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BOMAG BW 211 D-40 SERVICE MANUAL

Table of Contents
Safety regulations
Important Notes
Special safety regulations
General repair instructions
Hydraulic System
Air conditioning system
Fuel hoses
Ball and roller bearings
 Service - Manual

BW 211 / 212 / 213 D-40

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

Single drum roller

Catalogue number.
008 911 63 03/2008
 Table of Contents

General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 24
Maintenance 29
2.1 General notes on maintenance 30
2.2 Table of fuels and lubricants 32
2.3 Running-in instructions 33
2.4 Maintenance chart 34
Technical data 37
3.1 Technical data 38
Connection overview 47
4.1 Connection overview 48
Tests and adjustments 51
5.1 Special tools, tests and adjustments 52
5.2 Checking the rotation speeds 56
5.3 Checking / adjusting the neutral positions of the travel pump 58
5.4 Pressure tests in the travel circuit 60
5.5 Checking / adjusting the vibrator shaft speeds 62
5.6 Pressure measurements in the vibration circuit 63
5.7 Check the leakage rate of the vibration motor 64
5.8 Pressure test in steering circuit 65
Flushing and bleeding 67
6.1 Special tools for flushing 68
6.2 Flushing - general 73
6.3 Flushing schematic travel circuit (distribution travel pump) 75
6.4 Flushing the travel circuit (travel pump distribution) 77
6.5 Flushing schematic travel circuit (distribution axle motor) 83
6.6 Flushing the travel circuit (axle motor distribution) 88
6.7 Flushing schematic for vibration drive 93
6.8 Flushing the vibration circuit 94
6.9 Bleeding the travel circuit 98
6.10 Bleeding the vibration circuit 100
Fundamental electrics 103
7.1 Understanding circuit diagrams 104
7.2 Terminal designations 109
7.3 Current and voltage 113
7.4 CAN-Bus 116
7.5 Resistance 118
7.6 Series / parallel connection 120
7.7 Ohm's law 122
7.8 Electrical energy 122
7.9 Formula diagram 123
7.10 Metrology 124
7.11 Diodes, relays, fuses 127

008 911 63 BOMAG 3

Table of Contents

7.12 Batteries 130

7.13 Three-phase generator 133
7.14 Electric starter 141
7.15 Telemecanique switch 144
7.16 Inductive proximity switches 147
7.17 Angle sensors 148
7.18 Plug connectors 150
7.19 Deutsch plug, series DT and DTM 150
7.20 Plugs and terminals in spring clamping technology 157
7.21 Electric modules 160
Special tools, electrics 161
8.1 Special tools, electrics 162
Electronic modules 171
9.1 BEM, BOMAG Evib-meter 173
9.2 Electric module K04 234
9.3 Heating/air conditioning control 238
Speedometer Module 245
10.1 Speedometer module 246
Service Training 249
11.1 Service Training 251
Engine 315
12.1 Diesel engine, general 316
12.2 Service side 317
12.3 Starter side 318
12.4 Lubrication oil circuit 319
12.5 Oil pressure switch and low oil pressure circuitry 321
12.6 Check the engine oil level 322
12.7 Changing engine oil and oil filter cartridges 323
12.8 Coolant circuit 325
12.9 Coolant temperature switch 327
12.10 Disassembling and assembling the coolant temperature switch 328
12.11 Replacing the thermostat 329
12.12 Checking the thermostat in disassembled state 330
12.13 Check the coolant level 331
12.14 Change the coolant 331
12.15 Checking the anti-freeze concentration 332
12.16 Clean the cooling fins on engine and hydraulic oil cooler 333
12.17 Three-phase generator 334
12.18 Fuel supply 336
12.19 Injection system 339
12.20 Injection pump replacement during service 340
12.21 Injection valve replacement during service 349
12.22 Checking / repairing injection valves 352
12.23 Fuel filter 357
12.24 Check, clean the water separator 359
12.25 Change the fuel pre-filter cartridge 359
12.26 Change the fuel filter cartridge 361

