82 OHM 167A 60OHM 120 OHM 120 OHM

4UF004 MAX. 1,23A MAX. 1,23A FE5B MAX. 0,12A MAX. 0,12A

FE5B

008 911 63

18.3


16.11.2005 Vogt 16.11.2005 Seis


582 702 09

X1:63 X1:64 X1:65 X1:66 X1:67 X1:68 X1:69 X1:71 X1:72 X1:73 X1:74 X1:75 X1:76 X1:77 X1:78 X1:79 X1:80 X1:81 X1:82 X1:82 X1:83 X1:84 X1:85 X1:86 X1:87 X1:88 X1:89 X1:90 X1:91 X1:92 X1:93 X1:96 X1:97 X1:98 X1:99 X1:100 X1:101 X1:102 X1:105 X1:106 X1:107 X1:108 X1:109 X1:110 X1:111 X1:112 X1:113 X1:114 X1:115 X1:116 X1:117 X1:117 X1:117 X1:117 X1:118 X1:124 X1:124 X1:124 X1:129 X1:137 X1:138 X1:141 X1:141 X1:142 X1:143 X1:143 X1:144 X1:145 X1:146 X1:147 X1:148 X1:149 X1:149 X1:149 X1:149 X1:150 X1:151 X1:152 X1:153 X1:154 X1:155 X1:156 X1:157 X1:158 X1:159 X1:15A X1:15E X1:160 X1:161 X1:162 X1:163 X1:164 X1:165 X1:166 X1:167 X1:168 X1:168 X1:169 X1:170

008 911 63

Bl. 002 003 002 002 004 004 004 004 004 004 004 003 004 004 003 002 002 002 004 006 008 008 006 004 004 005 004 004 008 003 003 008 003 003 003 003 003 003 004 004 004 004 004 004 004 004 004 004 005 005 004 004 004 004 005 005 005 005 004 005 005 005 005 005 005 005 005 006 006 004 004 004 005 005 005 004 002 002 004 005 003 004 005 005 005 002 002 005 005 005 010 010 010 010 010 002 010 010 010

Pf. 16 3 5 6 15 17 13 15 17 17 16 4 17 16 4 10 14 14 11 15 5 4 15 10 13 11 10 9 17 19 19 17 9 10 10 11 9 10 12 14 19 20 12 14 19 20 5 8 16 14 5 8 12 14 14 3 6 8 6 4 4 3 8 6 3 8 6 5 5 5 2 1 12 13 19 5 18 18 6 13 9 2 13 13 16 10 10 16 14 7 3 5 3 4 10 8 10 7 7

Benennung WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK

title

TYP

WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO, E−box WAGO, E−box WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO, E−box WAGO, E−box WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO, E−box WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO, E−box WAGO, E−box WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX

BOMAG

957

18.3 Name

16.11.2005 Vogt 16.11.2005 Seis


582 702 09

958

X1:171 X1:172 X1:173 X1:174 X1:17A X1:17E X1:18A X1:18E X1:19A X1:19E X1:21A X1:21E X1:22A X1:22E X1:23A X1:23E X1:24A X1:24E X1:25A X1:25E X1:26A X1:26E X1:27A X1:27E X1:28A X1:28E X1:29A X1:29E X1:301 X1:302 X1:303 X1:304 X1:305 X1:306 X1:307 X1:308 X1:309 X1:30A X1:30E X1:310 X1:311 X1:312 X1:313 X1:314 X1:315 X1:315 X1:315 X1:316 X1:316 X1:316 X1:319 X1:31A X1:31E X1:320 X1:321 X1:322 X1:323 X1:323 X1:324 X1:324 X1:32A X1:32E X1:33A X1:33E X1:34A X1:34E X1:35A X1:35E X2:47 X2:48 X2:49 X2:49 X2:50 X2:51 X2:52 X2:53 X2:54 X2:55 X2:56 X2:57 X2:57 X2:58 X2:59 X2:60 X2:61 X2:62 X2:63 X2:63 X2:64 X2:65 X2:66 X2:66 X2:67 X2:68 X2:69 X2:70 X2:70 X2:71 X2:73

Wiring diagram 582 702 09 Bl. 003 003 003 003 002 002 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 002 002 003 003 004 004 008 008 008 008 008 008 008 008 008 002 002 008 008 008 008 008 008 008 008 008 008 008 008 004 004 008 008 008 008 008 008 008 005 005 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 007 007 006 007 006 006 006 006 006 006 006 006 007 006 006

Pf. 14 15 15 14 16 16 2 2 15 15 10 10 12 12 6 6 8 8 18 18 5 5 18 18 9 9 2 2 5 5 9 15 18 18 18 15 2 19 19 2 7 7 17 19 2 7 17 2 7 19 6 10 10 8 18 19 6 18 8 19 18 18 2 2 5 5 4 4 18 19 9 19 17 18 13 8 7 8 7 2 10 9 10 9 15 16 13 18 14 14 14 14 11 12 12 15 18 14 11

Benennung WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK

title

TYP

WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip.

BOMAG

008 911 63

18.3


16.11.2005 Vogt 16.11.2005 Seis


582 702 09

X2:74 X2:75 X2:76 X2:77 X2:78 X3:1 X3:1 X3:2 X3:3 X3:4 X3:5 X3:6 X3:7 X3:8 X3:9 X3:10 X3:11 X3:12 X3:13 X3:14 X3:15 X3:16 X3:17 X4:A X4:B X4:C X4:D X4:E X4:F X4:G X4:M X4:N X6:1 X6:2 X7:1 X7:2 X8:1 X8:2 X9:1 X9:2 XS XS X10:2 X10:3 X11:1 X11:2 X12:1 X12:2 X12:3 X13:1 X13:2 X13:3 X14:A X14:B X17:1 X17:2 X17:3 X17:4 X18:1 X18:2 X19:1 X19:2 X20:1 X20:2 X20:3 X20:4 X21:1 X21:2 X36:A X36:B X37:A X37:B X38:A X42:1 X42:2 X42:3 X42:4 X42:5 X44:1 X44:3 X44:4 X44:5 X44:7 X44:9 X44:14 X44:15 X44:23 X44:26 X44:27 X44:28 X44:29 X44:30 X44:31 X44:32 X44:33 X44:35 X44:36 X44:37 X44:38

008 911 63

Bl. 006 006 006 006 006 008 009 009 009 008 008 009 009 009 010 010 010 010 010 010 009 009 009 006 006 006 006 006 007 007 007 007 005 005 005 005 004 004 004 004 009 009 004 004 005 005 004 004 004 004 004 004 005 005 010 010 010 010 010 010 010 010 010 010 010 010 004 004 002 002 002 002 002 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006

Pf. 11 10 10 11 11 11 10 10 2 10 12 2 2 2 3 3 4 4 7 10 7 6 6 14 14 14 14 15 18 18 16 15 14 14 16 16 19 20 8 8 1 20 12 12 13 13 2 2 1 6 6 6 13 13 3 3 4 5 10 10 7 7 7 7 7 7 17 17 4 4 10 11 11 18 19 19 18 18 13 15 14 14 10 12 5 5 11 18 17 2 7 9 8 6 18 5 6 7 4

Benennung WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK STECKER ROPS/SD STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER ROPS/SD STECKER ROPS/SD STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH Steckdose Steckdose AMP SUPERSEAL AMP SUPERSEAL DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH STECKER LÜFTER HKL STECKER LÜFTER HKL STECKER LÜFTER HKL STECKER LÜFTER HKL STECKER THERMOFÜHLER STECKER THERMOFÜHLER STECKER EISSCHUTZ HKL STECKER EISSCHUTZ HKL STECKER DRUCKSCH. KLI STECKER DRUCKSCH. KLI STECKER DRUCKSCH. KLI STECKER DRUCKSCH. KLI STECKER KÜHLMITTEL STECKER KÜHLMITTEL EINSPEISUNG SCHALTKAS EINSPEISUNG SCHALTKAS ST. ZÜNDSCHLOß E−KAST ST. ZÜNDSCHLOSS E−KAS ST.STARTER E−KASTEN STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER

title

TYP

Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. conn. ROPS/SR conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. ROPS/SR conn. ROPS/SR conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector Socket Socket AMP connector AMP connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector conn. blower conn. blower conn. blower conn. blower conn. sender temp. conn. sender temp. conn. anti−ice air−cond. conn. anti−ice air−cond. conn. pressuresitch air−cond. conn. pressuresitch air−cond. conn. pressuresitch air−cond. conn. pressuresitch air−cond. connector coolant sensor connector coolant sensor supply e−box supply e−box connector ignition switch connector ignition switch, e−box connector starter e−box conector adapter BOP conector adapter BOP conector adapter BOP conector adapter BOP conector adapter BOP MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker

BOMAG

959

18.3 Name

16.11.2005 Vogt 16.11.2005 Seis


582 702 09

960

Wiring diagram 582 702 09 Benennung

title

X44:38 X44:41 X44:46 X44:47 X44:53 X44:54 X44:55 X44:56 X44:57 X44:58 X44:59 X44:60 X44:65 X44:66 X44:67 X44:68 X46:A X46:B X46:D X46:E X46:F X47:A X47:B X47:C X48:1 X48:2 X48:3 X48:4 X49:1 X49:2 X49:3 X49:4 X53:B X53:C X53:H X53:L X53:M X54:1 X54:2 X54:3 X54:4 X54:6 X54:11 X54:12 X55:1 X55:2 X55:3 X55:4 X56:1 X56:2 X56:3 X56:4 X58:2 X58:3 X58:5 X58:6 X58:6 X58:6 X59:2 X59:3 X59:5 X59:6 X59:6 X59:6 X60:1 X60:2 X60:3 X60:4 X61:1 X61:2 X61:3 X61:4 X74:1 X74:2 X74:3 X74:4 X74:5 X75:2 X75:7 X76:1 X76:2 X77:1 X77:2

Bl. 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 010 010 010 010 010 010 010 010 010 010 010 010 009 009 009 009 009 009 009 009 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 006 006 006 006 006 007 007 007 007 010 010

Pf. 7 7 11 10 17 5 13 4 4 4 5 5 13 13 14 14 19 18 18 19 18 11 12 12 8 7 7 8 10 9 9 10 3 4 4 3 3 11 11 10 10 7 10 11 11 10 10 10 14 13 13 13 17 7 2 2 7 17 19 7 2 2 7 19 18 18 6 6 19 19 8 8 14 14 14 15 14 16 15 17 17 13 13

MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER STECKER BOP STECKER BOP STECKER BOP STECKER BOP STECKER BOP STECKER AUFN. PLEIGER STECKER AUFN. PLEIGER STECKER AUFN. PLEIGER STECKER AUFN. VORNE STECKER AUFN. VORNE STECKER AUFN. VORNE STECKER AUFN. VORNE STECKER AUFN. HINTEN STECKER AUFN. HINTEN STECKER AUFN. HINTEN STECKER AUFN. HINTEN STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER WISCHER HINTE STECKER WISCHER HINTE STECKER WISCHER HINTE STECKER WISCHER HINTE STECKER WISCHER VORNE STECKER WISCHER VORNE STECKER WISCHER VORNE STECKER WISCHER VORNE STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO HL STECKER STVZO HL STECKER STVZO HL STECKER STVZO HL STECKER STVZO HR STECKER STVZO HR STECKER STVZO HR STECKER STVZO HR STECKER DRUCKER STECKER DRUCKER STECKER DRUCKER STECKER DRUCKER STECKER DRUCKER SUB−D STECKER BCM INT SUB−D STECKER BCM INT STECKER VERS. BCM STECKER VERS. BCM STECKER PUMPE STANDHE STECKER PUMPE STANDHE

MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker Connector BOP Connector BOP Connector BOP Connector BOP Connector BOP conn. sender PLEIGER conn. sender PLEIGER conn. sender PLEIGER conn. sender front conn. sender front conn. sender front conn. sender front conn. sender rear conn. sender rear conn. sender rear conn. sender rear conn. blowerswitch conn. blowerswitch conn. blowerswitch conn. blowerswitch conn. blowerswitch conn. heating controller conn. heating controller conn. heating controller conn. heating controller conn. heating controller conn. heating controller conn. heating controller connector wiper rear connector wiper rear connector wiper rear connector wiper rear conn. wiper front conn. wiper front conn. wiper front conn. wiper front Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO BL Con. STVZO BL Con. STVZO BL Con. STVZO BL Con. STVZO BR Con. STVZO BR Con. STVZO BR Con. STVZO BR con. printer con. printer con. printer con. printer con. printer con. SUB−D BCM con. SUB−D BCM con. Power−sup. BCM con. Power−sup. BCM Conn. pump add. heater Conn. pump add. heater

Y01 Y04 Y07 Y08 Y13 Y14 Y15 Y30 Y31 Y31 Y120 Y138 Y140 Y141

002 004 005 005 002 010 010 005 005 005 002 010 006 006

12 5 14 16 18 13 7 6 3 8 16 10 10 11

Magnetventil Startmehrmenge Magnetventil Bremse Magnetventil Vibration vorne gross Magnetventil Vibration vorne klein Hubmagnet Motor Kraftstoffpumpe Heizgeraet Magnetkupplung Klimakompressor Magnetventil Stufenumschaltung vorn Magnetventil Stufenumschaltung hinten Magnetventil Stufenumschaltung hinten Magnetventil Motordrehzahl hoch Magnetveentil Heizung Magnetventil Erreger auf Magnetventil Erreger ab

Solenoid valve, start boost fuel Solenoid valve, brake Solenoid valve, vibration, front, high Solenoid valve, vibration, front, low Shut off solenoid, engine Fuel pump, heating unit Magnetic clutch, air conditioning compr. Solenoid valve, speed range sel., front Solenoid valve, speed range sel., rear Solenoid valve, speed range sel., rear Solenoid valve, rpm engine high Solenoid valve, heating unit solenoid valve exciter up solenoid valve exciter down

BOMAG

TYP

MAX. 3.9A MAX. 1,8A MAX. 2,5A MAX. 2,5A MAX. 3.8A 3,5A MAX. 1,67A MAX. 1,23A MAX. 1,23A 3,5A

008 911 63

X36

X37

X38

K11

008 911 63

BOMAG A68

961

Name: Seis

Gepr.: 19.10.2005

Name: Vogt

Gez.: 19.10.2005

K04

K09

overview e-box BW 177...219 D-4/D-40

Übersicht Schaltkasten BW 177...219 D-4/D-40

Nur wenn kein Sitzkontakt angebaut only acc. if no seatswitch is assembled

Nur wenn Sitzkontakt angebaut only acc. if seatswitch is assembled

K26

K114

K61

K48

K35

K22 Nur bei Klimaanlage only acc. to aircond.

