0% found this document useful (0 votes)

101 views1,286 pages

Service - Manual: BW 216 D-40 / PD-40

Uploaded by

aboda01200

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

0% found this document useful (0 votes)

101 views1,286 pages

Service - Manual: BW 216 D-40 / PD-40

Uploaded by

aboda01200

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 1286

Service - Manual

BW 216 D-40 / PD-40

S/N 101 583 39 1023 > / S/N 101 583 40 . . . .

Single drum roller

This manual addresses the professionally qualified

personnel or the after sales service of BOMAG, and
should be of help and assistance in correct and effi-
cient repair and maintenance work.
This manual describes the disassembly, dismantling,
assembly, installation and repair of components and
assemblies. The repair of components and assem-
blies is only described as this makes sense under due
consideration of working means and spare parts sup-
ply.

Documentation
For the BOMAG machines described in this manual
the following documentation is additionally available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Service information
4 Fundamental electrics

Use only 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 an updating service; for
this reason we would like to draw your attention to our
additional "Technical Service Bulletins".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this manual must not
be reproduced and distributed, nor must they be used
for the purpose of competition. All rights according to
the copyright law remain expressly reserved.

! Danger

These safety regulations must be read and ap-

plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG

8 BOMAG 008 924 17

Safety regulations 1.2
Important notes Block the articulated joint with the articulation lock.
1.2 Safety regulations
l

l Use protective clothes like hard hat, safety boots

These safety regulations must be read and ap-
and gloves.
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident l Keep unauthorized persons away from the machine
prevention instructions and the safety regulations during repair work.
in the operating and maintenance instructions l Tools, lifting gear, lifting tackle, supports and other
must be additionally observed.
auxiliary equipment must be fully functional and in
Repair work shall only performed by appropriately safe condition.
trained personnel or by the after sales service of l Use only safe and approved lifting gear of sufficient
BOMAG. load bearing capacity to remove and install parts or
components from and to the machine.
Workshop equipment and facilities as well as the
use and waste disposal of fuels and lubricants, l Do not use easily inflammable or harmful substanc-
cleaning agents and solvent as well as gases and es, such as gasoline or paint thinners for cleaning.
chemicals are subject to legal regulations, which l Do not smoke or use open fire and avoid sparks
are intended to provide a minimum on safety. It is when cleaning or repairing a tank.
obviously your own responsibility to know and
adhere to these regulations.
l When performing welding work strictly comply with
the respective welding instructions.
This manual contains headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to inform about and avoid dan- Transport work with cranes and lifting
gers to persons, property and the environment. tackle

i Note i Note
Paragraphs marked like this contain technical infor- Cranes must only be operated by instructed persons
mation for the optimal economical use of the machine. who had been trained in handling cranes.
l Follow the operating instructions of the manufactur-
Caution
! er when working with cranes.
Paragraphs marked like this highlight possible l Follow the operating instructions of the operator
dangers for machines or parts of the machine. when working with cranes.
l Always comply with the applicable accident preven-
Danger
!
tion instructions when working with cranes and lift-
ing tackle.
Paragraphs marked like this highlight possible
dangers for persons.
Precautions and codes of conduct for
welding work
Environment
Welding work must only be carried out by properly
Paragraphs marked like this point out practices
trained personnel.
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Danger
!
Observe the regulations for the protection of the
environment. Electric shock!
Sparks, fire hazard, burning of skin!
General Infrared or ultraviolet radiation (arc), flashing of
l
For repair and maintenance work move the ma- eyes!
chine on a firm base and shut it down. Health hazard caused by welding work on highly
l
Always secure the machine against unintended roll- alloyed work pieces, metal coatings, paint coat-
ing. ings, plastic coatings, oil containing dirt deposits,
grease or solvent residues, etc.!
l Secure the engine reliably against unintentional
starting.
l Check welding equipment and cables for damage
before use (also the validity of inspection stickers).
l Mark a defective machine and a machine under re-
pair by attaching a clearly visible warning label to
l Ensure good conductivity between ground cable
the dashboard. and workpiece, avoid joints and bearings.

008 924 17 BOMAG 9

1.2 Safety regulations

l Start the extraction fan before starting work and Operation of high-voltage systems
guide with the progressing work as required.
l Always isolate the burner when laying it down (re- i Note
move possible electrode residues).
The rules and statutory regulations valid in the corre-
l Protect cables from being damaged, use cables sponding do apply in addition to the notes given here.
with insulated couplings.
l Ensure sufficient fire protection, keep a fire extin- !Caution
guisher at hand. The high-voltage system must only be operated
l Welding work in areas where there is a risk of fire or and serviced by qualified and authorized person-
explosion, must only be carried out with welding nel.
permission.
Before starting operation the operator must check
l Remove any combustible materials from the weld- the proper condition of the system.
ing area or cover such items appropriately.
l Name a fire watch during and after welding work. !Danger
l Place welding rod holders and inert gas welding Possibility of injury or even death caused by elec-
guns only on properly insulated bases. tric shock:
l Place the inert gas bottles in a safe place and se- l if persons come into contact with live parts,
cure them against falling over. l in case of faulty insulation of live parts,
l
Use a protective screen or hand shield with welding l
inadequate, unsuitable insulation,
filter, wear welding gloves and clothes. l
if melted parts flake off in case of short circuits.
l
Switch the welding unit off before connecting weld-
ing cables. Old oils
l
Check electrode holders and electric cables at reg- Prolonged and repetitive contact with mineral oils will
ular intervals. remove the natural greases from the skin and causes
Behaviour in case of faults dryness, irritation and dermatitis. Moreover, used en-
gine oils contain potentially hazardous contaminants,
l
In case of faults on the welding unit switch of the which could cause skin cancer. Appropriate skin pro-
welding unit immediately and have it repaired by ex- tection agents and washing facilities must therefore
pert personnel. be provided.
l
In case of failure of the extraction system switch the l
Wear protective clothes and safety gloves, if possi-
system off and have it repaired by expert personnel. ble.
Maintenance; waste disposal l
If there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or
l
Replace damaged insulating jaws and welding rod
full face visor; a facility suitable for rinsing the eyes
holders immediately.
should also be available.
l
Replace the welding wire reels only in de-energized l
Avoid longer and repetitive contacts with oils. In
state.
case of open incisions and injuries seek medical ad-
What to do in case of accidents; First Aid vice immediately.
l
Keep calm. l
Apply protective cream before starting work, so that
oil can be easier removed from the skin.
l Call first air helpers.
l
Wash affected skin areas with water and soap (skin
l
Report the accident.
cleansers and nail brushes will help). Lanolin con-
l
In case of an electric accident: Interrupt the power taining agents will replace natural skin oils that were
supply and remove the injured person from the lost.
electric circuit. If breathing and heart have stopped l
Do not use gasoline, kerosene, diesel, thinner or
apply reactivation measures and call for an emer-
solvents to wash the skin.
gency doctor.
l
Do not put oil soaked cloths into your pockets.
l Avoid clothes getting soiled by oil.
l
Overalls must be washed at regular intervals. Dis-
pose of non-washable clothes environmentally.
l
If possible degrease components before handling.

10 BOMAG 008 924 17

Safety regulations 1.2
Environment l Fire extinguishers charged with FOAM, CO2 GAS
It is strictly prohibited to drain off oil into the soil, or POWDER must be available wherever fuel is
the sewer system or into natural waters. Old oil stored, filled in, drained off, or where work on fuel
must be disposed of according to applicable envi- systems is performed.
ronmental regulations. If in doubt you should con- l The vehicle battery must always be disconnected,
sult your local authorities. BEFORE work in the fuel system is started. Do not
disconnect the battery while working on the fuel
Hydraulics system. Sparks could cause explosion of the fuel
fumes.
l Always relieve the pressure in the hydraulic system
before disconnecting any lines. Hydraulic oil escap-
l Wherever fuel is stored, filled, drained off or where
ing under pressure can penetrate the skin and work on fuel systems is carried out, all potential ig-
cause severe injury. nition sources must be extinguished or removed.
Search lights must be fire proof and well protected
l Always make sure that all screw fittings have been against possible contact with running out fuel.
tightened properly and that hoses and pipes are in
mint condition before pressurizing the system
again.
Hot fuels
Please apply the following measures before draining
l Hydraulic oil leaking out of a small opening can
of fuel to prepare for repair work:
hardly be noticed, therefore please use a piece of
cardboard or wood when checking for leaks. When l Allow the fuel to cool down, to prevent any contact
injured by hydraulic oil escaping under pressure with a hot fluid.
consult a physician immediately, as otherwise this l
Vent the system, by removing the filler cap in a well
may cause severe infections. ventilated area. Screw the filler cap back on, until
l Do not step in front of or behind the drums, wheels the tank is finally emptied.
or crawler tracks when performing adjustment work
in the hydraulic system while the engine is running. Synthetic rubber
Block drums, wheels or crawler tracks with wedges.
Many O-rings, hoses, etc. are made of synthetic ma-
Reattach all guards and safety installations after terial, a so-called fluorocarbon elastomer. Under nor-
all work has been completed. mal 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 oil into the soil,
caustic hydrofluoric acid, which can cause severe
the sewer system or into natural waters. Oil oil
burns in contact with skin.
must be disposed of according to applicable envi-
ronmental regulations. If in doubt you should con- l
If the material is in such a state it must only be
sult your local authorities. touched with special protective gloves. The protec-
tive gloves must be disposed of according to appli-
Fuels cable environmental regulations immediately after
use.
l
If the material has contacted the skin despite these
!Danger
measures, take off the soiled clothes and seek
Repair work shall only performed by appropriately medical advice immediately. In the meantime cool
trained personnel or by the after sales service of and wash the affected area of skin over a sufficient
BOMAG. time with cold water or lime water.
Follow the valid accident prevention instructions when
handling fuels. Poisonous substances
The following notes refer to general safety precau- Some of the fluids and substances used are toxic and
tions for danger free handling of fuel. must under no circumstances be consumed.
Fuel vapours not only are easily inflammable, but also Skin contact, especially with open wounds, must be
highly explosive inside closed rooms and toxic; dilu- avoided.
tion with air creates an easily inflammable mixture. These fluids and substances are, amongst others,
The vapours are heavier than air and therefore sink anti-freeze agents, hydraulic oils, fuels, washing addi-
down to the ground. Inside a workshop they may eas- tives, refrigerants, lubricants and various bonding
ily become distributed by draft. Even the smallest por- agents.
tion of spilled fuel is therefore potentially dangerous.

008 924 17 BOMAG 11

1.2 Safety regulations

Engine air conditioning system. The development of heat

may cause the refrigerant to develop toxic and high-
ly corrosive breakdown products.
Danger
!
l Pungent smell! The toxic substances, which are re-
Do not work on the fuel system while the engine is
sponsible for the pungent smell, must not be in-
running. (Danger to life!)
haled, since this may cause damage to the
Once the engine has stopped wait approx. 1 min- respiratory system, the lung and other organs. Ex-
utes for the system to depressurize. The systems tract toxic breakdown products with a suitable ex-
are under high pressure. (Danger to life!) traction system (workshop extraction system).
Keep out of the danger zone during the initial test l
When blowing out components with compressed air
rung. Danger caused by high pressure in case of and when flushing with nitrogen the gas mixture es-
leaks. (Danger to life!) caping from the components must be extracted via
When performing work on the fuel system make suitable extraction facilities (workshop extraction
sure that the engine cannot be started uninten- systems).
tionally during repair work. (Danger to life!) Handling pressure vessels
l Maintenance and cleaning work on the engine must l Since the fluid container is pressurized, the manu-
only be performed with the engine stopped and facture and testing of these pressure vessels is gov-
cooled down. Make sure that the electric system is erned by the pressure vessel directive. The
switched off and sufficiently secured against being pressure vessels must be repetitively tested by an
switched on again (e.g. pull off ignition key, attach a expert as specified in TRB 532 Inspection by Ex-
warning label). perts, Repetitive Tests. In this case periodically re-
l Observe the accident prevention regulations for curring inspections consist of external
electric systems (e.g. -VDE-0100/-0101/-0104/- examinations, normally on containers in operation.
0105 Electric precautions against dangerous con- In combination with the inspection, the refrigerant
tact voltages). collector must be visually examined two times per
year. Special attention must thereby be paid to
l Cover all electric components properly before wet
signs of corrosion and mechanical damage. If the
cleaning.
container is in no good condition, it should be re-
placed for safety reasons, in order to protect the op-
Air conditioning system erator or third parties against the dangers when
handling or operating pressure vessels.
!Caution l
Secure pressure vessels against tipping over or roll-
Work on air conditioning systems must only be ing away.
carried out by persons who can provide sufficient l
Do not throw pressure vessels! Pressure vessels
evidence of their ability (proof of professionalism) may thereby be deformed to such an extent, that
and only with the appropriate technical equip- they will crack. The sudden evaporation and escape
ment. of refrigerant releases excessive forces. This ap-
l
Always wear goggles and protective clothing when plies also when snapping off valves on bottles. Bot-
performing maintenance and repair work on air con- tles must therefore only be transported with the
ditioning systems. Refrigerant withdraws heat from safety caps properly installed.
the environment when evaporating, which can l
Refrigerant bottles must never be placed near heat-
cause injury by freezing when in contact with skin ing radiators. Higher temperatures will cause higher
(boiling point of R134a -26,5 °C at normal pres- pressures, whereby the permissible pressure of the
sure). vessel may be exceeded.
l Perform maintenance and repair work on air condi- l Do not heat up refrigerant bottles with an open
tioning systems only in well ventilated rooms! Es- flame. Excessive temperatures can damage the
caping refrigerant vapours will mix with the ambient material and cause the decomposition of refriger-
air and displace the oxygen required for breathing ant.
(danger of suffocating).
l
Do not overfill refrigerant bottles, since any temper-
l Smoking is prohibited when performing mainte- ature increase will cause enormous pressures.
nance and repair work on air conditioning systems!
Toxic breakdown products may be generated if re-
frigerant comes into contact with heat. Environment
It is strictly prohibited to release refrigerant into
l Refrigerant should always be extracted and re-
the atmosphere during operation, maintenance
moved by flushing with nitrogen before starting
welding or soldering work near components of the

12 BOMAG 008 924 17

Safety regulations 1.2
and repair work and when taking air conditioning l Dispose of used filters in accordance with applica-
systems into or out of service. ble environmental regulations.
l When performing repair and maintenance work col-
Battery lect oils and fuels in suitable containers and dispose
l Always wear goggles and protective clothing to of in compliance with applicable environmental reg-
service or clean batteries! Battery acid can cause ulations.
severe injury by cauterization when coming in con- l Do not heat up oils higher than 160 °C because they
tact with skin. may ignite.
l Work only well ventilated rooms (formation of oxy- l Wipe off spilled or overflown oil using suitable
hydrogen gas). cleaning means and dispose of in accordance with
l Do not lean over the battery while it is under load, applicable environmental regulations.
being charged or tested (danger of explosion). l Dispose of old batteries according to applicable en-
l Keep ignition sources away from the battery. Burn- vironmental regulations.
ing cigarettes, flames or sparks can cause explo-
sion of the battery
l There is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature! Allow
l Use battery chargers etc. only in strict compliance
engine and hydraulic system to cool down to a suf-
with the operating instructions.
ficient level.
l After an accident with acid flush the skin with a suf- l Do not exceed the max. permissible tire pressure.
ficient amount of water and seek medical advice.
l Do not allow children access to batteries.
l
When mixing battery fluid always pour acid into wa-
ter, never vice-versa.

Special safety regulations

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

008 924 17 BOMAG 13

1.3 General repair instructions

General Electrics
1.3 General repair instructions

l
Before removing or disassembling parts, assem- General
blies, components or hoses mark these parts for
easier assembly. Due to the fast technical development electric and
electronic vehicle systems become more intelligent
l Before assembling and installing parts, assemblies and more comprehensive day by day, and can hardly
or components oil or grease all movable parts or be dispensed with in hydraulic and mechanical vehicle
surfaces as required and in compliance with the systems.
compatibility of materials.
Diagnostics according to plan
Well structured trouble shooting procedures can save
time and money.
Random tests have revealed that purely electronic
components or control units only very rarely are the
actual cause of failures:
l In approx. 10 % of the examined cases the prob-
lems were caused by control units.
l In approx. 15 % sensors and actuators were the
cause of the problems.
By far the highest proportion of all faults could be
traced back to wiring and connections (plugs, etc.).

General:
l
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Knowledge in basic electrics is re-
quired for this purpose. If a fault was diagnosed
without having pulled the plug of the control unit or
inspected the wiring, this should be done before
changing any parts.
l
Check for good cable and ground contacts, there-
fore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
l
Always use the machine related wiring diagram for
testing. If one or more faults were detected, these
should be corrected immediately.
l
Do not disconnect or connect battery or generator
while the engine is running.
l
Do not operate the main battery switch under load.
l
Do not use jump leads after the battery has been re-
moved.
l Sensors and electric actuators on control units must
never be connected individually or between exter-
nal power sources for the purpose of testing, but
only in connection with the control unit in question.
l
It is not permitted to pull plugs off while the voltage
supply is switched on (terminal 15 "ON")! Switch the
voltage supply "OFF" first and pull out the plug.
l Even with an existing polarity reversal protection in-
correct polarity must be strictly avoided. Incorrect
polarity can cause damage to control units!

14 BOMAG 008 924 17

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

008 924 17 BOMAG 15

1.3 General repair instructions

Generator Starter motor

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

16 BOMAG 008 924 17

General repair instructions 1.3
Hydraulic system l Perform measurements at operating temperature of
the hydraulic oil (approx. 40 ¯C).

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

008 924 17 BOMAG 17

1.3 General repair instructions

Air conditioning system l Damaged or leaking parts of the air conditioning

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

18 BOMAG 008 924 17

General repair instructions 1.3
l If the air conditioning system had been opened for Fuel hoses
repair work, a new drier should be installed in the re-
frigerant circuit.
l After completion of repair work screw locking caps
(with seals) on all valve connections service con-
nections.
l Before start up of the air conditioning system after a
new filling: - Turn the compressor approx. 10 revo-
lutions by hand using the clutch or V-belt pulley of
the magnetic clutch. - Start the engine with the com-
pressor/control valve switched off. - Once the idle
speed of the engine has stabilized switch on the
compressor and run it for at least 10 minutes at idle Fig. 1
speed and maximum cooling power.
l Never run the compressor with an insufficient ! Caution
amount of refrigerant. All fuel hoses have two layers of material, a rein-
forced rubber coating outside and an internal Vi-
ton hose. If a fuel hose has come loose one must
make absolutely sure that the internal Viton layer
has not been separated from the reinforced outer
layer. In case of a separation the hose needs to be
replaced.

008 924 17 BOMAG 19

1.3 General repair instructions

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

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

i Note
If possible, use an assembly sleeve (1 (Fig. 2)), to
protect the lip from being damaged by sharp edg-
es, threads or splines. If no assembly sleeve is avail-

20 BOMAG 008 924 17

General repair instructions 1.3
Feather keys and keyways Ball and roller bearings

Caution
! !Caution
Feather keys may only be reused if they are free of Ball and roller bearings may only be reused if they
damage. are free of damage and do not show any signs of
wear.

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

Fig. 5
l If a ball or roller bearing of a bearing pair shows de-
fects, both ball or roller bearings need to be re-
placed.
l
Remove any lubricant residues from the ball or roll-
er bearing to be examined by washing it with gaso-
line or any other appropriate degreasing agent.
Ensure strict cleanliness.
l
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. Replace the ball or roller bearing if
necessary.
l
Check the ball or roller bearing for clearance and re-
sistance between the inner and outer races, replace
if necessary.
l
Lubricate the ball or roller bearing with the recom-
mended type of grease before assembly or reas-
sembly.
l
On greased bearings (e.g. wheel bearings) fill the
space between ball or roller bearing and outer seal
with the recommended type of grease before as-
sembling the seal.

008 924 17 BOMAG 21

1.3 General repair instructions

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

22 BOMAG 008 924 17

General repair instructions 1.3
Strength classes, metric screws Strength classes of metric nuts
The strength classes (from 3.6 to 12.9) are specified Nuts are differentiated by three load groups. Each
for all strength classes from a nominal diameter of load group has a special designation system for the
5mm. The corresponding identification can be found strength class assigned, so that the load group can be
where allowed for by the shape of the screw. clearly identified.

Nuts for screw joints with full load capability (4, 5,

6, 8, 10, 12)

Fig. 8 Identification of nuts

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

Strength class of Strength class of associated

nut screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
Fig. 7 Identification of screws 6 6.8
8 8.8
Example: A screw is identified with 12.9.
9 9.8
The first number corresponds with 1/100 of the nomi- 10 10.8
nal tensile strength (minimum tensile strength) in N/ 12 12.8
mm2.
Nuts for screw joints with limited load factor (04,
l
The nominal tensile strength is 12 X 100 N/mm2 = 05)
1200 N/mm2.
The preceding "0" indicates that, due to their low
The second number specifies 10-times the ration be- height, nuts 2 (Fig. 8) in this group are only able to
tween lower yield point and nominal tensile strength withstand the force of a screw to a limited extent.
(yield point ratio). Nut height below 0,8 d (d = nominal dimension).

Nuts for screw joints without specified load factor

i Note
(11H, 14H, 17H, 22H)
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas- This standard contains strength classes (hardness
tic deformation). classes) for nuts 3 (Fig. 8), for which no load values
can be specified, e.g. because of their shape and di-
When exceeding the upper yield point the material will mensions, but which can only be classified by their
not restore its original shape after being relieved. hardness.
l The lower tensile strength is 9/10 X 1200 N/mm2 = Nut height below 0,5 d (d = nominal dimension).
1080 N/mm2.

i Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.

008 924 17 BOMAG 23

1.3 General repair instructions

Identification in clock system Identification of UNF-threads

Fig. 9 Identification of nuts in clock system

For small nuts (Fig. 9) the clock system can be used
for identification.
l The 12 o'clock position is identified by a dot or the
manufacturer's symbol.
l
The strength class is identified by a dash (b).
Fig. 10

Screws
The screw head is marked with a stamped in, round
cavity 3 (Fig. 10).

Nuts
An uninterrupted series of stamped in circles parallel
to the axis of the nut on a hexagon area (2).

Studs and brake rods

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

24 BOMAG 008 924 17

General repair instructions 1.3
Cotter pins

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

008 924 17 BOMAG 25

1.4 Tightening torques

The values specified in the table apply for screws:

1.4 Tightening torques

l black oiled
l with surface protection A4C
l with surface protection DACROMET

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

Tightening torques for screws with metric unified thread*

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M4 3 5 5
M5 6 9 10
M6 10 15 18
M8 25 35 45
M10 50 75 83
M12 88 123 147
M14 137 196 235
M16 211 300 358
M18 290 412 490
M20 412 578 696
M22 560 785 942
M24 711 1000 1200
M27 1050 1480 1774
M30 1420 2010 2400
* Coefficient of friction μ tot. = 0,14

Tightening torques for screws with metric unified fine thread*

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M8 x 1 26 37 48
M10 x 1.25 52 76 88
M12 x 1,25 98 137 126
M12 x 1.5 93 127 152
M14 x 1.5 152 216 255
M16 x 1.5 225 318 383
M18 x 1.5 324 466 554
M20 x 1.5 461 628 775
M22 x 1.5 618 863 1058
M24 x 2 780 1098 1294
M27 x2 1147 1578 1920
M30 x 2 1568 2254 2695
* Coefficient of friction μ tot. = 0,14

26 BOMAG 008 924 17

Tightening torques 1.4
Tightening torques for screws treated with anti-seizure paste OKS 240* (copper paste)

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M16 169 240 287
M16 x 1.5 180 255 307
M18 232 330 392
M18 x 1.5 260 373 444
M20 330 463 557
M20 x 1.5 369 502 620
M22 448 628 754
M22 x 1.5 495 691 847
M24 569 800 960
M24 x 2 624 879 1036
M27 840 1184 1520
M27 X 2 918 1263 1536
M30 1136 1608 1920
M30 x 2 1255 1804 2156
3/4“ - 10 UNC 276 388 464
3/4“ - 16 UNC 308 432 520
* Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to high temperatures and corrosive
effects. Prevents seizure and corrosion.

Tightening torques for wheel nuts (fine thread) * **

Tightening torques Nm
Thread diameter
10.9
M12x1.5 100
M14x1.5 150
M18x1.5 300 - 350
M20x1.5 400 - 500
M22x1.5 500 - 600
* Coefficient of friction μ tot. = 0,14
** These values result in a 90% utilization of the yield point

008 924 17 BOMAG 27

1.4 Tightening torques

The values specified in the table apply for screws:

l black oiled
l with surface protection A4C
l with surface protection DACROMET

i Note
The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks,
as the metric ISO-thread, whereas Withworth has a flank of only 55°.
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.

Tightening torques for screws with UNC thread, * UNC Unified Coarse Thread Series, American Unified
Coarse Thread

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1/4“ - 20 11 15 19
5/16“ - 18 23 32 39
3/8“ - 16 39 55 66
7/16“ - 14 62 87 105
1/2“ - 13 96 135 160
9/16“ - 12 140 200 235
5/8“ - 11 195 275 330
3/4“ - 10 345 485 580
7/8“ - 9 560 770 940
1“ - 8 850 1200 1450
1 1/8“ - 7 1200 1700 2000
1 1/4“ - 7 1700 2400 2900
1 3/8“ - 6 2200 3100 3700
1 1/2“ - 6 3000 4200 5100
* Coefficient of friction μ tot. = 0,14

Tightening torques for screws with UNF thread, * UNF Unified National Fine Thread Series, American
Unified Fine Thread

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1/4“ - 28 13 18 22
5/16“ - 24 25 35 42
3/8“ - 24 45 63 76
7/16“ - 20 70 100 120
1/2“ - 20 110 155 185
9/16“ - 18 155 220 260
5/8“ - 18 220 310 370
3/4“ - 16 385 540 650
7/8“ -14 620 870 1050

28 BOMAG 008 924 17

Tightening torques 1.4
Tightening torques for screws with UNF thread, * UNF Unified National Fine Thread Series, American
Unified Fine Thread

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1“ - 12 930 1300 1600
1 1/8“ - 12 1350 1900 2300
1 1/4“ - 12 1900 2700 3200
1 3/8“ - 12 2600 3700 4400
1 1/2“ - 12 3300 4600 5600
* Coefficient of friction μ tot. = 0,14

008 924 17 BOMAG 29

1.4 Tightening torques

30 BOMAG 008 924 17

2 Technical data

008 924 17 BOMAG 31

2.1 Technical data

Fig. 12

BW 216 D-40 A B D H H2 K L O1 O2 S W
Dimensions in 2960 2300 1500 2268 2985 490 5930 85 85 35 2130
mm

Weights
Max. operating weight kg 17100
Max. axle load, drum (CECE) kg 11700
Max. axle load, wheels (CECE) kg 5400
Operating weight (CECE) kg 15200
Axle load, drum (CECE) kg 10200
Axle load, wheels (CECE) kg 5000
Static linear load (CECE) kg/cm 47.9
Max. static linear load (CECE) kg/cm 54.9

Travel characteristics
Travel speed (1) km/h 0–4
Travel speed (2) km/h 0–5
Travel speed (3) km/h 0–7
Travel speed (4) km/h 0 – 11
Max. gradability without/with vibration (soil dependent) % 48/45

Drive
Engine manufacturer Deutz
Type BF4M 1013 C
Cooling Water
Number of cylinders 4
Rated power DIN ISO 3046 kW 114
Rated power SAE J 1995 hp 153
Rated speed min-1 2200
Fuel Diesel
Electrical equipment V 12
Drive system hydrostatic
Permissible ambient temperatures °C -20 ... +50

Tires
Tire size 23.1-26/12PR
Air pressure, nominal value bar 1.4
Air pressure, span bar 0.8 - 1.4

32 BOMAG 008 924 17

Technical data 2.1

Brakes
Service brake hydrostatic
Parking brake hydro-mechanical

Steering
Type of steering articulated
Steering operation hydrostatic
Steering/oscillation angle ±° 35/12
Inner track radius mm 3494

Vibration
Drive system hydrostatic
Frequency (1/2) Hz 30/36
Amplitude (1/2) mm 1.80/0.90
Centrifugal force (1/2) kN 275/202

Filling capacities
Fuel (diesel) l approx. 250

i Note
Subject to technical alterations.

008 924 17 BOMAG 33

2.1 Technical data

Fig. 13

BW 216 PD-40 A B D H H2 K L O1 O2 S W
Dimensions in 2960 2300 1480 2268 2985 490 5930 85 85 25 2130
mm

Weights
Max. operating weight kg 16400
Max. axle load, drum (CECE) kg 11000
Max. axle load, wheels (CECE) kg 5400
Operating weight (CECE) kg 15700
Axle load, drum (CECE) kg 10700
Axle load, wheels (CECE) kg 5000

Drums and tires

Tire size 23.1-26/12PR
Air pressure, nominal value bar 1.4
Air pressure, span bar 0.8 - 1.4
Padfeet, quantity 150

34 BOMAG 008 924 17

Technical data 2.1

Height of padfeet mm 100

Area of one padfoot cm2 137

Brakes
Service brake hydrostatic
Parking brake hydro-mechanical

Steering
Type of steering articulated
Steering operation hydrostatic
Steering/oscillation angle ±° 35/12
Inner track radius mm 3494

Vibration
Drive system hydrostatic
Frequency (1/2) Hz 30/36
Amplitude (1/2) mm 1.70/0.86
Centrifugal force (1/2) kN 275/202

Filling capacities
Fuel (diesel) l approx. 250

i Note
Subject to technical alterations.

008 924 17 BOMAG 35

2.1 Technical data

Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 900 ± 200
High idle speed rpm 2430 ± 50
Specific fuel consumption g/kWh 235
Valve clearance intake mm 0.3
Valve clearance exhaust mm 0.5
Injection valves opening pressure bar 275
Starter power kW 3.1

Travel pump
Manufacturer Sauer
Type 90R075
System Axial piston/swash plate
Max. displacement cm3/rev 75
Max. flow capacity l/min 163.65
High pressure limitation bar 420 + 20
Charge pressure, high idle bar 26 + 3

Drum reduction gear

Type CR31
Transmission ratio 45.6

Drum drive motor

Manufacturer Sauer
Type 51C 110
System Axial piston – bent axle
Displacement (stage 1) cm3/rev 110
Displacement (stage 2) cm3/rev 39
Perm. leak oil rate l/min 2
Flushing rate l/min 16
Flushing limitation bar 16

Axle drive motor

Manufacturer Sauer
Type 51D 110
System Axial piston – bent axle
Max. displacement (stage 1) cm3/rev 110
Min. displacement (stage 2) cm3/rev 39
Perm. leak oil rate l/min 2
Flushing rate l/min 16
Flushing limitation bar 16

Vibration pump
Manufacturer Sauer
Type 42R 041
System Axial piston/swash plate
Max. displacement cm3/rev 41
Starting pressure bar 350 + 50
Operating pressure (soil dependent) bar approx. 100

Vibration motor
Manufacturer Bosch-Rexroth
Type A10FM45
System Axial piston/swash plate
Displacement cm3/rev 45

36 BOMAG 008 924 17

Technical data 2.1
Flushing rate l/min 6
Flushing pressure limitation bar 13

Steering/charge pump
Type HY/ZFFS11/16
System Gear pump
Displacement cm3/rev 16
Max. steering pressure when bar 200 + 20
steered against end stops

Steering valve
Manufacturer Danfoss
Type OSPC 500 ON
System Rotary spool

Rear axle
Manufacturer Dana
Type CHC 193/66LD
Differential No-Spin
Degree of locking % 100
Reduction ratio 65.08

008 924 17 BOMAG 37

2.1 Technical data

38 BOMAG 008 924 17

3 Maintenance

008 924 17 BOMAG 39

3.1 General notes on maintenance

3.1 General notes on maintenance l The fuel drum must rest for a longer period of time
before drawing off fuel.
When performing maintenance work always comply l The rest in the drum is not suitable for the engine
with the appropriate safety regulations.
and should only be used for cleaning purposes.
Thorough maintenance of the machine guarantees far
longer safe functioning of the machine and prolongs
Notes on the performance of the engine
the lifetime of important components. The effort need-
ed for this work is only little compared with the prob- On diesel engines both combustion air and fuel injec-
lems that may arise when not observing this rule. tion quantities are thoroughly adapted to each other
and determine power, temperature level and exhaust
The terms right/left correspond with travel direction
gas quality of the engine.
forward.
If your engine has to work permanently in "thin air" (at
l Support the engine hood for all maintenance and higher altitudes) and under full load, you should con-
repair work.
sult the customer service of BOMAG or the customer
l Do not touch hot engine parts. service of the engine manufacturer.
l Always clean machine and engine thoroughly be-
fore starting maintenance work. Notes on the cooling system
l For maintenance work stand the machine on level Prepare and check coolant with highest care, since
ground. otherwise the engine may be damaged by corrosion,
cavitation and freezing.
l Perform maintenance work only with the engine
shut down. Coolant is prepared by adding an ethylene-glycol
based anti-freeze agent with corrosion inhibiting prop-
l
Relieve hydraulic pressures before working on hy- erties to the cooling water.
draulic lines.
Mixing with cooling system protection agent is neces-
l
Before working on electric parts of the machine dis- sary in all climatic zones. It prevents corrosion, lowers
connect the battery and cover it with insulation ma- the freezing point and raises the boiling point of the
terial. coolant.
l
When working in the area of the articulated joint at-
tach the articulation lock (transport lock). Notes on the hydraulic system
During maintenance work on the hydraulic system
Environment cleanliness is of major importance. Make sure that no
During maintenance work catch all oils and fuels dirt or other contaminating substances can enter into
and do not let them seep into the ground or into the system. Small particles can produce flutes in
the sewage system. Dispose of oils and fuels en- valves, cause pumps to seize, clog nozzles and pilot
vironmentally. bores, thereby making expensive repairs inevitable.

Keep used filters in a separate waste container

l
If, during the daily inspection of the oil level the hy-
and dispose of environmentally. draulic oil level is found to have dropped, check all
lines, hoses and components for leaks.
Catch biodegradable oils separately.
l Seal external leaks immediately. If necessary in-
form the responsible customer service.
Notes on the fuel system
l
Do not store drums with hydraulic oil outdoors, or at
The lifetime of the diesel engine depends to a great
least under a cover. Water can be drawn in through
extent on the cleanliness of the fuel.
the bunghole when the weather changes.
l Keep fuel free of contaminants and water, since this l We recommend to use our filling and filtering unit
will damage the injection elements of the engine.
with fine filter to fill the system. This ensures finest
l Drums with inside zinc lining are not suitable to filtration of the hydraulic oil, prolongs the lifetime of
store fuel. the hydraulic oil filter and protects the hydraulic sys-
l When choosing the storage place for fuel make tem.
sure that spilled fuel will not harm the environment. l
Clean fittings, filler covers and the area around such
l
Do not let the hose stir up the slurry at the bottom of parts before disassembly to avoid entering of dirt.
the drum. l Do not leave the tank opening unnecessarily open,
but cover it so that nothing can fall in.

40 BOMAG 008 924 17

Fuels and lubricants 3.2
3.2 Fuels and lubricants

Engine oil
Quality
For use in DEUTZ engines the lubrication oils are
classified in DEUTZ Lubrication Oil Quality Classes
(DQC).

Approved engine oils

Deutz ACEA* API** DHD

DQC II-05 E3-96, CG-4, DHD-1

E5-02, CH-4,
E7-08, CI-4,
E4-07 CI-4 Plus

DQC II-05 - - -

DQC IV-05 - - -
* Association des Constructeurs European d’Automobiles
** American Petroleum Institute

The list of approved lubrication oils is also available in

the Internet under the following address:

www.deutz.com
Fig. 14
de >>SERVICE >> Fuels and lubricants and Optimal operating conditions can be achieved by us-
diagnostics >> DeutzQualityClass >> ing the oil viscosity chart (Fig. 14) as a reference.
DQC-Release list
At ambient temperatures below -40 °C the lubrication
en >>SERVICE >> Fuels and lubricants and oil must be pre-heated (e.g. by parking the machine
diagnostics >> DeutzQualityClass >>DQC- indoors).
release list The viscosity is classified acc. to SAE. Multi-purpose
oils should generally be used.
Consult your local service station if in doubt.
Oil change intervals
l Use winter grade engine oil for winter operation!
The longest permissible time a lubrication oil should
Oil viscosity remain in an engine is 1 year. If the following oil
Since lubrication oil changes its viscosity with the tem- change intervals are not reached over a period of 1
perature, the ambient temperature at the operating lo- year, the oil change should be performed at least once
cation of the engine is of utmost importance when per year, irrespective of the operating hours reached.
choosing the viscosity class (SAE-class) . DQC II, DQC
Too high viscosity can cause starting difficulties, too III, DQC IV= 500 operating hours
low ´viscosity can jeopardize the lubrication effect and
result in a high lubrication oil consumption. ! Caution
When using fuels with a sulphur content of more
than 0,5% to 1% or under permanent ambient tem-
peratures below -10°C and when using biodegrad-
able diesel fuel the oil change intervals must be
halved.

Fuels
You should only use commercially available brand
diesel fuel with a sulphur content of less than 0.5%
and ensure strict cleanliness when filling in. A higher

008 924 17 BOMAG 41

3.2 Fuels and lubricants

sulphur content has a negative effect on the oil

change intervals. Fresh water analysis values

The fuel level should always be topped up in due time Conversion to other units:
so that the fuel tank is never run dry, as otherwise filter
and injection lines need to be bled. - German degree (°dH)] max. 20

Quality - English degree (°eH)] max. 25

The following fuel specifications are permitted: - French degree (°fH)] max. 36.5
l
EN 590
corresponds with a content of max. 356
l
DIN 51628 CaCO3 (mg/l) (ppm)
l
ASTM D975 Grade-No. 1-D and 2-D.
l
JIS K 2204 Grade Fuel 1 and Grade Fuel 2 with lu- Information concerning the water quality can be ob-
brication properties acc. to EN 590 tained from the waterworks.

Winter fuel If the fresh water analysis values are unknown, these
must be determined with the help of a water analysis.
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. Diesel If the values of the analysis deviate, the water must be
fuels suitable for temperatures down to -44 °C (-47 treated accordingly.
°F) are available for Arctic climates. At very low tem- l pH-value too low
peratures disturbing paraffin separation can also be Adding of caustic lye of soda or caustic potash so-
expected when using winter diesel fuel. lution.
The admixture of petroleum and the addition of "flow l
Water hardness too high:
enhancing additives" (fuel additives) is not permitted. Mix with soft, distilled or fully demineralized water
l
Chlorides and/or sulphates too high:
Coolant Mix with soft, distilled or fully demineralized water
For fluid cooled engines the cooling fluid must be pre- l
Total hardness or carbonate hardness too low:
pared by admixing a cooling system protection agent Mix with hardened water (harder water is in most
to the fresh water and should be checked within the cases available in the form of drinking water).
specified maintenance intervals.
This prevents damage caused by corrosion, cavita-
!Caution
tion, freezing and overheating.
Another analysis must be made after the fresh wa-
Fresh water quality ter has been prepared.
The correct quality of water is highly important when
Cooling system protection agent
preparing coolant. Clear and clean water within the
boundaries of the following analysis values should As a protection against frost, corrosion and boiling
generally be used. point anti-freeze agents must be used under any cli-
matic conditions.
Coolant for fluid cooled engines is prepared by adding
Fresh water analysis values an ethylene-glycol based anti-freeze agent with corro-
sion inhibiting properties to the cooling water.
pH-value at 20 °C (68 °F) 6.5 - 8.5
We therefore highly recommend our BOMAG cooling
Chloride ion content (mg/l) (ppm) max. 100 system protection agent.
Sulphate ion content (mg/l) max. 100 If our cooling system protection agent is not available
(ppm) for any important reasons, you may, in exceptional
cases, use products that have been approved by the
Water hardness (ion content of max. 3.56 engine manufacturer.
calcium and magnesium )
The list of approved cooling system protection agents
(mmol/l)]
is also available in the Internet under the following ad-
dress:

42 BOMAG 008 924 17

Fuels and lubricants 3.2
Mineral oil based hydraulic oil
www.deutz.com The hydraulic system is operated with hydraulic oil HV
46 (ISO) with a kinematic viscosity of 46 mm2/s at 40
de >>SERVICE >> Betriebsstoffe und Addi- °C and 8 mm2/s at 100 °C. For topping up or for oil
tive >> Kühlsystemschutz >> Kühlsystem- changes use only high-quality hydraulic oil, type
schutz Technisches Rundschreiben HVLP according to DIN 51524, part 3, or hydraulic oils
type HV according to ISO 6743/3. The viscosity index
en >>SERVICE >> Operating Liquids and Ad- (VI) should be at least 150 (observe information of
ditives >> Cooling System Conditioner >> manufacturer).
Flyer Cooling System Conditioner Techni-
cal Circular
Bio-degradable hydraulic oil
Products of the same product group (see Deutz Tech- The hydraulic system can also be operated with a syn-
nical Circular Cooling System Protection Agents) can thetic ester based biodegradable hydraulic oil.
be mixed with each other. The biologically quickly degradable hydraulic oil Pan-
The BOMAG cooling system protection agent corre- olin HLP Synth.46 meets all demands of a mineral oil
sponds with product group A. based hydraulic oil according to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.46
! Caution always use the same oil to top up.
Do not mix different coolants and additives of any When changing from mineral oil based hydraulic oil to
other kind. an ester based biologically degradable oil, you should
consult the lubrication oil service of the oil manufactur-
Before changing the product you must clean the er for details.
entire cooling system.
Consult your local service station if in doubt.
! Caution
To ensure proper corrosion protection you must use Check the filter more frequently after this change.
the cooling system protection agent all year around,
whereby the following concentration must not be fall- Perform regular oil analyses for content of water
en short of or exceeded. and mineral oil.
Replace the hydraulic oil filter element every 500
operating hours.
Mixing ratio

Cooling sys- Fresh water Cold protec- Gear oil

tem protection tion down to For the gearboxes use only ,ulti-purpose gear oils ISO
agent VG 220 of API-GL5-class with a minimum viscosity of
20 mm2/s at 100 °C.
min. 35% 65% -22 °C (-8 °F)
This is a hypoid lubricant of highest quality class for
40% 60% -28 °C (-18 °F) extremely loaded transmissions.
The additives in this oil ensure low wear lubrication
45% 55% -35 °C (-31 °F)
under all operating conditions.
max. 50% 50% -41 °C (-42 °F)
Exciter shaft oil
! Caution For the exciter unit use a fully synthetic gear oil SAE
A proportion of more than 50% of cooling system 75W-90, API GL5.
protection agent causes a drop in cooling power.
Lubrication grease
The use of corrosion protection oils as cooling
system protection agents is not permitted. For lubrication purposes use an EP-high pressure
grease, lithium saponified (penetration 2), acc. to DIN
51502 KP 2G.
i Note
When working at temperature below -41 °C(-42 °F)
you should consult our local service representative.

Environment
Coolant must be disposed of environmentally.

008 924 17 BOMAG 43

3.3 Table of fuels and lubricants

Assembly Fuel or lubricant Quantity

Summer Winter Attention

Observe the level marks

Motor

- Engine oil ACEA: E3-96, E5-02, E7-08, E4-07 approx. 14 litres

API: CG-4, CH-4, CI-4, CI-4 Plus

SAE 10W-40 (-15 °C to +40 °C)

(BOMAG 009 920 06; 20 l)

SAE 15W-40 (-5 °C to +40 °C)

SAE 5W-40 (-30 °C to +40 °C)

- Fuel Diesel Winter diesel fuel approx. 250 litres

- Coolant Mixture of water and anti-freeze agent approx. 16 litres

(see "Fuels and Lubricants - Colant")

Hydraulic system Hydraulic oil (ISO), HLP 46 approx. 80 litres

(BOMAG 009 930 09; 20 l)
or
ester based biodegradable hydraulic oil

Vibration bearings SAE 75W-90, API GL-5 approx. 1.0 l each

(BOMAG 009 925 05; 20 l)

Drive axle SAE 80W-140, API GL-5 approx. 11 litres

(BOMAG 009 925 07; 20 l)

Wheel hubs SAE 80W-140, API GL-5 approx. 2 litres (per side)
(BOMAG 009 925 07; 20 l)

Axle reduction gear SAE 80W-140, API GL-5 approx. 1.9 litres
(BOMAG 009 925 07; 20 l)

Drum drive reduction gear SAE 80W-140, API GL-5 approx. 3.2 litres
(BOMAG 009 925 07; 20 l)

Tires Water approx. 295 litres

Calcium chloride (CaCl2) or magnesium chloride approx. 100 kg

(MgCl2)

Air conditioning system Refrigerant R134a approx. 1500 g

44 BOMAG 008 924 17

Running-in instructions 3.4
3.4 Running-in instructions
The following maintenance work must be per-
formed when running in new machines or over-
hauled engines:

! Caution
Up to approx. 250 operating hours check the en-
gine oil level twice every day.
Depending on the load the engine is subjected to,
the oil consumption will drop to the normal level
after approx. 100 to 250 operating hours.

After a running-in time of 30 minutes

l Retighten the V-belt

After 250 operating hours

l Retighten bolted connections on intake and exhaust
tubes, oil sump and engine mounts.
l Retighten the bolted connections on the machine.
l Retighten all wheel fastening screws with the spec-
ified tightening torque.
l Change engine oil and oil filter
l 1. Oil change vibration bearings
l Oil change in drive axle
l Oil change in wheel hubs
l Oil change, axle reduction gear
l 1. Oil change in drum drive reduction gear

No. Maintenance work Comment

as required
5.49 Tightening torques X
5.50 Engine conservation X
* oil change after 250 and 500 operating hours, then every 500 operating hours
** Running-in instructions: oil change after 250, 500 and 1000 operating hours, then every 1000 operating hours
*** Running-in instructions: oil change after 250 and 1000 operating hours, then every 1000 operating hours
**** Running-in instructions: oil change after 250 and 1000 operating hours, then every 1000 operating hours
*****Also after repairs in the hydraulic system.

48 BOMAG 008 924 17

4 Electrics

008 924 17 BOMAG 49

4.1 Proximity switches

4.1 Proximity switches cillator is thus dampened and the resulting change in
current consumption is evaluated.

PNP circuitry

Fig. 3 PNP circuitry

On sensors with PNP-circuitry the output stage con-
tains a PNP-transistor, which switches the load
against the positive operating voltage. The load is
connected between the output and the negative oper-
ating voltage. The switch is designed with a normally
Fig. 1 Proximity switches on travel control lever open contact, i.e. the contact closes when the initiator
comes in "contact" with metal.
B13 Initiator for brake
NPN circuitry
B14 Initiator for reverse detection

General
In all automated sequences the use of sensors as a
source of information for the electronic control is indis-
pensable. The sensors deliver the necessary signals
about positions, end positions, filling levels or serve as
pulse transducers for counting tasks or speed detec-
tion. In industrial applications inductive and capacitive Fig. 4 NPN circuitry
proximity switches are today indispensable. Com- On sensors with NPN-circuitry the output stage con-
pared with mechanical switches they provide almost tains a NPN-transistor, which switches the load
ideal prerequsites: contactless, wear-free operation, against the negative operating voltage. The load is
high switching frequency and switching accuracy as connected between the output and the positive oper-
well as high protection against vibration, dust and ating voltage.
moisture. Inductive sensors detect all metals without
contact, capacitive sensors detect almost all solid and Breaking and making contacts
liquid media, such as metal, glass, wood, plastic, wa-
ter, oil, etc.

Working principle

Fig. 2
The working principle is based on the principle of the
dampened LC-oscillator. The coil of the oscillation cir-
Fig. 5
cuit forms a high-frequency magnetic stray field.
Proximity switches are used as breaking or making
This stray field leaks out from the active area of the contacts. Depending on the design the switching dis-
proximity switch. If metal or non-ferrous metal enters
into the response range energy is absorbed. The os-

50 BOMAG 008 924 17

Level sensor in diesel tank (R03) 4.2
tances are 2 or 4 mm. The maximum amperage is 300 4.2 Level sensor in diesel tank
mA.
(R03)
The LED (Fig. 5) lights up, when the initiator has de-
tected metal in its stray field.

Fig. 1
The fluid of the level to be measured carries a float,
which lowers or rises with the fluid level. Contact
springs mounted on the float thereby slide along two
resistor wires arranged parallel to the movement of
the float and generate a resistance value, which is
proportionate to the fluid filling level. The correspond-
ing resistance value is measured by an electric meter
and displayed as fluid level value.

Monitoring module, old design

Fig. 6 Circuit diagram, making contact

The circuit diagram (Fig. 6) shows a proximity switch
with normally open contact.
Brown = voltage supply
Blue = ground supply
Black = switching output
The initiator switches the relay (K05)

Fig. 2 old design

n = Fuel level gauge
00 Ohm = Tank full
26 Ohm = Tank 1/2 full
65 Ohm = Tank empty
If no level switch is connected or the cable is broken,
the fuel level gauge will go out.

008 924 17 BOMAG 51

4.3 Differential pressure switch for hydraulic oil filter, B21

Monitoring module, new design 4.3 Differential pressure switch

for hydraulic oil filter, B21

Fig. 3 new design

m = Fuel level gauge
00 Ohm = Tank full
40 OHM = Tank 1/2 full
95 Ohm = Tank empty Fig. 1
If no level switch is connected or the cable is broken, l The differential pressure switches (Fig. 1) switch to
the fuel level gauge will go out. ground at a pressure differential of Δ 3.6 bar.
When the pressure switch switches , the monitoring
board (Pin13 old design, Pin17 new design) is con-
nected to ground. The warning lamp e(Fig. 2) or i (Fig.
3) lights up.

Monitoring module, old design

Fig. 2 old design

e yellow = Lights when the hydraulic oil filter is dirty,
the warning buzzer sounds. The engine
is shut down after 2 minutes. Check hy-
draulic system, replace hydraulic oil fil-
ter.

i Note
The warning buzzer is activated by the monitoring
board (Pin1).
The engine is shut down by the monitoring board
(Pin9) via relay (K22).

52 BOMAG 008 924 17

Differential pressure switch for hydraulic oil filter, B21 4.3
Monitoring module, new design

Fig. 3 new design

i yellow = Lights when the hydraulic oil filter is dirty,
the warning buzzer sounds. The engine
is shut down after 2 minutes. Check hy-
draulic system, replace hydraulic oil fil-
ter.

i Note
The warning buzzer is activated by the monitoring
board (Pin23).
The engine is shut down by the monitoring board
(Pin24) via relay (K22).

008 924 17 BOMAG 53

4.4 Acceleration transducer

Fig. 1 When this combination is set to oscillate, the seismic

BVC machines and machines with E-VIB meter are (sluggish) mass transfers a force to the piezo disc. Ac-
equipped with two piezo-electric acceleration trans- cording to NewtonsLawtheresultantforceisthepro-
ducers, which are mounted to the drum. ductofaccelerationandmass.'
During operation these transducers transmit the ac- A small wire connects the piezo element with the sen-
celeration signals to the measuring ESX. sor socket.
The function of the piezo electric acceleration trans- The piezo electric effect generates a charge on the
ducer is based on the self-charging effect of quartz electrodes, which is proportional to the force and thus
crystals under mechanical load (pressure, tension, also to the acceleration.
torsion) in vertical direction to the polar axes, which
was discovered in 1880 by J. and P. Curie.

Mode of action
The piezo electric acceleration transducer consists of
two basic components:
l
Piezo electric material
l Seismic mass
Once side of the piezo disc is connected with the so-
called seismic mass, the other one with a rigid carrier.

54 BOMAG 008 924 17

Battery service 4.5
4.5 Battery service

! Danger

Danger of cauterisation ! Danger of explosion!

When working on the battery do not use open fire,
do not smoke!
The battery contains acid. Do not let acid come in
contact with skin or clothes!
Fig. 1 Wear protective clothing!
1 Seismic mass Do not lay any tools on the battery!
2 Piezo electric material For recharging remove the plugs from the battery
3 Acceleration to avoid the accumulation of highly explosive gas-
es.

Environment
Dispose of the old battery environmentally.

i Note
Maintenance free batteries also need care. Mainte-
nance free only means that the fluid level does not
need to be checked. Each battery suffers under self-
discharge, which may, in not checked occasionally,
even cause damage to the battery as a result of ex-
haustive discharge.

The following therefore applies for the service life:

l
Switch off all consumers (e.g. ignition, light, inside
light, radio).
l
Check open-circuit voltage of the battery at regular
intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V =
50% discharged.
l
Recharge the battery immediately after an open-cir-
cuit voltage of 12.25 V or less is reached. Do not
perform quick charging.
The open-circuit voltage of the battery occurs approx.
10 hours after the last charging process or one hour
after the last discharge.
l
After each charging process allow the battery to rest
for one hour before taking it into service.
l
For resting periods of more than one month you
should always disconnect the battery. Do not forget
to perform regular open-circuit voltage measure-
ments.

Caution
!

Exhausted batteries (batteries with formation of

sulphate on the plates) are not covered under war-
ranty!
l Remove the battery cover.

008 924 17 BOMAG 55

4.6 Starting with jump wires

Fig. 2
l Remove the battery (Fig. 2) and clean the battery
compartment. Fig. 3

l Clean the outside of the battery.

!Caution
l Clean battery poles and pole clamps and grease
them with pole grease (Vaseline). A wrong connection will cause severe damage in
the electric system.
l Check the fastening of the battery.
l
Bridge the machine only with a 12 Volt auxiliary bat-
l On serviceable batteries check the acid level, if nec-
tery.
essary top up to the filling mark with distilled water.
l
When jump starting with an external battery connect
both plus poles first.
l
Then connect the ground cable first to the minus
pole of the current supplying auxiliary battery and
then to engine or chassis ground, as far away from
the battery as possible (Fig. 3).
l
Start as described under 'Starting the engine'.
l
Once the engine is running switch on a powerful
consumer (working light, etc.).

!Caution
If no powerful consumer is switched on voltage
peaks may occur when separating the connecting
cables between the batteries, which could dam-
age electrical components.
l
After starting disconnect the negative poles (ground
cable) first and the positive poles after.
l
Switch off the consumer.

56 BOMAG 008 924 17

Generator 4.7
4.7 Generator Three-phase generator
The AC-generator first of all produces AC-voltage /
General
AC-current.
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve- Why does AC-current need to be rectified?
hicle with electric current at a steady voltage already There are a few components for which can either be
at idling speed. operated with alternating current or direct current, be-
cause they work independently from the current flow
Terminal designations
direction.
l B61, L = charge control This includes :
l B+, B = battery plus, also with the designation "30" l
Incandescent lamps
l
B- = battery minus, also with the designation "31" l
Fluorescent lamps
l D+ = dynamo plus corresponds with terminal "61" l Glow lamps
and "L" l Electric heating elements.
l D- = dynamo minus (this designation is only found There are also a few components that could be oper-
on D.C. generators or A.C. generators with regula- ated either with alternating current, direct current or
tor removed) three-phase current, if the components were designed
accordingly.
l DF = dynamo field (this designation is only found on
D.C. generators or A.C. generators with regulator This includes :
removed). Note: The designation DF is also found l
Electric motors
on older alternators with externally arranged regula- l
Relays.
tor on the connection of the exciting coil to the reg-
ulator or on the regulator itself Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc-
l
DF1 = dynamo field 1 es work with alternating or three-phase current.
l
DF2 = dynamo field 2 This includes :
l
IG = "15" ignition switch l
Accumulators
l
Control units
l
All electronics
l
Communication equipment.

Design and function

Fig. 4
1 Fan
2 Holding plate
3 Stator core
4 Stator winding
5 Brush

008 924 17 BOMAG 57

4.7 Generator

6 Brush holder
7 Rectifier
8 Bearing cover
9 Rotor winding
10Rotor
11V-belt pulley

Fig. 7 3-phase current

Fig. 5 Rotor with claw poles The wiring diagram (Fig. 7) shows the 3 windings in Y-
connection and the 6 associated rectifier diodes (D1
In the generator the armature windings are located in-
to D6).
side the stationary stator (Fig. 6), whereas the exciter
winding is arranged on the internally revolving rotor The diodes D1, D2, D3 are also referred to as minus
(Fig. 5). diodes, because they have B- as common connection
(minus plate). The other diodes are the plus diodes.
The rectifier diodes have the effect that the negative
half-wave is suppressed and only the positive section
of the wave is allowed to pass, resulting in a pulsating
D.C. voltage.

Fig. 6 Stator
The three stator windings (Fig. 6) 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.

58 BOMAG 008 924 17

Generator 4.7
Charge control light Any other behaviour would indicate a defect on the
The charge control light has two duties: generator (rectifier, carbon brushes, regulator) or a
defect on the lamp, presumed the on-board battery is
l Indication of the correct generator function not discharged.
l External excitation of the generator during the start- A far more important function of the lamp is the transi-
ing phase tion and provision of field current. At standstill there is
no magnetic field in the de-energized generator. Since
this is necessary for the generation of electric current,
the rotor must be supplied with current, so that a weak
field can build up.
The current flows from the ignition switch via the
charge control light through the generator winding
against ground (terminal 31) and is limited to approx.
300 mA by the light bulb (4 W) (without the lamp the
current flow would be 2 to 5 A). While the rotor is ro-
tating current is induced into the stator winding,
whereby a small part (2–5 A, depending on speed)
flows through the charge regulator into the field wind-
ing of the rotor and the major part flows to the output
terminals (B+), where it can be tapped as useful cur-
rent. If the charge control light is defective or no bat-
Fig. 8 plus controlled charging regulator tery is available or the battery is discharged, external
(Fig. 8) shows the current flow with the ignition excitation is no longer possible at standstill and no
switched on, engine stopped. voltage will be generated, even when the generator is
running.
With used, older generators a weak permanent mag-
netic field may have developed over the lifetime,
which does even exist when no voltage is applied.
This type of machines can even start without charge
control light and produce current during operation.
However, this is an unintended effect and you should
not presume that a generator without charge control
light or external excitation can be started up.

Fig. 9 plus controlled charging regulator

(Fig. 9) shows the current flow with the ignition
switched on, engine running.
1 Battery
2 Charge controller
3 Ignition switch
4 Charge control light
5 Rectifier
6 Rotor
7 Sliprings / carbon brush
8 Auxiliary rectifier
Normally the charge control light lights with the engine
stopped and the ignition switched on and goes out at
low engine speed, but at the latest after a single,
short-term increase in engine speed from idle speed,
because there is no longer a voltage difference on the
lamp.

008 924 17 BOMAG 59

4.7 Generator

Charge controller
The charge controller has the following functions
l To regulate the voltage generated by the generator
l To protect against overloads caused by too high
output current
l Protection against reverse current
If the output voltage or the output current of the gen-
erator exceeds the determined maximum values, the
field current and thus the electric power is reduced.

Electronic charge regulator

Fig. 11 plus controlled regulator

Fig. 10
In AC-generators the electrically generated exciter
field of the generator rotor is influenced by an at-
tached electronic charge regulator. Together with the Fig. 12 minus controlled regulator
holder for the carbon brushes this regulator forms a
unit, which transfers the field current to the sliprings of
the rotor.
The regulator compares the rectified actual current of
the generator with the a stable reference voltage in
the regulator and matches the strength of the exciter
field (field current) by increasing or reducing the cur-
rent flow (PWM, switching controller) in such a way,
that the actual voltage of the generator remains con-
stant, irrespective of load and speed. The generator
voltage is thereby regulated, the generator current,
however, is not measured, but limited by the construc-
tion dependent internal resistance of the stator coils or
thermal monitoring.

60 BOMAG 008 924 17

Generator 4.7
Checking the generator Checking the pre-exciter circuit, D+ generator
First one must check whether the generator is actually The most common reason for a 3-phase alternator not
defective. charging is a too low pre-excitation current. The pre-
excitation current through connection D+ depends on
l This can be easily found out by checking whether
the connected consumer (resistance), e.g. charge
the charge control light in the dashboard lights up. If
control light or relay of a MD+ engine control.
the light does not go out, even at higher speeds,
there must be a defect on the generator, the regula- The pre-excitation current should be approx. 250 mA
tor, the wiring or the V-belt. at 12 Volt. This corresponds with a 3 Watt light bulb or
l When the engine is at rest, the charge control light an equivalent combination of light bulb + resistance or
must light up. If not, the lamp may probably be de- an LED + resistance.
fective. Defects on generator or wiring are obviously The total resistance of the disconnected dead supply
also possible. line D+ max. should not exceed 48 Ohm.
The following points allow to contain faults in the volt- In case of faults like
age supply within certain limits. l charge control light stays on
l Cable connections on the generator OK? l no voltage increase, e.g. from 12 V to 14 V
l V-belt OK?
one should check that the correct resistance is as-
l Generator ground (engine ground) OK?
sured.
l Pre-excitation from vehicle electronics OK?
Only if all criteria mentioned above are OK, the fault
must be in the generator itself. In this case it must be
replaced or the following trouble shooting procedure
must be performed.

Fig. 13 Connections on the three-phase alternator (exemplary de-

sign)
If the charge control light or LED stays on when the
engine is running, you should proceed as follows:
l Temporarily bridge connections D+ and B+ on the
three-phase alternator (Fig. 13). The bridging must
be made using an insulated cable with a cross-sec-
tion of approx. 1.0 mm, which is stripped for approx.
5 mm on either end. This cable must be fitted with a
consumer (X), e.g. a light bulb of 21 W, 12 V, in
case of a 12 V system.
If this measure does not clear the fault, the alternator
must be defective.

008 924 17 BOMAG 61

4.7 Generator

Checking the rotor

Measuring the charge current
l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact. i Note
The rotor coils can only be measured in disassembled
l The generator ground connection must be OK.
state.
l During the measurement switch on as many con-
sumers as possible.
1 Attach the clip-on ammeter around the B+ line.
2 Gradually increase the engine speed.
3 The generator current must be at least as high as
the total current of all switched on consumers.

Fig. 14
l Measure the resistance between the sliprings.
l If the resistance does not comply with the factory
specification, replace the rotor.
l Use the resistance range of the continuity tester to
check the continuity between slipring and core.
l Replace the rotor if no infinite value is indicated.

i Note
Factory specification for resistance: 2.8 to 5 OHM.

62 BOMAG 008 924 17

Generator 4.7
Checking the stator Checking the bearings

i Note
The stator coils can only be measured in disassem-
bled state.

Fig. 16
l Check whether the bearing rotates without obstruc-
tion.
l Replace the bearing if it does not rotate properly.
Fig. 15
l Use the resistance range of the continuity tester to
measure the resistance between the individual lines
of the stator winding.
l If the measuring value does not comply with the fac-
tory specification, replace the stator.
l Use the resistance range of the continuity tester to
check the continuity between the individual stator
windings and the core.
l Replace the stator if no infinite value is indicated.

i Note
Factory specification for resistance: Less than 1 OHM.

008 924 17 BOMAG 63

4.7 Generator

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

Fig. 18
l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
Fig. 17 l The generator ground connection must be OK.
The generator test assesses the regulator voltage and l
The battery should be in good condition – the idle
the ripple factor of the generator voltage. voltage of the battery should be at least 12.6 Volt.
l
All plug-and-socket connectors must be free of cor- l
If possible switch off all consumers.
rosion and intermittent contact. l
Perform the measurement at raised engine speed.
l
The generator ground connection must be OK. l
The voltage (B+) should adjust itself at 13 to 14 Volt.
l
The battery should be in good condition – the idle
voltage of the battery should be at least 12.6 Volt.
l
If possible switch off all consumers.
l
Perform the measurement at raised engine speed.

64 BOMAG 008 924 17

Generator 4.7
Checking the regulator in disassembled state
On a Bosch generator unscrew two fastening screws
for the regulator and lift the regulator off. For this work
the generator does not need to be removed.
The Delco-Remy generator needs to be removed
and partly dismantled, if the regulator needs to be dis-
assembled. Unscrew the housing screws to do so.
Pull rotor with drive bearing and V-belt pulley out of
the stator. Unscrew the ends of the stator winding
from the diode carrier and separate the stator from the
collector ring bearing. Disassemble exciter diodes and
brush holders and remove also the regulator. Fig. 20
E.g minus controlled regulator
i Note One connects the regulator (Fig. 20) with D+ and D- to
When testing the regulator one should be aware that the power source, as shown in the illustration, and the
there are 2 different types of regulators: lamp to both carbon brushes, instead of the exciter
winding. When slowly increasing the voltage the lamp
l If the carbon brush is not connected to ground the will first become brighter, because the regulator al-
regulator is a so-called minus controlled regulator. lows all lamp current (= exciter current) to flow at volt-
The exciter winding is positioned between D+ and age values up to 14.4V. Once the regulator voltage is
DF, the regulator therefore regulates the exciter reached, the regulator switches the lamp current off.
winding on the ground side. The other carbon brush When returning the voltage back below the control
is connected with the cathodes of the exciter di- voltage, the regulator will switch the lamp back on.
odes, terminal D+. This leaves one further terminal,
With this test the major difficulty is the problem to re-
this is DF.
move the regulator an identify terminals D+, DF and
D+ (vehicle wiring system) D-.
D- (ground contact, mostly located on one of the fas-
tening screws)
DF (Dynamo Field)

Fig. 21

Fig. 22
Fig. 19
The illustrations (Fig. 21) and (Fig. 22) show two dif-
l If the carbon brush is connected to ground the reg-
ferent regulator types.
ulator is a so-called plus controlled regulator. The
exciter winding is positioned between DF and D-,
the regulator therefore regulates the exciter winding
on the plus side. The other carbon brush is then
connected with terminal DF. This leaves one further
terminal, this is D+.
The basic function of a disassembled regulator can be
easily tested with a 12V lamp and an adjustable D.C.
power supply unit (0V ... 20V).

008 924 17 BOMAG 65

4.8 Replacing the voltage regulator

Replacing carbon brushes 4.8 Replacing the voltage regula-

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

Fig. 1
l Loosen the hexagon nuts M5 (Fig. 1).
l Take off hexagon nuts and washers.
l Remove the plastic cover.

i Note
Optional:
Unscrew the hexagon nut M5 from terminal W, take
off washer and flat plug connector.

Fig. 2
l Check whether washers are present. Take off the
washers (3x) (Fig. 2), to prevent these from falling
into the generator.

66 BOMAG 008 924 17

Replacing the voltage regulator 4.8

Fig. 3
l Slacken the screws M3 (A) (Fig. 3). Fig. 2
l Loosen the hexagon nuts M5 (B). l Check whether the rubber seal is present on the
brush holder (Fig. 2).
l Remove screw and hexagon nuts.
l Take off the voltage regulator.

Assembling the voltage regulator

Fig. 3
l
Attach the voltage regulator (Fig. 3).
l Tighten the screw M3 (A).- Tightening torque 0.7-
1.0 Nm.
Fig. 1 l
Tighten the screw M5 (B).- Tightening torque 3.5-
l
Check for correct fit of sealing ring on protective 4.5 Nm.
cover (Fig. 1).

Fig. 4
l Install the washers (Fig. 4).

008 924 17 BOMAG 67

4.9 Electric starter

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

68 BOMAG 008 924 17

Electric starter 4.9
Directly acting electric starter 5 Ignition switch
This shows the design of this starter. It consists of a 6 Actuating lever
starter motor and a magnetic switch. 7 Ring gear
8 Pinion
9 Freewheeling clutch
10(Battery

Pinion meshes with the ring gear

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

Fig. 7 Magnetic switch open

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

008 924 17 BOMAG 69

4.9 Electric starter

Engine running 4 Resetting spring

5 Magnetic switch
6 Ignition switch
7 Pinion
8 Ring gear
9 Battery

Fig. 9
Once the engine is running and drives the pinion (1)
via the ring gear (2), the freewheeling clutch (3) will
open and prevent the armature (4) from being driven
by the engine.
1 Pinion
2 (Ring gear
3 Freewheeling clutch
4 Armature

Ignition switch released

Fig. 10
When releasing the ignition switch (6) it will return
from position "START" to "ON" and interrupt the start-
er current circuit. Current will now flow from the bat-
tery (9) through the contact plate in the pick-up
winding (3) and the holding winding (2). Since both
coils generate opposed magnetic fields, the magnetic
field will collapse and the resetting spring (4) takes the
armature (1) back to its initial position.
This opens the current circuit on the contact plate and
the pinion (7) is pulled back from the ring gear (8) and
stops.
1 Armature
2 Holding winding
3 Pick-up winding

70 BOMAG 008 924 17

Electric starter 4.9
Magnetic switch Freewheeling clutch

Fig. 11 Direct acting electric motor Fig. 13 Freewheeling clutch

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

Fig. 12 Geared motor

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

008 924 17 BOMAG 71

4.9 Electric starter

Trouble shooting "Starter" Testing and measuring the starter

Function control with the starter removed
i Note
The most frequent fault is definitely a fully discharged
Caution
!
battery.
Fasten the starter to make sure that it will not
If the starter rotates too slowly, either the brushes come loose during the test.
are partly worn off, or parts of the exciter or armature
winding is shorted. In some cases oxidized electric
contacts or a soiled ground connection causing ex-
tremely high voltage losses in the overall starter sys-
tem are the cause of problems.
If the starter only emits a clicking sound,- either
the magnetic switch is defect / soiled (dismantle and
clean))- the main contacts on the magnetic switch are
worn off / soiled (scrape off carefully with a file and
clean)- the starter motor is defective / soiled (remove
armature and clean), cover cleaned, moveable parts
with grease.
Frequently a jammed return mechanism is the reason
for a starter failure. Fig. 14
Occasionally worn contacts are found on the magnetic l
Connect a jumper lead between start terminal (1)
return switch and battery plus (2).
Defects on the actual starter motor including pinion l
Connect a jumper cable instantaneously between
and carbon brushes are very rare. starter housing and battery minus (3).
With a trouble shooting chart the faults in the starter
system can be narrowed down. The starter system i Note
can only work when many conditions are fulfilled at
If the motor does not start, the starter is defective. Re-
the same time.
pair or replace the starter.
l Immobilizer deactivated?
l Ignition switch OK? Checking the magnetic switch
l Travel lever in correct position?
l Emergency stop not actuated?
l Battery sufficiently charged?
l Battery poles OK?
l Main battery fuse OK?
l Main battery switch closed?
l Main starter cable (terminal 30) OK?
l Starter control cable (terminal 50) OK, voltage
drop?
l Ground cable OK?
l Switching of magnetic switches OK?
Fig. 15
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
l
Connect a jumper lead between start terminal (1)
and battery plus (2).
l the experience of the specialist
l
Connect a jumper cable instantaneously between
l the failure probability of the component to be tested
starter housing and battery minus (3).
and the testing effort for the respective part.
Only if all criteria mentioned above are OK, the fault
must be in the starter itself. In this case it can be re- i Note
paired or replaced. If the pinion does not disengage, the magnetic switch
is defective. Repair or replace the starter.

72 BOMAG 008 924 17

Electric starter 4.9
Continuity test for the magnetic switch

Fig. 16
l
Use a continuity tester to check for continuity be-
tween terminal (1) and terminal (29 while holding
the pin depressed.
l Replace the magnetic switch if no continuity is de-
tected.

008 924 17 BOMAG 73

4.10 Coolant temperature switch

Fig. 1 Coolant temperature switch

Pos. Designation in Designation Technical data

circuit diagram
B152 Coolant temperature switch Contact switches at approx. 110° C
to engine ground

74 BOMAG 008 924 17

Oil pressure switch and low oil pressure circuitry 4.11
4.11 Oil pressure switch and low oil
pressure circuitry

Fig. 1
1 Oil pressure switch

Pos. Designation in Designation Technical data

circuit diagram
1 B06 Oil pressure switch Below 0.8 bar the contact switches to
engine ground, closed without pres-
sure. Tightening torque 20 ± 2 Nm
with copper ring.

008 924 17 BOMAG 75

4.11 Oil pressure switch and low oil pressure circuitry

Fig. 2 Oil pressure switch

The oil pressure switch (B06) is mounted to the en-
gine oil filter. After starting it reports when a safe op-
erating pressure has been reached and causes the
warning light in the monitoring board (A15) to light, if
the engine oil pressure drops below approx. 0.8 bar.
In case of too low engine oil pressure with the engine
running, the monitoring board (A15) will send a time
delayed (10 sec.) 12 V signal to relay (K22, terminal
86). The relay interrupts the electric power supply to
the solenoid valve (Y13) and the diesel engine is shut
down.

76 BOMAG 008 924 17

Boost fuel solenoid valve 4.12
4.12 Boost fuel solenoid valve for rising the engine torque during the acceleration
phase after starting. For this compensation and to as-
During the starting process the solenoid valve is sup- sure starting of the cold engine additional fuel needs
plied with 12 Volt. to be injected at the time of starting and accelerating.
This injection adaptation serves the purpose of com-
pensating for condensation and leakage losses and

Fig. 3
1 Boost fuel solenoid valve

Pos. Designation in Designation Technical data

circuit diagram
1 Y01 Boost fuel solenoid valve 12 Volt, approx. 3,5 Amp.

008 924 17 BOMAG 77

4.13 Engine shut-down solenoid

Fig. 1
1 Engine shut-down solenoid

Pos. Designation in Designation Technical data

circuit diagram
1 Y13 Engine solenoid 12 Volt, approx. 4 Amp.

General
When switching the ignition on, the engine solenoid is
supplied with 12 Volt.
Interrupting this power supply shuts down the engine.
The engine shut-down can be triggered through the
ignition switch (S00), the emergency stop button
(S01) or the monitoring board in case of too low oil
pressure.

78 BOMAG 008 924 17

Electric throttle control 4.14
4.14 Electric throttle control

Fig. 1 Engine solenoid

Throttle control switch

Fig. 2 Throttle control switch

The throttle control switch (S120) is used to change
from "MIN" to "MAX" idle speed and vice versa.

008 924 17 BOMAG 79

4.14 Electric throttle control

Throttle control solenoid Y120

i Note
When switching on, the solenoid plunger is pulled
against the stop. The limit switch then switches the
pick-up and holding winding in series. The current flow
is reduced from approx. 70 A to approx. 3.5 A.

Fig. 3 Electric circuit of solenoid

The throttle control solenoid 5 (Fig. 3)) is equipped
with a pick-up winding (4) and a holding winding (3), Fig. 5
both switched in series. The holding winding has a l
Measure the gap between stop screw 1 (Fig. 5) and
much higher resistance than the pick-up winding. The
throttle lever (2).
"aux"-connection is connected between the two wind-
ings. The engine solenoid is equipped with a limit
switch (2), which is mechanically connected with the ! Caution
governor rod (1) on the diesel engine. This switch The gap should be min. 0.1 mm and max. 0.5 mm.
bridges the holding winding until the end position of
the governor rod is reached (high engine speed) If the gap is too small, the limit switch in the sole-
noid may not be able to operate.
This bridging has the effect, that the "aux"-terminal
has the same potential as the "+"-terminal. If the In case of a too wide gap the engine will not reach
bridge is open, the "aux"-terminal has almost the its maximum speed.
same potential as the "-" terminal, because of the low
resistance of the pick-up winding and the high resist-
ance of the holding winding.

Adjusting the solenoid

Fig. 4
l Switch on the ignition.
l Turn the rotary switch (Fig. 4) to position "MAX".

80 BOMAG 008 924 17

Heating flange on engine 4.15
4.15 Heating flange on engine the engine must be avoided and trouble shooting
should be performed instead.
Several successive starting attempts can cause
overheating of the heating flange .

Fig. 1 Heating flange

The heating flange is a component with an electrically
operated heating wire and high energy density used to
heat up the intake air in case of very low ambient tem-
peratures.
The heating power is approx. 2000 Watt.
The heating power improves the cold starting charac-
teristics and the exhaust emissions (white smoke) of
the diesel engine. Fig. 2 Heating flange (R19) with hose socket BF4M 2012 C
A differentiation is made between preheating, to as-
sure the cold start ability of the engine, and subse-
quent heating.

i Note
Pre-heating is triggered by switching on the ignition
(12 Volt on control unit A13, terminals 15(7) and S(2)).
With a coolant temperature of -30°C the preheating
time will be max. 52 seconds, with +5°C the minimum
time will be 38 seconds. During the preheating period
the control light in the monitoring board is permanently
on. In case of a fault the lamp will flash.
After-heating is triggered by the starting process (12
Volt on control unit A13, terminal 50(5)). With a cool-
ant temperature of -30°C the subsequent heating time
will be max. 180 seconds, with +25°C the minimum
time will be 35 seconds. This after-heating time is not
indicated by the control light.

! Caution
Multiple activation of the heater control in short
term operation (low generator running time) dis-
charges the starter battery.
If the engine does not start properly in case of au-
tomatic starting of the heating flange because the
starter does not get energized due to a fault and
does not crank the engine, the starting process
must be completely aborted (ignition key to OFF,
voltage supply to heating flange interrupted). In
order to avoid damage to heating flange or charge
air hoses caused by overheating, another start of

008 924 17 BOMAG 81

4.15 Heating flange on engine

Fig. 3
1 Heating control unit (A13)
2 Heating relay (K14)

Fig. 4 Coolant temperature sensor

1 Temperature sensor (B113) for heating flange
control (A13)
2 Coolant temperature switch (B30)

82 BOMAG 008 924 17

Heating flange on engine 4.15

Pos. Designation in Designation Technical data

circuit diagram
R19 Heating flange With a coolant temperature of -30°C
(Fig. 2) the preheating time will be max. 52
seconds, with +5°C the minimum
time will be 38 seconds.
With a coolant temperature of -30°C
the after-heating time will be max.
180 seconds, with +25°C the mini-
mum time will be 35 seconds.
12 Volt
approx. 2000 Watt
approx. 167 A
approx. 0.07 Ohm

2 (Fig. 3)) A13 Heating control unit 12 Volt

3 (Fig. 3) K14 Heating relay 12 Volt

1 (Fig. 4) B113 Temperature sensor for heating approx. 2 Ohm at 20°C

flange control (A13)
2 (Fig. 4) B30 Coolant temperature switch Contact switches at approx. 110° C
to ground

Fig. 5 Heating flange function diagram

1 Heating start
2 Signal lamp
3 Start
4 Switching relay
5 Condition
6 Terminal 15/S
7 Terminal L
8 Terminal 50
9 Terminal R
10 Start process
11 Ready for starting: 0 sec.

008 924 17 BOMAG 83

4.16 Checking the heating flange control

4.16 Checking the heating flange perature sensor is pulled off (simulated sensor fail-
ure), a coolant temperature of 0° C is assumed.
control
l Start the heating process.

Depending on the coolant temperature the control

light (K)(Fig. 1) will light between 30s and 50s, the
heating flange relay is energized.
l Place a tong-test ammeter over the heating flange
connecting line.

Rated current: 165 Amp +- 10 Amp.

i Note
The relay must remain energized for another approx.
15 seconds, after the control light has gone out.
After the engine has started the after heating time
must continue for 35 to 180 seconds. This after-heat-
Fig. 1 Monitoring module, old design (A15)
ing time is not indicated by the control light.

Fig. 2 Monitoring module, new design (A15)

i Note
During the preheating period the control light K (Fig.
1), c (Fig. 2) is permanently on. In case of a fault the
lamp will flash.
l The lamp flashes with a frequency of 1 Hz during
the pre-heating phase.

Sensor failure: Either short circuit or cable break-

age at the input to the control unit (A13), terminal
T(4)
l The lamp flashes with a frequency of 2.5 Hz over
the entire heating phase.

Heating flange failure: Either short circuit or cable

breakage at the output of the control unit (A13),
terminal R(6)

i Note
The heating flange only becomes active at a coolant
temperature below 25°C. When the plug of the tem-

84 BOMAG 008 924 17

Engine monitoring 4.17
4.17 Engine monitoring

Fig. 1 Monitoring module, old design Tank gauge, Pin 2: (0Ω ⇒ tank fuel, 65Ω ⇒ tank emp-
Output warning buzzer, Pin 1: +UB switching. ty, 26Ω ⇒ tank ½. If no level switch is connected or the
cable is broken, the gauge will go out.
Output engine shut down, Pin 9: +UB switching.
Water separator, Pin 3 and 4: Resistance <500kΩ .

Pos. Designation Control light Warning Engine Engine Remedy

buzzer shut-down shut-down
time time

10 sec. 2 min.
a Control light, over- red, flashing X X Switch off vibration, run
heating of engine Low-active engine with idle speed or
shut down engine if nec-
essary, clean engine oil
cooler and radiator, if
necessary repair engine.
b Engine oil pressure red, flashing X X Check the engine oil lev-
control light Low-active el, if necessary repair the
engine.
c Control light for en- not used
gine air filter Low-active
d Charge control light yellow, lights Check V-belt, if neces-
High-active sary repair the generator
i Control light, water yellow, lights X X Check, clean the water
in diesel filter separator
k Control light, pre- yellow, lights
heating monitoring Low-active
j Coolant provision not used
Low-active
e Hydraulic oil filter yellow, lights X X Change the hydraulic oil
Low-active filter

008 924 17 BOMAG 85

4.17 Engine monitoring

Fig. 2 Monitoring module, new design Tank gauge, Pin 1: (0Ω ⇒ tank fuel, 65Ω ⇒ tank emp-
Output warning buzzer, Pin 23: +UB switching. ty, 26Ω ⇒ tank ½. If no level switch is connected or the
cable is broken, the gauge will go out.
Output engine shut down, Pin 24: +UB switching.
Water separator, Pin 21 and 22: Resistance <500kΩ .

Pos. Designation Control light Warning Engine Engine Remedy

buzzer shut-down shut-down
time time

10 sec. 2 min.
g Control light, over- red, flashing X X Switch off vibration, run
heating of engine Low-active engine with idle speed or
shut down engine if nec-
essary, clean engine oil
cooler and radiator, if
necessary repair engine.
d Engine oil pressure red, flashing X X Check the engine oil lev-
control light Low-active el, if necessary repair the
engine.
h Control light for en- not used
gine air filter Low-active
f Charge control light yellow, lights Check V-belt, if neces-
High-active sary repair the generator
a Control light, water in yellow, lights X X Check, clean the water
diesel filter Low-active separator
b Control light, preheat- yellow, lights
ing monitoring Low-active
e Coolant provision not used
Low-active
i Hydraulic oil filter yellow, lights X X Change the hydraulic oil
Low-active filter

86 BOMAG 008 924 17

Engine monitoring 4.17
Water separator l Push the plug back on, the plug interlock clicks into
place.
l Check the plug interlock by lightly pulling on the wir-
ing loom.

Engine overheating

Fig. 3 Sensor water separator

l Press the plug interlock and disconnect the plug
(Deutsch plug).
l Bridge both contacts on the plug of the wiring loom.
Fig. 5 Coolant temperature switch
i Note l Press on the locking wire (Fig. 5) and pull off the
Control light i (Fig. 1) a (Fig. 2) lights up. An audible plug.
warning will sound and the engine is shut down after l Bridge both contacts on the plug of the wiring loom.
2 minutes.
l
Push the plug back together, the plug interlock
clicks into place.
i Note
Control light a (Fig. 1) g (Fig. 2) flashes. An audible
l Check the plug interlock by lightly pulling on the wir- warning will sound and the engine is shut down after
ing loom. 2 minutes.
Engine oil pressure l Push the plug back on, the plug interlock clicks into
place.
l
Check the plug interlock by lightly pulling on the wir-
ing loom.

Emergency stop switch

Fig. 4 Oil pressure switch

l Press on the locking wire and pull off the plug 1 (Fig.
4).
l
Apply the contact to engine ground. Fig. 6 Emergency stop switch
l
Press the emergency stop switch (Fig. 6). The en-
i Note gine should stop immediately.
The control light b (Fig. 1) d (Fig. 2) flashes. An audi-
ble warning will sound and the engine is shut down af-
ter 10 seconds.

008 924 17 BOMAG 87

4.18 Overview of electric components

1) Wiring loom cabin

88 BOMAG 008 924 17

Overview of electric components 4.18

1) Wiring loom engine

008 924 17 BOMAG 89

4.18 Overview of electric components

1) Wiring loom supply central electrics

2) Wiring loom battery-starter
3) Wiring loom ground, engine-frame
4) Wiring loom, battery-fuses
5) Wiring loom ground, battery-frame

90 BOMAG 008 924 17

Overview of electric components 4.18

1) Wiring loom rear frame

008 924 17 BOMAG 91

4.18 Overview of electric components

4) Wiring loom speedometer

92 BOMAG 008 924 17

Overview of electric components 4.18

4) Wiring loom wiring of frequency display

8) Wiring loom transducer for vibration frequency
9) Wiring loom adapter transducer

008 924 17 BOMAG 93

4.18 Overview of electric components

13) Wiring loom, tachograph-cabin

94 BOMAG 008 924 17

Overview of electric components 4.18

7) Wiring loom working lights

008 924 17 BOMAG 95

4.18 Overview of electric components

11) Wiring loom, lighting on railing

96 BOMAG 008 924 17

Overview of electric components 4.18

3) Wiring loom heating fan, new design

4) Wiring loom air conditioning, new design

008 924 17 BOMAG 97

4.18 Overview of electric components

1) Wiring loom acceleration transducer

5) Wiring (P16)

98 BOMAG 008 924 17

Description of indicators and control elements 4.19
4.19 Description of indicators and
control elements

Fig. 7 4 A108, rotary switch for air conditioning*

1 S00, start switch 5 Vent for heating and ventilation, driver
2 A15, instrument cluster
3 A108, rotary switch for cabin fan * Optional equipment

008 924 17 BOMAG 99

4.19 Description of indicators and control elements

6 Vent for heating and ventilation, footwell

7 S13, push button for vibration
8 Travel lever
9 S35, rotary switch vibration, high/low frequency
10 S42, rotary switch, travel speed ranges
11 S01, Emergency Stop switch
12 S03, push button, warning horn
13 S120, rotary momentary contact switch for engine
speed
14 S37, rotary switch for direction indicators*
15 S14, rotary switch for hazard light system*
16 S15, rotary switch for lighting (StVZO)* Fig. 8

17 S53, rotary switch for working lights* a = S38, toggle switch for flashing beacon
18 Steering wheel adjustment lever
b = S20, toggle switch for front windscreen wiper/
19 Rotary switch for cabin heater washer
1 S00, starter switch up = windscreen wiper moves to end
2 A15, Instrument cluster position and stops.
3 A108, rotary switch for cabin fan* down = Switches on front windscreen wip-
1 ing.
4 A108 Rotary switch for air conditioning
5 Vent for heating and ventilation, driver Push button = Front windscreen is sprayed dur-
ing wiping.
6 Vent for heating and ventilation, footwell
7 S13, push button for vibration c = S21, toggle switch for rear windscreen wiper/
washer
8 Travel lever
9 S35, rotary switch for vibration, amplitude pre-se- up = windscreen wiper moves to end
lection position and stops.
10 S42, rotary switch, travel speed ranges down = Switches on wiping of rear wind-
screen.
11 S01, Emergency Stop switch
Push button = Rear windscreen is sprayed dur-
12 S03, Push button, warning horn
ing wiping.
13 S120, Rotary button for engine speed
14 S37, rotary switch for direction indicators1
15 S14, rotary switch for hazard light system1
16 S15, rotary switch for lighting1
17 S53, rotary switch for working lights1
18Rotary switch for cabin heater1

* Optional equipment

100 BOMAG 008 924 17

Fuses 4.20
d = S163, toggle switch for rear windscreen heat- 4.20 Fuses
ing

Fig. 10
Fig. 9

g = E29, Reading and dashboard light ! Danger

h = S45, Toggle switch for cabin lamp Fire hazard!

i = S158, Toggle switch for reading and dashboard Do not use fuses with higher ampere ratings and
light do not bridge fuses.
(1) 15A = (F43) Wiper/washer, rear
j = E70, Cabin lamp
(2) 15A = (F44) Wiper/washer, front
(3) 10A = (F130) Night light
(4) 25A = (F31) Cabin ventilator
(5) 10A = (F41) Flashing beacon
(6) 15A = (F144) Cab socket
(7) 15A = (F143) Rear windscreen heating
(8) 10A = (F42) Cab lights

Fig. 11
No. 1 = Fuses in electric junction box

! Danger

Fire hazard!
Do not use fuses with higher ampere ratings and
do not bridge fuses.
(15) 30A = (F13) Start switch
(16) 5A = (F68) Electronic immobilizer
(17) 20A = (F105) Engine speed

008 924 17 BOMAG 101

4.20 Fuses

(18) 15A = (F11) Front head lights

i Note
(19) 15A = (F07) Hazard light The main fuse is located in the battery compartment
(21) 15A = (F22) Working headlights, rear
(22) 15A = (F19) Working headlights, rear
(23) 15A = (F09) Parking and tail light, left
(24) 15A = (F10) Parking and tail light, right
(25) 15A = (F08) Direction indicators
(26) 10A = (F18) Pre-fuse for working head lights
(27) 15A = (F14) Engine solenoid
(28) 10A = (F23) Warning horn
(29) 10A = (F25) solenoid valve for driving and brak-
ing
(30) 15A = (F39) Main fuse for cabin
(31) 10A = (F24) Instruments
(32) 15A = (F03) Vibration
(33) 10A = (F148) Control MESX, potential 15
(34) 10A = (F84) Control, contact 54
(35) 15A = (F146) Control MESX, potential 30
(37) 25A = (F124) Fuel pre-heating

Fig. 12
(80) 5A = (F150) GPS Receiver

Fig. 13
No. 2 = Main fuse for battery
125A = (F00) Main fuse

102 BOMAG 008 924 17

5 Electronic modules

008 924 17 BOMAG 103

104 BOMAG 008 924 17
5.1 BEM, BOMAG Evib-meter

008 924 17 BOMAG 105

5.1 BEM, BOMAG Evib-meter

Bild 14

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

106 BOMAG 008 924 17

BEM, BOMAG Evib-meter 5.1

Service Training
Electrics
MESX

Version 4.02

Status: 21.12.2011 Page 1 of 69

Author: T.Löw / TE
File name: c:\documents and settings\kneip\desktop\neuer ordner\schulung elektrik mesx_v4.03_02.12.11_en.docx

008 924 17 BOMAG 107

5.1 BEM, BOMAG Evib-meter

Service Training MESX

Table of contents
1 Document alteration list .....................................................................................................................3
2 Proof of software change MESX .......................................................................................................5
3 Proof of software change BOP ..........................................................................................................8
4 Known faults ......................................................................................................................................9
5 How to proceed when replacing components? ...............................................................................10
5.1 How to proceed when replacing an ESX control? ...................................................................10
5.2 How to proceed when replacing a rear axle sensor? ...............................................................10
5.3 Which components can be replaced without a subsequent adjustment procedure? ..............10
5.4 List of machine types ...............................................................................................................11
6 Possible adjustments on machines without BOP ............................................................................14
6.1 Description of the Display Module ...........................................................................................14
6.2 Input of code numbers .............................................................................................................14
6.3 Changing the machine type (only via display module) ............................................................15
6.4 Inverting the direction signal (only via display module) ...........................................................16
6.5 Changing the bit rate (only with display module) .....................................................................17
7 Adjustment/display possibilities on machines with BOP .................................................................18
7.1 Adjusting the machine type (BOP) ...........................................................................................18
7.2 Inverting the direction signal via the BOP control terminal ......................................................20
7.3 Accessing the diagnostics menu..............................................................................................22
7.3.1 Extended diagnostics on machines with circular exciter (BTMplus, BTMprof) .................. 24
7.3.2 Operating hours meter on machines with circular exciter (BTMplus, BTMprof) ................ 25
7.3.3 Extended diagnose BVC machines ......................................................................................... 26
7.3.4 Operating hour meter BVC machines ..................................................................................... 27
7.4 Simulation mode ......................................................................................................................28
7.5 Changing the printout language ...............................................................................................32
7.6 Setting the machine serial number ..........................................................................................34
7.7 Teaching distance pulses ........................................................................................................36
7.8 Activating the amplitude limitation (only BVC machines).........................................................38
7.9 Changing the display mode (metric/imperial) ..........................................................................40
7.10 Position to switch over the acceleration transducer (only BVC machines) ..........................42
7.11 Switching the GPS Receiver Voltage Supply Mode .............................................................44
8 Possible settings on the BCM05mobile...........................................................................................46
8.1 Reading the software version ..................................................................................................46
8.2 Changing the language ............................................................................................................46
8.3 Changing the unit system (metric/imperial) .............................................................................46
9 Block diagram BEM .........................................................................................................................47
10 Block diagram BTMplus / VARIOCONTROL ...............................................................................48
11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile ................................................49
12 Description of the signals on the ESX-control .............................................................................50
13 Fault codes of the ESX control ....................................................................................................55
13.1 Overview...............................................................................................................................55
13.2 Description of fault reactions ................................................................................................56
13.3 Detailed description of fault codes and their possible causes .............................................57
14 Input codes for ESX control (only via BEM display module) .......................................................61
14.1 Travel system .......................................................................................................................61
14.2 Vibration ...............................................................................................................................62
14.3 Light ......................................................................................................................................62
14.4 Acceleration transducer ........................................................................................................63
14.5 Diesel engine ........................................................................................................................63
14.6 Setting the machine type ......................................................................................................64
14.7 Parameter change ................................................................................................................65
15 Terminology in connection with ESX ...........................................................................................66

Status: 21.12.2011 Page 2 of 69

Author: T.Löw / TE

108 BOMAG 008 924 17

BEM, BOMAG Evib-meter 5.1

Service Training MESX

1 Document alteration list

Version Date Description of changes resp.

0.00 27.04.200 Creation of version 1 Löw
4
1.00 05.05.200 Î Block diagrams added Löw
4 Î Description of display module extended
Î "Proof of software change" added
1.01 23.07.200 Î Description of BOP display pages added. Löw
4
2.00 31.08.04 Î Input code 4602 replaced by code 4606 Löw
Î Machine type BW219D added
3.00 15.10.200 Î Item "How to proceed when replacing components?" added Löw
4 Î Description for ESX Pin 0:35 added
Î Description fault code 4601 and 4606 corrected
Î Description Software Version 3.00 added
3.01 14.02.200 Î Description Code 7534 from version 3.00 added Löw,
5 Î Description Software change V3.01 added Horch
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
4.00 01.05.200 Î Description of "GPS Mode" menu added Löw
7 Î Item "Change language" changed for BCM 05
Î Description fault code 4531 and 4532 extended
Î List of machine types extended

4.01 20.11.200 Î further SN added Vogt,

9 Î List of machine types extended Löw
Î Software version history extended
4.02 10.03.201 Î List of machine types extended Löw
0 Î further SN added Vogt
30.03.201 Î further SN added Vogt
0 Vogt
13.09.201
Î further SN added
0
30.09.201
0
4.03 02.12.201 New part-number added Kahren
1 Description of "Operating hour meter" menu added
Description of "Acc Sensor Position" menu added
Description of simulation screen added

Status: 21.12.2011 Page 3 of 69

Author: T.Löw / TE

008 924 17 BOMAG 109

5.1 BEM, BOMAG Evib-meter

Service Training MESX

Status: 21.12.2011 Page 4 of 69

Author: T.Löw / TE

110 BOMAG 008 924 17

BEM, BOMAG Evib-meter 5.1

5.1 BEM, BOMAG Evib-meter

Service Training MESX

3 Proof of software change BOP

Version Date Description of changes resp.

1.00 25.03.200 first software version for series production Löw
4
1.01 13.04.200 Revision of BVC diagnostics screen Löw
4
1.02 23.04.200 2-stage jump information (yellow and red) Löw
4
3.00 15.10.200 Î Realization of imperial display Löw
4 Î Simulation mode implemented on BOP
Î New TN 582 701 92
3.01 24.1.2005 Î Part-No. changed to 58 701 93 Löw
Î Designation "ESX" replaced by "MESX" and "BOP" by
"BOP"
3.02 10.02.200 Î Amplitude bar graph in imperial display mode corrected Löw
5
4.00 01.05.200 Î Flags for all EU-languages and additionally Japan and Löw
7 China stored in OPUS
Î Page for changing over GPS Receiver Mode implemented
Î Triggering for fault LED in BVC diagnostics page 2
activated

4.01 04.11.200 Î - additional variable for brightness control OPUS21C added Löw
8 Î - Representation of SW TN instead of "High-TN"
Î - Return to diagnostic page corrected for French
version
Î - SimulScreen activated for French version
Î - Changeover of GPS-mode prevented (jump to page
GPS-mode deactivated)
4.02 13.01.200 Î Return to selection page "Scale type" corrected. Löw
9
5.00 09.11.201 Î Menu "Hourmeter" and "Acc Sensor Position" created Kahren
1

Status: 21.12.2011 Page 8 of 69

Author: T.Löw / TE

114 BOMAG 008 924 17

BEM, BOMAG Evib-meter 5.1

Service Training MESX

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"

Status: 21.12.2011 Page 9 of 69

Author: T.Löw / TE

008 924 17 BOMAG 115

5.1 BEM, BOMAG Evib-meter

Service Training MESX

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: 7.6
Set the printer language (only machines with printer), see: 7.5

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.

Author: T.Löw / TE

008 924 17 BOMAG 119

5.1 BEM, BOMAG Evib-meter

Service Training MESX

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.

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).
Vorzeichen

057 667 72
15/54

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:

1. 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.
2. 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 0 .
3. 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.

Status: 21.12.2011 Functions of the ESX control Page 14 of 69

Author: T.Löw / TE

120 BOMAG 008 924 17

BEM, BOMAG Evib-meter 5.1

Service Training MESX

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 a default machine type setting 7 5 0 0 .

Status: 21.12.2011 Functions of the ESX control Page 15 of 69

Author: T.Löw / TE

008 924 17 BOMAG 121

5.1 BEM, BOMAG Evib-meter

Service Training MESX

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").

Status: 21.12.2011 Functions of the ESX control Page 16 of 69

Author: T.Löw / TE

122 BOMAG 008 924 17

BEM, BOMAG Evib-meter 5.1

Service Training MESX

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.

Status: 21.12.2011 Functions of the ESX control Page 17 of 69

Author: T.Löw / TE

008 924 17 BOMAG 123

5.1 BEM, BOMAG Evib-meter

Service Training MESX

7 Adjustment/display possibilities on machines with BOP

7.1 Adjusting the machine type (BOP)

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 exit the screen page.

Check on the printout or in the diagnostics menu whether the travel direction has been correctly
detected.

Status: 21.12.2011 Functions of the ESX control Page 21 of 69

Author: T.Löw / TE

008 924 17 BOMAG 127

5.1 BEM, BOMAG Evib-meter

Service Training MESX

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:

Status: 21.12.2011 Functions of the ESX control Page 22 of 69

Author: T.Löw / TE

128 BOMAG 008 924 17

BEM, BOMAG Evib-meter 5.1

Service Training MESX

If an actual error is present the corresponding error code will be displayed in the field "Actual Errors".

Press "ESC" to exit the screen page.

By pressing key "A" you can change into a machine specific, more detailed diagnostics menu (see
below).

Status: 21.12.2011 Functions of the ESX control Page 23 of 69

Author: T.Löw / TE

008 924 17 BOMAG 129

5.1 BEM, BOMAG Evib-meter

Service Training MESX

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)

Ligths: 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.

Press "ESC" to exit the screen page.

By pressing key "B" you can display an operating hour meter (see below).

Status: 21.12.2011 Functions of the ESX control Page 24 of 69

Author: T.Löw / TE

130 BOMAG 008 924 17

BEM, BOMAG Evib-meter 5.1

Service Training MESX

7.3.2 Operating hours meter on machines with circular exciter (BTMplus,

BTMprof)

Engine: Operating hours of engine

Vib. manual: Operating hours with vibration driven in manual mode

Vib. auto: Operating hours with vibration driven in automatic mode

Vib. small ampl.: Operating hours with vibration driven with small amplitude mode

Status: 21.12.2011 Functions of the ESX control Page 25 of 69

Author: T.Löw / TE

008 924 17 BOMAG 131

5.1 BEM, BOMAG Evib-meter

Service Training MESX

7.3.3 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)

Ligths: 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 (10cm steps). The actually detected
travel direction can be recognized by the roller symbol above.

Press "ESC" to exit the screen page.

By pressing key "B" you can display an operating hour meter (see below).

Status: 21.12.2011 Functions of the ESX control Page 26 of 69

Author: T.Löw / TE

132 BOMAG 008 924 17

BEM, BOMAG Evib-meter 5.1

Service Training MESX

7.3.4 Operating hour meter BVC machines

Engine: Operating hours of engine

Vib. manual: Operating hours with vibration driven in manual mode

Vib. auto: Operating hours with vibration driven in automatic mode

Ampl. < 1.25 mm: Operating hours with vibration driven with small amplitude mode

Status: 21.12.2011 Functions of the ESX control Page 27 of 69

Author: T.Löw / TE

008 924 17 BOMAG 133

5.1 BEM, BOMAG Evib-meter

Service Training MESX

7.4 Simulation mode

From software version 3.00 it is possible to run the control in a so-called simulation mode. This mode
allows to swivel the Vario exciter at standstill and without vibration.

BEM, BOMAG Evib-meter 5.1

Service Training MESX

The control is in simulation mode.

The simulated travel direction can be selected with keys "F5", "F6", "F7". The detected travel
direction is displayed in the roller symbol underneath.

7.7 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:

Status: 21.12.2011 Functions of the ESX control Page 36 of 69

Author: T.Löw / TE

142 BOMAG 008 924 17

BEM, BOMAG Evib-meter 5.1

Service Training MESX

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 exit the screen page.

"0" OFF GPS Receiver always switched off

"1" ON GPS Receiver switched on as soon as the ignition is switched on.
"2" AUTO GPS Receiver switched on as soon as the BCM transmits data to MESX

Status: 21.12.2011 Functions of the ESX control Page 45 of 69

Author: T.Löw / TE

008 924 17 BOMAG 151

5.1 BEM, BOMAG Evib-meter

Service Training MESX

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
touchscreen "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 touchscreen now shows 4 switches near the right hand edge, choose
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.

Status: 21.12.2011 Functions of the ESX control Page 46 of 69

155
156
5.1

Service Training MESX Description of signals

12 Description of the signals on the ESX-control

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.

ESX terminal Signal description Nominal values (voltage / current)

X44:1 AGND = Analogue ground: Ground potential for sensors (steering approx. 0 V measured against ground (terminal 31)
joystick, speed range switch etc.)
X44:2

X44:3 Output Evib Display PWM signal (100 Hz): ) approx. 0..6 V
PWM (max. 2.5 A)
X44:4 Interface RS 232 RxD, used for printer control. Measurement not possible!

X44:5 Interface RS 232 TxD, used for printer control. Measurement not possible!

X44:6

BOMAG
X44:7 Input acceleration transducer VH20g/HR15g Acceleration signal (measured against AGND)

Open circuit voltage (vibration off): ) 4,2..4,3 V

Analog input / voltage input 0..8.5 V
X44:8

X44:9 Input exciter position front Position of front exciter (measured against AGND)
Analog input / voltage input 0..8.5 V Stop bottom ) approx. 2.2 V
Neutral position ) approx. 4.25 V
Stop top ) approx. 6.6 V

Status: 21.12.2011 Description of signals Page 50 of 69

Author: T. Löw / TE
BEM, BOMAG Evib-meter

008 924 17
Service Training MESX Description of signals

008 924 17
ESX terminal Signal description Nominal values (voltage / current)
X44:10

X44:11

X44:12

X44:13
BEM, BOMAG Evib-meter

X44:14

X44:15 Input vibration 1 On Vibration on: ) >6V

Digital input active high Vibration off: ) approx.0 V
X44:16 Input button "START" (option) Push button pressed ) 12 V
Digital input active high Button not pressed ) 2V
X44:17 Input button "STOP" (option) Push button pressed ) 12 V
Digital input active high Button not pressed ) 2V
X44:18 Input button "PRINT" (option) Push button pressed ) 12 V
Digital input active high Button not pressed ) 2V
X44:19 Input button "CLEAR" (option) Push button pressed 12 V

BOMAG
)
Digital input active high Button not pressed ) 2V
X44:20

X44:21

X44:22

X44:23 Output voltage supply for sensors Nominal voltage = 8.5 V

This output supplies steering joystick, travel speed range switch, etc. Permissible range: approx. 7.65 .. 9.35 V
Without this voltage the control cannot work correctly and will switch to This voltage must be measured against AGND.
override condition (limp home operation).
X44:24

Status: 21.12.2011 Description of signals Page 51 of 69

Author: T. Löw / TE
5.1

157
158
5.1

Service Training MESX Description of signals

ESX terminal Signal description Nominal values (voltage / current)

X44:25

X44:26 Interface CAN-Bus Wire -, is used to communicate with the BOP Measurement not possible!
operating unit.
X44:27 Interface CAN-Bus Wire +, is used to communicate with the BOP Measurement not possible!
operating unit.

X44:28 Input potential terminal 15 Control switched on ) 12 V

Digital input active high Control switched off ) approx. 2 V
This signal must be present, so that the control can work.
X44:29 Input acceleration transducer VV/VL15g Acceleration signal (measured against AGND)

Open circuit voltage (vibration off): ) 4,2..4,3 V

Analog input / voltage input 0..8.5 V
X44:30 Input acceleration transducer VH/VR15g Acceleration signal (measured against AGND)

Open circuit voltage (vibration off): ) 4,2..4,3 V

Analog input / voltage input 0..8.5 V

BOMAG
X44:31 Input acceleration transducer VV20g/HR15g Acceleration signal (measured against AGND)

Open circuit voltage (vibration off): ) 4,2..4,3 V

Analog input / voltage input 0..8.5 V
X44:32

X44:33 Interface CAN-Bus2 Wire -, is used to communicate with the BCM05. Measurement not possible!
X44:34

X44:35 Input distance transducer Transducer delivers square-wave pulses Frequency depends on machine
type.
Digital input active high

Status: 21.12.2011 Description of signals Page 52 of 69

Author: T. Löw / TE
BEM, BOMAG Evib-meter

008 924 17
Service Training MESX Description of signals

008 924 17
ESX terminal Signal description Nominal values (voltage / current)
X44:36

X44:37 Input D+ generator Engine running / engine being started ) 12 V

Digital input active high Engine stopped ) 0V
X44:38 Input vibration 2 On Vibration on: ) >6V
Digital input active high Vibration off: ) approx.0 V
X44:39
BEM, BOMAG Evib-meter

X44:40

X44:41

X44:42

X44:43

X44:44

X44:45

BOMAG
X44:46 Output valve 1 front valid current range: approx. 0..1.5 A
PWM digital output (max. 4 A)
X44:47 Output valve 2 front valid current range: approx. 0..1.5 A
PWM digital output (max. 4 A)
X44:48

X44:49

X44:50

X44:51

X44:52

Status: 21.12.2011 Description of signals Page 53 of 69

Author: T. Löw / TE
5.1

159
160
5.1

Service Training MESX Description of signals

ESX terminal Signal description Nominal values (voltage / current)

X44:53 Interface CAN-Bus2 Wire +, is used to communicate with the BCM05. Measurement not possible!
X44:54 Voltage supply for electronics Emergency stop not actuated ) 12 V
Emergency stop actuated ) 0V
X44:55 Ground connection electronics 0 V measured against ground

X44:56 Voltage supply for outputs approx. 12 V measured against ground

X44:57 Voltage supply for outputs approx. 12 V measured against ground

X44:58 Voltage supply for outputs approx. 12 V measured against ground

X44:59 Voltage supply for outputs approx. 12 V measured against ground

X44:60 Voltage supply for outputs approx. 12 V measured against ground

X44:61

BOMAG
X44:62

X44:63

X44:64

X44:65 Mouse port Baby Boards approx. 0 V

X44:66 Mouse port Baby Boards approx. 0 V

X44:67 Mouse port Baby Boards approx. 0 V

X44:68 Mouse port Baby Boards approx. 0 V

Status: 21.12.2011 Description of signals Page 54 of 69

Author: T. Löw / TE
BEM, BOMAG Evib-meter

008 924 17
BEM, BOMAG Evib-meter 5.1

Service Training Fault codes of the ESX Control

13 Fault codes of the ESX control

13.1 Overview

Fault code Description of fault

4501 - Position controller (exciter potentiometer, valves)
4540
4601 - Acceleration transducer
4620
8000 - Internal software errors
8250

Status: 21.12.2011 Fault codes of the ESX control Page 55 of 69

Author: T.Löw / TE

008 924 17 BOMAG 161

162
5.1

Service Training MESX Description of fault codes of the ESX control

13.2 Description of fault reactions

Fault reaction Description of fault reaction

1 Warning.
Fault code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
2 Impairment of function, the faulty function is overridden by an emergency function.
Fault code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
3 Fault of a partial function, 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.
4 Fault of a partial function, 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

BOMAG
) the diesel engine is shut down.
Fault code is displayed.
Signal light in BOP (option) lights in 1 second intervals.
5 Fatal fault. The function of the control is no longer assured.
The control will be switched off.
Error code is displayed.
Signal light in BOP (option) lights permanently.

Note: Errors with error reaction 1 are only warning messages and are NOT stored in the error log.

Status: 21.12.2011 Fault Code Description ESX control Page 56 of 69

Author: T. Löw / TE
BEM, BOMAG Evib-meter

008 924 17
Service Training MESX Description of fault codes of the ESX control

008 924 17
13.3 Detailed description of fault codes and their possible causes

Fault Description of fault Possible cause Terminal Input Fault

code on ESX code for reaction
diagnose
450 Input exciter potentiometer front ) Wire breakage in current path X44:09 5
1 The voltage applied to the input is below the ) Current path has short circuit to ground
BEM, BOMAG Evib-meter

specified range (see signal description). ) No voltage supply to potentiometer

) Fuse FM ? has tripped or wire breakage in voltage supply current
path
) Potentiometer defective
450 Input exciter potentiometer front ) Current path has connection to +12 V / +8,5 V X44:09 5
2 The voltage applied to the input is above the ) Potentiometer not connected to ground
specified range (see signal description). ) Potentiometer defective

BOMAG
Status: 21.12.2011 Fault Code Description ESX control Page 57 of 69
Author: T. Löw / TE
5.1

163
164
5.1

Service Training MESX Description of fault codes of the ESX control

Fault Description of fault Possible cause Terminal Input Fault

code on ESX code for reaction
diagnose
452 Output proportional solenoid front ) Current path has short circuit to voltage supply X44:46 2
1 Valve for exciter down ) Current path has non-permitted connection to another current
Output current too low. path
) Current path is interrupted
452 Output proportional solenoid front ) Current path has short circuit to ground X44:46 2
2 Valve for exciter down ) Current path has non-permitted connection to another current
Output current too high. path

452 Output proportional solenoid front ) Current path is interrupted X44:46 2

3 Valve for exciter down ) Current path has impermissible connection to another current
Fault when calibrating the valve path / ground

452 Output proportional solenoid front ) Current path has short circuit to voltage supply X44:47 2
6 Valve for exciter up ) Current path has non-permitted connection to another current
Output current too low. path

BOMAG
) Current path is interrupted
452 Output proportional solenoid front ) Current path has short circuit to ground X44:47 2
7 Valve for exciter up ) Current path has non-permitted connection to another current
Output current too high. path

452 Output proportional solenoid front ) Current path is interrupted X44:47 2

8 Valve for exciter up ) Current path has impermissible connection to another current
Fault when calibrating the valve path / ground

Status: 21.12.2011 Fault Code Description ESX control Page 58 of 69

Author: T. Löw / TE
BEM, BOMAG Evib-meter

008 924 17
Service Training MESX Description of fault codes of the ESX control

008 924 17
Fault Description of fault Possible cause Terminal Input Fault
code on ESX code for reaction
diagnose
453 Position controller positive limit reached ) Supply and ground terminal on exciter potentiometer mixed up X44:09 5000 2
1 The exciter does not move to the desired ) Valves for "Exciter up" and "Exciter down" mixed up X44:37
direction or does not move at all. ) MD+ input has 12 V potential, even though the engine is not
running
) Air in hydraulic system, hydraulic pressure too low
BEM, BOMAG Evib-meter

453 Position controller negative limit reached ) Supply and ground terminal on exciter potentiometer mixed up X44:09 5000 2
2 The exciter does not move to the desired ) Valves for "Exciter up" and "Exciter down" mixed up X44:37
direction or does not move at all. ) MD+ input has 12 V potential, even though the engine is not
running
) Air in hydraulic system, hydraulic pressure too low

460 Input acceleration transducer 1 ) Current path has no connection to +12 V / +8,5 V X44:29, 4601 2
1 The voltage applied to the input is below the ) Current path connected to ground or
specified range (see signal description). ) Transducer defective X44:31

460 Input acceleration transducer 1 ) Current path has connection to +12 V / +8,5 V X44:29, 4601 2

BOMAG
2 The voltage applied to the input is above the ) Current path not connected to ground or
specified range (see signal description). ) Transducer defective X44:31

460 Input acceleration transducer 2 ) Current path has no connection to +12 V / +8,5 V X44:30, 4606 2
6 The voltage applied to the input is below the ) Current path connected to ground or
specified range (see signal description). ) Transducer defective X44:07

460 Input acceleration transducer 2 ) Current path has connection to +12 V / +8,5 V X44:30, 4606 2
7 The voltage applied to the input is above the ) Current path not connected to ground or
specified range (see signal description). ) Transducer defective X44:07

Status: 21.12.2011 Fault Code Description ESX control Page 59 of 69

Author: T. Löw / TE
5.1

165
166
5.1

Service Training MESX Description of fault codes of the ESX control

Fault Description of fault Possible cause Terminal Input Fault

code on ESX code for reaction
diagnose
800 Error message "Incorrect BOP Software version" - - 2
0 The software version of the BOP is too old, i.e.
various functions cannot be displayed.
This fault cannot be rectified on the machine. The
BOP needs to be replaced.
800 Fault message "severe software fault in control" - - - 5
1 - This fault cannot be rectified on the machine. The
899 control must be immediately replaced.
9
900 Error message "Communication via CAN bus ) Wire breakage in CAN bus lines X44:26 - 2
0 - disturbed" ) Short circuit between CAN bus lines X44:27-
919 The modules controlled via the CAN bus cannot ) One or both CAN bus line(s) has (have) connection to +12 V or
9 be addressed by the main control (ESX). The ground
respective machine functions are not available

920 Fault message "Severe internal fault in control" - - - 5

BOMAG
0 - The control has automatically switched off. This
999 fault cannot be rectified on the machine. The
9 control must be immediately replaced.
Ct0 Display module has no connection to ESX- ) Wire breakage in CAN bus lines X44:26 - -
control. ) Short circuit between CAN bus lines X44:27
) One or both CAN bus line(s) has (have) connection to +12 V or
ground
) Incorrect bit rate in display module (nominal value: 125 kBit)

Status: 21.12.2011 Fault Code Description ESX control Page 60 of 69

Author: T. Löw / TE
BEM, BOMAG Evib-meter

008 924 17
Service Training MESX Description of control input codes

008 924 17
14 Input codes for ESX control (only via BEM display module)

14.1 Travel system

Input code Description of display function Display values

1000 Transducer for travel direction 0000 ) 0V
Show status of transducer. 0001 ) 12 V
BEM, BOMAG Evib-meter

1001 Travel direction 1000 ) Forward travel detected

Displays the travel direction derived by the control from the 0000 ) Neutral position
"transducer for travel direction". 000I ) Reverse travel detected

1002 Transducer for distance pulses Display value = travel distance in 10 cm

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.
1003 Travel speed Display value = max. speed in km/h

BOMAG
Shows the actual speed.
1010 Parameter "Show distance pulses per 10m" Depending on the selected machine type, e.g. 5896 for
Eeprom Parameter is displayed BW177 BVC
1011 Parameter "Invert travel direction" 0000 ) Direction signal is not inverted
Eeprom Parameter is displayed 000I ) Direction signal is inverted

Status: 21.12.2011 Description of Control Input Codes Page 61 of 69

Author: T. Löw / TE
5.1

167
168
5.1

Service Training MESX Description of control input codes

14.2 Vibration

Input code Description of display function Display values

3000 Vibration status general 0000 ) Vibration OFF
The status of vibration is displayed. 0001 ) Vibration ON
3001 Vibrations status low amplitude 0000 ) Vibration OFF
The vibration status for low amplitude is displayed. 0001 ) Vibration ON
3002 Vibrations status high amplitude 0000 ) Vibration OFF
The vibration status for high amplitude is displayed. 0001 ) Vibration ON

14.3 Light

Input code Description of display function Display values

3010 Input light switch 0000 ) Light OFF
The status of the lighting is displayed. 0001 ) Light ON

BOMAG
Status: 21.12.2011 Description of Control Input Codes Page 62 of 69
Author: T. Löw / TE
BEM, BOMAG Evib-meter

008 924 17
Service Training MESX Description of control input codes

008 924 17
14.4 Acceleration transducer

Input code Description of display function Display values

4601 Acceleration transducer 1 Display value = voltage in V
Shows the voltage of transducer 1.
4606 Acceleration transducer 2 Display value = voltage in V
Shows the voltage of transducer 2.
BEM, BOMAG Evib-meter

14.5 Diesel engine

Input code Description of display function Display values

5000 Input MD+ 0000 ) Engine OFF
Show status of diesel engine. 0001 ) Engine ON

BOMAG
Status: 21.12.2011 Description of Control Input Codes Page 63 of 69
Author: T. Löw / TE
5.1

169
170
5.1

Service Training MESX Description of control input codes

14.6 Setting the machine type

Input code Description of display function Display values

7000 Shows the adjusted machine type
7010 Switches on function "Set machine type"
7011 Confirms entered machine type
7500..76 Pre-select machine type
99

BOMAG
Status: 21.12.2011 Description of Control Input Codes Page 64 of 69
Author: T. Löw / TE
BEM, BOMAG Evib-meter

008 924 17
Service Training MESX Description of control input codes

008 924 17
14.7 Parameter change

Input code Description of display function Display values

7600 Switch on function "Invert travel direction" Display value 7 6 0 0
7601 Inverts the actually adjusted travel direction see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
BEM, BOMAG Evib-meter

BOMAG
Status: 21.12.2011 Description of Control Input Codes Page 65 of 69
Author: T. Löw / TE
5.1

Author: T.Löw / TE

174 BOMAG 008 924 17

BEM, BOMAG Evib-meter 5.1

Service Training MESX

Current and voltage measurement

Ohm’s law:
U R I
U = Voltage
R = Resistance U
I
I = Current 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 48)

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: 21.12.2011 Terminology Page 69 of 69

Author: T.Löw / TE

008 924 17 BOMAG 175

5.1 BEM, BOMAG Evib-meter

176 BOMAG 008 924 17

5.2 Electrics module A68

008 924 17 BOMAG 177

5.2 Electrics module A68

178 BOMAG 008 924 17

Electrics module A68 5.2

Seat contact switch

Only machines with cabin are equipped with the seat contact circuitry.
This circuit also contains the vibration relay. Machines with ROPS or sun canopy are not equipped with
the seat contact circuitry.

The following applies in general:

When the seat is not occupied it can be assumed that in the worst case the machine may perform
uncontrolled movements. In such an instance the machine must be shut down at the latest after 4
seconds. During these 4 seconds the driver must be warned about this condition by the warning buzzer
in the dashboard and the area around the machine by the backup alarm. To start travel movement of
the machine the driver's seat must be occupied, as otherwise the diesel engine will be shut down
immediately. This prevents the machine from being started from the outside (e.g. through the open
window).

1. Starting of the engine should only be possible with the travel lever in position "Brake".

2. Driver standing (seat contact control light does not light up): While the engine is running shift the travel
lever to travel operation --- then engine shut be shut down immediately, the seat contact light lights up,
warning buzzer and backup alarm sound. If the travel lever is returned to "Brake" position during the
shut-down process, the fuel solenoid is switched on again and the engine will automatically start.
Otherwise the engine must be restarted.

3. Driver seated: (seat contact control light does not light up): Normal operation, no warning active.
Driver gets up --- control light comes on and both warning buzzers sound. Driver sits down again within
4 seconds --- machine returns to normal operation. Driver does not sit down again within 4 s --- engine
is shut down. If the driver sits down again while the engine is being shut down, the fuel solenoid is
switched on again and the engine will automatically start. Otherwise the engine must be restarted.

In addition to the seat monitoring system all

monitoring functions are implemented by the

Module UPM2

008 924 17 BOMAG 179

5.2 Electrics module A68

The hardware us available under BOMAG part-number 057 664 81.

Stay-Alive LED

Programmierstecker

Spannungs- Status-
versorgung Leuc htdioden
1

4
3

5
2

7
8
9

14
15
6

13
12
11

Vibrationstaster
Versorgungsspannung (+UB)

Sitzkontaktschalter
Versorgungsspannung (+UB)

Vibration
Haltewicklung Abstellmagnet

Masseanschluß

Generator / D+ Signal
Anzugswicklung Abstellmagnet
Bremsventil
Warnsummer

Masseanschluß

Öldruck
Fahrhebel

Fig. 1: Module

The complete module (including the specific software) is available under

BOMAG part-number 582 701 68.
The following applies when measuring the signal levels:

PIN Potential with LED on Potential with LED off

Inputs Ground 0V Input open
Output PIN8 Ground 0V Output open
Outputs general ≈ operating voltage (UB- 0,7V) Ground 0V (<< 1V)

180 BOMAG 008 924 17

Electrics module A68 5.2

Emergency operation

If a bridge is inserted between PIN 2 and PIN 3 of the module, the bias coil is permanently
supplied with current (as long as the ignition is on) and the vibration is switched on (vibration
can be switched on/off with the vibration selector switch).
Inserting a bridge between PIN 10 and the connecting cable to PIN 8 opens the brake (the
brake can then be switched on/off e.g. via the parking position of the travel lever). The
module is then bridged (only with motors without pickup winding.

Description of function

In addition to m onitoring the seat occupation this m odule can also be used to control the
hydraulic brake and the function of the vibration relay.
The following sequences were used in the UPM2 software to realize the seat occupation
m onitoring system :

Sw itching on the ignition

- The Stay-Alive-LED on the m odule shows the software version (currently version 3) once
by m eans of a flashing code (changes to perm anent light).
- W hen the travel lever is in neutral position (PIN12 = Active-LO W ) the bias coil of the
shut-down solenoid (PIN4 = Active-HIG H) is switched on and the pickup winding (PIN7 =
Active-H IG H) is energized for 2 seconds. In this situation the seat contact switch has no
effect. T here will be no visual or audible warning if the driver's seat is not occupied.
- If the travel lever is returned to neutral position after the ignition has been switched on,
the bias coil is autom atically switched on and the pickup winding is autom atically
energized for 2 seconds (starting is now possible).
- As long as no D+ signal is detected (starting has not yet been perform ed and the engine
is therefore not yet running), the vibration can be switched on by the vibration control
switch.
- Vibration is switched off.

Starting the engine is only possible with the travel lever in neutral position. Since the starter
does still rotate despite this fact, external blockage of the starter is required when the travel
lever is operated.

Starting the engine

- If running of the engine is detected through D+, the hydraulic brake is autom atically
released (if it is no longer activated by the travel lever in parking position).
- If the travel lever is not in neutral position (irrespective of the seat contact), the bias coil
of the shut-down solenoid is switched off again.

008 924 17 BOMAG 181

5.2 Electrics module A68

Engine running
- Vibration can be switched on with the vibration push button when D+ or oil pressure is
applied (OR-linkage).
- The bias coil remains switched on.
- There will be no visual or audible warning when the driver's seat is unoccupied even
though the travel lever is out of neutral position.
- If the driver's seat is not occupied and the travel lever is actuated in this condition, the
bias coil of the shut-down solenoid is immediately switched off and the engine will stop.
The signalling device (horn) is activated.
W hen D+ is no longer applied (engine not running) the signalling device is switched off
and the hydraulic brake closes after 1.5 seconds.
- W hen leaving the driver's seat after shifting the travel lever out of neutral, the signalling
device will be activated. 4 seconds later the bias coil of the shut-down solenoid will be
switched off and the engine will stop.

Engine stops
- If the engine stops, but D+ is still applied, the bias coil is switched on again and the
pickup winding is energized for 2 seconds, as soon as the driver takes his seat or the
travel lever is returned to neutral position.
- The signalling device is switched off. The module is then in Engine Running mode and
responds as described above.

Engine has stopped

The following applies in all cases (irrespective of travel lever and seat contact) if the D+
signal is missing:
- If the D+ signal is no longer applied the module will decide that the engine has stopped.
- The bias coil of the shut down solenoid is immediately switched off and the brake closes
1.5 seconds later.
- The machine can be restarted by switching the ignition off and on again (new start).
- However, if the D+ signal (for what ever reason) returns by itself, the bias coil of the shut
down solenoid is automatically switched on and the pickup winding is energized for 2
seconds, if the driver has sat down.
- If the driver is not sitting while D+ returns, the reaction will be as described above in
Engine Running mode, depending on the history (was the driver's seat left or the travel
lever actuated first?).
- If, in addition to the missing D+, there is no oil pressure, the vibration will be shut down.
The vibration is not automatically switched on if one of the signals returns!

182 BOMAG 008 924 17

Electrics module A68 5.2

New start
A new start (after the engine has been shut down) is only possible after switching the ignition
on again (see Switching on ignition) or after D+ has returned (see Engine has stopped).

Miscellaneous
Due to the design of the Perkins engines restarting of a still turning engine by returning the
travel lever to neutral or sitting down on the driver's seat is not possible.
On machines with Perkins engine restarting always requires the ignition, if the bias coil of
the shut down solenoid hd been switched off (picking up of the winding only possible after
the engine has stopped).

The pickup winding must be triggered by an additional relay, because the module is only
able to supply a current of 4 ampere.
The module works from a supply voltage of 7 Volt.

008 924 17 BOMAG 183

5.2 Electrics module A68

0 Hardware description

The seat occupation monitoring module consists of the modified UPM2 module.
The inputs are configured to match the following table:

Input Behaviour Comment

Input PIN11 LOW-active LED lights when applying ground potential (0V)!
Input PIN12 LOW- active LED lights when applying ground potential (0V)!
Input PIN13 LOW- active LED lights when applying ground potential (0V)!
Input PIN14 LOW- active LED lights when applying ground potential (0V)!
Input PIN15 LOW- active LED lights when applying ground potential (0V)!

0.1 Pin assignment of inputs

Signal name Module Signal at input

pin
Seat contact switch 11 0V = driver sits, LED on
+U B = driver stands up, LED off
Travel lever 12 0V = travel lever neutral position LED on
+U B = travel lever actuated LED off
Oil pressure 13 0V = oil pressure fault LED on
+U B = no oil pressure fault LED off
Generator / D+ signal 14 0V = engine stopped LED on
+U B = engine running LED off
Vibration button 15 0V = Vib. on/off LED on
+U B = Vib. off/on LED off

0.2 Pin assignment of outputs

Manual testing of the speedometer

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

194 BOMAG 008 924 17

Speedometer module 6.1

Pin-no. module Pin name Description

Test E_ANZEIGENTEST Input HIGH active: Activate manual display test

IN E_WEGIMPULSE Input: Path pulses
Learn E_LERNMODUS Input: HIGH active: Activate teach mode

OUT - Display - Output: Ground connection for speedometer

OUT + Display + Output: Output voltage for speedometer

GND (2X) Ground Input: Module ground connection

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

Teaching the module

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

! Caution
BW24RH, BW27RH, C550H and C560H = travel 18
meters.
All other machines = travel 10 meters.

i Note
If the module is in teach mode the LED on output
"OUT +" will flash with the frequency of the path puls-
es arriving at input (IN).
Disconnect the cable bridge from "Teach" to "15/
54“.
Switch the ignition off and on again (Reset).

The module has now learned the pulses of the

speed sensor.
Connect the speedometer (0 to 6 Volt) to "OUT +"
and "OUT –“.

008 924 17 BOMAG 195

6.1 Speedometer module

196 BOMAG 008 924 17

7 Hydraulics

008 924 17 BOMAG 197

7.1 Hydraulic circuit

Open circuit

Fig. 1 Open circuit

Open in this case means that the suction line of a pump) (Fig. 1) normally is situated below the fluid level, the
surface of which is in open contact with atmospheric pressure. Reliable equalization of pressure between the air
in the hydraulic oil tank and the ambient air ensures problem free suction of the pump.
In an open circuit the hydraulic fluid is fed to the consumer (2 or 3) and also returned to the tank through way
valves.

198 BOMAG 008 924 17

Hydraulic circuit 7.1
Closed circuit

Filter

Cooler (option)

Fig. 2 Closed circuit

One talks about a closed hydraulic system, when the hydraulic oil flows from the consumer (3) (Fig. 2) directly
back to the pump (2).
The closed circuit consists of a high and a low pressure side, depending on the load direction (take-off moment
on the consumer).
The high pressure side is protected by pressure relief valves (4), which release oil into the low pressure side.
The medium remains in the circuit.
Only the permanent leakage on pump and motor needs to be replenished. This is accomplished by a charge
pump (1), which permanently delivers a sufficient amount of fluid (charge capacity) through a check valve (5)
into the low pressure side of the closed circuit. Any excess oil delivered by the charge pump, which works in an
open circuit, runs through a charge pressure relief valve (6) back into the tank. Charging the low pressure side
enables the pump (2) to work with higher operating data.

008 924 17 BOMAG 199

7.2 Connection overview

Fig. 1 Travel pump

200 BOMAG 008 924 17

Connection overview 7.2
1 Control solenoid, high frequency 21 Connection D, charge pressure to filter
2 Control solenoid, low frequency 22 Muliti function valve 345 bar (boost check and
3 Multi-function valve 400 bar (boost check and pressure relief valve), vibration drive high frequen-
pressure relief valve), travel system cy
4 Connection, charge pressure to brake solenoid 23 Connection S, suction line charge pump from hy-
valve, travel speed range selection and charge oil draulic oil tank
supply for vibration pump 24 Muliti function valve 345 bar (boost check and
5 Multi-function valve 400 bar (boost check and pressure relief valve), vibration drive low frequen-
pressure relief valve), travel system cy
6 Setscrew, mechanical neutral position 25 Charge pressure relief valve, vibration pump
(blocked)
7 Connection L, leak oil connection to vibration
pump 26 Connection E, charge oil from travel pump
8 Lever, travel control 27 Connection L1, leak oil connection to travel pump
9 Charge pressure test port 28 Pressure test port MB, high pressure reverse
10 High pressure port B, high pressure reverse 29 Charge oil from filter
11 Charge pressure relief valve, 26 bar 30 Pressure test port MA, high pressure forward
12 Adjustment screw, low frequency 31 High pressure port A, high pressure forward
13 Connection L2, leak oil to tank 32 Setscrew, mechanical neutral position, vibration
14 Pressure test port MB, high frequency 33 Leak oil connection D, leak oil from axle drive mo-
tor
15 High pressure test port MA, low frequency
34 Leak oil connection A, leak oil from travel pump
16 High pressure port A, low frequency
35 Leak oil connection G, leak oil from drum drive
17 High pressure port B, high frequency
motor
18 Charge pump, internal
36 Leak oil connection F, leak oil from vibration motor
19 Connection L2, to drum drive motor (flushing)
37 Radiator inlet
20 Adjustment screw, high frequency

008 924 17 BOMAG 201

7.3 Travel pump 075

Variable displacement pumps, 90R055 and 90R075

7.3 Travel pump 075

Caution
!

The variable displacement axial piston pump must be filled with pressure fluid and purged during start-
up and operation. This must also be considered for longer periods of rest, because the system may run
empty through the hydraulic lines.
The variable displacement axial piston pump generates, controls and regulates a volumetric pressure fluid flow.
It has been designed for mobile applications, e.g. in construction equipment.
The pump is a variable displacement axial piston pump in swash plate design for hydrostatic drives in closed
circuits. The volumetric flow is proportional to the drive speed and the displacement.

Mechanical displacement control (MDC)

The mechanical displacement control converts a mechanical input signal (control lever position 1 (Fig. 2)) into a
position controlling output signal by means of a spring centred 4-way servo valve. This valve opens the hydraulic
pressure to one side of the control cylinder. The control piston inside the control cylinders moves the swash plate
within a swashing angle range of ±17° and thereby changes the displacement of the pump from maximuim dis-
placement to the one direction to the maximum displacement to the opposite direction.
The mechanical displacement control has no adjustment elements. The control is held in neutral position by re-
setting springs and washers at both ends of the control piston. Since there are no further resetting springs on
the input shaft of the control, the shaft will automatically be correctly positioned when it is mounted to the pump.

Fig. 2

1 Actuating lever 5 Cylinder block

2 Drive shaft 6 Valve plate
3 Bearing for swashing cradle 7 Control piston
4 Pistons with slipper pads

202 BOMAG 008 924 17

Travel pump 075 7.3

Fig. 3

1 Drive shaft 5 Cylinder block

2 Drive shaft bearing 6 Multi-function valves
3 Swash plate 7 Charge pump ( optional)
4 Pistons with slipper pads 8 Valve plate

008 924 17 BOMAG 203

7.3 Travel pump 075

Hydraulic diagram

Servo control

Multi-function valve

Charge pressure relief valve

Fig. 4
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.
Since the control is spring centred, the swash plate will automatically return to neutral position under the follow-
ing conditions, thereby interrupting the oil flow and braking the machine:
when shutting the engine down
if the external control cable comes loose
if the pressure in the charge circuit drops below a certain value.

1 to the control 6 Drive shaft

2 Multi-function valves 7 to the control piston
3 Charge pump 8 to the control piston
4 Charge pressure relief valve A Connection A
5 Charge pressure relief valve B Connection B

Multi-function valve
The multi-function valve consists of:
the no-stroke pressure controller
the high pressure relief valve

204 BOMAG 008 924 17

Travel pump 075 7.3
the boost check valve
and the bypass function

Fig. 5 Multi-function valves

Pumps of series 90 are equipped with so-called multi-function valves, which activate a pressure override and a
pressure relief valve, one after the other.
The multi-function valve contains a no-stroke pressure controller and a high pressure relief valve. When the pr-
adjusted pressure value is reached, the no-stroke pressure controller will return the pump very quickly back to-
wards neutral, thereby limiting the system pressure. In case of a unusually sudden pressure increase the high
pressure relief valve will immediately limit the system pressure by opening the system flow to the low pressure
side of the hydraulic circuit. The no-stroke pressure controller serves as pre-control unit for the piston of the high
pressure relief valve. The high pressure relief valve is designed for responding to pressures approx. 35 bar
above the nominal value of the no-stroke pressure.
Boost check valves The boost check valves are cone valves inside the multi-function valve. It enables flow
from the charge pump into the low pressure side of the working circuit, if the system pressure drops below a
certain value. With this feature pressure losses caused leakages or other factors can be compensated. Since
the variable displacement pump is able to work to either direction, two boost check valves are needed.
Bypass function The bypass function is also integrated in the multi-function valves and can be manually oper-
ated.when the vehicle (or the mechanical function) is to be moved, without the pump running.
Adjusting (opening) the bypass function

! Caution
When working on the bypass valves switch off the drive and keep the high pressure circuit pressureless.
The bypass valves must be open on both multi-function valves to be able to achieve the bypass function.

Fig. 6

Attach an open end spanner to the medium size hexagon of the multi-function valve and attach an open end
spanner to the large hexagon to prevent the valve body from turning. Turn the medium size hexagon for three

008 924 17 BOMAG 205

7.3 Travel pump 075

turns in anti-clockwise direction to open the bypass valve. Do not turn more than 3-1/2 turns, because oth-
erwise pressure fluid will run out.
Before moving the vehicle set the control lever for the mechanical displacement control on the pump to full
forward. Hold the control lever in this position throughout the bypass function.

! Caution
"Towing" only at very low speed and only over short distances.

Charge pressure relief valve

Pumps of series 90 are equipped with a charge pressure relief valve that can be adjusted from outside. Charge
pressure is adjusted by loosening the counter nut and turning the setscrew accordingly with a large screwdriver
or a 1/2" open end spanner.
Turning the setscrew clockwise increases the value, turning anti-clockwise reduces the value (by approx. 3.9
bar per revolution). The counter nut needs to be tightened with 52 Nm.

Fig. 7
The charge pressure relief valve has the function of maintaining the charge pressure at a specified value. A cone
valve reduces the charge pressure if this value is exceeded. This nominal value is measured against case pres-
sure and adjusted at 1500 rpm. This nominal setting assumes that the pump is running in idle position (zero
flow); the charge pressureb is slightly lower in forward or reverse.

206 BOMAG 008 924 17

Travel pump 075 7.3
Connections

Fig. 8

1 Pressure test port M2 system pressure, B 8 Suction port S

2 Leak oil connection L1 9 System pressure, port B
3 Pressure test port M4 control pressure 10 Speed transducer (option)
4 Pressure test port M5 control pressure 11 Charge pressure port
5 Leak oil connection L2 12 Charge pressure test port, M3
6 Pressure test port M1 system pressure, A 13 Control pressure port, X3
7 System pressure, port A

008 924 17 BOMAG 207

7.4 Vibration pump 42R 041

Variable displacement pumps, 42R041 / 42R055

7.4 Vibration pump 42R 041

Caution
!

The variable displacement axial piston pump must be filled with pressure fluid and purged during start-
up and operation. This must also be considered for longer periods of rest, because the system may run
empty through the hydraulic lines.
The variable displacement axial piston pump generates, controls and regulates a volumetric pressure fluid flow.
It has been designed for mobile applications, e.g. in construction equipment.
The 42R041/055 is a variable displacement axial piston pump in swash plate design for hydrostatic drives in
closed circuits. The volumetric flow is proportional to the drive speed and the displacement.

EDC, electric two-point control, with control solenoid

Fig. 9

Pos Designation Pos Designation

1 Control unit 6 Charge pump, optional
2 Servo piston 7 Drive shaft
3 Bearing for swashing cradle 8 Pistons with slipper pads
4 Attachment plate 9 Swash plate
5 Spool valve 10 Valve plate
11 Control lever, not used with EDC-control

208 BOMAG 008 924 17

Vibration pump 42R 041 7.4
Hydraulic diagram

Charge pump

Pump drive
High pressure limitation

4/3 way valve

Fig. 10
When operating a 4/3-way solenoid valve on the pump control pilot oil from the charge circuit is guided to one
of the two control piston sides. The swash plate inside the pump will swash to the corresponding side and the
pump will deliver oil to the vibration motor. The vibration motor starts and rotates the vibrator shaft inside the
drum.
When altering the position of the swash plate through the neutral position to the opposite side, the oil flow will
change its direction and the vibration motor will change its sense of rotation.
Since the end stops for the swash plate are set to different swashing angles to both directions, the angle for the
piston stroke is also different to both sides. This angle influences the length of the piston stroke and thereby the
actual displacement of the pump.
Large angle = high displacement = high vibrator shaft speed (frequency)
Small angle = low displacement = slow vibrator shaft speed (frequency)

High pressure relief valves (Fig. 10)

1 From the charge pump 3 High pressure relief valve with integrated
boost check valve
2 Closed circuit

Pressure peaks occurring during very fast swashing processes, as well as the maximum pressures are safe-
guarded by superordinate high pressure relief valves, which open when the adjusted value is exceeded and re-

008 924 17 BOMAG 209

7.4 Vibration pump 42R 041

lieve oil into the low pressure side. The fluid quantity always remains constant in the closed hydraulic circuit.
Leakages in pump and motor are compensated by the charge pump.
The boost check valves are integrated in the high pressure relief valves. These valves open to the low pressure
side and allow cool and filtered oil flow from the charge oil circuit to flow into the closed hydraulic circuit, in order
to compensate leaks and flushing quantities.

Charge pump
The charge pump is needed to supply the system with cool hydraulic fluid, to maintain a positive pressure in the
working circuit, to ensure a certain pressure level, to operate the control system and to compensate internal leak-
ages.
The charge pump is a fixed displacement Gerotor-type pump, integrated in the variable displacement pump and
driven by the pump shaft.

210 BOMAG 008 924 17

Axial piston swash plate principle / pump 7.5
Swash plate principle, pump
7.5 Axial piston swash plate principle / pump

Fig. 11
The swash plate pump is a positive displacement machine with oil displacing pistons arranged axially to the drive
shaft. The pistons are thereby supported by the swash plate.
Axial piston units based on the swash plate principle with fixed or variable displacement can be used as hydraulic
pumps or hydraulic motors. In pump mode the mechanical energy is converted to hydrostatic energy, when used
in motor mode the hydrostatic energy is converted to mechanical energy. When used as a pump, the flow volume
is proportional to the drive speed and the swashing angle. The available (pump) torque increases with the pres-
sure drop between high and low pressure side.
Variable displacement pumps and motors can be change their displacement, i.e. the pump delivery rate or motor
throughput, by simply changing the angle of the swash plate.

Description of function

Fig. 12

008 924 17 BOMAG 211

7.5 Axial piston swash plate principle / pump

Pos. Designation Pos. Designation

1 Drive shaft 8 Through drive
2 Piston 9 Valve plate
3 Piston area 10 Top dead centre TDC
4 Piston stroke 11 Bottom dead centre BTC
5 Slipping disc 12 Control slots in suction side of swash plate (for
sense of rotation shown)
6 Adjusting angle 13 Control slot on pressure side
7 Cylinder

Driven by the engine, the drive shaft rotates and drives the cylinder via a splined connection. The cylinder rotates
with the drive shaft and drives the 9 pistons. The pistons rest with their slipper pads on the sliding face of the
swashing cradle and perform an axial movement. The slipper pads are held on the sliding face and are positively
guided by a retaining device. During a complete rotation of the cylinder block each piston moves through the
bottom and top dead centre back to its initial position. From dead centre to dead centre is performs a full piston
stroke. During this process the flow volume determined by the stroke is drawn in through the control slots in the
valve plate or pumped out. During the suction stroke the hydraulic fluid is drawn into the increasing piston cham-
ber, i.e. it is actually pressed in. On the opposite side the oil is pressed out of the piston bores into the hydraulic
system during the compression stroke.

212 BOMAG 008 924 17

Troubleshooting axial piston pumps 7.6
7.6 Troubleshooting axial piston pumps
The following table should be of help when performing troubleshooting This table is by no means complete.
In practice you may encounter problems that have not been listed here.

Procedure
Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and
changing of settings can lead to a situation in which the original cause of a fault can no longer be detected.
Get an overview over the function of the product in connection with the overall system.
Try to clarify whether the product was able to deliver the required function within the overall system before the
fault occurred.
Develop a clear understanding of the troubleshooting process. If necessary ask the direct operator or machine
driver.
Try to detect changes to the overall system, the product is installed in:
Have conditions or area of application of the product been changed?
Were changes (e.g. changeovers) or repairs made to the overall system (machine/plant, electrics, control) or
to the product? If yes: What kind?
Has the product or the machine been operated as intended?
How does the fault occur?

Fault Possible cause Remedy

Unusual noises Insufficient suction conditions, e.g.Machine or system manufacturer
air in the suction line, inadequate di-
(e.g. optimize feed conditions, use
ameter of the suction line, excessivesuitable pressure fluid).
viscosity of the pressure fluid, ex- Completely purge the axial piston
treme suction height, too low suctionunit, fill the suction line with pres-
pressure, foreign bodies in the suc- sure fluid.
tion line. Remove foreign bodies from inside
the suction line.
Inappropriate fastening of the axial Check the fastening of the axial pis-
piston unit. ton unit as specified by the machine
or plant manufacturer. Observe the
tightening torques.
Inappropriate fastening of attach- Fasten attachment parts as speci-
ment parts, e.g. coupling and hy- fied by the coupling or fittings manu-
draulic lines. facturer.
Pressure relief valves of the axial Purge the axial piston unit, check
piston unit (charge pressure, high the viscosity of the pressure fluid,
pressure, pressure override). consult the service department.
Mechanical damage to the axial pis- Replace the axial piston unit, con-
ton unit. sult the service department.

008 924 17 BOMAG 213

7.6 Troubleshooting axial piston pumps

Fault Possible cause Remedy

No or insufficient volumetric flow Faulty mechanical drive (e.g. defec- Check and repair the drive.
tive coupling).
Drive speed too low. Consult the service department.
Insufficient suction conditions, e.g. Completely purge the axial piston
air in the suction line, inadequate di- unit, fill the suction line with pres-
ameter of the suction line, excessive sure fluid.
viscosity of the pressure fluid, ex- Remove foreign bodies from inside
treme suction height, too low suction the suction line.
pressure, foreign bodies in the suc-
tion line.
Pressure fluid not within the optimal Use appropriate pressure fluid.
viscosity range.
External control and setting facilities Check the external control.
defective.
Pilot or control pressure too low. Check pilot and control pressure,
consult the service department.
Functional disturbance in the control Consult the service department.
facility or the regulator on the axial
piston unit.
Wear of the axial piston unit. Replace the axial piston unit.
Mechanical damage to the axial pis- Replace the axial piston unit.
ton unit.

214 BOMAG 008 924 17

Troubleshooting axial piston pumps 7.6
Fault Possible cause Remedy
No or insufficient pressure Faulty mechanical drive (e.g. defec- Check and repair the drive.
tive coupling).
Poor drive power. Consult the service department.
Insufficient suction conditions, e.g. Completely purge the axial piston
air in the suction line, inadequate di- unit, fill the suction line with pres-
ameter of the suction line, excessive sure fluid.
viscosity of the pressure fluid, ex- Remove foreign bodies from inside
treme suction height, too low suction the suction line.
pressure, foreign bodies in the suc-
tion line.
Pressure fluid not within the optimal Use appropriate pressure fluid.
viscosity range.
External control and setting facilities Check the external control.
defective.
Pilot or control pressure too low. Check pilot and control pressure.
Functional disturbance in the control Consult the service department.
facility or the regulator on the axial
piston unit.
Wear of the axial piston unit. Replace the axial piston unit.
Mechanical damage to the axial pis- Replace the axial piston unit.
ton unit.
Drive unit defective (e.g. hydraulic Check the drive unit, replace if nec-
motor or cylinder). essary.
Fluctuations in pressure/volumetric Axial piston unit not or insufficiently Completely purge the axial piston
flow purged. unit.
Insufficient suction conditions, e.g. Completely purge the axial piston
air in the suction line, inadequate di- unit, fill the suction line with pres-
ameter of the suction line, excessive sure fluid.
viscosity of the pressure fluid, ex- Remove foreign bodies from inside
treme suction height, too low suction the suction line.
pressure, foreign bodies in the suc-
tion line.
Pressure fluid too hot. Excessive input temperature on axi- Check the system, e.g. malfunction
al piston unit. of the cooler, pressure fluid level in
tank too low.
Malfunction of the pressure control Consult the service department.
valves (e.g. high pressure relief
valve, pressure override, pressure
controller).
Malfunction of the flushing valve Consult the service department.
(not for nominal size 18).
Wear of the axial piston unit. Replace the axial piston unit.

008 924 17 BOMAG 215

7.7 Travel motor 51 C/D 110

Swash plate motor with variable displacement, series 51

7.7 Travel motor 51 C/D 110

Designs: C and D

Fig. 13

Product description
A plug-in fixed displacement motor converts the hydrostatic volumetric flow into mechanical rotary motion. It has
mainly been designed for installation into mechanical gear drives.

Function
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
an axial stroke, thereby causing a rotary motion of the output shaft.
Once the respective piston has passed its dead centre (max. extended position), it will change to the low pres-
sure 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.

Flushing valve
In a closed circuit the same pressure fluid keeps permanently circulating between pump and motor. This can
cause overheating of the pressure fluid.
The flushing valve has the function to support cooling of the oil circuit by flushing the motor and thus to prolong
the service life of the motor. If the hydraulic motor is operated under load, the flushing valve opens during clock-
wise and anti-clockwise rotation, whereby a defined flushing quantity is discharged through an orifice from the
low pressure side of the circuit. This flushed out amount of oil then flows through the case drain back to the tank,
normally through a cooler. Any pressure fluid removed from the closed circuit must be replaced by cool oil from
the charge pump. The flushing valve thereby ensures permanent renewal and cooling of the pressure fluid. The
flushing pressure relief valve has a fixed setting of 16 bar and has the function of securing the minimum charge
pressure.

Control
The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle between
cylinder block and output shaft.

216 BOMAG 008 924 17

Travel motor 51 C/D 110 7.7
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 piston
rod side (test port M4) is thereby permanently pressurized with the actual travel pressure. In 1st speed range
(solenoid de-energized) the piston side (pressure test port, M3) is connected with the tank. In the 2nd speed
range the solenoids are energized, the valve switches and the piston side is also pressurized with the actual
travel pressure. Due to the area differential between piston rod side and piston side and the force resulting from
this, the pilot control moves to Qmin position.

Fig. 14

1 Control piston 7 Taper roller bearing

2 4-way valve 8 SAE-flange
3 Proportional valve 9 Synchronizing joint
4 Minimum swashing angle setting 10 Speed sensor
5 Valve segment 11 Piston
6 Bearing plate 12 Flushing pressure relief valve

008 924 17 BOMAG 217

7.8 Trouble shooting, variable displacement axial piston motor

The following table should be of help when performing troubleshooting This table is by no means complete.
In practice you may encounter problems that have not been listed here.

Fault Possible cause Remedy

Unusual noises
Inappropriate fastening of the axial Check the fastening of the axial pis-
piston unit ton unit as specified by the machine
or plant manufacturer. Observe the
tightening torques!
Inappropriate fastening of attach- Fasten attachment parts as speci-
ment parts, e.g. coupling and hy- fied by the coupling or fittings manu-
draulic lines. facturer.
Mechanical damage to the axial pis- Replace the axial piston unit
ton unit.
Fluctuations in pressure/volumetric Axial piston unit not or insufficiently Completely purge the axial piston
flow purged. unit.

218 BOMAG 008 924 17

Trouble shooting, variable displacement axial piston motor 7.8
Fault Possible cause Remedy
Operation data are not reached. Insufficient flow from hydraulic Check the function of the hydraulic
pump pump
Minimum displacement incorrectly Consult the service department.
set
External control and setting facilities Check the external control.
defective.
Control pressure too low Check control pressure, consult the
service department.
Functional disturbance in the control Consult the service department.
facility or the regulator on the axial
piston unit.
Pressure fluid not within the optimal Use appropriate pressure fluid.
viscosity range.
Wear of the axial piston unit Replace the axial piston unit
Mechanical damage to the axial pis- Replace the axial piston unit
ton unit.
Pressure fluid too hot. Excessive input temperature on axi- Check the system, e.g. malfunction
al piston unit. of the cooler, pressure fluid level in
tank too low.
Malfunction of the pressure control Consult the service department.
valves (e.g. high pressure relief
valve, pressure override, pressure
controller).
Failure of the flushing valve Consult the service department.
Wear of the axial piston unit Replace the axial piston unit

008 924 17 BOMAG 219

7.9 Vibration motor A10FM 45

Vibration motor
7.9 Vibration motor A10FM 45

The vibration motor is an axial piston motor with fixed displacement in swash plate design. Since the motor can
be subjected to pressure from both sides, it is most suitable for the use in closed hydraulic circuits.
The output speed of the motor depends on the oil quantity supplied by the vibration pump.
The output torque raises with increasing pressure difference between low and high pressure side in the closed
circuit.
Changing the flow direction of the oil will also change the sense of rotation of the vibration motor.
When switching the vibration on the motor must first start to move the resting exciter shaft. This resistance caus-
es a hydraulic starting pressure, which is limited by the pressure override. Once the exciter shaft has reached
its final speed, the pressure will drop to 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
Soft ground = Low operating pressure

Fig. 15 Cross-sectional drawing

1 Flushing valve block 6 Drive shaft

2 Flushing valve 7 Swash plate
3 Working pistons with slipper pads 8 Retaining plate
4 Roller bearing for output shaft 9 Pre-tensioning spring
5 Radial seal 10 Flushing pressure relief valve

The vibration motor is equipped with an integrated flushing valve.

In the closed hydraulic circuit the flushing and charge pressure relief valve is used to avoid excessive tempera-
tures and to secure the minimum charge pressure (16 bar, other pressures optionally also possible). The valve
is integrated in the connecting plate.
A certain amount of pressure fluid, which is determined by the size of an orifice, is taken out of the corresponding
low pressure side and discharged into the motor housing. This fluid is returned to the tank, together with the leak
oil. The pressure fluid taken out of the circuit is then replaced by cooled oil from the charge pump.

Caution
!

For start-up and operation the axial piston pump must be filled with pressure fluid and purged. This must
also be considered for longer periods of rest, because the system may run empty through the hydraulic
lines.

220 BOMAG 008 924 17

Axial piston swash plate principle / motor 7.10
Swash plate principle, motor
7.10 Axial piston swash plate principle / motor

Fig. 16
The swash plate pump is a positive displacement machine with oil displacing pistons arranged axially to the drive
shaft. The pistons are thereby supported by the swash plate.
Axial piston units based on the swash plate principle with fixed or variable displacement can be used as hydraulic
pumps or hydraulic motors. In pump mode the mechanical energy is converted to hydrostatic energy, when used
in motor mode the hydrostatic energy is converted to mechanical energy. Variable displacement motors can
change their displacement, i.e. the pump delivery rate or motor throughput, by simply changing the angle of the
swash plate.
If the unit is used as motor, the output speed is proportional to the supplied volume of fluid. The available (motor)
torque increases with the pressure drop between high and low pressure side.

Description of function

Fig. 17

008 924 17 BOMAG 221

7.10 Axial piston swash plate principle / motor

1 Drive shaft 8 Through drive

2 Piston 9 Valve plate
3 Piston area 10 Top dead centre TDC
4 Piston stroke 11 Bottom dead centre BTC
5 Slipping disc 12 Control slots in suction side of swash plate (for
sense of rotation shown)
6 Adjusting angle 13 Control slot on pressure side
7 Cylinder

The motor function is a reversal of the pump function. In this case the hydraulic fluid the hydraulic system directs
the oil flow to the hydraulic motor. The medium flows through control slots in the valve plate to the cylinder bores.
4 or 5 cylinder bores are opposed to the kidney shaped control slots in the pressure side. The other control slot
is in this case connected with the rest of the cylinder bores, which in turn are connected with the return flow side
or are partly covered by the connecting web between the kidney shaped control slots. By loading the piston it
slides down the slanted swash plate and drives the cylinder that guides it. The cylinder with the 9 pistons rotates
with the drive shaft, whereby the piston perform a stroke-like movement. The hydraulic pressure generates the
torque on the cylinder and thus the rotation of the drive shaft. The supplied fluid quantity determines the output
speed.

222 BOMAG 008 924 17

External gear pumps 7.11
External gear pumps
7.11 External gear pumps

External gear pumps mainly consist of the friction bearing mounted gear pair and the housing with front and rear
covers. The drive shaft, which is sealed with a radial seal, protrudes from the front cover. The bearing forces are
absorbed by friction bearings. These have been designed for high pressures and have excellent antifriction prop-
erties - particularly at low speeds. The gears have 12 teeth each. This keeps flow pulses and noise emissions
at a low level.

Axial seal Outer pressure field Inner pressure field Radial seal

Sealing zone
Cover Flange Compensation forces
Fig. 18 Axial compensation of gear pump
Internal sealing of the pressure chambers is achieved by flow volume dependent forces. This results in an ex-
cellent rate of efficiency. On the rear side the moveable bearing bushings are pressurized and thus tightly
pressed against the gears. The pressurized pressure fields are thereby limited by special seals. Sealing around
the circumference of the gears to the housing is assured by small gaps, which appears between gears and hous-
ing in dependence on the pressure.

Function

Fig. 19
The increasing volume caused by a tooth exiting a tooth gap results in a vacuum in the suction chamber. The
pressure fluid is transported into the pressure chamber. There the meshing of teeth and tooth gaps displaces
the pressure fluid into the upper supply line.

008 924 17 BOMAG 223

7.11 External gear pumps

Fig. 20

Pos. Designation Pos. Designation

1 Cover 6 Gear (driven)
2 Seals and gaskets 7 Shaft
3 Housing 8 Flange
4 Gear (driving) 9 Bearing plate
5 Displacement chamber 10 Bearing plate

224 BOMAG 008 924 17

Travel circuit 7.12
Travel system
7.12 Travel circuit

The travel circuit is a closed hydraulic circuit.

Fig. 1

1 Cooler 8 Drive axle with brake

2 Steering valve 9 Rear travel motor, with speed range selector
Y31
3 Steering/charge pump 10 Travel gear with brake discs
4 Travel pump 11 Front travel motor, with speed range selector
Y30
5 Vibration pump 12 Return flow manifold with thermal element
6 Charge oil filter with differential pressure switch, 13 Hydraulic oil tank
B21
7 Brake valve, Y04

008 924 17 BOMAG 225

7.12 Travel circuit

Travel pump and vibration pump are mounted together to a tandem unit which is driven by the flywheel side of
the engine via an elastic coupling. The travel pump has the function of supplying the travel circuit with hydraulic
oil.

Travel gear with travel motor, drum drive

The drive motor is a swash plate controlled axial piston motor of series 51C110 with variable displacement.
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.

Fig. 2 Reduction gear CR 31

1 Travel motor
2 Taper roller bearing
3 Spur wheel
4 Ring gear
5 Planet gear
6 Sun gear
7 Planet carrier
8 Brake discs
9 Mechanical seal
10 Brake piston

Travel motor rear, axle motor

The drive motor is a swash plate controlled axial piston motor of series 51D110 with variable displacement.

226 BOMAG 008 924 17

Travel circuit 7.12

Fig. 3 Drive axle

1 Drive axle
2 Travel motor

Charge circuit
The gear pump driven by the auxiliary drive of the engine serves as steering pump and also as charge pump,
because the oil flow from steering valve is flowing to the charge port on travel and vibration pump. Furthermore,
the vibration pump has an integrated charge pump, both charge oil flows are united before the charge pressure
filter.
The charge circuit provides the oil for the charge system and the control functions in the closed circuits for travel
and vibration drive, as well as to release the parking brakes.
The charge circuit is equipped with a 12µ fine filter with bypass valve. These open at a pressure differential
(pressure difference between filter inlet and filter outlet) of Δp = 3.5 bar. This pressure differential depends on
the filter contamination and the viscosity of the hydraulic oil.
The differential pressure switch (B21) switches when a differential pressure of Δ p 2.5 bar is reached. The
fault information will therefore already be available before the bypass valve opens.

Return flows
All return flows pass through the return flow manifold with temperature controlled valve (thermostat). This ther-
mostat guides the oil flow directly back to the hydraulic oil tank, until the operating temperature is reached. At
an oil temperature of 55 °C the valve starts to switch over and at 70 °C the total amount of oil will flow through
the hydraulic oil cooler.

008 924 17 BOMAG 227

7.12 Travel circuit

Option, cabin with heating

Fig. 4

228 BOMAG 008 924 17

Travel circuit 7.12

1 Cooler 8 Drive axle with brake

Brake control
During operation the closed hydrostatic travel circuit has the function of a service brake.
When the travel lever is returned towards neutral position, the displacement of the travel motor is adjusted to-
wards zero accordingly and the machine is hydraulically braked.
To avoid creeping movements of the machine, the machine is additionally equipped with multi-disc parking
brakes in the axle. These close in neutral position of the travel lever and when the engine is stopped.
The parking brakes are electrically operated by proximity switches (B13) on the travel lever via relay (K48) and
the 3/2-way solenoid valve (Y04). In de-energized state the charge oil supply to the brake pistons is interrupted,
allowing the hydraulic oil to return to the tank via the 3/2-way valve. When moving the travel lever out of neutral
position, the connection to the tank is interrupted and charge oil is directed to the brake piston. This hydraulic
pressure works against the spring force applied to the brake piston by the brake springs and relieves the brake
discs.

Travel lever

Fig. 5

B13 Initiator for brake Y04 Brake valve

B14 Initiator for reverse detection

008 924 17 BOMAG 229

7.13 Stopping the machine, operating the parking brake

7.13 Stopping the machine, operat-

ing the parking brake

Fig. 6

Return the travel lever (Fig. 6) slowly to "neutral"-

position and engage it to the right in braking posi-
tion.
The machine is automatically braked by the hydrostat-
ic drive and the parking brake is applied.

Fig. 7
The parking brake warning lamp (k) (Fig. 7) lights up.

i Note
The parking brake also closes automatically when
shutting the engine down.

230 BOMAG 008 924 17

Towing in case of an engine failure 7.14
7.14 Towing in case of an engine
failure

!Danger
Danger of accident! Danger of injury!
Before releasing the parking brake secure the ma-
chine against unintended rolling by using appro-
priate means (e.g. metal wheel chocks).
When using towing ropes tow the machine only
uphill.
When towing downhill you must use a rigid towing
Fig. 9
device.
The machine cannot be steered.
! Caution
Use a towing vehicle with sufficient traction and
Do not turn the valves out completely!
braking power for the unbraked towed load.
Do not touch hot engine parts. Slacken the middle hexagon on both valves (Fig. 9)
for approx. 2 to 3 turns.

! Caution
Tow the machine only after having released the
parking brake.
Towing speed 1 km/h, max. towing distance 500
m.
Secure the machine with wheel chocks against un-
intentional rolling.

Fig. 10
2.

1. To release the brake turn counter nuts (1) (Fig. 10)

approx. 8 mm back.

! Caution
From this stop turn the screw in for maximum an-
other turn to release the brake!
583196

Fig. 8 Turn the screws in evenly on both sides.

Attach chains (Fig. 8) or towing ropes to the lifting Turn the brake releasing screws (2) in alternately
hooks. for ¼ turn at a time.

Open the engine compartment hood and secure it. Repeat this measure on the opposite wheel side.

After towing

! Caution
Before loosening the drawbar secure the machine
against unintended rolling by using appropriate
means (e.g. metal wheel chocks).

008 924 17 BOMAG 231

7.15 Adjust the parking brake

Turn the high pressure relief valve cartridges tightly 7.15 Adjust the parking brake
back in.
Turn all brake releasing screws of the axle evenly
! Caution
back out, until they are light moving again.
Have adjustment work on the brakes only carried
out by a specialist! Always adjust both sides.
Secure the machine with wheel chocks against roll-
ing.
Start the diesel engine to relieve the brake.

Fig. 11

Turn the brake releasing screws (Fig. 11) back in

again, until they abut against the brake piston.

Fig. 13

Disengage the travel lever (Fig. 13) to the left, but

do not move to position "I" or "II".
The parking brake is released

Fig. 12

Unscrew the brake releasing screws (Fig. 12) for

two turns and tighten the counter nuts.
Repeat this adjustment procedure on the opposite
wheel side.

i Note Fig. 14

If necessary replace the sealing ring under the coun- Unscrew locking plate 2 (Fig. 14).
ter nut if it is leaking. Turn the square (1) in anti-clockwise direction
For this purpose completely unscrew the brake re- against the stop.
leasing screw, replace the seal ring and lubricate the
screw with silicone grease.
Reinstall the screw with a new seal ring and adjust the
protrusion as described above.

232 BOMAG 008 924 17

Check the parking brake 7.16
7.16 Check the parking brake

! Danger

Life hazard!
Before checking the parking brake make sure that
there are no persons or obstacles in front or be-
hind the machine.
Park the machine on level ground.
Open the engine hood.

Fig. 15

In order to adjust the brake clearance turn the

square 1 (Fig. 15) three turns back in clockwise di-
rection.
Fasten the locking plate again.
Pull the plug off the brake solenoid valve and per-
form the drive test.
The machine must be braked.

583161

Fig. 16

Pull the plug off the brake solenoid valve(Fig. 16).

Start the engine.

Fig. 17

Turn the rotary momentary contact switch for en-

gine speed (Fig. 17) clockwise to "MAX".

008 924 17 BOMAG 233

7.17 Check the oil level in the wheel hubs

7.17 Check the oil level in the wheel

hubs

!Caution
Check the oil level in both wheel hubs.
For quality of oil refer to the "table of fuels and lu-
bricants".

Fig. 18

Shift the travel lever (Fig. 18) out of braking position

to the left to disengage.
Pull the travel lever back first.
Then shift the travel lever forward.

! Caution
The machine should not move during this test.
Fig. 19
However, if the machine moves the parking brake
needs to be adjusted or repaired. Park the machine so that the plug (1) (Fig. 19) is in
horizontal position.
Adjustments to the parking brake must only be
made by authorized service personnel! Clean the area around the plug and unscrew the
plug.
Only operate the machine after the travel control
has been repaired. Check the oil level. The oil level must reach the bot-
tom edge of the bore, top up oil if necessary.
Reconnect the plug to the parking brake solenoid
valve (Fig. 16). Screw the plug back in tightly.
Close the engine hood.

234 BOMAG 008 924 17

Check the oil level in the axle reduction gear 7.18
7.18 Check the oil level in the axle 7.19 Check the oil level in the drum
reduction gear reduction gear

Check

Fig. 20

Unscrew the filler and oil level inspection plug (Fig.

20) and check the oil level. Fig. 21

The oil level must reach the bottom edge of the bore, Unscrew the oil level inspection plug (Fig. 21) and
top up oil if necessary. check the oil level.

For quality of oil refer to the table of fuels and lu- The oil level must reach the bottom edge of the bore,
bricants. top up oil if necessary.

Retighten the filler and level inspection plug.

Filling up
Move the drum until drain and filler plugs are exactly
vertically in line.

Fig. 22

Unscrew the filler plug at the top (Fig. 22) and fill in
oil, until it reaches the bottom edge of the inspection
bore.

! Caution
Investigate the cause for the oil loss, if necessary
seal the gearbox

For quality of oil refer to the table of fuels and lu-

bricants.
Retighten the filler and level inspection plug.

008 924 17 BOMAG 235

7.20 Vibration circuit

Vibration circuit
7.20 Vibration circuit

The vibration circuit is a closed hydraulic circuit, it consists mainly of the vibration pump with the integrated safety
elements and the vibration motors.
Travel pump and vibration pump are mounted together to a tandem unit which is driven by the flywheel side of
the engine via an elastic coupling. The vibration pump has the function of supplying the vibration circuit with hy-
draulic oil.
When changing the swashing angle in the vibration pump through the neutral position to the opposite side, the
flow direction of the oil and the sense of rotation of the vibration motor will change.
Since the displacement of the vibration pump is different to the two flow directions, the speeds of the vibration
motor are also different.

high amplitude

low amplitude

Fig. 1
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.
The eccentric weights on the vibrator shaft are fitted with additional change-over weights. Depending on the
sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic weights.
Basic weight + change-over weight = high amplitude
Basic weight - change-over weight = low amplitude

236 BOMAG 008 924 17

Vibration circuit 7.20

Fig. 2

1 Drum shell 8 Change-over weight

2 Vibration bearings 9 Coupling vib. motor – exciter shaft
3 Basic weight 10 Travel bearings
4 Vibration housing 11 Travel bearing housing
5 Cooling fan 12 Rubber buffer
6 Exciter shaft 13 Vibration motor
7 Elastic coupling between shafts 14 Flanged bearing housing

The vibration motor output shaft is joined with the exciter shafts in the drum via a Bowex coupling. Rotation of
the exciter shaft with the bolted on eccentric weights causes the vibration of the elastically suspended drums.

008 924 17 BOMAG 237

7.20 Vibration circuit

Fig. 3

1 Cooler 6 Charge circuit filter

2 Steering valve 7 Vibration motor
3 Steering/charge pump 8 Return flow manifold with thermal element
4 Travel pump 9 Hydraulic oil tank
5 Vibration pump, Y07 high amplitude, Y08 low ampli-
tude

Vibration motor
The vibration motor is a fixed displacement axial piston motor type A10FM 45.

238 BOMAG 008 924 17

Vibration circuit 7.20

Fig. 4

1 High pressure port high amplitude 4 Flushing spool

2 High pressure port, low amplitude 5 Flushing valve
3 Leak oil and flushing port

Charge circuit
The gear pump driven by the auxiliary drive of the engine serves as steering pump and also as charge pump,
because the oil flow from steering valve is flowing to the charge port on travel and vibration pump. Furthermore,
the vibration pump has an integrated charge pump, both charge oil flows are united before the charge pressure
filter.
The charge circuit provides the oil for the charge system and the control functions in the closed circuits for travel
and vibration drive, as well as to release the parking brakes and to change the travel speed ranges.
The charge circuit is equipped with a 12µ fine filter with bypass valve. These open at a pressure differential
(pressure difference between filter inlet and filter outlet) of Δp = 3.5 bar. This pressure differential depends on
the filter contamination and the viscosity of the hydraulic oil.
The differential pressure switch (B21) switches when a differential pressure of Δ p 2.5 bar is reached. The
fault information will therefore already be available before the bypass valve opens.

008 924 17 BOMAG 239

7.20 Vibration circuit

Option, cabin with heating

Fig. 5

1 Cooler 6 Charge circuit filter

2 Steering valve 7 Vibration motor
3 Steering/charge pump 8 Return flow manifold with thermal element
4 Travel pump 9 Hydraulic oil tank
5 Vibration pump, Y07 high amplitude, Y08 low ampli- 10 Silencer, it is always subjected to hydraulic oil
tude flow and has the function of eliminating any vi-
brations and noises.

240 BOMAG 008 924 17

1 Steering valve 4 Hydraulic oil tank

2 Steering and charge pump with pressure test port 5 Steering cylinder
3 Charge circuit filter

244 BOMAG 008 924 17

Steering circuit 7.22
Option, cabin with heating

Fig. 2

1 Steering valve 4 Hydraulic oil tank

Articulated joint
Front and rear frames of the single drum rollers are connected by an oscillating articulated joint. This ensures
that drum and wheels are at all times in contact with the ground, even when driving extreme curves.
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 bear-
ings 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.

008 924 17 BOMAG 245

7.22 Steering circuit

Articulated joint
Steering cylinder
Fig. 3
When turning the steering wheel the steering cylinders will extend or retract. The piston rods swivel the front
console around the vertical bolts. This articulates the machine and results in a steering movement.

Steering valve
The steering valve consists mainly of:
the distributor valve
the rating pump
the steering pressure relief valve
the shock valves

246 BOMAG 008 924 17

Steering circuit 7.22

Fig. 4 Steering valve

1 Neutral setting springs 6 Ring gear

2 Housing 7 Gear
3 Inner spool 8 Check valve
4 Outer spool 9 Pressure relief valve
5 Universal shaft

When turning the steering wheel the distributor valve guides the oil flow to the corresponding steering cylinder
sides. 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 valve contains also a pressure relief valve. This valve limits the steering pressure to 175 bar. Since
the oil is available for the charge circuit after it as left the steering unit, the charge pressure must be added to
this value. The maximum steering pressure is therefore approx. 200 bar.
Suddenly occurring pressure peaks, which may be caused by e.g. external influences like driving against a curb
stone, are compensated by two shock valves, which are integrated in the steering valve. Each of these shock
valves is fitted with an additional anti-cavitation valve. These anti-cavitation valves protect the system against
cavitation which could be caused by the reaction of the shock valves.
A check valve inside the steering unit makes sure that the hydraulic oil cannot flow to the steering pump if forces
are introduced from outside. In such a case the steering cylinders would act as pumps and press the oil back to
the pump.

i Note
This steering system is a dynamic steering system, i.e. a small quantity of oil (approx. 1 - 2 l/min) will always flow
via the LS-line.

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 cylin-
ders or to the boost check valves for travel and vibration circuits.

008 924 17 BOMAG 247

7.23 Check the hydraulic oil level

! Caution
In hydraulic systems filled with Panolin HLP
Synth. 46 always use the same oil to top up. With
other ester based oils consult the lubrication oil
service of the respective oil manufacturer.

Fig. 5

Check the hydraulic oil level in the inspection glass

(Fig. 5).

Normal level
approx. 3 cm below the top edge of the inspection
glass.

Minimum level
Middle of inspection glass.

! Caution
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.
If necessary fill in hydraulic oil through the filler
neck.

For quality and quantity of oil refer to the table of

fuels and lubricants.

248 BOMAG 008 924 17

Changing hydraulic oil and breather filter 7.24
7.24 Changing hydraulic oil and
breather filter

i Note
See also the notes on the hydraulic system in the
chapter "General notes on maintenance".

! Danger
Danger of scalding!
When draining off hot hydraulic oil!
Fig. 6
! Caution Unscrew the plug (Fig. 6) and drain off all hydraulic
The hydraulic oil must also be changed after ma- oil.
jor repairs in the hydraulic system.
Check the seal ring, replace if necessary and turn
Perform the oil change when the hydraulic oil is the plug tightly back in.
warm.
Replace the hydraulic oil filter elements with every
hydraulic oil change.
Change the filter only after the hydraulic oil
change and after the test run.
Clean the area round hydraulic oil tank, filler
opening and breather filter.
Do not start the engine after draining the hydraulic
oil.
Do not use any detergents to clean the system.
Use only lint-free cleaning cloths.
For quality and quantity of oil refer to the "table of
fuels and lubricants". Fig. 7

When changing from mineral oil based hydraulic Remove the filler cap (Fig. 7).
oil to an ester based biologically degradable oil, Fill in new hydraulic oil through the screen.
you should consult the lubrication oil service of
the oil manufacturer for details.
i Note
We recommend to use the BOMAG filling and filtering
Environment unit with fine filter to fill the system. This ensures finest
Catch running out hydraulic oil and dispose of en- filtration of the hydraulic oil, prolongs the lifetime of the
vironmentally. hydraulic oil filter and protects the hydraulic system.
Check the oil level in the inspection glass.

Nominal value:
approx. 3 cm below the upper edge of the inspection
glass

i Note
The breather filter for the hydraulic oil tank is integrat-
ed in the filler cap. You should therefore replace the
complete filler cap.
Close the tank with a new cover.

008 924 17 BOMAG 249

7.25 Changing the hydraulic oil filter

7.25 Changing the hydraulic oil fil- Take the old filter element (3) out and clean the filter
bowl and the thread.
ter
Reinstall the filter bowl with the new filter element,
check the condition of the O-rings (1) and (2), re-
!Danger place if necessary.
Danger of scalding! After a test run check the filter for leaks.
There is a danger of scalding by hot oil when un-
screwing the filter.

! Caution
If the filter has to be changed together with the hy-
draulic oil, the filter should in any case be
changed after the oil change and the test run.
Do not use the oil in the filter bowl.

Environment
Catch running out oil, dispose of oil and filter ele-
ment environmentally.

i Note
The filter element must be changed with every hy-
draulic oil change and after major repairs in the hy-
draulic system.

Fig. 8

Unscrew the cap nut 4 (Fig. 8) and take the filter

bowl (5) with the filter element (3) off.
Examine the sealing face on the filter element thor-
oughly for any visible dirt.

! Caution
Visible impurities may be an early indicator for a
failure of system components and predict the pos-
sible malfunction of important parts. In such a
case you should perform trouble shooting and re-
place or repair the defective components. Nonob-
servance may lead to total damage of the
hydraulic system.
Do not clean or reuse the filter element.

250 BOMAG 008 924 17

8 Tests and adjustments

008 924 17 BOMAG 251

8.1 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

252 BOMAG 008 924 17

Special tools, tests and adjustments 8.1
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

008 924 17 BOMAG 253

8.1 Special tools, tests and adjustments

9. Hydraulic test case, small

BOMAG part-no.: 079 930 01

i Note
2X 60 bar pressure gauge
2X 600 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

254 BOMAG 008 924 17

Special tools, tests and adjustments 8.1
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

008 924 17 BOMAG 255

8.2 Adjusting the solenoid for engine speed control

8.2 Adjusting the solenoid for engine

speed control
15. Remove screw 3 (Fig. 1).
16. Switch on the ignition.
17. Switch on the solenoid (2) (move to full load posi-
tion).

i Note
When switched on, the plunger of the solenoid is
pulled in against the stop and the integrated limit
switch deactivates the pickup winding. The cur-
rent flow is reduced from approx. 70 A to approx.
3.5 A.
18. Push the throttle lever (1) to the right.
Fig. 1

i Note
There must be a gap of max. 0.5 mm between
stop screw (5) and throttle lever (1). Insert a dou-
ble folded piece of paper to check.
19. Keep adjusting the linkage (4), until the screw (3)
can be easily installed.
20. Retighten the screw (3).

256 BOMAG 008 924 17

Checking the rotation speeds 8.3
8.3 Checking the rotation speeds
Special tools
Vibration reed frequency meter, RPM-meter for
diesel engines.

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
2. Block the wheels with suitable chocks.

Fig. 1

Check the engine speed

i Note
If necessary, the engine speed may also be
checked with the vibration Reed frequency meter.
1. Connect the RPM-meter to the injection line (Fig.
2).
2. Run the engine with maximum speed.
3. Apply the brake.
4. Measure the rotation speeds.

Nominal value idle speed:

Low idle speed, see technical data.
High idle speed, see technical data.
5. Switch the vibration on .

Nominal value nominal speed:

Fig. 2
See technical data.

Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting for the engine.

008 924 17 BOMAG 257

8.3 Checking the rotation speeds

Checking the exciter shaft speed

1. Switch the vibration on at max. engine speed.
2. Apply the brake.
3. Measure the speed of the vibrator shaft, rest the
tester on your thumb (Fig. 3).

Nominal value:
See technical data.

Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting in the vibration circuit.

Fig. 3

258 BOMAG 008 924 17

Checking / adjusting the neutral positions of the travel pump 8.4
8.4 Checking / adjusting the neutral posi-
tions of the travel pump
Special tools
Hydraulic test case

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Block drums and wheels with suitable chocks
(Fig. 1).

Fig. 1
2. Unhook the travel cable (Fig. 2) from the pump.

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

Fig. 3

008 924 17 BOMAG 259

8.4 Checking / adjusting the neutral positions of the travel pump

4. Connect 600 bar pressure gauges to high pres-

sure test ports MA and MB (Fig. 4).

Fig. 4
5. Connect the control chamber ports X3 and X4
(Fig. 5) with a hose

Fig. 5
6. Start the engine and run it with maximum speed.

Nominal value
Both pressure gauges (Fig. 6) must show equal
pressure (charge pressure).

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

Fig. 6
Evaluation of test

If pressure builds up on one side, adjust the me-

chanical neutral position (Fig. 7), until the pres-
sures on both pressure gauges are identical.

Fig. 7

260 BOMAG 008 924 17

Pressure tests in the travel circuit 8.5
8.5 Pressure tests in the travel circuit
Special tools
Hydraulic test case

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Block drums and wheels with suitable chocks
(Fig. 1).

Fig. 1
2. Pull the plug (Fig. 3) off the brake solenoid valve
to close the brake.

Fig. 2
3. Connect 600 bar pressure gauges to the high
pressure test ports for "forward travel" and "re-
verse travel" and a 60 bar pressure gauge to the
charge pressure test port (Fig. 2).
4. Start the engine and run it with maximum speed.
5. Read charge and high pressure gauges.

Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pressure at
high idle
High pressure gauge = charge pressure at high
Fig. 3 idle

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

008 924 17 BOMAG 261

8.5 Pressure tests in the travel circuit

Measurement with quickly operated travel le-

ver
6. Move the travel lever (Fig. 4) quickly forward,
read the pressure gauge.

Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pressure at
high idle
High pressure gauge = pressure override

Evaluation of test

Fig. 4
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 in-
dividually.

262 BOMAG 008 924 17

Checking / adjusting the vibrator shaft speeds 8.6
8.6 Checking / adjusting the vibrator shaft
speeds
Special tools
Vibration reed frequency meter

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Drive the machine on an elastic base (rubber
buffers) (Fig. 1).
2. Apply the parking brake and block the wheels ad-
ditionally with suitable chocks.
3. Start the engine and run it with maximum speed.
4. Switch on vibration high frequency / low ampli-
tude or low frequency / high amplitude.

Fig. 1
5. Measure the speed (Fig. 2), rest the tester on
your thumb.

Nominal value
high amplitude/
low frequency = see technical data
low amplitude/
high frequency = see technical data

Evaluation of test
In case of deviations exceeding 10% determine
the cause, perform trouble shooting for engine /
vibration circuit and check vibration motor.
Fig. 2
6. Adjust the speed on the corresponding adjust-
ment screw (Fig. 2).

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

Fig. 3

008 924 17 BOMAG 263

8.7 Pressure measurements in the vibration circuit

8.7 Pressure measurements in the vibra-

tion circuit
Special tools
Hydraulic test case

Fig. 1
4. Connect a 60 bar pressure gauge (Fig. 2) to the
charge pressure test port.
5. Connect a 600 bar pressure gauge each to the
high pressure test ports for "high amplitude" and
"low amplitude".
6. Start the engine and run it with maximum speed.
7. Switch on vibration with high or low frequency.

Nominal value
Charge pressure = charge pressure at high idle
(see technical data of travel pump).
Start-up pressure = vibration pump start-up pres-
Fig. 2 sure (see technical data of vibration pump).
Operating pressure = vibration pump operating
pressure (see technical data of vibration pump).

Evaluation of test
If the charge pressure drops, check the compo-
nents individually.
If the starting pressure is not reached, check the
vibration pump.
If the starting pressure is only reached for one fre-
quency, check the high pressure relief valves.

264 BOMAG 008 924 17

Check the leakage rate of the vibration motor 8.8
8.8 Check the leakage rate of the vibration
motor

! Caution
Perform measurements at operating tempera-
ture 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 ad-
ditionally with suitable chocks.
2. Apply the brake.

Fig. 1
3. Block the flushing valve (Fig. 2) with washers.

Fig. 2
4. Disconnect the leak oil hose (Fig. 3), connect a
measuring hose and hold it into a measuring
beaker.
5. Start the engine and run it with maximum speed.
6. Switch the vibration on and measure the running
out leak oil during one timed minute.

Nominal value
max. 1.5 litre/min

Evaluation of test
If the permissible leak oil rate is exceeded, re-
place the vibration motor.
Fig. 3

008 924 17 BOMAG 265

8.9 Pressure test in steering circuit

Special tools
Hydraulic test case, gear pump testing equipment

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (approx. 50 °C).

Measurement 1
1. Connect a 600 bar pressure gauge to the steering
pressure test port (Fig. 1).
2. Start the engine and run it at idle speed.

! Danger
Danger of crushing, do not access the articu-
lation area of the machine!
3. Turn the steering against an end stop.
4. Read the pressure gauge.

Nominal value

Fig. 1
see technical data, max. steering pressure of
steering/charge pump.

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

Fig. 2
6. Disconnect the hydraulic hoses from ports L and
R (Fig. 3) (machines with two steering cylinder)
on the steering cylinders and close them with
plugs.
7. Start the engine and run it at idle speed.
8. Turn the steering wheel.
9. Read the pressure gauge.

Nominal value
see technical data for steering/charge pump.

Fig. 3

266 BOMAG 008 924 17

Pressure test in steering circuit 8.9
Evaluation of test 2
If the nominal value is reached, replace the steer-
ing cylinder.
If the nominal value is not reached, check the
steering/charge pump.
10. Reconnect the hydraulic hoses to the steering
cylinders.
Measurement 3
11. Actuate the emergency stop switch.

Fig. 4
12. Close the pump outlet port (Fig. 5) with the gear
pump test equipment.
13. Crank the engine with the starter

Nominal value
see technical data for steering/charge pump.

Evaluation of test 3
If the nominal value is reached, replace the steer-
ing valve.
If the nominal value is not reached, replace the
steering/charge pump.

Fig. 5

008 924 17 BOMAG 267

8.9 Pressure test in steering circuit

268 BOMAG 008 924 17

9 Flushing and bleeding

008 924 17 BOMAG 269

9.1 Special tools for flushing

i Note
The following list informs about special tools for
flushing. You should choose the corresponding
tool for the work to be carried out.
14. Filling and filtering unit

BOMAG part-no.: 058 240 22

Fig. 1
15. Flushing filter (S connection)

BOMAG part-no.: 007 000 01

16. Filter element 1μ

BOMAG part-no.: 079 930 52

17. Flushing hose 20S - 25S (2 pieces)

BOMAG part-no.: 055 509 19

18. Screw socket R1“ - 25S (2 pieces)

BOMAG part-no.: 055 400 52

Fig. 2
19. Flushing filter (L connection)

BOMAG part-no.: 079 390 29

20. Filter element

BOMAG part-no.: 079 390 14

21. Flushing hose 15L (2 pieces)

BOMAG part-no.: 055 510 09

22. Screw socket R3/4“ -- 15L (2 pieces)

BOMAG part-no.: 055 400 89

Fig. 3
23. SAE-flange 1“ - 20S

BOMAG part-no.: 058 142 60

24. O-ring

BOMAG part-no. 062 203 30

Fig. 4

270 BOMAG 008 924 17

Special tools for flushing 9.1
25. Flanged plate 1“ - 25S

BOMAG part-no.: 007 160 18

26. O-ring

BOMAG part-no. 062 202 22

Fig. 5
27. Reducing fitting 18L - 15L

BOMAG part-no.: 055 422 92

Fig. 6
28. Reducing fitting 25S - 20S

BOMAG part-no.: 055 422 98

Fig. 7
29. Reducing fitting 20S - 16S

BOMAG part-no.: 055 423 26

Fig. 8

008 924 17 BOMAG 271

9.1 Special tools for flushing

30. Connecting socket 15L

BOMAG part-no.: 055 426 55

Fig. 9
31. Connecting socket 18L

BOMAG part-no.: 055 426 06

Fig. 10
32. Connecting socket 16S

BOMAG part-no.: 055 459 43

Fig. 11
33. Connecting fitting 20S

BOMAG part-no.: 055 459 44

Fig. 12

272 BOMAG 008 924 17

Special tools for flushing 9.1
34. Connecting fitting 25S

BOMAG part-no.: 055 459 45

Fig. 13
35. Angular fitting 18L

BOMAG part-no.: 055 421 26

Fig. 14
36. Elbow fitting 16L

BOMAG part-no.: 055 421 36

Fig. 15
37. Elbow 20S

BOMAG part-no.: 055 421 37

Fig. 16

008 924 17 BOMAG 273

9.1 Special tools for flushing

38. Elbow 25S

BOMAG part-no.: 055 421 38

Fig. 17
39. Pipe connection 16S - 16S

BOMAG part-no.: 493 301 01

Fig. 18
40. Connecting hose 15L

BOMAG part-no.: 055 510 09

Fig. 19

274 BOMAG 008 924 17

Flushing - general 9.2
9.2 Flushing - general Solid particles in the circuit will very quickly
cause damage to machine components.
Changing a component

Always flush the complete oil circuit after

you have replaced a component.

Fig. 1 Chips (abrasion) in the oil

Effect of contamination l Open and clean all components in the oil
circuit, replace if necessary.
Coarse particles (> 15 µm)
Sudden failure of components. l Clean all high pressure hoses in the oil cir-
cuit, replace if necessary.
Fine particle contamination (5 – 15 µm)
l If abrasion is found in the travel circuit you
Wear of components, internal leaks, inaccurate
should also flush the vibration circuit.
controlling behaviour, blockage of valves.
l If abrasion is found in the vibration circuit
Extra fine particle contamination (< 2 – 5 you should also flush the travel circuit.
µm)
Silting of oil, accelerated aging of oil, corrosion.

Water in oil
Increased wear, accelerated aging of oil.

008 924 17 BOMAG 275

9.2 Flushing - general

Before flushing Bleeding

Change the filter element

Fig. 3

Fig. 1
l Always bleed closed hydraulic circuits if
lines had been removed or connected.
Clean the hydraulic tank
Servicing the flushing filter kit

Fig. 4
Fig. 2
l Replace the filter element of the flushing fil-
ter when the red control pin of the contami-
! nation indicator is pressed out during the
Change the oil in case of excessive contam- filtering process.
ination, oil discoloration or if the oil change l Clean hoses and connections and store the
interval is almost due. flushing kit in a clean and protected envi-
l Filter the tank content with the filling and fil- ronment.
tering unit and pump it into an oil container.
l Mark all hoses and disconnect them from
the hydraulic oil tank.
l Clean the oil tank thoroughly from inside, if
necessary remove the tank cover.
l Reconnect all hoses.
l Fill the hydraulic oil tank again with the fill-
ing and filtering unit.

276 BOMAG 008 924 17

Flushing schematic travel circuit (distribution axle motor) 9.3

008 924 17 BOMAG 277

9.3 Flushing schematic travel circuit (distribution axle motor)

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)

278 BOMAG 008 924 17

Flushing the travel circuit (axle motor distribution) 9.4
9.4 Flushing the travel circuit (axle motor
distribution)

Flushing the drum drive

Replacing the hydraulic oil filter element

Cleaning the hydraulic oil tank

i
Observe the chapter "Flushing - General"
Installing the flushing filter

Before the installation of the filters check hos-

es 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 chap-
ter "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 out-
let "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 cir-
cuit by joining the high pressure hoses (12 and
13) on the drum drive motor together.

