Bomag Roller BW 216 219 DH-3 BW 219 PDH-3 BW 225 D-3 BW 225 PD-3 Instructions for Repair Manual

Instructions for repair

BW 216 / 219 DH-3 / BW 219 PDH-3 BW 225 D-3 / BW 225 PD-3

Single drum roller

Catalogue number

008 912 46

09/2002

Table of Contents

General

5 1.1 Foreword

6

1.2 Safety regulations

7

1.3 General repair instructions

9

1.4 Tightening torques

11

1.5 Connection overview

12

Tests and adjustments

15 2.1 Technical data

16

2.2 Technical data

19

2.3 Technical data

22

2.4 Technical data

25

2.5 Special tools

28

2.6 Checking the rotation speeds

29

2.7 Checking / adjusting the mechanical neutral position of the travel pump

31

2.8 Pressure tests in the travel circuit

34

2.9 Checking / adjusting the vibrator shaft speeds

36

2.10 Pressure measurements in the vibration circuit

38

2.11 Checking the leakage rate of the vibration motor

39

2.12 Pressure test in steering circuit

40

Flushing

43 3.1 Special tools for flushing

44

3.2 Flushing schematic for drum drive

46

3.3 Flushing schematic for axle drive

48

3.4 Flashing the travel circuit

50

3.5 Flushing schematic for vibration drive

60

3.6 Flushing the vibration circuit

62

Trouble shooting

69 4.1 General

70

4.2 Trouble shooting diagram

71

Drum

95 5.1 Special tools

96

5.2 Repair overview for drum

98

5.3 Removing and installing the drum

100

5.4 Repairing the drum

104

5.5 Dismantling, assembling the change-over weights

136

5.6 Changing the rubber buffers Drum 6.1 Repair overview drum, Vario Oscillating articulated joint

142 145

7.1 Special tools

146

7.2 Repair overview oscillating articulated joint

148

7.3 Removing and installing the oscillating articulated joint

150

7.4 Dismantling the oscillating articulated joint

152

7.5 Assembling the oscillating articulated joint Suppliers documentation

155 159

8.1 Travel pump series 90R 008 912 46

139 141

BOMAG

161 3

Table of Contents

4

8.2 Vibration pump 42R 041

251

8.3 Travel drive series 51

289

8.4 Transmission CR

371

8.5 Brake system, axle

397

BOMAG

008 912 46

1 General

008 912 46

BOMAG

5

1.1

Foreword

Introduction 1.1

For eword

These repair instructions contain all necessary information for training and repair work.

Notes on maintenance, care and trouble shooting can be found in the operating and maintenance instructions.

1

General

2

Tests and adjustments

3

Flushing

4

Trouble shooting

5

Drum

6

Pivot steering

7

Components

This instruction manual contains only assembly groups needed for this type of machine.

The repair instructions describe the removal or dismantling and assembly of components and assembly groups.

The repair of disassembled assembly groups is described as far as this makes sense with respect to available tools and spare parts supply and as far as it can be understood by a skilled mechanic.

Danger Danger of injury !

Please observe strictly the safety regulations in these operating instructions and the applicable accident prevention regulations.

Spare parts needed for repairs can be taken from the spare parts catalogue for the machine.

You should only use genuine BOMAG spare parts.

These repair instructions are 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 notification.

Information and illustrations in this repair 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.

BOMAG GmbH Printed in Germany Copyright by BOMAG

6

BOMAG

008 912 46

1.2

Safety regulations Important notes 1.2

l

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

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

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

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

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

Safety regulations

These safety regulations must be read and applied by every person involved in the repair of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be additionally observed.

Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG. These repair instructions contain headers like „Note“, „Attention“, „Danger“ and „Environment“, which must be strictly complied with in order to avoid dangers for health and for the environment. !

Danger

Special safety regulations

Paragraphs marked like this highlight possible dangers for persons.

Use only genuine BOMAG spare parts for repair purposes. Original parts and accessories have been specially designed for this machine. l

We wish to make explicitly clear that we have not tested or approved any parts or accessories not supplied by us. The installation and/or use of such products may therefore have an adverse effect on the specific characteristics of the machine and thereby impair the active and/or passive driving safety. The manufacturer explicitly excludes any liability for damage caused by the use of non-original parts or accessories. l

Unauthorized changes to the machine are prohibited for safety reasons. l

If tests on the articulated joint need to be performed with the engine running, do not stand in the articulation area of the machine, danger of injury! l

Do not perform cleaning work while the engine is running. l

If tests must be performed with the engine running do not touch rotating parts of the engine, danger of injury. l

Exhaust gases are highly dangerous. Always ensure an adequate supply of fresh air when starting the engine in closed rooms. l

Refuel only with the engine shut down. Ensure strict cleanliness and do not spill any fuel. l

Keep used filters in a separate waste container and dispose of environmentally. l

Dispose of oils and fuel environmentally when performing repair or maintenance work. l

Do not refuel in closed rooms. l

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

Wipe off spilled oil and fuel.

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

l

!

i Note Paragraphs marked like this contain technical information for the optimal economical use of the machine.

Environment Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.

Observe the regulations for the protection of the environment.

General l

Before starting repair work stand the machine on level and solid ground. l

Always secure the machine against unintended rolling. l

Secure the engine reliably against unintentional starting.

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

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

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

l

Keep unauthorized persons away from the machine during repair work.

008 912 46

BOMAG

7

1.2

Safety regulations

l

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

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

Old batteries contain lead and must be properly disposed of. l

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

on machines with rubber tires a tire may busr if incorrectly assembled. This can cause severe injury. l

Do not exceed the specified highest permissible tire pressure.

Hydraulics l

Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. You should therefore relieve the pressure in the system before disconnecting any lines. l

Before applying pressure to the system make sure that all line connections and ports have been properly tightened and are in perfect condition. l

Hydraulic oil leaking out of a small opening can hardly be noticed, therefore please use a piece of cardboard or wood when checking for leaks. When being injured by hydraulic oil consult a physician immediately, as otherwise this may cause severe infections. l

Do not step in front of or behind the drums/wheels when performing adjustment work in the hydraulic system while the engine is running. Block drums and/or wheels with wedges.

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

8

BOMAG

008 912 46

1.3

General repair instructions General 1.3

l

Fill new hydraulic units with hydraulic oil before starting operation. l

After changing a component thoroughly flush and bleed the entire hydraulic system. l

Perform measurements at operating temperature of the hydraulic oil (approx. 40 °C). l

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

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

After the completion of all tests perform a test run and then check all connections and fittings for leaks with the engine still stopped and the hydraulic system depressurized.

Gener al repair instructions

Before removing or disassembling and parts, hoses or components mark these parts for easier assembly. l

Before assembly oil or grease all parts, as far as this is necessary. l

Hydraulic system !

Caution

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

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

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

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

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

Do not run pumps and motors without oil. l

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

Chemical and rubber soluble cleansing agents may only be used to clean metal parts. Do not use such substances to clean seals and gaskets. l

Before commissioning l

After changing a component clean the hydraulic oil tank thoroughly. l

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

Use only hydraulic oils according to the specification in the maintenance instructions. l

After changing a component clean the hydraulic system as described in the flushing instructions in order to prevent all other components from being damaged by abrasion and metal chips remaining in the system.

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

l

Change the hydraulic oil filter.

l

Bleed the hydraulic circuits.

l

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

l

Start up the system without load. l

l

Grease must not used as a sliding agent for assembly work. Use hydraulic oil.

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

l

Do not start the engine after the hydraulic oil has been drained off.

Commissioning

After commissioning Check system pressures and speeds.

l

l

Check fittings and flanges for leaks. l

After each repair check all adjustment data, rotational speeds and nominal values in the hydraulic system, adjust if necessary. l

Do not adjust pressure relief valves and control valves to values above their specified values.

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

l

Clean ports and fittings before removal so that no dirt can enter into the hydraulic system. l

l

Check the hydraulic oil level before and after the work. l

Use only clean oil according to specification. l

Check the hydraulic system for leaks, find and rectify the cause.

008 912 46

Electrical system l

Always disconnect the battery before starting work in the electrical system. l

Ensure correct polarity when connecting the battery.

BOMAG

9

1.3

General repair instructions

l

Do not check voltage by tapping against ground. l

When performing welding work always fasten the earth clamp of the welding unit in the immediate vicinity of the welding location. Strictly disconnect the cables from the generator before starting work.

Seals and gaskets l

Generally use new seals and gaskets when performing assembly work. The required seal kits are available as spare parts.

10

BOMAG

008 912 46

1.4

Tightening torques Tightening torques 1.4

Tightening tor ques

l

Tighten fastening screws and nuts according to the table of tightening torques. l

Tightening torques deviating from the ones in the table are specially mentioned in the repair instructions.

Caution Self-locking nuts must be generally renewed. !

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

Tightening torque Nm* (ft-lb) 8.8 3 (2) 6 (4) 10 (7) 25 (18) 50 (37) 88 (65) 137 (101) 211 (156) 290 (213) 412 (304) 560 (413) 711 (524) 1050 (774) 1420 (1047)

10.9 5 (4) 9 (7) 15 (11) 35 (26) 75 (55) 123 (91) 196 (145) 300 (221) 412 (303) 578 (426) 785 (559) 1000 (738) 1480 (1092) 2010 (1482)

12.9 5 (4) 10 (7) 18 (13) 45 (33) 83 (61) 147 (108) 235 (173) 358 (264) 490 (361) 696 (513) 942 (695) 1200 (885) 1774 (1308) 2400 (1770)

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

Tightening torques Nm * (ft-lb) 8.8 26 (19) 52 (38) 98 (72) 93 (69) 152 (112) 225 (166) 324 (239) 461 (340) 618 (456) 780 (575) 1147 (846) 1568 (1156)

10.9 37 (27) 76 (56) 137 (101) 127 (94) 216 (159) 318 (235) 466 (344) 628 (463) 863 (636) 1098 (808) 1578 (1164) 2254 (1662)

12.9 48 (35) 88 (65) 126 (119) 152 (112) 255 (188) 383 (282) 554 (409) 775 (572) 1058 (780) 1294 (1416) 1920 (1416) 2695 (1988)

Strength classes for screws with untreated, non-lubricated surface.

The values result in a 90% utilization of the screw’s yield point at a coefficient of friction µ total = 0,14.

Compliance with the tightening torques is checked with torque wrenches.

Tightening torques deviating from the ones mentioned in the table are specially mentioned in these descriptions.

The values specified in the table apply for screws black, oiled and with surface protection A4C. The quality designation of the screws is stamped on the screw heads.

