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Service Manual BM 2000

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5 views990 pages

Service Manual BM 2000

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kirill.nagaev.98

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Service - Manual

BM 2000/60-2
BM 2000/60-2_PB
S/N 821 836 26 1001 ....
S/N 821 836 31 1001 ....

Cold Milling Machine

Catalogue number.
008 917 69 03/2012
Table of Contents

General 9
1.1 Introduction 10
1.2 Safety regulations 11
1.3 General repair instructions 15
1.4 Tightening torques 25
Technical data 29
2.1 Technical data 30
Maintenance 37
3.1 General notes on maintenance 38
3.2 Fuels and lubricants 39
3.3 Table of fuels and lubricants 41
3.4 Running-in instructions 42
3.5 Maintenance table 43
Fundamental electrics 47
4.1 Understanding wiring diagrams 48
4.2 Terminal designations in wiring diagram 55
4.3 Identification of switch blocks in the wiring diagram 57
4.4 Battery ground and analog ground 58
4.5 Processor signals 58
4.6 Current and voltage 59
4.7 Pulse Width Modulation (PWM) 61
4.8 Characteristic of PWM solenoid valves 63
4.9 Resistance 64
4.10 Series / parallel connection 66
4.11 Ohm's law 68
4.12 Electrical energy 68
4.13 Formula diagram 69
4.14 Metrology 70
4.15 Diodes, relays, fuses 74
4.16 Inductive proximity switches 77
4.17 Plug connectors 78
4.18 Magnetic coil plug 79
4.19 Deutsch plug, series DT and DTM 81
4.20 Plugs and terminals in spring clamping technology 85
4.21 Inductive proximity switches 89
4.22 Batteries 90
4.23 Battery maintenance 94
4.24 Starting with jump wires 95
4.25 Generator 97
4.26 Generator repair 102
4.27 Electric starter 106
4.28 Repair of starter 112
Electrics 117
5.1 Component overview 118
5.2 Control panel, left (B17), middle (B18), right (B19) 121
5.3 Control panel front right (B9) 123

008 917 69 BOMAG 3

Documentation
For the BOMAG machines described in this manual
the following documentation is additionally available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Wiring diagram*
4 Hydraulic diagram*
5 Service Information

Use only genuine BOMAG spare parts.

Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
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
* The applicable documents valid at the date of print-
ing are part of this manual.

10 BOMAG 008 917 69

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.

008 917 69 BOMAG 11

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.

12 BOMAG 008 917 69

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.

008 917 69 BOMAG 13

1.2 Safety regulations

Engine 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
Danger
!
machine and thereby impair the active and/or pas-
Do not work on the fuel system while the engine is sive driving safety. The manufacturer explicitly ex-
running. (Danger to life!) cludes any liability for damage caused by the use of
non-original parts or accessories.
Once the engine has stopped wait approx. 1 min-
utes for the system to depressurize. The systems l Unauthorized changes to the machine are prohibit-
are under high pressure. (Danger to life!) ed for safety reasons.
Keep out of the danger zone during the initial test l
Do not perform any cleaning work while the engine
rung. Danger caused by high pressure in case of is running.
leaks. (Danger to life!) l If tests on the articulated joint need to be performed
When performing work on the fuel system make with the engine running, do not stand in the articu-
sure that the engine cannot be started uninten- lation area of the machine (danger of crushing!).
tionally during repair work. (Danger to life!) l If tests must be performed with the engine running
l Maintenance and cleaning work on the engine must do not touch rotating parts of the engine (danger of
only be performed with the engine stopped and injury!).
cooled down. Make sure that the electric system is l Always ensure an adequate supply of fresh air
switched off and sufficiently secured against being
when starting in closed rooms. Exhaust gases are
switched on again (e.g. pull off ignition key, attach a
highly dangerous!
warning label).
l
Refuel only with the engine shut down. Ensure strict
l Observe the accident prevention regulations for
cleanliness and do not spill any fuel.
electric systems (e.g. -VDE-0100/-0101/-0104/-
0105 Electric precautions against dangerous con- l
Always ensure an adequate supply of fresh air
tact voltages). when refuelling in closed rooms.
l Cover all electric components properly before wet l
Dispose of used filters in accordance with applica-
cleaning. ble environmental regulations.
l
When performing repair and maintenance work col-
Battery lect oils and fuels in suitable containers and dispose
l Always wear goggles and protective clothing to of in compliance with applicable environmental reg-
service or clean batteries! Battery acid can cause ulations.
severe injury by cauterization when coming in con- l
Do not heat up oils higher than 160 °C because they
tact with skin. may ignite.
l Work only well ventilated rooms (formation of oxy- l
Wipe off spilled or overflown oil using suitable
hydrogen gas). cleaning means and dispose of in accordance with
l Do not lean over the battery while it is under load, applicable environmental regulations.
being charged or tested (danger of explosion). l Dispose of old batteries according to applicable en-
l Keep ignition sources away from the battery. Burn- vironmental regulations.
ing cigarettes, flames or sparks can cause explo-
sion of the battery
l
There is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature! Allow
l Use battery chargers etc. only in strict compliance engine and hydraulic system to cool down to a suf-
with the operating instructions. ficient level.
l After an accident with acid flush the skin with a suf- l Do not exceed the max. permissible tire pressure.
ficient amount of water and seek medical advice.
l Do not allow children access to batteries.
l When mixing battery fluid always pour acid into wa-
ter, never vice-versa.

Special safety regulations

l Use only genuine BOMAG spare parts for repair
and maintenance work. Genuine spare parts and
original accessories were specially developed, test-
ed and approved for the machine.

14 BOMAG 008 917 69

General repair instructions 1.3
General Electrics
1.3 General repair instructions

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

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

008 917 69 BOMAG 15

1.3 General repair instructions

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.

16 BOMAG 008 917 69

General repair instructions 1.3
Generator Starter motor
Before removing the generator you must disconnect So-called jump starting (using an additional external
the ground cable from the minus pole of the battery battery) without the battery connected is dangerous.
while the ignition is switched off. Do not disconnect When disconnecting the cables from the poles high in-
the generator while the engine is running, because ductivities (arcs, voltage peaks) may occur and de-
this may cause extremely high voltage peaks in the stroy the electrical installation.
vehicle wiring system ("Load Dump"), which could For purposes like e.g. purging the fuel systems, start-
possibly damage control units, radios or other elec- ers may be operated for maximum 1 minute without
tronic equipment. interruption. Then you should wait for at least 30 min-
When disassembling the battery cable, the B+-nut un- utes (cooling down) until trying again. During the 1
derneath on the generator side may also be loosened. minute starting period this process should not be inter-
This nut must in this case be retightened. rupted.
When connecting e.g. the battery cable to the terminal Starter motors must not be cleaned with high pressure
of the generator you must make sure that the polarity steam cleaning equipment.
is correct (generator B+ to the + pole of the battery). The contacts on starter terminals 30, 45, 50 must be
Mixing up the polarities by mistake causes short cir- protected against unintended shorting (jump protec-
cuit and damage to the rectifier elements - the gener- tion).
ator will be out of function.
When replacing the starter the ring gear on the engine
The generator can only be operated with the battery flywheel must be checked for damage and its number
connected. Under special conditions emergency op- of teeth - if necessary replace the ring gear.
eration without battery is permitted, the lifetime of the
generator is in such cases especially limited. Always disconnect the battery before starting assem-
bly work in the starter area of the engine or on the
Plus and minus cables must be disconnected during starter itself.
rapid charging of the battery or electric welding on the
vehicle.
When cleaning the generator with a steam or water jet
make sure not to direct the steam or water jet directly
on or into the generator openings or ball bearings. Af-
ter cleaning the generator should be operated for
about 1 - 2 minutes to remove any deposits of water
from the generator.

008 917 69 BOMAG 17

1.3 General repair instructions

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.

18 BOMAG 008 917 69

General repair instructions 1.3
Fuel hoses Gaskets and mating surfaces
Leaking sealing faces can mostly be traced back to in-
correct assembly of seals and gaskets.
l Before assembling a new seal or gasket make sure
that the sealing surface is free of pitting, flutes, cor-
rosion or other damage.
l Inappropriately stored or handled seals (e.g. hang-
ing from hooks or nails) must under no circumstanc-
es be used.
l Assemble seals and gaskets only with sealing com-
pound, grease or oil, if this is specifically specified
Fig. 1 in the repair instructions.
l If necessary remove any old sealing compound be-
! Caution fore assembling. For this purpose do not use any
tools that could damage the sealing surfaces.
All fuel hoses have two layers of material, a rein-
forced rubber coating outside and an internal Vi- l Sealing compound must be applied thin and evenly
ton hose. If a fuel hose has come loose one must on the corresponding surfaces; take care that the
make absolutely sure that the internal Viton layer compound does not enter into oil galleries or blind
has not been separated from the reinforced outer threaded bores.
layer. In case of a separation the hose needs to be l
Examine the contact faces for scratches and burrs,
replaced. remove these with a fine file or an oilstone; take
care that no grinding dust and dirt enters into
tapped bores or enclosed components.
l
Blow out lines, ducts and gaps with compressed air,
replace any O-rings and seals that have been dis-
lodged by the compressed air.

Assembly of radial seals

Fig. 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-

008 917 69 BOMAG 19

1.3 General repair instructions

able, you should use a plastic tube or adhesive tape Feather keys and keyways
to prevent the sealing lip from being damaged.
l Lubricate the outer rim (arrow 3 (Fig. 2)) of the seal Caution
!
and press it flat on the housing seat.
Feather keys may only be reused if they are free of
damage.

Fig. 3
l
Press or knock the seal into the housing, until it is
flush with the housing surface.

i Note
Fig. 4
If possible, use a "bell" (1 (Fig. 3)), to make sure that
the seal will not skew. In some cases it may be ad-
l Clean and thoroughly examine the feather key.
visable to assemble the seal into the housing first, be- l Deburr and thoroughly clean the edges of the key-
fore sliding it over the shaft. Under no circumstances way with a fine file before reassembling.
should the full weight of the shaft rest on the seal.
If you have no proper service tools at hand, use a suit-
able drift punch with a diameter which is about 0,4 mm
smaller than the outer diameter of the seal. Use VERY
LIGHT blows with the hammer if no press is available.

20 BOMAG 008 917 69

General repair instructions 1.3
Ball and roller bearings l Check shaft and bearing housing for discolouration
or other signs of movement between ball or roller
bearing and seats.
!Caution
l Make sure that shaft and housing are free of burrs
Ball and roller bearings may only be reused if they
before assembling the ball or roller bearing.
are free of damage and do not show any signs of
wear. l Always mark the individual parts of separable ball or
roller bearings (e.g. taper roller bearings) to enable
correct reassembling. Never assemble the rollers to
an outer race that has already been used, replace
the complete ball or roller bearing instead.

Fig. 6

!Caution
When assembling the ball or roller bearing to the
shaft load must only be applied to the inner race 1
(Fig. 6).
When fitting the bearing into the housing load
must only be applied to the outer race (2).

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.

008 917 69 BOMAG 21

1.3 General repair instructions

Screws and nuts Strength classes, metric screws

The strength classes (from 3.6 to 12.9) are specified
Tightening torque
for all strength classes from a nominal diameter of
5mm. The corresponding identification can be found
!Caution where allowed for by the shape of the screw.
Tighten nuts or screws with the tightening tor-
ques specified in the following tables of tighten-
ing torques. Tightening torques deviating from
the ones in the table are specially mentioned in
the repair instructions.
Damaged screws must under no circumstances
be used any longer. Recutting threads with thread
cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or cor-
roded thread pitches can cause incorrect torque
value readings.
Self-locking nuts must generally be replaced after
disassembly.
The use of screws with too high strength can
cause damage!
l Nut of a higher strength can generally be used in-
stead of nuts of a lower strength classification.
l When checking or retightening screw joints to the
specified tightening torque you should first relieve
Fig. 7 Identification of screws
by a quarter turn and then tighten to the correct
torque. Example: A screw is identified with 12.9.
l Before tightening you should lightly oil the thread, in The first number corresponds with 1/100 of the nomi-
order to ensure low friction movement. The same nal tensile strength (minimum tensile strength) in N/
applies for self-locking nuts. mm2.
l Make sure that no oil or grease will enter into blind l
The nominal tensile strength is 12 X 100 N/mm2 =
tapped bores. The hydraulic power generated when 1200 N/mm2.
turning in the screw could cause breakage of the ef-
fected part. The second number specifies 10-times the ration be-
tween lower yield point and nominal tensile strength
(yield point ratio).

i Note
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas-
tic deformation).
When exceeding the upper yield point the material will
not restore its original shape after being relieved.
l The lower tensile strength is 9/10 X 1200 N/mm2 =
1080 N/mm2.

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

22 BOMAG 008 917 69

General repair instructions 1.3
Strength classes of metric nuts Identification in clock system
Nuts are differentiated by three load groups. Each
load group has a special designation system for the
strength class assigned, so that the load group can be
clearly identified.

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

6, 8, 10, 12)

Fig. 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.
Fig. 8 Identification of nuts l
The strength class is identified by a dash (b).
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
6 6.8
8 8.8
9 9.8
10 10.8
12 12.8

Nuts for screw joints with limited load factor (04,

05)
The preceding "0" indicates that, due to their low
height, nuts 2 (Fig. 8) in this group are only able to
withstand the force of a screw to a limited extent.
Nut height below 0,8 d (d = nominal dimension).

Nuts for screw joints without specified load factor

(11H, 14H, 17H, 22H)
This standard contains strength classes (hardness
classes) for nuts 3 (Fig. 8), for which no load values
can be specified, e.g. because of their shape and di-
mensions, but which can only be classified by their
hardness.
Nut height below 0,5 d (d = nominal dimension).

008 917 69 BOMAG 23

1.3 General repair instructions

Identification of UNF-threads 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.
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 008 917 69

Tightening torques 1.4
The values specified in the table apply for screws:
1.4 Tightening torques

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

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

Tightening torques for screws with metric unified thread*

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

Tightening torques for screws with metric unified fine thread*

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  tot. = 0,14

008 917 69 BOMAG 25

1.4 Tightening torques

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  tot. = 0,14
** These values result in a 90% utilization of the yield point

26 BOMAG 008 917 69

Tightening torques 1.4
The values specified in the table apply for screws:
l black oiled
l with surface protection A4C
l with surface protection DACROMET

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

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

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  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

008 917 69 BOMAG 27

1.4 Tightening torques

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  tot. = 0,14

28 BOMAG 008 917 69

2 Technical data

008 917 69 BOMAG 29

2.1 Technical data

Fig. 12

Dimensions in A B B2 H H2 H3 K L L1
mm
BM 2000/60 4720 2500 1870 2960 3990 4500 1120 14900 12000

* BM 2000/60

Weights
Operating weight (CECE) kg 30300
Basic weight kg 28100
Max. operating weight kg 32500

Rotor
Milling depth mm 0-320
Milling width mm 2000
Diameter mm 1070
Number of teeth Pieces 168
Milling line distance mm 15
Rated speed rpm 108
Power per cutter kW 2.62

Travel characteristics
Working speed m/min 0 - 40
Travel speed km/h 0-5
Max perm. inclination % 100
Max perm. slope % 9
Inner track radius m 2.1

Drive
Engine manufacturer Deutz
Type TCD 2015
Cooling Water
Number of cylinders 8V
Rated power ISO 3046 kW(HP) 440 (600)
Rated speed rpm 1900
Fuel Diesel

Crawler tracks
Dimensions LxWxH front mm 1700x300x640
Dimensions LxWxH rear mm 1700x300x640

30 BOMAG 008 917 69

Technical data 2.1
*
BM 2000/60

Electric system
Voltage V 24
Batteries (2) Ah 2x155
Generator A 80

Conveyor system
Belt width, gathering belt mm 800x2400
Belt width, loading belt mm 800x7600

Filling capacities
Diesel fuel l 1200
Hydraulic oil l 230
Water l 3500
* The right for technical modifications remains reserved

008 917 69 BOMAG 31

2.1 Technical data

Additional engine data

Combustion principle 4-stroke diesel
Idle speed rpm 715 - 745
Top speed rpm 1970 - 2020

HYDRAULIC PUMPS
Travel pump
Manufacturer Bosch-Rexroth
Type A4VG
Quantity 1
System Axial piston variable displacement
pump
Displacement cm3/rev 71
Max. flow capacity l/min 234
Maximum pressure bar 410 - 430
Charge pressure bar 25 - 31
High pressure limitation bar 450

Service pump
Manufacturer Bosch-Rexroth
Type A10VO
Quantity 1
System Axial piston variable displacement
pump
Displacement cm3/rev 45
Max. flow capacity l/min 117
Working pressure on main valve block bar 190 - 210
Maximum pressure bar 230 - 250
High pressure limitation bar 350
Press down back door bar 5-9
Press down break door bar 3-7
Lift side doors bar 90 - 110
Press down side doors bar 30
Activate clutch bar 44 - 46
Pressure to tension the milling drum V-belt bar 33 - 37
Clutch speed rpm 790 - 810
Extend front left column by 200mm sec 7.0 - 8.0
Extend front right column by 200mm sec 7.0 - 8.0
Retract front left column by 200mm sec 7.0 - 8.0
Retract front right column by 200mm sec 7.0 - 8.0
Extend rear columns by 200mm sec 6.5 - 7.5
Retract rear columns by 200mm sec 6.5 - 7.5

Conveyor belt pump

Manufacturer Bosch-Rexroth
Type A10VG
Quantity 1
System Axial piston variable displacement
pump
Displacement cm3/rev 45
Max. flow capacity l/min 152
Maximum pressure bar 260 - 280
Charge pressure bar 25 - 31
High pressure limitation bar 350

Fan pump
Manufacturer Sauer Danfoss

32 BOMAG 008 917 69

Technical data 2.1
Type SNP3
Quantity 1
System Gear
Displacement cm3/rev 44
Max. flow capacity l/min 55
Maximum pressure bar 190 - 210
High pressure limitation bar 270

Pump high pressure cleaner

Manufacturer Neron International
Type HWB 250
Quantity 1
System Axial piston

Pump sprinkling water

Manufacturer Hypro Pumps
Type 9303C-HM2C
Quantity 1
System Centrifugal
Minimum flow rate l/min/nozzle 1.6 - 1.8
Maximum flow rate l/min/nozzle 2.4 - 2.6

HYDRAULIC MOTORS
Travel motors
Manufacturer Bosch-Rexroth
Type A6VE
Quantity 4
System Plug-in variable displacement mo-
tors
Maximum displacement cm3/rev 0
Minimum displacement cm3/rev 28
Nominal pressure bar 400
Top pressure bar 450

Conveyor belt motor (short and long belt)

Manufacturer Sauer Danfoss
Type OMT 400
Quantity 2
System Orbital
Displacement cm3/U 411
Maximum pressure bar 300
Nominal pressure bar 210
Maximum speed rpm 305 - 345

Fan motor
Manufacturer Bosch-Rexroth
Type A2FM
System Fixed displacement motor
Displacement cm3/U 56
Maximum pressure bar 450
Nominal pressure bar 400
Lower speed (normal temperature  high temp.) rpm 365 - 465  770 - 870
Upper speed (normal temperature  high temp.) rpm 1400 - 1600  2040 - 2140

Motor for water filling

Manufacturer
Type PLM 20.8S0

008 917 69 BOMAG 33

2.1 Technical data

GEARBOX
Travel gear
Manufacturer Bonfiglioli
Type 705C3H
Quantity 4
Reduction ratio 1:80
Continuous torque Nm 6000
Brake: Brake torque Nm 180 - 220
minimum brake release pressure bar 15

OTHER COMPONENTS
Electric pump for hydraulic auxiliary drive
Manufacturer C.F.R. S.r.l.
Type Electro-hydraulic pump
Quantity 1
Maximum pressure bar 185 - 200

34 BOMAG 008 917 69

Technical data 2.1
The following noise and vibration data acc. to

- EC Machine Regulation edition 2006/42/EC

- the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC

- Vibration Protection Regulation 2002/44/EC

were determined during conditions typical for this type of equipment and by application of harmonized
standards.

During operation these values may vary because of the existing operating conditions.

Noise value
Sound pressure level on the place of the operator:
LpA = 92 dB(A), determined acc. to ISO 11204 and EN 500

Guaranteed sound power level:

LWA = 114 dB(A), determined acc. to ISO 3744 and EN 500

! Danger
Wear your personal noise protection means (ear defenders) before starting operation.

Vibration value
Vibration of the entire body (driver’s seat)
The weighted effective acceleration value determined acc. to ISO 7096, is  0.5 m/s2.

Hand-arm vibration values

The weighted effective acceleration value, determined acc. to EN 500/ISO 5349, is  2.5 m/s2.

008 917 69 BOMAG 35

2.1 Technical data

36 BOMAG 008 917 69

3 Maintenance

008 917 69 BOMAG 37

3.1 General notes on maintenance

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

38 BOMAG 008 917 69

Fuels and lubricants 3.2
3.2 Fuels and lubricants pecially at ambient temperatures below -20 °C and
when working at altitudes of 1500 m and more.

Engine oil Diesel fuel specifications: With respect to the percent-

age (ppm) of sulphur the fuel used in the engine must
Quality comply with all relevant exhaust emission regulations
in the are of use of the engine.
Lubrication oils are classified according to their per-
formance and quality class. Oils according to other It is highly recommended to use a fuel with a sulphur
comparable specifications may be used. content of less than 0,10 % (1000 ppm).
Only engine oils of API*-classification CF and CI-4 When using a diesel fuel with a high sulphur content
must be used in connection with low sulphur fuel (< of 0.50 % (5000 ppm) to 1.0 % (10.000 ppm), the en-
0.05 %). gine oil change intervals must behalved.

Caution
! ! Caution
Engine oils of API-classification CF-4, CG-4 and Do not use any fuels with a sulphur content of
CH-4 must not be used. more than 1,0 % (10000 ppm).

Oil viscosity It is recommended to use diesel fuel that complies

with the specifications EN590 or ASTM D975.
Multi-purpose oils should be generally used.
Diesel fuel with the designation no. 2-D is a destillate
Since lubrication oil changes its viscosity with the tem-
fuel with low volatility, which is especially suitable for
perature, the ambient temperature at the operating lo-
industrial engines and heavy-duty commercial vehi-
cation of the engine is of utmost importance when
cles (SAE J313 JUN87).
choosing the viscosity class (SAE-class) .
As an alternative to no. 2-D you may also use diesel
Optimal operating conditions can be achieved by us-
fuel no. 2-D S500 or S15; with ambient temperatures
ing the following oil viscosity chart as a reference.
below -10 °C the diesel fuel no. 1-D S500 or S15
should be used fir no. 1-D.
Ambient temperature Viscosity The fuel level should always be topped up in due time
so that the fuel tank is never run dry, as otherwise filter
SAE 30 and injection lines need to be bled.
over 25 °C! SAE 10W-30
Winter fuel
SAE 15W-40

SAE 20 ! Danger
0°C to 25°C SAE 10W-30 Fire hazard!
SAE 15W-40 Diesel fuels must never be mixed with gasoline.
below 0 °C SAE 10 For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At very
SAE 10W-30
low temperatures disturbing paraffin separation can
SAE 15W-40 also be expected when using winter diesel fuel.

Oil change intervals Coolant

The longest permissible time a lubrication oil should
Always use a mixture of anti-freeze agent and clean,
remain in an engine is 1 year.
dehardened water with a mixing ratio of 1:1.
If the 500 operating hours are not reached over a pe-
Under particularly extreme temperature conditions
riod of 1 year, the oil change should be performed at
you should consult the service representation of the
least once per year, irrespective of the operating
engine manufacturer with respect to the anti-freeze
hours reached.
agent to be used.
There are various types of anti-freeze agents availa-
Fuels ble. For this engine you should use ethylene glycol.
Quality Before filling in the coolant mixed with anti-freeze
Cetan index number: The recommended minimum in- agent the radiator must be flushed with clean water.
dex number for the Cetan value is 45. A Cetan index This procedure should be repeated two to three times
number higher than 50 should preferably be used, es- to clean the inside of radiator and engine block.

* American Petroleum Institute

008 917 69 BOMAG 39

3.2 Fuels and lubricants

Mixing the anti-freeze agent: Prepare a mixture of

50 % anti-freeze agent and 50 % low mineral, clean
water. Stirr well before filling it into the radiator. The
method for mixing water and anti-freeze agent de-
pends on the brand of the anti-freeze agent. In this re-
spect see standard SAE J1034 and also the standard
SAE J814c.
Add anti-freeze agent: If the coolant level drops be-
cause of evaporation,only clean water is to be used
for topping up. In case of leakages you must always
fill in anti-freeze agents of the same brand and the
same mixing ratio.

! Caution
Do not mix different coolants and additives of any
other kind.
Do not use any radiator cleaning agent after the anti-
freeze agent has been mixed in. The anti-freeze agent
also contains a corrosion protection agent. If this mix-
es with cleaning agent it may cause the development
of sludge, which could damage the cooling system.

Anti-freeze concentration
50% = -37 °C

Environment
Coolant must be disposed of environmentally.

Mineral oil based hydraulic oil

The hydraulic system is operated with hydraulic oil HV
46 (ISO) with a kinematic Viskosität von 46 mm2/s bei
40 °C und 8 mm2/s bei 100 °C betrieben. For topping
up or for oil changes use only high-quality hydraulic
oil, type HVLP according to DIN 51524, part 3, or hy-
draulic oils type HV according to ISO 6743/3. The vis-
cosity index (VI) should be at least 150 (observe
information of manufacturer).

Gear oil
Quality
For the gearboxes use only multi-purpose gear oils of
API-GL5-class, SAE 80W- 90.
This is a hypoid lubricant of highest quality class for
extremely loaded transmissions.
The additives in this oil ensure low wear lubrication
under all operating conditions.

Lubrication grease
For lubrication use only EP-high pressure grease, lith-
ium saponified (NLGI 3).

40 BOMAG 008 917 69

Table of fuels and lubricants 3.3
3.3 Table of fuels and lubricants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level marks

Engine Engine oil SAE 10 W-40 ACEA: E4-99/E6-04 or approx. 47 litres incl. oil fil-
ter

Fuel

Diesel Winter diesel fuel approx. 1200 litres

Hydraulic system Hydraulic oil (ISO), HLP 46 approx. 230 litres

Milling drum drive reduc- Gear oil on basis of POLY-ETHYLEN-GLYCOL acc. approx. 18 litres
tion gear to DIN 51502 or gear oil on basis of POLY-ALPHA-
OLEFIN (PAO) acc. to DIN 51517-3G of viscosity
class ISO VG 220.

Milling drum bearings Gear oil on basis of POLY-ETHYLEN-GLYCOL acc. approx. 1 litres
to DIN 51502 or gear oil on basis of POLY-ALPHA-
OLEFIN (PAO) acc. to DIN 51517-3G of viscosity
class ISO VG 220.

Transfer case Gear oil SAE 90, API GL5 approx. 3,5 litres

Crawler track drive gear Gear oil SAE 90, API GL5 approx. 4 x 1.3 litres

Engine cooling system Water and cooling system protection agent approx. 100 litres

Milling drum Water and cooling system protection agent approx. 355 litres

Lubrication points: High pressure, lithium saponified EP NLGI 2) as required

Loading belt, supporting
rollers, swinging fork
Gathering belt, supporting
rollers
Steering linkage front and
rear
Steering linkage, front and
rear crawler tracks
Bushings of the 4 posts
Milling drum bearing

Lubrication points: High pressure, lithium saponified EP NLGI 3 25 g every 250 operating
Clutch, milling drive BOMAG part-no.: 00996009 hours

Water tank, spray system Water approx. 3300 litres

008 917 69 BOMAG 41

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 engine V-belts

After 50 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 Change engine oil and filter
l Oil change in milling drum reduction gear
l Oil change milling drum bearings
l Change the oil in the transfer box.

every 250 oper. hours
No. Maintenance work Comment

as required
5.46 Service the combustion air filter min. 1x per X
year 
Safety car-
tridge at least
every 2 years
5.47 Clean water tank and water filter X
5.48 Water spray system, maintenance in X
case of frost
5.49 Clean the pressure cleaner water filter X
5.50 Tightening torques X
5.51 Engine conservation X
* Oil change intervals depend on quality of oil and fuel (sulphur content)
** Also in case of repair in the hydraulic system.
*** Also after 500 operating hours

008 917 69 BOMAG 45

3.5 Maintenance table

46 BOMAG 008 917 69

4 Fundamental electrics

008 917 69 BOMAG 47

4.1 Understanding wiring diagrams

Electric circuit diagrams are graphic presentations of control logical conditions in the electric system. They do
not contain any information on the type of wiring, their purpose is solely the clarification of control logics.
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system.
This plan provides the following information:
l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses,
switches, consumers, relays, ...
l The sequence in which current flows through the individual elements in the electric circuit.
l Connections between the examined, faulty electric circuit and other circuits in the vehicle wiring system.
l Pin assignment of plug-and-socket connections.

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

Fig. 1 Table of contents, page 1.1

48 BOMAG 008 917 69

Understanding wiring diagrams 4.1
Layout
Example operating console rear left, B3:
The operating console can be found on the following pages in the wiring diagram:
201.2.2 = Page 201.2, current path 2
214.1.0 = Page 214.1, current path 0
226.8.1 = Page 226.8, current path 0
236.1.0 = Page 236.1, current path 0

0 1 2 3 4 5 6 7 8 9

B3
201.2.2
214.1.0
226.8.1
236.1.0
B8
LEFT
REAR 201.2.1
BOX 202.0
226.5.1
234.1.1
240.4
B5 266.0
201.2.4
LEFT
202.2
FRONT
226.4.1
BOX
226.7.1
264.5.1
266.2
LEFT
REAR
BOX

B1
264.6.6
STEER
ADJUST

B6
B2 201.2.8 B7 B9 B10
202.7
214.3.2 226.4.6 170.7 201.2.5 246.7
BACK 226.7.4 200.1.3 202.5 250.2
DOOR 264.5.6 214.3.5 226.5.3 EMERGENCY
BOX 266.6 BACK 234.1.6 BOX
DASH 238.8.6
RIGHT 266.4
REAR PANEL
BOX RIGHT
FRONT
BOX
B4
201.2.7
214.1.5
226.8.3
236.1.4
RIGHT
REAR
BOX

1.6 100.1

Design.: Zuccarino Luca

BM/60-2 LAYOUT D: DE012009 pag. 100
date: 29.Apr.2010 DISPOSIZIONE

Resp.USER: ING.ZANIBONI

Fig. 2 Layout page 100

Current paths
The pages of a circuit diagram are sub-divided into current paths (Fig. 3) (0 ..... 9).

Fig. 3 Current paths

008 917 69 BOMAG 49

4.1 Understanding wiring diagrams

Function groups
On the individual pages the electric circuits are combined to function groups.
The individual current paths must be read as follows:
l From top (plus potential) to bottom (minus potential).
l From left to right.
l From function group to function group.
l Via cross references for potentials and relays.

0 1 2 3 4 5 6 7 8 9

B13
100.1.1
BATTERY
BAT-50A /180.2
COMPARTMENT

BAT-EME /246.7

BAT-150A /250.2

PREHEAT /170.4.8

B21
FUSES
BOX

F1 F2 F3 F4
80A 25A 150A 80A
MAIN EMERGENCY EMERGENCY PREHEAT
PUMP

STARTER /170.5.2

G1
BATTERY
-

G2
BATTERY
-

3
C3
MANUAL 4
SWITCH

NEG-ENGINE /170.5.2

NEG /180.2

GND

118 170

Design.: Zuccarino Luca

BM/60-2 BATTERY COMPARTMENT D: DE012009 pag. 150
date: 29.Apr.2010 VANO BATTERIA

Resp.USER: ING.ZANIBONI

Fig. 4 Function group, page 150

Potential cross references

Potential cross references serve the purpose of tracking signals, which are transmitted from one function group
to another.

Example:
Potential "STARTER/170.5.2" on page 150, continues on page 170.5 in current path 2.

50 BOMAG 008 917 69

Understanding wiring diagrams 4.1
Relay cross references
Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing
contacts.

Fig. 5 Relay cross references

Apart from this there is a contact plan under each contactor coil providing information about the contact types of
a relay and where these appear in the wiring diagram.

Example:
The coil of relay (K2) is located on page 2 in current path 2.
The contact pictogram under the relay specifies that a normally open contact with clamps 5 and 9 in current path
3 is triggered.

008 917 69 BOMAG 51

4.1 Understanding wiring diagrams

PLC pages from page 500.1 (Fig. 6)

Here you find representations of the I/O-modules.

0 1 2 3 4 5 6 7 8 9

B17
106.1
LEFT U1
PANEL U1
110.2 X1.1 DI1 UP LEFT COL. 226.1 B17-S7:13 110.2 X2.1 DI9 UP RIGHT COL. 226.1.1 B17-S8:13

X1.2 +VCC 226.2 X2.2 +VCC 226.1.2

X1.3 DI2 DOWN LEFT COL. 226.1 B17-S7:23 X2.3 DI10 DOWN RIGHT COL. 226.1.1 B17-S8:23

X1.4 +VCC 226.3 X2.4 +VCC 226.1.3

X1.5 DI3 MAN LEFT COL. 226.2 B17:NC X2.5 DI11 MAN RIGHT COL. 226.1.2 B17:NC

X1.6 X2.6

X1.7 DI4 AUTO LEFT COL. 226.3 B17:NC X2.7 DI12 AUTO RIGHT COL. 226.1.3 B17:NC

X1.8 X2.8

X1.9 X2.9

X1.10 +VCC 242.2 X2.10 +VCC 212.2

X1.11 DI5 ON WATER SPRAY 242.2 B17-S15:13 X2.11 DI1 ON MILLING DRUM 212.2 B17-S5:13

X1.11 X2.11

X1.12 DI6 OFF WATER SPRAY 242.1 B17-S15:23 X2.12 DI2 OFF MILLING DRUM 212.1 B17-S5:23

X1.12 X2.12

X1.13 X2.13

X1.14 GND 226.4 X2.14 GND 226.1.4

X1.15 DI4 AUTO LEFT COL. LED 226.4 B17:NC X2.15 DO15 AUTO RIGHT COL. LED 226.1.4 B17:NC

X1.15 X2.15

X1.16 X2.16

X1.17 DO8 ON WATER SPRAY LED 242.3 B17-H10:A X2.17 DO16 ON MILLING DRUM LED 212.3 B17-H6:A

X1.17 X2.17

X1.18 GND 242.3 X2.18 GND 212.3

U1
110.2 X3.1 +VCC 204.2

X3.2 GND 204.2

X3.3 +VCC 204.2

X3.4 GND 204.2

X3.5 CAN-L 204.2 B20-XA:16

X3.6 CAN-H 204.3 B20-XA:15

300.7 500.2

Design.: Zuccarino Luca

BM/60-2 PLC D: DE012009 pag. 500.1
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI

Fig. 6 PLC page 500.1

DO ... = Digital output
AO = Analog output
DI ... = Digital input
AI ... = Analog input

Example: Terminal X1.17

DO 08 = In the circuit diagram digital output (LED for water sprinkling system on, B17-H10: terminal A) is
found on page 242 in current path 3 and is located in the operating console B17.

Example: Terminal X2.3

DI 10 = In the circuit diagram digital input (joystick for right column down, B17-S8: terminal 32) is found on
page 226.1 in current path 1 and is located in the operating console B17.

Example: Installation location I/O-module 110U1

l The I/O-module U1 is located in operating console left (B17) on layout page 106 in current path 1

52 BOMAG 008 917 69

Understanding wiring diagrams 4.1

0 1 2 3 4 5 6 7 8 9

B17
106.1
LEFT
PANEL

U1 U2 U3 U4 U5
204.1 204.3 204.5 204.6 204.8
212.1 206.1 206.5.1 264.1 236.1
226.1 206.1.1 214.1 264.1.1 238.1
226.1.1 206.2.1 234.1 264.2.1 264.3.1
242.1 206.3.1 238.1.1 500.4.1 264.4.1
500.1.1 206.4.1 244.1 500.4.1 500.5.1
500.1.1 226.2.1 500.3.1 500.4.5 500.5.1
500.1.5 500.2.1 500.3.1 500.5.5
12 DI
500.2.1 500.3.5
12 DI 4AI 12 DI
500.2.5
4AI 12 DI 4DO 4AI
4DO 12 DI 4AI NODE ID 4 4DO
NODE ID 1 4AI 4DO I/O MODULE NODE ID 5
I/O MODULE 4DO NODE ID 3 I/O MODULE
NODE ID 2 I/O MODULE
I/O MODULE

106.1 112

Design.: Zuccarino Luca

BM/60-2 LEFT PANEL D: DE012009 pag. 110
date: 29.Apr.2010 PANNELLO SINISTRO

Resp.USER: ING.ZANIBONI

Fig. 7 left hand operating console, page 110

The I/O-module (U1) can be found on the following pages of the circuit diagram:
204. 1 = Page 204, current path 1
212. 1 = Page 212, current path 1
226. 1 = Page 226, current path 1
226.1.1 = Page 226.1, current path 1
242. 1 = Page 242, current path 1
500.1.1 = Page 500.1, current path 1
500.1.5 = Page 500.1, current path 5

Module equipment I/O-module 110U1

l 12 (DI) digital inputs
l 4 /(AI) analogue inputs
l 4 (DO) digital outputs

ID-identification*, I/O-module 110U1

l ID-node 01

* Name used to differentiate between the equipment / subscribers connected to a system or between the subscribers exchanging mes-
sage packages.

008 917 69 BOMAG 53

4.1 Understanding wiring diagrams

Component list starting from page 1000

Here you find all components used in alpha-numerical order, related to the name of the component.

0 1 2 3 4 5 6 7 8 9

DISTMACC3.SKO

NOME QUANTITA' PAGINA/COLONNA TESTO FUNZIONALE

NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

B1 0 100. 1 STEER ADJUST

B1-C17 0 264.6. 6 STEER ADJUST
B1-XC17 0 264.6. 6
B2 0 100. 1 BACK DOOR BOX
B2-S1 0 214.3. 3 BACK DOOR
B3 0 100. 2 LEFT REAR BOX
B3-GND 0 201.2. 3
B3-GND 0 214.1. 4
B3-GND 0 226.8. 1
B3-GND 0 236.1. 2
B3-H1 0 214.1. 4 BACK DOOR
B3-H2 0 236.1. 2 UP LEFT SIDE DOOR
B3-S2 0 214.1. 1 BACK DOOR
B3-S3 0 214.1. 2 BACK DOOR
B3-S4 0 236.1. 1 LEFT SIDE DOOR
B3-XC66 0 226.8. 1 LEV.SYSTEM
B4 0 100. 2 RIGHT REAR BOX
B4-GND 0 201.2. 7
B4-GND 0 214.1. 9
B4-GND 0 226.8. 4
B4-GND 0 236.1. 6
B4-H1 0 214.1. 9 BACK DOOR
B4-H2 0 236.1. 6 UP RIGHT SIDE DOOR
B4-S2 0 214.1. 6 BACK DOOR
B4-S3 0 214.1. 7 BACK DOOR
B4-S4 0 236.1. 5 RIGHT SIDE DOOR
B4-XC67 0 226.8. 4 LEV.SYSTEM
B5 0 100. 2 LEFT REAR BOX
B5-GND 0 201.2. 4
B5-GND 0 226.7. 1
B5-S1 0 202. 3 EMERGENCY PUSHBUTTON
B5-S3 0 264.5. 2 REAR STEERING
B5-S4 0 266. 3 HORN
B5-S5 0 226.4. 2 REARS COLUMNS
B5-XC23 0 226.7. 1 COLUMNS
B6 0 100. 2 RIGHT REAR BOX
B6-GND 0 201.2. 9
B6-GND 0 226.7. 4
B6-S1 0 202. 8 EMERGENCY PUSHBUTTON
B6-S3 0 264.5. 7 REAR STEERING

504.4 1001

Design.: Zuccarino Luca

BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1000
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI

Fig. 8 Component list, page 1000

54 BOMAG 008 917 69

Terminal designations in wiring diagram 4.2
4.2 Terminal designations in wiring diagram
l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a
terminal designation. In Germany the designation of the individual connection terminals is determined by the
standard DIN 72552. The following table shows some examples from this DIN standard.

Terminal designation Meaning

15 Switch plus (after battery) : Output of ignition switch

15a Output from dropping resistor to ignition coil and starter

17 Preheating starter switch, preheating

19 Preheating starter switch, starting

30 Battery plus direct

30a Battery changeover relay 12V / 24V, input from battery 2 plus

31 Battery minus direct or ground

31a Battery changeover relay 12V / 24V return line to battery 2 minus
31b Return line to battery minus or ground via switch or relay (switched minus)
31c Battery changeover relay 12V / 24V return line to battery 1 minus

49 Input flasher relay

49a Output flasher relay
49b Flasher relay output 2nd flasher circuit
49c Flasher relay output 3rd flasher circuit

50 Starter, starter control

50a Battery changeover relay, output for starter control

53 Wiper motor input (+)

53a Wiper motor (+) end limit shut down
53b Wiper shunt winding

56 Head light
56a Head light, travel light and travel light control
56b Head lights, dimmed head light
56d Head lights, flash light

57 Parking light for motor cycles (abroad also for cars and trucks)
57a Parking light
57L Parking light left
57R Parking light right

58 Side lights, tail light, number plate light, dashboard light

58b Tail light changeover for single axle trailers
58c Trailer plug for single core wired and trailer fused tail light
58d Adjustable dashboard light, tail light and side light
58L Side light, left
58R Side light, right

61 Generator control

75 Radio, cigarette lighter

76 Loudspeaker

87 Relay contact on breaker and two-way contact, input

008 917 69 BOMAG 55

4.2 Terminal designations in wiring diagram

Terminal designation Meaning

87a Relay contact on breaker and two-way contact, output 1 (breaker side)
87b Relay contact on breaker and two-way contact, output 2
87c Relay contact on breaker and two-way contact, output 3
87z Relay contact on breaker and two-way contact, input 1
87y Relay contact on breaker and two-way contact, input 2
87x Relay contact on breaker and two-way contact, input 3

88 Relay contact for maker

88a Relay contact on maker and two-way contact, (maker side) output 1
88b Relay contact on maker and two-way contact, (maker side) output 2
88c Relay contact on maker and two-way contact, (maker side) output 3
88z Relay contact on maker, input 1
88y Relay contact on maker, input 2
88x Relay contact on maker, input 3

B+ Battery positive
B- Battery minus
D+ Dynamo Plus
D- Dynamo Minus
DF Dynamo field (generator excitation current)
DF1 Dynamo field 1 (generator excitation current)
DF2 Dynamo field 2 (generator excitation current)

56 BOMAG 008 917 69

Identification of switch blocks in the wiring diagram 4.3
4.3 Identification of switch blocks in the wiring diagram

Switches of modular design

l For normally open contacts the contact symbols "_3/_4" are used.
l For normally closed contacts the contact symbols "_1/_2" are used.
In combination with the contact block numbering described above each individual connection is clearly defined.

5 C 6

3 B 4

1 A 2

Travel direction

Fig. 9

Example:
The contact block marked with the "circle" is referred to as "43"/ "44" if it is a normally open contact and "41" /
"42" if it is a normally closed contact.
The contact block marked with "X" is referred to as "23"/ "24" if it is a normally open contact and "21" / "22" if it
is a normally closed contact.
The contact block marked with "Z" is referred to as "13"/ "14" if it is a normally open contact and "11" / "12" if it
is a normally closed contact.
The contact block marked with "Y" is referred to as "53"/ "54" if it is a normally open contact and "51" / "52" if it
is a normally closed contact.

008 917 69 BOMAG 57

4.4 Battery ground and analog ground

4.4 Battery ground and analog 4.5 Processor signals

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

58 BOMAG 008 917 69

Current and voltage 4.6
4.6 Current and voltage The following statements concerning electric volt-
age can be made
electric voltage is the pressure or force applied to
General
l

free electrons.
If one wants to describe electric current, this can most l the electric voltage is the cause of electric current
simply be accomplished by means of a comparison:
l electric voltage is a result of the equalization at-
One simply compares electric current with water. tempt of electric charges.
Voltage is measured with a Voltmeter.
Voltage
Unit, Volt

The electric voltage (U) is measured in Volt (V).

Fig. 1
1 (Fig. 1) Charge
2 Voltage
3 Current
The equalization attempt between different electric
charges is referred to as electric voltage.
Voltage sources have two poles of different charge.
On the one side we have the plus pole with a lack of
electrons, on the opposite side the minus pole with a
surplus of electrons. This electric "pressure" is known
as electric voltage.

Fig. 2
If there is a connection between these two poles a dis-
charge will take place, resulting in the flow of an elec-
tric current.
Plus pole= lack of electrons
Minus pole = excess of electrons

008 917 69 BOMAG 59

4.6 Current and voltage

Current Types of current

Electric current generally describes the directed Direct current (D.C.)
movement of charge carriers.
l The charge carriers may either be electrons or ions.
l Electric current can only flow if there is a sufficient
amount of free moving charge carriers.
l The higher the number of electrons flowing through
a conductor per second, the higher the amperage.
Current is measured with an ammeter.

Unit, Ampere Fig. 1 Direct current (D.C.)

The electric amperage (I) is measured in Ampere Direct current flows with steady voltage and amper-
(A). age from the plus to the minus pole.
Pure D.C.-voltages are only delivered by accumula-
The technical flow direction is specified from
tors or batteries.
PLUS to MINUS.
The voltage in the vehicle wiring system is no pure
D.C.-voltage. Even without the generator running, but
i Note the consumers switched on, the voltage is not con-
Current actually flows from minus to plus, because the stant, but drops gradually according to the battery
current flow is made up of negatively charged elec- charge condition.
trons.
The internal resistance of the battery also causes per-
But since this was only discovered after the poles of a manent changes in the vehicle voltage, as soon as
current source had already been designated, the as- consumers are switched on or off.
sumption that current flows from plus to minus was
maintained for historic reasons. Alternating current (A.C.)

Circuit

Fig. 2 Alternating current (A.C.)

Fig. 3 Circuit Alternating current not only changes its direction, but
also its amperage.
A simple circuit consists of a current source 1 (Fig. 3),
a consumer (3) and the connecting wiring.
When the circuit is closed, current can flow.
The circuit can be interrupted or closed with a switch
(2).
The system is protected by a fuse (4).

60 BOMAG 008 917 69

Pulse Width Modulation (PWM) 4.7
4.7 Pulse Width Modulation ! Caution
(PWM) PWM-solenoid valves must not be interference
suppressed with suppressor diodes.
Pulse width modulation (PWM)
What does a PWM-output do?
PWM is the abbreviation for Pulse Width Modulation,
frequently also referred to as "Pulse Pause Modula- Digital outputs normally deliver a fixed output voltage,
tion" (PPM). It is used in the field of controls for mobile as soon as they are switched on. The value of the out-
and robust applications, mainly to control proportional put voltage can in this case not be changed. In con-
valves (PWM-valves). trast to this, PWM-outputs divide the voltage into a
quick sequence of many square-wave pulses. The ra-
The following applies:
tio of pulse period "switched on" to pulse period
l The signal voltage cannot be measured. "switched off" determines the effective value of the de-
l The current can be measured. sired output voltage. One refers to the duty cycle (in
percent).

Fig. 1
(Fig. 1)Course of PWM-voltage U and coil current I at
10 % duty cycle The effective coil current Ieff is also
10 %.

Fig. 1
(Fig. 1) Course of PWM-voltage U and coil current I at
50 % duty cycle The effective coil current Ieff is also
50 %.

008 917 69 BOMAG 61

4.7 Pulse Width Modulation (PWM)

Fig. 1
(Fig. 1) Course of PWM-voltage U and coil current I at
100 % duty cycle The effective coil current Ieff is also
100 %.

What does Dither mean?

When a proportional hydraulic valve is triggered, its
spool will not move immediately and at the beginning
it will also not move proportionally to the coil current.
Due to this "Slip-Stick effect" - a kine of "breakaway
torque" - the valve right at the beginning requires a
slightly higher current to be able to move the spool out
of rest position. The same takes place with any other
position change of the valve spool. Especially with
very low actuating speeds this effect becomes appar-
ent by jerky movements.
Engineering tackles this problem by subjecting the
valve spool to an almost insignificant shuttle move-
ment (the dither). The piston thereby permanently per-
forms a shuttle movement and can therefore not
"stick". Even very small position changes now take
place without delay, just like a "flying start".
Advantage: The hydraulic cylinder actuated this way
can be controlled with a much higher sensitivity.
Disadvantage: With dither the valves becomes notice-
ably warmer, because the valve spool is permanently
in action.

62 BOMAG 008 917 69

Characteristic of PWM solenoid valves 4.8
4.8 Characteristic of PWM sole-
noid valves Name Description
X Nominal value input
Typical characteristic of a hydraulic valve XH Max. input value [increments]
XL Min. input value [increments]
YH Max. output value [increments], e.g.:
Valve current [mA] / flow [l/min]
YL Min. output value [increments], e.g.:
Valve current [mA] / flow [l/min]

Example: Current curve for one of the proportion-

al valves, YA25/YB25 (Fig. 3).

Fig. 1
The oil flow only starts when approx. 20% of the coil
current is reached.
At the beginning the oil flow is not linear (Fig. 1).
Fig. 3
X = the current actually made available for
the proportional solenoid valve is 335
mA.
XHV = the max. current for forward travel at
1000 ppt is 620 mA.
XLV = the min. current for forward travel at 1 ppt
is 120 mA.
XLR = the min. current for reverse travel at 1 ppt
is 120 mA.
XHR = the max. current for reverse travel at
1000 ppt is 620 mA.

Fig. 2
Characteristic of the function (Fig. 2).

008 917 69 BOMAG 63

4.9 Resistance

4.9 Resistance l The cleaner the contacts, the better the current.
l The quality of the ground cable is of the same im-
portance as the supply line.
Resistance and voltage drop
While current flows through a conductor the current
Unnecessary resistances
flow is more or less inhibited by the conductor, this in-
hibitation is referred to as Resistance. Unnecessary resistances are frequently caused by
mechanical connections, even clean ones, but mainly
soiled and oxidizes terminals, too thin cables, material
with poor conductivity or bent open cable lugs.

Bad

Fig. 1 Various size resistors

Fig. 1 Screw-type terminals
Each conductor has its specific resistance, which is
characteristic for the corresponding material. A good Copper wires are squashed and thus become faulty.
conductor has a low resistance, a poor conductor has
Better
a high resistance.

Fig. 2 Spring clamps

Connecting clamps for flexible conductors
BOMAG No. 057 565 72
Ampacity up to 20 Amp.
Cable cross-section 0.08 to 2.5 qmm
Fig. 2 Potentiometer, infinitely adjustable resistor
The resistance can only be measured with a Multime-
ter.

Symbol, R

Unit, Ohm 

The electric resistance (R) is measured in Ohm .

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

64 BOMAG 008 917 69

Resistance 4.9
Sometimes the flanks of flat plugs bend open. If these
are closed again with the help of pliers the flanks will
be excessively strained at the bend and will definitely
break sooner or later. It is better to place a small nail
under the bottom of the cable lug before bending.

Fig. 3
In many cases it is better to replace the contact. Soiled
or oxidized contacts should be cleaned with Ballistol
(Fig. 4) and subsequently wetted with copper paste.
Copper paste is a heat resistant grease, which has
been mixed with copper powder. The paste protects
electric contacts against oxidation. Copper paste
keeps water away.

Fig. 5
Hint for practice:
A tool you cannot buy. The pliers were converted, the
nail is permanently present.

Fig. 4 Balistol oil

008 917 69 BOMAG 65

4.10 Series / parallel connection

4.10 Series / parallel connection l In series connection the plus pole of the first battery
must be connected with the minus pole of the sec-
Series connection ond battery.
In a series circuit the resistors (consumers) are lined l The sum of all individual voltages is applied to the
up one after the other and the same current (I) passes free poles.
through each of the consumers However, series con- l The total capacity (Ah) is identical with the capacity
nection of consumers is not suitable in practice, as of the individual battery.
each resistance causes a voltage drop. In the vehicle
wiring system all consumers are designed for the
same vehicle voltage (e.g. 12 Volt).

Fig. 1 Series connection

Current
In series connection the current is identical at every
point.
Itotal = I1 = I2 = I3

Voltage
The sum of all partial voltages is identical with the total
voltage.
Utotal = U1 + U2 + U3

Resistance
The sum of all partial resistances is identical with the
total resistance.
Rtotal = R1 + R2 + R3

Series connection of batteries

Fig. 2
In order to achieve a vehicle voltage of 24 V two bat-
teries of the same type and capacity must be connect-
ed in series mode.

66 BOMAG 008 917 69

Series / parallel connection 4.10
Parallel connection l In parallel connection the plus pole of the first bat-
In parallel connection all resistances (consumers) are tery is connected with the plus pole of the second
connected between feed and return line. battery and the minus pole of the first battery with
the minus pole of the second battery.
l All resistances (consumers) are supplied with the
same voltage.
l Plus and minus poles have the voltage of the single
battery applied.
l Each of the resistances (consumers) draws as
much current as required.
l The total capacity (Ah) is identical with the sum of
all battery capacities.
The disadvantage of a parallel connection becomes
apparent, by equalizing currents flowing between par-
allel batteries, if the batteries have different states of
charging.

Fig. 3 Parallel connection

Current
The total current is the sum of all currents.
Itotal = I1 + I2 + I3

Voltage
The voltage values are identical at every resistance
(consumer).
Utotal = U1 = U2 = U3

Resistance
The total resistance is less than the lowest individual
resistance.

Parallel connection of batteries

Fig. 4
By connecting 2 batteries of same type and capacity
in parallel mode the capacity can be doubled, be-
cause the individual capacities add up to the total ca-
pacity.

008 917 69 BOMAG 67

4.11 Ohm's law

4.11 Ohm's law 4.12 Electrical energy

In a closed electric circuit voltage, current and resist-
ance must always be considered in close relation.
This relation is represented by Ohm's Law.

Fig. 1
In a closed electric circuit current and voltage gener-
ate energy.
Fig. 1 If a current of 1 Ampere flows at a voltage of 1 Volt,
According to this law a voltage of 1V is required to let energy of 1 Watt is produced.
1A (ampere) flow through a conductor with a resist-
Advice
ance of 1 (Ohm ).
By means of this triangle the formula can be easily re-
Advice arranged, the value you are looking form must just be
By means of this triangle the formula can be easily re- blanked off with a finger.
arranged, the value you are looking form must just be
Energy P = I multiplied with U
blanked off with a finger.
Amperage I = P divided by U
Voltage U = I multiplied with R
Voltage U = P divided by I
Resistance R = U divided by I
U = Voltage in Volt
Amperage I = U divided by R
I = Current in Ampere
U = Voltage in Volt
P = Power in Watt
I = Current in Ampere
R = Resistance in OHM 

68 BOMAG 008 917 69

Formula diagram 4.13
4.13 Formula diagram
Description:
l Select the desired value from the inner circle.
l Determine the formula variables in the quarter circle
l Calculate

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

Fig. 1 Formula diagram

Resistance, R Ohm 

Voltage, U Volt

Current, I Ampere

Power, P Watt

008 917 69 BOMAG 69

4.14 Metrology

4.14 Metrology Multimeter

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

Fig. 1 Multimeter
In order to avoid damage:
Fig. 1 Test lamp
l
the range selector switch must be correctly set for
the corresponding measurement.
! Caution l
the test cable must be plugged into the correct
This type of tester must not be used for testing on socket.
electronic components. The high power con- l
the voltage type (AC/DC) must be set.
sumption of the test lamp may destroy electronic l
In case of direct voltage the correct polarity must be
components in the control units.
assured.
Diode test lamp l
the measuring range should be chosen higher at
This instrument is used for simple voltage measure- the beginning of the test.
ments. The test lamp consists of two test points. The l In order to avoid any influence on the circuitry to be
negative measuring cable is connected to ground and measured, the internal resistance of the voltage
the positive measuring cable to the corresponding tester should be as high as possible.
measuring location.

Fig. 2 Diode test lamp

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

70 BOMAG 008 917 69

Metrology 4.14
Resistance and continuity measurement with mul- Voltage and voltage drop measurement with mul-
timeter timeter

Fig. 2
The continuity tester of the multimeter can be used to Fig. 4 Measuring voltage
measure whether there is a connection between 2 l Measurement at the voltage source measures the
measuring points. currently available Voltage.
l The meter is always connected parallel to consum-
er, component or power source.

Fig. 3
The following information should be observed when
measuring resistance and continuity: Fig. 5 Voltage measurement
l The component to be measured must not be con- l
A measurement at the consumer measures the volt-
nected to the power supply during the measure- age drop at this component.
ment.
l At least one side of the component to be measured
must be disconnected from the circuitry, as other-
wise the measuring result may be influenced by
parallel components.
l Polarity is of no significance.

008 917 69 BOMAG 71

4.14 Metrology

Current measurement with the multimeter Clip-on measuring instrument

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

Fig. 6 Measuring current

l The meter is connected in series with the consum-
er. Fig. 1 Clip-on measuring instrument
l During the measurement the current must be able
to flow through the meter, i.e. the electric circuit
must be opened.

Fig. 2
l
For measuring current the individual conductor
must be fully enclosed by the measuring tongs, the
actual measurement takes place without contact.
Fig. 7 Current measurement

Advice
If the electric circuit is difficult to access and the inter-
nal resistance of the consumer is known, the voltage
may also be measured at the consumer.
The current value can then be calculated with the help
of Ohm's law.

72 BOMAG 008 917 69

Metrology 4.14
Magnet tester Power measurement
The electric power of a module within a circuit can be
indirectly determined (calculated) by separate meas-
uring of current and voltage.
However, there are also pure power meters with 4
connections available. The power meter has a electro-
dynamic measuring mechanism. The current circuit
must be opened for measuring. Take care when per-
forming power measurements: Voltage or current path
may already be overloaded during the measurement,
even though the end stop in the meter has not yet
been reached.

Fig. 1 Magnet tester

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

Fig. 2

008 917 69 BOMAG 73

4.15 Diodes, relays, fuses

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

Diodes

Fig. 1
A diode consists of two different semi-conductors,
which are connected by a separating layer. The max.
conducting state current must not be exceeded.
Plus-voltage on diode:
l At 0.6 – 0.7 Volt (silicium diode) the diode becomes
conductive.
Negative voltage on diode:
l The diode does not allow current to pass through.

Fig. 2 Marking of the cathode

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

Fig. 3 Diode circuitry

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

74 BOMAG 008 917 69

Diodes, relays, fuses 4.15
Light emitting diodes Relays

Fig. 1 Relays
Relays are commonly used to realize switching proc-
esses.
Fig. 4 LED
A free-wheeling diode prevents induction voltage from
The light emitting diode, also referred to as LED, is a
flowing back from the coil into the vehicle wiring sys-
semi-conductor diode, which generates (emits) light
tem, which would cause interference with electronic
during operation in forward direction. A semi-conduc-
components (control units).
tor crystal thereby emits a light signal, which is con-
verged or scattered by the lenticular shape of the With the possibility of using breaker - maker contacts
head. Light emitting diodes are available in various the effect of an information can be reversed.
colours, sizes and shapes. They are for this reason
used as signal lamps. This component is constructed
of different semi-conductor crystals, depending on its
colour. It works like any other semi-conductor diode.

Fig. 2 Relay circuitry

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

008 917 69 BOMAG 75

4.15 Diodes, relays, fuses

85 = Ground supply for coil Fuses

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

Fig. 1
Fuses are used to protect lines and equipment against
overloads and short circuit. If the fuse is overloaded
the fusible wire heats up with increasing current, until
it finally melts.

Caution
!

Fuses must not be repaired or bridged.

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

76 BOMAG 008 917 69

Inductive proximity switches 4.16
4.16 Inductive proximity switches NPN circuitry

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

Working principle

Fig. 2
The working principle is based on the principle of the
dampened LC-oscillator. The coil of the oscillation cir-
cuit forms a high-frequency magnetic stray field. Fig. 5

This stray field leaks out from the active area of the Proximity switches are used as breaking or making
proximity switch. If metal or non-ferrous metal enters contacts. Depending on the design the switching dis-
into the response range energy is absorbed. The os- tances are 2 or 4 mm. The maximum amperage is 300
cillator is thus dampened and the resulting change in mA.
current consumption is evaluated. The LED (Fig. 5) lights up, when the initiator has de-
tected metal in its stray field.
PNP circuitry

Fig. 3 PNP circuitry

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

008 917 69 BOMAG 77

4.17 Plug connectors

Duties and requirements
Electric plug connectors must provide a reliable con-
nection between different system components and
thus ensure the safe function of the systems under
any operating condition. There design ensures that
they will withstand the applied loads throughout the
lifetime of the machine.
Examples for these loads are:
l Vibration acceleration
l
Temperature fluctuations, high and low tempera-
tures
l Dampness
l Micro movements of the contact with resulting fric-
tion corrosion.
These loads may increase the transition resistances
of the contacts, up to total interruption. Even the insu-
lation resistances may drop and thus cause short cir-
cuits in neighbouring lines. Electric plug connectors
must therefore have the following properties:
l
Low transition resistances of the conductive parts.
l
High insulation strength between conductive parts
Fig. 6 Circuit diagram, making contact
with different voltage potentials.
The circuit diagram (Fig. 6) shows a proximity switch
l
Excellent leak tightness against water and mois-
with normally open contact. ture.
Brown = voltage supply
Blue = ground supply
Black = switching output
The initiator switches the relay (K05)

78 BOMAG 008 917 69

Magnetic coil plug 4.18
4.18 Magnetic coil plug Assembly of magnetic coil plugs
These instructions are intended to explain the correct
Magnetic coil plug with LED and suppres- installation of the magnetic coil plug. The objective of
sor diode the instructions is the correct installation of the plug
and to avoid malfunctions in the field caused by mois-
The plug is equipped with a polarized function display ture and any related corrosion damage.
and a suppressor diode as protection against over-
voltages.

Fig. 7
The plug is reverse polarity protected, it does not mat-
ter whether Pin1 or Pin 2 is supplied with current, Pin
3 is not used. The LED lights if voltage is applied to the Fig. 10 Solenoid valve plug with pointed cable
solenoid valve.

Fig. 8

Fig. 11
l Connect the plug with the coil connection and press
it firmly onto the connecting housing.

Fig. 9 Switching symbol in circuit diagram

Magnetic coil plug without LED and with-

out supressor diode
The plug has no LED and no suppressor diode as pro-
tection against overvoltages.

008 917 69 BOMAG 79

4.18 Magnetic coil plug

Fig. 12 Fig. 15
l
Fasten the screw with a suitable screwdriver.
! Caution
There should be no gap between plug and sole-
noid coil!

Fig. 13
l
Press the plug firmly on again.

Fig. 16 Correctly installed plug without gap

Fig. 14
l Retighten the screw.

80 BOMAG 008 917 69

Deutsch plug, series DT and DTM 4.19
4.19 Deutsch plug, series DT and DT Series
DTM

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

Fig. 1 DT plug connection

Fig. 17 Crimp connections

Fig. 2 DT Series
Caution
!

Do not crimp more than one lead per pin or per

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

008 917 69 BOMAG 81

4.19 Deutsch plug, series DT and DTM

DT Series
Installing DT contacts

Fig. 4
l Insert the contacts through the rubber grommet until they click into place.
l Insert the orange wedge in direction of arrow.

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

i Note
Use the same method when assembling the socket.

Disassembling DT contacts

Fig. 5
l Pull the orange wedge out with long nose pliers.
l Slightly pull the lead and unlock the interlocking hook with a screw driver.
l Pull the contact out of the socket.

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

82 BOMAG 008 917 69

Deutsch plug, series DT and DTM 4.19
DTM Series

Fig. 6 DTM Series

Fig. 7 Sectional drawing

Installing DTM contacts

Fig. 8
l Insert the contacts through the rubber grommet until they click into place.
l Insert the orange wedge, until it clicks into place.

008 917 69 BOMAG 83

4.19 Deutsch plug, series DT and DTM

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

i Note
Use the same method when assembling the socket.

Removing DTM contacts

Fig. 9
l
Pull the orange wedge (interlock) out with long nose pliers.
l
Slightly pull the lead and unlock the interlocking hook with a screw driver.
l
Pull the contact out of the socket.

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

84 BOMAG 008 917 69

Plugs and terminals in spring clamping technology 4.20
4.20 Plugs and terminals in spring clamping technology

General

Fig. 1

!Caution
The spring clamp technology is not suitable for extra fine conductors. Extra fine conductors can be eas-
ily pulled out of the spring clamp!
Spring clamp technology (Fig. 1) for quick, vibration resistant and maintenance-free connection of all conven-
tional copper conductors (single, multiple or fine stranded) with or without wire and ferrule.

Connecting terminal for quick repairs

Fig. 2 That's how it works

BOMAG part-no.: 057 565 72

The connecting clamp clamps up to 3 or 5 stripped fine conductors of 0.08 mm2 to 4 mm2, single or multiple
strand up to 2.5 mm2. And this even without tools (Fig. 2).

That's how it works

l Strip 9-10 mm of the lead.
l
Open the actuating lever and insert the strand.
l Return the actuating lever to initial position.

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

008 917 69 BOMAG 85

4.20 Plugs and terminals in spring clamping technology

Series clamp

Fig. 3 That's how it works

That's how it works

l Insert a screw driver into the actuating opening until it bottoms.
l Strip 9-10 mm of the lead and insert it into the clamp.
l Pull out the screw driver.

Caution
!

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

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

Fig. 4 Test adapter

86 BOMAG 008 917 69

Plugs and terminals in spring clamping technology 4.20
X-COM System
The X-COM-SYSTEM, a synthesis of plug connector and series clamp, has grown up to a construction kit for
universal system wiring, ever since it was introduced in 1997. All the familiar series clamping functions have thus
become pluggable.

X-COM plug clamp

Fig. 5 That's how it works

That's how it works

l
Insert a screw driver into the actuating opening until it bottoms.
l
Strip 9-10 mm of the lead and insert it into the plug.
l
Pull out the screw driver.

Caution
!

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

Fig. 6 X-COM plug with measuring cable

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

008 917 69 BOMAG 87

4.20 Plugs and terminals in spring clamping technology

Measuring signals

Fig. 7 X-COM plug plugged onto the series clamp

88 BOMAG 008 917 69

Inductive proximity switches 4.21
4.21 Inductive proximity switches NPN circuitry

General
In all automated sequences the use of sensors as a
source of information for the electronic control is indis-
pensable. The sensors deliver the necessary signals
about positions, end positions, filling levels or serve as
pulse transducers for counting tasks or speed detec-
tion. In industrial applications inductive and capacitive Fig. 10 NPN circuitry
proximity switches are today indispensable. Com-
pared with mechanical switches, they offer almost ide- On sensors with NPN-circuitry the output stage con-
al prerequisites: non-contact, wear free operation, tains a NPN-transistor, which switches the load
high switching frequencies and switching accuracies, against the negative operating voltage. The load is
as well as high protection against vibration, dust and connected between the output and the positive oper-
moisture. Inductive sensors detect all metals without ating voltage.
contact, capacitive sensors detect almost all solid and Breaking and making contacts
liquid media, such as metal, glass, wood, plastic, wa-
ter, oil, etc.

Working principle

Fig. 8
The working principle is based on the principle of the
dampened LC-oscillator. The coil of the oscillation cir-
cuit forms a high-frequency magnetic stray field. Fig. 11

Fig. 9 PNP circuitry

008 917 69 BOMAG 89

4.22 Batteries

4.22 Batteries
Battery – accumulator

Fig. 1
In vehicles batteries are used to start the engine. The
ability to start the engine depends on the charge con-
dition of the batteries.
Lead collectors or accumulators are secondary ele-
ments, i.e they can be recharged after discharging
electric current.
The basic element of a lead accumulator is the cell. It
contains the plate blocks consisting of positive and
Fig. 12 Circuit diagram, making contact
negative plates. These plates are separated from
each other by separators.
The circuit diagram (Fig. 6) shows a proximity switch
with normally open contact. All positive plates are arranged parallel to the plus
pole, the negative plates parallel to the minus pole of
Brown = voltage supply the cells.
Blue = ground supply
Black = switching output
The initiator switches the relay (K05)

Fig. 2
All cells are filled with a conductive fluid, the electro-
lyte. For a 12 Volt battery 6 cells are connected in se-
ries.

Capacity
is a synonym for the amount of current taken up and
discharged by a battery over a specified period of
time.

90 BOMAG 008 917 69

Batteries 4.22
Battery maintenance Batteries with screw plugs
Checking the electrolyte level
i Note
Maintenance free batteries are gaining more and
more significance, this freedom from maintenance,
however, is only limited to the fact that no water needs
to be added.
If the battery is not charged and discharged over a
longer period of time, the battery will slowly discharge
by itself.
The accumulator may only be discharged down to a fi-
nal discharging voltage of 10.5 Volt, as otherwise
there is a risk of sulphation, i.e. the generated lead
sulphate forms increasingly coarser crystals, which
will finally not react at all or only very sluggishly during Fig. 3
a subsequent charging process. 1 Upper filling level mark
In the worst case the accumulator can only be dis- 2 Lower filling level mark
posed of after such an exhaustive discharge. l If the electrolyte level only reaches up to the lower
The following therefore applies for longer downtimes: filling level mark (2), fill distilled water into the corre-
l Remove the battery and store it in a cool, dry and sponding cells.
frost protected room.
l Check the open circuit voltage on the battery at reg-
ular intervals (at least once every month).
l Recharge immediately if the open circuit voltage
has dropped to 12.25 Volt (no rapid charging).

i Note
The open circuit voltage of batteries occurs approx. 10
h after the last charging or approx. 1 h after the last
discharge.

Battery test in general

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

008 917 69 BOMAG 91

4.22 Batteries

Checking the electrolyte density Do not draw too much electrolyte into the pipe.
Make sure that the float is not obstructed in its move-
ment and hold the electrolyte tester at eye level.
The electrolyte tester must be read at the highest
electrolyte level.
l If the electrolyte temperature deviates from the
electrolyte tester calibration temperature, the indi-
cated value for the specific electrolyte weight must
be corrected acc. to the formula (reference) below.

Reference
The specific weight varies slightly with temperature.
To be exact, the specific weight drops by 0.0007 per 1
°C temperature increase (by 0.0004 per 1 °F) and in-
Fig. 4
creases by 0,0007 per 1 °C temperature reduction (by
The cells are filled with diluted sulphuric acid as elec- 0,0004 per 1 °F) . If e.g. a temperature of 20 °C (68 °F)
trolyte (approx. 25 Vol% sulphuric acid in distilled wa- is used as reference, the indicated value of the specif-
ter), also referred to as accumulator acid, which has a ic weight must be corrected acc. to the following for-
density of 1.285 kg/dm3 at a temperature of +27° Cel- mula.
sius. This means that one litre of electrolyte has a l Specific weight at 20 °C = measuring value +
weight of 1.285 kg. As the cell is being discharged
0,0007 × (electrolyte temperature: 20 °C)
lead sulphate (PbSO4) will form on both electrodes
and the electrolyte will increasingly change to water.
l
Specific weight at 68 °F = measuring value + 0,0004
Since water has a lower specific weight than diluted × (electrolyte temperature: 68 °F)
sulphuric acid, the density of the electrolyte will also Acid density at 27 °C in kg/dm3
drop during the discharge and with a fully discharged
cell and a temperature of 27°C it will only be 1.18 kg/
l
1.25 -1.28, open-circuit voltage approx. 12.7 Volt.
dm3. Battery is charged.
l
1.20 -1.24, open circuit voltage approx.12.4 to 12.5
With a lead cell the acid density is therefore a meas-
Volt, is 50% discharged. Charging is necessary.
ure for the charge condition. This characteristic is
used to determine the charge condition of a lead bat- l
1.19 and less, open circuit voltage less than 12.3
tery. The so-called electrolyte tester (densimeter) is Volt. Battery is insufficiently charged. The battery
used for this purpose. needs to be recharged immediately.
l
If there is a deviation of the specific weight of more
than 0.05 between any of the cells, the battery
needs to be replaced.
l
If the current consumption during charging is not 1/
20 of the nominal capacity (example 100 Ah battery:
100Ah x 1/20 = 5 A) or full recharging of the battery
results in a final electrolyte density of only 1.24 kg/
dm3 or less, the battery shows normal wear by ag-
ing. The battery was insufficient charging or ex-
haustive discharge.

Fig. 5 Checking the electrolyte density:

1) correct
2) poor
3) poor

i Note
(Hold the pipe of the electrolyte tester vertically, with-
out taking it out of the electrolyte.

92 BOMAG 008 917 69

Batteries 4.22
Testing batteries without screw plugs
On closed batteries the acid density cannot be meas-
ured, we therefore recommend testing with the follow-
ing mobile tester:

Fig. 6 Battery and generator tester

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

i Note
Before testing clean the poles and ensure good con-
nection between clamps and poles.
The test program calculates the text messages "good"
or "replace" on the basis of the charge condition (de-
rived from the battery voltage) and the currently avail-
able starting power of the battery. A battery with 45%
starting power may thus be rated good and another
one with 75% starting power as poor ("replace").
The starting power represents the ratio of detected
cold testing current to the entered cold testing current
of the battery.
The starting power can exceed 100%.

008 917 69 BOMAG 93

4.23 Battery maintenance

! Danger

Danger of cauterisation ! Danger of explosion!

When working on the battery do not use open fire,
do not smoke!
The battery contains acid. Do not let acid come in
contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
Fig. 7
Environment l Remove the batteries (Fig. 7) and clean the battery
Dispose of the old battery environmentally. compartment.
l Clean the outside of the battery.
i Note l Clean battery poles and pole clamps and grease
Maintenance free batteries also need care. Mainte- them with pole grease (Vaseline).
nance free only means that the fluid level does not
need to be checked. Each battery suffers under self-
l Check the fastening of the battery.
discharge, which may, in not checked occasionally, l On serviceable batteries check the acid level, if nec-
even cause damage to the battery as a result of ex- essary top up to the filling mark with distilled water.
haustive discharge.
Charging voltage recommendation
The following therefore applies for the service life:
l
Switch off all consumers (e.g. ignition, light).
l
Check open-circuit voltage of the battery at regular
intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V =
50% discharged.
l
Recharge the battery immediately after an open-cir-
cuit voltage of 12.25 V or less is reached. Do not
perform boost charging.
The open-circuit voltage of the battery occurs approx.
10 hours after the last charging process or one hour
after the last discharge.
l
After each charging process allow the battery to rest Fig. 8
for one hour before taking it into service.
l
For resting periods of more than one month you
should always disconnect the battery. Do not forget
to perform regular open-circuit voltage measure-
ments.

Caution
!

Exhausted batteries (batteries with formation of

sulphate on the plates are not covered under war-
ranty!
l
Open the battery flap at the rear of the machine.

94 BOMAG 008 917 69

Starting with jump wires 4.24
4.24 Starting with jump wires

! Caution
When using external starting aid two external bat-
teries (24 V system) are required, one for each on-
board battery.
A wrong connection will cause severe damage in
the electric system.

Fig. 10

Main battery switch

Position "I" = Normal position, operation
Position "II" = Separates batteries from the on-
board electrics in case of cable fire
and fire in the engine compart-
ment as well as protection against
unauthorized use.

Fig. 9 ! Caution
l
First connect the plus poles with the jump lead. Pull out the main battery switch at the earliest 40
l
Then connect the ground cable first to the minus seconds after switching off the ignition, except in
pole of the current supplying auxiliary battery and cases of emergency.
then to engine or chassis ground, as far away from
the battery as possible (Fig. 9).
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. Fig. 11
No. 1 = Fuses in battery compartment
l
Switch off the consumer.
F1 = 80A - Ignition
F2 = 25A - Emergency stop
F3 = 150A - Emergency hydraulic pump
F4 = 80A - Preheating of diesel engine

008 917 69 BOMAG 95

4.24 Starting with jump wires

F29 = 1A, speed sensor

F30 = 7.5A, I/O levelling
F31 = 1A, control box, scraper plate
F32 = 1A, wire sensor
F33 = 1A, inclination sensor
F34 = 1A, post transmitter
F35 = 7.5A, external levelling
F36 = 7.5A, levelling system
F37 = 7.5A, conveyor belt
F38 = 7.5A, water filling and cleaning
Fig. 12 system
No. 2 = Fuses in electric installation box F39 = 7.5A, water spraying system
F40 = 1A, rope sensor, control
! Danger F41 = 7.5A, signal horn
Fire hazard! F42 = 10A, working lights
Do not use fuses with higher ampere ratings and F43 = 10A, working lights
do not bridge fuses. F44 = 10A, working lights
F1 = 15A, EMR F45 = 10A, working lights
F2 = 25A, EMR F46 = 10A, working lights
F3 = 7.5A, EMR F47 = 10A, working lights
F4 = 10A, converter 24V/12V F48 = 7.5A, flashing beacon
F5 = 1A, converter 24V/12V F49 = 25A, fuel lift pump
F6 = 1A, control box front left F50 = 1A, sensors
F7 = 1A, control box rear left F51 = 1A, sensors
F8 = 1A, control box rear left F52 = 7.5A, warning buzzer
F9 = 1A, control box front right F53 = 1A, display control panel
F10 = 1A, control box rear right F54 = 10A, working lights roof
F11 = 1A, control box rear right F55 = 7.5A, milling drum drive*
F12 = 1A, control cabinet
a Rotary switch 204.4 S1
F13 = 1A, control cabinet
Software update (only for service)
F14 = 1A, control cabinet
F15 = 1A, control cabinet
F16 = 7.5A, ECU
F17 = 7.5A, ECU
F18 = 7.5A, ECU
F19 = 15A, I/O module
F20 = 4A, I/O module
F21 = 4A, I/O module
F22 = 15A, I/O module
F23 = 15A, I/O module
F24 = 4A, I/O module
F25 = 15A, I/O module
F26 = 4A, I/O module
F27 = 7.7A, Can-bus
F28 = 1A, engine
* Optional equipment

96 BOMAG 008 917 69

Generator 4.25
4.25 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. 13
1 Fan
2 Holding plate
3 Stator core
4 Stator winding
5 Brush

008 917 69 BOMAG 97

4.25 Generator

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

Fig. 16 3-phase current

Fig. 14 Rotor with claw poles The wiring diagram (Fig. 16) 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. 15), whereas the excit-
er winding is arranged on the internally revolving rotor The diodes D1, D2, D3 are also referred to as minus
(Fig. 14). 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. 15 Stator
The three stator windings (Fig. 15) are electrically off-
set to each other by 120°. The excitation of the mag-
netic field requires direct current, which is fed to the
rotor via two carbon brushes and slip rings.

98 BOMAG 008 917 69

Generator 4.25
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. 17 plus controlled charging regulator tery is available or the battery is discharged, external
(Fig. 17) 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. 18 plus controlled charging regulator

(Fig. 18) 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.

008 917 69 BOMAG 99

4.25 Generator

Charge controller Checking the generator

The charge controller has the following functions
l To regulate the voltage generated by the generator !Caution
l To protect against overloads caused by too high Before removing the generator you must discon-
output current nect the ground cable from the minus pole of the
battery while the ignition is switched off. Do not
l Protection against reverse current disconnect the generator while the engine is run-
If the output voltage or the output current of the gen- ning, because this may cause extremely high volt-
erator exceeds the determined maximum values, the age peaks in the vehicle wiring system ("Load
field current and thus the electric power is reduced. Dump"), which could possibly damage control
units, radios or other electronic equipment.
Electronic charge regulator
When disassembling the battery cable, the B+-nut
underneath on the generator side may also be
loosened. This nut must in this case be retight-
ened.
When connecting e.g. the battery cable to the ter-
minal of the generator you must make sure that
the polarity is correct (generator B+ to the + pole
of the battery). Mixing up the polarities by mistake
causes short circuit and damage to the rectifier el-
ements - the generator will be out of function.
The generator can only be operated with the bat-
tery connected. Under special conditions emer-
gency operation without battery is permitted, the
lifetime of the generator is in such cases especial-
ly limited.
Fig. 19 Regulator, Kubota engine
Plus and minus cables must be disconnected dur-
In AC-generators the electrically generated exciter ing rapid charging of the battery or electric weld-
field of the generator rotor is influenced by an ating on the vehicle.
tached electronic charge regulator. Together with the
holder for the carbon brushes this regulator forms a When cleaning the generator with a steam or wa-
unit, which transfers the field current to the sliprings of ter jet make sure not to direct the steam or water
the rotor. jet directly on or into the generator openings or
ball bearings. After cleaning the generator should
The regulator compares the rectified actual current of be operated for about 1 - 2 minutes to remove any
the generator with the a stable reference voltage in deposits of water from the generator.
the regulator and matches the strength of the exciter
field (field current) by increasing or reducing the cur- First one must check whether the generator is actually
rent flow (PWM, switching controller) in such a way, defective.
that the actual voltage of the generator remains con- l
This can be easily found out by checking whether
stant, irrespective of load and speed. The generator the charge control light in the dashboard lights up. If
voltage is thereby regulated, the generator current, the light does not go out, even at higher speeds,
however, is not measured, but limited by the construc- there must be a defect on the generator, the regula-
tion dependent internal resistance of the stator coils or tor, the wiring or the V-belt.
thermal monitoring. l
When the engine is at rest, the charge control light
must light up. If not, the lamp may probably be de-
fective. Defects on generator or wiring are obviously
also possible.
The following points allow to contain faults in the volt-
age supply within certain limits.
l Cable connections on the generator OK?
l V-belt OK?
l Generator ground (engine ground) OK?
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

100 BOMAG 008 917 69

Generator 4.25
replaced or the following trouble shooting procedure
must be performed.

008 917 69 BOMAG 101

4.26 Generator repair

4.26 Generator repair Rotor

Dismantling and assembling

Front housing flange

Fig. 3
l Unscrew 4 screws and take off the bearing cover.
l Temporarily screw the V-belt pulley nut on the rotor
shaft and knock the rotor out.
Fig. 1 Brushes
1 Front housing flange
2 Rear housing flange
3 (Screw
l Unscrew screws (3).
l Separate front (1) and rear housing flanges (2).

V-belt pulley

Fig. 4
l
After the rotor has been taken out one can see 2
carbon brushes protruding into the shaft bore.

Assembling the brushes

Fig. 2
l Carefully clamp the claw-type rotor in a vice.
l Loosen the nut with a size 24 ring spanner.

i Note
V-belt pulley tightening torque 58.4 to 78.9 Nm.

Fig. 5
l Insert the brushes with their sliding side in clock-
wise direction when viewed from the front.

102 BOMAG 008 917 69

Generator repair 4.26
2 Bearing
3 Puller
l Slightly clamp the rotors (1) in a vice to protect it
against being damaged and disassemble the bear-
ing (2) with a puller (3).

Fig. 6

Caution
!

Both brushes must be deep in the brush holder.

Otherwise both rotor and rear housing flange can-
not be correctly positioned.
Use a hexagon key (4.0 mm) to push the brushes
to furthest rear position.
Use a pointed (2.0 mm) punch or nail to secure the
brushes against popping out, as shown in the il-
lustration.

Fig. 7
l Align the marking lines (arrows) on front and rear
housing flange to each other.
l
Tighten 4 screws and pull the pointed punch out of
the brush holder.

Bearing on slipring side

Fig. 8
1 Rotor

008 917 69 BOMAG 103

4.26 Generator repair

Check Stator

Bearing

Fig. 2
l Use the resistance range of the continuity tester to
Fig. 1
measure the resistance between the individual lines
l Check whether the bearing rotates without obstruc- of the stator winding.
tion. l If the measuring value does not comply with the fac-
l Replace the bearing if it does not rotate properly. 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.

104 BOMAG 008 917 69

Generator repair 4.26
Rotor Slipring

Fig. 3 Fig. 4
l Measure the resistance between the sliprings. l Check the slipring for score marks.
l If the resistance does not comply with the factory l If score marks are found rework the slipring with
specification, replace the rotor. emery cloth or on a lathe.
l Use the resistance range of the continuity tester to l Measure the outer diameter of the slipring with a
check the continuity between slipring and core. vernier caliper.
l
Replace the rotor if no infinite value is indicated. l
Replace if the measuring value is below the permis-
sible limit.
i Note
Factory specification for resistance: 2.8 to 3.3 . i Note
Outer slipring diameter: 22.7 mm.
Permissible limit: 22.1 mm.

008 917 69 BOMAG 105

4.27 Electric starter

Wear on carbon brushes 4.27 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:
l to accelerate the combustion engine to start speed
Fig. 5
with lowest possible current consumption.
l Measure the brush length with a vernier caliper.
l establish the gear connection between starter and
combustion engine.
l Replace if the measuring value is below the permis-
sible limit.
l to maintain this connection.
l Make sure that the brush is light moving.
l to switch on the starter current.
l A defective carbon brush must be replaced. After starting the engine:
l
to return the starter pinion to initial position.
i Note l
to switch off the starter current.
Brush: 18.5 mm.
Permissible limit: 5.0 mm.

106 BOMAG 008 917 69

Electric starter 4.27
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

008 917 69 BOMAG 107

4.27 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

108 BOMAG 008 917 69

Electric starter 4.27
Starter with planetary gear Magnetic switch
The reduction gear is a planetary gear which reduces
the speed of the armature shaft (9) at the drive shaft
in the ratio of approx. 1:5.
The actuator lever (2) forces the pinion (4) with the
freewheeling clutch (5) against the ring gear.

Fig. 12 Direct acting electric motor

Fig. 11 with planetary gear

The working principle of this starter is the same as

with the "direct acting electric starter".
1 Holding plate
2 Actuating lever
3 Magnetic switch
4 Pinion
5 Freewheeling clutch
6 Output shaft Fig. 13 Geared motor
7 Transmission Armature (4), contact plate (3) and armature guide (6)
8 (8) Pinion form a closed unit. When the ignition switch is turned
9 (9) Armature shaft 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

008 917 69 BOMAG 109

4.27 Electric starter

Freewheeling clutch Trouble shooting "Starter"

i Note
The most frequent fault is definitely a fully discharged
battery.
If the starter rotates too slowly, either the brushes
are partly worn off, or parts of the exciter or armature
winding is shorted. In some cases oxidized electric
contacts or a soiled ground connection causing 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
Fig. 14 Freewheeling clutch worn off / soiled (scrape off carefully with a file and
clean)- the starter motor is defective / soiled (remove
The freewheeling clutch is designed in such a way,
armature and clean), cover cleaned, moveable parts
that the flow of force is automatically interrupted if the
with grease.
pinion (5) of the clutch rotates faster than the free-
wheeling ring (1) at higher engine speeds. Frequently a jammed return mechanism is the reason
for a starter failure.
This makes sure that the armature will only drive the
ring gear, but can never be driven by the engine. Occasionally worn contacts are found on the magnetic
return switch
1 Freewheeling ring
2 Roller Defects on the actual starter motor including pinion
and carbon brushes are very rare.
3 Roller spring
With a trouble shooting chart the faults in the starter
4 Splined shaft
system can be narrowed down. The starter system
5 Pinion can only work when many conditions are fulfilled at
6 Pinion the same time.
l Immobilizer deactivated?
l Ignition switch OK?
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?
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
l the experience of the specialist
l the failure probability of the component to be tested
and the testing effort for the respective part.
Only if all criteria mentioned above are OK, the fault
must be in the starter itself. In this case it can be re-
paired or replaced.

110 BOMAG 008 917 69

Electric starter 4.27
Testing and measuring the starter Continuity test for the magnetic switch

Function control with the starter removed

Caution
!

Fasten the starter to make sure that it will not

come loose during the test.

Fig. 17
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.
Fig. 15
l
Connect a jumper lead between start terminal (1)
and battery plus (2).
l
Connect a jumper cable instantaneously between
starter housing and battery minus (3).

i Note
If the motor does not start, the starter is defective. Re-
pair or replace the starter.

Checking the magnetic switch

Fig. 16
l
Connect a jumper lead between start terminal (1)
and battery plus (2).
l
Connect a jumper cable instantaneously between
starter housing and battery minus (3).

i Note
If the pinion does not disengage, the magnetic switch
is defective. Repair or replace the starter.

008 917 69 BOMAG 111

4.28 Repair of starter

Dismantling and assembling

4.28 Repair of starter

Fig. 1
! Caution
1 Gear
Before separating the frame (11) mark both the
2 Front bracket frame (11) and the front bracket (2).
3 Magnetic switch
Record the position of the seal kit (8) and the
4 Freewheeling clutch screw.
5 Inner gear Do not damage carbon bushes or collector.
6 Planet gears
Assembly
7 Ball bearing
l Apply some grease to the parts marked in the illus-
8 Seal kit
tration.
9 Through bolt l Tightening torque fastening nut for starter terminal
10 Armature B: 9.8 to 11.0 Nm
11 Stand
12 Brush holder
13 Rear bearing plate

Dismantling
l
Disconnect the magnetic switch (3).
l
Remove both through bolts (9) and 2 brush holder
fastening screws. Remove the rear bearing plate
(13) and take out the brush holder (12).
l
Separate the armature (10) from the frame (11). Re-
move also the ball bearing (7) from the tip of the ar-
mature.
l
Remove seal kit (8), 4 planet wheels (6) and the oth-
er seal.
l
Take out the shaft assembly. Make a note of the le-
ver position.

112 BOMAG 008 917 69

Repair of starter 4.28
Check Collector and mica capacitor

Freewheel

Fig. 2
l Check the contact surface of the collector for wear
Fig. 1
and rework it with sanding paper if it is slightly worn.
l Check the pinion for wear or damage.
l Replace the freewheeling assembly if found defec-
tive
l
Make sure that the pinion rotates freely in the free-
wheeling direction and does not slip in starting di-
rection.
l
If the pinion slips or does not rotate to both direc-
tions, replace the freewheel assembly.

i Note
Do not wash the grease in the freewheel out with
chemicals or oils.
Fig. 3
l Measure the outer diameter of the collector at sev-
eral points with an outside micrometer.
l If the smallest outside diameter is below the permis-
sible limit, the rotor must be replaced.

i Note
Factory specification, collector outside diameter:
32.0 mm.
Permissible limit: 31.4 mm.

Fig. 4
1 Segment
2 Counterdraft

008 917 69 BOMAG 113

4.28 Repair of starter

3 Mica capacitor Wear on carbon brushes

a) correct
b) not correct
l Measure the counterdraft on the collector.
l If the counterdraft falls short of the lower limit value,
correct it with a saw blade and bevel the segment
edges.

i Note
Factory specification, collector counterdraft: 0.5 mm.
Permissible limit: 0.2 mm.

Fig. 5
l If the contact area of the carbon brush is dirty or
dusty, clean it with emery cloth.
l Measure the brush length (A) with a vernier caliper.
l If the length is shorter than the permissible limit, the
brush holder must be replaced.

i Note
Factory specification, brush length: 18.0 mm.
Permissible limit: 11.0 mm.

114 BOMAG 008 917 69

Repair of starter 4.28
Brush holder Armature coil

Fig. 7
Fig. 6 l Use the resistance range of the continuity tester to
l Use a continuity tester to check the continuity be- check the continuity between collector and arma-
tween brush holder and holder carrier. ture coil.
l If continuity is found replace the brush holder. l If continuity is found replace the armature.

Fig. 8
l
Use the resistance range of the continuity tester to
check the continuity between the collector seg-
ments.
l
If no continuity is found replace the armature.

008 917 69 BOMAG 115

4.28 Repair of starter

Field coil

Fig. 9
1 Replace the
2 Brush
3 Stator
l Use the continuity tester to check the continuity be-
tween line (1) and brush (2).
l If no continuity is found replace the stator frame.

Fig. 10
l
Use the continuity tester to check the continuity be-
tween brush (2) and stator (3).
l
If continuity is found replace the stator frame.