K36

K05

K06

R10

K16

A02

Nur bei StvzO only acc. To StvZO illumination

Replaces:

Ers. f.:

page: 1

Seite: 1

from: 2

von: 2

582 702 09 Sheet No.: 201

Blatt Nr.: 201


18.3

F1

F2

962 A83 Messtechnik Steuerung

CAN 1

Nur bei VM8 only acc. To VM8

BOMAG

008 911 63

overview e-box door BW 177...219 D-4/D-40

Gepr.: 19.10.2005 Name: Seis

Name: Vogt

Übersicht Schaltkasten-Tür BW 177...219 D-4/D-40

BCM

Replaces:

Ers. f.:

page: 2

Seite: 2

OPUS 21

Gez.: 19.10.2005

CAN 3

CAN 1

from: 2

von: 2

582 702 09 Sheet No.: 201

Blatt Nr.: 201


18.3


WAGO smart DESIGNER 4.1 1

05756417

2

05756421

3

2 x 05756425 "L" + 793-501

5

2 x 05756425 "L" + 05756420 + 793-501

7

05756422

8

4 x 05756423 "L" + 05756419 + 793-501

12

18 x 05756436 "R" + 05756419 + 793-501

12

Flachsicherung DIN 72581-C30 / 057 510 99

13


14


15


16


17


19


20


21


22


23


24


25


26


27


28


Optional1 :

Projektgruppe :

Walzenzüge-4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Absicherung D-4 Version

Lieferadresse :

Optional3 : Optional4 : Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Größe der Bohrung :

Optional7 :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten. 17.11.2005 07:47:59

008 911 63

BOMAG

Seite 1

963

18.3



2 x 05756436 "R" + 793-501

32

05756435

33

05756417

Optional1 :

Projektgruppe :


Optional2 :




Lieferadresse :



Optional6 :


Optional7 :

210-112 5.20 x 25.00 [mm]


964

BOMAG

Seite 2

008 911 63

18.3


WAGO smart DESIGNER 4.1

Optional1 :

Projektgruppe :


Optional2 :




Lieferadresse :



Optional6 :


Optional7 :

210-112 5.20 x 25.00 [mm]


008 911 63

BOMAG

Seite 3

965

18.3



Optional1 :

Projektgruppe :


Optional2 :




Lieferadresse :



Optional6 :


Optional7 :

210-112 5.20 x 25.00 [mm]


966

BOMAG

Seite 4

008 911 63

18.3



05756417

2

2 x 05756540 "R" + 793-501 + 05756536

4

2 x 05756540 "R" + 793-501

6

3 x 05756539 "R" + 793-501

9

05756537

10

4 x 05756538 "R" + 793-501

14

05756537

15

3 x 05756538 "R" + 793-501

18

05756537

19

3 x 05756540 "R" + 793-501

22

05756535 "R" + 793-501

23

05756537

24

5 x 05756540 "R" + 793-501

29

05756537

30

2 x 05756538 "R" + 793-501

32

2 x 05756539 "R" + 793-501

34

05756537

35

4 x 05756538 "R" + 793-501

39

05756537

40

4 x 05756540 "R" + 793-501

44

2 x 05756539 "R" + 793-501

46

05756537

47

05756540 "R" + 793-501

48

05756535 "R" + 793-501

Optional1 :

Projektgruppe :


Optional2 :



Kabelbäume D Version

Lieferadresse :



Optional6 :


Optional7 :

210-112 5.20 x 25.00 [mm]


008 911 63

BOMAG

Seite 1

967

18.3



05756537

50

2 x 05756538 "R" + 793-501

52

05756537

53

4 x 05756540 "R" + 793-501

57

05756539 "R" + 793-501

58

05756537

59

4 x 05756540 "R" + 793-501

63

05756537

64

05756540 "R" + 793-501

65

05756535 "R" + 793-501

66

05756537

67

05756540 "R" + 793-501

68

05756535 "R" + 793-501

69

05756537

70

05756538 "R" + 793-501

71

2 x 05756540 "R" + 793-501

73

05756539 "R" + 793-501

74

05756537

75

05756417

Optional1 :

Projektgruppe :


Optional2 :




Lieferadresse :



Optional6 :


Optional7 :

210-112 5.20 x 25.00 [mm]


968

BOMAG

Seite 2

008 911 63

18.3



Optional1 :

Projektgruppe :


Optional2 :




Lieferadresse :



Optional6 :


Optional7 :

210-112 5.20 x 25.00 [mm]


008 911 63

BOMAG

Seite 3

969

18.3



Optional1 :

Projektgruppe :


Optional2 :




Lieferadresse :



Optional6 :


Optional7 :

210-112 5.20 x 25.00 [mm]


970

BOMAG

Seite 4

008 911 63

18.3



1

05756417

2

2 x 05756540 "R" + 793-501

4

05756539 "R" + 793-501

5

05756537

6

05756538 "R" + 793-501

7

2 x 05756540 "R" + 793-501

9

05756538 "R" + 793-501

10

05756537

11

2 x 05756540 "R" + 793-501

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :


Messtechnik D


Klemmenleiste X2

Lieferadresse :



Optional6 :


Optional7 :

210-112 5.20 x 25.00 [mm]


008 911 63

BOMAG

Seite 1

971

18.3



05756539 "R" + 793-501

14

05756537

15

05756540 "R" + 793-501

16

05756538 "R" + 793-501

17

05756540 "R" + 793-501

18

05756537

19

05756417

Optional1 :

Projektgruppe :


Optional2 :


Messtechnik D


Klemmenleiste X2

Lieferadresse :



Optional6 :


Optional7 :

210-112 5.20 x 25.00 [mm]


972

BOMAG

Seite 2

008 911 63

18.3



Optional1 :

Projektgruppe :


Optional2 :


Messtechnik D


Klemmenleiste X2

Lieferadresse :



Optional6 :


Optional7 :

210-112 5.20 x 25.00 [mm]


008 911 63

BOMAG

Seite 3

973

18.3



Optional1 :

Projektgruppe :


Optional2 :


Messtechnik D


Klemmenleiste X2

Lieferadresse :



Optional6 :


Optional7 :

210-112 5.20 x 25.00 [mm]


974

BOMAG

Seite 4

008 911 63

18.3



1

05756417

1

Nur bei ZA E2 StvZO Beleuchtung

2

4 x 05756540 "R" + 793-501

2


3


4


5


6

05756537

6


7

2 x 05756540 "R" + 793-501

7


8


9


10


11


12


13


14


9

13

4 x 05756538 "R" + 793-501

2 x 05756539 "R" + 793-501

15

05756537

15


16

05756417

16


Optional1 :

Projektgruppe :


Optional2 :


E2 Beleuchtung


Option E2 StvZO Beleuchtung

Lieferadresse :



Optional6 :


Optional7 :

210-112 5.20 x 25.00 [mm]


008 911 63

BOMAG

Seite 1

975

18.3



Optional1 :

Projektgruppe :


Optional2 :


E2 Beleuchtung



Lieferadresse :



Optional6 :


Optional7 :

210-112 5.20 x 25.00 [mm]


976

BOMAG

Seite 2

008 911 63

008 911 63

BOMAG X22

X48 X49

X48 X49

X22

X58

X59

X58

X59

X19

X18

X5 X54

X19

X18

X53

X76 X56 X17

X17

X53 X54

X74 X75

X5

X56 X76

X74 X75

X38 X2 X44

X1

X4 X3

977

Name: Seis

Gepr.: 19.10.2005

Name: Vogt

Gez.: 19.10.2005

X38

X37 X44 X2

X36

X14

X20

X20

X77

X55

X77 X4 X3

X37 X1

X36

X14

X42 X11 X12 X46 X13

X46

X42

X11 X12 X13

X55

X8 X10

X8 X10

X6 X7

X61

X60

X6 X7

X60

X9

X61

X9

Connector overview BW 177...219 D-4/D-40

Steckerübersicht BW 177...219 D-4/D-40

X21

X21

Replaces:

Ers. f.:

page: 1

Seite: 1

von: 1 from: 1

582 702 09 Sheet No.: 301

Blatt Nr.: 301


18.3

18.3

978


BOMAG

008 911 63


008 911 63

BOMAG

979

18.4


Wiring diagram 582 702 29 Design status: June 2007 to February 2008

980

BOMAG

008 911 63

008 911 63

001 002 003 004 005 006 007 008 009 010 011 012 101


582 582 582 582 582 582 582 582 582 582 582 582 582

702 702 702 702 702 702 702 702 702 702 702 702 702

29 29 29 29 29 29 29 29 29 29 29 29 29

BOMAG

03.01.2007 Vogt 03.01.2007 Seis


Stromlaufplan Versorgung, Starten, Motordrehzahl Motor−Heizflansch, Signalhorn, Kraftstoffvorwärmung Bremse, Rückfahrwarneinr., Überwachung Anzeigen Fahrstufen, Sitzkontaktsch., Vibration ZA Messtechnik BOMAG Compaction Management BCM ZA Beleuchtung und StvZO ZA Kabine, Beleuchtung, Radio, Tachograph ZA Kabinenheizung, Klimaanlage, Zusatzheizung Diebstahlschutzsystem D−4, D−40, DHC−4, DH−40 Bauteilliste

Funktionsgruppe

BW 177..219 D−4/D−40 BW 177..219 D−4/D−40



001

001

18.4 001

582 702 29

Circuit Diagram supply, starting unit, engine−speed engine heating−flange cont., warning horn, fuel pre−heater brake, back up alarm, monitoring indicators speed−ranges, seat−switch, vibr. option measurement equipm. BOMAG Compaction Management BCM opt. illumination and StvZO opt. cabin, headlights, radio, tachograph opt. cabin−heater, air conditioning, add. heater anti − theft system component listing

function unit


981

2

1

87(4)

Sicherung Heizflansch

F48

1

2

1

−

G03 +

S30

heating−flange

2

F00

X36:B

Option option

Trennschalter Batterie break switch battery Heizflansch Batterie heating−flange battery

31

R19

3:5

167A

K14

125A

30(3)

1

2

−

G01 +

125A


03.01.2007 Vogt 03.01.2007 Seis

Batterie battery

X1

X1

K61

4:4

W 5:2

K36

7:2

85

86

30A

F13

X37:A

X1:15A

X1

3:2

85

86

19 17

M01

87a

30

50a

Starter starter

−

50

X38:A

X1 X1 7 8

M

30

4:3 87

K05

X37:B

2:5 B+

K11:86

X1:4

79

54 58 15:54 2:13

30


2:18

2

1

15

X1:55

K11

X1:3


87a

30

K09

X1:168

11:7

85

86

4:13

2:5 R10 82 OHM 87

K61/85

2

1

D+ MESX

X1:66

W

D+

65

1

85

86

Generator generator

2:8

B−

G02

B+

125mA

K61

2

1

2:11

V01

B+

S00

nur bei Klimaanlage only acc.to air conditioning

X1:9

X36:A

X1:15E

125mA

15:54

Schalter Motordrehzl switch engine speed Startmehrmenge start boost fuel

1

Y01 2

X1:53

87

K114

X1

80

3:2

2:16

12

11

X1

30

K05/87

S120

87a

K35 2:16

2:10

1

85

−

AW + HW

2x2.5qmm


62 63

1

K11

X1:151

K22

12

11

X1 55

2

1

54

87a

30

X1:152

22

21

27A

2

1

1

32

31

31

?

?

S01:21

F14:2

K32:86

X1:30A

15A

1 F39

X1:30E

2

7:1

3:1

6:9

6:9

10:2

K11/87 3:1

30


008 911 63

002

582 702 29


Y13

87

4:9

87a

30

27E

X1

X1

15A

F14

X1

2:10 87


S01

nur ohne Sitzkontaktschalter without switch seat−contact X1 X1 58 59

87

17A

2

1

17E

X1 X1

70A/1A

Y120

V47

2

X1:60

K35

30

86

87a

K114 2:14

2:13

X1:56

85

86

81

24

23

X1

20A

F105

X1

4qmm

X1:10


31−1

3.9A

10:2

AUX

K30

50A / 10A

BOMAG

3.8A

4:5

982 7:5

18.4

2:13

31

X1

3

2

4

BOMAG

X1

64

2

24

14

X1

4.2A

100


X1

2

B11 1

1


R79

X1

25A

F124

X1

X1:218

2

1

X1:217

37A

2

37E 1

Kraftstoffvorwärmung fuel pre−heater

Motor−Heizflansch, Signalhorn, Kraftstoffvorwärmung engine heating−flange cont., warning horn, fuel pre−heater


2

B11 1

99

X1 97 98 X1 X1 101 102

X1

23

13

X1:155

28A

2

V22

03.01.2007 Vogt 03.01.2007 Seis

2:2


K14

1

S03

X1

10A

28E 1

1

57

6

1

75

78

F23

X1

2

2

1

7

X1

X1

4:19

V21


A13

5

52

GLÜH

2

2:20

K05/87


X1

B113

K11:86


2:10



K11/87

4.2A

008 911 63

2:20

1

1

18.4 003

582 702 29

31 4:1

K11/87 4:1


983

Option Winterpaket option winter package


geöffnet in 0

BL/BU

B13


3:20

31

X1:149

X12

4:3

K48

3 X12

SW/BK

BR/BN

X12

X1:156

1

29A

2

K48 4:2 87a

2:11

85

86

K05

X1:148

2


X1

87

85

86

87

X1:117

2

1

X1

K26

4:8

129

7:2 BRAKE MESX

X1:150

12

X1:147 11

SW/BK

BR/BN

1

X1

H14+ − X9

X9

K26/87A

87

30

X1:117

2

1

114

K26 4:6 87a

6:9

X1

+

X1

X1

P

89

BEL

Bel.

OUT1

OUT2

X1:82

X10

R03

X10

X1

X1

69

14

5 4 3 2 1

X1

X1

X1:117

P

B21

87

4

3

106

110

13

X1:57

P

B03

X1

X1

4

3

67

71

15

2

B30

_t

1

P

Motoröldruck

X1

X1

B06

X1:74

X1:77

17

2

1

73

76

16

6:9 Q

B55

B06:1

5

Sitz

X21:2

X21:1

X1:68

GLÜH

B124

−

+

2

108

112

1

1

6:9

9:17

9:17

9:16

3:5

31 5:1

1 X8

X1 107

X1

X8

X1 111

X1

A68/6

BL−L

BL−R

BL−W



Blinker links

Blinker rechts

Warnbl.

Vorglühen

X1:72

3

4

12

18

19

7

6

K11/87 6:1

008 911 63

004

582 702 29

Sensor Wasserabschei Motoröldruck Luftfilter sens. water separator air cleaner engine oil pressure Kühlmittelstand Öltemperatur Hydraulikölfilter coolant stock level hydraulik oil cleaner oil temperature


K48:87A 4:3

X1

11

201918 1716151413 121110

9 8 7 6

HOURS

2:6

X1

X1:117

3

bl

2 or

105

109

2

FUEL

X5:1−20


10

8

1

9

20

SITZWARN. 6:9

9:5

86

15/54

Sammelanzeige monitoring module F24:2 5:1 A15

2

1


85

86

90

F24:2

X1:31A

10A

Bremse, Rückfahrwarneinr., Überwachung brake, back up alarm, monitoring

K22

6:2

2:18

F25:2


85

86

X1:153

X13 3 X13 2

BL/BU

B14


Y04

X1:113

S01 2:18

6:9

4:13

30

03.01.2007 Vogt 03.01.2007 Seis

K48:87A K48/86

87a

K36 2:7

30

X13


F24

GND

10A

6:9 D+

X1:31E

D+

K61/85

Bremse

29E 1

Hydraulikölfilter

F25

125mA

125mA

Luftfilter

X1

125mA

Tankanzeige


Öltemperatur

K11/87

2.5A

300mA

5:6 X1:61 B30:2

3:20

H07

BOMAG

Sensor

Wasserabscheider

984 Kühlmittelfüllstand

18.4

4:20

BOMAG

31

2:6

P12

W

−

X1:70

G

−

2

1

R04

X1:223

X1:227

G

P02

+

03.01.2007 Vogt 03.01.2007 Seis

−

Hydrauliköltemperatur hydraulic oil temperature

Hydrauliköltemperatur hydr.oil temp.

X1:82

n

+

P03

+

Voltmeter volt meter

V

Drehzahlmesser RPM meter

−

X1:228

X1:226

G

P14

Kühlmitteltemperatur collant temperature + br

bei BW213 bl

bei BW177 sw

B16

X1:187

X1:190

ws

A06

X22:3

X22:4

OUT+

15/54

−

1

3

Elektronik transducer

sw

gg

X1:191

−

PIN 3: + PIN 3: +

BW 216 DHC−4 BW 219 D−4

Anzeigen indicators

ZA Frequenzanzeige option frequency meter

PIN 1: −

BW 213−214 DHC−4/DH−40

−−−− −−−− PIN 1: −

X1:192

P05

4

OUT−

BW 177−179 D−4/40 BW 177−179 DHC−4/DH−40 BW 211−216 D−4/40

bl

−

+

br

bei BW177 bl

X1:225

bei BW213 sw

F24:2

B30:2

4:15

+

X22:1 X22:2

−

+

X1:173 speed X1:172

dir.