Fig. 2

008 924 17 BOMAG 279

9.4 Flushing the travel circuit (axle motor distribution)

Bleeding the travel circuit

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

Fig. 3
Flushing the hoses

i
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

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

280 BOMAG 008 924 17

Flushing the travel circuit (axle motor distribution) 9.4
Flushing the drum drive motor

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

Fig. 8

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 min-
utes. 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

008 924 17 BOMAG 281

9.4 Flushing the travel circuit (axle motor distribution)

Flushing the axle motor

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

Fig. 11

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 min-
utes. 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 chap-
ter).

Keep circulating the tank content.

23. After completing the bleeding process circulate
the tank content with the filtering unit for another
15 minutes.

282 BOMAG 008 924 17

Flushing the travel circuit (axle motor distribution) 9.4
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 for-
ward 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

008 924 17 BOMAG 283

9.5 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)

284 BOMAG 008 924 17

Flushing the vibration circuit 9.6
9.6 Flushing the vibration circuit
Replacing the hydraulic oil filter element

Cleaning the hydraulic oil tank

i
Observe the chapter "Flushing - General"

Installing the flushing filter

Before the installation of the filters check hos-

es 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 chap-
ter "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 vibra-
tion pump.
Disconnect the vibration motor
3. Take the vibration motor out of the hydraulic cir-
cuit by joining the high pressure hoses (10 and
11) on the vibration motor together.

Fig. 2

008 924 17 BOMAG 285

9.6 Flushing the vibration circuit

Bleeding the vibration circuit

i
Bleeding the vibration circuit, see chapter "Bleed-
ing the vibration circuit".

Fig. 3
Flushing the hoses
4. Block drums and wheels with suitable chocks.

Fig. 4

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

Fig. 5

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 ap-
prox. 30 seconds.
8. Shut down the engine.
9. Reconnect the hydraulic hoses (10 and 11) to the
Fig. 6 vibration motor.

286 BOMAG 008 924 17

Flushing the vibration circuit 9.6
Flushing the vibration motor
10. Unscrew the fastening screws for the vibration
motor and pull the motor out of the coupling.

Fig. 7

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

Fig. 8

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 min-
utes. 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 vibra-
tion 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.

008 924 17 BOMAG 287

9.6 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

288 BOMAG 008 924 17

Bleeding the travel circuit 9.7
9.7 Bleeding the travel circuit

Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure 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

008 924 17 BOMAG 289

9.7 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 repeat-
ing this procedure, until the gauge shows a con-
stant charge pressure reading.

Fig. 4

! Caution
With the flushing filter installed shift the travel
lever only to travel direction forward, as oth-
erwise 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 for-
ward 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 bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.

290 BOMAG 008 924 17

Bleeding the vibration circuit 9.8
9.8 Bleeding the vibration circuit

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 repeat-
ing 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

008 924 17 BOMAG 291

9.8 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 pro-
cedure, until the pressure gauge shows a con-
stant 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 direc-
tion.
10. For bleeding switch on vibration with high fre-
quency (Fig. 5).
11. Start the engine.
12. After running the engine 1 to 2 minutes pause for
approx. one minute.

Fig. 5 i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.

292 BOMAG 008 924 17

10 582 502 15 dust protection / 582 502 16 gasket

008 924 17 BOMAG 293

10.1 Assembling the dust protection

1. Unscrew the fastening screws (Fig. 1).

Fig. 1
2. Lift the operating console up and out (Fig. 2).

Fig. 2
3. Pull the wiring loom carefully out of the dash-
board(Fig. 3).

Fig. 3
4. Attach the new gasket to the back of the operat-
ing console (Fig. 4).

i Note
Pull the adhesive strip off the gasket and stick on
the gasket.

Fig. 4

294 BOMAG 008 924 17

Assembling the dust protection 10.1
5. Pull the dust protection bag over the operating
console (Fig. 5), (Fig. 6) and (Fig. 7).

Fig. 5

Fig. 6

Fig. 7
6. Tighten the screws for the operating console
hand tight (Fig. 8).

i Note
Ensure the seal/gasket is fitted correctly.

Fig. 8

008 924 17 BOMAG 295

10.1 Assembling the dust protection

7. Disassemble the dashboard, for this purpose un-

screw the fastening screws (4X), take off spacers
and washers (Fig. 9).

Fig. 9
8. Lift the dashboard up (Fig. 10) and.....

Fig. 10
9. ... fold it back (Fig. 11).

Fig. 11
10. Wrap the dust protection bag around the wiring
looms and fasten it with cable straps (Fig. 12).

Fig. 12

296 BOMAG 008 924 17

Assembling the dust protection 10.1
11. Assemble the dashboard (Fig. 13).

Fig. 13
12. Fasten the dashboard with fastening screws (4X),
spacers and washers (Fig. 14).

Fig. 14
13. Tighten the fastening screws (Fig. 15).

i Note
Check the function of control switches.

Fig. 15

008 924 17 BOMAG 297

10.1 Assembling the dust protection

298 BOMAG 008 924 17

11 Air conditioning system

008 924 17 BOMAG 299

11.1 Physical basics

11.1 Physical basics A - heat absorption

In order to understand the working principle of an air B- Heat dissipation

conditioning system one must first become familiar
with the physical basics of such a system.
The four well known physical conditions of water apply
also for the refrigerant in the air conditioning system.

1. gaseous (invisible)

2. vaporous

3. liquid

4. solid

Fig. 2
Heat always flows from the warmer to the colder mat-
ter. Any matter consists of a mass of moving mole-
cules. The rapidly moving molecules or a warmer
matter dissipate part of their energy to the slower
moving molecules with less heat. The movement of
the molecules in the warmer matter becomes slower
and the molecules in the cooler matter are accelerat-
ed. This process continued, until all molecules in the
two matters move with identical speed. The matters
have then reached an identical temperature and the
transfer of heat stops.

Fig. 1
If the water in a container is heated up (absorption of
heat), the rising steam is visible. If the steam is heated
up further, due to the absorption of heat, the visible
steam will turn into invisible gas. This process is re-
versible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into
water and finally into ice.

300 BOMAG 008 924 17

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

Fig. 4 Pressure - Temperature Diagram

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

008 924 17 BOMAG 301

11.1 Physical basics

Excerpt from the wet steam table * R134a

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

302 BOMAG 008 924 17

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

Steam pressure:
Chemical formula:
In an incompletely filled, closed container, vaporous
CH2F-CF3 or CF3-CH2F refrigerant will volatilize from the surface in the same
quantity that will turn liquid in combination with steam
particles. This state of equilibrium occurs under pres-
Chemical designation: sure and is frequently referred to as steam pressure.
Tetrafluoroethane The steam pressure is independent from the temper-
ature.

Boiling point at 1 bar:

- 26.5 °C Physical properties of R134a:
The steam pressure curves of R134a and other refrig-
erants are partly very similar, making a clear differen-
Solidification point: tiation solely by pressure impossible. With R 134a the
compressor is lubricated by special synthetic refriger-
-101.6 °C
ation oils, e.g. PAG-oils (polyalkylene glycol oils).

Critical temperature:
Behaviour with metals:
100,6 °C
In pure condition refrigerant R134a is chemically sta-
ble and does not attack iron and aluminium. However,
contamination of the refrigerant, e.g. with chlorine
Critical pressure:
compounds, leads to aggressiveness against certain
40.56 bar (absolute) metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.

Critical point:
Critical point (critical temperature and critical pres- Critical temperature / critical pressure:
sure) means that above this point there is no separat- Up to a gas pressure of 39.5 bar overpressure (this
ing interface between liquid and gas. Above its critical corresponds with a temperature of 101 °C) the refrig-
point any substance is gaseous. At temperatures be- erant R134a remains chemically stable, above this
low the critical point all refrigerant types in pressure temperature the refrigerant decomposes (see com-
containers have a liquid and a gaseous phase, i.e. a bustibility).
gas cushion is above the liquid. As long as gas is in
the container, besides the liquid, the pressure de-
pends on the ambient temperature. Water content:
In liquid refrigerant water can only be dissolved in very
low quantities. In contrast to this refrigerant steam
mixes with water steam at any ratio. If the dryer in the

008 924 17 BOMAG 303

11.3 Compressor oil / refrigeration oil

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

304 BOMAG 008 924 17

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

008 924 17 BOMAG 305

11.6 Description of components

Monitoring chain 11.6 Description of components

Compressor

Fig. 2 Monitoring chain consisting of:

l 1 Switch
l 2 Fuse
l 3 Thermostat
l 4 Low pressure switch contact Fig. 1
l 5 High pressure switch contact The compressor is mounted to the engine and has the
duty to build up the refrigerant pressure required for
l
6 Relay
the function of the system. Coupling and decoupling is
l
7 Connection for magnetic clutch accomplished by an electromagnetically controlled
l
8 Pressure switch mechanical clutch, which is integrated in the V-belt
pulley of the compressor.

Compressor data
Displacement: 155 cm²
Weight: 6.9 kg
max. rpm: 6000
Sense of rotation: clockwise
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.

306 BOMAG 008 924 17

Description of components 11.6
Reason of oil loss Amount of oil lost Condenser
Loss when emptying approx. 15 gr
Defective A/C hose approx. 30 gr
Hose change approx. 15 gr
Replacement of condens- approx. 30 gr
er
Replacement of evapora- approx. 30 gr
tor
Replacement of liquid con- approx. 30 gr
tainer
Replacement of expan- approx. 15 gr
sion valve

! Caution
Please bear in mind, that the new compressor is
delivered with a filling of 207 gr. compressor oil. Fig. 1
To avoid excessive oil in the A/C-system and thus The condenser is located in front of the the radiator for
a poor cooling effect, the oil level in the A/C-sys- the machine. It emits heat energy from the system into
tem must be adjusted accordingly. the surrounding air and liquefies the gaseous refriger-
The quantity depends on the amount of oil that ant.
may have been lost in connection with the possi-
ble replacement of other components.
i Note
The compressor oil quantity must be 10% of the The fins must be free of dirt and damage.
refrigerant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system re- ! Caution
quires a compressor oil / refrigerant oil filling of
100 gr. When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
Procedure: changing the components, must be replaced with
Drain and measure the compressor oil from the fresh oil.
old compressor.
Drain the compressor oil from the new compres-
sor and only fill in the exact quantity that had been
drained out of the old compressor. The compres-
sor oil from the new compressor can be used for
this purpose.

i Note
Topping up compressor oil / refrigeration oil is possi-
ble on a pressureless compressor directly into the oil
pan, in a pressureless refrigeration system directly
into the pressure side, but it is also possible to draw it
into the pressure side of the refrigeration system dur-
ing the evacuation process.

008 924 17 BOMAG 307

11.6 Description of components

Dryer / filter / fluid container / inspection Pressure relief valve

glass

Fig. 2

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

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

Installation position: However, incorrect evacuation or filling may also be

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

308 BOMAG 008 924 17

Description of components 11.6
i Note Expansion valve
Air in the system is characterized by high pressures
and temperatures.
On R134a refrigeration systems from KONVEKTA the
inspection glasses are equipped with moisture indica-
tors. In addition to the float, the dryer/collector/inspec-
tion glass combination has an indicator pearl
integrated in the inspection glass, which changes its
colour when absorbing moisture.
The refrigerant level should be inside the inspection
glass and should only be checked after approx. 5 min-
utes continuous operation, because the refrigerant
must first evenly distribute all over the system.

! Danger

In case of mechanical damage or corrosion on

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

i Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in-
let.+

008 924 17 BOMAG 309

11.6 Description of components

Evaporator Thermostat
Thermostat with fixed setting

Fig. 1
The evaporator is mounted inside the HKL-module in
Fig. 1
the cabin. It consists of a heat exchanger (inside air -
refrigerant), with refrigerant flowing to a pipe system The feeler of a defroster thermostat to switch off the
with cooling flanges. magnetic clutch in case of icing up or to switch the
clutch back on after defrosting, is mounted on the
As with the condenser, correct operation of all fans evaporator.
and cleanliness of the fins must be assured.
With fixed temperature controls the control switches
Air conditioning systems have a circulation air filter the compressor off at about +1 °C and back on again
mounted in the air flow in front of the evaporator, at about +2.5°C to +5.5 °C.
which should be cleaned or changed by the operator
after each third trip, depending on the amount of dirt. Adjustable thermostat
A condensation water filter is mounted in the air flow With adjustable temperature regulators the switching
after the evaporator. This filter has the function to col- point can be changed so that the compressor is al-
lect the water that has condensed from the air in the ready shut down at higher temperatures. This enables
evaporator block and to discharge this water into the regulation of the air temperature.
water pan With a defective condensation water filter
condensation water may flow into the inside of the ve-
hicle.

! Caution
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
changing the components, must be replaced with
fresh oil.

Fig. 2 adjustable temperature controller

i Note
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on.

310 BOMAG 008 924 17

Description of components 11.6
Pressure switch Pipes and hoses
Pipes and hoses in air conditioning systems must
meet very high requirements with respect to resist-
ance against heat and pressure. The requirements
concerning leak tightness and, in case of hoses,
against diffusion, i.e. seepage of refrigerant through
the hose material, are very high. Pipes and hoses to
be used must therefore be specially made for air con-
ditioning purposes. For this reason the hoses have an
inside lining of butyl rubber and an outside coating of
EDPM rubber. Hose sections exposed to heat are pro-
vided with a special heat insulation.
O-rings are made of a special type of chloroprene rub-
ber (neoprene). Before assembly of the air condition-
ing system these O-rings must be lubricated with
Fig. 1
compressor oil / refrigeration oil. The O-rings must al-
ways be replaced when assembling A/C-components.
After a minimum pressure is reached in the low pres-
sure side or a maximum pressure in the high pressure Recommended tightening torques for O-ring
side, the pressure switch will switch of the magnetic sealed fittings
clutch of the compressor, thus to avoid destruction of
system components by excessive pressure or draw- Thread Spanner width Torque
ing in external gases and foreign matter as a result of 5/8“ 17 or 19 13,6 - 20,3 Nm
too low pressure. 3/4“ 32,5 - 39,3 Nm
7/8“ 27 35,3 - 42,0 Nm
Working pressure:
1 1/16“ 32 40,7 - 47,5 Nm
Low pressure off: 1,5 ±0,5 bar M30X2 36 105,0 - 115,0
Low pressure on: 3.5 bar Nm
M36X2 41 165,0 - 175,0
Overpressure off: 25,0 ±1,5 bar
Nm
Overpressure on: 18,0 ±1,5 bar
Bending radii for air conditioning hoses

Hose type Nominal width Bending radius

GH 134 NW8 min. 50 mm
GH 134 NW10 min. 65 mm
GH 134 NW12 min. 75 mm
GH 134 NW16 min. 100 mm
GH 494 NW20 min. 160 mm
GH 494 NW25 min. 194 mm
GH 494 NW32 min. 225 mm

008 924 17 BOMAG 311

11.7 Measuring the compressor oil level

11.7 Measuring the compressor oil 11.8 Checking the magnetic clutch
level l Measure the voltage.

!Caution i Note
The compressor oil level must be checked after Nominal value = vehicle voltage
replacing a system component or if a leak in the l
Check the magnetic coil locking ring for secure fit.
system is suspected. Use only compressor oil / re-
frigeration oil PAG SP-20 (H14-003-404). l
Check the current consumption.
l Run the compressor for 10 minutes at engine idle
speed.
l remove the refrigerant from the air conditioning sys-
tem.

Fig. 1

Fig. 1 i Note
l
Turn the compressor, as shown in (Fig. 1), if neces- at 12 Volt vehicle voltage approx. 3.5 Amp.
sary remove V-belt and hoses.
at 24 Volt vehicle voltage approx. 1.75 Amp.
l
Remove the oil plug.
Overcurrent indicates a short circuit inside the mag-
netic coil.
i Note No current indicates an interrupted electric circuit.
The oil level must reach the bottom edge of the bore,
top up or drain off oil if necessary.
l
Close the oil plug again.

!Caution
The contact area must be clean and should be free
of damage.
Tightening torque 15 to 25 Nm
l Refill the air conditioning system.

Fig. 2 Measuring the air gap

l Measure the air gap on the magnetic clutch be-
tween V-belt pulley (2) and thrust plate (1).

312 BOMAG 008 924 17

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

008 924 17 BOMAG 313

11.10 Checking, replacing the refrigerant compressor V-belt

11.10Checking, replacing the refrig- l Press the compressor in direction of arrow, until the
correct V-belt tension is reached.
erant compressor V-belt* l Retighten all fastening screws.

Danger
! Changing the V-belt
Danger of injury! l Slightly slacken the fastening screws 1, 2 and 3.
Work on the V-belt must only be performed with l Press the compressor against the direction of arrow
the engine shut down. completely against the engine.
Wear safety goggles. l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
Check the V-belt
l Tension the V-belt as previously described.

Caution
!

Check the V-belt tension after a running time of 30

minutes.

Fig. 4
l
Inspect the entire circumference of the V-belt (Fig.
4) visually for damage and cracks. Replace dam-
aged or cracked V-belts.
l Check with thumb pressure whether the V-belt can
be depressed more than 10 to 15 mm (0.4 – 0.6
inches) between the V-belt pulleys, retighten if nec-
essary.

Tighten the V-belt.

Fig. 5
l
Slightly slacken fastening screws 1, 2 and 3 (Fig.
5).

* Optional equipment

314 BOMAG 008 924 17

Service the air conditioning 11.11
11.11Service the air conditioning*

Clean the condenser

! Danger

Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
age or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.
Fig. 7
l Turn the rotary switch for the cab ventilator (Fig. 7)
Caution
!
to position "1".
A soiled condenser results in a considerable re-
duction of air conditioning power.
Under extremely dusty conditions it may be nec-
essary to clean the condenser several times per
day.
If, during operation of the air conditioning system,
the warning buzzer sounds switch the air condi-
tioning off and clean the condenser.
In case of formation of foam have the air condi-
tioning system inspected by the service depart-
ment.

Fig. 8
l Choose a cooling temperature with the rotary switch
for the air conditioning system (Fig. 8) in the blue
section.
l
Open the air outlet nozzles.
l
Check, whether the out flowing air is noticeably
cooler.

i Note
The adjusted temperature must be below the actual
Fig. 6 temperature inside the cabin, so that the compressor
will be switched on.
l Unscrew the condenser fastening screws (Fig. 6)
and fold the condenser forward.
l
Clean the condenser fins on front and back with
compressed air or cold water .

Checking the refrigerant level

l
Start the engine.

* Optional equipment

008 924 17 BOMAG 315

11.11 Service the air conditioning

Checking the moisture level of the drying

agent

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

Caution
!

Have the drier/collector unit replaced by the serv-

ice department every year before the operating
season.

Checking the condition of the drier/col-

lector unit

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

! Danger

Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be replaced,
to avoid bursting and further damage.

316 BOMAG 008 924 17

Drying and evacuation 11.12
11.12Drying and evacuation
Evacuation of air conditioning systems using R-type
refrigerants not only has the purpose of emptying the
system of all air before filling in refrigerant, but also to
verify the leak tightness over a longer lifetime in the
achieved vacuum. However, the most important factor
in this work step is the drying of the system.
Any water residues in the refrigerant circuit will com-
bine with the refrigerant, which will lead to the previ-
ously described consequential damage.
Vacuum pumps with a capacity of more than 100 l/min
and a final pressure of less than 30 micron, i.e. 0.039
Fig. 12 mbar should be used to evacuate the refrigeration
l Check the drier/collector unit (Fig. 12) for mechani- system.
cal damage or rust. The refrigerant compressor is not suitable for the pur-
pose of evacuation, because it is not able to achieve
a sufficient final vacuum and, apart from this, may be
mechanically damaged because of a lack of lubrica-
tion when running empty during evacuation.
It is common practice to evacuate the refrigeration
system to a final vacuum of 1 Torr, i.e. 1.33 mbar.
An exact time for evacuation and drying cannot be
predicted. It can only be determined by means of a
vacuum meter. However, if there is no vacuum meter
at hand it is generally better to evacuate 1 hour longer
than 1 hour too less.

Function drying:
Under normal ambient pressure (1.013 mbar) evapo-
rates absolute at 100° C. If the pressure is reduced,
water will already evaporate, e.g. under a pressure of
10 mbar, at an ambient temperature of almost 7°C,
but the water will not evaporate all at once. Since it is
very difficult to separate the steam from the vacuum in
the system, the evacuation process is supported by
the co-called vacuum breaking (filling the circuit with
dried nitrogen). With vacuum breaking the filled in
dried nitrogen absorbs the moisture in the refrigerant
circuit, which can then be easily discharged together
with the nitrogen.

008 924 17 BOMAG 317

11.13 Emptying in case of repair

11.13Emptying in case of repair 11.14Leak test

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

Leak test with soap bubbles

Fig. 2 Soap bubble test

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

318 BOMAG 008 924 17

Filling instructions 11.15
11.15Filling instructions

Filling of refrigerant into the dried, vented and oil filed

machines takes place under various conditions.
In most large series production facilities highly compli-
cated equipment is available for this purpose, where-
as individual machines at the place of installation must
be filled directly from the refrigerant container.
Liquid refrigerant is only used to pre-fill the pressure
side of the evacuated refrigeration system (protective
filling).
After switching the refrigeration system on and watch-
ing the inspection glass, gaseous refrigerant can be
filled into the system while the engine is running, if the
refrigerant level is found to be too low (gas bubbles in
the inspection glass).

! Caution
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
When filling the air conditioning system directly from
the refrigerant bottle care must be taken not to overfill
the system. As an additional control and for statistical
purposes, e.g. for refilling, it is important to write down
the weight of the filled in refrigerant.
With correct operation of the air conditioning the re-
frigerant container should be about 1/3 filled with liq-
uid refrigerant, the evaporator should be maximally
filled at the calculated evaporation temperature, i.e.
the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the
pressure gauge.

i Note
White frost on the suction line is no measure for as-
sessing the filling.

008 924 17 BOMAG 319

11.15 Filling instructions

Fig. 1

Pos. Designation Pos. Designation

1 High pressure - gaseous 13 Manual shut-off valve (not used)
2 High pressure - liquid 14 Pressure switch with high and low pressure contacts
3 Low pressure - gaseous 15 Defroster thermostat
4 Compressor 16 Vacuum meter
5 Compressor pressure switch (not 17 Low pressure gauge
used)
6 not used 18 High pressure gauge
7 Evaporator 19 Pressure reducing valve
8 Expansion valve 20 Vacuum pump
9 Inspection glass 21 Nitrogen bottle
10 Filter dryer 22 Refrigerant bottle
11 Fluid container 23 Pressure gauge bar
12 Capacitor

320 BOMAG 008 924 17

Filling instructions 11.15
Filling instructions sure side is reached (reading of pressure gaug-
es).
1 Connect the service adapter with the blue hand
wheel in the suction side. 18 Close the red hand wheel.
2 Connect the service adapter with the red hand 19 Perform a leak test with the electronic leak detec-
wheel in the pressure side (the hand wheels on tor.
the service adapters must be fully backed out - left 20 Start the engine and switch on the system.
hand stop) 21 Open the blue hand wheel and continue filling in
3 Connect the blue suction hose below the blue refrigerant until the inspection glass is free or air
hand wheel on the pressure gauge bar to the blue bubbles (in fluid container/dryer combinations the
service adapter. white pearl should float in the upper third of the in-
4 Connect the red pressure hose below the red spection glass). Then close the refrigerant bottle.
hand wheel on the pressure gauge bar to the red 22 Close the blue hand wheel on the pressure gauge
service adapter. bar.
5 Connect the yellow hose below the yellow hand 23 Preparing the test run: -Close windows and doors
wheel on the manometer bar to the 2-stage vacu- -Fan on full speed stage -Mount measuring feel-
um pump. ers to air discharge and air intake.
6 Connect the last hose below the black hand wheel 24 Run the system for approx. 20 minutes with medi-
on the nitrogen bottle via the pressure reducing um engine speed.
valve. 25 The temperature difference between air discharge
7 Check on the pressure gauge bar that all hand and air intake should be (depending on type of air
wheels are closed. condition) 8-10°C. Ambient temperature in this
8 Turn the hand wheels on both service adapter case approx. 20 °C. (These data are only refer-
clockwise. This opens the valves (right hand ence values, which may be influenced by possible
stop). insolation)
9 Open the valve on the nitrogen bottle (only via 26 Switch off system and engine and check for leaks
pressure reducer); pressure approx. 20 bar. again.
10 Open the black and red hand wheels on the pres- 27 Turn out (left hand stop) and remove the hand
sure gauge bar and fill nitrogen into the system, wheels on both service adapters.
until a pressure of approx. 3.5 to 5.0 bar is indicat- 28 Fit all valves with dust caps.
ed on the suction side. 29 Perform a leak test.
11 Then open the blue hand wheel and raise the 30 Mark the system with the corresponding type
pressure in the suction side (max. 10 bar). Check plates and information decals, such as type of oil
for leaks with a leak detection fluid or soapsuds. 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 pres-
sure gauges show -1, close all hand wheels on the
pressure gauge bar.
16 Switch off the vacuum pump, watch the pressure
gauges to see whether the vacuum is maintained.
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 pres-

008 924 17 BOMAG 321

11.16 Trouble shooting in refrigerant circuit, basic principles

11.16Trouble shooting in refriger-

ant circuit, basic principles

Basic principles
Requirements
For trouble shooting two requirements must be ful-
filled:
l Expert knowledge
l technical equipment

Technical equipment
Pressure gauge and thermometer are the most impor-
tant auxiliary means for trouble shooting. The refriger-
ant states, such as overheating and undercooling,
provide important information when performing trou-
ble shooting. Even your own senses should not be un-
derrated in trouble shooting. Bubbles in the inspection
glass, contamination and white frost are visible indica-
tors. If the compressor draws in wet steam, this is vis-
ible in the suction line and may also be audibly Fig. 2 Pressure gauge
perceptible. An overloaded compressor can even be
Example:
smelled.
A totally empty air conditioning system holds an at-
The following tools and auxiliary means should be
mospheric pressure of approx. Pambp = 1 bar.
available for trouble shooting:
Filling the system with refrigerant causes an overpres-
l
Service station
sure of Pe = 3 bar.
l
Pressure gauge
l
Thermometer Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
l
dry nitrogen Evacuating the system down to Pe = -0.6 bar, creates
a "vacuum" (negative overpressure).
l
Refrigerant bottle for new refrigerant
l
Container for old oil Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
l
Vacuum pump
l
Hoses
l Scales
l Suction station
l Leak detector
The measuring equipment must be checked at regular
intervals. Calibration can only be made by an ap-
proved testing authority.

Pressure gauge
Most pressure gauges used in practice are (for cost
reasons) overpressure 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 = Overpressure (pressure gauge reading)

322 BOMAG 008 924 17

Trouble shooting in refrigerant circuit, basic principles 11.16
Pressure gauge with saturation temperature scale not compressible and must therefore not enter into the
compression chamber of the compressor.
If the suction condition of the compressor is directly on
the dew line, an e.g. incorrect evaporator load can
cause "wet suction". This can lead to two processes,
which are destructive for the compressor. The liquid
refrigerant washes off the lubricating film between pis-
ton and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in
the cylinder causes a direct energy transfer from pis-
ton to cylinder cover during compression. The valve
plate may then be damaged by so-called fluid strokes.
Apart from protecting the compressor against fluid,
overheating has further advantages. Since the fluid
proportions in the drawn in steam reduces the flow
rate of the compressor, it may be increased by a over-
heating. Overheating also improves the oil recircula-
tion.

Common overheating values

The optimal overheating value is approx. 5 - 8 Kelvin.
Fig. 3 Absolute pressure gauge With this overheating the maximum system power is
Temperature scales on the pressure gauges always reached. However, the thermostatic expansion valve
refer to the absolute pressures Pabs. Please note that is unable to regulate this value exactly. Depending on
it is not possible to measure a temperature directly design and operating conditions overheating fluctu-
with a pressure gauge. The indicated temperatures ates within a range between 4 and 12 Kelvin. The in-
are just reference values. Only the saturation temper- fluence of the ambient air on the suction line causes
ature is assigned to the measured pressure. an additional overheating effect.
If the refrigerant is fluid, the temperature is below the Overheating is calculated as follows:
saturation temperature.
Δ to2h = to2h - to
If the refrigerant is gaseous, the temperature is above
the saturation temperature. Δ to2h, overheating at evaporator outlet in K
Pressure gauges must indicate 0 bar when not con- to2h, temperature at evaporator outlet in °C
nected to the system. to, evaporation temperature in °C
Low pressure gauges have a blue, high pressure "h" represents "overheated"
gauges a red border.

Thermometer Supercooling
The thermometers used are normally digital thermom-
eters with surface or attachment sensors. Good heat
It is the function of the expansion valve to reduce the
insulation of the measuring location must be assured,
refrigerant to a lower pressure level (evaporation
especially in case of big temperature differences. An
pressure) after it has been liquefied. For an optimal
economical use of heat-conduction paste is recom-
function of the valve pure fluid must be applied to its
mended. If the measuring location is excessively con-
inlet port.
taminated, it needs to be cleaned and possibly treated
with a fine emery cloth. Only the temperature of the The refrigerant must "squeeze" (literally speaking)
sensor is measured. Temperature differences be- through a throttle gap inside the expansion valve.
tween the measured and the actual values of a few When comparing a certain mass of refrigerant in liquid
degree Kelvin may be caused by missing heat insula- and vaporous condition (under constant pressure),
tion and by insulating oxide layers on the cable. the vaporous refrigerant requires a much higher vol-
ume. That's why the vaporous refrigerant needs a
much longer time to "squeeze" through the throttle
Overheating
gap.
Vaporous refrigerant in front of the expansion valve
Due to its design a refrigerant compressor can only reduces the flow rate and results in an undersupply of
deliver gaseous or vaporous substances. Fluids are the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.

008 924 17 BOMAG 323

11.16 Trouble shooting in refrigerant circuit, basic principles

If the refrigeration system is operated with the "expan-

sion valve inlet" condition directly on the boiling curve,
slightest fluctuations in operating condition may cause
a formation of bubbles in front of the expansion ele-
ment.
For this reason one shifts the condition "Expansion
Valve Inlet" away from the boiling curve into the fluid
area and refers to this condition as Supercooling. This
supercooling ensures a fluid supply in front of the ex-
pansion valve.

Common supercooling values

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

Supercooling is calculated as follows:

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"

324 BOMAG 008 924 17

Trouble shooting in refrigerant circuit, basic principles 11.16

Fig. 1 Refrigerant circuit with t, h- diagram

Pos Designation Pos Designation

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

008 924 17 BOMAG 325

11.17 Trouble shooting, refrigerant circuit diagram

11.17Trouble shooting, refrigerant

circuit diagram

Fig. 1 Refrigerant circuit diagram

Pos. Designation Pos. Designation

1 Cold air 9 Pressure switch with high and low pressure contacts
2 Evaporator 10 Dryer
3 Thermostat 11 Fluid container
4 Warm air 12 Hot air
5 Gebläse 13 Compressor
6 Inspection glass 14 Condenser
7 Expansion valve 15 Cooling air
8 Pressure gauge, high pressure 16 Pressure gauge, low pressure

326 BOMAG 008 924 17

Trouble shooting procedure 11.18
11.18Trouble shooting procedure l Evaporator and heating (with highest fresh air fan
speed) do not draw leak air.
l The fresh air fan runs when the engine is running
Procedure
and the air conditioning system is set to max. cool-
Knowledge ing power.
Trouble shooting is not possible with exact knowledge
l Ambient temperature above 15 °C.
about the system design, the installed components l The thermostat is correctly installed and the switch-
and their function in the system trouble shooting is not ing temperatures are correct.
possible:

Visual inspection
With the appropriate experience some faults can be
visually detected or felt. Frequently occurring con-
denser soiling or formation of steam bubbles in the in-
spection glass can be quickly detected.
In case of unusual formation of hoarfrost on the evap-
orator the hoarfrost pattern provides useful informa-
tion. Hoarfrost only occurring at the inlet side is a clear
indication of insufficient refrigerant feed, which in turn
indicates an incorrectly working expansion valve or a
lack of refrigerant.. Complete hoarfrost covering indi-
cates load problems, i.e. no or insufficient air flow.
Even overheating can sometimes be detected with the
naked eye. At the end of the evaporator there should
be an area which is dry or at least drier at evaporator
temperatures above -2 °C.
The fluid line in the refrigeration system is warm. If a
local cooling can be felt or if condensation develops,
this is a clear indicator for an extreme pressure drop
in the line. Similar phenomena can be noticed in case
of blocked filters.
Unusually cold pressure lines indicate "wet" intake of
the compressor.
The oil level in the compressor sight glass provides in-
formation about the oil quantity and the oil recircula-
tion in the system. However, the oil level may also be
considerably influenced by condensing refrigerant.
Discoloration informs about the state of the oil.
Water in the system can simply be detected through
the inspection glass with moisture indicator.

i Note
The dangerous part of common rules is that they ap-
ply in most, but not in all cases. The refrigerant states
in the individual piping sections or components must
therefore be exactly determined by means of pressure
and temperature measurements.

Test prerequisites
l Cooler and condenser are clean, clean if neces-
sary.
l The ribbed belt for compressor and generator is
correctly tightened.
l All air ducts, covers and seals are OK and correctly
fitted. Flaps reach their end positions.
l The engine has operating temperature.

008 924 17 BOMAG 327

11.18 Trouble shooting procedure

Measuring points and measurements

Fig. 2 Flow diagram with measuring points to assess the filling quantity. In systems with fluid con-
l C, condenser measuring points tainer the inspection glass is most suitable to check
l E, expansion valve measuring points the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
l O, evaporator measuring points
The hot gas temperature can be used to check wheth-
l V, compressor measuring points
er the compressor runs in the permissible operating
The flow diagram contains "Minimum Requirements" range.
which must be fulfilled to be able to check the system
or perform trouble shooting. Example: Measurement of overheating
Temperature and pressure at the evaporator outlet
l a) Which measuring equipment is required?
can be used to derive the overheating of the evapora- l b) Where to measure with which size?
tor. Overheating is a clear indicator for the evaporator l c) A pressure gauge connected to the evaporator
filling level. In case of excessive overheating the re- indicates "Peo2 = 1.7 bar". How high is the evapora-
frigerant quantity fed into the evaporator is too low, in tor pressure "Po" ?
case of insufficient overheating it is too high. In indi-
vidual cases one must then check if this situation is l
d) How high is the evaporator temperature "to" ?
caused by the expansion element or by insufficient fill- l e) A thermal sensor attached to the evaporator out-
ing. A differentiation is only possible if there is a clear let measures the temperature "to2h = +3 °C". How
indicator for the refrigerant filling quantity. high is the overheating „Δto2h“ ?
Pressure and temperature at the condenser outlet can l
f) Evaluation of the measured overheating.
be used to derive the supercooling. This can be used

328 BOMAG 008 924 17

Trouble shooting procedure 11.18
Solution: be a defect in the expansion valve or problems in the
l a) Pressure gauge, thermometer, steam table oil recirculation.
l b) Evaporation pressure "Peo2" and temperature The following list contains pressure values in a sys-
"to2h" are measured at the same point on the evap- tem, that can be expected at various ambient temper-
atures (measured at medium speeds).
orator outlet.
l c) Po = Peo2 + Pamb, "Evaporation pressure = Suction pressure (low pressure gauge)
pressure on evaporator + atmospheric pressure" =
Ambient temperature in °C Excess pressure in bar
1.7 bar + 1 bar = 2.7 bar.
25 approx. 2,0
l
d) "Pc" = 2,7 bar can then be used to derive an con- 30 approx. 2,5
densing temperature "to" of -2,2 °C from the steam 35 approx. 3
table for R134a. High pressure (high pressure gauge)
l e) Δto2h = to2h - to, „Overheating at evaporator out-
Ambient temperature in °C Excess pressure in bar
let = evaporator outlet temperature - evaporation
temperature" = 3 °C - (-2.2 °C) = 5.2 Kelvin. 25 approx. 8,0
35 approx. 13
l f) The determined overheating is within the usual
40 approx. 16
range of 4 - 12 Kelvin.
45 approx. 18
Example: Measuring supercooling
l a) Which measuring equipment is required?
l
b) Where to measure with which size?
l
c) A pressure gauge connected to the condenser in-
dicates "Pec2 = 15 bar". How high is the condensing
pressure "Pc" ?
l
d) How high is the condensing temperature "tc" ?
l
e) A thermal sensor attached to the condenser out-
let measures the temperature "tc2u = 58 °C". How
high is the supercooling "Δtc2u" ?
l
f) Evaluation of the measured supercooling.

Solution:
l
a) Pressure gauge, thermometer, steam table
l
b) Condensing pressure "Pec2" and temperature
"tc2u" are measured at the same point on the con-
denser.
l c) Pc = Pec2 + Pamb, "Evaporation pressure =
pressure on evaporator + atmospheric pressure" =
15 bar + 1 bar = 16 bar.
l d) "Pcc = 16 bar can then be used to derive an con-
densing temperature "tc" of 57.9 °C from the steam
table for R134a.
l e) Δtc2u = tc - tc2u, "Supercooling at condenser out-
let = condensing temperature - condenser outlet
temperature" = 57.9°C - 58 °C) = -0.1 Kelvin.
l f) The determined overheating is within the usual
range of approx. "0" Zero Kelvin.

Typical faults and possible causes

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

008 924 17 BOMAG 329

11.18 Trouble shooting procedure

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

330 BOMAG 008 924 17

Trouble shooting procedure 11.18
Suction pressure too low (1), high pressure too
low to normal (2)

Fig. 3

Cause Possible effect Remedy

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

008 924 17 BOMAG 331

11.18 Trouble shooting procedure

Suction pressure normal (1), high pressure too

Paragraphs marked like this highlight possible

dangers for persons.

344 BOMAG 008 924 17

Preparations 12.1
12.1 Preparations

! Danger

Danger of accident!
For transport purposes the driver's seat must be
tied down with cable straps thus to operate the
seat contact switch. Before resuming operation of
the machine these cable straps must strictly be re-
moved to ensure safe and reliable function of the
seat contact switch.
Check the 4 lifting eyes on the cabin roof for tight
fit. Fig. 8
Fasten the lifting gear to all four lifting eyes. l Fasten the lifting gear to the four lifting eyes 1 (Fig.
Use lifting gear (chains or ropes) of sufficient load 8).
bearing capacity. The minimum load bearing ca- l Loosen possible fastening on the transport pallet.
pacity of the crane must be 1000 kg.
l Slowly list the crane with a crane.
Do not stand or step under loads being lifted.

Danger
!

Danger of accident!
Do not stand or step under loads being lifted.

Fig. 7
l
Make sure that all fastening screws, washers, spac-
ers and nuts to fasten the cabin are available (Fig.
7).
l
Check whether rear rack, foot mat, step plate and
fastening kit are available.

008 924 17 BOMAG 345

12.2 Cabin assembly

12.2 Cabin assembly i Note

Mount the cabin immediately after sticking on the
! Danger
sealing tape, because the sealing tape will swell.
Danger of accident!
Use lifting gear (chains or ropes) of sufficient load
bearing capacity. The minimum load bearing ca-
pacity of the crane must be 1000 kg.
Do not stand or step under loads being lifted.
l Clean the operator's stand of dirt, oil and moisture.

Fig. 11
l Spray the sealing tape with soapsuds (Fig. 11), to
be able to slide the cabin on the operator's stand.

Fig. 9
l
Stick the supplied sealing tape 1 (Fig. 9) along the
edge of the operator's stand.

!Caution
Only unroll and stick the sealing tape on just be-
fore mounting the cab to the operator's stand. The
sealing tape will swell a few minutes after being
unrolled. In this case the cabin can no longer be
Fig. 12
mounted!
l Slowly lower the cabin vertically to the operator's
stand (Fig. 12).

Caution
!

The cabine must be lowered vertically onto the op-

erator's stand.

Fig. 10
l Stick the sealing tape 1 (Fig. 10) all around the op-
erator's stand.
l Do not run the sealing tape across the front recess
in the operator's stand (2), since this is the air inlet
for the cabin ventilation.

346 BOMAG 008 924 17

Cabin assembly 12.2

Fig. 13 Fig. 16
l Tighten the bottom fastening screw on the access
Caution
! side (Fig. 16) with 578 Nm.
Take care that none of the hoses and electric ca-
bles become squashed (Fig. 13).
l Run cables and hoses from inside the cabin through
the operator's stand to the outside.

Fig. 17
l Loosen both fastening screws (Fig. 17) at the rear
of the cabin again.

Fig. 14 i Note
l Turn both fastening screws (Fig. 14) at the rear of The cabin will now slide into final assembly position.
the cabin in handtight. l Tighten both fastening screws (Fig. 17) at the rear
of the cabin with 578 Nm.

Fig. 15

Fig. 18
i Note l
Tighten the rear lateral fastening screw on the left
If the bores do not match the cabin can be moved into hand side with 578 Nm (Fig. 18).
position by means of a crow bar (Fig. 15).

008 924 17 BOMAG 347

12.2 Cabin assembly

Fig. 19 Fig. 22
l Tighten the rear lateral fastening screw on the right l Tighten the front lateral fastening screw on the right
hand side with 578 Nm (Fig. 19). hand side with 578 Nm (Fig. 22).

Fig. 20 Fig. 23
l Tighten the rear inside fastening screw on the right l Tighten the front lateral fastening screw on the left
hand side with 578 Nm (Fig. 20). hand side with 578 Nm (Fig. 23).

Fig. 21 Fig. 24
l Turn nuts with washers onto both studs and tighten l Cover all lateral fastening screws with plastic caps
with 200 Nm (Fig. 21). (Fig. 24).

348 BOMAG 008 924 17

Cabin assembly 12.2

Fig. 25 Fig. 28
l Insert the foot mat 1 (Fig. 25). l Insert the rear rack and knock both plastic fasteners
carefully into the bores with a hammer (Fig. 28).

Fig. 26
Fig. 29
l Attach the step plate 1 (Fig. 26) and tighten the
three fastening screws (2). l Connect the feed 1 (Fig. 29) and the return flow (2)
for the air conditioning system with quick release
couplings.
l Connect the feed (4) and the return flow (3) of the
heating. (Observe the marks on the hoses).

i Note
Run the connecting lines for the heating parallel to
each other (do not cross).

i Note
Check the function of air conditioning and heating
within the scope of the function test.
Fig. 27 Observe identical hose diameters when connecting.
l Insert the dashboard and fasten it with four fasten-
ing screws (Fig. 27).

008 924 17 BOMAG 349

12.2 Cabin assembly

Danger
!

Before starting to work on electric parts of the ma-

chine disconnect the battery and cover it with in-
sulating material.

Fig. 30
l Plug on both connecting plugs for the washing wa-
ter pumps (Fig. 30).

Fig. 33
l Connect the plug connection of the air conditioning
system (Fig. 33).

Fig. 31
l Plug on the hoses for the washing water supply to
front and rear windscreens 1 (Fig. 31).

i Note
Check the function of the washing water system within
the scope of the function test.

Fig. 32
l
Insert the plug 1 (Fig. 32) into the socket (2).
l
Close the bayonet catch by turning the corrugated
cap nut in clockwise direction against the stop.

350 BOMAG 008 924 17

Final function tests and checks 12.3
12.3 Final function tests and
checks

Caution
!

Make sure that all screws have been tightened

with the specified torque.

i Note
After the cabin assembly the following tests must be
performed to assure that all cables and lines are cor-
rectly connected.
l Insert the ignition key and turn clockwise to position
"1".
l Operate the switches for headlights, direction indi-
cators and interior light to check their function.
l Operate the switches for front and rear windscreen
washer system and check their correct function.

i Note
If the function of the windscreen washer system is re-
versed, the two washing water hoses must be inter-
changed.
l
Start the engine.
l Switch the air conditioning on by the switch. After a
five minute operation the cabin must become no-
ticeably cooler.
l
Switch the air heater on by the switch. After a five
minute operation the cabin must become noticeably
warmer.
l
Function of the seat contact switch.

!Caution
The machine must not be operated if the seat con-
tact switch is not functioning correctly.

008 924 17 BOMAG 351

12.3 Final function tests and checks

352 BOMAG 008 924 17

13 Replacing the cab window panes

008 924 17 BOMAG 353

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

354 BOMAG 008 924 17

Special tools, cabin windows 13.2
13.2 Special tools, cabin windows
1. Locking handle for fastening element

BOMAG part-no.: 055 705 84

Fig. 1
2. Suction lifter

commercial

Fig. 2
3. Cutter

Commercial

Fig. 3

008 924 17 BOMAG 355

13.3 Auxiliary materials

Safety gloves
4. Cutter

Commercial

Fig. 1
5. Window glass bonding agent

BOMAG part-no.: 009 780 32

Fig. 2
6. Activator

BOMAG part-no.: 009 780 33

Fig. 3

356 BOMAG 008 924 17

Auxiliary materials 13.3
7. Silicone sealant

BOMAG part-no.: 009 700 36

Fig. 4

008 924 17 BOMAG 357

13.4 Removing and installing the window pane

13.4 Removing and installing the window

pane

Environmental damage
Dispose of glass splinters fro0m machine and
cabin or inside cabin in an environmentally
friendly way.

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

358 BOMAG 008 924 17

Removing and installing the window pane 13.4
6. Turn the fixing and spacer washer hand-tight onto
the thread of the fastening element (Fig. 4).

i
Do not overtighten the thread.

Fig. 4
7. Lay an approx. 1 cm high triangular bead of glass
pane bonding agent on the inside of the pane, ap-
prox. 1.5 cm away from the edge (Fig. 5).

i
Apply window pane bonding agent only to the
sides (sealing areas) which have contact with the
cabin.

Fig. 5
8. Attach the suction lifter to the outside of the pane
(Fig. 6).
9. Install the window pane so that the fastening ele-
ments fit into the bores of the fastening bars.
10. Press the glass pane against the sealing surface.

Fig. 6
11. Assemble the washer and the self-locking hexa-
gon nut.
12. Fasten the window pane to the fastening bar us-
ing a locking handle and a ring spanner (Fig. 7).

i
Only use the locking handle to counter.
13. Press the protective cap onto the hexagon nut.

Fig. 7

008 924 17 BOMAG 359

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
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

360 BOMAG 008 924 17

Removing and installing the window pane 13.4
19. Then spray the joints from inside and outside with
water containing washing up liquid (Fig. 12).

Fig. 12
20. Treat the inside joint (Fig. 13)

Fig. 13
21. and the outside joint (Fig. 14) with a scraper or a
spattle.

i
Once the silicone sealing agent has cured it can
only be removed mechanically.

Fig. 14

008 924 17 BOMAG 361

13.4 Removing and installing the window pane

362 BOMAG 008 924 17

14 Drum

008 924 17 BOMAG 363

14.1 Special tools, drum, single drum rollers

14.1 Special tools, drum, single drum roll-

ers
1. Disassembly device for side plate

BOMAG part-no.: 007 211 55

Fig. 1
2. Assembly device for side plate

BOMAG part-no.: 971 079 21

Fig. 2
3. Assembly device for coupling hub and flanged
hub

Fig. 3

364 BOMAG 008 924 17

Special tools, drum, single drum rollers 14.1
4. Pressing plate for cylinder roller bearing

Fig. 4
5. Pressing plate for travel bearing

Fig. 5
6. Pressing bushing for radial seal

Fig. 6
7. Lifting device for exciter unit

BOMAG part-no.: 007 215 08

Fig. 7

008 924 17 BOMAG 365

14.2 Repair overview for drum

Fig. 1

Removing and installing the drum 14.3
14.3 Removing and installing the drum

i
After disassembling the side plate (vibration mo-
tor side) the drum can be lifted sideways out of
the frame (Fig. 1).

Fig. 1

i
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
The following section describes the procedure for
lifting the frame sideways out of the drum.

Environmental damage
Catch running out hydraulic oil and dispose
of environmentally.
8. Mark the hydraulic hoses (Fig. 3)on the travel mo-
tor and disconnect them from the ports.
9. Close all hydraulic hoses and motor ports with
suitable plugs.

Fig. 3

008 924 17 BOMAG 375

14.3 Removing and installing the drum

10. Mark the hydraulic hoses on the vibration motor

(Fig. 4) and disconnect them from the ports.
11. Close all hydraulic hoses and motor ports with
suitable plugs.

Fig. 4

Danger of squashing! Do not stand or step

under loads being loaded.
Always secure the machine against unintend-
ed rolling!
12. Unscrew bolts 1 (Fig. 5) and nuts and remove the
front scraper (2).
13. Unscrew bolts (3) and nuts and remove the rear
scraper (4).

Fig. 5
14. Support the front cross-member safely with suita-
ble trestles or wooden blocks (Fig. 6).

Fig. 6
15. Support the rear cross-member safely with suita-
ble trestles or wooden blocks (Fig. 7).

Fig. 7

376 BOMAG 008 924 17

Removing and installing the drum 14.3
16. Disassemble bracket 1 (Fig. 8) for the hydraulic
hoses.

Fig. 8
17. Fasten the lifting gear to the side plate on the vi-
bration motor side.
18. Unscrew bolts 1 (Fig. 9) from the spacer blocks
on vibration and travel motors.

Fig. 9

Danger of squashing! Do not stand or step

under loads being loaded.
19. Force out plug 1 (Fig. 10) and unscrew the bolts
(2) from the front and rear cross-members.
20. Take off the side plate.

Fig. 10
21. Fasten the lifting tackle to the drum and lift the
drum carefully sideways out of the front frame
(Fig. 11).

Danger of squashing! Do not stand or step

under loads being loaded.

Fig. 11

008 924 17 BOMAG 377

14.3 Removing and installing the drum

22. Check all rubber buffers (Fig. 12), replace if nec-

essary (see corresponding chapter).

Fig. 12
23. Check rectangular rubber buffers (Fig. 13), re-
place if necessary.

Fig. 13

Installing the drum

Danger of squashing!
Do not stand or step under loads being load-
ed.
1. Place the drum into the frame and align it parallel
to the frame (Fig. 14).

Fig. 14

i
Apply sliding lacquer OKS 240 to threads and
screw head contact face to ease assembly.
2. Attach the side plate, insert the bolts 2 (Fig. 15)
into rear and front cross-members and tighten
with 463 Nm.
3. Close the screw holes with plugs (1).

Fig. 15

378 BOMAG 008 924 17

Removing and installing the drum 14.3
4. Fasten the spacer blocks on travel and vibration
motor sides with bolts 1 (Fig. 16) and nuts to the
side plates.

Fig. 16
5. Connect hydraulic hoses to the connections on
travel motor and vibration motor according to the
marking (Fig. 17).

Fig. 17
6. Fasten bracket 1 (Fig. 18) for the hydraulic hoses.

Fig. 18
7. Assemble the front scraper 2 (Fig. 19), fasten
with bolts (1), washers and nuts.
8. Assemble the rear scraper (4), fasten with bolts
(3), washers and nuts.

i
Observe the adjustment measurement 30-35 mm

Fig. 19

008 924 17 BOMAG 379

14.3 Removing and installing the drum

Before resuming operation of the machine:

Bleed the hydraulic system and check for
function and leaks.
Adjust the pretension of the rubber buffers.
9. On the vibration drive side measure the distance
"X" between spacer block and side plate (Fig. 20).
10. Calculate the thickness of the compensation
plates.

Nominal value:

Fig. 20
Distance "X" + 2 mm

i
Compensation plates of 2 and 5 mm thickness
are available.
11. Turn in screws into each welded nut (Fig. 21) and
provide sufficient space to insert the compensa-
tion plates.

Fig. 21
12. Insert the compensation plates (Fig. 22).
13. Turn in the fastening screws.
14. Unscrew the screws from the welded nuts.
15. Tighten the fastening screws.

Fig. 22

380 BOMAG 008 924 17

Repairing the drum 14.4
14.4 Repairing the drum

Removing the travel motor

Danger of squashing!
Do not stand or step under suspended loads.
1. Attach the lifting tackle to travel drive 3 (Fig. 3).
2. Unscrew all nuts (1) from the rubber buffers.
3. Take drive disc (2) with travel drive off the rubber
buffers and lay it down.

Fig. 1
4. Unscrew fastening screws 3 (Fig. 4) and take off
support legs (4).
5. Unscrew fastening screws 1 and take off drive
disc (2).

Fig. 2

Disassembling the exciter unit (travel

motor side)
1. Unscrew both socket head cap screws from the
flange (Fig. 3).

Fig. 3

008 924 17 BOMAG 381

14.4 Repairing the drum

2. Mount bracket 1 (Fig. 10) for the lifting device to

the flange.
3. Unscrew screws (2) from the flange.

i
Do not unscrew the thin drawn screws.

Fig. 4
4. Slide the lifting device over the bracket.
5. Force the exciter unit off with two forcing screws
(Fig. 5).

Fig. 5

Danger of squashing!
Do not stand or step under suspended loads.
6. Pull the exciter unit out of the drum (Fig. 6).
7. Take the coupling element off the coupling half.

Fig. 6

382 BOMAG 008 924 17

Repairing the drum 14.4
Disassembling the exciter unit (travel
motor side)
1. Unscrew fastening screws 1 (Fig. 7) for the fan.
2. Loosen clamping screw (2).
3. Pull the coupling hub off the shaft.

Fig. 7
4. Unscrew all other fastening screws 1 (Fig. 8) from
the flange.
5. Press the flange off the flanged housing with forc-
ing screws (2).

Fig. 8

Environmental damage!
Catch running out oil and dispose of environ-
mentally.
6. Lift the flange off the flanged housing (Fig. 9).
7. Take the O-ring out of the groove in the flanged
housing.

Fig. 9

008 924 17 BOMAG 383

14.4 Repairing the drum

8. Unclip the circlip from the groove in the flange

(Fig. 10).

Fig. 10
9. Press the cylinder roller bearing with forcing
screws out of the flange (Fig. 11).

Fig. 11
10. Lift the exciter unit out of the flanged housing(Fig.
12).

Fig. 12
11. Knock the radial seal (Fig. 13) out of the flanged
housing.

Fig. 13

384 BOMAG 008 924 17

Repairing the drum 14.4
12. Unclip the circlip from the groove in the flanged
housing (Fig. 14).

Fig. 14
13. Press the cylinder roller bearing with forcing
screws out of the flanged housing (Fig. 15).

Fig. 15
14. Extract inner ring 1 (Fig. 16) for the radial seal
and inner bearing races (2).

Danger of burning!
Wear safety gloves.

i
If the rings are very tight, heat them up with a
torch.

Fig. 16
15. Unclip the circlip from the basic weight (Fig. 17).

Fig. 17

008 924 17 BOMAG 385

14.4 Repairing the drum

16. To change shaft 1 (Fig. 18) knock out dowel pins

(2 and 3) and press the shaft out of the basic
weight.

i
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).

Fig. 18

Disassembling the exciter unit (vibra-

tion motor side)
1. Unscrew fastening screw 1 (Fig. 19).
2. Take rectangular rubber buffer (2) with spacer
block (3) off the side plate.

i
Remove both rectangular rubber buffers.

Fig. 19
3. Unscrew fastening screws 1 (Fig. 20).
4. Force cover (2) together with the attached vibra-
tion motor off the side plate with forcing screws.

Fig. 20

386 BOMAG 008 924 17

Repairing the drum 14.4
5. To change the vibration motor loosen clamping
screw 1 (Fig. 21) and pull off coupling half (2).

Fig. 21
6. Unscrew nut 1 (Fig. 22), take off conical socket
(2) and conical disc (3).
7. Take the vibration motor off the cover.

Fig. 22
8. Remove the coupling element (Fig. 23).

Fig. 23
9. Fasten the lifting device.
10. Unscrew fastening screws 1 (Fig. 24).

The four short fastening screws (2) must re-

main screwed in (the two others are not visi-
ble).

Fig. 24

008 924 17 BOMAG 387

14.4 Repairing the drum

11. Press the exciter unit out of the drum with forcing
screws (Fig. 25).

i
The second forcing screw is covered by the side
plate.

Fig. 25

Danger of squashing!
Do not stand or step under suspended loads.
12. Pull the exciter unit out of the drum (Fig. 26).

Fig. 26

Removing, dismantling the side plate

1. Take off V-ring 1 (Fig. 27).
2. Unclip circlip (2).

Fig. 27
3. Attach the disassembly device to the side plate
(Fig. 28) and force off the side plate.

Fig. 28

388 BOMAG 008 924 17

Repairing the drum 14.4
4. Lift the side plate of the flanged hub (Fig. 29).

Fig. 29
5. Knock the grooved roller bearing out of the side
plate (Fig. 30) and take out the spacer ring.

Fig. 30
6. Unclip the circlip from the side plate (Fig. 31).

Fig. 31
7. Take the mechanical seal off the flanged hub
(Fig. 32).

Fig. 32

008 924 17 BOMAG 389

14.4 Repairing the drum

Dismantling the exciter unit (vibration

motor side)
1. Unscrew the fastening from the coupling hub.
2. Pull coupling hub (2) off the shaft using a pulling
device (Fig. 33).

Fig. 33
3. Loosen hose clamp 1 (Fig. 34).
4. Pull coupling hub (2) off the shaft.

Fig. 34
5. Unscrew all other fastening screws 1 (Fig. 35)
and press the flanged hub off the flanged housing
with forcing screws (2).
6. Take off the flanged hub.
7. Take the O-ring out of the groove in the flanged
housing.

Fig. 35

390 BOMAG 008 924 17

Repairing the drum 14.4
8. Unclip the circlip from the groove in the flanged
hub (Fig. 36).

Fig. 36
9. Knock the cylinder roller bearing out of the flang-
ed hub(Fig. 37).

Fig. 37

Environmental damage!
Catch running out oil and dispose of environ-
mentally.
10. Lift the exciter unit out of the flanged housing(Fig.
38).

Fig. 38
11. Knock the radial seal (Fig. 39) out of the flanged
housing.

Fig. 39

008 924 17 BOMAG 391

14.4 Repairing the drum

12. Unclip the circlip from the groove in the flanged

housing (Fig. 40).

Fig. 40
13. Press the cylinder roller bearing with forcing
screws out of the flanged housing (Fig. 41).

Fig. 41
14. Extract inner rings 1 (Fig. 42) for the radial seals
and inner bearing races (2) from the shaft.

Danger of burning!
Wear protective gloves.

i
If the rings are very tight, heat them up with a
torch.

Fig. 42
15. Unclip the circlip from the basic weight and re-
move the cover (Fig. 43).

i
The shafts cannot be pressed out. If damaged
they must be replaced with basic weight and cov-
er.
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).

Fig. 43

392 BOMAG 008 924 17

Repairing the drum 14.4
Assembling the exciter unit (vibration
motor side)
!

Ensure strict cleanliness.

i
If the shafts are damaged they must be inserted
into the basic weight or the cover as follows.

When working with liquid nitrogen protect

your face and wear gloves.
Do not place any unintended parts into liquid
Fig. 44 nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.

Close the bores on the short shaft with a

screw.
1. Cool the shaft down in liquid nitrogen.
2. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
44).
3. Secure shaft 1 (Fig. 45) with dowel pins (2 and 3).

Assemble the dowel pins with the grooves

offset by 180° to each other, but in line with
the axis of the shaft.

i
Unscrew the screw from the shaft.

Fig. 45

Close the bores on the short shaft with a

screw.
4. Cool the shaft down in liquid nitrogen.
5. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
46).

Fig. 46

008 924 17 BOMAG 393

14.4 Repairing the drum

6. Secure shaft 2 (Fig. 47) with dowel pins (1 and 3).

Assemble the dowel pins with the grooves

offset by 180° to each other, but in line with
the axis of the shaft.

i
Unscrew the screw from the shaft.

Fig. 47
7. Insert the fitting key into the keyway in the respec-
tive shaft (Fig. 48).

Fig. 48
8. Insert the circlip into the groove in the basic
weight and on the cover (Fig. 49).

Fig. 49

Danger of burning!
Wear safety gloves.
9. Heat the inner bearing race up to approx. 100° C
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 50).

Fig. 50

394 BOMAG 008 924 17

Repairing the drum 14.4
!

Danger of burning!
Wear safety gloves.
10. Heat the inner ring up to approx. 50° C and slide
it onto the short shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 51).

Fig. 51

Danger of burning!
Wear safety gloves.
11. Heat the inner bearing race up to approx. 100° C
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 52).

Fig. 52

Danger of burning!
Wear safety gloves.
12. Heat the inner ring up to approx. 50° C and slide
it onto the longer shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 53).

Fig. 53
13. Press cylinder roller bearing 1 (Fig. 54) with
pressing plate (2) into the flanged housing until it
bottoms.

Fig. 54

008 924 17 BOMAG 395

14.4 Repairing the drum

14. Insert the circlip into the groove in the flanged

housing (Fig. 55).

Fig. 55
15. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 56).
16. Fill approx. 1.2 l of oil SAE-15W/40 into the flang-
ed housing.

Fig. 56

Danger of squashing!
Do not stand or step under suspended loads.
17. Insert the exciter unit with the longer shaft for-
ward into the flanged housing (Fig. 57).

Fig. 57
18. Press cylinder roller bearing 1 (Fig. 58) with
pressing plate (2) into the flanged hub until it bot-
toms.

Fig. 58

396 BOMAG 008 924 17

Repairing the drum 14.4
19. Insert the circlip into the groove in the flanged hub
(Fig. 59).

Fig. 59
20. Attach the flanged hub to the flanged housing
(Fig. 60).

Fitting and contact surfaces must be abso-

lutely dry and free of grease, paint and con-
serving agents.
21. Unscrew eye bolts (1) and replace them with
short screws.
22. Turn short screws (2) into the tapped bores in the
flanged housing (four screws) and tighten them.

Fig. 60
23. Apply some grease to the sealing lip of radial seal
1 (Fig. 61).
24. Insert the radial seal into the flanged hub with the
sealing lip facing down and press it down against
the stop with pressing bushing (2).

Fig. 61

Danger of burning!
Wear protective gloves.
25. Heat the coupling hub up to approx. 80 °C and
slide it onto the shaft against the stop (Fig. 62).

Fig. 62

008 924 17 BOMAG 397

14.4 Repairing the drum

26. Apply some grease to the sealing lip of radial seal

1 (Fig. 63).
27. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).

Fig. 63
28. Cover the thread of screw 1 (Fig. 64) with a screw
retention agent (Loctite CVX strong, blue, 582).
29. Slide on the new U-seal ring (2), turn in and tight-
en the screws.

Fig. 64

Danger of burning!
Wear safety gloves.
30. Heat coupling hub 1 (Fig. 65) with marking letter
“L“ up to approx. 80° C and slide it over the shaft
against the shoulder.
31. Turn in and tighten clamping screw (2).

Fig. 65

398 BOMAG 008 924 17

Repairing the drum 14.4
Assembling and installing the side
plate
1. Fill grooved ball bearing 1 (Fig. 66) on both sides
with grease.
2. Press the grooved ball bearing completely in us-
ing pressing plate (2).

Fig. 66
3. Insert the circlip into the groove in the side plate
(Fig. 67).

Fig. 67
4. Apply a thick coat of grease to the spacer ring on
both sides and insert it into the side plate (Fig.
68).

Fig. 68

008 924 17 BOMAG 399

14.4 Repairing the drum

5. Fill grooved ball bearing 1 (Fig. 69) on one sides

with grease.
6. Insert the grooved ball bearing with the grease
side forward and press it completely in with
pressing plate (2).

i
Grease the other side after installing the exciter
unit.

Fig. 69
7. Insert the oiled loop-ring into the mechanical seal
(Fig. 70).
8. Clean the sliding surfaces of the mechanical seal
and cover them with oil.

Fig. 70
9. Lay one half of the radial seal on the flanged hub
with the sliding surface pointing up (Fig. 71).

Fig. 71
10. Lay the second half of the mechanical seal down
with the sliding face pointing down (Fig. 72).

Fig. 72

400 BOMAG 008 924 17

Repairing the drum 14.4
11. Bolt the threaded section of the assembly device
to the flanged hub (Fig. 73).

Fig. 73

Danger of squashing! Do not stand or step

under suspended loads.
12. Lay the side plate on the flanged hub (Fig. 74).

Fig. 74
13. Attach bushing 2 (Fig. 75) of the assembly device
and turn on nut (1).

Fig. 75
14. Pull the side plate with the assembly device onto
the flanged hub.

During assembly make sure that the mechan-

ical seal slides correctly into the side plate
and the loop rings are not damaged (Fig. 76).

Fig. 76

008 924 17 BOMAG 401

14.4 Repairing the drum

15. Remove the assembly device.

16. Insert the circlip into the groove in the flanged hub
(Fig. 77).

Fig. 77

Assembling the exciter unit (travel

motor side)
!

When working with liquid nitrogen protect

your face and wear gloves.
Do not place any unintended parts into liquid
nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.

Ensure strict cleanliness.

1. Cool the shaft down in liquid nitrogen.
Fig. 78
2. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
78).
3. Secure shaft 1 (Fig. 79) with dowel pins (2 and 3).

Assemble the dowel pins with the grooves

offset by 180° to each other, but in line with
the axis of the shaft.

Fig. 79

402 BOMAG 008 924 17

Repairing the drum 14.4
4. Insert the circlip into the groove in the basic
weight and on the cover (Fig. 80).

Fig. 80

Danger of burning!
Wear safety gloves.
5. Heat the inner bearing race up to approx. 100° C
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 81).

Fig. 81

Danger of burning!
Wear safety gloves.
6. Heat the inner ring up to approx. 50° C and slide
it onto the shaft against the shoulder with the wid-
er chamfer facing towards the outside (Fig. 82).

Fig. 82

Danger of burning!
Wear safety gloves.
7. Heat the inner bearing race up to approx. 100° C
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 83).

Fig. 83

008 924 17 BOMAG 403

14.4 Repairing the drum

8. Press cylinder roller bearing 1 (Fig. 84) with

pressing plate (2) into the flanged housing until it
bottoms.

Fig. 84
9. Insert the circlip into the groove in the flanged
housing (Fig. 85).

Fig. 85
10. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 86).
11. Fill approx. 1.2 l of oil SAE-15W/40 into the flang-
ed housing.

Fig. 86

Danger of squashing! Do not stand or step

under suspended loads.
12. Insert the exciter unit into the flanged housing
(Fig. 87).

Fig. 87

404 BOMAG 008 924 17

Repairing the drum 14.4
13. Press cylinder roller bearing 1 (Fig. 88) with
pressing plate (2) into the flange until it bottoms.

Fig. 88
14. Insert the circlip into the groove in the flange (Fig.
89).

Fig. 89
15. Lift the flange onto the flanged housing and align
it the bores (Fig. 90).

Fitting and contact surfaces must be abso-

lutely dry and free of grease, paint and con-
serving agents.

Fig. 90
16. Turn the screws into the tapped bores of the
flanged housing and tighten them (Fig. 91).

Fig. 91

008 924 17 BOMAG 405

14.4 Repairing the drum

17. Apply some grease to the sealing lip of radial seal

1 (Fig. 92).
18. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).

Fig. 92
19. Cover the thread of screw 1 (Fig. 93) with a screw
retention agent (e.g. Loctite CVX strong, blue,
582).
20. Slide on the new U-seal ring (2), turn in and tight-
en the screws.

Fig. 93
21. Insert the fitting key into the keyway of the shaft
(Fig. 94).

Fig. 94

Danger of burning!
Wear safety gloves.
22. Slide the fan with assembly disc over the shaft.
23. Heat coupling hub 1 (Fig. 95) with marking letter
“R“ up t approx. 80° C and slide it over the shaft
against the shoulder.
24. Turn in and tighten clamping screw (2).
25. Assemble the fan to the coupling hub.

Fig. 95

406 BOMAG 008 924 17

Repairing the drum 14.4
Assembling the exciter unit (travel
motor side)
1. Check coupling elements , replace if necessary.
2. Insert the coupling element into the coupling hub
(Fig. 96).

Fitting and contact surface of the connection

between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.
3. Fasten the lifting device to the exciter unit.

!
Fig. 96
Danger of squashing! Do not stand or step
under suspended loads.
4. Insert the vibrator unit into the drum (Fig. 97).

Fig. 97

i
Insert the exciter unit so that oil filler plug 1 (Fig.
98) is in line with bore (2) in the drum.

Fig. 98

008 924 17 BOMAG 407

14.4 Repairing the drum

5. Turn in and tighten screws 2 (Fig. 99).

6. Remove bracket (1) for the lifting device.

Fig. 99
7. Cover the thread of screws (Fig. 100) with a
screw retention agent (e.g. Loctite green 270).
8. Slide on the new U-seal ring, turn in and tighten
the screws.

Fig. 100

Installing the travel motor

1. Assemble drive disc 2 (Fig. 101) and support (4)
with screws (3).

Fig. 101

Danger of squashing!
Do not stand or step under suspended loads.
2. Attach the drive disc 2 (Fig. 102) with the assem-
bled travel drive to the rubber buffers. Turn on
and tighten the nuts (1).

Fig. 102

408 BOMAG 008 924 17

Repairing the drum 14.4
Installing the exciter unit (vibration
motor side)

Fitting and contact surface of the connection

between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.

Danger of squashing! Do not stand or step

under suspended loads.
1. Fasten the lifting gear to the exciter unit and insert
it into the drum (Fig. 103).

Fig. 103

Ensure correct engagement of coupling and

alignment of shaft (Fig. 104).
If the shafts are not correctly in line determine
the cause, if necessary measure the drum.

Fig. 104
2. Turn in and tighten screws 1 (Fig. 105).
3. Remove the lifting gear.
4. Fit cover (2) to the drum.

Fig. 105

008 924 17 BOMAG 409

14.4 Repairing the drum

5. Check the end float of the exciter shafts (Fig.

106).

Nominal value: 0.6...1.8 mm

Fig. 106
6. Attach disc 1 (Fig. 107), turn in and tighten the
fastening screws (2).

Fig. 107
7. Lay a new V-ring over the journal of the flanged
hub (Fig. 108).
8. Fill the grooved ball bearing with grease.

Fig. 108
9. Check coupling element , replace if necessary.
10. Insert the coupling element into the coupling hub
(Fig. 109).

Fig. 109

410 BOMAG 008 924 17

Repairing the drum 14.4
11. Fasten the vibration motor to the cover so that
sockets 1 (Fig. 110) and ventilation bore (2) are
opposite each other.

Fig. 110
12. Slide on coupling half 2 (Fig. 111) and secure with
clamping screw (1).

Fig. 111
13. Attach the cover with the installed vibration mo-
tor, turn in and tighten the screws (Fig. 112).

Fig. 112
14. Install rectangular rubber buffers 2 (Fig. 113) with
attached spacer block (3) and screws (1) to the
side plate.

i
Assemble both rectangular rubber buffers.

Fig. 113

008 924 17 BOMAG 411

14.5 Dismantling, assembling the change-over weights

14.5 Dismantling, assembling the change-

over weights

Dismantling the change-over weight

1. Unscrew all screws (Fig. 3).

Fig. 1
2. Force the cover off the basic weight with forcing
screws (Fig. 4).

Environmental damage!
Catch running out oil and dispose of environ-
mentally.

Fig. 2
3. Take the change-over weight out of the basic
weight (Fig. 5).

Fig. 3

412 BOMAG 008 924 17

Dismantling, assembling the change-over weights 14.5
4. Pull O-rings 1 and 2 (Fig. 4) out of the grooves.

Fig. 4

008 924 17 BOMAG 413

14.5 Dismantling, assembling the change-over weights

Assembling the change-over weights

Ensure strict cleanliness.

1. Install new O-rings 1 and 2 (Fig. 5) with grease.

Fig. 5
2. Insert the change-over weight into the basic
weight (Fig. 6).

Fig. 6
3. Fill silicon oil 47 V 1000 cst up to the upper edge
of the change-over weight (approx. 2,5 litres) into
the basic weight (Fig. 12).

Fig. 7
4. Attach the cover (Fig. 13), so that the raised are-
as are in line.
5. Turn in screws with screw retention agent (e.g.
Loctite blue 243) and tighten with 120 Nm.
6. Check the end float of the shaft.

i
There must be play.

Fig. 8

414 BOMAG 008 924 17

Changing the rubber buffers and adjusting the pretension 14.6
14.6 Changing the rubber buffers and ad-
justing the pretension
Relieve the rubber buffers
1. Lift the frame up by both sides, until rubber buff-
ers 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

008 924 17 BOMAG 415

14.6 Changing the rubber buffers and adjusting the pretension

5. Unscrew the screws (Fig. 4) from the welded

nuts.

Fig. 4

i
Check the rectangular rubber buffers, replace if
necessary.
Observe the assembly direction, arrow up.

Fig. 5
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. 6
Adjusting the pre-load
12. Measure distance "X" between spacer piece and
side plate (Fig. 7).
13. Calculate the thickness of the compensation
plates.

Nominal value:
Distance "X" + 2 mm

Fig. 7

416 BOMAG 008 924 17

Changing the rubber buffers and adjusting the pretension 14.6
14. Turn in screws into each welded nut and provide
sufficient space to insert the compensation plates
(Fig. 8).

Fig. 8
15. Assemble the compensation shims (Fig. 9).

Fig. 9
16. Unscrew the screws (Fig. 10) from the welded
nuts.

Fig. 10
17. Tighten the fastening screws (Fig. 11).
18. Lower the frame again.

Fig. 11

008 924 17 BOMAG 417

14.6 Changing the rubber buffers and adjusting the pretension

418 BOMAG 008 924 17

15 Oscillating articulated joint

008 924 17 BOMAG 419

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

15.1 Special tools, oscillating articulated

joint (BW177 to BW 216)
1. Pressing device for rocker bearings

Fig. 1
2. Pressing bushing for outer rocker bearing race

Fig. 2
3. Pressing bushing for inner rocker bearing race

Fig. 3

420 BOMAG 008 924 17

Special tools, oscillating articulated joint (BW177 to BW 216) 15.1
4. Guide pin

Fig. 4
5. Clamping device

Fig. 5
6. Disassembly device

Fig. 6

008 924 17 BOMAG 421

15.2 Repair overview oscillating articulated joint

422 BOMAG 008 924 17

Repair overview oscillating articulated joint 15.2

1 Housing 12 Cover
2 Seal ring 13 Cover
3 Cover 14 Intermediate ring
4 Self-aligning bearing 15 Self-aligning bearing
5 Bolt 16 Intermediate ring
6 Shim/supporting disc 17 Self-aligning bearing
7 Belleville springs 18 Carrier
8 Self-aligning bearing 19 Friction bearing
9 Console 20 V-ring
10 Belleville springs 21 Seal ring
11 Shim/supporting disc

008 924 17 BOMAG 423

15.2 Repair overview oscillating articulated joint

424 BOMAG 008 924 17

Repair overview oscillating articulated joint 15.2

008 924 17 BOMAG 425

15.3 Removing and installing the oscillating articulated joint

15.3 Removing and installing the oscillat-

ing 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 articu-
lated joint (Fig. 2) on both sides safely with tres-
tles or wooden blocks.

Fig. 2
3. Fasten the lifting tackle to the front frame near the
oscillating articulated joint (Fig. 3).

Fig. 3

426 BOMAG 008 924 17

Removing and installing the oscillating articulated joint 15.3
4. Unscrew fastening screws 1 (Fig. 4) and take off
axle holder (2).
5. Knock out bearing bolt (3).
6. Retract steering cylinder (4).

Fig. 4

Danger of accident!
7. Support the oscillating articulated joint in the mid-
dle 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 oscil-
lating articulated joint to the ground.
12. Pull out the oscillating articulated joint.

Fig. 6
Note on assembly
13. Insert the bolt for the steering cylinder so that
groove (2) is in line with tapped bores (1).

Fig. 7

008 924 17 BOMAG 427

15.4 Dismantling the oscillating articulated joint

15.4 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
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
The outer race of the rocker bearing is thereby
stripped off.

Fig. 3

428 BOMAG 008 924 17

Dismantling the oscillating articulated joint 15.4
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 re-
move 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
Remove the bolt on the opposite side in the same
way.

Fig. 5
11. Lift console 1 (Fig. 6) off housing (2).

Fig. 6
12. Take the seal rings out of the console (Fig. 7).

Fig. 7

008 924 17 BOMAG 429

15.4 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 sepa-
rate the carrier from the rocker bearings.

Fig. 11

430 BOMAG 008 924 17

Dismantling the oscillating articulated joint 15.4
19. Pull the housing off the beam (Fig. 12).

Fig. 12
20. Drive the outer race of the friction bearing out of
the housing (Fig. 13).

Fig. 13
21. Drive the friction bearing out of the housing (Fig.
14).

Fig. 14
22. Take seal ring 1 (Fig. 15) and V-ring (2) off the
beam.

Fig. 15

008 924 17 BOMAG 431

15.4 Dismantling the oscillating articulated joint

23. Check rocker bearings, if necessary press out of

the housing (Fig. 16).

Fig. 16

432 BOMAG 008 924 17

Assembling the oscillating articulated joint 15.5
15.5 Assembling the oscillating articulated
joint
1. If previously disassembled, press the rocker
bearing fully into the housing with a pressing
mandrel (Fig. 1).

i
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly

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

008 924 17 BOMAG 433

15.5 Assembling the oscillating articulated joint

5. Press the friction bearing fully into the housing

with the chamfered side pointing towards the out-
side (Fig. 4).

Fig. 4
6. Slide the housing over the beam (Fig. 5).

i
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 bear-
ing race with sliding agent OKS 571.

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

434 BOMAG 008 924 17

Assembling the oscillating articulated joint 15.5
10. Press inner rocker bearing race 1 (Fig. 8) in until
it bottoms, using pressing sleeve (2).

Fig. 8
11. Insert the intermediate ring (Fig. 9).

Fig. 9
12. Press inner rocker bearing race 1 (Fig. 10) in until
it bottoms, using pressing sleeve (2).

Fig. 10

i
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly

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

008 924 17 BOMAG 435

15.5 Assembling the oscillating articulated joint

14. Press in intermediate ring 1 (Fig. 12) until it bot-

toms.
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.

Check the measurement with an axial pre-

load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.
18. Slide the rod of the tensioning device in from un-
derneath, attach the plate, screw on the nut and
Fig. 13 tighten.
19. Measure the distance from housing edge to inter-
mediate ring (Fig. 13) and write it down, e.g. 4,7
mm.

i
From this measured value of 4.7 mm subtract the
fixed value of 4.0 mm to determine the shim thick-
ness.

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.

436 BOMAG 008 924 17

Assembling the oscillating articulated joint 15.5
21. Insert shim 2 (Fig. 14) of appropriate thickness
and backing disc (1) into the cover.

Fig. 14
22. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 15).

Fig. 15
23. Assemble cover 2 (Fig. 16) with Belleville springs,
shim and backing disc.
24. Turn in screws (1) and tighten crosswise.

Fig. 16
25. Press the new sealing rings into the respective
groove in the console (Fig. 17).

Fig. 17

008 924 17 BOMAG 437

15.5 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
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

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

438 BOMAG 008 924 17

Assembling the oscillating articulated joint 15.5
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 bear-
ing race with sliding agent OKS 571.

Do not use any grease.

34. Attach the outer rocker bearing race with the wid-
er outer rim facing towards the outside (Fig. 25)
and drive it in until it bottoms.

Fig. 25

008 924 17 BOMAG 439

15.5 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 in-
sert rod 1 (Fig. 27) of the tensioning device from
underneath. Attach plate (2), screw on nut (3) and
tighten.

Check the measurement with an axial pre-

load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 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
From this measured value of 3.4 mm subtract the
fixed value of 2.2 mm to determine the shim thick-
ness.

Calculation example:
3.4 mm - 2.2 mm = 1.2 mm
measured value: 3,4 mm
Fig. 28 fixed value: 2,2 mm
Shim thickness: 1.2 mm
39. Remove the tensioning device.

440 BOMAG 008 924 17

Assembling the oscillating articulated joint 15.5
40. Insert shims 2 (Fig. 29) of appropriate thickness
and backing disc (1) into the cover.

Fig. 29
41. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 30).

Fig. 30
42. Assemble cover 1 (Fig. 31) with Belleville springs,
shims and supporting discs.
43. Turn in screws (2) and tighten crosswise.

Fig. 31
44. Insert hexagon screw 1 (Fig. 32) so that the screw
head rests on the upper side of the console.

Fig. 32

008 924 17 BOMAG 441

15.5 Assembling the oscillating articulated joint

45. Assemble the washer, turn on and tighten the nut

with 120 Nm (Fig. 33).

Fig. 33

442 BOMAG 008 924 17

16 Suppliers documentation

008 924 17 BOMAG 443

444 BOMAG 008 924 17
16.1 Travel pump

008 924 17 BOMAG 445

16.1 Travel pump

Bild 34

446 BOMAG 008 924 17

Travel pump 16.1

Series 90 Pumps

Service Manual

008 924 17 BOMAG 447

16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
2EVISIONS

HISTORY OF REVISIONS Table of Revisions

Date Page Changed Rev.

December 2011 69 4ORQUE VALUES CHANGED FOR % !#

!PRIL 70 4ORQUE FOR ' ' ' ' " " " " CHANGED !"
TO .M ; LBFsFT=
3EPTEMBER - &IRST PRINTING REPLACES ",. !!

¹ 3AUER $ANFOSS !LL RIGHTS RESERVED

3AUER $ANFOSS ACCEPTS NO RESPONSIBILITY FOR POSSIBLE ERRORS IN CATALOGS BROCHURES AND
OTHER PRINTED MATERIAL 3AUER $ANFOSS RESERVES THE RIGHT TO ALTER ITS PRODUCTS WITHOUT
PRIOR NOTICE4HIS ALSO APPLIES TO PRODUCTS ALREADY ORDERED PROVIDED THAT SUCH ALTERATIONS
CAN BE MADE WITHOUT AFFECTING AGREED SPECIlCATIONS !LL TRADEMARKS IN THIS MATERIAL
ARE PROPERTIES OF THEIR RESPECTIVE OWNERS 3AUER $ANFOSS THE 3AUER $ANFOSS LOGOTYPE
THE 3AUER $ANFOSS 3 ICON 0,53 » 7HAT REALLY MATTERS IS INSIDE¸ AND +NOW (OW IN
-OTION» ARE TRADEMARKS OF THE 3AUER $ANFOSS 'ROUP
2 520L0818 s 2EV !# s December 2011

448 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
#ONTENTS

INTRODUCTION /VERVIEW ........................................................................................................................................................... 6

7ARRANTY ............................................................................................................................................................ 6
'ENERAL INSTRUCTIONS ...................................................................................................................................... 6
3AFETY PRECAUTIONS ......................................................................................................................................... 7
5NINTENDED MACHINE MOVEMENT ....................................................................................................... 7
&LAMMABLE CLEANING SOLVENTS ............................................................................................................... 7
&LUID UNDER PRESSURE ................................................................................................................................ 7
0ERSONAL SAFETY ........................................................................................................................................... 7
3YMBOLS USED IN 3AUER $ANFOSS LITERATURE.............................................................................................
$ESIGN ................................................................................................................................................................ 9
4HE SYSTEM CIRCUIT.........................................................................................................................................10

OPERATION #HARGE PUMP .................................................................................................................................................12

#HARGE RELIEF VALVE........................................................................................................................................12
-ULTI FUNCTION VALVES ..................................................................................................................................12
0RESSURE LIMITER AND HIGH PRESSURE RELIEF VALVES ................................................................................
3YSTEM CHECK VALVES ....................................................................................................................................
"YPASS VALVES .................................................................................................................................................
3PEED SENSORS ................................................................................................................................................
&ILTRATION OPTIONS ..........................................................................................................................................
0RESSURE OVERRIDE 0/2 n FRAME SIZE ONLY...................................................................................
-ANUAL DISPLACEMENT CONTROL -$# ....................................................................................................
.ON LINEAR -$# ............................................................................................................................................
3OLENOID OVERRIDE VALVE FOR -$# ............................................................................................................
.EUTRAL START SWITCH .33 ..........................................................................................................................
(YDRAULIC DISPLACEMENT CONTROL ($# .................................................................................................
%LECTRIC DISPLACEMENT CONTROL %$# ......................................................................................................
!UTOMOTIVE CONTROL &"! )) " ...................................................................................................................
0OSITION &.2 ELECTRIC CONTROL .............................................................................................................

OPERATING /VERVIEW .........................................................................................................................................................16

PARAMETERS )NPUT SPEED ....................................................................................................................................................16
3YSTEM PRESSURE ............................................................................................................................................16
#HARGE PRESSURE ............................................................................................................................................17
#HARGE INLET PRESSURE ..................................................................................................................................17
#ASE PRESSURE .................................................................................................................................................17
4EMPERATURE AND VISCOSITY ........................................................................................................................
4EMPERATURE .............................................................................................................................................
6ISCOSITY......................................................................................................................................................
&LUID AND lLTER RECOMMENDATIONS..........................................................................................................19

TECHNICAL /VERVIEW .........................................................................................................................................................20

SPECIFICATIONS &EATURES AND OPTIONS ..................................................................................................................................20
/PERATING PARAMETERS ................................................................................................................................20
&LUID SPECIlCATIONS ......................................................................................................................................20

520L0818 s 2EV !# s December 2011 3

008 924 17 BOMAG 449
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
#ONTENTS

INITIAL STARTUP 'ENERAL ............................................................................................................................................................21

PROCEDURES 3TART UP PROCEDURE ......................................................................................................................................21

PRESSURE 2EQUIRED TOOLS ...............................................................................................................................................

MEASUREMENTS 0ORT LOCATIONS AND GAUGE INSTALLATION ...................................................................................................

TROUBLESHOOTING /VERVIEW .........................................................................................................................................................26

.EUTRAL DIFlCULT OR IMPOSSIBLE TO lND ...................................................................................................26
3YSTEM OPERATING HOT .................................................................................................................................26
4RANSMISSION OPERATES NORMALLY IN ONE DIRECTION ONLY ..................................................................27
3YSTEM WILL NOT OPERATE IN EITHER DIRECTION.........................................................................................27
,OW MOTOR OUTPUT TORQUE .........................................................................................................................
)MPROPER MOTOR OUTPUT SPEED ................................................................................................................
3YSTEM NOISE OR VIBRATION ..........................................................................................................................
3YSTEM RESPONSE IS SLUGGISH .....................................................................................................................29

ADJUSTMENTS 3TANDARD PROCEDURES INSPECTIONS AND ADJUSTMENTS ......................................................................

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

4 520L0818 s 2EV !# s December 2011

450 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
#ONTENTS

MINOR REPAIR 3TANDARD PROCEDURES ..................................................................................................................................

3HAFT SEAL AND SHAFT REPLACEMENT ...........................................................................................................
-ULTI FUNCTION VALVE CARTRIDGES ...............................................................................................................
-ULTI FUNCTION VALVE CARTRIDGES PRE ..........................................................................................
0RESSURE OVERRIDE VALVE OPTION FOR FRAME SIZE .........................................................................
#HARGE PRESSURE RELIEF VALVE .....................................................................................................................
!UXILIARY PAD ..................................................................................................................................................
#HARGE PUMP .................................................................................................................................................
!DDING AN !UXILIARY PAD TO A PUMP PREVIOUSLY WITHOUT ONE .......................................................
)NTEGRAL CHARGE PRESSURE lLTER REPLACEMENT .......................................................................................
0UMP CONTROL COVER PLATE ..........................................................................................................................60
$ISPLACEMENT CONTROL ORIlCES ..................................................................................................................61
$ISPLACEMENT CONTROL ORIlCE CHECK VALVE ...........................................................................................61
$ISPLACEMENT CONTROL ADAPTER PLATE EARLY PRODUCTION PUMPS ONLY ...............................61
-ANUAL DISPLACEMENT CONTROL -$# ....................................................................................................62
3OLENOID OVERRIDE VALVE FOR -$# ............................................................................................................
3OLENOID OVERRIDE VALVE FOR -$# WITH PRESSURE RELEASED BRAKE .................................................
(YDRAULIC AND ELECTRIC DISPLACEMENT CONTROLS ...................................................................................
0RESSURE CONTROL PILOT 0#0 FOR ELECTRIC DISPLACEMENT CONTROL %$# ........................................66
0OSITION &.2 ELECTRIC CONTROL .............................................................................................................67
$ISPLACEMENT CONTROL lLTER SCREENS .......................................................................................................
3PEED SENSOR..................................................................................................................................................

TORQUE CHART &ASTENER SIZE AND TORQUE CHART ................................................................................................................69

0LUG SIZE AND TORQUE CHART ........................................................................................................................70
&ASTENERS AND PLUGS.....................................................................................................................................70

520L0818 s 2EV !# s December 2011 5

008 924 17 BOMAG 451
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NTRODUCTION

OVERVIEW 4HIS MANUAL INCLUDES INFORMATION FOR THE INSTALLATION MAINTENANCE AND MINOR REPAIR OF
3ERIES AXIAL PISTON CLOSED CIRCUIT PUMPS )T INCLUDES A DESCRIPTION OF THE UNIT AND ITS
INDIVIDUAL COMPONENTS TROUBLESHOOTING INFORMATION AND MINOR REPAIR PROCEDURES

0ERFORMING MINOR REPAIRS REQUIRES YOU REMOVE THE UNIT FROM THE VEHICLEMACHINE
4HOROUGHLY CLEAN THE UNIT BEFORE BEGINNING MAINTENANCE OR REPAIR ACTIVITIES 3INCE DIRT
AND CONTAMINATION ARE THE GREATEST ENEMIES OF ANY TYPE OF HYDRAULIC EQUIPMENT FOLLOW
CLEANLINESS REQUIREMENTS STRICTLY4HIS IS ESPECIALLY IMPORTANT WHEN CHANGING THE SYSTEM
lLTER AND WHEN REMOVING HOSES OR PLUMBING

! WORLDWIDE NETWORK OF 3AUER $ANFOSS 'LOBAL 3ERVICE 0ARTNERS '30S IS AVAILABLE FOR
MAJOR REPAIRS 3AUER $ANFOSS TRAINS '30S AND CERTIlES THEIR FACILITIES ON A REGULAR BASIS
9OU CAN LOCATE YOUR NEAREST !3# USING THE DISTRIBUTOR LOCATOR AT WWWSAUER DANFOSSCOM
#LICK ON THE Sales and Service LINK

WARRANTY 0ERFORMING INSTALLATION MAINTENANCE AND MINOR REPAIRS ACCORDING TO THE PROCEDURES IN
THIS MANUAL WILL NOT AFFECT YOUR WARRANTY -AJOR REPAIRS REQUIRING THE REMOVAL OF A UNITS
REAR OR SIDE COVER VOIDS THE WARRANTY UNLESS DONE BY A 3AUER $ANFOSS !UTHORIZED 3ERVICE
#ENTER

GENERAL INSTRUCTIONS &OLLOW THESE GENERAL PROCEDURES WHEN REPAIRING 3ERIES VARIABLE DISPLACEMENT CLOSED
CIRCUIT PUMPS

w Remove the unit

0RIOR TO PERFORMING MAJOR REPAIRS REMOVE THE UNIT FROM THE VEHICLEMACHINE #HOCK
THE WHEELS ON THE VEHICLE OR LOCK THE MECHANISM TO INHIBIT MOVEMENT "E AWARE THAT
HYDRAULIC mUID MAY BE UNDER HIGH PRESSURE ANDOR HOT )NSPECT THE OUTSIDE OF THE PUMP
AND lTTINGS FOR DAMAGE #AP HOSES AFTER REMOVAL TO PREVENT CONTAMINATION

e Keep it clean
#LEANLINESS IS A PRIMARY MEANS OF ASSURING SATISFACTORY PUMP LIFE ON EITHER NEW OR
REPAIRED UNITS #LEAN THE OUTSIDE OF THE PUMP THOROUGHLY BEFORE DISASSEMBLY4AKE CARE
TO AVOID CONTAMINATION OF THE SYSTEM PORTS #LEANING PARTS BY USING A CLEAN SOLVENT WASH
AND AIR DRYING IS USUALLY ADEQUATE

!S WITH ANY PRECISION EQUIPMENT KEEP ALL PARTS FREE OF FOREIGN MATERIALS AND CHEMICALS
0ROTECT ALL EXPOSED SEALING SURFACES AND OPEN CAVITIES FROM DAMAGE AND FOREIGN MATERIAL
)F LEFT UNATTENDED COVER THE PUMP WITH A PROTECTIVE LAYER OF PLASTIC

d Replace all O-rings and gaskets

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

t Secure the unit

&OR REPAIR PLACE THE UNIT IN A STABLE POSITION WITH THE SHAFT POINTING DOWNWARD )T WILL BE
NECESSARY TO SECURE THE PUMP WHILE REMOVING AND TORQUING END COVERS CONTROLS AND
valves.

6 520L0818 s 2EV !# s December 2011

452 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NTRODUCTION

SAFETY PRECAUTIONS !LWAYS CONSIDER SAFETY PRECAUTIONS BEFORE BEGINNING A SERVICE PROCEDURE 0ROTECT
YOURSELF AND OTHERS FROM INJURY4AKE THE FOLLOWING GENERAL PRECAUTIONS WHENEVER SERVICING A
HYDRAULIC SYSTEM

Unintended machine movement

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

Flammable cleaning solvents

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

Fluid under pressure

W Warning
%SCAPING HYDRAULIC mUID UNDER PRESSURE CAN HAVE SUFlCIENT FORCE TO PENETRATE YOUR SKIN
CAUSING SERIOUS INJURY ANDOR INFECTION4HIS mUID MAY ALSO BE HOT ENOUGH TO CAUSE BURNS
5SE CAUTION WHEN DEALING WITH HYDRAULIC mUID UNDER PRESSURE 2ELIEVE PRESSURE IN THE
SYSTEM BEFORE REMOVING HOSES lTTINGS GAUGES OR COMPONENTS .EVER USE YOUR HAND
OR ANY OTHER BODY PART TO CHECK FOR LEAKS IN A PRESSURIZED LINE 3EEK MEDICAL ATTENTION
IMMEDIATELY IF YOU ARE CUT BY HYDRAULIC mUID

Personal safety
W Warning
0ROTECT YOURSELF FROM INJURY 5SE PROPER SAFETY EQUIPMENT INCLUDING SAFETY GLASSES AT ALL
TIMES

520L0818 s 2EV !# s December 2011 7

008 924 17 BOMAG 453
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NTRODUCTION

SYMBOLS USED IN  7!2.).' MAY RESULT IN INJURY  4IP HELPFUL SUGGESTION

SAUER-DANFOSS
LITERATURE  #!54)/. MAY RESULT IN DAMAGE TO  ,UBRICATE WITH CLEAN HYDRAULIC mUID
PRODUCT OR PROPERTY
 !PPLY GREASEPETROLEUM JELLY
 2EUSABLE PART
 !PPLY LOCKING COMPOUND
 .ON REUSABLE PART USE A NEW PART
 )NSPECT FOR WEAR OR DAMAGE
 .ON REMOVABLE ITEM
 #LEAN AREA OR PART
 /PTION n EITHER PART MAY EXIST
 "E CAREFUL NOT TO SCRATCH OR DAMAGE
 3UPERSEDED n PARTS ARE NOT
INTERCHANGEABLE  .OTE CORRECT ORIENTATION

 -EASUREMENT REQUIRED  -ARK ORIENTATION FOR REINSTALLATION

 &LATNESS SPECIlCATION  4ORQUE SPECIlCATION

 0ARALLELISM SPECIlCATION  0RESS IN n PRESS lT

 %XTERNAL HEX HEAD  0ULL OUT WITH TOOL n PRESS lT

 )NTERNAL HEX HEAD  #OVER SPLINES WITH INSTALLATION

sleeve
 4ORX HEAD
 0RESSURE MEASUREMENTGAUGE
 / RING BOSS PORT LOCATION OR SPECIlCATION

4HE SYMBOLS ABOVE APPEAR IN THE ILLUSTRATIONS AND TEXT OF THIS MANUAL4HEY ARE INTENDED
TO COMMUNICATE HELPFUL INFORMATION AT THE POINT WHERE IT IS MOST USEFUL TO THE READER
)N MOST INSTANCES THE APPEARANCE OF THE SYMBOL ITSELF DENOTES ITS MEANING4HE LEGEND
ABOVE DElNES EACH SYMBOL AND EXPLAINS ITS PURPOSE

8 520L0818 s 2EV !# s December 2011

454 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NTRODUCTION

DESIGN 3AUER $ANFOSS 3ERIES CLOSED CIRCUIT PISTON PUMPS CONVERT INPUT TORQUE INTO HYDRAULIC
POWER4HE INPUT SHAFT TRANSMITS ROTATIONAL FORCE TO THE CYLINDER BLOCK "EARINGS SUPPORT
THE INPUT SHAFT AT THE FRONT AND REAR OF THE PUMP4HE SHAFT IS SPLINED INTO THE CYLINDER
BLOCK ! LIP SEAL AT THE FRONT END OF THE PUMP PREVENTS LEAKAGE WHERE THE SHAFT EXITS
THE PUMP HOUSING4HE SPINNING CYLINDER BLOCK CONTAINS NINE RECIPROCATING PISTONS !
BALL JOINT AT ONE END CONNECTS EACH PISTON TO A BRASS SLIPPER &IXED CLEARANCE HOLD DOWN
BRACKETS KEEP THE SLIPPERS IN CONTACT WITH THE SWASHPLATE4HE RECIPROCATING MOVEMENT
OF THE PISTONS OCCURS AS THE SLIPPERS SLIDE AGAINST THE INCLINED SWASHPLATE DURING ROTATION
4HE VALVE PLATE CONNECTS ONE HALF OF THE CYLINDER BLOCK TO LOW PRESSURE AND THE OTHER
HALF TO HIGH PRESSURE !S EACH PISTON CYCLES IN AND OUT OF ITS BORE mUID IS DRAWN FROM THE
INLET AND DISPLACED TO THE OUTLET THEREBY IMPARTING HYDRAULIC POWER INTO THE SYSTEM !
SMALL AMOUNT OF mUID mOWS FROM THE CYLINDER BLOCKVALVE PLATE AND SLIPPERSWASHPLATE
INTERFACES FOR LUBRICATION AND COOLING #ASE DRAIN PORTS RETURN THIS mUID TO THE RESERVOIR

4HE ANGLE OF THE SWASHPLATE CONTROLS THE VOLUME OF mUID DISPLACED INTO THE SYSTEM4HE
SERVO PISTON FORCES THE SWASHPLATE INTO AN INCLINED POSITION4HE PUMP CONTROL ACTING
ON INPUT FROM THE OPERATOR BY MODULATING PRESSURE BALANCE ACROSS THE SERVO PISTON SETS
DISPLACEMENT IN THE SYSTEM CIRCUIT

Cross section
Piston
Slipper
Displacement control
Slider block Servo arm
Servo piston

Feedback linkage

Cradle bearing
Bushing

Cylinder block Roller bearing

Shaft
Valve plate seal

Rear
bushing

Input shaft

Charge pump Swashplate Cradle guide P106 648E

520L0818 s 2EV !# s December 2011 9

008 924 17 BOMAG 455
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NTRODUCTION

THE SYSTEM CIRCUIT The basic closed circuit Basic closed circuit diagram
(YDRAULIC LINES CONNECT THE MAIN PORTS
OF THE PUMP TO THE MAIN PORTS OF THE
MOTOR &LUID mOWS IN EITHER DIRECTION
FROM THE PUMP TO THE MOTOR THEN BACK
Reservoir
TO THE PUMP IN THIS CLOSED CIRCUIT %ITHER
OF THE HYDRAULIC LINES CAN BE UNDER HIGH Input PV MF Output
PRESSURE )N PUMPING MODE THE POSITION
OF THE PUMP SWASHPLATE DETERMINES
WHICH LINE IS HIGH PRESSURE AS WELL AS THE
DIRECTION OF mUID mOW
Flow (Bi-directional)

Case drain line

P104 120E

Case drain and heat exchanger

4HE PUMP AND MOTOR REQUIRE CASE DRAIN LINES TO REMOVE HOT mUID FROM THE SYSTEM
4HE TOPMOST PORT DRAINS THE MOTOR TO ENSURE THE CASE REMAINS FULL OF mUID &LUID ROUTES
THROUGH THE LOWER DRAIN PORT ON THE PUMP AND OUT THE TOPMOST PORT TO THE RESERVOIR
! HEAT EXCHANGER WITH A BYPASS VALVE COOLS THE CASE DRAIN mUID BEFORE IT RETURNS TO THE
reservoir.

System circuit diagram

Control handle Displacement control valve

Heat exchanger bypass valve

Reservoir
Orificed check
valve Vacuum gauge

Heat exchanger
Purge relief valve
Charge pressure relief valve P102 000

Reversible variable Servo control cylinder Multi-function valve Fixed displacement motor
displacement pump

To
pump
case
Servo
pressure
relief valves

Charge pump
Input shaft Output shaft
Multi-function valve Motor swashplate
Pump swashplate
Servo control cylinder Loop flushing valve

Pump Motor

Working loop (high pressure) Working loop (low pressure) Suction line Control fluid Case drain fluid

10 520L0818 s 2EV !# s December 2011

456 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NTRODUCTION

THE SYSTEM CIRCUIT

(continued)

Pump schematic

X5
A

M5
M4

L1 S L2

P104 126E

520L0818 s 2EV !# s December 2011 11

008 924 17 BOMAG 457
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
/PERATION

CHARGE PUMP 4HE CHARGE PUMP IS NECESSARY TO SUPPLY Pump charge system
COOL mUID TO THE SYSTEM TO MAINTAIN
Case
POSITIVE PRESSURE IN THE MAIN SYSTEM drain Charge relief valve
line
LOOP TO PROVIDE PRESSURE TO OPERATE System
check
THE CONTROL SYSTEM AND TO MAKE UP FOR valves
INTERNAL LEAKAGE #HARGE PRESSURE MUST Input PV PF
BE AT ITS SPECIlED PRESSURE UNDER ALL Charge
pump
CONDITIONS TO PREVENT DAMAGE TO THE
TRANSMISSION
4HE CHARGE PUMP IS A lXED
DISPLACEMENT GEROTOR TYPE PUMP DRIVEN Inlet filter
OFF THE MAIN PUMP SHAFT4HE CHARGE Tank P104 121E
RELIEF VALVE LIMITS CHARGE PRESSURE

CHARGE RELIEF VALVE 4HE CHARGE RELIEF VALVE ON THE PUMP Charge pressure relief valve
MAINTAINS CHARGE PRESSURE AT A
DESIGNATED LEVEL ! DIRECT ACTING
POPPET VALVE RELIEVES mUID WHEN CHARGE
PRESSURE REACHES A CERTAIN LEVEL4HIS
LEVEL IS NOMINALLY SET REFERENCING CASE
PRESSURE AT RPM4HIS NOMINAL
SETTING ASSUMES THE PUMP IS IN NEUTRAL
ZERO mOW )N FORWARD OR REVERSE CHARGE
PRESSURE IS LOWER4HE PUMP MODEL CODE
SPECIlES THE CHARGE RELIEF VALVE SETTING
Charge pressure P106 157E

MULTI-FUNCTION VALVES 4HE MULTI FUNCTION VALVE INCORPORATES Multi-function valve

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

ARE DESCRIBED SEPARATELY4HERE ARE TWO Pressure limiter

MULTI FUNCTION VALVE CARTRIDGES IN EACH adjustment screw

3ERIES PUMP TO HANDLE FUNCTIONS

Bypass
IN EITHER DIRECTION 3EE CORRESPONDING actuator Pressure limiter
Bypass
P104 122E
SECTIONS FOR ADJUSTMENTS AND REPAIRS valve poppet

3OME MULTI FUNCTION VALVES DO NOT INCLUDE A PRESSURE LIMITER VALVE

12 520L0818 s 2EV !# s December 2011

458 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
/PERATION

PRESSURE LIMITER AND 3ERIES PUMPS HAVE A SEQUENCED Circuit diagram showing pressure
HIGH PRESSURE RELIEF PRESSURE LIMITING SYSTEM AND HIGH control mechanism
VALVES PRESSURE RELIEF VALVES7HEN THE SYSTEM
To control
PRESSURE REACHES THE PRESET THE PRESSURE
LIMITER SYSTEM RAPIDLY DE STROKES THE Multi-function valve
PUMP TO LIMIT SYSTEM PRESSURE &OR
UNUSUALLY RAPID LOAD APPLICATION THE Servo piston Bypass
adjustment
HIGH PRESSURE RELIEF VALVE IMMEDIATELY Port "A"
LIMITS SYSTEM PRESSURE BY CROSS PORTING Servo Pres.
Relief Valve
SYSTEM mOW4HE PRESSURE LIMITER VALVE
Port "B"
ACTS AS THE PILOT FOR THE HIGH PRESSURE
Servo piston Charge
RELIEF VALVE SPOOL4HE HIGH PRESSURE pressure
RELIEF VALVE IS SEQUENCED TO OPERATE AT relief valve

APPROXIMATELY BAR PSI ABOVE THE Multi-function valve

LEVEL THAT INITIATES THE PRESSURE LIMITER P104 123E

valve.

&OR SOME APPLICATIONS SUCH AS DUAL PATH VEHICLES THE PRESSURE LIMITER FUNCTION MAY BE
DEFEATED SO THAT ONLY THE HIGH PRESSURE RELIEF VALVE FUNCTION REMAINS

SYSTEM CHECK VALVES 4HE SYSTEM CHECK VALVES ALLOW PRESSURIZED mOW FROM THE CHARGE PUMP TO ENTER THE LOW
PRESSURE SIDE OF THE LOOP4HIS IS NEEDED AS THE PUMP GENERALLY LOSES SYSTEM PRESSURE
DUE TO LUBRICATIONCOOLING mOW AND OTHER FACTORS 3INCE THE PUMP OPERATES IN EITHER
DIRECTION THE SYSTEM USES TWO CHECK VALVES TO DIRECT THE CHARGE SUPPLY INTO THE LOW
PRESSURE LINES4HE SYSTEM CHECK VALVES ARE PART OF THE MULTI FUNCTION VALVE ASSEMBLY

BYPASS VALVES 9OU CAN OPERATE THE BYPASS VALVES TO MOVE THE VEHICLE OR MECHANICAL FUNCTION WHEN THE
PUMP IS NOT RUNNING -ANUALLY RESETTING THE VALVE POSITION OPENS THE VALVE4HE BYPASS
VALVES ARE BUILT INTO THE MULTI FUNCTION VALVES

SPEED SENSORS !N OPTIONAL SPEED SENSOR CAN PROVIDE UNIT SPEED INFORMATION4HE SENSOR READS A
MAGNETIC RING ON THE UNITS CYLINDER BLOCK 3EE THE CORRESPONDING SECTION TO LOCATE
INSTALL AND ADJUST THE SPEED SENSOR

520L0818 s 2EV !# s December 2011 13

008 924 17 BOMAG 459
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
/PERATION

FILTRATION OPTIONS 3ERIES PUMPS MAY HAVE EITHER SUCTION Suction ﬁltration
OR CHARGE PRESSURE lLTRATION TO lLTER THE Hydraulic fluid reservoir Manometer

mUID ENTERING THE CIRCUIT

Charge pump
Filter

Suction ﬁltration – option S

4HE SUCTION lLTER IS IN THE CIRCUIT BETWEEN
THE RESERVOIR AND THE INLET TO THE CHARGE Adjustable
To low charge pressure relief valve
PUMP AS SHOWN BELOW4HE USE OF A lLTER loop and
P102 003E
CONTAMINATION MONITOR IS RECOMMENDED control To pump case

Charge pressure ﬁltration – option R, Charge pressure ﬁltration

T, P, and L Screen
4HE PRESSURE lLTER CAN BE MOUNTED
ON THE PUMP OR REMOTELY FOR EASE OF Hydraulic fluid reservoir
Adjustable
SERVICING9OU WILL TYPICALLY lND A charge pressure
relief valve
M MESH SCREEN IN THE RESERVOIR OR
Charge pump
THE CHARGE INLET4HIS SYSTEM REQUIRES A
lLTER CAPABLE OF WITHSTANDING CHARGE Filter
To low To pump case
PRESSURE REFERENCE TO ATMOSPHERE ADD pressure
CASE PRESSURE side and
P102 004E
control

PRESSURE OVERRIDE 4HE 0RESSURE /VER2IDE VALVE 0/2 POR-Valve (180 frame size only)
(POR) – 180 FRAME SIZE MODULATES CONTROL PRESSURE TO MAINTAIN To control
ONLY A PUMP DISPLACEMENT WHICH PRODUCES A
SYSTEM PRESSURE LEVEL LESS THAN OR EQUAL
TO THE 0/2 SETTING &OR UNUSUALLY RAPID Multi-function valve

LOAD APPLICATION THE HIGH PRESSURE RELIEF Pressure

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

pressure level. Shuttle

valve
Port "B"

4HE PRESSURE OVERRIDE CONSISTS OF A THREE

WAY NORMALLY OPEN VALVE WHICH OPERATES
IN SERIES WITH THE PUMP DISPLACEMENT Multi-function valve
Charge pressure
CONTROL #ONTROL SUPPLY PRESSURE NORMALLY relief valve
PORTS THROUGH THE 0/2 VALVE TO THE P104 124E
DISPLACEMENT CONTROL VALVE )F THE SYSTEM
DEMANDS A PRESSURE ABOVE THE OVERRIDE
SETTING THE 0/2 VALVE OVERRIDES THE
CONTROL BY REDUCING THE PRESSURE TO THE DISPLACEMENT CONTROL !S THE CONTROL PRESSURE
REDUCES THE INTERNAL FORCES ROTATING THE SWASHPLATE OVERCOME THE FORCE OF THE SERVO
PISTONS AND DECREASES THE PUMPS DISPLACEMENT

14 520L0818 s 2EV !# s December 2011

460 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
/PERATION

MANUAL DISPLACEMENT 4HE MANUAL DISPLACEMENT CONTROL CONVERTS A MECHANICAL INPUT SIGNAL TO A HYDRAULIC
CONTROL (MDC) SIGNAL USING A SPRING CENTERED FOUR WAY SERVO VALVE4HIS VALVE PORTS HYDRAULIC PRESSURE
TO EITHER SIDE OF A DUAL ACTING SERVO PISTON4HE SERVO PISTON ROTATES THE CRADLE
SWASHPLATE THROUGH AN ANGULAR ROTATION OF ¼² VARYING THE PUMPS DISPLACEMENT FROM
FULL IN ONE DIRECTION TO FULL IN THE OPPOSITE DIRECTION4HE ANGULAR POSITION OF THE PUMP
SWASHPLATE IS PROPORTIONAL TO THE ROTATION OF THE CONTROL INPUT SHAFT

NON-LINEAR MDC 4HE NON LINEAR MANUAL DISPLACEMENT CONTROL OPERATES IN THE SAME MANNER EXCEPT THAT IT
IS DESIGNED SO THE CHANGE IN THE ANGULAR POSITION OF THE PUMP SWASHPLATE PROGRESSIVELY
INCREASES AS THE CONTROL INPUT SHAFT IS ROTATED TOWARD ITS MAXIMUM DISPLACEMENT POSITION

SOLENOID OVERRIDE ! SOLENOID OVERRIDE VALVE OPTION IS AVAILABLE FOR THE -$#4HIS SAFETY FEATURE RETURNS THE
VALVE FOR MDC SWASHPLATE TO ZERO DISPLACEMENT )T IS AVAILABLE IN NORMALLY OPEN ACTIVATE TO ALLOW OR
NORMALLY CLOSED ACTIVATE TO DISALLOW OPTIONS

NEUTRAL START SWITCH 4HE NEUTRAL START SWITCH IS AN OPTIONAL FEATURE AVAILABLE WITH THE -$#7HEN CONNECTED
(NSS) PROPERLY WITH THE VEHICLES ELECTRICAL SYSTEM THE NEUTRAL START SWITCH ENSURES THAT THE
PRIME MOVER CAN START ONLY WHEN THE CONTROL IS IN NEUTRAL POSITION

HYDRAULIC 4HE HYDRAULIC DISPLACEMENT CONTROL USES A HYDRAULIC INPUT SIGNAL TO OPERATE A SPRING
DISPLACEMENT CENTERED FOUR WAY SERVO VALVE4HIS VALVE PORTS HYDRAULIC PRESSURE TO EITHER SIDE OF A
CONTROL (HDC) DUAL ACTING SERVO PISTON4HE SERVO PISTON ROTATES THE CRADLE SWASHPLATE THROUGH AN
ANGULAR ROTATION OF ¼² THUS VARYING THE PUMPS DISPLACEMENT FROM FULL DISPLACEMENT IN
ONE DIRECTION TO FULL DISPLACEMENT IN THE OPPOSITE DIRECTION4HE ANGULAR POSITION OF THE
PUMP SWASHPLATE IS PROPORTIONAL TO INPUT PRESSURE

ELECTRIC DISPLACEMENT 4HE ELECTRIC DISPLACEMENT CONTROL USES A 0RESSURE #ONTROL 0ILOT 0#0 VALVE TO MODULATE
CONTROL (EDC) PRESSURE BALANCE ACROSS THE SPRING CENTERED FOUR WAY SERVO VALVE4HE 0#0 VALVE
CONVERTS A $# ELECTRICAL INPUT SIGNAL TO A HYDRAULIC SIGNAL4HE SERVO VALVE PORTS HYDRAULIC
PRESSURE TO EITHER SIDE OF A DUAL ACTING SERVO PISTON4HE SERVO PISTON ROTATES THE
SWASHPLATE THROUGH AN ANGULAR ROTATION OF ¼² VARYING THE PUMPS DISPLACEMENT4HE
ANGULAR POSITION OF THE SWASHPLATE IS PROPORTIONAL TO THE %$# INPUT

AUTOMOTIVE CONTROL 4HE AUTOMOTIVE CONTROL ALLOWS THE OPERATOR TO DRIVE A VEHICLE SIMILAR TO AN AUTOMOBILE
(FBA II B) WITH AN AUTOMATIC TRANSMISSION4HE AUTOMOTIVE CONTROL INCLUDES A THREE POSITION
ELECTRIC CONTROL TO PROVIDE DIRECTION CONTROL

3-POSITION (FNR) 4HIS CONTROL UTILIZES A OR 6DC ELECTRICALLY OPERATED SPOOL VALVE TO PORT PRESSURE TO
ELECTRIC CONTROL EITHER SIDE OF THE PUMP SERVO PISTON %NERGIZING ONE OF THE SOLENOIDS CAUSES THE PUMP
TO GO TO ITS MAXIMUM DISPLACEMENT IN THE CORRESPONDING DIRECTION !LL FUNCTIONS OF THE
THREE POSITION &.2 ELECTRIC CONTROL ARE PRESET AT THE FACTORY

520L0818 s 2EV !# s December 2011 15

008 924 17 BOMAG 461
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
/PERATING PARAMETERS

OVERVIEW 4HIS SECTION DElNES THE OPERATING PARAMETERS AND LIMITATIONS FOR 3ERIES PUMPS WITH
REGARD TO INPUT SPEEDS AND PRESSURES &OR ACTUAL PARAMETERS REFER TO THE OPERATING
PARAMETERS FOR EACH DISPLACEMENT

INPUT SPEED Minimum speed IS THE LOWEST INPUT SPEED RECOMMENDED DURING ENGINE IDLE CONDITION
/PERATING BELOW MINIMUM SPEED LIMITS THE PUMPS ABILITY TO MAINTAIN ADEQUATE mOW FOR
LUBRICATION AND POWER TRANSMISSION

Continuous speed IS THE HIGHEST INPUT SPEED RECOMMENDED AT FULL POWER CONDITION
/PERATING AT OR BELOW THIS SPEED SHOULD YIELD SATISFACTORY PRODUCT LIFE

Maximum speed IS THE HIGHEST OPERATING SPEED PERMITTED %XCEEDING MAXIMUM SPEED
REDUCES PRODUCT LIFE AND CAN CAUSE LOSS OF HYDROSTATIC POWER AND BRAKING CAPACITY .EVER
EXCEED THE MAXIMUM SPEED LIMIT UNDER ANY OPERATING CONDITIONS

7HEN DETERMINING SPEED LIMITS FOR A PARTICULAR APPLICATION SEE 3AUER $ANFOSS
PUBLICATION BLN-9884 Pressure and speed limits.

W7ARNING
Unintended vehicle or machine movement hazard
%XCEEDING MAXIMUM SPEED MAY CAUSE A LOSS OF HYDROSTATIC DRIVE LINE POWER AND BRAKING
CAPACITY9OU MUST PROVIDE A BRAKING SYSTEM REDUNDANT TO THE HYDROSTATIC TRANSMISSION
SUFlCIENT TO STOP AND HOLD THE VEHICLE OR MACHINE IN THE EVENT OF HYDROSTATIC DRIVE POWER
loss.

SYSTEM PRESSURE System pressure IS THE DIFFERENTIAL PRESSURE BETWEEN SYSTEM PORTS ! AND " )T IS THE
DOMINANT OPERATING VARIABLE AFFECTING HYDRAULIC UNIT LIFE (IGH SYSTEM PRESSURE WHICH
RESULTS FROM HIGH LOAD REDUCES EXPECTED LIFE 3YSTEM PRESSURE MUST REMAIN AT OR BELOW
CONTINUOUS PRESSURE DURING NORMAL OPERATION TO ACHIEVE EXPECTED LIFE

Continuous pressure IS THE AVERAGE REGULARLY OCCURRING OPERATING PRESSURE /PERATING

AT OR BELOW THIS PRESSURE SHOULD YIELD SATISFACTORY PRODUCT LIFE

Maximum pressure IS THE HIGHEST INTERMITTENT PRESSURE ALLOWED -AXIMUM MACHINE

LOAD SHOULD NEVER EXCEED THIS PRESSURE &OR ALL APPLICATIONS THE LOAD SHOULD MOVE BELOW
THIS PRESSURE

!LL PRESSURE LIMITS ARE DIFFERENTIAL PRESSURES REFERENCED TO LOW LOOP CHARGE PRESSURE
3UBTRACT LOW LOOP PRESSURE FROM GAUGE READINGS TO COMPUTE THE DIFFERENTIAL

16 520L0818 s 2EV !# s December 2011

462 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
/PERATING PARAMETERS

CHARGE PRESSURE !N INTERNAL CHARGE RELIEF VALVE REGULATES CHARGE PRESSURE4HE CHARGE PUMP SUPPLIES THE
CONTROL WITH PRESSURE TO OPERATE THE SWASHPLATE AND TO MAINTAIN A MINIMUM PRESSURE IN
THE LOW SIDE OF THE TRANSMISSION LOOP

Minimum charge pressure IS THE LOWEST PRESSURE ALLOWED TO MAINTAIN A SAFE WORKING
CONDITION IN THE LOW SIDE OF THE LOOP -INIMUM CONTROL PRESSURE REQUIREMENTS ARE A
FUNCTION OF SPEED PRESSURE AND SWASHPLATE ANGLE AND MAY BE HIGHER THAN THE MINIMUM
CHARGE PRESSURE SHOWN IN THE OPERATING PARAMETERS TABLE

Maximum charge pressure IS THE HIGHEST CHARGE PRESSURE ALLOWED BY THE CHARGE RELIEF
ADJUSTMENT AND PROVIDES NORMAL COMPONENT LIFE9OU CAN USE ELEVATED CHARGE PRESSURE
AS A SECONDARY MEANS TO REDUCE THE SWASHPLATE RESPONSE TIME

4HE CHARGE PRESSURE SETTING IN THE ORDER CODE IS THE SET PRESSURE OF THE CHARGE RELIEF
VALVE WITH THE PUMP IN NEUTRAL OPERATING AT MIN-1 RPM AND WITH A mUID VISCOSITY
OF MM2SEC 353 4HE CHARGE PRESSURE SETTING IS REFERENCED TO CASE PRESSURE
#HARGE PRESSURE IS THE DIFFERENTIAL PRESSURE ABOVE CASE PRESSURE

CHARGE INLET PRESSURE !T NORMAL OPERATING TEMPERATURE CHARGE INLET PRESSURE MUST NOT FALL BELOW rated charge
inlet pressure.

Minimum charge inlet pressure IS ONLY ALLOWED AT COLD START CONDITIONS )N SOME
APPLICATIONS IT MAY BE NECESSARY TO WARM UP THE mUID BY RUNNING THE ENGINE AT LIMITED
SPEED UNTIL THE SYSTEM mUID TEMPERATURE REACHES AN ACCEPTABLE LEVEL

5NDER NORMAL OPERATING CONDITIONS DO NOT EXCEED THE rated case pressure $URING COLD
CASE PRESSURE START MAINTAIN THE CASE PRESSURE BELOW MAXIMUM INTERMITTENT CASE PRESSURE

C#AUTION
Possible component damage or leakage
/PERATION WITH CASE PRESSURE IN EXCESS OF STATED LIMITS MAY DAMAGE SEALS GASKETS ANDOR
HOUSINGS CAUSING EXTERNAL LEAKAGE 0ERFORMANCE MAY ALSO BE AFFECTED SINCE CHARGE AND
SYSTEM PRESSURE ARE ADDITIVE TO CASE PRESSURE

520L0818 s 2EV !# s December 2011 17

008 924 17 BOMAG 463
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
/PERATING PARAMETERS

TEMPERATURE AND Temperature

VISCOSITY 4HE HIGH TEMPERATURE LIMITS APPLY AT THE HOTTEST POINT IN THE TRANSMISSION LOOP WHICH
IS NORMALLY THE MOTOR CASE DRAIN -AINTAIN SYSTEM TEMPERATURE BELOW THE QUOTED rated
temperature.

.EVER EXCEED THE maximum intermittent temperature.

#OLD OIL WILL GENERALLY NOT AFFECT THE DURABILITY OF THE TRANSMISSION COMPONENTS BUT IT
MAY AFFECT THE ABILITY OF OIL TO mOW AND TRANSMIT POWER THEREFORE TEMPERATURES SHOULD
REMAIN ²# ; ²&= ABOVE THE POUR POINT OF THE HYDRAULIC mUID
4HE minimum temperature RELATES TO THE PHYSICAL PROPERTIES OF COMPONENT MATERIALS
3IZE HEAT EXCHANGERS TO KEEP THE mUID WITHIN THESE LIMITS4EST HEAT EXCHANGERS TO VERIFY
THAT THESE TEMPERATURE LIMITS ARE NOT EXCEEDED

Viscosity
&OR MAXIMUM EFlCIENCY AND BEARING LIFE ENSURE THE mUID VISCOSITY REMAINS IN THE
recommended range.

Minimum viscosity SHOULD BE ENCOUNTERED ONLY DURING BRIEF OCCASIONS OF MAXIMUM

AMBIENT TEMPERATURE AND SEVERE DUTY CYCLE OPERATION

Maximum viscosity SHOULD BE ENCOUNTERED ONLY AT COLD START

18 520L0818 s 2EV !# s December 2011

464 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
/PERATING PARAMETERS

FLUID AND FILTER 4O ENSURE OPTIMUM PUMP LIFE PERFORM REGULAR MAINTENANCE OF THE mUID AND lLTER
RECOMMENDATIONS #ONTAMINATED mUID IS THE MAIN CAUSE OF UNIT FAILURE -AINTAIN mUID CLEANLINESS WHEN
SERVICING

#HECK THE RESERVOIR DAILY FOR PROPER mUID LEVEL THE PRESENCE OF WATER AND RANCID mUID
ODOR &LUID CONTAMINATED BY WATER MAY APPEAR CLOUDY OR MILKY OR FREE WATER MAY
SETTLE IN THE BOTTOM OF THE RESERVOIR 2ANCID ODOR INDICATES THE mUID HAS BEEN EXPOSED
TO EXCESSIVE HEAT #HANGE THE mUID IMMEDIATELY IF THESE CONDITIONS OCCUR #ORRECT THE
PROBLEM IMMEDIATELY

)NSPECT VEHICLE FOR LEAKS DAILY

Fluid and ﬁlter change interval
#HANGE THE mUID AND lLTER PER THE Reservoir type Max oil change interval
VEHICLEMACHINE MANUFACTURERS 3EALED HOURS
RECOMMENDATIONS OR AT THE INTERVALS "REATHER HOURS
SHOWN IN THE TABLE #HANGE mUID AFTER
lRST HOURS

C#AUTION
(IGH TEMPERATURES AND PRESSURES RESULT IN ACCELERATED mUID AGING #HANGE mUID MORE
FREQUENTLY IF OPERATING UNDER EXTREME CONDITIONS

#HANGE THE mUID MORE FREQUENTLY IF IT BECOMES CONTAMINATED WITH FOREIGN MATTER DIRT
WATER GREASE ETC OR IF THE mUID IS SUBJECTED TO TEMPERATURE LEVELS GREATER THAN THE
RECOMMENDED MAXIMUM

$ISPOSE OF USED HYDRAULIC mUID PROPERLY .EVER REUSE HYDRAULIC mUID

#HANGE lLTERS WHENEVER THE mUID IS CHANGED OR WHEN THE lLTER INDICATOR INDICATES A lLTER
CHANGE 2EPLACE ALL mUID LOST DURING lLTER CHANGE

&OR DETAILED lLTRATION INFORMATION SEE 3AUER $ANFOSS PUBLICATION 520L0463 Fluids
and Filtration &OR INFORMATION ON BIODEGRADABLE mUIDS SEE 3AUER $ANFOSS PUBLICATION
520L0465 Biodegradable Hydraulic Fluids.

520L0818 s 2EV !# s December 2011 19

008 924 17 BOMAG 465
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
4ECHNICAL SPECIlCATIONS

OVERVIEW 3PECIlCATIONS AND OPERATING PARAMETERS FOR PUMPS APPEAR HERE FOR REFERENCE

FEATURES AND OPTIONS Model Series 90 Pumps

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

OPERATING Parameter Unit Pressure

PARAMETERS 2ATED ;=
bar
3YSTEM PRESSURE -AXIMUM ;=
;PSI=
-INIMUM LOW LOOP ;=
Minimum bar ;=
#HARGE PRESSURE
-AXIMUM ;PSI= ;=
2ATED BAR ABSOLUTE ;=
#HARGE INLET PRESSURE
-INIMUM COLD START ;IN (G VACUUM= ;=
2ATED bar ;=
#ASE PRESSURE
-AXIMUM ;PSI= ;=

Frame size
Parameter Unit
042 055 075 100 130 180 250
Displacement cm³ 100
MAXIMUM ;INÃ= ;= ;= ;= ;= ;= ;= ;=
Minimum speed min-1 RPM
Rated speed min-1 RPM 2600
Maximum speed min-1 RPM
Maximum attainable speed at
min-1 RPM
maximum displacement
.sMBAR
Theoretical torque at maximum 0.67 1.19 2.07
;LBFsIN
displacement ;= ;= ;= ;= ;= ;= ;=
PSI=
kg
Weight BASE UNIT ONLY
;LB= ;= ;= ;= ;= ;= ;= ;=

FLUID SPECIFICATIONS Parameter Unit Minimum Continuous Maximum

6ISCOSITY mm2SEC C3T 7 12-60 1600
;353= ;= ; = ;=
2ATINGS AND DATA ARE BASED 4EMPERATURE ²# ;²&= ; = ;= ;=
ON OPERATION WITH PREMIUM #LEANLINESS )3/ #LASS OR BETTER
PETROLEUM BASED HYDRAULIC &ILTRATION EFlCIENCY SUCTION lLTRATION 10
mUIDS CONTAINING OXIDATION CHARGE lLTRATION 10
AND FOAM INHIBITORS

20 520L0818 s 2EV !# s December 2011

466 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NITIAL START UP PROCEDURE

GENERAL &OLLOW THIS PROCEDURE WHEN STARTING UP A NEW PUMP INSTALLATION OR WHEN RESTARTING AN
INSTALLATION IN WHICH THE PUMP WAS REMOVED

W 7ARNING
5NINTENDED MOVEMENT OF THE MACHINE OR MECHANISM MAY CAUSE INJURY TO THE TECHNICIAN
OR BYSTANDERS4O PROTECT AGAINST UNINTENDED MOVEMENT SECURE THE MACHINE OR DISABLE
DISCONNECT THE MECHANISM WHILE SERVICING

0RIOR TO INSTALLING THE PUMP INSPECT FOR SHIPPING DAMAGE

START-UP PROCEDURE %NSURE THAT THE HYDRAULIC mUID AND SYSTEM COMPONENTS RESERVOIR HOSES VALVES
lTTINGS AND HEAT EXCHANGER ARE CLEAN AND FREE OF CONTAMINATION

)NSTALL NEW SYSTEM lLTER ELEMENTS IF NECESSARY #HECK THAT INLET LINE lTTINGS ARE
PROPERLY TIGHTENED AND THERE ARE NO AIR LEAKS

)NSTALL THE PUMP )NSTALL A BAR ; PSI= GAUGE IN THE CHARGE PRESSURE GAUGE PORT
-

&ILL THE HOUSING BY ADDING lLTERED mUID IN THE UPPER CASE DRAIN PORT /PEN THE CASE
PLUG IN THE TOP OF THE CONTROL TO ASSIST WITH AIR BLEED

&ILL THE RESERVOIR WITH HYDRAULIC mUID OF THE RECOMMENDED TYPE AND VISCOSITY 5SE A
MICRON lLLER lLTER &ILL INLET LINE FROM RESERVOIR TO PUMP

$ISCONNECT THE PUMP CONTROL INPUT SIGNAL

!FTER START UP THE mUID LEVEL IN THE RESERVOIR MAY DROP DUE TO lLLING OF THE SYSTEM
COMPONENTS #HECK THE LEVEL IN THE RESERVOIR TO MAINTAIN A FULL mUID LEVEL THROUGHOUT THE
START UP PROCEDURE

C #AUTION
$AMAGE TO HYDRAULIC COMPONENTS MAY OCCUR FROM FAILURE TO MAINTAIN mUID SUPPLY

5SE A COMMON METHOD TO DISABLE THE ENGINE TO PREVENT THE ENGINE FROM STARTING
#RANK THE STARTER FOR SEVERAL SECONDS $O NOT TO EXCEED THE ENGINE MANUFACTURERS
RECOMMENDATION7AIT SECONDS AND THEN CRANK THE ENGINE A SECOND TIME
4HIS OPERATION HELPS REMOVE AIR FROM THE SYSTEM LINES 2ElLL THE RESERVOIR TO
RECOMMENDED FULL mUID LEVEL

520L0818 s 2EV !# s December 2011 21

008 924 17 BOMAG 467
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NITIAL START UP PROCEDURE

START-UP PROCEDURE 7HEN CHARGE PRESSURE REACHES BAR ; PSI= ENABLE AND START ENGINE ,ET THE
(continued) ENGINE RUN FOR A MINIMUM OF SECONDS AT LOW IDLE TO ALLOW THE AIR TO WORK ITSELF OUT
OF THE SYSTEM #HECK FOR LEAKS AT ALL LINE CONNECTIONS AND LISTEN FOR CAVITATION #HECK
FOR PROPER mUID LEVEL IN RESERVOIR

C#AUTION
!IR ENTRAPMENT IN mUID UNDER HIGH PRESSURE MAY DAMAGE HYDRAULIC COMPONENTS

C#AUTION
$O NOT RUN AT MAXIMUM PRESSURE UNTIL SYSTEM IS FREE OF AIR AND mUID HAS BEEN THOROUGHLY
lLTERED

7HEN ADEQUATE CHARGE PRESSURE IS ESTABLISHED AS SHOWN IN MODEL CODE INCREASE
ENGINE SPEED TO NORMAL OPERATING RPM TO FURTHER PURGE RESIDUAL AIR FROM THE SYSTEM

3HUT OFF THE ENGINE #ONNECT THE PUMP CONTROL SIGNAL 3TART THE ENGINE CHECKING TO
BE CERTAIN THE PUMP REMAINS IN NEUTRAL 2UN THE ENGINE AT NORMAL OPERATING SPEED
AND CAREFULLY CHECK FOR FORWARD AND REVERSE CONTROL OPERATION

#ONTINUE TO CYCLE BETWEEN FORWARD AND REVERSE FOR AT LEAST lVE MINUTES TO BLEED ALL
AIR AND mUSH SYSTEM CONTAMINANTS OUT OF LOOP

.ORMAL CHARGE PRESSURE mUCTUATION MAY OCCUR DURING FORWARD AND REVERSE OPERATION

#HECK THAT THE RESERVOIR IS FULL 2EMOVE CHARGE PRESSURE GAUGE4HE PUMP IS NOW
READY FOR OPERATION

22 520L0818 s 2EV !# s December 2011

468 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
0RESSURE MEASUREMENT

REQUIRED TOOLS 9OU CAN PERFORM THE SERVICE PROCEDURES DESCRIBED IN THIS MANUAL USING COMMON
MECHANICS TOOLS 3PECIAL TOOLS IF REQUIRED ARE SHOWN 5SE CALIBRATED PRESSURE GAUGES TO
ENSURE ACCURACY 5SE SNUBBERS TO PROTECT PRESSURE GAUGES

PORT LOCATIONS AND 4HE FOLLOWING SECTIONS LIST THE PORTS FOR EACH TYPE OF HYDRAULIC UNIT4HE lTTING SIZE AND
GAUGE INSTALLATION RECOMMENDED PRESSURE GAUGE ARE ALSO SPECIlED

4HE FOLLOWING TABLE AND DRAWINGS SHOW THE PORT LOCATIONS AND GAUGE SIZES NEEDED

Port information
Port identiﬁer Pressure obtained Gauge size Port size
M1, M2 3YSTEM PRESSURE BAR ; PSI=
M3 (M6) #HARGE PRESSURE BAR ; PSI=
M4, M5 Servo pressure BAR ; PSI=
L1, L2 #ASE PRESSURE BAR ; PSI=

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

3!% SPLIT mANGE

520L0818 s 2EV !# s December 2011 23

008 924 17 BOMAG 469
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
0RESSURE MEASUREMENT

PORT LOCATIONS AND

GAUGE INSTALLATION
(continued)

Pump with side port end cap and manual displacement control

Case drain Servo / displacement

port L1 cylinder pressure
gauge port M4

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

Charge inlet pressure

(vacuum)

System pressure
gauge port M1

Carge pump
inlet port S System pressure
port A Case drain port L2 Charge pressure
gauge port M3 P106 158E

24 520L0818 s 2EV !# s December 2011

470 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
0RESSURE MEASUREMENT

PORT LOCATIONS AND

GAUGE INSTALLATION
(continued)

Pump with twin port end cap and manual displacement control
Servo / displacement
cylinder pressure
gauge port M4
Case drain
port L1

Servo / displacement
cylinder pressure
gauge port M5

System pressure
gauge port M2

System pressure
port B

Charge pump inlet

port S

System pressure
port A
System pressure
gauge port M1
Case drain port L2

P106 160E

Pump with side port end cap and remote pressure ﬁltration Pump with side port end cap and integral pressure
ﬁltration

Charge pressure
gauge port M6 Port E
(before the filter) (from filter)

Port D
(to filter)

Charge pressure
gauge port M3
Charge pressure (back side-after
gauge port M3 the filter)
(after the filter)

P106 163E

520L0818 s 2EV !# s December 2011 25

008 924 17 BOMAG 471
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
4ROUBLESHOOTING

OVERVIEW 4HIS SECTION PROVIDES GENERAL STEPS TO FOLLOW IF CERTAIN UNDESIRABLE SYSTEM CONDITIONS
OCCUR &OLLOW THE STEPS IN A SECTION UNTIL YOU SOLVE THE PROBLEM 3OME OF THE ITEMS
ARE SYSTEM SPECIlC &OR AREAS COVERED IN THIS MANUAL WE REFERENCE THE SECTION !LWAYS
OBSERVE THE SAFETY PRECAUTIONS LISTED IN THE Introduction SECTION PAGE AND THOSE
RELATING TO YOUR SPECIlC EQUIPMENT

NEUTRAL DIFFICULT OR
IMPOSSIBLE TO FIND

Item Description Action

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

SYSTEM OPERATING HOT

Item Description Action

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

26 520L0818 s 2EV !# s December 2011

472 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
4ROUBLESHOOTING

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

IMPROPER MOTOR
OUTPUT SPEED

Item Description Action

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

SYSTEM NOISE OR
VIBRATION

Item Description Action

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

28 520L0818 s 2EV !# s December 2011

474 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
4ROUBLESHOOTING

SYSTEM RESPONSE IS
SLUGGISH

Item Description Action

Oil level in reservoir )NSUFlCIENT HYDRAULIC mUID CAUSES SLUGGISH RESPONSE &ILL RESERVOIR TO PROPER LEVEL
-ULTI FUNCTION VALVES PRESSURE )NCORRECT PRESSURE SETTINGS AFFECTS SYSTEM REACTION !DJUST OR REPLACE MULTI FUNCTION VALVES
SETTINGS TIME
0UMP INLET VACUUM (IGH PUMP INLET VACUUM REDUCES SYSTEM PRESSURE -EASURE CHARGE INLET VACUUM )F HIGH REPLACE INLET lLTER
0RIME MOVER SPEED ,OW ENGINE SPEED REDUCES SYSTEM PERFORMANCE !DJUST ENGINE SPEED
#HARGE AND CONTROL PRESSURES )NCORRECT CHARGE OR CONTROL PRESSURES AFFECTS SYSTEM -EASURE CHARGE AND CONTROL PRESSURES AND CORRECT IF
performance. NECESSARY
3YSTEM INTERNAL LEAKAGE )NTERNAL LEAKAGE REDUCES SYSTEM PRESSURE #HECK FOR LEAKAGE IN / RINGS GASKETS AND OTHER lTTINGS

520L0818 s 2EV !# s December 2011 29

008 924 17 BOMAG 475
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

STANDARD
PROCEDURES, "EFORE WORKING ON THE PUMP CLEAN THE OUTSIDE OF THE PUMP
INSPECTIONS, AND
ADJUSTMENTS
CCaution
#ONTAMINATION CAN DAMAGE INTERNAL COMPONENTS AND VOID YOUR WARRANTY4AKE
PRECAUTIONS TO ENSURE SYSTEM CLEANLINESS WHEN REMOVING AND REINSTALLING SYSTEM LINES

7ITH THE PRIME MOVER OFF THOROUGHLY CLEAN THE OUTSIDE OF THE PUMP

)F REMOVING THE PUMP TAG EACH HYDRAULIC LINE CONNECTED TO THE PUMP )F HYDRAULIC
LINES ARE DISCONNECTED PLUG EACH OPEN PORT WITH A CLEAN PLUG TO ENSURE THAT DIRT AND
CONTAMINATION DO NOT GET INTO THE PUMP

%NSURE THE SURROUNDING AREAS ARE CLEAN AND FREE OF CONTAMINANTS

)NSPECT THE SYSTEM FOR CONTAMINATION

6ISUALLY INSPECT THE HYDRAULIC mUID FOR SIGNS OF SYSTEM CONTAMINATION mUID
DISCOLORATION FOAM IN THE mUID SLUDGE OR SMALL METAL PARTICLES

)F THERE ARE SIGNS OF CONTAMINATION IN THE HYDRAULIC mUID REPLACE ALL lLTERS DRAIN AND
mUSH THE HYDRAULIC SYSTEM AND lLL WITH THE CORRECT lLTERED HYDRAULIC mUID

&LUSH THE LINES BEFORE REPLACING THE HYDRAULIC mUID

30 520L0818 s 2EV !# s December 2011

476 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

ADJUSTMENTS 4HIS SECTION OFFERS INSTRUCTION ON INSPECTION AND ADJUSTMENT OF PUMP COMPONENTS 2EAD
THROUGH THE ENTIRE RELATED SECTION BEFORE BEGINNING A SERVICE ACTIVITY 2EFER TO Pressure
measurements PAGES AND FOR LOCATION OF GAUGE PORTS AND SUGGESTED GAUGE
SIZES

CHARGE PRESSURE 4HE FOLLOWING PROCEDURE EXPLAINS HOW TO CHECK AND ADJUST THE CHARGE PRESSURE RELIEF
RELIEF VALVE valve.
ADJUSTMENT
)NSTALL A BAR ; PSI= PRESSURE GAUGE IN THE PUMP CHARGE PRESSURE GAUGE PORT
W Warning - )NSTALL A BAR ; PSI= GAUGE TO MEASURE CASE PRESSURE TEE INTO , OR , OR
4HE FOLLOWING PROCEDURE USE SERVO GAUGE PORT - OR - /PERATE THE SYSTEM WITH THE PUMP IN NEUTRAL ZERO
MAY REQUIRE THE VEHICLE DISPLACEMENT WHEN MEASURING PUMP CHARGE PRESSURE
MACHINE TO BE DISABLED
WHEELS RAISED OFF THE 4HE TABLE SHOWS THE ACCEPTABLE PUMP CHARGE PRESSURE RANGE FOR SOME CHARGE RELIEF
GROUND WORK FUNCTION VALVE SETTINGS4HESE PRESSURES ASSUME MINÂ RPM AND A RESERVOIR TEMPERATURE
DISCONNECTED ETC IN ORDER OF ²# ;²&= AND ARE REFERENCED TO CASE PRESSURE
TO PREVENT INJURY TO THE
TECHNICIAN AND BYSTANDERS
4AKE NECESSARY SAFETY Charge pressure relief valve
Case drain port L1
PRECAUTIONS BEFORE MOVING
THE VEHICLEMACHINE M4 G )(*!
K90 B 1 1/16-12
Adjusting screw t .% $.t]
K10 M5
Lock nut
.% $.t]

Charge pressure gauge port M3

G )(*!
B
t .% $.t]

(()'()!++$ P106 162E

,ISTED PRESSURES ASSUME A PUMP SPEED Charge pressure ranges

OF MIN-1 RPM !T HIGHER PUMP Model code Measured charge pressure*
INPUT SPEEDS WITH HIGHER CHARGE mOWS n BAR
20
THE CHARGE PRESSURE WILL RISE OVER THE ; n PSI=
RATED SETTING n BAR

; n PSI=
n BAR

; n PSI=
4HIS IS THE ACTUAL CHARGE PRESSURE PORT GAUGE
READING MINUS THE CASE PRESSURE PORT GAUGE
READING

520L0818 s 2EV !# s December 2011 31

008 924 17 BOMAG 477
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

CHARGE PRESSURE %ARLIER PRODUCTION 3ERIES PUMPS HAVE A SHIM ADJUSTABLE CHARGE PRESSURE RELIEF
RELIEF VALVE VALVE 3HIM KITS ARE AVAILABLE FROM 3AUER $ANFOSS 2EMOVE THE PLUG USING A IN HEX
ADJUSTMENT WRENCH AND EXCHANGE SHIMS BEHIND THE SPRING TO ADJUST CHARGE PRESSURE4ORQUE
(continued) PLUG TO .sM ; LBFsFT=

,ATER PRODUCTION 3ERIES PUMPS HAVE AN EXTERNAL SCREW ADJUSTABLE CHARGE

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

Lock nut wrench size

Frame size Wrench size
n INCH
n INCH

#LOCKWISE ROTATION OF THE PLUG INCREASES THE SETTING AND COUNTERCLOCKWISE ROTATION
DECREASES THE SETTING AT A RATE OF APPROXIMATELY BAR ; PSI= PER TURN 4ORQUE
LOCK NUT TO .sM ; LBFsFT=

/NCE YOU ACHIEVE THE DESIRED CHARGE PRESSURE SETTING REMOVE THE GAUGES AND PLUG
THE PORTS

32 520L0818 s 2EV !# s December 2011

478 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

MULTI-FUNCTION VALVE 9OU ACCOMPLISH ADJUSTMENT OF THE PRESSURE LIMITER SETTING AND THE HIGH PRESSURE RELIEF
PRESSURE ADJUSTMENT VALVE (026 SETTING SIMULTANEOUSLY4HE (026 SETTING IS AUTOMATICALLY SET APPROXIMATELY
BAR ; PSI= ABOVE THE PRESSURE LIMITER SETTING

W7ARNING ,OCK THE MOTOR OUTPUT SHAFT BY LOCKING THE VEHICLES BRAKES OR RIGIDLY lXING THE WORK
4AKE NECESSARY PRECAUTIONS FUNCTION SO IT CANNOT ROTATE OR CAP THE SYSTEM PORTS W
THAT THE MOTOR SHAFT
REMAINS STATIONARY DURING
THE ADJUSTMENT PROCEDURE
Multi-function valve adjustment

Charge pressure gauge port M3

G 0 - 50 bar [0 - 1000 psi]
B 9/16-18
t 1% $1t]

I Adjusting screw
h Lo#&-,+%$$* /&-,
tLock nut torque ((*'(*!,,$

System pressure gauge port M2

G 0 - 1000 bar [0 - 10000 psi]
B 9/16-18
t 1% $1t]
System pressure gauge port M1
G 0 - 1000 bar [0 - 10000 psi]
B 9/16-18
t 1% $1t]
P106 168E

)NSTALL TWO BAR OR PSI PRESSURE GAUGES IN THE HIGH PRESSURE GAUGE
PORTS - AND - )NSTALL A BAR OR PSI PRESSURE GAUGE IN THE PUMP CHARGE
PRESSURE GAUGE PORT -

3TART THE PRIME MOVER AND OPERATE AT NORMAL SPEED

,OOSEN LOCKING NUT

)NSERT AN INTERNAL HEX WRENCH INTO THE PRESSURE ADJUSTING SCREW

! PLASTIC DUST PLUG IS INSTALLED IN THE ADJUSTING SCREW

520L0818 s 2EV !# s December 2011 33

008 924 17 BOMAG 479
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

MULTI-FUNCTION VALVE 4HE MODEL CODE SHOWS THE FACTORY PRESET PRESSURE LIMITER SETTING )T IS REFERENCED TO
PRESSURE ADJUSTMENT CHARGE PRESSURE SO THE PRESSURE LIMITER SETTING IS THE DIFFERENCE BETWEEN THE HIGH
(continued) AND LOW PRESSURE SIDES OF THE SYSTEM LOOP !CTIVATE OR MOVE THE CONTROL INPUT SO
THAT PRESSURE INCREASES IN THE HIGH PRESSURE SIDE OF THE CLOSED CIRCUIT TO THE PRESSURE
LIMITER PRESSURE SETTING4HE PRESSURE LIMITER SETTING IS REACHED WHEN THE PRESSURE
STOPS INCREASING AND REMAINS STEADY AT A GIVEN PRESSURE LEVEL AS SHOWN ON THE
GAUGES

2ETURN THE PUMP TO ITS NEUTRAL ZERO mOW POSITION AND ADJUST THE PRESSURE LIMITER
SETTING BY ROTATING THE PRESSURE ADJUSTING SCREW WITH AN INTERNAL HEX WRENCH

#LOCKWISE ROTATION OF THE PRESSURE ADJUSTMENT SCREW INCREASES THE PRESSURE SETTING
AND COUNTERCLOCKWISE ROTATION DECREASES THE PRESSURE SETTING %ACH COMPLETE
ROTATION OF THE PRESSURE ADJUSTING SCREW CHANGES THE PRESSURE AS SHOWN IN THE
FOLLOWING TABLE

Pressure limiter adjustment data

Frame size Lock nut wrench size and torque Adjusting Approximate pressure change
screw size per revolution of adjusting screw
EARLY MM .sM ; LBFsIN= MM BAR ; PSI=
MM .sM ; LBFsFT= MM BAR ; PSI=
EARLY MM .sM ; LBFsFT= MM BAR ; PSI=
MM .sM ; LBFsFT= MM BAR ; PSI=

4O VERIFY THE ACTUAL PRESSURE SETTING ACTUATE OR MOVE THE CONTROL INPUT SO THAT THE
PUMP AGAIN DEVELOPS PRESSURE IN THE HIGH PRESSURE CIRCUIT TO THE NEWLY ADJUSTED
PRESSURE LIMITER PRESSURE SETTING THEN READ THE HIGH PRESSURE GAUGE !LLOW THE PUMP
TO RETURN TO ITS NEUTRAL POSITION4HE PRESSURE IN THE HIGH PRESSURE CIRCUIT SHOULD
RETURN TO THE CHARGE PRESSURE SETTING

7HILE HOLDING THE PRESSURE ADJUSTING SCREW STATIONARY TIGHTEN THE PRESSURE ADJUSTING
SCREW LOCK NUT4ORQUE AS SHOWN IN THE TABLE

$O NOT OVERTORQUE

3HUT DOWN THE PRIME MOVER REMOVE THE GAUGES AND INSTALL THE GAUGE PORT PLUGS
2EPLACE THE PLASTIC DUST PLUGS IF USED

5SE THE SAME PROCEDURE FOR SETTING THE PRESSURE LIMIT OF THE OTHER MULTI FUNCTION VALVE
-OVE OR ACTIVATE THE CONTROL INPUT SIGNAL IN THE OPPOSITE DIRECTION SO THAT HIGH PRESSURE
DEVELOPS IN THE OPPOSITE SIDE OF THE CLOSED CIRCUIT

34 520L0818 s 2EV !# s December 2011

480 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

ENGAGING THE BYPASS 4HE MULTI FUNCTION VALVE CARTRIDGES PERFORM THE BYPASS FUNCTION 3HUT DOWN THE PRIME
FUNCTION MOVER WHEN ENGAGING THE BYPASS FUNCTION /PEN BOTH THE BYPASS VALVES TO ENGAGE THE
BYPASS FUNCTION

C#AUTION LOOSEN THE BYPASS ACTUATOR THREE Bypass actuator wrench size
$AMAGE TO THE PUMP AND TURNS 2EFER TO TABLE FOR WRENCH SIZE Frame size Wrench size
MOTOR CAN RESULT FROM NEWER n INCH
ROTATING THESE COMPONENTS $O NOT ROTATE MORE THAN n INCH
WITHOUT CHARGE mOW FOR REVOLUTIONS AS ADDITIONAL ROTATION WILL
LUBRICATION "YPASS VALVES PERMIT EXTERNAL LEAKAGE Multi-Function Valve with Bypass
ARE INTENDED FOR MOVING Function Engaged
A MACHINE OR VEHICLE FOR &OR UNITS WITH AN -$# TYPE CONTROL Opening bypass valve
allows flow to circuit
VERY SHORT DISTANCES AT VERY PRIOR TO MOVING THE VEHICLE OR Bypass through multi-function valves
SLOW SPEEDS4HEY ARE NOT OTHERWISE CAUSING THE MOTOR SHAFT actuator

TOW VALVES TO TURN MOVE THE CONTROL HANDLE OF

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

4O CLOSE THE BYPASS VALVE TIGHTEN THE

BYPASS ACTUATOR 3EE TABLE PROVIDED Bypass actuator torque
FOR PROPER TORQUE Frame size Torque
NEWER n .sM ; LBFsFT=
n .sM ; LBFsFT=

520L0818 s 2EV !# s December 2011 35

008 924 17 BOMAG 481
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

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

UNINTENDED MOVEMENT 7ITH THE PUMP OPERATING AT

SECURE THE MACHINE APPROXIMATELY DISPLACEMENT
OR DISABLEDISCONNECT LOAD THE WORK FUNCTION AND NOTE THE PRESSURE AS THE 0/2 VALVE OPERATES PUMP
THE MECHANISM WHILE DISPLACEMENT REDUCES TO ZERO
SERVICING
!DJUST THE PRESSURE OVERRIDE SETTING BY LOOSENING THE LOCK NUT WITH A INCH HEX
WRENCH AND TURNING THE ADJUSTMENT SCREW WITH A INCH INTERNAL HEX WRENCH
3ET THE 0/2 SETTING TO AT LEAST BAR ; PSI= BELOW THE HIGH PRESSURE RELIEF VALVE
SETTING OF THE MULTI FUNCTION VALVES

4ORQUE THE LOCK NUT TO .sM ; LBFsFT=

3HUT DOWN THE PRIME MOVER AND REMOVE THE GAUGES AND INSTALL THE GAUGE PORT
PLUGS

36 520L0818 s 2EV !# s December 2011

482 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

DISPLACEMENT LIMITER 9OU CAN LIMIT THE MAXIMUM DISPLACEMENT IN EITHER DIRECTION
ADJUSTMENT
,OOSEN THE LOCK NUT & WHILE Displacement limiter adjustment
HOLDING THE ADJUSTING SCREW &
STEADY

2OTATE THE ADJUSTING SCREW SOME

C#AUTION AMOUNT USING INFORMATION IN THE
4AKE CARE IN ADJUSTING FOLLOWING TABLE C2OTATING THE
DISPLACEMENT LIMITERS TO ADJUSTING SCREW CLOCKWISE DECREASES
AVOID UNDESIRABLE mOW OR THE MAXIMUM DISPLACEMENT OF THE
SPEED CONDITIONS 2E PUMP WHILE ROTATING THE ADJUSTING
TORQUE LOCK NUT & SCREW COUNTERCLOCKWISE INCREASES
AFTER EVERY ADJUSTMENT TO THE MAXIMUM DISPLACEMENT
PREVENT AN UNEXPECTED
F213
CHANGE IN OPERATING /NE TURN OF THE ADJUSTING SCREW IAdjusting screw
CONDITIONS AND TO PREVENT CHANGES THE MAXIMUM DISPLACEMENT
EXTERNAL LEAKAGE DURING AS SHOWN IN TABLE BELOW F212
Lock nut
UNIT OPERATION
Lock nut torque
!FTER ESTABLISHING THE DESIRED
MAXIMUM DISPLACEMENT SETTING
TORQUE THE LOCK NUT TO THE TORQUE P106 164E

SHOWN IN TABLE BELOW

Frame size Lock nut wrench size and torque Adjusting Approximate displacement change
screw size per revolution of adjusting screw
MM .sM ; LBFsFT= MM CMÃREV ; INÃREV=
MM .sM ; LBFsFT= MM CMÃREV ; INÃREV=
MM .sM ; LBFsFT= MM CMÃREV ; INÃREV=
MM .sM ; LBFsFT= MM CMÃREV ; INÃREV=
100 MM .sM ; LBFsFT= MM CMÃREV ; INÃREV=
MM .sM ; LBFsFT= MM CMÃREV ; INÃREV=
MM .sM ; LBFsFT= 6 mm CMÃREV ; INÃREV=
MM .sM ; LBFsFT= 6 mm CMÃREV ; INÃREV=

STANDARD MANUAL 4HERE ARE NO ADJUSTABLE ELEMENTS IN THE MANUAL DISPLACEMENT CONTROL #ENTERING SPRINGS
DISPLACEMENT AND WASHERS ON EACH END OF THE CONTROL SPOOL HOLD IT IN ITS NEUTRAL POSITION 3INCE THERE
CONTROL (MDC) IS NO CENTERING SPRING ON THE CONTROL INPUT SHAFT THE SHAFT AUTOMATICALLY ASSUMES THE
ADJUSTMENT APPROPRIATE POSITION WHEN THE CONTROL IS INSTALLED ON THE PUMP

520L0818 s 2EV !# s December 2011 37

008 924 17 BOMAG 483
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

NON-LINEAR MANUAL ! CENTERING SPRING LOCATED ON THE CONTROL INPUT SHAFT LOCATES THE CONTROL SHAFT IN ITS
DISPLACEMENT NEUTRAL POSITION ! BIAS SPRING ON THE CONTROL SPOOL MAINTAINS A FORCE ON THE SPOOL AND
CONTROL (MDC) THE CONTROL LINKAGE TO ELIMINATE FREE PLAY IN THE LINKAGE

.EUTRAL ADJUSTMENT IS THE ONLY ADJUSTMENT THAT CAN BE MADE ON THE NONLINEAR MANUAL
DISPLACEMENT CONTROL !LL OTHER FUNCTIONS ARE PRESET AT THE FACTORY 0ERFORM NEUTRAL
ADJUSTMENT ON A TEST STAND OR ON THE VEHICLEMACHINE WITH THE PRIME MOVER OPERATING

MDC neutral adjustment

Servo pressure gauge port M5
0 - 50 bar [0 - 1000 psi]
Servo pressure gauge port M4 9/16-18
$ $t]
G 0 - 50 bar [0 - 1000 psi]
B 9/16-18 M72
t $ $t] I

M90

$$t]
P106 165E

)NSTALL A BAR ; PSI= GAUGE IN EACH OF THE TWO SERVO CYLINDER GAUGE PORTS -
AND - $ISCONNECT THE EXTERNAL CONTROL LINKAGE FROM THE CONTROL HANDLE AND MAKE
CERTAIN THE CONTROL SHAFT IS IN ITS NEUTRAL POSITION 3TART THE PRIME MOVER AND OPERATE
AT NORMAL SPEED

,OOSEN THE LOCK NUT - ON THE NEUTRAL ADJUSTING SCREW - WITH A MM HEX
WRENCH

5SING A MM INTERNAL HEX WRENCH ROTATE THE NEUTRAL ADJUSTING SCREW CLOCKWISE UNTIL
THE PRESSURE INCREASES ON ONE OF THE PRESSURE GAUGES .OTE THE ANGULAR POSITION OF
THE WRENCH4HEN ROTATE THE ADJUSTING SCREW COUNTERCLOCKWISE UNTIL THE PRESSURE
INCREASES BY AN EQUAL AMOUNT ON THE OTHER GAUGE .OTE THE ANGULAR POSITION OF THE
WRENCH

2OTATE THE ADJUSTING SCREW CLOCKWISE HALF THE DISTANCE BETWEEN THE LOCATIONS NOTED
ABOVE4HE GAUGES SHOULD READ THE SAME PRESSURE INDICATING THAT THE CONTROL IS IN ITS
NEUTRAL POSITION

38 520L0818 s 2EV !# s December 2011

484 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

NON-LINEAR MANUAL (OLD THE ADJUSTING SCREW STATIONARY AND TIGHTEN THE LOCK NUT TO .sM ; LBFsFT=
DISPLACEMENT $O NOT OVERTORQUE THE NUT
CONTROL (MDC)
(continued) /NCE THE NEUTRAL POSITION IS SET STOP THE PRIME MOVER REMOVE THE GAUGES AND INSTALL
THE GAUGE PORT PLUGS 2ECONNECT THE EXTERNAL CONTROL LINKAGE

MDC NEUTRAL 4HE .EUTRAL 3TART 3WITCH .33 PROVIDES MDC with neutral start switch
START SWITCH (NSS) A MEANS TO PREVENT THE SYSTEM PRIME
A A
ADJUSTMENTS MOVER FROM STARTING WHILE THE PUMP
CONTROL HANDLE IS IN STROKE7HEN THE
Control shaft Switch cam
CONTROL INPUT SHAFT IS IN ITS NEUTRAL
POSITION THE SWITCH PIN ENGAGES A SLOT ON
THE ECCENTRIC CAM ATTACHED TO THE CONTROL Switch lock nut
SHAFT4HIS ALLOWS THE SPRING LOADED Neutral start switch
.33 TO CLOSE COMPLETING THE ELECTRICAL
Eccentric plug
STARTING CIRCUIT FOR THE PRIME MOVER
Switch pin
7HEN THE CONTROL INPUT SHAFT IS NOT IN ITS
Special lock nut
NEUTRAL POSITION THE ECCENTRIC CAM OPENS for eccentric plug
THE .33 SWITCH

4HE NEUTRAL START SWITCH IS THREADED INTO View at section A-A

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

520L0818 s 2EV !# s December 2011 39

008 924 17 BOMAG 485
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

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

SPOOL ENOUGH TO PORT HYDRAULIC

mUID TO THE PUMP DISPLACEMENT Control shaft

CONTROL CYLINDERS IS THE control

deadband4HESE DEADBANDS MUST
BE CONCENTRIC

3INCE YOU CANNOT ADJUST THE POSITION

OF THE CONTROL DEADBAND YOU MUST
ADJUST THE POSITION OF THE .33
DEADBAND TO MATCH IT

II 4HE .33 DEADBAND MUST BE WIDE

ENOUGH SO THE .33 WILL NOT OPEN
WITHIN THE LOOSE AREA OF CONTROL
HANDLE MOVEMENT CAUSED BY NORMAL P104 147E
OPERATING CLEARANCES IN THE CONTROL
LINKAGE CONTROL SHAFT FREE PLAY

"Y SETTING THE .33 TO OPEN OUTSIDE THIS AREA THE CONTROL SPOOL SPRINGS OR CONTROL
SHAFT CENTERING SPRING CAN ALWAYS RETURN THE HANDLE TO NEUTRAL AND RE CLOSE THE .33

III 4HE .33 DEADBAND MUST BE NARROW ENOUGH SO THE .33 WILL OPEN BEFORE THE UNIT
BUILDS BAR ; PSI= DIFFERENTIAL SYSTEM PRESSURE IN EITHER DIRECTION

40 520L0818 s 2EV !# s December 2011

486 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

MDC NEUTRAL Neutral start switch eccentric plug Eccentric plug adjustment tool
START SWITCH (NSS) adjustment (condition i)
12.7 9.14
ADJUSTMENTS #ENTER THE .33 DEADBAND AND THE [0.5] [0.36]
(continued) CONTROL DEADBAND IN RELATION TO EACH
OTHER 3INCE YOU CANNOT ADJUST THE
POSITION OF THE CONTROL DEADBAND YOU
MUST ADJUST THE POSITION OF THE .33 3.175 1.52
[0.125] [0.06]
DEADBAND TO MATCH IT4HE SWITCH PIN 25.4
IS LOCATED IN AN ECCENTRIC PLUG WHICH [1.0]

YOU TURN TO MOVE THE CENTER OF THE .33

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

(OLD THE SWITCH AND ECCENTRIC PLUG

FROM TURNING AND USE A INCH
WRENCH TO LOOSEN THE LOCK NUT B

W 7ARNING 2EMOVE THE NEUTRAL START SWITCH W Switch

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

FROM THE CONTROL #ASE ECCENTRIC PLUG IN PLACE WITH THE

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

THE PIN AND THE CAM ON THE CONTROL

SHAFT

520L0818 s 2EV !# s December 2011 41

008 924 17 BOMAG 487
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

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

ENGAGES THE CAM SLOT THE PIN WILL BE

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

4URN THE CONTROL SHAFT AN EQUAL

AMOUNT IN EITHER DIRECTION FROM
NEUTRAL4HE SWITCH PIN SHOULD MOVE OUT OF THE ECCENTRIC PLUG AN EQUAL DISTANCE
WHEN THE CONTROL SHAFT IS TURNED4URN THE ECCENTRIC PLUG TO CENTER THE SWITCH PIN
WITH THE CAM SLOT /NLY A SMALL AMOUNT OF ADJUSTMENT IN EITHER DIRECTION IS NEEDED TO
CENTER THE PIN

7HILE HOLDING THE ECCENTRIC PLUG IN PLACE TIGHTEN THE ECCENTRIC PLUG LOCK NUT TO
.sM ; LBFsFT= 2EINSTALL AND ADJUST THE SWITCH AS OUTLINED IN THE PREVIOUS SECTION

4HE ECCENTRIC PLUG NORMALLY REQUIRES BETWEEN AND TURNS TO INSTALL INTO THE
CONTROL HOUSING

C#AUTION
$O NOT TURN THE ECCENTRIC PLUG INTO OR OUT OF THE HOUSING BEYOND SPECIlCATIONS

/NCE THE SWITCH IS CORRECTLY ADJUSTED HOLD THE SWITCH IN PLACE AND TIGHTEN THE LOCK
NUT TO .sM ; LBFsFT= TORQUE

NSS deadband adjustment (conditions ii & iii)

4HE .33 DEADBAND MUST BE WIDE ENOUGH SO THE .33 WILL NOT OPEN WITHIN THE CONTROL
SHAFT FREE PLAY AREA AND IT MUST BE NARROW ENOUGH SO THE .33 WILL OPEN BEFORE THE UNIT
BUILDS BAR PSI DIFFERENTIAL SYSTEM PRESSURE IN EITHER DIRECTION

)NSTALL TWO BAR ; PSI= PRESSURE GAUGES IN THE SYSTEM PRESSURE GAUGE PORTS
- AND -

5SING TWO INCH WRENCHES HOLD THE NEUTRAL START SWITCH FROM TURNING AND
LOOSEN THE LOCK NUT

$ISCONNECT THE EXTERNAL CONTROL LINKAGE AND MAKE CERTAIN THE CONTROL SHAFT IS IN ITS
NEUTRAL POSITION

!TTACH A CONTINUITY CHECKER TO THE TERMINALS OF THE SWITCH7ITH THE CONTROL SHAFT IN
ITS NEUTRAL POSITION TURN THE SWITCH CLOCKWISE #7 UNTIL THE SWITCH OPENS THEN TURN
THE SWITCH COUNTERCLOCKWISE ##7 UNTIL IT CLOSES4URN THE SWITCH COUNTERCLOCKWISE
##7 AN ADDITIONAL TURN ² AFTER THE SWITCH CLOSES

42 520L0818 s 2EV !# s December 2011

488 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

MDC NEUTRAL (OLD THE SWITCH IN PLACE AND TIGHTEN Neutral start switch
START SWITCH (NSS) THE LOCK NUT TO .sM LBFsFT
ADJUSTMENTS TORQUE
(continued)
7ITH THE CONTINUITY CHECKER ATTACHED
TO THE SWITCH ROTATE THE CONTROL Control shaft

HANDLE OR THE CONTROL SHAFT IN EACH

DIRECTION TO ASSURE THE SWITCH OPENS
WHEN THE CONTROL IS NOT IN THE NEUTRAL Switch lock nut

POSITION Neutral start switch

Switch cam
)F THE SWITCH CLOSES IN NEUTRAL AND
SATISFACTORILY OPENS IN EACH DIRECTION Switch pin 1-1/8 in

PROCEED TO CHECK THE SWITCH WITH ##t)

THE PRIME MOVER RUNNING4HE SWITCH P104 148E

MUST OPEN BEFORE THE UNIT BUILDS

BAR ; PSI= DIFFERENTIAL SYSTEM
PRESSURE IN EITHER DIRECTION

)F THE SWITCH OPENS AFTER THE UNIT BUILDS SYSTEM PRESSURE IN EITHER DIRECTION LOOSEN
THE SWITCH LOCK NUT AND TURN THE SWITCH CLOCKWISE #7 TURN ² 4IGHTEN THE
SWITCH LOCK NUT AND RECHECK THE SWITCH OPERATION 2EPEAT THIS PROCEDURE IF NECESSARY

)F THE SWITCH DOES NOT OPEN WITH AN EQUAL MOVEMENT OF THE CONTROL HANDLE IN EACH
DIRECTION TURN OFF PRIME MOVER REMOVE THE PRESSURE GAUGES AND CONTINUE WITH THE
NEXT SECTION

)F NEUTRAL START SWITCH OPERATION IS SATISFACTORY TURN OFF THE PRIME MOVER REMOVE THE
PRESSURE GAUGES AND RECONNECT THE EXTERNAL CONTROL LINKAGE

520L0818 s 2EV !# s December 2011 43

008 924 17 BOMAG 489
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

CHECKING SWITCH 2ECHECK SWITCH CONTINUITY TO DETERMINE WHETHER ADDITIONAL ADJUSTMENT OF THE ECCENTRIC
CONTINUITY PLUG IS NECESSARY W

W 7ARNING )NSTALL A BAR ; PSI= GAUGE IN EACH OF THE TWO SERVO CYLINDER GAUGE PORTS -
4HE FOLLOWING PROCEDURE AND - !TTACH A CONTINUITY CHECKER TO THE TERMINALS OF THE NEUTRAL START SWITCH
MAY REQUIRE THE VEHICLE
MACHINE TO BE DISABLED
WHEELS RAISED OFF THE Checking switch continuity
GROUND WORK FUNCTION
Servo pressure gauge port M5
DISCONNECTED ETC WHILE
PERFORMING THE PROCEDURE G 0 - 50 bar [0 - 1000 psi]
IN ORDER TO PREVENT INJURY
Servo pressure gauge port M4 B 9/16-18
TO THE TECHNICIAN AND G 0 - 50 bar [0 - 1000 psi] t " "t]
BYSTANDERS4AKE NECESSARY B 9/16-18
SAFETY PRECAUTIONS BEFORE t " "t]
MOVING THE VEHICLE
MACHINE

P106 166E

%NERGIZE THE STARTER CIRCUIT AND START THE PRIME MOVER

7HILE OPERATING AT NORMAL SPEED AND WITH THE PUMP IN ITS NEUTRAL ZERO mOW
POSITION NOTE THE PRESSURE READING ON THE GAUGES .OTE THIS READING AS THE BASE
pressure.

3LOWLY MOVE THE CONTROL HANDLE IN ONE DIRECTION WHILE OBSERVING THE PRESSURE
GAUGES AND THE CONTINUITY CHECKER4HE SWITCH MUST OPEN BEFORE THE PRESSURE ON
EITHER GAUGE INCREASES MORE THAN BAR ; PSI= FROM THE BASE PRESSURE OBTAINED AT
NEUTRAL

3LOWLY MOVE THE CONTROL HANDLE IN THE OPPOSITE DIRECTION !GAIN 4HE SWITCH MUST
OPEN BEFORE THE GAUGE PRESSURE INCREASES MORE THAN BAR ; PSI= FROM BASE
pressure.

6ERIFY CONTINUITY AGAIN WHEN THE CONTROL IS RETURNED TO NEUTRAL

)F THE SWITCH DOES NOT OPEN AT BASE PRESSURE PLUS TO BAR ; TO PSI= IN EITHER
DIRECTION STOP THE PRIME MOVER AND READJUST THE ECCENTRIC PLUG AS DESCRIBED IN THE
PREVIOUS SECTION )F THE PRESSURE DIFFERENCE IS EQUAL IN EACH DIRECTION BUT GREATER
THAN BAR ; PSI= LOOSEN THE SWITCH LOCK NUT AND TURN THE SWITCH CLOCKWISE
TURN ² TO INCREASE THE SENSITIVITY 2ETIGHTEN THE LOCK NUT AND RECHECK PRESSURE
DIFFERENCES AND CONTINUITY

!FTER VERIFYING PROPER CONTROL AND SWITCH OPERATION STOP THE PRIME MOVER 2EMOVE
THE CONTINUITY CHECKER AND PRESSURE GAUGES 2EINSTALL THE SERVO PRESSURE PORT PLUGS
AND RECONNECT THE ELECTRICAL LEADS FROM THE MACHINE STARTER CIRCUIT TO THE .33 )NSTALL
AND ADJUST THE EXTERNAL CONTROL LINKAGE IF NECESSARY

44 520L0818 s 2EV !# s December 2011

490 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

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

HDC and EDC neutral adjustment

W 7ARNING
Servo pressure gauge port M5
4HE FOLLOWING PROCEDURE
MAY REQUIRE THE VEHICLE G 0 - 50 bar [0 - 1000 psi]
MACHINE TO BE DISABLED
Servo pressure gauge port M4 B 9/16-20
WHEELS RAISED OFF THE G 0 - 50 bar [0 - 1000 psi] t # #t]
GROUND WORK FUNCTION B 9/16-20 M72
DISCONNECTED ETC WHILE t # #t] I
PERFORMING THE PROCEDURE
IN ORDER TO PREVENT INJURY
TO THE TECHNICIAN AND
BYSTANDERS4AKE NECESSARY
SAFETY PRECAUTIONS BEFORE
MOVING THE VEHICLE
MACHINE M90
h
t # #t] or
##t]
P106 167E

)NSTALL A BAR ; PSI= GAUGE IN EACH OF THE TWO DISPLACEMENT CONTROL CYLINDER
GAUGE PORTS - AND - $ISCONNECT THE EXTERNAL CONTROL INPUT HYDRAULIC OR
ELECTRONIC FROM THE CONTROL 3TART THE PRIME MOVER AND OPERATE AT NORMAL SPEED

,OOSEN THE LOCK NUT - WITH A MM OR MM HEX WRENCH

5SING A MM OR MM INTERNAL HEX WRENCH ROTATE THE ADJUSTING SCREW -

CLOCKWISE UNTIL THE PRESSURE INCREASES IN ONE OF THE PRESSURE GAUGES .OTE THE
ANGULAR POSITION OF THE WRENCH 2OTATE THE NEUTRAL ADJUSTING SCREW COUNTERCLOCKWISE
UNTIL THE PRESSURE INCREASES BY AN EQUAL AMOUNT ON THE OTHER GAUGE !GAIN NOTE THE
ANGULAR POSITION OF THE WRENCH

2OTATE THE ADJUSTING SCREW CLOCKWISE HALF THE DISTANCE BETWEEN THE LOCATIONS NOTED
ABOVE4HE GAUGES SHOULD READ THE SAME PRESSURE CASE PRESSURE INDICATING THAT THE
CONTROL IS IN ITS NEUTRAL POSITION

(OLD THE NEUTRAL ADJUSTING SCREW STATIONARY4IGHTEN THE NEUTRAL ADJUSTING SCREW
LOCK NUT TO .sM ; LBFsIN= FOR THE MM SCREW OR .sM ; LBFsIN= FOR THE MM
SCREW $O NOT OVERTORQUE THE NUT

/NCE THE NEUTRAL POSITION IS SET STOP THE PRIME MOVER REMOVE THE GAUGES AND INSTALL
THE GAUGE PORT PLUGS 2ECONNECT THE EXTERNAL CONTROL INPUT

520L0818 s 2EV !# s December 2011 45

008 924 17 BOMAG 491
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
!DJUSTMENTS

SPEED SENSOR 7HEN INSTALLING OR ADJUSTING THE SPEED SENSOR ON A PUMP IT MUST BE SET AT A SPECIlC
ADJUSTMENT DISTANCE FROM THE SPEED RING ON THE UNITS CYLINDER4O LOCATE THE POSITION OF THE SPEED
SENSOR ON THE UNIT OR DESCRIPTION SEE THE CORRESPONDING SECTION

,OOSEN THE SENSOR LOCK NUT WITH AN Cross section view of speed sensor in
INCH HEX WRENCH variable pump

4URN THE SENSOR CLOCKWISE #7 BY

HAND UNTIL IT CONTACTS THE SPEED RING
Gap

4URN THE SENSOR COUNTERCLOCKWISE

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

UNTIL THE WRENCH mATS ON SENSOR BODY

ARE POSITIONED AT A ² ANGLE TO THE Positioning speed sensor relative to
PUMP SHAFT CENTER LINE pump shaft
Shaft centerline
1/2 inch wrench flats
-OST OPEN END WRENCHES HAVE A ²
HANDLE OFFSET 22° 22°

4HE lNAL SENSOR POSITION SHOULD BE Speed sensor with Speed sensor with
BETWEEN ² AND TURN ² packard connector turck connector

COUNTERCLOCKWISE ##7 FROM THE Shaft centerline

1/2 inch wrench flats
POINT WHERE THE SENSOR CONTACTS THE
SPEED RING
22° 22°
(OLD SENSOR IN POSITION WITH A
Speed sensor with Speed sensor with
INCH HEX WRENCH WHILE TIGHTENING packard connector turck connector
THE LOCK NUT TO .sM ; LBFsFT=
P104 155E

46 520L0818 s 2EV !# s December 2011

492 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

STANDARD PROCEDURES Removing the pump

"EFORE WORKING ON THE PUMP CLEAN THE OUTSIDE OF THE PUMP )F THE PUMP HAS AN AUXILIARY
PUMP ATTACHED REMOVE BOTH PUMPS AS A SINGLE UNIT4AG AND CAP ALL HYDRAULIC LINES AS
THEY ARE DISCONNECTED AND PLUG ALL OPEN PORTS TO ENSURE THAT CONTAMINATION DOES NOT
ENTER THE SYSTEM

CCaution
#ONTAMINATION CAN DAMAGE INTERNAL COMPONENTS AND VOID YOUR WARRANTY4AKE
PRECAUTIONS TO ENSURE SYSTEM CLEANLINESS WHEN REMOVING AND REINSTALLING SYSTEM LINES

Disassembly
7ITH THE PRIME MOVER OFF THOROUGHLY CLEAN THE OUTSIDE OF THE PUMP

2. 4AG CAP AND DISCONNECT EACH HYDRAULIC LINE CONNECTED TO THE PUMP !S HYDRAULIC
LINES ARE DISCONNECTED PLUG EACH OPEN PORT TO ENSURE THAT DIRT AND CONTAMINATION
DO NOT ENTER THE SYSTEM

2EMOVE THE PUMP AND ITS AUXILIARY PUMP IF APPLICABLE AS A SINGLE UNIT

Inspection
%NSURE THE WORK SURFACE AND SURROUNDING AREA ARE CLEAN AND FREE OF CONTAMINANTS

)NSPECT THE SYSTEM FOR CONTAMINATION

,OOK AT THE HYDRAULIC mUID FOR SIGNS OF SYSTEM CONTAMINATION mUID DISCOLORATION
FOAM SLUDGE OR SMALL METAL PARTICLES

Reassembly
"EFORE REPLACING THE PUMP ON THE MACHINE REPLACE ALL lLTERS AND DRAIN AND lLL THE
HYDRAULIC SYSTEM WITH THE CORRECT HYDRAULIC mUID

&LUSH THE LINES BEFORE REPLACING THE HYDRAULIC mUID

520L0818 s 2EV !# s December 2011 47

008 924 17 BOMAG 493
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

SHAFT SEAL AND SHAFT 9OU CAN REPLACE THE SHAFT AND SEAL WITHOUT MAJOR DISASSEMBLY OF THE UNIT #LEAN PUMP
REPLACEMENT AND SURROUNDING AREA THOROUGHLY $ISCONNECT AND REMOVE THE PUMP FROM THE UNIT AND
CLEAN IT THOROUGHLY BEFORE STARTING REPAIRS -ARK ALL CONNECTIONS FOR LATER REASSEMBLY

Shaft removal
0OSITION THE PUMP WITH THE SHAFT FACING UP

)F THE UNIT IS POSITIONED HORIZONTALLY OR MOVED OR JARRED WHILE THE SHAFT IS OUT THE CYLINDER
BLOCK COULD MOVE OUT OF PLACE MAKING SHAFT INSTALLATION DIFlCULT

2EMOVE THE THREE OR FOUR SCREWS , HOLDING THE RETAINER PLATE , AND SEAL
CARRIER , TO THE HOUSING USING A MM HEX WRENCH UNIT A MM INTERNAL
HEX WRENCH THROUGH UNITS OR A MM INTERNAL HEX WRENCH THROUGH
UNITS 2EMOVE THE RETAINER PLATE

#ERTAIN EARLIER PRODUCTION UNITS USE A Shaft assembly

ONE PIECE RETAINER PLATE AND SEAL CARRIER
L70

!FTER REMOVING THE SCREWS THE L60

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

2EMOVE THE / RING , FROM THE

SEAL CARRIER AND DISCARD L10

0LACE SEAL CARRIER AND SEAL IN AN ARBOR L100

PRESS AND PRESS OUT THE SEAL ,

2EMOVE SHAFT , AND ROLLER

BEARING ASSEMBLY , FROM
PUMP9OU CAN TRANSFER THE BEARING
ASSEMBLY TO THE NEW SHAFT

5SING SNAP RING PLIERS REMOVE THE

RETAINING RING , THAT SECURES THE
ROLLER BEARING ASSEMBLY 2EMOVE THE
ROLLER BEARING ASSEMBLY

P106 181E

48 520L0818 s 2EV !# s December 2011

494 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

SHAFT SEAL AND SHAFT Inspection

REPLACEMENT )NSPECT THE SEAL CARRIER THE NEW SEAL AND THE / RING FOR ANY DAMAGE OR NICKS
(continued)
)NSPECT THE SHAFT AND BEARING FOR RUST WEAR OR CONTAMINATION 3PIN THE BEARING IN
YOUR HAND FEELING FOR ROUGHNESS 2EPLACE IF NECESSARY

Reassembly
5SING THE ARBOR PRESS PRESS THE NEW SEAL , INTO SEAL CARRIER , "E CAREFUL NOT TO
DAMAGE THE SEAL

)F THE SHAFT IS NOT BEING REPLACED PROCEED TO STEP

0LACE ROLLER BEARING ASSEMBLY ON NEW SHAFT AND SECURE WITH THE RETAINING RING

)NSTALL AN INSTALLATION SLEEVE OR WRAP SPLINE OR KEYED END OF SHAFT WITH PLASTIC lLM TO
PREVENT DAMAGE TO THE SEALING LIP ON THE SEAL DURING INSTALLATION

,UBRICATE AND INSTALL A NEW / RING , ON THE SEAL CARRIER ,UBRICATE THE SEAL WITH
CLEAN PETROLEUM JELLY

!SSEMBLE THE SEAL CARRIER AND SEAL OVER THE SHAFT AND INTO THE HOUSING BORE )NSTALL
THE RETAINER PLATE IF USED

)NSTALL THE SCREWS AND TORQUE TO THE Shaft retainer screw torque
APPROPRIATE VALUE IN THE TABLE TO THE Frame size Torque
RIGHT n .sM ; LBFsFT=
n .sM ; LBFsFT=
4ORQUE THE SCREWS IN A SEQUENCED n .sM ; LBFsFT=
PATTERN THEN RECHECK

520L0818 s 2EV !# s December 2011 49

008 924 17 BOMAG 495
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

MULTI-FUNCTION VALVE Multi-function valve removal / installation

CARTRIDGES

/LDER MULTIFUNCTION
VALVES PRE CONTAIN
DIFFERENT COMPONENTS
See multifunction valves P2B1
- Pre 1988 PAGE FOR
DISASSEMBLY INSTRUCTIONS

P13
P06

P2A1

P106 180E

Removal Multi-function valve wrench size

2EMOVE MULTI FUNCTION VALVES 0! Frame size Wrench size
AND 0" USING HEX WRENCH LISTED IN n INCH
TABLE n INCH

2EMOVE AND DISCARD / RINGS 0 AND 0

2ELIEVE SPRING PRESSURE BY REMOVING BYPASS ACTUATOR 0 USING A WRENCH4O
RETAIN PRESSURE SETTING DO NOT SEPARATE ADJUSTING SCREW 0 AND LOCKNUT 0 FROM
BYPASS ACTUATOR 0

2EMOVE AND DISCARD / RING 0

-ULTI FUNCTION VALVES ARE SOLD AS COMPLETE UNITS ONLY9OU MAY PURCHASE / RINGS
SEPARATELY

4HE POPPET SEAT SECTION IS PRESSED OVER A LIP 0LACE THE CARTRIDGE IN A VISE AND PRY THE
POPPET SEAT 0 OFF WITH AN APPROPRIATE TOOL -AINTAIN SUFlCIENT CONTROL TO PREVENT
THE INTERNAL COMPONENTS FROM mYING LOOSE $O NOT DAMAGE PARTS DURING DISASSEMBLY

2EMOVE INTERNAL PARTS 0 0 0 0 0 0 0 AND 0

50 520L0818 s 2EV !# s December 2011

496 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

MULTI-FUNCTION VALVE Multi-function valve

CARTRIDGES
(continued) P04
P03
P01
P02
P05

P06

P07
P08
P17
P16
P15
P14
P09
P11
P13
P12

E101 531E

Inspection
#LEAN AND INSPECT ALL DISASSEMBLED PARTS

Reassembly
,UBRICATE AND INSTALL INTERNAL COMPONENTS 0 0 0 0 0 0 0 0 AND
0

0LACE THE CARTRIDGE IN A VISE AND PRESS ON THE POPPET SEAT 0

,UBRICATE AND INSTALL NEW / RINGS 0 0 0

)NSTALL BYPASS ACTUATOR 0 WITH PRESSURE LIMITER VALVE 0 4ORQUE TO .sM
; LBFsFT=

C#AUTION
)F PRESSURE LIMITER 0 WAS REMOVED FROM BYPASS ACTUATOR 0 ADJUST PRESSURE LIMITER
TO MODEL CODE SPECIlCATIONS

C#AUTION )NSTALL CARTRIDGES AND TORQUE AS SHOWN IN THE TABLE C

$O NOT OVERTORQUE THE
MULTI FUNCTION VALVE
CARTRIDGES Multi-function valve torque
Frame size Torque
n .sM ; LBFsFT=
n .sM ; LBFsFT=

520L0818 s 2EV !# s December 2011 51

008 924 17 BOMAG 497
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

MULTI-FUNCTION VALVE Removal Multi-function valve wrench size

CARTRIDGES - PRE 1988 2EMOVE MULTI FUNCTION VALVES USING Frame size Wrench size
HEX WRENCH LISTED IN TABLE n INCH
n INCH

2EMOVE AND DISCARD / RINGS 0 AND 0

)T IS NOT NECESSARY TO REMOVE THE BYPASS FUNCTION 0 EXCEPT FOR CLEANING7RENCH
SIZE IS

-ULTI FUNCTION VALVES ARE SOLD AS COMPLETE UNITS ONLY / RINGS MAY BE PURCHASED
SEPARATELY

4O RETAIN PRESSURE SETTING DO NOT DISASSEMBLE BYPASS FUNCTION 0

2EMOVE RETAINING RING 0 WITH A SNAP RING PLIERS

2EMOVE POPPET SEAT 0

2EMOVE INTERNAL PARTS 0 0 0 0 AND 0

Inspection
#LEAN AND INSPECT ALL DISASSEMBLED PARTS

Multi-function valve - pre 1988

P14

P19
P12

P06

P21
P15
P14
P09
P11
P13 P22

E101 532E

52 520L0818 s 2EV !# s December 2011

498 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

MULTI-FUNCTION VALVE Reassembly

CARTRIDGES - PRE 1988 ,UBRICATE AND INSTALL INTERNAL COMPONENTS 0 0 0 0 0 AND 0
(continued)
)NSTALL POPPET SEAT 0

)NSTALL RETAINING RING 0

)F PREVIOUSLY REMOVED LUBRICATE AND INSTALL / RING 0

)F PREVIOUSLY REMOVED REASSEMBLE AND INSTALL BYPASS ACTUATOR 0 4ORQUE TO
.sM ; LBFsFT=

,UBRICATE AND INSTALL NEW / RINGS 0 0

C#AUTION
)F PRESSURE LIMITER WAS REMOVED FROM BYPASS ACTUATOR 0 ADJUST PRESSURE LIMITER TO
MODEL CODE SPECIlCATIONS

C#AUTION )NSTALL CARTRIDGES AND TORQUE AS SHOWN IN THE TABLE BELOW C
$O NOT OVERTORQUE THE
MULTI FUNCTION VALVE
CARTRIDGES Multi-function valve torque
Frame size Torque
n .sM ; LBFsFT=
n .sM ; LBFsFT=

PRESSURE OVERRIDE Removal Pressure override valve components

VALVE (OPTION FOR 180 2EMOVE THE FOUR SCREWS ATTACHING
FRAME SIZE) THE PRESSURE OVERRIDE VALVE TO THE
Screws
PUMP END CAP WITH A MM INTERNAL
HEX WRENCH 2EMOVE AND DISCARD THE Pressure override
/ RINGS valve

Inspection
O-rings
#LEAN AND INSPECT VALVE FOR DAMAGE
TO PARTS

Reassembly
)NSTALL NEW / RINGS )NSTALL THE VALVE
ONTO THE PUMP END CAP AND TORQUE
THE SCREWS TO .sM ; LBFsFT=

E101 079E

520L0818 s 2EV !# s December 2011 53

008 924 17 BOMAG 499
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

CHARGE PRESSURE 4HE CHARGE PRESSURE RELIEF VALVE IS SHIM ADJUSTABLE EARLY MODELS OR SCREW ADJUSTABLE
RELIEF VALVE LATE MODELS 3CREW ADJUSTABLE CHARGE RELIEF VALVE IS SHOWN

Removal
2EMOVE THE SHIM ADJUSTABLE CHARGE RELIEF VALVE PLUG WITH A INCH HEX WRENCH

"EFORE REMOVING THE SCREW ADJUSTABLE RELIEF VALVE PLUG MARK THE PLUG + LOCK NUT
+ AND HOUSING TO APPROXIMATELY MAINTAIN THE ORIGINAL ADJUSTMENT WHEN ASSEM
BLING 2EMOVE THE SCREW ADJUSTABLE CHARGE RELIEF VALVE PLUG BY LOOSENING THE LOCK
NUT WITH A HEX WRENCH CORRESPONDING TO THE TABLE

5NSCREW THE PLUG USING A LARGE Lock nut wrench size

SCREWDRIVER OR INCH HEX WRENCH Frame size Wrench size
2EMOVE AND DISCARD THE / RING + n INCH
n INCH
2EMOVE THE SPRING + AND RELIEF
VALVE POPPET +
Charge pressure relief valve
Inspection
)NSPECT THE POPPET + AND MATING
K90
SEAT IN THE ENDCAP FOR DAMAGE OR h Lock nut
FOREIGN MATERIAL t Lock nut torque

7HEN INSPECTING SHIM ADJUSTABLE K10

VALVES DO NOT ALTER THE SHIMS OR h1/2 in
INTERCHANGE PARTS dK50 K

Reassembly K70
)NSTALL THE POPPET + AND SPRING
K80
+ &OR SHIM ADJUSTABLE VALVES
INSTALL THE SHIMS AND PLUG TORQUE
TO .sM ; LBFsFT= &OR SCREW
ADJUSTABLE VALVES INSTALL THE PLUG See appropriate table
WITH ITS LOCK NUT ALIGNING THE MARKS
MADE AT DISASSEMBLY AND TORQUE THE
LOCK NUT TO .sM ; LBFsFT=

#HECK THE CHARGE PRESSURE AND

ADJUST IF NECESSARY 2EFER TO Charge
pressure adjustments PAGE

P106 169E

54 520L0818 s 2EV !# s December 2011

500 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

AUXILIARY PAD Removal

2EMOVE THE FOUR END CAP SCREWS * 2EMOVE AND DISCARD SPECIAL WASHERS * .