116 BOMAG 008 917 69

5 Electrics

008 917 69 BOMAG 117

5.1 Component overview

Fig. 1

Fig. 2

118 BOMAG 008 917 69

Component overview 5.1

Fig. 3

Fig. 4 Steering sensor FRONT

008 917 69 BOMAG 119

5.1 Component overview

Fig. 5 Steering sensor REAR

Fig. 6 View of solenoid valves main valve block in engine compartment

120 BOMAG 008 917 69

Control panel, left (B17), middle (B18), right (B19) 5.2
5.2 Control panel, left (B17), middle (B18), right (B19)

B17

B18

B19

Fig. 7

008 917 69 BOMAG 121

5.2 Control panel, left (B17), middle (B18), right (B19)

1 B17/B19-S19 Push button for warning horn

2 B17/B19-S14 Control lever for loading belt
3 B17/B19-S18 Control lever for rear steering
4 B17/B19-S17 Control lever steering mode, rear
5 B17/B19-S7 Control lever, height adjustment front left
6 B17/B19-S7 Control lever, height adjustment front right
7 B17/B19-S9 Rotary switch height adjustment, total
8 B17/B19-S17 Control lever height adjustment, rear
9 B17/B19-S3 Rotary switch for travel speed ranges
10B17/B19-S4 Rotary switch for power limit control
11B17/B19-S2 Rotary switch for differential lock
12B17/B19-S13 Rotary switch for conveyor belts
13B17/B19-S15 Rotary switch for water sprinkling system
14B17/B19-S5 Rotary switch for milling drum
15B17/B19-S11 Rotary switch for break door
16B17/B19-S6 Rotary button for back door
17B17/B19-S16 Rotary button work on/off
18B17/B19-S12 Rotary switch for side door
19B17/B19-UJ2 Steering lever
20B17/B19-UJ1 Travel lever
21B17/B19-S1Emergency stop push button
22B18-S8 General fault warning light and diagnostics button
23B18-U1 Multi-function display
24B18-S6 Rotary button for protective roof
25B18-S5 Rotary button for engine hood
26B18-S9 Rotary switch for lighting
27B18-S7 Rotary switch for flashing beacon
28B18-S1 Ignition switch, engine
29B18-S2 Rotary button for engine speed
30B18-S10 Rotary switch to fold the loading belt
31B18-R1 Potentiometer for conveyor belt speed
32B18-S3 Rotary switch for side door

122 BOMAG 008 917 69

Control panel front right (B9) 5.3
5.3 Control panel front right (B9)

Fig. 8

1 B9-S4 Warning horn

2 not used
3 XC22 Plug, rope sensor
4 B9-S10 Rotary switch to fold/unfold the loader belt
5 B9-S2 Rotary button break door
6 B9-S1 Emergency Stop push button

008 917 69 BOMAG 123

5.4 Control panel rear left, top (B5) and bottom (B3)

Fig. 9

1 B5-S1 Emergency Stop push button

2 B5-S3 Steering rear
3 B5-S5 Rotary button height adjustment rear
4 B5-S4 Warning horn
5 Plug, external sensors for 3-point average levelling system
6 XC23 Plug, graphics display levelling control
7 B3-S3 Rotary button unfold back door
8 B3-S2 Rotary button lift back door
9 B3-S4 Rotary button side door, left
10Warning light

124 BOMAG 008 917 69

Control panel rear right, top (B6) and bottom (B4) 5.5
5.5 Control panel rear right, top (B6) and bottom (B4)

B4
B5

Fig. 10

1 Plug, external sensors for 3-point average levelling system

2 B6-S4 Warning horn
3 B6-S5 Rotary button height adjustment rear
4 B6-S3 Rotary button steering rear
5 B6-S1 Emergency Stop push button
6 Warning light
7 B4-S4 Rotary button right side door
8 B4-S2 Rotary button lift back door
9 B4-S3 Rotary button unfold back door
10XC69 Plug, graphics display levelling control

008 917 69 BOMAG 125

5.6 Control console front left (B8)

Fig. 11

1 B8-S1 Emergency Stop push button

2 B8-S2 Rotary button break door
3 B8-S3 Rotary switch water pump control
4 not used
5 XC24 Plug, rope sensor
6 B8-S4 Warning horn

126 BOMAG 008 917 69

Automatic levelling control 5.7
5.7 Automatic levelling control

Fig. 12

008 917 69 BOMAG 127

5.7 Automatic levelling control

1 Graphic display
2 Display of travel distance
3 Display, simultaneous adjustment on both sides
4 Display of actual value for depth or inclination right
5 Display of nominal value for depth or inclination right
6 Operating mode right hand side "A" Automatic, "M" Manual
7 Display of control status, depth or inclination right
8 Push button Automatic/Manual mode right
9 Button for depth/inclination sensor right
10Button for depth/inclination value increase right
11Button for depth/inclination value reduction right
12Button "0"- calibration, depth/inclination right
13not used
14not used
15not used
16Reset button, to reset to "0"
17not used
18not used
19not used
20Button "0"-calibration, depth/inclination left
21Button for depth/inclination value reduction left
22Button for depth/inclination value increase left
23Button for depth/inclination sensor left
24Button Automatic/Manual mode left
25Operating mode left hand side "A" Automatic, "M" Manual
26Display of control status for depth or inclination left
27Display of nominal value for depth or inclination left
28Display of actual value for depth or inclination left
29Speed display

128 BOMAG 008 917 69

Vie of ultrasonic levelling system 5.8
5.8 Vie of ultrasonic levelling system*

Fig. 13

1 Crank handle for height adjustment

2 Boom
3 Control unit
4 Connecting lead
5 Sensor head
6 Fixation button

* Optional equipment

008 917 69 BOMAG 129

5.9 High pressure sensor travel pump, C96

Fig. 1

Input Function ID-node Display status PIN

B14-C96:2 Hydraulic pressure sensor in travel ID 12 / AI 06 Analog 0...10V X1.12
drive

AI ... = Analog input

130 BOMAG 008 917 69

High pressure sensor travel pump, C96 5.9
The multi-function display is used to read out switching states of the ID-nodes, see chapter "CAN-Bus,
Parameters and Diagnose" Menu option, CHECK INPUT OUTPUT.

Fig. 2

Fig. 3
The actual pressure is shown in the multi-function display (position 6) (Fig. 3).

008 917 69 BOMAG 131

5.10 Hydraulic oil temperature sensor, C47

Fig. 1

i Note
The sensor is located inside the hydraulic oil tank.

Input Function ID-node Display status PIN

B14-C47:2 Hydraulic oil temperature sensor ID 12 / AI 05 Analog 0...10V X1.11

AI ... = Analog input

132 BOMAG 008 917 69

Hydraulic oil temperature sensor, C47 5.10
The multi-function display is used to read out switching states of the ID-nodes, see chapter "CAN-Bus,
Parameters and Diagnose" Menu option, CHECK INPUT OUTPUT.

Fig. 2

Fig. 3
The actual temperature is shown in the multi-function display (position 5) (Fig. 3).

008 917 69 BOMAG 133

5.11 Description of electronic temperature sensor IFM TN2530

Sensor
In the unit the sensor contains the actual sensing element, the Pt-T and the evaluation circuit. It is therefore re-
ferred to as temperature sensor with integrated evaluation circuit.

Fig. 4
The temperature sensor:
l detects the system temperature,
l shows the temperature in the display (optionally in °C or °F),
l generates 2 output signals in accordance with the set output configuration.

i Note
Pt is the chemical symbol for platinum.
For various reasons, e.g. the high chemical resistance, platinum is used for temperature dependent rheostats.

Measuring method
The analogue resistance value must be digitized for electronic evaluation. This is accomplished by a frequency
measurement, i.e. by measuring the number of oscillations over a fixed period of time. The temperature depend-
ent rheostat is part of a oscillator circuit. With changing temperature the resistance also changes and with it also
the frequency, i.e. the number of oscillations per unit of time.

134 BOMAG 008 917 69

Description of electronic temperature sensor IFM TN2530 5.11
Display

Measuring range: -40 bis +125°C, -40 to 257°F

Fig. 5
1 Indicator for displayed unit, i.e. reading for the unit used. If the LED does not light, the display will be in °C. If
it lights, the display will be in °F.
2 7-segment display, indication of system temperature, parameters and parameter values.
3 LED red, indication of switching state, lights when the output is switched through.
4 LED red, LED ON = displayed temperature + 0.5°.
5 Set-key, setting the parameter values (continuously by pressing permanently, step-by-step by single actua-
tion).
6 Key Mode / Enter, selection of parameters and confirmation of parameter values.

Resolution
The resolution is 0.5 °C, or 0.5 K. However, for values higher than 100 °C there is no fourth digit available. Here
the half degrees are indicated by the decimal point at the far right. E.g.
125 stands for 125.0 °C and
125. stands for 125.5 °C.
To say it more exactly, this is the resolution of the display. The measuring accuracy is ± 0.2 °C. With an analogue
output the resolution is higher (8 steps per K).

Run Mode / normal operation

This section describes what the device will show if the operator does not intervene.
After switching on the supply voltage the device is in Run mode. It performs its monitoring function, switches the
transistor output in accordance with the set parameters and converts the current temperature into an analogue
output signal. The display shows the current temperature, the red LED signalizes the switching state of the tran-
sistor output.

Fault indication
Besides displaying the medium temperature, the temperature sensor also indicates faults.
OL (overload) exceeding the measuring value by more than 3 %.
UL (underload) falling below the measuring value by more than 10 %.
SC [1 (short circuit) indicates short circuit in switching output 1. The output is blocked. In this case the display
flashes.
Err (error) indicates a general error, e.g. no sensor connected, fault or short circuit, cable breakage. In this case
the display flashes.

Display mode
Display of parameters and set parameter values. With short actuation of the button "Mode/Enter" the unit chang-
es to display mode. Internally it remains in working mode. The adjusted parameter values and the values of the
Min-Max log can be read, irrespective of the mode.

008 917 69 BOMAG 135

5.11 Description of electronic temperature sensor IFM TN2530

l Short actuation of the "Mode/Enter" button scrolls through the parameters.

l Short actuation of the button "Set" shows the corresponding parameter value/saved value for 5 seconds; the
unit will then return to Run-mode.

Fig. 6

Caution
!

The settings as specified in the wiring diagram must be strictly followed.

Parameter list
SP1 = Switching point: Top limiting value, at which the output changes its switching state.
rP1 = Reverse switching point: Bottom limiting value, at which the output changes its switching state.
rP1 is always lower than SP1. You can only enter values, which are lower than SP1. When chang-
ing the switching point, the reverse switching point is also changed (the hysteresis remains con-
stant). If the hysteresis is bigger than the new switching point, it is automatically reduced (rP1 is set
to the minimum setting).
OU1 = Switching output 4 switching functions can be set.

136 BOMAG 008 917 69

Description of electronic temperature sensor IFM TN2530 5.11

Switching functions Output

Hysteresis function /nor-
mally opened (Hno)
Analogue 4 ... 20mA (I)
Hysteresis function /nor-
mally closed (Hnc)
Window function /normally
opened (Fno)
Analogue 0 ... 10V (U)
Window function /normally
closed (Fnc)

ASP = Analogue starting point Measuring value, at which 4mA/0V is output.

AEP = Analogue end point Measuring value, at which 20mA/10V is output. Minimum distance ASP -
AEP: 10°C/18°F.
AOU = Configuration for analogue output: 2 switching functions are optionally available: I = 4 ... 20mA
/ U = 0 ... 10V.
diS = Display adjustment: 4 settings are optionally available: °C = display in °Celsius. °F = display in
°Fahrenheit. r °C = display in °Celsius (turned by 180°). r°F = display in °Fahrenheit (turned by
180°).

i Note
Set the display unit before you set the switching limits (SP1, rP1) and the limits for analogue values (ASP, AEP).
You thereby avoid rounding errors in the internal conversion to other units and receive exactly the desired val-
ues.
As delivered state: diS = °C
CAL = Line compensation: The internal measuring value (working value of the sensor) is offset against
the real measuring value.
Hi = Max. value log.
Lo = Min. value log.

008 917 69 BOMAG 137

5.11 Description of electronic temperature sensor IFM TN2530

Service function
Reading the min./max.-values
 Select [HI] or [LO], press [Set] instantaneously.
[HI] = Maximum value
[LO] = Minimum value.

Delete log
 Select [HI] or [LO].
 Press [Set] and hold depressed, until [----] is displayed.
 Press [Mode/Enter] instantaneously.

i Note
It makes sense to delete the log when the unit for the first time works under normal operating conditions.

Locking/unlocking
In order to impede unintended or inappropriate settings, the unit can be electronically locked and unlocked. For
this purpose press and hold both buttons for > 10 seconds in RUN mode. If attempts are made to change a pa-
rameter in locked condition, the display [Loc] will appear.

138 BOMAG 008 917 69

Description of electronic temperature sensor IFM TN2530 5.11
Programming mode
Programming

When pressing the "Set" button after choosing a parameter (display mode) the unit will change to programming
mode, until the displayed parameter value changes. Also in this case the unit will internally remain in working
mode. It will continue to perform its monitoring function with the existing parameters, until the change has been
completed.
You can use the "Set" button to change the parameter value and confirm it with the "Mode/Enter" button. If no
button is pressed for 5 seconds, the unit will return to Run-mode .

SP1, setting switching point

1. Mode

Fig. 7 Switching point setting 1

Actuate the Mode button. With this unit you can use this button to navigate through a sort of menu. The display
informs the operator about the currently active menu. Keep pressing the button, until the display shows SP1 for
switching point 1.

2. Set

Fig. 8 Switching point setting 2

Then operate the Set button. If this this only done instantaneously (short push), the set switching point is dis-
played with 0.5 K resolution. If the switching point is to be changed, the key must be held depressed for about
5 seconds. The value is then continuously increased.

3. Enter

Fig. 9 Switching point setting 3

Once the desired switching point value is displayed, it must be confirmed again. This is accomplished with the
Enter button. In Mode function it enables toggling between various menu options, in Enter function is is used to
confirm the adjusted value. After actuating the button, the set value becomes effective. The display once again
shows the selected function for about 5 seconds, in this case SP1. After this the unit changes to operating mode.
If no confirmation takes place, the previously set value remains valid. After approx. 30 seconds the unit returns
to operating mode, which gives you ample time to reconsider the setting.

008 917 69 BOMAG 139

5.11 Description of electronic temperature sensor IFM TN2530

Gone too far?

What to do if one has waited too long and the desired value has been exceeded? There is no button to change
the value downwards to lower values. More buttons would have made the unit more complicated and more ex-
pensive. The only possible thing to do is to run the display through one complete cycle. Once the maximum value
has been reached, the unit will restart with the minimum value. The next section describes how to reach the de-
sired value most conveniently.

Jog mode
The unit also provides the possibility of jog operation to reach the desired value easily and reliably. Once in Set
mode, which can be recognized by the value moving up, the Set button must only be released once for a mo-
ment.
While in Set mode, each actuation of the button then increases the value by one step. If one would like to set
the switching point to 10 bar, as shown in the example above, you should allow the switching point to increase
to 5 bar and release the button. Then actuate the button as many times as required to reach the exact value. Do
not forget to confirm.

140 BOMAG 008 917 69

Description of electronic temperature sensor IFM TN2530 5.11
Hysteresis
For reasons of clarity a thermometer is used to show the hysteresis (Fig. 10).

Fig. 10 Representation of the hysteresis

The hysteresis is the difference between switching point SP and the reverse switching point rP. The minimum
hysteresis is 0.5 °C. Since this point is within the range of the switching point accuracy, a lower value would not
make sense. The hysteresis range obviously depends on the switching point. If e.g. the switching point of a de-
vice is set to 10.0 °C, the hysteresis can be max. 50 K, because the minimum value of the reverse switching
point -40 °C. Then hysteresis range is shown in (Fig. 11).

Fixed hysteresis
In order to simplify the correction of entered values and to avoid input errors, the hysteresis value is maintained
when changing the switching point. If, as an example (SP = 10.0 °C, rP = 0.0 °C, i.e. hysteresis = 10.0 K), the
switching point is changed to 15.0 °C, the reverse switching point will automatically change to 5.0 °C. The value
of the hysteresis remains at 10.0 K.
In the opposite direction it is just the other way round. If, in case of the same initial values (SP = 10.0 °C, rP =
0.0 °C, i.e. hysteresis = 10.0 K), the switching point is changed to - 35 °C, the reverse switching point will remain
at - 39.5 °C, since this already is the minimum value. The hysteresis in this case is 4.5 K.

Fig. 11 Hysteresis range

Reverse switching point

Setting the hysteresis takes place by setting the reverse switching point. The sequence is identical with the one
for setting the switching point. Erroneous setting of the reverse switching point, e.g. above the switching point,
is not possible, because this area is not accessible.

rP1
Setting the reverse switching point takes place in the same way as setting the switching point. For this purpose
press the Mode-button to call up "rP1" in the display. "1" once again is of relevance in equipment with two switch-
ing outputs. Here the second reverse switching point is set via rP2.

Hno, Hnc
The output function is programmed together with the hysteresis function, normally opened or normally closed.

1. Mode OU1
The mode button is actuated, until the the display shows the reading OU1 (for output).

008 917 69 BOMAG 141

5.11 Description of electronic temperature sensor IFM TN2530

2. Set kno
After actuating the Set-button the display shows Hno. If the button is only pressed for a moment, the set function,
in this case Hno, is displayed. After 5 s the display changes to OU1. After another 5 s the equipment returns to
operating mode. If the function is to be changed, the Set-button must be held depressed for about 5 seconds.
In this case the display changes from Hno to Hnc. With this setting the output was inverted in comparison to Hnc.
Further functions are described in the next section .

3. Enter OU1
The setting is confirmed with the Enter button. The menu option OU1 is displayed . After approx. 5 s the equip-
ment changes back to operating mode.
If the setting is not to be changed, you may either wait for 5 s, until the display returns to OU1, or confirm the
value by pressing the Mode button again, as described under 3. If the Set-button has been pressed (longer than
5 s), e.g. to view various alternatives, the waiting time will be extended to approx. 30 s.
The setting on units with two switching outputs is made via OU2.

142 BOMAG 008 917 69

Description of electronic temperature sensor IFM TN2530 5.11
Setting the window

Fig. 1 Representation of the window

Fno, Fnc
With the window function the unit can be used to monitor a good range. With the setting Fno the output is open
(0-signal), if the temperature is below the reverse switching point or above the switching point.
The output is closed (1-signal), if the temperature is between the switching and the reverse switching point. With
the setting Fnc the output is inverted. When setting the window function the hysteresis is fixed to the minimum
value of 0.5 °C.
The setting is made as for the hysteresis:

1. Mode OU1
The mode button is actuated, until the the display shows the reading OU1.

2. Set Fno
After actuating the Set-button the display first of all shows e.g. Fno. If the button is only pressed for a moment,
the set function, in this case Fno, is displayed. After 5 s the display changes to OU1. After another 5 s the equip-
ment returns to operating mode.
If the function is to be changed, the Set-button must be held depressed for about 5 seconds. In this case the
display changes from Fno to Fnc. If the button is held depressed or jogged, the readings will be displayed again.
Once the desired function is reached, in the example Fno, the must be confirmed again.

3. Enter OU1
The setting is confirmed with the Enter button. The menu option OU1 is displayed . After approx. 5 s the equip-
ment changes back to operating mode.

Fixed window
As with the hysteresis also here the value in the window will be maintained, even when the switching point is
changed.
The setting on units with two switching outputs is made via OU2.

008 917 69 BOMAG 143

5.11 Description of electronic temperature sensor IFM TN2530

Analog output
The resolution in conversion is 8 steps per degree. This means that the overall measuring range (-40 °C to 150
°C) is resolved into 1520 steps (190 * 8). A higher resolution would not make sense, because of diverse meas-
uring errors.
The complete measuring range is hardly ever used. For this reason it is most practical to match the analog output
signal to the actual measuring range, e.g. for display or evaluation purposes. If e.g. temperatures between 0 °C
and 100 °C are to be monitored, it may be sensible to assign the analogue start value (0 V or 4 mA) to the tem-
perature of 0 °, and the analogue end value (10 V or 20 mA) to the temperature of 100 °C. The measuring ac-
curacy is ± 0.2 °C.
There should not be any misunderstanding. Spreading this scale does not increase the resolution. In the exam-
ple above the measuring range was practically halved. However, this does not mean that the smaller tempera-
ture interval is now resolved into 1520 steps. Since we have 8 steps per degree, the interval is resolved into 800
steps.

Asp
The analogue start value is determined via the ASP function (Analogue Start Point). The adjustment range is
between -40 and 140 in steps of 0.5 °C. The setting once again follows the common schematic.

1. Mode ASP
The mode key is actuated, until the the display shows the reading ASP.

2. Set 10.0
After actuating the Set-button the display shows the set value. If the key is only pressed for a moment, the value,
in this case 10.0, is displayed. After 5 s the display changes to ASP. After another 5 s the device returns to op-
erating mode. If the value is to be changed, the Set-button must be held depressed for about 5 seconds. The
display then scrolls through the adjustment range. When the value 0.0 is reached, it can be confirmed.

3. Enter ASP
The setting is confirmed with the Enter button. The menu option ASP is displayed . After approx. 5 s the equip-
ment changes back to operating mode.
If the setting is not to be changed, you may either wait for 5 s, until the display returns to ASP, or confirm the
value by pressing the Mode button again, as described under 3. If the Set-button has been pressed (longer than
5 s), e.g. to view various alternatives, the waiting time will be extended to approx. 30 s.

AEP
This function serves the purpose of setting the analogue end value (analogue end point). The adjustment range
in this case is between -30 and 150 °C. The setting is made as for ASP: When setting the value 100, the example
described above is realized.

Minimum interval
Due to the resolution and the measuring accuracy, the interval is limited to at least 10 K. This means, AEP =
ASP + 10. This results in maximum values for ASP and minimum values for AEP.
ASPmax = 140 °C
AEPmin = -30 °C
In contrast to the hysteresis or window function, the interval does not remain fixed when the start point ASP is
changed. This means, that ASP cannot run through the entire value range when the setting is made. ASP can
only be set to 140 of AEP has been set to 150. Otherwise ASP is limited to AEP - 10. The same applies, the
other way round, to AEP.

AOU
This function is used to set whether the output is a current or voltage output.

1. Mode AOU
The mode key is actuated, until the the display shows the reading AOU.

144 BOMAG 008 917 69

Description of electronic temperature sensor IFM TN2530 5.11
2. Set 1
After actuating the Set-button the display shows the set function. If the key is only pressed for a moment, the
function will be displayed, in the example current output (4-20 mA). After 5 s the display changes to AOU. After
another 5 s the device returns to operating mode. If the value is to be changed, the Set-button must be held
depressed for about 5 seconds. The display then changes between I and U for current or voltage output (0-10
V) Once the desired function is displayed, it must be confirmed again.

3. Enter AOU
The setting is confirmed with the Enter button. The menu option AOU is displayed . After approx. 5 s the equip-
ment changes back to operating mode.
If the setting is not to be changed, you may either wait for 5 s, until the display returns to AOU, or confirm the
value by pressing the Mode button again. If the Set-button has been pressed (longer than 5 s), e.g. to view var-
ious alternatives, the waiting time will be extended to approx. 30 s.

008 917 69 BOMAG 145

5.11 Description of electronic temperature sensor IFM TN2530

Further settings
dis
This function is used to set the type of representation (diS for display). This, on the one hand, concerns the unit
°C or °F. On the other hand you can also select the rotated representation. The user not always can choose the
installation location as desired. Moreover, there is always the possibility of installation faults. If the display can
hardly be read by the personnel because the representation is upside down, nothing must be changed mechan-
ically. The representation can simply be rotated by 180°.

1. Mode diS
Keep pressing the mode key, until the display shows diS.

2. Set °
By pressing the Set key the set unit and display, in this case °C, appears as usual. When holding the key longer
than 5 s, the display will change between °C, °F, r°C and r°F. r stands for rotated (upside down). Any change
needs to be confirmed.

3. Enter dis
Once the setting has been confirmed with the Enter-key, the display shows the active menu option. Further op-
eration of this button in Mode-function) brings you to other menu options, or one waits 5 s for the unit to return
to operating mode.

Min/Max
Another special feature of the temperature sensor is the display of the highest and lowest temperature, as with
a min./max. thermometer.

Hi
Display of the maximum temperature.

1. Mode ki
The Mode-button is actuated until the display shows the reading Hi (for high).

2. Set 40.5
Pressing the Set key displays the maximum value, in this example 40.5 °C. If the key is held depressed for 5 s,
the value will be deleted. The display will show three dashes.
Set (> 5 s) - - -

Enter ki
Once the deletion has been confirmed with the Enter-key, the display shows the active menu option. Further
operation of this button in Mode-function) brings you to other menu options, or one waits 5 s for the unit to return
to operating mode.

Lo
Display of the minimum temperature.

Line compensation
With longer supply lines to the sensor element the line or cable resistance can no longer be disregarded. It needs
to be compensated.The pump must be switched on. This is accomplished via the menu option CAL.

Cable resistance
The following table provides an overview over the measuring error, that is caused by the resistance in the supply
lines. It is assumed that cooper cables are used with an electric conductivity  of:
 = 58 m/mm2
The specified values refer to a Pt 1000.

146 BOMAG 008 917 69

Description of electronic temperature sensor IFM TN2530 5.11

Cable cross-section 0.5 0.75 1.5

Resulting error (K) in a ca-
ble length of
10 m 0.18 0.12 0.06
15 m 0.27 0.18 0.09

Coefficient
The cable resistance is also temperature dependent. This dependency is described by the temperature coeffi-
cient  of the electric resistance. For copper it is (at 20 °C):
 = 3.9 10-3 1/K
The resistance change is calculated as follows:
 = RT

( 4)
R ]: Resistance; R Resistance change; T[K]: Temperature change; [1/K]: Temperature coefficient.

CAL
Under this menu option the displayed temperature value can be offset by - 9.9 to + 9.9 °C in steps of 0.1 °C,
here referred to as calibration.

1. Mode AL
The mode key is actuated, until the the display shows the reading CAL.

2. Set 0.0
After actuating the Set-button the display shows the set value. If the key is only pressed for a moment, the value,
in this case 0.0 (default), is only displayed. After 5 s the display changes to CAL. After another 5 s the device
returns to operating mode. If the value is to be changed, the Set-button must be held depressed for about 5 sec-
onds. The display then scrolls through the adjustment range. When the desired value is reached, it must be con-
firmed.

3. Enter AL
The setting is confirmed with the Enter button. The menu option CAL is displayed . After approx. 5 s the equip-
ment changes back to operating mode.
If the setting is not to be changed, you may either wait for 5 s, until the display returns to CAL, or confirm the
value by pressing the Mode button again. If the Set-button has been pressed (longer than 5 s), e.g. to view var-
ious alternatives, the waiting time will be extended to approx. 30 s.

008 917 69 BOMAG 147

5.11 Description of electronic temperature sensor IFM TN2530

Overview
The functions are summarized once again to ease the overview over the manifold programming possibilities.

Fig. 2

Explanations
The value of 12.5 in line 2 is an example (all values in °C). The other entries in column 2 are specified readings
to inform the operator about the currently active menu option. The Mode-key brings you from one point to the
next.
The values in column 4 are always examples. If, as an example, the display SP1 appears after pressing the
Mode-button, the set switching point 1, e.g. 10.0, is displayed after pressing the Set-button. The current value
(12.5) in the example is higher than the switching point, output 1 should switch. The reverse switching point 1 in
the example is 8.0. The delay for the reverse switching point 1 (dr 1) was set to 4 s. The output function is set
to hysteresis and normally opened. The display is in the unit °C, the max. temperature value was 40.5 °C, the
min. value was 8.0 °C.
Columns 7-9 show the complete range of values that can be adjusted if the Set-button is held depressed longer
than 5 s when column 4 is displayed. The value in line 3 for SP1 would obviously not start at -54.5, but at the set
value of 10.0. But if one would wait until the complete range of values has been passed through, i.e. 124.5, the

148 BOMAG 008 917 69

Description of electronic temperature sensor IFM TN2530 5.11
system would restart at -54.5. However, the values in line 4 for the reverse switching point 1 (rP1) cannot pass
through the entire range. The lowest value is predetermined by the maximum hysteresis, the highest value by
the minimum hysteresis. Please remember, in the example SP1 was set to 10.0. This is the same with the func-
tions ASP and AEP. The value for ASP in the example would not start at -40, but at the displayed value of 0.0.
However column 7-9 should once again show the complete value range. The values of AEP can once again not
pass through the complete value range, because AEP must be at least ASP + 10. For the functions OU1, AOU
and diS there are no numerical values, but the switching or output function and the unit or the representation is
programmed. The values displayed at Hi and Lo can obviously not be changed, but can only be deleted.

Do not forge
If a value was changed by holding the Set-button depressed, this change must be confirmed with the Enter-but-
ton, as otherwise the previous value may remain valid.

008 917 69 BOMAG 149

5.12 Pressure sensor conveyor belt drive, C99

Fig. 1
Pressure range: 250 bar

Input Function ID-node Display status PIN

B14-C99:2 Hydraulic oil pressure sensor in conveyor circuit ID 12 / AI 06 Analog 0...10 Volt X2.12

AI ... = Analog input

150 BOMAG 008 917 69

Pressure sensor conveyor belt drive, C99 5.12

Fig. 2
The actual pressure is shown in the multi-function display (position 2) (Fig. 3).

008 917 69 BOMAG 151

5.13 Pressure sensor fan circuit, C100

Fig. 1
Pressure range: 250 bar

Input Function ID-node Display status PIN

B14-C100:2 Hydraulic pressure sensor in fan drive ID 12 / AI 14 Analog 0...10 Volt X2.12

AI ... = Analog input

Fig. 2
The actual pressure is shown in the multi-function display (position 7) (Fig. 3).

152 BOMAG 008 917 69

Pressure sensor clutch, C57 5.14
5.14 Pressure sensor clutch, C57

Fig. 1
Pressure range: 100 bar

Input Function ID-node Display status PIN

B14-C57:2 Hydraulic oil pressure sensor in clutch circuit ID 13 / AI 05 Analog 0...10 Volt X1.11

AI ... = Analog input

Fig. 2
The actual pressure is shown in the multi-function display (position 3) (Fig. 3).

008 917 69 BOMAG 153

5.15 Back door pressure sensor, C60

Fig. 1
Pressure range: 25 bar

Input Function ID-node Display status PIN

B14-C60:2 Hydraulic oil pressure sensor for back door ID 13 / AI 14 Analog 0...10 Volt X2.12
flap

AI ... = Analog input

Fig. 2
The actual pressure is shown in the multi-function display (position 4) (Fig. 3).

154 BOMAG 008 917 69

Pressure sensor break door, C50 5.16
5.16 Pressure sensor break door, C50

Fig. 1
Pressure range: 250 bar

Input Function ID-node Display status PIN

B14-C50:2 Hydraulic oil pressure sensor for break door ID 13 / AI 13 Analog 0...10 Volt X2.11

AI ... = Analog input

Fig. 2
The actual pressure is shown in the multi-function display (position 8) (Fig. 3).

008 917 69 BOMAG 155

5.17 Pressure sensor working hydraulics, C58

Fig. 1
Pressure range: 25 bar

Input Function ID-node Display status PIN

B14-C58:2 Hydraulic pressure sensor for working hydraulics ID 13 / AI 06 Analog 0...10 Volt X1.12
circuit

AI ... = Analog input

Fig. 2
The actual pressure is shown in the multi-function display (position 1) (Fig. 3).

156 BOMAG 008 917 69

Hydraulic oil temperature switch, C46 5.18
5.18 Hydraulic oil temperature switch, C46

Fig. 1

i Note
The switch is located inside the hydraulic oil tank.

Input Function ID-node Display status PIN

B14-C46 Hydraulic temperature switch ID 14 / DI 04 0/1 X1.7

In case of a fault the General Fault Lamp B18-S8 (Fig. 2) lights up.
DI ... = Digital input

008 917 69 BOMAG 157

5.18 Hydraulic oil temperature switch, C46

Fig. 2 Fault indicator lamp + button

flashes = Generic fault
Press the push button= The error message is displayed on the screen of the multi-function display (Fig. 3).

Fig. 3
5504 = Hydraulic oil temperature too high

158 BOMAG 008 917 69

Solenoid valve travel pump, YA25, YB25 5.19
5.19 Solenoid valve travel pump, YA25, YB25

Fig. 1

Output Function ID-node Display status PIN

YB25 Solenoid valve on travel pump for forward ID 30 / AO 04 PWM X.54
YA25 Solenoid valve on travel pump for reverse ID 30 / AO 05 PWM X.36

YA8 Solenoid valve for displacement of travel motor (slow ID 16 / AO 1-2 PWM X1
ON = solenoid valve OFF)

AO = Analog output

162 BOMAG 008 917 69

Solenoid valve conveyor pump, YA26, YB26 5.23
5.23 Solenoid valve conveyor pump, YA26, YB26

Fig. 1

Output Function ID-node Display status PIN

YB26 Solenoid valve on conveyor belt pump for forward ID 16 / AO 7 PWM X7
movement
YA26 Solenoid valve on conveyor belt pump for backwards ID 16 / AO 8 PWM X8
movement

AO = Analog output

008 917 69 BOMAG 163

5.24 Modules in engine compartment, CR2031

Fig. 1 Input/output modules to control the solenoid valves

1 U1 - ID node 16, protected by 204.5F1 (15 A) + 204.5F2 (4 A)
2 U2 - ID node 17, protected by 204.5F3 (15 A) + 204.5F4 (4 A)
3 U3 - ID node 18, protected by 204.5F5 (15 A) + 204.5F6 (4 A)
4 U4 - ID node 19, protected by 204.5F7 (15 A) + 204.5F8 (4 A)

Caution
!

As a measure to avoid contact corrosion between fastening screws and module housing you should not
use stainless steel or nickel plated screws.
Unused terminals on the I/O-module must be protected with protective caps.
The housing must be connected to GND (e.g. to vehicle ground) to ensure electric interference protec-
tion of the equipment.
Since the module does not contain any components that require servicing by the user, the housing must
not be opened. The module must only be repaired by the manufacturer.

164 BOMAG 008 917 69

Description of module CR2031 5.25
5.25 Description of module CR2031
Input/output module (CAN-Bus) with 8 digital outputs, 4 PWM outputs and 4 current inputs
l Switching current per output max. 4 A
l Total current max. 16 A

Fig. 1
(A) = Terminals

!Caution
Default value for baud rate "S1" (Fig. 1) is position 4 (125 Kbit/s.) The baud rate* must correspond with
the transmission speed of the other network subscribers.
Default value for (ID nodes IDH) "S2" is position 1.
Switching states for (ID nodes IDL) "S3" (0 to 3) defines the address of the modules.
After installing a new CR 2031 module, the address of this new module needs to be set. Each new mod-
ule is set to the address 32 by default.
U1 = ID node 16, switching state "S3" = 0

* Baud, abbreviation: Bd = unit for data transmission speed. The term "baud" specifies the number of state changes (steps, cycles) per
second in a transmission path. 1 MBd = 1024 x 1024 Bd = 1 048 576 Bd.

008 917 69 BOMAG 165

5.25 Description of module CR2031

U2 = ID node 17, switching state "S3" = 1

U3 = ID node 18, switching state "S3" = 2
U4 = ID node 19, switching state "S3" = 3

The address of the module CR2031 can be set by software (see chapter: Can-Bus, Parameter and Diag-
nose ® Can Bus Change Node ID.

Operation indicators with LEDs

l PWR = 1 LED (green)
l
DIA, diagnose = 1 LED (red)
l Status of outputs = 8 LED (yellow)

LED
OUT no supply voltage
On Module in standby mode
PWR, voltage supply
Outputs = off
(green)
flashing Module active
2 Hz Outputs are being updated
OUT Communication OK
DIA, diagnose (red)
On Communication disturbed
OUT (yellow) On Binary output: Output is triggered (ON)

Connection system

Screwdriver

Cable

Conductor

Fig. 2 Terminal
l
Insert the screwdriver and tilt it slightly. (The spring opens)
l
Insert the conductor.
l
Pull out the screw driver. (The spring closes)

i Note
Tighten the cover screws with a torque of 1.2 Nm when closing the terminal connection chamber.

166 BOMAG 008 917 69

Description of module CR2031 5.25
Assignment of connections

Fig. 3

008 917 69 BOMAG 167

5.25 Description of module CR2031

CANH CAN-interface (High) PWM Output for pulse-width-modulated signals

CANL CAN-interface (Low) VBBC Operating voltage (via plug CAN in/CAN out)Betrieb-
sspannung (über Stecker CAN in/CAN out)
CANO Ground (Output) VBBO Operating voltage (output)
CANS Ground (module) VBBS Operating voltage (module)

168 BOMAG 008 917 69

Description of module CR2012 5.26
5.26 Description of module CR2012
Input/output module for CAN-Bus connection of control and display elements.

Fig. 1 CR2012

!Caution
Default value for baud rate "S1" (Fig. 1) is position 4 (125 Kbit/s.) The baud rate* must correspond with
the transmission speed of the other network subscribers.
Switching state "S2" (1 to 14) defines the address (ID-node).
After installing a new CR 2012 module, the address of this new module needs to be set. Each new mod-
ule is set to the address 32 by default.

The address of the module CR2012 can be set by software (see chapter: Can-Bus, Parameter and Diag-
nose Parameter and Diagnose Can Bus Change Node ID.
The module saves the last 4 faults that have occurred.
The following I/O-configuration has been configured
l 16 digital inputs
l 4 analog inputs

008 917 69 BOMAG 169

5.26 Description of module CR2012

l 2 plus-switching outputs; short circuit and overload proof The supply voltage UB is switched without additional
fusing.. The output states can be read back. Switching current max. 500 mA.
l 2 PWM-outputs (High-Side), variable frequency. Switching current max. 500 mA.

Fig. 2

Plug X1
Pin Potential Inputs output
1 Channel 1 Bin IN 1 - -
2 +UB
3 Channel 2 Bin IN 2 - -
4 +UB
5 Channel 3 Bin IN 3 - -
6 +UB
7 Channel 4 Bin IN 4 - -
8 +UB
9 +UB
10 +UB
11 Channel 5 Bin IN 5 Ana IN 5 -
12 Channel 6 Bin IN 6 Ana IN 6 -
13 GND
14 GND
15 Channel 7 Bin IN 7 - Bin OUT 7
16 GND
17 Channel 8 Bin IN 8 - Bin OUT 8
18 GND

Plug X2
Pin Potential Inputs output
1 Channel 9 Bin IN 9 - -
2 +UB
3 Channel 10 Bin IN 10 - -
4 +UB
5 Channel 11 Bin IN 11 - -
6 +UB

170 BOMAG 008 917 69

Description of module CR2012 5.26
Plug X2
7 Channel 12 Bin IN 12 - -
8 +UB
9 +UB
10 +UB
11 Channel 13 Bin IN 12 Ana IN 13 -
12 Channel 14 Bin IN 14 Ana IN 14 -
13 GND
14 GND
15 Channel 15 Bin IN 15 - Bin OUT 15
16 GND
17 Channel 16 Bin IN 16 - Bin OUT 16
18 GND

Plug X3
Pin 1 = +UB each module is protected with a 1A fuse as overall system protection.
Pin 2 = GND
Pin 3 = +UB each module is protected with a 1A fuse as overall system protection.
Pin 4 = GND
Pin 5 = CAN-L
Pin 6 = CAN-H

i Note
The terminals of potential +UB (PIN 1 + Pin 3) are bridged on the circuit board, just like the terminals of potential
GND (PIN 2 + PIN 4).

Operation indicators with LEDs

l CANopen = 2 LEDs (green/red)
l Inputs/outputs = 16 LEDs (yellow)

008 917 69 BOMAG 171

5.26 Description of module CR2012

LEDs
OUT no supply voltage
On Module in standby mode
Inputs/outputs = off
flashing Module active
LED green
2.5 Hz CANopen status: OPERATIONAL
Inputs/ outputs are being updated
1 X On Me in stop mode
CANopen status: Stop
OUT Communication OK
On Communication disturbed
CAN Error Warning Level exceeded
1 X On Communication disturbed
LED red CAN-Bus Off
2 X On Communication disturbed
NodeGuard-/Heartbeat error
3 X On Communication disturbed
non Synch objects
IN OUT Output not triggered
LED yellow On Input not triggered
OUT Binary output is not triggered (OFF)
Analogue output:
OUT PWM nominal value < 1% measuring range
LED yellow On Binary output is triggered (ON)
Analogue output:
PWM nominal value > 2% measuring range

172 BOMAG 008 917 69

Rope sensors, height regulation 5.27
5.27 Rope sensors, height regulation
Sensor right (C22)
This sensor is mounted on the right hand side of the machine frame and the cable end is fastened to the right
side door.

Fig. 1 Rope sensor right

008 917 69 BOMAG 173

5.27 Rope sensors, height regulation

Sensor left (C24)

This sensor is mounted on the left hand side of the machine frame in front of the milling drum drive V-belt and
the cable end is fastened to the left side door.

Fig. 2 Rope sensor left

Picture Designation in Description Terminal in Measuring

circuit diagram electrical value
junction box
1 C22 Sensor right XD:35 0-10 V
2 C24 Sensor left XS:28 0-10 V

174 BOMAG 008 917 69

Rope sensors, height regulation 5.27
Function
Changing the height of the machine moves the wire rope. This in turn moves a potentiometer inside the sensor
via a mechanical device.
The further the wire rope is pulled out, the high the voltage on the potentiometer output.

Pin assignment

Fig. 3 Pin assignment

A = voltage supply
B = output voltage
C = ground (GND)
l There is a constant resistance between clamps A and C (Fig. 3).
l The resistance changing in dependence on the rope length can be measured between the clamps A and B .

008 917 69 BOMAG 175

5.28 Rope sensor for steering

The rope sensors detect the steering angle of the crawler tack drives. The measured value is transmitted to the
electronic control, which regulates the steering in dependence on the selected steering mode. There is a sensor
for the front crawler track drives and one for the rear crawler track drives.

Front steering, C14

Fig. 1 Rope sensor, front steering

The rope sensor is located at the left under the machine frame in front of the milling housing on the steering
cylinder.

176 BOMAG 008 917 69

Rope sensor for steering 5.28
Rear steering, C16

Fig. 2 Cable sensor, rear steering

The cable sensor is located at the left under the machine frame, behind the milling housing on the steering cyl-
inder.

Designation in cir- Description Terminal in Measuring

cuit diagram electrical junc- value
tion box
C14 Rope sensor for detection of steering angle on the front XS:57 0-10 V
crawler track drive
C16 Rope sensor for detection of steering angle on the rear XS:60 0-10 V
crawler track drive

008 917 69 BOMAG 177

5.28 Rope sensor for steering

Setting neutral position

i Note
After replacing a rope sensor the neutral position must be adjusted as follows:
l Align the crawler tracks to the longitudinal axis of the machine.
l
Adjust the sensor so that the rope performs the same movement on either side (sensor centered).
l
With the ignition switched off press buttons 14, 15 and 8 (Fig. 3) at the same time.
l
Switch the ignition back on with the buttons (14, 15 and 8) depressed (second person required).

Fig. 3
A page with three symbols (A, B and X) is displayed.
l Wait approx. 30 seconds, until the system has stabilized.
l Release the buttons and wait approx. 30 seconds, until the system has stabilized.
l Press button (11) "DIS 0" for zeroizing.
The display automatically shows the working page.

178 BOMAG 008 917 69

Sensors for height limitation rear, C50 and C51 5.29
5.29 Sensors for height limitation rear, C50 and C51

Sensors

Fig. 1 Height sensor on left rear lift cylinder

i Note
(Fig. 1) shows the sensor on the left rear column. The sensor on the right column is accordingly.

Designation in cir- Description Terminal in Measuring

cuit diagram electrical junc- value
tion box
C50 Proximity switch for height limitation left rear XS:31 0 / 24V
C51 Proximity switch for height limitation right rear XS:38 0 / 24V
l The machine can only be raised up to the switching point of one of the two sensors.

i Note
The sensors are fitted with a red and a green LED.
Green = not switched, contact open
Red = switched, contact closed

008 917 69 BOMAG 179

5.30 Inclination sensor height regulation, C19

This sensor is inside the central electrics.

Fig. 1 Inclinometer

Designation in circuit diagram Description Terminal in electrical junction Measuring

box value
C19 Inclination sensor XA:19 0.5 - 4.5 V

The voltage applied to the output pin varies in dependence on the inclination of the machine.
l -15° degree = 0,5 Volt
l 0° degree = 2,5 Volt
l +15° degree = 4,5 Volt

Pin assignment
1 = power supply 24 Volt
2 = voltage output 0,5 - 4,5 Volt
3 = vehicle ground (GND)

180 BOMAG 008 917 69

Limit switch on back door, C48 and C49 5.31
5.31 Limit switch on back door, C48 and C49
The limit switches detect the position of the back door. They are located at the right and left on the back door.

Limit switch left, C48

Fig. 1 Limit switch - C48

008 917 69 BOMAG 181

5.31 Limit switch on back door, C48 and C49

Limit switch right, C49

Fig. 2 Limit switch - C49

Designation in cir- Description Terminal in Measuring

cuit diagram electrical junc- value
tion box
C48 Switch, back door half lifted XS:22; X1:15 0 / 24 V
C49 Switch, back door completely opened XD:26; X1:17 0 / 24 V

Description of function

Back door raised

l The contacts of switch C48 (Fig. 1) open, when the back door is half lifted. In this position it is possible to leave
the material in the milled area. In this position milling is possible.

Back door completely opened

l The contacts of switch C49 (Fig. 1) are opening, when the back door is completely open and tilted back. Milling
and driving the machine is now not possible.

182 BOMAG 008 917 69

Limit switch on back door, C48 and C49 5.31
i Note
Once the back door is opened, it is no longer possible to drive the machine or to switch on the milling drum. This
is a special safety feature for the operator who has to undertake work on the milling drum.

The multi-function display can be used to query the operating states of the back door, see chapter
"Electrics multi-function display" menu option, MACHINE STATES PAGE 400.

The multi-function display can be used to read out the switching states of the ID-nodes, see chapter
"Electrics Can bus" menu option , CHECK INPUT OUTPUT.

008 917 69 BOMAG 183

5.32 Water sprinkling system

Fig. 1
1 YA10 Solenoid valve for water pump
2 Shut-off valve, supply for high pressure cleaner*
3 Pressure gauge for spraying pressure
4 Main shut-off valve
5 Press drain tap
6 Shut-off valve for gathering belt spray bar
7 Shut-off valve for milling drum spray bar
8 Flow control valve
9 Water filter
10 Connecting socket for external connection (low pressure)
11 Shut-off valve for external connection (cleaning)
12 C40 Pressure switch for water sprinkling system
13 YB10 Solenoid valve for water sprinkling system

Pos. Designation in Description Terminal in Measuring

circuit diagram electrical value
junction box
1 YA10 Solenoid valve for water pump X7:4 0 / 24 V
12 C40 Pressure switch for water sprinkling system XD:62 0 / 24 V
13 YB10 Solenoid valve for water sprinkler system X8:4 0 / 24 V

The pressure switch (12) serves the purpose of monitoring the water reservoir. This monitoring ensures that the
water pump will not run dry and thus be damaged.

* Optional equipment

184 BOMAG 008 917 69

Water sprinkling system 5.32

Fig. 2
When the rotary button (B17-S15 or B19-S15) (Fig. 2) is actuated, the solenoid valve (YB10) is energized and
opens the water flow. At the same time the solenoid valve (YA10) for the water pump is also energized and the
water spray pump delivers water. The control lamp (B17-H10 or B19-H10) on the rotary button (B17-S15 or B19-
S15) lights.

i Note
In case of a lack of water (water pressure 5 sec. < 1.5 bar) both solenoid valves and the control lamp will be
switched off.

008 917 69 BOMAG 185

5.33 Hydraulic oil differential pressure switches C102, C103 and

5.33 Hydraulic oil differential pressure switches C102, C103 and C104

Fig. 1 Differential pressure switch for travel circuit

Fig. 2 Differential pressure switch for conveyor belt circuit

186 BOMAG 008 917 69

Hydraulic oil differential pressure switches C102, C103 and 5.33

Fig. 3 Diffwerential pressure switch for service circuit

Designation in cir- Description Terminal in Measuring

cuit diagram electrical junc- value
tion box
C102 Differential pressure switch for travel circuit XD:81 - / Ground
C103 Differential pressure switch for conveyor belt circuit XD:82 - / Ground
C104 Diffwerential pressure switch for service circuit XD:83 - / Ground

008 917 69 BOMAG 187

5.34 Speed sensor, C53

Fig. 1 Speed sensor on rear right travel motor

Designation in circuit diagram Description Terminal in electrical junc- Measuring value

tion box
C53 RPM-sensor XD:16 2366 pulses per meter

Pin assignment
1 = power supply 24 Volt
2 = vehicle ground (GND)
3 = frequency output (0 - 3 kHz)

Working principle
The speed sensor records the distance travelled by the milling machine. The sensor signals are passed on to
the machine control and are there used to determine the milled distance. The milled distance results from the
signals of the sensor, linked with the signal of the switched on milling drum.

188 BOMAG 008 917 69

Terminal box 5.35
5.35 Terminal box

Overview
The terminal box contains the individual terminal strips, relays, fuses, controls, sensors and diagnostic sockets.
All actuators and sensors are connected in the control cabinet.

Fig. 2 Control cabinet

Arrangement of plugs

Fig. 3 I/O modules

008 917 69 BOMAG 189

5.35 Terminal box

Pos. Designation in Description Page in circuit diagram

circuit diagram
1 B20 - U5 I/O module (CR0505) 116; 204.4; 206.7; 226.5; 226.9; 264.6;
264.8; 290.4; 503.1
2 B20 - Z1 Interference suppressor 200
3 B20 - K1/K2/K3 Power relay (see circuit diagram) 200 (K2 & K3); 272 (K1)
4 B20 - U11 Voltage converter 24V  10V 200.1
5 B20 - S1 TEST switch 204.4
6 B20 - U10 Voltage converter 24V  12V 200.1
7 B20 - U13 Interface converter RS485  RS232 226.8
8 B20 - U12 Inclination sensor 266.5
9 B20 - F1  F54 Melting fuses 180; 200.1; 201.2; 204.2; 204.3; 204.4;
204.5; 204.6; 205; 206.7; 214.3; 226.5;
226.6; 226.7; 226.8; 238.8; 240; 242.2;
264.6; 266; 272.1; 272.2; 272.3; 272.4;
274; 280; 281; 290.1; 290.4
10 B20 - K4  K8; Relays 205; 214.2; 238.8; 238.9; 290.4
B20 - K10
11 B20 - U1 I/O module 116; 204.3; 205; 214.1; 226.4; 236.1;
290.3; 290.4; 503.1
12 B20 - U2 I/O module 116; 204.3; 234.1; 236.1; 236.2; 264.5;
290.1; 503.2
13 B20 - U3 I/O module 116; 204.3; 226.6; 242.1; 290.2; 290.3;
290.4; 503.3
14 B20 - U4 I/O module 116; 204.3; 214.2; 214.3; 238.2; 238.9;
290; 290.4; 503.4

190 BOMAG 008 917 69

Electronic control units 5.36
5.36 Electronic control units

Control units
Control units (ECU = electronic control unit or ECM = electronic control module) are electronic modules which
are mainly installed in places where something needs to be controlled or regulated. Control units are used in
almost any electronic sector in the automotive industry, but also to control machines, plants and other technical
processes.
Control units generally work according to the IPO-principle. IPO stands for Input-Processing-Output. Sensors
are available for input. Sensors determine a physical characteristic like e.g. rotary speed, pressure, temperature,
etc. This value is compared with a setpoint entered into or calculated in the control unit. If the measured value
does not match the stored value, the control unit regulates the physical process by means of actors, so that the
measured actual values match the setpoint again. This means that the actors correctively interfere with the on-
going process.

Fig. 1 Electronic control (ESX)

In current vehicles control units are linked via various system buses (CAN, LIN, MOST, Flexray). The units ex-
change information about operating states and other relevant data in vehicle across the system. Furthermore,
the on-board diagnostic or the diagnostic system of the vehicle is connected via such busses (and possible K-
lines). Furthermore, external diagnostic devices (alternatively Personal Computers or Notebooks plus matching
Interface) can communicate with the control units. In this case the system will be interrogated to find out whether
the permanent self tests of the control unit has revealed and registered any faults in itself or on the connected
sensors.

008 917 69 BOMAG 191

5.37 Description of module CR0505

Description
The CR0505 is a classic mobile control in Black-Box design for realizing a central or de-central system structure.
The control has a second CAN interface to be able to provide a Gateway function as specified in SAE J 1939.

Fig. 2 CR0505

Technical data

Housing closed, screened metal housing with flange fastening

Dimensions (H x W x T) 153 x 226 x 43 mm
Connection 1 connecting plug 55-pin, locked, protected against polarity reversal, type AMP or
Framatome contacts AMP-Junior-Timer, crimp connection 0.5/2.5 mm2
Protection class IP 67 (plugged in plug with single conductor sealing, e.g. EC2084)
Input/output channels max. 24 (the available number depends on the connection assignment and the config-
(total) uration of the control)
Operating voltage 10 ... 32V DC
Current draw < 160mA (without external load at 24V DC)
CAN interface 1 CAN interface 2.0 B, ISO 11898
Baud rate 50 kBit/s...1 MBit/s (default 125 kBit/s)
Communication profile CANopen, CiA DS 301 Version 4, CiA DS 401 Version 1.4
CAN interface 2 CAN interface 2.0 A/B, ISO 11898
Baud rate 50 kBit/s...1 MBit/s (default 125 kBit/s)
Communication profile SAE J 1939 or free protocol
Serial interface RS-232 C
Baud rate 9.6 / 19.2 / 28.8 / 38.4 / 57.6 kBit/s (default 57.6 kBit/s)
Topology point-to-point (max. 2 subscribers); Master-Slave connection
Protocol Pre-defined ifm protocol (INTELHEX)
Processor CMOS micro-controller 16 bit C167CS clock frequency 20/40 MHz
Status display Three-colour LED (green, yellow, red)

192 BOMAG 008 917 69

Description of module CR0505 5.37
Operating states (status LED)

LED-colour Flashing sequence Description

off without no operating voltage
Yellow 1x On Initialization or reset check
Green 5 Hz no operating system loaded
Green 2 Hz Run
on Stop
Red 2 Hz Run with error
on Fatal Error or stop with error

Inputs (possible configurations)

Maximum 24 inputs (corresponds with 0 outputs)

Quantity Signal Design Designation

8 digital for positive sensor signals, diagnosable BL
or analogue 0...10/32 V DC, 0/4...20 mA or ratio-metric A
8 digital for positive sensor signals BL
4 digital for positive sensor signals, diagnosable BL
or Frequency max. 50 kHz IL
4 digital for positive/negative sensor signals, diagnosable* BL/H
or Frequency max. 1 kHz IL
* only positive sensor signals are diagnosable

Outputs (possible configurations)

Maximum 8 outputs (corresponds with 16 inputs)

Quantity Signal Design Designation

8 digital pulse switching (High-Side). diagnosable BH
or PWM PWM-frequency 20...250 Hz PWM
or current controlled 0,1...4 A PWMI

008 917 69 BOMAG 193

5.37 Description of module CR0505

Assignment of connections

PIN Potential Designation

23 VBBS (10 ... 32 V DC) Supply for sensors and module
05 VBBO (10 ... 32 V DC) Supply for outputs
34 VBBR (10 ... 32 V DC) Supply via relay
01 GNDS Ground for sensors and module
15 GNDO Ground for outputs
12 GNDA Ground for analog inputs
CAN, RS-232, Error, Test
14 CAN 1H CAN-interface 1 (high)
32 CAN 1L CAN-interface 1 (low)
26 CAN 2H CAN-interface 2 (high)
25 CAN 2L CAN-interface 2 (low)
33 GND Ground (RS-232/CAN)
06 RxD RS-232 interface (programming) pin 03,
PC D-Sub
07 TxD RS-232 interface (programming) pin 02,
PC D-Sub
13 ERROR Error output BH
24 TEST Test input

194 BOMAG 008 917 69

Machine control CR0505 5.38
5.38 Machine control CR0505

Fig. 1 Machine control CR0505

The machine control is inside the control cabinet in travel direction left. It consists of:
l
24 digital inputs
l
8 analog outputs, 1 to 4 Amp.
l
8 PWM outputs
l CAN interface 1
l
CAN interface 2
l
Serial interface

! Caution
The housing must be connected to GND to ensure electric interference protection of the equipment.
Since the control does not contain any components that require servicing by the user, the housing must
not be opened. The control must only be repaired by the manufacturer. The unit must only be disposed
of in strict compliance with national provisions on protection of the environment.

008 917 69 BOMAG 195

5.38 Machine control CR0505

Operating indications with three-colour LEDs

Fig. 2

LED-colour Flashing sequence Description

off without no operating voltage
Yellow 1x On Initialization or reset check
Green 5 Hz no operating system loaded
Green 2 Hz Run
on Stop
Red 2 Hz Run with error
on Fatal Error or stop with error

196 BOMAG 008 917 69

Machine control CR0505 5.38
Hardware structure
The hardware structure shows schematic relations between the individual current paths (Fig. 3).
The ClassicController has 2 internal monitoring relays, each of which can isolate 12 outputs from the electric
power supply.
The following general diagram shows the dependency of the relays from the applied signals and the logic states
of the system markers.

Fig. 3 General structure of the monitoring concept

Function of the delayed shut-down

If the controllers are isolated from the electric power supply, normally all electric outputs are immediately
switched off, input signals are no longer read and the processing sequence of the controller software (operating
system and application program) is aborted. This takes place irrespective of the program step the controller is
currently in.

Clamp VBBS (23) connected with ignition switch

Clamp (23) disconnectibly supplies the controller via the ignition switch. In automobile technology this potential
is referred to as "Clamp 15". The clamp is internally monitored. If no supply voltage is applied, the system marker
CLAMP_15 is set to FALSE.

Clamp VBBO (5) connected with battery (not switched)

Clamp (5) supplies up to12 outputs of output group VBBO with electric power. At the same time this clamp also
supplies the latching function of the control electronics.

Latching
Latching is active when VBBO has voltage applied and the system marker RELAIS_CLAMP_15 (and thus the
relay "Clamp") is set.
If the system marker RELAIS_CLAMP_15 is reset, the relay [Clamp] drops off. If no voltage is applied to the
clamp (23) at this moment, latching is disabled and the controller will switch off automatically.

Monitoring the supply voltage VBBR (34)

Clamp (34) supplies up to 12 outputs of output group VBBR with electric power. The system additionally monitors
whether supply voltage is applied.

008 917 69 BOMAG 197

5.38 Machine control CR0505

Fuse

Fig. 4

i Note
The individual electric circuits are protected by fuses as a protection of the overall systemn (wiring and control).
All supply and signal lines are routed separately. Supply and ground cables for control and sensors/actuators
are connected through a common neutral point.

Designation Potential Pin Fuse

Supply voltage sensors/module VBBS 23 204.4F17
7.5A
Supply voltage outputs VBBO 05 204.4F16
7.5A
Supply voltage via relay VBBR 34 204.4F18
7.5A

6 CAN-Bus, Parameter and Diagnose

008 917 69 BOMAG 209

6.1 CAN BUS overview

Sensors

Actors

Valve block in engine compartment

Fig. 1

210 BOMAG 008 917 69

CAN BUS overview 6.1
B14 - U5 = EMR engine control unit.
B17 = Control console, left
B18 - U1 = Instrument cluster
B19 = Control console, right
B20 = Central electrics
B20 - U5 = Machine control

Characteristics of CAN
Bus = serial data transmission of several subscribers using the same line.
The individual bits are transmitted one after the other, only 2 lines are required.
Each bus subscriber can send messages (multi-master ability) This data exchange works similar to broadcast-
ing. Data are send on the bus without sender and address. The data are only marked by their identifier. It is the
duty of each subscriber to receive the transmitted data and use the identifier to check whether these data are of
relevance for this subscriber. This process is automatically performed by the CAN controller in connection with
the operating system.

CAN lines
CAN lines are twisted together 30 to 40 times per metre. Electromagnetic interferences therefore always occur
simultaneously in both lines, the software is thus able to filter out interfering signals more easily.

Measuring on the CAN

Signals transmitted through the bus line can generally not be measured with simple measuring instruments.
Testing is therefore quite complicated for the user. Correct connection of lines can only be checked by means
of a continuity test. The display module can be connected to the BUS to give engineers and user the possibility
to detect faults or to receive information from the BUS.

Why CAN?
l
Networking of control units for the realization of complex functions.
l
Reduction of the extend of wiring and plug connections.
l
Better diagnostics possibilities.

008 917 69 BOMAG 211

6.2 ID nodes, overview and fusing

ID = Identifier*
6.2 ID nodes, overview and fusing

ID- Module Type Installation location Elec- Fuse

node designa- tric cir-
tion cuit
dia-
gram
ID 01 B17-U1 CR2012 Control console left, B17 110 204F1, 1A
ID 02 B17-U2 CR2012 Control console left, B17 110 204F2, 1A
ID 03 B17-U3 CR2012 Control console left, B17 110 204F3, 1A
ID 04 B17-U4 CR2012 Control console left, B17 110 204F4, 1A
ID 05 B17-U5 CR2012 Control console left, B17 110 204F5, 1A
ID 06 B19-U1 CR2012 Control console right, B19 112 204.1F1, 1A
ID 07 B19-U2 CR2012 Control console right, B19 112 204.1F2, 1A
ID 08 B19-U3 CR2012 Control console right, B19 112 204.1F3, 1A
ID 09 B19-U4 CR2012 Control console right, B19 112 204.1F4, 1A
ID 10 B19-U5 CR2012 Control console right, B19 112 204.1F5, 1A
ID 11 B20-U1 CR2012 in main control cabinet first from left 116 204.3F1, 1A
ID 12 B20-U2 CR2012 in main control cabinet second from left 116 204.3F2, 1A
ID 13 B20-U3 CR2012 in main control cabinet third from left 116 204.3F3, 1A
ID 14 B20-U4 CR2012 in main control cabinet fourth from left 116 204.3F4, 1A
ID 15 not used
ID 16 B14-U1 CR2031 left in main control cabinet first from left 118 204.5F1, 15A
204.5F2, 4A
ID 17 B14-U2 CR2031 left in main control cabinet second from left 118 204.5F3, 15A
204.5F4, 4A
ID 18 B14-U3 CR2031 left in main control cabinet third from left 118 204.5F5, 15A
204.5F6, 4A
ID 19 B14-U4 CR2031 left in main control cabinet fourth from left 118 204.5F7, 15A
204.5F8, 4A
ID 20
ID 21
ID 22
ID 23
ID 24
not used
ID 25
ID 26
ID 27
ID 28
ID 29
ID 30 B20-U5 CR0505 Machine control in main control cabinet 116 204.4F1, 7,5A
204.4F2, 7,5A
204.4F3, 7,5A
ID 31
not used
ID 32

* Name used to differentiate between the equipment / subscribers connected to a system or between the subscribers exchanging mes-
sage packages.

212 BOMAG 008 917 69

ID-nodes, inputs 6.3
6.3 ID-nodes, inputs

Input Function ID-node Dis- PIN

play
status
B3: NC Connection AUX to lower the front left column ID 11 / DI 02 0/1 X1.3
(226.3.4)
B3: NC Connection AUX to lift the front left column ID 11 / DI 01 0/1 X1.1
(226.3.3)
B6: NC ( Connection AUX to lower the front right column ID 11 / DI 04 0/1 X1.7
226.3.6)
B6: NC Connection AUX to lift the front right column ID 11 / DI 03 0/1 X1.5
(226.3.7)
B14-C11 Warning switch for engine coolant level ID 13 / DI 11 0/1 X2.5
B18-S8: 13 Diagnostics switch in central operating console ID 11 / DI 06 0/1 X1.12
B14-C5: D+ D+ signal from generator ID 13 / DI 10 0/1 X2.3
B17-UJ1-S1 Safety push button switch in left hand travel lever ID 02 / DI 06 0/1 X1.12
B17-UJ1-S1 Safety push button switch in right hand travel lever ID 07 / DI 06 0/1 X1.12
B17-UJ1 -F- Micro-switch for FORWARD in left travel lever ID 02 / DI 01 0/1 X1.1
B19-UJ1 -F- Micro-switch for FORWARD in right travel lever ID 07 / DI 01 0/1 X1.1
B17-UJ1 -P- Potentiometer in left hand travel lever ID 02 / AI 05 Ana- X1.11
logue
B19-UJ1 -P- Potentiometer in right hand travel lever ID 07 / AI 05 Ana- X1.11
logue
B17-UJ1 -R- Micro-switch for REVERSE in left hand travel lever ID 02 / DI 02 0/1 X1.3
B19-UJ1 -R- Micro-switch for REVERSE in right hand travel lever ID 07 / DI 02 0/1 X1.3
B17-S2: 23 Rotary switch differential lock OFF in left hand operating con- ID 02 / DI 04 0/1 X1.7
sole
B19-S2: 23 Rotary switch differential lock OFF in right hand operating con- ID 07 / DI 04 0/1 X1.7
sole
B17-S2: 13 Rotary switch differential lock ON in left hand operating con- ID 02 / DI 03 0/1 X1.5
sole
B19-S2: 13 Rotary switch differential lock ON in right hand operating con- ID 07 / DI 03 0/1 X1.5
sole
B17-S3: 13 Rotary switch travel speed HIGH in left operating console ID 02 / DI 10 0/1 X2.3
B19-S3: 13 Rotary switch travel speed HIGH in right operating console ID 07 / DI 10 0/1 X2.3
B17-S3: 23 Rotary switch working speed LOW in left operating console ID 02 / DI 09 0/1 X2.1
B19-S3:23 Rotary switch working speed LOW in right operating console ID 07 / DI 09 0/1 X2.1
B17-S4: 13 Rotary switch power limit control OFF in left operating console ID 03 / DI 12 0/1 X2.7
B19-S4: 13 Rotary switch power limit control OFF in right operating con- ID 08 / DI 12 0/1 X2.7
sole
B17-S4: 23 Rotary switch power limit control ON in left operating console ID 03 / DI 11 0/1 X2.5
B19-S4: 23 Rotary switch power limit control ON in right operating console ID 08 / DI 11 0/1 X2.5
C53 Speed sensor on rear right travel motor ID 30 / DI 12 0/1 X.20
B17-S5: 13 Rotary switch milling drum ON in left operating console ID 01 / DI 01 0/1 X2.11
B19-S5: 13 Rotary switch milling drum ON in right operating console ID 06 / DI 01 0/1 X2.11
B17-S5: 23 Rotary switch milling drum OFF in left operating console ID 01 / DI 02 0/1 X2.12
B19-S5: 23 Rotary switch milling drum OFF in right operating console ID 06 / DI 02 0/1 X2.12
B3/B4-S2: 13 Rotary button back door in FLOAT POSITION from rear oper- ID 11 / DI 14 0/1 X2.12
ating consoles
B3/B4-S2: 23 Rotary button back door OPEN from rear operating consoles ID 11 / DI 13 0/1 X2.11
B3/B4-S3: 23 Rotary button back door CLOSE from rear operating consoles ID 11 / DI 12 0/1 X2.7
B3/B4-S3: 13 Rotary button back door OPEN from rear operating consoles ID 11 / DI 11 0/1 X2.5
C48 13 Limit switch back door RAISED ID 14 / DI 07 0/1 X1.15
C49: 13 Limit switch back door OPENED ID 14 / DI 08 0/1 X1.17
B2/B7-S1: 23 Rotary button to REDUCE the pre-pressure on the back door ID 14 / DI 09 0/1 X2.1
B2/B7-S1: 13 Rotary button to INCREASE the pre-pressure on the back door ID 14 / DI 10 0/1 X2.3
B17-S6: 23 Rotary switch for back door FLOAT POSITION in left operating ID 03 / DI 04 0/1 X1.7
console
B19-S6: 23 Rotary switch for back door in FLOATING POSITION in right ID 08 / DI 04 0/1 X1.7
operating console

008 917 69 BOMAG 213

6.3 ID-nodes, inputs

Input Function ID-node Dis- PIN

play
status
B17-S6: 13 Rotary switch for back door UP in left operating console ID 03 / DI 03 0/1 X1.5
B19-S6: 13 Rotary switch for back door UP in left operating console ID 08 / DI 03 0/1 X1.5
B17-S8: 13 Joystick for right front column UP in left operating console ID 01 / DI 09 0/1 X2.1
B19-S8: 13 Joystick for right front column UP in right operating console ID 06 / DI 09 0/1 X2.1
B17-S8: 23 Joystick for right front column DOWN in left operating console ID 01 / DI 10 0/1 X2.3
B19-S8: 23 Joystick for right front column DOWN in right operating con- ID 06 / DI 10 0/1 X2.3
sole
B17-S9: 23 Rotary switch for all columns UP + stop function in left operat- ID 02 / DI 13 0/1 X2.11
ing console
B19-S9: 23 Rotary switch for all columns UP + stop function in right oper- ID 07 / DI 13 0/1 X2.11
ating console
B17-S9: 13 Rotary switch for all columns UP in left operating console ID 02 / DI 14 0/1 X2.12
B19-S9: 13 Rotary switch for all columns UP in right operating console ID 07 / DI 14 0/1 X2.12
B17-S10: 13 Rotary switch for rear columns UP in left operating console ID 02 / DI 11 0/1 X2.5
B19-S10: 13 Joystick rear columns UP in right operating console ID 07 / DI 11 0/1 X2.5
B17-S10: 23 Rotary switch for rear columns DOWN in left operating console ID 02 / DI 12 0/1 X2.7
B19-S10: 23 Rotary switch for rear columns DOWN in right operating con- ID 07 / DI 12 0/1 X2.7
sole
B5/B6-S5: 23 Rotary button rear columns DOWN from rear operating con- ID 11 / DI 10 0/1 X2.3
soles
B5/B6-S5: 13 Rotary button rear columns UP from rear operating consoles ID 11 / DI 09 0/1 X2.1
C22 Rope sensor on side door right ID 30 / AI 04 Ana- X.27
logue
C24 Rope sensor on side door left ID 30 / AI 03 Ana- X.8
logue
B17-S7: 23 Joystick for left front column DOWN in left operating console ID 01 / DI 02 0/1 X1.3
B19-S7: 23 Joystick for left front column DOWN in right operating console ID 06 / DI 02 0/1 X1.3
B17-S7: 13 Joystick for left front column UP in left operating console ID 01 / DI 01 0/1 X1.1
B19-S7: 13 Joystick for left front column UP in right operating console ID 06 / DI 01 0/1 X1.1
B20-U12: s Inclination sensor ID 30 / AI 05 Ana- X.9
logue
C50: 4 Proximity switch on left rear column ID 13 / DI 01 0/1 X1.1
C52: 4 Proximity switch on right rear column ID 13 / DI 02 0/1 X1.3
C108: 4 Proximity switch on left front column ID 13 / DI 03 0/1 X1.5
C107: 4 Proximity switch on right front column ID 13 / DI 04 0/1 X1.5
B17-S11: 23 Rotary switch for break door FLOAT POSITION in left operat- ID 03 / DI 02 0/1 X1.3
ing console
B19-S11: 23 Rotary switch for break door FLOAT POSITION in right oper- ID 08 / DI 02 0/1 X1.3
ating console
B17-S11: 13 Rotary switch for break door UP in left operating console ID 03 / DI 01 0/1 X1.1
B19-S11: 13 Rotary switch for break door UP in right operating console ID 08 / DI 01 0/1 X1.1
B8/B9-S2: 23 Rotary button break door FLOAT POSITION in front operating ID 12 / DI 12 0/1 X2.7
consoles
B8/B9-S2: 13 Rotary button break door UP in front operating consoles ID 12 / DI 11 0/1 X2.5
B17-S12: 13 Rotary switch side door left UP/DOWN in left operating con- ID 05 / DI 09 0/1 X2.1
sole
B17-S12: 13 Rotary switch side door right UP/DOWN in right operating con- ID 10 / DI 09 0/1 X2.1
sole
B3-S4: 13 Rotary switch side door left UP/DOWN in rear left operating ID 12 / DI 09 0/1 X2.1
console
B4-S4: 13 Rotary switch side door right UP/DOWN in rear right operating ID 12 / DI 10 0/1 X2.3
console
B17-S12: 23 Rotary switch side door left PRESS DOWN in left operating ID 05 / DI 10 0/1 X2.3
console
B19-S12: 23 Rotary switch side door right PRESS DOWN in right operating ID 10 / DI 10 0/1 X2.3
console

214 BOMAG 008 917 69

ID-nodes, inputs 6.3
Input Function ID-node Dis- PIN
play
status
B3-S4:13 Rotary switch side door left PRESS DOWN in rear left operat- ID 11 / DI 01 0/1 X1.1
ing console
B4-S4: 23 Rotary switch side door right PRESS DOWN in rear right oper- ID 11 / DI 03 0/1 X1.5
ating console
B18-S3: 14 Rotary switch both side doors UP in central operating console ID 12 / DI 03 0/1 X1.5
B17-S13: 23 Rotary switch conveyor belt OFF in left operating console ID 05 / DI 01 0/1 X1.1
B19-S13: 23 Rotary switch conveyor belt OFF in right operating console ID 10 / DI 01 0/1 X1.1
B17-S13: 13 Rotary switch conveyor belt ON in left operating console ID 05 / DI 02 0/1 X1.3
B19-S13: 13 Rotary switch conveyor belt ON in right operating console ID 10 / DI 02 0/1 X1.3
B17-S14: 43 Joystick conveyor belt DOWN in left operating console ID 03 / DI 06 0/1 X1.12
B19-S14: 43 Joystick conveyor belt DOWN in right operating console ID 08 / DI 06 0/1 X1.12
B17-S14: 53 Joystick to swing conveyor belt to the RIGHT in the left oper- ID 03 / DI 14 0/1 X2.12
ating console
B19-S14: 53 Joystick to swing conveyor belt to the RIGHT in the right oper- ID 08 / DI 14 0/1 X2.12
ating console
B17-S14: 13 Joystick conveyor belt UP in left operating console ID 03 / DI 05 0/1 X1.11
B19-S14: 13 Joystick conveyor belt UP in right operating console ID 08 / DI 05 0/1 X1.11
B17-S14: 23 Joystick to swing conveyor belt to the LEFT in the left operating ID 03 / DI 13 0/1 X2.11
console
B19-S14: 23 Joystick to swing conveyor belt to the LEFT in the right operat- ID 08 / DI 13 0/1 X2.11
ing console
B18-R1: S Potentiometer for conveyor belt speed in middle operating ID 14 / AI 13 Ana- X2.11
console logue
C50: 4 Limit switch conveyor belt in working position ID 14 / DI 06 0/1 X1.12
B17-S15: 23 Rotary switch water sprinkling OFF in left operating console ID 01 / DI 06 0/1 X1.12
B19-S15: 23 Rotary switch water sprinkling OFF in right operating console ID 06 / DI 06 0/1 X1.12
B17-S15: 13 Rotary switch water sprinkling ON in left operating console ID 01 / DI 05 0/1 X1.11
B19-S15: 13 Rotary switch water sprinkling ON in right operating console ID 06 / DI 05 0/1 X1.11
C40 Pressure switch for water level indicator ID 13 / DI 09 0/1 X2.1
B17-S16: 13 Rotary switch for PAUSE OFF in left hand operating console ID 03 / DI 10 0/1 X2.3
B19-S16: 13 Rotary switch for PAUSE OFF in right hand operating console ID 08 / DI 10 0/1 X2.3
B17-S16: 23 Rotary switch for PAUSE ON in left hand operating console ID 03 / DI 09 0/1 X2.1
B19-S16: 23 Rotary switch for PAUSE ON in right hand operating console ID 08 / DI 09 0/1 X2.1
B17-S17: 43 Control lever steering mode COPY in left operating console ID 04 / DI 09 0/1 X2.1
B19-S17: 53 Control lever steering mode COPY in right operating console ID 09 / DI 09 0/1 X2.1
B17-S17: 53 Control lever steering mode MANUAL in left operating console ID 04 / DI 01 0/1 X1.1
B19-S17: 53 Control lever steering mode MANUAL in right operating con- ID 09 / DI 01 0/1 X1.1
sole
B17-S17: 13 Control lever steering mode CRABWALK in left operating con- ID 04 / DI 10 0/1 X2.3
sole
B19-S17: 13 Control lever steering mode CRABWALK in right operating ID 09 / DI 10 0/1 X2.3
console
B17-S17: 23 Control lever steering mode MIDDLE POSITION in left operat- ID 04 / DI 02 0/1 X1.3
ing console
B19-S17: 23 Control lever steering mode MIDDLE POSITION in right oper- ID 09 / DI 02 0/1 X1.3
ating console
B17-S18: 23 Control lever steering rear to the LEFT in the left operating ID 04 / DI 04 0/1 X1.7
console
B19-S18: 23 Control lever steering rear to the LEFT in the right operating ID 09 / DI 04 0/1 X1.7
console
B17-S18: 13 Control lever steering rear to the RIGHT in the left operating ID 04 / DI 03 0/1 X1.5
console
B19-S18: 13 Control lever steering rear to the RIGHT in the right operating ID 09 / DI 03 0/1 X1.5
console
B17-UJ2 -F- Micro-switch in left steering joystick to the LEFT ID 05 / DI 03 0/1 X1.5
B19-UJ2 -F- Micro-switch in right hand steering joystick to the LEFT ID 10 / DI 03 0/1 X1.5

008 917 69 BOMAG 215

6.3 ID-nodes, inputs

Input Function ID-node Dis- PIN

play
status
B17-UJ2 -P- Potentiometer in left hand steering joystick ID 05 / AI 05 Ana- X1.11
logue
B19-UJ2 -P- Potentiometer in right hand steering joystick ID 10 / AI 05 Ana- X1.11
logue
B17-UJ2 -R- Micro-switch in left hand steering joystick to the RIGHT ID 05 / DI 04 0/1 X1.7
B19-UJ2 -R- Micro-switch in right hand steering joystick to the RIGHT ID 10 / DI 04 0/1 X1.7
B5/B6-S3: 13 Rotary button rear steering to the LEFT in the rear operating ID 12 / DI 01 0/1 X1.1
consoles
B5/B6-S3: 23 Rotary button rear steering to the RIGHT in the rear operating ID 12 / DI 02 0/1 X1.3
consoles
C14 Rope sensor on front steering ID 30 / AI 08 Ana- X.29
logue
C16 Rope sensor on rear steering ID 30 / AI 09 Ana- X.11
logue
C17 Adjustment potentiometer for rear steering ID 30 / AI 10 Ana- X.30
logue
B14-C47: 2 Hydraulic oil temperature sensor ID 12 / AI 05 Ana- X1.11
logue
0...10V
B14-C96: 2 Hydraulic oil pressure sensor travel pump ID 12 / AI 06 Ana- X1.12
logue
0...10V
B14-C99: 2 Hydraulic oil pressure sensor in conveyor circuit ID 12 / AI 13 Ana- X2.11
logue
0...10V
B14-C100: 2 Hydraulic oil pressure sensor in fan circuit ID 12 / AI 14 Ana- X2.12
logue
0...10V
B14-C57: 2 Hydraulic oil pressure sensor in coupling circuit ID 13 / AI 05 Ana- X1.11
logue
0...10V
B14-C58: 2 Hydraulic oil pressure sensor in working hydraulics circuit ID 13 / AI 06 Ana- X1.12
logue
0...10V
B14-C50: 2 Hydraulic oil pressure sensor for break door ID 13 / AI 13 Ana- X2.11
logue
0...10V
B14-C60: 2 Hydraulic oil pressure sensor for back door ID 13 / AI 14 Ana- X2.12
logue
0...10V
B14-C102 Differential pressure switch for travel hydraulics ID 14 / DI 01 0/1 X1.1
B14-C103 Differential pressure switch for conveyor belt hydraulics ID 14 / DI 02 0/1 X1.3
B14-C104 Differential pressure switch for return flow filter ID 14 / DI 03 0/1 X1.5
B14-C46 Hydraulic temperature switch ID 14 / DI 04 0/1 X1.7
B14-C101 Hydraulic oil level switch ID 14 / DI 05 0/1 X1.11
B14-C9 Fuel level sensor ID 11 / AI 05 Ana- X1.11
logue

DI ... = Digital input

AI ... = Analog input

216 BOMAG 008 917 69

ID-nodes, outputs 6.4
6.4 ID-nodes, outputs

Output Function ID-node Dis- PIN

play
status
B18-S8+ Fault indicator lamp in middle console ID 13 / DO 08 0/1 X1.15
B20-K4 Relay to reduce the engine speed ID 11 / DO 07 0/1 X1.15
B20-K5 Relay to increase the engine speed ID 11 / DO 08 0/1 X1.17
B17-H1 LED brake CLOSED in left operating console ID 02 / DO 07 0/1 X1.15
B19-H1 LED brake CLOSED in right operating console ID 07 / DO 07 0/1 X1.15
B17-H2 LED differential lock ON in left operating console ID 02 / DO 08 0/1 X1.17
B19-H2 LED differential lock ON in right operating console ID 07 / DO 08 0/1 X1.17
B17-H3 LED working speed in left operating console ID 02 / DO 15 0/1 X2.15
B19-H3 LED working speed in right operating console ID 07 / DO 15 0/1 X2.15
B17-H4 LED for travel speed in left operating console ID 02 / DO 16 0/1 X2.17
B19-H4 LED for travel speed in right operating console ID 07 / DO 16 0/1 X2.17
B17-H5 LED power limit control ON in left operating console ID 03 / DO 16 0/1 X2.17
B19-H5 LED power limit control ON in right operating console ID 08 / DO 16 0/1 X2.17
B14-YA8 Solenoid valve, displacement travel motor (slow ON = sole- ID 16 / AO 1-2 PWM X1
noid valve OFF)
B14-YA9 Solenoid valve differential lock (differential lock ON = solenoid ID 16 / DO 04 0/1 X4
valve ON)
B14-YA7 Solenoid valve for brakes (brakes closed = solenoid valve ID 16 / DO 03 0/1 X3
OFF)
YB25 Solenoid valve on travel pump for forward ID 30 / AO 04 PWM X.54
YA25 Solenoid valve on travel pump for reverse ID 30 / AO 05 PWM X.36
B17-H6 LED milling drum ON in left operating console ID 01 / DO 16 0/1 X2.17
B19-H6 LED milling drum ON in right operating console ID 06 / DO 16 0/1 X2.17
B14-YA14 Solenoid valve to tension the drive belt ID 17 / DO 01 0/1 X1
B14-YB14 Solenoid valve to engage the clutch ID 17 / DO 02 0/1 X2
B17-H7 LED for back door FLOAT POSITION in left operating console ID 03 / DO 08 0/1 X1.15
B19-H7 LED for back door FLOAT POSITION in right operating con- ID 08 / DO 08 0/1 X1.17
sole
B3/B4-H1 LED for back door FLOAT POSITION in rear operating con- ID 11 / DO 16 0/1 X2.17
soles
YA18 Solenoid valve, back door UP ID 19 / DO 01 0/1 X1
B14-YB20 Solenoid valve, back door FLOAT POSITION ID 18 / AO 5-6 PWM X5
B14-YA20 Solenoid valve, back door UP ID 18 / DO 07 0/1 X7
B14-YA19 Solenoid valve, back door DOWN ID 18 / DO 08 0/1 X8
YA13 Solenoid valve, back door PRESS DOWN ID 19 / AO 5-6 PWM X5
B14-YA4 Temperature control valve fan circuit ID 16 / AO 5-6 PWM X5
B14-YA22 Solenoid valve to lift the LEFT column ID 30 / AO 00 PWM X.44
B14-YB22 Solenoid valve to lower the LEFT column ID 30 / AO 01 PWM X.45
B14-YB21 Solenoid valve for rear columns UP ID 17 / DO 03 0/1 X3
B14-YA21 Solenoid valve for rear columns DOWN ID 17 / DO 04 0/1 X4
B14-YA23 Solenoid valve to lift the RIGHT column ID 30 / AO 02 PWM X.46
B14-YB23 Solenoid valve to lower the RIGHT column ID 30 / AO 03 PWM X.47
B17-H8 LED for break door in FLOATING POSITION in left hand op- ID 03 / DO 07 0/1 X1.15
erating console
B19-H8 LED for break door in FLOATING POSITION in right hand op- ID 08 / DO 07 0/1 X1.15
erating console
B8/B9-H1 LED for break door in FLOATING POSITION in front operating ID 12 / DO 07 0/1 X1.15
consoles
B14-YB18 Solenoid valve for break door FLOAT POSITION ID 19 / DO 02 0/1 X2
B3-H2 Display light side door left lifted (only in left rear operating con- ID 12 / DO 15 0/1 X2.15
sole)
B4-H2 Display light side door right lifted (only in right rear operating ID 12 / DO 16 0/1 X2.17
console)
B14-YA33 Solenoid valve side door right UP ID 18 / AO 3-4 PWM X3.4
B14-YB33 Solenoid valve side door right DOWN ID 18 / DO 04 PWM X4.4
B14-YA3 Solenoid valve side door left UP ID 18 / AO 1-2 PWM X1.4

008 917 69 BOMAG 217

6.4 ID-nodes, outputs

Output Function ID-node Dis- PIN

play
status
B14-YB3 Solenoid valve side door left DOWN ID 18 / DO 03 PWM X2.4
B17-H9 LED for conveyor belt ON in left hand operating console ID 05 / DO 07 0/1 X1.15
B19-H9 LED for conveyor belt ON in right operating console ID 10 / DO 07 0/1 X1.15
B14-YA6 Solenoid valve to swing the conveyor belt to the left ID 17 / DO 07 0/1 X7
B14-YB6 Solenoid valve to swing the conveyor belt to the right ID 17 / DO 08 0/1 X8
B14-YA5 Solenoid valve conveyor belt UP ID 17 / DO 05 0/1 X5
B14-YB5 Solenoid valve conveyor belt DOWN ID 17 / DO 06 0/1 X6
B14-YA26 Solenoid valve on conveyor belt pump for forward movement ID 16 / AO 7-8 PWM X7
B14-YB26 Solenoid valve on conveyor belt pump for backwards move- ID 16 / AO 7-8 PWM X8
ment
B17-H10 LED water sprinkling ON in left operating console ID 01 / DO 08 0/1 X1.17
B19-H10 LED water sprinkling ON in right operating console ID 06 / DO 08 0/1 X1.17
B14-YA10 Solenoid valve for water sprinkling pump ID 19 / DO 07 0/1 X7
B14-YB10 Solenoid valve for water shut-off valve ID 19 / DO 08 0/1 X8
B17-H11 LED PAUSE ON in left operating console ID 03 / DO 15 0/1 X2.15
B19-H11 LED PAUSE ON in right operating console ID 08 / DO 15 0/1 X2.15
B17-H12 LED steering MAN in left operating console ID 04 / DO 07 0/1 X1.15
B19-H12 LED steering MAN in right operating console ID 09 / DO 07 0/1 X1.15
B17-H13 LED steering CENTER in left operating console ID 04 / DO 08 0/1 X1.17
B19-H13 LED steering CENTER in right operating console ID 09 / DO 08 0/1 X1.17
B17-H14 LED steering COPY in left operating console ID 04 / DO 15 0/1 X2.15
B19-H14 LED steering COPY in right operating console ID 09 / DO 15 0/1 X2.15
B17-H15 LED steering CRABWALK in left operating console ID 04 / DO 16 0/1 X2.17
B19-H15 LED steering CRABWALK in right operating console ID 09 / DO 16 0/1 X2.17
B14-YA17 Solenoid valve rear steering rear to LEFT ID 19 / AO 3-4 PWM X3
B14-YB17 Solenoid valve rear steering rear to RIGHT ID 19 / AO 3-4 PWM X4
B14-YB29 Solenoid valve steering front to the LEFT ID 30 / AO 06 PWM X.17
B14-YA29 Solenoid valve steering front to the RIGHT ID 30 / AO 07 PWM X.53
B20-K7: 13 Relay to switch the fault warning buzzer ID 14 / DO 16 0/1 X2.17
B20-K8: 13 Relay to switch the backup alarm ID 14 / DO 15 0/1 X2.15

DO ... = Digital output

AO = Analog output
AI ... = Analog input

218 BOMAG 008 917 69

7 Instrument cluster

008 917 69 BOMAG 219

7.1 Multi-function display

7.1 Multi-function display Scroll through pages

Page 2, hydraulic displays
Switching on
l Switch on the ignition.

Fig. 4
l Press key F5 (Fig. 4).
Fig. 2
The following information is displayed:
The initial screen is displayed (Fig. 2).
l 1 auxiliary hydraulics, current pressure

i Note l 2 conveyor belt drive, current pressure

Always wait until the basic screen is displayed l 3 clutch pressure, current pressure
l 4 scraper flap, current pressure
l 5 Hydraulic oil temperature
l 6 travel drive, current pressure
l 7 fan drive, current pressure
l 8 mouldboard, current pressure

Page 3, engine displays

Fig. 3
l The basic screen appears after approx. 10 seconds
(Fig. 3).

i Note
The display shows engine speed, operating hours, en-
gine oil pressure, coolant temperature, travel speed
and fuel level.
Fig. 5
l Press key F5 (Fig. 5).
The following information is displayed:
l 1 Engine speed
l 2 Coolant temperature
l
3 Temperature of air entering the engine, after inter-
cooler
l 4 Fuel consumption, current
l 5 Engine power with turbocharger

220 BOMAG 008 917 69

Multi-function display 7.1
l 6 Engine oil pressure
l 7 Battery / supply voltage
l 8 Turbocharger boost pressure
l 9 Fuel temperature
l 10 Fuel filling level

Settings
Setting brightness, contrast

Fig. 8
No. 3 = Multi-function display
The multi-function display serves the purpose of:
l displaying operation data
l indicating faults,
l reading out work parameters,
l and entering work parameters.

i Note
Fig. 6 The assignment of the individual function keys is dis-
played on the corresponding screen page.
l Press key F2 (Fig. 6).
OK = Turn for menu selection, press OK to
confirm selection.
F1 = ESC - back to the initial screen
F2 = extended functions
F3 = Function key
F4 = Scroll back in the screen
F5 = Scroll forward in the screen
F6 = Function key
See also "Multi-Function Display PLC" in the chapter
"Operation"

Fig. 7
l
The menu ADVANCED FUNCTIONS (Fig. 7) will
appear.
l Turn the (OK) selector switch choose the menu op-
tion DISPLAY AJUSTMENT. Press the switch to
confirm.

i Note
The other functions can be called up after entering a
password.
Only for service purposes.
l Adjust the desired brightness with the rotary button
(OK).
l
The ESC - key (F1) brings you back to the basic
screen.

008 917 69 BOMAG 221

7.2 Error messages, multi-function display

7.2 Error messages, multi-func- 5551 = Hydraulic charge circuit filter for travel
system dirty
tion display
5552 = Hydraulic charge circuit filter for convey-
In case of a fault the General Fault Lamp lights up or drive dirty
(Fig. 1). 9400 = CAN bus communication fault
3100 = Scrtaper opened
3101 = incorrect parameter
1101 = Fault rope sensor left
1102 = Fault rope sensor right
SPN = Diagnostic code for engine
FMI = Diagnostic code for engine

! Caution
A detailed reading out of fault codes for the diesel
engine is only possible with Deutz-Serdia.

Fig. 1
flashes = Generic fault
Press the push but-
ton = The error message is displayed on
the screen of the multi-function
display (Fig. 2).

Fig. 2
5140 = general engine fault
5200 = Fuel filling level too low
5112 = Engine oil pressure too low
5116 = Coolant temperature too high
5201 = Battery voltage too low
5024 = Coolant level too low
5114 = Combustion air temperature too high
5119 = Fuel temperature too high
5026 = Combustion air filter dirty
5504 = Hydraulic oil temperature too high
5550 = Hydraulic oil level too low
5502 = Hydraulic oil return flow filter dirty

222 BOMAG 008 917 69

Multi-function display, setup 7.3
7.3 Multi-function display, setup IP-Address*
l In the menu "PDM SETUP V1.0" select the option
To access the setup menu: "IP-Address" with the rotary encoder (Fig. 1).
l If no valid project is saved in the PDM: When re- l Confirm with "OK".
starting the device the PDM will automatically open
the setup menu.
l If the PDM already contains a valid project:If no val-
id project is saved in the PDM: Hold the key combi-
nation [F1]+[F5] depressed for about 1 second
when restarting the device.

Fig. 2
l Press control button "F2" ("Get IP") (Fig. 2).
l
Press keys "F3" and "F4" ("Edit Pos") to select the
desired 10 points and change these with the rotary
encoder.
Fig. 1 l
Confirm with "OK".
l Once all 10 numbers have been corrected press
key "F6" ("Save IP") and exit the menu, or press
"F1" to exit the menu without saving.

! Caution
The chosen IP-address will become valid after a
restart.

* The IP-address is a number that is needed for unambiguous

identification of a subscriber. For reasons of clarity this number
is written in 4 decimal values, e.g. 192.168. 82.247

008 917 69 BOMAG 223

7.3 Multi-function display, setup

Netmask* RTC Setting

l In the menu "PDM SETUP V1.0" select the option The Real-Time-Clock is intended for timer controlled
"Netmask" with the rotary encoder (Fig. 1). functions in the application. Time and date are already
displayed in the main screen of the setup menu
l Confirm with "OK".
l In the menu "PDM SETUP V1.0" select the option
"RTC Setting" with the rotary encoder (Fig. 1).
l Confirm with "OK".

Fig. 3
l Press control button "F2" ("Get IPmask") .
l Press keys "F3" and "F4" ("Edit Pos") to select the Fig. 4
desired 10 points and change these with the rotary
encoder.
l Press control button "F2" ("Get") .
l Confirm with "OK".
l Use the rotary encoder to select the desired field
and press the OK-key to edit the field.
l Once all 10 numbers have been corrected press
key "F6" ("Save Mask") and exit the menu, or press
l Confirm with "OK".
"F1" to exit the menu without saving. l Press key "F6" ("Enter") and exit the menu, or press
"F1" to exit the menu without saving.
!Caution
The selected netmask will only become effective
after a restart.

* By linking the IP-address the netmask additionally specifies

which IP-address to look for in the network and which device is
looking to connect to other networks. The individual network
and device setion of the IP-address results from the logic link
AND and its inverted value NOT.

224 BOMAG 008 917 69

Multi-function display, setup 7.3
(System) LED_Key Test
This menu option serves the purpose of checking the
!Caution function of control elements and LEDs on the
PDM360.
Danger of data loss!
l In the menu "PDM SETUP V1.0" select the option
In case of a data loss the PDM360 will no longer be
"LED_Key Test" with the rotary encoder (Fig. 1).
functional.
l Confirm with "OK".
The setup menu is password protected.

Fig. 6
Fig. 5
l
Use the rotary switch to change the value in [Test
Encoder].
l
Pressing a key [F1]...[F6] or the rotary encoder ac-
tivates the associated LED key illumination.
l
Press [F1 esc] "Main" to exit the setup menu option.

008 917 69 BOMAG 225

7.3 Multi-function display, setup

CAN-Test Exit
CAN telegrams can be sent to other CAN subscribers l In the menu "PDM SETUP V1.0" select the option
or CAN telegrams from other CAN subscribers can be "Exit" with the rotary encoder .
received to test the CAN interface. l Press "OK".

! Caution
Only suitable for persons who have specific
knowledge about control technology and PLC-
programming with IEC 61131-3, as well as with the
software CoDeSys®.

Fig. 8
l Press "F3".

Fig. 7

226 BOMAG 008 917 69

Adjustment parameters overview 7.4
7.4 Adjustment parameters over- CR0505:SW = the currently installed software
version for the machine control.
view
PDM360:SW = the currently installed software
version in the display.
l Turn the (OK) selector switch to choose the desired
menu option.
l Press the switch to confirm.

Fig. 1
l Press key F2 (Fig. 1).
l
The menu ADVANCED FUNCTIONS (Fig. 2) will
appear.

Fig. 2
TUNING PARAME-
TERS = Parameters for adjustment of side
doors, milling drum, steering, trav-
el drive, work breaks, levelling,
conveyor belts, back door and fan.
CHECK INPUT
OUTPUT = here one can read out the switch-
ing states of the ID-nodes.
DISPLAY ADJUSTA-
MENT = here one can adjust the brightness
of the display.
CAN BUS = to adjust CAN BUS modules.
MACHINE STATE= Here one can invoke different op-
erating states of the machine.
RS232 = Possibility to visualize the levelling
parameters (just as in the levelling
display VG1100).