4 BOMAG 008 911 63

 Table of Contents

12.27 Checking the compression 361

12.28 Check, adjust the valve clearance 362
12.29 Boost fuel solenoid valve 364
12.30 Engine shut-down solenoid 365
12.31 Air filter 366
12.32 Cleaning, changing the dry air filter cartridge 367
12.33 Heating flange on engine 369
12.34 Checking the heating flange control 372
12.35 Electric throttle control 373
12.36 Engine monitoring 375
12.37 Engine 378
12.38 Special tools, Deutz engine (BFM 2012) 380
Air conditioning system 393
13.1 Physical basics 394
13.2 Refrigerant R134a 397
13.3 Compressor oil / refrigeration oil 398
13.4 Working principle of the air conditioning system 399
13.5 Monitoring devices 399
13.6 Description of components 400
13.7 Checking the compressor oil level 406
13.8 Checking the magnetic clutch 407
13.9 Inspection and maintenance work 408
13.10 Checking, replacing the refrigerant compressor V-belt 408
13.11 Service the air conditioning 409
13.12 Drying and evacuation 412
13.13 Emptying in case of repair 412
13.14 Leak test 413
13.15 Filling instructions 414
13.16 Trouble shooting in refrigerant circuit, basic principles 417
13.17 Trouble shooting, refrigerant circuit diagram 421
13.18 Trouble shooting procedure 422
13.19 Steam table for R134a 432
Replacing the cab window panes 437
14.1 Assembly of window panes 438
14.2 Special tools 439
14.3 Auxiliary materials 440
14.4 Removing and installing the window pane 442
Drum 447
15.1 Special tools, drum, single drum rollers 448
15.2 Repair overview for drum 450
15.3 Removing and installing the drum 457
15.4 Repairing the drum 462
15.5 Disassembling and assembling the change-over weight 495
15.6 Changing the rubber buffers and adjusting the pretension 498
Oscillating articulated joint 501
16.1 Special tools, oscillating articulated joint (BW177 to BW 216) 502
16.2 Repair overview oscillating articulated joint 504

008 911 63 BOMAG 5

Table of Contents

16.3 Removing and installing the oscillating articulated joint 508

16.4 Dismantling the oscillating articulated joint 510
16.5 Assembling the oscillating articulated joint 515
Suppliers documentation 525
17.1 Travel pump 527
17.2 Vibration pump 617
17.3 Drum drive 655
17.4 Vibration motor 705
17.5 Axle drive motor 729
17.6 Axle 811
Circuit diagrams 933
18.1 Hydraulic diagram 581 202 10 935
18.2 Hydraulic diagram 581 202 11 939
18.3 Wiring diagram 582 702 09 943
18.4 Wiring diagram 582 702 29 979
18.5 Wiring diagram 582 702 41 1013

6 BOMAG 008 911 63

 1 General

008 911 63 BOMAG 7

1.1 Introduction

1.1 Introduction * The applicable documents valid at the date of print-

ing 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 suf-
ficiently trained and posses profound expert knowl-
edge, he should limit his work only to those parts and
components which will not affect the safety of the ve-
hicle 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 UN-
TERTAKE SUCH REPAIR WORK.
The repair instructions describe the removal or dis-
mantling 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 serv-
ice 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 notifica-
tion.
Information and illustrations in this manual must not
be reproduced and distributed, nor must they be used
for the purpose of competition. All rights according to
the copyright law remain expressly reserved.

Danger
!

Please observe strictly the safety regulations in

this manual, in the operating instructions as well
as the applicable accident prevention regulations.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG

8 BOMAG 008 911 63

Safety regulations 1.2
Important notes ● Mark a machine that is defective or being repaired
1.2 Safety regulations

by attaching a clearly visible warning tag to the

These safety regulations must be read and ap- steering wheel.
plied by every person involved in the repair of this ● On machines with articulated joint keep the articu-
machine. The applicable accident prevention in-
lated joint locked during work.
structions and the safety regulations in the oper-
ating and maintenance instructions must be ● Use protective clothes like hard hat, safety boots
additionally observed. and gloves.

Repair work shall only performed by appropriately

● Keep unauthorized persons away from the machine
trained personnel or by the after sales service of during repair work.
BOMAG. ● Tools, lifting gear, lifting tackle, supports and other
auxiliary equipment must be fully functional and in
Any suggestions, safety precautions and warn-
safe condition.
ings in this section are intended as a mnemonic
aid for well trained and experienced expert me- ● Use only safe and approved lifting gear of sifficient
chanics. This manual should not be considered a load bearing capacity to remove and install parts or
bible on workshop safety. components from and to the machine.

Workshop equipment and facilities as well as the

● Be careful with cleansing agents. Do not use easily
use and waste disposal of solvent, fluids, gases inflammable or harmful substances, such as gaso-
and chemicals are subject to legal regulations, line or paint thinners for cleaning.
which are intended to provide a minimum on safe- ● Cleaning or repair work on the fuel tank is very dan-
ty. It is obviously your own responsibility to know gerous. Do not smoke or allow any ignitable sparks
and adhere to these regulations. or open fire in the vicinity when cleaning or repairing
This manual contain headers like "Note", "Attention", a tank. .
"Danger" and "Environment", which must be strictly ●
When performing welding work strictly comply with
complied with in order to avoid dangers for health and the respective welding instructions.
for the environment.
Precautions and codes of conduct for
Danger
! welding work
Paragraphs marked like this highlight possible Welding work should only be performed by specially
dangers for persons. instructed expert personnel.