C#AUTION Aux. pad screw wrench size

/N EARLIER PRODUCTION FRAME SIZE Frame size Wrench sizes
PUMPS WITH TWIN PORTS SECURE THE END n EARLY MM INTERNAL HEX
CAP TO THE PUMP HOUSING WITH A CLAMP TO LATE MM INTERNAL HEX
AVOID GASKET DAMAGE MM HEX
n MM HEX
2EMOVE THE AUXILIARY PAD * AND n MM INTERNAL HEX
DISCARD THE / RINGS * AND * n MM INTERNAL HEX

Inspection
)NSPECT THE AUXILIARY PAD FOR DAMAGE AND REPLACE IF NECESSARY

4AKE CARE TO ASSURE THE SURFACES ARE CLEAN AND FREE OF ANY FOREIGN MATERIAL OR PAINT
PRIOR TO INSTALLING THE AUXILIARY PAD

C#AUTION
$O NOT ALLOW THE FORCE OF THE CYLINDER BLOCK SPRING AND SWASHPLATE LEVELER SPRINGS TO
SEPARATE THE END CAP FROM THE PUMP HOUSING 'ASKET DAMAGE AND EXTERNAL LEAKAGE MAY
RESULT

Auxiliary pad components (typical)

J50
J80
Endcap screw J70
Screw torque

J60
See appropriate table for wrench size and torque
E101 084E

Inspection
)NSPECT THE AUXILIARY PAD COMPONENTS FOR WEAR OR DAMAGE AND REPLACE IF ANY IS
FOUND

4AKE CARE TO ENSURE THE SURFACES ARE CLEAN AND FREE OF ANY FOREIGN MATERIAL OR PAINT
PRIOR TO INSTALLING THE AUXILIARY PAD

Reassembly
,UBRICATE AND INSTALL / RING * ON END CAP PILOT

)NSTALL THE AUXILIARY MOUNTING PAD End cap screw torque

* ON REAR OF ENDCAP Frame size Torque
.sM ; LBFsFT=
)NSTALL FOUR LARGE SCREWS * .sM ; LBFsFT=
4ORQUE ENDCAP SCREWS IN A AND NEW WASHERS * THROUGH .sM ; LBFsFT=
CRISS CROSS PATTERN THE MOUNTING PAD AND END CAP n .sM ; LBFsFT=
INTO THE HOUSING4ORQUE PER THE n .sM ; LBFsFT=
ACCOMPANYING TABLE
520L0818 s 2EV !# s December 2011 55
008 924 17 BOMAG 501
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

CHARGE PUMP 4HE FOLLOWING PROCEDURE SHOWS HOW TO REMOVE AND INSTALL A CHARGE PUMP

Removal
&OR PUMPS WITH AN AUXILIARY MOUNTING PAD REFER TO THE Auxiliary Pad INSTRUCTIONS
PAGE

C#AUTION
/N EARLIER PRODUCTION FRAME SIZE PUMPS WITH TWIN PORTS SECURE THE ENDCAP TO THE
PUMP HOUSING WITH A CLAMP TO AVOID GASKET DAMAGE

2EMOVE THE SIX SCREWS ( HOLDING THE CHARGE PUMP COVER RETAINER (

2EMOVE THE RETAINER ( AND THE Retainer screw wrench size
CHARGE PUMP COVER * 2EMOVE Frame size Wrench size
AND DISCARD / RING * .OTE THE n 10 mm
ORIENTATION OF THE GEROTOR ASSEMBLY n MM
(

Current charge pump conﬁguration

H40

H05

H60
H50
H31
J50
J15

J30

H70
E101 082E
H80

2EFER TO APPROPRIATE Sauer-Danfoss Series 90 service parts manual FOR EARLIER CHARGE PUMP
CONlGURATIONS

2EMOVE THE CHARGE PUMP COUPLING ( AND CHARGE PUMP DRIVE KEY (

2EMOVE THE CHARGE PUMP GEROTOR ASSEMBLY (

56 520L0818 s 2EV !# s December 2011

502 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

CHARGE PUMP 2EMOVE THE ALIGNMENT PIN (

(continued)
2EMOVE THE INNER PORT PLATE (

Inspection
)NSPECT ALL PARTS FOR ABNORMAL WEAR OR DAMAGE AND REPLACE IF NECESSARY

)F INSTALLING A DIFFERENT DISPLACEMENT CHARGE PUMP THE GEROTOR ASSEMBLY GEROTOR OUTER
ECCENTRIC RING AND INNER PORT PLATE EARLY AND LATE PRODUCTION PUMPS OR OUTER SPACER
PLATES INTERMEDIATE PRODUCTION PUMPS MUST BE REPLACED TOGETHER )F DIFFERENT
THICKNESS PORT PLATES ARE USED IN AN EARLY PRODUCTION CHARGE PUMP ASSEMBLY THE THICKER
PLATE IS THE INNER PORT PLATE INSTALLED NEXT TO THE PUMP END CAP

$IFFERENT PRODUCTION CHARGE PUMP ASSEMBLIES INCLUDE A DIFFERENT QUANTITY TYPE OF PORT
PLATES AND SPACER PLATES

Reassembly
"E SURE TO INSTALL THE CHARGE PUMP IN THE Orienting alignment pin
PROPER ORIENTATION )F UNSURE OF CHARGE
Discharge Gerotor Discharge
PUMP ROTATION REFER TO THE MODEL CODE assembly
Alignment pin

4HE ORIENTATION OF THE GEROTOR ASSEMBLY

Inlet Inlet
OUTER ECCENTRIC RING AND THE LOCATION
Alignment pin
OF THE ALIGNMENT PIN IN THE END CAP
Gerotor assembly
DETERMINE THE CHARGE PUMP ROTATION
Left hand rotation Right hand rotation
(outside looking into pump) (outside looking into pump)
$O NOT MIX CHARGE PUMP PARTS FROM P104 160E
DIFFERENT PRODUCTION PERIODS !LWAYS
INSTALL AS A COMPLETE ASSEMBLY

)NSTALL THE INNER PORT PLATE ( AND THE GEROTOR ASSEMBLY OUTER RING

)NSTALL THE ALIGNMENT PIN ( TO PROPERLY ORIENT THE PORT PLATES AND OUTER ECCENTRIC
RING FOR CORRESPONDING PUMP ROTATION

0RIOR TO INSTALLATION LUBRICATE THE )$ /$ AND SIDE FACES OF THE GEROTOR ASSEMBLY

)NSTALL THE GEROTOR ASSEMBLY (

)NSTALL THE OUTER PORT PLATE EARLY PRODUCTION AND INTERMEDIATE PRODUCTION PUMPS
ONLY

)NSTALL THE SPACER PLATE IF PRESENT INTERMEDIATE PRODUCTION PUMPS

)NSTALL THE CHARGE PUMP DRIVE KEY ( INTO THE CHARGE PUMP COUPLING ( AND
RETAIN WITH PETROLEUM JELLY

520L0818 s 2EV !# s December 2011 57

008 924 17 BOMAG 503
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

CHARGE PUMP )NTERMEDIATE PRODUCTION CMÃ AND CMÃ PUMPS USE THE SAME CHARGE PUMP
(continued) COUPLING4WO KEYWAYS ARE PROVIDED IN THE COUPLING FOR THE CHARGE PUMPS USED IN THESE
UNITS4HE REAR KEYWAY WITH IDENTIlER GROOVE IS USED IN CMÃ PUMPS4HE FRONT KEYWAY
CLOSEST TO THE INTERNALLY SPLINED END OF THE SHAFT IS USED IN CMÃ PUMPS

)NSTALL THE CHARGE PUMP COUPLING4HE INTERNALLY SPLINED END OF THE COUPLING MUST
ENGAGE THE MAIN PUMP SHAFT

4HE OUTSIDE DIAMETER OF THE INTERNALLY SPLINED END OF SOME EARLY PRODUCTION CHARGE
PUMP COUPLINGS WERE CHAMFERED %ARLY PRODUCTION END CAPS MAY NOT BE MACHINED TO
ACCEPT A NON CHAMFERED COUPLING !LWAYS USE A CHAMFERED CHARGE PUMP COUPLING IN
PUMPS WITH THE EARLY ENDCAP

&OR PUMPS WITH AN AUXILIARY MOUNTING PAD INSTALL THE AUXILIARY DRIVE COUPLING

&OR PUMPS WITH NO AUXILIARY PAD INSTALL A NEW / RING * ONTO CHARGE PUMP COVER
)F AN AUXILIARY PAD IS INSTALLED AN / RING IS NOT USED ON THE COVER

#AREFULLY REMOVE THE ALIGNMENT PIN FROM THE CHARGE PUMP PARTS )NSTALL THE PIN IN ITS
HOLE IN THE CHARGE PUMP COVER * SEE PREVIOUS PAGE FOR CORRECT ORIENTATION AND
RETAIN WITH PETROLEUM JELLY )NSTALL THE COVER WITH ALIGNMENT PIN INTO THE END CAP
AND ALIGNED CHARGE PUMP PARTS 4AKE CARE NOT TO DAMAGE THE COVER / RING IF USED

C#AUTION
)N ORDER TO AVOID LOSS OF CHARGE PRESSURE IN PUMPS WITH AN AUXILIARY MOUNTING PAD
ALWAYS INSTALL THE CHARGE PUMP COVER WITH THE PAD DRAIN HOLE LOCATED ON THE SAME SIDE
OF THE END CAP AS THE CHARGE INLET PORT 2EFER TO THE SECTION “Auxiliary Pad Installation” for
DETAILS

)NSTALL THE CHARGE PUMP COVER Retainer screw torque

RETAINER ( AND THE SIX INTERNAL Frame size Torque
HEX SCREWS ( 4ORQUE THE SCREWS n .sM ; LBFsFT=
PER THE TABLE AT THE RIGHT n .sM ; LBFsFT=

&OR PUMPS WITH AUXILIARY MOUNTING PADS INSTALL THE / RING AND AUXILIARY MOUNTING
PAD ADAPTOR ONTO THE END CAP 2EFER TO THE CORRESPONDING SECTION FOR INSTRUCTIONS ON
AUXILIARY PAD INSTALLATION

ADDING AN AUXILIARY )F INSTALLING AN AUXILIARY PAD KIT ON A PUMP THAT WAS PREVIOUSLY WITHOUT ONE CAREFULLY
PAD TO A PUMP REMOVE THE ALIGNMENT PIN FROM THE CHARGE PUMP PARTS
PREVIOUSLY WITHOUT
ONE )NSTALL THE PIN IN ITS HOLE IN THE NEW CHARGE PUMP COVER WITH HOLE FOR THE AUXILIARY
COUPLING AND RETAIN WITH PETROLEUM JELLY

)NSTALL THE NEW CHARGE PUMP COVER WITH ALIGNMENT PIN INTO THE END CAP AND THE
ALIGNED CHARGE PUMP PARTS

,UBRICATE AND INSTALL / RING )NSTALL AUXILIARY PAD 2EFER TO PREVIOUS SECTIONS Auxiliary
pad PAGE AND Charge pump PAGE FOR INSTRUCTIONS

58 520L0818 s 2EV !# s December 2011

504 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

INTEGRAL CHARGE Removal Lock nut wrench size and torque

PRESSURE FILTER 2EMOVE THE lLTER CANISTER . FROM Frame size Wrench size Torque
REPLACEMENT THE lLTER HEAD . AS DESCRIBED ON n INCH .sM ; LBFsFT=
THE CANISTER n INCH .sM ; LBFsFT=
n INCH .sM ; LBFsFT=
(OLD THE lLTER HEAD IN PLACE AND
LOOSEN THE LOCK NUT . USING THE WRENCH SIZE CORRESPONDING TO PUMP FRAME SIZE

2OTATE THE lLTER HEAD COUNTERCLOCKWISE TO REMOVE IT FROM THE HOUSING 2EMOVE AND
DISCARD THE / RING .

2EMOVE THE HYDRAULIC TUBE . FROM ITS BORE IN THE ENDCAP

Inspection
)NSPECT THE lLTER HEAD AND LOCK NUT SEALING SURFACES )F YOU lND ANY NICKS OR SCRATCHES
REPLACE THE DAMAGED COMPONENTS

Reassembly
)NSTALL THE HYDRAULIC TUBE . INTO ITS BORE IN THE ENDCAP )NSTALL THE lLTER HEAD .
INTO THE PORT USING A NEW / RING . 4HE HYDRAULIC TUBE SHOULD GO IN WITH LOW FORCE

!FTER ROTATING THE lLTER HEAD CLOCKWISE SO THAT THE THREADS ENGAGE WITH THE THREADS
C#AUTION IN THE ENDCAP CONTINUE TO ROTATE IT CLOCKWISE BETWEEN AND REVOLUTIONS 0OSITION
&AILURE TO INSTALL THE lLTER HEAD AS DESIRED C
MANIFOLD OR lLTER HEAD
TO A SUFlCIENT DEPTH IN 7HILE HOLDING THE lLTER HEAD IN THE DESIRED POSITION TIGHTEN THE SWIVEL LOCK NUT
THE END CAP WILL RESULT IN . AND TORQUE AS SHOWN IN TABLE
INSUFlCIENT ENGAGEMENT
OF THE TUBE IN THE END )NSTALL A NEW lLTER CANISTER . PER THE INSTRUCTIONS ON THE lLTER CANISTER
CAP BORE4HIS MAY ALLOW
UNlLTERED OIL TO BYPASS THE
lLTER AND ENTER THE CHARGE Integral charge pressure ﬁlter
SYSTEM

N25 N20
N15 Fi"!#"
#""! #
N36A

N36
11/16 in
$ $t]

N40

N10
N35A
N35
11/16 in
$ $t] P106 182E

520L0818 s 2EV !# s December 2011 59

008 924 17 BOMAG 505
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

PUMP CONTROL COVER Removal

PLATE 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF COVER PLATE

5SING A MM INTERNAL HEX WRENCH REMOVE THE SIX COVER PLATE MOUNTING SCREWS
- 2EMOVE THE COVER PLATE - AND GASKET - FROM HOUSING $ISCARD THE
GASKET

C#AUTION
0ROTECT EXPOSED SURFACES AND CAVITIES FROM DAMAGE AND FOREIGN MATERIAL

Reassembly
)NSTALL A NEW GASKET ON THE HOUSING )NSTALL THE COVER PLATE AND INSTALL THE SCREWS
4ORQUE THE SCREWS TO .sM ; LBFsFT=

)NSTALL A SEALING WASHER UNDER THE HEAD OF ANY MOUNTING SCREWS THAT ARE INSTALLED INTO
THROUGH HOLES IN THE HOUSING

Pump controls cover plate

M90 (x6)
h 5 mm
$$!]

M1
Seal washer
location (42, 180, 250 cc)

M11
d

P106 184E

60 520L0818 s 2EV !# s December 2011

506 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

DISPLACEMENT 2EMOVE THE CONTROL ASSEMBLY AS Underside of an HDC/EDC module showing

CONTROL ORIFICES DESCRIBED IN THE INSTRUCTIONS FOR THE oriﬁce locations
SPECIlC DISPLACEMENT CONTROL A
B
TA P
/RIlCE PLUGS MAY BE LOCATED IN TB
THE CONTROL ASSEMBLY AT THE PUMP
HOUSING FACE 2EMOVE THE ORIlCE
PLUGS ONE AT A TIME TO AVOID MIXING
THEM UP WITH A MM INTERNAL HEX
WRENCH .OTE THE LOCATION OF EACH Orifice plugs

PLUG DO NOT INTERCHANGE PLUGS Orifice check valve

#LEAN REINSTALL AND TORQUE THE ORIlCE E101 085E

PLUGS TO .sM ; LBFsFT=

!SSEMBLE THE CONTROL ONTO THE PUMP 2EFER TO THE INSTRUCTIONS FOR THE SPECIlC CONTROL

DISPLACEMENT 2EMOVE THE CONTROL ASSEMBLY AS Underside of an MDC module showing

CONTROL ORIFICE DESCRIBED IN THE INSTRUCTIONS FOR THE oriﬁce locations
CHECK VALVE SPECIlC DISPLACEMENT CONTROL
TA A B TB

4HE ORIlCE CHECK VALVE IS LOCATED IN P

THE CONTROL ASSEMBLY AT THE SURFACE

OF THE PUMP HOUSING FACE 2EMOVE
THE SPRING RETAINER AND SPRING FROM
Orifice plugs
THE ORIlCE CHECK VALVE CAVITY AND
THEN REMOVE THE ORIlCE CHECK VALVE
Orifice check valve
#LEAN AND INSTALL THE ORIlCE CHECK E101 086E

VALVE IN THE CAVITY AND THEN INSTALL

THE SPRING AND SPRING RETAINER TO HOLD THE ORIlCE CHECK VALVE IN POSITION

!SSEMBLE THE CONTROL ONTO THE PUMP 2EFER TO THE INSTRUCTIONS FOR THE SPECIlC CONTROL

DISPLACEMENT $O NOT REMOVE THE ADAPTER PLATE UNLESS Displacement control adapter plate (early
CONTROL ADAPTER LEAKAGE IS EVIDENT4HE MOUNTING SCREWS production 130 cm³ pumps only)
PLATE (EARLY WITH SEALING COMPOUND ARE DIFlCULT TO Adapter plate
screws
PRODUCTION 130 remove.
PUMPS ONLY) 6 mm
4HE SCREWS FASTENING THE CONTROL ADAPTER

PLATE TO THE HOUSING HAVE SEALING

COMPOUND ON THE THREADS9OU MAY O-rings Adapter plate
REMOVE THEM WITH A MM INTERNAL HEX
WRENCH IF NECESSARY 2EMOVE AND DISCARD
THE / RINGS AND SEALS Seal

7HEN INSTALLING THE ADAPTER PLATE

REPLACE SCREWS WITH SEALING COMPOUND
AND ENSURE THE NEW / RINGS AND SEAL ARE
E101 087E
IN THE PROPER POSITION4ORQUE THE SCREWS
TO .sM ; LBFsFT=
520L0818 s 2EV !# s December 2011 61
008 924 17 BOMAG 507
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

MANUAL DISPLACEMENT Removal

CONTROL (MDC) 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF CONTROL

5SING A MM INTERNAL HEX WRENCH REMOVE THE SIX CONTROL MOUNTING SCREWS -
2EMOVE THE CONTROL - WITH ORIlCE CHECK VALVE 4 AND SPRING 4 AND CONTROL
GASKET - FROM THE HOUSING $ISCARD THE GASKET

)F NECESSARY REMOVE THE CONTROL HANDLE - BY REMOVING THE LOCKING NUT - AND
WASHER -

C#AUTION
0ROTECT EXPOSED SURFACES AND CAVITIES FROM DAMAGE AND FOREIGN MATERIAL

Reassembly
)NSTALL A NEW GASKET - )NSPECT CONTROL TO ASSURE THAT THE CONTROL ORIlCE CHECK
VALVE AND SPRING ARE IN THEIR PROPER POSITION IN THE CONTROL

)NSTALL THE CONTROL %NGAGE THE PIN ON THE CONTROL LINKAGE INTO THE MATING HOLE IN THE
LINK ATTACHED TO THE SWASHPLATE

7ITH THE CONTROL IN POSITION MOVE CONTROL LEVER BOTH DIRECTIONS TO CHECK PROPER
ENGAGEMENT OF CONTROL LINKAGE PIN )F PROPERLY ASSEMBLED LEVER WILL RETURN TO
CENTER )F LEVER DOES NOT RETURN TO CENTER REMOVE THE CONTROL AND REPEAT THE ABOVE
PROCEDURE

MDC removal/installation
M72
S40 M71 h 8 mm
h 1-1/8 in M70 *" !*']
*" !*']

M90 (x6)
I 5 mm
*" !*']

M11
Seal washer d
location (42, 180, 250 cc)
T

T30 T40

P106 185E

62 520L0818 s 2EV !# s December 2011

508 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

MANUAL DISPLACEMENT )F REMOVED INSTALL THE CONTROL HANDLE - AND LOCKING NUT - WITH WASHER -
CONTROL (MDC) (OLD THE POSITION OF THE HANDLE AND TORQUE THE LOCKING NUT TO .sM ; LBFsFT= USING
(continued) AN MM HEX WRENCH

!LIGN THE CONTROL GASKET AND INSTALL THE SCREWS4ORQUE THE SCREWS TO .sM
; LBFsFT=

W 7ARNING )NSTALL A SEALING WASHER UNDER THE HEAD OF MOUNTING SCREWS THAT ARE INSTALLED INTO
4HE NEUTRAL START SWITCH THROUGH HOLES IN THE HOUSING
NEUTRAL MUST BE READJUSTED
AFTER REASSEMBLING THE
-$# MODULE )F THE CONTROL IS EQUIPPED WITH A NEUTRAL START SWITCH REFER TO MDC Neutral start switch
adjustment INSTRUCTIONS PAGE

SOLENOID OVERRIDE Removal

VALVE FOR MDC 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF VALVE

2EMOVE THE SOLENOID FROM THE VALVE BY REMOVING THE NUT WITH A INCH HEX
WRENCH 2EMOVE THE SOLENOID VALVE - FROM THE MANIFOLD - WITH A INCH
HEX WRENCH

5SING A MM INTERNAL HEX WRENCH REMOVE THE TWO SCREWS - AND REMOVE
SOLENOID MANIFOLD - FROM HOUSING 2EMOVE AND DISCARD THE GASKET -

Reassembly
4ORQUE VALVE - TO .sM ; LBFsFT=4ORQUE SOLENOID NUT TO .sM ; LBFsFT=
$O NOT OVERTORQUE THE SOLENOID NUT

)NSTALL A NEW GASKET ON THE CONTROL HOUSING )NSTALL THE MANIFOLD ONTO THE CONTROL
HOUSING ALIGN THE GASKET AND INSTALL THE SCREWS4ORQUE THE SCREWS TO .sM
; LBFsFT=

Solenoid override valve removal/installation

M90 (x6)
5 mm M77
] M76A
M76C
M76B
M76

M78 (x2)
5 mm
M75
]
P106 186E

520L0818 s 2EV !# s December 2011 63

008 924 17 BOMAG 509
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

SOLENOID OVERRIDE Removal

VALVE FOR MDC WITH 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF VALVE
PRESSURE RELEASED
BRAKE 5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR SOLENOID VALVE MOUNTING SCREWS
- 2EMOVE THE SOLENOID VALVE - WITH / RINGS FROM THE ADAPTER PLATE $ISCARD
THE / RINGS

5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR ADAPTER PLATE MOUNTING SCREWS
- 2EMOVE THE ADAPTER PLATE AND / RINGS - - AND - FROM THE CONTROL
HOUSING $ISCARD THE / RINGS

Reassembly
5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS - - - ON THE
ADAPTER PLATE 0LACE THE ADAPTER PLATE INTO POSITION AND INSTALL THE SCREWS -
4ORQUE THE SCREWS TO .sM ; LBFsFT=

5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS ONTO THE SOLENOID VALVE
ASSEMBLY - AND INSTALL THE SOLENOID VALVE ONTO THE ADAPTER PLATE )NSTALL THE
SCREWS - AND TORQUE TO .sM ; LBFsFT=

Solenoid override valve removal/installation

M98 (x4)
4 mm
M9
t]

M95
M96
M97 M92 (x4)
4 mm
t]
P106 192E

64 520L0818 s 2EV !# s December 2011

510 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

HYDRAULIC AND Removal

ELECTRIC DISPLACEMENT 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF CONTROL
CONTROLS
5SING A MM INTERNAL HEX WRENCH REMOVE THE SIX CONTROL MOUNTING SCREWS -
2EMOVE THE CONTROL - WITH ORIlCE CHECK VALVE 4 AND SPRING 4 AND CONTROL
GASKET - FROM HOUSING $ISCARD THE GASKET

C#AUTION
0ROTECT EXPOSED SURFACES AND CAVITIES FROM DAMAGE AND FOREIGN MATERIAL

Reassembly
)NSTALL A NEW GASKET - 6ERIFY THE CONTROL ORIlCE CHECK VALVE AND SPRING 4 ARE IN
THEIR PROPER POSITION IN THE CONTROL

0OSITION THE CONTROL ON THE HOUSING )NSERT THE CONTROL LINKAGE PIN INTO THE
SWASHPLATE LINK.

Hydraulic/Electric displacement control

M90 (x6)
I 5 mm
]

M11
d

T30
T40

P106 187E

520L0818 s 2EV !# s December 2011 65

008 924 17 BOMAG 511
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

7ITH THE CONTROL IN POSITION MOVE CONTROL ASSEMBLY LEFT AND RIGHT TO CHECK
ENGAGEMENT OF PIN IN THE LINK 0ROPER ENGAGEMENT IS INDICATED BY AN INCREASING
RESISTANCE AS THE CONTROL IS MOVED AWAY FROM CENTER POSITION .ON ENGAGEMENT OF
PIN IS INDICATED BY LACK OF SPRING FORCE )N CASE OF NON ENGAGEMENT REMOVE CONTROL
AND REPEAT THE ABOVE PROCEDURE

!LIGN THE CONTROL GASKET AND INSTALL THE SCREWS4ORQUE THE SCREWS TO .sM
; LBFsFT=

)NSTALL A SEALING WASHER UNDER THE HEAD OF ANY MOUNTING SCREWS THAT ARE INSTALLED INTO
THROUGH HOLES IN THE HOUSING

PRESSURE CONTROL Removal

PILOT (PCP) FOR 4HOROUGHLY CLEAN EXTERNAL SURFACES OF CONTROL
ELECTRIC DISPLACEMENT
CONTROL (EDC) 5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR SCREWS - AND REMOVE THE
0#0 -

Inspection
#HECK SURFACES FOR NICKS OR DAMAGE #LEAN INTERNAL SCREENS

Reassembly
)NSTALL NEW / RINGS - AND - IN 0#0 (OUSING 0LACE 0#0 AGAINST %$# HOUSING
AND INSTALL THE SCREWS - 4ORQUE TO .sM ; LBFsFT=

$O NOT REMOVE BLACK PLASTIC COVER FROM THE ALUMINUM PLATE4HIS IS NOT A SERVICEABLE ITEM
AND WILL VOID THE PRODUCT WARRANTY

PCP removal/installation M90 (x6)

5 mm
''$]

Seal washer
location
(42, 180, 250 cc)
M97

M96 (x3)

M98 (x4)
M9
4 mm
' 't] P106 194E

66 520L0818 s 2EV !# s December 2011

512 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

3-POSITION (FNR) Removal

ELECTRIC CONTROL 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF CONTROL

5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR SOLENOID VALVE MOUNTING SCREWS
7 2EMOVE THE SOLENOID VALVE 7 WITH / RINGS 7! AND ORIlCE FROM
THE ADAPTER PLATE

5SING A MM INTERNAL HEX WRENCH REMOVE THE SIX ADAPTER PLATE MOUNTING SCREWS
C#AUTION - 2EMOVE THE ADAPTER PLATE AND GASKET - FROM THE HOUSING $ISCARD THE
0ROTECT EXPOSED SURFACES GASKET C
AND CAVITIES FROM DAMAGE
AND FOREIGN MATERIAL Inspection
)NSPECT THE ORIlCE INSTALLED BETWEEN THE VALVE AND ADAPTER PLATE4HIS ORIlCE must be
INSTALLED IN THE CASE DRAIN PASSAGE FOR PROPER PRESSURE LIMITER OPERATION

Reassembly
)NSTALL A SEALING WASHER )NSTALL A NEW GASKET - ON THE HOUSING 0LACE THE ADAPTER PLATE INTO POSITION AND
UNDER THE HEAD OF ANY INSTALL THE SCREWS - C4ORQUE THE SCREWS TO .sM ; LBFsFT=
MOUNTING SCREWS THAT
ARE INSTALLED INTO THROUGH )NSTALL NEW / RINGS 7! AND THE ORIlCE ONTO THE SOLENOID VALVE ASSEMBLY AND
HOLES IN THE HOUSING INSTALL THE SOLENOID VALVE ONTO THE ADAPTER PLATE )NSTALL SCREWS 7 4ORQUE TO
.sM ; LBFsFT=

FNR removal/installation
W702 (x4)
I 5 mm
*" !*t]

W701A
M90 (x6) d
I 5 mm
*"!*'] T80
T70
T50 M900
M1

Seal washer
location (42, 180, 250 cc)
T

M11 T30
T40
d

P106 185E

520L0818 s 2EV !# s December 2011 67

008 924 17 BOMAG 513
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
Minor repair

DISPLACEMENT )F THE PUMP IS EQUIPPED WITH CONTROL Filter screen installation

CONTROL FILTER lLTER SCREENS IN THE PUMP HOUSING LATE B90
SCREENS PRODUCTION PRESS THEM INTO POSITION
WITH THE ROUNDED EDGE OF THE lLTER P106 690E

SCREENS FACING THE CONTROL UNTIL THEY ARE

mUSH TO MM ; INCH= BELOW THE
SURFACE OF THE HOUSING

SPEED SENSOR Removal

,OOSEN THE LOCK NUT USING A IN HEX WRENCH

5NSCREW THE SPEED SENSOR " FROM THE PUMP HOUSING 2EMOVE AND DISCARD THE
/ RING "!

Reassembly
)NSTALL A NEW / RING BEFORE REINSTALLING THE SENSOR

2EINSTALL THE SPEED SENSOR WITH LOCK NUT AND / RING INTO THE HOUSING !DJUST THE
GAP BETWEEN THE SENSOR AND THE MAGNETIC SPEED RING AS INSTRUCTED IN Speed sensor
adjustment PAGE AND TORQUE THE SENSOR LOCK NUT TO .sM ; LBFsFT=

)F A SPEED SENSOR IS NOT INSTALLED USE A IN INTERNAL HEX WRENCH TO TORQUE THE
HOUSING PLUG " TO .sM ; LBFsFT=

Typical location of speed sensor

B83 O-ring plug

]
B83A

B83 B83A

]

E101 095E

68 520L0818 s 2EV !# s December 2011

514 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
4ORQUE CHART

FASTENER SIZE AND Item Fastener Frame size Wrench size Torque
TORQUE CHART B83 3PEED SENSOR LOCK NUT IN HEX .sM ; LBFsFT=
E60 3IDE COVER SCREW MM HEX .sM ; LBFsFT=
"LIND HOLES MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
E60 3IDE COVER SCREW MM HEX .sM ; LBFsFT=
4HRU HOLES MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
& 3ERVO CYLINDER SCREW MM HEX .sM ; LBFsFT=
F211 MM HEX .sM ; LBFsFT=
' %ND CAP SCREW MM INTERNAL HEX .sM ; LBFsFT=
G97 MM INTERNAL HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
H80 #HARGE PUMP RETAINING SCREW MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
J80 %ND CAP SCREW MM INTERNAL HEX .sM ; LBFsFT=
EARLY MM INTERNAL HEX .sM ; LBFsFT=
LATE MM INTERNAL HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
K10 #HARGE PRESSURE VALVE PLUG IN HEX .!
K90 #HARGE PRESSURE LOCK NUT IN HEX .sM ; LBFsFT=
IN HEX .sM ; LBFsFT=
L70 3HAFT RETAINING SCREW MM HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
M72 -$# HANDLE NUT MM .sM ; LBFsFT=
M78 $E STROKE VALVE MANIFOLD SCREW MM INTERNAL HEX .sM ; LBFsFT=
M85 %CCENTRIC PLUG LOCK NUT IN HEX .sM ; LBFsFT=
M88 .EUTRAL START SWITCH LOCK NUT IN HEX .sM ; LBFsFT=
M90 #ONTROL MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
M92 3OLENOID VALVE MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
M98 0#0 MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
N10 &ILTER REDUCER ASSEMBLY IN HEX .sM ; LBFsFT=
IN HEX .sM ; LBFsFT=
IN HEX .sM ; LBFsFT=
N37 &ILTER PLUG ASSEMBLY IN INTERNAL HEX .sM ; LBFsFT=
0" -ULTI FUNCTION VALVE IN HEX .sM ; LBFsFT=
P2A1 IN HEX .sM ; LBFsFT=

520L0818 s 2EV !# s December 2011 69

008 924 17 BOMAG 515
16.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
4ORQUE CHART

PLUG SIZE AND TORQUE )F ANY PLUGS OR lTTINGS ARE REMOVED FROM THE PUMP DURING SERVICING INSTALL AND TORQUE AS
CHART INDICATED IN THE ACCOMPANYING TABLEC

!LWAYS INSTALL NEW / RINGS BEFORE REINSTALLING THE PLUGS OR lTTINGS

C#AUTION
4ORQUE PLUGS OR lTTINGS Item O-ring plug Wrench size Torque
INSTALLED INTO ALUMINUM B70, B72 INTERNAL HEX WRENCH .sM ; LBFsFT=
HOUSINGS TO THE LOWER B71 INTERNAL HEX WRENCH .sM ; LBFsFT=
VALUES SPECIlED FOR B80 INTERNAL HEX WRENCH .sM ; LBFsFT=
INTERNAL HEX PLUGS OF THE B82, B83 INTERNAL HEX WRENCH .sM ; LBFsFT=
SAME SIZE G18 INTERNAL HEX WRENCH .sM ; LBFsFT=
G45-G50 INCH HEX WRENCH .sM ; LBFsFT=
G52-G54 INTERNAL HEX WRENCH .sM ; LBFsFT=
H90 (not shown) INTERNAL HEX WRENCH .sM ; LBFsFT=
N35, N36 (not shown) INCH HEX WRENCH .sM ; LBFsFT=
N37 INTERNAL HEX WRENCH .sM ; LBFsFT=

516 BOMAG 008 924 17

Travel pump 16.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
.OTES

520L0818 s 2EV !# s December 2011 71

008 924 17 BOMAG 517
16.1 Travel pump

Products we offer: Sauer-Danfoss is a global manufacturer and supplier of high-

quality hydraulic and electronic components. We specialize in
Bent Axis Motors providing state-of-the-art technology and solutions that excel in
the harsh operating conditions of the mobile off-highway market.
Closed Circuit Axial Piston Pumps
Building on our extensive applications expertise, we work closely
and Motors
with our customers to ensure exceptional performance for a broad
Displays range of off-highway vehicles.
Electrohydraulic Power Steering
We help OEMs around the world speed up system development,
Electrohydraulics reduce costs and bring vehicles to market faster.
Sauer-Danfoss – Your Strongest Partner in Mobile Hydraulics.
Hydraulic Power Steering
Integrated Systems
Joysticks and Control Handles
Go to www.sauer-danfoss.com for further product information.
Microcontrollers and Software
Open Circuit Axial Piston Pumps
Orbital Motors Wherever off-highway vehicles are at work, so is Sauer-Danfoss.
PLUS+1™ GUIDE
We offer expert worldwide support for our customers, ensuring
Proportional Valves the best possible solutions for outstanding performance. And with
an extensive network of Global Service Partners, we also provide
Sensors
comprehensive global service for all of our components.
Steering
Transit Mixer Drives
Please contact the Sauer-Danfoss representative nearest you.

Local address:

Members of the Sauer-Danfoss Group:

Comatrol
www.comatrol.com

Schwarzmüller-Inverter
www.schwarzmueller-inverter.com
Sauer-Danfoss (US) Company Sauer-Danfoss ApS
2800 East 13th Street DK-6430 Nordborg, Denmark
Ames, IA 50010, USA Phone: +45 7488 4444
Turolla
Phone: +1 515 239 6000 Fax: +45 7488 4400
www.turollaocg.com Fax: +1 515 239 6618

Hydro-Gear Sauer-Danfoss GmbH & Co. OHG Sauer-Danfoss-Daikin LTD.

www.hydro-gear.com Postfach 2460, D-24531 Neumünster Shin-Osaka TERASAKI 3rd Bldg. 6F
Krokamp 35, D-24539 Neumünster, Germany 1-5-28 Nishimiyahara, Yodogawa-ku
Phone: +49 4321 871 0 Osaka 532-0004, Japan
Sauer-Danfoss-Daikin Fax: +49 4321 871 122 Phone: +81 6 6395 6066
Fax: +81 6 6395 8585
www.sauer-danfoss-daikin.com

520L0818 s 2EV !# s December 2011

www.sauer-danfoss.com
518 BOMAG 008 924 17
Travel pump 16.1

Series 90 Pumps

Repair Instructions

008 924 17 BOMAG 519

16.1 Travel pump
Series 90 Pumps
Repair Instructions
2EVISIONS

HISTORY OF REVISIONS Table of Revisions

Date Page Changed Rev.

!PRIL 79 4ORQUE FOR ' ' ' ' " " " " CHANGED !"
TO .M ; LBFsFT=
$EC &IRST PRINTING !!

¹ 3AUER $ANFOSS !LL RIGHTS RESERVED

3AUER $ANFOSS ACCEPTS NO RESPONSIBILITY FOR POSSIBLE ERRORS IN CATALOGS BROCHURES AND OTHER PRINTED MATERIAL
3AUER $ANFOSS RESERVES THE RIGHT TO ALTER ITS PRODUCTS WITHOUT PRIOR NOTICE4HIS ALSO APPLIES TO PRODUCTS
ALREADY ORDERED PROVIDED THAT SUCH ALTERATIONS ARENT IN CONmICT WITH AGREED SPECIlCATIONS !LL TRADEMARKS IN
THIS MATERIAL ARE PROPERTIES OF THEIR RESPECTIVE OWNERS 3AUER $ANFOSS AND THE 3AUER $ANFOSS LOGOTYPE ARE
TRADEMARKS OF THE 3AUER $ANFOSS 'ROUP
&RONT COVER ILLUSTRATIONS & & &

2 11019577 s 2EV !" s !PRIL

520 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
Contents

INTRODUCTION /VERVIEW

'ENERAL INSTRUCTIONS
3AFETY PRECAUTIONS
5NINTENDED MACHINE MOVEMENT
&LAMMABLE CLEANING SOLVENTS
&LUID UNDER PRESSURE
0ERSONAL SAFETY
3YMBOLS USED IN 3AUER $ANFOSS LITERATURE 7

DISASSEMBLY 3HAFT

-ULTI FUNCTION VALVE CARTRIDGES 9
-ULTI FUNCTION VALVE CARTRIDGES PRE
#HARGE PRESSURE RELIEF VALVE
0RESSURE OVERRIDE VALVE OPTION FOR FRAME SIZE
!UXILIARY PAD
#HARGE PUMP
)NTEGRAL CHARGE PRESSURE lLTER REPLACEMENT
0UMP CONTROL COVER PLATE
-ANUAL DISPLACEMENT CONTROL -$# 7
3OLENOID OVERRIDE VALVE FOR -$#
3OLENOID OVERRIDE VALVE FOR -$# WITH PRESSURE RELEASED BRAKE 9
(YDRAULIC AND ELECTRIC DISPLACEMENT CONTROLS 0
0RESSURE CONTROL PILOT 0#0 FOR ELECTRIC DISPLACEMENT CONTROL %$#
0OSITION &.2 ELECTRIC CONTROL
$ISPLACEMENT CONTROL ORIlCES %$#($# CONTROL
$ISPLACEMENT CONTROL ORIlCE CHECK VALVE -$# CONTROL
$ISPLACEMENT CONTROL ADAPTER PLATE EARLY PRODUCTION PUMPS ONLY
$ISPLACEMENT CONTROL lLTER SCREENS
3PEED SENSOR
3ERVO RELIEF VALVES
%NDCAP9
6ALVEPLATE0
3IDECOVER0
3IDECOVER DISASSEMBLY
#YLINDER BLOCK
#YLINDER BLOCK
3ERVO CYLINDERS
3WASHPLATE
0ISTON ASSEMBLY
3WASHPLATE

INSPECTION /VERVIEW 7

3HAFT ASSEMBLY 7
0ISTONS AND SLIPPERS7
#YLINDER BLOCK
%NDCAP JOURNAL BEARING
6ALVEPLATE
-ULTI FUNCTION VALVE CARTRIDGES9
#HARGE PRESSURE RELIEF VALVE 0
#HARGE PUMP0
11019577 s 2EV !" s !PRIL 3
008 924 17 BOMAG 521
16.1 Travel pump
Series 90 Pumps
Repair Instructions
Contents

INSPECTION (YDRAULIC AND ELECTRIC DISPLACEMENT CONTROLS

(CONTINUED) )NTEGRAL CHARGE PRESSURE lLTER
3WASHPLATE
3ERVO PISTON
#YLINDER BLOCK

ASSEMBLY #YLINDER BLOCK

3ERVO PISTON 2INGS
3ERVO ARM
3WASHPLATE GUIDE
2OLL PIN AND mAT WASHER
0ISTON ASSEMBLY 7
&IXED CLEARANCE HOLD DOWN BEARING
"EARING CAGE 0
(OUSING
3ERVO CYLINDER SCREWS
$ISPLACEMENT LIMITER
"EARING CAGE LOCATOR LINK
6ERIFY PROPER ASSEMBLY
3WASHPLATE LEVELER
)NSTALLING LEVELER AND SIDE COVER
3ETTING LEVELER NEUTRAL POSITION
#YLINDER BLOCK INSTALLATION7
0OSITIONING THE SIDE COVER 7
%ND CAP INSTALLATION
0REPARING FOR END CAP INSTALLATION
%ND CAP PARTS9
%ND CAP INSTALLATION9
3PEED SENSOR0
-ULTI FUNCTION VALVE CARTRIDGES PRE
0RESSURE OVERRIDE VALVE OPTION FOR FRAME SIZE
#HARGE PRESSURE RELIEF VALVE
#HARGE PUMP
!UXILIARY PAD
$ISPLACEMENT CONTROL lLTER SCREENS
)NTEGRAL CHARGE PRESSURE lLTER REPLACEMENT
0UMP CONTROL COVER PLATE7
$ISPLACEMENT CONTROL ADAPTER PLATE EARLY PRODUCTION PUMPS ONLY 7
(YDRAULIC AND ELECTRIC DISPLACEMENT CONTROLS
-ANUAL DISPLACEMENT CONTROL -$# 9
3OLENOID OVERRIDE VALVE FOR -$#70
3OLENOID OVERRIDE VALVE FOR -$# WITH PRESSURE RELEASED BRAKE 7
0RESSURE CONTROL PILOT 0#0 FOR ELECTRIC DISPLACEMENT CONTROL %$# 7
0OSITION &.2 ELECTRIC CONTROL 7
-ULTI FUNCTION VALVE CARTRIDGES7
)NSTALLING SHAFT AND BEARING7
&INAL ASSEMBLY AND TESTING 77
&ASTENER SIZE AND TORQUE CHART 7
0LUG SIZE AND TORQUE CHART 79
&ASTENERS AND PLUGS79

4 11019577 s 2EV !" s !PRIL

522 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
)NTRODUCTION

OVERVIEW 4HIS MANUAL DETAILS MAJOR REPAIR PROCEDURES FOR 3ERIES PUMPS4HESE INCLUDE THE
COMPLETE DISASSEMBLY INSPECTION AND REASSEMBLY OF THE UNIT7HERE REWORK OF WORN
OR DAMAGED COMPONENTS IS POSSIBLE SPECIlCATIONS APPEAR TO ENSURE THESE PARTS MEET
FACTORY TOLERANCES /NLY 3AUER $ANFOSS 'LOBAL 3ERVICE 0ARTNERS '30S ARE AUTHORIZED TO
PERFORM MAJOR REPAIRS 3AUER $ANFOSS TRAINS 'LOBAL 3ERVICE 0ARTNERS AND CERTIlES THEIR
FACILITIES ON A REGULAR BASIS

W 7ARNING
5SE OF COMPONENTS THAT DO NOT COMPLY WITH REWORK SPECIlCATIONS MAY RESULT IN LOSS OF
PERFORMANCE WHICH MAY CONSTITUTE A SAFETY HAZARD $O NOT REUSE COMPONENTS THAT DONT
COMPLY TO GIVEN SPECIlCATIONS REPLACE WITH GENUINE 3AUER $ANFOSS SERVICE PARTS

-INOR REPAIR PROCEDURES ADJUSTMENTS AND TROUBLESHOOTING INFORMATION APPEAR IN THE

Series 90 Pumps Service Manual 520L0818 -INOR REPAIRS INCLUDE SERVICE OPERATIONS YOU
CAN PERFORM WITHOUT REMOVING THE UNITS ENDCAP 2EMOVAL OF THE ENDCAP VOIDS YOUR
WARRANTY

&OLLOW THESE GENERAL PROCEDURES WHEN REPAIRING 3ERIES PUMPS

GENERAL INSTRUCTIONS
w Remove the unit
0RIOR TO PERFORMING MAJOR REPAIRS REMOVE THE UNIT FROM THE VEHICLEMACHINE #HOCK
THE WHEELS ON THE VEHICLE OR LOCK THE MECHANISM TO INHIBIT MOVEMENT "E AWARE THAT
HYDRAULIC mUID MAY BE UNDER HIGH PRESSURE ANDOR HOT )NSPECT THE OUTSIDE OF THE
PUMP AND lTTINGS FOR DAMAGE #AP HOSES AND PLUG PORTS AFTER REMOVAL TO PREVENT
CONTAMINATION

e Keep it clean
#LEANLINESS IS A PRIMARY MEANS OF ASSURING SATISFACTORY PUMP LIFE ON EITHER NEW OR
REPAIRED UNITS #LEAN THE OUTSIDE OF THE PUMP THOROUGHLY BEFORE DISASSEMBLY4AKE CARE
TO AVOID CONTAMINATION OF THE SYSTEM PORTS #LEANING PARTS IN A CLEAN SOLVENT WASH AND
AIR DRYING IS USUALLY ADEQUATE

l Lubricate moving parts

$URING ASSEMBLY COAT ALL MOVING PARTS WITH CLEAN HYDRAULIC mUID4HIS ASSURES THAT THESE
PARTS ARE LUBRICATED DURING START UP

d Replace all O-rings and gaskets

3AUER $ANFOSS RECOMMENDS THAT YOU REPLACE ALL / RINGS SEALS AND GASKETS ,IGHTLY
LUBRICATE ALL / RINGS WITH CLEAN PETROLEUM JELLY PRIOR TO ASSEMBLY

t Secure the unit

&OR MAJOR REPAIR PLACE THE UNIT IN A STABLE POSITION WITH THE SHAFT POINTING DOWNWARD )T
IS NECESSARY TO SECURE THE PUMP WHILE REMOVING AND TORQUING THE ENDCAP BOLTS

11019577 s 2EV !" s !PRIL 5

008 924 17 BOMAG 523
16.1 Travel pump
Series 90 Pumps
Repair Instructions
)NTRODUCTION

Unintended machine movement

Flammable cleaning solvents

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

Fluid under pressure

Personal safety
W Warning
0ROTECT YOURSELF FROM INJURY 5SE PROPER SAFETY EQUIPMENT INCLUDING SAFETY GLASSES AT ALL
TIMES

6 11019577 s 2EV !" s !PRIL

524 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
)NTRODUCTION

SYMBOLS USED IN  7!2.).' MAY RESULT IN INJURY  4IP HELPFUL SUGGESTION

SAUER-DANFOSS
LITERATURE  #!54)/. MAY RESULT IN DAMAGE TO  ,UBRICATE WITH HYDRAULIC mUID
PRODUCT OR PROPERTY
 !PPLY GREASEPETROLEUM JELLY
 2EUSABLE PART
 !PPLY LOCKING COMPOUND
 .ON REUSABLE PART USE A NEW PART
 )NSPECT FOR WEAR OR DAMAGE
 .ON REMOVABLE ITEM
 #LEAN AREA OR PART
 /PTION n EITHER PART MAY EXIST
 "E CAREFUL NOT TO SCRATCH OR DAMAGE
 3UPERSEDED n PARTS ARE NOT
INTERCHANGEABLE  .OTE CORRECT ORIENTATION

 -EASUREMENT REQUIRED  -ARK ORIENTATION FOR REINSTALLATION

 &LATNESS SPECIlCATION  4ORQUE SPECIlCATION

 0ARALLELISM SPECIlCATION  0RESS IN n PRESS lT

 %XTERNAL HEX HEAD  0ULL OUT WITH TOOL n PRESS lT

 )NTERNAL HEX HEAD  #OVER SPLINES WITH INSTALLATION

SLEEVE
 4ORX HEAD
 0RESSURE MEASUREMENTGAUGE
 / RING BOSS PORT LOCATION OR SPECIlCATION

11019577 s 2EV !" s !PRIL 7

008 924 17 BOMAG 525
16.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SHAFT Shaft and bearing Removing the shaft and bearing assembly
0OSITION PUMP WITH THE SHAFT
POINTING UP L70

.UMBER OF SCREWS AND WRENCH SIZE VARIES L60

BY MODEL
L30
2EMOVE THE THREE OR FOUR SCREWS
L40
, HOLDING THE RETAINER PLATE ,
AND SEAL CARRIER , TO THE HOUSING L50
USING A MM HEX WRENCH
L20
UNIT A MM INTERNAL HEX WRENCH
THROUGH UNITS OR A MM
INTERNAL HEX WRENCH THROUGH L10
UNITS 2EMOVE THE RETAINER PLATE

0RY THE SEAL CARRIER , FROM ITS L100

BORE9OU MAY TAP LIGHTLY ON THE END
OF THE SHAFT WITH A SOFT MALLET TO
FACILITATE REMOVAL

2EMOVE THE / RING , FROM THE

SEAL CARRIER AND DISCARD

0LACE SEAL CARRIER IN AN ARBOR PRESS

AND PRESS OUT THE SEAL , $ISCARD
SEAL
P106 181E

,IFT THE SHAFT AND BEARING ASSEMBLY

OUT OF THE PUMP

2EMOVE THE SNAP RING ,

2EMOVE THE BEARING WASHER AND

ROLLER ASSEMBLY ,

0RESS THE INNER BEARING RACE OFF THE

SHAFT ,

8 11019577 s 2EV !" s !PRIL

526 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

MULTI-FUNCTION VALVE Multi-function valve removal

CARTRIDGES

/LDER MULTIFUNCTION
VALVES PRE CONTAIN
DIFFERENT COMPONENTS P2B1
See multifunction valves
- Pre 1988 PAGE 0 FOR
DISASSEMBLY INSTRUCTIONS
P13

P06

P2A1

E101 537E

Removal Multi-function valve wrench size

2EMOVE MULTI FUNCTION VALVES 0! AND Frame size Wrench size
0" USING HEX WRENCH LISTED IN TABLE n INCH
n INCH

11019577 s 2EV !" s !PRIL 9

008 924 17 BOMAG 527
16.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

MULTI-FUNCTION VALVE Disassembly

CARTRIDGE (continued) 2EMOVE AND DISCARD / RINGS 0 AND 0

2ELIEVE SPRING PRESSURE BY REMOVING BYPASS ACTUATOR 0 USING A WRENCH4O
RETAIN PRESSURE SETTING DO NOT SEPARATE ADJUSTING SCREW 0 AND LOCKNUT 0 FROM
BYPASS ACTUATOR 0

2EMOVE AND DISCARD / RING 0

-ULTI FUNCTION VALVES ARE SOLD AS COMPLETE UNITS ONLY9OU MAY PURCHASE / RINGS
SEPARATELY

2EMOVE INTERNAL PARTS 0 0 0 0 0 0 0 AND 0

Multi-function valve

P04
P03
P01
P02

P05

P06

P07
P08
P17
P16
P15
P14
P09
P11
P13

P12

E101 531E

10 11019577 s 2EV !" s !PRIL

528 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

MULTI-FUNCTION VALVE Removal Multi-function valve wrench size

CARTRIDGES - PRE 1988 2EMOVE MULTI FUNCTION VALVES USING HEX Frame size Wrench size
WRENCH LISTED IN TABLE n INCH
n INCH

Disassembly
2EMOVE AND DISCARD / RINGS 0 AND 0

)T IS NOT NECESSARY TO REMOVE THE BYPASS ACTUATOR 0 EXCEPT FOR CLEANING7RENCH
SIZE IS

-ULTI FUNCTION VALVES ARE SOLD AS COMPLETE UNITS ONLY / RINGS MAY BE PURCHASED
SEPARATELY

4O RETAIN PRESSURE SETTING DO NOT DISASSEMBLE BYPASS ACTUATOR 0

2EMOVE RETAINING RING 0 WITH A SNAP RING PLIERS

2EMOVE POPPET SEAT 0

2EMOVE INTERNAL PARTS 0 0 0 0 AND 0

Multi-function valve - pre 1988

P14

P19

P12

P06

P21
P15
P14
P11 P22
P09
P1
P13

E101 532E

11019577 s 2EV !" s !PRIL 11

008 924 17 BOMAG 529
16.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

CHARGE PRESSURE 4HE CHARGE PRESSURE RELIEF VALVE IS Charge pressure relief valve
RELIEF VALVE SHIM ADJUSTABLE EARLY MODELS OR
SCREW ADJUSTABLE LATE MODELS 3CREW +
h ,OCK NUT
ADJUSTABLE CHARGE RELIEF VALVE IS SHOWN

Removal +
2EMOVE THE SHIM ADJUSTABLE CHARGE h IN
RELIEF VALVE PLUG WITH A INCH HEX d+ +
WRENCH 2ETAIN SHIMS
+
"EFORE REMOVING THE SCREW
ADJUSTABLE RELIEF VALVE PLUG MARK +
THE PLUG + LOCK NUT + AND
HOUSING TO APPROXIMATELY MAINTAIN
THE ORIGINAL ADJUSTMENT WHEN ASSEM
3EE TABLE FOr
BLING 2EMOVE THE SCREW ADJUSTABLE WRENCH SIZe
CHARGE RELIEF VALVE PLUG BY LOOSENING
THE LOCK NUT WITH A HEX WRENCH
CORRESPONDING TO THE TABLE

5NSCREW THE PLUG USING A LARGE

SCREWDRIVER OR INCH HEX WRENCH
2EMOVE AND DISCARD THE / RING +

2EMOVE THE SPRING + AND RELIEF

VALVE POPPET +

Lock nut wrench size

Frame size Wrench size
n INCH % %

n INCH

PRESSURE OVERRIDE Removal Pressure override valve components

VALVE (OPTION FOR 180 2EMOVE FOUR SCREWS ATTACHING
Screws
FRAME SIZE) THE PRESSURE OVERRIDE VALVE TO THE
END CAP WITH A MM INTERNAL HEX Pressure override
WRENCH valve

2EMOVE AND DISCARD THE / RINGS

O-rings

E101 079E

12 11019577 s 2EV !" s !PRIL

530 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

AUXILIARY PAD Removal

2EMOVE FOUR END CAP SCREWS * 2EMOVE AND DISCARD SEAL WASHERS *

2EMOVE THE AUXILIARY PAD * AND DISCARD THE / RING *

Auxiliary pad components (typical)

J50
J80
Endcap screw J70

J60
See table for wrench size and torque
E101 084E

Auxiliary pad screw wrench size

Frame size Wrench sizes
n EARLY MM INTERNAL HEX
LATE MM INTERNAL HEX
MM HEX
n MM HEX
n MM INTERNAL HEX
n MM INTERNAL HEX

11019577 s 2EV !" s !PRIL 13

008 924 17 BOMAG 531
16.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

CHARGE PUMP Removal

&OR PUMPS WITH AN AUXILIARY MOUNTING PAD REFER TO THE Auxiliary Pad instructions
PAGE

2EMOVE AND DISCARD SIX SCREWS ( FROM THE CHARGE PUMP COVER RETAINER (

2EMOVE RETAINER ( AND THE Retainer screw wrench size

CHARGE PUMP COVER * 2EMOVE Frame size Wrench size
AND DISCARD / RING * .OTE THE n MM
ORIENTATION OF THE GEROTOR ASSEMBLY n MM
(

Current charge pump conﬁguration

H40

H05

H60
H50
H31

J15

J50
J30

H70
E101 539E
H80

2EFER TO APPROPRIATE Sauer-Danfoss Series 90 service parts manual FOR EARLIER CHARGE PUMP
CONlGURATIONS

2EMOVE CHARGE PUMP COUPLING ( AND CHARGE PUMP DRIVE KEY (

2EMOVE THE CHARGE PUMP GEROTOR ASSEMBLY (

2EMOVE THE ALIGNMENT PIN (

2EMOVE THE VALVE PLATE (

14 11019577 s 2EV !" s !PRIL

532 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

INTEGRAL CHARGE Removal Lock nut wrench size and torque

PRESSURE FILTER 2EMOVE lLTER CANISTER . FROM THE Frame size Wrench size Torque
REPLACEMENT lLTER HEAD . AS DESCRIBED ON THE n INCH .sM ; LBFsFT=
CANISTER n INCH .sM ; LBFsFT=
n INCH .sM ; LBFsFT=

(OLD lLTER HEAD IN PLACE AND LOOSEN THE LOCK NUT . USING THE WRENCH SIZE IN THE
TABLE

2OTATE lLTER HEAD COUNTERCLOCKWISE TO REMOVE IT FROM THE HOUSING 2EMOVE AND
DISCARD THE / RING .

2EMOVE HYDRAULIC TUBE . FROM ITS BORE IN THE ENDCAP

Integral charge pressure ﬁlter

N25 N20
N15 Filter manifold lock nut

N36A

N36
11/16 in

N40

N10
N35A
N35
11/16 in
P106 182E

11019577 s 2EV !" s !PRIL 15

008 924 17 BOMAG 533
16.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

PUMP CONTROL COVER Removal

PLATE 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVING COVER PLATE

5SING A MM INTERNAL HEX WRENCH REMOVE SIX COVER PLATE MOUNTING SCREWS -
2EMOVE THE COVER PLATE - AND GASKET - FROM HOUSING $ISCARD THE GASKET

CCaution
0ROTECT EXPOSED SURFACES AND CAVITIES FROM DAMAGE AND FOREIGN MATERIAL

Pump controls cover plate

M90 X
MM
t .sM ; LBFsFT=

-
3EAL WASHER
LOCATION CC

-
d

0 %

16 11019577 s 2EV !" s !PRIL

534 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

MANUAL DISPLACEMENT Removal

CONTROL (MDC) 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVING CONTROL

5SING A MM INTERNAL HEX WRENCH REMOVE SIX CONTROL MOUNTING SCREWS -
2EMOVE THE CONTROL - WITH ORIlCE CHECK VALVE 4 AND SPRING 4 AND CONTROL
GASKET - FROM THE HOUSING $ISCARD THE GASKET

)F NECESSARY REMOVE THE CONTROL HANDLE - BY REMOVING THE LOCKING NUT - AND
WASHER -

CCaution
0ROTECT EXPOSED SURFACES AND CAVITIES FROM DAMAGE AND FOREIGN MATERIAL

MDC removal/installation
-
3 - h MM
h IN M70

- X
I MM

-
3EAL WASHER d
LOCATION CC
4

4 4

0 %

11019577 s 2EV !" s !PRIL 17

008 924 17 BOMAG 535
16.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SOLENOID OVERRIDE Removal

VALVE FOR MDC 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVING VALVE

2EMOVE THE SOLENOID FROM THE VALVE BY REMOVING THE COIL NUT WITH A INCH HEX
WRENCH 2EMOVE THE SOLENOID VALVE - FROM THE MANIFOLD - WITH A INCH
HEX WRENCH 2EMOVE THE / RINGS -! " AND BACKUP RING -# DISCARD

5SING A MM INTERNAL HEX WRENCH REMOVE TWO SCREWS - AND REMOVE SOLENOID
MANIFOLD - FROM HOUSING 2EMOVE AND DISCARD THE GASKET -

Solenoid override valve removal/installation

Seal washer
location
(42, 180, 250 cc)

M77
M76A
M76C
M76B
M76

M78 (x2)
5 mm
M75
P106 186E

18 11019577 s 2EV !" s !PRIL

536 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SOLENOID OVERRIDE Removal

VALVE FOR MDC WITH 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVING VALVE
PRESSURE RELEASED
BRAKE 5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR SOLENOID VALVE MOUNTING SCREWS
- 2EMOVE THE SOLENOID VALVE - WITH / RINGS FROM THE ADAPTER PLATE $ISCARD
THE / RINGS

5SING A MM INTERNAL HEX WRENCH REMOVE THE FOUR ADAPTER PLATE MOUNTING SCREWS
- 2EMOVE THE ADAPTER PLATE AND / RINGS - - AND - FROM THE CONTROL
HOUSING $ISCARD THE / RINGS

Solenoid override valve removal/installation

M98 (x4)
4 mm
M9

M95
M96
M97 M92 (x4)
4 mm

P106 192E

11019577 s 2EV !" s !PRIL 19

008 924 17 BOMAG 537
16.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

HYDRAULIC AND Removal

ELECTRIC DISPLACEMENT 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVING CONTROL
CONTROLS
5SING A MM INTERNAL HEX WRENCH REMOVE SIX CONTROL MOUNTING SCREWS -
$ISCARD SEAL WASHER IF PRESENT 2EMOVE CONTROL - WITH ORIlCE CHECK VALVE 4
AND SPRING 4 AND CONTROL GASKET - FROM HOUSING $ISCARD THE GASKET

CCaution
0ROTECT EXPOSED SURFACES AND CAVITIES FROM DAMAGE AND FOREIGN MATERIAL

Hydraulic/Electric displacement control

- X
I MM

-
d

4
4

0 %

20 11019577 s 2EV !" s !PRIL

538 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

PRESSURE CONTROL Removal

PILOT (PCP) FOR 4HOROUGHLY CLEAN EXTERNAL SURFACES OF CONTROL
ELECTRIC DISPLACEMENT
CONTROL (EDC) 5SING A MM INTERNAL HEX WRENCH REMOVE FOUR SCREWS - AND REMOVE THE 0#0
- 2EMOVE AND DISCARD THE / RINGS - -

$O NOT DISASSEMBLE THE

0#0 - )T IS AVAILABLE PCP removal/installation
ONLY AS A COMPLETE UNIT

M97

M96 (x3)

M98 (x4)
M9
4 mm
P106 194E

11019577 s 2EV !" s !PRIL 21

008 924 17 BOMAG 539
16.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

3-POSITION (FNR) Removal

ELECTRIC CONTROL 4HOROUGHLY CLEAN EXTERNAL SURFACES PRIOR TO REMOVAL OF CONTROL

5SING A MM INTERNAL HEX WRENCH REMOVE FOUR SOLENOID VALVE MOUNTING SCREWS
7 2EMOVE THE SOLENOID VALVE 7 WITH / RINGS 7! AND ORIlCE FROM
THE ADAPTER PLATE

5SING A MM INTERNAL HEX WRENCH REMOVE THE SIX ADAPTER PLATE MOUNTING SCREWS
CCaution - 2EMOVE THE ADAPTER PLATE AND GASKET - FROM THE HOUSING $ISCARD THE
0ROTECT EXPOSED SURFACES GASKET C
AND CAVITIES FROM DAMAGE
AND FOREIGN MATERIAL )F NECESSARY REMOVE AND CLEAN THE THREE ORIlCES 4 4 4 USING A MM
INTERNAL HEX WRENCH AND A MM INTERNAL HEX WRENCH

$O NOT DISASSEMBLE THE FNR removal/installation

&.2 CONTROL )T IS AVAILABLE 7 X
I MM
AS A COMPLETE UNIT ONLY

7!
- X d
I MM
4
4
4
-

3EAL WASHER
LOCATION CC
4

- 4
4
d

0 %

22 11019577 s 2EV !" s !PRIL

540 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

DISPLACEMENT 2EMOVE THE CONTROL ASSEMBLY AS Underside of an HDC/EDC module showing

CONTROL ORIFICES DESCRIBED IN THE INSTRUCTIONS FOR THE oriﬁce locations
(EDC/HDC CONTROL) SPECIlC DISPLACEMENT CONTROL A
B
TA P
9OU MAY lND ORIlCE PLUGS IN THE TB
CONTROL ASSEMBLY AT THE PUMP
HOUSING FACE4O AVOID MIXING THEM
UP REMOVE CLEAN AND REPLACE
ORIlCE PLUGS INDIVIDUALLY 5SE A MM
INTERNAL HEX WRENCH TO REMOVE THE Orifice plugs
PLUGS .OTE THE LOCATION OF EACH PLUG Orifice check valve
DO NOT INTERCHANGE PLUGS #LEAN E101 085E

REINSTALL AND TORQUE THE ORIlCE PLUGS

TO .sM ; LBFsFT=

DISPLACEMENT 2EMOVE THE CONTROL ASSEMBLY AS Underside of an MDC module showing

CONTROL ORIFICE DESCRIBED IN THE INSTRUCTIONS FOR THE oriﬁce locations
CHECK VALVE (MDC SPECIlC DISPLACEMENT CONTROL
CONTROL) TA A B TB

4HE ORIlCE CHECK VALVE IS IN THE P

CONTROL ASSEMBLY AT THE SURFACE OF

THE PUMP HOUSING FACE 2EMOVE THE
SPRING RETAINER AND SPRING FROM THE
Orifice plugs
ORIlCE CHECK VALVE CAVITY AND THEN
REMOVE THE ORIlCE CHECK VALVE
Orifice check valve
#LEAN AND INSTALL THE ORIlCE CHECK E101 086E

VALVE IN THE CAVITY AND THEN INSTALL

THE SPRING AND SPRING RETAINER
TO HOLD THE ORIlCE CHECK VALVE IN
POSITION

DISPLACEMENT $O NOT REMOVE THE ADAPTER PLATE UNLESS Displacement control adapter plate (early
CONTROL ADAPTER LEAKAGE IS EVIDENT4HE MOUNTING SCREWS production 130 cm³ pumps only)
PLATE (EARLY WITH SEALING COMPOUND ARE DIFlCULT TO Adapter plate
PRODUCTION 130 REMOVE screws
PUMPS ONLY)
4HE SCREWS FASTENING THE CONTROL ADAPTER 6 mm
PLATE TO THE HOUSING HAVE SEALING
t]
COMPOUND ON THE THREADS9OU MAY O-rings
REMOVE THEM WITH A MM INTERNAL HEX Adapter plate
WRENCH IF NECESSARY 2EMOVE AND DISCARD
THE / RINGS AND SEALS Seal

E101 087E

11019577 s 2EV !" s !PRIL 23

008 924 17 BOMAG 541
16.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

DISPLACEMENT )F YOU REMOVE THE SCREENS REPLACE WITH Filter screen installation
CONTROL FILTER NEW SCREENS 0RESS THEM INTO POSITION B90
SCREENS WITH THE ROUNDED EDGE OF THE SCREEN
FACING THE CONTROL UNTIL THEY ARE mUSH TO P106 690E

MM ; INCH= BELOW THE SURFACE OF

THE HOUSING

SPEED SENSOR Removal

,OOSEN THE LOCK NUT USING AN IN HEX WRENCH

5NSCREW SPEED SENSOR " FROM THE PUMP HOUSING 2EMOVE AND DISCARD THE / RING
"!

Typical location of speed sensor

B83 O-ring plug

ft]
B83A

B83 B83A

E101 095E

24 11019577 s 2EV !" s !PRIL

542 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SERVO RELIEF VALVES #ERTAIN FRAME SIZE PUMPS WITH TWIN PORT END CAPS MAY HAVE THE SERVO RELIEF VALVES AND
ROTATION PLUGS IN A REMOVABLE ROTATION BLOCK

5SING A MM INTERNAL HEX WRENCH REMOVE THE ROTATION BLOCK SCREWS

2EMOVE THE BLOCK

2EMOVE THE GASKET

3OME PUMPS HAVE A PRESSURE LIMITER FUNCTION

2EMOVE THE SERVO RELIEF VALVES FROM THE END CAP OR ROTATION BLOCK 5SE A
SCREWDRIVER

Servo relief valve removal

Veiw 'C'

View 'C'
View 'C'

P80
P802
P70

P702

With Pressure Limiters Without Pressure Limiters

P106 729E

Servo relief passage plugs

3OME PUMPS HAVE PRESSURE LIMITER VALVES ANDOR RELIEF VALVES

.OTE THE POSITION OF THE ROTATION PIPE PLUGS

5SING A INCH INTERNAL HEX WRENCH REMOVE THE SERVO RELIEF PASSAGE PLUGS FROM THE
END CAP OR ROTATION BLOCK

5SING A INCH INTERNAL HEX WRENCH REMOVE THE PIPE PLUGS FROM THE END CAP OR
ROTATION BLOCK

#LEAN PASSAGES WITH A SUITABLE SOLVENT

3EE THE ILLUSTRATIONS ON THE FOLLOWING PAGES FOR PROPER PLUG AND VALVE LOCATIONS ON
VARIOUS PUMPS

11019577 s 2EV !" s !PRIL 25

008 924 17 BOMAG 543
16.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SERVO RELIEF VALVES Installing servo relief valves

(continued) )NSTALL SERVO RELIEF VALVES OR RELIEF VALVE PASSAGE PLUGS INTO THE END CAP OR ROTATION
BLOCK

)NSTALL SERVO RELIEF VALVES IN THE END CAP OR ROTATION BLOCK OF PUMPS WITH PRESSURE
LIMITER FUNCTIONS OR RELIEF VALVES

)NSTALL THE ROTATION PIPE PLUGS INTO THE END CAP OR ROTATION BLOCK W

W 7ARNING
-AKE SURE THE PRESSURE LIMITER LOGIC PLUGS ARE IN THE CORRECT PORTS FOR PUMP ROTATION
5NCONTROLLABLE MACHINE MOVEMENT RESULTS FROM IMPROPER PLUG INSTALLATION6ERIFY CORRECT
PRESSURE LIMITER FUNCTION4EST THE PUMP BEFORE INSTALLING IN MACHINE !LSO TEST IT BEFORE
RELEASING THE MACHINE FROM REPAIR

4ORQUE THE SERVO RELIEF VALVES OR RELIEF VALVE PASSAGE PLUGS TO .sM ; LBFsFT=

4ORQUE THE ROTATION PIPE PLUGS TO .sM ; LBFsFT=

)NSTALL ROTATION BLOCK GASKET AND SCREWS IF USED

4ORQUE THE ROTATION BLOCK SCREWS TO .sM ; LBFsFT=

Speciﬁcations
Pressure limiter Pump rotation Holes with Holes with servo Holes with Open holes
Port A Port B pipe plugs relief valves O-ring plugs
9ES 9ES 2IGHT #7 .ONE
9ES 9ES ,EFT ##7 .ONE
.O .O %ITHER .ONE
9ES .O 2IGHT #7 .ONE
9ES .O ,EFT ##7 .ONE
9ES 9ES 2IGHT #7 WITH .ONE
AUTOMOTIVE CONTROL
9ES 9ES ,EFT ##7 WITH .ONE
AUTOMOTIVE CONTROL

030 twin ported end cap (early units) 030 Twin ported end cap

3 4
7 6
5 6
5
3 4
7
1 1

2
2

0 0

26 11019577 s 2EV !" s !PRIL

544 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SERVO RELIEF VALVES 042 twin ported end cap (early units) 042 twin ported end cap
(continued)
6 3 6
2 2
3
5

5 1 4 1
7 4 7

0
0

055 side ported end cap 055 twin ported end cap

6 6
2 2
4 5 4
1 1
7 7

5 3 3

0 0

075 side and twin ported end cap 075 twin ported end cap rotation block

6 1 2

4 2
1

5 4 3
5
7 3

0
6 7

11019577 s 2EV !" s !PRIL 27

008 924 17 BOMAG 545
16.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SERVO RELIEF VALVES 100 side ported end cap 100 twin ported end cap
(continued)

6 6 2
2

4 7 1 5 7

3
3
1
5 4

0
0

130 twin ported end cap 180 twin ported end cap rotation block

4 3
1 2
5

5 4
3

6 1 2 6
7

0
250 twin port end cap

5 4
3 6
7
2 1

28 11019577 s 2EV !" s !PRIL

546 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

ENDCAP 0LACE THE PUMP ON THE WORK SURFACE WITH ENDCAP ' FACING UP

.UMBER OF SCREWS AND WRENCH SIZE VARIES BY MODEL

5SING A OR MM INTERNAL HEX WRENCH OR A MM HEX WRENCH REMOVE THE OR

SCREWS '' FASTENING THE END CAP TO THE PUMP HOUSING

4HE SCREW ' RETAINS A SPACER ' A (J80) Screw removal

LIFTING BRACKET ' AND A WASHER ' Pump size Wrench size
CC MM INTERNAL HEX
2EMOVE SCREWS * IF PRESENT CC MM HEX
2EFER TO THE TABLE Screw removal FOR CC AND CC MM HEX
WRENCH SIZES CC MM INTERNAL HEX
CC AND CC MM INTERNAL HEX
2EMOVE END CAP ' FROM HOUSING

4HE ALIGNMENT PINS AND VALVE PLATE WILL USUALLY REMAIN WITH THE HOUSING

2EMOVE AND DISCARD END CAP GASKET '

2EMOVE THE HARDENED SHIMS % FROM THE END CAP POCKETS

Removing the end cap and gasket

G97
G95
G94
J80
G93
G90

G04

E24

E101 101

11019577 s 2EV !" s !PRIL 29

008 924 17 BOMAG 547
16.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

VALVEPLATE Valveplate and springs Removing internal parts

2EMOVE VALVE PLATE # NOTING
DIRECTION OF ARROWS ON VALVE PLATE

2EMOVE THE LONG SPRINGS % FROM

THE SWASHPLATE LEVELER D95

3OME UNITS HAVE DUAL SWASHPLATE LEVELER B50 (2X)

SPRINGS AN INNER SPRING NESTED INSIDE
EACH OF THE STANDARD SPRINGS
B10
2EMOVE THE SHORT SWASHPLATE HOLD
DOWN SPRING $ IF PRESENT E82
E101 102
Arrows C80
2EMOVE THE TWO ALIGNMENT PINS
"

SIDECOVER -ARK THE ORIENTATION OF THE SIDE Removing the side cover
COVER % TO THE HOUSING

3TRAIGHTEN THE LOCKING TABS USED ON

EARLIER PRODUCTION UNITS

2EMOVE THE SIDE COVER SCREWS

% 2EFER TO TABLE BELOW FOR WRENCH
SIZES

2EMOVE SIDE COVER ASSEMBLY FROM

PUMP HOUSING

Side cover screw removal

B10
Pump size Wrench size
CC MM HEX
CC THROUGH CC MM HEX
CC THROUGH CC MM HEX

E101 103
E60

30 11019577 s 2EV !" s !PRIL

548 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SIDECOVER Side cover components Leveler disassembly

DISASSEMBLY 2EMOVE SPACER WASHERS IF USED ON
E30
THE LEVELER SPRING SEATS %
E30

3OME UNITS WITH DUAL SWASHPLATE LEVELER

SPRINGS HAVE SPACER WASHERS ON THE
LEVELER SPRING SEATS
E22
2EMOVE SPRING SEATS % FROM
SWASHPLATE LEVELER %

3OME LEVELERS DO NOT HAVE REMOVABLE

Spacer
SPRING SEATS Washer

2EMOVE THE SEALING NUTS % AND

GUIDE POSTS % HOLDING THE LEVELER
% TO THE SIDE COVER % 2EFER TO
TABLE BELOW FOR WRENCH SIZES E90

Sealing nut removal

Pump size Wrench sizes
CC AND CC MM OPEN END
MM HEX

CC THROUGH CC INCH OPEN END
MM HEX
CC THROUGH CC MM OPEN END
MM HEX

E101 104
.OTE THE ORIENTATIONS OF THE LEVELER
% AND SIDE COVER % E40

2EMOVE LEVELER % FROM SIDE COVER

% Cylinder block removal

2EMOVE THE INSERT ASSEMBLY %

2EMOVE AND DISCARD SIDE COVER / C12

RING %

CYLINDER BLOCK 2EMOVE THE CYLINDER BLOCK # FROM

THE HOUSING

4HE SWASHPLATE AND PISTON ASSEMBLY

REMAINS IN THE HOUSING C4AKE CARE TO
PREVENT PISTONS FROM BEING SCRATCHED
WHILE THE CYLINDER BLOCK IS OUT OF THE
HOUSING 4HE PISTONS ARE NOT SELECTIVELY
lTTED HOWEVER UNITS WITH HIGH HOURLY
USAGE MAY DEVELOP WEAR PATTERNS
.UMBER THE PISTONS AND BORES FOR RE E101 131
ASSEMBLY IF THEY ARE TO BE REUSED

11019577 s 2EV !" s !PRIL 31

008 924 17 BOMAG 549
16.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

CYLINDER BLOCK -OST REPAIRS DO NOT REQUIRE BLOCK SPRING Cylinder block disassembly
REMOVAL 0ERFORM THIS PROCEDURE ONLY
IF YOU SUSPECT PROBLEMS WITH THE BLOCK
SPRING C16
W 7ARNING
2ISK OF PERSONAL INJURY
C15
#OMPRESSING THE BLOCK 5SING A PRESS APPLY PRESSURE ON
SPRING REQUIRES TO THE BLOCK SPRING WASHER # TO
. ; TO LBF = 5SE A COMPRESS THE BLOCK SPRING #
PRESS SUFlCIENT TO MAINTAIN #OMPRESS THE SPRING ENOUGH TO C14
THIS FORCE WITH REASONABLE SAFELY REMOVE THE SPIRAL RETAINING
EFFORT %NSURE THE SPRING IS RING # 7HILE MAINTAINING
SECURE BEFORE ATTEMPTING PRESSURE UNWIND THE SPIRAL RETAINING
TO REMOVE THE SPIRAL RING #AREFULLY RELEASE THE PRESSURE C13
RETAINING RING 2ELEASE THE AND REMOVE THE OUTER BLOCK SPRING
PRESSURE SLOWLY AFTER THE WASHER BLOCK SPRING AND INNER
RETAINING RING IS REMOVED BLOCK SPRING WASHER # FROM THE
CYLINDER BLOCK W

C12

E101-113

32 11019577 s 2EV !" s !PRIL

550 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SERVO CYLINDERS -ARK THE SERVO CYLINDERS && AND HOUSING " 4HIS HELPS TO IDENTIFY EACH
SERVO CYLINDER && WITH ITS RESPECTIVE SIDE OF THE HOUSING "

.UMBER OF SCREWS AND WRENCH SIZE VARIES BY MODEL

5SING A MM OR MM HEX WRENCH REMOVE THE OR SCREWS &&

RETAINING EACH SERVO CYLINDER && TO THE HOUSING "

A &OR EARLY PRODUCTION UNITS CAREFULLY PRY EACH CYLINDER && FROM THE
HOUSING " BY USING A SCREWDRIVER IN THE NOTCHES IN THE CYLINDER
4HE SERVO PISTON WILL
REMAIN IN THE HOUSING B &OR LATER PRODUCTION UNITS INSTALL AN MM OR MM SCREW IN THE THREADED
&OR LATER PRODUCTION UNITS HOLE IN THE CENTER OF EACH CYLINDER && AND PULL THE CYLINDERS FROM THE
WITH DISPLACEMENT LIMITERS HOUSING "
REMOVE THE NUT
&& AND LIMITER
SCREW && FROM Servo cylinder removal
EACH SERVO CYLINDER
F112 F113
&& AND INSTALL AN
MM OR MM SCREW IN
ITS PLACE AS A PULLER SCREW F40

F50

F40
F50

B10

F40
F50

F212
F213 E101 105E

11019577 s 2EV !" s !PRIL 33

008 924 17 BOMAG 551
16.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SWASHPLATE 2EMOVE THE SWASHPLATE BEARING CAGE LINK PIN $ FROM THE HOUSING THROUGH THE
CONTROL OPENING

CMÃ DISPLACEMENT 2EMOVE THE BEARING CAGE LOCATOR LINK $ FROM THE SWASHPLATE THROUGH THE CONTROL
PUMPS USE A SCREW AS THE OPENING
LINK PIN 2EMOVE IT WITH A
MM INTERNAL HEX WRENCH IF CC AND CC PUMPS HAVE SCREW TYPE LINK PINS /NE IS AT THE CONTROL OPENING4HE
NECESSARY OTHER IS AT THE SIDE COVER OPENING

2EMOVE THE SWASHPLATE $ AND PISTON ASSEMBLY # THROUGH THE HOUSING SIDE
COVER OPENING
5NITS WITH AN AUTOMOTIVE
CONTROL HAVE A THREADED $ISENGAGE THE SERVO ARM $ FROM THE SLIDER BLOCK & IN THE SERVO PISTON AS YOU
HOLE IN ONE END OF THE REMOVE THE ASSEMBLY
SERVO PISTON4HIS IS FOR THE
CENTERING ASSIST SPRING 2EMOVE THE SERVO PISTON AND SLIDER BLOCK & FROM HOUSING
ASSEMBLY &OR THESE UNITS
NOTE THE ORIENTATION OF 2EMOVE THE CRADLE BEARING CAGE AND RACES WITH LOCATING PINS
THE SERVO PISTON IN THE
HOUSING 4HE BEARING RACE LOCATING PINS ARE A LOOSE lT

Disassembling the swashplate

Locating Pin

Servo piston

F20

D10
D95 D85 Bearing race

D80 Bearing cage

C20

D10
D50
D80
D85

C20
D50 E101 106E

34 11019577 s 2EV !" s !PRIL

552 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

PISTON ASSEMBLY 5SING A MM OR MM HEX WRENCH REMOVE THE SCREWS C70 AND SPACERS #
HOLDING THE TWO SLIPPER GUIDE HOLD DOWN BEARINGS # TO THE SWASHPLATE $

$ISCARD SCREWS # 2EPLACE WITH NEW SCREWS WHEN PUMP IS ASSEMBLED

2EMOVE THE HOLD DOWN BEARINGS # AND SPACERS #

2EMOVE THE SLIPPER GUIDE # AND PISTONS # FROM THE SWASHPLATE $

2EMOVE THE PISTON ASSEMBLIES # FROM THE SLIPPER GUIDE #

Removing the piston/slipper assembly

C20

C30

C50
D50

C40

C20

C30

C50
D50

C40

E101 107E

11019577 s 2EV !" s !PRIL 35

008 924 17 BOMAG 553
16.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

SWASHPLATE 2EMOVE GUIDE $ AND FEEDBACK LINK - BY REMOVING SPECIAL LOCKING SCREW $
$ISCARD LOCKING SCREW 3EE TABLE Swashplate components BELOW FOR WRENCH SIZES

2EMOVE SERVO ARM $ FROM SWASHPLATE $ BY REMOVING LOCKING SCREW $
$ISCARD LOCKING SCREW 3EE TABLE Swashplate components BELOW FOR WRENCH SIZES

#LEAN THE THREADED HOLES FOR THE HOLD DOWN SCREWS IN SWASHPLATE $ OF ALL OLD
LOCKING COMPOUND 5SE A - 8 OR - 8 THREAD TAP FOR THIS PROCEDURE

#LEAN THE THREADED HOLES FOR THE LOCKING SCREWS $ $ IN SWASHPLATE $ OF ALL
OLD LOCKING COMPOUND 5SE A THREAD TAP GIVEN IN THE TABLE BELOW FOR THIS PROCEDURE

Swashplate components
Pump size D55 wrench size D55 thread size D65 wrench size D65 thread size
CC AND CC MM HEX - MM INTERNAL HEX -
CC AND CC MM HEX - MM INTERNAL HEX -
CC AND CC MM HEX - MM INTERNAL HEX -
CC AND CC MM HEX - MM INTERNAL HEX -

Removing the swashplate guide and servo arm

M14
M14
D10
D10

D50 D50

E101 191E

36 11019577 s 2EV !" s !PRIL

554 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
Inspection

OVERVIEW #LEAN ALL PARTS IN A SUITABLE SOLVENT 2EPLACE / RINGS GASKETS SHAFT SEAL )NSPECT ALL PARTS
FOR DAMAGE NICKS OR UNUSUAL WEAR PATTERNS 2EPLACE ALL PARTS WITH UNUSUAL OR EXCESSIVE
WEAR OR DISCOLORATION WHICH INDICATES EXCESSIVE HEAT

SHAFT ASSEMBLY Inspection

)NSPECT THE SEAL CARRIER FOR ANY DAMAGE OR NICKS )NSPECT THE SHAFT AND BEARING FOR RUST
WEAR OR CONTAMINATION 3PIN THE BEARING IN YOUR HAND FEELING FOR ROUGHNESS 2EPLACE IF
NECESSARY

Shaft assembly

Shaft

Bearing

Seal Carrier

E101 541E

PISTONS AND SLIPPERS )NSPECT THE PISTONS FOR DAMAGE AND Inspect pistons
DISCOLORATION $ISCOLORED PISTONS MAY
INDICATE EXCESSIVE HEAT DO NOT REUSE
Slipper
)NSPECT THE RUNNING SURFACE OF THE
SLIPPERS 2EPLACE ANY PISTON ASSEMBLIES
WITH SCORED OR ROUNDED SLIPPER EDGES
-EASURE THE SLIPPER FOOT THICKNESS
2EPLACE ANY PISTON ASSEMBLIES WITH P104 109E
WORN SLIPPERS #HECK THE SLIPPER AXIAL
END PLAY 2EPLACE ANY PISTON ASSEMBLIES
WITH EXCESSIVE END PLAY 2EFER TO 2EWORK
3PECIlCATIONS , FOR COMPONENT
REWORK GUIDELINES

11019577 s 2EV !" s !PRIL 37

008 924 17 BOMAG 555
16.1 Travel pump
Series 90 Pumps
Repair Instructions
Inspection

CYLINDER BLOCK %XAMINE THE RUNNING FACE OF THE CYLINDER Inspect cylinder block
BLOCK 4HE SURFACE SHOULD BE SMOOTH AND
FREE OF NICKS AND BURRS 2EMOVE ANY BURRS
%NSURE THAT NO SCRATCHES OR GROOVES EXIST
Cylinder
THESE MAY DRASTICALLY REDUCE OUTPUT block
mOW AND LIFE OF PUMP 2EFER TO 2EWORK
3PECIlCATIONS , FOR COMPONENT A
REWORK GUIDELINES

flat to 0.0026 mm check for burrs

[0.000100 in]
P106 692E

ENDCAP JOURNAL )NSPECT THE ENDCAP VALVE PLATE AND End cap and journal bearing
BEARING SEALING SURFACES FOR NICKS AND SCRATCHES
#HECK SURFACE mATNESS 2EFER TO 2EWORK
3PECIlCATIONS , FOR COMPONENT
REWORK GUIDELINES )F ANY OF THE BASE
W 7ARNING METAL IS VISIBLE THROUGH THE PLASTIC
$O NOT DAMAGE THE VALVE BEARING MATERIAL REPLACE THE END CAP
PLATE SURFACE OF THE END JOURNAL BEARING ' 5SE A SUITABLE
CAP WHEN REMOVING THE PULLER TO REMOVE THE BEARING W0RESS THE
BEARING JOURNAL BEARING INTO THE END CAP '
USING A PRESS PIN -AKE SURE BEARING IS
mUSH TO MM ; INCHES= BELOW
THE VALVE PLATE SURFACE OF THE END CAP
'

2EPLACE ENDCAP )F JOURNAL BEARING SPINS

IN THE ENDCAP
E101 108

VALVEPLATE )NSPECT VALVE PLATE FOR WEAR AND SCRATCHES 3CRATCHES DEEP ENOUGH FOR YOU TO FEEL WITH
YOUR lNGERNAIL OR A PENCIL TIP ARE NOT ACCEPTABLE $O NOT ATTEMPT TO REWORK 3ERIES
VALVE PLATES REPLACE IF DAMAGED

38 11019577 s 2EV !" s !PRIL

556 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
Inspection

MULTI-FUNCTION VALVE Inspection

CARTRIDGES #LEAN AND INSPECT ALL PARTS #ARTRIDGE IS AVAILABLE AS COMPLETE UNIT ONLY
/ RINGS ARE AVAILABLE SEPARATELY

Multi-function valve
P04
P03
P01
P02

P05

P06

P07
P08
P17
P16
P15
P14
P09
P11
P13

P12

E101 531E

Multi-function valve - pre 1988

P14

P19

P12

P06

P21
P15
P14
P11 P22
P09
P1
P13

E101 532E

11019577 s 2EV !" s !PRIL 39

008 924 17 BOMAG 557
16.1 Travel pump
Series 90 Pumps
Repair Instructions
Inspection

CHARGE PRESSURE Inspection

RELIEF VALVE )NSPECT THE POPPET + AND MATING SEAT IN THE ENDCAP FOR DAMAGE OR FOREIGN MATERIAL
7HEN INSPECTING SHIM ADJUSTABLE VALVES DO NOT ALTER THE SHIMS OR INTERCHANGE PARTS

Charge pressure relief valve

,OCK NUt

"ODY

/ RING

3PRING

Seat

% %

CHARGE PUMP Inspection

)NSPECT ALL PARTS FOR WEAR OR DAMAGE AND REPLACE IF NECESSARY #HECK GEROTOR ASSEMBLY
AND VALVE PLATE FOR PITTING FROM CAVITATION

Charge pump
H40

H05

H60
H50
H31
J50
J15

J30

H70
E101 542E
H80

40 11019577 s 2EV !" s !PRIL

558 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
Inspection

INTEGRAL CHARGE Inspection

PRESSURE FILTER )NSPECT THE lLTER HEAD AND LOCK NUT SEALING SURFACES )F YOU lND ANY NICKS OR SCRATCHES
REPLACE DAMAGED COMPONENTS

Integral charge pressure ﬁlter manifold

N25 N20
N15

N36A

N36

N10
N35A
N35
11/16 in
E101 543E

HYDRAULIC AND Inspection

ELECTRIC DISPLACEMENT )NSPECT MACHINED SURFACES ON CONTROL AND PUMP FOR NICKS AND SCRATCHES 2EPLACE CONTROL
CONTROLS IF YOU lND DAMAGE TO MACHINED SURFACES

Hydraulic/Electric displacement controls

% %

11019577 s 2EV !" s !PRIL 41

008 924 17 BOMAG 559
16.1 Travel pump
Series 90 Pumps
Repair Instructions
Inspection

SWASHPLATE )NSPECT RUNNING SURFACE FOR WEAR OR SCRATCHES )NSPECT HOLD DOWN SCREW HOLES FOR
DAMAGE )F SCREW HOLES ARE DAMAGED REPLACE SWASHPLATE )NSPECT FOR WEAR IN LEVELER PAD
AREAS EXCESSIVE WEAR MAY AFFECT PUMP NEUTRAL )F YOU lND DAMAGE REPLACE SWASHPLATE
)NSPECT SWASHPLATE GUIDE $ FOR WEAR 2EPLACE IF NECESSARY 2EFER TO 2EWORK
3PECIlCATIONS , FOR COMPONENT REWORK GUIDELINES

Swashplate and guide inspection

D50

Hold down
screw holes

Running surface

Leveler pad areas E101 548E

42 11019577 s 2EV !" s !PRIL

560 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
Inspection

SERVO PISTON )NSPECT THE SERVO PISTON FOR WEAR 2EMOVE AND DISCARD SEAL RINGS & AND EXPANDER
/ RINGS & 2EPLACE SERVO PISTON IF NECESSARY 2EPLACE / RINGS AND SEAL RINGS BEFORE
REASSEMBLY

Servo piston inspection

Servo piston

E101 112E

CYLINDER BLOCK 6ISUALLY INSPECT THE CYLINDER BLOCK Cylinder block inspection
SPRING AND WASHERS FOR INDICATIONS OF
WEAR OR DAMAGE 2EPLACE IF WEAR CRACKS C16
OR OTHER DAMAGE IS PRESENT

C15

C14

C13

C12

E101-113

11019577 s 2EV !" s !PRIL 43

008 924 17 BOMAG 561
16.1 Travel pump
Series 90 Pumps
Repair Instructions
Inspection

CYLINDER BLOCK #OAT ALL PARTS WITH CLEAN HYDRAULIC Cylinder block assembly
mUID PRIOR TO REASSEMBLY
W 7ARNING C16
2ISK OF PERSONAL INJURY )NSTALL THE INNER BLOCK SPRING WASHER
#OMPRESSING THE BLOCK # BLOCK SPRING # AND OUTER
SPRING REQUIRES TO WASHER # INTO THE CYLINDER C15
. ; TO LBF = 5SE A BLOCK 5SING A PRESS COMPRESS THE
PRESS SUFlCIENT TO MAINTAIN BLOCK SPRING ENOUGH TO EXPOSE THE
THIS FORCE WITH REASONABLE RETAINING RING GROOVE7IND THE SPIRAL
C14
EFFORT %NSURE THE SPRING IS RETAINING RING # INTO THE GROOVE
SECURE BEFORE ATTEMPTING IN THE CYLINDER BLOCK W
TO REMOVE THE SPIRAL
RETAINING RING 2ELEASE THE 2ELEASE PRESSURE ON SPRING6ISUALLY C13
PRESSURE SLOWLY AFTER THE CHECK THAT SPIRAL RETAINING RING IS
RETAINING RING IS REMOVED PROPERLY POSITIONED IN ITS GROOVE

C12

E101-113

SERVO PISTON RINGS )NSTALL NEW EXPANDER / RINGS & INTO THE SEAL GROOVES IN THE SERVO PISTON )NSTALL
THE SEAL RINGS & IN THE GROOVES OVER THE EXPANDER / RINGS & C

C Caution !LLOW THE ASSEMBLY TO SET FOR AT LEAST MINUTES4HIS ALLOWS THE SEAL RINGS & TO
$O NOT STRETCH THE RETURN TO THEIR ORIGINAL UNSTRETCHED SIZE
SEAL RINGS ANY MORE
THAN NECESSARY DURING Servo piston assembly
INSTALLATION

Servo piston

P106 730E

44 11019577 s 2EV !" s !PRIL

562 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

SERVO ARM )NSTALL THE SERVO ARM $

!LIGN PRESS lT DESIGN SERVO ARMS WITH THE SWASHPLATES SLOT AND THREADED HOLES WHILE
INSTALLING 0RESS COMPLETELY INTO THE SWASHPLATE SLOT

)NSTALL NEW LOCKING SCREW $ WITH PRE APPLIED LOCKING COMPOUND INTO SWASHPLATE

4ORQUE LOCKING SCREW $ 3EE TABLE BELOW FOR WRENCH SIZES AND TORQUES

Servo arm speciﬁcations

Pump size Wrench size (for D55) 4ORQUE .sM ;LBFsFT=
CC THROUGH CC MM HEX ;=
CC MM HEX ;=
CC MM HEX ;=
CC CC MM HEX ;=

Servo arm installation

D10 D10

D50 D50

E101 110

11019577 s 2EV !" s !PRIL 45

008 924 17 BOMAG 563
16.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

SWASHPLATE GUIDE !SSEMBLE THE SWASHPLATE GUIDE $ AND FEEDBACK LINK - TO THE SWASHPLATE
)NSTALL NEW LOCKING SCREW $ WITH PRE APPLIED LOCKING COMPOUND USING AN INTERNAL
HEX WRENCH

4ORQUE THE SCREW TO SPECIlCATIONS IN THE TABLE BELOW

7HEN INSTALLING THE GUIDE ONTO THE CC SWASHPLATE HOLD THE STRAIGHT SIDES OF THE
GUIDE PERPENDICULAR TO THE SLIPPER SURFACE OF THE SWASHPLATE $ WHILE TIGHTENING
SCREW
Special locking screw speciﬁcations
Pump size D65 wrench sizes 4ORQUE .sM ;LBFsFT=
CC AND CC MM INTERNAL HEX ;=
CC THROUGH CC MM INTERNAL HEX ;=
CC MM INTERNAL HEX ;=
CC AND CC MM INTERNAL HEX ;=

Attaching swashplate guide

D65

M14

D60

D50
D50

E101 111

Roll pin and ﬂat washer

)NSTALL THE HEADED ROLL PIN $ AND mAT WASHER $ IF REMOVED &OR PROPER DISTANCE
( BETWEEN THE WASHER $ AND THE SIDE OF THE SWASHPLATE FOLLOW THE TABLES Roll pin
speciﬁcations (A) AND (B) BELOW

Roll pin speciﬁcations (A) Pin and washer positions

Pump frame size Distance, H: + 0.1, -0.25 mm
; INCHES=
CC MM ; INCHES= Swashplate
NO WASHER D75

Roll pin speciﬁcations (B)

D70
Pump frame size Distance, H: ± 0.25 mm
;¼ INCHES=
Distance H
CC MM ; INCHES= P104 188E
CC THROUGH CC MM ; INCHES=
CC MM ; INCHES=
CC AND CC ;=
;=
0IN AT SIDE COVER POSITION
0IN AT CONTROL POSITION

46 11019577 s 2EV !" s !PRIL

564 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

PISTON ASSEMBLY Piston assembly

!SSEMBLE THE PISTON ASSEMBLIES # INTO THE SLIPPER GUIDE #

C Caution ,UBRICATE THE SLIPPER AND SWASHPLATE RUNNING SURFACES

-OST PARTS HAVE CRITICAL
HIGH TOLERANCE SURFACES #ENTER THE PISTONS # AND GUIDE # ON THE SWASHPLATE
4AKE CARE NOT TO DAMAGE
THESE SURFACES DURING
ASSEMBLY 0ROTECT EXPOSED Piston assembly
SURFACES OPENINGS AND
PORTS FROM DAMAGE AND
FOREIGN MATERIAL

D10

C20

D50

C20

D50

E101 114

11019577 s 2EV !" s !PRIL 47

008 924 17 BOMAG 565
16.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

PISTON ASSEMBLY Fixed-clearance hold-down bearing

(continued)
3OME EARLY PRODUCTION PUMPS USE A SPRING LOADED HOLD DOWN MECHANISM 3ERVICE PARTS
FOR THE SPRING LOADED HOLD DOWN MECHANISM ARE NO LONGER AVAILABLE4HE lXED CLEARANCE
HOLD DOWN BEARING MUST BE INSTALLED IF HOLD DOWN PARTS REQUIRE REPLACEMENT ON THESE
EARLY PUMPS 2EFER TO THE APPROPRIATE Service Parts Manual FOR MORE INFORMATION

!SSEMBLE ONE HALF OF THE lXED CLEARANCE SLIPPER GUIDE HOLD DOWN BEARINGS #

0OSITION SPACERS # OVER THE THREADED HOLES IN THE SWASHPLATE $

C Caution )NSTALL ONE SLIPPER GUIDE HOLD DOWN BEARING # AND SPACERS # C
0OSITION THE SPLIT BETWEEN
THE # SLIPPER GUIDE )NSTALL NEW SCREWS C70 THROUGH THE SLIPPER GUIDE HOLD DOWN BEARING # AND
BEARING PLATES IN LINE WITH SPACERS # C
THE $ SWASHPLATE ARM
,OCATE THE BEARING SURFACE C Caution
OF THE # BEARING PLATES !LWAYS USE NEW SCREWS WITH PROPER LOCKING COMPOUND
NEXT TO THE # SLIPPER
GUIDE 3TART THE SCREWS C70 INTO THE SWASHPLATE $ DO NOT TORQUE

0OSITION SLIPPER GUIDE WITH PISTONS UNDER lRST HOLD DOWN BEARING

!SSEMBLE SECOND SLIPPER GUIDE HOLD DOWN BEARING WITH SCREWS AND SPACERS ONTO THE
SWASHPLATE 3TART THE SCREWS DO NOT TORQUE

,UBRICATE SLIPPER GUIDE AND HOLD DOWN BEARINGS

Hold-down bearing installation

D50

D10

C30

C20

C40

C50

E101 115

48 11019577 s 2EV !" s !PRIL

566 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

PISTON ASSEMBLY Alternate hold-down bearing installation

(continued) D50

D10

C30

C20

C40

D50

C50

P106 542E

4ORQUE THE SLIPPER GUIDE HOLD DOWN Torque settings

SCREWS C70 TO THE SPECIlCATIONS IN Pump size 4ORQUE .sM ;LBFsFT=
Torque settings CC THROUGH CC ;=
CC THROUGH CC ;=

%NSURE THE SLIPPER GUIDE # AND PISTON SLIPPERS # SLIDE FREELY ON THE SWASHPLATE
AFTER ALL BOLTS ARE TORQUED

11019577 s 2EV !" s !PRIL 49

008 924 17 BOMAG 567
16.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

BEARING CAGE .EW PARTS HAVE LOCKING PIN " INTEGRAL TO BEARING RACE &OR OLDER PUMPS LOCKING PINS
ARE SEPARATE FROM RACES4HE LOCATING PINS ASSURE PROPER ASSEMBLY
2ETAIN THE RACES IN POSITION WITH PETROLEUM JELLY

)NSTALL THE BEARING RACES INTO THE HOUSING POSITIONING THE RACES ON THE LOCATING PINS
"

!SSEMBLE AND LUBRICATE THE BEARING CAGE

)NSTALL THE BEARING CAGE ON THE BEARING RACES

Bearing assembly

Bearing race

New parts have locking pin (B20) integral

to bearing race. For older pumps, locking
pins are separate from races. B20
B20

P106 513E

50 11019577 s 2EV !" s !PRIL

568 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

HOUSING 2EFER TO THE ILLUSTRATION Housing installations, NEXT PAGE FOR THE NEXT STEPS

0OSITION THE SERVO PISTON & IN THE HOUSING

&OR UNITS WITH AN ,UBRICATE AND INSTALL THE BRONZE SLIDER BLOCK & ONTO THE SERVO PISTON
AUTOMOTIVE CONTROL
THE SERVO PISTON HAS A #AREFULLY LOWER THE SWASHPLATE ASSEMBLY INTO THE HOUSING THROUGH THE END CAP
THREADED HOLE ON ITS OPENING 0ROTECT THE PISTONS FROM BEING SCRATCHED
MACHINED END 0UT THIS END
ON THE SIDE OF THE HOUSING (OLD THE SWASHPLATE ASSEMBLY APPROXIMATELY MM ;³ INCH= ABOVE THE CRADLE
WHERE THE CENTERING ASSIST BEARINGS
SPRING SLEEVE IS LOCATED
0OSITION THE FEEDBACK LINK $ IN THE CONTROL OPENING

,OWER THE SWASHPLATE ASSEMBLY ONTO THE CRADLE BEARINGS

C Caution 0OSITION THE SERVO PISTON ON THE SLIDER BLOCK & 4HE PARTS SHOULD SLIDE FREELY
"E SURE TO ASSEMBLE THE
CORRECT SERVO CYLINDER ON ,UBRICATE INSIDE THE SERVO CYLINDERS (OLD THE SERVO PISTON IN PLACE AND INSTALL THE
EACH SIDE OF THE HOUSING SERVO CYLINDERS C

&OR UNITS WITH AN AUTOMOTIVE CONTROL THERE IS A SPECIAL SERVO CYLINDER ON THE CENTERING
ASSIST SPRING SIDE OF THE HOUSING

)F PREVIOUSLY REMOVED INSTALL NEW SCREENS " 5SE PROPER INSTALLATION TOOL

11019577 s 2EV !" s !PRIL 51

008 924 17 BOMAG 569
16.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

HOUSING (continued) Servo cylinder screws

)NSTALL THE SERVO CYLINDERS & COMPLETELY INTO THE HOUSING BORES

C Caution .UMBER OF SCREWS AND WRENCH SIZES VARY BY MODEL

)F THE SERVO CYLINDERS ARE
NOT SEATED COMPLETELY INTO )NSTALL THE OR SCREWS && Servo cylinder screw torques
THE BORES TIGHTENING OF IN EACH SERVO CYLINDER C Pump size F111/F211
THE SCREWS CAN DAMAGE THE .sM ;LBFsFT=
/ RINGS 4ORQUE TO SPECIlCATIONS IN Servo CC ;=
cylinder screw torques CC ;=
CC ;=
&OR UNITS WITH AN AUTOMOTIVE CONTROL CC ;=
INSTALL THE SERVO CYLINDER SCREWS ON TO THE CC ;=
HOUSINGS CENTERING ASSIST SPRING SIDE CC ;=
CC AND CC ;=
)F PREVIOUSLY REMOVED REPLACE
SCREENS " WITH NEW SCREENS

Housing installations

F20

F10

F111

Swashplate assembly F112

D14

F111 F113

F213 B60
O

F212
F211

F211 E101 118E

52 11019577 s 2EV !" s !PRIL

570 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

HOUSING (continued) Displacement limiter.

)NSTALL DISPLACMENT LIMITERS & & INTO SERVO CYLINDERS TO LOCATION MARKED
DURRING DISASSEMBLY7RENCH SIZES ARE SHOWN IN TABLE BELOW

)NSTALL NEW SEAL LOCK NUTS & & ONTO DISPLACEMENT LIMITERS4ORQUE SEAL
LOCK NUTS WHILE HOLDING DISPLACEMENT LIMITER7RENCH SIZES AND TORQUE VALUES ARE
SHOWN IN TABLE BELOW 2EFER TO THE Series 90 Pumps Service Manual 520L0818 FOR
DISPLACEMENT LIMITER ADJUSTMENT INFORMATION

Displacment limiter and seal lock nut wrench sizes and torques
Pump size F113 F213 F112/F212 F112/F212
wrench size wrench 4ORQUE .sM ;LBFsFT=
CC CC MM MM ;=
CC MM MM ;=
CC AND CC MM MM ;=

Housing installations

F20

Servo piston

F111

Swashplate assembly F112

D14

F113
F111

F213
B60
O

F211
F212

F211
E101 118E

11019577 s 2EV !" s !PRIL 53

008 924 17 BOMAG 571
16.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

BEARING CAGE LOCATOR !LIGN THE SWASHPLATES BEARING CAGE SLOT WITH THE HEADED SPRING PIN !LIGN WITH THE
LINK HOUSINGS PIN HOLE 3EE ILLUSTRATION Locator link position FOR CORRECT ORIENTATION

(OOK THE CAGE LOCATOR LINK $ OVER THE SPRING PIN BETWEEN THE WASHER AND THE
SWASHPLATE

2OTATE THE LINK $ INTO THE BEARING CAGE SLOT

FRAME SIZE PUMPS DO NOT HAVE A WASHER ON THE SPRING PIN

!LIGN THE LOCATOR LINK $ HOLE WITH THE HOUSING HOLE

)NSTALL THE LINK PIN $ THROUGH THE LOCATOR LINK $ AND INTO THE HOUSING

AND PUMPS USE A mAT HEAD SCREW AS THE LINK PIN 3TEPS AND REFER TO THESE
C Caution PUMPS
!LWAYS USE A NEW SCREW
WITH PROPER LOCKING )NSTALL A NEW SCREW WITH LOCKING COMPOUND THROUGH THE LOCATOR LINK $ AND INTO
COMPOUND THE HOUSING C

C Caution 4IGHTEN THE SCREW INTO THE HOUSING $O THIS UNTIL THE HEAD OF THE SCREW IS AT A HEIGHT OF
$O ./4 TORQUE THIS SCREW TO MM ; TO INCHES= FROM THE PUMP HOUSINGS MACHINED SURFACE C
AGAINST THE $ LOCATOR
LINK4HE LINK MUST ROTATE Locator link position
FREELY Finished Assembly

Housing pin hole

D80
D85

Bearing cage slot

Headed spring
pin washer

E101 120E

54 11019577 s 2EV !" s !PRIL

572 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

VERIFY PROPER 0USH THE SWASHPLATE ASSEMBLY TOWARD THE CONTROL SIDE OF THE HOUSING UNTIL THE
ASSEMBLY SWASHPLATE GUIDE CONTACTS THE BEARING RACE

#HECK FOR CLEARANCE BETWEEN THE SERVO ARM AND THE SLIDER BLOCK

%NSURE SWASHPLATE ASSEMBLY MOVES FREELY ON BEARINGS

2OTATE SWASHPLATE ON BEARINGS TO CHECK FOR CONTROL LINK MOVEMENT AND PROPER
LOCATOR LINK POSITION

SWASHPLATE LEVELER 0LACE INSERTS % ONTO SIDE COVER Attach leveler to side cover
%
E30

0OSITION THE SWASHPLATE LEVELER %

ON THE SIDE COVER INSERTS %

.OTE THE ORIENTATION OF THE LEVELER

% AND THE SIDE COVER %

)NSTALL THE GUIDE POSTS %

E22
AND SEALING NUTS % 3EE Guide
post/sealing nut installation TABLE
FOR WRENCH SIZES AND TORQUE
SPECIlCATIONS E90

)NSTALL THE LEVELER SPRING SEATS % IF

NECESSARY

3OME PUMPS DO NOT HAVE REMOVABLE

SWASHPLATE LEVELER SPRING SEATS %

E40
E101 121

Guide post/sealing nut installation

Pump size Wrench sizes 4ORQUE .sM ;LBFsFT=
CC AND CC MM OPEN END ;=
MM HEX
CC THROUGH CC
INCH OPEN END ;=
MM HEX
CC THROUGH CC MM OPEN END ;=
MM HEX

11019577 s 2EV !" s !PRIL 55

008 924 17 BOMAG 573
16.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

INSTALLING LEVELER ,UBRICATE AND INSTALL A NEW SIDE COVER / RING %
AND SIDE COVER
)NSTALL THE SIDE COVER ASSEMBLY C

C Caution )NSTALL SIDE COVER SCREWS % WITHOUT LOCKING COMPOUND AT OCLOCK AND
3LIDE SWASHPLATE LEVELER OCLOCK LOCATIONS4IGHTEN ONLY TO HALF TORQUE
% TOWARD THE CASE DRAIN
PORT4HIS ALLOWS THE LEVELER 4HIS HOLDS THE % COVER WHILE CHECKING THE ZERO ANGLE POSITION OF THE SWASHPLATE
% TO CLEAR THE SIDE OF
THE SWASHPLATE DURING SIDE Setting leveler - neutral position
COVER INSTALLATION )F REUSING ORIGINAL PARTS ROTATE THE SIDE COVER % TO ALIGN THE MARKS ON THE COVER
AND HOUSING ADDED DURING DISASSEMBLY )F USING NEW SWASHPLATE LEVELER PARTS
ALIGNMENT MARKS MAY NOT BE ACCURATE

!PPLY A FORCE OF TO . ; TO LBF = TO THE SWASHPLATE LEVELER % 4HIS ENSURES

BOTH ARMS ARE IN CONTACT WITH THE SWASHPLATE #LAMP A mAT PLAT ONTO THE PUMP
HOUSING AS SHOWN IN Leveling swashplate DRAWING BELOW

%NSURE THE SWASHPLATE IS ON ITS BEARINGS

-EASURE WITH A DEPTH MICROMETER TO lND THE DISTANCE FROM THE END CAP FACE OF THE
HOUSING TO THE OUTER EDGE OF THE SWASHPLATE SURFACE
W 7ARNING
4HESE MEASUREMENTS MUST 4AKE A SECOND MEASUREMENT AT A POINT ² FROM THE lRST POINT OF MEASUREMENT AT
NOT VARY BY MORE THAN THE OPPOSITE EDGE OF SWASHPLATE SURFACE W
MM ; INCHES=

Side cover and O-ring installations

Slide towards this end
Blind housing screw when installing
torques and Through
8 AND 9 ARE MEASUREMENTS housing screw torques
Case drain
FROM THE TOP OF THE port
SWASHPLATE TO THE END OF
THE HOUSING $IFFERENCE
BETWEEN 8 AND 9 MUST BE E20
LESS THAN
MM ; IN=

Leveling swashplate E10

22-44 N [5-10 lb]

Y X
B10

E101 122E
P106 516E

56 11019577 s 2EV !" s !PRIL

574 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

INSTALLING LEVELER Positioning the side cover

AND SIDE COVER 2OTATE THE SIDE COVER % WHICH WILL ALSO ROTATE THE LEVELER AND SWASHPLATE UNTIL
(continued) THE MEASURED DEPTH ON EACH SIDE OF THE SWASHPLATE IS WITHIN MM ; IN=

)NSTALL THE REMAINING SCREWS % WITH PRE APPLIED LOCKING COMPOUND
W 7ARNING
4HESE MEASUREMENTS MUST 4ORQUE THESE SCREWS TO THE SPECIlCATIONS IN Blind housing screw torques AND Through
NOT VARY BY MORE THAN housing screw torques.
MM ; INCHES=
2EPLACE THE SCREWS % USED INITIALLY TO HOLD THE SIDE COVER ON WHILE SETTING
NEUTRAL WITH NEW SCREWS THAT HAVE LOCKING COMPOUND

4ORQUE THESE SCREWS TO THE SPECIlCATIONS IN Blind housing screw torques.

Through housing screw torques Blind housing screw torques

Pump size 4ORQUE .sM ;LBFsFT= Pump size 4ORQUE .sM ;LBFsFT=
CC AND CC ;= CC AND CC ;=
CC THROUGH CC ;= CC THROUGH CC ;=
CC THROUGH CC ;= CC THROUGH CC ;=

CYLINDER BLOCK 0OSITION PISTONS USING A TWISTING Installing cylinder block

INSTALLATION MOTION SO THAT THEY ALL LEAN IN A
Turn cylinder block
CLOCKWISE DIRECTION counterclockwise when
placing on pistons.
3ET CYLINDER BLOCK # ONTO PISTONS O
SO EACH BLOCK BORE SITS ON TOP OF A
PISTON
C12
0REVENT THE PISTONSSLIPPERS FROM
TURNING BY CAREFULLY PLACING a
SCREWDRIVER BETWEEN THE SLIPPER
RETAINER AND SWASHPLATE $O NOT
SCRATCH SWASHPLATE OR SLIPPERS
Lean pistons clockwise.
4URN THE CYLINDER BLOCK
COUNTERCLOCKWISE

4HIS MAKES THE PISTONS STAND UP STRAIGHT O

AND lT INTO THE BLOCK BORES

,OWER THE BLOCK ONTO THE PISTONS

2ELUBRICATE PISTON BORES AND CYLINDER

BLOCK

E101 130E

11019577 s 2EV !" s !PRIL 57

008 924 17 BOMAG 575
16.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

END CAP INSTALLATION Preparing for end cap installation Installing the valve plate
)NSTALL THE END CAP ALIGNMENT PINS
" INTO THE HOUSING

,UBRICATE THE RUNNING SURFACE OF THE B50

CYLINDER BLOCK
B50

)NSTALL THE VALVE PLATE # ON THE

ALIGNMENT PINS

.OTE THE DIRECTION OF THE ARROW CUT

OUTS IN THE VALVE PLATE

7HEN VIEWING FROM THE END CAP SIDE E101 123E

OF VALVE PLATE THE ARROWS MUST POINT IN

THE OPPOSITE DIRECTION OF PUMP ROTATION Installing the springs
&OR EXAMPLE A RIGHT HAND CLOCKWISE
ROTATION PUMP MUST HAVE THE ARROWS
POINTING IN THE COUNTERCLOCKWISE
DIRECTION E80
D95
)NSTALL THE LONG SPRINGS %
WITH INNER SPRINGS IF USED ON THE
SWASHPLATE LEVELER SPRING SEATS

)F USED INSTALL THE SHORT SPRING $

ON THE SERVO ARM BRACKET

3OME MODELS ARE BUILT WITH AN ALTERNATE

SERVO ARM WHICH DOES NOT REQUIRE SPRING
$
E101 124

0LACE NEW END CAP GASKET ' Installing the gasket

C Caution ON THE HOUSING IN THE ORIENTATION
$O NOT BEND OR DAMAGE SHOWN LOCATED BY THE ALIGNMENT
THE END CAP GASKET DURING PINS C
INSTALLATION
G30 C

E101 125E

58 11019577 s 2EV !" s !PRIL

576 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

END CAP INSTALLATION End cap parts Installations into end cap
(continued) ,UBRICATE THE END CAP JOURNAL
BEARING ' 0RESS BEARING INTO
HOUSING IF NECESSARY

)NSTALL THE HARDENED SHIMS %

IN THE END CAP POCKETS FOR THE
SWASHPLATE LEVELER SPRINGS

2ETAIN THE SHIMS USING PETROLEUM JELLY End cap

4HE SHIM POCKETS ARE DIFFERENT DEPTH IN

ENDCAP

E24
E101 126E

End cap installation Fastening end cap to housing

,OWER THE END CAP ONTO HOUSING
WHILE POSITIONING THE SPRINGS IN THEIR
END CAP POCKETS
G95
)NSTALL THE LARGE END CAP SCREWS G94
* G93
7HEN PROPERLY INSTALLED
THE END CAP ENGAGES 4IGHTEN THE LARGE END CAP SCREWS
THE ALIGNMENT PINS4HE * EVENLY 3EE Large end cap screw
SPRINGS HOLD THE END CAP torques
TO MM ; TO INCH=
AWAY FROM THE HOUSING .UMBER OF SCREWS AND WRENCH SIZE VARIES
BY MODEL
E101 127E
)NSTALL THE OR SMALLER SCREWS
'' HOLDING THE END CAP TO Torque 6 mm internal hex
THE HOUSING #"'#$)t]
Torque 8 mm internal hex
#"'#$ )t]
4HERE IS A LIFTING BRACKET ' SPACER
' AND WASHER ' ON THE END CAP See Large endcap screw
SCREW ' torques for appropriate J80
torque values.

4ORQUE THE MM INTERNAL HEX SCREWS

' ' TO .sM ; LBFsFT= Large end cap screw torques
Pump size 4ORQUE .sM ;LBFsFT=
4ORQUE THE MM INTERNAL HEX SCREWS CC ;=
' ' TO .sM ; LBFsFT= CC ;=
CC ;=
CC ;=
CC ;=
CC ;=
CC AND CC ;=

11019577 s 2EV !" s !PRIL 59

008 924 17 BOMAG 577
16.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

SPEED SENSOR Assembly

)NSTALL A NEW / RING "! ONTO THE SENSOR "

5SING AN WRENCH INSTALL THE SPEED SENSOR WITH LOCK NUT AND / RING INTO
THE HOUSING !DJUST THE GAP BETWEEN THE SENSOR AND THE MAGNETIC SPEED RING AS
INSTRUCTED IN Speed sensor adjustment in Series 90 Pumps Service Manual 520L0818
!FTER ADJUSTMENT TORQUE THE SENSOR LOCK NUT TO .sM ; LBFsFT=

)F A SPEED SENSOR IS NOT INSTALLED USE A IN INTERNAL HEX WRENCH TO TORQUE THE
HOUSING PLUG " TO .sM ; LBFsFT=

Speed sensor
B83 O-ring plug

ft]
B83A

B83 B83A

E101 095E

60 11019577 s 2EV !" s !PRIL

578 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

MULTI-FUNCTION VALVE Multi-function valve - pre 1988

CARTRIDGES - PRE 1988
P14

P19

P12

P06

P21
P15
P14
P11 P22
P09
P1
P13

E101 532E

Assembly
,UBRICATE AND INSTALL INTERNAL COMPONENTS 0 0 0 0 0 AND 0

)NSTALL POPPET SEAT 0

)NSTALL RETAINING RING 0

,UBRICATE AND INSTALL / RING 0

)F PREVIOUSLY REMOVED REASSEMBLE AND INSTALL BYPASS ACTUATOR 0 4ORQUE TO

.sM ; LBFsFT=

,UBRICATE AND INSTALL NEW / RINGS 0 0

CCaution
)F PRESSURE LIMITER WAS REMOVED FROM BYPASS ACTUATOR 0 ADJUST PRESSURE LIMITER TO
MODEL CODE SPECIlCATIONS

)NSTALL CARTRIDGES AND TORQUE AS SHOWN IN THE TABLE BELOW C

Multi-function valve wrench size Multi-function valve torque

Frame size Wrench size Frame size Torque
n INCH n .sM ; LBFsFT=
n INCH n .sM ; LBFsFT=

11019577 s 2EV !" s !PRIL 61

008 924 17 BOMAG 579
16.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

PRESSURE OVERRIDE Assembly Pressure override valve components

VALVE (OPTION FOR 180 )NSTALL NEW / RINGS
FRAME SIZE)
Screws
)NSTALL THE VALVE ONTO THE PUMP END
CAP AND TORQUE THE SCREWS TO .sM Pressure override
; LBFsFT= valve

O-rings

E101 079E

CHARGE PRESSURE Assembly Lock nut wrench size

RELIEF VALVE )NSTALL THE POPPET + AND SPRING Frame size Wrench size
+ n INCH
n INCH
&OR SHIM ADJUSTABLE VALVES INSTALL
THE SHIMS AND PLUG TORQUE TO
.sM ; LBFsFT= &OR SCREW ADJUSTABLE Charge pressure relief valve
VALVES INSTALL THE PLUG WITH ITS LOCK
NUT ALIGNING THE MARKS MADE AT
+
DISASSEMBLY AND TORQUE THE LOCK NUT h ,OCK NUT
TO .sM ; LBFsFT= t ,OCK NUT TORQUE

#HECK THE CHARGE PRESSURE AND +

ADJUST IF NECESSARY h IN

d+ +

3EE APPROPRIATE TABLE

62 11019577 s 2EV !" s !PRIL

580 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

CHARGE PUMP Current charge pump conﬁguration

H40

H05

H60
H50
H31
J50
J15

J30

H70
E101 082E
H80

Retainer screw wrench size

Frame size Wrench size
n MM
n MM

Assembly
"E SURE TO INSTALL THE CHARGE PUMP IN THE PROPER ORIENTATION )F UNSURE OF CHARGE PUMP
ROTATION REFER TO THE MODEL CODE

4HE ORIENTATION OF THE GEROTOR ASSEMBLY OUTER ECCENTRIC RING AND THE LOCATION OF THE
ALIGNMENT PIN IN THE END CAP DETERMINE THE CHARGE PUMP ROTATION $O NOT MIX CHARGE
PUMP PARTS FROM DIFFERENT PRODUCTION PERIODS !LWAYS INSTALL AS A COMPLETE ASSEMBLY

)NSTALL THE VALVE PLATE ( AND THE GEROTOR ASSEMBLY OUTER RING

)NSTALL THE ALIGNMENT PIN ( TO PROPERLY ORIENT THE VALVE PLATE AND OUTER ECCENTRIC
RING FOR CORRESPONDING PUMP ROTATION

0RIOR TO INSTALLATION LUBRICATE THE )$ /$ AND SIDE FACES OF THE GEROTOR ASSEMBLY

)NSTALL THE GEROTOR ASSEMBLY (

)NSTALL THE OUTER PLATE EARLY PRODUCTION AND INTERMEDIATE PRODUCTION PUMPS ONLY
NOT SHOWN

11019577 s 2EV !" s !PRIL 63

008 924 17 BOMAG 581
16.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

)NSTALL THE CHARGE PUMP COUPLING4HE INTERNALLY SPLINED END OF THE COUPLING MUST
ENGAGE THE MAIN PUMP SHAFT &OR PUMPS WITH AN AUXILIARY MOUNTING PAD INSTALL THE
AUXILIARY DRIVE COUPLING INSTEAD

4HE OUTSIDE DIAMETER OF THE INTERNALLY SPLINED END OF SOME EARLY PRODUCTION CHARGE
PUMP COUPLINGS WAS CHAMFERED %ARLY PRODUCTION END CAPS MAY NOT BE MACHINED TO
ACCEPT A NON CHAMFERED COUPLING !LWAYS USE A CHAMFERED CHARGE PUMP COUPLING IN
PUMPS WITH THE EARLY ENDCAP

&OR PUMPS WITH NO AUXILIARY PAD INSTALL A NEW / RING * ONTO CHARGE PUMP COVER
)F AN AUXILIARY PAD IS INSTALLED AN / RING IS NOT USED ON THE COVER

CCaution
)N ORDER TO AVOID LOSS OF CHARGE PRESSURE IN PUMPS WITH AN AUXILIARY MOUNTING PAD
ALWAYS INSTALL THE CHARGE PUMP COVER SO THE PAD DRAIN HOLE IS LOCATED ON THE SAME SIDE OF
THE END CAP AS THE CHARGE INLET PORT

)NSTALL THE CHARGE PUMP COVER Retainer screw torque

RETAINER ( AND THE SIX INTERNAL Frame size Torque
HEX SCREWS ( 4ORQUE THE SCREWS n .sM ; LBFsFT=
PER THE TABLE AT THE RIGHT n .sM ; LBFsFT=

&OR PUMPS WITH AUXILIARY MOUNTING PADS INSTALL THE / RING AND AUXILIARY MOUNTING
PAD ADAPTOR ONTO THE END CAP

64 11019577 s 2EV !" s !PRIL

582 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

AUXILIARY PAD Auxiliary pad components (typical)

J50
J80
Endcap screw J70

J60
See table for wrench size and torque
E101 084E

Assembly
,UBRICATE AND INSTALL / RING * ON END CAP PILOT

)NSTALL THE AUXILIARY MOUNTING PAD * ON REAR OF ENDCAP

4ORQUE AUX PAD SCREWS IN A )NSTALL FOUR LARGE SCREWS * AND NEW WASHERS * THROUGH THE MOUNTING PAD AND
CRISS CROSS PATTERN END CAP INTO THE HOUSING4ORQUE PER THE ACCOMPANYING TABLE

Aux. pad screw wrench size Aux pad screw torque

Frame size Wrench sizes Frame size Torque
n EARLY MM INTERNAL HEX .sM ; LBFsFT=
LATE MM INTERNAL HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
n MM HEX n .sM ; LBFsFT=
n MM INTERNAL HEX n .sM ; LBFsFT=
n MM INTERNAL HEX

DISPLACEMENT )F THE PUMP IS EQUIPPED WITH CONTROL Filter screen installation

CONTROL FILTER lLTER SCREENS IN THE PUMP HOUSING LATE B90
SCREENS PRODUCTION PRESS THEM INTO POSITION
WITH THE ROUNDED EDGE OF THE lLTER P106 690E

SCREENS FACING THE CONTROL UNTIL THEY ARE

mUSH TO MM ; INCH= BELOW THE
SURFACE OF THE HOUSING

11019577 s 2EV !" s !PRIL 65

008 924 17 BOMAG 583
16.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

INTEGRAL CHARGE Assembly

PRESSURE FILTER )NSTALL THE HYDRAULIC TUBE . INTO ITS BORE IN THE ENDCAP )NSTALL THE lLTER HEAD .
REPLACEMENT INTO THE PORT USING A NEW / RING . 4HE HYDRAULIC TUBE SHOULD GO IN WITH LOW FORCE

!FTER ROTATING THE lLTER HEAD CLOCKWISE SO THAT THE THREADS ENGAGE WITH THE THREADS
CCaution IN THE ENDCAP CONTINUE TO ROTATE IT CLOCKWISE BETWEEN AND REVOLUTIONS 0OSITION
&AILURE TO INSTALL THE lLTER HEAD AS DESIRED C
MANIFOLD OR lLTER HEAD
TO A SUFlCIENT DEPTH IN 7HILE HOLDING THE lLTER HEAD IN THE DESIRED POSITION TIGHTEN THE SWIVEL LOCK NUT
THE END CAP WILL RESULT IN . AND TORQUE AS SHOWN IN TABLE
INSUFlCIENT ENGAGEMENT
OF THE TUBE IN THE END )NSTALL A NEW lLTER CANISTER . PER THE INSTRUCTIONS ON THE lLTER CANISTER
CAP BORE4HIS MAY ALLOW
UNlLTERED OIL TO BYPASS THE
lLTER AND ENTER THE CHARGE Integral charge pressure ﬁlter
SYSTEM

N25 N20
N15 Filter manifold lock nut

N36A

N36
11/16 in

N40

N10
N35A
N35
11/16 in
P106 182E

Lock nut wrench size and torque

Frame size Wrench size Torque
n INCH .sM ; LBFsFT=
n INCH .sM ; LBFsFT=
n INCH .sM ; LBFsFT=

66 11019577 s 2EV !" s !PRIL

584 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

PUMP CONTROL COVER Assembly

PLATE )NSTALL A NEW GASKET ON THE HOUSING )NSTALL THE COVER PLATE

)NSTALL SCREWS - USING A MM INTERNAL HEX WRENCH4ORQUE THE SCREWS TO .sM
; LBFsFT=

)NSTALL A SEALING WASHER UNDER THE HEAD OF ANY MOUNTING SCREWS THAT ARE INSTALLED INTO
THROUGH HOLES IN THE HOUSING

Pump controls cover plate M90 X

MM
t .sM ; LBFsFT=

-
3EAL WASHER
LOCATION CC

-
d

0 %

DISPLACEMENT )NSTALL NEW / RINGS USING PETROLEUM Displacement control adapter plate (early
CONTROL ADAPTER JELLY TO RETAIN THEM production 130 cm³ pumps only)
PLATE (EARLY Adapter plate
PRODUCTION 130 )NSTALL ADAPTER PLATE screws
PUMPS ONLY)
)NSTALL SCREWS USING A MM INTERNAL 6 mm
HEX WRENCH4ORQUE TO .sM
; LBFsFT= t]
O-rings
Adapter plate

Seal

E101 087E

11019577 s 2EV !" s !PRIL 67

008 924 17 BOMAG 585
16.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

HYDRAULIC AND Assembly

ELECTRIC DISPLACEMENT )NSTALL A NEW GASKET - 6ERIFY THE CONTROL ORIlCE CHECK VALVE AND SPRING 4 ARE IN
CONTROLS THEIR PROPER POSITION IN THE CONTROL

0OSITION THE CONTROL - ON THE HOUSING )NSERT THE CONTROL LINKAGE PIN INTO THE
SWASHPLATE LINK

Hydraulic/Electric displacement control

- X
I MM

-
d

4
4

0 %

68 11019577 s 2EV !" s !PRIL

586 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

MANUAL DISPLACEMENT Assembly

CONTROL (MDC) )NSTALL A NEW GASKET - )NSPECT CONTROL TO ASSURE THAT THE CONTROL ORIlCE CHECK
VALVE AND SPRING ARE IN THEIR PROPER POSITION IN THE CONTROL

)NSTALL THE CONTROL %NGAGE THE PIN ON THE CONTROL LINKAGE INTO THE MATING HOLE IN THE
LINK ATTACHED TO THE SWASHPLATE

)F REMOVED INSTALL THE CONTROL HANDLE - AND LOCKING NUT - WITH WASHER -
(OLD THE POSITION OF THE HANDLE AND TORQUE THE LOCKING NUT TO .sM ; LBFsFT=
USING AN MM HEX WRENCH

MDC installation -

3 - h MM
h IN M70

- X
I MM

-
3EAL WASHER d
LOCATION CC
4

4 4

0 %

!LIGN THE CONTROL GASKET AND INSTALL THE SCREWS4ORQUE THE SCREWS TO .sM
; LBFsFT=
W 7ARNING
2ISK OF IMPROPER MACHINE )NSTALL A SEALING WASHER UNDER THE HEAD OF MOUNTING SCREWS IN THE LOCATION SHOWN
START UP )F EQUIPPED WITH
.EUTRAL 3TART 3WITCH .33 )F THE CONTROL IS EQUIPPED WITH A NEUTRAL START SWITCH REFER TO MDC Neutral start switch
PERFORM .33 ADJUSTMENT adjustment INSTRUCTIONS IN THE Series 90 Pumps Service Manual 520L0818
PROCEDURE IN SERVICE

11019577 s 2EV !" s !PRIL 69

008 924 17 BOMAG 587
16.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

SOLENOID OVERRIDE Solenoid override valve installationSeal washer

VALVE FOR MDC location
(42, 180, 250 cc)

M77
M76A
M76C
M76B
M76

M78 (x2)
5 mm
M75
P106 186E

Assembly
)NSTALL A NEW GASKET - ON THE CONTROL HOUSING )NSTALL THE MANIFOLD - ONTO
THE CONTROL HOUSING ALIGN THE GASKET AND INSTALL THE SCREWS - 4ORQUE THE SCREWS
TO .sM ; LBFsFT=

5SING A MM WRENCH TORQUE VALVE - TO .sM ; LBFsFT= )F SOLENOID WAS
REMOVED TORQUE SOLENOID NUT TO .sM ; LBFsFT= $O NOT OVERTORQUE THE SOLENOID
NUT

70 11019577 s 2EV !" s !PRIL

588 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

SOLENOID OVERRIDE Assembly

VALVE FOR MDC WITH 5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS - - - ON THE
PRESSURE RELEASED ADAPTER PLATE 0LACE THE ADAPTER PLATE INTO POSITION AND USING A MM INTERNAL HEX
BRAKE INSTALL THE SCREWS - 4ORQUE THE SCREWS TO .sM ; LBFsFT=

5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS ONTO THE SOLENOID VALVE
ASSEMBLY - AND INSTALL THE SOLENOID VALVE ONTO THE ADAPTER PLATE 5SING A MM
INTERNAL HEX INSTALL THE SCREWS - AND TORQUE TO .sM ; LBFsFT=

Solenoid override valve installation

M98 (x4)
4 mm
M9

M95
M96
M97 M92 (x4)
4 mm

P106 192E

11019577 s 2EV !" s !PRIL 71

008 924 17 BOMAG 589
16.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

PRESSURE CONTROL Assembly

PILOT (PCP) FOR 5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS - AND - IN 0#0
ELECTRIC DISPLACEMENT (OUSING
CONTROL (EDC)
0LACE 0#0 AGAINST %$# HOUSING AND USING A MM INTERNAL HEX INSTALL THE SCREWS
- 4ORQUE TO .sM ; LBFsFT=

$O NOT REMOVE BLACK PLASTIC COVER FROM THE ALUMINUM PLATE4HIS IS NOT A SERVICEABLE ITEM
AND REMOVAL VOIDS THE PRODUCT WARRANTY

PCP installation

M97

M96 (x3)

M98 (x4)
M9
4 mm
P106 194E

72 11019577 s 2EV !" s !PRIL

590 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

3-POSITION (FNR) Assembly

ELECTRIC CONTROL )NSTALL A NEW GASKET - ON THE HOUSING 0LACE THE ADAPTER PLATE INTO POSITION AND
USING A MM INTERNAL HEX INSTALL THE SCREWS - )NSTALL A SEALING WASHER UNDER THE
HEAD OF MOUNTING SCREWS THAT ARE INSTALLED INTO THROUGH HOLES IN THE HOUSING4ORQUE
THE SCREWS TO .sM ; LBFsFT=

)NSTALL ORIlCES 4 AND 4 INTO ADAPTER PLATE USING A OR MM
INTERNAL HEX WRENCH )NSTALL ORIlCE 4 INTO ADAPTER PLATE USING A OR MM
INTERNAL HEX WRENCH4ORQUE - THREADS TO .sM ; LBSsLFT= - THREADS TO .sM
; LBSsLFT= AND - THREADS TO .sM ; LBSsLFT=

5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS 7! ONTO THE SOLENOID
VALVE ASSEMBLY AND INSTALL THE SOLENOID VALVE ONTO THE ADAPTER PLATE 5SING A MM
INTERNAL HEX INSTALL SCREWS 7 4ORQUE TO .sM ; LBFsFT=

FNR installation
7 X
I MM

7!
- X d
I MM
4
4
4
-

3EAL WASHER
LOCATION CC
4

- 4
4
d

0 %

11019577 s 2EV !" s !PRIL 73

008 924 17 BOMAG 591
16.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

MULTI-FUNCTION VALVE Multi-function valve installation

CARTRIDGES

P2B1

P13
P06

P2A1

P106 180E

Multi-function valve

P04
P03
P01
P02

P05

P06

P07
P08
P17
P16
P15
P14
P09
P11
P13

P12

E101 531E

74 11019577 s 2EV !" s !PRIL

592 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

Assembly
,UBRICATE AND INSTALL INTERNAL COMPONENTS 0 0 0 0 0 0 0 0 AND
0

0LACE THE CARTRIDGE IN A VISE AND PRESS ON THE POPPET SEAT 0

,UBRICATE AND INSTALL NEW / RINGS 0 0 0

)NSTALL BYPASS ACTUATOR 0 WITH PRESSURE LIMITER VALVE 0 4ORQUE TO .sM
; LBFsFT=

CCaution
)F PRESSURE LIMITER 0 WAS REMOVED FROM BYPASS ACTUATOR 0 ADJUST PRESSURE LIMITER
TO MODEL CODE SPECIlCATIONS
CCaution
$O NOT OVERTORQUE THE )NSTALL CARTRIDGES AND TORQUE AS SHOWN IN THE TABLE C
MULTI FUNCTION VALVE
CARTRIDGES Multi-function valve wrench size Multi-function valve torque
Frame size Wrench size Frame size Torque
n INCH n .sM ; LBFsFT=
n INCH n .sM ; LBFsFT=

11019577 s 2EV !" s !PRIL 75

008 924 17 BOMAG 593
16.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY

INSTALLING SHAFT AND Shaft and bearing installation

BEARING 0OSITION THE PUMP ON ITS END CAP

0RESS THE ROLLER BEARING , ONTO THE INPUT SHAFT , &OR UNITS WITH A PIECE
BEARING PRESS THE INNER RACE ONTO THE SHAFT THEN INSTALL THE OUTER RACECAGE ASSEMBLY
AND SPECIAL WASHER C

5SING SUITABLE RETAINING RING PLIERS INSTALL THE BEARING RETAINING RING ,

C Caution
$O NOT DAMAGE THE SEALING SURFACE IN THE HOUSING DURING SHAFTBEARING INSTALLATION

,UBRICATE AND INSTALL SHAFT AND BEARING ASSEMBLY THROUGH FRONT OF HOUSING ALIGNING
THE SHAFT SPLINE WITH THE CYLINDER BLOCK SPLINE )F PUMP IS EQUIPPED WITH AUXILIARY
PAD ALIGN CHARGE PUMP SHAFT WITH AUXILIARY PAD COUPLING

#ONTINUE TO LOWER THE SHAFT INTO THE UNIT WHILE ALIGNING THE END OF THE SHAFT WITH END
CAP JOURNAL BEARING

)F NECESSARY COAT THE ,UBRICATE AND PRESS SEAL , IN Installing the shaft and bearing assembly
OUTSIDE DIAMETER OF THE CARRIER ,
L70
SEAL LIGHTLY WITH A SEALANT (see table)
SUCH AS ,OCTITE4- (IGH ,UBRICATE AND INSTALL / RING , IN
0ERFORMANCE 3EALANT CARRIER , L60
PRIOR TO INSTALLA
TION4HIS AIDS IN PREVENTING ,UBRICATE AND PRESS SEAL CARRIER INTO L30
LEAKS CAUSED BY DAMAGE ITS BORE IN THE HOUSING
L40
TO THE SEAL BORE IN THE SEAL
CARRIER )NSTALL RETAINER PLATE , AND BOLTS L50
, 7RENCH SIZES AND TORQUE VALUES
L20
FOR RETAINER PLATE BOLTS ARE SHOWN IN
TABLE BELOW
L10

L70 wrench sizes and torques

Pump size Wrench size 4ORQUE .sM ;LBFsFT= L100
CC MM HEX .sM ; LBFsFT=
CC MM .sM ; LBFsFT=
INTERNAL HEX
CC MM .sM ; LBFsFT=
INTERNAL HEX

E101 534E

76 11019577 s 2EV !" s !PRIL

594 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
!SSEMBLY

FINAL ASSEMBLY AND Final assembly and testing procedures

TESTING 2OTATE THE PUMP SHAFT WITH A TORQUE WRENCH TO ASSURE CORRECT ASSEMBLY4HE TABLE Torque
to turn shaft at 0° (with seal assembly installed) shows TORQUES NECESSARY TO TURN THE
SHAFT AFTER BREAK AWAY

Torque to turn shaft at 0° (with seal assembly installed)

Pump size -INIMUM TORQUE .sM ;LBFsFT= -AXIMUM TORQUE .sM ;LBFsFT=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=

W 7ARNING
4EST THE PUMP BEFORE PUTTING IT INTO SERVICE6ERIFY CORRECT PRESSURE LIMITER AND CONTROL
FUNCTION )MPROPER FUNCTION OF THESE SYSTEMS CAN RESULT IN UNCONTROLLABLE MOVEMENT OF
THE VEHICLEMACHINE

11019577 s 2EV !" s !PRIL 77

008 924 17 BOMAG 595
16.1 Travel pump
Series 90 Pumps
Repair Instructions
4ORQUE #HART

FASTENER SIZE AND Item Fastener Frame size Wrench size Torque
TORQUE CHART B83 3PEED SENSOR LOCK NUT IN HEX .sM ; LBFsFT=
E60 3IDE COVER SCREW MM HEX .sM ; LBFsFT=
"LIND HOLES MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
E60 3IDE COVER SCREW MM HEX .sM ; LBFsFT=
4HRU HOLES MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
F111/ 3ERVO CYLINDER SCREW MM HEX .sM ; LBFsFT=
F211 MM HEX .sM ; LBFsFT=
G90/ %ND CAP SCREW MM INTERNAL HEX .sM ; LBFsFT=
G97 MM INTERNAL HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
H80 #HARGE PUMP RETAINING SCREW MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
J80 %ND CAP SCREW MM INTERNAL HEX .sM ; LBFsFT=
EARLY MM INTERNAL HEX .sM ; LBFsFT=
LATE MM INTERNAL HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
MM HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
K10 #HARGE PRESSURE VALVE PLUG IN HEX .!
K90 #HARGE PRESSURE LOCK NUT IN HEX .sM ; LBFsFT=
IN HEX .sM ; LBFsFT=
L70 3HAFT RETAINING SCREW MM HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
MM INTERNAL HEX .sM ; LBFsFT=
M72 -$# HANDLE NUT MM .sM ; LBFsFT=
M78 $E STROKE VALVE MANIFOLD SCREW MM INTERNAL HEX .sM ; LBFsFT=
M85 %CCENTRIC PLUG LOCK NUT IN HEX .sM ; LBFsFT=
M88 .EUTRAL START SWITCH LOCK NUT IN HEX .sM ; LBFsFT=
M90 #ONTROL MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
M92 3OLENOID VALVE MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
M98 0#0 MOUNTING SCREW MM INTERNAL HEX .sM ; LBFsFT=
N10 &ILTER REDUCER ASSEMBLY IN HEX .sM ; LBFsFT=
IN HEX .sM ; LBFsFT=
IN HEX .sM ; LBFsFT=
N37 &ILTER PLUG ASSEMBLY IN INTERNAL HEX .sM ; LBFsFT=
P2B1/ -ULTI FUNCTION VALVE IN HEX .sM ; LBFsFT=
P2A1 IN HEX .sM ; LBFsFT=

78 11019577 s 2EV !" s !PRIL

596 BOMAG 008 924 17

Travel pump 16.1
Series 90 Pumps
Repair Instructions
4ORQUE #HART

– Market Leaders Worldwide
(YDROSTATIC TRANSMISSIONS
3AUER $ANFOSS IS A COMPREHENSIVE SUPPLIER PROVIDING COMPLETE
(YDRAULIC POWER STEERING
SYSTEMS TO THE GLOBAL MOBILE MARKET
%LECTRIC POWER STEERING
3AUER $ANFOSS SERVES MARKETS SUCH AS AGRICULTURE CONSTRUCTION ROAD
%LECTROHYDRAULIC POWER STEERING
BUILDING MATERIAL HANDLING MUNICIPAL FORESTRY TURF CARE AND MANY
#LOSED AND OPEN CIRCUIT AXIAL PISTON OTHERS
PUMPS AND MOTORS
'EAR PUMPS AND MOTORS 7E OFFER OUR CUSTOMERS OPTIMUM SOLUTIONS FOR THEIR NEEDS AND
DEVELOP NEW PRODUCTS AND SYSTEMS IN CLOSE COOPERATION AND
"ENT AXIS MOTORS PARTNERSHIP WITH THEM
/RBITAL MOTORS
3AUER $ANFOSS SPECIALIZES IN INTEGRATING A FULL RANGE OF SYSTEM
4RANSIT MIXER DRIVES COMPONENTS TO PROVIDE VEHICLE DESIGNERS WITH THE MOST ADVANCED
0LANETARY COMPACT GEARS TOTAL SYSTEM DESIGN

0ROPORTIONAL VALVES 3AUER $ANFOSS PROVIDES COMPREHENSIVE WORLDWIDE SERVICE FOR ITS
$IRECTIONAL SPOOL VALVES PRODUCTS THROUGH AN EXTENSIVE NETWORK OF 'LOBAL 3ERVICE 0ARTNERS
STRATEGICALLY LOCATED IN ALL PARTS OF THE WORLD
#ARTRIDGE VALVES
(YDRAULIC INTEGRATED CIRCUITS
,OCAL ADDRESS
(YDROSTATIC TRANSAXLES
)NTEGRATED SYSTEMS
&AN DRIVE SYSTEMS
%LECTROHYDRAULICS
-ICROCONTROLLERS AND SOFTWARE
%LECTRIC MOTORS AND INVERTERS
*OYSTICKS AND CONTROL HANDLES 3AUER $ANFOSS 53 #OMPANY 3AUER $ANFOSS !P3
$ISPLAYS %AST TH 3TREET $+ .ORDBORG $ENMARK
!MES )! 53! 0HONE
Sensors 0HONE &AX
&AX
3AUER $ANFOSS 'MB( #O /(' 3AUER $ANFOSS $AIKIN ,4$
0OSTFACH $ .EUMünster 3ANNOMIYA 'RAND "LDG &
+ROKAMP $ .EUMüNSTER 'ERMANY )SOGAMI DORI #HUO KU
0HONE +OBE (YOGO *APAN
&AX 0HONE
&AX

WWWSAUER DANFOSSCOM
11019577 s 2EV !" s !PRIL

598 BOMAG 008 924 17

16.2 Vibration pump

008 924 17 BOMAG 599

16.2 Vibration pump

600 BOMAG 008 924 17

Vibration pump 16.2

Series 42
Axial Piston Closed
Circuit Pumps

Service Manual

008 924 17 BOMAG 601

16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
2EVISIONS

History of Revisions Table of Revisions

Date Page Changed Rev.

.OVEMBER last NEW BACK PAGE #"

$ECEMBER all Major update CA
*ULY all Major update "!

¹ 3AUER $ANFOSS !LL RIGHTS RESERVED

2 520L0638 s 2EVISION #" s .OVEMBER

602 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
4ABLE OF #ONTENTS

Introduction /VERVIEW 5

7ARRANTY 5
'ENERAL INSTRUCTIONS 5
3AFETY PRECAUTIONS 6
3YMBOLS USED IN 3AUER $ANFOSS LITERATURE

1998 Model Release /VERVIEW 8

$ESCRIPTION OF CHANGE 8

Functional description 'ENERAL DESCRIPTION AND CROSS SECTIONAL VIEW

4HE SYSTEM CIRCUIT
0UMP FEATURES
Filtration options 2
$ISPLACEMENT LIMITERS3
#HARGE CHECK HIGH PRESSURE RELIEF VALVES3
"YPASS VALVES 3
!UXILIARY MOUNTING PADS 4

Control options -ANUAL DISPLACEMENT CONTROL -$# 5

%LECTRICAL DISPLACEMENT CONTROL %$# 5
(IGH CURRENT ELECTRICAL DISPLACEMENT CONTROL (# %$# 6
.ON FEEDBACK PROPORTIONAL HYDRAULIC .&0( control6
.ON FEEDBACK PROPORTIONAL ELECTRIC .&0% control
&ORWARD .EUTRAL 2EVERSE &.2 THREE POSITION ELECTRIC CONTROL

Technical speciﬁcations 3PECIlCATIONS8

Pressure measurement 2EQUIRED TOOLS

0ORT LOCATIONS AND PRESSURE GAUGE INSTALLATION
0ORTS AND PRESSURE GAUGES

Initial start-up procedure 'ENERAL2

3TART UP PROCEDURE 2

Fluid and ﬁlter 2ECOMMENDATIONS22

maintenance

Troubleshooting 3YSTEM OPERATING HOT 23

3YSTEM RESPONSE IS SLUGGISH24
3YSTEM WILL NOT OPERATE IN EITHER DIRECTION25
3YSTEM WILL NOT OPERATE IN ONE DIRECTION26
.EUTRAL DIFlCULT OR IMPOSSIBLE TO lND26

520L0638 s 2EVISION #" s .OVEMBER 3

008 924 17 BOMAG 603
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual

Adjustments $ISPLACEMENT LIMITER ADJUSTMENT2

Pump neutral adjustment 28
#ONTROL NEUTRAL ADJUSTMENT FOR -$# AND %$#(# %$#2

Minor repair Standard procedures 3

3IZE AND TORQUE FOR PLUGS AND lTTINGS3
#HARGE RELIEF VALVE32
Optional speed sensor34
-$# -ODULE 35
(# %$# AND %$# -ODULES 3
-$#%$# 3POOL LINKAGE AND NEUTRAL ADJUSTMENT SCREW 3
-$# .EUTRAL START BACKUP ALARM SWITCH 4
-$# 3OLENOID OVERRIDE VALVE43
&.2 .&0% AND .&0( #ONTROLS BOLT ON VALVES 44
&.2 .&0% AND .&0( #ONTROLS INTEGRAL VALVES 45
3YSTEM #HECK 2ELIEF 3#2 VALVES HIGH PRESSURE RELIEF CHARGE CHECK AND BYPASS VALVES 46
Filtration adapters4
!UXILIARY PADCHARGE PUMP COVER 4
#HARGE PUMP5
3ERVO PISTON COVERS AND .&0( CONTROL ORIlCE 54
,OOP mUSHING AND LOOP mUSHING RELIEF VALVE 56
3HAFT SEAL ROLLER BEARING AND SHAFT REPLACEMENT58

Appendix A - torques 4ORQUE TABLE 6

Appendix B - 0RE BLOCK POINT CHANGE62

Speciﬁcation tags 0OST BLOCK POINT CHANGE62

Appendix C - 0RE BLOCK POINT CHANGE NOMENCLATURE 63

nomenclature 0OST BLOCK POINT CHANGE NOMENCLATURE 64

4 520L0638 s 2EVISION #" s .OVEMBER

604 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
Introduction

Overview 4HIS MANUAL INCLUDES INFORMATION FOR THE INSTALLATION MAINTENANCE AND MINOR REPAIR OF
3ERIES AXIAL PISTON CLOSED CIRCUIT PUMPS )T INCLUDES A DESCRIPTION OF THE UNIT AND ITS
INDIVIDUAL COMPONENTS TROUBLESHOOTING INFORMATION AND MINOR REPAIR PROCEDURES

0ERFORMING MINOR REPAIRS REQUIRES YOU TO REMOVE THE UNIT FROM THE VEHICLEMACHINE
4HOROUGHLY CLEAN THE UNIT BEFORE BEGINNING MAINTENANCE OR REPAIR ACTIVITIES 3INCE DIRT
AND CONTAMINATION ARE THE GREATEST ENEMIES OF ANY TYPE OF HYDRAULIC EQUIPMENT FOLLOW
CLEANLINESS REQUIREMENTS STRICTLY4HIS IS ESPECIALLY IMPORTANT WHEN CHANGING THE SYSTEM
lLTER AND WHEN REMOVING HOSES OR PLUMBING

! WORLDWIDE NETWORK OF 3AUER $ANFOSS !UTHORIZED 3ERVICE #ENTERS !3#S IS AVAILABLE FOR
MAJOR REPAIRS 3AUER $ANFOSS TRAINS AND CERTIlES !3#S ON A REGULAR BASIS9OU CAN LOCATE
YOUR NEAREST !3# USING THE DISTRIBUTOR LOCATOR AT WWWSAUER DANFOSSCOM #LICK ON THE
Sales and Service LINK

Warranty 0ERFORMING INSTALLATION MAINTENANCE AND MINOR REPAIRS ACCORDING TO THE PROCEDURES IN
THIS MANUAL DOES NOT AFFECT YOUR WARRANTY -AJOR REPAIRS REQUIRING THE REMOVAL OF A UNITS
REAR COVER OR FRONT mANGE VOIDS THE WARRANTY UNLESS DONE BY A 3AUER $ANFOSS GLOBAL
SERVICE PARTNER

General instructions &OLLOW THESE GENERAL PROCEDURES WHEN REPAIRING 3ERIES VARIABLE DISPLACEMENT CLOSED
CIRCUIT PUMPS

w Remove the unit

0RIOR TO PERFORMING MINOR REPAIRS REMOVE THE UNIT FROM THE VEHICLEMACHINE #HOCK
THE WHEELS ON THE VEHICLE OR LOCK THE MECHANISM TO INHIBIT MOVEMENT "E AWARE THAT
HYDRAULIC mUID MAY BE UNDER HIGH PRESSURE ANDOR HOT )NSPECT THE OUTSIDE OF THE PUMP
AND lTTINGS FOR DAMAGE #AP HOSES AFTER REMOVAL TO PREVENT CONTAMINATION

e Keep it clean
#LEANLINESS IS A PRIMARY MEANS OF ASSURING SATISFACTORY PUMP LIFE ON EITHER NEW OR
REPAIRED UNITS #LEAN THE OUTSIDE OF THE PUMP THOROUGHLY BEFORE DISASSEMBLY4AKE CARE
TO AVOID CONTAMINATION OF THE SYSTEM PORTS #LEANING PARTS WITH A CLEAN SOLVENT WASH
AND AIR DRYING IS USUALLY ADEQUATE

!S WITH ANY PRECISION EQUIPMENT YOU MUST KEEP ALL PARTS FREE OF FOREIGN MATERIAL AND
CHEMICALS 0ROTECT ALL EXPOSED SEALING SURFACES AND OPEN CAVITIES FROM DAMAGE AND
FOREIGN MATERIAL )F LEFT UNATTENDED COVER THE PUMP WITH A PROTECTIVE LAYER OF PLASTIC

d Replace all O-rings and gaskets

3AUER $ANFOSS RECOMMENDS REPLACING ALL / RINGS GASKETS AND SEALS WHEN SERVICING
,IGHTLY LUBRICATE ALL / RINGS WITH CLEAN PETROLEUM JELLY PRIOR TO ASSEMBLY

t Secure the unit

&OR REPAIR PLACE THE UNIT IN A STABLE POSITION WITH THE SHAFT POINTING DOWNWARD)T IS NECESSARY
TO SECURE THE PUMP WHILE REMOVING AND TORQUING END COVERS CONTROLS AND VALVES

520L0638 s 2EVISION #" s .OVEMBER 5

008 924 17 BOMAG 605
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
Introduction

Safety precautions !LWAYS CONSIDER SAFETY PRECAUTIONS BEFORE BEGINNING A SERVICE PROCEDURE 0ROTECT
YOURSELF AND OTHERS FROM INJURY4AKE THE FOLLOWING GENERAL PRECAUTIONS WHENEVER SERVICING A
HYDRAULIC SYSTEM

Unintended machine movement

Flammable cleaning solvents

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

Fluid under pressure

Personal safety
W Warning
0ROTECT YOURSELF FROM INJURY 5SE PROPER SAFETY EQUIPMENT INCLUDING SAFETY GLASSES AT ALL
TIMES

6 520L0638 s 2EVISION #" s .OVEMBER

606 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
Introduction

Symbols used in Sauer-  7!2.).' MAY RESULT IN INJURY  4IP HELPFUL SUGGESTION
Danfoss literature
 #!54)/. MAY RESULT IN DAMAGE TO  ,UBRICATE WITH HYDRAULIC mUID
PRODUCT OR PROPERTY
 !PPLY GREASEPETROLEUM JELLY
 2EUSABLE PART
 !PPLY LOCKING COMPOUND
 .ON REUSABLE PART USE A NEW PART
 )NSPECT FOR WEAR OR DAMAGE
 .ON REMOVABLE ITEM
 Clean area or part
 /PTION n EITHER PART MAY EXIST
 "E CAREFUL NOT TO SCRATCH OR DAMAGE
 Superseded – parts are not
INTERCHANGEABLE  .OTE CORRECT ORIENTATION

 -EASUREMENT REQUIRED  -ARK ORIENTATION FOR REINSTALLATION

 &LATNESS SPECIlCATION  4ORQUE SPECIlCATION

 0ARALLELISM SPECIlCATION  0RESS IN n PRESS lT

 %XTERNAL HEX HEAD  0ULL OUT WITH TOOL n PRESS lT

 )NTERNAL HEX HEAD  #OVER SPLINES WITH INSTALLATION

sleeve
 4ORX HEAD
 0RESSURE MEASUREMENTGAUGE
 / RING BOSS PORT LOCATION OR SPECIlCATION

520L0638 s 2EVISION #" s .OVEMBER 7

008 924 17 BOMAG 607
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-ODEL 2ELEASE

Overview 0ARTS MAY OR MAY NOT BE INTERCHANGEABLE BETWEEN PRE AND POST MODEL
YEAR PUMPS -ANY PARTS INCLUDING THE HOUSING ASSEMBLY ARE UNIQUE TO THE MODEL YEAR
CHANGE

Description of change Housing

4HE PORT COVER FOR THE CONTROL SPOOL &/" OPTION CM3 ONLY CHANGED FROM A mAT PLATE
WITH TWO SCREWS TO AN 3!% / RING BOSS PLUG4HE SCREW HOLES FOR THE SERVO COVERS AND
FOUR OF THE SIX SCREW HOLES FOR THE SIDE COVER ARE DEEPER TO ACCEPT A MM LONGER SCREW
4HE TWO HOLES NEXT TO THE CHARGE PUMP COVER STAYED THE SAME LENGTH

Charge pump
4HE GEROTOR DRIVE PIN CHANGED TO A PARALLEL KEY ! RETAINING RING WAS ADDED TO THE CHARGE
PUMP SHAFT TO LOCATE THE GEROTOR4HE OUTER STEP ON THE GEROTOR COVER WAS ELIMINATED
AND THE LOCATING PIN SLOT DEPTH INCREASED

Auxiliary ﬂange shipping cover

4HE COVER CHANGED TO A mAT COVER PLATE WITH A SPECIAL SEAL RING NOT TO BE USED TO SEAL AN
AUXILIARY PUMP UNDER THE COVER ! PAD ONLY

Charge relief valve

4HE RELIEF VALVE CHANGED FROM A NON ADJUSTABLE TO AN ADJUSTABLE RELIEF VALVE4HIS CHANGE
REQUIRES A UPGRADE HOUSING

Spool - loop ﬂushing

4HE SPOOL CHANGED TO BECOME COMMON BETWEEN THE AND CM3 PUMPS4HIS
CHANGE REQUIRES A UPGRADE HOUSING

8 520L0638 s 2EVISION #" s .OVEMBER

608 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
&UNCTIONAL $ESCRIPTION

Overview 4HIS SECTION DESCRIBES THE OPERATION OF PUMPS AND THEIR SERVICEABLE FEATURES )T IS A USEFUL
REFERENCE FOR READERS UNFAMILIAR WITH THE FUNCTION OF THIS SPECIlC PUMP

General description and 4HE 3ERIES PUMPS ARE SERVO CONTROLLED AXIAL PISTON PUMPS DESIGNED FOR CLOSED
cross-sectional view CIRCUIT APPLICATIONS4HE INPUT SHAFT TURNS THE PUMP CYLINDER BLOCK CONTAINING NINE
RECIPROCATING PISTONS THAT ARE HELD TO THE SWASHPLATE WITH A BLOCK SPRING %ACH PISTON HAS
A BRASS SLIPPER CONNECTED TO ONE END BY A BALL JOINT4HE RECIPROCATING MOVEMENT OCCURS
AS THE SLIPPERS SLIDE ALONG THE INCLINED SWASHPLATE DURING ROTATION !S EACH PISTON CYCLES
IN AND OUT OF ITS BORE mUID IS DRAWN FROM THE INLET AND DISPLACED TO THE OUTLET THEREBY
IMPARTING HYDRAULIC POWER TO THE SYSTEM6IA THE VALVE PLATE ONE HALF OF THE CYLINDER
BLOCK IS CONNECTED TO LOW PRESSURE AND THE OTHER TO HIGH PRESSURE #LEARANCES ALLOW A
SMALL AMOUNT OF mUID TO mOW FROM THE CYLINDER BLOCKVALVE PLATE AND SLIPPERSWASHPLATE
INTERFACES FOR LUBRICATION AND COOLING #ASE DRAIN PORTS RETURN THIS mUID TO THE RESERVOIR

4HE ANGLE OF THE SWASHPLATE CONTROLS THE VOLUME OF mUID DISPLACED INTO THE SYSTEM
4HE SERVO PISTON FORCES THE SWASHPLATE INTO AN INCLINED POSITION INTO STROKE )NTERNAL
MOMENTS AND CENTERING SPRINGS WITHIN THE SERVO PISTON RETURN THE SWASHPLATE TO THE
NEUTRAL POSITION OUT OF STROKE

Cross section
Slipper
Swashplate
Piston

Cylinder block

Roller bearing Charge pump

Valve plate
0%

520L0638 s 2EVISION #" s .OVEMBER 9

008 924 17 BOMAG 609
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
&UNCTIONAL $ESCRIPTION

The system circuit System circuit diagram

Servo control cylinder
Displacement control valve

Heat exchanger Reservoir

bypass
Filter

Fixed
Control Heat displacement
handle exchanger motor
Cylinder Cylinder
block block
assembly Charge relief assembly
valve

Output
Charge shaft
pump
Input
shaft Variable Suction flow
displacement Check valves Charge pressure
pump with high pressure Servo pressure
relief valves High pressure
Case flow
0%
Closed circuit operation
(YDRAULIC LINES CONNECT THE MAIN PORTS Charge pump
OF THE PUMP TO THE MAIN PORTS OF THE O-ring
MOTOR &LUID mOWS IN EITHER DIRECTION
FROM THE PUMP TO THE MOTOR AND BACK
%ITHER OF THE HYDRAULIC LINES CAN BE UNDER Gerotor cover
HIGH PRESSURE4HE POSITION OF PUMP
SWASHPLATE DETERMINES WHICH LINE IS HIGH
PRESSURE AS WELL AS THE DIRECTION OF mOW
Seal
Case drain and heat exchanger
"OTH THE PUMP AND MOTOR MUST DRAIN Coupling
mUID ! CASE DRAIN LINE ACHIEVES THIS4HE Square key
LINE CONNECTS TO THE PUMP OR MOTOR
AT THE TOP MOST DRAIN PORT IN ORDER TO Gerotor set
MAINTAIN AN ADEQUATE mUID LEVEL IN THE
COMPONENTS &LUID COOLING DEMANDS MAY
REQUIRE A HEAT EXCHANGER WITH A BYPASS Retainer
VALVE TO COOL THE CASE DRAIN mUID BEFORE IT ring Orientation
pin
RETURNS TO THE RESERVOIR

Pump features Charge pump

4HE CHARGE PUMP IS NECESSARY TO SUPPLY
mUID TO MAINTAIN POSITIVE PRESSURE IN THE
SYSTEM LOOP TO PROVIDE PRESSURE TO OPERATE
THE CONTROL SYSTEM AND TO MAKE UP FOR
INTERNAL LEAKAGE AND LOOP mUSHING mOW4O
PREVENT DAMAGE TO THE TRANSMISSION THE
P108 065E
PUMP MUST MAINTAIN THE SPECIlED CHARGE
PRESSURE UNDER ALL CONDITIONS OF OPERATION
10 520L0638 s 2EVISION #" s .OVEMBER
610 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
&UNCTIONAL $ESCRIPTION

Pump features 4HE CHARGE PUMP IS A lXED DISPLACEMENT GEROTOR TYPE PUMP4HE MAIN PUMP DRIVES
(continued) THE CHARGE PUMP OFF THE MAIN SHAFT ! SPRING AND POPPET STYLE RELIEF VALVE LIMITS CHARGE
PRESSURE

4HE STANDARD CHARGE PUMP IS SATISFACTORY FOR MOST APPLICATIONS HOWEVER OTHER
DISPLACEMENTS ARE AVAILABLE ! GEAR PUMP MOUNTED TO THE AUXILIARY PAD MAY AUGMENT
CHARGE mOW IF ADDITIONAL VOLUME IS REQUIRED

Charge relief valve

4HE CHARGE RELIEF VALVE MAINTAINS CHARGE PRESSURE AT A DESIGNATED LEVEL4HE CHARGE RELIEF
VALVE IS A DIRECT ACTING POPPET VALVE WHICH OPENS AND DISCHARGES mUID TO THE PUMP CASE
WHEN PRESSURE REACHES THAT LEVEL )T IS NOMINALLY SET WITH THE PUMP RUNNING AT RPM
)N FORWARD OR REVERSE CHARGE PRESSURE IS SLIGHTLY LOWER THAN WHEN IN NEUTRAL POSITION 4HE
MODEL CODE OF THE PUMP SPECIlES THE CHARGE RELIEF VALVE SETTING

Loop ﬂushing valve

! LOOP mUSHING VALVE DUMPS mOW FROM THE LOW SIDE OF THE MAIN LOOP REMOVING HEAT AND
CONTAMINANTS 0UMPS EQUIPPED WITH AN INTEGRAL LOOP mUSHING VALVE ALSO INCLUDE A LOOP
mUSHING RELIEF VALVE4HE LOOP mUSHING RELIEF VALVE POPPET INCLUDES AN ORIlCE THAT CONTROLS
mUSHING mOW UNDER MOST CONDITIONS ! COMBINATION OF ORIlCE SIZE AND CHARGE PRESSURE
RELIEF SETTING PRODUCES A SPECIlC mUSHING mOW

Charge relief, loop ﬂushing relief, and loop ﬂushing valve

Charge relief
valve
Loop flushing
relief valve

Loop flushing
spool
Loop flushing
defeat spool
P108 095E

520L0638 s 2EVISION #" s .OVEMBER 11

008 924 17 BOMAG 611
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
&UNCTIONAL $ESCRIPTION

Filtration options 3ERIES PUMPS MAY BE EQUIPPED WITH PROVISIONS FOR EITHER SUCTION OR CHARGE PRESSURE
lLTRATION TO lLTER THE mUID ENTERING THE CIRCUIT

Suction ﬁltration
4HE SUCTION lLTER IS IN THE CIRCUIT BETWEEN THE RESERVOIR AND THE INLET TO THE CHARGE PUMP

Charge pressure ﬁltration Suction ﬁltration

4HE PRESSURE lLTER IS REMOTELY MOUNTED Filter
IN THE CIRCUIT AFTER THE CHARGE PUMP
Reservoir

9OU MAY USE PARTIAL OR FULL mOW PRESSURE

lLTRATION CIRCUITS WITH 3ERIES PUMPS Strainer
7ITHOUT A lLTER ADAPTER SUCTION lLTRATION To low pressure
side of loop and Charge
IS THE ONLY OPTION servo control pump

Charge
relief
valve
Filtration adapters
To pump case P001603

Partial ﬂow pressure ﬁltration

Reservoir
Strainer

Filter
Partial flow
pressure
filtration
Charge pump
To low pressure
side of loop and
servo control

Charge
Full flow Full flow relief valve
pressure suction
filtration
filtration To pump case 0%

Full ﬂow pressure ﬁltration

Reservoir

Strainer

Filter
with bypass
To low pressure
side of loop and Charge
servo control pump

Charge
P108 066E relief
pump

To pump case P001605E

12 520L0638 s 2EVISION #" s .OVEMBER

612 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
&UNCTIONAL $ESCRIPTION

Displacement limiters 3ERIES PUMPS ARE AVAILABLE WITH Displacement limiters

MECHANICAL DISPLACEMENT LIMITERS IN THE $ISPLACEMENT LIMITER
SERVO COVERS4HE DISPLACEMENT LIMITERS FACtoRY SET FOR MAXIMUM DISPLACEMENT
CAN LIMIT DISPLACEMENT OF THE PUMP
TO ANY VALUE FROM MAXIMUM TO ZERO IN
EITHER DIRECTION

Servo control
Charge check / high !LL SERIES PUMPS HAVE A COMBINATION cYLINDER
pressure relief valves CHARGE CHECKHIGH PRESSURE RELIEF VALVE $ISPLACEMENT LIMITER
4HE CHARGE CHECK FUNCTION ALLOWS SET FOR REDUCED MAXIMUM DISPLACEMENT
PRESSURIZED mOW FROM THE CHARGE PUMP 0%
TO ENTER THE LOW PRESSURE SIDE OF THE LOOP
4HIS mOW IS NECESSARY TO REPLENISH mUID High pressure relief valve
DISCHARGED TO THE PUMPMOTOR CASE FOR
LUBRICATION AND COOLING REQUIREMENTS High pressure
3INCE THE PUMP CAN OPERATE IN EITHER side of working loop
DIRECTION IT USES TWO CHARGE CHECK VALVES
TO DIRECT THE CHARGE SUPPLY INTO THE LOW
PRESSURE SIDE

(IGH PRESSURE RELIEF VALVES ARE AVAILABLE Charge check and

high pressure
IN A RANGE OF SETTINGS AS SHOWN IN THE relief valve
MODEL CODE4HE MODEL CODE MAY SPECIFY 0%
INDIVIDUAL PRESSURE SETTINGS4HE HIGH
PRESSURE RELIEF VALVE SETTINGS ARE REFERENCED TO CHARGE PRESSURE AND ARE SET AT LMIN ; 53
GALMIN= OF mOW

Bypass valves /PTIONAL BYPASS PLUNGERS ARE AVAILABLE Charge check and high pressure relief
FOR USE WHEN IT IS NECESSARY TO MOVE THE valves with bypass
VEHICLE OR MECHANICAL FUNCTION AND THE To/from other
bypass valve
PRIME MOVER IS NOT RUNNING
To/from
working loop
C#!54)/. 4OGETHER THESE VALVES CONNECT BOTH
"YPASS VALVES ARE FOR SIDES OF THE MAIN HYDRAULIC CIRCUIT
MOVING A MACHINE OR ALLOWING mUID TO CIRCULATE WITHOUT
VEHICLE FOR VERY SHORT ROTATING THE PUMP AND PRIME MOVER
DISTANCES AT VERY SLOW
SPEEDS4HEY ARE NOT TOW 4HE BYPASS FUNCTION IS INTEGRAL TO THE Charge check and
Bypass high pressure
VALVES )F PRESSURE BUILDS CHARGE CHECKHIGH PRESSURE RELIEF VALVE relief valve
plunger
WITHIN THE SYSTEM THE ASSEMBLY $EPRESSING THE PLUNGER IN P100394E
VALVES MAY CLOSE CAUSING THE PLUG OF THE VALVE ASSEMBLY OPENS
DAMAGE TO THE PUMP AND THE VALVE4HE VALVE REMAINS OPEN UNTIL THE PRIME MOVER RESTARTS OR PRESSURE BUILDS IN
MOTOR OR PRIME MOVER THE SYSTEM AND CAUSES THE VALVE THE CLOSE9OU MUST DEPRESS THE PLUNGERS IN BOTH OF THE
-OVE THE VEHICLEMACHINE CHECKRELIEF VALVE ASSEMBLIES FOR PROPER BYPASS OPERATION C
AT NO MORE THAN OF
TOP SPEED FOR NO MORE
THAN THREE MINUTES

520L0638 s 2EVISION #" s .OVEMBER 13

008 924 17 BOMAG 613
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
&UNCTIONAL $ESCRIPTION

Auxiliary mounting pads 3!% ! AND 3!% " AUXILIARY MOUNTING mANGES ARE AVAILABLE ON ALL 3ERIES PUMPS AND ARE
INTEGRAL TO THE CHARGE PUMP COVER4HIS mANGE ALLOWS MOUNTING OF AUXILIARY HYDRAULIC
PUMPS AND MOUNTING OF ADDITIONAL 3ERIES PUMPS TO MAKE TANDEM PUMPS4HE PADS
ALLOW FULL THROUGH TORQUE CAPABILITY

Auxiliary mounting pads

Charge pump cover

O-ring

U085

U035 (x8)

Cover plate
Pad seal
P108 096E

14 520L0638 s 2EVISION #" s .OVEMBER

614 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
Control Options

Manual displacement 4HE -ANUAL $ISPLACEMENT #ONTROL -$# USES A MECHANICAL INPUT TO OPERATE THE CONTROL SPOOL
control (MDC) IN THE PUMP! CAM CONNECTS THE INPUT HANDLE TO THE CONTROL SPOOL ALLOWING MANIPULATION OF
THE OPERATING CURVE USING DIFFERENT CAM PROlLES4HE CONTROL SPOOL MODULATES THE PRESSURE
BALANCE ACROSS THE PUMPS SERVO PISTON4HE ANGLE OF THE SWASHPLATE IS PROPORTIONAL TO THE
ANGULAR POSITION OF THE CONTROL INPUT! MECHANICAL FEEDBACK LINKAGE MOVES THE CONTROL SPOOL
TOWARD NEUTRAL AS THE SWASHPLATE ANGLE REACHES THE COMMANDED POSITION-ECHANICAL FEEDBACK
ALLOWS THE PUMP TO HOLD VERY ACCURATELY AT
THE COMMANDED DISPLACEMENT#ENTERING MDC on series 42 pump
SPRINGS AND INTERNAL MOMENTS RETURN
THE SWASHPLATE TO NEUTRAL POSITION IN THE
ABSENCE OF CONTROL INPUT

Solenoid override valve

! SOLENOID OVERRIDE VALVE IS AVAILABLE FOR THE
MANUAL DISPLACEMENT CONTROL4HIS SAFETY
FEATURE SHUNTS THE SERVO PISTON ALLOWING THE
PUMP TO RETURN TO NEUTRAL WHEN ACTIVATED
.ORMALLY OPEN OR NORMALLY CLOSED OPTIONS
ARE AVAILABLE
0

Neutral start switch (NSS)

4HE .EUTRAL 3TART 3WITCH .33 IS AN OPTIONAL CAM OPERATED BALL TYPE MICROSWITCH7HEN
CONNECTED PROPERLY TO THE VEHICLES ELECTRICAL SYSTEM THE .33 ENSURES THAT THE PRIME
MOVER WILL START ONLY WHEN THE CONTROL INPUT SHAFT IS IN THE NEUTRAL POSITION

Back-up alarm switch (BAS)

4HE "ACK UP !LARM 3WITCH "!3 IS AVAILABLE FOR THE -$# AND WORKS IN ASSOCIATION WITH
THE .337HEN CONNECTED PROPERLY TO THE VEHICLES ELECTRICAL SYSTEM THE "!3 CAN SOUND
AN ALARM WHEN THE CONTROL COMMANDS THE VEHICLE INTO REVERSE /NE CAM AND SWITCH
ASSEMBLY CONTROLS BOTH FUNCTIONS 2EPOSITIONING THE CAM ACCOMMODATES BOTH CLOCKWISE
AND COUNTERCLOCKWISE CONTROL HANDLE ROTATION TO REVERSE DIRECTION

Electrical displacement 4HE %LECTRICAL $ISPLACEMENT #ONTROL %$# IS A TWO STAGE CONTROL USING A $# INPUT CURRENT TO
control (EDC) CONTROL PUMP DISPLACEMENT3TAGE ONE THE 0RESSURE #ONTROL 0ILOT 0#0 VALVE USES THE $# INPUT
TO OPERATE A TORQUE MOTOR WHICH DRIVES A mAPPER VALVE4HE mAP IN THE 0#0 BLOCKS A PORTION OF
mOW FROM ONE OR THE OTHER OF TWO NOZZLES4HE TWO NOZZLES MODULATE PRESSURE BALANCE ACROSS A
SENSING PISTON IN THE CONTROL4HE CONTROL PISTON IS CONNECTED TO THE CONTROL SPOOL IN THE PUMP
BY A PIN AND LINKAGE4HE CONTROL SPOOL
MODULATES THE DIFFERENTIAL PRESSURE ACROSS EDC on series 42 pump
THE PUMPS SERVO PISTON THIS IS STAGE TWO
4HE ANGLE OF THE SWASHPLATE IS PROPORTIONAL
TO THE INPUT CURRENT! MECHANICAL FEEDBACK
LINKAGE MOVES THE CONTROL SPOOL TOWARD
NEUTRAL AS THE SWASHPLATE ANGLE REACHES THE
COMMANDED POSITION-ECHANICAL FEEDBACK
ALLOWS THE PUMP TO HOLD VERY ACCURATELY AT
THE COMMANDED DISPLACEMENT#ENTERING
SPRINGS AND INTERNAL MOMENTS RETURN
THE SWASHPLATE TO NEUTRAL POSITION IN THE
ABSENCE OF CONTROL INPUT
0

520L0638 s 2EVISION #" s .OVEMBER 15

008 924 17 BOMAG 615
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
Control Options

High current electrical 4HE (IGH #URRENT %LECTRICAL $ISPLACEMENT #ONTROL (# %$# IS A TWO STAGE CONTROL USING A
displacement control $# INPUT CURRENT WITH 0ULSE 7ITH -ODULATION 07- TO CONTROL PUMP DISPLACEMENT 3TAGE
(HC-EDC) ONE USES TWO 0ROPORTIONAL 0RESSURE 2EDUCING 6ALVES 0026 TO PROVIDE REDUCING PRESSURE
PROPORTIONAL TO THE INPUT CURRENT 4HE PRESSURE FROM EACH 0026 IS PROVIDED TO EACH END OF THE
SENSING PISTON IN THE CONTROLTHIS IS STAGE ONE4HE SENSING PISTON IS CONNECTED TO THE CONTROL
SPOOL IN THE PUMP BY A PIN AND LINKAGE4HE
CONTROL SPOOL MODULATES THE DIFFERENTIAL HC-EDC on series 42 pump
PRESSURE ACROSS THE PUMPS SERVO PISTON THIS
IS STAGE TWO4HE ANGLE OF THE SWASHPLATE IS
PROPORTIONAL TO THE INPUT CURRENT
! MECHANICAL FEEDBACK LINKAGE MOVES
THE CONTROL SPOOL TOWARD NEUTRAL AS THE
SWASHPLATE ANGLE REACHES THE COMMANDED
POSITION-ECHANICAL FEEDBACK ALLOWS
THE PUMP TO HOLD VERY ACCURATELY AT THE
COMMANDED DISPLACEMENT#ENTERING
SPRINGS AND INTERNAL MOMENTS RETURN
THE SWASHPLATE TO NEUTRAL POSITION IN THE
ABSENCE OF CONTROL INPUT P108 111E

Non-feedback 4HE .ON &EEDBACK 0ROPORTIONAL NFPH control on series 42 pump

proportional hydraulic (YDRAULIC .&0( CONTROL IS A HYDRAULIC
(NFPH) control DISPLACEMENT CONTROL %XTERNAL VALVING
SUPPLIES AN INPUT PRESSURE DIRECTLY TO THE
PUMP SERVO PISTON VIA CONTROL PORTS 8
AND 8 TO CONTROL PUMP DISPLACEMENT

0UMP DISPLACEMENT IS PROPORTIONAL TO THE

PRESSURE DIFFERENCE ACROSS THE SERVO PISTON
(OWEVER BECAUSE THIS CONTROL DOES NOT USE
MECHANICAL FEEDBACK DISPLACEMENT ALSO
DEPENDS UPON INPUT SPEED AND SYSTEM
PRESSURE4HIS CHARACTERISTIC PROVIDES
A POWER LIMITING FUNCTION BY REDUCING
DISPLACEMENT AS SYSTEM PRESSURE INCREASES 0

16 520L0638 s 2EVISION #" s .OVEMBER

616 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
Control Options

Non-feedback 4HE .ON &EEDBACK 0ROPORTIONAL %LECTRIC .&0% CONTROL IS AN ELECTRIC CONTROL ! 07- INPUT
proportional electric SIGNAL TO ONE OF TWO SOLENOIDS ON THE CONTROL VALVE PORTS CHARGE PRESSURE TO ONE SIDE OF THE
(NFPE) control SERVO PISTON

0UMP DISPLACEMENT IS PROPORTIONAL TO THE SIGNAL CURRENT (OWEVER BECAUSE THIS CONTROL
DOES NOT USE MECHANICAL FEEDBACK DISPLACEMENT ALSO DEPENDS ON INPUT SPEED AND
SYSTEM PRESSURE4HIS CHARACTERISTIC PROVIDES A POWER LIMITING FUNCTION BY REDUCING
DISPLACEMENT AS SYSTEM PRESSURE INCREASES

NFPE control on series 42 pump (28/32cc) NFPE control on series 42 pump (41/51cc)

P100 415
P108 112E

Forward-Neutral-Reverse 4HE &ORWARD .EUTRAL 2EVERSE &.2 IS A THREE POSITION CONTROL )T USES A OR 6DC
(FNR) three-position ELECTRICALLY OPERATED SPOOL VALVE TO PORT PRESSURE TO EITHER SIDE OF THE SERVO PISTON
electric control %NERGIZING ONE OF THE TWO SOLENOIDS WILL CAUSE THE PUMP TO GO TO ITS MAXIMUM
DISPLACEMENT IN THE CORRESPONDING DIRECTION4HE &.2 CONTROL DOES NOT USE MECHANICAL
FEEDBACK

!LL FUNCTIONS OF THE THREE POSITION &.2 ELECTRIC CONTROL ARE PRESET AT THE FACTORY

FNR control on series 42 pump (28/32cc) FNR control on series 42 pump (41/51cc)

P108 112E

520L0638 s 2EVISION #" s .OVEMBER 17

008 924 17 BOMAG 617
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
4ECHNICAL 3PECIlCATIONS

Speciﬁcations General speciﬁcations

Product line Series 42 pumps
Pump type )N LINE AXIAL PISTON POSITIVE DISPLACEMENT VARIABLE PUMPS INCLUDING CRADLE
SWASHPLATE AND SERVO CONTROL
Direction of input rotation #LOCKWISE OR COUNTERCLOCKWISE AVAILABLE
Installation position 0UMP INSTALLATION RECOMMENDED WITH THE CONTROL AT THE TOP OR SIDE #ONSULT
3AUER $ANFOSS FOR NON CONFORMANCE GUIDELINES (OUSING MUST ALWAYS BE lLLED
WITH HYDRAULIC mUID
Filtration conﬁguration 3UCTION OR CHARGE PRESSURE lLTRATION
Other system )NDEPENDENT BRAKING SYSTEM SUITABLE RESERVOIR AND HEAT EXCHANGER
requirements

Hardware speciﬁcations
Model 28 32 41 51
Pump conﬁguration 3INGLE PUMP 3INGLE PUMP 3INGLE PUMP 3INGLE PUMP
Displacement ;= ;= ;= ;=
3 3
cm /rev [in /rev]
Mass kg [lbm] ;= ;= ;= ;=

Case pressure
Rated pressure bar [psi] ;=
Maximum pressure (cold start) bar [psi] ;=

Speed limits
Frame size cm3 28 32 41 51
Minimum speed min¯¹ (rpm)
Rated speed at maximum displacement min¯¹ (rpm)
Maximum speed at maximum displacement min¯¹ (rpm)

System pressure
Frame size cm3 28 32 41 51
Rated pressure bar [psi] ;= ;= ;= ;=
Maximum pressure bar [psi] ;= ;= ;= ;=

Theoretical ﬂow
Frame size cm3 28 32 41 51
Theoretical ﬂow at rated speed l/min [US gal/min] ;= ;= ;= ;=

Inlet pressure
Rated pressure (absolute) bar [in Hg vacuum] ;=
Minimum pressure (absolute) (cold start) ;=
bar [in Hg vacuum]

18 520L0638 s 2EVISION #" s .OVEMBER

618 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
Pressure Measurement

Required tools 9OU CAN PERFORM THE SERVICE PROCEDURES IN THIS MANUAL USING COMMON MECHANICS HAND
TOOLS #ALIBRATE GAUGES FREQUENTLY TO ENSURE ACCURACY 5SE SNUBBERS TO PROTECT PRESSURE
GAUGES

Port locations and ! PUMP WITH A MANUAL DISPLACEMENT CONTROL -$# AND NO lLTRATION ADAPTER IS SHOWN
pressure gauge 7ITH NON FEEDBACK CONTROLS THE POSITIONS OF THE CASE DRAINS MAY VARY7ITH A lLTRATION
installation ADAPTER THE PORTING IN THE lLTRATION OPTIONS AREA VARIES

Ports and pressure 0ROPER SERVICE AND DIAGNOSIS MAY REQUIRE PRESSURE MEASUREMENT AT VARIOUS POINTS IN
gauges THE HYDRAULIC CIRCUIT4HE 3ERIES PUMP HAS SEVERAL LOCATIONS AT WHICH TO TAKE THESE
MEASUREMENTS4HE FOLLOWING ILLUSTRATION SHOWS THE LOCATIONS OF THE VARIOUS GAUGE PORTS
4HE TABLE SHOWS THE RECOMMENDED GAUGE SIZE AND THE lTTING SIZE FOR EACH PORT 2EFER TO
THIS INFORMATION WHEN INSTALLING PRESSURE GAUGES

Gauge ports
Gauge Pressure measured Recommended gauge O-ring boss
port size 28/32 cc 41 / 51 cc
- - 3YSTEM PRESSURE FOR PORTS ! AND " BAR ; PSI=
M3 #HARGE PRESSURE BAR ; PSI=
- - Servo pressure BAR ; PSI=
, , Case pressure BAR ; PSI=
S #HARGE PUMP INLET PRESSURE BAR ; IN (G VACUUM=

3OME OLDER MODELS MAY USE A / RING lTTING

28/32 cm3 base unit with MDC and no ﬁltration adapter

Servo pressure
gauge port M5
System pressure
gauge port M2 Charge pressure
Servo pressure
gauge port M3
gauge port M4
System (charge pressure
pressure supply for no
port B charge pump
option)
System
pressure
port A Case drain
Charge pump
port L1
inlet port S
Case Drain
System pressure Port L2
gauge port M1
LEFT SIDE VIEW RIGHT SIDE VIEW P108 067E

520L0638 s 2EVISION #" s .OVEMBER 19

008 924 17 BOMAG 619
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
Pressure Measurement

Ports and pressure 41/51 cm3 base unit with MDC and no ﬁltration adapter
gauges (continued)
System pressure Servo pressure
gauge port M2 gauge port M5 Charge pressure
gauge port M3
System Servo pressure
pressure gauge port M4
port B
Case drain
System port L2
pressure
port A
Case drain Charge pump
port L1 inlet port S

System pressure
gauge port M1 P108 068E
LEFT SIDE VIEW RIGHT SIDE VIEW

Filtration adapters (28/32 cm3, and 41/51 cm3 models)

Outlet to
filter, port D

Charge pressure Charge pressure

gauge, port M3 gauge, port M3

Inlet from
filter, port E
P108 084E

20 520L0638 s 2EVISION #" s .OVEMBER

620 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
)NITIAL 3TART 5P 0ROCEDURE

General &OLLOW THIS PROCEDURE WHEN STARTING UP A NEW 3ERIES INSTALLATION OR WHEN RESTARTING
AN INSTALLATION IN WHICH THE PUMP HAS BEEN REMOVED

WARNING
5NINTENDED MOVEMENT OF THE MACHINE OR MECHANISM MAY CAUSE INJURY TO THE TECHNICIAN
OR BYSTANDERS4O PROTECT AGAINST UNINTENDED MOVEMENT SECURE THE MACHINE OR DISABLE
DISCONNECT THE MECHANISM WHILE SERVICING

0RIOR TO INSTALLING THE PUMP INSPECT FOR DAMAGE INCURRED DURING SHIPPING -AKE CERTAIN
ALL SYSTEM COMPONENTS RESERVOIR HOSES VALVES lTTINGS HEAT EXCHANGER ETC ARE CLEAN
PRIOR TO lLLING WITH mUID

Start-up procedure #ONNECT THE PUMP TO THE PRIME MOVER %NSURE THAT PUMP SHAFT IS PROPERLY ALIGNED
WITH THE SHAFT OF THE PRIME MOVER 
 CAUTION
)NCORRECT SHAFT ALIGNMENT &ILL THE RESERVOIR WITH RECOMMENDED HYDRAULIC mUID !LWAYS lLTER mUID THROUGH A
MAY RESULT IN DAMAGE MICRON ABSOLUTE lLTER POURING INTO THE RESERVOIR .EVER REUSE HYDRAULIC mUID
TO DRIVE SHAFT BEARINGS
OR SEAL WHICH CAN CAUSE &ILL THE MAIN PUMP HOUSING WITH CLEAN HYDRAULIC mUID 0OUR lLTERED OIL DIRECTLY INTO
EXTERNAL OIL LEAKAGE THE UPPER MOST CASE DRAIN PORT

&ILL THE INLET LINE LEADING FROM THE PUMP TO THE RESERVOIR #HECK THE INLET LINE FOR
PROPERLY TIGHTENED lTTINGS AND BE CERTAIN IT IS FREE OF RESTRICTIONS AND AIR LEAKS

4O ENSURE THE PUMP STAYS lLLED WITH OIL INSTALL THE CASE DRAIN LINE IN THE UPPER MOST
CASE DRAIN PORT

)NSTALL A GAUGE AT PORT - TO MONITOR SYSTEM PRESSURE DURING START UP

&OLLOW RECOMMENDATIONS IN THE VEHICLEMACHINE OPERATORS MANUAL FOR PRIME MOVER

START UP PROCEDURES

7HILE WATCHING THE PRESSURE GAUGE AT - JOG THE PRIME MOVER OR RUN AT THE LOWEST
POSSIBLE SPEED UNTIL SYSTEM PRESSURE BUILDS TO NORMAL LEVELS MINIMUM BAR ;
PSI= /NCE SYSTEM PRESSURE IS ESTABLISHED INCREASE TO FULL OPERATING SPEED )F THE
PUMP DOES NOT MAINTAIN SYSTEM PRESSURE SHUT DOWN THE PRIME MOVER DETERMINE
CAUSE AND TAKE CORRECTIVE ACTION 2EFER TO Troubleshooting PAGE 2

/PERATE THE HYDRAULIC SYSTEM FOR AT LEAST lFTEEN MINUTES UNDER LIGHT LOAD CONDITIONS

#HECK AND ADJUST CONTROL SETTINGS AS NECESSARY AFTER INSTALLATION 2EFER TO Adjustments
PAGE 2.