Lern

SPEED TAC 10:6

SPEED MESX 7:2

DIR MESX 7:2

−

A05

Test 1



X1:174

B60

X1:171


15/54 in

X1:189 in X1:188

OUT+

P04

X1

X1

93

−

+

92

F24:2

Geschwindigkeitsanz. speedometer 1

18.4 005

582 702 29

31 6:1


OUT−

008 911 63

4:11


985

Frequenzanzeige frequency meter

Aufnehmer Vibration transducer vibration

5:20

31

Y30

X1:124

2

Y31

V03 1 2

1.23A

V05

SITZWARN. 4:10

4:19

A68/6

V09

4

1

Fahren

A68

13

D+

14

X1 88

6

S58

X14 A

4

3

X11

X14 S13

X1:157

B

11

X1:158

9

Modul Sitzschalter/Vibration module seatswitch/vibration

12

Öldruck


X1:124

2

1

X1:141

X1:143


X1:124

2

1

1

X1:162

F14:2

S01:21 2:20 K26/87A 4:8

2:20

1

03.01.2007 Vogt 03.01.2007 Seis

V02

X1:142

2

1 5 7 3



nur BW216+219D−4 only BW216+219D−4

X1:138

2

1

X1:137

2

X1:144


S42

1234

Y30

1

X1:141

X1:143

14

13


Y31

S42




1.23A

F25:2 4:8

1.23A

K48/86

X1:149

4:13 4:17 4:3

X11

Taster Vibration pushbutton vibration

D+ B06:1


BOMAG X1:149

2

2

X6

Y07

X1:116 X6

S35 13

14

1

15

a X7

Y08

X1:115 X7

2

1

b

X1:160

14

13



2

1

X1:161

24

23

X1:159

5


3.33A

K11/87

1

KA MESX

GA MESX

K04

X1:32A

15A

F03

X1:32E

1

7:2

7:2

S

30

2

1

56b

31

56

X1:149

4:20

K11/87 9:1


008 911 63

006

582 702 29

31 7:1

Modul Vibration modul vibration Nur ohne Sitzkontaktschalter without switch seat−contact

986 2

3.33A

1 X1:118

18.4

10:6 GA

6:20

2:6

4:5

5:17 5:17

6:17

6:17

F148:2

BRAKE MESX D+ MESX


31

15A

8:15

X1:35A

2

X44:57

03.01.2007 Vogt 03.01.2007 Seis


GA MESX

Pot. 15

X2:57

2

X44:28

10A

Leistung

X1:33A

X1:34A

10A

F84

X1:34E

X1:146

X44:38

F146

X44:58

F148

X44:56

S01 2:18

X44:59

X44:15

1

2

1

32

31

X44:54

X1:35E

X44:14

1

Elektronik

X2:54

X48:3

X48:2

X2:56

X2:58

X49:3

X49:2

X2:60

9:7

X2:49

GND


Anschluß ohne StvZO Bel. connection without StvZO

X2:79

X2:59

X49:4

15g/bl

−/gg

B62

X49:1

X2:57

BEL MESX 9:4

BEL MESX STVZO

X2:55

X48:4

15g/bl

−/gg

B62

X48:1

X2:53


X1:33E

Aufn. vorne 15g

+/sw X44:31

X1:145

Aufn. hinten 15g

Pot 15

X44:30

K11/87

X44:37


X44:25

9:20

X44:60

X44:35

X44:29 X44:41

GND

X2:52

X44:1

X2:71

X2:63

AGND MESX

X44:55

+/sw X44:7 GPS


Pot 30

GND

RxD

X2:66

TxD

X2:65

X4:B

X2:64

X74:2

X4:A

X2:70

X74:1

P11

X2:66

X44:67

30

X44:66

X4:C X74:3 X44:4

X4:E

X4:D X74:5

P16

−



X1:82

+ P07 E VIB

X1:85

X44:5

2:20

X44:3

+

CAN+

F1

CAN3+

1

CAN−

X2:50

F2

−


X42:2 X42:3 X46:A X46:E

X42:1 X46:B

1

CAN3+

31 8:1

18.4 007

582 702 29

8:15

CAN3− 8:15

CAN3−

X2:51

X42:5

X42:4

R20 1 2 60OHM

X46:F

X46:D

P33

X2:48 X2:49

X2:47

30 9:1



Drucker printer

EVIB


X44:27


X44:33

X74:4

X44:68

BOMAG

X44:53

CAN1−

008 911 63 X44:26



987

X44:36

988

BOMAG

7:20

31

03.01.2007 Vogt 03.01.2007 Seis

BOMAG Compaction Management BCM BOMAG Compaction Management BCM

CAN3−

F148:2

P15

BCM 05

X75:2



X75:7

X4:M

X4:N

CAN3−

X2:62

60 OHM

1 R242

X2:61

CAN3+

7:18 CAN3+

7:18

7:2

1

X76:2

X76:1

1

X2:63

X4:F

X4:G

X2:70


008 911 63

008

582 702 29

31 9:1

18.4

87a

31

2

2

E16 1 E17 1

7:8

X1:84

S53

9:10

14

13

32

31

85

86

03.01.2007 Vogt 03.01.2007 Seis

K06

BEL MESX



8:20

87

9:9

K16 30

S15

012


12

11

4:11

X1:23A

15A

F09

BEL MESX STVZO 7:8

X1:24A

15A

F10

X1:24E



X1:23E

BEL

23

24

9:2

86

X1:22E 4

23

4:19 4:19

S37

X1:25E

2

2

2 K16



2

E13 1 E12 1 E14 1 E15 1

15A

F19

E25 1 2

E23 1 2

2

2



X3:1

01

01

H06

14

13

X1:19A

−

+

24

4:19

BL−W



S14


E28 1

X3:5

X1:22A


85

E

5

87a

E27 1

X3:4

X1:21A

15A

F22

X1:21E

87

K06 9:4

24

14

A02

49L

23

13

E11 1 2

E10 1 2

2

2

R

E09 1

X1:96

X1:91

L

49R


E08 1

BL−R

BL−L

L0R

31 82

30

L0R

X1:25A X1:305

15A

X1:26A X1:83


X1:18A

30

X1:19E F08

X1:2 15A

X60:3 X1:319

X1:323 X60:4


10A

X1:311 X58:3 X1:315 X58:6

15A

0,42A

X58:5 X1:309

X1:315 X58:6

X59:3 X1:312 X1:316 X59:6

X1:301

X1:302

F07

0,42A

X59:5 X1:310

X1:316 X59:6

X1:303 0,125A

F18

0,42A

0,125A

X1:26E

X1:304

F11

0,42A

X1:308

X1:18E

4,6A

X61:3 X1:320 X1:324 X61:4


1

Blinkleuchte HR indicator rear, RH

1

18.4 009

582 702 29



31

10:1

K11/87 7:2 30

X58:6 X1:315

K11/87 30

4,6A

Arbeitsscheinwerfer hinten rechts working head lights, rear rh. 4,6A

X1:313 X58:2 1,75A

X60:2 X1:323


X1:306

X60:1 X1:321

X59:6 X1:316

7:19

1,75A

X61:2


X1:307

X59:2 X1:314 1,75A

X61:1 X1:322 1,75A

BOMAG

X1:324

008 911 63

6:20


989

12V

XS

Steckdose Fahrerst.

X3:3

R80

85

86

2

1

10:16 87

K141

15A

31


K32

−

+


10:6

9:20


S45

E29

10A

F42

TK

2

1

8

H

−

+

+

−

+

−

−

A12

B51 +

03.01.2007 Vogt 03.01.2007 Seis


S86

A01

2

E71 1

87a

30

7

G


F143


1,75A


X3:8


2:20

−

87a

3

4 A51 2

5

7,8,9


1

A16

5

C3

3

A2+A3

A5+A6

P09

15A

F43

S21

01W 7 01

F42 11:8 F130 10:14

X55:2

M05

M

5

2

1

A

3,8A



− M07

M

+

4

X55:1

15A

F44

X56:2

M04

M

5

2

2

B

10:9

+

4

E70

F130

10A

F130

S158

4

3

2

1

3

C

K141

I


10:2

9:13 9:13

2

1 E28

E72

E27

2

1

F130 11:7

STV1

STV2

1

2

−

+

1

XS 12V

1

5

5

E

15A

F144

11:2

11:14


008 911 63

010

582 702 29


31 11:1

11:11

−

+

6

F

K32:87

F41:5

KABINE 31

2

1

S38

10A

F41

ZA option

E32

1 E25

4,6A


2

1 E23

4,6A



15 31

1

S163 5


− M06

M

3,8A


S20

01W 7 01



B4

B3

A1

2

1

6


Radio radio

−

15 + + B51

87

X3:17 4 5:17 SPEED TAC

31

30

K32

10:2

X55:3

30

2,9A

X3:7

X56:4

K32:86

X56:3

2:11

X56:1

11:14

4,7A

0,83A


F42:H

3 min

4,6A

X3:6

5A

2:11 K30

X3:16 GA X3:15

6:17

KA 6:16

X55:4 X3:1

Abfallverzögert

BOMAG X3:2

Steckdose Kabine socket cabin

990 4,6A

18.4

10:20

31


ge

M09

rt

or

X3:12

ge


03.01.2007 Seis 03.01.2007 Seis


br

rt

M

or

2

V04 1

2

X18:2

_t

B131

X18:1

X1:167

X3:14

10:19

2

1

2

1 X54:1

KABINE 31


X1:168

Y138

1

X54:12

2

X54:2

3 A72 Steuergerät control unit 11 12

X54:3

X54:11

6

4

X54:4

−

+

2

1

Inline Sicherung inline fuse

Frischluft Lüfter blower fresch air

X69:2

M17

X69:1

3A

F97



1

HP

2

1

87a

30

Y15

X20:2

X1:170

B104 4 P LP 3

X19:2 X20:1

_t

B103

X19:1

X1:169

87

2:8

K09

X3:13

X54:6

V06

10:17 F130 Potential 15 aus Kabine F42 10:9 Potential 30 aus Kabine


X1:164

X17:4


X53:L

X3:9

X17:1 X1:163

0123

X53:C

X53:M

X3:10

X17:2 X1:165

S44

4

D

X53:H

X3:11

X17:3 X1:166

X53:B

20A

F31




K32:87

2.5qmm

1

1

A

2

3

BOX2

2

1

9

8

7

4

15


Power Stufe = 2,8A

große Stufe = 1.9A



Regel aus = 0,4A

12 11 13 14 16

10 6


X77:2

Y14

X77:1

5


20A

F40

10:19 F41:5 F42:H 10:4

Option option

10:20

X20:4

1A

BOMAG 3,5A


008 911 63 2.5qmm

1


2

5

6

8

4

12

31 12:1

9

10 1

BOX2

11 3 S28

7

2

B

18.4 011

582 702 29

5A

F15


991

992

ZA option

03.01.2007 Vogt 03.01.2007 MV009 Seis

Steuereinheit control unit

Diebstahlschutzsystem D−4, D−40, DHC−4, DH−40 anti − theft system

A66

A67 Keyboard keyboard

BOMAG −

VAL

0

ANN

+

9

8

7

H80

6

3

5

2

4

1

1

1


008 911 63

012

582 702 29

18.4

Name

Benennung

title

A02 A05 A06 A12 A13 A15 A16 A51 A66 A67 A68 A72 A83 A87

Bl. 009 005 005 010 003 004 010 010 012 012 006 011 007 008

Pf. 17 17 10 5 3 16 7 6 9 15 10 11 6 15

Blinkgeber Elektronik Geschwindigkeitsanzeige Elektronik Frequenzanzeige vorne Radio Steuergeraet Heizung Ueberwachungsmodul Elektronik Tachograph Platine Frequenzanzeige Elektronik Steuereinheit Eingabeeinheit Modul Sitzkontakt Steuergeraet Klimaanlage, Heizung Elektronik Messtechnik USB−CAN Schnittstelle BCM

flasher Electronic system, speedometer electronic frequency−meter, front Radio Control unit, heating monitoring module Electronic system, tachograph Circuit board,frequenzy meter Electronic control unit Keyboard Modul seat contact Control unit,air conditioning,heating electronic measurement−equipment USB−CAN Interface BCM

B03 B06 B11 B11 B13 B14 B16 B21 B30 B51 B51 B55 B60 B61 B62 B62 B103 B104 B113 B124 B131

004 004 003 003 004 004 005 004 004 010 010 004 005 007 007 007 011 011 003 004 011

15 17 9 11 2 6 9 14 16 5 6 17 14 12 8 10 7 7 3 19 10

Unterdruckschalter Luftfilter Druckschalter Motoroel Signalhorn Signalhorn Naeherungsinitiator Fahrhebel links Naeherungsinitiator Fahrhebel rechts Aufnehmer Vibrationsfrequenz vorne Differenzdruckschalter Hydr.−Oelfilter Temperaturschalter Motoroel Lautsprecher Radio Lautsprecher Radio Kuehlmittelstand Ausgleichsbehaelter Aufnehmer Achsgeschwindigkeit Aufnehmer Verstellzylinder Beschleunigungsaufnehmer Beschleunigungsaufnehmer Temperaturschalter Klimaanlage Druckschalter Klimaanlage EMR Temperaturgeber Kuehlmittel Geber Wasserstandsabscheider Diesel Temperaturschalter Heizung

Vacuum switch, air cleaner Pressure switch, engine oil Warning horn Warning horn Proximity switch, travel lever, lh. Proximity switch, travel lever, rh. Transducer, vibration frequency, front Pressure diff. switch, hydr. oil filter Temperature switch, engine oil Speaker radio Speaker radio Coolant charge expansion tank Sensor, axle speed Sensor, ajustable zylinder Acceleration sensor Acceleration sensor Temperature switch, air conditioning Pressure switch, air conditioning EMR Temperature switch, collant Sender, water separator fuel Temperature switch, heating

E08 E09 E10 E11 E12 E13 E14 E15 E16 E17 E23 E23 E25 E25 E27 E27 E28 E28 E29 E30 E32 E70 E71 E72

009 009 009 009 009 009 009 009 009 009 009 010 009 010 009 010 009 010 010 011 010 010 010 010

17 18 19 19 7 6 7 8 2 2 11 18 12 19 10 17 11 17 4 15 19 15 3 16

Blinkleuchte vorne links Blinkleuchte hinten links Blinkleuchte vorne rechts Blinkleuchte hinten rechts Parkleuchte links Schlussleuchte links Parkleuchte rechts Schlussleuchte rechts Scheinwerfer links Scheinwerfer rechts Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer hinten links Arbeitsscheinwerfer hinten links Arbeitsscheinwerfer hinten rechts Arbeitsscheinwerfer hinten rechts Innenleuchte Kabine Heizgeraet Kennleuchte Nachtleuchte Kontrolleuchte Schalter Heckscheibenheizung Beleuchtung Bedienschalter

Indicator, front, lh. Indicator, rear, lh. Indicator, front, rh. Indicator, rear, rh. Parking light, lh. Tail light, lh. Parking light, rh. Tail light, rh. Head light, lh. Head light, rh. Working head light, front, lh. Working head light, front, lh. Working head light, front, rh. Working head light, front, rh. Working head light, rear, lh. Working head light, rear, lh. Working head light, rear, rh. Working head light, rear, rh. Inside light, cabin Heating unit Warning light Night lamp indicator light switch rear screen illum. Switches

F00 F03 F07 F08 F09 F10 F11 F13 F14 F15 F18 F19 F22 F23 F24 F25 F31 F39 F40 F41 F42 F43 F44 F48 F68 F84 F97 FM4 F105 F124 F130 F143 F144 F146 F148

002 006 009 009 009 009 009 002 002 011 009 009 009 003 004 004 011 002 011 010 010 010 010 002 002 007 011 007 002 003 010 010 010 007 007

4 18 15 18 6 8 2 10 18 19 5 12 10 9 10 2 3 19 15 19 4 10 13 3 6 5 13 11 16 14 15 2 20 4 2

Hauptsicherung Batterie Sicherung Vibration Sicherung Warnblinker Sicherung Blinker u. Arbeitsscheinw. Sicherung Park− u. Schlussl. links Sicherung Park− u. Schlussl. rechts Sicherung Scheinwerfer links Sicherung Startschalter Sicherung Hubmagnet Motor Sicherung Heizgeraet Vorsicherung Arbeitsscheinw. vorne Sicherung Arbeitsscheinw. vorne li. Sicherung Arbeitsscheinwerfer hinten Sicherung Signalhorn Sicherung Ueberwachungsmodul Sicherung Magnetv. Fahren u. Bremse Sicherung Kabinenluefter Hauptsicherung Kabine Sicherung Kabinenheizung Sicherung Rundumkennleuchte Sicherung Kabineninnenleuchte Sicherung Wischermotor hinten Sicherung Wischermotor vorn Sicherung Gluehanlage Sicherung Potential 30 Sicherung Steuerung (Klemme 54) Sicherung Frischluftluefter Platinensicherung Sicherung Motordrehzahl Sicherung Kraftstoffvorwärmung Sicherung Nachtleuchte Sicherung Heckscheibenheizung Sicherung Kabinensteckdose Sicherung Steuerung MESX (Potential 30) Sicherung Steuerung MESX (Potential 15)

Fuse, main, battery Fuse, vibration Fuse, hazard light Fuse, indicators a. work. head light Fuse, parking and tail light, lh. Fuse, parking and tail light, rh. Fuse, head light, lh. Fuse, starter switch Fuse, shut off solenoid, engine Fuse, heating unit Primary fuse, work. head light, fr. Fuse, working head light, front, lh. Fuse, working head lights, rear Fuse, warning horn Fuse, monitoring module Fuse, sol. valve, travel and brake Fuse, cabin ventilator Main fuse, cab Fuse, heating unit cab Fuse, rotary beacon Fuse, inside light cab Fuse, wipermotor rear Fuse, wipermotor front Fuse, glow plug system Fuse, potential 30 Fuse, controller (Pin 54) fuse, blower fresh air Multifuse Fuse, motor speed Fuse, fuel pre−heating Fuse, night lamp fuse rear screen heating unit Fuse cabin−socket Fuse Controller (Pot. 30) Fuse Controller (Pot. 15)


03.01.2007 Vogt 03.01.2007 Seis


582 702 29

008 911 G01 63

002 4

Batterie

BOMAG Battery

TYP MODUL MODUL

18.4

MAX. 0,12A

MAX.5A MAX.5A

MAX. 1,75A MAX. 1,75A MAX. 1,75A MAX. 1,75A MAX. 0,42A MAX. 0,42A MAX. 0,42A MAX. 0,42A MAX. 4,6A MAX. 4,6A MAX. 4,6A 4,6A MAX. 4,6A 4,6A MAX. 4,6A 4,6A MAX. 4,6A 4,6A 1,75A 5A 0,83A 1,75A