Caution
! Danger
!
Paragraphs marked like this highlight possible Electric shock!
dangers for machines or parts of the machine.
Sparks, fire hazard, burning of skin!
Infrared or ultraviolet radiation (arc), flashing of
i Note
eyes!
Paragraphs marked like this contain technical infor-
mation for the optimal economical use of the machine. Health hazard caused by welding work on highly
alloyed work pieces, metal coatings, paint coat-
ings, plastic coatings, oil containing dirt deposits,
Environment grease or solvent residues, etc.!
Paragraphs marked like this point out practices ● Check welding equipment and cables for damage
for safe and environmental disposal of fuels and before use (also the validity of inspection stickers).
lubricants as well as replacement parts.
● Ensure good conductivity between earth cable and
Observe the regulations for the protection of the work piece.
environment.
● Start the extraction fan before starting work and
guide with the progressing work as required.
General
●
Always isolate the burner when laying it down (re-
●
Before starting repair work stand the machine on move possible electrode residues).
level and solid ground.
● Protect cables from being damaged, use cables
● Always secure the machine against unintended roll- with insulated couplings.
ing.
●
Ensure sufficient fire protection, keep a fire extin-
● Secure the engine reliably against unintentional guisher at hand.
starting.

008 911 63 BOMAG 9

1.2 Safety regulations

● In case of welding work in fire or explosion endan- full face visor; a facility suitable for rinsing the eyes
gered environments, you should always ask for a should also be available.
welding permission. ● Avoid prolonged and repetitive contact with oil, es-
● Remove combustible parts from the vicinity or cover pecially with old oil. In case of open incisions and in-
such parts. juries seek medical advice immediately.
● Name a fire watch during and after welding work. ● Apply protective cream before starting work, so that
oil can be easier removed from the skin.
● Do not clamp the welding rod holder and the inert
gas welding gun under your arm and lay these parts ● Wash with soap and water to ensure that all oil has
only on an insulated top. been removed (a skin cleaning agent and a nail
● Place the inert gas bottles in a safe place and se- brush will help). Lanolin containing agents will re-
cure them against falling over. place natural skin oils that were lost.
● Do not use gasoline, kerosene, diesel, thinner or
● Use a protective screen or an arcing shield with
solvents to wash the skin.
welding glass, wear welding gloves and clothes,
this applies also for assisting persons. ● Do not put oil soaked cloths into your pockets.
● Switch the welding unit off before connecting weld- ● Avoid clothes, especially underpants, getting soiled
ing cables. by oil.

Behaviour in case of faults

● Overalls must be washed at regular intervals.
Clothes that cannot be washed, must be disposed
● Check electrode holders and electric cables at reg- of.
ular intervals.
●
If possible degrease components before handling.
●
In case of deficiencies switch off the welding unit
and inform supervising persons.
Environment
●
In case of an extractor fan failure or any other fault
inform the supervising persons. It is strictly prohibited to drain off oil into the soil,
the sewer system or into natural waters. Entrust
Maintenance; waste disposal special companies with the waste disposal of old
●
Replace damaged insulating jaws and welding rod oil. If in doubt you should consult your local au-
holders immediately. thorities.
●
Replace the welding wire reels only in deenergized
Hydraulics
state.
● Hydraulic oil escaping under pressure can pene-
What to do in case of accidents; First Aid trate the skin and cause severe injury. You should
●
Keep calm. therefore relieve the pressure in the system before
disconnecting any lines.
●
Call first air helpers.
● Before applying pressure to the system make sure
●
Report the accident.
that all line connections and ports have been prop-
● In case of an electric accident: Interrupt the power erly tightened and are in perfect condition.
supply and remove the injured person from the ● Hydraulic oil leaking out of a small opening can
electric circuit. If breathing and heart have stopped
hardly be noticed, therefore please use a piece of
apply reactivation measures and call for an emer-
cardboard or wood when checking for leaks. When
gency doctor.
being injured by hydraulic oil consult a physician im-
mediately, as otherwise this may cause severe in-
Old oils fections.
Prolonged and repetitive contact with mineral oils will ● Do not step in front of or behind the drums/wheels/
remove the natural greases from the skin and causes crawler tracks when performing adjustment work in
dryness, irritation and dermatitis. Moreover, used en- the hydraulic system while the engine is running.
gine oils contain potentially hazardous contaminants, Block drums and/or wheels / crawler tracks with
which could cause skin cancer. Appropriate skin pro- wedges.
tection agents and washing facilities must therefore
be provided.
●
Wear protective clothes and safety gloves, if possi-
ble.
● If there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or