3HUT DOWN THE PRIME MOVER AND REMOVE THE PRESSURE GAUGE 2EPLACE PLUG AT PORT -

#HECK THE mUID LEVEL IN THE RESERVOIR ADD CLEAN lLTERED mUID IF NECESSARY

4HE PUMP IS NOW READY FOR OPERATION

520L0638 s 2EVISION #" s .OVEMBER 21

008 924 17 BOMAG 621
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
Fluid and Filter Maintenance

Recommendations 4O ENSURE OPTIMUM LIFE OF 3ERIES PRODUCTS PERFORM REGULAR MAINTENANCE OF THE mUID
AND lLTER #ONTAMINATED mUID IS THE MAIN CAUSE OF UNIT FAILURE4AKE CARE TO MAINTAIN mUID
CLEANLINESS WHEN SERVICING

#HECK THE RESERVOIR DAILY FOR PROPER mUID LEVEL THE PRESENCE OF WATER AND RANCID mUID
ODOR7ATER IN THE mUID MAY BE NOTED BY A CLOUDY OR MILKY APPEARANCE OR FREE WATER
IN THE BOTTOM OF THE RESERVOIR 2ANCID ODOR INDICATES THE mUID HAS BEEN EXPOSED TO
EXCESSIVE HEAT #HANGE THE mUID IMMEDIATELY IF THESE CONDITIONS OCCUR #ORRECT THE
PROBLEM IMMEDIATELY

#HANGE THE mUID AND lLTER PER THE Fluid and ﬁlter change intervals
VEHICLEMACHINE MANUFACTURERS Sealed reservoir HOURS
RECOMMENDATIONS OR AT THESE INTERVALS "REATHER RESERVOIR HOURS

#HANGE THE mUID MORE FREQUENTLY IF IT BECOMES CONTAMINATED WITH FOREIGN MATTER DIRT
WATER GREASE ETC OR IF THE mUID IS SUBJECTED TO TEMPERATURE LEVELS GREATER THAT THE
RECOMMENDED MAXIMUM

$ISPOSE OF USED HYDRAULIC mUID PROPERLY .EVER REUSE HYDRAULIC mUID

#HANGE lLTERS WHENEVER THE mUID IS CHANGED OR WHEN THE lLTER INDICATOR SHOWS THAT IT IS
NECESSARY TO CHANGE THE lLTER 2EPLACE ALL mUID LOST DURING lLTER CHANGE

22 520L0638 s 2EVISION #" s .OVEMBER

622 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
4ROUBLESHOOTING

Overview 4HIS SECTION PROVIDES GENERAL STEPS TO FOLLOW IF YOU OBSERVE CERTAIN UNDESIRABLE SYSTEM
CONDITIONS 3OME OF THE ITEMS ARE SYSTEM SPECIlC !LWAYS OBSERVE THE SAFETY PRECAUTIONS
LISTED IN THE INTRODUCTION OF THIS MANUAL )F STANDARD TROUBLESHOOTING PROCEDURES DO NOT
REMEDY THE PROBLEM CONTACT A 3AUER $ANFOSS 'LOBAL 3ERVICE 0ARTNER

System operating hot Item Description Action

Oil level in reservoir )NSUFlCIENT HYDRAULIC mUID WILL &ILL THE RESERVOIR TO THE PROPER LEVEL
NOT MEET THE COOLING DEMANDS OF WITH CLEAN HYDRAULIC OIL
SYSTEM
(EAT EXCHANGER IF EQUIPPED 4HE HEAT EXCHANGER IS NOT #HECK THE AIR mOW AND INPUT AIR
SUFlCIENTLY COOLING THE SYSTEM TEMPERATURE FOR THE HEAT EXCHANGER
#LEAN REPAIR OR REPLACE THE HEAT
EXCHANGER AS NECESSARY
"YPASS VALVE ! PARTIALLY ACTIVATED BYPASS VALVE 6ERIFY THAT THE BYPASS VALVE IS FULLY
MAY RESULT IN HEAT GENERATION WITHIN CLOSED AND THAT THE VALVE IS SEATING
THE SYSTEM PROPERLY 2EPAIR OR REPLACE IT AS
NECESSARY
3#2 3YSTEM #HECK 2ELIEF ! PARTIALLY ACTIVATED 3#2 VALVE OR 6ERIFY THAT THE 3#2 VALVE IS SEATING
6ALVES 3#2 VALVES WITH RELIEF SETTINGS TOO PROPERLY AND IS AT THE CORRECT RELIEF
LOW MAY RESULT IN HEAT GENERATION SETTING 2EPAIR OR REPLACE IT AS
WITHIN THE SYSTEM NECESSARY
/IL lLTERS #LOGGED OIL lLTERS MAY RESULT IN AN )NSPECT THE OIL lLTERS AND VERIFY THAT
INSUFlCIENT SUPPLY OF COOL OIL TO THE THEY ARE STILL OPERABLE 2EPLACE THEM
SYSTEM IF NECESSARY
-ACHINE LOAD %XCESSIVE LOADS OR EXTREME DUTY 6ERIFY THAT THE MACHINE IS OPERATING
CYCLES COULD RESULT IN THE PUMP AND WITHIN THE PARAMETERS FOR WHICH IT
OR MOTOR OPERATING AT SPEEDS AND WAS DESIGNED )F NECESSARY REDUCE
PRESSURES BEYOND SYSTEM DESIGN THE LOAD ON THE MACHINE
LIMITATIONS

520L0638 s 2EVISION #" s .OVEMBER 23

008 924 17 BOMAG 623
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
4ROUBLESHOOTING

System response is Item Description Action

sluggish 2ESERVOIR OIL LEVEL 4HERE IS AN INSUFlCIENT AMOUNT &ILL THE RESERVOIR TO THE PROPER LEVEL
OF HYDRAULIC mUID RESULTING IN AN WITH CLEAN HYDRAULIC mUID
INADEQUATE SUPPLY FOR THE SYSTEM
LOOP
)NPUT CONTROL SIGNAL 4HE PUMP IS RECEIVING A FAULTY 6ERIFY THAT THE INPUT SIGNAL IS CORRECT
LINKAGE CURRENT OR PRESSURE CONTROL SIGNAL -$# BINDING OR AND IDENTICAL IN BOTH DIRECTIONS
BROKEN LINKAGE %$# FAULTY OR
INADEQUATE ELECTRICAL SIGNAL ($#
BLOCKED OR INCORRECTLY ORIlCED
CONTROL LINES
Pump control ! DAMAGED PUMP CONTROL OR CONTROL 6ERIFY THAT THE PUMPS CONTROL IS
SPOOL WILL NOT CORRECTLY TRANSMIT THE OPERATING PROPERLY AND THAT THE
CONTROL INPUT SIGNAL TO THE PUMP CONTROL SPOOL IS NOT DAMAGED OR
WORN AND MOVES FREELY WITHIN ITS
BORE #LEAN REPAIR OR REPLACE IT AS
NECESSARY
"YPASS VALVE ! PARTIALLY ACTIVATED BYPASS VALVE 6ERIFY THAT THE BYPASS VALVE IS
WILL CAUSE CROSS PORT LEAKAGE CLOSED AND THAT THE VALVE IS SEATING
PROPERLY #LEAN REPAIR OR REPLACE IT
AS NECESSARY
3#2 SYSTEM CHECK RELIEF /NE OR BOTH OF THE 3#2 VALVES MAY 6ERIFY THAT THE 3#2 VALVES OPERATE
valves BE BINDING WITHIN THEIR BORES FREELY 2EPAIR OR REPLACE THEM AS
NECESSARY
#HARGE PRESSURE IN NEUTRAL 4HE IS LOW CHARGE PRESSURE RESULTING )NSPECT THE CHARGE PUMP FOR
FROM A DAMAGED CHARGE PUMP OR DAMAGE AND VERIFY THE CHARGE
LOW CHARGE PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE SETTING 2EPAIR
SETTING OR REPLACE IT AS NECESSARY
#HARGE PRESSURE IN STROKE 4HERE IS LOW CHARGE PRESSURE 2EPAIR OR REPLACE THE COMPONENT
RESULTING FROM INTERNAL LEAKAGE OR COMPONENTS WITHIN THE SYSTEM
WITHIN THE SYSTEM CAUSING THE INTERNAL LEAKAGE
Servo pressure 4HERE IS INSUFlCIENT PRESSURE #HECK SERVO PRESSURES AT PORT -
DIFFERENTIAL ACROSS THE SERVO PISTON AND - TO VERIFY SUFlCIENT PRESSURE
DELTA6ERIFY THAT THE SERVO SUPPLY
AND DRAIN PATHS ARE UNOBSTRUCTED
AND THAT ANY ORIlCES ARE OF THE
CORRECT SIZE AND FREE OF DEBRIS #LEAN
REPAIR OR REPLACE AS NECESSARY
#HARGE PUMP 4HE CHARGE PUMP HAS BEEN 6ERIFY THAT THE CHARGE PUMP IS IN
DAMAGED OR INSTALLED WITH THE GOOD WORKING ORDER AND THAT IT IS
INCORRECT ROTATIONAL ORIENTATION CORRECTLY INSTALLED 2EPAIR OR REPLACE
IT AS NECESSARY

24 520L0638 s 2EVISION #" s .OVEMBER

624 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
4ROUBLESHOOTING

System will not operate Item Description Action

in either direction Oil level in reservoir 4HERE IS INSUFlCIENT HYDRAULIC mUID &ILL THE RESERVOIR TO THE PROPER LEVEL
TO SUPPLY THE SYSTEM LOOP WITH CLEAN HYDRAULIC OIL
)NPUT CONTROL SIGNAL 4HE PUMP IS RECEIVING A FAULTY 6ERIFY THAT THE INPUT SIGNAL IS CORRECT
LINKAGE CURRENT OR PRESSURE CONTROL SIGNAL -$# BINDING OR AND IDENTICAL IN BOTH DIRECTIONS
BROKEN LINKAGE %$# FAULTY OR !DJUST CLEAN REPAIR OR REPLACE THE
INADEQUATE ELECTRICAL SIGNAL ($# INPUT DEVICE AS NECESSARY
BLOCKED OR INCORRECTLY ORIlCED
CONTROL LINES
/IL lLTERS #LOGGED OIL lLTERS MAY RESULT IN )NSPECT THE OIL lLTERS AND VERIFY THAT
AN INSUFlCIENT SUPPLY OF OIL TO THE THEY ARE STILL SERVICEABLE 2EPLACE
SYSTEM THEM AS NECESSARY
"YPASS VALVE ! PARTIALLY ACTIVATED BYPASS VALVE 6ERIFY THAT THE BYPASS VALVES ARE
MAY RESULT IN A CROSS PORT LEAKAGE CLOSED AND THAT THE VALVES ARE
SEATING PROPERLY #LEAN REPAIR OR
REPLACE THEM AS NECESSARY
#HARGE PRESSURE #HARGE PRESSURE MAY BE INSUFlCIENT )NSPECT THE CHARGE PUMP FOR
IN NEUTRAL TO RECHARGE THE SYSTEM LOOP DAMAGE AND VERIFY THAT THE CHARGE
PRESSURE RELIEF VALVE IS AT THE PROPER
SETTING 2EPAIR OR REPLACE IT AS
NECESSARY
#HARGE PRESSURE 4HERE IS LOW CHARGE PRESSURE 2EPAIR OR REPLACE THE COMPONENT
IN STROKE RESULTING FROM INTERNAL LEAKAGE OR COMPONENTS WITHIN THE SYSTEM
WITHIN THE SYSTEM CAUSING THE INTERNAL LEAKAGE
Servo pressure 4HERE IS AN INSUFlCIENT PRESSURE #HECK SERVO PRESSURES TO VERIFY
DIFFERENTIAL ACROSS THE SERVO PISTON SUFlCIENT PRESSURE DELTA6ERIFY THAT
THE SERVO SUPPLY AND DRAIN PATHS ARE
UNOBSTRUCTED AND THAT ANY ORIlCES
ARE OF THE CORRECT SIZE AND FREE OF
DEBRIS #LEAN REPAIR OR REPLACE THEM
AS NECESSARY
#HARGE PUMP 4HE CHARGE PUMP IS DAMAGED OR 6ERIFY THAT THE CHARGE PUMP IS IN
HAS BEEN INSTALLED WITH THE INCORRECT GOOD WORKING ORDER AND THAT IT IS
ROTATIONAL ORIENTATION CORRECTLY INSTALLED 2EPAIR OR REPLACE
IT AS NECESSARY
3#2 SYSTEM CHECK RELIEF 4HE 3#2 VALVES ARE MALFUNCTIONING 6ERIFY THAT THE 3#2 VALVES ARE
valves OR IMPROPERLY SET OPERATING AND PROPERLY SET 2EPAIR OR
REPLACE THEM AS NECESSARY
$ISPLACEMENT LIMITERS $ISPLACEMENT LIMITERS MAY BE 6ERIFY THAT THE DISPLACEMENT LIMITERS
IMPROPERLY ADJUSTED SUCH THAT THE ARE ADJUSTED TO THE PROPER SETTING
SERVO PISTON IS LOCKED IN PLACE

520L0638 s 2EVISION #" s .OVEMBER 25

008 924 17 BOMAG 625
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
4ROUBLESHOOTING

System will not operate Item Description Action

in one direction )NPUT CONTROL SIGNAL LINKAGE 4HE PUMP IS RECEIVING A FAULTY 6ERIFY THAT THE INPUT SIGNAL IS CORRECT
CURRENT OR PRESSURE CONTROL SIGNAL -$# BINDING OR AND IDENTICAL IN BOTH DIRECTIONS
BROKEN LINKAGE %$# FAULTY OR !DJUST CLEAN REPAIR OR REPLACE THE
INADEQUATE ELECTRICAL SIGNAL ($# CONTROL MODULE AS NECESSARY
BLOCKED OR INCORRECTLY ORIlCED
CONTROL LINES
3#2 3YSTEM #HECK2ELIEF 4HE 3#2 VALVES ARE MALFUNCTIONING 6ERIFY THAT THE 3#2 VALVES ARE
valves OR IMPROPERLY SET OPERATING PROPERLY 2EPAIR OR REPLACE
THEM AS NECESSARY
Pump control ! DAMAGED OR BIASED PUMP 6ERIFY THAT THE PUMPS CONTROL IS
CONTROL MAY BE SENDING A SIGNAL FUNCTIONING PROPERLY 2EPAIR OR
COMMANDING THE PUMP TO STROKE REPLACE IT AS NECESSARY
ONLY IN ONE DIRECTION
Servo pressure 4HE DRAIN OR SUPPLY PATH TO ONE SIDE 6ERIFY THAT THE SERVO SUPPLY AND
OF THE SERVO PISTON MAY BE BLOCKED DRAIN PATHS ARE UNOBSTRUCTED AND
THAT ANY ORIlCES ARE OF THE CORRECT
SIZE AND FREE OF DEBRIS #LEAN OR
REPAIR THEM AS NECESSARY
$ISPLACEMENT LIMITERS IF 4HE DISPLACEMENT LIMITERS MAY BE 6ERIFY THAT THE DISPLACEMENT LIMITERS
EQUIPPED IMPROPERLY ADJUSTED SUCH THAT THE ARE ADJUSTED PROPERLY
SERVO PISTON IS PREVENTED FROM
MOVING IN ONE DIRECTION

Neutral difﬁcult or Item $ESCRIPTION Action

impossible to ﬁnd )NPUT CONTROL SIGNAL LINKAGE 4HE PUMP IS RECEIVING A FAULTY 6ERIFY THAT THE INPUT SIGNAL IS CORRECT
CURRENT OR PRESSURE CONTROL SIGNAL -$# BINDING OR AND IDENTICAL IN BOTH DIRECTIONS
BROKEN LINKAGE %$# FAULTY OR !DJUST CLEAN REPAIR OR REPLACE
INADEQUATE ELECTRICAL SIGNAL ($# CONTROL MODULE AS NECESSARY
BLOCKED OR INCORRECTLY ORIlCED
CONTROL LINES
3YSTEM PRESSURE 7ITH NO INPUT SIGNAL TO THE CONTROL 2EADJUST PUMP NEUTRAL SETTING 2EFER
A PRESSURE DELTA MAY EXIST BETWEEN to adjustment procedure on PAGE
THE TWO SIDES OF THE WORKING LOOP
Servo pressure 7ITH NO INPUT SIGNAL TO THE CONTROL 2EADJUST THE CONTROL NEUTRAL SETTING
A PRESSURE DELTA MAY EXIST ACROSS THE 2EFER TO ADJUSTMENT PROCEDURE ON
SERVO PISTON PAGE
0#0 PRESSURE %$#S ONLY 7ITH NO INPUT SIGNAL TO THE CONTROL A 2EPLACE THE %$#
PRESSURE DIFFERENCE MAY EXIST ACROSS
THE CONTROL SPOOL

26 520L0638 s 2EVISION #" s .OVEMBER

626 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
Adjustments

Overview 4HIS SECTION OFFERS INSTRUCTION ON HOW TO PERFORM ADJUSTMENTS TO THE 3ERIES PUMP
2EAD THROUGH THE ENTIRE PROCEDURE BEFORE BEGINNING ANY SERVICE ACTIVITY

Displacement limiter -OUNT THE PUMP ON A TEST STAND CAPABLE Displacement limiters
L025
adjustment OF MEASURING SYSTEM mOW FROM THE ! AND Displacement
" PORTS limiter seal
lock nut
L020 13 mm
,OOSEN THE DISPLACEMENT LIMITER SEAL Displacement
.%
LOCK NUT , BUT DO NOT REMOVE IT limiter
$!.!+
4 mm
L001
3TART THE PRIME MOVER AND PLACE Servo
THE PUMP INTO FULL STROKE IN ONE piston
DIRECTION .OTE THE SYSTEM OUTPUT cover
7!2.).' mOW FROM EITHER THE ! OR " SYSTEM
4HE SEAL NUT LOCK NUT PORT
MUST BE RETORQUED AFTER
EVERY ADJUSTMENT AND THE !DJUST THE DISPLACEMENT LIMITER
LIMITER SCREW MUST HAVE ADJUSTMENT SCREW , UNTIL THE
FULL THREAD ENGAGEMENT DESIRED OUTPUT mOW IS REACHED
IN THE SERVO PISTON COVER 4URNING THE DISPLACEMENT LIMITER
to prevent unexpected ADJUSTMENT SCREW CLOCKWISE
CHANGES IN OPERATING DECREASES THE MAXIMUM OUTPUT mOW
conditions and to prevent SETTING4URNING THE DISPLACEMENT
EXTERNAL LEAKAGE DURING LIMITER ADJUSTMENT SCREW COUNTER
UNIT OPERATION CLOCKWISE INCREASES THE MAXIMUM RIGHT SIDE VIEW (M4)
M020
OUTPUT mOW SETTING Displacement
limiter M025
4HE PUMP ACHIEVES OVERALL MAXIMUM 4 mm Displacement
limiter seal
mOW WHEN THE DISPLACEMENT LIMITER DOES lock nut
NOT CONTACT THE SERVO PISTON WHILE THE 13 mm
UNIT IS IN FULL STROKE .%
M001
$!.!+
Servo
piston
/NE FULL TURN OF THE DISPLACEMENT LIMITER cover
ADJUSTMENT SCREW RESULTS IN APPROXIMATE
mOW OUTPUT CHANGES PER THE TABLE

/NCE YOU ACHIEVE THE PROPER OUTPUT

mOW TORQUE THE DISPLACEMENT
Displacement limiter LIMITER SEAL LOCK NUT , TO .sM
adjustment ; LBFsFT= WHILE HOLDING THE POSITION
Size Displacement change OF THE ADJUSTMENT SCREW ,
per turn
28 cm3 CM3REV ; IN3REV= )F REQUIRED REPEAT THIS PROCEDURE
32 cm3 CM3REV ; IN3REV= USING THE OPPOSITE DISPLACEMENT
CM3 CM3REV ; IN3REV= LIMITER TO SET THE OUTPUT mOW IN THE LEFT SIDE VIEW (M5)
CM3 CM3REV ; IN3REV= OTHER DIRECTION P108 077E

520L0638 s 2EVISION #" s .OVEMBER 27

008 924 17 BOMAG 627
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
Adjustments

Pump neutral adjustment :ERO OUTPUT mOW FROM THE PUMP DElNES THE NEUTRAL CONDITION4O ATTAIN ZERO OUTPUT
mOW THE PUMP MUST ACHIEVE BOTH MECHANICAL NEUTRAL AND CONTROL NEUTRAL CONDITIONS
-ECHANICAL NEUTRAL IS THE CONDITION WHEN THE SWASHPLATE IS AT ZERO ANGLE WITHOUT ANY
7!2.).' SIGNAL INPUT FROM THE CONTROL 3ET MECHANICAL NEUTRAL PRIOR TO SETTING CONTROL NEUTRAL
4O PREVENT INJURY DISABLE
THE MACHINE RAISE $ISABLE THE CONTROL INPUT TO THE Pump neutral adjustment screw
WHEELS OFF THE GROUND OR PUMP BY EQUALIZING THE PRESSURES ON T060
DISCONNECT THE MECHANISM BOTH ENDS OF THE PUMP SERVO PISTON Pump mechanical
4O ACCOMPLISH THIS CONNECT AN neutral adjustment
seal lock nut
3!% HOSE BETWEEN SERVO GAUGE See table
PORTS - AND - See table

)NSTALL PRESSURE GAUGES IN GAUGE T015

PORTS - AND - TO MEASURE SYSTEM Pump neutral
PRESSURE adjustment screw
See table
See table
3TART THE PRIME MOVER AND RUN AT
NORMAL OPERATING SPEED %%

MDC Shown
,OOSEN THE PUMP NEUTRAL
ADJUSTMENT SEAL LOCK NUT 4 IN Neutral adjustment gauge port readings
THE CENTER OF THE SERVO COVER ON THE M1 / M2
RIGHT SIDE OF THE PUMP M1 / M2

4URN THE ADJUSTMENT SCREW 4

CLOCKWISE UNTIL ONE OF THE GAUGES
REGISTERS AN INCREASE IN SYSTEM M1 / M2
PRESSURE -ARK THE POSITION OF THE
ADJUSTMENT SCREW4URN THE SCREW
COUNTERCLOCKWISE UNTIL THE OTHER
GAUGE REGISTERS AN INCREASE IN 0
SYSTEM PRESSURE -ARK THE POSITION
OF THE ADJUSTMENT SCREW4URN THE ADJUSTMENT SCREW CLOCKWISE TO A POSITION HALFWAY
BETWEEN THE MARKS4HE SYSTEM PRESSURE GAUGES SHOULD INDICATE EQUAL PRESSURES

7HILE HOLDING THE ADJUSTMENT SCREW IN POSITION TORQUE THE SEAL LOCK NUT 4
4ORQUE CM3 MODELS WITH AN -$# %$# OR AN (# %$# TO .sM ;
LBFsFT=4ORQUE ALL CM3 MODELS AND CM3 MODELS WITH .&0 CONTROLS TO
.sM ; LBFsFT=

3TOP THE PRIME MOVER AND REMOVE THE HOSE BETWEEN GAUGE PORTS - AND -
2EMOVE THE PRESSURE GAUGES IN GAUGE PORTS - AND - 2EINSTALL THE PLUGS IN THE
GAUGE PORTS

0ROCEED TO THE CONTROL NEUTRAL ADJUSTMENT SECTION ON THE NEXT PAGE

Frame size cm3 28/32 41/51

Control MDC/EDC/HC-EDC NFP MDC/EDC/HC-EDC NFP
Lock nut mm
Servo adjust screw mm [in] 5
,OCK NUT TORQUE .sM ;LBFsFT = ;= ;= ;= ;=

28 520L0638 s 2EVISION #" s .OVEMBER

628 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
Adjustments

Control neutral #ONTROL NEUTRAL ADJUSTMENT ALIGNS THE Control neutral adjustment screw
adjustment for MDC and PUMP SWASHPLATE AND THE CONTROL SPOOL D014
neutral
EDC/HC-EDC SO THAT A ZERO ANGLE CONTROL SETTING adjustment screw
PROVIDES A ZERO DEGREE SWASHPLATE 5 mm
SETTING 0ERFORM THIS ADJUSTMENT
7!2.).' WHENEVER YOU ADJUST OR MOVE ANY PART
4HE FOLLOWING PROCEDURE OF THE CONTROL OR SWASHPLATE MECHANISM
REQUIRES THE VEHICLEOR AFTER YOU ADJUST THE PUMP NEUTRAL
MACHINE TO BE DISABLED SETTING
WHEELS RAISED OFF THE
GROUND WORK FUNCTION 
DISCONNECTED ETC WHILE $ISCONNECT THE EXTERNAL CONTROL
D015
PERFORMING THE PROCEDURE LINKAGE FOR -$# OR CONTROL SIGNAL neutral
IN ORDER TO PREVENT INJURY INPUT FOR %$# AND (# %$# FROM THE adjustment lock nut
TO THE TECHNICIAN AND PUMP 17 mm

BYSTANDERS HC-EDC Shown
P108 080E
)NSTALL PRESSURE GAUGES IN THE SERVO
GAUGE PORTS - AND - TO MEASURE
PRESSURE ON THE PUMP SERVO PISTON
Equalization of pressure gauges using
3TART THE PRIME MOVER AND RUN AT pump neutral adjustment screw
NORMAL OPERATING SPEED M3 / M4

,OOSEN THE CONTROL NEUTRAL

ADJUSTMENT SEAL LOCK NUT $
M3 / M4
4URN THE ADJUSTMENT SCREW $
CLOCKWISE UNTIL ONE OF THE GAUGES
REGISTERS AN INCREASE IN PRESSURE ON
THE SERVO PISTON -ARK THE POSITION OF
THE ADJUSTMENT SCREW

4URN THE SCREW COUNTERCLOCKWISE M3 / M4

UNTIL THE OTHER GAUGE REGISTERS AN
P101 270E
INCREASE IN PRESSURE ON THE SERVO
PISTON -ARK THE POSITION OF THE
ADJUSTMENT SCREW

4URN THE ADJUSTMENT SCREW CLOCKWISE SO THAT IT IS MIDWAY BETWEEN THE MARKS
!DJUSTMENT SCREW MOVEMENT PRODUCES CONSTANT CHANGE FOR BOTH DIRECTIONS SO BOTH
THE PRESSURE GAUGES SHOULD INDICATE NEARLY EQUAL PRESSURES

7HILE HOLDING THE ADJUSTMENT SCREW $ IN POSITION TORQUE THE SEAL LOCK NUT
$ TO .sM ; LBFsFT=

3TOP THE PRIME MOVER AND REMOVE THE PRESSURE GAUGES 2EMOVE THE PLUGS IN THE
GAUGE PORTS

#ONNECT THE EXTERNAL CONTROL LINKAGE FOR -$# OR CONTROL SIGNAL INPUT FOR %$# AND
(# %$# TO THE PUMP 2ECONNECT THE WORK FUNCTION

520L0638 s 2EVISION #" s .OVEMBER 29

008 924 17 BOMAG 629
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Standard procedures Remove the pump

0RIOR TO PERFORMING CERTAIN MINOR REPAIRS ON THE 3ERIES PUMP IT MAY BE NECESSARY TO
REMOVE THE PUMP FROM THE MACHINE #HOCK THE VEHICLE TO PROHIBIT MOVEMENT "E AWARE
THAT HYDRAULIC mUID MAY BE UNDER HIGH PRESSURE AND MAY BE HOT )NSPECT THE OUTSIDE OF
THE PUMP AND lTTINGS FOR DAMAGE

Keep it clean
#LEANLINESS IS A PRIMARY MEANS OF ASSURING SATISFACTORY PUMP LIFE ON EITHER NEW OR REPAIRED
UNITS #LEAN THE OUTSIDE OF THE PUMP THOROUGHLY BEFORE DISASSEMBLY4AKE CARE TO AVOID
CONTAMINATION OF THE SYSTEM PORTS #LEAN PARTS USING A CLEAN SOLVENT WASH AND AIR DRY

Inspect for system contamination

)NSPECT THE PUMP FOR SYSTEM CONTAMINATION )F YOU lND CONTAMINATION FULLY DISASSEMBLE
CLEAN AND INSPECT ALL COMPONENTS OF THE PUMP USING 11007277 Series 42 Axial Piston
Closed Circuit Pumps Repair Manual IN CONJUNCTION WITH THIS MANUAL

Replace the O-rings and gaskets Pump face orientations

3AUER $ANFOSS RECOMMENDS YOU REPLACE Left face
ALL / RINGS AND GASKETS ,IGHTLY LUBRICATE
/ RINGS WITH CLEAN PETROLEUM JELLY PRIOR
TO ASSEMBLY Front face Top face

Lubricate all moving parts

$URING REASSEMBLY COAT ALL MOVING
PARTS WITH A lLM OF CLEAN HYDRAULIC
OIL4HIS WILL HELP TO LUBRICATE THESE
PARTS DURING START UP &OR mUID QUALITY
REQUIREMENTS REFER TO BULLETIN 520L0463
Bottom face
Hydraulic Fluids and Lubricants, Technical
Rear face
Information.

Right face P108 079E

30 520L0638 s 2EVISION #" s .OVEMBER

630 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Size and torque for plugs 0LUG AND lTTING SIZES APPEAR HERE Case drain plug
and ﬁttings 2EPLACE / RINGS AND LUBRICATE WITH F091 28/32 cm3 41/51 cm3
PETROLEUM JELLY WHENEVER A PLUG IS )NTERNAL HEX IN IN
REMOVED4ORQUE EACH AS INDICATED 4ORQUE .sM .sM
; LBFsFT= ; LBFsFT=

Size and torque for plugs and ﬁttings

Servo gauge
port M4

L010
11
/16 in
+!
+'

Charge pressure Charge pump

gauge port M3 inlet port S
F091 (position varies,
(see table) Case drain refer to Filtration
port L1 options)

Servo gauge
port M5

M010
11
/16 in
+!
+'

Case drain
port L2
F091
(see table)
N002
11
/16 in
+!
+'
F093
System 11
System ports gauge ports /16 in
A and B M1 and M2 +! +'

P108 097E

520L0638 s 2EVISION #" s .OVEMBER 31

008 924 17 BOMAG 631
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Charge relief valve 9OU MAY REMOVE THE CHARGE RELIEF VALVE FOR CLEANING AND INSTALLATION OF NEW / RINGS9OU
MAY CHANGE THE PRESSURE SETTING HOWEVER NOTE THAT THE SETTING WILL VARY FOR DIFFERENT
CHARGE mOWS DEPENDING ON CHARGE PUMP SIZE AND PUMP SPEED4HE FACTORY SETTING IS SET
RELATIVE TO A SPECIlC CHARGE mOW AT ²& AND MIN RPM INPUT SPEED4HE ACTUAL
CHARGE PRESSURE VARIES AT DIFFERENT SPEEDS

Shim adjustable style (pre-blockpoint change)

/N UNITS MANUFACTURED PRIOR TO THE BLOCK POINT CHANGE YOU ADJUST THE CHARGE
PRESSURE RELIEF VALVE BY CHANGING THE NUMBER OR SIZE OF SHIMS LOCATED BEHIND THE CHARGE
PRESSURE RELIEF VALVE SPRING

2EMOVE THE SHIM ADJUSTABLE CHARGE RELIEF VALVE PLUG ' FROM THE PUMP HOUSING
2EMOVE AND DISCARD THE / RING '! FROM THE PLUG

2EMOVE SHIMS ' SPRING ' Adjustable charge relief valve components
AND POPPET ' FROM HOUSING
G040
)NSPECT THE POPPET AND MATING SEAT Shim adjustable
charge relief valve plug
IN THE HOUSING FOR DAMAGE OR FOREIGN 1 in
MATERIAL 54-136 [40-100]

G040A
)NSTALL A NEW / RING '! ON G041
O-Ring
Shims
THE CHARGE RELIEF VALVE PLUG '
2EINSTALL THE POPPET ' SPRING
' AND SHIMS ' INTO THE G043 G042
Poppet Spring
PUMP HOUSING4O CONlRM THE
CHARGE RELIEF VALVE SETTING MEASURE
THE CHARGE PRESSURE AT PORT -4HE
CHARGE PRESSURE LEVELS OFF WHEN IT
REACHES THE RELIEF SETTING

)NSTALL PLUG ' 4ORQUE TO

.M LBFsFT

E100 016E

Pressure change per shim

Approximate pressure change Shim thickness
BAR ; PSI= MM ; IN=

32 520L0638 s 2EVISION #" s .OVEMBER

632 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
Adjustments

Charge relief valve

(continued) Externally adjustable style
4HE BLOCK POINT CHANGE DISCONTINUED THE USE OF THE SHIM ADJUSTABLE CHARGE RELIEF
VALVE AND MADE THE EXTERNALLY ADJUSTABLE CHARGE RELIEF VALVE STANDARD4HE CHARGE
PRESSURE CHANGES BY APPROXIMATELY BAR PSI PER QUARTER TURN OF THE ADJUSTABLE
CHARGE RELIEF VALVE PLUG THIS APPLIES TO BOTH EXTERNAL AND INTERNAL HEX STYLE PLUGS

-ARK THE ADJUSTABLE CHARGE RELIEF VALVE PLUG 4 LOCK NUT 4 AND THE PUMP
HOUSING PRIOR TO REMOVING THE CHARGE RELIEF VALVE IN ORDER TO APPROXIMATELY DUPLICATE
THE CHARGE PRESSURE RELIEF VALVES ORIGINAL SETTING UPON REASSEMBLY

,OOSEN THE LOCK NUT 4 AND UNSCREW THE ADJUSTABLE CHARGE RELIEF VALVE PLUG
4
Externally adjustable charge relief valve
2EMOVE AND DISCARD THE / RING components
4! FROM THE ADJUSTABLE CHARGE T041
RELIEF VALVE PLUG 4 Lock nut
1 1/16 in
28 cc: .m
2EMOVE THE SPRING 4 AND $.+
POPPET 4 FROM THE HOUSING 41 cc: .m
$.+

)NSPECT THE POPPET 4 AND SEAT T039A

WITHIN THE HOUSING FOR DAMAGE O-ring
OR FOREIGN MATERIAL 2EPLACE AS T039
NECESSARY T039 Anti-stall
Adjustable adjustable charge
charge relief T042 relief valve plug
)NSTALL THE POPPET 4 AND SPRING valve plug Spring 8.5 mm
4 INTO THE HOUSING ½ in T043
Poppet
)NSTALL A NEW / RING 4! ONTO THE
ADJUSTABLE CHARGE RELIEF VALVE PLUG
4

)NSTALL THE ADJUSTABLE CHARGE RELIEF

VALVE PLUG 4 AND THE LOCK NUT
4 INTO THE HOUSING ALIGNING THE
MARKS MADE PRIOR TO DISASSEMBLY

/N CM3 MODELS TORQUE THE

LOCK NUT 4 TO .sM ; LBFsFT=
AND ON CM3 MODELS TORQUE THE
P108 128E
LOCK NUT 4 TO .sM ; LBFsFT=
4HIS MAY CAUSE MISALIGNMENT OF THE
ORIGINAL POSITION MARKS MADE EARLIER

#ONlRM THE CHARGE RELIEF VALVE SETTING BY MEASURING CHARGE PRESSURE AT THE CHARGE
PRESSURE GAUGE PORT - 4HE CHARGE PRESSURE READING SHOULD LEVEL OFF WHEN THE
RELIEF SETTING IS REACHED

520L0638 s 2EVISION #" s .OVEMBER 33

008 924 17 BOMAG 633
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Optional speed sensor 7HEN INSTALLING OR ADJUSTING THE SPEED Speed sensor replacement
SENSOR ON A PUMP YOU MUST SET IT TO A
SPECIlC DISTANCE FROM THE SPEED RING ON
THE CYLINDER BLOCK N002
1-1/16 in N002 O-ring plug
11/16 in
Removal t]
t]
,OOSEN THE LOCK NUT USING A IN
HEX WRENCH N002A
N002A

5NTHREAD THE SPEED SENSOR .

FROM THE PUMP HOUSING 2EMOVE AND
DISCARD THE / RING .!

Reassembly
!LWAYS INSTALL A NEW / RING BEFORE
REINSTALLING THE SENSOR

2EINSTALL THE SPEED SENSOR WITH LOCK

P108 081E
NUT AND / RING INTO THE HOUSING
4URN THE SENSOR CLOCKWISE #7 BY
HAND UNTIL IT CONTACTS THE SPEED RING Cross section view of speed sensor in
variable pump
4URN THE SENSOR COUNTERCLOCKWISE
##7 TURN ² TO ESTABLISH THE
NOMINAL GAP OF MM ; INCH=
Gap

4HEN TURN THE SENSOR CLOCKWISE #7

UNTIL THE WRENCH mATS ON SENSOR BODY
Speed sensor
ARE POSITIONED AT A ² ANGLE TO THE Magnetic speed ring
PUMP SHAFT CENTER LINE Cylinder block
P104 152E

-OST ADJUSTABLE WRENCHES HAVE A ²

HANDLE OFFSET Positioning speed sensor relative to
pump shaft
4HE lNAL SENSOR POSITION SHOULD BE Shaft centerline
1/2 inch wrench flats
BETWEEN ² AND TURN ²
COUNTERCLOCKWISE ##7 FROM THE 22° 22°

POINT WHERE THE SENSOR CONTACTS THE

SPEED RING Speed sensor with Speed sensor with
packard connector turck connector

(OLD SENSOR IN POSITION WITH A Shaft centerline

1/2 inch wrench flats
INCH HEX WRENCH WHILE TIGHTENING
THE LOCK NUT TO .sM ; LBFsFT=
22° 22°

Speed sensor with Speed sensor with

packard connector turck connector

P104 155E

34 520L0638 s 2EVISION #" s .OVEMBER

634 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

MDC Module Removal

4HE MANUAL DISPLACEMENT CONTROL -$# ACTUATES THE CONTROL SPOOL THROUGH A CONNECTION
TO THE SUMMING LINK PIN4HE FOLLOWING PROCEDURE DESCRIBES HOW TO REMOVE AND INSTALL THE
CONTROL #ONTROL SPOOL AND LINKAGE REMOVAL IS EXPLAINED ON PAGES AND 4

#LEAN EXTERNAL SURFACES OF THE PUMP

)F NECESSARY REMOVE THE -$# HANDLE Link pin into cam slot
$ AND DISCONNECT .33 WIRING
$

"EING CAREFUL NOT TO LOSE THE

BACKLASH SPRING $ REMOVE THE
CONTROL SPOOL PLUGS $ AND $

2EMOVE THE SEVEN CONTROL BOLTS

$ THAT SECURE THE CONTROL TO THE
PUMP HOUSING 2EMOVE THE CONTROL
$ AND GASKET % FROM THE
Summing link
PUMP $ISCARD THE GASKET pin (D011)
MUST enter
the slot in the
%NSURE THAT THE HOUSING AND CONTROL control cam
SURFACES ARE CLEAN AND FREE OF GASKET
MATERIAL )F NECESSARY CLEAN THE
SURFACES WITH SOLVENT

Installation %%
0LACE A NEW GASKET % ON THE
control module MDC module assembly
D019
D003 D016
4HE CONTROL GASKET ACTS AS REGULATING 3
/16 in D017
ORIlCES #HECK THE 0ARTS -ANUAL CM3
, OR CM3 , AND D070
YOUR ORDER CODE TO CONlRM YOU HAVE THE D002
CORRECT CONTROL GASKET D040A
T-30
D040
&OR EXACT POSITIONING PLACE

THE -$# ALIGNMENT TOOL SEE
DIMENSIONED DIAGRAM NEXT PAGE E001
D032A
7!2.).' OVER THE EXPOSED SUMMING LINK
D91
5NINTENDED VEHICLE PIN )F -$# ALIGNMENT TOOL IS NOT
MACHINE MOVEMENT AVAILABLE SKIP TO MDC alignment
D032
HAZARD -$# MUST BE without tool STEPS A A 7/8 in
ALIGNED TO THE HOUSING
WITHIN INCH 3LIDE THE -$# $ OVER THE TOOL
)NACCURATE ALIGNMENT WHILE ENGAGING THE TOOL WITH THE SLOT
D035A
MAY CAUSE NEUTRAL TO IN THE -$# CAM AND ALLOW IT TO PASS
BE OFF CENTER OR MAKE IT THROUGH THE HOLE ON THE FRONT OF THE
IMPOSSIBLE TO SET -$# HOUSING
D035
5/16 in P108 087E
)NSTALL THE CONTROL SCREWS $ AND
TORQUE TO .sM ; LBFsFT=

520L0638 s 2EVISION #" s .OVEMBER 35

008 924 17 BOMAG 635
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

MDC Module (continued) 2EMOVE THE ALIGNMENT TOOL AND INSTALL PLUG $ TORQUE TO .sM ; LBFsFT=

2EPLACE THE SPRING $ AND SPOOL PLUGS $ AND $

!DJUST CONTROL NEUTRAL SEE PAGE MDC cam

MDC alignment without tool.

)F THE -$# ALIGNMENT TOOL IS NOT
AVAILABLE IT IS POSSIBLE TO LOCATE THE Point of
contact
APPROXIMATE POSITION OF THE PIN BY Summing
CREATING AN IMAGINARY CIRCLE AT THE link pin Imaginary circle
CORRECT LOCATION AS INDICATED IN THE
ILLUSTRATION4HE POINT AT WHICH THE
MDC cam
IMAGINARY CIRCLE CONTACTS THE SLOT IN THE
CAM IS THE SUGGESTED CONTACT POINT OF 0%
THE SUMMING LINK PIN7HEN ENGAGING
THE PIN IN THE CAM SLOT YOU MAY NEED TO MDC alignment tool
USE A mAT TOOL SUCH AS A SCREWDRIVER TO 16 mm
POSITION THE LINKAGE 6 mm Ø [0.63 in]
[0.236 in]
6.97 mm -0.05 Ø
&OR PROPER CONTROL OPERATION THE [0.2744 in -0.002]
SUMMING LINK MUST ENGAGE THE SLOT ON 20 mm 5.06 mm +0.05 Ø
THE CONTROL MODULE &OR EXACT PLACEMENT [0.79 in] [0.1992 in +0.002]
USE THE ALIGNMENT TOOL SHOWN ~ 100 mm
[3.94 in] 0%

A )NSTALL AND HAND TIGHTEN THE SEVEN MACHINED FROM MILD STEEL
CONTROL RETAINING SCREWS AND THEN
BACK OFF EACH SCREW ONE TURN Torque patterns (MDC, EDC and HC-EDC)
TORQUE BOLTS IN ORDER INDICATED
A !DJUST THE CONTROL POSITION SO THAT
THE SUMMING LINK PIN IS ALIGNED AS 4 3 6
DESCRIBED ABOVE AND TORQUE BOLTS
$ TO .sM ; LBFsFT=
1
A 2EPLACE THE COVER PLUG $ AND
TORQUE TO .sM ; LBFsFT= 7
2 5
#ONTINUE ABOVE TO STEP
8 Torque this bolt
first & last
P108 082E

36 520L0638 s 2EVISION #" s .OVEMBER

636 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

HC-EDC and EDC Module 4HE (IGH #URRENT %LECTRIC $ISPLACEMENT #ONTROL (# %$# AND THE %LECTRIC $ISPLACEMENT
#ONTROL %$# ACTUATE THE CONTROL SPOOL VIA A CONNECTION TO THE SUMMING LINK PIN4HE
FOLLOWING PROCEDURE DESCRIBES HOW TO REMOVE AND REPLACE THE CONTROL HOUSING

Removal
#LEAN THE EXTERNAL SURFACES OF THE PUMP )F NECESSARY REMOVE CONTROL INPUT

"EING CAREFUL NOT TO LOSE THE BACKLASH SPRING $ REMOVE THE CONTROL SPOOL PLUGS
$ AND $

2EMOVE THE SEVEN CONTROL BOLTS $$ .OTE THE POSITION OF THE DIFFERENT
LENGTH SCREWS 2EMOVE THE CONTROL AND CONTROL GASKET % FROM THE PUMP

EDC module assembly

D082
&&
D081
&& T-30
.&
T-30
% . ,
.&
% . ,

#'
.&
% . ,
E001 D032
D032A
(%
'
#')(+#,#('

-&&#'!
%#'$)#'
',r
,""(%#',"
(',*(%+%#*
D035A %($

D035
#'
.&
% . , P108 085E

520L0638 s 2EVISION #" s .OVEMBER 37

008 924 17 BOMAG 637
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

HC-EDC and EDC Module Replacement

(continued) #LEAN THE SEALING SURFACES OF THE CONTROL AND THE PUMP HOUSING 0LACE A NEW GASKET
% IN POSITION ON THE HOUSING
7!2.).'
&AILURE TO PROPERLY ENGAGE 4HE CONTROL ORIlCES ARE PART OF THE CONTROL GASKET 2EFER TO THE APPROPRIATE 3ERVICE 0ARTS
THE SUMMING LINK PIN WITH ,IST TO DETERMINE THE CORRECT GASKET
CONTROL SLIDER BLOCK WILL
result in incorrect control Torque patterns (MDC, EDC and HC-EDC)
OPERATION WHICH MAY LEAD  (OLD THE SUMMING LINK PIN $ TORQUE BOLTS IN ORDER INDICATED
TO LOSS OF CONTROL OF THE IN POSITION WHILE INSTALLING THE
VEHICLE MACHINE CONTROL4HE LINK PIN -534 ENGAGE 4 3 6
THE HOLE IN THE CONTROL SLIDER BLOCK
SEE DIAGRAM ON PREVIOUS PAGE
1

,AY THE SERVO PISTON SIDE OF THE CONTROL

7
DOWN lRST THEN WATCH THE LINK PIN
2 5
ENGAGE FROM THE CHARGE PUMP SIDE OF
THE PUMP
8 Torque this bolt
first & last
)NSTALL THE CONTROL BOLTS $$ P108 082E
TORQUE TO .sM ; LBFsFT=

2EPLACE THE SPRING $ )NSTALL NEW

/ RINGS ON CONTROL SPOOL PLUGS $
AND $ )NSTALL PLUGS AND TORQUE
TO .sM ; LBFsFT=

!DJUST THE NEUTRAL POSITION OF THE

CONTROL AS SHOWN ON PAGE

38 520L0638 s 2EVISION #" s .OVEMBER

638 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

MDC/EDC Spool, linkage, 9OU MAY REMOVE THE CONTROL SPOOL CONTROL LINKAGE AND CONTROL NEUTRAL ADJUSTMENT SCREW
and neutral adjustment FOR CLEANING AND TO CHANGE THE / RINGS OR THE SEAL LOCK NUT
screw
Removal
#LEAN THE EXTERNAL SURFACES OF THE PUMP

2EMOVE THE -$# %$# OR (# %$# MODULE AND THE CONTROL GASKET FROM THE PUMP
HOUSING $ISCARD GASKET 3EE PAGES THROUGH 3 FOR CONTROL REMOVAL PROCEDURE

2EMOVE THE SUMMING LINK $ .OTE THE MANNER IN WHICH THE PARTS ARE ASSEMBLED
AND THE WAY THE SUMMING LINK ENGAGES THE CONTROL SPOOL $

2EMOVE THE SUMMING LINK BY SLIDING IT OFF THE FEEDBACK LINK

MDC/EDC/HC-EDC spool and linkage

D011
D010 D015

D012 D014
D013 D032
D91 7/8 in

D90
D090

D035
5
/16 in

F034

F035

P036
T-30

P108 086E

520L0638 s 2EVISION #" s .OVEMBER 39

008 924 17 BOMAG 639
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

MDC / EDC Spool, linkage, 5SING A MM INTERNAL HEX WRENCH REMOVE THE SUMMING LINK PIVOT PIN $
and neutral adjustment 3LIDE THE FEEDBACK LINK $ TOWARDS THE SERVO PISTON TO DISENGAGE THE NEUTRAL
screw (continued) ADJUSTMENT LINK $ 9OU CAN NOW REMOVE ALL LINKAGES

2EMOVE THE TWO BORE PLUGS $ AND $ .OTE THE ORIENTATION OF THE CONTROL
SPOOL $ AND WHICH SIDE OF THE PUMP THE SPRING $ IS LOCATED SPRING IS ON THE
OPPOSITE SIDE FROM THE lLTER ADAPTER 2EMOVE SPRING AND SPOOL

0RIOR TO THE BLOCK POINT CHANGE THE FULL FEATURED CM3 HOUSING FOR THE 3ERIES
PUMP USED A CONTROL SPOOL COVER & GASKET & AND TWO SCREWS & INSTEAD OF
A BORE PLUG ON THE CONTROL SPOOLS NON SPRING SIDE $ISCARD THE CONTROL GASKET & AND
THOROUGHLY CLEAN THE MATING SURFACE

2EMOVE THE CONTROL NEUTRAL ADJUSTMENT SEAL NUT $ AND SCREW $

Installation
)NSTALL THE CONTROL NEUTRAL ADJUSTMENT SCREW $ AND SEAL LOCK NUT $ $O NOT
TIGHTEN THE NUT

,UBRICATE AND INSTALL THE CONTROL SPOOL $ AND SPRING $ NOTING PROPER
ORIENTATION )NSTALL THE TWO SIDE BORE PLUGS AND TORQUE TO .sM ; LBFsFT=

2EPLACE THE SUMMING LINK FEEDBACK LINK AND NEUTRAL ADJUSTMENT LINK

&IRST COMBINE THE CENTER PIN OF THE FEEDBACK LINK $ WITH THE MATING BORE OF THE
NEUTRAL ADJUSTMENT LINK $ )NSERT THE END OF THE FEEDBACK LINK INTO THE SERVO
PISTON SLOT -ATE THE NEUTRAL ADJUSTMENT LINK WITH THE CONTROL NEUTRAL ADJUSTMENT
SCREW $ )NSERT THE LINKAGE PIVOT SCREW $ AND TORQUE TO .sM ; LBFsFT=
)NSTALL THE SUMMING LINK $ )T MAY BE NECESSARY TO ROTATE THE CONTROL SPOOL SO
THAT THE SUMMING LINK FORK ENGAGES THE mATS ON THE CONTROL SPOOL

)NSTALL THE -$# %$# OR (# %$# ACCORDING TO PROCEDURES ON PAGES THROUGH

Servo piston linkage and control spool Feedback link (D012) must
enter slot in servo piston
D010
D091
4 mm Internal hex nut
Backlash spring

40 520L0638 s 2EVISION #" s .OVEMBER

640 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

MDC Neutral start / 4HE .EUTRAL 3TART 3WITCH .33 PREVENTS THE ENGINE AND PUMP FROM STARTING WHEN THE
backup alarm switch PUMP CONTROL HANDLE IS NOT IN NEUTRAL4HE .33 SHOULD BE WIRED IN SERIES WITH THE ENGINE
STARTING CIRCUIT4HE SWITCH CONTACT IS CLOSED AT THE CONTROL HANDLES NEUTRAL POSITION AND
OPENS WHEN THE CONTROL HANDLE IS ROTATED ² TO ² FROM NEUTRAL

4HE "ACKUP !LARM 3WITCH "!3 CLOSES WHEN THE CONTROL HANDLE IS IN A REVERSE POSITION
4HIS SWITCH IS NORMALLY WIRED IN SERIES WITH A BACKUP ALARM4HE SWITCH CONTACT IS OPEN
UNTIL THE CONTROL HANDLE IS ROTATED ² TO ² IN THE REVERSE DIRECTION 

7!2.).' Top view of NSS showing NSS cam positions

4HE CONTROL HANDLES
neutral position must
CONFORM TO THE PUMPS
NEUTRAL POSITION FOR
THE .33"!3 TO WORK
EFFECTIVELY 3EE PAGE FOR
control neutral adjustment
Control Control Control
Yoke cam Yoke cam Yoke cam

NSS cam NSS cam

I. NSS ONLY II. NSS WITH BAS III. NSS WITH BAS
(CW = REVERSE) (CCW = REVERSE)
0%

9OU CAN CONlGURE THE .33"!3 ASSEMBLY FOR THREE DIFFERENT SETTINGS
) .33 ONLY
)) .33 WITH "!3 FOR UNITS WHERE CLOCKWISE #7 HANDLE ROTATION RESULTS IN REVERSE
MOTION
))) .33 WITH "!3 FOR UNITS WHERE COUNTERCLOCKWISE ##7 HANDLE ROTATION RESULTS IN
REVERSE MOTION

4HE SETTING MUST BE IN ACCORDANCE WITH THE CONlGURATION OF THE UNIT 3EE THE MODEL
CODE IF UNCERTAIN OF THE TYPE OF .33 SETTING THE MACHINE IS EQUIPPED WITH

!DJUSTMENT IS NORMALLY NOT REQUIRED UNLESS THE FUNCTION OF THE .33 IS CHANGED BETWEEN
) )) OR )))

!DJUSTMENT OF THE .33 OR .33 AND

"!3 REQUIRES A SPECIAL ALIGNMENT TOOL Alignment tool
$IMENSIONS APPEAR AT RIGHT 4HE TOOL 0.04 x 45°
9/16 -18 UNF 2A thread
R 0.125 Ø 0.236 -0.03
POSITIONS THE CAM PRECISELY RELATIVE TO chamfer
Knurl
THE CONTROL HOUSING
35.0
1.250
0.306 0.354
2.000
Material: 0.75 Ø x 3 ETD150 0%
(All dimensions in inches)

520L0638 s 2EVISION #" s .OVEMBER 41

008 924 17 BOMAG 641
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

MDC Neutral start / 2EMOVE THE -$# MODULE FROM THE Side view of NSS and NSS cavity
backup alarm switch PUMP HOUSING 23.3 mm D039
(continued) D038
5SING A IN HEX WRENCH REMOVE 8 mm
THE .33"!3 $ m
1 mm D037

5SING A SCREWDRIVER TO PRY IT OUT
REMOVE AND DISCARD THE .33 COVER
$ "E CAREFUL NOT TO DAMAGE THE
D040
INTERNAL HARDWARE 7
/8 in
m
5SING AN MM HEX SOCKET REMOVE
THE NUT $ 0%

0RY THE CAM $ OFF THE SHAFT Apply locking pliers here.

/N THE UNDERSIDE OF THE -$#

MODULE GENTLY CLAMP A PAIR OF
LOCKING PLIERS AROUND THE SPRING
CONTACTS OF THE CONTROL CAM "E
CAREFUL NOT TO DAMAGE THE SPRING
WIRES4HE PLIERS HOLD THE NUB ON THE
CONTROL CAM TO THE PIN UNDERNEATH
4HIS HOLDS THE CONTROL CAM IN NEUTRAL
POSITION

3ET THE .33 CAM $ IN THE 0

PROPER ORIENTATION ) )) OR ))) 3EE THE
ILLUSTRATION ON PREVIOUS PAGE NSS assembly on MDC

4HREAD THE ALIGNMENT TOOL INTO THE D040

(with weatherpack
.33 CAVITY TO HOLD THE CAM IN PLACE connector)
D040
)NSTALL THE NUT $ ONTO THE CAM (with screw
terminals)
AND TORQUE TO .sM ; LBFsFT=

5SING AN APPROPRIATE PRESS PRESS

A NEW COVER $ INTO THE CAM
NSS Cavity
CAVITY5SE A TOOL WITH A DIAMETER OF
MM ; IN=0RESS THE NEW COVER
SO THAT IT SITS MM ; IN= BELOW THE
CAST SURFACE AS ILLUSTRATED ABOVE

2EMOVE THE ALIGNMENT TOOL AND

LOCKING PLIERS
D037
,UBRICATE AND INSTALL A NEW / RING ON D038
THE .33 $ AND INSTALL THE .33 TO D039 P108 088E

THE -$#4ORQUE TO .sM ; LBFsFT=

2EINSTALL THE -$# MODULE ONTO THE

PUMP HOUSING AS SHOWN ON PAGES AND 3
42 520L0638 s 2EVISION #" s .OVEMBER
642 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

MDC Solenoid override 4HE SOLENOID OVERRIDE VALVE IS A SAFETY Solenoid override assembly
valve FEATURE THAT SHUNTS BOTH ENDS OF THE D056B
SERVO CONTROL PISTON WHEN THE SOLENOID IS 3
/4 in
DE ENERGIZED4HE PUMP WILL STROKE ONLY "
D056 "!
WHEN THE VEHICLE CONTROLS ENERGIZE THE
SOLENOID
D056C
4HE SOLENOID OVERRIDE WITH BRAKE RELEASE D054
OPTION ALLOWS HYDRAULIC CONTROL OF A
SPRING APPLIED HYDRAULICALLY RELEASED
BRAKE7HEN DE ENERGIZED THE BRAKE D056 D056D
DRAINS THROUGH PORT 8
D056A
Removal D056F
5SING A INCH WRENCH REMOVE THE
COIL NUT $" FROM THE VALVE STEM D056G

2EMOVE THE COIL $ AND WASHER

D053
$#
P108 099E
5SING SNAP RING PLIERS REMOVE THE
RETAINING RING $ AT THE BASE OF
THE SOLENOID

2EMOVE THE VALVE STEM $$

PLUNGER $' SPRING $& AND
SPOOL $

2EMOVE THE / RING $! FROM THE

STEM AND DISCARD IT

Installation
,UBRICATE AND INSTALL A NEW / RING
$! ON THE VALVE STEM $$ Po ! X7

0LACE THE SPRING $& AND THE PLUNGER $' INSIDE OF THE STEM

!TTACH THE SPOOL $ TO THE PLUNGER $'

)NSERT THE SOLENOIDSPOOL ASSEMBLY INTO THE SOLENOID OVERRIDE CAVITY

5SING SNAP RING PLIERS INSTALL THE RETAINING RING $

)NSTALL THE WASHER $# ONTO THE VALVE STEM

)NSTALL THE COIL $ AND COIL NUT $" AND TORQUE TO .sM ; LBFsFT= $O NOT
OVER TORQUE COIL NUT

520L0638 s 2EVISION #" s .OVEMBER 43

008 924 17 BOMAG 643
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

FNR, NFPE, and NFPH 4HE &.2 .&0% AND .&0( ARE NON FEEDBACK TYPE CONTROLS4HE &.2 AND .&0% CONTROLS
Controls (bolt-on valves) CONSIST OF EXTERNAL SOLENOID ACTUATED SPOOL VALVES MOUNTED ON THE PUMP HOUSING4HE
PUMP RECEIVES HYDRAULIC INPUT FOR .&0( THROUGH PORTS ON THE PUMPS CONTROL SURFACE
n 3!% / RING BOSS PORT 4HESE PORTS CONNECT DIRECTLY TO THE SERVO PISTON

9OU MAY REMOVE THE &.2 AND .&0% CONTROLS TO CLEAN THE PORTS AND REPLACE THE / RINGS
HOWEVER THE CONTROLS ARE NOT SERVICEABLE4HE GASKET % CONTAINS CONTROL ORIlCES
/RIlCE PLUGS FOR .&0( PUMPS ARE BENEATH THE SERVO COVERS

Removal of FNR and NFPE modules (bolt-on valves)

#LEAN THE PUMP AND CONTROL HOUSINGS

2EMOVE THE FOUR SCREWS $ RETAINING THE MODULE TO THE HOUSING AND REMOVE
THE MODULE $ FROM THE PUMP HOUSING

2EMOVE AND DISCARD THE FOUR / RINGS $! %XAMINE THE PORTS FOR CLEANLINESS

Installation of FNR and NFPE modules (bolt-on valves)

#LEAN THE SEALING SURFACES )NSTALL NEW GASKET %

5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW / RINGS $! IN THE BOTTOM OF
THE CONTROL

2EPLACE THE BOLTS $ AND TORQUE TO .sM ; LBFsFT=

NEUTRAL ADJUST BOLT SIDE

FNR and NFPE assembly (bolt-on valves) D081

4 mm
Bolt torque patterns

Torque bolts in order indicated
D004
2 3

4 1

D004A
2 3

4 1

P101 580E
E074 41/51cc
Frame Size

P108 100E

44 520L0638 s 2EVISION #" s .OVEMBER

644 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

FNR, NFPE, and NFPH 4HE &.2 AND .&0% ARE NON FEEDBACK TYPE CONTROLS4HE &.2 AND .&0% CONTROLS CONSIST OF
Controls (integral valves) SOLENOID ACTUATED SPOOL VALVES MOUNTED ON THE PUMP HOUSING

9OU MAY REMOVE THE VALVES TO CLEAN THE PORTS AND REPLACE THE / RINGS HOWEVER THE
VALVES ARE NOT SERVICEABLE

Removal of FNR and NFPE modules (integral valve style)

#LEAN THE PUMP AND CONTROL HOUSINGS

2EMOVE THE COIL NUTS $ AND COILS $ $ISCARD / RINGS $ AND $ FROM
.&0% COILS

2EMOVE VALVE ACTUATER STEMS $ AND DISCARD / RINGS

%XAMINE THE PORTS FOR CLEANLINESS

Installation of FNR and NFPE modules (integral valve style)

#LEAN THE VALVES AND PORTS

)NSTALL NEW / RINGS ON VALVE ACTUATOR STEMS $

)NSTALL ACTUATOR STEMS $ AND TORQUE TO .sM ; LBFsFT=

)NSTALL COIL $ 5SE NEW / RINGS $ AND $ WITH .&0% COILS

4ORQUE COIL NUT PER ILLUSTRATION

FNR and NFPE assembly (integral valves)

D060 7/8 inch

"
"
D061 D062
D099 3/4 inch
includes
"
D063
and D064 "
D063
D061

D060 D064 D062

3/4 inch
"
1 inch "
"
" P108 123E

520L0638 s 2EVISION #" s .OVEMBER 45

008 924 17 BOMAG 645
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

System Check Relief 4HE 3YSTEM #HECK 2ELIEF VALVE ASSEMBLY System check relief valve components
(SCR) valves (high PERFORMS THE CHARGE CHECK HIGH PRESSURE K007
pressure relief, charge RELIEF AND LOOP BYPASS FUNCTIONS9OU 1 inch WITH
%" BYPASS
check, and bypass valves) MAY REMOVE THIS ASSEMBLY FOR CLEANING
AND REPLACEMENT OF / RINGS4HE MODEL !%$
WITHOUT
CODE SPECIlES WHICH CONlGURATION OF BYPASS
3#2 VALVES YOUR PUMP USES K007 K008
5
/16 mm K009
K008 K010
5SING A INCH WRENCH OR A %"
K009
INCH INTERNAL HEX WRENCH REMOVE !%$ ]
K010
THE VALVE SEAT PLUGS + FROM THE
J005
PUMP HOUSING 2EMOVE AND DISCARD
THE / RINGS AND BACKUP RINGS +
+ AND +
H005

2EMOVE THE CHECK POPPETRELIEF

VALVE ASSEMBLIES (* FROM THE
P108 089E
PUMP HOUSING

)NSPECT THE VALVES AND MATING SEATS

IN THE VALVE SEAT PLUGS + FOR
DAMAGE OR FOREIGN MATERIAL

4HE 3#2 VALVES (* ARE NON

SERVICEABLE REPLACE AS A COMPLETE UNIT

)NSTALL NEW OUTER / RING +

BACKUP RING + AND INNER / RING
+ ON EACH VALVE SEAT PLUG

6ERIFY THAT THE CONICAL SPRINGS ARE

PROPERLY RETAINED ON THE CHECK
POPPETSRELIEF VALVES (* )NSTALL THE CHECK POPPETRELIEF VALVE ASSEMBLIES
INTO THE PUMP HOUSING %NSURE THAT THE VALVE ASSEMBLY MOVES FREELY IN ITS BORE

5SING A INCH WRENCH OR A INCH INTERNAL HEX WRENCH INSTALL THE VALVE SEAT PLUGS
OR VALVE SEATBYPASS PLUGS INTO THE PUMP HOUSING AND TORQUE TO .sM ; LBFsFT=

46 520L0638 s 2EVISION #" s .OVEMBER

646 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Filtration adapters Filter-related pump hardware

&ILTRATION SYSTEMS FOR 3ERIES PUMP INCLUDE FULL mOW SUCTION lLTRATION PRESSURE
lLTRATION AND PARTIAL mOW PRESSURE lLTRATION 3AUER $ANFOSS PROVIDES A lLTRATION ADAPTER
FOR EACH CONlGURATION )F lLTRATION IS PROVIDED ELSEWHERE IN THE HYDRAULIC CIRCUIT THE
PUMP MAY NOT HAVE A lLTRATION ADAPTER
Housing with ﬁltration adapter
0UMPS HOUSINGS WITHOUT lLTRATION R043
ADAPTERS HAVE AN UNUSED AND PLUGGED Pre 1998: 7/8 in
CONSTRUCTION BORE NEXT TO THE CHARGE !
#
RELIEF VALVE7HEN THESE PUMPS USE #!
SUCTION lLTRATION THE FACTORY PLUGS
EXTERNAL CHARGE INLET
R042 (x7)
0UMP HOUSINGS WITH lLTRATION ADAPTERS
R040
HAVE AN APPROPRIATE ADAPTER AND GASKET T30
4HE POSITION OF THE - GAUGE PORT #
#!
VARRIES DEPENDING ON lLTRATION TYPE
R041
0UMPS MANUFACTURED AFTER HAVE
lLTER ADAPTER SCREWS THAT ARE MM
; IN= LONGER THAN THE SCREWS USED ON P108 090E

PRE PUMPS4HE LONGER SCREWS ARE

ONLY COMPATIBLE WITH POST PUMPS

Removal
#LEAN THE EXTERIOR OF THE PUMP

2EMOVE ANY HOSES OR PIPING FROM

THE lLTER ADAPTER

5SING A 4 4ORX DRIVER OR MM

INTERNAL HEX REMOVE THE SIX SCREWS Housing without ﬁltration adapter
2 SECURING THE lLTER ADAPTER TO
THE HOUSING
G004
2EMOVE THE lLTER ADAPTER 2

2EMOVE THE GASKET 2 AND

DISCARD4HOROUGHLY CLEAN ALL MATING
SURFACES

R045
5/8 in
P108 091E

Suction Filtration Only

520L0638 s 2EVISION #" s .OVEMBER 47

008 924 17 BOMAG 647
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Filtration adapters Replacement

(continued) )NSTALL A NEW GASKET 2 AND PLACE THE lLTER ADAPTER 2 ON THE HOUSING

5SING A 4 4ORX DRIVER OR MM INTERNAL HEX INSTALL BOLTS 2 AND TORQUE TO
.sM ; LBFsFT=

Bolt torque patterns

TORQUE BOLTS IN THE ORDER INDICATED
3
6
5

1
2
8
4 Torque this bolt 7
first and last
0

48 520L0638 s 2EVISION #" s .OVEMBER

648 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Auxiliary pad/charge 5SE THE FOLLOWING PROCEDURE TO INSTALL A NEW GASKET 5 OR TO CHANGE THE AUXILIARY PAD
pump cover OPTION 0ADS ARE AVAILABLE FOR 3!% ! AND 3!% " AUXILIARY PUMPS OR FOR OPTIONS WITH NO
AUXILIARY PAD

4HE CHARGE PUMP COVER INTEGRATES THE AUXILIARY MOUNTING PAD7HEN NO AUXILIARY PUMP
IS PRESENT ON AN 3!% ! OR 3!% " STYLE PAD THE PAD INCLUDES A SHIPPING PLATE 5 AND
/ RING 5

Removal of charge pump cover/auxiliary pad

/RIENT THE PUMP SO THAT THE CHARGE PUMP COVER OR PAD 5 IS FACING UP

)F PRESENT REMOVE THE AUXILIARY PUMP OR COVER 5 BY REMOVING THE TWO SCREWS
5 $ISCARD THE / RING 5

2EMOVE SCREWS 5 RETAINING THE CHARGE PUMP COVERPAD 2EMOVE THE CHARGE
PUMP COVERPAD 5 AND GASKET 5 9OU MAY REUSE THE GASKET #LEAN ALL
MATING SURFACES

2EMOVE AND DISCARD CHARGE PUMP SEAL ' ,EAVE ALIGNMENT PINS IN THE HOUSING

Auxiliary pad options

U040
No pad charge
U035 (x8) pump cover
6 mm
-$
#-)]

(x8)
U090
9 U035 G023
/16 in
-$
#-)] U080
U085
U030

U040
U035 SAE-A pad

U090
3
/4 in (x8)
-$
#-)]

U040
SAE-B pad
U080 P108 103E

U085

520L0638 s 2EVISION #" s .OVEMBER 49

008 924 17 BOMAG 649
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Auxiliary psd/charge Bolt torque patterns

pump cover Installation
TORQUE BOLTS IN ORDER INDICATED
(continued) )NSPECT THE CHARGE PUMP COVERPAD
GASKET 5 AND MATING SURFACES
)F UNDAMAGED YOU MAY REUSE THE
6 2 4 8
GASKET 2EPLACE THE GASKET IF YOU
SUSPECT LEAKAGE )NSTALL THE GASKET

)NSTALL A NEW CHARGE PUMP COVERPAD

SEAL '

)NSTALL THE CHARGE PUMP COVER

PAD 5 5SING A MM INTERNAL
HEX TORQUE THE SIX OR SEVEN BOLTS
3 1
5 TO .sM ; LBFsFT= USING THE
PATTERN AT THE RIGHT 7 5
9
2EPLACE THE / RING 5 AND Torque this bolt first and last.
COVER PLATE 5 OR AUXILIARY
PUMP )NSTALL AND TORQUE THE TWO
MOUNTING SCREWS 5 &OR 3!% !
PADS TORQUE THE MOUNTING SCREWS 6 2 4 8
TO .sM ; LBFsFT= &OR 3!% " PADS
TORQUE THE MOUNTING SCREWS TO
.sM ; LBFsFT=

4HE THREADED SCREW HOLES IN THE AUXILIARY

PUMP MOUNTING PAD IN EARLY PRODUCTION
PUMPS WITH THE 3!% ! PAD OPTION GO
CLEAR THROUGH THE CHARGE PUMP COVER
5SE -X INTERNAL HEX SET SCREWS TO 3 1
PLUG ANY HOLES NOT USED TO ATTACH THE
COVER PLATE OR AUXILIARY PUMP )NSTALL 7 5
HAND TIGHT TO PREVENT THE ENTRANCE OF 9
FOREIGN MATERIAL INTO THE PUMP Torque this bolt first and last
P108 083E

50 520L0638 s 2EVISION #" s .OVEMBER

650 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Charge pump 9OU MAY DISASSEMBLE THE CHARGE PUMP TO INSPECT CLEAN OR TO CHANGE THE AUXILIARY SHAFT
DRIVE COUPLING 5 0OST PUMPS CONTAIN A NUMBER OF NON INTERCHANGEABLE PARTS
WITHIN THE CHARGE PUMP SYSTEM

s 0RE PUMPS HAVE A GEROTOR DRIVE COUPLING WITH A DRIVE PIN FOR THE GEROTOR
ELEMENT WHILE POST RELEASE PUMPS WILL CONTAIN A COUPLING WITH A PARALLEL DRIVE
KEY4HIS CHANGE ALSO RESULTS IN A CHANGE TO THE GEROTOR SET7HEN SERVICING THE
GEROTOR THESE TWO ELEMENTS MUST BE PLACED IN COMBINATION ! SERVICE KIT IS AVAILABLE
FOR PRE CHARGE PUMPS 2EFER TO SERVICE BULLETIN

s 0OST RELEASE PUMPS ALSO CONTAIN A COUPLING WITH A RETAINING RING TO POSITIVELY
LOCATE THE COUPLING IN THE ASSEMBLY4HIS CHANGE ELIMINATED THE NEED FOR A COUPLING
SPACER

s 4HE OUTER STEP ON THE GEROTOR COVER Charge pump components

HAS BEEN REMOVED ON THE POST G023
RELEASE PUMPS
G020
Disassembly
2EMOVE ALIGNMENT PINS 5
G015
2EMOVE THE GEROTOR COVER ASSEMBLY
' 2EMOVE AND DISCARD U015
GEROTOR COVER / RING ' EARLY Use feeler
gauge
PRODUCTION 3!% ! PAD MODELS MAY G005
CONTAIN TWO OR THREE SEALS ONLY THE Keyway
INNER ' SEAL IS REQUIRED G010

2EMOVE THE DRIVE COUPLING 5 G006

U025
AND GEROTOR GEAR SET ' 2EMOVE U025
G065
RETAINING RING '

2EMOVE THE GEROTOR DRIVE PIN OR KEY

' 2EMOVE THE GEROTOR COVER
LOCATING PIN '

)NSPECT THE GEROTOR ASSEMBLY '

%NSURE THE UPPER AND LOWER SURFACES
OF THE GEROTOR ARE FREE OF NICKS AND
GROOVES4HE MATING SURFACES OF
THE INNER AND OUTER GEARS SHOULD
lT SNUGLY AND CREATE A TIGHT SEAL
)NSPECT THE KEYWAY FOR MAJOR WEAR )T P108 092E

IS NORMAL TO lND A SMALL IMPRESSION

FROM THE DRIVE PIN ' -EASURE
GEROTOR TIP CLEARANCE FOR WEAR
ILLUSTRATED ABOVE 3EAT THE GEROTOR ASSEMBLY INTO THE GEROTOR COVER AND ALIGN THE
ASSEMBLY SO THAT ONE OF THE TIPS OF THE INNER GEAR FULLY ENGAGES A VALLEY IN THE OUTER
GEAR 5SING A FEELER GAUGE MEASURE THE CLEARANCE OF THE OPPOSITE TIP #LEARANCE
SHOULD BE MM ; INCH= OR LESS 2EPLACE THE GEROTOR IF NECESSARY4HE
GEROTOR ASSEMBLY IS MACHINED AS A MATCHED PAIR

520L0638 s 2EVISION #" s .OVEMBER 51

008 924 17 BOMAG 651
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Charge pump )NSPECT THE DRIVE PIN OR KEY ' TO ENSURE THAT THE EDGES ARE NOT ROUNDED AND
(continued) THAT THE DRIVE COUPLINGS INTERNAL SPLINES ARE STRAIGHT AND FREE OF DAMAGE ON BOTH
ENDS #HECK FOR WEAR ON THE TOP AND BOTTOM SURFACES 2EPLACE THE DRIVE PIN OR KEY IF
WORN

)NSPECT THE GEROTOR COVER ' )T SHOULD BE FREE OF NICKS AND SCRATCHES4HE DRIVE
COUPLING JOURNAL BEARING ' IS ON THE INSIDE DIAMETER OF THE SMALL BORE OF THE
ALUMINUM GEROTOR COVER4HE DRIVE COUPLING SHOULD lT THE JOURNAL BEARING WITH
A RELATIVELY CLOSE lT )F THE COUPLING HAS WORN THROUGH THE BEARING AND INTO THE
ALUMINUM GEROTOR COVER REPLACE THE GEROTOR COVER AND DRIVE COUPLING )F THE lT IS
EXCESSIVELY LOOSE AND THE DRIVE COUPLING HAS NOT WORN INTO THE GEROTOR COVER REMOVE
THE OLD JOURNAL BEARING FROM THE GEROTOR COVER AND PRESS A NEW JOURNAL BEARING INTO
THE COVER FROM THE CAVITY SIDE 0RESS THE BEARING TO A DEPTH OF MM ; IN=
FROM THE BOTTOM CAVITY SIDE OF THE GEROTOR COVER

Assembly
)NSTALL THE TWO CHARGE PUMP COVERPAD ALIGNMENT PINS 5

)NSTALL THE GEROTOR COVER LOCATING PIN

' Charge pump orientation looking inside of
gerotor pump cover
)NSTALL THE CM3 SPACER NOT SHOWN G020
IF PREVIOUSLY REMOVED 3PACERS EXIST
12.88 mm
ON THE OLDER CM3 MODELS G015 [0.507 in]

)NSTALL THE DRIVE PIN OR KEY '

INTO THE DRIVE COUPLING 5SE
PETROLEUM JELLY TO HOLD IT IN PLACE

,UBRICATE AND INSTALL THE GEROTOR

SET ' ONTO THE DRIVE COUPLING CW CCW
5 !LIGN THE NOTCH IN THE INNER 0%
GEAR WITH THE DRIVE PIN OR KEY '

)F PRESENT INSTALL THE RETAINING RING ' ONTO THE DRIVE COUPLING

7ITH THE SMALLER END OF THE DRIVE COUPLING 5 FACING UP INSTALL THE DRIVE COUPLING
AND GEROTOR ONTO THE SHAFT

$IFFERENT DRIVE COUPLINGS ARE USED WITH DIFFERENT CHARGE PUMP COVERS

0LACE THE GEROTOR COVER ASSEMBLY '' OVER THE GEROTOR ASSEMBLY AND ROTATE
UNTIL THE COVER ENGAGES THE ORIENTATION PIN4HE COVER lTS mAT

,UBRICATE THE NEW GEROTOR COVER / RING ' WITH PETROLEUM JELLY AND PLACE IT ON
THE GEROTOR COVER ' %ARLY PRODUCTION ! PAD MODELS MAY CONTAIN TWO OR THREE
SEALS

)NSTALL THE CHARGE PUMP COVER GASKET CHARGE PUMP COVER AND AUXILIARY PUMP

52 520L0638 s 2EVISION #" s .OVEMBER

652 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Charge pump Units without integral charge pump

(continued) 6ARIABLE PUMPS WITHOUT AN INTEGRAL CHARGE PUMP HAVE A SPACER ' IN THE LOCATION
WHERE THE GEROTOR ASSEMBLY GOES ! PLUG . BLOCKS THE CHARGE PUMP INLET PORT
0UMPS WITHOUT AN INTEGRAL CHARGE PUMP THAT ARE NOT MACHINED TO ACCEPT A lLTRATION
ADAPTER CONTAIN A CHARGE PUMP DEFEAT PLUG 2 IN THE GEROTOR CAVITY OUTLET !N / RING
2! HOLDS THIS PLUG IN PLACE ,ATER MODELS HAVE AN - THREAD IN THE EXPOSED END OF
THE PLUG FOR EASIER REMOVAL 2EPLACE THE / RING WHEN REMOVING THE PLUG

0UMPS WITHOUT AN INTEGRAL CHARGE PUMP THAT ARE MACHINED TO ACCEPT A lLTRATION ADAPTER
DO NOT CONTAIN A CHARGE PUMP DEFEAT PLUG 0UMPS IN THIS CONlGURATION USE A FULL mOW
PRESSURE lLTRATION ADAPTER WITH A STEEL / RING PLUG 2 IN THE CHARGE mOW OUTLET PORT
4HE SUCTION lLTRATION ADAPTER DOES NOT SUIT THIS CONlGURATION NEITHER DOES THE PARTIAL
mOW PRESSURE lLTRATION ADAPTER )T BYPASSES THE CHARGE RELIEF VALVE

No charge pump option components

G023

G020

R020

U015
R020A

G010
Charge inlet

G006

G004
Charge inlet

To filter
G004

R086

P108 093E

Housing with ﬁltration adapter Housing without ﬁltration adapter

520L0638 s 2EVISION #" s .OVEMBER 53

008 924 17 BOMAG 653
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Servo piston covers and 9OU CAN REMOVE THE SERVO PISTON COVERS TO CHANGE THE GASKET OR TO INSPECTCHANGE THE
NFPH control oriﬁce .&0( CONTROL ORIlCES

Disassembly
2EMOVE LOCKNUT 4 FROM THE RIGHT SIDE SERVO COVER

5SING A 4 4ORX DRIVER OR MM INTERNAL HEX REMOVE THE SERVO COVER BOLTS -
0OST RELEASE PUMPS HAVE COVER BOLTS THAT ARE MM ; IN= LONGER THAN PRE
PUMPS4HE LONGER BOLTS ARE ONLY COMPATIBLE WITH POST PUMP HOUSING

2EMOVE THE SERVO PISTON COVERS ,-

4O REMOVE THE RIGHT SIDE SERVO COVER TURN THE NEUTRAL ADJUSTMENT SCREW 4
CLOCKWISE INWARD FAR ENOUGH FOR THE SERVO COVER TO CLEAR THE NEARBY CASE DRAIN PORT
4HEN PULL THE COVER AWAY FROM THE HOUSING AND TURN THE COVER COUNTERCLOCKWISE TO
REMOVE IT FROM THE ADJUSTMENT SCREW

2EMOVE THE GASKETS ,- #LEAN GASKET SURFACES

.&0( CONTROL ORIlCE PLUGS % AND % ARE LOCATED BENEATH THE SERVO COVERS )F
NECESSARY REMOVE AND CLEAN THE ORIlCES

Servo piston cover components

L005
5 mm M005
T060 T30 5 mm
$ #(' *" T30
&'! !*' *"
L001 !*'
L005
T060 (non-feedback
5 mm M001
$ #(' $#'%$!&$#!)
&'! T30
*" M002 E052
L001 !*' E051
NFPH orifice
NFPH orifice
L002 3 mm
3 mm
*"
*" !*'
!*'
T015

P108 104E

Frame size cm3

Control -$#%$#(# %$# .&0%.&0( -$#%$#(# %$# .&0%.&0(
,OCK NUT MM MM MM MM
3ERVO ADJUST SCREW 5 mm MM MM MM

54 520L0638 s 2EVISION #" s .OVEMBER

654 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Servo piston covers and Assembly Bolt torque patterns

NFPH control oriﬁce 2EPLACE THE .&0( CONTROL ORIlCE PLUGS TORQUE BOLTS IN ORDER INDICATED
(continued) % % IF THEY WERE REMOVED
2 3

)NSTALL NEW GASKETS ,-

7!2.).' /N THE RIGHT SIDE THREAD THE SERVO

5NINTENDED VEHICLE PISTON COVER , ONTO THE NEUTRAL
MOVEMENT HAZARD ADJUSTMENT SCREW4HEN WHILE
4 1
7HEN YOU REMOVE THE HOLDING THE COVER TURN THE NEUTRAL
RIGHT SIDE SERVO PISTON ADJUSTMENT SCREW 4 COUNTER
COVER YOU MUST SET NEUTRAL CLOCKWISE TO RUN THE COVER DOWN THE
AND CONTROL NEUTRAL 2EFER SCREW THREADS  6
Torque this
to PAGES AND bolt first and
5SING A 4 4ORX DRIVER OR MM 5
last
INTERNAL HEX INSTALL THE SERVO PISTON
COVER SCREWS ,- 4ORQUE 0
TO .sM ; LBFsFT= IN THE PATTERN
SHOWN

)NSTALL A NEW SEAL LOCK NUT 4 ONTO THE NEUTRAL ADJUSTMENT SCREW 4 $O NOT
TORQUE AT THIS TIME

0ERFORM PUMP NEUTRAL ADJUSTMENT AND CONTROL NEUTRAL ADJUSTMENT PROCEDURES 2EFER
to PAGES AND

2EMOVAL OF THE SERVO COVERS MAY CHANGE THE POSITION OF THE DISPLACEMENT LIMITERS
READJUST IF NECESSARY

520L0638 s 2EVISION #" s .OVEMBER 55

008 924 17 BOMAG 655
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Loop flushing and loop 4HE LOOP mUSHING FUNCTION CONSISTS OF THE Loop flushing valve and loop flushing
flushing relief valve LOOP mUSHING SHUTTLE VALVE AND THE LOOP defeat components
mUSHING RELIEF VALVE9OU MAY REMOVE THE Q050
11
ASSEMBLIES FOR CLEANING AND INSTALLATION /16 in
OF NEW / RINGS9OU MAY EXCHANGE

THE RELIEF VALVE POPPET FOR ONE WITH A Q060
5
DIFFERENT mOW RATING4AKE NOTICE THOUGH /8 in

PRE MODELS CONTAINED RELIEF SHIMS

DO NOT CHANGE THESE SHIMS UNLESS 3AUER
Q050A
$ANFOSS SPECIlCALLY INSTRUCTS YOU TO DO
SO9OU MAY ALSO DEFEAT THE LOOP mUSHING Q050A
Q060A
FUNCTION BY INSTALLING A DEFEAT SPOOL
Q051 Q051
Q061
3ERIES PUMPS BUILT PRIOR TO
USE UNIQUE LOOP mUSHING SPOOLS 0OST
Q062
RELEASE PUMPS USE A COMMON
LOOP mUSHING SPOOL4HEY ARE NOT
INTERCHANGEABLE P108 105E

Loop ﬂushing valve

2EMOVE THE LOOP mUSHING PLUG
1 $ISCARD THE / RING 1!

2EMOVE THE LOOP mUSHING SPOOL

ASSEMBLY 1 FROM THE HOUSING

)NSPECT THE PARTS FOR DAMAGE OR

FOREIGN MATERIAL %NSURE THE WASHER
SECURELY RETAINS THE CENTERING SPRING

)NSTALL THE LOOP mUSHING VALVE SPOOL ASSEMBLY 1 INTO ITS BORE )NSTALL A NEW
/ RING 1! ON THE LOOP mUSHING PLUG 1 TORQUE TO .sM ; LBFsFT=

Loop ﬂushing relief valve

4WO STYLES OF LOOP mUSHING RELIEF VALVE PLUGS EXIST4HE STYLE OF PLUG IS DEPENDS ON THE
CHARGE PRESSURE SPECIlCATION )F THE CHARGE PRESSURE IS GREATER THAN OR EQUAL TO BAR
; PSI= THE PLUG HAS TWO IDENTIlCATION GROOVES )F THE CHARGE PRESSURE IS LESS THAN
BAR ; PSI= THE PLUG HAS A SINGLE IDENTIlCATION GROOVE

2EMOVE THE LOOP mUSHING RELIEF VALVE PLUG 1 $ISCARD THE / RING 1!

2EMOVE THE SPRING 1 AND POPPET 1 FROM THE HOUSING

$O NOT ALTER THE SHIMS BETWEEN THE SPRING AND PLUG OR INTERCHANGE PARTS WITH
ANOTHER VALVE )NSPECT THE POPPET AND MATING SEAT IN THE HOUSING FOR DAMAGE OR
FOREIGN MATERIAL )NSPECT THE ORIlCE IN THE VALVE POPPET

)NSTALL A NEW / RING 1! ON THE PLUG 1 )NSTALL THE POPPET 1 SPRING
1 SHIMS AND PLUG INTO THE PUMP HOUSING TORQUE TO .sM ; LBFsFT=

56 520L0638 s 2EVISION #" s .OVEMBER

656 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Loop ﬂushing valve Defeating loop ﬂushing

(continued) 2EMOVE THE LOOP mUSHING PLUG 1 $ISCARD THE / RING 1!

2EMOVE THE LOOP mUSHING SPOOL ASSEMBLY 1 FROM THE PUMP HOUSING

)NSTALL THE DEFEAT SPOOL 1 INTO THE SPOOL BORE WITH TAPPED END FACING
OUTWARDS )NSTALL THE STANDARD PLUG WITH / RING INTO THE HOUSING AND TORQUE TO
.sM ; LBFsFT=

2EMOVE THE LOOP mUSHING RELIEF PLUG 1 $ISCARD THE / RING 1!

2EMOVE THE LOOP mUSHING RELIEF VALVE COMPONENTS 11

)NSTALL THE LOOP mUSHING RELIEF PLUG 1 WITH A NEW / RING 1! INTO THE
HOUSING AND TORQUE TO .sM ; LBFsFT=

520L0638 s 2EVISION #" s .OVEMBER 57

008 924 17 BOMAG 657
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Shaft seal, roller bearing, 3ERIES PUMPS USE A LIP TYPE SHAFT SEAL9OU CAN REPLACE THE SEAL ANDOR SHAFT WITHOUT
and shaft replacement MAJOR DISASSEMBLY

Seal removal
0OSITION THE PUMP WITH THE SHAFT FACING UP

)F THE UNIT IS POSITIONED HORIZONTALLY WHEN THE SHAFT IS REMOVED THE CYLINDER BLOCK COULD
MOVE OUT OF PLACE MAKING SHAFT INSTALLATION DIFlCULT

2EMOVE THE CASE DRAIN PLUG & TO RELIEVE ANY VACUUM THAT MAY BE PRESENT

2EMOVE THE SPIRAL RETAINING RING & 5SING A SCREWDRIVER PRY THE END OF THE RING
FREE AND UNWIND THE REMAINDER OF THE RING OUT OF THE GROOVE

2EMOVE THE SEAL CARRIER ASSEMBLY # ,OOSEN IT FROM THE UNIT BY PRYING ON THE
RAISED SURFACE OF THE SEAL CARRIER WITH A SCREWDRIVER

2EMOVEAND DISCARD / RING #

0RY OR PRESS LIP SEAL # FROM THE SEAL CARRIER # USE CAUTION TO AVOID
DAMAGING THE SEAL CARRIER $ISCARD
THE SEAL Shaft seal components

)NSPECT THE SEAL CARRIER # FOR

DAMAGE
F096
0RESS THE NEW SEAL # INTO
THE SHAFT BEARING SIDE OF THE SEAL
CARRIER "E CAREFUL TO ONLY PRESS ON C020
THE OUTSIDE DIAMETER OF THE LIP SEAL
/RIENT THE SEAL AS SHOWN IN THE
ILLUSTRATION "E CAREFUL NOT TO DAMAGE C017
THE SEAL

see table
Installation of shaft seal

C017 F091

C018

Seal carrier shown

C020 with the inside
facing up P108 069E

Case Drain Plug

Press seal to bottom of the carrier Frame Size CM3 CM3
E100 020E
)NTERNAL (EX IN IN
4ORQUE .sM .sM
; LBFsFT= ; LBFsFT=

58 520L0638 s 2EVISION #" s .OVEMBER

658 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Shaft seal, roller bearing, Shaft removal

and shaft replacement 'RIP THE SHAFT ASSEMBLY BY THE Shaft seal, roller bearing, and shaft
(continued) SPLINES OR KEYED END AND REMOVE replacement
FROM THE PUMP
C002
)NSPECT THE SHAFT FOR DAMAGE %NSURE
THE SHAFT AND SPLINES ARE STRAIGHT
AND FREE OF DAMAGE OR HEAVY WEAR C003
)NSPECT THE SURFACE WHERE THE REAR
SHAFT BEARING CONTACTS THE SHAFT )F
SPALLING IS PRESENT REPLACE THE SHAFT
AND REAR SHAFT BEARING
C001
2EPLACEMENT OF SHAFT REAR BEARING IS
A MAJOR REPAIR AND VIOLATES THE UNITS
WARRANTY POLICY UNLESS PERFORMED BY AN
AUTHORIZED 3AUER $ANFOSS 'LOBAL 3ERVICE
0ARTNER

)F NECESSARY CLEAN THE SEALING

AREA WITH A NONABRASIVE MATERIAL
,UBRICATE THE SHAFT WITH A LIGHT
COATING OF HYDRAULIC mUID

)NSPECT THE SHAFT BEARING #

FOR DAMAGE AND ROTATE TO ENSURE
SMOOTHNESS )F YOU SUSPECT
CONTAMINATION OR DAMAGE CLEAN WITH
SOLVENT AND LUBRICATE WITH HYDRAULIC
mUID 2EPLACE IF NECESSARY P108 107E

)F YOU ARE NOT REPLACING THE SHAFT OR

BEARING PROCEED WITH REASSEMBLY

Shaft bearing replacement

2EMOVE THE RETAINING RING #
USING SNAP RING PLIERS

/BSERVE THE ORIENTATION OF THE

CHAMFER ON THE BEARING 0RESS THE
BEARING OFF OF THE SHAFT

6ERIFY THE CHAMFER ON THE BEARING IS

FACING TOWARD THE PUMP 0RESS THE
NEW BEARING ONTO THE SHAFT 0RESS
ONLY ON THE INNER RACE OF THE ROLLER
BEARING

5SING SNAP RING PLIERS INSTALL THE

RETAINING RING #

520L0638 s 2EVISION #" s .OVEMBER 59

008 924 17 BOMAG 659
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
-INOR 2EPAIR

Shaft seal, roller bearing, Reassembly Shaft seal, roller bearing, and shaft
and shaft replacement %NSURE THAT THE CYLINDER KIT AND REAR replacement
(continued) BEARING ARE ALIGNED )NSERT THE SHAFT
ASSEMBLY INTO THE PUMP )T MAY BE
NECESSARY TO GRIP THE SPLINED END OF
THE SHAFT AND TWIST TO ALIGN IT WITH
THE BLOCK SPLINES AND PROPERLY SEAT IT
INTO THE REAR BEARING F096

,UBRICATE A NEW / RING # WITH

PETROLEUM JELLY AND SEAT IT INTO THE C020
HOUSING ON TOP OF THE BEARING

#OVER THE END OF THE SHAFT WITH AN C017

ASSEMBLY SLEEVE ,UBRICATE SHAFT SEAL
WITH PETROLEUM JELLY
see table
3LIDE THE SEAL CARRIER ASSEMBLY OVER
THE SHAFT AND INTO THE HOUSING 0RESS
F091
THE SEAL CARRIER AGAINST THE / RING
)T MAY BE NECESSARY TO USE A LARGE
SOCKET TO PRESS THE SEAL CARRIER DOWN
COMPLETELY

7IND THE SPIRAL RETAINING RING &

INTO THE GROOVE IN THE HOUSING
P108 069E

60 520L0638 s 2EVISION #" s .OVEMBER

660 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
!PPENDIX ! 4ORQUES

Torque table Sequence Part Description Tool Type Tool Size Torque
Number .sM ;LBFsFT=
$ -$# BOLTS 4ORX WRENCH )NTERNAL HEX 4 MM ;=
$ #OVER PLUG )NTERNAL HEX WRENCH 3
in ;=
$ ,INKAGE PIVOT SCREW )NTERNAL HEX WRENCH 4 mm ;=
$ -$#%$#(# %$# NEUTRAL %XTERNAL HEX WRENCH MM ;=
ADJUSTMENT SEAL LOCK NUT
$ #ONTROL SPOOL BORE PLUG %XTERNAL HEX WRENCH IN ;=
$ #ONTROL SPOOL BORE PLUG )NTERNAL HEX WRENCH IN ;=
$ Control nut %XTERNAL HEX WRENCH 8 mm ;=

$ .EUTRAL START SWITCH %XTERNAL HEX WRENCH 8 in ;=
$! 2ETAINING NUT %XTERNAL HEX WRENCH 3
4 in ;=
$ &.2.&0% BOLTS )NTERNAL HEX WRENCH 4 mm ;=
$$ %$#(# %$# BOLTS 4ORX WRENCH )NTERNAL HEX 4 MM ;=
% .&0( ORIlCE )NTERNAL HEX WRENCH 3 mm ;=

& #ASE DRAIN PLUG CM3 )NTERNAL HEX WRENCH in ;=
& #ASE DRAIN PLUG CM3 )NTERNAL HEX WRENCH 5
8 in ;=

& 3YSTEM GAUGE PORTS - AND - %XTERNAL HEX WRENCH in ;=
PLUGS
' 3HIM ADJUSTABLE CHARGE RELIEF %XTERNAL HEX WRENCH IN ;=
VALVE PLUG
+ 6ALVE SEAT PLUG %XTERNAL HEX WRENCH IN ;=
WITH BYPASS
+ 6ALVE SEAT PLUG )NTERNAL HEX WRENCH in
5
;=
WITHOUT BYPASS
,- 3ERVO PISTON COVER BOLTS 4ORX WRENCH )NTERNAL HEX 4 MM ;=

,- 3ERVO GAUGE PLUG %XTERNAL HEX WRENCH in ;=
,- $ISPLACEMENT LIMITER SEAL LOCK %XTERNAL HEX WRENCH MM ;=
nut

. 0ORT . PLUG %XTERNAL HEX WRENCH in ;=
0 #ONTROL SPOOL COVER SCREWS 4ORX WRENCH )NTERNAL HEX 4 MM ;=
PRE BLOCK POINT CHANGE

1" ,OOP mUSHING PLUG )NTERNAL HEX WRENCH 4 in ;=
PRE BLOCK POINT CHANGE

1" ,OOP mUSHING PLUG %XTERNAL HEX WRENCH in ;=
POST BLOCK POINT CHANGE
1" ,OOP mUSHING RELIEF VALVE PLUG %XTERNAL HEX WRENCH 5
8 in ;=
2 &ILTRATION ADAPTER BOLTS 4ORX WRENCH )NTERNAL HEX 4 MM ;=
4 ,OCK NUT CM3 %XTERNAL HEX WRENCH in ;=
4 ,OCK NUT CM3 %XTERNAL HEX WRENCH in ;=
4 0UMP MECHANICAL NEUTRAL %XTERNAL HEX WRENCH MM ;=
ADJUSTMENT SEAL LOCK NUT
cm3 -$#%$#(# %$#
4 0UMP MECHANICAL NEUTRAL %XTERNAL HEX WRENCH MM ;=
ADJUSTMENT SEAL LOCK NUT
cm3 .&0 CONTROL AND CM3
ALL CONTROLS
5 #HARGE PUMP COVER BOLTS 4ORX WRENCH )NTERNAL HEX 4 MM ;=

5 !UXILIARY PUMP SCREWS %XTERNAL HEX WRENCH in ;=
3!% ! PAD
5 !UXILIARY PUMP SCREWS %XTERNAL HEX WRENCH 4 in
3
;=
3!% " PAD

520L0638 s 2EVISION #" s .OVEMBER 61

008 924 17 BOMAG 661
16.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
!PPENDIX " 3PECIlCATION 4AGS

Pre-block point change

Ames, Iowa, U.S.A. Neumünster, Germany
Model Code
42L28 - C - ANN1 - 01 -
ANA - 2CNB - NN - NN - N - Model code
N - N - NNN - NNN
Model No. Ident Nr
4282051
A 97 23 67890
Serial No. Fabr Nr

MADE IN U.S.A.
3ERIAL NO
{ X XX XX

NUMBER
XXXXX
,OCATION 9EAR 7EEK 3EQUENCE

Post-block point change Name plate (USA)

Model
number
Model-No./Ident-No.
Model Model Code , # !.. !.!
code #." .. .. . . .
... ...
Serial
number
Serial-No. !
A=Ames, IA

Made in USA

P100438E Place of manufacture

Specifications
tag

Name plate (Japan)

Model
DAIKIN
Model-No./Ident-No.
number
428 XXXX
Model Model Code , # !.. !.!
code #." .. .. . . .
... ...
Serial
number
Serial-No. 9 8888
Y=Osaka, Japan
J=Osaka, Japan
Made in Japan

P108 106E Place of manufacture

62 520L0638 s 2EVISION #" s .OVEMBER

662 BOMAG 008 924 17
Vibration pump 16.2
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
.OTES

520L0638 s 2EVISION #" s .OVEMBER 67

008 924 17 BOMAG 663
16.2 Vibration pump

Products we offer: Sauer-Danfoss is a global manufacturer and supplier of high-

quality hydraulic and electronic components. We specialize in
• Bent Axis Motors providing state-of-the-art technology and solutions that excel in
the harsh operating conditions of the mobile off-highway market.
• Closed Circuit Axial Piston Pumps
Building on our extensive applications expertise, we work closely
and Motors
with our customers to ensure exceptional performance for a broad
• Displays range of off-highway vehicles.
• Electrohydraulic Power Steering
We help OEMs around the world speed up system development,
• Electrohydraulics reduce costs and bring vehicles to market faster.
Sauer-Danfoss – Your Strongest Partner in Mobile Hydraulics.
• Hydraulic Power Steering
• Integrated Systems
• Joysticks and Control Handles
Go to www.sauer-danfoss.com for further product information.
• Microcontrollers and Software
• Open Circuit Axial Piston Pumps
• Orbital Motors Wherever off-highway vehicles are at work, so is Sauer-Danfoss.
• PLUS+1™ GUIDE
We offer expert worldwide support for our customers, ensuring
• Proportional Valves the best possible solutions for outstanding performance. And with
an extensive network of Global Service Partners, we also provide
• Sensors
comprehensive global service for all of our components.
• Steering
• Transit Mixer Drives
Please contact the Sauer-Danfoss representative nearest you.

Local address:

Members of the Sauer-Danfoss Group:

Comatrol
www.comatrol.com

Hydro-Gear Sauer-Danfoss GmbH & Co. OHG Sauer-Danfoss-Daikin LTD.

www.sauer-danfoss.com
520L0638 s 2EVISION #" s .OVEMBER
664 BOMAG 008 924 17
16.3 Travel motor

008 924 17 BOMAG 665

16.3 Travel motor

666 BOMAG 008 924 17

Travel motor 16.3

Series 51 and 51-1

Bent Axis Motors

Service Manual

008 924 17 BOMAG 667

16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
2EVISIONS

HISTORY OF REVISIONS Table of Revisions

Date Page Changed Rev.

November 2009 14 correction to defeated loop flushing information AE

November 2009 19 11009442 is correct number for Series 51 two position AD
controls manual
April 2009 5 remove list of manuals AC
&EBRUARY 34 &RAME SIZE -INIMUM DISPLACEMENT RANGE TO CCM AB
$ECEMBER - First edition AA

¹ 3AUER $ANFOSS !LL RIGHTS RESERVED

2 11008567 s 2EV !% s .OVEMBER

668 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
Contents

INTRODUCTION /VERVIEW 5

/RDERING REPLACEMENT PARTS AND SERVICE 5
3AFETY PRECAUTIONS
5NINTENDED MACHINE MOVEMENT
&LAMMABLE CLEANING SOLVENTS
&LUID UNDER PRESSURE
0ERSONAL SAFETY
(AZARDOUS MATERIAL
3YMBOLS USED IN 3AUER $ANFOSS LITERATURE
'ENERAL INSTRUCTIONS 8
+EEP IT CLEAN 8
)NSPECT FOR SYSTEM CONTAMINATION 8
2EPLACE THE / RINGS AND GASKETS 8
,UBRICATE ALL MOVING PARTS 8
4ORQUING PROCEDURE 8
6ARIABLE DISPLACEMENT MOTORS
3ERIES MOTORS 1
Closed circuit 11
/PEN CIRCUIT11
3HAFTS 1

OPERATION ,OOP mUSHING13

$ISPLACEMENT LIMITERS15
-OUNTING CONlGURATIONS 1
3PEED SENSORS1
Controls18
4WO POSITION CONTROLS18
/VERVIEW18
0RESSURE COMPENSATOR CONTROLS 1
0ROPORTIONAL CONTROLS

TECHNICAL 'ENERAL SPECIlCATIONS 1

SPECIFICATIONS 4ECHNICAL DATA1
&LUID SPECIlCATIONS

PRESSURE 2EQUIRED TOOLS 3

MEASUREMENTS 0ORT LOCATIONS AND GAUGE INSTALLATION3

FLUID AND FILTER &LUID AND lLTER RECOMMENDATIONS5

MAINTENANCE (AZARDOUS MATERIAL 5

INITIAL STARTUP 0ROCEDURE

PROCEDURES

11008567 s 2EV !% s .OVEMBER 3

008 924 17 BOMAG 669
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
Contents

TROUBLESHOOTING 3LUGGISH SYSTEM 8

3YSTEM OPERATING HOT 8
%XCESSIVE NOISE OR VIBRATION
-OTOR OPERATES NORMALLY IN ONE DIRECTION ONLY
)MPROPER OUTPUT SPEED
,OW OUTPUT TORQUE3

ADJUSTMENTS /VERVIEW 31

#HARGE PRESSURE RELIEF VALVE31
-EASURING CHARGE PRESSURE31
!DJUSTING CHARGE PRESSURE3
-INIMUM DISPLACEMENT LIMITER33
!DJUSTING MINIMUM DISPLACEMENT33
-AXIMUM DISPLACEMENT LIMITER35
3ERIES MOTORS 35
3ERIES MOTORS 35

MINOR REPAIR )NSTALLATION AND ADJUSTMENT 3

$). AND 3!% mANGE UNITS 3
#ARTRIDGE UNITS 38
3HAFT SEAL REPLACEMENT3
3!% AND $). mANGED MOTORS 3
#ARTRIDGE mANGED MOTORS 41
,OOP mUSHING SHUTTLE VALVE 4
#HARGE RELIEF VALVE44
/VERVIEW44
0OPPET STYLE OLDER PRODUCTION 44
/RIlCED STYLE45
$EFEAT PLUG 4
-AXIMUM ANGLE STOP 3ERIES MOTORS 4
-AXIMUM ANGLE STOP 3ERIES MOTORS 48
-INIMUM ANGLE ADJUSTMENT SCREW5
7AY VALVE AND THRESHOLD SPRINGS5
4HRESHOLD ADJUSTMENT SCREW AND SPRINGS DISASSEMBLY 54

REPAIR PARTS (OUSING PLUGS AND SPEED SENSORS

&LANGE AND SHAFT SEAL 1
%NDCAP
3ERIES RAMP AND THRESHOLD4
3ERIES %NDCAP

4 11008567 s 2EV !% s .OVEMBER

670 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
Introduction

OVERVIEW 4HE COMPLETE SERVICE AND REPAIR INFORMATION FOR 3ERIES AND 3ERIES MOTORS IS
IN A MODULAR FORMAT 3ERVICE INFORMATION MODULES ARE AVAILABLE FOR THE BASIC MOTOR
COMPONENTS FOR EACH FAMILY OF MOTOR CONTROLS AND FOR MAJOR REPAIR PROCEDURES %ACH
MODULE CONTAINS INFORMATION ON THE FUNCTION ADJUSTMENT AND REPAIR OF EACH GROUP
OF COMPONENTS OR CONTROLS4HE REPAIR INSTRUCTIONS MODULE FOCUSES ON MAJOR REPAIR
PROCEDURES

&UNCTIONAL DESCRIPTION TECHNICAL SPECIlCATIONS ADJUSTMENT PROCEDURES MINOR REPAIR

PROCEDURES AND EXPLODED VIEW COMMON PARTS DRAWINGS FOR THE BASIC 3ERIES AND
3ERIES MOTOR COMPONENTS COMPRISE THIS MANUAL )T DISCUSSES THOSE MINOR REPAIRS
YOU CAN PERFORM WITHOUT REMOVING THE MOTORS END CAP4HESE REPAIRS WILL NOT AFFECT THE
UNITS WARRANTY

-AJOR REPAIRS REQUIRE REMOVING THE MOTORS END CAP4HIS MANUAL DOES NOT DESCRIBE
-AJOR REPAIRS PERFORMED THEM /NLY 3AUER $ANFOSS !UTHORIZED 3ERVICE #ENTERS AND OR ORIGINAL EQUIPMENT
BY PERSONS OTHER THAN A MANUFACTURERS TRAINED BY 3AUER $ANFOSS SHOULD PERFORM THESE REPAIRS
3AUER $ANFOSS !UTHORIZED
Service Center or trained &OR INFORMATION ON CONTROL TYPES SEE PAGES
/%- PERSONNEL MAY VOID
THE UNITS WARRANTY

ORDERING /RDER GENUINE 3AUER $ANFOSS REPLACEMENT PARTS TO ENSURE THE BEST PERFORMANCE &OR
REPLACEMENT PARTS lists of available service parts and service kits for Series 51 units SEE 520L0765 THROUGH
AND SERVICE 520L0770

3AUER $ANFOSS PROVIDES A COMPLETE REPAIR AND PARTS SERVICE FOR ALL PRODUCTS #ONTACT ANY
3AUER $ANFOSS !UTHORIZED 3ERVICE #ENTER FOR DETAILS #HECK OUR WEB SITE AT HTTPWWW
SAUER DANFOSSCOM TO SEE A LIST OF 3AUER $ANFOSS !UTHORIZED 3ERVICE #ENTER LOCATIONS

11008567 s 2EV !% s .OVEMBER 5

008 924 17 BOMAG 671
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
Introduction

Unintended machine movement

Flammable cleaning solvents

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

Fluid under pressure

Personal safety
W Warning
0ROTECT YOURSELF FROM INJURY 5SE PROPER SAFETY EQUIPMENT INCLUDING SAFETY GLASSES AT ALL
TIMES

Hazardous material
W Warning
(YDRAULIC mUID CONTAINS HAZARDOUS MATERIAL !VOID PROLONGED CONTACT WITH HYDRAULIC
mUID !LWAYS DISPOSE OF USED HYDRAULIC mUID ACMÃORDING TO STATE AND FEDERAL
ENVIRONMENTAL REGULATIONS

6 11008567 s 2EV !% s .OVEMBER

672 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
Introduction

SYMBOLS USED IN  7!2.).' MAY RESULT IN INJURY  4IP HELPFUL SUGGESTION

 -EASUREMENT REQUIRED  -ARK ORIENTATION FOR REINSTALLATION

 &LATNESS SPECIlCATION  4ORQUE SPECIlCATION

 0ARALLELISM SPECIlCATION  0RESS IN n PRESS lT

 %XTERNAL HEX HEAD  0ULL OUT WITH TOOL n PRESS lT

 )NTERNAL HEX HEAD  #OVER SPLINES WITH INSTALLATION

sleeve
 4ORX HEAD
 0RESSURE MEASUREMENTGAUGE
 / RING BOSS PORT LOCATION OR SPECIlCATION

11008567 s 2EV !% s .OVEMBER 7

008 924 17 BOMAG 673
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
Introduction

GENERAL INSTRUCTIONS Keep it clean

 9OU CAN COMPLETE MANY REPAIRS OR ADJUSTMENTS WITHOUT REMOVING THE UNIT FROM THE
MACHINE if THE UNIT IS ACCESSIBLE AND YOU CAN THOROUGHLY CLEAN IT BEFORE BEGINNING ANY
PROCEDURES

#LEANLINESS IS A PRIMARY MEANS OF ASSURING SATISFACTORY MOTOR LIFE ON EITHER NEW OR

REPAIRED UNITS Clean the outside of the motor thoroughly before disassembly. 4AKE CARE TO
AVOID CONTAMINATION OF THE SYSTEM PORTS #LEANING PARTS WITH A CLEAN SOLVENT WASH AND
AIR DRYING IS USUALLY ADEQUATE

!S WITH ANY PRECISION EQUIPMENT KEEP ALL PARTS FREE OF FOREIGN MATERIALS AND CHEMICALS
0ROTECT ALL EXPOSED SEALING SURFACES AND OPEN CAVITIES FROM DAMAGE AND FOREIGN MATERIAL
#AP ALL HOSES AFTER REMOVAL AND PLUG ALL OPEN PORTS #OVER ANY UNATTENDED PARTS WITH A
PROTECTIVE LAYER OF PLASTIC

Inspect for system contamination

 )NSPECT THE MOTOR FOR SIGNS OF SYSTEM CONTAMINATION )F YOU lND CONTAMINATION FULLY
DISASSEMBLE CLEAN AND INSPECT ALL COMPONENTS OF THE MOTOR

Replace the O-rings and gaskets

  2EPLACE ALL / RINGS AND GASKETS $ISCARD THEM ONLY AFTER YOU MAKE CERTAIN
THAT YOU HAVE THE CORRECT REPLACEMENT PARTS ,IGHTLY LUBRICATE ALL / RINGS WITH CLEAN
PETROLEUM JELLY BEFORE ASSEMBLY

Lubricate all moving parts

 $URING REASSEMBLY COAT ALL MOVING PARTS WITH A lLM OF CLEAN HYDRAULIC OIL4HIS HELPS
LUBRICATE THE SURFACES DURING START UP

&OR mUID QUALITY REQUIREMENTS REFER TO 520L0463 Hydraulic Fluids and Lubricants,
Technical Information

Torque procedure
 $URING REASSEMBLY CROSS TORQUE ALL RETAINING SCREWS TO THE GIVEN VALUE $O NOT
OVERTORQUE

8 11008567 s 2EV !% s .OVEMBER

674 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
Introduction

VARIABLE 3ERIES AND 3ERIES VARIABLE DISPLACEMENT MOTORS FEATURE A BENT AXIS ROTATING
DISPLACEMENT MOTORS GROUP THAT PROVIDES HIGH STARTING TORQUE AND HIGH SPEED4HE BALL END OF EACH PISTON
RUNS IN A BUSHING PRESSED INTO THE DRIVE SHAFT4HIS PERMITS THE TRANSFER OF HYDRAULIC
POWER DIRECTLY INTO ROTARY MOTION AT THE DRIVE SHAFT4HE PRESSURE BALANCED SPHERICAL
PISTON RINGS MAINTAIN CONTACT WITH THE CYLINDER BLOCK BORES PROVIDING HIGH VOLUMETRIC
EFlCIENCY AND LOW FRICTION ! CONSTANT VELOCITY JOINT SYNCHRONIZING SHAFT KEEPS THE
ROTATION OF THE CYLINDER BLOCK SYNCHRONIZED WITH THE MOTOR OUTPUT SHAFT

! SERVO PISTON CHANGES THE ANGLE OF THE ROTATING GROUP AND VARYS THE DISPLACEMENT OF
THE MOTOR $ECREASING DISPLACEMENT INCREASES SPEED )NCREASING DISPLACEMENT DECREASES
SPEED

3EVERAL HYDRAULIC AND ELECTROHYDRAULIC CONTROLS ARE AVAILABLE

4HE WAY SPOOL VALVE SHIFTS THE SERVO SUPPLY PRESSURE TO CHANGE THE MOTOR
DISPLACEMENT4HE SERVO SUPPLY PRESSURE CAN BE EXTERNAL OR INTERNAL

Series 51 motor cross section

-INIMUM DISPLACEMENt ValvE SEGMENt
liter 3PEED PICKUP RING
"EARING
(YDRAULIC PROPORtional PLATE
control 4APERED ROLLER BEARINGS

WAY
valve

3!% &LANGE

3PEED SENSOR 3YNCHRONIZING SHAFt

0ISTON

Servo
PISTON #HARGE PRESSURE RELIEF Valve 0 %

11008567 s 2EV !% s .OVEMBER 9

008 924 17 BOMAG 675
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
Introduction

SERIES 51-1 MOTORS 3ERIES MOTORS FEATURE SIMPLIlED END CAP AND CONTROL COMPONENTS4HE SERVO PISTON
IN THE 3ERIES HAS A DIFFERENTIAL AREA OF TO 4HE CONNECTING JOINT IS DESIGNED TO
DECREASE THE OVERALL LENGTH OF THE MOTOR

4HE 3ERIES CONTROL FEEDS SERVO PRESSURE DIRECTLY TO THE SERVO PISTON ,OW SYSTEM
LOOP PRESSURE FOR TWO POSITION CONTROLS AND HIGH SYSTEM LOOP PRESSURE FOR PRESSURE
COMPENSATING CONTROLS ACTUATES THE SERVO PISTON

2OTATING HARDWARE AND HOUSING COMPONENTS ARE COMMON BETWEEN 3ERIES AND 3ERIES

Series 51-1 motor cross section

-INIMUM ValvE SEGMENt
DISPLACEMENT LIMITER
"EARING PLATE 3PEED PICKUP RING

4APERED ROLLER BEARINGS

$). FLANGE

3YNCHRONIZING SHAFt
3PEED SENSOR
ServO PISTON
0ISTON

%LECTROHYDRAULIC TWO POSITION CONTROl

#HARGE PRESSURE RELIEF Valve 0 %

10 11008567 s 2EV !% s .OVEMBER

676 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
Introduction

CLOSED CIRCUIT )N A CLOSED CIRCUIT HYDRAULIC LINES CONNECT THE MAIN PORTS OF THE PUMP TO THE MAIN PORTS
OF THE MOTOR &LUID mOWS IN EITHER DIRECTION FROM THE PUMP TO THE MOTOR AND BACK TO THE
PUMP %ITHER OF THE HYDRAULIC LINES CAN BE UNDER HIGH PRESSURE

Case
drain
line

/UTPUT
)NPUT 06 MV

2ESERvoir FlOW "I DIRECTIONAL

0 %

4HE DIRECTION AND SPEED OF THE mUID mOW AND MOTOR OUTPUT SHAFT ROTATION DEPENDS
ON THE POSITION OF THE PUMP SWASH PLATE4HE PUMP mOW AND MOTOR DISPLACEMENT
DETERMINES MOTOR OUTPUT SHAFT SPEED4HE MACHINE LOAD DETERMINES THE SYSTEM
PRESSURE

OPEN CIRCUIT ! HYDRAULIC LINE CONNECTS THE OUTLET PORT OF THE PUMP TO A DIRECTIONAL VALVE IN AN OPEN
CIRCUIT4HE MAIN PORTS OF THE MOTOR CONNECT TO THE WORKING PORTS OF THIS VALVE7HEN THE
DIRECTIONAL VALVE IS ACTUATED mUID mOWS lRST FROM THE PUMP TO THE VALVE4HE DIRECTIONAL
VALVE THEN DIRECTS THE mUID TO THE MOTOR IN EITHER DIRECTION

FlOW FlOW
5NIDIRECTIONAL "I DIRECTIONAL
$)2%#4)/.!, VA,6%

)NPUT 05-0 MV /UTPUT

Case
drain
line

2ESERvoir
0 %

4HE DIRECTION OF mUID mOW AND MOTOR OUTPUT SHAFT ROTATION DEPENDS ON THE POSITION
OF THE DIRECTIONAL VALVE4HE MOTOR OUTPUT SPEED DEPENDS ON PUMP OUTPUT VOLUME
THE RESTRICTION OF THE VALVE OPENING AND MOTOR DISPLACEMENT4HE MACHINE LOAD
DETERMINES THE SYSTEM PRESSURE4HE DIRECTIONAL VALVE ROUTES mUID RETURNING FROM THE
MOTOR TO THE RESERVOIR !DDITIONAL COMPONENTS MAY BE NECESSARY TO PROVIDE DYNAMIC
BREAKING AND TO DEAL WITH OVERRUNNING LOADS
11008567 s 2EV !% s .OVEMBER 11
008 924 17 BOMAG 677
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
Introduction

SHAFTS -ANY SHAFT CONlGURATIONS ARE AVAILABLE ON 3ERIES AND 3ERIES MOTORS4HESE TABLES
SHOW SHAFTS THAT MAY BE ON EACH MOTOR mANGE CONlGURATION

Series 51-1 shaft options

Frame size 60 80 110
Order Cart/ Cart/ Cart/
Shaft description Flange SAE SAE SAE
code DIN DIN DIN
S1 TOOTH PITCH 34$ — 34$ — — —
# TOOTH PITCH /04 — — — — —
# TOOTH PITCH — — /04 — — —
C8 TOOTH PITCH — — — — — —
F1 TOOTH PITCH — — — — 34$ —
D1 7XXXXG PER $). — 34$ — — /04
$ 7XXXXG PER $). — /04 — 34$ — —
D3 7XXXXG PER $). — — — /04 — 34$
D4 7XXXXG PER $). — — — — — /04

Series 51 shaft options

Frame size 80 110 160 250

Order Shaft Cart/ Cart/ Cart/
Flange SAE SAE SAE SAE
code description DIN DIN DIN
S1 TOOTH PITCH 34$ — — — — — —
# TOOTH PITCH /04 — — — — — —
C8 TOOTH PITCH — — /04 — /04 — —
F1 TOOTH PITCH — — 34$ — 34$ — —
& TOOTH PITCH — — — — — — 34$
$ 7XXXXG PER $). — 34$ — — — — —
D3 7XXXXG PER $). — /04 — — — — —
D4 7XXXXG PER $). — — — 34$ — — —
D5 7XXXXG PER $). — — — — — 34$ —

12 11008567 s 2EV !% s .OVEMBER

678 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
/PERATION

LOOP FLUSHING 3ERIES AND MOTORS ARE DESIGNED TO ACCOMMODATE A LOOP mUSHING FUNCTION
)NSTALLATIONS THAT REQUIRE ADDITIONAL mUID REMOVAL FROM THE MAIN HYDRAULIC CIRCUIT BECAUSE
OF TRANSMISSION COOLING REQUIREMENTS USE A LOOP mUSHING FUNCTION4HE LOOP mUSHING
FUNCTION CONSISTS OF A SHUTTLE VALVE AND A POPPET STYLE RELIEF VALVE OR AN ORIlCED RELIEF
VALVE CARTRIDGE

4HE shuttle valve ACTS AS A RESOLVER DIRECTING mUID ONLY FROM THE LOW PRESSURE SIDE OF THE
LOOP TO THE MOTOR RELIEF VALVE4HE SHUTTLE VALVE IS SPRING CENTERED TO THE CLOSED POSITION
TO PREVENT HIGH PRESSURE mUID LOSS FROM THE CIRCUIT WHEN REVERSING DIRECTIONS

Loop ﬂushing cross-section showing oriﬁced relief valve

/RIFICED
RELIEF Valve 3HUTTLE Valve

0 %

4HE poppet style relief valve REGULATES THE CHARGE PRESSURE LEVEL IN THE SYSTEM CIRCUIT
WHEN THERE IS A PRESSURE DIFFERENTIAL IN THE MAIN LOOP7HEN YOU USE THIS VALVE THE
PRESSURE SETTING OF THE MOTOR MUST BE LESS THAN THE PUMPS CHARGE PRESSURE SETTING4HE
PRESSURE SETTING OF THIS VALVE IS CRITICAL TO ACHIEVING THE PROPER LOOP mUSHING mOW RATE

Loop ﬂushing cross-section showing poppet style relief valve

0OPPET STYLE
RELIEF VALVe
3HUTTLE Valve

0 %

11008567 s 2EV !% s .OVEMBER 13

008 924 17 BOMAG 679
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
/PERATION

LOOP FLUSHING 4HE oriﬁced relief cartridge CONTROLS mUSHING mOW UNDER MOST CONDITIONS !
(continued) COMBINATION OF ORIlCE SIZE AND CHARGE PRESSURE WILL PRODUCE A SPECIlC mUSHING mOW9OU
MAY EXCHANGE THE ORIlCED RELIEF CARTRIDGE FOR ONE WITH A DIFFERENT mOW RATING

Loop ﬂushing cross-section showing defeated relief valve

/RIFICED
RELIEF
valve
3HUTTLE
valve

! PLUG IS INSTALLED IN THE RELIEF VALVE CAVITY TO DEFEAT THE LOOP mUSHING FUNCTION

Defeated loop ﬂushing

Defeat
plug

Shuttle spool

P101 265E

14 11008567 s 2EV !% s .OVEMBER

680 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
/PERATION

DISPLACEMENT LIMITERS 3ERIES AND 3ERIES MOTORS INCORPORATE MECHANICAL DISPLACEMENT LIMITERS9OU CAN
SET A SPECIlC DISPLACEMENT RANGE BY LIMITING THE TRAVEL OF THE VALVE SEGMENTROTATING
GROUP

Displacement limiters Series 51

4AMPER RESISTANT
caP

WAY
valve MINIMUM
DISPLACEMENT
LIMITER

ValvE SEGMENt

3PACER

ServO PISTON

-AXIMUM
DISPLACEMENT
LIMITER 0 %

4HE maximum displacement OF THE MOTOR IS SET BY A SCREW AND SPACERS INSTALLED ON
THE END OF THE SERVO PISTON4HE minimum displacement OF THE MOTOR IS SET BY AN
ADJUSTABLE STOP IN THE MOTOR HOUSING

Displacement limiters Series 51-1

4AMPER
resistant caP

MINIMUM
DISPLACEMENT LIMITER

ValvE SEGMENt

Servo
PISTON

-AXIMUM DISPLACEMENT
3PACER

0 %

See Adjustments, PAGES FOR AVAILABLE SETTING RANGES

11008567 s 2EV !% s .OVEMBER 15
008 924 17 BOMAG 681
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
/PERATION

MOUNTING 3ERIES AND 3ERIES MOTORS ARE AVAILABLE IN THREE MOUNTING CONlGURATIONS4HEY
CONFIGURATIONS ARE DESIGNATED BY THE LETTERS 6 # OR $ FOLLOWING THE NUMBER IN THE MODEL CODE4HE
DESIGNATIONS REPRESENT
• 6 3!% # $ OR % MOUNTING mANGE
• # #ARTRIDGE STYLE MOUNTING
• $ $). )3/ MOUNTING mANGE

SAE conﬁguration

P101 197

Cartridge conﬁguration

P101 198

DIN conﬁguration

P101 199
16 11008567 s 2EV !% s .OVEMBER

682 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
/PERATION

SPEED SENSORS 3ERIES AND 3ERIES MOTORS ARE AVAILABLE WITH AN OPTIONAL SPEED SENSOR FOR DIRECT
MEASUREMENT OF MOTOR OUTPUT SPEED4HE SENSOR MAY ALSO BE USED TO SENSE THE DIRECTION
OF MOTOR ROTATION

Speed sensor with Packard connector

0ACKARD WEATHER PACK
PIN TOWER CONNECtor
2Ed
A
3UPPLY VOLTAGE
7HITe
B SPEED SIGNAL
BlacK
C GROUND COMMON
'REEn
D direction

$EUTZ CONNECtor
0 %

! SPECIAL MAGNETIC SPEED RING IS PRESSED ON TO THE OUTSIDE DIAMETER OF THE SHAFT ! (ALL
EFFECT SENSOR IS INSTALLED IN THE MOTOR HOUSING4HE SENSOR ACMÃEPTS SUPPLY VOLTAGE AND
OUTPUTS A DIGITAL PULSE SIGNAL IN RESPONSE TO THE SPEED OF THE RING

Speed sensor location cartridge motors

3PEED
sensor Conical end

0ISTON
"EARING

-AGNETIC RING
0 % PRESSED ONTO THE SHAFT

4HE OUTPUT CHANGES ITS HIGHLOW STATE AS THE NORTH AND SOUTH POLES OF THE PERMANENTLY
MAGNETIZED SPEED RING PASS BY THE FACE OF THE SENSOR4HE DIGITAL SIGNAL IS GENERATED AT
FREQUENCIES SUITABLE FOR MICROPROCESSOR BASED CONTROLS

Speed sensor location SAE / DIN ﬂange motors

4HE 3!% AND $). mANGE MOTORS USE A

mAT END SPEED SENSOR #ARTRIDGE mANGE
0ISTON MOTORS USE A CONICAL END SPEED SENSOR

-AGNETIC RING

3PEED SENSOR
0 %

11008567 s 2EV !% s .OVEMBER 17

008 924 17 BOMAG 683
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
/PERATION

CONTROLS Overview
4HERE ARE THREE BASIC CATEGORIES OF CONTROLS AVAILABLE FOR 3ERIES AND 3ERIES
• 4WO POSITION CONTROLS
• 0RESSURE COMPENSATOR CONTROLS
• 0ROPORTIONAL CONTROLS 3ERIES ONLY

TWO-POSITION 4WO POSITION CONTROLS SHIFT THE MOTOR TO Two-position control

CONTROLS ONLY TWO DISCRETE POSITIONS
• MAXIMUM DISPLACEMENT
• MINIMUM DISPLACEMENT

#ONTROL INPUT MAY BE EITHER BY HYDRAULIC

OR ELECTRICAL SIGNAL4O CHANGE MOTOR
DISPLACEMENT THE CONTROL ROUTES PILOT
G36
PRESSURE TO ONE END OF THE SERVO PISTON
G42
WHILE DRAINING THE OTHER 3ERIES G38
CONTROLS MAY DIRECT PILOT PRESSURE TO
G42
BOTH ENDS OF THE SERVO SIMULTANEOUSLY G38
ALLOWING THE DIFFERENTIAL AREA OF THE M16
PISTON TO STROKE THE MOTOR TO MINIMUM M16A
ANGLE
M18
M18A
3OME TWO POSITION CONTROLS ARE AVAILABLE M18 M10
WITH A Pressure COMPENSATOR OverRide M18A M12
PCOR FEATURE M1

4HE 0#/2 FEATURE ALLOWS NORMAL

M18
POSITION CONTROL WHILE CAUSING THE M18A M16A
MOTOR TO INCREASE DISPLACEMENT WHEN M16
SYSTEM PRESSURE REACHES A SET LEVEL M22
DUE TO LOAD4HE PRESSURE COMPENSATOR P101 268

PORTION OF THE CONTROL OVERRIDES THE

MINIMUM DISPLACEMENT POSITION COMMANDED BY THE CONTROL INPUT SIGNAL 0#/2 CONTROLS
ARE AVAILABLE WITH BRAKE PRESSURE DEFEAT TO PREVENT THE PRESSURE COMPENSATOR FROM
OPERATING DURING DYNAMIC BRAKING

#OMPLETE FUNCTIONAL DESCRIPTION MAINTENANCE AND REPAIR PROCEDURES FOR POSITION

CONTROLS ARE COVERED IN DETAIL IN THESE SUPPLEMENTS TO THIS MANUAL

• Series 51 Hydraulic and Electrohydraulic Two-position Controls

4YPES . (: % % & & ' ' 3

• Series 51-1 Controls Service Instructions

4YPES . % % % " " " 4 4 4 4! 4(

18 11008567 s 2EV !% s .OVEMBER

684 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
/PERATION

PRESSURE- 0RESSURE COMPENSATOR 0# CONTROLS

COMPENSATOR ALLOW THE MOTOR TO MATCH ITS
CONTROLS DISPLACEMENT TO THE SYSTEM LOAD 5SUALLY
THIS MEANS THAT THE MOTOR DEFAULTS TO
MINIMUM DISPLACEMENT WHILE ALLOWING
THE MOTOR TO INCREASE DISPLACEMENT
WHEN SYSTEM PRESSURE REACHES A SET LEVEL
DUE TO LOAD4HIS PERMITS THE MOTOR TO
REGULATE SYSTEM PRESSURE BY MODULATING
THE DISPLACEMENT ANGLE OF THE ROTATING
GROUP !S DISPLACEMENT INCREASES SO
DOES AVAILABLE TORQUE WHILE OUTPUT
SPEED DECREASES AND SYSTEM PRESSURE
REMAINS NEARLY CONSTANT AT THE 0# SETTING

0# CONTROLS ARE AVAILABLE WITH A BRAKE 0 %

Pressure DEFEAT BPD FEATURE4HE "0$
FEATURE DEFEATS THE OPERATION OF THE 0#
DURING DYNAMIC BREAKING WHEN THE
MOTOR IS RUNNING AS A PUMP

! SHUTTLE SPOOL UPSTREAM OF THE 0# VALVE DIRECTS ONLY ACMÃELERATION SYSTEM PRESSURE TO
THE 0# $URING DYNAMIC DECELERATION THE DYNAMIC BREAKING PRESSURE IS BLOCKED FROM
THE 0#4HE MOTOR REMAINS AT MINIMUM DISPLACEMENT LIMITING RAPID AND UNCONTROLLED
PRESSURES OR ENGINE OVER SPEEDING WHILE THE VEHICLEMACHINE IS SLOWING DOWN (YDRAULIC
OR ELECTRIC ACTUATION IS AVAILABLE 0# ON ONE SYSTEM PRESSURE SIDE IS ALSO AN OPTION

#OMPLETE FUNCTIONAL DESCRIPTION MAINTENANCE AND REPAIR PROCEDURES FOR PRESSURE

COMPENSATOR CONTROLS ARE COVERED IN DETAIL IN THE SUPPLEMENT TO THIS MANUAL

• Series 51 Two Position Controls Service Manual

4YPES4 4 4( 4! 0# 0$

11008567 s 2EV !% s .OVEMBER 19

008 924 17 BOMAG 685
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
/PERATION

PROPORTIONAL Proportional control 0ROPORTIONAL CONTROLS ALLOW THE MOTOR

CONTROLS TO OPERATE IN AN INlNITELY VARIABLE
DISPLACEMENT POSITION BASED ON A
HYDRAULIC OR ELECTRICAL INPUT SIGNAL

0ROPORTIONAL CONTROLS ARE AVAILABLE ON

3ERIES MOTORS 3ERIES MOTORS ARE
TWO POSITION ONLY 0ROPORTIONAL CONTROLS
ARE ALSO AVAILABLE WITH A 0#/2 FEATURE

4HE 0#/2 FEATURE ALLOWS NORMAL

PROPORTIONAL CONTROL WHILE CAUSING THE
MOTOR TO INCREASE DISPLACEMENT WHEN
SYSTEM PRESSURE REACHES A SET LEVEL
DUE TO LOAD4HE PRESSURE COMPENSATOR
PORTION OF THE CONTROL overrides ANY
POSITION LESS THAN MAXIMUM AS
COMMANDED BY THE CONTROL INPUT SIGNAL

0#/2 CONTROLS ARE AVAILABLE WITH "0$

TO PREVENT THE PRESSURE COMPENSATOR
FROM OPERATING DURING DYNAMIC BRAKING
3UPPLEMENTS TO THIS MANUAL DETAIL
FUNCTIONAL DESCRIPTION MAINTENANCE
AND REPAIR PROCEDURES FOR PROPORTIONAL
P001826
CONTROLS 3UPPLEMENTS INCLUDE

• Series 51 Single Input Hydraulic Proportional Controls

4YPES (: (! (" (% (3 (( * * * ++

• Series 51 Dual Input Hydraulic Proportional Controls

4YPES (0 (# *!

• Series 51 Electrohydraulic Proportional Controls

4YPES %0 %1 %2 %3 , , , ! $ $

20 11008567 s 2EV !% s .OVEMBER

686 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
4ECHNICAL SPECIlCATIONS

GENERAL -OST SPECIlCATIONS FOR 3ERIES AND MOTORS ARE LISTED ON THESE PAGES &OR
SPECIFICATIONS DElNITIONS OF THE VARIOUS SPECIlCATIONS SEE 520L0440 Series 51 Technical Information
Manual

.OT ALL HARDWARE OPTIONS ARE AVAILABLE FOR ALL CONlGURATIONS #ONSULT THE Series 51 Model
Code Supplement or price book FOR MORE INFORMATION

"ASIC REQUIREMENTS
• -OTOR TYPE !XIAL PISTON MOTOR WITH VARIABLE DISPLACEMENT BENT
AXIS DESIGN

• $IRECTION OF ROTATION #LOCKWISE AND COUNTER CLOCKWISE BI DIRECTIONAL

• )NSTALLATION POSITION $ISCRETIONARY THE HOUSING MUST ALWAYS BE lLLED WITH

HYDRAULIC mUID

• /THER SYSTEM REQUIREMENTS )NDEPENDENT BRAKING SYSTEM CIRCUIT OVERPRESSURE

PROTECTION SUITABLE RESERVOIR

4ECHNICAL DATA INCLUDES DIMENSION AND FRAME SIZE FOR DISPLACEMENT CASE AND SYSTEM
PRESSURE SPEED AND TORQUE4HESE TABLES ILLUSTRATE EACH FACET

TECHNICAL DATA
Frame size
Dimension 60 80 110 160 250
3
-AXIMUM DISPLACEMENT 6GMAX CM
[in3] ;= ;= ;= ;= ;=
-INIMUM DISPLACEMENT 6GMIN CM3
[in3] ;= ;= ;= ;= ;=
2ATED mOW 1 LMIN
;GALMIN= ;= ;= [81] ;= [145]
-AXIMUM CORNER POWER 0 CORNER K7
MAX ;HP= ;= ;= ;= ;= ;=
7EIGHT WITH CONTROL (Z M KG 44
LB ;= ;= ;= ;= ;
-ASS MOMENT OF INERTIA OF THE INTERNAL KGsM
ROTATING PARTS SLUGsFT ;= ;= ;= ;= ;=
4YPE OF MOUNTING &OUR BOLT mANGE 3!% OR $). mANGE CONlGURATION
4WO BOLT mANGE CARTRIDGE MOTOR CONlGURATION
0IPE CONNECTIONS -AIN PRESSURE PORTS 3!% mANGE
2EMAINING PORTS 3!% STRAIGHT THREAD / RING BOSS
Controls 4WO POSITION PROPORTIONAL 3ERIES HYDRAULIC OR ELECTRIC PRESSURE COMPENSATOR WWO OVERRIDE
WWO BRAKE PRESSURE DEFEAT
$ISPLACEMENT LIMITER !LL 3ERIES MOTORS INCORPORATE MECHANICAL MINIMUM AND MAXIMUM DISPLACEMENT LIMITERS
3HAFT CONlGURATION 3PLINED !.3) OR $). SHAFT

11008567 s 2EV !% s .OVEMBER 21

008 924 17 BOMAG 687
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
4ECHNICAL SPECIlCATIONS

TECHNICAL DATA Case pressure System pressure range

(continued)
bar psi bar psi
2ATED PRESSURE 3 44 -AXIMUM DELTA PRESSURE
-AXIMUM PRESSURE COLD START 5 -INIMUM LOW PRESSURE SIDE 145
-INIMUM PRESSURE 1 15

Speed limits
Frame size
-1
Speed min [rpm] 060 080 110 160 250
AT MAXIMUM DISPLACEMENT
2ATED SPEED
AT MINIMUM DISPLACEMENT
AT MAXIMUM DISPLACEMENT
-AXIMUM SPEED1
AT MINIMUM DISPLACEMENT
1
#ONTACT YOUR 3AUER $ANFOSS REPRESENTATIVE FOR MAXIMUM SPEED AT DISPLACEMENTS BETWEEN MAXIMUM AND
MINIMUM DISPLACEMENT

Theoretical torque
Frame size
Displacement condition 060 080 110 160 250
AT MAXIMUM .sMBAR
DISPLACEMENT ;LBFsIN PSI= 583
AT MINIMUM .sMBAR
DISPLACEMENT ;LBFsIN PSI= 313

FLUID SPECIFICATIONS Temperature range1 Viscosity

Calefaction °C °F mm2/s SUS
)NTERMITTENT COLD START -INIMUM INTERMITTENT
Continuous 2ECOMMENDED OPERATING
RANGE
)NTERMITTENT 115
1 -AXIMUM COLD START
!T THE HOTTEST POINT USUALLY THE CASE DRAIN PORT

Fluid cleanliness
Cleanliness level and βx-ratio
2EQUIRED mUID CLEANLINESS LEVEL )3/ #LASS
2ECOMMENDED βx RATIO FOR SUCTION lLTRATION B35-45 "≥
2ECOMMENDED βx RATIO FOR CHARGE PRESSURE lLTRATION B "≥
2ECOMMENDED INLET SCREEN SIZE FOR CHARGE PRESSURE lLTRATION μM μM

22 11008567 s 2EV !% s .OVEMBER

688 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
0RESSURE MEASUREMENTS

REQUIRED TOOLS 9OU CAN PERFORM SERVICE PROCEDURES DESCRIBED IN THIS MANUAL USING COMMON MECHANICS
HAND TOOLS 3PECIAL TOOLS IF REQUIRED ARE SHOWN #ALIBRATE PRESSURE GAUGES FREQUENTLY TO
ENSURE ACMÃURACY 5SE SNUBBERS TO PROTECT PRESSURE GAUGES

PORT LOCATIONS AND Series 51 motors

GAUGE INSTALLATION
Servo pressure supply Side port
for minimum angle or servo Y
pressure minimum angle
Guage port M3
System pressure B
M3

Main ports A+B Gauge port M2

Case drain L1

Y
side port
W
M1

Servo supply
M5

pressure
Guage port M5

System pressure A
Alternate position Gauge port M1
case drain L2 Control pressure
Guage port M7

Gauge information W
Servo pressure supply for
3YSTEM PRESSURE BAR ; PSI=
M1 maximum angle or
PORT A / RING lTTING servo pressure maximum angle
Guage port M4
3YSTEM PRESSURE BAR ; PSI=
-
PORT B / RING lTTING
0 %A

3ERVO PRESSURE BAR ; PSI=

M3
MINIMUM ANGLE / RING lTTING
3ERVO SUPPLY BAR ; PSI=
M4 PRESSURE
MAXIMUM ANGLE / RING lTTING

3ERVO SUPPLY BAR ; PSI= Axial port Y

M5
PRESSURE / RING lTTING
System pressure A+B
Guage port M1+M2 Main
port B
M3

Axial port W
M4
M5

Main
port A P107 757E

11008567 s 2EV !% s .OVEMBER 23

008 924 17 BOMAG 689
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
0RESSURE MEASUREMENTS

PORT LOCATIONS AND Series 51-1 motors

GAUGE INSTALLATION
Y
(continued)
3IDE POrt
,OOP FLUSHING
SHUTTLE Valve
X
#HARGE PRESSURe
RELIEF Valve
7

M4
#ASE DRAIN ,
3YSEM PRESSURE B
Y B A 'AUGE POrt -

-AIN PORTS ! "

3YSTEM PRESSURE A 7
'UAGE POrt M1
Alternate
POSITION
CASE DRAIN ,

Gauge information 'UAGE POrt M4

ServO PRESSURe
3YSTEM PRESSURE BAR ; PSI= 0 % MAXIMUM ANGLE
M1
PORT A / RING lTTING

3YSTEM PRESSURE BAR ; PSI=

-
PORT B / RING lTTING
BAR ; PSI=
3ERVO PRESSURE BAR ; PSI=
M3 MINIMUM ANGLE GAUGE FOR POSITION
ON CONTROL control
/ RING lTTING
BAR ; PSI=
BAR ; PSI= Y
3ERVO SUPPLY !XIAL POrt
M4 PRESSURE GAUGE FOR POSITION
MAXIMUM ANGLE control
/ RING lTTING
7
X
M4

B A
Main
POrt B

-AIN POrt A
3YSTEM PRESSURE ! "
'UAGE POrt - - 0 %

24 11008567 s 2EV !% s .OVEMBER

690 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
&LUID AND lLTER MAINTENANCE

FLUID AND FILTER 4O ENSURE OPTIMUM LIFE PERFORM REGULAR MAINTENANCE OF THE mUID AND lLTER
RECOMMENDATIONS #ONTAMINATED mUID IS THE MAIN CAUSE OF UNIT FAILURE4AKE CARE TO MAINTAIN mUID
CLEANLINESS WHEN SERVICING )NSPECT VEHICLE FOR LEAKS DAILY

#HECK THE RESERVOIR DAILY FOR PROPER mUID LEVEL THE PRESENCE OF WATER AND RANCID mUID
ODOR &LUID CONTAMINATED BY WATER MAY APPEAR CLOUDY OR MILKY OR FREE WATER MAY SETTLE
IN THE BOTTOM OF THE RESERVOIR 2ANCID ODOR INDICATES EXCESSIVE HEAT #HANGE THE mUID
IMMEDIATELY IF THESE CONDITIONS OCMÃUR #ORRECT THE PROBLEM IMMEDIATELY

#HANGE THE mUID AND lLTER PER THE Fluid and ﬁlter change interval
VEHICLEMACHINE MANUFACTURERS Reservoir type Max. oil change interval
RECOMMENDATIONS OR AT THESE INTERVALS Sealed HOURS
&IRST mUID CHANGE RECOMMENDED AT "REATHER HOURS
HOURS

(IGH TEMPERATURES AND PRESSURES RESULT IN ACMÃELERATED mUID AGING -ORE FREQUENT mUID
CHANGES MAY BE REQUIRED

#HANGE THE mUID MORE FREQUENTLY IF IT BECOMES CONTAMINATED WITH FOREIGN MATTER DIRT
WATER GREASE ETC OR IF THE mUID IS SUBJECTED TO TEMPERATURE LEVELS GREATER THAT THE
RECOMMENDED MAXIMUM $ISPOSE OF USED HYDRAULIC mUID PROPERLY .EVER REUSE HYDRAULIC
mUID

#HANGE lLTERS WHENEVER THE mUID IS CHANGED OR WHEN THE lLTER INDICATOR SHOWS THAT IT IS
NECESSARY TO CHANGE THE lLTER 2EPLACE ALL mUID LOST DURING lLTER CHANGE

Hazardous material
W Warning
(YDRAULIC mUID CONTAINS HAZARDOUS MATERIAL !VOID CONTACT WITH HYDRAULIC mUID !LWAYS
DISPOSE OF USED HYDRAULIC mUID ACMÃORDING TO STATE AND FEDERAL ENVIRONMENTAL
REGULATIONS

11008567 s 2EV !% s .OVEMBER 25

008 924 17 BOMAG 691
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
)NITIAL STARTUP PROCEDURES

PROCEDURE !LWAYS FOLLOW THIS PROCEDURE WHEN STARTING UP A NEW 3ERIES OR 3ERIES INSTALLATION
OR WHEN RESTARTING AN INSTALLATION IN WHICH EITHER THE PUMP OR MOTOR HAS BEEN REMOVED

 7!2.).' "EFORE INSTALLING THE MOTOR ANDOR PUMP INSPECT THE UNITS FOR DAMAGE INCURRED
4HIS SERVICE PROCEDURE DURING SHIPPING AND HANDLING
MAY REQUIRE DISABLING
THE VEHICLE MACHINE -AKE CERTAIN ALL SYSTEM COMPONENTS RESERVOIR HOSES VALVES lTTINGS HEAT EXCHANGER
RAISING THE WHEELS OFF THE AND SO FORTH ARE CLEAN BEFORE lLLING WITH mUID
GROUND DISCONNECTING
WORK FUNCTION AND SO &ILL THE RESERVOIR WITH RECOMMENDED HYDRAULIC mUID &ILTER USING A MICRON
FORTH WHILE PERFORMING NOMINAL NO BYPASS lLTER INTO THE RESERVOIR 5SING CONTAMINATED mUID MAY DAMAGE
TO PREVENT INJURY TO THE COMPONENTS WHICH MAY RESULT IN UNEXPECTED VEHICLEMACHINE MOVEMENT
TECHNICIAN AND BYSTANDERS
4AKE THE NECESSARY SAFETY &ILL THE INLET LINE LEADING FROM THE RESERVOIR TO THE PUMP
PRECAUTIONS
#HECK INLET LINE FOR PROPERLY TIGHTENED lTTINGS

-AKE SURE THE INLET LINE IS FREE OF RESTRICTIONS AND AIR LEAKS

&ILL THE MOTOR ANDOR PUMP HOUSING WITH CLEAN HYDRAULIC mUID BEFORE START UP &ILL BY
POURING lLTERED OIL INTO THE UPPER CASE DRAIN PORT

 Caution
.EVER START THE PRIME MOVER UNLESS THE MOTOR AND PUMP ARE ﬁlled completely WITH
CLEAN HYDRAULIC mUID

)NSTALL A BAR ; PSI= PRESSURE GAUGE IN THE CHARGE PRESSURE GAUGE PORT OF
THE PUMP TO MONITOR THE CHARGE PRESSURE DURING START UP

$ISCONNECT ANY EXTERNAL CONTROL INPUT SIGNAL LINKAGE FOR -$# HYDRAULIC LINES FOR
($# OR ELECTRICAL CONNECTIONS FOR %$# FROM THE PUMP CONTROL UNTIL AFTER INITIAL START
UP4HIS ENSURES THAT THE PUMP REMAINS IN ITS NEUTRAL POSITION

5SE A COMMON METHOD TO DISABLE THE PRIME MOVER *OG SLOWLY ROTATE PRIME MOVER
UNTIL CHARGE PRESSURE STARTS TO RISE

 7!2.).' %NABLE PRIME MOVER 3TART THE PRIME MOVER AND RUN AT THE LOWEST POSSIBLE SPEED
$O NOT START THE PRIME UNTIL CHARGE PRESSURE IS ESTABLISHED
MOVER UNLESS THE PUMP IS
IN NEUTRAL POSITION SWASH )F NECESSARY BLEED EXCESS AIR FROM THE HIGH PRESSURE LINES THROUGH THE HIGH PRESSURE
PLATE AT ² ANGLE 4AKE SYSTEM GAUGE PORT
NECESSARY PRECAUTIONS
TO PREVENT MACHINE /NCE CHARGE PRESSURE IS ESTABLISHED INCREASE SPEED TO NORMAL OPERATING SPEED
MOVEMENT IN CASE PUMP IS
ACTUATED IN STROKE DURING #HARGE PRESSURE SHOULD BE AS INDICATED IN THE PUMP MODEL CODE )F CHARGE PRESSURE IS
INITIAL START UP LOW SHUT DOWN AND DETERMINE CAUSE 3EE Troubleshooting PAGES

 Caution
,OW CHARGE PRESSURE MAY AFFECT THE OPERATORS ABILITY TO CONTROL THE MACHINE

26 11008567 s 2EV !% s .OVEMBER

692 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
)NITIAL STARTUP PROCEDURES

PROCEDURE (continued) 3HUT DOWN THE PRIME MOVER

#ONNECT THE EXTERNAL CONTROL INPUT SIGNAL

2ECONNECT THE MACHINE FUNCTION IF DISCONNECTED EARLIER

3TART THE PRIME MOVER CHECKING TO ENSURE THE PUMP REMAINS IN NEUTRAL

#HECK FOR FORWARD AND REVERSE MACHINE OPERATION WITH THE PRIME MOVER AT NORMAL
OPERATING SPEED

#HARGE PRESSURE MAY DECREASE SLIGHTLY DURING FORWARD OR REVERSE OPERATION

#ONTINUE TO CYCLE SLOWLY BETWEEN FORWARD AND REVERSE FOR AT LEAST lVE MINUTES

3HUT DOWN PRIME MOVER

2EMOVE GAUGES

0LUG THE GAUGE PORTS

#HECK RESERVOIR LEVEL

!DD lLTERED mUID TO THE RESERVOIR IF NEEDED

4HE MOTOR TRANSMISSION IS NOW READY FOR OPERATION

11008567 s 2EV !% s .OVEMBER 27

008 924 17 BOMAG 693
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
4ROUBLESHOOTING

SLUGGISH SYSTEM

Check Cause Corrective action

#ONTROL ORIlCES "LOCKED OR RESTRICTED ORIlCE WILL CAUSE SLUGGISH 2EMOVE INSPECT AND CLEAN ALL ORIlCES %NSURE THE
RESPONSE /RIlCES INSTALLED TO THE WRONG APPROPRIATE ORIlCES ARE INSTALLED
LOCATIONS WILL CAUSE 0#/2 CONTROL TO BE SLUGGISH
4HRESHOLD SETTING PROPORTIONAL )NAPPROPRIATELY HIGH THRESHOLD SETTING WILL SHIFT #HECK THRESHOLD SETTING !DJUST IF NECESSARY
CONTROLS THE MOTOR AT THE WRONG TIME
#ONTROL SPOOL OR PISTON ! STICKY WAY SPOOL OR CONTROL PISTON WILL CAUSE #LEAN AND INSPECT THE WAY VALVE SPOOL AND CONTROL
SLUGGISH RESPONSE PISTON 2EPLACE IF NECESSARY
0RESSURE COMPENSATOR SETTING )NAPPROPRIATELY LOW PRESSURE COMPENSATING #HECK PRESSURE COMPENSATOR SETTING !DJUST IF
SETTING WILL SHIFT MOTOR TO MAXIMUM NECESSARY
DISPLACEMENT AT LOWER PRESSURE
#ONTROL INPUT SIGNAL !N IMPROPER OR ERRATIC INPUT SIGNAL TO THE CONTROL #HECK INPUT SIGNAL OR ELECTRIC CURRENT AND CORRECT IF
MAY CAUSE SLUGGISH RESPONSE NECESSARY
#HARGE PRESSURE )NAPPROPRIATELY LOW PRESSURE SETTING AT LOOP -EASURE CHANGE PRESSURE IN FORWARD AND REVERSE
mUSHING RELIEF VALVE MAY CAUSE IMPROPER SUPPLY !DJUST LOOP mUSHING RELIEF VALVE IF NECESSARY
PRESSURE TO MOTOR CONTROL
3YSTEM PRESSURE )NAPPROPRIATELY LOW SYSTEM PRESSURE SETTING MAY -EASURE SYSTEM PRESSURE !DJUST PUMP PRESSURE
CAUSE SLUGGISH RESPONSE LIMITER OR SYSTEM RELIEF VALVE IF NECESSARY
)NTERNAL LEAKAGE %XCESSIVE LEAKAGE WILL CAUSE LOWER CHARGE )NSTALL LOOP mUSHING DEFEAT OPTION AND MONITOR CASE
PRESSURE AND AFFECT PERFORMANCE mOW )F CASE mOW IS EXCESSIVE MOTOR MAY REQUIRE
MAJOR REPAIR #ONTACT YOUR 3AUER $ANFOSS SERVICE
PROVIDER

SYSTEM OPERATING HOT

Check Cause Corrective action

Oil level )NSUFlCIENT HYDRAULIC mUID WILL CAUSE OVERHEATING &ILL RESERVOIR TO PROPER LEVEL
(EAT EXCHANGER "LOCKED HEAT EXCHANGER OR LOW AIR mOW WILL NOT #HECK TEMPERATURE UPSTREAM AND DOWNSTREAM
SUFlCIENTLY COOL THE SYSTEM OF HEAT EXCHANGER #LEAN REPAIR OR REPLACE HEAT
EXCHANGER IF NECESSARY
,OOP mUSHING CHARGE PRESSURE )NAPPROPRIATELY HIGH LOOP mUSHING RELIEF VALVE -ONITOR CASE DRAIN mOW )F LOW ADJUST LOOP mUSHING
SETTING WILL REDUCE OR PREVENT LOOP mUSHING mOW RELIEF VALVE SETTING OR REPLACE WITH ORIlCED TYPE
)MPROPER ORIlCE SIZE WILL NOT GIVE PROPER mOW FOR RELIEF
COOLING PURPOSES
3YSTEM PRESSURE )F SYSTEM RELIEF VALVE SETTINGS ARE TOO LOW EXCESS !DJUST SYSTEM RELIEF VALVE SETTINGS
HEAT WILL BE GENERATED
!IR IN SYSTEM %NTRAINED AIR GENERATES HEAT UNDER PRESSURE AND ,OOK FOR FOAM OR BUBBLES IN RESERVOIR #HECK FOR
causes cavitation LEAKS ON INLET SIDE OF CHARGE PUMP
)NTERNAL LEAKAGE %XCESSIVE INTERNAL LEAKAGE WILL OVERHEAT THE )NSTALL LOOP mUSHING DEFEAT OPTION AND MONITOR CASE
SYSTEM mOW )F CASE mOW IS EXCESSIVE MOTOR MAY REQUIRE
MAJOR REPAIR #ONTACT YOUR 3AUER $ANFOSS SERVICE
PROVIDER

28 11008567 s 2EV !% s .OVEMBER

694 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
4ROUBLESHOOTING

EXCESSIVE NOISE OR
VIBRATION
Check Cause Corrective action
Oil level in reservoir )NSUFlCIENT HYDRAULIC mUID WILL CAUSE CAVITATION &ILL RESERVOIR TO PROPER LEVEL
!IR IN SYSTEM !IR BUBBLES MAY LEAD TO CAVITATION ,OOK FOR FOAM OR BUBBLES IN RESERVOIR #HECK FOR
LEAKS ON INLET SIDE OF CHARGE PUMP
3HAFT COUPLING ,OOSE SHAFT COUPLING CREATES EXCESS NOISE 2EPLACE LOOSE SHAFT COUPLING 2EPLACE OR REPAIR
MOTOR IF SHAFT SPLINES ARE WORN EXCESSIVELY
3HAFT ALIGNMENT -ISALIGNED SHAFTS CREATE EXCESSIVE NOISE AND #ORRECT SHAFT MISALIGNMENT
DAMAGE MOTOR

MOTOR OPERATES
NORMALLY IN ONE
DIRECTION ONLY
Check Cause Corrective action
#HARGE PRESSURE )F CHARGE PRESSURE IS LOW IN ONE DIRECTION THE -EASURE CHARGE PRESSURE IN FORWARD AND REVERSE )F
LOOP mUSHING SHUTTLE SPOOL MAY BE STICKING TO PRESSURE DROPS IN ONE DIRECTION INSPECT AND REPAIR
ONE SIDE LOOP mUSHING SHUTTLE SPOOL
Motor control )F CONTROL SHIFTS MOTOR TO MINIMUM DISPLACEMENT -EASURE MAXIMUM AND MINIMUM SERVO PRESSURES
IN ONE DIRECTION MOTOR MAY NOT HAVE ENOUGH TO CHECK CONTROL OPERATION 2EPAIR CONTROL OR CORRECT
TORQUE TO OPERATE INPUT SIGNAL IF NECESSARY
0RESSURE COMPENSATOR CONTROL )F PRESSURE COMPENSATOR OPERATES IN ONE #HECK BRAKE PRESSURE DEFEAT SPOOL )T MAY BE
DIRECTION ONLY THE MOTOR WILL STAY AT MINIMUM STICKING OR RECEIVING AN IMPROPER SIGNAL 2EPAIR
DISPLACEMENT IN THE OTHER DIRECTION SPOOL OR CORRECT INPUT SIGNAL

IMPROPER OUTPUT
SPEED
Check Cause Corrective action
Oil level in reservoir )NSUFlCIENT HYDRAULIC mUID WILL REDUCE SYSTEM &ILL RESERVOIR TO PROPER LEVEL
EFlCIENCY
4HRESHOLD SETTING )MPROPER THRESHOLD SETTING WILL CAUSE MOTOR TO #HECK THRESHOLD SETTING 2EFER TO CONTROL SERVICE
HAVE WRONG DISPLACEMENT FOR GIVEN SIGNAL MANUAL FOR ADJUSTMENT PROCEDURE
0RESSURE COMPENSATOR SETTING )MPROPER PRESSURE COMPENSATOR SETTING SHIFTS #HECK PRESSURE COMPENSATOR SETTING !DJUST IF
MOTOR DISPLACEMENT AT WRONG PRESSURE NECESSARY
#ONTROL SPOOL OR PISTON 0RESSURE COMPENSATOR PISTON OR SPOOL STICKING #HECK PRESSURE COMPENSATOR PISTON OR SPOOL 2EPAIR
HOLDS MOTOR AT WRONG DISPLACEMENT OR REPLACE IF NEEDED
#ONTROL ORIlCES "LOCKED OR RESTRICTED ORIlCE CAUSES MOTOR TO SHIFT 2EMOVE INSPECT AND CLEAN ALL ORIlCES
IMPROPERLY
#ONTROL PISTON 3TICKY CONTROL PISTON CAUSES MOTOR TO SHIFT #HECK CONTROL PISTON FOR PROPER OPERATION 2EPAIR IF
IMPROPERLY NECESSARY
#ONTROL INPUT SIGNAL )MPROPER INPUT SIGNAL CAUSES MOTOR TO SHIFT #ORRECT CONTROL INPUT SIGNAL
IMPROPERLY
)NTERNAL LEAKAGE %XCESS INTERNAL LEAKAGE CAUSES LOWER CHARGE )NSTALL LOOP mUSHING DEFEAT OPTION AND MONITOR CASE
PRESSURE AND AFFECTS SYSTEM PERFORMANCE mOW )F CASE mOW IS EXCESSIVE MOTOR MAY REQUIRE
INCLUDING OUTPUT SPEED MAJOR REPAIR #ONTACT YOUR 3AUER $ANFOSS 3ERVICE
0ROVIDER

11008567 s 2EV !% s .OVEMBER 29

008 924 17 BOMAG 695
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
4ROUBLESHOOTING

LOW OUTPUT TORQUE

Check Cause Corrective action

3YSTEM PRESSURE ,OW SYSTEM PRESSURE AT MOTOR REDUCES OUTPUT -EASURE SYSTEM PRESSURE AT THE MOTOR )F THE
TORQUE PRESSURE LIMITER OR RELIEF VALVE SETTING IS LOW
INCREASE SETTING TO THE PROPER LEVEL
#HARGE PRESSURE ,OW LOOP mUSHING RELIEF VALVE SETTING MAY CAUSE -EASURE CHARGE PRESSURE IN FORWARD AND REVERSE
IMPROPER SUPPLY PRESSURE TO MOTOR CONTROL !DJUST LOOP mUSHING RELIEF VALVE SETTING IF NECESSARY
0RESSURE COMPENSATOR SETTING (IGH PRESSURE COMPENSATOR SETTING CAUSES #HECK AND ADJUST PRESSURE COMPENSATOR SETTING
IMPROPER MOTOR DISPLACEMENT FOR TORQUE
REQUIRED
#ONTROL ORIlCES "LOCKED OR RESTRICTED ORIlCE CAUSES MOTOR TO SHIFT 2EMOVE INSPECT AND CLEAN ALL ORIlCES
IMPROPERLY
0RESSURE COMPENSATOR PISTON OR 3TICKING PRESSURE COMPENSATOR PISTON OR SPOOL 2EMOVE AND INSPECT CONTROL SPOOL AND SENSING
SPOOL CAUSES CONTROL TO HOLD MOTOR AT MINIMUM PISTON 2EPAIR OR REPLACE IF NECESSARY
DISPLACEMENT
#ONTROL SPOOL OR PISTON 3TICKING WAY SPOOL OR CONTROL PISTON CAUSES 2EMOVE AND INSPECT WAY SPOOL AND CONTROL
MOTOR TO SHIFT IMPROPERLY PISTON 2EPAIR OR REPLACE IF NECESSARY
4WO POSITION SOLENOID 4WO POSITION CONTROL NOT SHIFTING MOTOR TO )NSPECT SOLENOID VALVE FOR BENT STEM OR BAD COIL
MAXIMUM DISPLACEMENT 2EPAIR OR REPLACE IF NECESSARY
#ONTROL INPUT SIGNAL )MPROPER CONTROL INPUT SIGNAL CAUSES MOTOR TO #ORRECT CONTROL INPUT SIGNAL
STAY AT MINIMUM DISPLACEMENT
4HRESHOLD SETTING )MPROPER THRESHOLD SETTING CAUSES IMPROPER #HECK AND ADJUST THRESHOLD SETTING
MOTOR DISPLACEMENT FOR TORQUE REQUIRED
)NTERNAL LEAKAGE %XCESS INTERNAL LEAKAGE CAUSES CHARGE PRESSURE )NSTALL LOOP mUSHING DEFEAT OPTION AND MONITOR CASE
TO DECAY REDUCING OUTPUT TORQUE mOW )F CASE mOW IS EXCESSIVE MOTOR MAY REQUIRE
MAJOR REPAIR #ONTACT YOUR 3AUER $ANFOSS 3ERVICE
0ROVIDER

30 11008567 s 2EV !% s .OVEMBER

696 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
!DJUSTMENTS

OVERVIEW !DJUST COMPONENTS OF THE 3ERIES AND 3ERIES MOTORS PER FOLLOWING PROCEDURES
WHERE NECESSARY REFER TO Pressure Measurement PAGES 4 FOR GAUGE PORT LOCATIONS
AND SIZES

Charge pressure relief valve

3ET THE CHARGE PRESSURE RELIEF VALVE TO THE MODEL ORDER CODE SPECIlCATIONS )N MOST
 7!2.).' APPLICATIONS THE MOTOR CHARGE RELIEF VALVE IS SET TO BAR ; TO PSI= below the setting
4HIS SERVICE PROCEDURE of the pump charge relief valve MEASURED WITH THE PUMP IN ITS NEUTRAL OR ZERO ANGLE
MAY REQUIRE DISABLING THE POSITION 4HIS SETTING ASSUMES A RESERVOIR TEMPERATURE OF ² # ;² &= #HARGE PRESSURE
VEHICLE MACHINE RAISING IS REFERENCED ADDITIVE TO CASE PRESSURE
THE WHEELS OFF THE GROUND
DISCONNECTING THE WORK Measuring charge pressure
FUNCTION AND SO FORTH )NSTALL A TO BAR ; TO PSI= Series 51 charge pressure relief valve
WHILE PERFORMING IN ORDER PRESSURE GAUGE IN PORT - OR - Adjustment
TO PREVENT INJURY TO THE USE WHICH EVER IS AT low LOOP plug
TECHNICIAN AND BYSTANDERS PRESSURE 1
1 /16
4AKE THE NECESSARY SAFETY lock nut
PRECAUTIONS )NSTALL A TO BAR ; TO PSI=
GAUGE IN PORT , OR , TO MEASURE
CASE PRESSURE

/PERATE THE SYSTEM WITH THE PRIME

MOVER AT NORMAL OPERATING SPEED
P101 208E
AND THE PUMP AT HALF STROKE FORWARD
OR REVERSE

/LDER 3ERIES AND 3ERIES MOTORS MAY BE EQUIPPED WITH AN EXTERNAL SCREW
ADJUSTABLE CHARGE PRESSURE RELIEF VALVE NOT SHOWN

11008567 s 2EV !% s .OVEMBER 31

008 924 17 BOMAG 697
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
!DJUSTMENTS

OVERVIEW (continued) Adjusting charge pressure

,OOSEN THE LOCK NUT USING A 1 HEX WRENCH

4URN THE ADJUSTMENT PLUG WITH A LARGE SCREWDRIVER OR MM HEX WRENCH
 7!2.).'
)NCORRECT CHARGE PRESSURE #LOCKWISE ROTATION OF THE PLUG INCREASES THE SETTING AND COUNTERCLOCKWISE ROTATION
SETTINGS MAY RESULT IN THE DECREASES THE SETTING4HE CHARGE PRESSURE SETTING WILL BE REDUCED OR INCREASED AT A RATE
INABILITY TO BUILD REQUIRED OF APPROXIMATELY BAR ; PSI= PER TURN
SYSTEM PRESSURE AND OR
INADEQUATE LOOP mUSHING !FTER ADJUSTING THE PLUG TORQUE THE LOCKNUT TO .sM ; LBFsFT= $O NOT OVERTORQUE
mOWS9OU MUST MAINTAIN
THE CORRECT CHARGE PRESSURE 2EMOVE THE GAUGES
UNDER ALL OPERATION
CONDITIONS TO MAINTAIN 2EINSTALL THE PORT PLUGS
PUMP PERFORMANCE
-OTORS WITH LOOP mUSHING DEFEATED OR EQUIPPED WITH AN ORIlCED CHARGE PRESSURE RELIEF
valve SEE charge relief valve, oriﬁced style ON PAGE DO NOT REQUIRE ADJUSTMENT

Series 51-1 charge pressure relief valve

11/16 inch

t]

Adjustment plug
0 %

32 11008567 s 2EV !% s .OVEMBER

698 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
!DJUSTMENTS

MINIMUM 4HE FACTORY SETS MINIMUM DISPLACEMENT ! TAMPER RESISTANT CAP COVERS THE ADJUSTMENT
DISPLACEMENT LIMITER SCREW

 Caution
4O AVOID UNEXPECTED CHANGES IN OPERATING CONDITIONS AND TO PREVENT EXTERNAL LEAKAGE
TORQUE THE LOCK NUT 9 AFTER every ADJUSTMENT

$ETECT CHANGES IN MOTOR DISPLACEMENT BY PROVIDING A CONSTANT mOW OF mUID TO THE

MOTOR WHILE MAINTAINING THE MOTOR AT MINIMUM DISPLACEMENT AND MONITORING THE
MOTOR OUTPUT SHAFT SPEED !N INCREASE IN DISPLACEMENT WILL RESULT IN A DECREASE IN SHAFT
SPEED WHILE A DECREASE IN DISPLACEMENT WILL RESULT IN AN INCREASE IN SHAFT SPEED

 7!2.).' Adjusting minimum displacement

!DJUSTMENT OF THE 2EMOVE THE TAMPER RESISTANT CAP 1 FROM THE ADJUSTING SCREW 9 2EMOVING
MINIMUM DISPLACEMENT THE TAMPER RESISTANT CAP DESTROYS THE LOCKING DEVICE
LIMITER CAN RESULT IN
UNDESIRABLE OR UNSAFE $ISCARD THE CAP 1 AFTER COMPARING IT WITH A NEW ONE TO MAKE SURE THE NEW ONE
SPEED CONDITIONS lTS
#ONSULT WITH THE /RIGINAL
%QUIPMENT -ANUFACTURER Minimum displacement limiter
OR YOUR 3AUER $ANFOSS Q120
REPRESENTATIVE BEFORE Tamper
CHANGING THE MINIMUM resistant
Y20
cap
DISPLACEMENT SETTING
!FTER ADJUSTMENT VERIFY Y10
MINIMUM DISPLACEMENT
SETTING BY USING AN
APPROPRIATE TEST APPARATUS

P101216E

(OLD ADJUSTING SCREW 9 USING A MM OR MM INTERNAL HEX WRENCH

,OOSEN THE SEALING LOCK NUT 9 USING A

• MM HEX WRENCH FOR CMÃ AND CMÃ FRAME SIZE MOTORS
or
• MM HEX WRENCH FOR CMÃ CMÃ AND CMÃ FRAME SIZE MOTORS

11008567 s 2EV !% s .OVEMBER 33

008 924 17 BOMAG 699
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
!DJUSTMENTS

MINIMUM 4URN THE ADJUSTMENT SCREW 9 FOR THE DESIRED DISPLACEMENT FOLLOWING THE TABLE
DISPLACEMENT LIMITER WITH A
(continued) • MM HEX WRENCH FOR CMÃ AND CMÃ FRAME SIZE MOTORS
or
• MM HEX WRENCH FOR CMÃ CMÃ AND CMÃ FRAME SIZE MOTORS

2OTATING THE ADJUSTMENT SCREW CLOCKWISE INCREASES THE MINIMUM DISPLACEMENT OF THE
MOTOR ROTATING THE ADJUSTMENT SCREW COUNTERCLOCKWISE DECREASES IT

4HE MINIMUM DISPLACEMENT SETTING CHANGES SEE CHART FOR EACH FULL REVOLUTION OF THE
ADJUSTMENT SCREW -AJOR CHANGES IN MINIMUM DISPLACEMENT SETTING MAY REQUIRE A
DIFFERENT SIZE ADJUSTMENT SCREW

Adjustment screw and displacement

Approximate change in minimum
Frame Minimum displacement Screw size and length displacement per revolution of
size range cm³ [in3] mm [in] adjusting screw
cm³/rev [in3/rev]
; = - X ;=
;=
; = - X ;=
; = - X ;=
;=
; = - X ;=
; = - X ;=
;=
; = - X ;=
; = - X ;=
;=
; = - X ;=
; = - X ;=
; = - X ;= ;=
; = - X ;=

C #AUTION !FTER ADJUSTMENT TORQUE THE LOCK NUT ON THE ADJUSTMENT SCREW TO
$O NOT OVERTORQUE LOCKNUT • .sM ; LBFsFT= FOR CMÃ AND CMÃ MOTORS
or
• .sM ; LBFsFT= FOR CMÃ CMÃ AND CMÃ MOTORS

)NSTALL A NEW TAMPER RESISTANT CAP

34 11008567 s 2EV !% s .OVEMBER

700 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
!DJUSTMENTS

MAXIMUM ,IMIT THE MAXIMUM DISPLACEMENT BY SETTING THE STROKE OF THE SERVO PISTON ! STOP SCREW
DISPLACEMENT LIMITER AND SPACER IS ON THE SERVO PISTON TO LIMIT THE MAXIMUM DISPLACEMENT OF THE MOTOR TO
LESS THAN 3PACERS ARE AVAILABLE IN INCREMENTS

 7!2.).' ,IMIT THE DISPLACEMENT BY USING SPACERS ON THE DISPLACEMENT STOP SCREW7HEN
!DJUSTING THE MAXIMUM CHANGING THE MAXIMUM DISPLACEMENT YOU MAY NEED A DIFFERENT LENGTH SCREW TO
DISPLACEMENT LIMITER CAN ACCOMMODATE THE ALTERNATE SPACERS
RESULT IN UNDESIRABLE OR
UNSAFE SPEED CONDITIONS $ETECT CHANGES IN MOTOR DISPLACEMENT BY PROVIDING A CONSTANT mOW OF mUID TO THE
#ONSULT WITH THE /RIGINAL MOTOR WHILE MAINTAINING THE MOTOR AT MAXIMUM DISPLACEMENT AND MONITORING THE
%QUIPMENT -ANUFACTURER MOTOR OUTPUT SHAFT SPEED
OR YOUR 3AUER $ANFOSS
REPRESENTATIVE BEFORE !N INCREASE IN DISPLACEMENT RESULTS IN A DECREASE IN SHAFT SPEED ! DECREASE IN
CHANGING THE MAXIMUM DISPLACEMENT RESULTS IN AN INCREASE IN SHAFT SPEED
DISPLACEMENT SETTING

Series 51 motors Series 51 Maximum displacement limiter

2EMOVE THE SCREWS ' RETAINING G24 G24
THE SERVO COVER ' USING F10* G24
• AN MM HEX WRENCH CMÃ
CMÃ CMÃ AND CMÃ F20* G24
G260
MOTORS
OR G36
• A MM HEX WRENCH CMÃ
G100
MOTORS

2EMOVE THE SERVO COVER ' AND

/ RINGS ' AND '
P101 223E
2EMOVE THE DISPLACEMENT LIMITER
SCREW & AND SPACER & IF USED
WITH A MM HEX WRENCH FOR CMÃ CMÃ CMÃ CMÃ AND CMÃ MOTORS

3AVE ORIGINAL SPACER REPLACING EACH WITH THE APPROPRIATE SPACER AND SCREW TO
ACHIEVE THE DESIRED MAXIMUM DISPLACEMENT 3EE THE chart on the next page

Series 51-1 Maximum displacement limiter Series 51-1 motors

M16 2EMOVE THE SCREWS -
RETAINING THE CONTROL ASSEMBLY USING
F10* M16 AN MM HEX WRENCH
F20*
2EMOVE THE CONTROL ASSEMBLY
Control
G36 2EMOVE INTERFACE ' AND / RINGS
' OR SEAL PLATE
or

G42
!DD APPROPRIATE SPACER &
AND SCREW TO ACHIEVE THE DESIRED
DISPLACEMENT SEE chart below
P101 222E

11008567 s 2EV !% s .OVEMBER 35

008 924 17 BOMAG 701
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
!DJUSTMENTS

MAXIMUM 5SING A LONGER SPACER DECREASES THE MAXIMUM DISPLACEMENT 5SING A SHORTER SPACER
DISPLACEMENT LIMITER INCREASES MAXIMUM DISPLACEMENT
(continued)
4ORQUE DISPLACEMENT LIMITER SCREW & TO
• .sM ; LBFsFT= FOR THE CMÃ AND CMÃ MOTORS
• .sM ; LBFsFT= FOR THE CMÃ MOTOR

 Caution
$O NOT OVERTORQUE SCREWS

Maximum displacement screw (F10) and spacer (F20)

% of full F10=screw
60 cm³ 80cm³ 110cm³ 160cm³ 250cm³
disp. F20=spacer
&. - X - X - X - X - X
&! & X - X - X - X - X

&! MM MM MM MM MM
&" - X - X - X - X - X

&" MM MM MM MM MM
&# - X - X - X - X - X
85
&# MM MM MM MM MM
&$ - X - X - X - X - X

&$ MM MM MM MM MM
&% M8 x 35 - X - X - X - X

&% MM MM MM MM MM
&& - X - X - X - X - X

&& MM MM MM MM MM
&' - X - X - X - X - X

&' MM MM MM MM MM

2EPLACE ALL / RINGS OR SEAL PLATE $O NOT DISCARD ANY / RING UNTIL YOU ARE CERTAIN THAT
YOU HAVE THE CORRECT REPLACEMENT

)NSTALL THE 3ERIES MINIMUM ANGLE SERVO COVER OR 3ERIES CONTROL

)NSTALL THE SERVO COVER ' OR CONTROL SCREWS -

4ORQUE THE SERVO COVER CONTROL SCREWS - TO

• .sM ; LBFsFT= FOR CMÃ CMÃ CMÃ AND CMÃ MOTORS USING AN MM
HEX WRENCH

• .sM ; LBFsFT= FOR CMÃ MOTOR USING A MM HEX WRENCH

 Caution
$O NOT OVERTORQUE SCREWS

36 11008567 s 2EV !% s .OVEMBER

702 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
!DJUSTMENTS

SPEED SENSOR DIN and SAE ﬂange units

INSTALLATION AND ,OOSEN LOCKNUT
ADJUSTMENT
+EEP ALL OLD PARTS UNTIL YOU RECEIVE AND INVENTORY NEW PARTS

Speed sensor installation

Speed sensor

4 pin turck
Air gap to be 1.52 [0.060] max.
(Approx. 1/2-1 turn of thread)
M12x1D6G thread

Keyway ref. Pin 1

16.2 power +
Pin 2
[0.64]
50.8 direction
[2.00]
61.2 Pin 4
[2.41]
Pin 3
Speed speed ground
ring
P101334E
12.7 [0.50]
flats

0USH THE / RING TOWARD CONNECTOR END OF SENSOR UNIT SO THAT THE / RING DOES NOT
CONTACT MOTOR HOUSING DURING STEP

Speed sensor with Turck connector Speed sensor with Packard connector
Shaft
centerline
1/2 inch
wrench flats

22°
22°

P101332Erev

Shaft
centerline 1/2 inch
wrench flats

22°
22°

11008567 s 2EV !% s .OVEMBER 37

008 924 17 BOMAG 703
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
!DJUSTMENTS

INSTALLATION 4HREAD SENSOR #7 INTO MOTOR HOUSING BY HAND UNTIL BOTTOM END TOUCHES THE
AND ADJUSTMENT SPEED RING
(continued)
"ACK OUT ##7 TURN

#ONTINUE BACKING OUT UNTIL THE mATS ARE ² EITHER SIDE OF THE MOTOR SHAFT CENTER LINE
² TO ² IS ACMÃEPTABLE

(OLD SENSOR WITH A INCH WRENCH TORQUE THE LOCKNUT USING AN INCH WRENCH
TO .sM ; LBFsFT=

 Caution
$O NOT OVERTORQUE LOCKNUT

Cartridge units
,OOSEN LOCKNUT

0USH / RING TOWARD CONNECTOR END OF SENSOR UNIT SO THAT THE / RING DOES NOT CONTACT
MOTOR HOUSING DURING STEP

4HREAD SENSOR #7 INTO MOTOR HOUSING BY HAND UNTIL BOTTOM END TOUCHES THE SPEED
RING

"ACK OUT ##7 TURNS

4URN IN OR OUT WHICHEVER IS CLOSEST UNTIL THE ORIENTATION NOTCH IS ² AWAY FROM
HOUSING

(OLD SENSOR WITH A INCH WRENCH TORQUE THE LOCKNUT USING AN INCH WRENCH
TO .sM ; LBFsFT=

 Caution
$O NOT OVERTORQUE LOCKNUT

Cartridge model speed sensor

Orientation
NOTCH IN
;=

;=
FLATS

5.& ! THREAD

3PEED RING
Orientation !IR GAP TO BE
NOTCH MM ; IN=
MAX APPROXIMATE
3PEED SENSOR TURN OF THREAD 0 %

38 11008567 s 2EV !% s .OVEMBER

704 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

SHAFT SEAL SAE and DIN ﬂanged motors

REPLACEMENT Disassembly
4HOROUGHLY CLEAN ALL EXTERNAL SURFACES BEFORE DISASSEMBLY

Internal parts of the shaft seal

L70

L35

L40
L50

2EMOVE THE SCREWS , RETAINING THE mANGE TO THE MOTOR HOUSING USING A
• MM HEX WRENCH FOR CMÃ AND CMÃ MOTORS
• MM HEX WRENCH FOR CMÃ AND CMÃ MOTORS
• MM HEX WRENCH FOR CMÃ MOTORS

2EMOVE THE mANGE , FROM THE MOTOR HOUSING USING AN APPROPRIATE PULLER

0RESS OUT THE SHAFT SEAL , FROM THE mANGE FRONT SIDE

Inspection
)NSPECT THE SHAFT SEAL CAVITY IN THE mANGE

)NSPECT THE SEALING AREA ON THE SHAFT FOR WEAR

Reassembly
/RIENT THE NEW SHAFT SEAL , WITH THE CUPPED SIDE FACING TOWARDS THE MOTOR SHAFT
BEARINGS

0RESS THE SHAFT SEAL , INTO THE mANGE FROM THE REAR SIDE 0RESS UNTIL THE SHAFT SEAL
BOTTOMS OUT IN THE CAVITY

2EMOVE THE / RING ,

$ISCARD THE / RING AFTER MAKING CERTAIN THAT YOU HAVE A CORRECT REPLACEMENT

11008567 s 2EV !% s .OVEMBER 39

008 924 17 BOMAG 705
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

SHAFT SEAL ,UBRICATE WITH PETROLEUM JELLY AND INSTALL NEW / RING , TO THE GROOVE IN THE
REPLACEMENT mANGE
(continued)
)NSTALL THE mANGE , TO THE HOUSING USING A SEAL PROTECTION SLEEVE ON THE SHAFT

)NSTALL THE SOCKET HEAD CAPSCREWS ,

4IGHTEN THE SOCKET HEAD CAPSCREWS , SLOWLY IN A CRISSCROSS PATTERN UNTIL THE
mANGE IS PULLED FULLY DOWN ONTO THE HOUSING

4ORQUE THE CAPSCREWS USING A CRISSCROSS PATTERN TO

• .sM ; LBFsFT= FOR CMÃ AND CMÃ MOTORS USING AN MM WRENCH
• .sM ; LBFsFT= FOR CMÃ MOTORS USING A MM WRENCH
• .sM ; LBFsFT= FOR CMÃ MOTORS USING A MM WRENCH
• .sM ; LBFsFT= FOR CMÃ MOTORS USING A MM WRENCH

 Caution
$O NOT OVERTORQUE CAPSCREWS

2EMOVE THE SHAFT PROTECTION SLEEVE

40 11008567 s 2EV !% s .OVEMBER

706 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

SHAFT SEAL Cartridge ﬂanged motors

REPLACEMENT Disassembly
(continued) 4HOROUGHLY CLEAN ALL EXTERNAL SURFACES BEFORE DISASSEMBLY

2EMOVE THE SEAL CARRIER SNAP RING , FROM THE MOTOR HOUSING USING APPROPRIATE
SNAP RING PLIERS

#AREFULLY PULL THE SEAL CARRIER , FROM THE HOUSING

 Caution
$O NOT DAMAGE THE HOUSING BORE OR SHAFT

2EMOVE THE / RING ,# FROM THE HOUSING BORE

$ISCARD THE / RING ,# AFTER INSPECTING THE NEW ONE TO MAKE CERTAIN THAT IT lTS

#AREFULLY PRESS THE SHAFT SEAL , FROM THE SEAL CARRIER

$ISCARD THE SHAFT SEAL , FROM THE SEAL CARRIER , AFTER MAKING CERTAIN THAT THE
NEW ONE lTS

 Caution
$O NOT DAMAGE THE SEAL CARRIER DURING REMOVAL

Inspection
)NSPECT THE SEAL CARRIER , AND HOUSING BORE FOR DAMAGE

)NSPECT THE SEALING AREA ON THE SHAFT FOR WEAR

Common parts of a cartridge ﬂanged motor L80

L75

L40

L50

L40
Shaft seal

L75 Seal carrier

P101225

11008567 s 2EV !% s .OVEMBER 41

008 924 17 BOMAG 707
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

SHAFT SEAL Reassembl;y

REPLACEMENT /RIENT THE NEW SHAFT SEAL , SO THE CUPPED SIDE FACES INWARD
(continued)
0RESS NEW SHAFT SEAL , INTO THE SEAL CARRIER ,

0RESS UNTIL THE SHAFT SEAL BOTTOMS OUT IN THE CAVITY

5SING PETROLEUM JELLY TO LUBRICATE INSTALL NEW / RING , TO THE GROOVE IN THE
HOUSING BORE

5SING A SEAL PROTECTION SLEEVE ON THE SHAFT PUSH THE SEAL CARRIER , INTO THE
HOUSING BORE UNTIL IT CLEARS THE SNAP RING GROOVE

)NSTALL SNAP RING , INTO THE GROVE IN THE HOUSING BORE USING THE APPROPRIATE SNAP
RING PLIERS

2EMOVE THE SHAFT SEAL PROTECTION SLEEVE

LOOP FLUSHING Disassembly

SHUTTLE VALVE 4HOROUGHLY CLEAN ALL EXTERNAL SURFACES BEFORE DISASSEMBLY

5SING AN INCH HEX WRENCH REMOVE THE TWO HEX PLUGS ' FROM THE ENDCAP

2EMOVE THE / RINGS '! FROM THE HEX PLUGS

Common parts of loop ﬂushing shuttle valve

G20

G20A
K14
K16

K18
K16

G20A
G20

K14

P101226

Legend for G20

h USE AN INCH WRENCH
t .sM ; LBFsFT=

42 11008567 s 2EV !% s .OVEMBER

708 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

LOOP FLUSHING $ISCARD THE / RINGS '! AFTER INSPECTING THE NEW ONES TO MAKE CERTAIN THEY lT
SHUTTLE VALVE
(continued) 2EMOVE THE SPRINGS + AND SEATS + OR SPRING SEAT ASSEMBLY FROM THE CAVITY

2EMOVE THE SPOOL + FROM THE CAVITY

Inspection
)NSPECT THE SPOOL + AND CAVITY FOR WEAR OR DAMAGE

#LEAN THE SPOOL AND CAVITY

Reassembly
!AFTER MAKING CERTAIN THAT YOU HAVE THE EXACT REPLACEMENT PARTS REPLACE PARTS AS
NECESSARY

)NSTALL THE SPRING SEAT + OR SPRINGSEAT ASSEMBLY TO ONE END OF THE SPOOL

,UBRICATE THE SPOOL WITH CLEAN HYDRAULIC OIL

3LIDE THE LUBRICATED SPOOL INTO THE CAVITY

)NSTALL THE OTHER SPRING SEAT + OR SPRINGSEAT ASSEMBLY TO THE SPOOL FROM THE
OPPOSITE END

)NSTALL NEW / RINGS '! TO THE HEX PLUGS '

0LACE THE + SPRINGS IN TO THE HEX PLUGS

)NSTALL THE HEX PLUGS

4ORQUE THE HEX PLUGS TO .sM ; LBFsFT= USING AN HEX WRENCH

 Caution
$O NOT OVERTORQUE HEX PLUGS

11008567 s 2EV !% s .OVEMBER 43

008 924 17 BOMAG 709
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

CHARGE RELIEF VALVE Overview

9OU MAY USE ONE OF TWO CHARGE RELIEF VALVES ON 3ERIES AND 3ERIES MOTORS EITHER
POPPET OR ORIlCED !LTERNATIVELY A DEFEAT PLUG MAY BLOCK THE CHARGE RELIEF VALVE CAVITY

Poppet style (older production)

Disassembly
4HOROUGHLY CLEAN ALL EXTERNAL SURFACES BEFORE DISASSEMBLY

,OOSEN THE LOCKNUT + USING A 1 HEX WRENCH

5NSCREW THE ADJUSTMENT SCREW + FROM THE CAVITY IN THE ENDCAP USING A STANDARD
SCREWDRIVER OR A MM WRENCH

2EMOVE THE / RING + FROM THE ADJUSTMENT SCREW

$ISCARD THE / RING + AFTER INSPECTING THE NEW ONE TO MAKE CERTAIN THAT IT lTS

2EMOVE THE SPRING + AND POPPET + FROM THE CAVITY

Inspection
)NSPECT THE PARTS AND CAVITY FOR WEAR OR DAMAGE

#LEAN THE CAVITY

Reassembly
2EPLACE ANY DAMAGED OR WORN PART MAKING CERTAIN THAT YOU HAVE THE EXACT
REPLACEMENT PARTS BEFORE DISCARDING THE WORN PARTS

)NSTALL THE POPPET + TO THE CAVITY

Poppet charge relief valve
)NSTALL THE SPRING + TO THE POPPET K90

)NSTALL A NEW / RING + TO THE K10

ADJUSTMENT SCREW +
K70
)NSTALL THE ADJUSTMENT SCREW IN THE K80
CAVITY
K50
(AND TIGHTEN THE LOCKNUT +

#HECK AND ADJUST THE CHARGE RELIEF

VALVE TO THE PROPER SETTING
P101 227

44 11008567 s 2EV !% s .OVEMBER

710 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

CHARGE RELIEF VALVE Oriﬁced style

(continued) Disassembly
4HOROUGHLY CLEAN ALL EXTERNAL SURFACES BEFORE DISASSEMBLY

2EMOVE CARTRIDGE + FROM THE CAVITY IN THE ENDCAP USING A INCH HEX WRENCH

2EMOVE / RING + FROM THE CARTRIDGE

$ISCARD / RING AFTER INSPECTING THE NEW ONE TO MAKE CERTAIN THAT IT lTS

$ISASSEMBLE CARTRIDGE + USING INCH AND INCH HEX WRENCHES

2EMOVE PLUG +

2EMOVE / RING +! Oriﬁced charge relief valve

K95
$ISCARD THE / RING AFTER INSPECTING
THE NEW ONE TO MAKE CERTAIN THAT IT K95A
lTS K70
K000
K80
2EMOVE SPRING + K10

2EMOVE POPPET +

K50
Inspection
)NSPECT THE CAVITY AND PARTS FOR WEAR
OR DAMAGE
P101 227
#LEAN THE CAVITY AND PARTS

Reassembly
2EPLACE PARTS AS NECESSARY AFTER INSPECTING THE NEW ONE TO MAKE CERTAIN THAT EACH
lTS

$ISCARD REPLACED PARTS

)NSTALL / RINGS + +! TO PLUGS + +

2EASSEMBLE THE CARTRIDGE

4ORQUE PLUG + TO .sM ; LBFsFT= USING AN HEX WRENCH

)NSTALL CARTRIDGE INTO THE CAVITY

4ORQUE CARTRIDGE TO .sM ; LBFsFT= USING A INCH HEX WRENCH

 Caution
$O NOT OVERTORQUE CARTRIDGE

11008567 s 2EV !% s .OVEMBER 45

008 924 17 BOMAG 711
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

CHARGE RELIEF VALVE Defeat plug

(continued) Disassembly
4HOROUGHLY CLEAN ALL EXTERNAL SURFACES BEFORE DISASSEMBLY

2EMOVE PLUG + FROM THE CAVITY IN THE ENDCAP USING A INCH WRENCH

2EMOVE / RING +! FROM THE PLUG

$ISCARD / RING +! AFTER INSPECTING THE NEW ONE TO MAKE CERTAIN THAT IT lTS

Inspection
#LEAN AND INSPECT THE CAVITY
Defeat plug
)NSPECT THE PLUG + K90

#LEAN OR REPLACE THE PLUG IF K90A

NECESSARY

Reassembly
)NSTALL A NEW / RING TO THE PLUG

)NSTALL THE PLUG INTO THE CAVITY

P101 227

4ORQUE PLUG + TO .sM ; LBFsFT= USING A INCH WRENCH

 Caution
$O NOT OVERTORQUE PLUG

46 11008567 s 2EV !% s .OVEMBER

712 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

MAXIMUM ANGLE Disassembly

STOP - SERIES 51 4HOROUGHLY CLEAN ALL EXTERNAL SURFACES BEFORE DISASSEMBLY
MOTORS
2EMOVE THE SCREWS ' RETAINING THE MINIMUM ANGLE SERVO COVER TO THE ENDCAP
USING
• AN MM HEX WRENCH FOR CMÃ CMÃ CMÃ AND CMÃ MOTORS
• A MM HEX WRENCH FOR CMÃ MOTOR

2EMOVE THE / RINGS ' AND '

$ISCARD THE / RINGS AFTER INSPECTING THE NEW ONES TO MAKE CERTAIN THAT THEY lT

2EMOVE THE MAXIMUM ANGLE STOP SCREW & FROM THE SERVO PISTON END USING
• AN MM INTERNAL HEX WRENCH FOR CMÃ MOTORS
• A MM INTERNAL HEX WRENCH FOR CMÃ CMÃ CMÃ AND CMÃ MOTORS

)F EQUIPPED REMOVE THE SPACER & FROM THE SERVO PISTON END

Inspection
)NSPECT ALL PARTS FOR WEAR OR DAMAGE 2EPLACE WORN OR DAMAGED PARTS

Legend
' for G24
I USE AN MM INTERNAL HEX WRENCH
t .sM ; LBFsFT= FOR CMÃ CMÃ CMÃ MOTORS

' for G24

I USE A MM INTERNAL HEX WRENCH

' t .sM ; LBFsFT= FOR CMÃ MOTORS

'
for F10
I USE AN MM INTERNAL HEX WRENCH
&
t .sM ; LBFsFT= FOR CMÃ MOTORS
& for F10
I USE A MM INTERNAL HEX WRENCH
t .sM ; LBFsFT= FOR CMÃ CMÃ CMÃ CMÃ
' MOTORS

Reassembly
)NSTALL THE STOP SCREW AND SPACER IF SO EQUIPPED TO THE SERVO PISTON END

4ORQUE THE STOP SCREW & TO

• .sM ; LBFsFT= FOR A CMÃ MOTOR USING AN MM INTERNAL HEX WRENCH
• .sM ; LBFsFT= FOR CMÃ CMÃ CMÃ AND CMÃ MOTORS USING A
MM INTERNAL HEX WRENCH

11008567 s 2EV !% s .OVEMBER 47

008 924 17 BOMAG 713
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

MAXIMUM ANGLE STOP - 5SING PETROLEUM JELLY TO RETAIN THEM INSTALL A NEW / RING ' AND ' TO THE END
SERIES 51 MOTORS CAP
(continued)
)NSTALL SERVO COVER TO ' THE ENDCAP

)NSTALL THE SCREWS ITEMS '

4ORQUE THE SCREWS ' TO

• .sM ; LBFsFT= FOR CMÃ CMÃ CMÃ AND CMÃ MOTORS USING AN MM
INTERNAL HEX WRENCH
• .sM ; LBFsFT= FOR CMÃ MOTORS USING A MM INTERNAL HEX WRENCH

 Caution
$O NOT OVERTORQUE SCREWS

MAXIMUM ANGLE STOP - Disassembly

SERIES 51-1 MOTORS 2EMOVE THE SCREWS - RETAINING THE CONTROL ASSEMBLY USING AN MM INTERNAL
HEX WRENCH

2EMOVE THE CONTROL ASSEMBLY

Series 51-1 maximum displacement limiter

M16 Legend
&
F10* I USING AN MM INTERNAL HEX WRENCH
M16 t .sM ; LBFsFT= FOR CMÃ MOTORS

F20* &
I USING A MM INTERNAL HEX WRENCH
Control t .sM ; LBFsFT= FOR CMÃ AND CMÃ MOTORS
G36
&
or I USING A MM INTERNAL HEX WRENCH
G42 t .sM ; LBFsFT= FOR CMÃ CMÃ AND CMÃ
MOTORS

P101 222E

2EMOVE INTERFACE ' AND / RINGS ' OR SEAL PLATE

2EMOVE THE SCREW & AND SPACER & IF PRESENT USING

s AN MM INTERNAL HEX WRENCH FOR CMÃ MOTORS AND
s A MM INTERNAL HEX WRENCH FOR CMÃ AND CMÃ MOTORS

48 11008567 s 2EV !% s .OVEMBER

714 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

MAXIMUM ANGLE STOP - Inspection

SERIES 51-1 MOTORS )NSPECT FOR ANY CONTAMINANTS
(continued)
Reassembly
#LEAN THE ENDCAP AND SERVO PISTON AREA

2EPLACE THE SCREW & AND SPACER & IF THEY WERE PRESENT

4ORQUE DISPLACEMENT LIMITER SCREW & TO

• .sM ; LBFsFT= FOR THE CMÃ AND CMÃ MOTORS USING A MM HEX WRENCH
• .sM ; LBFsFT= FOR THE CMÃ MOTOR USING AN MM HEX WRENCH

 Caution
$O NOT OVERTORQUE SCREW

2EPLACE ALL / RINGS

$ISCARD ALL PREVIOUSLY USED / RINGS $O NOT DISCARD ANY / RINGS UNTIL YOU ARE CERTAIN
THAT YOU HAVE THE CORRECT REPLACEMENT

)NSTALL THE CONTROL

)NSTALL THE CONTROL SCREWS '

4ORQUE THE CONTROL SCREWS - TO .sM ; LBFsFT= USING AN MM HEX WRENCH

 Caution
$O NOT OVERTORQUE SCREW

11008567 s 2EV !% s .OVEMBER 49

008 924 17 BOMAG 715
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

MINIMUM ANGLE Disassembly

ADJUSTMENT SCREW 4HOROUGHLY CLEAN ALL EXTERNAL SURFACES BEFORE DISASSEMBLY

2EMOVE THE TAMPER RESISTANT CAP 1 COVERING THE ADJUSTMENT SCREW

$ISCARD THE CAP 2EMOVING THE CAP DESTROYS THE LOCKING DEVICE

 7!2.).' -EASURE THE LENGTH OF THE SCREW 9 TO ASSURE CORRECT REINSTALLATION
)MPROPER ADJUSTMENT
OF THE MINIMUM Minimum displacement limiter
DISPLACEMENT LIMITER CAN Q120
Tamper
RESULT IN UNDESIRABLE OR resistant
UNSAFE SPEED CONDITIONS Y20
cap
#ONSULT WITH THE ORIGINAL
Y10
EQUIPMENT MANUFACTURER
OR YOUR 3AUER $ANFOSS
REPRESENTATIVE BEFORE
CHANGING THE MINIMUM
DISPLACEMENT SETTING !FTER
ADJUSTMENT VERIFY THE
MINIMUM DISPLACEMENT
SETTING BY TESTING USING AN
APPROPRIATE TEST APPARATUS

P101216E

,OOSEN THE LOCKNUT 9 ON THE MINIMUM ANGLE ADJUSTMENT SCREW USING
• A MM HEX WRENCH FOR CMÃ AND CMÃ MOTORS
OR
• MM HEX WRENCH FOR CMÃ CMÃ AND CMÃ MOTORS

2EMOVE THE ADJUSTMENT SCREW 9

• USING A MM HEX WRENCH FOR CMÃ AND CMÃ FRAME SIZE MOTORS
OR
• MM HEX WRENCH FOR CMÃ CMÃ AND CMÃ MOTORS

Inspection
)NSPECT THE ADJUSTMENT SCREW

Reassembly
)NSTALL THE ADJUSTMENT SCREW TO THE MOTOR HOUSING

4URN THE ADJUSTMENT SCREW THE APPROPRIATE NUMBER OF REVOLUTIONS TO SET THE
APPROXIMATE DISPLACEMENT LIMIT OR PROPER LENGTH

50 11008567 s 2EV !% s .OVEMBER

716 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

MINIMUM ANGLE #HECK THE MINIMUM DISPLACEMENT AND RESET AS REQUIRED

ADJUSTMENT SCREW
(continued) 6ERIFY MINIMUM DISPLACEMENT SETTING BY TESTING EITHER ON AN APPROPRIATE TEST
APPARATUS OR IN THE VEHICLE

See Adjustments, ON PAGES 4

7HILE HOLDING THE ADJUSTMENT SCREW TORQUE THE SEAL LOCKNUT 9 TO
• .sM ; LBFsFT= FOR CMÃ AND CMÃ MOTORS USING A MM HEX WRENCH
OR
• .sM ; LBFsFT= FOR CMÃ CMÃ AND CMÃ MOTORS USING A MM HEX
WRENCH

 Caution
$O NOT OVERTORQUE LOCKNUT

11008567 s 2EV !% s .OVEMBER 51

008 924 17 BOMAG 717
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

4-WAY VALVE AND 4-way valve disassembly

THRESHOLD SPRINGS 2EMOVE SCREWS - FROM THE CONTROL USING
• MM HEX WRENCH FOR CMÃ CMÃ CMÃ MOTORS
• MM HEX WRENCH FOR CMÃ AND CMÃ MOTORS

4-way valve and threshold springs expanded view

G110

U8**
(250)

T1** G110
T3**
G12 G30

T2**

G30 G36
U5**

G42
S10* S10 G90
(160, 250)

S20
S10*
G38
(060, 080
110) G38

G42

J30
M22
J10*

J20/S70
T7**

T8**

F32
F324
P101 240

52 11008567 s 2EV !% s .OVEMBER

718 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

4-WAY VALVE AND 2EMOVE THE CONTROL VALVE FROM THE ENDCAP
THRESHOLD SPRINGS
(continued) 2EMOVE THE INTERFACE / RINGS ' ' AND ' OR SEAL PLATE

$ISCARD THE / RINGS ONLY AFTER MAKING CERTAIN YOU HAVE THE CORRECT REPLACEMENTS

2EMOVE THE PLUGS ' AND ' COVERING ORIlCES 4 4 AND 4 USING A
• © INCH HEX WRENCH FOR ' PLUGS
• 18 INCH HEX WRENCH FOR ' PLUGS

2EMOVE THE / RINGS '! AND '! FROM PLUGS

$ISCARD THE / RINGS AFTER INSPECTING THE NEW ONE TO MAKE CERTAIN THAT IT lTS

2EMOVE THE ORIlCES 4 4 AND 4 USING A MM HEX WRENCH

4AG TO EACH ORIlCE RECORDING ITS LOCATION FOR REASSEMBLY

2EMOVE THE FOUR WAY SPOOL & FROM THE WAY VALVE SLEEVE

Inspection
)NSPECT ALL PARTS FOR WEAR OR DAMAGE 2EPLACE WORN OR DAMAGED PARTS

Reassembly
)NSTALL A MM SCREW INTO ONE OF THE THREADED HOLES IN THE SLEEVE

5SE THE SCREW TO PULL THE SLEEVE OUT OF THE CAVITY

2EMOVE THE / RINGS & FROM THE SLEEVE &

$ISCARD THE / RINGS & AFTER INSPECTING THE NEW ONES TO MAKE CERTAIN THAT THEY
lT

2EMOVE ORIlCES 4 AND 4 FROM THE SLEEVE & USING A MM INTERNAL HEX
WRENCH

11008567 s 2EV !% s .OVEMBER 53

008 924 17 BOMAG 719
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

4-WAY VALVE AND Threshold adjustment screw and springs disassembly

THRESHOLD SPRINGS 2EMOVE THRESHOLD SPRING GUIDE * FROM THE CAVITY
(continued)
2EMOVE THE THRESHOLD SPRINGS 3

2EMOVE THE THRESHOLD SPRING GUIDE *

Threshold springs

G12
G12A G30
G30A

T1 T3

T2
G30A
S10*
(160, 250)
S20
G30

J30
S10*
(060, 080
110)

J20
T7**

T8**

F32
F324
P101 240 0E!