125A MAX. 1,23A 15A 15A 10A 10A 15A 30A 15A BOX2 30A 30A 30A 10A 10A 10A 15A BOX2

125A 5A 10A 3A 20A 25A

103A

993

G02 G03

Name

Bl. Pf. Benennung 002 5 Generator 002 3 Batterie

Generator Battery

H06 H07 H14 H80

009 004 004 012

15 10 8 15

Meldeleuchte Warnblinker Warnsummer Betriebsstoerung Warnsummer Rueckwaertsfahrt Meldeleuchte Wegfahrsperre

Indicator light, hazard light Warning buzzer, breakdown Back−up alarm buzzer Indicator light, anti−theft device

MAX. 0,12A MAX. 0,12A LED

K04 K05 K06 K09 K11 K14 K16 K22 K26 K32 K35 K36 K48 K61 K114 K141

006 004 009 002 002 003 009 004 004 010 002 002 004 002 002 010

18 3 4 8 10 5 9 9 6 2 16 7 2 5 14 16

Schrittrelais Vibration Relais Startstrom Relais Scheinwerfer hinten Relais Klimageraet Relais Klemme 30 auf 15 Relais Vorgluehen Relais Scheinwerfer vorne Relais Hubmagnet Motor Relais Rueckfahrwarneinrichtung Relais Kabine Relais Selbsthaltung Relais Bremskontrolle Relais Fahrhebel 0−Stellung Relais Ladekontrolle Relais Motordrehzahl Relais Heckscheibenheizung

Toggle relay, vibration Relay, starting current Relay, head lights, rear Relay, air conditioning Relay, terminal 30 to 15 Relay, glow plug system Relay, head lights, front Relay, shut off solenoid, engine Relay, back up alarm Relay, cabin Relay, holding contact Relay, brake control Relay, travel lever 0−position Relay, charge control Relay, engine rpm relay, heating rear screen

MAX. 1,23A BOSCHW BOSCHW BOSCHW BOSCHW BOSCHL BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW

M01 M04 M05 M06 M07 M09 M09 M17

002 010 010 010 010 011 011 011

11 13 10 14 11 3 4 13

Starter Scheibenwischermotor vorne Scheibenwischermotor hinten Scheibenwaschermotor vorne Scheibenwaschermotor hinten Kabinenluefter Kabinenluefter Zusatzluefter

Starter Windscreen wiper motor, front Windscreen wiper motor, rear Windscreen washer motor, front Windscreen washer motor, rear Cabin ventilator Cabin ventilator Additional blower

2.3 KW 4,7A 2,9A MAX. 3,8A MAX. 3,8A

P02 P03 P04 P05 P07 P09 P11 P12 P14 P15 P16 P33

005 005 005 005 007 010 007 005 005 008 007 007

5 3 19 11 15 8 14 2 6 16 16 18

Temperaturanzeige Hydraulikoel Drehzahlmesser Geschwindigkeitsanzeige Frequenzanzeige vorne Omegameter Frequenz− und Geschwindigkeitsanzeige Drucker Voltmeter Anzeige Kuehlmitteltemperatur BCM 03 Bildschirm Diagnose, Variomatic Opus 21

Temperature gauge, hydraulic oil Rpm meter Speedometer Frequency meter, front Omegameter Frequency− and Speedometer Printer Volt meter Temperature gauge, coolant BCM 03 terminal Diagnostics, varimatic Opus 21

R03 R04 R10 R19 R20 R24 R79 R80

004 005 002 002 007 008 003 010

12 4 6 2 17 15 14 2

Geber Tankanzeige Geber Hydraulikoeltemperatur Parallelwiderstand Heizflansch Widerstand Widerstand Kraftstoffvorwärmung Heizung Heckscheibe

Sender, level gauge Sender, hydraulic oil temp. Parallel resistor heater flange Resistor Resistor fuel pre−heater heating rear screen


002 002 003 006 009 009 010 010 011 002 006 009 010 006 006 011 010 009 006 010 002 010 010

10 18 9 13 15 4 13 10 19 3 15 18 19 3 7 3 4 4 13 4 14 15 16



V01 V02 V03 V04 V05 V06 V09 V21 V22 V47

002 006 006 011 006 011 006 003 003 002

6 6 7 8 10 9 10 10 11 15



X1:1 X1:2 X1:3 X1:4 X1:7 X1:8 X1:9 X1:10

002 009 002 002 002 002 002 002

5 10 9 10 11 12 4 4

WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten

18.4

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title

WAGO,E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX BOMAG WAGO,E−BOX

TYP

Wiring diagram103A582 702 29

82 OHM 167A 60OHM 60 OHM 250W


FE5B

008 911 63

Name X1:52 X1:53 X1:54 X1:55 X1:55 X1:56 X1:57 X1:57 X1:58 X1:59 X1:60 X1:61 X1:62 X1:63 X1:64 X1:64 X1:65 X1:66 X1:67 X1:68 X1:69 X1:70 X1:71 X1:72 X1:73 X1:74 X1:75 X1:76 X1:77 X1:78 X1:79 X1:80 X1:81 X1:82 X1:82 X1:82 X1:83 X1:84 X1:85 X1:86 X1:87 X1:88 X1:89 X1:90 X1:91 X1:92 X1:93 X1:96 X1:97 X1:98 X1:99 X1:100 X1:101 X1:102 X1:105 X1:106 X1:107 X1:108 X1:109 X1:110 X1:111 X1:112 X1:113 X1:114 X1:115 X1:116 X1:117 X1:117 X1:117 X1:117 X1:118 X1:124 X1:124 X1:124 X1:129 X1:137 X1:138 X1:141 X1:141 X1:142 X1:143 X1:143 X1:144 X1:145 X1:146 X1:147 X1:148 X1:149 X1:149 X1:149 X1:149 X1:150 X1:151 X1:152 X1:153 X1:154 X1:155 X1:156 911 X1:15763

Bl. 003 002 002 002 002 002 003 004 002 002 002 004 002 002 003 012 002 002 004 004 004 005 004 004 004 004 003 004 004 003 002 002 002 004 005 007 009 009 007 004 004 006 004 004 009 005 005 009 003 003 003 003 003 003 004 004 004 004 004 004 004 004 004 004 006 006 004 004 004 004 006 006 006 006 004 006 006 006 006 006 006 006 006 007 007 004 004 004 006 006 006 004 002 002 004 006 003 004 006

Pf. 2 12 18 10 18 15 3 15 16 16 16 15 16 16 3 12 5 6 15 17 13 3 15 17 17 16 4 17 16 4 10 14 14 11 4 15 5 4 15 10 13 11 10 9 17 19 19 17 9 10 10 11 9 10 12 14 19 20 12 14 19 20 5 8 16 14 5 8 12 14 14 3 6 8 6 4 4 3 8 6 3 8 6 5 5 5 2 1 12 13 19 5 18 18 6 13 9 2 13

Benennung WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten


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title WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO, E−box WAGO,E−BOX WAGO, E−box WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO, E−box WAGO, E−box WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO, E−box WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO, E−box WAGO, E−box WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX BOMAG WAGO,E−BOX

TYP

18.4

995

Name

18.4

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X1:158 X1:159 X1:15A X1:15E X1:160 X1:161 X1:162 X1:163 X1:164 X1:165 X1:166 X1:167 X1:168 X1:168 X1:169 X1:16A X1:16E X1:170 X1:171 X1:172 X1:173 X1:174 X1:17A X1:17E X1:187 X1:188 X1:189 X1:18A X1:18E X1:190 X1:191 X1:192 X1:19A X1:19E X1:217 X1:218 X1:21A X1:21E X1:223 X1:225 X1:226 X1:227 X1:228 X1:22A X1:22E X1:23A X1:23E X1:24A X1:24E X1:25A X1:25E X1:26A X1:26E X1:27A X1:27E X1:28A X1:28E X1:29A X1:29E X1:301 X1:302 X1:303 X1:304 X1:305 X1:306 X1:307 X1:308 X1:309 X1:30A X1:30E X1:310 X1:311 X1:312 X1:313 X1:314 X1:315 X1:315 X1:315 X1:316 X1:316 X1:316 X1:319 X1:31A X1:31E X1:320 X1:321 X1:322 X1:323 X1:323 X1:324 X1:324 X1:32A X1:32E X1:33A X1:33E X1:34A X1:34E X1:35A X1:35E

Bl. 006 006 002 002 006 006 006 011 011 011 011 011 002 011 011 002 002 011 005 005 005 005 002 002 005 005 005 009 009 005 005 005 009 009 003 003 009 009 005 005 005 005 005 009 009 009 009 009 009 009 009 009 009 002 002 003 003 004 004 009 009 009 009 009 009 009 009 009 002 002 009 009 009 009 009 009 009 009 009 009 009 009 004 004 009 009 009 009 009 009 009 006 006 007 007 007 007 007 007

Pf. 13 16 10 10 16 14 7 3 5 3 4 10 8 10 7 6 6 7 14 15 15 14 16 16 9 10 10 2 2 9 11 11 15 15 14 14 10 10 4 6 6 4 7 12 12 6 6 8 8 18 18 5 5 18 18 9 9 2 2 5 5 9 15 18 18 18 15 2 19 19 2 7 7 17 19 2 7 17 2 7 19 6 10 10 8 18 19 6 18 8 19 18 18 2 2 5 5 4 4

Benennung WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK

title WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX BOMAG WAGO E−BOX

TYP


008 911 63

Name X1:37A X1:37E X2:47 X2:48 X2:49 X2:49 X2:50 X2:51 X2:52 X2:53 X2:54 X2:55 X2:56 X2:57 X2:57 X2:58 X2:59 X2:60 X2:61 X2:62 X2:63 X2:63 X2:64 X2:65 X2:66 X2:66 X2:67 X2:68 X2:69 X2:70 X2:70 X2:71 X2:77 X2:78 X2:79 X3:1 X3:1 X3:2 X3:3 X3:4 X3:5 X3:6 X3:7 X3:8 X3:9 X3:10 X3:11 X3:12 X3:13 X3:14 X3:15 X3:16 X3:17 X4:A X4:B X4:C X4:D X4:E X4:F X4:G X4:M X4:N X6:1 X6:2 X7:1 X7:2 X8:1 X8:2 X9:1 X9:2 XS XS X10:2 X10:3 X11:1 X11:2 X12:1 X12:2 X12:3 X13:1 X13:2 X13:3 X14:A X14:B X17:1 X17:2 X17:3 X17:4 X18:1 X18:2 X19:1 X19:2 X20:1 X20:2 X20:3 X20:4 X21:1 X21:2 911 X22:1 63

Bl. 003 003 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 008 008 007 008 007 007 007 007 007 007 007 007 008 007 007 007 007 009 010 010 010 009 009 010 010 010 011 011 011 011 011 011 010 010 010 007 007 007 007 007 008 008 008 008 006 006 006 006 004 004 004 004 010 010 004 004 006 006 004 004 004 004 004 004 006 006 011 011 011 011 011 011 011 011 011 011 011 011 004 004 005

Pf. 14 14 18 19 12 19 17 18 13 8 7 8 7 2 10 9 10 9 15 16 13 18 14 14 14 14 11 12 12 15 18 14 11 11 10 11 10 10 2 10 12 2 2 2 3 3 4 4 7 10 7 6 6 14 14 14 14 15 18 18 16 15 14 14 16 16 19 20 8 8 1 20 12 12 13 13 2 2 1 6 6 6 13 13 3 3 4 5 10 10 7 7 7 7 7 7 17 17 9

Benennung WAGO,E−Kasten WAGO,E−Kasten WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO ZENTRALELEKTRIK STECKER ROPS/SD STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER ROPS/SD STECKER ROPS/SD STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH Steckdose Steckdose AMP SUPERSEAL AMP SUPERSEAL DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH STECKER LÜFTER HKL STECKER LÜFTER HKL STECKER LÜFTER HKL STECKER LÜFTER HKL STECKER THERMOFÜHLER STECKER THERMOFÜHLER STECKER EISSCHUTZ HKL STECKER EISSCHUTZ HKL STECKER DRUCKSCH. KLI STECKER DRUCKSCH. KLI STECKER DRUCKSCH. KLI STECKER DRUCKSCH. KLI STECKER KÜHLMITTEL STECKER KÜHLMITTEL ST. VIBRATIONSAUFNEHM


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582 702 29

008

title WAGO,E−BOX WAGO,E−BOX Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. WAGO E−BOX conn. ROPS/SR conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. ROPS/SR conn. ROPS/SR conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector Socket Socket AMP connector AMP connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector conn. blower conn. blower conn. blower conn. blower conn. sender temp. conn. sender temp. conn. anti−ice air−cond. conn. anti−ice air−cond. conn. pressuresitch air−cond. conn. pressuresitch air−cond. conn. pressuresitch air−cond. conn. pressuresitch air−cond. connector coolant sensor connector coolant sensor BOMAG connector vibration sensor

TYP

18.4

997

Name

18.4

03.01.2007 Vogt 03.01.2007 Seis


582 702 29

998

X22:2 X22:3 X22:4 X36:A X36:B X37:A X37:B X38:A X42:1 X42:2 X42:3 X42:4 X42:5 X44:1 X44:3 X44:4 X44:5 X44:7 X44:9 X44:14 X44:15 X44:23 X44:25 X44:26 X44:27 X44:28 X44:29 X44:30 X44:31 X44:32 X44:33 X44:35 X44:36 X44:37 X44:38 X44:41 X44:53 X44:54 X44:55 X44:56 X44:57 X44:58 X44:59 X44:60 X44:65 X44:66 X44:67 X44:68 X46:A X46:B X46:D X46:E X46:F X47:A X47:B X47:C X48:1 X48:2 X48:3 X48:4 X49:1 X49:2 X49:3 X49:4 X53:B X53:C X53:H X53:L X53:M X54:1 X54:2 X54:3 X54:4 X54:6 X54:11 X54:12 X55:1 X55:2 X55:3 X55:4 X56:1 X56:2 X56:3 X56:4 X58:2 X58:3 X58:5 X58:6 X58:6 X58:6 X59:2 X59:3 X59:5 X59:6 X59:6 X59:6 X60:1 X60:2 X60:3

Bl. 005 005 005 002 002 002 002 002 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 011 011 011 011 011 011 011 011 011 011 011 011 010 010 010 010 010 010 010 010 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009

Pf. 9 10 10 4 4 10 11 11 18 19 19 18 18 13 15 14 14 10 12 5 5 11 10 18 17 2 7 9 8 6 18 5 6 7 4 7 17 5 13 4 4 4 5 5 13 13 14 14 19 18 18 19 18 11 12 12 8 7 7 8 10 9 9 10 3 4 4 3 3 11 11 10 10 7 10 11 11 10 10 10 14 13 13 13 17 7 2 2 7 17 19 7 2 2 7 19 18 18 6

Benennung ST. VIBRATIONSAUFNEHM ST. VIBRATIONSAUFNEHM ST. VIBRATIONSAUFNEHM EINSPEISUNG SCHALTKAS EINSPEISUNG SCHALTKAS ST. ZÜNDSCHLOß E−KAST ST. ZÜNDSCHLOSS E−KAS ST.STARTER E−KASTEN STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER STECKER BOP STECKER BOP STECKER BOP STECKER BOP STECKER BOP STECKER AUFN. PLEIGER STECKER AUFN. PLEIGER STECKER AUFN. PLEIGER STECKER AUFN. VORNE STECKER AUFN. VORNE STECKER AUFN. VORNE STECKER AUFN. VORNE STECKER AUFN. HINTEN STECKER AUFN. HINTEN STECKER AUFN. HINTEN STECKER AUFN. HINTEN STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER WISCHER HINTE STECKER WISCHER HINTE STECKER WISCHER HINTE STECKER WISCHER HINTE STECKER WISCHER VORNE STECKER WISCHER VORNE STECKER WISCHER VORNE STECKER WISCHER VORNE STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO HL STECKER STVZO HL STECKER STVZO HL

title

TYP

connector vibration sensor connector vibration sensor connector vibration sensor supply e−box supply e−box connector ignition switch connector ignition switch, e−box connector starter e−box conector adapter BOP conector adapter BOP conector adapter BOP conector adapter BOP conector adapter BOP MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker Connector BOP Connector BOP Connector BOP Connector BOP Connector BOP conn. sender PLEIGER conn. sender PLEIGER conn. sender PLEIGER conn. sender front conn. sender front conn. sender front conn. sender front conn. sender rear conn. sender rear conn. sender rear conn. sender rear conn. blowerswitch conn. blowerswitch conn. blowerswitch conn. blowerswitch conn. blowerswitch conn. heating controller conn. heating controller conn. heating controller conn. heating controller conn. heating controller conn. heating controller conn. heating controller connector wiper rear connector wiper rear connector wiper rear connector wiper rear conn. wiper front conn. wiper front conn. wiper front conn. wiper front Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO BL Con. STVZO BL BOMAG Con. STVZO BL