10 BOMAG 008 911 63

Safety regulations 1.2
Reattach all guards and safety installations after plastic material, a so-called fluoroelastomer. Under
all work has been completed. normal operating conditions this material is safe and
does not impose any danger to health.
Environment However, if this material becomes damaged by fire or
extreme heat, it may decompose and form highly
It is strictly prohibited to drain off hydraulic oil
caustic hydrofluoric acid, which can cause severe
into the soil, the sewer system or into natural wa-
burns in contact with skin.
ters. Entrust special companies with the waste
disposal of old oil. If in doubt you should consult ● If the material is in such a state it must only be
your local authorities. touched with special protective gloves. These
gloves must be disposed of directly after use.
Fuels ● If the material has contacted the skin despite these
measures, take off the soiled clothes and seek
medical advice immediately. In the meantime wash
Danger
!
the affected parts of the skin for 15 to 60 minutes
Repair work on fuel systems must only be per- with cold water or lime water.
formed by appropriately trained personnel.
The following notes refer to general safety precau- Poisonous substances
tions for danger free handling of fuel. These notes are
Some of the fluids and substances used are toxic and
only general instructions; in case of uncertainties you
must under no circumstances be consumed.
should consult the person responsible for fire protec-
tion. Skin contact, especially with open wounds, should be
strictly avoided.
Fuel vapours not only are easily inflammable, but also
highly explosive inside closed rooms and toxic; dilu- These fluids and substances are, amongst others,
tion with air creates an easily inflammable mixture. anti-freeze agents, hydraulic oils, washing additives,
The vapours are heavier than air and therefore sink lubricants and various bonding agents.
down to the ground. Inside a workshop they may eas-
ily become distributed by draft. Even the smallest por- Engine
tion of spilled fuel is therefore potentially dangerous.
● Fire extinguishers charged with FOAM, SCHAUM, Danger
!
CO2 GAS or POWDER must be available wherever
Do not work on the fuel system while the engine is
fuel is stored, filled in, drained off, or where work on
running - danger to life!
fuel systems is performed.
After the engine has stopped wait until the pres-
● The vehicle battery must always be disconnected,
sure has dropped (on Commonm Rail engines ap-
BEFORE work in the fuel system is started. While
prox. 5 minutes, other engines 1 minute), because
working on the fuel system you should not discon-
the system is under high pressure - danger to life!
nect the battery, because this could generate
sparks, which would ignite explosive fuel vapours. Keep out of the danger zone during the initial test
rung. Danger caused by high pressure in case of
●
Wherever fuel is stored, filled, drained off or where
leaks - danger to life!
work on fuel systems is carried out, all potential ig-
nition sources must be extinguished or removed. When performing work on the fuel system make
Search lights must be fire proof and well protected sure that the motor cannot be started unitention-
against possible contact with running out fuel. ally - danger to life!
● Maintenance and cleaning work on the engine must
Hot fuels onyl be performed with the engine stopped and
cooled down. Make sure that the electric system
Before draining fuel off the tank for repair work, you
has been switched off (ignition key pulled out).
must strictly apply the following measures:
● Observe the accident prevention regulations for
● Allow the fuel to cool down, to prevent any contact
electric systems (e.g. -VDE-0100/-0101/-0104/-
with a hot fluid.
0105 Electric precautions against dangerous con-
● Vent the system, by removing the filler cap in a well tact voltages).
ventilated area. Screw the filler cap back on, until ● Cover all electric components properly before wet
the tank is finally emptied.
cleaning.

Synthetic rubber
Many O-rings, hoses and similar parts, which are ap-
parently made of natural rubber, are actually made of