)F PRESENT REMOVE THE RAMP SPRINGS 3

4HERE ARE RAMP SPRINGS AND INTERMEDIATE SPRING GUIDES IN CMÃ AND CMÃ MOTORS

2EMOVE THE INTERMEDIATE RAMP SPRING GUIDE 3 IF PRESENT 2EMOVE THE OTHER
SPRING IF PRESENT

2EMOVE THE BOTTOM SPRING GUIDE 3

54 11008567 s 2EV !% s .OVEMBER

720 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

4-WAY VALVE AND 4URN THE MOTOR OVER TO ACCESS THE THRESHOLD ADJUSTMENT SCREW *
THRESHOLD SPRINGS
(continued) ,OOSEN LOCKNUT * Adjustment screws and springs
Exploded view — common parts
,OOSEN THE MOUNTING SLEEVE *
J70
HOLDING THE THRESHOLD ADJUSTMENT
J60
SCREW * USING A MM WRENCH J50

5NSCREW THE THRESHOLD ADJUSTMENT J90

SCREW ASSEMBLY
J40
2EMOVE THE / RING * FROM
THRESHOLD ADJUSTMENT SCREW

$ISCARD THE / RING AFTER INSPECTING

THE NEW ONE TO MAKE CERTAIN THAT IT
lTS N1U5
U5**
Inspection G90
#LEAN ALL PARTS
S10* S10
S20
)NSPECT ALL PARTS S20

JS10*
2EPLACE ANY PART AS NECESSARY
DISCARDING OLD OR WORN PARTS ONLY
AFTER MAKING CERTAIN YOU HAVE THE J30
CORRECT REPLACEMENTS J10*
J20/S70
Reassembly
T7**
)NSTALL NEW / RING * ON THRESHOLD
T8**
ADJUSTMENT SCREW

)NSTALL THE MOUNTING SLEEVE *

WITH THE THRESHOLD ADJUSTMENT SCREW
F324
F32
3LIDE SCREW * THROUGH THE HOLE IN THE
P101 231
FEEDBACK FORK

4ORQUE THE MOUNTING SLEEVE TO

.sM ; LBFsFT= USING A MM
WRENCH

4URN THE MOTOR OVER TO ACCESS THE WAY VALVE CAVITY

5SING A MAGNETIC PROBE CAREFULLY INSTALL THE RAMP SPRING GUIDE 3 IF PRESENT INTO
THE CAVITY

3LIDE GUIDE 3 INTO THE END OF THE THRESHOLD ADJUSTING SCREW

11008567 s 2EV !% s .OVEMBER 55

008 924 17 BOMAG 721
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

4-WAY VALVE AND )NSTALL THE RAMP SPRING 3 INTO THE CAVITY SITTING IT PROPERLY ON THE SPRING GUIDE
THRESHOLD SPRINGS 3 )NSTALL THE INTERMEDIATE SPRING GUIDE AND SECOND RAMP SPRING 3 INTO THE
(continued) CMÃ AND CMÃ UNITS
Ramp spring guide location
#AREFULLY INSTALL THE THRESHOLD SPRING J70
GUIDE * ON TO THE END OF THE J60
THRESHOLD ADJUSTING SCREW * USING J50
A MAGNETIC PROBE
J90
4HE GUIDE MUST SIT IN THE HOLE IN THE
THRESHOLD ADJUSTING SCREW * J40

)NSTALL THE THRESHOLD SPRING * ON

TO THE SPRING GUIDE *

)NSTALL THE REMAINING SPRING GUIDE S10* S10

* ON TO THE END OF THE RAMP
THRESHOLD SPRING 3 USING A S20
MAGNETIC PROBE S10*

J30

S10*
J20 P101 231

56 11008567 s 2EV !% s .OVEMBER

722 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

4-WAY VALVE AND Assembling the 4-way valve

THRESHOLD SPRINGS 5SING THE DIAGRAM OF ORIENTATION THAT YOU PREPARED WHEN DISASSEMBLING REASSEMBLE THE
(continued) WAY VALVE ACCORDINGLY PUTTING THE PARTS IN THE MARKED PLACES ON THE WAY VALVE IN
THAT ORDER

)NSTALL ORIlCES 4 AND 4 IN APPROPRIATE CAVITIES IN THE WAY VALVE SLEEVE USING A
MM HEX WRENCH

 Caution 4ORQUE THE ORIlCES TO .sM ; LBFsFT=

$O NOT OVERTORQUE ORIlCES
Assembly orientation

' '
'!
'!

4
4

4
5

3 3 '!

'

' '

3 '
3

* '
'
*
'
*3
4 -

&
&
0
Legend for T7/T8
I USE A MM HEX
WRENCH
FOR CMÃ CMÃ CMÃ CMÃ CMÃ MOTORS
t
t .sM ; LBFsFT=

11008567 s 2EV !% s .OVEMBER 57

008 924 17 BOMAG 723
16.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

4-WAY VALVE AND Assembling the 4-way valve (continued)

THRESHOLD SPRINGS )NSTALL NEW / RINGS & ON TO THE WAY VALVE SLEEVE &
(continued)
,UBRICATE THE SLEEVE AND / RINGS WITH CLEAN HYDRAULIC OIL

Assembly orientation

' '
'!
'!

4
4

4
5

3 3 '!

'

' '

3 '
3

* '
'
*
'
*3
4 -
Legend for T1, T2, T3
4 I USE A MM HEX WRENCH
FOR CMÃ CMÃ CMÃ CMÃ
t CMÃ MOTORS
t
t .sM ; LBFsFT=

&
&
0

0USH THE SLEEVE & INTO THE CAVITY

,UBRICATE THE WAY SPOOL WITH CLEAN HYDRAULIC OIL

)NSTALL THE WAY SPOOL IN THE CAVITY OF THE SLEEVE

)NSTALL ORIlCES 4 4 AND 4 IN THE APPROPRIATE CAVITIES

58 11008567 s 2EV !% s .OVEMBER

724 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Motors
Service Manual
-INOR REPAIR

4-WAY VALVE AND Assembling the 4-way valve (continued)

THRESHOLD SPRINGS 4ORQUE THE 4 4 AND 4 ORIlCES TO .sM ; LBFsFT= USING A MM HEX WRENCH
(continued)
)NSTALL NEW RINGS '! AND '! ON THE CAVITY PLUGS ' AND '

)NSTALL THE CAVITY PLUGS IN THE ORIlCE CAVITIES

4ORQUE THE CAVITY PLUGS ' TO .sM ; LBFsFT= USING A © INCH HEX WRENCH

4ORQUE THE CAVITY PLUGS ' TO .sM ; LBFsFT= USING A 18 INCH WRENCH

5SING PETROLEUM JELLY TO RETAIN IT INSTALL A NEW INTERFACE / RING '

5SING PETROLEUM JELLY TO RETAIN THEM INSTALL NEW INTERFACE / RINGS ' AND '

)NSTALL THE MOTOR CONTROL ANDOR MULTIFUNCTION BLOCK

)NSTALL THE SCREWS -

4ORQUE THE SCREWS

• .sM ; LBFsFT= USING A MM INTERNAL HEX WRENCH FOR CMÃ CMÃ
CMÃ MOTORS
• .sM ; LBFsFT= USING A MM INTERNAL HEX WRENCH FOR CMÃ AND CMÃ
MOTORS

 Caution
$O NOT OVERTORQUE SCREWS

11008567 s 2EV !% s .OVEMBER 59

008 924 17 BOMAG 725
16.3 Travel motor

Our Products Sauer-Danfoss Mobile Power and Control Systems

– Market Leaders Worldwide
/PEN CIRCUIT AXIAL PISTON PUMPS
3AUER $ANFOSS IS A COMPREHENSIVE SUPPLIER PROVIDING COMPLETE
'EAR PUMPS AND MOTORS SYSTEMS TO THE GLOBAL MOBILE MARKET
&AN DRIVE SYSTEMS
3AUER $ANFOSS SERVES MARKETS SUCH AS AGRICULTURE CONSTRUCTION ROAD
#LOSED CIRCUIT AXIAL PISTON PUMPS BUILDING MATERIAL HANDLING MUNICIPAL FORESTRY TURF CARE AND MANY
AND MOTORS OTHERS
"ENT AXIS MOTORS
7E OFFER OUR CUSTOMERS OPTIMUM SOLUTIONS FOR THEIR NEEDS AND
(YDROSTATIC TRANSMISSIONS DEVELOP NEW PRODUCTS AND SYSTEMS IN CLOSE COOPERATION AND
PARTNERSHIP WITH THEM
4RANSIT MIXER DRIVES
(YDROSTATIC TRANSAXLES 3AUER $ANFOSS SPECIALIZES IN INTEGRATING A FULL RANGE OF SYSTEM
COMPONENTS TO PROVIDE VEHICLE DESIGNERS WITH THE MOST ADVANCED
%LECTROHYDRAULICS
TOTAL SYSTEM DESIGN
)NTEGRATED SYSTEMS
3AUER $ANFOSS PROVIDES COMPREHENSIVE WORLDWIDE SERVICE FOR ITS
-ICROCONTROLLERS AND SOFTWARE
PRODUCTS THROUGH AN EXTENSIVE NETWORK OF 'LOBAL 3ERVICE 0ARTNERS
0,53 » '5)$% STRATEGICALLY LOCATED IN ALL PARTS OF THE WORLD
$ISPLAYS
*OYSTICKS AND CONTROL HANDLES ,OCAL ADDRESS

Sensors
/RBITAL MOTORS
Inverters
%LECTROHYDRAULIC POWER STEERING
(YDRAULIC POWER STEERING
(YDRAULIC INTEGRATED CIRCUITS ()# 3AUER $ANFOSS 53 #OMPANY 3AUER $ANFOSS !P3
%AST TH 3TREET $+ .ORDBORG $ENMARK
#ARTRIDGE VALVES !MES )! 53! 0HONE
$IRECTIONAL SPOOL VALVES 0HONE &AX
&AX
0ROPORTIONAL VALVES 3AUER $ANFOSS 'MB( #O /('
3AUER $ANFOSS $AIKIN ,4$
3HIN /SAKA 4%2!3!+) RD "LDG&
0OSTFACH $ .EUMünster .ISHIMIYAHARA 9ODOGAWA KU
+ROKAMP $ .EUMüNSTER 'ERMANY /SAKA *APAN
0HONE 0HONE
&AX &AX

WWWSAUER DANFOSSCOM
11008567 s 2EV !% s .OVEMBER

726 BOMAG 008 924 17

Travel motor 16.3

Series 51 and 51-1

Bent Axis Motors

Repair Instructions

008 924 17 BOMAG 727

16.3 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
2EVISIONS

HISTORY OF REVISIONS Table of Revisions

Date Page Changed Rev.

*ANUARY - First edition AA

¹ 3AUER $ANFOSS !LL RIGHTS RESERVED

3AUER $ANFOSS ACCEPTS NO RESPONSIBILITY FOR POSSIBLE ERRORS IN CATALOGS BROCHURES AND OTHER PRINTED MATERIAL
3AUER $ANFOSS RESERVES THE RIGHT TO ALTER ITS PRODUCTS WITHOUT PRIOR NOTICE4HIS ALSO APPLIES TO PRODUCTS
ALREADY ORDERED PROVIDED THAT SUCH ALTERATIONS ARENT IN CONmICT WITH AGREED SPECIlCATIONS !LL TRADEMARKS IN
THIS MATERIAL ARE PROPERTIES OF THEIR RESPECTIVE OWNERS 3AUER $ANFOSS AND THE 3AUER $ANFOSS LOGOTYPE ARE
TRADEMARKS OF THE 3AUER $ANFOSS 'ROUP
&RONT COVER ILLUSTRATIONS & 0%

2 11009449 s 2EV !! s *ANUARY

728 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
Contents

INTRODUCTION /VERVIEW 4

'ENERAL INSTRUCTIONS 4
3AFETY PRECAUTIONS 5
5NINTENDED MACHINE MOVEMENT 5
&LAMMABLE CLEANING SOLVENTS 5
&LUID UNDER PRESSURE 5
0ERSONAL SAFETY 5
3YMBOLS USED IN 3AUER $ANFOSS LITERATURE
3ECTION DIAGRAM 7

DISASSEMBLY %NDCAP
2OTATING COMPONENTS 9
3HAFT REMOVAL 3!% OR $). 1
3HAFT REMOVAL #ARTRIDGE 11
%NDCAP DISASSEMBLY1
FRAME1
FRAME1
FRAME1
!LL FRAME SIZES1
%NDCAP 14

INSPECTION 3HAFT ASSEMBLY 15

0ISTON RINGS1
"EARING PLATE VALVE SEGMENT AND CYLINDER BLOCK 17

ASSEMBLY %NDCAP ASSEMBLY1

!LL FRAME SIZES1
FRAME1
FRAME1
FRAMES
!LL FRAME SIZES1
3HAFT AND MOUNTING mANGE ASSEMBLY
3!%$). mANGE
#ARTRIDGE mANGE
#YLINDER BLOCK AND SYNCHRONIZING SHAFT5
3YNCHRONIZING SHAFT AND ROLLERS 5
#YLINDER BLOCK 7
"EARING PLATE AND VALVE SEGMENT9
"EARING PLATE 9
%NDCAP INSTALLATION

11009449 s 2EV !! s *ANUARY 3

008 924 17 BOMAG 729
16.3 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
Introduction

OVERVIEW 4HIS MANUAL DETAILS REPAIR PROCEDURES FOR 3ERIES BENT AXIS MOTORS4HESE INCLUDE THE
COMPLETE DISASSEMBLY INSPECTION AND REASSEMBLY OF THE UNIT7HERE REWORK OF WORN OR
DAMAGED COMPONENTS IS POSSIBLE SPECIlCATIONS ARE GIVEN TO ENSURE THESE PARTS MEET
FACTORY TOLERANCES /NLY 3AUER $ANFOSS 'LOBAL 3ERVICE 0ARTNERS MAY PERFORM MAJOR
REPAIRS 3AUER $ANFOSS TRAINS 'LOBAL 3ERVICE 0ARTNERS TO PERFORM MAJOR REPAIRS AND
CERTIlES THEIR FACILITIES ON A REGULAR BASIS

-INOR REPAIR PROCEDURES ADJUSTMENTS AND TROUBLESHOOTING INFORMATION ARE GIVEN IN THE
Series 51 and 51-1 Service Manual 11008567 -INOR REPAIRS INCLUDE SERVICE OPERATIONS
YOU CAN PERFORM WITHOUT REMOVING THE UNITS ENDCAP 2EMOVAL OF THE ENDCAP VOIDS YOUR
WARRANTY

GENERAL INSTRUCTIONS &OLLOW THESE GENERAL PROCEDURES WHEN REPAIRING 3ERIES BENT AXIS VARIABLE
DISPLACEMENT CLOSED CIRCUIT MOTORS

w Remove the unit

e Keep it clean
#LEANLINESS IS A PRIMARY MEANS OF ASSURING SATISFACTORY PUMP LIFE ON EITHER NEW OR
REPAIRED UNITS #LEAN THE OUTSIDE OF THE PUMP THOROUGHLY BEFORE DISASSEMBLY4AKE CARE
TO AVOID CONTAMINATION OF THE SYSTEM PORTS #LEANING PARTS WITH A CLEAN SOLVENT WASH
AND AIR DRYING IS USUALLY ADEQUATE

!S WITH ANY PRECISION EQUIPMENT YOU MUST KEEP ALL PARTS FREE OF FOREIGN MATERIALS AND
CHEMICALS 0ROTECT ALL EXPOSED SEALING SURFACES AND OPEN CAVITIES FROM DAMAGE AND
FOREIGN MATERIAL )F LEFT UNATTENDED COVER THE PUMP WITH A PROTECTIVE LAYER OF PLASTIC

l Lubricate moving parts

$URING ASSEMBLY COAT ALL MOVING PARTS WITH CLEAN HYDRAULIC OIL4HIS ASSURES THAT THESE
PARTS ARE LUBRICATED DURING START UP

d Replace all O-rings and gaskets

3AUER $ANFOSS RECOMMENDS YOU REPLACE ALL / RINGS GASKETS AND SEALS ,UBRICATE / RINGS
WITH CLEAN PETROLEUM JELLY PRIOR TO ASSEMBLY 'REASE MUST BE SOLUBLE IN HYDRAULIC mUID

t Secure the unit

&OR MAJOR REPAIR PLACE THE UNIT IN A STABLE POSITION WITH THE SHAFT POINTING DOWNWARD
3ECURE THE PUMP WHILE REMOVING AND TORQUING THE ENDCAP BOLTS

4 11009449 s 2EV !! s *ANUARY

730 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
Introduction

SAFETY PRECAUTIONS !LWAYS CONSIDER SAFETY PRECAUTIONS BEFORE BEGINNING A SERVICE PROCEDURE 0ROTECT
YOURSELF AND OTHERS FROM INJURY 4AKE THE FOLLOWING GENERAL PRECAUTIONS WHENEVER SERVICING
A HYDRAULIC SYSTEM

Unintended machine movement

W Warning
5NINTENDED MOVEMENT OF THE MACHINE OR MECHANISM MAY CAUSE INJURY TO THE TECHNICIAN
OR BYSTANDERS 4O PROTECT AGAINST UNINTENDED MOVEMENT SECURE THE MACHINE OR DISABLE
DISCONNECT THE MECHANISM WHILE SERVICING

Flammable cleaning solvents

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

Fluid under pressure

Personal safety
W Warning
0ROTECT YOURSELF FROM INJURY 5SE PROPER SAFETY EQUIPMENT INCLUDING SAFETY GLASSES AT ALL
TIMES

11009449 s 2EV !! s *ANUARY 5

008 924 17 BOMAG 731
16.3 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
Introduction

SYMBOLS USED IN  7!2.).' MAY RESULT IN INJURY  4IP HELPFUL SUGGESTION

SAUER-DANFOSS
LITERATURE  #!54)/. MAY RESULT IN DAMAGE TO  ,UBRICATE WITH HYDRAULIC mUID
PRODUCT OR PROPERTY
 !PPLY GREASE PETROLEUM JELLY
 2EUSABLE PART
 !PPLY LOCKING COMPOUND
 .ON REUSABLE PART USE A NEW PART
 )NSPECT FOR WEAR OR DAMAGE
 .ON REMOVABLE ITEM
 #LEAN AREA OR PART
 /PTION n EITHER PART MAY EXIST
 "E CAREFUL NOT TO SCRATCH OR DAMAGE
 Superseded – parts are not
INTERCHANGEABLE  .OTE CORRECT ORIENTATION

 -EASUREMENT REQUIRED  -ARK ORIENTATION FOR REINSTALLATION

 &LATNESS SPECIlCATION  4ORQUE SPECIlCATION

 0ARALLELISM SPECIlCATION  0RESS IN n PRESS lT

 %XTERNAL HEX HEAD  0ULL OUT WITH TOOL n PRESS lT

 )NTERNAL HEX HEAD  #OVER SPLINES WITH INSTALLATION

SLEEVE
 4ORX HEAD
 0RESSURE MEASUREMENT GAUGE
 / RING BOSS PORT LOCATION OR SPECIlCATION

6 11009449 s 2EV !! s *ANUARY

732 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
Introduction

SECTION DIAGRAM Series 51 bent axis variable motor

Multi-function
Pressure compensator Minimum displacement
block
override limiter

Control Valve segment

(hydraulic proportional) Motor output shaft
Bearing plate
Tapered roller bearings

4-way valve
and sleeve

Control
springs

Synchronizing
Piston
shaft and rollers

End cap Housing

Servo piston
Charge pressure
relief valve
Minimum angle
servo cover P104 085

11009449 s 2EV !! s *ANUARY 7

008 924 17 BOMAG 733
16.3 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
$ISASSEMBLY

ENDCAP &OLLOWING PROCEDURES IN THE Series 51 and 51-1 Service Manual 11008567 2EMOVE THE
CONTROL AND MULTI FUNCTION BLOCK IF INSTALLED 2EMOVE THE WAY VALVE SPOOL AND SLEEVE
IF INSTALLED 2EMOVE THE THRESHOLD SPRINGS AND GUIDES 2EMOVE THE CONTROL SPRINGS IF
INSTALLED 2EMOVE THE RAMP SPRINGS AND GUIDES IF INSTALLED 2EMOVE THE MINIMUM ANGLE
SERVO COVER FROM THE MOTOR 2EMOVE THE LOOP mUSHING VALVE AND CHARGE RELIEF VALVE

2EMOVE THE SCREWS ' AND ' RETAINING THE END CAP ASSEMBLY TO THE MOTOR
HOUSING

2EMOVE THE END CAP ASSEMBLY

2EMOVE THE GASKET ' DISCARD

2EMOVE THE ALIGNMENT PINS "

Endcap and rotating components

B05

C10
Note orientation of segment with end cap and housing

Note orientation of pins

C20

Note orientation of rollers with synchronizing shaft (recess faces the centerline of the shaft)
(later version rollers do not have recess and can be installed either way), and synchronizing
shaft with cylinder block and output shaft, small end into shaft and big end into block.
Note locations of longer and
C05 G32
shorter screws

060 and 080: 8mm

G34
110 and 160: 10mm
250: 12mm

End cap assembly

Q20
(side port configuration shown)
B50
G60

B50

P104 086
SAE flange version Cartridge version

8 11009449 s 2EV !! s *ANUARY

734 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
$ISASSEMBLY

ROTATING COMPONENTS 2EMOVE THE VALVE SEGMENT " AND SET ASIDE

2EMOVE THE BEARING PLATE # AND ALIGNMENT PINS #

2EMOVE THE CYLINDER BLOCK # AND SET ASIDE "E CAREFUL NOT TO SCRATCH THE RUNNING
SURFACE OF THE BLOCK

2EMOVE THE SYNCHRONIZING SHAFT ASSEMBLY # WITH ROLLERS AND PINS

Endcap and rotating components

B05

C10
Note orientation of segment with end cap and housing

Note orientation of pins

C20

060 and 080: 8mm

G34
110 and 160: 10mm
250: 12mm

End cap assembly

Q20
(side port configuration shown)
B50
G60

B50

P104 086
SAE flange version Cartridge version

11009449 s 2EV !! s *ANUARY 9

008 924 17 BOMAG 735
16.3 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
$ISASSEMBLY

SHAFT REMOVAL (SAE OR Shaft assembly SAE or DIN ﬂange version 2EMOVE SCREWS , RETAINING THE
DIN) MOUNTING mANGE , TO THE MAIN
HOUSING "

2EMOVE THE MOUNTING mANGE USING A

B10 SUITABLE PULLER

2EMOVE THE / RING , DISCARD

2EMOVE THE SHAFT SEAL , FROM THE

mANGE DISCARD

0RESS SHAFT ASSEMBLY OUT OF MAIN

HOUSING TAKING CARE NOT TO DAMAGE
THE SHAFT AND SPEED SENSOR RING IF
INSTALLED
Shaft assembly
C Caution
$O NOT DAMAGE PISTON SOCKETS

L50

L40
P104 087

L35

L70
060 and 080: 6mm
110: 8mm
160: 10mm
250: 12mm

10 11009449 s 2EV !! s *ANUARY

736 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
$ISASSEMBLY

SHAFT REMOVAL 2EMOVE RETAINING RING ,

(CARTRIDGE)
2EMOVE SEAL CARRIER ,

2EMOVE SHAFT SEAL , DISCARD

2EMOVE RETAINING RING , FOR THE SHAFT SEAL CARRIER , FROM THE BEARING
HOUSING ,

2EMOVE THE SCREWS , RETAINING THE BEARING HOUSING , TO THE MAIN HOUSING
"

3EPARATE THE BEARING HOUSING FROM THE MAIN HOUSING "

2EMOVE THE RETAINING RING , IF PRESENT

2EMOVE SPACER RING ,

2EMOVE / RINGS , AND , OR GASKET , DISCARD

0RESS SHAFT ASSEMBLY OUT OF BEARING HOUSING TAKING CARE TO NOT DAMAGE THE SHAFT
PISTON SOCKETS AND SPEED SENSOR RING IF INSTALLED

Shaft assembly, cartridge version

Prior to
N94-42

L80
L35
N94-42
L85 thru L40
L90 N98-32 L50
L95 L80
B80

L35 L750
L95
L81

L70
L82

L35 060 and 080: 6mm

N98-33 110: 8mm
and beyond 160: 10mm
250: 12mm

L95
L81
L90

L85 P104 088

B10

11009449 s 2EV !! s *ANUARY 11

008 924 17 BOMAG 737
16.3 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
$ISASSEMBLY

ENDCAP DISASSEMBLY 060 frame

2EMOVE END CAP PLUG ' 2EMOVE / RING '! FROM PLUG DISCARD

2EMOVE LOCK SCREWS & FROM SERVO PISTON &

2EMOVE CONE POINT SET SCREWS & FROM SERVO PISTON

2EMOVE FEEDBACK FORK & THROUGH THE HOLE IN THE END CAP

2EMOVE THE SETTING LUG & FROM INSIDE OF END CAP

End cap components

3 mm (060)
3 mm (060)
F30
F28 (060)

F26 F10
F11 F12
060: 3/8 inch
G80 080: 9/16 inch

G80A

F26
G10
F24 F28
(060)

F24
(080)

F10 F12
F11

End cap
(typical for 060 and 080 frame sizes)
F26 axial port style shown

F28
P104 089
5 mm (080)

080 frame
2EMOVE END CAP PLUG '

2EMOVE LOCK SCREW &

2EMOVE CONE POINT SET SCREW &

2EMOVE FEEDBACK FORK SETTING LUG & THROUGH HOLE IN END CAP

12 11009449 s 2EV !! s *ANUARY

738 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
$ISASSEMBLY

ENDCAP DISASSEMBLY 110 - 250 frame

(continued) 2EMOVE LOCK SCREW &

2EMOVE CONE POINT SET SCREW &

2EMOVE FEEDBACK FORK SETTING LUG & FROM INSIDE OF END CAP

Disassembling the end cap

F10 F12
5 mm (110, 160, 250)
F11

F26
G10
F28

F24
(110, 160, 250)

P104 090

End cap
(typical for 110, 160, and 250 frame sizes)
side port style shown

All frame sizes

2EMOVE SERVO PISTON & FROM END CAP & GLIDE RING END lRST

)NSPECT GLIDE RING & FOR DAMAGE OR WEAR

2EMOVE GLIDE RING & FROM SERVO PISTON IF YOU NEED TO REPLACE IT

2EMOVE / RING & FROM SERVO PISTON DISCARD

)NSPECT SERVO PISTON BORE IN END CAP FOR DAMAGE OR WEAR

11009449 s 2EV !! s *ANUARY 13

008 924 17 BOMAG 739
16.3 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
$ISASSEMBLY

ENDCAP DISASSEMBLY 51-1 Endcap

(continued) 2EMOVE SERVO PISTON & FROM END CAP ' GLIDE RING END lRST

)NSPECT GLIDE RING & FOR DAMAGE OR WEAR

2EMOVE GLIDE RING & FROM SERVO PISTON IF YOU NEED TO REPLACE IT

2EMOVE / RING & FROM SERVO PISTON DISCARD

)NSPECT SERVO PISTON BORE IN END CAP FOR DAMAGE OR WEAR

Disassembling the end cap

F11

F10

F12 Servo piston

G10 End cap assembly

P106 541E

14 11009449 s 2EV !! s *ANUARY

740 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
Inspection

SHAFT ASSEMBLY #HECK THE SEAL AREA OF THE SHAFT , Shaft assembly
FOR DAMAGE OR WEAR
C Caution
4HE OPTIONAL MAGNETIC #HECK THE OUTPUT SPLINES FOR DAMAGE
SPEED SENSOR RING IS OR WEAR
PRESSED ONTO A MACHINED
SURFACE OF THE SHAFT4AKE )NSPECT SYNCHRONIZING SHAFT RACEWAYS
CARE NOT TO DAMAGE THE FOR WEAR
SENSOR RING
)NSPECT SHAFT BEARINGS FOR WEAR AND L1
ROUGHNESS

#HECK THAT THE BEARING RETAINING NUT

IS lRMLY STAKED TO THE OUTPUT SHAFT
AND THAT NO NOTICEABLE LOOSENESS IS P104 091
PRESENT IN THE BEARINGS

#HECK THE PISTON ASSEMBLIES , FOR DAMAGE OR WEAR

"EARINGS AND PISTONS ARE NOT INDIVIDUALLY SERVICEABLE 2EPLACE THE ENTIRE SHAFT ASSEMBLY IF
ANY COMPONENTS ARE DAMAGED OR WORN

11009449 s 2EV !! s *ANUARY 15

008 924 17 BOMAG 741
16.3 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
Inspection

PISTON RINGS 5SE A SMALL PAIR OF RETAINING RING PLIERS TO SPREAD AND REMOVE THE PISTON RINGS ,
FROM THE PISTONS $ISCARD THE RINGS

)NSTALL NEW PISTON RINGS , %NSURE THE SPHERICAL SURFACE CONFORMS TO THE SHAPE OF
THE PISTON ! RADIAL IDENTIlCATION MARK APPEARS ON THE OUTER SIDE OF THE PISTON RINGS
$O NOT LET THE ENDS OF EACH PISTON RING OVERLAP EACH OTHER

Spherical piston rings

L230

Split line

Radial identification mark located

on this side of piston ring

The spherical surface of the piston ring must

conform to the spherical shape of the piston

P104 092

16 11009449 s 2EV !! s *ANUARY

742 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
Inspection

BEARING PLATE, )NSPECT THE BRONZE SURFACE OF THE BEARING PLATE # FOR DAMAGE AND EXCESSIVE WEAR
VALVE SEGMENT, AND 3EALING SURFACE MUST BE FREE FROM SCRATCHES AND NICKS4HE LOCATING PIN HOLES MUST
CYLINDER BLOCK NOT BE WORN 2EPLACE IF NECESSARY

Bearing plate Valve segment

C10 B05

P104 093
P106 350E

)NSPECT THE VALVE SEGMENT " FOR DAMAGE OR WEAR ON THE SEALING SURFACES

)NSPECT THE SPINDLE FOR WEAR

%NSURE THE SPINDLE IS LOCATED CORRECTLY IN THE VALVE SEGMENT BY MEASURING DISTANCE
A )F THIS DIMENSION IS NOT WITHIN THE RANGE SHOWN IN THE TABLE IT INDICATES THAT THE
SPINDLE HAS MOVED IN THE VALVE SEGMENT 2EPLACE IT

Valve segment Spindle location distance

Frame size Distance A MM ;IN=
A
¼ ; ¼ =
¼ ; ¼ =

P104 094
¼ ; ¼ =
¼ ; ¼ =
¼ ; ¼ =

$O NOT LAP THE VALVE SEGMENT TO REMOVE SCRATCHES4HE HARD TREATED SURFACE IS THIN AND
LAPPING MAY REMOVE THIS SURFACE 2EMOVING THE SPINDLE LOOSENS ITS TIGHT PRESS lT AND
ALLOWS IT TO MOVE

)NSPECT CYLINDER BLOCK ASSEMBLY FOR Cylinder block bearing

WEAR OR DAMAGE )F BEARING IS WORN
OR DAMAGED REPLACE THE COMPLETE Bearing
BLOCK ASSEMBLY4HE BEARING IS NOT
AVAILABLE AS A SEPARATE PART

4HE PISTON BORES MUST BE SMOOTH

4HE BEARING PLATE SURFACE MUST BE
FREE FROM SCRATCHES OR NICKS4HE P104 095
HOLES FOR THE BEARING PLATE LOCATING
PINS MUST BE FREE FROM WEAR4HE
RACES FOR THE SYNCHRONIZING SHAFT
ROLLERS MUST ALSO BE FREE FROM WEAR

11009449 s 2EV !! s *ANUARY 17

008 924 17 BOMAG 743
16.3 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
!SSEMBLY

ENDCAP ASSEMBLY All frame sizes

#AREFULLY INSTALL A NEW / RING & AND GLIDE RING & ON THE SERVO PISTON &

,UBRICATE THE GLIDE RING

)NSTALL THE SERVO PISTON INTO THE END CAP '

4HE END OF THE SERVO PISTON WITH THE GLIDE RING IS OPPOSITE THE MULTI FUNCTION BLOCK
CONTROL MOUNTING SURFACE OF THE END CAP

060 frame
)NSTALL THE SETTING LUG & INTO THE SERVO PISTON & FROM INSIDE OF END CAP

5SING A MM INTERNAL HEX WRENCH INSTALL THE CONE POINT SET SCREW & SO THAT ITS
POINT ENTERS THE GROOVE IN THE SETTING LUG AND TORQUE TO .sM ; LBFsIN=

)NSTALL THE LOCK SCREW &

5SING A MM HEX WRENCH TORQUE THE LOCK SCREW & TO .sM ; LBFsIN=

)NSTALL THE FEEDBACK FORK & INTO THE SERVO PISTON THROUGH THE HOLE IN THE END CAP

4HE CONTACT PADS ON THE FORK MUST FACE TOWARD THE MULTI FUNCTION BLOCKCONTROL END OF
THE END CAP

5SING A MM INTERNAL HEX WRENCH INSTALL THE OTHER CONE POINT SET SCREW & SO THAT
ITS POINT ENTERS THE GROOVE IN THE FEEDBACK FORK & $O NOT TIGHTEN THE SET SCREW
YET 3EE PAGE FOR lNAL ASSEMBLY INSTRUCTIONS

,UBRICATE AND INSTALL A NEW / RING '! ON THE END CAP PLUG ' )NSTALL THE PLUG

5SING A IN INTERNAL HEX WRENCH TORQUE THE END CAP PLUG TO .sM ; LBFsFT=

080 frame
)NSTALL FEEDBACK FORK SETTING LUG & INTO THE SERVO PISTON THROUGH THE HOLE IN THE
END CAP

4HE OFFSET OF THE FORK MUST BE FACING AWAY FROM THE MULTI FUNCTION BLOCK CONTROL END OF
THE END CAP

)NSTALL THE CONE POINT SET SCREW & SO THAT ITS POINT ENTERS THE GROOVE IN THE
FEEDBACK FORK & SETTING LUG & $O NOT TIGHTEN THE SET SCREW YET 3EE PAGE
FOR lNAL ASSEMBLY INSTRUCTIONS

)NSTALL THE END CAP PLUG '

5SING A IN INTERNAL HEX WRENCH TORQUE THE END CAP PLUG ' TO .sM
; LBFsFT=

18 11009449 s 2EV !! s *ANUARY

744 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
!SSEMBLY

ENDCAP ASSEMBLY
(continued) Setting lugs

$$ +(!-! /(+#!#+! $$

F11 0$ #0!%
F30
F26 (060) 0$ #0!%
F10
F12

!%h
+#*!+%*!&%
Groove #&"&%*(&# 0$
#)0* G80
F24 F26
G80A
(060)
F28 G10

End cap (axial port style shown)

F24
+(!*-!* /(+#!#+! (080)

+#*!+%*!&%
#&"&%*(&#
Groove
F10
F11 F12

F26
$$

P104 096

11009449 s 2EV !! s *ANUARY 19

008 924 17 BOMAG 745
16.3 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
!SSEMBLY

ENDCAP ASSEMBLY 110-250 frames

(continued) )NSTALL FEEDBACK FORK & SETTING LUG INTO THE SERVO PISTON FROM INSIDE OF THE
ENDCAP

4HE OFFSET OF THE FORK MUST BE AWAY FROM THE MULTI FUNCTION BLOCK CONTROL END OF THE
END CAP

)NSTALL THE CONE POINT SET SCREW & SO THAT ITS POINT ENTERS THE GROOVE IN THE
FEEDBACK FORK & SETTING LUG $O NOT TIGHTEN THE SET SCREW YET 3EE PAGE FOR
lNAL ASSEMBLY INSTRUCTIONS

Cone-point screw and feedback fork

Lubricate with hydraulic fluid

F10
F11 F12
Multi-function
Groove block/control

F26
G10

F24
(110, 160, 250)

End cap (side port style shown)

typical for 110, 160, and 250 frame sizes P104 097

20 11009449 s 2EV !! s *ANUARY

746 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
!SSEMBLY

ENDCAP ASSEMBLY All frame sizes

(continued) 0OSITION FEEDBACK FORK & CC OR FEEDBACK FORKSETTING LUG CC CC
PERPENDICULAR TO THE SETTING PISTON FOR PROPER CONTROL SPRING OPERATION

)NSERT A MM ; IN= DIAMETER ROD WITH THE END MACHINED PERPENDICULAR TO ITS
AXIS INTO THE VALVE SLEEVE BORE IN THE END CAP !LIGN THE FORK WHILE TIGHTENING THE
CONE POINT SET SCREW &

5SING A OR MM INTERNAL HEX WRENCH TORQUE THE CONE POINT SET SCREW TO .sM
; LBFsIN=

)NSTALL AND TORQUE THE LOCK SCREW & TO

• .sM ; LBFsIN= USING A MM INTERNAL HEX WRENCH FOR A CC MOTOR
• .sM ; LBFsFT= USING A MM INTERNAL HEX WRENCH FOR THE CC THROUGH CC
MOTORS

Cone-point set screws

3 mm
]

F28

F26
3 mm

060 frame size

F28
6 mm

]

F26
6 mm

080, 110, 160, 250, frame sizes

11009449 s 2EV !! s *ANUARY 21

008 924 17 BOMAG 747
16.3 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
!SSEMBLY

SHAFT AND MOUNTING SAE/DIN ﬂange

FLANGE ASSEMBLY 3UPPORT THE MAIN HOUSING " SO THE BEARING BORE IS VERTICAL

0RESS SHAFT ASSEMBLY , INTO MAIN HOUSING

)NSTALL NEW / RING , ON MOUNTING mANGE ,

)NSTALL NEW SEAL , IN mANGE

#OVER THE SHAFT SPLINES WITH AN INSTALLATION SLEEVE TO PROTECT THE SEAL DURING
ASSEMBLY )NSTALL mANGE ASSEMBLY ,

)NSTALL SCREWS ,

4ORQUE SCREWS , TO VALUE SHOWN IN THE DIAGRAM

SAE/DIN Flange version bearing bore and housing

# "" L70 ," !,(]
"" ," !,(]
"" ,"!,(]
"" ,"!,(]

)& ('!! %+ (&'

L35

L50

B10

19°

$)' #')%%$&( #%&''

' * +

22 11009449 s 2EV !! s *ANUARY

748 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
!SSEMBLY

SHAFT AND MOUNTING Cartridge ﬂange

FLANGE ASSEMBLY )NSTALL THE INNER RETAINING RING , FOR THE SHAFT SEAL CARRIER IN THE BEARING HOUSING
(continued)
0RESS SHAFT ASSEMBLY INTO BEARING HOUSING ,

C Caution )NSTALL SPACER RING , C

$O NOT DAMAGE THE PISTON
SOCKETS OR SHAFT SEAL )NSTALL THE END OF THE SPACER WITH THE LARGER INSIDE DIAMETER NEXT TO THE INNER SHAFT
SURFACE BEARING CUP

)NSTALL RETAINING RING ,

!LIGN ENDS OF THE RETAINING RING BETWEEN THE TWO BOLT HOLES TO ALLOW CLEARANCE FOR
SPEED SENSOR

Speed sensors
speed sensor

Notch

Locking nut

Spacer ring

Sensor

Axial notch on speed sensor

Retaining-ring (L81)

P104 100

11009449 s 2EV !! s *ANUARY 23

008 924 17 BOMAG 749
16.3 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
!SSEMBLY

SHAFT AND MOUNTING )NSTALL / RINGS , AND , OR GASKET ,
FLANGE ASSEMBLY
(continued) )NSTALL MAIN HOUSING " %NSURE SNAP RING , ENDS ALIGN WITH SPEED SENSOR PORT

)NSTALL SCREWS ,

4ORQUE SCREWS

• .sM ; LBFsFT= FOR CC AND CC
• .sM ; LBFsFT= FOR CC
• .sM ; LBFsFT= FOR CC

Cartridge version bearing bore and housing

Before N94-42

N94-42
through L80
L35
N98-32

L85
O
L40
L90 L50
L95 L80
B80

L35 L750
L95
O
L81
N98-33
and beyond
L70
L82
060 and 080: 6mm
110: 8mm
L35 160: 10mm
250: 12mm

L95
P104 101
L81

L90

B10 L85

24 11009449 s 2EV !! s *ANUARY

750 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
!SSEMBLY

CYLINDER BLOCK AND Synchronizing shaft and rollers

SYNCHRONIZING SHAFT 5SING PETROLEUM JELLY TO RETAIN IT INSTALL THE lRST SYNCHRONIZING SHAFT SUPPORT PIN
# INTO THE RECESS IN THE CYLINDER BLOCK

5SING PETROLEUM JELLY TO RETAIN THEM INSTALL THE SYNCHRONIZING SHAFT ROLLERS # ON
THE JOURNALS OF THE SYNCHRONIZING SHAFT #

0OSITION THE RECESS ON EACH ROLLER TO FACE THE CENTER LINE OF THE SYNCHRONIZING SHAFT

-OTORS BUILT AFTER SERIAL NUMBER . 88888 HAVE SYMMETRICAL ROLLERS
3EE SERVICE BULLETIN SB-2001-015

0OSITION EACH ROLLER WITH ITS OUTSIDE EDGE mUSH WITH THE END OF THE SYNCHRONIZING
SHAFT JOURNAL

Cylinder block and sync-shaft

Cylinder
block

C40

C50

C60

Q20
C60 C50
C40

P104 102

11009449 s 2EV !! s *ANUARY 25

008 924 17 BOMAG 751
16.3 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
!SSEMBLY

MOTOR ASSEMBLY Synchronizing shaft and rollers (continued)

(continued) )NSTALL THE SECOND # SYNCHRONIZING SHAFT SUPPORT PIN INTO THE MOTOR SHAFT
ASSEMBLY

)NSTALL THE SYNCHRONIZING SHAFT AND ROLLERS INTO THE MOTOR SHAFT

4HE CYLINDER BLOCK END OF THE SHAFT IS A LARGER DIAMETER THAN THE MOTOR SHAFT END ON ALL
FRAME SIZES4HE ROLLERS MUST ENTER THE RACES IN THE MOTOR SHAFT AND THE RECESS IN THE END
OF THE SYNCHRONIZING SHAFT MUST ENGAGE THE SUPPORT PIN

4IP AND ROTATE THE SYNCHRONIZING SHAFT IN ALL DIRECTIONS TO CHECK FOR BINDING4HE
SYNCHRONIZING SHAFT ROLLERS MUST MOVE FREELY IN THE RACES IN THE MOTOR SHAFT

Cylinder block and sync-shaft

Cylinder
block

C40

C50

C60

Q20
C60 C50
C40

P104 102

26 11009449 s 2EV !! s *ANUARY

752 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
!SSEMBLY

CYLINDER BLOCK AND Cylinder block Pistons

SYNCHRONIZING SHAFT ,UBRICATE THE PISTONS AND SYNC SHAFT Position the motor shaft
(continued) AND ROLLERS WITH CLEAN HYDRAULIC OIL as shown prior to installing
the cylinder block
AND ROTATE THE SHAFT TO THE POSITION
SHOWN IN THE ILLUSTRATION

4IP THE PISTONS CLOSEST TO THE

MINIMUM ANGLE STOP OUT TOWARD THE
HOUSING

4IP THE REMAINING PISTONS FORWARD

TOWARD THE LOWEST PART OF THE END
CAP MOUNTING SURFACE

4IP THE SYNCHRONIZING SHAFT FORWARD

TOWARD THE LOWEST PART OF THE END
CAP MOUNTING SURFACE
P104 103
0OSITION THE CYLINDER BLOCK SO ONE (Cylinder block not installed)
SYNCHRONIZING SHAFT ROLLER RACEWAY IS
ALIGNED BETWEEN TWO PISTONS

)NSTALL THE CYLINDER BLOCK AND ITS SUPPORT PIN # ON TO THE PISTONS AND
SYNCHRONIZING SHAFT

4HE SYNCHRONIZING SHAFT ROLLERS # ENTER THEIR RACES IN THE BLOCK WHILE EACH PISTON
ENTERS ITS CORRESPONDING BORE IN THE BLOCK

)NSERT A BRASS ROD THROUGH THE CYLINDER BLOCK KIDNEYS TO GUIDE THE PISTONS INTO
POSITION

3TART WITH THE FOUR PISTONS CLOSEST TO THE LOWEST PART OF THE END CAP MOUNTING
SURFACE

!FTER THE PISTONS ENTER THEIR BORES TILT THE CYLINDER BLOCK SO THE SYNCHRONIZING SHAFT
ROLLERS # ENTER THEIR RACES IN THE CYLINDER BLOCK AND THE NEXT TWO PISTONS ENTER
THEIR BORE

4HE SUPPORT PIN # ENTERS ITS RECESS IN THE SYNCHRONIZING SHAFT #

,IFT THE CYLINDER BLOCK SLIGHTLY

'UIDE THE REMAINING PISTONS INTO THEIR BORES

!FTER THE LAST PISTON IS IN POSITION CHECK THE POSITION OF THE ROLLERS CLOSEST TO THE
MINIMUM ANGLE STOP

-AINTAIN AN INWARD FORCE ON THE CYLINDER BLOCK

#AREFULLY PUSH IT TOWARD THE HIGHEST PART OF THE END CAP MOUNTING SURFACE

11009449 s 2EV !! s *ANUARY 27

008 924 17 BOMAG 753
16.3 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
!SSEMBLY

CYLINDER BLOCK AND #HECK THAT ALL OF THE SYNCHRONIZING SHAFT ROLLERS ARE IN POSITION
SYNCHRONIZING SHAFT
(continued) )F THE CYLINDER BLOCK IS PROPERLY INSTALLED THERE WILL BE VERY LITTLE ROTATIONAL FREE PLAY
BETWEEN THE CYLINDER BLOCK AND THE MOTOR SHAFT

Lubricate the pistons and cylinder

Cylinder block block bores with hydraulic oil

Cylinder block

Pistons

P104 104
SAE flange version shown
cartridge version similar

28 11009449 s 2EV !! s *ANUARY

754 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
!SSEMBLY

BEARING PLATE AND Bearing plate

VALVE SEGMENT )NSTALL THE BEARING PLATE LOCATING PINS # INTO THE CYLINDER BLOCK

)NSTALL THE LONGER END OF EACH SHOULDERED PIN INTO THE BLOCK

)NSTALL THE BEARING PLATE # ON THE CYLINDER BLOCK WITH STEEL SIDE FACING THE BLOCK

,UBRICATE THE BRONZE SIDE OF THE PLATE WITH HYDRAULIC OIL

)NSTALL THE END CAP ALIGNMENT PINS " )NSTALL A NEW GASKET '

,OCATE THE CYLINDER BLOCK IN THE APPROXIMATE CENTER OF THE HOUSING OPENING

4IP THE HOUSING UNTIL THE ENDCAP MOUNTING SURFACE IS LEVEL TO HELP KEEP THE BLOCK
CENTERED $O NOT ALLOW PISTONS OR SYNCHRONIZING SHAFT ROLLERS TO FALL OUT OF POSITION

5SING PETROLEUM JELLY INSTALL THE VALVE SEGMENT " INTO THE END CAP SO THE
SEGMENT SPINDLE ENGAGES THE SETTING LUG IN THE SERVO PISTON

/RIENT THE VALVE SEGMENT SO THE HOLE AT THE EDGE IS ALIGNED WITH THE LOOP mUSHING
VALVE DRAIN HOLE IN THE END CAP

,OCATE THE VALVE SEGMENT AND SERVO PISTON IN THE APPROXIMATE CENTER OF THEIR TRAVEL
G32
Bearing plate and valve segment
see page 30

G34

End cap
(typical side port
configuration shown)

B50 B05

C10

C20 G60

B50

SAE flange version shown

P104 105
(cartridge version similar)

11009449 s 2EV !! s *ANUARY 29

008 924 17 BOMAG 755
16.3 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
!SSEMBLY

ENDCAP INSTALLATION 2OTATE THE MOTOR SHAFT AND CHECK FOR PLAY BETWEEN THE SHAFT AND CYLINDER BLOCK !NY
PLAY INDICATES THAT THE SYNCHRONIZING SHAFT ROLLERS ARE NOT INSTALLED CORRECTLY
C Caution
$O NOT ALLOW THE PISTONS OR )NSTALL THE END CAP ASSEMBLY AND VALVE SEGMENT SO THE SPINDLE ENGAGES THE BEARING
SYNCHRONIZING SHAFT ROLLERS IN THE CYLINDER BLOCK C
TO FALL OUT OF POSITION
)NSTALL SCREWS ' AND ' TO RETAIN THE END CAP ASSEMBLY TO THE MOTOR

)NSTALL THE SCREWS IN THEIR PROPER LOCATIONS TO ENSURE ADEQUATE THREAD ENGAGEMENT4HE
INTERNAL SPRING IN THE MOTOR SHAFT WILL HOLD THE END CAP AWAY FROM THE HOUSING A SHORT
DISTANCE

C Caution 4IGHTEN THE SCREWS BY HAND IN A Endcap screw torque

$O NOT FORCE THE END DOUBLE 8 PATTERN WHILE ROTATING Frame size Wrench size 4ORQUE .sM
CAP INTO POSITION ON THE THE MOTOR SHAFT TO ENSURE PROPER ;LBFsFT=
HOUSING )F NECESSARY POSITIONING OF THE SYNCHRONIZING MM ;=
REASSEMBLE THE SHAFT ROLLERS
MM ;=
COMPONENTS TO ENSURE
PROPER ALIGNMENT 7HEN THE END CAP IS IN POSITION MM ;=
TORQUE THE SCREWS IN A DOUBLE 8 MM ;
PATTERN AS SHOWN IN THE TABLE C MM ;=

2ECHECK THE END CAP SCREW TORQUE

2EINSTALL THE MINIMUM ANGLE SERVO COVER CONTROL SPRINGS IF USED WAY VALVE SPOOL
AND SLEEVE IF USED AND CONTROL AND MULTIFUNCTION BLOCK IF USED 2EFER TO Series 51
and 51-1 Service Manual, 11008567 FOR INSTRUCTIONS

Torquing pattern

G34 see table

Endcap assembly 2/10
3/11 5/13
with valve segment G32 7/15

6/14 8/16
1/9 4/12
Double-X pattern torquing sequence
(110 frame size with side port end cap shown)

SAE flange version shown

cartridge version similar
P104 106

30 11009449 s 2EV !! s *ANUARY

756 BOMAG 008 924 17

Travel motor 16.3
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
!SSEMBLY

ENDCAP INSTALLATION &OLLOWING PROCEDURES IN THE Series 51 and 51-1 Service Manual 11008567 )NSTALL THE
(continued) CONTROL AND MULTI FUNCTION BLOCK IF INSTALLED )NSTALL THE WAY VALVE SPOOL AND SLEEVE IF
INSTALLED )NSTALL THE THRESHOLD SPRINGS AND GUIDES )NSTALL THE CONTROL SPRINGS IF INSTALLED
)NSTALL THE RAMP SPRINGS AND GUIDES IF INSTALLED )NSTALL THE MINIMUM ANGLE SERVO COVER
FROM THE MOTOR )NSTALL THE LOOP mUSHING VALVE AND CHARGE RELIEF VALVE

!FTER ASSEMBLY TEST AND ADJUST THE MOTOR AS NECESSARY BEFORE PLACING THE UNIT BACK IN
SERVICE 2EFER TO Series 51 and 51-1 Service Manual 11008567 FOR ADJUSTMENT PROCEDURES

11009449 s 2EV !! s *ANUARY 31

008 924 17 BOMAG 757
16.3 Travel motor

OUR PRODUCTS Sauer-Danfoss Mobile Power and Control Systems

0ROPORTIONAL VALVES 3AUER $ANFOSS PROVIDES COMPREHENSIVE WORLDWIDE SERVICE FOR ITS
$IRECTIONAL SPOOL VALVES PRODUCTS THROUGH AN EXTENSIVE NETWORK OF 'LOBAL 3ERVICE 0ARTNERS
STRATEGICALLY LOCATED IN ALL PARTS OF THE WORLD
#ARTRIDGE VALVES
(YDRAULIC INTEGRATED CIRCUITS
,OCAL ADDRESS
(YDROSTATIC TRANSAXLES
)NTEGRATED SYSTEMS
&AN DRIVE SYSTEMS
%LECTROHYDRAULICS
-ICROCONTROLLERS AND SOFTWARE
%LECTRIC MOTORS AND INVERTERS
*OYSTICKS AND CONTROL HANDLES 3AUER $ANFOSS 53 #OMPANY 3AUER $ANFOSS !P3
%AST TH 3TREET $+ .ORDBORG $E.sMARK
$ISPLAYS !MES )! 53! 0HONE
Sensors 0HONE &AX
&AX
3AUER $ANFOSS 'MB( #O /(' 3AUER $ANFOSS $AIKIN ,4$
0OSTFACH $ .EUMünster 3ANNOMIYA 'RAND "LDG &
+ROKAMP $ .EUMüNSTER 'ERMANY )SOGAMI DORI #HUO KU
0HONE +OBE (YOGO *APAN
&AX 0HONE
&AX

WWWSAUER DANFOSSCOM
11009449 s 2EV !! s *ANUARY

758 BOMAG 008 924 17

16.4 Vibration motor

008 924 17 BOMAG 759

16.4 Vibration motor

760 BOMAG 008 924 17

Vibration motor 16.4

A10FM

A10FE

RDE 92172-01-R/08.01
ersetzt / replaces 06.99

Reparaturanleitung - A10FM 28 - 60 Baureihe 5

A10FE 28 - 60 Baureihe 5
Repair instructions - A10FM 28 - 60 Series 5
A10FE 28 - 60 Series 5

008 924 17 BOMAG 761

RDE 92172-01-R/08.01
16.4
Hinweis / Inhalt
Vibration motor
Reparaturanleitung A10FM / A10FE
Notice / Contents Repair Instructions A10FM / A10FE

HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen Specifications, descriptions and illustrative material shown
entsprechen dem Informationsstand zum Zeitpunkt der herein were as accurate as known at the time this
Drucklegung dieser Unterlage. publication was approved for printing.
Änderungen können den Service am Produkt beein- BRUENINGHAUS HYDROMATIK reserves the right to
flussen, Verpflichtungen entstehen uns daraus nicht. discontinue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für specifications, materials, or design without notice and
deren Resultat wir keine Haftung übernehmen können. without incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Anga- Optional equipment and accessories may add cost to the
be der Fabrik-Nr. bestellt, sind die Basis guter Reparatu- basic unit, and some options are available only in
ren. combination with certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf For the available combinations refer to the relevant data
dem Teststand vorzunehmen. sheet for the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vor- Adjustment and tests have to be carried out on the test
kehrungen sicherzustellen. bench under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, Protection of personnel and property has to be guar-
vermitteln wir in unseren Schulungskursen. anteed by appropriate measures.
Expert knowledge, the precondition of any service work,
can be obtained in our training courses.

INHALT Seite/ CONTENTS

Page

A10FM / A10FE A10FM / A10FE

Schnittbild 3 Sectional view

Allgemeine Reparaturhinweise 4 General repair guidelines
Triebwelle abdichten 5-7 Sealing the drive shaft
Motor demontieren 8-14 Disassemble the motor
Überprüfungshinweise 15 Inspection hints
Motor montieren 16-19 Motor assembly
Spülventil demontieren 20 Disassembly of the flushing valve
Abstimmung- Lagerung / Hinweise 21 Bearing adjustment / Note
Werkzeuge / Hilfswerkzeuge / Tools / auxiliary tools /
Anziehdrehmomente 27 tightening torques

2 Brueninghaus Hydromatik
762 BOMAG 008 924 17
RDE 92172-01-R/08.01
Vibration motor
Schnittbild
16.4
Reparaturanleitung A10FM / A10 FE
Sectional view Repair Instructions A10FM / A10FE

A10FM

A10FE

Optional Option
Ausführung mit Spülventil Unit with flushing valve
für geschlossenen Kreislauf for closed circuit application

008 924 17 BOMAG Brueninghaus Hydromatik

763 3
RDE 92172-01-R/08.01
16.4
Allgemeine Reparaturhinweise
Vibration motor
Reparaturanleitung A10FM / A10FE
General repair guidelines Repair Instructions A10FM / A10FE

Achtung!
Nachfolgend Hinweise bei allen Reparaturarbeiten
an Hydraulikaggregaten beachten!

Attention!
Observe the following guidelines when carrying out repairs
on hydraulic units!

Alle Öffnungen der Hydraulikaggregate verschließen.

Close off all openings of the hydraulic unit.

Alle Dichtungen erneuern.

Nur original BRUENINGHAUS HYDROMATIK
Ersatzteile verwenden.

Replace all of the seals.

Use only original BRUENINGHAUS HYDROMATIK
spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.

Check all sealing and sliding surfaces for wear.

Attention: Re-work of the sliding surfaces by using, for
example abrasive paper, can damage the surface.

Hydraulikaggregate vor Inbetriebnahme mit

Hydrauliköl befüllen.

Fill the hydraulic unit with hydraulic oil

before commissioning.

4 Brueninghaus Hydromatik
764 BOMAG 008 924 17
RDE 92172-01-R/08.01
Vibration motor
Triebwelle abdichten
16.4
Reparaturanleitung A10FM / A10 FE
Sealing the drive shaft Repair Instructions A10FM / A10FE

2
1

2 1. Sicherungsring, 2. Wellendichtring
1
1. Circlip, 2. Shaft seal

3 (Paßfeder ausbauen bei Ausführung Paßfeder))

Triebwelle abkleben.
Sicherungsring ausbauen.

(Remove key, version with keyway)

Protect the drive shaft.
Remove the circlip.

008 924 17 BOMAG Brueninghaus Hydromatik

765 5
RDE 92172-01-R/08.01
16.4
Triebwelle abdichten
Vibration motor
Reparaturanleitung A10FM / A10FE
Sealing the drive shaft Repair Instructions A10FM / A10FE

4 Nach der Demontage des gelaufenen Wellendichtringes,

einfetten des neuen WDR.(Kontrolle der Laufflächen, Welle,
Gehäuse).

Change the shaft seal and check its sliding surface (drive shaft)
and housing, grease the sealing ring.

5 Welle mit Schutzhülse oder Klebeband versehen.

Use installation tool or plastic strip for assembling seal.

6 Mit geeignetem Rohr den WDR nur so tief montieren,

daß der Sicherungsring montierbar ist (zu tiefes Montieren
führt zum Ausfall: Berührung mit dem Wellenlager!).

Use a suitable pipe to mount the shaft seal ring, but don't
push it too deap. If the shaft ring touches the bearing ring
you will damage the seal ring.

7 Sicherungsring einsetzen.

Assemble the snap ring.

8 Sicherungsring ganz einrasten.

Assemble the snap ring in the correct position.

6 Brueninghaus Hydromatik
766 BOMAG 008 924 17
RDE 92172-01-R/08.01
Vibration motor
Triebwelle abdichten
16.4
Reparaturanleitung A10FM / A10 FE
Sealing the drive shaft Repair Instructions A10FM / A10FE

Hinweis! Note!
Die hier beschriebene Möglichkeit zum Wechsel der This discription showes how th change the drive shaft
Antriebswellen - Abdichtung stellt nicht die serienmäßi- sealing ring but it isn't the way of serial assembly.
ge Montage dar. Für sicheres Dichtungsverhalten ist eine The sealing ring is assembled together with the taper
Montage des Dichtringes zusammen mit dem Kegel- roller bearing from inside the motor housing normally to
rollenlager von innen her durch das Montagegehäuse get a secure sealing condition. If you decide to repair the
durchzuführen. Soll aus Gründen der Vereinfachung im motor in the shown way be very careful while handling
Reparaturfall die vorgehend beschriebene Vorgehens- so that the drive shaft wouldn't be damaged during
weise durchgeführt werden, so ist beim Ausbau der disassembly of the shaft sealing ring.
Dichtung besonders darauf zu achten, daß die Antriebs-
welle nicht beschädigt wird.

008 924 17 BOMAG Brueninghaus Hydromatik

767 7
RDE 92172-01-R/08.01
16.4
Motor demontieren
Vibration motor
Reparaturanleitung A10FM / A10FE
Disassemble the motor Repair Instructions A10FM / A10FE

A10FM

8 Brueninghaus Hydromatik
768 BOMAG 008 924 17
RDE 92172-01-R/08.01
Vibration motor
Motor demontieren
16.4
Reparaturanleitung A10FM / A10 FE
Disassemble the motor Repair Instructions A10FM / A10FE

A10FE

008 924 17 BOMAG Brueninghaus Hydromatik

769 9
RDE 92172-01-R/08.01
16.4
Motor demontieren
Vibration motor
Reparaturanleitung A10FM / A10FE
Disassemble the motor Repair Instructions A10FM / A10FE

11 Demontageposition
Lage der Anschlußplatte zum
Gehäuse kennzeichnen.

Disassembly position
Mark the location of the connection plate
on the housing.

12 Anschlußplattenbefestigung über Kreuz lösen.

Remove the connection plate fixing bolts crosswise.

13 Anschlußplatte abheben.
Verteilerplatte
kann herunterfallen - festhalten.
Verteilerplatte abheben.

Remove the connection plate.

Distributor plate
can drop down - hold tight.
Remove distributor plate.

10 Brueninghaus Hydromatik
770 BOMAG 008 924 17
RDE 92172-01-R/08.01
Vibration motor
Motor demontieren
16.4
Reparaturanleitung A10FM / A10 FE
Disassemble the motor Repair Instructions A10FM / A10FE

14 Verteilerplatte abheben.

Remove control plate.

15 Lageraußenring mit Abziehvorrichtung ausbauen.

Dichtfläche Verteilerplatte nicht beschädigen.

Remove bearing outer ring with withdrawal tool.

Do not damage the sealing surface.

16 Abheben des Kegelrollenlagers (anschlußplattenseitig).

Entfernen der Abstimmscheibe.

Disassemble the taper roller bearing (near by port plate)

Remove the adjustment shim.

008 924 17 BOMAG Brueninghaus Hydromatik

771 11
RDE 92172-01-R/08.01
16.4
Motor demontieren
Vibration motor
Reparaturanleitung A10FM / A10FE
Disassemble the motor Repair Instructions A10FM / A10FE

17 Triebwerk in horizontaler Lage herausziehen.

Remove the rotary group in a horizontal position.

18 Welle nach hinten herausziehen.

Remove the drive shaft to rear side.

19 Hubscheibe mit Sonderwerkzeug ausbauen (siehe Bild 20).

Remove swash plate with special tool (see picture 20).

20 Der Ausbau der Hubscheibe erfolgt mit einer Schleuder,

ein kleiner Haken - aus Rundmaterial Durchmesser 6 mm -
greift dabei unter die Hubscheibe.

Loosen the swash plate with a slide hammer ( a small

hook - diameter 6 mm - catches the end of the swash
plate at the bottom).

21 Lager mit Presse abziehen.

Press down bearing.

12 Brueninghaus Hydromatik
772 BOMAG 008 924 17
RDE 92172-01-R/08.01
Vibration motor
Motor demontieren
16.4
Reparaturanleitung A10FM / A10 FE
Disassemble the motor Repair Instructions A10FM / A10FE

22 Abziehen des Lageraußenringes im Pumpengehäuse.

Zweckmäßige Unterlage benutzen, zur Vermeidung von
Gehäusebeschädigungen (s. a. Hinweis Abb.xx).

The external front bearing ring is pulled out of the pump

housing (tool and surface infos see picture xx, too).

23 Sicherungsring entfernen.

Disassemblecirclip and shaft seal.

24 Wellendichtring und Fixierscheibe entnehmen

Remove shaft seal ring and shim.

008 924 17 BOMAG Brueninghaus Hydromatik

773 13
RDE 92172-01-R/08.01
16.4
Motor demontieren
Vibration motor
Reparaturanleitung A10FM / A10FE
Disassemble the motor Repair Instructions A10FM / A10FE

25 Feder mit Vorrichtung vorspannen.

Pre-tension the spring using a suitable device.

26 Sicherungsring demontieren.
Feder und Druckstifte ausbauen.

Remove circlip.
Remove spring and pressure pins.

14 Brueninghaus Hydromatik
774 BOMAG 008 924 17
RDE 92172-01-R/08.01
Vibration motor
Überprüfungshinweise
16.4
Reparaturanleitung A10FM / A10 FE
Inspection hints Repair Instructions A10FM / A10FE

28 Kontrolle!
Lauffläche (1) keine Kratzer, keine Metalleinlagerungen,
kein Axialspiel (2), (Kolben nur satzweise tauschen).

Check!
Check to see that there are no scratches or metal deposits
on the sliding surface (1), and that there is no axial play (2),
(pistons must only be replaced as a set).

29 Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).

Check!
Cylinder bores (1), splines (2).

30 Riefenfrei, keine Einlaufspuren

Free of grooves, no signs of wear.

31 Kontrolle!
Zylindergleitfläche riefenfrei, nicht eingelaufen, keine
Einlagerungen, Steuerplatte nicht riefig (nur satzweise
austauschen).

Check!
Cylinder sliding surface free of grooves, no wear, no
embedded foreign particles. That there are no scratches
on the control plate. (Only replace them as a set).

32 Kontrolle!
Auflagefläche - Steuerplatte ohne Beschädigung.

Check!
Mounting surface - control plate undamaged

008 924 17 BOMAG Brueninghaus Hydromatik

775 15
RDE 92172-01-R/08.01
16.4
Motor montieren
Vibration motor
Reparaturanleitung A10FM / A10FE
Motor assembly Repair Instructions A10FM / A10FE

33 Sicherungsring ins Gehäuse montieren.

Fit the circlip into the housing.

34 Wellendichtring und Fixierscheibe gegen

Sicherungsring einsetzen.

Assemble shaft seal ring and shim

against circlip.

35 Montage des Wellendichtringes 1 gegen den Sicherungsring 2,

3 anschließend Fixierscheibe 3 einlegen.

1 Assembly of the shaft seal 1 against the safety ring 2,

back up the shim 3 down to the seal ring.

36 Lageraußenring ins Gehäuse pressen.

Welle mit Lager vormontiert ins Gehäuse einstecken.

Wellendichtring nicht beschädigen.

Wellenverzahnung mit Klebeband umwickeln.

Press outer bearing ring into housing.

Shaft seal with pre-assembled bearing into housing.

Protect splines of the shaft with plastic strip

against damage of the seal lip.

16 Brueninghaus Hydromatik
776 BOMAG 008 924 17
RDE 92172-01-R/08.01
Vibration motor
Motor montieren
16.4
Reparaturanleitung A10FM / A10 FE
Motor assembly Repair Instructions A10FM / A10FE

37 Hubscheibe montieren.

Assemble swash plate.

38 Mit Vorrichtung Druckstifte montieren.

Fit pressure pins using an assembly aid.

39 Feder mit Vorrichtung vorspannen.

Pre-tension the spring using a suitable device.

41 Kolben mit Rückzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einölen.

Assemble piston with retaining plate.

Note:
Oil piston and slipper pad.

008 924 17 BOMAG Brueninghaus Hydromatik

777 17
RDE 92172-01-R/08.01
16.4
Motor montieren
Vibration motor
Reparaturanleitung A10FM / A10FE
Motor assembly Repair Instructions A10FM / A10FE

42 Rotationsgruppe montieren!

Montagehilfe:
Mit O-Ring Kolben festhalten.

Fit rotary group!

Assembly aid:
Hold the pistons by using an O-ring.

43 Lager (1) in Anschlußplatte montieren.

4 Zylinderstift (2) einsetzen.
O-Ring (3) einsetzen.
Verteilerplatte (4) aufsetzen.
3
Montagehilfe:
Teile mit Fett fixieren.
1

Fit bearing (1) in connection plate.

2 Fit cyilindrical pin (2).
Fit O-ring (3).
Fit distributor plate (4).

Assembly:
Hold the components in place with grease.

18 Brueninghaus Hydromatik
778 BOMAG 008 924 17
RDE 92172-01-R/08.01
Vibration motor
Motor montieren
16.4
Reparaturanleitung A10FM / A10 FE
Motor assembly Repair Instructions A10FM / A10FE

44 Verteilerplatte montieren.
Montagehilfe: Fett

Fit distributor plate.

Assembly aid: Grease

45 Anschlußplatte aufsetzen und mit Schrauben

über Kreuz anziehen.

Fit the connection plate and fix it with

the screws crosswise.

A10FM A10FE

008 924 17 BOMAG Brueninghaus Hydromatik

779 19
RDE 92172-01-R/08.01
16.4
Spülventil demontieren
Vibration motor
Reparaturanleitung A10FM / A10FE
Disassembly of the flushing valve Repair Instructions A10FM / A10FE

47 Beidseitig Schrauben 1 lösen und Federn mit Scheiben 2

entnehmen.

Loosen screws 1, take out springs and shims 2.

1
2

2
1

48 Spülschieber 3 vorsichtig zu einer Seite heausdrücken.

Take out spool carefully.

49 Verschlußschraube Speisedruckventil 4 lösen,

Feder und Einsatz entnehmen.

Loosen the screw of the boost valve and take out

the spring and the cartridge.

Montage in umgekehrter Reihenfolge!

Assembling by opposite steps!

20 Brueninghaus Hydromatik
780 BOMAG 008 924 17
RDE 92172-01-R/08.01
Vibration motor
Abstimmung- Lagerung / Hinweise
16.4
Reparaturanleitung A10FM / A10 FE
Bearing adjustment / Note Repair Instructions A10FM / A10FE

Montage - Abstimmung (Kegelrollenlager) / Taper roller bearing initial tension

AA10FM Baureihe 50
AA10FM Series 50
0 .... 0,05 mm

Pos. 12

Abstimmung der Triebwerkslagerung Adjustment of stopper min displacement

Die Vorspannung der Triebwerkslagerung muß im Cast iron housing must have initial tension of bearings:
Gußgehäuse von 0 bis 0,05 mm durch Abschleifen der 0 ...... 0,05 mm , grind Pos. 12 if necessary.
Abstimmscheibe Pos. 12 hergestellt werden.
Adjustment: Qmin- stopper
Einstellhinweis: Qmin-Anschlag With a given inflow and pressureless circulation adjust
Bei gegebenem Zusatzstrom wird bei drucklosem the stopper Qmin displacement so that the measured
Umlauf der Anschlag Qmin so eingestellt, daß die gemes- speed of the motors results in a displacement of 12 cm3
sene Drehzahl des Motors einem Schluckvolumen von (vgmin).
12 cm3 entspricht (vgmin). Increase of adjustment is possible to vgmax = 45 cm3
Eine kontinuierliche Verstellung bis vgmax = 45 cm3 ist Differential volume is appr. 3,1 cm3 (see page 3).
möglich - Volumenänderung pro Gewindestiftum-
Q inflow x 1000
drehung ca. 3,1 cm3 (s. a. Seite 3). Displacement vgmin =
Measurement speed
Q Zulauf x 1000
Schluckvolumen vgmin =
Meßdrehzahl

Achtung: Falsch eingestellte Qmin Anschläge können zu Attention: Wrong adjustments of stopper Qmin
überhöhten Drehzahlen bis hin zum Ausfall der Bauteile displacement increases the speed of the motor up to a
führen. possible failure of parts of the unit.

008 924 17 BOMAG Brueninghaus Hydromatik

781 21
RDE 92172-01-R/08.01
16.4
Werkzeuge / Hilfswerkzeuge / Anziehdrehmomente
Vibration motor
Reparaturanleitung A10FM / A10FE
Tools / auxiliary tools / tightening torques Repair Instructions A10FM / A10FE

49 Plastikhammer

Soft hammer

50 Schleuder

...

Anziehdrehmomente /
Tightening torques

Festigkeitsklassen 8,8; 10,9; 12,9

Bolt tensile strength grade:

M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 M30

8,8 2,3 5,0 8,5 21 41 72 115 176 240 350 600 1220

Ma 10,9 3,2 7,2 12 29 58 100 165 250 350 490 840 1670

12,9 4,1 8,5 14,5 35 70 121 195 300 410 590 990 2000

Ma (Nm) = max. Anziehdrehmoments (geölte Schrauben μ = 0,125)

Ma (Nm) = max. tightening torques (lubricated screws μ = 0,125)
51

22 Brueninghaus Hydromatik
782 BOMAG 008 924 17
16.5 Drum reduction gear

008 924 17 BOMAG 783

16.5 Drum reduction gear

784 BOMAG 008 924 17

Drum reduction gear 16.5

3ERIES #2
#OMPACT
2OLLER $RIVE

3ERVICE -ANUAL AND

2EPAIR )NSTRUCTION

008 924 17 BOMAG 785

16.5 Drum reduction gear

3ERIES #2 n #OMPACT 2OLLER $RIVE

3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
)NTRODUCTION

).42/$5#4)/. 4HIS BROCHURE REPRESENTS INFORMATION FOR NORMAL SERVICE AS WELL AS AN INSTRUCTION FOR
MINOR REPAIRS OF 3AUER $ANFOSS PLANETARY DESIGNED COMPACT GEARS 3ERIES #2

-INOR REPAIRS INCLUDES REPLACEMENT OF BRAKE GEARS CARRIERS AND BEARINGS OF THE #2 GEAR
DRIVE

4HE ASSEMBLING OF THE SPINDLE GROUP " REQUIRES A SPECIAL TOOL IN ORDER TO HANDLE THE
TORQUE OF .M ; LBFsIN= FOR #2 AND .M ; LBFsIN= FOR THE #2

)N ANY CASE OF AN ECONOMICALLY REPAIRABLE FAILURE AT THIS GROUP THE WHOLE GEARBOX SHOULD
BE RETURNED TO 3AUER $ANFOSS .EUMàNSTER

¹ 3AUER $ANFOSS

3AUER $ANFOSS CAN ACCEPT NO RESPONSIBILITY FOR POSSIBLE ERRORS IN CATALOGUES BROCHURES AND OTHER PRINTED MATERIAL 3AUER $ANFOSS RESERVES THE
RIGHT TO ALTER ITS PRODUCTS WITHOUT PRIOR NOTICE4HIS ALSO APPLIES TO PRODUCTS ALREADY ORDERED PROVIDED THAT SUCH ALTERATIONS CAN BE MADE WITHOUT
SUBSEQUENT CHANGES BEING NECESSARY IN SPECIlCATIONS ALREADY AGREED !LL TRADEMARKS IN THIS MATERIAL ARE PROPERTIES OF THE RESPECTIVE COMPANIES
3AUER $ANFOSS AND THE 3AUER $ANFOSS LOGOTYPE ARE TRADEMARKS OF THE 3AUER $ANFOSS 'ROUP !LL RIGHTS RESERVED
&RONT PAGE & & & & 0

$+-(03$ , 2EV ! n

786 BOMAG 008 924 17

Drum reduction gear 16.5
3ERIES #2 n #OMPACT 2OLLER $RIVE
3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
#ONTENTS

#/.4%.43 )NTRODUCTION
-ODEL #ODE
$ESCRIPTION
0OWER &LOW $IAGRAM
4ECHNICAL &EATURES
3CHEMATIC
$ESIGN
4YPE OF -OUNTING
$IRECTION OF 2OTATION
)NSTALLATION 0OSITION
,UBRICANTS
4EMPERATURE 2ANGE
,UBRICANT 6ISCOSITY ,IMITS
4ECHNICAL $ATA
"RAKE
3TART 5P AND -AINTENANCE 0ROCEDURE
-ECHANICAL 2ELEASING OF THE "RAKE
2EESTABLISH "RAKING #APABILITY
/UTLINE $RAWINGS
2OLLER $RIVE 'EARBOX WITH #ARTRIDGE -OTOR n #2
2OLLER $RIVE 'EARBOX WITH #ARTRIDGE -OTOR n #2
2EPAIR )NSTRUCTION
'ENERAL
$ISASSEMBLY
'EAR AND 0LANET #ARRIERS $ISASSEMBLY
"RAKE !SSEMBLY
!SSEMBLY
'EAR AND 0LANET #ARRIERS
"RAKE !SSEMBLY
3CREW 4ORQUE
%XPLODED 6IEWS
%XPLODED 6IEW n #2 !
%XPLODED 6IEW n #2 !
%XPLODED 6IEW n #2
#ROSS 3ECTION 6IEWS
#ROSS 3ECTION 6IEW n #2 !
#ROSS 3ECTION 6IEW n #2 !
#ROSS 3ECTION 6IEW n #2
0ARTS ,IST

$+-(03$ , 2EV ! n

008 924 17 BOMAG 787

16.5 Drum reduction gear

3ERIES #2 n #OMPACT 2OLLER $RIVE

3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
-ODEL #ODE

490% $%3)'.!4)/. !.$ /2$%2 #/$%

# 2 !

3ERIES OR 0RODUCT 2EVISION STATUS OF UNIT

3ERIES #2
#2 #OMPACT 2OLLER
$RIVES

3PECIAL HARDWARE FEATURES

WITHOUT SPECIAL HARDWARE
/UTPUT TORQUE
4"
.M SPECIAL NAMETAG CUSTOMER
! 4$
; LB FsIN =
. M
!
; LB FsIN =
. M

; LB FsIN = 3HAFT SPLINE MOTOR 2 A T IO
# 7XXX M
# $ ). M
TEETH
3PINDLE AND MOTOR CONFIGURATION M
PITCH !.3)
WITH MECH BRAKE RELEASE
! M M
#
WITH SPECIAL BRAKE RELEASE
! M
+
WITH SPECIAL BRAKE RELEASE "RAKE
! M
+ / NOT AVAILABLE BRAKE
WITH SPECIAL BRAKE RELEASE WITH BRAKE
! M +
# STATIC BRAKE TORQUE INPUT SHAFT .M ; LBFsIN=

.OT AVAILABLE
M /PTIONAL

$+-(03$ , 2EV ! n

788 BOMAG 008 924 17

Drum reduction gear 16.5
3ERIES #2 n #OMPACT 2OLLER $RIVE
3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
$ESCRIPTION 0OWER &LOW $IAGRAM

$%3#2)04)/. 2OLLER $RIVES CONSIST OF TWO OR THREE SIMPLE PLANETARY STAGES CONNECTED IN SERIES
%ACH PLANETARY STAGE CONSISTS OF A SUN PINION INPUT GEAR AN INTERNAL TOOTH RING GEAR AND
A SET OF PLANET OR SATELLITE GEARS MOUNTED TO A PLANET CARRIER4HE SUN GEAR hmOATSv WITHIN
THE PLANET GEARS TO ALLOW UNIFORM LOAD DISTRIBUTION AT THE MULTIPLE GEAR MESH POINTS

! HYDROSTATIC CARTRIDGE MOTOR DRIVES THE SUN PINION WHICH IN TURN DRIVES THE PLANET GEARS
WITHIN THE RING GEAR CAUSING ROTATION OF THE PLANET CARRIER4HE PLANET CARRIER IS COUPLED
DIRECTLY TO THE SUN GEAR OF THE NEXT STAGE

4HE OUTPUT PLANET CARRIER IS lXED NON ROTATING AND THE RING GEAR TRANSMITS MAIN TORQUE
TO THE OUTPUT /UTPUT HUB ROTATION IS OPPOSITE TO THE INPUT ROTATION

4HE PLANET GEARS ARE SUPPORTED ON FULL COMPLEMENT ROLLER BEARINGS4HE OUTPUT HUB IS
SUPPORTED ON TAPERED ROLLER BEARINGS TO PROVIDE LARGE EXTERNAL LOAD CARRYING CAPABILITY

!LL GEARS AND SHAFTS ARE MACHINED FROM CASE HARDENED STEEL OR HIGH TENSILE ALLOY STEEL AND
ALL HOUSINGS ARE CAST IRON OR NODULAR IRON OR STEEL ACCORDING TO LOAD REQUIREMENTS

0/7%2 &,/7 $)!'2!- #OMPACT 2OLLER $RIVE n #2

/UTPUT

)NPUT

0
0OWER mOW

$+-(03$ , 2EV ! n

008 924 17 BOMAG 789

16.5 Drum reduction gear

3ERIES #2 n #OMPACT 2OLLER $RIVE

3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
4ECHNICAL &EATURES

3#(%-!4)#

$%3)'. 4WO OR THREE STAGE SERIES PLANETARY GEARING COMBINED WITH OPTIONAL lXED DISPLACE
MENT AXIAL PISTON AND VARIABLE DISPLACEMENT BENT AXIS HYDROSTATIC MOTORS

490% /& -/5.4).' &RAME MOUNTING AND DRUM MOUNTING PILOTED AND INTERNALLY THREADED HOLES ON A BOLT
CIRCLE DIAMETER

$)2%#4)/. /& 2/4!4)/. #LOCKWISE AND COUNTERCLOCKWISE OUTPUT ROTATION OPPOSITE TO THE INPUT ROTATION

).34!,,!4)/. 0/3)4)/. .ORMAL INSTALLATION IS HORIZONTAL CONTACT MANUFACTURER FOR OTHER POSITIONS

,5"2)#!.43 'EAR LUBRICANTS SEE , (YDRAULIC &LUIDS AND ,UBRICANTS

4%-0%2!452% 2!.'% * MIN ²# ; ²&=

* MAX ²# ; ²&=

,5"2)#!.4 6)3#/3)49 N MIN MMS ; 353 =

,)-)43 N MAX MMS ; 353 =

353 3AYBOLT 5NIVERSAL 3ECOND

4%#(.)#!, $!4! 4ECHNICAL DATA

$IMENSION #2 ! #2 ! #2
.M
)NTERMITTENT
-AXIMUM ;LBFsIN= ; = ; = ; =
OUTPUT TORQUE .M
#ONTINUOUS
;LBFsIN= ; = ; = ; =
$YN LOAD CAPACITY MAXIMUM K. ;LBF = ; = ; = ; =
/UTPUT SPEED MAXIMUM MIN RPM
"RAKE TORQUE MAXIMUM STATIC .M ;LBFsIN= ;= ;= ;=
2ATIO I
,UBRICANT CAPACITY APPROX L ;53 GAL= ;= ;= ;=
7EIGHT WITHOUT LUBRICANT KG ;LB= ;= ;= ;=

.OTE &OR FURTHER DETAILS SEE /UTLINE DRAWINGS ON PAGES

$+-(03$ , 2EV ! n

790 BOMAG 008 924 17

Drum reduction gear 16.5
3ERIES #2 n #OMPACT 2OLLER $RIVE
3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
"RAKE

"2!+% )NPUT BRAKES HAVE BEEN DESIGNED TO BE USED AS STATIC HOLDING OR PARKING BRAKES4HESE
BRAKES ARE MECHANICALLY SPRING APPLIED AND HYDRAULIC PRESSURE IS REQUIRED TO RELEASE
THEM

)N ADDITION THE UNITS ARE EQUIPPED WITH AN EASY MECHANICAL BRAKE RELEASE FOR TOWING
CONDITIONS4HERE IS NO SPECIAL TOOLING REQUIRED FOR APPLYING THE MECHANICAL BRAKE
RELEASE #ARE MUST BE TAKEN WHEN SIZING AN APPLICATION TO ENSURE THAT THE BRAKE TORQUE
AND GEAR RATIO SELECTED MATCH THE CAPACITY OF THE HYDROSTATIC MOTOR AND GEARBOX

4HE TABLE BELOW SHOWS BRAKE OPTIONS

)NPUT BRAKES
&RAME SIZE
$IMENSION #2 #2
/PTION +
3TATIC TORQUE .M ;LBFsIN= ;=
2ELEASE PRESSURE -INIMUM BAR ;PSI= ;=
2ELEASE PRESSURE -AXIMUM BAR ;PSI= ;=

$+-(03$ , 2EV ! n

008 924 17 BOMAG 791

16.5 Drum reduction gear

3ERIES #2 n #OMPACT 2OLLER $RIVE

3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
3TART UP AND -AINTENANCE 0ROCEDURE

34!24 50 !.$ 4HE GEARBOX IS SHIPPED WITHOUT OIL

-!).4%.!.#%
"EFORE START UP lLL GEAR WITH %0 GEAR LUBRICANT 3!% !0) #LASSIlCATION ', &:' POWER
STAGE ACCORDING $). !T HIGHER TEMPERATURES WE RECOMMEND GEAR LUBRICANTS
WITH 3!% 6ISCOSITY GRADE

&ILL WITH LUBRICANT TO LEVEL OF CONTROL BORE , APPROX L ; 53 GAL= FOR #2 L
; 53 GAL= FOR #2 AND CHECK OIL LEVEL REGULARLY &IRST OIL CHANGE AFTER WORKING
HOURS THEN AFTER EVERY HOURS BUT AT LEAST ONCE A YEAR

0ERIODICALLY CLEAN THE GEAR HOUSING AND INSPECT FOR LOOSENED SCREWS AND BOLTS
)T IS RECOMMENDED TO CHECK THE OIL LEVEL EVERY WORKING HOURS AND ADD IT IF NECESSARY

3%26)#).' 4(% -ECHANICAL RELEASING OF THE BRAKE

#/-0!#4 '%!23
)N CASE OF LACKING BRAKE BLEEDING PRESSURE IT MAY BE NECESSARY TO MOVE A STATIONARY
MACHINE &OR THIS PURPOSE IT IS POSSIBLE TO RELEASE THE BRAKE MECHANICALLY
7HILE THE BRAKE IS
MECHANICALLY RELEASED THE &OR MECHANICAL RELEASING TWO SOCKET HEAD SCREWS ARE LOCATED AT THE SPINDLE FRONT SIDE
PISTON MOTOR LOSES ITS SEE CHAPTER /UTLINE DRAWINGS ON PAGES &OR BRAKE RELEASING THE TWO SOCKET HEAD
MECHANICAL BRAKING SCREWS MUST BE TURNED UNIFORMLY IN A CLOCKWISE DIRECTION ALTERNATELY ROTATION IN
CAPABILITY4HE MECHANICAL ORDER TO AVOID COCKING OF THE PISTON
BRAKING CAPABILITY OF THE
VEHICLE MUST BE 4URNING THE SCREWS INWARD PUSHES THE PISTON AGAINST THE EFFECT OF THE CUP SPRING AND
MAINTAINED BY MEANS OF THUS THE BRAKING EFFECT IS NEUTRALIZED
A VEHICLE BRAKE OR FOR
STATIONARY EQUIPMENT 4URN THE SCREWS INWARD UNTIL THEY COME INTO A CONTACT WITH THE PISTON AND CONTINUE UNTIL
MUST BE MAINTAINED BY THE PISTON COMES AGAINST THE STOP4HE BRAKE HAS BEEN RELEASED
MEANS OF AN EQUIPMENT
BRAKE IN ORDER TO AVERT ANY
DANGER TO LIFE AND LIMB

$+-(03$ , 2EV ! n

792 BOMAG 008 924 17

Drum reduction gear 16.5
3ERIES #2 n #OMPACT 2OLLER $RIVE
3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
3TART UP AND -AINTENANCE 0ROCEDURE

3%26)#).' 4(% 2EESTABLISH BRAKING CAPABILITY

#/-0!#4 '%!23
CONTINUED 2EESTABLISH BRAKING CAPABILITY BY UNSCREWING THE SCREWS FOR THE LOOSENING OF THE BRAKE
TO THE POINT WHERE CONTACT WITH THE PISTON IS JUST LOST !FTER THIS THE SCREWS MUST BE
TURNED OUTWARD COUNTER CLOCKWISE AGAINST STOP
)F THE SCREWS FOR
MECHANICAL RELEASING OF #HECK BRAKING EFFECT ACCORDING THE INSTRUCTIONS OF THE MANUFACTURER OF THE MACHINE OR
THE BRAKE ARE NOT ADJUSTED VEHICLE
IN THE WAY DESCRIBED IN
CASE OF WEAR OF THE BRAKE 4HE COMPACT GEAR #2 ! IS EQUIPPED WITH AN ADAPTER mANGE FOR THE SMALLER SIZE OF
DISKS THE PISTON MAY COME HYDROMOTOR &OR MECHANICAL BRAKE RELEASING AT THIS COMPACT GEAR REMOVE THE SCREWS
TO REST PREMATURELY ON THE )TEM " THAT lX THE ADAPTER mANGE AND MOVE MOTOR ADAPTER WITH MOTOR MM OUT
SCREWS )N THAT CASE THE AGAINST THE STOP WHICH IS GIVEN BY THE SCREWS )TEM "
BRAKING EFFECT WILL BE
CONSIDERABLY REDUCED OR !FTER REESTABLISH OF BRAKING CAPABILITY THE SCREWS " HAVE TO BE TORQUED TO
COMPLETELY NEUTRALIZED .M ; LBFsIN=

$+-(03$ , 2EV ! n

008 924 17 BOMAG 793

16.5 Drum reduction gear

3ERIES #2 n #OMPACT 2OLLER $RIVE

3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
/UTLINE $RAWINGS

2/,,%2 $2)6% '%!2"/8 7)4( #!242)$'% -/4/2 n #2

"RAKE RELEASE PRESSURE PORT

- X &ORM 8 $). 4 4HREAD - X X

;= ,UBRICATION OIL OUTLET

.AME PLATE - X $).
;= ;=
;=
4HREAD - X X ;= ;=

; 2
= ;=

O
;=
!

=
F

;=
;=

$
;
;=

O
X

;=
O X

X
O

#ONTROL BORE FOR OIL LEVEL

4HREAD 4 X - X $).
4HREAD DEPTH , MIN ,
,
,UBRICATION OIL OUTLET
- X $). ,
-ECHANICAL BRAKE RELEASE
4O RELEASE THE BRAKE TURN SCREWS
ALTERNATELY CLOCKWISE TO THE STOP 0 %

#2
&RAME , , , , 4 $ !
3ERIES $ESIGN O
SIZE MM ;IN= MM ;IN= MM ;IN= MM ;IN= MM ;IN=

+ - X
;= ;= ;= ;=

+ - X
;= ;= ;= ;= ;=

# - X
;= ;= ;= ;= ;=

# - X
;= ;= ;= ;= ;=

$+-(03$ , 2EV ! n

794 BOMAG 008 924 17

Drum reduction gear 16.5
3ERIES #2 n #OMPACT 2OLLER $RIVE
3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
/UTLINE $RAWINGS

2/,,%2 $2)6% '%!2"/8 7)4( #!242)$'% -/4/2 n #2

"RAKE RELEASE PRESSURE PORT 4HREAD - X X

- X &ORM 8 $). 4

;=
.AME PLATE ,UBRICATION OIL INTLET
- X $). ;= ;=
;=
4HREAD - X X
4HREAD DEPTH MM MIN ;= ;=

; 2
=
;=

O

O
¼
O

=
F

;
O

;=
;=
;=

O
O

X O

X
O X

,UBRICATION OIL OUTLET

4HREAD - X X #ONTROL BORE FOR OIL LEVEL - X $).
4HREAD DEPTH MM MIN - X $).
=
;
;=

-ECHANICAL BRAKE RELEASE
;=
4O RELEASE THE BRAKE TURN SCREWS
ALTERNATELY CLOCKWISE TO THE STOP 0 %

$+-(03$ , 2EV ! n

008 924 17 BOMAG 795

16.5 Drum reduction gear

3ERIES #2 n #OMPACT 2OLLER $RIVE

3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
2EPAIR )NSTRUCTION

'%.%2!, 4HIS INSTRUCTION DESCRIBES PROCEDURES FOR REPLACEMENT OF BRAKE GEARS CARRIERS AND
BEARINGS OF PLANET GEARBOXES FOR #2 SERIES #OMPACT 'EAR DRIVES

2EPAIR OF SPINDLE GROUP 4HE GEARBOX MUST BE REMOVED FROM THE VEHICLE OIL DRAINED AND THE EXTERIOR CLEANED
" REQUIRES SPECIAL BEFORE PERFORMING THIS SERVICE PROCEDURE
ASSEMBLY TOOLS TO TIGHTEN
THE NUT HENCE WE $ISASSEMBLY AND ASSEMBLY OF GEARBOX MUST BE DONE IN CLEAN AND DUSTLESS PLACES
RECOMMEND THAT ANY )TEM NUMBERS OF THE PARTS USED IN THIS INSTRUCTION ARE RELATED TO DRAWINGS SEE CHAPTER
REPAIRS OF THIS GROUP %XPLODED VIEWS ON PAGES
SHOULD BE PERFORMED BY
3AUER $ANFOSS .EUMàNSTER
3AUER $ANFOSS EXPRESSLY
DISCLAIMS ANY LIABILITY FOR
WORKMANSHIP RELATED
FAILURES RESULTING FROM
REPAIRS PERFORMED
BY ANY PERSON 'EARS AND PLANET CARRIERS DISASSEMBLY

$)3!33%-",9 #2
2EMOVE SCREWS $ FROM BACK COVER $
2EMOVE BACK COVER $
2EMOVE SUN PINION GEAR $
2EMOVE SPACER RING $
2EMOVE ST STAGE CARRIER $ WITH PLANET GEARS $ AND ND STAGE SUN GEAR $
2EMOVE RETAINING RINGS $ AND PULL OUT THE PLANET GEARS $ WITH BEARINGS
USING SUITABLE TOOL
2EMOVE RETAINING RINGS $ FROM PLANET GEARS $ AND PUSH OUT THE BEARING
$ USING SUITABLE TOOL
2EMOVE RETAINING RING $ AND PULL OUT THE ND STAGE SUN GEAR $ FROM THE
CARRIER $
2EMOVE RETAINING RINGS " AND PULL OUT THE PLANET GEARS " FROM THE SPINDLE
GROUP " USING SUITABLE TOOL

#2
2EMOVE SCREWS $ FROM BACK COVER $
2EMOVE BACK COVER $
2EMOVE SUN PINION GEAR $
2EMOVE ST STAGE PLANET CARRIER $ WITH PLANET GEARS $ AND ND STAGE SUN
GEAR $
2EMOVE RETAINING RINGS $ AND PRESS OUT THE ND STAGE PLANET GEAR $ FROM
PLANET CARRIER USING A SUITABLE TOOL
2EMOVE RETAINING RING $ AND PULL OUT THE ND STAGE SUN GEAR $ FROM CARRIER
$
0ULL OUT ND STAGE CARRIER $ WITH PLANET GEARS $ AND RD STAGE SUN GEAR $
2EMOVE RETAINING RINGS $ AND PULL OUT PLANET GEARS $ WITH BEARINGS FROM
CARRIER USING A SUITABLE TOOL
2EMOVE THE RETAINING RINGS $ FROM PLANET GEARS $ AND PUSH OUT THE BEAR
ING $ USING A SUITABLE TOOL
2EMOVE THE RETAINING RING $ AND PULL OUT THE RD STAGE SUN GEAR $ FROM
THE CARRIER $
2EMOVE THE RETAINING RINGS " AND PULL OUT THE PLANET GEARS " FROM THE
SPINDLE GROUP " USING A SUITABLE TOOL

$+-(03$ , 2EV ! n

796 BOMAG 008 924 17

Drum reduction gear 16.5
3ERIES #2 n #OMPACT 2OLLER $RIVE
3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
2EPAIR )NSTRUCTION

$)3!33%-",9 "RAKE DISASSEMBLY

CONTINUED
#2 ! #2
0USH SPACER RING " USING A SUITABLE TOOL TO RELEASE RETAINING RING "
2EMOVE RETAINING RING "
5SING A SUITABLE TOOL REMOVE SPACER RING " AND SPRINGS #
2EMOVE BRAKE PISTON # AND / RINGS # #
2EMOVE BRAKE PLATES #
2EMOVE CLUTCH $

#2 !
2EMOVE SCREWS "
2EMOVE BUSHING "
2EMOVE SCREWS "
0ULL OUT ADAPTER " WITH BRAKE PISTON #
2EMOVE / RINGS # #
2EMOVE SCREWS " AND REMOVE BUSHINGS "
2EMOVE SPRINGS #
2EMOVE BRAKE PLATES #
2EMOVE CLUTCH $

!33%-",9 %VERY PART MUST BE CLEAN ESPECIALLY MUST BE RUSTLESS ON THE BEARING SEATING AND SLIDING
SURFACES 0ARTS MUST BE lTTED TO UNIT EASY WHEN THEY ARE OILED BY TRANSMISSION OIL

%VERY / RING AND SEAL )T IS NECESSARY TO EASY COAT THE / RINGS WITH GREASE EG 3HELL !,6!.)! '
HAS TO BE REPLACED
&OLLOWING PARTS ARE ORDERABLE ONLY AS SUBASSEMBLIES

3UBASSEMBLIES
#2 #2
3PINDLE GROUP " "
0LANET GEAR ASSEMBLY
$
ST STAGE
0LANET GEAR ASSEMBLY
"
ND STAGE
0LANET GEAR ASSEMBLY
"
RD STAGE

2OLLING BEARINGS MUST BE UNPACKED FROM ORIGINAL PACKAGE ONLY DIRECTLY TO INSTALLATION
)T MUST BE INSTALLED ONLY USING THE SUITABLE INSTALLING TOOLS
3CREW TORQUE SEE CHAPTER 3CREW TORQUE ON PAGE

$+-(03$ , 2EV ! n

008 924 17 BOMAG 797

16.5 Drum reduction gear

3ERIES #2 n #OMPACT 2OLLER $RIVE

3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
2EPAIR )NSTRUCTION

!33%-",9 'EAR AND PLANET CARRIERS ASSEMBLY

CONTINUED
#2
(EAT THE PLANET GEARS " TO TEMPERATURE ²# ; ²&= PRESS PLANET
GEARS ON PINS OF SPINDLE GROUP " USING PRESS AND INSURE IT USING RETAINING RING
"
.EVER INSTALL BEARING #LEAN UP INNER SURFACE OF THE GEAR $ AND GENTLY OIL IT )NSTALL RETAINING RING
WITH THE GEAR USING STRIKE $ FROM ONE SIDE 5NPACK BEARING $ AND INSERT IT INTO GEAR UNTIL RETAINING
RING USING A TOOL )NSTALL SECOND RETAINING RING $
)NSTALL ND STAGE SUN GEAR $ TO ST STAGE CARRIER $ AND INSURE IT USING
RETAINING RING $
)NSTALL PLANET GEAR $ ACCORDING TO STEP ON CARRIER $ USING INNER RING OF
THE BEARING AND PRESS )NSURE IT USING RETAINING RING $ 0LANET CARRIER MUST BE
SUPPORTED ON THE PITCH CIRCLE ZONE DURING PRESS OF PLANET GEAR
)NSTALL CARRIER $ ACCORDING TO STEP TO SPINDLE GROUP " 4URN HUB TO CHECK
SMOOTH TURN
)NSTALL SPACER RING $ BETWEEN PLANET GEAR $ AND CARRIER $ SO THAT THE
SPACER INSIDE DIAMETER IS LOCATED OPPOSITE THE INSIDE DIAMETER OF ND STAGE SUN GEAR
)NSTALL SUN GEAR $
)NSTALL COVER WITH / RING ON HUB AND INSTALL SCREWS $ RETAINING COVER TO THE
HUB
5SE ALWAYS NEW SCREWS
$ FOR COVER ASSEMBLY
#2
(EAT THE PLANET GEARS " TO TEMPERATURE ²# ; ²&= PRESS PLANET
GEARS ON PINS OF SPINDLE GROUP " USING PRESS AND INSURE IT USING RETAINING RING
"
.EVER INSTALL BEARING #LEAN UP INNER SURFACE OF THE GEAR $ AND GENTLY OIL IT )NSTALL RETAINING RING
WITH THE GEAR USING STRIKE $ FROM ONE SIDE 5NPACK BEARING $ AND INSERT IT INTO THE GEAR UNTIL
RETAINING RING USING SUITABLE TOOL )NSTALL SECOND RETAINING RING $
)NSTALL RD STAGE SUN GEAR $ TO ND STAGE CARRIER $ AND INSURE IT USING
RETAINING RING $
)NSTALL PLANET GEAR $ ACCORDING TO STEP ON ND STAGE PLANET CARRIER $ USING
INNER RING OF THE BEARING AND PRESS )NSURE IT USING RETAINING RING $ 0LANET CARRIER
MUST BE SUPPORTED ON THE PITCH CIRCLE ZONE DURING PRESS OF PLANET GEAR
)NSTALL CARRIER $ ACCORDING TO STEP INTO SPINDLE GROUP " 4URN HUB TO CHECK
SMOOTH TURN
)NSTALL ND STAGE SUN GEAR $ TO ST STAGE CARRIER $ AND INSURE IT USING
RETAINING RING $
)NSTALL PLANET GEAR $ ON CARRIER $ USING INNER RING OF THE BEARING AND PRESS
)NSURE IT USING RETAINING RING $ 0LANET CARRIER MUST BE SUPPORTED ON THE PITCH
CIRCLE ZONE DURING PRESS OF PLANET GEAR
)NSTALL CARRIER $ ACCORDING TO STEP TO SPINDLE GROUP " 4URN HUB TO CHECK
SMOOTH TURN
)NSTALL SUN GEAR $
)NSTALL COVER WITH / RING ON HUB AND INSTALL SCREWS $ RETAINING COVER TO THE
HUB
5SE ALWAYS NEW SCREWS
$ FOR COVER ASSEMBLY

$+-(03$ , 2EV ! n

798 BOMAG 008 924 17

Drum reduction gear 16.5
3ERIES #2 n #OMPACT 2OLLER $RIVE
3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
2EPAIR )NSTRUCTIONS

$)3!33%-",9 "RAKE ASSEMBLY

CONTINUED
#2 ! #2
)NSTALL / RINGS # # INTO SPINDLE GROUP "
)NSTALL CLUTCH $ INTO SPINDLE GROUP "
)NSTALL OUTER AND INNER BRAKE PLATES # START WITH OUTER PLATE )NSTALL INNER PLATES
ON THE CLUTCH $
,IGHTLY OIL BRAKE PISTON # ON THE OUTER SURFACE #AREFULLY PUSH IT UNTIL THE PLATES
#
)NSTALL SPRINGS # INTO BRAKE PISTON #
)NSTALL SPACER RING " AND RETAINING RING "
0RESS SPACER RING " USING TOOL AS RETAINING RING EXPOSE THE GROOVE IN SPINDLE
GROUP " )NSPECT THAT RETAINING RING SEATS PROPERLY IN THE GROOVE

#2 !
)NSTALL / RINGS # # INTO SPINDLE GROUP "
)NSTALL CLUTCH $ INTO SPINDLE GROUP "
)NSTALL OUTER AND INNER BRAKE PLATES # START WITH OUTER PLATE )NSTALL INNER PLATES
ON THE CLUTCH $
)NSTALL SPRINGS # INTO BRAKE PISTON #
)NSTALL / RINGS " AND " ON ADAPTER " 0UT ADAPTER " ON SPRINGS
# SO THAT SCREW HOLES IN ADAPTER ARE LOCATED OPPOSITE THE PISTON ONES
)NSTALL SCREWS " WITH BUSHINGS " THROUGH ADAPTER " INTO PISTON #
0USH SPRINGS # USING CONSECUTIVE ROUND TIGHTENING OF SCREWS
,IGHTLY OIL BRAKE PISTON # ON THE OUTER SURFACE AND CAREFULLY PUSH IT TOGETHER
WITH SCREWED ADAPTER " UNTIL PLATES #
)NSTALL SCREWS "
)NSTALL SCREWS " WITH BUSHINGS " THROUGH ADAPTER " INTO THE SPINDLE
GROUP "

3CREW TORQUE

3CREW 4ORQUE
'EARBOX .AME 4ORQUE
.UMBER 3CREW 4HREAD .M ;LBFsIN=

#2
" =
0LUG - X ;
"
$ 3CREW - ; =

#2 #2 !
" 0LUG 5.& " ; =

#2 !
" =
3CREW SOCKET - ;
"
" 3CREW SOCKET - ; =

$+-(03$ , 2EV ! n

008 924 17 BOMAG 799

16.5 Drum reduction gear

3ERIES #2 n #OMPACT 2OLLER $RIVE

3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
%XPLODED 6IEWS

%80,/$%$ 6)%7 n #2 !

%
$
$

#
#
#
#
#
"
" "
"

#
#

"
"
$
$
$

"
" "
"
"
% "

$ $ %

$
$ "
$ $
"
$
$

$
%

$ $

$+-(03$ , 2EV ! n

800 BOMAG 008 924 17

Drum reduction gear 16.5
3ERIES #2 n #OMPACT 2OLLER $RIVE
3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
%XPLODED 6IEWS

%80,/$%$ 6)%7 n #2 !

%
$
$

#
#
#
#
#
"
" "
"
"

"
"

" "

#
" #

$
%
$
$

" "
"

$ $ %

$
$ "
$ $
"
$
$

$
%

$ $

$+-(03$ , 2EV ! n

008 924 17 BOMAG 801

16.5 Drum reduction gear

3ERIES #2 n #OMPACT 2OLLER $RIVE

3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
%XPLODED 6IEWS

%80,/$%$ 6)%7 n #2
%
$
$

#
#
#
#
#
"
" "
"

#
#

"
"
$
$
$

"
"
"
"
"
% "

$
$

$ $

$ "
$
$ "
$
$ $
$
$
$

$ $
$ $
$
%
$
$
$

$+-(03$ , 2EV ! n

802 BOMAG 008 924 17

Drum reduction gear 16.5
3ERIES #2 n #OMPACT 2OLLER $RIVE
3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
#ROSS 3ECTION 6IEWS

#2/33 3%#4)/. 6)%7 n #2 !

" " " " " $

$
"
$
"
$
!
"
! $

! $

" $
"
$
%
% $

% $
"
$
"

"
"
"
"
"
#
#
"
#
#
"
#
#
"
"

# $ $

$+-(03$ , 2EV ! n

008 924 17 BOMAG 803

16.5 Drum reduction gear

3ERIES #2 n #OMPACT 2OLLER $RIVE

3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
#ROSS 3ECTION 6IEWS

#2/33 3%#4)/. 6)%7 n #2 !

" " " " " " $

" $
" !
$
!
! $

$
%
% $
%
$

" $
" $
"
"
"
"
"

#
#
"
#
#
"
#
#

" " " $ # $ $

$+-(03$ , 2EV ! n

804 BOMAG 008 924 17

Drum reduction gear 16.5
3ERIES #2 n #OMPACT 2OLLER $RIVE
3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
#ROSS 3ECTION 6IEWS

#2/33 3%#4)/. 6)%7 n #2

" " " " " " $ $ $

" $
" ! $
!
$
!
$
$ $
$

$
$
$
$

$
%
% $
%
"
"
"
"
"
"
"
#
"
"
#
"
#
#
"
"
"
#
#
$ # $ $ $ $

$+-(03$ , 2EV ! n

008 924 17 BOMAG 805

16.5 Drum reduction gear

3ERIES #2 n #OMPACT 2OLLER $RIVE

3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
0ARTS ,IST

0!243 ,)34 1UANTITY

)TEM $ESCRIPTION
#2 ! #2 ! #2
! 2OTATING MECHANICAL SEAL
! 4APERED ROLLER BEARING
! .UT
" 3PINDLE GROUP
" 3PINDLE
" (UB
" 2OLLER BEARING
" 0LANET GEAR
" 0LANET GEAR SUBASSEMBLY
" 2ETAINING RING
" 0LUG
" 0LUG
" 3EALING RING
" #AM
" 3PINDLE
" / RING
" / RING
" 0LUG
" 3PACER RING
" 2ETAINING RING
" !DAPTER
" / RING
" / RING
" "USHING
" 3CREW
" 3CREW
" 3CREW
# 3PACER RING
# 2ETAINING RING
# "RAKE PLATES SUBASSEMBLY
# / RING
# / RING
# "RAKE PISTON
# 3PRING
$ #LUTCH
$ 2ETAINING RING
$ 3UN GEAR
$ 3PACER RING
$ #ARRIER
$ 2ETAINING RING
$ 2OLLER BEARING
$ 0LANET GEAR
$ 0LANET GEAR
$ 0LANET GEAR SUBASSEMBLY
$ 2ETAINING RING
$ 3UN GEAR

$+-(03$ , 2EV ! n

806 BOMAG 008 924 17

Drum reduction gear 16.5
3ERIES #2 n #OMPACT 2OLLER $RIVE
3ERVICE -ANUAL AND 2EPAIR )NSTRUCTION
0ARTS ,IST

0!243 ,)34 1UANTITY

CONTINUED )TEM $ESCRIPTION
#2 ! #2 ! #2
$ 2ETAINING RING
$ #ARRIER
$ 2OLLER BEARING
$ 2ETAINING RING
$ 0LANET GEAR
$ 2ETAINING RING
$ 3UN GEAR
$ 2ETAINING RING
$ / R IN G
$ #OVER
$ 3CREW
VALID FROM *ANUARY

$+-(03$ , 2EV ! n

008 924 17 BOMAG 807

16.5 Drum reduction gear

/52 02/$5#43 3AUER $ANFOSS (YDRAULIC 0OWER 3YSTEMS

n -ARKET ,EADERS 7ORLDWIDE
(YDROSTATIC TRANSMISSIONS
3AUER $ANFOSS IS A COMPREHENSIVE SUPPLIER PROVIDING COMPLETE
(YDRAULIC POWER STEERING SYSTEMS TO THE GLOBAL MOBILE MARKET
%LECTRIC POWER STEERING
3AUER $ANFOSS SERVES MARKETS SUCH AS AGRICULTURE CONSTRUCTION ROAD
#LOSED AND OPEN CIRCUIT AXIAL PISTON BUILDING MATERIAL HANDLING MUNICIPAL FORESTRY TURF CARE AND MANY
PUMPS AND MOTORS OTHERS

'EAR PUMPS AND MOTORS 7E OFFER OUR CUSTOMERS OPTIMUM SOLUTIONS FOR THEIR NEEDS AND
DEVELOP NEW PRODUCTS AND SYSTEMS IN CLOSE COOPERATION AND
"ENT AXIS MOTORS
PARTNERSHIP WITH THEM
2ADIAL PISTON MOTORS
3AUER $ANFOSS SPECIALIZES IN INTEGRATING A FULL RANGE OF SYSTEM
/RBITAL MOTORS COMPONENTS TO PROVIDE VEHICLE DESIGNERS WITH THE MOST ADVANCED
TOTAL SYSTEM DESIGN
4RANSIT MIXER DRIVES

0LANETARY COMPACT GEARS 3AUER $ANFOSS PROVIDES COMPREHENSIVE WORLDWIDE SERVICE FOR ITS
PRODUCTS THROUGH AN EXTENSIVE NETWORK OF !UTHORIZED 3ERVICE
0ROPORTIONAL VALVES #ENTERS STRATEGICALLY LOCATED IN ALL PARTS OF THE WORLD

$IRECTIONAL SPOOL VALVES

#ARTRIDGE VALVES

(YDRAULIC INTEGRATED CIRCUITS

(YDROSTATIC TRANSAXLES

)NTEGRATED SYSTEMS

&AN DRIVE SYSTEMS 3AUER $ANFOSS 53 #OMPANY

%LECTROHYDRAULIC CONTROLS %AST TH 3TREET
!MES )! 53!
$IGITAL ELECTRONICS AND SOFTWARE 0HONE &AX

"ATTERY POWERED INVERTER 3AUER $ANFOSS .EUMàNSTER 'MB( #O /('

0OSTFACH $ .EUMàNSTER
3ENSORS
+ROKAMP $ .EUMàNSTER 'ERMANY
0HONE &AX

3AUER $ANFOSS .ORDBORG !3

$+ .ORDBORG $ENMARK
0HONE &AX

$+-(03$ , 2EV ! n WWWSAUER DANFOSSCOM

808 BOMAG 008 924 17

16.6 Steering valve

008 924 17 BOMAG 809

16.6 Steering valve

810 BOMAG 008 924 17

Steering valve 16.6
Hydrostatic
Steering Unit Type
OSPB, OSPC and
OSPF

Service Manual

008 924 17 BOMAG 811

16.6 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
Table of Contens

Table of contens
%XPLODED VIEW /30B 3
%XPLODED VIEW /30# /30F 4
Tools
$ISMANTLINg
$ISMANTLING THE PRESSURE RELIEF VALVE FOR /30C
!SSEMBLINg
!SSEMBLY PATTERN FOR STANDARD BEARINg
)NSTALLATION INSTRUCTION FOR / RING ROTO 'LYd
!SSAMBLY OF THE PRESSURE RELIEF VALVE FOR /30C
!SSAMBLY OF THE SHOCK VALVES FOR /30#/30# ,3/30# ,32
-AX TIGHTENING TORQUE AND HYDRAULIC CONNECTIONs

¹ 3AUER $ANFOSS !LL RIGHTS RESERVED 0RINTED IN %UROPA

3AUER $ANFOSS ACCEPTS NO RESPONSIBILITY FOR POSSIBLE ERRORS IN CATALOGS BROCHURES AND OTHER PRINTED MATERIAL
3AUER $ANFOSS RESERVES THE RIGHT TO ALTER ITS PRODUCTS WITHOUT PRIOR NOTICE4HIS ALSO APPLIES TO PRODUCTS
ALREADY ORDERED PROVIDED THAT SUCH ALTERATIONS ARENT IN CONmICT WITH AGREED SPECIlCATIONS !LL TRADEMARKS IN
THIS MATERIAL ARE PROPERTIES OF THEIR RESPECTIVE OWNERS 3AUER $ANFOSS AND THE 3AUER $ANFOSS LOGOTYPE ARE
TRADEMARKS OF THE 3AUER $ANFOSS 'ROUP
&RONT COVER ILLUSTRATIONS & & &
$RAWING FA

2 520L0066 s 2EV "" s -AY

812 BOMAG 008 924 17

Steering valve 16.6
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
%XPLODED 6IEW /30"

$UST SEAL RING

(OUSING SPOOL SLEEVE
"ALL MM ; IN=
4HREAD BUSHING
/ RING WITH KIN RING OR
2OTO 'LYD
"EARING ASSEMBLY $ISTRIBUTOR PLATE
2ING FOR SPRINGS 'EARWHEEL
#ROSS PIN s MM / RING s MM ; s IN=
; s IN= %ND COVER
.EUTRAL POSITION SPRINGS 7ASHER s s MM ; s s IN=
#ARDAN SHAFT 3PECIAL SCREW
3PACER 3CREW
/ RING s MM .AME LABEL
; s IN= 3PACER

520L0066 s 2EV "" s -AY 3

008 924 17 BOMAG 813
16.6 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
%XPLODED 6IEW /30# /30&

$UST SEAL RING 3PACER .AME PLATE

(OUSING SPOOL AND SLEEVE #ARDAN SHAFT #OMPLETE RELIEF VALVE
#HECK VALVE AND THE SEATS FOR RELIEF 3ET OF SPRINGS 3PRING WIRE
AND SHOCK VALVES ARE LOCKTITED / RING #OMPLETE SHOCK VALVE
"ALL MM ; IN= $ISTRIBUTOR PLATE 33 Ball 3 in
4HREAD BUSHING 'EARWHEEL SET 3PRING
/ RING USED WITH KIN RING ITEM / RING 2OLLED PIN
+IN RING %ND COVER "USHING
"EARING ASSEMBLY 7ASHER "ALL
2ING 3PECIAL SCREW +IN RING
#ROSS PIN 3CREW / RING

4 520L0066 s 2EV "" s -AY

814 BOMAG 008 924 17

Steering valve 16.6
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
Tools

Tools Holding tool

#ODE NUMBER 3*

'UIDE RING
#ODE NUMBER 3*

!SSEMBLY TOOL FOR / RING AND KIN RING

2OTO 'LYD
#ODE NUMBER 3*
#ODE NUMBER 3* .

!SSEMBLY TOOL FOR LIP SEAL

#ODE NUMBER 3*

520L0066 s 2EV "" s -AY 5

008 924 17 BOMAG 815
16.6 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
Tools

Tools !SSEMBLY TOOL FOR CARDAN SHAFT

#ODE NUMBER 3*

!SSEMBLY TOOL FOR DUST SEAL

#ODE NUMBER 3*

4ORQUE WRENCH .M

MM SOCKET SPANNER
AND MM SOCKETS
MM SCREWDRIVER
MM ; IN= SCREWDRIVER
MMRING SPANNER
AND MM SOCKET SPANNERS
0LASTIC HAMMER
4WEEZERS

4HE TOOLS ARE NOT AVAILABLE FROM 3AUER

&
$ANFOSS

6 520L0066 s 2EV "" s -AY

816 BOMAG 008 924 17

Steering valve 16.6
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
$ISMANTLING

Dismantling $ISMANTLE STEERING COLUMN FROM STEERING

UNIT AND PLACE THE STEERING UNIT IN THE
HOLDING TOOL
3CREW OUT THE SCREWS IN THE END COVER
OFF PLUS ONE SPECIAL SCREW

2EMOVE THE END COVER SIDEWAYS

,IFT THE GEARWHEEL SET WITH SPACER IF

lTTED OFF THE UNIT4AKE AUT THE TWO /
RINGS

2EMOVE THE CARDAN SHAFT

520L0066 s 2EV "" s -AY 7

008 924 17 BOMAG 817
16.6 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
$ISMANTLING

Dismantling 2EMOVE DISTRIBUTOR PLATE

3CREW OUT THE THREADED BUSH OVER THE

CHECK VALVE

2EMOVE / RING

/30" /30" ,3 /30"8 ,3

3HAKE OUT THE CHECK VALVE BALL MM

/30# ,3 /30# ,32

3HAKE OUT THE CHECK VALVE BALL AND
SUCTION VALVE PINS AND BALLS

/N SOME PINS IN THE /30# THERE ARE

TWO SPRINGS SEE PAGE POS
2EPLACE THIS PINS PRIOR TO THE REASSEMBLY
&

8 520L0066 s 2EV "" s -AY

818 BOMAG 008 924 17

Steering valve 16.6
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
$ISMANTLING

Dismantling 4AKE CARE TO KEEP THE CROSS PIN IN THE

SLEEVE AND SPOOL HORIZONTAL4HE PIN
CAN BE SEEN THROUGH THE OPEN END
OF THE SPOOL 0RESS THE SPOOL INWARDS
AND THE SLEEVE RING BEARING RACES
AND NEEDLE BEARING WILL BE PUSHED
OUT OF THE HOUSING TOGETHER

4AKE RING BEARING RACES AND NEEDLE

BEARING FROM SLEEVE AND SPOOL
4HE OUTER THIN BEARING RACE CAN
SOMETIMES hSTICKv IN THE HOUSING
THEREFORE CHECK THAT IT HAS COME OUT

0RESS OUT THE CROSS PIN 5SE THE

SPECIAL SCREW FROM THE END COVER
.OTE NEXT POINTPARAGRAPH

/30" #. AND /30# #.

#. OSPF
! SMALL MARK HAS BEEN MADE WITH
A PUMICE STONE ON BOTH SPOOL AND
SLEEVE CLOSE TO ONE OF THE SLOTS FOR THE
NEUTRAL POSITION SPRINGS SEE DRAW m
ING
)F THE MARK IS NOT VISIBLE REMEMBER
TO LEAVE A MARK OF YOUR OWN ON SLEEVE
AND SPOOL BEFORE THE NEUTRAL POSITION
SPRINGS ARE DISMANTLED

&OR /30& BOTH MARKS SHOULD BE

PLACED OPPOSITE EACH OTHER &

520L0066 s 2EV "" s -AY 9

008 924 17 BOMAG 819
16.6 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
$ISMANTLING

Dismantling #AREFULLY PRESS THE SPOOL OUT OF THE

SLEEVE

0RESS THE NEUTRAL POSITION SPRINGS OUT

OF THEIR SLOTS IN THE SPOOL

2EMOVE DUST SEAL AND / RING +IN

RING 2OTO 'LYD

2EMOVE PLUGS FROM SHOCK VALVES

USING A MM IHEXAGON SOCKET
spanner

10 520L0066 s 2EV "" s -AY

820 BOMAG 008 924 17

Steering valve 16.6
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
$ISMANTLING

Dismantling 2EMOVE SEAL WASHERS OFF

5NSCREW THE SETTING SCREWS USING A

MM I HEXAGON SOCKET SPANNER

3HAKE OUT THE TWO SPRINGS AND TWO

VALVE BALLS INTO YOUR HAND4HE VALVE
SEATS ARE BONDED INTO THE HOUSING
AND CANNOT BE REMOVED

4HE SHOCK VALVES ARE NOW DISMANTLED

520L0066 s 2EV "" s -AY 11

008 924 17 BOMAG 821
16.6 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
$ISMANTLING THE 0RESSURE 2ELIEF 6ALVE FOR /30#

Dismantling 3CREW OUT THE PLUG USING AND

MM IHEXAGON SOCKET SPANNER
2EMOVE SEAL WASHERS

5NSCREW THE SETTING SCREW USING AN

MM IHEXAGON SOCKET SPANNER

3HAKE OUT SPRING AND PISTON4HE

VALVE SEAT IS BONDED INTO THE HOUSING
AND CANNOT BE REMOVED

4HE PRESSURE RELIEF VALVE IS NOW

DISMANTLED

12 520L0066 s 2EV "" s -AY

822 BOMAG 008 924 17

Steering valve 16.6
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
$ISMANTLING THE 0RESSURE 2ELIEF 6ALVE #ARTRIDGE

Dismantling the Pressure 3CREW OUT THE PRESSURE RELIEF VALVE

Relief Valve (Cartridge) USING AND MM IHEXAGON SOCKET
for OSPC LS / OSPC LSR SPANNER 2EMOVE THE SEAL RING )F THE
VALVE IS DEFECTIVE IT MUST BE REPLACED

4HE PRESSURE RELIEF VALVE IS NOW

DISMANTLED

4HE STEERING UNIT /30" IS NOW COM

PLETELY DISMANTLED

4HE STEERING UNIT /30" ,3 IS NOW

COMPLETELY DISMANTLED

520L0066 s 2EV "" s -AY 13

008 924 17 BOMAG 823
16.6 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
$ISMANTLING THE 0RESSURE 2ELIEF 6ALVE #ARTRIDGE

Dismantling the Pressure 4HE STEERING UNIT /30# IS NOW

Relief Valve (Cartridge) COMPLETELY DISMANTLED
for OSPC LS / OSPC LSR 2EPLACE THIS PINS PRIOR TO THE REAS
SEMBLY

4HE STEERING UNIT /30# ,3 IS NOW

COMPLETELY DISMANTLED
2EPLACE THIS PINS PRIOR TO THE REAS
SEMBLY

Cleaning Lubrication
#LEAN ALL PARTS CAREFULLY IN 3HELLSOL + "EFORE ASSEMBLY LUBRICATE ALL PARTS WITH
OR THE LIKE HYDRAULIC OIL

Inspection and replacement

2EPLACE ALL SEALS AND WASHERS
#HECK ALL PARTS CAREFULLY AND MAKE
ANY REPLACEMENTS NECESSARY

14 520L0066 s 2EV "" s -AY

824 BOMAG 008 924 17

Steering valve 16.6
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
!SSEMBLING

Assembling

0LACE THE TWO mAT NEUTRAL POSITION

SPRINGS IN THE SLOT
0LACE THE CURVED SPRINGS BETWEEN
&
THE mAT ONES AND PRESS THEM INTO
PLACE

,INE UP THE SPRING SET

'UIDE THE SPOOL INTO THE SLEEVE -AKE

SURE THAT SPOOL AND SLEEVE FOR /30"
,3 /30"8 ,3 /30# ,3 /30# ,32 AND
OSPF are placed correctly in relation
TO EACH OTHER SEE PAGE

520L0066 s 2EV "" s -AY 15

008 924 17 BOMAG 825
16.6 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
!SSEMBLING

Assembling !SSEMBLE SPOOL AND SLEEVE

OSPB LS, OSPBX LS, OSPC LS, OSPC

LSR and OSPF

7HEN ASSEMBLING SPOOL AND

SLEEVEONLY ONE OF TWO POSSIBLE WAYS
OF POSITIONING THE SPRING SLOTS IS
CORRECT 4HERE ARE THREE SLOTS IN THE
SPOOL AND THREE HOLES IN THE SLEEVE IN
THE END OF THE SPOOLSLEEVE OPPOSITE
&
TO THE END WITH SPRING SLOTS 0LACE
THE SLOTS AND HOLES OPPOSITE EACH
OTHER SO THAT PARTS OF THE HOLES IN THE
SLEEVE ARE VISIBLE THROUGH THE SLOTS IN
THE SPOOL

OSPB CN and OSPC CN

!SSEMBLE THE SPOOLSLEEVE AND MAKE
SURE THE MARKS ON SPOOL AND SLEEVE
ARE OPPOSITE EACH OTHER SEE DRAWING
PAGE
&

0RESS THE SPRINGS TOGETHER AND PUSH

THE NEUTRAL POSITION SPRINGS INTO
PLACE IN THE SLAVE

,INE UP THE SPRINGS AND CENTRE THEM

16 520L0066 s 2EV "" s -AY

826 BOMAG 008 924 17

Steering valve 16.6
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
!SSEMBLING

Assembling 'UIDE THE RING DOWN OVER THE SLEEVE

4HE RING SHOULD BE ABLE TO MOVE

FREE OF SPRINGS

&IT THE CROSS PIN INTO THE SPOOLSLEEVE

Fit bearing races and needle bearings

AS SHOWN ON THE DRAWING NEXT PAGE

520L0066 s 2EV "" s -AY 17

008 924 17 BOMAG 827
16.6 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
!SSEMBLY 0ATTERN FOR 3TANDARD "EARING

Assembling for Assembly pattern for standard bearing

Standard Bearing
/UTER BEARING RACE
.EEDLEBEARING
3 Inner bearing race
4 Spool
3LEEVE

Assembly pattern for double bearing

7ASHER FOR AXIAL BEARING

/UTER NEEDLEBEARING
3 Outer bearing race
4 Spool
3LEEVE
)NNER NEEDLEBEARING
)NNER BEARING RACE

4HE INSIDE CHAMFER ON THE INNER BEARING RACE MUST FACE THE INNER SPOOL

18 520L0066 s 2EV "" s -AY

828 BOMAG 008 924 17

Steering valve 16.6
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
)NSTALLATION )NSTRUCTION FOR / RING +IN RING 2OTO 'LYD

Installation 4URN THE STEERING UNIT UNTIL THE BORE

Instructions for IS HORIZONTAL 'UIDE THE OUTER PART OF
O-ring / Kin-ring THE ASSEMBLY TOOL INTO THE BORE FOR
Roto glyd THE SPOOLSLEEVE

'REASE O RING AND KING RINGROTO

'LYD WITH HYDRAULIC OIL AND PLACE
THEM ON THE TOOL

(OLD THE OUTER PART OF THE ASSEMBLY

TOOL IN THE BOTTOM OF THE STEERING
UNIT HOUSING AND GUIDE THE INNER
PART OF THE TOOL RIGHT TO THE BOTTOM

0RESS AND TURN THE O RINGKIN RING

INTO POSITION IN THE HOUSING

520L0066 s 2EV "" s -AY 19

008 924 17 BOMAG 829
16.6 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
)NSTALLATION )NSTRUCTION FOR / RING +IN RING 2OTO 'LYD

Installation $RAW THE INNER AND OUTER PARTS OF

Instructions for THE ASSEMBLY TOOL OUT OF THE STEERING
O-ring / Kin-ring / UNIT BORE LEAVING THE GUIDE FROM THE
Roto Glyd INNER PART IN THE BORE

20 520L0066 s 2EV "" s -AY

830 BOMAG 008 924 17

Steering valve 16.6
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
)NSTALLATION )NSTRUCTION FOR ,IP 3EAL

Installation ,UBRICATE THE LIP SEAL WITH HYDRAULIC

Instructions for OIL AND PLACE IT ON THE ASSEMBLY TOOL
Lip Seal

'UIDE THE ASSEMBLY TOOL RIGHT TO THE

BOTTOM

0RESS AND TURN THE LIP SEAL INTO PLACE

IN THE HOUSING

7ITH A LIGHT TURNING MOVEMENT

GUIDE THE SPOOL AND SLEEVE INTO THE
BORE

&IT THE SPOOL SET HOLDING THE CROSS PIN

HORIZONTAL

520L0066 s 2EV "" s -AY 21

008 924 17 BOMAG 831
16.6 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
)NSTALLATION )NSTRUCTION FOR ,IP 3EAL

Installation 4HE SPOOL SET WILL PUSH OUT THE

Instructions for ASSEMBLY TOOL GUIDE4HE O RING
Lip Seal AND KIN RINGROTO 'LYD ARE NOW IN
POSITION

4URN THE STEARING UNIT UNTIL THE BORE

IS VERTICAL AGAIN 0UT THE CHECK VALVE
BALL INTO THE HOLE INDICATED BY THE
ARROW

3CREW THE THREADED BUSH LIGHTLY INTO

THE CHECK VALVE BORE4HE TOP OF THE
BUSH MUST LIE JUST BELOW THE SURFACE
OF THE HOUSING

0LACE A BALL IN THE TWO HOLES INDICATED

BY THE ARROWS

22 520L0066 s 2EV "" s -AY

832 BOMAG 008 924 17

Steering valve 16.6
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
)NSTALLATION )NSTRUCTION FOR ,IP 3EAL

Installation 0LACE A NEW PIN IN THE SAME TWO

Instructions for HOLES
Lip Seal

)N SOME CASES A SPRING HAS TO BE

lTTED SEE PAGE POS ON THE PIN
BEFORE IT IS PLACED IN THE
HOUSING

'REASE THE O RING WITH MINERAL OIL

APPROX VISCOSITY MMS ;353=
AT ²# ; ²&=

0LACE THE DISTRIBUTOR PLATE SO THAT THE

CHANNEL HOLES MATCH THE HOLES IN THE
HOUSING

520L0066 s 2EV "" s -AY 23

008 924 17 BOMAG 833
16.6 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
)NSTALLATION )NSTRUCTION FOR ,IP 3EAL

Installation 'UIDE THE CARDAN SHAFT DOWN INTO THE

Instructions for BORE SO THAT THE SLOT IS PARALLEL WITH
Lip Seal THE CONNECTION mANGE

0LACE THE CARDAN SHAFT AS SHOWN

SO THAT IT IS HELD IN POSITION BY THE
MOUNTING FORK

'REASE THE TWO O RINGS WITH MINERAL

OIL APPROX VISCOSITY MMS ;353=
AT ²# ;²&= AND PLACE THEM IN THE
TWO GROOVES IN THE GEAR RIM &IT THE
GEARWHEEL AND RIM ON THE CARDAN
SHAFT

Caution

&IT THE GEARWHEEL ROTOR AND CARDAN

SHAFT SO THAT A TOOTH BASE IN THE ROTOR
IS POSITIONED IN RELATION TO THE SHAFT
SLOT AS SHOWN4URN THE GEAR RIM SO
THAT THE SEVEN TROUGH HOLES MATCH
THE HOLES IN THE HOUSING

24 520L0066 s 2EV "" s -AY

834 BOMAG 008 924 17

Steering valve 16.6
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
)NSTALLATION )NSTRUCTION FOR ,IP 3EAL

Installation &IT THE SPACER IF ANY

Instructions for
Lip Seal

0LACE THE END COVER IN POSITION

&IT THE SPECIAL SCREW WITH WASHER AND

PLACE IT IN THE HOLE SHOWN

&IT THE SIX SCREWS WITH WASHERS

AND INSERT THEM
#ROSS TIGHTEN ALL THE SCREWS AND THE
ROLLED PIN WITH A TORQUE OF 
.M ; LBFIN=
4HE /30" /30" ,3 AND /30"8 ,3 CAN
NOW BE FUNCTION TESTED

520L0066 s 2EV "" s -AY 25

008 924 17 BOMAG 835
16.6 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
!SSAMBLY OF THE 0RESSURE 2ELIEF 6ALVE FOR /30#

Assembly of the Pressure &IT THE PISTON

Relief Valve for OSPC

&IT THE SPRING

3CREW IN THE SETTING SCREW WITH AN

MM HEXAGON SOCKET SPANNER
-AKE THE PRESSURE SETTING ON A PANEL
OR THE VEHICLE

3CREW PLUG WITH DUST SEAL INTO THE

HOUSING USING AN MM IHEXAGON
SOCKET SPANNER
4IGHTENING TORQUE  .M
; LBFIN=

26 520L0066 s 2EV "" s -AY

836 BOMAG 008 924 17

Steering valve 16.6
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
!SSAMBLY OF THE 3HOCK 6ALVES FOR /30#/30# ,3/30# ,32

Assambly of the Shock 0UT A BALL IN THE TWO HOLES INDICATED

Valves for OSPC/OSPC LS/ BY THE ARROWS
OSPC LSR

Place springs and valve cones over

THE TWO BALLS

4HE BLUE SPRING APPLIES TO SETTING

RANGE BAR ; PSI=4HE
untreated spring applies to setting
RANGE BAR ; PSI=

3CREW IN THE TWO SETTING SCREWS USING

A MM IHEXAGON SOCKET SPANNER
-AKE THE PRESSURE
SETTING ON A PANEL OR THE VEHICLE

3CREW PLUG WITH SEAL RING INTO THE

TWO SHOCK VALVES AND TIGHTEN THEM
WITH A TORQUE OF 
.M ; LBFIN= USING
A MM IHEXAGON SOCKET SPANNER
3TEERING UNIT TYPE /30# /30# ,3 OR
/30# ,32 IS NOW ASSEMBLED

520L0066 s 2EV "" s -AY 27

008 924 17 BOMAG 837
16.6 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
!SSAMBLY OF THE 3HOCK 6ALVES FOR /30#/30# ,3/30# ,32

Assambly of the Shock 0LACE THE DUST SEAL RING IN THE

Valves for OSPC/OSPC LS/ HOUSING7ITH THE /30# /30# ,3 AND
OSPC LSR /30# ,32 THE DUST SEAL RING MUST BE
PLACED ONLY AFTER THE PRESSURE RELIEF
VALVE AND SHOCK VALVES HAVE BEEN
lTTED

&IT THE DUST SEAL RING IN THE HOUSING

USING SPECIAL TOOL 3*
SEE PAGE AND A
PLASTIC HAMMER

0RESS THE PLASTIC PLUGS INTO THE

CONNECTION PORTS
$O NOT USE A HAMMER

28 520L0066 s 2EV "" s -AY

838 BOMAG 008 924 17

Steering valve 16.6
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
-AX4IGHTENING 4ORQUE AND (YDRAULIC #ONNECTIONS

Max. Tightening Torque 4 4ANK

and Hydraulic Connec-
tions , ,EFT PORT

0 0UMP

2 2IGHT PORT

Max. tightening torque N.m [lbf.in]

Screwed With cooper With aluminium

With cutting edge With O-ring
connection washer washer
' 4 ;= ;= ;=
3
' ;= ;= ;=
' ;= ;= ;=

5.& ;=
3
4 5.& ;=
- s ;= ;= ;= ;=
- s ;= ;= ;= ;=
- s ;= ;= ;= ;=

520L0066 s 2EV "" s -AY 29

008 924 17 BOMAG 839
16.6 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
.OTES

30 520L0066 s 2EV "" s -AY

840 BOMAG 008 924 17

Steering valve 16.6
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
.OTES

520L0066 s 2EV "" s -AY 31

008 924 17 BOMAG 841
16.6 Steering valve

Our Products Sauer-Danfoss Mobile Power and Control Systems

– Market Leaders Worldwide
(YDROSTATIC 4RANSMISSIONS
3AUER $ANFOSS IS A COMPREHENSIVE SUPPLIER PROVIDING COMPLETE
(YDRAULIC 0OWER 3TEERING
SYSTEMS TO THE GLOBAL MOBILE MARKET
%LECTRIC 0OWER 3TEERING
3AUER $ANFOSS SERVES MARKETS SUCH AS AGRICULTURE CONSTRUCTION ROAD
%LECTROHYDRAULIC 0OWER 3TEERING
BUILDING MATERIAL HANDLING MUNICIPAL FORESTRY TURF CARE AND MANY
#LOSED AND /PEN #IRCUIT !XIAL 0ISTON OTHERS
0UMPS AND -OTORS
'EAR 0UMPS AND -OTORS 7E OFFER OUR CUSTOMERS OPTIMUM SOLUTIONS FOR THEIR NEEDS AND
DEVELOP NEW PRODUCTS AND SYSTEMS IN CLOSE COOPERATION AND
"ENT !XIS -OTORS PARTNERSHIP WITH THEM
Orbital Motors
3AUER $ANFOSS SPECIALIZES IN INTEGRATING A FULL RANGE OF SYSTEM
4RANSIT -IXER $RIVES COMPONENTS TO PROVIDE VEHICLE DESIGNERS WITH THE MOST ADVANCED
0ROPORTIONAL 6ALVES TOTAL SYSTEM DESIGN

$IRECTIONAL 3POOL 6ALVES 3AUER $ANFOSS PROVIDES COMPREHENSIVE WORLDWIDE SERVICE FOR ITS
#ARTRIDGE 6ALVES PRODUCTS THROUGH AN EXTENSIVE NETWORK OF 'LOBAL 3ERVICE 0ARTNERS
STRATEGICALLY LOCATED IN ALL PARTS OF THE WORLD
Hydraulic Integrated Circuits
(YDROSTATIC 4RANSAXLES
,OCAL ADDRESS
)NTEGRATED 3YSTEMS
&AN $RIVE 3YSTEMS
%LECTROHYDRAULICS
-ICROCONTROLLERS AND 3OFTWARE
%LECTRIC -OTORS AND )NVERTERS
*OYSTICKS AND #ONTROL (ANDLES
$ISPLAYS 3AUER $ANFOSS 53 #OMPANY 3AUER $ANFOSS !P3
%AST TH 3TREET $+ .ORDBORG $ENMARK
Sensors !MES )! 53! 0HONE
0HONE &AX
&AX
3AUER $ANFOSS 'MB( #O /(' 3AUER $ANFOSS $AIKIN ,4$
0OSTFACH $ .EUMàNSTER 3ANNOMIYA 'RAND "LDG &
+ROKAMP $ .EUMàNSTER 'ERMANY )SOGAMI DORI #HUO KU
0HONE +OBE (YOGO *APAN
&AX 0HONE
&AX

520L0066 s 2EV "" s -AY WWWSAUER DANFOSSCOM

842 BOMAG 008 924 17
16.7 Axle

008 924 17 BOMAG 843

16.7 Axle

844 BOMAG 008 924 17

Axle 16.7

008 924 17 BOMAG 845

16.7 Axle

846 BOMAG 008 924 17

Axle 16.7

008 924 17 BOMAG

1 847
16.7 Axle

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 responsabiliteÂ pour l'utilisation de pieÁces non originales ou d'accessoires non testeÂs et homologueÂs.

848 BOMAG
2 008 924 17
Axle 16.7

INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX

INTRODUCTION ..........................................................5 DIFFERENTIAL UNIT

GB MAINTENANCE AND LUBRICANTS . Removal and disassembly ....................................................44
. Definition of viewpoints............................................7 . Assembly and installation .....................................................54
. Data plate ..............................................................................7 REDUCTION GEAR AND BEVEL PINION
. Maintenance points ................................................................7 . Disassembly.........................................................................68
. Maintenance intervals.............................................................8 . Installation and adjustment ...................................................74
. Adjustment and checks ..........................................................8
. Conversion tables...................................................................9 SPECIAL TOOLS ......................................................................82
. Tightening torques .................................................................9
. Screw-locking, sealing, and lubricating materials ...................10
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

INTRODUZIONE .......................................................5 GRUPPO DIFFERENZIALE

ITA . Rimozione e smontaggio.......................................................44
MANUTENZIONE E LUBRIFICANTI
. Definizione viste ..................................................7 . Assemblaggio ed installazione ..............................................54
. Targa matricola ......................................................................7 RIDUTTORE E PIGNONE CONICO
. Punti di manutenzione ............................................................7 . Smontaggio..........................................................................68
. Intervalli di manutenzione .......................................................8 . Installazione e registrazione..................................................74
. Registrazione e controlli .........................................................8 ATTREZZI SPECIALI.................................................................82
. Tabelle di conversione............................................................9
. Coppie di serraggio ................................................................9
. Materiali per bloccaggio viti, tenuta e lubrificazione................10
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

VORAUSSETZUNG .................................................5 DIFFERENTIAL

D . Abmontieren und zerlegen ....................................................44
WARTUNG UND SCHMIERSTOFFE
. Definition der Ansichten......................................7 . Montieren und installieren.....................................................54
. Kennummernschild.................................................................7 REDUZIERER UND KEGELRAD
. Wartungsstellen .....................................................................7 . Abmontieren ........................................................................68
. Wartungsintervalle..................................................................8 . Installieren und einstellen .....................................................74
. Einstellungen und Kontrollen ..................................................8 SONDERWERZZEUGE ..............................................................82
. Umrechnungstabellen.............................................................9
. Anziehdrehmomente...............................................................9
. Material zur Blockierung von Schrauben und
fuÈr Dichtungen und Schmiermittel .........................................10
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

008 924 17 BOMAG

3 849
16.7 Axle
INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX

PROLOGO................................................................ 5 GRUPO DIFERENCIAL

ESP MANTENIMIENTO Y LUBRICANTES . Remocion y desmontaje ....................................................... 44
. Definicion vistas................................................... 7 . Montaje e instalacion ........................................................... 54
. Matricula ............................................................................... 7 REDUCTOR Y PINÄON CONICO
. Puntos de manutencion.......................................................... 7 . Remocion ............................................................................ 68
. Intervalos de manutencioÁn...................................................... 8 . Instalacion y ajuste .............................................................. 74
. Ajuste y controles .................................................................. 8 HERRAMIENTAS ESPECIALES................................................. 82
. Tablas de conversion ............................................................. 9
. Pares de torsion .................................................................... 9
. Materiales para el bloqueo, estanqueidad y lubricacion ......... 10
NORMAS CONCERNIENTES A LA SEGURIDAD ....................... 13
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 GROUPE DIFFERENTIEL

F ENTRETIEN ET LUBRIFIANTS . Depose et demontage .......................................................... 44
. DeÂfinition vues ..................................................... 7 . Assemblage et installation .................................................... 54
. Plaque d'immatriculation ........................................................ 7 REDUCTEUR ET PIGNON CONIQUE
. Points d'entretien................................................................... 7 . Depose................................................................................ 68
. Intervalle de service ............................................................... 8 . Installation et reglage ........................................................... 74
. Reglages et controles............................................................. 8 OUTILS SPECIAL ..................................................................... 82
. Tableaux de conversion ......................................................... 9
. Couples de serrage................................................................ 9
. MateÂriaux pour le blocage vis, eÂtancheÂiteÂ et lubrification........ 10
NOTES EN MATIERE DE SECURITE......................................... 13
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

850 BOMAG
4 008 924 17
Axle 16.7
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION

The efficiency and continued operation of mechan- martelli in plastica o rame, leve appropriate estrattori e chiavi
GB ical units depend on constant, correct maintenance specifiche, al fine di facilitare il lavoro salvaguardando nel
and also on efficient repair work, should there be a contempo le superfici lavorate e la sicurezza degli operatori.
break-down or malfunction. The instructions contained in this Prima di procedere al disassemblaggio delle parti e scaricare
manual have been based on a complete overhaul of the unit. l'olio, eÁ opportuno eseguire un'accurata pulizia del ponte,
However, it is up to the mechanic to decide whether or not it is asportando incrostazioni ed accumuli di grasso.
necessary to assemble only individual components, when
partial repair work is needed. The manual provides a quick PREMESSA: Tutti gli organi meccanici smontati, devono
and sure guide which, with the use of photographs and essere accuratamente puliti con prodotti appropriati, quindi
diagrams illustrating the various phases of the operations, ripristinati o sostituiti nel caso presentino danni, usura,
allows accurate work to be performed. incrinature, grippaggi, ecc. In particolare, verificare l'integritaÁ
All the information needed for correct disassembly, checks and di tutte quelle parti in movimento (cuscinetti, ingranaggi, coppia
assembly of each individual component is set out below. In conica, alberi) e di tenuta (anelli OR, paraolio), soggette a
order to remove the differential unit from the vehicle, the maggiori sollecitazioni ed usura. EÁ consigliabile, comunque, la
manuals provided by the vehicle manufacturer should be sostituzione degli organi di tenuta ogni qualvolta si proceda alla
consulted. In describing the following operations it is presumed revisione o riparazione dei componenti. Al momento del
that the unit has already been removed from the vehicle.
montaggio, gli anelli di tenuta devono essere lubrificati sui
IMPORTANT: In order to facilitate work and protect both bordi di tenuta. Nel caso della coppia conica, la sostituzione di
working surfaces and operators, it is advisable to use proper uno dei suoi ingranaggi comporta anche la sostituzione
equipment such as: trestles or supporting benches, plastic or dell'altro. In fase di montaggio sono da rispettare scrupolosa-
copper hammers, appropriate levers, pullers and specific mente i giochi, i precarichi e le coppie prescritte.
spanners or wrenches. Á : Il manuale fornisce le validitaÁ dei gruppi sotto forma
VALIDITA
Before going on to disassemble the parts and drain the oil, it is
di matricola. Al fine di una corretta interpretazione, le validitaÁ
best to thoroughly clean the unit, removing any encrusted or
sono indicate come:
accumulated grease.
= fino alla matricola
INTRODUCTORY REMARKS: All the disassembled mechan-
ical units should be thoroughly cleaned with appropriate = dalla matricola
products and restored or replaced if damage, wear, cracking or
seizing have occurred. Se non sono indicate validitaÁ, le operazioni di smontaggio ed
In particular, thoroughly check the condition of all moving parts assemblaggio sono comuni a tutte le versioni.
(bearings, gears, crown wheel and pinion, shafts) and sealing
parts (O-rings, oil shields) which are subject to major stress and MANUTENZIONE E RIPARAZIONE: Al fine di facilitare
wear. In any case, it is advisable to replace the seals every time interventi sui gruppi ponte differenziali e cambi di velocitaÁ la
a component is overhauled or repaired. During assembly, the SPICER CLARK-HURTH, ha ritenuto opportuno compilare
sealing rings must be lubricated on the sealing edge. In the queste istruzioni di manutenzione e riparazione. I disegni delle
case of the crown wheel and pinion, replacement of one attrezzature specifiche eventualmente necessarie per l'esecu-
component requires the replacement of the other one. During zione di interventi di manutenzione e riparazione possono
assembly, the prescribed pre-loading, backlash and torque of essere acquistati direttamente presso il costruttore; i ricambi
parts must be maintained. possono essere ordinati tramite il costruttore della macchina o
direttamente presso la DANA ITALIA S.p.A..
CLASSIFICATION: This manual classifies units according to
part numbers. For a correct interpretation, classification is
indicated as follows:
= up to the part number Die Leistung und Lebensdauer der mechanischen
D Teile haÈngt nicht nur von einer staÈndigen und
= from the part number on richtig durchgefuÈhrten Wartung sondern auch von
einem sofortigen Eingriff im StoÈrungsfall ab. Um dieses
When no classification is given, disassembly and assembly Handbuch zu erstellen sind wir von einer allgemeinen U È ber-
operations are the same for all versions. pruÈfung der Einheit ausgegangen, doch entscheidet der
Mechaniker ob die einzelnen Teile bei Reparaturen montiert
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of werden muÈssen oder nicht. Das Handbuch ist schnell und
all specific tools required for maintenance and repair work can einfach nachzuschlagen und ermoÈglicht es anhand der Abbild-
be found at the end of this manual ; spare parts may be ordered ungen und der Zeichnungen, die die verschiedenen VorgaÈnge
either from the vehicle manufacturer or directly from the darstellen, gezielt einzugreifen. Nachstehend sind alle Infor-
Service Centers or Authorised Distributors of DANA ITALIA mationen und Hinweise aufgefuÈhrt, die zur Zerlegung, PruÈfung
S.p.A.. und Montage der Einzelteile noÈtig sind. Um die Differentia-
lachse des Fahrzeugs abzumontieren, lesen Sie bitte die
Anweisungen in den HandbuÈchern des Fahrzeugherstellers.
Die nachstehenden Beschreibungen gehen davon aus, daû die
Il rendimento e la continuitaÁ degli organi meccanici Fahrzeugachse schon abmontiert worden ist.
ITA dipendono oltre che da una costante e corretta
manutenzione, anche dal tempestivo intervento, WICHTIG: Um die Arbeit zu erleichtern und gleichzeitig die
nell'eventualitaÁ di guasti o anomalie. verarbeiteten FlaÈchen zu schuÈtzen und die Sicherheit der
Nel proporre questo manuale si eÁ considerata l'ipotesi di una Arbeiter zu gewaÈhrleisten, empfehlen wir geeignete Werk-
revisione generale del gruppo ma eÁ il meccanico a valutare la zeuge wie BoÈcke, Tisch, Gummi- oder Kupferhammer, geeig-
necessitaÁ di montare solo i singoli componenti nel caso di nete Abzieher und SchluÈssel zu verwenden.
Bevor mit der Zerlegung der Teile begonnen und das O Èl
riparazione. Il manuale eÁ una guida rapida e sicura che
consente interventi precisi, tramite le fotografie ed i disegni abgelassen wird, muû die Achse sorgfaÈltig gereinigt und
prospettici che illustrano le varie fasi delle operazioni. Di Verkrustungen und Fettablagen abgetragen werden.
seguito sono riportate tutte quelle informazioni ed avvertenze VORAUSSETZUNG: Alle abmontierten mechanischen Teile
necessarie al corretto disassemblaggio, alle relative verifiche muÈssen sorgfaÈltig mit geeigneten Reinigungsmitteln gereinigt
ed all'assemblaggio dei singoli componenti. Per la rimozione oder, wenn beschaÈdigt, verschleiût, gerissen, festgefressen
del ponte differenziale dal veicolo, eÁ necessario consultare i usw. ausgewechselt werden. Insbesondere muû der einwand-
manuali forniti dal costruttore del veicolo. Nel descrivere le freie Zustand aller beweglichen Teile (Lager, ZahnraÈder,
operazioni seguenti, si presuppone che il ponte sia giaÁ stato Kegelradpaare, Wellen) und der Dichtungen (O-Ringe, O È lab-
rimosso dal veicolo. dichtungen), die am meisten beansprucht werden und ver-
schleiûen, kontrolliert werden. Wir empfehlen auf jeden Fall die
IMPORTANTE: In tutte le operazioni, eÁ consigliabile usare Abdichtungselemente immer auszuwechseln, wenn eine U È ber-
attrezzature idonee quali cavalletti o banchi di sostegno, holung oder eine Reparatur der Teile vorgenommen wird. Bei
008 924 17 BOMAG
5 851
16.7 Axle
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION

der Montage muÈssen die RaÈnder der Dichtringe geschmiert Si no ha sido indicada validez, las operacioÂn de desmontaje y
werden. Wenn beim Kegelradpaar ein Zahnrad ausgewechselt montaje son comunes a todas las versiones.
werden muû, muû auch das andere Zahnrad ausgewechselt
werden. Bei der Montage muÈssen die vorgeschriebenen HERRAMIENTAS ESPECIFICAS Y RECAMBIOS: Los planos de
Spiele, Vorspannungen und Drehmomente strengstens ein- las herramientas especificas necesarias para la ejecucioÂn de las
gehalten werden. intervenciones de mantenimiento figuran al final del manual; los
recambios se pueden pedir al fabricante de la maÂquina o
È LTIGKEIT: Das Handbuch gibt an zu welchen Kennummern directamente al Service Center o a Distribuidores autorizados de
GU DANA ITALIA S.p.A..
die Einheiten gehoÈren. Der Einfachheit halber sind die
AngehoÈrigkeiten folgendermaûen aufgefuÈhrt:
= bis Kennummer

= ab Kennummer Le rendement et la continuiteÂ des organes meÂca-

F niques deÂpendent, non seulement d'une mainte-
Wenn keine AngehoÈrigkeit angegeben ist, verstehen sich die nance correcte et constante, mais eÂgalement de la
Arbeiten zur Zerlegung und Montage fuÈr alle AusfuÈhrungen rapiditeÂ d'intervention en cas de pannes ou d'anomalies. En
guÈltig. vous proposant ce manuel, on envisage l'hypotheÁse d'une
reÂvision geÂneÂrale du groupe, mais c'est au meÂcanicien
SPEZIFISCHE WERKZEUGE UND ERSATZTEILE: die Zeich- d'eÂvaluer la neÂcessiteÂ de monter ou non chacun des
nungen der fuÈr Wartungsarbeiten erforderlichen spezifischen composants en cas de reÂparation. Le manuel est un guide
Werkzeuge, sind am Ende des Handbuchs aufgefuÈhrt; Ersatz- rapide et suÃr consentant des interventions preÂcises, au travers
teile koÈnnen beim Fahrzeughersteller oder direkt bei der de photographies et de dessins prospectifs qui illustrent les
Kundendienststelle oder bei einem zugelassenen HaÈndler der diffeÂrentes phases des opeÂrations. Ensuite, sont reporteÂes
DANA ITALIA S.p.A. bezogen werden. 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
El rendimiento y la duracioÂn de los oÂrganos mecaÂnicos
fournis par le constructeur du veÂhicule. En deÂcrivant les
ESP depende, ademaÂs que del constante y correcto opeÂrations suivantes, on preÂsume que le pont ait deÂjaÁ eÂteÂ
mantenimiento, tambieÂn de la intervencioÂn inmediata enleveÂ du veÂhicule.
en caso de averõÂas o anomalõÂas.
Al proponer este manual, ha sido considerada la suposicioÂn de una IMPORTANT: Pour faciliter le travail en sauvegardant en
revisioÂn general del grupo, pero es el mecaÂnico quien tiene que meÃme temps les surfaces usineÂes et la seÂcuriteÂ des opeÂra-
valorar la necesidad de montar cada uno de los componentes en teurs, il est preÂconiseÂ d'utiliser des installations approprieÂes
caso de reparacioÂn. El manual es una guõÂa raÂpida y segura que telles que des eÂtais ou banc de support, maillets en plastique
permite intervenciones precisas por medio de fotografõÂas y de ou cuivre, leviers approprieÂs, extracteurs et cleÂs speÂcifiques.
planos que muestran las distintas fases de las operaciones. A
continuacioÂn figuran todas las informaciones y advertencias Avant de proceÂder au deÂmontage des parties et vidanger
necesarias para ejecutar un montaje correcto, para las comproba- l'huile, il vaut mieux nettoyer soigneusement le pont, en
ciones y el montaje de cada uno de los componentes. Para enlevant incrustations et blocs de gras.
remover el puente diferencial del vehõÂculo hay que consultar los
manuales de los fabricantes del vehõÂculo. En la descripcioÂn de las PRELIMINAIRE: Tous les organes meÂcaniques deÂmonteÂs
operaciones siguientes se supone que el puente ya ha sido sacado doivent eÃtre soigneusement nettoyeÂs aÁ l'aide de produits
del vahõÂculo. approprieÂs et reÂpareÂs ou remplaceÂs dans le cas ouÁ ils seraient
abõÃmeÂs, useÂs, feÃleÂs, grippeÂs, etc. VeÂrifier, l'inteÂgriteÂ, en
IMPORTANTE: Para facilitar el trabajo salvaguardando al mismo particulier, de toutes les parties en mouvement (paliers,
tiempo las superficies mecanizadas y la seguridad de los
operadores, se aconseja que se usen equipos y herramientas engrenages, couple conique, arbres) et l'eÂtancheÂiteÂ des
adecuados como caballetes y bancos de soporte, martillos de bagues (bagues OR, parahuile), qui sont sujettes aÁ plus de
plaÂstico o de cobre, palancas adecuadas, extractores y llaves sollicitations et aÁ l'usure. Il est preÂconiseÂ, de toute facËon, de
especõÂficas. substituer les organes d'eÂtancheÂiteÂ, chaque fois que l'on
Antes de desmontar las partes y descargar el aceite, es effectue une reÂvision ou une reÂparation des composants. Au
conveniente que se haga una limpieza minuciosa del puente moment du montage, les bagues d'eÂtancheÂiteÂ doivent eÃtre
sacando las incrustaciones y acumulaciones de grasa. lubrifieÂes sur les bords eÂtanches. Dans le cas du couple
conique, la substitution de l'un de ses engrenages comporte
INTRODUCCION: Todos los oÂrganos mecaÂnicos desmontados eÂgalement la substitution de l'autre. En phase de montage, il
tienen que ser limpiados minuciosamente con productos adecua-
dos y restaurados o sustituidos en el caso de que presenten danÄos, faut respecter scrupuleusement les jeux, les preÂcharges et les
desgaste, rajaduras, agarrotamientos, etc. En particular, compro- couples prescrits.
bar la integridad de todas las partes en movimiento (cojinetes,
engranajes, par coÂnico, ejes) y de estanqueidad (anillos OR, VALIDITE: Le manuel fournit la validiteÂ des groupes sous
detenedor de aceite) sujetas a mayores solicitaciones y desgaste. forme de matricule. Pour une meilleure interpreÂtation, les
Se aconseja, de todas formas, que se sustituyan los oÂrganos de validiteÂs sont indiqueÂes comme:
estanqueidad cada vez que se ejecute la revisioÂn o reparacioÂn de
los componentes. = jusqu'aÁ l'immatriculation
Al volver a montar, los segmentos de compresioÂn tienen que estar
lubricados en los bordes de estanqueidad. En el caso del par = aÁ partir de l'immatriculation et apreÁs
coÂnico, la sustitucioÂn de uno de sus engranajes comporta tambieÂn
la sustitucioÂn del otro. Al montar hay que tener en cuenta Si les validiteÂs ne sont pas indiqueÂes, les opeÂrations de
escrupulosamente los juegos, las precargas y los pares descriptos.
deÂmontage et d'assemblage sont pareilles dans toutes les
VALIDEZ: El manual suministra la validez de los grupos en forma versions.
de matrõÂcula. Para poder tener una interpretacioÂn correcta, la
validez estaÂ indicada: INSTALLATIONS SPECIFIQUES ET PIECES DETACHEES:
Les dessins des installations speÂcifiques neÂcessaires pour
= hasta la matrõÂcula effectuer des interventions d'entretien sont reporteÂes aÁ la fin du
manuel, les pieÁces deÂtacheÂes peuvent eÃtre commandeÂes au
= desde la matrõÂcula en adelante constructeur de la machine ou directement aux Centres de
Services, ou Distributeurs agreÂeÂs de la SocieÂteÂ DANA ITALIA
S.p.A..

852 BOMAG
6 008 924 17
Axle
MAINTENANCE AND LUBRICANT - MANUTENZIONE E LUBRIFICANTI - WARTUNG UND SCHMIERSTOFFE
16.7
MANTENIMIENTO Y LUBRICANTES - ENTRETIEN ET LUBRIFIANTS

DEFINITION OF VIEWPOINTS - DEFINIZIONE VISTE - DEFINITION DER ANSICHTEN - DEFINICION VISTAS - DEÂFINITION VUES

LEFT SIDE RIGHT SIDE

LATO SINISTRO LATO DESTRO
LINKE SEITE RECHTE SEITE
LADO IZQUIERDO LADO DERECHO
COTE GAUCHE COTE DROITE

D1240138

DATA PLATE - TARGA MATRICOLA - KENNUMMERNSCHILD - MATRICULA - PLAQUE D'IMMATRICULATION

Type and model unit - modification index

1
Tipo e modello gruppo - indice di modifica
Typ und Modelleles Antriebes - AÈ nderungsverzeichnis
Tipo y modelo grupo - indice de modificacion
Type et modeÂle de ensemble - tableau des modifications

1 2 Serial number

2
Numero di serie
Seriennummer
3 NuÂmero de serie
Numero de serie
MFG. BY CLARK-HURTH COMPONENTS S.P.A. Lubricant

3
38062 Arco (Trento) Lubrificante
Schmieroel
MADE IN ITALY Lubricante
Lubrificant
D1240011

MAINTENANCE POINTS - PUNTI DI MANUTENZIONE - WARTUNGSSTELLEN - PUNTOS DE MANUTENCION - POINTS D'ENTRETIEN

3 1 1 1 3

2 2 2 2
2

1
Oil filling plug - Tappo di carico
EinfuÈllstopfen - Tapon de carga
Bouchon de ravitaillement

2
Oil draining plug - Tappo di scarico
1 3 Ablasstopfen - Tapon de descarga
Bouchon de vidange

2
3
Check level plug - Tappo controllo livello
È lpegelkontrolle -
Stopfen zur O
Tapon de contrl de nivel - Jauge de niveau
D1240139

008 924 17 BOMAG

7 853
16.7 Axle

MAINTENANCE INTERVALS - INTERVALLI DI MANUTENZIONE - WARTUNGSINTERVALLE - INTERVALOS DE MANUTENCIOÁN - INTERVALLE DE SERVICE

OPERATION - OPERAZIONE - FREQUENCY - PERIODICITAÁ

LUBRICANTS - LUBRIFICANTI - SCHMIERSTOFFE -
ARBEITSVORGANG - - ZEITABSTAND -
LUBRICANTES - LUBRIFIANTS
OPERACION - OPERATION FRECUENCIA - PERIODICITE
Differential monthly
Differenziale mensile
Im differential monatlich . SAE85W90 (API GL4 - MIL L-2105)
. Check levels: Diferencial cada mes With additives for oil-bath brakes
. Controllo livelli: Differentiel mensuel Con additivi per freni a bagno d'olio
. È
Olstandkontrolle: Mit Zusatzmittel fuÈr Bremsen in OÈ lbad
. Control niveles: Planetary reduction every 200 hours
Con aditivos para frenos de banÄo de aceite
. ControÃle niveaux: Riduzione epicicloidale ogni 200 ore
Avec adjuvants pour freins en bain d'huile
Planetengetrieb alle 200 Std.
ReduccioÂn epicicloidal cada 200 horas . SAE85W90 (API GL5 - MIL 2105-B)
Reduction epicycloidale toutes les 200 heures With additives for oil-bath brakes, for units pre-
Differential every 800 hours ] senting hypoid crown wheel and pinion and /or
Differenziale ogni 800 ore self-locking differential gear
Im differential alle 800 Std. Per esecuzioni con coppia conica ipoide e/o con
Diferencial cada 800 horas differenziale autobloccante, con additivi per freni
Differentiel toutes les 800 heures a bagno d'olio
Bei AusfuÈhrungen mit Kegel- und Telleradpaar
. Oil change: Planetary reduction every 1000 hours ]
und/oder Selbstsperrdifferential, mit Zusatzmit-
. Cambio olio: Riduzione epicicloidale ogni 1000 ore È lbad
È lwechsel: teln fuÈr Bremsen in O
. O Planetengetrieb alle 1000 Std.
Para ejecuciones con par coÂnico hipoide y/o con
. Cambio aceite: ReduccioÂn epicicloidal cada 1000 horas
diferencial autobloqueante con aditivos para fre-
. Vidange huile: Reduction epicycloidale toutes les 1000 heures
nos de banÄo de aceite.
Self-locking differential gear every 700 hours ] r Pour exeÂcutions avec couple conique hypoõÈde et/
Differenziale autobloccante ogni 700 ore ou diffeÂrentiel autobloquant, avec adjuvants pour
Selbstsperrdifferential alle 700 Std. freins en bain d'huile
Diferencial autobloqueante cada 700 horas
Differentiel autobloquant toutes les 700 heures
] 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
Normal work monthly
Lavori normali mensile
Normale Arbeit monatlich
Greasing Articulations Trabajos normales cada mes
Ingrassaggio Snodi TaÃches ordinaires mensuel
Schmieren Gelenk MOLIKOTE
Engrase RoÂtula Awkward work Weekly
Graissage Articulations Lavori gravosi Settimanale
Schwere Arbeit WoÈchentlich
Trabajos pesados Semanal
TaÃches extraordinaires Hebdomadaire

ADJUSTMENT AND CHECKS - REGISTRAZIONE E CONTROLLI - EINSTELLUNGEN UND KONTROLLEN - AJUSTE Y CONTROLES - REGLAGES ET CONTROLES

UNIT - GRUPPO - OPERATION - OPERAZIONE FREQUENCY - PERIODICITAÁ - SERVICE BRAKE CIRCUIT - CIRCUITO COMANDO FRENI -
AGGREGAT - ARBEITSVORGANG - ZEITABSTAND - BREMSKREISLAUF - CIRCUITO MANDOS FRENOS -
GRUPO - GROUPE OPERACION - OPERATION FRECUENCIA - PERIODICITE CIRCUIT DE COMMANDE DES FREINS
Negative brake Adjustment every 1000 hours ]
Freno negativo Registrazione ogni 1000 ore Only for mineral oil use e.g. ATF Dexron II. Make sure
Federspeicherbremse Einstellen alle 1000 Std. that master cylinder seals are suitable for mineral oil.
Freno negativo Ajuste cada 1000 horas Usare esclusivamente olio minerale ATF Dexron II. Ac-
Frein neÂgatif ReÂglage toutes les 1000 hours certarsi che le guarnizioni del cilindro master siano
adatte a questo olio.
Service brake Adjustment every 500 hours È l verwenden, z.B.: ATF Dexron II.
Nur mineralisches O
Freni di servizio Registrazione ogni 500 ore
Achtung: Dichtringe des Hauptbremszylinders muÈs-
Hilfsbremse Einstellen alle 500 Std. È l geeignet sein.
sen fuÈr dieses O
Frenos de ejercicio Ajuste cada 500 horas
Usar exclusivamente aceite mineral ATF Dexron II.
Freins de service ReÂglage toutes les 500 hours
Asegurarse de que las juntas del cilindro principal
Wheel nuts Tightening every 200 hours son adecuadas para este aceite.
Dadi ruota Serraggio - ogni 200 ore Utiliser exclusivement huile mineÂrale ATF Dexron II.
Radmuttern Festziehen alle 200 Std. VeÂrifier que les joints du maõÃtre-cylindre, soien compa-
Tuercas rueda Apriete cada 200 horas tibles avec cette huile.
Ecrous de roue Serrage toutes les 200 hours
] 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
854 BOMAG
8 008 924 17
Axle 16.7

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 Units of torque - UnitaÁ di coppia - Drehmomenteinheiten
Unidad de peso - UniteÂs de poids 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

TYPE OF BOLT - TIPO VITE - GEWINDE - TIPO DE TORNILLO - TYPE DE VIS
SIZE OF BOLT
MISURA VITE
SCHRAUBENMASS 8.8 10.9 12.9
TAMAN Ä O TORNILLO
MESURE VIS Normali Normali Normali Normali Normali Normali
+ Loctite 242 + Loctite 270 + Loctite 242 + Loctite 270 + Loctite 242 + Loctite 270
M6 x 1 9,5-10,5 10,5-11,5 14,3-15,7 15,2-16,8 16,2-17,8 18,1-20,0
COARSE PITCH - PASSO GROSSO - GROûER
SCHRITT - PASO GRUESO - GROS PAS

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
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

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
M12 x 1,5 86-95 94-104 120-132 133-147 143-158 159-175
PASO FINO - PAS FIN

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

008 924 17 BOMAG

9 855
16.7 Axle

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

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'eÂtancheÂiteÂ 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 APPLICATION - APPLICAZIONE - ANWENDUNG - APLICACION - APPLICATION
DENOMINACION
DENOMINATION
. Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength loc-
king. 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 re-
sistenza. 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 Wi-
derstandskraÈfte geeignet. Darf erst aufgetragen werden, wenn die FlaÈchen von Schmiermittel richtig sauber
Loctite 242
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. UtiliseÂ pour le freinage
demi reÂsistant. Il doit eÃtre utiliseÂ apreÁs avoir enleveÂ 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
Loctite 243 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
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 sorg-
Loctite 270
faÈltig 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 de-
spueÂs 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 utiliseÂ apreÁs avoir
enleveÂ 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,
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
Loctite 275 widerstandsfaÈhig, verschleierungsbestaÈndig, und zum Siegeln von Rohrleitungen geeignet; kann Kupplun-
gen 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 adapteÂ au freinage et au scellage aÁ haute reÂsistance des parties fileteÂes, boulons et pri-
sonniers de grandes dimensions, protection anti-alteÂration et scellage de tuyauteries; il peut sceller des ac-
couplements ayant un jeu diameÂtral maximal de 0,25 mm.

856 BOMAG
10 008 924 17
Axle 16.7

DENOMINATION
DENOMINAZIONE
BEZEICHNUNG APPLICATION - APPLICAZIONE - ANWENDUNG - APLICACION - APPLICATION
DENOMINACION
DENOMINATION
. 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.
. Anaerobes Produkt zur Abdichtung von FluÈssigkeiten an Flanschen und Schrauben mit LoÈcher, die mit FluÈs-
Loctite 510
sigkeiten 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 co-
municante 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
it, remove any lubricant with the specific activator. After polymerisation, disassembly may result rather dif-
ficult, 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 ab-
getragen worden ist.
Loctite 577
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'eÂtancheÂiteÂ des filetages des raccords coniques ou cylindriques
jusqu'aÁ M80. Il doit eÃtre utiliseÂ apreÁs qu'on ait enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
Une certaine difficulteÂ de deÂmontage se preÂsente apreÁs la polymeÂrisation, on peut donc avoir la neÂcessiteÂ 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 to-
gether 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.
. Anaerober Klebstoff fuÈr groûe WiderstandskraÈfte fuÈr Zylinderkupplungen aus Metall geeignet (Wellenna-
Loctite 638
ben). 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.
. Anaerober Klebstoff fuÈr mittlere WiderstandskraÈfte fuÈr Zylinderkupplungen aus Metall geeignet (Wellenna-
Loctite 648 ben). 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
diameter of sealing rings for rotating shafts with outer metal reinforcement.
(AREXONS) . Mastice sigillante per guarnizioni elastiche a base di solvente, essicante per evaporazione.
Repositionable jointing
compound for seals Viene utilizzato per la tenuta sul diamentro esterno di anelli di tenuta per alberi rotanti con armatura metallica
Mastice per guarnizioni esterna.
riposizionabile . Klebstoff fuÈr Gummidichtung auf LoÈsemittelbasis, trocknet durch Verdampfung.
Klebstoff fuÈr verstellbare Wird am aÈuûeren Durchmesser von Dichtungsringe bei rotierenden Wellen mit Metallmantel verwendet.
Dichtungen . Pasta para juntas de sellado para juntas elaÂsticas a base de disolvente, deshidratante por evaporacioÂn.
Pasta para juntas Se utiliza para la estanqueidad en el diaÂmetro externo de segmentos de compresioÂn, para ejes giratorios con
reposicionable
armadura metaÂlica exterior.
Mastic pour garnitures aÁ
remettre en place . Mastic adheÂsif aÁ base de solvants pour garnitures eÂlastiques, seÂchant par eÂvaporation.
Il sert garder eÂtanche le diameÁtre exteÂrieur des bagues d'eÂtancheÂiteÂ des arbres rotatifs ayant une arma-
ture meÂtallique externe.

008 924 17 BOMAG

11 857
16.7 Axle

DENOMINATION
DENOMINAZIONE
BEZEICHNUNG APPLICATION - APPLICAZIONE - ANWENDUNG - APLICACION - APPLICATION
DENOMINACION
DENOMINATION
. Semi-fluid adhesive material used for sealing and filling and to protect components from environmental and
physical elements. Polymerises with non-corrosive dampness.
Silicone . Materiale adesivo semifluido usato per sigillatura, riempimenti e per la protezione di componenti dagli elementi
Silicone ambientali e fisici. Polimerizza con umiditaÁ non corrosiva.
. HalbfluÈssiger Klebstoff zum Befestigen, FuÈllen und zum Schutz von Bestandteilen vor aÈuûeren Einwirkun-
Silikon
gen. Polymerisiert durch nicht korrosive Feuchtigkeit
Silicona . Material adhesivo semifluido usado para el sellado, llenado y para la proteccioÂn de componentes de elemen-
Silicone tos ambientales y fõÂsicos. Polimeriza con humedad no corrosiva.
. Produit adheÂsif semi-fluide utiliseÂ pour le scellage, remplissage et protection des eÂleÂments ambiants et phy-
siques. PolymeÂrise aÁ une humiditeÂ non corrosive.
. Highly adhesive synthetic grease, with silicone compounds added.
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.
(TECNO LUPE/101) Applicato su viti di registrazione a foro comunicante con fluidi di tipo oleoso.
Silicone-based grease Usato quando si richiedono frequenti interventi di registrazione.
Grasso al silicone . Synthetisches Fett mit hoher Haftfestigkeit, mit silikonhaltigen Stoffen legiert.
Wird auf Stellschrauben mit Loch, die mit oÈlhaltigen FluÈssigkeiten in Kontakt stehen, angebracht.
Silikonfett Wird verwendet, wenn die Schraub oÈfters eingestellt werden muû.
Grasa a la silicona . Grasa sinteÂtica con elevado grado de adhesioÂn, aditivada con componentes silicoÂnicos.
Graisse au silicone 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 degreÂ d'adheÂsiviteÂ eÂleveÂ, adjuveÂ de composeÂs au silicone.
AppliqueÂ sur les vis de reÂglage aÁ trou communiquant avec des fluides du type huileux.
UtiliseÂ 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 pre-
venire incollamenti ed ossidazioni di particolari non lubrificati in modo continuo.
Molikote . Schmierstoff mit MolybidaÈndisulfid; wird zum Schmieren von Gelenkstiften und gegen Ankleben und Oxy-
(DOW CORNING) dation von nicht dauergeschmierten Einzelteilen verwendet.
. Compuesto lubricante que contiene bisulfuro de molibdeno, usado para la lubricacioÂn de roÂtulas y para pre-
venir encoladuras y oxidaciones de piezas no lubricadas de manera continua.
. ComposeÂ lubrifiant contenant du bisulfure de molybdeÁne, utiliseÂ pour lubrifier les axes d'articulation et preÂ-
venir collages et oxydations des pieÁces qui ne sont pas continuellement lubrifieÂes.
. Applied to bearings, sliding parts and used to lubricate seals or parts during assembly
(Lithium-based) Grease . Applicato a cuscinetti, parti scorrevoli e per lubrificare guarnizioni o pezzi in fase di montaggio.
Grasso (al Litio) . Wird auf Lager, Gleitteilen aufgetragen und zum Schmieren von Dichtungen oder von Teilen bei der Mon-
(Lithium) Fett tage verwendet.
Grasa (al Litio) . Aplicada a cojinetes, partes deslizables o para lubricar juntas o piezas en fase de montaje.
Graisse (au Lithium) . AppliqueÂ sur les paliers, parties coulissantes et pour lubrifier les garnitures ou pieÁces pendant la phase de
montage.