008 911 63

Name

Benennung

title

X60:4 X61:1 X61:2 X61:3 X61:4 X65:1 X65:2 X65:3 X65:4 X65:5 X65:7 X65:8 X65:9 X65:10 X65:11 X65:12 X68:1 X68:2 X69:1 X69:2 X74:1 X74:2 X74:3 X74:4 X74:5 X75:2 X75:7 X76:1 X76:2 X77:1 X77:2

Bl. 009 009 009 009 009 012 012 012 012 012 012 012 012 012 012 012 012 012 011 011 007 007 007 007 007 008 008 008 008 011 011

Pf. 6 19 19 8 8 5 5 5 5 5 5 12 5 5 5 5 15 16 13 13 14 14 14 15 14 16 15 17 17 15 15

STECKER STVZO HL STECKER STVZO HR STECKER STVZO HR STECKER STVZO HR STECKER STVZO HR KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD STECKER LED STECKER LED STECKER FRISCHLUFT LÜ STECKER FRISCHLUFT LÜ STECKER DRUCKER STECKER DRUCKER STECKER DRUCKER STECKER DRUCKER STECKER DRUCKER SUB−D STECKER BCM INT SUB−D STECKER BCM INT STECKER VERS. BCM STECKER VERS. BCM STECKER PUMPE STANDHE STECKER PUMPE STANDHE

Con. STVZO BL Con. STVZO BR Con. STVZO BR Con. STVZO BR Con. STVZO BR Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard connector led connector led connector fresh air blower connector fresh air blower con. printer con. printer con. printer con. printer con. printer con. SUB−D BCM con. SUB−D BCM con. Power−sup. BCM con. Power−sup. BCM Conn. pump add. heater Conn. pump add. heater

Y01 Y04 Y07 Y08 Y13 Y14 Y15 Y30 Y30 Y31 Y31 Y120 Y138

002 004 006 006 002 011 011 006 006 006 006 002 011

13 5 14 16 18 15 7 4 6 3 8 16 10

Magnetventil Startmehrmenge Magnetventil Bremse D*Prop. Ventil Vibration groß D*Prop. Ventil Vibration groß Hubmagnet Motor Kraftstoffpumpe Heizgeraet Magnetkupplung Klimakompressor Magnetventil Stufenumschaltung vorn Magnetventil Stufenumschaltung vorn Magnetventil Stufenumschaltung hinten Magnetventil Stufenumschaltung hinten Magnetventil Motordrehzahl hoch Magnetveentil Heizung

Solenoid valve, start boost fuel Solenoid valve, brake E*prop. Valve vibration high E*prop. Valve vibration high Shut off solenoid, engine Fuel pump, heating unit Magnetic clutch, air conditioning compr. Solenoid valve, speed range sel., front Solenoid valve, speed range sel., front Solenoid valve, speed range sel., rear Solenoid valve, speed range sel., rear Solenoid valve, rpm engine high Solenoid valve, heating unit


TYP

18.4

03.01.2007 Vogt 03.01.2007 Seis

MAX. 3.9A MAX. 1,8A MAX. 2,5A MAX. 2,5A MAX. 3.8A 3,5A MAX. 1,67A MAX. 1,67A MAX. 1,23A MAX. 1,23A

Bauteilliste component listing

3,5A

7 7 107

582 702 29

008 911 63

BOMAG

999

X36

X37

1000

BOMAG

K11


X38

A68

K04

K09

008 911 63

Übersicht Schaltkasten BW 177...219 D-4/D-40 overview e-box BW 177...219 D-4/D-40


Name: Vogt

Gez.: 03.01.2007


K26

K114

K61

K48

K35


K36

K05

K06

R10

K16

A02


Replaces:

Ers. f.:

page: 1

Seite: 1

von: 2 from: 2

582 702 29 Sheet No.: 201

Blatt Nr.: 201


F1

F2

008 911 63 A83 Messtechnik Steuerung

CAN 1


BOMAG overview e-box door BW 177...219 D-4/D-40

Gepr.: 03.01.2007

1001

Name: Seis

Name: Vogt


BCM

Replaces:

Ers. f.:

page: 2

Seite: 2

OPUS 21

Gez.: 03.01.2007

CAN 3

CAN 1

von: 2 from: 2

582 702 29 Sheet No.: 201

Blatt Nr.: 201


18.4

18.4



057 564 17

2

057 564 21

3

2 x 057 564 25 "L" + 793-501

5

2 x 057 564 25 "L" + 057 564 20 + 793-501

7

057 564 22

8

4 x 057 564 23 "L" + 057 564 19 + 793-501

12

18 x 057 564 36 "R" + 057 564 19 + 793-501

30

2 x 057 564 36 "R" + 793-501

32

057 564 35

33

057 564 17

Optional1 :

Projektgruppe :


Optional2 :


D-4/40

Optional3 : Optional4 :

Absicherung D-4 komplett

Optional5 :


Optional6 :


Optional7 :

M. Vogt TEE

Lieferadresse :

210-112 5.20 x 25.00 [mm]


1002


BOMAG

Seite 1

008 911 63

18.4



Optional1 :

Projektgruppe :


Optional2 :


D-4/40


Absicherung D-4 komplett

Optional5 :


Optional6 :


Optional7 :

M. Vogt TEE

Lieferadresse :

210-112 5.20 x 25.00 [mm]


008 911 63


BOMAG

Seite 2

1003

18.4



1

057 564 17

2

2 x 057 565 40 "R" + 793-501 + 057 565 36

4

2 x 057 565 40 "R" + 793-501

6

3 x 057 565 39 "R" + 793-501

9

057 565 37

10

4 x 057 565 38 "R" + 793-501

14

057 565 37

15

3 x 057 565 38 "R" + 793-501

18

057 565 37

19

3 x 057 565 40 "R" + 793-501

22

057 565 35 "R" + 793-501

23

057 565 37

24

5 x 057 565 40 "R" + 793-501

29

057 565 37

30

2 x 057 565 38 "R" + 793-501

32

2 x 057 565 39 "R" + 793-501

34

057 565 37

35

4 x 057 565 38 "R" + 793-501

39

057 565 37

40

4 x 057 565 40 "R" + 793-501

Optional1 :

Projektgruppe :


Optional2 :


D-4/40


Kabelbäume D-4 komplett

Optional5 :


Optional6 :


Optional7 :

M. Vogt TEE

Lieferadresse :

210-112 5.20 x 25.00 [mm]


1004


BOMAG

Seite 1

008 911 63

18.4



057 565 39 "R" + 793-501

45

057 565 35 "R" + 793-501

46

057 565 37

47

2 x 057 565 40 "R" + 793-501

49

057 565 37

50

057 565 40 "R" + 793-501

51

057 565 38 "R" + 793-501

52

057 565 37

53

4 x 057 565 40 "R" + 793-501

57

057 565 39 "R" + 793-501

58

057 565 37

59

4 x 057 565 40 "R" + 793-501

63

057 565 37

64

057 565 40 "R" + 793-501

65

057 565 35 "R" + 793-501

66

057 565 37

67

057 565 40 "R" + 793-501

68

057 565 35 "R" + 793-501

69

057 565 37

70

057 565 38 "R" + 793-501

71

2 x 057 565 40 "R" + 793-501

73

057 565 38 "R" + 793-501

74

057 565 37

75

4 x 057 565 40 "R" + 793-501

79

057 565 37

80

057 565 40 "R" + 793-501

81

057 565 39 "R" + 793-501

82

057 565 37

83

057 565 40 "R" + 793-501

84

2 x 057 565 38 "R" + 793-501

86

057 565 39 "R" + 793-501

87

057 565 37

88

057 564 17

Optional1 :

Projektgruppe :


Optional2 :


D-4/40



Optional5 :


Optional6 :


Optional7 :

M. Vogt TEE

Lieferadresse :

210-112 5.20 x 25.00 [mm]


008 911 63


BOMAG

Seite 2

1005

18.4



Optional1 :

Projektgruppe :


Optional2 :


D-4/40



Optional5 :


Optional6 :


Optional7 :

M. Vogt TEE

Lieferadresse :

210-112 5.20 x 25.00 [mm]


1006


BOMAG

Seite 3

008 911 63

18.4



Optional1 :

Projektgruppe :


Optional2 :


D-4/40



Optional5 :


Optional6 :


Optional7 :

M. Vogt TEE

Lieferadresse :

210-112 5.20 x 25.00 [mm]


008 911 63


BOMAG

Seite 4

1007

18.4



1

057 564 17

2

2 x 057 565 40 "R" + 793-501 + 057 565 36

4

057 565 39 "R" + 793-501

5

057 565 37

6

057 565 38 "R" + 793-501

7

2 x 057 565 40 "R" + 793-501

9

057 565 38 "R" + 793-501

10

057 565 37

11

2 x 057 565 40 "R" + 793-501

13

057 565 39 "R" + 793-501

14

057 565 37

15

057 565 40 "R" + 793-501

16

057 565 38 "R" + 793-501

17

057 565 40 "R" + 793-501

18

057 565 37

19

057 564 21

20

057 564 25 "L" + 793-501

21

057 564 17

Optional1 :

Projektgruppe :


Optional2 :


Messtechnik D


Klemmenleiste X2

Optional5 :


Optional6 :


Optional7 :

M. Vogt TEE

Lieferadresse :

210-112 5.20 x 25.00 [mm]


1008


BOMAG

Seite 1

008 911 63

18.4



Optional1 :

Projektgruppe :


Optional2 :


Messtechnik D


Klemmenleiste X2

Optional5 :


Optional6 :


Optional7 :

M. Vogt TEE

Lieferadresse :

210-112 5.20 x 25.00 [mm]


008 911 63


BOMAG

Seite 2

1009

18.4



1

057 564 17

2

4 x 057 565 40 "R" + 793-501

6

057 565 37

7

2 x 057 565 40 "R" + 793-501

9

4 x 057 565 38 "R" + 793-501

13

2 x 057 565 39 "R" + 793-501

15

057 565 37

16

057 564 17

Optional1 :

Projektgruppe :


Optional2 :


E2 Beleuchtung



Optional5 :


Optional6 :


Optional7 :

M. Vogt TEE

Lieferadresse :

210-112 5.20 x 25.00 [mm]


1010


BOMAG

Seite 1

008 911 63

18.4



Optional1 :

Projektgruppe :


Optional2 :


E2 Beleuchtung



Optional5 :


Optional6 :


Optional7 :

M. Vogt TEE

Lieferadresse :

210-112 5.20 x 25.00 [mm]


008 911 63


BOMAG

Seite 2

1011

1012

BOMAG X22

X48 X49

X48 X49

X22

X58

X59

X58

X59

X19

X18

X69

X5 X54

X19

X18

X53

X76 X56 X17

X17

X53 X54

X74 X75

X69

X5

X56 X76

X74 X75

X38 X2 X44

X1

X4 X3

X14

X13

X6 X7

X60

X9

X61

X9

008 911 63

Name: Seis

Name: Vogt


X67 X8 X10

X61

X60

X6 X7

Gepr.: 03.01.2007

X20

X21

X67 X8 X10


X55

X77

X20

X21

Gez.: 03.01.2007

X38

X37 X44 X2

X36

X46

X77 X4 X3

X37 X1

X36

X14

X42 X11 X12

X46

X42

X13

X11 X12

X55

Replaces:

Ers. f.:

page: 1

Seite: 1

von: 1 from: 1

582 702 29 Sheet No.: 301

Blatt Nr.: 301



008 911 63

BOMAG

1013

18.5


Wiring diagram 582 702 41 Design status: from February 2008

1014

BOMAG

008 911 63

008 911 63

001 002 003 004 005 006 007 008 009 010 011 012 013 101


582 582 582 582 582 582 582 582 582 582 582 582 582 582

702 702 702 702 702 702 702 702 702 702 702 702 702 702

41 41 41 41 41 41 41 41 41 41 41 41 41 41

BOMAG

06.12.2007 Vogt 06.12.2007 Seis


Stromlaufplan Versorgung, Starten, Motordrehzahl Motor−Heizflansch, Signalhorn, Kraftstoffvorwärmung Bremse, Rückfahrwarneinr., Überwachung Anzeigen Fahrstufen, Sitzkontaktsch., Vibration ZA Messtechnik BOMAG Compaction Management BCM, GPS ZA Beleuchtung und StvZO ZA Kabine, Beleuchtung, Radio, Tachograph ZA Kabinenheizung, Klimaanlage, Zusatzheizung Diebstahlschutzsystem D−4, D−40, DHC−4, DH−40 Bauteilliste

Funktionsgruppe

BW 177..219 D−4/D−40 BW 177..219 D−4/D−40



001

001

18.5 001

582 702 41

Circuit Diagram supply, starting unit, engine−speed engine heating−flange cont., warning horn, fuel pre−heater brake, back up alarm, monitoring indicators speed−ranges, seat−switch, vibr. option measurement equipm. BOMAG Compaction Management BCM, GPS opt. illumination and StvZO opt. cabin, headlights, radio, tachograph opt. cabin−heater, air conditioning, add. heater anti − theft system component listing

function unit


1015


BOMAG

50A

1

2

125A

F00

1

2

Batterie battery

31

S30

06.12.2007 Vogt 06.12.2007 Seis

2

X1

X1

K61/85

4:4

W 6:2

K36

8:2

5:6

K09

X37:A

2:18

X1:55

K11

X1:3

X1

15

2

1

3:2

85

86

K05 4:3 87

K11:86

X1:4

79

M −

Y01

S120

BW 177D−4

2

Y139 1

45

2

Y01 1

12

11

X1

X1

3:2

80

87

2:16

K114

2

1

K05/87A

87a

30

Startmehrmenge start boost fuel Minusangleichung boost−fuel

50

15:54

K35 2:16

2:10

Schalter Motordrehzl switch engine speed 211...219D−4/40 177...213 D−40 USA

X1:53

50a

X38:A

Starter starter

30

M01

87a

30

X37:B

19 17

X1 X1 8 7

54 58 15:54 2:13

30

11:2


85

86

87a

30

30A

X1:15A


X1:168

12:7

85

86

K61 R10 82 OHM 2:6 2 87

1

D+ MESX

X1:66

W

D+

65

1

85

1

2:10

V01

B+

K61 86

125mA

Generator generator

2:8

B−

G02

B+

Trennschalter Batterie break switch battery

Batterie battery

2

1

−

1

F159

3:2

3:2

−

50A

2

F159:2

F158:2

X1:9

G01 +

1

F158

Sicherung Glühwendelkerze 1 fuse Glow plug 1

X36:B

Sicherung Glühwendelkerzw 2 fuse glow plug 2

S00

nur bei Klimaanlage

F13

only acc.to air conditioning

X1:10

Nur bei BW 177D−4 only at BW 177 D−4

X1:15E

125mA

X36:A


G03 +

125A

2

Sicherung Heizflansch fuse heating−flange

F48

3:2

85

86

81

24

23

2:14

85

−

AW + HW

2x2.5qmm


62 63

1

K11

X1:151

K22

12

11

X1 55

2

1

54

87a

30

X1:152

22

21

27A

2

1

1

32

31

31 3:1

?

?