008 917 69 BOMAG 227

7.5 Menu option, Tuning Parameters

7.5 Menu option, Tuning Parame- Enter the password

ters
Parameters for adjustment of side doors, milling
drum, steering, travel drive, work breaks, level-
ling, conveyor belts, back door and fan.

Fig. 3 Page 105

l Enter the password by turning the rotary switch, un-
til the first square is reached, then press the OK-
button.
l
Turn the rotary switch, until the figure 9 is displayed,
then press OK.
l
The ESC - key (F1) brings you back to the basic
Fig. 1
screen.
l
Press key F2.
l
The menu ADVANCED FUNCTIONS will appear. i Note
Fill all four squares in the same way.
Pressing the function key F6 longer than 10 seconds
overwrites the password. The page for TUNING PA-
RAMETERs is opened.

After entering the correct password the PAGE 106

(Fig. 4) with the TUNING PARAMETERS is opened.

Fig. 2
l
Turn the (OK) selector switch to choose the menu
option TUNING PARAMETERS.
l Press the switch to confirm.

Fig. 4 Page 106

SIDE DOORS = Parameter for setting the function
of the doors on the milling drum
housing.
MILLING DRUM= Parameter for setting switching on
speed.
STEERING = Parameter for setting the steering
function front and rear.

228 BOMAG 008 917 69

Menu option, Check Input Output 7.6
TRAVELLING = Parameter for setting the travel 7.6 Menu option, Check Input Out-
power and the engine load control.
put
PAUSE = Parameter for setting the time for
the pause function. Here one can read out the switching states of the
COLUMNS = Parameter for setting the levelling ID-nodes.
function.
CONVEYOR = Parameter for setting the convey-
or belt drive.
BACKDOOR = Parameter for setting the function
of the back door on the milling
drum housing.
FAN = Parameter for setting the tempera-
ture.
LOAD/SAVE = Possibility to download parame-
ters from the machine control to
the operating console and vice
versa.
l Turn the (OK) selector switch to choose the desired
menu option.
l
Press the switch to confirm. Fig. 1
l
To set/change the parameter turn the rotary switch, l
Press key F2.
until the square is approx. on the desired parame- l
The menu ADVANCED FUNCTIONS will appear.
ter, then press the OK-key. Turn the rotary switch,
until the correct value is displayed, then press OK.
The parameter is immediately saved.

Fig. 2
l
Turn the (OK) selector switch to choose the menu
option CHECK INPUT OUTPUT.
l Press the switch to confirm.

008 917 69 BOMAG 229

7.6 Menu option, Check Input Output

The following pages can be opened.

Fig. 6

Fig. 3

Fig. 4

Fig. 5

230 BOMAG 008 917 69

Menu option, Display Adjustment 7.7
7.7 Menu option, Display Adjust-
ment
Here one can adjust the brightness of the display.

Fig. 3
l
Adjust the desired brightness with the rotary button
(OK).
l The ESC - key (F1) brings you back to the basic
screen.
Fig. 1
l
Press key F2 (Fig. 1).
l
The menu ADVANCED FUNCTIONS (Fig. 2) will
appear.

Fig. 2
l
Turn the (OK) selector switch choose the menu op-
tion DISPLAY AJUSTMENT.
l
Press the switch to confirm.

008 917 69 BOMAG 231

7.8 Menu option, Can-Bus

7.8 Menu option, Can-Bus Enter the password

To adjust CAN-BUS modules.

Fig. 3 Page 105

l Enter the password by turning the rotary switch, un-
til the first square is reached, then press the OK-
button.
Fig. 1 l
Turn the rotary switch, until the figure 9 is displayed,
l Press key F2. then press OK.
l
The menu ADVANCED FUNCTIONS will appear. l
The ESC - key (F1) brings you back to the basic
screen.

i Note
Fill all four squares in the same way.
Pressing the function key F6 longer than 10 seconds
overwrites the password. The page for CAN BUS
SCAN is opened.

Fig. 2
l Turn the (OK) selector switch to choose the menu
option CAN-BUS.
l
Press the switch to confirm.

232 BOMAG 008 917 69

Menu option, Machine States 7.9
The following pages can be opened. 7.9 Menu option, Machine States
Here one has the possibility to invoke different op-
erating states of the machine.

Fig. 4

Fig. 1
l
Press key F2.
l
The menu ADVANCED FUNCTIONS will appear.

Fig. 5

Fig. 2
l Turn the (OK) selector switch to choose the menu
option MACHINE STATES.
l
Press the switch to confirm.

008 917 69 BOMAG 233

7.9 Menu option, Machine States

The following pages can be opened.

Fig. 5
l Travelling
Fig. 3
l Gear
l Back Door
l Differential Lock
l Break Door
l Milling drum
l Engine Load Control
l
Conveyor
l
Left Door
l
Fan
l
Right Door
l
Engine
l
Water Spray
l
Pause

Fig. 4
l Front Left Column
l Front Right Column
l Front Steering
l Rear Steering
l Steering Limitation
l Rear Columns

234 BOMAG 008 917 69

Menu option, RS232 7.10
7.10 Menu option, RS232 7.11 Milling Drum
Possibility to visualize the levelling parameters
(just as in the levelling display VG1100). i Note
Access via menu option TUNING PARAMETERs (see
corresponding chapter).

Adjusting the switch-on point

Fig. 1
l Press key F2.
l The menu ADVANCED FUNCTIONS will appear.

Fig. 4
750 = the milling drum can only be activated
when the engine speed has reached at
least 750 min-1.
l
The ESC - key (F1) brings you back to the basic
screen.

Fig. 2
l
Turn the (OK) selector switch to choose the menu
option RS232.
l
Press the switch to confirm.

Fig. 5
l Press key F4 to return to the previous page.
l
Pressing key F5 opens the next page.
l The ESC - key (F1) brings you back to the basic
screen.

Fig. 3

008 917 69 BOMAG 235

7.12 Steering, Joysticks

7.12 Steering, Joysticks Pot. Joystick Right

Mid = -1000 = the value transmitted
when the right steering joystick is
i Note in middle position..
Access via menu option TUNING PARAMETERs (see Pot. Joystick Right
corresponding chapter). Right = 990 = the value transmitted when
the right steering joystick is shifted
Calibration of steering joysticks fully to the right.

Fig. 1
Pot. Joystick Left= -1000 = the actual value transmit-
ted by the left joystick (B17-UJ2). Fig. 2

Pot. Joystick Left

l
Press key F4 to return to the previous page.
Left = 990 = the value transmitted when l
Pressing key F5 opens the next page.
the left steering joystick is shifted l
The ESC - key (F1) brings you back to the basic
fully to the left.
screen.
Example for Pot. Joystick Left Left
l
Shift the left steering joystick fully to the left. Hold it
in this position.
l
Keep turning the rotary switch, until the square
reaches the symbol for ACCEPT, which corre-
sponds with the desired designation.
l
Press the OK-button. The actual value will be added
to the desired value field.
Pot. Joystick Left
Mid = -1000 = the value transmitted
when the left steering joystick is in
middle position.
Pot. Joystick Right
Mid = 997 = the value transmitted when
the left steering joystick is shifted
fully to the right.
Pot. Joystick Right
Mid = -1000 = the actual value transmit-
ted by the right joystick (B19-UJ2).
Pot. Joystick Right
Left = 995 = the value transmitted when
the right steering joystick is shifted
fully to the left.

236 BOMAG 008 917 69

Steering, Pistons 7.13
7.13 Steering, Pistons mm Piston Front
OUT = 290 = the distance in mm (cylinder
housing to pivot point of cylinder)
i Note with the front steering cylinder fully
Access via menu option TUNING PARAMETERs (see extended.
corresponding chapter). mm Piston Front IN= 23 = the distance in mm (cylin-
der housing to pivot point of cylin-
Calibration of steering pistons der) with the front steering cylinder
fully retracted.
Pot. Piston Rear= 1193 = the actual value transmit-
ted from the rear steering Yo-Yo
(C16).
Pot. Piston Rear
OUT = 1773 = the value with the rear
steering cylinder fully extended.
Pot. Piston Rear IN= 667 = the value with the rear
steering cylinder fully retracted.
mm Piston Rear
OUT = 290 = the distance in mm (cylinder
housing to pivot point of cylinder)
with the rear steering cylinder fully
extended.
Fig. 1 mm Piston Rear IN= 23 = the distance in mm (cylin-
der housing to pivot point of cylin-
Pot. Piston Front= 1132 = the actual value transmit-
der) with the rear steering cylinder
ted from the front steering Yo-Yo
fully retracted.
(C14).

Example for front piston to OUTSIDE:

l
Steer the front tracks fully to the left (the steering
piston is fully extended).
l
Turn the rotary switch until the square has reached
the symbol ACCEPT, which corresponds with the
desired designation.
l
Press the OK-button. The actual value will be added
to the desired value field.
l
Measure the distance between cylinder housing
and pivot point of the Yo-Yo rope.
l
Enter this value into the value field for mm piston
front TO OUTSIDE: by turning the rotary switch until
a square covers the parameter field, which corre-
sponds with the required parameter.
l Press the OK-button. Fig. 2
l
Turn the rotary switch, until the correct value is dis- l
Press key F4 to return to the previous page.
played. l
Pressing key F5 opens the next page.
l
Press the OK-button. l
The ESC - key (F1) brings you back to the basic
Pot. Piston Front screen.
OUT = 1729 = the value with the front
steering cylinder fully extended.
Pot. Piston Front
IN = 629 = the value with the front
steering cylinder fully retracted.

008 917 69 BOMAG 237

7.14 Steering, Adjust Potentiometer

7.14 Steering, Adjust Potentiome-

ter

i Note
Access via menu option TUNING PARAMETERs (see
corresponding chapter).

Calibration of potentiometer for rear

steering

Fig. 2
l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic
screen.

Fig. 1
Pot. Adjust = 2110 = the actual value transmit-
ted by the potentiometer for set-
ting the rear steering (B1-C17).
Pot. Adjust Min = 5 = the value at which the adjust-
ing potentiometer for rear steering
is fully turned to the left.
Pot. Adjust Max= 4053 = the value at which the ad-
justing potentiometer for rear
steering is fully turned to the right.

Example for potentiometer setting Min:

l
Turn the potentiometer for rear steering fully to the
left.
l Turn the rotary switch until the square has reached
the symbol ACCEPT, which corresponds with the
desired designation.
l Press the OK-button. The actual value will be added
to the desired value field.

238 BOMAG 008 917 69

Steering, Central Position Calibration 7.15
7.15 Steering, Central Position Pos. Pot. Adjust Cen-
tral = 25 = the central position of the ad-
Calibration justing potentiometer for rear
steering in mm.
i Note
Access via menu option TUNING PARAMETERs (see
corresponding chapter).

Calibration of central steering position

Fig. 2
l
Press key F4 to return to the previous page.
l
Pressing key F5 opens the next page.
Fig. 1 l
The ESC - key (F1) brings you back to the basic
Pos. Piston Front= 145 = the actual position of the screen.
front steering piston (distance be-
tween cylinder housing and piston
pivot point in mm).
Pos. Piston Front
Central = 149 = the central position of the
front steering piston (distance be-
tween cylinder housing and piston
pivot point in mm).

Example for the central position of the front pis-

ton:
l
Steer the front tracks to central position (tracks in
line with machine frame).
l Turn the rotary switch until the square has reached
the symbol ACCEPT, which corresponds with the
desired designation.
l
Press the OK-button. The actual value will be added
to the desired value field.
Pos. Piston Rear= 149 = the actual position of the
rear steering piston (distance be-
tween cylinder housing and piston
pivot point in mm).
Pos. Piston Rear
Central = 151 = the central position of the
rear steering piston (distance be-
tween cylinder housing and piston
pivot point in mm).
Pot. Adjust = 26 = the actual position of the ad-
justing potentiometer for rear
steering in mm.

008 917 69 BOMAG 239

7.16 Steering, Pistons Position Limit

7.16 Steering, Pistons Position

Limit

i Note
Access via menu option TUNING PARAMETERs (see
corresponding chapter).

Calibration of the front steering stop

Fig. 2
l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic
screen.

Fig. 1
Pos. Piston Front= 145 = the actual position of the
front steering piston (distance be-
tween cylinder housing and piston
pivot point in mm).
Pos. Piston Front
Max Left = 185 = the position of the front
steering piston (the distance be-
tween cylinder housing and piston
pivot point in mm) with the ma-
chine fully steered to the left and
completely lowered..
Pos. Piston Front
Max Right = 122 = the position of the front
steering piston (the distance be-
tween cylinder housing and piston
pivot point in mm) with the ma-
chine fully steered to the right and
completely lowered..

Calibration
l Lower the front of the machine.
l Steer the front tracks fully to the left (make sure that
the tracks do not touch the gthering belt).
l
Turn the rotary switch until the square has reached
the symbol ACCEPT, which corresponds with the
desired designation.
l Press the OK-button. The actual value will be added
to the desired value field.
l
Repeat this process when fully steered to the right.

240 BOMAG 008 917 69

Steering, Front-Rear link 7.17
7.17 Steering, Front-Rear link

i Note
Access via menu option TUNING PARAMETERs (see
corresponding chapter).

Fig. 4
l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic
Fig. 3 screen.
Link Factor Front-
Rear = 100% = link factor between front
and rear steering.
Dead Band Hystere-
sis = 100% = 100% hysteresis means
no play/tolerance. Rear steering
starts exactly at the same time
when the front steering piston has
moved more than 4 mm and will
stop, when this measurement of 4
mm is fallen short of.
Min current = Minimum current to the solenoid
valve in mA.
Max current = Maximum current to the solenoid
valve in mA.
Manual current = ppt = parts per thousand of the
maximum current in case of man-
ual operation of the rear steering.

008 917 69 BOMAG 241

7.18 Steering, Front Prop. Solenoid Valve

7.18 Steering, Front Prop. Solenoid l Pressing key F5 opens the next page.
Valve l The ESC - key (F1) brings you back to the basic
screen.

i Note
Access via menu option TUNING PARAMETERS
(see corresponding chapter).

The current curves for the proportional

solenoid valves (B14-YB29 and B14-
YA29) are shown using the actuation of
the front steering as an example.

Fig. 1
1500 mA = Maximum current at 1000 ppt to the right.
500 mA = Minimum current at 1 ppt to the right.
-500 mA = Minimum current at 1 ppt to the left.
-1500 = Maximum current at 1000 ppt to the left.
Actual current
= Shows the current actually applied to the
solenoid valve.

Fig. 2
l Press key F4 to return to the previous page.

242 BOMAG 008 917 69

Travelling, Joysticks Potentiometer 7.19
7.19 Travelling, Joysticks Potenti- Pot. Joystick Right
Fwd = 989 = the value transmitted when
ometer the right travel lever is shifted fully
to forward.
i Note Pot. Joystick Right
Access via menu option TUNING PARAMETERs (see Mid = -1000 = the value transmitted
corresponding chapter). when the right travel lever is in
central position.
Calibration of travel lever Pot. Joystick Right
Bwd = 996 = the value transmitted when
the right travel lever is shifted fully
to backward.

Fig. 3
Pot. Joystick Left= -1000 = the actual value transmit-
ted by the left travel lever (B17-
UJ1).
Fig. 4
Pot. Joystick Left
Fwd = 996 = the value transmitted when l
Press key F4 to return to the previous page.
the left travel lever is shifted fully l
Pressing key F5 opens the next page.
to forward.
l
The ESC - key (F1) brings you back to the basic
Example for Pot. Joystick left forward: screen.
l
Shift the left travel lever fully forward. Hold it in this
position.
l
Turn the rotary switch until the square has reached
the symbol ACCEPT, which corresponds with the
desired designation.
l
Press the OK-button. The actual value will be added
to the desired value field.
Pot. Joystick Left
Mid = -1000 = the value transmitted
when the left travel lever is in cen-
tral position.
Pot. Joystick Left
Bwd = 996 = the value transmitted when
the left travel lever is shifted fully
to backward.
Pot. Joystick Right= -1000 = the actual value trans-
mitted by the right travel lever
(B19-UJ1).

008 917 69 BOMAG 243

7.20 Travelling, Softgear

7.20 Travelling, Softgear 7.21 Travelling, Engine Load Man-

ager
i Note
Access via menu option TUNING PARAMETERs (see i Note
corresponding chapter). Access via menu option TUNING PARAMETERS
When increasing this value the machine will travel (see corresponding chapter).
faster in low speed range.

Fig. 7

Fig. 5 RPM = 1840 = Engine speed for engine

load control. The control always
Extra Speed Low
tries to reach this speed. As the
Gear = 400 ppt = 40% higher current to
engine load increases, the control
travel motor in low speed range.
will reduce the speed of the ma-
chine, until the engine speed has
once again reached the intended
value.
Kp = 1200 = proportional actuation val-
ue of a P-part of the proportional
integral differential controller (PID-
controller) for deceleration.
Ki = 15 = proportional actuation value
of an I-part of the proportional inte-
gral differential controller (PID-
controller) for deceleration.
Kd = 350 = proportional actuation value
of a D-part of the proportional inte-
gral differential controller (PID-
controller) for deceleration.
Eng. RPM = 1890 = the actual engine speed.
Fig. 6 Bal. Kp% = 20 = proportional actuation value
l
Press key F4 to return to the previous page. of a P-part of the proportional inte-
gral differential controller (PID-
l Pressing key F5 opens the next page.
controller) for acceleration (Kp *
l
The ESC - key (F1) brings you back to the basic Bal. Kp %).
screen. Bal. Ki% = 100 = proportional actuation value
of a I-part of the proportional inte-
gral differential controller (PID-
controller) for acceleration (Kp *
Bal. Ki %).
Bal. Kd% = 100 = proportional actuation value
of a D-part of the proportional inte-

244 BOMAG 008 917 69

Travelling, Time Ramps 7.22
gral differential controller (PID- 7.22 Travelling, Time Ramps
controller) for acceleration (Kp *
Bal. Kd%).
i Note
Speed = 0 = actual current to engine to con-
trol the engine speed. Access via menu option TUNING PARAMETERs (see
corresponding chapter).
PID = 0 = Actual value for PID-controller
in the SW.
Speed Scaling Max
% = 99 = maximum slope of engine ac-
celeration or deceleration in per-
cent.
Speed Scaling Min
% = 70 = minimum slope of engine ac-
celeration or deceleration in per-
cent.

Fig. 9
Accelaration Fwd
Higth = 2200 ms = Acceleration time at
travel speed in forward travel.
Deceleration Fwd
Higth = 600 ms = Deceleration time at
travel speed in forward travel.
Accelaration Fwd
Low = 4400 ms = Acceleration time at
working speed in forward travel.
Deceleration Fwd
Fig. 8 Low = 600 ms = Deceleration time at
l
Press key F4 to return to the previous page. working speed in forward travel.
l
Pressing key F5 opens the next page. Braking Time After
Stop = 1000 ms = time until application of
l The ESC - key (F1) brings you back to the basic brakes after stopping the machine
screen. in forward travel.

008 917 69 BOMAG 245

7.23 Travelling, Var. displ. pump

i Note
Access via menu option TUNING PARAMETERs (see
corresponding chapter).

Fig. 10
Accelaration Bwd
Higth = 2200 ms = Acceleration time at
travel speed in backward travel.
Deceleration Bwd
Higth = 600 ms = Deceleration time at
travel speed in backward travel. Fig. 12
Accelaration Bwd 620 mA = Maximum current for forward travel at
Low = 2200 ms = Acceleration time at 1000 ppt.
working speed in backward travel. 120 mA = Minimum current for forward travel at 1
Deceleration Bwd ppt.
Low = 600 ms = Deceleration time at -150 mA = Minimum current for reverse travel at 1
working speed in backward travel. ppt.
Braking Time After -620 mA = Maximum current for reverse travel at
Stop = 1000 ms = time until application of 1000 ppt.
brakes after stopping the machine
in backward travel. Actual current
= Shows the current actually applied to the
solenoid valve.

Fig. 11
l Press key F4 to return to the previous page. Fig. 13
l
Pressing key F5 opens the next page. l Press key F4 to return to the previous page.
l The ESC - key (F1) brings you back to the basic l
Pressing key F5 opens the next page.
screen.
l The ESC - key (F1) brings you back to the basic
screen.

246 BOMAG 008 917 69

Travelling, Var. displ. Motor 7.24
7.24 Travelling, Var. displ. Motor 7.25 Pause, Time In Sequence

i Note i Note
Access via menu option TUNING PARAMETERs (see Access via menu option TUNING PARAMETERs (see
corresponding chapter). corresponding chapter).

Fig. 14 Fig. 16

600 = the max. current for the displacement at Travelling Pause In= 200 ms = time until start of de-
1000 ppt is 600 mA. celeration of travel drive after
switching off the PAUSE switch
310 = the min. current for the displacement at 1
(e.g. B17-S16).
ppt is 310 mA.
Ramp = 1000 ms = deceleration time of
Actual current
travel drive after switching off the
= Shows the current actually applied to the
PAUSE switch (B17-S16).
solenoid valve.
Water Pause In = 3000 ms = time until stop of sprin-
kling system after switching off the
PAUSE switch (B17-S16).
Conveyor Pause In= 7000 ms = time until stop of con-
veyor belt after switching off the
PAUSE switch (B17-S16).
Energy Pause In= 7600 ms = time until start of decel-
eration of engine speed in ECO-
MODE after switching off the
PAUSE switch (B17-S16).
Ramp = 6000 ms = deceleration time of
engine speed in ECOMODE after
switching off the PAUSE switch
(B17-S16).

Fig. 15
l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic
screen.

008 917 69 BOMAG 247

7.26 Pause, Time Out Sequence

i Note
Access via menu option TUNING PARAMETERs (see
corresponding chapter).

Fig. 17
l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic
screen. Fig. 18
Engine Pause Out= 200 ms = time until start of accel-
eration of engine speed in WORK-
ING MODE after switching on the
PAUSE switch (B17-S16).
Ramp = 4000 ms = acceleration time of
engine speed in WORKING
MODE after switching on the
PAUSE switch (B17-S16).
Conveyor Pause
Out = 7000 ms = time until start of con-
veyor belt after switching on the
PAUSE switch (B17-S16).
Water Pause Out= 1000 ms = time until start of sprin-
kling system after switching on the
PAUSE switch (B17-S16).
Travelling Pause
Out = 8000 ms = time until start of accel-
eration of travel drive after switch-
ing on the PAUSE switch (B17-
S16).
Ramp = 6000 ms = acceleration time of
travel drive after switching on the
PAUSE switch (B17-S16).

248 BOMAG 008 917 69

Columns, Levelling Wire Sensor 7.27
7.27 Columns, Levelling Wire Sen-
sor

i Note
Access via menu option TUNING PARAMETERS
(see corresponding chapter).

Fig. 19
l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic
screen.
Fig. 20
Kp = -1300 = proportional actuation val-
ue of a P-part of the PI-controller
for the levelling control via rope
sensor.
Ki = -30 = proportional actuation value
of an I-part of the PI-controller for
the levelling control via rope sen-
sor.
Max Kp Act = 750 ppt = parts per thousand,
750‰? or 75% of the maximum
current (P-part) is made available
to the proportional solenoid valve
to actuate the levelling control via
rope sensor.
Max Ki Act = 200 ppt = parts per thousand,
200‰? or 20% of the maximum
current (I-part) is made available
to the proportional solenoid valve
to actuate the levelling control via
rope sensor.
Max Tot Act = 700 ppt = parts per thousand,
700‰? or 70% of the maximum
current (total) is made available to
the proportional solenoid valve to
actuate the levelling control via
rope sensor.
Live Band Ki Act= 4 = limit for the integrated measur-
and in the SW, if the integrated
part reaches the nominal value, it
will switch over and work in the
proportional and integral part.

008 917 69 BOMAG 249

7.28 Columns, Levelling Slope Sensor

7.28 Columns, Levelling Slope

Sensor

i Note
Access via menu option TUNING PARAMETERS
(see corresponding chapter).

Fig. 21
l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic
screen.
Fig. 22
Kp = -1650 = proportional actuation val-
ue of a P-part of the PI-controller
for the levelling control via inclina-
tion sensor.
Ki = -60 = proportional actuation value
of an I-part of the PI-controller for
the levelling control via inclination
sensor.
Max Kp Act = 600 ppt = parts per thousand,
600‰? or 60% of the maximum
current (P-parts) is made available
to the proportional solenoid valve
to actuate the levelling control via
inclination sensor.
Max Ki Act = 300 ppt = parts per thousand,
300‰? or 30% of the maximum
current (P-parts) is made available
to the proportional solenoid valve
to actuate the levelling control via
inclination sensor.
Max Tot Act = 700 ppt = parts per thousand,
700‰? or 70% of the maximum
current (P-parts) is made available
to the proportional solenoid valve
to actuate the levelling control via
inclination sensor.
Live Band Ki Act= 2 = limit for the integrated value in
the SW, if the integrated part
reaches the nominal value, it will
switch over and work in the pro-
portional and integrated part.

250 BOMAG 008 917 69

Columns, Speed 7.29
7.29 Columns, Speed

i Note
Access via menu option TUNING PARAMETERS
(see corresponding chapter).

Fig. 23
l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic
screen. Fig. 24
Manual Up = 420 ppt = parts per thousand,
420? or 42% of the maximum cur-
rent is made available to the pro-
portional solenoid valve to lift the
front left and right columns.
Manual Down = -300 ppt = parts per thousand,
300? or 30% of the maximum cur-
rent is made available to the pro-
portional solenoid valve to lower
the front left and right columns.

Calibration of column speed

l Make a 200 mm mark on the columns.
l Lower the machine at the front and measure the
time. For this distance of 200 mm 8 seconds should
be needed.
l
Lift the machine at the front and measure the time.
For this distance of 200 mm 8 seconds should be
needed.

008 917 69 BOMAG 251

7.30 Columns, Calibration Levelling Sensor

7.30 Columns, Calibration Level-

ling Sensor

i Note
Access via menu option TUNING PARAMETERS
(see corresponding chapter).

Fig. 25
l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic
screen.
Fig. 26
Conversion Factor
Wire Left Sensor= 4213 = Conversion value for the
type of the left hand Yo-Yo.
Conversion Factor
Wire Rigth Sensor= 4213 = Conversion value for the
type of the right hand Yo-Yo.
Conversion Factor
Slope Sensor = 2041 = Conversion value for the
type of the slope sensor.
Averaging = 10 = Average for the slope sensor.
The sensor sends the signal and
the program determines the aver-
age always after 10 signals.
APulses/Meter = 2340 Adjusting value for slope
sensor. The actually installed sen-
sor generates 2340 pulses per
meter in the metric and 2263 puls-
es in the imperial system.

252 BOMAG 008 917 69

Columns, Left Column Prop. Valve 7.31
7.31 Columns, Left Column Prop.
Valve

i Note
Access via menu option TUNING PARAMETERs (see
corresponding chapter).

Fig. 27
l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic
screen.
Fig. 28
900 mA = Maximum current to lift the left column at
1000 ppt.
190 mA = Minimum current to lift the left column at
1 ppt.
-190 mA = Minimum current to lower the left column
at 1 ppt.
-900 mA = Maximum current to lower the left column
at 1000 ppt.
Actual current
= Shows the current actually applied to the
solenoid valve.

Fig. 29
l
Press key F4 to return to the previous page.

008 917 69 BOMAG 253

7.32 Columns, Right Column Prop. Valve

l Pressing key F5 opens the next page. 7.32 Columns, Right Column Prop.
l The ESC - key (F1) brings you back to the basic Valve
screen.

i Note
Access via menu option TUNING PARAMETERs (see
corresponding chapter).

Fig. 30
900 mA = Maximum current to lift the left column at
1000 ppt.
190 mA = Minimum current to lift the left column at
1 ppt.
-190 mA = Minimum current to lower the left column
at 1 ppt.
-900 mA = Maximum current to lower the left column
at 1000 ppt.
Actual current
= Shows the current actually applied to the
solenoid valve.

Fig. 31
l
Press key F4 to return to the previous page.

254 BOMAG 008 917 69

Conveyor, Potentiometer 7.33
l Pressing key F5 opens the next page. 7.33 Conveyor, Potentiometer
l The ESC - key (F1) brings you back to the basic
screen.
i Note
Access via menu option TUNING PARAMETERS
(see corresponding chapter).

Fig. 32
Potentiometer = 999 = the actual value transmitted
by the potentiometer for conveyor
belt speed (B18-R1).
Potentiometer Min= -1000 = the value at which the
potentiometer for conveyor belt
speed is fully turned to the left.
Potentiometer Max= 996 = the value at which the po-
tentiometer for conveyor belt
speed is fully turned to the right.

Calibration of potentiometer for conveyor belt

speed.
Example for potentiometer setting Min:
l
Turn the potentiometer for conveyor belt speed fully
to the left.
l Turn the rotary switch until the square has reached
the symbol ACCEPT, which corresponds with the
desired designation.
l Press the OK-button. The actual value will be added
to the desired value field.

008 917 69 BOMAG 255

7.34 Conveyor, Var. displ. pump

i Note
Access via menu option TUNING PARAMETERs (see
corresponding chapter).

Fig. 33
l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic
screen. Fig. 34
630 mA = Maximum current for forward run at 1000
ppt.
200 mA = Maximum current for forward run at 1
ppt.
-200 mA = Maximum current for backwards run at 1
ppt.
-400 mA = Maximum current for backwards run at
1000 ppt.
Actual current
= Shows the current actually applied to the
solenoid valve.

Fig. 35
l Press key F4 to return to the previous page.
l
Pressing key F5 opens the next page.
l The ESC - key (F1) brings you back to the basic
screen.

256 BOMAG 008 917 69

Backdoor, Set-Up 7.35
7.35 Backdoor, Set-Up 7.36 Backdoor, Solenoid Valve

i Note i Note
Access via menu option TUNING PARAMETERS Access via menu option TUNING PARAMETERS
(see corresponding chapter). (see corresponding chapter).

Fig. 36
Fig. 38
Backdoor Pressure= 400 ppt = parts per thousand,
1050 mA = Maximum current for floating position of
400‰? or 40% of the maximum
the back door at 1000 ppt.
current is made available to the
proportional solenoid valve to pre- 200 mA = Minimum current for floating position of
pressurize the back door. The pre- the back door at 1 ppt.
pressure of the back door can be Actual current
adjusted. This can also be accom- = Shows the current actually applied to the
plished with switch (B17-S6). solenoid valve.

Fig. 37 Fig. 39
l Press key F4 to return to the previous page. l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page. l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic l
The ESC - key (F1) brings you back to the basic
screen. screen.

008 917 69 BOMAG 257

7.37 Fan

i Note
Access via menu option TUNING PARAMETERS
(see corresponding chapter).

Fig. 41
l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic
Fig. 40 screen.

If one of the specified max. temperatures is

reached, the fan will run with high speed.
Min Intake Manifold
Temperature = 50°C = if the temperature in the in-
take manifold is below 50 °C, the
fan will run with low speed (1550
min-1).
Max Intake Manifold
Temperature = 60°C = if the temperature in the in-
take manifold is higher than 60 °C,
the fan will run with full speed
(2090 min-1).
Min Coolant Temper-
ature = 85°C = if the engine coolant tem-
perature is below 85 °C, the fan
will run with low speed (1550 min-
1).

Max Coolant Tem-

perature = 95°C = if the engine coolant tem-
perature is higher than 95 °C, the
fan will run with full speed (2090
min-1).
Min Hydraulic Oil
Temperature = 55°C = if the hydraulic oil temper-
ature is below 55 °C, the fan will
run with low speed (1550 min-1).
Max Hydraulic Oil
Temperature = 70°C = if the hydraulic oil temper-
ature is higher than 70 °C, the fan
will run with full speed (2090 min-
1
).

258 BOMAG 008 917 69

Fan, Solenoid Valve 7.38
7.38 Fan, Solenoid Valve

i Note
Access via menu option TUNING PARAMETERs (see
corresponding chapter).

Fig. 42
900 mA = Maximum current for the cooling
fan drive at 1000 ppt.
200 mA = Minimum current for the cooling
fan drive at 1 ppt.
Actual current = Shows the current actually applied
to the solenoid valve.

Fig. 43
l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic
screen.

008 917 69 BOMAG 259

7.39 Check Input Output, ID-node CR0505

ID = Identifier
Name used to differentiate between the equipment / subscribers connected to a system or between the sub-
scribers exchanging message packages.

Fig. 1

Reading out ID-nodes

i Note
Access via menu option CHECK INPUT OUTPUT (see corresponding chapter).
The multi-function display can be used to read out the switching states of the ID-node.

Fig. 2
CR0505 NODE-ID 30 = this selection brings you to PAGE 204, to the view of switching states of the CAN-Bus
node CR0505.

260 BOMAG 008 917 69

Check Input Output, ID-node CR0505 7.39

Fig. 3
DI ... = Digital input, switching state 0 or 1
AI ... = Analog input (mA)
DO ... = Digital output, switching state 0 or 1
AO = PWM analog output (mA)

Fig. 4
l Press key F4 to return to the previous page.
l
Pressing key F5 opens the next page.
l The ESC - key (F1) brings you back to the basic screen.

008 917 69 BOMAG 261

7.40 Check Input Output, ID-node CR2012

ID = Identifier
Name used to differentiate between the equipment / subscribers connected to a system or between the sub-
scribers exchanging message packages.

Fig. 5

Reading out ID-nodes

The machine is equipped with 14 modules (CR2012), each module is assigned to an ID-node.
The multi-function display can be used to read out the switching states of the ID-nodes.

i Note
Access via menu option CHECK INPUT OUTPUT (see corresponding chapter).

Fig. 6
CR2012 NODE-ID 01...14 = this selection brings you to PAGE 201, to the view of switching states of the CAN-
Bus nodes CR2012.

262 BOMAG 008 917 69

Check Input Output, ID-node CR2012 7.40

Fig. 7
DI ... = Digital input, switching state 0 or 1
AI ... = Analog input (mA)
DO ... = Digital output, switching state 0 or 1
The bottom lines show the fault codes, which may be displayed in case of module problems.

EMCY Code Fault- Additional code Description

No.:
0x6100 0x11 0x00 "Internal Software":
Overflow of a Rx-Queue;
e.g. frequency of Rx PDOs too high;
Reset only externally via entry in 1003 00
0x6101 0x11 0x00 "Internal Software":
- Overflow of a Tx-Queue;
e.g. equipment unable to access bus;
Reset only externally via entry in 1003 00
0x8100 0x11 0x00 "Monitoring" (Guarding Error)
no guard object received during the "guard time" x "life time
factor" Reset by restarting communication
0x8100 0x11 0x00 "Monitoring" (Synch Error)
no synch object received during the "communication cy-
cle".
Only in OPERATIONAL Reset for synch-OBJ or PREOP

008 917 69 BOMAG 263

7.40 Check Input Output, ID-node CR2012

Fig. 8
l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic screen.

264 BOMAG 008 917 69

Check Input Output, ID-node CR2012 7.41
7.41 Check Input Output, ID-node CR2012
ID = Identifier
Name used to differentiate between the equipment / subscribers connected to a system or between the sub-
scribers exchanging message packages.

Fig. 1

Reading out ID-nodes

The machine is equipped with 4 modules (CR2031), each module is assigned to an ID-node.
The multi-function display can be used to read out the switching states of the ID-nodes.

i Note
Access via menu option CHECK INPUT OUTPUT (see corresponding chapter).

Fig. 1
CR2031 NODE-ID 16...19 = this selection brings you to PAGE 201, to the view of switching states of the CAN-
Bus nodes CR2031.

008 917 69 BOMAG 265

7.41 Check Input Output, ID-node CR2012

Fig. 2
AI ... = Analog input (mA)
DO ... = Digital output, switching state 0 or 1
AO = PWM analog output (mA)
The bottom lines show the fault codes, which may be displayed in case of module problems.

266 BOMAG 008 917 69

Check Input Output, ID-node CR2012 7.41

EMCY Code Fault- Additional code Description

No.:
0x3300 0x05 0x00 "Output Voltage"
Supply voltage VBBO Or output missing
0x6100 0x11 0x00 "Internal Software":
Overflow of a Rx-Queue;
e.g. frequency of Rx PDOs too high;
Reset only externally via entry in 1003 00
0x6101 0x11 0x00 "Internal Software":
Overflow of a Tx-Queue;
e.g. equipment unable to access bus.
Reset only externally via entry in 1003 00
0x6200 0x81 bit-encoded "User Software":
I/O-configuration not permitted.
EMCY object contains faulty channel pair;
each bit represents a channel pair.
0000 0010 channel pair 1, 2
0000 1000 channel pair 3, 4
0010 0000 channel pair 5, 6
1100 0000 channel pair 7, 8
0x8000 0x11 0x00 "Monitoring" (Synch Error)
For "communication cycle"
no synch object is received;
(only in OPERATIONAL).
Reset for synch-OBJ or PREOP
0x8130 0x11 0x00 "Monitoring" (Guarding Error/Heartbeat Error)
For "guard time" x "life time factor"
no Guard Object is received or
Heartbeat Object outside expected time.
Reset when restarting communication
0xFF00 0x81 bit-encoded "Device Specific"
Current value cannot be reached, because
load impedance is too high/too low
0000 0001 Channel 1
0000 0010 Channel 2
0000 0100 Channel 3
0000 1000 Channel 4
0001 0000 Channel 5
0010 0000 Channel 6
0100 0000 Channel 7
1000 0000 Channel 8

Only the first error of an error group is reported.

If e.g. the error "Load impedance too high/to low" occurs first on channel 1 and then on channel 2, only the error
that occurred first will be reported. CANopen does not provide for reporting to identical EMCY-objects in succes-
sion.

008 917 69 BOMAG 267

7.41 Check Input Output, ID-node CR2012

Fig. 3
l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic screen.

268 BOMAG 008 917 69

Can Bus, Scan 7.42
7.42 Can Bus, Scan

i Note
Access via menu option CAN BUS (see correspond-
ing chapter).

The bottom line on PAGE 500 (Fig. 3) shows the

CAN-BUS states.
CAN BUS 1 OFF= False = no fault in CAN Bus 1.
CAN BUS 1 OFF= True = fault in CAN-Bus 1.

Check the following:

l
LED flashing codes on modules
l
Module configurations (baud rate and address)
l Integrity and correctness of transmitting line
Fig. 5
l
CAN BUS termination resistor
l Press key F4 to return to the previous page.
l
Configuration of display PDM360
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic
screen.

Fig. 4
CAN BUS 2 OFF= False = no fault in CAN Bus 2.
CAN BUS 2 OFF= True = fault in CAN-Bus 2.

Check the following:

l
Configuration of engine control EMR
l
Integrity and correctness of transmitting line
l
CAN BUS termination resistor
CAN BUS 1 Warn-
ing = False = no warning in CAN-Bus 1.
CAN BUS 1 Warn-
ing = True = warning in CAN-Bus 1.
CAN BUS 2 Warn-
ing = False = no warning in CAN-Bus 2.
CAN BUS 2 Warn-
ing = True = warning in CAN-Bus 2.

008 917 69 BOMAG 269

7.43 Can Bus, Change Node ID

7.43 Can Bus, Change Node ID l Keep turning the rotary switch, until the OLD
NODE-ID appears in a square.
i Note l Press the OK-button.
Access via menu option CAN BUS (see correspond- l Turn the rotary switch, until the desired value (actu-
ing chapter). al address, e.g. 32) is displayed.
l Press the OK-button.
!Caution l Keep turning the rotary switch, until the NEW
After installing a new I/O-module the address of NODE-ID appears in a square.
this new module needs to be set. Each new mod-
ule is set to the address 32 by default.
l Press the OK-button.
l Turn the rotary switch to the desired value (e.g. 9,
l If the new address has not yet been determined, all
this is the NODE-ID that has been replaced be-
existing and connected modules can be scanned by
cause of a failure).
pressing key F3 for longer than 2 seconds.
l Press the OK-button.
l Pressing the key F3 longer than 2 seconds saves
the value.

Fig. 6
l
Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic Fig. 7
screen.

"PAGE 501" (Fig. 7) allows you to change the ad-

dress ("Node-ID").

ID-Node overview, see chapter "ID-Nodes, over-

view and security".

Fig. 8
l Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l The ESC - key (F1) brings you back to the basic
screen.

270 BOMAG 008 917 69

ID nodes, overview and fusing 7.44
ID = Identifier*
7.44 ID nodes, overview and fusing

Machine States, Page 402 7.47
Function Possible status Description
Conveyor OFF Conveyor belt stopped (does not turn)
Conveyor belt OUT
ON FORWARD Conveyor belt turns forward
EIN VORWÄRTS
ON BACKWARD Conveyor belt turns backward
EIN RÜCKWÄRTS
PAUSE Conveyor belt stopped (no movement), because in PAUSE
PAUSE mode
NOT ENABLED The conveyor belt cannot be switched on for certain reasons
NICHT FREIGEGEBEN (e.g. loading belt folded in)
Fan ON Fan drive switched on
Fan IN
OFF Fan drive switched off
OUT
Engine MANUAL The engine runs with idle speed
Verbrennungsmo- MANUELL
tor AUTOMATIC ON The engine speed is increased, because PAUSE mode has
AUTOMATIK EIN been switched off
AUTOMATIC PAUSE The engine speed is reduced, because PAUSE mode has
AUTOMATIK PAUSE been switched on
START MILLING DRUM The milling drum is switched on and starts to rotate
START FRÄSWALZE
RPM PLUS the engine speed is increased
DREHZAHL PLUS
RPM MINUS the engine speed is reduced
DREHZAHL MINUS

Fig. 2
l
Press key F4 to return to the previous page.
l Pressing key F5 opens the next page.
l
The ESC - key (F1) brings you back to the basic screen.

008 917 69 BOMAG 279

7.47 Machine States, Page 402

280 BOMAG 008 917 69

8 Engine

008 917 69 BOMAG 281

8.1 Diesel engine

8.1 Diesel engine It features the following positive characteristics:

l compact design
The BM2000/60 is powered by a water cooled V8 die- l low noise level
sel engine series TCD 2015 from Deutz.
l almost vibration free operation
The cylinder rows are arranged to each other under
an angle of 90°.
l low fuel consumption
The engine features four-valve technology with turbo
l low exhaust emission EPA/COM IIl
charger and intercooler. It is extremely compact and is l high power density
fitted with a solenoid valve controlled electronic injec- l good access to all service points.
tion system (MVS). l high reliability
Emission limit values acc. to EPA/ COM/ Tier/ stage lll l low running costs,
The engine has been designed with an exhaust gas l long lifetime
recirculation system.

Fig. 1 Deutz diesel engine TCD 2015

282 BOMAG 008 917 69

Engine description TCD 2015 V 8 cylinder 8.2
8.2 Engine description TCD 2015
V 8 cylinder

Fig. 1 Deutz diesel engine TCD 2015 V08 right hand side 16 Connection from air filter
1 Crankcase ventilation 17 Exhaust turbo charger
2 Connection to coolant heat exchanger 18 Connection to exhaust silencer
3 Charge air duct
4 Coolant pump
5 Connection from coolant heat exchanger
6 Vibration damper / V-belt pulley
7 Lubrication oil sump
8 Generator
9 Oil drain plug
10 Fuel lift pump
11 Connection from intercooler left (optional: right)
12 Connection to intercooler
13 Cylinder head cover
14 Transport angle
15 Exhaust manifold

008 917 69 BOMAG 283

8.2 Engine description TCD 2015 V 8 cylinder

Fig. 2 Deutz diesel engine TCD 2015 V08 left hand side

19 Injection pump (plug-type pump)

20Transmission connection (SAE)
21Flywheel
22 Starter
23 Lubrication oil filter cartridge
24 Injection line
25 Lubrication oil cooler

284 BOMAG 008 917 69

Lubrication oil circuit TCD 2015 8.3
8.3 Lubrication oil circuit TCD
2015

Fig. 1 Lubrication oil schematic 16 Plunger with rocker arm pulse lubrication
17 Push rod, oil supply to rocker arm lubrication
1 Lubrication oil sump 18 Rocker arm
2 Lubrication oil suction pipe 19 Oil return bore in cylinder head leading to crank-
3 Lubrication oil pump case
4 Pressure relief valve 20 Oil pressure sensor / oil pressure switch
5 Lubrication oil cooler 21 Oil line to exhaust turbo charger
6 Lubrication oil filter 22 Exhaust turbo charger
7 Main oil galleries 23 Oil line to crankshaft and camshaft, compressor /
hydraulic pump
8 Crankshaft bearings
24 Compressor (optional)
9 Conrod bearings
25 Hydraulic pump (optional)
10 Camshaft bearings
26 Pressure retaining valve (adjustable)
11 Oil flow to individual injection pumps
27 Return flow from compressor / hydraulic pump to
12 Injection pump with injection valve
crankcase
13 Camshaft lubrication
28 Return flow from exhaust turbo charger
14 Line to spray nozzle
15 Spray nozzle with pressure retaining valve for pis-
ton cooling

008 917 69 BOMAG 285

8.4 Coolant circuit TCD 2015

Fig. 1 Coolant diagram

1 Coolant pump
2 Lubrication oil cooler
3 Coolant channel
4 Cooling of cylinder liner/cylinder head (number-
ing/arrangement of cylinders depending on en-
gine series)
5 Compressor (optional)
6 Transmission oil cooler (optional)
7 Additional cooler (optional)
8 Temperature sensor
9 Thermostat
10 Compensation tank
11 Filler socket
12 Heat exchanger
13 Cabin heater (optional)

286 BOMAG 008 917 69

Fuel circuit TCD 2015 8.5
8.5 Fuel circuit TCD 2015

Fig. 1 Fuel diagram

1 Fuel tank
2 min. distance 500 mm
3 Fuel supply line from tank
4 Manual priming pump for bleeding
5 Fuel pre-filter (example)
6 Fuel priming pump
7 Fuel twin filter
8 Fuel supply line to injection pumps
9 Injection pump
10 Injection line
11 Injection valves
12 Fuel supply line to injection pumps
13 Fuel return line from injection pumps
14 Pressure retaining valve
15 Fuel return line to fuel tank

008 917 69 BOMAG 287

8.5 Fuel circuit TCD 2015

Fuel pre-cleaner

Fig. 2 Fuel pre-cleaner

1 Filter bracket
2 Filter cartridge
3 Water collecting bowl
4 Electric connection
5 Drain plug
6 Manual fuel pump
7 Bleeding screw
8 Sealing face
A Electric water level sensor, C13

288 BOMAG 008 917 69

Fuel circuit TCD 2015 8.5
Fuel filter system

Fig. 3 Fuel pre-cleaner

008 917 69 BOMAG 289

8.5 Fuel circuit TCD 2015

Fig. 4 Fuel pressure filter

290 BOMAG 008 917 69

Injection system (MVS) TCD 2015 8.6
8.6 Injection system (MVS) TCD The solenoid valve closes the fuel bypass in the
plunger chamber, thus causing an increase in injec-
2015 tion pressure and finally triggers the injection when
The solenoid valve system (MVS) is a new fully elec- the nozzle opening pressure is reached. If injection is
tronically controlled diesel injection system without to be ended, the valve will open the bypass, the sys-
mechanical link to the operator (no governor rod). In tem pressure drops and the spring force closes the
contrast to conventional injection systems the MVS nozzle needle.
enables an absolutely unrestricted control of delivery The solenoid valves are triggered by the electronic
period (injection quantity) and start of delivery (injec- control unit in dependence on the operatig parame-
tion timing) and thus ensures reliable compliance with ters. The system is capable of providing a wide range
current emission regulations. of limp-home functions, should any of the sensors fail.
The MVS consists of a pump with solenoid valve and This ensures a reliable and safe completion of travel
injection nozzle for each individual cylinder. and work.

Overview of electronic diesel fuel control

Sensors Control unit (EMR3) Actuators

Fig. 1 MVS - Injection system TCD 2015

008 917 69 BOMAG 291

8.6 Injection system (MVS) TCD 2015

Injection pump with solenoid valve

Fig. 2 Pump/solenoid valve TCD 2015

Pump

Nozzle

Fig. 3 Injection pump and nozzle

292 BOMAG 008 917 69

Exhaust gas recirculation TCD 2015 8.7
8.7 Exhaust gas recirculation TCD
2015
In order to be able to meet the exhaust gas stand-
ards EC and stage/Tier3, all engines are designed
with exhaust gas recirculation.

On 6 and 8 cylinder engines TCD 2015 the exhaust

gas recirculation has been realized internally
through the exhaust valves. For this purpose the
camshaft has been manufactured with an addi-
tional cam for short-term opening of the exhaust
valve

Exhaust valves

Camshaft

Fig. 1 Exhaust valve control TCD 2015

008 917 69 BOMAG 293

8.8 Wastegate - charge pressure controller on TCD-engines

The Wastegate is a exhaust gas bypass valve and is located on or in the exhaust turbocharger

The Wastegate (exhaust gas bypass valve) is used to control the charge pressure
The charge pressure control takes place by means of a charge pressure triggered pressure valve in connection
with the exhaust gas bypass valve. Depending on this bypass valve hot exhaust gases flow past the exhaust
gas turbine into the exhaust without the available energy being utilized

The bypass valve is normally closed

Control line

Pressure contro

Bypass valve
closed

Fig. 1 Exhaust gas turbocharger with Wastegate

Wastegate active, charge pressure control, i.e. bypass valve open

Bypass valve
open

Fig. 1 Exhaust gas turbocharger with Wastegate

294 BOMAG 008 917 69

Wastegate - charge pressure controller on TCD-engines 8.8
Wastegate on TCD 2013

Fig. 2 Exhaust gas turbocharger with Wastegate

008 917 69 BOMAG 295

8.9 Check, adjust the valve clearance

8.9 Check, adjust the valve clear-

ance Overlapping of valves adjustment
A1 B3
B4 A3
!Caution
A4 B2
We recommend to have this work carried out by
B1 A2
trained personnel or our after sales service.
B3 A1
Before checking the valve clearance let the engine B4
A3
cool down for at least 30 minutes. The engine oil
B2 A4
temperature must be less than 80 °C.
A2 B1

l Turn the crankshaft until the valves are overlapping.

!Caution
This engine is equipped with an internal exhaust
recirculation system. During the exhaust cycle the
intake valve opens for a short moment.
This must not be mistaken as overlapping of
valves!

Check the valve clearance

Fig. 3
l
Remove all valve covers (Fig. 3).

Fig. 5
Intake valves: 0,25 mm
Exhaust valves: 0,30 mm
l A feeler gauge of appropriate thickness (1) must fit
with little resistance between rocker arm (2) (Fig. 5)
and valve (3).
l If the gap is too narrow or too wide for the feeler
gauge, the valve must be adjusted.

Adjusting the valve clearance

l Loosen counter nut (4) (Fig. 5) for 2 to 3 turns.
l Adjust the setscrew (5) with a screwdriver, until the
feeler gauge can be inserted and pulled out with lit-
tle resistance after retightening the counter nut.
Fig. 4
Adjustment schematic (Fig. 4)
l Repeat the adjustment procedure on each cylinder.

296 BOMAG 008 917 69

Check the engine oil level 8.10
8.10 Check the engine oil level

i Note
The machine must be in horizontal position. Just be-
fore testing run the engine approx. 2 minutes with idle
speed. Shut down the engine.

Fig. 6
l Assemble all cylinder head covers with new gaskets
(Fig. 6), tightening torque: 22 Nm.
l After a short test run check the engine for leaks.

Fig. 7
l
Pull the dipstick (Fig. 7) out, wipe it off with a lint-
free, clean cloth and reinsert it until it bottoms.
l Pull the dipstick back out again.
l
The oil level must be near the ”Max”-mark.
l
If the oil level is too low top up oil immediately.

For quality of oil refer to the table of fuels, lubri-

cants and filling capacities.

008 917 69 BOMAG 297

8.11 Changing engine oil and oil filter cartridges

8.11 Changing engine oil and oil fil-

ter cartridges

i Note
Drain the engine oil only when the engine is warm.
Preferably use oils of ACEA-classification E4-99 -
SAE 10W / 40. This enables utilization of the longest
oil change intervals.

Oil change intervals (operating hours) for ACEA

quality
E4-99 = 250 operating hours
Fig. 9
l Thoroughly clean the outside of both filter cartridges
Danger
!
(Fig. 9).
Danger of scalding!
l Unscrew the filter cartridges using an appropriate
Danger of scalding when draining off hot oil! filter wrench.
l Clean the sealing face on the filter carrier from any
Environment dirt.
Environmental damage! l Slightly oil the rubber seal on the new filter cartridg-
Do not let old oil seep into the ground, but dispose es.
off environmentally.

Fig. 10
Fig. 8 l
Turn the new filter cartridges (Fig. 10) on by hand,
l
Open the bottom cover (Fig. 8). until the seal contacts.
l Unscrew the drain plug and catch running out oil. l Tighten the filter cartridges for another half turn.
l
Turn the drain plug tightly back in.

Fig. 11
l Fill in new engine oil (Fig. 11).

298 BOMAG 008 917 69

Check the coolant level 8.12
For quality and quantity of oil refer to the table of 8.12 Check the coolant level
fuels and lubricants.
l Tighten the oil filler cap properly.
! Danger

Danger of scalding!
! Caution
Fill up coolant only when the engine is cold.
Before starting crank the engine with the starter
motor until the oil pressure warning light goes
out. ! Caution
l After a short test run check the oil level on the dip- If, during the daily inspection the coolant level is
stick, if necessary top up to the top dipstick mark. found to have dropped, check all lines, hoses and
engine for leaks.
l Check filter cartridge and drain plug for leaks after a
short test run.
l Shut the engine down and wait for about 15 min-
utes, so that all oil can flow back into the oil sump.
l Check the oil level again, if necessary fill up to the
Max.-mark.

Fig. 12
l
Unscrew the radiator cap (Fig. 12) and check the
coolant level.
l
Fill in coolant up to the “MAX” mark to refill.

For quality of coolant refer to the chapter 5.2, fuels

and lubricants.

008 917 69 BOMAG 299

8.13 Changing the coolant

8.13 Changing the coolant 8.14 Checking the thermostat in

disassembled state
! Danger
The thermostat serves the optimal temperature con-
Danger of scalding! trol of the coolant, in order to promote efficient com-
Change the coolant only when the engine is cold. bustion and to bring the engine quickly to operating
temperature after starting. At temperatures below ap-
prox. 83°C the thermostat is closed. Once the coolant
Environment temperature has reached about 83°C, the thermostat
Catch running out coolant and dispose of environ- will start to open, at about 95° C it is fully open. In this
mentally. condition the full coolant flow is guided through the ra-
diator.

Fig. 13
Fig. 1
l
Unscrew the plug, open the drain tap (Fig. 13), let l Measure and write down the measurement "a" on
the coolant run out and catch it.
the thermostat (Fig. 1).
l
Screw the plug back in and close the drain tap once
all coolant has run out.
!Caution
Take note of different opening temperatures (Fig.
2) (arrows) of the thermostats.

Fig. 14
Fig. 2
l Open the radiator cap (Fig. 14) and fill in coolant.

For quality of coolant refer to the chapter 5.2, fuels i Note

and lubricants. "a" = Start of stroke (A-Bank, colour mark black ven-
l Start the diesel engine and run it warm to operating tilation groove at top) at approx. 79°C
temperature.
"a" = Start of stroke (B-Bank, ventilation groove at top)
l Let the engine cool down and check the coolant lev- at approx. 87°C
el again, top up if necessary.

300 BOMAG 008 917 69

Cleaning the engine 8.15
8.15 Cleaning the engine

! Caution
After cleaning the coolers it is mandatory to clean
the engine.
Cover all parts of the electrical system, do not
subject to the direct water jet.
l Blow the engine dry with compressed air. Flush lose
dirt with a water jet out of the V-shaped space be-
tween the cylinders.

Fig. 3
l
Warm up the thermostat in a water bath (Fig. 3).

i Note
In order to determine the exact start of opening the
temperature should be measured as close to the ther-
mostat as possible, but without touching it.
The water must thereby be stirred continuously, to en-
sure even temperature distribution.
The temperature increase should not exceed 1°C/
min, as otherwise the start of opening will be delayed
accordingly. Fig. 5
l
Drain bores 1 (Fig. 5) and 2 (Fig. 6) must be free,
remove blockage if necessary.
l
In case of oily contamination spray the engine with
cold cleansing agent and spray it off with a water jet
after s sufficient soaking time.

Fig. 4
l
Measure and write down the measurement "b" on
the thermostat . (Fig. 4).
l Calculate the stroke.

Stroke = b - a
Fig. 6

i Note l Drain bores 2 (Fig. 6) and 1 (Fig. 5) must be free,

Stroke length min. 8 mm. remove blockage if necessary.
l After wet cleaning run the engine warm to evapo-
rate all water residues and to avoid corrosion.
l
Reinstall the service covers.

008 917 69 BOMAG 301

8.16 Check, clean the water separator

8.16 Check, clean the water separa- 8.17 Change the fuel pre-filter car-
tor tridge

Danger
! Danger
!

Danger of injury! Fire hazard!

Support the engine hood for all maintenance and When working on the fuel system do not use open
repair work. fire, do not smoke and do not spill any fuel.
Catch running out fuel, do not let it seep into the
i Note ground.
The service intervals for the water separator depend Do not inhale any fuel fumes.
on the water content in the fuel and can therefore not
be determined precisely. After taking the engine into
operation you should therefore check the water sepa-
rator every day for signs of water.
If a to high quantity is drained off, the filter must be re-
filled with fuel. See chapter "maintenance as re-
quired", bleeding the fuel system.

Environment
Catch running out fuel and dispose of environ-
mentally.

Fig. 8
l
Pull off the cable and unscrew the fuel filter car-
tridge (Fig. 8) using an appropriate filter wrench.
l
Clean the sealing face on the filter carrier from any
dirt.

Fig. 7
l
Slacken the drain plug (Fig. 7) for a few turns and
catch running out fuel / water.
l Tighten the drain plug again and check for leaks, if
necessary replace the seal ring.

Fig. 9
l Unscrew the water separator from the filter car-
tridge (Fig. 9).

302 BOMAG 008 917 69

Change the fuel pre-filter cartridge 8.17

Fig. 10 Fig. 11
l Apply a thin coat of oil to the rubber seal of the water l Slacken the bleeding screw (Fig. 11) on the fuel
separator 1 (Fig. 10). pre-filter for 2 to 3 turns.
l Screw the water separator on by hand (2), until the l Operate the hand pump manually, until fuel flows
seal contacts. out of the slackened bleeding screw (Fig. 11) with-
l Tighten the water separator for another half turn (3). out air bubbles.
l Then tighten the bleeding screw while pumping.
l Fill the filter cartridge with clean diesel fuel (4).
l Apply some oil to the rubber seal of the filter ele-
ment (5) and screw it on by hand, until the seal con-
tacts.
l Tighten the filter element for another half turn (6).
l Plug the water sensor cable back on.
l Check the filter cartridge for leaks after a short test
run.

i Note
Air in the fuel system causes irregular running of the
engine, a drop in engine power, stalls the engine and
makes starting impossible.
Therefore bleed the fuel system after changing the
fuel pre-filter.

Environment
Catch running out fuel and dispose of environ-
mentally.

008 917 69 BOMAG 303

8.18 Change the fuel filter cartridge

! Danger

Fire hazard!
Avoid open fire, do not smoke, do not spill any fu-
el.
Do not inhale any fuel fumes.

Environment
Catch running out fuel, do not let it seep into the
ground.
Fig. 14
l
Open the left hand engine compartment doors. l If necessary bleed the fuel system with the help of
the hand pump on the pre-filter (Fig. 14).
l Check the filter cartridge for leaks after a short test
run.

Fig. 12
l
Loosen both fuel filters (Fig. 12) using a suitable fil-
ter wrench and screw it off.
l
Clean the sealing face on the filter carriers from any
dirt.

Fig. 13
l
Slightly oil the rubber seal on the new filter cartridg-
es (Fig. 13).
l Fill the filter cartridge with clean diesel fuel.
l Turn the new filter cartridge on by hand, until the
seal contacts.
l
Then tighten hand-tight.

304 BOMAG 008 917 69

Checking, replacing the generator V-belt 8.19
8.19 Checking, replacing the gen- Changing the V-belt
erator V-belt

Danger
!

Danger of injury!
Work on the generator V-belt must only be per-
formed with the engine shut down.

Check the V-belt

Fig. 17
l Slacken the fastening screws 3 and 4 (Fig. 17)
slightly.
l Loosen the counter nut (2).
l Turn tensioning screw (1) in direction of arrow to the
stop.

Fig. 15
l
Inspect the entire circumference of the V-belt (Fig.
15) 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 5 to 10 mm between the V-
belt pulleys, retighten if necessary.

Retighten the V-belt

Fig. 18
l
Unscrew the fastening screw 2 (Fig. 18) for the
spacer disc (1).
l
Unscrew clamping screws (4).
l Push the flexible coupling (3) to the side.
l Take the old V-belt off the V-belt pulley.
l
Fit the new V-belt to the V-belt pulleys.
l Tension the V-belt as previously described.
l Reassemble the coupling.

Fig. 16 i Note
l Slacken the fastening screws 3 and 4 (Fig. 16) Retighten new V-belts after a running time of 15 min-
slightly. utes.
l
Loosen the counter nut (2).
l Turn down tensioning screw (1) in direction of ar-
row, until the correct V-belt tension is reached.
l Retighten hexagon screws and counter nut.

008 917 69 BOMAG 305

8.20 Service the combustion air filter

8.20 Service the combustion air fil-

ter

Caution
!

Perform cleaning, maintenance and repair work

only with the engine shut down. Do not start the
engine after removing the filter element.

Fig. 21
l Pull the main filter element (Fig. 21) with light turn-
ing movements.

Cleaning the main filter element

!Caution
If necessary, the main filter element may be
Fig. 19 cleaned up to five times. It must be renewed at the
Maintenance of the dry air filter is due when the gen- latest after a maximum utilization period of two
eral fault warning light flashes and the message years.
"Service air filter" appears in the fault message screen The number of cleaning intervals of the main filter
(Fig. 19). element can be marked on the safety element with
However, the filter cartridge must be replaced at the a ball pen or a felt pen.
latest after two years. Cleaning does not make sense if the main filter el-
After completion of the filter service reset the indicator ement is covered with a sooty deposit. Use a new
piston back to "Zero" by pressing the button. filter cartridge.
l
Open the engine hood completely and secure it. Incorrectly handled inserts may be ineffective be-
cause of damage (e.g. cracks) and cause damage
to the engine.
Removing the main filter element
Replace the safety cartridge if the main filter ele-
ment is defective!
Additional cleaning intervals between two filter
services signalized by the fault monitoring board
are not necessary.

Fig. 20
l Open the service flap 1 (Fig. 20) in front of the air
filter.
l
Unscrew the wing nut from the air filter lid and re-
move the lid. Fig. 22
l
Blow the cartridge out with compressed air (max. 5
bar) from inside to outside by moving the tube up

306 BOMAG 008 917 69

Service the combustion air filter 8.20
and down inside the cartridge, until it if free of dust
(Fig. 22).

Fig. 24
l Unscrew the wing nut and pull the safety element
(Fig. 24) out by turning it lightly.
Fig. 23
l Install the new safety cartridge and fasten it with the
l Examine the filter cartridge with a torch for cracks
wing nut.
and holes in the paper bellows (Fig. 23).
l Reassemble main filter element and cover.
Caution
!

Do not continue to run the machine with a dam- Caution

aged main filter element. If in doubt use a new Make sure that the cover locks engage correctly.
main filter element.

Installing the main filter element

l
Slide the main filter element carefully into the hous-
ing.
When closing the housing cover the main filter ele-
ment is automatically forced in the correct position.

Changing the safety filter element

Caution
!

The safety filter element must not be cleaned and

should not be used again after it has been re-
moved.
Break the seal only to replace the safety filter ele-
ment.
The safety filter element must be replaced:
if the main filter element is defective,
after five service intervals of the filter cartridge,
at the latest after 2 years,
if the warning light comes on again after servicing
the main filter cartridge.
l
Remove the housing cover and pull the main filter
element off.

008 917 69 BOMAG 307

8.21 Intercooler, draining oil and condensation water

8.21 Intercooler, draining oil and 8.22 Check fastening of engine /

condensation water turbocharger / combustion air
hoses
Environment
Catch running out substances, do not let them
seep into the ground.

Fig. 26
l Check charge air line (Fig. 26) and intercooler for
tight fit and leaks.
Fig. 25 l Check exhaust pipe and lubrication oil line to and
l
Unscrew the plug (Fig. 25) and let oil or condensa- from the exhaust turbo charger for tight fit and
tion water flow out. leaks.
l
Turn the plug tightly back on. l Check connecting sockets for tight fit.
l Check combustion air pipe and connecting sockets
for leak tightness and tight fit.

308 BOMAG 008 917 69

Engine conservation 8.23
8.23 Engine conservation
If the engine is to be shut down for a longer period of
time (e.g. over winter), please consult the service de-
partment of the engine manufacturer for further de-
tails.

008 917 69 BOMAG 309

8.24 General trouble shooting chart TCD 2015

8.24 General trouble shooting

chart TCD 2015

Faults Causes Action

Temperature below starting limit
Engine oil with wrong SAE viscosity class Change the lubrication oil
Fuel quality not as specified in the operating Change the fuel
Engine does not
instructions
start or starts
Air in the fuel system Bleed the fuel system
poorly
Battery defective or not charged Check the battery
Cable to starter loose or oxidized Check cable connection
Starter defective or pinion does not engage Check starter
Engine does not Engine electronics prevent starting Check fault by fault code, repair as necessary
start and diag-
nostic lamp flash-
ing
Engine starts, but Fuel quality not as specified in the operating Change the fuel
runs irregularly or instructions
misfires Injection line leaking Check the injection line
Injection valve defective Check the injection valve / replace if neces-
sary
Speed changes Engine electronics detected a system fault Check fault by fault code, repair as necessary
are possible and and activates a substitute speed
diagnostic lamp
lights
Oil level too low Fill up lubrication oil
Engine oil level too high Check oil level, drain off if necessary
Air filter clogged / exhaust turbocharger de- Check / replace if necessary
Engine overheat-
fective
ing. Temperature
Air filter service switch / indicator defective Check / replace if necessary
warning system
Fan defective / V-belt torn or loose Check fan / V-belt, replace if necessary
responds
Short circuit of heat in cooling system Check the cooling system
Resistance in cooling system too high / flow Check the cooling system
quantity too low
Engine oil level too high Check the oil level
Fuel quality not as specified in the operating Change the fuel
instructions
Air filter clogged / exhaust turbocharger de- Check / replace if necessary
Insufficient en-
fective
gine power
Air filter service switch / indicator defective Check / replace if necessary
Charge air pipe leaking Check the charge air pipe
Injection line leaking Check the injection line
Injection valve defective Check the injection valve
Insufficient en- Engine electronics reducing the output power Check fault by fault code, repair as necessary
gine power and
diagnostic lamp
lights
Engine does not Injection line leaking Check the injection valve / replace if neces-
work with all cyl- sary
inders Injection valve defective Check the injection valve / replace if neces-
sary

310 BOMAG 008 917 69

General trouble shooting chart TCD 2015 8.24
Faults Causes Action
Oil level too low Fill up lubrication oil
Engine has to low Extremely slanted position of engine Check engine pillow blocks / reduce the en-
or no oil pressure gine inclination
Engine oil of wrong SAE class or quality Change the lubrication oil
Engine has ex- Engine oil level too high Check oil level, drain off if necessary
cessive oil con- Extremely slanted position of engine Check engine pillow blocks / reduce the en-
sumption gine inclination
Blue engine ex- Engine oil level too high Check oil level, drain off if necessary
haust smoke Extremely slanted position of engine Check engine pillow blocks / reduce the en-
gine inclination
Temperature below starting limit
Fuel quality not as specified in the operating Change the fuel
White engine ex-
instructions
haust smoke
Injection valve defective Check the injection valve / replace if neces-
sary
Air filter clogged / exhaust turbocharger de- Check / replace if necessary
fective
Black engine ex- Air filter service switch / indicator defective Check / replace if necessary
haust smoke Charge air pipe leaking Check the charge air pipe
Injection valve defective Check the injection valve / replace if neces-
sary

008 917 69 BOMAG 311

8.25 Special tools, Deutz engine (TCD 2015)

8.25 Special tools, Deutz engine

(TCD 2015)

TCD 2015 Standard tools

8005
Compression pressure tester 057 250 67
for diesel engines
10 - 40 bar
Checking compression pressure

8008
Nozzle tester
with spray mist collecting vessel
Check injection nozzles

8011
Hose clip pliers
Loosen and fasten hose clips
e. g. fuel return pipe

312 BOMAG 008 917 69

Special tools, Deutz engine (TCD 2015) 8.25

Standard tools TCD 2015

8015
Socket wrench insert
SW 14, reinforced
Unscrew and tighten big end bearing screws.

8016
Socket wrench insert
SW 17, reinforced
Unscrew and tighten flywheel screws.

8018
Claw wrench
SW 17, reinforced
Unscrew and tighten union nuts of the injection pipes.

008 917 69 BOMAG 313

8.25 Special tools, Deutz engine (TCD 2015)

TCD 2015 Standard tools

8024
Assembly pliers 057 250 68
e. g. removing valve stem seals

8115
V-belt tension measuring device
150 to 600 N
079 947 09
Check V-belt tension

8189
Pricker 057 250 76
Removing rotary shaft lip seal

314 BOMAG 008 917 69

Special tools, Deutz engine (TCD 2015) 8.25

Standard tools TCD 2015

8190
Rotation angle disc
with magnet (e. g. setting valve clearance)
057 250 72

7
8191
Socket wrench insert 057 250 74
with slotted screwdriver insert (8x1.6)
(e. g. setting valve clearance)

8.25 Special tools, Deutz engine (TCD 2015)

Special tools TCD 2015

170120
Disassembly and assembly tool
Pressing the ball stud of the rocker arm shaft out and in

170160
Stoppers/caps 079 947 29
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system

330 BOMAG 008 917 69

9 Engine electrics

008 917 69 BOMAG 331

9.1 Engine control unit

! Caution
Pulling off the plug connectors of the control unit
while the control unit is working (i.e. with the pow-
er supply to terminal 15switched on) is not permit-
ted. Correct procedure: Switch off the electric
power supply (normally with the ignition key), wait
until the main relay has switched off (with a delay
of up to 15 seconds, listen for clicking sound),
then pull off the plugs from the control unit.
Sensors and actuators must not be connected to
external power sources for the purpose of testing,
but must only be operated on the EMR3. Other-
wise components may be permanently damaged.
The engine control unit is the central component of the
EMR3-system. It has the function of ensuring optimal
performance of the engine with the following goals
l excellent exhaust gas characteristics,
l low fuel consumption,
l smooth running of engine,
l long lifetime of engine,
l efficient servicing
under all operating conditions. For this purpose the
engine control unit uses the recorded measuring val-
ues and the parameters stored in its data memory to
run a number of calculations, which form the basis or
all the available functions. The most important func-
tions include:
l exact control of the injection process (among others
the number, start and duration of injections), Fig. 27
l
idle speed regulation, The EMR3-E (TCD 2015) (Fig. 27) engine control unit
is fitted with three sockets on the upper side of the
l regulation of exhaust gas recirculation,
housing:
l optimization of smooth running (by means of injec- l socket D2.1 to connect the vehicle wiring loom,
tion quantity correction),
l
socket D2.2 to connect the engine wiring loom for
l
engine monitoring,
sensors and actuators,
l system diagnose. l socket D2.3 to connect the engine wiring loom for
fuel metering unit and injection valves.

Main relay
When shutting down the engine, the ignition switch
isolates the electronic system from terminal 15. Meter
readings are saved in the non-volatile memory. After
approx. 10 seconds the internal main relay switches
off and disconnects the control unit from the power
supply. During this time the system must not be dis-
connected from terminal 30 (+Ubatt).

332 BOMAG 008 917 69

Engine control unit 9.1
Replacing the control unit

! Caution
It is not permitted to interchange control units
from one manufacturing series or against another
engine number. In this case the warranty will be-
come null and void.
Each control unit is clearly designated to the engine,
in accordance with the respective application. In case
of a replacement the control unit therefore needs to be
completed with the engine specific data set. When or-
dering a new control unit you must not only specify the
part-number, but also the engine serial number (see
sticker on EMR-control unit).

i Note
The Deutz part-number specified on the EMR-control
unit is the part number without software specific for
the engine. The correct part number can be found in
the spare parts catalogue.

008 917 69 BOMAG 333

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338 BOMAG 008 917 69

Pin assignment 9.2
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WKH(05V\VWHP 6HH&LUFXLWGLDJUDP

008 917 69 BOMAG 339

9.3 Diagnose with SERDIA

SERDIA
With the diagnostics tool SERDIA and a hardware in-
terface one can read out / delete and save the error
log of the control unit.

EDC16
EMR3

Fig. 1 Service-Software TCD 2012 / 2013 Assignment of inputs/outputs

The SERDIA software is first choice for any diagnos- Display of the current input and output assignment of
tics task. the EMR-control.
SERDIA is a software program from Deutz which can
be used in connection with a laptop computer to per-
form more detailed fault analyses, especially reading
out of the error log.
This displays information on
l Location of fault (e.g. ’coolant temperature sensor’)
l Nature of fault (e.g. ’fallen short of bottom limit val-
ue’, ’sporadic fault’)
l Environmental data / operating data (speed and op-
erating hours at the time of the last fault occurrence)
l Number of fault locations and frequency of fault
l Fault status (active – fault present / passive- fault no
longer present)
l Fault messages for non-present / rectified faults can
be deleted with SERDIA.

Function test
The control outputs can be activated with the engine
shut down.

340 BOMAG 008 917 69

Diagnose with SERDIA 9.3
Representation of measuring values

Fig. 2
There is a vast variety of measuring values available
for selection which can even be used if no EMR-fault
is present (start behaviour, engine sawing, lack of
power).

008 917 69 BOMAG 341

9.3 Diagnose with SERDIA

Representation of fault log

Fig. 3
When looking for the cause of a fault in the EMR3-sys-
tem examining the fault log of the engine control unit
usually provides useful information.

342 BOMAG 008 917 69

CAN BUS overview 9.4
9.4 CAN BUS overview

Sensors

Actors

Valve block in engine compartment

Fig. 1

008 917 69 BOMAG 343

9.4 CAN BUS overview

B14 - U5 = EMR engine control unit.

B17 = Control console, left
B18 - U1 = Instrument cluster
B19 = Control console, right
B20 = Central electrics
B20 - U5 = Machine control

Measuring on the CAN

Why CAN?
l
Networking of control units for the realization of complex functions.
l
Reduction of the extend of wiring and plug connections.
l
Better diagnostics possibilities.

344 BOMAG 008 917 69

Diagnose with CAN-bus 9.5
9.5 Diagnose with CAN-bus
The CAN-bus is used to transfer standard messages of the SAE J 1939.
The display is a compact, robust and integratable modules which enables the user to invoke engine data and to
display these in the following formats:
l Analog display
l Digital data
l Multi data (a combination of analog and digital data)
l Alarm messages currently present
The different diagnostic screens enable detailed examination of the engine data flow

Fig. 1
Display for EMR control (Fig. 1).

008 917 69 BOMAG 345

9.6 Diagnostics interface

SerDia connection

Fig. 1 Control unit (B14 - U5) in engine compartment

SerDia connection

Fig. 2 Diagnostic interface in engine compartment

i Note
In the circuit diagram the diagnostics interface can be found on page 170 ("Diagnostic").

346 BOMAG 008 917 69

Diagnostics interface 9.6

Fig. 3 Diagnostic link

O = Battery plus (+)
B = Battery minus (-)
F = CAN2 low
G = CAN1 low
H = CAN1 high
K = K-Line
M = CAN2 high

008 917 69 BOMAG 347

9.6 Diagnostics interface

SERDIA connection

Fig. 4
The KWP-protocol with encrypted data flow is used via the K-line. For this purpose the PC or laptop (Fig. 4) is
connected to the diagnostic interface by means of a special interface cable.
Operation of SERDIA is described in a separate operation manual.

CAN-bus display connection

Operation of the display is described in a separate operation manual.

Fig. 5
Display for EMR control (Fig. 5).

348 BOMAG 008 917 69

Diagnostics interface 9.6
BOMAG part-no.: 057 189 94

Fig. 6
The display is connected to the diagnostic interface by means of a special cable.
Wiring loom for display (Fig. 6)

BOMAG part-no.: 079 900 19

008 917 69
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

18 / 730 / ArHt2.................................................................. 5 62 / 702 / Dummy2CD_SigNpl.........................................17 128 / 523611 / FrmMngTOTSC1VR................................ 29

19 / 676 / ArHtCD_NoLd.................................................... 5 69 / 2791 / EGRCD_Max .................................................17 131 / 523500 / FrmMngTxTO .......................................... 30
20 / 676 / ArHtCD_RlyErr .................................................. 5 70 / 2791 / EGRCD_Min ..................................................18 133 / 174 / FTSCD........................................................... 30
22 / 168 / BattCD ............................................................... 6 71 / 2791 / EGRCD_SigNpl..............................................18 134 / 174 / FTSCDSysReac ............................................ 30
23 / 168 / BattCDSysReac................................................. 6 72 / 2791 / EGRCDIntEGR ..............................................18 136 / 523618 / GOTSCD ................................................. 31
24 / 523561 / BIPCyl1........................................................ 6 74 / 923 / EngCDTrqCalcOut ...........................................19 137 / 523619 / GOTSCDSysReac................................... 31
25 / 523562 / BIPCyl2........................................................ 7 75 / 190 / EngMBackUp ...................................................19 138 / 29 / HdThrt ............................................................. 31
26 / 523563 / BIPCyl3........................................................ 7 76 / 190 / EngMCaS1.......................................................19 139 / 1638 / HOTSCD ..................................................... 32
27 / 523564 / BIPCyl4........................................................ 7 77 / 190 / EngMCrS1........................................................20 140 / 1638 / HOTSCDSysReac....................................... 32
28 / 523565 / BIPCyl5........................................................ 8 78 / 190 / EngMOfsCaSCrS.............................................20 141 / 523617 / HWEMonCom.......................................... 32
29 / 523566 / BIPCyl6........................................................ 8 79 / 190 / EngPrtSysReacFOC ........................................20 142 / 630 / HWEMonEEPROM........................................ 33
30 / 523567 / BIPCyl7........................................................ 8 80 / 190 / EngPrtSysReacORC........................................21 143 / 523612 / HWEMonRcyLocked ............................... 33
31 / 523568 / BIPCyl8........................................................ 9 81 / 703 / ESLpCD ...........................................................21 144 / 523612 / HWEMonRcySuppressed........................ 33

BOMAG
32 / 102 / BPSCD .............................................................. 9 82 / 1074 / ExFlCD...........................................................21 145 / 523612 / HWEMonRcyVisible ................................ 34
33 / 102 / BPSCDSysReac................................................ 9 83 / 975 / FanCD..............................................................22 146 / 523612 / HWEMonUMaxSupply............................. 34
37 / 111 / CLSCDSysReac .............................................. 10 85 / 1639 / FanCDEval.....................................................22 147 / 523612 / HWEMonUMinSupply.............................. 34
38 / 1323 / CmbChbMisfire1............................................ 10 86 / 523602 / FanCDSysReac .........................................22 149 / 105 / IATSCD ......................................................... 35
39 / 1324 / CmbChbMisfire2............................................ 10 87 / 97 / FlFCD.................................................................23 150 / 105 / IATSCDSysReac........................................... 35
40 / 1325 / CmbChbMisfire3............................................ 11 89 / 97 / FlFCD_WtLvl......................................................23 153 / 523350 / InjVlvBnk1A ............................................. 35
41 / 1326 / CmbChbMisfire4............................................ 11 90 / 94 / FlPSCD ..............................................................23 154 / 523351 / InjVlvBnk1B ............................................. 36
42 / 1327 / CmbChbMisfire5............................................ 11 91 / 94 / FlPSCDSysReac................................................24 155 / 523352 / InjVlvBnk2A ............................................. 36
43 / 1328 / CmbChbMisfire6............................................ 12 94 / 523239 / FrmMngDecV1...........................................24 156 / 523353 / InjVlvBnk2B ............................................. 36
44 / 1450 / CmbChbMisfire7............................................ 12 95 / 523240 / FrmMngFunModCtl ....................................24 157 / 523354 / InjVlvChipA.............................................. 37
45 / 1451 / CmbChbMisfire8............................................ 12 106 / 523212 / FrmMngTOEngPrt....................................25 158 / 523355 / InjVlvChipB.............................................. 37
46 / 1322 / CmbChbMisfireMul ........................................ 13 110 / 523216 / FrmMngTOPrHtEnCmd............................25 159 / 651 / InjVlvCyl1A .................................................... 37
47 / 1346 / CmbChbSysReac .......................................... 13 112 / 523218 / FrmMngTORxCCVS ................................25 160 / 651 / InjVlvCyl1B .................................................... 38
48 / 1109 / CoEngShOffDemIgr....................................... 13 113 / 523604 / FrmMngTORxEngTemp...........................26 161 / 652 / InjVlvCyl2A .................................................... 38
52 / 1072 / CRERCD ....................................................... 14 117 / 523238 / FrmMngTOSwtOut...................................26 162 / 652 / InjVlvCyl2B .................................................... 38
53 / 1081 / CSLpCD......................................................... 14 118 / 523222 / FrmMngTOTCO1 .....................................26 163 / 653 / InjVlvCyl3A .................................................... 39
54 / 704 / CTLpCD........................................................... 14 120 / 523605 / FrmMngTOTSC1AE.................................27 164 / 653 / InjVlvCyl3B .................................................... 39
55 / 110 / CTSCD ............................................................ 15 121 / 523606 / FrmMngTOTSC1AR.................................27 165 / 654 / InjVlvCyl4A .................................................... 39

DEUTZ AG, TE-CE, Fi Seite 1 Rev. 2.1, 22.10.2008

008 917 69
EMR3 List of fault codes
Sensors 9.8
9.8 Sensors

! Caution
Sensors and actuators must not be connected to
external power sources for the purpose of testing,
but must only be operated on the EMR3. Other-
wise components may be permanently damaged.
Sensors must under no circumstances be re-
paired, but must be replaced if they are defective.

Fig. 1
1 Oil pressure sensor
2 Fuel temperature sensor
3 Sensor for charge air temperature and charge air
pressure
4 Engine control unit
5 Coolant temperature sensor
6 Oil level sensor, option
7 Central plug
8 Rotary speed sensor for crankshaft
9 Rotary speed sensor for camshaft
10 Wiring loom connecting cable

008 917 69 BOMAG 421

9.8 Sensors

Fig. 2

Fig. 3

422 BOMAG 008 917 69

Oil pressure sensor 9.9
9.9 Oil pressure sensor

Fig. 1 transmitted via the CAN-bus connection to the dis-

play.
In case of a fault the General Fault Lamp lights up
(Fig. 3).

Fig. 2 Oil pressure sensor

Oil pressure monitoring

The operator is warned if
l the oil pressure falls short of the warning limit and/or
Fig. 3
l the power is reduced by the EMR after a pre-warn- flashes = Generic fault
ing time, or
Press the push but-
l the oil pressure falls short of the shut-down limit and ton = The error message is displayed on
the engine is shut down after a pre-warning time. the screen of the multi-function
display (Fig. 4).
Fault message
The oil pressure sensor is electronically monitored by
the EMR-control. In case of a fault a fault code is

008 917 69 BOMAG 423

9.9 Oil pressure sensor

Fig. 5
Fig. 4
The current oil pressure appears in the display (Fig. 5)
(position 6).
i Note
Diagnostics code see corresponding chapter.

! Caution
A detailed reading out of fault codes for the diesel
engine is only possible with Deutz-Serdia.

424 BOMAG 008 917 69

Oil pressure sensor 9.9
Removing and installing the pressure sensor Installing the pressure sensor

!Caution
Ensure absolute cleanliness when working in the
lubrication oil system.
Thoroughly clean the area around the affected
component. Dry off wet locations with com-
pressed air.
Immediately close all connections and openings
with new and clean plugs/caps.
Only remove plugs/caps just before assembling.

Environment
Catch engine oil and dispose of environmentally.

Removing the pressure sensor

Fig. 7
l Insert the oil pressure sensor with a new seal ring
and tighten.

i Note
Tightening torque: 20 Nm

Fig. 6
l Unlock and pull out the cable plug (Fig. 6).
l
Unscrew the oil pressure sensor with a socket
spanner.
l Check the component visually.

Fig. 8
l
Plug in the cable plug.

i Note
Delete the fault entry in the fault log of the engine con-
trol unit.

008 917 69 BOMAG 425

9.10 Fuel temperature sensor

Fig. 1
l Temperature correction for injection quantity

Fig. 3
flashes = Generic fault
Fig. 2 Press the push but-
ton = The error message is displayed on
Fault message
the screen of the multi-function
The temperature sensor is electronically monitored by display (Fig. 4).
the EMR-control. In case of a fault a fault code is
transmitted via the CAN-bus connection to the dis-
play.
In case of a fault the General Fault Lamp lights up
(Fig. 3).

426 BOMAG 008 917 69

Fuel temperature sensor 9.10

Fig. 5
Fig. 4
The fuel temperature appears in the display (Fig. 5)
(position 9).
i Note
Diagnostics code see corresponding chapter.

! Caution
A detailed reading out of fault codes for the diesel
engine is only possible with Deutz-Serdia.

008 917 69 BOMAG 427

9.11 Charge air temperature - charge air pressure sensor

Fig. 1
i Note
With a faulty pressure sensor the engine continues to
run with charge pressure simulation.
With a defective temperature sensor the engine also
carries on running.

Charge air temperature monitoring

The operator is warned if
l
the temperature exceeds the warning limit and/or
l the power is reduced by the EMR 3 after a pre-
warning time, or
l the temperature exceeds the shut-down limit and
the engine is shut down after a pre-warning time.

Fault message
The sensor is electronically monitored by the EMR-
control. In case of a fault a fault code is transmitted via
Fig. 2 the CAN-bus connection to the display.
This sensor unites two functions in one housing. The In case of a fault the General Fault Lamp lights up
one function measures the charge air pressure in the (Fig. 3).
and adapts the injection quantity in dependence on
the measured pressure. On the other hand the EMR
now detects the temperature of the passing air flow.
This is used for the smoke limitation.

428 BOMAG 008 917 69

Charge air temperature - charge air pressure sensor 9.11

Fig. 3
flashes = Generic fault Fig. 5

Press the push but- The boost pressure appears in the display (Fig. 5) (po-
ton = The error message is displayed on sition 8).
the screen of the multi-function The charge air temperature (3) is also indicated in the
display (Fig. 4). display.

Fig. 4

i Note
Diagnostics code see corresponding chapter.

! Caution
A detailed reading out of fault codes for the diesel
engine is only possible with Deutz-Serdia.

008 917 69 BOMAG 429

9.11 Charge air temperature - charge air pressure sensor

Removing and assembling the sensor

Removing the sensor

Fig. 8
l Carefully insert the pressure/temperature sensor
(Fig. 8).
Fig. 6 l Plug on the cable plug and engage the lock.
l Unlock and pull out the cable plug (Fig. 6). l Tighten the screw (1).
l Unscrew the screw.
l Remove the pressure/temperature sensor. i Note
l Check the component visually. Delete the fault entry in the fault log of the engine con-
trol unit.
Installing the sensor

Fig. 7
l Install a new O-ring (Fig. 7).
l Slightly cover the O-ring with grease.

430 BOMAG 008 917 69

Coolant temperature sensor 9.12

Fig. 1 Fault message

The sensor is electronically monitored by the EMR-
control. In case of a fault a fault code is transmitted via
the CAN-bus connection to the display.
In case of a fault the General Fault Lamp lights up
(Fig. 3).

Fig. 2
The coolant temperature has an effect on the calculat-
ed injection quantity and the preheating behaviour of
the glow plugs.

Coolant temperature monitoring

The operator is warned if Fig. 3
l
the temperature exceeds the warning limit and/or flashes = Generic fault
l the power is reduced by the EMR after a pre-warn- Press the push but-
ing time, or ton = The error message is displayed on
the screen of the multi-function
l
the temperature exceeds the shut-down limit and
display (Fig. 4).
the engine is shut down after a pre-warning time.

008 917 69 BOMAG 431

9.12 Coolant temperature sensor

Fig. 5
Fig. 4
The coolant temperature appears in the display (Fig.
5) (position 2).
i Note
Diagnostics code see corresponding chapter.

! Caution
A detailed reading out of fault codes for the diesel
engine is only possible with Deutz-Serdia.

432 BOMAG 008 917 69

Coolant temperature sensor 9.12
Removing and installing the temperature sensor Installing the temperature sensor

Environment
Catch running out fluids in a suitable vessel and
dispose of environmentally.

i Note
Follow the corresponding documentation in the oper-
ating instructions to drain and fill the cooling system.

Removing the temperature sensor

Fig. 8
l Tighten the coolant temperature sensor (Fig. 8).

i Note
Make sure that the seal rings are present .
Tightening torque: 22±2 Nm.

Fig. 6
l Unlock and pull out the cable plug (Fig. 6).

Fig. 9
l Push on the cable plug (Fig. 9).

i Note
Delete the fault entry in the fault log of the engine con-
Fig. 7 trol unit.
l Unscrew the coolant temperature sensor (Fig. 7).
l
Check the component visually.

008 917 69 BOMAG 433

9.13 Cant level sensor, C11 and C18

Fig. 1
The sensor works according to the capacitive principle. The capacity change, that is generated when an air sur-
rounded, insulated electrode is submerged in a liquid medium, is detected. This capacity change on the sensor
electrode excites an oscillator.
These sensors have a short circuit proof switching output. Since they do not contain any moveable parts, their
function can neither be impaired by dirt particles, nor by other influences.
1 C18, coolant level sensor The sensor is electronically monitored by the EMR-control. In case of a fault a fault
code is transmitted via the CAN-bus connection to the display (B18 - U1).
2 C11, coolant level sensor is not monitored by the engine control unit. The signal is picked up by the CAN-
bus module (B20 - U3) and evaluated in the control (B20 - U5).

Input Function ID-node Display status PIN

B14 - C11 Coolant level sensor. ID 92 / DI 11 0/1 X2.5

Output Function ID-node Display status PIN

B18 - S8 Fault indicator lamp ID 92 / DO 08 0/1 X1.15

DI ... = Digital input

DO ... = Digital output
In case of a fault the fault indicator lamp B18 - S8 (Fig. 2) lights up.

434 BOMAG 008 917 69

Cant level sensor, C11 and C18 9.13

Fig. 2 Fault indicator lamp + button

flashes = Generic fault
Press the push button= The error message is displayed on the screen of the multi-function display (Fig. 3).

Fig. 3
5024 = Coolant level too low

008 917 69 BOMAG 435

9.14 Speed sensor for diesel engine

Camshaft speed sensor

9.14 Speed sensor for diesel engine

Fig. 4
l
Inductive sensor
l
Determination of TDC
l
Limp-home function in case of crankshaft sensor
failure

436 BOMAG 008 917 69

Speed sensor for diesel engine 9.14
Crankshaft speed sensor

Fig. 5
l
Inductive sensor
l
Exact determination of engine speed
l
Limp-home function in case of camshaft sensor fail-
ure

Fault message
The inductive sensors are electronically monitored by
the EMR-control. In case of a fault a fault code is
transmitted via the CAN-bus connection to the dis-
play.
In case of a fault the General Fault Lamp lights up
(Fig. 6).
Fig. 6
flashes = Generic fault
Press the push but-
ton = The error message is displayed on
the screen of the multi-function
display (Fig. 7).

008 917 69 BOMAG 437

9.14 Speed sensor for diesel engine

Fig. 8
Fig. 7
The actual engine speed is shown in the display (Fig.
8).
i Note
Diagnostics code see corresponding chapter.

! Caution
A detailed reading out of fault codes for the diesel
engine is only possible with Deutz-Serdia.

438 BOMAG 008 917 69

Preheating system 9.15
9.15 Preheating system the area around the affected component. Dry off
wet locations with compressed air.

Glow plugs Immediately close all connections and openings

with new and clean plugs/caps. Only remove
The engines are fitted with glow plugs as cold starting plugs/caps just before assembling.
aids by standard.

Environment
Catch running out fluids in a suitable vessel and
dispose of environmentally.

Disassembling the glow plug

Fig. 1 Glow plug R02

Once the preheating temperature is reached, a sole-
noid valve directs fuel into the evaporation zones of
the glow plug. This generates a flame which sustaina-
bly heats up the intake air and thus enables reliably,
comfortable and environmentally friendly starting,
Fig. 3
also at low temperatures.
l Remove the fuel lines 1 (Fig. 3).

Fig. 2 Solenoid valve Fig. 4

l Unscrew the nut 1 (Fig. 4).
Removing and installing the glow plug l
Disconnect the cable.

! Caution
Follow the safety regulations and country specific
regulations concerning the handling of fuel.
Ensure absolute cleanliness when working in the
fuel system. Remove any existing paint and dirt
particles before disassembling. Thoroughly clean

008 917 69 BOMAG 439

9.15 Preheating system

Installing the glow plug

Fig. 5
l
Loosen counter nut 1 (Fig. 5).
l Unscrew the glow plug.

Fig. 7
l
Install the new gasket.
l
Screw in the glow plug.

i Note
Observe measurement (X) (Fig. 7).
Measurement (X) = 60 - 3 mm

Fig. 6
l Remove the seal 1 (Fig. 6).
l Check the component visually.

Fig. 8
l
Install the fuel lines 1 (Fig. 8).
l Tighten the counter nut (2).