008 912 46

BOMAG

11

1.5

Connection overview

Fig. 1 Travel pump

12

BOMAG

008 912 46

1.5

Connection overview 1

Travel pump

2

Multi-function valve 425 bar (boost check and pressure relief valve), travel system

3

Adjustment screw, mechanical neutral position of travel pump

19 Charge pressure relief valve blocked, vibration pump 20 Pressure test port Mb, high pressure vibration system 21 Port L, leak oil to tank port A

4

Port charge oil to vibration pump and connection P to solenoid valve for speed range selector pump

22 Connection L, connection to vibration pump

5

Multi-function valve 425 bar (boost check and pressure relief valve), travel system

24 High pressure port A, to wheel drive motor, right

6

Multi-function valve 425 bar (boost check and pressure relief valve), vibration system

7

Multi-function valve 425 bar (boost check and pressure relief valve), vibration system

8

Port L, leak oil from travel pump

9

Port D, charge pressure to hydraulic oil filter

27 Adjustment screw, frequency

30 Pressure test port Ma, high pressure vibration drive 31 High pressure port B, vibration

12 Adjustment screw, mechanical neutral position of vibration pump 13 Pressure test port Mb, high pressure travel system

16 High pressure port B, to drum drive motor, rear

26 Charge pressure relief valve, 25 bar

29 High pressure port A, vibration

11 Adjustment screw, frequency

15 High pressure port B, to wheel drive motor, left

25 Pressure test port Ma, high pressure travel system

28 Port S, suction line from hydraulic tank, internal charge pump

10 Connection E, charge pressure from travel pump (charge system)

14 Connection, charge oil from hydraulic oil filter

23 High pressure port A, to drum drive motor, front

32 Internal charge pump 33 Connection C, connection from solenoid valve for brake/travel speed range selection 34 Leak oil connection D, leak oil from axle drive motor 35 Leak oil connection A, leak oil from travel pump

17 Port L, leak oil to drum drive motor

36 Leak oil connection G, leak oil from drum drive motor

18 Vibration pump

37 Leak oil connection F, leak oil from vibration motor 38 Leak oil connection B, leak oil to cooler

008 912 46

BOMAG

13

1.5

14

Connection overview

BOMAG

008 912 46

2 Tests and adjustments

008 912 46

BOMAG

15

2.1 2.1

Technical data

Technical data

Fig. 1

Dimensions in mm

A

B

D

H2

H

K

L

O1

O2

S

W

BW 216 DH-3

3123

2300

1500

2970

2268

490

6114

85

85

35

2130

BW 216 PDH-3

3123

2300

1480

2970

2268

490

6114

85

85

25

2130

*

Weights Operating weight (CECE) with ROPS and cabin Front axle load (CECE) Rear axle load (CECE) Static linear load Travel characteristics Travel speed (1) Travel speed (2) Travel speed (3) Max. gradability with vibration Drive Engine manufacturer Type Cooling Number of cylinders Rated power DIN ISO 9249 Rated speed Fuel high idle speed Electrical equipment Drive system Driven axles

16

BW 216 DH-3

BW 216 PDH-3

kg

16150

16650

kg kg kg/cm

10200 5950 47,9

10700 5950 -

km/h km/h km/h %

0 ... 3,5 0 ... 6,3 0 ... 12 55

0 ... 3,5 0 ... 6,3 0 ... 12 55

kW

KHD BF6M 2012 C Water 6 143

KHD BF6M 2012 C Water 6 143

2300 Diesel 2350 ±100 12 hydrostatic 2

2300 Diesel 2350 ±100 12 hydrostatic 2

1 rpm 1 rpm V

BOMAG

008 912 46

2.1

Technical data *

Electrical equipment Voltage supply Generator Voltage/current Battery voltage/capacity Starter voltage/power Travel pump Manufacturer Type System Displacement High pressure limitation Charge pressure limitation Drum drive motor Manufacturer Type System Displacement, max.

Axle drive motor Manufacturer Type System Displacement, max.

Vibration pump Manufacturer Type System Displacement Start up pressure Operating pressure (soil dependent) Vibration motor Manufacturer Type System Displacement max. leak oil rate (without flushing) Steering/charge pump Type System Displacement Steering valve Manufacturer Type Pressure limitation Steering pressure

008 912 46

BW 216 DH-3

BW 216 PDH-3

V/A V/AH V/kW

12 3-phase current 14/55 2 x 12/102 12/3,1

12 3-phase current 14/55 2 x 12/102 12/3,1

cm3/rev. bar bar

Sauer 90R100 Axial piston/swash plate 100 435 29

Sauer 90R100 Axial piston/swash plate 100 435 29

cm3/rev.

Sauer 51C 110 Axial piston – bent axle 110

Sauer 51C 110 Axial piston – bent axle 110

cm3/rev.

Sauer 51D 160 Axial piston – bent axle 160

Sauer 51D 160 Axial piston – bent axle 160

cm3/rev. bar bar

Sauer 42R 41 Axial piston/swash plate 41 410 approx. 120

Sauer 42R 41 Axial piston/swash plate 41 410 approx. 120

cm3/rev. l/min

Sauer MMF044 Axial piston/swash plate 44 approx. 1

Sauer MMF044 Axial piston/swash plate 44 approx. 1

cm3/rev.

Bosch Gear 16

Bosch Gear 16

V

Danfoss Danfoss OSPC 500 ON OSPC 500 ON bar 240 240 bar approx. 175 + charge pres- approx. 175 + charge pressure sure BOMAG

17

2.1

Technical data

*

BW 216 DH-3

BW 216 PDH-3

bar

hydrostatic mechanical min. 15

hydrostatic mechanical min. 15

Steering Type of steering Steering operation Oscillation angle Steering angle

±° ±°

Oscill.-articul. hydrostatic 12 35

Oscill.-articul. hydrostatic 12 35

Vibration system Drive system Frequency Amplitude

Hz mm

hydrostatic 31/36 1,8/0,9

hydrostatic 31/36 1,6/0,9

Brakes Service brake Parking brake Brake releasing pressure

*

18

The right for technical modifications remains reserved

BOMAG

008 912 46

2.2

Technical data 2.2

Technical data

Fig. 1

Dimensions in mm

A

B

D

H2

H

K

L

O1

O2

S

W

BW 219 DH-3

3123

2300

1600

3000

2288

450

6114

85

85

40

2130

BW 219 PDH-3

3123

2300

1600

3000

2288

450

6114

85

85

35

2130

*

Weights Operating weight (CECE) with ROPS and cabin Front axle load (CECE) Rear axle load (CECE) Static linear load Travel characteristics Travel speed (1) Travel speed (2) Travel speed (3) Max. gradability with vibration Drive Engine manufacturer Type Cooling Number of cylinders Rated power DIN ISO 9249 Rated speed Fuel Electrical equipment Drive system Driven axles

008 912 46

BW 219 DH-3

BW 219 PDH-3

kg

19220

19560

kg kg kg/cm

12780 6440 60

13120 6440 -

km/h km/h km/h %

0 ... 3,2 0 ... 5,6 0 ... 12 57

0 ... 3,2 0 ... 5,6 0 ... 12 57

kW

Deutz BF6M 2012 C Water 6 143

Deutz BF6M 2012 C Water 6 143

2200 Diesel 12 hydrostatic 2

2200 Diesel 12 hydrostatic 2

1 rpm V

BOMAG

19

2.2

Technical data

*

Electrical equipment Voltage supply Generator Voltage/current Battery voltage/capacity Starter voltage/power Travel pump Manufacturer Type System Displacement High pressure limitation Charge pressure limitation Drum drive motor Manufacturer Type System Displacement, max.

Axle drive motor Manufacturer Type System Displacement, max.

Vibration pump Manufacturer Type System Displacement Start up pressure Operating pressure (soil dependent) Vibration motor Manufacturer Type System Displacement max. leak oil rate (without flushing) Steering/charge pump Type System Displacement Steering valve Manufacturer Type Pressure limitation Steering pressure

20

BW 219 DH-3

BW 219 PDH-3

V/A V/AH V/kW

12 3-phase current 14/55 2 x 12/102 12/3,1

12 3-phase current 14/55 2 x 12/102 12/3,1

cm3/rev. bar bar

Sauer 90R100 Axial piston/swash plate 100 435 29

Sauer 90R100 Axial piston/swash plate 100 435 29

cm3/rev.

Sauer 51C 110 Axial piston – bent axle 110

Sauer 51C 110 Axial piston – bent axle 110

cm3/rev.

Sauer 51D 160 Axial piston – bent axle 160

Sauer 51D 160 Axial piston – bent axle 160

cm3/rev. bar bar

Sauer 42R 41 Axial piston/swash plate 41 410 approx. 120

Sauer 42R 41 Axial piston/swash plate 41 410 approx. 120

cm3/rev. l/min

Sauer 90M055 Axial piston/swash plate 55 approx. 1

Sauer 90M055 Axial piston/swash plate 55 approx. 1

cm3/rev.

Bosch Gear 16

Bosch Gear 16

V

Danfoss Danfoss OSPC 500 ON OSPC 500 ON bar 240 240 bar approx. 175 + charge pres- approx. 175 + charge pressure sure BOMAG

008 912 46

2.2

Technical data *

BW 219 DH-3

BW 219 PDH-3

bar

hydrostatic mechanical min. 15

hydrostatic mechanical min. 15

Steering Type of steering Steering operation Oscillation angle Steering angle

±° ±°

Oscill.-articul. hydrostatic 12 35

Oscill.-articul. hydrostatic 12 35

Vibration system Drive system Frequency Amplitude

Hz mm

hydrostatic 26/30 2,1/1,2

hydrostatic 26/30 1,9/1,1

Brakes Service brake Parking brake Brake releasing pressure

*

The right for technical modifications remains reserved

008 912 46

BOMAG

21

2.3 2.3

Technical data

Technical data

Fig. 1

Dimensions in mm

A

B

D

H2

H

K

L

O1

O2

S

W

BW 225 D-3

3123

2300

1600

3000

2273

450

6114

85

85

40

2130

BW 225 PD-3

3123

2300

1600

3000

2288

450

6114

85

85

35

2130

*

Weights Operating weight (CECE) with ROPS and cabin Front axle load (CECE) Rear axle load (CECE) Static linear load Travel characteristics Travel speed (1) Travel speed (2) Travel speed (3) Max. gradability with vibration Drive Engine manufacturer Type Cooling Number of cylinders Rated power DIN ISO 9249 Rated speed Fuel Electrical equipment Drive system Driven axles

22

BW 225 DH-3

BW 225 PD-3

kg

25220

24820

kg kg kg/cm

17040 8180 80

16640 8180 -

km/h km/h km/h %

0 ... 3,2 0 ...5,5 0 ... 10 40

0 ... 3,2 0 ... 5,5 0 ... 10 40

kW

KHD BF6M 2012 C Water 6 143

KHD BF6M 2012 C Water 6 143

2200 Diesel 12 hydrostatic 2

2200 Diesel 12 hydrostatic 2

1 rpm V

BOMAG

008 912 46

2.3

Technical data *

Electrical equipment Voltage supply Generator Voltage/current Battery voltage/capacity Starter voltage/power Travel pump Manufacturer Type System Displacement High pressure limitation Charge pressure limitation Drum drive motor Manufacturer Type System Displacement, max.