858 BOMAG
12 008 924 17
Axle 16.7

NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR

SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE
1 - During all operations described in this manual, the LoÈsemittel muÈssen als SondermuÈll und auf jeden Fall laut den
GB axle should be fastened onto a trestle, while the oÈrtlich geltenden Vorschriften entsorgt werden.
other parts mentioned should rest on supporting 9- Zur Reinigung ausschlieûlich schwache LoÈsemittel wie Petroleum,
benches. Terpentin oder wasserhaltige LoÈsemittel verwenden. Auf keinen
2 - When removing one of the arms, an anti-tilting safety trestle Fall TrichloraÈthylen, tuolol- oder xylolhlatige LoÈsemittel usw.
should be placed under the other arm. verwenden.
3 - When working on an arm that is fitted on the machine, make sure 10 - Um die ArbeitsvorgaÈnge verstaÈndlich abzubilden, werden in
that the supporting trestles are correctly positioned and that the einigen Fotos die Aggregate ohne Einzelteile gezeigt, die sonst
machine is locked lengthways. bei der Arbeit nicht abmontiert werden muÈssen.
4 - Do not admit any other person inside the work area; mark off the Nur die beschriebenen Teile abmontieren.
area, hang warning signs and remove the ignition key from the 11 - Unter RECHTS und LINKS versteht man in diesem Handbuch die
machine. Seite einer Person, die zur Achse schaut und zwar dem Antrieb
5 - Use only clean, quality tools; discard all worn, damaged, low- entgegengesetzt.
quality or improvised wrenches and tools. Ensure that all 12 - Nach beendeten Arbeiten und um Rostbildungen zu vermeiden,
dynamometric wrenches have been checked and calibrated. die Teile an denen der Lack ggf. beschaÈdigt worden ist,
6 - Always wear gloves and non-slip rubber shoes when performing anstreichen.
repair work. 1 - Las operaciones descritas se refieren al eje blo-
7 - Should you stain a surface with oil, remove marks straight away. ESP queado en un caballete y a algunas partes apoyadas
8 - Dispose of all lubricants, seals, rags and solvents once work has en el banco de trabajo.
been completed. Treat them as special waste and dispose of them 2- Cuando se saca un brazo del eje, colocar debajo del otro un
according to the relative law provisions obtaining in the country caballete de seguridad antivuelco.
where the axles are being overhauled. 3- Si se trabaja con un eje montado en la maÂquina, asegurarse de
9 - Make sure that only weak solvents are used for cleaning haber colocado caballetes soporte y de haber inmovilizado
purposes; avoid using turpentine, dilutants and toluol-, xylol- longitudinalmente la maÂquina.
based or similar solvents; use light solvents such as Kerosene, 4- No permitir que personas extranÄas entren en la zona de trabajo;
mineral spirits or water-based, environment friendly solvents. delimitar esta zona, colgar carteles de aviso de hombres
10 - For the sake of clarity, the parts that do not normally need to be trabajando y sacar las llaves de arranque de la maÂquina.
removed have not been reproduced in some of the diagrams. 5- Usar soÂlo y exclusivamente herramientas limpias y de buena
11 - The terms RIGHT and LEFT in this manual refer to the position of cualidad; descartar llaves o herramientas gastadas o danÄadas, de
the operator facing the axle from the side opposite the drive. calidad mediocre o improvisadas. Asegurarse de que las llaves
12 - After repair work has been completed, accurately touch up any dinamomeÂtricas han sido controladas y calibradas.
coated part that may have been damaged. 6- Durante las operaciones de reparacioÂn, llevar siempre guantes y
calzado antideslizamiento.
1 - Le operazioni descritte sono riferite all'assale bloc- 7- Limpiar inmediatamente las zonas que pudieran estar sucias de
ITA cato su cavalletto ed alcuni particolari appoggiati su aceite.
un banco di lavoro.
8- Los lubricantes, las juntas, los trapos para la limpieza y los
2 - Quando si asporta un braccio dell'assale, sistemare sotto l'altro disolventes usados hay que eliminarlos como desechos especia-
braccio un cavalletto di sicurezza antiribaltamento. les y, de todas formas, de acuerdo con las normativas vigentes en
3 - Se si opera su un'assale montato sulla macchina, assicurarsi di el paõÂs en el que se revisan los ejes.
aver sistemato dei cavalletti di sostentamento e di aver immobi- 9- Para limpiar, utilizar soÂlo disolventes deÂbiles excluyendo en
lizzato longitudinalmente la macchina. absoluto tricloroetileno, diluyentes y disolventes a base de toluol,
4 - Non permettere che persone estranee entrino nella zona di lavoro; silol, etc.; usar soÂlo disolventes ligeros como queroseno, aguarraÂs
delimitare questa zona, appendere dei cartelli di avviso di lavori in minerales o disolventes ecoloÂgicos a base de agua.
corso ed asportare le chiavi di avviamento della macchina. 10 - Para que resulte clara la exposicioÂn y la ilustracioÂn, en las figuras
5 - Usare solo ed esclusivamente attrezzi puliti e di buona qualitaÁ; de algunos grupos faltan algunas piezas que por lo general se
scartare chiavi od attrezzi usurati o danneggiati, di bassa qualitaÁ pueden dejar montadas. Sacar soÂlo las partes descritas.
od improvvisati. Assicurarsi che le chiavi dinamometriche siano 11 - Las palabras DERECHA E IZQUIERDA usadas en el manual se
state controllate e tarate. refieren a la persona que mira el eje del lado opuesto a la toma de
6 - Durante le operazioni di riparazione, indossare sempre guanti e movimiento.
scarpe antiscivolo. 12 - Al final de las reparaciones, para evitar oxidaciones, retocar
7 - Pulire immediatamente le zone eventualmente imbrattate d'olio. cuidadosamente las partes pintadas que estuvieran danÄadas.
8 - I lubrificanti, le guarnizioni, gli eventuali stracci di pulizia ed i
solventi usati devono essere smaltiti come rifiuti speciali e 1 - Les opeÂrations deÂcrites se rapportent aÁ l'essieu
comunque secondo le normative vigenti nel Paese ove vengono F bloqueÂ sur chevalet et de quelques pieÁces poseÂes
revisionati gli assali. sur un eÂtabli de travail.
9 - Per la pulizia, usare solo solventi deboli escludendo categorica- 2- Quand on enleÁve un essieu monteÂ sur la machine, ajuster sous
mente trielina, diluenti e solventi a base di toluolo, xilolo, ecc.; l'autre bras un chevalet de seÂcuriteÂ contre tout basculement.
usare solo solventi leggeri quali cherosene, ragie minerali o 3- Si on oeuvre sur un essieu monteÂ sur la machine, s'assurer
solventi ecologici a base d'acqua. d'avoir ameÂnageÂ des chevalets de soutien et d'avoir bloqueÂ la
10 - Per chiarezza di illustrazione ed esposizione, sulle figure di alcuni machine en longueur.
gruppi mancano dei particolari che, normalmente, possono essere 4- Ne jamais permettre aÁ des eÂtrangers de peÂneÂtrer dans la zone de
lasciati montati. Rimuovere solo i particolari descritti. travail; deÂlimiter cette zone, mettre des pancartes de signalisation
11 - I termini DESTRA e SINISTRA usati nel manuale sono riferiti alla de travaux en cours et enlever les cleÂs de contact de la machine.
persona che guarda l'assale dal lato opposto alla presa di moto. 5- N'utiliser que des outils propres et de bonne qualiteÂ; eÂliminer cleÂ
12 - Al termine delle riparazioni, per evitare dannose ossidazioni, ou autres outils useÂs, abõÃmeÂs, de mauvaise qualiteÂ ou improviseÂs.
ritoccare con cura le parti verniciate eventualmente danneggiate. Veiller aÁ ce que les cleÂs dynamomeÂtriques aient eÂteÂ controÃleÂes et
calibreÂes.
1 - Die beschriebenen VorgaÈnge werden an der Achse 6- Pendant les opeÂrations de reÂparation, endosser toujours gants et
D vorgenommen, wenn diese auf einem Bock blockiert chaussures antideÂrapantes.
ist. Zur Bearbeitung der Einzelteile, werden diese 7- Nettoyer tout de suite les eÂventuelles zones souilleÂes d'huile.
auf die Werkbank gelegt. 8- Les lubrifiants, les garnitures, les eÂventuels chiffons servant au
2- Wenn eine Achse abgenommen wird, einen Sicherheitsbock unter nettoyage et les solvants utiliseÂs devront eÃtre reÂcolteÂs et traiteÂs
den zweiten Arm legen. comme rebut speÂcial conformeÂment aux lois en vigueur dans le
3- Werden Arbeiten an der Achse vorgenommen, wenn diese noch pays ouÁ les essieux sont en reÂvision.
an der Maschine montiert ist, BoÈcke zur Halterung unter die 9- Pour le nettoyage, n'utiliser que des solvants aÁ base de toluol,
Achse stellen und die Maschine der LaÈnge nach blockieren. xylol, etc.; n'utiliser que des solvants leÂgers tels que keÂroseÁne,
4- Es duÈrfen sich keine fremde Personen in der NaÈhe der Maschine essences mineÂrales, ou solvants eÂcologiques aÁ base d'eau.
waÈhrend der Arbeiten aufhalten; diesen Bereich absperren und 10 - En ce qui concerne la clarteÂ en matieÁre d'illustration et exposition,
mit Schilder kennzeichnen, die auf die laufenden Arbeiten sur les figures de certains groupes, il y a des pieÁces manquantes
hinweisen. ZuÈndschluÈssel von der Maschine abnehmen. qui normalement peuvent rester monteÂes.
5- Nur saubere Werkzeuge guter QualitaÈt verwenden; alte, beschaÈ- Enlever uniquement les pieÁces deÂcrites.
digte oder improvisierte Hilfsmittel nicht verwenden. Sicher- 11 - Les termes DROITE et GAUCHE utiliseÂs dans ce manuel se
stellen, daû die Dynamometer gepruÈft und geeicht worden sind. rapportent aÁ la personne regardant l'essieu du coÃteÂ opposeÂ aÁ celui
6- Bei Reparaturen, stets Handschuhe und rutschfeste Schuhe tragen. de la prise de mouvement.
7- Mit OÈ l beschmutzte Stellen, sofort reinigen. 12 - A la fin des opeÂrations, afin d'eÂviter un risque d'oxydation
8- Gebrauchte Schmiermittel, Dichtungen, Reinigungslappen und nuisible, retoucher soigneusement les parties vernies eÂventuelle-
ment abõÃmeÂes.
008 924 17 BOMAG
13 859
16.7 Axle
SIMBOLI

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 1
Zusasmmenbauen von Baugruppen
Ensamblaje de subgrupos
Montage des sous-groupes
Remove obstruction parts T1
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 S
Attenzione, indicazione importante
Achtung, wichtiger Hinweis F1241070 F1241071
¡ 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. CHECKING WEAR Introduce tool T1 between the disks and check shim "S".
Controler, regler p.e. couples, mesures, pressions ecc. CAUTION! Perform operations on both arms. Minimum size of "S": 4.5 mm.
T=Special tool P=page Remove the oil-level plug (1).
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 P
Kontrollieren -PruÈfen
Examinar mediante inspeccioÂn visual
Controler, examiner, controle visuel 3
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 2
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 F1241072 F1241073
Entsichern-Sichern
Quitar-colocar el seguro
Enlever-mettre la securite
Lock-adhere (liquid sealant)
Mettere la sicura, incollare (mastice liquido)
Sichern-Kleben (fluÈssige Dichtung) ADJUSTING THE BRAKES Remove screw (2) and safety plate (3).
Colocar el seguro, pegar (mastique lõÂquido) Connect an external pump to the union piece "P" of the negative
Mettre la securite, coller (mastic liquide) brake and introduce a pressure of 15 ± 30 bar to eliminate the
Guard against material damage, damage to parts pressure of the Belleville washers (11).
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) 6
Marquer avant le demontage (pour le montage)
Filling - topping up - refilling e.g. oil, cooling water, etc.
Caricare - riempire (olio - lubrificante)
7
EinfuÈllen - AuffuÈllen - NachfuÈllen (OÈl-Schmiermittel)
Cargar - llenar (aceite lubricante)
Charger - remplir (huile - lubrifiant)
4
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
8
Inserire pressione nel circuito idraulico F1241074 F1241075
Leitung unter Druck setzen
Introducir presioÂn en el circuito hidraÂulico
Inserer pression dans le circuit hydraulique
To clean
Pulire Turn the brake clearance adjustment pinion (4) clockwise and as REPLACING THE BRAKING DISKS
Reinigen
Limpiar far as the limit stop. Sling the arm (6) to be removed and connect it to a hoist.
Nettoyer Release pressure and disconnect the tubes. Loosen and remove screws (7) and nuts (8).
Lubricate - grease NOTE. Remove the lower plug (5) and drain the oil.
Lubrificare - ingrassare
Schmieren - einfetten
Lubrificar - Engrasar
860 Lubrifier - Graisser BOMAG 008 924 17
Axle 16.7

CONTROLLO USURA Introdurre l'attrezzo T1 tra i dischi e controllare lo

ITA ATTENZIONE! Eseguire le operazioni per i due ITA spessore "S".
bracci. "S" minimo: 4,5 mm
Asportare il tappo (1) di livello olio.

VERSCHLEISS KONTROLLIEREN Werkzeug T1 zwischen den Scheiben einsetzen und

D D die StaÈrke "S" kontrollieren.
ACHTUNG! Die VorgaÈnge an beiden Armen vorneh-
men. "S" Minimum: 4,5 mm
È
OleinfuÈllstopfen (1) abnehmen.
a b
CONTROL DESGASTE Introducir la herramienta T1 entre los discos y
ESP ESP controlar el espesor "S".
ATENCION! Efectuar las operaciones por los dos
ejes. «S» minimo: 4,5 mm.
Sacar el tapon (1) de nivel aceite.

CONTROLE USURE Introduire l'outil T1 entre les disques et controÃler la

F F cale "S".
ATTENTION! Effectuer les opeÂrations aux deux bras.
Enlever le bouchon (1) du niveau d'huile. "S" minimum: 4,5 mm

REGISTRAZIONE FRENI Asportare la vite (2) e la piastrina di sicurezza (3).

ITA Collegare al raccordo "P" del freno negativo una pompa ITA
esterna ed immettere una pressione di 15v30 bar per
eliminare la pressione delle molle a tazza (11).

BREMSEN EINSTELLEN Schraube (2) und SicherheitsplaÈttchen (3) abnehmen.

D AnschluûstuÈck "P" der Federspeicherbremse an eine D
aÈuûere Pumpe anschlieûen und Druck bei 15v30 bar
einlassen, um Tellerfedern (11) zu entlasten.
c d
REGISTRACION FRENOS Sacar el tornillo (2) y la placa de securidad (3).
ESP Conectar al empalme «P» del freno negativo una ESP
pompa esterna y introducir una presion de 15v30 bar
para eliminar la presion de los muelles a taza (11).

REGLAGE DES FREINS Enlever les vis (2) et la plaquette de seÂcuriteÂ (3).
F Brancher au raccord "P" du frein neÂgatif une pompe F
externe et envoyer une pression de 15v30 bar pour
eÂliminer la pression des ressorts belleville (11).

Ruotare in senso orario il pignone (4) di regolazione SOSTITUZIONE DISCHI FRENO

ITA gioco freni fino a fondo corsa. ITA Imbragare il braccio (6) da asportare e collegarlo ad un
Rilasciare la pressione e scollegare i tubi. mezzo di sollevamento.
NOTA. Rimuovere il tappo inferiore (5) e scaricare l'olio. Allentare ed asportare le viti (7) ed i dadi (8).

Das Kegelrad (4) zur Einstellung des Bremsspiels bis BREMSSCHEIBEN AUSWECHSELN
D zum Endanschlag drehen. D Den abzunehmenden Arm (6) anschlagen und an eine
Druck ablassen und die Leitungen abtrennen. Hebezeug befestigen.
BEMERKUNG. Unteren Stopfen (5) abnehmen und das O È l. Schrauben (7) und Muttern (8) lockern und abschrauben.
e f
Girar en sentido horario el pinon (4) de regulacioÁn SUBSTITUCION DISCOS FRENOS.
ESP juego frenos hasta final carrera. ESP Atar el eje (6) de sacar y conectarlo a un medio de
Dejar la presion y desconectar los tubos. levantamiento.
NOTA. Remover el tapon inferior (5) y descargar el aceite. Aflojar y sacar los tornillos (7) y las tuercas (8).

Tourner le pignon de reÂglage du jeu des freins (4) dans Substitution des disques frein
F le sens des aiguilles d'une montre jusqu'en fin de F Elinguer le bras (6) aÁ enlever et brancher celui-ci aÁ un
course. moyen de relevage.
LibeÂrer la pression et deÂbrancher les tubes. Desserrer et enlever les vis (7), les eÂcrous (8).
REMARQUE: Enlever le bouchon infeÂrieur (5) et vidanger l'huile.

008 924 17 BOMAG

15 861
16.7 CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS Axle
KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
CONTROÃLE USURE ET SUBSTITUTION DES DISQUES FREINS

F1241076 F1241077

GB a GB b
Remove arm (6) together with brakes and axle shafts; lay down the Loosen screws (9) in an alternate manner and remove them.
arm vertically.

11
12

10 10

F1241078 F1241079

GB c GB d
Move the cylinder (10) outwards while supporting the Belleville Remove the cylinder (10) complete with piston (12).
washers (11).
Remove the Belleville washers (11) and note down direction of
assembly.

12
13
12

F1241080 F1241081

bar GB e GB f
Slowly introduce low-pressure compressed air through the con- Remove O-rings (13) and (14) from the piston (12).
nection member for the negative brake, in order to extract the NOTE. The O-rings (13) and (14) must be replaced each time the
piston (12). unit is disassembled.
CAUTION! Hold the piston (12) back, as it may be suddenly ejected
and damaged.

862 BOMAG
16 008 924 17
Axle 16.7

Rimuovere il braccio (6) completo di freni e semiassi; Allentare in modo alternato le viti (9) ed asportarle.
ITA deporre il braccio in modo verticale. ITA

Den Arm (6) samt Bremsen und Halbachsen ab- Abwechselnd die Schrauben (9) lockern und ab-
D nehmen; den Arm senkrecht ablegen. D schrauben.

a b
Remover el eje (6) completo de frenos y semi-ejes; Aflojar de manera alternada los tornillos (9) y sacarlas.
ESP colocar el eje de manera vertical. ESP

Enlever le bras (6) complet de freins et demi-essieux; Desserrer les vis (9) en alternance, puis les enlever.
F deÂposer le bras en vertical. F

Spostare verso l'esterno il cilindro (10) sostenendo le Rimuovere il cilindro (10) completo di pistone (12).
ITA molle a tazza (11). ITA
Rimuovere le molle (11) ed annotare il senso di
montaggio.

Den Zylinder (10) nach auûen verstellen und dabei die Zylinder (10) samt Kolben (12) abnehmen.
D Tellerfedern (11) stuÈtzen. D
Federn (11) abnehmen und die Montagerichtung
notieren.
c d
Desplazar hacia el esterior el cilindro (10) sosteniendo Remover el cilindro (10) completo de piston (12).
ESP los muelles a taza (11). ESP
Remover los muelles (11) y anotar el sentido de
montaje.

DeÂplacer le cylindre (10) vers l'exteÂrieur en soutenant Enlever le cylindre (10) complet de piston (12).
F le ressort belleville (11). F
Enlever le ressort (11) et prendre note du sens de son
montage.

Immettere lentamente aria compressa a bassa pres- Rimuovere dal pistone (12) gli anelli OR (13) e (14).
ITA sione attraverso l'attacco per il freno negativo per ITA
NOTA. Gli anelli OR (13) e (14) devono essere
estrarre il pistone (12). sostituiti ad ogni smontaggio.
ATTENZIONE! Trattenere il pistone (12) che puoÁ essere espulso
velocemente ed essere danneggiato.

Langsam Druckluft bei Niederdruck durch den An- Kolben (12) und O-Ringe (14) und (14) abnehmen.
D schluû der Federspeicherbremse einlassen, um den D
BEMERKUNG. Die O-Ringe (13) und (14) muÈssen
Kolben (12) heraus zu druÈcken. jedesmal ausgewechselt werden, wenn das Teil zer-
ACHTUNG! Den Kolben (12) halten, da er ploÈtzlich heraus springen legt wird.
e und beschaÈdigt werden koÈnnte. f
Introducir lentamente aire comprimida a baja presioÁn Remover del piston (12) los anillos OR (13) y (14).
ESP atraves el empalme por el freno negativo para sacar el ESP
NOTA. Los anillos OR (13) y (14) deben de ser
piston (12). sobstituidos cada desmontaje.
ATENCION! Tener el piston (12) que puede ser expulso rapida-
mente y estropearse.

Envoyer lentement de l'air comprimeÂ aÁ basse pression Enlever le piston (12), les anneaux O'RING (13) et
F aÁ travers le raccord du frein neÂgatif pour extraire le F (14).
piston (12). REMARQUE. Les anneaux O'RING (13) et (14) sont aÁ
ATTENTION! Tenir le piston (12) qui pourrait eÃtre expulser substituer aÁ chaque deÂmontage.
rapidement et endommager.

008 924 17 BOMAG

17 863
16.7 CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS Axle
KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
CONTROÃLE USURE ET SUBSTITUTION DES DISQUES FREINS

A
16

F1241082 F1241083

GB a GB b
Remove checking and guiding screws (15) from the pressure plate Remove the pressure plate (16).
(16). CAUTION! Note down the direction of assembly; flow regulator wall
NOTE. Loosen screws (15) in sequence and proportionally. "A" and oil drain holes must face the oil drain plug.

17
18

F1241084 F1241085

GB c GB d
Remove springs (17). Remove braking discs (18) and (19), noting down direction of
NOTE. Accurately check the condition of springs. They should not assembly.
be warped. NOTE. If disks are not to be replaced, avoid changing their
Any deformation of the springs requires spring replacement. position.

4 21

F1241086 F1241087

GB e GB f
Remove pinion (4) complete with O-ring (20). Unscrew and extract the braking disk clearance adjustment crown
NOTE. The O-ring must be replaced each time the unit is wheel (21).
disassembled.

864 BOMAG
18 008 924 17
Axle 16.7

Rimuovere le viti (15) di ritegno e guida dello Rimuovere lo spingidisco (16).

ITA spingidisco (16). ITA
ATTENZIONE! Annotare il senso di montaggio; la
NOTA. Allentare le viti (15) in modo sequenziale ed in parete frangiflusso "A" e gli scarichi olio, devono
uguale misura. essere rivolti verso il tappo di scarico olio.

Befestigungsschrauben (15) und die FuÈhrung der Druckplatte (16) abnehmen.

D Druckplatte (16) abnehmen. D
ACHTUNG! Montagerichtung notieren; der Strahlreg-
BEMERKUNG. Abwechselnd Schrauben (15) im È lablaûoÈffnungen muÈssen in Richtung
ler "A" und die O
gleichen Maû lockern. È
des Olablaûstopfens gerichtet sein.
a b
Remover los tornillos (15) de retencioÁn y guõÁa del Remover el empuja-disco (16).
ESP empuya-disco (16). ESP
ATENCION. Anotar el sentido de montaje; la pared
NOTA. Aflojar los tornillos (15) de manera secuencial rompe-flujo "A" y los descarge aceite, deben de ser
y en la misma mesura. dirijidos hacia el tapon de descarga aceite.

Enlever vis (15) de fixation et guide du plateau de Enlever le plateau de pression (16).
F pression (16). F
ATTENTION! Prendre noter du sens du montage; la
REMARQUE: Desserrer les vis (15) en seÂquence et en paroi brise-jet "A" et les eÂcoulements d'huile sont
eÂgale mesure. tourneÂs vers le bouchon de vidange d'huile.

Rimuovere le molle (17). Rimuovere i dischi di frenatura (18) e (19) annotando

ITA ITA l'ordine di montaggio.
NOTA. Controllare attentamente lo stato delle molle
che non devono essere deformate. NOTA. Se i dischi non devono essere sostituiti, evitare
Ogni deformazione deve portare alla sostituzione. lo scambio di posizione.

Federn (17) abnehmen. Bremsscheiben (18) und (19) abnehmen und Monta-
D D gerichtung notieren.
BEMERKUNG. Die Federn sorgfaÈltig kontrollieren; sie
duÈrfen nicht verformt sein. Sollte dies der Fall sein, BEMERKUNG. Falls die Scheiben ausgewechselt
Federn auswechseln. werden muÈssen, ihre Position nicht verwechseln.
c d
Remover los muelles (17). Remover los discos de frenadura (18) y (19) anotando
ESP ESP el orden de montaje.
NOTA. Controlar atentamente el estado de los
muelles que no deben de ser deformes. NOTA. Si los discos no deben de ser sobstituidos,
A cada deformacioÁn deben de ser cambiados. evitar el cambio de possicioÁn.

Enlever les ressorts (17). Enlever les disques de freinage (18) et (19) et prendre
F F note de l'ordre du montage.
REMARQUE. ControÃler attentivement l'eÂtat des res-
sorts, ils ne doivent pas eÃtre deÂformeÂs. REMARQUE. Si les disques doivent eÃtre substitueÂs,
Toute deÂformation veut dire substitution. eÂviter d'eÂchanger leur position.

Rimuovere il pignone (4) completo di anello OR (20). Svitare ed asportare la corona (21) di regolazione del
ITA ITA gioco dischi di frenatura.
NOTA. L'anello OR deve essere sostituito ad ogni
smontaggio.

Das Kegelrad (4) samt O-Ring (20) entfernen. Den Kranz (21) zur Einstellung des Bremsscheibens-
D D piels abnehmen.
BEMERKUNG. Den O-Ring bei jedem Zerlegen aus-
wechseln.
e f
Remover el pinon (4) completo de anillo OR (20). Destornillar y sacar la corona (21) de regulacioÁn del
ESP ESP juego discos de frenadura.
NOTA. El anillo OR debe de ser sobstituido a cada
desmontaje.

Enlever le pignon (4) complet de l'anneau O'RING DeÂvisser et enlever la couronne (21) de reÂglage du jeu
F (20). F des disques de freinage.
REMARQUE. L'anneau O-Ring est aÁ remplacer aÁ
chaque deÂmontage.

008 924 17 BOMAG

19 865
16.7 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS - MONTAJE DE LOSAxle
GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS

11
13
12

10 14

9
18

18
15
21 17
23
16
6 19

19
7
19

4
20
1

3
5 2
24

26 8
25 D1240130

6
21 4

6 20

21
F1241133 F1241134

GB a GB b
Lubricate the threaded portion of the crown wheel (21) and screw it Replace the O-ring (20) of pinion (4).
down into the arm (6) as far as it will go. Lubricate and install the pinion in the slot provided on the arm (6),
inserting the toothing into crown wheel (21).

866 BOMAG
20 008 924 17
Axle 16.7

ESP

ITA

Lubrificare la filettatura della corona (21) ed avvitarla a Sostituire l'anello OR (20) del pignone (4).
ITA fondo nel braccio (6). ITA Lubrificare il pignone e montarlo nella sede del braccio
(6) innestando la dentatura nella corona (21).

Das Gewinde des Kranzes (21) schmieren und in den O-Ring (20) des Kegelrads (4) auswechseln. Kegelrad
D Arm (6) festschrauben. D schmieren und in den Sitz des Arms (6) montieren;
dabei die ZaÈhne des Kranzes (21) einrasten.

a b
Lubrificar la rosca de la corona (21) y atornillar a Sobstituir el anillo OR (20) del pinon (4).
ESP hondo en el eje (6). ESP Lubrificar el pinon y montarlo en la sed del eje (6)
introduciendo la dentadura en la corona (21).

Lubrifier le filetage de la couronne (21), puis visser Substituer l'anneau O'RING (20) du pignon (4).
F celle-ci aÁ fond dans le bras (6). F Lubrifier le pignon, puis monter celui-ci dans le
logement du bras (6) en introduisant en meÃme temps
la denture dans la couronne (21).

008 924 17 BOMAG

21 867
16.7 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS - MONTAJE DE LOSAxle
GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS

19
18
B

F1241088 F1241089

GB a GB b
Lubricate the first friction disk (19) and install it on the axle shaft .
Lightly lubricate the first steel braking disk (18), then install it on the Complete the assembly, alternating steel disks and friction disks.
arm (6). CAUTION! Oval holes "B" of friction disks must be lined up.

16
17

6 A
F1241084 F1241083

GB c GB d
Position springs (17) in the appropriate slots of the arm (6). 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.

15
15

F1241082 F1241090

GB e GB f
Lock the pressure plate into position (16) with screws (15). Lock screws (15) with a dynamometric wrench.
CAUTION! Tighten screws in sequence and a little at a time. Torque wrench setting: 20 ± 30 Nm.

868 BOMAG
22 008 924 17
Axle 16.7

Lubrificare leggermente il primo disco di frenatura in Lubrificare il primo disco di attrito (19) e montarlo sul
ITA acciaio (18) e montarlo nel braccio (6). ITA semiasse.
Completare il montaggio alternando dischi di acciaio e
dischi di attrito.
ATTENZIONE! I dischi di attrito devono avere il foro ovale "B"
allineato.

Die erste Bremsscheibe aus Stahl (18) etwas schmie- Die erste Reibscheibe (19) schmieren und auf die
D ren und in den Arm (6) montieren. D Halbachse montieren.
Dann die Stahlscheiben abwechselnd mit den Reibs-
cheiben montieren.
a b ACHTUNG! Die LangloÈcher "B" der Reibscheiben muÈssen ge-
fluchtet sein.

Lubrificar ligermente el primer disco de frenadura en Lubrificar el primer disco de strito (19) y montarlo
ESP acero (18) y montarlo en el eje (6). ESP 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.

Lubrifier leÂgeÁrement le premier disque de freinage en Lubrifier le premier disque de friction (19), puis monter
F acier (18), puis monter celui-ci dans le bras (6). F 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.

Posizionare nelle sedi del braccio (6) le molle (17). Montare lo spingidisco (16).
ITA ITA
ATTENZIONE! Controllare attentamente l'orientamen-
to; il frangiflusso "A" e gli scarichi olio, devono essere
orientati verso il tappo di scarico olio del braccio.

In den Sitz des Arms (6) die Federn (17) einsetzen. Die Druckplatte (16) montieren.
D D
ACHTUNG! SorgfaÈltig die Montagerichtung kontroll-
È lablaûoÈffnungen
ieren; den Stahlregler "A" und die O
muÈssen zum Ablaûstopfen des Arms gerichtet sein.
c d
Colocar en las sedes del eje (6) los muelles (17). Montar el empuja-disco (16).
ESP ESP
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.

Mettre en place les ressorts (17) dans les logements Monter le plateau de pression (16).
F du bras (6). F
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.

Fissare la posizione dello spingidisco (16) con le viti Bloccare le viti (15) con chiave dinamometrica.
ITA (15). ITA Coppia di serraggio: 20v30 Nm
ATTENZIONE! Serrare le viti in modo sequenziale ed
in piuÁ tempi.

Die Druckplatte (16) mit den Schrauben (15) be- Schrauben (15) mit dem Dynamometer blockieren.
D festigen. D Anzugsmoment: 20v30 Nm.
ACHTUNG! Die Schrauben der Reihe nach und
schrittweise festziehen.
e f
Fijar la posicioÁn del empuja-disco (16) con los tornillos Bloquear los tornillos (15) con llave dinamometrica.
ESP (15). ESP Par de serraje: 20v30 Nm.
ATENCION! Apretar los tornillos de manera secuen-
cial y en mas tiempos.

Fixer le plateau de pression (16) aÁ sa place avec les Bloquer les vis (15) aÁ l'aide de la cleÂ dynamomeÂtrique.
F vis (15). F Couple de serrage: 20v30 Nm.
ATTENTION! Serrer les vis en plusieurs temps en
ordre seÂquentiel.

008 924 17 BOMAG

23 869
16.7 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS - MONTAJE DE LOSAxle
GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS

14 12
12

13 10

10
F1241091 F1241092

GB a GB b
Fit O-rings (13) and (14) onto the piston (12). Using a plastic hammer, ram the piston (12) into the cylinder (10).
Lubricate the piston and the O-rings and install the unit into the NOTE. Lightly hammer all around the edge in an alternate
cylinder (10). sequence.
NOTE. Piston relief «C» must face downwards.

22 11

F1241079 F1241078

GB c GB d
Check the condition and the position of the O-ring (22); lubricate Position the Belleville washers (11) and engage the cylinder (10).
the O-ring and position the cylinder on the studs without fastening. NOTE. Check the sense of direction of washers (11) and relative
centring.

10 23
6
9

F1241093 F1241094

GB e GB f
Lock the cylinder (10), tightening the screws (9) with a dynamo- Check integrity and position of the arm's O-ring (23); install the
metric wrench set to a torque of 86 ± 89 Nm. complete arm (6).
NOTE. To assist axle shaft centring, slightly move the wheel hub.

870 BOMAG
24 008 924 17
Axle 16.7

Montare sul pistone (12) gli anelli OR (13) e (14). Utilizzando un mazzuolo in materiale plastico, inserire
ITA Lubrificare il pistone e gli anelli OR e montare il ITA a fondo il pistone (12) nel cilindro (10).
gruppo nel cilindro (10). NOTA. Battere leggeri colpi distribuiti in modo
NOTA. Lo scarico "C" del pistone deve essere rivolto verso il alternato su tutta la circonferenza.
basso.

Auf den Kolben (12) die O-Ringe (13) und (14) Mit einem Gummihammer den Kolben (12) in den
D montieren. D Zylinder (10) bis zum Anschlag einschlagen.
Den Kolben und die O-Ringe schmieren und das BEMERKUNG. Den Kolben abwechselnd rund um die
Aggregat in den Zylinder (10) montieren. gesamte Kreislinie leicht schlagen.
a BEMERKUNG. Die AblaûoÈffnung "C" des Kolbens muû nach unten b
gerichtet sein.

Montar sobre el piston (12) los anillos OR (13) y (14). Utilizando un martillo de materia plastica, introducir a
ESP Lubrificar el piston y los anillos OR y montar el grupo ESP fondo el piston (12) en el cilindro (10).
en los cilindros (10). NOTA. Pegar ligeros golpes distribuidos de manera
NOTA. El escargo "C" del piston debe de ser dirijido hacia el bajo. alternada sobre toda la circonferencia.

Monter sur le piston (12), les anneaux O'RING (13) et A l'aide d'un maillet en matieÁre plastique, introduire le
F (14). F piston (12) aÁ fond dans le cylindre (10).
Lubrifier le piston et les anneaux O'RING, puis monter REMARQUE. Donner de leÂgers coups reÂguliers tout
le groupe dans le cylindre (10). autour de la circonfeÂrence.
REMARQUE. L'eÂcoulement "C" du piston doit eÃtre tourneÂ vers le
bas.

Controllare lo stato ed il posizionamento dell'anello Posizionare le molle a tazza (11) e mandare in battuta
ITA OR (22); lubrificare l'anello OR e posizionare il cilindro ITA il cilindro (10).
sui prigionieri senza mandarlo in battuta. NOTA. Controllare il senso di orientamento delle molle
a tazza (11) e la loro centratura.

Den Zustand und die Position des O-Ringes (22) Tellerfedern (11) positionieren und den Zylinder (10)
D kontrollieren; den O-Ring schmieren und den Zylinder D bis zum Anschlag einsetzen.
auf die Stiftschrauben positionieren, ohne ihn bis zum BEMERKUNG. Orientierung der Tellerfedern (11) und
Anschlag ganz einzusetzen. ihre Zentrierung kontrollieren.
c d
Controlar el estado y la colocacioÁn del anillo OR (22); Colocar los muelles a taza (11) y mandar a tope el
ESP lubrificar el anillo OR y colocar el cilindro sobre los ESP cilindro (10).
prigioneros sin llevarlo a tope. NOTA. Controlar el sentido de orientamiento de los
muelles a taza (11) y su centraje.

ControÃler l'eÂtat et la position de l'anneau O'RING (22); Positionner les ressorts belleville (11) et inseÂrer aÁ fond
F lubrifier l'anneau O'RING et positionner le cylindre sur F le cylindre (10).
les prisonniers sans l'envoyer en buteÂe. REMARQUE. ControÃler l'orientation des ressorts
belleville (11) et leur centrage.

Bloccare il cilindro (10) con le viti (9) serrate con chiave Verificare l'integritaÁ ed il posizionamento dell'anello
ITA dinamometrica ad un coppia di 86v89 Nm. ITA OR (23) del braccio; installare il braccio completo (6).
NOTA. Per agevolare la centratura del semiasse,
muovere lentamente il mozzo portaruota.

Den Zylinder (10) mit den Schrauben (9) mit einem Am Arm den Zustand und die Position des O-Ringes
D Dynamometer und einem Anzugsmoment von 86v89 Nm D (23) kontrollieren; den gesamten Arm (6) installieren.
blockieren. BEMERKUNG. Um die Halbachse leichter zentrieren
zu koÈnnen, die Radhalternabe etwas bewegen.
e f
Bloquear el cilindro (10) con los tornillos (9) apretados Averiguar la integridad y la colocacioÁn del anillo OR
ESP con llave dinamometrica a un par de 86v89 Nm. ESP (23) del eje; colocar el eje completo (6).
NOTA. Para facilitar el centraje del semi-eje, mover
lentamente el cubo porta-rueda.

Bloquer le cylindre (10) avec les vis (9), serrer aÁ l'aide VeÂrifier le bon eÂtat et le positionnement de l'anneau
F de la cleÂ dynamomeÂtrique aÁ un couple de 86v89 Nm. F O'RING (23) du bras; installer le bras complet (6).
REMARQUE. Afin de rendre plus aiseÂ le centrage du
demi-essieu, bouger lentement le moyeu porte-roue.

008 924 17 BOMAG

25 871
16.7 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS - MONTAJE DE LOSAxle
GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS

T2
6

8
F1241095 F1241096

GB a GB b
Temporarily lock the arm (6) with nuts (8) previously coated with Check the flatness of the arms, using tool T2; then lock the arms
Loctite 242; tighten lightly to make the unit touch the main body. 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.

F1241097 F1241074

bar GB c GB d
Connect an external pump to the union piece "A" of the negative Rotate the adjustment pinion (4) anticlockwise (±) to eliminate all
brake and introduce pressure to 15 ± 30 bar. existing clearance between the braking disks.
Rotate up to a torque of 8 ± 10 Nm.

+ 3

4
-- 2

D1240132
F1241073

GB e GB f
Rotate pinion (4) clockwise (+) to determine the required clearance Install safety plate (3) and lock with screw (2).
of 1 mm. Torque wrench setting: 10 ± 11 Nm.
NOTE. A turn of the adjuster produces a clearance of 0.25 mm
(1mm = 4 turns).

872 BOMAG
26 008 924 17
Axle 16.7

Fissare provvisoriamente il braccio (6) con i dadi (8) Controllare la planaritaÁ dei bracci con l'attrezzo T2 e
ITA spalmati con Loctite 242 e serrati leggermente per ITA fissarli definitivamente con le viti (7) spalmate con
frizionare il gruppo sul corpo centrale. Loctite 242.
Coppia di serraggio: 182v202 Nm
NOTA. Serrare con il metodo incrociato.

VoruÈbergehend den Arm (6) mit den mit Loctite 242 Die Ebenheit der Arme mit dem Werkzeug T2 kontroll-
D geschmierten Muttern (8) befestigen und Muttern D ieren und endguÈltig mit den mit Loctite 242 ge-
zuschrauben bis das Aggregat an dem ZentralkoÈrper schmierten Schrauben (7) befestigen.
anliegt. Anzugsmoment: 182v202 Nm
a b BEMERKUNG. Im Kreuz fest drehen.

Fijar provisoriamente el eje (6) con las tuercas (8) Controlar la planaridad de los ejes con la herramienta
ESP pasados con Loctite 242 y apretados ligermente para ESP T2 y fijarlos definitivamente con los tornillos (7) pasar
fricionar el grupo sobre el cuerpo central. con Loctite 242.
Par de serraje: 182v202 Nm
NOTA. Apretar de manera cruzada.

Fixer provisoirement le bras (6) avec les eÂcrous (8) ControÃler la planeÂiteÂ des bras aÁ l'aide de l'outil T2,
F enduits avec du Loctite 242, et serrer ceux-ci pour F puis fixer ceux-ci deÂfinitivement avec les vis (7)
frotter le groupe du corps central. enduites de Loctite 242.
Couple de serrage: 182v202 Nm.
REMARQUE. Serrer avec la meÂthode croiseÂe.

Collegare al raccordo "P" del freno negativo una pompa Ruotare in senso antiorario (±) il pignone di registro (4)
ITA esterna ed immettere una pressione di 15v30 bar. ITA per eliminare totalmente il gioco tra i dischi di frenatura.
Ruotare fino ad ottenere una coppia di 8v10 Nm.

An das AnschluûstuÈck "P" der Federspeicherbremse Gegen den Uhrzeigersinn (±) das Kegelrad (4),
D eine aÈuûere Pumpe schlieûen und Druck bei 15v30 bar D drehen, bis kein Spiel zwischen den Bremsscheiben
einlassen. mehr uÈbrig bleibt. Anzugsmoment: 8v10 Nm.

c d
Conectar al empalme "P" del freno negativo una Girar en sentido anti-horario (±) el pinon de registro (4)
ESP pompa externa y introducir presion de 15v30 bar. ESP para eliminar totalmente el juego entre discos de
frenadura.
Girar hasta obtener un par de 8v10 Nm.

Brancher au raccord "P" du frein neÂgatif une pompe Tourner le pignon de reÂglage (4) dans le sens contraire
F externe et envoyer une pression de 15v30 bar. F 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.

Ruotare il pignone (4) in senso orario (+) per Montare la piastrina di sicurezza (3) e bloccarla con la
ITA determinare il gioco prescritto di 1 mm. ITA vite (2).
NOTA. Un giro del registro crea un gioco di 0,25 mm Coppia di serraggio: 10v11 Nm
(1 mm=4 giri).

Das Kegelrad (4) in den Uhrzeigersinn (+) drehen, bis Die Sicherheitsplatte (3) montieren und mit der
D das vorgeschriebene Spiel von 1 mm erreicht ist. D Schraube (2) blockieren.
BEMERKUNG. Eine Umdrehung gleicht einem Spiel Anzugsmoment: 10v11 Nm
von 0,25 mm (1 mm=4 Umdrehungen).
e f
Girar el pinon (4) en sentido horario (+) para Montar la plaqua de seguridad (3) y bloquearla con los
ESP determinar el juego prescrito de 1 mm. ESP tornillos 829.
NOTA. Un giro del registro crea un juego de 0,25 mm Par de serraje: 10v11 Nm
(1mm=4 giros).

Tourner le pignon (4) dans le sens des aiguilles d'une Monter la plaquette de seÂcuriteÂ (3), bloquer celle-ci aÁ
F montre (+) pour deÂfinir le jeu prescrit de 1 mm. F l'aide de la vis (2).
REMARQUE. Un tour de reÂgleur donne un jeu de 0,25 Couple de serrage: 10v11 Nm
mm (1mm=4 tours).

008 924 17 BOMAG

27 873
16.7 MECHANICAL AND MANUAL RELEASE OF THE AXLE - SBLOCCAGGIO MECCANICO MANUALE DELL'ASSALE - Axle
ACHSE MECHANISCH MANUELL ENTSICHERN - DESBLOQUEO MANUAL DE LOS AXAL -
DEBLOCAGE MECANIQUE MANUEL DE L'ESSIEU

11 16

24
25
25

26 24
D1240133
F1241098

GB a GB b
MANUAL EMERGENCY RELEASE Tighten screws (25) so as to fasten them onto the pressure plate
Loosen nuts (24) of screws (25) provided for the mechanical and (16).
manual release of the braking units, then move the nuts backwards
by approx. 8 mm.

25 26
24
25

F1241099 F1241100

GB c GB d
Using a wrench, tighten the screws (25) in an alternate sequence ADJUSTMENT AFTER MANUAL RELEASE
by 1/4 turn at a time so as to compress the Belleville washers (11) Remove screws (25) complete with nuts (24) and seals (26).
and disengage the braking disks. Replace seals (26), apply silicone-based Tecno Lupe /101 grease
IMPORTANT. Tighten max. by one turn. to the screws (25) and install all parts into the arm.

34 + 0,5
0

F1241101 F1241102

GB e GB f
+0.5
Adjust screws (25) to obtain a jut of 34 0 mm in relation to the arm. 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.

874 BOMAG
28 008 924 17
Axle 16.7

SBLOCCAGGIO MANUALE D'EMERGENZA Avvitare le viti (25) fino a mandarle in battuta sullo
ITA Allentare i dadi (24) delle viti (25) per lo sblocco ITA spingidisco (16).
meccanico manuale dei gruppi di frenatura e far
arretrare i dadi di circa 8 mm.

MANUELLE NOT-ENTSICHERUNG Schrauben (25) bis zum Anschlag an die Druckplatte

D Die Muttern (24) der Schrauben (25) zur mechani- D (16) zudrehen.
schen manuellen Entsicherung der Bremsaggregate
lockern und die Muttern um 8 mm zuruÈck drehen.
a b
DESBLOQUEO MANUAL DE EMERGENCIA Atornillar los tornillos (25) hasta llegar al tope sobre el
ESP Aflojar las tuercas (24) de los tornillos (25) para el ESP empuja-disco (16).
desbloqueo mecanico manual de los grupos de
frenadura y hacer pasar las tuercas de 8 mm approx.

DEBLOCAGE MANUEL D'EMERGENCE Visser les vis (25) puis les envoyer en buteÂe sur le
F Desserrer les eÂcrous (24) des vis (25) pour le F plateau de pression (16).
deÂblocage meÂcanique manuel des groupes de frei-
nage en faisant reculer les eÂcrous d'environ 8 mm.

Utilizzando una chiave, avvitare le viti (25) in modo REGOLAZIONE DOPO LO SBLOCCAGGIO MANUALE
ITA alternato di 1/4 di giro alla volta, per comprimere le ITA Rimuovere le viti (25) complete dei dadi (24) e delle
molle a tazza (11) e liberare i dischi di frenatura. guarnizioni (26).
IMPORTANTE. Avvitare per max. un giro. 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 EINSTELLUNG NACH DER MANUELLEN ENTSICHERUNG
D jeweils um 1/4 Umdrehung zudrehen, um die Tellerfe- D Die Schrauben (25) mit den Muttern (24) und den
dern (11) einzudruÈcken und die Bremsscheiben frei- Dichtungen (26) abnehmen.
zusetzen. Die Dichtungen (26) auswechseln, die Schrauben (25) mit Silikon-
c WICHTIG. Maximal um eine Umdrehung zuschrauben. d fett Tecno Lupe/101 schmieren und das ganze Teil in den Arm
montieren.

Utilizando una llave, atornillar los tornillos (25) de REGULACION DESPUES DEL DESBLOQUEO MANUAL
ESP manera alternada de 1/4 de giro a la vez, para ESP Remover los tornillos (25) completas de guarniciones
comprimir los muelles a taza (11) y librar los discos (26).
de frenadura. Sobstituir las guarniciones (26), lubrificar los tornillos (25) con
IMPORTANTE. Atornillar por max. un giro. grasa al silicone Tecno Lupe/101 y montar todo en el eje.

A l'aide d'une cleÂ, visser les vis (25) alternativement 1/ REGLAGE FAISANT SUITE AU DEBLOCAGE MANUEL
F 4 de tour aÁ la fois, pour contraindre le ressort belleville F Enlever les vis (25) compleÁtes d'eÂcrous (24) et de
(11) et deÂgager les disques de freinage. garnitures (26).
IMPORTANT. Visser pour max. un tour. Substituer les garnitures (26), lubrifier les vis (25) avec de la graisse
au silicone Tecno Lupe/101, monter le tout dans le bras.

Regolare le viti (25) fino ad avere una sporgenza Bloccare la posizione con i dadi (24).
ITA rispetto al braccio di 34+0,5
0 mm
ITA
ATTENZIONE! Mantenere la posizione delle viti (25)
quando si bloccano i dadi (24); dopo il bloccaggio,
ricontrollare la sporgenza delle viti (25).

È berstand zum Arm

Schrauben (25) einstellen, bis der U Die Position mit den Muttern (24) blockieren.
D 34+0.5
0 mm betraÈgt. D
ACHTUNG! Die Position der Schrauben (25) darf sich
beim Festziehen der Muttern (24) nicht aÈndern; nach
der Blockierung den U È berstand der Schrauben (25) nochmals
e f kontrollieren.

Regular los tornillos (25) hasta obtener una parte Bloquear la colocacioÁn con las tuercas (24).
ESP saliente respecto al eje de 34+0,5
0 mm
ESP
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).

ReÂgler les vis (25) jusqu'aÁ avoir une saillie de 34+0.5

0 mm Bloquer dans la position aÁ l'aide des eÂcrous (24).
F par rapport au bras. F
ATTENTION! Tenir les vis (25) en place quand on
bloque les eÂcrous (24); apreÁs avoir fixeÂ, controÃler la
saillie des vis (25).

008 924 17 BOMAG

29 875
16.7DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-Axle
TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

4
12
9 11
10
3

8 13

14
7
16
15

2
1 D1240131

1
3

2
F1241103 F1241104

GB a GB b
Remove the locking screws (1) of planetary cover (2). Using two screwdrivers or two levers inserted in the slots provided,
pry the planetary cover (2) away from the wheel hub (3).

876 BOMAG
30 008 924 17
Axle 16.7

SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE

NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR

GB The axle shafts can only be removed once the 2 - Achse zuerst von der Maschine abmontieren und auf eine
extraction of the planetary cover has been performed. Werkbank legen.
Different procedures need to be followed depending on
the kind of repair work required: 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 La remocioÁn de los semi-ejes puede ser efectuada solo
carried out on the bench, but the stages apply to all versions. ESP despues de la remocioÁn de las tapas lleva-satelites y de
manera deversificada, en funcion del tipo de repara-
cion de efectuar:
1 - Desmontaje con axal montado sobre la maquina colocada sobre
caballetes de seguridad;
2 - Desmontaje con axial desmontado desde la maquina y susten-
tado de apositas herramientas (al banco).
Las explicaciones reportadas se refieren a la remocioÁn efectuada al
La rimozione dei semiassi puoÁ essere eseguita solo banco, ma las fases son comunes.
ITA dopo la rimozione del coperchio portasatelliti ed in
modo diversificato, in funzione del tipo di riparazione
da eseguire:
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 Le deÂgagement des demi-essieux ne peut se faire
banco, ma le fasi sono comuni. F qu'apreÁs avoir enleveÂ le couvercle porte-satellites
d'une facËon diversifieÂe, en fonction du type de
reÂparations aÁ effectuer:
1 - DeÂmontage essieu monteÂ sur machine deÂposeÂe sur des baÃtis de
seÂcuriteÂ.
1 - DeÂmontage essieu deÂmonteÂ de la machine et soutenu par un
outil speÂcial (sur banc).
Les explications reporteÂes se reÂfeÁrent au deÂgagement effectueÂ au
Die Halbachse kann erst abmontiert werden, wenn der banc, mais les phases sont communes.
D Deckel des Planetenradhalters abgenommen worden
ist; auûerdem wird sie je nach Reparatur unterschied-
lich abmontiert:
1 - Mit Achse abmontieren, die an der Maschine montiert und durch
SicherheitsbloÈcke gestuÈtzt ist.

Rimuovere le viti (1) di fissaggio del coperchio Utilizzando due cacciaviti o due leve inserite nelle
ITA portasatelliti (2). ITA cave predisposte, staccare il coperchio portasatelliti
(2) dal mozzo portaruota (3).

Schrauben (1) abschrauben, die den Deckel des Zwei Schraubenzieher oder zwei Hebel in die vorge-
D Planetenradhalters (2) befestigen. D sehenen Nuten stecken und den Deckel (2) des
Planetenradhalters von den Radhalternaben (3) ab-
heben.
a b
Remover los tornillos (1) de fisaje de la tapa porta- Utilizando dos destornilladores o dos palancas inser-
ESP satelites (2). ESP tadas en las ranuras predispuestas, destacar la tapa
lleva-satelites (2) del cubo lleva-rueda (3).

Enlever les vis (1) de fixation du couvercle porte- A l'aide de deux tournevis ou de deux leviers dans les
F satellites (2). F creux preÂdisposeÂs, deÂgager le couvercle porte-satel-
lites (2) du moyeu porte-roue (3).

008 924 17 BOMAG

31 877
16.7DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-Axle
TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

2 3
5

F1241105 F1241106

GB a GB b
Rotate the wheel hub (3) until one of the screw holes (1) appears at Only in case of replacement of component parts not requiring
the top. the disassembly of the crown wheel (5).
Apply a "U" piece to the screw hole; connect to a hoist and remove Countermark the position between one of the teeth of the axle shaft
the cover (2). (4) and the crown wheel (5).

F1241107 F1241108

GB c GB d
Remove the axle shaft (4). Loosen the screws (6) and remove them.
NOTE. The removal of the axle shaft allows for the substitution of
the snap ring as described in the following paragraphs.

3 5

7
F1241109 F1241110

GB e GB f
Remove the safety flange (7). 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).

878 BOMAG
32 008 924 17
Axle 16.7

Ruotare il mozzo portaruota (3) fino a portare un foro Solo se si devono sostituire dei componenti che
ITA per le viti (1) in posizione alta. ITA non richiedono lo smontaggio della corona (5).
Applicare un grillo ad "U" nel foro vite; collegare un Contrassegnare la posizione tra un dente del semias-
mezzo di sollevamento e rimuovere il coperchio (2). se (4) e la corona (5).

Nur wenn Bestandteile ausgewechselt werden

D Die Radhalternabe (3) drehen bis ein Loch fuÈr die D muÈssen, fuÈr die der Kranz (5) nicht abmontiert
Schrauben (1) in der oberen Position liegt. werden muû.
Einen U-foÈrmigen BuÈgel in das Schraubenloch stecken; ein Die Position zwischen einem Zahn der Halbachse (4) und dem
a Hebezeug anschlieûen und den Deckel (2) abnehmen. b Kranz (5) markieren.

Girar el cubo lleva-rueda (3) hasta hacer un agujero Solo si se deben de sobstituir algunos componentes
ESP para los tornillos (1) en posicioÁn alta. ESP que no comportan el desmontaje de la corona (5).
Aplicar un grillo a "U" en el agujero tornillos; conectar Senalar la colocacioÁn entre un diente del semi-eje (4) y
un medio de levantamiento y remover la tapa (2). la corona (5).

Tourner le moyeu porte-roue (3) jusqu'aÁ aÁ amener un Uniquement si on doit substituer des composants qui
F des trous pour les vis (1) en haut. F ne veulent pas le deÂmontage de la couronne (5).
Appliquer une manille en "U" dans le trou de vis; Marquer la position entre une dent du demi-essieu (4)
appliquer un moyen de relevage et enlever le couvercle (2). et la couronne (5).

Asportare il semiasse (4). Allentare le viti (6) ed asportarle.

ITA ITA
NOTA. L'asportazione del semiasse permette la
sostituzione dell'anello di tenuta come descritto di
seguito.

Die Halbachse (4) abnehmen. Schrauben (6) abschrauben.

D D
BEMERKUNG. Bei abgenommener Halbachse kann
der Dichtring, wie nachstehend beschrieben, ausge-
wechselt werden.
c d
Sacar el semi-eje (4). Aflojar los tornillos (6) y sacarlos.
ESP ESP
NOTA. Sacar el semi-eje permite la sobstitucioÁn del
anillo de tenida como descrito a seguir.

Enlever le demi-essieu (4). Desserrer les vis (6) puis les enlever.
F F
REMARQUE. Le deÂgagement du demi-essieu consent
la substitution de l'anneau d'eÂtancheÂiteÂ comme deÂcrit
par la suite.

Asportare la flangia di sicurezza (7). Avvitare parzialmente, in modo alternato ed in uguale

ITA ITA 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
D D Schrauben (6) zuschrauben.
Mit einem Abzieher den Kranz (5) aus der Nabe (3)
ziehen und dabei auf die Schrauben (6) wirken.
e f
Sacar la arandela de seguridad (7). Atornillar parcialmente, de manera alternada y en
ESP ESP 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 seÂcuriteÂ (7). Visser partiellement, en alternance et de la meÃme

F F 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).

008 924 17 BOMAG

33 879
16.7DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-Axle
TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

3
F1241111 F1241112

GB a GB b
Remove screws (6) and crown wheel (5). 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).

3
9

8
10
3
F1241113 F1241114

GB c GB d
Remove the bearing (8) and the hub (3). Extract the hub (3) complete with snap ring (9) and internal bearing
(10).

14
13

11 12
F1241115 F1241116

GB e GB f
Using an extractor, remove at the same time the snap ring (11) and Remove the safety spring rings (13) of the planetary gears (14).
the centring ring (12).
NOTE. Note down the direction of assembly of snap and centring
rings.

880 BOMAG
34 008 924 17
Axle 16.7

Rimuovere le viti (6) e la corona (5). Imbragare il mozzo (3) e collegarlo ad un mezzo di
ITA ITA sollevamento; avvitare parzialmente una vite (6) e, con
un mazzuolo, smuovere il mozzo (3) ed il cuscinetto
esterno (8).

Schrauben (6) und Kranz (5) abnehmen. Nabe (3) anschlagen und an ein Hebezeug befestigen;
D D Schrauben (6) etwas zudrehen und mit einem Ham-
mer die Naben (3) und das aÈuûere Lager (8) bewegen.

a b
Remover los tornillos (6) y la corona (5). Atar el cubo (3) y conectarlo a un medio de
ESP ESP levantamiento; atornillar parcialmente un tornillo (6)
y, con un martillo, mover el cubo (3) y el cojinete
externo (8).

Enlever les vis (6) et la couronne (5). Elinguer le moyeu (3) puis relier celui-ci aÁ un moyen de
F F relevage; visser partiellement une vis (6), puis aÁ l'aide
d'un maillet, bouger le moyeu (3) et le palier externe
(8).

Rimuovere il cuscinetto (8) ed il mozzo (3). Asportare il mozzo (3) completo di anello di tenuta (9) e
ITA ITA cuscinetto interno (10).

Lager (8) und Nabe (3) abnehmen. Nabe (3) samt Dichtring (9) und inneres Lager (10)
D D abnehmen.

c d
Remover el cojinete (8) y el cubo (3). Sacar el cubo (3) completo de anillo de retencioÁn (9) y
ESP ESP cojinete interno (10).

Enlever le palier (8) et le moyeu (3). Enlever le moyeu (3) complet de bague d'eÂtancheÂiteÂ
F F (9) et de palier interne (10).

Utilizzando un estrattore, rimuovere contemporanea- Rimuovere gli anelli elastici (13) di ritegno satelliti (14).
ITA mente l'anello di tenuta (11) e l'anello centratore (12). ITA
NOTA. Annotare il senso di montaggio degli anelli di
tenuta e di centratura.

Mit einem Abzieher gleichzeitig den Dichtring (11) und Kolbenringe (13) und Planetenhalter (14) abnehmen.
D den Zentrierring (12) abnehmen. D
BEMERKUNG. Montagerichtung der Dicht- und Zen-
trierringe notieren.
e f
Utilizando un extractor, remover contemporaneamen- Remover los anillos elasticos (13) de retencioÁn
ESP te el anillo de retencioÁn (11) y el anillo centrador (12). ESP satelites (14).
NOTA. Anotar el sentido de montaje de los anillos de
retencioÁn y de centraje.

A l'aide d'un extracteur enlever en meÃme temps Enlever les anneaux ressorts (13) de fixation des
F l'anneau d'eÂtancheÂiteÂ (11) et l'anneau centreur (12). F satellites (14).
REMARQUE. Prendre note du sens de montage des
anneaux d'eÂtancheÂiteÂ et de centrage.

008 924 17 BOMAG

35 881
16.7DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-Axle
TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

F1241117 F1241118

GB a GB b
Remove the planetary gears (14). Only if necessary.
NOTE. Note down direction of assembly of planetary gears. Using an extractor, remove the shim washer (15) from the planet
carrier.

9 9

3 10

F1241119 F1241120

GB c GB d
Remove the snap ring (9) from the hub (3). Remove the internal bearing (10).
NOTE. Note down direction of assembly.
CAUTION! The snap ring may not be reused.

10
8

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.

882 BOMAG
36 008 924 17
Axle 16.7

Asportare gli ingranaggi satelliti (14). Solo se necessario.

ITA ITA Utilizzando un estrattore, rimuovere dal portasatelliti la
NOTA. Annotare il senso di montaggio dei satelliti.
rondella di rasamento (15).

Planetengetriebe (14) abnehmen. Nur wenn notwendig.

D D Mit einem Abzieher vom Planetenradhalter die Zwi-
BEMERKUNG. Montagerichtung notieren.
schenlegscheibe (15) abnehmen.

a b
Sacar los engranajes satelites (14). Solo si necesario.
ESP ESP Utilizando un extractor, remover del lleva-satelites la
NOTA. Anotar el sentido de desmontaje de los
satelites. arandela de rasamiento (15).

Enlever les engrenages satellites (14). Uniquement si besoin.

F F A l'aide d'un extracteur, enlever du porte-satellite la
REMARQUE. Prendre note du sens de montage.
rondelle de rasage (15).

Rimuovere dal mozzo (3) l'anello di tenuta (9). Rimuovere il cuscinetto interno (10).
ITA ITA
NOTA. Annotare il senso di montaggio.
ATTENZIONE! L'anello di tenuta non puoÁ essere
riutilizzato.

Von der Nabe (3) den Dichtring (9) abnehmen. Das innere Lager (10) abnehmen.
D D
BEMERKUNG. Montagerichtung notieren.
ACHTUNG! Der Dichtring darf nicht wieder verwendet
werden.
c d
Remover del cubo (3) los anillos de retencioÁn (9). Remover el cojinete interior (10).
ESP ESP
NOTA. Anotar el sentido de montaje.
ATENCION! El anillo de retencioÁn no puede ser
reutilizado.

Oter du moyeu (3) l'anneau d'eÂtancheÂiteÂ (9). Enlever le palier interne (10).
F F
REMARQUE. Prendre note du sens de montage.
ATTENTION! L'anneau d'eÂtancheÂiteÂ ne peut pas eÃtre
reÂutiliseÂ.

Rimuovere le ralle esterne dei cuscinetti (8) e (10)

ITA utilizzando un cacciaspine. ITA
NOTA. Battere in modo alternato per evitare impunta-
menti e deformazioni delle ralle.

Die aÈuûeren Scheiben (8) und (10) mit einem DuÈbel

D abnehmen. D
BEMERKUNG. Abwechselnd schlagen, um ein Durch-
schlagen und Verformungen der Scheiben zu vermeiden.
e f
Remover las ranguas externas de los cojinetes (8) y
ESP (10) utilizando un extractor de clavijas. ESP
NOTA. Pegar de manera alternada para evitar
empuntamientos y deformacioÁnes de las ranguas.

Enlever les crapaudines externes des paliers (8) et

F (10) aÁ l'aide d'un chasse-clou. F
REMARQUE. Donner des coups alterneÂs pour eÂviter
talonnages et deÂformations des crapaudines.

008 924 17 BOMAG

37 883
16.7ASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-Axle
TRIEBE UND HALBACHSE ZUSAMMENBAUEN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

T3 10 9

3
10

F1241122 F1241123

GB a GB b
Position the wheel hub (3) under a press; lubricate the seat of the Install the bearing (10).
external bearing and, using tool T3, install the thrust block of the Apply an appropriate sealant to the outer surface of the snap ring
bearing (10). (9).
Position the snap ring (9) into the hub (3).
NOTE. Check orientation of the ring.

T4 T3
9 3

8
F1241124 F1241125

GB c GB d
Position tool T4 and press the snap ring (9) down into its seat. Turn the hub (3) upside down, lubricate the seat of the bearing and,
using tool T3, install the thrust block of the bearing (8).

15
2 14

F1241126 F1241117

GB e GB f
Only if shim washer has previously been removed. Fit the planetary gear (14) onto the planetary gear cover (2).
Apply a sealant for removable seals to the outer surface of the shim CAUTION! The jointed portion of the internal ring of the bearings
washer (15) and, using a driver, fit it into the planetary gear cover must face the bottom of the pin.
(2).

884 BOMAG
38 008 924 17
Axle 16.7

Posizionare il mozzo ruota (3) sotto una pressa; Installare il cuscinetto (10).
ITA lubrificare la sede del cuscinetto esterno e, utilizzando ITA Spalmare la superficie esterna dell'anello di tenuta (9)
l'attrezzo T3, montare la ralla del cuscinetto (10). con sigillante per guarnizioni.
Posizionare l'anello di tenuta (9) nel mozzo (3).
NOTA. Controllare l'orientamento dell'anello.

Die Radnabe (3) unter eine Presse positionieren; den Lager (10) installieren.
D Sitz des aÈuûeren Lagers schmieren und mit dem D AÈuûere FlaÈche des Dichtringes (9) mit etwas Dicht-
Werkzeug T3 die Scheibe des Lagers (10) montieren. masse schmieren.
Dichtring (9) in die Nabe (3) positionieren.
a b BEMERKUNG. Richtung des Ringes kontrollieren.

Colocar el cubo rueda (3) bajo una prensa; lubrificar la Colocar el cojinete (10).
ESP sed del cojinete externo y, utilizando la herramienta ESP Pasar la superficie externa del anillo de retencioÁn (9)
T3, montar la rangua del cojinete (10). con sigilante para guarniciones.
Colocar el anillo de retencioÁn (9) en el cubo (3).
NOTA. Controlar el orientamiento del anillo.

Positionner le moyeu roue (3) sous la presse; lubrifier Installer le palier (10).
F le logement du palier externe, puis aÁ l'aide de l'outil F Enduire la superficie externe de l'anneau d'eÂtancheÂiteÂ
T3, monter la crapaudine du palier (10). (9) avec de la colle aÁ garnitures.
Positionner l'anneau d'eÂtancheÂiteÂ (9) dans le moyeu (3).
REMARQUE. ControÃler la bonne direction de l'anneau.

Posizionare l'attrezzo T4 e pressare in sede l'anello di Capovolgere il mozzo (3), lubrificare la sede cuscinetto
ITA tenuta (9). ITA e, utilizzando l'attrezzo T3, montare la ralla del
cuscinetto (8).

Das Werkzeug T4 positionieren und den Dichtring (9) Die Nabe (3) wenden, den Lagersitz schmieren und
D in seinen Sitz druÈcken. D mit dem Werkzeug T3 die Nabe des Lagers (8)
montieren.

c d
Colocar la herramienta y apretar en sed el anillo de Volcar el cubo (3), lubrificar la sed cojinete y,
ESP retencioÁn (9). ESP utilizando la herramienta T3, montar la rangua del
cojinete (8).

Placer l'outil T4 et presser dans son logement Faire basculer le moyeu (3), lubrifier le logement du
F l'anneau d'eÂtancheÂiteÂ (9). F palier, puis aÁ l'aide de l'outil T3, monter la crapaudine
dans le palier (8).

Solo se eÁ stata rimossa. Montare sui perni del coperchio portasatelliti (2) gli
ITA Spalmare la superficie esterna della rondella di ITA ingranaggi planetari (14).
rasamento (15) con sigillante per guarnizioni removibili ATTENZIONE! La parte raccordata dell'anello interno
e, utilizzando uno spintore, montarla nel coperchio portasatelliti (2). dei cuscinetti deve essere rivolta verso il fondo del perno.

Nur wenn zuvor abgenommen. Auf die Stifte des Deckels des Planetenradhalters (2)
D AÈuûere FlaÈche der Zwischenlegscheibe (15) mit D die Planetengetriebe (14) montieren.
Dichtmasse fuÈr abnehmbare Dichtungen schmieren ACHTUNG! Das AnschluûstuÈck des inneren Lagerrin-
und mit einem StoÈûel diese Zwischenlegscheibe in den Deckel des ges muû zur unteren Seite des Stiftes gerichtet sein.
e Planetenradhalters (2) montieren. f
Solo si ha sido desplazada. Montar sobre los pernos de la tapa lleva-satelites (2)
ESP Pasar la superficie externa de la arandela de ESP los engranajes planetares (14).
rasamiento (15) con sigilante para guarnicioÁnes ATENCION! La parte empalmada del anillo interno de
removibles y, utilizando un empuje, montarla en la tapa lleva- los cojinetes debe de ser dirijida hacia el fondo de la rotula.
satelites (2).

Uniquement si elle a eÂteÂ enleveÂe. Monter sur les pivots du couvercle porte-satellites (2)
F Enduire la superficie externe de la rondelle de rasage F les engrenages planeÂtaires (14).
(15) avec de la colle pour garnitures amovibles, aÁ ATTENTION! La partie raccordeÂe de l'anneau aÁ
l'aide d'un poussoir monter celle-ci dans le couvercle porte- l'inteÂrieur du palier doit eÃtre tourneÂe vers la partie basse du pivot.
satellites (2).

008 924 17 BOMAG

39 885
16.7ASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-Axle
TRIEBE UND HALBACHSE ZUSAMMENBAUEN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

T5
13

11 12
F1241127 F1241128

GB 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.

3
9

3
F1241114 F1241113

GB c GB d
Grease the snap ring (9) and the hub of the arm. Install the external bearing (8).
Install the wheel hub (3). NOTE. Move the bearing to the limit stop by hammering lightly all
around the edge.

7
F1241129 F1241109

GB e GB f
Install the crown wheel (5) and, using a driver with adequate Using Tecno Lupe /101, grease the surface of the safety flange (7)
diameter, fasten it onto the hub of the arm. that touches the crown wheel.

886 BOMAG
40 008 924 17
Axle 16.7

Fissare la posizione degli ingranaggi satelliti (14) con Lubrificare e montare sull'attrezzo T5 l'anello centra-
ITA gli anelli elastici (13). ITA tore (12) e l'anello di tenuta (11); montare gli anelli nel
braccio.
ATTENZIONE! Controllare attentamente il senso di montaggio
degli anelli.

Die Position der Planetengetriebe (14) mit den Das Werkzeug T5 schmieren und darauf den Zen-
D Kolbenringen (13) festigen. D trierring (12) und den Dichtring (11) montieren; die
Ringe in den Arm montieren.
ACHTUNG! Montagerichtung der Ringe sorgfaÈltig kontrollieren.
a b
Fijar la posicioÁn de los engranajes satelites (14) con Lubrificar y montar sobre la herramienta T5 el anillo
ESP los anillos elasticos (13). ESP central (12) y el anillo de retencioÁn (11); montar los
anillos en el eje.
ATENCION! Controlar atentamente el sentido de montaje de los
anillos.

Fixer les engrenages porte-satellites (14) aÁ leur place Lubrifier et monter sur l'outil T5 l'anneau centreur (12)
F avec les anneaux ressorts (13). F et l'anneau d'eÂtancheÂiteÂ (11); monter les anneaux
dans le bras.
ATTENTION! ControÃler attentivement le sens du montage des
anneaux.

Lubrificare con grasso l'anello di tenuta (9) ed il mozzo Montare il cuscinetto esterno (8).
ITA del braccio. ITA
NOTA. Mandare a fondo corsa il cuscinetto con
Montare il mozzo portaruota (3). leggeri colpi di mazzuolo distribuiti su tutta la
circonferenza.

Mit Fett den Dichtring (9) und die Armnabe schmieren. AÈuûeres Lager (8) montieren.
D Radhalternabe (3) montieren. D
BEMERKUNG. Das Lager bis zum Anschlag mit
leichten HammerschlaÈgen an der gesamten Kreislinie
einsetzen.
c d
Lubrificar con grasa el anillo de retencioÁn (9) y el cubo Montar el cojinete esterno (8).
ESP del eje. ESP
NOTA. Mandar a tope el cojinete con ligeros colpes de
Montar el cubo lleva-rueda (3). martillo repartidos sobre toda la circonferencia.

Lubrifier avec de la graisse l'anneau d'eÂtancheÂiteÂ (9), Monter le palier externe (8).
F le moyeu du bras. F
REMARQUE. Envoyer en buteÂe le palier avec de
Monter le moyeu porte-roue (3). leÂgers coups de maillet distribueÂs tout autour de la
circonfeÂrence.

Montare la corona (5) e, utilizzando uno spintore di Lubrificare con grasso Tecno Lupe /101 la superficie
ITA diametro adatto, mandarla in battuta sul mozzo del ITA della flangia di sicurezza (7) a contatto con la corona.
braccio.

Den Kranz (5) montieren und mit einem geeigneten Mit Fett Typ Tecno Lupe/ 101 die FlaÈche des Sicher-
D StoÈûel den Kranz bis zum Anschlag an der Armnabe D heitsflanschs (7), der am Kranz anliegt, schmieren.
einsetzen.

e f
Montar la corona (5) y, utilizando un empuje de Lubrificar con grasa Tecno Lupe/101 la superficie de
ESP diametro apto, mandarla a tope sobre el cubo del eje. ESP la brida de seguridad (7) a contacto con la corona.

Monter la couronne (5), puis aÁ l'aide d'un poussoir Lubrifier avec de la graisse Tecno Lupe/ 101 la
F d'un diameÁtre adapteÂ, envoyer celle-ci en buteÂe sur le F superficie de la flasque de seÂcuriteÂ (7) au contact de
moyeu du bras. la couronne.

008 924 17 BOMAG

41 887
16.7ASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-Axle
TRIEBE UND HALBACHSE ZUSAMMENBAUEN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU

4
F1241130 F1241107

GB a GB b
Coat the screws (6) with Loctite 270 and screw them. Lubricate the snap ring (11), the toothed portions and the sealing
Tighten screws (6) in two stages, using the criss-cross method. surface of the axle shaft.
Initial torque wrench setting: 120 Nm Install the axle shaft (4), making sure that it is properly inserted into
Final torque wrench setting: 219 ± 242 Nm braking disks and differential unit.

3 1
2
2

16
F1241131 F1241132

GB c GB d
Fit the planetary gear cover (2) onto the wheel hub (3). Lock the planetary gear cover (2) onto the wheel hub (3) with
CAUTION! 1 - Check the condition and position of the O-ring (16). screws (1).
2 - Line up the locating release points. Screws torque wrench setting: 40 ± 0 Nm.

GB e GB f

888 BOMAG
42 008 924 17
Axle 16.7

Spalmare le viti (6) con Loctite 270 ed avvitarle. Lubrificare l'anello di tenuta (11), le dentature e la
ITA Serrare le viti (6) in due tempi e con il metodo del ITA superficie di tenuta del semiasse.
serraggio incrociato. Montare il semiasse (4) assicurandosi che si innesti
Coppia di serraggio iniziale: 120 Nm nei dischi freni e nel differenziale.
Coppia di serraggio finale: 219v242 Nm

Die Schrauben (6) mit Loctite 270 schmieren und Dichtring (11), ZaÈhne und DichtflaÈche der Halbachse
D festschrauben. D schmieren.
Schrauben (6) im Kreuz schrittweise festziehen. Halbachse (4) montieren und darauf achten, daû sie in
Anzugsmoment zuerst: 120Nm die Bremsscheiben und in das Differential einrastet.
a Anzugsmoment am Ende: 219v242 Nm b
Pasar los tornillos (6) con Loctite 270 y atornillarlos. Lubrificar el anillo de retencioÁn (11), las dentaduras y
ESP Apretar los tornillos (6) en doss tiempos con el metodo ESP la superficie del semieje.
de torsion cruzada. Montar el semieje (4) asegurandose que se encaje en
Par de torsion inicial: 120 Nm. los discos y en el diferencial.
Par de torsion final: 219v242 Nm.

Enduire les vis (6) avec du Loctite 270 puis visser. Lubrifier l'anneau d'eÂtancheÂiteÂ (11), les dents, la
F Serrer les vis (6) en deux temps avec la meÂthode du F superficie eÂtanche des demi-essieux.
serrage croiseÂ. Monter le demi-essieu (4) en veillant aÁ ce qu'il
Couple de serrage initial: 120Nm s'enclenche bien dans les disques freins et dans le diffeÂrentiel.
Couple de serrage final: 219v242 Nm.

Montare il coperchio portasatelliti (2) sul mozzo Bloccare il coperchio portasatelliti (2) sul mozzo
ITA portaruota (3). ITA portaruota (3) con le viti (1).
ATTENZIONE! 1 - Controllare lo stato e la posizione Coppia di serraggio viti: 40v50 Nm
della guarnizione OR (16).
2 - Allineare gli scarichi di riferimento.

Den Deckel des Planetenradhalters (2) auf die Nabe Den Deckel des Planetenradhalters (2) an der Rad-
D des Radhalters (3) montieren. D halternabe (3) mit den Schrauben (1) blockieren.
ACHTUNG! 1 - Zustand und Position der O-Ringe (16) Anzugsmoment der Schrauben: 40v50 Nm
kontrollieren.
c 2 - Die Bezugsstellen bzw. AblaûoÈffnung fluchten. d
Montar la tapa lleva-satelites (2) sobre el cubo lleva- Bloquear la tapa lleva-satelietes (2) sobre el cubo
ESP rueda (3). ESP lleva-rueda (3) con los tornillos (1).
ATENCION! 1 - Controlar el estado y la posicioÁn de la Par de torsion tornillos: 40v50 Nm
guarnicioÁn OR (16).
2 - Alinear los descarges de referencia.

Monter le couvercle porte-satellite (2) sur le moyeu Bloquer le couvercle porte-satellite (2) sur le moyeu
F porte-roue (3). F porte-roue (3) aÁ l'aide des vis (1).
ATTENTION! 1 - ControÃler l'eÂtat et la position des Couple de serrage des vis: 40v50 Nm.
garnitures O'Ring (16).
2 - Aligner les points de deÂcharge de reÂfeÂrence.

ITA ITA

D D

e f

ESP ESP

F F

008 924 17 BOMAG

43 889
16.7 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

T7A

F1241141 F1241142

GB a GB b
REMOVAL OF THE DIFFERENTIAL UNIT Apply tool T6 - for crown wheel side centring - with relative distance
Remove the whole arms, the cylinders, and the whole reduction pieces and lock it with two nuts.
unit. Apply centring tool T7A as well.
For details, see «CHECKING WEAR AND REPLACING THE
BRAKING DISKS» and «REMOVAL OF REDUCTION GEAR».

1 T7B

F1241143 F1241144

GB c GB d
Remove the stud screws and remove the intermediate cover (1) on Install centring tool T7B on the opposite side of the crown wheel.
the crown wheel opposite side.

2 T7B
A

4
3
5 6

F1241145 F1241146

GB e GB f
Remove centring tools T6 and T7A from crown wheel side; remove Position a stop block «A» made from tender material (aluminium,
the studs and the intermediate cover (2) on the crown wheel side. 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).

890 BOMAG
44 008 924 17
Axle 16.7

RIMOZIONE DIFFERENZIALE Applicare l'attrezzo T6 di centraggio dal lato corona

ITA Rimuovere i bracci completi, i cilindri freni ed il ITA con i relativi distanziali e fissarlo con due dadi.
riduttore completo. Applicare anche l'attrezzo T7A di centratura.
Per i dettagli, vedere «CONTROLLO USURA E SOSTITUZIONE
DISCHI FRENO» e «RIMOZIONE RIDUTTORE».

DIFFERENTIAL ABNEHMEN Das Werkzeug T6 zur Zentrierung an der Kranzseite

D Die kompletten Arme, die Bremszylinder und den D mit den entsprechenden DistanzstuÈcken anbringen
kompletten Reduzierer abnehmen. und das Werkzeug mit zwei Muttern befestigen.
Siehe «VERSCHLEISS KONTROLLIEREN UND BREMSSCHEI- Das Werkzeug T7A zur Zentrierung anbringen.
a BEN AUSWECHSELN» und «REDUZIERER ABNEHMEN». b
REMOCION DIFERENCIAL Aplicar la herramienta T6 de centraje del lado corona
ESP Remover los ejes completos, los cilindros frenos y el ESP con los relativos distanciales y fijarla con dos tuercas.
reductor completo. Aplicar tambien la herramienta T7A de centradura.
Para los detalles, vease «CONTROL DESGASTE Y SOBSTITU-
CION DISCOS FRENOS» y «REMOCION REDUCTOR».

DEGAGEMENT DU DIFFERENTIEL Appliquer l'outil T6 de centrage du coÃteÂ couronne

F Enlever les bras entieÁrement, les cylindres freins et le F avec les entretoises correspondantes et fixer l'outil
reÂducteur tout entier. avec deux eÂcrous.
Pour de plus amples deÂtails, voir "CONTROLE DE L'USURE ET Appliquer eÂgalement l'outil de centrage T7A.
SUBSTITUTION DU DISQUE FREIN" et "DEGAGEMENT DU
REDUCTEUR".

Rimuovere le viti prigioniere e rimuovere il coperchio Montare l'attrezzo T7B di centraggio sul lato opposto
ITA intermedio (1) dal lato opposto corona. ITA corona.

Die Stiftschrauben und den Zwischendeckel (1) von Das Werkzeug T7B zur Zentrierung an der dem Kranz
D der dem Kranz entgegengesetzte Seite abnehmen. D entgegengesetzte Seite montieren.

c d
Remover los tornillos prigioneros y remover la tapa Montar la herramienta T7B de centraje sobre el lado
ESP intermedia (1) del lado opuesto corona. ESP opuesto corona.

Enlever les vis prisonnieÁres et enlever le couvercle Monter l'outil de centrage T7B du coÃteÂ opposeÂ aÁ la
F intermeÂdiaire (1) du coÃteÂ opposeÂ aÁ la couronne. F couronne.

Rimuovere gli attrezzi T6 e T7A di centraggio del lato Posizionare tra il corpo centrale (3) e la dentatura della
ITA corona; asportare i prigionieri e rimuovere il coperchio ITA corona (4) un blocchetto "A" di contrasto in materiale
intermedio (2) lato corona. tenero (alluminio ecc.).
Mantenendo in appoggio la corona (4) sul blocchetto "A",
rimuovere ed asportare le viti (5) e le rondelle elastiche (6).

Die Werkzeuge T6 und T7A zur Zentrierung an der Zwischen dem ZentralkoÈrper (3) und den ZaÈhnen des
D Kranzseite entfernen; die Stiftschrauben und den D Kranzes (4) den Block "A" aus weichem Material
Zwischendeckel (2) an der Kranzseite abnehmen. (Aluminium usw.) legen.
Den Kranz (4) am Block "A" anliegen lassen und die Schrauben (5)
e f und die Federscheiben (6) abnehmen.

Remover las herramientas T6 y T7A de centraje del Colocar entre el cuerpo central 83) y la dentadura de
ESP lado corona; sacar los prigioneros y remover la tapa ESP la corona (4) un bloque "A" de contraste de material
intermedia (2) lado corona. tierno (aluminio ect.).
Manteniendo en apoyo la corona (4) sobre el bloque "A", remover y
sacar los tornillos (5) y las arandelas elasticas (6).

Enlever les outils T6 et T7A de centrage du coÃteÂ Placer entre le corps central (3) et la denture de la
F couronne; enlever les prisonniers et deÂplacer le F couronne (4) un petit bloc "A" en mateÂriel leÂger
couvercle intermeÂdiaire (2) du coÃteÂ couronne. (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).

008 924 17 BOMAG

45 891
16.7 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

7
7

F1241147 F1241148

GB a GB b
Using a driver, push the differential unit (7) or (8) towards the Extract the whole differential unit (7) or (8).
opposite side of the crown so as to disengage it from the crown (4).

T7B 3 3

4
4

F1241223 F1241174

GB c GB d
Remove tool T7B from the crown opposite side. Extract the crown (4).

B
9
9

F1241149 F1241150

GB e GB f
DISASSEMBLY OF THE DIFFERENTIAL UNIT DISASSEMBLY OF THE NO-SPIN DIFFERENTIAL UNIT
Using an extractor, remove bearings (9) from the differential unit. Insert stay "B" provided for holding into position the no-spin unit
(14) and screw tight the wing nut.

892 BOMAG
46 008 924 17
Axle 16.7

Utilizzando uno spintore, spingere il differenziale (7) o Estrarre il gruppo differenziale (7) o (8) completo.
ITA (8) verso il lato opposto corona fino a disimpegnarlo ITA
dalla corona (4).

Mit einem StoÈûel das Differential (7) oder (8) in die dem Das komplette Differentialaggregat (7) oder (8) ab-
D Kranz entgegengesetzte Seite druÈcken und aus dem D ziehen.
Kranz (4) freisetzen.

a b
Utilizando un empuje, empujar el diferencial (7) o (8) Sacar el grupo diferencial (7) o (8) completo.
ESP hacia el lado opuesto corona hasta desempenarlo de ESP
la corona (4).

A l'aide d'un poussoir, pousser le diffeÂrentiel (7) ou (8) Extraire le groupe diffeÂrentiel (7) ou (8) tout entier.
F du coÃteÂ opposeÂ aÁ la couronne jusqu'aÁ le deÂgager de la F
couronne (4).

Rimuovere l'attrezzo T7B montato sul lato opposto Estrarre la corona (4).
ITA corona. ITA

Das Werkzeug T7B abnehmen, das an der dem Kranz Kranz (4) abziehen.
D entgegengesetzte Seite montiert ist. D

c d
Remover la herramienta T7B montado sobre el lado Extraer la corona (4).
ESP opuesto corona. ESP

DeÂplacer l'outil T7B monteÂ du coÃteÂ opposeÂ aÁ la Extraire la couronne (4).

F couronne. F

SMONTAGGIO DIFFERENZIALE SMONTAGGIO DIFFERENZIALE NO-SPIN

ITA Utilizzando un estrattore, asportare i cuscinetti (9) dal ITA Inserire il tirante "B" di trattenimento del gruppo no-
gruppo differenziale. spin (14) ed avvitare a fondo il dado ad alette.

DIFFERENTIAL ABMONTIEREN DAS NO-SPIN DIFFERENTIAL ABMONTIEREN

D Mit einem Abzieher die Lager (9) vom Differentialag- D Sie Spannstange "B" einsetzen, um das No-Spin
gregat abnehmen. Aggregat (14) festzuhalten und die FluÈgelmutter fest-
ziehen.
e f
DESMONTAJE DIFERENCIAL DESMONTAJE DIFERENCIAL NO-SPIN
ESP Utilizando un extractor, sacar los cojinetes (9) del ESP Introducir el tirante "B" de detencion del grupo no-spin
grupo diferencial. (14) y atornillar hasta el fondo la tuerca a aletas.

DEMONTAGE DU DIFFERENTIEL DEMONTAGE DU DIFFERENTIEL NO-SPIN

F A l'aide d'un extracteur, enlever les paliers (9) du F Introduire la tringle "B" de retenue du groupe no-spin
groupe diffeÂrentiel. (14), puis visser l'eÂcrou aÁ ailettes aÁ fond.

008 924 17 BOMAG

47 893
16.7 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

10 11

F1241151 F1241152

GB a GB b
Remove the screws (10) and the spring washers (11) jointing the Using a plastic hammer, take the half box (12) to pieces.
differential unit half box (12). NOTE. Note down the coupling marks.

14
F1241153 F1241154

GB c GB d
Extract the no-spin unit (13). 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.

19
16
17
18

20 21

F1241155 F1241156

GB e GB f
DISASSEMBLY OF THE 45% SELF-LOCKING DIFFERENTIAL UNIT Remove the differential cover (18), any shims (19) and the friction
Remove the screws (16) and the spring washers (17) jointing the (20) complete with ring (21).
differential unit. 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.
894 BOMAG
48 008 924 17
Axle 16.7

Rimuovere le viti (10) e le rondelle elastiche (11) di Utilizzando un mazzuolo in materiale plastico scom-
ITA unione della semiscatola differenziale (12). ITA porre la semiscatola differenziale (12).
NOTA. Annotare la marcatura di accoppiamento.

Schrauben (10) und Federscheiben (11) abnehmen, Mit einem Gummihammer das halbe Differentialge-
D die das halbe DifferentialgehaÈuse (12) zusammen D haÈuse (12) zerlegen.
halten. BEMERKUNG. Die Kupplungsmarkierung notieren.
a b
Remover los tornillos (10) y las arandelas elasticas Utilizando un martillo en material plastico decomponer
ESP (11) de union de la semi-caja diferencial (12). ESP la semicaja diferencial (12).
NOTA. Anotar la marcatura de acoplamiento.

Enlever les vis (10) et les rondelles eÂlastiques (11) A l'aide d'un maillet en matieÁre plastique deÂcomposer
F d'union de la moitieÂ du boõÃtier diffeÂrentiel (12). F la moitieÂ du boõÃtier diffeÂrentiel (12).
REMARQUE. Prendre note de la marque d'accou-
plement.

Estrarre il gruppo no-spin (13). Svitare il dado ad alette del tirante "B" e scomporre il
ITA ITA gruppo no-spin per rimuovere il distanziale (14) contro
lo scorrimento assiale dei semiassi.

Das No-Spin Aggregat (13) abziehen. Die FluÈgelmutter der Spannstange "B" abschrauben
D D und das No-Spin Aggregat zerlegen, um das Differen-
tial (14) an der Achsengleitung der Halbachsen
abnehmen zu koÈnnen.
c d
Sacar el grupo no-spin (13). Destornillar la tuerca a aletas del tirante "B" y
ESP ESP decomponer el grupo no-spin para remover el distan-
cial (14) contra el deslizamiento axial de los semi-ejes.

Extraire le groupe no-spin (13). DeÂvisser l'eÂcrou aÁ ailettes de la tringle "B" et

F F deÂcomposer le groupe no-spin pour enlever le
diffeÂrentiel (14) contre le coulisseau axial des demi-
essieux.

SMONTAGGIO DIFFERENZIALE AUTOBLOCCANTE AL 45% Rimuovere il coperchio differenziale (18), gli eventuali
ITA Rimuovere le viti (16) e le rondelle elastiche (17) di ITA spessori (19) e la frizione (20) completa dell'anello (21).
unione del corpo differenziale. 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.

DAS ZU 45% SELBSTHEMMENDE DIFFERENTIAL ABMONTIEREN Differentialdeckel (18) und evtl. Unterlegscheiben (19)
D Schrauben (16) und Federscheiben (17), die den D und die Kupplung (20) mit dem Ring (21) abnehmen.
DifferentialkoÈrper verbinden, abnehmen. ACHTUNG! 1 - Die Position der Kupplungsscheiben
nicht verwechseln.
e f 2 - Die GesamtstaÈrke der Kupplung muû mehr als 17,3 mm betragen;
sollte dies nicht der Fall sein, beide Kupplungen auswechseln.

DESMONTAJE DIFERENCIAL AUTOBLOQUEO AL 45% Remover la tapa diferencial (18), los eventuales
ESP Remover los tornillos (16) y las arandelas elasticas ESP espesores (19) y la fricion (20) completa del anillo (21).
(17) de union del cuerpo diferencial. 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.

DEMONTAGE DU DIFFERENTIEL AUTOBLOQUANT A 45% Enlever le couvercle diffeÂrentiel (18), les eÂventuelles
F Enlever les vis (16), les rondelles eÂlastiques (17) F cales (19) et la friction (20) compleÁte d'anneau (21).
d'union du corps diffeÂrentiel. 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.

008 924 17 BOMAG

49 895
16.7 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

22
25 23

26 24
26

F1241157 F1241158

GB a GB b
Remove the planetary gear (22). Remove the long planetary carrier journal (23) and the two short
Mark the 37 mm value on a pin-driver; using the same pin-driver, journals (24).
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).

29
28
33
32

F1241159 F1241160

GB c GB d
Extract the cross journal (27), the planet wheels (28) complete with Remove the 2nd friction (20) complete with ring (21). Also remove
shim washers (29) and the second planetary gear (22). 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.

25
23 24
1
9
F1241161 F1241162

GB e GB f
Extract the spring pins (25) from journals (23) and (24). Only if bearings are replaced.
Remove the thrust blocks of bearings (9) from the intermediate
covers (1) and (2).

896 BOMAG
50 008 924 17
Axle 16.7

Rimuovere l'ingranaggio planetario (22). Rimuovere il perno porta satelliti lungo (23) ed i due
ITA Segnare su un cacciaspine un contrassegno a 37 mm; ITA perni corti (24).
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).

Das Planetengetriebe (20) abnehmen. An einem DuÈ- Den langen Planetenradhalterstift (23) und die beiden
D bel das Maû von 37 mm markieren; mit diesem DuÈbel D kurzen Planetenradhalterstifte (24) entfernen.
die Federstifte (25) in die Stifte (23) und (24) einsetzen.
BEMERKUNG. Die Federstifte sind in den Stiften (23) und (24)
a zentriert, wenn das markierte Maû auf der HoÈhe des Differential- b
koÈrpers (26) liegt.

Remover el engranaje planetario (22). Senalizar sobre Remover la rotula porta satelites largo (23) y las dos
ESP un extractor de clavijas un contra-segno a 37 mm; ESP rotulas cortas (24).
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).

Enlever l'engrenage planeÂtaire (22). Marquer d'une Enlever le pivot porte-satellite long (23) et les deux
F estampille le chasse-clou aÁ 37 mm; a l'aide de ce meÃme F pivots courts (24).
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).

Estrarre la crociera (27), i satelliti (28) completi delle Rimuovere la 2ã frizione (20) completa dell'anello (21).
ITA rondelle di rasamento (29) ed il 2ë ingranaggio ITA Rimuovere anche gli eventuali spessori (19).
planetario (22). 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.

Das Kreuz (27), die Planetengetriebe (28) samt Die 2. Kupplung (20) mit Ring (21) abnehmen.
D Zwischenlegscheiben (29) und das 2. Planetengetrie- D Eventuelle Unterlegscheiben (19) auch entfernen.
be (30) abziehen. ACHTUNG! 1 - Die Position der Kupplungsscheiben
nicht verwechseln.
c d 2 - Kontrollieren, ob die GesamtstaÈrke der Kupplung mehr als 17,3 mm
betraÈgt; anderenfalls beide Kupplungen auswechseln.

Sacar la cruceta (27), los satelites (28) completos de Remover la 2ë fricion (30) completa del anillo (21).
ESP las arandelas de rasamiento (29) y el 2ë engranaje ESP Remover tambien los eventuales espesores (19).
planetario (22). 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.

Extraire le croisillon (27), les satellites (28) complet de Enlever la 2ë friction (20) compleÁte d'anneau (21).
F rondelles de rasage (29), puis le 2ë engrenage F Enlever eÂgalement les eÂventuelles cales (19).
planeÂtaire (22). 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.

Estrarre le spine elastiche (25) dai perni (23) e (24). Solo se si sostituiscono i cuscinetti
ITA ITA Rimuovere le ralle dei cuscinetti (9) dai coperchi
intermedi (1) e (2).

Die Federstifte (25) von den Stiften (23) und (24) Nur falls die Lager ausgewechselt werden.
D abziehen. D Die Scheiben von den Lagern (9) der Zwischendeckel
(1) und (2) abnehmen.

e f
Sacar las clavijas elasticas (25) de las rotulas (23) y Solo si se sobstituiyen los cojinetes
ESP (24). ESP Remover las ranguas de los cojinetes (9) de las tapas
intermedias (1) y (2).

Extraire les goupilles eÂlastiques (25) des pivots (23) et Uniquement en cas de substitution des paliers.
F (24). F Enlever les crapaudines des paliers (9) des couvercles
intermeÂdiaires (1) et (2).

008 924 17 BOMAG

51 897
16.7 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL

30
4 33
35 36 3 34
32
7
45 31
1
8

38
44 40
GB a GB b
6 41

39
37

43 47
32
42

GB
33 34
c GB d
31

D1240134

GB e GB f

898 BOMAG
52 008 924 17
Axle 16.7

ITA ITA
18

20 9
29
D 25 22 D
28
a b
24 19 16

ESP 29 ESP 21 17
27
20 29
25

19 24
28
F F
22 29
21 25

23 10
11
ITA 7ITA

26 12
14
9
D D

15
c d 9
9
ESP ESP

F F 8

D1240135

ITA ITA

D D

e f

ESP ESP

F F

008 924 17 BOMAG

53 899
16.7 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

12
13

14
F1241154 F1241163

GB a GB b
ASSEMBLY OF THE NO-SPIN DIFFERENTIAL UNIT Fit the no-spin unit into the differential unit half box (15).
Assemble the no-spin unit (13), inserting the distance piece (14) Centre the half box (12) and fasten.
and using stay "B". CAUTION! Make sure the connection marks coincide.

F1241164 F1241150

GB c GB d
Fit the spring washers (11) onto the screws (10). Remove stay "B".
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.

21
20
21
20 26

17,6

19
F1241224 F1241160

GB e GB f
ASSEMBLY OF THE 45% SELF-LOCKING DIFFERENTIAL UNIT Insert in the body of the differential unit (26) any required shims
Using a depth gauge, check the shim of friction units complete with (19) and the friction (20) complete with ring (21).
rings (21). If thickness is lower than 17.6 mm, add more shims (19). CAUTION! Ring (21) must touch the planetary gear (22).
CAUTION! Shims must be placed right behind the body of the
differential unit (26).

900 BOMAG
54 008 924 17
Axle 16.7

ASSEMBLAGGIO DIFFERENZIALE NO-SPIN Montare il gruppo no-spin nella semiscatola differen-

ITA Assemblare il gruppo no-spin (13) inserendo il distan- ITA ziale (15).
ziale (14) ed utilizzando il tirante "B". Centrare la semiscatola (12) e mandarla in battuta.
ATTENZIONE! Controllare che le marcature di accoppiamento
coincidano.

NO-SPIN DIFFERENTIAL ZUSAMMENBAUEN Das No-Spin Aggregat in das halbe Differentialge-

D Das No-Spin (13) Aggregat zusammenbauen; dazu D haÈuse (15) montieren.
das DistanzstuÈck (14) mit der Spannstange "B" Das halbe GehaÈuse (12) zentrieren und bis zum
einsetzen. Anschlag einsetzen.
a b ACHTUNG! Kontrollieren, ob die Kupplungsmarkierungen uÈberein-
stimmen.

MONTAJE DIFERENCIAL NO-SPIN Montar el grupo no-spin en la semi-caja diferencial

ESP Asemblaje el grupo no-spin (13) introduciendo el ESP (15).
diferencial (14) y utilizando el tirante "B". Centrar la semi-caja (12) y mandarla a tope.
ATENCION! Controlar que las marcaduras de acoplamiento
coincidan.

ASSEMBLAGE DU DIFFERENTIEL NO-SPIN Monter le groupe no-spin dans la moitieÂ du boõÃtier

F Assembler le groupe no-spin (13) en introduisant F diffeÂrentiel (15).
l'entretoise (14), puis aÁ l'aide de la tringle "B". Centrer la moitieÂ du boõÃtier (12) et l'envoyer en buteÂe.
ATTENTION! ControÃler que les estampilles d'accouplement
correspondent.

Infilare sulle viti (10) le rondelle elastiche (11). Rimuovere il tirante "B".
ITA Spalmare le viti (10) con Loctite 270 ed avvitarle a ITA
fondo per comporre la scatola differenziale.
Serrare le viti con il metodo incrociato ad una coppia di serraggio di
86v89 Nm.

Federscheiben (11) in die Schrauben (10) einsetzen. Spannstange "B" abnehmen.

D Die Schrauben (10) mit Loctite 270 schmieren und D
festziehen, um das DifferentialgehaÈuse zusammenzu-
bauen.
c Die Schrauben im Kreuz und mit einem Anzugsmoment von 86v89
Nm festziehen.
d
Insertar sobre tornillos (10) las arandelas elasticas Remover el tirante "B".
ESP (11). ESP
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.

Passer sur les vis (10) les rondelles eÂlastiques (11). Enlever la tringle "B".
F Enduire les vis (10) avec du Loctite 270, puis visser F
celles-ci aÁ fond pour recomposer le boõÃtier diffeÂrentiel.
Serrer les vis avec la meÂthode croiseÂe aÁ un couple de serrage de
86v89 Nm.

ASSEMBLAGGIO DIFFERENZIALE AUTOBLOCCANTE AL 45% Inserire nella corpo differenziale (26) gli eventuali
ITA Controllare con un calibro di profonditaÁ lo spessore ITA spessori (19) e la frizione (20) completa dell'anello
delle frizioni complete degli anelli (21). Se lo spessore (21).
eÁ inferiore a 17,6 mm, aggiungere degli spessori (19). ATTENZIONE! L'anello (21) deve rimanere a contatto dell'ingra-
ATTENZIONE! Gli spessori devono essere posizionati a ridosso del naggio planetario (22).
corpo differenziale (26).

ZU 45% SELBSTHEMMENDE DIFFERENTIAL ZUSAMMENBAUEN In den DifferentialkoÈrper (26) eventuelle Unterleg-

D Mit Hilfe einer Tiefenlehre die StaÈrke der Kupplungen D scheiben (19) und die Kupplung (20) samt Ring (21)
mit den Ringen (21) messen. Sollte das Maû weniger einsetzen.
als 17,6 mm betragen, noch Unterlegscheiben (19) hinzufuÈgen. ACHTUNG! Der Ring (21) muû am Planetengetriebe (22) anliegen.
e ACHTUNG! Die Unterlegscheiben muÈssen am DifferentialkoÈrper f
(26) anliegen.

MONTAJE DIFERENCIAL AUTO-BLOQUEO AL 45% Introducir en el cuerpo diferencial (26) los eventuales
ESP Controlar con un calibro de profundidad el espesor de ESP espesores (19) y la fricion (20) completa del anillo (21).
las friciones completas de los anillos (21). Si el ATENCION! El anillo (33) debe quedar a contacto del
espesor es inferior a 17,6 mm, sumar de los espesorees (19). engranaje planetario (22).
ATENCION! Los espesores deben de ser colocados detraÁs del
cuerpo diferencial (26).

ASSEMBLAGE DU DIFFERENTIEL AUTOBLOQUANT A 45% Introduire le corps diffeÂrentiel (26), les eÂventuelles
F ControÃler aÁ l'aide d'un calibre de profondeur l'eÂpais- F cales (19) et la friction (20) compleÁte d'anneau (21.
seur des frictions compleÁtes d'anneaux (21). Si le ATTENTION! L'anneau (21) doit rester au contact de
calage est infeÂrieur aÁ 17,6 mm, ajouter des cales (19). l'engrenage planeÂtaire (22).
ATTENTION! Les cales doivent eÃtre placeÂes aÁ l'abri du corps
diffeÂrentiel (226).

008 924 17 BOMAG

55 901
16.7 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

27
22 28

26
23

F1241165 F1241166

GB a GB b
Install the planetary gear (22) and three of the planet wheels (28), Install the cross journal (27), holding it into position with the long
complete with shim washers (29). journal (23).
Hold the planet wheels (28) and relative washers (29) into position Before inserting journal (23) completely, install the last planet
with pins (24). wheel (28) and the relative washer (29).

19
22
25

20
26 21
26
25,5

F1241167 F1241168

GB c GB d
Countermark a point at 25.5 mm on a pin-driver; using the same Install the second planetary gear (22) and the friction (20) complete
pin-driver, engage the journals (23) and (24) with the spring pins with ring (21) and any shims required (19).
(25). CAUTION! Ring (21) must be installed right behind the planetary
NOTE. When the countermark is lined up with the edge of the body gear (22) and the shims (19) right behind the differential cover (18).
of the differential unit (26), the journals are engaged by half.

16 17

F1241169 F1241170

GB e GB f
Position the differential cover (18). Fit the spring washers (17) onto the screws (16).
NOTE. Make sure that the assembly marks coincide. Coat the screws (16) with Loctite 270 and screws tight.
Tighten screws using the criss-cross method and a torque of
135 ± 138 Nm.

902 BOMAG
56 008 924 17
Axle 16.7

Montare l'ingranaggio planetario (22) e tre degli Montare la crociera (27) e mantenerla in posizione con
ITA ingranaggi satelliti (28) completi di rondelle di rasa- ITA il perno lungo (23).
mento (29). Prima di inserire completamente il perno (23), montare
Mantenere in posizione gli ingranaggi satelliti (28) e le relative l'ultimo satellite (28) e la relativa rondella (29).
rondelle (29) con i perni (24).

Das Planetengetriebe (22) und drei der Planetenge- Das Kreuz (27) montieren und in der Position mit
D triebe (28) samt Zwischenlegscheiben (29) montieren. D einem langen Stift (23) festhalten.
Die Planetengetriebe (28) und die Zwischenlegschei- Bevor der Stift (23) ganz eingesetzt wird, das letzte
ben (29) mit den Stiften (24) in der Position festhalten. Planetengetriebe (28) und die Unterlegscheibe (29) montieren.
a b
Montar el engranaje planetario (22) y tres de los Montar la cruceta (27) y mantenerla en posicion con la
ESP engranajes satelites (28) completos de las arandelas ESP rotula larga (28).
de rasadura (29). Antes de insertar completamente la rotula (23), montar
Mantener en posicion los engranajes satelites (28) y las relativas el ultimo satelite (28) y la relativa arandela (29).
arandelas (29) con las rotulas (24).

Monter l'engrenage planeÂtaire (22) et trois des Monter le croisillon (27) et maintenir celui-ci aÁ sa place
F engrenages satellites (28) complets de rondelles de F aÁ l'aide du pivot long (23).
rasage (29). Avant d'introduire entieÁrement le pivot (23), monter le
Maintenir les engrenages satellites (28) et relatives rondelles (29) aÁ dernier satellite (28) et sa rondelle (29).
leur place avec les pivots (24).

Segnare sul cacciaspine un contrassegno a 25,5 mm; Montare il secondo ingranaggio planetario (22) e la
ITA utilizzando lo stesso cacciaspine impegnare i perni ITA frizione (20) completa dell'anello (21) e degli eventuali
(23) e (24) con le spine elastiche (25). spessori (19).
NOTA. Le spine impegnano metaÁ dei perni quando il contrassegno ATTENZIONE! L'anello (21) deve essere montato a ridosso
arriva a filo del corpo differenziale (26). 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 Das zweite Planetengetriebe (22) und die Kupplung
D demselben DuÈbel die Stifte (23) und (24) mit den D (20) mit dem Ring (21) und eventuelle Unterlegschei-
Federstiften (25) einsetzen. ben (19) montieren.
BEMERKUNG. Die Stifte sind durch die Federstifte zur HaÈlfte ACHTUNG! Der Ring (21) muû nach der Montage am Planetenge-
c eingesetzt, wenn die Markierung auf halber HoÈhe des Differential- d triebe (22) und die eventuellen Unterlegscheiben (19) muÈssen am
koÈrpers (26) liegt. Differentialdeckel (18) anliegen.

Senalar sobre el extractor de clavijas un contra-segno Montar el segundo engranaje planetario (22) y la
ESP a 25,5 mm; utilizando el mismo extractor de clavijas ESP fricion (20) completa del anillo (21) y de los eventuales
empegnar las rotulas (23) y (24) con las clavijas espesores (19).
elasticas (25). ATENCION! El anillo (21) debe deser montado detras del
NOTA! Las clavijas empegnan midad de las rotulas cuando el engranaje planetario (22) y los eventuales espesores (19) detras
contra-segno llega al borde del cuerpo diferencial (26). de la tapa diferencial (18).

Marquer d'une estampille le chasse-clou aÁ 25,5 mm; Monter le second engrenage planeÂtaire (22), la friction
F a l'aide de ce meÃme chasse-clou, engager les pivots F (20) compleÁte d'anneau (21) et des eÂventuelles cales
(23) et (24) et les goupilles eÂlastiques (25). (19).
REMARQUE. Les goupilles arrivent aÁ la moitieÂ des pivots quand ATTENTION! L'anneau (21) est aÁ monter aÁ l'abri de l'engrenage
l'estampille atteint le bord du corps diffeÂrentiel (26). planeÂtaire (22) et les eÂventuelles cales (19) aÁ l'abri du couvercle
diffeÂrentiel (18).

Posizionare il coperchio differenziale (18). Infilare sulle viti (16) le rondelle elastiche (17).
ITA ITA Spalmare le viti (16) con Loctite 270 ed avvitarle a
NOTA. Controllare che le marcature di montaggio
coincidano. fondo.
Serrare le viti con il metodo incrociato ad una coppia di serraggio di
135v138 Nm.

Den Differentialdeckel (18) positionieren. Auf die Schrauben (16) die Federscheiben (17)
D D montieren.
BEMERKUNG. Kontrollieren, ob die Montagemarkie-
rungen uÈbereinstimmen. Die Schrauben (16) mit Loctite 270 schmieren und
festziehen. Die Schrauben im Kreuz mit einem Anzugsmoment von
e f 135v138 Nm festziehen.

Colocar la tapa diferencial (18). Introducir sobre los tornillos (16) las arandelas
ESP ESP elasticas (17).
NOTA. Colocar que las marcaduras de montaje
coincidan. 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.

Mettre le couvercle diffeÂrentiel (18) en place. Passer sur les vis (16) les rondelles eÂlastiques (17).
F F Enduire les vis (16) avec du Loctite 270 et visser
REMARQUE. ControÃler que les estampilles de mon-
tage coõÈncident. celles-ci aÁ fond.
Serrer les vis avec la meÂthode croiseÂe aÁ un couple de serrage de
135v138 Nm.

008 924 17 BOMAG

57 903
16.7 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

9 9 9 9

7
8
8 7

F1241171 F1241172

GB a GB b
INSTALLATION OF THE DIFFERENTIAL UNIT Turn the unit upside down and install the second bearing (9).
Position the differential unit (7) or (8) under a press and, using a CAUTION! Pay particular attention; position a shim with adequate
driver with an adequate diameter, install the first bearing (9). diameter in order to engage the internal ring of bearing (9) without
engaging the cage.

T8
9

F1241173 F1241174

GB c GB d
Only if bearings are replaced Position the crown wheel (4) in the main body (3).
Using tool T8, insert the thrust blocks of the bearings (9) into the
intermediate covers (1) and (2).

T7B 7 8

F1241175 F1241176

GB e GB f
Fit tool T7B on the crown wheel opposite side, holding it in position Install the differential unit (7) or (8), by fitting it into the hole of tool
with two studs and two nuts. T7B.
NOTE. Engage the crown (4) onto 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.

904 BOMAG
58 008 924 17
Axle 16.7

INSTALLAZIONE DIFFERENZIALE Capovolgere il gruppo e montare il secondo cuscinetto

ITA Posizionare il differenziale (7) o (8) sotto una pressa ed ITA (9).
utilizzando uno spintore di diametro adatto montare il ATTENZIONE! Prestare molta attenzione e posiziona-
primo cuscinetto (9). re uno spessore di diametro adatto al fine di impegnare l'anello
interno del cuscinetto (9) senza impegnare la gabbia.

DIFFERENTIAL ZUSAMMENBAUEN Das Aggregat wenden und das zweite Lager montie-
D Das Differential (7) oder (8) unter eine Presse legen D ren (9).
und mit einem geeigneten Dynamometer-StoÈûel das ACHTUNG! Den Vorgang mit groûer Sorgfalt durch-
erste Lager (9) montieren. fuÈhren und einen fuÈr die StaÈrke geeigneten Dynamometer
a b verwenden, um den Ring des inneren Lagers (9) einzusetzen,
ohne den KaÈfig einzuklemmen.

INSTALACION DIFERENCIAL Volcar el grupo y montar el segundo cojinete (9).

ESP Colocar el diferencial (7) y (8) bajo una prensa y ESP
ATENCION! Tener mucho cuidado y colocar un
utilizando un empuje de diametro adapto montar el espesor de diametro apto al fin de empegnar el anillo
primer cojinete (9). interno del cojinete (9) si empegnar la jaula.

INSTALLATION DU DIFFERENTIEL Faire basculer le groupe et monter le second palier (9).

F Mettre le diffeÂrentiel (7) ou (8) en place sous la presse, F
ATTENTION! Faire treÁs attention, mettre une cale au
aÁ l'aide d'un poussoir au diameÁtre adeÂquat, monter le diameÁtre adeÂquat afin d'engager l'anneau interne du
premier palier (9). palier (9) sans y engager la cage.

Solo se si sostituiscono i cuscinetti Posizionare la corona (4) dentro il corpo centrale (3).
ITA Utilizzando l'attrezzo T8 inserire le ralle dei cuscinetti ITA
(9) nei coperchi intermedi (1) e (2).

Nur wenn die Lager ausgewechselt werden. Den Kranz (4) in den zentralen KoÈrper (3) einsetzen.
D Mit dem Werkzeug T8 die Scheiben der Lager (9) in D
die Zwischendeckel (1) und (2) einsetzen.

c d
Solo si se sobstituyen los cojinetes Colocar la corona (4) dentro del cuerpo central (3).
ESP Utilizando la herramienta T8 Introducir las ranguas de ESP
los cojinetes (9) en las tapa intermedias (1) y (2).

Uniquement en cas de substitution des paliers Mettre la couronne (4) en place dans le corps central
F A l'aide de l'outil T8, introduire la crapaudine des F (3).
paliers (9) dans les couvercles intermeÂdiaires (1) et (2).

Montare l'attrezzo T7B sul lato opposto corona, Montare il gruppo differenziale (7) o (8) impegnandolo
ITA trattenendolo con due prigionieri e due dadi. ITA nel foro dell'attrezzo T7B.
NOTA. Impegnare la corona (4) sull'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 entgegen- Das Differentialaggregat (7) oder (8) montieren und im
D gesetzten Seite montieren und mit zwei Stiftschrauben D Loch des Werkzeuges T7B einrasten.
und zwei Muttern festhalten. Den Kranz (4) auf das Differential (7) oder (8)
BEMERKUNG. Den Kranz (4) in das Werkzeug T7B einrasten. montieren und bis zum Anschlag am Flansch einsetzen.
e f BEMERKUNG. Die FlanschloÈcher muÈssen mit den KranzloÈchern
uÈbereinstimmen.

Montar la herramienta T7B sobre el lado opuesto Montar el grupo diferencial (7) o (8) empegnandolo en
ESP corona, deteniendo con dos prigionieros y dos ESP el agujero de la herramienta T7B.
tuercas. Montar la corona (4) sobre el diferencial (7) y (8)
NOTA. Empegnar la corona (4) sobre la herramienta T7B. 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 coÃteÂ opposeÂ aÁ la couronne, en le Monter le groupe diffeÂrentiel (7) ou (8) en l'engageant
F tenant aÁ l'aide de deux prisonniers et de deux eÂcrous. F dans le trou de l'outil T7B.
REMARQUE. Engager la couronne (4) sur 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.

008 924 17 BOMAG

59 905
16.7 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

35
5 A

F1241177 F1241145

GB a GB b
Fit spring washers (6) onto the screws (5). Check the condition and position of the O-ring (30); lubricate the
Coat screws with Loctite 270 and screw them tight into the crown. seal and install the intermediate cover (2) on crown wheel side.
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.

2
T6
31
T7A

F1241178 F1241179

GB c GB d
Lock the intermediate cover (2) with the journals (31) tightened to a Install tool T6 on the journals (31) on the crown wheel side, placing
torque of 129 ± 143 Nm. 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 1
30

F1241180 F1241181

GB e GB f
Remove tool T7B on crown opposite side. 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.

906 BOMAG
60 008 924 17
Axle 16.7

Montare sulle viti (5) le rondelle elastiche (6). Controllare lo stato ed il posizionamento dell'anello
ITA Spalmare le viti con Loctite 270 ed avvitarle a fondo ITA OR (30); lubrificare la guarnizione e montare il
nella corona. Posizionare il blocchetto "A" di contra- coperchio intermedio (2) lato corona.
sto; 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.

Auf die Schrauben (5) die Federscheiben (6) montieren. Den Zustand und die Position des O-Ringes (30)
D Die Schrauben mit Loctite 270 schmieren und in den D kontrollieren; die Dichtung schmieren und den Zwi-
Kranz schrauben. Den Block "A" positionieren; den schendeckel (2) an der Kranzseite montieren.
Kranz am Block anliegen lassen und die Schrauben (5) mit einem
a Anzugsmoment von 135v138 Nm festziehen. b
ACHTUNG! Die Schrauben im Kreuz festziehen.

Montar sobre los tornillos (5) las arandelas elasticas (6). Controlar el estado y la colocacion del anillo OR (30);
ESP Pasar los tornillos con Loctite 270 y atornillarlos a ESP lubrificar la guarnicion y montar la tapa intermedia (2)
fondo en la corona. Colocar el bloque "A" de contraste; lado corona.
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.

Monter les vis (5), les rondelles eÂlastiques (6). ControÃler l'eÂtat et le positionnement de l'anneau
F Enduire les vis avec du Loctite 270, puis visser celles- F O'Ring (30); lubrifier la garniture, puis monter le
ci aÁ fond dans la couronne. Mettre le petit bloc "A" de couvercle intermeÂdiaire (2) du coÃteÂ couronne.
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.

Bloccare il coperchio intermedio (2) con i prigionieri Montare l'attrezzo T6 sui prigionieri (31) lato corona,
ITA (31) serrati ad una coppia di 129v143 Nm. ITA 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).

Den Zwischendeckel (2) mit den Stiftschrauben (31) Das Werkzeug T6 an den Stiftschrauben (31) an der
D blockieren und mit einem Anzugsmoment von D Kranzseite montieren und dabei DistanzstuÈcke einsetzen
129v143 Nm festziehen. und mit zwei Muttern befestigen. In das Werkzeug T6 das Werkzeug
T7A zur Zentrierung und Halterung des Differentials einsetzen.
c d BEMERKUNG. Sicherstellen, daû das Differential fest im Zwischen-
deckel (2) sitzt.

Bloquear la tapa intermedia(2) con los prigioneros (31) Montar la herramienta T6 sobre los prigioneros (31)
ESP apretados a un par de 129v143 Nm. ESP 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).

Bloquer le couvercle intermeÂdiaire (2) aÁ l'aide des Monter l'outil T6 sur les prisonniers (31) coÃteÂ cou-
F prisonniers (31) serreÂs aÁ un couple de 129v143 Nm. F ronne, 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 engageÂ aÁ fond dans
le couvercle intermeÂdiaire (2).

Rimuovere l'attrezzo T7B del lato opposto corona. Controllare lo stato ed il posizionamento dell'anello
ITA ITA 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 Den Zustand und die Position des O-Ringes (30)
D Seite abnehmen. D kontrollieren; die Dichtung schmieren und den Zwi-
schendeckel (1) an der dem Kranz entgegengesetzten
Seite montieren. Den Zwischendeckel (1) mit den Stiftschrauben
e f (31) und einem Anzugsmoment von 129v143 Nm befestigen und
die Werkzeuge T6 und T7A entfernen.

Remover la herramienta T7B del lado opuesto corona. Controlar el estado y la colocacion del anillo OR (30);
ESP ESP 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.

Enlever l'outil T7B du coÃteÂ opposeÂ aÁ la couronne. ControÃler l'eÂtat et le positionnement de l'anneau
F F O'Ring (30); lubrifier la garniture, puis monter le
couvercle intermeÂdiaire (1) du coÃteÂ opposeÂ 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.

008 924 17 BOMAG

61 907
16.7 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

1 32

32 T9

33 F1241182 F1241183

GB a GB b
Remove the screws (33) and remove the safety tabs (34). 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.

37 3

F1241184 F1241185

GB c GB d
Remove the spring ring (35) and extract the cap (36) to allow Coat the surface of the main body (3) with Loctite 510 and install
checking of the clearance between pinion and crown to take place. the reduction gear (37) complete with pinion.
NOTE. Make sure that a continuous layer of sealant runs around
the locking holes.

38 32

F1241186 F1241183

GB e GB f
Coat screws (38) with Loctite 242 and screw tight. Tighten screws Screw ring nut (32) on crown wheel side until clearance between
(38), using the criss-cross method and a tightening torque of pinion and crown equals zero, then unscrew by 1/4 turn approx.
129 ± 143 Nm.

908 BOMAG
62 008 924 17
Axle 16.7

Asportare le viti (33) e rimuovere le linguette di Utilizzando la chiave T9 rimuovere le ghiere (32) di
ITA sicurezza (34). ITA registrazione ed asportare ogni traccia di frenafiletti.
Riavvitare le ghiere dopo averle spalmate con
Loctite 242.

Die Schraube (33) abschrauben und den Sicherheits- Mit einem SchluÈssel T9, die Nutmuttern (32) zur
D keil (34) abnehmen. D Einstellung entfernen und jede alle uÈberschuÈssigen
Reste der SchraubensicherungsloÈsung sorgfaÈltig ent-
fernen.
a b Nutmuttern mit Loctite 242 schmieren und wieder festschrauben.

Sacar los tornillos (33) y remover les lengues de Utilizando la llave T9, remover las virolas (32) de
ESP seguridad (34). ESP registracion y sacar cada senal de frenaroscas.
Restornillas las virolas despues de haberias pasadas
con Loctite 242.

Enlever le vis (33), puis deÂplacer le languettes de A l'aide de la cleÂ T9, enlever les eÂcrous annulaires (32)
F seÂcuriteÂ (34). F de reÂglage et toute trace de l'agent d'arreÃt de vis.
Enduire les eÂcrous annulaires avec Loctite 242 et
visser.

Asportare l'anello elastico (35) e rimuovere il tappo Spalmare la superficie del corpo centrale (3) con
ITA (36) per poter controllare il gioco tra pignone e corona. ITA Loctite 510 ed installare il riduttore (37) completo di
pignone.
NOTA. Assicurarsi che il sigillante crei un velo continuo attorno ai
fori di fissaggio.

Den Kolbenring (35) abnehmen und den Stopfen (363) Die FlaÈche des ZentralkoÈrpers (3) mit Loctite 510
D entfernen, um das Spiel zwischen Kegelrad und Kranz D schmieren und den Reduzierer (37) samt Kegelrad
kontrollieren zu koÈnnen. installieren.
BEMERKUNG. Sicherstellen, daû die Dichtmasse einen gleich-
c d maÈûigen Film um die BefestigungsloÈcher herum bildet.

Sacar el anillo elastico (35) y remover la tapa (36) para Pasar la superficie del cuerpo central (3) con Loctite
ESP poder controlar el juego entre pignon y corona. ESP 510 y instalar el reductor (37) completo de pignon.
NOTA. Asegurarse que el sigilante cree una pelicula
continua alrededor a los agujeros de fisaje.

Enlever l'anneau eÂlastique (35), enlever le bouchon Enduire la superficie du corps central (3) avec du
F (36) pour controÃler le jeu existant entre pignon et F Loctite 510, installer le reÂducteur (37) complet de
couronne. pignon.
REMARQUE. S'assurer que la couche de colle entoure bien les
trous de fixation.

Spalmare le viti (38) con Loctite 242 e avvitarle a fondo. Avvitare la ghiera (32) lato corona fino ad azzerare i
ITA Serrare le viti (38) con il metodo incrociato ad una ITA giochi tra pignone e corona e poi svitare per circa 1/4
coppia di serraggio di 129v143 Nm. di giro.

Die Schrauben (38) mit Loctite 242 schmieren und Nutmuttern (32) an der Kranzseite zuschrauben bis
D festziehen. Die Schrauben (38) im Kreuz mit einem D zwischen Rad und Kranz kein Spiel mehr uÈbrig bleibt;
Anzugsmoment von 129v143 Nm festziehen. danach um 1/4 Umdrehung aufschrauben.

e f
Pasar los tornillos (38) con Loctite 242 y atornillas a Atornillar las virolas (32) lado corona hasta acerar los
ESP fondo. ESP juegos entre el pinion y corona y despues destornillar
Apretar los tornillos (38) con el metodo cruzado y un por cerca 1/4 de giro.
par de torsion de 129v143 Nm.

Enduire les vis (38) avec du Loctite 242, puis visser Visser l'eÂcrou annulaire (32) du coÃteÂ couronne jusqu'aÁ
F celles-ci aÁ fond. F annuler le jeux entre pignon et couronne, puis
Serrer les vis (38) avec la meÂthode croiseÂe aÁ un couple deÂvisser 1/4 de tour.
de serrage de 129v143 Nm.

008 924 17 BOMAG

63 909
16.7 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

F1241187 F1241188

GB a GB b
Allow pinion to turn a few times in both directions to allow bearings Introduce a comparator with rotary key "C" through the rear cap
to set. Pre-load the bearings through the ring nut on crown opposite hole (43).
side to increase pinion torque up to a value of 140 ± 210 Ncm Position comparator on the centre of one of the crown teeth (4), pre-
checked by means of a torque meter. set it to 1 mm and reset it to zero.
CAUTION! If bearings are old, check static torque. If new, check Manually move the crown (4) in both directions to check the
continuous torque. existing clearance between pinion and crown.

RATIO - RAPPORTO CLEARANCE - GIOCO - SPIEL

VERHAÈ LTNIS JUEGO - JEU 32
RAPORTE - RAPPORT MIN. MAX.
T9
6v43 0,18 0,23
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.
F1241183

GB 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 proportion-
ally.
Normal clearance: see table.

36
34

F1241189 F1241190

GB e GB f
Install safety tabs (41) and lock them with screws (40). Using a driver, fit the cap (36) and position it in its seat with the
Screws tightening torque: 10 ± 11 Nm. snap ring (35).

910 BOMAG
64 008 924 17
Axle 16.7

Far compiere al pignone alcuni giri nei due sensi per Posizionare, attraverso il foro per il tappo posteriore
ITA assestare i cuscinetti. Precaricare i cuscinetti tramite la ITA (43), un comparatore a tasto orientabile "C".
ghiera lato opposto corona, per incrementare la coppia di Posizionarlo sul centro di un dente della corona (4),
rotazione pignone fino a 140v210 Ncm controllati con un torsiometro. precaricarlo di circa 1 mm ed azzerarlo.
ATTENZIONE! Con cuscinetti usati, controllare la coppia di spunto; Muovere manualmente nei due sensi la corona (4) per controllare il
con cuscinetti nuovi, controllare la coppia di rotazione continua. gioco esistente tra pignone e corona.

Das Kegelrad um einige Umdrehungen in beide Richtungen Durch das Loch des hinteren Stopfens (43) eine
D drehen, um das Lager in die richtige Position zu bringen. Die D Meûuhr mit schwenkbarer Taste "C" einsetzen.
Lager durch die Nutmutter an der dem Kranz entgegengesetzte Seite Die Meûuhr auf die Mitte eines Zahnes des Kranzes (4)
vorbelasten, um das Gegenmoment des Kegelrads bis auf 140v210 Ncm positionieren und um 1mm vorbelasten; danach zuruÈckstellen.
a zu erhoÈhen. Den Wert mit einem Drehungsmesser kontrollieren.
ACHTUNG! Bei gebrauchten Lagern, das Anlaufdrehmoment kontrollieren; b Von Hand in beide Richtungen den Kranz (4) bewegen, um das
Spiel zwischen Kegelrad und Kranz zu kontrollieren.
bei neuen Lagern, das kontinuierliche Gegenmoment kontrollieren.

Hacer efectuar al pignon algunos giros en los dos sentidos Colocar, atraves el agujero para la tapa posterior (43),
ESP para ordenar los cojinetes. Precargar los cojinetes a ESP un comparador a tecla orientable "C".
traves de las virolas lado opuesto corona, para crecer el par de rotacion Colocarlo sobre el centro de un diente de la corona (4),
pignon hasta 140v210 Ncm controlados con un torsiometro. precargarlo de 1 mm aprox y azerarlo.
ATENCION! Con cojinetes usados, controlar el par de principio; con Mover manualmente en los dos sentidos la corona (4) para
cojinetes nuevos, controlar el par de rotacion continua. controlar el juego esistente entre pignon y corona.

Faire tourner le pignon plusieurs fois dans les deux sens Placer aÁ travers le trou servant au bouchon arrieÁre
F pour ajuster les paliers. PreÂcharger les paliers au moyen de F (43), un comparateur aÁ touche orientable "C".
l'eÂcrou annulaire, du coÃteÂ opposeÂ aÁ la couronne, pour augmenter le couple Positionner celui-ci au centre d'une des dents de la
de rotation du pignon jusqu'aÁ 140v210 Ncm controÃleÂs par un torsiomeÁtre. couronne (4), preÂcharger celui-ci d'environ 1 mm et mettre aÁ zeÂro.
ATTENTION! Avec des paliers usageÂs, controÃler le couple de pointe; avec DeÂplacer manuellement la couronne (4) dans les deux sens pour
des paliers neufs, controÃler le couple de rotation continu. controÃler le jeu existant entre pignon et couronne.

Contrassegnare la posizione delle ghiere (32) rispetto i

ITA ITA 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.

Die Position der Nutmuttern (32) im VerhaÈltnis zu den

D D Zwischendeckeln markieren.
Mit dem SchluÈûel T9, das Spiel zwischen Rad und
Kranz einstellen, in dem eine Nutmutter (32) gelockert und die
c d entgegengesetzte festgezogen wird.
Normales Spiel: siehe Tabelle.

Contrasenalr la colocacion de las virolas (32) respecto

ESP ESP 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.

Marquer la position de l'eÂcrou annulaire (32) par

F F rapport aux couvercles intermeÂdiaires.
A l'aide de la cleÂ T9, reÂgler le jeu entre pignon et
couronne en deÂvissant l'eÂcrou annulaire (32) et en vissant l'eÂcrou
annulaire opposeÂ de la meÃme mesure.
Jeu normal: voir tableau.

Montare le linguette di sicurezza (41) e fissarle con le Con uno spintore, montare il tappo (36) ed assicurarlo
ITA viti (40). ITA in sede con l'anello elastico (35).
Coppia di serraggio viti: 10v11 Nm

Den Sicherheitskeil (41) montieren und mit den Mit einem StoÈûel den Stopfen (36) montieren und in
D Schrauben (40) befestigen. D seinem Sitz mit dem Kolbenring (35) befestigen.
Anzugsmoment der Schrauben: 10v11 Nm

e f
Montar las lenguetas de seguridad (41) y fijarlas con Con un empujador, montar la tapa (36) y asegurarlo en
ESP los tornillos (40). ESP sed con el anillo elastico (36).
Par de serraje tornillos: 10v11 Nm

Monter les languettes de seÂcuriteÂ (41), fixer celles-ci aÁ A l'aide d'un poussoir, monter le bouchon (36), ajuster
F l'aide des vis (40). F celui-ci dans son logement avec l'anneau eÂlastique
Couple de serrage des vis: 10v11 Nm. (35).

008 924 17 BOMAG

65 911
16.7 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL

37
36

40
F1241190 F1241192

GB 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.

41 44

40
46

42 43
F1241193 F1241194

GB c GB d
Lock the cover (40), using the snap washers (43) and the screws Install the breath union piece (44) with the relative sealing washers
(42) and (41) adequately tightened to a torque of 82 ± 91 Nm. (45) and plugs (47) and (46); tighten to a torque of 35 ± 50 Nm.
Tighten screws (42) and (41) with a tightening torque of 82 ± 91 Nm.

GB 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».

912 BOMAG
66 008 924 17
Axle 16.7

Utilizzando uno spintore ed un mazzuolo in materiale Spalmare la superficie del corpo riduttore (37) con
ITA plastico, montare l'ingranaggio conduttore (39). ITA Loctite 510 ed installare il coperchio (40).
NOTA. Assicurarsi che il sigillante crei un velo
continuo attorno ai fori di fissaggio.

Mit einem StoÈûel und einem Gummihammer das Die FlaÈche des KoÈrpers des Reduzierers (37) mit
D Getriebe (39) montieren. D Loctite 510 schmieren und den Deckel (40) installie-
ren.
BEMERKUNG. Sicherstellen, daû die Dichtmasse einen gleich-
a b maÈûigen Film um die BefestigungsloÈcher herum bildet.

Utilizando un empujador y un martillo en material Pasar la superficie del cuerpo reductor (37) con Loctite
ESP plastico, montar el engranaje conductor (39). ESP 510 y instalar la tapa (40).
NOTA. Asegurarse que el sigilante cree una pelicula
continua alrededor de los agujeros de fisaje.

A l'aide d'un poussoir et d'un maillet en matieÁre Enduire la superficie du corps reÂducteur (37) avec du
F plastique, monter l'engrenage conducteur (39). F Loctite 510, installer le couvercle (40).
REMARQUE. S'assurer que la couche de colle
entoure bien les trous de fixation.

Bloccare il coperchio (40) utilizzando le rondelle Montare il raccordo di sfiato (44) con le relative rosette
ITA elastiche (43) e le viti (42) e (41) serrate con una ITA di tenuta (45) ed i tappi (47) e (46); serrarli con una
coppia di 82v91 Nm. coppia di 35v50 Nm.

Den Deckel (40) mit den Federscheiben (42) und (41) Das abgezogene VerbindungsstuÈck (44) mit den
D und den Schrauben (42) und (41) bei einem Anzu- D Dichtscheiben (45) und den Stopfen (47) und (46)
gsmoment von 82v91 Nm blockieren. montieren; Anzugsmoment 35v50 Nm.

c d
Bloquear la tapa (40) utilizando las arandelas elasti- Montar el recorde de escape (441) con las relativas
ESP cas (43) y los tornillos (42) y (41) apretadas con un par ESP rosas de tenida (45) y las tapas (47) y (46); apretarlos
de 82v91 Nm. con un par de 35v50 Nm.

Bloquer le couvercle (40) aÁ l'aide des rondelles Monter le raccord d'eÂvent (44), les relatives rosettes
F eÂlastiques (43) et des vis (42) et (41) serreÂes aÁ un F d'eÂtancheÂiteÂ (45) et les bouchons (47) et (46), serrer
couple de 82v91 Nm. ceux-ci aÁ un couple de 35v50 Nm.

Completare l'assemblaggio dell'assale installando

ITA nell'ordine i cilindri freni ed i bracci completi. ITA
Per i dettagli, vedere «ASSEMBLAGGIO GRUPPI
FRENO».

Die Achse fertig zusammenbauen und der Reihe nach

D die Bremszylinder und die kompletten Arme installie- D
ren.
Siehe «ZUSAMMENBAU DER BREMSAGGREGATE».
e f
Completar el asemblaje del axial instalando en el
ESP orden los cilindros frenos y los ejes completos. ESP
Para los detalles, vease «ASEMBLAJE GRUPOS
FRENOS».

Achever l'assemblage de l'essieu en y installant dans

F l'ordre les cylindres freins et les bras complets. F
Pour de plus amples deÂtails voir "ASSEMBLAGE DU
GROUPE FREIN".

008 924 17 BOMAG

67 913
16.7DISASSEMBLY OF REDUCTION GEAR AND BEVEL PINION - SMONTAGGIO RIDUTTORE E PIGNONE CONICO - REDUZIERER UND KEGELRADAxle
ABMONTIEREN - REMOCION REDUCTOR Y PINÄON CONICO - DEMONTAGE DU REDUCTEUR ET PIGNON CONIQUE

1 7

6 5
F1241141 F1241195

GB a GB b
Remove the whole arms and the differential unit. Loosen and remove screws (1) and (2) and the washers (3) locking
For details, see «CHECKING WEAR AND REPLACING THE the cover (4), the plugs (5) and (6) for oil fill and oil drain, and the
BRAKING DISKS» and «REMOVAL OF DIFFERENTIAL UNIT». bleed union piece (7).
NOTE. Leave two screws (2) in position for safety.

4
13 A

4 12
F1241196 F1241197

GB c GB d
Using a plastic hammer, remove the cover (4) and move it away. Place a block of tender material (aluminium, etc.) between the
NOTE. If operations on the differential unit need to be performed, reduction body (11) and the gear (12) of the pinion.
remove the complete reduction gear unit (screws (9) and (10)). Loosen and remove the pinion locking nut (13).

14
12

14
F1241198 F1241199

GB e GB f
Remove the gear of the pinion (12) and the driving gear (14) Take the driving gear to pieces (14), extracting the bearing (15).
complete with bearing (15). NOTE. If necessary, use an extractor.
NOTE. To remove the gear (14), use a lever.

914 BOMAG
68 008 924 17
Axle 16.7

Rimuovere i bracci completi ed il differenziale. Allentare ed asportare le viti (1) e (2) e le rondelle (3) di
ITA Per i dettagli, vedere «CONTROLLO USURA E ITA ritegno coperchio (4), i tappi (5) e (6) di carico e scarico
SOSTITUZIONE DISCHI FRENO» e «RIMOZIONE olio ed il raccordo di sfiato (7).
GRUPPO DIFFERENZIALE». NOTA. Lasciare in posizione per sicurezza due viti (2) contrappo-
ste.

Die kompletten Arme und das Differential abnehmen. Schrauben (1) und (2) abschrauben und die Unter-
D Siehe «VERSCHLEISS KONTROLLIEREN UND D legscheiben (3) zur Halterung des Deckels (4), die
BREMSSCHEIBEN AUSWECHSELN» und «DIFFE- OÈ leinfuÈll- und Ablaûstopfen (5) und (6) sowie das
RENTIALAGGREGAT ABNEHMEN». EndluÈftungsstuÈck (7) abnehmen.
a b BEMERKUNG. Die entgegengesetzten Schrauben (2) zur Sicher-
heit zuruÈck lassen.

Remover los ejes completos y el duferencial. Aflojar y sacar los tornillos (1) y (2) y las arandelas (3)
ESP Para los detalles, vease «CONTROL DESGASTE Y ESP de retencion tapa (4), los tapones (5) y (6) de carga y
SOBSTITUCION DISCOS FRENOS» y «REMOCION descarga aceite y el recorde de escape (7).
GRUPO DIFERENCIAL». NOTA. Dejar en posicion de seguridad dos tornillos (2) contra-
puestas.

Enlever les bras complets et le diffeÂrentiel. Desserrer et enlever les vis (1) et (2), les rondelles (3)
F Pour de plus amples deÂtails, voir "CONTROLE F de fixation du couvercle (4), les bouchons (5) et (6) de
USURE ET SUBSTITUTION DES DISQUES FREIN" remplissage et vidange d'huile et le raccord d'eÂvent (7).
et "DEPOSE DU GROUPE DIFFERENTIEL". REMARQUE. Pour plus de suÃreteÂ, garder deux vis (2) super-
poseÂes.

Utilizzando un mazzuolo in materiale plastico, rimuo- Sistemare tra il corpo riduttore (11) e l'ingranaggio (12)
ITA vere il coperchio (4) ed asportarlo. ITA del pignone un blocchetto "A" di materiale tenero
NOTA. Se si deve intervenire sul gruppo differenziale, (alluminio, ecc.).
rimuovere il gruppo riduttore completo (viti (9) e (10)). Allentare ed asportare il dado (13) di ritegno pignone.

Mit einem Gummihammer den Deckel (4) ausrasten Zwischen dem ReduziererkoÈrper (11) und dem Getrie-
D und abnehmen. D be (12) des Kegelrads einen Block aus weichen
BEMERKUNG. Soll am Differentialaggregat gearbeitet Material einsetzen (Aluminium usw.)
werden, das komplette Reduzieraggregat abnehmen (Schrauben Mutter (13) zur Halterung des Kegelrads abschrauben.
c (9) und (10)). d
Utilizando un martillo en material plastico, remover la Colocar entre el cuerpo reductor (11) y el engranaje
ESP tapa (4) y sacarla. ESP (12) del pinon un bloquete "A" de material tierno
NOTA. Si se debe intervenir sobre el grupo diferen- (aluminio, ect.).
cial, remover el grupo reductor completo (tornillos (9) y (10)). Aflojar y sacar la tuerca (13) de retencion pinon.

A l'aide d'un maillet en matieÁre plastique, deÂplacer le Ajuster, entre le corps reÂducteur (11) et l'engrenage
F couvercle (4) et puis l'enlever. F (12) du pignon, un petit bloc "A" en mateÂriel leÂger
REMARQUE. S'il faut intervenir sur le groupe diffeÂ- (aluminium etc.).
rentiel, enlever le groupe reÂducteur complet (vis (9) et (10)). Desserrer et enlever l'eÂcrou (13) de fixation pignon.

Rimuovere l'ingranaggio del pignone (12) e l'ingra- Scomporre l'ingranaggio conduttore (14) estraendo il
ITA naggio conduttore (14) completo di cuscinetto (15). ITA cuscinetto (15).
NOTA. Per rimuovere l'ingranaggio (14), utilizzare una NOTA. Se necessario, usare un estrattore.
leva.

Das Getriebe (12) des Kegelrads und das Getriebe Das Getriebe (14) zerlegen; dazu das Lager (15)
D (14) samt Lager (15) entfernen. D abziehen.
BEMERKUNG. Um das Getriebe (14) abnehmen zu BEMERKUNG. Wenn noÈtig, einen Abzieher verwen-
koÈnnen, einen Hebel verwenden. den.
e f
Remover el engranaje del pinon (12) y el engranaje Descomponer el engranaje conductor (14) sacando el
ESP conductor (14) completo de cojinete (15). ESP cojinete (15).
NOTA. Para remover el engranaje (14), utilizar una NOTA. Si necesario, usar un extractor.
palanca.

DeÂplacer l'engrenage du pignon (12) et l'engrenage DeÂcomposer l'engrenage conducteur (14) en deÂga-
F conducteur (14) complet de palier (15). F geant le palier (15).
REMARQUE. Pour deÂplacer l'engrenage (14), utiliser REMARQUE. Si besoin, utiliser un extracteur.
un levier.

008 924 17 BOMAG

69 915
16.7DISASSEMBLY OF REDUCTION GEAR AND BEVEL PINION - SMONTAGGIO RIDUTTORE E PIGNONE CONICO - REDUZIERER UND KEGELRADAxle
ABMONTIEREN - REMOCION REDUCTOR Y PINÄON CONICO - DEMONTAGE DU REDUCTEUR ET PIGNON CONIQUE

10
F1241200 F1241201

GB a GB b
Loosen all screws (9) and (10) and remove the upper check screws Connect the whole reduction gear body (11) to a hoist and remove
(9) of the reduction gear body. the screws (10) previously left in place for safety.
NOTE. Leave the two lower screws (10) in position for safety. Using a plastic hammer, pull away the whole reduction gear body
(11).

11 16
17
17
19

16 20

17
F1241202 F1241203

GB c GB d
Position the reduction gear body (11) under a press and, using a Remove distance piece (20) and shims (19) from the pinion(16).
driver, extract the pinion (16) complete with internal bearing (17), Position the pinion under a press and remove the internal bearing
shims (19) and distance piece (20). (17).

21
22 17

11 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).

916 BOMAG
70 008 924 17
Axle 16.7

Allentare tutte le viti (9) e (10) ed asportare le viti (9) Collegare il corpo riduttore completo (11) ad un mezzo
ITA superiori di ritegno del corpo riduttore. ITA di sollevamento ed asportare le viti (10) lasciate in
NOTA. Lasciare in sede le due viti (10) inferiori per sede per sicurezza.
sicurezza. Utilizzando un mazzuolo in materiale plastico, rimuovere il corpo
riduttore (11) completo.

Alle Schrauben (9) und (10) lockern und die oberen Den kompletten ReduziererkoÈrper (11) an ein Hebe-
D Schrauben (9) zur Halterung des ReduziererkoÈrpers D zeug befestigen und die zuvor zur Sicherheit zuruÈck-
abnehmen. gelassenen Schrauben (10) abschrauben.
BEMERKUNG. Die beiden unteren Schrauben (10) zur Sicherheit Mit einem Gummihammer, den kompletten ReduziererkoÈrper (11)
a zuruÈck lassen. b abnehmen.

Aflojar todos los tornillos (9) y (10) y sacar los tornillos Conectar el cuerpo reductor completo (11) a un medio
ESP (9) superiores de retencion del cuerpo reductor. ESP de elevacion y sacar los tornillos (10) dejadas en su
NOTA. Dejar en su lugar los dos tornillos (10) lugar para seguridad.
inferiores para seguridad. Utilizando un martillo en material plastico, remover el cuerpo
reductor (11) completo.

Desserrer toutes les vis (9) et (10), enlever les vis Brancher le corps reÂducteur complet (11) aÁ un moyen
F supeÂrieures (9) de fixation du corps reÂducteur. F de relevage, puis enlever les vis laisseÂe (10) dans leur
REMARQUE. Garder les deux vis infeÂrieures (10) dans sieÁge pour plus de seÂcuriteÂ.
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, Rimuovere dal pignone (16) il distanziale (20) e gli
ITA utilizzando uno spintore, estrarre il pignone (16) ITA spessori (19).
completo di cuscinetto interno (17), spessori (19) ed Posizionare il pignone sotto una pressa e rimuovere il
il distanziale (20). cuscinetto interno (17).

Den ReduziererkoÈrper (11) unter eine Presse legen Vom Kegelrad (16) das DistanzstuÈck (20) und die
D und mit einem StoÈûel das Kegelrad (16) samt dem D Unterlegscheiben (19) abnehmen.
inneren Lager (17), den Unterlegscheiben (19) und Das Kegelrad unter eine Presse legen und das innere
dem DistanzstuÈck (20) abziehen. Lager (17) abnehmen.
c d
Colocar el cuerpo reductor (11) debajo de una prensa Remover del pinon (16) el distancial (20) y los
ESP y, utilizando un empujador (16) completo de cojinete ESP espesores (19).
interno (17), espesores (19) y el distancial (20). Colocar el pinon bajo una prensa y remover el cojinete
interno (17).

Placer le corps reÂducteur (11) sous une presse, aÁ Enlever du pignon (16) l'entretoise (20) et les cales
F l'aide d'un poussoir extraire le pignon (16) complet de F (19).
palier interne (17), cales (19) et entretoise (20). Placer le pignon sous une presse et enlever le palier
interne (17).

Con un estrattore, rimuovere dal corpo riduttore (11) le

ITA ralle dei cuscinetti (17) e (21) e l'anello di tenuta (22). ITA
NOTA. Annotare il senso di montaggio dell'anello di
tenuta (22).

Mit einem Abzieher vom ReduziererkoÈrper (11) die

D Scheiben der Lager (17) und (21) und den Dichtring D
(22) entfernen.
BEMERKUNG. Montagerichtung des Dichtringes (22) notieren.
e f
Con un extractor, remover del cuerpo reductor (11) las
ESP ranguas de los cojinetes (17) y (21) y el anillo de ESP
retencion (22).
NOTA. Anotar el sentido de desmontaje del anillo de retencion
(22).

A l'aide d'un extracteur, enlever le corps reÂducteur

F (11), les crapaudines des paliers (17) et (21) et F
l'anneau d'eÂtancheÂiteÂ (22).
REMARQUE. Prendre note du sens de montage de l'anneau
d'eÂtancheÂiteÂ (22).

008 924 17 BOMAG

71 917
16.7DISASSEMBLY OF REDUCTION GEAR AND BEVEL PINION - SMONTAGGIO RIDUTTORE E PIGNONE CONICO - REDUZIERER UND KEGELRADAxle
ABMONTIEREN - REMOCION REDUCTOR Y PINÄON CONICO - DEMONTAGE DU REDUCTEUR ET PIGNON CONIQUE

16
17
18
19
20

GB a GB b
7

11
9

8 15
14

4
1
13

22 5
21 12
6
GB c GB d
10 2

3
D1240136

GB e GB f

918 BOMAG
72 008 924 17
Axle 16.7

CAUTION! 1 - If disassembly has only been carried ATENCION! 1 - Si el desmontaje ha sido efectuado
GB out to replace the snap ring (22), position the new ring ESP solo para la sobstitucion del anillo de retencion (22),
and reassemble the unit, respecting the tightening proceder al alojamiento del nuevo anillo y remontar el
torques specified in the following section and using the specified grupo respectando los pares de serraje indicadas en el paragrafo
locking and sealing products. siguiente y utilizando los productos de bloqueo y tenida prescritos.
2 - If disassembly is performed to replace either crown wheel and 2 - Si el desmontaje viene efectuado para la sobstitucion del par
pinion, bearings, or planetary gears, take the unit to pieces and find conico, de los cojinetes o de los engranajes satelites, proceder a la
shims and clearances as specified in the sections relative to the descomposicion y a la busqueda de los espesores y de los juegos
removal, disassembly, assembly and installation of the differential como indicados en los paragrafos concernientes la remocion, el
unit and bevel pinion. desmontaje, el asemblaje y la instalacion del diferencial y del pinon
conico.

ATTENZIONE! 1 - Se lo smontaggio eÁ stato eseguito ATTENTION! 1 - Si le deÂmontage n'est effectueÂ que

ITA solo per la sostituzione dell'anello di tenuta (22), F pour substituer l'anneau d'eÂtancheÂiteÂ (22), positionner
procedere al posizionamento del nuovo anello e le nouvel anneau et remonter le groupe en respectant
rimontare il gruppo rispettando le coppie di serraggio indicate nel les couples de serrage indiqueÂs dans le paragraphe suivant aÁ l'aide
paragrafo seguente ed utilizzando i prodotti di bloccaggio e tenuta des produits de blocage et d'eÂtancheÂiteÂ prescrits.
prescritti. 2 - Si le montage est effectueÂ pour substituer le couple conique des
2 - Se lo smontaggio viene eseguito per la sostituzione della coppia paliers et des engrenages satellites, passer aÁ la deÂcomposition et aÁ
conica, dei cuscinetti o degli ingranaggi satelliti, procedere alla la recherche des cales et des jeux comme indiqueÂ dans les
scomposizione ed alla ricerca degli spessori e dei giochi come paragraphes concernant la deÂpose, le deÂmontage, l'assemblage et
indicato nei paragrafi riguardanti la rimozione, lo smontaggio, l'installation du diffeÂrentiel et du pignon conique.
l'assemblaggio e l'installazione del differenziale e del pignone
conico.

ACHTUNG! 1 - Falls das Teil zum Auswechseln des

D 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 Blok-
kierung und Abdichtung verwenden.
2 - Falls das Zerlegen zum Auswechseln des Kegelradpaars, der
Lager oder der Planetengetriebe vorgenommen wird, den An-
weisungen der Paragraphen zum Zerlegen, Abmontieren und
Zusammenbauen sowie zur Installation des Differentials und des
Kegelrads folgen und die StaÈrken und Spiele einhalten.

008 924 17 BOMAG

73 919
16.7 INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UNDAxle
EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE

MEASURE (42.35)
MISURA (42,35)
MAß (42,35) St
MESURA (42,35)
MESURE (42,35) B

MARK
CONTRASSEGNO
C C
B KENNZEICHEN
CONTRASENALACION
11
MARQUAGE

17
F1241205 F1241206

GB a GB b
Mark the thrust block and the internal bearing (17) on a faceplate, Lay two 20 mm gauged blocks "C" on the face of the reduction gear
allow the bearing to set by rotating them in both directions and by body (11). With depth gauge "B" (set to zero at the previous point),
applying a vertical thrust. With a centesimal, digital depth gauge measure space between the "C" blocks and the striking surface of
"B", check overall thickness of bearing (e.g.: 42.35 mm) and set the internal bearing (17). The size obtained (e.g.: 0.81 mm) is the
gauge to zero again. theoretical shim "St" (18) to be inserted under the thrust block of
bearing (17).

DIFFERENTIAL AXIS
ASSE DIFFERENZIALE
DIFFERENTIALACHSE
EJE DEFERENCIAL S
ESSIEU DIFFERENTIEL

Y
X
+ --
DEVIATION "X"
SCOSTAMENTI "X"
ABWEICHUNG "X" S = St + (± X)
DESPLAZAMIENTOS "X"
ECARTS "X"
D1240137
F1241225

GB c GB d
On the bar-hold of pinion (16), check the value "X" (in brackets) To calculate final thickness "S", add the negative value of "X" to
relative to the deviation from the theoretical centre distance. "St" or, alternatively, subtract the positive value of "X".
NOTE. "Y" is the number of pinion/crown coupling. 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
21

F1241227 F1241207

GB e GB f
Using a driver, mount the sealing ring (22) in the reduction unit (11). Place the reduction gear body (11) under a press and, using tool
NOTES. 1 - Carefully check the direction of assembly. T10, insert the thrust block of external bearing (21).
2 - Lubricate the outer surface of the sealing ring. CAUTION! Insert the thrust block of the bearing that is not
countermarked.

920 BOMAG
74 008 924 17
Axle 16.7

Contrassegnare la ralla ed il cuscinetto (17) interno su Appoggiare sul piano di appoggio del corpo riduttore
ITA un piano di riscontro, assestare il cuscinetto con delle ITA (11) due blocchetti calibrati da 20 mm "C". Con il
rotazioni parziali nei due sensi ed esercitando una calibro di profonditaÁ "B" (azzerato nella fase precedente), rilevare la
spinta verticale. Con un calibro di profonditaÁ digitale centesimale misura tra i blocchetti "C" ed il piano di battuta del cuscinetto
"B", rilevare lo spessore totale del cuscinetto (es 42,35 mm) ed interno (17). La misura risultante (es. 0,81 mm) eÁ lo spessore "St"
azzerare il calibro. (18) teorico da inserire sotto la ralla del cuscinetto (17).

Die Scheibe und das innere Lager (17) an einer Auf eine AuflageflaÈche des ReduziererkoÈrpers (11) zwei
D BezugsflaÈche markieren, das Lager durch hin und her D kalibrierte BloÈcke zu 20 mm "C" legen. Mit einer Tiefen-
Drehen und einem senkrechten Druck richtig ein- lehre "B" (zuvor zuruÈckgestellt) das Maû zwischen den BloÈcken "C" und
setzen. Mit einer digitalen hundertteiligen Tiefenlehre "B" die der AnschlagflaÈche des inneren Lagers (17) messen. Das ermittelte Maû
a GesamtstaÈrke des Lagers messen (z.B. 42,35 mm) und die Lehre
zuruÈckstellen.
b (z.B. 0,81 mm) entspricht der theoretischen Unterlegscheibe "St" (18),
die unter die Scheibe des Lagers (17) gelegt werden muû.

Senalar la rangua t el cojinete (17) interno sobre una Colocar sobre la superficie de apoyo del cuerpo reductor
ESP superficie de rescontre, ordenar el cojinete con unas ESP (11) dos bloques calibrados de 20 mm "C". Con el calibre
rotaciones parciales en los dos sentidos y ejercitando de profundidad "B" (azerando en la fase precediente),
un empuje vertical. Con un calibre de profundidad digital centesimal relevar la mesura entre los bloquetes "C" y la superficie del tope del
"B", relevar el espesor total del cojinete (es.:42,35 mm) y azerar el cojinete interno (17). La mesura resultante (es.: 0,81 mm) es el
calibre. espesor "St" (18) teorico de introducir bajo la rangua del cojinete (17).

Estampiller la crapaudine et le palier (17) interne sur DeÂposer sur un plan d'appui du corps reÂducteur (11),
F un marbre de controÃle, ajuster les paliers par des F deux petits blocs calibreÂs aÁ 20 mm "C". A l'aide du
rotations partielles dans les deux sens tout en calibre de profondeur "B" (mis aÁ zeÂro preÂceÂdemment),
poussant verticalement. A l'aide d'un calibre de profondeur relever la mesure existante entre les petits blocs "C" et le plan de
numeÂrique centeÂsimal "B", relever le calage total des paliers (ex. buteÂe du palier interne (17). La mesure reÂsultante (ex. 0,81 mm) est
42,35 mm), mettre le calibre aÁ zeÂro. le calage "St" (18) aÁ introduire sous la crapaudine du palier (17).

Controllare sul codolo del pignone (16) il valore "X" Per calcolare lo spessore "S" definitivo, aggiungere a
ITA (racchiuso tra parentesi) dello scostamento rispetto ITA "St", il valore "X" negativo oppure sottrarre il valore
l'interasse teorico. "X" positivo.
NOTA. Il numero "Y" eÁ il numero di accoppiamento pignone- Es.: Scostamento X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm
corona. 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 Um die endguÈltige StaÈrke "S" auszurechnen, "St" und
D Klammern angegeben) im VerhaÈltnis zum theoreti- D "X" addieren, wenn "X" neÂgatif ist oder "X" von "St"
schen Achsenabstand kontrollieren. abziehen, falls "X" postif ist.
BEMERKUNG. Die Zahl "Y" entspricht dem Kegelrad-Kranz- Beispiel: Abweichung X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm
c Kopplungsgrad. d 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.

Controlar sobre al espigon del pinon (16) el valor "X" Para calcolar el espesor "S" definitivo, adicionar a
ESP (serrado entre parantesis) del desplazamiento respec- ESP "St", el valor "X" negativo o detraer el valor "X"
to al intereje teorico. positivo.
NOTA. El numero "Y" y el numero de acoplamiento pinon-corona. 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" Pour calculer l'eÂpaisseur "S" deÂfinitif, additionner aÁ
F (entre parentheÁses) de l'eÂcart par rapport aÁ l'entraxe F "St" la valeur "X" neÂgative ou soustraire la valeur "X"
theÂorique. positive.
REMARQUE. Le numeÂro "Y" est le numeÂro de l'accouplement Ex. Ecart X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm
pignon-couronne. 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 Sistemare il corpo riduttore (11) sotto una pressa e,
ITA (11) l'anello di tenuta (22). ITA utilizzando l'attrezzo T10 inserire la ralla del cusci-
NOTE. 1 - Controllare attentamente il senso di netto esterno (21).
montaggio. ATTENZIONE! Inserire la ralla del cuscinetto non contrassegnato.
2 - Lubrificare la superficie esterna dell'anello di tenuta.

Mit einem StoÈûel den Dichtring (22) in den Reduzierer- Den ReduziererkoÈrper (11) unter eine Presse legen
D koÈrper (11). D und mit dem Werkzeug T10 die Scheibe des aÈuûeren
BEMERKUNG. 1 - SorgfaÈltig die Montagerichtung des Lagers (21) einsetzen.
Dichtrings kontrollieren. ACHTUNG! Die Scheibe des nicht gekennzeichneten Lagers
e È
2 - Auûere FlaÈche des Dichtrings schmieren. f einsetzen.

Utilizando un espesor, montar en el cuerpo reductor Colocar el cuerpo reductor (11) debajo de una prenso
ESP (11) el anillo de retencion (22). ESP y, utilizando la herramienta T10 insertar la rangua del
NOTA. 1 - Controlar atentamente el sentido de cojinete esterno (21).
montaje. ATENCION! Introducir la rangua del cojinete no segnalado.
2 - Lubrificar la superficie exterior del anillo de retencion.

A l'aide d'un poussoir, monter dans le corps reÂducteur Ajuster le corps reÂducteur (11) sous la presse, aÁ l'aide
F (11) l'anneau d'eÂtancheÂiteÂ (22). F de l'outil T10 introduire la crapaudine du palier
NOTE. 1 - ControÃ ler attentivement le sens de externe (21).
montage. ATTENTION! Introduire la crapaudine du palier non estampilleÂe.
2 - Lubrifier la surface externe de l'anneau d'eÂtancheÂiteÂ.

008 924 17 BOMAG

75 921
16.7 INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UNDAxle
EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE

17 T11

18
21
20
17

F1241208 F1241209

GB a GB b
Turn the reduction gear body (11) upside down and insert shim "S"; Fit tool T12 onto tool T11. Then, install bearings (17) and (21) so
then, with tool T10, insert the thrust block of the internal bearing that they are opposed to each other and spaced by the distance
(17). piece (20).
CAUTION! Insert the thrust block of the countermarked bearing. Position the depth comparator in one of the four radial holes; pre-
set the comparator to 3 ± 4 mm, then set it to zero.

T11
21

T11
F1241210 F1241211

GB c GB d
Remove the bearings from tool T11 and fit them in the thrust blocks Install tool T11 and tighten it manually to obtain a safe rolling
of the reduction gear body. torque.
CAUTION! Check that the countermarked bearing is fitted in the NOTE. During tightening, perform a few rotations to set the
centring hub of the body of the reduction gear and in the bearings.
countermarked thrust block too.

H + 0,13 ÷ 0,15 = S1
19 S1

F1241212 F1241221

GB e GB f
Introduce the previously reset comparator, in one of the four radial The deviation found is to be added to a fixed value of 0.13(0.15
holes and measure. The deviation from zero indicates the nominal mm. in order to: obtain shim "S1" (to be inserted between internal
value "H" relative to the shims that are to be inserted. 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
922 BOMAG
76 008 924 17
Axle 16.7

Capovolgere il corpo riduttore (11) ed inserire lo Montare sull'attrezzo T11 l'attrezzo T12. Quindi mon-
ITA spessore "S" e con l'attrezzo T10 la ralla del ITA tare i cuscinetti (17) e (21) contrapposti ed intervallati
cuscinetto interno (17). con il distanziale (20).
ATTENZIONE! Inserire la ralla del cuscinetto contrassegnato. Posizionare un comparatore di profonditaÁ in uno dei quattro fori
radiali; precaricare il comparatore di 3v4 mm ed azzerarlo.

Den RedurziererkoÈrper (11) wenden und die Unter- Auf das Werkzeug T11 das Werkzeug T12 montieren.
D legscheibe "S" einsetzen; mit dem Werkzeug T10 die D Dann die entgegengesetzten Lager (17) und (21)
Scheibe des inneren Lagers (17) einsetzen. montieren und dazwischen das DistanzstuÈck (20)
ACHTUNG! Die Scheibe des gekennzeichneten Lagers einsetzen. legen.
a b 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 Montar sobre la herramienta T11 la herramienta T12.
ESP "S" y con la herramienta T10 la rangua del cojinete ESP Entonces colocar los cojinetes (17) y (12) contra-
interno (17). puestos y intervalados con el distancial (20).
ATENCION! Introducir la rangua del cojinete segnalado. 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 Monter sur l'outil T11, l'outil T12. Ensuite monter les
F cale "S", et aÁ l'aide de l'outil T10 la crapaudine du F paliers (17) et (21) en les superposant et intercalant
palier interne (17). avec l'entretoise (20).
ATTENTION! Introduire la crapaudine du palier estampilleÂ. 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 Montare l'attrezzo T11 e serrarlo manualmente fino ad
ITA nelle ralle del corpo riduttore. ITA avere una sicura coppia di rotolamento.
ATTENZIONE! Controllare che il cuscinetto contras- NOTA. Durante il serraggio, eseguire alcune rotazioni
segnato sia montato nel mozzo di centratura del corpo riduttore e per assestare i cuscinetti.
quindi nella ralla contrassegnata.

Die Lager vom Werkzeug T11 abnehmen und in den Das Werkzeug T11 montieren und von Hand fest-
D Scheiben des ReduziererkoÈrpers montieren. D ziehen bis ein sicheres Gegenmoment erreicht ist.
ACHTUNG! Kontrollieren, ob das markierte Lager in BEMERKUNG. Beim Festziehen einige Umdrehungen
den Zentriernaben des ReduziererkoÈrpers und folglich in der vornehmen, um die Lager richtig in ihren Sitz zu bringen.
c markierten Scheibe montiert ist. d
Remover los cojinetes de la herramienta T11 y Montar la herramienta T11 y apretarla manualmente
ESP montarlos en las ranguas del cuerpo reductor. ESP hasta obtener una segura pareja de rotacion.
ATENCION! Controlar que el cojinete segnalado sea NOTA. Durante la torsion, efectuar algunas rotaciones
colocado en el cubo central del cuerpo reductor y por lo tanto en la para ordenar los cojinetes.
rangua segnalada.

Oter les paliers de l'outil T11, puis monter ces Monter l'outil T11 et serrer celui-ci aÁ la main jusqu'aÁ
F derniers dans les crapaudines du corps reÂducteur. F obtenir un couple de roulement assureÂ.
ATTENTION! ControÃler que le palier estampilleÂ soit REMARQUE. En serrant, effectuer quelques tours de
monteÂ dans le moyeu de centrage du corps reÂducteur, donc, dans rotation pour ajuster les paliers.
la crapaudine estampilleÂe.

Introdurre in uno dei fori radiali il comparatore Lo scostamento rilevato eÁ da sommare ad una misura
ITA azzerato precedentemente ed eseguire la lettura. ITA fissa di 0,13v0,15 mm, per ottenere lo spessore "S1"
Lo scostamento rispetto lo zero, indica il valore (19) da inserire tra cuscinetto interno (17) e distanziale (20) e
nominale "H" degli spessori da inserire. 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 Die ermittelte Abweichung muû mit einem Festmaû von 0,3 (0,15
D Meûuhr einsetzen und das Maû ablesen. D mm zusammengerechnet werden, um die Unterlegscheibe "S1"
Die Abweichung im VerhaÈltnis zur Null, gibt den (19) zu ermitteln, die zwischen dem inneren Lager (17) und das DistanzstuÈck (20)
Nennwert "H" der einzulegenden Unterlegscheiben an. gelegt werden muû und um die Vorbelastung der Lager festlegen zu koÈnnen.
e f ACHTUNG! Die Messungen sehr sorgfaÈltig vornehmen, da ein Unter-
schied von 0,01 mm das Gegenmoment um 20v40 Ncm veraÈndert.

Introducir en uno de los agujeros radiales el compa- El desplazamiento relevado es de sumarse a una
ESP rador acerado precedentemente y efectuar la lectura. ESP mesura fija de 0,13-0,15 mm, para obtener el espesor
El desplazamiento respecto a lo cero, indica el valor "S1" (19) de introducir entre cojinete interno (17) y distancial (20) y
nominal "H" de los espesores de introducir. 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 L'eÂcart releveÂ est aÁ additionner aÁ la mesure fixe 0,13v0,15 mm
F mis aÁ zeÂro preÂceÂdemment et en faire la lecture. F pour obtenir la cale "S1" (19) aÁ introduire entre le palier interne
L'eÂcart par rapport au zeÂro, indique la valeur nominale (17) et l'entretoise (20) et deÂfinir la preÂcharge eÂtablie pour les paliers.
"H" des cales aÁ introduire. ATTENTION! Effectuer soigneusement les mesurages parce qu'une diffeÂ-
rence de 0,01 mm ameÁne une variation du couple de rotation de 20v40 Ncm.

008 924 17 BOMAG

77 923
16.7 INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UNDAxle
EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE

16
16 11

F1241213 F1241214

GB a GB b
With the help of the press, install the internal, countermarked Fit the pinion (16), the shims (19), the distance piece (20) and the
bearing (17) onto the pinion (16). external bearing (21) into the body of the reduction gear (11) and
CAUTION! Lubricate pinion with oil. assemble the unit with a press.
CAUTION! Lubricate pinion with oil.

23
11
15
12
13

F1241215 F1241216

GB c GB d
Fit the reduction gear (11) into the main body (23) without Fit the gear (12) of the pinion; coat the nut (13) with Loctite 242 and
differential unit; lock temporarily with the two lower screws (9). hand-screw it.
Fit the bearing (15) of the motion in gear and lock it.

12
11

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.

924 BOMAG
78 008 924 17
Axle 16.7

Con la pressa, montare il cuscinetto interno e Montare nel corpo riduttore (11) il pignone (16), gli
ITA contrassegnato (17) sul pignone (16). ITA spessori (19), il distanziale (20) ed il cuscinetto esterno
ATTENZIONE! Lubrificare il pignone con olio. (21) ed assemblare il gruppo con la pressa.
ATTENZIONE! Lubrificare il pignone con olio.

Mit einer Presse, das innere und markierte Lager (17) In den ReduziererkoÈrper (11) das Kegelrad (16), die
D auf das Kegelrad (16) montieren. D Unterlegscheiben (19), das DistanzstuÈck (20) und das
ACHTUNG! Rad mit O È l schmieren. aÈuûere Lager (21) montieren und das Aggregat mit der
Presse zusammenbauen.
a b ACHTUNG! Rad mit O È l schmieren.

Con la prensa, montar el cojinete interno y segnalado Montar en el cuerpo reductor (11) el pinon (16) los
ESP (17) sobre el pinon (16). ESP espesores (19), el distancial (20) y el cojinete esterno
ATENCION! Lubrificar el pinon con aceite. (21) y asemblar el grupo con la prensa.
ATENCION! Lubrificar el pinon con aceite.

A l'aide de la presse, monter le palier interne Monter dans le corps reÂducteur (11), le pignon (16), les
F estampilleÂ (17) sur le pignon (16). F cales (19), l'entretoise (20) et le palier externe (21),
ATTENTION! Lubrifier le pignon avec de l'huile. assembler le groupe aÁ l'aide de la presse.
ATTENTION! Lubrifier le pignon avec de l'huile.

Montare il corpo riduttore (11) sul corpo centrale (23) Montare l'ingranaggio (12) del pignone; spalmare il
ITA privo di differenziale e fissarlo provvisoriamente con le ITA dado (13) con Loctite 242 ed avvitarlo manualmente.
due viti inferiori (9).
Montare il cuscinetto (15) dell'ingranaggio di entrata del moto e
mandarlo in battuta.

Den ReduziererkoÈrper (11) auf den zentralen KoÈrper Das Getriebe (12) des Kegelrads montieren; Mutter
D (23) ohne Differential montieren und voruÈbergehend D (13) mit Loctite 242 schmieren und von Hand
mit den zwei unteren Schrauben (9) befestigen. zuschrauben.
Das Lager (15) des Einganggetriebes montieren und bis zum
c Anschlag einsetzen. d
Montar el cuerpo reductor (11) sobre el cuerpo central Asemblar el engranaje (12) del pinon, pasar la tuerca
ESP (23) sin el diferencial y fijarlo provisoriamente con los ESP (13) con Loctite 242 y atornillarla manualmente.
dos tornillos inferiores (9).
Asemblar el cojinete (15) del engranaje de entrada del movimiento
y mandarlo a tope.

Monter le corps reÂducteur (11) sur le corps central (23) Monter l'engrenage (12) du pignon; enduire l'eÂcrou
F sans diffeÂrentiel et fixer provisoirement ce dernier F (13) avec du Loctite 242 et visser celui-ci aÁ la main.
avec les deux vis infeÂrieures (9).
Monter le palier (15) de l'engrenage d'acceÁs au mouvement, puis
l'envoyer en buteÂe.

Sistemare tra il corpo riduttore (11) e l'ingranaggio (12)

ITA del pignone il blocchetto "A" usato per lo smontaggio ITA
e serrare il dado (13) alla coppia minima di 500 Nm,
utilizzando una chiave a bussola ed una chiave dinamometrica.

Zwischen dem ReduziererkoÈrper (11) und dem Getrie-

D be (12) des Kegelrads den Block «A» legen, der zum D
Abmontieren verwendet wurde, und Mutter (13) mit
einem Anzugsmoment von mindestens 500 Nm mit einem
e InbuûschluÈssel und einem Dynamometer festziehen. f
Colocar entre el cuerpo reductor (11) y el engranaje
ESP (12) del pinon el bloquete "A" usado para el ESP
desmontaje y apretar la tierca (13) al valor minimo
de 500 Nm, utilizando una llave a manguito y una llave
dinamometrica.

Placer, entre le corps reÂducteur (11) et l'engrenage

F (12) du pignon, le petit bloc "A" utiliseÂ au deÂmontage, F
serrer l'eÂcrou (13) au couple minimum de 500 Nm aÁ
l'aide d'une cleÂ aÁ pipe et d'une cleÂ dynamomeÂtrique.

008 924 17 BOMAG

79 925
16.7 INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UNDAxle
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».

926 BOMAG
80 008 924 17
Axle 16.7

Far compiere al pignone alcuni giri nei due sensi per Das Kegelrad um einige Umdrehungen in beide
ITA assestare i cuscinetti. D Richtungen drehen, um die Lager richtig einzusetzen.
Applicare sul pignone (16) il codolo T13 e con un Am Kegelrad (16) den Schaft T13 anbringen und mit
torsiometro, controllare la coppia di rotazione del pignone. einem Drehungsmesser das Gegenmoment des Ke-
Coppia di rotazione: 140v150 Ncm gelrads kontrollieren.
ATTENZIONE! Se la coppia supera il valore massimo bisogna Gegenmoment: 140v150 Ncm.
aumentare lo spessore "S1" (19) tra cuscinetto (17) e distanziale ACHTUNG! Falls der Wert den Maximalwert uÈberschreitet, braucht
(20). es eine groÈûere Unterlegscheibe "S1" (19) zwischen Lager (17) und
Se la coppia di rotazione non raggiunge il valore stabilito, DistanzstuÈck (20).
aumentare la coppia di serraggio del dado (13) in piuÁ tempi fino a Falls das Gegenmoment den festgelegten Wert nicht erreicht, das
raggiungere il valore massimo ammesso di 700 Nm. Anzugsmoment der Mutter (13) schrittweise erhoÈhen, bis der
ATTENZIONE! Se la coppia di rotazione non raggiunge il valore maximal zulaÈssige Wert von 700 Nm erreicht worden ist.
minimo, eÁ necessario diminuire lo spessore "S1" (19). ACHTUNG! Falls das Gegenmoment den Mindestwert nicht
ATTENZIONE! Al fine di poter calcolare gli incrementi o la erreicht, muû die Unterlegscheibe "S1" (19) kleiner sein.
diminuzione dello spessore "S1", eÁ necessario considerare che la ACHTUNG! Um das hoÈhere oder niedrigere Maû der Unter-
variazione dello spessore (19) di 0,01 mm, fa variare la coppia di legscheibe "S1" ausrechnen zu koÈnnen, darauf achten, daû ein
rotazione del pignone (16) di 20v40 Ncm. Unterschied von 0,01 mm der Unterlegscheibe (19) das Gegen-
moment des Kegelrads (16) um 20v40 Ncm aÈndert.

a
Hacer efectuar al pinon algunos giros en los dos Faire faire quelques tours au pignon dans les deux
ESP sentidos para ordenar los cojinetes. F sens de manieÁre aÁ ajuster les paliers.
Aplicar sobre el pinon (16) el codolo T13 y con un Appliquer sur le pignon (16), la queue T13, puis aÁ
torsiometro, controlar el par de rotacion del pinon. l'aide d'un torsiomeÁtre, controÃler le couple de rotation du pignon.
Par de rotacion: 140v150 Ncm. Couple de rotation: 140v150 Ncm.
ATENCION! Si el par supera el valor maximo hay que augmentar el ATTENTION! Si le couple de rotation deÂpasse la valeur maximum,
espesor "S1" (19) entre cojinete (17) y distancial (20). augmenter la cale "S1" (19) entre le palier (17) et l'entretoise (20).
Si el par de rotacion no llega al valor establecido, augmentar el par Si le couple de rotation n'atteint pas la valeur eÂtablie, augmenter le
de torsion de la tuerca (13) en mas tiempos hasta llegar al valor couple de serrage de l'eÂcrou (13), en plusieurs temps, jusqu'aÁ
maximo admitido de 700 Nm. atteindre la valeur maximum admise de 700 Nm.
ATENCION! Si el par de rotacion no llega al valor minimo, es ATTENTION! Si le couple de rotation n'atteint pas la valeur
necesario disminuir el espesor "S1" (19). minimum, diminuer la cale "S1" (19).
ATENCION! Al fin de poder calcular los encrementos o la ATTENTION! Pour pouvoir calculer les augmentations et les
disminuciones del espesor "S1", es necesario considerar que la diminutions de la cale "S1", tenir compte que la diffeÂrence de
variacion del espesor (19) de 0,01 mm, hacer cambiar el par de 0,01 de la cale (19) fait varier le couple de rotation du pignon (16) de
rotacion del pinon (16) de 20v40 Ncm. 20v40 Ncm.

Rimuovere il corpo riduttore completo (11) e procedere

ITA con il montaggio del differenziale e dei bracci.
Per i dettagli, vedere «ASSEMBLAGGIO ED INSTAL-
LAZIONE GRUPPO DIFFERENZIALE - ASSEMBLAGGIO GRUP-
PO FRENO».

Den kompletten ReduziererkoÈrper (11) abnehmen und

D das Differential und die Arme montieren.
Siehe «ZUSAMMENBAU UND INSTALLATION DES
DIFFERENTIALAGGREGATS - ZUSAMMENBAU DES BREMSAG-
b GREGATS».

Remover el cuerpo reductor completo (11) y proceder

ESP con el montaje del diferencial y de los ejes.
Para los detalles, vease «ASEMBLAJE Y INSTALA-
CION GRUPO DIFERENCIAL - ASEMBLAJE GRUPO FRENO».

Enlever le corps reÂducteur complet (11) et aller de

F 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".

008 924 17 BOMAG

81 927
16.7 SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE
Axle
HERRAMIENTAS ESPECIALES - OUTILS SPECIAL

4.3 T1 T2

45°

20
25
1

=
32
32

200
=
90
= =

50
160
110

120± 0.1

120± 0.1
32

25
1

840
45°

10 4.5 930

2313 D1240046 2305 D1240043

T3 Ø40
T4
Ø40
32

3 x45°
3 x45°

150
150

190
195

0
R1
10
0
R1

8
17 13
40
25

32
45

32
32
3 x45°
32
Ø153
32

125
Ø154
20°
Ø178 Ø178
Ø189
Ø184
Ø200

1502 D1240120 1742 D1240121

T5
295
136 10 150
65 3 x45°
27.5
20
3 x15°
-- 0.05

-- 0.4
-- 0.6
-- 0.3
-- 0.4

-- 0.1
Ø80

Ø61

Ø35

Ø25
Ø45
Ø63

Ø46

32 32
0

32
32

107.5 ---- 0.2

0.3

1501 D1240122

928 BOMAG
82 008 924 17
Axle 16.7

75 Ø290
T6
5 Ø271
12
Ø20

Ø16
A Sez. B - B
1° 30'
° 2
32 17

°
17
32

7°
° 30' 17° 30' 1
3x15°
B
Ø150 H 7
Ø150 Hn 67
Ø318
B

43.60
° 17

82.13
113.48
17

134.91
°
17
°
Ø22
Ø16

17
21° 30'
Ø26

Ø22
Ø15

53.14
32
32

12 A
90.26
68 12
119.50
80 82
139.29
Sez. A - A n°2 pezzi
1545 D1240124

119.50 T7
190
53.14
Ø20
Ø16

9
Ø25

32 32
20
0 0 2 x30°
R1 R1 32 1° 30'
° 2
17
°

134.91
17
T7B

82.13
7°
17° 30' 7° 30' 1
Ø161.5 ±0.1

Ø264 ---- 0.15

0.25
Ø185 ---- 0.08
0.12

Ø262 ---- 0.15

0.25
Ø250
Ø172

Ø320

43.60
17°

113.49
32
°
17

17°
R5
'
21° 30
15°
15°
Ø16

5 x15° 90.26
16 20 138.29
110
32

Ø290 ±0.15
143
153
70
T7A 30 30
3 x15° 32
PROFILO HURT 45.5 x 40.5

A
Ø24

R5
Ø150 ---- 0.08
0.12

2
Ø140
Ø30

Ø38

0
R1 0
R1
Ø25 gH 67

Ø24
Ø23,9

40 74
1.2 h 11
200 200
Particolare A 400

1769 D1240125

008 924 17 BOMAG

83 929
16.7 SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE
Axle
HERRAMIENTAS ESPECIALES - OUTILS SPECIAL

T8 T9

5 - +0
.5
-0
Ø9
Ø25

13 ± 0..2
Ø102 +-- 0.2
Ø120
0
3 x45°
160
192

Sez. A-A
0
R1
22 10

0.8 600
Ø40
0.8

Es Ch 22
␣]

15 20
30
Ø]
Ø129

Ø16
] Bearing ref. 32017 DIN720 Acciaio Fe 42
] Ref. cuscinetto 32017 DIN720
] Lager Ref. 32017 DIN720
] Ref. cojinete 32017 DIN720
] ReÂf. palier 32017 DIN720
Acciaio Fe 42

0355 D1240123

Ø85.5

T10

490
Ø40

Ø25
R1
30

0
3 x45°

R2
48

40
10
22
150

A A
188

135

Acciaio 18 Ni Cr Mo 5
Cementazione 0.6÷0.8
Temprato HRC 60÷63
0
R1

35.5

32
1.5

40
8

32
30

3
4.5
32
32

20°
Ø23.9 ±-- 00.05
Ø104
H7
Ø25 g7
Ø109
Ø30
32

-- 0.1
Ø40.5-- 0.15

Ø80
Ø92

1487/B D1240126 1495 D1240128

930 BOMAG
84 008 924 17
Axle 16.7

T11 Ø49.8
T12
Ø41.5

4 x45°

93
M14 x1

40 300

Ø110 2323 D1240127

Ø65

T13
M14 x1
Ch
22
Ø20

20
M14 x1

61 –– 0.01
0.02
R5
3/4"
4"

41
1/
30
25 25

Ø20

Ø9
Ø41.2 +-- 0.03
0 14
195
95

45
35
Ø11

60
10
Ø80
10

wenden Sie sich bitte an:
VS-DI, Herr Sonntag
Tel.: 0221 822-3053
EMail: sonntag.j@deutz.com

Deutz AG
Service Information Systems
Ottostraße 1
D - 51149 Köln
Tel.: + 49 (0) 221-8 22-0
Fax: + 49 (0) 221-8 22-58 50
http://www.deutz.com

Best.-Nr. 0312 4018

© 2001
936 BOMAG 008 924 17
Diesel engine 16.8
VORWORT
Die sachgerechte Ausführung von Reparatur- und Einstellarbeiten ist Voraussetzung für einen
zuverlässigen Motorbetrieb.

In diesem Werkstatthandbuch sind die zweckmäßigen Arbeitsabläufe für anfallende Reparatur-

und Einstellarbeiten an Motor und Motorbauteilen beschrieben. Dabei wird vorausgesetzt, daß die
Arbeiten von qualifiziertem Fachpersonal durchgeführt werden.

Bei der Gestaltung des Werkstatthandbuches wurden im Sinne einer schnellen Erfassung der
Inhalte zusätzlich zu den knapp gehaltenen beschreibenden Texten Bildzeichen gesetzt, die den
jeweils behandelten Arbeitsgang visualisieren.

Betriebs- und Wartungshinweise sind der entsprechenden Betriebsanleitung zu entnehmen.

Zur Ersatzteilbestellung ist die jeweilige Ersatzteilliste zugrunde zu legen.

Das vorliegende Werkstatthandbuch unterliegt keinem Änderungsdienst. Änderungen werden

jeweils bei Neuauflage eingearbeitet.
Beachten Sie bei Reparaturen die Hinweise unserer Technischen Rundschreiben.

Allgemeine Hinweise:

- Lesen und beachten Sie die Informationen dieses Werkstatthandbuches. Sie

vermeiden Unfälle und verfügen über einen funktionstüchtigen und einsatzbereiten
Motor.

- Stellen Sie sicher, daß dieses Werkstatthandbuch jedem an Reparatur- oder

Einstellarbeiten Beteiligten zur Verfügung steht und daß der Inhalt verstanden wird.

- Die Nichtbeachtung dieser Reparaturanleitung kann zu Funktionsstörungen und

Motorschäden sowie Verletzungen von Personen führen, für die vom Hersteller
keine Haftung übernommen wird.

- Die einschlägigen Unfallverhütungsvorschriften sowie die sonstigen allgemeinen

anerkannten sicherheitstechnischen und arbeitsmedizinischen Regeln sind einzu-
halten.

- Voraussetzung für die fachgerechte Reparatur ist die Verfügbarkeit aller erforderli-
chen Ausrüstungen, Hand- und Spezialwerkzeuge sowie deren einwandfreier Zu-
stand.

- Höchste Wirtschaftlichkeit, Zuverlässigkeit und lange Lebensdauer ist nur bei

Verwendung von Original Teilen der DEUTZ AG sichergestellt.

- Motorteile wie Federn, Klammern, elastische Halteringe etc. beinhalten bei unsach-
gemäßer Behandlung erhöhte Verletzungsgefahr.

- Die Instandsetzung des Motors muß der bestimmungsgemäßen Verwendung -

definiert durch den Gerätehersteller - entsprechen. Bei Umbauten dürfen nur von der
DEUTZ AG für den jeweiligen Verwendungszweck freigegebene Teile eingesetzt
werden.

008 924 17 BOMAG 937

16.8 Diesel engine

FOREWORD
Reliable engine operation is dependent on properly executed repairs as well as adjustment work.

This Workshop Manual describes the appropriate operations for any repair and adjustment work
on the engine and engine components. It is presumed that this work will be carried out by qualified
personnel.

This operation manual has been designed for quick and easy understanding. Therefore the concise
text passages are accompanied by pictographs to illustrate the relevant operation.

The Workshop Manual has been laid out to ensure quick comprehension of the contents, i. e
illustrations have been placed adjacent to the brief text passages to clearly show the working
operations.

Aspects of operation and maintenance are dealt with in the respective Operation Manual.

For spare parts orders the respective spare parts catalogue should be referred to.

This Workshop Manual is not subject to engineering change service and is valid until next
issue.

Therefore please refer to the information in our Technical Circulars when carrying out repairs.

General information:

- Please read carefully and observe the instructions given in this Workshop Manual
to avoid accidents and ensure that your engine always functions properly and
reliably.

- Make sure that this Workshop Manual is readily available for all those carrying out
repairs or adjustments and that the contents are well understood.

- Non-compliance with these repair instructions may result in malfunction and engine
damage as well as personal injuries for which the manufacturer shall not accept any
liability.

- The accident prevention regulations and all other generally recognized regulations
on safety and occupational medicine are to be observed.

- A prerequisite for successful repair is that all required equipment, hand and special
tools are available and in perfect working order.

- Optimal operation economy, reliability and durability of the engine can only be
ensured when genuine parts of DEUTZ AG are used.

- Engine components such as springs, clamps, snap rings, etc. may cause injury if not
handled with care.

- Engine repairs must be carried out in accordance with intended use as defined by
the equipment manufacturer. For conversions, only parts approved by DEUTZ AG
for a specific purpose should be used.

938 BOMAG 008 924 17

Diesel engine 16.8
PRÉFACE
Un fonctionnement fiable du moteur suppose l’exécution en bonne et due forme des travaux de
réparation et de réglage.

Le présent Manuel d’atelier décrit la suite des travaux de réparation et de réglage à effectuer sur
le moteur et ses éléments. Cela suppose que les travaux sont réalisés par un personnel spécialisé
et qualifié.

En vue d’une compréhension rapide du contenu, le manuel d’atelier comporte, en plus des textes
brefs, des symboles visualisant l’opération à réaliser.

Le manuel d'atelier a été conçu de manière à assurer une rapide compréhension des textes concis
agrémentés d'illustrations et de symboles visualisant l'opération à effectuer.

Les indications relatives au service et à l’entretien figurent dans les instructions de service
correspondantes.

Pour la commande de pièces de rechange, il convient de se baser sur la liste des pièces de rechange
correspondante.

Le présent manuel d’atelier n’est soumis à aucun service de modifications. Les modifications
seront incorporées à chaque réédition du Manuel.

Pour les réparations, veuillez respecter les indications de nos circulaires techniques.

Remarques générales:

- Veuillez lire attentivement les informations du présent Manuel d’ Atelier et en tenir

compte. Vous éviterez ainsi des accidents et disposerez en même temps d’ un
moteur fonctionnel et en parfait état de marche.

- Assurez-vous que chaque personne chargée des travaux de réparation et de mise

au point dispose bien de ce Manuel d’ Atelier et en comprenne bien le contenu.

- Le non-respect de ces instructions de réparation peut entraîner des pannes, avaries

de moteur et accidents de personnes, pour lesquels le constructeur ne peut en aucun
cas assumer la responsabilité.

- Il convient de respecter les consignes générales de sécurité et de prévention des

accidents en vigueur.

- La condition préalable de la bonne exécution des réparations est la mise à disposition

de tous les équipements, outillages manuels et spéciaux requis, en parfait état de
fonctionnement.

- Seule l’utilisation de pièces de rechange d’origine DEUTZ AG garantit une rentabilité

et fiabilité optimales ainsi qu’une longue durée de vie.

- Les éléments du moteur notamment les ressorts, attaches, bagues élastiques etc.,
peuvent entraîner, en cas de non-respect des prescriptions, des blessures graves.

- La remise en état du moteur doit répondre à son utilisation propre, définie par le
constructeur de l’engin. En cas de modification, seules les pièces autorisées par
DEUTZ AG dans le cas de l’application concernée, peuvent être utilisées.

008 924 17 BOMAG 939

16.8 Diesel engine

PROLOGO
Una ejecución competente de trabajos de reparación y ajuste es requisito fundamental para un
funcionamiento seguro del motor.

En el presente manual para talleres han sido descritos los ciclos convenientes de trabajo para
reparaciones y ajustes del motor y de sus componentes. Se presupone, no obstante, que los
trabajos serán realizados por personal técnico especializado.

