BW213DH-4 BVC Service Manual E 00891179.l07.pdf

Service - Manual

BW 213 DH-4 BVC BW 213 DH-4 BVC with attachment plate Variocontrol / Variocontrol+ S/N 101 583 16 .... S/N 101 583 06 .... S/N 101 582 12 .... S/N 101 582 13 ....

Single drum roller Catalogue number.

008 911 79

12/2007

Table of Contents

General

7 1.1 Introduction

8

1.2 Safety regulations

9

1.3 General repair instructions

14

1.4 Tightening torques

26

Maintenance

31 2.1 General notes on maintenance

32

2.2 Fuels and lubricants

33

2.3 Table of fuels and lubricants

36

2.4 Running-in instructions

37

2.5 Maintenance chart

38

Technical data

41 3.1 Technical data

42

Connection overview

53 4.1 Connection overview

Tests and adjustments

57 5.1 Special tools, tests and adjustments

58

5.2 Activate service mode

62

5.3 Driving against the closed brake

64

5.4 Turn the steering against an end stop.

66

5.5 Pressure tests in the travel circuit

68

5.6 Checking / adjusting the neutral positions of the travel pump

70

5.7 Pressure measurements in the vibration circuit

72

5.8 Check the leakage rate of the vibration motor

73

5.9 Pressure test in steering circuit

74

Flushing and bleeding

77 6.1 Special tools for flushing

78

6.2 Flushing - general

83

6.3 Flushing schematic travel circuit (distribution travel pump)

85

6.4 Flushing the travel circuit (travel pump distribution)

87

6.5 Flushing schematic travel circuit (distribution axle motor)

93

6.6 Flushing the travel circuit (axle motor distribution)

98

6.7 Flushing schematic for vibration drive

103

6.8 Flushing the vibration circuit

104

6.9 Bleeding the travel circuit

108

6.10 Bleeding the vibration circuit

110

Fundamental electrics

008 911 79

54

113 7.1 Understanding circuit diagrams

114

7.2 Terminal designations

118

7.3 Current and voltage

122

7.4 Resistance

126

7.5 Series / parallel connection

128

7.6 Ohm's law

130

7.7 Electrical energy

130

7.8 Formula diagram

131

7.9 Metrology

132 BOMAG

3

Table of Contents 7.10 Diodes, relays, fuses

134

7.11 Batteries

137

7.12 Three-phase generator

140

7.13 Electric starter

148

7.14 Telemecanique switch

151

7.15 Inductive proximity switches

154

7.16 Angle sensor with current output

155

7.17 Plug connectors

156

7.18 Deutsch plug, series DT and DTM

157

7.19 Plugs and terminals in spring clamping technology

163

Special tools, electrics

167 8.1 Special tools, electrics

168

Machine related electrics

177

9.1 Machine related electrics

179

9.2 Electrics MESX

269

Service Training

331 10.1 Service Training Machine

333

10.2 Service Training BVC

411

Engine

467 11.1 Diesel engine

468

11.2 Engine description TCD 2012

469

11.3 Engine description TCD 2013, 4 and 6 cylinder

471

11.4 Lubrication oil circuit TCD 2012 / 2013

475

11.5 Coolant circuit TCD 2012 / 2013

476

11.6 Fuel system TCD 2012 / 2013

477

11.7 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013

481

11.8 Sensors TCD 2012 / 2013

487

11.9 Engine control EDC16 with EMR 3 for TCD 2012 / 2013

502

11.10 Exhaust gas recirculation TCD 2012 / 2013

507

11.11 Fault code monitoring with

display TCD 2012 / 2013

509

11.13 EMR3 List of fault codes

510

11.14 SerDia Service-Software TCD 2012 / 2013

520

11.15 General trouble shooting chart TCD 2012 / 2013

523

11.16 Valve adjustment TCD 2012 / 2013

525

11.17 Ribbed V-belt - fan drive TCD 2012 / 2013

528

11.18 Special tools, Deutz engine (TCD 2012 2V)

529

11.19 Special tools, Deutz engine (TCD 2013 2V) Air conditioning system

4

508

11.12 Fault code display TCD 2012 / 2013

544 563

12.1 Physical basics

564

12.2 Refrigerant R134a

567

12.3 Compressor oil / refrigeration oil

568

12.4 Working principle of the air conditioning system

569

12.5 Monitoring devices

569

12.6 Description of components

570

12.7 Checking the compressor oil level

576

12.8 Checking the magnetic clutch

577

BOMAG

008 911 79

Table of Contents 12.9 Inspection and maintenance work

578

12.10 Checking, replacing the refrigerant compressor V-belt

578

12.11 Service the air conditioning

579

12.12 Drying and evacuation

582

12.13 Emptying in case of repair

582

12.14 Leak test

583

12.15 Filling instructions

584

12.16 Trouble shooting in refrigerant circuit, basic principles

587

12.17 Trouble shooting, refrigerant circuit diagram

591

12.18 Trouble shooting procedure

592

12.19 Steam table for R134a

602

12.20 Heating control / air conditioning control

607

Replacing the cab window panes

613

13.1 Assembly of window panes

614

13.2 Special tools

615

13.3 Auxiliary materials

616

13.4 Removing and installing the window pane

618

Drum

623 14.1 Special tools, drum BW 213/226 DH-4 BVC and Variocontrol

624

14.2 Removing and installing the drum

626

14.3 Changing the rubber buffers and adjusting the pretension

634

Drum

637 15.1 Repair overview for drum 15.2 Assembly of tapered roller bearing

Articulated joint, electric steering

644 651

16.1 Special tools

652

16.2 Repair overview oscillating articulated joint

654

16.3 Removing and installing the oscillating articulated joint

658

16.4 Dismantling the oscillating articulated joint

661

16.5 Assembling the oscillating articulated joint Articulated joint, hydraulic steering

665 675

17.1 Special tools

676

17.2 Repair overview oscillating articulated joint

678

17.3 Removing and installing the oscillating articulated joint

681

17.4 Dismantling the oscillating articulated joint

683

17.5 Assembling the oscillating articulated joint Suppliers documentation

688 699

18.1 Travel pump / vibration pump series 90R

701

18.2 Vibration motor A2FM

791

18.3 Travel drive series 51

821

18.4 Transmission CR

903

18.5 Axle DANA 193

929

18.6 Auxiliary pump for plate, series Circuit diagrams

008 911 79

638

1019 1057

19.1 Wiring diagram

1059

19.2 Wiring diagram

1103

19.3 Wiring diagram

1145 BOMAG

5

Table of Contents 19.4 Hydraulic diagram

6

1187

BOMAG

008 911 79

1 General

008 911 79

BOMAG

7

1.1 1.1

Introduction

Introduction

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

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 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 79

1.2

Safety regulations Important notes 1.2

Safety regulations

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.

●

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

●

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

●

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

●

Keep unauthorized persons away from the machine during repair work.

●

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

●

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

●

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

●

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. .

●

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

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.! ●

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.

General ●

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 79

BOMAG

9

1.2

Safety regulations

●

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

●

Remove combustible parts from the vicinity or cover such parts.

● ●

●

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

Name a fire watch during and after welding work.

●

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.

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

●

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.

●

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.

●

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

Switch the welding unit off before connecting welding cables.

Behaviour in case of faults ●

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 ●

Replace damaged insulating jaws and welding rod holders immediately.

●

Replace the welding wire reels only in deenergized state.

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.

Hydraulics ●

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.

What to do in case of accidents; First Aid ●

Keep calm.

●

Call first air helpers.

●

Report the accident.

●

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.

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. ●

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 79

1.2

Safety regulations Reattach all guards and safety installations after all work has been completed.

plastic material, a so-called fluoroelastomer. Under normal operating conditions this material is safe and does not impose any danger to health.

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.

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.

Fuels

●

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.

●

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.

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. ●

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! ●

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.

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

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.

Synthetic rubber Many O-rings, hoses and similar parts, which are apparently made of natural rubber, are actually made of 008 911 79

BOMAG

11

1.2

Safety regulations

Air conditioning system

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.

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

●

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).

●

Secure pressure vessels against tipping over or rolling away.

●

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.

●

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.

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.

Battery ●

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.

Handling pressure vessels ●

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

12

BOMAG

008 911 79

1.2

Safety regulations ●

Always shield eyes and face towards the battery.

●

●

Do not use battery chargers or jump leads without following the operating instructions.

Do not heat up oil higher than 160 °C because it may ignite.

●

Wipe off spilled oil and fuel.

●

Keep the cell plugs closed.

●

●

After an accident with acid flush the skin with water and seek medical advice.

Do not smoke when refuelling or when checking the acid level in the battery.

●

●

Do not allow children access to batteries.

Do not check the acid level of the battery with a naked flame, danger of explosion!

●

When mixing battery fluid always pour acid into water, never vice-versa.

●

Old batteries contain lead and must be properly disposed of.

●

There is a danger of scalding when draining off engine or hydraulic oil at operating temperature.

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.

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.

Poisonous substances

These fluids and substances are, amongst others, anti-freeze agents, hydraulic oils, washing additives, lubricants and various bonding agents.

Special safety regulations ●

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.

008 911 79

BOMAG

13

1.3

General repair instructions

General 1.3

●

●

Electrics

General repair instructions

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: ●

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:

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 79

1.3

General repair instructions ●

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

●

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)! 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.

●

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

●

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!

●

●

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

●

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!

Battery Rules for the handling of batteries 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". 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.

Electrical system and welding work ●

Surge voltages in the electric system must be strictly avoided:

●

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

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 79

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15

1.3

General repair instructions

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

●

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

●

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.

●

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.

!

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

Clean fittings, filler covers and the area around such parts before disassembly to avoid entering of dirt.

Before commissioning

●

Before disconnecting hoses, pipes or similar relieve the system pressure with the engine shut down.

●

After changing a component clean the hydraulic oil tank thoroughly.

●

During repair work keep all openings closed with clean plastic plugs and caps.

●

Fill the housings of hydraulic pumps and motors with hydraulic oil.

●

Do not run pumps and motors without oil.

●

●

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

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.

●

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.

●

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.

●

Avoid the formation of rust on fine machined caused by hand sweat.

Commissioning ●

Bleed the hydraulic circuits.

●

Start up the system without load. Check the hydraulic oil level in the tank, fill up oil if necessary.

●

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.

After commissioning

●

Use only the specified pressure gauges. Risk of damaging the pressure gauges under too high pressure.

●

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.

●

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

●

Check system pressures and speeds.

●

Check fittings and flanges for leaks.

●

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.

BOMAG

008 911 79

1.3

General repair instructions Air conditioning system

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

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.

●

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-

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 79

BOMAG

17

1.3

General repair instructions

tion colouring matter makes any warranty claims null and void.

Notes on cleanliness for Common Rail engines

●

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.

Special requirements with respect to cleanliness in the fuel system do apply for commissioning, maintenance and repair work, particularly for TEIRIII engines with the DEUTZ Common Rail System. Contamination like dirt, welding residues or similar can lead to the failure of individual components and adversely affect engine operation.

●

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.

Fig. 1 ●

Spare parts should be left in their original packaging as long as possible and should only be unpacked just before use.

●

When parts are unpacked any connections must be closed with suitable plugs or caps, in order to prevent (Fig. 1) contamination of hose connections. If e.g. fuel hoses are connected to one side, while the second side cannot yet be connected, there is a danger of dirt entering into the system. The free connection must in this case also be appropriately closed.

Notes and measures to be applied before starting work in the fuel system

18

●

The fuel system must be closed. Visual examination for leaks / damage in the fuel system.

●

Before starting work in the fuel system clean the complete engine and the engine compartment with the system still closed.

●

The engine should be dry before work is started in the fuel system.

BOMAG

008 911 79

1.3

General repair instructions ●

Blow drying with compressed air is only permitted while the fuel system is still closed.

●

Do not use any previously used cleaning or testing fluids for cleaning.

●

When using steam cleaning equipment cover control unit, cable plugs, all other electrical connections and the generator beforehand and do not expose these items to the direct steam jet.

●

Compressed air should never be used for cleaning when the fuel system is open.

●

Work on disassembled components must only be carried out at a specially furnished work place.

●

When disassembling or assembling components you should not use any materials from which particles or fibres could flake off (cardboard, wood, towels).

●

Dismantled parts must only be wiped off with clean, lint-free cloths if required. No dirt particles must be wiped into the components.

●

Close openings on components and engine immediately with suitable plugs/caps.

●

Plugs/caps must only be removed just before the installation.

●

Keep plugs/caps in their original packaging, where they are protected against dust and dirt, dispose of after one time use.

●

Take new parts out of their original packaging just before installation.

●

Disassembled components must be stored in new, sealable bags or – if available – in the packaging material of the new components.

●

Always use the original packaging material of the new part to return the disassembled old component.

●

Electrical plug connections must be plugged in during jet cleaning.

●

Remove loose parts (e.g. paint scales that may have come off during assembly work) with an industrial vacuum cleaner or any means of extraction.

●

Vacuum cleaning equipment must generally be used for cleaning when the fuel system is open.

●

Perform work on the fuel system only in a clean environment (no dust, no grinding or welding work). Avoid draughts (dust). The workshop floor must be cleaned at regular intervals. No brake or power test stand should be present or operated in the same room.

●

●

Air movements, which could swirl up dust, such as brake repairs or starting of engines, must be strictly avoided. For work, such as disassembly and assembly of defective hydraulic components in the Common Rail System, it is strongly recommended to set up a separate workshop area, i.e. an area which is spatially separated from all other areas (general vehicle repairs, brake repairs).

●

No general machine tools should be operated in this room.

●

Periodic cleaning of this workshop area is obligatory, draughts, ventilation system and heating blowers must be minimized.

●

Engine compartment area where dirt particles could come loose, should be covered with new, clean foil.

●

Working means and tools must be cleaned before being used for work. Use only tools without damaged chromium coating, or tools without chromium coating.

Notes and measures to be applied during work in the fuel system ●

Wear clean working clothes.

●

Use only lint-free cleaning cloths for work in the fuel system.

●

●

Remove loose parts (e.g. paint scales that may have come off during assembly work) with an industrial vacuum cleaner or any means of extraction. Vacuum cleaning equipment must generally be used for cleaning when the fuel system is open.

Notes and measures concerning the workshop area ●

For work, such as disassembly and assembly of defective hydraulic components in the Common Rail System, it is strongly recommended to set up a separate workshop area, i.e. an area which is spatially separated from all other areas (general vehicle repairs, brake repairs).

●

The workshop floor must be sealed or tiled.

●

No welding equipment, grinding machines, general machine tools, brake or power test benches must be operated in this room.

●

Periodic cleaning of this workshop area is obligatory, draughts, ventilation system and heating blowers must be minimized.

Notes and measures for work place and tools in the workshop ●

A special work place must be set up for work on disassembled components.

●

Clean disassembly and assembly tools at regular intervals and keep these in a closed tool cabinet.

Working means and tools must be cleaned before being used for work. Use only tools without damaged chromium coating, or tools without chromium coating.

008 911 79

BOMAG

19

1.3

General repair instructions

●

Remove loose parts (e.g. paint scales that may have come off during assembly work) with an industrial vacuum cleaner or any means of extraction.

●

Working means and tools must be cleaned before being used for work. Use only tools without damaged chromium coating, or tools without chromium coating.

Fuel hoses

Fig. 2

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. !

20

BOMAG

008 911 79

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. ●

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.

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.

Fig. 4

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

Lubricate the outer rim 1 (Fig. 4) of the seal and press it flat on the housing seat.

●

i

Note

If possible, use a "bell" 1 (Fig. 4), 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. 3 ●

Lubricate sealing lips 1 (Fig. 3) 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. 3), to protect the lip from being damaged by sharp edges, 008 911 79

BOMAG

21

1.3

General repair instructions

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. 5 ●

Clean and thoroughly examine the feather key.

●

Debur and thoroughly clean the edges of the keyway with a fine file before reassembling.

Fig. 6

22

●

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 79

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.

●

Fig. 7

Caution When assembling the bearing to the shaft load must only be applied to the inner race 1 (Fig. 7). !

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! ●

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 79

BOMAG

23

1.3

General repair instructions

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. 9 Identification of nuts

In a connection with a screw, these nuts 1 (Fig. 9) must be able to bear the full pre-load at the yield point. Nut height above 0.8 d (d = nominal dimension).

Fig. 8 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. 9) in this group are only able to withstand the force of a screw to a limited extent. Nut height below 0.8 d (d = nominal dimension). Nuts for screw joints without specified load factor (11H, 14H, 17H, 22H) This standard contains strength classes (hardness classes) for nuts 3 (Fig. 9), for which no load values can be specified, e.g. because of their shape and 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.

24

BOMAG

008 911 79

1.3

General repair instructions Identification in clock system

Fig. 10 Identification of nuts in clock system

For small nuts (Fig. 10) 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 79

BOMAG

25

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

26

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

Coefficient of friction μ tot. = 0,14

BOMAG

008 911 79

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 79

BOMAG

27

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

Coefficient of friction μ tot. = 0,14

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

28

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 79

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

Coefficient of friction μ tot. = 0,14

008 911 79

BOMAG

29

1.4

30

Tightening torques

BOMAG

008 911 79

2 Maintenance

008 911 79

BOMAG

31

2.1 2.1

General notes on maintenance

General notes on maintenance

When performing maintenance work always comply with the appropriate safety regulations. Danger Danger of squashing!

Do not draw off fuel from near the bottom of the drum.

●

The rest in the drum is not suitable for the engine and should only be used for cleaning purposes.

Notes on the performance of the engine

!

Maintenance and service work must only be performed with the attachment plates in floating position. For safety reasons the extension plates are then lowered to the ground and the hydraulic lines depressurized. Thorough maintenance of the machine guarantees far longer safe functioning of the machine and prolongs the lifetime of important components. The effort needed for this work is only little compared with the problems that may arise when not observing this rule. The terms right/left correspond with travel direction forward. ●

Always clean machine and engine thoroughly before starting maintenance work.

●

For maintenance work stand the machine on level ground.

●

Perform maintenance work only with the engine shut down.

●

Relieve hydraulic pressures before working on hydraulic lines.

●

Before working on electric parts of the machine disconnect the battery and cover it with insulation material.

●

When working in the area of the articulated joint attach the articulation lock (transport lock).

Environment During maintenance work catch all oils and fuels and do not let them seep into the ground or into the sewage system. Dispose of oils, coolant and fuels environmentally.

On diesel engines both combustion air and fuel injection quantities are thoroughly adapted to each other and determine power, temperature level and exhaust gas quality of the engine. If your engine has to work permanently in "thin air" (at higher altitudes) and under full load, you should consult the customer service of BOMAG or the customer service of the engine manufacturer.

Notes on the hydraulic system During maintenance work on the hydraulic system cleanliness is of major importance. Make sure that no dirt or other contaminating substances can enter into the system. Small particles can produce flutes in valves, cause pumps to seize, clog nozzles and pilot bores, thereby making expensive repairs inevitable. ●

If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components for leaks.

●

Seal external leaks immediately. If necessary inform the responsible customer service.

●

Do not store drums with hydraulic oil outdoors, or at least under a cover. Water can be drawn in through the bunghole when the weather changes.

●

Always use the filling and filtering unit (BOMAG part-no. 007 610 01) to fill the hydraulic system. This unit is fitted with a fine filter to clean the hydraulic oil, thereby prolonging the lifetime of the filter.

●

Clean fittings, filler covers and the area around such parts before disassembly to avoid entering of dirt.

●

Do not leave the tank opening unnecessarily open, but cover it so that nothing can fall in.

Notes on the cooling system

Notes on the fuel system The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel. ●

Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.

●

Drums with inside zinc lining are not suitable to store fuel.

●

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

●

Do not let the hose stir up the slurry at the bottom of the drum.

32

●

For water-cooled engines the preparation and inspection of the coolant is of greatest importance, as otherwise the engine may be damaged by corrosion, cavitation and freezing. The coolant is prepared by mixing a cooling system protection agent into the coolant. The cooling system must be permanently monitored. Besides the inspection of the coolant level this includes also the inspection of the concentration of cooling system protection agent. The concentration of cooling system protection agent can be checked by means of commercial testers (glycomat).

BOMAG

008 911 79

2.2

Fuels and lubricants

2.2

Danger Health hazard! !

The mixing of nitrite based anti-freeze agents with amine based agents results in the formation of health affecting nitrosamines. Environment Cooling system protection agents must be disposed of environmentally.

Fuels and lubricants

Engine oil Quality Lubrication oils are classified according to their performance and quality class. Oils according to other comparable specifications may be used. Approved engine oils Deutz DQC II-05 ACAE E3/96/E5-02/ E7-04 API CG-4/CH-4/CI4 DHD DHD-1

DQC II-05 E4-99/E6-04 -

The exact assignment of the approved oil qualities and oil change intervals can be taken from the following section "Lubrication oil change intervals". Consult your local service station if in doubt. Oil viscosity Multi-purpose oils should be generally used. Since lubrication oil changes its viscosity with the temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class (SAE-class) . Optimal operating conditions can be achieved by using the opposite oil viscosity chart (Fig. 11) as a reference. Occasionally falling short of the temperature limits will impair the cold starting ability, but will not cause any engine damage. In order to keep the occurring wear as low as possible, occasional exceeding of the limits should not happen over a longer period of time.

008 911 79

BOMAG

33

2.2

Fuels and lubricants content of more than 1% you should consult the responsible service agency.

Fuels Quality You should only use commercially available brand diesel fuel with a sulphur content below 0.5% and ensure strict cleanliness when filling in. A higher sulphur content has a negative effect on the oil change intervals. Use only winter-grade diesel fuel under low ambient temperatures. The fuel level should always be topped up in due time so that the fuel tank is never run dry, as otherwise filter and injection lines need to be bled. When using fuels with a Cetan number < 49 poor starting and white smoke can be expected, in particular in connection with low ambient temperatures. The following fuel specifications are permitted: DIN/ EN 590; DIN 51 601; Nato Codes: F-54, F-75; BS 2869: A1 and A2; ASTM D 975-78: 1-D and 2-D.

Fig. 11

●

DIN/EN 590

●

BS 2869

●

ASTM D 975-78: 1-D and 2-D.

●

Nato Codes: F-54, F-34, F44 and XF63

With their better temperature and oxidation stability synthetic lubrication oils offer quite a few benefits.

Winter fuel

Oil change intervals

Danger Fire hazard! !

The longest permissible time a lubrication oil should remain in an engine is 1 year. If the following oil change intervals are not reached over a period of 1 year, the oil change should be performed at least once per year, irrespective of the operating hours reached.

Diesel fuels must never be mixed with gasoline.

ACEA1

For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel.

E3-96/E5-02/E7-04/ E4-99/ E6-04 = 500 operating hours

In most cases a sufficient cold resistance can also be achieved by adding flow enhancing fuel additives. Consult the engine manufacturer.

API2

Operation with rape seed oil methyl ester (RME „Bio Diesel“)

CG-4/CH-4/ CI-4

= 500 operating hours

Caution These intervals apply only when using a diesel fuel with maximum 0.5 % sulphur by weight and for ambient temperatures higher than -10 °C. !

When using fuels with a sulphur content of more than 0.5% to 1% or under ambient temperatures below -10 °C the oil change intervals specified in the table must be halved. For fuels with a sulphur

1 2

34

Due to the extreme quality differences of RMEW-fuels available on the market, which are caused by the nonexistence of a standardization, BOMAG does generally not approve any RME-fuels. If this is neglected the warranty will become null and void! However, if you still intend to operate the machine with RME-fuels you should observe the following information: ●

Reduced engine power (approx. 7%), higher fuel consumption.

●

The quality of RME-fuel should be in compliance with DIN draft 51606.

Association des Constructeurs European d’Automobiles American Petroleum Institute

BOMAG

008 911 79

2.2

Fuels and lubricants ●

Avoid longer periods of standstill (formation of resin, corrosion in injection system)

●

RME-fuel can damage the paint finish of the machine.

●

Fuel dilution of engine oil, therefore shortening of oil change intervals to half.

●

Rubber parts, such as leak fuel return lines, seats will be damaged in the long run and need to be replaced on a regular basis or should be replaced by parts made of fluorinated rubber. However, fluorinated rubber is not resistant against normal diesel fuel.

●

If the fuel filter is clogged the filter change intervals must be shortened accordingly.

Caution Do not mix different coolants and additives of any other kind. !

Danger Health hazard! !

The mixing of nitrite based anti-freeze agents with amine based agents results in the formation of health affecting nitrosamines. Environment Cooling system protection agents must be disposed of environmentally.

Coolant, anti-freeze agent

Hydraulic oil

The correct quality of water is highly important when preparing coolant. Clear and clean water within the boundaries of the following analysis values should generally be used.

The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mm2/s at 40°C. For topping up or for oil changes use only high-quality hydraulic oil, type HVLP according to DIN 51524, part 3, or hydraulic oils type HV according to ISO 6743/3. The viscosity index (VI) should be at least 150 (observe information of manufacturer).

Water quality Analysis values pH-value at 20 °C Chloride ion content [mg/dm3] Sulphate ion content [mg/dm3] Total hardness*1 [°dGH] ]

min. 6,5 3

max. 8,5 100 100 12

Bio-degradable hydraulic oil

*1Proportion of carbonate hardness on the total hardness min. 3 dGH Information concerning the water quality can be obtained from the waterworks. A test case for checking the water quality can be ordered from the engine manufacturer. If the values of the analysis deviate, the water must be treated accordingly.

On request the hydraulic system can also be filled with ester based biodegradable hydraulic oil (Panolin HLP Synth. 46). The biologically quickly degradable hydraulic oil meets all demands of a mineral oil based hydraulic oil according to DIN 51524. In hydraulic systems filled with Panolin HLP Synth. 46 always use the same oil to top up. When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil, you should consult the lubrication oil service of the oil manufacturer for details. Check the filter more frequently after this change.

pH-value too low Adding of caustic lye of soda or caustic potash solution.

Caution Oil change bio-degradable hydraulic oil:

●

Total hardness too high: Mixing with dehardenede water.

Perform regular oil analyses for content of water and mineral oil.

●

Total hardness or carbonate hardness too low: Mixing with harder water.

Replace the hydraulic oil filter element every 500 operating hours.

●

Chlorides and/or sulphates too high: Mixing with dehardenede water.

Oil for drive axle

●

As a protection against frost, corrosion and boiling point anti-freeze agents must be used under any climatic conditions. The proportion of cooling system protection agent must be between min. 35% and max. 45% to the water.

!

For the drive axle use only multi-purpose transmission oil of API-class GL5 with viscosity class SAE 90. The additives in this oil ensure low wear lubrication under all operating conditions.

Lubrication grease For lubrication use only EP-high pressure grease, lithium saponified (penetration 2).

008 911 79

BOMAG

35

2.3 2.3

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/ E7-04 or

approx. 15,5 litres incl. oil filter

API: CG-4/CH-4/CI-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. 340 litres approx. 60 litres

46 mm2/s at 40 °C Vario exciter drum

Engine oil SAE 15W/40

approx. 16,5 litres

Exciter housing attachment plates

Engine oil SAE 15W/40

2.7 litres each

Drive axle

Gear oil SAE 90, API GL5

approx. 12,5 litres

Wheel hubs

Gear oil SAE 90, API GL5

approx. 0,7 per side

Axle reduction gear

Gear oil SAE 90, API GL5

approx. 1,9 litres

Drum drive gear

Gear oil SAE 90, API GL5

approx. 3,2 litres

Air conditioning system

Refrigerant R134A

approx. 1400 g

Engine cooling system

Cooling system protection agent

approx. 16 litres

Water

approx. 300 litres

Tires

Calcium chloride (CaCl2) or magnesium chloride (MgCl2)

36

BOMAG

approx. 139 kg

008 911 79

2.4

Running-in instructions

2.4

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.

●

Oil change diesel engine and engine oil filter

●

1. Oil change in Vario exciter

●

Oil change in drive axle

●

Oil change, axle reduction gear

●

Oil change in wheel hubs

●

1. Oil change in drum drive gear

After 500 operating hours

008 911 79

●

2. Oil change in Vario exciter

●

2. Oil change in drum drive gear

BOMAG

37

2.5

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 axle reduction gear

X

5.17 Check the oil level in the drum reduction gear

X

5.18 Checking the Vario exciter oil level

X

5.19 Change engine oil and oil filter car- min. 1x per year tridge1

X

X

5.20 Change the fuel filter cartridge

X

X

5.21 Drain the sludge from the fuel tank 5.22 Battery maintenance

as required

Dipstick mark

every 6000 operating hours

Check the engine oil level

every 3000 operating hours

5.6

every 2000 operating hours

Remark

every 1000 operating hours

Maintenance work

every 500 operating hours

No.

every 250 operating hours

every 10 operating hours, daily

Maintenance chart

Running-in instructions after 250 operating hours

2.5

Maintenance chart

X Pole grease

X

5.23 Change the fuel pre-filter cartridge

X

5.24 Check, replace the refrigerant compressor V-belt

X

5.25 Service the air conditioning

X

5.26 Check, adjust the valve clearance Intake = 0,4 mm

X

Exhaust = 0,6 mm 5.27 Adjusting the control piston play

38

X

BOMAG

008 911 79

5.28 Checking, replacing the V-belt X

X

5.30 Oil change in drive axle

min. 1x per year

X

X

5.31 Oil change in wheel hubs

min. 1x per year

X

X

5.32 Oil change, axle reduction gear

min. 1x per year

X

X

5.33 Oil change in drum drive reduction min. 1x per year gear**

X

X

see foot note, min. X 1 x per year

X

5.35 Oil change exciter shaft housing at- min. 1x per year tachment plates

X

5.36 Retighten the fastening of the axle on the frame X

5.38 Check the ROPS

X X

min. 1x per year

X

5.40 Change hydraulic oil and breather at least every 2 years filter3

X

5.41 Change the hydraulic oil filter***

at least every 2 years

X

5.42 Change the steering oil filter***

at least every 2 years

X

5.43 Change the attachment plate oil fil- at least every 2 years ter***

X

5.44 Change the coolant

X

at least every 2 years

5.45 Replace the crankcase ventilation at least every 2 valve years 5.46 Electronic injector test EMR

X X

5.47 Cleaning, changing the dry air filter min. 1x per year, cartridge safety cartridge at least every 2 years

008 911 79

every 6000 operating hours

X X

5.37 Tighten the wheel nuts

5.39 Clean the oil bath air filter

every 3000 operating hours

X

5.29 Check the engine mounts

5.34 Oil change in Vario exciter2

every 2000 operating hours

every 1000 operating hours

every 500 operating hours

every 250 operating hours

Remark

every 10 operating hours, daily

Maintenance work

Running-in instructions after 250 operating hours

No.

as required

2.5

Maintenance chart

BOMAG

X

39

2.5

as required

every 6000 operating hours

every 3000 operating hours

every 2000 operating hours

every 1000 operating hours

every 500 operating hours

every 250 operating hours

Remark

every 10 operating hours, daily

Maintenance work

Running-in instructions after 250 operating hours

No.

Maintenance chart

5.48 Adjusting the scrapers

X

5.49 Adjust the parking brake

X

5.50 Change the tires

X

5.51 Change the fresh air filter in the cabin

X

5.52 Tightening torques

X

5.53 Engine conservation

X

1 2 3

40

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.

BOMAG

008 911 79

3 Technical data

008 911 79

BOMAG

41

3.1 3.1

Technical data Technical data

Fig. 12

Dimensions in mm

A

B

D

H

H2

K

L

O1

O2

S

W

BW 213 DH-4 BVC/P

2960

2250

1500

2268

2972

490

5808

60

60

35

2130

1

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

BW 213 DH-4 BVC/P

kg

15785

kg kg kg/cm

7598 8187 35,7

km/h %

0 ... 13 50

kW rpm V

Brakes Service brake Parking brake

hydrostatic hydr.-mech.

Steering Type of steering Steering operation

42

Deutz TCD 2013 L04 2V Water 4 119 2200 12 hydrostatic 2

articulated hydrostatic

BOMAG

008 911 79

3.1

Technical data 1

BW 213 DH-4 BVC/P

Vibration, drum Drive system Frequency Amplitude

Hz mm

hydrostatic 28 0 ... 2,4

Vibration, attachment plates Drive system Frequency

Hz

hydrostatic 40 ... 55

Tires Tire size Air pressure

bar

23.1/18-26/12PR 1,8

Litres Litres Litres

15 340 60

Filling capacities Engine Fuel Hydraulic oil 1

The right for technical modifications remains reserved

008 911 79

BOMAG

43

3.1

Technical data

Fig. 13

Dimensions in mm

A

B

D

H

H2

K

L

O1

O2

S

W

BW 213 DH-4 BVC

2960

2250

1500

2268

2972

490

5808

60

60

35

2130

1

Weights Operating weight (CECE) with ROPS and cabin Axle load, drum (CECE) Axle load, wheels (CECE) Static linear load Travel characteristics Speed Max. gradability (depending on soil) Engine Engine manufacturer Type Cooling Number of cylinders Rated power ISO 3046 Rated speed Electrical equipment Drive system Driven axles Permissible ambient temperatures

BW 213 DH-4 BVC

kg

14900

kg kg kg/cm

9200 5700 43,2

km/h %

0 ... 13 53

kW rpm V

°C

Brakes Service brake Parking brake

44

Deutz TCD 2013 L04 2V Water 4 119 2200 12 hydrostatic 2 -20 .... +50

hydrostatic hydr.-mech.

BOMAG

008 911 79

3.1

Technical data 1

BW 213 DH-4 BVC

Steering Type of steering Steering operation

articulated hydrostatic

Vibration Vibrating drum Drive system Frequency Amplitude

Hz mm

hydrostatic 28 0 ... 2,4

Tires Tire size Air pressure

bar

23.1-26/12 TL R3 1,4

Litres Litres Litres

15 340 60

Filling capacities Engine Fuel Hydraulic oil 1

The right for technical modifications remains reserved

008 911 79

BOMAG

45

3.1

Technical data

Fig. 14

Dimensions in mm

A

B

D

H

H2

K

L

O1

O2

S

W

Variocontrol

2960

2250

1500

2268

2972

490

5808

60

60

35

2130

1

Weights Operating weight (CECE) with ROPS and cabin Axle load, drum (CECE) Axle load, wheels (CECE) Static linear load Travel characteristics Speed Max. gradability (depending on soil) Engine Engine manufacturer Type Cooling Number of cylinders Rated power ISO 3046 Rated speed Electrical equipment Drive system Driven axles Permissible ambient temperatures

Variocontrol

kg

14900

kg kg kg/cm

9200 5700 43,2

km/h %

0 ... 13 53

kW rpm V

°C

Brakes Service brake Parking brake

Deutz TCD 2013 L04 2V Water 4 119 2200 12 hydrostatic 2 -20 .... +50

hydrostatic hydr.-mech.

Steering

46

BOMAG

008 911 79

3.1

Technical data 1

Variocontrol articulated hydrostatic

Type of steering Steering operation Vibration Vibrating drum Drive system Frequency Amplitude

Hz mm

hydrostatic 28 0 ... 2,4

Tires Tire size Air pressure

bar

23.1-26/12 TL R3 1,4

Litres Litres Litres

15 340 60

Filling capacities Engine Fuel Hydraulic oil 1

The right for technical modifications remains reserved

008 911 79

BOMAG

47

3.1

Technical data

Fig. 15

Dimensions in mm

A

B

D

H

H2

K

L

O1

O2

S

W

Variocontrol +

2960

2250

1500

2268

2972

490

5808

60

60

35

2130

1

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

Variocontrol +

kg

15785

kg kg kg/cm

7598 8187 35,7

km/h %

0 ... 13 50

kW rpm V

Brakes Service brake Parking brake

hydrostatic hydr.-mech.

Steering Type of steering Steering operation

48

Deutz TCD 2013 L04 2V Water 4 119 2200 12 hydrostatic 2

articulated hydrostatic

BOMAG

008 911 79

3.1

Technical data 1

Variocontrol +

Vibration, drum Drive system Frequency Amplitude

Hz mm

hydrostatic 28 0 ... 2,4

Vibration, attachment plates Drive system Frequency

Hz

hydrostatic 40 ... 55

Tires Tire size Air pressure

bar

23.1/18-26/12PR 1,8

Litres Litres Litres

15 340 60

Filling capacities Engine Fuel Hydraulic oil 1

The right for technical modifications remains reserved

008 911 79

BOMAG

49

3.1 Additional engine data Combustion principle Low idle speed High idle speed Spec. 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

Technical data

rpm rpm g/kWh mm mm bar

4-stroke diesel 700 - 800 2200 - 2250 226 0,4 0,6 DRC / 1600

cm3/rev. ccm x n l/min bar bar

Sauer 90R100 (EP) Axial piston/swash plate 75 75 400 25 ± 1

Drum reduction gear Type Transmission ratio Drum drive motor Manufacturer Type System Displacement (stage 1) Displacement (stage 2) Perm. leak oil rate Flushing rate Flushing limitation Axle drive motor Manufacturer Type System Max. displacement (stage 1) Min. displacement (stage 2) Perm. leak oil rate Flushing rate Flushing limitation Vibration pump Manufacturer Type System Max. displacement Start up pressure Operating pressure (soil dependent) Vibration motor Manufacturer Type System Displacement

50

CR 31 45,6

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

Sauer 51C 110 (EP) Axial piston – bent axle 110 31,4 2 ± 10 10 16

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

Sauer 51D 110 (EP) Axial piston – bent axle 110 55,3 2 ± 10 10 16

cm3/rev. bar bar

Sauer 90R 075 (EP) Axial piston/swash plate 75 365 ± 65 approx. 100

cm3/rev.

Bosch-Rexroth A2FM 56 HDD Axial piston/bent axle 56

BOMAG

008 911 79

3.1

Technical data Flushing rate Flushing pressure limitation Check steering/ Type System Displacement Max. steering pressure

l/min bar

6 13

cm3/rev. bar

HY/ZFFS11/16+8 Tandem gear pump 16 / 8 205 ± 15

Steering valve Manufacturer Type System

Danfoss OSPC 500 ON Rotary spool valve

Swivel motor Type System Rear axle Manufacturer Type Differential Degree of locking Reduction ratio Additional pump for plates Manufacturer Type System Max. displacement Start up pressure Charge pressure, high idle Vibration motor for plates Manufacturer Type System Displacement Frequency

008 911 79

STF 1-000-21 Piston rack

Dana CHC 193/66LD No-Spin 100 65,08

%

cm3/rev. bar bar

Sauer 42R 041 Axial piston/swash plate 41 370 ± 10 20 ± 2

cm3/rev. Hz

Bosch-Rexroth A2FM 16 Axial piston/swash plate 16 35-65/45-85

BOMAG

51

3.1

Technical data

The following noise and vibration data acc. to - EC Machine Regulation edition (98/37/EC) and - Noise Emission Regulation 2000/14/EC were determined at nominal speed of the drive engine and with vibration running. The machine was standing on an elastic base. During operation these values may vary because of the existing operating conditions.

Noise value The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is sound pressure level at the work place of the operator (with cabin): LpA

= 75 dB(A)

The nose emission value for the machine according to the noise emission regulation 2000/14/EG is guaranteed sound capacity level of the machine: LWA

= 104 dB(A)

These sound values were determined according to ISO 3744 for the sound capacity level (LwA) and ISO 11204 for sound pressure level (LpA) at the place of the operator.

Vibration value The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are: Vibration of the entire body (driver’s seat) The weighted effective acceleration value determined in accordance with ISO 7096 is γ ≤0.5 m/sec2. Hand-arm vibration values The weighted effective acceleration value determined in accordance with EN 500/ISO 5349, is γ ≤2.5 m/sec2.

52

BOMAG

008 911 79

4 Connection overview

008 911 79

BOMAG

53

4.1

Connection overview

Fig. 1

54

BOMAG

008 911 79

4.1

Connection overview 1

Proportional valve, vibration low frequency

16 Charge pressure test port

2

Proportional valve, vibration high frequency

3

Proportional valve, travel drive forward

17 Multi-function valve 400 bar (boost check and pressure relief valve), vibration high frequency

4

Proportional valve, travel drive reverse

5

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

6

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

20 Pressure test port, vibration high frequency

7

High pressure port B, reverse

22 High pressure port, low frequency

8

High pressure port A, forward

23 Charge pressure relief valve vibration pump

9

Charge pressure relief valve, travel pump

24 Port L2 (connection to travel pump 12)

10 Charge pressure (connection to travel pump 15) 11 Charge oil to filter

19 Pressure test port, vibration low frequency 21 High pressure port, high frequency

25 Leak oil port (connection to thermostat housing port A) 26 Port S, suction line between hydraulic oil tank and charge pump (charge pump in vibration pump)

12 Port L2 (connection to vibration pump 24) 13 Pressure test port MA, high pressure forward

27 Charge pump (only in vibration pump)

14 Pressure test port MB, high pressure reverse 15 Charge pressure to solenoid valve for brake and speed range selection (charge oil vibration 10)

008 911 79

18 Multi-function valve 400 bar (boost check and pressure relief valve), vibration low frequency

28 Pressure test port X1/X2, travel pump, control chamber 29 Adjustment screw, mechanical neutral position

BOMAG

55

4.1

56

Connection overview

BOMAG

008 911 79

5 Tests and adjustments

008 911 79

BOMAG

57

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

58

BOMAG

008 911 79

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 79

BOMAG

59

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

60

BOMAG

008 911 79

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 79

BOMAG

61

5.2

Activate service mode 5.2 Activate service mode Activate the input mode 1. Set the travel lever to braking position

i Note The function can only be activated when the travel lever is engaged in braking position. 2. Switch on the ignition. 3. Press both Info-buttons (Fig. 1) longer than three seconds to access the input mode.

Fig. 1

Activate service mode

T

i Note The input mode starts with flashing of the left hand digit (Fig. 2). Here you have the possibility to change to the service mode using access code "9999". The green buttons F2, F4 (Fig. 3) can be used to increase or reduce the corresponding digit. With the blue button F5, F3 (Fig. 4) you can jump to the corresponding next digit. Once the last digit has been entered the code will be transmitted to the control by pressing the right hand blue button (F3) again.

Fig. 2

T

4. Enter access code "9999".

Fig. 3

62

BOMAG

008 911 79

5.2

Activate service mode

i Note If the access code has been entered correctly, the "spanner" symbol appears in the display and the first digit flashes again. Individual operating states can now be interrogated, activated or deactivated by transmitting further input codes to the control. Deactivating the service mode 5. Quit the service mode by switching the ignition off. Fig. 4

008 911 79

BOMAG

63

5.3

Driving against the closed brake 5.3 Driving against the closed brake

i

Note On this machine the electric plug connection to the brake valve must not be pulled off, because the ESX-control would in this case detect a line interruption in the current path to the brake. Activate the input mode 1. Set the travel lever to braking position

i Note The function can only be activated when the travel lever is engaged in braking position. 2. Switch on the ignition. 3. Press both Info-buttons (Fig. 1) longer than three seconds to access the input mode.

Fig. 1

Activate service mode

T

i Note The input mode srats with flashing of the left hand digit (Fig. 2). Here you have the possibility to change to the service mode using access code "9999". The green buttons F2, F4 (Fig. 3) can be used to increase or reduce the corresponding digit. With the blue button F5, F3 (Fig. 4) you can jump to the corresponding next digit. Once the last digit has been entered the code will be transmitted to the control by pressing the right hand blue button (F3) again.

Fig. 2

T

4. Enter code number "9999".

Fig. 3

64

BOMAG

008 911 79

5.3

Driving against the closed brake

i Note If the access code has been entered correctly, the "spanner" symbol appears in the display and the first digit flashes again.

Fig. 4

Activating the brake function 5. Enter code number "0500" via the LC display (Fig. 5). The brake will not be released when actuating the travel lever. The warning buzzer sounds to inform the operator about this status. The brake control light in the LC display remains activated. Deactivating the brake function 6. Enter code number "501" or switch the ignition off to stop this function. Fig. 5

008 911 79

BOMAG

65

5.4

Turn the steering against an end stop. 5.4 Turn the steering against an end stop.

i

Note The steering is actuated against an "electronic" stop by the ESX-control. To actuate the steering against the mechanical stop the ESX-control must be switched to the mode "Teaching the electronic end stops of the angle transducer (BVC)". Activate the input mode 1. Set the travel lever to braking position

i Note The function can only be activated when the travel lever is engaged in braking position. 2. Switch on the ignition. 3. Press both Info-buttons (Fig. 1) longer than three seconds to access the input mode.

Fig. 1

Activate service mode

T

i Note The input mode starts with flashing of the left hand digit (Fig. 2). Here you have the possibility to change to the service mode using access code "9999". The green buttons F2, F4 (Fig. 3) can be used to increase or reduce the corresponding digit. With the blue button F5, F3 (Fig. 4) you can jump to the corresponding next digit. Once the last digit has been entered the code will be transmitted to the control by pressing the right hand blue button (F3) again.

Fig. 2

T

4. Enter code number "9999".

Fig. 3

66

BOMAG

008 911 79

5.4

Turn the steering against an end stop.

i Note If the access code has been entered correctly, the "spanner" symbol appears in the display and the first digit flashes again.

Fig. 4

Activating the mode 5. Enter code number "2010" (Fig. 5) to activate the mode "teaching the steering stops". The steering can now be actuated against the mechanical stop. The display shows the nominated steering position (0..1000). Deactivating the mode 6. Enter code number "501" or switch the ignition off to stop this function. Fig. 5

008 911 79

BOMAG

67

5.5

Pressure tests in the travel circuit 5.5 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

Danger The closed brake mode must be activated! !

i Note Drive against the closed brake, see corresponding chapter. 2. Enter code number "0500" to close the brake (Fig. 2).

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. 3). 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.

68

BOMAG

008 911 79

5.5

Pressure tests in the travel circuit

6. Move the travel lever (Fig. 4) quickly forward and backward, 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. If the charge pressure drops considerably during the high pressure test, check the components individually.

Fig. 4

Deactivate the closed brake mode 7. Quit this mode by switching the ignition off.

008 911 79

BOMAG

69

5.6

Checking / adjusting the neutral positions of the travel pump 5.6 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 ! Danger The closed brake mode must be activated!

i Note Drive against the closed brake, see corresponding chapter. 2. Enter code number "0500" to close the brake (Fig. 2).

Fig. 2

3. Connect a 600 bar pressure gauge each to the high pressure test ports for "forward travel" and "reverse travel" (Fig. 3).

Fig. 3

70

BOMAG

008 911 79

Checking / adjusting the neutral positions of the travel pump

5.6

! Danger The closed brake mode must be activated!

i

Note Drive against the closed brake, see corresponding chapter. 4. As a measure to avoid signal residues from the hydraulic neutral position connect both control chambers X1 and X2 with a hose (Fig. 4). 5. Start the engine and run it with maximum speed. Fig. 4

6. Read the high pressure gauges (Fig. 5). Nominal value Both pressure gauges (Fig. 5) must show equal pressure (charge pressure).

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

Fig. 5

Evaluation of test If pressure builds up on one side, adjust the mechanical neutral position (Fig. 6), until the pressures on both pressure gauges are identical.

Fig. 6

008 911 79

BOMAG

71

5.7

Pressure measurements in the vibration circuit 5.7 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 at high or low frequency and read the pressure gauge. 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.

72

BOMAG

008 911 79

5.8

Check the leakage rate of the vibration motor

5.8 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. 1. Apply the brake.

Fig. 1

2. Block the flushing pressure relief valve (Fig. 2) with washers.

Fig. 2

3. Disconnect the leak oil hose (Fig. 3), connect a measuring hose and hold it into a measuring beaker. 4. Start the engine and run it with maximum speed. 5. 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

008 911 79

BOMAG

73

5.9

Pressure test in steering circuit 5.9 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).

i Note The steering is actuated against an "electronic" stop by the ESX-control. To actuate the steering against the mechanical stop the ESX-control must be switched to the mode "Teaching the end stops of the angle transducer (BVC)".

Fig. 1

Activate teach mode

i Note Turn the steering against the mechanical stop, see corresponding chapter. 2. Enter code number "2010" (Fig. 2). 3. Start the engine and run it at idle speed. Danger Danger of crushing, do not access the articulation area of the machine! !

Fig. 2

4. Turn the steering against an end stop. 5. Set the travel lever to neutral position (no braking function). 6. Read the pressure gauge. Nominal value see technical data, max. steering pressure of steering/charge pump. Evaluation of test 1 If the nominal value is reached, check the steering cylinder. Deactivate the steering mode 7. Quit the teach mode by switching the ignition off.

74

BOMAG

008 911 79

5.9

Pressure test in steering circuit Measurement 2

8. Disconnect the hydraulic hoses from ports L and R (Fig. 3) on the steering cylinders and close them with plugs. 9. Start the engine and run it at idle speed. 10. Turn the steering wheel. 11. Read the pressure gauge. Nominal value see technical data for steering/charge pump. Evaluation of test 2 Fig. 3

If the nominal value is reached, replace the steering cylinder. If the nominal value is not reached, check the steering/charge pump. 12. Reconnect the hydraulic hoses to the steering cylinders. Measurement 3 13. Close the pump outlet port (Fig. 4) with the gear pump test equipment. 14. 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. 4

008 911 79

BOMAG

75

5.9

76

Pressure test in steering circuit

BOMAG

008 911 79

6 Flushing and bleeding

008 911 79

BOMAG

77

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

78

BOMAG

008 911 79

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 79

BOMAG

79

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

80

BOMAG

008 911 79

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 79

BOMAG

81

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

82

BOMAG

008 911 79

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.

●

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

●

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

●

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

●

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

●

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

●

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

●

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 79

BOMAG

●

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

83

6.2

Flushing - general

Servicing the flushing filter kit

Fig. 4

84

●

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 79

Flushing schematic travel circuit (distribution travel pump)

008 911 79

BOMAG

6.3

85

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

Flushing hose 25S - 20S (tool)

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)

86

BOMAG

008 911 79

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 79

BOMAG

87

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

88

BOMAG

008 911 79

Flushing the travel circuit (travel pump distribution)

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

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. !

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 79

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

BOMAG

89

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

90

BOMAG

008 911 79

Flushing the travel circuit (travel pump distribution)

6.4

Flushing the hoses 19. Block drums and wheels with suitable chocks.

Fig. 13

i

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

Fig. 14

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. !

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 79

BOMAG

91

6.4

Flushing the travel circuit (travel pump distribution)

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

Fig. 17

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. !

27. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward. 28. 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. 29. Shut down the engine. Fig. 18

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

92

BOMAG

008 911 79

Flushing schematic travel circuit (distribution axle motor)

008 911 79

BOMAG

6.5

93

6.5

94

Flushing schematic travel circuit (distribution axle motor)

BOMAG

008 911 79

Flushing schematic travel circuit (distribution axle motor)

008 911 79

BOMAG

6.5

95

6.5

96

Flushing schematic travel circuit (distribution axle motor)

BOMAG

008 911 79

Flushing schematic travel circuit (distribution axle motor)

6.5

1

Elbow union (tool)

13 High pressure hose (drum drive motor forward)

2

Connecting union (tool)

14 High pressure hose (B, axle motor reverse)

3

Drum drive motor

15 High pressure hose (A, axle motor forward)

4

Axle motor

16 High pressure hose (B, axle motor reverse)

5

Screw socket R1 - 25S (tool)

17 not used

6

not used

18 Flushing hose 25S - 20S (tool)

7

not used

19 Flushing hose 25S - 20S (tool)

8

Flushing filter with filter element 1μ (tool)

9

not used

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

008 911 79

BOMAG

97

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

98

BOMAG

008 911 79

Flushing the travel circuit (axle motor distribution)

6.6

Bleeding the travel circuit

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

Fig. 3

Flushing the hoses

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

Fig. 4

4. Block drums and wheels with suitable chocks.

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

008 911 79

BOMAG

99

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

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

Fig. 8

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. !

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

100

BOMAG

008 911 79

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

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

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.

18. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward. 19. 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. 20. Shut down the engine. Fig. 12

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 79

BOMAG

101

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

102

BOMAG

008 911 79

6.7

Flushing schematic for vibration drive

1

Elbow union (tool)

7

Flushing hose 25S - 20S (tool)

2

Connecting union (tool)

8

Flushing filter with filter element 1μ (tool)

3

Vibration motor

9

SAE flange (tool)

4

Vibration pump

10 High pressure hose (B, high frequency)

5

Screw socket R1 - 25S (tool)

11 High pressure hose (A, low frequency)

6

Flushing hose 25S - 20S (tool)

008 911 79

BOMAG

103

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

104

BOMAG

008 911 79

6.8

Flushing the vibration circuit Bleeding the vibration circuit

i Note Bleeding the vibration circuit, see chapter "Bleeding the vibration 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 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 79

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

BOMAG

105

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

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

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.

106

BOMAG

008 911 79

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 79

BOMAG

107

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

108

BOMAG

008 911 79

6.9

Bleeding the travel 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. 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 79

BOMAG

109

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

110

BOMAG

008 911 79

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

Note This waiting time is necessary to allow air bubbles to escape through the leak oil return line.

Fig. 5

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 79

BOMAG

111

6.10

112

Bleeding the vibration circuit

BOMAG

008 911 79

7 Fundamental electrics

008 911 79

BOMAG

113

7.1 7.1

Understanding circuit diagrams

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.

114

BOMAG

008 911 79

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

Relay cross reference

Potential cross references

Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing contacts.

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“.

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 79

BOMAG

115

7.1

Understanding circuit diagrams

Current paths The pages of a circuit diagram are sub-divided into current paths (Fig. 8) (0 ..... 20).

Fig. 8 Current paths

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

Fig. 9 List of components

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

116

BOMAG

008 911 79

7.1

Understanding circuit diagrams 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. 10 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. 11 Graphic symbol

1

Diode

2

Transistor

3

NPN-Transistor

4

changeable resistance

5

Condenser

6

Working current relay

008 911 79

BOMAG

117

7.2 7.2

Terminal designations

Terminal designations

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

118

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

008 911 79

7.2

Terminal designations Terminal designation 50c

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)

008 911 79

BOMAG

119

7.2

Terminal designations

Terminal designation 75

Meaning

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)

120

Radio, cigarette lighter

BOMAG

008 911 79

7.2

Terminal designations Terminal designation DF2

Meaning

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

008 911 79

Dynamo field 2 (generator excitation current)

BOMAG

121

7.3 7.3

Current and voltage

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

122

BOMAG

008 911 79

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.

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.

Pure D.C.-voltages are only delivered by accumulators or batteries. The voltage in the vehicle wiring system is no pure D.C.-voltage. Even without the generator running, but the consumers switched on, the voltage is not 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. 008 911 79

BOMAG

123

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. !

124

BOMAG

008 911 79

7.3

Current and voltage Controller Area Network (CAN) 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. 5 CAN

Characteristics of CAN

Why CAN?

It is a kind of serial data transmission. The individual bits are transmitted one after the other, only 2 lines are required.

●

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).

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

008 911 79

BOMAG

125

7.4 7.4

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.

126

BOMAG

008 911 79

7.4

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 79

BOMAG

127

7.5 7.5

Series / parallel connection

Series / parallel connection

●

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.

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).

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.

128

BOMAG

008 911 79

7.5

Series / parallel connection Parallel connection

●

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

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.

●

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

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.

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

●

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 79

BOMAG

129

7.6 7.6

Ohm's law

Ohm's law

7.7

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

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

Amperage I = U divided by R U = Voltage in Volt

I = Current in Ampere P = Power in Watt

I = Current in Ampere R = Resistance in OHM Ω

130

BOMAG

008 911 79

7.8

Formula diagram

7.8

Formula diagram

Example: P = 150 Watt

Description:

U = 24 Volt

●

Select the desired value from the inner circle.

●

Determine the formula variables in the quarter circle

●

Calculate

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 79

BOMAG

131

7.9 7.9

Metrology

Metrology

Multimeter 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 lamps 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.

132

BOMAG

008 911 79

7.9

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 79

BOMAG

133

7.10

Diodes, relays, fuses

7.10 Diodes, relays, fuses

Magnet tester

Diodes

Fig. 1 Fig. 1 Magnet tester

The magnet tester is used to test solenoid valves and magnetic coils.

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

The test lamp responds to the magnetic fields of A.Cvoltage, D.C.-voltage and permanent magnets.

Plus-voltage on diode:

●

The component to be tested does not need to be removed.

●

The magnetic coil can also be tested under a protective cap.

●

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:

134

●

For rectifying A.C. voltage.

●

For absorbing voltage peaks (free-wheeling diode).

●

For construction of logical circuits.

BOMAG

008 911 79

7.10

Diodes, relays, fuses Diode logics and free-wheeling diode

Light emitting diodes

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.

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 79

BOMAG

135

7.10

Diodes, relays, fuses

Relays

85 = Ground supply for coil 30 = Supply voltage 87 = Normally open contact 87a= Normally closed contact

Fuses

Fig. 1 Relays

Relays are commonly used to realize switching processes. 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. 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

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

136

BOMAG

008 911 79

7.11

Batteries

7.11 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.

In the worst case the accumulator can only be disposed of after such an exhaustive discharge.

Lead collectors or accumulators are secondary elements, i.e they can be recharged after discharging electric current.

●

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).

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.

The following therefore applies for longer downtimes:

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: ●

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

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.

008 911 79

BOMAG

137

7.11

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. Fig. 4 Battery and generator tester

i

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:

138

BOMAG

008 911 79

7.11

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.

008 911 79

BOMAG

139

7.12

Three-phase generator

7.12 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.

140

BOMAG

008 911 79

7.12

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.

008 911 79

BOMAG

141

7.12

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).

142

BOMAG

008 911 79

7.12

Three-phase generator 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.

●

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.

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.

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.

008 911 79

BOMAG

143

7.12

Three-phase generator

Checking the rotor

i

Checking the stator

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.

144

Fig. 12 Stator

i

Note

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

Measure the resistance of all three coils.

●

The coils should not have contact among each other.

BOMAG

008 911 79

7.12

Three-phase generator 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 ●

All plug-and-socket connectors must be free of corrosion and intermittent contact.

Fig. 13

●

The generator ground connection must be OK.

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 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.

●

The generator ground connection must be OK.

●

Perform the measurement at raised engine speed.

●

The battery should be in good condition – the idle speed voltage of the battery should be at least 12.6 Volt.

●

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

●

If possible switch off all consumers.

●

Perform the measurement at raised engine speed.

●

008 911 79

BOMAG

145

7.12

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.

Fig. 16

E.g minus controlled 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)

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).

146

BOMAG

008 911 79

7.12

Three-phase generator 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.

008 911 79

BOMAG

147

7.13

Electric starter

7.13 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.

●

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.

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.

148

●

Starter motors must not be cleaned with high pressure steam cleaning equipment.

10 Collector

!

establish the gear connection between starter and combustion engine.

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.

Fig. 1 Electric starter

1

●

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

BOMAG

008 911 79

7.13

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

3

Starter switch

4

Pull-in winding

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.

5

Holding winding

6

Exciter winding

7

Restoring spring

8

Driver

9

Pinion

10 Flywheel

008 911 79

BOMAG

149

7.13

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.

Note

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. !

●

Check the wear on the carbon brushes and their contact pressure.

●

Check the collector, it must not have electrical contact with the rotor shaft.

Emergency stop not actuated?

●

Check the drive pinion for excessive wear.

●

Battery sufficiently charged?

●

●

Battery poles OK?

●

Main battery fuse OK?

The return mechanism should not be tight, if necessary grease amply with silicon grease (Bosch PZ 2 V3) or a comparable grease.

●

Main battery switch closed?

●

●

Main starter cable (terminal 30) OK?

Measure the resistance of the magnetic switch main contact in disengaged condition. Maximum value 0.2 OHM Ω.

●

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

●

Ground cable OK?

●

Switching of magnetic switches OK?

●

Immobilizer deactivated?

●

Ignition switch OK?

●

Travel lever in correct position?

●

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.

150

BOMAG

008 911 79

7.14

Telemecanique switch

7.14 Telemecanique switch Example of terminal designations

Fig. 1 Terminal designations ●

Normally open contact 23 located on block 2

●

Normally open contact 24 located on block 2

●

Normally closed contact 12 located on block 1

●

Normally closed contact 11 located on block 1

●

Normally open contact 34 located on block 3

●

Normally open contact 33 located on block 3

●

Normally open contact 63 located on block 6

●

Normally open contact 64 located on block 6

●

Normally open contact 43 located on block 4

●

Normally open contact 44 located on block 4

i

Note

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

008 911 79

BOMAG

151

7.14

Telemecanique switch

Disassembly

Fig. 2 Disassembly ●

Lift up the interlock (5).

Fig. 4 Pulling out the front element ●

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

Fig. 3 Folding down the switch block ●

Fold down the switch block (4).

●

Loosen screw (1).

152

BOMAG

008 911 79

7.14

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.

008 911 79

BOMAG

153

7.15

Inductive proximity switches

7.15 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.

154

BOMAG

008 911 79

7.16

Angle sensor with current output

7.16 Angle 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)

008 911 79

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.

BOMAG

155

7.17

Plug connectors

7.17 Plug connectors 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. Examples for these loads are:

Fig. 2 Connection diagram

●

Vibration acceleration

●

Temperature fluctuations, high and low temperatures

●

Dampness

●

Micro movements of the contact with resulting friction corrosion.

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

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:

●

at -35° = 4 mA output current

●

at 0° = 12 mA output current

●

Low transition resistances of the conductive parts.

at +35° = 20 mA output current.

●

High insulation strength between conductive parts with different voltage potentials.

●

Excellent leak tightness against water and moisture.

●

156

BOMAG

008 911 79

7.18

Deutsch plug, series DT and DTM

7.18 Deutsch plug, series DT and DTM

DT Series

General Plug connectors DT and DTM have a wedge to hold the pins and sockets in their position. This wedge can be removed and replaced, without having to cut any leads.

Fig. 1 DT plug connection

Fig. 3 Crimp connections Fig. 2 DT Series

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

Sockets and pins must not be soldered to leads, they may only be crimped (see special tools for electrics). When connecting sockets and plugs these must engage with a noticeable click when both halves interlock. The plug connection should not be separable (without loosening the interlock). Fig. 3 Sectional drawing

Pulling test This pulling test ensures that the lead is perfectly crimped and the contact has correctly engaged in the housing. ●

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

008 911 79

BOMAG

157

7.18

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.

158

BOMAG

008 911 79

7.18

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.

008 911 79

BOMAG

159

7.18

Deutsch plug, series DT and DTM

DTM Series

Fig. 1 DTM plug connection

Fig. 2 DTM Series

Fig. 3 Sectional drawing

160

BOMAG

008 911 79

7.18

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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BOMAG

161

7.18

Deutsch plug, series DT and DTM

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.

162

BOMAG

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Plugs and terminals in spring clamping technology

7.19 Plugs and terminals in spring clamping technology

7.19

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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7.19

Plugs and terminals in spring clamping technology

Series clamp

Fig. 4 That's how it works

That's how it works ●

Insert a screw driver into the actuating opening until it bottoms.

●

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

●

Pull out the screw driver.

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

Measuring signals On these terminal blocks the bridge slot is most suitable for tapping off and measuring signals. Here you may directly insert a 4 mm test adapter (see special tools for electrics) for connecting a measuring lead. This test adapter is standard in the central electrics of heavy equipment machines.

Fig. 5 Test adapter

164

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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

7.19

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

Fig. 6 That's how it works

That's how it works ●

Insert a screw driver into the actuating opening until it bottoms.

●

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

●

Pull out the screw driver.

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

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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165

7.19

166

Plugs and terminals in spring clamping technology

BOMAG

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8 Special tools, electrics

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167

8.1

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

Fig. 9

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

Fig. 10

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. 11

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. 12

168

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Special tools, electrics

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. 13

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. 14

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. 15

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169

8.1

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

Fig. 16

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

Fig. 17

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

Fig. 18

Spring clamps (Wago or Weidmüller) 34. Cranked screwdriver (Fig. 19) to open spring clamps (Fig. 20). BOMAG part-no.: 972 024 68

Fig. 19

170

BOMAG

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Special tools, electrics

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

Fig. 20

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

Fig. 21

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. 22

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. 23

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171

8.1

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. 24

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. 25

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

Fig. 26

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

Fig. 27

172

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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. 28

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. 29

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

Fig. 30

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. 31

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173

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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. 32

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. 33

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

Fig. 34

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. 35

174

BOMAG

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8.1

Special tools, electrics

51. 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. 36

Universal tools 52. 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. 37

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

Fig. 38

Measuring adapter 54. Current measurement adapter for Hirschmann plugs. BOMAG part-no.: 057 503 83

Fig. 39

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175

8.1

Special tools, electrics 55. Voltage measurement adapter for Deutsch plugs, 8-piece (2 to 12 pole). BOMAG part-no.: 079 900 68

Fig. 40

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

Fig. 41

176

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9 Machine related electrics

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BOMAG

177

178

BOMAG

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Machine related electrics

BOMAG

179

9.1

180

Machine related electrics

BOMAG

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9.1

Machine related electrics

Service Training Electrics Single Drum Rollers – 4

P/N 00809703

Version 3.29

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

008 911 79

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Service Training WZ-4 from Version DH

Table of contents 1

Confirmation of changes................................................................................................5 1.1

Document..............................................................................................................................5

1.2

Software................................................................................................................................6

2

Displayed monitoring activities with fault reactions ...................................................7

3

The diagnostics system .................................................................................................9 3.1 3.2

Display functions .................................................................................................................9 General facts and operation ...............................................................................................9 3.2.1 3.2.2

3.3

Fault log – display and delete...........................................................................................12 3.3.1 3.3.2

3.4

Showing stored faults .......................................................................................................12 Delete all stored faults......................................................................................................12

Delete engine control error log ........................................................................................13 3.4.1 3.4.2

4

Calling up service mode .....................................................................................................9 Entering input codes.........................................................................................................10

Deleting logged engine errors ..........................................................................................13 Deleting active engine faults ............................................................................................13

Settings and queries.....................................................................................................14 4.1

Setting the machine type ..................................................................................................14

4.2

Driving against the closed brake .....................................................................................17

4.3

Teaching the travel direction sensor ...............................................................................17

4.4

Automatic detection of surge currents in travel system ...............................................17

4.5

Changing the steering unit on BVC-4 machines ............................................................19

4.6

Teaching the electronic end stops of the steering angle sensor (BVC) ......................20

4.7

Automatic detection of surge currents on steering valves (BVC)................................22 4.7.1

4.8

"Trimming" the speed measurement...............................................................................23 4.8.1 4.8.2

4.9

Reading out actual surge current values ..........................................................................23

Quick overview.................................................................................................................23 Explanation ......................................................................................................................23

Calibrating the speed detection (calibration of wheel diameter)..................................24 4.9.1 4.9.2

Quick overview.................................................................................................................24 Explanation ......................................................................................................................24

4.10 Activating/deactivating the vibration control..................................................................25 4.10.1

Quick overview.................................................................................................................25

4.11 Activating/deactivating the attachment plates ...............................................................25 4.11.1

Quick overview.................................................................................................................25

4.12 Setting the vibration motor type.......................................................................................26 4.12.1 4.12.2

Table of vibration motor types ..........................................................................................26 Table of pulse numbers....................................................................................................27

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Service Training WZ-4 from Version DH 5

Replacement of components .......................................................................................28 5.1

How to proceed when replacing components?..............................................................28

5.2

Replacement of an ESX-control .......................................................................................28

5.3

Replacement of a travel pump / axle drive motor / drum drive motor..........................28

5.4

Replacement of a steering valve (BVC) ...........................................................................28

5.5

Replacement of a steering angle sensor.........................................................................28

5.6

How to proceed when replacing a front / rear axle sensors? .......................................28

5.7

Component replacement without adjustment procedure..............................................29

6

Description of the signals on the ESX-control...........................................................30

7

Description of signals on the data collector ..............................................................35

8

Description of signals on the travel lever...................................................................37

9

Descriptions of signals on the LC - Display ...............................................................39

10 Description of Signals on DIOS-Module .....................................................................40 11 Fault codes of the ESX control ....................................................................................41 11.1 Overview .............................................................................................................................41 11.2 Description of fault reactions ...........................................................................................42 11.3 Note codes..........................................................................................................................43 11.4 Detailed description of fault codes and their possible causes....................................45 11.4.1 11.4.2 11.4.3 11.4.4 11.4.5 11.4.6 11.4.7 11.4.8 11.4.9 11.4.10 11.4.11 11.4.12 11.4.13 11.4.14

General ............................................................................................................................45 Brake................................................................................................................................46 Travel lever ......................................................................................................................46 Travel speed range selector switch ..................................................................................48 Travel system...................................................................................................................48 Steering............................................................................................................................52 Driver's seat arm rest sensor............................................................................................54 Vibration ...........................................................................................................................55 Attachment plates ............................................................................................................58 Diesel engine ...................................................................................................................59 Diesel engine EMR...........................................................................................................59 Miscellaneous ..................................................................................................................62 Machine type....................................................................................................................64 Optional functions ............................................................................................................64

12 Input Codes for ESX Control........................................................................................65 12.1 Fault log ..............................................................................................................................65 12.2 Value displays ....................................................................................................................65 12.2.1 12.2.2 12.2.3 12.2.4 12.2.5 12.2.6 12.2.7 12.2.8

General ............................................................................................................................65 Brake................................................................................................................................65 Travel lever / driving .........................................................................................................66 Travel speed range selector switch ..................................................................................66 Travel pump: Travel direction forward ..............................................................................67 Travel pump: Travel direction reverse ..............................................................................67 Travel motor front (drum) .................................................................................................68 Travel motor rear (wheel axle)..........................................................................................68

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Service Training WZ-4 from Version DH 12.2.9 Shut-down of drives..........................................................................................................68 12.2.10 Adaptation values for speed regulation ............................................................................69 12.2.11 Travel pressure sensor.....................................................................................................69 12.2.12 Inclination sensor .............................................................................................................69 12.2.13 Travel condition values.....................................................................................................69 12.2.14 Calibrating the wheel diameter .........................................................................................70 12.2.15 Speed limitation................................................................................................................70 12.2.16 Arm rest contact ...............................................................................................................70 12.2.17 Adoption values traction control .......................................................................................71 12.2.18 Steering: Steering valve ...................................................................................................71 12.2.19 Steering: Angle sensor in articulated joint ........................................................................71 12.2.20 Steering: Steering wheel ..................................................................................................72 12.2.21 Vibration ...........................................................................................................................72 12.2.22 Vibration (up to version 3.24 ) ..........................................................................................72 Vibration control; Vario and low amplitude circular exciter (from version 3.25 ) .................................73 Vibration control; high amplitude circular exciter (from version 3.25 ) ................................................73 12.2.23 Attachment plates, option (only BW213 BVC) ..................................................................74 12.2.24 Engine ..............................................................................................................................75 12.2.25 Hydraulics ........................................................................................................................75

12.3 Test settings .......................................................................................................................76 12.3.1 12.3.2

Brake................................................................................................................................76 Disable electric supply to wheel and drum drive motors (switch off).................................76

12.4 Settings / Teach / Emergency functions..........................................................................77 12.4.1 12.4.2 12.4.3 12.4.4 12.4.5 12.4.6 12.4.7 12.4.8 12.4.9 12.4.10 12.4.11 12.4.12 12.4.13 option 12.4.14

Changing the machine code.............................................................................................77 Automatic detection of surge currents in travel system ....................................................77 Speed detection, trimming of measuring values...............................................................77 Speed detection, teaching of distance pulses ..................................................................77 Detection of wheel rotation ...............................................................................................78 Steering: Automatic detection of surge currents on steering valve...................................79 Steering: Determining the steering stops .........................................................................79 Steering: Emergency function ..........................................................................................79 Steering: Other functions..................................................................................................79 Setting the vibration motor type........................................................................................79 Vibration: Travel speed dependent vibration lock.............................................................80 Vibration: Enable frequency setting..................................................................................80 Attachment plates (only circular exciter): Activating/deactivating the attachment plates 80 Plates: Preventing reversing with plates lowered .............................................................80

13 Terminology in connection with ESX..........................................................................81

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Service Training WZ-4 from Version DH

1 Confirmation of changes 1.1 No. 2.01 2.02 2.03 2.04 2.05 2.06 2.07 3.01 3.02

Document Date 23.04.2004 06.05.2004 11.05.2004 24.06.2004 23.01.2005 29.04.2005 22.05.2005 16.03.2006 11.08.2006

3.03 13.11.2006 26.01.2007 21.02.2007 22.02.2007 3.23 22.10.2007

Description of changes Creation of version 1.00 Revision, teach functions Revision, supplements version 1.01 Revision, supplements to version 1.02 Revision, supplement to software versions from 2.00 Revision, supplement to software versions from 2.06 Error code description 5121 changed. Supplements with respect to TIER3 engines. Fault treatment. List of "selected fault reactions" corrected Documentation of error codes revised List of machine types changed Fault codes 5127 and 5136 added. Machine types of new Tier 3 machines supplemented. Fault description for steering supplemented. Note for code list added Input codes 3070 to 3072 to activate/deactivate the towed plate option for circular exciter machines added.

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

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resp. Werner Fondel Seis MASH MASH Löw Löw Löw

Löw Vogt MASH MASH MASH

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Service Training WZ-4 from Version DH

1.2

Software

Ver. Date Description of changes 1.03 02.09.2004 Surge currents travel system teach function changed Known faults Revision of error codes Deactivation of electric steering on BVC machines How to proceed when replacing components? 2.00 16.12.2004 List of error codes extended 2.02 08.03.2005

Adaptive adaptation of gradability. Display codes for the factors "Front top" 1500 and "Tail top" 1501 Input code to shut down the speed dependent Vib-limitation (3047..3049). Error message (8440..8443) for invalid BabyBoard equipment of the ESX-travel control. Overspeed protection for wheel drives (axle and drum drives)

2.06 29.04.2005

Input codes (1158/1159) for manual adaptation of axle speed recording. Input codes to record the pulse frequency of the drives: Recording of speeds (1160..1169) Adapted tank characteristic. Change of speed limitation for operation with plates.

2.07 22.05.2005

Tank characteristic values changed.

Schroeder Fondel MASH MASH

MASH

MASH

2.16 22.02.2006 Explanation concerning error messages steering supple3.00 mented.

MASH

2.18 10.03.2006 3.01

Supplements with respect to TIER3 engines. Fault treatment extended. Description of "known faults" extended.

MASH Löw

2.19 20.03.2006 3.02 3.04 18.05.2006

Fault correction travel pressure monitoring. Fault monitoring steering wheel revised

MASH Löw MASH

3.05 10.07.2006

Problem with start-up of new controls eliminated

Löw

3.05 26.07.2006

Optimized CANopen functionality Fault treatment for steering changed (faults 2200 and 2201) Rotary speed (vibration frequency) control and fault monitoring changed 3.29 04.10.2006 Implementation of circular exciter machines with plate compactors.

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Service Training WZ-4 from Version DH

2 Displayed monitoring activities with fault reactions Symbol in fault message display

Warning

Warning

Engine stop

Code output without buzzer

Code output with buzzer

Code output with buzzer

Engine oil pressure (from EMR)

5100 5112

5101 5112

Coolant temperature (from EMR)

5100 5116

5101 5116

Coolant level

5024

5025

after 5s

after 10s

5026

5027

after 5s

after 2min.

Reaction Signal

Engine air filter

ASC

Various error causes and reaction times. See error codes Hydraulic oil filter

5502

5503

after 5s

after 2min.

Water separator in fuel filter TIER II Engines

5028

5029

after 5s

after 2min.

Water separator in fuel filter TIER III Engines

5100 5119 1300

Seat contact

Arm rest

2300

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Service Training WZ-4 from Version DH 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.

Effect: Display remains dark, no voltage Error code 5100, 5140 and engine does not respond to full speed switch or travel lever After switching on the display shows "Error code 8224"

Cause: PIN in display plug X 28 bent Switch the ignition off and on and restart the machine immediately. Code 8224 is no error code, but a software fault in the display software, which has been rectified in display firmware version 1.36 and higher The display shows various engine faults (Code Faulty assessment of engine faults in the EMR3 51xx), even though neither code 5100 nor 5101 is control unit. Remedy: Delete active and passive displayed. engine faults (see 3.4 Delete engine control error log)

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Service Training WZ-4 from Version DH

3 The diagnostics system The machine is equipped with a diagnostics system consisting of display unit (LCD) and button-type input unit (in the travel lever) to report machine faults, display measuring values and to set parameters.

3.1

Display functions

The field t in the LC-Display shows the following diagnostic readings: Type of indication

Fault message Warning Note

Flashing Flashing "d" warning triangle

* * *

Flashing "d" Of the fields next to the warning triangle

* * *

Comment

*

Display, measuring values

Values ranging from 0 0 0 0 ...9 9 9 9 to be called up via input codes Values ranging from 0 0 0 0 ...9 9 9 9 to be called up via input codes

Parameter setting

Negative display values are identified by a "Minus sign". If several faults are detected, the displayed fault codes will change in a 3 second cycle.

3.2

General facts and operation

The following chapter describes the operation of the LC display via travel lever buttons.

3.2.1 Calling up service mode For this purpose the display must be switched via input mode to service mode. Dies erfolgt über die beiden gelben Infotasten „INFO 1“ und „INFO 2“ an der Fahrhebelrückseite. Navigation in input and service mode takes place via the green and blue buttons on the front of the travel lever.

INFO 1 Taste (gelb)

Werte ändern (grün)

INFO 2 Taste (gelb)

Werte ändern (grün) Navigieren (blau) Functions of ESX Control

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Navigieren (blau)

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Service Training WZ-4 from Version DH The travel lever must be in locked braking position in order to activate input mode!Input mode is switched on by simultaneously pressing both INFO – buttons over a period of approx. 3 seconds.

3.2.2 Entering input codes Input mode starts with flashing of the left hand digit. Here service code9 9 9 9 provides the possibility to change to the service mode. The green buttons can be used to increase or reduce the values of the corresponding digit. By operating one of the blue buttons one can jump to the next (left or right) digit. Once the last right hand digit has been entered the code will be transferred to the control by pressing the right hand blue button once again. If the access code has been entered correctly, the "Spanner" symbol is displayed and the first input digit flashes again. Individual operating states of the machine can now be interrogated by transferring the input code to the control (as described above). When operating both INFO buttons again for approx. 3 seconds, another input code can be entered. The input of code "0 0 0 0 " or switching of the ignition quits the service mode. If the travel lever is shifted out of the brake lock while in service mode, all machine functions will become active, with the exception of the LC-display, which remains in service mode and continues to display the operating values requested last.

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Service Training WZ-4 from Version DH

Normalmodus (Fahrhebel in Bremsraste!) Aufruf optionaler Anzeigen über INFO - Taste 1 und INFO - Taste 2

„Eingabe“ - Modus: Betätigen INFO 1 + INFO 2 ca. 3s

Bet. INFO 1 + INFO 2 ca. 3s oder Fahrhebel aus Bremsr.

Umschaltung Displayfunktion Einstellungen Display Plattenverstellung inaktiv!

Eingabe Zugangangscode 9999

„Service“- Modus: CODE - Eingabe „0000" oder Zündung aus

Eingabe Diagnosecodes Fehlerspeicher abrufen / löschen Maschinentypen umstellen Plattenverstellung inaktiv!

Fahrhebel aus Bremsraste: Diagnosemodus im Vordergrund aktiv!

Version/Status: V3.29 / 13.11.07 Functions of ESX Control Author: Seis,MASH,LOEW / TE/TES

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Service Training WZ-4 from Version DH 3.3

Fault log – display and delete

3.3.1 Showing stored faults This function is only valid from software version 1.10! Switch on function "Show stored faults": Enter code number 0 7 0 0 ( !WITHOUT service code 9999). This code number enables the function „Show stored faults“. The faults stored in the ESX are displayed in flashing mode. If several faults are stored, these are successively displayed in cycles of 3 second. After the last fault has been displayed, the first fault will appear again. If no faults are stored in the ESX, the display will show "- - - - - "

Switch off function "Show stored faults": Enter code number 0 7 0 1 ( !WITHOUT service code 9999). This code number disables the function „Show stored faults“.

Note: Apart from the stored faults the current faults are also displayed. Note:

This function can only be activated / deactivated when the travel lever is locked in the brake gate. (Æ Input mode)

3.3.2 Delete all stored faults This function is only valid from software version 1.10! Execute the function „Delete all stored faults“: The engine must not be running! Enter code number 0 7 1 0 ( !WITHOUT service code 9999). Switch the ignition off and on again. All stored faults are now deleted.

Note: The stored faults can only be deleted when the engine Note:

This function can only be activated / deactivated when the travel lever is locked in the brake gate. (Æ Input mode)

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is not running.

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Service Training WZ-4 from Version DH

3.4

Delete engine control error log

3.4.1 Deleting logged engine errors This function is only valid from software version 2.18 or 3.01 respectively! Execute the function "Delete all logged faults in engine control unit": The engine must not be running! Service code 9 9 9 9 . Enter code number 0 7 6 0 . Switch the ignition off and on again. All stored engine faults are now deleted.

3.4.2 Deleting active engine faults This function is only valid from software version 2.18 or 3.01 respectively! Execute the function "Delete all logged faults in engine control unit": The engine must not be running! Service code 9 9 9 9 . Enter code number 0 7 6 1 . Switch the ignition off and on again. All active engine faults are now deleted.

Version/Status: V3.29 / 13.11.07 Functions of ESX Control Author: Seis,MASH,LOEW / TE/TES

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Service Training WZ-4 from Version DH

4 Settings and queries 4.1

Setting the machine type

Since the same control software is used for all single drum rollers of generation DH-4 (with electronically controlled engines), the control must be matched to the machine in which it is actually installed (setting the machine type). This is necessary during first time commissioning as well as in case of a spare parts replacement. This type setting is necessary, because different machine types/variants can have different parameter sets, e.g. different wheel or axle drive motors (different numbers of pulses) or electrically different hydraulic components (valve spools), or may be equipped with attachment plates or other optional equipment. For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the display module when switching the ignition on. It can also be checked by entering code 0720. The following machine types can be adjusted: Machine type Standard1 177 DH 177 PDH 179 DH 179 PDH 213 DH 213 DH 214 DH 214 DH 213 PDH 213 PDH 214 PDH 214 PDH 216 DH-4 216 DH-4 216 PDH-4 216 PDH-4 219 DH-4 219 DH-4 219 PDH-4 219 PDH-4 226 DH-4 147kW 226 DH-4 150kW 226 PDH-4 147kW 226 PDH-4 150kW 226 DH-4 174kW 226 PDH 174kW

First serial number

Last serial number

Code

-

-

7200

Available from version 1.00

101 582 21 1001 101 582 22 1001 101 582 24 1001 101 582 25 1001 101 582 51 1001 101 583 14 1001 101 582 58 1001 101 583 19 1001 101 582 52 1001 101 583 15 1001 101 582 59 1001 101 583 20 1001 101 582 60 1001 101 582 64 1001 101 582 61 1001 101 582 65 1001 101 582 70 1001 101 582 77 1001 101 582 71 1001 101 582 78 1001 101 582 80 1001 101 582 88 1001 101 582 81 1001 101 582 89 1001 101 582 83 1001 101 582 84 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 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 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 XXX XXX XX XXXX XXX XXX XX XXXX XXX XXX XX XXXX XXX XXX XX XXXX XXX XXX XX XXXX

7201 7202 7203 7204 7205

1.00 1.00 1.00 1.00 1.00

7206

1.00

7209

1.00

7210

1.00

7211

1.00

7212

1.00

7213

1.00

7214

1.00

7215 7216

1.00 1.00

1

The standard machine type does not represent a real machine, but is the initial point for not yet set controls during initial commissioning or after replacing a control.

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Service Training WZ-4 from Version DH 177 BVC 213 BVC

101 582 23 1001 101 582 53 1001

XXX XXX XX XXXX 101 582 53 1082

7250 7251

1.00 1.00

101 582 54 1001

101 582 54 1038

7252

1.00

101 582 82 1001 101 582 86 1001 101 582 85 1001 101 582 53 1083

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

7253

1.00

7254 7255

1.00 3.00

101 583 16 1001 101 582 12 1001

XXX XXX XX XXXX XXX XXX XX XXXX

101 582 54 1039

XXX XXX XX XXXX

7256

3.00

101 583 06 1001 101 582 13 1001

XXX XXX XX XXXX XXX XXX XX XXXX

up to engineering status 01.12.05

213 BVC plates up to engineering status 01.12.05

226 BVC 147kW 226 BVC 150kW 226 BVC 174kW 213 BVC from engineering status 01.12.05

213 BVC Variocontrol 213 BVC plates from engineering status 01.12.05

213 BVC plates Variocontrol +

EXAMPLE: Machine code for BW 219 PDH-4:

7212

Note: Parameter adjustments can only be performed when the engine is not running. This function can only be activated / deactivated when the travel lever is locked in the brake gate. (ÆInput mode)

Procedure for initial commissioning of a control: The control has been installed into the machine. Switch the ignition on. Approx. 4 seconds after switching on the word C O D E will appear for 3 seconds. After this the display changes and shows code 7000. Use the Arrow Up or Arrow Down keys to select the correct machine code from the list of codes. Confirm the selection with the Arrow Right key. After a period of approx. 7 seconds the adjusted machine code, e.g. 7 2 1 2 is displayed for approx. 3 seconds. The new parameters are loaded according to the machine type setting. Do not switch the ignition off during this time! After this switch the ignition off and on again to accept the configuration. After this the normal display will appear again. The following applies for a correction of the machine type code after it has been set. Enter code number 9 9 9 9 (activation of service mode) 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 2 0 0 . Select the machine code from the table above and confirm it with the Arrow Right key. After operating the Arrow Right key the control switches automatically off and on again. After a period of approx. 7 seconds the adjusted machine code, e.g. 7 2 1 2 is displayed for approx. 3 seconds. The new parameters are loaded according to the machine type setting. Do not switch the ignition off during this time! Version/Status: V3.29 / 13.11.07 Functions of ESX Control Author: Seis,MASH,LOEW / TE/TES

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Service Training WZ-4 from Version DH After this switch the ignition off and on again to accept the configuration. After this the normal display will appear again. 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 2 0 0 . This does not enable to drive or steer the machine. It only serves the purpose of commissioning.

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Service Training WZ-4 from Version DH 4.2

Driving against the closed brake

After entering the code number 0 5 0 0 the brake will not be released. If the travel lever is in this condition shifted out of the brake gate and moved to any travel direction, the travel pumps will be triggered according to the chosen travel direction. At the same time a warning (fault code 0 5 0 0 ) appears on the display and the warning buzzer is triggered, in order to keep the operator informed about the condition. The brake control light in the LC-display remains activated. In order to terminate this function and release the brake you must either enter code number 0 5 0 1 or switch the ignition off. After entering code number 0 5 0 1 the function is aborted and OK is displayed as confirmation for 5 seconds. After this the code needs to be entered again. Note:

4.3

This function can only be activated / deactivated when the travel lever is locked in the brake gate. (Æ Input mode)

Teaching the travel direction sensor

Teaching of the travel direction sensor is required for initial commissioning and after the replacement of a travel motor. Perform the following sequence Turn the speed range selector switch to "MAX" Shift the travel lever slowly out of neutral, until a travel speed of approx. 1 km/h is indicated. If one or both travel direction sensors detected a counteracting direction the error codes 1106 and/or 1116 will appear after approx. one machine length. Otherwise no error code will be displayed. The travel direction detection is now automatically set. However, should one of the two error codes appear, this must be caused by a sensor fault.

4.4

Automatic detection of surge currents in travel system

This function is only valid from software version 1.09! For a sensitive and exact function of the travel system the surge currents in the travel system must be determined for both travel directions. The surge currents are automatically determined after entering a code number, so that no electric meter is required. The surge currents must only be determined during initial commissioning in the factory, after a service during which the control on a steering valve or the complete steering valve has been replaced and after the replacement of the ESX-control. The measurement is identical for both travel directions: After entering the respective code number the current is increased by the control solenoid on the travel pump in steps of 5 mA, starting from 250mA.. After each current increase the system waits for 3 seconds. If a considerable drum movement is measured during the waiting time, the surge current is reached. In order to enhance the measuring result this measurement is performed three times. The final surge current is the mean value of these three measurements. This surge current is automatically stored and is valid from the next start of the machine. Before the measurement you should strictly make sure that the machine is parked on level ground and has a sufficient distance for movement to front and back, because the machine will move to the respective direction when performing the measurement. Attention! First set the machine to input mode (code 9 9 9 9 ). It must be strictly assured that the speed sensor (in front right hand hydraulic motor) is working correctly. For a function test enter code number 1 1 0 6 at the display module. This code can be used to display the number path pulses from the speed sensor. The displayed value must change when the machine is driven.

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Service Training WZ-4 from Version DH If this value does not change even though the machine is moving, the measurement must not be performed! The state of the speed sensor must first be corrected, as otherwise the movement of the drum will not be detected. (See also: „Resetting the surge currents in the travel system”) Attention! During the measurement the machine will move when the surge current is reached! Do not leave the machine while the measurement is progressing! During the measurement keep an eye on your environment! To stop the machine reset the travel lever to neutral position! The automatic measurement of the travel system surge currents is performed as follows: The speed selection switch must be in position ECO. If necessary enter code number 9 9 9 9 to access the service mode. Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents in the travel system"; the display now shows the reading 0 0 0 0 with the first digit flashing. This code number must be entered to be able to perform the following steps. From this point the machine can no longer be operated with the travel lever! The travel lever will only be in function again after the teach function has been completed or the machine has been restarted. The measurements (forward/reverse) must be started by entering a code number. The code number required to teach the travel direction is as follows: Determination of control surge currents

1 0 9 1

After the input of the above code number the display shows " F O R E ". Shifting the travel lever forward starts the first surge current measurement for forward travel. During the measurement the actual current is displayed (display value = current in mA). Once the surge current measurement is finished the display will show the reading O K for a period of 5 seconds. After this wait time the display reading changes to " B A C K ". Now shift the travel lever backward to start the surge current measurement in reverse. During the measurement the actual current is displayed (display value = current in mA). After completion of the measuring process in reverse the display will show O K again. The travel lever must now be returned to braking position. Once both surge currents have been learned correctly and the travel lever is in "braking position", the display shows the reading "D O N E", the values are saved and the function is completed. Now the machine can be operated again with the travel lever. The new surge current values for the travel system are valid from the next start. The teach function can at any time be aborted by operation of the emergency stop or the ignition switch. The following procedure applies for software versions 1.07 and 1.08: The automatic measurement of the travel system surge currents is performed as follows: The seat must be adjusted for travel direction forward! The speed selection switch must be in position ECO. If necessary enter code number 9 9 9 9 to access the service mode. Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents in the travel system"; the display now shows the reading 0 0 0 0 with the first digit flashing. This code number must be entered to be able to perform the following steps.

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Service Training WZ-4 from Version DH From this point the machine can no longer be operated with the travel lever! The travel lever will only be in function again after the teach function has been completed or the machine has been restarted. Both measurements (forward/reverse) must be started by entering a code number. The code numbers for both travel directions are: Determine surge current for control forward

1 0 9 1

Determine surge current for control reverse

1 0 9 2

After entering one of the above code numbers the measurement will only start after moving the travel lever to the respective travel direction. ATTENTION:The ASC fault indicator light will come on during the teach process. In this case this is of no relevance. The warning will disappear when restarting the machine. During the measurement the actual current is displayed (display value = current in mA). Teaching is required for both travel directions. When returning the travel lever to neutral position after the two measurements, the display will show O K for 3 seconds and the averaged values will be saved. Once both surge currents have been measured the machine can be operated again with the travel lever. The new surge current values for the travel system are valid from the next start. The teach function can at any time be aborted by operation of the emergency stop or the ignition switch.

4.5

Changing the steering unit on BVC-4 machines

Availability: From version 1.09 By standard all BVC-4 machines (code 725x) are equipped with electric steering. For machines with the Hydraulic Steering Option the steering mode (steering unit) in the travel control must be switched over (electric steering disabled): Enter code number 9999 (activation of service mode) Enter code number 2060. This code number activates the function "Adjusting the steering unit“. The following code numbers are available to activate the assembled steering unit. Hydraulic steering Electric steering

2062 2061

The display shows O K Attention:

The steering unit can only be changed when the engine is not running!

Version/Status: V3.29 / 13.11.07 Functions of ESX Control Author: Seis,MASH,LOEW / TE/TES

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Service Training WZ-4 from Version DH

4.6

Teaching the electronic end stops of the steering angle sensor (BVC)

Attention:

Note:

Does not apply for BVC machines with "hydraulic steering" option!

During the measurement the machine should be parked on level ground. The drum should be standing on old rubber tires or a metal plate. Specify the engine speed -> travel lever out of braking position = neutral position (Not while entering a code).

To prevent the steering from moving all the way to the mechanical stops of the steering cylinder it is necessary to determine a defined safety distance to these end stops. Enter code number 9 9 9 9 to access the service mode. Enter code number 2 0 1 0 to activate the mode "Teach steering stops". Return the travel lever to neutral position (no braking function, but to relieve the machine of strain). The display shows the standardized steering position (0..1000 right ... left). Now turn the electric steering wheel clockwise, until the mechanical stop is reached The displayed value should be in the range of 100..300. Then shift the travel lever to braking position and enter code number 2 0 1 2 (press both Info-buttons first to access the input mode). In case of acceptance the value 2 2 2 2 will appear for a moment.In case of a fault the value 9 9 9 9 upon acceptance (see below). Return the travel lever to neutral position (no braking function, but to relieve the machine of strain). The display shows the standardized steering position (0..1000 right ... left). Now turn the electric steering wheel anti-clockwise, until the mechanical stop is reached The displayed value should be in the range of 700..900. Then shift the travel lever to braking position and enter code number 2 0 1 3 (press both Info-buttons first to access the input mode). In case of acceptance the value 3 3 3 3 will appear for a moment. In case of a fault the value 9 9 9 9 upon acceptance (see below). To leave the mode the machine must be switched off or code 2 0 1 1 must be entered. Possible error causes (code 9 9 9 9 ) : -

Incorrect connection of hoses -> have checked by engineer -> correct. Connecting fault on potentiometer -> have checked by an electrician -> correct. Potentiometer faulty -> replace the potentiometer.

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Service Training WZ-4 from Version DH START Machine on level d Tires or metal plate under drum

Machine on level d Enter 9999 Enter 2010 Travel lever in neutral position Turn steering wheel CLOCKWISE, until STOP is reached (noise from pressure relief valve, cylinder fully Travel lever in braking position

Enter 2012

Display shows

Display shows

2222

9999

Display shows

Display shows

3333

9999

Travel lever in neutral position Turn steering wheel ANTI-CLOCKWISE, until STOP is reached (noise from pressure relief valve, cylinder fully Travel lever in braking position

Enter 2013

Switch the ignition off and on again.

OR

Enter 2011

FINISHED Version/Status: V3.29 / 13.11.07 Functions of ESX Control Author: Seis,MASH,LOEW / TE/TES

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4.7

Automatic detection of surge currents on steering valves (BVC)

Attention:

Note:

Does not apply for BVC machines with "hydraulic steering" option!

Perform this function only AFTER "Teaching the electronic end stops of the steering angle sensor" .

During the measurement the machine should be parked on level ground. Before the measurement both drums should be steered to straight ahead position. The travel motor must be moved out of braking position -> raised idle speed! To enable a sensitive and exact function of the steering the surge currents of the two control solenoids and both steering valves must be measured. The surge currents are automatically adjusted after entering a code number, so that no electric meter is required. The surge currents must only be adjusted during initial commissioning in the factory, after a service during which the control on a steering valve or the complete steering valve has been replaced and after the replacement of the ESX-control. The measurement is identical for both solenoids: Example BW 177 BVC: After entering the respective code numbers the current is increased by the control solenoid in steps of 5 mA, starting from 650mA.. After each increasing step the system waits for 2 seconds. If a change in drum angle is measured after the waiting time, the surge current is reached. In order to enhance the measuring result this measurement is performed three times. The final surge current is the mean value of these three measurements. This surge current is automatically stored and is valid from the next start of the machine. For all other machine types the same procedure is used, however, currents and times will vary. Before the measurement you must strictly make sure that the steering system is „bled“, because an air cushion in the steering cylinders would have a negative effect on the measurement and therefore on the steering performance of the machine. Sufficient bleeding is achieved by performing a few quick steering movements at full engine speed. The automatic measurement of the steering valve surge currents is performed as follows: The engine must be operated in ECO-mode! Enter code number 9 9 9 9 to access the service mode. Travel lever in neutral position (Brake must be released!) Enter code number 2 0 0 0 . This code number activates the function "Automatic detection of steering valve surge currents"; the display now shows the reading 0 0 0 0 with the first digit flashing. Now code number 2 0 0 1 must be entered. After entering one of the above mentioned code numbers the measurement of the surge current will start immediately. The drum is thereby first steered to the right and then to the left. During the measurement the actual valve current is displayed (display value in mA). Attention! During the measurement the drum cannot be steered ! The steering wheel has no effect. During the measurement the machine should not be driven ! Once the measurement is completed the display value OK will appear for 3 seconds, after this the code number 0000 is displayed with the first digit flashing, the next measurement can be started. The new surge current values are valid from the next start.

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Service Training WZ-4 from Version DH 4.7.1 Reading out actual surge current values Surge current values currently saved in the control can be read out with the following input codes. The values should not differ more than +/- 50! Show surge current for left hand valve control

2 1 0 6

Show surge current for right hand valve control

2 1 0 8

In case of excessively differing surge currents you should first of all run a new teach procedure. See also fault codes 2 2 0 0 and 2 2 0 1 !

4.8

"Trimming" the speed measurement

4.8.1 Quick overview Enter 9 9 9 9 : Switch on service mode. Enter 1 1 5 8 : Allow function "Trimming the speed measurement". Enter 1 1 5 9 : Start function "Trimming the speed measurement". Display shows: F O R E : Move the travel lever forward (or back). Green button up = raise indicated speed (measuring value too low) Green button down = reduce indicated speed (measuring value too high) Travel lever in braking position: D O N E = FINISHED! Procedure finished.

4.8.2 Explanation In order to adjust the speed display (LCD) e.g. to the BOMAG measuring system to reference tests benches, the machine integrated travel speed detection may be "trimmed", i.e. adjusted. For this purpose the input codes 1 1 5 8 (enable function) and 1 1 5 9 (start function) are used to activate the function Speed detection, trimming of measuring values (chapter 12.4.3, page 77). As a result, the travel speed measured by the machine appears in the LCD-Display. With the green button on the travel lever an internal calibration value can now be changed to such an extent, that the displayed speed corresponds with the actual travel speed. ATTENTION! If the speed detection is extremely falsified because of operating errors, this can lead to uncomfortable travel behaviour and a reduced ASR control quality.

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Service Training WZ-4 from Version DH 4.9

Calibrating the speed detection (calibration of wheel diameter)

4.9.1 Quick overview see also 12.2.14 Calibrating the wheel diameter Enter 9 9 9 9 : Switch on service mode. Enter 1 1 6 0 : Allow function "Calibrate the speed detection". Enter 1 1 6 1 : Start function "Calibration of speed detection" for a 5m distance. or enter 1 1 6 2 : For a 10m distance or enter 1 1 6 3 : For a 20m distance or enter 1 1 6 4 : For a 50m distance or enter 1 1 6 5 : For a 100m distance Display shows: F O R E : Move the travel lever forward (or back). Green button up = raise indicated speed (measuring value too low) Green button down = reduce indicated speed (measuring value too high) Travel lever in braking position: D O N E = FINISHED! Procedure finished. Enter 1 1 6 8 Enter 1 1 6 9

: Load original value. : Save the values.

4.9.2 Explanation The function Speed detection, teaching of distance pulses offers the possibility to calibrate the internal calibration value of the speed detection.. For this purpose the input code 1 1 6 0 (enable function) and 1 1 6 1 1165 (start the respective function) can be used to select a distance, which is then travelled with the machine (as exact as possible). During travel a numeric value is displayed. The measurement is subsequently saved by means of the input code 1 1 6 9 and is now a valid criterion for the speed detection. With the input code 1 1 6 8 it is also possible to adjust the basic value for series machines -> (1 1 6 0 - > 1 1 6 9 ). ATTENTION! If the speed detection is extremely falsified because of operating errors, this can lead to uncomfortable travel behaviour and a reduced ASR control quality.

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Service Training WZ-4 from Version DH 4.10

Activating/deactivating the vibration control

Availability: From version 3.20 (design status 01.05.2007) With design status 01.05.2007 machines with circular exciter (DH-4. Not BVC) were equipped with a switch in the dashboard to adjust the nominal vibration frequency. Machines with an older design status and without this switch need to be adjusted accordingly when using the the currently valid travelling software.

4.10.1 Quick overview see also 12.4.11 Vibration: Enable frequency setting Enter 9 9 9 9 Enter 3 0 9 1 Enter 3 0 9 2 or Enter 3 0 9 3

: Switch on service mode. : Enable function "Switch over frequency setting". : Activate frequency setting (machine with switch). : Disable frequency setting (machine WITHOUT switch).

Viewing the current setting: Enter 9 9 9 9 Enter 3 0 9 0

4.11

: Switch on service mode. : View the current setting.

Activating/deactivating the attachment plates

Availability: From version 3.29 (design status 01.09.2007) With design status 01.09.2007 the "attachment plate" option was released for machines with circular exciter (DH-4. Not BVC). ATTENTION: Machines with attachment plates are setup with the same software identification, as the machines without plates (213 DH-4 = 213DH-4-plates = 7205)!

4.11.1 Quick overview see also 12.4.13: Attachment plates (only circular exciter): Activating/deactivating the attachment plates option Enter 9 9 9 9 Enter 3 0 7 0 Enter 3 0 7 1 or Enter 3 0 7 2

: Switch on service mode. : Optional changeover enabled. : Activate option "attachment plates"). : Disable option "attachment plates".

Version/Status: V3.29 / 13.11.07 Functions of ESX Control Author: Seis,MASH,LOEW / TE/TES

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Service Training WZ-4 from Version DH

4.12

Setting the vibration motor type

Availability: From version 3.20 (design status 01.05.2007) or 3.21 (design status 01.06.2007) Other vibration motors (type 2) were introduced as standard for machines (Code numbers 7205 to 7210) from design status 01.05.2007 and for machines (Code numbers 7251, 7252, 7255, 7256) from design status 01.06.2007. Standard settings are shaded grey in the table (from design status 01.06.2007). ATTENTION! If a machine with an older design status is furnished with the up-to-date travelling software, the corresponding vibration motor type needs to be set (see 12.4.10). Example: BW213DH-4 (7205) with design status before 01.05.2007: -> 9 9 9 9 -> 3 0 3 1 -> 3 0 3 2 . Check: -> 3 0 3 0 , display: 47 (see 4.12.2).

4.12.1 Table of vibration motor types

Machine type code

Type1 (3032)

7201 7202 7203 7204 7205 7206 7207 7208 7209 7210 7211 7212 7213 7214 7215 7216

MMF025 MMF025 MMF025 MMF025 A2FM56 A2FM56 A2FM56 A2FM56 A2FM56 A2FM56 A2FM63 A2FM63 A2FM80 A2FM80 A2FM80 A2FM80

7250 7251 7252 7253 7254 7255 7256

MMF025 A2FM56 A2FM56 A2FM80 A2FM80 A2FM56 A2FM56

Type 2 (3033)

Type 3 (3034)

Vibration motor types Type 4 Type 5 Type 6 (3035) (3036) (3037)

Type 8 (3039)

90M055 90M055 90M055 90M055 90M055 90M055

90M055 90M055

90M055 90M055

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Type 7 (3038)

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Service Training WZ-4 from Version DH

4.12.2 Table of pulse numbers For correct detection of the vibration frequency, the control must be aware of the number of pulses (number of pulses per revolution) of the vibration motors. The pulse numbers are determined by the vibration motor type. The currently set pulse number can be read out with input code 3030.

Machine type code

Type 1 (3032)

7201 7202 7203 7204 7205 7206 7207 7208 7209 7210 7211 7212 7213 7214 7215 7216

43 43 43 43 47 47 47 47 47 47 47 47 53 53 53 53

7250 7251 7252 7253 7254 7255 7256

43 47 47 53 53 47 47

Type 2 (3033)

Type 3 (3034)

Pulse numbers Type 4 Type 5 (3035) (3036)

Type 6 (3037)

Type 8 (3039)

52 52 52 52 52 52

52 52

52 52

Version/Status: V3.29 / 13.11.07 Functions of ESX Control Author: Seis,MASH,LOEW / TE/TES

008 911 79

Type 7 (3038)

BOMAG

Page 27 of 84

207

9.1

Machine related electrics

Service Training WZ-4 from Version DH

5 Replacement of components 5.1

How to proceed when replacing components?

Each machine is adjusted individually during initial commissioning. This adjustment or teaching process is necessary to make sure that the travel and steering functions are almost identical on all machines. Background of these adjustment procedures are the tolerances of the components used, e.g. hydraulic pump for travel system, proportional valves for steering, steering angle sensors and ESX control. These tolerances apply for both mechanical as well as electrical functions and are unavoidable for manufacturing reasons. To enable simple and quick adjustment procedures we have decided to do without expensive tools. All that is needed is this manual and a bit of time. By following the described procedure it is possible to take a machine back into operation after the replacement of one of the components specified above and to re-establish the usual functional quality, with almost any previous knowledge. Even an incorrectly or incompletely conducted teaching procedure can be repeated without problems as often as necessary. At the first glance it seems to be at bit awkward to perform this adjustment work on every machine, but this procedure enables the operation of all machines with the same operating software. At the end of the day this considerably increases the spare parts availability.

5.2

Replacement of an ESX-control

Since the control stores all teach values of the machine, each teaching procedure must be performed with the new control after a replacement. Attention:

Before performing one of the following steps, the machine type must first be set (see chapter 3.3)! When changing the machine type all previously made adjustments will be lost!

Now the teach functions must be executed. From DH Automatic detection of travel system surge currents (see chapt. 3.6) On BVC Automatic detection of steering valve surge currents (see chapt. 3.7) Teaching the electronic end stops of the steering angle sensor (see chapt. 3.8)

5.3

Replacement of a travel pump / axle drive motor / drum drive motor Automatic detection of travel system surge currents (see chapt. 3.6)

5.4

Replacement of a steering valve (BVC) Automatic detection of steering valve surge currents (BVC) (see chapt. 3.7)

5.5

Replacement of a steering angle sensor Teaching the electric end stops of the steering angle sensor (see chapt. 3.8)

5.6

How to proceed when replacing a front / rear axle sensors? Teaching the travel direction sensor

Version/Status: V3.29 / 13.11.07 Functions of ESX Control Author: Seis,MASH,LOEW / TE/TES

208

BOMAG

Page 28 of 84

008 911 79

9.1

Machine related electrics

Service Training WZ-4 from Version DH

5.7 Component replacement without adjustment procedure Which components can be replaced without a subsequent adjustment procedure?

Display Data collector Joystick Electric steering wheel Diesel engine All switches in the dashboard Vibration motor Vibration pump

Note:

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

Version/Status: V3.29 / 13.11.07 Functions of ESX Control Author: Seis,MASH,LOEW / TE/TES

008 911 79

BOMAG

Page 29 of 84

209

210

Description of Signals on the ESX Control

BOMAG

Not used

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

X35:13

Page 30 of 84

active, i.e. high amplitude )approx. 12 V inactive, i.e. low amplitude ) 0V Warning buzzer active )approx. 12 V Warning buzzer inactive ) 0V Measurement not possible! Measurement not possible! ------------Signal changes between approx. 0V and approx. 12V, when machine is driving. Frequency with travel speed m/min Machine type: XX m/min )approx.XX Hz XX m/min )approx.XX Hz Machine type: XX m/min )approx.XX Hz XX m/min )approx.XX Hz Machine type: XX m/min )approx.XX Hz XX m/min )approx.XX Hz ---

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

Description of Signals on ESX Control

ESX terminal Signal description X35:1 AGND = Analogue ground: Ground potential for sensors (steering angle sensor, steering unit etc.) X35:2 Output amplitude changeover Digital output (max. 2.5 A) X35:3 Output warning buzzer Digital output (max. 2.5 A) X35:4 Interface RS 232 RxD, not used for normal operation. X35:5 Interface RS 232 TxD, not used for normal operation. X35:6 Not used X35:7 Not used X35:8 Not used X35:9 Not used X35:10 Not used X35:11 Not used X35:12 Input axle speed Frequency input (0...0.70.5kHz)

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

6 Description of the signals on the ESX-control

Service Training WZ – 4

9.1 Machine related electrics

008 911 79

008 911 79

BOMAG

Voltage supply for sensors This output supplies steering angle sensor and steering unit. Without this voltage the control cannot work correctly and will switch to override mode (emergency function). Output backup alarm Digital output (max. 2.5 A) Not used Interface CAN-Bus 1 Wire -, is used for communication with MESX, data collector, LCD-display and BOP. Interface CAN-Bus 1 Wire +, is used for communication with MESX, data collector, LCD-display and BOP. Input potential terminal 15 Digital input active high This signal must be present, so that the control can work. Input steering angle sensor Analogue input / voltage input 0..8,5 V

X35:23

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

X35:29

X35:28

X35:27

X35:25 X35:26

X35:24

X35:22

)approx. 12 V )approx.2 V

) 0V )approx. 12 V

Position steering angle sensor (measured against AGND) right hand stop ) 0.50.0.10.00 V

Control switched on Control switched off

Measurement not possible!

Measurement not possible!

Backup alarm inactive Backup alarm active ---

Description of Signals on ESX Control

Output steering left PWM digital output (max. 4 A) Output steering right PWM digital output (max. 4 A) Output vibration pump attachment plate PWM power output (max. 4A)

X35:20

X35:21

Input steering sensor (S1/B) Digital input active high

Page 31 of 84

Nominal values (voltage / current) --Seat operated ) 0V Seat not operated ) ?V --Brake released )approx. 12 V Brake applied ) 0V Signal changes between approx. 0V and 12V, when steering wheel is turned. Frequency depends on speed of turning Signal changes between approx. 0V and 12V, when steering wheel is turned. Frequency depends on speed of turning Steering left active )0.4.0.10.6 A Steering left inactive ) 0A Steering right active )0.4.0.10.6 A Steering right inactive ) 0A permissible current range: approx. 0.0.10.2 A Vibration pump active )0.6.0.10.2 A Vibration pump not active ) 0A Nominal voltage = 8.5 V Permissible range: approx. 7.65..90.35 V This voltage must be measured against AGND.