008 911 63 BOMAG 11

1.2 Safety regulations

Air conditioning system from April 1989). Paragraph 10 of the pressure ves-
sel directive demands that these pressure contain-
ers must be periodically inspected and tested by a
Caution
!
specialist, according to paragraph 32. In this case
Lines in the air conditioning system must only be periodically recurring inspections consist of external
loosened by trained and explicitly instructed ex- examinations, normally on containers in operation.
perts. The refrigerant container must be visually inspected
two times per year, within the frame work of major
● Wear safety goggles! Put on your safety goggles.
inspections. Special attention must thereby be paid
This will protect your eyes against coming into con-
to signs of corrosion and mechanical damage. If the
tact with refrigerant, which could cause severe
container is in no good condition, it should be re-
damage by freezing.
placed for safety reasons, in order to protect the op-
● Wear safety gloves and an apron! Refrigerant are erator or third parties against the dangers when
excellent solvents for greases and oils. In contact handling or operating pressure vessels.
with skin they will remove the protective grease film. ● Secure pressure vessels against tipping over or roll-
However, degreased skin is very sensitive against
ing away.
cold temperatures and germs.
● Do not throw pressure vessels. Pressure vessels
● Do not allow liquid refrigerants to come into contact
may thereby be deformed to such an extent, that
with skin! Refrigerant takes the heat required for
they will crack. The sudden evaporation and escape
evaporation from the environment. Very low tem-
of refrigerant releases excessive forces. This ap-
peratures may be reached. The results may be local
plies also when snapping off valves on bottles. Bot-
frost injuries (boiling point of R134a -26.5°C at am-
tles must therefore only be transported with the
bient pressure).
safety caps properly installed.
● Do not inhale higher concentrations of refrigerant ●
Refrigerant bottles must never be placed near heat-
vapours! Escaping refrigerant vapours will mix with
ing radiators. Higher temperatures will cause higher
the ambient air and displace the oxygen required for
pressures, whereby the permissible pressure of the
breathing.
vessel may be exceeded. The pressure vessel di-
● Smoking is strictly prohibited! Refrigerants may be rective therefore specifies that a pressure vessel
decomposed by a glowing cigarette. The resulting should not be warmed up to temperatures above 50
substances are highly toxic and must not be in- °C.
haled. ●
Do not heat up refrigerant bottles with an open
● Welding and soldering on refrigeration equipment! flame. Excessive temperatures can damage the
Before starting welding or soldering work on vehi- material and cause the decomposition of refriger-
cles, (in the vicinity ant.
of air conditioning components) all refrigerant must ●
Do not overfill refrigerant bottles, since any temper-
be drawn out and the rests removed by blowing out
ature increase will cause enormous pressures.
the system with nitrogen. The decomposition prod-
ucts created from the refrigerant under the influence
of heat not only are highly toxic, but also have a Environment
strong corrosive effect, so that pipes and system In operation, during maintenance and repair work
components may be attacked. The substance is and when taking refrigeration systems our of
mainly fluorohydrogen. service it is not permitted to let refrigerant escape
● Pungent smell! In case of a pungent smell the afore into the atmosphere, which would contradict the
mentioned decomposition products have already current status of technology.
been created. Extreme care must be exercised not
to inhale these substances, as otherwise the respi- Battery
ratory system, the lungs and other organs may be ● Wear goggles and face protection (acid).
harmed.
● Wear suitable clothes to protect face, hands and
● When blowing out components with compressed air
body (acid).
and nitrogen the gas mixture escaping from the
components must be extracted via suitable exhaust
●
Work and store accumulators only well ventilated
facilities (workshop exhaust systems). rooms. (Development of oxyhydrogen gas).
● Do not lean over the battery while it is under load,
Handling pressure vessels being charged or tested. (Danger of explosion).
● Since the fluid container is pressurized, the manu- ● Burning cigarettes, flames or sparks can cause ex-
facture and testing of these pressure vessels is gov- plosion of the accumulator
erned by the pressure vessel directive. (New edition ● Keep ignition sources away from the battery.

12 BOMAG 008 911 63

Safety regulations 1.2
● Always shield eyes and face towards the battery. ● There is a danger of scalding when draining off en-
● Do not use battery chargers or jump leads without gine or hydraulic oil at operating temperature.
following the operating instructions. ● on machines with rubber tires a tire may busr if in-
● Keep the cell plugs closed. correctly assembled. This can cause severe injury.
● After an accident with acid flush the skin with water ● Do not exceed the specified highest permissible tire
and seek medical advice. pressure.
● Do not allow children access to batteries.
● When mixing battery fluid always pour acid into wa-
ter, never vice-versa.

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 li-
ability for damage caused by the use of non-original
parts or accessories.
●
Unauthorized changes to the machine are prohibit-
ed for safety reasons.
●
If tests on the articulated joint need to be performed
with the engine running, do not stand in the articu-
lation area of the machine, danger of 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 en-
sure 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 per-
forming repair or maintenance work.
●
Do not refuel in closed rooms.
● Do not heat up oil higher than 160 °C because it
may ignite.
●
Wipe off spilled oil and fuel.
● Do not smoke when refuelling or when checking the
acid level in the battery.
● Do not check the acid level of the battery with a na-
ked flame, danger of explosion!
● Old batteries contain lead and must be properly dis-
posed of.