Con el fin de simplificar la comprensión del contenido del manual para talleres, se han agregado
símbolos significativos a los textos explicatorios, visualizando así el trabajo a realizar.

Para la rápida comprensión del contenido de los textos breves desciptivos se han introducido en
el manual de taller símbolos que visualizan la operación a realizar.

Informaciones con respecto al manejo y al servicio de entretenimiento del motor, se encuentran

en el Manual de Instrucciones de Servicio correspondiente.

Para pedidos de repuestos servirá de base el respectivo catálogo de repuestos.

El presente manual para talleres no está sujeto a un servicio continuado de modificaciones e

innovaciones. Cada nueva edición incluye todas las modificaciones del caso.

Al efectuar reparaciones, aconsejamos asimismo tomar en cuenta las advertencias pertinentes de

nuestras circulares técnicas.

Advertencias generales:

- Le recomendamos la detenida lectura y observancia de las informaciones con-

tenidas en este Manual de taller. Así evitará accidentes y dispondrá de un motor
que funciona perfectamente.

- Haga lo necesario para que este Manual esté a disposición de toda persona que
participe en trabajos de reparación y ajuste, y cuide de que sí comprenda el
contenido.

- Al no tenerse en cuenta estas instrucciones de reparación, podrán surgir

perturbaciones en el funcionamiento y averías en el motor así como lesiones de
personas para las cuales el fabricante no asume responsabilidad alguna.

- Se cumplirán las normas aplicables para la prevención de accidentes así como todas
las demás normas de seguridad y medicina laboral generalmente aceptadas.

- Es condición para la correcta reparación que estén disponibles todos los requeridos
equipos, herramientas manuales y especiales en perfecto estado.

- Máxima rentabilidad, fiabilidad y larga duración quedan garantizadas únicamente al

emplearse repuestos originales de DEUTZ AG.

- Piezas del motor, tales como resortes, garras, aros de sujeción elásticos, etc. ,
aumentan en caso de tratamiento incorrecto el peligro de lesiones.

- El reacondicionado del motor deberá corresponder al empleo previsto definido por

el fabricante del equipo. En caso de transformaciones, se deberán emplear
únicamente piezas admitidas por DEUTZ AG para el respectivo uso previsto.

940 BOMAG 008 924 17

Inhalts-Verzeichnis
Diesel engine 16.8
Table of Contents
Sommaire
Indice

Technische Daten / Bildzeichenerklärung

Specification data / Key to symbols
Caractéristiques techniques / Légende des symbols
Datos técnicos / Leyenda de símbolos

Prüfen und Einstellen

Checking and adjusting
Contrôle et réglage
Verificación y ajustes

Bauteile instand setzen

Repair of components
Mise en état des composants
Reparación de componentes

Demontage und Montage, Motor komplett

Disassembly and reassembly of complete engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkzeuge
Tools
Outils
Herramientas

008 924 17 BOMAG 941 5

16.8 Diesel engine

942 BOMAG 008 924 17

Diesel engine 16.8
Technische Daten

Specification data

Caractéristiques techniques

Datos técnicos BFM 1012/1013

Hinweis zum Gebrauch des Werkstatthandbuches

In diesem Werkstatthandbuch sind alle technischen Daten, Einstellwerte und
Anziehvorschriften den Stellen zugeordnet, wo sie bei Servicearbeiten, De- und
Montage am Motor benötigt werden.

Notes for the user of this Workshop Manual

In this Workshop Manual all specification data, adjustment values and
tightening specifications are allocated to those parts where they are needed for
service work, disassembly and reassembly on the engine.

Remarque quant à l’utilisazion du Manuel d’atelier

Dans le présent Manuel d’atelier, toutes les caractéristiques techniques, valeurs
de réglage et préconisations de serrage nécessaires se trouvent dans les
chapitres correspondant aux travaux de service après-vente et montage et
démontage du moteur.

Indicación para el uso del manual de taller

En este manual de taller se indican todos los datos técnicos, valores de ajuste y
prescripciones de apriete en los puntos donde son requeridos para la realización
de trabajos de servicio, desmontaje y montaje en el motor.

008 924 17 BOMAG 943

16.8 Diesel engine

944 BOMAG 008 924 17

Diesel engine 16.8

008 924 17 BOMAG 945

16.8 Diesel engine

946 BOMAG 008 924 17

Technische Daten
Diesel engine 16.8
Specification data
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 1012/E, BFM 1013/E

008 924 17 BOMAG 947

Technische Daten
16.8
Specification data Diesel engine
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 1012/E, BFM 1013/E

Deutsch English Français Español

Motorgewicht Engine weight Poids du moteur Peso del motor

nach DIN 70020 - A acc. to DIN 70020 - A selon DIN 70020 - A según DIN 70020 -A
1 ca. kg approx. kg approx. kg aprox. kg

Gesamthubvolumen Engine swept volume Cylindrée totale Cilindrada total

cm3 cm3 cm3 cm3

Bohrung Bore Alésage Calibre

mm mm mm mm

Hub Stroke Course Carrera

mm mm mm mm

Drehrichtung Direction of rotation Sens de rotation Sentido de giro

Nenndrehzahl Rated speed Régime nominal Régimen nominal

max. 1/min max. rpm maxi tr/mn máx. r/min

niedrigste Minimum Ralenti extrême Régimen mín.

Leerlaufdrehzahl idle speed en vacío
1/min rpm tr/mn r/min

Arbeitsweise Working cycle Principe de fonction- Sistema de trabajo

nement

1.00.02
948 BOMAG 008 924 17
Technische Daten
Diesel engine Specification data16.8
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 1012/E, BFM 1013/E

BF4M 1012 BF4M 1012 E BF6M 1012 BF6M 1012 E

BF4M 1013 BF4M 1013 E BF6M 1013 BF6M 1013 E

inklusive Kühlsystem ohne Kühlsystem inklusive Kühlsystem ohne Kühlsystem

incl. cooling system without cooling system incl. cooling system without cooling system
y compris circuit de réfroid. sans circuit de réfroid. y compris circuit de réfroid. sans circuit de réfroid.
incl. sistema de refrige. sin sistema de refrige. incl. sistema de refrige. sin sistema de refrige.
1
380 BFM 1012 330 BFM 1012 E 490 BFM 1012 435 BFM 1012 E
480 BFM 1013 430 BFM 1013 E 625 BFM 1013 570 BFM 1013 E

3192 BFM 1012/ E 4788 BFM 1012/ E

4764 BFM 1013/ E 7146 BFM 1013/ E

94 BFM 1012/ E
108 BFM 1013/ E

115 BFM 1012/ E

130 BFM 1013/ E

auf Schwungrad gesehen links

When facing flywheel counter-clockwise
Vu sur volant à gauche
Mirándose sobre el volante,a la izquierda

2500 BFM 1012/ E

2300 BFM 1013/ E

650

Viertakt - Diesel
Four-stroke diesel
Diesel 4 temps
Diesel a 4 tiempos

1.00.03
008 924 17 BOMAG 949
Technische Daten
16.8
Specification data Diesel engine
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 1012/E, BFM 1013/E

Deutsch English Français Español

Verbrennungs- Combustion Principe de Sistema de

verfahren system combustion combustión
1

Verdichtungs- Compression Taux de Relación de

verhältnis ratio compression compresión

Kompressionsdruck Compression pressure Compression Pressión de

compresión
bar bar bars
bar

Zündfolge Fiing order Ordre d'allumage Orden de

encendido

Abmessungen des Dimensions of Dimensions du Dimensiones del

Motors mit engine incl. moteur avec carter motor con
Anschlußgehäuse standard adapter d'adaption standard caja de adaptación
(normal) housing (normal)

größte Länge Max. length Longueur HT Longitud max.

mm mm mm mm

größte Breite Max. width Largeur HT Anchura máx.

mm mm mm mm

größte Höhe Max. height Hauteur HT Altura máx.

mm mm mm mm

1.00.04
950 BOMAG 008 924 17
Technische Daten
Diesel engine 16.8
Specification data
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 1012/E, BFM 1013/E

BF4M 1012 BF4M 1012 E BF6M 1012 BF6M 1012 E

BF4M 1013 BF4M 1013 E BF6M 1013 BF6M 1013 E

Direkteinspritzung
Direct injection
Injection directe 1
Inyectión directa

17,5 BFM 1012/ E

17,6 BFM 1013/ E

28 - 33 BFM 1012/ E
30 - 38 BFM 1013/ E

1-3-4-2 1-5-3-6-2-4

874 BFM 1012 775 BFM 1012 E 1120 BFM 1012 1003 BFM 1012 E
945 BFM 1013 862 BFM 1013 E 1239 BFM 1013 1146 BFM 1013 E

678 BFM 1012 540 BFM 1012 E 678 BFM 1012 540 BFM 1012 E
685 BFM 1013 616 BFM 1013 E 760 BFM 1013 622 BFM 1013 E

743 BFM 1012 742 BFM 1012 E 834 BFM 1012 827 BFM 1012 E
818 BFM 1013 844 BFM 1013 E 868 BFM 1013 852 BFM 1013 E

1.00.05
008 924 17 BOMAG 951
Technische Daten
16.8
Specification data Diesel engine
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 1012/E, BFM 1013/E

Deutsch English Français Español

Steuerzeiten ohne Valve timing without valve Calage distribution sans Cotas de reglaje sin
Stößel- und Ventilspiel clearance adjusted jeu aux culbuteurs juegos de válvulas y
réglé de empujadores
1

Einlaß öffnet Inlet opens Admission ouvre Admisión abre

vor OT before TDC avant PMH a.PMS

Grad degrees degrés grados

Einlaß schließt Inlet closes Admission ferme Admisión cierra

nach UT after BDC après PMB t.PMI

Grad degrees degrés grados

Auslaß öffnet Exhaust opens Echappement ouvre Escape abre

vor UT before BDC avant PMB a.PMI

Grad degrees degrés grados

Auslaß schließt Exhaust closes Echappement ferme Escape cierra

nach OT after TDC après PMH t.PMS

Grad degrees degrés grados

Absteuerventil Pressurestat Clapet régulateur Válvula reguladora

final final

bar bar bars bar

Schmieröldruck in Lube oil pressure at low Pression d'huile au bas Presión de aceite a
niedrigem Leerlauf idling ralent marcha lenta en vacío
Temperatur ca. 120° C Temperature approx. température ca. 120° C Temperatura aprox. 120° C
Öl SAE 15W/40 120° C oil SAE 15W/40 huile SAE 15W/40 aceite SAE 15W/40

Minimum bar min. bar mini bars mín. bar

1.00.06
952 BOMAG 008 924 17
Technische Daten
Diesel engine 16.8
Specification data
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 1012/E, BFM 1013/E

BF4M 1012 BF4M 1012 E BF6M 1012 BF6M 1012 E

BF4M 1013 BF4M 1013 E BF6M 1013 BF6M 1013 E

46 BFM 1012/ E
46,5 BFM 1013/ E

56 BFM 1012/ E
55,5 BFM 1013/ E

96 BFM 1012/ E
100,5 BFM 1013/ E

50 BFM 1012/ E
51,5 BFM 1013/ E

6 ± 0,75 10 ± 1

0,8

1.00.07
008 924 17 BOMAG 953
Technische Daten
16.8
Specification data Diesel engine
Caractéristiques techniques
Datos técnicos

Werkstatthandbuch BFM 1012/E, BFM 1013/E

954 BOMAG 008 924 17

Diesel engine 16.8

008 924 17 BOMAG 955

Ventilspieleinstellschema
16.8
Schematic for valve clearance adjustment Diesel engine
Schéma de réglage des soupapes
Esquema para el ajuste de holgura de válvulas

Werkstatthandbuch BFM 1012/E, BFM 1013/E

English Français Español

Crankshaft position 1 Position de l’arbre à cames 1 Posición del cigüeñal 1

Kurbelwellenstellung 11 Kurbelwellenstellung 2 1 1 Turn engine until valves of cylinder

No. 1 overlap.
Virer le moteur jusqu'au chevau- Gírese el motor, hasta que las válvulas
chement des soupapes au cylindre 1. del cilindro N° 1 coincidan en su
posición momentánea.
Motor bis zum Erreichen der Ventilüber- Motor um eine volle Umdrehung (360°)
Not ready for adjustment. non réglable no ajustable
schneidung am Zyl. Nr. 1 durchdrehen. weiterdrehen.
Crankshaft position 2: Position de l’arbre à cames 2 Posición del cigüeñal 2

nicht einstellbar einstellbar Turn engine further by one complete Tourner le moteur d’un tour complet Continuese girando el motor por una
revolution (360°). (360°) rotación completa (360°)

Ready for adjustment. réglable ajustable

1.00.09 1.00.09
956 BOMAG 008 924 17
Reihenfolge beim Anziehen der Zylinderkopfschrauben
Tightening
Diesel orderengine
for cylinder head bolts 16.8
Ordre à respecter lors du serrage d’approche et définitif des vis de cul.
Sucesión de los trabajos al apretar los tornillos de culata

Werkstatthandbuch BFM 1012/E, BFM 1013/E

1 1
Krümmerseite, Manifold side, Krümmerseite, Manifold side,
Coté coudes, Lado codo Coté coudes, Lado codo

14 6 4 12 14 6 4 12

18 10 2 8 16 18 10 2 8 16
4-Zylinder 4-Zylinder
4-cylinder 4-cylinder
4-cylindres 4-cylindres
4 cilindros 4 cilindros
17 9 1 7 15 17 9 1 7 15

13 5 3 11 13 5 3 11

Krümmerseite, Manifold side, Krümmerseite, Manifold side,

Coté coudes, Lado codo Coté coudes, Lado codo

22 14 6 4 12 20 22 14 6 4 12 20

26 18 10 2 8 16 24 26 18 10 2 8 16 24
6-Zylinder 6-Zylinder
6-cylinder 6-cylinder
6-cylindres 6-cylindres
6 cilindros 6 cilindros
25 17 9 1 7 15 23 25 17 9 1 7 15 23

21 13 5 3 11 19 21 13 5 3 11 19

1.00.11 1.00.11
008 924 17 BOMAG 957
16.8 Diesel engine

Bildzeichenerklärung

Werkstatthandbuch BFM 1012/E, BFM 1013/E

Bildzeichenerklärung Bildzeichenerklärung
Zerlegen Personenschäden verhüten Zerlegen Personenschäden verhüten

von Baugruppen Hinweis auf Gefahrenstelle von Baugruppen Hinweis auf Gefahrenstelle
1 1
Zusammenbauen Materialschaden verhüten Zusammenbauen Materialschaden verhüten

zu einer Baugruppe Teilbeschädigung zu einer Baugruppe Teilbeschädigung

Abbauen - Ausbauen Unterbauen - Abstützen - Abbauen - Ausbauen Unterbauen - Abstützen -

Abfangen Abfangen
behindernder Teile behindernder Teile

Einbauen - Anbauen Einölen Einbauen - Anbauen Einölen

Teile, die beim Ab-/ Ausbau hinderten Teile, die beim Ab-/ Ausbau hinderten

Achtung, wichtiger Hinweis Einfetten Achtung, wichtiger Hinweis Einfetten

Prüfen - Einstellen Markieren Prüfen - Einstellen Markieren

vor dem Zerlegen, beachten beim vor dem Zerlegen, beachten beim
z. B. Drehmomente, Maße, Drücke usw. Zusammenbau z. B. Drehmomente, Maße, Drücke usw. Zusammenbau

Spezialwerkzeug Wuchten Spezialwerkzeug Wuchten

Ausgleichen von Unwuchten Ausgleichen von Unwuchten

Einbaurichtung beachten Einfüllen - Auffüllen - Nachfüllen Einbaurichtung beachten Einfüllen - Auffüllen - Nachfüllen

z. B. Öl, Kühlwasser usw. z. B. Öl, Kühlwasser usw.

Kontrollieren - Prüfen Ablassen Kontrollieren - Prüfen Ablassen

Sichtprüfung z. B. Öl, Kühlwasser usw. Sichtprüfung z. B. Öl, Kühlwasser usw.

Bedingt wiederverwendbar Lösen Bedingt wiederverwendbar Lösen

Bei Bedarf auswechseln z. B. Lockern einer Spanneinrichtung Bei Bedarf auswechseln z. B. Lockern einer Spanneinrichtung

Beim Zusammenbau immer Spannen Beim Zusammenbau immer Spannen

erneuern erneuern
z. B. Anziehen einer Spanneinrichtung z. B. Anziehen einer Spanneinrichtung

Entsichern - Sichern Entlüften Entsichern - Sichern Entlüften

z. B. Splint, Sicherungsblech usw. z. B. Splint, Sicherungsblech usw.

Sichern - Kleben Spanabhebende Bearbeitung Sichern - Kleben Spanabhebende Bearbeitung

z. B. Dichtmittel flüssig z. B. Dichtmittel flüssig

1.00.21 1.00.21
958 BOMAG 008 924 17
Diesel engine 16.8
Key to Symbols

Werkstatthandbuch BFM 1012/E, BFM 1013/E

Key to Symbols Key to Symbols

Disassembly Guard against personal injury Disassembly Guard against personal injury

of assembly groups Indication of hazard of assembly groups Indication of hazard

1 1
Reassemble Guard against material damage Reassemble Guard against material damage

to form assembly group Damage to parts to form assembly group Damage to parts

Remove Prop up - Support - Hold Remove Prop up - Support - Hold

obstructing parts obstructing parts

Reinstall - Remount Oil Reinstall - Remount Oil

parts which had obstructed disassembly parts which had obstructed disassembly

Attention! Important notice! Grease Attention! Important notice! Grease

Check - Adjust Mark Check - Adjust Mark

before disassembly, observe marks when before disassembly, observe marks when
e.g. torque, dimensions, pressures, etc. reassembling e.g. torque, dimensions, pressures, etc. reassembling

Special tool Balance Special tool Balance

Eliminate any imbalance Eliminate any imbalance

Note direction of installation Filling - Topping up - Refilling Note direction of installation Filling - Topping up - Refilling

e. g. oil, cooling water, etc. e. g. oil, cooling water, etc.

Visual inspection Drain off Visual inspection Drain off

e. g. oil cooling water, etc. e. g. oil cooling water, etc.

Possibly still serviceable Loosen - Release Possibly still serviceable Loosen - Release

Renew if necessary e. g. loosening a clamping device Renew if necessary e. g. loosening a clamping device

Renew at each reassembly Tighten - Clamp Renew at each reassembly Tighten - Clamp

e. g. tightening a clamping device e. g. tightening a clamping device

Unlock - Lock Vent Unlock - Lock Vent

e. g. splint pin, locking plate, etc. e. g. splint pin, locking plate, etc.

Lock - Adhere Machining process Lock - Adhere Machining process

e.g. with liquid sealant e.g. with liquid sealant

1.00.21 1.00.21
008 924 17 BOMAG 959
16.8 Diesel engine

Légende des symboles

Werkstatthandbuch BFM 1012/E, BFM 1013/E

Légende des symboles Légende des symboles

Déassemblage Prévention aux accidents profession Déassemblage Prévention aux accidents profession

d'un ensemble constructif attirer l’attention sur un risque eventuel d'un ensemble constructif attirer l’attention sur un risque eventuel
d’accident
1 1 d’accident

Assemblage Prévention à la détérioration de Assemblage Prévention à la détérioration de

matériels matériels
des composants d’un ensemble constructif Risque d’endommager des piéces des composants d’un ensemble constructif Risque d’endommager des piéces

Démontage Monter sur tréteaux - freiner par Démontage Monter sur tréteaux - freiner par
sabots - immobiliser par un moyen sabots - immobiliser par un moyen
d’éléments entravant l’accés quelconque d’éléments entravant l’accés quelconque

Remontage - Remise en place Huiler Remontage - Remise en place Huiler

d’éléments qui entravaient l’accés d’éléments qui entravaient l’accés

Remarque importante! Graisser Remarque importante! Graisser

employer lubrificant plastique employer lubrificant plastique

Utilisation impérative Repérage en cours de démontage Utilisation impérative Repérage en cours de démontage

p.ex.: couple-moteur, cotes, pressions etc. perment un remontage correct! p.ex.: couple-moteur, cotes, pressions etc. perment un remontage correct!

Utilisation impérative Equilibrer Utilisation impérative Equilibrer

d’un outil specialise éliminer le balourd d’un outil specialise éliminer le balourd

Respecter l’ordre de montage Premier garnissage - remplissage - Respecter l’ordre de montage Premier garnissage - remplissage -
garnissage d’appoint garnissage d’appoint
p. ex.: Huile eau de refroidissement etc. p. ex.: Huile eau de refroidissement etc.

Vérification - Contrôle Vidanger - soutirer Vérification - Contrôle Vidanger - soutirer

à vue p. ex.: Huile eau de refroidissement etc. à vue p. ex.: Huile eau de refroidissement etc.

Réutilisation sous certaines Desserrer Réutilisation sous certaines Desserrer

conditions conditions
à remplacer, si besoin est p. ex.: desserrage d’un dispositiv à remplacer, si besoin est p. ex.: desserrage d’un dispositiv

A remplacer systématiquement Serrer A remplacer systématiquement Serrer

lors de remontage p. ex.: serrage entre un dispositif lors de remontage p. ex.: serrage entre un dispositif

Arracher la goupille - goupiller Faire la purge d’air Arracher la goupille - goupiller Faire la purge d’air

freiner par tôle-arrétoir freiner par tôle-arrétoir

Freiner - coller Usinage par enlèvement de copeaux Freiner - coller Usinage par enlèvement de copeaux

p. ex.: avec páte hermétique, ou frein liquide p. ex.: avec páte hermétique, ou frein liquide

1.00.21 1.00.21
960 BOMAG 008 924 17
Diesel engine 16.8
Leyenda de símbolos

Werkstatthandbuch BFM 1012/E, BFM 1013/E

Leyenda de símbolos Leyenda de símbolos

Desarmar Evitar accidentes Desarmar Evitar accidentes

grupos de construcción indica puntos peligro grupos de construcción indica puntos peligro
1 1
Rearmar Evitar daños materiales Rearmar Evitar daños materiales

un grupo de construcción avería de piezas un grupo de construcción avería de piezas

Desmontar Calzar - Apoyar Desmontar Calzar - Apoyar

partes que puedan estorbar partes que puedan estorbar

Montar - Incorporar Aceitar Montar - Incorporar Aceitar

partes que puedan estorbar en el desmontaje partes que puedan estorbar en el desmontaje

!Atención! Indicación importante Engrasar !Atención! Indicación importante Engrasar

Verificar - Graduar - Ajustar Marcar Verificar - Graduar - Ajustar Marcar

antes del desmontaje - controlar la antes del desmontaje - controlar la
(p. ej. pares, medidas, presiones) marcación en el remontaje (p. ej. pares, medidas, presiones) marcación en el remontaje

Herramienta especial Equilibar Herramienta especial Equilibar

Eliminar desequilibros o excentricidades Eliminar desequilibros o excentricidades

Observar la dirección de montaje Llenar - Rellenar - Completar Observar la dirección de montaje Llenar - Rellenar - Completar

p. ej. aceite, agua refrigerante, etc. p. ej. aceite, agua refrigerante, etc.

Control - Examen Evacuar - Vaciar Control - Examen Evacuar - Vaciar

verificatión visual p. ej. aceite, agua refrigerante, etc. verificatión visual p. ej. aceite, agua refrigerante, etc.

Re - utilización condicional Soltar Re - utilización condicional Soltar

sustituir en caso necesario p. ej. un sistema de fijación o tensado sustituir en caso necesario p. ej. un sistema de fijación o tensado

Sustituir en cada montaje Tensar - Apretar Sustituir en cada montaje Tensar - Apretar

p. ej. un sistema de fijación o tensado p. ej. un sistema de fijación o tensado

Desafianzar - Afianzar (mecánicamente) Purgar el aire Desafianzar - Afianzar (mecánicamente) Purgar el aire
(p. ej. pasador de aletas, chapa de seguridad, (p. ej. pasador de aletas, chapa de seguridad,
etc). etc).

Afianzar - Pegar Mecanización con arranque de Afianzar - Pegar Mecanización con arranque de
virutas virutas
p. ej. con medio liquido p. ej. con medio liquido

1.00.21 1.00.21
008 924 17 BOMAG 961
16.8 Diesel engine
Prüfen und Einstellen

Checking and adjusting

Contrôle et réglage

Verificación y ajustes BFM 1012/1013

962 BOMAG 008 924 17

Diesel engine 16.8

008 924 17 BOMAG 963

Inhalts-Verzeichnis Prüfen und Einstellen
16.8Table of Contents Checking andengine
Diesel adjusting
Sommaire Contrôle et réglage
Indice Verificación y ajustes

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

2. Prüfen und Einstellen Seite

Ventilspiel _______________________________________ 2.00.01 - 2.00.02

Kompressionsdruck _______________________________________ 2.00.03 - 2.00.04
-

English

2. Checking and adjusting Page

Valve clearance _______________________________________ 2.00.01 - 2.00.02

Compression pressure _______________________________________ 2.00.03 - 2.00.04 2
-

Français

2. Contrôle et réglage Page

Jeu aux soupapes _______________________________________ 2.00.01 - 2.00.02

Taux de compression _______________________________________ 2.00.03 - 2.00.04
-

Español

2. Verificación y ajustes Pagina

Juego de válvulas _______________________________________ 2.00.01 - 2.00.02

Presión de compresión _______________________________________ 2.00.03 - 2.00.04
-

964 BOMAG 008 924 17

Prüfen und Einstellen Ventilspiel
Checking
Dieseland adjusting
engine 16.8
Valve clearance
Contrôle et réglage Jeu de soupapes
Verificación y ajustes Holgura de válvulas

English Français Español

Special tool required: Outillage usuel: Herramienta especial:

Turning gear 100 320 Dispositif vireur 100 320 Dispositivo de viraje 100 320
Turning gear 100 330 Dispositif vireur 100 330 Dispositivo de viraje 100 330

The standard valve clearance can be Le réglage standard du jeu aux El ajuste del juego estándar de válvulas
adjusted: soupapes est possible: es posible:

with engine cold or warm after cooling Sur moteur froid ou chaud après une Con el motor frío o, según el caso,
down for at least 0.5 h. période de refroidissement d’au moins caliente después de transcurrir por lo
Oil temperature ≤ 80°C. 30 mi-nutes. Température de l’huile ≤ menos media hora para su
80°C. enfriamiento. Temperatura del aceite:
≤ 80°C.

Note: The valve clearance is to be Nota: à chaque changement du joint Nota: Cada vez que se cambia la junta
increased by 0.1 mm at every de culasse augmenter le jeu aux de la culata, debe aumentarse el
cylinder head gasket renewal. culbuteurs de 0,1 mm. juego por 0,1 mm.
The standard valve clearance is Après 50-150 heures de marche Tras 50-150 horas de servicio
2 to be adjusted after completion procéder au réglage standard se ajustará el juego estándar.
of 50-150 hours of operation. des culbuteurs.

Cylinder head cover and crankcase Le cache-culbuteurs et l’évent de La tapa de culatas y la ventilación del
breather have been removed carter ont été déposés. cárter del cigüeñal están
desmontadas.

1. Turn engine until valves of cyl. 1. Virer le moteur jusqu’à ce que les 1. Girar el cigüeñal hasta que se
No. 1 overlap. soupapes soient en bascule, crucen las válvulas en el cilindro 1.
cyl. no. 1.

See specification data for valve Schéma de réglage du jeu aux Para el esquema de ajuste del juego
clearance adjustment schematic. culbuteurs voir caractéristiques de válvulas, véanse los Datos
techniques. Técnicos.

1.1 If the engine is not freely accessible 1.1 Si la poulie à gorge du moteur 1.1 Si el motor no ofrece un libre
at the V-belt pulley, turning gear n´est pas bien accessible, utiliser, acceso a la polea acanalada, es
100 320 may be used with the après avoir déposé la pompe posible utilizar el dispositivo de
hydraulic pump removed. hydraulique, le dispositif vireur viraje 100 320, una vez
100 320. desmontada la bomba hidráulica.

Note: Valves overlapping means: Nota: le chevauchement des Nota: Cruce de válvulas significa:
Exhaust valve about to close. soupapes signifie: La válvula de escape aún no
Inlet valve about to open. soupaped’échappement n’est está cerrada y la de admisión
Neither pushrod can be turned pas encore fermée et soupape comienza a abrirse. En este
in this position. d’admission commence à momento, no es posible girar
s’ouvrir. Les deux tiges de las dos varillas de empuje.
culbuteurs ne peuvent plus
tourner.

2.00.01
008 924 17 BOMAG 965
Ventilspiel Prüfen und Einstellen
16.8Valve clearance Checking andengine
Diesel adjusting
Jeu de soupapes Contrôle et réglage
Holgura de válvulas Verificación y ajustes

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Spezialwerkzeug:

Durchdrehvorrichtung ____________ 100 320

Durchdrehvorrichtung ____________ 100 330

Die Standard-Ventilspieleinstellung ist möglich:

Am kalten- oder am warmen Motor nach einer

Abkühlzeit von mindestens 0,5 h.
Öltemperatur ≤ 80° C

Hinweis: Bei jedem Zylinderkopf-Dichtungs-

wechsel ist das Ventilspiel um 0,1 mm
zu erhöhen.
9
Nach 50-150 Bh ist das Standard-
Ventilspiel einzustellen. 7 Neues Bild 38-2-3
2
mit Durvchdreh-
Zylinderkopfhaube und vorrichtung
Kurbelgehäuseentlüftung ist abgebaut.

1. Motor durchdrehen bis zum Erreichen der

Ventilüberschneidung, Zyl. Nr. 1

Ventilspieleinstellschema siehe Techn. Daten 9

7 Änderung von 38-2-1
1.1 Ist der Motor an der Keilriemenscheibe nicht 100 320
frei zugänglich, kann bei abgebauter Hydrau-
likpumpe die Durchdrehvorrichtung 100 320
verwendet werden.

Hinweis: Ventilüberschneidung bedeutet:

Auslaßventil ist noch nicht geschlos-
sen, Einlaßventil beginnt zu öffnen.
9
Dabei sind beide Stoßstangen nicht
drehbar.
5

2.00.01
966 BOMAG 008 924 17
Prüfen und Einstellen Ventilspiel
Checking
Dieseland adjusting
engine 16.8
Valve clearance
Contrôle et réglage Jeu de soupapes
Verificación y ajustes Holgura de válvulas

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

2. Ventilspieleinstellung am entsprechenden
Neues Bild mit Schraubendreher 6 Zylinder mit Fühlerlehrenblatt einstellen.
Änderung von 28-2-4
5 Hinweis: Ventilspiel Einlaß: _______ 0,3 mm
Ventilspiel Außlaß: _______ 0,5 mm

3. Kontermutter mit einem Drehmoment von

20 ± 2 Nm festdrehen. Einstellung nochmals
mit Fühlerlehrenblatt überprüfen.

4. Dichtung aufsetzen.
2
2 0

5. Zylinderkopfhaube und Abdeckblech montie-

4 ren. Schrauben mit einem Drehmoment von
9 ± 1 Nm festdrehen.

6. Kurbelgehäuseentlüftung anbauen.
4 Schrauben mit einem Drehmoment von
9 ± 1 Nm festdrehen.

2.00.02
008 924 17 BOMAG 967
Ventilspiel Prüfen und Einstellen
16.8
Valve clearance Checking andengine
Diesel adjusting
Jeu de soupapes Contrôle et réglage
Holgura de válvulas Verificación y ajustes

English Français Español

2. Adjust valve clearance on respec- 2. Régler le jeu aux soupapes au 2. Ajustar el juego de válvulas en el
tive cylinder with feeler gauge. cylindre correspondant avec une cilindro correspondiente con la
jauge d’épaisseur. galga de espesores.

Note: Inlet valve clearance: 0.3 mm Nota: Jeu soupape ADM: 0,3 mm Nota: Juego de válvulas
Exhaust valve Jeu soupape ECH: 0,5 mm - admisión: 0,3 mm
clearancee: 0.5 mm - escape: 0,5 mm

3. Tighten locknut with a torque of 3. Serrer le contre-écrou au couple de 3. Apretar la contratuerca con un par
20 ± 2 Nm. Recheck the adjust- 20 ± 2 Nm. Effectuer un nouveau de 20 ± 2 Nm. Comprobar
ment with feeler gauge. contrôle du serrage avec une jauge nuevamente el ajuste efectuado,
d’épaisseur. con la galga de espesores.

4. Position gasket in place. 4. Mettre en place le joint. 4. Poner la junta en su sitio.

5. Fit cylinder head cover and cover 5. Monter le cache-culbuteurs et la 5. Montar la tapa de culata y la chapa
plate. Tighten bolts with a torque of tôle de recouvrement. Serrer de recubrimiento. Apretar los
9 ± 1 Nm. les vis au couple de 9 ± 1 Nm. tornillos con un par de 9 ± 1 Nm.

6. Fit crankcase breather. Tighten 6. Monter l’évent de carter. Serrer les 6. Montar el sistema de ventilación
bolts with a torque of 9 ± 1 Nm. vis au couple de 9 ± 1 Nm. del cárter. Apretar los tornillos con
un par de 9 ± 1 Nm.

2.00.02
968 BOMAG 008 924 17
Prüfen und Einstellen Kompressionsdruck
Checking
Dieseland adjusting
engine 16.8
Compression pressure
Contrôle et réglage Taux de compression
Verificación y ajustes Presión de compresión

English Français Español

Commercial tools required: Outillage usuel: Herramientas corrientes en el

comercio:

Compression tester 8005 Compressiomètre 8005 Compresímetro 8005

Torx tool kit 8189 Jeu d’outils Torx 8189 Juego de herramientas Torx 8189

Special tool required: Outil spécial: Herramienta especial:

Connector 100 110 Pièce de raccordement 100 110 Pieza de empalme 100 110

Injectors have been removed, valve Les injecteurs ont été déposés et le Los inyectores están desmontados y
clearance has been checked. jeu aux soupapes contrôlé. el juego de válvulas controlado.

1. Insert connector with new special 1. Mettre en place la pièce de 1. Introducir la pieza de empalme con
2 seal. raccordement avec un joint spécial una junta especial nueva.
neuf.

2. Fit clamping pad. Tighten bolt. 2. Placer la griffe de serrage et serrer 2. Colocar la garra de sujeción.
le boulon. Apretar el tornillo.

3. If necessary, screw on adapter for 3. Si nécessaire mettre en place 3. De ser necesario, enroscar el
connector. l’adaptateur de la pièce de adaptador de la pieza de empalme.
raccordement.

2.00.03
008 924 17 BOMAG 969
Kompressionsdruck Prüfen und Einstellen
16.8Compression pressure Checking andengine
Diesel adjusting
Taux de compression Contrôle et réglage
Presión de compresión Verificación y ajustes

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Handelsübliche Werkzeuge:

Kompressionsdruckprüfer ____________ 8005

Torx-Werkzeugsatz _________________ 8189

Spezialwerkzeug:

Anschlußstück __________________ 100 110

Einspritzventile sind ausgebaut, Ventilspiel ist

kontrolliert
4
1. Anschlußstück mit Dichtung der Einspritzdüse
einsetzen 7 2
0

2. Spannpratze aufsetzen. Schraube fest-

drehen. 4

3. Falls notwendig Adapter für Anschlußstück

aufschrauben.
4

2.00.03
970 BOMAG 008 924 17
Prüfen und Einstellen Kompressionsdruck
Checking
Dieseland adjusting
engine Compression pressure16.8
Contrôle et réglage Taux de compression
Verificación y ajustes Presión de compresión

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

4. Kompressionsdruckprüfer anschließen.
4 Motor mit Starter durchdrehen.
Kompressionsdruck: BFM 1012 28-33 bar

6 BFM 1013 30-38 bar

Der gemessene Kompressionsdruck ist

abhängig von der Anlaßdrehzahl während des
Meßvorganges und der Höhenlage des Motor-
aufstellortes.
9 Grenzwerte sind daher nicht genau festlegbar.
Empfohlen wird die Kompressionsdruck-

2 5 messung nur als Vergleichsmessung aller

Zylinder eines Motors untereinander anzusehen.
Sind mehr als 15% Abweichung ermittelt
worden, sollte durch die Demontage der
betroffenen Zylindereinheit die Ursache
ermittelt werden.

Hinweis: Einspritzventile mit neuen Spezial-

dichtungen einsetzen. Spannpratzen
aufsetzen und Schrauben lose ein-
schrauben.
Neue Einspritzleitungen anbauen.
Überwurfmuttern fingerfest auf-
schrauben.
Die Dichtkonen müssen exakt aufein-
andersitzen.
Ein Nachbiegen ist nicht zulässig.
Die Einspritzleitungen dürfen nicht
2x verwendet werden.
Schrauben der Spannpratzen mit
einem Drehmoment von 16 + 5 Nm
festdrehen. Überwurfmuttern der
Einspritzleitungen an den Einspritz-
pumpen und Einspritzventilen mit
einem Drehmoment von ca. 5 Nm
vorspannen. Danach die Überwurf-
muttern mit einem Drehmoment von
25 + 3,5 Nm festdrehen.
Leckölleitungen sind grundsätzlich
zu erneuern.
Zylinderkopfhaube mit einem Dreh-
moment von 9 ± 1 Nm festdrehen.

2.00.04
008 924 17 BOMAG 971
Kompressionsdruck Prüfen und Einstellen
16.8
Compression pressure Checking andengine
Diesel adjusting
Taux de compression Contrôle et réglage
Presión de compresión Verificación y ajustes

English Français Español

4. Connect compression tester. Turn 4. Brancher le compressiomètre. 4. Conectar el compresímetro. Girar el

engine with starter. motor con ayuda del arrancador.
Compression pressure: Pression de compression: Presión de compresión:
BFM 1012 28-33 bar BFM 1012 28-33 bars BFM 1012 28-33 bar
BFM 1013 30-38 bar BFM 1013 30-38 bars BFM 1013 30-38 bar

The measured compression pressure Le taux de compression mesuré El valor de compresión medido
is dependent on the starting speed dépend de la vitesse de démarrage depende de la velocidad de arranque
during the measuring process and also pendant le relevé des mesures, et du durante la medición y de la altitud del
on the altitude of the engine site. niveau du lieu d’implantation du lugar de instalación del motor.
Therefore it is difficult to specify moteur. Por tanto, no es posible fijar valores
precise limit values. It is recommended Des valeurs limites précises ne límite exactos. La medición de
to use the compression pressure peuvent donc pas être fixées. Il est compresión se aconseja solamente
measurement only for comparison of conseillé de considérer la mesure du como una medida de comparación 2
compression pressures of all cylinders taux de compression uniquement entre todos los cilindros de un mismo
in one engine. If a difference in comme mesure comparative pour tous motor, Si se verifican diferencias
pressure in excess of 15% is deter- les cylindres d’un moteur. En cas superiores al 15%, es conveniente
mined, the cylinder unit concerned d’écart supérieur à 15%, la cause buscar la causa, desmontando la
should be dismantled to establish the pourra être déterminée en démontant unidad de cilindro afectada.
cause. l’unité cylindre concernée.

Note: Fit injectors with new special Nota: Utiliser des injecteurs avec de Nota: Montar los inyectores provistos
seals. Position clamping pads nouveaux joints spéciaux. Placer de juntas especiales nuevas.
and start bolts. les griffes de serrage et serrer Colocar las patas de sujeción y
Fit new injection lines. Screw on les vis sans serrer. enroscar los tornillos, dejándo-
cap nuts fingertight. Monter des conduites d’injection los sueltos.
The sealing cones must match neuves. Montar tuberías de inyección
precisely. Serrer les écrous-raccords mo- nuevas. Enroscar las tuercas de
Rebending is not permissible. dérément à la main. empalme con la mano.
The injection lines may not be Les cônes d´étanchéité doivent Los conos de obturación deben
used twice. parfaitement correspondre. quedar asentados uno exacta-
Tighten bolts of clamping pads Un recintrage n’est pas auto- mente sobre el otro.
with a torque of 16 + 5 Nm. risé. Ne jamais utiliser deux Es inadmisible corregir el cur-
Preload cap nuts of injection fois les conduites d’injection. vado. La tuberías de inyección
lines on injection pumps and Bloquer les vis des griffes de no deben ser empleadas dos
injectors with a torque of serrage au couple de 16 + 5 Nm. veces.
approx. 5 Nm. Thereafter tighten Préserrer les écrous-raccords Apretar los tornillos de las patas de
cap nuts with a torque of 25 + des conduites d’injection et injec- sujeción con un par de 16 + 5 Nm.
3.5 Nm. teurs au couple d’environ 5 Nm. Apretar las tuercas de empalme
Leakage fuel lines must always Ensuite bloquer les écrous-rac- de las tuberías de inyección en
be renewed. cords au couple de 25 + 3,5 Nm. las bombas de inyección e in-
Tighten cylinder head cover with Toujours renouveller les con- yectores inicialmente con un par
a torque of 9 ± 1 Nm. duites de retour des fuites. de aprox. 5 Nm y, luego, con un
Bloquer le cache-culasse au par de 25 + 3,5 Nm.
couple de 9 ± 1 Nm. Las tuberías de combustible
sobrante han de sustituirse
siempre por otras nuevas.
Apretar la tapa de culatas con un
par de 9 ± 1 Nm.

2.00.04
972 BOMAG 008 924 17
Prüfen und Einstellen
Checking
Dieseland adjusting
engine 16.8
Contrôle et réglage
Verificación y ajustes

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

008 924 17 BOMAG 973

16.8 Diesel engine
Bauteile instand setzen

Repair of components

Mise en état des composants

Reparación de componentes BFM 1012/1013

974 BOMAG 008 924 17

Diesel engine 16.8

06 07
19 11

08
38
27

10 39
83
01 38

15
17
05

83 05
33

72
01

008 924 17 BOMAG 975

16.8 Diesel engine

976 BOMAG 008 924 17

Diesel engine 16.8

008 924 17 BOMAG 977

Hydraulikpumpe mit Befestigungsflansch Bauteile instand setzen
16.8Hydraulic pump with fastening flange Repair of components
Diesel engine
Pompe hydraulique avec bride de fixation Mise en état des composants
Bomba hidráulica con brida de fijación Reparación de componentes

978 BOMAG 008 924 17

Bauteile instand setzen Hydraulikpumpe mit Besfestigungsflansch
Repair of components
Diesel engine Hydraulic pump with fastening flange16.8
Mise en état des composants Pompe hydraulique avec bride de fixation
Reparación de componentes Bomba hidráulica con brida de fijación

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

5. Neue Dichtung und Befestigungsflansch

2 auf Hydraulikpumpe auflegen.

6. Zahnrad montieren.
2 Hinweis: Auf Vorhandensein der Paßfeder

5 achten.

7. Mutter mit einem Drehmoment von 80 Nm

2 festdrehen.

3
6

3.83.118
008 924 17 BOMAG 979
Hydraulikpumpe mit Befestigungsflansch Bauteile instand setzen
16.8
Hydraulic pump with fastening flange Repair of components
Diesel engine
Pompe hydraulique avec bride de fixation Mise en état des composants
Bomba hidráulica con brida de fijación Reparación de componentes

English Français Español

5. Place new gasket together with 5. Placer un joint neuf et la bride de 5. Colocar una junta nueva y la brida
fastening flange on hydraulic fixation sur la pompe hydraulique. de fijación sobre la bomba
pump. hidráulica.

6. Mount gear. 6. Monter le pignon. 6. Montar la rueda dentada.

Note: Make sure that key is inserted. Nota: veiller à la présence de la Nota: Las lengüetas de ajuste deben
clavette. estar en su sitio.

7. Tighten nut with a torque of 7. Serrer l’écrou au couple de 7. Apretar la tuerca con un par de
80 Nm. 80 Nm. 80 Nm.

3.83.118
980 BOMAG 008 924 17
Bauteile instand setzen
Repair of components
Diesel engine 16.8
Mise en état des composants
Reparación de componentes

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

008 924 17 BOMAG 981

16.8 Diesel engine
Demontage und Montage, Motor komplett

Disassembly and reassembly of complete engine

Démontage et montage moteur complet

Despiece y ensamblado conjunto de moteur

BFM 1012/1013

982 BOMAG 008 924 17

Diesel engine 16.8

008 924 17 BOMAG 983

Inhalts-Verzeichnis Demontage und Montage, Motor komplett
16.8Table of Contents Disassembly and reassembly ofDiesel
complete engine
engine
Sommaire Démontage et montage moteur complet
Indice Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E

Deutsch
4. Demontage und Montage, Motor komplett Seite

Motor zerlegen ___________________________________ 4.00.01 - 4.00.16

Motor zusammenbauen:
Ölspritzdüsen ___________________________________ 4.00.17
Stößel/Nockenwelle ___________________________________ 4.00.18
Kurbelwellenlagerung ___________________________________ 4.00.18 - 4.00.21
Massenausgleichswellen BFM 1012 ___________________________________ 4.00.22 - 4.00.27
Antriebsrad/Regler ___________________________________ 4.00.27
Regelstange ___________________________________ 4.00.27 - 4.00.28
Räderkastendeckel ___________________________________ 4.00.28 - 4.00.29
Vorderer Deckel ___________________________________ 4.00.29 - 4.00.30
Kolben mit Pleuel ___________________________________ 4.00.30 - 4.00.31
Einspritzpumpe einbauen ___________________________________ 4.00.32 - 4.00.40
Schwungrad/Keilriemenscheibe ___________________________________ 4.00.41
Zylinderkopf ___________________________________ 4.00.42 - 4.00.47
Abstellmagnet ___________________________________ 4.00.47
Einspritzventil/Einspritzleitungen ___________________________________ 4.00.48 - 4.00.49
Luftansaugrohr/Abgassammelrohr ___________________________________ 4.00.49 - 4.00.50
Zylinderkopfhaube ___________________________________ 4.00.50 - 4.00.51
Schmierölkühler ___________________________________ 4.00.51 - 4.00.52
Kühlmittelpumpe ___________________________________ 4.00.52 - 4.00.54
Kraftstoffpumpe ___________________________________ 4.00.54
Ölsaugrohr/Ölwanne ___________________________________ 4.00.54 - 4.00.56
Regler ___________________________________ 4.00.57 - 4.00.58
Kabelbaum ___________________________________ 4.00.59
Anschlußgehäuse ___________________________________ 4.00.60
Starter ___________________________________ 4.00.61
Entlüftungsleitung ___________________________________ 4.00.61 - 4.00.62
Öldruckschalter ___________________________________ 4.00.62 - 4.00.63
Kurbelgehäuseentlüftung ___________________________________ 4.00.63
Abgasturbolader ___________________________________ 4.00.64 - 4.00.65
Ölrücklaufrohr/Druckölleitung ___________________________________ 4.00.65 - 4.00.68
Ansaugkrümmer ___________________________________ 4.00.68 - 4.00.70
Ladeluftkrümmer BFM 1013 ___________________________________ 4.00.70 - 4.00.71
Ölmeßstab ___________________________________ 4.00.71
Generator ___________________________________ 4.00.72
Keilriemen spannen ___________________________________ 4.00.72 - 4.00.74
Motoraufhängung/Aufstellfüße ___________________________________ 4.00.74

Bauteile für integrierte Kühlung ab - und anbauen BFM 1012:

Bauteile abbauen ___________________________________ 4.00.75 - 4.00.82
Bauteile anbauen ___________________________________ 4.00.83 - 4.00.94

Austausch der Wellendichtringe am kompletten Motor: 4

Räderkastendeckel Schwungradseite ___________________________________ 4.00.95 - 4.00.96
Vorderer Deckel ___________________________________ 4.00.96 - 4.00.97

Nebenabtriebe ab- und anbauen:

Luftpresser ab- und anbauen ___________________________________ 4.00.99 - 4.00.100
Lenkhilfspumpe ab- und anbauen ___________________________________ 4.00.101 - 4.00.102
Hydraulikpumpe ab- und anbauen ___________________________________ 4.00.103
Hydraulikpumpe mit Konsole ab- und anbauen ___________________________ 4.00.105 - 4.00.107

Austausch der Einspritzpumpen im Servicefall __________________________ 4.00.109 - 4.00.112

984 BOMAG 008 924 17

Demontage und Montage, Motor komplett Inhalts-Verzeichnis
Disassembly and reassembly of complete engine
Diesel engine Table of Contents 16.8
Démontage et montage moteur complet Sommaire
Despiece y ensamblado conjunto de motor Indice

Werkstatthandbuch BFM 1012/E, BFM 1013/E

English
4. Disassembly and reassembly of complete engine Page

Dismantling engine ___________________________________ 4.00.01 - 4.00.16

Reassembling engine:
Oil spray nozzles ___________________________________ 4.00.17
Tappets/camshaft ___________________________________ 4.00.18
Crankshaft bearings ___________________________________ 4.00.18 - 4.00.21
Mass balancing shafts BFM 1012 ___________________________________ 4.00.22 - 4.00.27
Drive gear/governor ___________________________________ 4.00.27
Control rod ___________________________________ 4.00.27 - 4.00.28
Timing chest cover ___________________________________ 4.00.28 - 4.00.29
Front cover ___________________________________ 4.00.29 - 4.00.30
Piston with connecting rod ___________________________________ 4.00.30 - 4.00.31
Installing injection pump ___________________________________ 4.00.32 - 4.00.40
Flywheel/V-belt pulley ___________________________________ 4.00.41
Cylinder head ___________________________________ 4.00.42 - 4.00.47
Shutdown solenoid ___________________________________ 4.00.47
Injector/injection lines ___________________________________ 4.00.48 - 4.00.49
Air intake/exhaust manifold ___________________________________ 4.00.49 - 4.00.50
Cylinder head cover ___________________________________ 4.00.50 - 4.00.51
Lube oil cooler ___________________________________ 4.00.51 - 4.00.52
Coolant pump ___________________________________ 4.00.52 - 4.00.54
Fuel pump ___________________________________ 4.00.54
Oil suction pipe/oil pan ___________________________________ 4.00.54 - 4.00.56
Governor ___________________________________ 4.00.57 - 4.00.58
Cable harness ___________________________________ 4.00.59
Adapter housing ___________________________________ 4.00.60
Starter ___________________________________ 4.00.61
Breather pipe ___________________________________ 4.00.61 - 4.00.62
Öil pressure switch ___________________________________ 4.00.62 - 4.00.63
Crankcase breather ___________________________________ 4.00.63
Exhaust turbocharger ___________________________________ 4.00.64 - 4.00.65
Oil return pipe/pressure oil pipe ___________________________________ 4.00.65 - 4.00.68
Intake elbow ___________________________________ 4.00.68 - 4.00.70
Charge air elbow BFM 1013 ___________________________________ 4.00.70 - 4.00.71
Oil dipstick ___________________________________ 4.00.71
Alternator ___________________________________ 4.00.72
Tensioning V-belt ___________________________________ 4.00.72 - 4.00.74
Engine mounting/mounting feet ___________________________________ 4.00.74

Removing and refitting components for integrated cooling system, BFM 1012:
Removing components ___________________________________ 4.00.75 - 4.00.82
Refitting components ___________________________________ 4.00.83 - 4.00.94

4 Replacing shaft seals on complete engine

Timing chest cover flywheel end ___________________________________ 4.00.95 - 4.00.96
Front cover ___________________________________ 4.00.96 - 4.00.97

Removing and refitting PTOs:

Removing and refitting air compressor _________________________________ 4.00.99 - 4.00.100
Removing and refitting power steering pump ____________________________ 4.00.101 - 4.00.102
Removing and refitting hydraulic pump _________________________________ 4.00.103
Removing and refitting hydraulic pump together with bracket _______________ 4.00.105 - 4.00.107

Replacing injection pumps in case of service ___________________________ 4.00.109 - 4.00.112

008 924 17 BOMAG 985

Werkstatthandbuch BFM 1012/E, BFM 1013/E

Français
4. Démontage et montage moteur complet Page

Démontage du moteur ___________________________________ 4.00.01 - 4.00.16

Montage du moteur:
Injecteurs ___________________________________ 4.00.17
Poussoir/arbre à cames ___________________________________ 4.00.18
Logement du vilebrequin ___________________________________ 4.00.18 - 4.00.21
Arbre à masses d’équilibrage BFM 1012 _______________________________ 4.00.22 - 4.00.27
Pignon d’entraînement / régulateur ___________________________________ 4.00.27
Crémaillère ___________________________________ 4.00.27 - 4.00.28
Couvercle de carter de distribution ___________________________________ 4.00.28 - 4.00.29
Couvercle avant ___________________________________ 4.00.29 - 4.00.30
Piston-bielle ___________________________________ 4.00.30 - 4.00.31
Montage de la pompe d’injection ___________________________________ 4.00.32 - 4.00.40
Volant-moteur / poulie à gorge ___________________________________ 4.00.41
Culasse ___________________________________ 4.00.42 - 4.00.47
l’électroaimant d’arrêt ___________________________________ 4.00.47
Injecteur / tuyauteries d’injection ___________________________________ 4.00.48 - 4.00.49
Collecteur d’admission / collecteur d’échappement ________________________ 4.00.49 - 4.00.50
Cache-culbuteurs ___________________________________ 4.00.50 - 4.00.51
Radiateur à huile ___________________________________ 4.00.51 - 4.00.52
Pompe à eau ___________________________________ 4.00.52 - 4.00.54
Pompe à combustible ___________________________________ 4.00.54
Tube d’aspiration d’huile / carter d’huile ________________________________ 4.00.54 - 4.00.56
Régulateur ___________________________________ 4.00.57 - 4.00.58
Faisceau de câbles ___________________________________ 4.00.59
Carter d’adaptation ___________________________________ 4.00.60
Démarreur ___________________________________ 4.00.61
Conduite de dégazage ___________________________________ 4.00.61 - 4.00.62
Manocontact de pression d'huile ___________________________________ 4.00.62 - 4.00.63
Event de carter ___________________________________ 4.00.63
Turbocompresseur ___________________________________ 4.00.64 - 4.00.65
Tube de retour d’huile / tube de refoulement d’huile _______________________ 4.00.65 - 4.00.68
Tubulure d’aspiration ___________________________________ 4.00.68 - 4.00.70
Tubulure d’air de sualimentation BFM 1013 _____________________________ 4.00.70 - 4.00.71
Jauge d’huile ___________________________________ 4.00.71
Alternateur ___________________________________ 4.00.72
Tension de la courroie ___________________________________ 4.00.72 - 4.00.74
Suspension moteur/pieds ___________________________________ 4.00.74

Démontage et montage des composants du refroidissement intégré BFM 1012:

Démontage des composants ___________________________________ 4.00.75 - 4.00.82
Montage des composants ___________________________________ 4.00.83 - 4.00.94

Changement des joints d’arbre sur moteur complet : 4

Couvercle de carter de distribution côté volant moteur ____________________ 4.00.95 - 4.00.96
Couvercle AV ___________________________________ 4.00.96 - 4.00.97

Montage et démontage des équipements auxiliaires :

Montage et démontage compresseur __________________________________ 4.00.99 - 4.00.100
Montage et démontage pompe auxiliaire de direction ______________________ 4.00.101 - 4.00.102
Montage et démontage pompe hydraulique ______________________________ 4.00.103
Montage et démontage pompe hydraulique avec console ___________________ 4.00.105 - 4.00.107

Changement de pompes d’injection en SAV ____________________________ 4.00.109 - 4.00.112

986 BOMAG 008 924 17

Werkstatthandbuch BFM 1012/E, BFM 1013/E

Español
4. Despiece y ensamblado, conjunto de motor Pàgina

Desarmado del motor ___________________________________ 4.00.01 - 4.00.16

Rearmado del motor:
Toberas de refrigeración de pistón ___________________________________ 4.0017
Empujadores / árbol de levas ___________________________________ 4.00.18
Apoyos del cigüeñal ___________________________________ 4.00.18 - 4.00.21
Arboles compensadores de masa BFM 1012 _____________________________ 4.00.22 - 4.00.27
Rueda de accionamiento / regulador ___________________________________ 4.00.27
Barra cremallera ___________________________________ 4.00.27 - 4.00.28
Tapa del cárter de la distribución ___________________________________ 4.00.28 - 4.00.29
Tapa delantera ___________________________________ 4.00.29 - 4.00.30
Pistón con biela ___________________________________ 4.00.30 - 4.00.31
Montaje de bombas de inyección ___________________________________ 4.00.32 - 4.00.40
Volante / polea acanalada ___________________________________ 4.00.41
Culata ___________________________________ 4.00.42 - 4.00.47
solenoide de parada ___________________________________ 4.00.47
Inyector / tuberías de inyección ___________________________________ 4.00.48 - 4.00.49
Colector de admisión / colector de escape ______________________________ 4.00.49 - 4.00.50
Tapa de culata ___________________________________ 4.00.50 - 4.00.51
Refrigerador de aceite lubricante ___________________________________ 4.00.51 - 4.00.52
Bomba de líquido refrigerante ___________________________________ 4.00.52 - 4.00.54
Bomba de combustible ___________________________________ 4.00.54
Tubo de aspiración de aceite / cárter de aceite ___________________________ 4.00.54 - 4.00.56
Regulador ___________________________________ 4.00.57 - 4.00.58
Mazo de cables ___________________________________ 4.00.59
Cárter de adaptación ___________________________________ 4.00.60
Arrancador ___________________________________ 4.00.61
Tubería de ventilación ___________________________________ 4.00.61 - 4.00.62
Interrupteur de presiónde aceite ___________________________________ 4.00.62 - 4.00.63
Ventilación del cárter del cigüeñal ___________________________________ 4.00.63
Turbocompresor ___________________________________ 4.00.64 - 4.00.65
Tubo de retorno de aceite / tubería de aceite a presión _____________________ 4.00.65 - 4.00.68
Codo de aspiración ___________________________________ 4.00.68 - 4.00.70
Codo de aire de sobrealimentación BFM 1013 ____________________________ 4.00.70 - 4.00.71
Varilla de medición de nivel de aceite __________________________________ 4.00.71
Alternador ___________________________________ 4.00.72
Tensado de correas trapezoidales ___________________________________ 4.00.72 - 4.00.74
Suspensión del motor / patas de colocación _____________________________ 4.00.74

Desmontaje y remontaje de componentes de la refrigeración integrada - BFM 1012:

Desmontaje de componentes ___________________________________ 4.00.75 - 4.00.82
Remontaje de componentes ___________________________________ 4.00.83 - 4.00.94

4 Cambio de los retenes en el motor completo:

Tapa del cárter de la distribución, lado volante ___________________________ 4.00.95 - 4.00.96
Tapa delantera ___________________________________ 4.00.96 - 4.00.97

Desmontaje y remontaje de accionamientos secundarios:

Desmontaje y remontaje del compresor de aire ___________________________ 4.00.99 - 4.00.100
Desmontaje y remontaje de la servobomba de dirección ____________________ 4.00.101 - 4.00.102
Desmontaje y remontaje de la bomba hidráulica __________________________ 4.00.103
Desmontaje y remontaje de la bomba hidráulica y consola __________________ 4.00.105 - 4.00.107

Cambio de las bombas de inyección en el caso de servicio ________________ 4.00.109 - 4.00.112

008 924 17 BOMAG 987

Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

988 BOMAG 008 924 17

Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Dismantling engine Démontage du moteur Desarmado del motor

Commercial tools required: Outillage usuel : Herramientas comerciales:

Torx tool kit 8189 Jeu d´outils Torx 8189 Juego de herramientas Torx 8189
Torx socket wrench E 14 8113 Clé à douilles Torx E 14 8113 Llave de vaso Torx E 14 8113
Torx socket wrench E 18 8116 Clé à douilles Torx E 18 8116 Llave de vaso Torx E 18 8116
Torx socket wrench E 20 8114 Clé à douilles Torx E 20 8114 Llave de vaso Torx E 20 8114
Spring clamp pliers 9090 Pince de serrage pour ressorts 9090 Alicates para pinzas elásticas 9090
Spring clamp pliers 9088 Pince de serrage pour ressorts 9088 Alicates para pinzas elásticas 9088
Auxiliary tool for glow Outil pour accouplement de câble de Herramienta auxiliar para
plug cable coupler 9115 bougie de préchauffage 9115 acoplamientos de cables de bujías de
Cobra clamp pliers 8011 Pince de serrage Cobra 8011 incandescencia 9115
Alicates Cobra 8011

Special tools required: Outillage spécial: Herramientas especiales:

Engine assembly stand Chevalet de montage de moteur Caballete de montaje para motor
BFM 1012 6067 BFM 1012 6067 BFM 1012 6067
BFM 1013 6066 BFM 1013 6066 BFM 1013 6066
Angled clamping plate BFM 1012 Support dáblocage BFM 1012 pour Soportes de fijación BFM 1012
for external cooling system 6067/118 refroidissement externe 6067/118 para refrigeración externa 6067/118
Angled clamping plate BFM 1012 Support dáblocage BFM 1012 pour Soportes de fijación BFM 1012
for integrated cooling system 6067/119 refroidissement intégré 6067/119 para refrigeración integrada 6067/119
Angled clamping plate Equerre dáblocage Angulares de fijación
BFM 1013 6066/158 BFM 1013 6066/158 BFM 1013 6066/158
Extractor for injector 110 030 Extracteur dínjecteur 110 030 Extractor para inyector 110 030
Special device for Dispositif spécial Dispositivo especial para
extractor 150 800 déxtracteur 150 800 dispositivo de extracción 150 800
filter cartridges 170 050 Cartouches de filtre 170 050 Cartuchos filtrantes 170 050

The repair procedure outlined in this Les travaux de réparation indiqués ne Los trabajos de reparación descritos
chapter refers to the standard tiennent pas compte de la diversité des en este capítulo se refieren al volumen
specification, i.e. components for volumes de livraison des clients, c’est- de suministro estándar, o sea, no se
customizing the engine are not shown. à-dire que les pièces annexes muestran los componentes adosados
différentes du modèle standard ne sont que difieren del mismo.
pas présentées dans le présent
Manuel.

1. Mount angled clamping plate. 1. Monter le dispositif d’ablocage. 1. Montar los soportes de fijación.

Illustration shows BFM 1012. Illustration BFM 1012 Representado BFM 1012.

BFM 1012 BFM 1012 BFM 1012

4
2. Clamp engine in swivelling 2. Aligner le moteur sur le chevalet de 2. Alinear el motor en el caballete de
assembly stand and align. Tighten montage pivotable. montaje orientable. Apretar los
bolts. tornillos.

Drain and catch remaining Vidanger les restes d’huile ou Evacuar el aceite o los restos del
oil and coolant and dispose of de réfrigérant et les récupérer mismo y el refrigerante, recogerlos
in accordance with anti- selon la réglementation y eliminarlos en forma
pollution regulations. antipollution. reglamentaria.

4.00.01
008 924 17 BOMAG 989
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Motor zerlegen

Handelsübliche Werkzeuge:

Torx-Werkzeugsatz ________________ 8189

Torx-Steckschlüssel E14 ____________ 8113
Torx-Steckschlüssel E18 ____________ 8116
Torx-Steckschlüssel E20 ____________ 8114
Federklemmenzange _______________ 9090
Federklemmenzange _______________ 9088
Hilfswerkzeug für Glühkerzen-
Kabelkupplung ____________________ 9115
Cobraklemmenzange _______________ 8011

Spezialwerkzeuge:

Motor-Montagebock BFM 1012 _______ 6067

BFM 1013 _______ 6066
Aufspannhalter BFM 1012
für externe Kühlung _____________ 6067/118
Aufspannhalter BFM 1012
für integrierte Kühlung ___________ 6067/119
Aufspannwinkel BFM 1013 _______ 6066/158
Auszieher für Einspritzventil _______ 110 030
Spezialvorrichtung für
Ausziehvorrichtung ______________ 150 800
Filterpatronen __________________ 170 050

Bei dem gezeigten Reparaturablauf sind unter-

schiedliche Kundenumfänge nicht berücksich-
s
tigt, d.h., von der Standard-Ausführung
abweichende Anbauteile werden nicht gezeigt. 7

1. Aufspannhalter anbauen.

Darstellung BFM 1012.

BFM 1012

2. Motor im schwenkbaren Montageblock

s 4
ausrichten. Schrauben festdrehen.
Öl bzw. Restöl und Kühlmittel ablassen,
7
auffangen und vorschriftsmäßig entsor-
gen. ü

4.00.01
990 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

BFM 1013
s 2.1 Motor in doppelseitigen schwenkbaren

7 Montagebock aufnehmen und ausrichten.

Schrauben festdrehen.

ü Öl bzw. Restöl und Kühlmittel ablassen,

auffangen und vorschriftsmäßig entsor-
gen.

Bei Teildemontage und Drehen des Motors

3 um 180° ist das Druckregelventil zu
entfernen.
Restöl und Kühlmittel auffangen und
vorschriftsmäßig entsorgen.

3. Generator abbauen.
3

4. Kraftstoffpumpe lösen. Keilriemen abneh-

4 3 men.

4.00.02
008 924 17 BOMAG 991
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

BFM 1013 BFM 1013 BFM 1013

2.1 Clamp engine in double-sided 2.1 Monter puis aligner le moteur sur 2.1 Alojar el motor en el caballete de
swivelling assembly stand and le double chevalet de montage. montaje bilateral orientable y
align.Tighten bolts. Bloquer les vis. alinearlo. Apretar los tornillos.

Drain and catch remaining oil Vidanger les restes d’huile ou de Evacuar el aceite o los restos del
and coolant and dispose of in réfrigérant et les récupérer selon mismo y el refrigerante,
accordance with anti-pollution la réglementation antipollution. recogerlos y eliminarlos en forma
regulations. reglamentaria.

In case of parts assembly and En cas de montage partiel et s’il En caso de despiece parcial y
turning of engine by 180° the faut virer le moteur de 180° retirer volteo del motor por 180°, hay que
pressure control valve is to be la vanne de régulation de retirar la válvula reguladora de
removed. pression. presión.
Catch any remaining oil Récupérer l’huile Recoger y eliminar en forma
and coolant and dispose of in restante et le liquide de reglamentaria los restos de aceite
accordance with anti-pollution refroidissement. y el líquido refrigerante.
regulations.

3. Remove alternator. 3. Déposer l’alternateur. 3. Desmontar el alternador.

4. Loosen fuel pump. Remove V-belt. 4. Desserrer la pompe à combustible. 4. Aflojar la bomba de combustible.
Retirer la courroie trapézoïdale. Quitar la correa trapezoidal.
4

4.00.02
992 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

5. Remove bracket. 5. Déposer la console. 5. Desmontar la consola.

6. Remove coolant pipe. 6. Déposer le tube de liquide de 6. Desmontar el tubo de líquido

refroidissement. refrigerante.

7. Remove breather pipe using special 7. Retirer le tube de purge avec une 7. Desmontar el tubo de ventilación,
spring clamp pliers. pince à crampon spéciale. utilizando las tenazas especiales
para pinzas elásticas.

8. Remove intake hose. 8. Déposer le flexible d’aspiration. 8. Desmontar la manguera de

aspiración.
4
Note: Cover up opening of exhaust Nota: boucher orifice du Nota: Cerrar la boca del
turbo charger. turbocompresseur. turbocompresor.

4.00.03
008 924 17 BOMAG 993
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

5. Konsole abbauen.
3

6. Kühlmittelrohr abbauen.
3

7. Entlüftungsleitung mit spez. Federklem-

menzange abbauen. 3

8. Ansaugschlauch abbauen.

Hinweis: Öffnung von Abgasturbolader

3 4
verschließen.
5

4.00.03
994 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

9. Öldruckleitung und Ölrücklaufleitung

3 BFM 1012 abbauen.

10. Abgasturbolader BFM 1012 abbauen.

3 Schadhaften Abgasturbolader austau-
schen.

10.1 Öldruckleitung, Ölrücklaufleitung,

3 Ladeluftkrümmer und Abgasturbolader
BFM 1013 abbauen.
0 Schadhaften Abgasturbolader austau-
schen.

11. Steckstück herausziehen.

4 3

4.00.04
008 924 17 BOMAG 995
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

9. Remove BFM 1012 oil pressure 9. Déposer la conduite de pression 9. En BFM 1012, desmontar la tubería
pipe and oil return pipe. d’huile du BFM 1012. de presión de aceite y la tubería de
retorno de aceite.

10. Remove BFM 1012 exhaust 10. Déposer le turbocompresseur du 10. En BFM 1012, desmontar el
turbocharger. Replace damaged BFM 1012. Remplacer le turbocompresor.
turbocharger. turbocompresseur endommagé. Si está defectuoso, sustituirlo por
otro nuevo.

10.1 Remove BFM 1013 oil pressure _ 10.1 Déposer la conduite de 10.1 En BFM 1013, desmontar la
pipe, oil return pipe, charge air refoulement d’huile, la conduite tubería de presión de aceite, la
elbow and exhaust turbocharger. de retour d’huile, la tubulure d’air tubería de retorno de aceite, el
Replace damaged turbocharger. de suralimentation et le turbo- codo de aire de sobrealimentación
compresseur d’échappement du y el turbocompresor.
BFM 1013. Remplacer tout Si el turbocompresor está
turbocompresseur endommagé. defectuoso, sustituirlo por otro
nuevo.

11. Pull out plug-in element 11. Retirer l’élément enfichable. 11. Retirar la pieza de enchufe.

4.00.04
996 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

12. Remove pressure control valve 12. Déposer la vanne de régulation de 12. Desmontar la válvula reguladora de
together with hose. pression et le flexible. presión en conjunto con la
manguera.

13. Remove air pipe to manifold 13. Déposer la conduite d´air du 13. Desmontar la tubería de aire que va
presssure compensator (LDA) and correcteur de débit (LDA) et la al tope de plena carga dependiente
breather pipe. conduite de purge. de la presión de sobrealimentación
(LDA), y la tubería de ventilación.

14. Remove starter. 14. Déposer le démarreur. 14. Desmontar el arrancador.

15. Remove lifting lugs. 15. Déposer les oeillets de 15. Desmontar las argollas de
manutention. transporte.
4

4.00.05
008 924 17 BOMAG 997
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

12. Druckregelventil mit Schlauch abbauen.

13. Luftleitung zum LDA und Entlüftungs-

leitung abbauen. 3

14. Starter abbauen.

15. Transportösen abbauen.

3 4

4.00.05
998 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

16. Drehzahlregler abbauen.

17. Kraftstoff-und Ölfilter mit Spezialvor-

3 richtung abbauen.
Restöl und Kraftstoff vorschriftsmäßig

7 entsorgen.

18. Öleinfüllstutzen falls vorhanden

3 abbauen.

19. Kraftstoffleitungen abbauen.

4 3 Hinweis: Cobraklemmenzange benutzen.

4.00.06
008 924 17 BOMAG 999
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

16. Remove governor. 16. Déposer le régulateur de vitesse. 16. Desmontar el regulador de
velocidad.

17. Remove fuel and oil filter using 17. Déposer le filtre à combustible et le 17. Sirviéndose del dispositivo
special device for filter cartridges. filtre à huile avec une pince especial, desmontar el filtro de
Dispose of remaining oil and fuel spéciale. combustible y el filtro de aceite.
in accordance with anti-pollution Eliminer les restes d’huile ou de Eliminar el aceite restante y
regulations. réfrigérant selon la combustible en forma
réglementation antipollution. reglamentaria.

18. Remove oil filler neck if any. 18. Déposer la tubulure de remplissage 18. Desmontar la tubuladura de llenado
si le moteur en est doté d’un. de aceite, si existe.

19. Remove fuel lines. 19. Déposer les tuyauteries de 19. Desmontar las tuberías de
combustible. combustible.
4
Note: Use Cobra clamp pliers. Nota: utiliser la pince de serrage Nota: Utilizar los alicates Cobra.
Cobra.

4.00.06
1000 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

20. Remove fuel pump with clamping 20. Déposer la pompe à combustible 20. Desmontar la bomba de
plate. avec la griffe de serrage. combustible en conjunto con la
corredera.

21. Remove lube oil cooler. Remove 21. Déposer le radiateur à huile. Si le 21. Desmontar el refrigerador de aceite
also retainer for cable connector if moteur en a un, déposer le collier lubricante.
any. de liaison des câbles. Desmontar también el soporte para
el conectador de cables, si lo hay.

22. Remove coolant pump together 22. Déposer la pompe à réfrigérant 22. Desmontar la bomba de líquido
with thermostat housing. avec le boîtier du thermostat. refrigerante en conjunto con la caja
del termostato.

23. Disconnect glow plug cable coupler 23. Si le moteur en a un, désolidariser 23. Si existe, separar el acoplamiento
if any. For such purpose introduce le coupleur de câbles des bougies de cables de las bujías de
4 auxiliary tool carefully into rubber de préchauffage. Pour ce faire incandescencia. Para ello,
grommet without turning it in any introduire avec précaution l’outil introducir cuidadosamente, sin
way and disconnect cable. auxiliaire dans la douille en movimiento giratorio, la
caoutchouc sans tourner puis herramienta auxiliar en el manguito
séparer le câble. de goma y separar los cables.

4.00.07
008 924 17 BOMAG 1001
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

20. Kraftstoffpumpe mit Spannlasche ab-

bauen.
3

21. Schmierölkühler abbauen.

Falls vorhanden, Halter für Kabelverbinder
mit abbauen.
3

22. Kühlmittelpumpe mit Thermostatgehäuse

abbauen. 3

23. Falls vorhanden, Glühkerzen-Kabel-

kupplung trennen. Hierzu Hilfswerkzeug
vorsichtig ohne Drehbewegung in die
3 4
Gummitülle einführen und Kabel trennen.
r

4.00.07
1002 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

24. Zylinderkopfhaube abbauen.

3 Falls vorhanden, Verkabelung mitabbauen.

25. Leckölleitung mit Überströmventil

3 abbauen.

26. Abstellmagnet ausbauen.

27. Einspritzleitungen mit Dichtgummis ab-

4 3 bauen.

5 Hinweis: Öffnungen verschließen.

4.00.08
008 924 17 BOMAG 1003
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

24. Remove cylinder head cover. 24. Déposer la culasse.Si le moteur est 24. Desmontar la tapa de culata.
Remove cabling as well if any. équipé d’un câblage, le déposer. Retirar también los cables, si
existen.

25. Remove backleakage pipe together 25. Déposer le tuyau de retour des 25. Desmontar la tubería de
with overflow valve. fuites avec la soupape de décharge. combustible sobrante en conjunto
con la válvula de rebose.

26. Remove shutdown solenoid. 26. Déposer l’électroaimant d’arrêt. 26. Desmontar el solenoide de parada.

26. Remove injection lines complete 27. Déposer les tuyauteries d’injection 27. Desmontar las tuberías deinyección
with sealing rubber. avec les caoutchoucs d’étanchéité. con las piezas obturantes de goma.
4
Note: Cover up openings. Nota: obturer les orifices. Nota: Cerrar las aberturas.

4.00.08
1004 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

28. Remove injectors. 28. Déposer les injecteurs. 28. Desmontar los inyectores.

Note: If sticking, use disassembly tool Nota: en cas de blocage utiliser Nota: En caso de asiento fijo, utilizar
No. 150 800 with extractor dispositif No. 150 800 avec el dispositivo de extracción
No. 110 030. extracteur No. 110 030. No. 150 800 con el extractor
No.110 030.

29. Remove glow plugs if any. 29. Si le moteur est équipé de bougies 29. Desmontar las bujías de
de préchauffage, les déposer. incandescencia, si las hay.

30. Remove rocker arm brackets. 30. Déposer les supports de 30. Desmontar los soportes de
culbuteurs. balancines.

31. Take out pushrods. 31. Retirer les tiges de culbuteurs. 31. Sacar las varillas de empuje.

4.00.09
008 924 17 BOMAG 1005
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

28. Einspritzventile ausbauen.

Hinweis: Bei Festsitz Ausziehvorrichtung

3
Nr.150 800 mit Auszieher Nr.110 030
verwenden. 5

29. Falls vorhanden, Glühkerzen ausbauen.

30. Kipphebelböcke abbauen.

31. Stoßstangen herausnehmen.

3 4

4.00.09
1006 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

32. Ladeluftleitung abbauen.

33. Abgassammelrohr abbauen.

34. Zylinderkopf abbauen. Dichtung entfernen.

3 Hinweis: Torx E14 / E18 verwenden.
5

35. Einspritzpumpen ausbauen.

4 3 Hinweis: Auf Ausgleichsscheiben achten.

4.00.10
008 924 17 BOMAG 1007
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

32. Remove charge air pipe. 32. Déposer la conduite d’air de 32. Desmontar el conducto de aire de
suralimentation. sobrealimentación.

33. Remove exhaust manifold. 33. Déposer le collecteur 33. Desmontar el colector de escape.
d’échappement.

34. Remove cylinder head. Take off 34. Déposer la culasse. Oter le joint. 34. Desmontar la culata. Retirar la
gasket. junta.

Note: Use E14/E18 Torx tool. Nota: utiliser l’outil Torx E14/E18. Nota: Utilizar la herramienta
Torx E14 / E18.

35. Remove injection pumps. 35. Déposer les pompes d’injection. 35. Desmontar las bombas de i
nyección.
4
Note: Watch out for shims. Nota: veiller aux rondelles de Nota: Prestar atención a las arandelas
compensation. de reglaje.

4.00.10
1008 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

36. Take out roller tappets together 36. Retirer le poussoir à galets avec les 36. Retirar los empujadores de rodillo
with shims. rondelles de compensation. con las arandelas de reglaje.

37. Pull out oil dipstick. 37. Retirer la jauge d’huile. 37. Sacar la varilla de medición del
nivel de aceite.

38. Remove cover plate. 38. Déposer la tôle de recouvrement. 38. Desmontar la chapa de
Turn engine by 180°. Virer le moteur de 180°. recubrimiento.
Girar el motor por 180°.

Note: Catch any escaping oil and Nota: récupérer l’huile qui s’écoule en Nota: Recoger el aceite que sale,
dispose of in accordance with respectant la réglementation eliminándolo en forma
anti-pollution regulations. antipolution. reglamentaria.

39. Turn engine by 90°. Remove 39. Virer le moteur de 90°. Déposer le 39. Girar el motor por 90°. Desmontar
adapter housing. carter d’adaptation. el cárter de adaptación.
4
Note: Use Torx tools E20 and E14. Nota: utiliser Torx E20 et E14. Nota: Utilizar las herramientas
Torx E20 y E14.

4.00.11
008 924 17 BOMAG 1009
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

36. Rollenstößel mit Ausgleichscheiben

herausnehmen.
3

37. Ölmeßstab herausziehen.

38. Abdeckblech abbauen.

Motor um 180° drehen. 3
Hinweis: Auslaufendes Öl auffangen und vor-
schriftsmäßig entsorgen.
5

39. Motor um 90° drehen. Anschlußgehäuse

abbauen. 3 4
Hinweis: Torx E20 und E14 verwenden.
5

4.00.11
1010 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

40. Motor um 90° drehen. Ölwanne abbauen.

3 Hinweis: Einbaulage des Ölsumpfs markieren.

41. Ölansaugrohr abbauen.

42. Kolben mit Pleuel ausbauen.

43. Keilriemenscheibe abbauen.

4 3 Hinweis: Torx E20 verwenden.

4.00.12
008 924 17 BOMAG 1011
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

40. Turn engine by 90°. Remove oil 40. Virer le moteur de 90°. Déposer le 40. Girar el motor por 90°. Desmontar
pan. carter d’huile. el cárter de aceite.

Note: Mark installation position of oil Nota: repérer le sens de montage du Nota: Marcar la posición de montaje
sump. carter d’huile. del sumidero de aceite.

41. Remove oil suction pipe. 41. Déposer le tube d’aspiration 41. Desmontar el tubo de aspiración de
d’huile. aceite.

42. Remove piston complete with 42. Déposer l’ensemble piston-bielle. 42. Desmontar el pistón con la biela.
connecting rod.

43. Remove V-belt pulley. 43. Déposer la poulie à gorge. 43. Desmontar la polea acanalada.

Note: Use Torx tool E20. Nota: utiliser Torx E20. Nota: Utilizar la herramienta 4
Torx E20.

4.00.12
1012 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

44. Remove front cover. 44. Déposer le couvercle avant. 44. Desmontar la tapa delantera.

45. Remove flywheel. 45. Déposer le volant moteur. 45. Desmontar el volante.

46. Remove timing chest cover. 46. Déposer le couvercle du carter de 46. Desmontar la tapa del cárter de la
distribution. distribución.

47. Remove main bearing caps. 47. Déposer le chapeau de palier de 47. Desmontar las tapas de los
vilebrequin. cojinetes de apoyo.
4

4.00.13
008 924 17 BOMAG 1013
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

44. Vorderen Deckel abbauen.

45. Schwungrad abbauen.

46. Räderkastendeckel abbauen.

47. Hauptlagerdeckel ausbauen.

3 4

4.00.13
1014 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

48. Kurbelwelle herausnehmen.

49. Anlaufringe und Lagerschalenhälften

3 herausnehmen.

50. Falls vorhanden, Antriebsräder für Aus-

3 gleichswellen ausbauen.

51. Falls vorhanden, Anlaufscheiben für

4 3 Ausgleichswellen abbauen.

4.00.14
008 924 17 BOMAG 1015
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

48. Lift out crankshaft. 48. Extraire le vilebrequin. 48. Retirar el cigüeñal.

49. Take out thrust rings and bearing 49. Retirer les flasques de butée et les 49. Sacar las arandelas de tope y los
shell halves. demi-coussinets. semicojinetes.

50. Remove drive gears for balancing 50. Retirer les pignons d’entraînement 50. Desmontar las ruedas de
shafts if any. des arbres à masse d’équilibrage si accionamiento de los árboles
le moteur en est équipé. compensadores de masa, si
existen.

51. Remove thrust washers for 51. Selon l’équipement du moteur 51. Desmontar las arandelas de tope de
balancing shafts if any. déposer les flasques de butée des los árboles compensadores, si
arbres à masse d’équilibrage. existen. 4

4.00.14
1016 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

52. Take out balancing shafts if any. 52. Selon l’équipement du moteur 52. Extraer los árboles
retirer les arbres à masses compensadores, si existen.
d’équilibrage.

53. Remove drive gear for governor. 53. Dépose le pignon d’entraînement 53. Desmontar la rueda de
du régulateur de vitesse. accionamiento del regulador de
velocidad.

54. Take out camshaft. 54. Retirer l’arbre à cames. 54. Extraer el árbol de levas.

55. Remove guide sleeve. Take out 55. Déposer la douille de guidage et 55. Desmontar el manguito de guía.
control rod. retirer la crémaillère. Sacar la barra cremallera.
4

4.00.15
008 924 17 BOMAG 1017
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

52. Falls vorhanden, Ausgleichswellen heraus-

nehmen.
3

53. Antriebsrad für Drehzahlregler ausbauen.

54. Nockenwelle herausnehmen.

55. Führungsbuchse abbauen. Regelstange

herausnehmen. 3 4

4.00.15
1018 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

56. Stößel herausnehmen.

57. Ölspritzdüsen herausdrücken.

3 Ölkanäle auf freien Durchlaß prüfen.

4.00.16
008 924 17 BOMAG 1019
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

56. Take out tappets. 56. Retirer les poussoirs. 56. Retirar los empujadores.

57. Press out oil spray nozzles. 57. Extraire les gicleurs d’huile. Vérifier 57. Sacar a presión las toberas de
Check oil ducts for free passage. le libre passage des canalisations refrigeración de pistón. Comprobar
d’huile. si los conductos de aceite están
despejados.

4.00.16
1020 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Reassembling engine Démontage et montage moteur Rearmado del motor

complet

Commercial tools required: Outillage usuel : Herramientas usuales en el comercio:

Torx tool set _______________ 8189 Jeu d´outils Torx ____________ 8189 Juego de herramientas Torx ___ 8189
Torx socket wrench E14 ______ 8113 Clé à douille Torx E14 ________ 8113 Llave de vaso Torx E14 _______ 8113
Torx socket wrench E18 ______ 8116 Clé à douille Torx E18 ________ 8116 Llave de vaso Torx E18 _______ 8116
Torx socket wrench E20 ______ 8114 Clé à douille Torx E20 ________ 8114 Llave de vaso Torx E20 _______ 8114
Hose clamp pliers ___________ 9090 Pince pour tuyaux souples ____ 9090 Alicates para pinzas
Hose clamp pliers __________ 9088 Pince pour tuyaux souples ____ 9088 elásticas ___________________ 9090
V-belt tension gauge _________ 8115 Appareil de mesure de tension de Alicates para pinzas
Serrated wrench for trapézoïdale ________________ 8115 elásticas ___________________ 9088
turning I.P. ________________ 8117 Clé à douille (polygomale) Verificador de tensión para
Cobra clamp pliers ___________ 8011 pour pompe d´injection _______ 8117 correas trapezoidal __________ 8115
Pince de serrage Cobra _______ 8011 Llave (estrella) de giro
para bomba de inyección ______ 8117
Alicates Cobra ______________ 8011

Special tools required: Outillage spécial : Herramientas especiales:

Dial gauge M2T __________ 100 400 Comparateur M2T ________ 100 400 Comparador M2T ________ 100 400
Measuring device ________ 100 750 Appareil de mesure _______ 100 750 Dispositivo de medición ___ 100 750
Measuring device Dispositif de montage Dispositivo de medición
BFM 1012 ______________ 100 780 BFM 1012 ______________ 100 780 BFM 1012 ______________ 101 780
100 860 100 860 100 860
BFM 1013 ______________ 100 840 BFM 1013 ______________ 100 840 BFM 1013 ______________ 101 840
Measuring device/locking device Appareil de mesure / appareil à bloquer Dispositivo de medición/bloqueo
for control rod ___________ 100 800 pour crémaillère _________ 100 800 para cremallera __________ 100 800
Adjusting pin for mass Pige de réglage pour arbres Perno de ajuste para ejes
balancing shafts BFM 1012 _ 100 810 équilibreurs BFM 1012 ____ 100 810 compensadores de
Graduated disc __________ 101 020 Echelle graduée __________ 101 020 masas, BFM 1012 ________ 100 810
Adapter for graduated disc _ 101 030 Adaptateur pour échelle Disco graduado __________ 101 020
Pointer _________________ 101 300 graduée _________________ 101 030 Adaptador para disco
Piston ring compressor Index graduée ___________ 101 300 graduado _______________ 101 030
BFM 1012 ______________ 130 630 Sangle à comprimer les segments de Indicador _______________ 101 300
BFM 1013 ______________ 130 640 piston Compresor de aros de pistón
BFM 1012 ______________ 130 630 BFM 1012 ______________ 130 630
BFM 1013 ______________ 130 640 BFM 1013 ______________ 130 640

Oil spray nozzles Gicleurs de refroidissement Toberas de refrigeración de pistón

4 1. Press in oil spray nozzles as far as 1. Insérer les gicleurs jusqu’en 1. Introducir a presión hasta el tope
they will go. position de butée. las toberas de refrigeración de
pistón.

4.00.17
008 924 17 BOMAG 1021
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Motor zusammenbauen

Handelsübliche Werkzeuge:

Torx-Werkzeugsatz ________________ 8189

Torx-Steckschlüssel E14 ____________ 8113
Torx-Steckschlüssel E18 ____________ 8116
Torx-Steckschlüssel E20 ____________ 8114
Schlauchklemmenzange ____________ 9090
Schlauchklemmenzange ____________ 9088
Keilriemenspannungsmeßgerät _______ 8115
Verdrehschlüssel (Vielzahn)
für E.-Pumpe _____________________ 8117
Cobraklemmenzange _______________ 8011

Spezialwerkzeuge:

Meßuhr M2T ___________________ 100 400

Meßgerät ______________________ 100 750
Meßvorrichtung
BFM 1012 _____________________ 100 780
100 860
BFM 1013 _____________________ 100 840
Meßgerät / Blockiergerät
für Regelstange _________________ 100 800
Einstellbolzen für
MAG Wellen BFM 1012 ___________ 100 810
Gradscheibe ____________________ 101 020
Adapter für Gradscheibe __________ 101 030
Zeiger ________________________ 101 300
Kolbenringspannband
BFM 1012 _____________________ 130 630
BFM 1013 _____________________ 130 640

Ölspritzdüsen

1. Ölspritzdüsen bis Anlage eindrücken.

4 4

4.00.17
1022 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

Stößel/Nockenwelle
4 2. Stößel einsetzen.

3. Nockenwelle einsetzen.
4
z

Kurbelwellenlagerung
6 4. Innenmeßgerät einstellen.

BFM 1012 auf 36 mm

BFM 1013 auf 38 mm

5. Paßlagerbreite der Kurbelwelle messen und

4 6 notieren. Maß “a”

Zapfenbreite normal:
BFM 1012 _____________ 36 + 0,04 mm
BFM 1013 ____________ 38 + 0,06 mm
Grenzmaß für Übermaßstufe:
BFM 1012 ____________ 36,4 + 0,04mm
BFM 1013 ____________ 38,4 + 0,06mm

4.00.18
008 924 17 BOMAG 1023
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Tappets/camshaft Poussoir/arbre à cames Empujadores / árbol de levas

2. Insert tappets. 2. Mettre en place le poussoir. 2. Introducir los empujadores

3. Introduce camshaft. 3. Mettre en place l’arbre à cames. 3. Introducir el árbol de levas.

Crankshaft bearings Paliers de vilebrequin Apoyos del cigüeñal

4. Set internal gauge: 4. Régler l’appareil de mesure selon le 4. Ajustar el micrómetro de interiores.
moteur:

BFM 1012 to 36 mm BFM 1012 à 36 mm. BFM 1012 a 36 mm

BFM 1013 to 38 mm BFM 1013 à 38 mm. BFM 1013 a 38 mm

5. Gauge width of crankshaft thrust 5. Mesurer la largeur des portées du 5. Medir el ancho de muñón del
bearing journal and record. palier de butée du vilebrequin et la cojinete de empuje del cigüeñal y
Dimension „a“ noter. Cote „a“. registrarlo. Medida „a“. 4
Standard journal width: Largeur normale du tourillon : Ancho de muñón normal:
BFM 1012 _______ 36 + 0.04 mm BFM 1012 _______ 36 + 0,04 mm BFM 1012 _______ 36 + 0,04 mm
BFM 1013 _______ 38 + 0.06 mm BFM 1013 _______ 38 + 0,06 mm BFM 1013 _______ 38 + 0,06 mm

Limit for oversize: Cote limite de réparation: Límite de sobremedida:

BFM 1012 _____ 36.4 + 0.04 mm BFM 1012 _____ 36,4 + 0,04 mm BFM 1012 _____ 36,4 + 0,04 mm
BFM 1012 _____ 38.4 + 0.06 mm BFM 1013 _____ 38,4 + 0,06 mm BFM 1013 _____ 38,4 + 0,06 mm

4.00.18
1024 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

6. Insert bearing shells. 6. Mettre en place les coussinets. 6. Colocar los semicojinetes.

7. Insert bearing shells in main 7. Placer les coussinets dans le 7. Colocar los semicojinetes en las
bearing caps. chapeau de palier de vilebrequin. tapas de los cojinetes de apoyo.

8. Place half thrust rings on thrust 8. Adapter les demi-flasques de butée 8. Colocar las medias arandelas de
bearing cap, gauge and record au chapeau du palier de butée, en tope en la tapa de cojinete de
width. Dimension „b“ mesurer la largeur et la noter. Cote empuje, medir el ancho y
„b“. registrarlo. Medida „b“.

9. Determine end float. 9. Calculer le jeu axial. 9. Determinar el juego axial.

4 Example BFM 1012: Exemple BFM 1012: EjemploBFM 1012:

Dimension a = 36.04 mm cote a = 36,04 mm medida a = 36,04 mm
Dimension b = 35.90 mm cote b = 35,90 mm medida b = 35,90 mm
Dimension a - dimension b cote a - cote b = jeu axial medida a - medida b = juego axial
= end float = 0.14 mm = 0,14 mm = 0,14 mm

Permissible end float for: Jeu axial admis pour Juego axial admisible para:
BFM 1012 = 0.10 - 0.30 mm BFM 1012 = 0,10 - 0,30 mm BFM 1012 = 0,10 - 0,30 mm
BFM 1013 = 0.10 - 0.30 mm BFM 1013 = 0,10 - 0,30 mm BFM 1013 = 0,10 - 0,30 mm

4.00.19
008 924 17 BOMAG 1025
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

6. Lagerschalen einsetzen.
4
8

7. Lagerschalen in Hauptlagerdeckel einset-

zen. 4
8

8. Anlaufringhälften an Paßlagerdeckel
anlegen, Breite messen und notieren.
Maß “b”
4
8
6

9. Axialspiel ermitteln.

Beispiel BFM 1012: 4

Maß a = 36,04 mm
Maß b = 35,90 mm
Maß a - Maß b = Axialspiel
= 0,14 mm

Zulässiges Axialspiel für:

BFM 1012 = 0,10 - 0,30 mm
BFM 1013 = 0,10 - 0,30 mm

4.00.19
1026 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

10. Kurbelwelle vor Einbau markieren.

11. Nockenwelle markieren und positionieren.

12. Kurbelwelle einsetzen.

4 Beim Einbau müssen die Markierungen in
Überdeckung stehen.
i
z

13. Anlaufringhälften ohne Führungsnase

4 4 einsetzen.

5 Hinweis: Anlaufringe müssen mit der Lauf-

schichtseite zum Wangenspiegel der

8 Kurbelwelle weisen.

4.00.20
008 924 17 BOMAG 1027
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

10. Mark crankshaft prior to 10. Avant de le monter repérer le 10. Marcar el cigüeñal antes de
installation. vilebrequin. proceder a su montaje.

11. Mark camshaft and place in 11. Repérer l’arbre à cames et le 11. Marcar el árbol de levas y
position. positionner. posicionarlo.

12. Introduce crankshaft. 12. Mettre en place le vilebrequin. 12. Introducir el cigüeñal.
Marks must be in line. Au montage il faut que les repères Las marcas deben corresponderse
coïncident. en el montaje.

13. Insert half thrust rings without lug. 13. Mettre en place les demi-flasques 13. Poner las medias arandelas de tope
de butée sans taquet de guidage. sin talón de guía en su sitio.
4
Note: Running layer of thrust rings Nota: les flasques de butée avec leur Nota: La capa de roce de las
must face towards crankweb. face de roulement doivent être arandelas debe indicar hacia la
orientées vers la joue du cara lateral de las manivelas del
vilebrequin. cigüeñal.

4.00.20
1028 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

14. Stick half thrust rings with lug to 14. Avec un peu de graisse coller sur le 14. Pegar, mediante grasa, las medias
thrust bearing cap using some chapeau de palier de butée les arandelas de tope con talón de guía
grease. demi-flasques de butée avec le contra la tapa del cojinete de
taquet de guidage. empuje.

Note: Running layer of thrust rings Nota: le chapeau de palier no. 1 estdu Nota: La capa de roce de las
must face towards crankweb. côté du volant moteur. Les arandelas debe indicar hacia la
bossages doivent être orientés cara lateral de las manivelas del
vers le volant moteur. cigüeñal.

15. Mount thrust bearing cap. 15. Mettre en place le chapeau de 15. Montar la tapa del cojinete de
palier de butée. empuje.

Note: Bearing cap No. 1 at flywheel Nota: le chapeau de palier no. 1 est Nota: La tapa de cojinete No. 1 se
end. Bosses must face towards orienté côté volant moteur. encuentra en el lado de volante.
flywheel on BFM 1012. Sur le BFM 1012 les bossages En BFM 1012, los salientes
doivent être orientés vers le deben indicar hacia el volante.
volant moteur.

16. Mount main bearing caps, paying 16. Monter le chapeau de palier de 16. Montar las tapas de los cojinetes
attention to the numbering. vilebrequin selon la numérotation. de apoyo, teniendo en cuenta la
numeración.

17. Tighten main bearing bolts 17. Serrer les vis de palier principal 17. Apretar los tornillos de los
according to specification. selon les préconisations de cojinetes de apoyo según
4 serrage. prescripción.
Initial tightening torque Valeur de préserrage Apriete inicial
BFM 1012: ___________ 30 Nm BFM 1012: ___________ 30 Nm BFM 1012: ___________ 30 Nm
BFM 1013: ___________ 50 Nm BFM 1013: ___________ 50 Nm BFM 1013: ___________ 50 Nm
1st tightening angle ______ 60° 1er serrage à l’angle _____ 60° 1er reapriete ___________ 60°
2nd tightening angle _____ 60° 2ème serrage à l’angle ___ 60° 2o reapriete ____________ 60°

Note: Bolts may be used 3x if Nota: après preuve à l’appui les vis Nota: Si es comprobable, se pueden
evidence can be provided peuvent être utilisées 3 fois. utilizar los tornillos tres veces.
concerning their use.

4.00.21
008 924 17 BOMAG 1029
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

14. Anlaufringhälften mit Führungsnase am

Paßlagerdeckel mit etwas Fett ankleben.
4
Hinweis: Anlaufringe müssen mit der Lauf-
schichtseite zum Wangenspiegel der u
Kurbelwelle weisen.
5
8

15. Paßlagerdeckel aufbauen

Hinweis: Lagerdeckel Nr. 1 ist schwungrad-

4
seitig.
Bei BFM 1012 müssen die Butzen 8
5
zum Schwungrad weisen.

16. Hauptlagerdeckel entsprechend der

Numerierung montieren. 4
9

17. Hauptlagerschrauben nach Anziehvor-

schrift festdrehen. 4 4
Vorspannwert
BFM 1012 ___________________ 30 Nm 6
BFM 1013 ___________________ 50 Nm
1. Nachspannwert ________________ 60° 5
2. Nachspannwert ________________ 60°

Hinweis: Schrauben können bei Nachweisbar-

keit 3x verwendet werden.

4.00.21
1030 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

Massenausgleichswellen BFM 1012

3 (falls vorhanden)

Motor um 180° drehen.

18. Verschlußschrauben herausdrehen.

19. Massenausgleichswelle einbauen.

4 Hinweis: Die Gewichtslage muß zur Ölwannen-

z dichtfläche weisen.

20. Einstellbolzen für Massenausgleichswelle

4 in das Kurbelgehäuse bis zum Anschlag
einschrauben.
7 Hinweis: Bohrung der Massenausgleichswelle

5
muß mit der Bohrung im Kurbelwel-
lengehäuse in Überdeckung stehen.

21. Anlaufscheibe anbauen und zur Wellen-

4 4 achse ausrichten.

4.00.22
008 924 17 BOMAG 1031
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Mass balancing shafts BFM 1012 Arbres à masse d’équilibrage Arboles compensadores de masa -
(if any) BFM 1012 BFM 1012
(selon l’équipement du moteur) (si existen)

Turn engine by 180°. Virer le moteur de 180°. Girar el motor por 180°

18. Turn out screw plugs. 18. Dévisser et sortir les vis filetées. 18. Desenroscar los tapones de cierre.

19. Introduce mass balancing shaft. 19. Monter l’arbre à masses 19. Introducir uno de los árboles
d’équilibrage. compensadores de masa.

Note: The weights must be positioned Nota: les poids doivent être orientés Nota: Las masas deben estar
towards oil pan sealing surface. vers le plan d’étanchéité du orientadas hacia la superficie de
carter d’huile. cierre del cárter de aceite.

20. Screw adjusting pin for mass 20. Visser la pige de réglage de l’arbre 20. Enroscar el perno de ajuste del
balancing shaft into crankcase as à masses d’équilibrage dans le bloc árbol compensador de masa en el
far as it will go. moteur jusqu’en position de butée. bloque motor hasta que haga tope.

Note: Bore of mass balancing shaft Nota: l’alésage de l’arbre à masses Nota: El orificio existente en el árbol
must be in line with bore in d’équilibrage doit correspondre compensador de masa debe
crankcase. à l’alésage du bloc moteur. coincidir con el del bloque
motor.

21. Fit thrust washer and align relative 21. Monter la flasque de butée en 21. Montar la arandela de tope y
to shaft axis. l’orientant vers l’axe de l’arbre. alinearla con el eje del árbol.
4

4.00.22
1032 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

22. Tighten bolt with a torque of 22. Serrer la vis au couple de 29 Nm. 22. Apretar el tornillo con un par de
29 Nm. 29 Nm.

23. Turn crankshaft and bring cyl. 1 to 23. Mettre le vilebrequin cyl. 1 en 23. Girando el cigüeñal, poner el cil. 1
TDC. TDC position is reached when position de PMH. Le PMH est en PMS.Se ha alcanzado el PMS,
the crankshaft marking coincides atteint quand le repère sur le cuando la marca puesta en el
with the centerline of crankshaft vilebrequin se trouve à cigüeñal se encuentra en la línea
and camshaft. l’intersection entre les points milieu que une los centros del cigüeñal y
du vilebrequin et de l’arbre à árbol de levas.
cames.

24. Position idler gear and press down 24. Mettre en place le pignon 24. Instalar la rueda intermedia y
lightly until it meshes with the intermédiaire et l’enfoncer forzarla ligeramente hasta que
crankshaft gear. légèrement dans l’engrènement du engrane en la rueda dentada del
pignon du vilebrequin. cigüeñal.

25. Mark opposite teeth. 25. Repérer les dents se trouvant en 25. Marcar los dientes que se
regard les unes des autres. enfrenten.
4

4.00.23
008 924 17 BOMAG 1033
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

22. Schraube mit einem Drehmoment von

29 Nm festdrehen.
4
6

23. Kurbelwelle Zyl. 1 auf OT stellen.

OT ist dann erreicht, wenn die Markierung
auf der Kurbelwelle in Verbindungslinie
4
der Mittelpunkte von Kurbelwelle und
Nockenwelle liegt.
9

24. Zwischenrad einsetzen und leicht in den

Eingriff des Zahnrades der Kurbelwelle
drücken.
4

25. Die gegenüberliegenden Zähne markieren.

i 4

4.00.23
1034 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

26. Kurbelwelle im Uhrzeigersinn drehen, bis

9 3 Zähne übergesprungen sind.

27. Kurbelwelle entgegen dem Uhrzeigersinn

9 drehen, bis Bohrungen in Überdeckung
stehen.

28. Lagerzapfen einsetzen.

4 Hinweis: Durch leichtes Hin- und Herdrehen
z der Kurbelwelle prüfen, ob Lager-
zapfen in der Bohrung zentriert ist.

29. Schraube einsetzen und mit einem

4 4 Drehmoment von 29 Nm festdrehen.

4.00.24
008 924 17 BOMAG 1035
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

26. Turn crankshaft in clockwise 26. Virer le vilebrequin dans le sens 26. Girar el cigüeñal en sentido horario
direction until 3 teeth have horaire jusqu’à ce que 3 dents hasta que hayan engranado 3
engaged. sautent. dientes.

27. Turn crankshaft in anti-clockwise 27. Virer le vilebrequin dans le sens 27. Girar el cigüeñal en sentido
direction until bores are in line. antihoraire jusqu’à ce que les contrario al de las agujas del reloj
alésages correspondent. hasta que coincidan los orificios.

28. Insert bearing journal. 28. Mettre en place le tourillon. 28. Introducir el muñón de soporte.

Note: Check whether bearing journal Nota: déplacer légèrement par un Nota: Imprimiendo al cigüeñal un
is centered in bore by slightly mouvement de va-et-vient le ligero movimiento giratorio de
turning crankshaft back and vilebrequin pour vérifier si le vaivén, comprobar si el muñón
forth. tourillon est bien centré dans queda centrado en el orificio.
l’alésage.

29. Insert bolt and tighten with a 29. Placer la vis et la serrer au couple 29. Meter el tornillo y apretarlo con
torque of 29 Nm. de 29 Nm. 29 Nm.
4

4.00.24
1036 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

30. Introduce 2nd mass balancing 30. Monter le 2ème arbre à masses 30. Introducir el segundo árbol
shaft. d’équilibrage. compensador de masa.

Note: The weights must be positioned Nota: les poids doivent être orientés Nota: Las masas deben estar
towards oil pan sealing surface. vers le plan de joint du carter orientadas hacia la superficie de
d’huile. cierre del cárter de aceite.

31. Screw adjusting pin for mass 31. Visser la pige de réglage de l’arbre 31. Enroscar el perno de ajuste del
balancing shaft into crankcase as à masses d’équilibrage dans le bloc árbol compensador de masa en el
far as it will go. moteur jusqu’en position de butée. bloque motor hasta el tope .

32. Fit thrust washer and align relative 32. Monter la flasque de butée en 32. Colocar la arandela de tope y
to shaft axis. l’orientant vers l’axe de l’arbre. alinearla con el eje del árbol.

33. Tighten bolt with a torque of 33. Serrer la vis au couple de 29 Nm. 33. Apretar el tornillo con un par de
29 Nm. 29 Nm.
4

4.00.25
008 924 17 BOMAG 1037
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

30. 2. Massenausgleichswelle einbauen.

Hinweis: Die Gewichtslage muß zur Ölwannen-

4
dichtfläche weisen.
z
5

31. Einstellbolzen für Massenausgleichswelle

in das Kurbelgehäuse bis zum Anschlag
einschrauben.
4
Hinweis: Bohrung der Massenausgleichswelle 7
5
muß mit der Bohrung im Kurbel-
gehäuse in Überdeckung stehen.

32. Anlaufscheibe anbauen und zur

Wellenachse ausrichten. 4
9

33. Schraube mit einem Drehmoment von

29 Nm festdrehen. 4 4
6

4.00.25
1038 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

34. Zwischenrad so einsetzen, daß Bohrungen

4 in Überdeckung stehen.

35. Lagerzapfen einsetzen.

4
z

36. Schraube einsetzen und mit einem

4 Drehmoment von 29 Nm festdrehen.

37. Beide Einstellbolzen entfernen.

4 3

4.00.26
008 924 17 BOMAG 1039
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

34. Insert idler gear so that bores are in 34. Placer le pignon intermédiaire de 34. Instalar la rueda intermedia,
line. manière à ce que les alésages teniendo en cuenta que coincidan
correspondent. los orificios.

35. Insert bearing journal. 35. Mettre en place le tourillon. 35. Introducir el muñón de soporte.

36. Insert bolt and tighten with a 36. Placer la vis et serrer au couple de 36. Meter el tornillo y apretarlo con un
torque of 29 Nm. 29 Nm. par de 29 Nm.

37. Remove both adjusting pins. 37. Oter les deux piges de calage. 37. Retirar ambos pernos de ajuste.

4.00.26
1040 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

38. Cover up bores with new Cu seals. 38. Obturer les alésages avec des 38. Cerrar los orificios con anillos de
bagues d’étanchéité Cu neuves. cobre nuevos.

Drive gear/governor Pignon d’entraînement/régulateur Rueda de accionamiento/regulador

39. Insert governor drive gear 39. Mettre en place le pignon 39. Instalar la rueda de accionamiento
complete with bearing journal. d’entraînement du régulateur avec del regulador con el muñón de
le tourillon. soporte.

40. Insert bolt and tighten with a 40. Placer la vis et la serrer au couple 40. Meter el tornillo y apretarlo con un
torque of 21 Nm. de 21 Nm. par de 21 Nm.

Control rod Crémaillère Barra cremallera

4 41. Fit control rod complete with guide 41. Monter la crémaillère avec la 41. Instalar la barra cremallera con el
sleeve. douille de guidage. manguito de guía puesto.

4.00.27
008 924 17 BOMAG 1041
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

38. Bohrungen mit neuen Cu-Dichtringen

verschließen.
4
ß

Antriebsrad/Regler

39. Antriebsrad für Regler mit Lagerzapfen

4
einsetzen.
z

40. Schraube einsetzen und mit einem Dreh-

moment von 21 Nm festdrehen. 4
6

Regelstange

41. Regelstange mit Führungsbuchse

4 4
einbauen.

4.00.27
1042 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

42. Schraube mit Sicherungmittel Deutz

4 DW 71 einsetzen und mit einem
Drehmoment von 10 + 2 Nm festdrehen.

w
6

Räderkastendeckel
4 43. Dichtfläche des Räderkastendeckels mit

w Dichtmittel Deutz DW 67 bestreichen.

BFM 1012

BFM 1013
4
w

4
44. Räderkastendeckel anbauen. Schrauben
beidrehen und Räderkastendeckel zur
4 Ölwannendichtfläche ausrichten.
9

4.00.28
008 924 17 BOMAG 1043
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

42. Apply Deutz DW 71 locking 42. Monter la vis à la pâte de frein 42. Meter el tornillo con sellante
compound to bolt and tighten with DEUTZ DW 71 et la serrer au Deutz DW 71 y apretarlo con un
a torque of 10 + 2 Nm. couple de 10 + 2 Nm. par de 10 + 2 Nm.

Timing chest cover Couvercle de carter de distribution Tapa del cárter de la distribución

43. Apply Deutz DW 67 sealing 43. Enduire le produit Deutz DW 67 la 43. Aplicar sellante Deutz DW 67 a la
compound to sealing surface of surface d'étanchéité du couvercle superficie de cierre de la tapa del
timing chest cover. de la distribution. cárter de la distribución.

BFM 1012 BFM 1012 BFM 1012

BFM 1013 BFM 1013 BFM 1013

44. Mount timing chest cover. Start 44. Monter le couvercle de la 44. Montar la tapa en el cárter de la
bolts and align timing chest cover distribution. Server les vis à la main distribución. Apretar con la mano
relative to oil pan sealing surface. et aligner le couvercle de la los tornillos hasta que se apoyen y 4
distribution par rapport au plan alinear la tapa con respecto a la
d'appui du carter d'huile. superficie de cierre del cárter de
aceite.

4.00.28
1044 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

45. Tighten bolts with a torque of 45. Serrer les vis au couple de 45. Apretar los tornillos con un par de
21 ± 2 Nm. 21 ± 2 Nm. 21 ± 2 Nm.

Front cover Couvercle avant Tapa delantera

46. Lightly oil rotors in front cover. 46. Huiler légèrement les rotors du 46. Untar con un poco de aceite los
couvercle avant. rotores en la tapa delantera.

47. Stick gasket to front cover using 47. Coller le joint du couvercle avant 47. Pegar con un poco de grasa la
some grease. avec un peu de graisse. junta en la tapa delantera.

Turn engine by 180°. Oil pan sealing Virer le moteur de 180°. Le plan de Girar el motor por 180°. La superficie
surface must point downward. joint du carter d’huile doit être dirigé de cierre del cárter de aceite tiene que
4 vers le bas. indicar hacia abajo.

48. Position rotor relative crankshaft. 48. Positionner le rotor par rapport au 48. Posicionar el rotor con respecto al
vilebrequin. cigüeñal.

4.00.29
008 924 17 BOMAG 1045
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

45. Schrauben mit einem Drehmoment von

21 ± 2 Nm festdrehen.
4
6

Vorderer Deckel

46. Rotoren im vorderen Deckel leicht ölen.

4
z

47. Dichtung für vorderen Deckel mit etwas

Fett ankleben. 4
u
ß

Motor 180° drehen. Ölwannnendichtfläche

muß nach unten weisen. 4 4
48. Rotor zur Kurbelwelle positionieren.
9

4.00.29
1046 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

49. Vorderen Deckel anbauen, Deckel nach

4 oben drücken und zur Ölwannendichtfläche
ausrichten. Schrauben leicht andrehen.

50. Schrauben für vorderen Deckel mit einem

4 Drehmoment von 21 ± 2 Nm festdrehen.

Kolben mit Pleuel

4 51. Pleuellagerschalen in Pleuelstange
8 einbauen.

52. Kolbenringstöße 90-120° zueinander

4 9 versetzt anordnen.

4.00.30
008 924 17 BOMAG 1047
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

49. Mount front cover, press cover 49. Monter le couvercle avant, le serrer 49. Montar la tapa delantera,
upward and align relative to oil pan vers le haut et l'aligner par rapport presionarla hacia arriba y alinearla
sealing surface. Start bolts. au plan de joint du carter d’huile. con respecto a la superficie de
Serrer les vis modérément. cierre del cárter de aceite. Enroscar
los tornillos con la mano hasta que
se apoyen.

50. Tighten bolts for front cover with a 50. Serrer les vis du couvercle avant au 50. Apretar los tornillos para la tapa
torque of 21 ± 2 Nm. couple de 21 ± 2 Nm. delantera con un par de 21 ± 2 Nm.

Piston complete with connecting rod Ensemble piston-bielle Conjunto pistón-biela

51. Insert bearing shells in connecting 51. Monter les coussinets dans la 51. Insertar los coijnetes en la biela.
rod. bielle.

52. Piston ring gaps must be staggered 52. Tiercer les coupes de segment de 52. Cuidar de que los cortes de los
by 90-120°. 90-120°. aros de pistón estén desplazados
entre sí por 90-120°. 4

4.00.30
1048 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

53. Introduce piston complete with 53. Insérer le piston complet et la bielle 53. Introducir el pistón completo con la
connecting rod into crankcase with dans le bloc moteur. biela en el bloque de motor.
integrated cylinder liners.

Note: Flywheel symbol must point Nota: le symbole du volant doit être Nota: El símbolo del volante tiene que
towards flywheel. orienté vers le volant. indicar hacia el volante.

54. Press connecting rod against 54. Enfoncer la bielle en exerçant une 54. Presionando la biela contra su
crankpin. Fit pertinent big end pression contre le maneton. muñequilla, montar la tapa de biela
bearing cap. Monter le chapeau de bielle correspondiente.
correspondant.

55. Tighten new conrod bolts in 55. Serrer les vis de bielle neuves 55. Apretar los tornillos de biela
accordance with specification. selon les consignes de serrage. nuevos, según prescripción.

Initial tightening torque ___ 30 Nm Serrage d'approche ______ 30 Nm Apriete inicial: __________ 30 Nm
1st tightening angle ________ 60° 1. Serrage à l’angle ________ 60° 1er ángulo de reapriete ______ 60°
2nd tightening angle 2. Serrage à l’angle 2o ángulo de reapriete
BFM 1012 _____________ 30° BFM 1012 _____________ 30° BFM 1012 _____________ 30°
BFM 1013 _____________ 60° BFM 1013 _____________ 60° BFM 1013 _____________ 60°

56. Check that connecting rods can be 56. Contrôler les bielles: elles doivent 56. Comprobar las bielas para ver si
easily moved back and forth on the se déplacer légèrement au niveau pueden moverse fácilmente sobre
4 crankpin. du maneton. sus muñequilla.

Note: Turn engine by 180°. Nota: virer le moteur de 180°. Nota: Girar el motor por 180°.

4.00.31
008 924 17 BOMAG 1049
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

53. Kolben komplett mit Pleuel in das

Zylinderkurbelgehäuse einschieben. 4
Hinweis: Schwungradsymbol muß zum
Schwungrad weisen. z
7
5

54. Pleuelstange gegen den Hubzapfen

drücken. Dazugehörigen Pleuellagerdeckel
montieren.
4
z
9

55. Neue Pleuelschrauben nach Anziehvor-

schrift festdrehen. 4
Vorspannwert ________________ 30 Nm
1. Nachspannwinkel _____________ 60° 6
ß
2. Nachspannwinkel
BFM 1012 ___________________ 30°
BFM 1013 ___________________ 60°

56. Pleuelstangen kontrollieren, ob sie sich

auf dem Hubzapfen leicht verschieben
lassen.
9 4
Hinweis: Motor um 180° drehen. 5

4.00.31
1050 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

Einspritzpumpen einbauen
4 Regelstangenweg messen ohne Einspritz-

7 pumpen

57. Feststellvorrichtung für Regelstange an-

bauen.

58. Von Vorrichtung bis zur Stopstellung der

6 Regelstange messen.

58.1 Von Vorrichtung bis zur Startstellung der

6 Regelstange messen.

9 Differenz zur Stopstellung ergibt Regel-

stangenweg.

Beispiel:
Stopstellung = 30,7 mm
Startstellung = 13,4 mm
Regelstangenweg = 17,3 mm

Sollmaß = 17,0 mm - 17,5 mm

59. Vorrichtung drehen. Regelstange mit

4 s Rändel-Feststellschraube von Hand in

Stopstellung drücken.

4.00.32
008 924 17 BOMAG 1051
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Installing injection pumps Monter les pompes d’injection Montaje de las bombas de inyección

Gauging control rod travel without Mesurer le déplacement de la Determinación del recorrido de la
injection pumps installed crémaillère sans pompes d’injection. cremallera sin las bombas de
inyección

57. Fit control rod locking device. 57. Monter le dispositif de fixation de la 57. Montar el dispositivo de bloqueo de
crémaillère. la cremallera.

58. Gauge from locking device to stop 58. Mesurer la distance entre le 58. Medir la distancia entre el
position of control rod. dispositif et la position stop de la dispositivo y la cremallera en
crémaillère. posición de parada.

58.1 Gauge from locking device tostart 58.1 Mesurer la distance entre le 58.1 Medir la distancia entre el
position of control rod. dispositif et la position de dispositivo y la cremallera en
démarrage de la crémaillère. posición de arranque.

Difference between start and stop La différence par rapport à la La diferencia entre ambos valores
positions equals control rod travel. position de stop est le déplacement es el recorrido de la cremallera.
de la crémaillère.
Example: Exemple: Ejemplo:
stop position = 30.7 mm position stop = 30,7 mm Posición de parada = 30,7 mm
start position = 13.4 mm position démarrage = 13,4 mm Posición de arranque = 13,4 mm
control rod travel = 17.3 mm déplacement crémaillère =17,3 mm Recorrido de
Specified dimension = 17.0 mm Valeur de consigne = 17,0 mm la cremallera = 17,3 mm
- 17.5 mm -17,5 mm Valor prescrito = 17,0 mm
-17,5 mm
59. Turn locking device. Press control 59. Tourner le dispositif. A la main 59. Girar el dispositivo. Apretando el
rod in stop position by hand with enfoncer la crémaillère avec la vis tornillo de bloqueo, forzar la
knurled-head setscrew. d’immobilisation en position de cremallera para que se sitúe en la 4
stop. posición de parada.

4.00.32
1052 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

60. Fit graduated disc to flywheel 60. Monter le disque gradué sur la 60. Fijar el disco graduado a la brida
flange. bride du volant moteur. del volante.

61. Fit pointer. 61. Monter l’index gradué. 61. Montar el indicador.

Determining TDC of piston pertaining Calculer le PMH du piston de la Determinación del PMS de com-
to injection pump to be timed. pompe d’injection à caler. presión del pistón que corresponda a
la bomba de inyección a ajustar.

62. Position TDC measuring bar 62. Mettre en place la barre de mesure 62. Colocar la regleta de medición del
together with spacing washers. du PMH avec des plaquettes PMS con las plaquitas
Turn crankshaft in direction of d’écartement. Virer le vilebrequin distanciadoras. Girar el cigüeñal en
engine rotation until pointer of dial dans le sens de rotation du moteur el sentido de giro normal del motor
gauge has reached its reversal jusqu’à ce que l’index du hasta que la aguja del comparador
point. comparateur atteigne son point haya alcanzado su punto de
Set dial gauge to „0“. d’inversion. inversión.
Régler le comparateur sur „0“. Ajustar el comparador a „0“.

63. Turn crankshaft by about 90° in 63. Virer le vilebrequin de 90° environ 63. Girar el cigüeñal unos 90° en
direction of engine rotation. dans le sens opposé au sens de sentido contrario al del motor y a
4 Thereafter turn again in opposite rotation du moteur. Ensuite virer à continuación otra vez en el sentido
direction of engine rotation until nouveau dans le sens de rotation de giro normal del mismo hasta
8 mm before TDC (reversal point of du moteur jusqu’à 8 mm avant le 8 mm delante del PMS (punto de
dial gauge). PMH (point d’inversion du inversión del comparador).
Set graduated disc to „0“. comparateur). Ajustar el disco graduado a „0“.
Régler le disque gradué sur „0“.

4.00.33
008 924 17 BOMAG 1053
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

60. Gradscheibe an Schwungradflansch

anbauen.
4
7

61. Zeiger anbauen.

4
7

Zünd O.T. des Kolbens ermitteln, der zur

einzustellenden Einspritzpumpe gehört. 4
62. O.T.-Meßbalken mit Abstandsplättchen
auflegen. Kurbelwelle in Motordreh- 6
7
richtung drehen bis der Zeiger der Meßuhr
seinen Umkehrpunkt erreicht hat.
Meßuhr auf "0" stellen.

63. Kurbelwelle ca. 90° entgegen der Motor-

drehrichtung drehen. Danach wieder in
Motordrehrichtung bis 8 mm vor O.T.
6 4
(Umkehrpunkt der Meßuhr) drehen.
Gradscheibe auf “0” stellen.

4.00.33
1054 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

64. Kurbelwelle ca. 90° in Motordrehrichtung

6 drehen. Danach wieder entgegen der
Motordrehrichtung bis 8 mm vor O.T.
(Umkehrpunkt der Meßuhr) drehen.
Ermittelten Wert ablesen.
Beispiel: 50°

65. Ermittelten Wert halbieren. Halbierter

9 Wert ist O.T.
0°+ 50°
Beispiel: = 25° IST
2

Kurbelwelle auf halbierten Wert drehen.

66. Kurbelwelle jetzt nicht mehr verdrehen.

a 2 Rändelschrauben lösen und Gradscheibe
auf "0" stellen.
6

67. Rollenstößel einsetzen

4 4
z

4.00.34
008 924 17 BOMAG 1055
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

64.Turn crankshaft by about 90° in 64. Virer le vilebrequin de 90° environ 64. Girar el cigüeñal aprox. 90° en
direction of engine rotation. dans le sens opposé au sens de sentido de giro normal del motor y
Thereafter turn again in opposite rotation du moteur. Ensuite virer à a continuación de nuevo en sentido
direction of engine rotation until nouveau dans le sens de rotation contrario al mismo hasta 8 mm
8 mm before TDC (reversal point of du moteur jusqu’à 8 mm avant le delante del PMS (punto de
dial gauge). Read off determined PMH (point d’inversion du inversión del comprador). Tomar
value. comparateur). Lire la valeur lectura del valor determinado.
Example: 50° obtenue. Ejemplo: 50°
Exemple : 50°

65. Halve the value determined. The 65. Diviser la valeur calculée par deux. 65. Dividir el valor determinado por
halved value equals TDC. La valeur divisée par deux est le dos. El valor dividido por dos es el
PMH. PMS.

Example: 0°+50° = 25° ACTUAL Exemple: 0°+50° = 25° REEL Ejemplo: 0°+50° = 25° REAL
2 value 2 2

Turn crankshaft until halved value Virer le vilebrequin d’après cette Girar el árbol de manlvela al valor
is reached. valeur divisée par deux. dividido en dos.

66. Stop turning crankshaft. Loosen 2 66. Ne plus virer le vilebrequin. 66. A partir de ahora, no debe
knurled-head screws and set Desserrer les 2 vis moletées puis cambiarse la posición del cigüeñal.
graduated disc to „0“. régler le disque gradué sur 0. Soltar 2 tornillos de cabeza
moleteada y poner el disco
graduado en „0“.

67. Insert roller tappet. 67. Mettre en place le poussoir à galet. 67. Introducir el empujador de rodillo.

4.00.34
1056 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Determining commencement of Calcul du début d’injection sur la Determinación del comienzo de

delivery with Bosch injection pump pompe d’injection Bosch alimentación - bomba de inyección
Bosch

The commencement of delivery and Le début d’injection et depuis juillet El comienzo de alimentación y, desde
since about 07.96 also the type of 1996 le type de l’arbre à cames sont aprox. julio de 1996, también el tipo
camshaft are stamped on the rating indiqués sur la plaque signalétique. del árbol de levas figuran en la placa
plate. de fabricante.

68. Set dial gauge of measuring device 68. Régler le comparateur dans le 68. Ajustar el comparador del
under preload to 0. dispositif de mesure à la valeur 0. dispositivo de medición con
precarga a „0“.
Set value: Cote de réglage: Medida de ajuste:
BFM 1012 115 mm (100 780) BFM 1012 115 mm (100 780) BFM 1012 115 mm (100 780)
126 mm (100 860) 126 mm (100 860) 126 mm (100 860)
BFM 1013 150 mm (100 840) BFM 1013 150 mm (100 840) BFM 1013 150 mm (100 840)

69. Position roller tappet of the 69. Régler le poussoir à galet de la 69. El empujador de rodillo de labomba
injection pump to be timed on pompe d’injection à tarer sur le de inyección a ajustar debe
base circle. For that purpose turn cercle de base. Pour cela virer le encontrarse sobre el círculo base.
crankshaft by about 180° opposite vilebrequin d’environ 180° dans le Para ello, girar el cigüeñal aprox.
to direction of engine rotation. sens opposé au sens de rotation du 180° en sentido contrario al de giro
moteur. normal del motor.

70. Insert measuring device carefully. 70. Mettre en place le dispositif de 70. Introducir el dispositivo de
mesure avec la plus grande medición cuidadosamente.
précaution.

71. Measure dimension „L“, and enter 71. Mesurer le cote „L“ puis incrire 71. Medir el valor „L“ y registrarlo en la
in table 1, chapter 1. cette valeur dans le tableau, voir tabla, ver capítulo 1.
4 chap. 1.
Example: Exemple: Ejemplo:
BFM 1012 116.26 mm BFM 1012 116,26 mm BFM 1012 116,26 mm
126.57 mm 126,57 mm 126,57 mm
BFM 1013 152.22 mm BFM 1013 152,22 mm BFM 1013 152,22 mm

4.00.35
008 924 17 BOMAG 1057
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Förderbeginn ermitteln Bosch-

Einspritzpumpe
9
Der Förderbeginn und seit ca. 07.96 auch der
Nockenwellentyp, sind auf dem Firmenschild 6
angegeben.

68. Meßuhr in Meßvorrichtung mit Vor-

7
spannung auf 0 stellen.
Einstellmaß:
BFM 1012 115 mm (100 780)
126 mm (100 860)
BFM 1013 150 mm (100 840)

69. Rollenstößel der zur einzustellenden

Einspritzpumpe auf Grundkreis stellen.
Hierzu Kurbelwelle ca. 180° entgegen der
9
Motordrehrichtung drehen.

70. Meßvorrichtung vorsichtig einsetzen.

4
r

71. Maß “L” messen und in Tabelle, siehe

Kapitel 1, eintragen. 6 4
Beispiel:
BFM 1012 116,26 mm
126,57 mm
BFM 1013 152,22 mm
"L"

4.00.35
1058 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

72. Meßuhr über den Außenring auf Zeiger-

6 Nullstellung drehen.

5 Hinweis: Bei der Vorhubeinstellung darf die

Drehrichtung nicht mehr verändert
werden.

73. Kurbelwelle in Motordrehrichtung drehen

9 bis Meßuhr auf Vorhubmaß anzeigt.
Siehe Tabelle 1.

6 Beispiel BFM 1012: Förderbeginn 9°

Nockenwelle Typ C
Vorhub 4,63 mm
Beispiel BFM 1013: Förderbeginn 10°
Nockenwelle Typ A
Vorhub 5,31 mm

74. Förderbeginn IST ablesen und in Tabelle,

9 siehe Kapitel 1, eintragen.
Beispiel: BFM 1012 8°
BFM 1013 10°

75. Maß “A” = Kennzahl für Einspritzpumpen-

4 9 länge ablesen und in Tabelle, siehe Kapitel 1,
eintragen.
Beispiel: BFM 1012 53
BFM 1013 133

4.00.36
008 924 17 BOMAG 1059
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

72. Set pointer of dial gauge to 0 with 72. Virer le comparateur au niveau de 72. Poner la aguja del comparador
outer ring. la bague extérieure en position 0. mediante el anillo exterior en
posición „0“.

Note: The direction of rotation must Nota: pour le réglage de la précourse Nota: Para el ajuste de la carrera
not be changed anymore when ne plus modifier le sens de previa, ya no se debe modificar
the pre-stroke position has rotation. el sentido de giro.
been reached.

73. Turn crankshaft in direction of 73. Virer le vilebrequin dans le sens 73. Girar el cigüeñal en el sentido de
engine rotation until dial gauge de rotation jusqu’à ce que le giro normal del motor hasta que el
indicates pre-stroke dimension, comparateur indique la cote de comparador marque el valor de la
see table 1. précourse. Voir tableau 1. carrera previa. Ver tabla 1.

Example BFM 1012: Exemple BFM 1012: Ejemplo: BFM 1012:

Comencement of delivery 9° début d’injection 9° comienzo de alimentación 9°
Camshaft type C arbre à cames type C árbol de levas, tipo C
Pre-stroke 4.63 mm précourse 4,63 mm carrera previa 4,63 mm
Example BFM 1013: Exemple BFM 1013: Ejemplo: BFM 1013:
Commencement of delivery 10° début d’injection 10° comienzo de alimentación 10°
Camshaft type A arbre à cames type A árbol de levas, tipo A
Pre-stroke 5.31 mm précourse 5,31 mm carrera previa 5,31 mm

74. Read off ACTUAL commencement 74. Lire début d’injection VALEUR 74. Leer el comienzo de alimentación
of delivery and enter in table, REELLE et l’inscrire sur le tableau, REAL y registrarlo en la tabla, ver
chapter 1. voir chap. 1. capítulo 1.
Example: Exemple: Ejemplo:
BFM 1012 8° BFM 1012 8° BFM 1012 8°
BFM 1013 10° BFM 1013 10° BFM 1013 10°

75. Read off dimension „A“ = code for 75. Lire cote „A“ = indice de longueur 75. Leer el valor „A“ = índice de l
injection pump length and enter in de pompe d’injection et inscrire la ongitud de la bomba de inyección y
table, chapter 1. valeur sur le tableau, voir chap. 1. registrarlo en la tabla, vercapítulo1. 4
Example: Exemple: Ejemplo:
BFM 1012 53 BFM 1012 53 BFM 1012 53
BFM 1013 133 BFM 1013 133 BFM 1013 133

4.00.36
1060 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

76. Remove measuring device. 76. Déposer l’appareil de mesure. 76. Desmontar el aparato de medición.
Determine shims. Calculer l’épaisseur de la rondelle Determinar la arandela de reglaje.
See chapter 1. de compensation. Voir chap. 1. Ver capítulo 1.

77. Position selected shim on roller 77. Placer la rondelle de compensation 77. Colocar la arandela de reglaje
tappet. calculée sur le poussoir à galet. determinada sobre el empujador de
rodillo.

Note: The measuring procedures Nota: effectuer le relevé des mesures Nota: Las operaciones de medicióndel
under items 62-77 is to be indiquées aux points 62 à 77 punto 62 al punto 77 han de
carried out for each injection pour chaque pompe d’injection. repetirse para cada bomba de
pump. inyección.

Injection pump Pompe d’injection Bomba de inyección

78. Turn injection pump linkage lever 78. Virer le levier de la pompe 78. Girar la palanca de dirección de la
to approx. middle position. d’injection approximativement en bomba de inyección
position milieu. aproximadamente a la posición
intermedia.

Note: The assembly procedure under Nota: effectuer l'opération de Nota: Realizar La operación de
items 78-84 is to be carried out montage du position 78 à 84 montaje, puntos 78 - 84, para
for each injection pump. pour n' importe quelle pompe cada bomba de inyección.
d'injection.

79. Position roller tappet of relevant 79. Placer le poussoir à galet du 79. Colocar el empujador del cilindro
cylinder on base circle. Lightly oil cylindre concerné sur le cercle de correspondiente sobre el círculo
4 receiving bore in crankcase and O- base. Huiler légèrement les joints base. Untar con un poco de aceite
seals of injection pump. Carefully toriques de la pompe d’injection et el taladro de alojamiento en el
introduce injection pump linkage l’alésage de positionement du bloc bloque motor y los anillos tóricos
lever into control rod. moteur. Insérer avec précaution le de la bomba de inyección.
levier de direction de la pompe Introducir cuidadosamente la
d’injection sur la crémaillère. palanca de dirección de bomba de
inyección en la cremallera.

4.00.37
008 924 17 BOMAG 1061
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

76. Meßgerät abbauen.

Ausgleichsscheiben ermitteln.
Siehe Kapitel 1.
3
9

77. Ermittelte Ausgleichsscheibe auf

Rollenstößel auflegen. 4
Hinweis: Der Meßvorgang von Pos. 62 - 77 ist
für jede Einspritzpumpe durchzufüh- 5
ren.

Einspritzpumpe

78. Einspritzpumpenlenkhebel auf ca. Mittel-

9
stellung drehen .
6
Hinweis: Der Montagevorgang von Pos. 78 -
84 ist für jede Einspritzpumpe 5
durchzuführen.

79. Rollenstößel des jeweiligen Zylinders auf

Grundkreis stellen.
Aufnahmebohrung im Kurbelgehäuse und
4 4
Runddichtringe der Einspritzpumpe leicht
einölen.
9
Einspritzpumpenlenkhebel vorsichtig in die
Regelstange einführen. z

4.00.37
1062 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

80. Flansch auflegen.

4 Hinweis: Anfasung muß zum Einspritzpum-

5 penkörper weisen.

81. Schrauben leicht einölen und mit einem

4 Drehmoment von 5 Nm gleichmäßig fest-
drehen.

z
6

82. Schrauben wieder 60° lösen.

3
6

83. Einspritzpumpe mit Verdrehschlüssel

4 4 gegen Uhrzeigersinn vorsichtig bis zum

fühlbaren Anschlag drehen.
6

4.00.38
008 924 17 BOMAG 1063
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

80. Position flange. 80. Mettre en place la bride. 80. Colocar la brida.

Note: Chamfer must face injection Nota: le chanfreinage doit être Nota: El biselado debe indicar hacia el
pump body. orienté vers le corps de la cuerpo de la bomba inyectora.
pompe d’injection.

81. Lightly oil bolts and tighten 81. Huiler modérément les vis et les 81. Untar con un poco de aceite los
uniformly with a torque of 5 Nm. serrer uniformément au couple de tornillos y apretarlos
5 Nm. uniformemente con un par de
5 Nm.

82. Loosen bolts again by 60°. 82. Desserrer à nouveau les vis de 60°. 82. Volver a aflojar los tornillos 60°.

83. Turn injection pump with wrench 83. Serrer avec précaution la pompe 83. Sirviéndose de la Ilave de giro,
carefully counter-clockwise until d’injection dans le sens antihoraire girar la bomba de inyección
tangible stop. jusqu’en position de butée sensible. cuidadosamente en el sentido anti- 4
horario hasta el tope perceptible.

4.00.38
1064 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

84. Tighten bolts by 60° and then 84. Serrer à nouveau lesvis à 60° et par 84. Apretar los tornillos de nuevo con
alternately with a torque of passes successives au couple de 60° y apretarlos en escalones con
7 Nm, 10 Nm and 30 Nm. 7 Nm, 10 Nm et 30 Nm. un par de 7 Nm, 10 Nm y 30 Nm.

Note: Start with the outer bolt, remote Nota: commencer á chaque fois par la Nota: Comenzar siempre con el
of the flywheel (see arrow). vis extérieure la plus éloignée tornillo exterior, más alejado del
du volant moteur (voir flèche). volante (ver la flecha).

Gauging control rod travel with Mesurer le déplacement de la Determinación del recorrido de la
injection pumps installed crémaillère avec les pompes cremallera con las bombas de
d’injection inyección montadas.

85. Undo setscrew from locking device. 85. Dévisser et extraire la vis 85. Desenroscar del dispositivo el
Turn locking device. d’immobilisation du dispositif. Virer tornillo de bloqueo. Girar el
le dispositif. dispositivo.

86. Gauge from locking device to stop 86. Mesurer la distance entre le 86. Medir la distancia entre el
position of control rod. dispositif et la position stop de la dispositivo y la cremallera en
crémaillère. posición de parada.

86.1 Gauge from locking device to 86.1 Mesurer la distance entre le 86.1 Medir la distancia entre el
start position of control rod. dispositif et la position dispositivo y la cremallera en
démarrage de la crémaillère. posición de arranque.

Difference between stop and start La différence par rapport à la position La diferencia entre ambos valores da el
positions equals control rod travel. stop donne la course de la crémaillère. recorrido de la cremallera.
4
Example: Exemple : Ejemplo:
stop position = 30.5 mm position stop = 30,5 mm Posición de parada = 30,5 mm
start position = 13.4 mm position démarrage = 13,4 mm Posición de arranque = 13,4 mm
control rod travel = 17.1 mm déplacement de la Recorrido de la cremallera = 17,1 mm
crémaillère = 17,1 mm
Min. control rod travel 16.8 mm Déplacement de la Recorrido mínimo de la
crémaillère 16,8 mm cremallera 16,8 mm

4.00.39
008 924 17 BOMAG 1065
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

84. Schrauben wieder 60° festdrehen und in

Stufen mit einem Drehmoment von 7 Nm,
10 Nm und 30 Nm festdrehen.
4
Hinweis: Mit der jeweils außenliegenden, vom 6
5
Schwungrad entfernteren Schraube
beginnen. (siehe Pfeil)

Regelstangenweg messen mit Einspritz-

pumpen 3
85. Feststellschraube aus Vorrichtung heraus-
schrauben. Vorrichtung drehen.

86. Von Vorrichtung bis zur Stopstellung der

Regelstange messen. 6

86.1 Von Vorrichtung bis zur Startstellung der

Regelstange messen. 6 4
Differenz zur Stopstellung ergibt Regel-
stangenweg.
9
Beispiel: Stopstellung = 30,5 mm
Startstellung = 13,4 mm
Regelstangenweg = 17,1 mm

Regelstangenweg mindestens 16,8 mm

4.00.39
1066 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

87. Feststellvorrichtung, Zeiger und Grad-

3 scheibe abbauen.

Leichtgängigkeit der Regelstange prüfen

9 88. Beim langsamen Hineinschieben der
Regelstange darf kein ungleichmäßiger
Widerstand auftreten.
Nach dem Loslassen muß die Regelstange
durch die Feder aus jeder Position in die
Ausgangslage zurückgedrückt werden.

Regelstangenweg messen für Regleran-

6 passung

89. Regelstangenweg (Rückstandsmaß) vom

Räderkastendeckel bis zur Stopstellung
messen.

Dieses ermittelte Maß ist bei Regleraus-

tausch oder Reglerreparatur unbedingt
anzugeben.

4.00.40
008 924 17 BOMAG 1067
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

87. Remove locking device, pointer and 87. Déposer le dispositif 87. Desmontar el dispositivo de
graduated disc. d’immobilisation, l’index et le bloqueo, el indicador y el disco
disque gradué. graduado.

Checking ease of movement of Contrôle du libre coulissement de la Comprobar el fácil movimiento de la

control rod crémaillère cremallera

88. When slowly introducing the 88. Lors de l'introduction lente de la 88. Introciendo lentamente la
control rod, there must not occur crémaillère, aucune résistance cremallera no se deberá percibir
any unequal resistance. irrégulière ne doit se produire. ninguna resistencia desigual.
After detaching the control rod, the Après avoir relâché la crémaillère Al soltar la cremallera deberá volver
spring must press it from any doit pouvoir revenir, grâce au a su posición de partida desde
position back into its original ressort, dans sa position de départ cualquier posición, por fuerza del
position â partir de n'importe quelle resorte.
position.

Gauging control rod travel for Mesurer la course de la crémaillère Determinación del recorrido de la
governor adjustment par ajustement du régulateur cremallera para la adaptación del
regulador
89. Gauge control rod travel from 89. Mesurer la cource de la crémaillère
surface of timing chest cover to (côte de retrait) du couvercle de la 89. Medir el recorrido (medida de
stop position. distribution à la position stop. retroceso) de la tapa del cárter de
It is mandatory to indicate the Toujours indiquer cette cote lors la distribución a la posición de
dimension determined when d'un changement ou d'une parada.
replacing or repairing the governor. réparation du régulateur. El valor determinado de esta
manera, tendrá que ser indicado,
imprescindiblemente, para la
reparación o sustitución del
regulador.

4.00.40
1068 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Flywheel/V-belt pulley Volant moteur/poulie à gorge Volante / polea acanalada

90. Position flywheel, using a selfmade 90. Mettre en place le volant moteur en 90. Colocar el volante en su sitio,
guide mandrel. Secure bolts utilisant un mandrin de guidage de utilizando un mandril de guía de
fingertight. fabrication locale. Serrer les vis à la confección propia. Apretar los
main. tornillos a mano.

91. Retain flywheel. Tighten bolts 91. Maintenir le volant moteur. Serrer 91. Retener el volante. Apretar los
according to specification. les vis selon les consignes de Tornillos según prescripción.
serrage. Apriete inicial:
Initial tightening torque Valeur de préserrage tornillos 30 - 45 mm long
Bolts 30 - 45 mm long 20-30 Nm Vis 30 - 45 mm de long 20-30 Nm ________________ 20-30 Nm
Bolts 50 - 85 mm long 30-40 Nm Vis 50 - 85 mm de long 30-40 Nm tornillos 50 - 85 mm long
1st tightening angle 1er serrage à l’angle ________________ 30-40 Nm
bolts 30 - 85 mm long ______ 60° vis 30 - 85 mm de long _____ 60° 1er ángulo de reapriete
2nd tightening angle 2e serrage à l’angle tornillos 30 - 85 mm long ___ 60°
bolts 30 mm long __________ 30° vis 30 mm de long _________ 30° 2o ángulo de reapriete
bolts 35-85 mm long _______ 60° vis 35 - 85 mm de long _____ 60° tornillos 30 mm long _______ 30°
tornillos 35 - 85 mm long ___ 60°
Note: Bolts may be used 5x if Nota: les vis peuvent être utilisées, Nota: Los tornillos son reutilizables
evidence can be furnished selon la pratique, 5 fois au hasta 5 veces, siempre que
concerning their use. maximum. esto se pueda comprobar.

92. Fit V-belt pulley and retain against 92. Monter la poulie et maintenir le 92. Montar la polea acanlada, retenerla
flywheel. Tighten bolts according to volant moteur. Serrer les vis selon en el volante y apretar los tornillos
specifications. les consignes de serrage. según prescripción.

Initial tightening torque 40-50 Nm Valeur de préserrage _ 40 - 50 Nm Apriete inicial: _______ 40-50 Nm
1st tightening angle 1er serrage à l'angle 1er ángulo de reapriete:
bolts 60 mm long __________ 60° vis 60 mm de long _________ 60° tornillos 60 mm long _______ 60°
bolts 80 mm long __________ 60° vis 80 mm de long _________ 60° tornillos 80 mm long _______ 60°

2nd tightening angle 2e serrage à l'angle 2° ángulo de reapriete:

bolts 60 mm long __________ 30° vis 60 mm de long _________ 30° tornillos 60 mm long _______ 30°
bolts 80 mm long __________ 60° vis 80 mm de long _________ 60° tornillos 80 mm long _______ 60°

Note: Use Torx socket wrench E20. Nota: utiliser la clé à douille Torx E20. Nota: Utilizar la llave de vaso Torx
4 Bolts may be used max. 5x if Les vis peuvent être utilisées, E20. Los tornillos son
evidence can be furnished selon la pratique, 5 fois au reutilizables hasta 5 veces,
concerning their use. maximum. siempre que esto se pueda
comprobar.

4.00.41
008 924 17 BOMAG 1069
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Schwungrad/Keilriemenscheibe

90. Schwungrad unter Verwendung eines

4
selbstgefertigten Führungsdornes
aufsetzen. Schrauben handfest anziehen.

91. Schwungrad gegenhalten. Schrauben nach

Anziehvorschrift festdrehen. 4
Vorspannwert:
Schrauben 30 - 45 mm lang __ 20-30 Nm
Schrauben 50 - 85 mm lang __ 30-40 Nm
6
1. Nachspannwinkel
Schrauben 30 - 85 mm lang _______ 60°
5
2. Nachspannwinkel
Schrauben 30 mm lang ___________ 30°
Schrauben 35 - 85 mm lang _______ 60°

Hinweis: Schrauben können bei Nachweis-

barkeit max. 5x wiederverwendet
werden.
4
92. Keilriemenscheibe anbauen und am
Schwungrad gegenhalten. Schrauben nach
Anziehvorschrift festdrehen.
6
Vorspannwert: ______________ 40-50 Nm
1. Nachspannwinkel
5
Schrauben 60 mm lang ____________ 60°
Schrauben 80 mm lang ____________ 60°
2. Nachspannwinkel
Schrauben 60 mm lang ____________ 30°
Schrauben 80 mm lang ____________ 60°
Hinweis: Torx-Steckschlüssel E20 verwenden.
Schrauben können bei Nachweis-
barkeit max. 5x wiederverwendet 4
werden.

4.00.41
1070 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

Zylinderkopf
4 93. Zylinderkopfdichtung bestimmen.

7 94. Abstandsplättchen auf die Dichtfläche des

6
Zylinderkurbelgehäuse legen und Meßuhr
auf “0” stellen.

95. Meßuhr an den Meßstellen auf den Kolben

4 setzen und den größten Kolbenüberstand
ermitteln.
6 Hinweis: Alle Kolben müssen vermessen

5
werden.

96. Meßpunkte beachten.

9
90

BFM 1012 90 mm
BFM 1013 95 mm

4.00.42
008 924 17 BOMAG 1071
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Cylinder head Culasse Culata

93. Determine cylinder head gasket. 93. Définir le joint de culasse. 93. Determinar junta de culata.

94.Place spacers on sealing surface of 94. Placer les plaquettes d’écartement 94. Poner las plaquitas distanciadoras
crankcase with integrated liners sur le plan de joint du bloc moteur sobre la superficie de cierre del
and set dial gauge to „0“. et régler le comparateur sur „0“. bloque motor y ajustar el
comparador a „0“.

95. Position dial gauge on piston at 95. Placer le comparateur aux points 95. Colocar el comparador sobre el
gauge points and determine max. de mesure sur le piston et calculer pistón en los puntos de medición y
piston projection. la plus grande cote d dépassement. determinar el saliente máximo del
pistón.

Note: All pistons must be gauged. Nota: le relevé des mesures doit être Nota: Este valor deberá determinarse
fait sur tous les pistons. para todos los pistones.

96. Watch gauge points. 96. Veiller aux points de mesure. 96. Observar los puntos de medición.

BFM 1012 90 mm BFM 1012 90 mm BFM 1012 90 mm

BFM 1013 95 mm BFM 1013 95 mm BFM 1013 95 mm

4.00.42
1072 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

97. Compare max. value with table and 97. Comparer à l’aide du tableau la 97. Comparar el valor máximo con la
determine appropriate cylinder valeur la plus élevée puis définir le tabla y definir la junta de culata
head gasket. joint de culasse correspondant. correspondiente.

BFM 1012 BFM 1012 BFM 1012

Piston Marking of Cote de Caractéristique Saliente de pistón Marcación de la

projection cylinder head gasket dépassement joint culasse junta de culata
piston

0.43 - < 0.64 mm 1 hole 0,43 - < 0,64 mm 1 trou 0,43 - < 0,64 mm 1 agujero
0.64 - < 0.74 mm 2 holes 0,64 - < 0,74 mm 2 trous 0,64 - < 0,74 mm 2 agujeros
0.74 - 0.85 mm 3 holes 0,74 - 0,85 mm 3 trous 0,74 - 0,85 mm 3 agujeros

BFM 1013 BFM 1013 BFM 1013

Piston Marking of Cote de Caractéristique Saliente de pistón Marcación de la

projection cylinder head gasket dépassement joint culasse junta de culata
piston

0.28 - < 0.54 mm 1 hole 0,28 - < 0,54 mm 1 trou 0,28 - < 0,54 mm 1 agujero
0.54 - < 0.64 mm 2 holes 0,54 - < 0,64 mm 2 trous 0,54 - < 0,64 mm 2 agujeros
0.64 - 0.75 mm 3 holes 0,64 - 0,75 mm 3 trous 0,64 - 0,75 mm 3 agujeros

98. Position cylinder head gasket. 98. Placer le joint de culasse. 98. Colocar la junta de culata.

Note: Sealing surfaces for cylinder Nota: les plans de joint du joint de Nota: Las superficies de cierre para la
head gasket must be clean and culasse doivent être propres et junta de culata deben estar
free of oil. Watch out for dowel sans huile. Veiller aux douilles limpias y exentas de aceite.
sleeves. d’ajustage. Prestar atención a los
casquillos de ajuste.

4.00.43
008 924 17 BOMAG 1073
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

97. Größten Wert mit der Tabelle vergleichen

und entsprechende Zylinderkopfdichtung
ermitteln.
9
BFM 1012

Kolbenüberstand Kennzeichnung der

Zylinderkopfdichtung

0,43 - < 0,64 mm 1 Loch

0,64 - < 0,74 mm 2 Löcher
0,74 - 0,85 mm 3 Löcher

BFM 1013

Kolbenüberstand Kennzeichnung der

9
Zylinderkopfdichtung

0,28 - < 0,54 mm 1 Loch

0,54 - < 0,64 mm 2 Löcher
0,64 - 0,75 mm 3 Löcher

98. Zylinderkopfdichtung auflegen.

Hinweis: Dichtflächen für Zylinderkopfdich-

4
tung müssen sauber und ölfrei sein.
Auf Paßhülsen achten.
8
5

4.00.43
1074 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

Zylinderkopf mit Ventiltrieb BFM 1012

4 99. Zylinderkopf aufsetzen. Kurze Zylinderkopf-

z schrauben leicht einölen und beidrehen.

5
Hinweis: Zylinderkopfschrauben können
bei Nachweisbarkeit max. 5x
verwendet werden.

100. Stoßstangen einsetzen.

101. Kipphebelbock montieren und zu den

4 Stoßstangen/Ventilen ausrichten.

102. Lange Zylinderkopfschrauben leicht

4 4 einölen und beidrehen. M8 Schraube

einsetzen und beidrehen.
z Hinweis: Zylinderkopfschrauben können

5 bei Nachweisbarkeit max. 5x

verwendet werden.

4.00.44
008 924 17 BOMAG 1075
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Cylinder head with valve gear Culasse et culbuterie du BFM 1012 Culata con accionamiento de
BFM 1012 válvulas, BFM 1012

99. Position cylinder head. Lightly oil 99. Mettre en place la culasse. Huiler 99. Colocar la culata. Untar con un
and start short cylinder head bolts. légèrement les vis de culasse et les poco de aceite los tornillos de
serrer modérément. culata cortos y apretarlos hasta que
se apoyen.

Note: Cylinder head bolts may be Nota: réutiliser les vis de culasse au Nota: Los tornillos de culata son
reused max. 5x if evidenced can moins 5 fois. reutilizables hasta 5 veces,
be furnished concerning their siempre que esto se pueda
use. comprobar.

100. Insert pushrods. 100. Mettre en place les tiges de 100. Introducir las varillas de empuje.
culbuteurs.

101. Fit rocker arm bracket and align 101. Monter le support des 101. Montar el soporte de balancines
relative to pushrods/valves. culbuteurs et l’aligner par y alinearlo con respecto a las
rapport aux tiges de culbuteurs/ varillas de empuje / válvulas.
soupapes.

102. Lightly oil and start long 102. Huiler légèrement les vis de 102. Untar con un poco de aceite los
cylinder head bolts. Insert and culasse longues et les serrer tornillos de culata largos y
start M8 bolt. modérément. Placer une vis M8 apretarlo hasta que se apoyen. 4
et serrer à la main. Meter el tornillo M8 y apretarlo
hasta que se apoye.

Note: Cylinder head bolts may be Nota: réutiliser les vis de culasse au Nota: Si es comprobable, se pueden
reused max. 5x if evidenced can moins 5 fois. utilizar los tornillos a lo sumo
be furnished concerning their 5 veces.
use.

4.00.44
1076 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

103. Tighten M8 bolt with a torque 103. Serrer la vis M8 au couple de 103. Apretar el tornillo M8 con un
of 21 Nm. 21Nm. par de 21 Nm.

104. Tighten cylinder head bolts 104. Serrer les vis de culasse selon 104. Apretar los tornillos de culata
according to specification. les préconisations de serrage: según prescripción.

Initial tightening torque: Valeur préserrage Apriete inicial:

1st stage ____________ 30 Nm 1ère phase __________ 30 Nm 1ª fase _____________ 30 Nm
2nd stage ___________ 80 Nm 2ème phase _________ 80 Nm 2ª fase _____________ 80 Nm

Tightening angle: _____________ 90° Serrage définiti: ______________ 90° Reapriete: _____________ 90°

Note: Observe tightening order for Nota: tenir compte de l’ordre de Nota: Observar el orden de sucesión
cylinder head bolts. See serrage des vis de culasse. Voir al apretar los tornillos de culata.
Specification Data. caractéristiques techniques. Ver Datos técnicos.

Note: Adjust valve clearance - see Nota: pour le réglage du jeu aux Nota: Ajustar el juego de válvulas, ver
chapter 2. soupapes voir chapitre 2. capítulo 2.

Cylinder head with valve gear Culasse et culbuterie BFM 1013 Culata con accionamiento de
BFM 1013 válvulas, BFM 1013
4
105. Position cylinder head. Lightly 105. Mettre la culasse en place. 105. Colocar la culata. Untar con un
oil and start cylinder head bolts. Huiler légèrement les vis de poco de aceite los tornillos de
culasse et les serrer à la main. culata cortos y apretarlos hasta
que se apoyen.
Note: Cylinder head bolts may beused Nota: les vis de culasse sont Nota: Los tornillos de culata son
max. 5x if evidence can be réutilisables au moins 5 fois. reutilizables hasta 5 veces,
furnished concerning their use. siempre que esto se pueda
comprobar.

4.00.45
008 924 17 BOMAG 1077
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

103. M8 Schraube mit einem Drehmoment von

21 Nm festdrehen.
4
6

104. Zylinderkopfschrauben nach Anziehvor-

schrift festdrehen. 4
Vorspannwert:
1. Stufe ____________________ 30 Nm 6
5
2. Stufe ____________________ 80 Nm
Nachspannen: __________________ 90°

Hinweis: Reihenfolge beim Anziehen der

Zylinderkopfschrauben beachten.
Siehe Techn. Daten.

Hinweis: Ventilspiel einstellen siehe Kapitel 2.

Zylinderkopf mit Ventiltrieb BFM 1013

105. Zylinderkopf aufsetzen. Zylinderkopf-

4 4
schrauben leicht einölen und beidrehen.
z
5
Hinweis: Zylinderkopfschrauben können bei
Nachweisbarkeit max. 5x verwendet
werden.

4.00.45
1078 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

106. Zylinderkopfschrauben nach Anziehvor-

4 schrift festdrehen.

6 Vorspannwert:
1. Stufe ____________________ 50 Nm

5
2. Stufe ___________________ 130 Nm
Nachspannen: __________________ 90°

Hinweis: Reihenfolge beim Anziehen der

Zylinderkopfschrauben beachten.
Siehe Techn. Daten.

107. Stoßstangen einsetzen.

108. Kipphebelbock montieren und zu den

4 Stoßstangen/Ventilen ausrichten.

109. Schraube mit einem Drehmoment von

4 4 21 Nm festdrehen.

6 Hinweis: Ventilspiel einstellen, siehe Kapitel 2.

4.00.46
008 924 17 BOMAG 1079
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

106. Tighten cylinder head bolts 106. Serrer les vis de culasse selon 106. Apretar los tornillos de culata
according to specification. les préconisations de serrage. según prescripción.

Initial tightening torque: Valeur préserrage: Apriete inicial:

1st stage ___________ 50 Nm 1ère phase __________ 50 Nm 1ª fase _____________ 50 Nm
2nd stage _________ 130 Nm 2ème phase ________ 130 Nm 2ª fase ___________ 130 Nm
Tightening angle: ________ 90° Serrage définitif ________ 90° Reapriete: _____________ 90°

107. Insert pusrods. 107. Introduire les tiges de culbuteurs. 107. Introducir las varillas de empuje.

108. Fit rocker arm bracket and align 108. Monter le support des culbuteurs 108. Montar el soporte de balancines y
towards pushrods/valves. et l’aligner par rapport aux tiges alinearlo con respecto a las
de culbuteurs/soupapes. varillas de empuje / válvulas.

109. Tighten bolt with a torque of 109. Serrer la vis M8 au couple de 109. Apretar el tornillo con un par de
21 Nm. 21 Nm. 21 Nm.
4
Note: Adjust valve clearance, see Nota: pour le réglage du jeu aux Nota: Ajustar el juego de válvulas, ver
chapter 2. soupapes voir chapitre 2. capítulo 2.

4.00.46
1080 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

110. Fit pencil-type glow plugs or 110. Monter les bougies de 110. Montar las piezas de cierre o
blanking parts. préchauffage ou les éléments de bujías de espiga de
fermeture. incandescencia.

111. Tighten pencil-type glow plugs or 111. Serrer les bougies de 111. Apretar las piezas de cierre o
blanking parts with a torque of préchauffage ou les éléments de bujías de espiga de
20 ± 2 Nm. fermeture au couple de incandescencia con un par de
20 ± 2 Nm. 20 ± 2 Nm.

Shutdown solenoid Electroaimant d'arrêt Solenoide de parada

112. Press control rod into stop posi- 112. Pousser et maintenir la crémail- 112. Empujar la barra cremallera en la
tion and hold in place. Fit shut- lère en position de stop. Monter posición de parada, reteniéndola.
down solenoid with new O-seal. électroaimant d’arrêt avec un Montar el solenoide de parada
joint torique neuf. con un anillo tórico nuevo.

Note: Lightly oil O-seal. Nota: huiler légèrement le joint Nota: Untar con un poco de aceite el
torique. anillo tórico.

113. Tighten bolts with a torque 113. Serrer les vis au couple 113. Apretar los tornillos con un par
of 21 Nm. de 21 Nm. de 21 Nm.
4

4.00.47
008 924 17 BOMAG 1081
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

110. Glühstiftkerzen oder Verschlußteile

einbauen.
4

111. Glühstiftkerzen oder Verschlußteile mit

einem Drehmoment von 20 ± 2 Nm
festdrehen.
4
6

Abstellmagnet

112. Regelstange in Stop-Stellung drücken und

4
festhalten. Abstellmagnet mit neuem Rund-
dichtring einbauen.
ß
Hinweis: Runddichtring leicht einölen. 5

113. Schrauben mit einem Drehmoment von

21 Nm festdrehen. 4 4
6

4.00.47
1082 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

Einspritzventil/Einspritzleitungen
4 114. Neue Dichtung mit etwas Fett auf das

ß Einspritzventil aufschieben und Einspritz-

ventil einsetzen.

u Hinweis: Leckölanschluß muß zur Abgasseite

weisen.
5

115. Spannpratzen aufsetzen. Schraube lose ein-

4 schrauben.

116. Neue Einspritzleitung mit Dichtgummi an-

4 bauen. Überwurfmuttern fingerfest auf-
schrauben.
38-4-193 ß Hinweis: Bei Montage der Einspritzleitungen

5
müssen die Dichtkonen exakt aufein-
andersitzen.
Ein Nachbiegen ist nicht zulässig.
Die Einspritzleitungen dürfen nicht
2x verwendet werden.

117.Schraube der Spannpratzen mit einem Dreh-

4 4 moment von 16 + 5 Nm festdrehen.

4.00.48
008 924 17 BOMAG 1083
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Injector/injection lines Injecteur/conduites d’injection Inyector/tuberías de inyección

114. Slide new seal over injector using 114. Insérer avec un peu de graisse un 114. Colocar la junta nueva con un
some grease and insert injector. joint neuf sur l’injecteur et mettre poco de grasa sobre el inyector
en place l’injecteur. e instalar éste.

Note: leakage fuel line connection Nota: le raccordement de la conduite Nota: El racor de combustible
must face the exhaust side. de retour des fuites doit être sobrante debe indicar hacia el
orienté dans le sens lado de escape.
échappement.

115. Position clamping pads. Start 115. Placer les griffes de serage et 115. Colocar las patas de sujeción.
bolt. visser boulon sans serrer. Enroscar el tornillo, dejándolo
suelto.

116. Fit new injection line with sealing 116. Monter une conduite d’injection 116. Montar la tubería de inyección
rubber. Screw on cap nuts finger- neuve avec un caoutchouc d’étan- nueva con una junta de goma.
tight. chéité. Serrer les écrous-raccords Enroscar las tuercas de empalme
modérément à la main. con la mano.

Note: When fitting the injection lines, Nota: au montage des conduites Nota: Al montar las tuberías de
the sealing cones must match d’injection les cônes inyección, se deberá cuidar de
pecisely. d’étanchéité doivent que los conos de obturación
Rebending is not permissible. parfaitement correspondre. queden asentados unos
The injection lines must not Un recintrage n’est pas exactamente sobre los otros.
be used twice. autorisé. Ne jamais utiliser Es inadmisible corregir el
deux fois les conduites curvado. La tuberías de
d’injection. inyección no deben ser
empleadas dos veces.
117. Tighten bolt of clamping pads 117. Visser le boulon des griffes de 117. Apretar el tornillo de las patas de
with a torque of 16 + 5 Nm. serrage au couple de 16 + 5 Nm. sujeción con un par de 16 + 5 Nm.
4

4.00.48
1084 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

118. Preload cap nuts of injection line 118. Préserrer les écrous-raccords de 118. Apretar las tuercas de empalmede
on injection pump and injector la conduite d’injection de la pom- las tuberías de inyección en la
with a torque of approx. 5 Nm. pe d’injection et de l’injecteur au bomba de inyección e inyector
Thereafter tighten cap nuts with couple d’environ 5 Nm. Ensuite inicialmente con un par de aprox.
a torque of 25 + 3.5 Nm. bloquer les écrous-raccords au 5 Nm y, luego, con un par de
couple de 25 + 3,5 Nm. 25 + 3,5 Nm.

119. Fit leakage fuel line and 119. Monter la conduite de retour des 119. Montar la tubería de combustible
introduce through sealing rubber. fuites et la faire passer à travers sobrante y hacarla pasar a través
les caouchoucs d’étanchéité. de las piezas obturantes de goma.

Note: Leaage fuel lines must always Nota: Il faut en principe renouveler les Nota: Las tuberías de combustible
be replaced. conduites de retour d’huile de sobrante deberán ser
fuite. sustituidas siempre por otras
nuevas.

120. Fit overflow valve with new Cu 120. Monter la soupape de décharge 120. Montar la válvula de rebose
seals and leakage fuel line.Tighten avec des joints Cu neufs et la provista de juntas de cobre
overflow valve with a torque of conduite de retour des fuites. nuevas y la tubería de
30 Nm. Serrer la soupape de décharge combustible sobrante. Apretar la
au couple de 30 Nm. válvula de rebose con un par de
30 Nm.

Air intake/exhaust manifold Collecteur d’admission/collecteur Colector de admisión / colector de

d’échappement escape
4
121. Mount air intake manifold with 121. Monter le collecteur d’admission 121. Montar el colector de admisión
new gaskets. avec des joints neufs. con juntas nuevas.

4.00.49
008 924 17 BOMAG 1085
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

118. Überwurfmuttern der Einspritzleitung an Ein-

spritzpumpe und Einspritzventil mit einem
Drehmoment von ca. 5 Nm vorspannen.
4
Danach die Überwurfmuttern mit einem
Drehmoment von 25 + 3,5 Nm festdrehen. 6

119. Leckölleitung anbauen und durch Dicht-

gummis einführen.
4
Hinweis: Leckölleitungen sind grundsätzlich
zu erneuern. 5
ß

120. Überströmventil mit neuen Cu-Dichtun-

gen und Leckölleitung anbauen.
Überströmventil mit einem Drehmoment
4
von 30 Nm festdrehen.
ß
6

Luftansaugrohr/Abgassammelrohr

121. Luftansaugrohr mit neuen Dichtungen

4 4
anbauen.
ß

4.00.49
1086 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

122. Schrauben für Ladeluftleitung mit einem

4 Drehmoment von 11 ± 1 Nm festdrehen.

123. Abgassammelrohr mit neuen Dichtungen

4 anbauen.
Die Umbördelung der Dichtung muß zum

ß Zylinderkopf weisen.

8
Hinweis: Stiftschrauben mit Deutz S1
Never Seize-Paste einstreichen.

124. Muttern für Abgassammelrohr mit einem

4 Drehmoment von 25 ± 2,5 Nm festdre-
hen.
6

Zylinderkopfhaube

4 4 125. Dichtung aufsetzen.

4.00.50
008 924 17 BOMAG 1087
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

122. Tighten bolts for charge air pipe 122. Serrer les vis de la conduite d’air 122. Apretar los tornillos de la tubería
with a torque of 11 ± 1 Nm. de suralimentation au couple de de aire de sobrealimentación con
11 ± 1 Nm. un par de 11 ± 1 Nm.

123. Mount exhaust manifold with new 123. Monter le collecteur 123. Montar el colector de escape con
gaskets. d’échappement avec des joints juntas nuevas.
The gasket bead must point neufs. El bordeado de la juntadebe
towards the cylinder head. Le bord rabattu du joint doit être indicar a la culata.
orienté vers la culasse.

Note: Apply Deutz S1 Never Seize Nota: enduire les goujons filetés de Nota: Aplicar a los espárragos pasta
paste to studs. pâte Deutz S1 Never Seize. Deutz S1 Never Seize.

124. Tighten nuts for exhaust manifold 124. Serrer les écrous du collecteur 124. Apretar las tuercas del colector de
with a torque of 25 ± 2.5 Nm. d’échappement au couple de escape con un par de
25 ± 2,5 Nm. 25 ± 2,5 Nm.

Cylinder head cover Culasse Tapa de culata

125. Position gasket. 125. Mettre en place le joint. 125. Colocar la junta. 4

4.00.50
1088 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

126. Fit cylinder head cover together 126. Monter la vis de culasse avec la 126. Montar la tapa de culata con
with cover plate and cable tôle de recouvrement et le chapa de recubrimiento y mazo
harness. Tighten bolts with a faisceau de câbles. Serrer les vis de cables. Apretar los tornillos
torque of 9 ± 1 Nm. au couple de 9 ± 1 Nm. con un par de 9 ± 1 Nm.

Lube oil cooler Radiateur à huile Refrigerador de aceite lubricante

127. Mount lube oil cooler with new 127. Monter le radiateur avec un 127. Montar el refrigerador de aceite
gasket. joint neuf. lubricante con una junta nueva.

128. Tighten bolts with a torque of 128. Serrer les vis au couple de 128. Apretar los tornillos con un par
21 ± 2 Nm. 21 ± 2 Nm. de 21 ± 2 Nm.

Note: Fit retainer for cable connector Nota: selon l’équipement du moteur Nota: Si lo hay, montar también el
as well if any. monter le support de liaison soporte para la conexión de
des câbles. cables.

129. Fit both screw plugs with new 129. Monter les deux tubulures à 129. Instalar ambos enchufes con
Cu seals. visser avec un joint Cu neufs. una junta de cobre nuevas.
4

4.00.51
008 924 17 BOMAG 1089
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

126. Zylinderkopfhaube mit Abdeckblech und

Kabelbaum montieren. Schrauben mit
einem Drehmoment von 9 ± 1 Nm fest-
4
drehen.
6

Schmierölkühler

127. Schmierölkühler mit neuer Dichtung

4
anbauen.
ß

128. Schrauben mit einem Drehmoment von

21 ± 2 Nm festdrehen. 4
Hinweis: Falls vorhanden, Halter für Kabel-
verbindung mitanbauen. 6
5

129. Beide Einschraubstutzen mit neuer Cu-

Dichtung anbauen. 4 4
ß

4.00.51
1090 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

130. Muttern mit einem Drehmoment von

4 50 ± 5 Nm festdrehen.

131. Kraftstoffilterdichtung leicht einölen.

4 Kraftstoffilterpatrone handfest andrehen.

132. Ölfilterdichtung leicht einölen.

4 Ölfilterpatrone handfest andrehen.

Kühlmittelpumpe

4 4 133. Steckstück.
ß Neue Runddichtringe aufziehen.

5
Hinweis: Runddichtringe mit Montagegleitmit-
tel AP25N bestreichen.

4.00.52
008 924 17 BOMAG 1091
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

130. Tighten nut with a torque of 130. Serrer les écrous au couple de 130. Apretar la tuerca con un par de
50 ± 5 Nm. 50 ± 5 Nm. 50 ± 5 Nm.

131. Lightly oil fuel filter gasket. 131. Huiler légèrement le joint du filtre 131. Untar con un poco de aceite la
Secure fuel filter cartridge à combustible. Serrer la junta del filtro de combustible.
fingertight. cartouche filtrante à la main. Apretar el cartucho filtrante con la
mano.

132. Lightly oil oil filter gasket. Secure 132. Huiler légèrment le joint du filtre à 132. Untar con un poco de aceite la
oil filter cartridge fingertight. huile. Serrer la cartouche filtrante junta del filtro de aceite. Apretar el
à la main. cartucho filtrante con la mano.

Coolant pump Pompe à réfrigérant Bomba de líquido refrigerante

133. Plug-in element 133. Pièce d'insertion. Monter les 133. Pieza de enchufe. 4
Slide on O-seals. joints toriques neufs. Colocar anillos tóricos nuevos.

Note: Apply lubricant AP25N to Nota: enduire le joint torique de Nota: Aplicar lubricante de montaje
O-seals. lubrifiant de montage AP25N. AP25N a los anillos tóricos.

4.00.52
1092 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

134. Press plug-in element into 134. Insérer l’élément enfichable dans 134. Introducir a presión la pieza de
thermostat housing and coolant le boîtier du thermostat et la enchufe en la caja del termostato
pump. pompe à réfrigérant. y en la bomba de líquido
refrigerante.

135. Insert new O-seals into 135. Monter le joint toique neuf dans 135. Montar un anillo tórico nuevo en
thermostat housing. le carter du thermostat. la caja del termostato.

Note: Apply lubricant AP25N to Nota: enduire le joint torique de Nota: Aplicar lubricante de montaje
O-seals. lubrifiant de montage AP25N. AP25N a los anillos tóricos.

136. Mount preassembled coolant 136. Monter la pompe à réfrigérant 136. Montar la bomba de líquido
pump with new gasket. préassemblée avec un joint neuf. refrigerante premontada, con una
junta nueva.

137. Tighten bolts alternately with a 137. Serrer alternativement les vis au 137. Apretar alternativamente los
torque of 21 ± 2 Nm. couple de 21 ± 2 Nm. tornillos con un par de
4 21 ± 2 Nm.

4.00.53
008 924 17 BOMAG 1093
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

134. Steckstück in Thermostatgehäuse und

Kühlmittelpumpe eindrücken.
4

135. Neuen Runddichtring in Thermostatge-

häuse einsetzen. 4
Hinweis: Runddichtring mit Montagemittel
AP25N bestreichen. ß
5

136. Vormontierte Kühlmittelpumpe mit neuer

Dichtung anbauen. 4
ß

137. Schrauben wechselseitig mit einem Dreh-

moment von 21 ± 2 Nm festdrehen. 4 4
6

4.00.53
1094 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

138. Kühlmitteltemperaturgeber mit neuer

4 Dichtung und Isolierschlauch, falls vor-
handen, mit einem Drehmoment von

ß 18 ± 2 Nm festdrehen.

Kraftstoffpumpe
4 139. Kraftstoffpumpe anbauen

5 Hinweis: Schrauben leicht andrehen.

140. Kraftstoffleitungen mit neuen Cu-Dichtun-

4 gen anbauen.
Cobraklemmenzange benutzen.
ß Hinweis: Achtung - Gewinde für Anschluß der

5
Zulaufleitung an der Kraftstoffpumpe
ist M16x1,5.

Ölansaugrohr/Ölwanne

4 4 141. Motor 180° drehen. Ölansaugrohr mit

ß neuer Dichtung anbauen.

5 Hinweis: Halter mitanbauen. Schrauben nicht

festdrehen.

4.00.54
008 924 17 BOMAG 1095
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

138. Fit coolant temperature sensor 138. Serrer au couple de 18 ± 2 Nm 138. Apretar con un par de 18 ± 2 Nm
with new seal and insulating hose, le capteur de produit refrigérant el transmisor de temperatura de
if any, and tighten with a avec un joint neuf et un tuyau refrigerante con una junta nueva
torque of 18 ± 2 Nm. isolant , si le moteur en est y, si existe, manguera aislante.
équipé d'un.

Fuel pump Pompe à combustible Bomba de combustible

139. Fit fuel pump. 139. Monter la pompe à combustible. 139. Montar la bomba de combustible.

Note: Start bolts. Nota: serrer légèrement les vis. Nota: Apretar ligeramente a mano los
tornillos.

140. Fit fuel lines with new Cu seals. 140. Monter les tuyauteries de 140. Montar las tuberías de
Use Cobra clamp pliers. combustible avec des joint Cu combustible con juntas de cobre
neufs. Utiliser la pince de serrage nuevas. Utilizar los alicates Cobra.
Cobra.

Note: Attention - thread for feed line Nota: attention - filetage du raccord Nota: Atención - la rosca para la
connection on fuel pump is de la conduite d’arrivée à la unión la tubería de entrada a la
M16x1.5. pompe à combustible est bomba de combustible es
M16x1,5. M16x1,5.

Oil suction pipe/oil pan Tube d’aspiration d’huile/carter Tubo de aspiración de aceite/cárter
d’huile de aceite
4
141. Turn engine by 180°. Fit oil 141. Virer le moteur de 180°. Monter le 141. Girar el motor por 180°. Montar el
suction pipe with new gasket. tube d’aspiration d’huile en tubo de aspiración de aceite con
utilisant un joint neuf. una junta nueva.

Note: Fit retainer as well. Do not Nota: monter le dispositif de Nota: Montar también el soporte. No
tighten bolts. maintien.Ne pas serrer les vis à apretar los tornillos.
fond.

4.00.54
1096 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

142. Order of tightening. 142. Ordre de serrage. 142. Orden de sucesión a seguir para
el apriete:

1. Bolts of oval flange 1. Vis de la bride ovale 1. Tornillos de la brida ovalada.

2. Retainer of oil suction pipe 2. Serrer le support de maintien 2. Soporte del tubo de aspiración
with a torque of 21 ± 2 Nm. du tube d’aspiration d’huile au de aceite, apretar con un par de
couple de 21 ± 2 Nm. 21 ± 2 Nm.

143. Cut off projecting gasket. 143. Sectionner la partie du joint qui 143. Cortar lo que sobresale de la
dépasse. junta.

144. Fill up joints of oil pan sealing 144. Remplir les joints du plan de joint 144. Tapar las juntas de la superficie
surface with Deutz DW 47. du carter d’huile de Deutz DW 47. de cierre del cárter de aceite con
Deutz DW 47.

145. Position new gasket on 145. Placer un joint neuf sur le bloc 145. Colocar una junta nueva sobre el
crankcase. moteur. bloque motor.
4

4.00.55
008 924 17 BOMAG 1097
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

142. Reihenfolge beim Festdrehen.

1. Schrauben des Ovalflansches

4
2. Halter des Ölansaugrohres
mit einem Drehmoment von 21 ± 2 Nm 6
festdrehen.

143. Überstehende Dichtung abschneiden.

144. Fugen der Ölwannendichtfläche mit Deutz

DW 47 auffüllen. 4
w

145. Neue Dichtung auf das Kurbelgehäuse

auflegen. 4 4
ß

4.00.55
1098 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

146. Bei Dichtung für Blechölwanne alle

w Aussparungen mit Deutz DW 74 auffüllen.

147. Bei Blechölwanne:

4 Ölwanne anbauen.

5 Hinweis: Markierte Einbaulage beachten.

148. Bei Gußölwanne:

4 Ölwanne anbauen und zum Räderkasten-
deckel ausrichten.
9

149. Schrauben gleichmäßig/wechselseitig mit

4 4 einem Drehmoment von 21 ± 2 Nm bei

Blechölwanne oder
6 29 ± 2 Nm bei Gußölwanne festdrehen.

4.00.56
008 924 17 BOMAG 1099
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

146. Fill up all recesses in the gasket 146. En présence du joint du carter 146. Si el cárter es de chapa:
for the sheet metal oil pan with d’huile en tôle remplir tous les Rellenar todas las escotaduras de
Deutz DW 74. évidements de Deutz DW 74. la junta con Deutz DW 74.

147. With sheet metal oil pan: 147. En présence d’un carter d’huile en 147. Si el cárter es de chapa:
Mount oil pan. tôle : monter le carter d’huile. Montar el cárter.

Note: Watch marked installation Nota: veiller au sens de montage Nota: Observar la posición marcada
position. indiqué. para el montaje.

148. With cast oil pan: 148. En présence d’un carter d’huile en 148. Si el cárter es de fundición:
Mount oil pan and align relative to fonte: Montar el cárter y alinearlo con
timing chest cover. Monter le carter et l’aligner respecto a la tapa del cárter de la
par rapport au couvercle du carter distribución.
de distribution.

149. Tighten bolts uniformly/alternately 149. Serrer uniformément l’une après 149. Apretar uniforme/alternativamente
with a torque of 21 ± 2 Nm with l’autre les vis au couple de os tornillos con un par de
sheet metal oil pan or with 21 ± 2 Nm pour le carter d’huile 21 ± 2 Nm en el caso del cárter de 4
29 ± 2 Nm with cast oil pan. en tôle ou au couple de 29 ± 2Nm chapa o de 29 ± 2 Nm en el
pour le carter d’huile en fonte. caso del cárter de fundición.

4.00.56
1100 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Governor Régulateur Regulador

150. Apply sealing compound 150. Enduire de pâte d’étanchéité 150. Aplicar sellante Deutz DW 48 al
Deutz DW 48 to governor. Deutz DW 48 le régulateur. regulador.
Sealing string dia.: 1.5 + 0.5 mm Epaisseur du fil d’étanchéité: Espesor del filo sellante:
ø 1,5 + 0,5 mm ø 1,5 + 0,5 mm

Note: Sealing surface must be free of Nota: le plan de joint doit être exempt Nota: La superficie de cierre debe
oil and grease. d’huile et de graisse. estar exenta de aceite y de
grasa.

151. Turn engine by 180°, mount 15.1 Virer le moteur de 180° et monter le 151. Girar el motor 180°. Montar el
governor. régulateur. regulador.

152. Tighten bolts in the order 152. Serrer les vis au couple de 152. Apretar los tornillos con un par
1-2-3-4-5 with a torque of 17 ± 1,5 Nm dans l’ordre 1-2-3-4-5. de 17 ± 1,5 Nm en el orden de
17 ± 1.5 Nm. sucesión 1-2-3-4-5.

153. Fit new O-seal to cover and 153. Monter le joint torique neuf sur le 153. Montar un anillo tórico nuevo
grease lightly. couvercle de fermeture et le sobre la tapa de cierre y
4 graisser légèrement. engrasarlo ligeramente.

4.00.57
008 924 17 BOMAG 1101
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Regler

150. Dichtmittel Deutz DW 48 auf Regler

4
auftragen.
Dichtfadenstärke ø 1,5 + 0,5 mm w
Hinweis: Dichtfläche muß öl- und fettfrei sein. 5 47
,5
21 R
R

151. Motor um 180° drehen. Regler anbauen.

152. Schrauben in der Reihenfolge 1-2-3-4-5

mit einem Drehmoment von 17 ± 1,5 Nm
festdrehen.
4
6
3 1
4

5 2

153. Neuen Runddichtring auf Verschluß-

deckel montieren und leicht einfetten. 4 4
ß
u

4.00.57
1102 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

154. Verschlußdeckel montieren.

4 Hinweis: Auf Abstandshülsen achten.

155. Schrauben mit einem Drehmoment von

4 21 ± 2 Nm festdrehen.

156. Halteplatte an Regler anbauen.

4
157. Schrauben mit einem Drehmoment von
21 ± 2 Nm festdrehen.
4
6

4.00.58
008 924 17 BOMAG 1103
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

154. Fit cover. 154. Monter le couvercle de fermeture. 154. Montar la tapa de cierre.

Note: Watch out for spacer sleeves. Nota: veiller aux douilles Nota: Prestar atención a los
d’écartement. casquillos distanciadores.

155. Tighten bolts with a torque of 155. Serrer les vis au couple de 155. Apretar los tornillos con un par de
21 ± 2 Nm. 21 ± 2 Nm. 21 ± 2 Nm.

156. Fit retaining plate to governor. 156. Monter plaque d’appui sur 156. Montar la placa de soporte en el
régulateur. regulador.

157. Tighten bolts with a torque of 157. Serrer les vis au couple de 157. Apretar los tornillos con un par de
21 ± 2 Nm. 21 ± 2 Nm. 21 ± 2 Nm.
4

4.00.58
1104 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Cable harness Faisceau de câbles Mazo de cables

158. Fit cable lug to governor. 158. Monter cosse de câble sur le 158. Montar el terminal de cable en el
régulateur. regulador.

159. Fit cable lug to shutdown 159. Monter cosse de câble sur 159. Montar el terminal de cable en el
solenoid. l’électroaimant d’arrêt. solenoide de parada.

160. Put together glow plug cable 160. Assembler coupleurs de câble de 160. Unir las dos partes de los
couplers. bougie de préchauffage. acoplamientos de cables de las
bujías de incandescencia.

4.00.59
008 924 17 BOMAG 1105
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Kabelbaum

158. Kabelschuh an Regler anbauen.

159. Kabelschuh an Abstellmagnet anbauen.

160. Glühkerzen-Kabelkupplungen zusammen-

stecken. 4

4 4

4.00.59
1106 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

Anschlußgehäuse
4 (Darstellung BFM 1012)

5 161. Motor 90° drehen. Anschlußgehäuse

anbauen.

Hinweis: Auf Vorhandensein der Zentrierhül-

sen achten.

162. Schrauben nach Anziehvorschrift

4 festdrehen.
Schrauben M 12 = 99 ± 10 Nm

6 Schrauben M 16 = 243 ± 25 Nm

5
Hinweis: Torx Werkzeug verwenden.
E 14 lange Ausführung
E 20 lange Ausführung

163. Abdeckblech anbauen.

4.00.60
008 924 17 BOMAG 1107
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Adapter housing Carter d’adaptation Cárter de adaptación

(BFM 1012 shown here) (Illustration BFM 1012) (Representado BFM 1012)

161. Turn engine by 90°. Mount 161. Virer le moteur de 90° puis monter 161. Voltear el motor 90°. Montar el
adapter housing. le carter d’adaptation. cárter de adaptación.

Note: Make sure that centering sleeve Nota: veiller à la présence des Nota: Los casquillos de centraje
are fitted. douilles de centrage. deben estar en su sitio.

162. Tighten bolts according to 162. Serrer les vis selon les 162. Apretar los tornillos según
specification. préconisations de serrage : prescripción:

M 12 = 99 ± 10 Nm Vis M 12 = 99 ± 10 Nm tornillos M 12 = 99 ± 10 Nm
M 16 = 243 ± 25 Nm Vis M 16 = 243 ± 25 Nm tornillos M 16 = 243 ± 25 Nm

Note: Use Torx tool. Nota: utiliser les outils Torx Nota: Utilizar las herramientas
E 14 long version E 14 modèle long Torx.
E 20 long version E 20 modèle long E 14 - tipo largo
E 20 - tipo largo

163. Mount cover plate. 163. Monter la tôle de recouvrement. 163. Montar la chapa de
recubrimiento.

4.00.60
1108 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Starter Démarreur Arrancador

164. Mount starter. Tighten bolts with 164. Monter le démarreur. Serrer les vis 164. Montar el arrancador. Apretar los
a torque of 70 Nm. au couple de 70 Nm. tornillos con un par de 70 Nm.

Note: Tighten collar nut, if any, with a Nota: selon l’équipement du Nota: Apretar la tuerca de collarín, si
torque of 40 Nm. moteurserrer l’écrou à embase existe, con un par de 40 Nm.
au couple de 40 Nm.

165. Fit cable and fastening clips. 165. Monter le câble et les colliers de 165. Montar el cable y las abrazaderas
fixation. de fijación.

Breather pipe Conduite de dégazage Tubería de ventilación

166. Fit breather pipe with new Cu 166. Monter la conduite de dégazage 166. Unir la tubería de ventilación con
seals. avec des joints d'étanchiété Cu anillos de junta de cobre nuevos.
neufs.

167. Tighten bolts for breather pipe 167. Serrer la vis de la conduite de 167. Apretar el tornillo para la tubería
with a torque of 11 ± 1 Nm. degazage au couple de de ventilación con un par de
4 11 ± 1 Nm. 11 ± 1 Nm.

4.00.61
008 924 17 BOMAG 1109
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Starter

164. Starter anbauen. Schrauben mit einem

4
Drehmoment von 70 Nm festdrehen.
6
5
Hinweis: Falls vorhanden, Bundmutter mit
einem Drehmoment von 40 Nm fest-
drehen.

165. Kabel und Befestigungsschellen anbauen.

Entlüftungsleitung

166. Entlüftungsleitung mit neuen Cu-Dicht-

4
ringen anbauen.
ß

167. Schraube für Entlüftungsleitung mit

einem Drehmoment von 11 ± 1 Nm
festziehen.
4 4
6

4.00.61
1110 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

168. Luftleitung zum LDA anbauen.

169. Transportösen anbauen. Schrauben mit

4 einem Drehmoment von 47 ± 4 Nm
festdrehen.
6

170. Kabelschuh an Kühlmitteltemperaturgeber

4 anbauen.

38-4-206

Öldruckschalter

4 4 171. Öldruckschalter mit neuem Cu- Dichtring

ß anbauen und mit einem Drehmoment von
18 ± 2 Nm festdrehen.

4.00.62
008 924 17 BOMAG 1111
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

168. Fit air pipe to manifolf pressure 168. Monter la conduite d'air du 168. Unir la tubería de aire al tope de
compensator (LDA) correcteur de débit (LDA). plena carga dependiente de la
presión de
sobrealimentación(LDA).

169. Fit lifting lugs. Tighten bolts with 169. Monter les oeillets de manutention 169. Montar las argollas de transporte.
a torque of 47 ± 4 Nm. et serrer les vis au couple de Apretar los tornillos con un par de
47 ± 4 Nm. 47 ± 4 Nm.

170. Fit cable lug to coolant 170. Monter la cosse de câble sur la 170. Montar el terminal de cable en el
temperature sensor. sonde de température de transmissor de temperatura del
réfrigérant. liquido refrigerante.

Oil pressure switch Manocontact de pression d'huile Interruptor de presión de aceite

171. Fit oil pressure switch with new 171. Monter le manocontact de 171. Montar el interruptor de presión 4
Cu seal and tighten with a torque pression d'huile avec un joint de aceite con un anillo de junta de
of 18 ± 2 Nm. d'étanchéité Cu neuf et serrer au cobre nuevo y apretar con un par
couple de 18 ± 2 Nm. de 18 ± 2 Nm.

4.00.62
1112 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

172. Fit cable lug to oil pressure 172. Monter la cosse de câble sur le 172. Montar el terminal de cable en el
switch. manocontact de pression d’huile. interruptor de presión de asceite.

Crankcase breather Event de carter Ventilación del cárter

173. Assemble crankcase breather. 173. Compléter l’assemblage de l’évent 173. Completar la ventilación del
de carter. cárter.
Order of parts assembly: Suite du montage: Orden del montaje:
1 Seal 1 Joint 1 Junta
2 Pressure control valve 2 Soupape de régulation de 2 Válvula reguladora de presión
3 Rubber sleeve pression 3 Manguito de goma
3 Manchon en caoutchouc
Note: Pay attention to positioning aids Nota: veiller aux points de Nota: Prestar atención a las ayudas
on pressure control valve and positionnement sur la soupape de posicionamiento existentes
rubber sleeve. Slide on rubber de régulation de pression et de en la válvula reguladora de
sleeve as far as it will go. manchon en caoutchouc. presión y en el mangito de
Insérer le manchon en goma, Colocar éste hasta el
caoutchouc jusqu'en position tope.
de butèe.
174. Press rubber sleeve as far as it 174. Enfoncer le manchon en 174. Introducir a presión el manguito
will go into timing chest bore. Fit caoutchouc dans l'alésage de la de goma hasta el tope en el
pressure control valve to cylinder distribution puis monter la taladro existente en el cárter de la
head. soupape de régulation de distribución. Montar la válvula
pression sur la culasse. reguladora de presión en la
culata.
Note: Lightly grease receiving bore in Nota: huiler légèrement l'alésage de Nota: Lubricar con un poco de grasa
cylinder head. positionement dans la culasse. el taladro de alojamiento en la
culata.

175. Tighten bolts with a torque of 175. Serrer les vis au couple de 175. Apretar los tornillos con un par de
8,5 ± 1 Nm. 8,5 ± 1 Nm. 8,5 ± 1 Nm.
4

4.00.63
008 924 17 BOMAG 1113
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

172. Kabelschuh an Öldruckschalter

anbauen.
4

Kurbelgehäuseentlüftung

173. Kurbelgehäuseentlüftung komplettieren.

4
Folge der Einzelmontage: 0
5
1 Dichtung
2 Druckregelventil
3 Gummimuffe

Hinweis: Auf Positionierhilfen an Druckregel-

ventil und Gummimuffe achten.
Gummimuffe bis Anschlag aufschie-
ben.