Description of Signals on the ESX Control

X35:19

ESX terminal Signal description X35:14 Not used X35:15 Input seat contact switch Digital input active high X35:16 Arm rest switch X35:17 Input BTS brake (from travel lever) Digital input active high X35:18 Input steering sensor (S1/A) Digital input active high

Service Training WZ – 4

Machine related electrics

9.1

211

212

Input hydraulic pressure travel pump circuit Analogue input (current input 4mA..20mA) from pressure sensor on travel pump Not used Interface CAN-Bus 2 Wire -, is used to communicate with the travel lever and engine EMR. Input drum speed Frequency input (0...0.70.5kHz)

X35:31

BOMAG

Page 32 of 84

Signal changes between approx. 0V and approx. 12V, when machine is driving. Frequency with travel speed m/min Machine type: XX m/min )approx.XX Hz XX m/min )approx.XX Hz Machine type: XX m/min )approx.XX Hz XX m/min )approx.XX Hz Machine type: XX m/min )approx.XX Hz XX m/min )approx.XX Hz Frequency with vibration frequency in Hz Machine type: Vib. frequency XX Hz )approx.XX Hz Vib. frequency XX Hz )approx.XX Hz Machine type: Vib. frequency XX Hz )approx.XX Hz Vib. frequency XX Hz )approx.XX Hz Machine type: Vib. frequency XX Hz )approx.XX Hz Vib. frequency XX Hz )approx.XX Hz Sense of rotation forward )approx. 12 V

Measurement not possible!

---

Description of Signals on ESX Control

Input sense of rotation of vibration motor

X35:36

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Input vibration motor Frequency input (0....2,0kHz)

X35:35

X35:34

X35:32 X35:33

Input longitudinal inclination of machine Analogue input / voltage input 0..8,5 V

Nominal values (voltage / current) straight ahead / neutral / middle ) ..V left hand stop ) 6.80.0.80.70 V Inclination of machine (measured against AGND) -45° axle high ) 0.50.0.20.49 V Neutral position ) 2.50 V maximum down ) 2,51..4,50 V 0 bar ) approx.4 mA 600 bar ) approx.20 mA

Description of Signals on the ESX Control

X35:30

ESX terminal Signal description

Service Training WZ – 4

9.1 Machine related electrics

008 911 79

008 911 79

BOMAG

Output emergency steering

Not used Not used Not used Output drum drive motor PWM power output (max. 4 A)

Output axle motor PWM power output (max. 4 A)

Output vibration pump PWM power output (max. 4A)

Output travel pump forward PWM power output (max. 4 A)

Not used Not used

X35:42

X35:43 X35:44 X35:45 X35:46

X35:47

X35:48

X35:49

X35:50 X35:51

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Input steering sensor (S2/B) Digital input active high

X35:41

ESX terminal Signal description (currently not used) Digital input active high X35:37 Input sense of rotation of drum Digital input active high X35:38 Input sense of rotation of axle Digital input active high X35:39 Not used X35:40 Input steering sensor (S2/A) Digital input active high

Service Training WZ – 4

Description of Signals on ESX Control

Sauer components with EDC Travel forward active Travel forward inactive -----

)18.0.80 mA ) 0 mA

Page 33 of 84

Sense of rotation forward )approx. 12 V Sense of rotation backward )approx.2 V Sense of rotation forward )approx. 12 V Sense of rotation backward )approx.2 V --Signal changes between approx. 0V and 12V, when steering wheel is turned. Frequency depends on speed of turning Signal changes between approx. 0V and 12V, when steering wheel is turned. Frequency depends on speed of turning Emergency steering active )approx. 12 V Emergency steering inactive ) 0V ------permissible current range: approx. 0.0.00.6 A Drum drive motor active )0.0.0.20.0 A Drum drive motor not active ) 0A permissible current range: approx. 0.0.00.6 A Axle motor active )0.0.0.20.0 A Axle motor not active ) 0A permissible current range: approx. 0.0.00.6 A Axle motor active )0.0.0.20.0 A Axle motor not active ) 0A Travel forward active )0.0.0.20.0 A Travel forward inactive ) 0A

Nominal values (voltage / current) Sense of rotation backward )approx.2 V

Description of Signals on the ESX Control

Machine related electrics

9.1

213

214

BOMAG

Test connection Baby Boards

Test connection Baby Boards

Test connection Baby Boards

X35:66

X35:67

X35:68

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

approx. 0 V

approx. 0 V

approx. 0 V

Sauer components with EDC Travel forward active Travel forward inactive approx. 0 V

Description of Signals on ESX Control

Test connection Baby Boards

X35:65

X35:64

X35:63

X35:62

Ground connection electronics Voltage supply for outputs (permanent voltage) Voltage supply for outputs (permanent voltage) Voltage supply for outputs (permanent voltage) Voltage supply for outputs (permanent voltage) Voltage supply for outputs (permanent voltage) Output brake Digital output (max. 4 A) Output blower coupling stage 2 (currently not used) Digital output (max. 4 A) Output blower coupling stage 3 (currently not used) Digital output (max. 4 A) Output travel pumps reverse PWM power output (max. 4 A)

X35:55 X35:56 X35:57 X35:58 X35:59 X35:60 X35:61

)18.0.80 mA ) 0 mA

Control running )approx. 12 V Control not running ) 0V 0 V (measured against ground) approx. 12 V (measured against ground) approx. 12 V (measured against ground) approx. 12 V (measured against ground) approx. 12 V (measured against ground) approx. 12 V (measured against ground) Open brake )approx. 12 V Close brake ) 0V Active )approx. 12 V Inactive ) 0V Active )approx. 12 V Inactive ) 0V Travel forward active )0.0.0.20.0 A Travel forward inactive ) 0A

Measurement not possible!

Nominal values (voltage / current) ---

Description of Signals on the ESX Control

ESX terminal Signal description X35:52 Not used X35:53 Interface CAN-Bus 2 Wire +, is used to communicate with the travel lever and engine EMR. X35:54 Voltage supply for electronics (permanent voltage)

Service Training WZ – 4

Page 34 of 84

9.1 Machine related electrics

008 911 79

008 911 79

Description of Signals on the Data Collector

BOMAG

0V ?V )approx. 12 V ) 0V ) 0V ) ?V )approx. 12 V ) 0V ) 0V ) ?V

) )

Page 35 of 84

The voltage signal changes with the filling level in the fuel tank Fuel tank empty ) ?? V Fuel tank full ) ?? V --Voltage supply O.K. ) approx.12 V

Description of Signals on Data Collector

Not used Voltage supply for monitoring of water separation (PIN X27:9)

Indicator right active Indicator right inactive Indicator left active Indicator left inactive Engine running Engine not running --Filter clogged Filter OK --Air conditioning on Air conditioning off Filter clogged Filter OK Illumination on Illumination off Coolant supply too low Sufficient coolant supply --0V (measured against ground)

Input indicator right Digital input active high Input indicator left Digital input active high Input engine running (D+) Digital input active high Not used Input hydraulic oil filter differential pressure Digital input active low Not used Input air conditioning Digital input active high Input engine air filter Digital input active low Input background illumination Digital input active high Input coolant supply Digital input active low Not used Ground connection Not used Input fuel level Analog input

)approx. 12 V ) 0V )approx. 12 V ) 0V )approx. 12 V ) 0V

Nominal values (voltage / current)

Signal description

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

X27:3 X27:4

X26:11 X26:12 X27:1 X27:2

X26:10

X26:9

X26:8

X26:6 X26:7

X26:4 X26:5

X26:3

X26:2

PIN data collector X26:1

Notes: 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.

7 Description of signals on the data collector

Service Training WZ – 4

Machine related electrics

9.1

215

216

BOMAG

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

X27:10 X27:11 X27:12

)

0V

Page 36 of 84

Control running )approx. 12 V Control not running ) 0V If a sufficient amount of water has been separated, a low current flows over the over the contacts and the water in the separator bowl. This input analyses this current. No water separated ) I= 0A Water separated ) I 0,03mA -------

Measurement not possible!

No voltage supply 0V (measured against ground) Measurement not possible!

Nominal values (voltage / current)

Description of Signals on Data Collector

Input water separation Current input

X27:9

X27:8

Not used Not used Not used

Ground connection Interface CAN-Bus 1 Wire +, is used for communication with MESX, ESX, LCD-display and BOP. Interface CAN-Bus 1 Wire -, is used for communication with MESX, ESX, LCD-display and BOP. Voltage supply (permanent voltage)

X27:5 X27:6

X27:7

Signal description

Description of Signals on the Data Collector

PIN data collector

Service Training WZ – 4

9.1 Machine related electrics

008 911 79

008 911 79

Description of Signals on the Travel Lever

BOMAG

Not used Not used Input high amplitude

)approx. 12 V ) 0V

Page 37 of 84

Connection to machine ground (0V) Connection to machine ground (0V) The voltage signal changes with the adjusted travel speed range Travel stage min. ) ?? V Travel stage max. ) ?? V ----High amplitude active )approx. 12 V

approx. 0 V measured against ground (terminal 31)

Measurement not possible!

Measurement not possible!

Nominal voltage = approx. 5,0 V Permissible range: approx. 4.8.0.50.2 V This voltage must be measured against AGND.

Description of Signals on Travel Lever

Ground connection Output BTS brake Digital output (max. 4 A) Output BTS (not used) Digital output (max. 4 A) Output voltage supply for additional analog evaluations This output supplies the 24-stage travel range selector switch. This voltage is required to connect and evaluate further analog switches to the travel lever. Interface CAN-Bus 2 Wire +, is used to communicate with ESX and engine EMR. Interface CAN-Bus 2 Wire -, is used to communicate with ESX and engine EMR. AGND = Analogue ground: Ground potential for additional analog evaluations Reference to PIN X23:5 Node address addressing 1 Node address addressing 2 Input travel stage selector switch Analog input

Electronics functioning Electronics not working 0V (measured against ground) Brake opens Brake closes

Voltage supply (permanent voltage)

)approx. 12 V ) 0V

Nominal values (voltage / current)

Signal description

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

X23:12 X24:1 X24:2

X23:9 X23:10 X23:11

X23:8

X23:7

X23:6

X23:5

X23:4

X23:2 X23:3

PIN travel lever X23:1

Notes: 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.

8 Description of signals on the travel lever

Service Training WZ – 4

Machine related electrics

9.1

217

218

BOMAG

Description of Signals on Travel Lever

0V (measured against ground)

Voltage supply active Voltage supply inactive

High amplitude inactive Low amplitude active Low amplitude inactive -------

Digital input active high Input low amplitude Digital input active high Not used Not used Input arm rest left (not yet realized) Digital input active high Output voltage supply for additional digital evaluations This output supplies the amplitude selector switch. This voltage is required to connect and evaluate further digital switches to the travel lever. Output voltage supply ground potential In connection with PIN X24:7 this output enables the control of additional components (relays, displays etc.) )approx. 12 V ) 0V

) 0V )approx. 12 V ) 0V

Nominal values (voltage / current)

Description of Signals on the Travel Lever

Signal description

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

X24:8

X24:7

X24:4 X24:5 X24:6

X24:3

PIN travel lever

Service Training WZ – 4

Page 38 of 84

9.1 Machine related electrics

008 911 79

008 911 79

Description of Signals on the LC-Display

BOMAG

Status: Author:

X29:8

X29:5 X29:6 X29:7

X29:4

X29:3

X29:2

X28:6 X29:1

X28:5

13.11.07 Seis,MASH,LOEW / TE/TES

---

Electronics functioning Electronics not working --Adjustment active Adjustment inactive Adjustment active Adjustment inactive High idle active High idle inactive Low idle active Low idle inactive ----Voltage supply active Voltage supply inactive

Measurement not possible!

)approx. 12 V ) 0V

)approx. 12 V ) 0V )approx. 12 V ) 0V )approx. 12 V ) 0V )approx. 12 V ) 0V

)approx. 12 V ) 0V

Nominal values (voltage / current) Electronics functioning )approx. 12 V Electronics not working ) 0V 0V (measured against ground) Measurement not possible!

Description of Signals on the LC-Display

Not used Input lower frequency Digital input active high Input higher frequency Digital input active high Input engine speed high idle Digital input active high Input engine speed low idle Digital input active high Not used Not used Output voltage supply for additional digital evaluations This output supplies the engine speed switch and the switch for frequency adjustment. This voltage is required to connect and evaluate further digital switches to the LCD. Not used

Ground connection Interface CAN-Bus 1 Wire +, is used for communication with MESX, ESX, data collector and BOP. Interface CAN-Bus 1 Wire -, is used for communication with MESX, ESX, data collector and BOP. Voltage supply (permanent voltage "Battery +“ for RTC)

X28:2 X28:3

X28:4

Signal description Voltage supply (permanent voltage "ignition on")

PIN Display X28:1

Notes: 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.

9 Descriptions of signals on the LC - Display

Service Training WZ – 4

Page 39 of 84

Machine related electrics

9.1

219

220

BOMAG

Voltage supply for outputs

Ground connection Input proximity switch, plates top Digital input active high Output plates float position 1 Digital output (max. 4 A) Output plates priority Digital output (max. 4 A) Output plates float position 2 Digital output (max. 4 A) Not used

X62:9

X62:10

X62:11 X62:12

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

X62:16

X62:15

X62:14

X62:13

X62:8

X62:7

X62:6

X62:5

Ignition ON: Ignition OFF: Plates in middle position Plates outside middle position Up active Up inactive Down active Down inactive Sliding to left active Sliding to left inactive Sliding to right active Sliding to right inactive Ignition ON: Ignition OFF: Ignition ON: Ignition OFF: 0 V measured against ground Plates lifted above sensor Plates lowered below sensor Float position active Float position inactive Priority active Priority inactive Float position active Float position inactive ---

Measurement not possible!

Description of Signals on the DIOS Module

Input proximity switch, plates middle Digital input active high Output plates up Digital output (max. 4 A) Output plates down Digital output (max. 4 A) Output plates left Digital output (max. 4 A) Output plates right Digital output (max. 4 A) Voltage supply for outputs

X62:4

X62:3

X62:2

Signal description Interface CAN-Bus 1 Wire +, is used to communicate with the ESXcontrol. Interface CAN-Bus 1 Wire -, is used to communicate with the ESXcontrol. Voltage supply for electronics

DIOS terminal X62:1

(only for option with attachment plates)

) 0V )approx. 12 V )approx. 12 V ) 0V )approx. 12 V ) 0V )approx. 12 V ) 0V

)approx. 12 V ) 0V )approx. 12 V ) 0V )approx. 12 V ) 0V )approx. 12 V ) 0V )approx. 12 V ) 0V )approx. 12 V ) 0V )approx. 12 V ) 0V )approx. 12 V ) 0V

Nominal values (voltage / current) Measurement not possible!

Description of Signals on the DIOS Module

10 Description of Signals on DIOS-Module

Service Training WZ – 4

Page 40 of 84

9.1 Machine related electrics

008 911 79

9.1

Machine related electrics

Service Training

Fault codes of the ESX control

11 Fault codes of the ESX control 11.1

Overview

Fault code 0000 0999 1000 1999 2000 2499 2500 2999 3000 4499 4500 4999 5000 5499 5500 5999 6000 6999 7000 7499 7500 7899 7900 7999 8000 8999 9000 9999 1

Fault description General faults / warnings / machine tests Fault in travel system Fault in steering system Fault in remote control Faults in work functions (vibration, attachment plates, rotor, chip spreader) Fault in measuring systems Fault diesel engine Fault hydraulic system Fault anti-theft warning system, localization system, access system, time account, etc. Input of machine codes Input of codes for measuring technology Operating hours, load spectrum, etc. Severe software error 1 Errors of external IO-nodes (joystick, data collector, Dios module, LC-display, etc.) 1

These faults are not broken down hereunder!

Version/Status: V3.29 / 13.11.07 Fault Codes on ESX Control Author: Seis,MASH,LOEW / TE/TES

008 911 79

BOMAG

Page 41 of 84

221

222

BOMAG

Description of Control Error Codes

Errors with error reaction 1 and 2 are only warning messages and are NOT stored in the error log!

Severe fault. The function of the control can no longer be guaranteed. ) Control is switched off. ) the diesel engine is shut down, if possible. The fault code is displayed, the signal light in the monitoring board is permanently on. No audible signal!

6

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Note:

Partial function faulty, the partial function cannot be overridden by an emergency function. ) the diesel engine is shut down. The machine is no longer able to drive, e.g. because parts of the travel system are defective Fault code is displayed. Audible signal

5

Function affected, the faulty function is replaced by an emergency function. Fault code is displayed. Audible signal

3

Partial function faulty, the partial function cannot be overridden by an emergency function. The machine is stopped if this fault occurs. 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. Audible signal

Warning. Fault code is displayed. Audible signal

2

4

Warning. Fault code is displayed.

Description of Control Error Codes

1

Description of fault reaction

Description of fault reactions

Fault reaction

11.2

Service Training WZ – 4

Page 42 of 84

9.1 Machine related electrics

008 911 79

008 911 79

Note codes

Description of Control Error Codes

BOMAG

Warning ! Attachment plate lowered and backward travel

Diesel engine stalled

3060

5013

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Arm rest raised Î Machine does not pick up throttle and is braked to stop.

(Only machine with electric steering)

sensor (BVC)

The attachment plates are lowered and an attempt is made to drive backwards various

The arm rest has been raised or the magnetic switch under the left hand arm rest is defective

The function "Teaching steering stops" for the electric steering has not yet been executed. Î New machine/replacement of control

The function "Teaching surge currents" for the electric steering has not yet been executed. Î New machine/replacement of control

This display is a Note, if steering at standstill is not possible. At standstill the steering forces may not be high enough. This is just a possible operating state.

Due to counter-rotating drive units the machine was stopped and the brake applied. The brake can be released again after shifting the travel lever to braking position, travel operation can be resumed.

The function "Teaching pump surge currents" for the travel pump has not yet been executed. Î New machine/replacement of control

Possible causes

Description of Control Error Codes

Electric steering, steering end stops Teaching of steering stops for electric steering NOT yet executed. See 4.6 Teaching the electronic end stops of the steering angle

2300

2198

(Only machine with electric steering)

(BVC)

Valves steering pump surge currents Surge currents for steering pump have NOT been learned. See 4.7 Automatic detection of surge currents on steering

2068

valves

Steering logic Difference between steering wheel movement and steering movement too big -> machine has stopped!

Warning "Dangerous condition ASC"

1500

system

2201

Travel pump valve surge currents Surge currents for travel pump have NOT been learned. See 4.4 Automatic detection of surge currents in travel

Fault description

1088

Note Code

X

X

X

X

X

X

X

X

X

X

X

X

X

Input code for diagnose

Page 43 of 84

Assignment BVC-4

X

DH-4

Notes are a special form of fault messages. The display shows note codes in the same way as fault codes, however, these do not require any service action, because they are just notes on particular operating states of the machine.

11.3

Service Training WZ – 4

Machine related electrics

9.1

223

224

Fault description

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Note Code

Service Training WZ – 4

Description of Control Error Codes

Possible causes

Description of Control Error Codes DH-4

Input code for diagnose

Page 44 of 84

Assignment BVC-4

9.1 Machine related electrics

BOMAG

008 911 79

008 911 79

BOMAG

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

562

0561

Overvoltage 8,5V The voltage level of the 8,5V range is impermissibly exceeded (see signal description) Undervoltage 8,5V The voltage level of the 8,5V range is impermissibly fallen short of (see signal description) Error "Voltage Override Relay" The voltage level of the 8,5V range is...

Drum drive deactivated - warning Test mode "Drum drive deactivated" was activated.

0507

0560

Ant- Slip Control (ASC) deactivated - warning The function "Anti Slip Control (ASC)" is deactivated

0504

Axle drive deactivated - warning Test mode "Axle drive deactivated" was activated.

Simulated engine run - warning The function "Simulated engine run" is activated

0502

0508

Driving against brake – warning The function "Driving against brake" is activated

Fault description

0500

Fault Code

Description of Control Error Codes

Description of Control Error Codes

Connection of voltage level to ground, another voltage potential or control defective

Connection of voltage level to operating voltage, another voltage potential or control defective

A corresponding input code has been entered

A corresponding input code has been entered

A corresponding input code has been entered

A corresponding input code has been entered

A corresponding input code has been entered

Possible causes

Detailed description of fault codes and their possible causes

11.4.1 General

11.4

Service Training WZ – 4

X35:23

X35:23

Terminal

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Assignment BVC-4

X

DH-4

2

2

2

2

2

2

2

2

Fault reaction

Page 45 of 84

Input code for diagnose

Machine related electrics

9.1

225

226

BOMAG

Brake valve short circuit Ub Signal outside the valid range (see signal description)

Brake valve Overheating of output driver in ESX

BTS brake / plausibility (BTS=output driver) Plausibility conflict in evaluation of travel lever X- axis to the brake contact signal

1003

1004

1005

Travel lever cable breakage X-axis Signal outside the valid range (see signal description)

Travel lever parameterization X-axis

Travel lever direction evaluation X-axis The direction of travel lever movement could not be determined

1026

1027

1028

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Travel lever sum error X-axis Error in redundant evaluation of axis

1025

Fault Code

Fault description

Brake valve short circuit to ground Signal outside the valid range (see signal description)

1002

11.4.3 Travel lever

Brake valve line breakage The required control power cannot be transmitted to the control solenoid.

Fault description

1001

Fault Code

11.4.2 Brake

Service Training WZ – 4

Possible causes

Hardware defect on travel lever Connection between ESX and travel lever interrupted

Description of Control Error Codes

Internal fault in travel lever -> Replace travel lever.

Internal fault in travel lever -> Replace travel lever.

Cable breakage in travel lever -> Replace travel lever.

Internal fault in travel lever -> Replace travel lever.

) )

) The connecting cable has short circuit to ground ) Coil defective

) The connecting cable has short circuit to battery voltage

) The connecting cable has short circuit to ground ) Coil defective

) The connecting line between output of control and control solenoid is interrupted. ) The solenoid is defective

Possible causes

Description of Control Error Codes

CAN

CAN

CAN

CAN

Terminal

X35:17 X33:3

X35:61

X35:61

X35:61

X35:61

Terminal

X

X

X

X

X

X

X

X

X

X

X

Assignment BVC-4

X

DH-4

X

X

X

X

X

Assignment BVC-4

X

DH-4

3

3

3

3

Fault reaction

5

6

6

6

6

Fault reaction

Page 46 of 84

Input code for diagnose

1001

1001

1001

1001

Input code for diagnose

9.1 Machine related electrics

008 911 79

008 911 79

BOMAG

Travel lever cable breakage Y-axis Signal outside the valid range (see signal description)

Travel lever parameterization Y-axis

Travel lever direction evaluation Y-axis The direction of travel lever movement could not be determined

Travel lever difference error Y-axis Error in redundant evaluation of travel lever signal

Travel lever software error Y-axis Software does not work fault free

1032

1033

1034

1035

1036

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Travel lever sum error Y-axis Error in redundant evaluation of axis

1031

Fault description

Travel lever software error X-axis Software does not work fault free

1030

Fault Code

Travel lever difference error X-axis Error in redundant evaluation of travel lever signal

Fault description

1029

Fault Code

Service Training WZ – 4

Description of Control Error Codes

Internal fault in travel lever -> Replace travel lever.

Internal fault in travel lever -> Replace travel lever.

Internal fault in travel lever -> Replace travel lever.

Internal fault in travel lever -> Replace travel lever.

Cable breakage in travel lever -> Replace travel lever.

Internal fault in travel lever -> Replace travel lever.

Possible causes

Internal fault in travel lever -> Replace travel lever.

Internal fault in travel lever -> Replace travel lever.

Possible causes

Description of Control Error Codes

CAN

CAN

CAN

CAN

CAN

CAN

Terminal

CAN

CAN

Terminal

X

X

X

X

X

X

X

X

X

X

X

X

Assignment BVC-4

X

DH-4

X

X

Assignment BVC-4

X

DH-4

3

3

3

3

3

3

Fault reaction

3

3

Fault reaction

Page 47 of 84

Input code for diagnose

Input code for diagnose

Machine related electrics

9.1

227

228

Travel range selector switch "Supply connection" Signal outside the valid range (see signal description)

Travel speed range selector switch Signal outside the valid range (see signal description)

1041

1042

BOMAG

Short circuit of connecting line (control to proportional valve) to Output travel pump forward Supply voltage UB applied to the output to the proportional voltage supply valve. - Short circuit of connecting line (control to proportional valve) Output travel pump forward to machine frame or a ground cable. Output to proportional valve shorted to ground. - Proportional valve defective. Machine mechanically blocked Error in teaching the surge current forward Travel system bypass valves out of adjustment

1073

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

1075

1074

Fault of current regulator forward

1072

Description of Control Error Codes

Faults in valve control Check wiring.

Fault of current regulator forward

1071

The connecting line from the output of the control to the proportional solenoid is interrupted or the proportional solenoid is defective -> Line interrupted/cable breakage. Faults in valve control Check wiring.

Possible causes

Output travel pump forward The required control power cannot be transmitted to the proportional solenoid.

Fault description

Cable breakage in ground line, or Connecting cable between switch and ground connection has come loose Cable breakage in connecting line, or The connecting cable between switch and supply line has come loose Higher contact resistances have possibly caused a faulty signal. The switch must be replaced.

Possible causes

Description of Control Error Codes

1070

Fault Code

11.4.5 Travel system

Travel range selector switch "Ground connection" Signal outside the valid range (see signal description)

Fault description

1040

Fault Code

11.4.4 Travel speed range selector switch

Service Training WZ – 4

X35:49

X35:49

X35:49

X35:49

X35:49

X35:49

Terminal

X23:11

X23:5

X23:8

Terminal

X

X

X

X

X

X

X

X

X

X

X

X

X

Assignment BVC-4

X

DH-4

X

X

X

Assignment BVC-4

X

DH-4

5

5

5

5

5

5

Fault reaction

3

3

3

Fault reaction

Page 48 of 84

Input code for diagnose

1040

1040

1040

Input code for diagnose

9.1 Machine related electrics

008 911 79

008 911 79

Short circuit of connecting line (control to proportional valve) to Output travel pumps reverse Supply voltage UB applied to the output to the proportional voltage supply valve. - Short circuit of connecting line (control to proportional valve) Output travel pumps reverse to machine frame or a ground cable. Output to proportional valve shorted to ground. - Proportional valve defective. Machine mechanically blocked Error in teaching the surge current reverse Travel system bypass valves out of adjustment

Travel pump surge currents Surge currents for travel pump have NOT been learned. See 4.4

1083

1088

BOMAG

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

1085

1084

Fault of current regulator reverse

1082

Description of Control Error Codes

Note, no fault! See 11.3 Note codes

Faults in valve control Check wiring.

Faults in valve control Check wiring.

Fault of current regulator reverse

1081

The connecting line from the output of the control to the proportional solenoid is interrupted or the proportional solenoid is defective ) Line interrupted/cable breakage.

Possible causes

Output travel pumps reverse The required control power cannot be transmitted to the proportional solenoid.

Fault description

Description of Control Error Codes

1080

Fault Code

Service Training WZ – 4

X35:64

X35:64

X35:64

X35:64

X35:64

X35:64

Terminal

X

X

X

X

X

X

X

X

X

X

X

X

X

Assignment BVC-4

X

DH-4

1

3

4

5

5

5

5

Fault reaction

Page 49 of 84

Input code for diagnose

Machine related electrics

9.1

229

230

Output front travel motor Supply voltage UB applied to the output to the proportional valve. Output front travel motor Output to proportional valve shorted to ground.

Output rear travel motor The required control power cannot be transmitted to the proportional solenoid.

Speed sensor pulses rear travel motor Incorrect or non-existent signal "Frequency"

Speed sensor direction signal rear travel motor Incorrect or non-existent signal "Direction"

Output rear travel motor Supply voltage UB applied to the output to the proportional valve. Output rear travel motor Output to proportional valve shorted to ground.

1107

1110

1115

1116

1117

BOMAG

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

1118

1108

Direction signal pulses front travel motor Incorrect or non-existent signal "Direction"

1106

Description of Control Error Codes

Short circuit of connecting line (control to proportional valve) to machine frame or a ground cable. - Proportional valve defective.

-

Short circuit of connecting line (control to proportional valve) to voltage supply

Check connecting lines and plugs on wheel speed sensor, if necessary replace the wheel speed sensor

Check connecting lines and plugs on wheel speed sensor, if necessary replace the wheel speed sensor

The connecting line from the output of the control to the proportional solenoid is interrupted or the proportional solenoid is defective Î Line interrupted/cable breakage.

Short circuit of connecting line (control to proportional valve) to machine frame or a ground cable. - Proportional valve defective.

-

Short circuit of connecting line (control to proportional valve) to voltage supply

Check connecting lines and plugs on wheel speed sensor, if necessary replace the wheel speed sensor

Check connecting lines and plugs on wheel speed sensor, if necessary replace the wheel speed sensor

X35:46

X35:47

X35:38

X35:12

X35:47

X35:46

X35:46

X35:37

X35:34

X

X

X

X

X

X

X

X

X

Speed sensor pulses front travel motor Incorrect or non-existent signal "Frequency"

X35:46

1105

The connecting line from the output of the control to the proportional solenoid is interrupted or the proportional solenoid is defective Î Line interrupted/cable breakage. X

X

X

X

X

X

X

X

X

X

X

Assignment BVC-4

Output front travel motor The required control power cannot be transmitted to the proportional solenoid.

Terminal

1100

Possible causes DH-4

Fault description

Description of Control Error Codes

Fault Code

Service Training WZ – 4

4

4

4

4

4

4

5

4

4

4

Fault reaction

Page 50 of 84

Input code for diagnose

9.1 Machine related electrics

008 911 79

008 911 79

Inclination sensor "Supply connection" Signal outside the valid range (see signal description)

Inclination sensor "Ground connection" Signal outside the valid range (see signal description)

1146

BOMAG

Warning "Dangerous condition ASC"

1500

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Seat connect not occupied

1300

Description of Control Error Codes

Note, no fault! See 11.3 Note codes

Cable breakage in signal line, or driver's seat not occupied (driver not seated!)

Cable breakage in connecting line, or connecting cable between sensor and power supply has come loose Cable breakage in ground line, or Connecting cable between sensor and ground connection has come loose

No pressure connection on sensor, or supply line blocked or no travel pressure built up

X35:15

X35:?? .. X35:30 X35:1

X35:31

X35:31

X

X

X

X

X

X

1145

1142

1141

X35:31

X

The connecting line between control output and pressure sensor is interrupted, or The pressure sensor is defective The pressure sensor is defective

Travel system pressure sensor "Signal" The current signal is not transmitted (see signal specification Travel system pressure sensor "Signal range" The current signal is outside the valid range (see signal specification) Travel system pressure sensor "no pressure" The electric signal indicates that the travel pressure is permanently missing.

X

X

X

X

X

X

X

Assignment BVC-4

1140

Terminal DH-4

Possible causes

Fault description

Description of Control Error Codes

Fault Code

Service Training WZ – 4

2

2

3

3

4

1

1

Fault reaction

Page 51 of 84

Input code for diagnose

Machine related electrics

9.1

231

232

BOMAG

Output steering valve left Fault current regulator

Short circuit of connecting line (control to proportional valve) to Output steering valve left Supply voltage UB applied to the output to the proportional voltage supply valve. - Short circuit of connecting line (control to proportional valve) Output steering valve left to machine frame or a ground cable. Output to proportional valve shorted to ground. Proportional valve defective.

2052

2053

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

2054

Description of Control Error Codes

Faults in valve control Check wiring.

Faults in valve control Check wiring.

Output steering valve left Fault current regulator

2051

2044

The connecting line from the output of the control to the proportional solenoid is interrupted or the proportional solenoid is defective Î Line interrupted/cable breakage.

Faults in valve control Check wiring.

Output steering valve left The required control power cannot be transmitted to the proportional solenoid.

Output steering valve right Fault current regulator

2042

Faults in valve control Check wiring.

2050

Output steering valve right Fault current regulator

2041

The connecting line from the output of the control to the proportional solenoid is interrupted or the proportional solenoid is defective Î Line interrupted/cable breakage.

Short circuit of connecting line (control to proportional valve) to Output steering valve right Supply voltage UB applied to the output to the proportional voltage supply valve. - Short circuit of connecting line (control to proportional valve) Output steering valve right to machine frame or a ground cable. Output to proportional valve shorted to ground. - Proportional valve defective.

Output steering valve right The required control power cannot be transmitted to the proportional solenoid.

2040

Possible causes

Description of Control Error Codes

2043

Limp home steering valves active

2000

(Only machine with electric steering) Fault Fault description Code

11.4.6 Steering

Service Training WZ – 4

X35:21

X35:21

X35:21

X35:21

X35:21

X35:20

X35:20

X35:20

X35:20

X35:20

Terminal DH-4

X

X

X

X

X

X

X

X

X

X

X

Assignment BVC-4

4

5

4

4

4

4

5

4

4

4

1

Fault reaction

Page 52 of 84

Input code for diagnose

9.1 Machine related electrics

008 911 79

008 911 79

BOMAG

Steering wheel (arm rest) "Sensor 1 pulse range" The detected steering pulses on steering sensor 1 are outside the valid range (see signal description)

Steering wheel (arm rest) "Sensor 2 pulse range" The detected steering pulses on steering sensor 2 are outside the valid range (see signal description)

Steering wheel A45 (arm rest) "Sensor 1"

Steering wheel A45 (arm rest) "Sensor 2"

Steering wheel A45 (arm rest) "Sensor 1 cable breakage" Steering wheel A45 (arm rest) "Sensor 2 cable breakage" Steering wheel A45 (arm rest) "Sensor 1 sensor fault"

Steering wheel A45 (arm rest) "Sensor 2 sensor fault"

2173

2174

2175

2176

2179

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

2178

2177

codes

Wiring fault or steering sensor in left hand arm rest defective

Note, no fault! See 11.3 Note

Drum was not moved, maximum current was reached, steering is blocked (e.g. articulation lock applied) Drum was not moved, maximum current was reached Steering is blocked (e.g. joint lock engaged)

Possible causes

Description of Control Error Codes

Description of Control Error Codes

Sensor fault. If this occurs frequently, change steering wheel.

Check the connecting lines to steering sensor 1, or replace the steering sensor in the left hand arm rest, if required. Check the connecting lines to steering sensor 2, or replace the steering sensor in the left hand arm rest, if required. Sensor fault. If this occurs frequently, change steering wheel.

Steering sensor in left hand arm rest defective.

Steering sensor in left hand arm rest defective.

Check the connecting lines to steering sensor 2, or replace the steering sensor in the left hand arm rest, if required.

Check connecting line to steering sensor 1 or replace the steering sensor in the left hand arm rest, if necessary

Steering sensor in left hand arm rest defective. Steering valve (arm rest) "Pulse coverage" High difference in measuring values between sensor 1 and 2

(Only machine with electric steering) Steering valve (arm rest) "direction change"

2172

2171

2170

2068

ing valves (BVC)

Error when teaching the surge current for the right hand valve Error when teaching the surge current for the left hand valve Valves steering pump surge currents Surge currents for steering pump have NOT been learned. See 4.7 Automatic detection of surge currents on steer-

2065

2066

Fault description

Fault Code

Service Training WZ – 4

X35:18 X35:19 X35:40 X35:41 X35:18 X35:19 X35:40 X35:41

X35:40 X35:41

X35:18 X35:19 X35:40 X35:41 X35:18 X35:19 X35:40 X35:41 X35:18 X35:19

X35:21

X35:20

Terminal DH-4

X

X

X

X

X

X

X

X

X

X

X

X

X

Assignment BVC-4

4

4

4

4

4

4

4

4

4

4

1

4

4

Fault reaction

Page 53 of 84

Input code for diagnose

Machine related electrics

9.1

233

234

Steering angle sensor B65 "Ground cable breakage"

Electric steering, steering end stops Teaching of steering stops for electric steering NOT yet executed. See 4.6 Teaching the electronic end stops of the steer-

2193

2198

BOMAG

Ground cable breakage -> !!Machine can be driven normally!!

2303

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

2302

2301

Information message! "Arm rest raised" -> Machine does not pick up throttle and remains braked. Signal fault Signal outside the valid range (see signal description) -> !!Machine can be driven normally!! Supply cable breakage -> !!Machine can be driven normally!!

2300

(Only machine with electric steering) Fault Fault description Code

11.4.7 Driver's seat arm rest sensor

2201

2200

Note, no fault! See 11.3 Note

codes

Voltage supply line to steering angle sensor interrupted or steering angle sensor on articulated joint defective - Ground connection of signal line Ground cable to the steering angle sensor interrupted, or Steering angle sensor on the articulated joint defective.

Steering angle sensor on the articulated joint

Replace the control

Possible causes

Description of Control Error Codes

codes

Description of Control Error Codes

Ground cable to the magnetic switch interrupted, or Magnetic switch under left hand arm rest defective

Voltage supply line to magnetic switch interrupted or magnetic switch under left hand arm rest defective.

Cable breakage in magnetic switch signal line, or Magnetic switch under left hand arm rest defective

Note, no fault! See 11.3 Note

Possible causes

(Only machine with electric steering) Steering valve "jammed". No hydraulic oil supply. Steering logic Difference between steering wheel movement and steering movement too big -> machine travelling! Surge currents have not been taught (correctly) see also 4.7 Automatic detection of surge currents on steering valves (BVC). Steering logic Difference between steering wheel moveNote, no fault! See 11.3 Note codes ment and steering movement too big -> machine has stopped!

ing angle sensor (BVC)

Steering angle sensor B65 "Supply cable breakage"

2192

2191

Steering "steering angle sensor... initialization" Internal control fault. Steering angle sensorB65 "Measuring value"

Fault description

2190

Fault Code

Service Training WZ – 4

X35:16

X35:16

X35:16

X35:16

Terminal

X35:1

X35:23

X35:29

Terminal

DH-4

DH-4

X

X

X

X

Assignment BVC-4

X

(X)

X

X

X

X

Assignment BVC-4

4

4

2

2

Fault reaction

2

4

4

4

4

4

Fault reaction

Page 54 of 84

Input code for diagnose

Input code for diagnose

9.1 Machine related electrics

008 911 79

008 911 79

BOMAG

The connecting line between control output and proportional solenoid is interrupted, or The proportional solenoid is defective changeover relay / bridge missing System fault! Replace the control!

Faults in control line, or Connection to another potential (e.g. operating voltage)

Description of Control Error Codes

X

X

X35:48

X

X35:48 X35:48

X

X

X

X

X

X

X

X35:48

X35:48

X35:48

X35:48

X35:48

X35:48

System fault! Replace the control!

Valve vibration pump (low amplitude on DH) Internal system fault. Faults in connecting line, incorrect valve coil, or Valve vibration pump (low amplitude on DH) "Control Connection to another potential (e.g. operating voltage) fault regulation down" The control current is outside the valid range (see signal specification) Faults in connecting line, incorrect valve coil, or Valve vibration pump (low amplitude on DH) "Control Connection to another potential (e.g. operating voltage) fault regulation up" The control current is outside the valid range (see signal specification) System fault! Replace the control! Valve vibration pump (low amplitude on DH) Internal system fault. Short circuit of connecting line (control to proportional valve) to Valve vibration pump (low amplitude on DH) Supply voltage UB applied to the output to the proportional voltage supply valve. - Short circuit of connecting line (control to proportional valve) Valve vibration pump (low amplitude on DH) to machine frame or a ground cable. Output to proportional valve shorted to ground. - Proportional valve defective.

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

3010

3009

3008

3007

3006

3005

3004

3003

3002

X35:48

Details in 3004 – 3008

Valve vibration pump (low amplitude on DH) General fault. Valve vibration pump (low amplitude on DH) Internal system fault. Valve vibration pump (low amplitude on DH) "Current range" The control current is outside the valid range (see signal specification) Valve vibration pump (low amplitude on DH) Line interruption

3001

X35:35

Check connecting lines and plugs to the vibration sensor, or replace the sensor in the vibration motor, if necessary.

X

X

X

X

X

X

X

X

X

X

X

X

Assignment BVC-4

Vibration sensor "No signal" The sensor in the vibration motor does not pick up any pulses.

Terminal

3000

Possible causes DH-4

Fault description

Description of Control Error Codes

Fault Code

11.4.8 Vibration

Service Training WZ – 4

1

1

1

1

1

1

1

1

1

1

1

Fault reaction

Page 55 of 84

Input code for diagnose

Machine related electrics

9.1

235

236

BOMAG

Vibration pump valve (only DH: high amplitude) Internal system fault.

Line interruption

(only DH: high amplitude)

Vibration pump valve (only DH: high amplitude) General fault. Vibration pump valve (only DH: high amplitude) Internal system fault. Vibration pump valve (only DH: high amplitude) "Current range" The control current is outside the valid range (see signal specification) Valve vibration pump "Cable breakage"

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

3025

3024

3023

3022

3021

3014

3013

3012

Vibration adaptation control (low amplitude on DH) "Frequency adaptation" Adjustment range reached! (see signal specification) Vibration adaptation control (low amplitude on DH) "Frequency adaptation" Upper adjustment range reached! (see signal specification) Vibration adaptation control (low amplitude on DH) "Frequency adaptation" Lower adjustment range reached! (see signal specification) Vibration frequency (low amplitude on DH) Frequency/speed to high

Description of Control Error Codes

The connecting line between control output and proportional solenoid is interrupted, or The proportional solenoid is defective changeover relay / bridge missing System fault! Replace the control!

Faults in control line, or Connection to another potential (e.g. operating voltage)

System fault! Replace the control!

X35:48

X35:48

X35:48

X35:48

X35:48

X35:48

Vibrations frequency exceeded by more than 5Hz. Emergency shut down to protect bearings. After replacement of a vibration pump or peripheral equipment in the vibration circuit this fault may occur as a result of unfavourable component tolerances. In this case normal operation can be reached by multiple activation of the vibration, after the fault has been rectified. ATTENTION! It must be assured, that the fault has not be caused by a faulty component (pump, control, valve.

Details in 3014 – 3018

X35:48

X35:48

X35:48

Wear or damage in vibration system hydraulic circuit. Valve sticking/defective.

Wear or damage in vibration system hydraulic circuit. Valve sticking/defective.

Wear or damage in vibration system hydraulic circuit. Valve sticking/defective.

X

X

X

X

X

X

X

X

X

X

X

X

Assignment BVC-4

X

Terminal

3011

Possible causes DH-4

Fault description

Description of Control Error Codes

Fault Code

Service Training WZ – 4

1

1

1

1

1

4

2

2

2

Fault reaction

Page 56 of 84

Input code for diagnose

9.1 Machine related electrics

008 911 79

008 911 79 Assignment BVC-4

BOMAG

Vibration adaptation control (only DH: high amplitude) Frequency adaptation Limits of adaptation range exceeded (see signal specification) Vibration adaptation control (only DH: high amplitude) "Frequency adaptation" Upper adjustment range reached! (see signal specification) Vibration adaptation control (only DH: high amplitude) "Frequency adaptation" Lower adjustment range reached! (see signal specification) Vibration frequency (only DH: high amplitude) Frequency/speed to high

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

3034

3033

3032

3031

3030

3029

3028

3027

X35:48

Vibrations frequency exceeded by more than 5Hz. Emergency shut down to protect bearings. After replacement of a vibration pump or peripheral equipment in the vibration circuit this fault may occur as a result of unfavourable component tolerances. In this case normal operation can be reached by multiple activation of the vibration, after the fault has been rectified. ATTENTION! It must be assured, that the fault has not be caused by a faulty component (pump, control, valve.

Description of Control Error Codes

X35:48

X35:48

X

X

X

X

X

X35:48

X35:48

X

X

X35:48 X35:48

X

X35:48

X35:48

Wear or damage in vibration system hydraulic circuit. Valve sticking/defective.

Wear or damage in vibration system hydraulic circuit. Valve sticking/defective.

Wear or damage in vibration system hydraulic circuit.

Faults in connecting line, incorrect valve coil, or Vibration pump valve (only DH: high amplitude) Connection to another potential (e.g. operating voltage) "Control fault regulating up" The control current is outside the valid range (see signal specification) Faults in connecting line, incorrect valve coil, or Vibration pump valve (only DH: high amplitude) Connection to another potential (e.g. operating voltage) "Control fault regulating down" The control current is outside the valid range (see signal specification) System fault! Replace the control! Vibration pump valve (only DH: high amplitude) Internal system fault. Short circuit of connecting line (control to proportional valve) to Vibration pump valve (only DH: high amplitude) Supply voltage UB applied to the output to the proportional voltage supply valve. - Short circuit of connecting line (control to proportional valve) Vibration pump valve (only DH: high amplitude) to machine frame or a ground cable. Output to proportional valve shorted to ground. - Proportional valve defective.

X

Terminal

3026

Possible causes DH-4

Fault description

Description of Control Error Codes

Fault Code

Service Training WZ – 4

4

2

2

2

2

2

1

1

1

Fault reaction

Page 57 of 84

Input code for diagnose

Machine related electrics

9.1

237

238

Vibration pump, plates, valve "current range" The control current is outside the valid range (see signal specification)

Vibration pump, plates, valve "Cable breakage" Line interruption

3053

3054

BOMAG

Vibration pump, plates, valve "Control fault positive limit" The control current is outside the valid range (see signal specification) Vibration pump, plates, valve "Control fault negative limit" The control current is outside the valid range (see signal specification) Vibration pump, plates, valve Internal system fault.

Warning ! Attachment plate lowered and backward travel

3056

3060

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

3058

3057

Vibration pump, plates, valve Internal system fault.

3055

Fault description

Vibration pump, plates, valve "hysteresis"

3052

Fault Code

Vibration pump, plates, valve General fault.

Fault description

3051

Fault Code

11.4.9 Attachment plates

Service Training WZ – 4

codes

Description of Control Error Codes

Note, no fault! See 11.3 Note

System fault! Replace the control!

System fault! Replace the control!

Possible causes

The connecting line between control output and proportional solenoid is interrupted, or The proportional solenoid is defective changeover relay / bridge missing

Details in 3052 – 3058, this fault always is connected with one of the faults listed below

Possible causes

Description of Control Error Codes

X35:22

X35:22

X35:22

X35:22

Terminal

X35:22

X35:22

X35:22

X35:22

Terminal

DH-4

DH-4

X

X

X

X

X

Assignment BVC-4

X

X

X

X

Assignment BVC-4

2

1

1

1

1

Fault reaction

1

1

1

1

Fault reaction

Page 58 of 84

Input code for diagnose

Input code for diagnose

9.1 Machine related electrics

008 911 79

008 911 79

BOMAG

Diesel engine EMR has more than one logged fault.

5102

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Diesel engine EMR "red stop light"

5101

Collective message for engine shut down

Description of Control Error Codes

) see further fault code for more accurate fault diagnose

Collective message for engine shut down

) see further fault code for more accurate fault diagnose X

X

X

Collective warning

) see further fault code for more accurate fault diagnose

X

X X X X X

X

X

X

X

Assignment BVC-4

Diesel engine EMR "Warning light"

Terminal

5100

Possible causes

X

DH-4

Fault description

Water or other dirt in fuel filter

Fault Code

11.4.11 Diesel engine EMR

Water separator fault shut-down

5029

X X X X X

X X26:10 X26:10 X26:8 X26:8 X27:4 X27:9 X27:4 X27:9

Diesel engine "Coolant level" warning Diesel engine "Coolant level" fault shut-down Diesel engine "Air filter" warning Diesel engine "Air filter" fault shut-down Water separator warning

Note, no fault! See 11.3 Note codes Coolant level too low or sensor defective Coolant level too low or sensor defective Air filter soiled or sensor defective Air filter soiled or sensor defective Water or other dirt in fuel filter

Diesel engine stalled

Assignment BVC-4

5024 5025 5026 5027 5028

Terminal

5013

Possible causes DH-4

Fault description

Description of Control Error Codes

Fault Code

11.4.10 Diesel engine

Service Training WZ – 4

2

2

2

Fault Reaction

5

2 5 2 5 2

1

Fault Reaction

Page 59 of 84

Input code for diagnose

Input code for diagnose

Machine related electrics

9.1

239

240

BOMAG

Diesel engine EMR "CAN communication"

Diesel engine EMR "CAN communication"

Diesel engine EMR "Nominal speed value"

Diesel engine EMR CAN communication

Diesel engine EMR CAN communication

Diesel engine EMR CAN communication

5120

5121

5122

5123

5124

5125

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Water separator (EMR3)

5119

Description of Control Error Codes

) CAN communication between EMR and ESX

) CAN communication between EMR and ESX

) CAN connection has short circuit against ground, against +12 V or connection between CAN+ and CAN-. ) EMR without voltage supply. ) CAN connection between ESX and EMR interrupted ) CAN connection has short circuit against ground, against +12 V or connection between CAN+ and CAN-. ) ESX without voltage supply ) Battery charge level too low ) CAN communication between EMR and ESX

) ESX without voltage supply ) Battery charge level too low ) CAN connection between ESX and EMR interrupted

+12 V or connection between CAN+ and CAN-.

) CAN connection between ESX and EMR interrupted ) CAN connection has short circuit against ground, against

Water or other dirt in fuel filter

rupted

X30:12 X30:13 X30:12 X30:13 X30:12 X30:13

X31:13 X31:11

X31:21 X31:24 X31:4 X31:9

X X X

X X

X

X

X

X

X

X

X

X

X X X X X X X

X

X

X X X X X X X

Diesel engine EMR "Engine oil filling level" Diesel engine EMR "Oil pressure" Diesel engine EMR "Charge air pressure" Diesel motor EMR "Temperature in intake line" Diesel engine EMR "Coolant temperature" Diesel engine EMR "Fuel temperature" Diesel engine EMR "Engine speed"

5111 5112 5113 5114 5116 5117 5118

) ESX without voltage supply ) Battery charge level too low ) Engine oil filling level too low ) Engine oil pressure too low ) Charge air pressure too low ) Charge air temperature too high ) Coolant temperature too high ) Fuel temperature too high ) Speed sensor 1 or 2 defective ) Connection between EMR and speed sensor 1 or 2 inter-

+12 V or connection between CAN+ and CAN-.

) CAN connection between ESX and EMR interrupted ) CAN connection has short circuit against ground, against

X

Assignment BVC-4

Diesel engine EMR "Nominal speed value"

Terminal

5110

Possible causes DH-4

Fault description

Description of Control Error Codes

Fault Code

Service Training WZ – 4

2

2

2

2

5

2

2

2 2 2 2 2 2 2

2

Fault Reaction

Page 60 of 84

Input code for diagnose

9.1 Machine related electrics

008 911 79

008 911 79

Diesel engine EMR CAN communication

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

5126

Service Training WZ – 4

Description of Control Error Codes

Occurs also when the ESX travel control switches off for longer than 5 seconds (LCD-display flickers) while the engine is running.

) CAN communication between EMR and ESX.#

Description of Control Error Codes X30:12 X30:13

X

X

Page 61 of 84

2

Machine related electrics

9.1

BOMAG

241

242

BOMAG

Diesel engine EMR "unknown fault"

5140

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

X X X X

"Hydraulic oil filter" warning "Hydraulic oil filter" fault shut-down "Oil temperature" warning "Oil temperature" fault shut-down

5502 5503 5504 5005

Description of Control Error Codes

Hydraulic oil filter soiled or sensor defective Hydraulic oil filter soiled or sensor defective Hydraulic oil temperature too high or sensor defective Hydraulic oil temperature too high or sensor defective

X

X

X

X

X

X

X

X

X X X X

Assignment BVC-4

X

X

X

X

DH-4

Terminal

X31:13 X31:23 X31:40

X31:10 X31:11 X31:12 X31:13

X

X

X31:4 X31:23 X31:25 X31:8 X31:9

X

X

X

Assignment BVC-4

X

DH-4

X31:23 X31:24 X31:25

X31:13 X31:23 X31:40 X31:20 X31:21 X31:22

Terminal

Fault description

Possible causes

Fault diagnostics only possible with DEUTZ diagnostics tool (SERDIA)

) Sensor defective ) Wire breakage in current path ) Current path has short circuit to ground

Water or other dirt in fuel filter

) Sensor defective ) Wire breakage in current path ) Current path has short circuit to ground ) Sensor defective ) Wire breakage in current path ) Current path has short circuit to ground ) Sensor defective ) Wire breakage in current path ) Current path has short circuit to ground ) Sensor defective ) Wire breakage in current path ) Current path has short circuit to ground ) Speed sensor 1 or 2 defective

) Fuel pre-pressure too low (possibly filter clogged)

Possible causes

Description of Control Error Codes

Fault Code

11.4.12 Miscellaneous

Diesel engine EMR "Fuel low pressure sensor"

5136

Diesel engine EMR "Coolant temperature sensor"

5133

Water separator (EMR2)

Diesel engine EMR "Charge air temperature"

5132

5135

Diesel engine EMR "Charge air pressure sensor"

5131

Diesel engine EMR "Speed sensor"

Diesel engine EMR "Oil pressure sensor"

5130

5134

Diesel engine EMR "Low pressure fuel pressure"

Fault description

5127

Fault Code

Service Training WZ – 4

2 5 2 5

Fault Reaction

2

2

2

2

2

2

2

2

2

Fault Reaction

Page 62 of 84

Input code for diagnose

Input code for diagnose

9.1 Machine related electrics

008 911 79

008 911 79

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Service Training WZ – 4

Description of Control Error Codes

Description of Control Error Codes

Page 63 of 84

Machine related electrics

9.1

BOMAG

243

244

BOMAG

Communication error travel control engine control

Fault description

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

9400

Fault Code

11.4.14 Optional functions

7012

Warning "Change of machine type" This warning is displayed when the machine type is changed. "Conflict machine type" This error message is displayed if the set machine does not comply with the basic parameters of the machine.

Description of Control Error Codes

) Fault on CAN (2) line ) Travel lever defective ) Immobilizer not yet unlocked

Possible causes

Only change the machine type after applying appropriate measures; e.g. conversion from D to PD (different rolling circumference of roller drum) The machine type has been changed to such an extent, that the enter type parameters no longer match the basic parameters the correct machine code or one of the basic machine parameters was changed (e.g. different axle)

X34:C X34:D

Terminal

X

X

Assignment BVC-4 X

DH-4

X

X

Assignment BVC-4

X

Terminal

7011

Possible causes DH-4

Fault description

Description of Control Error Codes

Fault Code

11.4.13 Machine type

Service Training WZ – 4

4

Fault reaction

4

6

Fault reaction

Page 64 of 84

Input code for diagnose

Input code for diagnose

9.1 Machine related electrics

008 911 79

008 911 79

Description of Control Input Codes

Fault log

Description of display function Function "Show stored faults“ activated Function "Show stored faults“ deactivated Delete stored faults

BOMAG

Display values Display in V (e.g. 12.6 corresponds with 12,6V)

Display values e.g.: "1.13" for software version V 1.13 e.g. "1.36" for version 1.36 e.g. "1.11" for version 1.11 The machine code is displayed (72xx) (see chapt. 3.6)

Display values Fault codes are displayed one after the other 0000 once the fault log is deleted it is returned to 0000

Description of Control Input Codes

Description of display function Display of voltage at control output "Valve Brake"

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Input code 1001

12.2.2 Brake

Input code 0555 0556 0557 0720

Description of display function Display of "machine control software version ( ESX)" Display of Firmware version "LCD Display" Display of Firmware version "Data Collector" Display of "Machine Code"

Value displays

12.2.1 General

12.2

Input code 0700 0701 0710

without service code!

12.1

Display and adjustment functions can generally only be accessed by entering "service code" 9999 beforehand!

12 Input Codes for ESX Control

Service Training WZ – 4

Page 65 of 84

Machine related electrics

9.1

245

246

BOMAG

Display values Position of travel range selector switch from 1...24 Stages 0..0.4 = 4 Stages 5..0.9 = 3 Stages 10..0.14 = 2 Stages 15..0.19 = 1 Stages 20...24 = 0

Display values 100 = Forward 0 = Neutral 10 = Reverse 1000 = Left 10000 = Right Combinations are possible, e.g. 1100 for forward 0..1000 = Forward 0..-1000 = Reverse left -> - 1000..0..1000 -> right, i.e. brake gate 100 = Forward 0 = Neutral 1 = Reverse 0 = Neutral 1 = Forward 2 = Reverse 0 = locked 1 = released

Description of Control Input Codes

Description of display function Display "Speed range / gear" Display "Voltage value for speed range / gear"

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Input code 1040 1041

12.2.4 Travel speed range selector switch

Display "Travel lever release"

1027

Display "Values for axle right left" Display "Travel lever actuating direction"

1022 1025

Display "Travel direction"

Display "Values for axle forward reverse"

1021

1026

Description of display function Display "Travel lever end positions"

Description of Control Input Codes

Input code 1020

12.2.3 Travel lever / driving

Service Training WZ – 4

Page 66 of 84

9.1 Machine related electrics

008 911 79

008 911 79

Display "Speed range / gear" end value

1044

BOMAG

Description of Control Input Codes

Display in mA (permitted range 350mA..600mA) Display in mA (permitted range 1,150mA.0.1400mA)

Initial current value (learned surge current) of the valve Maximum current value (derived end current) of the valve

1088 1089

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Display values Display in mA (0.0.400..1300) Display in mA (0.0.400..1300)

Description of display function Display "Actual current value travel pump reverse" Display "Nominal current value travel pump reverse"

Input code 1080 1081

12.2.6 Travel pump: Travel direction reverse

Display in mA (permitted range 350mA..600mA) Display in mA (permitted range 1,150mA.0.1400mA)

Initial current value (learned surge current) of the valve Maximum current value (derived end current) of the valve

1078 1079

Page 67 of 84

Stage 3 875 Stage 6 756 Stage 9 637 Stage 12 517 Stage 15 396 Stage 18 279 Stage 21 160 Stage 24 40 Stage 3 = 1‘250 Stage 6 = 2‘500 Stage 9 = 3‘750 Stage 12 = 5‘000 Stage 15 = 6‘250 Stage 18 = 8‘333 Stage 21 = 13‘334 Stage 24 = 23‘333

Display values Display in mA (0..350..1300) Display in mA (0..350..1300)

Stage 2 916 Stage 5 795 Stage 8 675 Stage 11 557 Stage 14 436 Stage 17 318 Stage 20 200 Stage 23 80 Stage 2 = 833 Stage 5 = 2‘089 Stage 8 = 3‘333 Stage 11 = 4‘583 Stage 14 = 5‘833 Stage 17 = 7‘500 Stage 20 = 10‘000 Stage 23 = 20‘000

Description of display function Display "Actual current value travel pump forward" Display "Nominal current value travel pump forward"

Display values Stage 1 956 Stage 4 835 Stage 7 716 Stage 10 597 Stage 13 478 Stage 16 357 Stage 19 238 Stage 22 120 Stage 1 = 417 Stage 4 = 1‘667 Stage 7 = 2‘917 Stage 10 = 4‘167 Stage 13 = 5‘417 Stage 16 = 6‘667 Stage 19 = 9‘167 Stage 22 = 16‘667

Input code 1070 1071

12.2.5 Travel pump: Travel direction forward

Description of display function Display "Voltage value for speed range / gear standardized"

Description of Control Input Codes

Input code 1042

Service Training WZ – 4

Machine related electrics

9.1

247

248

Travel direction logics

1108

BOMAG

Travel direction logics

1118

Description of Control Input Codes

Settings will not be saved. After shutting down the machine all drives are engaged again!

Display values

Display values Display in mA (600..1000) Display in mA (600..1000) Display in m/min Counts the pulses up to 99‘999 and starts again at 0 2 = Forward 1 = Standstill and reverse 1 = Forward 0 = Standstill 2 = Reverse

Display values Display in mA (0.0.600.0.1000) Display in mA (0.0.600.0.1000) Display in m/min Counts the pulses up to 99‘999 and starts again at 0 2 = Forward 1 = Standstill and reverse 1 = Forward 0 = Standstill 2 = Reverse

Description of Control Input Codes

Description of display function Enable shut-down (force max. displacement) Drum drive Wheel drive

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

1

Input code 1120 1121 1122

12.2.9 Shut-down of drives1

Description of display function Actual coil current Coil current Nominal value Travel speed Pulses of speed sensor Direction signal of speed sensor

Input code 1110 1111 1115 1116 1117

12.2.8 Travel motor rear (wheel axle)

Description of display function Actual coil current Coil current Nominal value Travel speed Pulses of speed sensor Direction signal of speed sensor

Input code 1100 1101 1105 1106 1107

12.2.7 Travel motor front (drum)

Service Training WZ – 4

Page 68 of 84

9.1 Machine related electrics

008 911 79

008 911 79

Description of display function Pre-control factor forward travel Pre-control factor reverse travel

BOMAG

Description of display function Current travel speed (in km/h)

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Input code 1150

Display values 0,00..20,00

Display values –1000..0..1000. (0 = 0%) 0..8,5V (-> 0..1000) 0..8,5V = 0..1000 0=Not initialized, 1=Normal operation, 2=Fault

Description of Control Input Codes

Description of display function Standardized measuring value Raw measuring value (voltage in V) Standardized measuring tube value Function status (internal logic -> diagnose)

12.2.13 Travel condition values

Input code 1145 1146 1147 1148

Display values 0..600 0.0.5V 0..1000 0, 1, 2

Display values 7000..10000 7000..10000

Description of Control Input Codes

Description of display function Pressure in bar Raw measuring value (voltage in V) Standardized measuring value Function status (internal logic -> diagnose)

12.2.12 Inclination sensor

Input code 1140 1141 1142 1143

12.2.11 Travel pressure sensor

Input code 1128 1129

12.2.10 Adaptation values for speed regulation

Service Training WZ – 4

Page 69 of 84

Machine related electrics

9.1

249

250

BOMAG

Description of display function Current setting (in km/h)

Display values 1= arm rest up; 2= arm rest down Display in mV 1= Driving permitted; 2= Driving disabled

Display values 0 = No limitation 6 = 6 Kmh 7 = 7 Kmh 8 = 8 Kmh 9 = 9 Kmh 10 = 10 Kmh 11 = 11 Kmh 12 = 12 Kmh

Description of Control Input Codes

Description of display function Function status Raw measuring value (voltage in V) Travel operation status by arm rest contact

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Input code 1300 1301 1302

12.2.16 Arm rest contact

Input code 1210

Display values

Description of Control Input Codes

Description of display function Activate the function Travel a distance of 5m Travel a distance of 10m Travel a distance of 20m Travel a distance of 50m Travel a distance of 100m Setting of standard values Saving the measuring value. Speed detection has been parameterized anew!

12.2.15 Speed limitation

Input code 1160 1161 1162 1163 1164 1165 1168 1169

See 4.9 Calibrating the speed detection

12.2.14 Calibrating the wheel diameter

Service Training WZ – 4

Page 70 of 84

9.1 Machine related electrics

008 911 79

008 911 79

Description of display function Pre-control factor front Pre-control factor rear

BOMAG

Standardized actual steering angle position

2112

Description of Control Input Codes

Standardized measuring value

2111

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Description of display function Raw measuring value (voltage in V)

Input code 2110

Page 71 of 84

Display values 0...8,5VDC - Middle position approx. 4,5V - Steering left = lower voltage (approx. 2V..4,5V) - Steering right = lower voltage (approx. 4,5V..4.7V) 0...1000 (left= high value (approx. 750), right = low value (approx. 220) -1000...0...1000 (left = negative value, right positive value)

Display in mA Display in mA Display in mA Display in mA

Display "Current min value (surge current) left hand steering valve" Display „Current max value left hand steering valve“ Display "Current min value (surge current) right hand steering valve" Display „Current max value right hand steering valve“

2106 2107 2108 2109

12.2.19 Steering: Angle sensor in articulated joint

Display values 0– 1200mA Display in mA 0– 1200mA Display in mA

Description of display function Display „Current setpoint right hand steering valve“ Display „Current actual value right hand steering valve“ Display „Current setpoint left hand steering valve“ Display „Current actual value left hand steering valve“

Display values 400..24000 400..24000

Description of Control Input Codes

Input code 2100 2101 2102 2103

12.2.18 Steering: Steering valve

Input code 1500 1501

12.2.17 Adoption values traction control

Service Training WZ – 4

Machine related electrics

9.1

251

252

Steering wheel sensor 2 track 1 absolute pulses Steering wheel sensor 2 track 1 absolute pulses Steering wheel sensor 2 total pulses of sensor Steering wheel sensor 2 sense of rotation

2140 2141 2142 2143

BOMAG

Display "Status of vibration relay“

3001

BVC off on ---

Display value = Hz Display value = Hz 2000 – 8000 (machine type dependent)

Display value = mA

Display values Display value = mA

Display values Value DH4 0 off 1 low amplitude 2 high amplitude 0 = Relay K43 not switched 1 = Relay K43 switched

_

Page 72 of 84

1=steering wheel steers to the right (clockwise); 2=steering wheel steers to the left

Description of Control Input Codes

Description of display function Display "Vibration pump valve current" The display shows the actual pump current. Display "Vibration pump valve current" (high amplitude on DH) The display shows the actual pump current. Actual working frequency (low amplitude on DH) Actual working frequency (high amplitude on DH) Actual control factor (low amplitude on DH)

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

3004 3005 3006

3003

Input code 3002

12.2.22 Vibration (up to version 3.24 )

Description of display function Display "Switch for vibration mode"

Input code 3000

12.2.21 Vibration

Number of total pulses Number of total pulses

Steering wheel sensor 1 track 1 absolute pulses Steering wheel sensor 1 track 2 absolute pulses Steering wheel sensor 1 total pulses of sensor Steering wheel sensor 1 sense of rotation

2130 2131 2132 2133

1=steering wheel steers to the right (clockwise); 2=steering wheel steers to the left Number of total pulses Number of total pulses

Display values -1000...0...1000

Description of display function Standardized nominal steering angle position

Description of Control Input Codes

Input code 2120

12.2.20 Steering: Steering wheel

Service Training WZ – 4

9.1 Machine related electrics

008 911 79

008 911 79

Description of display function Actual control factor (high amplitude on DH) Actual Vario status (only BVC)

BOMAG

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Display values 30 ... 60

Display value = Hz 2000 – 8000 (machine type dependent) 2000 – 8000 (machine type dependent) 1000

Display value = mA

Description of Control Input Codes

Description of display function Vibration motor number of pulses per revolution (vibration motor type dependent) (see 4.12 „Setting the vibration motor type“)

Input code 3030

3014 3016 3017 3018

3013

Description of display function Display "Vibration pump valve current" The display shows the actual pump current. Display "Vibration pump nominal valve current" The display shows the nominal pump current. Current working frequency Current control factor frequency controller Current control factor valve current controller Current fault counter valve current controller

Input code 3012

Display values Display value = mA

Description of display function Display values Display "Vibration pump valve current" (low amplitude on DH) Display value = mA The display shows the actual pump current. Display "Vibration pump nominal valve current" (low amplitude on DH) Display value = mA The display shows the nominal pump current. Actual working frequency (low amplitude on DH) Display value = Hz Actual control factor for frequency controller (low amplitude on DH) 2000 – 8000 (machine type dependent) Actual control factor valve flow controller (high amplitude on DH) 2000 – 8000 (machine type dependent) Actual fault counter valve flow controller (high amplitude on DH) 1000

Vibration control; high amplitude circular exciter (from version 3.25 )

3004 3006 3007 3008

3003

Input code 3002

Display values 2000 – 8000 (machine type dependent) -1 ... 7

Description of Control Input Codes

Vibration control; Vario and low amplitude circular exciter (from version 3.25 )

Input code 3007 3009

Service Training WZ – 4

Page 73 of 84

Machine related electrics

9.1

253

254

BOMAG

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

3062

3061

3060

3059

Description of Control Input Codes

Page 74 of 84

Control status valve "move up" (Pin 5 DIOS module) Control status valve "move down" (Pin 6 DIOS module) Control status valve "retract sideways" (Pin 8 DIOS module) Control status valve "extend sideways" (Pin 7 DIOS module) Control status valve "floating position" (Pin 13 + 15 DIOS module) Control status valve "Priority change-over" (Pin 14 DIOS module)

3057

3058

OFF = Output not triggered ON = Output triggered OFF = Output not triggered ON = Output triggered OFF = Output not triggered ON = Output triggered OFF = Output not triggered ON = Output triggered OFF = Output not triggered ON = Output triggered OFF = Output not triggered ON = Output triggered

Display "Potentiometer value frequency setting of plates"

Display "Switch for float position"

3054

3056

Display "Logic vibration On-Off“

3053

Display "Contact plates coupled"

Display "Sensor for middle position"

3052

3055

Display "Sensor for height shut-down"

3051

OFF = Vibration switched off ON = Vibration switched on OFF = Switch switched off ON = Switch switched on Attention! Float position is not always activated when switch is in ON-position! OFF = Plates are not hydraulically connected with the machine ON = Plates are connected with the machine 0..1000 standard, 0 = min. frequency, 1000 = max. frequency

Description of display function Display "Attachment plates activated"

Input code 3050

Display values OFF, i.e. software for plates switched off ON, i.e. software for plates switched on OFF = Sensor has switched, senses metal, plates raised ON = Sensor has not switched, senses no metal, plates lowered OFF = Sensor has not switched, senses no metal ON = Sensor has switched, senses metal, plates in middle

Description of Control Input Codes

12.2.23 Attachment plates, option (only BW213 BVC)

Service Training WZ – 4

9.1 Machine related electrics

008 911 79

008 911 79

BOMAG

Description of display function Display "Status hydraulic oil filter"

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Input code 5502

12.2.25 Hydraulics

Description of Control Input Codes

Display values 0= Hydraulic oil filter OK 1= Hydraulic oil filter contaminated

0..300 -> 0..3bar

Display "Status of water separator"

5028

Charge air pressure (in bar * 100)

Display "Status engine air filter"

5026

5050

0= Coolant level OK 1= Coolant level too low 0= Air filter OK 1= Air filter soiled 0= Water separator OK 1= Water or dirt in fuel filter

Display "Status engine coolant level"

5024

Display values 0..3000 0..3000 600..1000 1600..3000

Actual speed (rpm) Nominal speed (rpm) Idle speed (EMR parameter) (rpm) Maximum speed (EMR parameter) (rpm)

Description of display function

Description of Control Input Codes

Input code 5000 5001 5010 5011

12.2.24 Engine

Service Training WZ – 4

Page 75 of 84

Machine related electrics

9.1

255

256

Test settings

Deactivates the function "Driving against the closed brake"

0501

BOMAG

Display values

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Display values 500 and brake control light stays on when shifting the travel lever out of the brake gate O K for 3seconds, then 0000

Description of Control Input Codes

Description of display function Enable function Switch off function "Disable electric supply for drum drive motor" Motor valve not energized. The motor should now swash to max. displacement position. Function "Disable electric supply for drum drive motor" Motor valve not energized. The motor should now swash to max. displacement position. Function "Switch of power supply for drum drive motor TOGETHER WITH wheel drive motor" Motor valves not energized. The motors should now swash to max. displacement position. Switch off function "Disable electric supply for drum drive motor" The motor valve is max. energized. The motor should now swash to min. displacement position. Function "Disable electric supply for wheel drive motor" The motor valve is max. energized. The motor should now swash to min. displacement position. Function "Switch on power supply for drum drive motor TOGETHER WITH wheel drive motor" Motor valves max. energized. The motors should now swash to min. displacement position.

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

1126

1125

1124

1123

1122

Input code 1120 1121

12.3.2 Disable electric supply to wheel and drum drive motors (switch off)

Description of display function Activates the function "Driving against the closed brake"

Description of Control Input Codes

Input code 0500

12.3.1 Brake

12.3

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9.1 Machine related electrics

008 911 79

008 911 79

Settings / Teach / Emergency functions

Description of display function Change "Machine code"

Description of display function Activate the function Function "Determine surge currents forward" (only Vers.1.07 and 1.08) Function "Determine surge currents reverse" (only Vers.1.07 and 1.08)

BOMAG

Description of display function Enable function Activate the function

Pulses read Pulses read Pulses read Pulses read Pulses read "saved" "saved"

Display values

Pulses per 10m. 4000 - 15000

Display values

see chapt. "Teach travel system surge currents"

Display values see chapt. "Teach travel system surge currents" see chapt. "Teach travel system surge currents"

Description of Control Input Codes

Description of display function Permit teach function Activate the function: Measurement over a travel distance of 5m Activate the function: Measurement over a travel distance of 10m Activate the function: Measurement over a travel distance of 20m Activate the function: Measurement over a travel distance of 50m Activate the function: Measurement over a travel distance of 100m Reset to basic values Storing the learned values

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Input code 1160 1161 1162 1163 1164 1165 1168 1169

12.4.4 Speed detection, teaching of distance pulses

Input code 1158 1159

12.4.3 Speed detection, trimming of measuring values

1092

Input code 1090 1091

Display values see chapter "Change machine code"

Description of Control Input Codes

12.4.2 Automatic detection of surge currents in travel system

Input code 7010

12.4.1 Changing the machine code

12.4

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258

Description of Control Input Codes

Raise travel speed over 10m/min

Display values

Description of Control Input Codes

Only optional function! The logical sense of rotation is automatically adjusted

Description of display function Permit teach function Teach sense of rotation1

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

1

Input code 1200 1201

12.4.5 Detection of wheel rotation

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9.1 Machine related electrics

BOMAG

008 911 79

008 911 79

Description of display function Activate function "Teach steering start current" Function "Teach steering start current"

Description of display function Activate function "Teach steering stops" Deactivate function "Teach steering stops" Function "Accept right hand steering stop" Function "Accept left hand steering stop"

BOMAG

Description of display function Steering with joystick buttons Steering with steering wheel (uncontrolled)

Description of display function Activates function „Change steering unit“ Activate: Electric steering unit Activate: Hydraulic steering unit

Display values see chapter 4.12 see chapter 4.12 see chapter 4.12

Display values see chapter 4.5 see chapter 4.5 see chapter 4.5

Display values "OK". In case of steering wheel failure "OK". In case of steering angle potentiometer failure

Display values see chapter 4.6 0000 see chapter 4.6 see chapter 4.6

Description of Control Input Codes

Description of display function View current setting of pulse numbers Activate function „Adjust vibration motor type“ Select vibration motor type 1..8. Follow the selection table in 4.12.

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Input code 3030 3031 3032..30 39

12.4.10 Setting the vibration motor type

Input code 2060 2061 2062

12.4.9 Steering: Other functions

Input code 2050 2051

12.4.8 Steering: Emergency function

Input code 2010 2011 2012 2013

12.4.7 Steering: Determining the steering stops

Input code 2000 2001

Display values see chapter 0 see chapter 0

Description of Control Input Codes

12.4.6 Steering: Automatic detection of surge currents on steering valve

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260

Description of display function Enable function "Changeover of travel speed dependent vibration lock" Activate vibration lock from travel speed stage 12 Disable vibration lock.

Description of display function View the current setting. Enable function "Switch over frequency setting". Activate frequency setting (machine with switch). Disable frequency setting (machine WITHOUT switch).

Display values 0, 1

BOMAG

Description of Control Input Codes

Description of display function Activate function "Prevent reversing with plates lowered" Allow reversing with plates lowered. Prevent reversing with plates lowered.

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

Input code 3077 3078 3079

Page 80 of 84

Code "Plate pump energized without plates attached"

3076

Display values

Attention – danger of collision! Use only in case of a sensor fault! Only for initial commissioning!

Code "Plate adjustment without sensors"

3075

12.4.14 Plates: Preventing reversing with plates lowered

Display values

Description of display function Enable optional changeover. Activate option "attachment plates". Disable option "attachment plates".

Input code 3070 3071 3072

12.4.13 Attachment plates (only circular exciter): Activating/deactivating the attachment plates option

Input code 3090 3091 3092 3093

12.4.12 Vibration: Enable frequency setting

3048 3049

Input code 3047

Display values

Description of Control Input Codes

12.4.11 Vibration: Travel speed dependent vibration lock

Service Training WZ – 4

9.1 Machine related electrics

008 911 79

9.1

Machine related electrics

Service Training WZ – 4

13 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) rubbed through chafed mostly in connection with a short circuit to ground

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

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Terminology

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Service Training WZ – 4 Short circuit to ground Line, terminal has direct connection to vehicle ground, often in connection with wire breakage

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

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

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Terminology

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Service Training WZ – 4 Control Controlling describes the process during which an input value influences a distance (the value to be controlled), following a fixed command. For this purpose all possible interfering factors (e.g. temperature, humidity ...) must be known.

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

Marking Operating path:

Closed loop control closed (closed loop control circuit) Measurement and Value to be adjusted is meascomparison of value to ured and compared. be adjusted: Reaction to faults (ge- Counteracts to all faults tarnerally): geting 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.

Version/Status: V3.29 / 13.11.07 Author: Seis,MASH,LOEW / TE/TES

008 911 79

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

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Service Training WZ – 4 Current and voltage measurement

Ohm’s law: U = Voltage R = Resistance I = Current

U =R∗I U R U R= I

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.

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.

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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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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

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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

Status:05.06.2007 Author: T.Löw / TE

008 911 79

resp. Löw Löw

Löw Löw Löw

Löw, Horch

Löw

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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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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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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:

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

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:

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

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:

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

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

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

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

Service Training MESX

Block diagram

Block diagram

commande

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308

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10 Block diagram BTMplus / VARIOCONTROL

Service Training MESX

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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310

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

Description of signals

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!

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

Description of signals

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)

Description of signals

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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311

312

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.

Measurement not possible!

Open circuit voltage (vibration off):

Acceleration signal (measured against AGND)

Open circuit voltage (vibration off):

Acceleration signal (measured against AGND)

Open circuit voltage (vibration off):

Acceleration signal (measured against AGND)

Description of signals

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

Measurement not possible!

Measurement not possible!

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

Nominal values (voltage / current)

Description of signals

ESX terminal Signal description X44:25

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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)

) ) ) )

Description of signals

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

Nominal values (voltage / current)

Description of signals

ESX terminal Signal description X44:36

Service Training MESX

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12 V 0V >6V approx.0 V

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313

314

Voltage supply for outputs

Voltage supply for outputs

Voltage supply for outputs

X44:57

X44:58

X44:59

BOMAG

Mouse port Baby Boards

Mouse port Baby Boards

X44:67

X44:68

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Mouse port Baby Boards

X44:66

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Mouse port Baby Boards

X44:65

X44:64

X44:63

X44:62

X44:61

Voltage supply for outputs

Voltage supply for outputs

X44:56

X44:60

approx. 12 V measured against ground

Ground connection electronics

X44:55

Description of signals

approx. 0 V

approx. 0 V

approx. 0 V

approx. 0 V

approx. 12 V measured against ground

approx. 12 V measured against ground

approx. 12 V measured against ground

approx. 12 V measured against ground

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

Description of signals

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

Service Training MESX

12 V 0V

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Fault codes of the ESX control

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

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

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BOMAG

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316

BOMAG

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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

Service Training MESX

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Description of fault codes of the ESX control

Fault description

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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

Fault Code Description ESX Control

) 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

Service Training MESX

X44:09

X44:09

Terminal on ESX

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5

Input Fault code for reaction diagnose 5

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317

318

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

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

Fault Code Description ESX Control

) 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

Description of fault codes of the ESX control

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

Fault code

Service Training MESX

X44:47

X44:47

X44:47

X44:46

X44:46

X44:46

Terminal on ESX

Page 48 of 59

2

2

2

2

2

Input Fault code for reaction diagnose 2

9.2 Electrics MESX

008 911 79

008 911 79

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

Fault Code Description ESX Control

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

Description of fault codes of the ESX control

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

Service Training MESX

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

Electrics MESX

9.2

319

320

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)

Fault Code Description ESX Control

-

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

Description of fault codes of the ESX control

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

Service Training MESX

-

-

-

-

Page 50 of 59

-

5

2

5

Input Fault code for reaction diagnose 2

9.2 Electrics MESX

008 911 79

008 911 79

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

Description of Control Input Codes

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)

Service Training MESX

Page 51 of 59

Electrics MESX

9.2

321

322

BOMAG

Status: Author:

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

Description of Control Input Codes

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 Control Input Codes

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

Service Training MESX

Page 52 of 59

9.2 Electrics MESX

008 911 79

008 911 79

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

Service Training MESX

Description of Control Input Codes

Display values 0000 ) Engine OFF 0001 ) Engine ON

Display value = voltage in V

Display values Display value = voltage in V

Description of Control Input Codes

Page 53 of 59

Electrics MESX

9.2

BOMAG

323

324

Status: Author:

Description of Control Input Codes

Display values

Description of Control Input Codes

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

Service Training MESX

Page 54 of 59

9.2 Electrics MESX

BOMAG

008 911 79

008 911 79

Status: Author:

Description of Control Input Codes

Display values Display value 7 6 0 0 see adjustment instructions

Description of Control Input Codes

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

Service Training MESX

Page 55 of 59

Electrics MESX

9.2

BOMAG

325

9.2

Electrics MESX

Service Training MESX

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:

326

05.06.2007 T.Löw / TE

Terminology

BOMAG

Page 56 of 59

008 911 79

9.2

Electrics MESX

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 79

01.04.2005 T.Löw / TE

General terminology

BOMAG

Page 57 of 59

327

9.2

Electrics MESX

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:

328

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 79

9.2

Electrics MESX

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 79

01.04.2005 T.Löw / TE

General terminology

BOMAG

Page 59 of 59

329

9.2

330

Electrics MESX

BOMAG

008 911 79

10 Service Training

008 911 79

BOMAG

331

332

BOMAG

008 911 79

10.1 Service Training Machine

008 911 79

BOMAG

333

10.1

334

Service Training Machine

BOMAG

008 911 79

10.1

Service Training Machine

008 911 79

BOMAG

335

10.1

Service Training Machine

Service Training Table of contents Foreword

A1

Documentation

A2

General

A3

New developments

A5

Travel system

E1

Travel pump

E3

Control

E7

Charge pressure relief valve

E8

High pressure relief valve

E9

Pressure override

E11

Axle drive motor

E14

Drum drive motor

E17

Test and adjustment points, travel system

E19

Trouble shooting travel system

E27

BW 213 / 214 DH / PDH -4

336

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Vibration

F1

Vibration pump

F3

High pressure relief valves

F6

Control

F7

Vibration motor

F8

Drum

F11

Test and adjustment points, vibration system

F13

Trouble shooting vibration

F15

Steering

G1

Charge pump

G2

Steering pump

G3

Steering valve

G5

Articulated joint

G7

Measuring and adjustment points

G9

Trouble shooting steering

G10

BW 213 / 214 DH / PDH -4

008 911 79

BOMAG

337

10.1

Service Training Machine

Service Training Foreword and novelties Reliable construction equipment is of greatest advantage for all parties involved: • for the customer/user it is a basis for an exact calculation of utilization periods and the completion of projects as scheduled. • in the rental business it means that the equipment can be reliably used and planned without having to stock a large number of stand-by machines. • for the manufacturer it means that customers are satisfied, provides him with a good image and gives him a feeling of confidence. It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. This aspect of simple and easy maintenance was one of the key issues when developing and designing the machine: • the location of components in the machine eases maintenance work, • the high quality standard of BOMAG is the basis for the considerable extension of the service and maintenance intervals. • the After Sales Service of BOMAG, including excellent operating and maintenance instruction manuals, high quality training courses and on-site machine demonstrations helps the customer to maintain their machines in good condition over a long period of time. Permanent training of BOMAG’s own service personnel as well as the service personnel of BOMAG Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service. This program of permanent training is only possible with appropriate and up-to-date training material for trainers as well as persons attending the training courses. This training manual has not only been written as a support for the professional work of the trainer, but also for the trainees attending these training courses. The different levels of product training demand, that the training performed by BOMAG, its Profit Centres or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in Boppard. For this reason we invested a lot of time in the preparation of these materials . The structure of this training manual enables us to change or up-date individual chapters in case of alterations to the machine.

BW 213 / 214 DH / PDH -4

338

-A1-

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Documentation For valid BOMAG single drum roller serie -4 :

BW 213 DH-4 with serialnumber of the machine: 58314, 58315 BW 214 DH-4 with serialnumber of the machine: 58319, 58320

For the BOMAG machines described in this training manual the following documentation is additionally available: Attention! The currently valid part numbers for the documents can be taken from the Doclist or the Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial number of the machine.

1. Operating and maintenance instructions 2. Spare parts catalogue 3. Wiring diagram * 4. Hydraulic diagram * 5. Repair instructions 6. Service Information * The document versions valid at the date of printing are part of this training manual.

BW 213 / 214 DH / PDH -4

008 911 79

-A2-

BOMAG

339

10.1

Service Training Machine

Service Training General The new single drum rollers serie -4 from BOMAG are essentially further developments of their predecessors, the machines of product range serie -3. These machines have been successfully and reliably used for years on construction sites all over the world, especially in earth construction and on sanitary landfill sites. High compaction power and excellent traction are characteristics, which are of utmost importance for this type of machine. All components installed in these machines are manufactured in series production and are subjected to stringent quality tests. This guarantees a high level of reliability and safety. As with many other BOMAG products, and here especially with the large single drum rollers of the new generation, we have decided to use the same successful drive concept with diesel engine (water cooled) and hydrostatic drives also for these machines. The hydrostatic drives transfer the output power of the engine directly to drum, drive wheels and steering. The drive wheels are driven by fast rotating hydraulic motors and axle, whereas the drum is driven by slow running radial piston motors. On construction machines the work place of the operator is of utmost importance. Under such working conditions the health and safety of the operator must be the greatest concern. The cabin is very spacious and clearly arranged. The driver’s seat is very comfortable and can be individually adjusted for every operator, even for his weight. All control elements and gauges are within the reach and in the sight of the operator. A monitoring display with light emitting diodes and clear pictograms informs the operator about any operating faults. The operator is therefore always informed about the present condition of the machine. The generously glazed cabin with windscreen wiper and washer systems for front and rear windscreens, as well as a heated rear windscreen, offers clear vision to all sides.

BW 213 / 214 DH / PDH -4

340

-A3-

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Important characteristics of the new generation of single drum rollers are • strong ROPS/FOPS according to SAE-standard • wear free service brake by closed hydrostatic travel circuits • disc brakes in axle and drum drive motor serve as parking and emergency brakes • high stability due to low centre of gravity and the use of an articulated joint • operating safety due to the use of monitoring boards for all important system data • automatic engine shut-down at too engine temperature, too low hydraulic oil level (when reaching the lowest permissible level the engine will be shut down after 20 seconds) and too low engine oil pressure. The new single drum roller serie -4 are well designed down to the smallest detail, so that they can meet the toughest demands on large scale construction sites all over the world.

BW 213 / 214 DH / PDH -4

008 911 79

-A4-

BOMAG

341

10.1

Service Training Machine

Service Training Novelties The multi-function travel lever and the display

BW 213 / 214 DH / PDH -4

342

-A5-

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Control, operation, data collector,

BW 213 / 214 DH / PDH -4

008 911 79

-A6-

BOMAG

343

10.1

Service Training Machine

Service Training Diesel engine with EMR

BW 213 / 214 DH / PDH -4

344

-A7-

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Travel System

BW 213 / 214 DH / PDH -4

008 911 79

-A8-

BOMAG

345

10.1

Service Training Machine

Service Training

Charging from Charge pressure filter

15

Travel system

BW 213 / 214 DH / PDH-4 -E1-

346

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Pos.

Designation

10 12

Travel pump, electr.- prop. 90R075 Drum drive motor electr.-prop. 51C110 Axle drive motor, electr.-prop. 51D110 Axle Reduction gear CR 31

13 14 15

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

10 12 13 14

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 with reduction gear; • axle drive motor, • 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 425 bar (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 pump inside the vibration pump draws hydraulic oil out of the tank and delivers it through the hydraulic oil filter to the boost check valves in travel and vibration pump. The return flow from the steering system also flows through the hydraulic oil filter and is then available for the closed circuit charging system. The charge circuit also provides the oil for the control functions in the closed circuits for travel and vibration drive and to release the parking brakes. Both travel motors and the travel and vibration pumps are electrically proportionately controlled.

BW 213 / 214 DH / PDH-4 -E2-

008 911 79

BOMAG

347

10.1

Service Training Machine

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.

3

1

4

2

Charging

Pos.

Designation

1 2 3 4

Travel pump, electr.- prop. 90R075 Charge pressure relief valve Control, electr.-prop. Multi-function valve

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

10

BW 213 / 214 DH / PDH-4 -E3-

348

BOMAG

008 911 79

10.1

Service Training Machine

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. 1: Travel pump 1

Electric prop. control

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.

BW 213 / 214 DH / PDH-4 -E4-

008 911 79

BOMAG

349

10.1

Service Training Machine

Service Training Cross-sectional view of travel pump

2 4 5

1

3 6 7

9

10

8

11 Fig. 2: 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

6

Feedback device

BW 213 / 214 DH / PDH-4 -E5-

350

BOMAG

008 911 79

10.1

Service Training Machine

Service Training View of the rotating group 1 2

5

4

3

Fig. 3: Travel pump, view of the rotating group 1

Working pistons

2

Slipper pad

3

Pre-tensioning spring

4

Cylinder block

5

Drive shaft

BW 213 / 214 DH / PDH-4 -E6-

008 911 79

BOMAG

351

10.1

Service Training Machine

Service Training Description of function

2

4

3

5

6

1

8

6

7

Fig. 4: 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 213 / 214 DH / PDH-4 -E7-

352

BOMAG

008 911 79

10.1

Service Training Machine

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 213 / 214 DH / PDH-4 -E8-

008 911 79

BOMAG

353

10.1

Service Training Machine

Service Training Tandem pump, connections and adjustment points

38

Thermostat housing

Fig. 5: Connections and adjustment points

BW 213 / 214 DH / PDH-4 -E9-

354

BOMAG

008 911 79

10.1

Service Training Machine

Service Training 1

Rear vibration pump connecting plate, turned by 90° !!!

2

Proportional solenoid (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

Pump flange

7

Port L, leak oil to vibration pump

8

Electr.-prop. control (travel pump)

9

Pressure test port, pilot pressure

10

High pressure port B, high pressure reverse

11

Charge pressure relief valve, 26 bar

12

not on EP-pumps

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

Charge pump (only in vibration pump)

19

Port L2, (connection to vibration pump)

20

not on EP-pumps

21

Filter block for charge circuit

22

Multi-function valve 400 bar (charging and pressure limitation), vibration high frequency

23

Port S, suction line between hydraulic oil tank and charge pump

24

Multi-function valve 400 bar (charging and pressure limitation), vibration low frequency

25

Charge pressure relief valve, vibration pump (fixed setting 40 bar)

26

Filter block for charge circuit

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

Thermostat housing: 32

Port C, from solenoid valve for brake/speed range selection

33

Leak oil port D, leak oil from axle drive motor

34

Leak oil port A, leak oil from travel pump

35

Leak oil port G, leak oil from drum drive motor

36

Leak oil port F, leak oil from vibration motor

37

Leak oil port B, leak oil to oil cooler

BW 213 / 214 DH / PDH-4 - E 10 -

008 911 79

BOMAG

355

10.1

Service Training Machine

Service Training servo control The servo control (mechanical – hydraulic displacement control) converts the mechanical input signal from the proportional valve 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 input signal from the proportional valve. A mechanical feedback device ensures the fixed correlation between the proportional valve input signal and the swashing angle of the swash plate (displacement of pump). Servo cylinder

Control piston

Sliding block

Servo arm

Control piston in pump

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: • when shutting the engine down, • if the pressure in the charge circuit drops below a certain value.

BW 213 / 214 DH / PDH-4 - E 11 -

356

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Multi-function valves High pressure limitation Pumps of series 90 are equipped with a follower valve, which activates a pressure override and a pressure relief valve, one after the other.

1

2

7 3 A

6

5

B 4 7

2 Fig. 6: 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

Charge pressure relief valve

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 213 / 214 DH / PDH-4 - E 12 -

008 911 79

BOMAG

357

10.1

Service Training Machine

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. 7: 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 213 / 214 DH / PDH-4 - E 13 -

358

BOMAG

008 911 79

10.1

Service Training Machine

Service Training 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, the speed range selection and to operate the multi-disc 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 213 / 214 DH / PDH-4 - E 14 -

008 911 79

BOMAG

359

10.1

Service Training Machine

Service Training Axle drive motor

The axle drive motor is a swash plate controlled Sauer-Danfoss axial piston motor of series 51 D 110 with an electrical proportional control for variable displacement. HD-Pump

Charge pressure

Brake valve

6

5 4 2

Leak oil 3

HD-Pump

Fig. 1Hydraulic diagram, axle drive motor 1

Motor drive

2

Control piston

3

Proportional control with proportional solenoid

4

Flushing valve with flushing pressure limitation valve

5

Axle with brake

6)

Rotary speed sensor (flange sensor)

BW 213 / 214 DH / PDH-4 - E 15 -

360

BOMAG

008 911 79

10.1

Service Training Machine

Service Training .

5

8

7

6 9

1

11 4

2

10

3 Fig. 2: Axle drive motor, 1

Control piston

7

Cylinder block

2

Flushing valve

8

Universal joint

3

Proportional control

9

Output shaft

4

Spindle with ball

10

Output shaft bearing

5

Qmin-screw

11

Working piston

6

Valve plate

BW 213 / 214 DH / PDH-4 - E 16 -

008 911 79

BOMAG

361

10.1

Service Training Machine

Service Training 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.

Control The motor is electric-proportionally controlled. 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.

The front travel motor (drum drive) also is an axial travel motor from Sauer-Danfoss.

51C110

BW 213 / 214 DH / PDH-4 - E 17 -

362

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Flushing valve 2

1 Fig. 8Cross-section of flushing valve 1 Flushing spool 2 Flushing pressure relief valve The flushing valves are integrated in the axle drive motor, or on DH/PDH machines, also in the drum 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 flushed out oil quantity 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 213 / 214 DH / PDH-4 - E 18 -

008 911 79

BOMAG

363

10.1

Service Training Machine

Service Training Manual releasing of brake on axle drive For manual releasing of the brakes on the rear axle you should proceed as follows:

Fig. 9: 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 213 / 214 DH / PDH-4 - E 19 -

364

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Drum drive motor 51C110 with reduction gear CR 31 The drums on the DH-4 and PDH-4 versions are driven by a swash plate operated Sauer axial piston motor 51C110. This motor is almost identical with the rear axle motor. Another detailed description at this point is therefore not necessary. 2 4

3

1

5

6

7

8

10 9 Fig. 10: Reduction gear CR 31 1

Travel motor

6

Sun gear

2

Tapered roller bearing

7

Planet carrier

3

Spur wheel

8

Brake discs

4

Hollow wheel

9

Mechanical seal

5

Planet wheel

10

Brake piston

This motor is a fast rotating hydraulic motor. Since the output speed of this motor is much too high to drive the drum, a reduction gear reduces the output speed to the actually required drum drive speed.

BW 213 / 214 DH / PDH-4 - E 20 -

008 911 79

BOMAG

365

10.1

Service Training Machine

Service Training Brake control

During operation the closed hydrostatic travel circuit has the function of a service brake. When moving the travel lever from full forward or reverse position towards neutral, the travel pump will follow towards zero position relative to the movement of the travel lever. The oil flow is thereby reduced and the machine is hydraulically braked. When moving the travel lever to neutral position, the pump will also return to neutral, the supply of oil is interrupted and the hydraulic circuit brakes the machine to standstill.

However, since minor leaks cannot be avoided in any hydraulic circuit and such minor leaks will cause creeping of the machine when it is parked on a slope with the engine running, the machine is additionally equipped with multi-disc brakes in drum drive and both wheel drives. When engaging the travel lever in neutral position the multi-disc brakes will close and the machine can be parked on slopes with the engine running and without the risk of creeping.

However, these parking brakes can also be operated via a 3/2-way solenoid valve. In de-energized condition the multi-disc brakes in the travel drives are unloaded. The charge pressure to the brakes is interrupted and the oil from the brake housings flows as leak oil back into the tank.

If the brake solenoid valve is supplied with current while the engine is running and the brake is open, the connection of the brake line to the tank is interrupted and oil from the charge circuit is guided to the brake pistons. The oil pressure works against the spring force of the brake spring and relieves the brake discs.

BW 213 / 214 DH / PDH-4 - E 21 -

366

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Manual drum drive brake release (in the reduction gear) Brake releasing device in operation position

Brake releasing device in position “brake manually released”

For manual brake release both screws on the drum drive reduction gear (marked with arrow) must be turned in uniformly, until the drum is able to rotate freely.

BW 213 / 214 DH / PDH-4 - E 22 -

008 911 79

BOMAG

367

10.1

Service Training Machine

Service Training Travel circuit with drum drive motor 51C110 and CR 31 (position of components)

2

9 Travel lever forward

1

3 8

4 7

5

6 a Tr

High pressure Low pressure Charge pressure Leak oil

l ve

ec dir

n ti o

1 2 3 4 5 6 7 8 9

Travel pump Vibration pump Hydraulic oil filter Rear axle Axle drive motor Reduction gear Drum drive motor Hydraulic oil tank Travel lever

Fig. 11: Travel circuit with 51 C 110 and CR 31

BW 213 / 214 DH / PDH-4 - E 23 -

368

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Brake control BW 213 (with Sauer motor 51C110 and CR 31)

Brake valve

Charge pressure Brake releasing pressure Leak oil

BW 213 / 214 DH / PDH-4 - E 24 -

008 911 79

BOMAG

369

10.1

Service Training Machine

Service Training Test and adjustment points, travel system Charge pressure filter and travel pump

2 3 1 5 4

Pos.

Designation

1 2

charge oil filter Charge oil filter pressure differential switch Pressure test port, charge pressure Travel pump - pressure test port Travel pressure forward Test port travel pump forward A

3 4 5

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

07 Δp 3,5 bar

B21 MA 10 / A / MD

26+/-3 bar max. 426 bar

10 / A

BW 213 / 214 DH / PDH-4 - E 25 -

370

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Travel pump

2 2 3

3 1

Pos.

Designation

1

Travel pump - pressure test port Travel pressure reverse Prop. solenoid travel forward Prop. solenoid travel reverse

2 3

1

Pos. in wiring diagram

Bl.004 / Y17 / X16 Bl.004 / Y16 / X15

Pos. in hydraulic diagram

Measuring values

10 / B / MC

max.426 bar 12V / 0,4-1,2 A 12V / 0,4-1,2 A

BW 213 / 214 DH / PDH-4 - E 26 -

008 911 79

BOMAG

371

10.1

Service Training Machine

Service Training Travel and vibration pump

1

2

Pos.

Designation

1 2

Test port travel pump reverse B Pressure test port, charge pressure

Pos. in wiring diagram

Pos. in hydraulic diagram

10 / B MA

Measuring values

26+/-3 bar

BW 213 / 214 DH / PDH-4 - E 27 -

372

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Travel motor (drum drive)

3

4 5

2

2

5 3

1

1

4

Pos.

Designation

1 2 3 4 5

Pressure travel forward Pressure travel reverse Port X Prop. solenoid Speed flange sensor PPU

Pos. in wiring diagram

Pos. in hydraulic diagram

12 - A 12 - B X1 Y30 B59

Measuring values

approx. 26bar 12V / 0,4-1,2 A

BW 213 / 214 DH / PDH-4 - E 28 -

008 911 79

BOMAG

373

10.1

Service Training Machine

Service Training Travel motor (axle drive)

2

1

3

5 6 4

Pos.

Designation

Pos. in wiring diagram

1 2 3 4

Prop. solenoid Port X Travel pressure sensor High pressure travel pump forward and further to drum drive motor High pressure travel pump reverse and further to drum drive motor Speed sensor (flange sensor)

Y 31

5 6

Pos. in hydraulic diagram

X1 B 112

Measuring values

12V / 0,4-1,2 A approx. 26bar 26 -426 bar

13 - B 13 - A B 60

BW 213 / 214 DH / PDH-4 - E 29 -

374

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Speed sensor and travel pressure sensor

1 2 1 3

2 1

NEW : Speed flange sensors in both travel motors and a pressure sensor at the front left hand side under the operator's platform!

Pos.

Designation

Pos. in wiring diagram

1

Speed flange sensor PPU axle motor Speed flange sensor PPU drum drive motor Travel pressure sensor in frame, front left under operator's platform

B60

1 2

Pos. in hydraulic diagram

travel

Measuring values

B59 B112

BW 213 / 214 DH / PDH-4 - E 30 -

008 911 79

BOMAG

375

10.1

Service Training Machine

Service Training Brake valve

5

2 1 3

1

4

3

Pos.

Designation

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

1

Brake valve

Y 04

08

0V closed open

12V

BW 213 / 214 DH / PDH-4 - E 31 -

376

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Travel lever

5

4

Multi-function travel lever

For a detailed description of the travel lever buttons please refer to the page on "Electrics" (Service Training Electrics)

BW 213 / 214 DH / PDH-4 - E 32 -

008 911 79

BOMAG

377

10.1

Service Training Machine

Service Training Trouble shooting The display shows the fault codes

For a detailed description of how to read out fault codes and the display please refer to the page on "Electrics" (Service Training Electrics)

All electric faults are mainly shown by the display

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.

BW 213 / 214 DH / PDH-4 - E 33 -

378

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Procedure: The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.

Hydrauliköl wird zu heiss

Max.Fahrgeschwindigkeit wird nicht erreicht

Maschine fährt mit Fahrhebel in Stellung 'Neutral'

Maschine fährt nur in eine Fahrtrichtung

SYMPTOME

FEHLERSUCHE FAHRANTRIEB BW 213/214 DH/PDH-4

Maschine fährt nicht (vor und zurück)

The number specified in the table indicate the probability of the fault cause and thereby the recommended trouble shooting sequence, based on our latest field experience.

MÖGLICHE URSACHEN Bremsventil (elektrisch/mechanisch/hydraulisch) Bremse Achse/Bandagenmotor (mechanisch/hydraulisch) Fahrpropverstellung /defekt/Verkabelung Speisepumpe / Speisedruckbegrenzungsventil(e) verschmutzt/defekt Pumpenansteuerung (Servoverstellung) Druckabschneidung/ Hochdruckbegrenzung Fahrpumpe verschmutzt/verstellt/defekt Fahrhebel Nullage Fahrpumpe Fahrpumpe(n) defekt Stellventil Fahrmotoren (elektrisch / mechanisch / hydraulisch) Spülventil Fahrmotoren hängt Fahrmotor(en) defekt Hydraulikölkühler verschmutzt (intern/extern) Thermostat (Hydraulik) verschmutzt/verklemmt/defekt Kupplung Dieselmotor-Pumpe Dieselmotor Drehzahl-Flanschsensoren im Fahrmotor (Verkabelung)

1 2

2 1

2

3

3

2

1

3

2

2

1 3 3

3

3 3

3

2 3 2 1

2

3 3

3 1 2

2 1

1

1 2

FEHLERSUCHE BW 213 / 214 DH / PDH-4 - E 34 -

008 911 79

BOMAG

379

10.1

Service Training Machine

Service Training

2

4

3

Vibration

Pos.

Designation

1 2 3

Vibration pump 75 cm³ Integrated charge pump 17 cm³ Multi-function valves with high pressure limitation and boost check valve function Proportional control

4

Pos. in wiring diagram

Measuring values

11

BW 213 / 214 DH / PDH -4

380

Pos. in hydraulic diagram

-F1-

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Pos.

Designation

5

Vibration motor with flushing valve

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

15

The vibration system on these single drum rollers works with different frequencies and tow amplitudes. This enables perfect adaptation of the machine to various types of soil and different applications.

The vibration circuit is also a closed hydraulic circuit, similar to the travel circuit. The main components of this circuit are vibration pump, Vibration motor and the pressure resistant hydraulic hoses.

Vibration pump and travel pump are joined to a tandem unit, which is driven by the flywheel end of the diesel engine. By operation of a proportional valve the pilot oil is guided to one of the control piston sides. This actuates the pump from neutral position to one of the two possible maximum displacement positions. When changing the swashing angle through the neutral position to the opposite side, the flow direction of the oil and the sense of rotation of the vibration motors will change.

Since the engine speed is variable in "Position AUTO", the pump displacement must always be proportionately adapted in order to maintain the vibration frequency at a constant level.

The vibration motor output shaft is joined with the exciter shaft in the drum via a Bowex coupling. The rotation of the exciter shaft with the bolted on eccentric weights causes the vibration of the elastically suspended drums. The eccentric weights on the vibrator shaft are fitted with additional change-over weights.

BW 213 / 214 DH / PDH -4

008 911 79

-F2-

BOMAG

381

10.1

Service Training Machine

Service Training Depending on the sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic weights. Basic weight + change-over weight = high amplitude Basic weight - change-over weight = low amplitude

The displacement of the pump may be different to both flow directions. This results in different exciter shaft speeds for the different senses of rotation of the motor. The vibration system is designed in such a way, that the high exciter shaft speed (frequency) is coupled with the low amplitude and the low exciter shaft speed (frequency) with the high amplitude.

Sense of rotation of exciter shaft

BW 213 / 214 DH / PDH -4

382

-F3-

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Vibration pump The vibration pump is a swash-plate controlled axial piston pump with variable displacement of type 90 R 075 EP from Sauer-Danfoss. The pump is fitted with all control and safety elements needed for operation in a closed hydraulic circuit.

5

4

2

Pos.

Designation

1 2 3

Vibration pump 75 cm³ Integrated charge pump 17 cm³ Multi-function valves with high pressure limitation and boost check valve function Prop. solenoids servo control Safety valve in charge circuit

4 5 6

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

11

X 6 and X 7

BW 213 / 214 DH / PDH -4

008 911 79

3

6

-F4-

BOMAG

383

10.1

Service Training Machine

Service Training Function

1

2

6

5

4

3

Cross-section of vibration pump 1 Servo piston 2 Working pistons 3 Charge pump 4 Valve plate 5 Roller bearing 6 Swash plate

BW 213 / 214 DH / PDH -4

384

-F5-

BOMAG

008 911 79

10.1

Service Training Machine

Service Training 1 2 5

3

4

Cross-section of vibration pump 1 Control 2 Servo piston 3 Friction free swash plate bearing 4 Attachment plate 5 Spool valve

BW 213 / 214 DH / PDH -4

008 911 79

-F6-

BOMAG

385

10.1

Service Training Machine

Service Training 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. 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 converts the electric proportional input signal into a load controlling output signal.

The vibration pump has an integrated charge pump, an internal gear pump with a displacement of 17 cm³ per revolution

The vibration pump is equipped with an integrated charge pressure relief valve, which is set to a pressure of 40 bar. This valve only has a safety function in the charge circuit.

BW 213 / 214 DH / PDH -4

386

-F7-

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Multi-function valve 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

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. 426 bar (pressure difference between high and low pressure side = 400 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.

BW 213 / 214 DH / PDH -4

008 911 79

-F8-

BOMAG

387

10.1

Service Training Machine

Service Training Vibration motor The vibration motor is a Bosch-Rexroth axial piston motor of series A2FM 56 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.

BW 213 / 214 DH / PDH -4

388

-F9-

BOMAG

008 911 79

10.1

Service Training Machine

Service Training 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 426 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

Circuit diagram of vibration motor 1 Vibration motor 2 Flushing valve 3 Flushing pressure relief valve

BW 213 / 214 DH / PDH -4

008 911 79

- F 10 -

BOMAG

389

10.1

Service Training Machine

Service Training Flushing valve The vibration motor is equipped with an integrated flushing valve. This flushing valve is located inside the bolted on connecting block. 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

Flushing valve 1 Flushing spool 2 Flushing pressure relief valve The flushing valve is fitted with a downstream 16 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 213 / 214 DH / PDH -4

390

- F 11 -

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Speed sensor The fixed displacement vibration motor A2FM56 is equipped with a Bosch-Rexroth speed sensor HDD1L16 or HDD2L16 with an installation depth of 16 mm, which uses the Hall-effect.

Fixed displacement motor A2FM56

Connection in wiring diagram, vibration speed sensor B16 on page 006

BW 213 / 214 DH / PDH -4

008 911 79

- F 12 -

BOMAG

391

10.1

Service Training Machine

Service Training Drum

4

14

5

9

2

6

13

7 10

3

8

11

12

1 Fig. 1 Cross-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 213 / 214 DH / PDH -4

392

- F 13 -

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Test and adjustment points, vibration system Vibration pump

7 6

6

1

8 72

6

8

5

7 5 5 3

2 4 Pos.

Designation

1

Pressure test port, vibration pressure low amplitude Pressure test port, vibration pressure high amplitude High pressure port low amplitude High pressure port high amplitude Multi-function valve with high pressure limitation low amplitude Multi-function valve with high pressure limitation high amplitude Solenoid valve, low amplitude Solenoid valve, high amplitude

2 3 4 5 6 7 8

4

4

1 3

2 Pos. in wiring diagram

3 Pos. in hydraulic diagram

Measuring values

11 - B - ME

Starting pressure 330 -400 bar Starting pressure 330 -400 bar max. 426 bar max. 426 bar

11 - A - MF 11 - B 11 - A 11 - B 11 - A Y07 / X 8 Y07 / X 7

BW 213 / 214 DH / PDH -4

008 911 79

1

11 - B 11 - A

12V / 0,4 - 1,2A 12V / 0,4 - 1,2A

- F 14 -

BOMAG

393

10.1

Service Training Machine

Service Training Vibration motor

3

5 1

1

2 2

4 3 4

2 Pos.

Designation

1 2 3 4

High pressure port high amplitude High pressure port, low amplitude Flushing valve Leakage and flushing

Pos. in wiring diagram

Pos. in hydraulic diagram

15 - A 15 - B 15 15 - L1

BW 213 / 214 DH / PDH -4

394

31 Measuring values

approx. 2.5 l.. Flushing quantity

- F 15 -

BOMAG

008 911 79

10.1

Service Training Machine

Service Training

1

Pos.