S01:21

F14:2

K32:86

X1:30A

15A

1 F39

X1:30E

2

8:1

7:9

7:9

11:2

K11/87 3:1

30


008 911 63

002

582 702 41


Y13

87

5:2

87a

30

27E

X1

X1

15A

F14

X1

2:10 87


S01

nur ohne Sitzkontaktschalter without switch seat−contact X1 X1 58 59

87

17A

2

1

17E

X1 X1

70A/1A

Y120

X1:56

1

V47

2

X1:60

K35

86

87a

K114 2:14

30

X1

20A

F105

X1

AUX

K30

4qmm

F48:2

B+

option Option

2:6

3.8A

4:5

1016 8:5

18.5

F158:2

2:2


BOMAG

2

1

87(4)

30(3)

52

X1

3

7

4

X1

6

1

64

3:2

K14


06.12.2007 Vogt 06.12.2007 Seis

2

1

X1

X1

78

75

220K−OHM

2

1

H

50A

R78

3:9

K14.1

2

1

87

30

Glühwendelkerze 1 glow plug 1 Glühwendelkerze 2 glow plug 2

50A

R02

31

Glühzeit Steuergerät modul−glowing−control

Nur bei BW 177 D−4 only at BW 177 D−4

X67:2

R79

X67:1

X1:218

2

1

X1:217

Kraftstoffvorwärmung fuel pre−heater

Motor−Heizflansch, Signalhorn, Kraftstoffvorwärmung engine heating−flange cont., warning horn, fuel pre−heater

3:12

57

85

86

A13 R

X1

K14.1

L

15 TK 50 30

S03

23

24

13

14

X1:155

28A

2

X1


2

B11 1

1

99

X1 97 98 X1 X1 101 102

X1

X1

10A

28E 1

1

57

2

1

5

37A

2

F23

X1

V21


Sensor Kühlmitteltemperatur sensor collant temperature

A13

2

2

R26

1

X1

25A

37E 1

4.2A

100

1


X1

2

B11 1

1

Heizflansch heating−flange

31

R19

3:5

K14

X1

F124

X1

2

2:20

K11:86

F48:2

167A

2:10

B113

2:14 K05/87A


F159:2

GLÜH

2:3


2:3

2

5:12

K11/87 4:1

003

31 4:1


K11/87

4.2A

008 911 63

2:20


18.5

V22

1017

Option Winterpaket option winter package


geöffnet in 0

BL/BU

B13


3:20

31

X1:149

X12

4:3

K48

3 X12

SW/BK

BR/BN

X12

X1:156

X1

10A

F25

2:11

85

86

K05

87

85

86

5:6

30

87

X1:117

2

1

X1

06.12.2007 Vogt 06.12.2007 Seis

K26

4:8

129

8:2 BRAKE MESX

X1:150

12

X1:147 11

SW/BK

BR/BN

X13 1

X1

H14+ − X9

X9

K26/87A

87

30

X1:117

2

1

114

K26 4:6 87a

F25:2


85

86

X1:153

X13 3 X13 2

BL/BU

B14


Y04

X1:113

S01 7:9 2:18

K48:87A

87a

K36 2:7

30

K48/86

K48 4:2 87a

X1:148

2

1

29A

2

29E 1


X1

125mA

K11/87

125mA


3:20

2.5A

BOMAG 300mA

1018

125mA

7:9

Bremse, Rückfahrwarneinr., brake, back up alarm,

7:2

1

1


008 911 63

004

582 702 41

31 5:1

K11/87 5:1

18.5

4:20

2:18

31

K22

X1

+

X1

X1

P

89

10:5

86

F24:2

7:9

Bel.

X1:82

SITZ

BEL

OUT1

OUT2

15/54

06.12.2007 Vogt 06.12.2007 Seis

X10

R03

X10

X1

X1

X1

69

10

HOURS

X1

Bremse

X1

X1:117

P

Hydraulikölfilter

X1

B21

87

4

4

3

106

110

17

X1

B03

X1:57

P

Luftfilter

X1

4

3

67

71

16

X1:61 2

B30

_t

1 P

Motoröldruck

X1

X1

B06

X1:74

X1:77

8

2

1

73

76

11

B06:1

7:9 Q

B55

15

Sitz

X21:2

X21:1

X1:68

GLÜH

1 X8

X8

−

+

X1 107

X1

B124

X1 111

X1

A68/6

BL−L

BL−R

BL−W

2

108

112

Überwachung monitoring

7:9

10:16

10:16

10:16

3:7


Blinker links

Blinker rechts

Warnbl.

Vorglühen

X1:72

21

22

9

13

12

14

3

Wasserabscheider

Öltemperatur

Sensor Wasserabschei Luftfilter Motoröldruck sens. water separator air cleaner engine oil pressure Kühlmittelstand Öltemperatur Hydraulikölfilter coolant stock level hydraulik oil cleaner oil temperature


K48:87A 4:3

2:7

X1:117

3

bl

2 or

105

109

1

FUEL


25

5

23

24

26

Sammelanzeige monitoring module A15 6:1


85

86

90

X1:31A

2

GND

1

Tankanzeige

10A

D+

K61/85

7:9

D+

F24

6:6 B30:2

X1:31E

H07

BOMAG Sensor

K11/87

Kühlmittelfüllstand

008 911 63

4:20

20 21

25

1

26

19

7 13

5

8

3

14

1


1

31 6:1

18.5 005

582 702 41

X5:1−26

K11/87 7:1


1019

5:20

31

2:6

P12

W

−

X1:70

G

−

2

1

R04

X1:223

X1:227

G

P02

+

06.12.2007 Vogt 06.12.2007 Seis

Option option

−

Hydrauliköltemperatur hydraulic oil temperature

Hydrauliköltemperatur hydr.oil temp.

X1:82

n

+

P03

+

Voltmeter volt meter

V

Drehzahlmesser RPM meter

+

−

X1:228

X1:226

G

P14

X1:225

B30:2


F24:2

br

bei BW213 bl

bei BW177 sw

B16

X1:187

X1:190

ws

A06

X22:3

X22:4

OUT+

15/54

−

1

3

Elektronik transducer

sw

gg

X1:191

−

PIN 3: + PIN 3: +

BW 216 DHC−4 BW 219 D−4

Anzeigen indicators

ZA Frequenzanzeige option frequency meter

PIN 1: −

BW 213−214 DHC−4/DH−40

−−−− −−−− PIN 1: −

X1:192

P05

4

OUT−

BW 177−179 D−4/40 BW 177−179 DHC−4/DH−40 BW 211−216 D−4/40

bl

−

+

br

bei BW177 bl

X22:1 X22:2

+

−

+

P03:E1

E03

Lern

2

1

2

OUT+ P07:E1

E73

11:6

1

P04

X1

X1

93

−

+

92

2

1

1

2

31 7:1

10:5


008 911 63

006

582 702 41

PXX:E1

E22

1

BEL ANZ


Beleuchtung Anzeigen illumination indicators

P04:E1

E04

1

SPEED TAC

SPEED MESX 8:2

DIR MESX 8:2

−

A05

Test


X1:172

speed

dir. X1:173


X1:174

B60

X1:171


15/54 in

5:4

BOMAG

5:8

bei BW213 sw

X1:189 in X1:188

Geschwindigkeitsanz. speedometer

1020 OUT−

18.5

Frequenzanzeige frequency meter

Aufnehmer Vibration transducer vibration

6:20

31

Y30

X1:124

2

Y31

V03 1 2

1.23A

5:3

5:12 SITZ

A68/6

V09

1

A68

V05

4

1

13

D+

14

X1 88

6

S58

X14 A

4

3

X11

X14 S13

X1:157

B

11

X1:158

9

Modul Sitzschalter/Vibration module seatswitch/vibration

12

Öldruck


X1:124

2

1

X1:141

X1:143


X1:124

2

1

1

X1:162

F14:2

K48/86

S01:21 2:20 K26/87A 4:8

2:20

4:3

D+

Fahren

1

06.12.2007 Vogt 06.12.2007 Seis

V02

X1:142

2

1 5 7 3



nur BW216+219D−4 only BW216+219D−4

X1:138

2

1

X1:137

2

X1:144


S42

1234

Y30

1

X1:141

X1:143

14

13


Y31

S42




1.23A

F25:2 4:8

1.23A

B06:1

X1:149

5:6 5:10


X11

Taster Vibration pushbutton vibration X1:149

BOMAG 2

X6

Y07

X1:116 X6

S35 13

14

1

15

a X7

Y08

X1:115 X7

2

1

b

X1:160

14

13



2

1

X1:161

24

23

X1:159

5


3.33A

2 X1:118

2

3.33A

K11/87

1

KA MESX

GA MESX

K04

X1:32A

15A

F03

X1:32E

1

8:2

8:2

S

30

2

1

56b

31

56

X1:149

008 911 63

K11/87 10:1

18.5 007

582 702 41

31 8:1

Modul Vibration modul vibration Nur ohne Sitzkontaktschalter without switch seat−contact

5:20


1021

11:6 GA

10A

7:20

2:7

4:5

6:17 6:17

7:17

7:17

F148:2

BRAKE MESX D+ MESX


31

15A

9:2

X1:35A

2

X44:57

06.12.2007 Vogt 06.12.2007 Seis


GA MESX

Pot. 15

X2:57

2

Leistung

X1:33A

X44:28

F146

X1:34A

10A

F84

X1:34E

X1:146

X44:38

F148

X44:56

S01 2:18

X44:58

1

X44:59

X44:15

X1:35E

2

1

32

31

X44:54

1

X44:14

X1:33E

Elektronik

X2:54

X48:3

X48:2

X2:56

X2:58

X49:3

X49:2

X2:60

10:7 X2:79

X2:59

X49:4

15g/bl

−/gg

B62

X49:1

X2:57

X44:25

9:2

X2:49

GND


Anschluß ohne StvZO Bel. connection without StvZO

BEL MESX 10:4

BEL MESX STVZO

X2:55

X48:4

15g/bl

−/gg

B62

X48:1

X2:53


X1:145

Aufn. vorne 15g

+/sw X44:31

Pot 15

Aufn. hinten 15g

F146:1 9:2

X44:30

K11/87

X44:37


X44:25

10:20

X44:60

X44:35

X44:29 X44:41

GND

X2:52

X44:1

X2:71

X2:63

AGND MESX

X44:55

Pot 30

GND

RxD

X2:66

TxD

X2:65

X4:B

X2:64

X74:2

X4:A

X2:70

X74:1

P11

X2:66

X44:67

+/sw X44:7 GPS


X4:C X74:3 X44:4

X4:E

X4:D X74:5

P16

−


+

CAN+

F1

CAN3+

1

CAN−

X2:50

F2

−



X1:82

+ P07 E VIB

X1:85

X44:5

30

X44:3

2:20

X44:66

Drucker printer

EVIB


X44:27


X42:2 X42:3 X46:A X46:E

X42:1 X46:B

1

CAN3+

31 9:1


008 911 63

008

582 702 41

9:2

CAN3− 9:2

CAN3−

X2:51

X42:5

X42:4

R20 1 2 60OHM

X46:F

X46:D

P33

X2:48 X2:49

X2:47

30 10:1


X44:33

X74:4

X44:68

BOMAG

X44:53

CAN1−



1022 X44:26

18.5

X44:36

008 911 63

BOMAG

8:20

31

8:4

8:10

8:2

F146:1

X44:25

F148:2

8:18 CAN3+

8:18 CAN3−

06.12.2007 Vogt 06.12.2007 Seis

GND

RxD1

TxD1

RxD2

TxD2

15

30

X71:7

X71:3

X71:10

X71:8

X71:5

X71:6

X71:12

X78:1

X78:4

X78:3

X78:2

X72:C

X72:D

X72:E

X72:B

X72:A

BOMAG Compaction Management BCM, GPS BOMAG Compaction Management BCM, GPS

nur bei StarFire GPS only at StarFire GPS

GPS Empfänger StarFire GPS Receiver StarFire

A93

X73:C

X73:B

X73:A

5A

X4

X2

H

X4 J

X4

X2 X2 43 44

2 X2 80A

X2 80E 1

F150

X75:7

X4

X2

N

X76:2

X70:5

X70:2

X70:3

X76:1

X2:63

1

1


BCM 05

P15

X75:2

X4

X2

R92 1 2 60 OHM

61


X4:F

G

70

CAN3+

M

62

CAN3−

31 10:1

Wiring diagram 582 702 41 009

582 702 41

18.5

1023

87a

31

2

2

E16 1 E17 1

8:8

X1:84

S53

10:10

14

13

32

31

85

86

06.12.2007 Vogt 06.12.2007 Seis

K06

BEL MESX



9:20

87

10:9

K16 30

S15

012


24

23

BEL MESX STVZO 8:8

2

2

2

10:2

K16



2

E13 1 E12 1 E14 1 E15 1

5:4

6:19

X1:24A

15A

15A

X1:23A

F10

F09

X1:24E



X1:23E

BEL

BEL ANZ

12

11


86

X1:22E 15A

F19

4

E25 1 2

E23 1 2

2

2



X3:1

01

H06

14

13

X1:19A

5:12 5:12

S37

−

+

24

23

BL−W

L0R 24

14

49L

23

13

A02

E11 1 2

E10 1 2

2

2

R

E09 1

L

49R


1

008 911 63

010

582 702 41


1

Wiring diagram 582 702 41 Blinkleuchte HR indicator rear, RH

31

11:1

K11/87 8:2 30

E08 1

X1:96

X1:91

31 82

30

L0R

X1:25A X1:305


5:12

BL−R

BL−L



S14


E28 1

X3:5

X1:22A


85

E

5

87a

E27 1

X3:4

X1:21A

15A

F22

X1:21E

87

10:4

K06

15A

X1:26A X1:83

X60:3 X1:319

X1:323 X60:4

X1:18A

X1:25E F08

30

X1:19E 15A

X1:2

10A

X1:311 X58:3 X1:315 X58:6

15A

0,42A

X58:5 X1:309

X1:315 X58:6

X59:3 X1:312 X1:316 X59:6


F07

0,42A

X1:301

X1:302

F18

0,42A

0,125A

X1:26E

0,42A

X59:5 X1:310

X1:316 X59:6

X1:303 0,125A

F11

X1:304

X1:18E

4,6A

X61:3 X1:320 X1:324 X61:4


X1:308

K11/87 30

X58:6 X1:315

8:19

4,6A

Arbeitsscheinwerfer hinten rechts working head lights, rear rh. 4,6A

X1:313 X58:2 1,75A

X60:2 X1:323


X1:306

X60:1 X1:321

X59:6 X1:316

7:20

1,75A

X59:2 X1:314

X61:2


X1:307

X61:1 X1:322 1,75A

BOMAG

X1:324

1024 1,75A

18.5

12V

XS

11:6

10:20

X3:3

R80

85

86

2

1

11:16 87

K141

31


K32

−

+


S45

E29

10A

F42

TK

2

1

8

H

−

+

+

−

+

−

−

A12

B51 +

06.12.2007 Vogt 06.12.2007 Seis


S86

A01

2

E71 1

87a

30

7

G


15A

1,75A


F143


X3:8

−

87a

3

4 A51 2

5

7,8,9


1

A16

5

3

2

1

6


Radio radio

−

15 + + B51

87

X3:17 4 6:17 SPEED TAC

31

30

K32

11:2

A5+A6

P09

A2+A3

X55:2

M05

M

5

2

1

A

3,8A



− M07

M

+

4

X55:1

15A

F44

X56:2

M04

M

5

2

2

B 10A

F130

+

E70

11:9 F130

4

S158

4

3

2

1

3

C

K141

I


11:2

2

1 E28

E72

E27

2

1

F130 12:7

STV1

STV2

1

2

−

+

1

XS 12V

1

5

5

E

15A

F144

12:2

12:14


31 12:1

12:11

−

+

6

F

K32:87

F41:5

KABINE 31

2

1

S38

10A

F41

ZA option

E32

1 E25

4,6A


2

1 E23

4,6A



15 31

1

S163 5

10:13 10:13


− M06

M

3,8A


S20

01W 7 01



C3

B4

B3

A1

S21

01W 7 01

F42 12:8 F130 11:14

15A

F43

X55:3

2:20

2,9A

30

X56:4

X3:7

X56:3

2:11

X56:1

12:14

4,7A

0,83A


F42:H

4,6A

K32:86


Steckdose Fahrerst.