440 BOMAG 008 917 69

Sensor, water in fuel, C13 9.16
i Note 9.16 Sensor, water in fuel, C13
Tightening torque of counter nut 25 Nm

Fig. 9
l Push on the cable lug (Fig. 9).
l Install the washer.
l
Tighten the nut.

i Note Fig. 1

Tightening torque of nut = 5 Nm. 1 Sensor for water separator

Fault message
The analog sensor is electronically monitored by the
EMR-control. In case of a fault a fault code is transmit-
ted via the CAN-bus connection to the display.
In case of a fault the General Fault Lamp lights up
(Fig. 2).

Fig. 2
flashes = Generic fault
Press the push but-
ton = The error message is displayed on
the screen of the multi-function
display (Fig. 3).

008 917 69 BOMAG 441

9.17 Air filter vacuum switch, C12

Fig. 3

i Note
Diagnostics code see corresponding chapter.
Fig. 1

! Caution The vacuum switch operates at a vacuum of > 50

mbar.
A detailed reading out of fault codes for the diesel
engine is only possible with Deutz-Serdia. Fault message
The pressure switch is electronically monitored by the
EMR-control. In case of a fault a fault code is transmit-
ted via the CAN-bus connection to the display.
In case of a fault the General Fault Lamp lights up
(Fig. 2).

Fig. 2
flashes = Generic fault
Press the push but-
ton = The error message is displayed on
the screen of the multi-function
display (Fig. 3).

442 BOMAG 008 917 69

Air filter vacuum switch, C12 9.17

Fig. 3

i Note
Diagnostics code see corresponding chapter.

! Caution
A detailed reading out of fault codes for the diesel
engine is only possible with Deutz-Serdia.

008 917 69 BOMAG 443

9.17 Air filter vacuum switch, C12

444 BOMAG 008 917 69

10 Pump transfer case

008 917 69 BOMAG 445

10.1 Transfer case

Fig. 1 Engine with transfer case

A highly elastic coupling (3) (Fig. 1) between engine (4) and transfer case (1) ensures a clearance free connec-
tion between coupling hub and drive shaft.
A spare flat drive belt (2) is stored on the transfer case, packed up water and dust tight. Should the originally
installed flat belt need to be replaced, one can use the spare belt without having to disconnect tghe transfer case
from the engine.

446 BOMAG 008 917 69

Transfer case 10.1

Fig. 2 Clutch

008 917 69 BOMAG 447

10.1 Transfer case

Fig. 3 Cross section of transfer case

Technical data:
l
Rigid housing made of grey cast iron
l
Induction hardened gears with ground tooth flanks
l
Oil bath lubrication, pressure circulation lubrication

448 BOMAG 008 917 69

Transfer case 10.1
Notes on assembly:
Heavy blows with a hammer must be strictly avoided, because roller bearings, circlips and other internal parts
could be damaged!
Hydraulic pumps must be oil tight connected to the mounting flanges and should not apply any axial pressure to
the gearbox shafts!
The coupling pieces or splines must be thoroughly lubricated before assembly, we recommend the use of Opti-
mol White T or Staburags NBU 30 PTM.

Fig. 4 Pump transfer case without pumps

008 917 69 BOMAG 449

10.1 Transfer case

Fig. 5 Pump transfer case with pumps

450 BOMAG 008 917 69

Check the oil level in the pump drive gear 10.2
10.2 Check the oil level in the pump 10.3 Change the oil in the pump
drive gear drive gear

i Note i Note
Check the oil level only in cold condition and with the Drain oil only at operating temperature.
engine shut down.
Danger
!

Danger of scalding!
Danger of scalding when draining off hot oil!

Environment
Environmental damage!
Catch old oil and dispose of environmentally.
l Remove the bottom cover.

Fig. 6
l Unscrew the plug (Fig. 6).
l
Check the oil level on the dipstick.
l
The oil level must be near the "Max"-mark.
l Top up oil, if necessary.

For quality of oil refer to the table of fuels, lubri-

cants and filling capacities.

Fig. 7
l Unscrew the drain hose (Fig. 7) from the socket.
l Drain off and catch old oil.
l
Once all old oil has run out remove the oil drain
hose.

Fig. 8
l
Fill in new oil (Fig. 8).

008 917 69 BOMAG 451

10.3 Change the oil in the pump drive gear

For quality and quantity of oil refer to the table of

fuels, lubricants and filling capacities.

Since the torque is proportional to the oil pressure, it is very important that the correct pressure is applied to the
clutch at all times. (Nominal value see chapter “Technical data”).

Clutch - repair

! Danger

Perform repair or service work only with the engine shut down, the emergency stop switch depressed
and the machine reliably secured against accidental starting.
Danger of burning! The clutch may be very hot.
Fire hazard! The clutch must not come in contact with caustic or grease containing cleansing agents.
Fire hazard! The friction linings must never be cleaned with solvents like gasoline, acetone or kerosene.
Oily and contaminated clutch linings must be replaced.
Unprofessional disassembly of the clutch can lead to severe injury. The clutch is preloaded with a
spring force!

456 BOMAG 008 917 69

Milling drive 11.1
Danger of injury! Before commissioning of the machine make sure that all tools and working aids have
been removed from the clutch.

! Caution
Ensure strict cleanliness when performing repair work. Leaks occurring a short while after a repair can
almost every time be traced back to dirty hydraulic connections.
Friction discs must be free of oil and grease.
The specified hydraulic pressure must not be exceeded (not even temporarily).
Check the supply line for leaks.
Observe the tightening torques.
After a shut-down caused by blockage you should always allow the system to cool down for approx. 20
minutes, to prevent unnecessary overheating of the clutch.

i Note
During repair and maintenance work the roller bearings should be checked. In case of bearing damage (e.g.
grinding noises) these must be replaced by new bearings.

i Note
The seals should be checked when performing repair work on the clutch. They should be replaced if any wear
or damage is found.

008 917 69 BOMAG 457

11.1 Milling drive

Fig. 5 Overview clutch repair

1 Ring gear
2 Outer discs / friction discs
3 Inner discs
4 Pressure disc
5 Coupling hub
6 Piston
7 Cylinder
8 Rotary connection
9 Oil supply, axial bore
10 Pressure springs
11 Bolt
12 Grooved ball bearing

458 BOMAG 008 917 69

Milling drive 11.1
13 Self-aligning roller bearing
14 Socket head cap screw
15 Intermediate flange
16 Elastic coupling
17 Flanged shaft
18 Circlip
19 Belleville springs
20 Bell

Checking the friction liner wear

Fig. 6 Visual examination on rubber element

i Note
Friction lining wear can only be checked after the clutch has been disconnected from the engine.

Procedure
l Remove loose dirt from the clutch.
l Examine the clutch for cracks, splintering or missing parts.
l Replace defective and missing parts.
Check the zones marked with arrows (Fig. 6) for cracks and adhering rubber and metal particles (a). If cracks
are deeper than 3 mm the rubber element must be replaced (d).
Tooth wear of 3-4 mm on the load side (c) is permissible. At standstill there is a gap of 1-2 mm between flange
and rubber element. At operating speed the centrifugal force ensures contact between rubber gearing and flange
(b).

008 917 69 BOMAG 459

11.1 Milling drive

Clutch - maintenance

! Danger
Perform repair or service work only with the engine shut down, the emergency stop switch depressed
and the machine reliably secured against accidental starting.
Danger of burning! The clutch may be very hot.
Fire hazard! The clutch must not come in contact with caustic or grease containing cleansing agents.
Fire hazard! The friction linings must never be cleaned with solvents like gasoline, acetone or kerosene.
Oily and contaminated clutch linings must be replaced.
Unprofessional disassembly of the clutch can lead to severe injury. The clutch is preloaded with a
spring force!
Danger of injury! Before commissioning of the machine make sure that all tools and working aids have
been removed from the clutch.

The clutch requires only little maintenance. The oil pressure must only be monitored during operation and the
wear on the friction linings must be checked at certain intervals.

460 BOMAG 008 917 69

Milling drive 11.1
Monitoring the oil pressure

Fig. 7 Instrument cluster

The clutch pressure can be read in the multi-function display (position 3) (Fig. 7).

Nominal value
See chapter "Technical Data".

008 917 69 BOMAG 461

11.1 Milling drive

Fig. 8 Overview clutch repair

462 BOMAG 008 917 69

Milling drive 11.1
13 Self-aligning roller bearing
14 Socket head cap screw
15 Intermediate flange
16 Elastic coupling
17 Flanged shaft
18 Circlip
19 Belleville springs
20 Bell

Bearing
l The grooved ball bearings (12) (Fig. 8) are lifetime lubricated.
l The self-aligning roller bearing (13) (Fig. 8) is fitted with a relubrication device.

i Note
During repair and maintenance work the roller bearings should be checked. In case of bearing damage (e.g.
grinding noises) these must be replaced by new bearings.

Seals and gaskets

l
Seals and gaskets do not require any particular maintenance.

i Note
The seals should be checked when performing repair work on the clutch. They should be replaced if any wear
or damage is found.

Clutch - possible malfunctions

Possible malfunctions of the clutch

The clutch slips under load

Cause Remedy
Oil pressure too low Adjust oil pressure to required level
Outer discs worn Replace outer discs
Grease on friction areas Clean the affected steel or cast iron parts with gasoline or
acetone
Grease on outer discs Replace the outer discs with new ones

Hub and pressure disc heat up to more than 120°C when engaged
Cause Remedy
Clutch slipping, oil pressure too low Adjust oil pressure to required level

Hub and pressure disc heat up when switched off

Cause Remedy
Pressure disc (4) and inner disc (3) seized on bolt Reestablish light axial movement of parts (3 +4) on bolt
(11) (11)
The pressure disc does not release, because the Ensure appropriate relieving of the cylinder
pressure in the cylinder (7) does not drop
Pressure disc (4) does not release, because the Install new pressure springs
pressure springs (10) have settled

008 917 69 BOMAG 463

11.1 Milling drive

Clutch - concentricity deviations and axial runouts

Fig. 9

Inspection of concentricity faults and side runouts on flywheel and centrings on engine housing and on
the guide bearing.

The more accurate the alignment, the more reliable the drive the higher the lifetime of the clutch.

464 BOMAG 008 917 69

Milling drive 11.1
1 Check the axial runout TPM of the flywheel to the centring on the engine housing using a dial gauge with
magnetic stand. The permissible deviation is 0.2mm.
2 Check the concentricity deviation (eccentricity) TRM of the flywheel to the centring on the engine housing
using a dial gauge with magnetic stand. The permissible deviation is 0.2 mm.
3 Check the axial runout TPS of engine housing to the centering on the flywheel by means of a dial gauge with
magnetic stand. The permissible deviation is 0.05 mm over a radius of 100 mm.
4 Check the concentricity deviation TRS of the engine housing to the centring on the flywheel using a dial
gauge with magnetic stand. The permissible deviation is 0.13 mm. Mark the point of the largest deviation.
5 Check the concentricity fault TRF of the engine housing to the centring on the guide bearing using a dial
gauge with magnetic stand. The permissible deviation is 0.13 mm. Mark the point of the largest deviation.
6 Calculation of the concentricity deviation Tm of the centrings on flywheel and guide bearing.
Tm = TRS - TRF / 2
Points with highest deviation are on the same side.
Tm = TRS + TRF / 2
Points of highest deviation are opposite each other.
The permissible deviation is 0.2 mm.

The permissible concentricity deviation is 0.15 mm.

008 917 69 BOMAG 465

11.1 Milling drive

V-belt unit

Power transmission
The hydraulically tensioned V-belt (Fig. 10) transfers the torque to the milling drum drive.

Fig. 10 Power transmission

1 Clutch with V-belt pulley 4 V-belt

2 Tensioning cylinder 5 V-belt pulley on milling drive gearbox
3 Idler pulley

466 BOMAG 008 917 69

Milling drive 11.1

Fig. 11 V-belt tensioning device

An idler pulley (1) keeps the V-belt correctly under tension at all times. For this purpose the hydraulic cylinder
(2) presses against the lever (3) as soon as the engine is started (Fig. 11).

008 917 69 BOMAG 467

11.1 Milling drive

Fig. 12 V-belt pulley on milling drive gearbox

At the lower end of the V-belt unit the torque is transmitted to the milling drum gearbox (Fig. 12).

468 BOMAG 008 917 69

Milling drive 11.1
Milling drum gearbox

Fig. 13 Gear - milling drum

The milling drum gearbox (3) (Fig. 13) reduces the input speed and thereby increases the torque of the milling
drum (2).
The gearbox (3) is mounted to the milling drum (2). Gearbox (3) and milling drum (2) are assembled together
into the milling unit (1).

008 917 69 BOMAG 469

11.1 Milling drive

470 BOMAG 008 917 69

12 Milling drive, repair

008 917 69 BOMAG 471

12.1 Checking, replacing the milling drum V-belt

12.1 Checking, replacing the milling Changing the V-belt

drum V-belt l Start the engine and raise the machine to
highest position.
!
Danger
l Shut down the engine.
Danger of accident!
l Open the side flap and remove the cover
Perform this work only with the engine shut
down!
i Note
Check the V-belt Before loosening the stop screw measure the
length and write it down.

Fig. 14
Fig. 16
l Check the entire circumference of the V-
belts (Fig. 14) for damage and cracks. Re- l Loosen the counter nut 1 (Fig. 16) and tight-
place damaged or cracked V-belts. en the stop screw (2).
l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
l Return the idler pulley to its original position
and tighten the counter nut.
l Reassemble the cover.

Fig. 15

l Check the V-belt pulley for signs of wear

(Fig. 15).

new V-belt pulley A=14.24

Worn V-belt pulley A=15.24

472 BOMAG 008 917 69

Change the oil in the milling drum reduction gear 12.2
12.2 Change the oil in the milling drum re- 12.3 Oil change in milling drum bearing
duction gear
!
Caution
!
Danger Drain oil only at operating temperature.
Life hazard!
Shut down the engine and remove the igni- Environment
tion key before accessing the milling drum. Catch old oil and dispose of environmental-
Additionally attach a warning tag stating ly.
"Do not start the engine!" to the dashboard. l Park the machine horizontally.

Environment
Catch the oil and dispose of environmental-
ly.
l Park the machine so that milling drum is in
horizontal position.

Fig. 18

l Clean and unscrew the drain and level con-

trol plugs (Fig. 18).
l Drain and catch all oil.
l Screw the drain plug back in and tighten it.
Fig. 17

l Turn the milling drum with the crank handle

2 (Fig. 17) until the drain plug (3) is in bot-
tom position.
l Clean and unscrew plug (3).
l Drain and catch all oil.
l Turn drain plug (3) in and tighten it.
l Fill in oil through the oil level control bore
(1), until it has reached the bottom edge of
the bore.

For quality of oil refer to the table of fuels, Fig. 19

lubricants and filling capacities.
l Fill in oil through the oil level control bore,
until it reaches the bottom edge of the bore.
(Fig. 19).
l Screw the level control plug back in and
tighten it.

For quality of oil refer to the table of fuels,

lubricants and filling capacities.

008 917 69 BOMAG 473

12.4 Lubricating the milling drum

12.4 Lubricating the milling drum Lubricating the clutch

i Note ! Caution
The bearings of the milling drum and the laby- Use a special lubrication grease.
rinth seal must be lubricated in regular inter-
See section "Table of fuels and lubricants".
vals. The interval can be taken from the
operating and maintenance instructions.

Fig. 1
1. Lubricate the bearing with special grease from
the grease gun (quantity: 3 strokes from the
grease gun) (Fig. 1)

474 BOMAG 008 917 69

Lubricating the milling drum 12.4

Fig. 2
2. Lubricate the bearing of the labyrinth seal with
special grease from the grease gun (quantity: 3
strokes from the grease gun) (Fig. 2)

008 917 69 BOMAG 475

12.4 Lubricating the milling drum

476 BOMAG 008 917 69

13 Clutch, repair

008 917 69 BOMAG 477

13.1 Lubricating the clutch of the milling drum drive

13.1 Lubricating the clutch of the milling

drum drive

i Note
The bearings of the clutch must be lubricated in
regular intervals. The interval can be taken from
the operating and maintenance instructions.

Lubricating the clutch

1. Lubricate the bearing with special grease from
the grease gun (quantity: max. 25 gram) (Fig. 1)

! Caution
Use a special lubrication grease.
See section "Table of fuels and lubricants".

Fig. 1

478 BOMAG 008 917 69

Checking the wear of the friction lining 13.2
13.2 Checking the wear of the friction lin-
ing

i Note
Measuring the wear of the friction lining is accom-
plished by determining measurement "X".
For this purpose the clutch must be switched on,
but with the drive stopped.

Determining measurement "X"

1. Disassemble the plug (1) (Fig. 1).
2. Switch on the clutch.
3. Use appropriate measuring tools to determine
measurement "X".

Nominal value: < 15mm.

(Condition upon delivery = 6mm)

i Note
If the measurement exceeds 15 mm, the friction
discs must be replaced. See chapter
"Clutch_Repairs, section "Replacing the clutch
Fig. 1
friction discs".

008 917 69 BOMAG 479

13.3 Friction lining / replacing the outer discs

13.3 Friction lining / replacing the outer

discs

! Danger
Perform repair or service work only with the
engine shut down, the emergency stop switch
depressed and the machine reliably secured
against accidental starting.
Danger of burning! The clutch may be very
hot.
Fire hazard! The clutch must not come in con-
tact with caustic or grease containing cleans-
ing agents.
Fire hazard! The friction linings must never be
cleaned with solvents like gasoline, acetone
or kerosene. Oily and contaminated clutch lin-
ings must be replaced.
Unprofessional disassembly of the clutch can
lead to severe injury. The clutch is prloaded
with spring force!
Danger of injury! Before commissioning of
the machine make sure that all tools and
working aids have been removed from the
clutch.

! Caution
Ensure strict cleanliness when performing re-
pair work. Leaks occurring a short while after
a repair can almost every time be traced back
to dirty hydraulic connections.
Friction discs must be free of oil and grease.
The specified hydraulic pressure must not be
exceeded (not even temporarily).
Check the supply line for leaks.
Observe the tightening torques.
After a shut-down caused by blockage you
should always allow the system to cool down
for approx. 20 minutes, to prevent unneces-
sary overheating of the clutch.

480 BOMAG 008 917 69

Friction lining / replacing the outer discs 13.3
Remove the clutch
1. Take off the milling drive V-belt.
2. Remove the bracket (1) of the oil line (Fig. 1).

Fig. 1
3. Loosen the spigot nut (1) of the hydraulic line and
take off the line (Fig. 2).
4. Take off all screws (2) and washers.
5. Take off the V-belt pulley (3).
6. Remove the bell support.

Fig. 2
7. Unscrew both covers (1) from the clutch bell (Fig.
3).
8. Fasten appropriate lifting tackle.

Fig. 3

!Danger
Danger of injury!
Make sure that the lifting tackle has been cor-
rectly fastened!
9. Unscrew the fastening screws from the clutch bell
(Fig. 4).

Fig. 4

008 917 69 BOMAG 481

13.3 Friction lining / replacing the outer discs

10. Take the clutch bell off the engine (Fig. 5).

Fig. 5

Dismantling the clutch

1. Unscrew the socket head cap screw with washer
(Fig. 6).
2. Disassemble clutch and intermediate flange.
3. Remove the clutch from the flanged shaft using
the extraction thread in the hub and a suitable ex-
tracting device.

Fig. 6

! Danger

Unprofessional disassembly of the clutch can

lead to severe injury.
The clutch is prloaded with spring force!
4. Secure clutch hub (1), inner disc (2), outer disc
(3) and pressure disc (4) with two threaded rods
M12 and hexagon nuts (Fig. 7).
5. Remove circlip (6) and loosen the hexagon nuts
carefully, until the springs (5) are relieved.
6. Remove all parts mounted to hub (1).
7. Check the friction areas on parts (1), (2) and (4)
Fig. 7 for wear and cracks.

i Note
In case of cracks or flatness faults the affected
parts must be replaced or their friction faces need
to be reworked (dead smoothing).
8. Check the length of the relieved compression
springs (5).

i Note
If the springs have settled for more than 10%,
they must be replaced by new ones.

482 BOMAG 008 917 69

Friction lining / replacing the outer discs 13.3
Nominal value of the relieved spring = 127.8
mm
Assembling the clutch
! Danger
Unprofessional assembly of the clutch can
lead to severe injury.
The clutch is preloaded with spring force!
1. Assemble all parts to hub (1) (Fig. 8).
2. Press clutch hub (1), inner disc (2), outer disc (3)
and pressure disc (4) together with the threaded
rods M12 and the hexagon nuts.
3. Assemble the circlip (6) and loosen the hexagon
nuts carefully.

Fig. 8
4. Mount the clutch to the flanged shaft (Fig. 9).
5. Assemble the elastic clutch and the intermediate
flange.
6. Assemble the socket head cap screw.

Fig. 9

Installing the clutch

1. Position the clutch bell on the engine (Fig. 10).

Fig. 10

008 917 69 BOMAG 483

13.3 Friction lining / replacing the outer discs

2. Push the rubber disc of the elastic clutch into the

outer ring gear and slide the bell with intermedi-
ate flange into the centring in the engine housing
(Fig. 11).

Fig. 11
3. Insert the fastening screws with Loctite and tight-
en (Fig. 12).

Fig. 12
4. Remove the lifting tackle (Fig. 13).
5. Fasten both covers (1) on the clutch bell.

Fig. 13
6. Install the bell support.
7. Assemble the V-belt pulley (3) and fasten with
washers and screws (2).
8. Position the hydraulic line and fasten with spigot
nut (19 (Fig. 14):

Fig. 14

484 BOMAG 008 917 69

Friction lining / replacing the outer discs 13.3
9. Install the bracket (1) of the oil line (Fig. 15).
10. Assemble the milling drive V-belt.

! Caution
Check the oil supply for leaks.

Fig. 15

008 917 69 BOMAG 485

13.3 Friction lining / replacing the outer discs

486 BOMAG 008 917 69

14 Milling drum, repair

008 917 69 BOMAG 487

14.1 Repair overview milling drum

Fig. 1 Repair overview milling drum

1 Tool holder
2 Flange
3 Shell tube

i Note
The milling drum shown here serves as an example. Different versions of milling drums are available. The
design of all milling drums is almost identical.

488 BOMAG 008 917 69

Replacing tool holders 14.2
14.2 Replacing tool holders

! Danger
Wear safety goggles!
Wear safety gloves.

1. Use suitable tools and remove the welding seam

(2) (Fig. 1).
2. Remove the tool holder (1).

Fig. 1
1. Make sure that the contact surface (2) for the tool
holder (1) is clean (Fig. 2).
2. Use the positioning pins (3) to position the new
tool holder (1) correctly.
3. Tack weld the front corners.
4. Tack weld the diagonally opposite rear edge.
5. Weld in several layers.

Fig. 2

008 917 69 BOMAG 489

14.3 Check/replace cutting tools, scraper

i
Note
The cutting tools are mounted in replaceable
holders.

!
Danger
Life hazard!
Shut down the engine and remove the igni-
tion key before accessing the milling drum.
Additionally attach a warning tag stating
"Do not start the engine!" to the dashboard. Fig. 5

l Shut down the engine (Fig. 5) and pull out

Preparations without electro-hy- the ignition key.
draulic drive l Attach a warning tag "Do not start the en-
l Raise the machine completely. gine, maintenance work" to the dashboard.

! Danger

Life hazard!
Access the space under the machine only
with the milling drum stopped.

Fig. 3

l Unlock all four safety supports and fold

them down (Fig. 3).
l If necessary turn the rear track drives in
"Manual" mode fully to the right.
Fig. 6

l Fold out the seat (Fig. 6).

Preparations with electro-hydraulic

drive*
l Raise the machine completely.

Fig. 4

l Swing the scraper plate completely open,

until the safety hooks (Fig. 4) click into
place.
The warning lamps on both sides are flashing. * Optional equipment

490 BOMAG 008 917 69

Check/replace cutting tools, scraper 14.3

Fig. 7 Fig. 9

l Unlock all four safety supports and fold l Remove the control box for rotor drive (Fig.
them down (Fig. 7). 9) (magnetic holder).
l If necessary turn the rear track drives in
"Manual" mode fully to the right.

Fig. 10

l Fasten the control box on the opened

Fig. 8 scraper plate (Fig. 10).
l Swing the scraper plate completely open,
until the safety hooks (Fig. 8) click into
place.
The warning lamps on both sides are flashing.
l Shut down the engine and switch on the ig-
nition.
l Attach a warning tag "Do not start the en-
gine, maintenance work" to the dashboard.

!
Danger
Life hazard!
Fig. 11
Access the space under the machine only
with the milling drum stopped. l Fold out the seat (Fig. 11).

Check the cutting tools

l Rotate the drum by hand and check cutting
tools and holders.
l Check whether the cutting tools rotate in
their holders.

008 917 69 BOMAG 491

14.3 Check/replace cutting tools, scraper

Fig. 12 Fig. 15
Cutting tool in good condition (Fig. 12). Cutting tool showing uneven wear (Fig. 15).
The cutting tool must be replaced immediately.

Fig. 13
Cutting tool with even wear (Fig. 13), must be Fig. 16
replaced after short term use. Tool tip with eroded body (Fig. 16). The cutting
tool must be replaced immediately.

Fig. 14
If the cutting tool is in this condition (Fig. 14), Fig. 17
the holder must perhaps also be changed, be- Tool tip broken off (Fig. 17). The cutting tool
cause the cutting tool cannot rotate. This caus- must be replaced immediately.
es uneven wear.
Replace the cutting tool

! Danger

Wear goggles and gloves when changing

the cutting tools. Injury by hard metal splin-
ters!

492 BOMAG 008 917 69

Check/replace cutting tools, scraper 14.3

Fig. 18 Fig. 21

l Knock out damaged or worn off cutting If the tool holder is in such a condition (Fig. 21)
tools with a hammer and a special tool (Fig. it must be replaced immediately.
18).
Replacing the tool holders

Fig. 19
Fig. 22
l Knock in the new cutting tool fully with a
copper or plastic hammer (Fig. 19) and l Knock out damaged or worn off cutting tool
check whether it can rotate freely. holders with a hammer and a special tool
(Fig. 22).
Checking the tool holders

Fig. 23
Fig. 20 l Knock in the new cutting tool holders fully
Tool holder in good condition (Fig. 20). with a copper or plastic hammer (Fig. 23)
and check whether the cutting tool can ro-
tate freely.

008 917 69 BOMAG 493

14.3 Check/replace cutting tools, scraper

Checking the scraper bars

Fig. 24
Check the condition of the scraper bars (Fig.
24), replace if necessary.
Replace the scraper bars when the edges are
blunt or broken.

Replacing the scraper bars

Fig. 25
Unscrew fastening screws 1 (Fig. 25) and take
off scraper bars (2).
Mount the new scraper bars and tighten the fas-
tening screws.

494 BOMAG 008 917 69

15 Milling unit, description

008 917 69 BOMAG 495

15.1 Description of milling unit

Milling unit
15.1 Description of milling unit

The milling unit system consists mainly of:

l the milling drum
l the milling box

Milling drum
The milling drum is the heart of the cold milling machine. It removes the material by simply rotating in opposite
direction to the travel direction of the cold milling machine and cutting with the milling cutters on the milling drum
through the material.

Fig. 26 Milling drum - structure

Structure
Both the milling cutters (1) (Fig. 26) and the loading tool (4) are arranged on the shell of the milling drum.
The milling cutters are held by cutter holders (2), which in turn are fastened in tool holders (3). Through a hole
in the tool holder (3) the milling cutter (1) can be knocked out for replacement. (Tool change)
The loading tool (4) transports the milled material to the conveyor belt, which directs the material to the haulage
vehicle. The tool is attached to the milling drum at various points and thus guarantees problem free discharge
of the milled material.

Milling housing
The main function of the milling box is to take up the milling drum. Furthermore, it guides the milled material to
the conveyor belts and carries the side doors, the break doors and the back doors.

496 BOMAG 008 917 69

Description of milling unit 15.1

Fig. 27 Milling housing

1 Break door
2 Side plate left
3 Milling drive
4 Milling housing
5 Back door (here not visible)
The milling box is fixed to the road milling machine. The milling depth is achieved by altering the height of the
milling drum. Both side doors, as well as break doors and back doors can be hydraulically adjusted in height.

008 917 69 BOMAG 497

15.1 Description of milling unit

Break door
Description of function

Fig. 28 Break door

1 Break door
2 Transport protection
3 Milling drum
4 Sliding pads
5 Conveyor belt receptacle

i Note
The transport protection shown (2) is only needed in te factory, if the break door (1) is to be fixed without hy-
draulic cylinder. The transport protection is not available for the operator.

Functions
The break door (1) (Fig. 28) has the following functions:
l It prevents parts of the asphalt being lifted and broken out in lumps.
l Protection of operator during milling operation. (Milling box closed.)
l It prevents milling material from being discharged to the outside.
l The break door carries the gathering belt. The gathering belt is fastened to the break door.

498 BOMAG 008 917 69

Description of milling unit 15.1
Working principle of break door
During milling operation the break door (1) (Fig. 28) makes sure that no bigger pieces will break off the asphalt.
These could obstruct the milling process. The operator therefore brings the break door to float position. In this
position the break door glides over the asphalt. Exchangeable slipper pads (4) on the bottom side of the break
door reduce the wear of the break door.
Shovels on the milling drum (3) throw the milled material through the opening in the break door on the pick-up
belt.
When driving the milling machine in reverse, the break door is automatically lifted. This prevents the break door
from hitting against the edge of the asphalt and being damaged.

008 917 69 BOMAG 499

15.1 Description of milling unit

Back door
Description of function

Fig. 29 Back door

1 Hydraulic cylinder
2 Guide
3 Back door bar
4 Back door
The back door (4) (Fig. 29) seals the milling box to the rear and prevents milling material from being discharged
to the outside. The hydraulic cylinders (1) move the back door (4). Depending on the position of the back door
(4) the milled material is either fed on the conveyor belt, or it remains in the milled area.
Since the back door bar (4) is always in direct contact with the material, it is subject to high wear. It can therefore
be replaced.

500 BOMAG 008 917 69

Description of milling unit 15.1
Back door guide

Fig. 30 Back door guide

NEW in Generation "2" is the geometry of the back door guide (Fig. 30). The design ensures that there is more
lateral clearance in the lower area (2). This prevents the back door from becoming jammed in the guide when
cornering. The further the back door is lifted, the tighter the guide (1) and the smaller the lateral clearance.

008 917 69 BOMAG 501

15.1 Description of milling unit

Unfold the back door to change or inspect the tools.

Fig. 31 Back door opened - tool change

In order to check or change the milling cutters, the back door (1) is moved up completely and folded back (Fig.
31). The back door must be locked with the help of the locking device (2) in order to protect the operator. To
lower the back door from this position, it must first be slightly lifted up. Once the locking device has been disen-
gaged, the back door can be closed and lowered.

Fixing the back door

If the machine has to mill at a greater depth, it may happen that the machine already dives in deeper than the
back door, right at the beginning of the milling process. If the back door touches down on the asphalt, the back
door may be folded backwards. Inserting two counter brackets (Fig. 32) changes the shifting gate so that the
back door can no longer be push backwards. The back door in this case slides up along the counter bracket.

502 BOMAG 008 917 69

Description of milling unit 15.1

Fig. 32 Assembling the counter bracket

1 = Assembling the counter bracket
2 = New shifting gate after assembling the counter bracket (red arrow)

Working principle

Fig. 33 Shield floating

For neat levelling of the milled area (Fig. 33) the shield floats over the processed material and seals the back of
the milling housing.

008 917 69 BOMAG 503

15.1 Description of milling unit

Fig. 34 Shield fixed

For clean levelling (Fig. 34) of the milled area to a loose gravel or sand layer the shield is hydraulically fixed in
the desired position.

Fig. 35 Shield fixed

If material is to be left laying (Fig. 35) or for partial loading the shield can be hydraulically fixed in any desired
height.

504 BOMAG 008 917 69

Description of milling unit 15.1
Side plate
Description of function

Fig. 36 Side plate - right

1 Fastening position of rope sensor (C22) (not installed here)
2 Safety chain
3 Fastening hooks for safety chain
4 Fastening eyelet for rope sensor
5 Hydraulic cylinder
6 Milling drum bearings
7 Side door
8 Indicators
The side door (7) seals the milling box and prevents milling material from being discharged to the outside (Fig.
36).
The hydraulic cylinders (5) lift and lower the side door.
A wire rope is connected with the side door (on eyelet (4)) and the rope sensor (fastened in position (1)). The
sensor detects the position of the side door and passes this information on to the control.
The safety chain (2) is fastened to the hook of the side door when required (e.g. when performing maintenance
work) and prevents the side door from dropping down or lowering.

008 917 69 BOMAG 505

15.1 Description of milling unit

Indicators on the side door

Fig. 37 Indicators for start and end of milling area.

These indicators (8) (Fig. 36) are a help for the machine operator. They indicate the beginning and the end of
the milled area (Fig. 37). The numbers in the picture represent the milling depths (5, 10, 15, 20, 25, 30) in cm.
Example: If the milling depth has been set to 10 cm, the operator watches the indicator for 10 cm milling depth
(marked "X" in the picture) and positions the machine so that the start of milling (e.g. marking on the asphalt)
lines up with the marking on the side door. At the end of the area to be milled the operator must lift the machine
again when the front "10 cm" marks (marked "Y" in the picture) is reached.

506 BOMAG 008 917 69

Description of milling unit 15.1
Peculiarities on the left side door

Fig. 38 Side door - left lowered

Fig. 39 Side door - left raised

1 Cover for milling drum drive belt
2 End disc

008 917 69 BOMAG 507

15.1 Description of milling unit

3 Side plate
4 Weight
The left hand side door (3) only differs from the right hand side door by the opening for the shaft of the milling
drum drive (see cover for milling drum drive belt (1)). This opening is closed by end disc (2), so that no milled
material can escape.
When the left side door (3) is raised, the end disc (2) turns in clockwise direction around its fastening point. When
lowering the side door (3), the weight of the end disc (2) pulls the disc anti-clockwise and closes the milling box.
An additional weight (4) on the end disc (2) makes sure that the end plate (2) will move down.

508 BOMAG 008 917 69

16 Travel drive, description

008 917 69 BOMAG 509

16.1 Travel drive - description

Travel system
16.1 Travel drive - description

Travel system
The travel system consists of four steerable crawler tracks.

Crawler track
The crawler tracks mainly consist of:
l the frame
l the track with polyurethane track plates
l the drive and tensioning wheel
l the supporting rollers
l a track tensioner
l the travel motor
l the travel gear

Fig. 40
Characteristics:
l
Steerable crawler tracks with highly resistant polyurethane track plates.
l
Differential lock for slippage free traction
l
Height adjustable supports.

510 BOMAG 008 917 69

Travel drive - description 16.1

Fig. 41 Travel gear

i Note
The travel gears are mounted to the outside of the crawler tracks.

008 917 69 BOMAG 511

16.1 Travel drive - description

Fig. 42 Travel motor

i Note
The travel motors are located at the inside of the crawler track drives.

512 BOMAG 008 917 69

Travel drive - description 16.1

Fig. 43 Crawler track - overview

1 Crawler track tensioning device 5 Drive gear

2 Travel motor 6 Drive chain
3 Frame 7 Polyurethane plate
4 Travel gear 8 Supporting rollers

008 917 69 BOMAG 513

16.1 Travel drive - description

Four track steering

Fig. 44 Four track steering

The following steering modes are possible:
l Front and rear, rear steering optionally with automatic centring.
l
Front and rear automatically synchronized.
l
Crab walk.

i Note
The crawler tracks must be aligned exactly parallel to one another. This setting is made by the tie rods. (See
chapter "Travel_system_repair")

514 BOMAG 008 917 69

17 Travel drive, repair

008 917 69 BOMAG 515

17.1 Checking the track plates

17.1 Checking the track plates 17.2 Retightening the track shoe
fastening screws

Fig. 45
l Check the condition of the track plate coating (Fig. Fig. 46
45), replace if necessary. l Retighten all fastening screws for the track shoes
(Fig. 46).

516 BOMAG 008 917 69

Checking the track drive 17.3
17.3 Checking the track drive Checking bolts and bushings

Danger
! i Note
Danger of accident! The inner wear of bolts and bushings cannot be
checked as long as the track remains assembled.
Perform this work only with the engine shut down! Wear is characterized by an extension of the track.

Checking the track tension

! Caution
A wrong track tension causes higher wear.

Fig. 49
l
Measure the length over the centers of five track
link bolts with a tape measure (Fig. 49).

new track B=560 mm

Fig. 47
Replace the track if B=566 mm
l
Check the track tension, if necessary adjust on the
track tensioner (Fig. 47).
l
In order to tension the track clean the fitting (arrow)
and press in grease with a grease gun.

Checking the track links

Fig. 50
l Measure the outer diamter of the bush (Fig. 50).

new bush C=37 mm

Replace the track if C=34.3 mm

Fig. 48
l Measure the height of the track links (Fig. 48). Replacing the track

new track link A=70 mm ! Caution

Replace the track if A=68.2 mm Replace also the track drive wheel.
l Move the machine until the connecting bolt with the
notch is in top position.

008 917 69 BOMAG 517

17.3 Checking the track drive

l Shut down the engine and pull out the ignition key. Checking the track wheels
l Relieve the track.

Fig. 53
Fig. 51 l Check the height of the running surface to the guid-
l Press the connecting bolt (Fig. 51) out with an hy- ing (Fig. 53).
draulic press.
new track wheel E=16 mm
l Take off the track and remove the track plates.
l Clean the track plates, check their condition and fit Replace the track wheel if E=18 mm
them to the new track.
Checking the track drive wheel
Checking the supporting rollers
!Caution
i Note Always replace the track drive wheel when replac-
For easier measuring you may choose one supporting ing the crawler track.
roller each at the beginninga and the end of the track
drive.

Fig. 54
l Check the wear on the teeth (Fig. 54).
Fig. 52
l Check the diameter of both running surfaces (Fig.
i Note
52).
Replace when the depth of the wearijng is close to the
hardening depth.
new supporting roller D=135 mm
Nominal value:
Replace the supporting roller if D=132.5 mm
F=4,2 mm hardening depth

518 BOMAG 008 917 69

Lubricating the crawler track drive 17.4
17.4 Lubricating the crawler track 17.5 Lubricating the steering sys-
drive tem

Crawler track drive Steering

Fig. 55 Fig. 56
l Lubricate the pin (Fig. 55) with three strokes from l Lubricate the tie rods (Fig. 56) with three strokes
the grease gun. from the grease gun.

Fig. 57
l
Lubricate the steering cylinder bearings (Fig. 57)
with three strokes from the grease gun.

008 917 69 BOMAG 519

17.6 Lubricating the chassis columns

17.6 Lubricating the chassis col- 17.7 Oil change in track drive gear
umns
! Caution
Columns Drain oil only at operating temperature.

Environment
Catch old oil and dispose of environmentally.
l Park the machine horizontally.

Fig. 58
l Lubricate the bushings (Fig. 58) with three strokes
from the grease gun.

Fig. 59
l
Move the machine, until the drain plug (Fig. 59) is in
lowest position.
l
Clean and unscrew the drain and level control
plugs.
l
Drain and catch all oil.
l
Screw the drain plug back in and tighten it.

Fig. 60
l Fill in oil through the oil level control bore, until it
reaches the bottom edge of the bore. (Fig. 60).
l Screw the level control plug back in and tighten it.

For quality of oil refer to the table of fuels, lubri-

cants and filling capacities.

520 BOMAG 008 917 69

18 Conveyor belt, description

008 917 69 BOMAG 521

18.1 Conveyor belt - decription

Conveyor belts
18.1 Conveyor belt - decription

General
Two belts are used to load up the milled material. The gathering belt picks up the milled material from the milling
box and transports it to the loading belt, which conveys the milled material to the transport truck.
The belt speed can be infinitely adjusted by a potentiometer on the control console. Here we must emphasize
that the pick-up belt runs slightly slower than the loading belt This makes sure that the loading belt will not be
congested by material, because it always discharges more material than the gathering belt is able to deliver.
For optimal loading of the milled material the loading belt can be infinitely swivelled, lowered or lifted.

Gathering belt
The gathering belt is fastened to the break door. This unit can be hydraulically lifted or can glide in floating mode.

Fig. 61 Gathering belt with break door and gathering foot

522 BOMAG 008 917 69

Conveyor belt - decription 18.1
Loading belt
The loading belt is fastened to the belt yoke. This yoke can be swivelled sideways and thus moves the loading
belt to left or right. The damping rubber prevents material from falling down and guides it perfectly onto the load-
ing belt (Fig. 62).

Belt yoke

Damping rubber

Fig. 62 Belt yoke

Fig. 63 Loading belt, high and low belt speed

The belt speed is infinitely adjustable (Fig. 63).

008 917 69 BOMAG 523

18.1 Conveyor belt - decription

Folding mechanism
For optimal loading of the road milling machine the conveyor belt can be hydraulically folded in.

Fig. 64 Loading belt, folded in

Fig. 65 Loading belt folded in

524 BOMAG 008 917 69

Conveyor belt - decription 18.1

Fig. 66 Folding the conveyor belt

Description of function
The user only needs to fold up the safety catches (3) (Fig. 66) to fold the conveyor belt in or out. With the safety
catches in bottom (shown) position, they are in transport position and prevent accidental unfolding of the con-
veyor belt.
By actuating the corresponding switch in the control panel, the front section of the conveyor belt is folded for-
ward. This adjustment is accomplished by hydraulic cylinders, which are fastened to the outside of the wings.
Once the conveyor belt has been unfolded, this is detected by the sensor (2). This signal causes the safety hook
(Fig. 67) to lower and to lock the front section of the conveyor belt mechanically. Only now the conveyor belt can
be switched on.
The conveyor belt is folded in by actuating the corresponding switch in the control panel. This initially lifts the
hook and then folds in the conveyor belt. Finally the user only needs to bring the safety catches back to bottom
position.

Fig. 67 Safety hook

008 917 69 BOMAG 525

18.2 Folding / unfolding the loading conveyor belt

18.2 Folding / unfolding the loading

conveyor belt

Folding the loading conveyor belt in

Fig. 71
l Insert the securing clamps (Fig. 71) on both sides.

Unfolding the loading belt

l Perform these steps in reverse order to unfold the
Fig. 68 conveyor belt.
l Raise the loading conveyor belt (Fig. 68).

Fig. 69
l
Turn the momentary contact switch (Fig. 69) anti-
clockwise.

Fig. 70
l Fold the conveyor belt in completely (Fig. 70).

526 BOMAG 008 917 69

19 Conveyor belt, repair

008 917 69 BOMAG 527

19.1 Check, tighten the conveyor belts

19.1 Check, tighten the conveyor belts Tensioning loading and unloading
belts
Danger
!

Danger of injury! i Note

Keep a safe distance when the conveyor Tension evenly on both sides.
belt is running. Center the belt.
Do not adjust the tension while the belt is Increase the tension on the side to which the
running. belt is running off, or reduce the tension on the
opposite side.
Check Run the conveyor belt a few minutes to check.

Fig. 72 Fig. 73

l Check the condition of the conveyor belts l For tensioning the gathering belt loosen the
(Fig. 72). counter nuts (Fig. 73) on both sides and
tension the conveyor belt with the screw.
l Conveyor belts showing cracks and peel-
offs must be replaced immediately.
l Check supporting and reversing rollers for
cleanliness, clean if necessary.

i Note
Dirt deposits on the rollers cause the belt to run
out of centre.
l Check the conveyor belt tension.
With correct tension the belt does not touch the
supporting rollers.

Fig. 74
i
Note
Tension of gathering belt: l For tensioning the loading belt loosen the
counter nuts (Fig. 74) on both sides and
Compression depth in middle of conveyor belt
tension the conveyor belt with the screw.
50 mm under a force of 100 - 150 N.
Tension of loading belt:
Compression depth in middle of conveyor belt
70 mm under a force of 100 - 150 N.

528 BOMAG 008 917 69

Checking the safety ropes 19.2
Checking the supporting rollers 19.2 Checking the safety ropes

Fig. 75 Fig. 76

l Check the condition and movability of the l Check the condition of the safety ropes
rollers (Fig. 75). (Fig. 76), replace if necessary.
l If necessary remove any dirt deposits from
the rollers.
l Switch on the conveyor belt and check the
centring.

008 917 69 BOMAG 529

19.3 Lubricating the conveyor belts

19.3 Lubricating the conveyor belts Gathering belt

Loading belt

Fig. 79

l Lubricate the front drive roller holders (Fig.

Fig. 77 79) with three strokes from the grease gun.
l Lubricate the front roller bracket (Fig. 77)
on both sides with three strokes from the
grease gun.

Fig. 80

l Lubricate the bearings (Fig. 80) with three

strokes from the grease gun.
Fig. 78

l Lubricate the roller bearings (Fig. 78) on

both sides with three strokes from the
grease gun.

530 BOMAG 008 917 69

20 Hydraulics

008 917 69 BOMAG 531

20.1 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.

532 BOMAG 008 917 69

Hydraulic circuit 20.1
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.

008 917 69 BOMAG 533

20.2 Component overview -- hydraulics

Arrangement of hydraulic pumps

Fig. 3

Pos. Description
1 Service pump
2 Conveyor belt pump
3 Travel pump
4 Pump for fan drive

534 BOMAG 008 917 69

Component overview -- hydraulics 20.2
Arrangement of valves

Fig. 4 Valve block operation

Fig. 5 Emergency valve block - Emergency

008 917 69 BOMAG 535

20.2 Component overview -- hydraulics

Fig. 6 Brake releasing valve

536 BOMAG 008 917 69

Component overview -- hydraulics 20.2
Arrangement of flow divider

Fig. 7 Flow divider of differential lock

Arrangement of thermal control valve

Fig. 8 Thermal control valve for fan motor

008 917 69 BOMAG 537

20.3 Description of travel pump

Variable displacement pumps, A4VG28EP to A4VG180EP

20.3 Description of travel pump

EP control with proportional solenoid

Fig. 9 A4VG

1 Drive shaft 7 Auxiliary pump

2 Retracting plate 8 High pressure side
3 Control piston 9 Cylinder
4 Control unit 10 Piston
5 Valve plate 11 Slipper pad
6 Low pressure side 12 Swashing cradle

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.

538 BOMAG 008 917 69

Description of travel pump 20.3
Hydraulic diagram

Control unit
High pressure limitation

High pressure limitation Pressure override valve

Charge valve
Fig. 10 Hydraulic diagram, A4VG EP

A Work connection MH Port for balanced high pressure

B Work connection PS Control pressure inlet
G Pressure port for charge circuit R Ventilation
Fa Filter outlet S Suction line for charge oil
Fa1 Filter outlet (attachment filter) T1 Leak oil
Fe Filter inlet T2 Leak oil
FS Port from filter to suction line (cold start) X 1 X2 Port for control pressures, pressure in front of
nozzle
MA Pressure test port, pressure A
MB Pressure test port, pressure B

008 917 69 BOMAG 539

20.3 Description of travel pump

Connection overview

A4VG28

Fig. 11 A4VG 28

A4VG 40 to 56

Fig. 12 A4VG 40 to 56

A4VG 71 to 180

540 BOMAG 008 917 69

Description of travel pump 20.3

Fig. 13 A4VG 71 to 180

High pressure relief and charge pressure valve

Pressure override valve

HP-valve with bypass

Charge pressure relief valve

Fig. 14 Valve plate

High pressure relief valves with integrated boost check valves and bypass (only travel pump / for tow-
ing)
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-
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.
HP-valves are always adjusted 10% higher than the pressure override.
The boost check valves are integrated in the high pressure relief valves. These valves open to the low pressure
side and let cool and filtered oil flow from the charge oil circuit into the closed hydraulic circuit, in order to com-
pensate leaks and flushing quantities.

008 917 69 BOMAG 541

20.3 Description of travel pump

Bypass control
In this case the travel system is switched to free circulation. For this purpose the high pressure relief valves in-
tegrated in the variable displacement pump have a so-called bypass function. This means that by turning the
screw (1) (Fig. 15) the valve insert is relieved to such an extent, that the oil is able to circulate freely.

Fig. 15 Bypass control

l Shut down the engine.
l
Loosen the counter nuts by turning them with a hexagon spanner (SW 134) half a turn in anti-clockwise direc-
tion.
l Use an Allen key (SW 4) to turn the screws clockwise, until the screw touches the spring cup, which can be
noticed by the increasing resistance.
l Turn the screw half a turn into the spring cup.

Towing finished
After towing back the screw out again. This resets the high pressure valves to their original setting.

i Note
Tightening torque for counter nut 22 Nm.

Charge pressure relief valve

The charge pressure valve belongs to the group of safety elements in a closed hydraulic circuit. This valve limits
the pressure in the charge circuit to the pre-adjusted value.

Pressure override valve

The pressure override limits the operating pressure. The pressure override is a kind of pressure regulation,
which, when the adjusted nominal pressure is reached, reduces the displacement of the pump to such an extent,
that the adjusted pressure is just maintained.

542 BOMAG 008 917 69

Description of travel pump 20.3
EP - control

Fig. 16 EP - control

1 Setscrew for mechanical neutral position 5 Proportional solenoid valve

2 Neutral setting spring 6 Valve spool
3 Control piston 7 Feedback lever
4 Control chamber

Fig. 17 EP control
Depending on the pre-selected ampacity "I" on the two proportional solenoids, the control cylinder on the pump
is supplied with control pressure through the EP control unit. This way the swash plate and thus the displacement
of the pump can be infinitely varied. Each proportional solenoid has a flow direction assigned.

! Caution
The spring reset in the control unit is no safety feature.
Internal contamination – like e.g. contaminated hydraulic fluid, abrasion or dirt residues from system
components – can cause blockage of the spool valve in the control unit. The flow volume from the var-
iable displacement pump will in this case no longer follow the instructions of the operator.

008 917 69 BOMAG 543

20.3 Description of travel pump

Auxiliary pump
The auxiliary pump permanently delivers a sufficient amount of fluid (charging volume) from a small tank through
a check valve into the low pressure side of the closed circuit, in order to replace internal leakages in variable
displacement pump and consumers.

544 BOMAG 008 917 69

View of the machine 20.4
Travel pump - viewed on the machine
20.4 View of the machine

Fig. 18 Travel pump BM 2000/60-2

008 917 69 BOMAG 545

20.5 Description of working pump

Axial piston pumps, A10VO/VSO 18 to 100 DFR1

20.5 Description of working pump

i Note
This document is valid for pump types VO and VSO!
The pump delivers oil only to one direction, i.e. the swash plate moves out of neutral position only to one direc-
tion. It is therefore particularly suitable for the use in open hydraulic circuits.

! Caution
The 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 hy-
draulic lines.

Fig. 19

DFR1, pressure-flow controller

Pressure regulator
The pressure control valve keeps the pressure in an hydraulic system at a constant level within the control range
of the pump. This way the pump will only deliver as much hydraulic fluid as can be absorbed by the hydraulic
consumers. The pressure can be infinitely adjusted on the control valve.

DFR1 – pressure and flow controller

In addition to the function of a pressure controller an orifice records the differential pressure before and after the
orifice, which then controls the flow rate of the pump. The pump delivers the pressure fluid quantity actually re-
quired by the consumer.
The pressure controller is superimposed.

546 BOMAG 008 917 69

Description of working pump 20.5

Pressure regulator

Flow control valve Resetting piston

Control piston
Fig. 20 Sectional drawing

Pressure regulator
Orifice

Flow control valve

Control piston

Resetting piston

Fig. 21 Hydraulic diagram

B Working line S Suction

L / L1 Leak oil X Pilot pressure

008 917 69 BOMAG 547

20.5 Description of working pump

Working principle

Control piston Control piston

1 Resetting piston
2 Resetting piston
Flow control valve Flow control valve

Pressure regulator Pressure regulator

Fig. 22
l When the engine is not running (1) (Fig. 22) the swash plate is in max. displacement position. The spring
inside the control piston of the pump holds the swash plate in this position.
l When starting the engine pressure will build up at the pump outlet (no consumer active (2). The building up
pressure moves the flow controller until the set value is reached and opens a connection (between pump
flow and pressure controller) to the resetting piston side. Since the effective area of this resetting piston is
much bigger than the area of the control piston, the increasing pressure moves the swash plate towards zero
(despite the spring force supporting the control piston). The setting of the flow control valve ensures a so-
called ”stand-by pressure” in the system.

Control piston Control piston

3 4
Resetting piston Resetting piston
Flow control valve Flow control valve

Pressure regulator Pressure regulator

Fig. 23
l If the system pressure increases because of active consumers (3) (Fig. 23), this pressure will displace the
spool of the pressure controller. High pressure is thereby guided to the piston area of the resetting piston and
the swash plate is reset towards zero.
l If the pressure drops below the adjusted value (4), the spring in the pressure control valve will be able to close
the pressure control valve again, the pump can return to a higher displacement.

548 BOMAG 008 917 69

View of the machine 20.6
Working pump - viewed on the machine
20.6 View of the machine

Fig. 24 Working pump BM 2000/60-2

008 917 69 BOMAG 549

20.7 Description of conveyor belt pump

Variable displacement pumps, A10VG28/45/56 EZ

20.7 Description of conveyor belt pump

EZ, electric two-point control, with control solenoid

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 10VG 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.
The control cylinder on the pump is supplied with control pressure through the EZ control unit by switching the
control current to the control solenoids on or off. This way the swash plate and thus the displacement can be
infinitely adjusted between Vg = 0 and Vg max. Each control solenoid has a flow direction assigned.

Fig. 25 A10VG

1 Drive shaft 8 Valve plate

2 Retracting plate 9 Suction port auxiliary pump
3 Control piston 10 High pressure side
4 Control unit 11 Cylinder
5 Pressure override, not available on all models 12 Piston
6 Low pressure side 13 Slipper pad
7 Auxiliary pump, not available on all models 14 Swashing cradle

Caution
!

550 BOMAG 008 917 69

Description of conveyor belt pump 20.7
Hydraulic diagram

Control unit Charge valve

High pressure limitation
Auxiliary pump

High pressure limitation Pressure override valve

Fig. 26 Hydraulic diagram, A10VG EZ

i Note
Charge valve, pressure override valve and auxiliary pump are not available in some machine models, see hy-
draulic diagram of machine.

A Work connection PS Control pressure inlet

B Work connection R Ventilation
G Pressure port for charge circuit S Suction line for auxiliary pump
Fe Filter inlet T1 Leak oil
MA Pressure test port, pressure A T2 Leak oil
MB Pressure test port, pressure B X 1 X2 Port for control pressures, pressure in front of
nozzle

008 917 69 BOMAG 551

20.7 Description of conveyor belt pump

Connection overview

Fig. 27

High pressure relief and charge pressure valve

Pressure override valve

HP-valve without bypass HP-valve without bypass

Charge valve
Fig. 28 Valve plate

i Note
Charge valve not used in vibration pumps

High pressure relief valves with integrated boost check valves without bypass
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-
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.

552 BOMAG 008 917 69

Description of conveyor belt pump 20.7
HP-valves are always adjusted 10% higher than the pressure override.

Pressure override valve

Control
The control is part of the pump and consists mainly of the 4/3-way solenoid valve, the control piston and the
swash plate with swashing lever.
If one of the two solenoids is energized, the 4/3 way solenoid valve is switched to open position. Pilot oil flows
now to the corresponding control piston side. The control piston slides to the corresponding direction and moves
the swash plate via the swashing lever. The pump delivers oil.

Fig. 29 Control

1 Solenoid valve 4 Neutral setting spring

2 Valve spool 5 Control piston
3 Setscrew for mechanical neutral position 6 Control chamber

The oil from the opposite control chamber flows through the 4/3-way valve as leak oil into the pump housing.
When the 4/3-way valve is in neutral position, the pressure values in both control chambers are identical (case
pressure = max. 3 bar).

008 917 69 BOMAG 553

20.8 View of the machine

Conveyor belt pump - viewed on the machine

20.8 View of the machine

Fig. 30 Conveyor belt pump BM 2000/60-2

554 BOMAG 008 917 69

Description of fan pump 20.9
External gear pumps
20.9 Description of fan pump

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. 31 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. 32
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.

008 917 69 BOMAG 555

20.9 Description of fan pump

Fig. 33

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

556 BOMAG 008 917 69

View of the machine 20.10
Fan pump - viewed on the machine
20.10 View of the machine

Fig. 34 Fan pump BM 2000/60-2

008 917 69 BOMAG 557

20.11 Desxcription of travel motor BOSCH REXROTH

Description of function
20.11 Desxcription of travel motor BOSCH REXROTH

i Note
The travel motors A6VM and A6VE just differ by a different housing.
The A6VM/VE is a variable displacement axial piston motor with a tapered axial piston drive in swash plate de-
sign for hydrostatic drives in open and closed hydraulic circuits. Due to this bent axle design the torque is gen-
erated directly on the drive shaft. The pistons only apply very little transverse forces to the cylinder, which has
a favourable effect on wear, efficiency and starting torque.

Fig. 35

1 Drive shaft 6 Cylinder

2 Control piston 7 Piston
3 Control piston 8 Setscrew for control start
4 Connecting plate 9 Setscrew, Vg min
5 Valve plate

In variable displacement axial piston in bent axle design the pistons (7) are arranged in an inclined position to
the drive shaft (1). The pistons perform an axial movement, which is then converted to a rotary movement by
the piston joint on the drive shaft flange. The cylinder (6) is driven by the pistons.

Motor function
A variable displacement axial piston motor converts the hydrostatic energy into mechanical energy. Pressure
fluid is fed through the connecting plate (4) and the valve plate (5) into the cylinder bores. The pistons (7) inside
the cylinder bores perform an axial movement, which is then converted to a rotary movement by the piston joint
on the drive shaft flange (1). The pistons thereby drive the cylinder (6) and thereby generate the output torque
on the drive shaft. The output torque is generated by the force resulting from pressure and piston area. The out-
put speed is proportionate to the inflowing volume and the displacement, which can be changed by altering the
swashing angle. The output torque increases with the pressure drop between high and low pressure sides and
increasing displacement.

Sensors
The A6VM/VE...U version has been designed with a gearing on the drive. An attached rotary speed sensor en-
ables the detection signals proportional to the motor speed.

558 BOMAG 008 917 69

Desxcription of travel motor BOSCH REXROTH 20.11

Fig. 36
The DSM sensor is fastened to the specially intended connection with a fastening screw

Control
In a variable displacement axial piston motor the angle of the bent axle can be infinitely adjusted within certain
limits. The change in swashing angle of the bent axle causes a difference in stroke length and thus a change in
displacement. The swashing angle of the bent axle is hydraulically changed via the control piston (3). The valve
plate rests light moving in a slideway. Enlarging the swashing angle increases the displacement and the torque,
reducing the angle reduces the values accordingly, while the output speed increases.. Various control facilities
are available to meet different requirements.

008 917 69 BOMAG 559

20.12 View of the machine

Travel motor - viewed on the machine

20.12 View of the machine

Fig. 37 Travel motor BM 2000/60-2

560 BOMAG 008 917 69

Fan motor, A2FM56 20.13
Description of function
20.13 Fan motor, A2FM56

i Note
The plug-in fixed displacement motors A2FE and A2FM just differ by a different housing.
The A2FE/FM is a plug-in fixed displacement axial piston motor with a tapered axial piston drive in swash plate
design for hydrostatic drives in open and closed hydraulic circuits. Due to this bent axle design the torque is gen-
erated directly on the drive shaft. The pistons only apply very little transverse forces to the cylinder, which has
a favourable effect on wear, efficiency and starting torque.

Fig. 38

1 Drive shaft 4 Valve plate

2 Piston 5 Connecting plate
3 Cylinder 6 Flushing valve (optional)

In fixed displacement motors in bent axle design the pistons (2) (Fig. 38) are arranged in an inclined position to
the drive shaft (1). The pistons perform an axial movement, which is then converted to a rotary movement by
the piston joint on the drive shaft flange. The cylinder (3) is driven by the pistons.

Motor function
A fixed displacement plug-in motor converts the hydrostatic energy into mechanical energy. Pressure fluid is fed
through the connecting plate (5) and the valve plate (4) into the cylinder bores. The pistons (2) inside the cylinder
bores perform an axial movement, which is then converted to a rotary movement by the piston joint on the drive
shaft flange (1). The pistons thereby drive the cylinder (3) and thereby generate the output torque on the drive
shaft. The output torque is generated by the force resulting from pressure and piston area. The output speed is
proportional to the supplied fluid volume and the displacement. The available motor output torque increases with
the pressure drop between high and low pressure side.

008 917 69 BOMAG 561

20.14 View of the machine

Fan motor - viewed on the machine

20.14 View of the machine

Fig. 39 Fan motor BM 2000/60-2

562 BOMAG 008 917 69

Checking the hydraulic oil level 20.15
20.15Checking the hydraulic oil lev- 20.16Clean the cooling fins on en-
el gine and hydraulic oil cooler
l Open the service flap on the right hand side.
Danger
!

Danger of injury!
Perform cleaning work only after the engine has
cooled down and with the engine stopped.

Caution
!

Do not damage any cooling fins on the cooler core

when cleaning.

i Note
Dirt on fan blades and oil cooler reduce the cooling ef-
fect. Dirt deposits in these areas are substantially sup-
Fig. 40 ported by oil and fuel on these surfaces. For this
l Check the hydraulic oil level in the inspection glass reason you should always seal any oil or fuel leaks in
(Fig. 40). the vicinity of the cooling fan or the oil cooler and clean
the cooling surfaces after.
Normal level
approx. 3 cm below the top edge of the inspection Cleaning with compressed air
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.
l
Open the engine hood.

Fig. 42

i Note
Start to blow out from the exhaust side.
l Blow the cooler (Fig. 42) out with compressed air.

Cleaning with cold cleansing agent

Caution
!
Fig. 41 Protect electrical equipment such as generator,
l If necessary fill in hydraulic oil (Fig. 41) through the regulator and starter against the direct water jet.
filler neck. l
Spray the engine with a suitable cleansing agent,
e.g. cold cleanser, let it soak in for a while and spray
For quality and quantity of oil refer to the table of
it off with a strong water jet.
fuels and lubricants.
l
Run the engine warm for a while to avoid corrosion.

008 917 69 BOMAG 563

20.17 Change the hydraulic oil

20.17Change the hydraulic oil

i Note
See also chapter 5.1 "Notes on the hydraulic system".

!Caution
Apart from the normal oil change intervals, the hy-
draulic oil must also be changed after major re-
pairs in the hydraulic system.
Perform the oil change when the hydraulic oil is
warm.
Fig. 44
Clean the area round hydraulic oil tank, filler
opening and breather filter. l Remove the filler cap (Fig. 44).
Do not use any detergents to clean the system. l Fill in new hydraulic oil through the screen.
Do not start the engine after draining the hydraulic
oil.
Replace the hydraulic oil filter element with every
hydraulic oil change.

! Danger

Danger of scalding!
Danger of scalding by hot oil.

Environment
Catch running out oil and dispose of environmen-
tally. Fig. 45
l Check the oil level in the inspection glass (Fig. 45).
i Note
Generally replace the hydraulic oil filter element after Nominal value:
the test run. approx. 3 cm below the upper edge of the inspection
glass

For quality and quantity of oil refer to the table of

fuels and lubricants.
l
Close the tank with the filler cap.

Fig. 43
l Unscrew the drain hose (Fig. 43) and drain off all
hydraulic oil.
l Reassemble the drain hose.

564 BOMAG 008 917 69

Changing the hydraulic oil filter 20.18
20.18Changing the hydraulic oil fil- High pressure filter for charge and con-
ter veyor belt circuit

! Danger
Danger of scalding!
Danger of scalding by hot oil when unscrewing
the oil filter.

! Caution
If the filter has to be changed together with the hy-
draulic oil, the filter must only be changed after
the oil change and after the test run.
Do not use the oil in the filter bowl again.
Fig. 46

Environment l Unscrew the filter housing (Fig. 46) and remove fil-
Catch running out oil, dispose of oil and filter ele- ter bowl with filter element.
ment environmentally. l Examine the surface of the filter element thoroughly
for any visible dirt.
i Note l Assemble the filter bowl with new filter element,
Filter elements and filter cartridges must also be check the condition of the seal rings, if necessary
changed after each hydraulic oil change and after ma- use new ones.
jor repairs in the hydraulic system. l After a short test run check the filter for leaks.

! Caution Return flow filter

Visible dirt may be an early sign for the failure of
system components and indicate the possible fail-
ure of components. In this case determine the
cause and replace or repair the defective compo-
nents, if necessary. Negligence may cause de-
struction to the entire hydraulic system.
Do not clean or reuse the filter element.

Fig. 47
l
Loosen and unscrew the fuel filter cartridge (Fig.
47) using an appropriate filter wrench.
l Slightly oil the rubber seal on the new filter car-
tridge.
l Turn the new filter cartridge on by hand, until the
seal contacts.
l
Tighten the filter element for another half turn.
l Check the filter cartridge for leaks after a short test
run.

008 917 69 BOMAG 565

20.18 Changing the hydraulic oil filter

Breather filter on hydraulic oil tank

Fig. 48
l Loosen and unscrew the fuel filter cartridge (Fig.
48) using an appropriate filter wrench.
l Turn the new filter cartridge on by hand, until the
seal contacts.
l Tighten the filter element for another half turn.

566 BOMAG 008 917 69

21 Hydraulics - overview of hoses

008 917 69 BOMAG 567

21.1 Hydraulic hose installation

Travel system
21.1 Hydraulic hose installation

Travel circuit

Fig. 49 Travel circuit - overview

The travel pump (1) (Fig. 49) supplies the travel circuit with hydraulic oil from the hydraulic oil tank. The oil is
cleaned by a pressure filter (2), which is arranged between the integrated charge pump and the travel pump (1).
From the travel pump (1) the hydraulic oil flows through a distributor block (5) to the travel motors. The returning
oil flows through the flow divider (4).

568 BOMAG 008 917 69

Hydraulic hose installation 21.1
Flow divider

Fig. 50 Flow divider - differential lock - excerpt from the hydraulic diagram
The flow divider (5) controls the hydraulic oil flow returning from the travel pump (1). It has the function of a
switchable differential lock.
In "normal" operation the oil flows from the four travel motors through the ports "A", "B", "C" and "D" into the flow
divider (Fig. 50) and from there in one collected flow back to the travel pump. When the solenoid valve (1) is
operated, he piston moves to the left. The returning oil is now no longer passed through restrictors, but through
pressure maintaining valves (one each per travel motor). These pressure maintaining valves recognize a possi-
ble pressure drop (possibly caused by accidental lifting of a track drive). In case of such a pressure drop the
pressure maintaining valve will close, making sure that there is sufficient pressure for all other motors. This way
it is theoretically possible to drive the machine, even if three crawler tracks have no traction (theory !!!!).

008 917 69 BOMAG 569

21.1 Hydraulic hose installation

Levelling

Fig. 51 Levelling - overview

The valve block (Fig. 51) supplies the hydraulic levelling cylinders with hydraulic oil.
The height of the front cylinders can be individually adjusted. The rear cylinders always move up or down togeth-
er.

570 BOMAG 008 917 69

Hydraulic hose installation 21.1
Steering
Front steering

Fig. 52 Front steering - overview

The service pump supplies the valve block (1) (Fig. 52) with hydraulic oil. The oil is passed on in dependence
on the position of the proportional valve. Block (2) distributes the oil to the left and right hand sides. The blocks
are equipped with pressure test ports (M), on which one can check the steering pressure for service purposes.
From these blocks (3) the oil flows to the steering cylinders (4) which then move the front columns to the left or
right.

008 917 69 BOMAG 571

21.1 Hydraulic hose installation

Rear steering

Fig. 53 Rear steering - overview

The service pump supplies the valve block (1) (Fig. 53) with hydraulic oil. The oil is passed on in dependence
on the position of the proportional valve. It is distributed by the distributor units (2). The oil then flows to the steer-
ing cylinders (3) which then move the rear columns to the left or right.

572 BOMAG 008 917 69

Hydraulic hose installation 21.1
Clutch and belt tensioner
Overview

Fig. 54 Clutch - overview

Clutch operation
Switching the corresponding solenoid valve activates the clutch (4) (Fig. 49) for the milling drum drive. If the
valve is no longer switched, the clutch will interrupt the transfer of power to the milling drum.

Belt tensioner
Once the engine is running, the hydraulic cylinder (5) of the belt tensioner is supplied with hydraulic oil through
the valve block (1) (Fig. 49) - the belt is tensioned. The pressure accumulator (3) makes sure that the drive belt
will not be relieved immediately when the engine is shut down.

008 917 69 BOMAG 573

21.1 Hydraulic hose installation

Side plates
Overview

Fig. 55 Side plates - overview

The hydraulic cylinders (3) are supplied with hydraulic oil via valve block (1) (Fig. 55) and the distributor blocks
(2).

574 BOMAG 008 917 69

Hydraulic hose installation 21.1
Break door
Overview

Fig. 56 Break door - overview

The hydraulic cylinders (4) for the break door are supplied with hydraulic oil via valve block (1) (Fig. 56) and the
blocks (3).
The reducing valve (2) restricts the oil flow to lower the break door. THis is due to the weight of the break door,
on which the gathering belt is fastened,.

008 917 69 BOMAG 575

21.1 Hydraulic hose installation

Back door
Overview

Fig. 57 Back door - overview

The hydraulic cylinders (4) are supplied with hydraulic oil via valve block (1) (Fig. 57) and the distributor blocks
(2). The movement speed of the back door can be altered with the help of adjustable reducing valves (3). How-
ever, this is already done in the factory and only need to be done in the field in exceptional cases.

576 BOMAG 008 917 69

Hydraulic hose installation 21.1
Conveyor belt
Conveyor belt drive - overview

Fig. 58 Conveyor belt drive - overview

The pump (1) (Fig. 49) draws hydraulic oil from the tank (4). Once the oil has been cleaned by the integrated
charge pump passing it through the filter (2), it enters into the drive motor (5) for the gathering belt. From here
the oil flows through a pipe system on the conveyor belt to the front and finally into the drive motor (6) of the
loading belt. Port "T" on the conveyor belt pump serve sthe supply of the charge oil circuit.

008 917 69 BOMAG 577

21.1 Hydraulic hose installation

Conveyor belt
Folding the conveyor belt - overview

Fig. 59 Folding/unfolding the conveyor belt - overview

The valve block (1) (Fig. 49) supplies the hydraulic cylinders (2) and (3) with hydraulic oil. The hydraulic cylinders
(2) have the function to fold the conveyor belt in or out. The cylinders (3) move the locking hook down after
unfolding and up before folding in.

578 BOMAG 008 917 69

Hydraulic hose installation 21.1
Conveyor belt
Swinging the conveyor belt - overview

Fig. 60 Swinging the conveyor belt - overview

The hydraulic cylinders (3) and (4) are supplied with hydraulic oil via valve block (1) (Fig. 49) and the distributor
blocks (2). The hydraulic cylinders (3) thereby have the function to swing the conveyor belt to the left or right.
Zylinder (4) lifts and lowers the conveyor belt.

008 917 69 BOMAG 579

21.1 Hydraulic hose installation

Fan circuit
Overview

Fig. 61 Fan circuit - overview

The fan pump (1) (Fig. 49) supplies the fan circuit with hydraulic oil from the hydraulic oil tank (6). The thermostat
(2) controls the oil supply to the fan motor (5) in dependence on the oil temperature. The warmer the oil, the
faster the motor rotation (5).
The oil flowing back from the valve block (7) flows through the filter elements (3) to the cooler. From there the
cooled oil flows back to the thermostat valve (2).

580 BOMAG 008 917 69

Hydraulic hose installation 21.1
Emergency operation
Overview

Fig. 62 Emergency operation - overview

The electrically driven pump (6) (Fig. 49) delivers hydraulic oil from the hydraulic oil tank (3) to the emergency
valve block (5) and to the main valve block (4).
The emergency valve block (5) distributes the oil either to the main cylinders for the cabin roof (1) or to the cyl-
inders for opening or closing the engine hood (2).

008 917 69 BOMAG 581

21.1 Hydraulic hose installation

582 BOMAG 008 917 69

22 Hydraulic cylinder

008 917 69 BOMAG 583

22.1 Repairing hydraulic cylinders

22.1 Repairing hydraulic cylinders Danger

Before disconnecting any hydraulic connections

i Note you must make sure that the engine has been shut
down and the system pressure has been relieved.
Piston rod seals are the main causes for friction and
leakage. With increasing age of the seals it may hap- All vertically arranged cylinders must be lowered,
pen that the hydraulic cylinder will move slower with pressure accumulators must be emptied and all
reduced power. consumers, the movement of which could possi-
bly generate pressure, must be blocked.
All components that had been removed and all
lines must be closed, so that no dirt can enter into
the system.

Fig. 1 Hydraulic cylinder Sealing

1 Piston rod l
Once the cylinder has been removed, retract the
2 Interlock piston rod completely and disconnect all connec-
3 Piston seals tions.
4 O-ring
5 O-ring i Note
6 Seal The cylinder can be carefully operated with com-
pressed air.
7 Dust seal
8 Cylinder l
Drain off all hydraulic fluid by operating the cylinder
manually.
9 Cylinder head
10 Ring nut
11 Bushing Environment
Catch running out hydraulic oil and dispose of en-
12 Piston
vironmentally.
l
Disassemble ring nut 10 (Fig. 1) and cylinder head
(9).
l
Pull piston rod (1) with piston (12) out of the cylinder
(8).
l
Remove the interlock (2) and disassemble the pis-
ton (12) from the piston rod (1).

Caution
!

Before assembling the sealing elements you

should clean the complete cylinder system from

584 BOMAG 008 917 69

Repairing hydraulic cylinders 22.1
processing residues, chips, dirt and other foreign
particles.
During assembly seals should not be pulled over
sharp edges, threads, fitting keyways etc. Such
points must be thoroughly covered before assem-
bly. Sharp edges must be deburred or provided
with a chamfer or a radius.
Sharp tools must never be used.
Seals, piston rod and cylinder tube must be oiled
or greased before assembly.
l
Replace seals (3, 4, 5, 6 and 7) and check bushing
(11).
l Reassemble the piston (12) to the piston rod (1) and
install the interlock (2).
l Push piston (12) with piston rod (1) into the housing.

! Caution
Take care of the seals.
l Slide the cylinder head (9) over the piston rod (1)
and tighten the ring nut (10).

Commissioning

i Note
Operate the cylinder several times with low load and
pressure. Due to trapped air hydraulic cylinders may
initially perform erratically, but normally vent them-
selves after a few stroked
Check for leaks before taking the machine back into
service.

008 917 69 BOMAG 585

22.1 Repairing hydraulic cylinders

586 BOMAG 008 917 69

23 Tests and adjustments

008 917 69 BOMAG 587

23.1 Special tools, tests and adjustments

i Note
The following list informs about special tools for
testing and adjustment work. You should choose
the corresponding tool for the work to be carried
out.
6. Vibration reed frequency meter
1000 - 4.000 rpm
17 - 67 Hz
BOMAG part-no.: 300 120 80

Fig. 1
7. Sirometer (frequency meter)
800 - 50.000 rpm
14 - 750 Hz
BOMAG part-no.: 059 710 02

Fig. 2
8. 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. Plastic, temper-
ature range: down to -40 °C

BOMAG part-no.: 050 100 75

Fig. 3

588 BOMAG 008 917 69

Special tools, tests and adjustments 23.1
9. Digital rpm-meter for petrol engines

BOMAG part-no.: 079 948 99

Fig. 4
10. Digital rpm-meter for petrol engines

BOMAG part-no.: 059 711 12

Fig. 5
11. Digital rpm-meter, optical/mechanical, universal
use

BOMAG part-no.: 079 948 98

Fig. 6
12. Infrared hand-held thermometer, -18 to 275°C

BOMAG part-no.: 057 668 06

Fig. 7

008 917 69 BOMAG 589

23.1 Special tools, tests and adjustments

13. 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
14. Hydraulic test case, small

BOMAG part-no.: 079 930 01

i Note
2X 60 bar pressure gauges
2X 600 bar pressure gauges
4 pressure test hoses

Fig. 9
15. Pressure test hoses
1000 mm BOMAG part-no.: 079 930 02
2500 mm BOMAG part-no.: 079 930 03

Fig. 10
16. Pressure gauge
60 bar BOMAG part-no.: 059 721 07
600 bar BOMAG part-no.: 059 721 04

Fig. 11

590 BOMAG 008 917 69

Special tools, tests and adjustments 23.1
17. Adapter for pressure test hose

BOMAG part-no.: 055 439 02

Fig. 12
18. Gear pump testing device

BOMAG part-no.: 007 610 05

Fig. 13
19. Vacuum pump for hydraulic oil tank
BOMAG part-no.: 007 610 04 (12 Volt)
BOMAG part-no.: 007 610 24 (24 Volt)

Fig. 14

008 917 69 BOMAG 591

23.2 Checking & adjusting the travel pump

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).

Special tools
Hydraulic test case [BOMAG Part-No.: 079 930
01]

The following pressures can be measured on

he travel pump: Pressure test forward/re-
verse, as well as charge pressure.

Pressure test forward

1. Shut down the engine.

! Danger

Danger of injury!
Before connecting the pressure gauge make
sure that the engine has been shut down!
2. Connect a high pressure gauge (600 bar) to pres-
sure test port (1) on the pump (Fig. 1).

i Note
The arrangement of hydraulic components is
Fig. 1
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
3. Start the engine.

! Caution
Run the following pressure test only for max.
5 seconds.
4. Shift the travel lever to "forward" position (Fig. 2).
5. Read the pressure in the pressure gauge.
6. Return the travel lever to "Neutral".

Nominal value
See chapter "Technical Data".
Fig. 2

592 BOMAG 008 917 69

Checking & adjusting the travel pump 23.2
i Note
If the nominal pressure relief value is not
reached, adjust the pressure relief valve (2) (Fig.
3).

Fig. 3
7. Loosen the counter nut (2) and turn the setscrew
(1) in or out, until the nominal value is reached
(Fig. 4).

i Note
Turning clockwise increases the pressure, turn-
ing anti-clockwise reduces the pressure!
8. Check the pressure once again (see above).
9. Retighten the counter nut (2).

! Danger
Fig. 4 Danger of injury!
Before disconnecting the pressure gauge
make sure that the engine has been shut
down!
10. Disconnect the pressure gauge.

Pressure test in reverse

11. Shut down the engine.

! Danger
Danger of injury!
Before connecting the pressure gauge make
sure that the engine has been shut down!
12. Connect a high pressure gauge (600 bar) to pres-
sure test port (4) on the pump (Fig. 5).

i Note
The arrangement of hydraulic components is
Fig. 5
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".

008 917 69 BOMAG 593

23.2 Checking & adjusting the travel pump

13. Start the engine.

! Caution
Run the following pressure test only for max.
5 seconds.
14. Shift the travel lever to "reverse" position (Fig. 6).
15. Read the hydraulic oil pressure in the pressure
gauge.
16. Return the travel lever to "Neutral".

Nominal value
See chapter "Technical Data".
Fig. 6

i Note
If the nominal pressure relief value is not
reached, adjust the pressure relief valve (1) (Fig.
7).

Fig. 7
17. Loosen the counter nut (2) and turn the setscrew
(1) in or out, until the nominal value is reached
(Fig. 8).

i Note
Turning clockwise increases the pressure, turn-
ing anti-clockwise reduces the pressure!
18. Check the pressure once again (see above).
19. Retighten the counter nut (2).

! Danger

Fig. 8 Danger of injury!

Before disconnecting the pressure gauge
make sure that the engine has been shut
down!
20. Disconnect the pressure gauge.

594 BOMAG 008 917 69

Checking & adjusting the travel pump 23.2
Charge pressure test
21. Shut down the engine.

! Danger
Danger of injury!
Before connecting the pressure gauge make
sure that the engine has been shut down!
22. Connect a high pressure gauge (60 bar) to pres-
sure test port (3) on the pump (Fig. 9).

i Note
The arrangement of hydraulic components is
Fig. 9
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
23. Start the engine.
24. Read the hydraulic oil pressure in the pressure
gauge.
25. Shut down the engine.

Nominal value
See chapter "Technical Data".
26. Disconnect the pressure gauge.

008 917 69 BOMAG 595

23.2 Checking & adjusting the travel pump

596 BOMAG 008 917 69

24 Suppliers documentation

008 917 69 BOMAG 597

598 BOMAG 008 917 69
24.1 Steering and working pump

008 917 69 BOMAG 599

24.1 Steering and working pump

600 BOMAG 008 917 69

Steering and working pump 24.1

RDE 92703-02-R/12.00

Reparaturanleitung - A10VO 25 DFR Baureihe 52

A10VNO 41-85 DFR Baureihe 52

Repair instructions - A10VO 25 DFR Series 52

A10VNO 41-85 DFR Series 52

008 917 69 BOMAG 601

24.1
RDE 92703-02-R/12.00
Steering and working pump
Hinweis / Inhalt Reparaturanleitung A10V(N)O
Notice / Contents Repair Instructions A10V(N)O

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- For repair, please use only original spare parts.
flussen, Verpflichtungen entstehen uns daraus nicht. Optional equipment and accessories may add cost to the
Methoden und Vorrichtungen sind Empfehlungen, für basic unit, and some options are available only in
deren Resultat wir keine Haftung übernehmen können. combination with certain models or other options.
Reparaturen nur mit Original-Ersatzteilen durchführen. For the available combinations refer to the relevant data
sheet for the basic unit and the desired option.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf
Adjustment and tests have to be carried out on the test
dem Teststand vorzunehmen.
bench under operating temperatures.
Schutz von Personen und Eigentum ist durch Vor- Protection of personnel and property has to be guar-
kehrungen sicherzustellen. anteed by appropriate measures.
Sachkenntnis, die Voraussetzung für jede Servicearbeit, Expert knowledge, the precondition of any service work,
vermitteln wir in unseren Schulungskursen. can be obtained in our training courses.

INHALT Seite/ CONTENTS

Page

A10V(N)O A10V(N)O

Schnittbild 3 Sectional view

Allgemeine Reparaturhinweise 4 General repair guidelines
Triebwelle abdichten 5-6 Sealing the drive shaft
Steuerventil abdichten / reinigen 7 Sealing / cleaning the control valve
Pumpe demontieren 8-10 Disassemble the pump
Triebwerk ausbauen 11 Remove rotary group
Stellsystem ausbauen 12 Remove control device
Welle / Lager ausbauen 13 Remove shaft / beaerings
Überprüfungshinweise 14-15 Inspection hints
Pumpe montieren 16-17 Pump assembly
Abstimmung Lagerung 18 Adjustment of taper roller bearing
Pumpe montieren 19-24 Pump assembly
Steuerventil: Hinweise für DR, DFR, DFR 1 25 Control valve: Guidelines for the DR, DFR, DFR 1
Werkzeuge / Hilfswerkzeuge / Anziehdrehmomente 26 Tools, auxiliary tools, tightening torques

2 Brueninghaus Hydromatik
602 BOMAG 008 917 69
24.1
RDE 92703-02-R/12.00
Steering and working pump
Schnittbild Reparaturanleitung A10V(N)O
Sectional view Repair Instructions A10V(N)O

NG 41-85
Verschlußschraube OHNE Ringnut
Size 41-85
Plug WITHOUT groove

NG 25
Verschlußschraube MIT Ringnut
Size 25
Plug WITH groove

008 917 69 BOMAG Brueninghaus Hydromatik

603 3
24.1
RDE 92703-02-R/12.00
Steering and working pump
Allgemeine Reparaturhinweise Reparaturanleitung A10V(N)O
General repair guidelines Repair Instructions A10V(N)O

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
604 BOMAG 008 917 69
24.1
RDE 92703-02-R/12.00
Steering and working pump
Triebwelle abdichten Reparaturanleitung A10V(N)O
Sealing the drive shaft Repair Instructions A10V(N)O

2
1

1 2

1. Sicherungsring, 2. Wellendichtring, 3. Lager

1. Circlip, 2. Shaft seal, 3. Bearing

Triebwelle abkleben.
Sicherungsring ausbauen.
Wellendichtring nach vorne entnehmen.

Protect the drive shaft.

Remove the circlip.
Remove shaft seal to front.

008 917 69 BOMAG Brueninghaus Hydromatik

605 5
24.1
RDE 92703-02-R/12.00
Steering and working pump
Triebwelle abdichten Reparaturanleitung A10V(N)O
Sealing the drive shaft Repair Instructions A10V(N)O

Nach der Demontage des gelaufenen Wellendicht-

rings, einfetten des neuen WDR.
Sichtkontrolle Welle, Gehäuse.

Change the shaft seal and check its sliding surface

(drive shaft) and housing, grease the sealing ring.
Visual check shaft seal and housing.

Wellendichtring vorsichtig mit Montagewerkzeug bis

Anschlagring einpressen.

Assembling of the sealing ring carefully down to the

distance ring.

Sicherungsring einsetzen.

Assemble the snap ring.

Sitzkontrolle des Sicherungsrings in der Nut.

Visual check to ensure that the circlip is correctly

located in the groove.

6 Brueninghaus Hydromatik
606 BOMAG 008 917 69
24.1
RDE 92703-02-R/12.00
Steering and working pump
Steuerventil abdichten / reinigen Reparaturanleitung A10V(N)O
Sealing / cleaning the control valve Repair Instructions A10V(N)O

Steuerventil abbauen
* Maß * festhalten!
Dichtfläche (1) kontrollieren.
O-Ringe (2) kontrollieren.

Remove the control valve

Measure dimension * and note
* down!
Check sealing surface (1).
Check O-rings (2).

2
1

008 917 69 BOMAG Brueninghaus Hydromatik

607 7
24.1
RDE 92703-02-R/12.00
Steering and working pump
Pumpe demontieren Reparaturanleitung A10V(N)O
Disassemble the pump Repair Instructions A10V(N)O

Übersicht
Overview

8 Brueninghaus Hydromatik
608 BOMAG 008 917 69
24.1
RDE 92703-02-R/12.00
Steering and working pump
Pumpe demontieren Reparaturanleitung A10V(N)O
Disassemble the pump Repair Instructions A10V(N)O

Demontageposition
Lage der Anschlußplatte zum Gehäuse der
Pumpe kennzeichnen.

Disassembly position
Mark the location of the connection plate
on the housing of pump.

Steuerventil abbauen.

Remove the control valve.

008 917 69 BOMAG Brueninghaus Hydromatik

609 9
24.1
RDE 92703-02-R/12.00
Steering and working pump
Pumpe demontieren Reparaturanleitung A10V(N)O
Disassemble the pump Repair Instructions A10V(N)O

*
*

4 Befestigungsschrauben * ausbauen.

Remove the 4 socket screws *.

Anschlußplatte abheben und absetzen.

Verteilerplatte kann herunterfallen - festhalten
beim Abheben der Anschlußplatte.

Remove connection plate and store down.

Control plate can drop down - keep tight
while removing connection plate.

10 Brueninghaus Hydromatik
610 BOMAG 008 917 69
24.1
RDE 92703-02-R/12.00
Steering and working pump
Triebwerk ausbauen Reparaturanleitung A10V(N)O
Remove rotary group Repair Instructions A10V(N)O

Lager der Anschlußplatte mit Abzieher

ausbauen.
Dichtfläche nicht beschädigen.

Pull bearing of the connection plate out using

a bearing puller.
Do not damage the sealing surface.

Lager und Scheibe ausbauen.

Dichtfläche nicht beschädigen.

Remove bearing and shim.

Do not damage the sealing surface.

Triebwerk in horizontaler Lage herausziehen.

Remove the rotary group in a horizontal

position.

008 917 69 BOMAG Brueninghaus Hydromatik

611 11
24.1
RDE 92703-02-R/12.00
Steering and working pump
Stellsystem ausbauen Reparaturanleitung A10V(N)O
Remove control device Repair Instructions A10V(N)O

1
2
3

Verschlußschraube (1) mit Dichtring (2)

ausbauen.
Verstellkolben (3) (-flache Seite*- ) mit
Werkzeug fassen und herausziehen.

Remove plug (1) with seal (2).

Pull out control piston (3)
(-flat surface*-) with tool.

Ausbau Kolbenstange und

Schwenkwiege
Innenliegende Schwenkwiege (5) mit
5
Werkzeug fassen und in Pumpe um
Z-Achse leicht drehen.
Z Kolbenstange (4) entnehmen.
Schwenkwiege (5) entnehmen.

Remove piston rod and swash plate.

Turn swash plate (5) inside of the
housing slightly along Z-axis with tool.
Remove piston rod (4).
Remove swash plate (5).

Lagerschalen und Feder entnehmen.

Auf Einbaulage achten!

Remove bearing shells and bearing.

Attention for position!

12 Brueninghaus Hydromatik
612 BOMAG 008 917 69
24.1
RDE 92703-02-R/12.00
Steering and working pump
Welle / Lager ausbauen Reparaturanleitung A10V(N)O
Remove shaft / bearings Repair Instructions A10V(N)O

Triebwelle mit Lager entnehmen.

Remove drive shaft with bearing.

Sicherungsring und Wellendichtring ausbauen.

Remove circlip and shaft seal.

Kegelrollenlager-Außenring mit Ab- und

Auszieher aus Gehäuse-Preßsitz herausziehen.
Alle Verschlußschrauben demontieren.

Pull out outer race of tapered bearing out of

housing press seat.
Use bearing puller.
Remove all plugs.

008 917 69 BOMAG Brueninghaus Hydromatik

613 13
24.1
RDE 92703-02-R/12.00
Steering and working pump
Überprüfungshinweise Reparaturanleitung A10V(N)O
Inspection hints Repair Instructions A10V(N)O

Alle Lager und Dichtungen erneuern.

Renew all bearings and seals.

Kontrolle:
1. Verzahnung ausgeschlagen, Passungsrost
2. Einlaufrille vom Wellendichtring
5 3. Lagersitz
2 3 4 4. Verzahnung - Mitnahme Zylinder
1
5. Lagersitz

Check:
1. Wear on slines, fretting
2. Drive shaft seal wear grooves
3. bearing seat
4. Splines for cylinder drive
5. Bearing seat

Kontrolle:
* Gleitfläche riefenfrei.
* Beweglichkeit Kolbenstange prüfen

Check:
Sliding surface free of grooves.
* Check for freedom of piston rod movement

Kontrolle:
Lagerbahnen

Check:
Bearing surfaces

Kontrolle!
Rückzugeinrichtung riefenfrei, keine Einlaufspuren
im Gleitschuhbereich.

Check!
That the retaining plate is free of grooves and
that there is no wear in the slipper pad area.

14 Brueninghaus Hydromatik
614 BOMAG 008 917 69
24.1
RDE 92703-02-R/12.00
Steering and working pump
Überprüfungshinweise Reparaturanleitung A10V(N)O
Inspection hints Repair Instructions A10V(N)O

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).

Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).

Check!
Cylinder bores (1), splines (2).

Riefenfrei, keine Einlaufspuren

Free of grooves, no signs of wear.

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).

Kontrolle!
Auflagefläche - Steuerplatte ohne Beschädigung.

Check!
Mounting surface - control plate undamaged

008 917 69 BOMAG Brueninghaus Hydromatik

615 15
24.1
RDE 92703-02-R/12.00
Steering and working pump
Pumpe montieren Reparaturanleitung A10V(N)O
Pump assembly Repair Instructions A10V(N)O

Lageraußenring mit Vorrichtung einpressen.

Press-in distance ring with tool.

Welle in Lager einstecken.

Wellendichtring nicht beschädigen!

Assemble shaft in correct position.

Do not cut shaft seal!

16 Brueninghaus Hydromatik
616 BOMAG 008 917 69
24.1
RDE 92703-02-R/12.00
Steering and working pump
Pumpe montieren Reparaturanleitung A10V(N)O
Pump assembly Repair Instructions A10V(N)O

Lageraußenringe des hinteren Lagers mit Vorrich-

tung in Anschlußplatte einpressen.

Press-in outer racer of rear bearing into

connection plate

Anschlußplatte gemäß der Kennzeichnung

montieren.
4 Befestigungsschrauben anziehen.

Assemble connection plate to pump acc. sign.

Pull 4 socket screws tight.

Abstimmung der Triebwerkslagerung siehe

Folgeseite.
Anschließend Anschlußplatte demontieren.

Adjustment of taper roller bearing set see

following page.
Disassemble connection plate.

008 917 69 BOMAG Brueninghaus Hydromatik

617 17
24.1
RDE 92703-02-R/12.00

Abstimmung Lagerung
Steering and working pump
Reparaturanleitung A10V(N)O
Adjustment of taper roller bearing Repair Instructions A10V(N)O

Montage Abstimmung (Kegelrollenlager)

Taper roller bearing initial tension

Pos. 12

0 - 0,05

Abstimmung der Triebwerkslagerung Adjustment of taper roller bearing set

Die Vorspannung der Triebwerkslagerung muß im Cast iron housing must have initial tension of the
Gußgehäuse von 0 bis 0,05 mm durch Abschleifen der bearings: 0 ..... 0,05 mm, grind Pos. 12 if necessary.
Abstimmscheibe Pos. 12 hergestellt werden.

18 Brueninghaus Hydromatik
618 BOMAG 008 917 69
24.1
RDE 92703-02-R/12.00
Steering and working pump
Pumpe montieren Reparaturanleitung A10V(N)O
Pump assembly Repair Instructions A10V(N)O

Montagehinweis Wellendichtring siehe Seite 6.

Assembly instruction shaft seal see page 6.

Lagerschalen und Feder einlegen

Mit Fett fixieren.

Fit in bearing shells and spring.

Fix with grease.

008 917 69 BOMAG Brueninghaus Hydromatik

619 19
24.1
RDE 92703-02-R/12.00
Steering and working pump
Pumpe montieren Reparaturanleitung A10V(N)O
Pump assembly Repair Instructions A10V(N)O

5 Schwenkwiege (5) und Kolbenstange (4)

Z einsetzen.
4 Anschlag Feder beachten.
Richtige Lage der Feder beachten.

Assemble swash plate (5) and piston rod (4)

into pump.
Spring guide pin in correct position.
Check correct position of the spring.

1 Kolbenstange (4), Verstellkolben (3), Dichtung (2),

und Verschlußschraube (1) montieren.
2
Verschlußschraube anziehen.
3 Nenngröße 25, 45, 63 MA =190 Nm + 20 Nm
Nenngröße 85 MA = 320 Nm + 20 Nm
Mit Loctite 242 sichern.