Designation

Pos. in wiring diagram

Pos. in hydraulic diagram

1

Speed-sensor

B 16

15

BW 213 / 214 DH / PDH -4

008 911 79

Measuring values

- F 16 -

BOMAG

395

10.1

Service Training Machine

Service Training Trouble shooting The display shows the fault codes

For a detailed description of how to read out fault codes and the display please refer to the page on "Electrics" (Service Training Electrics)

All electric faults are mainly shown by the display

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.

BW 213 / 214 DH / PDH -4

396

- F 17 -

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Procedure: The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.

SYMPTOME

FEHLERSUCHE VIBRATION BW 213/214 DH/PDH-4

Keine Vibration (Speisedruck OK) Vibration nur in einer Amplitude Erregerwellendrehzahl nicht korrekt

The number specified in the table indicate the probability of the fault cause and thereby the recommended trouble shooting sequence, based on our latest field experience.

MÖGLICHE URSACHEN Vibrationschalter (Amplitudenvorwahl) Fahrhebel, Taster Vibration (an/aus), Verkabelung Elektrik defekt / Verkabelung Pumpenansteuerung (elektrisch / hydraulisch) Druckabschneidung/ Hochdruckbegrenzung Vibrationspumpe verschmutzt/verstellt/defekt Speisepumpe / Speisedruckbegrenzungsventil verschmutzt/defekt Frequenzeinstellung Vibrationspumpe Vibrationspumpe defekt Kupplung zwischen Dieselmotor und Fahrpumpe defekt Erregerwellenlager defekt Vibrationsmotorkupplung defekt Vibrationsmotor defekt Dieselmotor Drehzahlsensor (Verkabelung) Spülventil Vibmotor hängt

1 1 1 2 2 1 1 2 2 2

2 2

3 2 2 1 1 1 1 1 1 1 2

FEHLERSUCHE BW 213 / 214 DH / PDH -4

008 911 79

- F 18 -

BOMAG

397

10.1

Service Training Machine

Service Training Steering Single drum rollers of series BW 213 / 214 DH-4 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 213 / 214 DH / PDH -4

398

-G1-

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Charge pump The charge pump for travel circuit and vibration works also as steering pump The pump is an external gear pump with fixed displacement. The oil flow generated by the charge pump 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 213 / 214 DH / PDH -4

008 911 79

-G2-

BOMAG

399

10.1

Service Training Machine

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 213 / 214 DH / PDH -4

400

-G3-

BOMAG

008 911 79

10.1

Service Training Machine

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 213 / 214 DH / PDH -4

008 911 79

-G4-

BOMAG

401

10.1

Service Training Machine

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 213 / 214 DH / PDH -4

402

-G5-

BOMAG

008 911 79

10.1

Service Training Machine

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 213 / 214 DH / PDH -4

008 911 79

-G6-

BOMAG

403

10.1

Service Training Machine

Service Training Articulated joint Front and rear frames of the single drum rollers BW 177 D-4 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 213 / 214 DH / PDH -4

404

-G7-

BOMAG

008 911 79

10.1

Service Training Machine

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 213 / 214 DH / PDH -4

008 911 79

-G8-

BOMAG

405

10.1

Service Training Machine

Service Training Test and adjustment points steering points

5

3

1

4

2 2

Steering pump Pos.

Designation

1 2

Steering pump (and charge pump) Steering pressure test port

Pos. in wiring diagram

09 MB

BW 213 / 214 DH / PDH -4

406

Pos. in hydraulic diagram

Measuring values

200 +/-10 bar

-G9-

BOMAG

008 911 79

10.1

Service Training Machine

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 213 / 214 DH / PDH -4

008 911 79

- G 10 -

BOMAG

407

10.1

Service Training Machine

Service Training Trouble shooting The display shows the fault codes

For a detailed description of how to read out fault codes and the display please refer to the page on "Electrics" (Service Training Electrics)

All electric faults are mainly shown by the display

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.

BW 213 / 214 DH / PDH -4

408

- G 11 -

BOMAG

008 911 79

10.1

Service Training Machine

Service Training Procedure: The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.

SYMPTOME

FEHLERSUCHE LENKUNG BW 213/214 DH/PDH-4

Keine Lenkfunktion Endanschläge werden nicht erreicht Lenkung schwergängig

The number specified in the table indicate the probability of the fault cause and thereby the recommended trouble shooting sequence, based on our latest field experience.

MÖGLICHE URSACHEN Lenkorbitrol Lenk- Speisepumpe Lenkzylinder Knickgelenk

2 1 3 3

BW 213 / 214 DH / PDH -4

008 911 79

2 1 3 3

1 2 3 2

- G 12 -

BOMAG

409

10.1

410

Service Training Machine

BOMAG

008 911 79

10.2 Service Training BVC

008 911 79

BOMAG

411

10.2

412

Service Training BVC

BOMAG

008 911 79

10.2

Service Training BVC

Service Training

Variocontrol Single drum roller - 4 BW 177 / 213 / 226 BVC 12/2004

Teile-Nr. 008 099 94

008 911 79

BOMAG

413

10.2

Service Training BVC

Service Training Table of contents Foreword

A1

Documentation

A2

General

B1

Peculiarities

B3

Electric steering

C1

Steering circuit

C2

Steering pump

C4

Steering wheel

C5

Steering valve

C6

Steering angle sensor

C12

Trouble shooting

C15

Compaction measuring system

D1

BEM

D1

BTM plus

D2

BTM prof.

D3

BVC

D4

BVC - System

E1

Exciter system

E4

Gear pump

E5

Valve block

E7

Swashing motor

E9

Acceleration transducer

E 10

MESX-control

E 11

BOP

E 12

Working principle of the system

F1

Variocontrol Single Drum Rollers Series 4

414

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Repair and adjustments

G1

Replacement of swashing motor

G2

Replacement of potentiometer

G3

Potentiometer adjustment

G4

Trouble shooting

H1

Electrics

I1

Service Training MESX - Service Training Wiring diagram Hydraulic diagrams

Variocontrol Single Drum Rollers Series 4

008 911 79

BOMAG

415

10.2

Service Training BVC

Service Training Foreword Reliable construction equipment is of greatest advantage for all parties involved: • for the customer/user it is a basis for an exact calculation of utilization periods and the completion of projects as scheduled. • in the rental business it means that the equipment can be reliably used and planned without having to stock a large number of stand-by machines. • for the manufacturer it means that customers are satisfied, provides him with a good image and gives him a feeling of confidence. It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. This aspect of simple and easy maintenance was one of the key issues when developing and designing the machine: • the location of components in the machine eases maintenance work, • the high quality standard of BOMAG is the basis for the considerable extension of the service and maintenance intervals. • the After Sales Service of BOMAG, including excellent operating and maintenance instruction manuals, high quality training courses and on-site machine demonstrations helps the customer to maintain their machines in good condition over a long period of time. Permanent training of BOMAG’s own service personnel as well as the service personnel of BOMAG Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service. This program of permanent training is only possible with appropriate and up-to-date training material for trainers as well as persons attending the training courses. This training manual has not only been written as a support for the professional work of the trainer, but also for the trainees attending these training courses. The different levels of product training demand, that the training performed by BOMAG, its Profit Centres or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in Boppard. For this reason we invested a lot of time in the preparation of these materials . The structure of this training manual enables us to change or up-date individual chapters in case of alterations to the machine.

Variocontrol Single Drum Rollers Series 4

416

-A1-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Documentation These Variocontrol training documents are valid for the following single drum rollers of series 4:

BW 177 DH-4 BVC BW 213 DH-4 BVC BW 213 DH-4 BVC + vibratory plates BW 226 DH-4 BVC

For the BOMAG machines described in this training manual the following documentation is additionally available:

Attention! The currently valid part numbers for the documents can be taken from the Doclist or the Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial number of the machine.

1. Operating and maintenance instructions 2. Spare parts catalogue 3. Wiring diagram * 4. Hydraulic diagram * 5. Repair instructions 6. Service Information * The document versions valid at the date of printing are part of this training manual.

Variocontrol Single Drum Rollers Series 4

008 911 79

-A2-

BOMAG

417

10.2

Service Training BVC

Service Training General BOMAG VARIOCONTROL (BVC) The increased demands concerning quantity and quality in the application and compaction of soils and rolled asphalt inevitably requires a permanent further development of vibratory rollers. From the contractor's point of view a vibratory roller must fulfil three major requirements: 1. efficient operation 2. fulfilment of a task according to specification 3.flexible in use Due to the inflexible parameterization, standard compaction systems are not able to adapt to the permanently changing construction conditions in an optimal way. However, this problem can be solved by the introduction of intelligent compaction systems. The control values required for an automatic optimization of the compaction parameters are directly gained from the interaction between drum and material to be compacted. BOMAG VARIOCONTROL is a compaction system, which improves the quality and reproducibility of compaction and enhances the efficiency of the roller, independently from the roller operator. BOMAG VARIOCONTROL offers the user the following advantages: 1.Automatic adaptation of the emitted compaction energy to the actual compaction status 2. Better, reproducible results on all materials 3.No jump operation and therefore no particle destruction or loosening of material 4. The resulting direction of force is automatically adapted to the travel direction. This improves the surface quality of the material and the gradability of the roller. 5.Low vibration loads for driver and environment The further development of the VARIOCONTROL system for earthwork was founded on experiences gained with the VARIOMATIC system used for asphalt compaction . The basic difference between VARIOCONTROL and VARIOMATIC is the new exciter system.

It meets the demands of many users for an "intelligent" roller with automatic adaptation of compaction.

Variocontrol Single Drum Rollers Series 4

418

-B1-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Part of this new further development is the new display and control element Operation Panel) in connection with the MESX.

BOP (Bomag

Besides the display of the entire operation of the measuring technology the BOP also enables a simple self diagnose of the overall system. The operation of the BOP is described in detail in the operating and maintenance instructions. Error and input codes can be found on the electrics page (MESX Service Training).

BOP

-----

Bomag Operation Panel

Variocontrol Single Drum Rollers Series 4

008 911 79

-B2-

BOMAG

419

10.2

Service Training BVC

Service Training Specialities All BVC single drum rollers of series 4 are equipped with an electric steering system as standard. The hydraulic steering is also available as an option.

Variocontrol Single Drum Rollers Series 4

420

-B3-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Electric steering The electric steering consists of an electronically controlled closed control loop and a hydraulic steering circuit. The electronically controlled circuit consists of a small electric steering wheel (in the left hand seat armrest), the ESX-control (located in the electric junction box), which converts the signal from the steering wheel into electric signals for the proportional solenoids of the steering valve and the steering angle sensor (located on the articulated joint), which feeds the steering angle back to the control. The hydraulic steering circuit consists of steering pump, high pressure filter, steering valve and steering cylinders.

Variocontrol Single Drum Rollers Series 4

008 911 79

-C1-

BOMAG

421

10.2

Service Training BVC

Service Training

Variocontrol Single Drum Rollers Series 4

422

-C2-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Hydraulic steering circuit

06

to charging

to emergency steering and Vario control valve

MG

from hydr. tank

Variocontrol Single Drum Rollers Series 4

008 911 79

-C3-

BOMAG

423

10.2

Service Training BVC

Service Training Pos.

Designation

05 05

one steering cylinder on BW 177 two steering cylinders on BW 213 and 226 Steering valve with 2 proportional solenoids and an integrated accumulator High pressure filter 12µm Steering pump and charge pump additional gear pump 5.5 cm³ on BW 177 BVC additional gear pump 8 cm³ on BW 213 and 226 BVC High pressure line filter for Variocontrol 100 µm Optional emergency steering valve with 2 B/W solenoids

06

07 09 17 17 20 21

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

05 05 Y92 / Y93 Page 006

06

07 09 / MB 17 / MG

200 +/-10 bar 80 bar

17 / MG

120 bar

20 Y112 / Y113 Page 006

21

Emergency steering: The emergency steering valve is only an option and can only be operated via a special input code. The valve is supplied by the additional Variocontrol gear pump.

Variocontrol Single Drum Rollers Series 4

424

-C4-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Steering pump with filter

Steering pump

Pressure test port Steering pressure

Filter outlet

High pressure filter Steering circuit 12 µm with Pressure differential switc 3,5 bar

Filter inlet

Variocontrol Single Drum Rollers Series 4

008 911 79

-C5-

BOMAG

425

10.2

Service Training BVC

Service Training Steering wheel The small steering wheel is located in the left hand armrest of the driver's seat

VCC 8,5 V

Pos.

Designation

Electric steering wheel

Pos. in wiring diagram

Measuring values

A 45 Page 006

Variocontrol Single Drum Rollers Series 4

426

Pos. in hydraulic diagram

-C6-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Steering valve, electrically proportional The steering valve, together with the optional emergency steering valve, is located behind a protection box on the right hand side of the frame under the operator's stand or the cabin.

to the Steerin cylinder

from the pump

to the charge system

Variocontrol Single Drum Rollers Series 4

008 911 79

-C7-

BOMAG

427

10.2

Service Training BVC

Service Training Steering valve

5 3 7

6

8

1

Pos.

Designation

1 2 3 4 5 6

Steering valve port P Steering valve port T Steering valve ports A and B Steering valve, pressure relief valve Steering valve, shock valves Steering valve, accumulator

7 8 9

Steering valve, prop. solenoid Steering valve, prop. solenoid Emergency steering valve B/W solenoid Emergency steering valve B/W solenoid

10

4 Pos. in wiring diagram

06 06 06 06 06 06 Y 93 Y 92 Y 113

Page 006 Page 006 Page 006

Y 112

Page 006

Variocontrol Single Drum Rollers Series 4

428

Pos. in hydraulic diagram

2 Measuring values

175 + 25 bar 230 bar Accumulator pressure 50bar 0,4 - 1,2 A 0,4 - 1,2 A 0/12 V 0/12 V

-C8-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Emergency steering valve (option, can only be operated via input code) !!!

9

10

Variocontrol Single Drum Rollers Series 4

008 911 79

-C9-

BOMAG

429

10.2

Service Training BVC

Service Training BW 177 BVC

2

3

1

Pos.

Designation

Pos. in wiring diagram

Pos. in hydraulic diagram

1 2 3

Steering valve Optional emergency steering valve High pressure line filter 100µm in Vario-circuit

Y92 / Y93 Y112 / Y113

06 21 20

Variocontrol Single Drum Rollers Series 4

430

Measuring values

- C 10 -

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Piping BW 177

Variocontrol Single Drum Rollers Series 4

008 911 79

- C 11 -

BOMAG

431

10.2

Service Training BVC

Service Training BW 213 and 226 BVC

5

3

4

2

1

Pos.

Designation

Pos. in wiring diagram

Pos. in hydraulic diagram

1 2 3

Steering valve Optional emergency steering valve Pressure retaining valve, Variocontrol circuit Accumulator for Variocontrol circuit

Y92 / Y93 Y112 / Y113

06 21 22

4 5

High pressure line filter 100µm Vario-circuit

23

in

110 / 99 bar Accumulator pressure 85bar

20

Variocontrol Single Drum Rollers Series 4

432

Measuring values

- C 12 -

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Piping BW 213 and 226

Variocontrol Single Drum Rollers Series 4

008 911 79

- C 13 -

BOMAG

433

10.2

Service Training BVC

Service Training Steering angle sensor The steering angle potentiometer is located on the articulated joint BW 177 and BW 213

The steering angle potentiometer is located inside the articulated joint BW 226

Variocontrol Single Drum Rollers Series 4

434

- C 14 -

BOMAG

008 911 79

10.2

Service Training BVC

Service Training BW 177 and 213 BVC

Variocontrol Single Drum Rollers Series 4

008 911 79

- C 15 -

BOMAG

435

10.2

Service Training BVC

Service Training BW 226 BVC

Variocontrol Single Drum Rollers Series 4

436

- C 16 -

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Trouble shooting The display shows error codes

A detailed description of how to read out the error codes and on the display can be found in chapter "Electrics" (Service Training "Electrics")

All electric faults are primarily displayed in the display.

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.

Variocontrol Single Drum Rollers Series 4

008 911 79

- C 17 -

BOMAG

437

10.2

Service Training BVC

Service Training Procedure: The following trouble shooting chart mainly lists mechanical and hydraulic faults.

SYMPTOME

FEHLERSUCHE elektr.LENKUNG BVC-4 Maschinen

Keine Lenkfunktion Endanschläge werden nicht erreicht Lenkung schwergängig

The number specified in the table indicate the probability of the fault cause and thereby the recommended trouble shooting sequence, based on our latest field experience.

MÖGLICHE URSACHEN Lenkventil Lenk- Speisepumpe Lenkzylinder Knickgelenk

2 1 3 3

2 1 3 3

1 2 3 2

FEHLERSUCHE Variocontrol Single Drum Rollers Series 4

438

- C 18 -

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Compaction measuring system for single drum rollers: BEM (Bomag E-vib Meter) for circular exciters

CAN Bus I

BMFSA

E vib 150 50

200

! Beschleunigung VV / VL 15g

D+ Signal

Signale

0

MESX

E VIB 250 MN/mm²

Befehle

Neutral Pos. Bedienfunktionen Beschleunigung VH / VL 15g

Vibrationspumpe Stromsignal

Variocontrol Single Drum Rollers Series 4

008 911 79

-D1-

BOMAG

439

10.2

Service Training BVC

Service Training BTM prof (Bomag Terrameter) for circular exciters

CAN Bus I RS 232

Drucker BOP

Beschleunigung VV / VL 15g

Drehzahlsensor hinten

D+ Signal

Signale

!

MESX

Neutral Pos. Bedienfunktionen Beschleunigung VH / VL 15g

Vibrationspumpe Stromsignal

Variocontrol Single Drum Rollers Series 4

440

-D2-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training BTM plus (Bomag Terrameter) for circular exciters

CAN Bus I

BOP

Signale

! Beschleunigung VV / VL 15g

Drehzahlsensor hinten

D+ Signal

MESX

Neutral Pos. Bedienfunktionen Beschleunigung VH / VL 15g

Vibrationspumpe Stromsignal

Variocontrol Single Drum Rollers Series 4

008 911 79

-D3-

BOMAG

441

10.2

Service Training BVC

Service Training BVC (Bomag Variocontrol) for Vario exciters

CAN Bus I RS 232

Drucker BOP

Beschleunigung VV / VL 15g

Drehzahlsensor hinten

Signale

!

MESX

Befehle Lageregelung Ventil 2 vorn

D+ Signal

Lageregelung Ventil 1 vorn

Neutral Pos. Bedienfunktionen Beschleunigung VH / VL 15g

Vibrationspumpe Stromsignal

Erreger Position vorn

Variocontrol Single Drum Rollers Series 4

442

-D4-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training BVC - System BOMAG VARIOCONTROL is able to control the compaction power, independently from the driver. For this purpose the size and direction of the effective amplitude is automatically adjusted in dependence on compaction status and travel direction of the roller. This optimal adaptation of compaction ensures that the roller emits the max. compaction power to the soil at any time. Apart from this, jumping of the drum with the related over-compaction of the material is automatically prevented.

The VARIOCONTROL components:

system

consists

of

the

following

1.

Exciter unit

2.

Additional gear pump with line filter

3.

Valve block with pressure relief valve and shock valves and (accumulator on BW 213 and BW 226)

4.

Variable displacement motor with integrated potentiometer based distance measuring system

5.

2 acceleration transducers

6.

Programmable logic control = MESX

7.

Display and control unit = BOP

8. )

Optional printer

Variocontrol Single Drum Rollers Series 4

008 911 79

primary

-E1-

BOMAG

443

10.2

Service Training BVC

Service Training BVC Circuit diagram for BW 177 DH-4 Legend from the hydraulic diagram: front

17) External gear pump 5.5 cm³

rear

18) Valve block with 80 bar pressure relief valve 19) Swivel drive, variable displacement motor 20) High pressure line filter

Y141

20

Y140

to the tank

from tank to filter to steering system

Variocontrol Single Drum Rollers Series 4

444

-E2-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training BVC Circuit diagram for BW 213 / 226 DH-4 Legend from the hydraulic diagram: 17) External gear pump 8cm³

front

rear

Y141

Y140

18) Valve block with pressure relief valve (120 bar) 19) Swivel drive, variable displacement motor 20) High pressure line filter 22) Pressure override valve (99-110 bar) 23) Accumulator (1.4l, 85bar)

to Emergency steering

to the tank from tank to filter Steering valve

Variocontrol Single Drum Rollers Series 4

008 911 79

-E3-

BOMAG

445

10.2

Service Training BVC

Service Training Exciter unit BVC uses a new type of exciter system with two counter-rotating, concentrically arranged shafts, generating directed vibrations (see Fig. below). One common shaft carries three eccentrics, the two smaller weights near the ends and the larger eccentric weight in the middle of the exciter shaft. The middle eccentric weight rotates in opposite direction to the outer weights. The resulting centrifugal forces add up to a directed vibration. The effective direction of this directed vibration can be adjusted by turning the complete vibrator unit. Any desired angle position between horizontal and vertical oscillating direction is possible. The adjustment of the exciter unit is accommodated by a hydraulic swashing motor with integrated displacement measuring system (potentiometer). The vibrator system is driven by a hydraulic motor, the eccentrics are synchronized by gears.

General design of the VARIOCONTROL - exciter unit

Variocontrol Single Drum Rollers Series 4

446

-E4-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Gear pump with high pressure filter

additional gear pump for Variocontrol system

Test port input Variocontrol system

BW 177 BVC Filter Input

High pressure Line filter

Filter Output

Variocontrol Single Drum Rollers Series 4

008 911 79

-E5-

BOMAG

447

10.2

Service Training BVC

Service Training BW 213 and 226 BVC The pressure retaining valve with accumulator is located between Vario pump and valve block. It helps to keep any losses through the pressure relief valve as low as possible.

7

1 2

8 3 9

4 5 6

Pos.

Designation

Pos. in wiring diagram

1 2 3 4 5

22 22 22 22 22

6

P3 Input P5 to valve block T T Pressure retaining valve, opens and closes P6 to accumulator

7 8 9

High pressure line filter T1 P4

22 22 22

23

Variocontrol Single Drum Rollers Series 4

448

Pos. in hydraulic diagram

Measuring values

110 bar / 99 bar Preload pressure 85bar

-E6-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Valve block The valve block has the function of triggering the adjusting motor. It consists of an electrical proportional valve. On BW 213 and BW 226 the valve is equipped with an upstream pressure retaining valve. Assignment of valves to adjusting motor with exciter:

Y140 ---- valve outlet B ----- control Direction vertical forward Y141 ---- valve outlet A ----- control Direction vertical backward

8

1

9

2 3 4

10

5 6

8

7

11 Pos.

Designation

1 1 2 3 4 5 6 7 8 9 10 11

Test port BW 177 Test port BW 213 and 226 P2 A T1 P1 B T2 Shock valves Prop. solenoid Prop. solenoid Pressure relief valve BW 177

Pos. in wiring diagram

Y 141 Y 140

Page 008 Page 008

Variocontrol Single Drum Rollers Series 4

008 911 79

Pos. in hydraulic diagram

Measuring values

18 18 18 18 18 18 18 18 18 18 18 18

80 bar 120 bar

120 bar 0,4 - 1,2 A 0,4 - 1,2 A 80 bar

-E7-

BOMAG

449

10.2

Service Training BVC

Service Training Pos.

Designation

Pos. in wiring diagram

11

Pressure relief valve BW 213 and 226

Pos. in hydraulic diagram

Measuring values

18

120 bar

Valve block installation front left and protection housing for electric connections

Pressure relief valve

Potentiometer

Variocontrol Single Drum Rollers Series 4

450

-E8-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training

Under the protection housing there are the cable connections for X 22 - speed sensor X 47 - potentiometer for swa X 48 - Acceleration tranducer front X 49 - Acceleration transducer rear

Variocontrol Single Drum Rollers Series 4

008 911 79

-E9-

BOMAG

451

10.2

Service Training BVC

Service Training Swashing motor with integrated potentiometer based distance measuring system As with the VARIOMATIC system, the resulting force may occur at any angle position between horizontal and vertical direction of vibration. The adjusting motor is equipped with an integrated displacement measuring system. This displacement measuring system is based on a potentiometer mounted on the motor output shaft. Each position of the motor has a resistance or voltage value assigned. Potentiometer voltage: Vertical forward approx. 2 V, approx. 6,5 V

Horizontal approx. 4,25 V,

Vertical backward

Swashing motor, principle – cross-sectional view (Pleiger)

Variocontrol Single Drum Rollers Series 4

452

- E 10 -

BOMAG

008 911 79

10.2

Service Training BVC

Service Training

Variocontrol Single Drum Rollers Series 4

008 911 79

- E 11 -

BOMAG

453

10.2

Service Training BVC

Service Training Acceleration transducer The Variocontrol system is equipped with two acceleration transducers arranged one after the other on the gearbox on the left hand side of the drum. These are mounted under an angle of 45° on either side of the vertical. These transducer permanently deliver acceleration signals, which form the basis for the entire control system.

There are two connection assignments the signal outputs of the transducers: BW 177 BVC signal brown 20g BW 213 and 226 BVC signal blue 15g see wiring diagram, page 008, path 8 and10, B62

Acceleration transducer

Variocontrol Single Drum Rollers Series 4

454

- E 12 -

BOMAG

008 911 79

10.2

Service Training BVC

Service Training MESX-control The MESX-control is located inside the electric junction box, below the ESX-travel control inside the door of the electrics terminal box. The MESX takes over the function to control the Variocontrol system. The sticker on the MESX control informs about the installed software version.

A detailed description can be found in the chapter "Electrics", Training MESX.

Service

MESX

Variocontrol Single Drum Rollers Series 4

008 911 79

- E 13 -

BOMAG

455

10.2

Service Training BVC

Service Training BOP Bomag Operation Panel The operation of the BOP is described in detail in the operating and maintenance instructions!

1

EVIB display

11) Rotary switch for mode selection (Automatic/Manual)

2

not used

3

Push button F5 START

4

Push button F6 STOP

5

Push button F7 PRINT

6

Push button F8 DELETE

7

Display of vibration frequency

8

Rotary switch for setpoint adjustment (automatic operation)

9

Push button F14 setpoint increase

12) Push button F12 automatic operation 13) Push button F11 manual operation 14) Rotary switch, manual setting of amplitude direction 15) Push button F10 vertical effective direction 16) Push button F9 horizontal effective direction 17) Travel speed display 18) Amplitude display

19) Optional measuring value printer

10 Push button F13 Setpoint reduction

Variocontrol Single Drum Rollers Series 4

456

- E 14 -

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Working principle of system Die Messung der Bodenkontaktkraft zwischen der Bandage und dem Einbaumaterial erfolgt durch die beiden Beschleunigungsaufnehmer an der Bandage, die das dynamische Verhalten kontinuierlich überwachen. Die Beschleunigungssignale, die aus der dynamischen Wechselwirkung zwischen dem Walzenkörper und der Unterlage resultieren, werden an die MESX-Steuerung weitergeleitet. Werden bestimmte Grenzzustände bzw. Sollzustände erreicht, wird von der MESX ein Signal auf die Verstelleinheit gegeben und dadurch die Verdichtungsenergie an den neuen Einbauzustand angepaßt. Signalisieren die Beschleunigungsaufnehmer eine geringe Bodensteifigkeit, schwenkt das Erregersystem so weit in Richtung der vertikalen Arbeitsrichtung, bis die maximal mögliche Verdichtungsenergie abgegeben wird. Nimmt die Bodensteifigkeit zu und werden bestimmte Grenzwerte bzw. Sollwerte erreicht, schwenkt das Erregersystem in Richtung der horizontalen Arbeitsrichtung, bis die Sollwerte unterschritten werden. Das Ergebnis dieser Regelung ist, daß das VARIOCONTROL-System die maximal mögliche Verdichtungsenergie automatisch an den jeweiligen Einbauzustand anpaßt. Das System muß dabei sehr schnell auf die Steifigkeitsänderungen reagieren. Die Verstellzeiten von vertikaler zu horizontaler Arbeitsrichtung liegen unter einer Sekunde. Damit kann das System 1. auf Veränderungen der Bodensteifigkeit unmittelbar reagieren 2. und zerstörende Bewegungen der Bandage verhindern.

Variocontrol Single Drum Rollers Series 4

008 911 79

-F1-

BOMAG

457

10.2

Service Training BVC

Service Training Vibration parameters Für den Verdichtungserfolg ist schon die erste dynamische Überfahrt von entscheidender Bedeutung. Die VARIOCONTROL Walzenzüge sind daher auf besonders hohe Zentrifugalkräfte bzw. Amplituden ausgelegt. Hierdurch wird eine sehr hohe Verdichtung und eine gute Tiefenwirkung erzeugt. Durch die große Amplitude würde die VARIOCONTROL Walzenzüge früher springen als Standardwalzenzüge gleichen Betriebsgewicht. Durch die Automatik wird aber der Vertikalanteil der Amplitude dann automatisch zurückgenommen und so ein Springen der Walze verhindert.

Dichte Hochleistungswalze große Amplitude Standardwalze

0

1

2

3

BW 177

5

BW 213

6

7

Übergänge

BW 219

BW 225

BVC

Standard

BVC

Standard

Standard

BVC

Standard

Schwingende Masse

kg

2440

1970

4800

4250

5500

6630

6300

Zentrifugalkraft

kN

189

126/100

365

275/198

326/250

402

330/182

Amplitude

mm

2,5

1,8 / 1,0

2,4

1,8 / 0,9

2,1 / 1,2

2,3

2,0 / 1,1

Frequenz

Hz

28

30 / 36

28

30 / 36

26 / 30

26

26 / 26

Variocontrol Single Drum Rollers Series 4

458

4

-F2-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Repair and adjustments Replacement of swashing motor and potentiometer

Swashing motor

Potentiometer

Fastening screws Potentiometer

Variocontrol Single Drum Rollers Series 4

008 911 79

-G1-

BOMAG

459

10.2

Service Training BVC

Service Training

Locking screw vertical reverse

Locking screw horizontal

Variocontrol Single Drum Rollers Series 4

460

-G2-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Replaceing the swashing motor 1. If necessary remove the vibration motor 2. Unscrew the bottom plug (Pos.26, P/N 076 320 16) from the gearbox 3. Disconnect the hydraulic hoses and the electric connections from the potentiometer on the swashing motor 4. Connect the hand pump to the front port (in travel direction) of the swashing motor (Pos.5) and pump to the right, until the locking recess in the gear is in line with the bore in the gearbox. 5. Turn the locking screw (P/N 955 822 11) into the gearbox, the exciter is thus blocked in position vertical reverse.

6. Remove the manual pump 7. Remove the swashing motor 8. Connect the manual pump again zo the front port of the new swashing motor and pump to the right to the same position as with the removed swashing motor (position vertical forward) 9. Install the swashing motor, grease the splined shaft (with Optimol White P/N 009 960 01) and connect hydraulically and electrically. 10. Remove the bottom locking screw (P/N 955 822 11) again and turn in the plug (Pos.26, 076 320 16) with seal ring.

P/N

11. Tighten all fastening screws with the specified torque.

Variocontrol Single Drum Rollers Series 4

008 911 79

-G3-

BOMAG

461

10.2

Service Training BVC

Service Training

Variocontrol Single Drum Rollers Series 4

462

-G4-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Adjusting the potentiometer

1. Unscrew the top plug (Pos.16, P/N 076 320 16) from the gearbox

2. Connect the hand pump to the rear port (in travel direction) of the swashing motor (Pos.4) and pump to the left (middle position of swashing motor), until the locking recess in the upper gear is in line with the bore in the gearbox.

3. Turn the locking screw (P/N 955 821 69) into the upper bore in the gearbox, the exciter is thus blocked in position horizontal.

4. Loosen the fastening screws for the potentiometer so that it can be adjusted in the slots.

Variocontrol Single Drum Rollers Series 4

008 911 79

-G5-

BOMAG

463

10.2

Service Training BVC

Service Training 5. Switch on the ignition and measure the supply voltage between X2:67 and X2:68 (e.g. U=8,42V). 6. Measure the signal voltage between X2:69 (white cable) and X2:68 (AGND). The terminal bar X2 for the volatge measurement is located inside the electrics junction box. 7. Nominal value = 1/2 supply voltage (e.g. 8,42/2 = 4,21V) in case of deviations turn the potentiometer, until the nominal value is reached.

Wiring diagram Bl 008, Pf 11, B61 8. Fasten the potentiometer. 9. Remove the blocking screw and insert the plug with a new seal ring. 10. Check the swashing motor by pumping it to both end positions with the hand pump and measure the voltage values. Nominal values: left hand stop vertical forward approx. 2V and right hand stop vertical reverse approx. 6,5V

This process 1 - 10 must also be performed when changing a potentiometer.

Variocontrol Single Drum Rollers Series 4

464

-G6-

BOMAG

008 911 79

10.2

Service Training BVC

Service Training Exciter lock in vertical reverse

Exciter lock in horizontal

Variocontrol Single Drum Rollers Series 4

008 911 79

-G7-

BOMAG

465

10.2

Service Training BVC

Service Training Trouble shooting In case of a fault in the Vario system the red triangular lamp lights up. Show the fault code by pressing button „?“ followed by button „F5“ Red fault light

Button „F5“

Button „?“

For detail info on reading out fault codes please refer to the chapter "Electrics, Training MESX".

Variocontrol Single Drum Rollers Series 4

466

-H1-

BOMAG

008 911 79

11 Engine

008 911 79

BOMAG

467

11.1

Diesel engine

11.1 Diesel engine

The engines are characterized by the following positive features:

Series 4 single drum rollers are powered by 4 or 6 cylinder Deutz diesel engines type TCD 2013 or a 6-cylinder engine TCD 2012. The engines are water cooled in-line engines with EMR3 electronics. The engines are mainly designed in two-valve technology with turbo charging and intercooler. They are highly compact and come with a Deutz-Common-Rail injection system, called DCR in short. All engines are designed with exhaust gas recirculation and thus reach emission values complying with EPA/ COM/ Tier/ stage lll

●

compact design

●

low noise level

●

almost vibration free operation

●

low fuel consumption

●

low exhaust emission EPA/COM IIl

●

high power density

●

excellent access to all service locations.

●

high reliability

●

low running costs,

●

long lifetime

Fig. 1 Deutz diesel engine TCD 2012 and 2013

468

BOMAG

008 911 79

11.2

Engine description TCD 2012

11.2 Engine description TCD 2012

13 Flywheel or (transmission connection SAE)

Fig. 1 Deutz diesel engine TCD 2012, right hand side

14 Crankcase ventilation valve 1

Lubrication oil filling neck

15 Transport device

2

Combustion air inlet

16 Charge air line

3

Cover

17 Fuel control unit

4

Fan

5

Generator

6

Fuel lift pump

7

Idler pulley

8

Lubrication oil cooler

9

Fuel filter

10 Replaceable lubrication oil filter 11 Lubrication oil sump 12 Possible installation of hydraulic pump or compressor (optional) 008 911 79

BOMAG

469

11.2

Engine description TCD 2012

Fig. 2 Deutz diesel engine TCD 2012, left hand side

1

Exhaust manifold

2

Exhaust turbo charger

3

Lubrication oil filling neck (optional)

4

Engine mounts

5

Lubrication oil return line from exhaust gas turbo charger

6

Relay (starter)

7

Ribbed V-belt

8

Coolant inlet

9

Coolant outlet

10 Coolant pump 11 Connection cabin heater ort compensation line

470

BOMAG

008 911 79

Engine description TCD 2013, 4 and 6 cylinder

11.3

11.3 Engine description TCD 2013, 4 and 6 cylinder

14 Fuel control unit

Fig. 1 Deutz diesel engine TCD 2013 L04 2V, right hand side

15 High pressure pump 1

Combustion air inlet (possibility to install a heating flange, optionally)

16 Crankcase ventilation valve

2

Connection cabin heater ort compensation line

18 Lubrication oil filling neck

3

Fan

4

Generator

5

Belt pulley on crankshaft

6

V-belt

7

Fuel lift pump drive

8

Fuel filter

9

Replaceable lubrication oil filter

17 Injector

10 Lubrication oil cooler 11 Possible installation of hydraulic pump or compressor (optional) 12 Lubrication oil return line crankcase ventilation 13 Central plug (for engine control) 008 911 79

BOMAG

471

11.3

Engine description TCD 2013, 4 and 6 cylinder

Fig. 2 Deutz diesel engine TCD 2013 L04 V2, left hand side

1

Lubrication oil filling neck (optional)

2

Transmission connection (SAE)

3

Engine mounts

4

Lubrication oil drain plug

5

Lubrication oil sump

6

Starter motor

7

Lubrication oil return line from exhaust gas turbo charger

8

Exhaust turbo charger

9

Coolant inlet

10 Charge air connection to intercooler 11 Coolant outlet 12 Exhaust manifold 13 Charge air line 14 Transport device

472

BOMAG

008 911 79

Engine description TCD 2013, 4 and 6 cylinder

Fig. 3 Deutz diesel engine TCD 2013 L06 2V, right hand side

11.3

17 Crankcase ventilation valve 18 Injector

1

Combustion air inlet

2

Lubrication oil filling neck

3

Transport device

4

Fan hub

5

Generator

6

Replaceable lubrication oil filter

7

Fuel filter

8

Lubrication oil sump

9

Oil dipstick

10 Lubrication oil drain plug 11 Oil return line crankcase ventilation 12 Engine mounts 13 Transmission connection (SAE) 14 Central plug (for engine control) 15 High pressure pump 16 Rail

008 911 79

BOMAG

473

11.3

Engine description TCD 2013, 4 and 6 cylinder

Fig. 4 Deutz diesel engine TCD 2013 L06 2V, left hand side

1

Exhaust turbo charger

2

Exhaust manifold

3

Starter motor

4

Lubrication oil flow to exhaust turbo charger

5

Coolant drain plug

6

Coolant inlet

7

Ribbed V-belt

8

Fan hub

9

Idler pulley

10 Connection cabin heater ort compensation line 11 Ventilation line to compensation tank 12 Coolant line from engine to radiator

474

BOMAG

008 911 79

11.4

Lubrication oil circuit TCD 2012 / 2013

11.4 Lubrication oil circuit TCD 2012 / 2013 25

26

23

12

18

22

19

12 123

20

21

17

15

11

12

7

8

5

6

24

27

1 1

1

14

13 16

10

9

4

2

3

Fig. 1 Lubrication oil diagram

17 Piston cooling nozzle with pressure maintaining valve

1

Lubrication oil sump

18 Plunger with rocker arm pulse lubrication

2

Lubrication oil suction pipe

3

Lubrication oil pump

19 Push rod, lubrication oil supply for rocker arm lubrication

4

Pressure relief valve

5

Lubrication oil cooler

6

Return flow check valve (only on 2012)

7

By-pass valve

8

By-pass valve lubrication oil filter

9

Pressure control valve

10 Replaceable lubrication oil filter

20 Rocker arm 21 Return line to lubrication oil sump 22 Lubrication oil flow to exhaust turbo charger 23 Exhaust turbo charger 24 Return line from compressor / hydraulic pump to crankcase 25 Compressor or hydraulic pump

11 Main lubrication oil lines

26 Lubrication oil line to crankshaft and camshaft, compressor / hydraulic pump

12 Internally switched exhaust gas recirculation

27 Return flow from exhaust turbo charger

13 Crankshaft bearings 14 Conrod bearings 15 Camshaft bearings 16 Line to spray nozzle 008 911 79

BOMAG

475

11.5

Coolant circuit TCD 2012 / 2013

11.5 Coolant circuit TCD 2012 / 2013

Fig. 1 Fuel diagram

1

Coolant outlet on radiator

2

Thermostat

3

Coolant - supply to water pump

4

Coolant pump

5

Lubrication oil cooler

6

Cylinder cooling

7

Cylinder liner / head cooling

8

Coolant flow to heater

9

Cabin heater (optional)

10 Coolant to thermostat 11 Connection for cabin heater 12 Compensation line 13 Ventilation line to compensation tank 14 Coolant outlet to radiator 15 Compensation tank 16 Compensation line to heat exchanger

476

BOMAG

008 911 79

11.6

Fuel system TCD 2012 / 2013

11.6 Fuel system TCD 2012 / 2013

12 Fuel return flow on cylinder head

Fig. 1 Coolant diagram

13 Fuel return line to fuel tank 1

Fuel tank A= minimum distance 500 mm

2

Fuel pre-filter with pre-pressure pumping possibility to fill the low pressure section (provided by customer)

3

Line to fuel lift pump

4

Fuel lift pump

5

Fuel filter

6

Fuel supply line to fuel control unit

7

Rail

8

High pressure pump

9

Fuel supply line to injector

14 Fuel lines from fuel control unit to high pressure pumps and rail 15 Fuel lift pump 2013

10 Injector 11 FCU (Fuel Control Unit)

008 911 79

BOMAG

477

11.6

Fuel system TCD 2012 / 2013

Fuel pre-filter

Fig. 2 Fuel pre-filter

1

Fuel supply to pump

2

Fuel return flow from FCU (Fuel Control Unit)

3

Manual fuel pump with bayonet lock to lock and unlock

4

Thermostat valve with shut-down lever

5

Filter cartridge

6

Possibility to connect an electric water level sensor

7

Drain tap

8

Water collecting bowl

9

Fuel inlet from fuel tank

10 Fuel return flow to fuel tank A Electric water level sensor

478

BOMAG

008 911 79

11.6

Fuel system TCD 2012 / 2013 TCD 2013 Fuel filter system

5 2

2

2

4 11

13 4

4

Fig. 3 TCD 2013 Fuel system

1

Fuel pre-filter

2

Hand pump

3

Fuel pressure filter min. 3µm

4

Input fuel control unit

5

Fuel low pressure sensor

008 911 79

BOMAG

479

11.6

Fuel system TCD 2012 / 2013

TCD 2012 Fuel filter system

2

2

2 5 4 1

1

1

4

3

4

Fig. 4 TCD 2012 Fuel system

1

Fuel pre-filter

2

Hand pump

3

Fuel pressure filter min. 3µm

4

Input fuel control unit

5

Fuel low pressure sensor

480

BOMAG

008 911 79

11.7

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013

11.7 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 The diesel engines type TCD 2012 and 2013 are equipped with a "Deutz Common Rail" injection system, DCR in short. The English term "Common Rail" indicates that the system is based on a common rail. It describes the use of a common high pressure fuel line with corresponding branches to supply all cylinders with fuel. The "Common Rail" injection is an injection system for combustion engines, in which a high pressure pump pressurizes the fuel to a high pressure level. The pressurized fuel fills a piping system, which is permanently under pressure while the engine is running. The general idea is the total isolation of the pressure generation from the actual injection process. An injec-

tion solely controlled by mapping is only possible under this condition. Injection timing and injection quantity are controlled by the engine electronics. The electric signals control an electrically operated valve per cylinder, which is integrated in the injection nozzle. The short distances between valve and injection nozzle result in short pressure rise times, which has a positive effect on the combustion process and its control. Various types of injection van be realized, e.g. pre-injection, main injection and post-injection. These are freely controllable, in dependence on the control unit. The electric control is accomplished by the electronic control unit (EDC16) with EMR3, in dependence on the operating parameters. The system is capable of providing a wide range of limp-home functions, should any of the sensors fail. This ensures a reliable and safe completion of travel and work.

Overview of electronic diesel fuel control

Sensors

Control unit (EMR3)

Actuators Injector

Rail

Pump

Fig. 1 TCD 2012 and 2013

008 911 79

BOMAG

481

11.7

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013

10

8

7

5 6

11

9 4

1

12

Fig. 2 Schematic of the Deutz Common Rail System "DCR"

Under normal conditions the rail pressure is between 300 and 1350 bar

1

Fuel filter high pressure

The PRV is set to 1600 bar

2

Fuel low pressure sensor (5-7bar) B145

3

High pressure pumps

4

Fuel lift pump

5

Rail (high pressure pipe up to 1600 bar)

6

PRV (max. rail pressure limitation 1600bar)

7

Rail pressure sensor (B145)

8

Injectors (B148)

9

FCU Fuel Control Unit (Y137)

10 Engine control EDC16 - EMR3 11 Fuel filter with water separator 12 Hand pump

482

If the PRV is defective or always open, the pressure in the rail will only build up to max. 700 bar. The rail pressure must be at least 1.5 bar to start the diesel engine The fuel low pressure sensor is located after the fuel filter and the pressure is normally between 5 and 7 bar. The solenoid valve of the Fuel Control Unit (FCU) is dead, open towards the tank. The voltage applied to the injectors is normally approx. 40 V.

BOMAG

008 911 79

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013

11.7

FCU Fuel Control Unit (Y137)

electric connection

Fig. 3 Fuel Control Unit FCU

Two high pressure pumps

High pressure

Low pressure

High pressu pumps

Fig. 4 High pressure pump

008 911 79

BOMAG

483

11.7

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013

Injector ( Y148 )

electric connections

Return flow Armature group Nozzle

Supply

Fig. 5 Injector

Wiring diagram page 4

Engine control EDC16 - EMR3

FCUFCU

Fig. 6 Excerpt from the wiring diagram

484

BOMAG

008 911 79

11.7

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 TCD 2013

7

5

6

2

4

1

3

Fig. 7 TCD 2013

1

Fuel pre-filter

2

Hand pump

3

Fuel filter

4

FCU Fuel Control Unit (Y137)

5

Rail

6

Fuel low pressure sensor (B145)

7

Connecting plug EMR3

008 911 79

BOMAG

485

11.7

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013

TCD 2012

2

5

6

7 4 2

4 5

1

6

3

Fig. 8 Diesel engine TCD 2012

1

Rail pressure sensor (B93)

2

Rail pressure PRV

3

Fuel filter

4

FCU Fuel Control Unit (Y137)

5

Rail

6

Fuel low pressure sensor (B145)

7

Connecting plug EMR3

486

BOMAG

008 911 79

11.8

Sensors TCD 2012 / 2013

11.8 Sensors TCD 2012 / 2013

Diagnostics interface 10 Serdia connection

Fig. 1 Sensors TCD 2013

1

Fuel control unit (FCU)

2

Coolant temperature sensor

3

Sensor for charge air temperature and charge air pressure

4

Possibility to connect a control unit

5

Engine control unit

6

Rotary speed sensor for crankshaft

7

Rail pressure sensor

8

Optional oil level sensor

9

Oil pressure sensor

10 Fuel pressure sensor 11 Rotary speed sensor for camshaft 12 Central plug for engine control

008 911 79

BOMAG

487

11.8

Sensors TCD 2012 / 2013

Fig. 2 Sensors TCD 2013

Fig. 3 Wiring loom TCD 2013

488

BOMAG

008 911 79

11.8

Sensors TCD 2012 / 2013 Camshaft speed sensor, B114 ●

Inductive sensor

●

Determination of TDC

●

Limp-home function in case of crankshaft sensor failure

Crankshaft speed sensor, B130 ●

Inductive sensor

●

Exact determination of engine speed

●

Limp-home function in case of camshaft sensor failure

Charge pressure sensor, B133 ●

Pressure sensor

●

Avoidance of smoke development

●

Adaptation of injection pump in case of too low charge pressure

●

Determination of air mass for cylinder

Oil pressure sensor, B88 ●

Pressure sensor

●

Monitors the oil pressure

●

Engine protection by switching of in case of too low oil pressure

Charge air temperature sensor, B133 ●

Temperature sensor

●

Temperature correction of air mass

●

Optimized injection quantity during cold start

Coolant temperature sensor, B113 ●

Temperature sensor

●

Engine protection in case of excessive temperature by reduction of injection quantity

●

Optimized injection quantity during cold start

Rail pressure sensor, B93 ●

Pressure sensor

●

Monitoring the injection pressure)

Fuel low pressure sensor ●

Pressure sensor

●

Monitoring the inlet pressure approx. 5-7 bar

008 911 79

BOMAG

489

11.8

Sensors TCD 2012 / 2013

TCD 2012 Crankshaft speed sensor (B130)

Fig. 4 Crankshaft speed sensor TCD 2012

Adjustment measurement or sensor gap measurement 1

Toothed disc on crankshaft

2

Speed sensor

Gap measurement C = 0,6mm +/- 0.5mm

Fig. 5 Crankshaft speed sensor

490

BOMAG

008 911 79

11.8

Sensors TCD 2012 / 2013 TCD 2013 Crankshaft speed sensor (B130)

Fig. 6 Crankshaft speed sensor TCD 2013

Adjustment measurement or sensor gap measurement 1

Toothed disc on crankshaft

2

Speed sensor

Gap measurement C = 0,6mm +/- 0,1mm

Fig. 7 Crankshaft speed sensor

008 911 79

BOMAG

491

11.8

Sensors TCD 2012 / 2013

Camshaft speed sensor (B114)

Fig. 8 Camshaft speed sensor TCD 2012/2013

Adjustment measurement or sensor gap measurement 1

Camshaft sprocket

2

Speed sensor

Gap measurement C = 1mm +/- 0.5mm

Fig. 9 Camshaft speed sensor

492

BOMAG

008 911 79

11.8

Sensors TCD 2012 / 2013 Measuring and testing

Camshaft Fig. 10 Electric wiring diagram, page 004

Crankshaft Sensor test Resistance measurement between Pin1 and Pin2 is approx. 3.8 KOhm If a magnetically conductive material is moved along a sensor at a certain distance, a positive semi-wave must be created on Pin 1, 2. At a rotary speed of approx. 25 rpm there is a signal voltage amplitude of at least 200mV from peak to peak.

Fig. 11 Speed sensor

008 911 79

BOMAG

493

11.8

Sensors TCD 2012 / 2013

Combination sensor for charge air pressure and charge air temperature (B133)

Fig. 12 TCD 2012

Fig. 13 TCD 2013

494

BOMAG

008 911 79

11.8

Sensors TCD 2012 / 2013 Measuring and testing Pin 4

Fig. 14 Charge air pressure and temperature sensor

3

2

1

Charge air temperature Pin 2--- NTC-Temperature Resistance R=2510 Ohm = 20°C Resistance R=851 Ohm = 50°C Charge air pressure Pin4 0.5 Volt = 0 bar at 5 V feed voltage 4,5 Volt = 4 bar at 5 V feed voltage

Fig. 15 Electric wiring diagram, page 004

008 911 79

BOMAG

495

11.8

Sensors TCD 2012 / 2013

Oil pressure sensor (B88)

Fig. 16 TCD 2012

Fig. 17 TCD 2013

496

BOMAG

008 911 79

11.8

Sensors TCD 2012 / 2013 Measuring and testing

Fig. 18 Electric wiring diagram, page 004

Measurement Pin 2 = Signal 0.5 Volt = 0 bar at 5 V feed voltage 4,5 Volt = 10 bar at 5 V feed voltage

Fig. 19 Assignment of connections

008 911 79

BOMAG

497

11.8

Sensors TCD 2012 / 2013

Coolant temperature senor (B113)

Fig. 20 TCD 2013

Measurement Pin 1 = Signal Resistance R=2500 Ohm = 20 °C Resistance R=186 Ohm = 100 °C

Fig. 21 Electric wiring diagram, page 004

498

BOMAG

008 911 79

11.8

Sensors TCD 2012 / 2013 Rail pressure senor (B93)

Fig. 22 TCD 2012

Measurement Pin 2 = Signal 0.5 Volt = 0 bar at 5 V feed voltage 4,5 Volt = 1800 bar at 5 V feed voltage

Fig. 23 Electric wiring diagram, page 004

008 911 79

BOMAG

499

11.8

Sensors TCD 2012 / 2013

Fuel low pressure sensor (B145)

Fig. 24 TCD 2012

Fig. 25 TCD 2013

500

BOMAG

008 911 79

11.8

Sensors TCD 2012 / 2013 Measuring and testing

Measurement

Fig. 26 Electric wiring diagram, page 004

Pin 2 = Signal 0.5 Volt = 0 bar at 5 V feed voltage 4,5 Volt = 7 bar at 5 V feed voltage

Pin 2 Signal Pin 4 Ground

Pin 1 +

Fig. 27 Connecting plug

008 911 79

BOMAG

501

11.9

Engine control EDC16 with EMR 3 for TCD 2012 / 2013

11.9 Engine control EDC16 with EMR 3 for TCD 2012 / 2013

●

Working range 9-31 V

●

Engine start possible from 6 V

Control unit EDC 16 - EMR 3 ●

Operating voltage 12 V DC and 24 V DC

Connection Engine side

Connection Vehicle side

Fig. 1 EDC 16 - EMR 3 TCD 2012 and 1013

502

BOMAG

008 911 79

11.9

Engine control EDC16 with EMR 3 for TCD 2012 / 2013 EMR 3 - interface description

Engine side D 2.1 Pin 1-60 in wiring diagram Page 004 X31:1 to X31:90

Vehicle side D 2.2 Pin 1-94 in wiring diagram Page 004 X30:1 to X30:94

Fig. 2 EMR 3 - connecting plug TCD 2012 and 2013

16

Engine side

Vehicle side

Fig. 3 Connecting plug EMR3

008 911 79

BOMAG

503

11.9

Engine control EDC16 with EMR 3 for TCD 2012 / 2013

Interface on engine side X31:

Fig. 4 Electric wiring diagram, page 004

504

BOMAG

008 911 79

Engine control EDC16 with EMR 3 for TCD 2012 / 2013

11.9

Interface on vehicle side X30:

Fig. 5 Electric wiring diagram, page 004

008 911 79

BOMAG

505

11.9

Engine control EDC16 with EMR 3 for TCD 2012 / 2013

Engine control EDC16 / EMR3 The EDC16 is located under the operator's stand

Fig. 6 EMR3-position in the machine under the operator's stand

506

BOMAG

008 911 79

Exhaust gas recirculation TCD 2012 / 2013

11.10

11.10Exhaust gas recirculation TCD 2012 / 2013 In order to be able to meet the exhaust gas standards EC and stage/Tier3, all engines are designed with exhaust gas recirculation. On 4-cylinder engines TCD 2012/2013 the exhaust gas recirculation has been realized internally through the intake valves, on 6-cylinders through the exhaust valves. For this purpose the camshaft has been manufactured with an additional cam for short-term opening of the intake valve or exhaust valve respectively.

Fig. 1 Exhaust/intake valve control TCD 2012 / 2013

008 911 79

BOMAG

507

11.11

Fault code monitoring with display TCD 2012 / 2013

11.11Fault code monitoring with display TCD 2012 / 2013

k yellow = lights when temperatures are low (preheating for starting)

Fig. 1 Display

LCD display

i

Note

With the ignition switch in position I all gauges and instruments are switched on for 3 seconds.

l yellow = Charge control light, lights if the battery is not being charged. Check V-belt, if necessary repair the generator. m red

= Water separator in fuel pre-cleaner. Lights when the water proportion in the transparent section of the fuel filter reaches the contacts.

o

= Fault code display

t red

= The seat occupation monitoring system lights when the seat is not occupied. If the machine is travelling the warning buzzer will sound, engine is shut down after 4 seconds.

v red

= Central warning light, lights if a fault code is displayed

x

= Engine rpm-meter

Toggling between the displays is described in the chapter "Operation". b

= Fuel level gauge

c

= Upper display field, shows either the time or the coolant temperature

e red

= flashes if engine oil pressure too low, engine is shut down after 10 seconds. Check engine oil level, repair the engine if necessary.

f red

= flashes if the engine overheats (oil temperature), the warning buzzer sounds, the engine is shut down after 2 minutes. Switch off vibration, run engine with idle speed or shut down engine if necessary, clean engine oil cooler and radiator, if necessary repair engine.

g yellow = lights if combustion air filter cartridge is soiled, clean or replace if necessary. h red

508

= flashes when the coolant (filling) level is too low. Engine is shut down after 10 seconds.

BOMAG

008 911 79

11.12

Fault code display TCD 2012 / 2013

11.12Fault code display TCD 2012 / 2013 The display shows the fault codes

Fig. 1 Display

For a detailed description of how to read out fault codes and the display please refer to the page on electrics in the Service Training Manual. Caution All detected faults are displayed !

Fault codes 5000 - 5499 are diesel engine related A detailed reading out of fault code for the diesel engine is only possible through Deutz-Serdia

008 911 79

BOMAG

509

11.13

EMR3 List of fault codes

11.13EMR3 List of fault codes

510

BOMAG

008 911 79

11.13

EMR3 List of fault codes

008 911 79

BOMAG

511

11.13

512

EMR3 List of fault codes

BOMAG

008 911 79

11.13

EMR3 List of fault codes

008 911 79

BOMAG

513

11.13

514

EMR3 List of fault codes

BOMAG

008 911 79

11.13

EMR3 List of fault codes

008 911 79

BOMAG

515

11.13

516

EMR3 List of fault codes

BOMAG

008 911 79

11.13

EMR3 List of fault codes

008 911 79

BOMAG

517

11.13

518

EMR3 List of fault codes

BOMAG

008 911 79

11.13

EMR3 List of fault codes

008 911 79

BOMAG

519

11.14

SerDia Service-Software TCD 2012 / 2013

11.14SerDia Service-Software TCD 2012 / 2013

EDC16 EMR3

Fig. 1 Service-Software TCD 2012 / 2013

SerDIA is a software program from Deutz which enables the use of a laptop computer to run a more detailed fault analysis and to read out the error log in particular. This procedure displays information like: Location of fault (e.g. ’coolant temperature sensor’)

which can even be used if no EMR-fault is present (start behaviour, engine sawing, lack of power). Connection For this purpose the PC or laptop is connected to the diagnostic interface by means of an interface cable. Work with SERDIA is described in separate operating instructions.

Type of fault (e.g. 'bottom limit value fallen short of', 'sporadic fault') Environmental data/operating data (speed and operating hours at the time of the last occurrence of the fault). Number of fault locations. Frequency of fault Fault status (active - fault present / passive - fault no longer present). Fault messages for faults that are no longer active or have been rectified can be deleted with SERDIA. Other possible displays: Function test: Control outputs and governor rod travel can be activated with the engine stopped. Assignment of inputs / outputs: Display of the current assignment of inputs and outputs on the EMR-control Representation of measuring values: There is a vast variety of measuring values available for selection 520

BOMAG

008 911 79

11.14

SerDia Service-Software TCD 2012 / 2013

SerDia connection

Serdia connection socket

Any other EMR components (sensors etc) must under no circumstances be repaired, but must be replaced if they are defective.

Fig. 2 Serdia connection socket electric cabinet

Replacing the EMR3 control unit Each control unit is firmly assigned to the engine, according to its application. In case of replacement the control unit must therefore be completed with an engine specific data set. When ordering a new control unit the engine serial number (sticker on EMR control unit) must be specified alongside the part number. Note: The Deutz part number specified on the EMR control unit is the part number without engine specific software. The correct part number is to be taken from the spare parts catalogue.

Replacing the EMR or DCR components On TCD-engines with Common Rail technology the system pressure is so high, that in case of leaks or repair all parts need to be replaced. When replacing sensors or other electric components, the new parts must be calibrated with the EMR control unit. The calibration must be made with the help of SERDIA (Level IIIa). (see also SERDIA manual). 008 911 79

BOMAG

521

11.14

SerDia Service-Software TCD 2012 / 2013

SerDia screen shot

Fig. 3 Error log

522

BOMAG

008 911 79

11.15

General trouble shooting chart TCD 2012 / 2013

11.15General trouble shooting chart TCD 2012 / 2013 Faults

Engine does not start or starts poorly

Causes Temperature below starting limit Oil level too low Lubrication oil level too high

Check Fill up lubrication oil Check the lubrication oil level, drain off if necessary Lubrication oil cooler defective Check Exhaust gas counter pressure too high Check V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose Engine oil with wrong SAE viscosity class Change the lubrication oil Fuel quality not as specified in the operating Change the fuel instructions Air in the fuel system Bleed the fuel system Battery defective or not charged Check the battery Cable to starter loose or oxidized Check cable connection Starter defective or pinion does not engage Check starter Engine electronics prevent starting Check fault by fault code, repair as necessary

Engine does not start and diagnostic lamp flashing Engine starts, but V-belt/ribbed V-belt (fuel pump in belt drive) runs irregularly or Incorrect valve clearance misfires Injector defective Glow plugs defective Air in the fuel system Fuel pre-filter/fuel pre-cleaner soiled Fuel quality not as specified in the operating instructions Injection line leaking Injection valve defective Speed changes Engine electronics detected a system fault are possible and and activates a substitute speed diagnostic lamp lights Bleeding line clogged Engine shut-down lever still in stop position (shut-down solenoid defective) Injector defective Coolant heat exchanger soiled Coolant pump defective (V-belt torn or loose) Lack of coolant Charge air pipe leaking V-belt/ribbed V-belt (fuel pump in belt drive) Engine overheatLubrication oil filter on air or lubrication oil ing. Temperature side soiled warning system Lubrication oil level too low responds Lubrication oil level too high Air filter clogged / exhaust turbocharger defective Air filter service switch / indicator defective Fan defective / V-belt torn or loose Short circuit of heat in cooling system Resistance in cooling system too high / flow quantity too low

008 911 79

Action

BOMAG

check, whether torn or loose Adjust replaced replace bleed Clean Change the fuel Check the injection line Check / replace the injection valve Check fault by fault code, repair as necessary

Clean Check/replace replace Clean check, whether torn or loose top up Check the charge air pipe check, whether torn or loose replace Fill up lubrication oil Check the lubrication oil level, drain off if necessary Check/replace Check/replace Check fan / V-belt, replace if necessary Check the cooling system check

523

11.15 Faults

Insufficient engine power

General trouble shooting chart TCD 2012 / 2013 Causes Engine oil level too high Engine shut-down lever still in stop position Fuel quality not as specified in the operating instructions Air filter clogged / exhaust turbocharger defective Air filter service switch / indicator defective Charge air pipe leaking Intercooler soiled Injection line leaking Injector defective Injection valve defective Engine electronics reducing the output power

Insufficient engine power and diagnostic lamp lights Engine does not Injection line leaking work with all cylinders Injection valve defective

Oil level too low Engine has to low Extremely slanted position of engine or no oil pressure Engine oil of wrong SAE class or quality Engine has exEngine oil level too high cessive oil con- Extremely slanted position of engine sumption Blue engine ex- Engine oil level too high haust smoke Extremely slanted position of engine

Action Check the oil level Shut-down solenoid defective Change the fuel Check/replace Check/replace Check the charge air pipe Clean Check the injection line replace Check the injection valves Check fault by fault code, repair as necessary

Check the injection valve / replace if necessary Check the injection valve / replace if necessary Fill up lubrication oil Check engine pillow blocks / reduce the engine inclination Change the lubrication oil Check oil level, drain off if necessary Check engine pillow blocks / reduce the engine inclination Check oil level, drain off if necessary Check engine pillow blocks / reduce the engine inclination

Temperature below starting limit Fuel quality not as specified in the operating Change the fuel White engine exinstructions haust smoke Injection valve defective Check the injection valve / replace if necessary Air filter clogged / exhaust turbocharger de- Check / replace if necessary fective Air filter service switch / indicator defective Check / replace if necessary Black engine exCharge air pipe leaking Check the charge air pipe haust smoke Injection valve defective Check the injection valve / replace if necessary Injector defective replace

524

BOMAG

008 911 79

11.16

Valve adjustment TCD 2012 / 2013

11.16Valve adjustment TCD 2012 / 2013

Fig. 1 TCD 2012 and 2013

Sense of rotation

General definition

Viewed on drive side (flywheel side) turning ccw: counter-clockwise (see example)

Cylinder arrangement, engine side and sense of rotation

Engine sides: Viewed on power take-off side. left = left = exhaust side right = right = operation side

The cylinders must be successively numbered, starting with 1 at the flywheel .

Fig. 1 TCD 2012 / 2013 Valves

Adjusting the valve clearance (without exhaust gas recirculation)

Turn the rotation angle disc (3) clockwise, until the specified angle is reached: Engine TCD 2012

Loosen the counter nut (1).

IN = intake valve 75°

Attach the rotation angle disc (3) and the spanner socket (4) to the valve clearance adjustment screw (2).

EX = exhaust valve 120°

Fix the magnet (5) of the rotation angle disc (3). Turn the rotation angle disc (3) clockwise against the stop (rocker arm no clearance) and set the scale to zero.

008 911 79

Engine TCD 2013 IN = intake valve 90° EX = Exhaust valve 150°Hold the rotation angle disc (3) against turning Tighten the counter nut (1).

BOMAG

525

11.16

Valve adjustment TCD 2012 / 2013

Then adjust the second valve on the rocker arm as described above. Repeat the adjustment procedure on each cylinder.

526

BOMAG

008 911 79

11.16

Valve adjustment TCD 2012 / 2013

Fig. 2 TCD 2012 / 2013 Valves

Adjusting the valve clearance (with exhaust gas recirculation) For the exhaust valves the same adjustment procedure is to be used as for engines with exhaust gas recirculation. Adjusting the intake valves

TCD 2012 / 2013 - 4 cylinder Overlapping of valves 1 3 4 2

adjustment 4 2 1 3

TCD 2012 / 2013 - 6 cylinder Overlapping of valves 1 5 3 6 2 4

adjustment 6 2 4 1 5 3

Loosen the counter nut (6). Attach the rotation angle disc (3) with the special spanner (8) to the valve adjustment screw (7) on the intake valve. Fix the magnet (5) of the rotation angle disc (3). Turn the rotation angle disc (3) clockwise against the stop (rocker arm no clearance) and set the scale to zero. Turn the rotation angle disc (3) clockwise, until the specified angle is reached: Engine TCD 2012 IN = intake valve 75° Engine TCD 2013 IN = intake valve 90° Hold the rotation angle disc (3) tight to prevent it from turning. Tighten the counter nut (6). Then adjust the second valve on the rocker arm as described above. Repeat the adjustment procedure on each cylinder. Valve clearance adjustment schematic Overlapping of valves: Exhaust valve not yet closed, intake valve starts to open.

Caution These engines are equipped with an exhaust gas recirculation system. !

During the exhaust cycle the intake valve opens for a short moment. This must not be mistaken as overlapping of valves!

008 911 79

BOMAG

527

11.17

Ribbed V-belt - fan drive TCD 2012 / 2013

11.17Ribbed V-belt - fan drive TCD 2012 / 2013

Fig. 1 Ribbed V-belt

i

Note

Check the distance between the tongue of the moveable tensioner arm and the stop on the fixed tensioner housing. If the distance "a" is smaller than 3 mm, replace the belt.

528

BOMAG

008 911 79

11.18

Special tools, Deutz engine (TCD 2012 2V)

11.18Special tools, Deutz engine (TCD 2012 2V)

 TCD 2012 2V

Standard tools

8002 Pressure pump Checking fuel system for leak-tightness

057 250 66

© 35409-2

8005 Compression pressure tester for diesel engines 10 - 40 bar

057 250 67

© 35410-3

8024 Assembly pliers Removing valve stem gaskets

057 250 68

© 37509-2

008 911 79

BOMAG

529

11.18

Special tools, Deutz engine (TCD 2012 2V)

TCD 2012 2V

Standard tools 8113 Socket wrench insert Torx - E 14

057 250 69

© 43022-0

8114 Socket wrench insert Torx - E 20

057 250 70

© 35415-1

8115 V-belt tension meter 150 to 600 N for checking the V-belt tension

079 947 09

© 35416-3

530

BOMAG

008 911 79

Special tools, Deutz engine (TCD 2012 2V)

 TCD 2012 2V

11.18

Standard tools

8189 Torx tool set Case containing:  - Double-ended ring spanner E6/E8 - Double-ended ring spanner E10/E12 Socket wrench insert E8 and E10 (1/4 inch) - Socket wrench insert E10 and E12 (3/8 inch) - Socket wrench insert E18 (1/2 inch)

079 947 01

© 39432-1

8190 Rotation angle disc with magnet Setting valve clearance

057 250 72

© 43528-0

8191 Screwdriver insert for slotted screw Valve clearance setting

057 250 74

© 43060-0

008 911 79

BOMAG

531

11.18

Special tools, Deutz engine (TCD 2012 2V)

TCD 2012 2V

Standard tools 8192 Bowl wrench Fuel pre-filter (type: Racor)

057 250 73

© 43193-1

8194 Screwdriver insert with hexagonal socket (size 4 mm), 1/2 inch, long version (in conjunction with rotation angle disc 8190)

057 250 75

© 43183-0

8196 Open end wrench adapter Size 13,  for torque wrench Tightening of lock nut of the valve clearance setting screw

057 250 71

© 43019-0

532

BOMAG

008 911 79

11.18

Special tools, Deutz engine (TCD 2012 2V)

 TCD 2012 2V

Standard tools

8198 Pricker Removing rotary shaft lip seal

057 250 76

© 43206-0

8199 Crowfoot wrench Size 15 3/4 inch (in connection with rotation angle disc 8190)

057 250 77

© 44309-0

9017 Assembly lever Example: Removing and installing the valves

057 250 78

© 37511-2

008 911 79

BOMAG

533

11.18

Special tools, Deutz engine (TCD 2012 2V)

 TCD 2012 2V

Special tools

100 190 Connection piece (in conjunction with compression pressure tester 8005)

057 250 79

© 42524-1

100 320 Turning gear flywheel side

057 250 80

© 35422-1

100 330 Turning gear V-belt pulley Turning crankshaft on torsional vibration damper

079 947 19

© 35423-1

3/12

534

BOMAG

008 911 79

11.18

Special tools, Deutz engine (TCD 2012 2V)

TCD 2012 2V

Special tools 100 400 Dial gauge with fixing wheel Measuring range 0 -10mm / 0.01mm

057 250 81

© 35424-1

100 410 Digital gauge Measuring range 0 -30 mm / 0.01 mm

057 250 82

© 43205-0

100 750 Measuring apparatus Measuring bar with two spacing washers (in conjunction with 100 400 or 100 410) Checking valve lag dimension Checking piston projection

057 250 83

© 39402-1

008 911 79

BOMAG

535

11.18

Special tools, Deutz engine (TCD 2012 2V)

 TCD 2012 2V

Special tools

103 050 Socket wrench insert Size 15 for valve clearance setting with removed exhaust return module (in connection with 8190)

057 250 84

© 43023-0

103 220 Special pliers for removing the roller tappet

057 250 85

© 43010-0

110 500 Special wrench Size 17 Removing and installing high-pressure lines

057 250 86

© 35436-1

536

BOMAG

008 911 79

11.18

Special tools, Deutz engine (TCD 2012 2V)

TCD 2012 2V

Special tools 110 700 Socket wrench insert long Assembling/disassembling pressure sensors (rail pressure, oil pressure, fuel pressure)

057 250 87

© 43198-2

110 900 Assembly case Case for O-rings, complete with: Disassembly tool 110 901 and three assembly sleeves with guide: - High pressure pump (Ø 36), 110 902 - Injector, 2V motor (Ø 16), 110 903 - Injector, 4V motor (Ø 23), 110 904 Disassembling/assembling O-rings

057 250 88 © 43208-0

120 430 Assembly tool Removing and installing the heating plugs

057 250 89

© 43020-0

008 911 79

BOMAG

537

11.18

Special tools, Deutz engine (TCD 2012 2V)

 TCD 2012 2V

Special tools

120 900 Support bracket pivoting Clamping cylinder head

057 250 90

© 35438-3

120 910 Base plate for support bracket (in conjunction with support bracket 120 900 if support bracket is not screwed tightly)

057 250 91

© 35439-3

121 410 Assembly tool Assembling valve stem gaskets

057 250 92

© 37614-2

538

BOMAG

008 911 79

11.18

Special tools, Deutz engine (TCD 2012 2V)

TCD 2012 2V

Special tools 121 420 Assembly sleeves Set of assembly sleeves for valve stem gasket

057 250 93

© 43210-0

130 300 Universal piston ring pliers Removing and installing the piston rings

057 250 94

© 43021-0

130 440 Trapezoidal groove wear gauge for piston diameter 101 mm Check piston ring groove

057 250 95

© 36461-2

008 911 79

BOMAG

539

11.18

Special tools, Deutz engine (TCD 2012 2V)

 TCD 2012 2V

Special tools

130 450 Trapezoidal groove wear gauge for piston diameter 98 mm Check piston ring groove

057 250 96

© 36461-2

130 660 Piston ring tensioning band Piston diameter 98 mm

057 250 97

© 39408-1

130 670 Piston ring tensioning band Piston diameter 101 mm

057 250 98

© 39408-1

540

BOMAG

008 911 79

11.18

Special tools, Deutz engine (TCD 2012 2V)

TCD 2012 2V

Special tools 142 670 Assembly tool Assembling crankshaft sealing ring (opposite side to flywheel)

079 947 26

© 35445-1

142 830 Assembly tool for crankshaft (flywheel side)

079 947 27

© 35446-1

144 800 Counter support Torsional vibration damper

057 250 99

© 35453-1

008 911 79

BOMAG

541

11.18

Special tools, Deutz engine (TCD 2012 2V)

 TCD 2012 2V

Special tools

170 050 Special wrench Unscrew the filter cartridges

079 947 28

© 37629-2

170 160 Stoppers/caps 1 set of differently-sized stoppers and caps Sealing openings on the fuel system

079 947 29

© 43663-0

6066 Assembly block Engine clamping, double-sided

079 947 30

© 35451-2

542

BOMAG

008 911 79

11.18

Special tools, Deutz engine (TCD 2012 2V)

TCD 2012 2V

Special tools 6066/158 Clamping bracket consisting of: 1 holder 6066/158-1 rear right, 1 holder 6066/158-2 rear left, 1 holder 6066/158-3 front right, 1 holder 6066/158-4 front left (in connection with assembly block 6066) Clamping of the engine, double-sided

079 947 31

© 35452-1

008 911 79

BOMAG

543

11.19

Special tools, Deutz engine (TCD 2013 2V)

11.19Special tools, Deutz engine (TCD 2013 2V)

 TCD 2013 2V

Standard tools

8002 Pressure pump Checking cooling system for leak-tightness

057 250 66

© 35409-2

8005 Compression pressure tester for diesel engines 10 - 40 bar

057 250 67

© 35410-3

8011 Hose clip pliers e. g. fuel return pipe

© 39426-1

544

BOMAG

008 911 79

11.19

Special tools, Deutz engine (TCD 2013 2V)

TCD 2013 2V

Standard tools 8024 Assembly pliers Removing valve stem gaskets

057 250 68

© 37509-2

8035 Socket wrench insert reinforced, size 22 removing and installing main bearing

© 37504-2

8113 Socket wrench insert Torx - E 14

057 250 69

© 43022-0

008 911 79

BOMAG

545

11.19

Special tools, Deutz engine (TCD 2013 2V)

 TCD 2013 2V

Standard tools

8114 Socket wrench insert Torx - E 20

© 35415-1

8115 V-belt tension measuring device 150 to 600 N for checking the V-belt tension

079 947 09

079 947 09

© 35416-3

8189 Torx tool set Contents of case:  - Double-ended ring spanner E6/E8 - Double-ended ring spanner E10/E12 Socket wrench insert E8 and E10 (1/4 inch) - Socket wrench insert E10 and E12 (3/8 inch) - Socket wrench insert E18 (1/2 inch)

079 947 01

079 947 01

© 39432-1

546

BOMAG

008 911 79

11.19

Special tools, Deutz engine (TCD 2013 2V)

TCD 2013 2V

Standard tools 8190 Rotation angle disc with magnet Setting valve clearance

057 250 80

© 43528-0

8191 Screwdriver insert for slotted screw Valve clearance setting

057 250 74

© 43060-0

8192 Bowl wrench Fuel pre-filter (type: Racor)

057 250 73

© 43193-1

008 911 79

BOMAG

547

11.19

Special tools, Deutz engine (TCD 2013 2V)

 TCD 2013 2V

Standard tools

8193 Screwdriver insert with pressed in hexagonal pin (5 mm),  1/2 inch, long version (in conjunction with rotation angle disc 8190)

© 43183-0

8194 Screwdriver insert with hexagon socket (size 4 mm), 1/2 inch, long version (in conjunction with rotation angle disc 8190)

057 250 75

© 43183-0

8195 Multi-toothed screwdriver set 260 mm long remove and install air compressor

© 43195-0

548

BOMAG

008 911 79

11.19

Special tools, Deutz engine (TCD 2013 2V)

TCD 2013 2V

Standard tools 8196 Open end wrench adapter Size 13,  for torque wrench Tightening of lock nut of the valve clearance setting screw

057 250 71

© 43019-0

8198 Pricker Removing rotary shaft lip seal

057 250 76

© 43206-0

8199 Crowfoot wrench Size 15 3/4 inch (in connection with rotation angle disc 8190)

057 250 77

© 44309-0

008 911 79

BOMAG

549

11.19

Special tools, Deutz engine (TCD 2013 2V)

 TCD 2013 2V

Standard tools

9017 Assembly lever Example: Removing and installing the valves

057 250 78

© 37511-2

9090 Spring band pliers 320 mm tighten spring band clamp

© 35420-3

550

BOMAG

008 911 79

Special tools, Deutz engine (TCD 2013 2V)

 TCD 2013 2V

11.19

Special tools

100 190 Connector (in conjunction with compression pressure tester 8005)

057 250 79

© 42524-1

100 320 Turning gear flywheel side

057 250 80

© 35422-1

100 330 Turning gear V-belt pulley Turning crankshaft on torsional vibration damper

079 947 19

© 35423-1

008 911 79

BOMAG

551

11.19

Special tools, Deutz engine (TCD 2013 2V)

TCD 2013 2V

Special tools 100 400 Dial gauge with fixing wheel Measuring range 0 - 10 mm / 0.01 mm

057 250 81

© 35424-1

100 410 Digital gauge Measuring range 0 - 30 mm / 0.01 mm

057 250 82

© 43205-0

100 750 Measuring device Measuring bar with two shims (in conjunction with 100400 and 100410) Checking valve lag dimension Checking piston projection

057 250 83

© 39402-1

552

BOMAG

008 911 79

Special tools, Deutz engine (TCD 2013 2V)

 TCD 2013 2V

11.19

Special tools

103 050 Socket wrench insert Size 15 for valve clearance setting with removed exhaust return module (in connection with 8190)

057 250 84

© 43023-0

103 220 Special pliers for removing the roller tappet

057 250 85

© 43010-0

110 500 Special wrench Size 17 Removing and installing high-pressure lines

057 250 86

© 35436-1

008 911 79

BOMAG

553

11.19

Special tools, Deutz engine (TCD 2013 2V)

TCD 2013 2V

Special tools 110 640 Lever tool Remove injector

© 43941-0

110 700 Socket wrench insert long Installing and removing pressure sensors (rail pressure, oil pressure, fuel pressure)

057 250 87

© 43198-2

110 900 Assembly case Case for O-rings, complete with: Disassembly tool 110 901 and three assembly sleeves with guide: - High pressure pump (Ø 36), 110 902 - Injector, 2V motor (Ø 16), 110 903 - Injector, 4V motor (Ø 23), 110 904 Removing and installing O-rings

057 250 88

© 43208-0

554

BOMAG

008 911 79

Special tools, Deutz engine (TCD 2013 2V)

 TCD 2013 2V

11.19

Special tools

120 430 Assembly tool Removing and installing the glow plugs

057 250 89

© 43020-0

120 680 Puller (in conjunction with slide hammer 150 800) Removing fixed injector sealing ring

© 35437-1

120 900 Support bracket pivoting Clamping cylinder head

057 250 90

© 35438-3

008 911 79

BOMAG

555

11.19

Special tools, Deutz engine (TCD 2013 2V)

TCD 2013 2V

Special tools 120 910 Base plate (in conjunction with support bracket 120 900 if support bracket is not screwed tightly)

057 250 91

© 35439-3

121 330 Assembly lever Removing and installing the valves

© 43185-0

121 420 Assembly sleeves Set of assembly sleeves for valve stem gasket

057 250 93

© 43210-0

556

BOMAG

008 911 79

Special tools, Deutz engine (TCD 2013 2V)

 TCD 2013 2V

11.19

Special tools

130 300 Universal piston ring pliers Removing and installing the piston rings

057 250 94

© 43021-0

130 420 Trapezoidal groove wear gauge Piston diameter 108 mm

© 36461-2

130 640 Piston ring compressor Piston diameter 108 mm

© 39408-1

008 911 79

BOMAG

557

11.19

Special tools, Deutz engine (TCD 2013 2V)

TCD 2013 2V

Special tools 142 810 Assembly tool Installing crankshaft sealing ring (flywheel side)

© 35446-1

142 820 Assembly tool Installing crankshaft sealing ring (opposite side to flywheel)

© 35445-1

150 170 Puller, universal Comprising traverse, support and threaded rod (in conjunction with disc 150 171) Removing cylinder liner

© 43207-0

558

BOMAG

008 911 79

Special tools, Deutz engine (TCD 2013 2V)

 TCD 2013 2V

11.19

Special tools

150 171 Plate (in conjunction with puller 150 170) for liner diameter: 108 mm Removing cylinder liner

© 43204-0

150 180 Liner holder (Set comprises 7 holders) Turning crankshaft with cylinder head removed

© 43181-0

150 190 Assembly lever Lever with bolts  (in conjunction with disc 150 191) Installing cylinder liner

© 43209-2

008 911 79

BOMAG

559

11.19

Special tools, Deutz engine (TCD 2013 2V)

TCD 2013 2V

Special tools 150 191 Washer (in conjunction with assembly tool 150 190) for liner diameter: 108 mm Installing cylinder liner

© 43203-2

150 800 Slide hammer (in conjunction with puller 120 680) Removing injector sealing ring

079 947 18

079 947 18

© 35449-2

170 050 Special wrench Unscrewing the filter cartridges

079 947 28

© 37629-2

560

BOMAG

008 911 79

Special tools, Deutz engine (TCD 2013 2V)

 TCD 2013 2V

11.19

Special tools

170 160 Stoppers/caps 1 set of differently-sized stoppers and caps Sealing openings on the fuel system

079 947 29

© 43663-0

6066 Assembly block Engine clamping, double-sided

079 947 30

© 35451-2

6066/158 Clamping bracket consisting of: 1 holder 6066/158-1 rear right, 1 holder 6066/158-2 rear left, 1 holder 6066/158-3 front right, 1 holder 6066/158-4 front left (in connection with assembly block 6066) Clamping of the engine, double-sided

079 947 31

© 35452-1

008 911 79

BOMAG

561

11.19

Special tools, Deutz engine (TCD 2013 2V)

TCD 2013 2V

Special tools 6068 Engine lifting device Version for commercial vehicles with worm gear, ultimate load (2t), 3-point suspension, spindle clamp, traverse, chains and hooks

© 43184-0

6692 Slotted nut wrench Cable plug

© 43199-0

562

BOMAG

008 911 79

12 Air conditioning system

008 911 79

BOMAG

563

12.1

Physical basics

12.1 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.

564

BOMAG

008 911 79

12.1

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 79

BOMAG

565

12.1

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

566

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 79

12.2

Refrigerant R134a

12.2 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: - 26.5 °C

Physical properties of R134a:

Solidification point:

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).

-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 79

BOMAG

567

12.3

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.

12.3 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.

568

BOMAG

008 911 79

Working principle of the air conditioning system

12.4 Working principle of the air conditioning system

12.4

12.5 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 79

BOMAG

569

12.6 Monitoring chain

Description of components

12.6 Description of components Compressor

Fig. 2 Monitoring chain consisting of: ●

1 Switch

●

2 Fuse

●

3 Thermostat

●

4 Low pressure switch contact

Fig. 1

●

5 High pressure switch contact

●

6 Relay

●

7 Connection for magnetic clutch

●

8 Pressure switch

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. 570

BOMAG

008 911 79

12.6

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 79

BOMAG

571

12.6

Description of components

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!

572

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 79

12.6

Description of components

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 79

BOMAG

573

12.6

Description of components

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.

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.

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.

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. !

574

BOMAG

008 911 79

12.6

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

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

Low pressure on: 3.5 bar Overpressure off: 25,0 ±1,5 bar Overpressure on: 18,0 ±1,5 bar

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 79

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

575

12.7

Checking the compressor oil level

12.7 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 ●

576

Refill the air conditioning system.

BOMAG

008 911 79

12.8

Checking the magnetic clutch

12.8 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

Nominal value approx. 3.5 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 79

BOMAG

577

12.9

Inspection and maintenance work

12.9 Inspection and maintenance work

12.10Checking, replacing the refrigerant compressor V-belt1

●

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 the routing of hoses and hoses on the attachment box or in the cabin.

●

Check all hose and screw fittings for leaks.

●

Check the fastening of the condenser unit.

●

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.

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

Fig. 4

●

Check the electric control panel. If discolorations on conductors are found, these should be replaced and possibly also the corresponding relays.

●

Inspect the entire circumference of the V-belt (Fig. 4) visually for damage and cracks. Replace damaged or cracked V-belts.

●

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.

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.

●

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

Tighten the V-belt.

Fig. 5 ●

Slightly slacken fastening screws 1, 2 and 3 (Fig. 5).

1

578

BOMAG

Optional equipment

008 911 79

12.11

Service the air conditioning ●

Press the compressor in direction of arrow, until the correct V-belt tension is reached.

●

Retighten all fastening screws.

12.11Service 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 79

●

Start the engine.

1

Optional equipment

BOMAG

579

12.11

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. ●

580

Note Refrigerant must be filled up, if necessary check the air conditioning system for leaks.

BOMAG

008 911 79

12.11

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

Fig. 12 ●

Check the drier/collector unit (Fig. 12) for mechanical damage or rust.

Fig. 11

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 79

BOMAG

581

12.12

Drying and evacuation

12.12Drying and evacuation

12.13Emptying 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.

582

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 79

12.14

Leak test

12.14Leak 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 79

BOMAG

583

12.15

Filling instructions

12.15Filling 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.

584

BOMAG

008 911 79

12.15

Filling instructions

Fig. 1

10 Filter dryer

1

High pressure - gaseous

11 Fluid container

2

High pressure - liquid

12 Condenser

3

Low pressure - gaseous

13 Manual shut-off valve (not used)

4

Compressor

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 79

BOMAG

585

12.15

Filling instructions

19 Pressure reducing valve

16 Switch off the vacuum pump, watch the pressure gauges to see whether the vacuum is maintained.

20 Vacuum pump

Filling instructions

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

18 Close the red hand wheel.

21 Nitrogen bottle 22 Refrigerant bottle 23 Pressure gauge bar

2

Connect the service adapter with the blue hand wheel in the suction side. 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)

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.

586

BOMAG

008 911 79

Trouble shooting in refrigerant circuit, basic principles

12.16

12.16Trouble 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 79

BOMAG

587

12.16

Trouble shooting in refrigerant circuit, basic principles

Pressure gauge with saturation temperature scale

If the suction condition of the compressor is directly on the dew line, an e.g. incorrect evaporator load can cause "wet suction". This can lead to two processes, which are destructive for the compressor. The liquid refrigerant washes off the lubricating film between 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 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.

588

to, evaporation temperature in °C

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. 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 79

Trouble shooting in refrigerant circuit, basic principles

12.16

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 79

BOMAG

589

12.16

Trouble shooting in refrigerant circuit, basic principles

Fig. 1 Refrigerant circuit with t, h- diagram

1

Hot gas line (overheated steam)

2

Deheating (overheated steam)

3

Condenser / liquefier

4

Condensation (wet steam)

5

Fluid line (supercooled fluid)

6

Expansion valve

7

Injection line (wet steam)

8

Evaporation (wet steam)

9

Evaporator

10 Overheating (overheated steam) 11 Suction steam line (overheated steam) 12 Compressor 13 Supercooling (fluid) 14 Compression 15 Expansion

590

BOMAG

008 911 79

Trouble shooting, refrigerant circuit diagram

12.17

12.17Trouble shooting, refrigerant circuit diagram

Fig. 1 Refrigerant circuit diagram

13 Compressor

1

Cold air

14 Condenser

2

Evaporator

15 Cooling air

3

Thermostat

16 Pressure gauge, low pressure

4

Warm air

5

Fan

6

Inspection glass

7

Expansion valve

8

Pressure gauge, high pressure

9

Pressure switch with high and low pressure contacts

10 Dryer 11 Fluid container 12 Hot air

008 911 79

BOMAG

591

12.18

Trouble shooting procedure

12.18Trouble shooting procedure Procedure

●

Evaporator and heating (with highest fresh air fan speed) do not draw leak air.

●

The fresh air fan runs when the engine is running 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.

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: 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.

592

BOMAG

008 911 79

12.18

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 79

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

593

12.18

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 different causes. An evaporator showing hoarfrost may be quite normal. However, there may also

594

BOMAG

008 911 79

12.18

Trouble shooting procedure Values effecting the operating pressures

tions, it is mandatory to know these dependencies. The following table contains some of these dependencies.

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 Vehicle interior temperature

increases

Ambient temperature

increases

X

drops

increases

X X

X X

X X

X X

drops

008 911 79

X X

drops Humidity

High pressure increases drops X

X

BOMAG

X

595

12.18

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 Screen or nozzle in expansion valve high overheating clean clogged Filter dryer clogged Bubbles in inspection glass, high Change filter dryer overheating, filter dryer cold Heat power too low Frequent low pressure shut off, Check the control thawing thermostat / rotary thermostat switching too frequently

596

BOMAG

008 911 79

12.18

Trouble shooting procedure

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 Leak gas (air) high hot gas temperature, low renew filling measured supercooling, low cooling power Restriction between compressor and high hot gas temperature, low cool- Check lines and valves condenser ing power

008 911 79

BOMAG

597

12.18

Trouble shooting procedure Suction pressure too high (1), high pressure too low to normal (2)

Fig. 5

Cause Compressor defective

598

Possible effect Cooling power too low

BOMAG

Remedy Replace the compressor

008 911 79

12.18

Trouble shooting procedure

Suction pressure too high (1), high pressure too high (2)

Fig. 6

Cause Expansion valve defective

008 911 79

Possible effect Remedy overheating too low, wet operation Replace the valve of compressor

BOMAG

599

12.18

Trouble shooting procedure Other faults

Symptom Cause Possible effect Remedy Hot gas temperature too Lack of refrigeration oil increased compressor Refill refrigeration oil high, the hot gas line bewear comes so hot that it cannot be touched long with a hand Compressor does not start Pressure switch or any oth- System stopped Check the control units, check cause for switching er safety feature has trigand rectify gered, electrical fault, cylinder filled with liquid refrigerant Compressor switches con- Switching difference too Cycling of compressor, in- Check the control units, small, triggering of a tinuously creased wear, too low cool- check cause for switching 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 evaporator valve, check the refrigerant sion valve, lack of refriger- into the evaporator filling ant Evaporator fully covered Load problem, too low air low cooling power of sys- Clean the evaporator, with hoarfrost flow volume check the evaporator fan tem Fluid line is warm and Pressure drop in fluid line, low cooling power Eliminate the pressure shows condensation filter dryer clogged drop, replace the filter dryer Exceptionally cold pres"Wet intake" of the com- low cooling power, exces- Clean the compressor, resure lines pressor due to insufficient sive wear of compressor place if necessary, replace overheating of evaporator the expansion valve if necessary 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

600

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 79

12.18

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 The low pressure contact has System pressure fallen short of, re- Clean the evaporator, replace the switched off the magnetic clutch expansion valve, check the evaporafrigerant level too low, expansion 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 evaporator fan low

008 911 79

BOMAG

601

12.19 Tempera- Presture sure

Steam table for R134a

Density of the fluid

602

of the steam

spec. volume

spec. enthalpy

of the fluid of the steam

of the fluid of the steam

BOMAG

Evaporation heat

008 911 79

12.19

Steam table for R134a

008 911 79

BOMAG

603

12.19

604

Steam table for R134a

BOMAG

008 911 79

12.19

Steam table for R134a

008 911 79

BOMAG

605

12.19

606

Steam table for R134a

BOMAG

008 911 79

12.20Heating control / air conditioning control

008 911 79

BOMAG

607

12.20

608

Heating control / air conditioning control

BOMAG

008 911 79

Heating control / air conditioning control

008 911 79

BOMAG

12.20

609

12.20

610

Heating control / air conditioning control

BOMAG

008 911 79

Heating control / air conditioning control

008 911 79

BOMAG

12.20

611

12.20

612

Heating control / air conditioning control

BOMAG

008 911 79

13 Replacing the cab window panes

008 911 79

BOMAG

613

13.1

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

614

BOMAG

008 911 79

13.2

Special tools 13.2 Special tools 1. Locking handle for fastening element BOMAG part-no.: 055 705 84

Fig. 1

2. Suction lifter commercial

Fig. 2

008 911 79

BOMAG

615

13.3

Auxiliary materials 13.3 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

616

BOMAG

008 911 79

13.3

Auxiliary materials 6. Silicone sealant BOMAG part-no.: 009 700 36

Fig. 4

008 911 79

BOMAG

617

13.4

Removing and installing the window pane 13.4 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

618

BOMAG

008 911 79

13.4

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 79

BOMAG

619

13.4

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

620

BOMAG

008 911 79

13.4

Removing and installing the window pane

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 79

BOMAG

621

13.4

622

Removing and installing the window pane

BOMAG

008 911 79

14 Drum

008 911 79

BOMAG

623

14.1

Special tools, drum BW 213/226 DH-4 BVC and Variocontrol 14.1 Special tools, drum BW 213/226 DH-4 BVC and Variocontrol 1. Mechanical fixation, assembly of gearbox cover with weights pointing downward (vertical amplitude) . BOMAG part-no.: 955 822 11

Fig. 1

2. Mechanical fixation, adjustment of potentiometer for horizontal amplitude. BOMAG part-no.: 955 821 69

Fig. 2

3. Auxiliary assembly rings, side plate. BOMAG part-no.: 972 051 73

Fig. 3

624

BOMAG

008 911 79

Special tools, drum BW 213/226 DH-4 BVC and Variocontrol

14.1

4. Centring sleeve for side plate 10 (Fig. 4) and flanged hub (8). BOMAG part-no.: 972 051 74

Fig. 4

5. Pressing tool, inner races of tapered roller bearings BOMAG part-no.: 972 051 76

Fig. 5

6. Pressing tool, outer races of tapered roller bearings BOMAG part-no.: 972 051 75

Fig. 6

008 911 79

BOMAG

625

14.2

Removing and installing the drum 14.2 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. 7. Unscrew the fastening screws and remove the protection hood (Fig. 3).

Fig. 3

626

BOMAG

008 911 79

14.2

Removing and installing the drum

1. Open the hose brackets (Fig. 4) on both sides of the drum.

Fig. 4

Environment Environmental damage Catch running out hydraulic oil and dispose of environmentally. 2. Mark the hydraulic hoses on the vibration motor (Fig. 5) and disconnect them from the ports. 3. Close all hydraulic hoses and vibration motor ports with suitable plugs.

Fig. 5

4. Mark the hydraulic hoses on the slewing motor (Fig. 6) and disconnect them from the ports. 5. Close all hydraulic hoses and slewing motor ports with suitable plugs.

Fig. 6

6. Mark the hydraulic hoses on the control valve block (Fig. 7) and disconnect them from the ports. 7. Close all hydraulic hoses and control valve ports with suitable plugs. 8. Pull off both plugs (2) from the solenoid valve. 9. Disassemble the protection hood (1) for the plug of the wiring loom.

Fig. 7

008 911 79

BOMAG

627

14.2

Removing and installing the drum 10. Disconnect all plugs (Fig. 8).

Fig. 8

11. Mark the hydraulic hoses (Fig. 9) on the travel motor and disconnect them from the ports. 12. Close all hydraulic hoses and travel motor ports with suitable plugs. 13. Disassemble the guard plates for speed range selection solenoid valve (1) and speed sensor (2).

Fig. 9

14. Disconnect the plug from the speed sensor solenoid valve (Fig. 10). 15. Close the connections with plugs.

Fig. 10

16. Disassemble the front scraper 1 (Fig. 11). 17. Disassemble the rear scraper (2).

Fig. 11

628

BOMAG

008 911 79

14.2

Removing and installing the drum ! Danger Danger of accident!

Do not start or run the engine during repair work. 18. Support the front cross-member safely (Fig. 12).

Fig. 12

19. Properly support the rear cross-member on both sides (Fig. 13).

Fig. 13

20. Attach the lifting tackle to the side plate (Fig. 14). 21. Unscrew the front and rear fastening screws from the side plate.

Fig. 14

22. Unscrew the fastening screws (Fig. 15) from the spacer block on the vibration motor. Danger Danger of accident! Do not stand or step under loads being loaded. !

23. Take off the side plate and lay it down.

Fig. 15

008 911 79

BOMAG

629

14.2

Removing and installing the drum 24. Unscrew the fastening screws on the travel motor side (Fig. 16).

Fig. 16

25. Fasten the lifting tackle to the drum and lift the drum carefully sideways out of the front frame (Fig. 17). ! Danger Danger of squashing! Do not stand or step under loads being loaded.

Fig. 17

26. Examine all rubber buffers on the travel motor side (Fig. 18) for wear, replace if necessary. 27. Check the rectangular rubber buffers on the vibration motor side, replace if necessary.

Fig. 18

630

BOMAG

008 911 79

14.2

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. 19).

Fig. 19

Assemble the side plate 2. Attach the lifting tackle and assemble the side plate (Fig. 20).

i Note Apply sliding lacquer OKS 240 to threads and screw head contact face to ease assembly. 3. Turn in the front and rear fastening screws and tighten with 463 Nm.

Fig. 20

4. Turn in and tighten the fastening screws on the travel motor side (Fig. 21).

Fig. 21

Adjust the pretension of the rubber buffers. 5. On the vibration motor side measure the distance „X“ between spacer block 1 (Fig. 22) and side plate. 6. Calculate the thickness of the compensation plates. Nominal value: Distance „X“ + 2 mm 7. Turn in one screw (3) into each welded nut (2) on the spacer blocks and provide sufficient space to insert the compensation plates. Fig. 22

008 911 79

BOMAG

631

14.2

Removing and installing the drum 8.

Insert the compensation plates (Fig. 23).

9. Turn in the fastening screws. 10. Unscrew the screws from the welded nuts. 11. Tighten the fastening screws.

Fig. 23

Connecting the travel motor side 12. Connect hydraulic hoses to the travel motor ports according to the marks made during disassembly (Fig. 24). 13. Connect the plugs (Solenoid valve for travel speed range selection and speed sensor) and reassemble the guard plates (1) and (2).

Fig. 24

Connecting the vibration motor side 14. Connect the hydraulic hoses to the ports on the vibration motor according to the marking (Fig. 25).

Fig. 25

15. Connect hydraulic hoses to the slewing motor ports according to the marks made during disassembly (Fig. 26).

Fig. 26

632

BOMAG

008 911 79

14.2

Removing and installing the drum

16. Connect all cable plugs and reassemble the protection hood 1 (Fig. 27). Caution Ensure correct routing of the wiring harnesses! !

17. Connect the hydraulic hoses to the ports on the control valve block according to the marking. 18. Plug in both plugs (2) on the solenoid valve.

Fig. 27

19. Fasten the brackets (Fig. 28) for the hydraulic hoses on both sides.

Fig. 28

Adjusting the scrapers 20. Assemble the front scraper 1 (Fig. 29). 21. Assemble the rear scraper (2).

i Note Observe the adjustment measurement 30-35 mm.

Fig. 29

22. Assemble the protection hood (Fig. 30). Caution Check the hydraulic system for function and leak tightness before putting the machine back into service. !

Adjust the potentiometer (see Technical Manual VC). Adjust the slewing motor (see Technical Manual VC).

Fig. 30

008 911 79

BOMAG

633

14.3

Changing the rubber buffers and adjusting the pretension 14.3 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 (Fig. 3).

Fig. 3

634

BOMAG

008 911 79

Changing the rubber buffers and adjusting the pretension

14.3

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 79

BOMAG

635

14.3

Changing the rubber buffers and adjusting the pretension 15. Assemble the compensation shims (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

636

BOMAG

008 911 79

15 Drum

008 911 79

BOMAG

637

15.1

Repair overview for drum

Fig. 1 Vario drum

638

BOMAG

008 911 79

15.1

Repair overview for drum 1

Eccentric weight

2

Swivel motor

3

Swashing shaft

4

Vibrator shaft

5

Eccentric weight

6

Rectangular rubber buffer (BW 213, 4 pieces / BW 226, 8 pieces)

7

Vibration motor

8

Flanged hub

9

Mechanical seal

10 Side plate 11 Drum shell 12 Taper roller bearing 13 Intermediate rings 14 Spacer ring 15 Circlip 16 Clamping ring ! Caution a) The thread must be free of grease, oil, paint and conserving agents.

b) Fitting and contact surfaces of the connection between exciter unit and drum must be absolutely dry and free of grease, oil, paint and conserving agent. c) Allow the bearing to cool down before pressing in. d) Tighten the screws cross-wise.

008 911 79

BOMAG

639

15.1

Repair overview for drum

Fig. 2

Caution 4) Open the gearbox cover only after consulting BOMAG. !

1) (Fig. 2) Cover the bearing with grease AUTOL TOP 2000 Temp (00996001), fill the bearing housing with grease. 2) Protect the splined shaft with Optimol (00970037), fill the chambers with paste.

5) Assemble the O-ring with grease.

3) Coat the gearbox from inside with grease AUTOL TOP 2000 Temp (00996001).

640

BOMAG

008 911 79

15.1

Repair overview for drum

Fig. 3

1) Assemble the O-ring with grease (Fig. 3). 2) Protect the splined shaft with Optimol White (00970037), fill the chambers with paste. 3) Secure with LOCTITE Blue No. 243. 4) Sealed with Hylomar SQ32/M.

008 911 79

BOMAG

641

15.1

Repair overview for drum

Exciter fixation for vertical amplitude Caution The mechanical fixation for vertical amplitude adjustment must only be made by BOMAG. !

Fig. 5 Fixation of vertical amplitude

i

Note

Mechanical fixation for assembly of gearbox cover with weights pointing downward (vertical amplitude) (Fig. 5). ●

Motor is mounted to gearbox cover in zero position, this applies also for the gear wheel.

●

The motor is then swivelled with the gear for 90° (pumping) and assembled in this position.

Fig. 4 Fixation of vertical amplitude

i

Note

View from outside into drum (Fig. 4). Assembly position for gearbox: Eccentric weight vertical (vertical amplitude). a) Mark on swashing motor b) Middle of tooth on swashing motor (= zero position)

Fig. 6 Fixation of vertical amplitude

642

BOMAG

008 911 79

15.1

Repair overview for drum Exciter fixation for horizontal amplitude Caution The mechanical fixation for horizontal amplitude potentiometer adjustment must only be made by BOMAG. !

Fig. 8 Fixation Fig. 7 Fixation of horizontal amplitude

i

Note

View from outside into drum (Fig. 7). Position: Eccentric weights horizontal, horizontal amplitude. a) Mark on swashing motor b) Middle of tooth on swashing motor (= zero position)

Fig. 9 Fixation

008 911 79

BOMAG

643

15.2

Assembly of tapered roller bearing

Fig. 1 Cross-sectional drawing of right hand drum side

644

BOMAG

008 911 79

15.2

Assembly of tapered roller bearing 1 2

Swivel motor

3

Swashing shaft

4 5 6

Rectangular rubber buffer (BW 213, 4 pieces / BW 226, 8 pieces)

7

Vibration motor

8

Flanged hub

9

Mechanical seal

10 Side plate 11 Drum shell 12 Taper roller bearing 13 Intermediate rings 14 Spacer ring 15 Circlip 16 Clamping ring

Fig. 2 ●

1. Insert half of mechanical seal 9 (Fig. 2) into flanged hub (8).

●

Grease the seal ring and fill the space between mechanical seal and flanged hub with grease.

Fig. 3 ●

008 911 79

Attach the auxiliary assembly rings to the flanged hub 8 (Fig. 3).

BOMAG

645

15.2

Assembly of tapered roller bearing

Fig. 4 ●

2. Insert half of mechanical seal 9 (Fig. 4) into side plate (10).

●

Grease the sealing ring. Fig. 6

Brush some grease on the collar of the side plate (Fig. 6).

●

Fig. 5 ●

Use the centring sleeve to slide the side plate 10 (Fig. 5) on the flanged hub (8).

●

Remove the centring sleeve.

Fig. 7

Heat the inner ring of the 1st tapered roller bearing up to approx. 100°C.

●

Danger Danger of burning! !

Wear protective gloves.

646

●

Insert the inner race into the side plate (Fig. 7).

●

Press down with a pressing tool.

●

Fill the space between inner race and side plate collar with grease.

BOMAG

008 911 79

15.2

Assembly of tapered roller bearing

Fig. 8

Cool the outer race of the 1st tapered roller bearing with liquid nitrogen down to approx. -30°C.

●

Danger Persons handling liquid oxygen must learn the following safety instructions:

Fig. 9 ●

Insert the two matching intermediate rings of the tapered roller bearing set 13 (Fig. 9).

!

Safety instructions, handling low temperature liquid gases Safety instructions, lack of oxygen.

! Caution The bearing set must only be assembled with the associated intermediate rings. Replacement of individual bearings without intermediate rings is not permitted! ●

Safety instructions, oxygen enrichment.

Fill the chamber with grease.

Safety instructions, frost bites and congelation. ●

Assemble the outer race (Fig. 8).

●

Press down with a pressing tool.

Caution The outer race must firmly rest against the shoulder of the side plate. !

Fig. 10 ●

008 911 79

Cool the outer race of the 2nd tapered roller bearing with liquid nitrogen down to approx. -30°C.

BOMAG

647

15.2

Assembly of tapered roller bearing

Danger Persons handling liquid oxygen must learn the following safety instructions: !

Safety instructions, handling low temperature liquid gases

Caution During the assembly process rotate the side plate only to one direction, so that the tapered rollers in the bottom bearing rest against the big collar of the inner ring. !

Safety instructions, lack of oxygen. Safety instructions, oxygen enrichment. Safety instructions, frost bites and congelation. ●

Assemble the outer race (Fig. 10).

●

Press down with a pressing tool.

Fig. 13

Heat the inner ring of the 2nd tapered roller bearing up to approx. 100°C.

●

Danger Danger of burning! !

Wear protective gloves. Fig. 11 ●

Insert the spacer ring 14 (Fig. 11).

Fig. 12 ●

Remove the auxiliary assembly ring (Fig. 12).

648

●

Insert the inner ring (Fig. 13).

●

Press down with a pressing tool.

Fig. 14 ●

Install circlip 15 (Fig. 14).

BOMAG

008 911 79

15.2

Assembly of tapered roller bearing

Fig. 15

Fasten the clamping ring 16 (Fig. 15) with screws.

●

Caution When turning the side plate while tensioning the screws an increase in the required force should be noticed. !

Follow the procedure described next to tighten the screws: a) Tighten the screws crosswise with 80 Nm, then rotate the side plate three times. b) Retighten the screws crosswise with 100 Nm, rotate the side plate three times. c) Retighten the screws crosswise with 120 Nm, rotate the side plate three times. d) Mark the position of the screws to the clamping ring, then loosen one screw at a time and screw it back in with Loctite 2701 and tighten it to the mark. Inspection: There must be clearance between clamping ring and flanged hub, check with a feeler gauge.

008 911 79

BOMAG

649

15.2

650

Assembly of tapered roller bearing

BOMAG

008 911 79

16 Articulated joint, electric steering

008 911 79

BOMAG

651

16.1

Special tools 16.1 Special tools 1. Pressing device for rocker bearings

Fig. 1

2. Pressing sleeve for inner and outer rocker bearing races

Fig. 2

3. Guide pin

Fig. 3

4. Clamping device

Fig. 4

652

BOMAG

008 911 79

16.1

Special tools

008 911 79

BOMAG

653

16.2

654

Repair overview oscillating articulated joint

BOMAG

008 911 79

Repair overview oscillating articulated joint

008 911 79

BOMAG

16.2

655

16.2

656

Repair overview oscillating articulated joint

BOMAG

008 911 79

Repair overview oscillating articulated joint

008 911 79

BOMAG

16.2

657

16.3

Removing and installing the oscillating articulated joint 16.3 Removing and installing the oscillating articulated joint 1. Jack up the frame at the back on both sides and secure it with trestles or wooden blocks (Fig. 1). ! Danger Make sure that front and rear frames are properly secured against rolling and tipping over.

Danger of accident! Do not stand or step under loads being loaded. Do not work in the articulation area of the roller while the engine is running. Caution Do not start the engine during repair work on the articulated joint! !

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

658

BOMAG

008 911 79

Removing and installing the oscillating articulated joint

16.3

4. Unscrew the fastening screws and lift off the angle sensor (Fig. 5).

i Note Does not apply for BVC machines with the hydraulic steering option.

Fig. 4

5. Unscrew fastening screws 1 (Fig. 5) and take off axle holder (2). 6. Knock out bearing bolt (3). 7. Retract steering cylinder (4).

Fig. 5

Danger Danger of accident! !

8. Support the oscillating articulated joint in the middle with a suitable jack or a similar device. 9. Unscrew fastening screws 1 (Fig. 6) and take off with disc (2).

Fig. 6

10. Unscrew nuts 3 (Fig. 7) and take off the clamping washers (2). 11. Pull out the fastening screws (1). 12. Slightly raise the front frame and lower the oscillating articulated joint to the ground. 13. Pull out the oscillating articulated joint.

Fig. 7

008 911 79

BOMAG

659

16.3

Removing and installing the oscillating articulated joint Notes on assembly 14. Insert the bolt for the steering cylinder so that groove 2 (Fig. 8) is in line with tapped bores (1).

Fig. 8

i

Note Does not apply for BVC machines with the hydraulic steering option. 15. Align the angle sensor (Fig. 9).

i Note Observe the marks. 16. Teach the electric end stops for the steering angle sensor.

i Note Teaching the electric end stops of the steering angle sensor, see electrics of machine.

Fig. 9

660

BOMAG

008 911 79

16.4

Dismantling the oscillating articulated joint

16.4 Dismantling the oscillating articulated joint 1. Unscrew the nut from the long hexagon screw and pull out the hexagon screw downwards (Fig. 1). 2. Unscrew the screws for the upper cover. 3. Take off the upper cover with Belleville springs, shim and backing disc. 4. Remove the bottom cover.