174. Gummimuffe bis zum Anschlag in die

Räderkastenbohrung eindrücken. Druck-
4
regelventil an Zylinderkopf anbauen.
5
38-4-209

Hinweis: Aufnahmebohrung im Zylinderkopf

leicht einfetten.

175. Schrauben mit einem Drehmoment von

8,5 ± 1 Nm festdrehen. 4 4
6

4.00.63
1114 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

Kühlmittelrohr

38-4-210
4 176. Kühlmittelrohr mit Dichtmittel Deutz DW

w 67 anbauen. Schrauben mit einem

Drehmoment von 21 ± 2 Nm festdrehen.

Abgasturbolader BFM 1012

4 Schwungradseite

ß 177. Zwischenstück

u
Neue Runddichtringe aufziehen und
fetten.

178. Zwischenstück bis Anschlag eindrücken.

179. Abgasturbolader mit neuer Dichtung

4 4 anbauen.

ß Hinweis: Stiftschrauben mit Deutz S1 Never

Seize Paste einstreichen.

4.00.64
008 924 17 BOMAG 1115
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Coolant pipe Conduite de réfrigérant Tubo de líquido refrigerante

176. Mount coolant pipe with sealing 176. Monter la conduite de réfrigérant 176. Montar el tubo de líquido
compound Deutz DW 67. Tighten avec de la pâte d’étanchéité refrigerante con sellante
bolts with a torque of 21 ± 2 Nm. Deutz DW 67. Serrer les vis au Deutz DW 67. Apretar Los
couple de 21 ± 2 Nm. tornillos con un par de
21 ± 2 Nm.

Exhaust turbocharger BFM 1012 Turbocompresseur sur échappement Turbocompresor, BFM 1012
Flywheel end BFM 1012. Côté volant moteur Lado del volante

177. Adapter 177. Pièce intermédiaire 177. Pieza intermedia

Slide on new O-seals and grease. Monter des joints toriques neufs et Colocar los anillos tóricos nuevos
les graisser. y engrasarlos.

178. Press in adapter as far as it will 178. Introduire la pièce intermédiaire 178. Introducir a presión la pieza
go. jusqu’en position de butée. intermedia hasta el tope.

179. Mount exhaust turbocharger with 179. Monter le turbocompresseur avec 179. Montar el turbocompresor con
new gasket. un joint neuf. una junta nueva.
4
Note: Apply Deutz S1 Never Seize Nota: enduire les goujons filetés de Nota: Aplicar a los espárragos pasta
paste to studs. pâte d’étanchéité Deutz S1 Deutz S1 Never Seize.
Never Seize.

4.00.64
1116 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

180. Tighten nuts with a torque of 180. Serrer les écrous au couple de 180. Apretar las tuercas con un par de
21 ± 2 Nm. 21 ± 2 Nm. 21 ± 2 Nm.

Exhaust turbocharger BFM 1013 Turbocompresseur sur échappement Turbocompresor, BFM 1013
Central arrangement BFM 1013 Posición intermedia
Position milieu

181. Mount exhaust turbocharger with 181. Monter le turbocompresseur avec 181. Montar el turbocompresor con
new gasket. un joint neuf. una junta nueva.

Note: Apply Deutz S1 Never Seize Nota: enduire les goujons filetés de Nota: Aplicar a los tornillos pasta
paste to bolts. pâte d’étanchéité Deutz S1. Deutz S1 Never Seize.

182. Tighten bolts according to 182. Serrer les vis selon les 182. Apretar los tornillos según
specification. préconisations de serrage prescripción.
Bolts M8 21 ± 2 Nm vis M8 21 ± 2 Nm Tornillos M8 21 ± 2 Nm
or ou o
Bolts M10 40.5 ± 4 Nm vis M10 40,5 ± 4 Nm tornillos M10 40,5 ± 4 Nm

Oil return pipe/pressure oil pipe Tube de retour d’huile/conduite Tubo de retorno de aceite/tubería de
BFM 1012 d’huile sous pression BFM 1012 aceite a presión, BFM 1012
4
183. Slide on new O-seals and grease. 183. Monter un joint torique neuf et 183. Colocar anillos tóricos nuevos y
le graisser. engrasarlos.

4.00.65
008 924 17 BOMAG 1117
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

180. Muttern mit einem Drehmoment von

21 ± 2 Nm festdrehen. 4
6

Abgasturbolader BFM 1013

Mittig 4
181. Abgasturbolader mit neuer Dichtung
anbauen. ß 30-4-211

Hinweis: Schrauben mit Deutz S1 Never Seize 5

Paste einstreichen.

182. Schrauben nach Anziehvorschrift fest-

drehen.
Schrauben M8 21 ± 2 Nm
4
oder
Schrauben M10 40,5 ± 4 Nm 6
38-4-212

Ölrücklaufrohr/Druckölleitung BFM 1012

183. Neue Runddichtringe aufziehen und

4 4
fetten.
ß
u

4.00.65
1118 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

184. Einschraubstutzen mit neuem Cu-Dicht-

4 ring und einem Drehmoment von
40 ± 2 Nm festdrehen.

6
ß

185. Ölrücklaufleitung anbauen. Halter fest-

4 schrauben.

186. Druckölleitung anbauen:

4 Hohlschrauben mit neuen Cu-Dichtringen
ß anbauen und mit einem Drehmoment von
Pos. 1 29 ± 3 Nm

6
Pos. 2 39 ± 4 Nm
festdrehen.

5 Hinweis: Abgasturbolader durch einen

Spritzer Öl in die Ölzulaufbohrung
vorölen.

Druckölleitung/Ölrücklaufrohr BFM 1013

4 4 187. Druckölleitung mit neuer Dichtung

ß anbauen.

5 Hinweis: Abgasturbolader durch einen

Spritzer Öl in die Ölzulaufbohrung
vorölen.

4.00.66
008 924 17 BOMAG 1119
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

184. Tighten screw plug with new Cu 184. Serrer la tubulure avec un joint 184. Apretar el enchufe roscado,
seal and a torque of 40 ± 2 Nm. d'étanchéité Cu neuf et au provisto de un anillo de junta de
couple de 40 ± 2 Nm. cobre nuevo, con un par de
40 ± 2 Nm.

185. Mount oil return pipe. Tighten 185. Monter la conduite de retour d’huile 185. Montar la tubería de de retorno de
retainer. et serrer le support. aceite. Atornillar el sujetador.

186. Mount pressure oil pipe: 186. Monter la conduite de refoulement 186. Montar la tubería de aceite a
d’huile . presión:

Fit banjo bolts with new Cu seals Serrer les vis creuses avec des Enroscar los tornillos racor,
and tighten with a torque of joints d'étanchéité neufs et au provistos de anillos de junta de
item 1 29 ± 3 Nm couple de cobre nuevos, y apretarlos con un
item 2 39 ± 4 Nm. Pos. 1 29 ± 3 Nm par de
Pos. 2 39 ± 4 Nm. 29 ± 3 Nm = pos. 1
39 ± 4 Nm = pos. 2.
Note: Pre-lubricate turbocharger by Nota: huiler le turbocompresseur en Nota: Preaceitar el turbocompresor
spraying a drip of oil into the oil injectant un peu d'huile dans proyectando una gota de aceite
supply bore. l'alésage d'arrivée. al interior del taladro de
alimentación de aceite.

Pressure oil pipe/oil return pipe Conduite de refoulement d’huile/ Tubería de aceite a presión/tubo de
BFM 1013 tuyau de retour d’huile BFM 1013 retorno de aceite BFM 1013
4
187. Mount pressure oil pipe with new 187. Monter la conduite de refoulement 187. Montar la tubería de aceite a
gasket. d’huile avec un joint neuf. presión con una junta nueva.

Note: Pre-lubricatel turbocharger by Nota: huiler le turbocompresseur en Nota: Montar la tubería de aceite a
spraying a drip of oil into the oil injectant un peu d'huile dans presión con una junta nueva.
supply bore. l'alésage d'arrivée d'huile.

4.00.66
1120 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

188. Tighten bolts with a torque of 188. Serrer les vis au couple de 188. Apretar los tornillos con un par de
21 ± 2 Nm. 21 ± 2 Nm. 21 ± 2 Nm.

189. Fit banjo bolt with new Cu seals 189. Monter la vis creuse avec des 189. Montar el tornillo racor con
and tighten with a torque of joints d'étanchéite Cu neufs et anillos de junta de cobre nuevos y
39 ± 3 Nm. serrer au couple de 39 ± 3 Nm. apretar con un par de 39 ± 3 Nm.

190. Slide on new O-seals and apply 190. Monter les joints toriques neufs et 190. Colocar anillos tóricos nuevos y
dehydrated lubricant. les enduire d’un produit de untarlos con lubricante de
montage anhydre. montaje exento de agua.

191. Mount oil return pipe with new 191. Monter tube de retour avec joint 191. Acoplar el tubo de retorno
gasket. neuf. provisto de una junta nueva.
4
Note: Apply dehydrated lubricant to Nota: enduire alésage de logement du Nota: Aplicar al alojamiento en el
receiving bore in crankcase. bloc moteur d’un produit de bloque motor lubricante de
montage anhydre. montaje exento de agua.

4.00.67
008 924 17 BOMAG 1121
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

188. Schrauben mit einem Drehmoment von

21 ± 2 Nm festdrehen.
4
6

189. Hohlschraube mit neuen Cu-Dichtringen

anbauen und mit einem Drehmoment von
39 ± 3 Nm festdrehen.
4
ß
6

190. Neue Runddichtringe aufziehen und mit

wasserfreiem Montagemittel einstreichen.
4
ß

191. Rücklaufrohr mit neuer Dichtung an-

bauen. 4 4
Hinweis: Aufnahmebohrung im Kurbelge-
häuse mit wasserfreiem Montage-
ß
mittel einstreichen.
5

4.00.67
1122 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

192. Schrauben mit einem Drehmoment von

4 21 ± 2 Nm festdrehen.

193. Haltebügel anbauen. Schraube mit einem

4 Drehmoment von 21 ± 2 Nm festdrehen.

Ansaugkrümmer BFM 1012

4 194. Ansaugkrümmer (Schlauch) mit
Schlauchschelle befestigen.

195. Winkelstutzen mit Schlauchschelle ein-

4 4 setzen.

5 Hinweis: Schlauchschelle noch nicht

festdrehen.

4.00.68
008 924 17 BOMAG 1123
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

192. Tighten bolts with a torque of 192. Serrer les vis au couple de 192. Apretar los tornillos con un par de
21 ± 2 Nm. 21 ± 2 Nm. 21 ± 2 Nm.

193. Fit clamping yoke. Tighten bolt 193. Monter l’étrier de fixation etserrer 193. Montar el estribo de sujeción.
with a torque of 21 ± 2 Nm. la vis au couple de 21 ± 2 Nm. Apretar el tornillo con un par de
21 ± 2 Nm.

Intake elbow BFM 1012 Tubulure d’aspiration BFM 1012 Codo de aspiración, BFM 1012

194. Fasten intake elbow (hose) with 194. Fixer la tubulure d’aspiration 194. Fijar el codo de aspiración
hose clip. (flexible) à l’aide d’un collier. (manguera) mediante abrazadera.

195. Insert elbow nipple with hose clip. 195. Placer le raccord en équerre avec le 195. Colocar la tubuladura acodada
collier de serrage. con abrazadera.
4
Note: Do not tighten hose clip yet. Nota: ne pas encore serrer le Nota: La abrazadera todavía no debe
collier. apretarse.

4.00.68
1124 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

196. Mount breather hose and fasten. 196. Monter flexible de purge et le 196. Montar la manguera de purga de
Tighten hose clip. fixer. Serrer collier de fixation. aire y fijarla. Apretar la
abrazadera.

Intake elblow BFM 1013 Tubulure d’aspiration BFM 1013 Codo de aspiración, BFM 1013

197. Mount intake elbow (hose). 197. Fixer la tubulure d’aspiration 197. Montar el codo de aspiración de
(flexible). aire (manguera).

Note: Do not tighten hose clip yet. Nota: ne pas encore bloquer le Nota: La abrazadera todavía no debe
collier de fixation. apretarse.

198. Mount breather pipe with retainer 198. Monter conduite de purge avec 198. Montar sin tensiones la tubería de
free of stress. support sans tension. purga de aire con soporte.

199. Fit spring-loaded clamp. 199. Monter les colliers à ressort. 199. Instalar las pinzas elástica.

4 Note: Use spring clamp pliers. Nota: utiliser la pince à crampon Nota: Utilizar los tornillos para pinzas
élastique. elásticas.

4.00.69
008 924 17 BOMAG 1125
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

196. Entlüftungsschlauch montieren und

befestigen. Schlauchschelle festdrehen.
4

Ansaugkrümmer BFM 1013

197. Ansaugkrümmer (Schlauch) anbauen.

4
Hinweis: Schlauchschelle noch nicht fest- 5
drehen.

198. Entlüftungsleitung mit Halter span-

nungsfrei anbauen. 4

199. Federklemmen montieren.

Hinweis: Federklemmenzange benutzen.

4 4
5

4.00.69
1126 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

200. Federklemme montieren.

4 Hinweis: Federklemmenzange benutzen.

201. Schlauchschelle festdrehen.

Ladeluftkrümmer BFM 1013

4 202. Steckstück eindrücken.
5 Hinweis: Dichtprofil und Aufnahmebohrung
mit Montagemittel einstreichen.

203. Ladeluftkrümmer mit neuer Dichtung

4 4 anbauen.

4.00.70
008 924 17 BOMAG 1127
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

200. Fit spring-loaded clamp. 200. Monter crampon à ressort. 200. Instalar la pinza elástica.

Note: Use spring clamp pliers. Nota: utiliser la pince à crampon à Nota: Utilizar las tenazas especiales
ressort. para pinzas.

201. Secure hose clip. 201. Serrer le collier de fixation. 201. Apretar la abrazadera de
manguera.

Charge air elbow BFM 1013 Conduite d’air de suralimentation Codo de aire de sobrealimentación,
BFM 1013 BFM 1013

202. Press in plug-in element. 202. Introduire le manchon. 202. Introducir a presión la pieza de
enchufe.

Note: Apply lubricant to sealing Nota: enduire d’un produit de Nota: Aplicar lubricante de montaje al
section and receiving bore. montage le profilé d’étanchéité perfil de cierre y al alojamiento.
et l’alésage du logement.

203. Mount charge air elbow with new 203. Monter la conduite d’air de 203. Montar el codo de aire de
seal. suralimentation avec un joint sobrealimentación provisto de
neuf. una junta nueva. 4

4.00.70
1128 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

204. Tighten bolts with a torque of 204. Serrer les vis au couple de 204. Apretar los tornillos con un par de
22 ± 2 Nm. 22 ± 2 Nm. 22 ± 2 Nm.

205. Fit oil filler neck, if any, complete 205. Selon l’équipement du moteur 205. Si existe, montar la tubuladura de
with new seal and tighten with a serrer la tubulure de remplissage llenado de aceite con una junta
torque of 21 ± 2 Nm. d’huile au couple de 21 ± 2 Nm en nueva y apretar con un par de
utilisant un joint neuf. 21 ± 2 Nm.

Oil dipstick Jauge d’huile Varilla de medición del nivel de

aceite

206. Slide on new O-seal. 206. Monter un joint torique neuf. 206. Colocar un anillo tórico nuevo.

207. Press in oil dipstick as far as it 207. Insérer la jauge d’huile jusqu’en 207. Presionar adentro la varilla de
will go. position d’appui. medición hasta que haga tope.
4

4.00.71
008 924 17 BOMAG 1129
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

204. Schrauben mit einem Drehmoment von

22 ± 2 Nm festdrehen.
4
6

205. Falls vorhanden, Öleinfüllstutzen mit

neuer Dichtung anbauen und mit einem
Drehmoment von 21 ± 2 Nm festdrehen.
4
ß
6

Ölmeßstab

206. Neuen Runddichtring aufziehen.

4
ß

207. Ölmeßstab bis Anlage eindrücken.

4 4

4.00.71
1130 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

Generator
4 208. Konsole anbauen. Schrauben mit einem

6 Drehmoment von 21 ± 2 Nm festdrehen.

209. Generator anbauen. Sechskantschraube

4 leicht andrehen.

210. Spannlasche mit Abstandsbuchsen an-

4 bauen. Sechskantschrauben leicht an-
drehen.

Keilriemen spannen

4 4 211. Keilriemen auflegen.

4.00.72
008 924 17 BOMAG 1131
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Alternator Alternateur Alternador

208. Fit alternator bracket. Tighten 208. Monter la console et serrer les vis 208. Montar la consola. Apretar los
bolts with a torque of au couple de 21 ± 2 Nm. tornillos con un par de
21 ± 2 Nm. 21 ± 2 Nm.

209. Mount alternator. Start hex. bolt. 209. Monter l’alternateur. Serrer 209. Montar el alternador. Apretar el
modérément la vis six pans. tornillo hexagonal ligeramente
con la mano.

210. Fit clamping plate together with 210. Monter la griffe de serrage avec 210. Montar la corredera con los
spacer bushes. Start hex. bolts. des douilles d’écartement. Serrer casquillos distanciadores. Apretar
légèrement les vis six pans. los tornillos hexagonales
ligeramente con la mano.
ensado de correas trapezoidales

Tensioning V-belt Tendre la courroie trapézoïdale Tensar la correa trapezoidal

211. Position V-belt. 211. Monter la courroie trapézoïdale. 211. Colocar la correa trapezoidal. 4

4.00.72
1132 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

212. Tension V-belt. Tighten bolts with 212. Tendre la courroie trapézoïdale et 212. Tensar la correa trapezoidal.
a torque of 21 ± 2 Nm. serrer les vis au couple de Apretar los tornillos con un par de
21 ± 2 Nm. 21 ± 2 Nm.

213. Check V-belt tension with belt 213. Contrôler la tension de la courroie 213. Comprobar la tensión de la correa
tension gauge. trapézoïdale à l’aide d'un utilizando un verificador de
tensiomètre. tensión.
Belt back width 10 mm Largeur du dos de la courroie Ancho de correa 10 mm
Initial assembly ____ 450 ± 50 N 10 mm Primer montaje ____ 450 ± 50 N
Check value after 15 min.of Première monte ____ 450 ± 50 N Control tras una marcha
operation under load 300 ± 50 N Contrôle après 15 min de marche de 15 min. bajo carga 300 ± 50 N
When reusing belt __ 300 ± 50 N Sous charge ______ 300 ± 50 N Para reutilización ___ 300 ± 50 N
Après réutilisation __ 300 ± 50 N
Belt back width 13 mm Ancho de correa 13 mm
Initial assembly ____ 550 ± 50 N Largeur du dos de la courroie Primer montaje ____ 550 ± 50 N
Check value after 15 min.of 13 mm Control tras una marcha
operation under load 400 ± 50 N Première monte ____ 550 ± 50 N de 15 min. bajo carga 400 ± 50 N
When reusing belt __ 400 ± 50 N Contrôle après 15 min de marche Para reutilización ___ 400 ± 50 N
Sous charge ______ 400 ± 50 N
Après réutilisation __ 400 ± 50 N

214. Position V-belt. 214. Monter la courroie. 214. Colocar la correa trapezoidal.

215. Tension V-belt. Tighten bolts with 215.Tendre la courroie trapézoïdale et 215. Tensar la correa trapezoidal.
a torque of 30 Nm. serrer les vis au couple de 30 Nm. Apretar los tornillos con un par de
4 30 Nm.

4.00.73
008 924 17 BOMAG 1133
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

212. Keilriemen spannen. Schrauben mit einem

Drehmoment von 21 ± 2 Nm festdrehen.
s
4
6

213. Keilriemenspannung mit einem

Spannungsmeßgerät prüfen. s
Riemenrückenbreite 10 mm
Erstmontage _____________ 450 ± 50 N 6
Kontrolle nach 15 Min. Lauf
unter Last _______________ 300 ± 50 N
Bei Wiederverwendung _____ 300 ± 50 N

Riemenrückenbreite 13 mm
Erstmontage _____________ 550 ± 50 N
Kontrolle nach 15 Min. Lauf
unter Last _______________ 400 ± 50 N
Bei Wiederverwendung _____ 400 ± 50 N

214. Keilriemen auflegen. 4

215. Keilriemen spannen. Schrauben mit einem

Drehmoment von 30 Nm festdrehen. s 4
4
6

4.00.73
1134 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

216. Keilriemenspannung mit einem

s Spannungsmeßgerät prüfen.

6 Erstmontage _____________ 450 ± 50 N

Kontrolle nach 15 Min. Lauf
unter Last ______________ 300 ± 50 N
Bei Wiederverwendung ____ 300 ± 50 N

217. Nach dem Riemenspannen sind die

4 übrigen Schrauben festzudrehen und die
Kabel anzuklemmen.

3
Motor von Montagebock abbauen.

Motoraufhängung/Aufstellfüße
4 218. Motoraufhängung anbauen. Schrauben
6 mit einem Drehmoment von 260 Nm
festdrehen.

219. Aufstellfüße anbauen. Schrauben mit

4 4 einem Drehmoment von 95 Nm

festdrehen.
6

4.00.74
008 924 17 BOMAG 1135
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

216. Check V-belt tension with belt 216. Vérifier la tension de courroie avec 216. Comprobar la tensión de la correa
tension gauge. un appareil de mesure. trapezoidal mediante un
verificador de tensión.

Initial assembly ___ 450 ± 50 N Première monte ___ 450 ± 50 N Primer montaje ___ 450 ± 50 N
Check value after 15 min. of Contrôle après une marche de Control tras 15 minutos
operation under load 300 ± 50 N 15 min de marcha bajo carga
When reusing belt __ 300 ± 50 N sous charge ______ 300 ± 50 N _______________ 300 ± 50 N
Pour réutilisation __ 300 ± 50 N Para reutilización __ 300 ± 50 N

217. After tensioning of belt tighten 217. Après avoir tendu la courroie 217. Una vez tensadas las correas, se
remaining bolts and connect serrer les autres vis et brancher apretarán los demás tornillos y se
cables. les câbles. conectarán los cables.

Remove engine from assembly Déposer le moteur du chevalet de Desmontar el motor del caballete
stand. montage. de montaje.

Engine mounting/mounting feet Suspension moteur / pieds Suspensión del motor / patas de
colocación

218. Fit engine mounting. Tighten bolts 218. Monter la suspension du moteur. 218. Montar la suspensión del motor.
with a torque of 260 Nm. Serrer les vis au couple de Apretar los tornillos con un par de
serrage de 260 Nm. 260 Nm.

219. Fit mounting feet. Tighten bolts 219. Monter les pieds du moteur. Serrer 219. Montar las patas de colocación.
with a torque of 95 Nm. les vis au couple de 95 Nm. Apretar los tornillos con un par de
95 Nm. 4

4.00.74
1136 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Removing and refitting components Montage et démontage des éléments Desmontaje y remontaje de
for integrated cooling system - du refroidissement intégré du - componentes de la refrigeración
BFM 1012 BFM 1012 integrada - BFM 1012

The components may differ from the Selon le volume de livraison du moteur Los componentes adosados pueden
illustrations shown here, depending on les pièces auxiliaires peuvent être diferir de los indicados en estas
the engine scope of supply. différentes des croquis. ilustraciones, según el volumen de
suministro del motor.

Drain and catch coolant and oil. Vidanger et récupérer le liquide de Dejar salir y recoger el líquido
refroidissement usagé ou l’huile usée. refrigerante y aceite.

Removing components Dépose des composants Desmontaje de elementos

1. Loosen tension pulley, take off 1. Desserrer le galet tendeur et retirer 1. Soltar la polea tensora, quitar la
V-belt. la courroie. correa trapezoidal.

2. Remove tension pulley together 2. Déposer la galet tendeur et la 2. Desmontar la polea tensora con
with bracket. console. consola.

3. Remove air guide ring. 3. Déposer le diffuseur d'air. 3. Desmontar el aro guía de aire.

4.00.75
008 924 17 BOMAG 1137
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Bauteile für integrierte Kühlung ab- und

anbauen - BFM 1012

Je nach Lieferumfang des Motors können die

Anbauteile von den gezeigten Abbildungen
abweichen.

Kühlflüssigkeit bzw. Öl ablassen und auffan-

gen.

Bauteile abbauen

1. Spannrolle lösen, Keilriemen abnehmen.

2. Spannrolle mit Konsole abbauen.

3. Lufttrichter abbauen.
3 4

4.00.75
1138 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

4. Generator und Kraftstoffpumpe lösen.

3 Keilriemen abnehmen. Generator und
Kraftstoffpumpe abbauen.

5. Keilriemenscheibe am Schwungrad gegen-

3 halten. Keilriemenscheibe und Schwin-
gungsdämpfer abbauen.

6. Entlüftungsleitung abbauen.
3

7. Schaulochblech abbauen.

4 3

4.00.76
008 924 17 BOMAG 1139
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

4. Loosen alternator and fuel pump, 4. Desserrer l'alternateur et la pompe 4. Soltar el alternador y la bomba de
take of V-belt. Remove alternator de combustible. Retirer la courroie combustible. Quitar la correa
and fuel pump. trapézoïdale. Déposer l'alternateur trapezoidal. Desmontar el
et la pompe de combustible. alternador y la bomba de
combustible.

5. Retain V-belt pulley against 5. Maintenir la poulie à gorge du 5. Retener la polea acanalada en el
flywheel. Remove V-belt pulley and volant moteur. Déposer la poulie et volante. Desmontar la polea
vibration damper. l'amortisseur de vibrations. acanalada y el amortiguador de
vibraciones.

6. Remove breather pipe. 6. Déposer la conduite de purge. 6. Desmontar la tubería de purga de

aire.

7. Remove inspection hole plate. 7. Déposer la tôle à trou de regard. 7. Desmontar la chapa de la abertura
de inspección.
4

4.00.76
1140 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

8. Remove top cover plate. 8. Déposer la tôle de recouvrement 8. Desmontar la chapa de

supérieure. recubrimiento superior.

9. Remove central cover plate. 9. Déposer la tôle de recouvrement du 9. Desmontar la chapa de

milieu. recubrimiento intermedia.

10. Remove bottom cover plate. 10.Déposer la tôle de recouvrement 10. Desmontar la chapa de
inférieure. recubrimiento inferior.

11. Remove retainer from radiator. 11. Déposer le support du 11. Desmontar los soportes del
refoidisseur à liquide. refrigerador de líquido.
4

4.00.77
008 924 17 BOMAG 1141
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

8. Abdeckblech oben abbauen.

9. Abdeckblech mitte abbauen.

10. Abdeckblech unten abbauen.

11. Halter vom Flüssigkeitskühler abbauen.

3 4

4.00.77
1142 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

12. Flüssigkeitskühler abbauen.

3 Hinweis: Auslaufendes Restkühlmittel auffan-

5 gen.

13. Halter abbauen.

14. Verkabelung Niveauschalter Kühlmittel

3 abbauen.

15. Kabel von Starter und Anschlussbolzen

4 3 abbauen.

4.00.78
008 924 17 BOMAG 1143
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

12. Remove radiator. 12. Déposer le radiateur. 12. Desmontar el refrigerador de

líquido.

Note: Catch any escaping coolant that Nota: récupérer le réfrigérant qui Nota: Recoger los restos de
has remained in the radiator. s’écoule. refrigerante.

13. Remove retainer. 13. Déposer le support. 13. Desmontar los sujetadores.

14. Remove cabling from coolant level 14. Déposer le câblage d'interrupteur 14. Desmontar el cable del interruptor
switch. du niveau du réfrigérateur. de nivel de refrigerante.

15. Remove cables from starter and 15. Déposer le câble du démarreur et le 15. Desmontar el cable del arrancador
terminal stud. boulon de fixation. y bulón de conexión.
4

4.00.78
1144 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

16. Remove cover plate. 16. Déposer la tôle d’extrémité. 16. Desmontar la chapa final.

17. Remove oil pressure pipe. 17. Déposer la conduite de refoulement 17. Desmontar la tubería de presión de
d'huile. aceite.

18. Remove oil return pipe. 18. Déposer le tuyau de retour d'huile. 18. Desmontar el tubo de retorno de
aceite.

19. Remove cover plate. 19. Déposer la tôle de recouvrement. 19. Desmontar la chapa de
recubrimiento.
4

4.00.79
008 924 17 BOMAG 1145
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

16. Abschlußblech abbauen.

17. Öldruckleitung abbauen.

18. Ölrücklaufrohr abbauen.

19. Abdeckblech abbauen.

3 4

4.00.79
1146 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

20. Schrauben für Flansch herausschrauben.

3 Hinweis: Auf Position der Sicherungsscheibe

5 achten.

21. Kühlmittelleitung abbauen.

22. Kühlmittelleitung abbauen.

23. Klemmprofil abnehmen.

4 3

4.00.80
008 924 17 BOMAG 1147
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

20. Unscrew bolts for flange. 20. Dévisser et retirer les vis de la 20. Desenroscar los tornillos para la
bride. brida.

Note: Pay attention to position of Nota: veiller au bon positionnement Nota: Prestar atención a la posición
locking washer. de la rondelle d'arrêt. de la arandela de seguridad.

21. Remove coolant pipe. 21. Déposer la conduite de réfrigérant. 21. Desmontar la tubería de
refrigerante.

22. Remove coolant pipe. 22. Déposer la conduite de réfrigérant. 22. Desmontar la tubería de
refrigerante.

23. Take off clamping section. 23. Retirer le profilé de serrage. 23. Quitar el perfil de apriete.

4.00.80
1148 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

24. Remove coolant compensating 24. Déposer la conduite de compensation 24. Desmontar la tubería de
pipe. de réfrigérant. compensación de refrigerante.

25. Remove complete blower. 25. Déposer entièrement la soufflante de 25. Desmontar por completo la turbina
refroidissement. de refrigeración.

Note: Catch any escaping coolant. Nota: récupérer le réfrigérant qui Nota: Recoger el refrigerante quesale.
s’écoule.

26. Detach cable connections. 26. Désolidariser les connexions des 26. Separar las conexiones de cables.
câbles.

27. Remove cable harness. 27. Déposer le faisceau des câbles. 27. Desmontar el mazo de cables.

4.00.81
008 924 17 BOMAG 1149
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

24. Kühlmittel-Ausgleichsleitung abbauen.

25. Kühlgebläse komplett abbauen.

Hinweis: Auslaufendes Kühlmittel auffangen.

3
5

26. Kabelverbindungen trennen.

27. Kabelbaum abbauen.

3 4

4.00.81
1150 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

28. Kühlmitteltemperaturgeber ausbauen.

29. Öldruckschalter ausbauen.

3 Alle Bauteile sichtprüfen. Schadhafte

9 Bauteile austauschen.

4.00.82
008 924 17 BOMAG 1151
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

28. Remove coolant temperature 28. Déposer l’interrupteur de température 28. Desmontar el transmisor de
sensor. de réfrigérant. temperatura de refrigerante.

29. Remove oil pressure switch. 29 .Déposer le manostat de pressio 29. Desmontar el interruptor de
d’huile. presión de aceite.

Inspect all components, replace if Contrôler visuellement tous les Examinar visualmente todos los
damaged. composants. Remplacer ceux qui componentes y sustituir los que
sont détériorés. estén defe.

4.00.82
1152 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Refitting components: Repose des éléments: Montaje de los componentes:

Oil pressure switch/ Manocontact de pression d’huile/ Interruptor de presión de aceite/

Coolant temperature sensor capteur de température de réfrigérant transmisor de temperatura de
refrigerante

30. Fit oil pressure switch with new Cu 30. Monter l’interrupteur de pression 30. Montar el interruptor de presión de
seal and tighten with a torque of d’huile avec une bague neuve Cu aceite con un anillo de cobre nuevo
18 ± 2 Nm. puis serrer au couple de y apretar con un par de 18 ± 2 Nm.
18 ± 2 Nm.

31. Fit coolant temperature sensor with 31. Monter l’interrupteur de 31. Montar el transmisor de
new Cu seal and tighten with a température de réfrigérant avec une temperatura de refrigerante con un
torque of 18 ± 2 Nm. bague Cu neuve et serrer au couple anillo de cobre nuevo y apretar con
de 18 ± 2 Nm. un par de 18 ± 2 Nm.

Cable harness Faisceau de câbles Mazo de cables

32. Fit cable harness. 32. Monter le faisceau de câbles. 32. Montar el mazo de cables.

33. Tighten fastening bolts with a 33. Serrer les vis de fixation au couple 33. Apretar los tornillos de fijación con
torque of 21 ± 2 Nm. de 21 ± 2 Nm. un par de 21 ± 2 Nm.
4

4.00.83
008 924 17 BOMAG 1153
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Bauteile anbauen:

Öldruckschalter/
4
Kühlmitteltemperaturgeber
ß 38-4-167

6
30. Öldruckschalter mit neuem Cu-Ring
anbauen und mit einem Drehmoment von
18 ± 2 Nm festdrehen.

31. Kühlmitteltemperaturgeber mit neuem

Cu-Ring anbauen und mit einem
Drehmoment von 18 ± 2 Nm festdrehen.
4
ß 38-4-168

Kabelbaum

32. Kabelbaum anbauen.

33. Befestigungsschrauben mit einem Dreh-

moment von 21 ± 2 Nm festdrehen. 4 4
6

4.00.83
1154 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

34. Kabelbaum verlegen und mit Haltebänder

4 befestigen.

Kühlgebläseträger
4 35. Kühlgebläseträger kompl. mit Keilriemenan-

6 schlag anbauen und mit einm Drehmoment

von 21 ± 2 Nm festdrehen.

36. Kühlmittelausgleichsleitung mit neuen

4 Cu-Ringen anbauen.

37. Neue Runddichtringe aufziehen.

4 4 Hinweis: Runddichtringe mit Montage-

ß gleitmittel AP 25 N bestreichen.

4.00.84
008 924 17 BOMAG 1155
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

34. Lay cable harness and fasten with 34. Poser la faisceau de câbles et fixer 34. Colocar el mazo de cables y fijarlo
holding straps. à l'aide de colliers. con cintas de sujeción.

Blower carrier Support de soufflante de Soporte de la turbina de refrigeración

refroidissement

35. Fit blower carrier complete with V- 35. Monter entièrement le support de 35. Montar el soporte de la turbina de
belt stop and secure with a torque soufflante et la butée de courroie, refrigeración completo con el tope
of 21 ± 2 Nm. puis serrer au couple de de correa trapezoidal y apretar con
21 ± 2 Nm. un par de 21 ± 2 Nm.

36. Fit coolant compensating pipe with 36. Monter la conduite de 36. Montar la tubería de compensación
new Cu seals. compensation de réfrigérant avec de refrigerante con anillos de cobre
des bagues Cu neuves. nuevos.

37. Slide on new O-seals. 37. Monter des joints toriques neufs. 37. Colocar anillos tóricos nuevos.

Note: Apply lubricant AP 25N to O- Nota: enduire les joints toriques de Nota: Aplicar lubricante de montaje 4
seals. lubrifiant de montage type AP 25N a los anillos tóricos.
AP 25N.

4.00.84
1156 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

38. Insert coolant. Tighteen bolts with 38. Placer un tube de réfrigérant. Serrer 38. Colocar el tubo de refrigerante.
a torque of 28 Nm. les vis au couple de 28 Nm. Apretar los tornillos con un par de
28 Nm.

Vibration damper/V-belt pulley Amortisseur de vibrations/poulie à Amortiguador de vibraciones/polea

gorge acanalada

39. Fit V-belt pulley and vibration 39. Déposer la poulie à gorge et 39. Montar la polea acanalada y el
damper. l'amortisseur de vibrations. amortiguador de vibraciones.

40. Fit V-belt pulley and retain against 40. Monter la poulie à gorge et la 40. Montar la polea acanalada y retener
flywheel. Tighten bolts according to maintenir au niveau du volant. en el volante. Apretar los tornillos
specification. Serrer les vis selon le serrage según prescripción.
d'approche.
Initial tightening torque: __ 40-50 Nm Valeur de préserrage _____ 40-50 Nm Apriete inicial: __________ 40-50 Nm
1st tightening angle 1er serrage à l'angle 1er ángulo de reapriete:
bolts 60 mm long ____________ 60° Vis 60 mm de long ___________ 60° tornillos 60 mm long __________ 60°
bolts 80 mm long ____________ 60° Vis 80 mm de long ___________ 60° tornillos 80 mm long __________ 60°

2nd tightening angle 2e serrage à l'angle 2° ángulo de reapriete:

bolts 60 mm long ____________ 30° Vis 60 mm de long ___________ 30° tornillos 60 mm long __________ 30°
bolts 80 mm long ____________ 60° Vis 80 mm de long ___________ 60° tornillos 80 mm long __________ 60°

Note: Use Torx socket wrench E20. Nota: utiliser la clé à douile Torx E20. Nota: Utilizar la llave de vaso Torx
Bolts may be used max. 5x if Les vis peuvent être utilisées E20. Los tornillos son
evidence can be furnished selon la pratique, 5 fois au reutilizables hasta 5 veces,
4 concerning their use. maximum. siempre que esto se pueda
comprobar.
41. Fit fuel pump loosely. 41. Reposer la pompe à l'huile sans 41. Montar la bomba de combustible,
serrer. dejándola todavía suelta.

4.00.85
008 924 17 BOMAG 1157
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

38. Kühlmittelrohr einsetzen. Schraube mit

einem Drehmoment von 28 Nm festdre-
hen.
4
6

Schwingungsdämpfer/Keilriemenscheibe

39. Keilriemenscheibe mit Schwingungs-

4
dämpfer anbauen.

40. Keilriemenscheibe anbauen und am

Schwungrad gegenhalten. Schrauben nach
Anziehvorschrift festdrehen.
4
Vorspannwert: ____________ 40-50 Nm
1. Nachspannwinkel
6
Schrauben 60 mm lang ____________ 60°
Schrauben 80 mm lang ____________ 60° 5
2. Nachspannwinkel
Schrauben 60 mm lang ____________ 30°
Schrauben 80 mm lang ____________ 60°
Hinweis: Torx Steckschlüssel E20 verwenden.
Schrauben können bei Nachweisbar-
keit max. 5x verwendet werden.
41. Kraftstoffpumpe lose anbauen.
4 4

4.00.85
1158 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

42. Keilriemen auflegen und spannen.

4 Schrauben mit einem Drehmoment von
21 ± 2 Nm festdrehen.

s
6

43. Keilriemenspannung mit einem

s Spannungsmeßgerät prüfen.
Riemenrückenbreite 10 mm
6 Erstmontage ______________ 450 ± 50 N
Kontrolle nach 15 min. Lauf
unter Last ________________ 300 ± 50 N
Bei Wiederverwendung ______ 300 ± 50 N
Riemenrückenbreite 13 mm
Erstmontage ______________ 550 ± 50 N
Kontrolle nach 15 min. Lauf
unter Last ________________ 400 ± 50 N
Bei Wiederverwendung ______ 400 ± 50 N

44. Generatorkonsole anbauen und mit einem

4 Drehmoment von 60 Nm festdrehen.

38-4-221
6

4
45. Generator anbauen. Schrauben leicht
andrehen.
4
38-4-222

4.00.86
008 924 17 BOMAG 1159
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

42. Position V-Belt in place and 42. Placer la courroie trapézoïdale et 42. Colocar la correa trapezoidal y
tension. Tighten bolts with a torque tendre. Serrer les vis au couple de tensarla. Apretar los tornillos de
of 21 ± 2 Nm. 21 ± 2 Nm. fijación con un par de 21 ± 2 Nm.

43. Check V-belt tension with belt 43. Contrôler la tension de la courroie 43. Comprobar la tensión de la correa
tension gauge. trapézoïdale à l'aide d'un utilizando un verificador de tensión.
tensiomètre.
Belt back width 10 mm Largeur du dos de la courroie Ancho de correa 10 mm
Initial assembly _____ 450 ± 50 N 10 mm Primer montaje _____ 450 ± 50 N
Check value after 15 min.of Première monte _____ 450 ± 50 N Control tras una marcha
operation under load _ 300 ± 50 N Contrôle après 15 min. de marche 15 min. bajo carga ___ 300 ± 50 N
When reusing belt ___ 300 ± 50 N Sous charge ________ 300 ± 50 N Para reutilización ____ 300 ± 50 N
Après réutilisation ___ 300 ± 50 N
Belt back width 13 mm Ancho de correa 13 mm
Initial assembly 550 ± 50 N Largeur du dos de la couronne Primer montaje _____ 550 ± 50 N
Check value after 15 min.of 13 mm Control tras una marcha
operation under load 400 ± 50 N Première monte _____ 550 ± 50 N 15 min. bajo carga ___ 400 ± 50 N
When reusing belt __ 400 ± 50 N Contrôle après 15 min. de marche Para reutilización ____ 400 ± 50 N
Sous charge ________ 400 ± 50 N
Après réutilisation ___ 400 ± 50 N

44. Fit alternator bracket and secure 44. Monter la console de l´alternateur 44. Montar la consola del alternator y
within a torque of 60 Nm. et serrer au couple 60 Nm. apretar con un par de 60 Nm.

45. Mount alternator. Start bolts. 45. Monter l'alternateur et serrer les vis 45. Montar el alternador. Enroscar los
modérément. tornillos con la mano hasta que se
apoyen con su cabeza. 4

4.00.86
1160 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

46. Position V-belt in place and 46. Placer la courroie trapézoïdale et 46. Colocar la correa trapezoidal y
tension. Tighten bolts with a torque tendre. Serrer les vis au couple de tensarla. Apretar los tornillos con
of 31 Nm. Turn belt drive 2-3 31 Nm. Virer l'entraînement de un par de 31 Nm. Darle a la polea
revolutions. courroie de 2 à 3 tours. acanalada 2 a 3 vueltas.

47. Check V-belt tension with belt 47. Contrôler la tension de la courroie 47. Comprobar la tensión de la correa
tension gauge. trapézoïdale à l'aide d'un utilizando un verificador de tensión.
tensiomètre.
Initial assembly _____ 450 ± 50 N Première monte _____ 450 ± 50 N Premer montaje _____ 450 ± 50 N
Check value after 15 min.of Contrôle après 15 min. Controle tras una marcha
operation under load _ 300 ± 50 N Marche sous charge _ 300 ± 50 N de 15 min. bajo carga 300 ± 50 N
When reusing belt ___ 300 ± 50 N Après réutilisation ___ 300 ± 50 N para reutilización ____ 300 ± 50 N

48. Fit air guide ring. Tighten bolts and 48. Monter le diffuseur d'air. Serrer les 48. Montar el aro guía de aire. Apretar
nuts with a torque of 11 Nm. vis et les écrous au couple de los tornillos y tuercas con un par
11 Nm. de 11 Nm.

49. Fit tension pulley together with 49. Monter le galet tendeur et la 49. Montar la polea tensora con
bracket and secure with a torque of console et serrer au couple de consola y apretar con un par de
4 29 Nm. 29 Nm. 29 Nm.

4.00.87
008 924 17 BOMAG 1161
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

46. Keilriemen auflegen und spannen.

Schrauben mit einem Drehmoment von
31 Nm festdrehen.
4
Riementrieb 2-3 Umdrehungen durchdre-
hen. s
6

47. Keilriemenspannung mit Spannungsmeß-

gerät prüfen. s
Erstmontage ______________ 450 ± 50 N
Kontrolle nach 15 min. 6
Lauf unter Last ___________ 300 ± 50 N
Bei Wiederverwendung _____ 300 ± 50 N

48. Luftrichter anbauen. Schrauben und

Muttern mit einem Drehmoment von
11 Nm festdrehen.
4
6

49. Spannrolle mit Konsole anbauen und mit

einem Drehmoment von 29 Nm fest-
drehen.
4 4
6

4.00.87
1162 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

49.1 Keilriemen auflegen und spannen.

4 Schrauben mit einem Drehmoment von
29 Nm festdrehen.

s
6

50. Keilriemenspannung mit Spannungs-

s meßgerät prüfen.

6 Erstmontage ______________ 450 ± 50 N

Kontrolle nach 15 min.
Lauf unter Last ____________ 300 ± 50 N
Bei Wiederverwendung ______ 300 ± 50 N

51. Kabel anbauen.

4
i
9

52. Kabel für Kühlmitteltemperaturgeber

4 4 anbauen.

4.00.88
008 924 17 BOMAG 1163
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

49.1 Position V-belt in place and 49.1 Placer la courroie trapézoîdale et 49.1 Colocar la correa trapezoidal y
tension. Tighten bolts with a tendre. Serrer les vis au couple tensarla. Apretar los tornillos con
torque of 29 Nm. de 29 Nm. un par de 29 Nm.

50. Check V-belt tension with belt 50. Contrôler la tension de la courroie 50. Comprobar la tensión de la correa
tension gauge. trapézoîdale à l'aide d'un utilizando un verificador de
tensionmètre. tensión.

Initial assembly ____ 450 ± 50 N Première monte _____ 450 ± 50 N Primer montaje _____ 450 ± 50 N
Check value after 15 min.of Contrôle après 15 min. Control tras 15 minutos
operation under load 300 ± 50 N Marche sous charge _ 300 ± 50 N de marcha bajo carga _ 300 ± 50 N
When reusing belt __ 300 ± 50 N Après réutilisation ___ 300 ± 50 N Para reutilización ____ 300 ± 50 N

51. Fit cable. 51. Monter le câble. 51. Montar el cable.

52. Fit cable for coolant temperature 52. Monter le câble du capteur de 52. Montar el cable para el transmisor
sensor. température du réfrigérant. de temperatura de refrigerante.
4

4.00.88
4.00.89
1164 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Coolant pipe Tuyau de réfrigérent Tubo de refrigerante

53. Slide on new O-seals. 53. Monter des joints toriques neufs. 53. Colocar anillos tóricos nuevos.

Note: Apply lubricant AP 25 N to Nota: enduire les joints toriques de Nota: Aplicar deslizante de montaje
O-seals lubrifiant de montage AP 25 N. AP 25 N a los anillos tóricos.

54. Preassemle coolant pipe with 54. Préassembler le tuyau de 54. Preensamblar el tubo de
flange. réfrigérant avec la bride. refrigerante con la brida.

55. Apply sealing compound DEUTZ 55. Enduire la plan de joint de la bride à 55. Aplicar a la superficie de cierre de
DW 67 to flange sealing surface. Fit l'aide d'unproduit d'étanchéité la brida pasta sellante
coolant pipe. DEUTZ DW 67. Monter le tuyau de DEUTZ DW 67. Montar el tubo de
réfrigérant. refrigerante.

56. Tighten bolts with a torque of 56. Serrer les vis au couple de 28 Nm. 56. Apretar los tornillos con un par de
28 Nm. 28 Nm.
4
Note: Pay attention to correct position Nota: veiller au bon positionnement Nota: Pretar atención a la correcta
of locking washer. de la rondelle d'arrêt. posición de la arandela de
seguridad.

4.00.89
008 924 17 BOMAG 1165
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Kühlmittelrohr

53. Neue Runddichtringe aufziehen.

4
Hinweis: Runddichtringe mit Montagegleit- ß
5
mittel AP 25 N bestreichen.

54. Kühlmittelrohr mit Flansch vormontieren.

55. Dichtfläche des Flansches mit Dichtmasse

DEUTZ DW 67 bestreichen. Kühlmittelrohr
anbauen.
4
w

56. Schrauben mit einem Drehmoment von

28 Nm festdrehen. 4 4
Hinweis: Auf richtige Position der Sicher-
ungsscheibe achten. 6
5

4.00.89
1166 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

Verblechung
4 57. Abdeckblech anbauen.

Ölrücklaufrohr/Druckölleitung
4 58. Neue Runddichtringe aufziehen und fetten.
ß
u

59. Einschraubstutzen mit neuem Cu-Dichtring

4 mit einem Drehmoment von 40 ± 2 Nm
festdrehen.
6
ß

4
60. Ölrücklaufleitung und Halter anbauen.
Schraube mit einem Drehmoment von
4 22 ± 2 Nm festdrehen.
6

4.00.90
008 924 17 BOMAG 1167
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Panelling Tôle Chapas

57. Fit cover plate. 57. Monter la tôle de recouvrement. 57. Montar la chapa de recubrimiento.

Oil return pipe/pressure oil pipe Tuyau de retour d'huile/conduite de Tubo de retorno de aceite/tubería de
refoulement d'huile aceite a presión

58. Slide on new O-seals and grease. 58. Monter les joint toriques neufs et 58. Colocar anillos tóricos nuevos y
graisser. engrasarlos con grasa.

59. Tighten screw plug with new Cu 59. Serrer les tubulures à visser avec 59. Apretar los enchufes roscados,
seal with a torque of 40 ± 2 Nm. un joint d'étanchiété au couple de provistos de un anillo de junta de
40 ± 2 Nm. cobre nuevo, con un par de
40 ± 2 Nm.

60. Fit oil return pipe and retainer. 60. Monter le tuyau de retour d'huile et 60. Montar la tubería de retorno de
Tighten bolt with a torque of le support. Serrer la vis au couple aceite y los sujetadores. Apretar los
22 ± 2 Nm. de 22 ± 2 Nm. tornillos de fijación con par de 4
22 ± 2 Nm.

4.00.90
1168 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

61. Fit pressure oil pipe. Tighten banjo 61. Monter la conduite de refoulement 61. Montar la tubería de aceite a
bolts with new Cu seals and with a d'huile. Serrer les vis creuses avec presión:
torque of des joints d'étanchéité Cu neufs. Enroscar los tornillos racor,
item 1 29 ± 3 Nm Pos. 1 29 ± 3 Nm provistos de anillos de junta de
item 2 39 ± 4 Nm. Pos. 2 39 ± 4 Nm. cobre nuevos, y apretarlos con un
par de
29 ± 3 Nm = pos. 1
39 ± 4 Nm = pos. 2.

62. Fit cover plate. 62. Monter la tôle d’extrémité. 62. Montar la chapa final.

63. Fit cable to starter and terminal 63. Monter le câble sur le démarreur et 63. Unir el cable al arrancador y bulón
stud. le boulon de fixation. de conexión.

Tighening specifications: Consigne de serrage: Prescripción de apriete:

Hex. nut on terminal stud Ecrou hexagonal sur le boulon de Tuerca hexagonal en el bulón de
35 ± 4 Nm fixation 35 ± 4 Nm conexión 35 ± 4 Nm
Hex. nut on starter (terminal 30) Ecrou hexagonal sur le démarreur Tuerca hexagonal en el arrancador
28 ± 2 Nm (borne 30) 28 ± 2 Nm (borne 30) 28 ± 2 Nm.

64. Introduce cable harness through 64. Introduire le faisceau de câble par 64. Hacer pasar el mazo de cables a
cover plate. Fit rubber grommet. la tôle de recouvrement. Monter le través de la chapa de
4 passe-câble. recubrimiento. Montar el
pasacables.

4.00.91
008 924 17 BOMAG 1169
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

61. Druckölleitung anbauen:

Hohlschrauben mit neuen Cu-Dichtringen

4
und mit einem Drehmoment von
Pos. 1 29 ± 3 Nm
Pos. 2 39 ± 4 Nm
festdrehen.

62. Abschlußblech anbauen.

63. Kabel an Starter und Anschlußbolzen an-

bauen. 4
Anziehvorschrift:
Sechskantmutter am Anschlußbolzen
6
35 ± 4 Nm
Sechskantmutter am Starter (Klemme 30)
28 ± 2 Nm

64. Kabelbaum durch Abdeckblech durchführen.

Gummitülle montieren 4 4
9

4.00.91
1170 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

65. Niveauschalter mit neuer Gummimuffe

4 einbauen.
Schraube mit einem Drehmoment von

ß 28 Nm festdrehen.

66. Verkabelung mit Haltebinder und Halter

4 anbauen.
Schrauben mit einem Drehmoment von
38-4-226 6 9 Nm festdrehen.

67. Klemmprofil anbauen.

Flüssigkeitskühler

4 4 68. Neue Runddichtringe für Flüssigkeits-

ß kühler einsetzen.

4.00.92
008 924 17 BOMAG 1171
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

65. Install level switch with new rubber 65. Monter l'interrupteur du niveau 65. Instalar el interruptor de nivel con
sleeve. Tighten bolt with a torque of avec le manchon en caoutchouc un manguito de goma nuevo.
28 Nm. neuf. Serrer la vis au couple de Apretar el tornillo con un par de
28 Nm. 28 Nm.

66. Fit cabling with fixing strap and 66. Monter le câblage avec le collier de 66. Montar los cables con atacables y
holder. Tighten bolts with a torque fixation et le support. Serrer les vis sujetadores.
of 9 Nm. au couple de 9 Nm. Apretar los tornillos con un par de
9 Nm.

67. Fit clamping section. 67. Monter le profilé de serrage. 67. Colocar anillos tóricos nuevos para
el refrigerador de líquido.

Radiator Refroidisseur à liquide Refrigerador de líquido

68. Insert new O-seals for radiator. 68. Placer les joints toriques neufs 68. Colocar anillos tóricos nuevos para 4
dans le refroidisseur de liquide. el refrigerador de líquido.

4.00.92
1172 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

69. Fit retainer for radiator. 69. Monter le support du refroidisseur 69. Montar los soportes para el
Tighten bolts with a torque of à liquide. Serrer les vis au couple refrigerador.
21 Nm. de 21 Nm. Apretar los tornillos con un par de
21 Nm.

70. Mount radiator. Tighten bolts with 70. Monter le refroidisseur à liquide. 70. Montar el refrigerador. Apretar los
a torque of 9 ± 1 Nm. Serrer les vis au couple de tornillos de fijación con un par de
9 ± 1 Nm. 9 ± 1 Nm.

71. Fit cover plate. 71. Monter la tôle de recouvrement. 71. Montar la chapa de rccubrimiento.

72. Fit cover plate. 72. Monter la tôle de recouvrement. 72. Montar la chapa de rccubrimiento.
4

4.00.93
008 924 17 BOMAG 1173
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

69. Halter für Flüssigkeitskühler anbauen.

Schrauben mit einem Drehmoment von
21 Nm festdrehen.
4
6

70. Flüssigkeitskühler anbauen. Schrauben mit

einem Drehmoment von 9 ± 1 Nm
festdrehen.
4
6

71. Abdeckblech anbauen.

72. Abdeckblech anbauen.

4 4

4.00.93
1174 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

73. Abdeckblech anbauen.

4 Hinweis: Schrauben noch nicht festdrehen.

74. Entlüftungsleitung mit neuen Cu-Ringen

4 anbauen. Halter gemeinsam mit Abdeck-
blech festdrehen.

4
75. Schaulochblech anbauen.

4 4
7

4.00.94
008 924 17 BOMAG 1175
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

73. Fit cover plate. 73. Monter la tôle de recouvrement. 73. Montar la chapa de rccubrimiento.

Note: Do not tighten bolts yet. Nota: ne pas encore serrer les vis. Nota: Los tornillos todavia no deben
appretarse.

74. Fit breather pipe with new Cu seals. 74. Monter la conduite de dégazage 74. Montar la tubería de ventilación con
Tighten retainer together with cover avec des joints Cu neufs. Serrer le anillos de cobre nuevos. Apretar el
plate. support avec la tôle de sujetador junto con la chapa de
recouvrement. recubrimiento.

75. Fit inspection hole cover plate. 75. Monter la tôle-regard. 75. Montar la chapa de la abuerta de
inspección.

4.00.94
1176 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Replacing shaft seals on complete Remplacement des joints d’arbre sur Cambio de los retenes en el motor
engine moteur complet completo

Special tools required: Outillage spécial : Herramientas especiales:

Extractor for Extracteur de Dispositivo de extracción

shaft seals ______________ 142 710 joints d’arbre ___________ 142 710 para retenes _____________ 142 710
Assembly tool, rear Dispositif de montage AR Dispositivo de montaje, atrás
BFM 1012 _________ 142 890 BFM 1012 ___________ 142 890 BFM 1012 ___________ 142 890
BFM 1013 _________ 142 910 BFM 1013 ___________ 142 910 BFM 1013 ___________ 142 910
Assembly tool, front Dispositif de montage AV Dispositivo de montaje, delante
BFM 1012 _________ 142 900 BFM 1012 ___________ 142 900 BFM 1012 ___________ 142 900
BFM 1013 _________ 142 920 BFM 1013 ___________ 142 920 BFM 1013 ___________ 142 920

- Timing chest cover flywheel end - - Couvercle de carter de distribution - Tapa del cárter de la distribución,
côté volant moteur - lado de volante -

Flywheel has been removed. Le volant moteur a été déposé. El volante está desmontado.

1. Press extractor into shaft seal. 1. Insérer le crochet extracteur dans le 1. Introducir a presión el gancho
joint d’arbre. extractor en el retén.

2. Lift shaft seal with extractor out of 2. A l’aide de l’extracteur retirer le 2. Haciendo palanquilla con el
timing chest cover. joint d’arbre du couvercle du carter dispositivo de extracción, sacar el
de distribution. retén de su alojamiento en la tapa
del cárter de la distribución.

3. Fit guide sleeve. 3. Monter la douille de guidage. 3. Montar la consola.

4.00.95
008 924 17 BOMAG 1177
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Austausch der Wellendichtringe am komplet-

ten Motor
4
Spezialwerkzeuge:
6
Ausziehvorrichtung für
Wellendichtringe ________________ 142 710
Montagevorrichtung hinten
BFM 1012 ________ 142 890
BFM 1013 ________ 142 910
Montagevorrichtung vorne
BFM 1012 ________ 142 900
BFM 1013 ________ 142 920

- Räderkastendeckel Schwungradseite -

Schwungrad ist abgebaut.

4
1. Abziehhaken in den Wellendichtring 7
eindrücken.

2. Wellendichtring mit Ausziehvorrichtung aus

dem Räderkastendeckel hebeln. 3
7

3. Führungsbuchse anbauen.
4 4
7

4.00.95

1178 BOMAG 008 924 17

Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

0 ± 0,5 4. Einbautiefe beachten.

1 4 Pos.1 Einbautiefe Erstmontage

6 Pos. 2 Maximale Einbautiefe

2 3 ± 0,5
10-4-307

4.1 Dichtlippen einölen. Wellendichtring mit

4 Eindrückvorrichtung montieren.
Dichtlippe weist zur Kurbelwelle.

z
7
8

- Vorderer Deckel -
4 Keilriemenscheibe ist abgebaut.
7 1. Abziehhaken in den Wellendichtring
eindrücken.

2. Wellendichtring mit Ausziehhaken aus

4 3 dem vorderen Deckel hebeln.

4.00.96
008 924 17 BOMAG 1179
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

4. Pay attention to the installation 4. Tenir compte de la profondeur de 4. Observar la profundidad de

depth. montage montaje.

Item 1 installation depth initial Rep. 1 Profondeur de montage Pos. 1 Profundidad de montaje
assembly première monte primer montaje
Item 2 maximum installation depth Rep. 1 Profondeur de montage Pos. 1 Profundidad máxima de
maximale montaje

4.1 Oil sealing lips. Fit shaft seal with 4.1 Huiler les lèvres d’étanchéité. 4.1 Aceitar los labios obturantes.
assembly tool. Sealing lip faces Monter le joint d’arbre à l’aide du Montar el retén mediante el
crankshaft. dispositif d’insertion. La lèvre dispositivo de montaje a presión.
d’étanchéité est dirigée vers le El labio indica hacia el cigüeñal.
vilebrequin.

- Front cover - - Couvercle AV - - Tapa delantera -

V-belt pulley has been removed. La poulie à gorge a été déposée. La polea acanalada está desmontada.

1. Press extractor into shaft seal. 1. Introduire le crochet extracteur 1. Introducir a presión el gancho
dans le joint d’arbre. extractor en el retén.

2. Lift shaft seal with extractor out of 2. A l’aide du crochet extracteur 2. Haciendo palanquilla con el
front cover. dégager et retirer le joint d’arbre dispositivo extractor, sacar el retén
du couvercle avant. de la tapa delantera. 4

4.00.96
1180 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

3. Fit guide sleeve. 3. Monter la douille de guidage. 3. Montar el manguito de guía.

4. Pay attention to the installation 4. Tenir compte de la profondeur de 4. Observar la profundidad de

depth. montage montaje.

4.1 Oil sealing lips. Fit shaft seal with 4.1 Huiler les lèvres d’étanchéité. 4.1 Aceitar los labios de obturantes.
assembly tool. Sealing lip faces Monter le joint d’arbre à l’aide du Montar el retén mediante el
crankshaft. dispositif d’insertion. La lèvre dispositivo correspondiente.
d’étanchéité est dirigée vers le El labio indica hacia el cigüeñal.
vilebrequin.

4.00.97
008 924 17 BOMAG 1181
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

3. Führungsbuchse anbauen.
4
7

4. Einbautiefe beachten.

Pos.1 Einbautiefe Erstmontage

4 1 5
Pos. 2 Maximale Einbautiefe
6
8
2

10-4.311

4.1 Dichtlippen einölen. Wellendichtring mit

Eindrückvorrichtung montieren.
Dichtlippe weist zur Kurbelwelle.
4
z
7
8

4.00.97
1182 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

008 924 17 BOMAG 1183

Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

1184 BOMAG 008 924 17

Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Removing and refitting air Pose et dépose du compresseur à air Desmontaje y remontaje del
compressor compresor de aire.

1. Remove air compressor and oil 1. Déposer le compresseur à air et les 1. Desmontar el compresor de aire y
pressure pipes. conduites de refoulement d’huile. las tuberías de presión de aceite.

Note: Inspect all single parts and Nota: contrôler visuellement toutes Nota: Examinar visualmente todas las
replace if necessary. les pièces, les changer le cas piezas y reemplazarlas según
échéant. necesidad.

2. Fit new O-seal. 2. Monter un joint torique neuf. 2. Montar un aro tórico nuevo.

3. Fit oil pressure pipe together with 3. Monter la conduite de refoulement 3. Montar la tubería de presión de
new Cu seals prior to mounting air d’huile avec des joints neufs en Cu aceite con juntas de cobre nuevas
compressor. avant de mettre en place le antes de adosar el compresor.
compresseur à air.

Note: Do not yet tighten banjo bolt. Nota: ne pas encore serrer la vis Nota: El tornillo racor todavía no debe
creuse. apretarse.

4. Mount air compressor. 4. Monter le compresseur. Monter les 4. Montar el compresor de aire.
Insert bolts with locking compound vis avec de la pâte de sécurité Meter los tornillos con sellante
4 Deutz DW 72 and tighten with a Deutz DW 72 puis serrer au couple DEUTZ DW 72 y apretar con un par
torque of 61 ± 6 Nm. de 61 ± 6 Nm. de 61 ± 6 Nm.

4.00.99
008 924 17 BOMAG 1185
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Luftpresser ab- und anbauen.

1. Luftpresser und Öldruckleitungen abbauen.

3
Hinweis: Alle Teile sichtprüfen, ggf. austau- 5
schen.

2. Neuen Runddichtring montieren.

4
ß

3. Öldruckleitung mit neuen Cu-Dichtungen

vor Luftpresseranbau montieren.
4
Hinweis: Noch nicht festdrehen.
ß
5

4. Luftpresser anbauen.
Schrauben mit Sicherungsmittel Deutz DW
72 einsetzen und mit einem Drehmoment
4 4
von 61 ± 6 Nm festdrehen.
w
6

4.00.99
1186 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

5. Zweite Öldruckleitung mit neuen Cu-

4 Dichtungen anbauen.

6. Öldruckleitungen am Kurbelgehäuse und

4 Luftpresser festdrehen.

4.00.100
008 924 17 BOMAG 1187
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

5. Fit 2nd oil pressure pipe with new 5. Monter la 2éme conduite de 5. Montar la segunda tubería de
Cu seals. refoulement d´heule avec des joints presión de aceite con juntas de
en Cu neufs. cobre nuevas.

6. Secure oil pressure pipes on 6. Serrer les conduites du 6. Apretar la tuberías de presión de
crankcase and air compressor. refoulement d´huile et le aceite en el bloque motor y en el
compresseur á air. compresor de aire

4.00.100
1188 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Removing and refitting power Pose et dépose de la pompe direction Desmontaje y remontaje de la
steering pump auxiliaire servobomba de dirección.

1. Fit power steering pump. Take off 1. Dé poser la pompe de direction 1. Desmontar la servobomba de
driver disc. auxiliare. Retirer le disque dirección. Retirar el disco
déntraînement. arrastrador.

Note: Inspect all single parts and Nota: contrôler visuellement toutes Nota: Examinar visualmente todas las
replace if necesarry. les piéces, les changer le cas piezas y reemplazarlas según
échéant, necesidad.

2. Fit driver disc. 2. Monter le disque déntraînement. 2. Instalar el disco arrastrador.

3. Fit new O-seal and apply dehydated 3. Monter un joint torique neuf et 3. Montar un anillo tórico nuevo y
lubricant. lénduire de lubrifiant anhydre. untarlo con lubricante exento de
agua.

4. Fit power steering pump and make 4. Monter la pompe de direction 4. Montar la servobomba de
sure that drivers engage in driver auxiliare. Veiller á ce que les tocs dirección, prestando anteción a que
4 disc. soient bien en prise dans les los arrastradores entren en el disco
disques déntraînemement. arrastrador.

4.00.101
008 924 17 BOMAG 1189
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Lenkhilfspumpe ab- und anbauen.

1. Lenkhilfspumpe abbauen. Mitnehmer-

3
scheibe abnehmen.
5
Hinweis: Alle Teile sichtprüfen, ggf. austau-
schen.

2. Mitnehmerscheibe einbauen.
4

3. Neuen Runddichtring montieren und mit

wasserfreiem Schmiermittel bestreichen. 4
ß

4. Lenkhilfspumpe anbauen. Darauf achten, daß die

Mitnehmer in die Mitnehmerscheibe greifen.
4 4
9

4.00.101
1190 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

5. Schrauben mit einem Drehmoment von

4 43,5 ± 4 Nm festdrehen.

6 Hinweis: Auf Spezialscheiben achten.

4.00.102
008 924 17 BOMAG 1191
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

5. Tighten bolts with a torque of 5. Serrer les vis au couple de 5. Apretar los tornillos con un par de
43.5 ± 4 Nm. 43.5 ± 4 Nm. 43,5 ± 4 Nm.

Note: Watch out for special washers. Nota: veiller aux cales spêciales. Nota: Tener en cuenta las arandelas
especiales.

4.00.102
1192 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Removing and refitting hydraulic Pose et dépose de la pompe Desmontaje y remontaje de la bomba
pump hydraulique hidráulica.

1. Unscrew bolts from hydraulic 1. Dévisser puis retirer les vis de la 1. Desenroscar los tornillos de la
pump. pompe hydraulique. bomba hidráulica.

2. Unscrew bolts from guide flange. 2. Devisser puis retirer les vis de la 2. Desenroscar los tornillos de la
Remove hydraulic pump complete bride de guidage. brida de guía.
with guide flange. Retirer entiérement la pompe Retirar la bomba hidráulica
hydraulique avec la bride de completamente con la brida de
guidage. guía.

Note: Inspect all single parts and Nota: enduire visuellement toutesles Nota: Examinar visualmente todas las
replace if necessary. piéces, les changer le cas piezas y reemplazarlas según
échéant. necesidad.

3. Mount preassembled hydraulic 3. Monter la pompe hydraulique 3. Montar la bomba hidráulica

pump together with guide flange. préassemblée avec la bride de premontada, con la brida de guía.
Tighten guide flange bolts with a guidage. Apretar los tornillos de la brida de
torque of 21 ± 2 Nm. Serrer les vis de la bride de guidage guía con un par de 21 ± 2 Nm.
au couple de 21 ± 2 Nm.

Note: Apply dehydrated lubricant to Nota: enduire el joint torique et Nota: Aplicar lubricante exento de
seal/receiving bore. l´alésager du legement de agua al anillo tórico/
lubrifiant anhydre. alojamiento.

4. Move gasket into installation 4. Insérer el joint en position de 4. Colocar la junta en su posición de
position. Tighten hydraulic pump montage. Serrer les vis de la montaje. Apretar los tornillos de la
4 bolts with a torque of 50 ± 10 Nm. pompe hyfraulique au couple de bomba hidráulica con un par de
50 ± 10 Nm. 50 ± 10 Nm.

4.00.103
008 924 17 BOMAG 1193
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Hydraulikpumpe ab- und anbauen.

1. Schrauben von Hydraulikpumpe heraus-

3
schrauben.

2. Schrauben von Führungsflansch heraus-

schrauben.
Hydraulikpumpe komplett mit Führungs-
3
flansch abnehmen.
5
Hinweis: Alle Teile sichtprüfen, ggf. austau-
schen.

3. Vormontierte Hydraulikpumpe mit

Führungsflansch anbauen.
Schrauben von Führungsflansch mit einem
4
Drehmoment von 21 ± 2 Nm festdrehen.
6
5
Hinweis: Runddichtring/Aufnahmebohrung
mit wasserfreiem Schmiermittel be-
streichen.

4. Dichtung in Einbaulage schieben. Schrau-

ben von Hydraulikpumpe mit einem Dreh-
moment von 50 ± 10 Nm festdrehen.
4 4
6

4.00.103
1194 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

008 924 17 BOMAG 1195

Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

1196 BOMAG 008 924 17

Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Removing and refitting hydraulic Poset et dépose de la pompe Desmontaje y remontaje de la bomba
pump together with bracket hydraulique hidráulica y consola

1. Remove oil pressure pipe 1. Monter conduite de refoulement 1. Desmontar la tubería de presión de
d´huile. aceite.

2. Remove hydraulic pump. 2. Déposer la pompe hydraulique. 2. Desmontar la bomba hidráulica.

3. Remove bracket. 3. Déposer la console. 3. Desmontar la consola.

Note: Inspect all single parts and Nota: effectuer un contrôle visuel de Nota: Inspeccionar todas las piezas
replace if necessary. Renew toutes les pièces, au besoin les visualmente, sustituyéndolas en
gaskets. Check bore in hollow remplacer. Renouveller les caso necesario. Renovar las
shaft and drive shaft for free joints. Contrôler le libre juntas. Comprobar los taladros
passage. passage de l'alésage de l'arbre en el eje hueco y eje arrastrador
creux d'entraînement. para ver si están despejados.

4. Fit preassembled bracket. 4. Monter la console préassemblée. 4. Montar la consola premontada.

4 Note: Lightly oil O-seal/bore. Nota: huiler légérement le joint Nota: Untar con un poco de aceite el
torique/l´alésage. anillo tórico/alojamiento.

4.00.105
008 924 17 BOMAG 1197
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Hydraulikpumpe mit Konsole ab- und

anbauen
3
1. Öldruckleitung abbauen.

2. Hydraulikpumpe abbauen.
3

3. Konsole abbauen.

Hinweis: Alle Teile sichtprüfen, ggf. austau-

3
schen. Dichtungen erneuern.
Bohrung in Hohl- und Mitnehmer- 5
welle auf freien Durchgang prüfen.

4. Vormontierte Konsole anbauen.

Hinweis: Runddichtring/Bohrung leicht ein-

4 4
ölen.
5

4.00.105
1198 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

5. Neuen Runddichtring auf Befestigungs-

4 flansch auflegen.

6. Befestigungsflansch anbauen.
4 Schrauben nach Anziehvorschrift fest-
drehen.

6 Schrauben M 8 = 21 ± 2 Nm
Schrauben M 10 = 40,5 ± 4 Nm

5 Hinweis: Schrauben M10 sind mikrover-

kapselt. Eine Wiederverwendung ist
nicht zulässig.

7. Führungshülse einsetzen.
4 Hinweis: Auf Sicherungsring in der Mitte der

5 Führungshülse achten.

8. Neue Dichtung auflegen. Hydraulikpumpe

4 4 anbauen.

4.00.106
008 924 17 BOMAG 1199
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

5. Position new O-seal on fastening 5. Placer un joint torique neuf sur la 5. Colocar un anillo tórico nuevo
flange. bride de fixation. sobre la brida de fijación.

6. Fit fastening flange. Tighten bolts 6. Monter la bride de fixation. 6. Montar la brida de fijación.
according to specification. Serrer les vis selon les préconisations Apretar los tornillos según
de serrage prescripción.
Bolts M 8 = 21 ± 2 Nm vis M 8 = 21 ± 2 Nm Tornillos M8 = 21 ± 2 Nm
Bolts M 10= 40.5 ± 4 Nm vis M 10 = 40,5 ± 4 Nm Tornillos M10 = 40,5 ± 4 Nm

Note: Bolts M10 are micro- Nota: les vis M10 sont dotées d'une Nota: Los tornillos M10 tienen un
encapsulated. Their re-use is microcapsule. recubrimiento sellante. Es
not permissible. inadmisible volver a utilizarlos.

7. Insert guide bush. 7. Mettre en place la douille de guidage. 7. Introducir el manguito de guía.

Note: Watch out for circlip in the Nota: veiller à ce que le circlip soit au Nota: Prestar atención al anillo de
middle of guide bush. milieu de la douille de guidage. retención en medio del
manguito de guía.

8. Position new gasket. Mount 8. Placer un joint neuf puis monter la 8. Colocar una junta nueva. Montar la
hydraulic pump. pompe. bomba hidráulica.
4

4.00.106
1200 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

9. Tighten bolts with a torque of 9. Serrer les vis au couple de 9. Apretar los tornillos de fijación con
50 ± 10 Nm. 50 ± 10 Nm. un par de 50 ± 10 Nm.

10. Fit oil pressure pipe with new Cu 10. Monter la conduite du refoulement 10. Montar la tubería de presión de
seals. d’huile avec des joints Cu neufs. aceite con juntas de cobre nuevas.

4.00.107
008 924 17 BOMAG 1201
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

9. Schrauben mit einem Drehmoment von

50 ± 10 Nm festdrehen.
4
6

10. Öldruckleitung mit neuen Cu-Dichtungen

anbauen. 4
ß

4.00.107
1202 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Diesel engine 16.8
Disassembly and reassembly of complete engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

008 924 17 BOMAG 1203

Demontage und Montage, Motor komplett
16.8 and reassembly of complete engine
Disassembly Diesel engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

1204 BOMAG 008 924 17

Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

Replacing injection pump in case of Remplacement de la pompe Cambio de las bombas de inyección
service d’injection en SAV en el caso de servicio
This repair method only refers to the La présente méthode de réparation ne Este método de reparación sólo está
replacement of injection pumps. If concerne que le remplacement des pensado para el cambio de las bombas
other components are to be replaced pompes d’injection. En cas de de inyección. Si adicionalmente han de
as well, e.g. roller tappets, governor, remplacement supplémentaire d’autres cambiarse otras piezas, como el
etc., proceed according to chapter 4 pièces comme p. ex. les poussoirs à empujador de rodillo, regulador, etc.,
„Installing injection pump“. galet, le régulateur etc. procéder se procederá como se indica en el
comme au chapitre 4 „montage capítulo 4 „Montaje de bombas de
pompes d’injection“. inyección“.

Special tool required: Outillage spécial: Herramientas especiales:

Press-on device for Dispositif de montage de Dispositivo de presión para
control rod ______________ 100 830 crémaillère ______________ 100 830 la cremallera ____________ 100 830
Extracting device _________ 150 800 Extrateur _______________ 150 800 Dispositivo de extracción ___ 150 800
Extractor for injector ______ 110 030 Extrateur pour injecteur ____ 110 030 Extractor para inyector ____ 110 030

1. Remove crankcase breather and 1. Déposer l’évent de carter et le cache- 1. Desmontar la ventilación del cárter
cylinder head cover. culbuteurs. y la tapa de culata.

2. Pull off cable plug. 2. Retirer le contacteur de câble. 2. Sacar el enchufe de cable.
Remove shutdown solenoid or Déposer l’électroaimant d’arrêt ou Desmontar el solenoide de parada
screw plug. le bouchon de fermeture. o el tapón de cierre.

3. Press control rod with shutdown 3. A l’aide du levier d’arrêt pousser la 3. Presionar la barra cremallera
4 lever into stop position. Insert crémaillère en position de stop. mediante la palanca de parada en
press-on device and screw on. Monter l’outil de montage et serrer. posición de parada. Introducir el
dispositivo de presión y atornillarlo.

4.00.109
008 924 17 BOMAG 1205
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

Austausch der Einspritzpumpe im Servicefall

Diese Reparaturmethode ist nur für den Aus-

tausch der Einspritzpumpen gedacht. Sollten
zusätzlich noch andere Teile getauscht werden,
z.B. Rollenstößel, Regler etc., ist wie in Kapitel
4 „Einspritzpumpen Einbau“ zu verfahren.

Spezialwerkzeug:
Andrückvorrichtung für
Regelstange ____________________ 100 830
Ausziehvorrichtung ______________ 150 800
Auszieher für Einspritzventil _______ 110 030

1. Kurbelgehäuseentlüftung und Zylinderkopf-

haube abbauen.
3

2. Kabelstecker abziehen.
Abstellmagnet oder Verschlußstopfen aus-
bauen.
3

3. Regelstange mittels Abstellhebel in Stop-

stellung drücken. Andrückvorrichtung ein-
setzen und verschrauben.
4 4
7

4.00.109
1206 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

4. Regelstange mit Rändel-Feststellschraube

s in Stopstellung drücken.

5 Hinweis: Rändel-Feststellschraube von Hand

festdrehen.

5. Zylinder der auszubauenden Einspritzpum-

Zünd OT 6 pe auf Zünd-O.T. stellen.
Kurbelwelle ca. 120° entgegen der Motor-

5 drehrichtung drehen.

Hinweis: Darstellung Blickrichtung auf

Schwungrad.

120

6. Einspritzleitung und Einspritzpumpe

3 abbauen.

7. Ausgleichsscheibe mit Stabmagnet vorsich-

4 3 tig herausnehmen.

5 Hinweis: Neue Ausgleichsscheibe ermitteln,

siehe für BFM 1012 Seite 1.00.15
für BFM 1013 Seite 1.00.17

4.00.110
008 924 17 BOMAG 1207
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

4. Press control rod with knurled- 4. A l’aide de la vis de blocage 4. Presionar la cremallera en posición
head setscrew into stop position. moletée amener la crémaillère en de parada con ayuda del tornillo de
position de stop. cabeza moleteada, de bloqueo.

Note: Tighten knurled-head setscrew Nota: serrer la vis de blocage moletée Nota: Apretar con la mano el tornillo
by hand. à la main. de cabeza moleteada, de
bloqueo.

5. Move cylinder of injection pump to 5. Placer le cylindre de la pompe 5. Poner el cilindro que corresponda a
be removed to firing TDC. d’injection à déposer en position la bomba de inyección a
Turn crankshaft about 120°against d’allumage PMH. desmontar, en el PMS de
direction of engine rotation. Virer le vilebrequin d’environ 120° compresión.
dans le sens opposé au sens de Girar el cigüeñal aprox. 120° en
rotation du moteur. sentido opuesto al de giro normal
del motor.

Note: Flywheel is faced on the Nota: illustration observateur Nota: Representado con dirección de
illustration at the left. regardant le volant moteur. la mirada al volante.

6. Remove injection line and 6. Déposer la conduite d'injection et la 6. Desmontar la tubería de inyección y
injection pump. pompe d'injection. la bomba de inyección.

7. Carefully take out shim using bar 7. Retirer avec précaution la rondelle 7. Retirar la arandela de reglaje
magnet. d’épaisseur à l’aide d’une barre cuidadosamente mediante el imán
magnétique. de barra. 4
Note: Determine new shim, see Nota: calcul de l’épaisseur de la Nota: Determinar la arandela de
page 1.00.15 for BFM 1012, rondelle, voir page reglaje nueva:
page 1.00.17 for BFM 1013. 1.00.15 pour le BFM 1012 para BFM 1012 ver pág. 1.00.15
et page para BFM 1013 ver pág. 1.00.17
1.00.17 pour le BFM 1013

4.00.110
1208 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

8. Position new shim previously 8. Placer la rondelle d’épaisseur 8. Colocar la arandela de reglaje
determined on roller tappet. nouvellement calculée sur le determinada sobre el empujador de
poussoir à galet. rodillo.

Note: See page 4.00.37 items Nota: montage pompe d’injection Nota: Para el montaje de la bomba de
78 - 84 for installation of voir page 4.00.37 à partir inyección, ver la pág. 4.00.37 a
injection pump. des pts 78 - 84. partir del punto 78 - 84.

9. Remove injector. 9. Déposer l’injecteur. 9. Desmontar el inyector.

Note: If jammed, use extracting Nota: si les pièces sont bloquées Nota: Si está fijo, utilizar el dispositivo
device No. 150 800 together utiliser d’extraction de extracción
with extractor No. 110 030. No. 150 800 avec l’extracteur No. 150 800 con extractor
No. 110 030. No. 110 030.

See page 4.00.48 from items 114 Monter l’injecteur et la con- Montar el inyector y la tubería de
for fitting injector and injection duite voir page 4.00.48 pt. 114. inyección,
line. ver pág. 4.00.48, a partir del punto
114.

10. Turn back knurled-head setscrew. 10. Dévisser la vis de blocage moletée 10. Girar hacia atrás el tornillo de
Remove press-on device. puis déposer l’outil de montage. cabeza moleteada, de bloqueo.
Desmontar el dispositivo de
presión.

Note: Check whether control rod Nota: vérifier si la crémaillère Nota: Comprobar la facilidad de
moves easily from stop to start coulisse librement de la movimiento de la cremallera
position. For this purpose position stop à la position de entre la posición de parada y la
actuate shutdown lever of démarrage. Pour cela actionner de arranque, lo que se hace
governor. le levier d’arrêt du régulateur. accionando la palanca de
parada del regulador.

11. Press control rod with shutdown 11. A l’aide du levier d’arrêt pousser la 11. Sirviéndose de la palanca de
lever into stop position. Fit crémaillère en position de stop. parada, llevar la cremallera a la
4 shutdown solenoid with new Monter l’électroaimant d’arrêt avec posición de parada.
O- seal. un joint torique neuf. Incorporar el solenoide de parada
con un anillo tórico nuevo.

Note: Lightly oil O-seal. Nota: huiler légèrement le joint Nota: Untar con un poco de aceite el
torique. anillo tórico.

4.00.111
008 924 17 BOMAG 1209
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E

8. Neu ermittelte Ausgleichscheibe auf Rollen-

stößel auflegen.
4
Hinweis: Einspritzpumpen - Einbau, siehe
Seite 4.00.37 ab Pos. 78 - 84. 5

9. Einspritzventil ausbauen.

Hinweis: Bei Festsitz Ausziehvorrichtung

3
Nr. 150 800 mit Auszieher
Nr. 110 030 verwenden. 5
Einspritzventil und Einspritzleitung anbauen,
siehe Seite 4.00.48 ab Pos. 114

10. Rändel-Feststellschraube zurückdrehen.

Andrückvorrichtung abbauen. a
Hinweis: Prüfen ob Regelstange von Stop-
stellung zur Startstellung leichtgän- 3
5
gig ist. Hierzu Abstellhebel des
Reglers betätigen.

11. Regelstange mittels Abstellhebel in Stop-

stellung drücken.
Abstellmagnet mit neuem Runddichtring
4 4
einbauen.
ß
Hinweis: Runddichtring leicht einölen.
5

4.00.111
1210 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

12. Schrauben mit einem Drehmoment von

4 21 Nm festdrehen. Kabelstecker montieren.

13. Zylinderkopfhaube montieren. Schrauben

4 mit einem Drehmoment von 9 ± 1 Nm
festdrehen.

6 Hinweis: Bei Bedarf Dichtung erneuern.

4
14. Runddichtring leicht einölen. Kurbelgehäu-
seentlüftung anbauen. Schrauben mit
einem Drehmoment von 9 ± 1 Nm fest-
z drehen.

6 Hinweis: Bei Bedarf Runddichtring erneuern.

4.00.112
008 924 17 BOMAG 1211
Demontage und Montage, Motor komplett
16.8 Disassembly and reassembly ofDiesel
complete engine
engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

English Français Español

12. Tighten bolts with a torque of 12. Serrer les vis au couple de 21 Nm. 12. Apretar los tornillos de fijación con
21 Nm. Fit cable plug. Monter les fiches de câble. un par de 21 Nm. Montar el
enchufe de cable.

13. Fit cylinder head cover. Tighten 13. Monter le cache-culbuteurs et 13. Montar la tapa de culata. Apretar
bolts with a torque of 9 ± 1 Nm. serrer les vis au couple de los tornillos de fijación con un par
9 ± 1 Nm. de 9 ± 1 Nm.

Note: Renew gasket if necessary. Nota: au besoin renouveller le joint. Nota: De ser necesario, sustituir la
junta por otra nueva.

14. Lightly oil O-seal. Fit crankcase 14. Huiler légèrement le joint torique. 14. Untar con un poco de aceite el
breather. Tighten bolts with a Monter l’évent de carter et serrer anillo tórico. Montar la ventilación
torque of 9 ± 1 Nm. les vis au couple de 9 ± 1 Nm. del cárter.

Note: Renew O-seal if necessary. Nota: au besoin renouveller le joint Nota: De ser necesario, sustituir el
torique. anillo tórico por otro nuevo.

4.00.112
1212 BOMAG 008 924 17
Demontage und Montage, Motor komplett
Disassembly and reassembly of complete engine
Diesel engine 16.8
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor

Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch

008 924 17 BOMAG 1213

16.8 Diesel engine
Werkzeuge

Tools

Outils

Herramientas BFM 1012/1013

1214 BOMAG 008 924 17

Diesel engine 16.8

008 924 17 BOMAG 1215

Handelsübliche Werkzeuge
16.8 Commercial
Diesel enginetools
Outils usuels
Herramientas comerciales

BFM 1012
BFM 1013
Deutsch English Français Español No. Werkstatthandbuch BFM 1012/1013

Druckpumpe für Kühlmitteldichtheitsprüfung 8002 ● ●

Pressure Pump for coolant leakage

Pompe refoulante pour contrôle de l'étanchéité

du liquide de refroidisseur

Bomba de presión para pruebas de

estanqueidad sistema de liquido refrigerante
Verschlußdeckel

Kompressionsdruckprüfer 8005 ● ●

Compression tester

Compressiomètre

Compresímetro

Düsenprüfgerät 8008 ● ●

Nozzle tester

Banc d´essais d´injecteurs

Comprobador para inyectors

Cobraklemmenzange 8011 ● ●

Cobra clamp pliers

Pince à colier Cobra

Alicates Cobra

5.00.01
1216 BOMAG 008 924 17 5
Handelsübliche Werkzeuge
Commercial tools
Diesel engine 16.8
Outils usuels
Herramientas comerciales

BFM 1012
BFM 1013
Werkstatthandbuch BFM 1012/1013 No. Deutsch English Français Español

● ● 8012 Stecknuß SW 15, lange Ausführung für

Einspritzventil (Überwurfmutter)

Socket a/flats 15, long version for injector

(Cap nut)

Douille de 15 modèle long pour injecteur (écrou-

raccord)

Dado de vaso de 15, tipo largo, para inyectores

(tuerca de unión)

● ● 8112 Schraubendrehereinsatz

Screw driver socket

Embout de tournevis

Punta recambiable de destornillador

● ● 8113 Torx-Steckschlüssel-Einsätze,
lange Ausführung

● 8116 Torx sockets long version

● ● 8114 Embouts de clé à douille Torx, modèle long

Llaves de caja Torx, tipo largo

● ● 8115 Keilriemenspannungsmeßgerät

V-belt tension gauge

Appareil de vérification de la tension de la

courroie trapézoïdale

Verificador de tensión para correas

trapezoidales

5.00.02
5 008 924 17 BOMAG 1217
Handelsübliche Werkzeuge
16.8 Commercial
Diesel enginetools
Outils usuels
Herramientas comerciales

BFM 1012
BFM 1013
Deutsch English Français Español No. Werkstatthandbuch BFM 1012/1013

Verdrehschlüssel (Vielzahn) für Einspritzpumpe 8117 ● ●

Serrated wrench for turning injection pump

Clé polygonale pour pompe d´injection

Llave de estrella para giro de bombas de inyección

Torx-Werkzeugsatz 8189 ● ●

Torx tool kit

Jeu d’outils Torx

Juego de herramientas TorxTorx-Werkzeugsatz

Ventilfedermontagehebel 9017 ● ●

Valve spring assembly lever

Levier de montage pour ressort de soupape

Palanca de montaje para muelles de válvula

Federklemmenzange 9088 ● ●

Spring clamp pliers

Pince à crampon élastique

Tenazas para pinzas elásticas.

5.00.03
1218 BOMAG 008 924 17 5
Handelsübliche Werkzeuge
Commercial tools
Diesel engine 16.8
Outils usuels
Herramientas comerciales

BFM 1012
BFM 1013
Werkstatthandbuch BFM 1012/1013 No. Deutsch English Français Español

● ● 9090 Federklemmenzange

Spring clamp pliers

Pince à crampon élastique

Tenazas para pinzas elásticas

● ● 9115 Hilfswerkzeug für Glühkerzen-Kabelkupplung

Auxiliary tool for glow plug cable coupler

Outil auxilaire pour racords de câbles de

bougies de préchauffage

Herramienta auxiliar para acoplamiento de cables

de bujías de incandescencia

5.00.04
5 008 924 17 BOMAG 1219
16.8 Diesel engine

1220 BOMAG 008 924 17

Spezialwerkzeuge
Diesel engine 16.8
Special tools
Outils spéciaux
Herramientas especiales

BFM 1012
BFM 1013
Deutsch English Français Español No. Werkstatthandbuch BFM 1012/1013

Anschlußstück für Kompressionsdruckprüfer 100 110 ● ●

Connector for compression tester

Raccord pour compressiomètre

Pieza de empalme para el compresímetro

Durchdrehvorrichtung 100 320

Turning gear

Dispositif vireur

Dispositivo de viraje

Durchdrehvorrichtung 100 330

Turning gear

Dispositif vireur

Dispositivo de viraje

Meßuhr M2T mit Feststellring 100 400 ● ●

Dial gauge M2T with locking ring

Comparateur M2T avec bague d’immobilisation

Comparador M2T con anillo de fijación

5.00.05
008 924 17 BOMAG 1221 5
Spezialwerkzeuge
16.8
Special tools Diesel engine
Outils spéciaux
Herramientas especiales

BFM 1012
BFM 1013
Werkstatthandbuch BFM 1012/1013 No. Deutsch English Français Español

● ● 100 750 Meßbalken mit Abstandsblättchen zum Messen

des OT und des Kolbenüberstandes

Measuring bar with spacers for gauging TDC

and piston projection

Barre de mesure avec plaquettes d’écartement

pour mesurer le PMH et la cote de dépassement
du piston

Regleta de medición con plaquitas distanciadoras

para la medición del PMS y saliente de pistón

● 100 780 Meßvorrichtung für Grundkreismessung

" Einspritzpumpe und Förderbeginn "

● 100 860 Measuring device for base circle measurement

„injection pump and commencement of
delivery“
● 100 840 Dispositif de mesure du cercle de base „pompe
d’injection et début d’injection“

Dispositivo para la medición del círculo

base „bomba de inyección y comienzo de
alimentación“

● ● 100 800 Meßgerät zum Messen und Blockieren der

Regelstange

Measuring device for measuring and locking

control rod

Appareil de mesure et de blocage de la crémaillère

Dispositivo para la medición y bloqueo de la

barra cremallera

● 100 810 Einstellbolzen für MAG-Wellen.

Adjusting pin for mass balancing shafts

Pige de calage pour arbres à masses d’équilibrage

(MAG)

Pernos de ajuste para ejes compensadores de

masa „MAG“.

5.00.06
5 1222 BOMAG 008 924 17
Spezialwerkzeuge
Diesel engine 16.8
Special tools
Outils spéciaux
Herramientas especiales

BFM 1012
BFM 1013
Deutsch English Français Español No. Werkstatthandbuch BFM 1012/1013

Andrückvorrichtung für Regelstange 100 830 ● ●

Press-on device for control rod

Dispositif de montage de crémaillère

Dispositivo de presión para la cremallera

Gradscheibe 360° mit Befestigung an der 101 020 ● ●

Schwungscheibe für OT und FB Einstellung

Graduated disc 360° with device for fastening

to flywheel for TDC and COD setting

Disque gradué 360° avec fixation sur volant

moteur pour PMH et point de calage du début
d’injection

Disco graduado 360° con los elementos de

fijación al volante para el ajuste del PMS y
comienzo de alimentación (FB)

Adapter für Gradscheibe 101 030 ● ●

Adapter for graduated disc

Adaptateur pour disque gradué

Adaptador para el disco graduado

Auszieher für Einspritzventil in Verbindung mit 110 030 ● ●

150 800

Extractor for injectors, to be used with tool

150 800

Extrcteur pour injecteur, à utiliser avec

150 800

Extractor para inyectores, en combinación

con herramienta 150 800

5.00.07
008 924 17 BOMAG 1223 5
Spezialwerkzeuge
16.8
Special tools Diesel engine
Outils spéciaux
Herramientas especiales

BFM 1012
BFM 1013
Werkstatthandbuch BFM 1012/1013 No. Deutsch English Français Español

● ● 110 110 Halter für Einspritzventil SW11

Dolly for injector a/flats 11

Dispositif d’immobilisation d’injecteur SW 11

Dispositivo de montaje de para inyectores, de 11

● 110 470 Montagewerkzeug für Regelstangen-Buchsen

● 110 480 Assembly tool for control rod sleeves

Outil de montage pour bague de crémaillère

Herramienta de montaje para manguitos de la

barra cremallera

● ● 120 900 Aufspannbock für Zylinderkopf

Swivelling clamping stand for cylinder head

Chevalet d’ablocage pour culasse

Soporte de fijación para culatas

● ● 120 910 Aufspannplatte für 120 900

Clamping plate for 120 900

Plaque d’ablocage pour 120 900

Placa de fijación para 120 900

5.00.08
5 1224 BOMAG 008 924 17
Spezialwerkzeuge
Diesel engine 16.8
Special tools
Outils spéciaux
Herramientas especiales

BFM 1012
BFM 1013
Deutsch English Français Español No. Werkstatthandbuch BFM 1012/1013

Kolbenring-Auflegezange 130 300 ● ●

Piston ring pliers

Pince à monter les segments de piston

Alicates para colocar aros de pistón

Kolbenringspannband 130 630 ●

Piston ring compressor 130 640 ●

Collier à comprimer les segments de piston

Fleje compresor de aros de pistón

Montagewerkzeug für Kolbenbolzenbuchse 131 070 ●

Assembly tool for small end bush 131 090 ●

Outil de montage de bague de pied de bielle

Dispositivo de montaje para casquillos de pie de

biela

Demontagewerkzeug für Kolbenbolzen- 131 080 ●

sicherungsring

Disassembly tool for piston pin circlip

Appareil de démontage de circlip d’axe de piston

Dispositivo de desmontaje para el anillo de

retención de bulones de pistón

5.00.09
008 924 17 BOMAG 1225 5
Spezialwerkzeuge
16.8
Special tools Diesel engine
Outils spéciaux
Herramientas especiales

BFM 1012
BFM 1013
Werkstatthandbuch BFM 1012/1013 No. Deutsch English Français Español

● ● 142 710 Demontagewerkzeug (Haken) für Kurbelwellen-

dichtringe vorn und hinten

Puller (hook) for front and rear crankshaft

seals

Outil de démontage (crochet) de joint d’étanchéité

de vilebrequin AV et AR

Dispositivo de desmontaje (ganchos) para los

retenes delantero y trasero del cigüeñal

● 142 890 Montagewerkzeug für Kurbelwellendichtring

hinten

● 142 910 Assembly tool for rear crankshaft seal

Outil de montage de joint d’étanchéité de

vilebrequin AR

Dispositivo de montaje para el retén trasero del

cigüeñal

● 142 900 Montagewerkzeug für Kurbelwellendichtring

vorn

● 142 920 Assembly tool for front crankshaft seal

Outil de montage de joint d’étanchéité de

vilebrequin AV

Dispositivo de montaje para el retén delantero del

cigüeñal

● 143 780 Montagewerkzeug für MAG-Buchsen

Assembly tool for engine balancer bushes

Outil de montage de douilles d’arbres à masses

d’équilibrage

Herramienta de montaje para casquillos de

compensación de masa „MAG“

5.00.10
5 1226 BOMAG 008 924 17
Spezialwerkzeuge
Diesel engine 16.8
Special tools
Outils spéciaux
Herramientas especiales

BFM 1012
BFM 1013
Deutsch English Français Español No. Werkstatthandbuch BFM 1012/1013

Montagewerkzeug für Nockenwellen-Buchsen 143 790 ●

Assembly tool for camshaft sleeves 143 810 ●

Outil de montage de douilles d’arbre à cames

Herramienta de montaje para casquillos de árbol

de levas

Montagewerkzeug für Zylinderlaufbuchse 150 100 ●

Assembly tool for cylinder liner

Outil de montage pour chemise

Herramienta de montaje para camisas de

cilindro

Montagewerkzeug für Druckregelventil 150 110 ●

Assembly tool for pressure control valve

Outil de montage pour soupape de régulation

de pression

Herramienta de montaje para la válvula

reguladora de presión

Ausziehvorrichtung 150 800 ● ●

Extractor

Extracteur

Dispositivo de extracción

5.00.11
008 924 17 BOMAG 1227 5
Spezialwerkzeuge
16.8
Special tools Diesel engine
Outils spéciaux
Herramientas especiales

BFM 1012
BFM 1013
Werkstatthandbuch BFM 1012/1013 No. Deutsch English Français Español

● ● 170 050 Spezialvorrichtung zum Abschrauben der

Filterpatrone

Special device for screwing off filter cartridge

Dispositif spécial pour dévisser les cartouches

filtrantes

Herramienta especial para desenroscar cartuchos

filtrantes

● ● 170 090 Montagewerkzeug für Kühlmittelthermostat

Assembly tool for coolant thermostat

Outil de montage de thermostat à réfrigérant

Dispositivo de montaje para el termostato de

líquido refrigerante

● ● 170 630 Gegenhalter für Zahnrad Luftpresser

Dolly for air compressor gear

Dispositif de maintien pour pignon de

compresseur d´air

Dispositivo de retención para la rueda dentada

del compressor de aire

● 6066 Motormontagebock für doppelseitige Auf-

spannung

Engine assembly stand for double-sided

chucking

Chevalet de montage moteur avec double

ablocage

Cabellete de montaje para fijación bilateral del

motor

5.00.12
5 1228 BOMAG 008 924 17
Spezialwerkzeuge
Diesel engine 16.8
Special tools
Outils spéciaux
Herramientas especiales

BFM 1012
BFM 1013
Deutsch English Français Español No. Werkstatthandbuch BFM 1012/1013

1 Satz Aufspannwinkel für doppelseitige 6066/158 ●

Aufspannung

1 Set of angled clamping plates for double-

sidet chucking

1 jeu d´équerre de fixation pour double

ablocage

1 juego de angulares para fijación bilateral

Motormontagebock für einseitige Aufspannung 6067 ●

Engine assembly stand for one-sidet chucking

Chevalet de montage moteur pour simple

ablocage

Caballete de montaje para fijación unilateral del

motor

1 Satz Aufspannwinkel für Motor mit externer 6067/118 ●

Kühlung

1 Set of angled clamping plates for engine with

external cooling system.

1 jeu d’équerre de fixation pour moteur à

refroidissement externe

1 juego de angulares de fijación para el motor con

refrigeración externa

1 Satz Aufspannwinkel für Motor mit integrieter 6067/119 ●

Kühlung.

1 Set of angled clamping plates for for engine

with integrated cooling system

1 jeu d’équerre de fixation pour moteur à

refroidissement intégré

1 juego de angulares de fijación para el motor con

refrigeración integrada

5.00.13
008 924 17 BOMAG 1229 5
16.8 Diesel engine

1230 BOMAG 008 924 17

17 Circuit diagrams

008 924 17 BOMAG 1231

1232 BOMAG 008 924 17
17.1 Hydraulic diagram 581 202 06

008 924 17 BOMAG 1233

17.1 Hydraulic diagram 581 202 06

1234 BOMAG 008 924 17

Hydraulic diagram 581 202 06 17.1

008 924 17 BOMAG 1235

17.1 Hydraulic diagram 581 202 06

1236 BOMAG 008 924 17

17.2 Wiring diagram 9

008 924 17 BOMAG 1237

1238
17.2

%RPDJ*PE+

,QGXVWULHJHELHW+HOOHUZDOG
'%RSSDUG

BOMAG
008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW &RYHUVKHHW
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
'HFNEODWW (LQEDXRUW (3(
7DEOHRIFRQWHQWV

008 924 17
,QKDOWVYHU]HLFKQLV
3DJH +LJKHUOHYHOIXQFWLRQ )XQFWLRQ
%ODWW $QODJH )XQNWLRQ 'HVFULSWLRQ %HVFKUHLEXQJ
&RYHUVKHHW 'HFNEODWW
7DEOHRIFRQWHQWV ,QKDOWVYHU]HLFKQLV
Wiring diagram 9

7DEOHRIFRQWHQWV ,QKDOWVYHU]HLFKQLV
6XSSO\6WDUWLQJXQLW 9HUVRUJXQJ6WDUWHQ
3UHKHDWLQJ)XHOSUHKHDWLQJ 9RUJOKHQ.UDIWVWRIIYRUZlUPXQJ
)XVHSURWHFWLRQSRWHQWLDO $EVLFKHUXQJ3RWHQWLDO
)XVHSURWHFWLRQSRWHQWLDO $EVLFKHUXQJ3RWHQWLDO
(QJLQHVSHHG%UDNH%DFNXSDODUP 0RWRUGUHK]DKO%UHPVH5FNIDKUZDUQHLQULFKWXQJ
6HDWFRQWDFW9LEUDWLRQ 6LW]NRQWDNW9LEUDWLRQ
6SHHGUDQJHVHOHFWLRQ:DUQLQJKRUQV )DKUVWXIHQ:DUQK|UQHU
0RQLWRULQJ)DLOXUHLQGLFDWRUV hEHUZDFKXQJ6W|UPHOGXQJHQ
,QGLFDWRUV6SHHGVHQVRU $Q]HLJHQ*HVFKZLQGLJNHLWVDXIQHKPHU
6XSSO\0HDVXUHPHQWFRQWUROOHU 9HUVRUJXQJ0HVVWHFKQLNVWHXHUXQJ
2SWLRQ0HDVXUHPHQWHTXLSPHQW 2SWLRQ0HVVWHFKQLN
2SWLRQ0HDVXUHPHQWHTXLSPHQW 2SWLRQ0HVVWHFKQLN
%20$*&RPSDFWLRQ0DQDJHPHQW%&0*36 %20$*9HUGLFKWXQJVPDQDJHPHQW%&0*36
2SWLRQ6WY=2LOOXPLQDWLRQ 2SWLRQ6WY=2%HOHXFKWXQJ
5RSV/LJKWLQJ6RFNHW 5RSV%HOHXFKWXQJ6WHFNGRVH

BOMAG
&DELQ6XSSO\)XVHSURWHFWLRQ .DELQH9HUVRUJXQJ$EVLFKHUXQJ
&DELQ/LJKWLQJ6RFNHW .DELQH%HOHXFKWXQJ6WHFNGRVH
&DELQ&DELQHTXLSPHQW5DGLR7DFKRJUDSK .DELQH.DELQHQDXVUVWXQJ5DGLR7DFKRJUDSK
&DELQ+HDWLQJ$LUFRQGLWLRQLQJ$GGLWLRQDO+HDWHU .DELQH+HL]XQJ.OLPDDQODJH=XVDW]KHL]XQJ
(OHFWURQLFDO%XUJODU\SURWHFWLRQ (OHNWURQLVFKH'LHEVWDKOVLFKHUXQJ
%RPDJWHOHPDWLFV %RPDJ7HOHPDWLN
'HYLFHWDJOLVW %HWULHEVPLWWHOOLVWH
'HYLFHWDJOLVW %HWULHEVPLWWHOOLVWH
'HYLFHWDJOLVW %HWULHEVPLWWHOOLVWH
'HYLFHWDJOLVW %HWULHEVPLWWHOOLVWH
'HYLFHWDJOLVW %HWULHEVPLWWHOOLVWH
'HYLFHWDJOLVW %HWULHEVPLWWHOOLVWH
7HUPLQDOVWULSRYHUYLHZ; .OHPPOHLVWHQEHUVLFKW;
7HUPLQDOVWULSRYHUYLHZ; .OHPPOHLVWHQEHUVLFKW;
3OXJRYHUYLHZ 6WHFNHUEHUVLFKW
3OXJRYHUYLHZ 6WHFNHUEHUVLFKW
3OXJRYHUYLHZ 6WHFNHUEHUVLFKW
3OXJRYHUYLHZ 6WHFNHUEHUVLFKW
3OXJRYHUYLHZ 6WHFNHUEHUVLFKW
3LQRYHUYLHZ$ 3LQhEHUVLFKW$
3LQRYHUYLHZ$ 3LQhEHUVLFKW$
17.2

1239

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 7DEOHRIFRQWHQWV
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
,QKDOWVYHU]HLFKQLV (LQEDXRUW (3(
1240
17.2
7DEOHRIFRQWHQWV
,QKDOWVYHU]HLFKQLV
3DJH +LJKHUOHYHOIXQFWLRQ )XQFWLRQ
%ODWW $QODJH )XQNWLRQ 'HVFULSWLRQ %HVFKUHLEXQJ
2YHUYLHZ&HQWUDO(OHFWULF hEHUVLFKW=HQWUDOHOHNWULN
2YHUYLHZ&HQWUDO(OHFWULF hEHUVLFKW=HQWUDOHOHNWULN
9LHZ7HUPLQDOVWULS;EHORZ $QVLFKW.OHPPOHLVWH;XQWHQ
9LHZ7HUPLQDOVWULS;DERYH $QVLFKW.OHPPOHLVWH;REHQ
9LHZ7HUPLQDOVWULS;DERYH $QVLFKW.OHPPOHLVWH;REHQ
9LHZ7HUPLQDOVWULS;6W9=2 $QVLFKW.OHPPOHLVWH;6W9=2
9LHZ7HUPLQDOVWULS; $QVLFKW.OHPPOHLVWH;
2YHUYLHZSOXJORFDWLRQ hEHUVLFKW6WHFNHUSRVLWLRQ

BOMAG
008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 7DEOHRIFRQWHQWV
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
,QKDOWVYHU]HLFKQLV (LQEDXRUW (3(
)

) .

008 924 17
)

; $ % )

; $

Wiring diagram 9

) ) ) ) 6

$ $ $ $ D
,JQLWLRQVZLWFK
6WDUWVFKDOWHU

6
; ; %

; ;

)XVHJORZSOXJ
)XVHJORZSOXJ

)XVHKHDWLQJIODQJH
6LFKHUXQJ+HL]IODQVFK
6LFKHUXQJ*OKNHU]H
6LFKHUXQJ*OKNHU]H
.

)XVHPDLQ&HQWUDOHOHFWULF
; D

2QO\DW%:'3'
1XUEHL%:'3'
5HOD\VWDUWLQJFXUUHQW

+DXSWVLFKHUXQJ=HQWUDOHOHNWULN
9 5HODLV6WDUWVWURP

;

5 . ;
ƻ D .D
.
5HOD\FKDUJHFRQWURO
9

5HODLV/DGHNRQWUROOH
5HOD\FKDUJHFRQWURO
5HODLV/DGHNRQWUROOH

* *
9$K 9$K $ <
%DWWHU\ %DWWHU\ $
; ;
%DWWHULH %DWWHULH
%:''

BOMAG
'0(6;
%:'86$
'70
RSWLRQ
2SWLRQ

2QO\DW'86$YHUVLRQDQG%:'RWKHUZLVHRSWLRQZLQWHUSDFNDJH
1XUEHL'86$9HUVLRQXQG%:'VRQVW2SWLRQ:LQWHUSDFNHW
'
; 0

6 % '
2QO\DWDLUFRQGLWLRQLQJ
1XUEHL.OLPDDQODJH

$
'LVFRQQHFWVZLWFKEDWWHU\ * < <
%DWWHULHWUHQQVFKDOWHU
* . . .
9 9 9

% :
%:'3'
%. ;
PPð

%. : ;
PPð
*URXQG&HQWUDO(OHFWULF
0DVVH=HQWUDOHOHNWULN

*URXQG(QJLQH
0DVVH0RWRU

*URXQG)UDPH5HDU
0DVVH+LQWHUUDKPHQ

D D D

*HQHUDWRU 5HOD\EUDNHFRQWURO 5HOD\SRWHQWLDORQ 6ROHQRLGYDOYHVWDUWERRVWIXHO 6WDUWHU

*HQHUDWRU 5HODLV%UHPVNRQWUROOH 5HODLV3RWHQWLDODXI 0DJQHWYHQWLO6WDUWPHKUPHQJH 6WDUWHU
5HOD\DLUFRQGLWLRQHU 6ROHQRLGYDOYHERRVWIXHO
5HODLV.OLPDDQODJH 0DJQHWYHQWLO0LQXVDQJOHLFKXQJ
17.2

1241

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 6XSSO\6WDUWLQJXQLW
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
9HUVRUJXQJ6WDUWHQ (LQEDXRUW (3(
1242
)
17.2

)
)

;

)
$

*ORZFRQWUROXQLW
*OK]HLWVWHXHUJHUlW

$ 7.

. 5
Nƻ +

*ORZFRQWUROXQLW

*OK]HLWVWHXHUJHUlW

5HODLV9RUJOKHQ
5HOD\JORZSOXJV\VWHP
/ 5 +

BOMAG

.

5HOD\JORZSOXJV\VWHP
5HODLV9RUJOKHQ
;
2QO\DW%:'3'
1XUEHL%:'3'
2SWLRQ:LQWHUSDFNDJH
2SWLRQ:LQWHUSDNHW

; ;

5 % . *ORZ . 5 5 5

2QO\DW'86$YHUVLRQDQG%:'RWKHUZLVHRSWLRQZLQWHUSDFNDJH
1XUEHL'86$9HUVLRQXQG%:'VRQVW2SWLRQ:LQWHUSDFNHW
$ 9 9 $ $ :

;

*URXQG(QJLQH
0DVVH0RWRU

*URXQG&HQWUDO(OHFWULF
0DVVH=HQWUDOHOHNWULN

+HDWLQJIODQJH 5HOD\JORZSOXJV\VWHP 5HOD\JORZSOXJV\VWHP ORZSOXJ ORZSOXJ )XHOSUHKHDWHU

+HL]IODQVFK 5HODLV9RUJOKHQ 5HODLV9RUJOKHQ *OKVWLIWNHU]H *OKVWLIWNHU]H .UDIWVWRIIYRUKHL]XQJ
6HQVRUFRRODQWWHPSHUDWXUH
6HQVRU.KOPLWWHOWHPSHUDWXU

008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 3UHKHDWLQJ)XHOSUHKHDWLQJ
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
9RUJOKHQ.UDIWVWRIIYRUZlUPXQJ (LQEDXRUW (3(
1243 BOMAG 008 924 17
(UVWHOOW

*HSUIW
&UHDWHG

&KHFNHG

09RJW

0:HUQHU
$
)
5HODLV$UEHLVVFKHLQZHUIHU
5HOD\ZRUNLQJOLJKWV

.

;
;

)XVHZRUNLQJOLJKWVUHDU

6LFKHUXQJ$UEHLVVFKHLQZHUIHUKLQWHQ

(

$
;

$
)

;
;

)XVHZRUNLQJOLJKWVIURQW

6LFKHUXQJ$UEHLWVVFKHLQZHUIHUYRUQH
(

2QO\DWRSWLRQPHDVXUHPHQWHTXLSPHQW
1XUEHL0HVVWHFKQLN
$
)

6

;
;

)XVHFRQWUROOHU SLQ

6LFKHUXQJ6WHXHUXQJ .RQWDNW

(

%:''

$
)

;
;

)XVHFRQWUROOHU0(6; SRW

6LFKHUXQJ6WHXHUXQJ0(6; 3RWHQWLDO
(

2QO\DWRSWLRQ*36

1XUEHL2SWLRQ*36
$
)
:+

;
;

)XVH*36UHFHLYHU
PPð

6LFKHUXQJ*365HFHLYHU
:+

(

$
PPð

;

;

;

)
$
)

;
;

)XVHLJQLWLRQVZLWFK

6LFKHUXQJ6WDUWVFKDOWHU
(

$EVLFKHUXQJ3RWHQWLDO

2QO\DWRSWLRQHOHFWURQLFDOEXUJODU\SURWHFWLRQ

)XVHSURWHFWLRQSRWHQWLDO
1XUEHL2SWLRQHOHNWURQLVFKH'LHEVWDKOVLFKHUXQJ
$
)

;
;

)XVHEXUJODU\SURWHFWLRQ

6LFKHUXQJ'LHEVWDKOVLFKHUXQJ
(

$
)

;
;

)XVHHQJLQHVSHHG

6LFKHUXQJ0RWRUGUHK]DKO
(

2QO\DW6WY=2LOOXPLQDWLRQ
1XUEHL6WY=2%HOHXFKWXQJ
$
)

;
;

)XVHKHDGOLJKWIURQW

6LFKHUXQJ6FKHLQZHUIHUYRUQH

(

$
$
)

;
;

$QODJH
)XVHKD]DUGOLJKW

)XQFWLRQ
)XQNWLRQ

(LQEDXRUW

6LFKHUXQJ:DUQEOLQNHU

(

0RXQWLQJORFDWLRQ
+LJKHUOHYHOIXQFWLRQ

%ODWW
3DJH

)
)
)
;
)
)

)

)
)
)

YRQ
IURP

(3(
17.2 Wiring diagram 9
1244
.
17.2

.

5HOD\SRWHQWLDORQ
5HODLV3RWHQWLDODXI

; ( ; ( ; ( ; ( ; ( ; ( ; ( ; ( ; ( ; (

) ) ) ) ) ) ) ) ) )
$ $ $ $ $ $ $ $ $ $
; $ ; $ ; $ ; $ ; $ ; $ ; $ ; $ ; $ ; $

)XVHYLEUDWLRQ

)XVHLQGLFDWRUV
)XVHPDLQFDELQ

6LFKHUXQJ%OLQNHU
)XVHVLJQDOKRUQV
6LFKHUXQJ9LEUDWLRQ

)XVHIXHOSUHKHDWLQJ
+DXSWVLFKHUXQJ.DELQH

6LFKHUXQJ6LJQDOK|UQHU

6LFKHUXQJ+XEPDJQHW0RWRU
)XVHVKXWRIIVROHQRLGHQJLQH

3ULPDU\IXVHZRUNKHDGOLJKW
)XVHFRQWUROOHU0(6; SRW

6LFKHUXQJ.UDIWVWRIIYRUKHL]XQJ
9RUVLFKHUXQJ$UEHLWVVFKHLQZHUIHU
2QO\ZLWKRXWVHDWFRQWDFW
1XURKQH6LW]NRQWDNW

)XVHPRQLWRULQJPRGXOHLQGLFDWRUV

BOMAG
)XVHVROHRQLGYDOYHVWUDYHODQGEUDNH
6LFKHUXQJ0DJQHWY)DKUHQX%UHPVH
6LFKHUXQJ6WHXHUXQJ0(6; 3RWHQWLDO

6LFKHUXQJhEHUZDFKXQJVPRGXO$Q]HLJHQ
) )

2QO\DW6WY=2LOOXPLQDWLRQ
1XUEHL6WY=2%HOHXFKWXQJ
)

)

008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW )XVHSURWHFWLRQSRWHQWLDO
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
$EVLFKHUXQJ3RWHQWLDO (LQEDXRUW (3(
)

)

008 924 17
6 ;

; )

; ;
Wiring diagram 9

%1 %8 %8 %1
% %

. . 3UR[LPLW\VZLWFKWUDYHOOHYHUSRVLWLRQ 3UR[LPLW\VZLWFKWUDYHOOHYHUIRUZDQGSRVLWLRQ
D D ,QLWLDWRU)DKUKHEHO ,QLWLDWRU)DKUKHEHOYRUZlUWVX
5HOD\KROGLQJFRQWDFW 5HOD\HQJLQHUSP 2SHQHGLQEUHDNSRVLWLRQ %. &ORVHGLQIRUZDUGDQGSRVLWLRQ %.
5HODLV6HOEVWKDOWXQJ 5HODLV0RWRUGUHK]DKO JH|IIQHWLQ%UHPVSRVLWLRQ JHVFKORVVHQLQYRUZlUWVXQGSRVLWLRQ

; . ;
D
5HOD\WUDYHOOHYHUSRVLWLRQ
;
)ZG 5HODLV)DKUKHEHO6WHOOXQJ

;
6 . . .
6ZLWFKHQJLQHVSHHG 9 D D

6FKDOWHU0RWRUGUHK]DKO 5HOD\KROGLQJFRQWDFW 5HOD\EUDNHFRQWURO 5HOD\EDFNXSDODUP
5HODLV6HOEVWKDOWXQJ 5HODLV%UHPVNRQWUROOH 5HODLV
5FNIDKUZDUQVXPPHU

5HY .D

BOMAG
;

6
6ZLWFKHPHUJHQF\RII
6FKDOWHU127$86
;

$ %UDNH0(6;

; ;
$:+:
$8;
. < 9 . . < . +
$
9 $$ 9 9 9 P$

;

*URXQG&HQWUDO(OHFWULF
0DVVH=HQWUDOHOHNWULN

D D D D D

5HOD\HQJLQHUSP 6ROHQRLGYDOYHUSPHQJLQHKLJK 5HOD\WUDYHOOHYHUSRVLWLRQ 6ROHQRLGYDOYHEUDNH 5HOD\EDFNXSDODUP %DFNXSDODUP%X]]HU

5HODLV0RWRUGUHK]DKO 0DJQHWYHQWLO0RWRUGUHK]DKOKRFK 5HODLV)DKUKHEHO6WHOOXQJ 0DJQHWYHQWLO%UHPVH 5HODLV5FNIDKUZDUQVXPPHU 5FNIDKUZDUQVXPPHU
5HOD\VWDUWLQJFXUUHQW
5HODLV6WDUWVWURP
17.2

1245

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW (QJLQHVSHHG%UDNH%DFNXSDODUP
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
0RWRUGUHK]DKO%UHPVH5FNIDKUZDUQHLQULFKWXQJ (LQEDXRUW (3(
1246
)
17.2

$ $

)
$
0RGXOHVHDWFRQWDFW
0RGXO6LW]NRQWDNW

)DKUHQ
'ULYLQJ
'$OWHUQDWRU
'*HQHUDWRU
0RWRU|OGUXFN
2QO\ZLWKRXWVHDWFRQWDFW
1XURKQH6LW]NRQWDNW

(QJLQHRLOSUHVVXUH

1RWDW%:'3'
1LFKWEHL%:'3'
.
0RGXOHYLEUDWLRQ
0RGXO9LEUDWLRQ
6 E

RKQH6LW]NRQWDNW
ZLWKRXWVHDWFRQWDFW
ZLWKRXWVHDWFRQWDFW
2QO\DW%:'3'
RKQH6LW]NRQWDNW
1XUEHL%:'3'

ZLWKRXWVHDWFRQWDFW
RKQH6LW]NRQWDNW

2QO\DW%:'3'
1XUEHL%:'3'
; 9

6 . .D $
6ZLWFKHPHUJHQF\RII D
6FKDOWHU127$86
;

5HOD\HQJLQHVKXWRII

BOMAG
5HODLV0RWRUDEVFKDOWXQJ
ORZ

KLJK

;
6
6ZLWFKYLEUDWLRQORZKLJK
9LEUDWLRQVVFKDOWHUNOHLQJUR
; ;
. *$7$&
D
.$7$&

2QO\DW%:'3'
1XUEHL%:'3'
.$0(6;
%

5HOD\VKXWRIIVROHQRLGHQJLQH
; ; ; ;

5HODLV+XEPDJQHW$EVFKDOWXQJ0RWRU
*$0(6;
6 %8 6 ; ;

< . 6: < <
$
9 $ $ $ %

; $ ; ; %%:' ; $%:'
%:' %:'
%:' %:'
E' D'

2QO\DW%:'3'ZLWKVHDWFRQWDFW
1XUEHL%:'3'PLW6LW]NRQWDNW
;

*URXQG&HQWUDO(OHFWULF
0DVVH=HQWUDOHOHNWULN

6KXWRIIVROHQRLGHQJLQH 5HOD\HQJLQHVKXWRII 6ZLWFKVHDWFRQWDFW 6ROHQRLGYDOYHYLEUDWLRQIURQWORZ

+XEPDJQHW0RWRUDEVFKDOWXQJ 5HODLV0RWRUDEVFKDOWXQJ 6FKDOWHU6LW]NRQWDNW 0DJQHWYHQWLO9LEUDWLRQYRUQHNOHLQ
6ZLWFKYLEUDWLRQWUDYHOOHYHUULJKW 6ROHQRLGYDOYHYLEUDWLRQIURQWKLJK
6FKDOWHU9LEUDWLRQ)DKUKHEHOUHFKWV 0DJQHWYHQWLO9LEUDWLRQYRUQHJURVV

008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 6HDWFRQWDFW9LEUDWLRQ
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
6LW]NRQWDNW9LEUDWLRQ (LQEDXRUW (3(
)

)

008 924 17
RQO\'%:'3' 6WDQGDUG'PDFKLQHV'3'86$'3'
QXU'%:'3' 6WDQGDUG'0DVFKLQHQ'3'86$'3' ;
Wiring diagram 9

6 6 6
6ZLWFKVSHHGUDQJHVHOHFWRU 6ZLWFKVSHHGUDQJHVHOHFWRU 3XVKEXWWRQZDUQLQJKRUQ
6FKDOWHU)DKUVWXIHQ 6FKDOWHU)DKUVWXIHQ 7DVWHU6LJQDOKRUQ

; ;

9 9

BOMAG
;

< < < < 9 % % 9
$
$ $ $ $ $

;

RQO\%:'3'
QXU%:'3'
QRWDW%:'3'
QLFKWEHL%:'3'
*URXQG&HQWUDO(OHFWULF
0DVVH=HQWUDOHOHNWULN

6ROHQRLGYDOYHVSHHGUDQJHVHOHFWLRQD[OH 6ROHQRLGYDOYHVSHHGUDQJHVHOHFWLRQGUXP 6ROHQRLGYDOYHVSHHGUDQJHVHOHFWLRQD[OH :DUQLQJKRUQ :DUQLQJKRUQ

0DJQHWYHQWLO)DKUVWXIH$FKVH 0DJQHWYHQWLO)DKUVWXIH%DQGDJH 0DJQHWYHQWLO)DKUVWXIH$FKVH 6LJQDOKRUQ 6LJQDOKRUQ
6ROHQRLGYDOYHVSHHGUDQJHVHOHFWLRQGUXP
0DJQHWYHQWLO)DKUVWXIH%DQGDJH
17.2

1247

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 6SHHGUDQJHVHOHFWLRQ:DUQLQJKRUQV
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
)DKUVWXIHQ:DUQK|UQHU (LQEDXRUW (3(
1248
) ) $
0RQLWRULQJPRGXOH
17.2

hEHUZDFKXQJVPRGXO
; $UPDWXUHFDUULHU
$UPDWXUHQWUlJHU
; ; +D]DUGOLJKW
:DUQEOLQNOLFKW +$=

8E ;
8E ; ,QGLFDWRUULJKW
;
%OLQNHUUHFKWV
,1'5

; *ORZLQJ ;
*ORZ
*OKHQ ; ,QGLFDWRUOHIW ;
%OLQNHUOLQNV
,1'/

; &KDUJHFRQWURO ;
'
/DGHNRQWUROOH ; 1LJKWGLPRXW
1DFKWDEGXQNOXQJ ,//

; %UDNH ;
.D
%UHPVH ; :DWHUWUDS
6KXWRIIPLQ :DVVHUDEVFKHLGHU
; 6HDW ;
$
6LW] ; :DWHUWUDS
6KXWRIIPLQ :DVVHUDEVFKHLGHU

6KXWRIIPLQ 6KXWRIIPLQ 6KXWRIIVHF 6KXWRIIVHF

;

*1'
*1'
/XIWILOWHU
$LUFOHDQHU

)XHOJDXJH

7DQNDQ]HLJH
&RRODQWOHYHO

0RWRU|OGUXFN

+\GURLOILOWHU

2XW0RWRUVWRS
2XW0RWRU6WRS
+\GUDXOLN|OILOWHU
9

2XW:DUQVXPPHU

.KOPLWWHOIOOVWDQG

(QJLQHRLOSUHVVXUH

2XWZDUQLQJEX]]HU

BOMAG
&RRODQWWHPSHUDWXUH
.KOPLWWHOWHPSHUDWXU
;
$

%
;

; ; ;

Ĭ
+ . 5 % 3 % 3 % % 3 % %
P$ 9 ƻ

; ;

;

*URXQG(QJLQH
0DVVH0RWRU

RQO\DW''86$RSWLRQDW'
QXUEHL''86$2SWLRQEHL'

*URXQG&HQWUDO(OHFWULF
0DVVH=HQWUDOHOHNWULN
QRWDW'DQG%:'3'
QLFKWEHL'XQG%:'3'

QRWDW'
D QLFKWEHL'

:DUQLQJEX]]HUEUHDNGRZQ 6HQGHUOHYHOJDXJH 9DFXXPVZLWFKDLUFOHDQHU 3UHVVXUHVZLWFKHQJLQHRLO :DWHUWUDS

:DUQVXPPHU%HWULHEVVW|UXQJ *HEHU7DQNDQ]HLJH /XIWILOWHUZDUWXQJVVFKDOWHU 'UXFNVFKDOWHU0RWRU|O :DVVHUDEVFKHLGHU
5HOD\VKXWRIIVROHQRLGHQJLQH 3UHVVXUHGLIIVZLWFKK\GURLOILOWHU 7HPSHUDWXUHVZLWFKHQJLQHRLO )ORDWLQJVZLWFK&RRODQWH[SDQVLRQWDQN
5HODLV+XEPDJQHW$EVFKDOWXQJ0RWRU 'LIIHUHQ]GUXFNVFKDOWHU+\GUgOILOWHU 7HPSHUDWXUVFKDOWHU0RWRU|O 6FKZLPPHUVFKDOWHU.KOPLWWHODXVJOHLFKVEHKlOWHU

008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 0RQLWRULQJ)DLOXUHLQGLFDWRUV
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
hEHUZDFKXQJ6W|UPHOGXQJHQ (LQEDXRUW (3(
)

;

008 924 17
;
%1

;
Wiring diagram 9

: %

;

%1
* *

DW%:DQG%:%1
DW%:3,1&
*1<( 3 3

DW%:DQG%::+
QRWDW%:
; ',50(6;
GLU GLU :+ ;
3 Q 3 9 3 3 % +] %
VSHHG VSHHG %8 ;

63(('0(6;
6SHHGRPHWHU

* %.
;

)UHTXHQ]DQ]HLJH
)UHTXHQF\PHWHU
( (;; (;; (;;

6HQVRUD[OHVSHHG
(;; 6SHHG7$& (
*HVFKZLQGLJNHLWVDQ]HLJH

%.
;

$XIQHKPHU9LEUDWLRQVIUHTYRUQH
$XIQHKPHU$FKVJHVFKZLQGLJNHLW

9ROWPHWHU
9ROWPHWHU

530PHWHU

7UDQVGXFHUYLEUDWLRQIUHTXHQF\IURQW
;

DW%:3,1$

'UHK]DKOPHVVHU
DW%:DQG%:%8

DW%:DQG%:%.
DW%:3,1%
$ $

7HPSHUDWXUHJDXJHFRRODQW
;

$Q]HLJH.KOPLWWHOWHPSHUDWXU
,1 287 287 ,1 287 287

7HPSHUDWXUDQ]HLJH+\GUDXOLN|O
7HPSHUDWXUHJDXJHK\GUDXOLFRLO
%8

BOMAG
;
(OHFWURQLFVSHHGRPHWHU

;

(OHFWURQLFIUHTXHQF\PHWHUIURQW
(OHNWURQLN)UHTXHQ]DQ]HLJHYRUQH
(OHNWURQLN*HVFKZLQGLJNHLWVDQ]HLJH

*1' *1'

Ĭ
5

%:'
%:'+&'+

6HQVRU+\GUDXOLN|OWHPSHUDWXU
6HQVRUK\GUDXOLFRLOWHPSHUDWXUH
%:' 3,1*1'
%:'+&'+ 3,1*1'
%:'+& 3,1
;
%:' 3,1

*URXQG&HQWUDO(OHFWULF
0DVVH=HQWUDOHOHNWULN

RQO\DWRSWLRQ
PHDVXUHPHQWHTXLSPHQW
2SWLRQ 2SWLRQIUHTXHQF\PHWHU VSHHGRPHWHUDQGWDFKRJUDSK 2SWLRQVSHHGRPHWHU
2SWLRQ 2SWLRQ)UHTXHQ]DQ]HLJH 1XUEHL2SWLRQ0HVVWHFKQLN 2SWLRQ*HVFKZLQGLJNHLWVDQ]HLJH
*HVFKZLQGLJNHLWVDQ]HLJH7DFKRJUDSK
17.2

1249

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW ,QGLFDWRUV6SHHGVHQVRU
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
$Q]HLJHQ*HVFKZLQGLJNHLWVDXIQHKPHU (LQEDXRUW (3(
1250
)
17.2

) $

URXQGKRXVLQJ URXQG(OHFWURQLF URXQG%DE\%RDUG URXQG%DE\%RDUG URXQG%DE\%RDUG URXQG%DE\%RDUG

0DVVH*HKlXVH 0DVVH(OHNWURQLN 0DVVH%DE\%RDUG 0DVVH%DE\%RDUG 0DVVH%DE\%RDUG 0DVVH%DE\%RDUG
(6; (6; (6; (6; (6; (6;
0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU

$ $ $ $ $ $

*URXQG+RXVLQJ *1' ;*1' ;*1' ;*1' ;*1'
ER[ ; ; ; ; ;

;

BOMAG
; ; ; ; ; ; ;
8( ' 8% 8% 8% 8% 8%
$ $ $ $ $ $ $

0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU

(6; (6; (6; (6; (6; (6; (6;
,JQLWLRQ 3RZHU6XSSO\ (OHFWURQLF 3RZHU6XSSO\ 2XWSXWV 3RZHU6XSSO\ 2XWSXWV 3RZHU6XSSO\ 2XWSXWV 3RZHU6XSSO\ 2XWSXWV 3RZHU6XSSO\ 2XWSXWV
=QGXQJ 6SDQQXQJVYHUV (OHNWURQLN 6SDQQXQJVYHUV $XVJlQJH 6SDQQXQJVYHUV $XVJlQJH 6SDQQXQJVYHUV $XVJlQJH 6SDQQXQJVYHUV $XVJlQJH 6SDQQXQJVYHUV $XVJlQJH

$
0HDVXUHPHQWFRQWUROOHU
0HVVWHFKQLN6WHXHUXQJ

;

*URXQG&HQWUDO(OHFWULF
0DVVH=HQWUDOHOHNWULN

008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 6XSSO\0HDVXUHPHQWFRQWUROOHU
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
9HUVRUJXQJ0HVVWHFKQLNVWHXHUXQJ (LQEDXRUW (3(
) )

008 924 17
; ;

;
;
Wiring diagram 9

; & ' ( ; % $ (

; ;
;
3 3
%. *1<( %. *1<( 3 *1' *< *5 5' 57 :+ :6

2SXV
2SXV

% %

3ULQWHU
J J

'UXFNHU
J J

7UDQVGXFHUDFFHOHUDWLRQ
%1 %8

7UDQVGXFHUDFFHOHUDWLRQ
%1 %8
'LDJQRVH9DULRPDWLF

%HVFKOHXQLJXQJVDXIQHKPHU
%HVFKOHXQLJXQJVDXIQHKPHU
'LDJQRVWLFVYDULRPDWLF
; ;

&$1 &$1 3. 56 %8 %/
2QO\DW%70SURI 2QO\DW%(0 2QO\DW%70SURI
1XUEHL%70SURI 1XUEHL%(0 1XUEHL%70SURI
;

; ' )

$ %

BOMAG
; ;

5
;

ƻ
; ; ; ; ; ; ; ; ;

; ; ; ; ; ; ; ; ;

$, $, $, $, $*1' 5[' 7[' :LUH :LUH
$ $ $ $ $ $ $ $ $

0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU

(6; (6; (6; (6; (6; (6; (6; (6; (6;
7UDQVGXFHU$FFHOHUDWLRQIURQWJ 7UDQVGXFHU$FFHOHUDWLRQIURQWJ 7UDQVGXFHU$FFHOHUDWLRQUHDUJ 7UDQVGXFHU$FFHOHUDWLRQUHDUJ $*1' 5[' 7[' &$1 &$1
%HVFKOHXQLJXQJVDXIQYRUQHJ %HVFKOHXQLJXQJVDXIQYRUQHJ %HVFKOHXQLJXQJVDXIQKLQWHQJ %HVFKOHXQLJXQJVDXIQKLQWHQJ $QDORJPDVVH 5[' 7[' &$1 &$1

*URXQG&HQWUDO(OHFWULF
0DVVH=HQWUDOHOHNWULN
17.2

1251

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 2SWLRQ0HDVXUHPHQWHTXLSPHQW
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
2SWLRQ0HVVWHFKQLN (LQEDXRUW (3(
1252
.$0(6; ,//0(6;
17.2

*$0(6; ,//0(6;679=2

63(('0(6;

',50(6;

%UDNH0(6;

'0(6;

; ; ; ; ; ; ;

', ' ', ' ', ' ', ' ', ' ', ' ', '
$ $ $ $ $ $ $

0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU

(6; (6; (6; (6; (6; (6; (6;
'$OWHUQDWRU %UDNH 'ULYLQJGLUHFWLRQ 'ULYLQJVSHHG 9LEUDWLRQKLJKDPSOLWXGH 9LEUDWLRQORZDPSOLWXGH ,OOXPLQDWLRQ
'*HQHUDWRU %UHPVH )DKUWULFKWXQJ )DKUJHVFKZLQGLJNHLW 9LEUDWLRQJURH$PSOLWXGH 9LEUDWLRQNOHLQH$PSOLWXGH %HOHXFKWXQJ

(YLE0HWHU
(YLE0HWHU
(6;
0HDVXUHPHQWFRQWUROOHU

BOMAG
'2 $
;

;

3
9
(YLE0HWHU
(YLE0HWHU

2QO\DW%(0
1XUEHL%(0
(

;

*URXQG&HQWUDO(OHFWULF
0DVVH=HQWUDOHOHNWULN

008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 2SWLRQ0HDVXUHPHQWHTXLSPHQW
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
2SWLRQ0HVVWHFKQLN (LQEDXRUW (3(
) 3RZHUVXSSO\*36
6SDQQXQJVYHUVRUJXQJ*36
(6;
)
0HDVXUHPHQWFRQWUROOHU

008 924 17
$
'2 $
&$1 &$1
&$1 &$1 ;
(6; (6;
;
0HDVXUHPHQWFRQWUROOHU 0HDVXUHPHQWFRQWUROOHU

;
Wiring diagram 9

$ $
:LUH :LUH
; ;
; ;

; ; ; * ; + ; -
5

; ƻ ; $ ; %

; 1 0
; $ ; %

;
$
$ *365HFHLYHU6WDU)LUH
86%&$1,QWHUIDFH%&0 *36(PSIlQJHU6WDU)LUH
86%&$16FKQLWWVWHOOH%&0 ;

;
;

;
;

86%
;

BOMAG
86% ;

;

86%
3
%&0 86% ;
9FF
%&0

; ' ( &

;
5['

;
7['

; &
;
$*1'

; )
;
*1' ;

*URXQG&HQWUDO(OHFWULF
0DVVH=HQWUDOHOHNWULN
17.2

1253

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW %20$*&RPSDFWLRQ0DQDJHPHQW%&0*36
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
%20$*9HUGLFKWXQJVPDQDJHPHQW%&0*36 (LQEDXRUW (3(
1254
)
17.2

)

; ;

;

/ 5
6 6
6ZLWFKKD]DUGOLJKW 6ZLWFKLQGLFDWRU
6 &RQQHFWLRQZRUNLQJKHDGOLJKWV :DUQEOLQNVFKDOWHU 6FKDOWHU%OLQNHU
ZLWKRXW6WY=2
6ZLWFKOLJKWLQJ6W9=2 $QVFKOX$UEHLWVVFKHLQZHUIHU
6FKDOWHU%HOHXFKWXQJ6W9=2 RKQH6WY=2 +$=
;
.
; D
5HOD\KHDGOLJKWVIURQW ; :E /( 5(
5HODLV6FKHLQZHUIHUYRUQH
+
; $
)ODVKHU
,//
%OLQNJHEHU
/$ 5$

6ZLWFKZRUNLQJOLJKWV ; ( ; (

6FKDOWHU$UEHLWVEHOHXFKWXQJ

( ( ( (;; 6 ) )
$ $ ,1'5
)XVHSDUNLQJDQG )XVHSDUNLQJDQG
9 9 9
; $ ; $
0HOGHOHXFKWH:DUQEOLQNHU

WDLOOLJKWOK WDLOOLJKWUK

,QGLFDWRUOLJKWKD]DUGOLJKW

6LFKHUXQJ3DUN 6LFKHUXQJ3DUN ,1'/

9 X6FKOXVVOOLQNV X6FKOXVVOUHFKWV

BOMAG
&RQQHFWLRQLOOXPLQDWLRQ
,//0(6;679=2
LQVWUXPHQWVZLWKRXW6WY=2
$QVFKOX%HOHXFKWXQJ
,QVWUXPHQWHRKQH6WY=2

%HOHXFKWXQJ(YLEPHWHU
,OOXPLQDWLRQHYLEPHWHU

,OOXPLQDWLRQ530PHWHU
;

,OOXPLQDWLRQVSHHGRPHWHU

%HOHXFKWXQJ'UHK]DKOPHVVHU
,//0(6;

%HOHXFKWXQJ=XVDW]LQVWUXPHQW
&RQQHFWLRQ,OOXPLQDWLRQ
0(6;ZLWKRXW6WY=2

,OOXPLQDWLRQDGGLWLRQDOLQVWUXPHQW
; ; ; ; ; ; ; ; ; ;
$QVFKOX%HOHXFKWXQJ

%HOHXFKWXQJ*HVFKZLQGLJNHLWVDQ]HLJH
0(6;RKQH6WY=2

. ( ( ( ( . ( ( ( ( ( (
9 : : : : 9 : : : : : :

; ; ; ; ; ;

;

*URXQG&HQWUDO(OHFWULF
0DVVH=HQWUDOHOHNWULN

D D

5HOD\ZRUNLQJOLJKWV 5HOD\KHDGOLJKWVIURQW
5HODLV$UEHLVVFKHLQZHUIHU 5HODLV6FKHLQZHUIHUYRUQH
7DLOOLJKWOK 3DUNLQJOLJKWUK +HDGOLJKWOK ,QGLFDWRUIURQWOHIW ,QGLFDWRUIURQWULJKW
6FKOXVVOHXFKWHOLQNV 3DUNOHXFKWHUHFKWV 6FKHLQZHUIHUOLQNV %OLQNOHXFKWHYRUQHOLQNV %OLQNOHXFKWHYRUQHUHFKWV
3DUNLQJOLJKWOK 7DLOOLJKWUK +HDGOLJKWUK ,QGLFDWRUUHDUOHIW ,QGLFDWRUUHDUULJKW

008 924 17
Wiring diagram 9

3DUNOHXFKWHOLQNV 6FKOXVVOHXFKWHUHFKWV 6FKHLQZHUIHUUHFKWV %OLQNOHXFKWHKLQWHQOLQNV %OLQNOHXFKWHKLQWHQUHFKWV

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 2SWLRQ6WY=2LOOXPLQDWLRQ
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
2SWLRQ6WY=2%HOHXFKWXQJ (LQEDXRUW (3(
) )

)

008 924 17
)
Wiring diagram 9

;

$FFHVVLRQDW&DELQ
$QVFKOXEHL.DELQH

:OUHDU&DE

:OIURQW&DE

BOMAG
:RUNLQJKHDGOLJKWUHDUOK
$UEHLWVVFKHLQZHUIHUKLQWHQOLQNV
:RUNLQJKHDGOLJKWUHDUUK
$UEHLWVVFKHLQZHUIHUKLQWHQUHFKWV
:RUNLQJKHDGOLJKWIURQWOK
$UEHLWVVFKHLQZHUIHUYRUQHOLQNV
:RUNLQJKHDGOLJKWIURQWUK
$UEHLWVVFKHLQZHUIHUYRUQHUHFKWV
5RSV6RFNHW
5RSVVWHFNGRVH

( ( ( (
: : : : ;6
9

$FFHVVLRQDW5RSV
$QVFKOXEHL5RSV
;

*URXQG&HQWUDO(OHFWULF
0DVVH=HQWUDOHOHNWULN
17.2

1255

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 5RSV/LJKWLQJ6RFNHW
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
5RSV%HOHXFKWXQJ6WHFNGRVH (LQEDXRUW (3(
1256
;
17.2

5' 5' 5'

PPð PPð PPð

;

5' 5' 5'

PPð PPð PPð

5'
PPð

.

5HOD\FDELQ
:+
5HODLV.DELQH PPð

:+
PPð
)%

$ & ( *

) ) ) )

$ $ $ $
)XVHURWDU\
)XVHZLSHUPRWRUUHDU )XVHQLJKWODPS )XVHUHDUVFUHHQKHDWLQJXQLW
6LFKHUXQJ:LVFKHUPRWRUKLQWHQ 6LFKHUXQJ1DFKWOHXFKWH EHDFRQ 6LFKHUXQJ+HFNVFKHLEHQKHL]XQJ
6LFKHUXQJ
5XQGXPNHQQOHXFKWH

BOMAG
) ) ) ) )

2SWLRQ

.
%1 %1 9
PPð PPð % ' ) +

) ) ) )

$ $ $ $
)XVHZLSHUPRWRUIURQW )XVHFDELQYHQWLODWRU )XVHFDELQVRFNHW )XVHLQVLGHOLJKWFDE
6LFKHUXQJ:LVFKHUPRWRUYRUQ 6LFKHUXQJ.DELQHQOIWHU 6LFKHUXQJ.DELQHQVWHFNGRVH 6LFKHUXQJ.DELQHQLQQHQOHXFKWH
;

*URXQG&HQWUDO(OHFWULF *URXQG&DELQ ) ) ) ) )+
0DVVH=HQWUDOHOHNWULN 0DVVH.DELQH

5HOD\FDELQ 2SWLRQ
5HODLV.DELQH

008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW &DELQ6XSSO\)XVHSURWHFWLRQ
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
.DELQH9HUVRUJXQJ$EVLFKHUXQJ (LQEDXRUW (3(
) )

) )

008 924 17
)

)

:OIURQW&DE

:OUHDU&DE
Wiring diagram 9

6 ( ( (
6ZLWFK5RWDU\EHDFRQ : : 9
6FKDOWHU5XQGXPNHQQOHXFKWH ,QVLGHOLJKWFDELQ 1LJKWODPS
,QQHQOHXFKWH.DELQH 1DFKWOHXFKWH

LOOXP6ZLWFKHV
%HOHXFKWXQJ%HGLHQVFKDOWHU

BOMAG

6 6
7.

:RUNLQJKHDGOLJKWUHDUOK
$UEHLWVVFKHLQZHUIHUKLQWHQOLQNV
:RUNLQJKHDGOLJKWUHDUUK
$UEHLWVVFKHLQZHUIHUKLQWHQUHFKWV
:RUNLQJKHDGOLJKWIURQWOK
$UEHLWVVFKHLQZHUIHUYRUQHOLQNV
:RUNLQJKHDGOLJKWIURQWUK
$UEHLWVVFKHLQZHUIHUYRUQHUHFKWV

( ( ( ( (
: : : : $ ;6
9

2SWLRQ

*URXQG&DELQ
0DVVH.DELQH

*URXQG&DELQ

5RWDU\EHDFRQ &DELQVRFNHW 6ZLWFKFDELQLQVLGHOLJKW 6ZLWFKFDELQQLJKWODPS

5XQGXPNHQQOHXFKWH .DELQHQVWHFNGRVH 6FKDOWHU.DELQHQLQQHQOHXFKWH 6FKDOWHU1DFKWEHOHXFKWXQJ
17.2

1257

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW &DELQ/LJKWLQJ6RFNHW
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
.DELQH%HOHXFKWXQJ6WHFNGRVH (LQEDXRUW (3(
1258
)
17.2

6SHHG7$&

)

) ;

)

(OHFWURQLFV\VWHP $
WDFKRJUDSK
(OHNWURQLN
3
7DFKRJUDSK $$

$ %

%
6
% %
6ZLWFKUHDU
6 6 &
VFUHHQKHDWLQJ $ ZKLWH
XQLW
% \HOORZ
6FKDOWHU $$
& UHG

6ZLWFKZLQGVFUHHQZLSHUUHDU

6ZLWFKZLQGVFUHHQZLSHUIURQW
6FKDOWHU6FKHLEHQZLVFKHUYRUQH
$

6FKDOWHU6FKHLEHQZLVFKHUKLQWHQ
+HFNVFKHLEHQKHL]XQJ
5DGLR
5DGLR 7DFKRJUDSK
7DFKRJUDSK

BOMAG
. 2QO\DWRSWLRQ5DGLR
1XUEHL2SWLRQ5DGLR
D
$
&LUFXLWERDUGIUHTXHQ]\PHWHU

5HOD\KHDWLQJUHDUVFUHHQ
3ODWLQH)UHTXHQ]DQ]HLJH

5HODLV+HFNVFKHLEHQKHL]XQJ
E E
>EOXZKW@ >EOX@ >EOXZKW@ >EOX@
; ; ;
.$7$&

D E D E
D D ;
*$7$&
>EON@ >EONEOX@ >EON@ >EONEOX@
0 0 ,
$ $
5 ( .
9 9

0 0
$ $

,QGLFDWRUOLJKWVZLWFKUHDUVFUHHQKHDWHU
.RQWUROOHXFKWH6FKDOWHU+HFNVFKHLEHQKHL]XQJ

2QO\DWRSWLRQ7DFKRJUDSK
1XUEHL2SWLRQ7DFKRJUDSK
; ;

*URXQG&DELQ
0DVVH.DELQH

:LQGVFUHHQZLSHUPRWRUUHDU :LQGVFUHHQZLSHUPRWRUIURQW +HDWHUUHDUVFUHHQ 5HOD\KHDWLQJUHDUVFUHHQ

6FKHLEHQZLVFKHUPRWRUKLQWHQ 6FKHLEHQZLVFKHUPRWRUYRUQH +HFNVFKHLEHQKHL]XQJ 5HODLV+HFNVFKHLEHQKHL]XQJ
:LQGVFUHHQZDVKHUPRWRUUHDU :LQGVFUHHQZDVKHUPRWRUIURQW
6FKHLEHQZDVFKHUPRWRUKLQWHQ 6FKHLEHQZDVFKHUPRWRUYRUQH

008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW &DELQ&DELQHTXLSPHQW5DGLR7DFKRJUDSK
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
.DELQH.DELQHQDXVUVWXQJ5DGLR7DFKRJUDSK (LQEDXRUW (3(
)%

) )

008 924 17
) )+

;

$ %
;
) ) )
Wiring diagram 9

$ $ $
$ ,QOLQH)XVH )XVHKHDWLQJXQLWFDE )XVHKHDWLQJXQLW
;
+HDWLQJFOLPDWLFXQLW ,QOLQHVLFKHUXQJ 6LFKHUXQJ.DELQHQKHL]XQJ 6LFKHUXQJ+HL]JHUlW
+HL].OLPD(LQKHLW )XVHEORZHUIUHVKDLU %2; %2;
6XSSO\
6LFKHUXQJ)ULVFKOXIWOIWHU %2; %2;
5'

6ZLWFKFDELQKHDWLQJ
6FKDOWHU.DELQHQKHL]XQJ

%.*1 %. 6
2XW *QG
(
; +HDWLQJXQLW
+HL]JHUlW
PD[$

;

;

.
D
5HOD\DLUFRQGLWLRQHU
5HODLV.OLPDDQODJH

BOMAG
6
; 6ZLWFKVXVSHQVLRQVHDW
6FKDOWHU/XIWIHGHUVLW]
;

VZ EU
% 3
/3 +3 03
VZJH EUVZ

; ; ;

'UXFNVFKDOWHU.OLPDDQODJH
0
0
9$ UW

3UHVVXUHVZLWFKDLUFRQGLWLRQLQJ

'HOLYHU\HTXLSPHQW*5$00(5
/LHIHUXPIDQJ*5$00(5

9 < 0 <
$ P$
; VZ

; ; ;

*URXQG&HQWUDO(OHFWULF *URXQG&DELQ
0DVVH=HQWUDOHOHNWULN 0DVVH.DELQH

2SWLRQ$LUFRQGLWLRQHU 2SWLRQVXVSHQVLRQVHDW 2SWLRQDFWLYDWHGFKDUFRDOILOWHU 2SWLRQ$GGLWLRQDOKHDWHU

2SWLRQ.OLPDDQODJH 2SWLRQ/XIWIHGHUVLW] 2SWLRQ$NWLYNRKOHILOWHU 2SWLRQ=XVDW]KHL]XQJ

0DJQHWLFFOXWFKDLUFRQGLWLRQLQJFRPSUHVVRU &RPSUHVVRUVXVSHQVLRQRSHUDWRUVVHDW $GGLWLRQDOEORZHU )XHOSXPSKHDWLQJXQLW

0DJQHWNXSSOXQJ.OLPDNRPSUHVVRU .RPSUHVVRU/XIWIHGHUVLW] =XVDW]OIWHU .UDIWVWRIISXPSH+HL]JHUlW
17.2

1259

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW &DELQ+HDWLQJ$LUFRQGLWLRQLQJ$GGLWLRQDO+HDWHU
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
.DELQH+HL]XQJ.OLPDDQODJH=XVDW]KHL]XQJ (LQEDXRUW (3(
1260
17.2

$
.H\ERDUG
7DVWDWXU

$
(OHFWURQLFFRQWUROXQLW
(OHNWURQLN6WHXHUHLQKHLW

;

BOMAG
008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW (OHFWURQLFDO%XUJODU\SURWHFWLRQ
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
(OHNWURQLVFKH'LHEVWDKOVLFKHUXQJ (LQEDXRUW (3(
$
(OHFWURQLFV\VWHPERPDJWHOHPDWLFV
(OHNWURQLN%RPDJ7HOHPDWLN

008 924 17
$
$QWHQQDERPDJWHOHPDWLFV
$QWHQQH%RPDJ7HOHPDWLN
Wiring diagram 9

*36 *60

&$1B/
&$1B+
3RW
3RW
,1
,1
*1'
*60
*36

BOMAG
)

'70

*URXQG&HQWUDO(OHFWULF
0DVVH=HQWUDOHOHNWULN
17.2

1261

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW %RPDJWHOHPDWLFV
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
%RPDJ7HOHPDWLN (LQEDXRUW (3(
1262
17.2
'HYLFHWDJOLVW
%HWULHEVPLWWHOOLVWH
+LJKHUOHYHO
'HYLFHWDJ 3DJH 3DWK 0RXQWLQJORFDWLRQ IXQFWLRQ FKDUDFWHULVWLFV
%0. %ODWW 3IDG (LQEDXRUW
)XQFWLRQWH[W )XQNWLRQVWH[W 7HFKQ.HQQJU|HQ
$QODJH

$ )ODVKHU %OLQNJHEHU

.OHPPOHLVWHQEHUVLFKW
7HUPLQDOVWULSFHQWUDOHOHFWULF
; .OHPPOHLVWH=HQWUDOHOHNWULN
0RXQWLQJORFDWLRQ (OHFWURER[
(LQEDXRUW (OHNWURNDVWHQ
'HYLFHWDJ 3DJH 3DWK 'HYLFHWDJ 3DJH 3DWK 'HYLFHWDJ 3DJH 3DWK 'HYLFHWDJ 3DJH 3DWK 'HYLFHWDJ 3DJH 3DWK 'HYLFHWDJ 3DJH 3DWK
%0. %ODWW 3IDG %0. %ODWW 3IDG %0. %ODWW 3IDG %0. %ODWW 3IDG %0. %ODWW 3IDG %0. %ODWW 3IDG
; ;$ ; ; ; ;
; ;( ; ; ; ;
; ;$ ; ; ; ;
; ;( ; ; ; ;
; ;$ ; ; ; ;
; ;( ; ; ; ;
; ;$ ; ; ; ;
; ;( ; ; ; ;
;$ ;$ ; ; ; ;
;( ;( ; ; ; ;
;$ ;$ ; ; ; ;
;( ;( ; ; ; ;
;$ ;$ ; ; ; ;

BOMAG
;( ;( ; ; ; ;
;$ ; ; ; ; ;
;( ; ; ; ; ;
;$ ; ; ; ; ;
;( ; ; ; ; ;
;$ ; ; ; ; ;
;( ; ; ; ; ;
;$ ; ; ; ; ;
;( ; ; ; ; ;
;$ ; ; ; ; ;
;( ; ; ; ; ;
;$ ; ; ; ; ;
;( ; ; ; ; ;
;$ ; ; ; ; ;
;( ; ; ; ; ;
;$ ; ; ; ; ;
;( ; ; ; ; ;
;$ ; ; ; ; ;
;( ; ; ; ; ;
;$ ; ; ; ; ;
;( ; ; ; ; ;
;$ ; ; ; ; ;

008 924 17
Wiring diagram 9

;( ; ; ; ;

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 7HUPLQDOVWULSRYHUYLHZ;
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
.OHPPOHLVWHQEHUVLFKW; (LQEDXRUW (3(
7HUPLQDOVWULSRYHUYLHZ
.OHPPOHLVWHQEHUVLFKW

008 924 17
7HUPLQDOVWULSFHQWUDOHOHFWULFPHDVXUHPHQWHTXLSPHQW
; .OHPPOHLVWH=HQWUDOHOHNWULN0HVVWHFKQLN
0RXQWLQJORFDWLRQ (OHFWURER[
(LQEDXRUW (OHNWURNDVWHQ
Wiring diagram 9

'HYLFHWDJ 3DJH 3DWK

%0. %ODWW 3IDG
;
;
;
;
;
;
;
;
;
;
;
;
;
;

BOMAG
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;$
;(
17.2

1269

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 7HUPLQDOVWULSRYHUYLHZ;
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
.OHPPOHLVWHQEHUVLFKW; (LQEDXRUW (3(
1270
3OXJRYHUYLHZ
17.2

6WHFNHUEHUVLFKW
'HVLJQDWLRQ 0RXQWLQJORFDWLRQ )XQFWLRQWH[W 'HVLJQDWLRQ 0RXQWLQJORFDWLRQ )XQFWLRQWH[W
%H]HLFKQXQJ (LQEDXRUW )XQNWLRQVWH[W %H]HLFKQXQJ (LQEDXRUW )XQNWLRQVWH[W
(OHFWURER[ 3OXJVXSSO\FDELQURSVVXQURRI $UPDWXUHFDUULHU 3OXJPRQLWRULQJPRGXOH
; (OHNWURNDVWHQ 6WHFNHU9HUVRUJXQJ.DELQH5RSV6RQQHQGDFK ; $UPDWXUHQWUlJHU 6WHFNHUhEHUZDFKXQJVPRGXO
&RQWDFW 3DJH 3DWK 7\SH &RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S +'3 .RQWDNW %ODWW 3IDG 7\S $036XSHUVHDOSROH

5HDUIUDPH 3OXJ6ROHQRLGYDOYHYLEUDWLRQIURQWKLJK
; +LQWHUUDKPHQ 6SHFNHU0DJQHWYHQWLO9LEUDLWRQYRUQHJUR
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S $03-37'7SROH

(OHFWURER[ 3OXJFRQQHFWLRQPHDVXUHPHQWHTXLSPHQWFDELQ 5HDUIUDPH 3OXJ6ROHQRLGYDOYHYLEUDWLRQIURQWORZ
; (OHNWURNDVWHQ 6WHFNHU0HVVWHFKQLN.DELQH ; +LQWHUUDKPHQ 6SHFNHU0DJQHWYHQWLO9LEUDLWRQYRUQHNOHLQ
&RQWDFW 3DJH 3DWK 7\SH &RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S +'3 .RQWDNW %ODWW 3IDG 7\S $03-37'7SROH

BOMAG
$
%
& 5HDUIUDPH 3OXJ:DWHU,Q)XHO6HQVRU
' ; +LQWHUUDKPHQ 6WHFNHU6HQVRU:DVVHULP.UDIWVWRII
&RQWDFW 3DJH 3DWK 7\SH
( .RQWDNW %ODWW 3IDG 7\S '7SROH
)
*
+ 5HDUIUDPH 3OXJEDFNXSDODUPEX]]HU
- ; +LQWHUUDKPHQ 6WHFNHU5FNIDKUZDUQVXPPHU
0 &RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '7SROH
1
$UPDWXUHFDUULHU 3OXJPRQLWRULQJPRGXOH
; $UPDWXUHQWUlJHU 6WHFNHUhEHUZDFKXQJVPRGXO
&RQWDFW 3DJH 3DWK 7\SH 5HDUIUDPH 3OXJVHQGHUOHYHOJDXJH
.RQWDNW %ODWW 3IDG 7\S $036XSHUVHDOSROH ; +LQWHUUDKPHQ 6WHFNHU7DXFKURKUJHEHU
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S $036XSHUVHDOSROH

&RQVROHULJKWVHDW 3OXJSXVKEXWWRQYLEUDWLRQWUDYHOOHYHU
; .RQVROH6LW]UHFKWV 6WHFNHU7DVWHU9LEUDWLRQ)DKUKHEHO
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '70SROH

008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 3OXJRYHUYLHZ
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
6WHFNHUEHUVLFKW (LQEDXRUW (3(
3OXJRYHUYLHZ
6WHFNHUEHUVLFKW

008 924 17
'HVLJQDWLRQ 0RXQWLQJORFDWLRQ )XQFWLRQWH[W 'HVLJQDWLRQ 0RXQWLQJORFDWLRQ )XQFWLRQWH[W
%H]HLFKQXQJ (LQEDXRUW )XQNWLRQVWH[W %H]HLFKQXQJ (LQEDXRUW )XQNWLRQVWH[W
&RQVROHULJKWVHDW 3OXJSUR[LPLW\VZLWFKWUDYHOOHYHUSRVLWLRQ (OHFWURER[ 3OXJVXSSO\FHQWUDOHOHFWULF
; .RQVROH6LW]UHFKWV 6WHFNHU,QLWLDWRU)DKUKHEHO ; (OHNWURNDVWHQ 6WHFNHU9HUVRUJXQJ=HQWUDOHOHNWULN
&RQWDFW 3DJH 3DWK 7\SH &RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '70SROH .RQWDNW %ODWW 3IDG 7\S 07$SROH
Wiring diagram 9

$
%
(OHFWURER[ 3OXJVXSSO\LJQLWLRQVZLWFK
&RQVROHULJKWVHDW 3OXJSUR[LPLW\VZLWFKWUDYHOOHYHUIRUZDUGDQGSRVLWLRQ
; (OHNWURNDVWHQ 6WHFNHU9HUVRUJXQJ6WDUWVFKDOWHU
; .RQVROH6LW]UHFKWV 6WHFNHU,QLWLDWRU)DKUKHEHOYRUZlUWVX &RQWDFW 3DJH 3DWK 7\SH
&RQWDFW 3DJH 3DWK 7\SH .RQWDNW %ODWW 3IDG 7\S 07$SROH
.RQWDNW %ODWW 3IDG 7\S '70SROH $
%
(OHFWURER[ 3OXJVXSSO\VWDUWHU
; (OHNWURNDVWHQ 6WHFNHU9HUVRUJXQJ6WDUWHU
&RQWDFW 3DJH 3DWK 7\SH
6HDW 3OXJVZLWFKVHDWFRQWDFW
.RQWDNW %ODWW 3IDG 7\S 07$SROH
; 6LW] 6WHFNHU6LW]NRQWDNWVFKDOWHU
&RQWDFW 3DJH 3DWK 7\SH $
.RQWDNW %ODWW 3IDG 7\S '7SROH &RQVROHULJKWVHDW 3OXJFRQQHFWLRQDGDSWHU%23
; .RQVROH6LW]UHFKWV 6WHFNHU$QVFKOX$GDSWHU%23
$ &RQWDFW 3DJH 3DWK 7\SH
% .RQWDNW %ODWW 3IDG 7\S '70SROH
&DELQ 3OXJKHDWLQJFOLPDWLFXQLW
; .DELQH 6WHFNHU+HL].OLPD(LQKHLW

&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '73SROH

BOMAG

(OHFWURER[ 3OXJPHDVXUHPHQWFRQWUROOHU
5HDUIUDPH 3OXJSUHVVXUHVZLWFKDLUFRQGLWLRQLQJ
; (OHNWURNDVWHQ 6WHFNHU0HVVWHFKQLNVWHXHUXQJ
; +LQWHUUDKPHQ 6WHFNHU'UXFNVFKDOWHU.OLPDDQODJH &RQWDFW 3DJH 3DWK 7\SH
&RQWDFW 3DJH 3DWK 7\SH .RQWDNW %ODWW 3IDG 7\S $03SROH
.RQWDNW %ODWW 3IDG 7\S '7SROH

5HDUIUDPH 3OXJ)ORDWLQJVZLWFK&RRODQWH[SDQVLRQWDQN
; +LQWHUUDKPHQ 6WHFNHU6FKZLPPHUVFKDOWHU.KOPLWWHODXVJOHLFKVEHKlOWHU
&RQWDFW 3DJH 3DWK 7\SH

.RQWDNW %ODWW 3IDG 7\S '70SROH

)URQWIUDPH 3OXJWUDQVGXFHUYLEUDWLRQIUHTXHQF\IURQW
; 9RUGHUUDKPHQ 6WHFNHU$XIQHKPHU9LEUDWLRQVIUHTXHQ]YRUQH
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '7SROH

17.2

1271

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 3OXJRYHUYLHZ
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
6WHFNHUEHUVLFKW (LQEDXRUW (3(
1272
3OXJRYHUYLHZ
17.2

6WHFNHUEHUVLFKW
'HVLJQDWLRQ 0RXQWLQJORFDWLRQ )XQFWLRQWH[W 'HVLJQDWLRQ 0RXQWLQJORFDWLRQ )XQFWLRQWH[W
%H]HLFKQXQJ (LQEDXRUW )XQNWLRQVWH[W %H]HLFKQXQJ (LQEDXRUW )XQNWLRQVWH[W
(OHFWURER[ 3OXJPHDVXUHPHQWFRQWUROOHU &DELQ 3OXJZLQGVFUHHQZLSHUPRWRUIURQW
; (OHNWURNDVWHQ 6WHFNHU0HVVWHFKQLNVWHXHUXQJ ; .DELQH 6WHFNHU6FKHLEHQZLVFKHUPRWRUYRUQH
&RQWDFW 3DJH 3DWK 7\SH &RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S $03SROH .RQWDNW %ODWW 3IDG 7\S 31$7

&DELQ5RSV 3OXJKHDGOLJKWIURQWOHIW
; .DELQH5RSV 6WHFNHU6FKHLQZHUIHUYRUQHOLQNV
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '7SROH

&DELQ5RSV 3OXJKHDGOLJKWIURQWULJKW
&RQVROHULJKWVHDW 3OXJERPDJRSHUDWLRQSDQHO %23 ; .DELQH5RSV 6WHFNHU6FKHLQZHUIHUYRUQHUHFKWV
; .RQVROH6LW]UHFKWV 6WHFNHU%RPDJ2SHUDWLRQ3DQHO %23 &RQWDFW 3DJH 3DWK 7\SH
&RQWDFW 3DJH 3DWK 7\SH .RQWDNW %ODWW 3IDG 7\S '7SROH
.RQWDNW %ODWW 3IDG 7\S %XUQG\SROH
$
%

BOMAG
'
( 5HDUIUDPH 3OXJWDLOOLJKWUHDUOHIW
) ; +LQWHUUDKPHQ 6WHFNHU5FNOHXFKWHOLQNV
)URQWIUDPH 3OXJWUDQVGXFHUDFFHOHUDWLRQIURQW &RQWDFW 3DJH 3DWK 7\SH
; 9RUGHUUDKPHQ 6WHFNHU%HVFKOHXQLJXQJVDXIQHKPHUYRUQH .RQWDNW %ODWW 3IDG 7\S '7SROH
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '7SROH

5HDUIUDPH 3OXJWDLOOLJKWUHDUULJKW
; +LQWHUUDKPHQ 6WHFNHU5FNOHXFKWHUHFKWV
)URQWIUDPH 3OXJWUDQVGXFHUDFFHOHUDWLRQUHDU &RQWDFW 3DJH 3DWK 7\SH
; 9RUGHUUDKPHQ 6WHFNHU%HVFKOHXQLJXQJVDXIQHKPHUKLQWHQ .RQWDNW %ODWW 3IDG 7\S '7SROH
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '7SROH

(OHFWURER[ 3OXJHOHFWURQLFDOEXUJODU\SURWHFWLRQ
; (OHNWURNDVWHQ 6WHFNHU(OHNWURQLVFKH'LHEVWDKOVLFKHUXQJ
&DELQ 3OXJZLQGVFUHHQZLSHUPRWRUUHDU &RQWDFW 3DJH 3DWK 7\SH
; .DELQH 6WHFNHU6FKHLEHQZLVFKHUPRWRUKLQWHQ .RQWDNW %ODWW 3IDG 7\S '7SROH
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S 31$7

008 924 17
Wiring diagram 9

008 924 17
'HVLJQDWLRQ 0RXQWLQJORFDWLRQ )XQFWLRQWH[W 'HVLJQDWLRQ 0RXQWLQJORFDWLRQ )XQFWLRQWH[W
%H]HLFKQXQJ (LQEDXRUW )XQNWLRQVWH[W %H]HLFKQXQJ (LQEDXRUW )XQNWLRQVWH[W
(OHFWURER[ 3OXJHOHFWURQLFDOEXUJODU\SURWHFWLRQ &DELQ 3OXJDFFHVV*365HFHLYHU
; (OHNWURNDVWHQ 6WHFNHU(OHNWURQLVFKH'LHEVWDKOVLFKHUXQJ ; .DELQH 6WHFNHU$QVFKOX*36$QWHQQH
&RQWDFW 3DJH 3DWK 7\SH &RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '7SROH .RQWDNW %ODWW 3IDG 7\S %XUQG\SROH
Wiring diagram 9

(
&DELQ 3OXJVXSSO\*366\VWHP
; .DELQH 6WHFNHU6SDQQXQJVYHUVRUJXQJ*366\VWHP
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '7SROH
5HDUIUDPH 3OXJIXHOSUHKHDWHU
; +LQWHUUDKPHQ 6WHFNHU.UDIWVWRIIYRUKHL]XQJ
$
&RQWDFW 3DJH 3DWK 7\SH %
.RQWDNW %ODWW 3IDG 7\S '73SROH &
&DELQ 3OXJSULQWHU
; .DELQH 6WHFNHU'UXFNHU
&RQWDFW 3DJH 3DWK 7\SH
3OXJNH\ERDUGHOHFWURQLFDOEXUJODU\SURWHFWLRQ
.RQWDNW %ODWW 3IDG 7\S $030DWHQORFSROH
; 6WHFNHU7DVWDWXU(OHNWURQLVFKH'LHEVWDKOVLFKHUXQJ
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S 68%'SROH

&DELQ 3OXJDGGLWLRQDOEORZHU
; .DELQH 6WHFNHU=XVDW]OIWHU
&RQWDFW 3DJH 3DWK 7\SH

&DELQ 3OXJ&$1%&0'RQJOH
.RQWDNW %ODWW 3IDG 7\S '70SROH ; .DELQH 6WHFNHU&$1%&0'RQJOH
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S 68%'SROH

BOMAG
&DELQ 3OXJ$FFHVV*36%&0
; .DELQH 6WHFNHU$QVFKOX*36%&0
&RQWDFW 3DJH 3DWK 7\SH

&DELQ 3OXJVXSSO\%&0
.RQWDNW %ODWW 3IDG 7\S 68%'SROH ; .DELQH 6WHFNHU9HUVRUJXQJ%&0
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '7SROH

*365HFHLYHU6WDU)LUH 3OXJ*365HFHLYHU6WDU)LUH
; *36(PSIlQJHU6WDU)LUH 6WHFNHU*36$QWHQQH6WDU)LUH 5HDUIUDPH 3OXJIXHOSXPSDGGLWLRQDOKHDWHU
&RQWDFW 3DJH 3DWK 7\SH ; +LQWHUUDKPHQ 6WHFNHU.UDIWVWRIISXPSH=XVDW]KHL]XQJ
.RQWDNW %ODWW 3IDG 7\S '7SROH &RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '70SROH

*365HFHLYHU6WDU)LUH 3OXJDGGLWLRQDORSWLRQV*365HFHLYHU
; *36(PSIlQJHU6WDU)LUH 6WHFNHU=XVDW]RSWLRQHQ*36$QWHQQH
&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S '7SROH

&DELQ 3OXJDFFHVV*365HFHLYHU
; .DELQH 6WHFNHU$QVFKOX*36$QWHQQH

&RQWDFW 3DJH 3DWK 7\SH
.RQWDNW %ODWW 3IDG 7\S %XUQG\SROH
$ &DELQ5RSV 3OXJVXVSHQVLRQVHDW
; .DELQH5RSV 6WHFNHU/XIWIHGHUVLW]
% &RQWDFW 3DJH 3DWK 7\SH
& .RQWDNW %ODWW 3IDG 7\S 31$7
'
17.2

1273

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 3OXJRYHUYLHZ
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
6WHFNHUEHUVLFKW (LQEDXRUW (3(
1274
3OXJRYHUYLHZ
17.2

BOMAG
008 924 17
Wiring diagram 9

008 924 17
0RQLWRULQJPRGXOH
$ hEHUZDFKXQJVPRGXO
3LQ 3DJH 3DWK 'HVFULSWLRQ
6LJQDO 6LJQDO
.RQWDNW %ODWW 3IDG %HVFKUHLEXQJ
Wiring diagram 9

; )XHOJDXJH 7DQNDQ]HLJH
; *ORZLQJ *OKHQ
; %UDNH %UHPVH
; 1LJKWGLPRXW 1DFKWDEGXQNOXQJ
; 6KXWRIIPLQ &RRODQWWHPSHUDWXUH .KOPLWWHOWHPSHUDWXU
; 6HDW 6LW]
; &KDUJHFRQWURO /DGHNRQWUROOH
; 6KXWRIIVHF (QJLQHRLOSUHVVXUH 0RWRU|OGUXFN
; ,QGLFDWRUULJKW %OLQNHUUHFKWV
; ,QGLFDWRUOHIW %OLQNHUOLQNV
; +D]DUGOLJKW :DUQEOLQNOLFKW
; 6KXWRIIVHF &RRODQWOHYHO .KOPLWWHOIOOVWDQG
; $LUFOHDQHU /XIWILOWHU
; 6KXWRIIPLQ +\GURLOILOWHU +\GUDXOLN|OILOWHU
; 6KXWRIIPLQ :DWHUWUDS :DVVHUDEVFKHLGHU
; 6KXWRIIPLQ :DWHUWUDS :DVVHUDEVFKHLGHU

BOMAG
; 2XWZDUQLQJEX]]HU 2XW:DUQVXPPHU
; 2XW0RWRUVWRS 2XW0RWRU6WRS
; *1' *1'
; 8E 8E
17.2

1275

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 3LQRYHUYLHZ$
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
3LQhEHUVLFKW$ (LQEDXRUW (3(
1276
17.2
3LQRYHUYLHZ
3LQhEHUVLFKW
0HDVXUHPHQWFRQWUROOHU
$ 0HVVWHFKQLN6WHXHUXQJ
3LQ 3DJH 3DWK 'HVFULSWLRQ
6LJQDO 6LJQDO
.RQWDNW %ODWW 3IDG %HVFKUHLEXQJ
ER[ *URXQG+RXVLQJ *URXQGKRXVLQJ 0DVVH*HKlXVH
; $*1' $*1' $QDORJPDVVH
; '2 $ (YLE0HWHU (YLE0HWHU
; 5[' 5[' 5['
; 7[' 7[' 7['
; $, 7UDQVGXFHU$FFHOHUDWLRQUHDUJ %HVFKOHXQLJXQJVDXIQKLQWHQJ
; ', ' 'ULYLQJGLUHFWLRQ )DKUWULFKWXQJ
; ', ' 9LEUDWLRQORZDPSOLWXGH 9LEUDWLRQNOHLQH$PSOLWXGH
; '2 $ 3RZHUVXSSO\*36 6SDQQXQJVYHUVRUJXQJ*36
; :LUH &$1 &$1
; :LUH &$1 &$1
; ' 3RZHU6XSSO\ (OHFWURQLF 6SDQQXQJVYHUV (OHNWURQLN
; $, 7UDQVGXFHU$FFHOHUDWLRQIURQWJ %HVFKOHXQLJXQJVDXIQYRUQHJ
; $, 7UDQVGXFHU$FFHOHUDWLRQUHDUJ %HVFKOHXQLJXQJVDXIQKLQWHQJ
; $, 7UDQVGXFHU$FFHOHUDWLRQIURQWJ %HVFKOHXQLJXQJVDXIQYRUQHJ

BOMAG
; :LUH &$1 &$1
; ', ' 'ULYLQJVSHHG )DKUJHVFKZLQGLJNHLW
; ', ' %UDNH %UHPVH
; ', ' '$OWHUQDWRU '*HQHUDWRU
; ', ' 9LEUDWLRQKLJKDPSOLWXGH 9LEUDWLRQJURH$PSOLWXGH
; ', ' ,OOXPLQDWLRQ %HOHXFKWXQJ
; :LUH &$1 &$1
; 8( ,JQLWLRQ =QGXQJ
; *1' *URXQG(OHFWURQLF 0DVVH(OHNWURQLN
; 8% 3RZHU6XSSO\ 2XWSXWV 6SDQQXQJVYHUV $XVJlQJH
; 8% 3RZHU6XSSO\ 2XWSXWV 6SDQQXQJVYHUV $XVJlQJH
; 8% 3RZHU6XSSO\ 2XWSXWV 6SDQQXQJVYHUV $XVJlQJH
; 8% 3RZHU6XSSO\ 2XWSXWV 6SDQQXQJVYHUV $XVJlQJH
; 8% 3RZHU6XSSO\ 2XWSXWV 6SDQQXQJVYHUV $XVJlQJH
; ;*1' *URXQG%DE\%RDUG 0DVVH%DE\%RDUG
; ;*1' *URXQG%DE\%RDUG 0DVVH%DE\%RDUG
; ;*1' *URXQG%DE\%RDUG 0DVVH%DE\%RDUG
; ;*1' *URXQG%DE\%RDUG 0DVVH%DE\%RDUG

008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 3LQRYHUYLHZ$
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
3LQhEHUVLFKW$ (LQEDXRUW (3(
008 924 17
Wiring diagram 9

BOMAG
17.2

1277

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 2YHUYLHZ&HQWUDO(OHFWULF
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
hEHUVLFKW=HQWUDOHOHNWULN (LQEDXRUW (3(
1278
17.2

BOMAG
008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 2YHUYLHZ&HQWUDO(OHFWULF
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
hEHUVLFKW=HQWUDOHOHNWULN (LQEDXRUW (3(
008 924 17
Wiring diagram 9

BOMAG
17.2

1279

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 9LHZ7HUPLQDOVWULS;EHORZ
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
$QVLFKW.OHPPOHLVWH;XQWHQ (LQEDXRUW (3(
1280
17.2

BOMAG
008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 9LHZ7HUPLQDOVWULS;DERYH
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
$QVLFKW.OHPPOHLVWH;REHQ (LQEDXRUW (3(
008 924 17
Wiring diagram 9

BOMAG
17.2

1281

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 9LHZ7HUPLQDOVWULS;DERYH
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
$QVLFKW.OHPPOHLVWH;REHQ (LQEDXRUW (3(
1282
17.2

BOMAG
008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 9LHZ7HUPLQDOVWULS;6W9=2
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
$QVLFKW.OHPPOHLVWH;6W9=2 (LQEDXRUW (3(
008 924 17
Wiring diagram 9

BOMAG
17.2

1283

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 9LHZ7HUPLQDOVWULS;
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
$QVLFKW.OHPPOHLVWH; (LQEDXRUW (3(
1284
17.2

BOMAG
008 924 17
Wiring diagram 9

+LJKHUOHYHOIXQFWLRQ 3DJH IURP
&UHDWHG 09RJW $QODJH %ODWW YRQ
)XQFWLRQ
(UVWHOOW 2YHUYLHZSOXJORFDWLRQ
)XQNWLRQ
&KHFNHG 0:HUQHU %:'' 0RXQWLQJORFDWLRQ
*HSUIW
hEHUVLFKW6WHFNHUSRVLWLRQ (LQEDXRUW (3(

BW211D-40 Service Manual Sn. 861583551267 - and Up 00891964.a13
No ratings yet
BW211D-40 Service Manual Sn. 861583551267 - and Up 00891964.a13
1,140 pages
BW219D-4 Sn. 861 582 758 259 SM 00892453.j13
100% (2)
BW219D-4 Sn. 861 582 758 259 SM 00892453.j13
932 pages
BW211D-40 Service Training Sn. 861583551267 - Up 00891968.a13
100% (1)
BW211D-40 Service Training Sn. 861583551267 - Up 00891968.a13
468 pages
BW211D-40 Sn. 861583001001 and Up SM 00891163.k10
No ratings yet
BW211D-40 Sn. 861583001001 and Up SM 00891163.k10
1,332 pages
SM Bomag BW218 4d
100% (6)
SM Bomag BW218 4d
1,446 pages
Service Manuel BW211D-40
93% (46)
Service Manuel BW211D-40
972 pages
Roller - BW211D-40 PDF
100% (1)
Roller - BW211D-40 PDF
972 pages
Dokumen - Tips - bw211 212 213d 40 Service Manual e 00891163c08pdf PDF
100% (2)
Dokumen - Tips - bw211 212 213d 40 Service Manual e 00891163c08pdf PDF
1,040 pages
b08 PDF
100% (1)
b08 PDF
1,046 pages
Bomag 211 - 213 - D4 - EN PDF
100% (5)
Bomag 211 - 213 - D4 - EN PDF
996 pages
Bomag BW 211 D-40 Service Manual: Safety Regulations
100% (1)
Bomag BW 211 D-40 Service Manual: Safety Regulations
22 pages
Service Manual BW161
No ratings yet
Service Manual BW161
1,174 pages
BW 226 Di-4 Service Manual
No ratings yet
BW 226 Di-4 Service Manual
1,220 pages
Manual de Servicio Rodillo Bomag Modelo BW 213 Dh-4 Pdh-4 Bw214dh4 Pdh-4
100% (9)
Manual de Servicio Rodillo Bomag Modelo BW 213 Dh-4 Pdh-4 Bw214dh4 Pdh-4
1,030 pages
BW219D-4 Service Manual
100% (2)
BW219D-4 Service Manual
840 pages
Shop BW219D-4 Bomag
95% (20)
Shop BW219D-4 Bomag
840 pages
Training BW226DH-4 BVC
No ratings yet
Training BW226DH-4 BVC
1,492 pages
Bw213-214en
100% (8)
Bw213-214en
1,108 pages
Bomag BW 120 Ad-4 SN 101880091167
100% (2)
Bomag BW 120 Ad-4 SN 101880091167
588 pages
Service - Manual: BW 211 / 212 / 213 D-40 BW 211 / 212 / 213 PD-40
50% (2)
Service - Manual: BW 211 / 212 / 213 D-40 BW 211 / 212 / 213 PD-40
21 pages
BW211 212 213D 40 Service Manual E 00891163 c08 PDF
100% (2)
BW211 212 213D 40 Service Manual E 00891163 c08 PDF
1,040 pages
BW 219 DH-4 Manual
No ratings yet
BW 219 DH-4 Manual
1,094 pages
Bomag BW211 212 213D 40 Service Manual E 00891163 c08 PDF
67% (3)
Bomag BW211 212 213D 40 Service Manual E 00891163 c08 PDF
6 pages
Bw216d4-101583-Service Manual
100% (6)
Bw216d4-101583-Service Manual
974 pages
Training Manual Bw214dh4i
No ratings yet
Training Manual Bw214dh4i
680 pages
BW24 RH
100% (2)
BW24 RH
620 pages
BW24 RH Manual de Servicio
No ratings yet
BW24 RH Manual de Servicio
346 pages
BW24RH Service Manual PDF
100% (2)
BW24RH Service Manual PDF
606 pages
BW 219 (58290) Ser
100% (1)
BW 219 (58290) Ser
962 pages
Boamg Earth Compactor BC772 RB-2 Service Manual 00892363 2013
No ratings yet
Boamg Earth Compactor BC772 RB-2 Service Manual 00892363 2013
694 pages
SM BC972,1172 RB 101 570 80 Up 00891488.d08
No ratings yet
SM BC972,1172 RB 101 570 80 Up 00891488.d08
798 pages
BW213DH-4 BVC Service Manual E 00891179.l07 PDF
89% (53)
BW213DH-4 BVC Service Manual E 00891179.l07 PDF
1,192 pages
BF300P - Service Manual-821 837 68 1001 - 821 837 81 1001.... 00891745.h12
100% (1)
BF300P - Service Manual-821 837 68 1001 - 821 837 81 1001.... 00891745.h12
756 pages
BW211-212-213-D-40 Bomag
100% (8)
BW211-212-213-D-40 Bomag
834 pages
Instructions For Repair: BW 213 DH / PDH - 4 BW 214 DH / PDH - 4
100% (4)
Instructions For Repair: BW 213 DH / PDH - 4 BW 214 DH / PDH - 4
838 pages
Manual de Servicio BW 120 AD-4 PDF
97% (31)
Manual de Servicio BW 120 AD-4 PDF
560 pages
BW211D-4 Manual de Taller 00891368.j05 PDF
100% (2)
BW211D-4 Manual de Taller 00891368.j05 PDF
862 pages
SM BC972,1172 RB, RS-2 101 570 82 Up 00891157.d08
No ratings yet
SM BC972,1172 RB, RS-2 101 570 82 Up 00891157.d08
934 pages
Service Manual BM 1300 30 Vecchiola
100% (1)
Service Manual BM 1300 30 Vecchiola
826 pages
Service Manual
100% (2)
Service Manual
612 pages
Operating Instructions Maintenance Instructions: BW 141 AD-4 / BW 151 AD-4 BW 151 AC-4 / BW 161 ADCV
No ratings yet
Operating Instructions Maintenance Instructions: BW 141 AD-4 / BW 151 AD-4 BW 151 AC-4 / BW 161 ADCV
20 pages
BW141 151 161 AC AD-4 Operation-Maintenance
100% (2)
BW141 151 161 AC AD-4 Operation-Maintenance
110 pages
BW 135,138 AD, AC 101 650 16 Up 00891444.j07
No ratings yet
BW 135,138 AD, AC 101 650 16 Up 00891444.j07
478 pages
BW211 212 213 D 40 - Recovered
No ratings yet
BW211 212 213 D 40 - Recovered
31 pages
Service - Manual: BW 211 D-4 / PD-4 BW 213 D-4 / PD-4 BW 214 D-4
50% (2)
Service - Manual: BW 211 D-4 / PD-4 BW 213 D-4 / PD-4 BW 214 D-4
6 pages
Bomag BW213
82% (11)
Bomag BW213
148 pages
BW 2111
No ratings yet
BW 2111
5 pages
Bomag BC 462 EB Service Manual 00892355.i13
No ratings yet
Bomag BC 462 EB Service Manual 00892355.i13
782 pages
Bomag BC 462 EB Service Manual 00891713.b12
No ratings yet
Bomag BC 462 EB Service Manual 00891713.b12
774 pages
Bomag MPH 122 2 Service Manual
100% (71)
Bomag MPH 122 2 Service Manual
20 pages
120 Ad4 Servicemanual
100% (3)
120 Ad4 Servicemanual
438 pages
BW141-151AD4 Op Mu
No ratings yet
BW141-151AD4 Op Mu
108 pages
Service - Training: Catalogue Number
No ratings yet
Service - Training: Catalogue Number
1,050 pages
SM BW24 RH 101 538 01 Up 00891504.e08
No ratings yet
SM BW24 RH 101 538 01 Up 00891504.e08
528 pages
00891153.j10 Bomag
100% (6)
00891153.j10 Bomag
1,022 pages
Review- The Soul of Mbira Twenty Years On- A Retrospect Reviewed Work(s)- The Soul of Mbira- Music and Traditions of the Shona People of Zimbabwe by Paul Berliner Review by- Keith Goddard and John M. Chernoff
No ratings yet
Review- The Soul of Mbira Twenty Years On- A Retrospect Reviewed Work(s)- The Soul of Mbira- Music and Traditions of the Shona People of Zimbabwe by Paul Berliner Review by- Keith Goddard and John M. Chernoff
21 pages
Intro Page - Community Health Project
No ratings yet
Intro Page - Community Health Project
3 pages
G20 Social Science
67% (3)
G20 Social Science
286 pages
Corinthian Gardens Vs Tanjangco
No ratings yet
Corinthian Gardens Vs Tanjangco
21 pages
Xamrain PDF
No ratings yet
Xamrain PDF
121 pages
Night Breaker Led Compatibility List Cars Campers Special Vehicles en
No ratings yet
Night Breaker Led Compatibility List Cars Campers Special Vehicles en
43 pages
22-Indophil Textile Mill Workers Union vs. Calica
No ratings yet
22-Indophil Textile Mill Workers Union vs. Calica
4 pages
Farm Bills (2020)
No ratings yet
Farm Bills (2020)
1 page
SP Xuv5101
No ratings yet
SP Xuv5101
2 pages
Social Science Exam Guide 2020-21
No ratings yet
Social Science Exam Guide 2020-21
5 pages
HY - G - XI Revision Test-2-Answer Key - 2025-26-1
No ratings yet
HY - G - XI Revision Test-2-Answer Key - 2025-26-1
5 pages
(2019) ICME For Advanced Materials
No ratings yet
(2019) ICME For Advanced Materials
7 pages
Cabin 33
No ratings yet
Cabin 33
5 pages
Parent Concent Form
No ratings yet
Parent Concent Form
1 page
Airframe - Aircraft Drawing Part 2022
80% (5)
Airframe - Aircraft Drawing Part 2022
22 pages
679713b86cdd397868371745 - ## - Linear Equation in One Variable - Practice Sheet - (Only PDF) - Mathematics Olympiad Beginners Program 2025
No ratings yet
679713b86cdd397868371745 - ## - Linear Equation in One Variable - Practice Sheet - (Only PDF) - Mathematics Olympiad Beginners Program 2025
4 pages
Crisis Recovery Report-1
No ratings yet
Crisis Recovery Report-1
2 pages
Virtual Eye for the Blind
No ratings yet
Virtual Eye for the Blind
6 pages
8th End Term1 2023 RAJA ABC
No ratings yet
8th End Term1 2023 RAJA ABC
4 pages
Lesson Plan For Science
No ratings yet
Lesson Plan For Science
4 pages
Crdetails - OS 20022021
No ratings yet
Crdetails - OS 20022021
14 pages
EP Chapter 7 Notes - Sun-Earth-Moon
No ratings yet
EP Chapter 7 Notes - Sun-Earth-Moon
36 pages
Benefits of Having A CRM System in Addition PDF
No ratings yet
Benefits of Having A CRM System in Addition PDF
49 pages
DLD Number System and Conversion
No ratings yet
DLD Number System and Conversion
18 pages
Tomographic Image Reconstruction
No ratings yet
Tomographic Image Reconstruction
2 pages
Prof - Ed Raw
No ratings yet
Prof - Ed Raw
19 pages
HamroBazar Report
No ratings yet
HamroBazar Report
13 pages
Chapter 10
No ratings yet
Chapter 10
33 pages
Biblical Text Abbreviations Guide
No ratings yet
Biblical Text Abbreviations Guide
2 pages
Cast Metal Restorations 11146 ConDent-T 11-02-2021
No ratings yet
Cast Metal Restorations 11146 ConDent-T 11-02-2021
305 pages