Axle drive motor Manufacturer Type System Displacement, max.

Vibration pump Manufacturer Type System Displacement Start up pressure Operating pressure (soil dependent) Vibration motor Manufacturer Type System Displacement max. leak oil rate (without flushing) Steering/charge pump Type System Displacement Steering valve Manufacturer Type Pressure limitation Steering pressure

008 912 46

BW 225 DH-3

BW 225 PD-3

V/A V/AH V/kW

12 3-phase current 14/55 2 x 12/102 12/3,1

12 3-phase current 14/55 2 x 12/102 12/3,1

cm3/rev. bar bar

Sauer 90R100 Axial piston/swash plate 100 435 29

Sauer 90R100 Axial piston/swash plate 100 435 29

cm3/rev.

Sauer 51C 110 Axial piston – bent axle 110

Sauer 51C 110 Axial piston – bent axle 110

cm3/rev.

Sauer 51D 160 Axial piston – bent axle 160

Sauer 51D 160 Axial piston – bent axle 160

cm3/rev. bar bar

Sauer 42R 41 Axial piston/swash plate 41 410 approx. 120

Sauer 42R 41 Axial piston/swash plate 41 410 approx. 120

cm3/rev. l/min

Sauer 90M055 Axial piston/swash plate 55 approx. 1

Sauer 90M055 Axial piston/swash plate 55 approx. 1

cm3/rev.

Bosch Gear 16

Bosch Gear 16

V

Danfoss Danfoss OSPC 500 ON OSPC 500 ON bar 240 240 bar approx. 175 + charge pres- approx. 175 + charge pressure sure BOMAG

23

2.3

Technical data

*

BW 225 DH-3

BW 225 PD-3

bar

hydrostatic mechanical min. 15

hydrostatic mechanical min. 15

Steering Type of steering Steering operation Oscillation angle Steering angle

±° ±°

Oscill.-articul. hydrostatic 12 35

Oscill.-articul. hydrostatic 12 35

Vibration system Drive system Frequency Amplitude

Hz mm

hydrostatic 26/26 2,0/1,1

hydrostatic 26/26 2,2/1,25

Brakes Service brake Parking brake Brake releasing pressure

*

24

The right for technical modifications remains reserved

BOMAG

008 912 46

2.4

Technical data 2.4

Technical data

Fig. 1

Dimensions in mm

A

B

D

H2

H

K

L

O1

O2

S

W

BW 225 D-3 Vario

3313

2380

1700

3050

2300

430

6563

125

125

40

2130

*

Weights Operating weight (CECE) with ROPS-cabin Front axle load (CECE) Rear axle load (CECE) Static linear load Travel characteristics Travel speed (1) Travel speed (2) Travel speed (3) Max. gradability with vibration (soil dependent) Engine Engine manufacturer Type Cooling Number of cylinders Rated power DIN ISO 9249 Rated speed Fuel Electrical equipment Drive system Driven axles

008 912 46

BW 225 D-3 Vario

kg

25770

kg kg kg/cm

17590 8180 82,6

km/h km/h km/h %

0 ... 3,2 0 ... 5,5 0 ... 10 40

kW

KHD BF6M 2012 C Water 6 143

1 rpm V

BOMAG

2200 Diesel 12 hydr.

2

25

2.4

Technical data

*

BW 225 D-3 Vario

Electrical equipment Voltage supply Generator Voltage/current Battery voltage/capacity Starter voltage/power

V V/AH V/A V/AH V/kW

12 3-phase current 14/55 2 x 12/102 12/3,1

cm3/rev. bar bar

Sauer 90R 100 Axial piston/swash plate 100 435 29

cm3/rev.

Sauer 51C 110 Axial piston – swash plate 110

cm3/rev.

Sauer 51D 160 Axial piston – bent axle 160

cm3/rev. bar bar

Sauer 42R 41 Axial piston – swash plate 41 410 approx. 120

cm3/rev. l/min

Sauer 90M 055 Axial piston – swash plate 55 approx. 1

cm3/rev.

Bosch Gear 16

Steering valve Manufacturer Type Pressure limitation Steering pressure

bar bar

Danfoss OSPC 500 ON 240 approx. 175 + charge pressure

26

BOMAG

Travel pump Manufacturer Type System Displacement High pressure limitation Charge pressure limitation Drum drive motor Manufacturer Type System Displacement, max.

Axle drive motor Manufacturer Type System Displacement, max.

Vibration pump Manufacturer Type System Displacement Start up pressure Operating pressure (soil dependent) Vibration motor Manufacturer Type System Displacement max. leak oil rate (without flushing) Steering/charge pump Type System Displacement

008 912 46

2.4

Technical data *

BW 225 D-3 Vario

Brakes Service brake Parking brake Brake releasing pressure

bar

hydrostatic mechanical min. 15

Steering Type of steering Steering operation Oscillation angle Steering angle

±° ±°

Oscill.-articul. hydrostatic 12 35

Vibration system Drive system Frequency Amplitude

Hz mm

hydrostatic 26 2,3

*

The right for technical modifications remains reserved

008 912 46

BOMAG

27

2.5

Special tools 2.5 Special tools 1. Vibration Reed frequency meter BOMAG part-no.: 300 120 80

Fig. 1

2. Hydraulic test case BOMAG part-no.: 007 610 03

Fig. 2

3. Gear pump testing valve (200 bar) BOMAG part-no.: 007 610 05

Fig. 3

28

BOMAG

008 912 46

2.6

Checking the rotation speeds 2.6 Checking the rotation speeds Special tools Vibration reed frequency meter

Caution Perform measurements at operating temperature of the hydraulic oil (40 °C). !

1. Drive the machine with both drums on an elastic base (rubber buffers) (Fig. 1).

2. Apply the parking brake and block the wheels additionally with suitable chocks.

3. Start the diesel engine and shift the throttle lever to max. speed position.

Fig. 1

Checking the exciter shaft speed 1. Switch the vibration on .

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

Nominal value BW 216 DH/PDH-3 low frequency 31 Hz (1860 rpm) high frequency 36 Hz (2160 rpm) BW 219 DH/PDH-3 low frequency 26 Hz (1560 rpm) high frequency 30 Hz (1800 rpm) BW 225 D/PD-3 low frequency 26 Hz (1560 rpm) high frequency 26 Hz (1560 rpm)

Fig. 2

Evaluation of test: If the nominal value is not reached, check the engine speed.

If the engine speed is correct, perform trouble shooting in the vibration circuit.

008 912 46

BOMAG

29

2.6

Checking the rotation speeds Checking the engine speed 1. Measure the speed, rest the tester (Fig. 3) on your thumb.

Nominal value low idle speed 750 ... 850 rpm high idle speed approx. 2280 ... 2330 rpm 2. Switch the vibration on.

Nominal value Nominal speed 2300 rpm Evaluation of test: If the nominal value is not reached, perform trouble shooting on the engine or in the hydraulic vibration system.

Fig. 3

30

BOMAG

008 912 46

Checking / adjusting the mechanical neutral position of the

2.7

2.7 Checking / adjusting the mechanical neutral position of the travel pump Special tools Hydraulic test case !

Caution

Perform measurements at operating temperature of the hydraulic oil (40 °C).

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

Fig. 1

2. Pull the plug additionally (Fig. 2) off the brake solenoid valve.

Fig. 2

3. Unhook the travel cable (Fig. 3) from the pump.

Fig. 3

008 912 46

BOMAG

31

2.7

Checking / adjusting the mechanical neutral position of the 4. Connect 600 bar pressure gauges to high pressure test ports MA and MB (Fig. 4).

Fig. 4

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

Fig. 5

6. Start the diesel engine and shift the throttle lever (Fig. 6) to max. speed position.

Fig. 6

Nominal value Both pressure gauges (Fig. 7) must show equal pressure (charge pressure).

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

Fig. 7

32

BOMAG

008 912 46

Checking / adjusting the mechanical neutral position of the

2.7

Evaluation of test If pressure builds up on one side, adjust the mechanical neutral position (Fig. 8), until the pressures on both pressure gauges are identical.

Fig. 8

008 912 46

BOMAG

33

2.8

Pressure tests in the travel circuit 2.8 Pressure tests in the travel circuit Special tools: Hydraulic test case Caution Perform measurements at operating temperature of the hydraulic oil (40 °C). !

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

Fig. 1

2. Additionally pull the plug (Fig. 2) off the brake solenoid valve.

Fig. 2

3. Connect 600 bar pressure gauges to high pressure test ports MA and MB and a 60 bar pressure gauge to the charge pressure test port (Fig. 3).

4. Start the engine and run it at idle speed.

5. Read charge and high pressure gauges.

Nominal value Charge pressure gauge: 24 ... 29 bar High pressure gauge: Both identical pressure (charge pressure).

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

Fig. 3

34

BOMAG

008 912 46

2.8

Pressure tests in the travel circuit

6. Run the engine with maximum speed (Fig. 4).

7. Read charge and high pressure gauges.

Nominal value Charge pressure gauge: 28 ... 30 bar High pressure gauge: Both identical pressure (charge pressure).

Fig. 4

8. Move the travel lever (Fig. 5) quickly forward and backward, read the pressure gauge.

Nominal value Charge pressure: min. 28 bar High pressure: 420 ... 450 bar (to both travel directions).

Evaluation of test If the charge pressure drops below 28 bar during the high pressure test, check the individual components.

If the specified high pressure is not reached, check the travel pump.

Fig. 5

008 912 46

BOMAG

35

2.9

Checking / adjusting the vibrator shaft speeds 2.9 Checking / adjusting the vibrator shaft speeds Special tools Vibration reed frequency meter !

Caution

Perform measurements at operating temperature of the hydraulic oil (40 °C).