Fig. 1

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. 2

6. Force inner race 1 (Fig. 5) 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. 3

008 911 79

BOMAG

661

16.4

Dismantling the oscillating articulated joint 9. Unscrew fastening screws 1 (Fig. 6). 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. 4

11. Lift console 1 (Fig. 7) off housing (2).

Fig. 5

12. Take the seal rings out of the console (Fig. 8).

Fig. 6

13. Remove the cover from the housing. 14. Take off shims 1 (Fig. 7), backing disc (2) and Belleville springs (3).

Fig. 7

662

BOMAG

008 911 79

16.4

Dismantling the oscillating articulated joint

15. Unscrew bolts 1 (Fig. 8) and take off cover (2).

Fig. 8

16. Take the intermediate ring out of the housing (Fig. 9).

Fig. 9

17. Place the plate 1 (Fig. 10) on the beam. 18. Attach the puller (2) to the housing (3) and separate the carrier from the rocker bearings.

Fig. 10

19. Pull the housing off the beam (Fig. 11).

Fig. 11

008 911 79

BOMAG

663

16.4

Dismantling the oscillating articulated joint 20. Drive the outer race of the friction bearing out of the housing (Fig. 12).

Fig. 12

21. Drive the friction bearing out of the housing (Fig. 13).

Fig. 13

22. Take seal ring 1 (Fig. 14) and V-ring (2) off the beam.

Fig. 14

23. Check rocker bearings, if necessary press out of the housing (Fig. 15).

Fig. 15

664

BOMAG

008 911 79

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 79

BOMAG

665

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. 5).

Fig. 4

6. Slide the housing over the beam (Fig. 6).

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. 7).

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. 8) in until it bottoms with the wider outer rim forward using pressing sleeve (2).

Fig. 7

666

BOMAG

008 911 79

16.5

Assembling the oscillating articulated joint

10. Press inner rocker bearing race 1 (Fig. 7) in until it bottoms, using pressing sleeve (2).

Fig. 8

11. Insert the intermediate ring (Fig. 8).

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 79

BOMAG

667

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 M16-8.8 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 4.7mm subtract the fixed value of (3.9 mm, BW177) (4.0 mm, BW213) to determine the shim thickness. Calculation example BW 177: 4,7 mm - 3,9 mm = 0,8 mm Shim thickness = 0,8 mm Calculation example BW 213: 4,7 mm - 4,0 mm = 0,7 mm Shim thickness = 0.7 mm 20. Remove the tensioning device.

668

BOMAG

008 911 79

16.5

Assembling the oscillating articulated joint

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 79

BOMAG

669

16.5

Assembling the oscillating articulated joint 26. Lift console 1 (Fig. 18) over the housing (2).

Fig. 18

Remove the bolts from both sides. 27. Turn four guide pins into the housing bores (Fig. 19).

Fig. 19

28. Slide the bolt over the guide pins and drive in until it bottoms (Fig. 20).

i

Note Spray the mating surfaces with sliding lacquer OKS 571 or cover with grease to ease assembly .

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

670

BOMAG

008 911 79

16.5

Assembling the oscillating articulated joint 29. Unscrew the guide pins .

30. Turn in the screws and tighten with 75 Nm (Fig. 22).

i Note Repeat steps 27 to 30 on the opposite side of the joint.

Fig. 22

31. Cover the rod with LOCTITE blue 243 and insert it into the upper joint bolt (Fig. 23).

i Note Does not apply for BVC machines with the hydraulic steering option.

Fig. 23

Assemble the rocker bearings on both sides. 32. Slide the backing discs over the bolt (Fig. 24).

Fig. 24

33. Drive the inner rocker bearing race on against the end stop with the wider outer rim forward (Fig. 25).

Fig. 25

008 911 79

BOMAG

671

16.5

Assembling the oscillating articulated joint 34. Spray the sliding surface of the outer rocker bearing race with sliding agent OKS 571. Caution Do not use any grease. !

35. Attach the outer rocker bearing race with the wider outer rim facing towards the outside (Fig. 26) and drive it in until it bottoms.

i

Note Repeat steps 32 to 35 on the opposite side of the joint.

Fig. 26

36. Attach the lower cover 1 (Fig. 27). 37. Turn in screws (2) and tighten crosswise.

Fig. 27

Determining the shim thickness 38. Determine the shim thickness, for this purpose insert rod 1 (Fig. 28) 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 M16-8.8 tightening torque 90Nm. !

Fig. 28

39. Measure the distance from outer rocker bearing race to console surface (Fig. 29) and write it down, e.g. 3.2mm.

i Note From this measured value of 3,2mm subtract the fixed value of 1,9mm to determine the shim thickness. Calculation example: 3,2mm - 1,9mm = 1,3mm Shim thickness = 1,3mm

Fig. 29

40. Remove the tensioning device. 672

BOMAG

008 911 79

16.5

Assembling the oscillating articulated joint

41. Insert shims 2 (Fig. 30) of appropriate thickness and backing disc (1) into the upper cover.

Fig. 30

42. Lay the Belleville springs into the upper cover with the curvature pointing down (Fig. 31).

Fig. 31

43. Assemble the upper cover with Belleville springs, shims and backing disc (Fig. 32). 44. Turn in the cover fastening screws and tighten crosswise. 45. Push in the long hexagon screw from underneath, assemble the washer, screw on the nut and tighten with 120 Nm.

Fig. 32

008 911 79

BOMAG

673

16.5

674

Assembling the oscillating articulated joint

BOMAG

008 911 79

17 Articulated joint, hydraulic steering

008 911 79

BOMAG

675

17.1

Special tools 17.1 Special tools 1. Pressing mandrel for rocker bearings

Fig. 1

2. Pressing sleeve for outer race of rocker bearing

Fig. 2

3. Pressing sleeve for inner race of rocker bearing

Fig. 3

4. Guide journal

Fig. 4

676

BOMAG

008 911 79

17.1

Special tools 5. Clamping device

Fig. 5

6. Disassembly device

Fig. 6

008 911 79

BOMAG

677

17.2

Repair overview oscillating articulated joint

Fig. 1

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 Beam

8

Self-aligning bearing

19 Friction bearing

9

Console

20 V-ring

10 Belleville springs

21 Seal ring

11 Shim/supporting disc

678

BOMAG

008 911 79

Repair overview oscillating articulated joint

17.2

Fig. 2

008 911 79

BOMAG

679

17.2

Repair overview oscillating articulated joint

Fig. 3

680

BOMAG

008 911 79

Removing and installing the oscillating articulated joint

17.3

17.3 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

008 911 79

BOMAG

681

17.3

Removing and installing the oscillating articulated joint 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

682

BOMAG

008 911 79

17.4

Dismantling the oscillating articulated joint

17.4 Dismantling the oscillating articulated joint 1. Unscrew the nuts from hexagon screw 1 (Fig. 1) and pull out the hexagon screw. 2. Unscrew the screws (2) for the cover.

Fig. 1

3. Take off the cover with Belleville springs, shim and backing disc (Fig. 2). 4. Disassemble also the cover from the opposite side.

i Note No Belleville springs, shim and backing disc are under this cover.

Fig. 2

5. Drive the console with a plastic hammer to one side against the end stop (Fig. 3).

i Note The outer race of the rocker bearing is thereby stripped off.

Fig. 3

008 911 79

BOMAG

683

17.4

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

684

BOMAG

008 911 79

17.4

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

008 911 79

BOMAG

685

17.4

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

686

BOMAG

008 911 79

17.4

Dismantling the oscillating articulated joint

23. Check rocker bearings, if necessary press out of the housing (Fig. 16).

Fig. 16

008 911 79

BOMAG

687

17.5

Assembling the oscillating articulated joint 17.5 Assembling the oscillating articulated joint 1. If previously disassembled, press the rocker bearing fully into the housing with a pressing mandrel (Fig. 1).

i Note Apply sliding lacquer OKS 571 to mating surfaces to ease assembly Caution Do not use any grease. !

Fig. 1

2. Slide the new V-ring on the beam against the stop with the lip facing up (Fig. 2).

Fig. 2

3. Lay the seal ring into the beam (Fig. 3). 4. Fill the space between V-ring and seal ring with multi-purpose grease.

Fig. 3

688

BOMAG

008 911 79

17.5

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

008 911 79

BOMAG

689

17.5

Assembling the oscillating articulated joint 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

690

BOMAG

008 911 79

17.5

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.

008 911 79

BOMAG

691

17.5

Assembling the oscillating articulated joint 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

692

BOMAG

008 911 79

17.5

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

008 911 79

BOMAG

693

17.5

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

694

BOMAG

008 911 79

17.5

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.

008 911 79

BOMAG

695

17.5

Assembling the oscillating articulated joint 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

696

BOMAG

008 911 79

17.5

Assembling the oscillating articulated joint

45. Assemble the washer, turn on and tighten the nut with 120 Nm (Fig. 33).

Fig. 33

008 911 79

BOMAG

697

17.5

698

Assembling the oscillating articulated joint

BOMAG

008 911 79

18 Suppliers documentation

008 911 79

BOMAG

699

700

BOMAG

008 911 79

18.1 Travel pump / vibration pump series 90R

008 911 79

BOMAG

701

18.1

702

Travel pump / vibration pump series 90R

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Axial Piston Pumps and Motors Service Manual

008 911 79

BOMAG

703

18.1

Travel pump / vibration pump series 90R

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

704

BOMAG

008 911 79

Travel pump / vibration pump series 90R

Series 90

18.1 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 79

BOMAG

705

18.1

Travel pump / vibration pump series 90R

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

706

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

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 79

BOMAG

707

18.1

Travel pump / vibration pump series 90R

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

708

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Functional Description

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 79

BOMAG

709

18.1

Travel pump / vibration pump series 90R

Series 90

Functional Description

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

710

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Functional Description

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

Multi-Function Valve

9

008 911 79

BOMAG

711

18.1

Travel pump / vibration pump series 90R

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

Multi-Function Valve

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

712

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Functional Description

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 79

BOMAG

713

18.1

Travel pump / vibration pump series 90R

Series 90

Functional Description Pressure Override (POR) - 180 Frame Size Only

To Control

Multi-Function Valve

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"

Multi-Function Valve

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

714

BOMAG

008 911 79

Travel pump / vibration pump series 90R

Series 90

18.1 Functional Description

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 79

BOMAG

715

18.1

Travel pump / vibration pump series 90R

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

716

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Functional Description

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 79

BOMAG

717

18.1

Travel pump / vibration pump series 90R

Series 90

Functional Description

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

718

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Technical Specifications

Technical Specifications General Specifications Port Connections (for details see chapter "Pressure Measurement")

Design 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 79

BOMAG

719

18.1

Travel pump / vibration pump series 90R

Series 90

Technical Specifications

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

720

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Technical Specifications

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 79

BOMAG

721

18.1

Travel pump / vibration pump series 90R

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

722

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Pressure Measurement

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

System Pressure Gauge Port M1

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 79

BOMAG

723

18.1

Travel pump / vibration pump series 90R

Series 90

Pressure Measurement

System Pressure Gauge Port M2

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

724

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Pressure Measurement

Fixed Motor

Gauge Size and Fitting

Port

Function

Gauge Size and Fitting

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 Rear View

Speed Sensor

Left Side 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 79

BOMAG

725

18.1

Travel pump / vibration pump series 90R

Series 90

Pressure Measurement

Variable Motor

Port

Function

Gauge Size and Fitting

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

Gauge Size and Fitting

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

System Pressure Gauge Port M2

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)

System Pressure Port B

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

726

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

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 79

BOMAG

727

18.1

Travel pump / vibration pump series 90R

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

728

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

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.

If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center.

27

008 911 79

BOMAG

729

18.1

Travel pump / vibration pump series 90R

Series 90

Toubleshooting

Transmission Operates Normally in One Direction Only 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.

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.

If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center.

System Will Not Operate in Either Direction Check

Description

Action

1. Oil level in reservoir.

Insufficient hydraulic fluid to supply system loop.

Fill reservoir to proper level.

2. Input to pump control.

Input to control module is operating improperly.

Check control input and repair or replace as necessary.

3. Pump displacement control.

Control linkages are not secure, control orifices are blocked, etc.

Repair or replace control module as necessary.

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

730

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Toubleshooting

10. Pump displacement control.

Control linkages are not secure, control orifices are blocked, etc.

Repair or replace control module as necessary.

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).

If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center.

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.

If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center.

Improper Motor Output Speed Check

Description

Action

1. Oil level in reservoir.

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.

Internal leakage will reduce system pressure.

Check for leakage in O-rings, gaskets, and other fittings. Repair unit as required, or replace leaky unit.

If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center.

29

008 911 79

BOMAG

731

18.1

Travel pump / vibration pump series 90R

Series 90

Toubleshooting

Excessive Noise and/or Vibration Check

Description

Action

1. Oil in reservoir.

Insufficient hydraulic fluid will lead to cavitation.

Fill reservoir to proper level.

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.

If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center.

System Response is Sluggish Check

Description

Action

1. Oil level in reservoir.

Insufficient hydraulic fluid will reduce output pressure.

Fill reservoir to proper level.

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.

Internal leakage will reduce system pressure.

Check for leakage in O-rings, gaskets, and other fittings.

If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center.

30

732

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

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 79

BOMAG

733

18.1

Travel pump / vibration pump series 90R

Series 90

Inspections and Adjustments

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

734

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Inspections and Adjustments

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 79

BOMAG

735

18.1

Travel pump / vibration pump series 90R

Series 90

Inspections and Adjustments

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

736

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Inspections and Adjustments

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 Size 1-1/16 inch 1-3/8 inch T002 272E

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 79

BOMAG

737

18.1

Travel pump / vibration pump series 90R

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

738

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Inspections and Adjustments

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 79

BOMAG

739

18.1

Travel pump / vibration pump series 90R

Series 90

Inspections and Adjustments

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

740

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Inspections and Adjustments

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 79

BOMAG

741

18.1

Travel pump / vibration pump series 90R

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

742

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Inspections and Adjustments

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 79

BOMAG

743

18.1

Travel pump / vibration pump series 90R

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

744

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Inspections and Adjustments

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 79

BOMAG

745

18.1

Travel pump / vibration pump series 90R

Series 90

Inspections and Adjustments

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

746

BOMAG

008 911 79

Travel pump / vibration pump series 90R

Series 90

18.1 Inspections and Adjustments

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 79

BOMAG

747

18.1

Travel pump / vibration pump series 90R

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

748

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Inspections and Adjustments

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 79

BOMAG

749

18.1

Travel pump / vibration pump series 90R

Series 90

Inspections and Adjustments

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

750

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Inspections and Adjustments

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 79

BOMAG

751

18.1

Travel pump / vibration pump series 90R

Series 90

Inspections and Adjustments

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 Turck Connector

Speed Sensor with Packard 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

752

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

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.

Protect all exposed sealing surfaces and open cavities from damage and foreign material.

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.

items must be kept free of foreign materials and chemicals.

51

008 911 79

BOMAG

753

18.1

Travel pump / vibration pump series 90R

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

SAE Flange MV

Cartridge Flange MV

52

754

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

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)

9/16-18 O-ring 11/16 inch Hex Wrench

37 Nm (27 lbf ft)

9/16-18 O-ring 1/4 inch Internal Hex Wrench

23 Nm (17 lbf ft)

3/4-16 O-ring 7/8 inch Hex Wrench

68 Nm (50 lbf ft)

3/4-16 O-ring 5/16 inch Internal Hex Wrench

68 Nm (50 lbf ft)

7/8-14 O-ring 1 inch Hex Wrench

95 Nm (70 lbf ft)

7/8-14 O-ring 3/8 inch Internal Hex Wrench

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 79

BOMAG

755

18.1

Travel pump / vibration pump series 90R

Series 90

Minor Repair Instructions

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

756

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

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 79

BOMAG

757

18.1

Travel pump / vibration pump series 90R

Series 90

Minor Repair Instructions

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

Wrench Size 1-1/4 inch 1-5/8 inch T002 284E

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 Actuator

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

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

758

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

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

Wrench Size 1-1/16 inch 1-5/8 inch T002 286E

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 79

BOMAG

759

18.1

Travel pump / vibration pump series 90R

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

760

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90 Note:

Minor Repair Instructions

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 79

BOMAG

761

18.1

Travel pump / vibration pump series 90R

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

762

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

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.

Minor Repair Instructions

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 79

BOMAG

763

18.1

Travel pump / vibration pump series 90R

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

764

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90 6.

Minor Repair Instructions

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 79

BOMAG

765

18.1

Travel pump / vibration pump series 90R

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

Torque 70 Nm (52 lbf ft) 122 Nm (90 lbf ft) 156 Nm (115 lbf ft) T002 291E

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

Torque 70 Nm (52 lbf ft) 122 Nm (90 lbf ft) 156 Nm (115 lbf ft) T002 292E

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

766

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

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 79

BOMAG

767

18.1

Travel pump / vibration pump series 90R

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

768

BOMAG

008 911 79

Travel pump / vibration pump series 90R

Series 90

18.1 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 79

BOMAG

769

18.1

Travel pump / vibration pump series 90R

Series 90

Minor Repair Hydraulic and Electric Displacement Controls 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

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

770

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Minor Repair

3-Position (FNR) Electric Control 1.

Thoroughly clean external surfaces prior to removal of control.

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 79

BOMAG

771

18.1

Travel pump / vibration pump series 90R

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

772

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

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 79

BOMAG

773

18.1

Travel pump / vibration pump series 90R

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

774

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

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 79

BOMAG

775

18.1

Travel pump / vibration pump series 90R

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

776

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

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).

O-ring Backup Washer

O-ring Backup Washer

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.

O-ring Backup Washer

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.

O-ring Backup Washer

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

O-ring Backup Washer

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 79

BOMAG

777

18.1

Travel pump / vibration pump series 90R

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

778

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

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

1-1/16 in. hex wrench Torque: 13 Nm (10 lbf ft) After adjustment!

or

Housing Plug 1/4 in. int. hex wrench Torque: 23 Nm (17 lbf ft)

Speed Sensor

90000858E

Typical Location of Speed Sensor - MF

1-1/16 in. hex wrench Torque: 13 Nm (10 lbf ft) After adjustment!

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 79

BOMAG

779

18.1

Travel pump / vibration pump series 90R

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

780

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

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 79

BOMAG

781

18.1

Travel pump / vibration pump series 90R

Series 90

Exploded View Parts Drawings / Parts Lists

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

782

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Exploded View Parts Drawings / Parts Lists

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 79

BOMAG

783

18.1

Travel pump / vibration pump series 90R

Series 90

Exploded View Parts Drawings / Parts Lists

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

784

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Exploded View Parts Drawings / Parts Lists

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

Ames, Iowa, U.S.A. Model Code

Model Code Model Number

Neumünster, Germany Typ

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

Place of Manufacture

Name Plate (German Production)

Name Plate (U.S.A. Production)

83

008 911 79

BOMAG

785

18.1

Travel pump / vibration pump series 90R

Series 90

Exploded View Parts Drawings / Parts Lists

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

786

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Exploded View Parts Drawings / Parts Lists

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

Ames, Iowa, U.S.A. Model Code

Neumünster, Germany Typ

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

Ames, Iowa, U.S.A. Model Code

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.

Neumünster, Germany Typ

Model Code

Ident Nr

312918 N – 91 – 26 – 67890 Serial No. Fabr Nr MADE IN GERMANY

Place of Manufacture

Place of Manufacture

Name Plate (German Production)

Name Plate (U.S.A. Production)

85

008 911 79

BOMAG

787

18.1

Travel pump / vibration pump series 90R

Series 90

Exploded View Parts Drawings / Parts Lists

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

788

BOMAG

008 911 79

18.1

Travel pump / vibration pump series 90R

Series 90

Exploded View Parts Drawings / Parts Lists

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

Ames, Iowa, U.S.A. Model Code

Neumünster, Germany Typ

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.

Place of Manufacture

Name Plate (U.S.A. Production) 87

008 911 79

BOMAG

789

18.1

Travel pump / vibration pump series 90R

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

790

BOMAG

008 911 79

18.2 Vibration motor A2FM

008 911 79

BOMAG

791

18.2

792

Vibration motor A2FM

BOMAG

008 911 79

18.2

Vibration motor A2FM Industrial Hydraulics

Electric Drives and Controls

Linear Motion and Assembly Technologies

Pneumatics

Service Automation

Mobile Hydraulics

Konstantmotor A2FM/E Fixed Displacement Motor A2FM/E

RDE 91 001-03-R/05.03 ersetzt / replaces 04.00

Baureihe / Series 61 Reparaturanleitung / Repair Instructions

008 911 79

BOMAG

793

18.2 Bosch Rexroth AG | Mobile Hydraulics

2

A2F | RDE 91motor 001-03-R/05.03 Vibration A2FM

Hinweis / Inhalt Notice / Contents

HINWEIS Bezeichnungen, Beschreibungen und Darstellungen entsprechen dem Informationsstand zum Zeitpunkt der Drucklegung dieser Unterlage.

NOTICE Specifications, descriptions and illustrative material shown here in were as accurate as known at the time this publication was approved for printing.

Änderungen können den Service am Produkt beeinflussen, Verpflichtungen entstehen uns daraus nicht.

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.

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.

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 guar-anteed by appropriate measures. Expert knowledge, the precondition of any service work, can be obtained in our training courses.

INHALT

Seite/ Page

A2F Schnittbild Allgemeine Reparaturhinweise Dichtsätze und Baugruppen Triebwelle abdichten Anschlußplatte abdichten Triebwerk ausbauen Überprüfungshinweise Triebwerk einbauen Anziehdrehmomente Sicherheitsbestimmungen

794

CONTENTS

A2F 3-6 7 8-9 10 11-14 15-16 17-18 19-21 22-24 25

Sectional view General repair instructions Seal kits and sub-assemblies Sealing of the drive shaft Sealing of the cover plate Removal the rotary group Inspection guidelines Installing rotary group Tightening torques Safety regulations

BOMAG

008 911 79

RDE 91 001-03-R/05.03 | A2F Vibration motor A2FM

Mobile Hydraulics | Bosch Rexroth AG

18.23

Schnittbild Sectional view

A2FM

Pos.B

Pos.D

Pos.A

Meßpunkte: Siehe Serviceinfo

008 911 79

Measuring points: See service information

BOMAG

795

18.2 Bosch Rexroth AG | Mobile Hydraulics

4

A2F | RDE 91motor 001-03-R/05.03 Vibration A2FM

Schnittbild Sectional view

A2FM mit Spülventil / A2FM with flushing valve

796

BOMAG

008 911 79

RDE 91 001-03-R/05.03 | A2F Vibration motor A2FM

Mobile Hydraulics | Bosch Rexroth AG

18.25

Schnittbild Sectional view

A2FE

008 911 79

BOMAG

797

18.2 Bosch Rexroth AG | Mobile Hydraulics

6

A2F | RDE 91motor 001-03-R/05.03 Vibration A2FM

Schnittbild Sectional view

A2FE

798

BOMAG

008 911 79

RDE 91 001-03-R/05.03 | A2F Vibration motor A2FM

Mobile Hydraulics | Bosch Rexroth AG

18.27

Allgemeine Reparaturhinweise General repair instructions

Achtung! Nachfolgende Hinweise bei allen Reparaturarbeiten an Hydraulikaggregaten beachten! Attention! Observe the following notices when carrying out repair work at hydraulic aggregates!

Alle Öffnungen der Hydraulikaggregate verschließen. Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern. Nur ORIGINAL BRUENINGHAUS HYDROMATIK -Ersatzteile verwenden. Replace all seals. Use only OR IG I NAL B R U E N I NG HAUS HYDROMATIK spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen. Achtung: Nacharbeiten an Dichtflächen z.B. durch Schleifpapier kann die Oberfläche beschädigen. Check all seal and sliding surfaces for wear. Attention: Rework of sealing area f. ex. with abrasive paper can damage surface.

Hydraulikaggregate vor Inbetriebnahme mit Betriebsmedium befüllen bzw. entlüften. Before start-up fill up hydraulic aggregates with hydraulic oil respectively deaerate.

008 911 79

BOMAG

799

18.2 Bosch Rexroth AG | Mobile Hydraulics

8

A2F | RDE 91motor 001-03-R/05.03 Vibration A2FM

Dichtsätze und Baugruppen Seal kits and sub-assemblies

Dichtsatz Seal kit

Triebwerk, mechanischer Teil / Rotary group, mechanical part

Triebwerk, mechanischer Teil; muß abgestimmt werden Pos. "A". (siehe Serviceinfo)

Rotary group, mechanical part; has to be adjusted to item "A". (see service info)

Lagersatz, komplett abgestimmt. Pos. B (Stützscheibe und Sicherungsring nicht tauschbar) zusätzliche Abstimmung Pos. "A". (siehe Serviceinfo) Bearing set, matched Item B (support disc and circlip are not exchangeable) Additional adjustment item "A". (see service info)

800

BOMAG

008 911 79

RDE 91 001-03-R/05.03 | A2F Vibration motor A2FM

Mobile Hydraulics | Bosch Rexroth AG

18.29

Dichtsätze und Baugruppen Seal kits and sub-assemblies

Triebwerk, hydraulischer Teil / Rotary group, hydraulic part

Triebwerk, hydraulischer Teil; Abstimmung hydraulischer Teil Pos. "D". (siehe Serviceinfo) Rotary group, hydraulic part; Adjustment of the hydraulic part Pos. "D". (see service info)

Triebwerk komplett; - fertig vorabgestimmt Abstimmung hydraulischer Teil Pos. "D". (siehe Serviceinfo) Complete rotary group, - pre-adjusted Adjustment of the hydraulic part Pos. "D". (see service info)

Spülventil Flushing valve

Ventil Valve

008 911 79

BOMAG

801

18.2 Bosch Rexroth AG | Mobile Hydraulics

10

A2F | RDE 91motor 001-03-R/05.03 Vibration A2FM

Triebwelle abdichten Sealing of the drive shaft

Bei nicht verzahnten Triebwellen: Paßfeder abnehmen. Triebwelle abkleben, For non-splined shafts: remove key. Protect the drive shaft (e.g. tape).

Sicherungsring ausbauen, Verschlußring abdrücken Remove circlip, prise off cover.

Sichtkontrolle Wellendichtring (1), Verschlußring (2), Triebwelle (3), Gehäuse (4), O-Ring (5). Visual check Shaft seal (1), cover (2), drive shaft (3), housing (4), O-ring (5).

802

BOMAG

008 911 79

RDE 91 001-03-R/05.03 | A2F Vibration motor A2FM

Mobile Hydraulics | Bosch Rexroth AG

11 18.2

Triebwelle abdichten Sealing of the drive shaft

Wellendichtring demontieren. Remove shaft seal.

Neuen Wellendichtring lagerichtig mit passender Büchse einpressen. Press in the new shaft seal,ensuring that it is correctly orientated, using a suitable bush.

Neuen O-Ring einlegen, auf bündiges Anliegen achten. O-Ring sowie Dicht- und Staublippe des Wellendichtringes einfetten. (siehe Serviceinfo) Fit new O-ring, ensure that it is correctly located. Grease the O-ring as well as the seal and dust lips of the shaft seal. (see service information)

Sicherungsring einbauen. Sitzkontrolle des Sicherungsringes in der Nut. Fit circlip. Check to ensure that the circlip is correctly located within the groove.

008 911 79

BOMAG

803

18.2 Bosch Rexroth AG | Mobile Hydraulics

12

A2F | RDE 91motor 001-03-R/05.03 Vibration A2FM

Anschlußplatte abdichten Sealing of the cover plate

Lage der Anschlußplatte zum Gehäuse kennzeichnen (Pfeil), Befestigungsschrauben lösen. Mark the position of the cover plate with regard to the housing (arrow), loosen the fixing screws.

Anschlußplatte um Verdrillstift schwenken (1) und abheben (2). Swing the connection plate about the locating pin (1) and lift off (2).

804

BOMAG

008 911 79

RDE 91 001-03-R/05.03 | A2F Vibration motor A2FM

Mobile Hydraulics | Bosch Rexroth AG

13 18.2

Anschlußplatte abdichten Sealing of the cover plate

Auf Montagestellung des Verdrillstiftes achten (Pfeile). Take the assembly position of the locating pin (arrow) into account.

Saugseite / Suction side

Druckseite / Pressure side

Pumpe, Drehrichtung rechts. (Blick auf sphärische Fläche.) Druckseite / Pressure side

Saugseite / Suction side

Pump, clockwise rotation. (viewed on spherical surface.)

Pumpe, Drehrichtung links. (Blick auf sphärische Fläche.) Pump, anti-clockwise rotation. (viewed on spherical surface.)

Motor, beide Drehrichtungen. (Blick auf sphärische Fläche.) Motor, bi-directional. (Viewed on spherical surface.)

008 911 79

BOMAG

805

18.2 Bosch Rexroth AG | Mobile Hydraulics

14

A2F | RDE 91motor 001-03-R/05.03 Vibration A2FM

Anschlußplatte abdichten Sealing of the cover plate

Sichtkontrolle O-Ring (1), Einstich (2), Platte (3). Visual check O-ring (1), Groove (2), Plate (3).

Neuen O-Ring einlegen, zuvor leicht einfetten. Lightly grease and fit O-ring.

Anschlußplatte aufsetzen, auf Kennzeichnung und Lage des Verdrillstiftes achten. Place the cover plate onto the housing taking into account the location mark and position of the locating pin.

Befestigungsschrauben mit Drehmomentenschlüssel anziehen. Tighten fixing screws using a torque wrench.

806

BOMAG

008 911 79

RDE 91 001-03-R/05.03 | A2F Vibration motor A2FM

Mobile Hydraulics | Bosch Rexroth AG

15 18.2

Triebwerk ausbauen Removal the rotary group

Lagersatz / Bearing set

Demontage der Anschlußplatte. Steuerplatte abheben. Zylinder am Mittelzapfen mit Schraube befestigen. Removal of the connection plate. Lift off the control plate. Secure the cylinder to the centre pin using a screw.

Gewindestift,Zylinderschraube / Threaded pin,socket head screw

008 911 79

BOMAG

NG / Size

(mm)

10; 12; 16 23; 28; 32 45 56; 63 80; 90 107; 125; 131 160; 180

M3 x 35 M5 x 45 M5 x 50 M5 x 55 M5 x 60 M6 x 70 M6 x 85

807

18.2 Bosch Rexroth AG | Mobile Hydraulics

16

A2F | RDE 91motor 001-03-R/05.03 Vibration A2FM

Triebwerk ausbauen Removal the rotary group

Verschlußring, O-Ring und Paßscheibe ausbauen. Remove the cover, O-ring and shim.

Triebwerk mit Vorrichtung ausbauen. Withdraw the rotary group using an extractor.

Befestigungsschraube ausbauen. Zylinder abheben. Remove the fixing screw. Lift off the cylinder.

Rückzugplatte demontieren, Schrauben sind eingeklebt. Komplettes Triebwerk bei ca. 120o C im Ölbad erwärmen. Danach Befestigungsschrauben lösen! Disassemble the retaining plate, screws are locked with an adhesive. Heat up the complete rotary group in an oil bath to approx 120o C, then remove the fixing screws.

808

BOMAG

008 911 79

RDE 91 001-03-R/05.03 | A2F Vibration motor A2FM

Mobile Hydraulics | Bosch Rexroth AG

17 18.2

Überprüfungshinweise Inspection guidelines

1

2

4

4

3

Triebwelle 1. kein Passungsrost, nicht ausgeschlagen. 2. keine Einlaufspuren, riefenfrei. 3. Kalotten riefenfrei und keine Pittings. 4. Keine Laufspuren (Lagerdreher)

3 Drive shaft 1. No wear, or fretting 2. No traces of wear, free of scratches. 3. Cups free of wear and no pitting. 4. No traces of wear, (bearing rotation).

1 1. Axiales Kolbenspiel 1. Axial play of piston.

Alt / Old Kolben Riefenfrei, keine Pittings. Piston Free of scratches, no pitting.

Neu / New

1

2

Mittelzapfen 1. Riefenfrei, ohne Pittings. 2. Riefenfrei. Center pin 1. Free of scratches, no pittings. 2. Free of scratches.

Rückzugplatte Riefenfrei, keine Ausbrüche. Retaining plate Free of scratches, no wear.

008 911 79

BOMAG

809

18.2 Bosch Rexroth AG | Mobile Hydraulics

18

A2F | RDE 91motor 001-03-R/05.03 Vibration A2FM

Überprüfungshinweise Inspection guidelines

Zylinder/Steuerplatte 1. Bohrungen riefenfrei, nicht ausgelaufen. 2. Gleichmäßiges Tragbild, riß- und riefenfrei. Cylinder / control plate 1. Bores unscratched, and no traces of wear. 2. Even load distribution, free of cracks and grooves.

Gehäuse Im Lagerbereich riefenfrei und keine Einlaufspuren. Housing No traces of wear in the bearing area.

Nur kompletten Kolbensatz austauschen. Only exchange the pistons as a complete set.

Zylinder und Steuerplatte nur gemeinsam austauschen. Only replace the cylinder and control plate as a pair.

810

BOMAG

008 911 79

RDE 91 001-03-R/05.03 | A2F Vibration motor A2FM

Mobile Hydraulics | Bosch Rexroth AG

19 18.2

Triebwerk einbauen Installing rotary group

Triebwelle mit Lager vormontiert verwenden. Use a pre-assembled drive shaft with bearings.

Abstimmung Pos. A / Adjustment item A

S

A = A* + S S = Nennmaß - Sicherungsring /Safety ring

A*

A

Rückzugplatte mit Kolben und Mittelzapfen einsetzen. Schrauben mit Precote-Beschichtung verwenden. Fit retaining plate complete with pistons and centre pin. Uses screws with a Precote coating.

1 Druckfeder (1) und Abstimmscheibe (2) einbauen. Fit the compression spring (1) and shim(2).

2

Zylinder in Neutralposition befestigen. Fix the cylinder in the neutral position.

008 911 79

BOMAG

811

18.2 Bosch Rexroth AG | Mobile Hydraulics

20

A2F | RDE 91motor 001-03-R/05.03 Vibration A2FM

Triebwerk einbauen Installing rotary group

Triebwerk max. ausschwenken. Swivel the rotary group to max.

Neuer Radialwellendichtring montiert? Is the new shaft seal fitted?

Gehäuse auf ca. 80o C erwärmen. Heat the housing to approx. 80o C.

Heißes Gehäuse bis zum Anschlag aufsetzen. Push on the hot housing until the stop is reached.

Neue Montagestellung. New assembly position.

812

BOMAG

008 911 79

RDE 91 001-03-R/05.03 | A2F Vibration motor A2FM

Mobile Hydraulics | Bosch Rexroth AG

21 18.2

Triebwerk einbauen Installing rotary group

Paßscheibe, O-Ring einlegen. Verschlußring montieren. O-Ring, Zwischenraum Wellendichtring einfetten (siehe Serviceinfo). Fit the shim and O-ring. Then fit the cover. Grease the O-ring as well as the seal and dust lipsof the shaft seal.

Triebwerk gegen Verschlußring ziehen. Kontrolle: Verschlußring spielfrei. Pull the rotary group against the cover. Check: to see that the cover is free of play.

Befestigungsschraube ausbauen. Steuerplatte lagerichtig aufsetzen. Fertigmontage Abstimmung Pos. D - siehe Serviceinfo Remove fixing screw. Fit the control plate into its correct location. Final assembly For adjustment of Pos. D - see service info

Abstimmung Pos. D / Adjustment item D Pos. D

Anschlüsse mit Staubschutz abdichten. Korrosionsschutz (innen/außen). Fertig! Seal connections to protect against dust. Corrosion proctection (internal/external). Assembly complete.

008 911 79

BOMAG

813

18.2 Bosch Rexroth AG | Mobile Hydraulics

22

A2F | RDE 91motor 001-03-R/05.03 Vibration A2FM

Montageanweisung für Anziehdrehmomente Assembly guidelines for tightening torques

1.

Schaftschrauben (nach N 08.001)

1.

Die Werte gelten für Schaftschrauben mit metrischem ISO-Gewinde nach DIN 13 Teil 13, sowie Kopfauflagemaßen nach DIN 912 Zylinderschrauben, DIN 931 Sechskantschrauben mit Schaft bzw. DIN 933 Sechskantschrauben mit Gewinde bis Kopf.

Bolts (to N 08.001) The values stated are valid for bolts with metric ISO threads to DIN 13 part 13, as well as head areas to DIN 912 socked head cap screws, DIN 931 hexagon bolt or DIN 933 hexagon bolts with threads up to the head.

Festigkeitsklassen / Tensile strength class Gewinde / Thread

814

8.8 10.9 12.9 Anziehdrehmoment / Tightening torque M A in Nm

M3 M4

1,1 3,1

1,6 4,5

1,9 5,3

M5 M6

6,1 10,4

8,9 15,5

10,4 18

M8 M10

25 51

37 75

43 87

M12 M14

87 140

130 205

150 240

M16 M18

215 300

310 430

370 510

M20 M22

430 580

620 830

720 970

M24

740

1060

1240

BOMAG

008 911 79

RDE 91 001-03-R/05.03 | A2F Vibration motor A2FM

Mobile Hydraulics | Bosch Rexroth AG

23 18.2

Montageanweisung für Anziehdrehmomente Assembly guidelines for tightening torques

Verschlußschrauben mit Innensechskant und Profildichtring (nach N 02.009).

2.

Plugs with internal hexagon and profile seal ring (to N 02.009).

G

2.

EOLASTICDichtung / Seal

008 911 79

Gewinde / Thread

Anziehdrehmoment / Tightening torque MA in Nm

Gewinde / Thread

Anziehdrehmoment Tightening torque MA in Nm

M8 x 1 M10 x 1 M12 x 1,5 M14 x 1,5 M16 x 1,5 M18 x 1,5 M20 x 1,5 M22 x 1,5 M26 x 1,5 M27 x 2 M30 x 1,5 M33 x 2 M42 x 2 M48 x 2

5 10 20 30 35 40 50 60 70 90 100 140 240 300

G 1/8 A G 1/4 A G 3/8 A G 1/2 A G 3/4 A G1 A G 1 1/4 A G 1 1/2 A

10 30 35 60 90 140 240 300

BOMAG

815

18.2 Bosch Rexroth AG | Mobile Hydraulics

24

A2F | RDE 91motor 001-03-R/05.03 Vibration A2FM

Montageanweisung für Anziehdrehmomente Assembly guidelines for tightening torques

7.

Linsenschrauben

7.

mit Innen-TORX, Gewindevorbeschichtung mit "precote"

Oval head screw with inner TORX, thread precoated with "precote"

Standard / Standard

precote 80 - Rot / Red

Variante / Variant

precote 86 - Blau / Blue *

Ι 2602493 Ι 2602395

M5 x 16 M6 x 20

siehe Stückliste / as to parts list

* mit Unterkopfbeschichtung - farblos * with head bottom coating - colorless

Gewinde / Thread M3

816

Festigkeitsklassen / Tensile strength class 10.9 Anziehdrehmoment / Tightening torque M A in Nm 2,1

M4 M5

4,7 9,1

M6 M8

15,8 37,7

BOMAG

008 911 79

RDE 91 001-03-R/05.03 | A2F Vibration motor A2FM

Mobile Hydraulics | Bosch Rexroth AG

25 18.2

Sicherheitsbestimmungen Safety regulations

Allgemein

General advice

● Machen Sie sich mit der Ausstattung der Maschine vertraut. ● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den Bedien- und Steuerelementen sowie der Arbeitsweise der Maschine vertraut gemacht haben. ● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, Sicherheitsschuhe und Gehörschutz. ● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ● Benutzen Sie die Maschine nur für den ihr zugedachten Zweck.

● Make yourself familiar with the equipment of the machine. ● Only operate the machine if your are completely familiar with the operating and control elements as well as the functioning of the machine. ● Use your safety equipment like helmet, safety shoes and hearing protection. ● Make yourself familiar with your working field. ● Only operate the machine for its intended purpose.

Beachten Sie bitte die Richtlinien der Berufsgenossenschaft und des Maschinenherstellers

Please observe the guidelines of the Professional Association and the machine manufacturer.

Hydraulikanlage

Hydraulic equipment

1. Hydraulikanlage steht unter hohem Druck! Unter hohem Druck austretende Hochdruck-Flüssigkeiten (Kraftstoff, Hydrauliköl) können die Haut durchdringen und schwere Verletzungen verursachen. Daher sofort einen Arzt aufsuchen, da anderenfalls schwere Infektionen entstehen können!

1. Hydraulic equipment is standing under high pressure. High pressure fluids (fuel, hydraulic oil) which escape under high pressure can penetrate the skin and cause heavy injuries. Therefore immediately consult a doctor as otherwise heavy infections can be caused.

2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr geeignete Hilfsmittel verwenden!

2. When searching leakages use appropriate auxiliary devices because of the danger of accidents.

3. Vor Arbeiten an der Hydraulikanlage diese unbedingt drucklos machen und angebaute Geräte absenken!

3. Before working at the hydraulic equipment, lower pressure to zero and lower working arms of the rnachine.

4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor abstellen und Traktor gegen Wegrollen sichern (Feststellbremse, Unterlegkeil)!

4. When working at the hydraulic equipment, absolutely stop motor and secure tractor against rolling away (parking brake, shim)!

5. Beim Anschließen von Hydraulikzylindern und -motoren ist auf vorgeschriebenen Anschluß der Hydraulikschläuche zu achten!

5. When connecting hydraulic cylinders and motor pay attention to correct connection of hydraulic flexible hoses.

6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen (z.B. Heben/Senken) - Unfallgefahr! 7. Hydraulikschlauchleitungen regelmäßig kontrollieren und bei Beschädigung und Alterung austauschen! Die Austausch schlauchleitungen müssen den technischen Anforderungen des Geräteherstellers entsprechen!

6. In case of exchanging the ports, the tunctions are vice versa (f. ex. lift-up/lower) - danger of accidents! 7. Check hydraulic flexible hoses regularly and replace them in case of dammage or wear! The new hose pipes must comply with the technical requirements of the machine manufacturer! Orderly disposal or recycling of oil, fuel and filters!

Öle, Kraftstoffe und Filter ordnungsgemäß entsorgen!

008 911 79

BOMAG

817

18.2 Bosch Rexroth AG | Mobile Hydraulics

26

818

A2F | RDE 91motor 001-03-R/05.03 Vibration A2FM

BOMAG

008 911 79

RDE 91 001-03-R/05.03 | A2F Vibration motor A2FM

008 911 79

Mobile Hydraulics | Bosch Rexroth AG

BOMAG

27 18.2

819

18.2

Vibration motor A2FM

Bosch Rexroth AG Mobile Hydraulics Produktbereich Axialkolbenmaschinen Werk / Plant Elchingen Glockeraustraße 2 89275 Elchingen, Germany Telefon +49 (0) 73 08 82-0 Telefax +49 (0) 73 08 72 74 [email protected] www.boschrexroth.com/brm

© 2003 by Bosch Rexroth AG, Mobile Hydraulics, 89275 Elchingen All rights reserved. No part of this document may be reproduced or stored, processed, duplicated or circulated using electronic systems, in any form or by any means, without the prior written authorization of Bosch Rexroth AG. In the event of contravention of the above provisions, the contravening party is obliged to pay compensation. The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The given information does not release the user from the obligation of own judgement and verification. It must be remembered that our products are subject to a natural process of wear and aging.

© 2003 by Bosch Rexroth AG, Mobile Hydraulics, 89275 Elchingen Alle Rechte vorbehalten. Kein Teil des Werkes darf in irgendeiner Form ohne vorherige schriftliche Zustimmung der Bosch Rexroth AG reproduziert oder unter Verwendung elektronischer Systeme gespeichert, verarbeitet, vervielfältigt oder verbreitet werden. Zuwiderhandlungen verpflichten zu Schadensersatz. Die angegebenen Daten dienen allein der Produktbeschreibung. Eine Aussage über eine bestimmte Beschaffenheit oder eine Eignung für einen bestimmten Einsatzzweck kann aus unseren Angaben nicht abgeleitet werden. Die Angaben entbinden den Verwender nicht von eigenen Beurteilungen und Prüfungen. Es ist zu beachten, dass unsere Produkte einem natürlichen Verschleiß- und Alterungsprozess unterliegen.

Printed in Germany RDE 91 001-03-R/05.03

820

BOMAG

008 911 79

18.3 Travel drive series 51

008 911 79

BOMAG

821

18.3

822

Travel drive series 51

BOMAG

008 911 79

18.3

Travel drive series 51

saue Series 51

Bent Axis Variable Motors Service Manual

008 911 79

BOMAG

823

18.3

Travel drive series 51

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

824

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

3

BOMAG

825

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

826

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

5

BOMAG

827

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

828

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

7

BOMAG

829

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

830

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

9

BOMAG

831

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

B1 U5 (plug for ext. servo press.)

T7, T8 T1

Servo B Pressure internal L1

M9 X3 (M5) Servo press, external M2

51000085

Fig. 10-16 - S1 Control Schematic

10 - 6

10

832

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

M9 X3 (M5) Servo press, external M2

M7 51000017

Fig. 10-19 - HZ Control Schematic

10 - 7

008 911 79

11

BOMAG

833

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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.)

M9 X3 (M5) Servo press, external M2

T1

Servo B Pressure internal L1 M7

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

834

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

13

BOMAG

835

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

B1 U5 (plug for ext. servo press.)

T7, T8 T1

Servo B Press, internal L1

M9 X3 (M5) Servo press, external M2

X2 X1

Fig. 10-28 - HP Control Schematic

51000025

10 - 10

14

836

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

51000160

15

BOMAG

837

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

B1 U5 (plug for ext. servo press.)

T7, T8 T1

Servo B Pressure internal L1 M7

X1

M9 X3 (M5) Servo press, external M2

M8 51000028

Fig. 10-34 - EP and EQ Control Schematic

10 - 12

16

838

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

17

BOMAG

839

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

840

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

19

BOMAG

841

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

842

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

● 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

843

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

Series 51

Notes

20 - 2

22

844

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

View"U" (HZ)

23

BOMAG

845

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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"

Packard Connector

Port X1: External PCP supply pressure

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

Motor Charge Pressure

60 bar or 1000 psi Gauge

M6 M7 M8 L1 L2

Control Test Port Case Pressure

X1 X2 X3 XA XB

Control Pressure

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

600 bar or 10,000 psi Gauge

M1

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 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

60 bar or 1000 psi Gauge Tee into Defeat Pressure Line(s) 30 - 2

24

846

Defeat Pressure

9/16 — 18 O-Ring Fitting

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

25

BOMAG

847

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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. Recommended Fluids

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: • 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

848

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

27

BOMAG

849

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

850

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

060 080 110 160

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)

250

2.63 (.41)

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. 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. 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 79

29

BOMAG

851

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

852

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

31

BOMAG

853

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

854

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

33

BOMAG

855

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

856

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

35

BOMAG

857

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

858

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

Inspect Inlet Filter and Replace if Necessary

Repair or Replace

Align Shafts

Fill to Proper Level

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

Fill to Proper Level

Clean, Repair or Replace

Repair as Required

Inspect Inlet Filter and Replace if Necessary

Replace Transmission (Pump and Motor)

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 79

37

BOMAG

859

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

Replace Transmission (Pump and Motor)

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

Fill to Proper Level

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

860

OK

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

Series 51

Notes

30 - 17

008 911 79

39

BOMAG

861

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

Series 51

Notes

30 - 18

40

862

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

Neumünster, Germany Typ

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

Place of Manufacture

Name Plate (German Production) 40 - 1

008 911 79

41

BOMAG

863

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 M11/T3A1-A9 T3B0-B6 T3C2-C7

G12

G20 S20

G12A M11/T1A1-A9 T1B0-B6 T1C2-C7

OR K16 (060—160) K16 (250) K14 G20A

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

864

S10 (160, 250)

T7A1-A9 T7B0-B6 T7C2-C7

G42 G36 M11/T2A1-A9 T2B0-B6 T2C2-C7

OR

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

43

BOMAG

865

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

866

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

45

BOMAG

867

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

868

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

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

869

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

Series 51

Exploded View of the Series 51 Variable Motor (Continued) Item

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

870

Description

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

Series 51

Exploded View of the Series 51 Variable Motor (Continued) Item

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 79

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

871

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

Series 51

Exploded View of the Series 51 Variable Motor (Continued) Item

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

872

Description

Y••• Y10 Y20 Y30

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

51

BOMAG

873

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

874

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

51000060

Fig. 50-11 - Seal Installed in Carrier (Cartridge) 53

BOMAG

875

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

876

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

55

BOMAG

877

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

878

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

51000079

Fig. 50-35 - Install Solenoid 57

BOMAG

879

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

880

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

59

BOMAG

881

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

882

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

51000093

Fig. 50-57 - Install Solenoid 61

BOMAG

883

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

884

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

51000102

Fig. 50-68 - Install Cover, Gasket, and Screws

63

BOMAG

885

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

886

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

51000110

Fig. 50-82 - Remove HC Control Housing

65

BOMAG

887

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

888

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

51000121

Fig. 50-95 - Torque Control Cover Screws 67

BOMAG

889

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

890

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

51000131

Fig. 50-106 - Install PCP Valve

69

BOMAG

891

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

892

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

71

BOMAG

893

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

894

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

73

BOMAG

895

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

896

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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 79

51000153

Fig. 50-141 - Install PCOR Defeat Spool Stop Plug

75

BOMAG

897

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

898

BOMAG

008 911 79

18.3

Travel drive series 51

saue Bent Axis Variable Displacement Motors

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

Torque

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)

37 Nm (27 ft•lbsf) 20 Nm (15 ft•lbsf) 9 Nm (7 ft•lbsf) 4 Nm (35 in•lbsf)

50 - 27

008 911 79

77

BOMAG

899

900

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

Genuine Service Parts

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!

18.3 Travel drive series 51

a

Series 51 MV Sheet 1 of 2

Minor Repair Instructions 4-Way Valve and Feedback Springs

78

008 911 79

008 911 79

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

Genuine Service Parts

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!

Travel drive series 51

18.3

a

Series 51 MV Sheet 2

Minor Repair Instructions 4-Way Valve and Feedback Springs - HC Control

79

901

18.3

Travel drive series 51

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 Axial Piston Pumps and Motors

Cartridge Motors/ Compact Wheel Drives

Heavy Duty Bent Axis Variable Motors F000 685 F000 688

Medium Duty Axial Piston Pumps and Motors

F000 690

Microcontrollers and Electrohydraulic Controls F000 689

Open Circuit Axial Piston Pumps

F000 686

F000 684

Hydrostatic Transmission Packages F000 687

Gear Pumps and Motors

F000 693

Genuine Service Parts

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

902

BOMAG

008 911 79

18.4 Transmission CR

008 911 79

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903

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3ERIES#2n#OMPACT2OLLER$RIVE 3ERVICE-ANUALAND2EPAIR)NSTRUCTION 2EPAIR)NSTRUCTION !33%-",9 CONTINUED

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008 911 79

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18.4

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PRINTED IN ITALY Copyright By DANA ITALIA S.p.A. Vietata la riproduzione anche parziale di testo ed illustrazioni Realizzazione a cura dell'Ufficio Post Vendita della DANA ITALIA S.p.A. Impaginazione: TEMAS s.r.l. - Gallarate (Va) Stampa: Agosto 1999 (N.L. 7416) Data subject to change without notice. We decline all responsability for the use of non-original components, or accessories which have not been tested and submitted for approval. Dati soggetti a modifiche senza impegno di preavviso. Si declina ogni responsabilitaÁ per l'utilizzo di componenti non originali o accessori non collaudati ed approvati. AÈnderungen ohne vorherige AnkuÈndingung vorbehalten. Es wird jede Verantwortung fuÈr die Verwendung von Nichtoriginalteilen oder nicht abgenommenem und genehmigtem ZubehoÈr abgelehnt. Los datos pueden ser modificados sin aviso previo. Se declina toda responsabilidad en el caso de uso de componentes no originales o bien de accesorios no ensayados y aprobados. Le constructeur se reÂserve le droit d'apporter des modifications aÁ sa production, sans pour cela eÃtre tenu d'en donner preÂavis. Nous deÂclinons toute responsabilite pour l'utilisation de pieÁces non originales ou d'accessoires non testeÂs et homologueÂs.

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18.5

Axle DANA 193

INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX INTRODUCTION ..........................................................5 MAINTENANCE AND LUBRICANTS . Definition of viewpoints............................................7 Data plate ..............................................................................7 Maintenance points ................................................................7 Maintenance intervals.............................................................8 Adjustment and checks ..........................................................8 Conversion tables...................................................................9 Tightening torques .................................................................9 Screw-locking, sealing, and lubricating materials ...................10

GB . . . . . . .

DIFFERENTIAL UNIT . Removal and disassembly ....................................................44 . Assembly and installation .....................................................54 REDUCTION GEAR AND BEVEL PINION . Disassembly.........................................................................68 . Installation and adjustment ...................................................74 SPECIAL TOOLS ......................................................................82

NOTES ON SAFETY PRECAUTIONS ........................................13 CHECKING WEAR AND REPLACING THE BRAKING DISKS . Disassembling the braking units............................................14 . Assembling the braking units ................................................20 . Mechanical and manual release of the axle ...........................28 PLANETARY REDUCTION AND AXLE SHAFT . Disassembly.........................................................................30 . Assembly .............................................................................38

ITA . . . . . . .

INTRODUZIONE .......................................................5

MANUTENZIONE E LUBRIFICANTI . Definizione viste ..................................................7 Targa matricola ......................................................................7 Punti di manutenzione ............................................................7 Intervalli di manutenzione .......................................................8 Registrazione e controlli .........................................................8 Tabelle di conversione............................................................9 Coppie di serraggio ................................................................9 Materiali per bloccaggio viti, tenuta e lubrificazione................10

GRUPPO DIFFERENZIALE . Rimozione e smontaggio.......................................................44 . Assemblaggio ed installazione ..............................................54 RIDUTTORE E PIGNONE CONICO . Smontaggio..........................................................................68 . Installazione e registrazione..................................................74 ATTREZZI SPECIALI.................................................................82

NOTE RIGUARDANTI LA SICUREZZA ......................................13 CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO . Smontaggio gruppi di frenatura .............................................14 . Assemblaggio dei gruppi di frenatura ....................................20 . Sbloccaggio meccanico manuale dell'assale..........................28 RIDUTTORE EPICICLOIDALE E SEMIASSE . Smontaggio..........................................................................30 . Assemblaggio ......................................................................38

D

. . . . . . .

VORAUSSETZUNG .................................................5

WARTUNG UND SCHMIERSTOFFE . Definition der Ansichten......................................7 Kennummernschild.................................................................7 Wartungsstellen .....................................................................7 Wartungsintervalle..................................................................8 Einstellungen und Kontrollen ..................................................8 Umrechnungstabellen.............................................................9 Anziehdrehmomente...............................................................9 Material zur Blockierung von Schrauben und fuÈr Dichtungen und Schmiermittel .........................................10

DIFFERENTIAL . Abmontieren und zerlegen ....................................................44 . Montieren und installieren.....................................................54 REDUZIERER UND KEGELRAD . Abmontieren ........................................................................68 . Installieren und einstellen .....................................................74 SONDERWERZZEUGE ..............................................................82

BEMERKUNGEN ZUR SICHERHEIT...........................................13 VERSCHLEISS KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN . Bremsaggregate abmontieren ...............................................14 . Bremsaggregate montieren ...................................................20 . Achse mechanisch manuell entsichern ..................................28 PLANETENGETRIEBE UND HALBACHSE . Abmontieren ........................................................................30 . Montieren ............................................................................38

008 911 79

BOMAG 3

935

18.5

INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX

PROLOGO................................................................ 5 MANTENIMIENTO Y LUBRICANTES . Definicion vistas................................................... 7 . Matricula ............................................................................... 7 . Puntos de manutencion.......................................................... 7 . Intervalos de manutencioÁn...................................................... 8 . Ajuste y controles .................................................................. 8 . Tablas de conversion ............................................................. 9 . Pares de torsion .................................................................... 9 . Materiales para el bloqueo, estanqueidad y lubricacion ......... 10 NORMAS CONCERNIENTES A LA SEGURIDAD ....................... 13

ESP

Axle DANA 193

GRUPO DIFERENCIAL . Remocion y desmontaje ....................................................... 44 . Montaje e instalacion ........................................................... 54 REDUCTOR Y PINÄON CONICO . Remocion ............................................................................ 68 . Instalacion y ajuste .............................................................. 74 HERRAMIENTAS ESPECIALES................................................. 82

CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO . Montaje de los grupos de frenado......................................... 14 . Desmontaje de los grupos de frenado................................... 20 . Desbloqueo manual de los axal ............................................ 28 REDUCTOR EPICICLOIDAL Y SEMIEJES . Desmontaje ......................................................................... 30 . Montaje ............................................................................... 38

INTRODUCTION ....................................................... 5 ENTRETIEN ET LUBRIFIANTS . DeÂfinition vues ..................................................... 7 . Plaque d'immatriculation ........................................................ 7 . Points d'entretien................................................................... 7 . Intervalle de service ............................................................... 8 . Reglages et controles............................................................. 8 . Tableaux de conversion ......................................................... 9 . Couples de serrage................................................................ 9 . MateÂriaux pour le blocage vis, eÂtancheÂite et lubrification........ 10 NOTES EN MATIERE DE SECURITE......................................... 13

F

GROUPE DIFFERENTIEL . Depose et demontage .......................................................... 44 . Assemblage et installation .................................................... 54 REDUCTEUR ET PIGNON CONIQUE . Depose................................................................................ 68 . Installation et reglage ........................................................... 74 OUTILS SPECIAL ..................................................................... 82

CONTROLE D'USURE ET SUBSTITUTION DES DISQUES DE FREINAGE . Desassemblage des groupes de freinage .............................. 14 . Assemblage des groupes de freinage ................................... 20 . Deblocage mecanique manuel de l'essieu............................. 28 REDUCTEUR EPICICLOIDALE ET DU DEMI-ESSIEU . Demontage.......................................................................... 30 . Assemblage......................................................................... 38

936

BOMAG 4

008 911 79

Axle DANA 193

INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION

The efficiency and continued operation of mechanical units depend on constant, correct maintenance and also on efficient repair work, should there be a break-down or malfunction. The instructions contained in this manual have been based on a complete overhaul of the unit. However, it is up to the mechanic to decide whether or not it is necessary to assemble only individual components, when partial repair work is needed. The manual provides a quick and sure guide which, with the use of photographs and diagrams illustrating the various phases of the operations, allows accurate work to be performed. All the information needed for correct disassembly, checks and assembly of each individual component is set out below. In order to remove the differential unit from the vehicle, the manuals provided by the vehicle manufacturer should be consulted. In describing the following operations it is presumed that the unit has already been removed from the vehicle.

GB

IMPORTANT: In order to facilitate work and protect both working surfaces and operators, it is advisable to use proper equipment such as: trestles or supporting benches, plastic or copper hammers, appropriate levers, pullers and specific spanners or wrenches. Before going on to disassemble the parts and drain the oil, it is best to thoroughly clean the unit, removing any encrusted or accumulated grease. INTRODUCTORY REMARKS: All the disassembled mechanical units should be thoroughly cleaned with appropriate products and restored or replaced if damage, wear, cracking or seizing have occurred. In particular, thoroughly check the condition of all moving parts (bearings, gears, crown wheel and pinion, shafts) and sealing parts (O-rings, oil shields) which are subject to major stress and wear. In any case, it is advisable to replace the seals every time a component is overhauled or repaired. During assembly, the sealing rings must be lubricated on the sealing edge. In the case of the crown wheel and pinion, replacement of one component requires the replacement of the other one. During assembly, the prescribed pre-loading, backlash and torque of parts must be maintained. CLASSIFICATION: This manual classifies units according to part numbers. For a correct interpretation, classification is indicated as follows: = up to the part number

martelli in plastica o rame, leve appropriate estrattori e chiavi specifiche, al fine di facilitare il lavoro salvaguardando nel contempo le superfici lavorate e la sicurezza degli operatori. Prima di procedere al disassemblaggio delle parti e scaricare l'olio, eÁ opportuno eseguire un'accurata pulizia del ponte, asportando incrostazioni ed accumuli di grasso. PREMESSA: Tutti gli organi meccanici smontati, devono essere accuratamente puliti con prodotti appropriati, quindi ripristinati o sostituiti nel caso presentino danni, usura, incrinature, grippaggi, ecc. In particolare, verificare l'integritaÁ di tutte quelle parti in movimento (cuscinetti, ingranaggi, coppia conica, alberi) e di tenuta (anelli OR, paraolio), soggette a maggiori sollecitazioni ed usura. EÁ consigliabile, comunque, la sostituzione degli organi di tenuta ogni qualvolta si proceda alla revisione o riparazione dei componenti. Al momento del montaggio, gli anelli di tenuta devono essere lubrificati sui bordi di tenuta. Nel caso della coppia conica, la sostituzione di uno dei suoi ingranaggi comporta anche la sostituzione dell'altro. In fase di montaggio sono da rispettare scrupolosamente i giochi, i precarichi e le coppie prescritte. Á : Il manuale fornisce le validitaÁ dei gruppi sotto forma VALIDITA di matricola. Al fine di una corretta interpretazione, le validitaÁ sono indicate come: = fino alla matricola = dalla matricola Se non sono indicate validitaÁ, le operazioni di smontaggio ed assemblaggio sono comuni a tutte le versioni. MANUTENZIONE E RIPARAZIONE: Al fine di facilitare interventi sui gruppi ponte differenziali e cambi di velocitaÁ la SPICER CLARK-HURTH, ha ritenuto opportuno compilare queste istruzioni di manutenzione e riparazione. I disegni delle attrezzature specifiche eventualmente necessarie per l'esecuzione di interventi di manutenzione e riparazione possono essere acquistati direttamente presso il costruttore; i ricambi possono essere ordinati tramite il costruttore della macchina o direttamente presso la DANA ITALIA S.p.A..

Die Leistung und Lebensdauer der mechanischen Teile haÈngt nicht nur von einer staÈndigen und richtig durchgefuÈhrten Wartung sondern auch von einem sofortigen Eingriff im StoÈrungsfall ab. Um dieses È berHandbuch zu erstellen sind wir von einer allgemeinen U pruÈfung der Einheit ausgegangen, doch entscheidet der Mechaniker ob die einzelnen Teile bei Reparaturen montiert werden muÈssen oder nicht. Das Handbuch ist schnell und einfach nachzuschlagen und ermoÈglicht es anhand der Abbildungen und der Zeichnungen, die die verschiedenen VorgaÈnge darstellen, gezielt einzugreifen. Nachstehend sind alle Informationen und Hinweise aufgefuÈhrt, die zur Zerlegung, PruÈfung und Montage der Einzelteile noÈtig sind. Um die Differentialachse des Fahrzeugs abzumontieren, lesen Sie bitte die Anweisungen in den HandbuÈchern des Fahrzeugherstellers. Die nachstehenden Beschreibungen gehen davon aus, daû die Fahrzeugachse schon abmontiert worden ist.

D

= from the part number on When no classification is given, disassembly and assembly operations are the same for all versions. SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of all specific tools required for maintenance and repair work can be found at the end of this manual ; spare parts may be ordered either from the vehicle manufacturer or directly from the Service Centers or Authorised Distributors of DANA ITALIA S.p.A..

Il rendimento e la continuitaÁ degli organi meccanici dipendono oltre che da una costante e corretta manutenzione, anche dal tempestivo intervento, nell'eventualitaÁ di guasti o anomalie. Nel proporre questo manuale si eÁ considerata l'ipotesi di una revisione generale del gruppo ma eÁ il meccanico a valutare la necessitaÁ di montare solo i singoli componenti nel caso di riparazione. Il manuale eÁ una guida rapida e sicura che consente interventi precisi, tramite le fotografie ed i disegni prospettici che illustrano le varie fasi delle operazioni. Di seguito sono riportate tutte quelle informazioni ed avvertenze necessarie al corretto disassemblaggio, alle relative verifiche ed all'assemblaggio dei singoli componenti. Per la rimozione del ponte differenziale dal veicolo, eÁ necessario consultare i manuali forniti dal costruttore del veicolo. Nel descrivere le operazioni seguenti, si presuppone che il ponte sia giaÁ stato rimosso dal veicolo.

ITA

IMPORTANTE: In tutte le operazioni, eÁ consigliabile usare attrezzature idonee quali cavalletti o banchi di sostegno,

008 911 79

18.5

BOMAG 5

WICHTIG: Um die Arbeit zu erleichtern und gleichzeitig die verarbeiteten FlaÈchen zu schuÈtzen und die Sicherheit der Arbeiter zu gewaÈhrleisten, empfehlen wir geeignete Werkzeuge wie BoÈcke, Tisch, Gummi- oder Kupferhammer, geeignete Abzieher und SchluÈssel zu verwenden. Èl Bevor mit der Zerlegung der Teile begonnen und das O abgelassen wird, muû die Achse sorgfaÈltig gereinigt und Verkrustungen und Fettablagen abgetragen werden. VORAUSSETZUNG: Alle abmontierten mechanischen Teile muÈssen sorgfaÈltig mit geeigneten Reinigungsmitteln gereinigt oder, wenn beschaÈdigt, verschleiût, gerissen, festgefressen usw. ausgewechselt werden. Insbesondere muû der einwandfreie Zustand aller beweglichen Teile (Lager, ZahnraÈder, È labKegelradpaare, Wellen) und der Dichtungen (O-Ringe, O dichtungen), die am meisten beansprucht werden und verschleiûen, kontrolliert werden. Wir empfehlen auf jeden Fall die È berAbdichtungselemente immer auszuwechseln, wenn eine U holung oder eine Reparatur der Teile vorgenommen wird. Bei

937

18.5

INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION

der Montage muÈssen die RaÈnder der Dichtringe geschmiert werden. Wenn beim Kegelradpaar ein Zahnrad ausgewechselt werden muû, muû auch das andere Zahnrad ausgewechselt werden. Bei der Montage muÈssen die vorgeschriebenen Spiele, Vorspannungen und Drehmomente strengstens eingehalten werden. È LTIGKEIT: Das Handbuch gibt an zu welchen Kennummern GU die Einheiten gehoÈren. Der Einfachheit halber sind die AngehoÈrigkeiten folgendermaûen aufgefuÈhrt:

Axle DANA 193

Si no ha sido indicada validez, las operacioÂn de desmontaje y montaje son comunes a todas las versiones. HERRAMIENTAS ESPECIFICAS Y RECAMBIOS: Los planos de las herramientas especificas necesarias para la ejecucioÂn de las intervenciones de mantenimiento figuran al final del manual; los recambios se pueden pedir al fabricante de la maÂquina o directamente al Service Center o a Distribuidores autorizados de DANA ITALIA S.p.A..

= bis Kennummer = ab Kennummer Wenn keine AngehoÈrigkeit angegeben ist, verstehen sich die Arbeiten zur Zerlegung und Montage fuÈr alle AusfuÈhrungen guÈltig. SPEZIFISCHE WERKZEUGE UND ERSATZTEILE: die Zeichnungen der fuÈr Wartungsarbeiten erforderlichen spezifischen Werkzeuge, sind am Ende des Handbuchs aufgefuÈhrt; Ersatzteile koÈnnen beim Fahrzeughersteller oder direkt bei der Kundendienststelle oder bei einem zugelassenen HaÈndler der DANA ITALIA S.p.A. bezogen werden.

El rendimiento y la duracioÂn de los oÂrganos mecaÂnicos depende, ademaÂs que del constante y correcto mantenimiento, tambieÂn de la intervencioÂn inmediata en caso de averõÂas o anomalõÂas. Al proponer este manual, ha sido considerada la suposicioÂn de una revisioÂn general del grupo, pero es el mecaÂnico quien tiene que valorar la necesidad de montar cada uno de los componentes en caso de reparacioÂn. El manual es una guõÂa raÂpida y segura que permite intervenciones precisas por medio de fotografõÂas y de planos que muestran las distintas fases de las operaciones. A continuacioÂn figuran todas las informaciones y advertencias necesarias para ejecutar un montaje correcto, para las comprobaciones y el montaje de cada uno de los componentes. Para remover el puente diferencial del vehõÂculo hay que consultar los manuales de los fabricantes del vehõÂculo. En la descripcioÂn de las operaciones siguientes se supone que el puente ya ha sido sacado del vahõÂculo.

ESP

IMPORTANTE: Para facilitar el trabajo salvaguardando al mismo tiempo las superficies mecanizadas y la seguridad de los operadores, se aconseja que se usen equipos y herramientas adecuados como caballetes y bancos de soporte, martillos de plaÂstico o de cobre, palancas adecuadas, extractores y llaves especõÂficas. Antes de desmontar las partes y descargar el aceite, es conveniente que se haga una limpieza minuciosa del puente sacando las incrustaciones y acumulaciones de grasa. INTRODUCCION: Todos los oÂrganos mecaÂnicos desmontados tienen que ser limpiados minuciosamente con productos adecuados y restaurados o sustituidos en el caso de que presenten danÄos, desgaste, rajaduras, agarrotamientos, etc. En particular, comprobar la integridad de todas las partes en movimiento (cojinetes, engranajes, par coÂnico, ejes) y de estanqueidad (anillos OR, detenedor de aceite) sujetas a mayores solicitaciones y desgaste. Se aconseja, de todas formas, que se sustituyan los oÂrganos de estanqueidad cada vez que se ejecute la revisioÂn o reparacioÂn de los componentes. Al volver a montar, los segmentos de compresioÂn tienen que estar lubricados en los bordes de estanqueidad. En el caso del par coÂnico, la sustitucioÂn de uno de sus engranajes comporta tambieÂn la sustitucioÂn del otro. Al montar hay que tener en cuenta escrupulosamente los juegos, las precargas y los pares descriptos. VALIDEZ: El manual suministra la validez de los grupos en forma de matrõÂcula. Para poder tener una interpretacioÂn correcta, la validez esta indicada: = hasta la matrõÂcula = desde la matrõÂcula en adelante

938

Le rendement et la continuite des organes meÂcaniques deÂpendent, non seulement d'une maintenance correcte et constante, mais eÂgalement de la rapidite d'intervention en cas de pannes ou d'anomalies. En vous proposant ce manuel, on envisage l'hypotheÁse d'une reÂvision geÂneÂrale du groupe, mais c'est au meÂcanicien d'eÂvaluer la neÂcessite de monter ou non chacun des composants en cas de reÂparation. Le manuel est un guide rapide et suÃr consentant des interventions preÂcises, au travers de photographies et de dessins prospectifs qui illustrent les diffeÂrentes phases des opeÂrations. Ensuite, sont reporteÂes toutes les informations et preÂcautions neÂcessaires pour un deÂmontage correct et les veÂrifications et assemblage de chaque composant. En ce qui concerne le deÂplacement du pont d'eÂtai du veÂhicule, il est neÂcessaire consulter les manuels fournis par le constructeur du veÂhicule. En deÂcrivant les opeÂrations suivantes, on preÂsume que le pont ait deÂjaÁ eÂte enleve du veÂhicule.

F

IMPORTANT: Pour faciliter le travail en sauvegardant en meÃme temps les surfaces usineÂes et la seÂcurite des opeÂrateurs, il est preÂconise d'utiliser des installations approprieÂes telles que des eÂtais ou banc de support, maillets en plastique ou cuivre, leviers approprieÂs, extracteurs et cleÂs speÂcifiques. Avant de proceÂder au deÂmontage des parties et vidanger l'huile, il vaut mieux nettoyer soigneusement le pont, en enlevant incrustations et blocs de gras. PRELIMINAIRE: Tous les organes meÂcaniques deÂmonteÂs doivent eÃtre soigneusement nettoyeÂs aÁ l'aide de produits approprieÂs et reÂpareÂs ou remplaceÂs dans le cas ouÁ ils seraient abõÃmeÂs, useÂs, feÃleÂs, grippeÂs, etc. VeÂrifier, l'inteÂgriteÂ, en particulier, de toutes les parties en mouvement (paliers, engrenages, couple conique, arbres) et l'eÂtancheÂite des bagues (bagues OR, parahuile), qui sont sujettes aÁ plus de sollicitations et aÁ l'usure. Il est preÂconiseÂ, de toute facËon, de substituer les organes d'eÂtancheÂiteÂ, chaque fois que l'on effectue une reÂvision ou une reÂparation des composants. Au moment du montage, les bagues d'eÂtancheÂite doivent eÃtre lubrifieÂes sur les bords eÂtanches. Dans le cas du couple conique, la substitution de l'un de ses engrenages comporte eÂgalement la substitution de l'autre. En phase de montage, il faut respecter scrupuleusement les jeux, les preÂcharges et les couples prescrits. VALIDITE: Le manuel fournit la validite des groupes sous forme de matricule. Pour une meilleure interpreÂtation, les validiteÂs sont indiqueÂes comme: = jusqu'aÁ l'immatriculation = aÁ partir de l'immatriculation et apreÁs Si les validiteÂs ne sont pas indiqueÂes, les opeÂrations de deÂmontage et d'assemblage sont pareilles dans toutes les versions. INSTALLATIONS SPECIFIQUES ET PIECES DETACHEES: Les dessins des installations speÂcifiques neÂcessaires pour effectuer des interventions d'entretien sont reporteÂes aÁ la fin du manuel, les pieÁces deÂtacheÂes peuvent eÃtre commandeÂes au constructeur de la machine ou directement aux Centres de Services, ou Distributeurs agreÂeÂs de la SocieÂte DANA ITALIA S.p.A..

BOMAG 6

008 911 79

Axle DANA 193

MAINTENANCE AND LUBRICANT - MANUTENZIONE E LUBRIFICANTI - WARTUNG UND SCHMIERSTOFFE MANTENIMIENTO Y LUBRICANTES - ENTRETIEN ET LUBRIFIANTS

18.5

DEFINITION OF VIEWPOINTS - DEFINIZIONE VISTE - DEFINITION DER ANSICHTEN - DEFINICION VISTAS - DEÂFINITION VUES RIGHT SIDE LATO DESTRO RECHTE SEITE LADO DERECHO COTE DROITE

LEFT SIDE LATO SINISTRO LINKE SEITE LADO IZQUIERDO COTE GAUCHE

D1240138

DATA PLATE - TARGA MATRICOLA - KENNUMMERNSCHILD - MATRICULA - PLAQUE D'IMMATRICULATION

2

1 3

MFG. BY CLARK-HURTH COMPONENTS S.P.A. 38062 Arco (Trento) MADE IN ITALY

1

Type and model unit - modification index Tipo e modello gruppo - indice di modifica È nderungsverzeichnis Typ und Modelleles Antriebes - A Tipo y modelo grupo - indice de modificacion Type et modeÂle de ensemble - tableau des modifications

2

Serial number Numero di serie Seriennummer NuÂmero de serie Numero de serie

3

Lubricant Lubrificante Schmieroel Lubricante Lubrificant

D1240011

MAINTENANCE POINTS - PUNTI DI MANUTENZIONE - WARTUNGSSTELLEN - PUNTOS DE MANUTENCION - POINTS D'ENTRETIEN

3 1

2

1

2

2

1 3

2

2

1 3 2 D1240139

008 911 79

BOMAG 7

1 2 3

Oil filling plug - Tappo di carico Èllstopfen - Tapon de carga Einfu Bouchon de ravitaillement Oil draining plug - Tappo di scarico Ablasstopfen - Tapon de descarga Bouchon de vidange Check level plug - Tappo controllo livello È lpegelkontrolle Stopfen zur O Tapon de contrl de nivel - Jauge de niveau

939

18.5

Axle DANA 193

MAINTENANCE INTERVALS - INTERVALLI DI MANUTENZIONE - WARTUNGSINTERVALLE - INTERVALOS DE MANUTENCIOÁN - INTERVALLE DE SERVICE

. . . . .

. . . . .

]

OPERATION - OPERAZIONE FREQUENCY - PERIODICITAÁ ARBEITSVORGANG - ZEITABSTAND OPERACION - OPERATION FRECUENCIA - PERIODICITE Differential monthly Differenziale mensile Im differential monatlich Check levels: Diferencial cada mes Controllo livelli: Differentiel mensuel È Olstandkontrolle: Planetary reduction every 200 hours Control niveles: Riduzione epicicloidale ogni 200 ore ControÃle niveaux: Planetengetrieb alle 200 Std. ReduccioÂn epicicloidal cada 200 horas Reduction epicycloidale toutes les 200 heures Differential every 800 hours ] ogni 800 ore Differenziale alle 800 Std. Im differential cada 800 horas Diferencial toutes les 800 heures Differentiel Planetary reduction every 1000 hours ] Oil change: Riduzione epicicloidale Cambio olio: ogni 1000 ore È lwechsel: Planetengetrieb alle 1000 Std. O ReduccioÂn epicicloidal cada 1000 horas Cambio aceite: Reduction epicycloidale toutes les 1000 heures Vidange huile: Self-locking differential gear every 700 hours ] r Differenziale autobloccante ogni 700 ore Selbstsperrdifferential alle 700 Std. Diferencial autobloqueante cada 700 horas Differentiel autobloquant toutes les 700 heures

LUBRICANTS - LUBRIFICANTI - SCHMIERSTOFFE LUBRICANTES - LUBRIFIANTS

.

.

SAE85W90 (API GL4 - MIL L-2105)

With additives for oil-bath brakes Con additivi per freni a bagno d'olio È lbad Mit Zusatzmittel fuÈr Bremsen in O Con aditivos para frenos de banÄo de aceite Avec adjuvants pour freins en bain d'huile

SAE85W90 (API GL5 - MIL 2105-B)

With additives for oil-bath brakes, for units presenting hypoid crown wheel and pinion and /or self-locking differential gear Per esecuzioni con coppia conica ipoide e/o con differenziale autobloccante, con additivi per freni a bagno d'olio Bei AusfuÈhrungen mit Kegel- und Telleradpaar und/oder Selbstsperrdifferential, mit ZusatzmitÈ lbad teln fuÈr Bremsen in O Para ejecuciones con par coÂnico hipoide y/o con diferencial autobloqueante con aditivos para frenos de banÄo de aceite. Pour exeÂcutions avec couple conique hypoõÈde et/ ou diffeÂrentiel autobloquant, avec adjuvants pour freins en bain d'huile

Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de 100 horas de trabajo - Initialement apreÁs 100 heures de travail r When it starts sounding noisy - Anche ai primi cenni di rumorositaÁ - Auch falls ungewoÈhnliche GeraÈusche zu bemerken sind - TambieÂn al primer indicio de ruido - MeÃme aux premiers signaux de bruit OPERATION - OPERAZIONE - MEMBER - ORGANO - CONDITIONS - CONDIZIONI - FREQUENCY - PERIODICITAÁ - LUBRICANTS - LUBRIFICANTI ARBEITSVORGANG ELEMENT BEDINGUNG ZEITABSTAND SCHMIERSTOFFE OPERACION - OPERATION ORGANO - ORGANE CONDICIONES - CONDITIONS FRECUENCIA - PERIODICITE LUBRICANTES - LUBRIFIANTS

Greasing Ingrassaggio Schmieren Engrase Graissage

Articulations Snodi Gelenk RoÂtula Articulations

Normal work Lavori normali Normale Arbeit Trabajos normales TaÃches ordinaires

monthly mensile monatlich cada mes mensuel

Awkward work Lavori gravosi Schwere Arbeit Trabajos pesados TaÃches extraordinaires

Weekly Settimanale WoÈchentlich Semanal Hebdomadaire

MOLIKOTE

ADJUSTMENT AND CHECKS - REGISTRAZIONE E CONTROLLI - EINSTELLUNGEN UND KONTROLLEN - AJUSTE Y CONTROLES - REGLAGES ET CONTROLES UNIT - GRUPPO AGGREGAT GRUPO - GROUPE

OPERATION - OPERAZIONE FREQUENCY - PERIODICITAÁ - SERVICE BRAKE CIRCUIT - CIRCUITO COMANDO FRENI ARBEITSVORGANG ZEITABSTAND BREMSKREISLAUF - CIRCUITO MANDOS FRENOS OPERACION - OPERATION FRECUENCIA - PERIODICITE CIRCUIT DE COMMANDE DES FREINS

Negative brake Freno negativo Federspeicherbremse Freno negativo Frein neÂgatif

Adjustment Registrazione Einstellen Ajuste ReÂglage

every 1000 hours ] ogni 1000 ore alle 1000 Std. cada 1000 horas toutes les 1000 hours

Service brake Freni di servizio Hilfsbremse Frenos de ejercicio Freins de service Wheel nuts Dadi ruota Radmuttern Tuercas rueda Ecrous de roue

Adjustment Registrazione Einstellen Ajuste ReÂglage

every 500 hours ogni 500 ore alle 500 Std. cada 500 horas toutes les 500 hours every 200 hours ogni 200 ore alle 200 Std. cada 200 horas toutes les 200 hours

Tightening Serraggio Festziehen Apriete Serrage

Only for mineral oil use e.g. ATF Dexron II. Make sure that master cylinder seals are suitable for mineral oil. Usare esclusivamente olio minerale ATF Dexron II. Accertarsi che le guarnizioni del cilindro master siano adatte a questo olio. È l verwenden, z.B.: ATF Dexron II. Nur mineralisches O Achtung: Dichtringe des Hauptbremszylinders muÈsÈ l geeignet sein. sen fuÈr dieses O Usar exclusivamente aceite mineral ATF Dexron II. Asegurarse de que las juntas del cilindro principal son adecuadas para este aceite. Utiliser exclusivement huile mineÂrale ATF Dexron II. VeÂrifier que les joints du maõÃtre-cylindre, soien compatibles avec cette huile.

] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de 100 horas de trabajo - Initialement apreÁs 100 heures de travail

940

BOMAG 8

008 911 79

18.5

Axle DANA 193

CONVERSION TABLES - TABELLE DI CONVERSIONE - UMRECHNUNGSTABELLEN TABLAS DE CONVERSION - TABLEAUX DE CONVERSION Units of pressure - UnitaÁ di pressione - Druckeinheiten Unidad de presioÂn - UniteÂs de pression:

1 Atm%1 bar%105 PA%14.4 PSi

Units of weight - UnitaÁ di peso - Gewichtseinheiten Unidad de peso - UniteÂs de poids

Units of torque - UnitaÁ di coppia - Drehmomenteinheiten Unidad de par - UniteÂs de couple

N

daN

kN

kg

lbs

Nm

daNm

kNm

kgm

lb-in

1N

1

0,1

0,001

0,102

0,225

1Nm

1

0,1

0,001

0,102

8,854

1daN

10

1

0,01

1,02

2,25

1daNm

10

1

0,01

1,02

88,54

1kN

1000

100

1

102

225

1kNm

1000

100

1

102

8854

1kg

9,81

0,981

0,00981

1

2,205

1kgm

9,81

0,981

0,00981

1

86,8

1lb-in

0,1129

0,01129 0,0001129 0,01152

1

TIGHTENING TORQUES - COPPIE DI SERRAGGIO - ANZIEHDREHMOMENTE PARES DE TORSION - COUPLES DE SERRAGE

Unit - UnitaÁ di misura - Meûeinheiten - Unidad de medida - UniteÂs de mesure: Nm SIZE OF BOLT MISURA VITE SCHRAUBENMASS Ä O TORNILLO TAMAN MESURE VIS

TYPE OF BOLT - TIPO VITE - GEWINDE - TIPO DE TORNILLO - TYPE DE VIS

8.8

10.9

12.9

Normali + Loctite 242

Normali + Loctite 270

Normali + Loctite 242

Normali + Loctite 270

9,5-10,5

10,5-11,5

14,3-15,7

15,2-16,8

16,2-17,8

18,1-20,0

M8 x 1,25

23,8-26,2

25,6-28,4

34,2-37,8

36,7-40,5

39,0-43,0

43,7-48,3

M10 x 1,5

48-53

52-58

68-75

73-81

80-88

88-97

M12 x 1,75

82-91

90-100

116-128

126-139

139-153

152-168

M14 x 2

129-143

143-158

182-202

200-221

221-244

238-263

M16 x 2

200-221

219-242

283-312

309-341

337-373

371-410

M18 x 2,5

276-305

299-331

390-431

428-473

466-515

509-562

M20 x 2,5

390-431

428-473

553-611

603-667

660-730

722-798

COARSE PITCH - PASSO GROSSO - GROûER SCHRITT - PASO GRUESO - GROS PAS

Normali + Loctite 270

M6 x 1

M22 x 2,5

523-578

575-635

746-824

817-903

893-987

974-1076

M24 x 3

675-746

732-809

950-1050

1040-1150

1140-1260

1240-1370

M27 x 3

998-1103

1088-1202

1411-1559

1539-1701

1710-1890

1838-2032

M30 x 3,5

1378-1523

1473-1628

1914-2115

2085-2305

2280-2520

2494-2757

FINE PITCH - PASSO FINE - KLEINER SCHRITT PASO FINO - PAS FIN

Normali + Loctite 242

M8 x 1

25,7-28,3

27,5-30,5

36,2-39,8

40,0-44,0

42,8-47,2

47,5-52,5

M10 x 1,25

49,4-54,6

55,2-61,0

71,5-78,5

78,0-86,0

86,0-94,0

93,0-103,0

M12 x 1,25

90-100

98-109

128-142

139-154

152-168

166-184

008 911 79

M12 x 1,5

86-95

94-104

120-132

133-147

143-158

159-175

M14 x 1,5

143-158

157-173

200-222

219-242

238-263

261-289

M16 x 1,5

214-236

233-257

302-334

333-368

361-399

394-436

M18 x 1,5

312-345

342-378

442-489

485-536

527-583

580-641

M20 x 1,5

437-483

475-525

613-677

674-745

736-814

808-893

M22 x 1,5

581-642

637-704

822-908

903-998

998-1103

1078-1191

M24 x 2

741-819

808-893

1045-1155

1140-1260

1235-1365

1363-1507

M27 x 2

1083-1197

1178-1302

1520-1680

1672-1848

1834-2027

2000-2210

M30 x 2

1511-1670

1648-1822

2138-2363

2332-2577

2565-2835

2788-3082

BOMAG 9

941

18.5

Axle DANA 193

SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS - MATERIALI PER BLOCCAGGIO VITI, TENUTA E LUBRIFICAZIONE - MATERIAL ZUR BLOCKIERUNG VON SCHRAUBEN UND FUÈR DICHTUNGEN UND SCHMIERMITTEL - MATERIALES PARA EL BLOQUEO, ESTANQUEIDAD Y LUBRICACION MATEÂRIAUX POUR LE BLOCAGE VIS, EÂTANCHEÂITE ET LUBRIFICATION 1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor. I materiali per il bloccaggio, tenuta e lubrificazione specifica indicati nel manuale, sono quelli usati in fabbrica. Die Materialien zur Blockierung von Schrauben, fuÈr Dichtungen und Schmiermittel, die im Handbuch aufgefuÈhrt sind, sind dieselben die auch vom Hersteller verwendet werden. Los materiales para el bloqueo, estanqueidad y lubricacioÂn especõÂfica indicados en el manual, son los que se usan en la faÂbrica Les mateÂriaux de blocage, d'eÂtancheÂite et de lubrification speÂcifieÂs indiqueÂs dans ce manuel sont ceux employeÂs aÁ l'usine. 2 - The table below gives an account of the typical applications of each single material, in order to facilitate replacement with similar products marketed by different brand names with different trade marks. Di questi materiali, vengono riportate le applicazioni tipiche che li distinguono, in modo da poterli sostituire con prodotti similari commercializzati da altre marche e quindi con altre sigle. Von diesen Materialien werden die typischen Anwendungen genannt, um sie mit aÈhnlichen Materialien zu ersetzen, die unter anderen Namen und Kennzeichnungen im Handel erhaÈltlich sind. De estos materiales damos las aplicaciones tõÂpicas que los distinguen, de manera que se puedan sustituir con productos similares comercializados por otras marcas y por tanto con otras siglas. De ces mateÂriaux ne sont reporteÂes que les applications typiques qui les distinguent de telle sorte qu'ils puissent eÃtre substitueÂs par des produits semblables se trouvant dans le commerce sous d'autres marques et par conseÂquent sous d'autres sigles. DENOMINATION DENOMINAZIONE BEZEICHNUNG DENOMINACION DENOMINATION

APPLICATION - APPLICAZIONE - ANWENDUNG - APLICACION - APPLICATION

. Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength locking. Before using it, completely remove any lubricant by using the specific activator.

. Prodotto anaerobico adatto a prevenire l'allentamento di viti, dadi e tappi. Usato per la frenatura a media resistenza. Deve essere usato dopo aver asportato ogni traccia di lubrificante con l'attivatore specifico.

. Anaerobes Produkt, um das Lockern von Schrauben, Muttern und Stopfen zu verhindern. FuÈr mittlere WiLoctite 242

Loctite 243

derstandskraÈfte geeignet. Darf erst aufgetragen werden, wenn die FlaÈchen von Schmiermittel richtig sauber sind. Dazu das entsprechende Produkt verwenden. . Producto anaeroÂbico apto para prevenir el aflojamiento de tornillos, tuerca y tapones. Usado para el frenado de media resistencia. Tiene que ser usado soÂlo despueÂs de haber quitado todo residuo de lubricante con el activador especõÂfico. . Produit anareÂobic servant aÁ preÂvenir le relaÃchement des vis, eÂcrous et bouchons. Utilise pour le freinage demi reÂsistant. Il doit eÃtre utilise apreÁs avoir enleve toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.

. The oleocompatible alternative to 242. Does not require the activation of lubricated surfaces. . Prodotto alternativo al 242 che, essendo oleocompatibile, non richiede l'attivazione di superfici lubrificate. . Alternatives Produkt zu Loctite 242. Da es oÈlkompatibel ist muÈssen die geschmierten FlaÈchen nicht aktiviert werden.

. Producto alternativo al 242 que, siendo oleocompatible, no requiere la activacioÂn de superficies lubricadas. . Produit en alternance avec le 242 lequel eÂtant oleÂocompatible ne requiert aucune activation des surfaces lubrifieÂes.

. Anaerobic product for very-high strength locking of screws and nuts. Before using it, completely remove any lubricant by using the specific activator. To remove parts, it may be necessary to heat them at 80ëC approx.

. Prodotto anaerobico adatto per la frenatura ad altissima resistenza di viti e dadi. Deve essere usato dopo aver Loctite 270

asportato ogni traccia di lubrificante con l'attivatore specifico. La rimozione delle parti, puoÁ richiedere un riscaldamento a circa 80ëC. . Anaerobes Produkt fuÈr hohe WiderstandskraÈfte fuÈr Schrauben und Muttern geeignet. Zuerst die FlaÈche sorgfaÈltig aktivieren. Um die FlaÈchen zu saÈubern, diese auf ca. 80ëC erwaÈrmen. . Producto anaeroÂbico apto para el frenado de alta resistencia de tornillos y tuercas. tiene que ser usado despueÂs de haber quitado todo residuo de lubricante con el activador especõÂfico. La remocioÂn de las partes, puede requerir un calentamiento a unos 80ëC. . Produit anareÂobic apte au freinage aÁ treÁs haute reÂsistance des vis et des eÂcrous. Il doit eÃtre utilise apreÁs avoir enleve toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.

. Anaerobic product suitable for high-strength locking and sealing of large threaded parts, bolts and stud bolts, .

Loctite 275

. . .

942

for pipe sealing and for protecting parts against tampering; suitable for sealing coupling surfaces with a max. diametrical clearance of 0.25 mm. Prodotto anaerobico adatto per la frenatura e sigillatura ad alta resistenza di parti filettate, bulloni e prigionieri di grandi dimensioni, protezione antimanomissione e sigillatura di tubazioni; puoÁ sigillare accoppiamenti con gioco diametrale massimo di 0,25 mm. Anaerobes Produkt zum Bremsen und Siegeln von groûen Gewinden, Muttern und Stiftschrauben , sehr widerstandsfaÈhig, verschleierungsbestaÈndig, und zum Siegeln von Rohrleitungen geeignet; kann Kupplungen mit einer maximalen Lagerluft von 0,25 mm siegeln. Producto anaerobico apto para el frenado y selladura a alta resistencia de tornillos, tuercas y prisioneros de grandes dimensiones, protecion anti manomision y selladura de tubaciones ; puede sellar encolcados con juego diametral. Produit anaeÂrobie adapte au freinage et au scellage aÁ haute reÂsistance des parties fileteÂes, boulons et prisonniers de grandes dimensions, protection anti-alteÂration et scellage de tuyauteries; il peut sceller des accouplements ayant un jeu diameÂtral maximal de 0,25 mm.

BOMAG 10

008 911 79

18.5

Axle DANA 193

SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS - MATERIALI PER BLOCCAGGIO VITI, TENUTA E LUBRIFICAZIONE - MATERIAL ZUR BLOCKIERUNG VON SCHRAUBEN UND FUÈR DICHTUNGEN UND SCHMIERMITTEL - MATERIALES PARA EL BLOQUEO, ESTANQUEIDAD Y LUBRICACION MATEÂRIAUX POUR LE BLOCAGE VIS, EÂTANCHEÂITEÂ ET LUBRIFICATION DENOMINATION DENOMINAZIONE BEZEICHNUNG DENOMINACION DENOMINATION

APPLICATION - APPLICAZIONE - ANWENDUNG - APLICACION - APPLICATION

. Anaerobic product for the hermetic sealing of flanged units and screw holes communicating with fluids. Can seal clearances between flanges up to 0.2 mm.

. Prodotto anaerobico adatto alla tenuta ermetica di fluidi tra assiemi flangiati e di viti a foro comunicante con i fluidi. PuoÁ sigillare giochi tra le flange fino a 0,2 mm.

Loctite 510

. Anaerobes Produkt zur Abdichtung von FluÈssigkeiten an Flanschen und Schrauben mit LoÈcher, die mit FluÈssigkeiten in Kontakt stehen. Kann ein Spiel zwischen Flanschen bis 0,2 mm abdichten.

. Producto anaeroÂbico apto para le estanqueidad de fluidos entre grupos bridados y de tornillos de orificio comunicante con los fluidos. Puede sellar juegos entre las bridas hasta 0,2 mm.

. Produit anareÂobic apte aÁ la tenue eÂtanche des fluides entre les pieÁces aÁ brides et des vis aÁ trou en contact avec les fluides. Il peut sceller un jeu parmi les flasques jusqu'aÁ 0,2 mm.

. Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to M80. Before using .

. Loctite 577

.

.

it, remove any lubricant with the specific activator. After polymerisation, disassembly may result rather difficult, so heating may be necessary for larger diameters. Prodotto anaerobico sigillante rapido per la tenuta di filettature di raccordi conici o cilindrici fino a M80. Deve essere usato dopo aver asportato ogni traccia di lubrificante con l'attivatore specifico. Dopo la polimerizzazione presenta una moderata difficoltaÁ di smontaggio per cui puoÁ richiedere, per i diametri maggiori, un riscaldamento. Anaerobes Produkt zum schnellen Siegeln und Abdichten von Kegel- oder Zylinderkupplungen bis M80. Darf erst aufgetragen werden, nachdem mit einem spezifischen Wirkstoff jede Spur von Schmiermittel abgetragen worden ist. Nach der Polymerisation koÈnnte das Abmontieren etwas schwierig sein weshalb groÈûere Durchmesser zuerst erhitzt werden muÈssen. Producto anaerobico sellante rapido para el estanqueido de tornillos de empalme conico o cilindrico hasta M80. Debe de ser utilisado despues de haber quitado cada mancha de lubrificante con activador especifico. Despues de la polimeracion presenta una moderada dificultaÁde desmontaje por lo tanto puede necesitar, para los diametros majores, un calientamiento. Produit anaeÂrobie collage rapide assurant l'eÂtancheÂite des filetages des raccords coniques ou cylindriques jusqu'aÁ M80. Il doit eÃtre utilise apreÁs qu'on ait enleve toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial. Une certaine difficulte de deÂmontage se preÂsente apreÁs la polymeÂrisation, on peut donc avoir la neÂcessite de devoir chauffer preÂalablement pour de plus amples diameÁtres.

. Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints (hub on shaft). Can glue together parts with clearance ranging between 0.1 and 0.25 mm.

. Adesivo anaerobico per l'incollaggio rapido ad alta resistenza di giunti cilindrici in metallo (mozzo su albero). PuoÁ incollare particolari con gioco tra 0,1 e 0, 25 mm.

Loctite 638

. Anaerober Klebstoff fuÈr groûe WiderstandskraÈfte fuÈr Zylinderkupplungen aus Metall geeignet (Wellennaben). Kann Einzelteil mit einem Radialspiel zwischen 0,1 mm und 0,25 mm zusammenkleben.

. Adhesivo anaeroÂbico para el encolado raÂpido de alta resistencia de juntas cilõÂndricas de metal (cubo en el eje). Puede encolar piezas con juego entre 0,1 mm y 0,25 mm.

. AdheÂsif anaeÂrobic servant aÁ un collage rapide et hautement reÂsistant des joints cylindriques en meÂtal (moyeu sur l'arbre). Il peut servir aÁ coller des pieÁces avec un jeu allant de 0,1 aÁ 0,25 mm.

. Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints (hub on shaft). Can glue together parts with radial clearance below 0.1 mm.

. Adesivo anaerobico per l'incollaggio rapido a media resistenza di giunti cilindrici in metallo (mozzo su albero). PuoÁ incollare particolari con gioco radiale inferiore a 0,1 mm.

Loctite 648

. Anaerober Klebstoff fuÈr mittlere WiderstandskraÈfte fuÈr Zylinderkupplungen aus Metall geeignet (Wellennaben). Kann Einzelteil mit einem Radialspiel von weniger als 0,1 mm zusammenkleben.

. Adhesivo anaeroÂbico para encolado raÂpido de media resistencia juntas cilõÂndricas de metal (cubo en el eje). Puede encolar piezas con juego radial inferior a 0,1 mm.

. AdheÂsif anaeÂrobic servant aÁ un collage rapide moyennement reÂsistant des joints cylindriques en meÂtal (moyeu sur l'arbre). Il peut servir aÁ coller des pieÁces avec un jeu radial infeÂrieur aÁ 0,1 mm.

. Solvent-based sealing compound for elastic seals, drying through evaporation. Used for sealing the outer (AREXONS)

Repositionable jointing compound for seals Mastice per guarnizioni riposizionabile Klebstoff fuÈr verstellbare Dichtungen Pasta para juntas reposicionable Mastic pour garnitures aÁ remettre en place

008 911 79

diameter of sealing rings for rotating shafts with outer metal reinforcement.

. Mastice sigillante per guarnizioni elastiche a base di solvente, essicante per evaporazione.

Viene utilizzato per la tenuta sul diamentro esterno di anelli di tenuta per alberi rotanti con armatura metallica esterna. . Klebstoff fuÈr Gummidichtung auf LoÈsemittelbasis, trocknet durch Verdampfung. Wird am aÈuûeren Durchmesser von Dichtungsringe bei rotierenden Wellen mit Metallmantel verwendet. . Pasta para juntas de sellado para juntas elaÂsticas a base de disolvente, deshidratante por evaporacioÂn. Se utiliza para la estanqueidad en el diaÂmetro externo de segmentos de compresioÂn, para ejes giratorios con armadura metaÂlica exterior. . Mastic adheÂsif aÁ base de solvants pour garnitures eÂlastiques, seÂchant par eÂvaporation. Il sert garder eÂtanche le diameÁtre exteÂrieur des bagues d'eÂtancheÂite des arbres rotatifs ayant une armature meÂtallique externe.

BOMAG 11

943

18.5

Axle DANA 193

SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS - MATERIALI PER BLOCCAGGIO VITI, TENUTA E LUBRIFICAZIONE - MATERIAL ZUR BLOCKIERUNG VON SCHRAUBEN UND FUÈR DICHTUNGEN UND SCHMIERMITTEL - MATERIALES PARA EL BLOQUEO, ESTANQUEIDAD Y LUBRICACION MATEÂRIAUX POUR LE BLOCAGE VIS, EÂTANCHEÂITEÂ ET LUBRIFICATION DENOMINATION DENOMINAZIONE BEZEICHNUNG DENOMINACION DENOMINATION

APPLICATION - APPLICAZIONE - ANWENDUNG - APLICACION - APPLICATION

. Semi-fluid adhesive material used for sealing and filling and to protect components from environmental and physical elements. Polymerises with non-corrosive dampness.

Silicone Silicone Silikon Silicona Silicone

. Materiale adesivo semifluido usato per sigillatura, riempimenti e per la protezione di componenti dagli elementi ambientali e fisici. Polimerizza con umiditaÁ non corrosiva.

. HalbfluÈssiger Klebstoff zum Befestigen, FuÈllen und zum Schutz von Bestandteilen vor aÈuûeren Einwirkungen. Polymerisiert durch nicht korrosive Feuchtigkeit

. Material adhesivo semifluido usado para el sellado, llenado y para la proteccioÂn de componentes de elementos ambientales y fõÂsicos. Polimeriza con humedad no corrosiva.

. Produit adheÂsif semi-fluide utilise pour le scellage, remplissage et protection des eÂleÂments ambiants et physiques. PolymeÂrise aÁ une humidite non corrosive.

. Highly adhesive synthetic grease, with silicone compounds added.

(TECNO LUPE/101) Silicone-based grease Grasso al silicone Silikonfett Grasa a la silicona Graisse au silicone

. . . .

Applied to adjustment screws with hole communicating with oil-type fluids. Used when frequent adjusting is required. Grasso sintetico con elevato grado di adesivitaÁ, additivato con composti siliconici. Applicato su viti di registrazione a foro comunicante con fluidi di tipo oleoso. Usato quando si richiedono frequenti interventi di registrazione. Synthetisches Fett mit hoher Haftfestigkeit, mit silikonhaltigen Stoffen legiert. Wird auf Stellschrauben mit Loch, die mit oÈlhaltigen FluÈssigkeiten in Kontakt stehen, angebracht. Wird verwendet, wenn die Schraub oÈfters eingestellt werden muû. Grasa sinteÂtica con elevado grado de adhesioÂn, aditivada con componentes silicoÂnicos. Aplicada en tornillos de ajuste de orificio comunicante con fluidos de tipo oleoso. Se usa cuando se requieren frecuentes intervenciones de ajuste. Graisse syntheÂtique ayant un degre d'adheÂsivite eÂleveÂ, adjuve de composeÂs au silicone. Applique sur les vis de reÂglage aÁ trou communiquant avec des fluides du type huileux. Utilise quand il y a besoin de reÂglages freÂquents.

. Lubricating compound containing molybdenum disulphide, used to lubricate articulation pins and to prevent sticking and oxidation of parts that are not lubricated on a regular basis.

. Composto lubrificante contenente bisolfuro di molibdeno, usato per la lubrificazione di perni snodo e per preMolikote (DOW CORNING)

venire incollamenti ed ossidazioni di particolari non lubrificati in modo continuo.

. Schmierstoff mit MolybidaÈndisulfid; wird zum Schmieren von Gelenkstiften und gegen Ankleben und Oxydation von nicht dauergeschmierten Einzelteilen verwendet.

. Compuesto lubricante que contiene bisulfuro de molibdeno, usado para la lubricacioÂn de roÂtulas y para prevenir encoladuras y oxidaciones de piezas no lubricadas de manera continua.

. Compose lubrifiant contenant du bisulfure de molybdeÁne, utilise pour lubrifier les axes d'articulation et preÂvenir collages et oxydations des pieÁces qui ne sont pas continuellement lubrifieÂes.

(Lithium-based) Grease Grasso (al Litio) (Lithium) Fett Grasa (al Litio) Graisse (au Lithium)

944

. Applied to bearings, sliding parts and used to lubricate seals or parts during assembly . Applicato a cuscinetti, parti scorrevoli e per lubrificare guarnizioni o pezzi in fase di montaggio. . Wird auf Lager, Gleitteilen aufgetragen und zum Schmieren von Dichtungen oder von Teilen bei der Montage verwendet.

. Aplicada a cojinetes, partes deslizables o para lubricar juntas o piezas en fase de montaje. . Applique sur les paliers, parties coulissantes et pour lubrifier les garnitures ou pieÁces pendant la phase de montage.

BOMAG 12

008 911 79

18.5

Axle DANA 193

NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE GB

1 - During all operations described in this manual, the axle should be fastened onto a trestle, while the other parts mentioned should rest on supporting

benches. 2 - When removing one of the arms, an anti-tilting safety trestle should be placed under the other arm. 3 - When working on an arm that is fitted on the machine, make sure that the supporting trestles are correctly positioned and that the machine is locked lengthways. 4 - Do not admit any other person inside the work area; mark off the area, hang warning signs and remove the ignition key from the machine. 5 - Use only clean, quality tools; discard all worn, damaged, lowquality or improvised wrenches and tools. Ensure that all dynamometric wrenches have been checked and calibrated. 6 - Always wear gloves and non-slip rubber shoes when performing repair work. 7 - Should you stain a surface with oil, remove marks straight away. 8 - Dispose of all lubricants, seals, rags and solvents once work has been completed. Treat them as special waste and dispose of them according to the relative law provisions obtaining in the country where the axles are being overhauled. 9 - Make sure that only weak solvents are used for cleaning purposes; avoid using turpentine, dilutants and toluol-, xylolbased or similar solvents; use light solvents such as Kerosene, mineral spirits or water-based, environment friendly solvents. 10 - For the sake of clarity, the parts that do not normally need to be removed have not been reproduced in some of the diagrams. 11 - The terms RIGHT and LEFT in this manual refer to the position of the operator facing the axle from the side opposite the drive. 12 - After repair work has been completed, accurately touch up any coated part that may have been damaged. 1 - Le operazioni descritte sono riferite all'assale blocITA cato su cavalletto ed alcuni particolari appoggiati su un banco di lavoro. 2 - Quando si asporta un braccio dell'assale, sistemare sotto l'altro braccio un cavalletto di sicurezza antiribaltamento. 3 - Se si opera su un'assale montato sulla macchina, assicurarsi di aver sistemato dei cavalletti di sostentamento e di aver immobilizzato longitudinalmente la macchina. 4 - Non permettere che persone estranee entrino nella zona di lavoro; delimitare questa zona, appendere dei cartelli di avviso di lavori in corso ed asportare le chiavi di avviamento della macchina. 5 - Usare solo ed esclusivamente attrezzi puliti e di buona qualitaÁ; scartare chiavi od attrezzi usurati o danneggiati, di bassa qualitaÁ od improvvisati. Assicurarsi che le chiavi dinamometriche siano state controllate e tarate. 6 - Durante le operazioni di riparazione, indossare sempre guanti e scarpe antiscivolo. 7 - Pulire immediatamente le zone eventualmente imbrattate d'olio. 8 - I lubrificanti, le guarnizioni, gli eventuali stracci di pulizia ed i solventi usati devono essere smaltiti come rifiuti speciali e comunque secondo le normative vigenti nel Paese ove vengono revisionati gli assali. 9 - Per la pulizia, usare solo solventi deboli escludendo categoricamente trielina, diluenti e solventi a base di toluolo, xilolo, ecc.; usare solo solventi leggeri quali cherosene, ragie minerali o solventi ecologici a base d'acqua. 10 - Per chiarezza di illustrazione ed esposizione, sulle figure di alcuni gruppi mancano dei particolari che, normalmente, possono essere lasciati montati. Rimuovere solo i particolari descritti. 11 - I termini DESTRA e SINISTRA usati nel manuale sono riferiti alla persona che guarda l'assale dal lato opposto alla presa di moto. 12 - Al termine delle riparazioni, per evitare dannose ossidazioni, ritoccare con cura le parti verniciate eventualmente danneggiate. 1 - Die beschriebenen VorgaÈnge werden an der Achse vorgenommen, wenn diese auf einem Bock blockiert ist. Zur Bearbeitung der Einzelteile, werden diese auf die Werkbank gelegt. Wenn eine Achse abgenommen wird, einen Sicherheitsbock unter den zweiten Arm legen. Werden Arbeiten an der Achse vorgenommen, wenn diese noch an der Maschine montiert ist, BoÈcke zur Halterung unter die Achse stellen und die Maschine der LaÈnge nach blockieren. Es duÈrfen sich keine fremde Personen in der NaÈhe der Maschine waÈhrend der Arbeiten aufhalten; diesen Bereich absperren und mit Schilder kennzeichnen, die auf die laufenden Arbeiten hinweisen. ZuÈndschluÈssel von der Maschine abnehmen. Nur saubere Werkzeuge guter QualitaÈt verwenden; alte, beschaÈdigte oder improvisierte Hilfsmittel nicht verwenden. Sicherstellen, daû die Dynamometer gepruÈft und geeicht worden sind. Bei Reparaturen, stets Handschuhe und rutschfeste Schuhe tragen. È l beschmutzte Stellen, sofort reinigen. Mit O Gebrauchte Schmiermittel, Dichtungen, Reinigungslappen und

D 234-

5678-

008 911 79

BOMAG 13

9-

10 -

11 12 -

LoÈsemittel muÈssen als SondermuÈll und auf jeden Fall laut den oÈrtlich geltenden Vorschriften entsorgt werden. Zur Reinigung ausschlieûlich schwache LoÈsemittel wie Petroleum, Terpentin oder wasserhaltige LoÈsemittel verwenden. Auf keinen Fall TrichloraÈthylen, tuolol- oder xylolhlatige LoÈsemittel usw. verwenden. Um die ArbeitsvorgaÈnge verstaÈndlich abzubilden, werden in einigen Fotos die Aggregate ohne Einzelteile gezeigt, die sonst bei der Arbeit nicht abmontiert werden muÈssen. Nur die beschriebenen Teile abmontieren. Unter RECHTS und LINKS versteht man in diesem Handbuch die Seite einer Person, die zur Achse schaut und zwar dem Antrieb entgegengesetzt. Nach beendeten Arbeiten und um Rostbildungen zu vermeiden, die Teile an denen der Lack ggf. beschaÈdigt worden ist, anstreichen. 1 - Las operaciones descritas se refieren al eje bloqueado en un caballete y a algunas partes apoyadas en el banco de trabajo. Cuando se saca un brazo del eje, colocar debajo del otro un caballete de seguridad antivuelco. Si se trabaja con un eje montado en la maÂquina, asegurarse de haber colocado caballetes soporte y de haber inmovilizado longitudinalmente la maÂquina. No permitir que personas extranÄas entren en la zona de trabajo; delimitar esta zona, colgar carteles de aviso de hombres trabajando y sacar las llaves de arranque de la maÂquina. Usar soÂlo y exclusivamente herramientas limpias y de buena cualidad; descartar llaves o herramientas gastadas o danÄadas, de calidad mediocre o improvisadas. Asegurarse de que las llaves dinamomeÂtricas han sido controladas y calibradas. Durante las operaciones de reparacioÂn, llevar siempre guantes y calzado antideslizamiento. Limpiar inmediatamente las zonas que pudieran estar sucias de aceite. Los lubricantes, las juntas, los trapos para la limpieza y los disolventes usados hay que eliminarlos como desechos especiales y, de todas formas, de acuerdo con las normativas vigentes en el paõÂs en el que se revisan los ejes. Para limpiar, utilizar soÂlo disolventes deÂbiles excluyendo en absoluto tricloroetileno, diluyentes y disolventes a base de toluol, silol, etc.; usar soÂlo disolventes ligeros como queroseno, aguarraÂs minerales o disolventes ecoloÂgicos a base de agua. Para que resulte clara la exposicioÂn y la ilustracioÂn, en las figuras de algunos grupos faltan algunas piezas que por lo general se pueden dejar montadas. Sacar soÂlo las partes descritas. Las palabras DERECHA E IZQUIERDA usadas en el manual se refieren a la persona que mira el eje del lado opuesto a la toma de movimiento. Al final de las reparaciones, para evitar oxidaciones, retocar cuidadosamente las partes pintadas que estuvieran danÄadas.