4,6A

X3:6

5A

2:11 K30

X3:16 GA X3:15

7:17

KA 7:16

X55:4 X3:1

3 min

BOMAG X3:2

Steckdose Kabine socket cabin

008 911 63 Abfallverzögert


011

582 702 41

18.5

1025


11:20 31

ge

M09

rt

or

X3:12

ge


06.12.2007 Seis 06.12.2007 Seis


br

rt

M

or

2

V04 1

2

X18:2

_t

B131

X18:1

X1:167

X3:14

11:19

2

1

2

1 X54:1

KABINE 31


X1:168

Y138

1

X54:12

2

X54:2

3 A72 Steuergerät control unit 11 12

X54:3

X54:11

6

4

X54:4

M −

+

2

1

Inline Sicherung inline fuse

Frischluft Lüfter blower fresch air

X69:2

M17

X69:1

3A

F97



1

HP

2

1

87a

30

Y15

X20:2

X1:170

B104 4 P LP 3

X19:2 X20:1

_t

B103

X19:1

X1:169

87

2:8

K09

X3:13

X54:6

V06

11:17 F130 Potential 15 aus Kabine F42 11:9 Potential 30 aus Kabine


X1:164

X17:4


X53:L

X3:9

X17:1 X1:163

0123

X53:M

X3:10

X17:2 X1:165

S44

X53:C

X53:H

X3:11

X17:3 X1:166

X53:B

4

D


20A


F31

X20:4 3,5A

1A

BOMAG X1:154


11:20 K32:87 Potential 15 aus Kabine

2.5qmm

1

1

A

2

3

BOX2

2

1

9

8

7

4

15


Power Stufe = 2,8A

große Stufe = 1.9A



Regel aus = 0,4A

12 11 13 14 16

10 6


X77:2

Y14

X77:1

5


20A

F40

11:19 F41:5 F42:H 11:4

Option option

1026 2.5qmm

1


2

5

6

8

4

12

31 13:1

9

10 1

BOX2

11 3 S28

7

2

B


008 911 63

012

582 702 41

5A

F15

18.5

ZA option

06.12.2007 Vogt 06.12.2007 Seis

MV014

Steuereinheit control unit

008 911 63 Diebstahlschutzsystem D−4, D−40, DHC−4, DH−40 anti − theft system

A66

A67 Keyboard keyboard

6 9 VAL

8 0

7 ANN

3

5

2

4

1

1

1

18.5

BOMAG 013

582 702 41


1027

Name

title

TYP

Bl. 010 006 006 011 003 003 005 011 011 013 013 007 012 008 009 009

Pf. 17 17 10 5 4 9 9 7 6 9 15 10 11 6 18 7

Blinkgeber Elektronik Geschwindigkeitsanzeige Elektronik Frequenzanzeige vorne Radio Steuergeraet Heizung Steuergeraet Heizung Ueberwachungsmodul Elektronik Tachograph Platine Frequenzanzeige Elektronik Steuereinheit Eingabeeinheit Modul Sitzkontakt Steuergeraet Klimaanlage, Heizung Elektronik Messtechnik USB−CAN Schnittstelle BCM GPS Antenne

flasher Electronic system, speedometer electronic frequency−meter, front Radio Control unit, heating Control unit, heating monitoring module Electronic system, tachograph Circuit board,frequenzy meter Electronic control unit Keyboard Modul seat contact Control unit,air conditioning,heating electronic measurement−equipment USB−CAN Interface BCM GPS antenna

B03 B06 B11 B11 B13 B14 B16 B21 B30 B51 B51 B55 B60 B61 B62 B62 B103 B104 B113 B124 B131

005 005 003 003 004 004 006 005 005 011 011 005 006 008 008 008 012 012 003 005 012

8 10 16 18 2 6 9 7 9 5 6 11 14 12 8 10 7 7 4 12 10

Unterdruckschalter Luftfilter Druckschalter Motoroel Signalhorn Signalhorn Naeherungsinitiator Fahrhebel links Naeherungsinitiator Fahrhebel rechts Aufnehmer Vibrationsfrequenz vorne Differenzdruckschalter Hydr.−Oelfilter Temperaturschalter Motoroel Lautsprecher Radio Lautsprecher Radio Kuehlmittelstand Ausgleichsbehaelter Aufnehmer Achsgeschwindigkeit Aufnehmer Verstellzylinder Beschleunigungsaufnehmer Beschleunigungsaufnehmer Temperaturschalter Klimaanlage Druckschalter Klimaanlage EMR Temperaturgeber Kuehlmittel Geber Wasserstandsabscheider Diesel Temperaturschalter Heizung

Vacuum switch, air cleaner Pressure switch, engine oil Warning horn Warning horn Proximity switch, travel lever, lh. Proximity switch, travel lever, rh. Transducer, vibration frequency, front Pressure diff. switch, hydr. oil filter Temperature switch, engine oil Speaker radio Speaker radio Coolant charge expansion tank Sensor, axle speed Sensor, ajustable zylinder Acceleration sensor Acceleration sensor Temperature switch, air conditioning Pressure switch, air conditioning EMR Temperature switch, collant Sender, water separator fuel Temperature switch, heating

E03 E04 E08 E09 E10 E11 E12 E13 E14 E15 E16 E17 E22 E23 E23 E25 E25 E27 E27 E28 E28 E29 E30 E32 E70 E71 E72 E73

006 006 010 010 010 010 010 010 010 010 010 010 006 010 011 010 011 010 011 010 011 011 012 011 011 011 011 006

16 17 17 18 19 19 7 6 7 8 2 2 19 11 18 12 19 10 17 11 17 4 15 19 15 3 16 18

Beleuchtung Drehzahlmesser Beleuchtung Geschwindigkeitsanzeige Blinkleuchte vorne links Blinkleuchte hinten links Blinkleuchte vorne rechts Blinkleuchte hinten rechts Parkleuchte links Schlussleuchte links Parkleuchte rechts Schlussleuchte rechts Scheinwerfer links Scheinwerfer rechts Beleuchtung Temperaturanzeige Hydr.−oel Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer hinten links Arbeitsscheinwerfer hinten links Arbeitsscheinwerfer hinten rechts Arbeitsscheinwerfer hinten rechts Innenleuchte Kabine Heizgeraet Kennleuchte Nachtleuchte Kontrolleuchte Schalter Heckscheibenheizung Beleuchtung Bedienschalter Beleuchtung, Evib−Meter

Illumination, rpm meter Illumination, speedometer Indicator, front, lh. Indicator, rear, lh. Indicator, front, rh. Indicator, rear, rh. Parking light, lh. Tail light, lh. Parking light, rh. Tail light, rh. Head light, lh. Head light, rh. Illumination, temp. gauge, hydraulic oil Working head light, front, lh. Working head light, front, lh. Working head light, front, rh. Working head light, front, rh. Working head light, rear, lh. Working head light, rear, lh. Working head light, rear, rh. Working head light, rear, rh. Inside light, cabin Heating unit Warning light Night lamp indicator light switch rear screen illum. Switches Illumination, Evib−meter

F00 F03 F07 F08 F09 F10 F11 F13 F14 F15 F18 F19 F22 F23 F24 F25 F31 F39 F40 F41 F42 F43 F44 F48 F68 F84 F97 FM4 F105 F124 F130

002 007 010 010 010 010 010 002 002 012 010 010 010 003 005 004 012 002 012 011 011 011 011 002 002 008 012 008 002 003 011

4 18 15 18 6 8 2 10 18 19 5 12 10 16 3 2 3 19 15 19 4 10 13 2 6 5 13 11 16 14 15

Hauptsicherung Batterie Sicherung Vibration Sicherung Warnblinker Sicherung Blinker u. Arbeitsscheinw. Sicherung Park− u. Schlussl. links Sicherung Park− u. Schlussl. rechts Sicherung Scheinwerfer links Sicherung Startschalter Sicherung Hubmagnet Motor Sicherung Heizgeraet Vorsicherung Arbeitsscheinw. vorne Sicherung Arbeitsscheinw. vorne li. Sicherung Arbeitsscheinwerfer hinten Sicherung Signalhorn Sicherung Ueberwachungsmodul Sicherung Magnetv. Fahren u. Bremse Sicherung Kabinenluefter Hauptsicherung Kabine Sicherung Kabinenheizung Sicherung Rundumkennleuchte Sicherung Kabineninnenleuchte Sicherung Wischermotor hinten Sicherung Wischermotor vorn Sicherung Gluehanlage Sicherung Potential 30 Sicherung Steuerung (Klemme 54) Sicherung Frischluftluefter Platinensicherung Sicherung Motordrehzahl Sicherung Kraftstoffvorwärmung Sicherung Nachtleuchte

18.5

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1028

Benennung

A02 A05 A06 A12 A13 A13 A15 A16 A51 A66 A67 A68 A72 A83 A87 A93

Wiring diagramMODUL 582 702 41

Fuse, main, battery Fuse, vibration Fuse, hazard light Fuse, indicators a. work. head light Fuse, parking and tail light, lh. Fuse, parking and tail light, rh. Fuse, head light, lh. Fuse, starter switch Fuse, shut off solenoid, engine Fuse, heating unit Primary fuse, work. head light, fr. Fuse, working head light, front, lh. Fuse, working head lights, rear Fuse, warning horn Fuse, monitoring module Fuse, sol. valve, travel and brake Fuse, cabin ventilator Main fuse, cab Fuse, heating unit cab Fuse, rotary beacon Fuse, inside light cab Fuse, wipermotor rear Fuse, wipermotor front Fuse, glow plug system Fuse, potential 30 Fuse, controller (Pin 54) fuse, blower fresh air Multifuse Fuse, motor speed Fuse, fuel pre−heating BOMAG Fuse, night lamp

MODUL

MAX. 0,12A

MAX.5A MAX.5A

MAX. 1,75A MAX. 1,75A MAX. 1,75A MAX. 1,75A MAX. 0,42A MAX. 0,42A MAX. 0,42A MAX. 0,42A MAX. 4,6A MAX. 4,6A MAX. 4,6A 4,6A MAX. 4,6A 4,6A MAX. 4,6A 4,6A MAX. 4,6A 4,6A 1,75A 5A 0,83A 1,75A

125A MAX. 1,23A 15A 15A 10A 10A 15A 30A 15A BOX2 30A 30A 30A 10A 10A 10A 15A BOX2

125A 5A 10A 3A 20A 25A

008 911 63

Name

Pf. 2 20 4 2 14 3 3

Benennung

Bl. 011 011 008 008 009 002 002

G01 G02 G03

002 4 002 5 002 2

H06 H07 H14

010 15 Meldeleuchte Warnblinker 005 3 Warnsummer Betriebsstoerung 004 8 Warnsummer Rueckwaertsfahrt

Indicator light, hazard light Warning buzzer, breakdown Back−up alarm buzzer

K04 K05 K06 K09 K11 K14 K16 K22 K26 K32 K35 K36 K48 K61 K114 K14.1 K141

007 004 010 002 002 003 010 005 004 011 002 002 004 002 002 003 011

18 3 4 8 10 5 9 2 6 2 16 7 2 6 14 9 16

Schrittrelais Vibration Relais Startstrom Relais Scheinwerfer hinten Relais Klimageraet Relais Klemme 30 auf 15 Relais Vorgluehen Relais Scheinwerfer vorne Relais Hubmagnet Motor Relais Rueckfahrwarneinrichtung Relais Kabine Relais Selbsthaltung Relais Bremskontrolle Relais Fahrhebel 0−Stellung Relais Ladekontrolle Relais Motordrehzahl

Toggle relay, vibration Relay, starting current Relay, head lights, rear Relay, air conditioning Relay, terminal 30 to 15 Relay, glow plug system Relay, head lights, front Relay, shut off solenoid, engine Relay, back up alarm Relay, cabin Relay, holding contact Relay, brake control Relay, travel lever 0−position Relay, charge control Relay, engine rpm

Relais Heckscheibenheizung

relay, heating rear screen

M01 M04 M05 M06 M07 M09 M09 M17

002 011 011 011 011 012 012 012

10 13 10 14 11 3 4 13

Starter Scheibenwischermotor vorne Scheibenwischermotor hinten Scheibenwaschermotor vorne Scheibenwaschermotor hinten Kabinenluefter Kabinenluefter Zusatzluefter

Starter Windscreen wiper motor, front Windscreen wiper motor, rear Windscreen washer motor, front Windscreen washer motor, rear Cabin ventilator Cabin ventilator Additional blower

P02 P03 P04 P05 P07 P09 P11 P12 P14 P15 P16 P33

006 006 006 006 008 011 008 006 006 009 008 008

5 3 19 11 15 8 14 2 6 18 16 18

Temperaturanzeige Hydraulikoel Drehzahlmesser Geschwindigkeitsanzeige Frequenzanzeige vorne Omegameter Frequenz− und Geschwindigkeitsanzeige Drucker Voltmeter Anzeige Kuehlmitteltemperatur BCM 03 Bildschirm Diagnose, Variomatic Opus 21

Temperature gauge, hydraulic oil Rpm meter Speedometer Frequency meter, front Omegameter Frequency− and Speedometer Printer Volt meter Temperature gauge, coolant BCM 03 terminal Diagnostics, varimatic Opus 21

R02 R03 R04 R10 R19 R20 R26 R78 R79 R80 R92

003 005 006 002 003 008 003 003 003 011 009

10 5 4 7 2 17 9 12 14 2 18

Gluehkerze Geber Tankanzeige Geber Hydraulikoeltemperatur Parallelwiderstand Heizflansch Widerstand Widerstand Glühkerze Vorglühen Kraftstoffvorwärmung Heizung Heckscheibe Abschlußwiderstand (1) CAN 3

Glow plug Sender, level gauge Sender, hydraulic oil temp. Parallel resistor heater flange Resistor Resistor glow plug, pre−glowing fuel pre−heater heating rear screen termination resistor (1) CAN 3


002 002 003 007 010 010 011 011 012 002 007 010 011 007 007 012 011 010 007 011 002 011 011

10 18 16 13 15 4 13 10 19 4 15 18 19 3 7 3 4 4 13 4 14 15 16



V01 V02 V03 V04 V05 V06 911 V09

002 007 007 012 007 012 007

6 6 7 8 11 9 10

Diode Diode Diode Diode Diode Diode Diode

Sicherung Heckscheibenheizung Sicherung Kabinensteckdose Sicherung Steuerung MESX (Potential 30) Sicherung Steuerung MESX (Potential 15) Sicherung GPS Receiver Sicherung Gluehkerze 1 Sicherung Glühkerze 2

fuse rear screen heating unit Fuse cabin−socket Fuse Controller (Pot. 30) Fuse Controller (Pot. 15) Fuse, GPS receiver fuse glow plug 1 fuse glow plug 2

Batterie Generator Batterie

Battery Generator Battery


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008

title

F143 F144 F146 F148 F150 F158 F159

63

Diode Diode Diode Diode Diode Diode BOMAG Diode

TYP

18.5 5A 50A 50A 103A 103A

MAX. 0,12A MAX. 0,12A MAX. 1,23A BOSCHW BOSCHW BOSCHW BOSCHW BOSCHL BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHL BOSCHW

4,7A 2,9A MAX. 3,8A MAX. 3,8A

50A

82 OHM 167A 60OHM 220K−OHM 50A 250W 60 OHM


1029

V21 V22 V47

Name

Bl. Pf. Benennung 003 17 Diode 003 19 Diode 002 15 Diode (A7)

X1:1 X1:2 X1:3 X1:4 X1:7 X1:8 X1:9 X1:10 X1:52 X1:53 X1:54 X1:55 X1:55 X1:56 X1:57 X1:57 X1:57 X1:58 X1:59 X1:60 X1:61 X1:62 X1:63 X1:64 X1:64 X1:65 X1:66 X1:67 X1:68 X1:69 X1:70 X1:71 X1:72 X1:73 X1:74 X1:75 X1:76 X1:77 X1:78 X1:79 X1:80 X1:81 X1:82 X1:82 X1:82 X1:83 X1:84 X1:85 X1:86 X1:87 X1:88 X1:89 X1:90 X1:91 X1:92 X1:93 X1:96 X1:97 X1:98 X1:99 X1:100 X1:101 X1:102 X1:105 X1:106 X1:107 X1:108 X1:109 X1:110 X1:111 X1:112 X1:113 X1:114 X1:115 X1:116 X1:117 X1:117 X1:117 X1:117 X1:118 X1:124 X1:124 X1:124 X1:129 X1:137 X1:138 X1:141 X1:141 X1:142 X1:143 X1:143 X1:144 X1:145 X1:146 X1:147

002 010 002 002 002 002 002 002 003 002 002 002 002 002 003 003 005 002 002 002 005 002 002 003 013 002 002 005 005 005 006 005 005 005 005 003 005 005 003 002 002 002 005 006 008 010 010 008 005 005 007 005 005 010 006 006 010 003 003 003 003 003 003 005 005 005 005 005 005 005 005 004 004 007 007 004 004 005 005 007 007 007 007 004 007 007 007 007 007 007 007 007 008 008 004

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6 10 9 10 11 11 4 4 2 11 18 10 18 15 4 9 8 16 16 16 8 16 16 4 12 6 6 8 11 6 3 8 11 10 9 7 10 9 7 10 14 14 4 4 15 5 4 15 3 6 11 3 2 17 19 19 17 16 17 17 18 16 17 5 7 12 13 5 7 12 13 5 8 16 14 5 8 5 7 14 3 6 8 6 4 4 3 8 6 3 8 6 5 5 5

WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten

title Diode Diode Diode (A7) WAGO,E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO, E−box WAGO,E−BOX WAGO, E−box WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO, E−box WAGO, E−box WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO, E−box WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO, E−box WAGO, E−box WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX BOMAG WAGO,E−BOX

TYP

Wiring diagram 582 702 41 FE5B

008 911 63

Name X1:148 X1:149 X1:149 X1:149 X1:149 X1:150 X1:151 X1:152 X1:153 X1:154 X1:154 X1:155 X1:156 X1:157 X1:158 X1:159 X1:15A X1:15E X1:160 X1:161 X1:162 X1:163 X1:164 X1:165 X1:166 X1:167 X1:168 X1:168 X1:169 X1:16A X1:16E X1:170 X1:171 X1:172 X1:173 X1:174 X1:17A X1:17E X1:187 X1:188 X1:189 X1:18A X1:18E X1:190 X1:191 X1:192 X1:19A X1:19E X1:217 X1:218 X1:21A X1:21E X1:223 X1:225 X1:226 X1:227 X1:228 X1:22A X1:22E X1:23A X1:23E X1:24A X1:24E X1:25A X1:25E X1:26A X1:26E X1:27A X1:27E X1:28A X1:28E X1:29A X1:29E X1:301 X1:302 X1:303 X1:304 X1:305 X1:306 X1:307 X1:308 X1:309 X1:30A X1:30E X1:310 X1:311 X1:312 X1:313 X1:314 X1:315 X1:315 X1:315 X1:316 X1:316 X1:316 X1:319 X1:31A X1:31E 911 X1:32063