1. Drive the machine on an elastic base (e.g. rubber buffers) (Fig. 1).

2. Apply the parking brake and block the wheels additionally with suitable chocks.

3. Start the diesel engine and shift the throttle lever to max. speed position.

Fig. 1

4. Switch on vibration high frequency / low amplitude (Fig. 2) or low frequency / high amplitude.

Fig. 2

5. Measure the speed (Fig. 3), rest the tester on your thumb.

Nominal values: BW 216 DH/PDH-3 low frequency 31 Hz (1860 rpm) high frequency 36 Hz (2160 rpm) BW 219 DH/PDH-3 low frequency 26 Hz (1560 rpm) high frequency 30 Hz (1800 rpm) BW 225 D/PD-3 low frequency 26 Hz (1560 rpm) high frequency 26 Hz (1560 rpm) Fig. 3

!

Caution In case of deviations beyond 10%, determine the cause. Check engine, vibration pump and vibration motor!

36

BOMAG

008 912 46

Checking / adjusting the vibrator shaft speeds

2.9

6. Adjust the speeds on the corresponding adjustment screws (Fig. 4).

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

Fig. 4

008 912 46

BOMAG

37

2.10

Pressure measurements in the vibration circuit 2.10 Pressure measurements in the vibration circuit Special tools Hydraulic test case !

Caution

Perform measurements at operating temperature of the hydraulic oil (40 °C).

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

Fig. 1

2. Connect 600 bar pressure gauges to high pressure test ports MA and MB and a 60 bar pressure gauge to the charge pressure test port (Fig. 2).

3. Start the diesel engine and shift the throttle lever to max. speed position.

Fig. 2

4. Switch on vibration with high or low frequency (Fig. 3).

Nominal value Charge pressure 24 bar Starting pressure 390 ... 430 bar (both frequencies) Operating pressure (soil dependent) approx. 100 ... 150 bar Evaluation of test If the charge pressure drops below 24 bar during the high pressure test, check the individual components.

Fig. 3

If the starting pressure is not reached, check the vibration pump.

If the starting pressure is only reached for one frequency, check the high pressure relief valves.

38

BOMAG

008 912 46

2.11

Checking the leakage rate of the vibration motor

2.11 Checking the leakage rate of the vibration motor !

Caution

Perform measurements at operating temperature of the hydraulic oil (40 °C).

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

Fig. 1

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

Fig. 2

3. Disconnect the leak oil hose (Fig. 3), connect a measuring hose and hold it into a measuring beaker.

4. Start the diesel engine and shift the throttle lever to max. speed position.

5. Switch the vibration on and measure the running out leak oil during one timed minute.

Nominal value max. 1.5 litre/min Evaluation of test If the permissible leak oil rate is exceeded, replace the vibration motor.

Fig. 3

008 912 46

BOMAG

39

2.12

Pressure test in steering circuit 2.12 Pressure test in steering circuit Caution Perform measurements at operating temperature of the hydraulic oil (40 °C). !

1. Connect a 600 bar pressure gauge to the steering pressure test port (Fig. 1).

2. Start the engine and run it at idle speed. !

Danger

Danger of squashing!

Do not stand in the articulation area of the machine.

3. Turn the steering against an end stop.

4. Read the pressure gauge.

Nominal value

Fig. 1

approx. 210 bar Evaluation of test If the nominal value is reached, check the steering cylinder.

5. Disconnect the hydraulic hoses from ports L and R (Fig. 2) on the steering cylinders and close them with plugs.

6. Start the engine and run it at idle speed.

7. Turn the steering wheel.

8. Read the pressure gauge.

Nominal value approx. 210 bar Evaluation of test If the nominal value is reached, replace the steering cylinder.

Fig. 2

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

9. Reconnect the hydraulic hoses to the steering cylinders.

10. Close the pump outlet (Fig. 3) with a 200 bar pressure relief valve 11. Crank the engine with the starter Nominal value approx. 200 bar Evaluation of test If the nominal value is reached, replace the steering valve.

If the nominal value is not reached, replace the steering/charge pump.

Fig. 3

40

BOMAG

008 912 46

2.12

Pressure test in steering circuit

008 912 46

BOMAG

41

2.12

42

Pressure test in steering circuit

BOMAG

008 912 46

3 Flushing

008 912 46

BOMAG

43

3.1

Special tools for flushing 3.1 Special tools for flushing 1. Filling and filtering unit with oil bag BOMAG part-no.: 007 610 01

Fig. 1

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

6. SAE-flange 1“ - 25S BOMAG part-no.: 055 142 60 7. O-ring BOMAG part-no.: 062 203 30

Fig. 3

8. Connecting fitting 25S BOMAG part-no.: 055 459 45

Fig. 4

44

BOMAG

008 912 46

3.1

Special tools for flushing 9. Reducing fitting 25S - 20S BOMAG part-no.: 055 422 98

Fig. 5

10. Flanged plate 1“ - 25S BOMAG part-no.: 007 160 18 11. O-ring BOMAG part-no.: 062 202 22

Fig. 6

12. Elbow 25S BOMAG part-no.: 055 421 38

Fig. 7

008 912 46

BOMAG

45

3.2

Flushing schematic for drum drive

Fig. 1

46

BOMAG

008 912 46

3.2

Flushing schematic for drum drive 1

Flushing hose 20S - 25S

5

Elbow 25S

2

Flushing filter

6

Travel pump

3

Screw socket R1 - 25S

7

Drum drive motor

4

Reducing fitting 25 S - 20S

8

Connecting fitting 25S

After changing a component

Flushing filter installation (Fig. 1)

1. Always flush the closed circuit.

1. Connect the flushing filter outlet "OUT" with the travel pump.

2. Connect the flushing filter inlet „IN“ with the hoses from the travel motor.

Caution Solid particles remaining in the circuit will damage the components again within a short period of time. !

!

Caution

The flushing filter must be installed in the low pressure side in the return flow to the pump, so that only cleaned oil will enter the travel pump.

In case of excessive oil contamination (abrasion) 1. Open and clean all other components.

With the connection shown in the illustration the travel pump must therefore be actuated to forward direction.

2. If necessary replace the hydraulic hoses.

3. Flush also the vibration circuit.

Befor flushing

Flushing of the hoses

1. Change the hydraulic oil filter element.

1. Take the drum drive motor out of the circuit, for this purpose join the high pressure lines together.

2. Clean the inside of the hydraulic oil tank.

3. Filter the hydraulic oil with the filtering unit.

Flushing the complete system

i Note

1. Reconnect the drum drive motor and raise the drum for flushing, so that the drum can rotate freely without load.

For filtering use the filling and filtering unit.

Pump the tank contents through a fine filter into the oil bag or a clean container.

Bleeding Environment Catch hydraulic oil and dispose of environmentally! For filling use also the filtering unit.

1. Always bleed the closed hydraulic circuit if lines had been removed or connected.

Change the oil: in case of excessive contamination, oil discoloration, oil change interval almost reached.

008 912 46

BOMAG

47

3.3

Flushing schematic for axle drive

Fig. 1

48

BOMAG

008 912 46

3.3

Flushing schematic for axle drive 1

Flushing hose 25S - 20S

6

Travel pump

2

Flushing filter

7

Travel motor

3

Screw socket R1 - 25S

8

Connecting fitting 25S

4

Reducing fitting 25S - 20S

9

Flanged plate 1“ - 25S

5

Elbow 25S

After changing a component

Flushing filter installation (Fig. 1)

1. Always flush the closed circuit. !

1. Connect the flushing filter outlet "OUT" with the travel pump.

2. Connect the flushing filter inlet „IN“ with the hoses from the travel motor.

Caution

Solid particles remaining in the circuit will damage the components again within a short period of time.

Caution The flushing filter must be installed in the low pressure side in the return flow to the pump, so that only cleaned oil will enter the travel pump. !

In case of excessive oil contamination (abrasion) 1. Open and clean all other components.

With the connection shown in the illustration the travel pump must therefore be actuated to forward direction.

2. If necessary replace the hydraulic hoses.

3. Flush also the vibration circuit.

Befor flushing

Flushing of the hoses

1. Change the hydraulic oil filter element.

1. Take the axle drive motor out of the circuit, for this purpose join the high pressure lines on the travel motor together.

2. Clean the inside of the hydraulic oil tank.

3. Filter the hydraulic oil with the filtering unit.

Flushing the complete system

i Note

1. Reconnect the travel motor and raise the axle for flushing, so that the wheels can rotate freely without load.

For filtering use the filling and filtering unit.

Pump the tank contents through a fine filter into the oil bag or a clean container.

Danger Danger of accident! !

Environment Catch hydraulic oil and dispose of environmentally! For filling use also the filtering unit.

Change the oil:

Always lift up both wheels, as otherwise the locking differential will engage.

Bleeding

in case of excessive contamination,

1. Always bleed the closed hydraulic circuit if lines had been removed or connected.

oil discoloration, oil change interval almost reached.

008 912 46

BOMAG

49

3.4

Flashing the travel circuit 3.4 Flashing the travel circuit Cleaning the hydraulic oil tank 1. Pump the hydraulic oil from the hydraulic oil tank into a clean container or an oil bag using the filling and filtering unit.

2. Mark all hoses (Fig. 1) and disconnect them from the tank cover.

3. Unscrew the fastening screws for the cover and remove the cover.

Environment Catch hydraulic oil and dispose of environmentally!

4. Clean the hydraulic oil tank thoroughly from inside, reassemble cover and hoses.

Fig. 1

Filter installation for flushing the travel circuit !

Caution Before installing the flushing filter check hoses and connections for cleanliness, clean if necessary.

1. Disconnect the upper high pressure hose (Fig. 2) from the travel pump.

Fig. 2

2. Connect flushing hose 7 (Fig. 3) from the filter outlet to the travel pump using elbow (5) and reducing fitting (6).

3. Connect flushing hose (4) from the filter inlet to the disconnected high pressure hose (1) using reducing fitting (3) and double end union (2).

Fig. 3

50

BOMAG

008 912 46

3.4

Flashing the travel circuit

4. Connect flushing hose 1 (Fig. 4) to travel pump with flushing filter outlet „OUT“.

5. Connect flushing hose (2) joined to the high pressure hose for the drum drive motor to the flushing filter inlet "IN".

Fig. 4

6. Unscrew the high pressure hoses 3 (Fig. 5) from the drum drive motor and join them together with angle fittings (2) and socket (1).

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

8. Keep circulating the tank contents throughout the complete flushing process.

i Note If the hydraulic oil change interval is almost reached use new hydraulic oil.