008 911 63 BOMAG 13

1.3 General repair instructions

General Electrics
1.3 General repair instructions

●
Before removing or disassembling and parts, hoses General
or components mark these parts for easier assem-
The electric and electronic systems in construction
bly.
equipment are becoming more and more extensive.
● Before assembly oil or grease all parts, as far as this Electronic elements are increasingly gaining impor-
is necessary. tance 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. Understand-
ing electronic controls requires the knowledge of
some basic terms concerning their general perform-
ance. 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 prob-
lems were caused by control units.
●
In approx. 15 % sensors and actuators were the
cause of the problems.
By far the highest proportion of all faults could be
traced back to wiring and connections (plugs, etc.).

General:
●
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Electric signals must be checked at
the locations to which they are applied, i.e. on con-
trol 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, there-
fore 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 vari-
ety 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, trou-
ble shooting must be continued. Several faults very
rarely occur at the same time, but it is not impossi-
ble.
●
Do not disconnect or connect battery or generator
while the engine is running.
● Do not operate the main battery switch under load.

14 BOMAG 008 911 63

General repair instructions 1.3
● Do not use jump leads after the battery has been re- Battery
moved.
Rules for the handling of batteries
● Sensors and electric actuators on control units must
never be connected individually or between exter- Even though it may be conveniently installed in the
nal power sources for the purpose of testing, but engine compartment, it should never be used as a rest
only in connection with the control unit in question, for tools. When connecting the poles, e.g. by means
as otherwise there may be a risk of destruction of a spanner, the battery will become an "electric
(damage)! welder".
●
Disconnecting the control unit plug connectors with As a measure to avoid short circuits you should first
the control unit switched on, i.e. with the power sup- disconnect the negative pole during disassembly and
ply (terminal 15 "On"), is not permitted. Switch the reconnect the negative pole last during assembly.
voltage supply "off" first - then pull out the plug. Terminal clamps should be assembled with as little
● Even with an existing polarity reversal protection in- force as possible.
correct polarity must be strictly avoided. Incorrect Poles and terminal clamps should always be kept
polarity can cause damage to control units! clean to avoid transition resistances during starting
and the related development of heat.
● Plug-in connectors on control units are only dust
and water tight if the mating connector is plugged You should obviously also pay attention to secure fas-
on! Control units must be protected against spray tening of the battery in the vehicle.
water, until the mating connector is finally plugged
on!
●
Unauthorized opening of the control electronics (mi-
cro 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 out-
side antenna or in the vicinity of the control electron-
ics!

Electrical system and welding work

●
Surge voltages in the electric system must be strict-
ly avoided:
●
When performing welding work always fasten the
earth clamp of the welding unit in the immediate vi-
cinity 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 63 BOMAG 15

1.3 General repair instructions

Hydraulic system ● After changing a component perform a high and

charge pressure test, if necessary check the speed
of the exciter shaft.
Caution
!
● The operating pressure of the exciter shaft to a
Do not open any hydraulic components if you
great extent depends on the base under the vibrat-
have not been properly trained and without exact
ing drum. If the soil is too hard place the drums on
knowledge.
old rubber tires. Do not activate the vibration on a
Please note hard, concreted base, danger of bearing damage.
Cleanliness is of utmost importance. Make sure that ●
After the completion of all tests perform a test run
no dirt or other contaminating substances can enter and then check all connections and fittings for leaks
into the system. with the engine still stopped and the hydraulic sys-
tem depressurized.
● 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 ● After changing a component clean the hydraulic oil
the system pressure with the engine shut down. tank thoroughly.
● During repair work keep all openings closed with ● Fill the housings of hydraulic pumps and motors
clean plastic plugs and caps. with hydraulic oil.
● Do not run pumps and motors without oil. ● Use only hydraulic oils according to the specifica-
● When cleaning hydraulic components take care not tion in the maintenance instructions.
to damage any fine machine surfaces. ●
After changing a component clean the hydraulic
● Chemical and rubber soluble cleansing agents may system as described in the flushing instructions in
only be used to clean metal parts. Do not let such order to prevent all other components from being
substances come in contact with sealing material. damaged by abrasion and metal chips remaining in
the system.
● Rinse of cleaned parts thoroughly, dry them with
compressed air and apply anti-corrosion oil immedi-
●
Change the hydraulic oil filter.
ately. Do not install parts that show traces of corro- Commissioning
sion.
●
Bleed the hydraulic circuits.
● Avoid the formation of rust on fine machined caused
by hand sweat. ●
Start up the system without load.
● Grease must not used as a sliding agent for assem- ●
Check the hydraulic oil level in the tank, fill up oil if
bly work. Use hydraulic oil. necessary.
●
Do not start the engine after the hydraulic oil has After commissioning
been drained off. ●
Check system pressures and speeds.
● Use only the specified pressure gauges. Risk of ● Check fittings and flanges for leaks.
damaging the pressure gauges under too high pres-
sure. ● After each repair check all adjustment data, rota-
tional speeds and nominal values in the hydraulic
● Clean ports and fittings before removal so that no
system, adjust if necessary.
dirt can enter into the hydraulic system.
● Do not adjust pressure relief valves and control
●
Check the hydraulic oil level before and after the
valves to values above their specified values.
work.
● Use only clean oil according to specification.
● Check the hydraulic system for leaks, find and rec-
tify the cause.
● Fill new hydraulic units with hydraulic oil before
starting operation.
●
After changing a component thoroughly flush and
bleed the entire hydraulic system.
● Perform measurements at operating temperature of
the hydraulic oil (approx. 40 ¯C).