Assemble piston rod (4), control piston (3),

seal (2), and plug (1).
Pull plug tight.
Size 25, 45, 63 MA =190 Nm + 20 Nm
Size 85 MA = 320 Nm + 20 Nm
Secure with Loctite 242.

20 Brueninghaus Hydromatik
620 BOMAG 008 917 69
24.1
RDE 92703-02-R/12.00
Steering and working pump
Pumpe montieren Reparaturanleitung A10V(N)O
Pump assembly Repair Instructions A10V(N)O

Mit Vorrichtung Druckstifte montieren.

Fit pressure pins using an assembly aid.

Feder mit Vorrichtung vorspannen.

Pre-tension the spring using a suitable device.

Kolben mit Rückzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einölen.

Assemble piston with retaining plate.

Note:
Oil piston and slipper pad.

008 917 69 BOMAG Brueninghaus Hydromatik

621 21
24.1
RDE 92703-02-R/12.00
Steering and working pump
Pumpe montieren Reparaturanleitung A10V(N)O
Pump assembly Repair Instructions A10V(N)O

Rotationsgruppe montieren!
Montagehilfe:
Mit O-Ring Kolben festhalten.

Fit rotary group!

Assembly aid:
Hold the pistons by using an O-ring.

Lager und Abstimmscheibe auf Welle

montieren.

Assemble bearing and adjustment shim to

shaft.

22 Brueninghaus Hydromatik
622 BOMAG 008 917 69
24.1
RDE 92703-02-R/12.00
Steering and working pump
Pumpe montieren Reparaturanleitung A10V(N)O
Pump assembly Repair Instructions A10V(N)O

O-Ring in Anschlußplatte einlegen.

Mit Fett fixieren.
Verteilerplatte auf Anschlußplatte legen.
Mit Fett fixieren.
Auf richtigen Sitz zum Fixierstift achten.

Fit O-ring.
Fix with grease.
Fit control plate.
Fix with grease.
Check correct position to pin.

Anschlußplatte montieren.
Auf richtige Lage zum Gehäuse achten.
Markierung
Schrauben entsprechend Tabelle Seite 26
anziehen.

Assemble connection plate.

Check the correct position to housing.

Sign
Pull screws tight acc. list page 26.

008 917 69 BOMAG Brueninghaus Hydromatik

623 23
24.1
RDE 92703-02-R/12.00
Steering and working pump
Pumpe montieren Reparaturanleitung A10V(N)O
Pump assembly Repair Instructions A10V(N)O

Ventil anbauen.

Assemble control valve.

Fertigmontage

Nochmals die Gehäusemarkierungen prüfen.

Final pump assembly

Double check of the housing signs.

24 Brueninghaus Hydromatik
624 BOMAG 008 917 69
24.1
RDE 92703-02-R/12.00
Steering and working pump
Steuerventil: Hinweise für DR, DFR, DFR 1 Reparaturanleitung A10V(N)O
Control valve: Guidelines for the DR, DFR, DFR 1 Repair Instructions A10V(N)O

Alle abgebildeten Ventile dieser Seite in Blendenlage offen (s. Skizzen-Einbaulage).

All of the valves shown on this page have the orifice shown in its open condition (see sketches - installation location)

Steuerventil DR / DR control valve

Beide X-Anschlüsse verschlossen / Both X-ports are plugged
Förderstromregler blockiert / Flow controller is blocked

Einbaulage der Blende ∅ 0,6

Blende / Orifice 0,6 mm Position of the orifice ∅ 0,6

Steuerventil DFR / DFR control valve

Ein X-Anschluß verschlossen / One X-port is plugged Bypassdüse /
X
X Decompression-orifice

P A T

Steuerventil DFR 1 / DFR 1 control valve

Ein X-Anschluß verschlossen / One X-port is plugged
Bypassdüse X-T mit Stopfen verschlossen / Bypass orifice X-T is closed using a plug

Stopfen / Plug X

P A T

Adapter am DFR-Steuerventil für metrische Verrohrung

des Steueranschlusses X (ohne Blende).

Adapter on the DFR control valve for metric piping

of the pilot connection X (without orifice).

008 917 69 BOMAG Brueninghaus Hydromatik

625 25
24.1
RDE 92703-02-R/12.00
Steering and working pump
Werkzeuge / Hilfswerkzeuge / Anziehdrehmomente Reparaturanleitung A10V(N)O
Tools / auxiliary tools / tightening torques Repair Instructions A10V(N)O

Verwendete Loctite-Sorten
alle Abreißstopfen Nr. 601
sonst Nr. 242

Loctite types used:

For all break-off plugs No. 601
For all other parts No. 242

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. Anziehdrehmoment (geölte Schrauben μ = 0,125)

MA (Nm) = max. tightening torque (lubricated screws μ = 0,125)

26 Brueninghaus Hydromatik
626 BOMAG 008 917 69
24.1
RDE 92703-02-R/12.00
Steering and working pump
Reparaturanleitung A10V(N)O
Repair Instructions A10V(N)O

Brueninghaus Hydromatik GmbH, Werk Elchingen, Glockeraustraße 2, D-89275 Elchingen, Tel. (07308) 820, Fax (07308) 7274, E-Mail: service.elchingen@bru-hyd.com
Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb, Tel. (07451) 920, Fax (07451) 8221, E-Mail: service.horb@bru-hyd.com

008 917 69 BOMAG Brueninghaus Hydromatik

627 27
24.1 Steering and working pump

628 BOMAG 008 917 69

24.2 Travel pump

008 917 69 BOMAG 629

24.2 Travel pump

630 BOMAG 008 917 69

Travel pump
Electric Drives Linear Motion and
24.2
and Controls Hydraulics Assembly Technologies Pneumatics Service

Verstellpumpe A4VG 71–180 RDE 92 003-21-R/01.06

Variable Pump A4VG 71–180

Baureihe/Series 32 R1
Reparaturanleitung / Repair Manual
Baugruppen / Assembly Groups

008 917 69 BOMAG 631

2/40
24.2
Bosch Rexroth AG
Travel pump
Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06

Vermeidung von Gefahren Avoiding Dangers

Für einen sicheren Betrieb und um Schäden bei der Reparatur To ensure safe operations and avoid damages during repairs,
zu vermeiden, lesen Sie diese Reparaturanleitung sorgfältig read this complete repair manual carefully and attentively.
und aufmerksam durch!
Für Personen- oder Maschinenschäden, die durch Nichtbe- Bosch Rexroth AG accepts no responsibility for personal
achtung dieser Reparaturanleitung entstehen, verfällt jegliche injuries or damages to the machine that arise from disregarding
Gewährleistung von Bosch Rexroth AG. this repair manual.

1 Zu dieser Anleitung 1 About this Manual

Diese Anleitung unterstützt Sie bei der Reparatur, den Über- This manual supports you in the repair, adjustment and recom-
prüfungen und der Wiederinbetriebnahme von Rexroth A4VG missioning of Rexroth A4VG variable pumps, sizes 71–180.
Verstellpumpen, NG 71–180. Diese Anleitung umfasst die The manual is structured as follows:
folgenden Kapitel:
x „Sicherheit“ auf Seite 7 x “Safety” on page 7
Hier erhalten Sie grundsätzliche Hinweise zum sicheren This chapter provides you with basic hints and tips regarding
Umgang mit Verstellpumpen und zu deren Betrieb. working with and operating variable pumps.
Lesen Sie dieses Kapitel bevor Sie anfangen zu arbeiten. Read this chapter before you start working.
x „Produktbeschreibung“ auf Seite 11 x “Product Description” on page 11
Hier erfahren Sie, wie Sie den Typ einer Verstellpumpe This chapter explains how you identify the variable pump.
feststellen. Ferner ﬁnden Sie hier eine Übersicht über die Addtionally, it provides you an overview of the how the vari-
Funktionsweise und Informationen zur bestimmungsgemäßen able pump and information regarding the correct usage.
Verwendung der Verstellpumpe. Read this chapter to refresh your knowledge of the variable
Lesen Sie dieses Kapitel, um Ihr Grundwissen über die pumps.
Verstellpumpe aufzufrischen.
x „Austausch externer Baugruppen“ auf Seite 15 x “Exchanging Extermnal Assembly Groups” on page 15
Dieses Kapitel erklärt Ihnen, wie Sie Baugruppen einer Ver- Rexroth provides various replacement parts for repairs. This
stellpumpe austauschen. section provides you an overview of the available spare parts
subassemblies.
x „Überprüfungen“ auf Seite 33 x “Checking” on page 33
Dieses Kapitel erklärt Ihnen, wie Sie die Einstellarbeiten an Read this chapter to be able to restore the settings on an
einer Verstellpumpe vornehmen. variable pump after a repair.

632 BOMAG 008 917 69

Travel pump
RDE 92 003-21-R/01.06 Reparaturanleitung/Repair Manual A4VG 71–180
24.23/40
Bosch Rexroth AG

1.1 Inhaltsverzeichnis 1.1 Contents

1. Zu dieser Anleitung 2 1. About this Manual 2

1.1 Inhaltsverzeichnis 3 1.1 Contents 3
1.2 Gültigkeitsbereich dieser Anleitung 4 1.2 Validity of this Manual 4
1.3 Wichtige Unterlagen 5 1.3 Important Documents 5
1.4 Gefahrenkennzeichnungen und Pictogramme 6 1.4 Danger Labels and Pictograms 6
2. Sicherheit 7 2. Safety 7
2.1 Grundlegende Sicherheitshinweise 7 2.1 Basic Safety Information 7
2.2 Anforderungen an das Personal 10 2.2 Requirements on the Personnel 10
3. Produktbeschreibung 11 3. Product Description 11
3.1 Typschild 11 3.1 Name Plate 11
3.2 Funktionsbeschreibung 11 3.2 Functional Description 11
3.3 Technische Daten 14 3.3 Technical Data 14
4. Austausch externer Baugruppen 15 4. Exchanging External Assembly Groups 15
4.1 Wellendichtring austauschen 16 4.1 Exchanging the Shaft Seal 16
4.2 Dichtungen austauschen 18 4.2 Exchanging Seals 18
4.3 Hilfspumpe austauschen 24 4.3 Exchanging the Backing Pump 24
4.4 Steuergerät austauschen 26 4.4 Exchanging the Control Unit 26
5. Überprüfungen 33 5. Checking 33
5.1 Niederdruck (Speisedruck) überprüfen 34 5.1 Checking Low Pressure (Charge Pressure) 34
5.2 Hochdruck überprüfen 34 5.2 Checking High Pressure 34
5.3 Mechanische Nulllage überprüfen 35 5.3 Checking the Mechanical Zero Stroke 35
5.4 Hydraulische Nulllage überprüfen 36 5.4 Checking the Hydraulic Zero Stroke 36

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Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

1.2 Gültigkeitsbereich dieser 1.2 Validity of this Manual

Anleitung
Diese Reparaturanleitung gilt für die Axialkolben-Verstellpumpe This manual is valid for the Bosch Rexroth axial piston variable
A4VG NG 71–180 der Bosch Rexroth AG. Informationen zu pump A4VG NG 71–180. Refer to the system manufacturer for
zugelassenen Druckflüssigkeiten entnehmen Sie den Angaben information about the allowed hydraulic fluids.
des Anlagenherstellers.
Diese Reparaturanleitung richtet sich an: This repair manual is directed at:
x Anlagenbetreiber, x the system operator
x den autorisierten Fachbetrieb bzw. Händler, x authorized dealers
x den Anlagenhersteller. x the system manufacturer
Für den Anlagenhersteller sind zusätzlich auch die jeweilige For the system manufacturer, the installation drawing, the
Einbauzeichnung, das technische Datenblatt, die Betriebsan- catalog sheet, the manual, and the confirmation of order from
leitung und die Auftragsbestätigung der Bosch Rexroth AG the Bosch Rexroth AG are also obligatory.
verbindlich.

634 BOMAG 008 917 69

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RDE 92 003-21-R/01.06 Reparaturanleitung/Repair Manual A4VG 71–180 Bosch Rexroth AG
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1.3 Wichtige Unterlagen 1.3 Important Documents

Bevor Sie mit den in dieser Anleitung beschriebenen Arbeiten Before you start any of the procedures described in this manu-
anfangen, stellen Sie sicher, dass Sie folgende Unterlagen al, make sure you have the following documents:
griffbereit haben:
x Auftragsbestätigung x Confirmation of order
Die Auftragsbestätigung enthält die voreingestellten techni- The confirmation of order contains the values set during the
schen Daten. Die Axialkolbenmaschine darf nur unter den in commissioning by Rexroth. Before you can recommission the
der Auftragsbestätigung angegebenen Werten und Bedin- axial piston unit after a repair, you have to restore the values
gungen betrieben werden. originally set by Rexroth.
x Einbauzeichnung x Installation drawing
Die Einbauzeichnung der Axialkolbenmaschine enthält die The installation drawing of the axial piston unit contains the
Außenabmessungen, sämtliche Anschlüsse und den Schalt- sizes of all connections.
plan.
x Technisches Datenblatt x Technical data sheet
Das technische Datenblatt RD 92 003 enthält u.a. die zuläs- The technical data sheet RE 92 003 contains the maximum
sigen technischen Daten für die Axialkolbenmaschine. allowed performance data.
x Gesamtschaltplan der Maschine bzw. Anlage x Hydraulic diagramWiring diagram
Der Hydraulikschaltplan und der elektrische Schaltplan der The hydraulic diagram and the wiring diagram of the unit
Maschine bzw. Anlage enthalten die Informationen zu den or system contain the information related to the respective
hydraulischen bzw. elektrischen Anschlüssen. Diese Daten machine.You need this data to work with the axial piston as
brauchen Sie, um mit der Axialkolbenmaschine als Teil der part of the machine or system. You can get this information
Maschine bzw. Anlage zu arbeiten. Die Unterlagen erhalten from the unit or system manufacturer.
Sie vom Maschinen- bzw. Anlagenhersteller.
x RD 90 300-B: Allgemeine Betriebsanleitung für Axialkol- x RE 90 300-B: General Manual for Axial Piston Units
benmaschinen The general manual supports you during the installation,
Die allgemeine Betriebsanleitung unterstützt Sie bei Installa- initiation, and operation of Rexroth axial piston units.
tion, Inbetriebnahme und Betrieb von Rexroth-Axialkolbenma-
schinen.
x Produktspezifische Betriebsanleitung x Product Specific Manual
Die produktspezifische Betriebsanleitung enthält spezielle, The product-specific manual contains information specially
für die Axialkolbenmaschine gültige Informationen. Informie- designed for the axial piston unit. Get in touch with Rexroth
ren Sie sich bei Rexroth, ob es zu Ihrer Axialkolbenmaschine to find out if there is any product-specific information on your
eine produktspezifische Betriebsanleitung gibt. specific axial piston unit.
Folgende Rexroth-Druckschriften geben Ihnen weitere Informa- The following Rexroth publications provide additional informati-
tionen zu Installation und Betrieb der Axialkolbenmaschine: on to the installation and operation of axial piston units:
x RD 90 220: Druckflüssigkeiten auf Mineralölbasis x RE 90 220: Mineral-oil Based Pressure Fluids
Beschreibt die Anforderungen an eine Druckflüssigkeit auf This publication describes the requirements on a hydraulic
Mineralölbasis für den Betrieb mit Rexroth-Axialkolbenma- fluid for operation in an axial piston unit and supports you in
schinen und unterstützt Sie bei der Wahl einer Druckflüssig- the selection of a hydraulic fluid for your installation.
keit für Ihre Anlage.
x RD 90 221: Umweltfreundliche Druckflüssigkeiten HEES, x RE 90 221: Environmentally Acceptable Hydraulic Fluids
HEPG, HETG für Axialkolbenmaschinen HEES, HEPG, HETG for Axial Piston Units
Beschreibt die Anforderungen an eine umweltfreundliche Describes the demands on environmentally compatible, rea-
Druckflüssigkeit für den Betrieb mit Rexroth-Axialkolbenma- dily biodegradeable hydraulic fluids HEPG, HEES that can
schinen und unterstützt Sie bei der Wahl einer Druckflüssig- be used in Rexroth axial piston units and supports you by the
keit für Ihre Anlage. choice of a hydraulic fluid for your system.
x RD 90 223: Axialkolbenmaschinen für den Betrieb mit x RE 90 223: Axial Piston Units for Use with HF Fluids
HF-Druckflüssigkeiten Provides additional information for the use of Rexroth axial
Enthält zusätzliche Informationen zum Einsatz von Rexroth- piston units with HF hydraulic fluids.
Axialkolbenmaschinen mit HF-Druckflüssigkeiten.
x RD 90 300-03-B: Hinweise zum Einsatz von hydrauli- x RE 90 300-03-B: Instructions on the Use of Hydrostatic
schen Antrieben bei tiefen Temperaturen Drives at Low Temperatures
Enthält zusätzliche Informationen zum Einsatz von Rexroth- Provides additional information for the use of Rexroth axial
Axialkolbenmaschinen bei tiefen Temperaturen. piston units for low temperatures.

008 917 69 BOMAG 635

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Bosch Rexroth AG
Travel pump
Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06

1.4 Gefahrenkennzeichnungen 1.4 Danger Labels and Pictograms

und Piktogramme
Diese Anleitung unterscheidet zwischen Kategorien von Gefah- This manual differentiates between the following categories of
ren gemäß ISO Guide 37: danger according to ISO Guide 37:
! GEFAHR ! DANGER

Weist auf hohes Risiko und die Gefahr von Tod oder schwe- Indicates high risk, mortal danger and serious injuries.
ren Verletzungen hin.

! WARNUNG ! WARNING

Weist auf mittleres Risiko und die Gefahr von Verletzungen Indicates middle risk, injuries or serious material damage.
und schweren Sachschäden hin.

! VORSICHT ! CAUTION

Weist auf geringes Risiko und Sachschäden hin. Indicates low risk or material damage.

Hinweis Note

Kennzeichnet Informationen, die zum besseren Verständnis Indicates information that contributes to a better understan-
der Maschinenabläufe beitragen oder weist auf einen beson- ding of the machine processes or indicates important informa-
deren bzw. wichtigen Sachverhalt hin. tion.

Tipp Tip

Kennzeichnet Informationen, die zum efﬁzienteren Arbeiten Indicates information that contributes to more efﬁcient work.
beitragen.

636 BOMAG 008 917 69

Travel pump
RDE 92 003-21-R/01.06 Reparaturanleitung/Repair Manual A4VG 71–180 Bosch Rexroth AG
24.27/40

2 Sicherheit 2 Safety
Lesen Sie dieses Kapitel sorgfältig durch, bevor Sie mit Arbei- Read through this chapter carefully before you start any work
ten an der Verstellpumpe beginnen. on the variable pump.
Die Rexroth-Verstellpumpen sind im Sinne der Maschinenricht- The Rexroth variable pump are in the sense of the machine gui-
linie 98/37/EG Komponenten, die zum Einbau in eine Anlage deline 98/37/EG components of a larger machine or system.
bestimmt sind. Die Sicherheitsrichtlinien in dieser Anleitung be- The safety guidelines in this manual only cover the variable
ziehen sich nur auf die Verstellpumpe. Beachten Sie zusätzlich pump. You must additionally follow the system manufacturer’s
die Sicherheitsrichtlinien des Anlagenherstellers. safety guidelines.
Informieren Sie sich an Hand der allgemeinen Betriebsanlei- Read the general manual for axial piston units to get more infor-
tung für Axialkolbenmaschinen über die bestimmungsgemäße mation on the designated use and the operator‘s obligation to
Verwendung und die Sorgfaltspﬂicht des Betreibers und exercise dilligence.
Bedieners.

2.1 Grundlegende 2.1 Basic Safety Information

Sicherheitshinweise
Befolgen Sie die folgenden Sicherheitshinweise und die des Pay exact attention to the following safety information and that
Anlagenherstellers genau, um Verletzungen und Gesundheits- of the system manufacturer to eliminate injuries and health
schäden sowie Sach- und Umweltschäden auszuschließen. damages as well as damages to material or the environment.

! GEFAHR ! DANGER

Lebensgefahr Danger to Life

Das Arbeiten an nicht stillgelegten Maschinen bzw. Anlagen Working on systems that have not been shut down is life-thre-
stellt eine Gefahr für Leib und Leben dar. atening.
Die in diesem Dokument beschriebenen Arbeiten dürfen nur The work described in this document can only be carried out
an stillgelegten Maschinen bzw. Anlagen vorgenommen on a shut down system. Before you start any of the tasks:
werden. Bevor Sie mit den Arbeiten beginnen:
x Stellen Sie sicher, dass der Antriebsmotor nicht eingeschal- x Make sure that the engine / motor cannot be switched on.
tet werden kann.
x Stellen Sie sicher, dass sämtliche kraftübertragenden Kom- x Make sure that all components and connections that carry
ponenten und Anschlüsse (elektrisch, pneumatisch, hydrau- energy (electrical, pneumatic, hydraulic) have been shut
lisch) gemäß den Herstellerangaben ausgeschaltet sind und down according to the manufacturer’s instructions and
nicht eingeschaltet werden können. Falls möglich, entfernen cannot be switched on. If possible, disable the main fuse.
Sie die Hauptsicherung der Maschine bzw. Anlage.
x Stellen Sie sicher, dass die Maschine bzw. Anlage komplett x Make sure that the system is completely unloaded. Follow
hydraulisch entlastet ist (drucklos). Folgen Sie hierzu den the instructions of the the system manufacturer.
Angaben des Maschinen- bzw. Anlagenherstellers.

! WARNUNG ! WARNING

Verletzungsgefahr Danger of injuries

Um Verletzungen zu vermeiden, beachten Sie bitte folgende To avoid injuries, pay attention to the following regarding
Empfehlungen betreffend Sicherheitskleidung: safety clothing.
x Tragen Sie bei Arbeiten an Maschine bzw. Anlage Sicher- x When working on the system, wear steel-toed safety shoes.
heitsschuhe mit Stahlkappen.
x Tragen Sie bei Arbeiten mit gefährlichen Stoffen (beispiels- x When working with dangerous substances (for example,
weise Druckﬂüssigkeiten) Schutzhandschuhe und Schutz- certain hydraulic ﬂuids), wear protective gloves and protec-
brille. tive glasses.

008 917 69 BOMAG 637

24.2
8/40 Bosch Rexroth AG
Travel pump
Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06

! GEFAHR ! DANGER

Vergiftungs- und Verletzungsgefahr Danger of poisoing or injuries

Der Kontakt mit Drückflüssigkeiten ruft Gesundheitsschäden Contact with hydraulic fluids can cause health damage (eye
hervor (z.B. Augenverletzungen, Haut- und Gewebeschädi- injuries, skin damage, poisoning due to inhalation).
gungen, Vergiftungen beim Einatmen).
x Überprüfen Sie vor jeder Inbetriebnahme die Leitungen auf x Always check the hydraulic lines for wear and damage prior
Verschleiß bzw. Beschädigungen. to putting the unit into operation.
x Tragen Sie dabei Schutzhandschuhe und Schutzbrille. x Always wear protective gloves and safety glasses.
x Wenn dennoch Druckflüssigkeit in die Augen gelangt oder x Should pressure fluid come into contact with your eyes or
in die Haut eindringt, konsultieren Sie unmittelbar einen skin: Get medical help immediately!
Arzt.
x Beachten Sie beim Umgang mit Druckflüssigkeiten unbe- x When handling hydraulic fluids, pay exact attention to the
dingt die Sicherheitsangaben des Druckflüssigkeitsherstel- manaufacturer’s safety instructions.
lers.

! WARNUNG ! WARNING

Verbrennungsgefahr Danger of burns

Die Axialkolbenmaschine erwärmt sich während des Betriebs. The variable pump heats up during operation. The unit’s sole-
Auch die Magnete an der Axialkolbenmaschine werden im noids get hot during operation. Touching the variable pump or
laufenden Betrieb heiß. Bei Berührung der Axialkolbenma- solenoids can lead to severe injuries.
schine oder der Magnete können schwere Brandverletzungen
entstehen.
x Lassen Sie die Axialkolbenmaschine vor jedem Kontakt x Let the variable pump cool down prior to any contact.
abkühlen.
x Schützen Sie sich mit hitzebeständigen Handschuhen und x Protect yourself from burns by wearing safety gloves and
Schutzkleidung. protective clothing.

! GEFAHR ! DANGER

Vergiftungs- und Verletzungsgefahr Danger of poisoning

Beim Suchen nach Leckstellen kann entweichende Druckﬂüs- When looking for leaks, escaping hydraulic ﬂuid can break
sigkeit in die Haut eindringen und schwerste Vergiftungen und into the skin and cause serious poisoning.
Verletzungen hervorrufen.
x Suchen Sie nur bei abgestellter und druckloser Maschine x Always use a piece of cardboard or paper to look for leaks.
nach Leckstellen.

! WARNUNG ! WARNING

Verletzungs- und Beschädigungsgefahr Danger of injuries or damage

Durch falsch angeschlossene Komponenten können erhebli- Incorrectly connected components can considerably impair
che Fehlfunktionen entstehen. the functionality of a hydraulic system.
x Achten Sie auf korrekte Verrohrung gemäß Schaltplan. x Make sure that the hydraulic lines are connected properly.
x Führen Sie komponentenorientierte Funktionstests durch. x Check the correct functioning of all components.

638 BOMAG 008 917 69

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RDE 92 003-21-R/01.06 Reparaturanleitung/Repair Manual A4VG 71–180 Bosch Rexroth AG
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! GEFAHR ! DANGER

Feuergefahr Danger of ﬁre

Hydraulische Druckflüssigkeit ist brennbar. Hydraulic fluid is inflammable.
x Halten Sie offenes Feuer von der Verstellpumpe fern. x Keep open fires away from the variable pump.

! WARNUNG ! WARNING

Gehörschäden Danger of hearing loss

Die Geräuschemission von Axialkolbenmaschinen ist u.a. von The noise emission produced by axial piston units depends
Drehzahl, Betriebsdruck und Einbauverhältnissen abhängig. on speed, operating pressure, and installation. During normal
Es ist damit zu rechnen, dass der Schalldruckpegel bei nor- application conditions, over 70 dBA can be anticipated. This
malen Einsatzbedingungen über 70 dBA steigt. Dies kann zu can lead to hearing damage.
Gehörschäden führen.
x Schützen Sie sich stets mit Gehörschutz bei Arbeiten in x Always wear hearing protection when working in the vicinity
der Nähe der Axialkolbenmaschine während des laufenden of the variable pump during operation.
Betriebs.

! WARNUNG ! WARNING

Umweltschäden Risk of damage to the environment

Druckflüssigkeiten sind wassergefährdende Flüssigkeiten. Hydraulic fluid leakage leads to contamination of the ground
Das Austreten von Druckflüssigkeiten kann zu Grundwasser- and ground water.
vergiftung und Bodenverseuchung führen.
x Bringen Sie unter der Axialkolbenmaschine eine Auffang- x A basin for catching any hydraulic fluid must be placed
wanne an. under the variable pump.
x Beseitigen Sie Leckstellen unverzüglich. x Leaks must be cleaned up immediately.
x Es sind stets die nationalen Gesetze und Vorschriften zu x In Europe, hydraulic systems are considered “Systems
beachten. In Deutschland sind hydraulische Maschinen bzw. using water-threatening substances” in the sense of the
Anlagen „Anlagen zum Umgang mit wassergefährdenden Water Management Law (WHG).Therefore, pay special
Stoffen im Sinne des Wasserhaushaltsgesetzes (WHG)“. attention to §1 and §19 WHG( §19g, 19i, 19l). Additionally
Beachten Sie in diesem Zusammenhang besonders §1 und pay attention to any national regulations and norms.
§19 WHG (§19g, 19i, 19l).
x Weitere Informationen zum richtigen Umgang mit Rexroth- x For further information regarding the correct use of Bosch
Hydraulikprodukten finden Sie in unseren Druckschriften Rexroth hydraulic products, see the publications RE 90 220
„Allgemeine Produktinformationen für Hydraulikprodukte“, “Mineral-oil Based Pressure Fluids” and RE 90 221 “En-
RD 90 220 und „Umweltschonende, biologisch schnell vironmentally Acceptable Hydraulic Fluids HEES, HEPG,
abbaubare Druckflüssigkeiten HEPG, HEES für Axialkol- HETG for Axial Piston Units“, RD 90 221.
benmaschinen“, RD 90 221.

008 917 69 BOMAG 639

24.2
10/40Bosch Rexroth AG
Travel pump
Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06

2.2 Anforderungen an das Personal 2.2 Requirements on the Personnel

Diese Reparaturanleitung richtet sich an Fachkräfte mit This repair manual is directed at qualified personnel with
Hydraulik-Fachwissen, die an einer Service-Schulung bei specialized hydraulics know-how who have taken part at a
Rexroth teilgenommen haben. service training at Rexroth.
Als Fachkraft gilt, wer aufgrund seiner fachlichen Ausbildung Qualified personnel is defined as persons who have sufficient
und Erfahrung ausreichende Kenntnisse hat, sowie mit den knowledge on the basis of specialized training and experience,
einschlägigen Bestimmungen so weit vertraut ist, dass er and are familiar with the relevant regulations, so that they are
able to
x die ihm übertragenene Arbeiten beurteilen kann, x judge the delegated tasks,
x mögliche Gefahren erkennen kann, x recognize possible dangers,
x die notwendigen Maßnahmen zur Beseitigung von Gefahren x take the necessary measures for the elimination of dangers,
ergreifen kann,
x Kenntnisse über die möglichen Gesundheitsgefahren von x judge the possible health risks from hydraulic fluids,
Druckflüssigkeiten hat
x und die erforderlichen Reparatur- und Montagekenntnisse x and have the required repair and installation know-how.
hat.
Hydraulik-Fachwissen bedeutet, das Personal muss, Specialized hydraulics know-how means that these persons
must:
x in der Lage sein, die Hydraulikpläne zu lesen und vollständig x be able to read and completely understand hydraulic plans,
zu verstehen,
x insbesondere die Zusammenhänge bezüglich der eingebau- x especially understand the connections regarding the in-
ten Sicherheitseinrichtungen vollständig verstehen stalled safety equipment,
x und Kenntnisse über Funktion und Aufbau von hydraulischen x and are familiar with the function and structure of hydraulic
Bauteilen haben. components.

640 BOMAG 008 917 69

Travel pump
RDE 92 003-21-R/01.06 Reparaturanleitung/Repair Manual A4VG 71–180
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Bosch Rexroth AG

3 Produktbeschreibung 3 Product Description

Dieses Kapitel gibt Ihnen einen allgemeinen Überblick über die This chapter provides a general overview of the functionality of
Funktionalität der Rexroth A4VG Verstellpumpe. the A4VG variable pump.
Machen Sie sich mit den Inhalten dieses Kapitels vertraut, You should be familiar with the contents of this chapter before
bevor Sie mit Arbeiten an einer Verstellpumpe beginnen. starting any work on the variable pump.

3.1 Typschild 3.1 Name Plate

Die Verstellpumpe ist am Typschild zu identiﬁzieren: The variable pump can be identiﬁed on its name plate:

1 3FYSPUI
D-89275 Elchingen

2 TYP: A4VG90DA2D2/32R-NZF02F001SP 7
3 MNR: R90XXXXXXX
7202 8
4 SN: 12345678
5 FD: 05W28 Rotation:
9
6 n = XXXX min -1
P = XXX kW

Made in Germany 10

Folgende Informationen ﬁnden Sie auf dem Typschild: The following information can be found on the name plate:
1 Hersteller 1 Manufacturer
2 Typschlüssel 2 Ordering code
3 Materialnummer der Axialkolbenmaschine 3 Material number of the axial piston unit
4 Seriennummer 4 Serial number
5 Fertigungsdatum 5 Date of manufacturing
6 Drehzahl 6 Speed
7 interne Werksbezeichnung 7 Internal manufacturing code
8 Drehrichtung (bei Blick auf die Welle; hier: rechts) 8 Direction of rotation (when facing the shaft; here: clockwi-
se)
9 vorgesehener Platz für Prüfstempel 9 Designated space for certiﬁcation stamp
10 Leistung 10 Power
Stellen Sie sicher, dass Typ und Nenngröße der zu reparieren- Ensure that the variable pump to be repaired is of the type and
den Verstellpumpe mit dieser Anleitung übereinstimmen. size covered by this manual.

3.2 Funktionsbeschreibung 3.2 Functional Description

Damit Sie in der Lage sind, Probleme an der Verstellpumpe To make sure that you are able to identify problems with a vari-
zu identifizieren und gezielt Reparaturen durchzuführen, sind able pump and to carry out specific repairs, familiarity with how
Kenntnisse der Funktionsweise und des Aufbaus erforderlich. the unit functions and its assembly are required. This section
Dieser Abschnitt gibt Ihnen eine grobe Übersicht. provides you with a rough overview.
Die A4VG Verstellpumpe ist eine Axialkolben-Verstellpum- The variable displacement axial piston pump type A4VG in
pe in Schrägscheibenbauart für hydrostatische Antriebe im swashplate design is designed for closed circuit hydrostatic
geschlossenen Kreislauf. Der Volumenstrom ist proportional zu drives. The flow is proportional to the input drive speed and
der Antriebsdrehzahl und dem Verdrängungsvolumen. Durch displacement. By adjusting the swashplate, it is possible to
die Verstellung der Schrägscheibe ist eine stufenlose Volumen- infinitely vary the flow.
stromänderung möglich.

008 917 69 BOMAG 641

24.2
12/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

3.2.1 Schnittzeichnung 3.2.1 Sectional Drawing

Die folgenden Schnittzeichnungen zeigen das Zusammenspiel The following drawings show the interrelation of the compon-
der Komponenten der A4VG Verstellpumpe. ents of the A4VG variable pump.

Seitenansicht / Side View Steuergerät (siehe unten) /

Control unit (see below)

Schwenkwiege /
Cradle

Antriebswelle /
Drive Shaft
Anschlussplatte
mit Hilfspumpe /
Port Plate with
Auxiliary Pump
Wellendichtring /
Shaft Seal Ring

Triebwerk /
Rotary Group
Draufsicht Verstellungen/
Top View with Controllers
Steuergerät
HWD Control unit DAD

Antriebswelle
Antriebswelle Drive Shaft
Drive Shaft

Verstellkolben
Control Piston

EPD HDD

Antriebswelle
Drive Shaft
Antriebswelle
Drive Shaft

Steuergerät
Control unit

642 BOMAG 008 917 69

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RDE 92 003-21-R/01.06 Reparaturanleitung/Repair Manual A4VG 71–180
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Bosch Rexroth AG

Ansicht Anschlussplatte /
View Port Plate

HWD / EPD / HDD

DAD

008 917 69 BOMAG 643

24.2
14/40Bosch Rexroth AG
Travel pump
Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06

3.3 Technische Daten 3.3 Technical Data

Die technischen Daten der Verstellpumpe finden Sie in der Auf- You can find the technical data for the variable pump in the
tragbestätigung. Ergänzend dazu ist das jeweilige technische Confirmation of Order. This is supplemented by the unit‘s data
Datenblatt. Für die A4VG Verstellpumpe gilt das technische sheet. For the A4VG variable pump, the valid data sheet is
Datenblatt RD 92 003. RE 92 003.

644 BOMAG 008 917 69

Travel pump
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4 Austausch externer 4 Exchanging External
Baugruppen Assembly Groups
Dieses Kapitel beschreibt den Austausch von extern zugängli- This chapter describes the replacement of the externally acces-
chen Baugruppen der Verstellpumpe A4VG. sible assembly groups of the variable pump A4VG.
Der Austausch folgender Baugruppen wird beschrieben: The exchange of the following assembly groups is described:
x Wellendichtring x Shaft seal
x Dichtungen x Seals
x Hilfspumpe x Auxiliary pump
x Steuergerät x Control unit

Hinweis Note

Alle in nachfolgenden Zeichnungen dargestellten Steuergerä- All the following illustrations are only examples and do not
te sind nur stellvertretend und müssen nicht der Konﬁguration have to completely correspond with the conﬁgrations of your
Ihrer Axialkolbenmaschine entsprechen. axial piston unit.

! WARNUNG ! WARNING

Gefahr von Verschleiß und Funktionsstörungen Danger of wear and malfunction

Die Sauberkeit der Druckflüssigkeit und die Lebensdauer der The durability of the hydraulic unit depends to a great extent
Hydraulikanlage stehen in unmittelbarem Zusammenhang. on how clean the unit is kept. Dirt in the hydraulic fluid can
Verschmutzung der Druckflüssigkeit führt zu Verschleiß und lead to malfunctions. Especially hard foreign matter in the
Funktionsstörungen. Insbesondere harte Fremdkörper in den hydraulic conduits, for example, welding beads and cuttings,
Hydraulikleitungen, wie z.B. Schweißperlen und Metallspäne, can damage the axial piston unit.
können die Axialkolbenmaschine beschädigen.
Beachten Sie daher unbedingt folgende Hinweise: Therefore you should observe the following instructions:
x Achten Sie auf äußerste Sauberkeit. Die Axialkolbenmaschi- x Make sure everything is kept extremely clean. The axial pis-
ne muss schmutzfrei eingebaut werden. Verunreinigungen ton unit must be installed in a dirt-free environment. Conta-
in der Druckflüssigkeit können die Funktion und Lebensdau- mination of the hydraulic fluid can lead to considerable wear
er der Axialkolbenmaschine erheblich beeinträchtigen. and malfunctions of the axial piston unit.
x Achten Sie besonders bei der Installation darauf, dass x Espacially during the istallation, you should make sure that
Anschlüsse, Hydraulikleitungen und Anbauteile (z.B. Mess- ports, hydraulic conduits, and mounting components (for
geräte) sauber sind. Reinigen Sie diese gründlich, bevor example, gauges) are clean. Clean these thoroughly before
Sie Anschlüsse öffnen. Stellen Sie sicher, dass auch beim you open connections. After that, when sealing the ports,
nachfolgenden Verschließen der Anschlüsse keine Verunrei- make sure that contaminating elements cannot enter the
nigungen eindringen. system.
x Verwenden Sie für die Beseitigung von Schmiermitteln und x When removing grease and other dirt you should use ap-
anderen starken Verschmutzungen geeignete flüssige Reini- propriate liquid cleaning agents. Cleaning agents must not
gungsmittel. Es darf kein Reinigungsmittel in das Hydraulik- enter the hydraulic system.
system eindringen.
x Verwenden Sie zur Reinigung keine Putzwolle oder fasern- x Do not use cotton waste or rags which lose threads.
de Putzlappen.
x Verwenden Sie als Dichtungsmittel keinesfalls Hanf oder x Never use hemp or putty as a sealant.
Kitt.

008 917 69 BOMAG 645

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RDE 92 003-21-R/01.06

4.1 Wellendichtring austauschen 4.1 Exchanging the Shaft Seal

Dieser Abschnitt erklärt, wie Sie den Wellendichtring austau- This section explains how you can replace the shaft seal.
schen.
Benötigtes Sonderwerkzeug: Required Special Tools:
x Montagehülse x Mounting sleeve
Die Materialnummern sind je nach Pumpenmodell verschie- The material number depends on the pump model.
den:
– A4VG71: Mat.-nr. R909877509 – A4VG71: Mat. no. R909877509
– A4VG90: Mat.-nr. R909877510 – A4VG90: Mat. no. R909877510
– A4VG125: Mat.-nr. R909877511 – A4VG125: Mat. no. R909877511
– A4VG180: Mat.-nr. R909877512 – A4VG180: Mat. no. R909877512
NG 71, 90, 125

NG 180

b
a
a: Sicherungsring Circlip
b: Wellendichtring Shaft Seal
c: Triebwelle Drive Shaft

Um den Wellendichtring auszutauschen: To exchange the shaft seal:

1 Kleben Sie die Triebwelle (c) ab, um Beschädigungen am 1 Mask the drive shaft (c) for protection against damage of the
Wellendichtring (b) zu vermeiden. shaft seal (b).
2 Entfernen Sie den Sicherungsring (a). 2 Remove the safety ring (a).

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3 Drehen Sie Blechschrauben in die mit Gummi gefüllten 3 Screw the tapping screw into the rubber lined holes of the
Löcher des Wellendichtrings (b) und ziehen Sie den Wellen- shaft seal (b), and use pliers to pull the shaft seal out.
dichtring mit einer Zange heraus.

4 Fetten Sie den Wellendichtring zwischen Dicht- und Staub- 4 Grease the shaft seal between the seal and dust lip to avoid
lippe leicht ein, um Trockenlauf zu vermeiden. a dry run.
5 Pressen Sie den Wellendichtring mit Hilfe der Montagehülse 5 Using the mounting sleeve (special tool), press the shaft seal
(Sonderwerkzeug) auf Anschlag ein. until it is in stop position.

6 Führen Sie den Sicherungsring so ein, dass er in die dafür 6 Place the safety ring so that it locks into place in the respec-
vorgesehene Nut einrastet. tive slot.
7 Entfernen Sie die Abklebung an der Triebwelle. 7 Remove the mask on the drive shaft.

008 917 69 BOMAG 647

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4.2 Dichtungen austauschen 4.2 Exchanging Seals

Die Baugruppe „Dichtungssatz komplett“ enthält Dichtungen The assembly group "complete seal set" contains seals for the
für folgende Komponenten: following components:
x Stellkolbendeckel x Positioning piston covers
x Ventile x Valves
x Druckabschneidung x Pressure cut-off
x Hilfspumpe (siehe „Hilfspumpe austauschen“) x Auxiliary pump (refer to "Exchanging the Auxiliary Pump")
x Steuerung (siehe „Steuergerät austauschen“) x Control unit (refer to "Exchanging the Control Unit")

Benötigtes Sonderwerkzeug: Keines Required Special Tools: none

Dichtung an den Stellkolbendeckeln austauschen Exchanging the valve positioning piston covers
Die beiden Seiten des Stellkolbens sind mit zwei unterschiedli- Both sides of the positioning piston have their own different
chen Deckeln abgedeckt. Die nötigen Schritte zum Austausch covers. The required steps to exchange the covers are threre-
der Deckeldichtungen unterscheiden sich daher. fore different.
a

c
d

c c
b

e
f
a: Linker Deckel Left cover
b: Rechter Deckel Right cover
c: O-Ring O-ring
d: Stellschraube Adjustment screw
e: Kontermutter Counter nut
f: Befestigungsschrauben Fastening screw

Um die Dichtung an den Stellkolbendeckeln auszutauschen: To exchange the valves of the positioning pistons:
1 Kennzeichnen Sie die Lage des linken Deckels (a) und ent- 1 Mark the position of the left cover (a) and remove the faste-
fernen Sie die Befestigungsschrauben (f). ning screws (f).
2 Verdrehen Sie den Deckel (a) und lösen Sie ihn vorsichtig 2 Twist the cover (a) and carefully loosen it by tapping it with a
mit leichten Hammerschlägen (Gummihammer). (rubber) hammer.

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3 Entfernen Sie den alten O-Ring (c). Kontrollieren Sie die 3 Remove the old o-ring (c). Check the slot (h) and the
Nut (h) und das Gehäuse (g) auf Verschleiß und Verunreini- housing (g) for wear and dirt.
gungen.
c

h g

4 Setzen Sie einen neuen O-Ring ein und schrauben Sie den 4 Install a new o-ring and screw the cover shut.
linken Deckel fest.
5 Markieren Sie die Lage des rechten Deckels (b), damit Sie 5 Mark the position of the right cover (b) so that you can set it
ihn nach dem Abdichten wieder lagerichtig aufsetzen kön- back to its original position after sealing.
nen.
Messen und notieren Sie das Maß X der Kontermutter (e) für Measure and write down the dimension X of the counter
die spätere Montage. nut (e). You need this for the subsequent assembly.
Entfernen Sie die Kontermutter (e). Halten Sie dazu die Remove the counter nut (e). To do so, grip the positioning
Stellschraube (d) fest. screw (d).
b

e
X
d
X

6 Schrauben Sie den Deckel von der Stellschraube durch 6 Unscrew the cover from the positioning screw.
Drehen ab.

7 Entfernen Sie die beiden O-Ringe (c). Kontrollieren Sie die 7 Remove the two o-rings (c). Check the slots (h) and housing
Nuten (h) und das Gehäuse (g) auf Verschleiß und Verunrei- (g) for wear and dirt.
nigungen.
c

g h
h

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8 Kleben Sie das Gewinde ab, um Beschädigungen des O- 8 Mask the screw thread to avoid damaging the o-ring, and
Rings zu vermeiden, und schieben Sie den kleinen O-Ring push the smaller o-ring up to the designated slot.
bis zur vorgesehenen Nut auf.

9 Setzen Sie den großen O-Ring ein, entfernen Sie die Abkle- 9 Insert the larger o-ring, remove the masking and screw the
bung und schrauben Sie den Deckel fest. cover back on.
10 Schrauben Sie die Kontermutter (e) per Hand ein. Blockie- 10 Screw in the counter nut (e) manually. Block the adjusting
ren Sie die Stellschraube (d) während Sie die Kontermutter- screw (d) while you tighten the counter nut.
festziehen.
Kontrollieren Sie das Maß X nach der Montage. Check the dimension X after assembly.
b

e
X
d
X

Hinweis Note

Nach dem Einbau im Gerät bzw. Prüfstand muss die korrekte After the installation of the unit or the test rig, the correct
mechanische Nulllagen-Einstellung erfolgen, siehe „Überprü- mechnical zero stroke must be adjusted, refer to "Checking",
fungen“ auf Seite 29. page 29.

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Ventildichtungen austauschen Exchanging the valve seals

Hinweis Note

Möglicherweise sind nicht alle in den Zeichnungen gezeigten It is possible that the valves displayed in these illustrations are
Ventile an Ihrer Einheit vorhanden. not all present in your unit.

Hochdruckventil /
High-pressure valve

Niederdruckventil
Low-pressure valve

Um die Ventildichtungen auszutauschen: To exchange the valve seals:

1 Schrauben Sie das Niederdruckventil heraus. 1 Unscrew the low pressure valve.
2 Kleben Sie die Gewinde der Niederdruckventile ab, um 2 Mask the screw thread to avoid damage to the o-rings.
Beschädigungen der O-Ringe zu vermeiden.

3 Setzen Sie die neuen O-Ringe ein, entfernen Sie die Abkle- 3 Insert the new o-rings, remove the masking from the screw
bungen an den Gewinden und schrauben Sie das Nieder- thread, and screw the low pressure valve back in.
druckventil wieder ein.
Ziehen Sie es mit einem Drehmoment von 70 Nm fest. Tighten it with a torque of 70 Nm.
4 Schrauben Sie die Hochdruckventile heraus. 4 Unscrew the high-pressure valves.
Beachten Sie: Bei NG 71–90 gibt es zwei O-Ringe und Note: NG 71–90 have two o-rings and one There are two
einen Stützring, bei NG 125 und 180 nur einen O-Ring. types of this valve: with or without bypass function.
Sicherungskappe / Tamper prof cap

O-Ring
O-Ring

Stützring /
Support ring

O-Ring

NG 71–90 NG 125, 180

008 917 69 BOMAG 651

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5 Entfernen Sie die O-Ringe und den Stützring (NG 71–90) 5 Remove the o-rings and the supprot ring (NG 71–90) and
und kontrollieren Sie das Gehäuse auf Verschleiß und Verun- check the housing for wear and dirt.
reinigungen.
6 Bauen Sie das Hochdruck-Ventil ein und ziehen Sie es mit 6 Install the high-pressure valve and tighten it with a torque of
einem Drehmoment von 150 Nm (NG 71–90) bzw. 200 Nm 150 Nm (NG 71–90) or 200 Nm (NG 125, 180).
(NG 125, 180) fest.

Hinweis Hinweis

Nach dem Einbau muss eine Überprüfung des Hochdrucks Nach dem Einbau muss eine Überprüfung des Hochdrucks
erfolgen, siehe „Überprüfungen“ auf Seite 29. erfolgen, siehe „Überprüfungen“ auf Seite 29.

Dichtung der Druckabschneidung austauschen Exchanging the seals of the pressure cut-off
Um die Dichtung der Druckabschneidung auszutauschen: To exchange the seal of the pressure cut-off:
1 Notieren Sie das Einstellmaß X der Dichtmutter für die späte- 1 Write down the sealing nut's setting dimension X for the
re Montage. subsequent assembly.
2 Bauen Sie die Dichtmutter (a) und die Verschlussschraube 2 Extract the sealing nut (a) and the locking screw (b).
(b) aus.
Entfernen Sie den O-Ring (c). Remove the o-ring (c).
a

b X

3 Setzen Sie einen neuen O-RIng (c) ein. 3 Install a new o-ring (c).
4 Setzen Sie die Verschlussschraube (b) ein und ziehen Sie 4 Install the locking screw (b) and tighten it with a torque of 35
sie mit einem Drehmoment von 35 Nm fest. Nm.
5 Bauen Sie eine neue Dichtmutter (a) ein und stellen Sie das 5 Install the new sealing nut (a) and adjust to the setting
notierte Einstellmaß X ein. measure X that you wrote down previously.
Ziehen Sie die Dichtmutter mit 25 Nm fest. Tighten it with a torque of 25 Nm.

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Dichtung des Regelventils austauschen Exchanging the control valve

b
a

a: Regelventil Control valve

b: O-Ring O-ring

Um die Dichtung am Regelventil auszutauschen: To exchange the control valve:

1 Schrauben Sie das Regelventil (a) aus. 1 Unscrew the control valve (a).
2 Kleben Sie das Gewinde zur Vermeidung von Beschädigun- 2 Mask the screw thread to avoid damaging the o-ring.
gen des O-Rings ab.

3 Schieben Sie den neuen O-Ring auf. 3 Slide the new o-ring on.
4 Entfernen Sie die Abklebung und schrauben Sie das Regel- 4 Remove the masking and screw the control valve back on.
ventil ein.
Ziehen Sie sie mit einem Drehmoment von 50 Nm fest. Tighten them with a torque of 50 Nm.

008 917 69 BOMAG 653

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4.3 Hilfspumpe austauschen 4.3 Exchanging the Auxiliary Pump

Die nachfolgenden Schritte gelten sowohl für den Austausch The following steps apply to the exchange of an auxiliary pump
einer Hilfspumpe als auch für den Austausch eines O-Rings. as well as to the exchange of an o-ring.
Benötigtes Sonderwerkzeug: Keines Required Special Tools: none
Um die Hilfspumpe auszutauschen: To exchange the auxiliary pump:
1 Markieren Sie die Lage des Deckels (a), damit Sie ihn nach 1 Mark the position of the cover (a), so that you can replace it
dem Abdichten wieder lagerichtig aufsetzen können. in its original position after the sealing.

2 Entfernen Sie die vier Befestigungsschrauben (b). 2 Remove the four fastening screws (b).
3 Drücken Sie den Deckel wie gezeigt ab. 3 Press the cover off as illustrated.

4 Entfernen Sie die Hilfspumpe und untersuchen Sie die Teile 4 Remove the auxiliary punp and check the part for wear and
der Hilfspumpe auf Verschleiß und Verunreinigungen. dirt.
Markieren Sie vorher die Lage der Hilfspumpe, damit Sie sie Mark the position of the auxiliary pump beforehand, so that
später wieder lagerichtig einbauen können (sofern Sie die you can return it to its original position afterwards (if you
alte Hilfspumpe weiter verwenden). keep the old auxiliary pump in use).

Hinweis Note

Die Hilfspumpe kann nur komplett ausgetauscht werden. The auxiliary pump can only be exchanged as a whole.

5 Setzen Sie zwei neue O-Ringe (c) ein. 5 Install two new o-rings (c).

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Bosch Rexroth AG

6 Setzen Sie die (neue) Hilfspumpe ein. 6 Install the (new) auxiliary pump.
Achten Sie darauf, dass die angefaste „Seite“ (d) zum De- Pay attention that the chamfered "side" (d) is assembled
ckel (a) montiert wird. facing the cover (a).

d a
d

Hinweis Note

Die Hilfspumpe wird mit Haltestopfen (e) geliefert. Diese wer- The auxiliary pump is delivered with ﬁxing plugs (e). These are
den bei der Montage auf die Anschlussplatte in die entspre- pressed into the bore of the port plate during assembly.
chenden Bohrungen eingepresst.

7 Schrauben Sie den Deckel (a) fest. Beachten Sie dabei die 7 Screw the cover (a) back on. Pay attention to the marking
vorher angebrachte Markierung. made previously.

008 917 69 BOMAG 655

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4.4 Steuergerät austauschen 4.4 Exchanging the Control Unit

Die nachfolgenden Schritte gelten sowohl für den Austausch The following steps apply to the exchange of the whole control
des ganzen Steuergeräts als auch für den Austausch eines O- unit as well as to the exchange of an o-ring.
Rings am Steuergerät.
Benötigtes Sonderwerkzeug: Required Special Tools:
x NG 71: Keines x NG 71: none
x NG 90–180: 2 Hilfsschrauben (Mat.-nr. R02774871) x NG 90–180: 2 auxiliary screws (Mat. no. R02774871)
Hinweis Note

Es gibt eine Vielzahl von Steuergeräten (siehe Abbildung). There exists a multitude of control units (as illustrated).
Bitte beachten Sie, dass hier exemplarisch nur der Austausch Please pay attention to the fact that only the example of an
eines HW Steuergeräts gezeigt wird. HW controller is described here.

alt / old

neu / new alt / old

neu / new
EP
HW alt / old

neu / new

Polrohr
Anziehmoment 19 Nm /
Pole tube
Tightening torque 19 Nm

Anziehmoment 5+1 Nm
Steckschlüssel SW 26 /
Tightening torque 5+1 Nm
26 A/F socket spanner

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Austausch des Steuergeräts bei NG 71 Exchanging the Control Unit with NG 71
Um das Steuergerät bei NG 71 auszutauschen: To exchange the control unit:
1 Entfernen Sie die fünf Befestigungsschrauben (a). 1 Remove all ﬁve fastening screws (a).

2 Drücken Sie das Steuergerät (b) wie gezeigt ab. 2 Press the control unit (b) off as illustrated.

3 Entfernen Sie den O-Ring (c) und die Flachdichtung (e). 3 Remove the o-ring (c) and the gasket (e). Check the sealing
Kontrollieren Sie die Dichtﬂächen (d) auf Beschädigungen surfaces (d) for wear and dirt.
und Verunreinigungen.
Tauschen Sie das Steuergerät bei Bedarf aus. Exchange the control unit if required.

Hinweis Note

Das Steuergerät kann nur komplett ausgetauscht werden. The control unit can only be exchanged as a whole.

d
e
e
d

4 Setzen Sie einen neuen O-Ring (c) und eine neue Flachdich- 4 Insert the new o-ring (c) and the new gasket (e).
tung (e) ein.

008 917 69 BOMAG 657

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5 Setzen Sie das (neue) Steuergerät ein. 5 Insert the new control unit.
6 Zentrieren Sie die Dichtung (e) mit zwei Befestigungsschrau- 6 Center the seal (e) with two fastening screws (a) and install
ben (a) und bauen Sie das Steuergerät ein. the control unit.
Ziehen Sie alle vier Befestigungsschrauben mit halbem Screw all four fastening screws tight with half the torque.
Drehmoment an.
a

a: Befestigungsschraube Fixing screw

b: Steuergerät Control unit
e: Dichtung Seal

7 Setzen Sie die fünfte Schraube (f) ein und ziehen Sie sie mit 7 Insert the ﬁfth screw (f) and tighten it with a torque of
einem Drehmoment von 10,4 Nm fest. 10.4 Nm.
Ziehen Sie die anderen vier Schrauben (a) nach Drehmo- Tighten the other four screws (a) crosswise and according
ment über Kreuz fest. to torque.

Hinweis Note

Nach der Montage des Steuergeräts muss die hydraulische After installing the control unit, the hydraulic zero stroke must
Nulllage neu eingestellt werden (gilt nicht für DA-Regelung), be re-established. This does not apply to DA-control. Please
siehe „Überprüfungen“ auf Seite 33. refer to "Checking", page 33.

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Austausch des Steuergeräts bei NG 90–180 Exchanging the Control Unit with NG 90–180
Hinweis Note

Die folgende Handlungsanweisung behandelt exemplarisch The following instructions show how to exchange an HD
den Austausch eines HD-Steuergeräts. control unit, exemplarily.

Um das HD-Steuergerät bei NG 90–180 auszutauschen: To exchange the HD control unit with NG 90–180:
1 Entfernen Sie die vier Befestigungsschrauben (a). 1 Remove all four fastening screws (a).
Entfernen Sie den Deckel (g) und die Flachdichtung (d). Remove the cover (g) and the gasket (d).

g
d
a

2 Entfernen Sie die zwei Zylinderschrauben (f). 2 Remove the two assembly screws (f).
f

3 Drücken Sie das Steuergerät (b) wie gezeigt ab. 3 Press the control unit (b) off as illustrated.

008 917 69 BOMAG 659

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4 Entfernen Sie die O-Ringe (c). Kontrollieren Sie die Dichtﬂä- 4 Remove the o-rings (c). Check the sealing surfaces for wear
chen auf Beschädigungen und Verunreinigungen. and dirt.
Tauschen Sie Steuergerät bei Bedarf aus. Exchange the control unit if required.
Hinweis Note

Das Steuergerät kann nur komplett ausgetauscht werden. The control unit can only be exchanged as a whole.

c
d

5 Setzen Sie neue O-Ringe (c) und eine neue Flachdichtung 5 Insert the new o-rings (c) and the new gasket (d).
(d) ein.
6 Setzen Sie das (neue) Steuergerät (b) ohne Deckel auf. 6 Insert the (new) control unit (b) without cover.
Schrauben Sie das Steuergerät diagonal mit zwei Hilfs- Tighten the control unit with two auxiliary screws (e) (special
schrauben (e) (Sonderwerkzeug) an (mit 7 Nm). tools) diagonally (with a torque of 7 Nm).
Schrauben Sie es mit zwei Zylinderschrauben (f) an (mit Fix it with two assembly screws (f) (with a torque of
10,4 Nm). 10,4 Nm).
f e

7 Entfernen Sie die Hilfsschrauben (e) wieder. 7 Remove the auxiliary screws (e).
8 Kontrollieren Sie, ob die Zugfedern richtig in den Kerben des 8 Make sure that both spring catches are hooked to the pair of
Hebelpaares eingehängt sind. leavers.

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9 Setzen Sie den Deckel (g) mit der Dichtung (d) auf und 9 Put on the cover (g) with the gasket (d) and ﬁx it with the
schrauben Sie ihn mit den vier Befestigungsschrauben fest. four fastening screws.
Ziehen Sie die schrauben mit 10,4 Nm fest. Tighten the screws with a torque of 10,4 Nm.
a

g
d

Hinweis Note

008 917 69 BOMAG 661

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5 Überprüfungen 5 Checking
Bei der ersten Inbetriebnahme nach einer Reparatur müssen When starting up for the ﬁrst time after a repair, you must
Sie die ursprünglichen Einstellungen der Verstellpumpe kontrol- check the original settings of the variable pump. This chapter
lieren. Dieses Kapitel erklärt folgende Überprüfungen: describes the following checkings:
• Niederdruck • Low pressure
• Hochdruck • High pressure
• Mechanische Nulllage • Mechanical zero stroke
• Hydraulische Nulllage • Hydraulic zero stroke
Hinweis Note

Führen Sie alle Überprüfungen bei Betriebstemperatur durch. Carry out checkings at operating temperature.

Hinweis Note

Wenn die überprüften Werte von den ursprünglichen Einstel- If the checked values differ from the original settings, please
lungen abweichen, setzen Sie sich bezüglich der Einstellung contact Rexroth in terms of adjusting the settings.
bitte mit dem Rexroth-Service in Verbindung.

! WARNUNG ! WARNING

Verletzungsgefahr Danger of injuries

Arbeiten an der Verstellpumpe bei Betriebstemperatur sind Working on the variable pump at operating temperature is
gefährlich. dangerous.
x Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“ x Pay exact attention to the safety advice (refer to "Safety",
auf Seite 7). page 7).

! WARNUNG ! WARNING

Gefahr von Verschleiß und Funktionsstörungen Danger of wear and malfunction

Die Sauberkeit der Druckﬂüssigkeit und die Lebensdauer der The durability of the hydraulic unit depends to a great extent
Hydraulikanlage stehen in unmittelbarem Zusammenhang. on how clean the unit is kept.
x Achten Sie bei Überprüfungen darauf, dass Messanschlüs- x When checking settings, you should make sure that gauge
se, Schläuche und Messgeräte sauber sind. Reinigen Sie ports, hydraulic conduits, and und gauges are clean. Clean
diese gründlich bevor Sie die Messpunkte öffnen und mit these thoroughly before you open gauge ports and begin
den Einstellarbeiten beginnen. adjusting settings.
x Stellen Sie sicher, dass auch beim nachfolgenden Verschlie- x After that, when sealing the ports, make sure that contami-
ßen der Messpunkte keine Verunreinigungen eindringen. nating elements cannot enter the system.

008 917 69 BOMAG 663

34/40
24.2
Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180
Travel pump
RDE 92 003-21-R/01.06

5.1 Niederdruck (Speisedruck) überprüfen 5.1 Checking Low Pressure (Charge Pressure)
Dieser Abschnitt erklärt, wie Sie ND-Ventile überprüfen. This section describes how to check the low pressure valves.
Um den Niederdruck zu überprüfen: To check the low pressure:
1 Schließen Sie wie gezeigt ein Manometer an Anschluss G 1 Connect a manometer to connection G as displayed.
an.

bei DA-
Ausführung /
with DA
version

2 Überprüfen Sie den Niederdruck (G). 2 Check the low pressure (G):

Hinweis Note

Die genauen Einstelldaten entnehmen Sie dem Technischen Refer to the catalog sheet RE 92 003 and your speciﬁcation
Datenblatt RD 92 003 und Ihrer Speziﬁkation. for the detailed setting data.

5.2 Hochdruck überprüfen 5.2 Checking the High Pressure

Die Begrenzung des Hochdrucks erfolgt über die Druckab- The limitation of the operating pressure is performed by a high
schneidung. Zusätzlich ist ein Hochdruckbegrenzungsventil pressure relief valve. Additionally, a high pressure relief valve
(Sicherheitsventil) überlagert. Der Druckwert der Druckab- (safety valve) is in superposition. The pressure value of the
schneidung liegt ca. 10 % unter dem Wert des Hochdruckbe- pressure cut-off is 10 % below that of the high pressure relief
grenzungsventils. valve.
Es kann also nur der Druckwert der Druckabschneidung über- Therefore, only the pressure value of the pressure cut-off can
prüft werden. be measured.
Hinweis Note

Die genauen Einstelldaten entnehmen Sie Ihrer Speziﬁkation. Refer to your speciﬁcation for the detailed setting data.

664 BOMAG 008 917 69

Travel pump
RDE 92 003-21-R/01.06 Reparaturanleitung/Repair Manual A4VG 71–180
24.235/40
Bosch Rexroth AG

5.3 Mechanische Nulllage überprüfen 5.3 Checking the Mechanical Zero Stroke
Dieser Abschnitt erklärt, wie Sie die mechanische Nulllage bei This section describes how to check the mechanical zero stro-
HW-, HD-, EP- und DA-Steuergeräten überprüfen. ke for HW, HD, EP, and DA controllers.

HW HD EP DA

! WARNUNG ! WARNING

Verletzungsgefahr Danger of injuries

Die im Folgenden beschriebenen Arbeiten an der Verstellpum- The following procedures carried out on the variable pump are
pe sind gefährlich. dangerous.
x Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“ x Please pay attention to the safety advice (refer to "Safety",
auf Seite 7). page 7).
x Blockieren Sie das Fahrzeug bzw. entlasten Sie die Anlage x Block the machinery or unit before you carry out the installa-
bevor Sie die Einstellarbeiten durchführen. tion.

mind. / at least
Nennweite 6 / Nominal Width 6

Messbereich/
Metering range
0 ... 600 bar

Um die mechanische Nulllage zu überprüfen: To check the mechanical zero stroke:

1 Verbinden Sie beide Stellkammern über einen Schlauch mit 1 Connect the two position chambers with a hose (with at
mindestens Nennweite NW6. least nominal width NW6).
Dadurch stellen Sie sicher, dass ein Restsignal aus dem Thus, you ensure that a residual signal from the controller
Steuergerät keine Auswirkung auf die Einstellung der me- has no inﬂuence on the setting of the hydraulic zero stroke.
chanischen Nullage hat.
2 Schließen Sie an die Messanschlüsse MA und M B Manome- 2 Connect manometers to the measuring ports MA and M B.
ter an.
3 Überprüfen Sie, ob bei blockiertem Antrieb beide Manometer 3 Check if both manometers show the same pressure value
den gleichen Druckwert anzeigen. when the unit is blocked.

008 917 69 BOMAG 665

24.2
36/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180
Travel pump
RDE 92 003-21-R/01.06

5.4 Hydraulische Nulllage überprüfen 5.4 Checking the Hydraulic Zero Stroke
Dieser Abschnitt erklärt, wie Sie die hydraulische Nulllage bei This section describes how to check the hydraulic zero stroke
HW-, HD- und EP-Steuergeräten überprüfen. for HW, HD, and EP controllers.

! WARNUNG ! WARNING

Verletzungsgefahr Danger of injuries

Die folgenden Arbeiten an der Verstellpumpe sind gefährlich. The following procedures carried out on the variable pump are
dangerous.
x Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“
auf Seite 7). x Pay attention to the safety advice (refer to "Safety",
page 7).
x Blockieren Sie das Fahrzeug bzw. entlasten Sie die Anlage x Block the machinery or unload the unit before you procede
bevor Sie die Einstellarbeiten durchführen. with the installation.

HW HD EP

Messbereich/
Metering range
0 ... 60 bar

Um die hydraulische Nulllage zu überprüfen: To check the hydraulic zero stroke:

1 Schließen Sie an die Anschlüsse X1 und X2 Manometer an. 1 Connect manometers to the ports X1 und X2.
2 Überprüfen Sie, ob bei blockiertem Antrieb beide Manometer 2 Check if both manometers show the same pressure value
den gleichen Druckwert anzeigen. when the unit is blocked

Hinweis Note

Verdrehen Sie die Exzenterjustierung (a) am Steuergerät nicht Never turn the eccentric calibration (a) of the controller over
über ±90°. ±90 degrees.

666 BOMAG 008 917 69

Travel pump
RDE 92 003-21-R/01.06 Reparaturanleitung/Repair Manual A4VG 71–180
24.237/40
Bosch Rexroth AG

008 917 69 BOMAG 667

24.2
38/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180
Travel pump
RDE 92 003-21-R/01.06

668 BOMAG 008 917 69

Travel pump
RDE 92 003-21-R/01.06 Reparaturanleitung/Repair Manual A4VG 71–180
24.239/40
Bosch Rexroth AG

008 917 69 BOMAG 669

24.2 Travel pump

Bosch Rexroth AG
Hydraulics
Produktsegment
Axialkolbenmaschinen
Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72-74
info.brm-ak@boschrexroth.de
www.boschrexroth.com/brm

© This document, as well as the data, © Alle Rechte bei Bosch Rexroth AG,
specifications and other information auch für den Fall von Schutzrechtsan-
set forth in it, are the exclusive proper- meldungen. Jede Verfügungsbefugnis,
ty of Bosch Rexroth AG. It may not be wie Kopier- und Weitergaberecht,
reproduced or given to third parties bei uns.
without its consent.
Die angegebenen Daten dienen
The data specified above only serve to allein der Produktbeschreibung.
describe the product. No statements Eine Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
information given does not release werden. Die Angaben entbinden
the user from the obligation of own den Verwender nicht von eigenen
judgment and verification. It must be Beurteilungen und Prüfungen. Es ist
remembered that our products are
zu beachten, dass unsere Produkte
subject to a natural process of wear
einem natürlichen Verschleiß- und
and aging.
Alterungsprozess unterliegen.
Subject to change. Änderungen vorbehalten.

Printed in Germany
RDE 92 003-21-R/01.06

670 BOMAG 008 917 69

24.3 Travel motor

008 917 69 BOMAG 671

24.3 Travel motor

This repair manual describes the fixed displacement motor A6VM, which is identical with the travel motor A6VE,
which differs only by a different housing design.

672 BOMAG 008 917 69

Travel motor 24.3
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

RDE 91 604-01-R/03.03
Verstellmotor A6VM 28...200 ersetzt/replaces 08.01

Variable Displ. Motor A6VM 28...200

Reparaturanleitung / Repair Instructions

008 917 69 BOMAG 673

24.3 Bosch Rexroth AG | Mobile Hydraulics
2 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Typschlüssel
Typschlüssel A6V M / 6 3 W
Axialkolbenmaschine
Schrägachsenbauart, verstellbar A6V
Betriebsart
Motor (Einschubmotor A6VE siehe RD 91606) M
Nenngröße
≅ Schluckvolumen Vg max (cm3) 28 55 80 107 140 160 200
NG 28...200: Fertigung Werk Elchingen
Regel- und Verstelleinrichtung 28 55 80 107 140 160 200
Hydraulische Verstellung Steuerdruckanstieg 10 bar HD1 HD1 *
steuerdruckabhängig 25 bar HD2 HD2 *
35 bar HD3 – – – – – – – HD3 *
Hydraulische Zweipunktverstellung HZ – – – – – – – HZ .
HZ1 – – – HZ1 *
HZ3 – – – – HZ3
Elektrische Verstellung, Steuerspannung 12 V EP1 EP1 *
mit Proportionalmagnet 24 V EP2 EP2 *
Elektrische Steuerspannung 12 V EZ1 – – – EZ1 *
Zweipunktverstellung, 24 V EZ2 – – – EZ2 *
mit Schaltmagnet 12 V EZ3 – – – – EZ3
24 V EZ4 – – – – EZ4
Automatische Verstellung, ohne Druckanstieg HA1 HA1 *
hochdruckabhängig mit Druckanstieg Δp = 100 bar HA2 HA2 *
Hydraulische Verstellung, drehzahlabhängig DA – – – – – – – DA *
pSt/pHD = 5/100, hydraulisches Fahrtrichtungsventil DA1 DA1 *
elektrisches Fahrtrichtungsventil 12 V DA2 DA2 *
+ elektrische Vg max-Schaltung 24 V DA3 DA3 *
pSt/pHD = 8/100, hydraulisches Fahrtrichtungsventil DA4 DA4 *
elektrisches Fahrtrichtungsventil 12 V DA5 DA5 *
+ elektrische Vg max-Schaltung 24 V DA6 DA6 *
Druckregelung (nur für HD, EP) 28 55 80 107 140 160 200
ohne Druckregelung (kein Zeichen)
Druckregelung, direktgesteuert D
direktgesteuert, mit 2. Druckeinstellung E
fernsteuerbar – – – – – – – G
Übersteuerung der HA-Verstellung (nur für HA1, HA2)
ohne Übersteuerung (kein Zeichen)
hydraulische Übersteuerung T
elektrische Übersteuerung Steuerspannung 12 V U1
24 V U2
elektrische Übersteuerung Steuerspannung 12 V R1
+ elektrisches Fahrtrichtungsventil 24 V R2

* Differentialkolben Gleichgangkolben

674 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.33
Type code
Type code A6V M / 6 3 W
Axial piston unit
Bent axis design, variable displacement A6V
Mode of operation
Motor (plug-in motor A6VE see RE 91606) M
Size
≅ Displacement Vg max (cm3) 28 55 80 107 140 160 200
Sizes 28...200: production plant Elchingen
Control device 28 55 80 107 140 160 200
Hydraulic control pilot pressure increase 10 bar HD1 HD1 *
pilot pressure related 25 bar HD2 HD2 *
35 bar HD3 – – – – – – – HD3 *
Hydraulic two-position control HZ – – – – – – – HZ .
HZ1 – – – HZ1 *
HZ3 – – – – HZ3
Electrical control, control voltage 12 V EP1 EP1 *
with proportional solenoid 24 V EP2 EP2 *
Electrical control voltage 12 V EZ1 – – – EZ1 *
two-position control, 24 V EZ2 – – – EZ2 *
with switching solenoid 12 V EZ3 – – – – EZ3
24 V EZ4 – – – – EZ4
Automatic control, without pressure increase HA1 HA1 *
high pressure related with pressure increase Δp = 100 bar HA2 HA2 *
Hydraulic control, speed related DA – – – – – – – DA *
pSt/pHD = 5/100, hydraulic valve for travel direction DA1 DA1 *
electrical valve for travel direction 12 V DA2 DA2 *
+ electrical Vg max-switch 24 V DA3 DA3 *
pSt/pHD = 8/100, hydraulic valve for travel direction DA4 DA4 *
electrical valve for travel direction 12 V DA5 DA5 *
+ electrical Vg max-switch 24 V DA6 DA6 *
Pressure control (only for HD, EP) 28 55 80 107 140 160 200
without pressure control (no code)
Pressure control, direct control D
direct control, with 2nd pressure setting E
remote control – – – – – – – G
Override of HA-control (only for HA1, HA2)
without override (no code)
Hydraulic override T
Electrical override control voltage 12 V U1
24 V U2
Electrical override control voltage 12 V R1
+ el. valve for travel direction 24 V R2

* Differential piston Synchronizing piston

008 917 69 BOMAG 675

24.3 Travel motor

676 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.35
Schnittbild
Sectional drawing

A6VM 55-107 HZ3

A B

max. min.

X T

A6VM 55-107 EZ3

A B

max. min.

A6VM 55-107 HA3

A B

max. min.

A6VM 55-107 HA3U

A B

max. min.

008 917 69 BOMAG 677

24.3 Bosch Rexroth AG | Mobile Hydraulics
6 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Schnittbild
Sectional drawing

A6VM 28-200 HD

A B

max min

X
G

M1 T(T1)

A6VM 28-200 HD
mit Spülventil / with flushing valve

A B

max min

M1 T(T1)

A6VM 28-200 HD1D

mit Druckregelventil / with pressure
control valve

A B

max min

X
G

M1 T(T1)

678 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.37
Schnittbild
Sectional drawing

A6VM 28-200 EP

A B

max min

M1 T(T1)

A6VM 28-200 EP./..A

A B

max min

T(T1) M1

A6VM 28-200 EP./..A

A B

max min

T(T1) M1

008 917 69 BOMAG 679

24.3 Bosch Rexroth AG | Mobile Hydraulics
8 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Schnittbild
Sectional drawing

A6VM ... DA1

Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.

Replace all seals.

Use only OR IG I NAL B R U E N I NG HAUS
HYDROMATIK spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.

Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.

Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befüllen.

Fill up hydraulic aggregates with medium

before start- up.

682 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
11

Dichtsätze und Baugruppen

Seal kits and sub assembly groups

Dichtsatz für Triebwelle.

Seal kit for drive shaft.

Äußerer Dichtsatz.

External seal kit.

Gehäuse

Housing

Triebwerk komplett
Hinweis: Pos. 1 - Für Anschlußplatte mit
Pos. 2 Differentialkolben
Pos. 2 - Für Anschlußplatte mit
Gleichgangkolben

Complete rotary group

Note: Pos. 1 - For port plate with differential
piston
Pos. 2 - For port plate with
synchronizing piston
Pos. 1

Pos. 1 Pos. 2 Anschlußplatte mit Stellkolben

Hinweis: Pos. 1 - Für Anschlußplatte mit
Differentialkolben
Pos. 2 - Für Anschlußplatte mit
Gleichgangkolben

Port plate with control piston

Note: Pos. 1 - For port plate with differential
piston
Pos. 2 - For port plate with
synchronizing piston

008 917 69 BOMAG 683

24.3 Bosch Rexroth AG | Mobile Hydraulics
12 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Dichtsätze und Baugruppen

Seal kits and sub assembly groups

Schaltmagnet / Proportionalmagnet

Solenoid

Deckel mit * Drosselstift.

* Drosselstift "Auftragsbezogen".
* Cover with * throttle pin.
* Throttle pin "as to order requirement".
*
*

*
*
Deckel mit Spül- und Speisedruckventil
* und * Drosselstift
* Drosselstift "Auftragsbezogen".
Cover with flushing and boost pressure valve
and * throttle pin.
* Throttle pin "as to order requirement".

684 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
13

Baugruppen / Steuerteile
Component groups / Control components

z. B. HA EP

HA2
Auftrags-
bezogen *
"as to order
DA
requirement".

008 917 69 BOMAG 685

24.3 Bosch Rexroth AG | Mobile Hydraulics
14 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Baugruppen / Steuerteile
Component groups / Control components

z. B. HZ3 / EZ3

HA3 / HA3U

686 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
15

Dichtmutter austauschen
Replace seal nut

Dichtmutter austauschen.
Zuerst Maß X messen und festhalten.

Replace seal nut.

First measure and record setting height.

Maß X

Beim Anziehen Einstellschraube gegenhalten,

anschließend Einstellhöhe kontrollieren.

When tightening, counterhold setting screw, then

check setting height.

008 917 69 BOMAG 687

24.3 Bosch Rexroth AG | Mobile Hydraulics
16 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Triebwelle abdichten
Sealing of the drive shaft

Triebwelle abkleben.
Sicherungsring und Scheibe ausbauen.

Protecting the drive shaft.

Remove retaining ring and shim.

Blechschraube in die mit Gummi gefüllten

Löcher eindrehen.
Mit Zange WDR herausziehen.

Screw in sheet metal screw into the holes

fitted with rubber.
Pull out seal with pliers.

Wellendichtring und Scheibe mit Montagehülse

einpressen.
Zwischen Dicht- und Staublippe, Wellendichtring
* leicht einfetten
Einpresstiefe beachten! * Marke für Einpresstiefe.
Sicherungsring einbauen.

Press in shaft seal ring and shim with bush to stop.

Take note of press-in depth!
Lightly grease the seal, dust lips and shaft seal ring.
Install * mark for press-in depth of safety ring.

688 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
17

Steuerteile abdichten
Sealing of the control parts

Achtung!
Federvorspannung

1 Attention!
Spring load

1. Deckel / Cover
2. Steuerteil / Control part
1
Kontrolle
Bohrung im Gehäuse, O-Ring, Nut.

Inspect
Drilling in housing, O-ring, groove.

Einstellschraube nicht ausbauen.

2 Kontrolle
O-Ring, O-Ring-Nut, Gehäuse

Do not remove adjustment screw.

Inspect
O-ring, O-ring groove, housing

Montagehilfe
Stift mit Fett einkleben.

2 Assembly aid
Insert pin with grease.

008 917 69 BOMAG 689

24.3 Bosch Rexroth AG | Mobile Hydraulics
18 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Verstellung abdichten
Sealing the hydraulic control

Beispiel: A6VM ... HD Verstellung

Demontageposition:
Deckel Pos. 1 abbauen.

Example: A6VM ... HD control

Pos.1 Disassembly position:
Remove cover pos. 1

1
1. O-Ring
2
2. Stellölzulauf
3. Drosselstift
Einbaulage je nach Steuerteil verschieden.

1. O-ring
2. Input flow of oil control
3. Throttle pin
Installation position differs according to the
3 control components

1
5
1. Stellölzulauf / Input flow of oil control
2 3 2. Hochdruck bzw. Niederdruck / High pressure /
low pressure
3. Hochdruck bzw. Niederdruck / High pressure /
low pressure
4. Lecköl / Leckage oil
4 5. Stellkolben / Control piston

690 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
19

Verstellung abdichten
Sealing the hydraulic control

Pos. 2

Beispiel: A6VM ... Verstellung - Differentialkolben

Demontageposition: Deckel Pos. 2 abbauen.
Achtung! Federvorspannung.
Maß x: Maß festhalten (Regelbeginn).
x
Example: A6VM... control - differential piston
Disassembly position: Remove cover pos. 2.
Attention! Spring load.
Dimension x: Note dimension (begin of regulation).

1. O-Ring Kontrolle

1. Check of O-ring

1
2 1. Hochdruck - kleine Stellkolbenseite
* 2. Stelldruck
3. Hochdruck - Rückschlagventil
4. Hochdruck - Rückschlagventil
* siehe Serviceinfo

1. High pressure - small control piston side

2. Control pressure
3
4 3. High pressure - check valve
4. High pressure - check valve
* see serviceinfo

008 917 69 BOMAG 691

24.3 Bosch Rexroth AG | Mobile Hydraulics
20 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Abschlußplatte demontieren
Disassembly of the port plate

x Differentialkolben:
Maß X festhalten.

Differential piston:
Note dimension x

Bei "Demontage" der Anschlußplatte

"Triebwerk" immer auf Null schwenken.
Kolbenringe hängen aus der Zylinder-
bohrung aus.

For disassembly of the port plate, swivel

always rotary group to zero position.
Piston rings to hang out of the cylinder
boring.
Qmin-Schraube
Qmin-screw

Qmin-Schraube ausbauen.
Triebwerk auf 0o schwenken.

Remove Qmin-screw.
Swivel rotary group to 0o.

692 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
21

Abschlußplatte demontieren
Disassembly of the port plate

x Gleichgangkolben:
Maß X festhalten.

Synchronizing piston:
Note dimension x.

Bei "Demontage" der Anschlußplatte "Triebwerk"

immer auf Null schwenken.
* Kolbenringe hängen sonst aus der Zylinder-
bohrung aus.
Qmin-Schraube
For disassembly of the port plate, swivel always
Qmin-screw
rotary group to zero position.
* Piston rings to hang out of the cylinder boring.

Qmin-Schraube und Verschlußschraube ausbauen.

Remove Qmin-screw and plug.

Mit Schraube Qmin Triebwerk auf 0o schwenken.

Swivel rotary group to zero position with screw Qmin

008 917 69 BOMAG 693

24.3 Bosch Rexroth AG | Mobile Hydraulics
22 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Abschlußplatte demontieren
Disassembly of the port plate

Anschlußplatte
Lage markieren. Schrauben lösen.
Abbauen

Port plate
Mark position. Loosen screws.
Removal

O-Ring austauschen.
Neuer O-Ring mit etwas Fett einkleben.
Triebwerk nicht ausschwenken.
Kolbenringe hängen aus der Zylinderbohrung aus.

Check O-ring.
Stick new O-ring with some grease.
Do not swivel rotary group.
Piston rings to hang out from the cylinder boring.

Steuerlinse in Gleitbahn mit Fett einkleben.

Fertigmontage in umgekehrter Reihenfolge.
Anschlußplatte aufsetzen.
Triebwerk senkrecht.

Stick control lens in sliding surface with grease.

Assembly in reversal order.
Mount port plate.
Rotary group vertical.

694 BOMAG 008 917 69

Travel motor 24.3

008 917 69 BOMAG 695

24.3 Travel motor

696 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
25

Triebwerk ausbauen
Remove rotary group

Gewindestift in Mittelzapfen einschrauben,

mit Schutzscheibe und Mutter Zylinder befestigen.
Qmax - Anschlagschraube ausbauen.

Screw in threaded pin into center pin.

Fix the cylinder with disc and locknut.
Remove Qmax -stop screw.

Nenngröße / Size 28 : M4 x 60 mm
55 : M5 x 80 mm
80 : M6 x 90 mm
107 : M6 x 100 mm
140 : M8 x 110 mm
160 : M8 x 110 mm
200 : M8 x 110 mm

Triebwerk auspressen!
Bei Wiederverwendung der Lager nicht schlagen.

Press out rotary group!

If the bearings are used again do not hit on the drive
shaft.

008 917 69 BOMAG 697

24.3 Bosch Rexroth AG | Mobile Hydraulics
26 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Triebwerk ausbauen
Remove rotary group

Oder mit Abziehvorrichtung ausdrücken.

Or press-out with extraction device.

698 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
27

Triebwerk austauschen
Exchanging of the rotary group

eingepresst
pressed in
Triebwerk komplett
Abstimmung hydraulischer
Teil notwendig.

Complete rotary group

Setting of hydraulic part
necessary.

Triebwerk Baugruppe
1.Mechanischer Teil: Triebwelle mit Lager abgestimmt.
2.Hydraulischer Teil: Abstimmung notwendig *.

Rotary group
1. Mechanical part: Adjust drive shaft with bearing.
2. Hydraulic part: Adjustment necessary *.

Triebwerk: Alle Bauteile

* Abstimmung
Abstimmwerte, Drehmomente siehe Serviceinfo.

Rotary group: All parts

* Setting
Setting value, torque see service information.

008 917 69 BOMAG 699

24.3 Bosch Rexroth AG | Mobile Hydraulics
28 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Triebwerk austauschen
Exchanging of the rotary group

Befestigungsschraube (Zylinder) ausbauen.

Zylinder abheben.

Remove fixing screw (cylinder).

Remove cylinder.

Rückzugplatte demontieren.
Schrauben sind eingeklebt. Nach Erwärmen auf
max 120o C mit Torx-Werkzeug demontieren.

Disassemble retaining plate.

Screws are glued. Warm it up to max. 120o C
and remove with Torx-tools.

700 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
29

Überprüfungshinweise
Inspection notes

Kein Passungsrost, nicht ausgeschlagen.

Free of corrosion, erosion or fretting;

no damage to splines or keyways.

Kolben
Riefenfrei und keine Pittings.

Pistons
No scoring and no pittings.

1 2

Mittelzapfen
Riefenfrei und keine Pittings.

Center pin
No scoring and no pittings.

Rückzugplatte
Riefenfrei und keine Ausbrüche.

Retaining plate
No scoring and no evidence of wear

Zylinder / Steuerlinse
1 Bohrungen riefenfrei, nicht ausgelaufen.
2 Gleichmäßiges Tragbild, riß- und riefenfrei.

Cylinder block / control lens

1 Bores free of scoring, no evidence of wear.
2 Faces smooth and even, free of cracks
and scoring.

008 917 69 BOMAG 701

24.3 Bosch Rexroth AG | Mobile Hydraulics
30 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Überprüfungshinweise
Inspection notes

Reglergehäuse
Gleitbahn und Seitenführung riefenfrei,
nicht ausgelaufen.

Control housing
Sliding surface and side guides free of scoring
and no wear.

Sichtkontrolle:
Im Lagerbereich riefenfrei und keine Einlaufspuren.

Visual check:
Bearing areas free of scoring and no evidence
of wear.

702 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
31

Triebwerk montieren / siehe Serviceinformation

Rotary group assembly / see service information

Triebwelle: mechanischer Teil

Rotary group: mechanical part

1 Abstimmung Maß * und Lagerdrehmomente

siehe Serviceinfo.

2
* Adjustment dimension * and bearing torque
see service infoprmation.

Lager aufpressen.
Beim Aufpressen Lagerdrehmoment nicht
überschreiten.

Press on bearing.
Do not exeed bearing torque during press-on.

BOJH
GG
DRTT
GHE

000
000
BOJH
GG
DRTT
GHE

Lager mit Montagehülse vorspannen und laufende Drehmomentenkontrolle.

Preload bearing with assembly sleeve and steady control of the torque.

008 917 69 BOMAG 703

24.3 Bosch Rexroth AG | Mobile Hydraulics
32 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Triebwerk montieren
Rotary group assembly

Sicherungsring 1 montieren.
Maß * für Abstimmscheibe mit Endmaß ermitteln
(überkreuz).
Abstimmscheibe einbauen.
Sicherungsring montieren.

1 Assemble safety ring.

Determine dimension * for adjustment disc with fi-
* nal dimensions (crossover)
Install adjustment shim.
Assemble safety ring.

Triebwelle einbaufertig.

Drive shaft ready for assembly.

704 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
33

Triebwerk montieren
Rotary group assembly

Rückzugplatte mit Kolben und Mittelzapfen

einsetzen.
Schrauben mit Precote-Beschichtung verwenden.
(Anziehdremoment siehe Seite 42).

Insert retaining plate with piston and center pin.

Use screw with Precote-coating.
(Tightening torque see page 42).

Auf richtige Schichtung aller Teile achten.

Make sure all parts are fitted in correctly.

Triebwerk auf Null schwenken und Zylinder mit

Gewindestift befestigen. (siehe Seite 25)

Swivel cylinder block to zero position and fix the

cylinder with a threaded pin (see page 25)

008 917 69 BOMAG 705

24.3 Bosch Rexroth AG | Mobile Hydraulics
34 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Triebwerk montieren
Rotary group assembly

Triebwerk komplett zum Einbau fertig.

Rotary group completely assembled ready

for assembly.

Montagehülse montieren.

Place assembly sleeve.

Gehäuse auf 80oC erwärmen.

Warm up housing to 80oC.

706 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
35

Triebwerk montieren
Rotary group assembly

Triebwerk ins Gehäuse auf Anschlag einsetzen.

Insert rotary group into housing to seat position.

Nach Einbau des Triebwerks im Gehäuse ist die

Triebwelle bis auf Anschlag nach vorne zu ziehen.

Pull the drive shaft after rotary groupassembly into

housing to seat position.

2 1

Zylinder in Nullposition
ausrichten.
1. Zylinderbefestigungsschraube
demontieren.
2. O-Ring einsetzen.

Fix zero position of cylinder

with Qmax-screw.
1. Disassemble cylinder
fixing screw.
2. Insert O-ring.

008 917 69 BOMAG 707

24.3 Bosch Rexroth AG | Mobile Hydraulics
36 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Triebwerksabstimmung (siehe Serviceinfo)

Rotary group adjustment (see service information)

Mit Schraube Zylinderausschwenkung

vermitteln.

Determine cylinder swivel range to

max. angle with screw.

* * Scheibe
* Disc

Zentrierscheibe aufsetzen.

Place centering disc.

Meßvorrichtung aufbauen.

Mount measuring device.

Maß X überprüfen.

Check dimension X.

708 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
37

Abschlußplatte montieren
Assembly of the port plate

1. Anschlußplatte mit Differential-

* kolben montieren.
Montageausführung beachten!
Befestigungsschrauben mit
Drehmoment anziehen.
2. Triebwerk in "Ausgangsstellung"
schwenken.
3. Qmin -Schraube auf
Maß * einstellen.
4. Verschlußschraube einbauen.
5. Montagehülse demontieren.

1. Assemble port plate with

differential piston.
Take care of assembly design!
Tighten fixing screws
with torque.
2. Swivel rotary group to "starting
position".
3. Set Qmin -screw to
dimension*.
4. Assemble plug.
5. Remove assembly sleeve.

Deckel montieren.

Assemble cover.

Steuerteil montieren.
x
Assemble control components.

008 917 69 BOMAG 709

24.3 Bosch Rexroth AG | Mobile Hydraulics
38 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Anschlußplatte montieren
Assembly of the port plate

1. Anschlußplatte mit Gleichgang-

kolben montieren.
Montageausführung beachten!
Befestigungsschrauben mit
* Drehmoment anziehen.
2. Triebwerk in "Ausgangsstellung"
schwenken.
3. Qmin -Schraube auf Maß * einstellen.
4. Verschlußschraube einbauen.
5. Montagehülse demontieren.

1. Assemble port plate with

synchronizing piston.
Take care of assembly design!
Tighten fixing screws
with torque.
2. Swivel rotary group to "starting
position".
3. Set Qmin -screw to dimension*.
4. Assemble plug.
5. Remove assembly sleeve.

Wellendichtring, Scheiben und Sicherungsring

montieren.
Mit Montagehülse einpressen.
Dicht- und Staublippe, Wellendichtring leicht
einfetten.
Einpresstiefe beachten!

Assemble shaft seal, disc and safety ring.

Press-in with assembly sleeve.
Lightly grease the seal, dust lips and shaft seal ring.
Take care of press-in depth.

710 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
39

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)

Die Werte gelten für Schaftschrauben mit metrischen The values stated are valid for bolts with metric ISO threads
ISO-Gewinde nach DIN 13 Teil 13, sowie Kopfauflage- to DIN 13 part 13, as well as head areas to DIN 912 socked
maßen nach DIN 912 Zylinderschrauben, DIN 931 head cap screws, DIN 931 hexagon bolt or
Sechskantschrauben mit Schaft bzw. DIN 933 hexagon bolts with threads up to the head.
DIN 933 Sechskantschrauben mit Gewinde bis Kopf.

Festigkeitsklassen / Tensile strength class

Gewinde / Thread 8.8 10.9 12.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 1,1 1,6 1,9
M4 3,1 4,5 5,3
M5 6,1 8,9 10,4
M6 10,4 15,5 18
M8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240

008 917 69 BOMAG 711

24.3 Bosch Rexroth AG | Mobile Hydraulics
40 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).

G
EOLASTIC-
Dichtung / Seal

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1,5 20 G 3/8 A 35
M14 x 1,5 30 G 1/2 A 60
M16 x 1,5 35 G 3/4 A 90
M18 x 1,5 40 G1 A 140
M20 x 1,5 50 G 1 1/4 A 240
M22 x 1,5 60 G 1 1/2 A 300
M26 x 1,5 70
M27 x 2 90
M30 x 1,5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300

712 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
41

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

5. Verschlußschrauben mit Innensechskant, 5. Plugs with internal hexagon, O-ring and UNF-,
O-Ring und UNF-, UN-Gewinde nach SAE J 514 UN- threads to SAE J 514 (nach N 02.106)
(nach N 02.106)

G
O-Ring / O-ring seal
Dichtung / Thread

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
7/16 - 20 UNF 15 M12 x 1,5 20
1/2 - 20 UNF 20 M14 x 1,5 30
9/16 - 18 UNF 25 M27 x 1,5 90
3/4 - 16 UNF 72
7/8 - 14 UN 127
1 1/16 -12 UN 147
1 3/16 -12 UN 173
1 5/16 -12 UN 198
1 5/8 -12 UN 320
1 7/8 -12 UN 390

008 917 69 BOMAG 713

24.3 Bosch Rexroth AG | Mobile Hydraulics
42 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

6. Linsenschrauben mit Innen-TORX, Gewindevor- 6. Oval head screw with inner TORX, thread precoated with
beschichtung mit "precote" "precote"

precote 80 - Rot / Red

Standard / Standard

precote 86 - Blau / Blue

Variante / Variant
* * mit Unterkopfbeschichtung - farblos
Ι 2602493 M5 x 16
Ι 2602395 M6 x 20
* with head bottom coating - colorless
siehe Stückliste / as to parts list

Festigkeitsklassen / Tensile strength class

Gewinde / Thread 10.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 2,1
M4 4,7
M5 9,1
M6 15,8
M8 37,7

7. SEAL-LOCK-Dichtmuttern (nach N 02.100) 7. SEAL-LOCK - sealing nuts (to N 02.100)

Gewinde / Anziehdrehmoment MA in Nm
Thread Tightening torque MA in Nm

M6 10
M6 x 0,5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1,5 72
M14 110
M14 x 1,5 120
M16 170
M16 x 1,5 180

714 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
43

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

A6V - Stellkolben / positioning piston

für / for A6V / A7V / A7F / A8V)

Anziehdrehmoment MA für Gewindestift (1) / Anziehdrehmoment MA für Schraube (2) /

Tightening torque MA for threaded pin (1) Tightening torque MA for shaft bolts (2)
(Verbindung: Stellkolben und Stellzapfen / (Verbindung: Stellkolben und Stellzapfen für A6V
Connection: Positioning piston and positioning trunnion Connection: Positioning piston and piston for A6V

M6 : 8,5 Nm M14 x 1,5 : 120 Nm

M8 : 14,0 Nm
M10 : 30,0 Nm
M12 : 52,0 Nm

008 917 69 BOMAG 715

24.3 Bosch Rexroth AG | Mobile Hydraulics
44 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Sicherheitsbestimmungen
Safety regulations

Allgemein General advice

● Machen Sie sich mit der Ausstattung der Maschine ● Make yourself familiar with the equipment of the
vertraut. machine.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den ● Only operate the machine if your are completely familiar with
Bedien- und Steuerelementen sowie der Arbeitsweise der the operating and control elements as well as the functioning
Maschine vertraut gemacht haben. of the machine.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, ● Use your safety equipment like helmet, safety shoes and
Sicherheitsschuhe und Gehörschutz. hearing protection.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ● Make yourself familiar with your working field.
● Benutzen Sie die Maschine nur für den ihr zugedachten ● Only operate the machine for its intended purpose.
Zweck.

Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.

Vor dem Start Before starting

● Beachten Sie die Bedienungshinweise vor dem Starten. ● Observe the operating instructions before starting.
● Prüfen Sie die Maschine auf auffällige Fehler. ● Check the machine for remarkable faults.
● Fahren Sie die Maschine nicht mit defekten Instrumenten, ● Do not operate the machine with defective instruments,
Kontrolleuchten oder Steuerorganen. warning lights or control elements.
● Alle Schutzvorrichtungen müssen fest auf ihrem Platz sein. ● All safety devices must be in a secure position.
● Nehmen Sie keine losen Gegenstände mit bzw. befestigen ● Do not carry with you movable objects or secure them to the
Sie diese an der Maschine. machine.
● Halten Sie die Maschine von öligem und zündfähigem ● Keep oily and inflammable material away from the machine.
Material frei. ● Before entering thc driver’s cabin, check if personsor
● Prüfen Sie vor dem Besteigen der Maschine, ob sich obstacles are beside or beneath the machine.
Personen oder Hindernisse neben oder unter der Maschine ● Be careful when entering the driver’s cabin, use stairs and
befinden. handles.
● Vorsicht beim Besteigen der Maschine, benützen Sie ● Adjust your seat before starting.
Treppen und Griffe.
● Stellen Sie vor dem Start Ihren Sitz ein.

716 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
45

Sicherheitsbestimmungen
Safety regulations

Starten Start
● Beim Starten müssen alle Bedienhebel in “Neutralstellung” ● When starting all operating levers must be in “neutral position”.
stehen. ● Only start the machine from the driver’s seat.
● Die Maschine nur vom Fahrersitz aus Starten. ● Check the indicating instruments after start to assure that all
● Prüfen Sie die Anzeigeinstrumente nach dem Start, um functions are in order.
sicher zu gehen, daß alles ordnungsgemäß funktioniert. ● Do not leave the machine unobserved when the motor is
● Lassen Sie die Maschine nicht unbewacht, während running.
der Motor läuft. ● When starting with battery connection cables connect plus
● Beim Start mit Batterieverbindungskabeln verbinden Sie Plus with plus and minus with minus. Always connect mass cable
mit Plus und Minus mit Minus. Massekabel (Minus) immer (minus) at last and cut off at first.
zuletzt anschliesen und zuerst abtrennen.

Vorsicht Attention
● Auspuffgase sind lebensgefährlich. Bei Start in ● Exhaust gas is dangerous. Assure sufficient fresh air when
geschlossenen Räumen für ausreichende Luftzufuhr starting in closed rooms!
sorgen!

Hydraulikanlage Hydraulic equipment

1. Hydraulikanlage steht unter hohem Druck! 1. Hydraulic equipment is standing under high pressure.
Unter hohem Druck austretende Hochdruck- Flüssig- High pressure fluids (fuel, hydraulic oil) which escape
keiten (Kraftstoff, Hydrauliköl) können die Haut durch- under high pressure can penetrate the skin and cause
dringen und schwere Verletzungen verursachen. Daher heavy injuries. Therefore immediately consult a doctor as
sofort einen Arzt aufsuchen, da anderenfalls schwere otherwise heavy infections can be caused.
Infektionen entstehen können! 2. When searching leakages use appropriate auxiliary devices
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr because of the danger of accidents.
geeignete Hilfsmittel verwenden! 3. Before working at the hydraulic equipment, lower pressure
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt to zero and lower working arms of the rnachine.
drucklos machen und angebaute Geräte absenken! 4. When working at the hydraulic equipment, absolutely stop
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor motor and secure tractor against rolling away (parking brake,
abstellen und Traktor gegen Wegrollen sichern shim)!
(Feststellbremse, Unterlegkeil)! 5. When connecting hydraulic cylinders and motor pay attention
5. Beim Anschließen von Hydraulikzylindern und -motoren ist to correct connection of hydraulic flexible hoses.
auf vorgeschriebenen Anschluß der Hydraulikschläuche zu 6. In case of exchanging the ports, the tunctions are vice versa
achten! (f. ex. lift-up/lower) - danger of accidents!
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen 7. Check hydraulic flexible hoses regularly and replace them in
(z.B. Heben/Senken) - Unfallgefahr! case of dammage or wear! The new hose pipes must comply
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und bei with the technical requirements of the machine manufacturer!
Beschädigung und Alterung austauschen! Die Austausch-
schlauchleitungen müssen den technischen Anforderungen Orderly disposal or recycling of oil, fuel and
des Geräteherstellers entsprechen! filters!

Öle, Kraftstoffe und Filter ordnungsgemäß

entsorgen!

008 917 69 BOMAG 717

24.3 Bosch Rexroth AG | Mobile Hydraulics
46 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Inbetriebnahme
Operating instruction

Einstellüberprüfung Setting test

(Regelbeginn von Vg max - Vg min ) (Begin of regulation of Vg max - Vg min )
z.Beispiel HD e.g HD

X - 10 bar

Einstellschraube - Regelbeginn / P
Set screw - begin of control
Vg min

G
X
Betriebsdruck /
Operating
pressure

~ P/2

1:2

Stelldruck /
Control pressure
Sicherheitsbestimmungen beachten! Observe safety regulations!
Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake).

A6VM - HD Vg max - Vg min A6VM - HD Vg max - Vg min

● Manometer "G" = 600 bar ● Pressure gauge "G" = 600 bar

● Manometer "M1" = 600 bar ● Pressure gauge "M1" = 600 bar
● Manometer "X" = 60 bar ● Pressure gauge "X" = 60 bar

Regelbeginn / Einstellung Begin of regulation / Setting

Beispiel: 10 bar Steuerdruck an X Example: 10 bar pilot pressure at X

Manometer an M1 beachten! Observe pressure gauge at M1!

Druckwert an X erhöhen bis an M1 die Hälfte Increase pressure value at X till half the pressure is generated
des Druckes von G ansteht ♦ Regelbeginn from G ♦ Begin of regulation

Einstellschraube im Uhrzeigersinn ♦ Regelbeginn Setscrew turned clockwise ♦ Begin of regulation earlier

früher
Setscrew turned anti-clockwise ♦ Begin of regulation later
Einstellschraube gegen Uhrzeigersinn ♦ Regelbeginn
später

718 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
47

Inbetriebnahme
Operating instruction

Einstellüberprüfung Setting test

(Regelbeginn von Vg max - Vg min ) (Begin of regulation of Vg max - Vg min )
z.Beispiel EP e.g EP

Einstellschraube - Regelbeginn /
Set screw - Begin of control
P

Vg min

Betriebsdruck /
Operating pressure

~ P/2

1:2

Stelldruck /
Control pressure

Sicherheitsbestimmungen beachten! Observe safety regulations!

Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake).

A6VM - EP Vg max - Vg min A6VM - HD Vg max - Vg min

● Manometer "G" = 600 bar ● Pressure gauge "G" = 600 bar

● Manometer "M1" = 600 bar ● Pressure gauge "M1" = 600 bar
● Magnet = Multimessgerät ● Solenoid = multi measuring device

Regelbeginn / Einstellung Begin of regulation / Setting

Beispiel: 200/400 mA Example: 200/400 mA

Manometer an M1 beachten! Observe pressure gauge at M1!

Strom erhöhen bis an M1 die Hälfte Increase current till half the pressure is generated
des Druckes von G ansteht ♦ Regelbeginn from G ♦ Begin of regulation

Einstellschraube im Uhrzeigersinn ♦ Regelbeginn Setscrew turned clockwise ♦ Begin of regulation earlier

früher
Setscrew turned anti-clockwise ♦ Begin of regulation later
Einstellschraube gegen Uhrzeigersinn ♦ Regelbeginn
später

008 917 69 BOMAG 719

24.3 Bosch Rexroth AG | Mobile Hydraulics
48 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Inbetriebnahme
Operating instruction

Einstellüberprüfung Setting test

(Regelbeginn von Vg min - Vg max ) (Begin of regulation of Vg min - Vg max )
z.Beispiel HA z.Beispiel HA

Vg min X M1

Stelldruck /
Control
pressure
1:2

Einstellschraube - Regelbeginn / G
Set screw - Begin of control Betriebsdruck /
Operating
pressure
Sicherheitsbestimmungen beachten! Observe safety regulations!
Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake)
Manometer 600 bar an G und M1 anschließen. Connect pressure gauge 600 bar at G and M1
Beispiel 1: Example 1:
Regelbeginn 200 bar, Begin of regulation 200 bar
Betriebsdruck langsam erhöhen bis Manometer an G 200 bar Increase service pressure slowly till pressure gauge at
Stelldruck Manometer M1 G = 200 bar
1 /2 des Betriebsdruckes = ca. 100 bar Positioning pressure gauge M1
♦ Regelbeginn 1/2 of the sevice pressure = approx. 100 bar.
Nachjustierung des Stelldruckes an ♦ Begin of control
Einstellschraube - Regelbeginn Readjust positioning pressure at set screw - start of control
Hinweis: Note:
Drehen im Uhrzeigersinn - Regelbeginn früher. Clockwise turning - begin of regulation earlier
Drehen gegen Uhrzeigersinn - Regelbeginn später. Anti-clockwise turning - begin of regulation later
Beispiel 2: Example 2:
Bei Anlagen mit zwei oder mehr Motoren z. B. Raupenfahrzeuge In systems with two or more motors, e.g. tracked vehicles,
kann folgende Einstellung zusätzlich erfolgen. the following setting may be carried out additionally.
Kontermutter von Einstellschraube Vgmin lösen - Remove safety cap from the setscrew Vg min - do not disturb
Einstellschraube nicht verdrehen. Maß X festhalten. setscrew.
Betriebsdruck langsam erhöhen bis Manometer an G 200 bar Increase service pressure slowly till pressure gauge is indicating
anzeigt. 200 bar at G.
Kontrolle: Einstellschraube Vg min "fest" (Steuerlinse wird gegen Verification: Vg min "fixed" (lens plate is pressed against setscrew).
die Einstellschraube gedrückt). Up from 200 bar service pressure the screw is becoming
Ab 200 bar Betriebsdruck wird die Schraube "lose" "movable".
(Steuerlinse schwenkt Richtung Vg max). (lens plate is stroking to direction Vg max).
♦ Regelbeginn ♦ Begin of control
Achtung! Attention
Einstellwert Vg min -Schraube nicht verändern. Do not modify setting data of Vg min screw.
Hinweis: Nachjustierung an Einstellschraube- Regelbeginn Note: Readjustment at the set screw - begin of regulation

720 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
49

Inbetriebnahme
Operating instruction

Einstellüberprüfung (Regelbeginn) G1
DA1/4, DA2,3,4,5,6 X3 Einstellschraube - Regelbeginn
Vg min
5/8

100

1:2

M1
DA1, DA2, DA3 = PST / PHD 5 / 100
DA4, DA5, DA6 = PST / PHD 8 / 100 Stelldruck

Beispiel: Betriebsdaten nach Geräteblatt

Verstellbeginn Vg min - Vg max bei 20 bar Steuerdruck X3
und 220 bar Betriebsdruck

● Manometer G = 600 bar Betriebsdruck

● Manometer X3 = 60 bar Steuerdruck
● Manometer M1 = 600 bar Stelldruck G
Fahrzeug beladen, Straßengang, Fahren (max. Geschwindigkeit
= max. Steuerdruck)
Manometer M1 beobachten, anbremsen für Druckaufbau an
"G", ab 220 bar Betriebsdruck baut sich Druck an M1 ab.
♦ Regelbeginn P/2.

DA1, DA2, DA3 PSt / PSt 5/100

X3 G M1 = 1/2 Betriebsdruck (Regelbeginn)

20 bar 200 bar 200 bar = Vg min
20 bar 220 bar 110 bar = Regelbeginn Vg min
♦ Vg max
20 bar 240 bar 0-50 bar = Vg max
* Einstellschraube - Regelbeginn - Drehen im Uhrzeigersinn - Regelbeginn später

nur 1/8 Umdrehung verstellen ♦ kontrollieren

DA4, DA5, DA6 PSt / PSt 8/100

X3 G M1
20 bar 207,5 bar 207,5 bar = Vg min M1
20 bar 220 bar 110 bar = Vg min ® Vg max
20 bar 225 bar 0 bar = Vg max Stelldruck

008 917 69 BOMAG 721

24.3 Bosch Rexroth AG | Mobile Hydraulics
50 Travel
A6VM | RDE 91 motor
604-01-R/03.03

Inbetriebnahme
Operating instruction

Setting test (Begin of Regulation) G1

DA1/4, DA2,3,4,5,6 X3
Setscrew - Begin of control
Vg min
5/8

100

1:2

M1
DA1, DA2, DA3 = PST / PHD 5 / 100
DA4, DA5, DA6 = PST / PHD 8 / 100 Control
pressure
X3
Example: Operation data as to machine specification sheet
Begin of regulation Vg min - Vg max at 20 bar pilot pressure
and 220 bar service pressure
G
● Pressure gauge G = 600 bar service pressure
● Pressure gauge X3 = 60 bar pilot pressure
● Pressure gauge M1 = 600 bar positioning pressure
Load vehicle, travel mode, travel (max. speed = max. pilot pressure
Observe pressure gauge M1, declarate at "G" for pressure generation,
up from 220 bar service pressure pressure at M1 is dropping.
♦ begin of regulation P/2.

DA1, DA2, DA3 PSt / PSt 5/100

X3 G M1 = 1/2 service pressure (begin of regulation)
20 bar 200 bar 200 bar = Vg min
20 bar 220 bar 110 bar = begin of regulation Vg min ♦ Vg max
20 bar 240 bar 0-50 bar = Vg max
* Setscrew - begin of regulation - turn clockwise - begin of regulation later

displace by 1/8 turn only ♦ verification

DA4, DA5, DA6 PSt / PSt 8/100

X3 G M1
20 bar 207,5 bar 207,5 bar = Vg min M1
20 bar 220 bar 110 bar = Vg min ♦ Vg max
20 bar 225 bar 0 bar = Vg max Control
pressure

722 BOMAG 008 917 69

Travel motor
RDE 91 604-01-R/03.03 | A6VM Mobile Hydraulics | Bosch Rexroth AG 24.3
51

008 917 69 BOMAG 723

24.3 Travel motor

Brueninghaus Hydromatik GmbH

Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
info.brm@boschrexroth.de
www.boschrexroth.com/brm

© 2003 by Brueninghaus Hydromatik © 2003 by Brueninghaus Hydromatik

GmbH, 89275 Elchingen GmbH, 89275 Elchingen
All rights reserved. No part of this Alle Rechte vorbehalten. Kein Teil des
document may be reproduced or Werkes darf in irgendeiner Form ohne
stored, processed, duplicated or vorherige schriftliche Zustimmung der
circulated using electronic systems, in Brueninghaus Hydromatik GmbH
any form or by any means, without the reproduziert oder unter Verwendung
prior written authorization of Bosch elektronischer Systeme gespeichert,
Rexroth AG. In the event of verarbeitet, vervielfältigt oder verbreitet
contravention of the above provisions, werden. Zuwiderhandlungen
the contravening party is obliged to verpflichten zu Schadensersatz.
pay compensation. Die angegebenen Daten dienen allein
The data specified above only serve to der Produktbeschreibung. Eine
describe the product. No statements Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
given information does not release the werden. Die Angaben entbinden den
user from the obligation of own Verwender nicht von eigenen
judgement and verification. It must be Beurteilungen und Prüfungen. Es ist zu
remembered that our products are beachten, dass unsere Produkte einem
subject to a natural process of wear natürlichen Verschleiß- und
and aging. Alterungsprozess unterliegen.

Printed in Germany
RDE 91 604-01-R/03.03

724 BOMAG 008 917 69

24.4 Conveyor belt pump

008 917 69 BOMAG 725

24.4 Conveyor belt pump

726 BOMAG 008 917 69

Conveyor belt pump 24.4
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

RDE 92 750-01-R/03.03
Verstellpumpe A10VG 28/63 ersetzt/replaces 10.02

Variable Pump A10VG 28/63

Baureihe/Series 10

Reparaturanleitung / Repair Instructions

008 917 69 BOMAG 727

24.4 Bosch Rexroth AG | Mobile Hydraulics
2 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Hinweis / Inhalt
Notice / Contents

HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen entsprechen Specifications, descriptions and illustrative material shown here
dem Informationsstand zum Zeitpunkt der Drucklegung dieser in were as accurate as known at the time this publication was
Unterlage. approved for printing.
Änderungen können den Service am Produkt beeinflussen, Ver- BRUENINGHAUS HYDROMATIK reserves the right to dis-
pflichtungen entstehen uns daraus nicht. continue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für deren Re- specifications, materials, or design without notice and without
sultat wir keine Haftung übernehmen können. incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Optional equipment and accessories may add cost to the basic
Fabrik-Nr. bestellt, sind die Basis guter Reparaturen. unit, and some options are available only in combination with
certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf dem
Teststand vorzunehmen. For the available combinations refer to the relevant data sheet for
the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vorkehrungen si-
cherzustellen. Adjustment and tests have to be carried out on the test bench
under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, vermit-
teln wir in unseren Schulungskursen. Protection of personnel and property has to be guar-anteed by
appropriate measures.
Expert knowledge, the precondition of any service work, can be
obtained in our training courses.

INHALT CONTENTS
Seite/
Page

A10VG A10VG

Schnittbild 3-4 Sectional view

Allgemeine Reparaturhinweise 5 General repair instructions
Dichtsätze und Baugruppen 6-8 Seal kits and sub assembly groups
Triebwelle abdichten 9 Sealing of the drive shaft
Hilfspumpe abdichten 10-12 Sealing of the boost pump
Stellkolbendeckel abdichten 13 Sealing of the control piston cover
Ventile abdichten 14 Sealing of the valves
Druckabschneidung abdichten 15 Sealing of the pressure cut-off valve
Regelventil abdichten 16 Sealing of the regulator valve
Steuergerät demontieren 17 Removal of the control unit
Ansteuergeräte 18-22 Control units
Pumpe demontieren 23-25 Pump disassembly
Triebwerk ausbauen 26 Removal of the rotary group
Stellkolben demontieren 27-28 Disassembly of the positioning piston
Überprüfungshinweise 29-31 Inspection notes
Turcon-Glyd-Ring montieren 32 Turcon-Glyd-ring
Pumpe montieren 33-35 Assembly of the pump
Triebwerk einbauen 36 Installation of the rotary group
Triebwerk einbauen HW, HD, EP 37-38 Installation of the rotary group HW, HD, EP
Triebwerk einbauen DA 39 Installation of the rotary group DA
Pumpe montieren 40-41 Assembly of the pump
Montageanweisung für Anziehdrehmomente 42-45 Assembly guidelines for tightening torques
Sicherheitsbestimmungen 46-47 Safety regulations
Einstellhinweise 48-55 Adjustment instructions

728 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.43
Schnittbild
Sectional view

mit Druckabschneidung
with pressure cut-off

ohne Druckabschneidung
without pressure cut-off

HDD EPD

008 917 69 BOMAG 729

24.4 Bosch Rexroth AG | Mobile Hydraulics
4 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Schnittbild
Sectional view

730 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.45
Allgemeine Reparaturhinweise
General repair instructions

Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!

Attention!
Observe the following notices when carrying out
repair work at hydraulic aggregates!

Alle Öffnungen der Hydraulikaggregate

verschließen.

Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.

Replace all seals.

Use only OR IG I NAL B R U E N I NG HAUS
HYDROMATIK spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.

Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.

Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befüllen.

Fill the hydraulic units with the operating medium

before commissioning.

008 917 69 BOMAG 731

24.4 Bosch Rexroth AG | Mobile Hydraulics
6 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Dichtsätze und Baugruppen

Seal kits and sub-assemblies

Dichtsatz für Triebwelle.

Seal kit for drive shaft.

Äußerer Dichtsatz.

Peripheral seal kit.

Triebwerk komplett.

Complete rotary group.

Stellkolben

Positioning piston

2 3
1. Anschlußplatte Standard,
1
2. Anschlußplatte mit Druckabschneidung
3. Anschlußplatte DA mit Druckabschneidung

1. Standard connection plate

2. Connection plate with pressure cut-off
3. DA connection

732 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.47
Dichtsätze und Baugruppen
Seal kits and sub-assemblies

Ansteuergerät HW

Control unit HW

Ansteuergerät HW mit Nullagenanzeige

Control unit HW with zero indicator

alt / old

neu / new Ansteuergerät HD

Control unit HD

alt / old

neu / new
Ansteuergerät EP

Control unit EP

alt / old

neu / new

4/3 Wegeventil DA

Control unit DA

008 917 69 BOMAG 733

24.4 Bosch Rexroth AG | Mobile Hydraulics
8 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Dichtsätze und Baugruppen

Seal kits and sub-assemblies

Hilfspumpe mit Verschleißplatte

Boost pump with wear plates

1
2

1. HD - Ventil
2. HD - Ventil mit Bypass
3. ND - Ventil

1. High pressure valve

2. High pressure valve with bypass function
3. Low pressure valve

Druckabschneidung

Pressure cut-off

3
2

1. DA - Regelventil, verstellbar mit Hebel

1
2. DA - Regelventil, festeingestellt
3. Zuschaltventil

1. DA control valve, adjustable via a lever

2. DA control valve, fixed
3. Switching valve

734 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.49
Triebwelle abdichten
Sealing of the drive shaft

Triebwelle abkleben.
Sicherungsring ausbauen.

Protect the drive shaft (e.g. masking tape).

Remove the retaining ring.

Blechschraube in die mit Gummi gefüllten Löcher

eindrehen.
Mit Zange WDR herausziehen.

Screw the metal screws into the holes that are

fitted with rubber.
Withdraw the shaft seal using pliers.

Wellendichtring mit Buchse auf Anschlag

einpressen.
Zwischen Dicht- und Staublippe, Wellendichtring
leicht einfetten.

Press-in shaft seal with bush to stop.

Lightly grease the seal, dust lips and shaft seal ring.

008 917 69 BOMAG 735

24.4 Bosch Rexroth AG | Mobile Hydraulics
10 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Hilfspumpe abdichten
Sealing of the boost pump

Achtung!
* "Angefaste Seite" zum Deckel montieren.

Note!
* Mount the "chamfered side" towards the cover.

Befestigungsschrauben ausbauen.

Remove fixing screws.

Deckel abdrücken.

Pry-off cover.

Einbaulage kennzeichnen.

Mark position.

736 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
11

Hilfspumpe abdichten
Sealing of the boost pump

O-Ring ausbauen.

Remove O-ring.

Hilfspumpe abdrücken.

Pry off the boost pump.

2
1. Verschleißplatte
2. Fixierstift

1. Wear plate
2. Locating pin
1

3 1. Kantsil-Ring
1
2. Entlastungsnut
2 3. Fixierstift

1. Kantsil-ring
2. Unloading channel
3. Locating pin

Verschleißplatte einsetzen.
Drehrichtung beachten!

Fit wear plate taking the direction of rotation

account.

008 917 69 BOMAG 737

24.4 Bosch Rexroth AG | Mobile Hydraulics
12 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Hilfspumpe abdichten
Sealing of the boost pump

Verschleißplatte einsetzen.
Drehrichtung "Rechts" bei Blick auf die Triebwelle.
Achtung! Fixierstift

Fit wear plate.

Direction of rotation "clockwise" looking on the drive
shaft.
* Attention! Locating pin

Saugseite - suction side

Verschleißplatte einsetzen.
Drehrichtung "Links" bei Blick auf die Triebwelle.
Achtung! Fixierstift

Fit wear plate.

Direction of rotation "anti-clockwise" looking on the
drive shaft.
*
Attention! Locating pin
Saugseite - suction side

Linkslauf - anti-clockwise

Rechtslauf - clockwise

Hilfspumpe montieren.

Fit boost pump

O-Ring und Deckel montieren.

Fit O-ring andcover plate.

738 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
13

Stellkolbendeckel abdichten
Sealing of the control piston cover

Achtung!
Korrekte mechanische 0-Lageneinstellung
überprüfen!

Attention!
Check that the mechanical "0"-position is
correct!

Kontermutter ausbauen, Stellschraube gegenhalten.

Maß X
Deckel kennzeichnen. Maß festhalten, Konter-
mutter lösen.

Remove lock unit, whilst holding the adjustment

screw, mark the cover plate, ascertain the
dimension, loosen locknut.

Deckel von Stellschraube "abschrauben".

Remove the cover from the adjustment screw by

unscrewing it from the adjustment screw.

Kontrolle! O-Ring (1), Nut (2), Gehäuse und

Deckel (3).
Achtung!
Korrekte mechanische 0-Lageneinstellung muß
nach Einbau im Gerät bzw. Prüfstand erfolgen.

Check! O-ring (1), groove (2), housing with

cover (3).
Attention!
The correct mechanical "0" position has to be
adjusted after the unit has been built into the
machine or on a test rig.

008 917 69 BOMAG 739

24.4 Bosch Rexroth AG | Mobile Hydraulics
14 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Ventile abdichten
Sealing of the valves

PHD -Ventil mit Bypass

PHD -valve with bypass-function

PSP-Ventil

PSP -valve

Gewinde vor Montage des neuen O-Ringes

abkleben.
(Beschädigungsschutz).

Cover threads before fitting new O-rings.

(Damage protection).

*
Ventilkegel mit Druckfeder ausbauen.
Stützring
* mit Bypassfunktion

Remove valve poppet with compression spring.

* with bypass function
*

O-Ring

O-Ring und Stützring mit Hilfswerkzeug (Hülse)

aufziehen.

Place on O-ring and back-up ring

with auxiliary tool (sleeve).

740 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
15

Druckabschneidung abdichten
Sealing of the pressure cut-off valve

Wechsel der Dichtmutter.

Einstellmaß festhalten (*).
*
Exchanging the sealing nut.
Ascertsion the adjustment dimension (*).

Achtung!
Nach Einbau "Ventileinstellung" überprüfen.

Attention!
After assembly check "valve setting".

008 917 69 BOMAG 741

24.4 Bosch Rexroth AG | Mobile Hydraulics
16 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Regelventil abdichten
Sealing of the control valve

Regelventil ausbauen.

Remove control valve.

Blendendurchmesser nicht beschädigen.

Kontrolle:
Blendendurchmesser

Do not damage the orifice diameter.

Check: Orifice diameter.

Gewinde vor Montage des neuen O-Ringes

abkleben.

Before fitting the new O-ring cover the threads

(e.g. tape).

742 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
17

Steuergerät demontieren
Removing of the control unit

alt / old
DA alt / old
neu / new

neu / new

EP alt / old
neu / new
HW mit Nullagenschalter
HW with zero position switch

* Befestigungsschrauben demontieren.
*
* Remove fixing screws.

Ansteuergerät abdrücken.

Pry-off the control unit.

Kontrolle
Dichtfläche (1), Flachdichtung (2), O-Ringe (3).

Check
Sealing surface (1), gasket (2), O-rings (3).

008 917 69 BOMAG 743

24.4 Bosch Rexroth AG | Mobile Hydraulics
18 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Ansteuergeräte
Control units

Ansteuergerät HW
NG / Size 28
HW control unit

NG / Size 45

4/3 Wegeventil DA

DA control unit

Anziehmoment 5+1 Nm
Steckschlüssel SW 26
Tightening torque 5+1 Nm
26 A/F socket spanner

Polrohr
Anziehmoment 19 Nm
Pole tube
Tightening torque 19 Nm

744 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
19

Ansteuergeräte
Control units

Ansteuergerät HD - EP alt
HD - EP control unit old
HD alt / old

EP alt / old

HD alt / old

EP alt / old

Neues Ansteuergerät HD - EP
New HD - EP control unit old

202,0 mm

131,0 mm
214,4 mm

77,4 mm

008 917 69 BOMAG 745

24.4 Bosch Rexroth AG | Mobile Hydraulics
20 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Ansteuergeräte
Control units

Ansteuergerät HD neu
HD - control unit new

Ansteuergerät EP neu
EP - control unit new

746 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
21

Ansteuergeräte
Control units

* Markierung Montageposition HD *
* Marking the assembly position HD
*

*
*

* Markierung * Assembly position marker HD

Montageposition HD

Wird von EP- auf HD-Ausführung umgebaut - Is converted from EP into the HD version -
Deckelposition beachten siehe Markierung take note of the cover position, see marker

Leckölkanal offen wird geschlossen. The open leakage port is plugged

Zugfeder tauschen! Exchange the tension spring!

008 917 69 BOMAG 747

24.4 Bosch Rexroth AG | Mobile Hydraulics
22 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Ansteuergeräte
Control units

Markierung Montageposition EP Die neuen Proportionalmagnete müssen bei der Inbe-

Assembly position marker EP triebnahme entlüftet werden. Wird die Luft nicht aus
* dem Ankerraum entfernt, kann es zum Schwingen der
Hydraulische Nullage
Ansteuerung kommen.
Hydraulic zero position
Zum Entlüften ist am Ende des Magneten, im Messing-
Klemmschraube teil, ein kleiner Gewindestift M4, SW 2 vorhanden.
Clamping screw Dieser Gewindestift ist max. 2 Umdrehungen heraus-
* zudrehen und nach dem Entlüften mit 1 Nm wieder
festzuziehen.
Bei der Ausführung mit Nothand mit Federrückzug muß
zum Entlüften die Kunststoffmutter mit Gummibalg
entfernt und nach dem Entlüften mit 5+1 Nm wieder
angeschraubt werden.

Entlüftungsschraube * max. 2 Umdrehungen herausdrehen. The new proportional solenoids must be bled during
Bleed screw *. Unscrew by commissioning. If the air is not removed from the
a max. of 2 turns armature chamber oscillations at the control can occur.
* For bleeding purposes there is, on the end of the sole-
* noid, in the brass component a small set screw M4,
2A/F. This can be unscrewed by a maximum of 2 turns
and then after completion of the bleeding tightened to
a maximum of 2 Nm.
For the version with hand override and spring return
the plastic nut with rubber coating has to be removed
for bleeding. After bleeding it has to be replaced and
tightened with 5+1 Nm.

Polrohr
Anziehmoment 19 Nm
Pole tube
Tightening torque 19 Nm

* *
Markierung
Klemmschraube 6,1 Nm Anziehmoment 5+1 Nm
Montageposition EP
Clamping screw 6,1 Nm Steckschlüssel SW 26
Assembly position
marker EP Tightening torque 5+1 Nm
26 A/F socket spanner
Hydraulische Nullage
Exzenterstift
Hydraulic
zero point
Eccentric pin
Beim Lösen der Klemmschraube
Exzenterstift - Hydraulische Nullage festhalten.

When loosening the clamping screw

Hold the eccentric pin - hydraulic zero point

748 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
23

Pumpe demontieren
Pump disassembly

HD alt/old

EP alt/old

HD neu/new

EP neu/new

Druckabschneidung
Pressure cut-off

DA alt/old
DA neu/new

Excenterschraube
Eccentric screw

008 917 69 BOMAG 749

24.4 Bosch Rexroth AG | Mobile Hydraulics
24 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Pumpe demontieren
Pump disassembly

Lage der Hilfspumpe und Anschlußplatte

markieren.
Hilfspumpe abbauen.

Mark position of the boost pump and the port plate.

Remove the boost pump.

DA-Ausführung:
Lage der Verdrillschraube markieren (1).
Verdrillschraube auf Demontageposition stellen (2).

DA-design:
Mark the position of the eccentric screw (1).
Set the eccentric screw to disassembly position
(2).

Anschlußplattenbefestigung lösen. Anschlußplatte

abheben.

Remove connecting plate fixing screws.

Lift off the connection plate.

Steuerplatte abdrücken.
Lage notieren.

Lift off control plate.

Note position.

Kontrolle!
2 4 O-Ring mit Nut (1)
3 O-Ring mit Nut (2)
Fixierstift - Steuerplatte (3) Bei DA - kein Stift
1 T - Ablauf verschlossen (4)
Check
O-ring and groove (1)
O-Ring and groove (2)
Locating pin - control plate (3) type DA has no pin
T drain plugged (4) open for type DA

750 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
25

Pumpe demontieren
Pump disassembly

DA-Ausführung
Zylinder nach unten drücken (1).
Verdrillschraube herausdrehen (2).
Triebwerk ausheben (3).

DA- version
Press the cylinder downwards (1).
Remove the eccentric screw (2).
Lift out the rotary group (3).

"Ausbauen"
1. Zylinder
2. Schwenkwiege
3. Gelenkstift

"Remove"
1. Cylinder
2. Swash plate
3. Joint pin

Sicherungsring, WDR ausbauen.

Remove retaining ring, remove drive shaft seal.

008 917 69 BOMAG 751

24.4 Bosch Rexroth AG | Mobile Hydraulics
26 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Triebwerk ausbauen
Removal of the rotary group

Triebwelle mit leichten Hammerschlägen austreiben.

Remove drive shaft with light hammer strokes.

Lagerschalen ausbauen.

Remove bearing shells.

Feder mit Vorrichtung vorspannen.

Pre-tension the spring using a suitable device.

Sicherungsring demontieren.
Feder und Druckstifte ausbauen.

Remove circlip.
Remove spring and pressure pins.

752 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
27

Stellkolben demontieren - Gehäuse mit Buchse

Disassembly of the positioning piston - housing with bush

Steuergerät abbauen.

Remove control unit.

Stellkolben (1) ziehen.

Pull out control piston (1).

Stellkolben zerlegen.

Disassemble the control piston.

008 917 69 BOMAG 753

24.4 Bosch Rexroth AG | Mobile Hydraulics
28 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Stellkolben demontieren - Gehäuse mit Turcon-Glyd-Ring

Disassembly of the positioning piston - housing with Turcon-Glyd-ring

Steuergerät abbauen.

Remove control unit.

Stellkolben (1) ziehen.

Pull out control piston (1).

Stellkolben zerlegen
(Gehäuse Turcon-Glyd-Ring Abdichtung).

Disassemble the control piston

(Housing Turcon-Glyd-ring).

754 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
29

Überprüfungshinweise
Inspection notes

Alle Lager erneuern.

Replace all bearings.

Kontrolle!
1. Verzahnung, ausgeschlagen, Passungsrost.
2. Lauffläche.
3. Einlaufrillen vom Wellendichtring.

Check!
1. Splines, wear steps, corrosion.
2. Running surfaces.
3. Grooves made by the shaft seal.

Stellkolbenlaufbüchse (1) riefenfrei, nicht

ausgelaufen.
1
Check that the control piston guide bush (1)
1
is free of grooves and is free of wear.

Kontrolle!
Stellkolben (1) riefenfrei.

Check!
Control piston (1) is not scored.

008 917 69 BOMAG 755

24.4 Bosch Rexroth AG | Mobile Hydraulics
30 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Überprüfungshinweise
Inspection notes

Kontrolle!
Gleitfläche riefenfrei.

Check!
Sliding surface free of grooves.

Kontrolle!
Verbindung Gleitstein/Schwenkzapfen spielfrei.

Check!
That the connection of slide ring/swivel pin is free
of play.

Kontrolle!
Rückzugeinrichtung riefenfrei (1), keine Einlaufs-
puren (2)
im Gleitschuhbereich.

Check!
That the retaining plate is free of grooves (1) and
that there is no wear (2) in the slipper pad area.

Kontrolle!
Lauffläche (1) keine Kratzer, keine Metallein-
lagerungen,
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).

Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).

Check!
Cylinder bores (1), splines (2).

756 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
31

Überprüfungshinweise
Inspection notes

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).

Kontrolle!
Auflagefläche - Steuerplatte ohne Beschädigung.

Check!
Mounting surface - control plate undamaged

Hinweis:
Bohrung bei DA-Regelung offen. (gültig nur bei
A10VG 45).

Information:
Hole for DA-control is open, without DA control valve
it is plugged.

Kontrolle!
Lagerbahnen (1)

Check!
Bearing surfaces (1)

Riefenfrei, keine Einlaufspuren

Free of grooves, no wear.

008 917 69 BOMAG 757

24.4 Bosch Rexroth AG | Mobile Hydraulics
32 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Gehäuse - Turcon-Glyd-Ring montieren

Assemble housing - Turcon-Glyd-ring

Dichtring in die Montagezange einlegen.

Fit the seal ring into the assembly tool.

Dichtring mit Zangenschenkel nierenförmig

zusammendrücken. Die Verformung von Turcon-
Dichtungen ist sorgfältig vorzunehmen, damit die
Dichtkanten nicht beschädigt werden.

Press the seal ring into the kidney shape using the
assembly tool. The deformation of the Turcon seal
has to be done with care so as not to damage the
sealing edges.

O-Ring in Nut einlegen.

Dichtring ins Gehäuse einführen und in der
Aufnahmenut plazieren. Dann Spannung lösen und
Montagezange herausziehen. Lage des Dicht-
ringes prüfen - eventuell mit dem Finger
egalisieren.

Position the seal ring into the groove.

Position the seal ring into the housing and place it
into the groove. Release the tension and withdraw
the assembly tool. Check the position of the seal
ring if necessary straighten using a finger.

Kalibrieren des Dichtringes mit einem Kalibrierdorn

(Stellkolben) - mit langer Schräge 10o bis 15o.

Calibrate the seal ring using a cylindrical plug gauge

(positioning piston) at an angle of 10o to 15o.

758 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
33

Pumpe montieren
Assembly of the pump

Lagerschalenpaar einsetzen.

Insert bearing shells.

Stellkolben ins Gehäuse einsetzen.

Hinweis:
Stellkolben vor Einbau einölen.

Insert positioning piston into the housing.

Instruction:
Oil positioning piston before assembly.

Stellkolben mit Hebel (Id.Nr. 2774491) ausrichten.

* Führung für Gleitstein - Schwenkwiege

Position stroke piston with lever (Id.No. 2774491).

* Sliding stone guidance in the piston.

Lager, Draht, Gleitstein und Gelenkstift montieren.

Montagehilfe: z.B. - Klammer / Gummiringe / Fett

Assemble the bearing, wire, slide ring and joint pin

Assemble aids:
e.g. - clips / rubber rings / grease

Schwenkwiege komplett ins Gehäuse einsetzen.

Auf korrekten Sitz der Schwenklager im Gehäuse
"achten".
Montagehilfe ausbauen.

Insert the swash plate into the housing.

Ensure that the swivel-bearing is correctly located
in the housing.
Remove assembly aid.

008 917 69 BOMAG 759

24.4 Bosch Rexroth AG | Mobile Hydraulics
34 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Pumpe montieren
Assembly of the pump

Kontrolle: Sitz der Schwenklager in der

Lagerbahn.
Mittig stellen mit Meßvorrichtung (Uhr oder
Tiefenmaß)
Punkt 1 und 2 kontrollieren - gleiches Maß.

Check: Location of the swivel-bearing

in the bearing.
Centralise by using a measuring device (dial gauge
or depth measurement).
Check points 1 and 2 - they should have the same
dimension.

Gelenkstift montieren.

Fit joint pin.

760 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
35

Pumpe montieren
Assembly of the pump

Haltevorrichtung montieren.
Mit Gewindestift Schwenkwiege festhalten.
Keine Gewaltanwendung.

Fit holding device.

Hold swash plate in position utilising the set screw.
Do not use force.

Haltevorrichtung "Schwenkwiege" A4V

Holding device "swivel cradle" A4V

Teil/Part 3 Teil/Part 4

∅ ∅
6, 7, 8, 9
∅ ∅
3, 4, 5

∅ ∅

Teil/Part 5
∅
2
∅
1

Pos./Item Benennung/Designation Stck./Qty.

1 Winkel/Angle 2
2 Gewindestift/Threaded pin 2
3 Scheibe/Shim 2
4 Scheibe/Shim 2
5 Scheibe/Shim 2
6 Zyl. Schraube/Cyl. screw M12 x 25 DIN 912 2
7 Zyl. Schraube/Cyl. screw M14 x 25 DIN 912 2
8 Zyl. Schraube/Cyl. screw M16 x 30 DIN 912 2
9 Zyl. Schraube/Cyl. screw M20 x 35 DIN 912 2

008 917 69 BOMAG 761

24.4 Bosch Rexroth AG | Mobile Hydraulics
36 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Triebwerk einbauen
Installation of the rotary group

Neue Montageposition!
Triebwelle mit Lager und Wellendichtring einbau-
en.

Assemble drive shaft with bearings and radial seal

rings.

Mit Vorrichtung Druckstifte montieren.

Fit pressure pins using an assembly aid.

Feder mit Vorrichtung vorspannen.

Pre-tension the spring using a suitable device.

Kolben mit Rückzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einölen.

Assemble piston with retaining plate.

Note:
Oil piston and piston pad.

762 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
37

Triebwerk einbauen HW / HD / EP
Installation of the rotary group HW / HD / EP

Vorrichtung ausbauen.
Zylinder mit Kolben und Rückzugeinrichtung
einbauen.

Remove holding device.

Fit cylinder complete with pistons and
retaining device.

Montagehilfe:
Mit O-Ring Kolben festhalten.

Assembly aid:
Hold the pistons by using an O-ring.

Bei Ausführung mit Verdrillschraube:

Zylinder nach unten drücken - Verdrillschraube
auf Maß x einschrauben.
* Kerbe in Montageposition.

For the version with eccentric screw:

Push the cylinder down - screw in the eccentric
screw in the eccentric screw until dimension x is
reached.
* groove in assembled position.

Fixierstift für Steuerplatte einsetzen.

Bei DA - Ausführung mit Verdrillschraube
ohne Fixierstift.

Fit locating pin for control plate.

For the DA version with eccentric screw without
locating pin.

008 917 69 BOMAG 763

24.4 Bosch Rexroth AG | Mobile Hydraulics
38 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Triebwerk einbauen HW / HD / EP
Installation of the rotary group HW / HD / EP

Steuerplatte Rechtslauf
* Fixierstift
* Control plate, clockwise rotation
* Locating pin

Steuerplatte Linkslauf
* * Fixierstift

Control plate, anti-clockwise rotation

* Locating pin

Zylinderflächen einölen, neue O-Ringe mit Fett

einreiben und einsetzen.

Oil the cylinder surfaces, grease the new O-rings

and fit into place.

Lagerichtig aufsetzen.
Hinweis:
HW, HD, EP Steuerplatte mit Fett auf
Anschlußplatte.

Place in correct position.

Note:
HW, HD, EP - Locate the control plate on the
connection plate using grease.

764 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
39

Triebwerk einbauen DA
Installation of the rotary group DA

Bei Ausführung mit Verdrillschraube:

Zylinder nach unten drücken - Verdrillschraube
auf Maß x einschrauben.
* Kerbe in Montageposition.

For the version with eccentric screw:

Push the cylinder down - screw in the eccentric
screw in the eccentric screw until dimension x is
reached.
* groove in assembled position.

Maß X mit Vorrichtung neu ermitteln.

Zylinder mit Vorrichtung nach unten drücken.
Verdrillschraube bis Anschlag einschrauben -
Maß X - Kerbe in Montageposition drehen.

Re-identify dimension X with device.

Push cylinder down with device.
Screw in eccentric screw till stop - Dimension X -
Turn groove in assembly position.

Ident. Nummer Hilfsvorrichtung/

Ident- No. Auxiliary device
NG / Size 28 = Ι 2 775 075
NG / Size 45 = Ι 2 774 882
NG / Size 63 = Ι 2 775 076

Steuerplatte Rechtslauf mit Verdrillschraube

Control plate, clockwise rotation with eccentric

screw

Max. Einschraubtiefe beachten.

Einstellhinweis beachten

Max. depth - take into account!

Lagerichtig aufsetzen.
Bei DA Steuerplatte auf Zylinderfläche legen.

Place in correct position.

For the DA version, place control plate on the
cylinder surface.

008 917 69 BOMAG 765

24.4 Bosch Rexroth AG | Mobile Hydraulics
40 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Pumpe montieren
Assembly of the pump

Schrauben über Kreuz anziehen.

Verdrillschraube auf Markierung drehen.

Tighten the screws aross corners.

Turn the eccentric screw until the marker is reached.

Hilfspumpe montieren.

Fit boost pump.

Ansteuergerät mit Dichtung montieren.

Fit control device with seal.

766 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
41

Pumpe montieren
Assembly of the pump

Ansteuergerät mit Dichtung montieren.

Fit control device with seal.

Dichtung mit zwei Befestigungschrauben

zentrieren und Ansteuergerät einbauen.
Alle vier Schrauben mit halbem Drehmoment an-
ziehen.

Centre the seal using two fixing screws and fit

the control unit.
Tighten all four screws to half of specified torque.

Fünfte Schraube einsetzen und mit

Drehmoment = 10,4 Nm festziehen.
Restliche vier Schrauben nach Drehmoment
festziehen.

Fit the fifth screw and tighten to a torque

of 10,4 Nm.
Then tighten the other four screws to there
correct torque.

008 917 69 BOMAG 767

24.4 Bosch Rexroth AG | Mobile Hydraulics
42 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)

Die Werte gelten für Schaftschrauben mit metri- The values stated are valid for bolts with metric
schem ISO-Gewinde nach DIN 13 Teil 13, sowie ISO threads to DIN 13 part 13, as well as head
Kopfauflagemaßen nach DIN 912 Zylinder- areas to DIN 912 socked head cap screws, DIN
schrauben, DIN 931 Sechskantschrauben mit 931 hexagon bolt or DIN 933 hexagon bolts with
Schaft bzw. DIN 933 Sechskantschrauben mit threads up to the head.
Gewinde bis Kopf.

Festigkeitsklassen / Tensile strength class

768 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
43

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).

G
EOLASTIC-
Dichtung / Seal

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

008 917 69 BOMAG 769

24.4 Bosch Rexroth AG | Mobile Hydraulics
44 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

5. Verschlußschrauben mit Innensechskant, 5. Plugs with internal hexagon, O-ring and UNF-,
O-Ring und UNF-, UN-Gewinde nach SAE J 514 UN- threads to SAE J 514 (nach N 02.106)
(nach N 02.106)

G
O-Ring / O-ring seal
Dichtung / Thread

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
7/16 - 20 UNF 15 M12 x 1,5 10
1/2 - 20 UNF 20 M14 x 1,5 30
9/16 - 18 UNF 25 M27 x 1,5 35
3/4 - 16 UNF 72
7/8 - 14 UN 127
1 1/16 -12 UN 147
1 3/16 -12 UN 173
1 5/16 -12 UN 198
1 5/8 -12 UN 320
1 7/8 -12 UN 390

6. SEAL-LOCK-Dichtmuttern (nach N 02.100) 6. SEAL-LOCK - sealing nuts (to N 02.100)

Gewinde / Anziehdrehmoment MA in Nm
Thread Tightening torque MA in Nm

M6 10
M6 x 0,5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1,5 72
M14 110
M14 x 1,5 120
M16 170
M16 x 1,5 180

770 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
45

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

A10V - Düsen / orifices

Gewinde / Anziehdremomente Nm /
Thread Tightening torques Nm
bisher / up to neu / new
M6 6,5 3
M10 28 12

008 917 69 BOMAG 771

24.4 Bosch Rexroth AG | Mobile Hydraulics
46 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Sicherheitsbestimmungen
Safety regulations

Allgemein General advice

Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.

Vor dem Start Before starting

772 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
47

Sicherheitsbestimmungen
Safety regulations

Hydraulikanlage Hydraulic equipment

Öle, Kraftstoffe und Filter ordnungsgemäß

entsorgen!

008 917 69 BOMAG 773

24.4 Bosch Rexroth AG | Mobile Hydraulics
48 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Einstellhinweise - ND-Ventil (Speisedruck)

Adjustment instructions - Low pressure valve (Boost pressure)

Achtung! Attention!
Sicherheitsbestimmungen beachten! Observe safety regulations!

Hinweis: Note:
Nachjustierung nur bei Betriebstemperatur. Readjusting only at operating temperature.

Manometer an "G" anschließen. Connect pressure gauge to "G".

Achtung! Attention!
* Speisedruckeinstellung! * Boost pressure setting!
Nenndruck pH - 20 bar Nominal pressure pH - 20 bar
Höchstdruck pH - 40 bar Peak pressure pH - 40 bar
Bei Max.-Drehzahl. at max. speed.

Hinweis: Note:
Einstelldaten nach Werksauftrag. Setting data is in accordance to the works order.

* bei DA-Ausführung * with the DA version

60 bar

"G"
*

774 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
49

Einstellhinweise - Mechanische "Nullage"

Adjustment instructions - Mechanical "zero position"

alt / old
alt / old
DA

neu / new

EP alt / old

neu / new
HW mit Nullagenschalter
HW with zero position switch

Achtung!
Sicherheitsbestimmungen beachten!
Mit Schlauch NW6 beide Stellkammern
verbinden. Vermeidung von Restsignal
aus hydraulischer Nullage.
Manometer an MA und MB anschließen.
Nullage so einstellen, daß bei blockiertem Antrieb
beide Manometer auf gleichem Druckwert stehen.
Hinweis:
Totband der Nullage - vermitteln.
600 bar
Attention!
Observe safety regulations!
Connect both control chambers with a nominal size
600 bar
6 hose. Avoidance of residual signals from hydraulic
zero position.
Connect pressure gauges to MA and MB. Adjust
the zero position so that with at blocked drive both
pressure gauges indicate the same pressure valve.
Note:
Ascertain the zero position dead band.

008 917 69 BOMAG 775

24.4 Bosch Rexroth AG | Mobile Hydraulics
50 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Einstellhinweise - Hydraulische "Nullage"

Adjustment instructions - Hydraulic "zero position"

HD neu/new Achtung!
Sicherheitsbestimmungen
HW beachten!
*
* HD alt/old Attention!
Observe safety regulations!
*

*
*

HW mit Nullagenschalter
HW with zero position switch EP alt/old

EP neu/new

60 bar

Manometer (60 bar) an X1 und X2 anschließen.

* Nullage so einstellen, daß bei blockiertem
Antrieb beide Manometer auf gleichem Druck-
wert stehen.
Hinweis:
Excenterjustierung - nicht über ± 90° verdrehen.

Connect pressure gauges(60 bar) to X1 and X2.

* Adjust the zero position so that with a block
drive both pressure gauges indicate the same
pressure value.
Note:
Eccentric adjusting - Do not turn more than ± 90°.

776 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
51

Einstellhinweise - HD- Ventile (Hochdruck) und Druckabschneidung

Adjustment instructions - HP- valves (High pressure) and pressure cut-off

Achtung!
Sicherheitsbestimmungen beachten!

HD-Ventil ohne Bypass

Druckabschneidung 1. HD-Ventile sind immer 10% höher eingestellt als die

Pressure cut-off 2 Druckabschneidung.
1 2. Nachjustierung nur bei Betriebstemperatur
Manometer (600 bar) an MA und MB anschließen.
Druckabschneidung:
Zum Blockieren der Druckabschneidung beim Überprüfen
der Hochdruckventile die Einstellschraube Pos. 1 mit
gelöster Kontermutter Pos. 2 bis zum Anschlag mit
max. 2 Nm im drucklosen Zustand eindrehen!

HD-Ventile: Mit geringer Pumpenmenge über Ventile fahren.

Einstellwert kontrollieren.
(Nur kurzzeitig "Temperatur“.)
Einstellwert verändern - siehe Serviceinfo

Druckabschneidung:
Einstellschraube auf Maß (*) zurückdrehen.
Druckwert kontrollieren bzw. nachjustieren.
Achtung! Differenz von 10% HD-Ventile und
Druckabschneidung beachten!
Hinweis: Einstelldaten nach Werksauftrag.

Attention!
Observe safety regulations.
HD- Ventile
HP- valves
HP valve without bypass-function
1. HP valves are always adjusted 10% higher than the
pressure cut-off.
2. Readjusting only at operating temperature.
Connect pressure gauge (600 bar) to MA and MB.
Pressure cut-off:
To block the pressure cut-off when testing the high
pressure valves, the adjustment screw (item 1), with the
lock-nut (item 2) loosened, has to be screwed in
with a max. torque of 2 Nm in the depressurised condition
until the end stop is reached.

HP valves: Operate the valves with small pump flow over the
valves.
Check setting value. (only for a short time "temperature“).
Change setting value - see service information.

Pressure cut-off:
Turn back setting screw to measurement (*).
Check pressure value and readjust if necessary.
Attention! Observe the 10% pressure difference
between the HP valves and the pressure cut-off!
Note: Setting data is in accordance with the works order.

008 917 69 BOMAG 777

24.4 Bosch Rexroth AG | Mobile Hydraulics
52 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Einstellhinweise - Bypassventil HW, HD, EP

Adjustment instructions - Bypass valve HW, HD, EP

1
1

Fahrzeuge mit rein-hydrostatischem Fahrantrieb bzw. mit hydro- Vehicle with a pure hydrostatic transmission or with a hydrostatic
statischem Fahrantrieb und Schaltgetriebe ohne Leerlaufstellung drive with gear box without free wheel position.
(Freilauf).
Hydrostatic transmission / Bypass condition
Hydrostatischer Antrieb / Bypaß-Schaltung
In this case the travel drive is switched on to the free wheel
In diesem Fall wird der Fahrantrieb auf freien Umlauf geschaltet. position. For this purpose the high pressure valves of the variable
Zu diesem Zweck haben die in der Verstellpumpe integrierten displacement pump have a so-called bypass function.
Hochdruckbegrenzungsventile eine sogenannte Bypaß-Funktion. By turning the relevant screw (item 1) the valve is so released
D.h. durch Drehen der entsprechenden Schraube (Pos.1) wird that free oil circulation is made possible.
der Ventil-Einsatz so entspannt, daß ein freier Öl-Umlauf möglich Bypass: Screw in item1 until it is level with the nut.
ist.
Bypass: Pos.1 einschrauben bis eben mit Mutter. Towing speed
Mutter wieder anziehen. The max. towing speed of 2 km/h should not be exceeded.
● Higher permissible speeds are depended on the hydraulic
Schleppgeschwindigkeit motor speed or the selected gear.
Die maximale Schleppgeschwindigkeit sollte 2 km/h nicht
überschreiten. Towing distance
● Höhere zulässige Schleppgeschwindigkeiten The towing distance should not exceed 1 km.
sind abhängig von der Hydromotordrehzahl
bzw. dem eingelegten Gang. ● With no boost avaiable the hydraulic circuit drains.
The heat generation in the hydraulic motor rotary group
Abschleppdistanz has to be taken into account.
Die Schleppentfernung sollte 1 km nicht überschreiten.
● Bei fehlender Einspeisung entleert sich der Termination of the towing operation
Hydraulik-Kreislauf. After termination of the towing operation turn back item 1.
Zu beachten ist die Wärmeentwicklung im The original set pressure value is thereby avaiable.
Hydromotor-Triebwerk. Valve function: Screw back item 1 up to stop.
Screw up the nut.
Abschleppvorgang beendet
Nach beendetem Abschleppvorgang Pos.1 zurückdrehen.
Der ursprüngliche Einstellwert der Hochdruckventile liegt somit
wieder vor.
Ventilfunktion: Pos.1 zurückschrauben bis
Anschlag. Mutter anziehen.

778 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
53

Einstellhinweise - Bypassventil DA
Adjustment instructions - Bypass valve DA

A10VG 28-45 Bypass: Pos.1 einschrauben bis Schraube am Federteller

DA-Control anliegt.Schraube maximal 1/2 Umdr. weiterdrehen!
Bypass: Screw in item 1 until contact, max 1/2 turn more.

Fahrzeuge mit rein-hydrostatischem Fahrantrieb bzw. mit hydro-

statischem Fahrantrieb und Schaltgetriebe ohne Leerlaufstellung
(Freilauf).
Hydrostatischer Antrieb / Bypaß-Schaltung Vehicle with hydrostatic transmission and gear shift without idling
In diesem Fall wird der Fahrantrieb auf freien Umlauf geschaltet. setting position (free wheeling).
Zu diesem Zweck haben die in der Verstellpumpe integrierten Hydrostatic transmission / Bypass-switching
Hochdruckbegrenzungsventile eine sogenannte Bypaß-Funktion. In this case the travel transmission is switched on to free
D.h. durch Drehen der entsprechenden Schraube (Pos.1) wird wheeling.For this purpose the variable displacement pump has
der Ventil-Einsatz so entspannt, daß ein freier Öl-Umlauf möglich incorporated high pressure relief valves with bypass function.
ist. The screw (item 1) is unscrewed to such an extent, that the valve
Bypass: Pos.1 einschrauben bis Schraube am cartridge is released and free oil circulation is possible.
Federteller anliegt.
Maximal 1/2 Umdrehung weiter drehen. Bypass: Screw in item1 until contact,
Max. 1/2 turn more.
Schleppgeschwindigkeit
Die maximale Schleppgeschwindigkeit sollte 2 km/h nicht
überschreiten. Towing speed
● Höhere zulässige Schleppgeschwindigkeiten sind The max. towing speed of 2 km/h should not be exceeded.
abhängig von der Hydromotordrehzahl bzw. dem ● Higher admissible towing speeds depend on the avaiable
eingelegten Gang. hydr. motor speed and engaged gear shift.

Abschleppdistanz Towing distance

Die Schleppentfernung sollte 1 km nicht überschreiten. The towing distance should not exceed 1 km.
● Bei fehlender Einspeisung entleert sich der Hydraulik- ● If there is a lack of oil boosting, the hydraulic circuit will get
Kreislauf. empty.
Zu beachten ist die Wärmeentwicklung im Hydromotor- Take care of the heat development in the hydr. motor-rotary
Triebwerk. group.

Abschleppvorgang beendet Towing operation terminated

Nach beendetem Abschleppvorgang Pos.1 zurückdrehen. Der After termination of the towing operation turn item 1 back. The
ursprüngliche Einstellwert der Hochdruckventile liegt somit original pressure value setting of the high pressure relief valves
wieder vor. will be avaiable again.
Ventilfunktion: Pos.1 zurückschrauben bis Anschlag. Valve function: Screw back item 1 up to stop.
Mutter anziehen. Screw up the nut.

008 917 69 BOMAG 779

24.4 Bosch Rexroth AG | Mobile Hydraulics
54 Conveyor
A10VG belt pump
| RDE 92 750-01-R/03.03

Einstellhinweise - DA- Regelung

Adjustment instructions - DA control

Achtung!
Sicherheitsbestimmungen beachten!

Überprüfung der Einstelldaten

Betriebstemperatur soll während des Über-
prüfungsvorgangs weitgehend konstant gehalten
werden.
Antriebsmotor starten, Leerlaufdrehzahl

Blockzustand
Fahrtrichtungsschalter "0“
Motordrehzahl langsam steigern bis zur max.
Motordrehzahl, dabei Meßgeräte beobachten.
Speisedruck:
Leerlaufdrehzahl
Psp = ca. 15-20 bar
max. Motordrehzahl
Psp = . . . . . . . . bar*

Blockzustand
Fahrtrichtungsschalter - vorwärts
(Straßengang und Festgebremst)
*
Einstelldaten Pumpe A10V/DA überprüfen
* Regelbeginn
HD 40 - 50 bar
Motordrehzahl . min.1 * Psp . . . . . bar*
HD . . . . . . bar
Nachjustierung - Regelbeginnschraube

Regelende
Verdrillung Regelbeginn
HD . . . . . bar*
Motordrehzahl . . . . . min.1 * Psp . . . . . bar*
Nachjustierung - Verdrillschraube

Hinweis:
Excenterjustierung - Drehrichtung beachten

Hinweis: * Einstelldaten nach Werksauftrag!

780 BOMAG 008 917 69

Conveyor belt pump
RDE 92 750-01-R/03.03 | A10VG Mobile Hydraulics | Bosch Rexroth AG 24.4
55

Einstellhinweise - DA- Regelung

Adjustment instructions - DA control

Attention!
Observe safety regulations!

Check setting data.

Operating temperature should be generally kept
constant during the checking procedure.
Start prime mover, idle speed.

Block position
Drive direction switch - "0“.
Slowly increase motor speed up to the max. motor
speed and observe measuring instruments.

Boost pressure:
Idle speed of prime mover
Psp = approx. 15 - 20 bar
max. motor speed
Psp = . . . . . . . . . bar*

Block position
* Drive direction switch - forwards
(Road gear and fully applied brake)

Check setting data pump A4VIDA

This repair manual describes the fixed displacement motor A2FM/E; the repair procedures are identical
with the ones for the fixed displacement motor A2FE32, which differs only by a different housing design.

802 BOMAG 008 917 69

Fan motor 24.6
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

RDE 91 001-03-R/05.03
Konstantmotor A2FM/E ersetzt / replaces 04.00

Fixed Displacement Motor A2FM/E

Baureihe / Series 61

Reparaturanleitung / Repair Instructions

008 917 69 BOMAG 803

24.6 Bosch Rexroth AG | Mobile Hydraulics
2 Fan motor
A2F | RDE 91 001-03-R/05.03

Hinweis / Inhalt
Notice / Contents

INHALT Seite/ CONTENTS

Page

A2F A2F

Schnittbild 3-6 Sectional view

Allgemeine Reparaturhinweise 7 General repair instructions
Dichtsätze und Baugruppen 8-9 Seal kits and sub-assemblies
Triebwelle abdichten 10 Sealing of the drive shaft
Anschlußplatte abdichten 11-14 Sealing of the cover plate
Triebwerk ausbauen 15-16 Removal the rotary group
Überprüfungshinweise 17-18 Inspection guidelines
Triebwerk einbauen 19-21 Installing rotary group
Anziehdrehmomente 22-24 Tightening torques
Sicherheitsbestimmungen 25 Safety regulations

804 BOMAG 008 917 69

Fan motor
RDE 91 001-03-R/05.03 | A2F Mobile Hydraulics | Bosch Rexroth AG 24.63
Schnittbild
Sectional view

A2FM Pos.B

Pos.D

Pos.A

Meßpunkte: Measuring points:

Siehe Serviceinfo See service information

008 917 69 BOMAG 805

24.6 Bosch Rexroth AG | Mobile Hydraulics
4 Fan motor
A2F | RDE 91 001-03-R/05.03

Schnittbild
Sectional view

A2FM mit Spülventil /

A2FM with flushing valve

806 BOMAG 008 917 69

Fan motor
RDE 91 001-03-R/05.03 | A2F Mobile Hydraulics | Bosch Rexroth AG 24.65
Schnittbild
Sectional view

A2FE

008 917 69 BOMAG 807

24.6 Bosch Rexroth AG | Mobile Hydraulics
6 Fan motor
A2F | RDE 91 001-03-R/05.03

Schnittbild
Sectional view

A2FE

808 BOMAG 008 917 69

Fan motor
RDE 91 001-03-R/05.03 | A2F Mobile Hydraulics | Bosch Rexroth AG 24.67
Allgemeine Reparaturhinweise
General repair instructions

Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!

Attention!
Observe the following notices when carrying out
repair work at hydraulic aggregates!

Alle Öffnungen der Hydraulikaggregate

verschließen.

Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.

Replace all seals.

Use only OR IG I NAL B R U E N I NG HAUS
HYDROMATIK spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.

Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.

Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befüllen bzw. entlüften.

Before start-up fill up hydraulic aggregates with

hydraulic oil respectively deaerate.

008 917 69 BOMAG 809

24.6 Bosch Rexroth AG | Mobile Hydraulics
8 Fan motor
A2F | RDE 91 001-03-R/05.03

Dichtsätze und Baugruppen

Seal kits and sub-assemblies

Dichtsatz

Seal kit

Triebwerk, mechanischer Teil /

Rotary group, mechanical part

Triebwerk, mechanischer Teil;

muß abgestimmt werden Pos. "A".
(siehe Serviceinfo)

Rotary group, mechanical part;

has to be adjusted to item "A".
(see service info)

Lagersatz, komplett abgestimmt.

Pos. B (Stützscheibe und Sicherungsring
nicht tauschbar)
zusätzliche Abstimmung Pos. "A".
(siehe Serviceinfo)

Bearing set, matched

Item B (support disc and circlip are
not exchangeable)
Additional adjustment item "A".
(see service info)

810 BOMAG 008 917 69

Fan motor
RDE 91 001-03-R/05.03 | A2F Mobile Hydraulics | Bosch Rexroth AG 24.69
Dichtsätze und Baugruppen
Seal kits and sub-assemblies

Triebwerk, hydraulischer Teil /

Rotary group, hydraulic part

Triebwerk, hydraulischer Teil;

Abstimmung hydraulischer Teil Pos. "D".
(siehe Serviceinfo)

Rotary group, hydraulic part;

Adjustment of the hydraulic part Pos. "D".
(see service info)

Triebwerk komplett; - fertig vorabgestimmt -

Abstimmung hydraulischer Teil Pos. "D".
(siehe Serviceinfo)

Complete rotary group, - pre-adjusted -

Adjustment of the hydraulic part Pos. "D".
(see service info)

Spülventil

Flushing valve

Ventil

Valve

008 917 69 BOMAG 811

24.6 Bosch Rexroth AG | Mobile Hydraulics
10 Fan motor
A2F | RDE 91 001-03-R/05.03

Triebwelle abdichten
Sealing of the drive shaft

Bei nicht verzahnten Triebwellen: Paßfeder abneh-

men. Triebwelle abkleben,

For non-splined shafts: remove key.

Protect the drive shaft (e.g. tape).

Sicherungsring ausbauen, Verschlußring abdrücken

Remove circlip, prise off cover.

Sichtkontrolle
Wellendichtring (1), Verschlußring (2),
Triebwelle (3), Gehäuse (4), O-Ring (5).

Visual check
Shaft seal (1), cover (2), drive shaft (3),
housing (4), O-ring (5).

812 BOMAG 008 917 69

Fan motor
RDE 91 001-03-R/05.03 | A2F Mobile Hydraulics | Bosch Rexroth AG 24.6
11

Triebwelle abdichten
Sealing of the drive shaft

Wellendichtring demontieren.

Remove shaft seal.

Neuen Wellendichtring lagerichtig mit

passender Büchse einpressen.

Press in the new shaft seal,ensuring that

it is correctly orientated, using a suitable bush.

Neuen O-Ring einlegen, auf bündiges Anliegen

achten. O-Ring sowie Dicht- und Staublippe des
Wellendichtringes einfetten. (siehe Serviceinfo)

Fit new O-ring, ensure that it is correctly located.

Grease the O-ring as well as the seal and dust lips
of the shaft seal. (see service information)

Sicherungsring einbauen.
Sitzkontrolle des Sicherungsringes in der Nut.

Fit circlip.
Check to ensure that the circlip is correctly located
within the groove.

008 917 69 BOMAG 813

24.6 Bosch Rexroth AG | Mobile Hydraulics
12 Fan motor
A2F | RDE 91 001-03-R/05.03

Anschlußplatte abdichten
Sealing of the cover plate

Lage der Anschlußplatte zum Gehäuse kenn-

zeichnen (Pfeil), Befestigungsschrauben lösen.

Mark the position of the cover plate with regard

to the housing (arrow), loosen the fixing screws.

Anschlußplatte um Verdrillstift schwenken (1)

und abheben (2).

Swing the connection plate about the locating

pin (1) and lift off (2).

814 BOMAG 008 917 69

Fan motor
RDE 91 001-03-R/05.03 | A2F Mobile Hydraulics | Bosch Rexroth AG 24.6
13

Anschlußplatte abdichten
Sealing of the cover plate

Auf Montagestellung des Verdrillstiftes achten

(Pfeile).

Take the assembly position of the locating

pin (arrow) into account.

Pumpe, Drehrichtung rechts.

Saugseite / (Blick auf sphärische Fläche.)
Suction side Druckseite /
Pressure side Pump, clockwise rotation.
(viewed on spherical surface.)

Saugseite /
Druckseite / Pumpe, Drehrichtung links.
Suction side
Pressure side (Blick auf sphärische Fläche.)

Pump, anti-clockwise rotation.

(viewed on spherical surface.)

Motor, beide Drehrichtungen.

(Blick auf sphärische Fläche.)

Motor, bi-directional.
(Viewed on spherical surface.)

008 917 69 BOMAG 815

24.6 Bosch Rexroth AG | Mobile Hydraulics
14 Fan motor
A2F | RDE 91 001-03-R/05.03

Anschlußplatte abdichten
Sealing of the cover plate

Sichtkontrolle
O-Ring (1), Einstich (2), Platte (3).

Visual check
O-ring (1), Groove (2), Plate (3).

Neuen O-Ring einlegen, zuvor leicht einfetten.

Lightly grease and fit O-ring.

Anschlußplatte aufsetzen, auf Kennzeichnung und

Lage des Verdrillstiftes achten.

Place the cover plate onto the housing taking into

account the location mark and position of the
locating pin.

Befestigungsschrauben mit Drehmomenten-

schlüssel anziehen.

Tighten fixing screws using a torque wrench.

816 BOMAG 008 917 69

Fan motor
RDE 91 001-03-R/05.03 | A2F Mobile Hydraulics | Bosch Rexroth AG 24.6
15

Triebwerk ausbauen
Removal the rotary group

Lagersatz / Bearing set

Demontage der Anschlußplatte.

Steuerplatte abheben.
Zylinder am Mittelzapfen mit Schraube befestigen.

Removal of the connection plate.

Lift off the control plate.
Secure the cylinder to the centre pin using a screw.

Gewindestift,Zylinderschraube /
Threaded pin,socket head screw

NG / Size (mm)

10; 12; 16 M3 x 35
23; 28; 32 M5 x 45
45 M5 x 50
56; 63 M5 x 55
80; 90 M5 x 60
107; 125; 131 M6 x 70
160; 180 M6 x 85

008 917 69 BOMAG 817

24.6 Bosch Rexroth AG | Mobile Hydraulics
16 Fan motor
A2F | RDE 91 001-03-R/05.03

Triebwerk ausbauen
Removal the rotary group

Verschlußring, O-Ring und Paßscheibe ausbauen.

Remove the cover, O-ring and shim.

Triebwerk mit Vorrichtung ausbauen.

Withdraw the rotary group using an extractor.

Befestigungsschraube ausbauen.
Zylinder abheben.

Remove the fixing screw.

Lift off the cylinder.

Rückzugplatte demontieren, Schrauben sind

eingeklebt.
Komplettes Triebwerk bei ca. 120o C im Ölbad
erwärmen. Danach Befestigungsschrauben lösen!

Disassemble the retaining plate, screws are locked

with an adhesive.
Heat up the complete rotary group in an oil bath
to approx 120o C, then remove the fixing screws.

818 BOMAG 008 917 69

Fan motor
RDE 91 001-03-R/05.03 | A2F Mobile Hydraulics | Bosch Rexroth AG 24.6
17

Überprüfungshinweise
Inspection guidelines

Triebwelle
4 4 1. kein Passungsrost, nicht ausgeschlagen.
1 2
3 2. keine Einlaufspuren, riefenfrei.
3. Kalotten riefenfrei und keine Pittings.
4. Keine Laufspuren (Lagerdreher)
3
Drive shaft
1. No wear, or fretting
2. No traces of wear, free of scratches.
3. Cups free of wear and no pitting.
4. No traces of wear, (bearing rotation).

1
1. Axiales Kolbenspiel

1. Axial play of piston.

Alt / Old

Kolben
Riefenfrei, keine Pittings.

Piston
Neu / New
Free of scratches, no pitting.

1 2
Mittelzapfen
1. Riefenfrei, ohne Pittings.
2. Riefenfrei.

Center pin
1. Free of scratches, no pittings.
2. Free of scratches.

Rückzugplatte
Riefenfrei, keine Ausbrüche.

Retaining plate
Free of scratches, no wear.

008 917 69 BOMAG 819

24.6 Bosch Rexroth AG | Mobile Hydraulics
18 Fan motor
A2F | RDE 91 001-03-R/05.03

Überprüfungshinweise
Inspection guidelines

Zylinder/Steuerplatte
1. Bohrungen riefenfrei, nicht ausgelaufen.
2. Gleichmäßiges Tragbild, riß- und riefenfrei.

Cylinder / control plate

1. Bores unscratched, and no traces of wear.
2. Even load distribution, free of cracks and
grooves.

Gehäuse
Im Lagerbereich riefenfrei und keine
Einlaufspuren.

Housing
No traces of wear in the bearing area.

Nur kompletten Kolbensatz austauschen.

Only exchange the pistons as a complete set.

Zylinder und Steuerplatte nur gemeinsam

austauschen.

Only replace the cylinder and control plate as a pair.

820 BOMAG 008 917 69

Fan motor
RDE 91 001-03-R/05.03 | A2F Mobile Hydraulics | Bosch Rexroth AG 24.6
19

Triebwerk einbauen
Installing rotary group

Triebwelle mit Lager vormontiert verwenden.

Use a pre-assembled drive shaft with bearings.

S Abstimmung Pos. A / Adjustment item A

A = A* + S
S = Nennmaß - Sicherungsring /Safety ring
A A*

Rückzugplatte mit Kolben und Mittelzapfen

einsetzen.
Schrauben mit Precote-Beschichtung verwenden.

Fit retaining plate complete with pistons and

centre pin.
Uses screws with a Precote coating.

Druckfeder (1) und Abstimmscheibe (2) einbauen.

Fit the compression spring (1) and shim(2).

Zylinder in Neutralposition befestigen.

Fix the cylinder in the neutral position.

008 917 69 BOMAG 821

24.6 Bosch Rexroth AG | Mobile Hydraulics
20 Fan motor
A2F | RDE 91 001-03-R/05.03

Triebwerk einbauen
Installing rotary group

Triebwerk max. ausschwenken.

Swivel the rotary group to max.

Neuer Radialwellendichtring montiert?

Is the new shaft seal fitted?

Gehäuse auf ca. 80o C erwärmen.

Heat the housing to approx. 80o C.

Heißes Gehäuse bis zum Anschlag aufsetzen.

Push on the hot housing until the stop is reached.

Neue Montagestellung.

New assembly position.

822 BOMAG 008 917 69

Fan motor
RDE 91 001-03-R/05.03 | A2F Mobile Hydraulics | Bosch Rexroth AG 24.6
21

Triebwerk einbauen
Installing rotary group

Paßscheibe, O-Ring einlegen. Verschlußring

montieren.
O-Ring, Zwischenraum Wellendichtring einfetten
(siehe Serviceinfo).

Fit the shim and O-ring. Then fit the cover.

Grease the O-ring as well as the seal and dust
lipsof the shaft seal.

Triebwerk gegen Verschlußring ziehen.

Kontrolle: Verschlußring spielfrei.

Pull the rotary group against the cover.

Check: to see that the cover is free of play.

Befestigungsschraube ausbauen.
Steuerplatte lagerichtig aufsetzen.
Fertigmontage
Abstimmung Pos. D - siehe Serviceinfo

Remove fixing screw. Fit the control plate into its

correct location.
Final assembly
For adjustment of Pos. D - see service info

Abstimmung Pos. D / Adjustment item D

Pos. D

Anschlüsse mit Staubschutz abdichten.

Korrosionsschutz (innen/außen). Fertig!

Seal connections to protect against dust.

Corrosion proctection (internal/external).
Assembly complete.

008 917 69 BOMAG 823

24.6 Bosch Rexroth AG | Mobile Hydraulics
22 Fan motor
A2F | RDE 91 001-03-R/05.03

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)

Festigkeitsklassen / Tensile strength class

824 BOMAG 008 917 69

Fan motor
RDE 91 001-03-R/05.03 | A2F Mobile Hydraulics | Bosch Rexroth AG 24.6
23

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).

G
EOLASTIC-
Dichtung / Seal

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

008 917 69 BOMAG 825

24.6 Bosch Rexroth AG | Mobile Hydraulics
24 Fan motor
A2F | RDE 91 001-03-R/05.03

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

7. Linsenschrauben 7. Oval head screw

mit Innen-TORX, Gewindevorbeschichtung mit "precote" with inner TORX, thread precoated with "precote"

Standard / Standard precote 80 - Rot / Red

precote 86 - Blau / Blue

Variante / Variant
*
Ι 2602493 M5 x 16
Ι 2602395 M6 x 20

siehe Stückliste / as to parts list

* mit Unterkopfbeschichtung - farblos

* with head bottom coating - colorless

Festigkeitsklassen / Tensile strength class

Gewinde / Thread 10.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 2,1
M4 4,7
M5 9,1
M6 15,8
M8 37,7

826 BOMAG 008 917 69

Fan motor
RDE 91 001-03-R/05.03 | A2F Mobile Hydraulics | Bosch Rexroth AG 24.6
25

Sicherheitsbestimmungen
Safety regulations

Allgemein General advice

Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.

Hydraulikanlage Hydraulic equipment

1. Hydraulikanlage steht unter hohem Druck! 1. Hydraulic equipment is standing under high pressure.
Unter hohem Druck austretende Hochdruck-Flüssig- High pressure fluids (fuel, hydraulic oil) which escape
keiten (Kraftstoff, Hydrauliköl) können die Haut durch- under high pressure can penetrate the skin and cause
dringen und schwere Verletzungen verursachen. heavy injuries.
Daher sofort einen Arzt aufsuchen, da anderenfalls Therefore immediately consult a doctor as otherwise
schwere Infektionen entstehen können! heavy infections can be caused.
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr 2. When searching leakages use appropriate auxiliary devices
geeignete Hilfsmittel verwenden! because of the danger of accidents.
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt 3. Before working at the hydraulic equipment, lower pressure
drucklos machen und angebaute Geräte absenken! to zero and lower working arms of the rnachine.
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor 4. When working at the hydraulic equipment, absolutely stop
abstellen und Traktor gegen Wegrollen sichern motor and secure tractor against rolling away
(Feststellbremse, Unterlegkeil)! (parking brake, shim)!
5. Beim Anschließen von Hydraulikzylindern und -motoren ist 5. When connecting hydraulic cylinders and motor pay
auf vorgeschriebenen Anschluß der Hydraulikschläuche attention to correct connection of hydraulic flexible hoses.
zu achten! 6. In case of exchanging the ports, the tunctions are vice versa
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen (f. ex. lift-up/lower) - danger of accidents!
(z.B. Heben/Senken) - Unfallgefahr! 7. Check hydraulic flexible hoses regularly and replace them in
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und case of dammage or wear! The new hose pipes must comply
bei Beschädigung und Alterung austauschen! Die with the technical requirements of the machine manufacturer!
Austausch schlauchleitungen müssen den technischen
Anforderungen des Geräteherstellers entsprechen! Orderly disposal or recycling of oil, fuel and
filters!
Öle, Kraftstoffe und Filter ordnungsgemäß
entsorgen!

008 917 69 BOMAG 827

24.6 Bosch Rexroth AG | Mobile Hydraulics
26 Fan motor
A2F | RDE 91 001-03-R/05.03

828 BOMAG 008 917 69

Fan motor
RDE 91 001-03-R/05.03 | A2F Mobile Hydraulics | Bosch Rexroth AG 24.6
27

008 917 69 BOMAG 829

24.6 Fan motor

Bosch Rexroth AG
Mobile Hydraulics
Produktbereich Axialkolbenmaschinen
Werk / Plant Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
info.brm-ak@boschrexroth.de
www.boschrexroth.com/brm

Mobile Hydraulics, 89275 Elchingen Mobile Hydraulics, 89275 Elchingen
All rights reserved. No part of this Alle Rechte vorbehalten. Kein Teil des
document may be reproduced or Werkes darf in irgendeiner Form ohne
stored, processed, duplicated or vorherige schriftliche Zustimmung der
circulated using electronic systems, in Bosch Rexroth AG reproduziert oder
any form or by any means, without the unter Verwendung elektronischer
prior written authorization of Bosch Systeme gespeichert, verarbeitet,
Rexroth AG. In the event of vervielfältigt oder verbreitet werden.
contravention of the above provisions, Zuwiderhandlungen verpflichten zu
the contravening party is obliged to Schadensersatz.
pay compensation. Die angegebenen Daten dienen allein
The data specified above only serve to der Produktbeschreibung. Eine
describe the product. No statements Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
given information does not release the werden. Die Angaben entbinden den
user from the obligation of own Verwender nicht von eigenen
judgement and verification. It must be Beurteilungen und Prüfungen. Es ist
remembered that our products are zu beachten, dass unsere Produkte
subject to a natural process of wear einem natürlichen Verschleiß- und
and aging. Alterungsprozess unterliegen.