Fig. 5

Bleeding the travel circuit Environment Catch hydraulic oil and dispose of environmentally.

1. Block drums and wheels with suitable chocks.

2. Install pressure test hoses to the charge pressure test port and to the high pressure test ports.

3. Hold the open ends of the pressure test hoses (Fig. 6) into a container.

4. Crank the engine approx. 30 seconds with the starter motor. Wait one minute and repeat this procedure, until oil starts to run out from the pressure test hoses.

5. Disconnect the pressure test hoses from the high pressure test ports.

Fig. 6

008 912 46

BOMAG

51

3.4

Flashing the travel circuit 6. Connect a 60 bar pressure gauge to the charge pressure test hose (Fig. 7) and run the engine max. 15 seconds at idle speed.

7. Repeat this procedure after a pause of approx. 30 seconds, until the pressure gauge shows a constant pressure of 28 bar.

i Note Perform these measures with the travel lever in neutral position. As soon as charge pressure is present you may start to bleed the system.

Fig. 7

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

8. For bleeding shift the travel lever (Fig. 8) approx.

1/3 in travel direction forward (I) while running the engine with idle speed.

9. After running the engine 1 to 2 minutes with idle speed pause for approx. one minute.

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

Repeat this measure, until the charge pressure reading immediately drops to zero when shutting the engine down.

Fig. 8

In this case the closed travel circuit is properly bled.

10. Remove the pressure test hoses.

52

BOMAG

008 912 46

3.4

Flashing the travel circuit

Flushing the lines to the drum drive motor 1. Run the engine with maximum speed.

2. Perform the flushing process at various engine speeds for approx. 10 minutes.

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

3. Perform the flushing process at various engine speeds for approx. 10 minutes.

4. Shut down the engine.

Flushing the drum drive motor

Fig. 9

1. Reconnect the high pressure hoses to the drum drive motor.

Danger Danger of squashing! !

Do not lay under the jacked up machine.

2. Jack up the front of the machine (Fig. 10), so that the drum can rotate freely.

3. Secure the rear wheels with chocks.

4. Repeat the bleeding process as previously described.

5. Switch to slow travel speed range (turtle). !

Caution

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

Fig. 10

6. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.

7. Run the flushing procedure for approx. 10 minutes. During this process keep changing the pump flow by shifting the travel lever several times between full and halve forward travel.

008 912 46

BOMAG

53

3.4

Flashing the travel circuit Filter installation for flushing the axle drive circuit !

Caution

Before installing the flushing filter check hoses and connections for cleanliness, clean if necessary.

1. Disconnect the bottom high pressure hose (Fig. 11) from the travel pump.

Fig. 11

2. Connect flushing hose 7 (Fig. 12) from the filter outlet to the travel pump using elbow (5) and reducing fitting (6).

3. Connect flushing hose (4) from the filter inlet to the disconnected high pressure hose (1) using reducing fitting (3) and double end union (2).

Fig. 12

4. Connect flushing hose 1 (Fig. 13) to travel pump with flushing filter outlet „OUT“.

5. Connect flushing hose (2) joined to the high pressure hose for the drum drive motor to the flushing filter inlet "IN".

Fig. 13

54

BOMAG

008 912 46

3.4

Flashing the travel circuit

6. Unscrew high pressure hoses 1 (Fig. 14) from the travel motor and join them together with flanged plate (2) and socket (3).

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

8. Keep circulating the tank contents throughout the complete flushing process.

Fig. 14

Bleeding the travel circuit Environment Catch hydraulic oil and dispose of environmentally.

1. Block drums and wheels with suitable chocks.

2. Install pressure test hoses to the charge pressure test port and to the high pressure test ports.

3. Hold the open ends of the pressure test hoses (Fig. 15) into a container.

4. Crank the engine approx. 30 seconds with the starter motor. Wait one minute and repeat this procedure, until oil starts to run out from the pressure test hoses.

5. Disconnect the pressure test hoses from the high pressure test ports.

Fig. 15

6. Connect a 60 bar pressure gauge to the charge pressure test hose (Fig. 16) and run the engine max. 15 seconds at idle speed.

7. Repeat this procedure after a pause of approx. 30 seconds, until the pressure gauge shows a constant pressure of 28 bar.

i Note Perform these measures with the travel lever in neutral position. As soon as charge pressure is present you may start to bleed the system.

Fig. 16

008 912 46

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

BOMAG

55

3.4

Flashing the travel circuit 8. For bleeding shift the travel lever (Fig. 17) approx. 1/3 in travel direction forward (I) while running the engine with idle speed.

9. After running the engine 1 to 2 minutes with idle speed pause for approx. one minute.

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

Repeat this measure, until the charge pressure reading immediately drops to zero when shutting the engine down.

Fig. 17

In this case the closed travel circuit is properly bled.

10. Remove the pressure test hoses.

56

BOMAG

008 912 46

3.4

Flashing the travel circuit

Flushing the lines to the travel motor 1. Run the engine with maximum speed (Fig. 18).

Fig. 18

2. Shift the travel lever (I) (Fig. 19) to travel direction forward.

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

3. Perform the flushing process at various engine speeds for approx. 10 minutes.

4. Shut down the engine.

Fig. 19

008 912 46

BOMAG

57

3.4

Flashing the travel circuit Flushing the axle drive motor 1. Reconnect the high pressure hoses to the drum drive motor.

Danger Danger of squashing! !

Do not lay under the jacked up machine.

2. Jack up the rear of the machine (Fig. 20), so that the wheels can rotate freely.

3. Secure the drum with chocks.

4. Repeat the bleeding process as previously described.

5. Switch to slow travel speed range (turtle).

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

Fig. 20

6. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.

7. Run the flushing procedure for approx. 10 minutes. During this process keep changing the pump flow by shifting the travel lever several times between full and halve forward travel.

Function test 1. Check the hydraulic oil level (Fig. 21) in the tank, fill up if necessary.

2. Check all connections for leaks with the engine running (visual inspection).

3. Perform a test drive, load the travel system in forward and forward, e.g. by driving uphill or starting on a gradient.

4. Check all ports and connections for leak tightness (visual inspection).

Fig. 21

Servicing the flushing filter kit 1. Replace the filter element of the flushing filter when the red control pin of the contamination indicator is pressed out during the filtering process.

58

BOMAG

008 912 46

3.4

Flashing the travel circuit

i Note This is also possible with very cold oil.

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

3. Change the flushing filter element of the filling and filtering unit when the red control pin of the contamination indicator is pressed out.

008 912 46

BOMAG

59

3.5

Flushing schematic for vibration drive

Fig. 1

60

BOMAG

008 912 46

3.5

Flushing schematic for vibration drive 1

Flushing hose 20S - 25S

5

Vibration motor

2

Screw socket R1 - 25S

6

Connecting fitting 25S

3

Flushing filter

7

Elbow 25S

4

Vibration pump

8

Flanged plate 1“ - 25S

After changing a component

Flushing filter installation (Fig. 1)

1. Always flush the closed circuit.

1. Connect the flushing filter outlet "OUT" with the vibration pump.

2. Connect the flushing filter inlet „IN“ with the hoses from the vibration motor.

Caution Solid particles remaining in the circuit will damage the components again within a short period of time. !

!

Caution

The flushing filter must be installed in the low pressure side in the return flow to the pump, so that only cleaned oil will enter the vibration pump.

In case of excessive oil contamination (abrasion) 1. Open and clean all other components.

With the connection shown in the illustration vibration must be switched on with high frequency.

2. If necessary replace the hydraulic hoses.

3. Flush also the travel circuit.

Befor flushing

Flushing of the hoses

1. Change the hydraulic oil filter element.

1. Take the vibration motor out of the circuit, for this purpose join the high pressure lines together.

2. Clean the inside of the hydraulic oil tank.

3. Filter the hydraulic oil with the filtering unit.

Flushing the complete system

i Note For filtering use the filling and filtering unit.

Pump the tank contents through a fine filter into the oil bag or a clean container.

Environment Catch hydraulic oil and dispose of environmentally! For filling use also the filtering unit.

1. Reconnect the vibration motor and pull it out of the coupling for flushing.

Bleeding 1. Always bleed the closed hydraulic circuit if lines had been removed or connected.

Function test 1. Perform a test drive.

Change the oil:

2. Check all ports and connections for leak tightness.

in case of excessive contamination, oil discoloration,

3. Check the exciter shaft speeds.

oil change interval almost reached.

008 912 46

BOMAG

61

3.6

Flushing the vibration circuit 3.6 Flushing the vibration circuit Cleaning the hydraulic oil tank Environment Catch hydraulic oil and dispose of environmentally!

1. Pump the hydraulic oil from the hydraulic oil tank into a clean container or an oil bag using the filling and filtering unit.

2. Mark all hoses (Fig. 1) and disconnect them from the tank cover.

3. Unscrew the fastening screws for the cover and remove the cover.

4. Clean the hydraulic oil tank thoroughly from inside, reassemble cover and hoses.

Fig. 1

Filter installation for flushing the vibration drive Caution Before installing the flushing filter check hoses and connections for cleanliness, clean if necessary. !

1. Disconnect the high pressure hose (Fig. 2) from the top of the vibration pump.

Fig. 2

62

BOMAG

008 912 46

3.6

Flushing the vibration circuit

2. Connect flushing hose 7 (Fig. 3) from the flushing filter outlet to the vibration pump using an SAEflange (6).

3. Connect flushing hose (5) from the filter inlet to the disconnected high pressure hose (1) using reducing fitting (4) and double end union (3) and flanged plate (2).

Fig. 3

4. Connect flushing hose 1 (Fig. 4) joined to the high pressure hose for the vibration motor to the flushing filter inlet "IN".

5. Connect flushing hose (2) from the vibration pump to the flushing filter outlet "OUT".

Fig. 4

6. Unscrew the high pressure hoses from the vibration motor and join them together with elbows 1 (Fig. 5), flanged plates (3) and sockets (2).

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

8. Keep circulating the tank contents throughout the complete flushing process.

i Note If the hydraulic oil change interval is almost reached use new hydraulic oil.

Fig. 5

008 912 46

BOMAG

63

3.6

Flushing the vibration circuit Bleeding the vibration circuit Environment Catch hydraulic oil and dispose of environmentally.

1. Install pressure test hoses (Fig. 6) to the charge pressure test port and to the high pressure test ports.

2. Hold the open ends of the pressure test hoses into a container.

3. Crank the engine approx. 10 seconds with the starter motor. Wait one minute and repeat this procedure, until oil starts to run out from the pressure test hoses.