16 BOMAG 008 911 63

General repair instructions 1.3
Air conditioning system damp air is drawn into the component by the differ-
ence in temperatures.
CFC - halon prohibition ● Damaged or leaking parts of the air conditioning
The CFC - halon prohibition from May 06, 1991 regu- must not be repaired by welding or soldering, but
lates the withdrawal from the use of CFC and the han- must generally be replaced.
dling of these refrigerants.
● Do not fill up refrigerant, but extract existing refrig-
Contents: erant and refill the system.
Since 1995 CFC (R12) is no longer permitted for use ● Different types of refrigerant must not be mixed.
in new systems.
Only the refrigerant specified for the corresponding
In operation, during maintenance and repair work and air conditioning system must be used.
when taking refrigeration systems our of service it is ● Refrigerant circuits with refrigerant type R134a
not permitted to let refrigerant escape into the atmos-
must only be operated with the compressor oil / re-
phere, which would contradict the current status of
frigeration oil approved for the compressor.
technology.
Work on refrigeration systems must only be carried
● Used compressor oil / refrigeration oil must be dis-
out by persons with well founded knowledge about posed of as hazardous waste.
such systems and who have the necessary technical ● Due to its chemical properties compressor oil / re-
equipment available. frigeration oil must never be disposed of together
The use of refrigerant must be documented. with engine or transmission oil.

Old systems should be converted to refrigerants

● Compressor oil / refrigeration oil is highly hydro-
harmless to ozone (refrigerant substitutes). scopic. Oil cans must strictly be kept closed until
use. Oil rests should not be used, if the can had
For this reason the Federal Environmental Agency at
been opened over a longer period of time.
the end of 1995 published suitable replacement refrig-
erants for R 12. As a consequence old systems must ●
All O-rings as well as pipe and hose fittings must be
no longer be filled with R12. As soon as such a system oiled with compressor/refrigeration oil be-
is opened for service, the system must be converted foreiassembly.
to a suitable replacement or service refrigerant. Old ●
When replacing a heat exchanger, e.g. evaporator
systems may still be used, as long as they are leak or condenser, any compressor oil / refrigeration oil
tight. R 134a was nominated as replacement for R 12. lost by exchanging the components, must be re-
Inside the European Union the "EU-Directive 2037/ placed with fresh oil.
2000 on substances causing decomposition of the ●
A too high compressor oil / refrigeration oil level ad-
ozone layer" regulates the production, use and avail- versely affects the cooling performance and a too
ability of CFC and H-CFC. low oil level has a negative effect on the lifetime of
● In case of a repair on the refrigeration system you the compressor.
should first evacuate the air conditioning system for ●
If a air conditioning unit needs to be opened, the
at least 45 minutes to remove any moisture from the dryer must be replaced in any case.
system, before you start to refill. Moisture bonded in
the compressor oil / refrigeration oil (PAG oil) can
● Always use new O-rings when reassembling the
only be removed from the system by changing the unit.
oil. ●
Always use two spanners when connecting pipes or
●
During repair work on refrigerant lines and compo- hoses, to prevent the pipe end from being damaged
nents, these must be kept closed as far as possible, .
in order to prevent the invasion of air, moisture and ● Tighten screw fittings with the specified torque.
dirt, because the operational reliability of the system ●
Check the connections of pipes, fittings or compo-
can only be assured if all components in the refrig-
nents thoroughly; do not use if damaged.
erant circuit are clean and dry from inside.
●
Do not leave the refrigerant circuit unnecessarily
● Make sure that no dirt or foreign parts can enter into
open to the atmosphere. Do not attempt to repair
the compressor or the air conditioning system. The
bent or burst pipes.
area around the refrigerant hoses should be
cleaned with a gasoline free solvent. ●
Compressor valves must only be opened after the
● All parts to be reused should be cleaned with a system has been properly sealed.
gasoline free solvent and blow-dried with clean ● The use of leak detection colouring matter is not
compressed air or dried with a lint-free cloth. permitted, because its chemical composition is un-
known and its effect on compressor oil and rubber
● Before opening all components should have
elements is not predictable. The use of leak detec-
warmed up to ambient temperature, to avoid that