Printed in Germany
RDE 91 001-03-R/05.03

830 BOMAG 008 917 69

25 Circuit diagrams

008 917 69 BOMAG 831

832 BOMAG 008 917 69
25.1 Electric circuit diagrams
2

008 917 69 BOMAG 833

25.1 Electric circuit diagrams

834 BOMAG 008 917 69

0 1 2 3 4 5 6 7 8 9

008 917 69
Industriegebiet Hellerwald
D-56154 Boppard
Electric circuit diagrams

BM/60-2
DEUTZ TIER3

BOMAG
ELECTRIC DRAWING

Drawing: DE012009

Created: 29.Apr.2010
Last update: 04.Ott.2011

Total Pages: 153

1.1
25.1

835
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BM/60-2 FRONT PAGE D: DE012009 pag. 1
date: 29.Apr.2010 PRIMA PAGINA

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836
PAGINA DESCRIZIONE COMMENTI PAGINA DESCRIZIONE COMMENTI
25.1

PAGE DESCRIPTION COMMENTS PAGE DESCRIPTION COMMENTS

1 FRONT PAGE 114 CENTRAL PANEL

PRIMA PAGINA PANNELLO CENTRALE

1.1 TABLE OF CONTENTS 116 ELECTRIC CABINET

INDICE QUADRO ELETTRICO

1.2 TABLE OF CONTENTS 118 ENGINE COMPARTMENT

INDICE VANO MOTORE

1.3 TABLE OF CONTENTS 150 BATTERY COMPARTMENT

INDICE VANO BATTERIA

1.4 TABLE OF CONTENTS 170 ENGINE EMR

INDICE MOTORE EMR

1.5 TABLE OF CONTENTS 170.1 ENGINE SENSORS

INDICE MOTORE SENSORI

1.6 TABLE OF CONTENTS 170.2 ENGINE PRE-HEAT

BOMAG
INDICE MOTORE PRERISCALDO

100 LAYOUT 170.4 ENGINE PRE-HEAT

DISPOSIZIONE MOTORE PRERISCALDO

100.1 LAYOUT 170.5 ENGINE STARTER

DISPOSIZIONE AVVIAMENTO MOTORE

106 LAYOUT 180 STARTING KEY

DISPOSIZIONE CHIAVE AVVIAMENTO

106.1 LAYOUT 200 POWER SUPPLY 24VDC

DISPOSIZIONE ALIMENTAZIONE 24VDC

110 LEFT PANEL 200.1 POWER SUPPLY 24VDC

PANNELLO SINISTRO ALIMENTAZIONE 24VDC

112 RIGHT PANEL 201.2 POWER SUPPLY 24VDC

PANNELLO DESTRO ALIMENTAZIONE 24VDC

008 917 69
Electric circuit diagrams

1 1.2

Design.: Zuccarino Luca

BM/60-2 TABLE OF CONTENTS D: DE012009 pag. 1.1
date: 29.Apr.2010 INDICE

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0 1 2 3 4 5 6 7 8 9

PAGINA DESCRIZIONE COMMENTI PAGINA DESCRIZIONE COMMENTI

PAGE DESCRIPTION COMMENTS PAGE DESCRIPTION COMMENTS

008 917 69
202 EMERGENCY PUSH BUTTONS 206.4 TRAVELLING
PULSANTI EMERGENZA AVANZAMENTO

204 CAN-BUS 206.5 TRAVELLING

AVANZAMENTO

204.1 CAN-BUS 206.6 TRAVELLING

AVANZAMENTO
Electric circuit diagrams

204.2 CAN-BUS 206.7 TRAVELLING

AVANZAMENTO

204.3 CAN-BUS 212 MILLING DRUM

RULLO FRESA

204.4 CAN-BUS 212.1 MILLING DRUM

RULLO FRESA

204.5 CAN-BUS 214 BACK DOOR

RIPPER

BOMAG
204.6 CAN-BUS 214.1 BACK DOOR
RIPPER

205 ENGINE RPM 214.2 BACK DOOR

MOTORE RPM RIPPER

206 TRAVELLING 214.3 BACK DOOR

AVANZAMENTO RIPPER

206.1 TRAVELLING 214.4 BACK DOOR

AVANZAMENTO RIPPER

206.2 TRAVELLING 214.5 BACK DOOR

AVANZAMENTO RIPPER

206.3 TRAVELLING 216 FAN

AVANZAMENTO VENTOLA

1.1 1.3
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838
PAGINA DESCRIZIONE COMMENTI PAGINA DESCRIZIONE COMMENTI
25.1

VOMERE SPRUZZATURA ACQUA

236 SIDE DOORS 242.1 WATER SPRAYING

PORTINE LATERALI SPRUZZATURA ACQUA

008 917 69
Electric circuit diagrams

1.2 1.4

Design.: Zuccarino Luca

BM/60-2 TABLE OF CONTENTS D: DE012009 pag. 1.3
date: 29.Apr.2010 INDICE

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0 1 2 3 4 5 6 7 8 9

PAGINA DESCRIZIONE COMMENTI PAGINA DESCRIZIONE COMMENTI

PAGE DESCRIPTION COMMENTS PAGE DESCRIPTION COMMENTS

008 917 69
242.2 WATER SPRAYING 266 HORN
SPRUZZATURA ACQUA CLAXON

244 PAUSE 266.1 HORN

PAUSA CLAXON

246 ROOF 272 WORKING LIGHTS

TETTOIA FARI DI LAVORO
Electric circuit diagrams

250 EMERGENCY SERVICES 272.1 WORKING LIGHTS

SERVIZI DI EMERGENZA FARI DI LAVORO

264 STEERING 272.2 WORKING LIGHTS

STERZATURA FARI DI LAVORO

264.1 STEERING 272.3 WORKING LIGHTS

STERZATURA FARI DI LAVORO

264.2 STEERING 272.4 WORKING LIGHTS

STERZATURA FARI DI LAVORO

BOMAG
264.3 STEERING 274 BEACON
STERZATURA GIROFARO

264.4 STEERING 280 FUEL FILLING

STERZATURA CARICAMENTO CARBURANTE

264.5 STEERING 281 DRUM MOVING

STERZATURA MOVIMENTAZIONE RULLO

264.6 STEERING 290 ALARMS

STERZATURA ALLARMI

264.7 STEERING 290.1 ALARMS

STERZATURA ALLARMI

264.8 STEERING 290.2 ALARMS

STERZATURA ALLARMI

1.3 1.5
25.1

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date: 29.Apr.2010 INDICE

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840
PAGINA DESCRIZIONE COMMENTI PAGINA DESCRIZIONE COMMENTI
25.1

PAGE DESCRIPTION COMMENTS PAGE DESCRIPTION COMMENTS

1.4 1.6

Design.: Zuccarino Luca

BM/60-2 TABLE OF CONTENTS D: DE012009 pag. 1.5
date: 29.Apr.2010 INDICE

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PAGINA DESCRIZIONE COMMENTI PAGINA DESCRIZIONE COMMENTI

PAGE DESCRIPTION COMMENTS PAGE DESCRIPTION COMMENTS

008 917 69
504.1 PLC 1009 BILL OF MATERIALS
DISTINTA BASE

504.2 PLC 1010 BILL OF MATERIALS

DISTINTA BASE

504.3 PLC 1011 BILL OF MATERIALS

DISTINTA BASE
Electric circuit diagrams

504.4 PLC 1012 BILL OF MATERIALS

DISTINTA BASE

1000 BILL OF MATERIALS 1013 BILL OF MATERIALS

DISTINTA BASE DISTINTA BASE

1001 BILL OF MATERIALS 1014 BILL OF MATERIALS

DISTINTA BASE DISTINTA BASE

1002 BILL OF MATERIALS 1015 BILL OF MATERIALS

DISTINTA BASE DISTINTA BASE

841
Design.: Zuccarino Luca
BM/60-2 TABLE OF CONTENTS D: DE012009 pag. 1.6
date: 29.Apr.2010 INDICE

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842
25.1

B3
201.2.2
214.1.0
226.8.1
236.1.0
B8
LEFT
REAR 201.2.1
BOX 202.0
226.5.1
234.1.1
240.4
B5 266.0
201.2.4
LEFT
202.2
FRONT
226.4.1
BOX
226.7.1
264.5.1
266.2
LEFT
REAR
BOX

BOMAG
B1
264.6.6
STEER
ADJUST

008 917 69
Electric circuit diagrams

1.6 100.1

Design.: Zuccarino Luca

BM/60-2 LAYOUT D: DE012009 pag. 100
date: 29.Apr.2010 DISPOSIZIONE

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0 1 2 3 4 5 6 7 8 9

008 917 69
Electric circuit diagrams

B13
150.1
290.4.5
BATTERY
COMPARTMENT

BOMAG
B14 M1 B15 B16
118.1 170.0 280.3 272.4.1 238.9.4
170.1.0 170.2.0 274.4 266.1.3
FUEL
170.4.0 170.5.1 266.1.3
FILL ROOF
204.5.0 205.1
206.6.0 212.1.1 CONVEYOR
214.4.0 214.5.0
216.2 226.9.0
234.2.2 236.3.0
238.6.0 238.7.0
242.2.1
264.7.2
264.8.0
290.0
290.1.1
290.2.2
290.3.0
504.1.0
504.2.0
504.3.0
504.4.0
ENGINE
COMPARTMENT

100 106
25.1

843
Design.: Zuccarino Luca
BM/60-2 LAYOUT D: DE012009 pag. 100.1
date: 29.Apr.2010 DISPOSIZIONE

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0 1 2 3 4 5 6 7 8 9

B17 B18 B19

844
110.1 202.0 114.1 112.1 202.7
204.0 206.0 170.2.0 204.1.0 206.4
206.1.0 206.2.0 180.0 206.1.5 206.2.5
206.3.0 206.4.0 204.2.0 206.3.5 206.4.5
206.5.0 212.0 205.1 206.5.5 212.5
25.1

214.0 226.0 226.8.3 214.5 226.5

226.1.0 226.2.0 236.2.0 226.1.5 226.2.5
234.0 236.1 238.2.0 234.5 236.5
238.0 238.1.0 238.8.2 238.5 238.1.5
242.0 244.0 246.0 242.5 244.5
264.0 264.1.0 272.3 264.5 264.1.5
264.2.1 264.3.0 274.3 264.2.5 264.3.5
264.4.0 290.4.0 264.4.5
266.0 501.1.2 266.6
272.0 272.7
CENTRAL
500.1.0 502.1.0
PANEL
500.2.0 502.2.0
500.3.0 502.3.0
500.4.0 502.4.0
500.5.0 502.5.0
LEFT RIGHT
PANEL PANEL

BOMAG
008 917 69
Electric circuit diagrams

100.1 106.1

Design.: Zuccarino Luca

BM/60-2 LAYOUT D: DE012009 pag. 106
date: 29.Apr.2010 DISPOSIZIONE

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0 1 2 3 4 5 6 7 8 9

B20
116.1 170.2.0 180.0
200.0 200.1.1 201.2.0
202.0 204.0 204.1.0
204.2.0 204.3.0 204.4.0
204.5.0 204.6.0 205.1
206.7.0 214.1.0 214.2.0
214.3.0 216.0 226.4.0

008 917 69
226.5.0 226.6.1 226.7.0
226.8.0 226.9.0 234.1.1
236.1.0 236.2.0 238.2.0
238.7.0 238.8.1 238.9.1
240.0 242.1.0 246.0
264.5.1 264.6.0 264.8.0
266.0 272.0 272.1.0
272.2.0 272.3.0 272.4.1
274.0 280.0 281.0
290.0 290.1.0 290.2.0
290.3.0 290.4.0 503.1.0
503.2.0 503.3.0
503.4.0 503.5.0
ELECTRIC
CABINET
Electric circuit diagrams

BOMAG
106 110
25.1

845
Design.: Zuccarino Luca
BM/60-2 LAYOUT D: DE012009 pag. 106.1
date: 29.Apr.2010 DISPOSIZIONE

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0 1 2 3 4 5 6 7 8 9

B17

846
106.1
LEFT
PANEL
25.1

U1 U2 U3 U4 U5
204.1 204.3 204.5 204.6 204.8
212.1 206.1 206.5.1 264.1 236.1
226.1 206.1.1 214.1 264.1.1 238.1
226.1.1 206.2.1 234.1 264.2.1 264.3.1
242.1 206.3.1 238.1.1 500.4.1 264.4.1
500.1.1 206.4.1 244.1 500.4.1 500.5.1
500.1.1 226.2.1 500.3.1 500.4.5 500.5.1
500.1.5 500.2.1 500.3.1 500.5.5
12 DI
500.2.1 500.3.5 4AI
12 DI 12 DI
500.2.5
4AI 12 DI 4DO 4AI
4DO 12 DI 4AI NODE ID 4 4DO
NODE ID 1 4AI 4DO I/O MODULE NODE ID 5
I/O MODULE 4DO NODE ID 3 I/O MODULE
NODE ID 2 I/O MODULE
I/O MODULE

BOMAG
008 917 69
Electric circuit diagrams

106.1 112

Design.: Zuccarino Luca

BM/60-2 LEFT PANEL D: DE012009 pag. 110
date: 29.Apr.2010 PANNELLO SINISTRO

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0 1 2 3 4 5 6 7 8 9

B19
106.6
RIGHT
PANEL

U1 U2 U3 U4 U5
204.1.1 204.1.3 204.1.5 204.1.6 204.1.8
212.6 206.5 206.5.6 264.6 236.6

008 917 69
226.5 206.1.5 214.6 264.1.6 238.6
226.1.5 206.2.6 234.5 264.2.6 264.3.6
242.6 206.3.5 238.1.6 502.4.1 264.4.5
502.1.1 206.4.5 244.6 502.4.1 502.5.1
502.1.1 226.2.6 502.3.1 502.4.5 502.5.1
502.1.5 502.2.1 502.3.1 502.5.5
12 DI
502.2.1 502.3.5 4AI
12 DI 12 DI
502.2.5
4AI 12 DI 4DO 4AI
4DO 12 DI 4AI NODE ID 9 4DO
NODE ID 6 4AI 4DO I/O MODULE NODE ID 10
I/O MODULE 4DO NODE ID 8 I/O MODULE
NODE ID 7 I/O MODULE
I/O MODULE
Electric circuit diagrams

BOMAG
110 114
25.1

847
Design.: Zuccarino Luca
BM/60-2 RIGHT PANEL D: DE012009 pag. 112
date: 29.Apr.2010 PANNELLO DESTRO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B18

848
106.4
CENTRAL
PANEL
U1
25.1

204.2.2
501.1.3
5,7" MONOCHROME DISPLAY
PDM 360

BOMAG
008 917 69
Electric circuit diagrams

112 116

Design.: Zuccarino Luca

BM/60-2 CENTRAL PANEL D: DE012009 pag. 114
date: 29.Apr.2010 PANNELLO CENTRALE

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B20
106.1.1
ELECTRIC
CABINET
U1 U2 U3 U4 U5
204.3.1 204.3.3 204.3.5 204.3.7 204.4.1
205.6 234.1.2 226.6.1 214.2.3 206.7.1

008 917 69
214.1.3 234.1.4 242.1.3 214.3.4 206.7.6
214.1.6 236.1.2 290.2.3 238.2.3 226.5.2
226.4.4 236.1.5 290.3.1 238.9.7 226.5.4
236.1.3 236.2.3 290.3.2 290.1 226.5.8
236.1.7 264.5.4 290.4.7 290.4.1 226.9.1
290.3.5 290.1.3 503.3.1 290.4.2 226.9.3
290.4.8 503.2.1 503.3.1 503.4.1 226.9.6
503.1.1 503.2.1 503.3.5 503.4.1 226.9.8
503.1.1 503.2.5 503.4.5 264.6.2
12 DI
503.1.5 264.6.4
12 DI 4AI 12 DI
264.6.7
12 DI 4AI 4DO 4AI
264.8.3
4AI 4DO NODE ID 13 4DO
264.8.5
4DO NODE ID 12 I/O MODULE NODE ID 14
503.5.1
NODE ID 11 I/O MODULE I/O MODULE
503.5.5
I/O MODULE
24DI 8DO 8AI
CR0505
Electric circuit diagrams

BOMAG
114 118
25.1

849
Design.: Zuccarino Luca
BM/60-2 ELECTRIC CABINET D: DE012009 pag. 116
date: 29.Apr.2010 QUADRO ELETTRICO

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0 1 2 3 4 5 6 7 8 9

850
25.1

B14
100.1.4
ENGINE
COMPARTMENT

U1 U2 U3 U4
204.5.1 204.5.3 204.5.5 204.5.7
206.6.2 212.1.2 214.4.2 214.5.4
206.6.4 212.1.6 214.4.4 234.2.3
206.6.6 226.9.3 214.4.6 234.2.5
216.2 226.9.5 236.3.1 242.2.2
238.7.1 238.6.1 236.3.3 242.2.5
238.7.5 238.6.3 236.3.5 264.7.3
504.1.1 238.6.5 236.3.7 264.7.5
504.1.1 238.6.7 504.3.1 504.4.1
504.1.5 504.2.1 504.3.1 504.4.1
504.2.1 504.3.5 504.4.5
8DO
504.2.5
NODE ID 16 8DO 8DO
OUTPUT 8DO NODE ID 18 NODE ID 19
MODULE NODE ID 17 OUTPUT OUTPUT
OUTPUT MODULE MODULE
MODULE

BOMAG
008 917 69
Electric circuit diagrams

116 150

Design.: Zuccarino Luca

BM/60-2 ENGINE COMPARTMENT D: DE012009 pag. 118
date: 29.Apr.2010 VANO MOTORE

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B13
100.1.1
BAT-50A /180.2
BATTERY
COMPARTMENT

008 917 69
BAT-EME /246.7

BAT-150A /250.2

PREHEAT /170.4.8
Electric circuit diagrams

B21
FUSES
BOX

F1 F2 F3 F4
80A 25A 150A 80A
MAIN EMERGENCY EMERGENCY PREHEAT
PUMP

STARTER /170.5.2

BOMAG
+

G1
BATTERY
-

G2
BATTERY
-

3
C3
MANUAL 4
SWITCH

NEG-ENGINE /170.5.2

NEG /180.2

GND

118 170
25.1

851
Design.: Zuccarino Luca
BM/60-2 BATTERY COMPARTMENT D: DE012009 pag. 150
date: 29.Apr.2010 VANO BATTERIA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

852
B14
100.1.4 U5
ENGINE 170.1.1
COMPARTMENT 170.1.6
25.1

170.2.1
170.4.1
205.2
EMR

+VCC
+VCC
+VCC
+VCC
GND
GND
GND
GND
+VCC
ISO K
CAN H 1
CAN L 1
CAN H 2
CAN L 2

XD2.1 2 3 8 9 5 6 10 11 40 89 53 52 35 34

XME A B C D XME U V W X XME E XME G H J K L

GND

EMR A
180.3 GND

BOMAG
EMR B D2.1:40 EMR EMR
200.1.2 170.1.6 CAN H CAN L
204.6.6 204.6.7

B7
100.5
XMB A K H G M F B
BACK
DASH
PANEL

DIAGNOSTIC

008 917 69
Electric circuit diagrams

150 170.1

Design.: Zuccarino Luca

BM/60-2 ENGINE EMR D: DE012009 pag. 170
date: 29.Apr.2010 MOTORE EMR

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B14
100.1.4
ENGINE U5 U5
COMPARTMENT
170.1 170.1
EMR EMR

008 917 69
AIR PRESSURE
+VCC
+GND
COOLANT LEVEL
OIL LEVEL
OIL LEVEL
+VCC
GND
STARTER +
STARTER -
WATER IN FUEL
GND

XD2.1 42 21 29 55 85 X27-2 5 2 3 8 7 10 11

XME Q R XME T S F
Electric circuit diagrams

GND GND

1
C13
XY 1 2 XJ 1 2 ENGINE 2
FUEL
FILTER

1 2 1 2

1
C12 P C11 C18
ENGINE 2 ENGINE ENGINE
AIR COOLANT COOLANT
LEVEL 2 3 LEVEL 3
FILTER

BOMAG
XY 3 XJ 3

START 1 /180.6

170.1S4 /290.3.2

D2.1:40
170.4

170 170.2
25.1

853
Design.: Zuccarino Luca
BM/60-2 ENGINE SENSORS D: DE012009 pag. 170.1
date: 29.Apr.2010 MOTORE SENSORI

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B18

854
106.4
CENTRAL
PANEL
25.1

A
H1
STATUS K
PREHEAT

B20
106.1.1
ELECTRIC
CABINET

U6A X 1 X 2
204.6.6
206.7.2
290.5
290.3.3
PCB

R1
1KOhm
1W

X 1A X 2A

BOMAG
XD 1 2

XD 1 2

B14
100.1.4
ENGINE
COMPARTMENT
XME M N

U5 XD2.1 54 13
170.1
EMR
+VCC

PREHEAT

008 917 69
Electric circuit diagrams

170.1 170.4

Design.: Zuccarino Luca

BM/60-2 ENGINE PRE-HEAT D: DE012009 pag. 170.2
date: 29.Apr.2010 MOTORE PRERISCALDO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B14
100.1.4
ENGINE
COMPARTMENT

150.6
PREHEAT

008 917 69
10MMQ

4MMQ
4MMQ
Electric circuit diagrams

X17.1 1 X17.1 2
4MMQ
4MMQ

85 50I

BOMAG
K10
K10
.7
PREHEAT 50 30
2.5MMQ
4MMQ
4MMQ

U5 X27.1 20 19 25
170.1
EMR
R3.1 R3.2

PREHEAT
PREHEAT
PREHEAT
OPTIONAL 30 50I .8
170.2 170.5
25.1

855
Design.: Zuccarino Luca
BM/60-2 ENGINE PRE-HEAT D: DE012009 pag. 170.4
date: 29.Apr.2010 MOTORE PRERISCALDO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

856
25.1

B14
100.1.4
ENGINE
COMPARTMENT

150.6/ STARTER

30
Connect only
B+
with BOSCH starter
D+
D+ /290.3.1 50f
G M
C5 3
C6 START 2 /180.7
W
GENERATOR NC STARTER
B-
31 START 3 /180.7

BOMAG
150.6/ NEG-ENGINE ENGINE GND

ENGINE GND

008 917 69
Electric circuit diagrams

170.4 180

Design.: Zuccarino Luca

BM/60-2 ENGINE STARTER D: DE012009 pag. 170.5
date: 29.Apr.2010 AVVIAMENTO MOTORE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B18
106.4
CENTRAL
PANEL 30 30 30 30 30 30 30 30
S1
.5 .4 .4 .4 .4 .4 .4 .4
.5 58 15/54 15/54 19 19 17 17 50a

008 917 69
.6
.6
.5
.6 54
.7
246.1
IGNITION
KEY

B20
106.1.1
ELECTRIC
Electric circuit diagrams

CABINET

F1
15A
15
EMR 200.2

30 /200.4

F2
25A
EMR

BOMAG
XP 1 XP 0 XD 3
GND

XP 1 XP 2 XD 31 XS 1

XD 3 XD 31 XS 1

XC6 1 XC6 2

NEG
150.6 EMR A
170.1 START 1 START 2 START 3
BAT-50A 170.1.8 170.5.7 170.5.7
150.6

170.5 200
25.1

857
Design.: Zuccarino Luca
BM/60-2 STARTING KEY D: DE012009 pag. 180
date: 29.Apr.2010 CHIAVE AVVIAMENTO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

858
25.1

B20
106.1.1
ELECTRIC
CABINET 180.5/ 15 180.4/ 30 30 /272.6 +24EC /200.1.2

XA 1

EM1 /202.1
EM2 /202.8

XA 2
+
Z1
SOPPRESSOR -

85 30
K2
K2
.2
EMERGENCY 86 87
EMERGENCY

85 30
K3

BOMAG
K3
.3
EMERGENCY 86 87
EMERGENCY

GND GND

008 917 69
Electric circuit diagrams

30 87 .4 30 87 .4
180 200.1

Design.: Zuccarino Luca

BM/60-2 POWER SUPPLY 24VDC D: DE012009 pag. 200
date: 29.Apr.2010 ALIMENTAZIONE 24VDC

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

008 917 69
B20
106.1.1
ELECTRIC
CABINET 200.8/ +24EC +24EC /201.2.1

F4
F3 F5
10A
7.5A CONV. 1A
EMR 24V/12V 24V-10V
Electric circuit diagrams

CONVERTER

XA 4 XA 7

+10EC /226.5.1

RED
RED
BLACK
U10
24V/12V +24V
CONV

U11
+12V GND 24V-10V +24VCC +10VCC
CONVERTER

GND GND

BOMAG
GREEN
BLACK
XA 5 6 XA 8 XA 9

XD 4 XD 5 6
BLUE
BLUE

GND GND

XD 4 XD 5 6

EMRB
170.4

B7
100.5
C101
BACK
DASH SOCKET
PANEL 12V

200 201.2
25.1

859
Design.: Zuccarino Luca
BM/60-2 POWER SUPPLY 24VDC D: DE012009 pag. 200.1
date: 29.Apr.2010 ALIMENTAZIONE 24VDC

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

860
25.1

B20
106.1.1
ELECTRIC
CABINET 200.1.7/ +24EC +24EC /204.2.5

F6 F7 F8 F9 F10 F11
1A 1A 1A 1A 1A 1A
LEFT LEFT LEFT RIGHT RIGHT RIGHT
FRONT REAR REAR FRONT REAR REAR
BOX BOX BOX BOX BOX BOX

XS 2 XS 3 XS 4 XD 7 XD 8 XD 9

BOMAG
XS 2 XS 3 XS 4 XD 7 XD 8 XD 9

GND GND GND GND GND GND

XAS K A XPSA K A XPSB K A XAD K A XPDA K A XPDB K A

W8 25X1 11 1 W4 25X1 11 6 W6 25X1 11 6 W9 25X1 11 1 W5 25X1 11 1 W7 25X1 11 1

B8 B3 B5 B9 B4 B6
100.6 100.2 100.2 100.6 100.2 100.2
LEFT LEFT LEFT RIGHT RIGHT RIGHT
FRONT +VCC REAR +VCC REAR +VCC FRONT +VCC REAR +VCC REAR +VCC
BOX B8 BOX B3 BOX B5 BOX B9 BOX B4 BOX B6
234.1.2 214.1.1 226.4.2 234.1.7 214.1.6 226.4.6

GND GND GND GND GND GND

008 917 69
Electric circuit diagrams

200.1 202

Design.: Zuccarino Luca

BM/60-2 POWER SUPPLY 24VDC D: DE012009 pag. 201.2
date: 29.Apr.2010 ALIMENTAZIONE 24VDC

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17 B19
106.1 106.6
LEFT RIGHT
PANEL 11 PANEL 11
S1 S1

008 917 69
EMERGENCY 12 EMERGENCY 12
PUSHBUTTON PUSHBUTTON

XE 1 2 XE 1 2

B20
106.1.1
XE1 1 2 XE3 1 2
ELECTRIC
CABINET
Electric circuit diagrams

EM1 EM2
200.2 200.2

XS 5 6 XD 10 11

BOMAG
XS 5 6 XD 10 11

XAS E F XPSB D E XAD F E XPDB E D

W8 25X1 5 6 W6 25X1 5 6 W9 25X1 11 1 W7 25X1 5 4

B8 B5 B9 B6
100.6 100.2 100.6 100.2
LEFT FRONT LEFT REAR RIGHT FRONT RIGHT REAR
BOX 11 BOX 11 BOX 11 BOX 11
S1 S1 S1 S1
EMERGENCY 12 EMERGENCY 12 EMERGENCY 12 EMERGENCY 12
PUSHBUTTON PUSHBUTTON PUSHBUTTON PUSHBUTTON
C39 C20 C32 C25

201.2 204
25.1

861
Design.: Zuccarino Luca
BM/60-2 EMERGENCY PUSH BUTTONS D: DE012009 pag. 202
date: 29.Apr.2010 PULSANTI EMERGENZA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17

862
106.1 U1 U3 U5
LEFT 110.2 110.5 110.7
PANEL
I/O I/O I/O
MODULE MODULE MODULE
25.1

+VCC
GND
+VCC
GND
CAN-L
CAN-H
+VCC
GND
+VCC
GND
CAN-L
CAN-H
+VCC
GND
+VCC
GND
CAN-L
CAN-H

X3.1
X3.2
X3.3
X3.4
X3.5
X3.6
X3.1
X3.2
X3.3
X3.4
X3.5
X3.6
X3.1
X3.2
X3.3
X3.4
X3.5
X3.6

X3 1 2 3 4 5 6 X3 1 2 3 4 5 6 X3 1 2 3 4 5 6

U2 U4
110.3 110.6
I/O I/O
MODULE MODULE

+VCC
GND
+VCC
GND
CAN-L
CAN-H
+VCC
GND
+VCC
GND
CAN-L
CAN-H

X3.1
X3.2
X3.3
X3.4
X3.5
X3.6
X3.1
X3.2
X3.3
X3.4
X3.5
X3.6

X3 1 2 3 4 5 6 X3 1 2 3 4 5 6

F1 R1 F2 F3 F4 F5
120Ohm
1A 1/2W 1A 1A 1A 1A
CR2012 CR2012 CR2012 CR2012 CR2012

XCL 3 2 1 5 4

BOMAG
GND XCB 1 2 3 4 5
1:GND 2:+VCC 3:CAN-GND 4:CAN-H 5:CAN-L

B20 XCB1 1 2 3 4 5
106.1.1
ELECTRIC
CABINET

GND CBF1:5 /204.6.5

GND GND CBF1:4 /204.6.3

CBF1:2 /204.6.2

008 917 69
Electric circuit diagrams

202 204.1

Design.: Zuccarino Luca

BM/60-2 CAN-BUS D: DE012009 pag. 204
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B19
106.6 U1 U3 U5
RIGHT 112.2 112.5 112.7
PANEL
I/O I/O I/O
MODULE MODULE MODULE

+VCC
GND
+VCC
GND
CAN-L
CAN-H
+VCC
GND
+VCC
GND
CAN-L
CAN-H
+VCC
GND
+VCC
GND
CAN-L
CAN-H

008 917 69
X3.1
X3.2
X3.3
X3.4
X3.5
X3.6
X3.1
X3.2
X3.3
X3.4
X3.5
X3.6
X3.1
X3.2
X3.3
X3.4
X3.5
X3.6

X3 1 2 3 4 5 6 X3 1 2 3 4 5 6 X3 1 2 3 4 5 6

U2 U4
112.3 112.6
I/O

+VCC
GND
+VCC
GND
CAN-L
CAN-H
+VCC
GND
+VCC
GND
CAN-L
I/O
CAN-H
MODULE MODULE
Electric circuit diagrams

X3.1
X3.2
X3.3
X3.4
X3.5
X3.6
X3.1
X3.2
X3.3
X3.4
X3.5
X3.6

X3 1 2 3 4 5 6 X3 1 2 3 4 5 6

F1 R1 F2 F3 F4 F5
120Ohm
1A 1/2W 1A 1A 1A 1A
CR2012 CR2012 CR2012 CR2012 CR2012

XCR 3 2 1 5 4

BOMAG
GND XCB 1 2 3 4 5
1:GND 2:+VCC 3:CAN-GND 4:CAN-H 5:CAN-L

GND

B20 XCB3 1 2 3 4 5
106.1.1
ELECTRIC
CABINET

GND
CBF3:5 /204.6.5
GND GND CBF3:4 /204.6.3

CBF3:2 /204.6.2

204 204.2
25.1

863
Design.: Zuccarino Luca
BM/60-2 CAN-BUS D: DE012009 pag. 204.1
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B18

864
106.4 U1
CENTRAL 114.4
6x0.5 mmq 1 BIANCO/WHITE
PANEL
PDM 360 2 MARRONE/BROWN
25.1

3 VERDE/GREEN

GND
+VCC SW
GND
CAN 1 H
CAN 1 L
+VCC
9 GIALLO/YELLOW
10 GRIGIO/GREY

X1.1
X1.9
X1.2
X1.5
X1.4
X1.3
11 ROSA/PINK

X1 1 9 2 5 4 3
4x0.25 mmq 4 BIANCO/WHITE
5 MARRONE/BROWN
13 VERDE/GREEN
14 GIALLO/YELLOW
XCC 1 2 3 4 5 8

2x0.25 mmq 7 GRIGIO/GREY

8 ROSA/PINK

F1
1A
DISPLAY

BOMAG
B20
106.1.1
ELECTRIC
CABINET
F53
1A
PDM 360

GND GND CBF2A:5 /204.6.5 201.2.8/ +24EC +24EC /204.3.1

CBF2A:4 /204.6.3

CBF2A:2 /204.6.2

008 917 69
Electric circuit diagrams

204.1 204.3

Design.: Zuccarino Luca

BM/60-2 CAN-BUS D: DE012009 pag. 204.2
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1
ELECTRIC
CABINET

008 917 69
U1 U2 U3 U4
116.2 116.3 116.4 116.6
I/O I/O I/O I/O
MODULE MODULE MODULE MODULE

+VCC
GND
+VCC
GND
CAN-L
CAN-H
+VCC
GND
+VCC
GND
CAN-L
CAN-H
+VCC
GND
+VCC
GND
CAN-L
CAN-H
+VCC
GND
+VCC
GND
CAN-L
CAN-H

X3.1
X3.2
X3.3
X3.4
X3.5
X3.6
X3.1
X3.2
X3.3
X3.4
X3.5
X3.6
X3.1
X3.2
X3.3
X3.4
X3.5
X3.6
X3.1
X3.2
X3.3
X3.4
X3.5
X3.6

X3 1 2 3 4 5 6 X3 1 2 3 4 5 6 X3 1 2 3 4 5 6 X3 1 2 3 4 5 6
Electric circuit diagrams

F12 F13 F14 F15

1A 1A 1A 1A
CR2012 CR2012 CR2012 CR2012

BOMAG
116U1 /204.6.3 116U2 /204.6.3 116U3 /204.6.3 116U4 /204.6.3
X3.6 X3.6 X3.6 X3.6

116U1 /204.6.5 116U2 /204.6.5 116U3 /204.6.5 116U4 /204.6.5

X3.5 X3.5 X3.5 X3.5

GND

204.2.6/ +24EC +24EC /204.4.1

204.2 204.4
25.1

865
Design.: Zuccarino Luca
BM/60-2 CAN-BUS D: DE012009 pag. 204.3
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

866
B20
106.1.1
25.1

ELECTRIC U5
CABINET
116.7
CR0505

+VCC
+VCC
TEST
ERROR
GND
GND
GND
CAN 1 H
CAN 1 L
CAN 2 H
CAN 2 L

+VCC
GND
RS232 2 Rx
RS232 2 Tx

X.5
X.23
X.34
X.24
X.13
X.1
X.15
X.12
X.6
X.7
X.33
X.14
X.32
X.26
X.25

X 5 23 34 24 13 1 15 12 6 7 33 14 32 26 25

GND GND GND

XA 11 12 13

GREEN
WHITE
BROWN

XRS 3 2 6 5 CR-26
13
204.6.7
S1
TEST 14
CR-25

BOMAG
CR-14 204.6.7
204.6.3

CR-32
204.6.5

F16 F17 F18 XA 10

7.5A 7.5A 7.5A

CR0505 CR0505 CR0505

204.3.8/ +24EC +24EC /204.5.1

008 917 69
Electric circuit diagrams

204.3 204.5

Design.: Zuccarino Luca

BM/60-2 CAN-BUS D: DE012009 pag. 204.4
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1
204.4.8/ +24EC +24EC /204.6.1
ELECTRIC
CABINET

008 917 69
F19 F20 F21 F22 F23 F24 F25 F26
15A 4A 15A 4A 15A 4A 15A 4A
CR2031 CR2031 CR2031 CR2031 CR2031 CR2031 CR2031 CR2031
Electric circuit diagrams

XS 7 8 9 10 11 12 13 14

204.6.5/ C-L

204.6.4/ C-H

BOMAG
B14
100.1.4
ENGINE
COMPARTMENT GND

XU1 1 2 3 4 5 XU2 1 2 3 4 5 XU3 1 2 3 4 5 XU4 1 2 3 4 5

GND GND GND GND

BLUE
YELLOW
BROWN
WHITE
WHITE
BLUE
YELLOW
BROWN
WHITE
WHITE
BLUE
YELLOW
BROWN
WHITE
WHITE
BLUE
YELLOW
BROWN
WHITE
WHITE

U1 U2 U3 U4
118.3 118.4 118.5 118.6
8DO 8DO 8DO 8DO
OUTPUT OUTPUT OUTPUT OUTPUT
MODULE 1 2 3 4 5 6 7 MODULE 1 2 3 4 5 6 7 MODULE 1 2 3 4 5 6 7 MODULE 1 2 3 4 5 6 7
X X X X

X.1
X.2
X.3
X.4
X.5
X.6
X.7
X.1
X.2
X.3
X.4
X.5
X.6
X.7
X.1
X.2
X.3
X.4
X.5
X.6
X.7
X.1
X.2
X.3
X.4
X.5
X.6
X.7

GND
GND
GND
GND
GND
GND
GND
GND

+VCC
+VCC
+VCC
+VCC
+VCC
+VCC
+VCC
+VCC
+VCC
+VCC
+VCC
+VCC

CAN H
CAN L
CAN H
CAN L
CAN H
CAN L
CAN H
CAN L

204.4 204.6
25.1

867
Design.: Zuccarino Luca
BM/60-2 CAN-BUS D: DE012009 pag. 204.5
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

868
B20
106.1.1
204.5.8/ +24EC +24EC /205.2
25.1

ELECTRIC
CABINET

F27
7.5A 204.1.3/ CBF3:4 204.1.3/ CBF3:5 204.4.8/ CR-25
CANBUS

204.3/ CBF1:4 204.3/ CBF1:5

204.2.3/ CBF2A:4 204.2.3/ CBF2A:5

204.4.8/ CR-26

204.3.3/ 116U1 204.3.3/ 116U1

X3.6 X3.5

204.3.5/ 116U2 204.3.5/ 116U2

X3.6 X3.5

U6A
204.3.6/ 116U3 204.3.6/ 116U3
170.2.5
X3.6 X3.5 X 4A X 4

BOMAG
PCB

XA 14 204.3.8/ 116U4 204.3.8/ 116U4

X3.6 X3.5
204.1.3/ CBF3:2 R2
120 Ohm
1/2W
204.3/ CBF1:2

204.4.8/ CR-14 204.4.8/ CR-32

204.2.3/ CBF2A:2 X 3A X 3

XA 15 16

XS 15 16 XD 12 13

C-H C-L EMR EMR

204.5.1 204.5.1 CAN H CAN L

008 917 69
Electric circuit diagrams

170.6 170.6
204.5 205

Design.: Zuccarino Luca

BM/60-2 CAN-BUS D: DE012009 pag. 204.6
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B18
106.4
CENTRAL
PANEL

23 13
S2
.5
24 .4 14

008 917 69
-
ENGINE +
RPM ENGINE
RPM

B20
106.1.1
ELECTRIC 2 2
CABINET K5 K4 U1
.7 .6 116.2

DO7
RPM
-
DO8
RPM
10 10 +
RPM+ RPM- I/O
MODULE
Electric circuit diagrams

X1.15
X1.17

X1 15 X1 17
5 5
K4 K5
.6 .7
9 9
RPM- RPM+
13 13
K4 K5
RPM- 14 RPM+ 14

F28
GND GND
1A
ENGINE XD 14 15

BOMAG
204.6.2/ +24EC +24EC /206.7.2

XD 14 15

B14 XME O P
100.1.4
ENGINE
COMPARTMENT
U5 XD2.1 64 31
170.1
EMR

RPM -
RPM +

2 10 .5 2 10 .4
204.6 206
5 9 .2 5 9 .3
25.1

869
Design.: Zuccarino Luca
BM/60-2 ENGINE RPM D: DE012009 pag. 205
date: 29.Apr.2010 MOTORE RPM

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17 B19

870
106.1 U2 106.6 U2
LEFT 110.3 RIGHT 112.3
PANEL PANEL
I/O MODULE I/O MODULE
25.1

DI2
TRAVEL.
BWD
DI1
TRAVEL.
FWD
+VCC
DI2
TRAVEL.
BWD
DI1
TRAVEL.
FWD

+VCC
X1.3
X1.1
X1.2
X1.3
X1.1

X1.2
X1 2 X1 3 X1 1 X1 2 X1 3 X1 1

UJ1 UJ1
206.1.1 206.1.5
XJ 1 6 7 XJ 1 6 7
206.2.1 206.2.6
JOYSTICK JOYSTICK
TRAVELLING TRAVELLING

BOMAG
R F R F
BACKWARD FORWARD BACKWARD FORWARD

008 917 69
Electric circuit diagrams

205 206.1

Design.: Zuccarino Luca

BM/60-2 TRAVELLING D: DE012009 pag. 206
date: 29.Apr.2010 AVANZAMENTO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17 B19
106.1 U2 106.6 U2
LEFT 110.3 RIGHT 112.3
PANEL PANEL
I/O MODULE I/O MODULE

008 917 69
GND
AI5
TRAVEL.
POTENT.
GND
AI5
TRAVEL.
POTENT.

+VCC
+VCC
+VCC
+VCC

X1.13
X1.9
X1.11
X1.8
X1.13
X1.9
X1.11
X1.8
X1 13 X1 9 X1 11 X1 8 X1 13 X1 9 X1 11 X1 8
Electric circuit diagrams

UJ1 UJ1
206.1 206.5
XJ 5 2 3 4 XJ 5 2 3 4
JOYSTICK JOYSTICK
TRAVELLING TRAVELLING

P P

BOMAG
10K+10K 10K+10K
POTENTIOMETER POTENTIOMETER

206 206.2
25.1

871
Design.: Zuccarino Luca
BM/60-2 TRAVELLING D: DE012009 pag. 206.1
date: 29.Apr.2010 AVANZAMENTO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

872
25.1

B17 B19
106.1 U2 106.6 U2
LEFT 110.3 RIGHT 112.3
PANEL PANEL
I/O MODULE I/O MODULE

+VCC
DI6
PUSH
BUTTON
TRAVEL.
DO7
BRAKE
LED
GND
+VCC
DI6
PUSH
BUTTON
TRAVEL.
DO7
BRAKE
LED
GND

X1.10
X1.12
X1.15
X1.14
X1.10
X1.12
X1.15
X1.14

X1 10 X1 12 X1 15 X1 14 X1 10 X1 12 X1 15 X1 14

UJ1 UJ1
206.1 206.5
XJ 9 8 XJ 9 8
JOYSTICK JOYSTICK
TRAVELLING TRAVELLING

A A
S H1 S H1
PUSH BRAKE K PUSH BRAKE K

BOMAG
BUTTON BUTTON

008 917 69
Electric circuit diagrams

206.1 206.3

Design.: Zuccarino Luca

BM/60-2 TRAVELLING D: DE012009 pag. 206.2
date: 29.Apr.2010 AVANZAMENTO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17 B19
106.1 106.6
LEFT RIGHT

008 917 69
PANEL
U2 PANEL
U2
110.3 112.3
I/O MODULE I/O MODULE

DO8
DIFF.
LOCK
LED
GND
DO8
DIFF.
LOCK
LED
GND

+VCC
DI4
DIFF.
LOCK
OFF
DI3
DIFF.
LOCK
ON
+VCC
DI4
DIFF.
LOCK
OFF
DI3
DIFF.
LOCK
ON

X1.4
X1.7
X1.5
X1.17
X1.16
X1.4
X1.7
X1.5
X1.17
X1.16

X1 4 X1 7 X1 5 X1 17 X1 16 X1 4 X1 7 X1 5 X1 17 X1 16
Electric circuit diagrams

23 13 A 23 13 A
S2 S2
H2 H2
.2 .2 .7 .6
24 14 DIFFERENTIAL K 24 14 DIFFERENTIAL K
OFF ON LOCK OFF ON LOCK
DIFFERENTIAL DIFFERENTIAL
LOCK LOCK

BOMAG
206.2 206.4
25.1

873
Design.: Zuccarino Luca
BM/60-2 TRAVELLING D: DE012009 pag. 206.3
date: 29.Apr.2010 AVANZAMENTO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

874
25.1

B17 B19
106.1 106.6
LEFT U2 RIGHT U2
PANEL PANEL
110.3 112.3
I/O MODULE I/O MODULE

DO15
LOW
SPEED
LED
GND
DO16
HIGH
SPEED
LED
GND
DO15
LOW
SPEED
LED
GND
DO16
HIGH
SPEED
LED
GND

DI9
LOW
SPEED
DI10
HIGH
SPEED
+VCC
DI9
LOW
SPEED
DI10
HIGH
SPEED
+VCC

X2.1
X2.3
X2.2
X2.15
X2.16
X2.17
X2.18
X2.1
X2.3
X2.2
X2.15
X2.16
X2.17
X2.18

X2 1 X2 3 X2 2 X2 15 X2 16 X2 17 X2 18 X2 1 X2 3 X2 2 X2 15 X2 16 X2 17 X2 18

23 13 A A 23 13 A A
S3 S3
H3 H4 H3 H4
.1 .1 .6 .6
24 14 LOW K HIGH K 24 14 LOW K HIGH K
LOW HIGH SPEED SPEED LOW HIGH SPEED SPEED
SPEED SPEED SPEED SPEED

BOMAG
008 917 69
Electric circuit diagrams

206.3 206.5

Design.: Zuccarino Luca

BM/60-2 TRAVELLING D: DE012009 pag. 206.4
date: 29.Apr.2010 AVANZAMENTO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17 B19
106.1 U3 106.6 U3
LEFT RIGHT

008 917 69
110.5 112.5
PANEL PANEL
I/O MODULE I/O MODULE

DO16
ENG.
LOAD
CONTROL
LED
GND
DO16
ENG.
LOAD
CONTROL
LED
GND

DI11
ENG.
LOAD
CONTROL
DI12
ENG.
LOAD
CONTROL
+VCC
DI11
ENG.
LOAD
CONTROL
DI12
ENG.
LOAD
CONTROL
+VCC

X2.5
X2.7
X2.6
X2.17
X2.18
X2.5
X2.7
X2.6
X2.17
X2.18

X2 5 X2 7 X2 6 X2 17 X2 18 X2 5 X2 7 X2 6 X2 17 X2 18
Electric circuit diagrams

23 13 A 23 13 A
S4 S4
H5 H5
.2 .1 .6 .6
24 14 ENGINE K 24 14 ENGINE K
ON OFF LOAD ON OFF LOAD
ENGINE ENGINE CONTROL ENGINE ENGINE CONTROL
LOAD LOAD LOAD LOAD
CONTROL CONTROL CONTROL CONTROL

BOMAG
206.4 206.6
25.1

875
Design.: Zuccarino Luca
BM/60-2 TRAVELLING D: DE012009 pag. 206.5
date: 29.Apr.2010 AVANZAMENTO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

876
25.1

B14
100.1.4
ENGINE U1 U1 U1
COMPARTMENT
118.3 118.3 118.3
8DO 8DO 8DO
OUTPUT OUTPUT OUTPUT

NC
CS
GND
DO
MOTOR
DISPLC.
SHELL
NC
CS
GND
DO
DIFF.
LOCK
SHELL
NC
CS
GND
DO
BRAKES
SHELL
MODULE MODULE MODULE

X1.1
X1.2
X1.3
X1.4
X1.5
X4.1
X4.2
X4.3
X4.4
X4.5
X3.1
X3.2
X3.3
X3.4
X3.5
X1 1 2 3 4 5 X4 1 2 3 4 5 X3 1 2 3 4 5

KA8 2 4 KA9 3 4 KA7 3 4

BOMAG
1 2 1 2 1 2
YA8 YA9 YA7
MOTOR DIFFERENTIAL BRAKES
DISPLACEMENT LOCK

SLOW SPEED ON=SOL.VALVE OFF DIFF.LOCK ON=SOL.VALVE ON BRAKES ENGAGGED=SOL.VALVE OFF

008 917 69
Electric circuit diagrams

206.5 206.7

Design.: Zuccarino Luca

BM/60-2 TRAVELLING D: DE012009 pag. 206.6
date: 29.Apr.2010 AVANZAMENTO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1
ELECTRIC
CABINET 205.3/ +24EC +24EC /214.2.7

008 917 69
U5
F29
116.7 U5
CR0505 1A 116.7
SPEED

DI12
SPEED
SENS.
SENSOR CR0505

AO04
FWD
TRAVEL.
AO05
BWD
TRAVEL.

X.20
X.36
X.54
X 20
X 36 X 54
Electric circuit diagrams

U6A
170.2.5
X 6A X 6
PCB

R3
5KOhm
1/2W
PICK-UP

BOMAG
X 5A X 5

GND
XD 16 XD 17 18 XD 19 20

XD 16 XD 17 18 XD 19 20

PK C A B

1 2

1 1
C53 YA25-YB25
SPEED FWD/BWD 2 2
SENSOR TRAVELLING
C53 3

GND GND
206.6 212
25.1

877
Design.: Zuccarino Luca
BM/60-2 TRAVELLING D: DE012009 pag. 206.7
date: 29.Apr.2010 AVANZAMENTO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

878
B17 B19
106.1 U1 106.6 U1
25.1

LEFT 110.2 RIGHT 112.2

PANEL PANEL
I/O MODULE I/O MODULE

DI2
OFF
MILLING
DRUM
DI1
ON
MILLING
DRUM
+VCC
DO16
ON
MILLING
DRUM
LED
GND
DI2
OFF
MILLING
DRUM
DI1
ON
MILLING
DRUM
+VCC
DO16
ON
MILLING
DRUM
LED
GND

X2.12
X2.11
X2.10
X2.17
X2.18
X2.12
X2.11
X2.10
X2.17
X2.18

X2 12 X2 11 X2 10 X2 17 X2 18 X2 12 X2 11 X2 10 X2 17 X2 18

23 13 A 23 13 A
S5 S5
H6 H6
.2 .1 .6 .6
24 14 ON K 24 14 ON K
OFF ON MILLING OFF ON MILLING
MILLING MILLING DRUM MILLING MILLING DRUM
DRUM DRUM DRUM DRUM

BOMAG
008 917 69
Electric circuit diagrams

206.7 212.1

Design.: Zuccarino Luca

BM/60-2 MILLING DRUM D: DE012009 pag. 212
date: 29.Apr.2010 RULLO FRESA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

008 917 69
B14
100.1.4 U2 U2
ENGINE 118.4 118.4
COMPARTMENT
8DO 8DO
OUTPUT OUTPUT

NC
CS
GND
DO
BELT
TAKE UP
SHELL
NC
CS
GND
DO
MILLING
DRUM
SHELL
MODULE MODULE

X1.1
X1.2
X1.3
X1.4
X1.5
X2.1
X2.2
X2.3
X2.4
X2.5
X1 1 2 3 4 5 X2 1 2 3 4 5
Electric circuit diagrams

BOMAG
1 2 1 2
YA14 YB14
BELT MILLING
TAKE DRUM
UP

212 214
25.1

879
Design.: Zuccarino Luca
BM/60-2 MILLING DRUM D: DE012009 pag. 212.1
date: 29.Apr.2010 RULLO FRESA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

880
25.1

B17 B19
106.1 U3 106.6 U3
LEFT 110.5 RIGHT 112.5
PANEL PANEL
I/O MODULE I/O MODULE

DO8
FLOAT
BACK
DOOR
LED
GND
DO8
FLOAT
BACK
DOOR
LED
GND

DI4
FLOAT
BACK
DOOR
DI3
UP
BACK
DOOR
+VCC
DI4
FLOAT
BACK
DOOR
DI3
UP
BACK
DOOR
+VCC

X1.7
X1.5
X1.6
X1.17
X1.16
X1.7
X1.5
X1.6
X1.17
X1.16

X1 7 X1 5 X1 6 X1 17 X1 16 X1 7 X1 5 X1 6 X1 17 X1 16

23 13 A 23 13 A
S6 S6
H7 H7
.2 .1 .7 .6
24 14 FLOAT K 24 14 FLOAT K
FLOAT UP BACK FLOAT UP BACK
BACK BACK DOOR BACK BACK DOOR
DOOR DOOR DOOR DOOR

BOMAG
008 917 69
Electric circuit diagrams

212.1 214.1

Design.: Zuccarino Luca

BM/60-2 BACK DOOR D: DE012009 pag. 214
date: 29.Apr.2010 RIPPER

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1 U1 U1
ELECTRIC 116.2 116.2
CABINET
12 DI 12 DI
4AI 4AI
4DO 4DO

DI1
UP
BACK
DOOR
DI14
FLOAT
BACK
DOOR
DO16
FLOAT
BACK
DOOR
LED

DI12
CLOSE
BACK
DOOR
DI11
OPEN
BACK
DOOR
I/O MODULE I/O MODULE

008 917 69
X2.7
X2.5
X2.11
X2.12
X2.17
X2 7 X2 5 X2 11 X2 12 X2 17
Electric circuit diagrams

XS 17 18 19 20 21 XD 21 22 23 24 25

BOMAG
XPSA B C D E F XPDA B C D E F

W4 25X1 2 3 4 5 6 W5 25X1 2 3 4 5 6

B3 B4
100.2 100.2
LEFT REAR 13 23 23 13 A RIGHT REAR 23 13 13 23 A
BOX S2 S3 BOX S2 S3
H1 H1
.2 .1 .3 .2 .6 .6 .8 .7
14 24 24 14 FLOAT K 24 14 14 24 FLOAT K
FLOAT UP OPEN CLOSE BACK FLOAT UP OPEN CLOSE BACK
BACK BACK BACK BACK DOOR BACK BACK BACK BACK DOOR
DOOR DOOR DOOR DOOR DOOR DOOR DOOR DOOR

GND GND

201.2.7/ +VCC +VCC /236.1.4

201.2.2/ +VCC +VCC /236.1.1 B4 B4
B3 B3

214 214.2
25.1

881
Design.: Zuccarino Luca
BM/60-2 BACK DOOR D: DE012009 pag. 214.1
date: 29.Apr.2010 RIPPER

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

882
B20
106.1.1 U4
206.7.7/ +24EC +24EC /214.3.2
25.1

ELECTRIC 116.6
CABINET
12 DI
4AI
4DO

DI7
BACKDOOR
1/2 OPEN
DI8
BACKDOOR
OPEN
I/O MODULE F30
7.5A
LEV.SYSTEM

X1.15
X1.17
X1 15 X1 17

13
K10
DRUM 14
MOVING

GND

XS 22 XS 23 XD 26 XD 27

BOMAG
NC NC

XMT A B XMF A B

13 21 13 21
C48 C49
LIMIT SWITCH 14 22 LIMIT SWITCH 14 22
BACK DOOR BACK DOOR
1/2 OPEN OPEN

XMT C XMF C

008 917 69
Electric circuit diagrams

2 10 281.1
214.1 214.3

Design.: Zuccarino Luca

BM/60-2 BACK DOOR D: DE012009 pag. 214.2
date: 29.Apr.2010 RIPPER

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1 U4
ELECTRIC 116.6
CABINET
I/O MODULE

008 917 69
DI9
PRESS.-
BACK
DOOR
DI10
PRESS.+
BACK
DOOR
214.2.7/ +24EC +24EC /226.5.7

X2.1
X2.3
F31
1A
PRESS X2 1 X2 3
REAR
MOULDER
Electric circuit diagrams

XD 28 29 30

BOMAG
XRO A XRO B XRO C

XRP A XRP B XRP C

W1 3X1 GY BL BR

B2 B7
100.1 100.5
BACK BACK
DOOR 23 13 DASH 23 13
BOX S1 PANEL S1
C106
.3 .3 .7 .6
24 14 24 14
PRES. - PRES. + PRES - PRES. +
BACK BACK BACK BACK
DOOR DOOR DOOR DOOR
C105

BR--->MARRONE
BL--->BLU
GY--->GIALLO/VERDE
214.2 214.4
25.1

883
Design.: Zuccarino Luca
BM/60-2 BACK DOOR D: DE012009 pag. 214.3
date: 29.Apr.2010 RIPPER

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

884
25.1

B14
100.1.4
ENGINE
COMPARTMENT
U3 U3 U3
118.5 118.5 118.5
8DO 8DO 8DO
OUTPUT OUTPUT OUTPUT

NC
CS
GND
DO
FLOAT
BACK
DOOR
SHELL
NC
CS
GND
DO
UP
LEFT
BACK
DOOR
SHELL
NC
CS
GND
DO
CLOSE
RIGHT
BACK
DOOR
SHELL
MODULE MODULE MODULE

X5.1
X5.2
X5.3
X5.4
X5.5
X7.1
X7.2
X7.3
X7.4
X7.5
X8.1
X8.2
X8.3
X8.4
X5 1 2 3 4 5 X7 1 2 3 4 5 X8 1 2 3 4 X8.5 5

BOMAG
1 2 1 2 1 2
YB20 YA20 YA19
FLOAT UP CLOSE
BACK LEFT RIGHT
DOOR BACK BACK
DOOR DOOR

008 917 69
Electric circuit diagrams

214.3 214.5

Design.: Zuccarino Luca

BM/60-2 BACK DOOR D: DE012009 pag. 214.4
date: 29.Apr.2010 RIPPER

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B14
100.1.4
ENGINE
COMPARTMENT

008 917 69
U4
118.6

NC
CS
GND
DO
PRES
BACK
DOOR
SHELL
8DO
OUTPUT
MODULE

X5.1
X5.2
X5.3
X5.4
X5.5
X5 1 2 3 4 5

KA13 2 4
Electric circuit diagrams

1 2
YA13
PRESS

BOMAG
BACK
DOOR

214.4 216
25.1

885
Design.: Zuccarino Luca
BM/60-2 BACK DOOR D: DE012009 pag. 214.5
date: 29.Apr.2010 RIPPER

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1

886
ELECTRIC
CABINET
25.1

XS 84 85 XD 99 100

BOMAG
B14
100.1.4 U1
ENGINE 118.3
COMPARTMENT
8DO
OUTPUT

NC
CS
GND
DO
FAN
SHELL
MODULE

X5.1
X5.2
X5.3
X5.4
X5.5
X5 1 2 3 4 5

KA4 2 4

1 2
YA4
FAN

008 917 69
Electric circuit diagrams

214.5 226

Design.: Zuccarino Luca

BM/60-2 FAN D: DE012009 pag. 216
date: 29.Apr.2010 VENTOLA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17 B19
106.1 U1 106.6 U1
LEFT 110.2 RIGHT 112.2
PANEL PANEL
I/O MODULE I/O MODULE

008 917 69
DI4
AUTO
LEFT
COL.
LED
GND
DI4
AUTO
LEFT
COL.
LED
GND

DI1
UP
LEFT
COL.
DI2
DOWN
LEFT
COL.
+VCC
DI3
MAN
LEFT
COL.
DI4
AUTO
LEFT
COL.
+VCC
DI1
UP
LEFT
COL.
DI2
DOWN
LEFT
COL.
+VCC
DI3
MAN
LEFT
COL.
DI4
AUTO
LEFT
COL.
+VCC

X1.1
X1.3
X1.2
X1.5
X1.7
X1.4
X1.15
X1.14
X1.1
X1.3
X1.2
X1.5
X1.7
X1.4
X1.15
X1.14

X1 1 X1 3 X1 2 X1 5 X1 7 X1 4 X1 15 X1 14 X1 1 X1 3 X1 2 X1 5 X1 7 X1 4 X1 15 X1 14

NC NC NC NC NC NC NC NC NC NC
Electric circuit diagrams

13 23 13 23
S7 S7
.1 .1 .6 .6
14 24 14 24
A C A C
UP DOWN UP DOWN
LEFT LEFT LEFT LEFT
COLUMN COLUMN COLUMN COLUMN

BOMAG
216 226.1
25.1

887
Design.: Zuccarino Luca
BM/60-2 COLUMNS D: DE012009 pag. 226
date: 29.Apr.2010 COLONNE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

888
B17 B19
25.1

106.1 106.6
LEFT U1 RIGHT U1
PANEL PANEL
110.2 112.2
I/O MODULE I/O MODULE

DO15
AUTO
RIGHT
COL.
LED
GND
DO15
AUTO
RIGHT
COL.
LED
GND

DI9
UP
RIGHT
COL.
DI10
DOWN
RIGHT
COL.
+VCC
DI11
MAN
RIGHT
COL.
DI12
AUTO
RIGHT
COL.
+VCC
DI9
UP
RIGHT
COL.
DI10
DOWN
RIGHT
COL.
+VCC
DI11
MAN
RIGHT
COL.
DI12
AUTO
RIGHT
COL.
+VCC

X2.1
X2.3
X2.2
X2.5
X2.7
X2.4
X2.15
X2.14
X2.1
X2.3
X2.2
X2.5
X2.7
X2.4
X2.15
X2.14

X2 1 X2 3 X2 2 X2 5 X2 7 X2 4 X2 15 X2 14 X2 1 X2 3 X2 2 X2 5 X2 7 X2 4 X2 15 X2 14

NC NC NC NC NC
NC NC NC NC NC

13 23 13 23
S8 S8
.1 .1 .6 .6
14 24 14 24
A C A C
UP DOWN UP DOWN
RIGHT RIGHT RIGHT RIGHT
COLUMN COLUMN COLUMN COLUMN

BOMAG
008 917 69
Electric circuit diagrams

226 226.2

Design.: Zuccarino Luca

BM/60-2 COLUMNS D: DE012009 pag. 226.1
date: 29.Apr.2010 COLONNE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17 B19
106.1 U2 106.6 U2
LEFT 110.3 RIGHT 112.3
PANEL PANEL
I/O MODULE I/O MODULE

008 917 69
DI13
UP
ALL
COL.
DI14
STOP
FUNC.
DI13
UP
ALL
COL.
DI14
STOP
FUNCTIONS

+VCC
DI11
UP
REARS
COL.
DI12
DOWN
REARS
COL.
+VCC
DI11
UP
REARS
COL.
DI12
DOWN
REARS
COL.

X2.11
X2.12
X2.4
X2.5
X2.7
X2.11
X2.12
X2.4
X2.5
X2.7

X2 11 X2 12 X2 4 X2 5 X2 7 X2 11 X2 12 X2 4 X2 5 X2 7
Electric circuit diagrams

23 13 13 23 23 13 13 23
S9 S10 S9 S10
.2 .1 .3 .3 .7 .6 .8 .8
24 14 14 24 24 14 14 24
A B A B A B A B
UP UP UP DOWN UP UP UP DOWN
ALL ALL REAR REAR ALL ALL REAR REAR
COLUMNS COLUMNS COLUMNS COLUMNS COLUMNS COLUMNS COLUMNS COLUMNS
STOP STOP
FUNCTIONS FUNCTIONS

BOMAG
226.1 226.4
25.1

889
Design.: Zuccarino Luca
BM/60-2 COLUMNS D: DE012009 pag. 226.2
date: 29.Apr.2010 COLONNE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

890
B20
106.1.1 U1
ELECTRIC 116.2
CABINET
25.1

12 DI
4AI

DI9
UP
REARS
COL.
DI10
DOWN
REARS
COL.
4DO
I/O MODULE

X2.1
X2.3
X2 1 X2 3

XS 25 26 XD 32 33

BOMAG
XPSB B C XPDB B C

W6 25X1 2 3 W7 25X1 2 3

B5 B6
100.2 100.2
LEFT REAR RIGHT REAR
BOX 23 13 BOX 13 23
S5 S5
.3 .2 .7 .7
24 14 14 24
UP DOWN UP DOWN
REARS REARS REARS REARS
COLUMNS COLUMNS COLUMNS COLUMNS

201.2.4/ +VCC +VCC /264.5.2 201.2.8/ +VCC +VCC /264.5.6

B5 B5 B6 B6

008 917 69
Electric circuit diagrams

226.2 226.5

Design.: Zuccarino Luca

BM/60-2 COLUMNS D: DE012009 pag. 226.4
date: 29.Apr.2010 COLONNE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1
200.1.7/ +10EC +10EC /264.6.1 BROWN
ELECTRIC
CABINET

WHITE PINK

008 917 69
F32
U5 U5 U12 U5
1A 116.7 116.7 SLOPE 24V GND S 116.7
WIRE SENSOR

AI04
RIGHT
WIRE
SENS.
SENSOR CR0505 CR0505 CR0505

AI03
LEFT
WIRE
SENS.
C19
AI05
SLOPE
SENS.

X.8
X.27
1 3 2
X.9

X 8 X 27 X 9
Electric circuit diagrams

GND

XA 17 18 19

GND

XS 27 28 29 XD 34 35 36 F33
1A
GND GND SLOPE
SENSOR

214.3.2/ +24EC +24EC /226.6.2

XS 27 28 29 XD 34 35 36

BOMAG
GND GND

XAS G H J XAD G H J

W8 25X1 7 8 10 W9 25X1 7 8 10

B8 B9
100.6 100.6
LEFT FRONT RIGHT FRONT
BOX BOX
XC68 A B C XC21 A B C

XC24 A B C XC22 A B C

C24 C22
LEFT RIGHT
WIRE SENSOR WIRE SENSOR
226.4 226.6
25.1

891
Design.: Zuccarino Luca
BM/60-2 COLUMNS D: DE012009 pag. 226.5
date: 29.Apr.2010 COLONNE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

892
B20
106.1.1
ELECTRIC
CABINET
25.1

U3
116.4
I/O
MODULE

DI1
PK
REAR
LEFT
COL.
DI2
PK
REAR
RIGHT
COL.
DI3
PK
FRONT
LEFT
COL.
DI4
PK
FRONT
RIGHT
COL.

X1.1
X1.3
X1.5
X1.7
X1 1 X1 3 X1 5 X1 7

226.5.7/ +24EC +24EC /226.7.1

F34
1A
PICKUP
COLUMNS

XS 30 31 XD 37 38 XS 32 33 XD 39 40

BOMAG
XS 30 31 XD 37 38 XS 32 33 XD 39 40

GND GND GND GND

XPXS 4 1 3 XPXD 4 1 3 XAXS 4 1 3 XAXD 4 1 3

1 3 1 3 1 3 1 3

4 4 4 4

C50 C51 C108 C107

PICKUP PICKUP PICKUP PICKUP
REAR REAR FRONT FRONT
LEFT RIGHT LEFT RIGHT
COLUMN COLUMN COLUMN COLUMN

008 917 69
Electric circuit diagrams

226.5 226.7

Design.: Zuccarino Luca

BM/60-2 COLUMNS D: DE012009 pag. 226.6
date: 29.Apr.2010 COLONNE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1
226.6.3/ +24EC +24EC /226.8.2
ELECTRIC
CABINET

F35

008 917 69
7.5A
EXTERNAL
LEV.SYSTEM

226.9.2 226.9.7
LEFT-UP RIGHT-UP

226.9.4 226.9.9
LEFT-DOWN RIGHT-DOWN
Electric circuit diagrams

XS 34 35 36 XD 41 42 43

BOMAG
XPSB F G H XPDB F G H

W6 25X1 6 7 8 W7 25X1 6 7 8

B5 B6
100.2 100.2
LEFT REAR RIGHT REAR
BOX GND BOX GND

XC23 A B D C XC69 A B D C

10 POLES MALE SCREW

UP
UP

GND
GND

+24V
DOWN
+24V
DOWN

LEFT RIGHT
SINISTRA DESTRA
226.6 226.8
25.1

893
Design.: Zuccarino Luca
BM/60-2 COLUMNS D: DE012009 pag. 226.7
date: 29.Apr.2010 COLONNE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B18

894
106.4
CENTRAL
PANEL XCL 1 2 3 4 5 6 XCR 1 2 3 4 5 6
25.1

GND GND

B20
106.1.1 U13
ELECTRIC RS485-RS232
CABINET 226.7.2/ +24EC +24EC /238.8.2 CONVERTER
XW2 3 2 6

F36
7.5A
LEV.SYSTEM

GREEN
BROWN
YELLOW
WHITE
RED
BLACK
XW1 2 3 4 5

GND GND
GND

GND

BOMAG
XA 20 21 22

XS 37 38 39 XD 44 45 46

XPSA G H J GND XPDA G H J GND

W4 25X1 7 8 10 W5 25X1 7 8 10

B3 B4
100.2 100.2
LEFT REAR RIGHT REAR
BOX GND BOX GND

XC66 1 2 3 4 5 6 XC67 1 2 3 4 5 6

008 917 69
Electric circuit diagrams

226.7 226.9

Design.: Zuccarino Luca

BM/60-2 COLUMNS D: DE012009 pag. 226.8
date: 29.Apr.2010 COLONNE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1
ELECTRIC
CABINET

U5 U5 U5 U5

008 917 69
116.7 116.7 116.7 116.7
CR0505 CR0505 CR0505 CR0505

AO00
LEFT
COL
UP
AO01
LEFT
COL
DOWN
AO02
RIGHT
COL
UP
AO03
RIGHT
COL
DOWN

X.44
X.45
X.46
X.47

226.7.2 226.7.2 226.7.6 226.7.6

X 44 X 45 X 46 X 47
LEFT-UP LEFT-DOWN RIGHT-UP RIGHT-DOWN
Electric circuit diagrams

XS 24 46 47 77

B14
1 1 1 1
100.1.4
ENGINE YA22 YB22 YA23 YB23
COMPARTMENT UP 2 DOWN 2 UP 2 DOWN 2

BOMAG
COLUMN CULUMN COLUMN CULUMN
LEFT LEFT RIGHT RIGHT
A22 B22 A23 B23
GND GND GND GND

U2 U2
118.4 118.4

NC
CS
GND
DO
UP
REARS
COL.
SHELL
NC
CS
GND
DO
DOWN
REARS
COL.
SHELL

8DO 8DO
OUTPUT OUTPUT
MODULE MODULE

X3.1
X3.2
X3.3
X3.4
X3.5
X4.1
X4.2
X4.3
X4.4
X4.5

X3 1 2 3 4 5 X4 1 2 3 4 5

1 2 1 2
YB21 YA21
UP DOWN
REARS REARS
COLUMS COLUMS
B21 A21

226.8 234
25.1

895
Design.: Zuccarino Luca
BM/60-2 COLUMNS D: DE012009 pag. 226.9
date: 29.Apr.2010 COLONNE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

896
B17 B19
106.1 106.6
LEFT U3 RIGHT U3
PANEL PANEL
25.1

110.5 112.5
I/O MODULE I/O MODULE

DO7
FLOAT
BREAK
BAR
LED
GND
DO7
FLOAT
BREAK
BAR
LED
GND

DI2
FLOAT
BREAK
BAR
DI1
UP
BREAK
BAR
+VCC
DI2
FLOAT
BREAK
BAR
DI1
UP
BREAK
BAR
+VCC

X1.3
X1.1
X1.2
X1.15
X1.14
X1.3
X1.1
X1.2
X1.15
X1 3 X1 1 X1 2 X1 15 X1 14 X1 3 X1 1 X1 2 X1 15 X1 X1.14 14

23 13 A 23 13 A
S11 S11
H8 H8
.1 .1 .6 .6
24 14 FLOAT K 24 14 FLOAT K
FLOAT UP BREAK FLOAT UP BREAK
BREAK BREAK BAR BREAK BREAK BAR
BAR BAR BAR BAR

BOMAG
008 917 69
Electric circuit diagrams

226.9 234.1

Design.: Zuccarino Luca

BM/60-2 BREAK BAR D: DE012009 pag. 234
date: 29.Apr.2010 VOMERE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1 U2 U2
ELECTRIC 116.3 116.3
CABINET
12 DI 12 DI

DO7
FLOAT
BREAK
BAR
LED
4AI 4AI

DI11
UP
BREAK
BAR
DI12
FLOAT
BREAK
BAR
4DO 4DO
I/O MODULE I/O MODULE

008 917 69
X2.5
X2.7
X1.15
X2 5 X2 7 X1 15
Electric circuit diagrams

XS 40 41 42 XD 47 48 49

XAS M N L XAD M N L

W8 25X1 W9 25X1

BOMAG
13 14 12 13 14 12

B8 B9
100.6 100.6
LEFT FRONT RIGHT FRONT
BOX BOX
23 13 A 13 23 A
S2 S2
H1 H1
.3 .2 .7 .7
24 14 FLOAT K 14 24 FLOAT K
UP FLOAT BREAK UP FLOAT BREAK
BREAK BREAK BAR BREAK BREAK BAR
BAR BAR S4 BAR BAR S3
C36 C31

201.2.1/ +VCC 201.2.5/ +VCC

B8 GND B9 GND

234 234.2
25.1

897
Design.: Zuccarino Luca
BM/60-2 BREAK BAR D: DE012009 pag. 234.1
date: 29.Apr.2010 VOMERE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

898
25.1

B14
100.1.4
ENGINE U4 U4
COMPARTMENT
118.6 118.6
8DO 8DO
OUTPUT OUTPUT

NC
CS
GND
DO
UP
BREAK
BAR
SHELL
NC
CS
GND
DO
FLOAT
BREAK
BAR
SHELL
MODULE MODULE

X1.1
X1.2
X1.3
X1.4
X1.5
X2.1
X2.2
X2.3
X2.4
X2.5
X1 1 2 3 4 5 X2 1 2 3 4 5

BOMAG
1 2 1 2
YA18 YB18
UP FLOAT
BREAK BREAK
BAR BAR
A18 B18

008 917 69
Electric circuit diagrams

234.1 236

Design.: Zuccarino Luca

BM/60-2 BREAK BAR D: DE012009 pag. 234.2
date: 29.Apr.2010 VOMERE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17 B19
106.1 106.6
LEFT U5 RIGHT U5
PANEL PANEL

008 917 69
110.7 112.7
I/O MODULE I/O MODULE

DI9
UP
LEFT
SIDE
DOOR
DI10
DOWN
LEFT
SIDE
DOOR
+VCC
DI9
UP
LEFT
SIDE
DOOR
DI10
DOWNP
RIGHT
SIDE
DOOR
+VCC

X2.1
X2.3
X2.2
X2.1
X2.3
X2.2

X2 1 X2 3 X2 2 X2 1 X2 3 X2 2
Electric circuit diagrams

13 23 13 23
S12 S12
.2 .2 .7 .7
14 24 14 24
UP DOWN UP DOWN
LEFT LEFT RIGHT RIGHT
SIDE SIDE SIDE SIDE
DOOR DOOR DOOR DOOR

BOMAG
234.2 236.1
25.1

899
Design.: Zuccarino Luca
BM/60-2 SIDE DOORS D: DE012009 pag. 236
date: 29.Apr.2010 PORTINE LATERALI

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

900
B20
106.1.1 U2 U1 U2 U1
ELECTRIC 116.3 116.2 116.3 116.2
CABINET
25.1

12 DI 12 DI 12 DI 12 DI
4AI 4AI 4AI 4AI

DI1
MAN
FRONT
LEFT
COL.
DI3
MAN
FRONT
RIGHT
COL.
4DO 4DO 4DO 4DO

DO15
UP
LEFT
SIDE
DOOR
LIGHT
DO16
UP
RIGHT
SIDE
DOOR
LIGHT

DI9
UP
LEFT
SIDE
DOOR
DI10
UP
RIGHT
SIDE
DOOR
I/O MODULE I/O MODULE I/O MODULE I/O MODULE

X1.1
X1.5

X2.1
X2.15
X2.3
X2.17
X1 1 X1 5
X2 1 X2 15 X2 3 X2 17

XS 43 44 XS 45 XD 50 51 XD 52

BOMAG
XPSA M N L XPDA M N L

W4 25X1 13 14 12 W5 25X1 13 14 12

B3 B4
13 23 + 13 23 +
100.2 S4 100.2 S4
LEFT REAR H2 RIGHT REAR H2
.2 .1 .5 .5
BOX 14 24 UP - BOX 14 24 UP -
UP DOWN LEFT UP DOWN RIGHT
LEFT LEFT SIDE RIGHT RIGHT SIDE
SIDE SIDE DOOR SIDE SIDE DOOR
DOOR DOOR L2 DOOR DOOR L1
C37 C29

214.1.3/ +VCC 214.1.8/ +VCC

B3 GND B4 GND

008 917 69
Electric circuit diagrams

236 236.2

Design.: Zuccarino Luca

BM/60-2 SIDE DOORS D: DE012009 pag. 236.1
date: 29.Apr.2010 PORTINE LATERALI

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B18
106.4
CENTRAL
PANEL
13
S3

008 917 69
SIDE DOORS 14
MILLING
DRUM
OFF
Electric circuit diagrams

B20
106.1.1
ELECTRIC
CABINET

BOMAG
XA 23 24

U2
116.3
X1 5 X1 6
12 DI
4AI
4DO
I/O MODULE

X1.5
X1.6

DI3
OFF

SIDE
DOOR
DRUM
+VCC

MILLING

236.1 236.3
25.1

901
Design.: Zuccarino Luca
BM/60-2 SIDE DOORS D: DE012009 pag. 236.2
date: 29.Apr.2010 PORTINE LATERALI

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

902
25.1

B14
100.1.4
ENGINE
COMPARTMENT
U3 U3 U3 U3
118.5 118.5 118.5 118.5

NC
CS
GND
DO
LEFT
SIDE
DOOR
OPEN
SHELL
NC
CS
GND
DO
LEFT
SIDE
DOOR
OPEN
SHELL
NC
CS
GND
DO
RIGHT
SIDE
DOOR
UP
SHELL
NC
CS
GND
DO
RIGHT
SIDE
DOOR
DOWN
SHELL
8DO 8DO 8DO 8DO
OUTPUT OUTPUT OUTPUT OUTPUT
MODULE MODULE MODULE MODULE

X1.1
X1.2
X1.3
X1.4
X1.5
X2.1
X2.2
X2.3
X2.4
X2.5
X3.1
X3.2
X3.3
X3.4
X3.5
X4.1
X4.2
X4.3
X4.4
X4.5

X1 1 2 3 4 5 X2 1 2 3 4 5 X3 1 2 3 4 5 X4 1 2 3 4 5

BOMAG
1 2 1 2 1 2 1 2
YA3 YB3 YA33 YB33
UP DOWN RIGHT RIGHT
LEFT LEFT SIDE SIDE
SIDE SIDE DOOR DOOR
DOOR DOOR OPEN OPEN

008 917 69
Electric circuit diagrams

236.2 238

Design.: Zuccarino Luca

BM/60-2 SIDE DOORS D: DE012009 pag. 236.3
date: 29.Apr.2010 PORTINE LATERALI

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17 B19
106.1 U5 106.6 U5
LEFT RIGHT

008 917 69
110.7 112.7
PANEL PANEL
I/O MODULE I/O MODULE

DO7
ON
CONV.
LED
GND
O7
ON
CONV.
LED
GND

DI1
OFF
CONV.
DI2
ON
CONV.
+VCC
DI1
OFF
CONV.
DI2
ON
CONV.
+VCC

X1.1
X1.3
X1.2
X1.15
X1.14
X1.1
X1.3
X1.2
X1.15
X1.14

X1 1 X1 3 X1 2 X1 15 X1 14 X1 1 X1 3 X1 2 X1 15 X1 14
Electric circuit diagrams

23 13 A 23 13 A
S13 S13
H9 H9
.2 .1 .6 .6
24 14 ON K 24 14 ON K
OFF ON CONVEYOR OFF ON CONVEYOR
CONVEYOR CONVEYOR CONVEYOR CONVEYOR

BOMAG
236.3 238.1
25.1

903
Design.: Zuccarino Luca
BM/60-2 CONVEYOR D: DE012009 pag. 238
date: 29.Apr.2010 NASTRO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

904
B17 B19
106.1 U3 106.6 U3
25.1

LEFT 110.5 RIGHT 112.5

PANEL PANEL
I/O MODULE I/O MODULE

DI6
DOWN
CONV.
DI5
UP
CONV.
DI14
RIGHT
CONV.
DI13
LEFT
CONV.
+VCC
DI6
DOWN
CONV.
DI5
UP
CONV.
DI14
RIGHT
CONV.
DI13
LEFT
CONV.
+VCC

X1.12
X1.11
X2.12
X2.11
X2.10
X1.12
X1.11
X2.12
X2.11
X2.10

X1 12 X1 11 X2 12 X2 11 X2 10 X1 12 X1 11 X2 12 X2 11 X2 10

43 13 53 23 43 13 53 23
S14 S14
.2 .1 .1 .1 .7 .6 .6 .6
.3 44 14 54 24 .8 44 14 54 24
C B D C B D
.2 UP RIGHT LEFT .7 UP RIGHT LEFT
A CONVEYOR CONVEYOR CONVEYOR A CONVEYOR CONVEYOR CONVEYOR
DOWN DOWN
CONVEYOR CONVEYOR

BOMAG
008 917 69
Electric circuit diagrams

238 238.2

Design.: Zuccarino Luca

BM/60-2 CONVEYOR D: DE012009 pag. 238.1
date: 29.Apr.2010 NASTRO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B18
106.4 CW
CENTRAL
PANEL

008 917 69
R1
SPEED
CONVEYOR

CCW
Electric circuit diagrams

B20
106.1.1
ELECTRIC

BOMAG
CABINET

XA 25 26 27

U4 X2 13 X2 11 X2 8
116.6
I/O MODULE
X2.8

X2.13
X2.11
+VCC

GND
AI13
SPEED
CONV.

238.1 238.6
25.1

905
Design.: Zuccarino Luca
BM/60-2 CONVEYOR D: DE012009 pag. 238.2
date: 29.Apr.2010 NASTRO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

906
B14
100.1.4
ENGINE
COMPARTMENT
25.1

U2 U2 U2 U2
118.4 118.4 118.4 118.4

NC
CS
GND
DO
UP
CONV.
SHELL
NC
CS
GND
DO
DOWN
CONV.
SHELL
NC
CS
GND
DO
LEFT
CONV.
SHELL
NC
CS
GND
DO
RIGHT
CONV.
SHELL
8DO 8DO 8DO 8DO
OUTPUT OUTPUT OUTPUT OUTPUT
MODULE MODULE MODULE MODULE

X5.1
X5.2
X5.3
X5.4
X5.5
X6.1
X6.2
X6.3
X6.4
X6.5
X7.1
X7.2
X7.3
X7.4
X7.5
X8.1
X8.2
X8.3
X8.4
X8.5

X5 1 2 3 4 5 X6 1 2 3 4 5 X7 1 2 3 4 5 X8 1 2 3 4 5

BOMAG
1 2 1 2 1 2 1 2
YA5 YB5 YA6 YB6
UP DOWN LEFT RIGHT
CONVEYOR CONVEYOR CONVEYOR CONVEYOR
A5 B5 A6 B6

008 917 69
Electric circuit diagrams

238.2 238.7

Design.: Zuccarino Luca

BM/60-2 CONVEYOR D: DE012009 pag. 238.6
date: 29.Apr.2010 NASTRO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1
ELECTRIC
CABINET

008 917 69
Electric circuit diagrams

XS 80 81 XD 95 96 XS 82 83 XD 97 98

BOMAG
B14 U1 U1
100.1.4 118.3 118.3

NC
CS
GND
DO
FWD
CONV
SHELL
NC
CS
GND
DO
BWD
CONV
SHELL

ENGINE 8DO 8DO

COMPARTMENT OUTPUT OUTPUT
MODULE MODULE

X7.1
X7.2
X7.3
X7.4
X7.5
X8.1
X8.2
X8.3
X8.4
X8.5

X7 1 2 3 4 5 X8 1 2 3 4 5

KA26 2 4 KB26 2 4

1 2 1 2
YA26 YB26
FWD BWD
CONVEYOR CONVEYOR

238.6 238.8
25.1

907
Design.: Zuccarino Luca
BM/60-2 CONVEYOR D: DE012009 pag. 238.7
date: 29.Apr.2010 NASTRO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B18 B9

908
106.4 100.6
CENTRAL RIGHT FRONT
PANEL BOX
25.1

23 13 23 13
S10 S10
.4 .4 .8 .7
24 14 24 14
TRANSPORT WORK TRANSPORT WORK
CONVEYOR CONVEYOR

W9 25X1 4 2 3

XAD D B C

XD 55 56 57

B20 XD 55 56 57
106.1.1
ELECTRIC
CABINET
238.8F1 /238.9.2

XA 28 XA 29 XA 30

BOMAG
SFC1 /238.9.2
F37
7.5A
CONVEYOR

5
226.8.2/ +24EC +24EC /240.3
K6
238.9.6
9

XS 48 49 50 51

nc nc

XS 48 51

1 1
YA15 YA16
CONVEYOR 2 CONVEYOR 2
FIX PIST. FIX PIST.
OUT IN
A15 A16

008 917 69
Electric circuit diagrams

GND GND
238.7 238.9

Design.: Zuccarino Luca

BM/60-2 CONVEYOR D: DE012009 pag. 238.8
date: 29.Apr.2010 NASTRO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1
238.8.6/ 238.8F1
ELECTRIC
CABINET
U4
238.8.4/ SFC1
116.6
12 DI

008 917 69
DI6
CONV.
CLOSED
4AI
4DO
I/O MODULE
13

X1.12
K6
CONVEYOR 14
LOCK

X1 12
GND
Electric circuit diagrams

GND
XS 52 XD 58 59 60 61

XS 52 XD 58 59 60 61

XNA 1 15 16 2

W10 16X1 1 7 GY 2

BOMAG
B16
100.1.8
CONVEYOR

XXA A B C XXB A B C

W11 3X1 BR BL GY W12 3X1 BR BL GY XAA 1 3 4

1
1 3 1 3 1 3
YA28
CONVEYOR 2
LOCK C50
A28
C96 C97
CONVEYOR
CONVEYOR CONVEYOR CLOSED
LOCK LOCK
C96 4 C97 4 4
GND

BR--->MARRONE
BL--->BLU
GY--->GIALLO/VERDE
5 9 238.8.4
238.8 240
25.1

909
Design.: Zuccarino Luca
BM/60-2 CONVEYOR D: DE012009 pag. 238.9
date: 29.Apr.2010 NASTRO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

910
B20
106.1.1
238.8.2/ +24EC +24EC /242.1.5
ELECTRIC
CABINET
25.1

F38
7.5A
WATER
FILLING
CLEANING

XS 53

XAS D

W8 25X1 4

B8
100.6
LEFT FRONT
BOX

BOMAG
23 13
S3
.5 .4
24 14
FILL CLEANING
WATER WATER
C74

W8 25X1 2 3

XAS B XAS C

1 1
YA11 YB11
WATER 2 CLEAN 2
FILL WATER
A11 B11

GND GND

WATER FILLING H.P.CLEANING

RIEMPIMENTO PULIZIA

008 917 69
Electric circuit diagrams

238.9 242

Design.: Zuccarino Luca

BM/60-2 WATER D: DE012009 pag. 240
date: 29.Apr.2010 ACQUA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17 B19
106.1 U1 106.6 U1
LEFT 110.2 RIGHT 112.2
PANEL PANEL
I/O MODULE I/O MODULE

008 917 69
DI6
OFF
WATER
SPRAY
DI5
ON
WATER
SPRAY
+VCC
DO8
ON
WATER
SPRAY
LED
GND
DI6
OFF
WATER
SPRAY
DI5
ON
WATER
SPRAY
+VCC
DO8
ON
WATER
SPRAY
LED
GND

X1.12
X1.11
X1.10
X1.17
X1.18
X1.12
X1.11
X1.10
X1.17
X1.18

X1 12 X1 11 X1 10 X1 17 X1 18 X1 12 X1 11 X1 10 X1 17 X1 18
Electric circuit diagrams

23 13 A 23 13 A
S15 S15
H10 H10
.2 .1 .6 .6
24 14 ON K 24 14 ON K
OFF ON WATER OFF ON WATER
WATER WATER SPRAY WATER WATER SPRAY
SPRAY SPRAY SPRAY SPRAY

BOMAG
240 242.1
25.1

911
Design.: Zuccarino Luca
BM/60-2 WATER SPRAYING D: DE012009 pag. 242
date: 29.Apr.2010 SPRUZZATURA ACQUA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

912
25.1

B20
106.1.1
ELECTRIC
CABINET
U3
240.5/ +24EC +24EC /266.3
116.4

DI9
WATER
PRESS
12 DI
4AI
4DO
I/O MODULE F39

X2.1
7.5A
WATER
SPRAY

X2 1

XD 62 63

BOMAG
XD 62 63

C40 P
WATER
IN PRESSURE
C40

008 917 69
Electric circuit diagrams

242 242.2

Design.: Zuccarino Luca

BM/60-2 WATER SPRAYING D: DE012009 pag. 242.1
date: 29.Apr.2010 SPRUZZATURA ACQUA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B14
100.1.4
ENGINE

008 917 69
COMPARTMENT
U4 U4
118.6 118.6

NC
CS
GND
DO
WATER
PUMP
SHELL
NC
CS
GND
DO
WATER
VALVE
SHELL
8DO 8DO
OUTPUT OUTPUT
MODULE MODULE

X7.1
X7.2
X7.3
X7.4
X7.5
X8.1
X8.2
X8.3
X8.4
X8.5
X7 1 2 3 4 5 X8 1 2 3 4 5
Electric circuit diagrams

KB10 3 4

BOMAG
1 2 1 2
YA10 YB10
WATER WATER
PUMP VALVE
A10 B10

242.1 244
25.1

913
Design.: Zuccarino Luca
BM/60-2 WATER SPRAYING D: DE012009 pag. 242.2
date: 29.Apr.2010 SPRUZZATURA ACQUA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

914
25.1

B17 B19
106.1 U3 106.6 U3
LEFT 110.5 RIGHT 112.5
PANEL PANEL
I/O MODULE I/O MODULE

DO15
ON
PAUSE
LED
GND
DO15
ON
PAUSE
LED
GND

DI9
ON
PAUSE
DI10
OFF
PAUSE
+VCC
DI9
ON
PAUSE
DI10
OFF
PAUSE
+VCC

X2.1
X2.3
X2.2
X2.15
X2.16
X2.1
X2.3
X2.2
X2.15
X2.16

X2 1 X2 3 X2 2 X2 15 X2 16 X2 1 X2 3 X2 2 X2 15 X2 16

23 13 A 23 13 A
S16 S16
H11 H11
.2 .1 .7 .6
24 14 ON K 24 14 ON K
ON OFF PAUSE ON OFF PAUSE
PAUSE PAUSE PAUSE PAUSE

BOMAG
008 917 69
Electric circuit diagrams

242.2 246

Design.: Zuccarino Luca

BM/60-2 PAUSE D: DE012009 pag. 244
date: 29.Apr.2010 PAUSA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B18
106.4
180.5/ 54 54 /272.4
CENTRAL
PANEL

008 917 69
23 13 23 13
S5 S6
.1 .1 .3 .2
24 14 24 14
DOWN UP DOWN UP
ENGINE ENGINE ROOF ROOF
COVER COVER

150.6
BAT-EME
Electric circuit diagrams

B20 XA 31 32 33 XA 34 XSE 1
106.1.1
ELECTRIC
CABINET
W3 12X1 1

B10
100.8
EMERGENCY
BOX 246S2 /250.3
U6C
290.3.1
X 1 X 3 X 5 X 7
DIODES
BOARD 23 13
S1
V1 V2 V3 V4
.8 .7
ROOF ROOF ROOF ROOF 24 14
DOWN UP

BOMAG
ROOF ROOF
X 8
X 2A X 2 X 4A X 4 X 6A X 6
X 8A

XA 35

W3 12X1 4 5
EM.PUMP /281.3

XD 64 65 XD 66 67 68
XSE 4 5
XD 64 65 XD 66 67 68

EM.PUMP /250.3

1 1 1 1
YB27 YA27 YA12 YB12
DOWN 2 UP 2 DOWN 2 UP 2
ENGIME ENGINE ROOF ROOF
COVER COVER A12 B12
B27 A27
GND GND GND GND
244 250
25.1

915
Design.: Zuccarino Luca
BM/60-2 ROOF D: DE012009 pag. 246
date: 29.Apr.2010 TETTOIA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

916
B10
100.8
246.8/ 246S2
25.1

EMERGENCY
BOX

13 23 13 23
S2 S2 S3
.5 .3 .6 .5
14 24 14 24
EMERGENCY EMERGENCY
SERVICES BREAKS
C43 C42

W3 12X1 6 3 2

XSE 6 3 2

246.4/ EM.PUMP
1 1

YA1 YA2
2 EMERGENCY 2

BOMAG
EMERGENCY
SERVICES BRAKES
A1 A2

GND GND
150.6
BAT-150A

C4
EMERGENCY
PUMP 5 13
C4 K K
.3 .2
9 14
EMERGENCY EMERGENCY
PUMP PUMP
JE4

+
T
THERMO TH
PROTECTION -

M M
2.2KW
C4

GND

008 917 69
Electric circuit diagrams

246 264

Design.: Zuccarino Luca

BM/60-2 EMERGENCY SERVICES D: DE012009 pag. 250
date: 29.Apr.2010 SERVIZI DI EMERGENZA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17 B19
106.1 106.6
LEFT RIGHT

008 917 69
PANEL
U4 PANEL
U4
110.6 112.6
I/O MODULE I/O MODULE

DO7
MAN
STEER,
LED
GND
DO8
CENTER
STEER.
LED
GND
DO7
MAN
STEER,
LED
GND
DO8
CENTER
STEER.
LED
GND

DI1
MAN
STEER.
DI2
CENTER
STEER.
+VCC
DI1
MAN
STEER.
DI2
CENTER
STEER.
+VCC

X1.1
X1.3
X1.2
X1.15
X1.16
X1.17
X1.18
X1.1
X1.3
X1.2
X1.15
X1.16
X1.17
X1.18

X1 1 X1 3 X1 2 X1 15 X1 16 X1 17 X1 18 X1 1 X1 3 X1 2 X1 15 X1 16 X1 17 X1 18
Electric circuit diagrams

53 23 A A 53 23 A A
S17 S17
H12 H13 H12 H13
264.1.2 .1 264.1.6 .6
.1 54 24 MAN K CENTER K .6 54 24 MAN K CENTER K
D STEERING STEERING D STEERING STEERING
264.1.1 CENTER 264.1.6 CENTER
MODE MODE MODE MODE
B STEERING B STEERING
MAN MODE MAN MODE
STEERING STEERING
MODE MODE

BOMAG
250 264.1
25.1

917
Design.: Zuccarino Luca
BM/60-2 STEERING D: DE012009 pag. 264
date: 29.Apr.2010 STERZATURA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

918
25.1

B17 B19
106.1 106.6
LEFT U4 RIGHT U4
PANEL PANEL
110.6 112.6
I/O MODULE I/O MODULE

DO15
COPY
STEER.
LED
GND
DO16
CRAB
STEER.
LED
GND
DO15
COPY
STEER.
LED
GND
DO16
CRAB
STEER.
LED
GND

DI9
COPY
STEER.
DI10
CRAB
STEER.
+VCC
DI9
COPY
STEER.
DI10
CRAB
STEER.
+VCC

X2.1
X2.3
X2.2
X2.15
X2.16
X2.17
X2.18
X2.1
X2.3
X2.2
X2.15
X2.16
X2.17
X2.18

X2 1 X2 3 X2 2 X2 15 X2 16 X2 17 X2 18 X2 1 X2 3 X2 2 X2 15 X2 16 X2 17 X2 18

43 13 A A 43 13 A A
S17 S17 S17 S17
H14 H15 H14 H15
264.1 264.1 264.6 264.6
44 14 COPY K CRAB K 44 14 COPY K CRAB K
A C STEERING STEERING A C STEERING STEERING
COPY CRAB MODE MODE COPY CRAB MODE MODE
STEERING STEERING STEERING STEERING
MODE MODE MODE MODE

BOMAG
008 917 69
Electric circuit diagrams

264 264.2

Design.: Zuccarino Luca

BM/60-2 STEERING D: DE012009 pag. 264.1
date: 29.Apr.2010 STERZATURA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17 B19
106.1 106.6
LEFT U4 RIGHT U4
PANEL PANEL

008 917 69
110.6 112.6
I/O MODULE I/O MODULE

DI4
LEFT
REAR
STEER.
DI3
RIGHT
REAR
STEER.
+VCC
DI4
LEFT
REAR
STEER.
DI3
RIGHT
REAR
STEER.
+VCC

X1.7
X1.5
X1.6
X1.7
X1.5
X1.6
X1 7 X1 5 X1 6 X1 7 X1 5 X1 6
Electric circuit diagrams

13 23 13 23
S18 S18
.2 .2 .7 .6
14 24 14 24
LEFT RIGHT LEFT RIGHT
REAR REAR REAR REAR
STEERING STEERING STEERING STEERING

BOMAG
264.1 264.3
25.1

919
Design.: Zuccarino Luca
BM/60-2 STEERING D: DE012009 pag. 264.2
date: 29.Apr.2010 STERZATURA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

920
B17 B19
106.1 106.6
LEFT U5 RIGHT U5
PANEL PANEL
25.1

110.7 112.7
I/O MODULE I/O MODULE

+VCC
DI4
RIGHT
FRONT
STEER.
DI3
LEFT
FRONT
STEER.
+VCC
DI4
RIGHT
FRONT
STEER.
DI3
LEFT
FRONT
STEER.

X1.4
X1.7
X1.5
X1.4
X1.7
X1.5
X1 4 X1 7 X1 5 X1 4 X1 7 X1 5

UJ2 UJ2
264.4.1 264.4.5
XJ 1 6 7 XJ 1 6 7
JOYSTICK JOYSTICK
FRONT FRONT
STEERING STEERING

BOMAG
R F R F
RIGHT LEFT RIGHT LEFT
FRONT FRONT FRONT FRONT
STEERING STEERING STEERING STEERING

008 917 69
Electric circuit diagrams

264.2 264.4

Design.: Zuccarino Luca

BM/60-2 STEERING D: DE012009 pag. 264.3
date: 29.Apr.2010 STERZATURA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17 B19
106.1 106.6
LEFT U5 RIGHT U5
PANEL PANEL

008 917 69
110.7 112.7
I/O MODULE I/O MODULE

GND
AI5
POTENT
STEER.
GND
AI5
POTENT
STEER.

+VCC
+VCC
+VCC
+VCC

X1.13
X1.9
X1.11
X1.8
X1.13
X1.9
X1.11
X1 13 X1 9 X1 11 X1 8 X1 13 X1 9 X1 11 X1 X1.8 8
Electric circuit diagrams

UJ2 UJ2
264.3.1 264.3.6
XJ 5 2 3 4 XJ 5 2 3 4
JOYSTICK JOYSTICK
FRONT FRONT
STEERING STEERING

P P
10K+10K 10K+10K

BOMAG
264.3 264.5
25.1

921
Design.: Zuccarino Luca
BM/60-2 STEERING D: DE012009 pag. 264.4
date: 29.Apr.2010 STERZATURA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20

922
106.1.1 U2
ELECTRIC 116.3
CABINET
12 DI
4AI
25.1

DI1
LEFT
REAR
STEER.
DI2
RIGHT
REAR
STEER.
4DO
I/O MODULE

X1.1
X1.3
X1 1 3

XS 54 55 XD 69 70

BOMAG
XPSB J L XPDB J L

W6 25X1 10 12 W7 25X1 10 12

B5 B6
100.2 100.2
LEFT REAR RIGHT REAR
BOX BOX

23 13 23 13
S3 S3
.2 .2 .7 .7
24 14 24 14
LEFT RIGHT LEFT RIGHT
REAR REAR REAR REAR
STEERING STEERING STEERING STEERING
C28

226.4.3/ +VCC 226.4.7/ +VCC

B5 B6

008 917 69
Electric circuit diagrams

264.4 264.6

Design.: Zuccarino Luca

BM/60-2 STEERING D: DE012009 pag. 264.5
date: 29.Apr.2010 STERZATURA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1
226.5.2/ +10EC
ELECTRIC
CABINET

F40

008 917 69
U5 U5 U5
1A 116.7 116.7 116.7
WIRE
SENSOR CR0505 CR0505 CR0505

AI08
FRONT
STEER.
AI09
REAR
STEER.
AI10
ADJUST
STEER.