4. Disconnect the pressure test hoses from the high pressure test ports.

Fig. 6

5. Connect a 60 bar pressure gauge to the charge pressure test hose (Fig. 7) and run the engine max. 15 seconds at idle speed.

6. Repeat this procedure after a pause of approx. 30 seconds, until the pressure gauge shows a constant pressure of 28 bar.

i Note Perform all these measures with the vibration switched off. As soon as charge pressure is present you may start to bleed the system.

Fig. 7

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

7. For bleeding switch on vibration with high frequency (Fig. 8).

8. After running the engine 1 to 2 minutes pause for approx. one minute.

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

Fig. 8

Repeat this measure, until the charge pressure reading immediately drops to zero when shutting the engine down.

In this case the closed travel circuit is properly bled.

9. Remove the pressure test hoses.

64

BOMAG

008 912 46

3.6

Flushing the vibration circuit Flushing hydraulic lines 1. Run the engine with maximum speed .

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

2. Switch on vibration with high frequency (Fig. 9).

3. Run the flushing procedure for approx. 10 minutes. Switch the vibration on and off at intervals of approx. 30 seconds.

4. Shut down the engine.

Fig. 9

Flushing the vibration motor 1. Unscrew the fastening screws for the vibration motor and pull the motor out of the coupling (Fig. 9).

2. Reconnect the high pressure hoses to the vibration motor.

3. Repeat the bleeding process as previously described.

4. Run the engine with maximum speed .

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

Fig. 10

5. Run the flushing procedure for approx. 10 minutes. Switch the vibration on and off at intervals of approx. 30 seconds.

6. Shut down the engine.

7. Remove the flushing filter and reinstall the vibration motor.

8. Repeat the bleeding process.

9. After completing the bleeding process circulate the tank contents with the filtering unit for another 15 minutes.

10. Remove the filtering unit and screw on the tank cap.

008 912 46

BOMAG

65

3.6

Flushing the vibration circuit Function test 1. Check the hydraulic oil level (Fig. 21) in the tank, fill up if necessary.

2. Perform a test drive.

3. Check all ports and connections for leak tightness (visual inspection).

Fig. 11

Servicing the flushing filter kit 1. Replace the filter element of the flushing filter when the red control pin of the contamination indicator is pressed out during the filtering process.

i Note This is also possible with very cold oil.

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

3. Change the flushing filter element of the filling and filtering unit when the red control pin of the contamination indicator is pressed out.

66

BOMAG

008 912 46

3.6

Flushing the vibration circuit

008 912 46

BOMAG

67

3.6

68

Flushing the vibration circuit

BOMAG

008 912 46

4 Trouble shooting

008 912 46

BOMAG

69

4.1

General

General notes on trouble shooting in hydraulic systems l

Check the hydraulic oil level before and after the work.

The following tests are performed for fault diagnostics and should enable you to encircle a fault in the hydraulic system.

l

Use only clean oil according to specification. l

Check the hydraulic system for leaks, find and rectify the cause. l

Ensure strict cleanliness, clean ports and fittings before disconnecting. l

Fill new hydraulic units with hydraulic oil before starting operation. l

After changing a component thoroughly flush and bleed the hydraulic system. l

AS far as possible conduct all measurements at operating temperature 40 ... 50 °C. l

After changing a component check charge and high pressure, if necessary check the rotational speed.

4.1

General

At this point it is assumed that there is no fault in the electric system, i.e. trouble shooting in the electric system has already been performed.

In some cases these tests may also be conducted to identify faults on hydraulic components of the power transmission system.

On the basis of preliminary tests the individual measurements have the purpose to limit the cause of the fault first of all to a general area and then to determine exactly which oil circuit or hydraulic component is not working correctly.

Important points for trouble shooting and fault rectification

Hydraulic hoses Danger Danger of injury !

Danger Danger of injury! !

Hydraulic hoses must be visually inspected at regular intervals.

Do not touch rotating parts of the engine.

Hydraulic hoses must be immediately replaced if:

When working on the travel pump and performing tests in the travel circuit block the drums with suitable wheel chocks.

the outer layer is damaged down to the inlay (e.g. chafing, cuts, cracks, etc.) l

the outer layer is brittle (formation of cracks in the hose material) l

the hose shows deformations in pressurized and depressurized condition, which do not comply with the genuine shape of the hydraulic hose l

the hose shows deformations in bends, e.g. squeezing, buckling, layer separation, formation of blisters l

the hose is leaking l

the hydraulic hose has separated from the fitting l

the fitting shows corrosion that impairs both function and strength l

the fitting is deformed in a way that both function and strength are affected l

the storage time and utilization period has expired.

Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. You should therefore relieve the pressure in the system before disconnecting any lines. Before repressurizing the system make sure that all line connections and ports are in perfect condition.

l

When being injured by hydraulic oil consult a physician immediately, as otherwise this may cause severe infections.

Caution It is not recommended to open or repair hydraulic units and components without comprehensive knowledge. !

Risk of damage to pressure gauges if incorrectly connected.

When performing trouble shooting it is assumed that the machine is correctly equipped and connected, that connections and hoses are free of faults and that setscrews have not been deadjusted without permission.

Progressive tests drawn up in the trouble shooting diagram lead to the detection of faults and their rectification by trained personnel. l

Ensure strict cleanliness, clean ports and fittings before disconnecting. l

Cover all openings and ports or close with plugs.

70

BOMAG

008 912 46

4.2

Trouble shooting diagram

4.2

Trouble shooting diagram The machine drives with the travel lever in „NEUTRAL“

Check the neutral position - Set the travel lever to „Neutral“ - Detach the travel cable from the pump - check, whether bores of ball socket and control lever are in line.

Adjust the travel control cable

Bores are in line?

no

yes

Check the mechanical 0-position - Connect the control chambers with a hose

Neutral position OK?

no

yes

008 912 46

BOMAG

71

4.2

Trouble shooting diagram

Adjust the mechanical 0-position - Install 600 bar pressure gauges to the high pressure test ports

- Adjust the mechanical 0-position so that both sides have identical pressure (charge pressure)

- Pull the plug off the brake solenoid valve and block the drum

- Repeat the test with 60 bar pressure gauges

- Run the diesel engine with max. speed - Read the pressure gauges

Check the servo control - Remove the servo control - Check moveability and wear of pistons and linkages

Servo control OK?

no

Replace the servo control

yes

Replace the travel pump

72

BOMAG

008 912 46

4.2

Trouble shooting diagram

The machine does not drive (to both travel directions) Check high and charge pressure - Install 600 bar pressure gauges to the high pressure test ports - Install 60 bar pressure gauges to the charge pressure test ports - Pull the plug off the brake solenoid valve - Start the engine and run it with max. speed - Drive the machine against the closed brake, actuate the travel lever for a moment and read the pressure gauges Nominal value: High pressure approx. 425 bar Charge pressure approx. 25 bar

High pressure OK?

yes

no

Check the magnetic coil of the brake valve - Start the engine and release the brake (disengage the travel lever) - Check voltage and current consumption of the coil with a measuring instrument Nominal value: 14V / approx 5A Magnetic coil OK?

no

Perform trouble shooting in the electric system

Check the travel control cable - Check whether the pump control lever is actuated when operating the travel lever.

Control cable OK?

no

yes

Replace the travel control cable

yes

008 912 46

BOMAG

73

4.2

Trouble shooting diagram

Check the brake releasing pressure - Install a 60 bar pressure gauge to the rake releasing hose and check whether the brake valve opens.

Nominal value: approx. 25 bar (charge pressure)

Brake valve OK?

no

Replace the solenoid valve

yes

Mechanical fault on axle, drum

Charge pressure OK?

no

yes

74

BOMAG

008 912 46

4.2

Trouble shooting diagram

Check the steering/ charge pump - Install a 600 bar pressure gauge to the steering pressure test port - Pull the plug off the starting solenoid and crank the engine with the starter - Turn the steering against the end stop and read the pressure gauge Nominal value: approx. 200 bar (battery fully charged)

Steering pressure OK?

no

Perform trouble shooting in the steering system

yes

Check the leakage of the brake - Unload the brake and repeat the charge pressure test

Charge pressure OK? yes

008 912 46

BOMAG

no

- Loosen the brake releasing lines to the drum motor and the axle motor one after the other, close them with plugs and repeat the charge pressure test.

- Repair the unit after the separation of which the charge pressure is OK.

75

4.2

Trouble shooting diagram

Check the charge pressure relief valve

Valve OK?

no

Replace the charge pressure relief valve

yes Check the flushing valve for the axle drive motor

Flushing valve OK?

no

Replace the flushing valve

yes

76

BOMAG

008 912 46

4.2

Trouble shooting diagram

Check the individual components Check the drum drive motor - Close the high pressure ports on the drum drive motor with plugs and repeat the pressure test

Pressures OK?

yes

Replace, repair the drum drive motor

no

Check axle drive motor / travel pump - Close the high pressure ports on the travel pump with plugs and repeat the pressure test

Pressures OK?

yes

Replace, repair the axle drive motor

no

008 912 46

BOMAG

77

4.2

Trouble shooting diagram

Check the servo control Remove the servo control - Check the nozzles, clean if necessary - Check the linkage, repair if necessary

Servo control OK?

no

Replace the servo control

yes

Replace, repair the travel pump

78

BOMAG

008 912 46

4.2

Trouble shooting diagram

Insufficient travel power, max. speed not reached

Check the engine speed Nominal value: 2200 rpm (nominal speed)

no

Speed OK?

Perform trouble shooting on the engine

yes

Check the travel control cable - Detach the travel cable - Check bores and pin for excessive play and wear

Control cable OK?

no

Replace the travel control cable

yes

008 912 46

BOMAG

79

4.2

Trouble shooting diagram

- Actuate the travel lever to forward and reverse - check, whether the control lever reaches the max. positions

max. positions reached?

Adjust/replace travel lever or control cable

no

yes

Check the charge pressure - Install a charge pressure gauge (60 bar) - Start the engine and run it with idle speed - Read the pressure gauge Nominal value: min. 24 bar

Charge pressure OK?

no

yes

80

BOMAG

008 912 46

4.2

Trouble shooting diagram

Check the steering/ charge pump - Install a 600 bar pressure gauge to the steering pressure test port - Pull the plug off the starting solenoid and crank the engine with the starter - Turn the steering against the end stop and read the pressure gauge Nominal value: approx. 200 bar (battery fully charged)

Steering pressure OK?

no

Perform trouble shooting in the steering system

yes

Check the leakage of the brake - Release the brake, to do so disengage the travel lever from brake position and repeat the charge pressure test.