ESP 2345-

678-

9-

10 11 12 -

1 - Les opeÂrations deÂcrites se rapportent aÁ l'essieu bloque sur chevalet et de quelques pieÁces poseÂes sur un eÂtabli de travail. Quand on enleÁve un essieu monte sur la machine, ajuster sous l'autre bras un chevalet de seÂcurite contre tout basculement. Si on oeuvre sur un essieu monte sur la machine, s'assurer d'avoir ameÂnage des chevalets de soutien et d'avoir bloque la machine en longueur. Ne jamais permettre aÁ des eÂtrangers de peÂneÂtrer dans la zone de travail; deÂlimiter cette zone, mettre des pancartes de signalisation de travaux en cours et enlever les cleÂs de contact de la machine. N'utiliser que des outils propres et de bonne qualiteÂ; eÂliminer cle ou autres outils useÂs, abõÃmeÂs, de mauvaise qualite ou improviseÂs. Veiller aÁ ce que les cleÂs dynamomeÂtriques aient eÂte controÃleÂes et calibreÂes. Pendant les opeÂrations de reÂparation, endosser toujours gants et chaussures antideÂrapantes. Nettoyer tout de suite les eÂventuelles zones souilleÂes d'huile. Les lubrifiants, les garnitures, les eÂventuels chiffons servant au nettoyage et les solvants utiliseÂs devront eÃtre reÂcolteÂs et traiteÂs comme rebut speÂcial conformeÂment aux lois en vigueur dans le pays ouÁ les essieux sont en reÂvision. Pour le nettoyage, n'utiliser que des solvants aÁ base de toluol, xylol, etc.; n'utiliser que des solvants leÂgers tels que keÂroseÁne, essences mineÂrales, ou solvants eÂcologiques aÁ base d'eau. En ce qui concerne la clarte en matieÁre d'illustration et exposition, sur les figures de certains groupes, il y a des pieÁces manquantes qui normalement peuvent rester monteÂes. Enlever uniquement les pieÁces deÂcrites. Les termes DROITE et GAUCHE utiliseÂs dans ce manuel se rapportent aÁ la personne regardant l'essieu du coÃte oppose aÁ celui de la prise de mouvement. A la fin des opeÂrations, afin d'eÂviter un risque d'oxydation nuisible, retoucher soigneusement les parties vernies eÂventuellement abõÃmeÂes.

F 2345-

678-

910 -

11 12 -

945

18.5

Axle DANA 193 CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO CONTROÃLE USURE ET SUBSTITUTION DES DISQUES FREINS

SIMBOLI

946

Disassembly of assembly groups Smontaggio di sottogruppi Zerlegen von Baugruppen Desmontaje de subgrupos Demontage des sous-groupes Reassemble to from assembly groups Montaggio di sottogruppi Zusasmmenbauen von Baugruppen Ensamblaje de subgrupos Montage des sous-groupes Remove obstruction parts Smontaggio di particolari ingombri Abbauen-Ausbauen Desmontaje de componentes abultados Demontage des pieces encombrante Reinstall-remount parts which had obstructed disassembly Montaggio di particolari ingombri Einbauen-Ausbauen Montaje de componentes abultados Montage des pieces encombrante Attention ! Important notice Attenzione, indicazione importante Achtung, wichtiger Hinweis ¡ Cuidado ! IndicacioÂn importante Attention, indication importante Check - adjust e.g. torque, dimensions, pressures, etc. Controllare - regolare p.e. coppie, misure, pressioni ecc. PruÈfen - Einstellen z.B. Momente, Maûe, Drucke u.s.cs. Controlar y ajustar, por ej. pares, medidas, presiones, etc. Controler, regler p.e. couples, mesures, pressions ecc. T=Special tool P=page T=Attrezzature speciali P=Pagina T=Spezialwerkzeug P=Seite T=Herramientas especiales P=PaÂgina T=Outils P=Page Note direction of installation Rispettare direzione di montaggio Einbaurichtung beachten Respetar la direccioÂn de ensamblaje Respecter direction de montage Visual inspection Esaminare con controllo visuale Kontrollieren -PruÈfen Examinar mediante inspeccioÂn visual Controler, examiner, controle visuel Possibly still serviceable, renew if necessary Eventualmente riutilizzare (sostituire se necessario) Bedingt weiderverwendbar Puede volver a utilizarse (reemplazar, si es preciso) Eventuellement a utiliser a noveau (remplacer si neÂcessaire) Renew at each reassembly Sostituire ad ogni montaggio Beim Zusammenbau immer erneuern Puede reemplazarse a cada ensamblaje Remplacer avec chaque montage Unlock - lock e.g. split pin, locking plate, etc. Togliere-mettere la sicura Entsichern-Sichern Quitar-colocar el seguro Enlever-mettre la securite Lock-adhere (liquid sealant) Mettere la sicura, incollare (mastice liquido) Sichern-Kleben (fluÈssige Dichtung) Colocar el seguro, pegar (mastique lõÂquido) Mettre la securite, coller (mastic liquide) Guard against material damage, damage to parts Evitare danni materiali, danni a pezzi Materialschaden verhuÈten Evitar danÄar los materials o las piezas Eviter dommages au materiaux, dommages au pieces Mark before disassembly, observe marks when reassembly Marchiare prima dello smontaggio (per il montaggio) Vor dem Ausbau markieren (fuÈr den Zusammenbau) Marcar antes de desmontar (para facilitar el ensamblaje) Marquer avant le demontage (pour le montage) Filling - topping up - refilling e.g. oil, cooling water, etc. Caricare - riempire (olio - lubrificante) EinfuÈllen - AuffuÈllen - NachfuÈllen (OÈl-Schmiermittel) Cargar - llenar (aceite lubricante) Charger - remplir (huile - lubrifiant) Drain off oil, lubricant Scaricare olio, lubrificante OÈl, bzw. Schmiermittel Ablassen Descargar aceite lubricante Vidanger, lubrifiant Tighten Tendere Spannen Tensar Tendre Apply pressure into hydraulic circuit Inserire pressione nel circuito idraulico Leitung unter Druck setzen Introducir presioÂn en el circuito hidraÂulico Inserer pression dans le circuit hydraulique To clean Pulire Reinigen Limpiar Nettoyer Lubricate - grease Lubrificare - ingrassare Schmieren - einfetten Lubrificar - Engrasar Lubrifier - Graisser

T1

S F1241070

F1241071

a

GB

bar

CHECKING WEAR CAUTION! Perform operations on both arms. Remove the oil-level plug (1).

b

GB

Introduce tool T1 between the disks and check shim "S". Minimum size of "S": 4.5 mm.

P

F1241072

bar

GB

F1241073

c

d

GB

ADJUSTING THE BRAKES Connect an external pump to the union piece "P" of the negative brake and introduce a pressure of 15 ± 30 bar to eliminate the pressure of the Belleville washers (11).

Remove screw (2) and safety plate (3).

F1241074

GB

F1241075

e

REPLACING THE BRAKING DISKS Sling the arm (6) to be removed and connect it to a hoist. Loosen and remove screws (7) and nuts (8).

Turn the brake clearance adjustment pinion (4) clockwise and as far as the limit stop. Release pressure and disconnect the tubes. NOTE. Remove the lower plug (5) and drain the oil.

BOMAG

f

GB

14

008 911 79

18.5

Axle DANA 193

CONTROLLO USURA ATTENZIONE! Eseguire le operazioni per i due bracci. Asportare il tappo (1) di livello olio.

ITA

Introdurre l'attrezzo T1 tra i dischi e controllare lo spessore "S". "S" minimo: 4,5 mm

VERSCHLEISS KONTROLLIEREN ACHTUNG! Die VorgaÈnge an beiden Armen vornehmen. È OleinfuÈllstopfen (1) abnehmen.

D

Werkzeug T1 zwischen den Scheiben einsetzen und die StaÈrke "S" kontrollieren. "S" Minimum: 4,5 mm

ESP

Introducir la herramienta T1 entre los discos y controlar el espesor "S". «S» minimo: 4,5 mm.

F

Introduire l'outil T1 entre les disques et controÃler la cale "S". "S" minimum: 4,5 mm

ITA

D

a

b

CONTROL DESGASTE ATENCION! Efectuar las operaciones por los dos ejes. Sacar el tapon (1) de nivel aceite.

ESP

F

CONTROLE USURE ATTENTION! Effectuer les opeÂrations aux deux bras. Enlever le bouchon (1) du niveau d'huile.

REGISTRAZIONE FRENI Collegare al raccordo "P" del freno negativo una pompa esterna ed immettere una pressione di 15v30 bar per eliminare la pressione delle molle a tazza (11).

ITA

BREMSEN EINSTELLEN AnschluûstuÈck "P" der Federspeicherbremse an eine aÈuûere Pumpe anschlieûen und Druck bei 15v30 bar einlassen, um Tellerfedern (11) zu entlasten.

D

ITA

D

c

Schraube (2) und SicherheitsplaÈttchen (3) abnehmen.

d

REGISTRACION FRENOS Conectar al empalme «P» del freno negativo una pompa esterna y introducir una presion de 15v30 bar para eliminar la presion de los muelles a taza (11).

ESP

REGLAGE DES FREINS Brancher au raccord "P" du frein neÂgatif une pompe externe et envoyer une pression de 15v30 bar pour eÂliminer la pression des ressorts belleville (11).

F

ESP

F

Sacar el tornillo (2) y la placa de securidad (3).

Enlever les vis (2) et la plaquette de seÂcurite (3).

Ruotare in senso orario il pignone (4) di regolazione gioco freni fino a fondo corsa. Rilasciare la pressione e scollegare i tubi. NOTA. Rimuovere il tappo inferiore (5) e scaricare l'olio.

SOSTITUZIONE DISCHI FRENO Imbragare il braccio (6) da asportare e collegarlo ad un mezzo di sollevamento. Allentare ed asportare le viti (7) ed i dadi (8).

Das Kegelrad (4) zur Einstellung des Bremsspiels bis zum Endanschlag drehen. Druck ablassen und die Leitungen abtrennen. È l. BEMERKUNG. Unteren Stopfen (5) abnehmen und das O

BREMSSCHEIBEN AUSWECHSELN Den abzunehmenden Arm (6) anschlagen und an eine Hebezeug befestigen. Schrauben (7) und Muttern (8) lockern und abschrauben.

ITA

ITA

D

e

Asportare la vite (2) e la piastrina di sicurezza (3).

D

f

Girar en sentido horario el pinon (4) de regulacioÁn juego frenos hasta final carrera. Dejar la presion y desconectar los tubos. NOTA. Remover el tapon inferior (5) y descargar el aceite.

SUBSTITUCION DISCOS FRENOS. Atar el eje (6) de sacar y conectarlo a un medio de levantamiento. Aflojar y sacar los tornillos (7) y las tuercas (8).

Tourner le pignon de reÂglage du jeu des freins (4) dans le sens des aiguilles d'une montre jusqu'en fin de course. LibeÂrer la pression et deÂbrancher les tubes. REMARQUE: Enlever le bouchon infeÂrieur (5) et vidanger l'huile.

Substitution des disques frein Elinguer le bras (6) aÁ enlever et brancher celui-ci aÁ un moyen de relevage. Desserrer et enlever les vis (7), les eÂcrous (8).

ESP

F

008 911 79

BOMAG 15

ESP

F

947

18.5

Axle DANA CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO CONTROÃLE USURE ET SUBSTITUTION DES DISQUES FREINS

F1241076

GB

F1241077

a

Remove arm (6) together with brakes and axle shafts; lay down the arm vertically.

Loosen screws (9) in an alternate manner and remove them.

F1241079

c

Move the cylinder (10) outwards while supporting the Belleville washers (11). Remove the Belleville washers (11) and note down direction of assembly.

GB

GB

948

F1241081

e

Slowly introduce low-pressure compressed air through the connection member for the negative brake, in order to extract the piston (12). CAUTION! Hold the piston (12) back, as it may be suddenly ejected and damaged.

d

Remove the cylinder (10) complete with piston (12).

F1241080

bar

b

GB

F1241078

GB

193

GB

f

Remove O-rings (13) and (14) from the piston (12). NOTE. The O-rings (13) and (14) must be replaced each time the unit is disassembled.

BOMAG 16

008 911 79

18.5

Axle DANA 193

ITA

Rimuovere il braccio (6) completo di freni e semiassi; deporre il braccio in modo verticale.

ITA

D

Den Arm (6) samt Bremsen und Halbachsen abnehmen; den Arm senkrecht ablegen.

D

Abwechselnd die Schrauben (9) lockern und abschrauben.

a

b ESP

Remover el eje (6) completo de frenos y semi-ejes; colocar el eje de manera vertical.

ESP

Aflojar de manera alternada los tornillos (9) y sacarlas.

F

Enlever le bras (6) complet de freins et demi-essieux; deÂposer le bras en vertical.

F

Desserrer les vis (9) en alternance, puis les enlever.

ITA

Spostare verso l'esterno il cilindro (10) sostenendo le molle a tazza (11). Rimuovere le molle (11) ed annotare il senso di

ITA

Den Zylinder (10) nach auûen verstellen und dabei die Tellerfedern (11) stuÈtzen. Federn (11) abnehmen und die Montagerichtung

D

montaggio.

D

c

notieren.

ESP montaje.

F montage.

Rimuovere il cilindro (10) completo di pistone (12).

Zylinder (10) samt Kolben (12) abnehmen.

d Desplazar hacia el esterior el cilindro (10) sosteniendo los muelles a taza (11). Remover los muelles (11) y anotar el sentido de

ESP

DeÂplacer le cylindre (10) vers l'exteÂrieur en soutenant le ressort belleville (11). Enlever le ressort (11) et prendre note du sens de son

F

Remover el cilindro (10) completo de piston (12).

Enlever le cylindre (10) complet de piston (12).

Immettere lentamente aria compressa a bassa pressione attraverso l'attacco per il freno negativo per estrarre il pistone (12). ATTENZIONE! Trattenere il pistone (12) che puoÁ essere espulso velocemente ed essere danneggiato.

ITA

Rimuovere dal pistone (12) gli anelli OR (13) e (14). NOTA. Gli anelli OR (13) e (14) devono essere sostituiti ad ogni smontaggio.

Langsam Druckluft bei Niederdruck durch den Anschluû der Federspeicherbremse einlassen, um den Kolben (12) heraus zu druÈcken. ACHTUNG! Den Kolben (12) halten, da er ploÈtzlich heraus springen und beschaÈdigt werden koÈnnte.

D

Kolben (12) und O-Ringe (14) und (14) abnehmen. BEMERKUNG. Die O-Ringe (13) und (14) muÈssen jedesmal ausgewechselt werden, wenn das Teil zer-

ITA

D

e

Allentare in modo alternato le viti (9) ed asportarle.

Introducir lentamente aire comprimida a baja presioÁn atraves el empalme por el freno negativo para sacar el piston (12). ATENCION! Tener el piston (12) que puede ser expulso rapidamente y estropearse.

ESP

Envoyer lentement de l'air comprime aÁ basse pression aÁ travers le raccord du frein neÂgatif pour extraire le piston (12). ATTENTION! Tenir le piston (12) qui pourrait eÃtre expulser rapidement et endommager.

F

008 911 79

BOMAG 17

f

legt wird.

ESP

Remover del piston (12) los anillos OR (13) y (14). NOTA. Los anillos OR (13) y (14) deben de ser sobstituidos cada desmontaje.

Enlever le piston (12), les anneaux O'RING (13) et (14). REMARQUE. Les anneaux O'RING (13) et (14) sont aÁ substituer aÁ chaque deÂmontage.

F

949

18.5

Axle DANA CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO CONTROÃLE USURE ET SUBSTITUTION DES DISQUES FREINS

193

A

F1241082

GB

F1241083

a

GB

b

Remove checking and guiding screws (15) from the pressure plate (16). NOTE. Loosen screws (15) in sequence and proportionally.

Remove the pressure plate (16). CAUTION! Note down the direction of assembly; flow regulator wall "A" and oil drain holes must face the oil drain plug.

F1241084

F1241085

GB

c

GB

d

Remove springs (17). NOTE. Accurately check the condition of springs. They should not be warped. Any deformation of the springs requires spring replacement.

Remove braking discs (18) and (19), noting down direction of assembly. NOTE. If disks are not to be replaced, avoid changing their position.

F1241086

F1241087

GB

e

Remove pinion (4) complete with O-ring (20). NOTE. The O-ring must be replaced each time the unit is disassembled.

950

GB

f

Unscrew and extract the braking disk clearance adjustment crown wheel (21).

BOMAG 18

008 911 79

18.5

Axle DANA 193

Rimuovere le viti (15) di ritegno e guida dello spingidisco (16). NOTA. Allentare le viti (15) in modo sequenziale ed in uguale misura.

Rimuovere lo spingidisco (16). ATTENZIONE! Annotare il senso di montaggio; la parete frangiflusso "A" e gli scarichi olio, devono essere rivolti verso il tappo di scarico olio.

Befestigungsschrauben (15) und die FuÈhrung der Druckplatte (16) abnehmen. BEMERKUNG. Abwechselnd Schrauben (15) im gleichen Maû lockern.

Druckplatte (16) abnehmen. ACHTUNG! Montagerichtung notieren; der StrahlregÈ lablaûoÈffnungen muÈssen in Richtung ler "A" und die O È des Olablaûstopfens gerichtet sein.

ITA

ITA

D

a

D

b

Remover los tornillos (15) de retencioÁn y guõÁa del empuya-disco (16). NOTA. Aflojar los tornillos (15) de manera secuencial y en la misma mesura.

Remover el empuja-disco (16). ATENCION. Anotar el sentido de montaje; la pared rompe-flujo "A" y los descarge aceite, deben de ser dirijidos hacia el tapon de descarga aceite.

Enlever vis (15) de fixation et guide du plateau de pression (16). REMARQUE: Desserrer les vis (15) en seÂquence et en eÂgale mesure.

Enlever le plateau de pression (16). ATTENTION! Prendre noter du sens du montage; la paroi brise-jet "A" et les eÂcoulements d'huile sont tourneÂs vers le bouchon de vidange d'huile.

Rimuovere le molle (17). NOTA. Controllare attentamente lo stato delle molle che non devono essere deformate. Ogni deformazione deve portare alla sostituzione.

Rimuovere i dischi di frenatura (18) e (19) annotando l'ordine di montaggio. NOTA. Se i dischi non devono essere sostituiti, evitare lo scambio di posizione.

Federn (17) abnehmen. BEMERKUNG. Die Federn sorgfaÈltig kontrollieren; sie duÈrfen nicht verformt sein. Sollte dies der Fall sein, Federn auswechseln.

Bremsscheiben (18) und (19) abnehmen und Montagerichtung notieren. BEMERKUNG. Falls die Scheiben ausgewechselt werden muÈssen, ihre Position nicht verwechseln.

ESP

ESP

F

F

ITA

ITA

D

c

D

d

Remover los muelles (17). NOTA. Controlar atentamente el estado de los muelles que no deben de ser deformes. A cada deformacioÁn deben de ser cambiados.

Remover los discos de frenadura (18) y (19) anotando el orden de montaje. NOTA. Si los discos no deben de ser sobstituidos, evitar el cambio de possicioÁn.

Enlever les ressorts (17). REMARQUE. ControÃler attentivement l'eÂtat des ressorts, ils ne doivent pas eÃtre deÂformeÂs. Toute deÂformation veut dire substitution.

Enlever les disques de freinage (18) et (19) et prendre note de l'ordre du montage. REMARQUE. Si les disques doivent eÃtre substitueÂs, eÂviter d'eÂchanger leur position.

ESP

ESP

F

F

ITA

Rimuovere il pignone (4) completo di anello OR (20). NOTA. L'anello OR deve essere sostituito ad ogni smontaggio.

ITA

Svitare ed asportare la corona (21) di regolazione del gioco dischi di frenatura.

D

Das Kegelrad (4) samt O-Ring (20) entfernen. BEMERKUNG. Den O-Ring bei jedem Zerlegen auswechseln.

D

Den Kranz (21) zur Einstellung des Bremsscheibenspiels abnehmen.

ESP

Destornillar y sacar la corona (21) de regulacioÁn del juego discos de frenadura.

F

DeÂvisser et enlever la couronne (21) de reÂglage du jeu des disques de freinage.

e

f ESP

Remover el pinon (4) completo de anillo OR (20). NOTA. El anillo OR debe de ser sobstituido a cada desmontaje.

Enlever le pignon (4) complet de l'anneau O'RING (20). REMARQUE. L'anneau O-Ring est aÁ remplacer aÁ chaque deÂmontage.

F

008 911 79

BOMAG 19

951

DANA 193 18.5 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS -Axle MONTAJE DE LOS GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS

D1240130

F1241133

GB

a

Lubricate the threaded portion of the crown wheel (21) and screw it down into the arm (6) as far as it will go.

952

F1241134

GB

b

Replace the O-ring (20) of pinion (4). Lubricate and install the pinion in the slot provided on the arm (6), inserting the toothing into crown wheel (21).

BOMAG 20

008 911 79

18.5

Axle DANA 193

GB

ESP

ITA

F

D

ITA

Lubrificare la filettatura della corona (21) ed avvitarla a fondo nel braccio (6).

ITA

Sostituire l'anello OR (20) del pignone (4). Lubrificare il pignone e montarlo nella sede del braccio (6) innestando la dentatura nella corona (21).

D

Das Gewinde des Kranzes (21) schmieren und in den Arm (6) festschrauben.

D

O-Ring (20) des Kegelrads (4) auswechseln. Kegelrad schmieren und in den Sitz des Arms (6) montieren; dabei die ZaÈhne des Kranzes (21) einrasten.

ESP

Sobstituir el anillo OR (20) del pinon (4). Lubrificar el pinon y montarlo en la sed del eje (6) introduciendo la dentadura en la corona (21).

a

b ESP

Lubrificar la rosca de la corona (21) y atornillar a hondo en el eje (6).

F

Lubrifier le filetage de la couronne (21), puis visser celle-ci aÁ fond dans le bras (6).

008 911 79

BOMAG 21

Substituer l'anneau O'RING (20) du pignon (4). Lubrifier le pignon, puis monter celui-ci dans le logement du bras (6) en introduisant en meÃme temps la denture dans la couronne (21).

F

953

DANA 193 18.5 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS -Axle MONTAJE DE LOS GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS

B

F1241088

F1241089

a

GB

Lightly lubricate the first steel braking disk (18), then install it on the arm (6).

GB

b

Lubricate the first friction disk (19) and install it on the axle shaft . Complete the assembly, alternating steel disks and friction disks. CAUTION! Oval holes "B" of friction disks must be lined up.

A F1241084

F1241083

c

GB Position springs (17) in the appropriate slots of the arm (6).

GB

Fit the pressure plate (16). CAUTION! Accurately check orientation: flow regulator "A" and oil drains must be oriented towards the arm's oil drain plug.

F1241082

GB Lock the pressure plate into position (16) with screws (15). CAUTION! Tighten screws in sequence and a little at a time.

954

d

F1241090

e

GB

f

Lock screws (15) with a dynamometric wrench. Torque wrench setting: 20 ± 30 Nm.

BOMAG 22

008 911 79

18.5

Axle DANA 193

ITA

Lubrificare leggermente il primo disco di frenatura in acciaio (18) e montarlo nel braccio (6).

Lubrificare il primo disco di attrito (19) e montarlo sul semiasse. Completare il montaggio alternando dischi di acciaio e dischi di attrito. ATTENZIONE! I dischi di attrito devono avere il foro ovale "B" allineato.

D

Die erste Bremsscheibe aus Stahl (18) etwas schmieren und in den Arm (6) montieren.

Die erste Reibscheibe (19) schmieren und auf die Halbachse montieren. Dann die Stahlscheiben abwechselnd mit den Reibscheiben montieren. ACHTUNG! Die LangloÈcher "B" der Reibscheiben muÈssen gefluchtet sein.

a

ITA

D

b ESP

Lubrificar ligermente el primer disco de frenadura en acero (18) y montarlo en el eje (6).

Lubrificar el primer disco de strito (19) y montarlo sobre el semi-eje. Completar el montaje alternando discos de acero y discos de atrito. ATENCION! Los discos de atrito deben tener el agujero oval «B» en linea.

F

Lubrifier leÂgeÁrement le premier disque de freinage en acier (18), puis monter celui-ci dans le bras (6).

Lubrifier le premier disque de friction (19), puis monter ce dernier sur le demi-essieu. Achever le montage en alternant les disques en acier et les disques de friction. ATTENTION! Les disques de friction doivent avoir le trou ovale "B" aligneÂ.

ITA

Posizionare nelle sedi del braccio (6) le molle (17).

Montare lo spingidisco (16). ATTENZIONE! Controllare attentamente l'orientamento; il frangiflusso "A" e gli scarichi olio, devono essere orientati verso il tappo di scarico olio del braccio.

D

In den Sitz des Arms (6) die Federn (17) einsetzen.

Die Druckplatte (16) montieren. ACHTUNG! SorgfaÈltig die Montagerichtung kontrollÈ lablaûoÈffnungen ieren; den Stahlregler "A" und die O muÈssen zum Ablaûstopfen des Arms gerichtet sein.

c

ESP

F

ITA

D

d Colocar en las sedes del eje (6) los muelles (17).

Montar el empuja-disco (16). ATENCION! Controlar atentamente el orientamiento; el rompe-flujo "A" y los descarga aceite, deben de ser orientados hacia el tapon de descarga aceite del eje.

F

Mettre en place les ressorts (17) dans les logements du bras (6).

Monter le plateau de pression (16). ATTENTION! ControÃler attentivement la direction; la paroi brise-jet "A" et les eÂcoulements d'huile doivent eÃtre dirigeÂs vers le bouchon de vidange d'huile du bras.

ITA

Fissare la posizione dello spingidisco (16) con le viti (15). ATTENZIONE! Serrare le viti in modo sequenziale ed

ESP

in piuÁ tempi.

ESP

Die Druckplatte (16) mit den Schrauben (15) befestigen. ACHTUNG! Die Schrauben der Reihe nach und schrittweise festziehen.

F

ITA

D

Schrauben (15) mit dem Dynamometer blockieren. Anzugsmoment: 20v30 Nm.

Fijar la posicioÁn del empuja-disco (16) con los tornillos (15). ATENCION! Apretar los tornillos de manera secuencial y en mas tiempos.

ESP

Bloquear los tornillos (15) con llave dinamometrica. Par de serraje: 20v30 Nm.

Fixer le plateau de pression (16) aÁ sa place avec les vis (15). ATTENTION! Serrer les vis en plusieurs temps en ordre seÂquentiel.

F

D

e

Bloccare le viti (15) con chiave dinamometrica. Coppia di serraggio: 20v30 Nm

ESP

F

008 911 79

BOMAG 23

f

Bloquer les vis (15) aÁ l'aide de la cle dynamomeÂtrique. Couple de serrage: 20v30 Nm.

955

DANA 193 18.5 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS -Axle MONTAJE DE LOS GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS

C

F1241091

GB

F1241092

a

GB

b

Fit O-rings (13) and (14) onto the piston (12). Lubricate the piston and the O-rings and install the unit into the cylinder (10). NOTE. Piston relief «C» must face downwards.

Using a plastic hammer, ram the piston (12) into the cylinder (10). NOTE. Lightly hammer all around the edge in an alternate sequence.

F1241079

F1241078

GB

c

GB

d

Check the condition and the position of the O-ring (22); lubricate the O-ring and position the cylinder on the studs without fastening.

Position the Belleville washers (11) and engage the cylinder (10). NOTE. Check the sense of direction of washers (11) and relative centring.

F1241093

F1241094

GB

e

Lock the cylinder (10), tightening the screws (9) with a dynamometric wrench set to a torque of 86 ± 89 Nm.

956

GB

f

Check integrity and position of the arm's O-ring (23); install the complete arm (6). NOTE. To assist axle shaft centring, slightly move the wheel hub.

BOMAG 24

008 911 79

18.5

Axle DANA 193

Montare sul pistone (12) gli anelli OR (13) e (14). Lubrificare il pistone e gli anelli OR e montare il gruppo nel cilindro (10). NOTA. Lo scarico "C" del pistone deve essere rivolto verso il basso.

Utilizzando un mazzuolo in materiale plastico, inserire a fondo il pistone (12) nel cilindro (10). NOTA. Battere leggeri colpi distribuiti in modo alternato su tutta la circonferenza.

Auf den Kolben (12) die O-Ringe (13) und (14) montieren. Den Kolben und die O-Ringe schmieren und das Aggregat in den Zylinder (10) montieren. BEMERKUNG. Die AblaûoÈffnung "C" des Kolbens muû nach unten gerichtet sein.

Mit einem Gummihammer den Kolben (12) in den Zylinder (10) bis zum Anschlag einschlagen. BEMERKUNG. Den Kolben abwechselnd rund um die gesamte Kreislinie leicht schlagen.

ITA

ITA

D

a

D

b

Montar sobre el piston (12) los anillos OR (13) y (14). Lubrificar el piston y los anillos OR y montar el grupo en los cilindros (10). NOTA. El escargo "C" del piston debe de ser dirijido hacia el bajo.

Utilizando un martillo de materia plastica, introducir a fondo el piston (12) en el cilindro (10). NOTA. Pegar ligeros golpes distribuidos de manera alternada sobre toda la circonferencia.

Monter sur le piston (12), les anneaux O'RING (13) et (14). Lubrifier le piston et les anneaux O'RING, puis monter le groupe dans le cylindre (10). REMARQUE. L'eÂcoulement "C" du piston doit eÃtre tourne vers le bas.

A l'aide d'un maillet en matieÁre plastique, introduire le piston (12) aÁ fond dans le cylindre (10). REMARQUE. Donner de leÂgers coups reÂguliers tout autour de la circonfeÂrence.

Controllare lo stato ed il posizionamento dell'anello OR (22); lubrificare l'anello OR e posizionare il cilindro sui prigionieri senza mandarlo in battuta.

Posizionare le molle a tazza (11) e mandare in battuta il cilindro (10). NOTA. Controllare il senso di orientamento delle molle a tazza (11) e la loro centratura.

Den Zustand und die Position des O-Ringes (22) kontrollieren; den O-Ring schmieren und den Zylinder auf die Stiftschrauben positionieren, ohne ihn bis zum Anschlag ganz einzusetzen.

Tellerfedern (11) positionieren und den Zylinder (10) bis zum Anschlag einsetzen. BEMERKUNG. Orientierung der Tellerfedern (11) und ihre Zentrierung kontrollieren.

ESP

ESP

F

ITA

F

ITA

D

c

D

d

ESP

Controlar el estado y la colocacioÁn del anillo OR (22); lubrificar el anillo OR y colocar el cilindro sobre los prigioneros sin llevarlo a tope.

Colocar los muelles a taza (11) y mandar a tope el cilindro (10). NOTA. Controlar el sentido de orientamiento de los muelles a taza (11) y su centraje.

F

ControÃler l'eÂtat et la position de l'anneau O'RING (22); lubrifier l'anneau O'RING et positionner le cylindre sur les prisonniers sans l'envoyer en buteÂe.

Positionner les ressorts belleville (11) et inseÂrer aÁ fond le cylindre (10). REMARQUE. ControÃler l'orientation des ressorts belleville (11) et leur centrage.

ITA

Bloccare il cilindro (10) con le viti (9) serrate con chiave dinamometrica ad un coppia di 86v89 Nm.

Verificare l'integritaÁ ed il posizionamento dell'anello OR (23) del braccio; installare il braccio completo (6). NOTA. Per agevolare la centratura del semiasse, muovere lentamente il mozzo portaruota.

D

Den Zylinder (10) mit den Schrauben (9) mit einem Dynamometer und einem Anzugsmoment von 86v89 Nm blockieren.

Am Arm den Zustand und die Position des O-Ringes (23) kontrollieren; den gesamten Arm (6) installieren. BEMERKUNG. Um die Halbachse leichter zentrieren zu koÈnnen, die Radhalternabe etwas bewegen.

e

ESP

F

ITA

D

f ESP

Bloquear el cilindro (10) con los tornillos (9) apretados con llave dinamometrica a un par de 86v89 Nm.

Averiguar la integridad y la colocacioÁn del anillo OR (23) del eje; colocar el eje completo (6). NOTA. Para facilitar el centraje del semi-eje, mover lentamente el cubo porta-rueda.

F

Bloquer le cylindre (10) avec les vis (9), serrer aÁ l'aide de la cle dynamomeÂtrique aÁ un couple de 86v89 Nm.

VeÂrifier le bon eÂtat et le positionnement de l'anneau O'RING (23) du bras; installer le bras complet (6). REMARQUE. Afin de rendre plus aise le centrage du demi-essieu, bouger lentement le moyeu porte-roue.

008 911 79

BOMAG 25

ESP

F

957

DANA 193 18.5 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS -Axle MONTAJE DE LOS GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS

T2

F1241095

GB

F1241096

a

Temporarily lock the arm (6) with nuts (8) previously coated with Loctite 242; tighten lightly to make the unit touch the main body.

GB

b

Check the flatness of the arms, using tool T2; then lock the arms into their final position, using screws (7) adequately coated with Loctite 242. Torque wrench setting: 182 ± 202 Nm. NOTE. Tighten using the criss-cross method.

P

F1241097

bar

GB

F1241074

c

Connect an external pump to the union piece "A" of the negative brake and introduce pressure to 15 ± 30 bar.

GB

d

Rotate the adjustment pinion (4) anticlockwise (±) to eliminate all existing clearance between the braking disks. Rotate up to a torque of 8 ± 10 Nm.

+

--

D1240132

GB

e

Rotate pinion (4) clockwise (+) to determine the required clearance of 1 mm. NOTE. A turn of the adjuster produces a clearance of 0.25 mm (1mm = 4 turns).

958

F1241073

GB

f

Install safety plate (3) and lock with screw (2). Torque wrench setting: 10 ± 11 Nm.

BOMAG 26

008 911 79

18.5

Axle DANA 193

a

ITA

Fissare provvisoriamente il braccio (6) con i dadi (8) spalmati con Loctite 242 e serrati leggermente per frizionare il gruppo sul corpo centrale.

Controllare la planaritaÁ dei bracci con l'attrezzo T2 e fissarli definitivamente con le viti (7) spalmate con Loctite 242. Coppia di serraggio: 182v202 Nm NOTA. Serrare con il metodo incrociato.

D

VoruÈbergehend den Arm (6) mit den mit Loctite 242 geschmierten Muttern (8) befestigen und Muttern zuschrauben bis das Aggregat an dem ZentralkoÈrper

Die Ebenheit der Arme mit dem Werkzeug T2 kontrollieren und endguÈltig mit den mit Loctite 242 geschmierten Schrauben (7) befestigen. Anzugsmoment: 182v202 Nm BEMERKUNG. Im Kreuz fest drehen.

anliegt.

ITA

D

b

ESP

Fijar provisoriamente el eje (6) con las tuercas (8) pasados con Loctite 242 y apretados ligermente para fricionar el grupo sobre el cuerpo central.

Controlar la planaridad de los ejes con la herramienta T2 y fijarlos definitivamente con los tornillos (7) pasar con Loctite 242. Par de serraje: 182v202 Nm NOTA. Apretar de manera cruzada.

F

Fixer provisoirement le bras (6) avec les eÂcrous (8) enduits avec du Loctite 242, et serrer ceux-ci pour frotter le groupe du corps central.

ControÃler la planeÂite des bras aÁ l'aide de l'outil T2, puis fixer ceux-ci deÂfinitivement avec les vis (7) enduites de Loctite 242. Couple de serrage: 182v202 Nm. REMARQUE. Serrer avec la meÂthode croiseÂe.

ITA

Collegare al raccordo "P" del freno negativo una pompa esterna ed immettere una pressione di 15v30 bar.

ITA

Ruotare in senso antiorario (±) il pignone di registro (4) per eliminare totalmente il gioco tra i dischi di frenatura. Ruotare fino ad ottenere una coppia di 8v10 Nm.

D

An das AnschluûstuÈck "P" der Federspeicherbremse eine aÈuûere Pumpe schlieûen und Druck bei 15v30 bar einlassen.

D

Gegen den Uhrzeigersinn (±) das Kegelrad (4), drehen, bis kein Spiel zwischen den Bremsscheiben mehr uÈbrig bleibt. Anzugsmoment: 8v10 Nm.

c

ESP

F

d ESP

Conectar al empalme "P" del freno negativo una pompa externa y introducir presion de 15v30 bar.

Girar en sentido anti-horario (±) el pinon de registro (4) para eliminar totalmente el juego entre discos de frenadura. Girar hasta obtener un par de 8v10 Nm.

F

Brancher au raccord "P" du frein neÂgatif une pompe externe et envoyer une pression de 15v30 bar.

Tourner le pignon de reÂglage (4) dans le sens contraire aux aiguilles d'une montre(-) le reÂgleur (4) pour faire disparaõÃtre entieÁrement le jeu existant entre les disques de freinage. Tourner jusqu'aÁ obtenir un couple de 8v10 Nm.

ESP

F

Ruotare il pignone (4) in senso orario (+) per determinare il gioco prescritto di 1 mm. NOTA. Un giro del registro crea un gioco di 0,25 mm (1 mm=4 giri).

ITA

Montare la piastrina di sicurezza (3) e bloccarla con la vite (2). Coppia di serraggio: 10v11 Nm

Das Kegelrad (4) in den Uhrzeigersinn (+) drehen, bis das vorgeschriebene Spiel von 1 mm erreicht ist. BEMERKUNG. Eine Umdrehung gleicht einem Spiel von 0,25 mm (1 mm=4 Umdrehungen).

D

Die Sicherheitsplatte (3) montieren und mit der Schraube (2) blockieren. Anzugsmoment: 10v11 Nm

Girar el pinon (4) en sentido horario (+) para determinar el juego prescrito de 1 mm. NOTA. Un giro del registro crea un juego de 0,25 mm (1mm=4 giros).

ESP

Montar la plaqua de seguridad (3) y bloquearla con los tornillos 829. Par de serraje: 10v11 Nm

Tourner le pignon (4) dans le sens des aiguilles d'une montre (+) pour deÂfinir le jeu prescrit de 1 mm. REMARQUE. Un tour de reÂgleur donne un jeu de 0,25 mm (1mm=4 tours).

F

Monter la plaquette de seÂcurite (3), bloquer celle-ci aÁ l'aide de la vis (2). Couple de serrage: 10v11 Nm

ITA

D

e

ESP

F

008 911 79

BOMAG 27

f

959

18.5

AxleMECHANICAL AND MANUAL RELEASE OF THE AXLE - SBLOCCAGGIO MECCANICO MANUALE DELL'ASSALE ACHSE MECHANISCH MANUELL ENTSICHERN - DESBLOQUEO MANUAL DE LOS AXAL DEBLOCAGE MECANIQUE MANUEL DE L'ESSIEU

D1240133

F1241098

a

GB

DANA 193

GB

b

MANUAL EMERGENCY RELEASE Loosen nuts (24) of screws (25) provided for the mechanical and manual release of the braking units, then move the nuts backwards by approx. 8 mm.

Tighten screws (25) so as to fasten them onto the pressure plate (16).

F1241099

F1241100

c

GB

Using a wrench, tighten the screws (25) in an alternate sequence by 1/4 turn at a time so as to compress the Belleville washers (11) and disengage the braking disks. IMPORTANT. Tighten max. by one turn.

GB

d

ADJUSTMENT AFTER MANUAL RELEASE Remove screws (25) complete with nuts (24) and seals (26). Replace seals (26), apply silicone-based Tecno Lupe /101 grease to the screws (25) and install all parts into the arm.

34 + 0,5 0

F1241101

e

GB +0.5 0

Adjust screws (25) to obtain a jut of 34

960

F1241102

mm in relation to the arm.

GB

f

Lock into position with nuts (24). CAUTION! Hold screws (25) into position while locking the nuts (24); after locking, check the jut of screws (25) once more.

BOMAG 28

008 911 79

18.5

Axle DANA 193

SBLOCCAGGIO MANUALE D'EMERGENZA Allentare i dadi (24) delle viti (25) per lo sblocco meccanico manuale dei gruppi di frenatura e far arretrare i dadi di circa 8 mm.

ITA

Avvitare le viti (25) fino a mandarle in battuta sullo spingidisco (16).

MANUELLE NOT-ENTSICHERUNG Die Muttern (24) der Schrauben (25) zur mechanischen manuellen Entsicherung der Bremsaggregate lockern und die Muttern um 8 mm zuruÈck drehen.

D

Schrauben (25) bis zum Anschlag an die Druckplatte (16) zudrehen.

DESBLOQUEO MANUAL DE EMERGENCIA Aflojar las tuercas (24) de los tornillos (25) para el desbloqueo mecanico manual de los grupos de frenadura y hacer pasar las tuercas de 8 mm approx.

ESP

Atornillar los tornillos (25) hasta llegar al tope sobre el empuja-disco (16).

DEBLOCAGE MANUEL D'EMERGENCE Desserrer les eÂcrous (24) des vis (25) pour le deÂblocage meÂcanique manuel des groupes de freinage en faisant reculer les eÂcrous d'environ 8 mm.

F

Visser les vis (25) puis les envoyer en buteÂe sur le plateau de pression (16).

ITA

D

a

b

ESP

F

Utilizzando una chiave, avvitare le viti (25) in modo alternato di 1/4 di giro alla volta, per comprimere le molle a tazza (11) e liberare i dischi di frenatura. IMPORTANTE. Avvitare per max. un giro.

REGOLAZIONE DOPO LO SBLOCCAGGIO MANUALE Rimuovere le viti (25) complete dei dadi (24) e delle guarnizioni (26). Sostituire le guarnizioni (26), lubrificare le viti (25) con grasso al silicone Tecno Lupe /101 e montare il tutto nel braccio.

Mit einem SchluÈssel, die Schrauben (25) abwechselnd jeweils um 1/4 Umdrehung zudrehen, um die Tellerfedern (11) einzudruÈcken und die Bremsscheiben frei-

EINSTELLUNG NACH DER MANUELLEN ENTSICHERUNG Die Schrauben (25) mit den Muttern (24) und den Dichtungen (26) abnehmen. Die Dichtungen (26) auswechseln, die Schrauben (25) mit Silikonfett Tecno Lupe/101 schmieren und das ganze Teil in den Arm montieren.

ITA

D

c

zusetzen. WICHTIG. Maximal um eine Umdrehung zuschrauben.

ITA

D

d

Utilizando una llave, atornillar los tornillos (25) de manera alternada de 1/4 de giro a la vez, para comprimir los muelles a taza (11) y librar los discos de frenadura. IMPORTANTE. Atornillar por max. un giro.

REGULACION DESPUES DEL DESBLOQUEO MANUAL Remover los tornillos (25) completas de guarniciones (26). Sobstituir las guarniciones (26), lubrificar los tornillos (25) con grasa al silicone Tecno Lupe/101 y montar todo en el eje.

A l'aide d'une cleÂ, visser les vis (25) alternativement 1/ 4 de tour aÁ la fois, pour contraindre le ressort belleville (11) et deÂgager les disques de freinage. IMPORTANT. Visser pour max. un tour.

REGLAGE FAISANT SUITE AU DEBLOCAGE MANUEL Enlever les vis (25) compleÁtes d'eÂcrous (24) et de garnitures (26). Substituer les garnitures (26), lubrifier les vis (25) avec de la graisse au silicone Tecno Lupe/101, monter le tout dans le bras.

ITA

Regolare le viti (25) fino ad avere una sporgenza rispetto al braccio di 34+0,5 0 mm

Bloccare la posizione con i dadi (24). ATTENZIONE! Mantenere la posizione delle viti (25) quando si bloccano i dadi (24); dopo il bloccaggio, ricontrollare la sporgenza delle viti (25).

D

È berstand zum Arm Schrauben (25) einstellen, bis der U Ègt. 34+0.5 0 mm betra

Die Position mit den Muttern (24) blockieren. ACHTUNG! Die Position der Schrauben (25) darf sich beim Festziehen der Muttern (24) nicht aÈndern; nach È berstand der Schrauben (25) nochmals der Blockierung den U kontrollieren.

ESP

ESP

F

e

F

ITA

D

f ESP

Regular los tornillos (25) hasta obtener una parte saliente respecto al eje de 34+0,5 0 mm

Bloquear la colocacioÁn con las tuercas (24). ATENCION! Mantener la posicion de los tornillos (25) cuando se bloquean las tuercas (24); despues del bloqueo, recontrolar la parte saliente de los tornillos (25).

F

ReÂgler les vis (25) jusqu'aÁ avoir une saillie de 34+0.5 0 mm par rapport au bras.

Bloquer dans la position aÁ l'aide des eÂcrous (24). ATTENTION! Tenir les vis (25) en place quand on bloque les eÂcrous (24); apreÁs avoir fixeÂ, controÃler la saillie des vis (25).

008 911 79

BOMAG 29

ESP

F

961

Axle- PLANETENGEDANA 193 18.5DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR EPICICLOIDALE ET DU DEMI-ESSIEU

D1240131

F1241103

GB Remove the locking screws (1) of planetary cover (2).

962

F1241104

a

GB

b

Using two screwdrivers or two levers inserted in the slots provided, pry the planetary cover (2) away from the wheel hub (3).

BOMAG 30

008 911 79

18.5

Axle DANA 193

SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR 2 - Achse zuerst von der Maschine abmontieren und auf eine Werkbank legen.

The axle shafts can only be removed once the extraction of the planetary cover has been performed. Different procedures need to be followed depending on the kind of repair work required:

GB

Nachstehende Beschreibung bezieht sich auf das Zerlegen an der Werkbank, doch ist die Vorgehensweise in beiden FaÈllen dieselbe.

1 - Disassembly with axle connected to the machine with machine resting on safety stands. 2 - Disassembly with the axle disconnected from the machine and supported by the appropriate equipment (at the bench). The explanations given herein refer to the removal operation as is carried out on the bench, but the stages apply to all versions.

La remocioÁn de los semi-ejes puede ser efectuada solo despues de la remocioÁn de las tapas lleva-satelites y de manera deversificada, en funcion del tipo de reparacion de efectuar:

ESP

1 - Desmontaje con axal montado sobre la maquina colocada sobre caballetes de seguridad;

ITA da eseguire:

2 - Desmontaje con axial desmontado desde la maquina y sustentado de apositas herramientas (al banco). Las explicaciones reportadas se refieren a la remocioÁn efectuada al banco, ma las fases son comunes.

La rimozione dei semiassi puoÁ essere eseguita solo dopo la rimozione del coperchio portasatelliti ed in modo diversificato, in funzione del tipo di riparazione

1 - Smontaggio con assale montato sulla macchina appoggiata su cavalletti di sicurezza. 2 - Smontaggio con assale smontato dalla macchina e sostenuto da apposita attrezzatura (al banco). Le spiegazioni riportate si riferiscono alla rimozione eseguita al banco, ma le fasi sono comuni.

Le deÂgagement des demi-essieux ne peut se faire qu'apreÁs avoir enleve le couvercle porte-satellites d'une facËon diversifieÂe, en fonction du type de reÂparations aÁ effectuer: 1 - DeÂmontage essieu monte sur machine deÂposeÂe sur des baÃtis de seÂcuriteÂ.

F

1 - DeÂmontage essieu deÂmonte de la machine et soutenu par un outil speÂcial (sur banc). Les explications reporteÂes se reÂfeÁrent au deÂgagement effectue au banc, mais les phases sont communes.

Die Halbachse kann erst abmontiert werden, wenn der Deckel des Planetenradhalters abgenommen worden ist; auûerdem wird sie je nach Reparatur unterschiedlich abmontiert:

D

1 - Mit Achse abmontieren, die an der Maschine montiert und durch SicherheitsbloÈcke gestuÈtzt ist.

ITA

Rimuovere le viti (1) di fissaggio del coperchio portasatelliti (2).

ITA

Utilizzando due cacciaviti o due leve inserite nelle cave predisposte, staccare il coperchio portasatelliti (2) dal mozzo portaruota (3).

D

Schrauben (1) abschrauben, die den Deckel des Planetenradhalters (2) befestigen.

D

Zwei Schraubenzieher oder zwei Hebel in die vorgesehenen Nuten stecken und den Deckel (2) des Planetenradhalters von den Radhalternaben (3) ab-

a

b

heben.

ESP

Remover los tornillos (1) de fisaje de la tapa portasatelites (2).

ESP

Utilizando dos destornilladores o dos palancas insertadas en las ranuras predispuestas, destacar la tapa lleva-satelites (2) del cubo lleva-rueda (3).

F

Enlever les vis (1) de fixation du couvercle portesatellites (2).

F

A l'aide de deux tournevis ou de deux leviers dans les creux preÂdisposeÂs, deÂgager le couvercle porte-satellites (2) du moyeu porte-roue (3).

008 911 79

BOMAG 31

963

Axle- PLANETENGEDANA 193 18.5DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR EPICICLOIDALE ET DU DEMI-ESSIEU

F1241105

GB

F1241106

a

GB

b

Rotate the wheel hub (3) until one of the screw holes (1) appears at the top. Apply a "U" piece to the screw hole; connect to a hoist and remove the cover (2).

Only in case of replacement of component parts not requiring the disassembly of the crown wheel (5). Countermark the position between one of the teeth of the axle shaft (4) and the crown wheel (5).

F1241107

F1241108

GB

c

Remove the axle shaft (4). NOTE. The removal of the axle shaft allows for the substitution of the snap ring as described in the following paragraphs.

GB Loosen the screws (6) and remove them.

F1241109

GB Remove the safety flange (7).

964

d

F1241110

e

GB

f

Partially tighten five of the ten screws (6) in an alternate and proportional manner. Using an extractor and applying a counter pressure to the screws (6), disengage the crown wheel (5) from the hub (3).

BOMAG 32

008 911 79

18.5

Axle DANA 193

Ruotare il mozzo portaruota (3) fino a portare un foro per le viti (1) in posizione alta. Applicare un grillo ad "U" nel foro vite; collegare un mezzo di sollevamento e rimuovere il coperchio (2).

a

ITA

Solo se si devono sostituire dei componenti che non richiedono lo smontaggio della corona (5). Contrassegnare la posizione tra un dente del semiasse (4) e la corona (5).

D

Nur wenn Bestandteile ausgewechselt werden muÈssen, fuÈr die der Kranz (5) nicht abmontiert werden muû. Die Position zwischen einem Zahn der Halbachse (4) und dem Kranz (5) markieren.

Die Radhalternabe (3) drehen bis ein Loch fuÈr die Schrauben (1) in der oberen Position liegt. Einen U-foÈrmigen BuÈgel in das Schraubenloch stecken; ein Hebezeug anschlieûen und den Deckel (2) abnehmen.

ITA

D

b

Girar el cubo lleva-rueda (3) hasta hacer un agujero para los tornillos (1) en posicioÁn alta. Aplicar un grillo a "U" en el agujero tornillos; conectar un medio de levantamiento y remover la tapa (2).

Solo si se deben de sobstituir algunos componentes que no comportan el desmontaje de la corona (5). Senalar la colocacioÁn entre un diente del semi-eje (4) y la corona (5).

Tourner le moyeu porte-roue (3) jusqu'aÁ aÁ amener un des trous pour les vis (1) en haut. Appliquer une manille en "U" dans le trou de vis; appliquer un moyen de relevage et enlever le couvercle (2).

Uniquement si on doit substituer des composants qui ne veulent pas le deÂmontage de la couronne (5). Marquer la position entre une dent du demi-essieu (4) et la couronne (5).

ESP

ESP

F

ITA seguito.

F

Asportare il semiasse (4). NOTA. L'asportazione del semiasse permette la sostituzione dell'anello di tenuta come descritto di

Die Halbachse (4) abnehmen. BEMERKUNG. Bei abgenommener Halbachse kann der Dichtring, wie nachstehend beschrieben, ausgewechselt werden.

ITA

D

c

D

Sacar el semi-eje (4). NOTA. Sacar el semi-eje permite la sobstitucioÁn del anillo de tenida como descrito a seguir.

ESP

F

Enlever le demi-essieu (4). REMARQUE. Le deÂgagement du demi-essieu consent la substitution de l'anneau d'eÂtancheÂite comme deÂcrit

F

ITA

D

008 911 79

Desserrer les vis (6) puis les enlever.

Avvitare parzialmente, in modo alternato ed in uguale misura, cinque delle dieci viti (6). Utilizzando un estrattore e facendo reazione sulle viti (6) disimpegnare la corona (5) dal mozzo (3).

Sicherheitsflansch (7) abnehmen.

Abwechselnd und im gleichen Maû fuÈnf von den zehn Schrauben (6) zuschrauben. Mit einem Abzieher den Kranz (5) aus der Nabe (3) ziehen und dabei auf die Schrauben (6) wirken.

ITA

D

f

F

Aflojar los tornillos (6) y sacarlos.

Asportare la flangia di sicurezza (7).

e ESP

Schrauben (6) abschrauben.

d

ESP

par la suite.

Allentare le viti (6) ed asportarle.

Sacar la arandela de seguridad (7).

Atornillar parcialmente, de manera alternada y en igual mesera, cinco de las diez tornillos (6). Utilizando un extractor y haciendo reacioÁn sobre los tornillos (6) desempenar la corona (5) del cubo (3).

Enlever la flasque de seÂcurite (7).

Visser partiellement, en alternance et de la meÃme facËon cinq des dix vis (6). A l'aide d'un extracteur, tout en faisant reÂagir les vis (6), deÂgager la couronne (5) du moyeu (3).

ESP

F

BOMAG 33

965

Axle- PLANETENGEDANA 193 18.5DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR EPICICLOIDALE ET DU DEMI-ESSIEU

F1241111

GB

F1241112

a

Remove screws (6) and crown wheel (5).

GB

Sling the hub (3) and connect it to a hoist; partially tighten a screw (6) and with the help of a hammer, shift the hub (3) and the external bearing (8).

F1241113

GB

F1241114

c

Remove the bearing (8) and the hub (3).

GB

F1241116

e

Using an extractor, remove at the same time the snap ring (11) and the centring ring (12). NOTE. Note down the direction of assembly of snap and centring rings.

966

d

Extract the hub (3) complete with snap ring (9) and internal bearing (10).

F1241115

GB

b

GB

f

Remove the safety spring rings (13) of the planetary gears (14).

BOMAG 34

008 911 79

18.5

Axle DANA 193

ITA

Rimuovere le viti (6) e la corona (5).

ITA esterno (8).

D

Schrauben (6) und Kranz (5) abnehmen.

a

D

Nabe (3) anschlagen und an ein Hebezeug befestigen; Schrauben (6) etwas zudrehen und mit einem Hammer die Naben (3) und das aÈuûere Lager (8) bewegen.

ESP

Atar el cubo (3) y conectarlo a un medio de levantamiento; atornillar parcialmente un tornillo (6) y, con un martillo, mover el cubo (3) y el cojinete

b ESP

Remover los tornillos (6) y la corona (5).

externo (8).

F

F

Elinguer le moyeu (3) puis relier celui-ci aÁ un moyen de relevage; visser partiellement une vis (6), puis aÁ l'aide d'un maillet, bouger le moyeu (3) et le palier externe

ITA

Asportare il mozzo (3) completo di anello di tenuta (9) e cuscinetto interno (10).

D

Nabe (3) samt Dichtring (9) und inneres Lager (10) abnehmen.

Enlever les vis (6) et la couronne (5). (8).

ITA

D

Rimuovere il cuscinetto (8) ed il mozzo (3).

Lager (8) und Nabe (3) abnehmen.

c

d ESP

Remover el cojinete (8) y el cubo (3).

ESP

Sacar el cubo (3) completo de anillo de retencioÁn (9) y cojinete interno (10).

F

Enlever le palier (8) et le moyeu (3).

F

Enlever le moyeu (3) complet de bague d'eÂtancheÂite (9) et de palier interne (10).

Utilizzando un estrattore, rimuovere contemporaneamente l'anello di tenuta (11) e l'anello centratore (12). NOTA. Annotare il senso di montaggio degli anelli di tenuta e di centratura.

ITA

Rimuovere gli anelli elastici (13) di ritegno satelliti (14).

Mit einem Abzieher gleichzeitig den Dichtring (11) und den Zentrierring (12) abnehmen. BEMERKUNG. Montagerichtung der Dicht- und Zentrierringe notieren.

D

Kolbenringe (13) und Planetenhalter (14) abnehmen.

Utilizando un extractor, remover contemporaneamente el anillo de retencioÁn (11) y el anillo centrador (12). NOTA. Anotar el sentido de montaje de los anillos de retencioÁn y de centraje.

ESP

Remover los anillos elasticos (13) de retencioÁn satelites (14).

A l'aide d'un extracteur enlever en meÃme temps l'anneau d'eÂtancheÂite (11) et l'anneau centreur (12). REMARQUE. Prendre note du sens de montage des anneaux d'eÂtancheÂite et de centrage.

F

Enlever les anneaux ressorts (13) de fixation des satellites (14).

ITA

D

e

Imbragare il mozzo (3) e collegarlo ad un mezzo di sollevamento; avvitare parzialmente una vite (6) e, con un mazzuolo, smuovere il mozzo (3) ed il cuscinetto

ESP

F

008 911 79

BOMAG 35

f

967

Axle- PLANETENGEDANA 193 18.5DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR EPICICLOIDALE ET DU DEMI-ESSIEU

F1241117

GB

F1241118

a

Remove the planetary gears (14). NOTE. Note down direction of assembly of planetary gears.

GB

Only if necessary. Using an extractor, remove the shim washer (15) from the planet carrier.

F1241119

GB

b

F1241120

c

GB

d

Remove the internal bearing (10).

Remove the snap ring (9) from the hub (3). NOTE. Note down direction of assembly. CAUTION! The snap ring may not be reused.

F1241121

GB

e

GB

f

Remove the external thrust blocks of bearings (8) and (10), using a pin-driver. NOTE. Hammer in an alternate sequence to prevent crawling and deformation of the thrust blocks.

968

BOMAG 36

008 911 79

18.5

Axle DANA 193

ITA

D

Asportare gli ingranaggi satelliti (14). NOTA. Annotare il senso di montaggio dei satelliti.

Planetengetriebe (14) abnehmen. BEMERKUNG. Montagerichtung notieren.

a

F

ITA riutilizzato.

D werden.

ESP reutilizado.

F reÂutiliseÂ.

Sacar los engranajes satelites (14). NOTA. Anotar el sentido de desmontaje de los satelites.

Enlever les engrenages satellites (14). REMARQUE. Prendre note du sens de montage.

D

Nur wenn notwendig. Mit einem Abzieher vom Planetenradhalter die Zwischenlegscheibe (15) abnehmen.

ESP

Solo si necesario. Utilizando un extractor, remover del lleva-satelites la arandela de rasamiento (15).

F

Uniquement si besoin. A l'aide d'un extracteur, enlever du porte-satellite la rondelle de rasage (15).

Rimuovere dal mozzo (3) l'anello di tenuta (9). NOTA. Annotare il senso di montaggio. ATTENZIONE! L'anello di tenuta non puoÁ essere

ITA

Von der Nabe (3) den Dichtring (9) abnehmen. BEMERKUNG. Montagerichtung notieren. ACHTUNG! Der Dichtring darf nicht wieder verwendet

D

Das innere Lager (10) abnehmen.

Remover del cubo (3) los anillos de retencioÁn (9). NOTA. Anotar el sentido de montaje. ATENCION! El anillo de retencioÁn no puede ser

ESP

Remover el cojinete interior (10).

Oter du moyeu (3) l'anneau d'eÂtancheÂite (9). REMARQUE. Prendre note du sens de montage. ATTENTION! L'anneau d'eÂtancheÂite ne peut pas eÃtre

F

Rimuovere le ralle esterne dei cuscinetti (8) e (10) utilizzando un cacciaspine. NOTA. Battere in modo alternato per evitare impuntamenti e deformazioni delle ralle.

ITA

Die aÈuûeren Scheiben (8) und (10) mit einem DuÈbel abnehmen. BEMERKUNG. Abwechselnd schlagen, um ein Durchschlagen und Verformungen der Scheiben zu vermeiden.

D

D

ESP

Enlever les crapaudines externes des paliers (8) et (10) aÁ l'aide d'un chasse-clou. REMARQUE. Donner des coups alterneÂs pour eÂviter talonnages et deÂformations des crapaudines.

F

F

008 911 79

BOMAG 37

Enlever le palier interne (10).

f

Remover las ranguas externas de los cojinetes (8) y (10) utilizando un extractor de clavijas. NOTA. Pegar de manera alternada para evitar empuntamientos y deformacioÁnes de las ranguas.

ESP

Rimuovere il cuscinetto interno (10).

d

ITA

e

Solo se necessario. Utilizzando un estrattore, rimuovere dal portasatelliti la rondella di rasamento (15).

b ESP

c

ITA

969

Axle DANA 193 18.5ASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGETRIEBE UND HALBACHSE ZUSAMMENBAUEN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR EPICICLOIDALE ET DU DEMI-ESSIEU

T3

F1241122

F1241123

a

GB

Position the wheel hub (3) under a press; lubricate the seat of the external bearing and, using tool T3, install the thrust block of the bearing (10).

GB

Install the bearing (10). Apply an appropriate sealant to the outer surface of the snap ring (9). Position the snap ring (9) into the hub (3). NOTE. Check orientation of the ring.

T3

T4

F1241124

F1241125

c

GB Position tool T4 and press the snap ring (9) down into its seat.

GB

GB

d

Turn the hub (3) upside down, lubricate the seat of the bearing and, using tool T3, install the thrust block of the bearing (8).

F1241126

F1241117

e

Only if shim washer has previously been removed. Apply a sealant for removable seals to the outer surface of the shim washer (15) and, using a driver, fit it into the planetary gear cover (2).

970

b

GB

f

Fit the planetary gear (14) onto the planetary gear cover (2). CAUTION! The jointed portion of the internal ring of the bearings must face the bottom of the pin.

BOMAG 38

008 911 79

18.5

Axle DANA 193

ITA

Posizionare il mozzo ruota (3) sotto una pressa; lubrificare la sede del cuscinetto esterno e, utilizzando l'attrezzo T3, montare la ralla del cuscinetto (10).

Installare il cuscinetto (10). Spalmare la superficie esterna dell'anello di tenuta (9) con sigillante per guarnizioni. Posizionare l'anello di tenuta (9) nel mozzo (3). NOTA. Controllare l'orientamento dell'anello.

D

Die Radnabe (3) unter eine Presse positionieren; den Sitz des aÈuûeren Lagers schmieren und mit dem Werkzeug T3 die Scheibe des Lagers (10) montieren.

Lager (10) installieren. AÈuûere FlaÈche des Dichtringes (9) mit etwas Dichtmasse schmieren. Dichtring (9) in die Nabe (3) positionieren. BEMERKUNG. Richtung des Ringes kontrollieren.

a

ITA

D

b ESP

Colocar el cubo rueda (3) bajo una prensa; lubrificar la sed del cojinete externo y, utilizando la herramienta T3, montar la rangua del cojinete (10).

Colocar el cojinete (10). Pasar la superficie externa del anillo de retencioÁn (9) con sigilante para guarniciones. Colocar el anillo de retencioÁn (9) en el cubo (3). NOTA. Controlar el orientamiento del anillo.

F

Positionner le moyeu roue (3) sous la presse; lubrifier le logement du palier externe, puis aÁ l'aide de l'outil T3, monter la crapaudine du palier (10).

Installer le palier (10). Enduire la superficie externe de l'anneau d'eÂtancheÂite (9) avec de la colle aÁ garnitures. Positionner l'anneau d'eÂtancheÂite (9) dans le moyeu (3). REMARQUE. ControÃler la bonne direction de l'anneau.

ITA

Posizionare l'attrezzo T4 e pressare in sede l'anello di tenuta (9).

ITA

Capovolgere il mozzo (3), lubrificare la sede cuscinetto e, utilizzando l'attrezzo T3, montare la ralla del cuscinetto (8).

D

Das Werkzeug T4 positionieren und den Dichtring (9) in seinen Sitz druÈcken.

D

Die Nabe (3) wenden, den Lagersitz schmieren und mit dem Werkzeug T3 die Nabe des Lagers (8) montieren.

c

ESP

F

d ESP

Colocar la herramienta y apretar en sed el anillo de retencioÁn (9).

ESP

Volcar el cubo (3), lubrificar la sed cojinete y, utilizando la herramienta T3, montar la rangua del cojinete (8).

F

Placer l'outil T4 et presser dans son logement l'anneau d'eÂtancheÂite (9).

F

Faire basculer le moyeu (3), lubrifier le logement du palier, puis aÁ l'aide de l'outil T3, monter la crapaudine dans le palier (8).

Solo se eÁ stata rimossa. Spalmare la superficie esterna della rondella di rasamento (15) con sigillante per guarnizioni removibili e, utilizzando uno spintore, montarla nel coperchio portasatelliti (2).

Montare sui perni del coperchio portasatelliti (2) gli ingranaggi planetari (14). ATTENZIONE! La parte raccordata dell'anello interno dei cuscinetti deve essere rivolta verso il fondo del perno.

Nur wenn zuvor abgenommen. AÈuûere FlaÈche der Zwischenlegscheibe (15) mit Dichtmasse fuÈr abnehmbare Dichtungen schmieren und mit einem StoÈûel diese Zwischenlegscheibe in den Deckel des Planetenradhalters (2) montieren.

Auf die Stifte des Deckels des Planetenradhalters (2) die Planetengetriebe (14) montieren. ACHTUNG! Das AnschluûstuÈck des inneren Lagerringes muû zur unteren Seite des Stiftes gerichtet sein.

ITA

ITA

D

e

D

f

Solo si ha sido desplazada. Pasar la superficie externa de la arandela de rasamiento (15) con sigilante para guarnicioÁnes removibles y, utilizando un empuje, montarla en la tapa llevasatelites (2).

Montar sobre los pernos de la tapa lleva-satelites (2) los engranajes planetares (14). ATENCION! La parte empalmada del anillo interno de los cojinetes debe de ser dirijida hacia el fondo de la rotula.

Uniquement si elle a eÂte enleveÂe. Enduire la superficie externe de la rondelle de rasage (15) avec de la colle pour garnitures amovibles, aÁ l'aide d'un poussoir monter celle-ci dans le couvercle portesatellites (2).

Monter sur les pivots du couvercle porte-satellites (2) les engrenages planeÂtaires (14). ATTENTION! La partie raccordeÂe de l'anneau aÁ l'inteÂrieur du palier doit eÃtre tourneÂe vers la partie basse du pivot.

ESP

F

008 911 79

BOMAG 39

ESP

F

971

Axle DANA 193 18.5ASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGETRIEBE UND HALBACHSE ZUSAMMENBAUEN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR EPICICLOIDALE ET DU DEMI-ESSIEU

T5

F1241127

GB

F1241128

a

GB

b

Lock into position the planetary gears (14) with the snap rings (13).

Lubricate and fit the centring ring (12) and snap ring (11) onto tool T5; install the rings into the arm. CAUTION! Pay particular attention to the direction of assembly of the rings.

F1241114

F1241113

GB

c

Grease the snap ring (9) and the hub of the arm. Install the wheel hub (3).

GB

Install the external bearing (8). NOTE. Move the bearing to the limit stop by hammering lightly all around the edge.

F1241129

GB

F1241109

e

Install the crown wheel (5) and, using a driver with adequate diameter, fasten it onto the hub of the arm.

972

d

GB

f

Using Tecno Lupe /101, grease the surface of the safety flange (7) that touches the crown wheel.

BOMAG 40

008 911 79

18.5

Axle DANA 193

ITA

Fissare la posizione degli ingranaggi satelliti (14) con gli anelli elastici (13).

Lubrificare e montare sull'attrezzo T5 l'anello centratore (12) e l'anello di tenuta (11); montare gli anelli nel braccio. ATTENZIONE! Controllare attentamente il senso di montaggio degli anelli.

D

Die Position der Planetengetriebe (14) mit den Kolbenringen (13) festigen.

Das Werkzeug T5 schmieren und darauf den Zentrierring (12) und den Dichtring (11) montieren; die Ringe in den Arm montieren. ACHTUNG! Montagerichtung der Ringe sorgfaÈltig kontrollieren.

a

ITA

D

b ESP

Fijar la posicioÁn de los engranajes satelites (14) con los anillos elasticos (13).

Lubrificar y montar sobre la herramienta T5 el anillo central (12) y el anillo de retencioÁn (11); montar los anillos en el eje. ATENCION! Controlar atentamente el sentido de montaje de los anillos.

F

Fixer les engrenages porte-satellites (14) aÁ leur place avec les anneaux ressorts (13).

Lubrifier et monter sur l'outil T5 l'anneau centreur (12) et l'anneau d'eÂtancheÂite (11); monter les anneaux dans le bras. ATTENTION! ControÃler attentivement le sens du montage des anneaux.

ITA

Lubrificare con grasso l'anello di tenuta (9) ed il mozzo del braccio. Montare il mozzo portaruota (3).

Montare il cuscinetto esterno (8). NOTA. Mandare a fondo corsa il cuscinetto con leggeri colpi di mazzuolo distribuiti su tutta la circonferenza.

D

Mit Fett den Dichtring (9) und die Armnabe schmieren. Radhalternabe (3) montieren.

c

ESP

F

ITA

D

d

einsetzen.

AÈuûeres Lager (8) montieren. BEMERKUNG. Das Lager bis zum Anschlag mit leichten HammerschlaÈgen an der gesamten Kreislinie

ESP

Lubrificar con grasa el anillo de retencioÁn (9) y el cubo del eje. Montar el cubo lleva-rueda (3).

F

Lubrifier avec de la graisse l'anneau d'eÂtancheÂite (9), le moyeu du bras. Monter le moyeu porte-roue (3).

ITA

Montare la corona (5) e, utilizzando uno spintore di diametro adatto, mandarla in battuta sul mozzo del braccio.

ITA

Lubrificare con grasso Tecno Lupe /101 la superficie della flangia di sicurezza (7) a contatto con la corona.

D

Den Kranz (5) montieren und mit einem geeigneten StoÈûel den Kranz bis zum Anschlag an der Armnabe einsetzen.

D

Mit Fett Typ Tecno Lupe/ 101 die FlaÈche des Sicherheitsflanschs (7), der am Kranz anliegt, schmieren.

e

ESP

Montar el cojinete esterno (8). NOTA. Mandar a tope el cojinete con ligeros colpes de martillo repartidos sobre toda la circonferencia.

Monter le palier externe (8). REMARQUE. Envoyer en buteÂe le palier avec de leÂgers coups de maillet distribueÂs tout autour de la circonfeÂrence.

F

f ESP

Montar la corona (5) y, utilizando un empuje de diametro apto, mandarla a tope sobre el cubo del eje.

ESP

Lubrificar con grasa Tecno Lupe/101 la superficie de la brida de seguridad (7) a contacto con la corona.

F

Monter la couronne (5), puis aÁ l'aide d'un poussoir d'un diameÁtre adapteÂ, envoyer celle-ci en buteÂe sur le moyeu du bras.

F

Lubrifier avec de la graisse Tecno Lupe/ 101 la superficie de la flasque de seÂcurite (7) au contact de la couronne.

008 911 79

BOMAG 41

973

Axle DANA 193 18.5ASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGETRIEBE UND HALBACHSE ZUSAMMENBAUEN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR EPICICLOIDALE ET DU DEMI-ESSIEU

F1241130

GB

F1241107

a

Coat the screws (6) with Loctite 270 and screw them. Tighten screws (6) in two stages, using the criss-cross method. Initial torque wrench setting: 120 Nm Final torque wrench setting: 219 ± 242 Nm

GB

Lubricate the snap ring (11), the toothed portions and the sealing surface of the axle shaft. Install the axle shaft (4), making sure that it is properly inserted into braking disks and differential unit.

F1241131

GB

GB

974

F1241132

c

Fit the planetary gear cover (2) onto the wheel hub (3). CAUTION! 1 - Check the condition and position of the O-ring (16). 2 - Line up the locating release points.

b

GB

d

Lock the planetary gear cover (2) onto the wheel hub (3) with screws (1). Screws torque wrench setting: 40 ± 0 Nm.

e

GB

BOMAG 42

f

008 911 79

18.5

Axle DANA 193

Spalmare le viti (6) con Loctite 270 ed avvitarle. Serrare le viti (6) in due tempi e con il metodo del serraggio incrociato. Coppia di serraggio iniziale: 120 Nm Coppia di serraggio finale: 219v242 Nm

Lubrificare l'anello di tenuta (11), le dentature e la superficie di tenuta del semiasse. Montare il semiasse (4) assicurandosi che si innesti nei dischi freni e nel differenziale.

Die Schrauben (6) mit Loctite 270 schmieren und festschrauben. Schrauben (6) im Kreuz schrittweise festziehen. Anzugsmoment zuerst: 120Nm Anzugsmoment am Ende: 219v242 Nm

Dichtring (11), ZaÈhne und DichtflaÈche der Halbachse schmieren. Halbachse (4) montieren und darauf achten, daû sie in die Bremsscheiben und in das Differential einrastet.

ITA

ITA

D

a

D

b

Pasar los tornillos (6) con Loctite 270 y atornillarlos. Apretar los tornillos (6) en doss tiempos con el metodo de torsion cruzada. Par de torsion inicial: 120 Nm. Par de torsion final: 219v242 Nm.

Lubrificar el anillo de retencioÁn (11), las dentaduras y la superficie del semieje. Montar el semieje (4) asegurandose que se encaje en los discos y en el diferencial.

Enduire les vis (6) avec du Loctite 270 puis visser. Serrer les vis (6) en deux temps avec la meÂthode du serrage croiseÂ. Couple de serrage initial: 120Nm Couple de serrage final: 219v242 Nm.

Lubrifier l'anneau d'eÂtancheÂite (11), les dents, la superficie eÂtanche des demi-essieux. Monter le demi-essieu (4) en veillant aÁ ce qu'il s'enclenche bien dans les disques freins et dans le diffeÂrentiel.

ESP

ESP

F

F

Montare il coperchio portasatelliti (2) sul mozzo portaruota (3). ATTENZIONE! 1 - Controllare lo stato e la posizione della guarnizione OR (16). 2 - Allineare gli scarichi di riferimento.

ITA

Bloccare il coperchio portasatelliti (2) sul mozzo portaruota (3) con le viti (1). Coppia di serraggio viti: 40v50 Nm

Den Deckel des Planetenradhalters (2) auf die Nabe des Radhalters (3) montieren. ACHTUNG! 1 - Zustand und Position der O-Ringe (16) kontrollieren. 2 - Die Bezugsstellen bzw. AblaûoÈffnung fluchten.

D

Den Deckel des Planetenradhalters (2) an der Radhalternabe (3) mit den Schrauben (1) blockieren. Anzugsmoment der Schrauben: 40v50 Nm

Montar la tapa lleva-satelites (2) sobre el cubo llevarueda (3). ATENCION! 1 - Controlar el estado y la posicioÁn de la guarnicioÁn OR (16). 2 - Alinear los descarges de referencia.

ESP

Bloquear la tapa lleva-satelietes (2) sobre el cubo lleva-rueda (3) con los tornillos (1). Par de torsion tornillos: 40v50 Nm

F

Monter le couvercle porte-satellite (2) sur le moyeu porte-roue (3). ATTENTION! 1 - ControÃler l'eÂtat et la position des garnitures O'Ring (16). 2 - Aligner les points de deÂcharge de reÂfeÂrence.

F

Bloquer le couvercle porte-satellite (2) sur le moyeu porte-roue (3) aÁ l'aide des vis (1). Couple de serrage des vis: 40v50 Nm.

ITA

ITA

D

D

ITA

D

c

d

ESP

e

f ESP

ESP

F

F

008 911 79

BOMAG 43

975

18.5

Axle DANA REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

193

T6 T7A

F1241141

GB

F1241142

a

REMOVAL OF THE DIFFERENTIAL UNIT Remove the whole arms, the cylinders, and the whole reduction unit. For details, see «CHECKING WEAR AND REPLACING THE BRAKING DISKS» and «REMOVAL OF REDUCTION GEAR».

b

GB

Apply tool T6 - for crown wheel side centring - with relative distance pieces and lock it with two nuts. Apply centring tool T7A as well.

T7B

F1241143

GB

F1241144

c

Remove the stud screws and remove the intermediate cover (1) on the crown wheel opposite side.

d

GB

Install centring tool T7B on the opposite side of the crown wheel.

T7B

A

F1241145

GB

e

Remove centring tools T6 and T7A from crown wheel side; remove the studs and the intermediate cover (2) on the crown wheel side.

976

F1241146

GB

f

Position a stop block «A» made from tender material (aluminium, etc.) between the main body (3) and the toothed portion of the crown wheel (4). With the crown (4) resting on block "A", remove and extract the screws (5) and the spring washers (6).

BOMAG 44

008 911 79

18.5

Axle DANA 193

RIMOZIONE DIFFERENZIALE Rimuovere i bracci completi, i cilindri freni ed il riduttore completo. Per i dettagli, vedere «CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO» e «RIMOZIONE RIDUTTORE».

ITA

DIFFERENTIAL ABNEHMEN Die kompletten Arme, die Bremszylinder und den kompletten Reduzierer abnehmen. Siehe «VERSCHLEISS KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN» und «REDUZIERER ABNEHMEN».

ITA

D

a

Applicare l'attrezzo T6 di centraggio dal lato corona con i relativi distanziali e fissarlo con due dadi. Applicare anche l'attrezzo T7A di centratura.

Das Werkzeug T6 zur Zentrierung an der Kranzseite mit den entsprechenden DistanzstuÈcken anbringen und das Werkzeug mit zwei Muttern befestigen. Das Werkzeug T7A zur Zentrierung anbringen.

D

b

REMOCION DIFERENCIAL Remover los ejes completos, los cilindros frenos y el reductor completo. Para los detalles, vease «CONTROL DESGASTE Y SOBSTITUCION DISCOS FRENOS» y «REMOCION REDUCTOR».

ESP

ESP

Aplicar la herramienta T6 de centraje del lado corona con los relativos distanciales y fijarla con dos tuercas. Aplicar tambien la herramienta T7A de centradura.

Appliquer l'outil T6 de centrage du coÃte couronne avec les entretoises correspondantes et fixer l'outil avec deux eÂcrous. Appliquer eÂgalement l'outil de centrage T7A.

DEGAGEMENT DU DIFFERENTIEL Enlever les bras entieÁrement, les cylindres freins et le reÂducteur tout entier. Pour de plus amples deÂtails, voir "CONTROLE DE L'USURE ET SUBSTITUTION DU DISQUE FREIN" et "DEGAGEMENT DU REDUCTEUR".

F

F

ITA

Rimuovere le viti prigioniere e rimuovere il coperchio intermedio (1) dal lato opposto corona.

ITA

Montare l'attrezzo T7B di centraggio sul lato opposto corona.

D

Die Stiftschrauben und den Zwischendeckel (1) von der dem Kranz entgegengesetzte Seite abnehmen.

D

Das Werkzeug T7B zur Zentrierung an der dem Kranz entgegengesetzte Seite montieren.

c

d ESP

Remover los tornillos prigioneros y remover la tapa intermedia (1) del lado opuesto corona.

ESP

Montar la herramienta T7B de centraje sobre el lado opuesto corona.

F

Enlever les vis prisonnieÁres et enlever le couvercle intermeÂdiaire (1) du coÃte oppose aÁ la couronne.

F

Monter l'outil de centrage T7B du coÃte oppose aÁ la couronne.

ITA

Rimuovere gli attrezzi T6 e T7A di centraggio del lato corona; asportare i prigionieri e rimuovere il coperchio intermedio (2) lato corona.

Posizionare tra il corpo centrale (3) e la dentatura della corona (4) un blocchetto "A" di contrasto in materiale tenero (alluminio ecc.). Mantenendo in appoggio la corona (4) sul blocchetto "A", rimuovere ed asportare le viti (5) e le rondelle elastiche (6).

D

Die Werkzeuge T6 und T7A zur Zentrierung an der Kranzseite entfernen; die Stiftschrauben und den Zwischendeckel (2) an der Kranzseite abnehmen.

Zwischen dem ZentralkoÈrper (3) und den ZaÈhnen des Kranzes (4) den Block "A" aus weichem Material (Aluminium usw.) legen. Den Kranz (4) am Block "A" anliegen lassen und die Schrauben (5) und die Federscheiben (6) abnehmen.

e

ITA

D

f ESP

Remover las herramientas T6 y T7A de centraje del lado corona; sacar los prigioneros y remover la tapa intermedia (2) lado corona.

Colocar entre el cuerpo central 83) y la dentadura de la corona (4) un bloque "A" de contraste de material tierno (aluminio ect.). Manteniendo en apoyo la corona (4) sobre el bloque "A", remover y sacar los tornillos (5) y las arandelas elasticas (6).

F

Enlever les outils T6 et T7A de centrage du coÃte couronne; enlever les prisonniers et deÂplacer le couvercle intermeÂdiaire (2) du coÃte couronne.

Placer entre le corps central (3) et la denture de la couronne (4) un petit bloc "A" en mateÂriel leÂger (aluminium etc.) de contraste. En maintenant la couronne (4) sur le petit bloc "A", deÂvisser et enlever les vis (5), et ensuite les rondelles eÂlastiques (6).

008 911 79

BOMAG 45

ESP

F

977

18.5

Axle DANA REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

F1241147

GB

F1241148

a

Using a driver, push the differential unit (7) or (8) towards the opposite side of the crown so as to disengage it from the crown (4).

193

b

GB Extract the whole differential unit (7) or (8).

T7B

F1241223

GB

F1241174

c

Remove tool T7B from the crown opposite side.

d

GB Extract the crown (4).

B

F1241149

GB

e

DISASSEMBLY OF THE DIFFERENTIAL UNIT Using an extractor, remove bearings (9) from the differential unit.

978

F1241150

GB

f

DISASSEMBLY OF THE NO-SPIN DIFFERENTIAL UNIT Insert stay "B" provided for holding into position the no-spin unit (14) and screw tight the wing nut.

BOMAG 46

008 911 79

18.5

Axle DANA 193

ITA

Utilizzando uno spintore, spingere il differenziale (7) o (8) verso il lato opposto corona fino a disimpegnarlo dalla corona (4).

ITA

D

Mit einem StoÈûel das Differential (7) oder (8) in die dem Kranz entgegengesetzte Seite druÈcken und aus dem Kranz (4) freisetzen.

D

a

Estrarre il gruppo differenziale (7) o (8) completo.

Das komplette Differentialaggregat (7) oder (8) abziehen.

b ESP

Utilizando un empuje, empujar el diferencial (7) o (8) hacia el lado opuesto corona hasta desempenarlo de la corona (4).

ESP

F

A l'aide d'un poussoir, pousser le diffeÂrentiel (7) ou (8) du coÃte oppose aÁ la couronne jusqu'aÁ le deÂgager de la couronne (4).

F

ITA

Rimuovere l'attrezzo T7B montato sul lato opposto corona.

ITA

D

Das Werkzeug T7B abnehmen, das an der dem Kranz entgegengesetzte Seite montiert ist.

D

c

Sacar el grupo diferencial (7) o (8) completo.

Extraire le groupe diffeÂrentiel (7) ou (8) tout entier.

Estrarre la corona (4).

Kranz (4) abziehen.

d ESP

Remover la herramienta T7B montado sobre el lado opuesto corona.

ESP

F

DeÂplacer l'outil T7B monte du coÃte oppose aÁ la couronne.

F

ITA

SMONTAGGIO DIFFERENZIALE Utilizzando un estrattore, asportare i cuscinetti (9) dal gruppo differenziale.

ITA

SMONTAGGIO DIFFERENZIALE NO-SPIN Inserire il tirante "B" di trattenimento del gruppo nospin (14) ed avvitare a fondo il dado ad alette.

D

DIFFERENTIAL ABMONTIEREN Mit einem Abzieher die Lager (9) vom Differentialaggregat abnehmen.

D

DAS NO-SPIN DIFFERENTIAL ABMONTIEREN Sie Spannstange "B" einsetzen, um das No-Spin Aggregat (14) festzuhalten und die FluÈgelmutter fest-

e

f

ziehen.

Extraer la corona (4).

Extraire la couronne (4).

ESP

DESMONTAJE DIFERENCIAL Utilizando un extractor, sacar los cojinetes (9) del grupo diferencial.

ESP

DESMONTAJE DIFERENCIAL NO-SPIN Introducir el tirante "B" de detencion del grupo no-spin (14) y atornillar hasta el fondo la tuerca a aletas.

F

DEMONTAGE DU DIFFERENTIEL A l'aide d'un extracteur, enlever les paliers (9) du groupe diffeÂrentiel.

F

DEMONTAGE DU DIFFERENTIEL NO-SPIN Introduire la tringle "B" de retenue du groupe no-spin (14), puis visser l'eÂcrou aÁ ailettes aÁ fond.

008 911 79

BOMAG 47

979

18.5

Axle DANA REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

F1241151

GB

F1241152

a

Remove the screws (10) and the spring washers (11) jointing the differential unit half box (12).

Using a plastic hammer, take the half box (12) to pieces. NOTE. Note down the coupling marks.

F1241154

c

Extract the no-spin unit (13).

GB

d

Unscrew the wing nut of stay "B" and take the no-spin unit to pieces in order to remove the distance piece (14) that prevents the axial sliding of the axle shafts.

F1241155

GB

F1241156

e

DISASSEMBLY OF THE 45% SELF-LOCKING DIFFERENTIAL UNIT Remove the screws (16) and the spring washers (17) jointing the differential unit.

980

b

GB

F1241153

GB

193

GB

f

Remove the differential cover (18), any shims (19) and the friction (20) complete with ring (21). CAUTION! 1 - Do not change the position of the disks forming the friction. 2 - Check that the overall thickness of friction exceeds 17.3 mm; if lower, substitute both friction units.

BOMAG 48

008 911 79

18.5

Axle DANA 193

ITA

Rimuovere le viti (10) e le rondelle elastiche (11) di unione della semiscatola differenziale (12).

ITA

Utilizzando un mazzuolo in materiale plastico scomporre la semiscatola differenziale (12). NOTA. Annotare la marcatura di accoppiamento.

D

Schrauben (10) und Federscheiben (11) abnehmen, die das halbe DifferentialgehaÈuse (12) zusammen halten.

D

Mit einem Gummihammer das halbe DifferentialgehaÈuse (12) zerlegen. BEMERKUNG. Die Kupplungsmarkierung notieren.

a

b ESP

Remover los tornillos (10) y las arandelas elasticas (11) de union de la semi-caja diferencial (12).

ESP

Utilizando un martillo en material plastico decomponer la semicaja diferencial (12). NOTA. Anotar la marcatura de acoplamiento.

F

Enlever les vis (10) et les rondelles eÂlastiques (11) d'union de la moitie du boõÃtier diffeÂrentiel (12).

F

A l'aide d'un maillet en matieÁre plastique deÂcomposer la moitie du boõÃtier diffeÂrentiel (12). REMARQUE. Prendre note de la marque d'accou-

plement.

ITA

D

Estrarre il gruppo no-spin (13).

ITA

Das No-Spin Aggregat (13) abziehen.

d

F

Die FluÈgelmutter der Spannstange "B" abschrauben und das No-Spin Aggregat zerlegen, um das Differential (14) an der Achsengleitung der Halbachsen abnehmen zu koÈnnen.

D

c ESP

Svitare il dado ad alette del tirante "B" e scomporre il gruppo no-spin per rimuovere il distanziale (14) contro lo scorrimento assiale dei semiassi.

Sacar el grupo no-spin (13).

Extraire le groupe no-spin (13).

ESP

Destornillar la tuerca a aletas del tirante "B" y decomponer el grupo no-spin para remover el distancial (14) contra el deslizamiento axial de los semi-ejes.

F

DeÂvisser l'eÂcrou aÁ ailettes de la tringle "B" et deÂcomposer le groupe no-spin pour enlever le diffeÂrentiel (14) contre le coulisseau axial des demi-

essieux.

ITA

SMONTAGGIO DIFFERENZIALE AUTOBLOCCANTE AL 45% Rimuovere le viti (16) e le rondelle elastiche (17) di unione del corpo differenziale.

Rimuovere il coperchio differenziale (18), gli eventuali spessori (19) e la frizione (20) completa dell'anello (21). ATTENZIONE! 1 - Non scambiare di posizione i dischi componenti la frizione. 2 - Controllare che lo spessore totale della frizione sia superiore a 17,3 mm; se eÁ inferiore sostituire ambedue le frizioni.

D

DAS ZU 45% SELBSTHEMMENDE DIFFERENTIAL ABMONTIEREN Schrauben (16) und Federscheiben (17), die den DifferentialkoÈrper verbinden, abnehmen.

Differentialdeckel (18) und evtl. Unterlegscheiben (19) und die Kupplung (20) mit dem Ring (21) abnehmen. ACHTUNG! 1 - Die Position der Kupplungsscheiben nicht verwechseln. 2 - Die GesamtstaÈrke der Kupplung muû mehr als 17,3 mm betragen; sollte dies nicht der Fall sein, beide Kupplungen auswechseln.

e

ITA

D

f ESP

DESMONTAJE DIFERENCIAL AUTOBLOQUEO AL 45% Remover los tornillos (16) y las arandelas elasticas (17) de union del cuerpo diferencial.

Remover la tapa diferencial (18), los eventuales espesores (19) y la fricion (20) completa del anillo (21). ATENCION! 1 - No cambiar de posicion los discos componentes la fricion. 2 - Controlar que el espesor total de la fricion sea superior a 17,3 mm; si es inferior sobstituir las dos friciones.

F

DEMONTAGE DU DIFFERENTIEL AUTOBLOQUANT A 45% Enlever les vis (16), les rondelles eÂlastiques (17) d'union du corps diffeÂrentiel.

Enlever le couvercle diffeÂrentiel (18), les eÂventuelles cales (19) et la friction (20) compleÁte d'anneau (21). ATTENTION! 1 - Ne pas changer la position des disques composant la friction. 2 - ControÃler que la calage total de la friction soit supeÂrieur aÁ 17,3 mm; s'il est infeÂrieur substituer les deux frictions.

008 911 79

BOMAG 49

ESP

F

981

18.5

Axle DANA REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

F1241157

GB

193

F1241158

a

GB

b

Remove the planetary gear (22). Mark the 37 mm value on a pin-driver; using the same pin-driver, insert the spring pins (25) into the journals (23) and (24). NOTE. The spring pins are centred in journals (23) and (24) when the countermark is lined up with the edge of the body of the differential unit (26).

Remove the long planetary carrier journal (23) and the two short journals (24).

F1241159

F1241160

GB

c

GB

d

Extract the cross journal (27), the planet wheels (28) complete with shim washers (29) and the second planetary gear (22).

Remove the 2nd friction (20) complete with ring (21). Also remove any shims (19). CAUTION! 1 - Do not change the position of the disks forming the friction. 2 - Check that the overall thickness of friction exceeds 17.3 mm; if lower, substitute both friction units.

F1241161

F1241162

GB Extract the spring pins (25) from journals (23) and (24).

982

e

GB

f

Only if bearings are replaced. Remove the thrust blocks of bearings (9) from the intermediate covers (1) and (2).

BOMAG 50

008 911 79

18.5

Axle DANA 193

Rimuovere l'ingranaggio planetario (22). Segnare su un cacciaspine un contrassegno a 37 mm; utilizzando lo stesso cacciaspine, inserire nei perni (23) e (24) le spine elastiche (25). NOTA. Le spine elastiche sono centrate nei perni (23) e (24) quando il contrassegno arriva a filo del corpo differenziale (26).

ITA

Rimuovere il perno porta satelliti lungo (23) ed i due perni corti (24).

Das Planetengetriebe (20) abnehmen. An einem DuÈbel das Maû von 37 mm markieren; mit diesem DuÈbel die Federstifte (25) in die Stifte (23) und (24) einsetzen. BEMERKUNG. Die Federstifte sind in den Stiften (23) und (24) zentriert, wenn das markierte Maû auf der HoÈhe des DifferentialkoÈrpers (26) liegt.

D

Den langen Planetenradhalterstift (23) und die beiden kurzen Planetenradhalterstifte (24) entfernen.

Remover el engranaje planetario (22). Senalizar sobre un extractor de clavijas un contra-segno a 37 mm; utilizando el mismo extractor de clavijas, introducir en los pernos (23) y (24) las clavijas elasticas (25). NOTA. Las clavijas elasticas son centradas en los pernos (23) y (24) cuando el contrasegno llega al hilo del cuerpo diferencial (26).

ESP

Remover la rotula porta satelites largo (23) y las dos rotulas cortas (24).

Enlever l'engrenage planeÂtaire (22). Marquer d'une estampille le chasse-clou aÁ 37 mm; a l'aide de ce meÃme chasse-clou, introduire dans les pivots (23) et (24) les goupilles eÂlastiques (25). REMARQUE. Les goupilles eÂlastiques sont centreÂes dans les pivots (23) et (24) quand l'estampille atteint le bord du corps diffeÂrentiel (26).

F

Enlever le pivot porte-satellite long (23) et les deux pivots courts (24).

ITA

D

a

b

ESP

F

ITA

Estrarre la crociera (27), i satelliti (28) completi delle rondelle di rasamento (29) ed il 2ë ingranaggio planetario (22).

Rimuovere la 2ã frizione (20) completa dell'anello (21). Rimuovere anche gli eventuali spessori (19). ATTENZIONE! 1 - Non scambiare di posizione i dischi componenti la frizione. 2 - Controllare che lo spessore totale della frizione sia superiore a 17,3 mm; se eÁ inferiore sostituire ambedue le frizioni.

D

Das Kreuz (27), die Planetengetriebe (28) samt Zwischenlegscheiben (29) und das 2. Planetengetriebe (30) abziehen.

Die 2. Kupplung (20) mit Ring (21) abnehmen. Eventuelle Unterlegscheiben (19) auch entfernen. ACHTUNG! 1 - Die Position der Kupplungsscheiben nicht verwechseln. 2 - Kontrollieren, ob die GesamtstaÈrke der Kupplung mehr als 17,3 mm betraÈgt; anderenfalls beide Kupplungen auswechseln.

c

ITA

D

d ESP

Sacar la cruceta (27), los satelites (28) completos de las arandelas de rasamiento (29) y el 2ë engranaje planetario (22).

Remover la 2ë fricion (30) completa del anillo (21). Remover tambien los eventuales espesores (19). ATENCION! 1 - No cambiar de posicion los discos componentes la fricion. 2 - Controlar que el espesor total de la fricion sea superior a 17,3 mm; si es inferior sobstituir las dos friciones.

F

Extraire le croisillon (27), les satellites (28) complet de rondelles de rasage (29), puis le 2ë engrenage planeÂtaire (22).

Enlever la 2ë friction (20) compleÁte d'anneau (21). Enlever eÂgalement les eÂventuelles cales (19). ATTENTION! 1 - Ne pas changer la position des disques composant la friction. 2 - ControÃler que la calage total de la friction soit supeÂrieur aÁ 17,3 mm; s'il est infeÂrieur substituer les deux frictions.

ITA

D

ESP

F

Estrarre le spine elastiche (25) dai perni (23) e (24).

Die Federstifte (25) von den Stiften (23) und (24) abziehen.

e

ITA

Solo se si sostituiscono i cuscinetti Rimuovere le ralle dei cuscinetti (9) dai coperchi intermedi (1) e (2).

D

Nur falls die Lager ausgewechselt werden. Die Scheiben von den Lagern (9) der Zwischendeckel (1) und (2) abnehmen.

f ESP

Sacar las clavijas elasticas (25) de las rotulas (23) y (24).

ESP

Solo si se sobstituiyen los cojinetes Remover las ranguas de los cojinetes (9) de las tapas intermedias (1) y (2).

F

Extraire les goupilles eÂlastiques (25) des pivots (23) et (24).

F

Uniquement en cas de substitution des paliers. Enlever les crapaudines des paliers (9) des couvercles intermeÂdiaires (1) et (2).

008 911 79

BOMAG 51

983

18.5

Axle DANA REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

193

GB

a

GB

b

GB

c

GB

d

D1240134

GB

984

e

GB

BOMAG 52

f

008 911 79

18.5

Axle DANA 193

ITA

ITA

D

D

a

b ESP

ESP

F

F

ITA

ITA

D

D

c

d ESP

ESP

F

F

D1240135

ITA

ITA

D

D

e

f ESP

ESP

F

F

008 911 79

BOMAG 53

985

18.5

Axle DANA REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

F1241154

F1241163

a

GB

ASSEMBLY OF THE NO-SPIN DIFFERENTIAL UNIT Assemble the no-spin unit (13), inserting the distance piece (14) and using stay "B".

193

b

GB Fit the no-spin unit into the differential unit half box (15). Centre the half box (12) and fasten. CAUTION! Make sure the connection marks coincide.

B

F1241164

F1241150

c

GB

Fit the spring washers (11) onto the screws (10). Coat the screws (10) with Loctite 270 and screw tight to form the differential box. Tighten screws using the criss-cross method and a torque of 86 ± 89 Nm.

GB

d

Remove stay "B".

17,6

F1241224

GB

e

ASSEMBLY OF THE 45% SELF-LOCKING DIFFERENTIAL UNIT Using a depth gauge, check the shim of friction units complete with rings (21). If thickness is lower than 17.6 mm, add more shims (19). CAUTION! Shims must be placed right behind the body of the differential unit (26).

986

F1241160

GB

f

Insert in the body of the differential unit (26) any required shims (19) and the friction (20) complete with ring (21). CAUTION! Ring (21) must touch the planetary gear (22).

BOMAG 54

008 911 79

18.5

Axle DANA 193

a

ITA

ASSEMBLAGGIO DIFFERENZIALE NO-SPIN Assemblare il gruppo no-spin (13) inserendo il distanziale (14) ed utilizzando il tirante "B".

Montare il gruppo no-spin nella semiscatola differenziale (15). Centrare la semiscatola (12) e mandarla in battuta. ATTENZIONE! Controllare che le marcature di accoppiamento coincidano.

D

NO-SPIN DIFFERENTIAL ZUSAMMENBAUEN Das No-Spin (13) Aggregat zusammenbauen; dazu das DistanzstuÈck (14) mit der Spannstange "B"

Das No-Spin Aggregat in das halbe DifferentialgehaÈuse (15) montieren. Das halbe GehaÈuse (12) zentrieren und bis zum Anschlag einsetzen. ACHTUNG! Kontrollieren, ob die Kupplungsmarkierungen uÈbereinstimmen.

einsetzen.

ITA

D

b

ESP

MONTAJE DIFERENCIAL NO-SPIN Asemblaje el grupo no-spin (13) introduciendo el diferencial (14) y utilizando el tirante "B".

Montar el grupo no-spin en la semi-caja diferencial (15). Centrar la semi-caja (12) y mandarla a tope. ATENCION! Controlar que las marcaduras de acoplamiento coincidan.

F

ASSEMBLAGE DU DIFFERENTIEL NO-SPIN Assembler le groupe no-spin (13) en introduisant l'entretoise (14), puis aÁ l'aide de la tringle "B".

Monter le groupe no-spin dans la moitie du boõÃtier diffeÂrentiel (15). Centrer la moitie du boõÃtier (12) et l'envoyer en buteÂe. ATTENTION! ControÃler que les estampilles d'accouplement correspondent.

ESP

F

Infilare sulle viti (10) le rondelle elastiche (11). Spalmare le viti (10) con Loctite 270 ed avvitarle a fondo per comporre la scatola differenziale. Serrare le viti con il metodo incrociato ad una coppia di serraggio di 86v89 Nm.

ITA

D

c

ITA

Federscheiben (11) in die Schrauben (10) einsetzen. Die Schrauben (10) mit Loctite 270 schmieren und festziehen, um das DifferentialgehaÈuse zusammenzu-

bauen. Die Schrauben im Kreuz und mit einem Anzugsmoment von 86v89 Nm festziehen.

D

Spannstange "B" abnehmen.

d

Insertar sobre tornillos (10) las arandelas elasticas (11). Pasar los tornillos (10) con Loctite 270 y atornillar hasta el fondo para componer la caja diferencial. Apretar los tornillos con el metodo cruzado y un par de serraje de 86v89 Nm.

ESP

Passer sur les vis (10) les rondelles eÂlastiques (11). Enduire les vis (10) avec du Loctite 270, puis visser celles-ci aÁ fond pour recomposer le boõÃtier diffeÂrentiel. Serrer les vis avec la meÂthode croiseÂe aÁ un couple de serrage de 86v89 Nm.

F

ESP

F

Remover el tirante "B".

Enlever la tringle "B".

ASSEMBLAGGIO DIFFERENZIALE AUTOBLOCCANTE AL 45% Controllare con un calibro di profonditaÁ lo spessore delle frizioni complete degli anelli (21). Se lo spessore eÁ inferiore a 17,6 mm, aggiungere degli spessori (19). ATTENZIONE! Gli spessori devono essere posizionati a ridosso del corpo differenziale (26).

Inserire nella corpo differenziale (26) gli eventuali spessori (19) e la frizione (20) completa dell'anello (21). ATTENZIONE! L'anello (21) deve rimanere a contatto dell'ingranaggio planetario (22).

ZU 45% SELBSTHEMMENDE DIFFERENTIAL ZUSAMMENBAUEN Mit Hilfe einer Tiefenlehre die StaÈrke der Kupplungen mit den Ringen (21) messen. Sollte das Maû weniger als 17,6 mm betragen, noch Unterlegscheiben (19) hinzufuÈgen. ACHTUNG! Die Unterlegscheiben muÈssen am DifferentialkoÈrper (26) anliegen.

In den DifferentialkoÈrper (26) eventuelle Unterlegscheiben (19) und die Kupplung (20) samt Ring (21) einsetzen. ACHTUNG! Der Ring (21) muû am Planetengetriebe (22) anliegen.

ITA

ITA

D

e

Rimuovere il tirante "B".

D

f

MONTAJE DIFERENCIAL AUTO-BLOQUEO AL 45% Controlar con un calibro de profundidad el espesor de las friciones completas de los anillos (21). Si el espesor es inferior a 17,6 mm, sumar de los espesorees (19). ATENCION! Los espesores deben de ser colocados detraÁs del cuerpo diferencial (26).

Introducir en el cuerpo diferencial (26) los eventuales espesores (19) y la fricion (20) completa del anillo (21). ATENCION! El anillo (33) debe quedar a contacto del engranaje planetario (22).

ASSEMBLAGE DU DIFFERENTIEL AUTOBLOQUANT A 45% ControÃler aÁ l'aide d'un calibre de profondeur l'eÂpaisseur des frictions compleÁtes d'anneaux (21). Si le calage est infeÂrieur aÁ 17,6 mm, ajouter des cales (19). ATTENTION! Les cales doivent eÃtre placeÂes aÁ l'abri du corps diffeÂrentiel (226).

Introduire le corps diffeÂrentiel (26), les eÂventuelles cales (19) et la friction (20) compleÁte d'anneau (21. ATTENTION! L'anneau (21) doit rester au contact de l'engrenage planeÂtaire (22).

ESP

F

008 911 79

BOMAG 55

ESP

F

987

18.5

Axle DANA REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

F1241165

GB

F1241166

a

GB

b

Install the cross journal (27), holding it into position with the long journal (23). Before inserting journal (23) completely, install the last planet wheel (28) and the relative washer (29).

25,5

Install the planetary gear (22) and three of the planet wheels (28), complete with shim washers (29). Hold the planet wheels (28) and relative washers (29) into position with pins (24).

193

F1241167

GB

F1241168

c

GB

d

Countermark a point at 25.5 mm on a pin-driver; using the same pin-driver, engage the journals (23) and (24) with the spring pins (25). NOTE. When the countermark is lined up with the edge of the body of the differential unit (26), the journals are engaged by half.

Install the second planetary gear (22) and the friction (20) complete with ring (21) and any shims required (19). CAUTION! Ring (21) must be installed right behind the planetary gear (22) and the shims (19) right behind the differential cover (18).

F1241169

F1241170

GB Position the differential cover (18). NOTE. Make sure that the assembly marks coincide.

988

e

GB

f

Fit the spring washers (17) onto the screws (16). Coat the screws (16) with Loctite 270 and screws tight. Tighten screws using the criss-cross method and a torque of 135 ± 138 Nm.

BOMAG 56

008 911 79

18.5

Axle DANA 193

Montare l'ingranaggio planetario (22) e tre degli ingranaggi satelliti (28) completi di rondelle di rasamento (29). Mantenere in posizione gli ingranaggi satelliti (28) e le relative rondelle (29) con i perni (24).

Montare la crociera (27) e mantenerla in posizione con il perno lungo (23). Prima di inserire completamente il perno (23), montare l'ultimo satellite (28) e la relativa rondella (29).

Das Planetengetriebe (22) und drei der Planetengetriebe (28) samt Zwischenlegscheiben (29) montieren. Die Planetengetriebe (28) und die Zwischenlegscheiben (29) mit den Stiften (24) in der Position festhalten.

Das Kreuz (27) montieren und in der Position mit einem langen Stift (23) festhalten. Bevor der Stift (23) ganz eingesetzt wird, das letzte Planetengetriebe (28) und die Unterlegscheibe (29) montieren.

ITA

ITA

D

a

D

b

Montar el engranaje planetario (22) y tres de los engranajes satelites (28) completos de las arandelas de rasadura (29). Mantener en posicion los engranajes satelites (28) y las relativas arandelas (29) con las rotulas (24).

Montar la cruceta (27) y mantenerla en posicion con la rotula larga (28). Antes de insertar completamente la rotula (23), montar el ultimo satelite (28) y la relativa arandela (29).

Monter l'engrenage planeÂtaire (22) et trois des engrenages satellites (28) complets de rondelles de rasage (29). Maintenir les engrenages satellites (28) et relatives rondelles (29) aÁ leur place avec les pivots (24).

Monter le croisillon (27) et maintenir celui-ci aÁ sa place aÁ l'aide du pivot long (23). Avant d'introduire entieÁrement le pivot (23), monter le dernier satellite (28) et sa rondelle (29).

Segnare sul cacciaspine un contrassegno a 25,5 mm; utilizzando lo stesso cacciaspine impegnare i perni (23) e (24) con le spine elastiche (25). NOTA. Le spine impegnano metaÁ dei perni quando il contrassegno arriva a filo del corpo differenziale (26).

Montare il secondo ingranaggio planetario (22) e la frizione (20) completa dell'anello (21) e degli eventuali spessori (19). ATTENZIONE! L'anello (21) deve essere montato a ridosso dell'ingranaggio planetario (22) e gli eventuali spessori (19) a ridosso del coperchio differenziale (18).

An dem DuÈbel das Maû von 25,5 mm markieren; mit demselben DuÈbel die Stifte (23) und (24) mit den Federstiften (25) einsetzen. BEMERKUNG. Die Stifte sind durch die Federstifte zur HaÈlfte eingesetzt, wenn die Markierung auf halber HoÈhe des DifferentialkoÈrpers (26) liegt.

Das zweite Planetengetriebe (22) und die Kupplung (20) mit dem Ring (21) und eventuelle Unterlegscheiben (19) montieren. ACHTUNG! Der Ring (21) muû nach der Montage am Planetengetriebe (22) und die eventuellen Unterlegscheiben (19) muÈssen am Differentialdeckel (18) anliegen.

ESP

ESP

F

F

ITA

ITA

D

c

D

d

Senalar sobre el extractor de clavijas un contra-segno a 25,5 mm; utilizando el mismo extractor de clavijas empegnar las rotulas (23) y (24) con las clavijas elasticas (25). NOTA! Las clavijas empegnan midad de las rotulas cuando el contra-segno llega al borde del cuerpo diferencial (26).

Montar el segundo engranaje planetario (22) y la fricion (20) completa del anillo (21) y de los eventuales espesores (19). ATENCION! El anillo (21) debe deser montado detras del engranaje planetario (22) y los eventuales espesores (19) detras de la tapa diferencial (18).

Marquer d'une estampille le chasse-clou aÁ 25,5 mm; a l'aide de ce meÃme chasse-clou, engager les pivots (23) et (24) et les goupilles eÂlastiques (25). REMARQUE. Les goupilles arrivent aÁ la moitie des pivots quand l'estampille atteint le bord du corps diffeÂrentiel (26).

Monter le second engrenage planeÂtaire (22), la friction (20) compleÁte d'anneau (21) et des eÂventuelles cales (19). ATTENTION! L'anneau (21) est aÁ monter aÁ l'abri de l'engrenage planeÂtaire (22) et les eÂventuelles cales (19) aÁ l'abri du couvercle diffeÂrentiel (18).

ITA

Posizionare il coperchio differenziale (18). NOTA. Controllare che le marcature di montaggio coincidano.

Infilare sulle viti (16) le rondelle elastiche (17). Spalmare le viti (16) con Loctite 270 ed avvitarle a fondo. Serrare le viti con il metodo incrociato ad una coppia di serraggio di 135v138 Nm.

D

Den Differentialdeckel (18) positionieren. BEMERKUNG. Kontrollieren, ob die Montagemarkierungen uÈbereinstimmen.