Bl. 004 004 007 007 007 004 002 002 004 007 012 003 004 007 007 007 002 002 007 007 007 012 012 012 012 012 002 012 012 002 002 012 006 006 006 006 002 002 006 006 006 010 010 006 006 006 010 010 003 003 010 010 006 006 006 006 006 010 010 010 010 010 010 010 010 010 010 002 002 003 003 004 004 010 010 010 010 010 010 010 010 010 002 002 010 010 010 010 010 010 010 010 010 010 010 010 005 005 010

Pf. 2 1 12 13 19 5 18 18 6 13 8 16 2 13 13 16 10 10 16 14 7 3 5 3 4 10 8 10 7 6 6 7 14 15 15 14 16 16 9 10 10 2 2 9 11 11 15 15 14 14 10 10 4 6 6 4 7 12 12 6 6 8 8 18 18 5 5 18 18 16 16 2 2 5 5 9 15 18 18 18 15 2 19 19 2 7 7 17 19 2 7 17 2 7 19 6 3 3 8

Benennung WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK


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582 702 41

008

title WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX BOMAG WAGO E−BOX

TYP

18.5

1031

Name

18.5

07.12.2007 Vogt 07.12.2007 Seis


582 702 41

1032

X1:321 X1:322 X1:323 X1:323 X1:324 X1:324 X1:32A X1:32E X1:33A X1:33E X1:34A X1:34E X1:35A X1:35E X1:37A X1:37E X2:43 X2:44 X2:47 X2:48 X2:49 X2:49 X2:50 X2:51 X2:52 X2:53 X2:54 X2:55 X2:56 X2:57 X2:57 X2:58 X2:59 X2:60 X2:61 X2:62 X2:63 X2:63 X2:64 X2:65 X2:66 X2:66 X2:67 X2:68 X2:69 X2:70 X2:70 X2:71 X2:77 X2:78 X2:79 X2:80A X2:80E X3:1 X3:1 X3:2 X3:3 X3:4 X3:5 X3:6 X3:7 X3:8 X3:9 X3:10 X3:11 X3:12 X3:13 X3:14 X3:15 X3:16 X3:17 X4:A X4:B X4:C X4:D X4:E X4:F X4:G X4:H X4:J X4:M X4:N X6:1 X6:2 X7:1 X7:2 X8:1 X8:2 X9:1 X9:2 XS XS X10:2 X10:3 X11:1 X11:2 X12:1 X12:2 X12:3

Bl. 010 010 010 010 010 010 007 007 008 008 008 008 008 008 003 003 009 009 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 009 009 008 009 008 008 008 008 008 008 008 008 009 008 008 008 008 009 009 010 011 011 011 010 010 011 011 011 012 012 012 012 012 012 011 011 011 008 008 008 008 008 009 009 009 009 009 009 007 007 007 007 005 005 004 004 011 011 005 005 007 007 004 004 004

Pf. 18 19 6 18 8 19 18 18 2 2 5 5 4 4 14 14 14 15 18 19 12 19 17 18 13 8 7 8 7 2 10 9 10 9 17 18 13 15 14 14 14 14 11 12 12 15 15 14 11 11 10 14 14 11 10 10 2 10 12 2 2 2 3 3 4 4 7 10 7 6 6 14 14 14 14 15 15 15 14 15 18 17 14 14 16 16 12 13 8 8 1 20 5 5 13 13 2 2 1

Benennung WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO ZENTRALELEKTRIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK STECKER ROPS/SD STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER ROPS/SD STECKER ROPS/SD STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH Steckdose Steckdose AMP SUPERSEAL AMP SUPERSEAL DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH

title WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. WAGO E−BOX Wago−measurement equip. Wago−measurement equip. conn. ROPS/SR conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. ROPS/SR conn. ROPS/SR conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector Socket Socket AMP connector AMP connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector BOMAG DEUTSCH connector

TYP


008 911 63

Name X13:1 X13:2 X13:3 X14:A X14:B X17:1 X17:2 X17:3 X17:4 X18:1 X18:2 X19:1 X19:2 X20:1 X20:2 X20:3 X20:4 X21:1 X21:2 X22:1 X22:2 X22:3 X22:4 X36:A X36:B X37:A X37:B X38:A X42:1 X42:2 X42:3 X42:4 X42:5 X44:1 X44:3 X44:4 X44:5 X44:7 X44:9 X44:14 X44:15 X44:23 X44:25 X44:26 X44:27 X44:28 X44:29 X44:30 X44:31 X44:32 X44:33 X44:35 X44:36 X44:37 X44:38 X44:41 X44:53 X44:54 X44:55 X44:56 X44:57 X44:58 X44:59 X44:60 X44:65 X44:66 X44:67 X44:68 X46:A X46:B X46:D X46:E X46:F X47:A X47:B X47:C X48:1 X48:2 X48:3 X48:4 X49:1 X49:2 X49:3 X49:4 X53:B X53:C X53:H X53:L X53:M X54:1 X54:2 X54:3 X54:4 X54:6 X54:11 X54:12 X55:1 X55:2 911 X55:3 63

Bl. 004 004 004 007 007 012 012 012 012 012 012 012 012 012 012 012 012 005 005 006 006 006 006 002 002 002 002 002 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 012 012 012 012 012 012 012 012 012 012 012 012 011 011 011

Pf. 6 6 6 13 13 3 3 4 5 10 10 7 7 7 7 7 7 11 11 9 9 10 10 4 4 10 11 11 18 19 19 18 18 13 15 14 14 10 12 5 5 11 10 18 17 2 7 9 8 6 18 5 6 7 4 7 17 5 13 4 4 4 5 5 13 13 14 14 19 18 18 19 18 11 12 12 8 7 7 8 10 9 9 10 3 4 4 3 3 11 11 10 10 7 10 11 11 10 10

Benennung DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH STECKER LÜFTER HKL STECKER LÜFTER HKL STECKER LÜFTER HKL STECKER LÜFTER HKL STECKER THERMOFÜHLER STECKER THERMOFÜHLER STECKER EISSCHUTZ HKL STECKER EISSCHUTZ HKL STECKER DRUCKSCH. KLI STECKER DRUCKSCH. KLI STECKER DRUCKSCH. KLI STECKER DRUCKSCH. KLI STECKER KÜHLMITTEL STECKER KÜHLMITTEL ST. VIBRATIONSAUFNEHM ST. VIBRATIONSAUFNEHM ST. VIBRATIONSAUFNEHM ST. VIBRATIONSAUFNEHM EINSPEISUNG SCHALTKAS EINSPEISUNG SCHALTKAS ST. ZÜNDSCHLOß E−KAST ST. ZÜNDSCHLOSS E−KAS ST.STARTER E−KASTEN STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER STECKER BOP STECKER BOP STECKER BOP STECKER BOP STECKER BOP STECKER AUFN. PLEIGER STECKER AUFN. PLEIGER STECKER AUFN. PLEIGER STECKER AUFN. VORNE STECKER AUFN. VORNE STECKER AUFN. VORNE STECKER AUFN. VORNE STECKER AUFN. HINTEN STECKER AUFN. HINTEN STECKER AUFN. HINTEN STECKER AUFN. HINTEN STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER WISCHER HINTE STECKER WISCHER HINTE STECKER WISCHER HINTE


07.12.2007 Vogt 07.12.2007 Seis


582 702 41

008

title DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector conn. blower conn. blower conn. blower conn. blower conn. sender temp. conn. sender temp. conn. anti−ice air−cond. conn. anti−ice air−cond. conn. pressuresitch air−cond. conn. pressuresitch air−cond. conn. pressuresitch air−cond. conn. pressuresitch air−cond. connector coolant sensor connector coolant sensor connector vibration sensor connector vibration sensor connector vibration sensor connector vibration sensor supply e−box supply e−box connector ignition switch connector ignition switch, e−box connector starter e−box conector adapter BOP conector adapter BOP conector adapter BOP conector adapter BOP conector adapter BOP MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker Connector BOP Connector BOP Connector BOP Connector BOP Connector BOP conn. sender PLEIGER conn. sender PLEIGER conn. sender PLEIGER conn. sender front conn. sender front conn. sender front conn. sender front conn. sender rear conn. sender rear conn. sender rear conn. sender rear conn. blowerswitch conn. blowerswitch conn. blowerswitch conn. blowerswitch conn. blowerswitch conn. heating controller conn. heating controller conn. heating controller conn. heating controller conn. heating controller conn. heating controller conn. heating controller connector wiper rear connector wiper rear BOMAG connector wiper rear

TYP

18.5

1033

Name

Benennung

title

TYP

X55:4 X56:1 X56:2 X56:3 X56:4 X58:2 X58:3 X58:5 X58:6 X58:6 X58:6 X59:2 X59:3 X59:5 X59:6 X59:6 X59:6 X60:1 X60:2 X60:3 X60:4 X61:1 X61:2 X61:3 X61:4 X65:1 X65:2 X65:3 X65:4 X65:5 X65:7 X65:8 X65:9 X65:10 X65:11 X65:12 X67:1 X67:2 X69:1 X69:2 X70:2 X70:3 X70:5 X71:3 X71:5 X71:6 X71:7 X71:8 X71:10 X71:12 X72:A X72:B X72:C X72:D X72:E X73:A X73:B X73:C X74:1 X74:2 X74:3 X74:4 X74:5 X75:2 X75:7 X76:1 X76:2 X77:1 X77:2 X78:1 X78:2 X78:3 X78:4

Bl. 011 011 011 011 011 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 013 013 013 013 013 013 013 013 013 013 013 003 003 012 012 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 008 008 008 008 008 009 009 009 009 012 012 009 009 009 009

Pf. 10 14 13 13 13 17 7 2 2 7 17 19 7 2 2 7 19 18 18 6 6 19 19 8 8 5 5 5 5 5 5 12 5 5 5 5 14 14 13 13 16 16 16 9 9 9 9 9 9 9 12 12 12 12 12 13 13 13 14 14 14 15 14 18 17 16 16 15 15 10 11 11 11

STECKER WISCHER HINTE STECKER WISCHER VORNE STECKER WISCHER VORNE STECKER WISCHER VORNE STECKER WISCHER VORNE STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO HL STECKER STVZO HL STECKER STVZO HL STECKER STVZO HL STECKER STVZO HR STECKER STVZO HR STECKER STVZO HR STECKER STVZO HR KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD STECKER KRAFTSTOFFHEI STECKER KRAFTSTOFFHEI STECKER FRISCHLUFT LÜ STECKER FRISCHLUFT LÜ SUB−D STECKER SUB−D STECKER SUB−D STECKER STECKER GPS ANTENNE STECKER GPS ANTENNE STECKER GPS ANTENNE STECKER GPS ANTENNE STECKER GPS ANTENNE STECKER GPS ANTENNE STECKER GPS ANTENNE STECKER ANSCHL. GPS STECKER ANSCHL. GPS STECKER ANSCHL. GPS STECKER ANSCHL. GPS STECKER ANSCHL. GPS STECKER VERS. GPS STECKER VERS. GPS STECKER VERS. GPS STECKER DRUCKER STECKER DRUCKER STECKER DRUCKER STECKER DRUCKER STECKER DRUCKER SUB D STECKER BCM INT SUB D STECKER BCM INT STECKER VERS. BCM STECKER VERS. BCM STECKER PUMPE STANDHE STECKER PUMPE STANDHE STECKER RTK−MODUL GPS STECKER RTK−MODUL GPS STECKER RTK−MODUL GPS STECKER RTK−MODUL GPS

connector wiper rear conn. wiper front conn. wiper front conn. wiper front conn. wiper front Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO BL Con. STVZO BL Con. STVZO BL Con. STVZO BL Con. STVZO BR Con. STVZO BR Con. STVZO BR Con. STVZO BR Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard connector fuel pre−heater connector fuel pre−heater connector fresh air blower connector fresh air blower SUB−D Connector SUB−D Connector SUB−D Connector connector GPS Receiver connector GPS Receiver connector GPS Receiver connector GPS Receiver connector GPS Receiver connector GPS Receiver connector GPS Receiver Connector GPS Connector GPS Connector GPS Connector GPS Connector GPS Connector Supply GPS Connector Supply GPS Connector Supply GPS con. printer con. printer con. printer con. printer con. printer SUB D Connector BCM SUB D Connector BCM con. Power−sup. BCM con. Power−sup. BCM Conn. pump add. heater Conn. pump add. heater Connector RTK−module GPS Connector RTK−module GPS Connector RTK−module GPS Connector RTK−module GPS

Y01 Y01 Y04 Y07 Y08 Y13 Y14 Y15 Y30 Y30 Y31 Y31 Y120 Y138 Y139

002 002 004 007 007 002 012 012 007 007 007 007 002 012 002

13 14 5 14 16 18 15 7 4 6 3 8 16 10 12

Magnetventil Startmehrmenge Magnetventil Startmehrmenge Magnetventil Bremse D*Prop. Ventil Vibration groß D*Prop. Ventil Vibration groß Hubmagnet Motor Kraftstoffpumpe Heizgeraet Magnetkupplung Klimakompressor Magnetventil Stufenumschaltung vorn Magnetventil Stufenumschaltung vorn Magnetventil Stufenumschaltung hinten Magnetventil Stufenumschaltung hinten Magnetventil Motordrehzahl hoch Magnetveentil Heizung Magnetventil Minusangleichung

Solenoid valve, start boost fuel Solenoid valve, start boost fuel Solenoid valve, brake E*prop. Valve vibration high E*prop. Valve vibration high Shut off solenoid, engine Fuel pump, heating unit Magnetic clutch, air conditioning compr. Solenoid valve, speed range sel., front Solenoid valve, speed range sel., front Solenoid valve, speed range sel., rear Solenoid valve, speed range sel., rear Solenoid valve, rpm engine high Solenoid valve, heating unit solenoid−valve boost−fuel

18.5


07.12.2007 Vogt 07.12.2007 Seis

Bauteilliste component listing

MAX. 1,8A MAX. 2,5A MAX. 2,5A MAX. 3.8A

7

3,5A MAX. 1,67A MAX. 1,67A MAX. 1,23A MAX. 1,23A

7

3,5A

107

582 702 41

1034

BOMAG

008 911 63

X36

X37

008 911 63

BOMAG

X1

X1

K11


X38

A68

K04

K09

Übersicht Schaltkasten BW 177...219 D-4/D-40 overview e-box BW 177...219 D-4/D-40

Gepr.: 06.12.2007

1035

Name: Seis

Name: Vogt

Gez.: 06.12.2007


K26

K114

K61

K48

K35


K36

K05

K06

R10

K16

A02


X1

Replaces:

Ers. f.:

page: 1

Seite: 1

von: 2 from: 2

582 702 41 Sheet No.: 201

Blatt Nr.: 201


18.5

F1

F2

1036 A83 Messtechnik Steuerung

CAN 1


BOMAG

008 911 63

overview e-box door BW 177...219 D-4/D-40


Name: Vogt


BCM

Replaces:

Ers. f.:

page: 2

Seite: 2

OPUS 21

Gez.: 06.12.2007

CAN 3

CAN 1

X2

von: 2 from: 2

582 702 41 Sheet No.: 201

Blatt Nr.: 201


008 911 63

BOMAG X22

X48 X49

X17

X58

X59

X54

X19

X18

X53

X77

X69

X5

X56

X75 X76

X17

X73 X74 X70

X72

X71

X19

X38 X2 X44

X1

X4 X3

X14

X13

X6 X7

X60

X9

X61

X9

1047

Name: Seis

Name: Vogt


X67 X8 X10

X61

X60

X6 X7

Gepr.: 06.12.2007

X20

X21

X67 X8 X10


X55

X77

X20

X21

Gez.: 06.12.2007

X38

X37 X44 X2

X36

X39 X40

X46

X77

X55

X4 X3

X37 X1

X36

X14

X42 X11 X12

X46

X42 X69

X13

X39 X11 X12 X58

X18

X53 X54

X40

X5

X56 X76

X59

X48 X49

X22

X70 X73

X71 X72 X74 X75 X77

Replaces:

Ers. f.:

page: 1

Seite: 1

von: 1 from: 1

582 702 41 Sheet No.: 301

Blatt Nr.: 301


18.5

18.5

1048


BOMAG

008 911 63

BW211-212-213D-40 Service Manual E 00891163.c08.pdf

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