Charge pressure OK? yes

008 912 46

BOMAG

no

- Loosen the brake releasing lines to the drum motor and the axle motor one after the other, close them with plugs and repeat the charge pressure test.

- Repair the unit after the separation of which the charge pressure is OK.

81

4.2

Trouble shooting diagram

Check the charge pressure relief valve

Valve OK?

no

Replace the charge pressure relief valve

yes Check the flushing valve for the axle drive motor

Flushing valve OK?

no

Replace the flushing valve

yes

82

BOMAG

008 912 46

4.2

Trouble shooting diagram

Check the individual components Check the drum drive motor - Close the high pressure ports on the drum drive motor with plugs and repeat the pressure test

Pressures OK?

yes

Replace, repair the drum drive motor

no

Check axle drive motor / travel pump - Close the high pressure ports on the travel pump with plugs and repeat the pressure test

Pressures OK?

yes

Replace, repair the axle drive motor

no

008 912 46

BOMAG

83

4.2

Trouble shooting diagram

Check the servo control - Remove the servo control - Check the nozzles, clean if necessary - Check the linkage, repair if necessary

Servo control OK?

no

Replace the servo control

yes

Replace, repair the travel pump

84

BOMAG

008 912 46

4.2

Trouble shooting diagram

Hydraulic oil overheating, >90 °C

Check the thermostat valve - Check, whether the hose to the cooler warms up at a hydraulic oil temperatrure of >60 °C

Thermostat opens

no

Replace the thermostat valve

yes

Check the multi-function valves - Pull the plug off the brake solenoid valve - Actuate the travel control lever to both travel directions and check the multi-function valves for overheating

- Check the hoses for kinks Valves overheating?

no

- Check the components for excessive heat

yes

Clean, replace the respective multi-function valve

008 912 46

BOMAG

85

4.2

Trouble shooting diagram

No vibration (travel system OK)

Check the magnetic coil of the vibration valve - Switch the ignition on - Switch the vibration on at high or low frequency - Check voltage and current consumption with a measuring instrument Nominal value: 12 V / 2,5 A

Voltage / curent OK?

no

Perform trouble shooting in the electric system

yes

Check the pilot pressure - Stand the drum on rubber tires - Unscrew the plugs from the control chambers and install pressure test ports - Install 60 bar pressure gauges - Run the diesel engine with max. speed - Switch the vibration on and read the pressure gauge Nominal value: approx. 20 bar

Pilot pressure OK?

no

Check the solenoid valve, replace if necessary

yes

86

BOMAG

008 912 46

4.2

Trouble shooting diagram

Check the vibration pump - Close the high pressure ports on the vibration pump with plugs - Install 600 bar pressure gauges to the high pressure test ports - Run the diesel engine with max. speed - Switch the vibration on and read the pressure gauge Nominal value: approx. 370 bar

High pressure OK?

Replace / repair the vibration pump

yes

no

Check the vibrator shaft bearings - Remove the vibration motor - Check the axial play and the moveability of the shaft - Check the condition of the coupling

Bearings and coupling OK?

no

Replace bearing or coupling

yes

Replace / repair the vibration motor

008 912 46

BOMAG

87

4.2

Trouble shooting diagram

Vibrator shaft speed too low

Check the engine speed Nominal value: 2200 rpm (nominal speed)

Engine speed OK?

no

Perform trouble shooting on the engine - Adjust the speeds for high or low frequency

yes

Drop in vibrator shaft speed > 10%

no

yes

Check the vibration pump - Install 600 bar pressure gauges to the high pressure test ports - Install 60 bar pressure gauges to the charge pressure test ports - Stand the drum on rubber tires - Run the diesel engine with max. speed - Switch the vibration on and read the pressure gauge Nominal value: Starting pressure 350 bar Operating pressure approx. 100 ... 150 bar Charge pressure min. 24 bar Charge pressure OK?

no

yes

88

BOMAG

008 912 46

4.2

Trouble shooting diagram

Check flushing valve and flushing spool

Flushing valve OK?

no

yes Replace the flushing valve

Check the steering/ charge pump - Install a 600 bar pressure gauge to the steering pressure test port - Pull the plug off the starting solenoid and crank the engine with the starter - Turn the steering against the end stop and read the pressure gauge Nominal value: approx. 200 bar (battery fully charged)

Steering pressure OK?

no

Perform trouble shooting in the steering system

yes

008 912 46

BOMAG

89

4.2

Trouble shooting diagram

Check the charge pressure relief valve

Valve OK?

no

Replace the charge pressure relief valve

yes Operating pressure OK?

yes

no

Starting pressure OK?

yes

no Check the leak oil rate of the vibration motor - Block the flushing valves with washers - Unscrew the leak oil hose and fit a testing hose - Switch the vibration on and measure the leakage rate Nominal value: max. 3 l/min at approx. 100 bar

Leak oil OK?

no

Replace / repair the vibration motor

yes

90

BOMAG

008 912 46

4.2

Trouble shooting diagram

Check the individual components - Close the high pressure ports on the vibration pump with plugs and repeat the pressure test

High pressure OK?

Replace / repair the vibration motor

yes

no

Check the vibrator shaft bearings - Remove the vibration motor - Check the axial play and the moveability of the shaft Check the multi-function valves

Valves OK?

no

yes Replace the multifunction valves

008 912 46

BOMAG

91

4.2

Trouble shooting diagram

Check the way-valve - Disassemble the way-valve - Check the nozzle (1), clean if necessary - Check the linkage

Way-valve OK?

Replace, repair the way-valve

yes

no

Replace, repair the way-valve

92

BOMAG

008 912 46

4.2

Trouble shooting diagram

No steering function / steering sticky / end stops not reached - Note: The steering pump serves also as charge pump Check the steering pressure - Install a 600 bar pressure gauge to the steering pressure test port - Pull the plug off the starting solenoid and crank the engine with the starter - Turn the steering against the end stop and read the pressure gauge Nominal value: approx. 200 bar (battery fully charged)

Steering pressure OK?

yes

Check moveability of articulated joint and steering cylinders

no

Check the steering cylinders - Close the hydraulic hoses at the steering cylinder ports „R“ and „L“ with plugs - Repeat the pressure test

Steering pressure OK?

yes

Replace the steering cylinders

no

008 912 46

BOMAG

93

4.2

Trouble shooting diagram

Check the steering/charge pump - Close the pump outlet port with a 200 bar pressure relief valve - Install a 600 bar pressure gauge - Crank the engine with the starter - Read the pressure gauge Nominal value: approx. 200 bar

Steering pressure OK?

yes

Replace, repair the steering valve

no

Replace, repair the steering/ charge pump

94

BOMAG

008 912 46

5 Drum

008 912 46

BOMAG

95

5.1

Special tools 5.1 Special tools 1. Disassembly device for side plate BOMAG part-no.: 007 211 55

Fig. 1

2. Assembly device for side plate BOMAG part-no.: 971 079 21

Fig. 2

3. Assembly device for coupling hub in flanged hub

Fig. 3

4. Pressing plate for cylinder roller bearing

Fig. 4

96

BOMAG

008 912 46

5.1

Special tools 5. Pressing plate for travel bearing

Fig. 5

6. Pressing bushing for radial seal

Fig. 6

7. Lifting device for exciter unit BOMAG part-no.: 007 215 08

Fig. 7

008 912 46

BOMAG

97

5.2

Repair overview for drum

Fig. 1

98

BOMAG

008 912 46

5.2

Repair overview for drum 1

Rubber buffer

12 Rectangular rubber buffer

2

Vibration bearings

13 Side plate

3

Housing cover, basic weight

14 Travel bearings

4

Flange

15 Oil level inspection plug

5

Flanged housing

16 Oil drain plug

6

Coupling hub

17 Basic weight

7

Mechanical seal

18 Change-over weight

8

Flanged hub

19 Radial seal

9

Vibration motor

20 Vibrator shaft

10 Compensation plates

21 Fan

11 Spacer block

22 Drum shell

008 912 46

BOMAG

99

5.3

Removing and installing the drum 5.3 Removing and installing the drum Removing the drum Environment Environmental damage Catch running out hydraulic oil and dispose of environmentally.

1. Mark the hydraulic hoses (Fig. 1) on the drum drive motor and disconnect them from the ports.

2. Close all hydraulic hoses and motor ports with suitable plugs.

Fig. 1

3. Mark the hydraulic hoses (Fig. 2) on the vibration motor and disconnect them from the ports.

4. Close all hydraulic hoses and motor ports with suitable plugs.

Fig. 2

5. Unscrew fastening screws 1 (Fig. 3) from holding plate (2) for the hydraulic hoses from both sides.

Fig. 3

100

BOMAG

008 912 46

5.3

Removing and installing the drum

6. Jack up and safely support the front frame (Fig. 4), so that all rubber buffers and rubber elements are unloaded.

Fig. 4

7. Unscrew the fastening screws from the distance block on vibration motor side (Fig. 5) and travel motor side. ! Danger Danger of squashing! Do not stand or step under loads being loaded.

Fig. 5

8. Fasten the lifting gear to the drum (Fig. 6) and lift it out.

i Note If suitable lifting gear is not available remove the front cross-member and roll out the drum.

Fig. 6

9. Check rubber buffers (Fig. 7), replace if necessary.

Fig. 7

008 912 46

BOMAG

101

5.3

Removing and installing the drum 10. Check rectangular rubber buffers (Fig. 8), replace if necessary.

Fig. 8

Installing the drum 1. Install a pressure test port to the brake connection on the drum drive motor (Fig. 9) and pressurize the brake with approx. 20 bar.

Fig. 9

2. Place the drum into the frame and align it parallel to the frame.

i Note Assemble the drum drive side first.

3. Fasten the spacer pieces with screws (Fig. 10) and nuts to the side plate.

Fig. 10

4. On the vibration drive side measure the distance „X“ between spacer piece and side plate (Fig. 11).

5. Calculate the thickness of the compensation plates.

Nominal value: Distance „X“ + 2 mm

i Note Compensation plates of 2 and 5 mm thickness are available.

Fig. 11

102

BOMAG

008 912 46

5.3

Removing and installing the drum

6. Turn in screws into each welded nut (Fig. 12) and provide sufficient space to insert the compensation plates.

Fig. 12

7. Insert the compensation plates 1 (Fig. 13).

8. Assemble fastening screws (2) with tensioning washers and nuts (3).

9. Unscrew the screws from the welded nuts.

10. Tighten the fastening screws.

Fig. 13

11.