008 911 63 BOMAG 17

1.3 General repair instructions

tion colouring matter makes any warranty claims Fuel hoses

null and void.
● Tools used on refrigeration circuits must be of ex-
cellent 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 condi-
tioning system. Observe the filling capacity.
● Before start up of the air conditioning system after a Fig. 1
new filling: - Turn the compressor approx. 10 revo-
lutions by hand using the clutch or V-belt pulley of
the magnetic clutch. - Start the engine with the com- ! Caution
pressor/control valve switched off. - Once the idle All fuel hoses have two layers of material, a rein-
speed of the engine has stabilized switch on the forced rubber coating outside and an internal Vi-
compressor and run it for at least 10 minutes at idle ton hose. If a fuel hose has come loose one must
speed and maximum cooling power. make absolutely sure that the internal Viton layer
has not been separated from the reinforced outer
●
Never operate the compressor over longer periods
layer. In case of a separation the hose needs to be
of time with high engine speeds without a sufficient
replaced.
amount of refrigerant in the system. This could
probably cause overheating and internal damage.

18 BOMAG 008 911 63

General repair instructions 1.3
Gaskets and mating surfaces threads or splines. If no assembly sleeve is availa-
ble, you should use a plastic tube or adhesive tape to
Leaking or failing seals and gaskets can in most cases
prevent the sealing lip from being damaged.
be tracked down to careless assembly, causing dam-
age not only to the seal or gasket, but also to the mat-
ing 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, cor-
rosion or other damage.
●
Inappropriately stored or handled seals (e.g. hang-
ing from hooks or nails) must under no circumstanc-
es be used.
● 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 Fig. 3
compound does not enter into oil galleries or blind ● Lubricate the outer rim 1 (Fig. 3) of the seal and
threaded bores.
press it flat on the housing seat.
●
Before assembly remove any residues of old seal-
ing compound. Do not use any tools that could dam-
age the sealing surfaces. i Note
If possible, use a "bell" 1 (Fig. 3), to make sure that
●
Examine the contact faces for scratches and burrs,
the seal will not skew. In some cases it may be ad-
remove these with a fine file or an oilstone; take
visable to assemble the seal into the housing first, be-
care that no grinding dust and dirt enters into
fore sliding it over the shaft. Under no circumstances
tapped bores or enclosed components.
should the full weight of the shaft rest on the seal.
●
Blow lines, ducts and gaps out with compressed air,
If you have no proper service tools at hand, use a suit-
replace any O-rings and seals that have been dis-
able drift punch with a diameter which is about 0.4mm
lodged by the compressed air.
smaller than the outer diameter of the seal. Use VERY
Assembly of radial seals LIGHT blows with the hammer if no press is available.
●
Press or knock the seal into the housing, until it is
flush with the housing surface.

Fig. 2
●
Lubricate sealing lips 1 (Fig. 2) with clean grease; in
case of double seals fill the space between the seal-
ing lips with a generous amount of grease.
●
Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.

i Note
If possible, use an assembly sleeve 1 (Fig. 2), to pro-
tect the lip from being damaged by sharp edges,

008 911 63 BOMAG 19

1.3 General repair instructions

Feather keys and keyways Ball and roller bearings

!Caution !Caution
Feather keys must only be reused if they show no Ball and roller bearings must only be reinstalled
differences to new feather keys, any notches must after it has been assured that they are in perfect
be considered as initial signs of wear. condition.

Fig. 4
● Clean and thoroughly examine the feather key.
● Debur and thoroughly clean the edges of the key-
way with a fine file before reassembling.

Fig. 5
● Remove any lubricant residues from the bearing to
be examined by washing it with gasoline or any oth-
er 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 vis-
ible 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 fin-
ger 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 rotat-
ing and replace the bearing if it does not work cor-
rectly.
● Lubricate the bearing with an appropriate lubricant
before reinstalling.

20 BOMAG 008 911 63