Auf die Schrauben (16) die Federscheiben (17) montieren. Die Schrauben (16) mit Loctite 270 schmieren und festziehen. Die Schrauben im Kreuz mit einem Anzugsmoment von 135v138 Nm festziehen.

ESP

ESP

F

e

F

ITA

D

f ESP

F

008 911 79

Colocar la tapa diferencial (18). NOTA. Colocar que las marcaduras de montaje coincidan.

Mettre le couvercle diffeÂrentiel (18) en place. REMARQUE. ControÃler que les estampilles de montage coõÈncident.

BOMAG 57

ESP

Introducir sobre los tornillos (16) las arandelas elasticas (17). Pasar los tornillos (16) con Loctite 270 y atornillarlos a

fondo. Apretar los tornillos con el metodo cruzado a un par de serraje de 135v138 Nm. Passer sur les vis (16) les rondelles eÂlastiques (17). Enduire les vis (16) avec du Loctite 270 et visser celles-ci aÁ fond. Serrer les vis avec la meÂthode croiseÂe aÁ un couple de serrage de 135v138 Nm.

F

989

18.5

Axle DANA REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

F1241171

GB

F1241172

a

INSTALLATION OF THE DIFFERENTIAL UNIT Position the differential unit (7) or (8) under a press and, using a driver with an adequate diameter, install the first bearing (9).

193

GB

b

Turn the unit upside down and install the second bearing (9). CAUTION! Pay particular attention; position a shim with adequate diameter in order to engage the internal ring of bearing (9) without engaging the cage.

T8

F1241173

GB

F1241174

c

Only if bearings are replaced Using tool T8, insert the thrust blocks of the bearings (9) into the intermediate covers (1) and (2).

GB

d

Position the crown wheel (4) in the main body (3).

T7B

F1241175

GB

e

Fit tool T7B on the crown wheel opposite side, holding it in position with two studs and two nuts. NOTE. Engage the crown (4) onto tool T7B.

990

F1241176

GB

f

Install the differential unit (7) or (8), by fitting it into the hole of tool T7B. Install the crown (4) onto the differential unit (7) or (8), and fasten it to the flange. NOTE. Make sure the holes of the flange match those of the crown.

BOMAG 58

008 911 79

18.5

Axle DANA 193

INSTALLAZIONE DIFFERENZIALE Posizionare il differenziale (7) o (8) sotto una pressa ed utilizzando uno spintore di diametro adatto montare il primo cuscinetto (9).

Capovolgere il gruppo e montare il secondo cuscinetto (9). ATTENZIONE! Prestare molta attenzione e posizionare uno spessore di diametro adatto al fine di impegnare l'anello interno del cuscinetto (9) senza impegnare la gabbia.

DIFFERENTIAL ZUSAMMENBAUEN Das Differential (7) oder (8) unter eine Presse legen und mit einem geeigneten Dynamometer-StoÈûel das erste Lager (9) montieren.

Das Aggregat wenden und das zweite Lager montieren (9). ACHTUNG! Den Vorgang mit groûer Sorgfalt durchfuÈhren und einen fuÈr die StaÈrke geeigneten Dynamometer verwenden, um den Ring des inneren Lagers (9) einzusetzen, ohne den KaÈfig einzuklemmen.

ITA

ITA

D

a

D

b

INSTALACION DIFERENCIAL Colocar el diferencial (7) y (8) bajo una prensa y utilizando un empuje de diametro adapto montar el primer cojinete (9).

Volcar el grupo y montar el segundo cojinete (9). ATENCION! Tener mucho cuidado y colocar un espesor de diametro apto al fin de empegnar el anillo interno del cojinete (9) si empegnar la jaula.

INSTALLATION DU DIFFERENTIEL Mettre le diffeÂrentiel (7) ou (8) en place sous la presse, aÁ l'aide d'un poussoir au diameÁtre adeÂquat, monter le premier palier (9).

Faire basculer le groupe et monter le second palier (9). ATTENTION! Faire treÁs attention, mettre une cale au diameÁtre adeÂquat afin d'engager l'anneau interne du palier (9) sans y engager la cage.

ESP

ESP

F

F

ITA

Solo se si sostituiscono i cuscinetti Utilizzando l'attrezzo T8 inserire le ralle dei cuscinetti (9) nei coperchi intermedi (1) e (2).

ITA

Posizionare la corona (4) dentro il corpo centrale (3).

D

Nur wenn die Lager ausgewechselt werden. Mit dem Werkzeug T8 die Scheiben der Lager (9) in die Zwischendeckel (1) und (2) einsetzen.

D

Den Kranz (4) in den zentralen KoÈrper (3) einsetzen.

c

d ESP

Solo si se sobstituyen los cojinetes Utilizando la herramienta T8 Introducir las ranguas de los cojinetes (9) en las tapa intermedias (1) y (2).

ESP

F

Uniquement en cas de substitution des paliers A l'aide de l'outil T8, introduire la crapaudine des paliers (9) dans les couvercles intermeÂdiaires (1) et (2).

F

ITA

Montare l'attrezzo T7B sul lato opposto corona, trattenendolo con due prigionieri e due dadi. NOTA. Impegnare la corona (4) sull'attrezzo T7B.

Montare il gruppo differenziale (7) o (8) impegnandolo nel foro dell'attrezzo T7B. Montare la corona (4) sul differenziale (7) o (8) mandandola in battuta sulla flangia. NOTA. Far coincidere i fori della flangia con i fori della corona.

Das Werkzeug T7B auf der dem Kranz entgegengesetzten Seite montieren und mit zwei Stiftschrauben und zwei Muttern festhalten. BEMERKUNG. Den Kranz (4) in das Werkzeug T7B einrasten.

Das Differentialaggregat (7) oder (8) montieren und im Loch des Werkzeuges T7B einrasten. Den Kranz (4) auf das Differential (7) oder (8) montieren und bis zum Anschlag am Flansch einsetzen. BEMERKUNG. Die FlanschloÈcher muÈssen mit den KranzloÈchern uÈbereinstimmen.

Mettre la couronne (4) en place dans le corps central (3).

ITA

D

e

Colocar la corona (4) dentro del cuerpo central (3).

D

f

Montar la herramienta T7B sobre el lado opuesto corona, deteniendo con dos prigionieros y dos tuercas. NOTA. Empegnar la corona (4) sobre la herramienta T7B.

Montar el grupo diferencial (7) o (8) empegnandolo en el agujero de la herramienta T7B. Montar la corona (4) sobre el diferencial (7) y (8) mandandola a tope sobre la brida. NOTA. Hacer coincidir los agujeros de la brida con los agujeros de la corona.

Monter l'outil T7B du coÃte oppose aÁ la couronne, en le tenant aÁ l'aide de deux prisonniers et de deux eÂcrous. REMARQUE. Engager la couronne (4) sur l'outil T7B.

Monter le groupe diffeÂrentiel (7) ou (8) en l'engageant dans le trou de l'outil T7B. Monter la couronne (4) sur le diffeÂrentiel (7) ou (8) puis l'envoyer en buteÂe sur la flasque. REMARQUE. Faire correspondre les trous de la flasque avec les trous de la couronne.

ESP

F

008 911 79

BOMAG 59

ESP

F

991

18.5

Axle DANA REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

193

A

F1241177

GB

F1241145

a

Fit spring washers (6) onto the screws (5). Coat screws with Loctite 270 and screw them tight into the crown. Position the stop block "A"; while holding the crown resting on the block, tighten the screws (5) to a torque of 135 ± 138 Nm. CAUTION! Tighten screws using the criss-cross method.

b

GB

Check the condition and position of the O-ring (30); lubricate the seal and install the intermediate cover (2) on crown wheel side.

T6 T7A

F1241178

GB

F1241179

c

Lock the intermediate cover (2) with the journals (31) tightened to a torque of 129 ± 143 Nm.

GB

d

Install tool T6 on the journals (31) on the crown wheel side, placing distance pieces and locking with two nuts. Insert differential centring and support tool T7A into tool T6. NOTE. Make sure that the differential unit is tightly engaged in the intermediate cover (2).

T7B

F1241180

GB Remove tool T7B on crown opposite side.

992

F1241181

e

GB

f

Check state and position of O-ring (30); lubricate the seal and fit the intermediate cover (1) on the crown opposite side. Lock the intermediate cover (1) with journals (31) tightened to a torque of 129 ± 143 Nm and remove tools T6 and T7A.

BOMAG 60

008 911 79

18.5

Axle DANA 193

Montare sulle viti (5) le rondelle elastiche (6). Spalmare le viti con Loctite 270 ed avvitarle a fondo nella corona. Posizionare il blocchetto "A" di contrasto; mantenendo in appoggio la corona sul blocchetto, serrare le viti (5) ad una coppia di 135v138 Nm. ATTENZIONE! Serrare le viti con il metodo incrociato.

ITA

Controllare lo stato ed il posizionamento dell'anello OR (30); lubrificare la guarnizione e montare il coperchio intermedio (2) lato corona.

Auf die Schrauben (5) die Federscheiben (6) montieren. Die Schrauben mit Loctite 270 schmieren und in den Kranz schrauben. Den Block "A" positionieren; den Kranz am Block anliegen lassen und die Schrauben (5) mit einem Anzugsmoment von 135v138 Nm festziehen. ACHTUNG! Die Schrauben im Kreuz festziehen.

D

Den Zustand und die Position des O-Ringes (30) kontrollieren; die Dichtung schmieren und den Zwischendeckel (2) an der Kranzseite montieren.

Montar sobre los tornillos (5) las arandelas elasticas (6). Pasar los tornillos con Loctite 270 y atornillarlos a fondo en la corona. Colocar el bloque "A" de contraste; manteniendo en apoyo la corona sobre el bloque, apretar los tornillos (5) y un par de 135v138 Nm. ATENCION! Apretar los tornillos con el metodo cruzado.

ESP

Controlar el estado y la colocacion del anillo OR (30); lubrificar la guarnicion y montar la tapa intermedia (2) lado corona.

Monter les vis (5), les rondelles eÂlastiques (6). Enduire les vis avec du Loctite 270, puis visser cellesci aÁ fond dans la couronne. Mettre le petit bloc "A" de contraste; en maintenant la couronne poseÂe sur le petit bloc, serrer les vis (5) aÁ un couple de 135v138 Nm. ATTENTION! Serrer les vis avec la meÂthode croiseÂe.

F

ControÃler l'eÂtat et le positionnement de l'anneau O'Ring (30); lubrifier la garniture, puis monter le couvercle intermeÂdiaire (2) du coÃte couronne.

ITA

D

a

b

ESP

F

ITA

Bloccare il coperchio intermedio (2) con i prigionieri (31) serrati ad una coppia di 129v143 Nm.

Montare l'attrezzo T6 sui prigionieri (31) lato corona, interponendo i relativi distanziali e bloccandolo con due dadi. Inserire nell'attrezzo T6 l'attrezzo T7A di centratura e sostegno del differenziale. NOTA. Assicurarsi che il differenziale sia impegnato a fondo nel coperchio intermedio (2).

D

Den Zwischendeckel (2) mit den Stiftschrauben (31) blockieren und mit einem Anzugsmoment von 129v143 Nm festziehen.

Das Werkzeug T6 an den Stiftschrauben (31) an der Kranzseite montieren und dabei DistanzstuÈcke einsetzen und mit zwei Muttern befestigen. In das Werkzeug T6 das Werkzeug T7A zur Zentrierung und Halterung des Differentials einsetzen. BEMERKUNG. Sicherstellen, daû das Differential fest im Zwischendeckel (2) sitzt.

c

ITA

D

d ESP

Bloquear la tapa intermedia(2) con los prigioneros (31) apretados a un par de 129v143 Nm.

Montar la herramienta T6 sobre los prigioneros (31) lado corona, interponiendo de los distanciales y bloqueando con dos tuercas. Introducir en la herramienta T6 la herramienta T7A de centradura y sosten del diferencial. NOTA. Asegurarse que el diferencial sea empegnado a fondo en la tapa intermedia (2).

F

Bloquer le couvercle intermeÂdiaire (2) aÁ l'aide des prisonniers (31) serreÂs aÁ un couple de 129v143 Nm.

Monter l'outil T6 sur les prisonniers (31) coÃte couronne, en y intercalant des entretoises, puis bloquer celui-ci avec deux eÂcrous. Introduire dans l'outil T6, l'outil T7A de centrage et de support du diffeÂrentiel. REMARQUE. S'assurer que le diffeÂrentiel soit engage aÁ fond dans le couvercle intermeÂdiaire (2).

Rimuovere l'attrezzo T7B del lato opposto corona.

Controllare lo stato ed il posizionamento dell'anello OR (30); lubrificare la guarnizione e montare il coperchio intermedio (1) lato opposto corona. Fissare il coperchio intermedio (1) con i prigionieri (31) serrati ad una coppia di 129v143 Nm e rimuovere gli attrezzi T6 e T7A.

Werkzeug T7B an der dem Kranz entgegengesetzten Seite abnehmen.

Den Zustand und die Position des O-Ringes (30) kontrollieren; die Dichtung schmieren und den Zwischendeckel (1) an der dem Kranz entgegengesetzten Seite montieren. Den Zwischendeckel (1) mit den Stiftschrauben (31) und einem Anzugsmoment von 129v143 Nm befestigen und die Werkzeuge T6 und T7A entfernen.

ITA

D

e

ESP

F

ITA

D

f ESP

F

Remover la herramienta T7B del lado opuesto corona.

Enlever l'outil T7B du coÃte oppose aÁ la couronne.

Controlar el estado y la colocacion del anillo OR (30); lubrificar la guarnicion y montar la tapa intermedia (1) lado opuesto corona. Fijar la tapa intermedia (1) con los prigioneros (31) apretados a un par de 129v143 Nm y remover las herramientas T6 y T7A.

ESP

F

ControÃler l'eÂtat et le positionnement de l'anneau O'Ring (30); lubrifier la garniture, puis monter le couvercle intermeÂdiaire (1) du coÃte oppose aÁ la

couronne. Fixer le couvercle intermeÂdiaire (1) aÁ l'aide des prisonniers (31) serreÂs aÁ un couple de 129v143 Nm, enlever les outils T6 et T7A.

008 911 79

BOMAG 61

993

18.5

Axle DANA REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

193

T9

F1241182

GB

F1241183

a

Remove the screws (33) and remove the safety tabs (34).

b

GB

Using wrench T9, extract the adjustment ring nuts (32) and remove any residue of thread locking substances. Screw ring nuts again after applying Loctite 242.

F1241184

GB

F1241185

c

Remove the spring ring (35) and extract the cap (36) to allow checking of the clearance between pinion and crown to take place.

d

GB

Coat the surface of the main body (3) with Loctite 510 and install the reduction gear (37) complete with pinion. NOTE. Make sure that a continuous layer of sealant runs around the locking holes.

T9

F1241186

GB

e

Coat screws (38) with Loctite 242 and screw tight. Tighten screws (38), using the criss-cross method and a tightening torque of 129 ± 143 Nm.

994

F1241183

GB

f

Screw ring nut (32) on crown wheel side until clearance between pinion and crown equals zero, then unscrew by 1/4 turn approx.

BOMAG 62

008 911 79

18.5

Axle DANA 193

ITA

Asportare le viti (33) e rimuovere le linguette di sicurezza (34).

ITA Loctite 242.

D

Die Schraube (33) abschrauben und den Sicherheitskeil (34) abnehmen.

a

D

b ESP

Sacar los tornillos (33) y remover les lengues de seguridad (34).

F

Enlever le vis (33), puis deÂplacer le languettes de seÂcurite (34).

Utilizzando la chiave T9 rimuovere le ghiere (32) di registrazione ed asportare ogni traccia di frenafiletti. Riavvitare le ghiere dopo averle spalmate con

Mit einem SchluÈssel T9, die Nutmuttern (32) zur Einstellung entfernen und jede alle uÈberschuÈssigen Reste der SchraubensicherungsloÈsung sorgfaÈltig ent-

fernen. Nutmuttern mit Loctite 242 schmieren und wieder festschrauben.

Utilizando la llave T9, remover las virolas (32) de registracion y sacar cada senal de frenaroscas. Restornillas las virolas despues de haberias pasadas con Loctite 242.

ESP

F visser.

A l'aide de la cle T9, enlever les eÂcrous annulaires (32) de reÂglage et toute trace de l'agent d'arreÃt de vis. Enduire les eÂcrous annulaires avec Loctite 242 et

ITA

Asportare l'anello elastico (35) e rimuovere il tappo (36) per poter controllare il gioco tra pignone e corona.

Spalmare la superficie del corpo centrale (3) con Loctite 510 ed installare il riduttore (37) completo di pignone. NOTA. Assicurarsi che il sigillante crei un velo continuo attorno ai fori di fissaggio.

D

Den Kolbenring (35) abnehmen und den Stopfen (363) entfernen, um das Spiel zwischen Kegelrad und Kranz kontrollieren zu koÈnnen.

Die FlaÈche des ZentralkoÈrpers (3) mit Loctite 510 schmieren und den Reduzierer (37) samt Kegelrad installieren. BEMERKUNG. Sicherstellen, daû die Dichtmasse einen gleichmaÈûigen Film um die BefestigungsloÈcher herum bildet.

c

ITA

D

d ESP

Sacar el anillo elastico (35) y remover la tapa (36) para poder controlar el juego entre pignon y corona.

Pasar la superficie del cuerpo central (3) con Loctite 510 y instalar el reductor (37) completo de pignon. NOTA. Asegurarse que el sigilante cree una pelicula continua alrededor a los agujeros de fisaje.

F

Enlever l'anneau eÂlastique (35), enlever le bouchon (36) pour controÃler le jeu existant entre pignon et couronne.

Enduire la superficie du corps central (3) avec du Loctite 510, installer le reÂducteur (37) complet de pignon. REMARQUE. S'assurer que la couche de colle entoure bien les trous de fixation.

ITA

Spalmare le viti (38) con Loctite 242 e avvitarle a fondo. Serrare le viti (38) con il metodo incrociato ad una coppia di serraggio di 129v143 Nm.

ITA

Avvitare la ghiera (32) lato corona fino ad azzerare i giochi tra pignone e corona e poi svitare per circa 1/4 di giro.

D

Die Schrauben (38) mit Loctite 242 schmieren und festziehen. Die Schrauben (38) im Kreuz mit einem Anzugsmoment von 129v143 Nm festziehen.

D

Nutmuttern (32) an der Kranzseite zuschrauben bis zwischen Rad und Kranz kein Spiel mehr uÈbrig bleibt; danach um 1/4 Umdrehung aufschrauben.

Pasar los tornillos (38) con Loctite 242 y atornillas a fondo. Apretar los tornillos (38) con el metodo cruzado y un par de torsion de 129v143 Nm.

ESP

Atornillar las virolas (32) lado corona hasta acerar los juegos entre el pinion y corona y despues destornillar por cerca 1/4 de giro.

Enduire les vis (38) avec du Loctite 242, puis visser celles-ci aÁ fond. Serrer les vis (38) avec la meÂthode croiseÂe aÁ un couple de serrage de 129v143 Nm.

F

Visser l'eÂcrou annulaire (32) du coÃte couronne jusqu'aÁ annuler le jeux entre pignon et couronne, puis deÂvisser 1/4 de tour.

e

ESP

F

f ESP

F

008 911 79

BOMAG 63

995

18.5

Axle DANA REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

193

T3

C

F1241187

a

GB

Allow pinion to turn a few times in both directions to allow bearings to set. Pre-load the bearings through the ring nut on crown opposite side to increase pinion torque up to a value of 140 ± 210 Ncm checked by means of a torque meter. CAUTION! If bearings are old, check static torque. If new, check continuous torque.

RATIO - RAPPORTO È LTNIS VERHA RAPORTE - RAPPORT

6v43

F1241188

b

GB

Introduce a comparator with rotary key "C" through the rear cap hole (43). Position comparator on the centre of one of the crown teeth (4), preset it to 1 mm and reset it to zero. Manually move the crown (4) in both directions to check the existing clearance between pinion and crown.

CLEARANCE - GIOCO - SPIEL JUEGO - JEU MIN.

MAX.

0,18

0,23

T9

Difference between MIN and MAX clearance for whole circumference should not exceed 0.09 mm. La differenza tra gioco MIN e MAX rilevata sull'intera circonferenza non deve superare il valore di 0,09 mm. Der Unterschied zwischen dem MIN e MAX Spiel der gesamten Kreislinie darf den Wert von 0,09 mm nicht uÈberschreiten. La diferencia entre el juego Min y Max determinada sobre la entera circonferencia no debe de superar el valor de 0,09 mm. La diffeÂrence de jeu entre MIN et MAX releveÂe sur toute la circonfeÂrence ne doit pas aller au-delaÁ de la valeur de 0,09 mm.

GB

F1241183

c

GB

d

Mark the position of the ring nuts (32) in relation to the intermediate covers. Using wrench T9, adjust clearance between pinion and crown by loosening one ring nut (32) and tightening the opposite proportionally. Normal clearance: see table.

F1241189

GB Install safety tabs (41) and lock them with screws (40). Screws tightening torque: 10 ± 11 Nm.

996

F1241190

e

GB

f

Using a driver, fit the cap (36) and position it in its seat with the snap ring (35).

BOMAG 64

008 911 79

18.5

Axle DANA 193

Far compiere al pignone alcuni giri nei due sensi per assestare i cuscinetti. Precaricare i cuscinetti tramite la ghiera lato opposto corona, per incrementare la coppia di rotazione pignone fino a 140v210 Ncm controllati con un torsiometro. ATTENZIONE! Con cuscinetti usati, controllare la coppia di spunto; con cuscinetti nuovi, controllare la coppia di rotazione continua.

Posizionare, attraverso il foro per il tappo posteriore (43), un comparatore a tasto orientabile "C". Posizionarlo sul centro di un dente della corona (4), precaricarlo di circa 1 mm ed azzerarlo. Muovere manualmente nei due sensi la corona (4) per controllare il gioco esistente tra pignone e corona.

Das Kegelrad um einige Umdrehungen in beide Richtungen D drehen, um das Lager in die richtige Position zu bringen. Die Lager durch die Nutmutter an der dem Kranz entgegengesetzte Seite vorbelasten, um das Gegenmoment des Kegelrads bis auf 140v210 Ncm zu erhoÈhen. Den Wert mit einem Drehungsmesser kontrollieren. ACHTUNG! Bei gebrauchten Lagern, das Anlaufdrehmoment kontrollieren; bei neuen Lagern, das kontinuierliche Gegenmoment kontrollieren.

Durch das Loch des hinteren Stopfens (43) eine Meûuhr mit schwenkbarer Taste "C" einsetzen. Die Meûuhr auf die Mitte eines Zahnes des Kranzes (4) positionieren und um 1mm vorbelasten; danach zuruÈckstellen. Von Hand in beide Richtungen den Kranz (4) bewegen, um das Spiel zwischen Kegelrad und Kranz zu kontrollieren.

ITA

a

ITA

D

b

Hacer efectuar al pignon algunos giros en los dos sentidos para ordenar los cojinetes. Precargar los cojinetes a traves de las virolas lado opuesto corona, para crecer el par de rotacion pignon hasta 140v210 Ncm controlados con un torsiometro. ATENCION! Con cojinetes usados, controlar el par de principio; con cojinetes nuevos, controlar el par de rotacion continua.

Colocar, atraves el agujero para la tapa posterior (43), un comparador a tecla orientable "C". Colocarlo sobre el centro de un diente de la corona (4), precargarlo de 1 mm aprox y azerarlo. Mover manualmente en los dos sentidos la corona (4) para controlar el juego esistente entre pignon y corona.

F

Faire tourner le pignon plusieurs fois dans les deux sens pour ajuster les paliers. PreÂcharger les paliers au moyen de l'eÂcrou annulaire, du coÃte oppose aÁ la couronne, pour augmenter le couple de rotation du pignon jusqu'aÁ 140v210 Ncm controÃleÂs par un torsiomeÁtre. ATTENTION! Avec des paliers usageÂs, controÃler le couple de pointe; avec des paliers neufs, controÃler le couple de rotation continu.

Placer aÁ travers le trou servant au bouchon arrieÁre (43), un comparateur aÁ touche orientable "C". Positionner celui-ci au centre d'une des dents de la couronne (4), preÂcharger celui-ci d'environ 1 mm et mettre aÁ zeÂro. DeÂplacer manuellement la couronne (4) dans les deux sens pour controÃler le jeu existant entre pignon et couronne.

ITA

Contrassegnare la posizione delle ghiere (32) rispetto i coperchi intermedi. Con la chiave T9, regolare il gioco tra pignone e corona allentando una ghiera (32) e serrando la ghiera opposta in egual misura. Gioco normale: vedere tabella.

D

Die Position der Nutmuttern (32) im VerhaÈltnis zu den Zwischendeckeln markieren. Mit dem SchluÈûel T9, das Spiel zwischen Rad und Kranz einstellen, in dem eine Nutmutter (32) gelockert und die entgegengesetzte festgezogen wird. Normales Spiel: siehe Tabelle.

ESP

ESP

F

ITA

D

c

d ESP

Contrasenalr la colocacion de las virolas (32) respecto a las tapaderas intermedias. Con la llave T9, regular el juego entre el pignon y la corona aflojando una virola (32) y apretando la virola opuesta en la misma mesura. Juego normal: vease el prospecto.

F

Marquer la position de l'eÂcrou annulaire (32) par rapport aux couvercles intermeÂdiaires. A l'aide de la cle T9, reÂgler le jeu entre pignon et couronne en deÂvissant l'eÂcrou annulaire (32) et en vissant l'eÂcrou annulaire oppose de la meÃme mesure. Jeu normal: voir tableau.

ESP

F

ITA

Montare le linguette di sicurezza (41) e fissarle con le viti (40). Coppia di serraggio viti: 10v11 Nm

ITA

Con uno spintore, montare il tappo (36) ed assicurarlo in sede con l'anello elastico (35).

D

Den Sicherheitskeil (41) montieren und mit den Schrauben (40) befestigen. Anzugsmoment der Schrauben: 10v11 Nm

D

Mit einem StoÈûel den Stopfen (36) montieren und in seinem Sitz mit dem Kolbenring (35) befestigen.

e

f ESP

Montar las lenguetas de seguridad (41) y fijarlas con los tornillos (40). Par de serraje tornillos: 10v11 Nm

ESP

Con un empujador, montar la tapa (36) y asegurarlo en sed con el anillo elastico (36).

F

Monter les languettes de seÂcurite (41), fixer celles-ci aÁ l'aide des vis (40). Couple de serrage des vis: 10v11 Nm.

F

A l'aide d'un poussoir, monter le bouchon (36), ajuster celui-ci dans son logement avec l'anneau eÂlastique (35).

008 911 79

BOMAG 65

997

18.5

Axle DANA REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

F1241190

GB

193

F1241192

a

GB

b

Using a driver and a plastic hammer, install the driving gear (39).

Apply Loctite 510 to the surface of the reduction gear body (37) and install the cover (40). NOTE. Make sure that a continuous layer of sealant runs around the locking holes.

F1241193

F1241194

GB

c

Lock the cover (40), using the snap washers (43) and the screws (42) and (41) adequately tightened to a torque of 82 ± 91 Nm. Tighten screws (42) and (41) with a tightening torque of 82 ± 91 Nm.

GB

GB

d

Install the breath union piece (44) with the relative sealing washers (45) and plugs (47) and (46); tighten to a torque of 35 ± 50 Nm.

e

GB

f

Complete assembly of the axle by installing, in the following order, brake cylinders and complete arms. For details, see «ASSEMBLING THE BRAKING UNITS».

998

BOMAG 66

008 911 79

18.5

Axle DANA 193

ITA

Utilizzando uno spintore ed un mazzuolo in materiale plastico, montare l'ingranaggio conduttore (39).

Spalmare la superficie del corpo riduttore (37) con Loctite 510 ed installare il coperchio (40). NOTA. Assicurarsi che il sigillante crei un velo continuo attorno ai fori di fissaggio.

D

Mit einem StoÈûel und einem Gummihammer das Getriebe (39) montieren.

Die FlaÈche des KoÈrpers des Reduzierers (37) mit Loctite 510 schmieren und den Deckel (40) installieren. BEMERKUNG. Sicherstellen, daû die Dichtmasse einen gleichmaÈûigen Film um die BefestigungsloÈcher herum bildet.

a

ITA

D

b ESP

Utilizando un empujador y un martillo en material plastico, montar el engranaje conductor (39).

Pasar la superficie del cuerpo reductor (37) con Loctite 510 y instalar la tapa (40). NOTA. Asegurarse que el sigilante cree una pelicula continua alrededor de los agujeros de fisaje.

F

A l'aide d'un poussoir et d'un maillet en matieÁre plastique, monter l'engrenage conducteur (39).

Enduire la superficie du corps reÂducteur (37) avec du Loctite 510, installer le couvercle (40). REMARQUE. S'assurer que la couche de colle entoure bien les trous de fixation.

ITA

Bloccare il coperchio (40) utilizzando le rondelle elastiche (43) e le viti (42) e (41) serrate con una coppia di 82v91 Nm.

ITA

Montare il raccordo di sfiato (44) con le relative rosette di tenuta (45) ed i tappi (47) e (46); serrarli con una coppia di 35v50 Nm.

D

Den Deckel (40) mit den Federscheiben (42) und (41) und den Schrauben (42) und (41) bei einem Anzugsmoment von 82v91 Nm blockieren.

D

Das abgezogene VerbindungsstuÈck (44) mit den Dichtscheiben (45) und den Stopfen (47) und (46) montieren; Anzugsmoment 35v50 Nm.

c

ESP

F

d ESP

Bloquear la tapa (40) utilizando las arandelas elasticas (43) y los tornillos (42) y (41) apretadas con un par de 82v91 Nm.

ESP

Montar el recorde de escape (441) con las relativas rosas de tenida (45) y las tapas (47) y (46); apretarlos con un par de 35v50 Nm.

F

Bloquer le couvercle (40) aÁ l'aide des rondelles eÂlastiques (43) et des vis (42) et (41) serreÂes aÁ un couple de 82v91 Nm.

F

Monter le raccord d'eÂvent (44), les relatives rosettes d'eÂtancheÂite (45) et les bouchons (47) et (46), serrer ceux-ci aÁ un couple de 35v50 Nm.

ITA

Completare l'assemblaggio dell'assale installando nell'ordine i cilindri freni ed i bracci completi. Per i dettagli, vedere «ASSEMBLAGGIO GRUPPI

ITA

FRENO».

Die Achse fertig zusammenbauen und der Reihe nach die Bremszylinder und die kompletten Arme installieren. Siehe «ZUSAMMENBAU DER BREMSAGGREGATE».

D

e

ESP FRENOS».

Completar el asemblaje del axial instalando en el orden los cilindros frenos y los ejes completos. Para los detalles, vease «ASEMBLAJE GRUPOS

Achever l'assemblage de l'essieu en y installant dans l'ordre les cylindres freins et les bras complets. Pour de plus amples deÂtails voir "ASSEMBLAGE DU GROUPE FREIN".

F

008 911 79

BOMAG 67

D

f ESP

F

999

Axle DANA 193 18.5DISASSEMBLY OF REDUCTION GEAR AND BEVEL PINION - SMONTAGGIO RIDUTTORE E PIGNONE CONICO - REDUZIERER UND KEGELRAD ABMONTIEREN - REMOCION REDUCTOR Y PINÄON CONICO - DEMONTAGE DU REDUCTEUR ET PIGNON CONIQUE

F1241141

GB

F1241195

a

Remove the whole arms and the differential unit. For details, see «CHECKING WEAR AND REPLACING THE BRAKING DISKS» and «REMOVAL OF DIFFERENTIAL UNIT».

GB

b

Loosen and remove screws (1) and (2) and the washers (3) locking the cover (4), the plugs (5) and (6) for oil fill and oil drain, and the bleed union piece (7). NOTE. Leave two screws (2) in position for safety.

A

F1241196

GB

F1241197

c

GB

d

Using a plastic hammer, remove the cover (4) and move it away. NOTE. If operations on the differential unit need to be performed, remove the complete reduction gear unit (screws (9) and (10)).

Place a block of tender material (aluminium, etc.) between the reduction body (11) and the gear (12) of the pinion. Loosen and remove the pinion locking nut (13).

F1241198

F1241199

GB

e

Remove the gear of the pinion (12) and the driving gear (14) complete with bearing (15). NOTE. To remove the gear (14), use a lever.

1000

GB

f

Take the driving gear to pieces (14), extracting the bearing (15). NOTE. If necessary, use an extractor.

BOMAG 68

008 911 79

18.5

Axle DANA 193

Rimuovere i bracci completi ed il differenziale. Per i dettagli, vedere «CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO» e «RIMOZIONE GRUPPO DIFFERENZIALE».

Allentare ed asportare le viti (1) e (2) e le rondelle (3) di ritegno coperchio (4), i tappi (5) e (6) di carico e scarico olio ed il raccordo di sfiato (7). NOTA. Lasciare in posizione per sicurezza due viti (2) contrapposte.

Die kompletten Arme und das Differential abnehmen. Siehe «VERSCHLEISS KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN» und «DIFFERENTIALAGGREGAT ABNEHMEN».

Schrauben (1) und (2) abschrauben und die Unterlegscheiben (3) zur Halterung des Deckels (4), die È leinfuÈll- und Ablaûstopfen (5) und (6) sowie das O EndluÈftungsstuÈck (7) abnehmen. BEMERKUNG. Die entgegengesetzten Schrauben (2) zur Sicherheit zuruÈck lassen.

ITA

ITA

D

a

D

b

Remover los ejes completos y el duferencial. Para los detalles, vease «CONTROL DESGASTE Y SOBSTITUCION DISCOS FRENOS» y «REMOCION GRUPO DIFERENCIAL».

Aflojar y sacar los tornillos (1) y (2) y las arandelas (3) de retencion tapa (4), los tapones (5) y (6) de carga y descarga aceite y el recorde de escape (7). NOTA. Dejar en posicion de seguridad dos tornillos (2) contrapuestas.

Enlever les bras complets et le diffeÂrentiel. Pour de plus amples deÂtails, voir "CONTROLE USURE ET SUBSTITUTION DES DISQUES FREIN" et "DEPOSE DU GROUPE DIFFERENTIEL".

Desserrer et enlever les vis (1) et (2), les rondelles (3) de fixation du couvercle (4), les bouchons (5) et (6) de remplissage et vidange d'huile et le raccord d'eÂvent (7). REMARQUE. Pour plus de suÃreteÂ, garder deux vis (2) superposeÂes.

Utilizzando un mazzuolo in materiale plastico, rimuovere il coperchio (4) ed asportarlo. NOTA. Se si deve intervenire sul gruppo differenziale, rimuovere il gruppo riduttore completo (viti (9) e (10)).

Sistemare tra il corpo riduttore (11) e l'ingranaggio (12) del pignone un blocchetto "A" di materiale tenero (alluminio, ecc.). Allentare ed asportare il dado (13) di ritegno pignone.

Mit einem Gummihammer den Deckel (4) ausrasten und abnehmen. BEMERKUNG. Soll am Differentialaggregat gearbeitet werden, das komplette Reduzieraggregat abnehmen (Schrauben (9) und (10)).

Zwischen dem ReduziererkoÈrper (11) und dem Getriebe (12) des Kegelrads einen Block aus weichen Material einsetzen (Aluminium usw.) Mutter (13) zur Halterung des Kegelrads abschrauben.

ESP

ESP

F

F

ITA

ITA

D

c

D

d

Utilizando un martillo en material plastico, remover la tapa (4) y sacarla. NOTA. Si se debe intervenir sobre el grupo diferencial, remover el grupo reductor completo (tornillos (9) y (10)).

Colocar entre el cuerpo reductor (11) y el engranaje (12) del pinon un bloquete "A" de material tierno (aluminio, ect.). Aflojar y sacar la tuerca (13) de retencion pinon.

A l'aide d'un maillet en matieÁre plastique, deÂplacer le couvercle (4) et puis l'enlever. REMARQUE. S'il faut intervenir sur le groupe diffeÂrentiel, enlever le groupe reÂducteur complet (vis (9) et (10)).

Ajuster, entre le corps reÂducteur (11) et l'engrenage (12) du pignon, un petit bloc "A" en mateÂriel leÂger (aluminium etc.). Desserrer et enlever l'eÂcrou (13) de fixation pignon.

ESP

ESP

F

ITA leva.

F

Rimuovere l'ingranaggio del pignone (12) e l'ingranaggio conduttore (14) completo di cuscinetto (15). NOTA. Per rimuovere l'ingranaggio (14), utilizzare una

Das Getriebe (12) des Kegelrads und das Getriebe (14) samt Lager (15) entfernen. BEMERKUNG. Um das Getriebe (14) abnehmen zu koÈnnen, einen Hebel verwenden.

D

e

ESP palanca.

F un levier.

008 911 79

f

ITA

Scomporre l'ingranaggio conduttore (14) estraendo il cuscinetto (15). NOTA. Se necessario, usare un estrattore.

D

Das Getriebe (14) zerlegen; dazu das Lager (15) abziehen. BEMERKUNG. Wenn noÈtig, einen Abzieher verwen-

den.

Remover el engranaje del pinon (12) y el engranaje conductor (14) completo de cojinete (15). NOTA. Para remover el engranaje (14), utilizar una

ESP

Descomponer el engranaje conductor (14) sacando el cojinete (15). NOTA. Si necesario, usar un extractor.

DeÂplacer l'engrenage du pignon (12) et l'engrenage conducteur (14) complet de palier (15). REMARQUE. Pour deÂplacer l'engrenage (14), utiliser

F

DeÂcomposer l'engrenage conducteur (14) en deÂgageant le palier (15). REMARQUE. Si besoin, utiliser un extracteur.

BOMAG 69

1001

Axle DANA 193 18.5DISASSEMBLY OF REDUCTION GEAR AND BEVEL PINION - SMONTAGGIO RIDUTTORE E PIGNONE CONICO - REDUZIERER UND KEGELRAD ABMONTIEREN - REMOCION REDUCTOR Y PINÄON CONICO - DEMONTAGE DU REDUCTEUR ET PIGNON CONIQUE

F1241200

GB

F1241201

a

GB

b

Loosen all screws (9) and (10) and remove the upper check screws (9) of the reduction gear body. NOTE. Leave the two lower screws (10) in position for safety.

Connect the whole reduction gear body (11) to a hoist and remove the screws (10) previously left in place for safety. Using a plastic hammer, pull away the whole reduction gear body (11).

F1241202

F1241203

GB

c

Position the reduction gear body (11) under a press and, using a driver, extract the pinion (16) complete with internal bearing (17), shims (19) and distance piece (20).

GB

d

Remove distance piece (20) and shims (19) from the pinion(16). Position the pinion under a press and remove the internal bearing (17).

F1241204

GB

e

GB

f

With the help of an extractor, remove the thrust blocks (17) and (21) of the bearings, and the snap ring (22). NOTE. Note down direction of assembly of snap ring (22).

1002

BOMAG 70

008 911 79

18.5

Axle DANA 193

Allentare tutte le viti (9) e (10) ed asportare le viti (9) superiori di ritegno del corpo riduttore. NOTA. Lasciare in sede le due viti (10) inferiori per

Collegare il corpo riduttore completo (11) ad un mezzo di sollevamento ed asportare le viti (10) lasciate in sede per sicurezza. Utilizzando un mazzuolo in materiale plastico, rimuovere il corpo riduttore (11) completo.

Alle Schrauben (9) und (10) lockern und die oberen Schrauben (9) zur Halterung des ReduziererkoÈrpers abnehmen. BEMERKUNG. Die beiden unteren Schrauben (10) zur Sicherheit zuruÈck lassen.

Den kompletten ReduziererkoÈrper (11) an ein Hebezeug befestigen und die zuvor zur Sicherheit zuruÈckgelassenen Schrauben (10) abschrauben. Mit einem Gummihammer, den kompletten ReduziererkoÈrper (11) abnehmen.

ITA sicurezza.

ITA

D

a

D

b

Aflojar todos los tornillos (9) y (10) y sacar los tornillos (9) superiores de retencion del cuerpo reductor. NOTA. Dejar en su lugar los dos tornillos (10) inferiores para seguridad.

Conectar el cuerpo reductor completo (11) a un medio de elevacion y sacar los tornillos (10) dejadas en su lugar para seguridad. Utilizando un martillo en material plastico, remover el cuerpo reductor (11) completo.

Desserrer toutes les vis (9) et (10), enlever les vis supeÂrieures (9) de fixation du corps reÂducteur. REMARQUE. Garder les deux vis infeÂrieures (10) dans leur sieÁge pour plus de seÂcuriteÂ.

Brancher le corps reÂducteur complet (11) aÁ un moyen de relevage, puis enlever les vis laisseÂe (10) dans leur sieÁge pour plus de seÂcuriteÂ. A l'aide d'un maillet en matieÁre plastique, enlever le corps reÂducteur (11) complet.

Posizionare il corpo riduttore (11) sotto una pressa e, utilizzando uno spintore, estrarre il pignone (16) completo di cuscinetto interno (17), spessori (19) ed il distanziale (20).

Rimuovere dal pignone (16) il distanziale (20) e gli spessori (19). Posizionare il pignone sotto una pressa e rimuovere il cuscinetto interno (17).

Den ReduziererkoÈrper (11) unter eine Presse legen und mit einem StoÈûel das Kegelrad (16) samt dem inneren Lager (17), den Unterlegscheiben (19) und dem DistanzstuÈck (20) abziehen.

Vom Kegelrad (16) das DistanzstuÈck (20) und die Unterlegscheiben (19) abnehmen. Das Kegelrad unter eine Presse legen und das innere Lager (17) abnehmen.

ESP

ESP

F

F

ITA

ITA

D

c

ESP

F

ITA tenuta (22).

D

d

Colocar el cuerpo reductor (11) debajo de una prensa y, utilizando un empujador (16) completo de cojinete interno (17), espesores (19) y el distancial (20).

ESP interno (17).

Placer le corps reÂducteur (11) sous une presse, aÁ l'aide d'un poussoir extraire le pignon (16) complet de palier interne (17), cales (19) et entretoise (20).

F interne (17).

Con un estrattore, rimuovere dal corpo riduttore (11) le ralle dei cuscinetti (17) e (21) e l'anello di tenuta (22). NOTA. Annotare il senso di montaggio dell'anello di

Mit einem Abzieher vom ReduziererkoÈrper (11) die Scheiben der Lager (17) und (21) und den Dichtring (22) entfernen. BEMERKUNG. Montagerichtung des Dichtringes (22) notieren.

D

f

Con un extractor, remover del cuerpo reductor (11) las ranguas de los cojinetes (17) y (21) y el anillo de retencion (22). NOTA. Anotar el sentido de desmontaje del anillo de retencion (22).

ESP

A l'aide d'un extracteur, enlever le corps reÂducteur (11), les crapaudines des paliers (17) et (21) et l'anneau d'eÂtancheÂite (22). REMARQUE. Prendre note du sens de montage de l'anneau d'eÂtancheÂite (22).

F

ESP

F

008 911 79

BOMAG 71

Enlever du pignon (16) l'entretoise (20) et les cales (19). Placer le pignon sous une presse et enlever le palier

ITA

D

e

Remover del pinon (16) el distancial (20) y los espesores (19). Colocar el pinon bajo una prensa y remover el cojinete

1003

Axle DANA 193 18.5DISASSEMBLY OF REDUCTION GEAR AND BEVEL PINION - SMONTAGGIO RIDUTTORE E PIGNONE CONICO - REDUZIERER UND KEGELRAD ABMONTIEREN - REMOCION REDUCTOR Y PINÄON CONICO - DEMONTAGE DU REDUCTEUR ET PIGNON CONIQUE

GB

a

GB

b

GB

c

GB

d

D1240136

GB

1004

e

GB

BOMAG 72

f

008 911 79

18.5

Axle DANA 193

CAUTION! 1 - If disassembly has only been carried out to replace the snap ring (22), position the new ring and reassemble the unit, respecting the tightening torques specified in the following section and using the specified locking and sealing products. 2 - If disassembly is performed to replace either crown wheel and pinion, bearings, or planetary gears, take the unit to pieces and find shims and clearances as specified in the sections relative to the removal, disassembly, assembly and installation of the differential unit and bevel pinion.

ATENCION! 1 - Si el desmontaje ha sido efectuado solo para la sobstitucion del anillo de retencion (22), proceder al alojamiento del nuevo anillo y remontar el grupo respectando los pares de serraje indicadas en el paragrafo siguiente y utilizando los productos de bloqueo y tenida prescritos. 2 - Si el desmontaje viene efectuado para la sobstitucion del par conico, de los cojinetes o de los engranajes satelites, proceder a la descomposicion y a la busqueda de los espesores y de los juegos como indicados en los paragrafos concernientes la remocion, el desmontaje, el asemblaje y la instalacion del diferencial y del pinon conico.

ATTENZIONE! 1 - Se lo smontaggio eÁ stato eseguito solo per la sostituzione dell'anello di tenuta (22), procedere al posizionamento del nuovo anello e rimontare il gruppo rispettando le coppie di serraggio indicate nel paragrafo seguente ed utilizzando i prodotti di bloccaggio e tenuta prescritti. 2 - Se lo smontaggio viene eseguito per la sostituzione della coppia conica, dei cuscinetti o degli ingranaggi satelliti, procedere alla scomposizione ed alla ricerca degli spessori e dei giochi come indicato nei paragrafi riguardanti la rimozione, lo smontaggio, l'assemblaggio e l'installazione del differenziale e del pignone conico.

ATTENTION! 1 - Si le deÂmontage n'est effectue que pour substituer l'anneau d'eÂtancheÂite (22), positionner le nouvel anneau et remonter le groupe en respectant les couples de serrage indiqueÂs dans le paragraphe suivant aÁ l'aide des produits de blocage et d'eÂtancheÂite prescrits. 2 - Si le montage est effectue pour substituer le couple conique des paliers et des engrenages satellites, passer aÁ la deÂcomposition et aÁ la recherche des cales et des jeux comme indique dans les paragraphes concernant la deÂpose, le deÂmontage, l'assemblage et l'installation du diffeÂrentiel et du pignon conique.

GB

ITA

ESP

F

ACHTUNG! 1 - Falls das Teil zum Auswechseln des Dichtringes (22) zerlegt wurde, den neuen Ring einsetzen und das Aggregat wieder montieren; dabei die Anzugsmomente einhalten, die im nachstehenden Kapitel angegeben sind und die vorgeschriebenen Materialien zur Blokkierung und Abdichtung verwenden. 2 - Falls das Zerlegen zum Auswechseln des Kegelradpaars, der Lager oder der Planetengetriebe vorgenommen wird, den Anweisungen der Paragraphen zum Zerlegen, Abmontieren und Zusammenbauen sowie zur Installation des Differentials und des Kegelrads folgen und die StaÈrken und Spiele einhalten.

D

008 911 79

BOMAG 73

1005

Axle DANA 193 18.5 INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UND EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE

MEASURE (42.35) MISURA (42,35) MAß (42,35) MESURA (42,35) MESURE (42,35)

St

B C

MARK CONTRASSEGNO KENNZEICHEN CONTRASENALACION MARQUAGE

B

C

F1241205

F1241206

a

GB

Mark the thrust block and the internal bearing (17) on a faceplate, allow the bearing to set by rotating them in both directions and by applying a vertical thrust. With a centesimal, digital depth gauge "B", check overall thickness of bearing (e.g.: 42.35 mm) and set the gauge to zero again.

b

GB

Lay two 20 mm gauged blocks "C" on the face of the reduction gear body (11). With depth gauge "B" (set to zero at the previous point), measure space between the "C" blocks and the striking surface of internal bearing (17). The size obtained (e.g.: 0.81 mm) is the theoretical shim "St" (18) to be inserted under the thrust block of bearing (17).

DIFFERENTIAL AXIS ASSE DIFFERENZIALE DIFFERENTIALACHSE EJE DEFERENCIAL ESSIEU DIFFERENTIEL

S

Y X +

-DEVIATION "X" SCOSTAMENTI "X" ABWEICHUNG "X" DESPLAZAMIENTOS "X" ECARTS "X"

S = St + (± X) D1240137

F1241225

GB

c

On the bar-hold of pinion (16), check the value "X" (in brackets) relative to the deviation from the theoretical centre distance. NOTE. "Y" is the number of pinion/crown coupling.

d

GB

To calculate final thickness "S", add the negative value of "X" to "St" or, alternatively, subtract the positive value of "X". For ex.: Deviation X=(±0.13 mm): S=St+X=0.81+0.13=0.94 mm Deviation X=(+0.12 mm): S=St ± X=0.81 ± 0.12=0.69 mm CAUTION! Round off to as close to 0.05 mm as possible.

T10

F1241227

GB

e

Using a driver, mount the sealing ring (22) in the reduction unit (11). NOTES. 1 - Carefully check the direction of assembly. 2 - Lubricate the outer surface of the sealing ring.

1006

F1241207

GB

f

Place the reduction gear body (11) under a press and, using tool T10, insert the thrust block of external bearing (21). CAUTION! Insert the thrust block of the bearing that is not countermarked.

BOMAG 74

008 911 79

18.5

Axle DANA 193

Contrassegnare la ralla ed il cuscinetto (17) interno su un piano di riscontro, assestare il cuscinetto con delle rotazioni parziali nei due sensi ed esercitando una spinta verticale. Con un calibro di profonditaÁ digitale centesimale "B", rilevare lo spessore totale del cuscinetto (es 42,35 mm) ed azzerare il calibro.

Appoggiare sul piano di appoggio del corpo riduttore (11) due blocchetti calibrati da 20 mm "C". Con il calibro di profonditaÁ "B" (azzerato nella fase precedente), rilevare la misura tra i blocchetti "C" ed il piano di battuta del cuscinetto interno (17). La misura risultante (es. 0,81 mm) eÁ lo spessore "St" (18) teorico da inserire sotto la ralla del cuscinetto (17).

Die Scheibe und das innere Lager (17) an einer BezugsflaÈche markieren, das Lager durch hin und her Drehen und einem senkrechten Druck richtig einsetzen. Mit einer digitalen hundertteiligen Tiefenlehre "B" die GesamtstaÈrke des Lagers messen (z.B. 42,35 mm) und die Lehre zuruÈckstellen.

Auf eine AuflageflaÈche des ReduziererkoÈrpers (11) zwei kalibrierte BloÈcke zu 20 mm "C" legen. Mit einer Tiefenlehre "B" (zuvor zuruÈckgestellt) das Maû zwischen den BloÈcken "C" und der AnschlagflaÈche des inneren Lagers (17) messen. Das ermittelte Maû (z.B. 0,81 mm) entspricht der theoretischen Unterlegscheibe "St" (18), die unter die Scheibe des Lagers (17) gelegt werden muû.

ITA

ITA

D

a

D

b

Senalar la rangua t el cojinete (17) interno sobre una superficie de rescontre, ordenar el cojinete con unas rotaciones parciales en los dos sentidos y ejercitando un empuje vertical. Con un calibre de profundidad digital centesimal "B", relevar el espesor total del cojinete (es.:42,35 mm) y azerar el calibre.

Colocar sobre la superficie de apoyo del cuerpo reductor (11) dos bloques calibrados de 20 mm "C". Con el calibre de profundidad "B" (azerando en la fase precediente), relevar la mesura entre los bloquetes "C" y la superficie del tope del cojinete interno (17). La mesura resultante (es.: 0,81 mm) es el espesor "St" (18) teorico de introducir bajo la rangua del cojinete (17).

Estampiller la crapaudine et le palier (17) interne sur un marbre de controÃle, ajuster les paliers par des rotations partielles dans les deux sens tout en poussant verticalement. A l'aide d'un calibre de profondeur numeÂrique centeÂsimal "B", relever le calage total des paliers (ex. 42,35 mm), mettre le calibre aÁ zeÂro.

DeÂposer sur un plan d'appui du corps reÂducteur (11), deux petits blocs calibreÂs aÁ 20 mm "C". A l'aide du calibre de profondeur "B" (mis aÁ zeÂro preÂceÂdemment), relever la mesure existante entre les petits blocs "C" et le plan de buteÂe du palier interne (17). La mesure reÂsultante (ex. 0,81 mm) est le calage "St" (18) aÁ introduire sous la crapaudine du palier (17).

Controllare sul codolo del pignone (16) il valore "X" (racchiuso tra parentesi) dello scostamento rispetto l'interasse teorico. NOTA. Il numero "Y" eÁ il numero di accoppiamento pignonecorona.

Per calcolare lo spessore "S" definitivo, aggiungere a "St", il valore "X" negativo oppure sottrarre il valore "X" positivo. Es.: Scostamento X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm Scostamento X=(+0,12 mm): S=St ± X=0,81 ± 0,12=0,69 mm ATTENZIONE! Arrotondare al valore piuÁ prossimo dei 0,05 mm.

Den Wert "X" der Gleitung am Kegelradschaft (16) (in Klammern angegeben) im VerhaÈltnis zum theoretischen Achsenabstand kontrollieren. BEMERKUNG. Die Zahl "Y" entspricht dem Kegelrad-KranzKopplungsgrad.

Um die endguÈltige StaÈrke "S" auszurechnen, "St" und "X" addieren, wenn "X" neÂgatif ist oder "X" von "St" abziehen, falls "X" postif ist. Beispiel: Abweichung X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm Abweichung X=(+0,12 mm): S=St ± X ± 0,81 ± 0,12=0,69 mm ACHTUNG! Auf einen Wert abrunden, der 0,05 mm am naÈchsten liegt.

ESP

ESP

F

F

ITA

ITA

D

c

D

d

Controlar sobre al espigon del pinon (16) el valor "X" (serrado entre parantesis) del desplazamiento respecto al intereje teorico. NOTA. El numero "Y" y el numero de acoplamiento pinon-corona.

Para calcolar el espesor "S" definitivo, adicionar a "St", el valor "X" negativo o detraer el valor "X" positivo. Es.: Desplazamiento X=(± 0,13mm): S=St+X=0,81+0,13=0,94 mm Desplazamiento X=(0,12mm): S=St ± X=0,81 ± 0,12=0.69 mm ATENCION! Acercar al valor mas cerca de 0,05 mm.

ControÃler sur la queue du pignon (16) la valeur "X" (entre parentheÁses) de l'eÂcart par rapport aÁ l'entraxe theÂorique. REMARQUE. Le numeÂro "Y" est le numeÂro de l'accouplement pignon-couronne.

Pour calculer l'eÂpaisseur "S" deÂfinitif, additionner aÁ "St" la valeur "X" neÂgative ou soustraire la valeur "X" positive. Ex. Ecart X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm Ecart X=(+0,12 mm): S=St ± X ± 0,81 ± 0,12=0,69 mm ATTENTION! Arrondir aÁ la valeur plus proche aÁ 0,05 mm.

Utilizzando uno spintore, montare nel corpo riduttore (11) l'anello di tenuta (22). NOTE. 1 - Controllare attentamente il senso di

Sistemare il corpo riduttore (11) sotto una pressa e, utilizzando l'attrezzo T10 inserire la ralla del cuscinetto esterno (21). ATTENZIONE! Inserire la ralla del cuscinetto non contrassegnato.

Mit einem StoÈûel den Dichtring (22) in den ReduziererkoÈrper (11). BEMERKUNG. 1 - SorgfaÈltig die Montagerichtung des Dichtrings kontrollieren. È 2 - Auûere FlaÈche des Dichtrings schmieren.

Den ReduziererkoÈrper (11) unter eine Presse legen und mit dem Werkzeug T10 die Scheibe des aÈuûeren Lagers (21) einsetzen. ACHTUNG! Die Scheibe des nicht gekennzeichneten Lagers einsetzen.

ESP

ESP

F

ITA

F

ITA

montaggio. 2 - Lubrificare la superficie esterna dell'anello di tenuta.

D

e

ESP

Colocar el cuerpo reductor (11) debajo de una prenso y, utilizando la herramienta T10 insertar la rangua del cojinete esterno (21). ATENCION! Introducir la rangua del cojinete no segnalado.

A l'aide d'un poussoir, monter dans le corps reÂducteur (11) l'anneau d'eÂtancheÂite (22). NOTE. 1 - Controà ler attentivement le sens de

Ajuster le corps reÂducteur (11) sous la presse, aÁ l'aide de l'outil T10 introduire la crapaudine du palier externe (21). ATTENTION! Introduire la crapaudine du palier non estampilleÂe.

montage. 2 - Lubrifier la surface externe de l'anneau d'eÂtancheÂiteÂ.

008 911 79

f

Utilizando un espesor, montar en el cuerpo reductor (11) el anillo de retencion (22). NOTA. 1 - Controlar atentamente el sentido de

montaje. 2 - Lubrificar la superficie exterior del anillo de retencion.

F

D

BOMAG 75

ESP

F

1007

Axle DANA 193 18.5 INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UND EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE

T11

F1241208

GB

F1241209

a

Turn the reduction gear body (11) upside down and insert shim "S"; then, with tool T10, insert the thrust block of the internal bearing (17). CAUTION! Insert the thrust block of the countermarked bearing.

b

GB

Fit tool T12 onto tool T11. Then, install bearings (17) and (21) so that they are opposed to each other and spaced by the distance piece (20). Position the depth comparator in one of the four radial holes; preset the comparator to 3 ± 4 mm, then set it to zero.

T11

T11 F1241210

GB

F1241211

c

Remove the bearings from tool T11 and fit them in the thrust blocks of the reduction gear body. CAUTION! Check that the countermarked bearing is fitted in the centring hub of the body of the reduction gear and in the countermarked thrust block too.

Install tool T11 and tighten it manually to obtain a safe rolling torque. NOTE. During tightening, perform a few rotations to set the bearings.

H + 0,13 ÷ 0,15 = S1

S

F1241212

GB

1008

F1241221

e

Introduce the previously reset comparator, in one of the four radial holes and measure. The deviation from zero indicates the nominal value "H" relative to the shims that are to be inserted.

d

GB

GB

f

The deviation found is to be added to a fixed value of 0.13(0.15 mm. in order to: obtain shim "S1" (to be inserted between internal bearing (17) and distance piece (20)) and, hence, produce the specified pre-load of bearings. CAUTION! Perform accurate measurements - a variation of 0.001 mm causes a variation in the torque by 20 ± 40 Nm

BOMAG 76

008 911 79

18.5

Axle DANA 193

Capovolgere il corpo riduttore (11) ed inserire lo spessore "S" e con l'attrezzo T10 la ralla del cuscinetto interno (17). ATTENZIONE! Inserire la ralla del cuscinetto contrassegnato.

Montare sull'attrezzo T11 l'attrezzo T12. Quindi montare i cuscinetti (17) e (21) contrapposti ed intervallati con il distanziale (20). Posizionare un comparatore di profonditaÁ in uno dei quattro fori radiali; precaricare il comparatore di 3v4 mm ed azzerarlo.

ITA

Den RedurziererkoÈrper (11) wenden und die Unterlegscheibe "S" einsetzen; mit dem Werkzeug T10 die Scheibe des inneren Lagers (17) einsetzen. ACHTUNG! Die Scheibe des gekennzeichneten Lagers einsetzen.

ITA

D

a

D

b

Montar sobre la herramienta T11 la herramienta T12. Entonces colocar los cojinetes (17) y (12) contrapuestos y intervalados con el distancial (20). Colocar un comparador de profundidad en uno de los cuatro agujeros radiales, precargar el comparador de 3-4 mm y acerarlo.

Faire basculer le corps reÂducteur (11), introduire la cale "S", et aÁ l'aide de l'outil T10 la crapaudine du palier interne (17). ATTENTION! Introduire la crapaudine du palier estampilleÂ.

Monter sur l'outil T11, l'outil T12. Ensuite monter les paliers (17) et (21) en les superposant et intercalant avec l'entretoise (20). Placer un comparateur de profondeur dans l'un des quatre trous radiaux; preÂcharger le comparateur aÁ 3v4 mm, puis le mettre aÁ zeÂro.

Rimuovere i cuscinetti dall'attrezzo T11 e montarli nelle ralle del corpo riduttore. ATTENZIONE! Controllare che il cuscinetto contrassegnato sia montato nel mozzo di centratura del corpo riduttore e quindi nella ralla contrassegnata.

Montare l'attrezzo T11 e serrarlo manualmente fino ad avere una sicura coppia di rotolamento. NOTA. Durante il serraggio, eseguire alcune rotazioni per assestare i cuscinetti.

Die Lager vom Werkzeug T11 abnehmen und in den Scheiben des ReduziererkoÈrpers montieren. ACHTUNG! Kontrollieren, ob das markierte Lager in den Zentriernaben des ReduziererkoÈrpers und folglich in der markierten Scheibe montiert ist.

Das Werkzeug T11 montieren und von Hand festziehen bis ein sicheres Gegenmoment erreicht ist. BEMERKUNG. Beim Festziehen einige Umdrehungen vornehmen, um die Lager richtig in ihren Sitz zu bringen.

ESP

F

F

ITA

ITA

D

D

d

Remover los cojinetes de la herramienta T11 y montarlos en las ranguas del cuerpo reductor. ATENCION! Controlar que el cojinete segnalado sea colocado en el cubo central del cuerpo reductor y por lo tanto en la rangua segnalada.

Montar la herramienta T11 y apretarla manualmente hasta obtener una segura pareja de rotacion. NOTA. Durante la torsion, efectuar algunas rotaciones para ordenar los cojinetes.

Oter les paliers de l'outil T11, puis monter ces derniers dans les crapaudines du corps reÂducteur. ATTENTION! ControÃler que le palier estampille soit monte dans le moyeu de centrage du corps reÂducteur, donc, dans la crapaudine estampilleÂe.

Monter l'outil T11 et serrer celui-ci aÁ la main jusqu'aÁ obtenir un couple de roulement assureÂ. REMARQUE. En serrant, effectuer quelques tours de rotation pour ajuster les paliers.

Introdurre in uno dei fori radiali il comparatore azzerato precedentemente ed eseguire la lettura. Lo scostamento rispetto lo zero, indica il valore nominale "H" degli spessori da inserire.

Lo scostamento rilevato eÁ da sommare ad una misura fissa di 0,13v0,15 mm, per ottenere lo spessore "S1" (19) da inserire tra cuscinetto interno (17) e distanziale (20) e quindi, determinare il precarico stabilito per i cuscinetti. ATTENZIONE! Curare le misurazioni in quanto la variazione di 0,01 mm fa variare la coppia di rotazione di 20v40 Ncm.

In eines der RadialloÈcher die zuvor zuruÈckgestellte Meûuhr einsetzen und das Maû ablesen. Die Abweichung im VerhaÈltnis zur Null, gibt den Nennwert "H" der einzulegenden Unterlegscheiben an.

Die ermittelte Abweichung muû mit einem Festmaû von 0,3 (0,15 mm zusammengerechnet werden, um die Unterlegscheibe "S1" (19) zu ermitteln, die zwischen dem inneren Lager (17) und das DistanzstuÈck (20) gelegt werden muû und um die Vorbelastung der Lager festlegen zu koÈnnen. ACHTUNG! Die Messungen sehr sorgfaÈltig vornehmen, da ein Unterschied von 0,01 mm das Gegenmoment um 20v40 Ncm veraÈndert.

ESP

ESP

F

F

ITA

ITA

D

e

legen. Eine Meûuhr in eines der vier RadialloÈcher positionieren; die Meûuhr auf 3v4 mm vorbelasten und dann zuruÈckstellen.

Volcar el cuerpo reductor (11) y introducir el espesor "S" y con la herramienta T10 la rangua del cojinete interno (17). ATENCION! Introducir la rangua del cojinete segnalado.

ESP

c

Auf das Werkzeug T11 das Werkzeug T12 montieren. Dann die entgegengesetzten Lager (17) und (21) montieren und dazwischen das DistanzstuÈck (20)

D

f

Introducir en uno de los agujeros radiales el comparador acerado precedentemente y efectuar la lectura. El desplazamiento respecto a lo cero, indica el valor nominal "H" de los espesores de introducir.

El desplazamiento relevado es de sumarse a una mesura fija de 0,13-0,15 mm, para obtener el espesor "S1" (19) de introducir entre cojinete interno (17) y distancial (20) y entonces, determinar el precario establecido para los cojinetes. ATENCION! Poner atencion a las mesuraciones porque la variacion de 0,01 mm hace cambiar de ratacion de 20v40Ncm.

Introduire dans l'un des trous radiaux le comparateur mis aÁ zeÂro preÂceÂdemment et en faire la lecture. L'eÂcart par rapport au zeÂro, indique la valeur nominale "H" des cales aÁ introduire.

L'eÂcart releve est aÁ additionner aÁ la mesure fixe 0,13v0,15 mm pour obtenir la cale "S1" (19) aÁ introduire entre le palier interne (17) et l'entretoise (20) et deÂfinir la preÂcharge eÂtablie pour les paliers. ATTENTION! Effectuer soigneusement les mesurages parce qu'une diffeÂrence de 0,01 mm ameÁne une variation du couple de rotation de 20v40 Ncm.

ESP

F

008 911 79

BOMAG 77

ESP

F

1009

Axle DANA 193 18.5 INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UND EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE

F1241213

GB

F1241214

a

GB

b

With the help of the press, install the internal, countermarked bearing (17) onto the pinion (16). CAUTION! Lubricate pinion with oil.

Fit the pinion (16), the shims (19), the distance piece (20) and the external bearing (21) into the body of the reduction gear (11) and assemble the unit with a press. CAUTION! Lubricate pinion with oil.

F1241215

F1241216

GB

c

Fit the reduction gear (11) into the main body (23) without differential unit; lock temporarily with the two lower screws (9). Fit the bearing (15) of the motion in gear and lock it.

GB

d

Fit the gear (12) of the pinion; coat the nut (13) with Loctite 242 and hand-screw it.

A

F1241217

GB

e

GB

f

Between the body of the reduction gear (11) and the gear (12) of the pinion, place block "A" used for disassembling, and tighten the nut (13) to a minimum required tightening torque of 500 Nm, using a box wrench and a dynamometric wrench.

1010

BOMAG 78

008 911 79

18.5

Axle DANA 193

ITA

Con la pressa, montare il cuscinetto interno e contrassegnato (17) sul pignone (16). ATTENZIONE! Lubrificare il pignone con olio.

Montare nel corpo riduttore (11) il pignone (16), gli spessori (19), il distanziale (20) ed il cuscinetto esterno (21) ed assemblare il gruppo con la pressa. ATTENZIONE! Lubrificare il pignone con olio.

D

Mit einer Presse, das innere und markierte Lager (17) auf das Kegelrad (16) montieren. È l schmieren. ACHTUNG! Rad mit O

In den ReduziererkoÈrper (11) das Kegelrad (16), die Unterlegscheiben (19), das DistanzstuÈck (20) und das aÈuûere Lager (21) montieren und das Aggregat mit der Presse zusammenbauen. È l schmieren. ACHTUNG! Rad mit O

a

ITA

D

b ESP

Con la prensa, montar el cojinete interno y segnalado (17) sobre el pinon (16). ATENCION! Lubrificar el pinon con aceite.

Montar en el cuerpo reductor (11) el pinon (16) los espesores (19), el distancial (20) y el cojinete esterno (21) y asemblar el grupo con la prensa. ATENCION! Lubrificar el pinon con aceite.

F

A l'aide de la presse, monter le palier interne estampille (17) sur le pignon (16). ATTENTION! Lubrifier le pignon avec de l'huile.

Monter dans le corps reÂducteur (11), le pignon (16), les cales (19), l'entretoise (20) et le palier externe (21), assembler le groupe aÁ l'aide de la presse. ATTENTION! Lubrifier le pignon avec de l'huile.

ESP

F

Montare il corpo riduttore (11) sul corpo centrale (23) privo di differenziale e fissarlo provvisoriamente con le due viti inferiori (9). Montare il cuscinetto (15) dell'ingranaggio di entrata del moto e mandarlo in battuta.

ITA

Montare l'ingranaggio (12) del pignone; spalmare il dado (13) con Loctite 242 ed avvitarlo manualmente.

Den ReduziererkoÈrper (11) auf den zentralen KoÈrper (23) ohne Differential montieren und voruÈbergehend mit den zwei unteren Schrauben (9) befestigen. Das Lager (15) des Einganggetriebes montieren und bis zum Anschlag einsetzen.

D

Das Getriebe (12) des Kegelrads montieren; Mutter (13) mit Loctite 242 schmieren und von Hand zuschrauben.

Montar el cuerpo reductor (11) sobre el cuerpo central (23) sin el diferencial y fijarlo provisoriamente con los dos tornillos inferiores (9). Asemblar el cojinete (15) del engranaje de entrada del movimiento y mandarlo a tope.

ESP

Asemblar el engranaje (12) del pinon, pasar la tuerca (13) con Loctite 242 y atornillarla manualmente.

Monter le corps reÂducteur (11) sur le corps central (23) sans diffeÂrentiel et fixer provisoirement ce dernier avec les deux vis infeÂrieures (9). Monter le palier (15) de l'engrenage d'acceÁs au mouvement, puis l'envoyer en buteÂe.

F

Monter l'engrenage (12) du pignon; enduire l'eÂcrou (13) avec du Loctite 242 et visser celui-ci aÁ la main.

Sistemare tra il corpo riduttore (11) e l'ingranaggio (12) del pignone il blocchetto "A" usato per lo smontaggio e serrare il dado (13) alla coppia minima di 500 Nm, utilizzando una chiave a bussola ed una chiave dinamometrica.

ITA

Zwischen dem ReduziererkoÈrper (11) und dem Getriebe (12) des Kegelrads den Block «A» legen, der zum Abmontieren verwendet wurde, und Mutter (13) mit einem Anzugsmoment von mindestens 500 Nm mit einem InbuûschluÈssel und einem Dynamometer festziehen.

D

ITA

D

c

d

ESP

F

ITA

D

e

f

Colocar entre el cuerpo reductor (11) y el engranaje (12) del pinon el bloquete "A" usado para el desmontaje y apretar la tierca (13) al valor minimo de 500 Nm, utilizando una llave a manguito y una llave dinamometrica.

ESP

Placer, entre le corps reÂducteur (11) et l'engrenage (12) du pignon, le petit bloc "A" utilise au deÂmontage, serrer l'eÂcrou (13) au couple minimum de 500 Nm aÁ l'aide d'une cle aÁ pipe et d'une cle dynamomeÂtrique.

F

ESP

F

008 911 79

BOMAG 79

1011

Axle DANA 193 18.5 INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UND EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE

T13

F1241217

GB

a

Allow the pinion to rotate a few times in both directions to enable bearings to set. Apply bar-hold T13 onto pinion (16) and, with a torque meter, check the torque of the pinion. Torque: 140 ± 150 Ncm. CAUTION! If torque exceeds the maximum value, then the shim "S1" (19) placed between bearing (17) and distance piece (20) needs to be increased. If torque does not reach the set value, increase the tightening torque setting of nut (13), in different stages, until the maximum admitted value of 700 Nm is obtained. CAUTION! If torque does not reach the minimum value, then the shim "S1" (19) needs to be reduced. CAUTION! In order to be able to calculate the increase or reduction of shim "S1", it is necessary to bear in mind that a 0.01 mm variation in the size of shim (19) results in the torque of the pinion (16) varying by 20 ± 40 Ncm.

F1241226

GB

b

Remove the whole reduction gear body (11) and continue with the assembly of the differential unit and arms. For details, see «ASSEMBLY AND INSTALLATION OF THE DIFFERENTIAL UNIT - ASSEMBLING THE BRAKING UNIT».

1012

BOMAG 80

008 911 79

18.5

Axle DANA 193

Far compiere al pignone alcuni giri nei due sensi per assestare i cuscinetti. Applicare sul pignone (16) il codolo T13 e con un torsiometro, controllare la coppia di rotazione del pignone. Coppia di rotazione: 140v150 Ncm ATTENZIONE! Se la coppia supera il valore massimo bisogna aumentare lo spessore "S1" (19) tra cuscinetto (17) e distanziale (20). Se la coppia di rotazione non raggiunge il valore stabilito, aumentare la coppia di serraggio del dado (13) in piuÁ tempi fino a raggiungere il valore massimo ammesso di 700 Nm. ATTENZIONE! Se la coppia di rotazione non raggiunge il valore minimo, eÁ necessario diminuire lo spessore "S1" (19). ATTENZIONE! Al fine di poter calcolare gli incrementi o la diminuzione dello spessore "S1", eÁ necessario considerare che la variazione dello spessore (19) di 0,01 mm, fa variare la coppia di rotazione del pignone (16) di 20v40 Ncm.

Das Kegelrad um einige Umdrehungen in beide Richtungen drehen, um die Lager richtig einzusetzen. Am Kegelrad (16) den Schaft T13 anbringen und mit einem Drehungsmesser das Gegenmoment des Kegelrads kontrollieren. Gegenmoment: 140v150 Ncm. ACHTUNG! Falls der Wert den Maximalwert uÈberschreitet, braucht es eine groÈûere Unterlegscheibe "S1" (19) zwischen Lager (17) und DistanzstuÈck (20). Falls das Gegenmoment den festgelegten Wert nicht erreicht, das Anzugsmoment der Mutter (13) schrittweise erhoÈhen, bis der maximal zulaÈssige Wert von 700 Nm erreicht worden ist. ACHTUNG! Falls das Gegenmoment den Mindestwert nicht erreicht, muû die Unterlegscheibe "S1" (19) kleiner sein. ACHTUNG! Um das hoÈhere oder niedrigere Maû der Unterlegscheibe "S1" ausrechnen zu koÈnnen, darauf achten, daû ein Unterschied von 0,01 mm der Unterlegscheibe (19) das Gegenmoment des Kegelrads (16) um 20v40 Ncm aÈndert.

Hacer efectuar al pinon algunos giros en los dos sentidos para ordenar los cojinetes. Aplicar sobre el pinon (16) el codolo T13 y con un torsiometro, controlar el par de rotacion del pinon. Par de rotacion: 140v150 Ncm. ATENCION! Si el par supera el valor maximo hay que augmentar el espesor "S1" (19) entre cojinete (17) y distancial (20). Si el par de rotacion no llega al valor establecido, augmentar el par de torsion de la tuerca (13) en mas tiempos hasta llegar al valor maximo admitido de 700 Nm. ATENCION! Si el par de rotacion no llega al valor minimo, es necesario disminuir el espesor "S1" (19). ATENCION! Al fin de poder calcular los encrementos o la disminuciones del espesor "S1", es necesario considerar que la variacion del espesor (19) de 0,01 mm, hacer cambiar el par de rotacion del pinon (16) de 20v40 Ncm.

Faire faire quelques tours au pignon dans les deux sens de manieÁre aÁ ajuster les paliers. Appliquer sur le pignon (16), la queue T13, puis aÁ l'aide d'un torsiomeÁtre, controÃler le couple de rotation du pignon. Couple de rotation: 140v150 Ncm. ATTENTION! Si le couple de rotation deÂpasse la valeur maximum, augmenter la cale "S1" (19) entre le palier (17) et l'entretoise (20). Si le couple de rotation n'atteint pas la valeur eÂtablie, augmenter le couple de serrage de l'eÂcrou (13), en plusieurs temps, jusqu'aÁ atteindre la valeur maximum admise de 700 Nm. ATTENTION! Si le couple de rotation n'atteint pas la valeur minimum, diminuer la cale "S1" (19). ATTENTION! Pour pouvoir calculer les augmentations et les diminutions de la cale "S1", tenir compte que la diffeÂrence de 0,01 de la cale (19) fait varier le couple de rotation du pignon (16) de 20v40 Ncm.

ITA

D

a ESP

F

Rimuovere il corpo riduttore completo (11) e procedere con il montaggio del differenziale e dei bracci. Per i dettagli, vedere «ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - ASSEMBLAGGIO GRUPPO FRENO».

ITA

Den kompletten ReduziererkoÈrper (11) abnehmen und das Differential und die Arme montieren. Siehe «ZUSAMMENBAU UND INSTALLATION DES DIFFERENTIALAGGREGATS - ZUSAMMENBAU DES BREMSAGGREGATS».

D

b

Remover el cuerpo reductor completo (11) y proceder con el montaje del diferencial y de los ejes. Para los detalles, vease «ASEMBLAJE Y INSTALACION GRUPO DIFERENCIAL - ASEMBLAJE GRUPO FRENO».

ESP

Enlever le corps reÂducteur complet (11) et aller de l'avant avec le montage du diffeÂrentiel et des bras. Pour de plus amples deÂtails, voir "ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL - ASSEMBLAGE DU GROUPE FREIN".

F

008 911 79

BOMAG 81

1013

18.5

Axle DANA 193

SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE HERRAMIENTAS ESPECIALES - OUTILS SPECIAL

T1

T2 =

200

=

32

32

1

25

20

45°

4.3

1

32

50

120± 0.1

120± 0.1

160

110 25

= =

8

32

90

45°

840 10

4.5

930

2313

2305

D1240046

D1240043

T3

T4

Ø40

32

32

Ø153

32

125

Ø154

20°

Ø178

3 x45°

32

32

17 13

40

25

45

8

R1

0

10

R1

0

195

190

150

150

3 x45°

3 x45°

32

Ø40

Ø178 Ø189

Ø184

Ø200

1502

1742

D1240120

D1240121

T5

295 10

136

150 3 x45°

65 27.5 20

Ø25 0 R1

32

Ø35

-- 0.4 -- 0.6

Ø45

Ø46

-- 0.05 -- 0.1

Ø61

Ø63

-- 0.3 -- 0.4

Ø80

3 x15°

32

107.5 ---- 0.2 0.3

32

32

1501

1014

D1240122

BOMAG 82

008 911 79

18.5

Axle DANA 193

T6

Ø290

75 5

Ø271

12 Ø16

Ø20

17 °

32

Sez. B - B

A

1° 30' ° 2 17

° 30' 17° 30' 1 ° 17 7° 17

Ø22

17 °

Ø15

32

32

Ø22

113.48

Ø26

21° 30'

Ø16

134.91

43.60 17

°

Ø318

Ø150 Hn 67

Ø150 H 7

B B 82.13

32

3x15°

90.26

68

12

119.50 82

80

139.29

n°2 pezzi

Sez. A - A

1545

53.14

A

12

D1240124

T7

119.50 53.14

Ø20

2 x30°

0

0

R1

R1

32

20 32

° 17

1 17° 30' 7° 30' 1 7°

° 17

15°

17°

Ø16

'

R5

21° 30

15°

32

113.49

17°

Ø320

Ø264 ---- 0.15 0.25

Ø262 ---- 0.15 0.25

Ø185 ---- 0.08 0.12

Ø161.5 ±0.1

Ø172

Ø250

T7B

1° 30' ° 2 17

5 x15°

90.26

16

20

138.29

110 143

32

134.91

32

82.13

Ø25

9

43.60

Ø16

190

Ø290

±0.15

153 70 30

30

3 x15°

32

Ø38

Ø30

2

0

1.2 h 11

40

74 200

Particolare A

200 400

1769

008 911 79

0

R1

Ø24

Ø23,9

Ø25 Hg 67

R1

Ø140

A

R5

Ø150 ---- 0.08 0.12

PROFILO HURT 45.5 x 40.5

Ø24

T7A

D1240125

BOMAG 83

1015

18.5

Axle DANA 193

SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE HERRAMIENTAS ESPECIALES - OUTILS SPECIAL

T9 -0 .5

Ø9 5 - +0

T8

192

Ø120

160

3 x45°

0 Ø102 +-- 0.2

13 ± 0..2

Ø25

600

0.8

0.8

Ø40 Es Ch 22 15 20

␣✽

Ø✽

30

22 10

R1 0

Sez. A-A

Ø16

Ø129

] Bearing ref. 32017 DIN720 ] Ref. cuscinetto 32017 DIN720 ] Lager Ref. 32017 DIN720 ] Ref. cojinete 32017 DIN720 ] ReÂf. palier 32017 DIN720

Acciaio Fe 42

Acciaio Fe 42

0355

D1240123

Ø85.5

490

T10 Ø40 Ø25

188

40

10

A

35.5 4.5

40

1.5 3

0 R1

32

8

32

32

32

30

135

150

22

48

R2

78

3 x45°

0

30

R1

A Acciaio 18 Ni Cr Mo 5 Cementazione 0.6÷0.8 Temprato HRC 60÷63

20°

Ø23.9 ±-- 00.05 Ø25

Ø109

H7 g7

Ø30

32

Ø104

-- 0.1

Ø40.5-- 0.15 Ø80 Ø92

1487/B

1016

D1240126

1495

D1240128

BOMAG 84

008 911 79

18.5

Axle DANA 193

T11

T12

Ø49.8

93

15

4 x45°

Ø41.5

M14 x1 300

40

2323

Ø110

D1240127

Ø65

T13

M14 x1 Ch

22

50

25 25

30

R5

61 –– 0.01 0.02

M14 x1

41

20

Ø20 3/4"

Ø20 Ø9

14

45

25 10

60

35

25

Ø80

50

Ø11

95

195

0 Ø41.2 +-- 0.03

10

4"

1/

Ø6.5 Ø35

2312

008 911 79

D1240075

BOMAG 85

0870

D1240129

1017

18.5

1018

Axle DANA 193

BOMAG

008 911 79

18.6 Auxiliary pump for plate, series

008 911 79

BOMAG

1019

18.6

1020

Auxiliary pump for plate, series

BOMAG

008 911 79

18.6

Auxiliary pump for plate, series

008 911 79

BOMAG

1021

18.6

Auxiliary pump for plate, series

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

Fluid Under High Pressure

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.

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

Disable Work Function

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.

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

1022 2

Copyright 1996-1998, Sauer-Sundstrand GmbH & Co. All rights reserved. Contents subject to change. Printed in Germany.

BOMAG

008 911 79

18.6

Auxiliary pump for plate, series

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

008 911 79

BOMAG

3 1023

18.6

1024

Auxiliary pump for plate, series

BOMAG

008 911 79

18.6

Auxiliary pump for plate, series

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)

Right Side View (Side "1") P100102 E

Series 42 41cc Variable Pump

008 911 79

BOMAG

5 1025

18.6

Auxiliary pump for plate, series

Series 42 3.2

Component and Port Locations

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

9/16-18 O-Ring Fitting

M3

Charge Pressure

60 bar or 1000 psi

3/4-16 O-Ring Fitting

3/4-16 O-Ring Fitting

M4 & M5

Servo Pressure

60 bar or 1000 psi

9/16-18 O-Ring Fitting

9/16-18 O-Ring Fitting

L1 & L2

Case Pressure

35 bar or 500 psi

1-1/16-12 O-Ring Fitting

1-5/16-12 O-Ring Fitting

Charge Pump Inlet Vacuum

1 bar, absolute or 30 in Hg Vacuum

1-1/16-12 O-Ring Fitting

1-5/16-12 O-Ring Fitting

M1 & M2

S

T000 025E

System Pressure Gauge Port M2

Servo Pressure Gauge Port M5 Servo Pressure Gauge Port M4

System Pressure Port B

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")

Right Side View (Side "1") P100103 E

28cc Base Unit with MDC and No Filtration Adapter

10266

BOMAG

008 911 79

18.6

Auxiliary pump for plate, series

Series 42

Component and Port Locations

Servo Pressure Gauge Port M5 Servo Pressure Gauge Port M4

System Pressure Gauge Port M2

System Pressure Port B

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)

008 911 79

BOMAG

7 1027

18.6

Auxiliary pump for plate, series

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) Case Drain 41cc: 5/8 in Int. Hex Port L1 125-250 Nm (90-190 ft•lbf) 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

10288

BOMAG

008 911 79

18.6

Auxiliary pump for plate, series

Series 42 4.2

Adjustments and Minor Repairs

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). 008 911 79

BOMAG

9 1029

18.6

Auxiliary pump for plate, series

Series 42 4.3

Adjustments and Minor Repairs

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. 10301 0

BOMAG

008 911 79

18.6

Auxiliary pump for plate, series

Series 42 4.4

Adjustments and Minor Repairs

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

008 911 79

BOMAG

F100201

11031 1

18.6

Auxiliary pump for plate, series

Series 42 4.5

Adjustments and Minor Repairs

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.

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.

10321 2

P100106 E

Summing link pin MUST enter the hole in the control piston fork!

E100006 E

EDC Control Module Assembly

BOMAG

008 911 79

18.6

Auxiliary pump for plate, series

Series 42 4.6

Adjustments and Minor Repairs

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). 008 911 79

BOMAG

11033 3

18.6

Auxiliary pump for plate, series

Series 42 4.7

Adjustments and Minor Repairs

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 Yolk Cam

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

10341 4

BOMAG

008 911 79

18.6

Auxiliary pump for plate, series

Series 42

Adjustments and Minor Repairs

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).

008 911 79

BOMAG

11035 5

18.6

Auxiliary pump for plate, series

Series 42 4.8

Adjustments and Minor Repairs

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

10361 6

BOMAG

008 911 79

18.6

Auxiliary pump for plate, series

Series 42 4.9

Adjustments and Minor Repairs

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

008 911 79

BOMAG

11037 7

18.6

Auxiliary pump for plate, series

Series 42

Adjustments and Minor Repairs

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)].

10381 8

BOMAG

008 911 79

18.6

Auxiliary pump for plate, series

Series 42

Adjustments and Minor Repairs

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)

008 911 79

BOMAG

11039 9

18.6

Auxiliary pump for plate, series

Series 42

Adjustments and Minor Repairs

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.

10402 0

BOMAG

Approximate Relief Setting vs Screw Revolution 2.8 bar / 1⁄4 turn

(40 psi / 1⁄4 turn) T000 024E

008 911 79

18.6

Auxiliary pump for plate, series

Series 42

Adjustments and Minor Repairs

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)]. 008 911 79

BOMAG

21041 1

18.6

Auxiliary pump for plate, series

Series 42

Adjustments and Minor Repairs

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

10422 2

BOMAG

008 911 79

18.6

Auxiliary pump for plate, series

Series 42

Adjustments and Minor Repairs

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

008 911 79

BOMAG

21043 3

18.6

Auxiliary pump for plate, series

Series 42

Adjustments and Minor Repairs

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 Charge 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.

Pump Cover

Pad Cover Screws 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.

10442 4

BOMAG

008 911 79

18.6

Auxiliary pump for plate, series

Series 42

Adjustments and Minor Repairs

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)

008 911 79

BOMAG

21045 5

18.6

Auxiliary pump for plate, series

Series 42

Adjustments and Minor Repairs

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)

10462 6

BOMAG

008 911 79

18.6

Auxiliary pump for plate, series

Series 42

Adjustments and Minor Repairs

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)

008 911 79

No Charge Pump Option Components (Housing without Filtration Adapter)

BOMAG

21047 7

18.6

Auxiliary pump for plate, series

Series 42

Adjustments and Minor Repairs

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.

10482 8

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.

BOMAG

008 911 79

18.6

Auxiliary pump for plate, series

Series 42

Adjustments and Minor Repairs

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.

008 911 79

BOMAG

21049 9

18.6

Auxiliary pump for plate, series

Series 42

Adjustments and Minor Repairs

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

Adjustment of the displacement limiters should be performed on a test stand.

Servo Piston Cover

Displacement Limiter

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.

10503 0

BOMAG

Displacement Limiter – Left Side (Side "2") (Exploded View, No Need to Remove Limiter or Nut) E100027 E

Displacement Limiters

008 911 79

18.6

Auxiliary pump for plate, series

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

008 911 79

BOMAG

31051 1

18.6

Auxiliary pump for plate, series

Series 42 5.2

Exploded View Parts Drawings

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

10523 2

BOMAG

008 911 79

18.6

Auxiliary pump for plate, series

Series 42 5.3

Exploded View Parts Drawings

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

008 911 79

BOMAG

31053 3

18.6

Auxiliary pump for plate, series

Series 42 5.4

Exploded View Parts Drawings

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

10543 4

BOMAG

008 911 79

18.6

Auxiliary pump for plate, series

Series 42

Exploded View Parts Drawings

Notes

008 911 79

BOMAG

31055 5

18.6

1056

Auxiliary pump for plate, series

BOMAG

008 911 79

19 Circuit diagrams

008 911 79

BOMAG

1057

Circuit diagrams ●

The circuit diagrams valid at the date of printing are part of these repair instructions.

●

The circuit diagrams valid for the machine serial number can be found in the spare parts catalogue for the machine.

1058

BOMAG

008 911 79

19.1 Wiring diagram

008 911 79

BOMAG

1059

19.1

Wiring diagram

Wiring diagram 582 702 07 from serial number 101 582 121 001 Variocontrol 101 582 511 081 BW 213 DH-4 101 582 521 013 BW 213 PDH-4 101 582 531 083 BW 213 DH-4 BVC 101 582 541 035 BW 213 DH-4 BVC /P 101 582 581 041 BW 214 DH-4 101 582 591 001 BW 214 PDH-4 101 582 641 001 BW 216 DH-4 101 582 651 001 BW 216 PDH-4 101 582 771 001 BW 219 DH-4 101 582 821 022 BW 226 DH-4 BVC 101 582 851 003 BW 226 DH-4 BVC 101 582 861 001 BW 226 DH-4 BVC 101 582 881 001 BW 226 DH-4 101 583 061 001 BW 213 DH-4 BVC /P 101 583 141 001 BW 213 DH-4 101 583 151 001 BW 213 PDH-4 101 583 161 001 BW 213 DH-4 BVC 101 583 191 001 BW 214 DH-4

1060

BOMAG

008 911 79

008 911 79

001 002 003 004 005 006 007 008 009 010 011 012 013 014 101

Blatt Nr.: sheet no.:

582 702 07 582 702 07 582 702 07 582 702 07 582 702 07 582 702 07 582 702 07 582 702 07 582 702 07 582 702 07 582 702 07 582 702 07 582 702 07 582 702 07 582 702 07

BOMAG

19.10.2005 Vogt 19.10.2005 Seis

Stromlaufplan circuit diagram

Stromlaufplan Versorgung, Starten, Hupe Motor Deutz EMR II Motor Deutz EMR III Fahrantrieb, Neigungssensor, Sitzkontakt Datensammler, LC−Display Lenkung, Vibration Fahrhebel, Vibrationsplatten Variocontrol, Messtechnik Bomag Compaction Management BCM Diebstahlschutz System Beleuchtung und StvZO Kabinenausrüstung, Beleuchtung, Radio, Tachograph Kabinenheizung, Klimaanlage, Zusatzheizung Bauteilliste

Funktionsgruppe

BW 177..226 DH−4

Zeichnungsnummer drawing − no.

Inhaltsverzeichnis: table of contents:

001

001

001

582 702 07

Circuit Diagram supply, starting unit, signal horn engine Deutz EMR II engine Deutz EMR III driving system, slope sensor, seat contakt switch data−collector, LC−display steering, vibration joystick, vibration−plates Variocontrol, measurement equipm. Bomag Compaction Management BCM anti − theft system illumination and StvZO cabin−equipment, headlights, radio, tachograph cabin−heater, air conditioning, add. heater component listing

function unit

Wiring diagram

19.1

1061

2

1

R81

2

1

R83

2

1

4:20

2

1

R85

Glühstiftkerzen glow plugs

31

R82

2

1

3

5

2

1

S30

G03

125A

F48

2

1

−

+

1

2

19.10.2005 Vogt 19.10.2005 Seis

Batterie battery

Trennschalter Batter break switch battery

2

1

3

5

nicht bei EMR III, bei BW177DH−4 Option not at EMR III, at BW177DH−4 option

Heizflansch heating−flange

R19

3:19

K14

167A

K14.2

R84

BOMAG

R86

Sicherung Heizflansch/Glühstiftkerzen heating−flange/glow plugs

Option option

X36:A

X1:10

−

+

1

2

Batterie battery

31 EMR 3:3

G01

125A

F00

2 x 10qmm

Hauptsicherung main fuse

nur bei EMR III only EMR III

2

B+

D+

X1:110

W

D+

X1:109

X1:1

1

K09

14:7

85

86

87a

30

X1:168

87

2:7

K61

K11

2:16 starter

X1:123

X1:3

54 58

85

86

19 17

50a

M −

Starter

M01

30

X1:7

8:3 87

X1:16A

10A

F05

X1:16E

X1:8

50

X38:A

87a

K05 30

X37:B

2:8 B+

X1:4

X1:79

Versorgung, Starten, Hupe supply, starting unit, signal horn

9:2

2:13

6:2

R10 82 OHM

1

D+ MESX

85

86

Generator generator

2:10

B−

G02

B+

125mA

K61

2

V01

2

1

15

30

X37:A

X1:15A

30A

F13

Startschalter starting swwitch

S00

nur bei Klimaanlage only acc.to air conditioning

X1:9 X36:B

X1:15E

Anzugsw.:50A / Haltew.:10A

1062 X34:P

2

1

NOT−Aus Emerg.−Stop

S01

X1:151

X1:27A

10A

F95

X1:27E

K30 13:1 30 4:1

K11 2:12

5:9

7:17

S03

B11

2

1

V02

1

2

14

13

X1:155

X1:28A

15A

F23

X1:28E

1

B11

31

X1:104

2

1

X1:102

−

+

K32:86

2

1

3:1

13:1

K11:87 6:1

Steckdose socket

XS 12V

X3:3

X1:30A

15A

F39

X1:98

24

23

2

1

X1:30E

1

008 911 79

002

582 702 07

Nur bei Geländer/ROPS/SD only at hand−rail/ROPS/sun−roof

Signalhörer warning horns

X1:103

1

2

X1:101

X1:97

V03

S01:22 3:1 F05:2 6:8

Taster Hupe push button, horn

X1:152

22 12 32 42 52 62

21 11 31 41 51 61

2

1

87

30

19.1 Wiring diagram

2:20

X30:10

L

X1:183

CAN2− 4:15 CAN2+ 4:15

X32:A

31

19.10.2005 Vogt 19.10.2005 Seis

31 EMR

X30:2

Ubat −

X1:182

X30:1

X31:20

X57:20

4:18

X31:11

B130

2

X31:14 6

X57:17

X31:15 1

5

4

X31:25

B115

3

Signal Temperatur

2

1

X31:9 B113

2

X31:8

X31:4

X31:23

X31:16 EMR Kühlmitteltemperatur EMR coolant temperature Ladeluftdruck + Temp charging air pressure + temperature

1

X31:24

X31:19

Motor Deutz EMR II engine Deutz EMR II

Y137

EMR Stellglied EMR commander

2

STG−

X57:14 7

STG+

X57:15

Motordrehzahlsensor sender engine rpm 2

X31:13

B114

Signal

X57:21

B88

1

X31:10

Motordrehzahlsensor sender engine rpm 1 EMR Motoröldruck EMR engine oil pressure

31 EMR

AGND

+5V

X57:22 1

AGND

X57:10

max 7A

CAN high

X30:12

X1:180

X30:13

X32:H

2:6

X31:21

2

X31:22 AGND

X57:12 1

X31:12

2

Signal

X57:13

3

Signal

X57:11

CAN low

X1:181

X32:G

Diagnosestecker EMR diagnosis interface EMR

X32:L

AGND

X57:23

X30:14

X30:11

K

X1:184

X32:K

X31:17 X57:18 RF−

+5V

X57:25

A48 Motorsteuerung EMR2 engine−controller EMR2

X32:B

X31:18 X57:19 RF REF

Signal

X57:9

EPC−Stecker

X31:2 1

X33:2

X33:7

X1:96

K14

X1:185 Steckerschnittstelle Deutz connector interface Deutz

Relais Heizflansch relay heating−flange

2:4

1

X33:3 X31:7

X31:1

X31:3

X1:179

X1:186

ESX Fahrst.

X34:N

X57:16 RF MESS

Signal Druck

X57:24

BOMAG X57:4

AGND

X57:8

X1:95

X33:5

008 911 79 X33:6

2:17 S01:22

31 4:1

X33:8

X33:4

X33:1

003

582 702 07

2

1

S01:22 4:1

Wiring diagram

19.1

1063

X57:6

X57:1

X31:6

X31:5

X31:47

X57:34

4:3

31

X57:40

19.10.2005 Vogt 19.10.2005 Seis

X31:48

X30:64

Y15.4

Y169

2

1

Nur bei EMRIII only EMRIII

X57:41

B40.2

1

B40.1

2

B130

3

X1:179

X30:28 B114

2

X31:12

X31:10

3

Y19

Y137

Motorsteuerung EMR3 (EDC 16) engine−controller EMR3 (EDC16)

A48

2

1

1

4

B48

3

X32:A 2

X32:M 3

X32:F

Motor Deutz EMR III engine Deutz EMR III

1

1

2

B43

B113

X31:58

X32:G

X57:37

3

B6

B88

2

EMR Kraftstoffdruck rail pressure sensor

1

2

3:5

B51

B145

3x2.5

31 EMR

4

1

1

EMR Niederdruck Kraftstoff EMR fuel low pressure sensor

EMR Motoröldruck EMR engine oil pressure

1

3

bei einer Kabelbaumumgebungstemperatur von 85 Grad C. (Querschnitt 4x2,5qmm)

max. Kabellänge von Batterie zum Steuergerät (Versorgungsleitung) max. 10m

in der hier dargestellten Installation (Querschnitt 2,5qmm)

max. Kabellänge von Batterie zum Steuergerät (Versorgungsleitung) max. 3.5m

EMR Kühlmitteltemperatur EMR coolant temperature

B49

B93

2

Ladeluftdruck + Temp charging air pressure + temperature

EMR Stellglied EMR commander

X31:7

Motordrehzahlsensor sender engine rpm 2

Motordrehzahlsensor sender engine rpm 1

1

X57:14

Injektor A6 jet pump A6

2

1

X31:32

Injektor A3 jet pump A3

Y15.3

Y149

X57:42

Injektor A5 jet pump A5

2

1

X31:31

Injektor A2 jet pump A2

Injektor A4 jet pump A4

Injektor A1 jet pump A1

3:20

Y15.2

2

X30:1

Y15.6

X57:36

Y170

1

2

1

X30:3

Y166

2

Y15.5

X31:16

Y148

X57:35

X30:63

X31:1

X30:5

X31:33

X1:198 X1:199

Sign.

X57:13

2.5 qmm

X57:15

X1:183

X31:50 AGND

X57:9

X30:72

X31:46

Y15.1

X57:39

Y147

1

X1:185

X31:27

X1:107 X1:108

X31:19

87a

X31:49

4:2 87

X31:23

85

X31:40

B124

X31:20 Sign.

X57:21

max 7A AGND

X57:1

Signal

X57:19

AGND

X57:20

AGND

X57:28

Signal Druck

X57:23

30

X31:14

X1:184 Signal Temperatur

X1:193 CAN 1 High

K41

X57:22

X32:K X30:25 X31:53

X1:191 CAN 2 High

X31:43

X1:192 CAN 2 Low

86

X31:56

K41

X31:51

2

X31:13

25A

X57:33

X1:14A

X57:28

F93

X31:40

X1:194 CAN 1 Low

X31:26

X30:82 AGND

X57:32

X30:60 Signal

X57:25

X32:H X30:62 X57:31

X30:61 X31:8

CAN2+ CAN2−

X31:13

3:4

AGND

X57:24

X32:B Signal

X57:30

3:4

Signal Druck

diagnosis interface EMR

X31:41 AGND

X57:27

K−Line

X57:29

Signal

X57:26

BOMAG

X57:23

Diagnosestecker EMR

AGND

X57:29

Wasserabscheider water−seperator

X31:23 GND

X1:180 X1:90

1

X30:2 GND

X1:181 X1:91

X1:14E

X30:4 GND

X1:182 X1:92

30 5:1 S01:22 7:1 CAN2+ 5:11 CAN2− 5:11

X66:2

X30:6

31 5:1

86

85

008 911 79

004

582 702 07

2:2

K14.2

X31:24

2:15 30 S01:22

X31:34

1064 X66:3

3:20

19.1 Wiring diagram

X1:186

31

−

X1:172

dir.

X35:28

X35:38

speed

dir.

X1:178

−

+

FM3 7:5

19.10.2005 Vogt 19.10.2005 Seis

Sensor Bandage sender drum

9:2 SPEED MESX

13:6 SPEED TAC

B59 9:2 DIR MESX

X1:44

Fahr−Steuerung driving controller

A34

Drucksensor Fahrpumpe pressure sensor drive pump

X1:45

+

X52:1

B112

X52:2

X35:12

X35:34

B57

−

+

2

1

7:4

X35:58

X1:34A

10A

F84

X1:34E

X1:46

4V

9:2

X34:G

X1:34A

2

1 X34:H

X34:C

X34:D

R22

120 OHM 1 2

R23

120 OHM 1 2

−

+

X1:117

X9:2

H14 −

+

X9:1

X1:114

X34:A

X34:B

R20

120 OHM 1 2

R21

120 OHM 1 2

X1:123

X16:1 1 Y17 b 2 X16:2

X1:144

Y30

1 2

Y31

X1:124

2

1

1

LC−Display, OPUS 21

Fahrhebel

Diagnosestecker Fahrzeug diagnosis interface equipment

CAN1− 6:8

Prop.−Ventil Achsmotor prop.−Valve axle motor

Prop.−Ventil Bandagenmotor prop.−Valve drum motor Prop.−Pumpe Rückw. prop−pump backwards

X1:123

X15:1 1 Y16 a 2 X15:2

X1:141

X1:143

X1:122

X1:121

Prop.−Pumpe Vorw. prop.−pump forwards Rückfahrwarnsummer back up alarm buzzer

Sitzkontaktschalter switch, seat contact

X1:149

X14:A

S06

X14:B

X1:158

Fahrantrieb, Neigungssensor, Sitzkontakt driving system, slope sensor, seat contakt switch

9:2

2,5V

1V

PITCH MESX

S

−45_G=0,5V

+45_G=4,5V

X35:57

Neigungssensor slope sensor

X1:55

X1:17A

15A

F67

X1:17E

X1:146 32

X35:59

sw

Leistung

31

X35:54 X35:30

rt

X35:56

S01 2:16

X35:5 X35:15

X1:120

X35:60

CAN2−

X35:4 X35:24 0,46A

X1:145

X1:51 X35:53 X35:49 Fahrpumpe vorw. 400 ... 1.200mA

Elektronik Neigung

X1:52 CAN2+

X1:53 X35:33 X35:64 Fahrpumpe rückw.

X1:119

Sensor Achse sender axle

4:20

X1:174

B60

X1:171

br

sw

X1:47 X35:27 X35:46

400 ... 1.200mA

X35:31

Richtung

X1:177

ws

TxD Sitzkontakt

X1:54 CAN2−

X1:49 X35:26 X35:47

400 ... 1.200mA

Drucksensor

X35:37

speed

X1:176

bl

RxD Rückfahrwarnsum.

X1:48 CAN1+ Bandagenmotor

X1:50 CAN1− Achsmotor 400 ... 1.200mA

CAN2+ 8:6 CAN2− 8:6 CAN1+ 6:8

Gehäuse housing

CAN2+

X35:55 1

X1:124

4:20 EMR Deutz 4:20

X35:65 1

X1:142

X1:2

X35:66 X1:142

F24:2 6:3

X35:67

31 6:1

30 6:1

005

582 702 07

X1:143

Pot. 15

Richtung

X1:173

ws

speed

bl

speed

X1:175

br

BOMAG

sw

30

X35:68 X1:143

008 911 79 X1:82

4:20

Wiring diagram

19.1

1065

5:20

2:8

31

D+

X27:8

X1:29A

10A

F24

2

1

X1:39

X34:R

X1:40

X1:117

P

B21

X1:106

A80 Datensammler data−collector

VCC

F24:2

X1:111

2

X1:94

P

1 B03

X1:112

X21:1

2

X1:117

X10:3

R03

X10:2

19.10.2005 Vogt 19.10.2005 Seis

X1:94

X21:2

Q

1 B55

X1:105

11:1

0 .. 67 OHM

5:3

X1:107

connector−colour: X26−grey; X27−black

Steckerfarbe: X26−grau; X27−schwarz

ESX Fahrsteuerung

X8:1

X8:2

B124

X1:108

2:17 F05:2 5:17 CAN1+ 5:17 CAN1−

CAN1 high

X27:6

X1:29E

CAN1 low

X27:7

K11:87

X1:164

X1:149

Datensammler, LC−Display data−collector, LC−display

BL 12:17 BR 12:17 BEL 12:4

X1:82

X1:87 X1:88

X1:80

DIOS Platten

A81 LC−Display LC−display

CAN1+ 8:14 CAN1− 8:14

24

23

1

Schalter Motordrehzahl switch engine−rpm mode

S127

ECO Low High

X1:86

Ub "15"

X28:1

30

X26:3

DIN3

X26:5

DIN5

Hydraulikölfilter hydraulic oil filter

2:20

Nur bei EMRII only EMRII

X1:41

X26:8

DIN8

Luftfilter air cleaner

X26:10

DIN10

Kühlmittelvorrat coolant stock level

X27:4 Sepa1

X27:2

UIN1

Füllstand Diesel fuel−level

BOMAG

Wasserabscheider water−seperator

X27:9 Sepa2

X26:9 DIN9

X26:1 DIN1

X26:2 DIN2

X26:6 DIN6

X26:4 DIN4

X26:11 DIN11

X27:10 UIN3

X27:11 UIN2

X27:12 AIN2

X27:1 AIN1

X27:3 GND/UIN3

X27:5 GND

X26:12 GND

CAN1 high

X28:3 X28:2 GND

CAN1 low

X28:4 X29:2 DIN2

X29:1 DIN1

X29:3 DIN3

Ub "30"

X28:5 X29:4 DIN4

not connected

X28:6 X29:5

not connected

X29:8 X29:6 DIN5

13

Ub out

14

X29:7

1066 DIN6

5:20

1

008 911 79

006

582 702 07

31 7:1

30 9:1 K11:87 8:14 F24:2 7:15

19.1 Wiring diagram

X43:2

6:20

31

B132

X1:149

X43:1

5:6

X34:J

X1:55

X51:3

X1:203

8,5V

1

1

X1:197

Y93 b

2

1

2

X1:197

Y92 d

1

2

2

1

X1:56 FM1 X1:57

X41:2

X39:4

X41:4 X40:4

X1:159 X1:162

X41:3 X40:1 VCC

0V

0V

X41:1 X39:1 VCC

X1:161 X1:160

A34 Fahr−Steuerung driving controller

1

2

Prop. Ventil lenken rechts prop. valve steering right

Prop. Ventil lenken links prop. valve steering left

Lenkwink.

2

X1:195

X35:23

X1:196

X35:29

19.10.2005 Vogt 19.10.2005 Seis

X1:154

−

X1:62 FM3 X1:63

A45

A X39:3

X40:3

X40:2

X39:2

X35:19

X35:43

X35:22

X35:41

Lenkung, Vibration steering, vibration

S1 A

S2

B

S1 B

X35:43

FM3

Schnellverschl.−Platten

S 5:4

X35:21

Lenkeinheit steering unit

X35:18

X1:201 B65 +

nur BVC only BVC

7:14

K43

8:13

8:13

85

86

2

1

X6:2 X1:118

KA MESX

2

Anbau 213DH: oben

Anbau 177DH: h.l. b

X7:2

gg

+

br

8:2 87a

X1:117

a1 2

1

1

9:2 X1:113 BRAKE MESX Y04 1

12

VIB

8:1

007

582 702 07

X1:190 31

S01:22

13:6

bl

BTS BREMSE 8:2

Magnetventil Bremse solenoid valve brake

H07

X1:150

2:16

X1:147 11

30 K48 87

S01

sw

X22:3

bei BW177 bl / bei BW213 sw

bei BW177 sw / bei BW213 bl

− X22:2

Aufnehmer Vibrationsmotor sensor vibration motor

Warnsummer Störung warning buzzer, failure

Prop−Ventil Vibration groß prop. valve vibration big

X1:82

−

+

9:2

9:2

X1:89

GA MESX

X7:1 Y07 1

X1:115

X1:37

X1:38

7:12 87a

Prop.−Ventil Vibration klein prop. valve vibration small

Anbau 213DH: unten

Anbau 177DH: h.r. a

X6:1 Y08

X1:116

K43 87

30

ws

X22:4

B16

br

X22:1

X1:187

X1:41

X1:189

X51:1

F24:2

Vib.− Richtung

Lenkwinkelsensor steering angle sensor

X1:55 X1:202

Armlehne

8:1

AGND

X35:1

X35:16

X41:5 X1:205

X41:7 X1:207

X41:6 X1:206

X23:1

6:20

X35:61

X1:148

X35:20

X1:188 X1:42

X41:8 X1:208 X35:22

Vib.− Frequenz

X35:35

Schalter Armlehne armrest−switch

X51:2

X35:40 Pumpe Vib.−Platten

BTS Bremse

S01:22

X1:60 FM5 X1:61

400 ... 1.200mA

X1:58 FM2 X1:59

400 ... 1.200mA

X35:2 Umsch. Amplitude

X35:3 Warnsummer

X35:48 Prop. out 400 ... 1.200mA

BOMAG

150mA

−

max.1.8A

Sig.

X35:17

008 911 79 Bremse

4:20

Wiring diagram

19.1

1067

7:17

7:20

31

K48

85

86

2:13

K05

Bremse auf = Ub

X1:149

85

86

X1:153

Ub in

9 10

2

1 3 4

19.10.2005 Vogt 19.10.2005 Seis

Add2

Add1

0V in

BTS zus.