X.29
X.11
X.30
X 29 X 11 X 30
Electric circuit diagrams

XA 36

XS 58 57 56 XS 61 60 59 XD 71 72 73
GND GND GND

XS 58 57 56 XS 61 60 59 XD 71 72 73

BOMAG
GND GND GND

XYA A B C XYP A B C XAC A B C

W2 3X1 GY BL BR

GND GND

XC14 A B C XC16 A B C B1
100.1
XC17 A B C
C17

C14 C16 C17 BR--->MARRONE

STEER STEER STEER
FRONT REAR
BL--->BLU
ADJUST
C14 C16 C17 GY--->GIALLO/VERDE

264.5 264.7
25.1

923
Design.: Zuccarino Luca
BM/60-2 STEERING D: DE012009 pag. 264.6
date: 29.Apr.2010 STERZATURA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

924
25.1

B14
100.1.4
ENGINE U4 U4
COMPARTMENT
118.6 118.6
8DO 8DO
OUTPUT OUTPUT

NC
CS
GND
DO
LEFT
REAR
STEER.
SHELL
NC
CS
GND
DO
RIGHT
REAR
STEER.
SHELL
MODULE MODULE

X3.1
X3.2
X3.3
X3.4
X3.5
X4.1
X4.2
X4.3
X4.4
X4.5
X3 1 2 3 4 5 X4 1 2 3 4 5

BOMAG
1 2 1 2
YA17 YB17
LEFT RIGHT
REAR REAR
STEERING STEERING
A17 B17

008 917 69
Electric circuit diagrams

264.6 264.8

Design.: Zuccarino Luca

BM/60-2 STEERING D: DE012009 pag. 264.7
date: 29.Apr.2010 STERZATURA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1
ELECTRIC U5 U5
CABINET
116.7 116.7
CR0505 CR0505

AO06
FRONT
STEER
LEFT
AO07
FRONT
STEER
RIGHT

008 917 69
X.17
X.53
X 17 X 53
Electric circuit diagrams

XS 78 79

BOMAG
B14
100.1.4
ENGINE
COMPARTMENT

1 1
YB29 YA29
LEFT 2 RIGHT 2
FRONT FRONT
STEERING STEERING
B29 A29

GND GND

264.7 266
25.1

925
Design.: Zuccarino Luca
BM/60-2 STEERING D: DE012009 pag. 264.8
date: 29.Apr.2010 STERZATURA

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

926
B19
B17 106.6
25.1

106.1 RIGHT
13 PANEL 13
LEFT
PANEL S19 S19
HORN 14 HORN 14

XE 3 4 XE 3 4

B20
106.1.1
XE1 3 4 242.1.5/ +24EC +24EC /274.3 XE3 3 4
ELECTRIC
CABINET

F41
7.5A
HORN

XA 37 38

BOMAG
XS 62 63 XD 74 75 76

XS 62 63 XD 74 75 76

HORN /266.1.1

XAS P O XPSB M N XAD P O XPDB M N

W8 25X1 16 15 W6 25X1 13 14 W9 25X1 16 15 W7 25X1 13 14

B8 B5 B9 B6
13 13 13 13
100.6 100.2 100.6 100.2
LEFT FRONT S4 LEFT REAR S4 RIGHT FRONT S4 RIGHT REAR S4
BOX HORN 14 BOX HORN 14 BOX HORN 14 BOX HORN 14
C35 C80 C77 C34

008 917 69
Electric circuit diagrams

264.8 266.1

Design.: Zuccarino Luca

BM/60-2 HORN D: DE012009 pag. 266
date: 29.Apr.2010 CLAXON

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

266.8/ HORN

008 917 69
Electric circuit diagrams

XNA 9

W10 16X1 9

B16 XMN 4
100.1.8
CONVEYOR

W13 3X1 W14 3X1

BOMAG
BL BL

+ +
BR--->MARRONE
C64 C70
HORN - HORN - BL--->BLU
C64 C70
GY--->GIALLO/VERDE

W13 3X1 GY W14 3X1 GY

B16
100.1.8
CONVEYOR
XMN 3

W10 16X1 10

XNA 10

GND

266 272
25.1

927
Design.: Zuccarino Luca
BM/60-2 HORN D: DE012009 pag. 266.1
date: 29.Apr.2010 CLAXON

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

928
25.1

B17 B18 B19

106.1 106.4 106.6
246.4/ 54
LEFT CENTRAL RIGHT
PANEL PANEL PANEL

11 23
S9
.5 .4
12 24
WORKING
LIGHTS
ON

XCC 6 7

+ + +
H16 H16 H16
DASHBOARD - XCL 6 DASHBOARD - DASHBOARD - XCR 6
LIGHT LIGHT LIGHT

GND GND GND

XE 5 XE 5

B20
106.1.1
XE1 5 XE3 5

BOMAG
ELECTRIC
CABINET

XA 39

200.5/ 30 30 /280.3

86 13 87 5
K1 K9
K1 K9
.2 .5
WORKING 85 ROOF 14 30 9
LIGHTS LIGHTS

GND GND LIGHTS ROOF

272.1.2 272.4.2

008 917 69
Electric circuit diagrams

30 87 .6 5 9 .7
266.1 272.1

Design.: Zuccarino Luca

BM/60-2 WORKING LIGHTS D: DE012009 pag. 272
date: 29.Apr.2010 FARI DI LAVORO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1
ELECTRIC
CABINET

008 917 69
272.6/ LIGHTS LIGHTS /272.2.2

F42 F43
Electric circuit diagrams

10A 15A
WORKING WORKING
LIGHTS LIGHTS

XS 64 XS 65

BOMAG
XWF 1 XWH 1 XWG 1 XWB 1 XWM 1 XWN 1

+ + + + + +
L10 L11 L17 L12 L22 L23
BREAK - BACK - LEFT - COLUMN - FRONT - REAR -
BAR DOOR SIDE REAR LEFT LEFT
LEFT LEFT LEFT

GND GND GND GND GND GND

272 272.2
25.1

929
Design.: Zuccarino Luca
BM/60-2 WORKING LIGHTS D: DE012009 pag. 272.1
date: 29.Apr.2010 FARI DI LAVORO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

930
B20
106.1.1
ELECTRIC
CABINET
25.1

272.1.6/ LIGHTS LIGHTS /272.3.3

F44 F45
15A 15A
WORKING WORKING
LIGHTS LIGHTS

XD 77 XD 78

BOMAG
XWC 1 XWD 1 XWO 1 XWE 1 XWA 1 XWI 1 XWL 1

+ + + + + + +
L14 L15 L26 L16 L13 L24 L25
BREAK - BACK - STAIR - RIGHT - COLUMN - FRONT - REAR -
BAR DOOR RIGHT SIDE REAR RIGHT RIGHT
RIGHT RIGHT RIGHT

GND GND GND GND GND GND GND

008 917 69
Electric circuit diagrams

272.1 272.3

Design.: Zuccarino Luca

BM/60-2 WORKING LIGHTS D: DE012009 pag. 272.2
date: 29.Apr.2010 FARI DI LAVORO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1
ELECTRIC
CABINET

008 917 69
272.2.6/ LIGHTS LIGHTS /272.4.4

F46
Electric circuit diagrams

10A
WORKING
LIGHTS

XD 79

BOMAG
XNA 13 14

W10 16X1 13 14
BR--->MARRONE
BL--->BLU
GY--->GIALLO/VERDE XMN 6 XMN 5

W13 3X1 W14 3X1 NC NC

BR BR

+ +
L5 L6 H1
WORKING - WORKING - WORKING
LIGHT LIGHT LIGHT
CONVEYOR CONVEYOR MAGNETIC

GND GND

272.2 272.4
25.1

931
Design.: Zuccarino Luca
BM/60-2 WORKING LIGHTS D: DE012009 pag. 272.3
date: 29.Apr.2010 FARI DI LAVORO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

932
B20
25.1

106.1.1
272.7/ ROOF 272.3.4/ LIGHTS
ELECTRIC
CABINET

F54 F47
7.5A 10A
ROOF WORKING
LIGHTS LIGHTS

XA 46

XS 86 XS 87
GND
GND
XRF 1 XRF 3 XS 86 XS 87

BOMAG
XRR 1 3

B15
100.1.6
ROOF

XVR 2 1 XVS 2 1 XVT 2 1 XVU 2 1

+ + + +
L19 L20 L18 L21
LEFT - RIGHT - LEFT - RIGHT -
FRONT FRONT REAR REAR
WORKING WORKING WORKING WORKING
LIGHT LIGHT LIGHT LIGHT

008 917 69
Electric circuit diagrams

272.3 274

Design.: Zuccarino Luca

BM/60-2 WORKING LIGHTS D: DE012009 pag. 272.4
date: 29.Apr.2010 FARI DI LAVORO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B18
106.4
CENTRAL

008 917 69
PANEL

13
S7
BEACON 14
Electric circuit diagrams

B20
106.1.1
ELECTRIC
CABINET
F48
7.5A
BEACON

266.3/ +24EC +24EC /281.1 GND

BOMAG
XS 88 89

XS 88 XS 89

XRR 5 4

B15
100.1.6
ROOF
XCF 2 1

+
H1
ROOF -
BEACON

272.4 280
25.1

933
Design.: Zuccarino Luca
BM/60-2 BEACON D: DE012009 pag. 274
date: 29.Apr.2010 GIROFARO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

934
B20
106.1.1
ELECTRIC
CABINET
25.1

272.8/ 30

F49
25A
FUEL FILL

XD 80

BOMAG
M1
100.1.5
FUEL FILL 13
CG S
FUEL 14
FILL

M M
FUEL
FILL
PUMP

GND

008 917 69
Electric circuit diagrams

274 281

Design.: Zuccarino Luca

BM/60-2 FUEL FILLING D: DE012009 pag. 280
date: 29.Apr.2010 CARICAMENTO CARBURANTE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1
ELECTRIC
CABINET 274.4/ +24EC +24EC /290.5 246.4/ EM.PUMP

008 917 69
F56
7.5A
DRUM MOVING

2
K10
214.2.5
10
GND
Electric circuit diagrams

XB 1 XB 2 XB 3

OPTIONAL
XB 1 XB 2 XB 3

XDM 1 XDM 2 XDM 3 XDM 4 XDM 5

BOMAG
M2
DRUM
MOVING

V1 V2 V3 V4

1 1 1 2
YA29-YB29 YA30
FWD/BWD 2 2 PISTON
DRUM MOVING DRUM MOVING
A17

13 23
S1
.2 .2
14 24
FWD BWD
DRUM DRUM

280 290
25.1

935
Design.: Zuccarino Luca
BM/60-2 DRUM MOVING D: DE012009 pag. 281
date: 29.Apr.2010 MOVIMENTAZIONE RULLO

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
281.2/ +24EC +24EC /290.1.1
106.1.1

936
ELECTRIC
CABINET
U4
F50
116.6
25.1

12 DI 1A

DI5
HIDR.
OIL
LEVEL
4AI SENSORS

DI1
TRAVEL
FILTER
DI2
CONV.
FILTER
DI3
SERV.
FILTER
DI4
HIDR.
OIL
TEMP
4DO
I/O MODULE
XA 42

X1.1
X1.3
X1.5
X1.7
X1.11
F50 /290.3.1

X1 1 3 5 7 11 +24PCB /290.3.4

U6A
170.2.5
X 8 8A 10 10A 12 12A 14 14A 16 16A
PCB

R4 R5 R6 R7 R8
1KOhm 1KOhm 1KOhm 1KOhm 1KOhm
1W 1W 1W 1W 1W

X 7 7A 9 9A 11 11A 13 13A 15 15A

BOMAG
XD 81 XD 82 XD 83 XS 66 XD 84

XD 81 XD 82 XD 83 XS 66 XD 84

B14 1 1 1 1 1
100.1.4
ENGINE
C102 P C103 P C104 P C46 C101
COMPARTMENT TRAVEL 2 CONVEYOR 2 SERVICES 2 HYDR.OIL 2 HYDR.OIL 2
FILTER FILTER FILTER TEMPERATURE LEVEL

GND GND GND GND GND

008 917 69
Electric circuit diagrams

281 290.1

Design.: Zuccarino Luca

BM/60-2 ALARMS D: DE012009 pag. 290
date: 29.Apr.2010 ALLARMI

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1 U2
290.6/ +24EC +24EC /290.4.4
ELECTRIC

008 917 69
116.3
CABINET
I/O
MODULE

AI5
HIDR
OIL
THERM.
AI6
TRAVEL.
PRESS.
AI13
CONV.
PRESS.
AI14
FAN
PRESS.
F51

X1.11
X1.12
X2.11
X2.12
1A
SENSORS

X1 11 X1 12 X2 11 X2 12
Electric circuit diagrams

FSENS /290.2.1

XS 67 XS 68 XD 85 86 87 88 89 90

XS 67 XS 68 XD 85 XD 86 XD 87 XD 88 XD 89 XD 90

BOMAG
B14
100.1.4
ENGINE
COMPARTMENT GND GND GND GND

XXA 1 2 3 XXB 1 2 3 XXC 1 2 3 XXD 1 2 3

1 1 1 1

C47 C96 C99 C100

-40+125' 600BAR 250BAR 250BAR
OIL TRAVELLING CONVEYOR FAN
HYDRAULIC 3 2 PRESSURE 3 2 PRESSURE 3 2 PRESSURE 3 2
THERMISTOR

SP1=37 OU2=U SP1=150 EF

rP1=35 diS=øC rP1=138 Uni=bAr
OU1=Hno CAL=0 OU1=Hno HI
ASP=0 HI OU2=U Lo
AEP=100 Lo dS1=0
dr1=0
dAP=60
diS=d2
290 290.2
25.1

937
Design.: Zuccarino Luca
BM/60-2 ALARMS D: DE012009 pag. 290.1
date: 29.Apr.2010 ALLARMI

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

938
25.1

B20
106.1.1
ELECTRIC U3
CABINET
116.4
I/O

AI5
CLUTCH
PRESS.
AI6
SERV
PRESS.
AI13
BREAK
BAR
PRESS.
AI14
BACK
DOOR
PRESS.

MODULE

X1.11
X1.12
X2.11
X2.12

X1 11 X1 12 X2 11 X2 12

290.1.8/ FSENS

XS 69 XS 70 71 72 73 74 75 76

XS 69 XS 70 XS 71 XS 72 XS 73 XS 74 XS 75 XS 76

B14
100.1.4

BOMAG
ENGINE
COMPARTMENT

GND GND GND GND

XXE 1 2 3 XXF 1 2 3 XXG 1 2 3 XXH 1 2 3

1 1 1 1

C57 C58 C50 C60

100 BAR 250BAR 25BAR 25BAR
CLUTCH SERVICES BREAK BACK
PRESSURE 3 2 PRESSURE 3 2 BAR 3 2 DOOR 3 2
PRESSURE PRESSURE

008 917 69
Electric circuit diagrams

290.1 290.3

Design.: Zuccarino Luca

BM/60-2 ALARMS D: DE012009 pag. 290.2
date: 29.Apr.2010 ALLARMI

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1
ELECTRIC U3 U3
CABINET 290.8/ +24PCB
116.4 116.4
I/O I/O

008 917 69
MODULE MODULE

DI10
D+
DI11
COOLANT

X2.3
X2.5
X2 3 X2 5 U6A U1 U6B
170.2.5 NC 116.2 NC

I/O

DI5
FUEL
LEVEL
MODULE
X 18 X 18A X 8A X 8 X 6A X 6 X 4A X 4 X 2A X 2
Electric circuit diagrams

X1.11
290.6/ F50
R9 R4 R3 R2 R1
1KOhm 1KOhm 1KOhm 1KOhm 1KOhm
1W X1 11 1W 1W 1W 1W

R3
100 Ohm
10W X 17 X 17A X 7 X 7A X 5 X 5A X 3 X 3A X 1 X 1A
GENERATOR

XA 43

U6C
246.4
X 17
DIODES
BOARD

BOMAG
3A

X 18A X 18

XD 91 XD 92 XD 93

B14
1
100.1.4
ENGINE
D+ 170.1S4 C9
170.5.3 170.1.4 2
COMPARTMENT FUEL
LEVEL
C9

GND

290.2 290.4
25.1

939
Design.: Zuccarino Luca
BM/60-2 ALARMS D: DE012009 pag. 290.3
date: 29.Apr.2010 ALLARMI

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B18

940
106.4
CENTRAL
PANEL
25.1

GND
- 13
S8
.8
S8
+ .7 14
DIAGNOSTIC

B20
106.1.1
ELECTRIC U4 U4
CABINET XA 44 XA 45
116.6 116.6
290.1.1/ +24EC
I/O I/O U3 U1

DO8
ACUST.
ALARM
DO7
REVER.
ACUST.
ALARM
MODULE MODULE
116.4 116.2
I/O I/O
MODULE X1 15 MODULE X1 12

X2.17
X2.15
F52
7.5A
ACUSTIC
X1.15
X1.12

ALLARM

X2 17 X2 15
DO8
DI6
ALARM
GENERAL

13 13 5 5
DIAGNOSTIC

K7 K8
K7 K8
.1 .2
ACUSTIC 14 REVERSE 14 9 9

BOMAG
ALARM ACUSTIC
ALARM

GND GND + +
UH1 UH2
BUZZER - BUZZER -
XD 94
GND GND

XD 94

GND

B13
100.1.1
XSR 1 2
BATTERY
COMPARTMENT
+
C15
ACUSTIC -
ALLARM
C15

008 917 69
Electric circuit diagrams

5 9 .4 5 9 .6
290.3 300

Design.: Zuccarino Luca

BM/60-2 ALARMS D: DE012009 pag. 290.4
date: 29.Apr.2010 ALLARMI

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

008 917 69
Electric circuit diagrams

BOMAG
290.4 300.1
25.1

941
Design.: Zuccarino Luca
BM/60-2 STRIP TERMINALS D: DE012009 pag. 300
date: 29.Apr.2010 LAY OUT MORSETTIERE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

942
25.1

BOMAG
008 917 69
Electric circuit diagrams

300 300.2

Design.: Zuccarino Luca

BM/60-2 STRIP TERMINALS D: DE012009 pag. 300.1
date: 29.Apr.2010 LAY OUT MORSETTIERE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

008 917 69
Electric circuit diagrams

BOMAG
300.1 300.3
25.1

943
Design.: Zuccarino Luca
BM/60-2 STRIP TERMINALS D: DE012009 pag. 300.2
date: 29.Apr.2010 LAY OUT MORSETTIERE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

944
25.1

BOMAG
008 917 69
Electric circuit diagrams

300.2 300.4

Design.: Zuccarino Luca

BM/60-2 STRIP TERMINALS D: DE012009 pag. 300.3
date: 29.Apr.2010 LAY OUT MORSETTIERE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

008 917 69
Electric circuit diagrams

BOMAG
300.3 300.5
25.1

945
Design.: Zuccarino Luca
BM/60-2 STRIP TERMINALS D: DE012009 pag. 300.4
date: 29.Apr.2010 LAY OUT MORSETTIERE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

946
25.1

BOMAG
008 917 69
Electric circuit diagrams

300.4 300.6

Design.: Zuccarino Luca

BM/60-2 STRIP TERMINALS D: DE012009 pag. 300.5
date: 29.Apr.2010 LAY OUT MORSETTIERE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

008 917 69
Electric circuit diagrams

BOMAG
300.5 300.7
25.1

947
Design.: Zuccarino Luca
BM/60-2 STRIP TERMINALS D: DE012009 pag. 300.6
date: 29.Apr.2010 LAY OUT MORSETTIERE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

948
25.1

BOMAG
008 917 69
Electric circuit diagrams

300.6 500.1

Design.: Zuccarino Luca

BM/60-2 STRIP TERMINALS D: DE012009 pag. 300.7
date: 29.Apr.2010 LAY OUT MORSETTIERE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17
106.1
LEFT U1 U1

008 917 69
PANEL
110.2 X1.1 DI1 UP LEFT COL. 226.1 B17-S7:13 110.2 X2.1 DI9 UP RIGHT COL. 226.1.1 B17-S8:13

X1.2 +VCC 226.2 X2.2 +VCC 226.1.2

X1.3 DI2 DOWN LEFT COL. 226.1 B17-S7:23 X2.3 DI10 DOWN RIGHT COL. 226.1.1 B17-S8:23

X1.4 +VCC 226.3 X2.4 +VCC 226.1.3

X1.5 DI3 MAN LEFT COL. 226.2 B17:NC X2.5 DI11 MAN RIGHT COL. 226.1.2 B17:NC

X1.6 X2.6

X1.7 DI4 AUTO LEFT COL. 226.3 B17:NC X2.7 DI12 AUTO RIGHT COL. 226.1.3 B17:NC

X1.8 X2.8

X1.9 X2.9
Electric circuit diagrams

X1.10 +VCC 242.2 X2.10 +VCC 212.2

X1.11 DI5 ON WATER SPRAY 242.2 B17-S15:13 X2.11 DI1 ON MILLING DRUM 212.2 B17-S5:13

X1.11 X2.11

X1.12 DI6 OFF WATER SPRAY 242.1 B17-S15:23 X2.12 DI2 OFF MILLING DRUM 212.1 B17-S5:23

X1.12 X2.12

X1.13 X2.13

X1.14 GND 226.4 X2.14 GND 226.1.4

X1.15 DI4 AUTO LEFT COL. LED 226.4 B17:NC X2.15 DO15 AUTO RIGHT COL. LED 226.1.4 B17:NC

X1.15 X2.15

X1.16 X2.16

X1.17 DO8 ON WATER SPRAY LED 242.3 B17-H10:A X2.17 DO16 ON MILLING DRUM LED 212.3 B17-H6:A

X1.17 X2.17

BOMAG
X1.18 GND 242.3 X2.18 GND 212.3

U1
110.2 X3.1 +VCC 204.2

X3.2 GND 204.2

X3.3 +VCC 204.2

X3.4 GND 204.2

X3.5 CAN-L 204.2 B20-XA:16

X3.6 CAN-H 204.3 B20-XA:15

300.7 500.2
25.1

949
Design.: Zuccarino Luca
BM/60-2 PLC D: DE012009 pag. 500.1
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

950
B17
25.1

106.1
LEFT
PANEL U2 U2
X1.1 DI1 TRAVEL. FWD 206.3 UJ1-F X2.1 DI9 LOW SPEED 206.4.1 B17-S3:23
110.3 110.3
X1.2 +VCC 206.1 X2.2 +VCC 206.4.2

X1.3 DI2 TRAVEL. BWD 206.1 UJ1-R X2.3 DI10 HIGH SPEED 206.4.1 B17-S3:13

X1.4 +VCC 206.3.1 X2.4 +VCC 226.2.2

X1.5 DI3 DIFF. LOCK ON 206.3.2 B17-S2:13 X2.5 DI11 UP REARS COL. 226.2.3 B17-S10:13

X1.6 X2.6

X1.7 DI4 DIFF. LOCK OFF 206.3.2 B17-S2:23 X2.7 DI12 DOWN REARS COL. 226.2.3 B17-S10:23

X1.8 +VCC 206.1.3 X2.8

X1.9 +VCC 206.1.2 X2.9

X1.10 +VCC 206.2.1 X2.10

X1.11 X2.11 DI13 UP ALL COL. 226.2.1 B17-S9:23

X1.11 AI5 TRAVEL. POTENT. 206.1.2 UJ1-P X2.11

X1.12 DI6 PUSH BUTTON TRAVEL. 206.2.2 UJ1-S X2.12 DI14 STOP FUNC. 226.2.2 B17-S9:13

X1.12 X2.12

X1.13 GND 206.1.1 X2.13

X1.14 GND 206.2.3 X2.14

X1.15 DO7 BRAKE LED 206.2.3 B17-H1:A X2.15 DO15 LOW SPEED LED 206.4.2 B17-H3:A

X1.15 X2.15

X1.16 GND 206.3.4 X2.16 GND 206.4.3

X1.17 DO8 DIFF. LOCK LED 206.3.3 B17-H2:A X2.17 DO16 HIGH SPEED LED 206.4.4 B17-H4:A

BOMAG
X1.17 X2.17

X1.18 X2.18 GND 206.4.4

U2
110.3 X3.1 +VCC 204.3

X3.2 GND 204.4

X3.3 +VCC 204.4

X3.4 GND 204.4

X3.5 CAN-L 204.4 B17-U1:X3.5

X3.6 CAN-H 204.4 B17-U1:X3.6

008 917 69
Electric circuit diagrams

500.1 500.3

Design.: Zuccarino Luca

BM/60-2 PLC D: DE012009 pag. 500.2
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17
106.1
LEFT
PANEL U3 U3

008 917 69
X1.1 DI1 UP BREAK BAR 234.1 B17-S11:13 110.5 X2.1 DI9 ON PAUSE 244.1 B17-S16:23
110.5
X1.2 +VCC 234.2 X2.2 +VCC 244.2

X1.3 DI2 FLOAT BREAK BAR 234.1 B17-S11:23 X2.3 DI10 OFF PAUSE 244.2 B17-S16:13

X1.4 X2.4

X1.5 DI3 UP BACK DOOR 214.2 B17-S6:13 X2.5 DI11 ENG. LOAD CONTROL 206.5.1 B17-S4:23

X1.6 +VCC 214.2 X2.6 +VCC 206.5.2

X1.7 DI4 FLOAT BACK DOOR 214.1 B17-S6:23 X2.7 DI12 ENG. LOAD CONTROL 206.5.2 B17-S4:13

X1.8 X2.8

X1.9 X2.9
Electric circuit diagrams

X1.10 X2.10 +VCC 238.1.3

X1.11 DI5 UP CONV. 238.1.2 B17-S14:13 X2.11 DI13 LEFT CONV. 238.1.3 B17-S14:23

X1.11 X2.11
X1.12 DI6 DOWN CONV. 238.1.1 B17-S14:43 X2.12 DI14 RIGHT CONV. 238.1.2 B17-S14:53

X1.12 X2.12

X1.13 X2.13

X1.14 GND 234.3 X2.14

X1.15 DO7 FLOAT BREAK BAR LED 234.3 B17-H8:A X2.15 DO15 ON PAUSE LED 244.3 B17-H11:A

X1.15 X2.15

X1.16 GND 214.3 X2.16 GND 244.3

X1.17 DO8 FLOAT BACK DOOR LED 214.3 B17-H7:A X2.17 DO16 ENG. LOAD CONTROL LED 206.5.3 B17-H5:A

X1.17 X2.17

BOMAG
X1.18 X2.18 GND 206.5.3

U3
110.5 X3.1 +VCC 204.5

X3.2 GND 204.5

X3.3 +VCC 204.5

X3.4 GND 204.5

X3.5 CAN-L 204.6 B17-U2:X3.5

X3.6 CAN-H 204.6 B17-U2:X3.6

500.2 500.4
25.1

951
Design.: Zuccarino Luca
BM/60-2 PLC D: DE012009 pag. 500.3
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

952
B17
25.1

106.1
LEFT
PANEL U4 U4 X2.1 DI9 COPY STEER. 264.1.1 B17-S17:43
110.6 X1.1 DI1 MAN STEER. 264.1 B17-S17:53 110.6
X2.2 +VCC 264.1.2
X1.2 +VCC 264.2
X2.3 DI10 CRAB STEER. 264.1.2 B17-S17:13
X1.3 DI2 CENTER STEER. 264.1 B17-S17:23
X2.4
X1.4
X2.5
X1.5 DI3 RIGHT REAR STEER. 264.2.2 B17-S18:23
X2.6
X1.6 +VCC 264.2.3
X2.7
X1.7 DI4 LEFT REAR STEER. 264.2.2 B17-S18:13
X2.8
X1.8
X2.9
X1.9
X2.10
X1.10
X2.11
X1.11
X2.11
X1.11
X2.12
X1.12
X2.12
X1.12
X2.13
X1.13
X2.14
X1.14
X2.15 DO15 COPY STEER. LED 264.1.3 B17-H14:A
X1.15 DO7 MAN STEER, LED 264.3 B17-H12:A
X2.15
X1.15
X2.16 GND 264.1.3
X1.16 GND 264.3
X2.17 DO16 CRAB STEER. LED 264.1.4 B17-H15:A
X1.17 DO8 CENTER STEER. LED 264.4 B17-H13:A

BOMAG
X2.17
X1.17
X2.18 GND 264.1.4
X1.18 GND 264.4

U4
110.6 X3.1 +VCC 204.7

X3.2 GND 204.7

X3.3 +VCC 204.7

X3.4 GND 204.7

X3.5 CAN-L 204.7 B17-U3:X3.5

X3.6 CAN-H 204.8 B17-U3:X3.6

008 917 69
Electric circuit diagrams

500.3 500.5

Design.: Zuccarino Luca

BM/60-2 PLC D: DE012009 pag. 500.4
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B17
106.1
LEFT U5
U5

008 917 69
PANEL X1.1 DI1 OFF CONV. 238.1 B17-S13:23 X2.1 DI9 UP LEFT SIDE DOOR 236.2 B17-S12:13
110.7 110.7
X1.2 +VCC 238.2 X2.2 +VCC 236.3

X1.3 DI2 ON CONV. 238.2 B17-S13:13 X2.3 DI10 DOWN LEFT SIDE DOOR 236.2 B17-S12:23

X1.4 +VCC 264.3.1 X2.4

X1.5 DI3 LEFT FRONT STEER. 264.3.3 UJ2-F X2.5

X1.6 X2.6

X1.7 DI4 RIGHT FRONT STEER. 264.3.2 UJ2-R X2.7

X1.8 +VCC 264.4.3 X2.8

X1.9 +VCC 264.4.2 X2.9

Electric circuit diagrams

X1.10 X2.10

X1.11 X2.11

X1.11 AI5 POTENT STEER. 264.4.2 UJ2-P X2.11

X1.12 X2.12

X2.12
X1.12

X1.13 GND 264.4.1 X2.13

X1.14 GND 238.3 X2.14

X1.15 DO7 ON CONV. LED 238.3 B17-H9:A X2.15

X1.15 X2.15

X1.16 X2.16

X1.17 X2.17

X2.17
X1.17

BOMAG
X1.18 X2.18

U5 X3.1 +VCC 204.8

110.7
X3.2 GND 204.8

X3.3 +VCC 204.8

X3.4 GND 204.9

X3.5 CAN-L 204.9 B17-U4:X3.5

X3.6 CAN-H 204.9 B17-U4:X3.6

500.4 501.1
25.1

953
Design.: Zuccarino Luca
BM/60-2 PLC D: DE012009 pag. 500.5
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

954
25.1

B18
106.4
CENTRAL U1
PANEL 114.4 X1.1 GND 204.2.2

X1.2 GND 204.2.3

X1.3 +VCC 204.2.6

X1.4 CAN 1 L 204.2.3 B20-XA:16

X1.5 CAN 1 H 204.2.3 B20-XA:15

X1.9 +VCC SW 204.2.3

BOMAG
008 917 69
Electric circuit diagrams

500.5 502.1

Design.: Zuccarino Luca

BM/60-2 PLC D: DE012009 pag. 501.1
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B19
106.6
RIGHT U1

008 917 69
PANEL X1.1 DI1 UP LEFT COL. 226.6 B19-S7:13 U1
112.2 X2.1 DI9 UP RIGHT COL. 226.1.6 B19-S8:13
112.2
X1.2 +VCC 226.7 X2.2 +VCC 226.1.7
X1.3 DI2 DOWN LEFT COL. 226.6 B19-S7:23 X2.3 DI10 DOWN RIGHT COL. 226.1.6 B19-S8:23
X1.4 +VCC 226.8 X2.4 +VCC 226.1.8
X1.5 DI3 MAN LEFT COL. 226.7 B19:NC X2.5 DI11 MAN RIGHT COL. 226.1.7 B19:NC
X1.6 X2.6
X1.7 DI4 AUTO LEFT COL. 226.8 B19:NC X2.7 DI12 AUTO RIGHT COL. 226.1.7 B19:NC
X1.8 X2.8
X1.9 X2.9
Electric circuit diagrams

X1.10 +VCC 242.7 X2.10 +VCC 212.7

X1.11 DI5 ON WATER SPRAY 242.6 B19-S15:13 X2.11 DI1 ON MILLING DRUM 212.6 B19-S5:13

X1.11 X2.11
X1.12 DI6 OFF WATER SPRAY 242.6 B19-S15:23 X2.12 DI2 OFF MILLING DRUM 212.6 B19-S5:23

X1.12 X2.12

X1.13 X2.13
X1.14 GND 226.9 X2.14 GND 226.1.9
X1.15 DI4 AUTO LEFT COL. LED 226.9 B19:NC X2.15 DO15 AUTO RIGHT COL. LED 226.1.8 B19:NC
X1.15 X2.15

X1.16 X2.16
X1.17 DO8 ON WATER SPRAY LED 242.7 B19-H10:A X2.17 DO16 ON MILLING DRUM LED 212.8 B19-H6:A
X1.17 X2.17

BOMAG
X1.18 GND 242.8 X2.18 GND 212.8

U1
X3.1 +VCC 204.1.1
112.2
X3.2 GND 204.1.2

X3.3 +VCC 204.1.2

X3.4 GND 204.1.2

X3.5 CAN-L 204.1.2 B20-XA:16

X3.6 CAN-H 204.1.2 B20-XA:15

501.1 502.2
25.1

955
Design.: Zuccarino Luca
BM/60-2 PLC D: DE012009 pag. 502.1
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

956
B19
25.1

106.6
RIGHT
PANEL U2 U2
X1.1 DI1 TRAVEL. FWD 206.7 UJ1-F X2.1 DI9 LOW SPEED 206.4.6 B19-S3:23
112.3 112.3
X1.2 +VCC 206.5 X2.2 +VCC 206.4.7

X1.3 DI2 TRAVEL. BWD 206.6 UJ1-R X2.3 DI10 HIGH SPEED 206.4.6 B19-S3:13

X1.4 +VCC 206.3.6 X2.4 +VCC 226.2.7

X1.5 DI3 DIFF. LOCK ON 206.3.7 B19-S2:13 X2.5 DI11 UP REARS COL. 226.2.8 B19-S10:13

X1.6 X2.6

X1.7 DI4 DIFF. LOCK OFF 206.3.6 B19-S2:23 X2.7 DI12 DOWN REARS COL. 226.2.8 B19-S10:23

X1.8 +VCC 206.1.8 X2.8

X1.9 +VCC 206.1.7 X2.9

X1.10 +VCC 206.2.6 X2.10

X1.11 X2.11 DI13 UP ALL COL. 226.2.6 B19-S9:23

X1.11 AI5 TRAVEL. POTENT. 206.1.7 UJ1-P X2.11

X1.12 DI6 PUSH BUTTON TRAVEL. 206.2.6 UJ1-S X2.12 DI14 STOP FUNCTIONS 226.2.7 B19-S9:13

X1.12 X2.12

X1.13 GND 206.1.6 X2.13

X1.14 GND 206.2.8 X2.14

X1.15 DO7 BRAKE LED 206.2.7 B19-H1:A X2.15 DO15 LOW SPEED LED 206.4.7 B19-H3:A

X1.15 X2.15

X1.16 GND 206.3.8 X2.16 GND 206.4.8

X1.17 DO8 DIFF. LOCK LED 206.3.8 B19-H2:A X2.17 DO16 HIGH SPEED LED 206.4.8 B19-H4:A

BOMAG
X1.17 X2.17

X1.18 X2.18 GND 206.4.9

U2
112.3 X3.1 +VCC 204.1.3

X3.2 GND 204.1.3

X3.3 +VCC 204.1.4

X3.4 GND 204.1.4

X3.5 CAN-L 204.1.4 B19-U1:X3.5

X3.6 CAN-H 204.1.4 B19-U1:X3.6

008 917 69
Electric circuit diagrams

502.1 502.3

Design.: Zuccarino Luca

BM/60-2 PLC D: DE012009 pag. 502.2
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B19
106.6
RIGHT U3 U3
PANEL X2.1 DI9 ON PAUSE 244.6 B19-S16:23

008 917 69
X1.1 DI1 UP BREAK BAR 234.6 B19-S11:13
112.5 112.5
X1.2 +VCC 234.7 X2.2 +VCC 244.7

X1.3 DI2 FLOAT BREAK BAR 234.6 B19-S11:23 X2.3 DI10 OFF PAUSE 244.7 B19-S16:13

X1.4 X2.4

X1.5 DI3 UP BACK DOOR 214.7 B19-S6:13 X2.5 DI11 ENG. LOAD CONTROL 206.5.6 B19-S4:23

X1.6 +VCC 214.7 X2.6 +VCC 206.5.7

X1.7 DI4 FLOAT BACK DOOR 214.6 B19-S6:23 X2.7 DI12 ENG. LOAD CONTROL 206.5.6 B19-S4:13

X1.8 X2.8

X1.9 X2.9
Electric circuit diagrams

X1.10 X2.10 +VCC 238.1.8

X1.11 DI5 UP CONV. 238.1.7 B19-S14:13 X2.11 DI13 LEFT CONV. 238.1.8 B19-S14:23

X1.11 X2.11

X1.12 DI6 DOWN CONV. 238.1.6 B19-S14:43 X2.12 DI14 RIGHT CONV. 238.1.7 B19-S14:53

X2.12
X1.12

X1.13 X2.13

X1.14 GND 234.8 X2.14

X1.15 DO7 FLOAT BREAK BAR LED 234.7 B19-H8:A X2.15 DO15 ON PAUSE LED 244.8 B19-H11:A

X1.15 X2.15

X1.16 GND 214.8 X2.16 GND 244.8

X1.17 DO8 FLOAT BACK DOOR LED 214.8 B19-H7:A X2.17 DO16 ENG. LOAD CONTROL LED 206.5.8 B19-H5:A

X1.17 X2.17

BOMAG
X1.18 X2.18 GND 206.5.8

U3
X3.1 +VCC 204.1.5
112.5
X3.2 GND 204.1.5

X3.3 +VCC 204.1.5

X3.4 GND 204.1.5

X3.5 CAN-L 204.1.6 B19-U2:X3.5

X3.6 CAN-H 204.1.6 B19-U2:X3.6

502.2 502.4
25.1

957
Design.: Zuccarino Luca
BM/60-2 PLC D: DE012009 pag. 502.3
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

958
25.1

B19
106.6
RIGHT
PANEL U4 U4
X1.1 DI1 MAN STEER. 264.6 B19-S17:53 X2.1 DI9 COPY STEER. 264.1.6 B19-S17:43
112.6 112.6
X1.2 +VCC 264.7 X2.2 +VCC 264.1.7

X1.3 DI2 CENTER STEER. 264.6 B19-S17:23 X2.3 DI10 CRAB STEER. 264.1.6 B19-S17:13

X1.4 X2.4

X1.5 DI3 RIGHT REAR STEER. 264.2.7 B19-S18:23 X2.5

X1.6 +VCC 264.2.7 X2.6

X1.7 DI4 LEFT REAR STEER. 264.2.6 B19-S18:13 X2.7

X1.8 X2.8

X1.9 X2.9

X1.10 X2.10

X1.11 X2.11

X1.12 X2.12

X1.13 X2.13

X1.14 X2.14

X1.15 DO7 MAN STEER, LED 264.7 B19-H12:A X2.15 DO15 COPY STEER. LED 264.1.7 B19-H14:A

X1.15 X2.15

X1.16 GND 264.8 X2.16 GND 264.1.8

BOMAG
X1.17 DO8 CENTER STEER. LED 264.8 B19-H13:A X2.17 DO16 CRAB STEER. LED 264.1.8 B19-H15:A

X1.17 X2.17

X1.18 GND 264.9 X2.18 GND 264.1.9

U4 X3.1 +VCC 204.1.6

112.6
X3.2 GND 204.1.7

X3.3 +VCC 204.1.7

X3.4 GND 204.1.7

X3.5 CAN-L 204.1.7 B19-U3:X3.5

X3.6 CAN-H 204.1.7 B19-U3:X3.6

008 917 69
Electric circuit diagrams

502.3 502.5

Design.: Zuccarino Luca

BM/60-2 PLC D: DE012009 pag. 502.4
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B19
106.6
RIGHT U5
PANEL
U5 X2.1 DI9 UP LEFT SIDE DOOR 236.7 B19-S12:13
X1.1 DI1 OFF CONV. 238.6 B19-S13:23

008 917 69
112.7 112.7
X1.2 +VCC 238.7 X2.2 +VCC 236.8

X1.3 DI2 ON CONV. 238.6 B19-S13:13 X2.3 DI10 DOWNP RIGHT SIDE DOOR 236.7 B19-S12:23

X1.4 +VCC 264.3.6 X2.4

X1.5 DI3 LEFT FRONT STEER. 264.3.8 UJ2-F X2.5

X1.6 X2.6

X1.7 DI4 RIGHT FRONT STEER. 264.3.7 UJ2-R X2.7

X1.8 +VCC 264.4.8 X2.8

X1.9 +VCC 264.4.7 X2.9

X2.10
Electric circuit diagrams

X1.10

X1.11 X2.11

X1.11 AI5 POTENT STEER. 264.4.7 UJ2-P X2.11

X1.12 X2.12

X2.12
X1.12
X2.13
X1.13 GND 264.4.6

X1.14 GND 238.8 X2.14

X1.15 O7 ON CONV. LED 238.8 B19-H9:A X2.15

X2.15
X1.15

X1.16 X2.16

X1.17 X2.17

X2.17
X1.17
X2.18

BOMAG
X1.18

U5
X3.1 +VCC 204.1.8
112.7
X3.2 GND 204.1.8

X3.3 +VCC 204.1.8

X3.4 GND 204.1.9

X3.5 CAN-L 204.1.9 B19-U4:X3.5

X3.6 CAN-H 204.1.9 B19-U4:X3.6

502.4 503.1
25.1

959
Design.: Zuccarino Luca
BM/60-2 PLC D: DE012009 pag. 502.5
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

960
25.1

B20
106.1.1
ELECTRIC
CABINET
U1 U1 X2.1 DI9 UP REARS COL. 226.4.4 B5-S5:23
X1.1 DI1 MAN FRONT LEFT COL. 236.1.4 B3-S4:23
116.2 116.2
X1.2 X2.2

X1.3 X2.3 DI10 DOWN REARS COL. 226.4.5 B5-S5:13

X1.4 X2.4

X1.5 DI3 MAN FRONT RIGHT COL. 236.1.7 B4-S4:23 X2.5 214.1.4 B3-S3:23

X1.6 X2.6

X1.7 X2.7 DI12 CLOSE BACK DOOR 214.1.3 B3-S3:13

X1.8 X2.8

X1.9 X2.9

X1.10 X2.10

X1.11 290.3.7 B14-C9:1 X2.11 214.1.5 B3-S2:23

X1.11 X2.11

X1.12 DI6 GENERAL ALARM 290.4.8 B18-S8:13 X2.12 214.1.5 B3-S2:13

X2.12
X1.12

X1.13 X2.13

X1.14 X2.14

X1.15 DO7 RPM - 205.6 B20-K4:13 X2.15

X1.15 X2.15

X1.16 X2.16

X1.17 DO8 RPM + 205.7 B20-K5:13 X2.17 214.1.6 B3-H1:A

BOMAG
X2.17
X1.17

X1.18 X2.18

U1 X3.1 +VCC 204.3.2

116.2
X3.2 GND 204.3.2

X3.3 +VCC 204.3.2

X3.4 GND 204.3.2

X3.5 CAN-L 204.3.2 B20-XA:16

X3.6 CAN-H 204.3.3 B20-XA:15

008 917 69
Electric circuit diagrams

502.5 503.2

Design.: Zuccarino Luca

BM/60-2 PLC D: DE012009 pag. 503.1
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1
ELECTRIC
CABINET U2

008 917 69
U2 X2.1 DI9 UP LEFT SIDE DOOR 236.1.2 B3-S4:13
X1.1 DI1 LEFT REAR STEER. 264.5.4 B5-S3:23
116.3 116.3
X1.2 X2.2

X1.3 DI2 RIGHT REAR STEER. 264.5.5 B5-S3:13 X2.3 DI10 UP RIGHT SIDE DOOR 236.1.6 B4-S4:13

X1.4 X2.4

X1.5 DI3 SIDE DOOR MILLING DRUM OFF 236.2.4 B18-S3:14 X2.5 DI11 UP BREAK BAR 234.1.2 B8-S2:23

X1.6 +VCC 236.2.5 X2.6

X1.7 X2.7 DI12 FLOAT BREAK BAR 234.1.3 B8-S2:13

X1.8 X2.8

X1.9 X2.9
Electric circuit diagrams

X1.10 X2.10

X1.11 AI5 HIDR OIL THERM. 290.1.3 B14-C47:2 X2.11 AI13 CONV. PRESS. 290.1.6 B14-C99:2

X1.11 X2.11

X1.12 AI6 TRAVEL. PRESS. 290.1.5 B14-C96:2 X2.12 AI14 FAN PRESS. 290.1.8 B14-C100:2

X2.12
X1.12

X1.13 X2.13

X1.14 X2.14

X1.15 DO7 FLOAT BREAK BAR LED 234.1.4 B8-H1:A X2.15 DO15 UP LEFT SIDE DOOR LIGHT 236.1.2 B3-H2:+

X1.15 X2.15

X1.16 X2.16

X1.17 X2.17 DO16 UP RIGHT SIDE DOOR LIGHT 236.1.6 B4-H2:+

X2.17
X1.17

BOMAG
X1.18 X2.18

U2
X3.1 +VCC 204.3.3
116.3
X3.2 GND 204.3.4

X3.3 +VCC 204.3.4

X3.4 GND 204.3.4

X3.5 CAN-L 204.3.4 B20-XA:16

X3.6 CAN-H 204.3.4 B20-XA:15

503.1 503.3
25.1

961
Design.: Zuccarino Luca
BM/60-2 PLC D: DE012009 pag. 503.2
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

962
B20
25.1

106.1.1
ELECTRIC
CABINET U3 U3
X1.1 DI1 PK REAR LEFT COL. 226.6.1 C50:4 X2.1 DI9 WATER PRESS 242.1.3 C40
116.4 116.4
X1.2 X2.2

X1.3 DI2 PK REAR RIGHT COL. 226.6.4 C51:4 X2.3 DI10 D+ 290.3.1 U6C-V5

X1.4 X2.4

X1.5 DI3 PK FRONT LEFT COL. 226.6.6 C108:4 X2.5 DI11 COOLANT 290.3.2 U6A-R9

X1.6 X2.6

X1.7 DI4 PK FRONT RIGHT COL. 226.6.7 C107:4 X2.7

X1.8 X2.8

X1.9 X2.9

X1.10 X2.10

X1.11 AI5 CLUTCH PRESS. 290.2.3 B14-C57:2 X2.11 AI13 BREAK BAR PRESS. 290.2.6 B14-C50:2

X1.11 X2.11

X1.12 AI6 SERV PRESS. 290.2.5 B14-C58:2 X2.12 AI14 BACK DOOR PRESS. 290.2.8 B14-C60:2

X2.12
X1.12

X1.13 X2.13

X1.14 X2.14

X1.15 DO8 DIAGNOSTIC 290.4.7 B18-S8:+ X2.15

X1.15 X2.15

X1.16 X2.16

X1.17 X2.17

X2.17

BOMAG
X1.17

X1.18 X2.18

U3
116.4 X3.1 +VCC 204.3.5

X3.2 GND 204.3.6

X3.3 +VCC 204.3.6

X3.4 GND 204.3.6

X3.5 CAN-L 204.3.6 B20-XA:16

X3.6 CAN-H 204.3.6 B20-XA:15

008 917 69
Electric circuit diagrams

503.2 503.4

Design.: Zuccarino Luca

BM/60-2 PLC D: DE012009 pag. 503.3
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B20
106.1.1
ELECTRIC U4 U4
CABINET X1.1 DI1 TRAVEL FILTER 290.1 U6A-R4 X2.1 DI9 PRESS.BACK DOOR 214.3.4 B2-S1:23

008 917 69
116.6 116.6

X1.2 X2.2

X1.3 DI2 CONV. FILTER 290.2 U6A-R5 X2.3 DI10 PRESS.+ BACK DOOR 214.3.5 B2-S1:13

X1.4 X2.4

X1.5 DI3 SERV. FILTER 290.3 U6A-R6 X2.5

X1.6 X2.6

X1.7 DI4 HIDR. OIL TEMP 290.4 U6A-R7 X2.7

X1.8 X2.8 +VCC 238.2.5

X1.9 X2.9
Electric circuit diagrams

X1.10 X2.10

X1.11 DI5 HIDR. OIL LEVEL 290.4 U6A-R8 X2.11

X1.11 X2.11 AI13 SPEED CONV. 238.2.4 B18-R1:S

X1.12 DI6 CONV. CLOSED 238.9.7 B16-C50:4 X2.12

X2.12
X1.12

X1.13 X2.13 GND 238.2.4

X1.14 X2.14

X1.15 X2.15 DO7 REVER. ACUST. ALARM 290.4.2 B20-K8:13

X1.15 DI7 BACKDOOR 1/2 OPEN 214.2.3 C48:13 X2.15

X1.16 X2.16

X1.17 X2.17 DO8 ACUST. ALARM 290.4.1 B20-K7:13

X2.17
X1.17 DI8 BACKDOOR OPEN 214.2.5 C49:13
X2.18

BOMAG
X1.18

U4
116.6 X3.1 +VCC 204.3.7

X3.2 GND 204.3.7

X3.3 +VCC 204.3.8

X3.4 GND 204.3.8

X3.5 CAN-L 204.3.8 B20-XA:16

X3.6 CAN-H 204.3.8 B20-XA:15

503.3 503.5
25.1

963
Design.: Zuccarino Luca
BM/60-2 PLC D: DE012009 pag. 503.4
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

964
B20
25.1

106.1.1
ELECTRIC
CABINET U5 U5
116.7 X.1 GND 204.4.5 X.27
116.7
X.2
X.27 AI04 RIGHT WIRE SENS. 226.5.4 C22
X.5 +VCC 204.4.1
X.28
X.6 RS232 2 Rx 204.4.6 B20 X.28
X.7 RS232 2 Tx 204.4.7 B20 X.29
X.8
X.29 AI08 FRONT STEER. 264.6.2 C14
X.8 AI03 LEFT WIRE SENS. 226.5.2 C24
X.30
X.9
X.30 AI10 ADJUST STEER. 264.6.7 B1-C17
X.9 AI05 SLOPE SENS. 226.5.9 B20-U12:S
X.32 CAN 1 L 204.4.8 B20-XA:16
X.10
X.33 GND 204.4.7
X.10
X.34 +VCC 204.4.2
X.11
X.36
X.11 AI09 REAR STEER. 264.6.4 C16
X.36 AO04 FWD TRAVEL. 206.7.6 YA25-YB25:1
X.12 GND 204.4.6
X.37
X.13 ERROR 204.4.5 B20
X.38
X.14 CAN 1 H 204.4.8 B20-XA:15
X.44
X.15 GND 204.4.5
X.44 AO00 LEFT COL UP 226.9.1 B14-YA22:1
X.17
X.45
X.17
X.45 AO01 LEFT COL DOWN 226.9.3 B14-YB22:1
X.18
X.46

BOMAG
X.19
X.46 AO02 RIGHT COL UP 226.9.6 B14-YA23:1
X.20 DI12 SPEED SENS. 206.7.1 U6A-R3
X.47
X.21
X.47 AO03 RIGHT COL DOWN 226.9.8 B14-YB23:1
X.23 +VCC 204.4.2
X.53
X.24 TEST 204.4.3 B20-S1:13
X.53
X.25 CAN 2 L 204.4.8 B20-XD:13
X.54
X.26 CAN 2 H 204.4.8 B20-XD:12
X.54 AO05 BWD TRAVEL. 206.7.6 YA25-YB25:1

X.55

008 917 69
Electric circuit diagrams

503.4 504.1

Design.: Zuccarino Luca

BM/60-2 PLC D: DE012009 pag. 503.5
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B14
100.1.4
ENGINE U1 U1
COMPARTMENT X1.1 118.3 X2.1

008 917 69
118.3
X1.2 X2.2

X1.3 X2.3

X1.4 X2.4

X1.5 X2.5

X4.1
X3.1
X4.2
X3.2
X4.3
X3.3
Electric circuit diagrams

X4.4
X3.4
X4.5
X3.5

X6.1
X5.1 NC 216.2 U1-X5:1
X6.2
X5.2 CS 216.3 B14-YA4:2
X6.3
X5.3 GND 216.3
X6.4
X5.4 DO FAN 216.3 B14-YA4:1
X6.5
X5.5 SHELL 216.3

X7.1 NC 238.7.1 U1-X7:1 X8.1 NC 238.7.5 U1-X8:1

X7.2 CS 238.7.1 B14-YA26:1 X8.2 CS 238.7.5 B14-YB26:1

BOMAG
X7.3 GND 238.7.1 X8.3 GND 238.7.6
X7.4 DO FWD CONV 238.7.1 B14-YA26:2 X8.4 DO BWD CONV 238.7.6 B14-YB26:2
X7.5 SHELL 238.7.2 X8.5 SHELL 238.7.6

U1
118.3 X.1 CAN H 204.5.1 XS:15

X.2 CAN L 204.5.1 XS:16

X.3 GND 204.5.1

X.4 GND 204.5.1

X.5 +VCC 204.5.2

X.6 +VCC 204.5.2

X.7 +VCC 204.5.2

503.5 504.2
25.1

965
Design.: Zuccarino Luca
BM/60-2 PLC D: DE012009 pag. 504.1
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

966
25.1

B14
100.1.4
ENGINE U2
COMPARTMENT U2
118.4 X1.1 NC 212.1.2 B14 X2.1 NC 212.1.6 B14
118.4
X1.2 CS 212.1.3 B14 X2.2 CS 212.1.6 B14

X1.3 GND 212.1.3 X2.3 GND 212.1.6

X1.4 DO BELT TAKE UP 212.1.3 B14-YA14:2 X2.4 DO MILLING DRUM 212.1.7 B14-YB14:2

X1.5 SHELL 212.1.3 X2.5 SHELL 212.1.7

X3.1 NC 226.9.3 U2-X3:1 X4.1 NC 226.9.5 U2-X4:1

X3.2 CS 226.9.3 U2-X3:2 X4.2 CS 226.9.5 U2-X4:2

X3.3 GND 226.9.4 X4.3 GND 226.9.6

X3.4 DO UP REARS COL. 226.9.4 B14-YB21:2 X4.4 DO DOWN REARS COL. 226.9.6 B14-YA21:2

X3.5 SHELL 226.9.4 X4.5 SHELL 226.9.6

X5.1 NC 238.6.1 U2-X5:1 X6.1 NC 238.6.3 U2-X6:1

X5.2 CS 238.6.2 U2-X5:2 X6.2 CS 238.6.4 U2-X6:2

X5.3 GND 238.6.2 X6.3 GND 238.6.4

X5.4 DO UP CONV. 238.6.2 B14-YA5:2 X6.4 DO DOWN CONV. 238.6.4 B14-YB5:2

X5.5 SHELL 238.6.2 X6.5 SHELL 238.6.4

BOMAG
X7.1 NC 238.6.5 U2-X7:1 X8.1 NC 238.6.7 U2-X8:1
X7.2 CS 238.6.6 U2-X7:2 X8.2 CS 238.6.8 U2-X8:2
X7.3 GND 238.6.6 X8.3 GND 238.6.8
X7.4 DO LEFT CONV. 238.6.6 B14-YA6:2 X8.4 DO RIGHT CONV. 238.6.8 B14-YB6:2
X7.5 SHELL 238.6.6 X8.5 SHELL 238.6.8

U2
X.1 CAN H 204.5.3 B14-U1:X.1
118.4
X.2 CAN L 204.5.3 B14-U1:X.2

X.3 GND 204.5.3

X.4 GND 204.5.4

X.5 +VCC 204.5.4

X.6 +VCC 204.5.4

X.7 +VCC 204.5.4

008 917 69
Electric circuit diagrams

504.1 504.3

Design.: Zuccarino Luca

BM/60-2 PLC D: DE012009 pag. 504.2
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

B14
100.1.4
ENGINE U3
COMPARTMENT U3

008 917 69
X1.1 NC 236.3.1 U3-X1:1 118.5 X2.1 NC 236.3.3 U3-X2:1
118.5
X1.2 CS 236.3.1 U3-X1:2 X2.2 CS 236.3.3 U3-X2:2

X1.3 GND 236.3.1 X2.3 GND 236.3.3

X1.4 DO LEFT SIDE DOOR OPEN 236.3.2 B14-YA3:2 X2.4 DO LEFT SIDE DOOR OPEN 236.3.3 B14-YB3:2

X1.5 SHELL 236.3.2 X2.5 SHELL 236.3.4

X3.1 NC 236.3.5 U3-X3:1 X4.1 NC 236.3.7 U3-X4:1

X3.2 CS 236.3.5 U3-X3:2 X4.2 CS 236.3.7 U3-X4:2

X3.3 GND 236.3.5 X4.3 GND 236.3.7

Electric circuit diagrams

X3.4 DO RIGHT SIDE DOOR UP 236.3.6 B14-YA33:2 X4.4 DO RIGHT SIDE DOOR DOWN 236.3.7 B14-YB33:2

X3.5 SHELL 236.3.6 X4.5 SHELL 236.3.8

X5.1 NC 214.4.2 B14 X6.1

X5.2 CS 214.4.3 B14 X6.2

X5.3 GND 214.4.3 X6.3

X5.4 DO FLOAT BACK DOOR 214.4.3 B14-YB20:2 X6.4

X5.5 SHELL 214.4.3 X6.5

X7.1 NC 214.4.4 B14 X8.1 NC 214.4.6 B14

X7.2 CS 214.4.5 B14 X8.2 CS 214.4.7 B14

BOMAG
X7.3 GND 214.4.5 X8.3 GND 214.4.7

X7.4 DO UP LEFT BACK DOOR 214.4.5 B14-YA20:2 X8.4 DO CLOSE RIGHT BACK DOOR 214.4.7 B14-YA19:2

X7.5 SHELL 214.4.5 X8.5 SHELL 214.4.7

U3
118.5 X.1 CAN H 204.5.5 B14-U2:X.1

X.2 CAN L 204.5.5 B14-U2:X.2

X.3 GND 204.5.6

X.4 GND 204.5.6

X.5 +VCC 204.5.6

X.6 +VCC 204.5.6

X.7 +VCC 204.5.6

504.2 504.4
25.1

967
Design.: Zuccarino Luca
BM/60-2 PLC D: DE012009 pag. 504.3
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

968
B14
25.1

100.1.4
ENGINE
COMPARTMENT U4 U4
118.6 X1.1 NC 234.2.3 U4-X1:1 118.6 X2.1 NC 234.2.5 U4-X2:1

X1.2 CS 234.2.3 U4-X1:2 X2.2 CS 234.2.5 U4-X2:2

X1.3 GND 234.2.4 X2.3 GND 234.2.6

X1.4 DO UP BREAK BAR 234.2.4 B14-YA18:2 X2.4 DO FLOAT BREAK BAR 234.2.6 B14-YB18:2

X1.5 SHELL 234.2.4 X2.5 SHELL 234.2.6

X3.1 NC 264.7.3 U4-X3:1 X4.1 NC 264.7.5 U4-X4:1

X3.2 CS 264.7.3 B14-YA17:1 X4.2 CS 264.7.5 B14-YB17:1

X3.3 GND 264.7.4 X4.3 GND 264.7.6

X3.4 DO LEFT REAR STEER. 264.7.4 B14-YA17:2 X4.4 DO RIGHT REAR STEER. 264.7.6 B14-YB17:2

X3.5 SHELL 264.7.4 X4.5 SHELL 264.7.6

X5.1 X6.1

X5.2 X6.2

X5.3 X6.3

X5.4 X6.4

X5.5 X6.5

X7.1 NC 242.2.3 U4-X7:1 X8.1 NC 242.2.5 U4-X8:1

BOMAG
X7.2 CS 242.2.3 U4-X7:2 X8.2 CS 242.2.6 U4-X8:2

X7.3 GND 242.2.3 X8.3 GND 242.2.6

X7.4 DO WATER PUMP 242.2.3 B14-YA10:2 X8.4 DO WATER VALVE 242.2.6 B14-YB10:2

X7.5 SHELL 242.2.3 X8.5 SHELL 242.2.6

U4 X.1 CAN H 204.5.7 B14-U3:X.1

118.6
X.2 CAN L 204.5.8 B14-U3:X.2

X.3 GND 204.5.8

X.4 GND 204.5.8

X.5 +VCC 204.5.8

X.6 +VCC 204.5.8

X.7 +VCC 204.5.9

008 917 69
Electric circuit diagrams

504.3 1000

Design.: Zuccarino Luca

BM/60-2 PLC D: DE012009 pag. 504.4
date: 29.Apr.2010
Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

DISTMACC3.SKO

NOME QUANTITA' PAGINA/COLONNA TESTO FUNZIONALE

NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

008 917 69
B1 0 100. 1 STEER ADJUST
B1-C17 0 264.6. 6 STEER ADJUST
B1-XC17 0 264.6. 6
B2 0 100. 1 BACK DOOR BOX
B2-S1 0 214.3. 3 BACK DOOR
B3 0 100. 2 LEFT REAR BOX
B3-GND 0 201.2. 3
B3-GND 0 214.1. 4
B3-GND 0 226.8. 1
Electric circuit diagrams

B3-GND 0 236.1. 2
B3-H1 0 214.1. 4 BACK DOOR
B3-H2 0 236.1. 2 UP LEFT SIDE DOOR
B3-S2 0 214.1. 1 BACK DOOR
B3-S3 0 214.1. 2 BACK DOOR
B3-S4 0 236.1. 1 LEFT SIDE DOOR
B3-XC66 0 226.8. 1 LEV.SYSTEM
B4 0 100. 2 RIGHT REAR BOX
B4-GND 0 201.2. 7
B4-GND 0 214.1. 9
B4-GND 0 226.8. 4
B4-GND 0 236.1. 6

BOMAG
B4-H1 0 214.1. 9 BACK DOOR
B4-H2 0 236.1. 6 UP RIGHT SIDE DOOR
B4-S2 0 214.1. 6 BACK DOOR
B4-S3 0 214.1. 7 BACK DOOR
B4-S4 0 236.1. 5 RIGHT SIDE DOOR
B4-XC67 0 226.8. 4 LEV.SYSTEM
B5 0 100. 2 LEFT REAR BOX
B5-GND 0 201.2. 4
B5-GND 0 226.7. 1
B5-S1 0 202. 3 EMERGENCY PUSHBUTTON
B5-S3 0 264.5. 2 REAR STEERING
B5-S4 0 266. 3 HORN
B5-S5 0 226.4. 2 REARS COLUMNS
B5-XC23 0 226.7. 1 COLUMNS
B6 0 100. 2 RIGHT REAR BOX
B6-GND 0 201.2. 9
B6-GND 0 226.7. 4
B6-S1 0 202. 8 EMERGENCY PUSHBUTTON
B6-S3 0 264.5. 7 REAR STEERING

504.4 1001
25.1

969
Design.: Zuccarino Luca
BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1000
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

970
DISTMACC3.SKO

NOME TESTO FUNZIONALE

25.1

QUANTITA' PAGINA/COLONNA
NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

B6-S4 0 266. 7 HORN

B6-S5 0 226.4. 7 REARS COLUMNS
B6-XC69 0 226.7. 5 COLUMNS
B7 0 100. 5 BACK DASH PANEL
B7-C101 0 200.1. 4 SOCKET 12V
B7-S1 0 214.3. 6 BACK DOOR
B7-XMB 0 170. 7 DIAGNOSTIC
B8 0 100. 6 LEFT FRONT BOX
B8-GND 0 201.2. 1
B8-GND 0 234.1. 4
B8-H1 0 234.1. 4 BREAK BAR
B8-S1 0 202. 1 EMERGENCY PUSHBUTTON
B8-S2 0 234.1. 2 BREAK BAR
B8-S3 0 240. 4 WATER
B8-S4 0 266. 1 HORN
B8-XC68 0 226.5. 1 COLUMNS
B9 0 100. 6 RIGHT FRONT BOX
B9-GND 0 201.2. 6
B9-GND 0 234.1. 8
B9-H1 0 234.1. 8

BOMAG
BREAK BAR
B9-S1 0 202. 6 EMERGENCY PUSHBUTTON
B9-S2 0 234.1. 7 BREAK BAR
B9-S4 0 266. 5 HORN
B9-S10 0 238.8. 7 CONVEYOR
B9-XC21 0 226.5. 3 COLUMNS
B10 0 100. 8 EMERGENCY BOX
B10-S1 0 246. 7 ROOF
B10-S2 0 250. 3 EMERGENCY SERVICES
B10-S3 0 250. 5 EMERGENCY BREAKS
B13 0 100.1. 1 BATTERY COMPARTMENT
B13-B21 0 150. 1 FUSES BOX
B13-C3 0 150. 2 MANUAL SWITCH
B13-C15 0 290.4. 6 ACUSTIC ALLARM
B13-G1 0 150. 2 BATTERY
B13-G2 0 150. 2 BATTERY
B13-GND 0 150. 2
B13-XSR 0 290.4. 6
B14 0 100.1. 4 ENGINE COMPARTMENT
B14-C5 0 170.5. 3 GENERATOR
B14-C6 0 170.5. 5 STARTER

008 917 69
Electric circuit diagrams

1000 1002

Design.: Zuccarino Luca

BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1001
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

DISTMACC3.SKO

NOME QUANTITA' PAGINA/COLONNA TESTO FUNZIONALE

NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

008 917 69
B14-C9 0 290.3. 5 FUEL LEVEL
B14-C11 0 170.1. 3 ENGINE COOLANT LEVEL 2
B14-C12 0 170.1. 1 ENGINE AIR FILTER
B14-C13 0 170.1. 8 ENGINE FUEL FILTER
B14-C18 0 170.1. 4 ENGINE COOLANT LEVEL
B14-C46 0 290. 4 HYDR.OIL TEMPERATURE
B14-C47 0 290.1. 3 OIL HYDRAULIC THERMISTOR
B14-C50 0 290.2. 6 BREAK BAR PRESSURE
B14-C57 0 290.2. 3
Electric circuit diagrams

CLUTCH PRESSURE
B14-C58 0 290.2. 4 SERVICES PRESSURE
B14-C60 0 290.2. 8 BACK DOOR PRESSURE
B14-C96 0 290.1. 4 TRAVELLING PRESSURE
B14-C99 0 290.1. 6 CONVEYOR PRESSURE
B14-C100 0 290.1. 7 FAN PRESSURE
B14-C101 0 290. 4 HYDR.OIL LEVEL
B14-C102 0 290. 1 TRAVEL FILTER
B14-C103 0 290. 2 CONVEYOR FILTER
B14-C104 0 290. 3 SERVICES FILTER
B14-GND 0 170. 3
B14-GND 0 170. 9
B14-GND 0 170.1. 7

BOMAG
B14-GND 0 170.1. 7
B14-GND 0 204.5. 1
B14-GND 0 204.5. 3
B14-GND 0 204.5. 5
B14-GND 0 204.5. 7
B14-GND 0 204.5. 9
B14-GND 0 226.9. 1
B14-GND 0 226.9. 3
B14-GND 0 226.9. 6
B14-GND 0 226.9. 8
B14-GND 0 264.8. 3
B14-GND 0 264.8. 5
B14-GND 0 290. 1
B14-GND 0 290. 2
B14-GND 0 290. 3
B14-GND 0 290. 4
B14-GND 0 290. 4
B14-GND 0 290.1. 4
B14-GND 0 290.1. 5

1001 1003
25.1

971
Design.: Zuccarino Luca
BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1002
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

972
DISTMACC3.SKO

NOME TESTO FUNZIONALE

25.1

QUANTITA' PAGINA/COLONNA
NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

B14-GND 0 290.1. 7
B14-GND 0 290.1. 8
B14-GND 0 290.2. 4
B14-GND 0 290.2. 5
B14-GND 0 290.2. 7
B14-GND 0 290.2. 9
B14-GND 0 290.3. 5
B14-K10 0 170.4. 7 PREHEAT
B14-KA4 0 216. 3
B14-KA7 0 206.6. 7
B14-KA8 0 206.6. 2
B14-KA9 0 206.6. 4
B14-KA13 0 214.5. 4
B14-KA26 0 238.7. 1
B14-KB10 0 242.2. 6
B14-KB26 0 238.7. 5
B14-U1 0 118. 3 OUTPUT MODULE
B14-U2 0 118. 4 OUTPUT MODULE
B14-U3 0 118. 5 OUTPUT MODULE
B14-U4 0 118. 6

BOMAG
OUTPUT MODULE
B14-U5 0 170. 1 EMR
B14-X17.1 0 170.4. 8 PREHEAT
B14-XJ 0 170.1. 4
B14-XME 0 170. 1
B14-XU1 0 204.5. 1
B14-XU2 0 204.5. 3
B14-XU3 0 204.5. 5
B14-XU4 0 204.5. 7
B14-XXA 0 290.1. 3 ALARM
B14-XXB 0 290.1. 4 ALARM
B14-XXC 0 290.1. 6 ALARM
B14-XXD 0 290.1. 7 ALARM
B14-XXE 0 290.2. 3 ALARM
B14-XXF 0 290.2. 4 ALARM
B14-XXG 0 290.2. 6 ALARM
B14-XXH 0 290.2. 8 ALARM
B14-XY 0 170.1. 3
B14-YA3 0 236.3. 1 LEFT SIDE DOOR
B14-YA4 0 216. 5 FAN
B14-YA5 0 238.6. 2 CONVEYOR

008 917 69
Electric circuit diagrams

1002 1004

Design.: Zuccarino Luca

BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1003
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

DISTMACC3.SKO

NOME QUANTITA' PAGINA/COLONNA TESTO FUNZIONALE

NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

008 917 69
B14-YA6 0 238.6. 6 CONVEYOR
B14-YA7 0 206.6. 7 BRAKES
B14-YA8 0 206.6. 2 MOTOR DISPLACEMENT
B14-YA9 0 206.6. 4 DIFFERENTIAL LOCK
B14-YA10 0 242.2. 3 WATER PUMP
B14-YA13 0 214.5. 4 BACK DOOR
B14-YA14 0 212.1. 3 BELT TAKE UP
B14-YA17 0 264.7. 3 REAR STEERING
B14-YA18 0 234.2. 4
Electric circuit diagrams

BREAK BAR
B14-YA19 0 214.4. 7 RIGHT BACK DOOR
B14-YA20 0 214.4. 5 LEFT BACK DOOR
B14-YA21 0 226.9. 6 REARS COLUMS
B14-YA22 0 226.9. 1 COLUMN LEFT
B14-YA23 0 226.9. 6 COLUMN RIGHT
B14-YA26 0 238.7. 3 CONVEYOR
B14-YA29 0 264.8. 5 FRONT STEERING
B14-YA33 0 236.3. 5 RIGHT SIDE DOOR OPEN
B14-YB3 0 236.3. 3 LEFT SIDE DOOR
B14-YB5 0 238.6. 4 CONVEYOR
B14-YB6 0 238.6. 8 CONVEYOR
B14-YB10 0 242.2. 6 WATER VALVE

BOMAG
B14-YB14 0 212.1. 6 MILLING DRUM
B14-YB17 0 264.7. 5 REAR STEERING
B14-YB18 0 234.2. 6 BREAK BAR
B14-YB20 0 214.4. 3 BACK DOOR
B14-YB21 0 226.9. 4 REARS COLUMS
B14-YB22 0 226.9. 3 CULUMN LEFT
B14-YB23 0 226.9. 8 CULUMN RIGHT
B14-YB26 0 238.7. 8 CONVEYOR
B14-YB29 0 264.8. 3 FRONT STEERING
B14-YB33 0 236.3. 7 RIGHT SIDE DOOR OPEN
B15 0 100.1. 6 ROOF
B15-H1 0 274. 5 BEACON
B15-L18 0 272.4. 5 LEFT REAR WORKING LIGHT
B15-L19 0 272.4. 3 LEFT FRONT WORKING LIGHT
B15-L20 0 272.4. 4 RIGHT FRONT WORKING LIGHT
B15-L21 0 272.4. 6 RIGHT REAR WORKING LIGHT
B15-XCF 0 274. 5 BEACON
B15-XVR 0 272.4. 3 ROOF
B15-XVS 0 272.4. 4 ROOF

1003 1005
25.1

973
Design.: Zuccarino Luca
BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1004
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

974
DISTMACC3.SKO

NOME TESTO FUNZIONALE

25.1

QUANTITA' PAGINA/COLONNA
NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

B15-XVT 0 272.4. 5 ROOF

B15-XVU 0 272.4. 6 ROOF
B16 0 100.1. 8 CONVEYOR
B16-C50 0 238.9. 7 CONVEYOR CLOSED
B16-C96 0 238.9. 4 CONVEYOR LOCK
B16-C97 0 238.9. 5 CONVEYOR LOCK
B16-XAA 0 238.9. 7 COLUMNS
B16-XMN 0 266.1. 4 HORN
B16-XXA 0 238.9. 4 CONVEYOR
B16-XXB 0 238.9. 5
B17 0 106. 1 LEFT PANEL
B17-F1 0 204. 2 CR2012
B17-F2 0 204. 3 CR2012
B17-F3 0 204. 5 CR2012
B17-F4 0 204. 7 CR2012
B17-F5 0 204. 8 CR2012
B17-GND 0 204. 0
B17-GND 0 272. 1
B17-H1 0 206.2. 3 BRAKE
B17-H2 0 206.3. 3

BOMAG
DIFFERENTIAL LOCK
B17-H3 0 206.4. 2 LOW SPEED
B17-H4 0 206.4. 4 HIGH SPEED
B17-H5 0 206.5. 3 ENGINE LOAD CONTROL
B17-H6 0 212. 3 MILLING DRUM
B17-H7 0 214. 3 BACK DOOR
B17-H8 0 234. 3 BREAK BAR
B17-H9 0 238. 3 CONVEYOR
B17-H10 0 242. 3 WATER SPRAY
B17-H11 0 244. 3 PAUSE
B17-H12 0 264. 3 STEERING MODE
B17-H13 0 264. 4 STEERING MODE
B17-H14 0 264.1. 3 STEERING MODE
B17-H15 0 264.1. 4 STEERING MODE
B17-H16 0 272. 1 DASHBOARD LIGHT
B17-R1 0 204. 2
B17-S1 0 202. 1 EMERGENCY PUSHBUTTON
B17-S2 0 206.3. 2 DIFFERENTIAL LOCK
B17-S3 0 206.4. 1 SPEED
B17-S4 0 206.5. 1 ENGINE LOAD CONTROL
B17-S5 0 212. 1 MILLING DRUM

008 917 69
Electric circuit diagrams

1004 1006

Design.: Zuccarino Luca

BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1005
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

DISTMACC3.SKO

NOME QUANTITA' PAGINA/COLONNA TESTO FUNZIONALE

NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

008 917 69
B17-S6 0 214. 1 BACK DOOR
B17-S7 0 226. 1 LEFT COLUMN
B17-S8 0 226.1. 1 RIGHT COLUMN
B17-S9 0 226.2. 1 ALL COLUMNS
B17-S10 0 226.2. 3 REAR COLUMNS
B17-S11 0 234. 1 BREAK BAR
B17-S12 0 236. 2 LEFT SIDE DOOR
B17-S13 0 238. 1 CONVEYOR
B17-S14 0 238.1. 1
Electric circuit diagrams

CONVEYOR
B17-S15 0 242. 1 WATER SPRAY
B17-S16 0 244. 1 PAUSE
B17-S17 0 264. 1 STEERING MODE
B17-S18 0 264.2. 2 REAR STEERING
B17-S19 0 266. 1 HORN
B17-U1 0 110. 2 I/O MODULE
B17-U2 0 110. 3 I/O MODULE
B17-U3 0 110. 5 I/O MODULE
B17-U4 0 110. 6 I/O MODULE
B17-U5 0 110. 7 I/O MODULE
B17-UJ1 0 206. 1 JOYSTICK TRAVELLING
B17-UJ2 0 264.3. 1 JOYSTICK FRONT STEERING

BOMAG
B17-XCB 0 204. 1 CANBUS
B17-XCL 0 204. 1 LEFT PANEL
B17-XE 0 202. 1 EXTRA SERVICES
B18 0 106. 4 CENTRAL PANEL
B18-F1 0 204.2. 3 DISPLAY
B18-GND 0 226.8. 4
B18-GND 0 226.8. 7
B18-GND 0 272. 4
B18-GND 0 290.4. 7
B18-H1 0 170.2. 5 STATUS PREHEAT
B18-H16 0 272. 4 DASHBOARD LIGHT
B18-R1 0 238.2. 4 SPEED CONVEYOR
B18-S1 0 180. 4 IGNITION KEY
B18-S2 0 205. 4 ENGINE RPM
B18-S3 0 236.2. 4 SIDE DOORS MILLING DRUM OFF
B18-S5 0 246. 1 ENGINE COVER
B18-S6 0 246. 2 ROOF
B18-S7 0 274. 5 BEACON
B18-S8 0 290.4. 8 DIAGNOSTIC

1005 1007
25.1

975
Design.: Zuccarino Luca
BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1006
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

976
DISTMACC3.SKO

NOME TESTO FUNZIONALE

25.1

QUANTITA' PAGINA/COLONNA
NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

B18-S9 0 272. 4 WORKING LIGHTS ON

B18-S10 0 238.8. 4 CONVEYOR
B18-U1 0 114. 4 PDM 360
B18-XCC 0 204.2. 2 CAN-BUS
B18-XCL 0 226.8. 3 LEV.SYSTEM
B18-XCR 0 226.8. 6 LEV.SYSTEM
B19 0 106. 6 RIGHT PANEL
B19-F1 0 204.1. 1 CR2012
B19-F2 0 204.1. 3 CR2012
B19-F3 0 204.1. 5 CR2012
B19-F4 0 204.1. 6 CR2012
B19-F5 0 204.1. 8 CR2012
B19-GND 0 204.1. 0
B19-GND 0 272. 7
B19-H1 0 206.2. 7 BRAKE
B19-H2 0 206.3. 8 DIFFERENTIAL LOCK
B19-H3 0 206.4. 7 LOW SPEED
B19-H4 0 206.4. 8 HIGH SPEED
B19-H5 0 206.5. 8 ENGINE LOAD CONTROL
B19-H6 0 212. 8

BOMAG
MILLING DRUM
B19-H7 0 214. 8 BACK DOOR
B19-H8 0 234. 7 BREAK BAR
B19-H9 0 238. 8 CONVEYOR
B19-H10 0 242. 7 WATER SPRAY
B19-H11 0 244. 8 PAUSE
B19-H12 0 264. 7 STEERING MODE
B19-H13 0 264. 8 STEERING MODE
B19-H14 0 264.1. 7 STEERING MODE
B19-H15 0 264.1. 8 STEERING MODE
B19-H16 0 272. 7 DASHBOARD LIGHT
B19-R1 0 204.1. 2
B19-S1 0 202. 8 EMERGENCY PUSHBUTTON
B19-S2 0 206.3. 6 DIFFERENTIAL LOCK
B19-S3 0 206.4. 6 SPEED
B19-S4 0 206.5. 6 ENGINE LOAD CONTROL
B19-S5 0 212. 6 MILLING DRUM
B19-S6 0 214. 6 BACK DOOR
B19-S7 0 226. 6 LEFT COLUMN
B19-S8 0 226.1. 6 RIGHT COLUMN
B19-S9 0 226.2. 6 ALL COLUMNS

008 917 69
Electric circuit diagrams

1006 1008

Design.: Zuccarino Luca

BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1007
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

DISTMACC3.SKO

NOME QUANTITA' PAGINA/COLONNA TESTO FUNZIONALE

NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

008 917 69
B19-S10 0 226.2. 8 REAR COLUMNS
B19-S11 0 234. 6 BREAK BAR
B19-S12 0 236. 7 RIGHT SIDE DOOR
B19-S13 0 238. 6 CONVEYOR
B19-S14 0 238.1. 6 CONVEYOR
B19-S15 0 242. 6 WATER SPRAY
B19-S16 0 244. 6 PAUSE
B19-S17 0 264. 6 STEERING MODE
B19-S18 0 264.2. 6
Electric circuit diagrams

REAR STEERING
B19-S19 0 266. 6 HORN
B19-U1 0 112. 2 I/O MODULE
B19-U2 0 112. 3 I/O MODULE
B19-U3 0 112. 5 I/O MODULE
B19-U4 0 112. 6 I/O MODULE
B19-U5 0 112. 7 I/O MODULE
B19-UJ1 0 206. 5 JOYSTICK TRAVELLING
B19-UJ2 0 264.3. 6 JOYSTICK FRONT STEERING
B19-XCB 0 204.1. 1 CANBUS
B19-XCR 0 204.1. 1 CANBUS
B19-XE 0 202. 8 EXTRA SERVICES
B20 0 106.1. 1 ELECTRIC CABINET

BOMAG
B20- 0 206.7. 3
B20-F1 0 180. 2 EMR
B20-F2 0 180. 3 EMR
B20-F3 0 200.1. 2 EMR
B20-F4 0 200.1. 4 CONV. 24V/12V
B20-F5 0 200.1. 6 24V-10V CONVERTER
B20-F6 0 201.2. 1 LEFT FRONT BOX
B20-F7 0 201.2. 2 LEFT REAR BOX
B20-F8 0 201.2. 4 LEFT REAR BOX
B20-F9 0 201.2. 5 RIGHT FRONT BOX
B20-F10 0 201.2. 7 RIGHT REAR BOX
B20-F11 0 201.2. 8 RIGHT REAR BOX
B20-F12 0 204.3. 2 CR2012
B20-F13 0 204.3. 3 CR2012
B20-F14 0 204.3. 5 CR2012
B20-F15 0 204.3. 7 CR2012
B20-F16 0 204.4. 1 CR0505
B20-F17 0 204.4. 2 CR0505
B20-F18 0 204.4. 2 CR0505

1007 1009
25.1

977
Design.: Zuccarino Luca
BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1008
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

978
DISTMACC3.SKO

NOME TESTO FUNZIONALE

25.1

QUANTITA' PAGINA/COLONNA
NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

B20-F19 0 204.5. 1 CR2031

B20-F20 0 204.5. 2 CR2031
B20-F21 0 204.5. 3 CR2031
B20-F22 0 204.5. 4 CR2031
B20-F23 0 204.5. 6 CR2031
B20-F24 0 204.5. 6 CR2031
B20-F25 0 204.5. 8 CR2031
B20-F26 0 204.5. 8 CR2031
B20-F27 0 204.6. 2 CANBUS
B20-F28 0 205. 2 ENGINE
B20-F29 0 206.7. 3 SPEED SENSOR
B20-F30 0 214.2. 7 LEV.SYSTEM
B20-F31 0 214.3. 2 REAR MOULDER
B20-F32 0 226.5. 1 WIRE SENSOR
B20-F33 0 226.5. 7 SLOPE SENSOR
B20-F34 0 226.6. 3 PICKUP COLUMNS
B20-F35 0 226.7. 1 EXTERNAL LEV.SYSTEM
B20-F36 0 226.8. 2 LEV.SYSTEM
B20-F37 0 238.8. 2 CONVEYOR
B20-F38 0 240. 4

BOMAG
WATER FILLING CLEANING
B20-F39 0 242.1. 5 WATER SPRAY
B20-F40 0 264.6. 1 WIRE SENSOR
B20-F41 0 266. 3 HORN
B20-F42 0 272.1. 3 WORKING LIGHTS
B20-F43 0 272.1. 5 WORKING LIGHTS
B20-F44 0 272.2. 2 WORKING LIGHTS
B20-F45 0 272.2. 5 WORKING LIGHTS
B20-F46 0 272.3. 4 WORKING LIGHTS
B20-F47 0 272.4. 5 WORKING LIGHTS
B20-F48 0 274. 4 BEACON
B20-F49 0 280. 4 FUEL FILL
B20-F50 0 290. 5 SENSORS
B20-F51 0 290.1. 1 SENSORS
B20-F52 0 290.4. 4 ACUSTIC ALLARM
B20-F53 0 204.2. 6 PDM 360
B20-F54 0 272.4. 3 ROOF LIGHTS
B20-F56 0 281. 1 DRUM MOVING
B20-GND 0 180. 3
B20-GND 0 200. 2
B20-GND 0 200. 7

008 917 69
Electric circuit diagrams

1008 1010

Design.: Zuccarino Luca

BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1009
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

DISTMACC3.SKO

NOME QUANTITA' PAGINA/COLONNA TESTO FUNZIONALE

NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

008 917 69
B20-GND 0 200.1. 6
B20-GND 0 200.1. 6
B20-GND 0 204. 0
B20-GND 0 204. 1
B20-GND 0 204. 1
B20-GND 0 204.1. 0
B20-GND 0 204.1. 1
B20-GND 0 204.1. 1
B20-GND 0 204.2. 2
Electric circuit diagrams

B20-GND 0 204.2. 3
B20-GND 0 204.3. 8
B20-GND 0 204.4. 5
B20-GND 0 204.4. 5
B20-GND 0 204.4. 6
B20-GND 0 205. 6
B20-GND 0 205. 7
B20-GND 0 206.7. 4
B20-GND 0 214.2. 5
B20-GND 0 226.5. 2
B20-GND 0 226.5. 4
B20-GND 0 226.5. 7

BOMAG
B20-GND 0 226.5. 8
B20-GND 0 226.8. 3
B20-GND 0 226.8. 5
B20-GND 0 226.8. 5
B20-GND 0 226.8. 6
B20-GND 0 238.9. 5
B20-GND 0 238.9. 6
B20-GND 0 264.6. 2
B20-GND 0 264.6. 4
B20-GND 0 264.6. 7
B20-GND 0 272. 2
B20-GND 0 272. 5
B20-GND 0 272.4. 4
B20-GND 0 272.4. 6
B20-GND 0 274. 5
B20-GND 0 281. 8
B20-GND 0 290.4. 1
B20-GND 0 290.4. 2
B20-GND 0 290.4. 4

1009 1011
25.1

979
Design.: Zuccarino Luca
BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1010
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

980
DISTMACC3.SKO

NOME TESTO FUNZIONALE

25.1

QUANTITA' PAGINA/COLONNA
NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

B20-GND 0 290.4. 5
B20-K1 0 272. 2 WORKING LIGHTS
B20-K2 0 200. 2 EMERGENCY
B20-K3 0 200. 3 EMERGENCY
B20-K4 0 205. 6 RPM-
B20-K5 0 205. 7 RPM+
B20-K6 0 238.9. 6 CONVEYOR LOCK
B20-K7 0 290.4. 1 ACUSTIC ALARM
B20-K8 0 290.4. 2 ACUSTIC ALARM
B20-K9 0 272. 5 ROOF LIGHTS
B20-K10 0 214.2. 5 DRUM MOVING
B20-R3 0 290.3. 1 GENERATOR
B20-S1 0 204.4. 3 TEST
B20-SL 0 226.5. 7
B20-U1 0 116. 2 I/O MODULE
B20-U2 0 116. 3 I/O MODULE
B20-U3 0 116. 4 I/O MODULE
B20-U4 0 116. 6 I/O MODULE
B20-U5 0 116. 7 CR0505
B20-U6A 0 170.2. 5

BOMAG
PCB
B20-U6B 0 290.3. 6
B20-U6C 0 246. 4 DIODES BOARD
B20-U10 0 200.1. 4 CONV
B20-U11 0 200.1. 6 24V-10V CONVERTER
B20-U12 0 226.5. 7 SLOPE SENSOR
B20-U13 0 226.8. 4 RS485-RS232 CONVERTER
B20-UH1 0 290.4. 4 BUZZER
B20-UH2 0 290.4. 5 BUZZER
B20-XA 0 200. 2
B20-XB 0 281. 1
B20-XCB1 0 204. 1 CANBUS
B20-XCB3 0 204.1. 1 CANBUS
B20-XD 0 170.2. 5
B20-XE1 0 202. 1 EXTRA SERVICES
B20-XE3 0 202. 8 EXTRA SERVICES
B20-XP 0 180. 2 POWER
B20-XRF 0 272.4. 3 ROOF
B20-XRS 0 204.4. 6 RS232
B20-XS 0 180. 7
B20-Z1 0 200. 7 SOPPRESSOR

008 917 69
Electric circuit diagrams

1010 1012

Design.: Zuccarino Luca

BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1011
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

DISTMACC3.SKO

NOME QUANTITA' PAGINA/COLONNA TESTO FUNZIONALE

NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

008 917 69
B21-F1 0 150. 2 MAIN
B21-F2 0 150. 3 EMERGENCY
B21-F3 0 150. 3 EMERGENCY PUMP
B21-F4 0 150. 4 PREHEAT
C4 0 250. 2 EMERGENCY PUMP
C4-K 0 250. 3 EMERGENCY PUMP
C4-M 0 250. 2
C4-T 0 250. 3 THERMO PROTECTION
C14 0 264.6. 1
Electric circuit diagrams

STEER FRONT
C16 0 264.6. 3 STEER REAR
C22 0 226.5. 3 WIRE SENSOR
C24 0 226.5. 1 WIRE SENSOR
C40 0 242.1. 3 WATER IN PRESSURE
C48 0 214.2. 3 LIMIT SWITCH BACK DOOR 1/2 OPEN
C49 0 214.2. 5 LIMIT SWITCH BACK DOOR OPEN
C50 0 226.6. 3 PICKUP REAR LEFT COLUMN
C51 0 226.6. 4 PICKUP REAR RIGHT COLUMN
C53 0 206.7. 3 SPEED SENSOR
C64 0 266.1. 4 HORN
C70 0 266.1. 5 HORN
C107 0 226.6. 7 PICKUP FRONT RIGHT COLUMN

BOMAG
C108 0 226.6. 6 PICKUP FRONT LEFT COLUMN
GND 0 201.2. 2
GND 0 201.2. 3
GND 0 201.2. 4
GND 0 201.2. 6
GND 0 201.2. 7
GND 0 201.2. 9
GND 0 204.1. 0
GND 0 206.7. 6
GND 0 206.7. 6
GND 0 226.5. 2
GND 0 226.5. 4
GND 0 226.6. 3
GND 0 226.6. 4
GND 0 226.6. 6
GND 0 226.6. 8
GND 0 226.8. 3
GND 0 226.8. 5
GND 0 238.8. 3

1011 1013
25.1

981
Design.: Zuccarino Luca
BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1012
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

982
DISTMACC3.SKO

NOME TESTO FUNZIONALE

25.1

QUANTITA' PAGINA/COLONNA
NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

GND 0 238.8. 8
GND 0 238.9. 2
GND 0 240. 4
GND 0 240. 5
GND 0 246. 1
GND 0 246. 1
GND 0 246. 2
GND 0 246. 3
GND 0 250. 2
GND 0 250. 5
GND 0 250. 6
GND 0 264.6. 2
GND 0 264.6. 2
GND 0 264.6. 4
GND 0 264.6. 4
GND 0 264.6. 7
GND 0 266.1. 4
GND 0 272.1. 2
GND 0 272.1. 3
GND 0 272.1. 4

BOMAG
GND 0 272.1. 5
GND 0 272.1. 6
GND 0 272.1. 7
GND 0 272.2. 1
GND 0 272.2. 2
GND 0 272.2. 3
GND 0 272.2. 4
GND 0 272.2. 5
GND 0 272.2. 5
GND 0 272.2. 6
GND 0 272.3. 3
GND 0 272.3. 4
GND 0 280. 4
GND 0 290.4. 7
H1 0 272.3. 6 WORKING LIGHT MAGNETIC
L5 0 272.3. 3 WORKING LIGHT CONVEYOR
L6 0 272.3. 4 WORKING LIGHT CONVEYOR
L10 0 272.1. 2 BREAK BAR LEFT
L11 0 272.1. 3 BACK DOOR LEFT
L12 0 272.1. 5 COLUMN REAR LEFT

008 917 69
Electric circuit diagrams

1012 1014

Design.: Zuccarino Luca

BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1013
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

DISTMACC3.SKO

NOME QUANTITA' PAGINA/COLONNA TESTO FUNZIONALE

NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

008 917 69
L13 0 272.2. 5 COLUMN REAR RIGHT
L14 0 272.2. 1 BREAK BAR RIGHT
L15 0 272.2. 2 BACK DOOR RIGHT
L16 0 272.2. 4 RIGHT SIDE
L17 0 272.1. 4 LEFT SIDE
L22 0 272.1. 6 FRONT LEFT
L23 0 272.1. 7 REAR LEFT
L24 0 272.2. 5 FRONT RIGHT
L25 0 272.2. 6
Electric circuit diagrams

REAR RIGHT
L26 0 272.2. 3 STAIR RIGHT
M1 0 100.1. 5 FUEL FILL
M1-M 0 280. 4 FUEL FILL PUMP
M1-S 0 280. 4 FUEL FILL
M2 0 281. 1 DRUM MOVING
M2-S1 0 281. 2 DRUM
M2-V1 0 281. 3
M2-V2 0 281. 3
M2-V3 0 281. 4
M2-V4 0 281. 4
PK 0 206.7. 1 TRAVELLING
U1-X 0 204.5. 1

BOMAG
U1-X1 0 204.2. 2
U1-X2 0 212. 1
U1-X3 0 204. 2
U1-X4 0 206.6. 4
U1-X5 0 216. 2 RIGHT FRONT STEERING
U1-X7 0 238.7. 1
U1-X8 0 238.7. 5
U2-X 0 204.5. 3
U2-X1 0 206. 1
U2-X2 0 206.4. 1
U2-X3 0 204. 3
U2-X4 0 226.9. 5 DOWN REARS COLUMS
U2-X5 0 238.6. 1 UP CONVEYOR
U2-X6 0 238.6. 3 DOWN CONVEYOR
U2-X7 0 238.6. 5 LEFT CONVEYOR
U2-X8 0 238.6. 7 RIGHT CONVEYOR
U3-X 0 204.5. 5
U3-X1 0 214. 1
U3-X2 0 206.5. 1

1013 1015
25.1

983
Design.: Zuccarino Luca
BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1014
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

984
DISTMACC3.SKO

NOME TESTO FUNZIONALE

25.1

QUANTITA' PAGINA/COLONNA
NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

U3-X3 0 204. 5
U3-X4 0 236.3. 7 LEFT SIDE DOOR OPEN
U3-X5 0 214.4. 2 FLOAT REAR MOULDER
U3-X7 0 214.4. 4 UP LEFT REAR MOULDER
U3-X8 0 214.4. 6 CLOSE RIGHT REAR MOULDER
U4-X 0 204.5. 7
U4-X1 0 214.2. 3
U4-X2 0 214.3. 4
U4-X3 0 204. 7
U4-X4 0 264.7. 5 RIGHT REAR STEERING
U4-X5 0 214.5. 4
U4-X7 0 242.2. 3 WATER PUMP
U4-X8 0 242.2. 5 WATER VALVE
U5-X 0 204.4. 1
U5-X1 0 238. 1
U5-X2 0 236. 2
U5-X3 0 204. 8
U5-X27-2 0 170.1. 6 EMR
U5-X27.1 0 170.4. 1 EMR
U5-XD2.1 0 170. 1

BOMAG
EMR
U6A-R1 0 170.2. 5
U6A-R2 0 204.6. 7
U6A-R3 0 206.7. 3 PICK-UP
U6A-R4 0 290. 5
U6A-R5 0 290. 6
U6A-R6 0 290. 7
U6A-R7 0 290. 7
U6A-R8 0 290. 8
U6A-R9 0 290.3. 4
U6A-X 0 170.2. 5
U6B-R1 0 290.3. 8
U6B-R2 0 290.3. 8
U6B-R3 0 290.3. 7
U6B-R4 0 290.3. 7
U6B-X 0 290.3. 7 PCB
U6C-V1 0 246. 4 ROOF
U6C-V2 0 246. 5 ROOF
U6C-V3 0 246. 5 ROOF
U6C-V4 0 246. 6 ROOF
U6C-V5 0 290.3. 1

008 917 69
Electric circuit diagrams

1014 1016

Design.: Zuccarino Luca

BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1015
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

DISTMACC3.SKO

NOME QUANTITA' PAGINA/COLONNA TESTO FUNZIONALE

NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

008 917 69
U6C-X 0 246. 4
U13-XW1 0 226.8. 5
U13-XW2 0 226.8. 5 RS232
UJ1-F 0 206. 3 FORWARD
UJ1-F 0 206. 7 FORWARD
UJ1-P 0 206.1. 2 POTENTIOMETER
UJ1-P 0 206.1. 7 POTENTIOMETER
UJ1-R 0 206. 1 BACKWARD
UJ1-R 0 206. 6
Electric circuit diagrams

BACKWARD
UJ1-S 0 206.2. 2 PUSH BUTTON
UJ1-S 0 206.2. 6 PUSH BUTTON
UJ1-XJ 0 206. 1 JOYSTICK
UJ2-F 0 264.3. 3 FRONT STEERING
UJ2-F 0 264.3. 8 FRONT STEERING
UJ2-P 0 264.4. 2
UJ2-P 0 264.4. 7
UJ2-R 0 264.3. 2 FRONT STEERING
UJ2-R 0 264.3. 7 FRONT STEERING
UJ2-XJ 0 264.3. 1
W1 0 214.3. 2
W2 0 264.6. 6

BOMAG
W3 0 246. 7
W4 0 201.2. 2
W5 0 201.2. 7
W6 0 201.2. 4
W7 0 201.2. 8
W8 0 201.2. 1
W9 0 201.2. 5
W10 0 238.9. 4
W11 0 238.9. 4
W12 0 238.9. 5
W13 0 266.1. 4
W14 0 266.1. 5
XAC 0 264.6. 6
XAD 0 201.2. 5
XAS 0 201.2. 1
XAXD 0 226.6. 7 COLUMNS
XAXS 0 226.6. 6 COLUMNS
XB 0 281. 1
XC6 0 180. 7

1015 1017
25.1

985
Design.: Zuccarino Luca
BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1016
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

986
DISTMACC3.SKO

NOME TESTO FUNZIONALE

25.1

QUANTITA' PAGINA/COLONNA
NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

XC14 0 264.6. 1
XC16 0 264.6. 3
XC22 0 226.5. 3 WIRE SENSOR
XC24 0 226.5. 1 WIRE SENSOR
XD 0 170.2. 5
XDM 0 281. 1
XMF 0 214.2. 5
XMN 0 272.3. 3
XMT 0 214.2. 3
XNA 0 238.9. 4
XPDA 0 201.2. 7
XPDB 0 201.2. 8
XPSA 0 201.2. 2
XPSB 0 201.2. 4
XPXD 0 226.6. 4 COLUMNS
XPXS 0 226.6. 1 COLUMNS
XRO 0 214.3. 2
XRP 0 214.3. 5
XRR 0 272.4. 5
XS 0 180. 7

BOMAG
XSE 0 246. 7 EMRGENCY SWITCHESBOX
XWA 0 272.2. 5
XWB 0 272.1. 5
XWC 0 272.2. 1
XWD 0 272.2. 2
XWE 0 272.2. 4
XWF 0 272.1. 2
XWG 0 272.1. 4
XWH 0 272.1. 3
XWI 0 272.2. 5
XWL 0 272.2. 6
XWM 0 272.1. 6
XWN 0 272.1. 7
XWO 0 272.2. 3
XYA 0 264.6. 1 STEERING
XYP 0 264.6. 3 STEERING
YA1 0 250. 5 EMERGENCY SERVICES
YA2 0 250. 6 EMERGENCY BRAKES
YA11 0 240. 4 WATER FILL
YA12 0 246. 2 ROOF

008 917 69
Electric circuit diagrams

1016 1018

Design.: Zuccarino Luca

BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1017
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
0 1 2 3 4 5 6 7 8 9

DISTMACC3.SKO

NOME QUANTITA' PAGINA/COLONNA TESTO FUNZIONALE

NAME AMOUNT PAGE/COLUMN FUNCTION TEXT

008 917 69
YA15 0 238.8. 3 CONVEYOR FIX PIST. OUT
YA16 0 238.8. 8 CONVEYOR FIX PIST. IN
YA25-YB25 0 206.7. 6 TRAVELLING
YA27 0 246. 1 ENGINE COVER
YA28 0 238.9. 2 CONVEYOR LOCK
YA29-YB29 0 281. 7 DRUM MOVING
YA30 0 281. 8 DRUM MOVING
YB11 0 240. 5 WATER
YB12 0 246. 3
Electric circuit diagrams

ROOF
YB27 0 246. 1 ENGIME COVER

BOMAG
1017
25.1

987
Design.: Zuccarino Luca
BM/60-2 BILL OF MATERIALS D: DE012009 pag. 1018
date: 29.Apr.2010 DISTINTA BASE

Resp.USER: ING.ZANIBONI
25.1 Electric circuit diagrams

988 BOMAG 008 917 69

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