BTS Bremse

1

2

7

3 4

Ub out

Schalter Amplitude switch amplitudes

nicht bei BVC not at BVC

14

S35 K0G 13

Stecker X24 3 4 5 6

Stecker X23

S55 Fahrhebel travel lever

DK Ext3

Bremse zu = 0V

DK Ext2

24

23

8

5

2 1

7

14

13

Nur bei BVC Only at BVC

S09

AK Ext2

AK Ext1

0V (Ref PIN5)

+5V out

CAN+

CAN−

8

X1:157

X1:156

14

13 S36

14

13

7:11

7:11

S139

S42

X35:22

X35:43 X1:215

S − +

X1:211

Y98

X1:210

Schalter Betriebsart Platten modesw. plates

X1:212

S

+

S

2

Y122 1

2

Y123 1

X62:7 2

Y142 1

X62:12 A54 Platten Steuerung plate−controller

bl

B134 −

20A

X1:209

X1:31A

2

1 F145

X1:31E

X1:214

CAN1+ 9:16 CAN1− 9:16 K11:87 9:1

2

2

Y144.2 1

Y144.1 1

2

Y143 1

X62:2

31

9:1

2

Y145 1

BTM

1

1

008 911 79

008

582 702 07

MV Platten heben MV Platten rechts plates up plates right MV Platten senken MV Platten Schwimmst plates down plates float−pos. Prop−Pumpe Platten MV Platten Priorität MV Platten links prop.−valve plates plates left plates priority

2

1

bl

B135 −

+

Näherungssch. Platten oben sensor plates up Näherungssch. Platten Mitte sensor plates centered

Schalter Schwimmstellung Platten sw. swimming pos. plates Frequenzverstellung Platten freq. adjust plates

S64

+ − S

Fahrstufenschalter speed range selector

Fahrhebel, Vibrationsplatten joystick, vibration−plates

Schalter Vibration Ein/Aus switch vibration on/off

11 12

8

7 6 5

Taster 8 = Infotaste 2 push button 8 = Info button 2

OV out

BTS BREMSE

DK Ext5

BOMAG

DK Ext4

7:18

DK Ext6

Taster 7 = Infotaste 1 push button 7 = info button 1

X50:2

Taster 5 = platten senken push button 5 = lower plates

X50:3

Taster 4 = Platten links push button 4 = plates left

X25:2 X25:4

X63:1 X63:2 X50:1

Taster 3 = Vibration EIN/AUS push button 3 = vibration ON/OFF

X25:3

X63:1 X63:2

Taster 2 = Platten heben push button 2 = lift plates

Schnellverschluss − Kupplung quick connecting clutch 400 .. 1.200 mA

br sw

X62:4

Taster 1 = Platten rechts push button 1 = plates right

X62:5

6:20

X62:11

br ws

CAN1− K11:87

X62:6

CAN1+

X62:3

6:14 6:14

X62:8

LC−Display

X62:9 X62:10

5:17 CAN2+ 5:17 CAN2−

X1:213 X62:1 X62:13

ESX Fahrst.

X62:15

1068 X62:14

7:2 X23:1

19.1 Wiring diagram

DK Ext1

8:20

2:8

7:17

5:3 5:3 5:8

7:15

7:15

8:20

X44:28

F148:2

10:15

2

Elektronik

X2:54

X48:3

X48:2

BEL MESX

X2:55

X48:4

15g/bl

−/gg

B62

X48:1

12:4

B62

X49:1

X2:57

X2:59

X49:4

15g/bl

−/gg

X2:49

X2:58

X49:3

X49:2

X2:60

31

BRAKE MESX D+ MESX

Y140

X44:60

PITCH MESX

X44:37

X2:75

19.10.2005 Vogt 19.10.2005 Seis

15A

X1:35A

X44:59

X2:53

Prop.

GA MESX SPEED MESX DIR MESX

KA MESX

A83 Messtechnik−Rechner measurement calc. unit

Pot. 15

X2:57

2

X44:32

10A

X44:15

X1:32A

Aufn. vorne 15g

X2:56

X44:29

1

Aufn. vorne 20g

F146

X44:56

X44:38

20g/br

+/sw X44:31

F148

Aufn. hinten 15g

X1:35E

X44:30

1

X44:41

20g/br Aufn. hinten 20g

X1:32E

Leistung

X44:57

X44:35

2

400 .. 1.200mA

Y141

X2:73

X2:74

X2:69

X47:C

2

1

S/ws

B61

X2:52

Variocontrol, Messtechnik Variocontrol, measurement equipm.

Prop−Ventil Erreger ab solenoid valve exciter down

Prop−Ventil Erreger auf solenoid−valve exciter up

X2:76

X44:47 1

X47:B

X47:A

+/rt

X2:68

2

1

X2:67

X2:78

FM4

X2:77

8.5V

X44:23

Pot 15

X44:46

Pot 30

Prop.

K11:87 12:1

400 .. 1.200mA

−/sw Erregerpos.

K11:87

X44:9

30

GND

5:9

X2:71

X44:1 X2:63

X2:66

RxD

X2:64

X4:A

X74:1

P11

X44:66

Drucker printer

X2:66

TxD

X2:65

X4:B

X74:2

X2:70

+

−

nur bei BEM only at BEM

EVIB−Meter EVIB−meter

X1:82

P07 E VIB

X1:85

8:20

8:20

F1

F2

CAN3+

CAN1+

X2:50

CAN1−

CAN1+

+

−

Bedieneinheit BEM control−unit BEM

P16

DIOS Platten

Aufnehmer Verstellmotor sens. adjust. motor

X44:67

Beschleunigungssensoren acc. sensor rear

X44:3

6:20

X44:58

X44:14

X44:54

X44:36

AGND MESX

X44:55

X4:C X74:3

X44:5

+/sw X44:7 v.l.

EVIB

CAN+

Beschleunigungssensoren acc. sensor front

v.r.

nur bei BTM prof only at BTM prof X44:65

X4:D X74:5 X44:4

X4:E X74:4

X44:68

CAN− X44:27 X44:53

BOMAG

0..6VDC

X42:5

1

CAN3+

CAN3−

CAN3−

10:15

10:15

31 10:1

X46:E

X42:3

X2:49

nur bei BTM+/BTM prof only at BTM+/BTM prof 009

582 702 07

CAN1−

X2:51

X46:F X42:4

P33

X46:D

R24 1 2 60 OHM

nur bei BEM only at BEM 1

X42:2 X46:A

X42:1 X46:B

X2:48

X2:47

30 12:1

Display Messtechnik BOP display measurem. BOP

X44:33

008 911 79 X44:26

X1:34A

Wiring diagram

19.1

1069

1070

9:20

31

19.10.2005 Vogt 19.10.2005 Seis

Bomag Compaction Management BCM Bomag Compaction Management BCM

CAN3−

F148:2

BOMAG

P15

BCM 05 BCM 05

X75:2

nur bei BCM only at BCM

A87 USB−CAN Schnittst. USB−CAN Interface BCM

X75:7

X4:M

X4:N

CAN3−

X2:62

60 OHM

1 R25 2

X2:61

CAN3+

9:18 CAN3+

9:18

9:4

1

X76:2

X76:1

1

X2:63

X4:F

X4:G

X2:70

008 911 79

010

582 702 07

31 11:1

19.1 Wiring diagram

87a

2

2

E16 1 E17 1

4,6A

9:7

Scheinwerfer rechts head light RH

31 Scheinwerfer links head light LH

11:12

87

12:9

K16 30

S15

85

86

X1:301

23

24

11

12

BEL 6:9

19.10.2005 Vogt 19.10.2005 Seis

K06

X1:43

BEL MESX

12:10

13

32

31

S16 14

X1:84

012

Anschluß Arbeitsschein− werfer ohne StvZO connection working head lights without StvZO

Schalter StvZO switch, StvZO

86

30

X1:22E 4

23

6:9 6:9

S37

X1:25E

connection working head lights without StvZO

Anschluß Arbeitsschein− werfer ohne StvZO

10A

10A

X1:24A

F10

F09

X1:23A

X1:24E

X1:23E

2

2

2 K16

Schlußleuchte rechts tail light, RH

12:2 Schlußleuchte links tail light, LH Parkleuchte links parking light, LH Parkleuchte rechts parking light, RH

2

E13 1 E12 1 E14 1 E15 1

85

5

E25 1 2

2

2

2

Beleuchtung und StvZO illumination and StvZO

Connection head lights acc.to ROPS/SD

Anschluß Arbeitsscheinwerfer bei ROPS/SD Aufbau

X3:1

01

H06

14

13

X1:19A

−

+

24

BR

BL

24

14

49L

23

13

A02 31 82

30

L0R

X1:25A X1:305

E09 1 2

E08 1 2

L

1

R

49R

Schalter Blinker switch indicator

2 2

012

582 702 07

Blinkleuchte VR indicator front, RH

1

13:1

Blinkleuchte HR indicator rear, RH

31

E11 1 E10 1

Blinkleuchte VL indicator front, LH Blinkleuchte HL indicator rear, LH

Bel. Warnbinkschalter illumination, switch hazard light

Warnblinkschalter switch, hazard light

S14

Anschluß Arbeitsscheinwerfer D bei Kabine Connection head lights with cabin STV1 13:17 STV2 13:17

E23 1

X3:5

X1:22A

15A

F19

E28 1

87a

E27 1

X3:4

X1:21A E

15A

F22

X1:21E

87

12:4

K06

15A

X1:26A X1:83

X1:320

X1:18A

X1:319

X60:3

X1:323 X60:4

X1:309

F08

0,42A

X1:310

15A

X1:311 X58:3 X1:315 X58:6

Schalter Arbeitsbele switch, working head lights

10A

0,42A

F07

0,42A

X58:5

X1:315 X58:6

X1:303 0,125A

X1:302

X1:19E

X1:304

15A

4,6A

X1:312 X59:3 X1:316 X59:6

Arbeitsscheinwerfer hinten links working head lights, rear lh. 4,6A

X59:5

X1:316 X59:6

Arbeitsscheinwerfer hinten rechts working head lights, rear rh. 4,6A

0,125A

X1:2

1,75A

X1:307

F18

0,42A

Arbeitsscheinwerfer vorne links working head lights, front lh. 4,6A

X61:3 X1:324 X61:4

Arbeitsscheinwerfer vorne rechts working head lights, front rh. 4,6A

X1:313 X1:315 X58:6

X1:314

X1:26E

1,75A

X1:306 X58:2

X1:321 X60:1 X1:323 X60:2

X1:322 X59:2 X1:316 X59:6

BOMAG

X61:1

F11

1,75A

K11:87 30

1,75A

008 911 79 X1:324 X61:2

9:3 K11:87 9:19 30 X1:18E

Wiring diagram

19.1

1071

3:6

85

86

R80

12:20 31

Relais Kabine relais cabin

K32

2:19

K32:86

2

1

13:16 87

K141

Heizung Heckscheibe heating rear screen

S45

E29

TK

2

1

8

−

+

+

−

A12

− −

B51 + +

19.10.2005 Vogt 19.10.2005 Seis

Türkontaktschalter door switch

S86

A01

2

E71 1

87a

30

1,75A

Innenleuchte inside light, cabin

7

Kontrolleuchte indicator

H

Schalter Innenleuche switches interior lights

10A

31

30

87a

3

VIB X3:18 5

7:18

2

1

6

7,8,9

X3:17 4 5:3 SPEED TAC A16

Tachographenmodul module, tachograph

Radio radio

− −

15 + + B51

87

A5+A6

P09

A2+A3

X55:2

M05

M

5

2

1

A

X55:1

Wischer hinten windscreen wiper, rear

Wascher hinten washer rear

− M07

M

+

4

3,8A

X56:2

M04

M

5

2

2

B

+

4

E70

S158

4

3

2

1

3

C

K141

I

Wascher vorn washer front

13:2

2

1 E28

E72

E27

2

1

1

2

−

+

1

XS 12V

1

5

5

E

K32:87

15A

F144

14:18

−

+

6

F

14:2

008 911 79

013

582 702 07

Rundumkennleuchte rotary beacon

31 14:1

KABINE 31

2

1

S38

10A

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

F130 14:7

STV2 12:13 12:13 STV1

Schalter Nachtleuchte switch, night illumination

− M06

M

10A

F130

13:9 F130

Wischer vorne windscreen wiper, rear

S20

01W 7 01

15A

F44

Kabinenausrüstung, Beleuchtung, Radio, Tachograph cabin−equipment, headlights, radio, tachograph

Tachograph tachograph

C3

B4

B3

A1

S21

01W 7 01

F42 14:8 F130 13:14

15A

F43

X55:3

F42

X56:3

G

2,9A

15A

X56:4

F143

4,7A

K32

X56:1

13:1

3,8A

X3:8

max. 13A

0,83A

Nachtleuchte night illumination

30

3 min

4,6A

X3:7

4,6A

X3:6

X55:4 X3:1

Abfallverzögert

BOMAG X3:2

5A

1072 Steckdose socket

2:15 K30

19.1 Wiring diagram

13:20 31

Stufe 3: 11.5A pro Lüfter

Stufe 2: 4.5A pro Lüfter

Stufe 1: 3.0A pro Lüfter

ge

M09

rt

M

br

Kabinenlüfter cab ventilator

Stromaufnahme Lüfter / current blower

Schalter Kabinenlüfter switch blower cabin

X53:L

X3:9

X17:1 X1:163

0123

X53:M

X3:10

X17:2 X1:165

S44

or

X3:12

ge

Bedienteil Kabinenheizung/Klimaanlage

Kabinenlüfter cab ventilator

br

rt

M

or

2

X54:3

X18:2

_t

B131

X18:1

X1:167

X3:14

X54:11

1 2

Magnetventil Heizung solenoid valve, heating unit

2

Y138 1

X1:168

X54:12

1

2

X54:2

3 A72 Steuergerät control unit 6 11 12

4

X54:4

X54:1

1

8

H

2

3

2

1

5

6

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

Kraftstoffpumpe fuel pump heating unit

Y14

10 9

E30 Zusatzheizung add. heater

20A

F40

Kabinenheizung, Klimaanlage, Zusatzheizung cabin−heater, air conditioning, add. heater

1

2

V06

Potential 30 aus Kabine

V04

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

2:10

K09

X3:13

X54:6

control−unit cab−heater /air conditioning

X1:164

X17:4

M09

19.10.2005 Vogt 19.10.2005 Seis

X53:C

X53:H

X3:11

X53:B

4

D

Thermofühler Klimaan temperature sensor air conditioning

20A

X20:3 Überwachung Kühlmitt monitoring coolant pressure

F31

X20:4 3,5A

X17:3 X1:166

13:17 F130 F42 Potential 15 aus Kabine 13:9

X1:190

BOMAG 1A

008 911 79 Thermofühler Heizung temperature sensor heating unit

13:19 K32:87 Potential 15 aus Kabine

S28

1

13:19

0123

5A

F15

1

KABINE 31

6 2 1 3

5

1

A

Schalter Kabinenzusatzheizung switch, cab add.−heater

014

582 702 07

31

Wiring diagram

19.1

1073

19.1

19.10.2005 Vogt 19.10.2005 Seis

Bauteilliste component listing 1 11 101

582 702 07

1074

Wiring diagram

Name

Bl. Pf. Benennung 004 12

title

A02 A12 A16 A34 A34 A45 A48 A48 A54 A66 A67 A72 A80 A81 A83 A87

012 013 013 005 007 007 003 004 008 011 011 014 006 006 009 010

17 5 6 6 6 9 3 9 17 9 15 11 3 18 6 15

Blinkrelais Radio Elektronik Tachograph Prozessorplatine Prozessorplatine Lenkrad Elektronische Motorsteuerung Elektronische Motorsteuerung Modul Pumpenansteuerung Elektronik Steuereinheit Eingabeeinheit Steuergeraet Klimaanlage, Heizung Modul Datensammler Anzeigeeinheit Elektronik Messtechnik USB−CAN Schnittstelle BCM

indicator relay Radio Electronic system, tachograph Prozessing circuit board Prozessing circuit board Steering wheel Electronic engine management Electronic engine management Modul pump control Electronic control unit Keyboard Control unit,air conditioning,heating modul data−collector Display−Unit electronic measurement−equipment USB−CAN Interface BCM

B03 B11 B11 B16 B21 B51 B51 B55 B57 B59 B60 B61 B62 B62 B65 B88 B88 B93 B103 B104 B112 B113 B113 B114 B114 B115 B124 B124 B126 B130 B130 B131 B132 B134 B135 B145

006 002 002 007 006 013 013 006 005 005 005 009 009 009 007 003 004 004 014 014 005 003 004 003 004 003 004 006 003 003 004 014 007 008 008 004

3 16 18 16 2 4 6 4 6 4 2 12 8 10 4 6 15 13 7 7 3 13 14 7 7 11 5 6 14 8 8 10 2 17 16 17

Unterdruckschalter Luftfilter Signalhorn Signalhorn Aufnehmer Vibrationsfrequenz vorne Differenzdruckschalter Hydr.−Oelfilter Lautsprecher Radio Lautsprecher Radio Kuehlmittelstand Ausgleichsbehaelter Neigungssensor Stufenumschaltung Aufnehmer Bandagengeschwindigkeit Aufnehmer Achsgeschwindigkeit Aufnehmer Verstellzylinder Beschleunigungsaufnehmer Beschleunigungsaufnehmer Sensor, Lenkwinkel vorn Druckgeber Motoroel Druckgeber Motoroel Leistungskraftstoffdruck Sensor RPS Temperaturschalter Klimaanlage Druckschalter Klimaanlage Druckgeber Fahrpumpe EMR Temperaturgeber Kuehlmittel EMR Temperaturgeber Kuehlmittel EMR Aufnehmer, Motordrehzahl 1 EMR Aufnehmer, Motordrehzahl 1 Geber Ladeluftdruck Geber Wasserstandsabscheider Diesel Geber Wasserstandsabscheider Diesel EMR Temperaturgeber Kraftstoff EMR Aufnehmer, Motordrehzahl 2 EMR Aufnehmer, Motordrehzahl 2 Temperaturschalter Heizung Inititator Armlehne links Näherungsschalter Platten oben Näherungsschalter Platten mitte Sensor Niederdruck Kraftstoff

Vacuum switch, air cleaner Warning horn Warning horn Transducer, vibration frequency, front Pressure diff. switch, hydr. oil filter Speaker radio Speaker radio Coolant charge expansion tank Slope sensor, speed range selection Sensor, drum speed Sensor, axle speed Sensor, ajustable zylinder Acceleration sensor Acceleration sensor Sensor, angularity steering, front Sender, engine oil pressure Sender, engine oil pressure Rail pressure sensor Temperature switch, air conditioning Pressure switch, air conditioning pressure sender, driving pump EMR Temperature switch, collant EMR Temperature switch, collant EMR Trancducer, engine speed 1 EMR Trancducer, engine speed 1 Sender, charging air pressure Sender, water separator fuel Sender, water separator fuel EMR fuel temperature sender EMR Trancducer, engine speed 2 EMR Trancducer, engine speed 2 Temperature switch, heating proximity switch left arm rest proximity switch, plate up proximity switch, plate middle fuel low pressure sensor

E08 E09 E10 E11 E12 E13 E14 E15 E16 E17 E23 E23 E25 E25 E27 E27 E28 E28 E29 E30 E32 E70 E71 E72

012 012 012 012 012 012 012 012 012 012 012 013 012 013 012 013 012 013 013 014 013 013 013 013

17 18 19 19 7 6 7 8 2 2 11 18 12 19 10 17 11 17 3 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 F05 F07 F08 F09 F10 F11 F13 F15 F18 F19 F22 F23 F24 F31 F39 F40 F41

002 002 012 012 012 012 012 002 014 012 012 012 002 006 014 002 014 013

6 14 15 18 6 8 2 11 18 5 12 10 18 2 3 19 13 19

Hauptsicherung Batterie Sicherung Steckdose Sicherung Warnblinker Sicherung Blinker u. Arbeitsscheinw. Sicherung Park− u. Schlussl. links Sicherung Park− u. Schlussl. rechts Sicherung Scheinwerfer links Sicherung Startschalter Sicherung Heizgeraet Vorsicherung Arbeitsscheinw. vorne Sicherung Arbeitsscheinw. vorne li. Sicherung Arbeitsscheinwerfer hinten Sicherung Signalhorn Sicherung Ueberwachungsmodul Sicherung Kabinenluefter Hauptsicherung Kabine Sicherung Kabinenheizung Sicherung Rundumkennleuchte

Fuse, main, battery Fuse, socket 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, 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, cabin ventilator Main fuse, cab Fuse, heating unit cab Fuse, rotary beacon

125A 10A 15A 15A 10A 10A 15A 30A 5A 30A 15A 15A 15A 10A 20A 15A 20A 10A

BOMAG

TYP

5A 0,83A 1,75A

008 911 79

19.1

Wiring diagram Name

19.10.2005 Vogt 19.10.2005 Seis

F42 F43 F44 F48 F67 F68 F84 F93 F95 FM1 FM2 FM3 FM4 FM5 F130 F143 F144 F145 F146 F148

Bl. 013 013 013 002 005 002 005 004 002 007 007 007 009 007 013 013 013 008 009 009

G01 G02 G03

Pf. 3 10 13 5 7 8 9 3 16 6 6 5 11 6 15 2 20 18 5 2

Benennung

title

TYP

Bauteilliste component listing 2 11 102

582 702 07

Sicherung Kabineninnenleuchte Sicherung Wischermotor hinten Sicherung Wischermotor vorn Sicherung Gluehanlage Sicherung Steuerung (Potential 30) Sicherung Potential 30 Sicherung Steuerung (Klemme 54) Sicherung Steuerung (Potential 30) Sicherung Motormanagement intern Platinensicherung Platinensicherung Platinensicherung Platinensicherung Platinensicherung Sicherung Nachtleuchte Sicherung Heckscheibenheizung Sicherung Kabinensteckdose Sicherung Anhängeplatten Sicherung Steuerung MESX (Potential 30) Sicherung Steuerung MESX (Potential 15)

Fuse, inside light cab Fuse, wipermotor rear Fuse, wipermotor front Fuse, glow plug system Fuse, controller (pot.30) Fuse, potential 30 Fuse, controller (Pin 54) Fuse, controller (pot. 30) Fuse, engine controller (internal) Multifuse Multifuse Multifuse Multifuse Multifuse Fuse, night lamp fuse rear screen heating unit Fuse cabin−socket fuse vibration plates Fuse Controller (Pot. 30) Fuse Controller (Pot. 15)

10A 15A 15A 125A 15A 5A 10A 25A 10A MULTIFUSE MULTIFUSE MULTIFUSE MULTIFUSE MULTIFUSE 10A 15A 15A 20A 15A 10A

002 6 002 7 002 5

Batterie Generator Batterie

Battery Generator Battery

103A 103A

H06 H07 H14

012 15 007 16 005 11

Meldeleuchte Warnblinker Warnsummer Betriebsstoerung Warnsummer Rueckwaertsfahrt

Indicator light, hazard light Warning buzzer, breakdown Back−up alarm buzzer

LED ROT 0.15A MAX O,46A

K05 K06 K09 K11 K14 K16 K32 K41 K43 K48 K61 K14.2 K141

008 012 002 002 003 012 013 004 007 008 002 004 013

3 4 10 12 19 9 1 2 12 2 7 20 16

Relais Startstrom Relais Scheinwerfer hinten Relais Klimageraet Relais Klemme 30 auf 15 Relais Vorgluehen Relais Scheinwerfer vorne Relais Kabine Trennrelais Relais Vibration Relais Fahrhebel 0−Stellung Relais Ladekontrolle

Relay, starting current Relay, head lights, rear Relay, air conditioning Relay, terminal 30 to 15 Relay, glow plug system Relay, head lights, front Relay, cabin Relay, separation Relay, vibration Relay, travel lever 0−position Relay, charge control

Relais Heckscheibenheizung

relay, heating rear screen

BOSCHW BOSCHW BOSCHW BOSCHL TYCOX BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW TYCOX BOSCHW

M01 M04 M05 M06 M07 M09 M09

002 013 013 013 013 014 014

13 12 10 13 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

P07 P09 P11 P15 P16 P33

009 013 009 010 009 009

15 8 14 16 16 18

Omegameter Frequenz− und Geschwindigkeitsanzeige Drucker BCM 03 Bildschirm Diagnose, Variomatic Opus 21

Omegameter Frequency− and Speedometer Printer BCM 03 terminal Diagnostics, varimatic Opus 21

R03 R10 R19 R20 R21 R22 R23 R24 R25 R80 R81 R82 R83 R84 R85 R86

006 002 002 005 005 005 005 009 010 013 002 002 002 002 002 002

5 8 4 15 15 12 12 17 15 2 1 1 2 2 2 3

Geber Tankanzeige Parallelwiderstand Heizflansch Widerstand Widerstand Widerstand Widerstand Widerstand Widerstand Heizung Heckscheibe Gluehstiftkerze 1 Gluehstiftkerze 2 Gluehstiftkerze 3 Gluehstiftkerze 4 Gluehstiftkerze 5 Gluehstiftkerze 6

Sender, level gauge Parallel resistor heater flange Resistor Resistor Resistor Resistor Resistor Resistor heating rear screen glow plug 1 glow plug 2 glow plug 3 glow plug 4 glow plug 5 glow plug 6

S00 S01 S03 S06 S09 S14 S15 S16 S20 S21 S28 S30 S35 S36 S37 S38 S42 S44 S45 S55 S64 S86 S127 S139

002 002 002 005 008 012 012 012 013 013 014 002 008 008 012 013 008 014 013 008 008 013 006 008

11 16 18 10 8 15 4 4 13 10 18 5 7 11 18 19 11 3 3 6 10 3 17 13

Startschalter Schalter NOT AUS Taster Signalhorn Sitzkontaktschalter links Vibrationsschalter vorne Warnblinkschalter Beleuchtungsschalter StVZO Schalter Arbeitsbeleuchtung vorne Schalter Scheibenwischer vorne Schalter Scheibenwischer hinten Schalter Kabinenheizung Batterietrennschalter Vibrationsschalter klein/gross Vibrationsschalter Schalter Blinker Schalter Kennleuchte Stufenumschalter schnell−langsam Schalter Kabinenluefter Schalter Kabineninnenleuchte Schalter Fahrhebel Schalter Schwimmstellung Schalter Tuer, links Schalter Motordrehzahl Schalter Frequenzverstellung

Starter switch Switch, emergency off Push button, warning horn Switch, seat contact, lh. Switch, vibration, front Switch, hazard light Switch, lighting StVZO Switch, working head lights, front Switch, windscreen wiper, front Switch, windscreen wiper, rear Switch, cabin heating Switch, battery disconnect Switch, vibration low/high Switch, vibration Switch, indicator Switch, warning light Speed range selector, fast−slow Switch, cabin ventilator Switch, cabin inside light Switch, travel control lever Switch, float position Switch door, lh. Switch, engine rpm Switch, frequency control

008 911 79

BOMAG

2.3 KW 4,7A 2,9A MAX. 3,8A MAX. 3,8A

0 .. 67 OHM 82 OHM 167A 120 OHM 120 OHM 120 OHM 120 OHM 60 OHM 60 OHM MAX. 13A

NOTAUSH

1075

19.1 Name

19.10.2005 Vogt 19.10.2005 Seis

Bauteilliste component listing 3 11 103

582 702 07

1076

Wiring diagram

S158 S163

Bl. Pf. Benennung 013 15 Schalter Nachtbeleuchtung 013 16 Schalter Heckscheibenheizung

Switch, cabin night lamp switch rear screen heating unit

title

V01 V02 V03 V04 V06

002 002 002 014 014

9 17 18 8 9

Diode Diode Diode Diode Diode

Diode Diode Diode Diode Diode

X1:1 X1:2 X1:2 X1:3 X1:4 X1:7 X1:8 X1:9 X1:10 X1:37 X1:38 X1:39 X1:40 X1:41 X1:41 X1:42 X1:43 X1:44 X1:45 X1:46 X1:47 X1:48 X1:49 X1:50 X1:51 X1:52 X1:53 X1:54 X1:55 X1:56 X1:57 X1:58 X1:59 X1:60 X1:61 X1:62 X1:63 X1:79 X1:80 X1:82 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 X1:94 X1:94 X1:95 X1:96 X1:97 X1:98 X1:101 X1:102 X1:103 X1:104 X1:105 X1:106 X1:107 X1:107 X1:108 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 X1:119 X1:120 X1:121 X1:122 X1:123 X1:123 X1:123 X1:124

002 005 012 002 002 002 002 002 002 007 007 006 006 006 007 007 012 005 005 005 005 005 005 005 005 005 005 005 007 007 007 007 007 007 007 007 007 002 006 005 006 007 009 012 012 009 006 006 006 007 004 004 004 006 006 003 003 002 002 002 002 002 002 006 006 004 006 004 006 002 002 006 006 007 005 007 007 005 006 006 007 007 005 005 005 005 002 005 005 005

7 9 10 11 12 13 14 6 6 15 15 2 2 3 16 17 4 3 2 8 14 15 16 16 12 12 13 13 4 6 6 6 6 6 6 5 5 12 16 17 13 16 15 5 4 15 16 13 14 16 18 18 19 3 4 19 19 16 18 16 18 16 18 5 2 5 6 5 7 7 7 3 4 17 11 15 14 11 2 5 17 14 2 4 12 13 12 12 13 16

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 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 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 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 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 ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK

WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX 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

FE5B FE5B FE5B FE5B

008 911 79

19.1

Wiring diagram Name

19.10.2005 Vogt 19.10.2005 Seis

Bauteilliste component listing 4 11 104

582 702 07

X1:124 X1:141 X1:142 X1:142 X1:143 X1:143 X1:143 X1:144 X1:145 X1:146 X1:147 X1:148 X1:149 X1:149 X1:149 X1:149 X1:14A X1:14E 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 X1:164 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 X1:175 X1:176 X1:177 X1:178 X1:179 X1:179 X1:17A X1:17E X1:180 X1:180 X1:181 X1:181 X1:182 X1:182 X1:183 X1:183 X1:184 X1:184 X1:185 X1:185 X1:186 X1:186 X1:187 X1:188 X1:189 X1:18A X1:18E X1:190 X1:190 X1:191 X1:192 X1:193 X1:194 X1:195 X1:196 X1:197 X1:197 X1:198 X1:199 X1:19A X1:19E X1:201 X1:202 X1:203 X1:205 X1:206 X1:207 X1:208 X1:209 X1:20A

008 911 79

Bl. 005 005 005 005 005 005 005 005 005 005 007 007 005 006 007 008 004 004 007 002 002 008 007 002 008 008 005 007 002 002 007 007 007 014 006 014 014 014 014 002 014 014 002 002 014 005 005 005 005 005 005 005 005 003 004 005 005 003 004 003 004 003 004 003 004 003 004 003 004 003 004 007 007 007 012 012 007 014 004 004 004 004 007 007 007 007 004 004 012 012 007 007 007 007 007 007 007 008 002

Pf. 18 16 18 19 15 19 19 15 9 9 17 2 10 12 2 3 3 3 17 16 16 3 4 18 9 9 10 7 11 11 7 7 7 3 11 5 3 4 10 10 10 7 14 14 7 2 2 2 2 4 6 5 4 2 9 7 7 3 18 3 18 5 19 2 3 2 13 19 2 4 20 16 17 16 2 2 19 8 14 14 13 13 6 5 5 6 5 5 15 15 4 4 4 11 11 11 11 18 8

Benennung 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 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 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 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 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 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 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

1077

19.1 Name

19.10.2005 Vogt 19.10.2005 Seis

Bauteilliste component listing 5 11 105

582 702 07

1078

X1:20E X1:210 X1:211 X1:212 X1:213 X1:214 X1:215 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 X1:309 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 X1:34A 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 X2:74 X2:75 X2:76 X2:77 X2:78 X3:1

Wiring diagram Bl. 002 008 008 008 008 008 008 012 012 012 012 012 012 012 012 012 012 012 012 002 002 002 002 006 006 012 012 012 012 012 012 012 012 002 002 012 012 012 012 012 012 012 012 012 012 012 012 008 008 012 012 012 012 012 012 012 009 009 005 005 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 010 010 009 010 009 009 009 009 009 009 009 009 010 009 009 009 009 009 009 009 012

Pf. 8 14 14 15 19 19 13 10 10 12 12 6 6 8 8 18 18 5 5 16 16 18 18 2 2 5 5 9 15 18 18 18 2 19 19 2 7 7 17 19 2 7 17 2 7 19 6 18 18 8 18 19 6 18 8 19 2 2 9 9 5 5 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 13 11 11 10 10 11 11 11

Benennung 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 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 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 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−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−MESSTECHNIK WAGO−MESSTECHNIK STECKER ROPS/SD

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−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−measurement equip. Wago−measurement equip. conn. ROPS/SR

BOMAG

008 911 79

19.1

Wiring diagram Name

19.10.2005 Vogt 19.10.2005 Seis

Bauteilliste component listing 6 11 106

582 702 07

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 X3:17 X3:18 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 X14:A X14:B X15:1 X15:2 X16:1 X16:2 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 X25:2 X25:3 X25:4 X26:1 X26:2 X26:3 X26:4 X26:5 X26:6 X26:8 X26:9 X26:10 X26:11 X26:12 X27:1 X27:2 X27:3 X27:4 X27:5 X27:6 X27:7 X27:8 X27:9 X27:10 X27:11 X27:12 X28:1 X28:2 X28:3 X28:4 X28:5 X28:6 X29:1 X29:2 X29:3 X29:4 X29:5 X29:6

008 911 79

Bl. 013 013 002 012 012 013 013 013 014 014 014 014 014 014 013 013 009 009 009 009 009 010 010 010 010 007 007 007 007 006 006 005 005 002 013 006 006 005 005 005 005 005 005 014 014 014 014 014 014 014 014 014 014 014 014 006 006 007 007 007 007 008 008 008 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006

Pf. 10 10 19 10 12 2 2 2 3 3 4 4 7 10 6 6 14 14 14 14 15 18 18 16 15 13 14 15 14 6 6 11 11 19 20 5 5 10 10 13 13 12 12 3 3 4 5 10 10 7 7 7 7 7 7 4 4 16 17 17 16 10 11 11 8 8 2 9 2 9 3 7 4 9 12 11 5 10 6 11 9 10 2 7 10 10 10 16 13 13 14 16 17 14 14 15 15 17 17

Benennung STECKER KABINE/ROPS STECKER KABINE/ROPS SETCKER 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 KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. STECKER VIBRATION GRO STECKER VIBRATION GRO STECKER VIBRATION KLE STECKER VIBRATION KLE STECKER WASSERABSCHEI STECKER WASSERABSCHEI STECKER RÜCKFAHRALARM STECKER RÜCKFAHRALARM Steckdose Steckdose STECKER TAUCHROHRGEBE STECKER TAUCHROHRGEBE STECKER SITZKONTAKT STECKER SITZKONTAKT STECKER FAHRPUMPE RÜC STECKER FAHRPUMPE RÜC STECKER FAHRPUMPE VOR STECKER FAHRPUMPE VOR 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 ST. FAHRSTUFENSCHALTE ST. FAHRSTUFENSCHALTE ST. FAHRSTUFENSCHALTE STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2

title

TYP

conn. cabin/ROPS conn. cabin/ROPS Con 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 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. conn. vibration big conn. vibration big conn. vibration small conn. vibration small connector water separator connector water separator conn. backupalarm conn. backupalarm Socket Socket connector fuel level sensor connector fuel level sensor connector seat contact switch connector seat contact switch connectoe driving pump back connectoe driving pump back connector driving pump front connector driving pump front 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 connector switch speed ranges connector switch speed ranges connector switch speed ranges connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2

BOMAG

1079

19.1 Name

19.10.2005 Vogt 19.10.2005 Seis

Bauteilliste component listing 7 11 107

582 702 07

1080

X29:7 X29:8 X30:1 X30:1 X30:2 X30:2 X30:3 X30:3 X30:4 X30:4 X30:5 X30:5 X30:6 X30:10 X30:11 X30:12 X30:13 X30:14 X30:15 X30:17 X30:22 X30:23 X30:24 X30:25 X30:25 X30:28 X30:60 X30:61 X30:62 X30:63 X30:64 X30:72 X30:82 X31:1 X31:1 X31:2 X31:3 X31:4 X31:5 X31:6 X31:7 X31:7 X31:8 X31:8 X31:9 X31:10 X31:10 X31:11 X31:12 X31:12 X31:13 X31:13 X31:13 X31:14 X31:14 X31:15 X31:16 X31:16 X31:17 X31:18 X31:19 X31:19 X31:20 X31:20 X31:21 X31:22 X31:23 X31:23 X31:23 X31:24 X31:24 X31:25 X31:26 X31:27 X31:31 X31:32 X31:33 X31:34 X31:40 X31:40 X31:41 X31:43 X31:46 X31:47 X31:48 X31:49 X31:50 X31:51 X31:53 X31:56 X31:58 X32:A X32:A X32:B X32:B X32:F X32:G X32:G X32:H

Wiring diagram Bl. 006 006 003 004 003 004 003 004 003 004 003 004 004 003 003 003 003 003 003 003 003 003 003 003 004 004 004 004 004 004 004 004 004 003 004 003 003 003 003 003 003 004 003 004 003 003 004 003 003 004 003 004 004 003 004 003 003 004 003 003 003 004 003 004 003 003 003 004 004 003 004 003 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 003 004 003 004 004 003 004 003

Pf. 18 17 5 3 5 18 8 3 7 18 7 3 19 2 2 3 3 2 7 6 5 6 6 6 13 9 13 14 14 5 5 2 13 16 5 17 17 12 14 15 17 9 13 14 13 8 7 8 7 8 7 16 17 9 12 9 11 1 10 10 10 10 6 8 6 6 11 11 18 11 19 12 13 9 4 6 3 20 12 17 15 13 2 1 5 11 7 15 13 16 14 2 12 3 14 13 3 14 3

Benennung STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose

title

TYP

connector LC−display 2 connector LC−display 2 EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis

BOMAG

008 911 79

19.1

Wiring diagram Name

19.10.2005 Vogt 19.10.2005 Seis

Bauteilliste component listing 8 11 108

582 702 07

X32:H X32:K X32:K X32:L X32:M X33:1 X33:2 X33:3 X33:4 X33:5 X33:6 X33:7 X33:8 X34:A X34:B X34:C X34:D X34:G X34:H X34:J X34:N X34:P X34:R X35:1 X35:2 X35:3 X35:4 X35:5 X35:12 X35:15 X35:16 X35:17 X35:18 X35:19 X35:20 X35:21 X35:22 X35:23 X35:24 X35:26 X35:27 X35:28 X35:29 X35:30 X35:31 X35:33 X35:34 X35:35 X35:37 X35:38 X35:40 X35:41 X35:43 X35:46 X35:47 X35:48 X35:49 X35:53 X35:54 X35:55 X35:56 X35:57 X35:58 X35:59 X35:60 X35:61 X35:64 X35:65 X35:66 X35:67 X35:68 X36:A X36:B X37:A X37:B X38:A X39:1 X39:2 X39:3 X39:4 X40:1 X40:2 X40:3 X40:4 X41:1 X41:2 X41:3 X41:4 X41:5 X41:6 X41:7 X41:8 X42:1 X42:2 X42:3 X42:4 X42:5 X43:1 X43:2

008 911 79

Bl. 004 003 004 003 004 003 003 003 003 003 003 003 003 005 005 005 005 005 005 007 003 002 006 007 007 007 005 005 005 005 007 007 007 007 007 007 007 007 005 005 005 005 007 005 005 005 005 007 005 005 007 007 007 005 005 007 005 005 005 005 005 005 005 005 005 007 005 005 005 005 005 002 002 002 002 002 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 009 009 009 009 009 007 007

Pf. 14 2 13 2 13 19 18 18 19 18 19 17 20 14 16 12 13 10 11 3 4 14 2 4 12 16 11 10 3 10 4 18 11 11 5 6 11 5 11 16 15 2 4 9 5 13 6 17 5 2 11 11 10 15 16 14 12 12 9 18 7 7 8 8 8 17 13 18 19 19 19 5 6 11 13 13 9 10 10 9 9 10 10 9 8 8 8 8 11 11 11 11 18 19 19 18 18 2 1

Benennung EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER EINSPEISUNG SCHALTKAS EINSPEISUNG SCHALTKAS ST. ZÜNDSCHLOSS E−KAS ST. ZÜNDSCHLOSS E−KAS STECKER STARTER E−KAS STECKER 1 LENKRAD STECKER 1 LENKRAD STECKER 1 LENKRAD STECKER 1 LENKRAD STECKER 2 LENKRAD STECKER 2 LENKRAD STECKER 2 LENKRAD STECKER 2 LENKRAD ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER SCHALTER ARML STECKER SCHALTER ARML

title

TYP

EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector supply e−box supply e−box connector ignition switch, e−box connector ignition switch, e−box connector starter, e−Box connector 1 steering unit connector 1 steering unit connector 1 steering unit connector 1 steering unit connector 2 steering unit connector 2 steering unit connector 2 steering unit connector 2 steering unit conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conector adapter BOP conector adapter BOP conector adapter BOP conector adapter BOP conector adapter BOP connector switch arm rest connector switch arm rest

BOMAG

1081

19.1 Name

19.10.2005 Vogt 19.10.2005 Seis

Bauteilliste component listing 9 11 109

582 702 07

1082

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 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 X50:1 X50:2 X50:3 X51:1 X51:2 X51:3 X52:1 X52:2 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 X57:1 X57:1 X57:2 X57:3 X57:4 X57:5 X57:6 X57:8 X57:9 X57:9 X57:10 X57:11 X57:12 X57:13 X57:13 X57:14 X57:14 X57:15 X57:15

Wiring diagram Bl. 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 008 008 008 007 007 007 005 005 014 014 014 014 014 014 014 014 014 014 014 014 013 013 013 013 013 013 013 013 003 004 003 003 003 003 003 003 003 004 003 003 003 003 004 003 004 003 004

Pf. 13 15 14 14 10 12 5 4 11 18 17 2 7 9 8 5 18 5 6 6 4 7 11 10 17 6 13 4 5 5 5 6 13 13 14 14 19 18 18 19 18 11 12 12 8 7 7 8 10 9 9 10 13 13 13 2 1 2 3 3 3 4 4 3 3 11 11 10 10 7 10 11 11 10 10 10 14 13 13 12 15 9 13 14 12 14 15 13 13 8 8 8 7 7 7 9 7 9 9

Benennung 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 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 ST. PLATTENFREQ. ST. PLATTENFREQ. ST. PLATTENFREQ. ST. 1 LENKRADKABELBAU ST. 1 LENKRADKABELBAU ST. 1 LENKRADKABELBAU STECKER DRUCKSENSOR STECKER DRUCKSENSOR 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 Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor

title

TYP

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 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. plate−freq. conn. plate−freq. conn. plate−freq. connector 1 steering wiring connector 1 steering wiring connector 1 steering wiring connector pressure sensor connector pressure sensor 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 connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine

BOMAG

008 911 79

19.1

Wiring diagram Name

19.10.2005 Vogt 19.10.2005 Seis

Bauteilliste component listing 10 11 110

582 702 07

X57:16 X57:17 X57:18 X57:19 X57:19 X57:20 X57:20 X57:21 X57:21 X57:22 X57:22 X57:23 X57:23 X57:23 X57:24 X57:24 X57:25 X57:25 X57:26 X57:27 X57:28 X57:28 X57:29 X57:29 X57:30 X57:31 X57:32 X57:33 X57:34 X57:35 X57:36 X57:37 X57:39 X57:40 X57:41 X57:42 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 X62:1 X62:2 X62:3 X62:4 X62:5 X62:6 X62:7 X62:8 X62:9 X62:10 X62:11 X62:12 X62:13 X62:14 X62:15 X63:1 X63:1 X63:2 X63:2 X65:1 X65:2 X65:3 X65:4 X65:5 X65:7 X65:8 X65:9 X65:10 X65:11 X65:12 X66:2 X66:3 X74:1 X74:2 X74:3 X74:4 X74:5 X75:2 X75:7 X76:1 X76:2

Bl. 003 003 003 003 004 003 004 003 004 003 004 003 004 004 003 004 003 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 011 011 011 011 011 011 011 011 011 011 011 004 004 009 009 009 009 009 010 010 010 010

Y04

007 17

008 911 79

Pf. 11 10 10 10 10 6 11 6 8 6 12 11 12 17 11 15 12 13 16 15 11 17 13 18 14 14 13 16 1 1 3 5 2 4 6 5 17 7 2 2 7 17 19 7 2 2 7 19 18 18 6 6 19 19 8 8 19 19 18 16 16 17 17 18 18 18 15 17 19 20 19 13 14 13 14 5 5 5 5 5 5 12 5 5 5 5 19 20 14 14 14 15 14 16 15 17 17

Benennung

title

Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor 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 DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN SCHNELLVERSCHLUSSKUPP SCHNELLVERSCHLUSSKUPP SCHNELLVERSCHLUSSKUPP SCHNELLVERSCHLUSSKUPP KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD ANSCHLUß EMR3 VORGLÜH ANSCHLUß EMR3 VORGLÜH 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

connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine 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. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates quick connecting clutch quick connecting clutch quick connecting clutch quick connecting clutch Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard connector EMR3 preglow connector EMR3 preglow 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

Magnetventil Bremse

Solenoid valve, brake

BOMAG

TYP

MAX. 1.8A

1083

19.1 Name

19.10.2005 Vogt 19.10.2005 Seis

Y07 Y08 Y14 Y15 Y16 Y17 Y30 Y31 Y92 Y93 Y98 Y122 Y123 Y137 Y137 Y138 Y140 Y141 Y142 Y143 Y144.1 Y144.2 Y145 Y147 Y148 Y149 Y166 Y169 Y170

Wiring diagram Bl. 007 007 014 014 005 005 005 005 007 007 008 008 008 003 004 014 009 009 008 008 008 008 008 004 004 004 004 004 004

Pf. 15 13 14 7 13 12 15 16 6 5 14 16 17 10 10 10 10 11 17 18 19 19 20 1 3 5 2 6 4

Benennung

title

Magnetventil Vibration vorne gross Magnetventil Vibration vorne klein Kraftstoffpumpe Heizgeraet Magnetkupplung Klimakompressor Magnetventil Fahrtrichtung vorwaerts Magnetventil Fahrtrichtung rueckwaerts Magnetventil Stufenumschaltung vorn Magnetventil Stufenumschaltung hinten Magnetventil Lenkung vorne rechts Magnetventil Lenkung vorne links Magnetventil Vibrationsfrequenz, hinten Magnetventil Platten heben Magnetventil Platten senken EMR Verstellung EMR Verstellung Magnetveentil Heizung Magnetventil Erreger auf Magnetventil Erreger ab Magnetventil Plattenverschieben Links Magnetventil Plattenverschieben rechts

Solenoid valve, vibration, front, high Solenoid valve, vibration, front, low Fuel pump, heating unit Magnetic clutch, air conditioning compr. Solenoid valve, travel direction forw. Solenoid valve, travel direction backw. Solenoid valve, speed range sel., front Solenoid valve, speed range sel., rear Solenoid valve, steering, front rh. Solenoid valve, steering, front lh. Solenoid valve, vibrat.freq.,rear Solenoid valve, lift plates Solenoid valve, let down plates EMR adjustment EMR adjustment Solenoid valve, heating unit solenoid valve exciter up solenoid valve exciter down solenoid valve, plate displace left solenoid−valve, plate displace right

Magnetventil Platten (Priorität) Injektor A1 Injektor A2 Injektor A3 Injektor A4 Injektor A6 Injektor A5

solenoid−valve, plate (priority) jet pump A1 jet pump A2 jet pump A3 jet pump A4 jet pump A6 jet pump A5

TYP 0.4 .. 1.2A 0.4 .. 1.2A 3,5A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A MAX. 1.8A MAX. 1.8A

1A 0.4 .. 1.2A 0.4 .. 1.2A MAX. 1.8A MAX. 1.8A MAX. 1.8A MAX. 1.8A MAX. 1.8A

Bauteilliste component listing 11 11 111

582 702 07

1084

BOMAG

008 911 79

X36 X37

X38

K11

008 911 79

BOMAG B57

1085

Name: Seis

Gepr.: 19.10.2005

Name: Vogt

Gez.: 19.10.2005

X32:1-12

K09

K16

A02

K41

K61

K48

K43

K06

K05

overview e-box BW 177...226 DH/BVC-4

Übersicht Schaltkasten BW 177...226 DH/BVC-4

X34:1-19

Nur bei Klimaanlage only acc. to aircond.

R10

Nur bei StvzO only acc. To StvZO illumination

Replaces:

Ers. f.:

page: 1

Seite: 1

A80

from: 2

von: 2

582 702 07 Sheet No.: 201

Blatt Nr.: 201

Wiring diagram

19.1

F1

F2

1086 A34 Fahrsteuerung

A83 Messtechnik Steuerung

CAN 1

Nur bei VM8 only acc. To VM8

BOMAG

008 911 79

Name: Seis

Gepr.: 19.10.2005

Name: Vogt

Gez.: 19.10.2005

overview e-box door BW 177...226 DH-4

Übersicht Schaltkasten-Tür BW 177...226 DH-4

BCM

Replaces:

Ers. f.:

page: 2

Seite: 2

OPUS 21

CAN 1

CAN 3

EMR + Fahrhebel

LCD+ Datensammler

CAN 2

CAN 1

from: 2

von: 2

582 702 07 Sheet No.: 201

Blatt Nr.: 201

19.1 Wiring diagram

19.1

Wiring diagram

WAGO smart DESIGNER 4.1 1

057 564 17

2

280-315

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

12

F93 Flachsicherung DIN 72581-C25 / 057 511 09 (Nur bei EMR III)

13

F13 Flachsicherung DIN 72581-C30 / 057 510 99

14

F05 Flachsicherung DIN 72581-C10 / 057 510 97

15

F67 Flachsicherung DIN 72581-C15 / 057 510 98

16

F11 Flachsicherung DIN 72581-C15 / 057 510 98 (Nur bei E2 StvZO Beleuchtung)

17

F07 Flachsicherung DIN 72581-C15 / 057 510 98 (Nur bei E2 StvZO Beleuchtung)

18

F68 Flachsicherung DIN 72581-C5 / 057 511 73 (Nur bei Diebstahlschutz)

19

F22 Flachsicherung DIN 72581-C15 / 057 510 98

20

F19 Flachsicherung DIN 72581-C15 / 057 510 98

21

F09 Flachsicherung DIN 72581-C10 / 057 510 97 (Nur bei E2 StvZO Beleuchtung)

22

F10 Flachsicherung DIN 72581-C10 / 057 510 97 (Nur bei E2 StvZO Beleuchtung)

23

F08 Flachsicherung DIN 72581-C15 / 057 510 98 (Nur bei E2 StvZO Beleuchtung)

24

F18 Flachsicherung DIN 72581-C10 / 057 510 97

25

F95 Flachsicherung DIN 72581-C10 / 057 510 97

26

F23 Flachsicherung DIN 72581-C15 / 057 510 98

27

F24 Flachsicherung DIN 72581-C10 / 057 510 97

28

F39 Flachsicherung DIN 72581-C15 / 057 510 98

29

F145 Flachsicherung DIN 72581-C20 / 057 511 00 (Nur bei AG28 Plattenanbau)

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Absicherung DH-4 komplett

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. 30.11.2005 08:36:29

008 911 79

BOMAG

Seite 1

1087

19.1

Wiring diagram

WAGO smart DESIGNER 4.1 30

3 x 057 564 36 "R" + 793-501

33

057 564 35

34

2 x 057 564 17

36

057 564 21

37

2 x 057 564 25 "L" + 793-501

39

3 x 057 564 25 "L" + 057 564 20 + 793-501

42

5 x 057 564 25 "L" + 793-501

47

8 x 057 564 25 "L" + 057 564 20 + 793-501

55

057 564 25 "L" + 793-501

56

4 x 057 564 38 "L" + 793-501

60

30

F148 Flachsicherung DIN 72581-C10 / 057 510 97 (Nur bei VM8-11 Messtechnik)

31

F84 Flachsicherung DIN 72581-C10 / 057 510 97 (Nur bei VM8-11 Messtechnik)

32

F146 Flachsicherung DIN 72581-C15 / 057 510 98 (Nur bei VM8-11 Messtechnik)

56

Nur bei BVC

57

Nur bei BVC

057 564 17

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Absicherung DH-4 komplett

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. 30.11.2005 08:36:29

1088

BOMAG

Seite 2

008 911 79

19.1

Wiring diagram

WAGO smart DESIGNER 4.1

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Absicherung DH-4 komplett

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. 30.11.2005 08:36:59

008 911 79

BOMAG

Seite 3

1089

19.1

Wiring diagram

WAGO smart DESIGNER 4.1

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Absicherung DH-4 komplett

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. 30.11.2005 08:36:59

1090

BOMAG

Seite 4

008 911 79

19.1

Wiring diagram

WAGO smart DESIGNER 4.1 1

05756417

2

3 x 05756540 "R" + 793-501

5

05756535 "R" + 793-501

6

05756537

7

3 x 05756540 "R" + 793-501

10

05756537

11

05756540 "R" + 793-501

12

05756535 "R" + 793-501

13

05756537

14

2 x 05756538 "R" + 793-501

16

2 x 05756539 "R" + 793-501

18

05756537

19

4 x 05756540 "R" + 793-501

23

05756537

24

4 x 05756540 "R" + 793-501

28

2 x 05756539 "R" + 793-501

30

05756537

31

05756540 "R" + 793-501

32

05756539 "R" + 793-501

33

05756537

34

4 x 05756540 "R" + 793-501

38

05756535 "R" + 793-501

39

05756537

40

4 x 05756540 "R" + 793-501

44

05756537

45

05756540 "R" + 793-501

46

05756535 "R" + 793-501

47

05756537

48

05756540 "R" + 793-501

49

05756535 "R" + 793-501

50

05756537

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Kabelbäume DH-4 komplett

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. 08.11.2005 11:25:37

008 911 79

BOMAG

Seite 1

1091

19.1

Wiring diagram

WAGO smart DESIGNER 4.1 51

05756538 "R" + 793-501

52

2 x 05756540 "R" + 793-501

54

05756538 "R" + 793-501

55

05756537

56

3 x 05756540 "R" + 793-501

59

05756538 "R" + 793-501

60

05756537

61

3 x 05756540 "R" + 793-501

64

05756535 "R" + 793-501

65

05756537

66

2 x 05756540 "R" + 793-501

66

Bei DH-4 TierIII und BVC

67

Bei DH-4 TierIII und BVC

68

05756535 "R" + 793-501

69

05756537

69

Bei DH-4 TierIII und BVC

70

3 x 05756540 "R" + 793-501

70

Nur bei Variocontrol

71

Nur bei Variocontrol

72

Nur bei Variocontrol

73

05756535 "R" + 793-501

73

Nur bei Variocontrol

74

05756537

74

Nur bei Variocontrol

75

2 x 05756540 "R" + 793-501

75

Nur bei AG28 Anbau-Vibrationsplatten

76

Nur bei AG28 Anbau-Vibrationsplatten

77

Nur bei AG28 Anbau-Vibrationsplatten

78

Nur bei AG28 Anbau-Vibrationsplatten

79

Nur bei AG28 Anbau-Vibrationsplatten

77

2 x 05756535 "R" + 793-501

79

05756537

80

05756417

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Kabelbäume DH-4 komplett

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. 08.11.2005 11:25:37

1092

BOMAG

Seite 2

008 911 79

19.1

Wiring diagram

WAGO smart DESIGNER 4.1

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Kabelbäume DH-4 komplett

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. 08.11.2005 11:26:35

008 911 79

BOMAG

Seite 3

1093

19.1

Wiring diagram

WAGO smart DESIGNER 4.1

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Kabelbäume DH-4 komplett

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. 08.11.2005 11:26:35

1094

BOMAG

Seite 4

008 911 79

19.1

Wiring diagram

WAGO smart DESIGNER 4.1

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

13

05756539 "R" + 793-501

14

05756537

15

05756540 "R" + 793-501

16

05756538 "R" + 793-501

17

05756540 "R" + 793-501

18

05756537

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

Messtechnik / BVC*

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Klemmenleiste X2

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. 08.11.2005 12:45:24

008 911 79

BOMAG

Seite 1

1095

19.1

Wiring diagram

WAGO smart DESIGNER 4.1 19

05756540 "R" + 793-501

19

Nur bei BVC

20

05756539 "R" + 793-501

20

Nur bei BVC

21

05756537

21

Nur bei BVC

22

2 x 05756438 "R" + 793-501

22

Nur bei BVC

23

Nur bei BVC

24

Nur bei BVC

24

05756421

25

05756417

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

Messtechnik / BVC*

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Klemmenleiste X2

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. 08.11.2005 12:45:24

1096

BOMAG

Seite 2

008 911 79

19.1

Wiring diagram

WAGO smart DESIGNER 4.1

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

Messtechnik / BVC*

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Klemmenleiste X2

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. 08.11.2005 12:45:47

008 911 79

BOMAG

Seite 3

1097

19.1

Wiring diagram

WAGO smart DESIGNER 4.1

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

Messtechnik / BVC*

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Klemmenleiste X2

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. 08.11.2005 12:45:47

1098

BOMAG

Seite 4

008 911 79

19.1

Wiring diagram

WAGO smart DESIGNER 4.1

1

05756417

1

Nur bei ZA E2 StvZO Beleuchtung

2

4 x 05756540 "R" + 793-501

2

Nur bei ZA E2 StvZO Beleuchtung

3

Nur bei ZA E2 StvZO Beleuchtung

4

Nur bei ZA E2 StvZO Beleuchtung

5

Nur bei ZA E2 StvZO Beleuchtung

6

05756537

6

Nur bei ZA E2 StvZO Beleuchtung

7

2 x 05756540 "R" + 793-501

7

Nur bei ZA E2 StvZO Beleuchtung

8

Nur bei ZA E2 StvZO Beleuchtung

9

Nur bei ZA E2 StvZO Beleuchtung

10

Nur bei ZA E2 StvZO Beleuchtung

11

Nur bei ZA E2 StvZO Beleuchtung

12

Nur bei ZA E2 StvZO Beleuchtung

13

Nur bei ZA E2 StvZO Beleuchtung

14

Nur bei ZA E2 StvZO Beleuchtung

9

13

4 x 05756538 "R" + 793-501

2 x 05756539 "R" + 793-501

15

05756537

15

Nur bei ZA E2 StvZO Beleuchtung

16

05756417

16

Nur bei ZA E2 StvZO Beleuchtung

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

E2 Beleuchtung

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Option E2 StvZO Beleuchtung

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. 08.11.2005 14:30:09

008 911 79

BOMAG

Seite 1

1099

19.1

Wiring diagram

WAGO smart DESIGNER 4.1

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

E2 Beleuchtung

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Option E2 StvZO Beleuchtung

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. 08.11.2005 14:30:27

1100

BOMAG

Seite 2

008 911 79

008 911 79

BOMAG (BVC) (BVC)

X47 X48 X49

(BVC) (BVC)

X47 X48 X49

X22

X48 X49

X52

X58

X59

X53

X54

X28 X19

X29 X18

X56

X76

X74 X75

X19

X17

X52

X77

X27

X35

X44

X32 X34

X27

1101

Name: Seis

Gepr.: 19.10.2005

Name: Vogt

Gez.: 19.10.2005

X38 X32 X34

X26

X4 X3 X37 X44 X2

X33

X43

X55

X36 X35 X1

X31

X30

X39 X40

X14

X46 X25 X41 X51 X20

X20

X77

X26

X38 X2

X37 X1

X4 X3

X36

X33

X42 X23 X24 X50

X31

X30

X14

X46

X17

X51 X43

X42

X58

X18

X55

X39 X23 X24 X50 X40 X25 X41 X13

X48 X49

X22

X53 X54

X59

X28

X29

X56 X76

X74 X75

X57

X57

X8 X10

X8 X10

X6 X7

X6 X7 X15 X16

X60

X9

X61

X9

X62

X61 X62

X60

X15 X16

overview e-box door BW 177...226 DH-4

Übersicht Schaltkasten-Tür BW 177...226 DH-4

X21

X21

Replaces:

Ers. f.:

page: 1

Seite: 1

von: 1 from: 1

582 702 07 Sheet No.: 301

Blatt Nr.: 301

Wiring diagram

19.1

19.1

1102

Wiring diagram

BOMAG

008 911 79

19.2 Wiring diagram

008 911 79

BOMAG

1103

19.2

Wiring diagram

Wiring diagram 582 702 32 from serial number 101 582 121 002 Variocontrol 101 582 641 060 BW 216 DH-4 101 582 651 005 BW 216 PDH-4 101 582 771 171 BW 219 DH-4 101 582 861 026 BW 226 DH-4 BVC 101 582 881 003 BW 226 DH-4 101 583 061 014 BW 213 DH-4 BVC /P 101 583 141 076 BW 213 DH-4 101 583 151 006 BW 213 PDH-4 101 583 161 027 BW 213 DH-4 BVC 101 583 191 005 BW 214 DH-4 101 583 201 001 BW 214 PDH-4

1104

BOMAG

008 911 79

008 911 79

001 002 003 004 005 006 007 008 009 010 011 012 013 014 101

Blatt Nr.: sheet no.:

582 582 582 582 582 582 582 582 582 582 582 582 582 582 582

702 702 702 702 702 702 702 702 702 702 702 702 702 702 702

32 32 32 32 32 32 32 32 32 32 32 32 32 32 32

BOMAG

08.03.2007 Vogt 08.03.2007 Seis

Stromlaufplan circuit diagram

Stromlaufplan Versorgung, Starten, Kraftstoffvorwärmung, Hupe Motor Deutz EMR II Motor Deutz EMR III Fahrantrieb, Neigungssensor, Sitzkontakt Datensammler, LC−Display Lenkung, Vibration Fahrhebel, Vibrationsplatten Variocontrol, Messtechnik Bomag Compaction Management BCM, GPS Diebstahlschutz System DH−4 Beleuchtung und StvZO Kabinenausrüstung, Beleuchtung, Radio, Tachograph Kabinenheizung, Klimaanlage, Zusatzheizung Bauteilliste

Funktionsgruppe

BW 177..226 DH−4 BW 177..226 DH−4

Zeichnungsnummer drawing − no.

Inhaltsverzeichnis: table of contents:

001

001

19.2 001

582 702 32

Circuit Diagram supply, starting unit, fuel pre−heater, signal horn engine Deutz EMR II engine Deutz EMR III driving system, slope sensor, seat contakt switch data−collector, LC−display steering, vibration joystick, vibration−plates Variocontrol, measurement equipm. Bomag Compaction Management BCM, GPS anti − theft system illumination and StvZO cabin−equipment, headlights, radio, tachograph cabin−heater, air conditioning, add. heater component listing

function unit

Wiring diagram

1105

2

2

1

R83

2

1

4:20

K14.2

2

1

R85

Glühstiftkerzen glow plugs

31

R81

1

R82

2

1

3

5

2

1

S30

G03

125A

F48

2

1

−

+

1

2

08.03.2007 Vogt 08.03.2007 Seis

Batterie battery

Trennschalter Batter break switch battery

2

1

3

5

nicht bei EMR III, bei BW177DH−4 Option not at EMR III, at BW177DH−4 option

Heizflansch heating−flange

R19

3:19

K14

167A

nur bei EMR III only EMR III

R84

BOMAG

R86

Sicherung Heizflansch/Glühstiftkerzen heating−flange/glow plugs

Option option

X36:B

2 x 10qmm

−

+

1

2

Batterie battery

31 EMR 3:3

G01

125A

F00

X1:10

Hauptsicherung main fuse

2

B+

D+

X1:109

X1:1

9:2

2:12

6:2

K09

14:7

85

86

87a

30

X1:168

87

2:7

K61

K11

2:15 starter

X1:123

X1:3

85

86

19 17

M −

Starter

M01

30

50

2

7:17 X1:152

B11

2

1

V02 V03

2

1

1

2

14

13

X1:155

X1:28A

15A

F23

X1:28E

1

B11

31

X1:104

2

1

X1:102

−

+

K32:86

2

1

3:1

13:1

K11:87 6:1

Steckdose socket

XS 12V

X3:3

X1:30A

15A

F39

X1:98

24

23

2

1

X1:30E

Wiring diagram

1

008 911 79

002

582 702 32

Nur bei Geländer/ROPS/SD only at hand−rail/ROPS/sun−roof

Signalhörer warning horns

X1:103

1

2

X1:101

X1:97

Taster Hupe push button, horn

S01:22 3:1 F05:2 6:8

S03

X1:33A

25A

F124

X1:33E

22 12 32 42 52 62

X1:218

2

1

Kraftstoffvorwärmung fuel pre−heater

X67:2

R79

X67:1

5:9

21 11 31 41 51 61

2

1

87

30

X1:217

X1:151

X1:27A

10A

F95

X1:27E

K11 2:11

NOT−Aus Emerg.−Stop

S01

K30 13:1 30 4:1 1

X1:8

X38:A

87a

30

F05

X1:16E

X1:16A

50a

X1:7

8:3 87

K05

X37:B

2:8 B+

X1:4

X1:79

54 58

10A

Versorgung, Starten, Kraftstoffvorwärmung, Hupe supply, starting unit, fuel pre−heater, signal horn

X1:110

W

1

R10 82 OHM

1

D+ MESX

85

86

D+

Generator generator

2:10

B−

G02

B+

125mA

K61

2

V01

2

1

Startschalter 15 starting swwitch

S00

30

X37:A

X1:15A

30A

F13

nur bei Klimaanlage only acc.to air conditioning

X1:9

X36:A

X1:15E

Anzugsw.:50A / Haltew.:10A

X34:P

1106 Option Winterpaket option winter package

19.2

2:20

CAN2− 4:15 CAN2+ 4:15

K

L

X30:10

X1:183

X32:L

X32:A

31

08.03.2007 Vogt 08.03.2007 Seis

31 EMR

X30:2

Ubat −

X1:182

X30:1

4:18

B88

Signal

X57:13

X31:12

AGND

X57:10 2

X31:11

B130

1

2

6

X57:17

X31:15 1

5

4

X31:25

B115

3

Signal Temperatur

2

1

X31:9 B113

2

X31:8

X31:4

X31:23

X31:16 EMR Kühlmitteltemperatur EMR coolant temperature Ladeluftdruck + Temp charging air pressure + temperature

1

X31:24

X31:19

Motor Deutz EMR II engine Deutz EMR II

Y137

EMR Stellglied EMR commander

7

STG−

X57:14

Motordrehzahlsensor sender engine rpm 2

X31:13

B114

2

X31:10

Motordrehzahlsensor sender engine rpm 1 EMR Motoröldruck EMR engine oil pressure

31 EMR

X31:20

X57:20

1

Signal

X57:11

max 7A

CAN high

X30:12

X1:180

X32:H

X30:13

2:6

AGND

Signal

X57:21

1

X31:14 STG+

X57:15

X30:14

X30:11

X1:184

X32:K

AGND

X57:23

CAN low

X1:181

X32:G

Diagnosestecker EMR diagnosis interface EMR

X31:21

+5V

X57:22

2

X31:22 AGND

X57:12

3

X31:17 X57:18 RF−

+5V

X57:25

A48 Motorsteuerung EMR2 engine−controller EMR2

X32:B

X31:18 X57:19 RF REF

Signal

X57:9

EPC−Stecker

X31:2 1

X33:2

X33:7

X1:96

K14

X1:95

X1:185 Steckerschnittstelle Deutz connector interface Deutz

2:4

1

X33:3 X31:7 X31:3

X31:1

X1:179

X1:186

ESX Fahrst.

X34:N

X57:16 RF MESS

Signal Druck

X57:24

BOMAG X57:4

AGND

X57:8

Relais Heizflansch relay heating−flange

X33:5

S01:22

X33:6

008 911 79 X33:1

X33:4

31 4:1

19.2 003

582 702 32

2

1

S01:22 4:1

X33:8

2:16

Wiring diagram

1107

X57:6

X57:1

X31:6

X31:5

X31:16

X57:35

3:20

X31:47

X30:72

X57:36

X30:1

4:3

Injektor A4 jet pump A4

2

08.03.2007 Vogt 08.03.2007 Seis

X31:48

X30:64

Y15.4

Y169

2

1

Nur bei EMRIII only EMRIII

X57:41

B40.2

1

B40.1

2

B130

3

X1:179

X30:28 B114

2

X31:12

X31:10

3

Y19

Y137

Motorsteuerung EMR3 (EDC 16) engine−controller EMR3 (EDC16)

A48

2

1

1

X57:37

4

B48

B133

3

X1:184

X32:A 2

3

Motor Deutz EMR III engine Deutz EMR III

X32:H X30:62

X1:192 1

1

2

B43

B113

X31:58

3

B6

B88

2

EMR Kraftstoffdruck rail pressure sensor

1

2

3:5

B51

B145

3x2.5

31 EMR

4

1

1

EMR Niederdruck Kraftstoff EMR fuel low pressure sensor

EMR Motoröldruck EMR engine oil pressure

1

3

bei einer Kabelbaumumgebungstemperatur von 85 Grad C. (Querschnitt 4x2,5qmm)

max. Kabellänge von Batterie zum Steuergerät (Versorgungsleitung) max. 10m

in der hier dargestellten Installation (Querschnitt 2,5qmm)

max. Kabellänge von Batterie zum Steuergerät (Versorgungsleitung) max. 3.5m

EMR Kühlmitteltemperatur EMR coolant temperature

B49

B93

2

Ladeluftdruck + Temp charging air pressure + temperature

EMR Stellglied EMR commander

X31:7

Motordrehzahlsensor sender engine rpm 2

Motordrehzahlsensor sender engine rpm 1

1

X57:14

Injektor A6 jet pump A6

2

1

X31:32

Injektor A3 jet pump A3

Injektor A5 jet pump A5

Injektor A2 jet pump A2

Y15.2

Y15.6

2

Y170

31

1

Y15.3

2

X31:31

Y149

1

X31:46

X30:63

X31:1

X30:5

X31:33

1

X57:40

Y15.5

X57:42

Y148

Sign.

X57:13

X1:198 X1:199

X31:50 AGND

X57:9

2.5 qmm

X31:27

X1:183

X30:3

Y166

2

1

X57:39

Injektor A1 jet pump A1

Y15.1

Y147

X57:34

X1:185

X57:15

X1:107 X1:108

X31:19

87a

X31:49

4:2 87

X31:23

85

X31:40

B124

X31:20 Sign.

X57:21

max 7A AGND

X57:1

Signal

X57:19

AGND

X57:20

AGND

X57:28

Signal Druck

X57:23

30

X31:14

K41

X57:22

X32:K X30:25 X31:53

X32:M X57:32

X1:194 CAN 1 Low

X1:191 CAN 2 High

X31:43

86

X31:51

K41

X31:56

2

X31:13

25A

X57:33

X1:14A

X31:11

F93

X57:28

X1:193 CAN 1 High AGND

X30:82 X31:26

X32:F X30:60 Signal

X57:25

X32:G X30:61 X31:8

CAN 2 Low

X57:31

CAN2+ CAN2−

X31:57

3:4

AGND

X57:24

X32:B Signal

X57:30

3:4

Signal Druck

diagnosis interface EMR

X31:41 AGND

X57:27

K−Line Signal Temperatur

X57:29

Signal

X57:26

BOMAG

X57:23

Diagnosestecker EMR

AGND

X57:29

Wasserabscheider water−seperator

X31:54 GND

X1:180 X1:90

1

X30:2 GND

X1:181 X1:91

X1:14E

X30:4 GND

X1:182

30 5:1 S01:22 7:1 CAN2+ 5:11 CAN2− 5:11

31 5:1

85

86

Wiring diagram

X66:2

X30:6

008 911 79

004

582 702 32

2:2

K14.2

X31:24

30 S01:22

X31:34

2:14

X66:3

3:20

X1:186

1108 X1:92

19.2

31

−

X52:2

X35:28

X35:38

X1:172

dir.

X35:12

speed

dir.

X1:178

−

+

FM3 7:5

08.03.2007 Vogt 08.03.2007 Seis

Sensor Bandage sender drum

9:2 SPEED MESX

13:6 SPEED TAC

B59 9:2 DIR MESX

X1:44

Fahr−Steuerung driving controller

A34

Drucksensor Fahrpumpe pressure sensor drive pump

X1:45

+

X52:1

B112

sw

X35:34

B57

−

+

2

1

7:4

X35:58

X1:34A

10A

F84

X1:34E

X1:46

4V

9:2

X34:G

X1:34A

2

1

32

X34:H

X34:C

X34:D

R22

120 OHM 1 2

R23

120 OHM 1 2

+

−

X1:117

X9:2

H14 −

+

X9:1

X34:A

X34:B

R20

120 OHM 1 2

R21

120 OHM 1 2

X1:123

X16:1 1 Y17 b 2 X16:2

X1:144

Y30

1 2

Y31

X1:124

2

1

1

LC−Display, OPUS 21

Fahrhebel

Diagnosestecker Fahrzeug diagnosis interface equipment

CAN1− 6:8

CAN2+ 8:6 CAN2− 8:6 CAN1+ 6:8

Prop.−Ventil Achsmotor prop.−Valve axle motor

Prop.−Ventil Bandagenmotor prop.−Valve drum motor Prop.−Pumpe Rückw. prop−pump backwards

X1:123

X15:1 1 Y16 a 2 X15:2

X1:141

X1:143

X1:122

X1:121

Prop.−Pumpe Vorw. prop.−pump forwards Rückfahrwarnsummer back up alarm buzzer

Sitzkontaktschalter switch, seat contact

X1:149

X14:A

S06

X14:B

X1:114

X1:158

Fahrantrieb, Neigungssensor, Sitzkontakt driving system, slope sensor, seat contakt switch

9:2

2,5V

1V

PITCH MESX

S

−45_G=0,5V

+45_G=4,5V

X35:57

Neigungssensor slope sensor

X1:55

X1:17A

15A

F67

X1:17E

Leistung

rt

X35:56

X1:146

X35:59

31

X35:54 X35:30

Sitzkontakt

S01 2:15

X35:5 X35:15

Rückfahrwarnsum.

X1:120

Richtung

X1:177

TxD

X35:4 X35:24 0,46A

X35:31

ws

RxD

CAN2−

X1:51 X35:53 X35:49 Fahrpumpe vorw. 400 ... 1.200mA

X1:145

X35:60

X1:52 CAN2+

X1:53 X35:33 X35:64 Fahrpumpe rückw. 400 ... 1.200mA

X1:119

Sensor Achse sender axle

4:20

X1:174

B60

X1:171

br

sw

X1:47 X35:27 X35:46 400 ... 1.200mA

Drucksensor

X35:37

speed

X1:176

bl

X1:54 CAN2−

X1:49 X35:26 X35:47 400 ... 1.200mA

Elektronik Neigung

X1:48 CAN1+ Bandagenmotor

X1:50 CAN1− Achsmotor

CAN2+

Gehäuse housing

4:20 EMR Deutz 4:20

X35:55 1

X1:124

X1:2

X35:65 1

X1:142

6:3

X35:66 X1:142

F24:2

X35:67

31 6:1

30 6:1

19.2 005

582 702 32

X1:143

Pot. 15

Richtung

X1:173

ws

speed

bl

speed

X1:175

br

sw

BOMAG

X1:82

30

X35:68 X1:143

008 911 79

4:20

Wiring diagram

1109

5:20

2:8

31

D+

X27:8

X1:29A

10A

F24

2

1

X1:39

X34:R

X1:40

F24:2

X1:117

P

B21

X1:106

A80 Datensammler data−collector

VCC

5:3

X1:111

2

X1:94

P

1 B03

X1:112

X21:1

2

X1:117

X10:3

R03

X10:2

08.03.2007 Vogt 08.03.2007 Seis

X1:94

X21:2

Q

1 B55

X1:105

11:1

0 .. 67 OHM

X1:29E

X1:107

connector−colour: X26−grey; X27−black

Steckerfarbe: X26−grau; X27−schwarz

ESX Fahrsteuerung

X8:1

X8:2

B124

X1:108

5:17

2:16 5:17

F05:2 CAN1+ CAN1−

CAN1 high

X27:6

K11:87

CAN1 low

X27:7

30

X26:3

DIN3

X26:5

DIN5

Hydraulikölfilter hydraulic oil filter

X1:164

X1:149

Datensammler, LC−Display data−collector, LC−display

BL 12:17 BR 12:17 BEL 12:4

X1:82

X1:87 X1:88

X1:80

DIOS Platten

A81 LC−Display LC−display

CAN1+ 8:14 CAN1− 8:14

14

13

1

Schalter Motordrehzahl switch engine−rpm mode

S127

ECO Low High

X1:86

Ub "15"

X28:1

2:20

Nur bei EMRII only EMRII

X1:41

X26:8

DIN8

Luftfilter air cleaner

X26:10

DIN10

Kühlmittelvorrat coolant stock level

X27:4

Sepa1

X27:2

UIN1

Füllstand Diesel fuel−level

BOMAG

Wasserabscheider water−seperator

X27:9 Sepa2

X26:9 DIN9

X26:1 DIN1

X26:2 DIN2

X26:6 DIN6

X26:4 DIN4

X26:11 DIN11

X27:10 UIN3

X27:11 UIN2

X27:12 AIN2

X27:1 AIN1

X27:3 GND/UIN3

X27:5 GND

X26:12 GND

CAN1 high

X28:3 X28:2 GND

CAN1 low

X28:4 X29:1 DIN1

X29:2 DIN2

X29:4 DIN4

Ub "30"

X28:5 X29:3 DIN3

not connected

X28:6 DIN5

X29:5

not connected

X29:8 X29:6 DIN6

Ub out

down

14

up

13

23

1

24

30 9:1 K11:87 8:14 F24:2 7:13

Wiring diagram

008 911 79

006

582 702 32

31 7:1

Schalter Frequenzverstellung switch frequency−control

24

S139

23

X29:7

1110

5:20

19.2

X43:2

6:20

31

B132

X51:3

X1:149

X43:1

5:6

X34:J

X1:55

8,5V

1

1

2

1

2

X1:203

Lenkwink.

2

X1:197

Y92 d

1

2

2

1

X1:56 FM1 X1:57

X1:162

X41:2

X41:4 X39:4

X40:4

X41:3 X40:1

X1:159

X41:1 X39:1

X1:161 X1:160

A34 Fahr−Steuerung driving controller

1

2

Prop. Ventil lenken rechts prop. valve steering right

Prop. Ventil lenken links prop. valve steering left

X1:197

Y93 b

X1:195

X35:23

X1:196

X35:29

08.03.2007 Vogt 08.03.2007 Seis

X1:154

−

X1:62 FM3 X1:63

0V

0V

VCC

VCC

A45

A

A

B

B

X39:3

X40:3

X40:2

X39:2

X35:19

X35:43

X35:22

X35:41

X35:18

Lenkung, Vibration steering, vibration

S1

S2

S1

X35:43

FM3

Schnellverschl.−Platten

S 5:4

X35:21

Lenkeinheit steering unit

nur BVC only BVC

7:14

K43

8:13

8:13

85

86

2

1

X6:2 X1:118

gg

+

br

sw

2

X7:1 1

Anbau 213DH: oben

−

+

9:2

9:2

8:2 87a

X1:117

a1 2

1

1

9:2 X1:113 BRAKE MESX Y04 1

12

VIB

8:1

19.2 007

582 702 32

X1:190 31

S01:22

13:6

bl

BTS BREMSE 8:2

Magnetventil Bremse solenoid valve brake

H07

X1:150

2:15

S01

X1:147 11

30 K48 87

Warnsummer Störung warning buzzer, failure

Prop−Ventil Vibration groß prop. valve vibration big

X1:82

GA MESX

KA MESX

X1:89

X22:3

bei BW177 u. 213 m. Sauer Motor bl / bei BW213−226 m. Rexroth Motor sw

Anbau 177DH: h.l. b

X7:2

Y07

X1:115

X1:37

X1:38

7:12 87a

X22:2

bei BW177 u. 213 m. Sauer Motor sw / bei BW213−226 m. Rexroth Motor bl

−

Aufnehmer Vibrationsmotor sensor vibration motor

Prop.−Ventil Vibration klein prop. valve vibration small

Anbau 213DH: unten

Anbau 177DH: h.r. a

X6:1 Y08

30 K43 87

X1:116

ws

X22:4

B16

br

X22:1

X1:187

X1:41

X1:189

X1:201 B65 +

Vib.− Richtung

X51:1

F24:2

X1:42 X1:188

Lenkwinkelsensor steering angle sensor

X1:55 X1:202

Armlehne

8:1

AGND

X35:1

X35:16

X23:1

X35:20

X41:5 X1:205

X41:7 X1:207

X41:6 X1:206

X41:8 X1:208 X35:22

X35:40 Pumpe Vib.−Platten

Vib.− Frequenz

X35:35

Schalter Armlehne armrest−switch

X51:2

X35:3

X1:148

6:20

X35:61

S01:22

X1:60 FM5 X1:61

400 ... 1.200mA

X1:58 FM2 X1:59

400 ... 1.200mA

X35:2 Umsch. Amplitude

X35:48 Prop. out 400 ... 1.200mA

BOMAG

max.1.8A

− Warnsummer

BTS Bremse

X35:17

Sig. 150mA

Bremse

008 911 79

4:20

Wiring diagram

1111

7:17

7:20

31

K48

85

86

2:12

K05

X1:149

85

86

X1:153

Ub in

9 10

2

1 3 4

08.03.2007 Vogt 08.03.2007 Seis

Add2

Add1

0V in

BTS zus.

BTS Bremse

1

DK Ext1

Bremse auf = Ub

2

Stecker X24 3 4 5 6

Stecker X23

S55 Fahrhebel travel lever

DK Ext2

Bremse zu = 0V

13

7

4

3

Schalter Amplitude switch amplitudes

8

5

2 1

24

23

7

14

13

Nur bei BVC Only at BVC

S09

AK Ext2

AK Ext1

0V (Ref PIN5)

+5V out

CAN+

CAN−

8

X1:157

X1:156

S

14

13 S36

14

13

7:11

7:11

S139

S42

X35:22

X35:43 X1:215

S − +

X1:211

Y98

X1:210

Schalter Betriebsart Platten modesw. plates

X1:212

S

+

S

2

Y122 1

2

Y123 1

X62:7 2

Y142 1

X62:12 A54 Platten Steuerung plate−controller

bl

B134 −

20A

X1:209

X1:31A

2

1 F145

X1:31E

X62:2

X1:214 2

2

Y144.2 1

Y144.1 1

2

Y143 1

CAN1+ 9:16 CAN1− 9:16 K11:87 9:1

31

9:1

2

Y145 1

BTM

Wiring diagram

1

1

008 911 79

008

582 702 32

MV Platten heben MV Platten rechts plates up plates right MV Platten Schwimmst MV Platten senken plates down plates float−pos. Prop−Pumpe Platten MV Platten Priorität MV Platten links prop.−valve plates plates left plates priority

2

1

bl

B135 −

+

Näherungssch. Platten oben sensor plates up Näherungssch. Platten Mitte sensor plates centered

Schalter Schwimmstellung Platten sw. swimming pos. plates Frequenzverstellung Platten freq. adjust plates

S64

+ −

Fahrstufenschalter speed range selector

Fahrhebel, Vibrationsplatten joystick, vibration−plates

Schalter Vibration Ein/Aus switch vibration on/off

11 12

8

7 6 5

Taster 8 = Infotaste 2 push button 8 = Info button 2

Taster 7 = Infotaste 1 push button 7 = info button 1

nicht bei BVC not at BVC

14

S35 K0G

DK Ext3

BTS BREMSE

DK Ext5

7:18

DK Ext4

Taster 5 = platten senken push button 5 = lower plates

Ub out

BOMAG DK Ext6

Taster 4 = Platten links push button 4 = plates left

X50:2

Taster 3 = Vibration EIN/AUS push button 3 = vibration ON/OFF

X50:3

Taster 2 = Platten heben push button 2 = lift plates

X25:2 X25:4

X63:1 X63:2 X50:1

Taster 1 = Platten rechts push button 1 = plates right

X25:3

X63:1

6:20

Schnellverschluss − Kupplung quick connecting clutch 400 .. 1.200 mA

br sw

X62:4

X63:2

CAN1− K11:87

X62:11

br ws

CAN1+

X62:3

6:14 6:14

X62:5

LC−Display

X62:8

CAN2−

X62:9 X62:10

CAN2+

X62:6

5:17 5:17

X1:213 X62:1 X62:13

ESX Fahrst.

X62:15

7:2 X23:1

X62:14

1112 OV out

19.2

8:20

2:8

7:17

5:3 5:3 5:8

7:15

7:15

F148:2

15A

10:2

X1:35A

08.03.2007 Vogt 08.03.2007 Seis

Elektronik

X44:32

X44:59

X2:54

X48:3

X48:2

BEL MESX

X2:55

X48:4

15g/bl

−/gg

B62

X48:1

12:4

B62

X49:1

X2:57

X2:59

X49:4

15g/bl

−/gg

X2:49

X2:58

X49:3

X49:2

X2:60

31

BRAKE MESX D+ MESX

Y140

X44:60

PITCH MESX

X44:37

X2:75

2

X2:53

Prop.

GA MESX SPEED MESX DIR MESX

KA MESX

A83 Messtechnik−Rechner measurement calc. unit

Pot. 15

X2:57

2

X44:28

10A

X44:15

X1:32A

Aufn. vorne 15g

X2:56

X44:29

1

Aufn. vorne 20g

F146

X44:56

X44:38

20g/br

+/sw X44:31

F148

Aufn. hinten 15g

X1:35E

X44:30

1

X44:41

20g/br Aufn. hinten 20g

X1:32E

Leistung

X44:57

X44:35

2

400 .. 1.200mA

Y141

X2:73

X2:74

X2:69

X47:C

2

1

S/ws

B61

X2:52

Variocontrol, Messtechnik Variocontrol, measurement equipm.

Prop−Ventil Erreger ab solenoid valve exciter down

Prop−Ventil Erreger auf solenoid−valve exciter up

X2:76

X44:47 1

X47:B

X47:A

+/rt

X2:68

2

1

X2:67

X2:78

FM4

X2:77

8.5V

X44:23

Pot 15

X44:46

F146:1 10:2

Prop.

K11:87 12:1

400 .. 1.200mA

−/sw Erregerpos.

K11:87

X44:9

8:20

GND

Pot 30

X44:1

X2:71

X2:63

AGND MESX

X44:55

30

X2:66

RxD

X2:64

X4:A

X74:1

P11

X44:66

5:9

X2:66

TxD

X2:65

X4:B

X74:2

X2:70

+

−

nur bei BEM only at BEM

EVIB−Meter EVIB−meter

X1:82

P07 E VIB

X1:85

8:20

8:20

F1

F2

X2:79

−

CAN3+

1

X44:25

CAN1+

X2:50

CAN1−

CAN1+

+

Bedieneinheit BEM control−unit BEM

P16

DIOS Platten

Drucker printer

X44:3

Aufnehmer Verstellmotor sens. adjust. motor

X44:67

CAN+

6:20

X44:58

X44:14

X44:54

X44:36

nur bei BTM prof only at BTM prof X44:65

X4:C X74:3 X44:4

X4:E

X4:D X74:5 X44:5

+/sw X44:7 v.l.

EVIB

Beschleunigungssensoren acc. sensor rear

X44:25

CAN− X44:27

Beschleunigungssensoren acc. sensor front

v.r.

GPS

X42:2

X42:5

X42:4

10:2

1

CAN3+

CAN3−

CAN3−

10:2

10:2

31 10:1

X46:E

X42:3

X2:49

19.2 009

582 702 32

CAN1−

X2:51

X46:F

X46:D

P33

X46:A

X42:1 X46:B

X2:48

X2:47

30 12:1

Display Messtechnik BOP display measurem. BOP

R24 1 2 60 OHM

nur bei BEM only at BEM X44:53

X74:4

X44:68

BOMAG

0..6VDC

X44:33

X1:34A

nur bei BTM+/BTM prof only at BTM+/BTM prof

008 911 79 X44:26

Wiring diagram

1113

1114

BOMAG

9:20

31

9:5

9:17

9:4

F146:1

X44:25

F148:2

9:18 CAN3+

9:18 CAN3−

08.03.2007 Vogt 08.03.2007 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

nur bei BCM only at BCM

BCM 05

P15

X75:2

X4

X2

R25 1 2 60 OHM

61

A87 USB−CAN Schnittst. USB−CAN Interface BCM

X4:F

G

70

CAN3+

M

62

CAN3−

Wiring diagram

008 911 79

010

582 702 32

31 11:1

19.2

ZA option

08.03.2007 Vogt 08.03.2007 Seis

Steuereinheit control unit

A66

Diebstahlschutz System DH−4 anti − theft system

A67 Keyboard keyboard

008 911 79

BOMAG

H80

+

−

X68:2

VAL

0

ANN

X68:1

9

8

7

6

3

5

2

4

1

1

1

19.2 011

582 702 32

Wiring diagram

1115

87a

2

2

E16 1 E17 1

9:7

Scheinwerfer rechts head light RH

31 Scheinwerfer links head light LH

11:12

87

12:9

S15

85

86

X1:301

12

11

24

23

BEL 6:9

08.03.2007 Vogt 08.03.2007 Seis

K06

X1:43

BEL MESX

12:10

13

32

31

S16 14

X1:84

012

Anschluß Arbeitsschein− werfer ohne StvZO connection working head lights without StvZO

Schalter StvZO switch, StvZO

X1:24A

10A

X1:23A

F10

10A

X1:24E

F09

X1:23E

connection working head lights without StvZO

Anschluß Arbeitsschein− werfer ohne StvZO

X1:312

K16 30

X1:309

X1:26A X1:83

2

2

2 K16

Schlußleuchte rechts tail light, RH

12:2 Schlußleuchte links tail light, LH Parkleuchte links parking light, LH Parkleuchte rechts parking light, RH

2

E13 1 E12 1 E14 1 E15 1

X1:323 X60:4

X1:310

86

85

E

5

X1:22E 4

01

R

Beleuchtung und StvZO illumination and StvZO

Connection head lights acc.to ROPS/SD

Anschluß Arbeitsscheinwerfer bei ROPS/SD Aufbau

X3:1

1

1

13:1

Wiring diagram Blinkleuchte HR indicator rear, RH

008 911 79

012

582 702 32

Blinkleuchte VR indicator front, RH

Blinkleuchte VL indicator front, LH Blinkleuchte HL indicator rear, LH

Bel. Warnbinkschalter illumination, switch hazard light

31

2 2

2

2

2

2

2

2

−

E11 1 E10 1

E09 1 +

24

23

BR

BL

L

49R

Schalter Blinker switch indicator

E08 1

H06

14

13

6:9 6:9

49L

24

14

A02 31 82

30

23

13

E25 1

Warnblinkschalter switch, hazard light

S14

Anschluß Arbeitsscheinwerfer D bei Kabine Connection head lights with cabin STV1 13:17 STV2 13:17

L0R

E23 1

X3:5

X1:22A

15A

F19

S37

15A

X1:25A X1:305

E28 1

87a

X1:19A

F08

X1:25E

K11:87 30

E27 1

X3:4

X1:21A

15A

F22

X1:21E

87

12:4

K06

30

X1:19E 15A

0,42A

X58:5

X1:315 X58:6

X1:319

X60:3

X1:320

X1:18A

4,6A

X1:311 X58:3 X1:315 X58:6

Arbeitsscheinwerfer hinten links working head lights, rear lh. 4,6A

Schalter Arbeitsbele switch, working head lights

10A

4,6A

X1:302

X1:2

X1:304

15A

4,6A

X1:303

F07

0,42A

Arbeitsscheinwerfer vorne links working head lights, front lh. 4,6A

X59:5

X1:316 X59:6

Arbeitsscheinwerfer hinten rechts working head lights, rear rh.

F18

4,6A

0,125A

X1:26E

1,75A

X59:3 X1:316 X59:6

X1:313 X1:315 X58:6

F11

0,42A

Arbeitsscheinwerfer vorne rechts working head lights, front rh.

X1:306

X1:18E

0,42A

X1:321 X1:323 X60:2

K11:87 30

1,75A

9:3

1,75A

X58:2

1,75A

0,125A

X1:307 X60:1

X1:316 X59:6

X61:3 X1:324 X61:4

X1:314 X59:2

X1:322 X61:1

BOMAG

X1:324 X61:2

1116

9:19

19.2

13:6

2:19

K32:86

85

86

12:20

31

Relais Kabine relais cabin

K32

R80

2

1

13:16 87

K141

S45

E29

10A

F42

TK

2

1

8

H

−

+

+

−

+

−

−

A12

B51 +

08.03.2007 Vogt 08.03.2007 Seis

Türkontaktschalter door switch

S86

A01

2

E71 1

87a

30

7

G

Kontrolleuchte indicator

15A

max. 13A

1,75A

Innenleuchte inside light, cabin

F143

Schalter Innenleuche switches interior lights

31

30

87a

7:18

VIB X3:18 5

7,8,9

X3:17 4 5:3 SPEED TAC A16

3

2

1

6

Tachographenmodul module, tachograph

Radio radio

− −

15 + + B51

87

A5+A6

P09

A2+A3

X55:2

M05

M

5

2

1

A

4

Wischer hinten windscreen wiper, rear

Wascher hinten washer rear

− M07

M

+

X55:1

X56:2

M04

M

5

2

2

B

4

13:9

E70

F130

10A

F130

S158

4

3

2

1

3

C

K141

I

Wascher vorn washer front

13:2

2

1 E28

E72

E27

2

1

F130 14:7

STV1

STV2

1

2

−

+

1

XS 12V

1

5

5

E

K32:87

F41:5

14:14

15A

F144

14:11

−

+

6

F

14:2

Rundumkennleuchte rotary beacon

31 14:1

KABINE 31

2

1

S38

10A

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

12:13 12:13

Schalter Nachtleuchte switch, night illumination

− M06

M

+

Wischer vorne windscreen wiper, rear

S20

01W 7 01

15A

F44

Kabinenausrüstung, Beleuchtung, Radio, Tachograph cabin−equipment, headlights, radio, tachograph

Tachograph tachograph

C3

B4

B3

A1

S21

01W 7 01

F42 14:8 F130 13:14

15A

F43

X55:3

30

2,9A

K32

3,8A

13:1

X56:4

X3:7

X56:3

X3:8

4,7A

14:14

X56:1

F42:H

3,8A

0,83A

Nachtleuchte night illumination

2:14

Heizung Heckscheibe heating rear screen

4,6A

X3:6

3 min

4,6A

K30

X55:4 X3:1

Abfallverzögert

BOMAG X3:2

Steckdose socket

008 911 79 5A

Wiring diagram

013

582 702 32

19.2

1117

Schalter Kabinenlüfter switch blower cabin

0123

13:20

31

Stufe 3: 11.5A pro Lüfter

Stufe 2: 4.5A pro Lüfter

rt

M

br

Kabinenlüfter cab ventilator

Stromaufnahme Lüfter / current blower

Stufe 1: 3.0A pro Lüfter

ge

M09

X53:L

X3:9

X17:1 X1:163

S44

or

X3:12

ge

Bedienteil Kabinenheizung/Klimaanlage

Kabinenlüfter cab ventilator

br

rt

M

or

2

X18:2

_t

B131

X18:1

X1:167

X3:14

13:19

2

1

2

1 X54:1

KABINE 31

Magnetventil Heizung solenoid valve, heating unit

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

Kabinenheizung, Klimaanlage, Zusatzheizung cabin−heater, air conditioning, add. heater

1

2

V06

Potential 30 aus Kabine

V04

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

2:10

K09

X3:13

X54:6

control−unit cab−heater /air conditioning

X1:164

X17:4

M09

08.03.2007 Vogt 08.03.2007 Seis

X53:C

X53:M

X3:10

X17:2 X1:165

X53:B

4

D

Thermofühler Klimaan temperature sensor air conditioning

20A

X53:H

X3:11

X17:3 X1:166

13:17 F130 F42 Potential 15 aus Kabine 13:9

X20:3 Überwachung Kühlmitt monitoring coolant pressure

F31

X20:4 3,5A

1A

BOMAG X1:190

Thermofühler Heizung temperature sensor heating unit

13:19 K32:87 Potential 15 aus Kabine

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

13:19 F41:5 F42:H 13:4

Option option

1118 2.5qmm

1

Schaltuhr Heizung heater timer 1

2

5

6

8

4

31

9

12

10 1

BOX2

11 3 S28

7

2

B

Wiring diagram

008 911 79

014

582 702 32

5A

F15

19.2

Name

Benennung

Bl. 012 013 013 005 007 007 003 004 008 011 011 014 006 006 009 010 010

Pf. 17 5 6 6 6 9 3 9 17 9 15 11 3 18 6 18 7

Blinkgeber Radio Elektronik Tachograph Prozessorplatine Prozessorplatine Lenkrad Elektronische Motorsteuerung Elektronische Motorsteuerung Modul Pumpenansteuerung Elektronik Steuereinheit Eingabeeinheit Steuergeraet Klimaanlage, Heizung Modul Datensammler Anzeigeeinheit Elektronik Messtechnik USB−CAN Schnittstelle BCM GPS Antenne

flasher Radio Electronic system, tachograph Prozessing circuit board Prozessing circuit board Steering wheel Electronic engine management Electronic engine management Modul pump control Electronic control unit Keyboard Control unit,air conditioning,heating modul data−collector Display−Unit electronic measurement−equipment USB−CAN Interface BCM GPS antenna

B03 B11 B11 B16 B21 B51 B51 B55 B57 B59 B60 B61 B62 B62 B65 B88 B88 B93 B103 B104 B112 B113 B113 B114 B114 B115 B124 B124 B126 B130 B130 B131 B132 B133 B134 B135 B145

006 002 002 007 006 013 013 006 005 005 005 009 009 009 007 003 004 004 014 014 005 003 004 003 004 003 004 006 003 003 004 014 007 004 008 008 004

3 16 18 14 2 4 6 4 6 4 2 12 8 10 4 6 15 13 7 7 3 13 14 7 7 11 5 6 14 8 8 10 2 12 17 16 17

Unterdruckschalter Luftfilter Signalhorn Signalhorn Aufnehmer Vibrationsfrequenz vorne Differenzdruckschalter Hydr.−Oelfilter Lautsprecher Radio Lautsprecher Radio Kuehlmittelstand Ausgleichsbehaelter Neigungssensor Stufenumschaltung Aufnehmer Bandagengeschwindigkeit Aufnehmer Achsgeschwindigkeit Aufnehmer Verstellzylinder Beschleunigungsaufnehmer Beschleunigungsaufnehmer Sensor, Lenkwinkel vorn Druckgeber Motoroel Druckgeber Motoroel Leistungskraftstoffdruck Sensor RPS Temperaturschalter Klimaanlage Druckschalter Klimaanlage Druckgeber Fahrpumpe EMR Temperaturgeber Kuehlmittel EMR Temperaturgeber Kuehlmittel EMR Aufnehmer, Motordrehzahl 1 EMR Aufnehmer, Motordrehzahl 1 Geber Ladeluftdruck Geber Wasserstandsabscheider Diesel Geber Wasserstandsabscheider Diesel EMR Temperaturgeber Kraftstoff EMR Aufnehmer, Motordrehzahl 2 EMR Aufnehmer, Motordrehzahl 2 Temperaturschalter Heizung Inititator Armlehne links Sensor Ladeluftdruck / −temperatur Näherungsschalter Platten oben Näherungsschalter Platten mitte Sensor Niederdruck Kraftstoff

Vacuum switch, air cleaner Warning horn Warning horn Transducer, vibration frequency, front Pressure diff. switch, hydr. oil filter Speaker radio Speaker radio Coolant charge expansion tank Slope sensor, speed range selection Sensor, drum speed Sensor, axle speed Sensor, ajustable zylinder Acceleration sensor Acceleration sensor Sensor, angularity steering, front Sender, engine oil pressure Sender, engine oil pressure Rail pressure sensor Temperature switch, air conditioning Pressure switch, air conditioning pressure sender, driving pump EMR Temperature switch, collant EMR Temperature switch, collant EMR Trancducer, engine speed 1 EMR Trancducer, engine speed 1 Sender, charging air pressure Sender, water separator fuel Sender, water separator fuel EMR fuel temperature sender EMR Trancducer, engine speed 2 EMR Trancducer, engine speed 2 Temperature switch, heating proximity switch left arm rest sesnor charging air prssure / temperature proximity switch, plate up proximity switch, plate middle fuel low pressure sensor

E08 E09 E10 E11 E12 E13 E14 E15 E16 E17 E23 E23 E25 E25 E27 E27 E28 E28 E29 E30 E32 E70 E71 E72

012 012 012 012 012 012 012 012 012 012 012 013 012 013 012 013 012 013 013 014 013 013 013 013

17 18 19 19 7 6 7 8 2 2 11 18 12 19 10 17 11 17 3 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 F05 F07 F08 F09 F10 F11 F13 F15 F18 F19 F22 F23 F24 F31 F39 F40 911 F41

002 002 012 012 012 012 012 002 014 012 012 012 002 006 014 002 014 013

6 13 15 18 6 8 2 11 19 5 12 10 18 2 3 19 15 19

Hauptsicherung Batterie Sicherung Steckdose Sicherung Warnblinker Sicherung Blinker u. Arbeitsscheinw. Sicherung Park− u. Schlussl. links Sicherung Park− u. Schlussl. rechts Sicherung Scheinwerfer links Sicherung Startschalter Sicherung Heizgeraet Vorsicherung Arbeitsscheinw. vorne Sicherung Arbeitsscheinw. vorne li. Sicherung Arbeitsscheinwerfer hinten Sicherung Signalhorn Sicherung Ueberwachungsmodul Sicherung Kabinenluefter Hauptsicherung Kabine Sicherung Kabinenheizung Sicherung Rundumkennleuchte

Wiring diagram

08.03.2007 Vogt 08.03.2007 Seis

Bauteilliste component listing 1 11 101

582 702 32

008

title

A02 A12 A16 A34 A34 A45 A48 A48 A54 A66 A67 A72 A80 A81 A83 A87 A93

79

Fuse, main, battery Fuse, socket 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, 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, cabin ventilator Main fuse, cab Fuse, heating unit cab BOMAG Fuse, rotary beacon

TYP

19.2

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 10A 15A 15A 10A 10A 15A 30A BOX2 30A 15A 15A 15A 10A 20A 15A BOX2 10A

1119

Name F42 F43 F44 F48 F67 F68 F84 F93 F95 F97 FM1 FM2 FM3 FM4 FM5 F124 F130 F143 F144 F145 F146 F148 F150

Bl. 013 013 013 002 005 002 005 004 002 014 007 007 007 009 007 002 013 013 013 008 009 009 010

G01 G02 G03

19.2

08.03.2007 Vogt 08.03.2007 Seis

Bauteilliste component listing 2 11 102

582 702 32

1120

Pf. 3 10 13 5 7 8 9 3 15 13 6 6 5 11 6 17 15 2 20 18 5 2 14

Benennung

title

TYP

Sicherung Kabineninnenleuchte Sicherung Wischermotor hinten Sicherung Wischermotor vorn Sicherung Gluehanlage Sicherung Steuerung (Potential 30) Sicherung Potential 30 Sicherung Steuerung (Klemme 54) Sicherung Steuerung (Potential 30) Sicherung Motormanagement intern Sicherung Frischluftluefter Platinensicherung Platinensicherung Platinensicherung Platinensicherung Platinensicherung Sicherung Kraftstoffvorwärmung Sicherung Nachtleuchte Sicherung Heckscheibenheizung Sicherung Kabinensteckdose Sicherung Anhängeplatten Sicherung Steuerung MESX (Potential 30) Sicherung Steuerung MESX (Potential 15) Sicherung GPS Receiver

Fuse, inside light cab Fuse, wipermotor rear Fuse, wipermotor front Fuse, glow plug system Fuse, controller (pot.30) Fuse, potential 30 Fuse, controller (Pin 54) Fuse, controller (pot. 30) Fuse, engine controller (internal) fuse, blower fresh air Multifuse Multifuse Multifuse Multifuse Multifuse Fuse, fuel pre−heating Fuse, night lamp fuse rear screen heating unit Fuse cabin−socket fuse vibration plates Fuse Controller (Pot. 30) Fuse Controller (Pot. 15) Fuse, GPS receiver

002 6 002 7 002 5

Batterie Generator Batterie

Battery Generator Battery

103A

H06 H07 H14 H80

012 007 005 011

15 16 11 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

LED ROT 0.15A MAX O,46A LED

K05 K06 K09 K11 K14 K16 K32 K41 K43 K48 K61 K14.2 K141

008 012 002 002 003 012 013 004 007 008 002 004 013

3 4 10 11 19 9 1 2 12 2 7 20 16

Relais Startstrom Relais Scheinwerfer hinten Relais Klimageraet Relais Klemme 30 auf 15 Relais Vorgluehen Relais Scheinwerfer vorne Relais Kabine Trennrelais D*Relais Vibration Relais Fahrhebel 0−Stellung Relais Ladekontrolle

Relay, starting current Relay, head lights, rear Relay, air conditioning Relay, terminal 30 to 15 Relay, glow plug system Relay, head lights, front Relay, cabin Relay, separation E*relay, vibration Relay, travel lever 0−position Relay, charge control

Relais Heckscheibenheizung

relay, heating rear screen

BOSCHW BOSCHW BOSCHW BOSCHL TYCOX BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW TYCOX BOSCHW

M01 M04 M05 M06 M07 M09 M09 M17

002 013 013 013 013 014 014 014

12 12 10 13 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

P07 P09 P11 P15 P16 P33

009 013 009 010 009 009

15 8 14 18 16 18

Omegameter Frequenz− und Geschwindigkeitsanzeige Drucker BCM 03 Bildschirm Diagnose, Variomatic Opus 21

Omegameter Frequency− and Speedometer Printer BCM 03 terminal Diagnostics, varimatic Opus 21

R03 R10 R19 R20 R21 R22 R23 R24 R25 R79 R80 R81 R82 R83 R84 R85 R86

006 002 002 005 005 005 005 009 010 002 013 002 002 002 002 002 002

5 8 4 15 15 12 12 17 18 15 2 1 1 2 2 2 3

Geber Tankanzeige Parallelwiderstand Heizflansch Widerstand Widerstand Widerstand Widerstand Widerstand Widerstand Kraftstoffvorwärmung Heizung Heckscheibe Gluehstiftkerze 1 Gluehstiftkerze 2 Gluehstiftkerze 3 Gluehstiftkerze 4 Gluehstiftkerze 5 Gluehstiftkerze 6

Sender, level gauge Parallel resistor heater flange Resistor Resistor Resistor Resistor Resistor Resistor fuel pre−heater heating rear screen glow plug 1 glow plug 2 glow plug 3 glow plug 4 glow plug 5 glow plug 6

S00 S01 S03 S06 S09 S14 S15 S16 S20 S21 S28 S30 S35 S36 S37 S38 S42 S44

002 002 002 005 008 012 012 012 013 013 014 002 008 008 012 013 008 014

11 15 18 10 8 15 4 4 13 10 19 5 7 11 18 19 11 3

Startschalter Schalter NOT AUS Taster Signalhorn Sitzkontaktschalter links Vibrationsschalter vorne Warnblinkschalter Beleuchtungsschalter StVZO Schalter Arbeitsbeleuchtung vorne Schalter Scheibenwischer vorne Schalter Scheibenwischer hinten Schalter Kabinenheizung Batterietrennschalter Vibrationsschalter klein/gross Vibrationsschalter Schalter Blinker Schalter Kennleuchte Stufenumschalter schnell−langsam Schalter Kabinenluefter

Starter switch Switch, emergency off Push button, warning horn Switch, seat contact, lh. Switch, vibration, front Switch, hazard light Switch, lighting StVZO Switch, working head lights, front Switch, windscreen wiper, front Switch, windscreen wiper, rear Switch, cabin heating Switch, battery disconnect Switch, vibration low/high Switch, vibration Switch, indicator Switch, warning light Speed range selector, fast−slow BOMAG Switch, cabin ventilator

10A 15A 15A 125A 15A 5A 10A 25A 10A 3A MULTIFUSE MULTIFUSE MULTIFUSE MULTIFUSE MULTIFUSE 25A 10A 15A 15A 20A 15A 10A 5A

Wiring diagram

103A

2.3 KW 4,7A 2,9A MAX. 3,8A MAX. 3,8A

0 .. 67 OHM 82 OHM 167A 120 OHM 120 OHM 120 OHM 120 OHM 60 OHM 60 OHM 250W MAX. 13A

NOTAUSH

008 911 79

Name

Benennung

Bl. 013 008 008 013 006 006 008 013 013

Pf. 3 6 10 3 17 19 13 15 16

Schalter Kabineninnenleuchte Schalter Fahrhebel Schalter Schwimmstellung Schalter Tuer, links Schalter Motordrehzahl Schalter Frequenzverstellung Schalter Frequenzverstellung Schalter Nachtbeleuchtung Schalter Heckscheibenheizung

Switch, cabin inside light Switch, travel control lever Switch, float position Switch door, lh. Switch, engine rpm Switch, frequency control Switch, frequency control Switch, cabin night lamp switch rear screen heating unit

V01 V02 V03 V04 V06

002 002 002 014 014

9 17 18 8 9

Diode Diode Diode Diode Diode

Diode Diode Diode Diode Diode

002 005 012 002 002 002 002 002 002 007 007 006 006 006 007 007 012 005 005 005 005 005 005 005 005 005 005 005 007 007 007 007 007 007 007 007 007 002 006 005 006 007 009 012 012 009 006 006 006 007 004 004 004 006 006 003 003 002 002 002 002 002 002 006 006 004 006 004 006 002 002 006 006 007 005 007 007 005 006 006 007 007 005

7 9 10 11 11 13 13 6 6 15 15 2 2 3 14 15 4 3 2 8 14 15 16 16 12 12 13 13 4 6 6 6 6 6 6 5 5 11 16 17 13 16 15 5 4 15 16 13 14 16 18 18 19 3 4 19 19 16 18 16 18 16 18 5 2 5 6 5 7 7 7 3 4 17 11 15 14 11 2 5 17 14 2

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 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 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 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 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 ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK

Wiring diagram

08.03.2007 Vogt 08.03.2007 Seis

Bauteilliste component listing 3 11 103

582 702 32

008

title

S45 S55 S64 S86 S127 S139 S139 S158 S163

X1:1 X1:2 X1:2 X1:3 X1:4 X1:7 X1:8 X1:9 X1:10 X1:37 X1:38 X1:39 X1:40 X1:41 X1:41 X1:42 X1:43 X1:44 X1:45 X1:46 X1:47 X1:48 X1:49 X1:50 X1:51 X1:52 X1:53 X1:54 X1:55 X1:56 X1:57 X1:58 X1:59 X1:60 X1:61 X1:62 X1:63 X1:79 X1:80 X1:82 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 X1:94 X1:94 X1:95 X1:96 X1:97 X1:98 X1:101 X1:102 X1:103 X1:104 X1:105 X1:106 X1:107 X1:107 X1:108 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 X1:118 911 X1:11979

WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX 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

19.2

FE5B FE5B FE5B FE5B

1121

Name

19.2

08.03.2007 Vogt 08.03.2007 Seis

Bauteilliste component listing 4 11 104

582 702 32

1122

X1:120 X1:121 X1:122 X1:123 X1:123 X1:123 X1:124 X1:124 X1:141 X1:142 X1:142 X1:143 X1:143 X1:143 X1:144 X1:145 X1:146 X1:147 X1:148 X1:149 X1:149 X1:149 X1:149 X1:14A X1:14E 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 X1:164 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 X1:175 X1:176 X1:177 X1:178 X1:179 X1:179 X1:17A X1:17E X1:180 X1:180 X1:181 X1:181 X1:182 X1:182 X1:183 X1:183 X1:184 X1:184 X1:185 X1:185 X1:186 X1:186 X1:187 X1:188 X1:189 X1:18A X1:18E X1:190 X1:190 X1:190 X1:191 X1:192 X1:193 X1:194 X1:195 X1:196 X1:197 X1:197 X1:198 X1:199 X1:19A X1:19E X1:201

Bl. 005 005 005 002 005 005 005 005 005 005 005 005 005 005 005 005 005 007 007 005 006 007 008 004 004 007 002 002 008 007 002 008 008 005 007 002 002 007 007 007 014 006 014 014 014 014 002 014 014 002 002 014 005 005 005 005 005 005 005 005 003 004 005 005 003 004 003 004 003 004 003 004 003 004 003 004 003 004 007 007 007 012 012 007 011 014 004 004 004 004 007 007 007 007 004 004 012 012 007

Pf. 4 12 13 11 12 13 16 18 16 18 19 15 19 19 15 9 9 17 2 10 12 2 3 3 3 17 15 15 3 4 18 9 9 10 7 11 11 7 7 7 3 11 5 3 4 10 10 10 7 13 13 7 2 2 2 2 4 6 5 4 2 9 7 7 3 18 3 18 5 19 2 3 2 13 19 2 4 20 14 15 14 2 2 19 12 8 14 14 13 13 6 5 5 6 5 5 15 15 4

Benennung 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 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 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 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 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 ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK 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

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

Wiring diagram

008 911 79

Name X1:202 X1:203 X1:205 X1:206 X1:207 X1:208 X1:209 X1:20A X1:20E X1:210 X1:211 X1:212 X1:213 X1:214 X1:215 X1:217 X1:218 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 X1:309 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 X2:43 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 X2:65 911 X2:66 79

Bl. 007 007 007 007 007 007 008 002 002 008 008 008 008 008 008 002 002 012 012 012 012 012 012 012 012 012 012 012 012 002 002 002 002 006 006 012 012 012 012 012 012 012 012 002 002 012 012 012 012 012 012 012 012 012 012 012 012 008 008 012 012 012 012 012 012 012 009 009 002 002 005 005 009 009 010 010 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 010 010 009 010 009 009 009

Pf. 4 4 11 11 11 11 18 8 8 14 14 15 19 19 13 15 15 10 10 12 12 6 6 8 8 18 18 5 5 15 15 18 18 2 2 5 5 9 15 18 18 18 2 19 19 2 7 7 17 19 2 7 17 2 7 19 6 18 18 8 18 19 6 18 8 19 2 2 17 17 9 9 5 5 14 15 18 19 9 19 17 18 13 8 7 8 7 2 10 9 10 9 17 18 13 15 14 14 14

Benennung 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 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 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 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 ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK 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

Wiring diagram

08.03.2007 Vogt 08.03.2007 Seis

Bauteilliste component listing 5 11 105

582 702 32

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−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 Wago−measurement equip.

TYP

19.2

1123

Name

19.2

08.03.2007 Vogt 08.03.2007 Seis

Bauteilliste component listing 6 11 106

582 702 32

1124

X2:66 X2:67 X2:68 X2:69 X2:70 X2:70 X2:71 X2:73 X2:74 X2:75 X2:76 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 X3:17 X3:18 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 X14:A X14:B X15:1 X15:2 X16:1 X16:2 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 X25:2 X25:3 X25:4 X26:1 X26:2 X26:3 X26:4 X26:5 X26:6 X26:8 X26:9 X26:10 X26:11 X26:12 X27:1 X27:2 X27:3 X27:4 X27:5

Bl. 009 009 009 009 009 010 009 009 009 009 009 009 009 009 010 010 012 013 013 002 012 012 013 013 013 014 014 014 014 014 014 013 013 009 009 009 009 009 010 010 010 010 010 010 007 007 007 007 006 006 005 005 002 013 006 006 005 005 005 005 005 005 014 014 014 014 014 014 014 014 014 014 014 014 006 006 007 007 007 007 008 008 008 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006

Pf. 14 11 12 12 15 15 13 11 11 10 10 11 11 16 14 14 11 10 10 19 10 12 2 2 2 3 3 4 4 7 10 6 6 14 14 14 14 15 15 15 14 15 18 17 13 14 15 14 6 6 11 11 19 20 5 5 10 10 13 13 12 12 3 3 4 5 10 10 7 7 7 7 7 7 4 4 14 15 15 14 10 11 11 8 8 2 9 2 9 3 7 4 9 12 11 5 10 6 11

Benennung 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 SETCKER 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 KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. STECKER VIBRATION GRO STECKER VIBRATION GRO STECKER VIBRATION KLE STECKER VIBRATION KLE STECKER WASSERABSCHEI STECKER WASSERABSCHEI STECKER RÜCKFAHRALARM STECKER RÜCKFAHRALARM Steckdose Steckdose STECKER TAUCHROHRGEBE STECKER TAUCHROHRGEBE STECKER SITZKONTAKT STECKER SITZKONTAKT STECKER FAHRPUMPE RÜC STECKER FAHRPUMPE RÜC STECKER FAHRPUMPE VOR STECKER FAHRPUMPE VOR 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 ST. FAHRSTUFENSCHALTE ST. FAHRSTUFENSCHALTE ST. FAHRSTUFENSCHALTE STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER

title 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 Con 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 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. conn. vibration big conn. vibration big conn. vibration small conn. vibration small connector water separator connector water separator conn. backupalarm conn. backupalarm Socket Socket connector fuel level sensor connector fuel level sensor connector seat contact switch connector seat contact switch connectoe driving pump back connectoe driving pump back connector driving pump front connector driving pump front 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 connector switch speed ranges connector switch speed ranges connector switch speed ranges connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector BOMAG connector data collector

TYP

Wiring diagram

008 911 79

Name X27:6 X27:7 X27:8 X27:9 X27:10 X27:11 X27:12 X28:1 X28:2 X28:3 X28:4 X28:5 X28:6 X29:1 X29:2 X29:3 X29:4 X29:5 X29:6 X29:7 X29:8 X30:1 X30:1 X30:2 X30:2 X30:3 X30:3 X30:4 X30:4 X30:5 X30:5 X30:6 X30:10 X30:11 X30:12 X30:13 X30:14 X30:15 X30:17 X30:22 X30:23 X30:24 X30:25 X30:25 X30:28 X30:60 X30:61 X30:62 X30:63 X30:64 X30:72 X30:82 X31:1 X31:1 X31:2 X31:3 X31:4 X31:5 X31:6 X31:7 X31:7 X31:8 X31:8 X31:9 X31:10 X31:10 X31:11 X31:11 X31:12 X31:12 X31:13 X31:13 X31:14 X31:14 X31:15 X31:16 X31:16 X31:17 X31:18 X31:19 X31:19 X31:20 X31:20 X31:21 X31:22 X31:23 X31:23 X31:24 X31:24 X31:25 X31:26 X31:27 X31:31 X31:32 X31:33 X31:34 X31:40 X31:41 911 X31:4379

Bl. 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 003 004 003 004 003 004 003 004 003 004 004 003 003 003 003 003 003 003 003 003 003 003 004 004 004 004 004 004 004 004 004 003 004 003 003 003 003 003 003 004 003 004 003 003 004 003 004 003 004 003 004 003 004 003 003 004 003 003 003 004 003 004 003 003 003 004 003 004 003 004 004 004 004 004 004 004 004 004

Pf. 9 10 2 7 10 10 10 16 13 13 14 16 17 14 14 15 15 17 17 18 17 5 3 5 18 8 3 7 18 7 3 19 2 2 3 3 2 7 6 5 6 6 6 13 9 13 14 14 5 5 2 13 16 5 17 17 12 14 15 17 9 13 14 13 8 7 8 17 7 8 7 16 9 12 9 11 1 10 10 10 10 6 8 6 6 11 11 11 19 12 13 9 4 6 3 20 12 15 13

Benennung STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor

Wiring diagram

08.03.2007 Vogt 08.03.2007 Seis

Bauteilliste component listing 7 11 107

582 702 32

008

title connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine BOMAG EMR−connector engine

TYP

19.2

1125

Name

19.2

08.03.2007 Vogt 08.03.2007 Seis

Bauteilliste component listing 8 11 108

582 702 32

1126

X31:46 X31:47 X31:48 X31:49 X31:50 X31:51 X31:53 X31:54 X31:56 X31:57 X31:58 X32:A X32:A X32:B X32:B X32:F X32:G X32:G X32:H X32:H X32:K X32:K X32:L X32:M X33:1 X33:2 X33:3 X33:4 X33:5 X33:6 X33:7 X33:8 X34:A X34:B X34:C X34:D X34:G X34:H X34:J X34:N X34:P X34:R X35:1 X35:2 X35:3 X35:4 X35:5 X35:12 X35:15 X35:16 X35:17 X35:18 X35:19 X35:20 X35:21 X35:22 X35:23 X35:24 X35:26 X35:27 X35:28 X35:29 X35:30 X35:31 X35:33 X35:34 X35:35 X35:37 X35:38 X35:40 X35:41 X35:43 X35:46 X35:47 X35:48 X35:49 X35:53 X35:54 X35:55 X35:56 X35:57 X35:58 X35:59 X35:60 X35:61 X35:64 X35:65 X35:66 X35:67 X35:68 X36:A X36:B X37:A X37:B X38:A X39:1 X39:2 X39:3 X39:4

Bl. 004 004 004 004 004 004 004 004 004 004 004 003 004 003 004 004 003 004 003 004 003 004 003 004 003 003 003 003 003 003 003 003 005 005 005 005 005 005 007 003 002 006 007 007 007 005 005 005 005 007 007 007 007 007 007 007 007 005 005 005 005 007 005 005 005 005 007 005 005 007 007 007 005 005 007 005 005 005 005 005 005 005 005 005 007 005 005 005 005 005 002 002 002 002 002 007 007 007 007

Pf. 2 1 5 11 7 15 13 18 16 17 14 2 12 3 14 13 3 14 3 14 2 13 2 13 19 18 18 19 18 19 17 20 14 16 12 13 10 11 3 4 13 2 4 12 16 11 10 3 10 4 18 11 11 5 6 11 5 11 16 15 2 4 9 5 13 6 15 5 2 11 11 10 15 16 14 12 12 9 18 7 7 8 8 8 17 13 18 19 19 19 6 5 11 12 13 9 10 10 9

Benennung EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER EINSPEISUNG SCHALTKAS EINSPEISUNG SCHALTKAS ST. ZÜNDSCHLOSS E−KAS ST. ZÜNDSCHLOSS E−KAS STECKER STARTER E−KAS STECKER 1 LENKRAD STECKER 1 LENKRAD STECKER 1 LENKRAD STECKER 1 LENKRAD

title EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector supply e−box supply e−box connector ignition switch, e−box connector ignition switch, e−box connector starter, e−Box connector 1 steering unit connector 1 steering unit connector 1 steering unit BOMAG connector 1 steering unit

TYP

Wiring diagram

008 911 79

Name X40:1 X40:2 X40:3 X40:4 X41:1 X41:2 X41:3 X41:4 X41:5 X41:6 X41:7 X41:8 X42:1 X42:2 X42:3 X42:4 X42:5 X43:1 X43:2 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 X44:46 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 X50:1 X50:2 X50:3 X51:1 X51:2 X51:3 X52:1 X52:2 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 X56:2 911 X56:3 79

Bl. 007 007 007 007 007 007 007 007 007 007 007 007 009 009 009 009 009 007 007 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 008 008 008 007 007 007 005 005 014 014 014 014 014 014 014 014 014 014 014 014 013 013 013 013 013 013 013

Pf. 9 10 10 9 8 8 8 8 11 11 11 11 18 19 19 18 18 2 1 13 15 14 14 10 12 5 4 11 16 18 17 2 7 9 8 5 18 5 6 6 4 7 11 10 17 6 13 4 5 5 5 6 13 13 14 14 19 18 18 19 18 11 12 12 8 7 7 8 10 9 9 10 13 13 13 2 1 2 3 3 3 4 4 3 3 11 11 10 10 7 10 11 11 10 10 10 14 13 13

Benennung STECKER 2 LENKRAD STECKER 2 LENKRAD STECKER 2 LENKRAD STECKER 2 LENKRAD ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER SCHALTER ARML STECKER SCHALTER ARML 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 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 ST. PLATTENFREQ. ST. PLATTENFREQ. ST. PLATTENFREQ. ST. 1 LENKRADKABELBAU ST. 1 LENKRADKABELBAU ST. 1 LENKRADKABELBAU STECKER DRUCKSENSOR STECKER DRUCKSENSOR 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

Wiring diagram

08.03.2007 Vogt 08.03.2007 Seis

Bauteilliste component listing 9 11 109

582 702 32

008

title connector 2 steering unit connector 2 steering unit connector 2 steering unit connector 2 steering unit conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conector adapter BOP conector adapter BOP conector adapter BOP conector adapter BOP conector adapter BOP connector switch arm rest connector switch arm rest 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 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. plate−freq. conn. plate−freq. conn. plate−freq. connector 1 steering wiring connector 1 steering wiring connector 1 steering wiring connector pressure sensor connector pressure sensor 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 BOMAG conn. wiper front

TYP

19.2

1127

Name

19.2

08.03.2007 Vogt 08.03.2007 Seis

Bauteilliste component listing 10 11 110

582 702 32

1128

X56:4 X57:1 X57:1 X57:2 X57:3 X57:4 X57:5 X57:6 X57:8 X57:9 X57:9 X57:10 X57:11 X57:12 X57:13 X57:13 X57:14 X57:14 X57:15 X57:15 X57:16 X57:17 X57:18 X57:19 X57:19 X57:20 X57:20 X57:21 X57:21 X57:22 X57:22 X57:23 X57:23 X57:23 X57:24 X57:24 X57:25 X57:25 X57:26 X57:27 X57:28 X57:28 X57:29 X57:29 X57:30 X57:31 X57:32 X57:33 X57:34 X57:35 X57:36 X57:37 X57:39 X57:40 X57:41 X57:42 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 X62:1 X62:2 X62:3 X62:4 X62:5 X62:6 X62:7 X62:8 X62:9 X62:10 X62:11 X62:12 X62:13 X62:14 X62:15 X63:1 X63:1 X63:2 X63:2 X65:1 X65:2 X65:3 X65:4

Bl. 013 003 004 003 003 003 003 003 003 003 004 003 003 003 003 004 003 004 003 004 003 003 003 003 004 003 004 003 004 003 004 003 004 004 003 004 003 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 011 011 011 011

Pf. 12 15 9 13 14 12 14 15 13 13 8 8 8 7 7 7 9 7 9 9 11 10 10 10 10 6 11 6 8 6 12 11 12 17 11 15 12 13 16 15 11 17 13 18 14 14 13 16 1 1 3 5 2 4 6 5 17 7 2 2 7 17 19 7 2 2 7 19 18 18 6 6 19 19 8 8 19 19 18 16 16 17 17 18 18 18 15 17 19 20 19 13 14 13 14 5 5 5 5

Benennung STECKER WISCHER VORNE Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor 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 DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN SCHNELLVERSCHLUSSKUPP SCHNELLVERSCHLUSSKUPP SCHNELLVERSCHLUSSKUPP SCHNELLVERSCHLUSSKUPP KEYBOARD KEYBOARD KEYBOARD KEYBOARD

title conn. wiper front connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine 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. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates quick connecting clutch quick connecting clutch quick connecting clutch quick connecting clutch Keyboard Keyboard Keyboard BOMAG Keyboard

TYP

Wiring diagram

008 911 79

Name X65:5 X65:7 X65:8 X65:9 X65:10 X65:11 X65:12 X66:2 X66:3 X67:1 X67:2 X68:1 X68:2 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. 011 011 011 011 011 011 011 004 004 002 002 011 011 014 014 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 009 009 009 009 009 010 010 010 010 014 014 010 010 010 010

Pf. 5 5 12 5 5 5 5 19 20 15 15 15 16 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

Y04 Y07 Y08 Y14 Y15 Y16 Y17 Y30 Y31 Y92 Y93 Y98 Y122 Y123 Y137 Y137 Y138 Y140 Y141 Y142 Y143 Y144.1 Y144.2 Y145 Y147 Y148 Y149 Y166 Y169 Y170

007 007 007 014 014 005 005 005 005 007 007 008 008 008 003 004 014 009 009 008 008 008 008 008 004 004 004 004 004 004

17 15 13 15 7 13 12 15 16 6 5 14 16 17 10 10 10 10 11 17 18 19 19 20 1 3 5 2 6 4

Benennung

title

KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD ANSCHLUß EMR3 VORGLÜH ANSCHLUß EMR3 VORGLÜH STECKER KRAFTSTOFFHEI STECKER KRAFTSTOFFHEI STECKER LED STECKER LED 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

Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard connector EMR3 preglow connector EMR3 preglow connector fuel pre−heater connector fuel pre−heater connector led connector led 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

Magnetventil Bremse D*Prop. Ventil Vibration groß D*Prop. Ventil Vibration groß Kraftstoffpumpe Heizgeraet Magnetkupplung Klimakompressor Magnetventil Fahrtrichtung vorwaerts Magnetventil Fahrtrichtung rueckwaerts Magnetventil Stufenumschaltung vorn Magnetventil Stufenumschaltung hinten Magnetventil Lenkung vorne rechts Magnetventil Lenkung vorne links Magnetventil Vibrationsfrequenz, hinten Magnetventil Platten heben Magnetventil Platten senken EMR Verstellung EMR Verstellung Magnetveentil Heizung Magnetventil Erreger auf Magnetventil Erreger ab Magnetventil Plattenverschieben Links Magnetventil Plattenverschieben rechts

Solenoid valve, brake E*prop. Valve vibration high E*prop. Valve vibration high Fuel pump, heating unit Magnetic clutch, air conditioning compr. Solenoid valve, travel direction forw. Solenoid valve, travel direction backw. Solenoid valve, speed range sel., front Solenoid valve, speed range sel., rear Solenoid valve, steering, front rh. Solenoid valve, steering, front lh. Solenoid valve, vibrat.freq.,rear Solenoid valve, lift plates Solenoid valve, let down plates EMR adjustment EMR adjustment Solenoid valve, heating unit solenoid valve exciter up solenoid valve exciter down solenoid valve, plate displace left solenoid−valve, plate displace right

Magnetventil Platten (Priorität) Injektor A1 Injektor A2 Injektor A3 Injektor A4 Injektor A6 Injektor A5

solenoid−valve, plate (priority) jet pump A1 jet pump A2 jet pump A3 jet pump A4 jet pump A6 jet pump A5

Wiring diagram

TYP

19.2

08.03.2007 Vogt 08.03.2007 Seis

Bauteilliste component listing

MAX. 1.8A 0.4 .. 1.2A 0.4 .. 1.2A 3,5A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A MAX. 1.8A MAX. 1.8A

1A 0.4 .. 1.2A 0.4 .. 1.2A MAX. 1.8A MAX. 1.8A MAX. 1.8A MAX. 1.8A MAX. 1.8A

11 11 111

582 702 32

008 911 79

BOMAG

1129

X36

X37

X38

K11

1130

BOMAG B57

X32:1-12

K09

K16

A02

008 911 79

overview e-box BW 177...226 DH/BVC-4

Gepr.: 08.03.2007 Name: Seis

Name: Vogt

Übersicht Schaltkasten BW 177...226 DH/BVC-4

K41

K61

K48

K43

K06

K05

Gez.: 08.03.2007

X34:1-19

Nur bei Klimaanlage only acc. to aircond.

R10

Nur bei StvzO only acc. To StvZO illumination

Replaces:

Ers. f.:

page: 1

Seite: 1

A80

von: 2 from: 2

582 702 32 Sheet No.: 201

Blatt Nr.: 201

19.2 Wiring diagram

F1

F2

008 911 79 A34 Fahrsteuerung

A83 Messtechnik Steuerung

CAN 1

Nur bei VM8 only acc. To VM8

BOMAG

Übersicht Schaltkasten-Tür BW 177...226 DH-4 overview e-box door BW 177...226 DH-4

Gepr.: 08.03.2007

1131

Name: Seis

Name: Vogt

Gez.: 08.03.2007

BCM

Replaces:

Ers. f.:

page: 2

Seite: 2

OPUS 21

CAN 1

CAN 3

EMR + Fahrhebel

LCD+ Datensammler

CAN 2

CAN 1

von: 2 from: 2

582 702 32 Sheet No.: 201

Blatt Nr.: 201

Wiring diagram

19.2

19.2

Wiring diagram

WAGO smart DESIGNER 4.1 1

057 564 17

2

280-315

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

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Absicherung DH-4 komplett

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. 12.03.2007 12:11:33

1132

BOMAG

Seite 1

008 911 79

19.2

Wiring diagram

WAGO smart DESIGNER 4.1 30

4 x 057 564 36 "R" + 793-501

34

057 564 35

35

057 564 17

36

057 564 21

37

2 x 057 564 25 "L" + 793-501

39

3 x 057 564 25 "L" + 057 564 20 + 793-501

42

5 x 057 564 25 "L" + 793-501

47

8 x 057 564 25 "L" + 057 564 20 + 793-501

55

057 564 25 "L" + 793-501

56

4 x 057 564 38 "L" + 793-501

60

057 564 17

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Absicherung DH-4 komplett

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. 12.03.2007 12:11:33

008 911 79

BOMAG

Seite 2

1133

19.2

Wiring diagram

WAGO smart DESIGNER 4.1

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Absicherung DH-4 komplett

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. 12.03.2007 12:11:46

1134

BOMAG

Seite 3

008 911 79

19.2

Wiring diagram

WAGO smart DESIGNER 4.1

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Absicherung DH-4 komplett

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. 12.03.2007 12:11:46

008 911 79

BOMAG

Seite 4

1135

19.2

Wiring diagram

WAGO smart DESIGNER 4.1 1

057 564 17

2

3 x 057 565 40 "R" + 793-501

5

057 565 35 "R" + 793-501

6

057 565 37

7

3 x 057 565 40 "R" + 793-501

10

057 565 37

11

057 565 40 "R" + 793-501

12

057 565 35 "R" + 793-501

13

057 565 37

14

2 x 057 565 38 "R" + 793-501

16

2 x 057 565 39 "R" + 793-501

18

057 565 37

19

4 x 057 565 40 "R" + 793-501

23

057 565 37

24

4 x 057 565 40 "R" + 793-501

28

2 x 057 565 39 "R" + 793-501

30

057 565 37

31

057 565 40 "R" + 793-501

32

057 565 39 "R" + 793-501

33

057 565 37

34

4 x 057 565 40 "R" + 793-501

38

057 565 35 "R" + 793-501

39

057 565 37

40

4 x 057 565 40 "R" + 793-501

44

057 565 37

45

057 565 40 "R" + 793-501

46

057 565 35 "R" + 793-501

47

057 565 37

48

057 565 40 "R" + 793-501

49

057 565 35 "R" + 793-501

50

057 565 37

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Kabelbäume DH-4 komplett

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. 12.03.2007 12:15:44

1136

BOMAG

Seite 1

008 911 79

19.2

Wiring diagram

WAGO smart DESIGNER 4.1 51

057 565 38 "R" + 793-501

52

2 x 057 565 40 "R" + 793-501

54

057 565 38 "R" + 793-501

55

057 565 37

56

3 x 057 565 40 "R" + 793-501

59

057 565 38 "R" + 793-501

60

057 565 37

61

3 x 057 565 40 "R" + 793-501

64

057 565 35 "R" + 793-501

65

057 565 37

66

2 x 057 565 40 "R" + 793-501

68

057 565 35 "R" + 793-501

69

057 565 37

70

3 x 057 565 40 "R" + 793-501

73

057 565 35 "R" + 793-501

74

057 565 37

75

2 x 057 565 40 "R" + 793-501

77

2 x 057 565 35 "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

057 564 17

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Kabelbäume DH-4 komplett

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. 12.03.2007 12:15:44

008 911 79

BOMAG

Seite 2

1137

19.2

Wiring diagram

WAGO smart DESIGNER 4.1

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Kabelbäume DH-4 komplett

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. 12.03.2007 12:15:57

1138

BOMAG

Seite 3

008 911 79

19.2

Wiring diagram

WAGO smart DESIGNER 4.1

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Kabelbäume DH-4 komplett

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. 12.03.2007 12:15:57

008 911 79

BOMAG

Seite 4

1139

19.2

Wiring diagram

WAGO smart DESIGNER 4.1

1

057 564 17

2

2 x 057 565 40 "R" + 793-501

4

057 565 37

5

2 x 057 565 40 "R" + 793-501 + 057 565 36

7

057 565 39 "R" + 793-501

8

057 565 37

9

057 565 38 "R" + 793-501

10

2 x 057 565 40 "R" + 793-501

12

057 565 38 "R" + 793-501

13

057 565 37

14

2 x 057 565 40 "R" + 793-501

16

057 565 39 "R" + 793-501

17

057 565 37

18

057 565 40 "R" + 793-501

19

057 565 38 "R" + 793-501

20

057 565 40 "R" + 793-501

21

057 565 37

22

057 565 40 "R" + 793-501

23

057 565 39 "R" + 793-501

24

057 565 37

25

057 564 21

26

2 x 057 564 38 "L" + 793-501

28

057 564 25 "L" + 793-501

29

057 564 36 "R" + 793-501

30

057 564 35

31

057 564 17

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

Messtechnik DH / BVC*

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Klemmenleiste X2

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. 12.03.2007 12:49:55

1140

BOMAG

Seite 1

008 911 79

19.2

Wiring diagram

WAGO smart DESIGNER 4.1

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

Messtechnik DH / BVC*

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Klemmenleiste X2

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. 12.03.2007 12:50:02

008 911 79

BOMAG

Seite 2

1141

19.2

Wiring diagram

WAGO smart DESIGNER 4.1

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 :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

E2 Beleuchtung

Optional3 : Optional4 :

Option E2 StvZO Beleuchtung

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Größe der Bohrung :

Optional7 :

M. Vogt TEE

Lieferadresse :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten. 03.01.2007 10:28:28

1142

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

BOMAG

Seite 1

008 911 79

19.2

Wiring diagram

WAGO smart DESIGNER 4.1

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Obere Ebenen : Ort : Tragschiene :

E2 Beleuchtung

Optional3 : Optional4 :

Option E2 StvZO Beleuchtung

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Größe der Bohrung :

Optional7 :

M. Vogt TEE

Lieferadresse :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten. 03.01.2007 10:28:30

008 911 79

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

BOMAG

Seite 2

1143

1144

BOMAG (BVC) (BVC)

X47 X48 X49

(BVC) (BVC)

X47 X48 X49

X70 X73

X71 X72

X52

X58

X59

X53

X54

X77

X69

X28 X19

X29 X18

X56

X75 X76

X17

X73 X74 X70

X72

X71

X19

X52

X77

X27

X35

X44

X32 X34

X27

X6 X7

X6 X7 X15 X16

X60

X9

X61

X9

X62

X61 X62

X60

X15 X16

008 911 79

Name: Seis

Name: Vogt

overview e-box door BW 177...226 DH-4

X67 X8 X10

X67 X8 X10

Gepr.: 08.03.2007

X57

X57

Übersicht Schaltkasten-Tür BW 177...226 DH-4

X20

X21

X21

Gez.: 08.03.2007

X38 X32

X26

X4 X3 X37 X44 X2

X33

X43

X55

X36 X35 X1

X31

X30

X39 X40

X14

X46 X25 X41 X13 X51

X20

X77

X26

X38 X2

X37 X1

X4 X3

X36

X33

X42 X23 X11 X24 X12 X50

X31

X30

X14

X46

X18

X51 X43

X42

X58 X69

X55

X39 X23 X11 X24 X12 X50 X40 X25 X41 X13

X17

X53 X54

X59

X28

X29

X56 X76

X74 X75 X77

Replaces:

Ers. f.:

page: 1

Seite: 1

von: 1 from: 1

582 702 32 Sheet No.: 301

Blatt Nr.: 301

19.2 Wiring diagram

19.3 Wiring diagram

008 911 79

BOMAG

1145

19.3

Wiring diagram

Serial number for wiring diagram 582 702 39 not yet available at the printing deadline.

1146

BOMAG

008 911 79

008 911 79

001 002 003 004 005 006 007 008 009 010 011 012 013 014 101

Blatt Nr.: sheet no.:

582 582 582 582 582 582 582 582 582 582 582 582 582 582 582

702 702 702 702 702 702 702 702 702 702 702 702 702 702 702

39 39 39 39 39 39 39 39 39 39 39 39 39 39 39

BOMAG

23.07.2007 Vogt 23.07.2007 Seis

Stromlaufplan circuit diagram

Stromlaufplan Versorgung, Starten, Kraftstoffvorwärmung, Hupe Motor Deutz EMR II Motor Deutz EMR III Fahrantrieb, Neigungssensor, Sitzkontakt Datensammler, LC−Display Lenkung, Vibration Fahrhebel, Vibrationsplatten Variocontrol, Messtechnik Bomag Compaction Management BCM, GPS Diebstahlschutz System DH−4 Beleuchtung und StvZO Kabinenausrüstung, Beleuchtung, Radio, Tachograph Kabinenheizung, Klimaanlage, Zusatzheizung Bauteilliste

Funktionsgruppe

BW 177..226 DH−4 BW 177..226 DH−4

Zeichnungsnummer drawing − no.

Inhaltsverzeichnis: table of contents:

001

001

19.3 001

582 702 39

Circuit Diagram supply, starting unit, fuel pre−heater, signal horn engine Deutz EMR II engine Deutz EMR III driving system, slope sensor, seat contakt switch data−collector, LC−display steering, vibration joystick, vibration−plates Variocontrol, measurement equipm. Bomag Compaction Management BCM, GPS anti − theft system illumination and StvZO cabin−equipment, headlights, radio, tachograph cabin−heater, air conditioning, add. heater component listing

function unit

Wiring diagram

1147

2

2

1

R83

2

1

4:20

K14.2

2

1

R85

Glühstiftkerzen glow plugs

31

R81

1

R82

2

1

3

5

2

1

S30

G03

125A

F48

2

1

−

+

1

2

23.07.2007 Vogt 23.07.2007 Seis

Batterie battery

Trennschalter Batter break switch battery

2

1

3

5

nicht bei EMR III, bei BW177DH−4 Option not at EMR III, at BW177DH−4 option

Heizflansch heating−flange

R19

3:19

K14

167A

nur bei EMR III only EMR III

R84

BOMAG

R86

Sicherung Heizflansch/Glühstiftkerzen heating−flange/glow plugs

Option option

X36:B

2 x 10qmm

−

+

1

2

Batterie battery

31 EMR 3:3

G01

125A

F00

X1:10

Hauptsicherung main fuse

2

B+

D+

X1:109

X1:1

9:2

2:12

6:2

K09

14:7

85

86

87a

30

X1:168

87

2:7

K61

K11

2:15 starter

X1:123

X1:3

85

86

19 17

M −

Starter

M01

30

50

2 X1:151

X1:27A

10A

F95

X1:27E

K11 2:11

7:17

X1:33A

B11

X1

2

1

K13 2:18 87

X1:152

X1 100

1

2

1

X1

Signalhörer warning horns

103

X1:101

87a

V03

2

1

104

2

1

X1 104 31

85

86

F39

−

+

3:1

K32:86

2

1

Steckdose socket

XS 12V

X3:3

X1:30A

15A

X1:98

4

3

2

1

K11:87 6:1 X1:30E

1

13:1

Wiring diagram

008 911 79

002

582 702 39

Nur bei Geländer/ROPS/SD only at hand−rail/ROPS/sun−roof

2:16

B11

X1:102

K13

S03

X1:155

X1:28A

15A

F23

X1:28E

Taster Hupe push button, horn

S01:22 3:1 F05:2 6:8

30

25A

F124

X1:33E

22 12 32 42 52 62

X1:218

2

1

Kraftstoffvorwärmung fuel pre−heater

X67:2

R79

X67:1

5:9

21 11 31 41 51 61

2

1

87

30

X1:217

NOT−Aus Emerg.−Stop

S01

K30 13:1 30 4:1 1

X1:8

X38:A

87a

30

F05

X1:16E

X1:16A

50a

X1:7

8:3 87

K05

X37:B

2:8 B+

X1:4

X1:79

54 58

10A

Versorgung, Starten, Kraftstoffvorwärmung, Hupe supply, starting unit, fuel pre−heater, signal horn

X1:110

W

1

R10 82 OHM

1

D+ MESX

85

86

D+

Generator generator

2:10

B−

G02

B+

125mA

K61

2

V01

2

1

Startschalter 15 starting swwitch

S00

30

X37:A

X1:15A

30A

F13

nur bei Klimaanlage only acc.to air conditioning

X1:9

X36:A

X1:15E

Anzugsw.:50A / Haltew.:10A

X34:P

1148 Option Winterpaket option winter package

19.3

2:20

CAN2− 4:15 CAN2+ 4:15

K

L

X30:10

X1:183

X32:L

X32:A

31

23.07.2007 Vogt 23.07.2007 Seis

31 EMR

X30:2

Ubat −

X1:182

X30:1

4:18

B88

Signal

X57:13

X31:12

AGND

X57:10 2

X31:11

B130

1

2

6

X57:17

X31:15 1

5

4

X31:25

B115

3

Signal Temperatur

2

1

X31:9 B113

2

X31:8

X31:4

X31:23

X31:16 EMR Kühlmitteltemperatur EMR coolant temperature Ladeluftdruck + Temp charging air pressure + temperature

1

X31:24

X31:19

Motor Deutz EMR II engine Deutz EMR II

Y137

EMR Stellglied EMR commander

7

STG−

X57:14

Motordrehzahlsensor sender engine rpm 2

X31:13

B114

2

X31:10

Motordrehzahlsensor sender engine rpm 1 EMR Motoröldruck EMR engine oil pressure

31 EMR

X31:20

X57:20

1

Signal

X57:11

max 7A

CAN high

X30:12

X1:180

X32:H

X30:13

2:6

AGND

Signal

X57:21

1

X31:14 STG+

X57:15

X30:14

X30:11

X1:184

X32:K

AGND

X57:23

CAN low

X1:181

X32:G

Diagnosestecker EMR diagnosis interface EMR

X31:21

+5V

X57:22

2

X31:22 AGND

X57:12

3

X31:17 X57:18 RF−

+5V

X57:25

A48 Motorsteuerung EMR2 engine−controller EMR2

X32:B

X31:18 X57:19 RF REF

Signal

X57:9

EPC−Stecker

X31:2 1

X33:2

X33:7

X1:96

K14

X1:95

X1:185 Steckerschnittstelle Deutz connector interface Deutz

2:4

1

X33:3 X31:7 X31:3

X31:1

X1:179

X1:186

ESX Fahrst.

X34:N

X57:16 RF MESS

Signal Druck

X57:24

BOMAG X57:4

AGND

X57:8

Relais Heizflansch relay heating−flange

X33:5

S01:22

X33:6

008 911 79 X33:1

X33:4

31 4:1

19.3 003

582 702 39

2

1

S01:22 4:1

X33:8

2:16

Wiring diagram

1149

X57:6

X57:1

X31:6

X31:5

X31:16

X57:35

3:20

X31:47

X30:72

X57:36

X30:1

4:3

Injektor A4 jet pump A4

2

23.07.2007 Vogt 23.07.2007 Seis

X31:48

X30:64

Y15.4

Y169

2

1

Nur bei EMRIII only EMRIII

X57:41

B40.2

1

B40.1

2

B130

3

X1:179

X30:28 B114

2

X31:12

X31:10

3

Y19

Y137

Motorsteuerung EMR3 (EDC 16) engine−controller EMR3 (EDC16)

A48

2

1

1

X57:37

4

B48

B133

3

X1:184

X32:A 2

3

Motor Deutz EMR III engine Deutz EMR III

X32:M X30:62

X1:192 1

1

2

B43

B113

X31:58

3

B6

B88

2

EMR Kraftstoffdruck rail pressure sensor

1

2

3:5

B51

B145

3x2.5

31 EMR

4

1

1

EMR Niederdruck Kraftstoff EMR fuel low pressure sensor

EMR Motoröldruck EMR engine oil pressure

1

3

bei einer Kabelbaumumgebungstemperatur von 85 Grad C. (Querschnitt 4x2,5qmm)

max. Kabellänge von Batterie zum Steuergerät (Versorgungsleitung) max. 10m

in der hier dargestellten Installation (Querschnitt 2,5qmm)

max. Kabellänge von Batterie zum Steuergerät (Versorgungsleitung) max. 3.5m

EMR Kühlmitteltemperatur EMR coolant temperature

B49

B93

2

Ladeluftdruck + Temp charging air pressure + temperature

EMR Stellglied EMR commander

X31:7

Motordrehzahlsensor sender engine rpm 2

Motordrehzahlsensor sender engine rpm 1

1

X57:14

Injektor A6 jet pump A6

2

1

X31:32

Injektor A3 jet pump A3

Injektor A5 jet pump A5

Injektor A2 jet pump A2

Y15.2

Y15.6

2

Y170

31

1

Y15.3

2

X31:31

Y149

1

X31:46

X30:63

X31:1

X30:5

X31:33

1

X57:40

Y15.5

X57:42

Y148

Sign.

X57:13

X1:198 X1:199

X31:50 AGND

X57:9

2.5 qmm

X31:27

X1:183

X30:3

Y166

2

1

X57:39

Injektor A1 jet pump A1

Y15.1

Y147

X57:34

X1:185

X57:15

X1:107 X1:108

X31:19

87a

X31:49

4:2 87

X31:23

85

X31:40

B124

X31:20 Sign.

X57:21

max 7A AGND

X57:1

Signal

X57:19

AGND

X57:20

AGND

X57:28

Signal Druck

X57:23

30

X31:14

K41

X57:22

X32:K X30:25 X31:53

X32:H X57:32

X1:194 CAN 1 Low

X1:191 CAN 2 High

X31:43

86

X31:51

K41

X31:56

2

X31:13

25A

X57:33

X1:14A

X31:11

F93

X57:28

X1:193 CAN 1 High AGND

X30:82 X31:26

X32:G X30:60 Signal

X57:25

X32:F X30:61 X31:8

CAN 2 Low

X57:31

CAN2+ CAN2−

AGND

X57:24

X32:B Signal

X57:30

3:4

X31:57

3:4

Signal Druck

diagnosis interface EMR

X31:41 AGND

X57:27

K−Line Signal Temperatur

X57:29

Signal

X57:26

BOMAG

X57:23

Diagnosestecker EMR

AGND

X57:29

Wasserabscheider water−seperator

X31:54 GND

X1:180 X1:90

1

X30:2 GND

X1:181 X1:91

X1:14E

X30:4 GND

X1:182

30 5:1 S01:22 7:1 CAN2+ 5:11 CAN2− 5:11

31 5:1

85

86

Wiring diagram

X66:2

X30:6

008 911 79

004

582 702 39

2:2

K14.2

X31:24

30 S01:22

X31:34

2:14

X66:3

3:20

X1:186

1150 X1:92

19.3

31

−

A34

speed

dir.

X1:178

−

+

23.07.2007 Vogt 23.07.2007 Seis

Sensor Bandage sender drum

9:2 SPEED MESX

13:6 SPEED TAC

B59 9:2 DIR MESX

X1:44

Fahr−Steuerung driving controller

X35:28

X35:38

X1:172

dir.

Sensor Achse sender axle

4:20

X1:174

X1:45

+

sw

Drucksensor Fahrpumpe pressure sensor drive pump

B112

X52:2

X35:12

X1:63 FM3 X1:62

B60

2

X52:1

rt

X35:34

B57

−

+

2

1

7:4

X35:58

X1:34A

10A

F84

X1:34E

X1:146

S01 2:15

X1:46

4V

9:2

X34:G

X1:34A

2

1

32

31

X34:H

X34:C

X34:D

R22

120 OHM 1 2

R23

120 OHM 1 2

+

−

X1:117

X9:2

H14 −

+

X9:1

X34:A

X34:B

R20

120 OHM 1 2

R21

120 OHM 1 2

X1:123

X16:1 1 Y17 b 2 X16:2

X1:144

Y30

1 2

Y31

X1:124

2

1

1

LC−Display, OPUS 21

Fahrhebel

Diagnosestecker Fahrzeug diagnosis interface equipment

CAN1− 6:8

Prop.−Ventil Achsmotor prop.−Valve axle motor

Prop.−Ventil Bandagenmotor prop.−Valve drum motor Prop.−Pumpe Rückw. prop−pump backwards

X1:123

X15:1 1 Y16 a 2 X15:2

X1:141

X1:143

X1:122

X1:121

Prop.−Pumpe Vorw. prop.−pump forwards Rückfahrwarnsummer back up alarm buzzer

Sitzkontaktschalter switch, seat contact

X1:149

X14:A

S06

X14:B

X1:114

X1:158

Fahrantrieb, Neigungssensor, Sitzkontakt driving system, slope sensor, seat contakt switch

9:2

2,5V

1V

PITCH MESX

S

−45_G=0,5V

+45_G=4,5V

X35:57

Neigungssensor slope sensor

X1:55

X1:17A

15A

F67

X1:17E

Leistung

X1:120

X35:56

6:3

X35:59

CAN2−

X35:54 X35:30

Sitzkontakt

X1:119

Richtung

X1:177

TxD

X35:5 X35:15

Rückfahrwarnsum.

X35:31

ws

RxD

X35:4 X35:24 0,46A

X1:145

X1:51 X35:53 X35:49 Fahrpumpe vorw. 400 ... 1.200mA

FM3 7:5

X35:60

X1:52 CAN2+

X1:53 X35:33 X35:64 Fahrpumpe rückw.

F24:2

Gehäuse housing

1

X1:171

br

sw

X1:47 X35:27 X35:46

400 ... 1.200mA

Drucksensor

X35:37

speed

X1:176

bl

X1:54 CAN2−

X1:49 X35:26 X35:47

400 ... 1.200mA

Elektronik Neigung

X1:48 CAN1+ Bandagenmotor

X1:50 CAN1− Achsmotor 400 ... 1.200mA

CAN2+ 8:6 CAN2− 8:6 CAN1+ 6:8

X35:55 1

X1:124

CAN2+

X35:65 1

X1:142

4:20 EMR Deutz 4:20

X35:66 X1:142

X1:2

X35:67

31 6:1

30 6:1

19.3 005

582 702 39

X1:143

Pot. 15

Richtung

X1:173

ws

speed

bl

speed

X1:175

br

sw

BOMAG

X1:82

30

X35:68 X1:143

008 911 79

4:20

Wiring diagram

1151

5:20

2:8

31

D+

X27:8

X1:29A

10A

F24

2

1

X1:39

X34:R

X1:40

F24:2

X1:117

P

B21

X1:106

A80 Datensammler data−collector

VCC

5:3

X1:111

2

X1:94

P

1 B03

X1:112

X21:1

2

X1:117

X10:3

R03

X10:2

23.07.2007 Vogt 23.07.2007 Seis

X1:94

X21:2

Q

1 B55

X1:105

11:1

0 .. 67 OHM

X1:29E

X1:107

connector−colour: X26−grey; X27−black

Steckerfarbe: X26−grau; X27−schwarz

ESX Fahrsteuerung

X8:1

X8:2

B124

X1:108

5:17

2:16 5:17

F05:2 CAN1+ CAN1−

CAN1 high

X27:6

K11:87

CAN1 low

X27:7

30

X26:3

DIN3

X26:5

DIN5

Hydraulikölfilter hydraulic oil filter

X1:164

X1:149

Datensammler, LC−Display data−collector, LC−display

BL 12:17 BR 12:17 BEL 12:4

X1:82

X1:87 X1:88

X1:80

DIOS Platten

A81 LC−Display LC−display

CAN1+ 8:14 CAN1− 8:14

14

13

1

Schalter Motordrehzahl switch engine−rpm mode

S127

ECO Low High

X1:86

Ub "15"

X28:1

2:20

Nur bei EMRII only EMRII

X1:41

X26:8

DIN8

Luftfilter air cleaner

X26:10

DIN10

Kühlmittelvorrat coolant stock level

X27:4

Sepa1

X27:2

UIN1

Füllstand Diesel fuel−level

BOMAG

Wasserabscheider water−seperator

X27:9 Sepa2

X26:9 DIN9

X26:1 DIN1

X26:2 DIN2

X26:6 DIN6

X26:4 DIN4

X26:11 DIN11

X27:10 UIN3

X27:11 UIN2

X27:12 AIN2

X27:1 AIN1

X27:3 GND/UIN3

X27:5 GND

X26:12 GND

CAN1 high

X28:3 X28:2 GND

CAN1 low

X28:4 X29:1 DIN1

X29:2 DIN2

X29:4 DIN4

Ub "30"

X28:5 X29:3 DIN3

not connected

X28:6 DIN5

X29:5

not connected

X29:8 X29:6 DIN6

Ub out

down

14

up

13

23

1

24

30 9:1 K11:87 8:14 F24:2 7:13

Wiring diagram

008 911 79

006

582 702 39

31 7:1

Schalter Frequenzverstellung switch frequency−control

24

S139

23

X29:7

1152

5:20

19.3

X43:2

6:20

31

B132

X51:3

X1:149

X43:1

5:6

X34:J

X1:55

FM3

1

1

2

8,5V

X1:203

Lenkwink.

2

X1:197

Y92 d

1

2

2

1

X1:56 FM1 X1:57

X1:162

X41:2

X41:4 X39:4

X40:4

X41:3 X40:1

X1:159

X41:1 X39:1

X1:161 X1:160

A34 Fahr−Steuerung driving controller

1

2

Prop. Ventil lenken rechts prop. valve steering right

Prop. Ventil lenken links prop. valve steering left

X1:197

Y93 b

X1:195

5:3

X1:60 FM5 X1:61

X1:196

X35:29

23.07.2007 Vogt 23.07.2007 Seis

X1:154

−

0V

0V

VCC

VCC

A

A

B

B

X39:3

X40:3

X40:2

X39:2

X35:19

X35:43

X35:22

X35:41

X35:18

Lenkung, Vibration steering, vibration

S1

S2

S1

X35:43

A45

Schnellverschl.−Platten

S

X35:21

Lenkeinheit steering unit

nur BVC only BVC

7:14

K43

8:13

8:13

85

86

2

1

X6:2 X1:118

gg

+

br

sw

2

X7:1 1

Anbau 213DH: oben

−

+

9:2

9:2

8:2 87a

X1:117

a1 2

1

1

9:2 X1:113 BRAKE MESX Y04 1

12

VIB

8:1

19.3 007

582 702 39

X1:190 31

S01:22

13:6

bl

BTS BREMSE 8:2

Magnetventil Bremse solenoid valve brake

H07

X1:150

2:15

S01

X1:147 11

30 K48 87

Warnsummer Störung warning buzzer, failure

Prop−Ventil Vibration groß prop. valve vibration big

X1:82

GA MESX

KA MESX

X1:89

X22:3

bei BW177 u. 213 m. Sauer Motor bl / bei BW213−226 m. Rexroth Motor sw

Anbau 177DH: h.l. b

X7:2

Y07

X1:115

X1:37

X1:38

7:12 87a

X22:2

bei BW177 u. 213 m. Sauer Motor sw / bei BW213−226 m. Rexroth Motor bl

−

Aufnehmer Vibrationsmotor sensor vibration motor

Prop.−Ventil Vibration klein prop. valve vibration small

Anbau 213DH: unten

Anbau 177DH: h.r. a

X6:1 Y08

30 K43 87

X1:116

ws

X22:4

B16

br

X22:1

X1:187

X1:41

X1:189

X1:201 B65 +

Vib.− Richtung

Lenkwinkelsensor steering angle sensor

F24:2

X1:42 X1:188

X51:1

8:1

X1:55 X1:202

Armlehne

X23:1

AGND

X35:1

X35:16

Schalter Armlehne armrest−switch

X51:2

X35:3

X1:148

6:20

X35:61

S01:22

X35:20

X41:5 X1:205

X41:7 X1:207

X41:6 X1:206

X41:8 X1:208 X35:22

X35:40 Pumpe Vib.−Platten

Vib.− Frequenz

X35:35

X1:58 FM2 X1:59

400 ... 1.200mA

X35:23

400 ... 1.200mA

X35:2 Umsch. Amplitude

X35:48 Prop. out 400 ... 1.200mA

BOMAG

max.1.8A

− Warnsummer

BTS Bremse

X35:17

Sig. 150mA

Bremse

008 911 79

4:20

Wiring diagram

1153

7:17

7:20

31

K48

85

86

2:12

K05

X1:149

85

86

X1:153

Ub in

9 10

2

1 3 4

23.07.2007 Vogt 23.07.2007 Seis

Add2

Add1

0V in

BTS zus.

BTS Bremse

1

DK Ext1

Bremse auf = Ub

2

Stecker X24 3 4 5 6

Stecker X23

S55 Fahrhebel travel lever

DK Ext2

Bremse zu = 0V

13

7

4

3

Schalter Amplitude switch amplitudes

8

5

2 1

24

23

7

14

13

Nur bei BVC Only at BVC

S09

AK Ext2

AK Ext1

0V (Ref PIN5)

+5V out

CAN+

CAN−

8

X1:157

X1:156

S

14

13 S36

14

13

7:11

7:11

S139

S42

X35:22

X35:43 X1:215

S − +

X1:211

Y98

X1:210

Schalter Betriebsart Platten modesw. plates

X1:212

S

+

S

2

Y122 1

2

Y123 1

X62:7 2

Y142 1

X62:12 A54 Platten Steuerung plate−controller

bl

B134 −

20A

X1:209

X1:31A

2

1 F145

X1:31E

X62:2

X1:214 2

2

Y144.2 1

Y144.1 1

2

Y143 1

CAN1+ 9:16 CAN1− 9:16 K11:87 9:1

31

9:1

2

Y145 1

BTM

Wiring diagram

1

1

008 911 79

008

582 702 39

MV Platten heben MV Platten rechts plates up plates right MV Platten Schwimmst MV Platten senken plates down plates float−pos. Prop−Pumpe Platten MV Platten Priorität MV Platten links prop.−valve plates plates left plates priority

2

1

bl

B135 −

+

Näherungssch. Platten oben sensor plates up Näherungssch. Platten Mitte sensor plates centered

Schalter Schwimmstellung Platten sw. swimming pos. plates Frequenzverstellung Platten freq. adjust plates

S64

+ −

Fahrstufenschalter speed range selector

Fahrhebel, Vibrationsplatten joystick, vibration−plates

Schalter Vibration Ein/Aus switch vibration on/off

11 12

8

7 6 5

Taster 8 = Infotaste 2 push button 8 = Info button 2

Taster 7 = Infotaste 1 push button 7 = info button 1

nicht bei BVC not at BVC

14

S35 K0G

DK Ext3

BTS BREMSE

DK Ext5

7:18

DK Ext4

Taster 5 = platten senken push button 5 = lower plates

Ub out

BOMAG DK Ext6

Taster 4 = Platten links push button 4 = plates left

X50:2

Taster 3 = Vibration EIN/AUS push button 3 = vibration ON/OFF

X50:3

Taster 2 = Platten heben push button 2 = lift plates

X25:2 X25:4

X63:1 X63:2 X50:1

Taster 1 = Platten rechts push button 1 = plates right

X25:3

X63:1

6:20

Schnellverschluss − Kupplung quick connecting clutch 400 .. 1.200 mA

br sw

X62:4

X63:2

CAN1− K11:87

X62:11

br ws

CAN1+

X62:3

6:14 6:14

X62:5

LC−Display

X62:8

CAN2−

X62:9 X62:10

CAN2+

X62:6

5:17 5:17

X1:213 X62:1 X62:13

ESX Fahrst.

X62:15

7:2 X23:1

X62:14

1154 OV out

19.3

8:20

2:8

7:17

5:3 5:3 5:8

7:15

7:15

F148:2

15A

10:2

X1:35A

23.07.2007 Vogt 23.07.2007 Seis

Elektronik

X44:32

X44:59

X2:54

X48:3

X48:2

BEL MESX

X2:55

X48:4

15g/bl

−/gg

B62

X48:1

12:4

B62

X49:1

X2:57

X2:59

X49:4

15g/bl

−/gg

X2:49

X2:58

X49:3

X49:2

X2:60

31

BRAKE MESX D+ MESX

Y140

X44:60

PITCH MESX

X44:37

X2:75

2

X2:53

Prop.

GA MESX SPEED MESX DIR MESX

KA MESX

A83 Messtechnik−Rechner measurement calc. unit

Pot. 15

X2:57

2

X44:28

10A

X44:15

X1:32A

Aufn. vorne 15g

X2:56

X44:29

1

Aufn. vorne 20g

F146

X44:56

X44:38

20g/br

+/sw X44:31

F148

Aufn. hinten 15g

X1:35E

X44:30

1

X44:41

20g/br Aufn. hinten 20g

X1:32E

Leistung

X44:57

X44:35

2

400 .. 1.200mA

Y141

X2:73

X2:74

X2:69

X47:C

2

1

S/ws

B61

X2:52

Variocontrol, Messtechnik Variocontrol, measurement equipm.

Prop−Ventil Erreger ab solenoid valve exciter down

Prop−Ventil Erreger auf solenoid−valve exciter up

X2:76

X44:47 1

X47:B

X47:A

+/rt

X2:68

2

1

X2:67

X2:78

FM4

X2:77

8.5V

X44:23

Pot 15

X44:46

F146:1 10:2

Prop.

K11:87 12:1

400 .. 1.200mA

−/sw Erregerpos.

K11:87

X44:9

8:20

GND

Pot 30

X44:1

X2:71

X2:63

AGND MESX

X44:55

30

X2:66

RxD

X2:64

X4:A

X74:1

P11

X44:66

5:9

X2:66

TxD

X2:65

X4:B

X74:2

X2:70

+

−

nur bei BEM only at BEM

EVIB−Meter EVIB−meter

X1:82

P07 E VIB

X1:85

8:20

8:20

F1

F2

X2:79

−

CAN3+

1

X44:25

CAN1+

X2:50

CAN1−

CAN1+

+

Bedieneinheit BEM control−unit BEM

P16

DIOS Platten

Drucker printer

X44:3

Aufnehmer Verstellmotor sens. adjust. motor

X44:67

CAN+

6:20

X44:58

X44:14

X44:54

X44:36

nur bei BTM prof only at BTM prof X44:65

X4:C X74:3 X44:4

X4:E

X4:D X74:5 X44:5

+/sw X44:7 v.l.

EVIB

Beschleunigungssensoren acc. sensor rear

X44:25

CAN− X44:27

Beschleunigungssensoren acc. sensor front

v.r.

GPS

X42:2

X42:5

X42:4

10:2

1

CAN3+

CAN3−

CAN3−

10:2

10:2

31 10:1

X46:E

X42:3

X2:49

19.3 009

582 702 39

CAN1−

X2:51

X46:F

X46:D

P33

X46:A

X42:1 X46:B

X2:48

X2:47

30 12:1

Display Messtechnik BOP display measurem. BOP

R24 1 2 60 OHM

nur bei BEM only at BEM X44:53

X74:4

X44:68

BOMAG

0..6VDC

X44:33

X1:34A

nur bei BTM+/BTM prof only at BTM+/BTM prof

008 911 79 X44:26

Wiring diagram

1155

1156

BOMAG

9:20

31

9:5

9:17

9:4

F146:1

X44:25

F148:2

9:18 CAN3+

9:18 CAN3−

23.07.2007 Vogt 23.07.2007 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

nur bei BCM only at BCM

BCM 05

P15

X75:2

X4

X2

R25 1 2 60 OHM

61

A87 USB−CAN Schnittst. USB−CAN Interface BCM

X4:F

G

70

CAN3+

M

62

CAN3−

Wiring diagram

008 911 79

010

582 702 39

31 11:1

19.3

ZA option

23.07.2007 Vogt 23.07.2007 Seis

Steuereinheit control unit

A66

Diebstahlschutz System DH−4 anti − theft system

A67 Keyboard keyboard

008 911 79

BOMAG

H80

+

−

X68:2

VAL

0

ANN

X68:1

9

8

7

6

3

5

2

4

1

1

1

19.3 011

582 702 39

Wiring diagram

1157

87a

2

2

E16 1 E17 1

9:7

Scheinwerfer rechts head light RH

31 Scheinwerfer links head light LH

11:12

87

12:9

S15

85

86

X1:301

12

11

24

23

BEL 6:9

23.07.2007 Vogt 23.07.2007 Seis

K06

X1:43

BEL MESX

12:10

13

32

31

S16 14

X1:84

012

Anschluß Arbeitsschein− werfer ohne StvZO connection working head lights without StvZO

Schalter StvZO switch, StvZO

X1:24A

10A

X1:23A

F10

10A

X1:24E

F09

X1:23E

connection working head lights without StvZO

Anschluß Arbeitsschein− werfer ohne StvZO

X1:312

K16 30

X1:309

X1:26A X1:83

2

2

2 K16

Schlußleuchte rechts tail light, RH

12:2 Schlußleuchte links tail light, LH Parkleuchte links parking light, LH Parkleuchte rechts parking light, RH

2

E13 1 E12 1 E14 1 E15 1

X1:323 X60:4

X1:310

86

85

E

5

X1:22E 4

01

R

Beleuchtung und StvZO illumination and StvZO

Connection head lights acc.to ROPS/SD

Anschluß Arbeitsscheinwerfer bei ROPS/SD Aufbau

X3:1

1

1

13:1

Wiring diagram Blinkleuchte HR indicator rear, RH

008 911 79

012

582 702 39

Blinkleuchte VR indicator front, RH

Blinkleuchte VL indicator front, LH Blinkleuchte HL indicator rear, LH

Bel. Warnbinkschalter illumination, switch hazard light

31

2 2

2

2

2

2

2

2

−

E11 1 E10 1

E09 1 +

24

23

BR

BL

L

49R

Schalter Blinker switch indicator

E08 1

H06

14

13

6:9 6:9

49L

24

14

A02 31 82

30

23

13

E25 1

Warnblinkschalter switch, hazard light

S14

Anschluß Arbeitsscheinwerfer D bei Kabine Connection head lights with cabin STV1 13:17 STV2 13:17

L0R

E23 1

X3:5

X1:22A

15A

F19

S37

15A

X1:25A X1:305

E28 1

87a

X1:19A

F08

X1:25E

K11:87 30

E27 1

X3:4

X1:21A

15A

F22

X1:21E

87

12:4

K06

30

X1:19E 15A

0,42A

X58:5

X1:315 X58:6

X1:319

X60:3

X1:320

X1:18A

4,6A

X1:311 X58:3 X1:315 X58:6

Arbeitsscheinwerfer hinten links working head lights, rear lh. 4,6A

Schalter Arbeitsbele switch, working head lights

10A

4,6A

X1:302

X1:2

X1:304

15A

4,6A

X1:303

F07

0,42A

Arbeitsscheinwerfer vorne links working head lights, front lh. 4,6A

X59:5

X1:316 X59:6

Arbeitsscheinwerfer hinten rechts working head lights, rear rh.

F18

4,6A

0,125A

X1:26E

1,75A

X59:3 X1:316 X59:6

X1:313 X1:315 X58:6

F11

0,42A

Arbeitsscheinwerfer vorne rechts working head lights, front rh.

X1:306

X1:18E

0,42A

X1:321 X1:323 X60:2

K11:87 30

1,75A

9:3

1,75A

X58:2

1,75A

0,125A

X1:307 X60:1

X1:316 X59:6

X61:3 X1:324 X61:4

X1:314 X59:2

X1:322 X61:1

BOMAG

X1:324 X61:2

1158

9:19

19.3

13:6

2:20

K32:86

85

86

12:20

31

Relais Kabine relais cabin

K32

R80

2

1

13:16 87

K141

S45

E29

10A

F42

TK

2

1

8

H

−

+

+

−

+

−

−

A12

B51 +

23.07.2007 Vogt 23.07.2007 Seis

Türkontaktschalter door switch

S86

A01

2

E71 1

87a

30

7

G

Kontrolleuchte indicator

15A

max. 13A

1,75A

Innenleuchte inside light, cabin

F143

Schalter Innenleuche switches interior lights

31

30

87a

7:18

VIB X3:18 5

7,8,9

X3:17 4 5:3 SPEED TAC A16

3

2

1

6

Tachographenmodul module, tachograph

Radio radio

− −

15 + + B51

87

A5+A6

P09

A2+A3

X55:2

M05

M

5

2

1

A

4

Wischer hinten windscreen wiper, rear

Wascher hinten washer rear

− M07

M

+

X55:1

X56:2

M04

M

5

2

2

B

4

13:9

E70

F130

10A

F130

S158

4

3

2

1

3

C

K141

I

Wascher vorn washer front

13:2

2

1 E28

E72

E27

2

1

F130 14:7

STV1

STV2

1

2

−

+

1

XS 12V

1

5

5

E

K32:87

F41:5

14:14

15A

F144

14:11

−

+

6

F

14:2

Rundumkennleuchte rotary beacon

31 14:1

KABINE 31

2

1

S38

10A

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

12:13 12:13

Schalter Nachtleuchte switch, night illumination

− M06

M

+

Wischer vorne windscreen wiper, rear

S20

01W 7 01

15A

F44

Kabinenausrüstung, Beleuchtung, Radio, Tachograph cabin−equipment, headlights, radio, tachograph

Tachograph tachograph

C3

B4

B3

A1

S21

01W 7 01

F42 14:8 F130 13:14

15A

F43

X55:3

30

2,9A

K32

3,8A

13:1

X56:4

X3:7

X56:3

X3:8

4,7A

14:14

X56:1

F42:H

3,8A

0,83A

Nachtleuchte night illumination

2:14

Heizung Heckscheibe heating rear screen

4,6A

X3:6

3 min

4,6A

K30

X55:4 X3:1

Abfallverzögert

BOMAG X3:2

Steckdose socket

008 911 79 5A

Wiring diagram

013

582 702 39

19.3

1159

Schalter Kabinenlüfter switch blower cabin

0123

13:20

31

Stufe 3: 11.5A pro Lüfter

Stufe 2: 4.5A pro Lüfter

rt

M

br

Kabinenlüfter cab ventilator

Stromaufnahme Lüfter / current blower

Stufe 1: 3.0A pro Lüfter

ge

M09

X53:L

X3:9

X17:1 X1:163

S44

or

X3:12

ge

Bedienteil Kabinenheizung/Klimaanlage

Kabinenlüfter cab ventilator

br

rt

M

or

2

X18:2

_t

B131

X18:1

X1:167

X3:14

13:19

2

1

2

1 X54:1

KABINE 31

Magnetventil Heizung solenoid valve, heating unit

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

Kabinenheizung, Klimaanlage, Zusatzheizung cabin−heater, air conditioning, add. heater

1

2

V06

Potential 30 aus Kabine

V04

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

2:10

K09

X3:13

X54:6

control−unit cab−heater /air conditioning

X1:164

X17:4

M09

23.07.2007 Vogt 23.07.2007 Seis

X53:C

X53:M

X3:10

X17:2 X1:165

X53:B

4

D

Thermofühler Klimaan temperature sensor air conditioning

20A

X53:H

X3:11

X17:3 X1:166

13:17 F130 F42 Potential 15 aus Kabine 13:9

X20:3 Überwachung Kühlmitt monitoring coolant pressure

F31

X20:4 3,5A

1A

BOMAG X1:190

Thermofühler Heizung temperature sensor heating unit

13:19 K32:87 Potential 15 aus Kabine

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

13:19 F41:5 F42:H 13:4

Option option

1160 2.5qmm

1

Schaltuhr Heizung heater timer 1

2

5

6

8

4

31

9

12

10 1

BOX2

11 3 S28

7

2

B

Wiring diagram

008 911 79

014

582 702 39

5A

F15

19.3

Name

Benennung

Bl. 012 013 013 005 007 007 003 004 008 011 011 014 006 006 009 010 010

Pf. 17 5 6 6 6 9 3 9 17 9 15 11 3 18 6 18 7

Blinkgeber Radio Elektronik Tachograph Prozessorplatine Prozessorplatine Lenkrad Elektronische Motorsteuerung Elektronische Motorsteuerung Modul Pumpenansteuerung Elektronik Steuereinheit Eingabeeinheit Steuergeraet Klimaanlage, Heizung Modul Datensammler Anzeigeeinheit Elektronik Messtechnik USB−CAN Schnittstelle BCM GPS Antenne

flasher Radio Electronic system, tachograph Prozessing circuit board Prozessing circuit board Steering wheel Electronic engine management Electronic engine management Modul pump control Electronic control unit Keyboard Control unit,air conditioning,heating modul data−collector Display−Unit electronic measurement−equipment USB−CAN Interface BCM GPS antenna

B03 B11 B11 B16 B21 B51 B51 B55 B57 B59 B60 B61 B62 B62 B65 B88 B88 B93 B103 B104 B112 B113 B113 B114 B114 B115 B124 B124 B126 B130 B130 B131 B132 B133 B134 B135 B145

006 002 002 007 006 013 013 006 005 005 005 009 009 009 007 003 004 004 014 014 005 003 004 003 004 003 004 006 003 003 004 014 007 004 008 008 004

3 16 17 14 2 4 6 4 6 4 2 12 8 10 4 6 15 13 7 7 3 13 14 7 7 11 5 6 14 8 8 10 2 12 17 16 17

Unterdruckschalter Luftfilter Signalhorn Signalhorn Aufnehmer Vibrationsfrequenz vorne Differenzdruckschalter Hydr.−Oelfilter Lautsprecher Radio Lautsprecher Radio Kuehlmittelstand Ausgleichsbehaelter Neigungssensor Stufenumschaltung Aufnehmer Bandagengeschwindigkeit Aufnehmer Achsgeschwindigkeit Aufnehmer Verstellzylinder Beschleunigungsaufnehmer Beschleunigungsaufnehmer Sensor, Lenkwinkel vorn Druckgeber Motoroel Druckgeber Motoroel Leistungskraftstoffdruck Sensor RPS Temperaturschalter Klimaanlage Druckschalter Klimaanlage Druckgeber Fahrpumpe EMR Temperaturgeber Kuehlmittel EMR Temperaturgeber Kuehlmittel EMR Aufnehmer, Motordrehzahl 1 EMR Aufnehmer, Motordrehzahl 1 Geber Ladeluftdruck Geber Wasserstandsabscheider Diesel Geber Wasserstandsabscheider Diesel EMR Temperaturgeber Kraftstoff EMR Aufnehmer, Motordrehzahl 2 EMR Aufnehmer, Motordrehzahl 2 Temperaturschalter Heizung Inititator Armlehne links Sensor Ladeluftdruck / −temperatur Näherungsschalter Platten oben Näherungsschalter Platten mitte Sensor Niederdruck Kraftstoff

Vacuum switch, air cleaner Warning horn Warning horn Transducer, vibration frequency, front Pressure diff. switch, hydr. oil filter Speaker radio Speaker radio Coolant charge expansion tank Slope sensor, speed range selection Sensor, drum speed Sensor, axle speed Sensor, ajustable zylinder Acceleration sensor Acceleration sensor Sensor, angularity steering, front Sender, engine oil pressure Sender, engine oil pressure Rail pressure sensor Temperature switch, air conditioning Pressure switch, air conditioning pressure sender, driving pump EMR Temperature switch, collant EMR Temperature switch, collant EMR Trancducer, engine speed 1 EMR Trancducer, engine speed 1 Sender, charging air pressure Sender, water separator fuel Sender, water separator fuel EMR fuel temperature sender EMR Trancducer, engine speed 2 EMR Trancducer, engine speed 2 Temperature switch, heating proximity switch left arm rest sesnor charging air prssure / temperature proximity switch, plate up proximity switch, plate middle fuel low pressure sensor

E08 E09 E10 E11 E12 E13 E14 E15 E16 E17 E23 E23 E25 E25 E27 E27 E28 E28 E29 E30 E32 E70 E71 E72

012 012 012 012 012 012 012 012 012 012 012 013 012 013 012 013 012 013 013 014 013 013 013 013

17 18 19 19 7 6 7 8 2 2 11 18 12 19 10 17 11 17 3 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 F05 F07 F08 F09 F10 F11 F13 F15 F18 F19 F22 F23 F24 F31 F39 F40 911 F41

002 002 012 012 012 012 012 002 014 012 012 012 002 006 014 002 014 013

6 13 15 18 6 8 2 11 19 5 12 10 18 2 3 19 15 19

Hauptsicherung Batterie Sicherung Steckdose Sicherung Warnblinker Sicherung Blinker u. Arbeitsscheinw. Sicherung Park− u. Schlussl. links Sicherung Park− u. Schlussl. rechts Sicherung Scheinwerfer links Sicherung Startschalter Sicherung Heizgeraet Vorsicherung Arbeitsscheinw. vorne Sicherung Arbeitsscheinw. vorne li. Sicherung Arbeitsscheinwerfer hinten Sicherung Signalhorn Sicherung Ueberwachungsmodul Sicherung Kabinenluefter Hauptsicherung Kabine Sicherung Kabinenheizung Sicherung Rundumkennleuchte

Wiring diagram

23.07.2007 Vogt 23.07.2007 Seis

Bauteilliste component listing 1 11 101

582 702 39

008

title

A02 A12 A16 A34 A34 A45 A48 A48 A54 A66 A67 A72 A80 A81 A83 A87 A93

79

Fuse, main, battery Fuse, socket 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, 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, cabin ventilator Main fuse, cab Fuse, heating unit cab BOMAG Fuse, rotary beacon

TYP

19.3

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 10A 15A 15A 10A 10A 15A 30A BOX2 30A 15A 15A 15A 10A 20A 15A BOX2 10A

1161

Name F42 F43 F44 F48 F67 F68 F84 F93 F95 F97 FM1 FM2 FM3 FM4 FM5 F124 F130 F143 F144 F145 F146 F148 F150

Bl. 013 013 013 002 005 002 005 004 002 014 007 007 005 009 007 002 013 013 013 008 009 009 010

G01 G02 G03

19.3

23.07.2007 Vogt 23.07.2007 Seis

Pf. 3 10 13 5 7 8 9 3 15 13 6 6 1 11 6 17 15 2 20 18 5 2 14

Benennung

title

TYP

Bauteilliste component listing

Sicherung Kabineninnenleuchte Sicherung Wischermotor hinten Sicherung Wischermotor vorn Sicherung Gluehanlage Sicherung Steuerung (Potential 30) Sicherung Potential 30 Sicherung Steuerung (Klemme 54) Sicherung Steuerung (Potential 30) Sicherung Motormanagement intern Sicherung Frischluftluefter Platinensicherung Platinensicherung Platinensicherung Platinensicherung Platinensicherung Sicherung Kraftstoffvorwärmung Sicherung Nachtleuchte Sicherung Heckscheibenheizung Sicherung Kabinensteckdose Sicherung Anhängeplatten Sicherung Steuerung MESX (Potential 30) Sicherung Steuerung MESX (Potential 15) Sicherung GPS Receiver

Fuse, inside light cab Fuse, wipermotor rear Fuse, wipermotor front Fuse, glow plug system Fuse, controller (pot.30) Fuse, potential 30 Fuse, controller (Pin 54) Fuse, controller (pot. 30) Fuse, engine controller (internal) fuse, blower fresh air Multifuse Multifuse Multifuse Multifuse Multifuse Fuse, fuel pre−heating Fuse, night lamp fuse rear screen heating unit Fuse cabin−socket fuse vibration plates Fuse Controller (Pot. 30) Fuse Controller (Pot. 15) Fuse, GPS receiver

10A 15A 15A 125A 15A 5A 10A 25A 10A 3A MULTIFUSE MULTIFUSE MULTIFUSE MULTIFUSE MULTIFUSE 25A 10A 15A 15A 20A 15A 10A 5A

002 6 002 7 002 5

Batterie Generator Batterie

Battery Generator Battery

103A

H06 H07 H14 H80

012 007 005 011

15 16 11 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

LED ROT 0.15A MAX O,46A LED

K05 K06 K09 K11 K13 K14 K16 K32 K41 K43 K48 K61 K14.2 K141

008 012 002 002 002 003 012 013 004 007 008 002 004 013

3 4 10 11 18 19 9 1 2 12 2 7 20 16

Relais Startstrom Relais Scheinwerfer hinten Relais Klimageraet Relais Klemme 30 auf 15 Relais Signalhorn Relais Vorgluehen Relais Scheinwerfer vorne Relais Kabine Trennrelais D*Relais Vibration Relais Fahrhebel 0−Stellung Relais Ladekontrolle

Relay, starting current Relay, head lights, rear Relay, air conditioning Relay, terminal 30 to 15 Relay, warning horn Relay, glow plug system Relay, head lights, front Relay, cabin Relay, separation E*relay, vibration Relay, travel lever 0−position Relay, charge control

Relais Heckscheibenheizung

relay, heating rear screen

BOSCHW BOSCHW BOSCHW BOSCHL BOSCHW TYCOX BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW TYCOX BOSCHW

M01 M04 M05 M06 M07 M09 M09 M17

002 013 013 013 013 014 014 014

12 12 10 13 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

P07 P09 P11 P15 P16 P33

009 013 009 010 009 009

15 8 14 18 16 18

Omegameter Frequenz− und Geschwindigkeitsanzeige Drucker BCM 03 Bildschirm Diagnose, Variomatic Opus 21

Omegameter Frequency− and Speedometer Printer BCM 03 terminal Diagnostics, varimatic Opus 21

R03 R10 R19 R20 R21 R22 R23 R24 R25 R79 R80 R81 R82 R83 R84 R85 R86

006 002 002 005 005 005 005 009 010 002 013 002 002 002 002 002 002

5 8 4 15 15 12 12 17 18 14 2 1 1 2 2 2 3

Geber Tankanzeige Parallelwiderstand Heizflansch Widerstand Widerstand Widerstand Widerstand Widerstand Widerstand Kraftstoffvorwärmung Heizung Heckscheibe Gluehstiftkerze 1 Gluehstiftkerze 2 Gluehstiftkerze 3 Gluehstiftkerze 4 Gluehstiftkerze 5 Gluehstiftkerze 6

Sender, level gauge Parallel resistor heater flange Resistor Resistor Resistor Resistor Resistor Resistor fuel pre−heater heating rear screen glow plug 1 glow plug 2 glow plug 3 glow plug 4 glow plug 5 glow plug 6

S00 S01 S03 S06 S09 S14 S15 S16 S20 S21 S28 S30 S35 S36 S37 S38 S42

002 002 002 005 008 012 012 012 013 013 014 002 008 008 012 013 008

11 15 18 10 8 15 4 4 13 10 19 5 7 11 18 19 11

Startschalter Schalter NOT AUS Taster Signalhorn Sitzkontaktschalter links Vibrationsschalter vorne Warnblinkschalter Beleuchtungsschalter StVZO Schalter Arbeitsbeleuchtung vorne Schalter Scheibenwischer vorne Schalter Scheibenwischer hinten Schalter Kabinenheizung Batterietrennschalter Vibrationsschalter klein/gross Vibrationsschalter Schalter Blinker Schalter Kennleuchte Stufenumschalter schnell−langsam

Wiring diagram

103A

2.3 KW 4,7A 2,9A MAX. 3,8A MAX. 3,8A

0 .. 67 OHM 82 OHM 167A 120 OHM 120 OHM 120 OHM 120 OHM 60 OHM 60 OHM 250W MAX. 13A

2 11 102

582 702 39

1162

Starter switch Switch, emergency off Push button, warning horn Switch, seat contact, lh. Switch, vibration, front Switch, hazard light Switch, lighting StVZO Switch, working head lights, front Switch, windscreen wiper, front Switch, windscreen wiper, rear Switch, cabin heating Switch, battery disconnect Switch, vibration low/high Switch, vibration Switch, indicator Switch, warning light BOMAG Speed range selector, fast−slow

NOTAUSH

008 911 79

Name

Benennung

Bl. 014 013 008 008 013 006 006 008 013 013

Pf. 3 3 6 10 3 17 19 13 15 16

Schalter Kabinenluefter Schalter Kabineninnenleuchte Schalter Fahrhebel Schalter Schwimmstellung Schalter Tuer, links Schalter Motordrehzahl Schalter Frequenzverstellung Schalter Frequenzverstellung Schalter Nachtbeleuchtung Schalter Heckscheibenheizung

Switch, cabin ventilator Switch, cabin inside light Switch, travel control lever Switch, float position Switch door, lh. Switch, engine rpm Switch, frequency control Switch, frequency control Switch, cabin night lamp switch rear screen heating unit

V01 V03 V04 V06

002 002 014 014

9 17 8 9

Diode Diode Diode Diode

Diode Diode Diode Diode

002 005 012 002 002 002 002 002 002 007 007 006 006 006 007 007 012 005 005 005 005 005 005 005 005 005 005 005 007 007 007 007 007 007 007 005 005 002 006 005 006 007 009 012 012 009 006 006 006 007 004 004 004 006 006 003 003 002 002 002 002 002 002 002 006 006 004 006 004 006 002 002 006 006 007 005 007 007 005 006 006 007 007

7 9 10 11 11 13 13 6 6 15 15 2 2 3 14 15 4 3 2 8 14 15 16 16 12 12 13 13 4 6 6 6 6 6 6 1 1 11 16 17 13 16 15 5 4 15 16 13 14 16 18 18 19 3 4 19 19 18 17 16 17 16 17 18 5 2 5 6 5 7 7 7 3 4 17 11 15 14 11 2 5 17 14

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 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 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 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 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 ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK

Wiring diagram

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Bauteilliste component listing 3 11 103

582 702 39

008

title

S44 S45 S55 S64 S86 S127 S139 S139 S158 S163

X1:1 X1:2 X1:2 X1:3 X1:4 X1:7 X1:8 X1:9 X1:10 X1:37 X1:38 X1:39 X1:40 X1:41 X1:41 X1:42 X1:43 X1:44 X1:45 X1:46 X1:47 X1:48 X1:49 X1:50 X1:51 X1:52 X1:53 X1:54 X1:55 X1:56 X1:57 X1:58 X1:59 X1:60 X1:61 X1:62 X1:63 X1:79 X1:80 X1:82 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 X1:94 X1:94 X1:95 X1:96 X1:98 X1:100 X1:101 X1:102 X1:103 X1:104 X1:104 X1:105 X1:106 X1:107 X1:107 X1:108 X1:108 X1:109 X1:110 X1:111 X1:112 X1:113 X1:114 X1:115 X1:116 X1:117 X1:117 X1:117 X1:117 911 X1:11879

WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX 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

19.3

FE5B FE5B FE5B

1163

Name

19.3

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Bauteilliste component listing 4 11 104

582 702 39

1164

X1:119 X1:120 X1:121 X1:122 X1:123 X1:123 X1:123 X1:124 X1:124 X1:141 X1:142 X1:142 X1:143 X1:143 X1:143 X1:144 X1:145 X1:146 X1:147 X1:148 X1:149 X1:149 X1:149 X1:149 X1:14A X1:14E 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 X1:164 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 X1:175 X1:176 X1:177 X1:178 X1:179 X1:179 X1:17A X1:17E X1:180 X1:180 X1:181 X1:181 X1:182 X1:182 X1:183 X1:183 X1:184 X1:184 X1:185 X1:185 X1:186 X1:186 X1:187 X1:188 X1:189 X1:18A X1:18E X1:190 X1:190 X1:190 X1:191 X1:192 X1:193 X1:194 X1:195 X1:196 X1:197 X1:197 X1:198 X1:199 X1:19A X1:19E

Bl. 005 005 005 005 002 005 005 005 005 005 005 005 005 005 005 005 005 005 007 007 005 006 007 008 004 004 007 002 002 008 007 002 008 008 005 007 002 002 007 007 007 014 006 014 014 014 014 002 014 014 002 002 014 005 005 005 005 005 005 005 005 003 004 005 005 003 004 003 004 003 004 003 004 003 004 003 004 003 004 007 007 007 012 012 007 011 014 004 004 004 004 007 007 007 007 004 004 012 012

Pf. 2 4 12 13 11 12 13 16 18 16 18 19 15 19 19 15 9 9 17 2 10 12 2 3 3 3 17 15 15 3 4 18 9 9 10 7 11 11 7 7 7 3 11 5 3 4 10 10 10 7 13 13 7 2 2 2 2 4 6 5 4 2 9 7 7 3 18 3 18 5 19 2 3 2 13 19 2 4 20 14 15 14 2 2 19 12 8 14 14 13 13 6 5 5 6 5 5 15 15

Benennung 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 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 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 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 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 ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK 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

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

Wiring diagram

008 911 79

Name X1:201 X1:202 X1:203 X1:205 X1:206 X1:207 X1:208 X1:209 X1:20A X1:20E X1:210 X1:211 X1:212 X1:213 X1:214 X1:215 X1:217 X1:218 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 X1:309 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 X2:43 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 X2:64 911 X2:65 79

Bl. 007 007 007 007 007 007 007 008 002 002 008 008 008 008 008 008 002 002 012 012 012 012 012 012 012 012 012 012 012 012 002 002 002 002 006 006 012 012 012 012 012 012 012 012 002 002 012 012 012 012 012 012 012 012 012 012 012 012 008 008 012 012 012 012 012 012 012 009 009 002 002 005 005 009 009 010 010 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 010 010 009 010 009 009

Pf. 4 4 4 11 11 11 11 18 8 8 14 14 15 19 19 13 14 14 10 10 12 12 6 6 8 8 18 18 5 5 15 15 18 18 2 2 5 5 9 15 18 18 18 2 19 19 2 7 7 17 19 2 7 17 2 7 19 6 18 18 8 18 19 6 18 8 19 2 2 17 17 9 9 5 5 14 15 18 19 9 19 17 18 13 8 7 8 7 2 10 9 10 9 17 18 13 15 14 14

Benennung 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 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 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 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 ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK 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

Wiring diagram

23.07.2007 Vogt 23.07.2007 Seis

Bauteilliste component listing 5 11 105

582 702 39

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−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 Wago−measurement equip.

TYP

19.3

1165

Name

19.3

23.07.2007 Vogt 23.07.2007 Seis

Bauteilliste component listing 6 11 106

582 702 39

1166

X2:66 X2:66 X2:67 X2:68 X2:69 X2:70 X2:70 X2:71 X2:73 X2:74 X2:75 X2:76 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 X3:17 X3:18 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 X14:A X14:B X15:1 X15:2 X16:1 X16:2 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 X25:2 X25:3 X25:4 X26:1 X26:2 X26:3 X26:4 X26:5 X26:6 X26:8 X26:9 X26:10 X26:11 X26:12 X27:1 X27:2 X27:3 X27:4

Bl. 009 009 009 009 009 009 010 009 009 009 009 009 009 009 009 010 010 012 013 013 002 012 012 013 013 013 014 014 014 014 014 014 013 013 009 009 009 009 009 010 010 010 010 010 010 007 007 007 007 006 006 005 005 002 013 006 006 005 005 005 005 005 005 014 014 014 014 014 014 014 014 014 014 014 014 006 006 007 007 007 007 008 008 008 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006

Pf. 14 14 11 12 12 15 15 13 11 11 10 10 11 11 16 14 14 11 10 10 19 10 12 2 2 2 3 3 4 4 7 10 6 6 14 14 14 14 15 15 15 14 15 18 17 13 14 15 14 6 6 11 11 19 20 5 5 10 10 13 13 12 12 3 3 4 5 10 10 7 7 7 7 7 7 4 4 14 15 15 14 10 11 11 8 8 2 9 2 9 3 7 4 9 12 11 5 10 6

Benennung 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 SETCKER 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 KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. STECKER VIBRATION GRO STECKER VIBRATION GRO STECKER VIBRATION KLE STECKER VIBRATION KLE STECKER WASSERABSCHEI STECKER WASSERABSCHEI STECKER RÜCKFAHRALARM STECKER RÜCKFAHRALARM Steckdose Steckdose STECKER TAUCHROHRGEBE STECKER TAUCHROHRGEBE STECKER SITZKONTAKT STECKER SITZKONTAKT STECKER FAHRPUMPE RÜC STECKER FAHRPUMPE RÜC STECKER FAHRPUMPE VOR STECKER FAHRPUMPE VOR 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 ST. FAHRSTUFENSCHALTE ST. FAHRSTUFENSCHALTE ST. FAHRSTUFENSCHALTE STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER

title 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 Con 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 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. conn. vibration big conn. vibration big conn. vibration small conn. vibration small connector water separator connector water separator conn. backupalarm conn. backupalarm Socket Socket connector fuel level sensor connector fuel level sensor connector seat contact switch connector seat contact switch connectoe driving pump back connectoe driving pump back connector driving pump front connector driving pump front 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 connector switch speed ranges connector switch speed ranges connector switch speed ranges connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector BOMAG connector data collector

TYP

Wiring diagram

008 911 79

Name X27:5 X27:6 X27:7 X27:8 X27:9 X27:10 X27:11 X27:12 X28:1 X28:2 X28:3 X28:4 X28:5 X28:6 X29:1 X29:2 X29:3 X29:4 X29:5 X29:6 X29:7 X29:8 X30:1 X30:1 X30:2 X30:2 X30:3 X30:3 X30:4 X30:4 X30:5 X30:5 X30:6 X30:10 X30:11 X30:12 X30:13 X30:14 X30:15 X30:17 X30:22 X30:23 X30:24 X30:25 X30:25 X30:28 X30:60 X30:61 X30:62 X30:63 X30:64 X30:72 X30:82 X31:1 X31:1 X31:2 X31:3 X31:4 X31:5 X31:6 X31:7 X31:7 X31:8 X31:8 X31:9 X31:10 X31:10 X31:11 X31:11 X31:12 X31:12 X31:13 X31:13 X31:14 X31:14 X31:15 X31:16 X31:16 X31:17 X31:18 X31:19 X31:19 X31:20 X31:20 X31:21 X31:22 X31:23 X31:23 X31:24 X31:24 X31:25 X31:26 X31:27 X31:31 X31:32 X31:33 X31:34 X31:40 911 X31:4179

Bl. 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 003 004 003 004 003 004 003 004 003 004 004 003 003 003 003 003 003 003 003 003 003 003 004 004 004 004 004 004 004 004 004 003 004 003 003 003 003 003 003 004 003 004 003 003 004 003 004 003 004 003 004 003 004 003 003 004 003 003 003 004 003 004 003 003 003 004 003 004 003 004 004 004 004 004 004 004 004

Pf. 11 9 10 2 7 10 10 10 16 13 13 14 16 17 14 14 15 15 17 17 18 17 5 3 5 18 8 3 7 18 7 3 19 2 2 3 3 2 7 6 5 6 6 6 13 9 13 14 14 5 5 2 13 16 5 17 17 12 14 15 17 9 13 14 13 8 7 8 17 7 8 7 16 9 12 9 11 1 10 10 10 10 6 8 6 6 11 11 11 19 12 13 9 4 6 3 20 12 15

Benennung STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor

Wiring diagram

23.07.2007 Vogt 23.07.2007 Seis

Bauteilliste component listing 7 11 107

582 702 39

008

title connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine BOMAG EMR−connector engine

TYP

19.3

1167

Name

19.3

23.07.2007 Vogt 23.07.2007 Seis

Bauteilliste component listing 8 11 108

582 702 39

1168

X31:43 X31:46 X31:47 X31:48 X31:49 X31:50 X31:51 X31:53 X31:54 X31:56 X31:57 X31:58 X32:A X32:A X32:B X32:B X32:F X32:G X32:G X32:H X32:H X32:K X32:K X32:L X32:M X33:1 X33:2 X33:3 X33:4 X33:5 X33:6 X33:7 X33:8 X34:A X34:B X34:C X34:D X34:G X34:H X34:J X34:N X34:P X34:R X35:1 X35:2 X35:3 X35:4 X35:5 X35:12 X35:15 X35:16 X35:17 X35:18 X35:19 X35:20 X35:21 X35:22 X35:23 X35:24 X35:26 X35:27 X35:28 X35:29 X35:30 X35:31 X35:33 X35:34 X35:35 X35:37 X35:38 X35:40 X35:41 X35:43 X35:46 X35:47 X35:48 X35:49 X35:53 X35:54 X35:55 X35:56 X35:57 X35:58 X35:59 X35:60 X35:61 X35:64 X35:65 X35:66 X35:67 X35:68 X36:A X36:B X37:A X37:B X38:A X39:1 X39:2 X39:3

Bl. 004 004 004 004 004 004 004 004 004 004 004 004 003 004 003 004 004 003 004 003 004 003 004 003 004 003 003 003 003 003 003 003 003 005 005 005 005 005 005 007 003 002 006 007 007 007 005 005 005 005 007 007 007 007 007 007 007 007 005 005 005 005 007 005 005 005 005 007 005 005 007 007 007 005 005 007 005 005 005 005 005 005 005 005 005 007 005 005 005 005 005 002 002 002 002 002 007 007 007

Pf. 13 2 1 5 11 7 15 13 18 16 17 14 2 12 3 14 14 3 13 3 13 2 13 2 14 19 18 18 19 18 19 17 20 14 16 12 13 10 11 3 4 13 2 4 12 16 11 10 3 10 4 18 11 11 5 6 11 6 11 16 15 2 4 9 5 13 6 15 5 2 11 11 10 15 16 14 12 12 9 18 7 7 8 8 8 17 13 18 19 19 19 6 5 11 12 13 9 10 10

Benennung EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER EINSPEISUNG SCHALTKAS EINSPEISUNG SCHALTKAS ST. ZÜNDSCHLOSS E−KAS ST. ZÜNDSCHLOSS E−KAS STECKER STARTER E−KAS STECKER 1 LENKRAD STECKER 1 LENKRAD STECKER 1 LENKRAD

title EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector supply e−box supply e−box connector ignition switch, e−box connector ignition switch, e−box connector starter, e−Box connector 1 steering unit connector 1 steering unit BOMAG connector 1 steering unit

TYP

Wiring diagram

008 911 79

Name X39:4 X40:1 X40:2 X40:3 X40:4 X41:1 X41:2 X41:3 X41:4 X41:5 X41:6 X41:7 X41:8 X42:1 X42:2 X42:3 X42:4 X42:5 X43:1 X43:2 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 X44:46 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 X50:1 X50:2 X50:3 X51:1 X51:2 X51:3 X52:1 X52:2 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 X56:1 911 X56:2 79

Bl. 007 007 007 007 007 007 007 007 007 007 007 007 007 009 009 009 009 009 007 007 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 009 008 008 008 007 007 007 005 005 014 014 014 014 014 014 014 014 014 014 014 014 013 013 013 013 013 013

Pf. 9 9 10 10 9 8 8 8 8 11 11 11 11 18 19 19 18 18 2 1 13 15 14 14 10 12 5 4 11 16 18 17 2 7 9 8 5 18 5 6 6 4 7 11 10 17 6 13 4 5 5 5 6 13 13 14 14 19 18 18 19 18 11 12 12 8 7 7 8 10 9 9 10 13 13 13 2 1 2 3 3 3 4 4 3 3 11 11 10 10 7 10 11 11 10 10 10 14 13

Benennung STECKER 1 LENKRAD STECKER 2 LENKRAD STECKER 2 LENKRAD STECKER 2 LENKRAD STECKER 2 LENKRAD ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER ADAPTER BOP STECKER SCHALTER ARML STECKER SCHALTER ARML 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 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 ST. PLATTENFREQ. ST. PLATTENFREQ. ST. PLATTENFREQ. ST. 1 LENKRADKABELBAU ST. 1 LENKRADKABELBAU ST. 1 LENKRADKABELBAU STECKER DRUCKSENSOR STECKER DRUCKSENSOR 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

Wiring diagram

23.07.2007 Vogt 23.07.2007 Seis

Bauteilliste component listing 9 11 109

582 702 39

008

title connector 1 steering unit connector 2 steering unit connector 2 steering unit connector 2 steering unit connector 2 steering unit conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conector adapter BOP conector adapter BOP conector adapter BOP conector adapter BOP conector adapter BOP connector switch arm rest connector switch arm rest 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 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. plate−freq. conn. plate−freq. conn. plate−freq. connector 1 steering wiring connector 1 steering wiring connector 1 steering wiring connector pressure sensor connector pressure sensor 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 BOMAG conn. wiper front

TYP

19.3

1169

Name

19.3

23.07.2007 Vogt 23.07.2007 Seis

Bauteilliste component listing 10 11 110

582 702 39

1170

X56:3 X56:4 X57:1 X57:1 X57:2 X57:3 X57:4 X57:5 X57:6 X57:8 X57:9 X57:9 X57:10 X57:11 X57:12 X57:13 X57:13 X57:14 X57:14 X57:15 X57:15 X57:16 X57:17 X57:18 X57:19 X57:19 X57:20 X57:20 X57:21 X57:21 X57:22 X57:22 X57:23 X57:23 X57:23 X57:24 X57:24 X57:25 X57:25 X57:26 X57:27 X57:28 X57:28 X57:29 X57:29 X57:30 X57:31 X57:32 X57:33 X57:34 X57:35 X57:36 X57:37 X57:39 X57:40 X57:41 X57:42 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 X62:1 X62:2 X62:3 X62:4 X62:5 X62:6 X62:7 X62:8 X62:9 X62:10 X62:11 X62:12 X62:13 X62:14 X62:15 X63:1 X63:1 X63:2 X63:2 X65:1 X65:2 X65:3

Bl. 013 013 003 004 003 003 003 003 003 003 003 004 003 003 003 003 004 003 004 003 004 003 003 003 003 004 003 004 003 004 003 004 003 004 004 003 004 003 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 004 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 011 011 011

Pf. 13 12 15 9 13 14 12 14 15 13 13 8 8 8 7 7 7 9 7 9 9 11 10 10 10 10 6 11 6 8 6 12 11 12 17 11 15 12 13 16 15 11 17 13 18 14 14 13 16 1 1 3 5 2 4 6 5 17 7 2 2 7 17 19 7 2 2 7 19 18 18 6 6 19 19 8 8 19 19 18 16 16 17 17 18 18 18 15 17 19 20 19 13 14 13 14 5 5 5

Benennung STECKER WISCHER VORNE STECKER WISCHER VORNE Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor 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 DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN SCHNELLVERSCHLUSSKUPP SCHNELLVERSCHLUSSKUPP SCHNELLVERSCHLUSSKUPP SCHNELLVERSCHLUSSKUPP KEYBOARD KEYBOARD KEYBOARD

title conn. wiper front conn. wiper front connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine 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. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates quick connecting clutch quick connecting clutch quick connecting clutch quick connecting clutch Keyboard Keyboard BOMAG Keyboard

TYP

Wiring diagram

008 911 79

Name X65:4 X65:5 X65:7 X65:8 X65:9 X65:10 X65:11 X65:12 X66:2 X66:3 X67:1 X67:2 X68:1 X68:2 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. 011 011 011 011 011 011 011 011 004 004 002 002 011 011 014 014 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 009 009 009 009 009 010 010 010 010 014 014 010 010 010 010

Pf. 5 5 5 12 5 5 5 5 19 20 14 14 15 16 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

Y04 Y07 Y08 Y14 Y15 Y16 Y17 Y30 Y31 Y92 Y93 Y98 Y122 Y123 Y137 Y137 Y138 Y140 Y141 Y142 Y143 Y144.1 Y144.2 Y145 Y147 Y148 Y149 Y166 Y169 Y170

007 007 007 014 014 005 005 005 005 007 007 008 008 008 003 004 014 009 009 008 008 008 008 008 004 004 004 004 004 004

17 15 13 15 7 13 12 15 16 6 5 14 16 17 10 10 10 10 11 17 18 19 19 20 1 3 5 2 6 4

Benennung

title

KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD KEYBOARD ANSCHLUß EMR3 VORGLÜH ANSCHLUß EMR3 VORGLÜH STECKER KRAFTSTOFFHEI STECKER KRAFTSTOFFHEI STECKER LED STECKER LED 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

Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard Keyboard connector EMR3 preglow connector EMR3 preglow connector fuel pre−heater connector fuel pre−heater connector led connector led 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

Magnetventil Bremse D*Prop. Ventil Vibration groß D*Prop. Ventil Vibration groß Kraftstoffpumpe Heizgeraet Magnetkupplung Klimakompressor Magnetventil Fahrtrichtung vorwaerts Magnetventil Fahrtrichtung rueckwaerts Magnetventil Stufenumschaltung vorn Magnetventil Stufenumschaltung hinten Magnetventil Lenkung vorne rechts Magnetventil Lenkung vorne links Magnetventil Vibrationsfrequenz, hinten Magnetventil Platten heben Magnetventil Platten senken EMR Verstellung EMR Verstellung Magnetveentil Heizung Magnetventil Erreger auf Magnetventil Erreger ab Magnetventil Plattenverschieben Links Magnetventil Plattenverschieben rechts

Solenoid valve, brake E*prop. Valve vibration high E*prop. Valve vibration high Fuel pump, heating unit Magnetic clutch, air conditioning compr. Solenoid valve, travel direction forw. Solenoid valve, travel direction backw. Solenoid valve, speed range sel., front Solenoid valve, speed range sel., rear Solenoid valve, steering, front rh. Solenoid valve, steering, front lh. Solenoid valve, vibrat.freq.,rear Solenoid valve, lift plates Solenoid valve, let down plates EMR adjustment EMR adjustment Solenoid valve, heating unit solenoid valve exciter up solenoid valve exciter down solenoid valve, plate displace left solenoid−valve, plate displace right

Magnetventil Platten (Priorität) Injektor A1 Injektor A2 Injektor A3 Injektor A4 Injektor A6 Injektor A5

solenoid−valve, plate (priority) jet pump A1 jet pump A2 jet pump A3 jet pump A4 jet pump A6 jet pump A5

Wiring diagram

TYP

19.3

23.07.2007 Vogt 23.07.2007 Seis

Bauteilliste component listing

MAX. 1.8A 0.4 .. 1.2A 0.4 .. 1.2A 3,5A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A MAX. 1.8A MAX. 1.8A

1A 0.4 .. 1.2A 0.4 .. 1.2A MAX. 1.8A MAX. 1.8A MAX. 1.8A MAX. 1.8A MAX. 1.8A

11 11 111

582 702 39

008 911 79

BOMAG

1171

X36

X37

X38

K11

1172

BOMAG B57

X32:1-12

K09

K16

A02

008 911 79

overview e-box BW 177...226 DH/BVC-4

Gepr.: 23.07.2007 Name: Seis

Name: Vogt

Übersicht Schaltkasten BW 177...226 DH/BVC-4

K13

K41

K61

K48

K43

K06

K05

Gez.: 23.07.2007

X34:1-19

Nur bei Klimaanlage only acc. to aircond.

R10

Nur bei StvzO only acc. To StvZO illumination

Replaces:

Ers. f.:

page: 1

Seite: 1

A80

von: 2 from: 2

582 702 39 Sheet No.: 201

Blatt Nr.: 201

19.3 Wiring diagram

F1

F2

008 911 79 A34 Fahrsteuerung

A83 Messtechnik Steuerung

CAN 1

Nur bei VM8 only acc. To VM8

BOMAG

Übersicht Schaltkasten-Tür BW 177...226 DH-4 overview e-box door BW 177...226 DH-4

Gepr.: 23.07.2007

1173

Name: Seis

Name: Vogt

Gez.: 23.07.2007

BCM

Replaces:

Ers. f.:

page: 2

Seite: 2

OPUS 21

CAN 1

CAN 3

EMR + Fahrhebel

LCD+ Datensammler

CAN 2

CAN 1

von: 2 from: 2

582 702 39 Sheet No.: 201

Blatt Nr.: 201

Wiring diagram

19.3

19.3

Wiring diagram

057 564 17

2

280-315

3

2 x 057 564 25 "L" + 793-501

5

057 564 25 "L" + 057 564 20 + 793-501

6

057 564 25 "L" + 793-501

7

057 564 22

8

057 564 23 "L" + 057 564 19 + 793-501

9

057 564 23 "L" + 793-501

10

057 564 23 "L" + 057 564 19 + 793-501

11

057 564 23 "L" + 793-501

12

057 564 36 "R" + 2 x 057 564 19 + 793-501

13

5 x 057 564 36 "R" + 057 564 19 + 793-501

18

057 564 36 "R" + 793-501

19

057 564 36 "R" + 057 564 19 + 793-501

20

057 564 36 "R" + 793-501

21

057 564 36 "R" + 057 564 19 + 793-501

22

057 564 36 "R" + 793-501

23

6 x 057 564 36 "R" + 057 564 19 + 793-501

29

5 x 057 564 36 "R" + 793-501

247,0 mm

1

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Plan : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Absicherung DH-4 komplett

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. 31.07.2007 09:11:11

1174

371,0 mm

WAGO smart DESIGNER 5.0

BOMAG

Seite 1

008 911 79

19.3

Wiring diagram

057 564 35

35

057 564 17

36

057 564 21

37

2 x 057 564 25 "L" + 793-501

39

057 564 25 "L" + 057 564 20 + 793-501

40

057 564 25 "L" + 793-501

41

057 564 25 "L" + 057 564 20 + 793-501

42

5 x 057 564 25 "L" + 793-501

47

057 564 25 "L" + 057 564 20 + 793-501

48

057 564 25 "L" + 793-501

49

057 564 25 "L" + 057 564 20 + 793-501

50

057 564 25 "L" + 793-501

51

057 564 25 "L" + 057 564 20 + 793-501

52

057 564 25 "L" + 793-501

53

057 564 25 "L" + 057 564 20 + 793-501

54

2 x 057 564 25 "L" + 793-501

56

4 x 057 564 38 "L" + 793-501

60

057 564 17

0,0 mm

123,5 mm

371,0 mm

34

0,5 mm

247,0 mm

WAGO smart DESIGNER 5.0

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Plan : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Absicherung DH-4 komplett

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. 31.07.2007 09:11:11

008 911 79

BOMAG

Seite 2

1175

19.3

Wiring diagram

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Plan : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Absicherung DH-4 komplett

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. 31.07.2007 09:11:15

1176

371,0 mm

247,0 mm

WAGO smart DESIGNER 5.0

BOMAG

Seite 3

008 911 79

19.3

Wiring diagram

0,0 mm

123,5 mm

371,0 mm

0,5 mm

247,0 mm

WAGO smart DESIGNER 5.0

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Plan : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Absicherung DH-4 komplett

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. 31.07.2007 09:11:15

008 911 79

BOMAG

Seite 4

1177

19.3

Wiring diagram

057 564 17

2

3 x 057 565 40 "R" + 793-501

5

057 565 35 "R" + 793-501

6

057 565 37

7

3 x 057 565 40 "R" + 793-501

10

057 565 37

11

057 565 40 "R" + 793-501

12

057 565 35 "R" + 793-501

13

057 565 37

14

057 565 40 "R" + 793-501 + 057 565 36

15

057 565 40 "R" + 793-501

16

2 x 057 565 39 "R" + 793-501

18

057 565 37

19

4 x 057 565 40 "R" + 793-501

23

057 565 37

24

4 x 057 565 40 "R" + 793-501

28

2 x 057 565 39 "R" + 793-501

30

057 565 37

31

057 565 40 "R" + 793-501

32

057 565 39 "R" + 793-501

33

057 565 37

34

4 x 057 565 40 "R" + 793-501

38

057 565 35 "R" + 793-501

39

057 565 37

40

4 x 057 565 40 "R" + 793-501

44

057 565 37

45

057 565 40 "R" + 793-501

46

057 565 35 "R" + 793-501

47

057 565 37

48

057 565 40 "R" + 793-501

49

057 565 35 "R" + 793-501

50

057 565 37

345,0 mm

1

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Plan : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Kabelbäume DH-4 komplett

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. 31.07.2007 09:08:54

1178

370,0 mm

WAGO smart DESIGNER 5.0

BOMAG

Seite 1

008 911 79

19.3

Wiring diagram

52

2 x 057 565 40 "R" + 793-501

54

057 565 38 "R" + 793-501

55

057 565 37

56

3 x 057 565 40 "R" + 793-501

59

057 565 38 "R" + 793-501

60

057 565 37

61

3 x 057 565 40 "R" + 793-501

64

057 565 35 "R" + 793-501

65

057 565 37

66

2 x 057 565 40 "R" + 793-501

68

057 565 35 "R" + 793-501

69

057 565 37

70

3 x 057 565 40 "R" + 793-501

73

057 565 35 "R" + 793-501

74

057 565 37

75

2 x 057 565 40 "R" + 793-501

77

2 x 057 565 35 "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

057 564 17

370,0 mm

057 565 38 "R" + 793-501

25,0 mm

51

345,0 mm

WAGO smart DESIGNER 5.0

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Plan : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Kabelbäume DH-4 komplett

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. 31.07.2007 09:08:54

008 911 79

BOMAG

Seite 2

1179

19.3

Wiring diagram

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Plan : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Kabelbäume DH-4 komplett

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. 31.07.2007 09:08:59

1180

370,0 mm

345,0 mm

WAGO smart DESIGNER 5.0

BOMAG

Seite 3

008 911 79

19.3

Wiring diagram

25,0 mm

370,0 mm

345,0 mm

WAGO smart DESIGNER 5.0

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Plan : Ort : Tragschiene :

DH-4

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Kabelbäume DH-4 komplett

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. 31.07.2007 09:08:59

008 911 79

BOMAG

Seite 4

1181

19.3

Wiring diagram

2 x 057 565 40 "R" + 793-501

4

057 565 37

5

057 565 40 "R" + 793-501 + 057 565 36

6

057 565 40 "R" + 793-501

7

057 565 39 "R" + 793-501

8

057 565 37

9

057 565 38 "R" + 793-501

10

2 x 057 565 40 "R" + 793-501

12

057 565 38 "R" + 793-501

13

057 565 37

14

2 x 057 565 40 "R" + 793-501

16

057 565 39 "R" + 793-501

17

057 565 37

18

057 565 40 "R" + 793-501

19

057 565 38 "R" + 793-501

20

057 565 40 "R" + 793-501

21

057 565 37

22

057 565 40 "R" + 793-501

23

057 565 39 "R" + 793-501

24

057 565 37

25

057 564 21

26

2 x 057 564 38 "L" + 793-501

28

057 564 25 "L" + 793-501

29

057 564 36 "R" + 793-501

30

057 564 35

31

057 564 17

130,5 mm

057 564 17

2

1,7 mm

1

240,0 mm

107,8 mm

WAGO smart DESIGNER 5.0

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Plan : Ort : Tragschiene :

Messtechnik DH / BVC*

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Klemmenleiste X2

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. 31.07.2007 09:12:14

1182

BOMAG

Seite 1

008 911 79

19.3

Wiring diagram

1,7 mm

130,5 mm

240,0 mm

107,8 mm

WAGO smart DESIGNER 5.0

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Plan : Ort : Tragschiene :

Messtechnik DH / BVC*

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

Klemmenleiste X2

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. 31.07.2007 09:12:17

008 911 79

BOMAG

Seite 2

1183

19.3

Wiring diagram

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

74,0 mm

057 564 17

14,0 mm

1

100,0 mm

12,0 mm

WAGO smart DESIGNER 5.0

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Plan : Ort : Tragschiene :

E2 Beleuchtung

Optional3 : Optional4 :

Option E2 StvZO Beleuchtung

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Größe der Bohrung :

Optional7 :

M. Vogt TEE

Lieferadresse :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten. 31.07.2007 09:11:41

1184

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

BOMAG

Seite 1

008 911 79

19.3

Wiring diagram

74,0 mm 14,0 mm

100,0 mm

12,0 mm

WAGO smart DESIGNER 5.0

Optional1 :

Projektgruppe :

Walzenzüge -4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Plan : Ort : Tragschiene :

E2 Beleuchtung

Optional3 : Optional4 :

Option E2 StvZO Beleuchtung

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Größe der Bohrung :

Optional7 :

M. Vogt TEE

Lieferadresse :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten. 31.07.2007 09:11:43

008 911 79

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : gezeichnet: : geprüft: :

BOMAG

Seite 2

1185

1186

BOMAG (BVC) (BVC)

X47 X48 X49

(BVC) (BVC)

X47 X48 X49

X70 X73

X71 X72

X52

X58

X59

X53

X54

X77

X69

X28 X19

X29 X18

X56

X75 X76

X17

X73 X74 X70

X72

X71

X19

X52

X77

X27

X35

X44

X32 X34

X27

X6 X7

X6 X7 X15 X16

X60

X9

X61

X9

X62

X61 X62

X60

X15 X16

008 911 79

Name: Seis

Name: Vogt

overview e-box door BW 177...226 DH-4

X67 X8 X10

X67 X8 X10

Gepr.: 23.07.2007

X57

X57

Übersicht Schaltkasten-Tür BW 177...226 DH-4

X20

X21

X21

Gez.: 23.07.2007

X38 X32

X26

X4 X3 X37 X44 X2

X33

X43

X55

X36 X35 X1

X31

X30

X39 X40

X14

X46 X25 X41 X13 X51

X20

X77

X26

X38 X2

X37 X1

X4 X3

X36

X33

X42 X23 X11 X24 X12 X50

X31

X30

X14

X46

X18

X51 X43

X42

X58 X69

X55

X39 X23 X11 X24 X12 X50 X40 X25 X41 X13

X17

X53 X54

X59

X28

X29

X56 X76

X74 X75 X77

Replaces:

Ers. f.:

page: 1

Seite: 1

von: 1 from: 1

582 702 39 Sheet No.: 301

Blatt Nr.: 301

19.3 Wiring diagram

19.4 Hydraulic diagram

008 911 79

BOMAG

1187

19.4

1188

Hydraulic diagram

BOMAG

008 911 79

19.4

Hydraulic diagram

008 911 79

BOMAG

1189

19.4

1190

Hydraulic diagram

BOMAG

008 911 79