Fasten holding plate 2 (Fig. 14) for hydraulic hoses with screws (1).

12. Connect hydraulic hoses to the connections on travel motor and vibration motor according to the marking.

Caution After connecting the hydraulic components and before starting operation bleed the hydraulic system, check the function and inspect the system for leaks. !

Fig. 14

008 912 46

BOMAG

103

5.4

Repairing the drum 5.4 Repairing the drum Disassemble the travel drive Danger Danger of squashing! !

Do not stand or step under suspended loads.

1. Attach the lifting tackle to travel drive 3 (Fig. 1).

2. Unscrew all nuts (1) from the rubber buffers.

3. Take drive disc (2) with travel drive off the rubber buffers and lay it down.

Fig. 1

4. Unscrew fastening screws 3 (Fig. 2) and take off support legs (4).

5. Unscrew fastening screws 1 and take off drive disc (2).

Fig. 2

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

2. Unscrew the fastening screws for the connection exciter unit – drum (1) out of the flange.

3. Unscrew two fastening screws (2) opposite each other out of the flanged housing.

Fig. 3

104

BOMAG

008 912 46

5.4

Repairing the drum

4. Mount bracket (Fig. 6) for the lifting device to the flange.

Fig. 4

5. Slide the lifting device over the bracket.

6. Force the exciter unit out of the drum using two forcing screws (Fig. 5).

Fig. 5 !

Danger

Danger of squashing!

Do not stand or step under suspended loads.

7. Pull the exciter unit out of the drum (Fig. 6).

8. Take the coupling element off the coupling half.

Fig. 6

008 912 46

BOMAG

105

5.4

Repairing the drum Dismantling the exciter unit (travel drive side) 1. Unscrew fastening screws 1 (Fig. 7) for the fan.

2. Loosen clamping screws (2) for the coupling hub.

3. Pull the coupling hub off the shaft.

Fig. 7

4. Unscrew all other fastening screws 1 (Fig. 8) from the flange.

5. Press the flange off the flanged housing with forcing screws (2).

Fig. 8

Environment Environmental damage!

Catch running out oil and dispose of environmentally.

6. Lift the flange off the flanged housing (Fig. 9).

7. Take the O-ring out of the groove in the flanged housing.

Fig. 9

106

BOMAG

008 912 46

5.4

Repairing the drum

8. Unclip the circlip from the groove in the flange (Fig. 10).

Fig. 10

9. Press the vibration bearing out of the flange (Fig. 11) with forcing screws.

Fig. 11

10. Take the exciter unit (Fig. 14) out of the flanged housing.

Fig. 12

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

Fig. 13

008 912 46

BOMAG

107

5.4

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

Fig. 14

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

Fig. 15

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

Danger

Danger of burning!

Wear safety gloves.

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

Fig. 16

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

Fig. 17

108

BOMAG

008 912 46

5.4

Repairing the drum

16. To change shaft 1 (Fig. 18) knock out dowl pin (2) and press the shaft out of the basic weight.

i Note If necessary disassemble, assemble the changeover weight (see corresponding chapter).

Fig. 18

Disassembling the exciter unit (vibration motor side) 1. Unscrew fastening screw 1 (Fig. 19).

2. Take rectangular rubber buffer (2) with spacer block (3) off the side plate.

i Note Remove both rectangular rubber buffers.

Fig. 19

3. Unscrew fastening screws 1 (Fig. 20).

4. Force the cover with the attached vibration motor (2) off the side plate with forcing screws.

Fig. 20

008 912 46

BOMAG

109

5.4

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

Fig. 21

6. Unscrew fastening screws 1 (Fig. 22) and take the vibration motor off the cover.

Fig. 22

7. Remove the coupling element (Fig. 23) for the vibration drive.

Fig. 23

8. Fasten the lifting device.

9. Unscrew fastening screws 1 (Fig. 24).

Caution The four short fastening screws (2) must remain screwed in (the two others are not visible). !

Fig. 24

110

BOMAG

008 912 46

5.4

Repairing the drum

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

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

Fig. 25

Caution Danger of squashing! !

Do not stand or step under suspended loads.

11. Pull the exciter unit out of the drum (Fig. 26).

Fig. 26

Removing, dismantling the side plate 1. Take off V-ring 1 (Fig. 27).

2. Unclip circlip (2).

Fig. 27

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

Fig. 28

008 912 46

BOMAG

111

5.4

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

Fig. 29

5. Knock the travel bearing out of the side plate (Fig. 30) and take out the spacer ring.

Fig. 30

6. Unclip the circlip from the side plate (Fig. 31).

7. Knock the travel bearing out of the side plate.

Fig. 31

8. Take the mechanical seal off the flanged hub (Fig. 32).

Fig. 32

112

BOMAG

008 912 46

5.4

Repairing the drum

Dismantling the exciter unit (vibration motor side) 1. Unscrew the fastening from the coupling hub.

2. Pull coupling hub (2) off the shaft using a pulling device (Fig. 33).

Fig. 33

3. Loosen hose clamp 1 (Fig. 34).

4. Pull coupling hub (2) off the shaft.

Fig. 34

5. Unscrew all other fastening screws (Fig. 35) and press the flanged hub off the flanged housing with forcing screws.

6. Take off the flanged hub.

7. Take the O-ring out of the groove in the flanged housing.

Fig. 35

008 912 46

BOMAG

113

5.4

Repairing the drum 8. Unclip the circlip from the groove in the flanged hub (Fig. 36).

Fig. 36

9. Knock the cylinder roller bearing out of the flanged hub (Fig. 37).

Fig. 37

Environment Environmental damage!

Catch running out oil and dispose of environmentally.

10. Lift the exciter unit out of the flanged housing (Fig. 38).

Fig. 38

11. Knock the radial seal (Fig. 39) out of the flanged housing.

Fig. 39

114

BOMAG

008 912 46

5.4

Repairing the drum

12. Unclip the circlip from the groove in the flanged housing (Fig. 40).

Fig. 40

13. Press the vibration bearing out of the flanged housing (Fig. 41) with forcing screws.

Fig. 41

14. Extract inner rings 1 (Fig. 42) for the radial seals and inner bearing races (2) from the shaft. !

Danger

Danger of burning!

Wear protective gloves.

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

Fig. 42

15. Unclip the circlip from the basic weight and remove the cover (Fig. 43).

i Note The shafts cannot be pressed out. If damaged they must be replaced with basic weight and cover.

If necessary disassemble, assemble the changeover weight (see corresponding chapter).

Fig. 43

008 912 46

BOMAG

115

5.4

Repairing the drum Assembling the exciter unit (vibration motor side)

i Note If the shafts are damaged they must be inserted into the basic weight or the cover as follows.

Danger When working with liquid nitrogen protect your face and wear gloves. !

Do not place any unintended parts into liquid nitrogen.

Observe the safety instructions for the handling of liquid nitrogen.

Fig. 44

Caution Close the bores on the short shaft with a screw. !

1. Cool the shaft down in liquid nitrogen.

2. Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig. 44).

3. Secure shaft 1 (Fig. 45) with dowel pin (2).

i Note Unscrew the screw from the shaft.

Fig. 45

Caution Close the bores on the short shaft with a screw. !

4. Cool the shaft down in liquid nitrogen.

5. Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig. 46).

Fig. 46

116

BOMAG

008 912 46

5.4

Repairing the drum

6. Secure shaft 2 (Fig. 47) with dowel pin (1).

i Note Unscrew the screw from the shaft.

Fig. 47

7. Insert the fitting key into the keyway in the respective shaft (Fig. 48).

Fig. 48

8.

Insert the circlip into the groove in the basic weight and on the cover (Fig. 49).

Fig. 49 !

Danger

Danger of burning!

Wear safety gloves.

9. Heat the inner bearing race up to approx. 100° C and press it onto the basic weight against the shoulder with the larger outer diameter forward (Fig. 50).

Fig. 50

008 912 46

BOMAG

117

5.4

Repairing the drum 10. Apply Loctite 603 to the recess in the shaft or the shoulder of the inner ring (Fig. 51). !

Danger

Danger of burning!

Wear safety gloves.

11. Heat the inner ring up to approx. 50° C and slide it onto the short shaft against the shoulder with the wider chamfer facing towards the outside.

Danger Danger of burning! !

Fig. 51

Wear safety gloves.

12. Heat the inner bearing race up to approx. 100 °C and press it onto the cover against the shoulder with the larger outer diameter forward (Fig. 52).

Fig. 52

13. Apply Loctite 603 to the recess in the shaft or the shoulder of the inner ring (Fig. 53). !

Danger

Danger of burning!

Wear protective gloves!

14. Heat the inner ring up to approx. 50 °C and slide it onto the longer shaft against the shoulder with the wider chamfer facing towards the outside.

Fig. 53

15. Press vibration bearing 1 (Fig. 54) with pressing plate (2) into the flanged housing until it bottoms.

Fig. 54

118

BOMAG

008 912 46

5.4

Repairing the drum

16. Insert the circlip into the groove in the flanged housing (Fig. 55).

Fig. 55

17. Fit the new radial seal with some grease into the groove in the flanged housing (Fig. 56).

18. Fill engine oil SAE-15W/40 into the flanged housing. approx. 1.8 l BW 219/225 D/DH/PD-3 approx. 1.0 l BW 216 DH/PDH-3

Fig. 56

Caution Danger of squashing! !

Do not stand or work under suspended loads!

19. Insert the exciter unit with the longer shaft forward into the flanged housing (Fig. 57).

Fig. 57

20. Press vibration bearing 1 (Fig. 58) with pressing plate (2) into the flanged hub until it bottoms.

Fig. 58

008 912 46

BOMAG

119

5.4

Repairing the drum 21. Insert the circlip into the groove in the flanged hub (Fig. 59).

Fig. 59

22. Attach the flanged hub to the flanged housing (Fig. 60).

23. Unscrew eye bolts (1) and replace them with short screws.

24. Turn short screws (2) into the tapped bores in the flanged housing (four screws) and tighten them.

Fig. 60

25. Apply some grease to the sealing lip of radial seal 1 (Fig. 61).

26. Insert the radial seal into the flanged hub with the sealing lip facing down and press it down against the stop with pressing bushing (2).

Fig. 61 !

Danger

Danger of burning!

Wear protective gloves.

27. Heat the coupling hub up to approx. 80 °C and slide it onto the shaft against the stop (Fig. 62).

Fig. 62

120

BOMAG

008 912 46

5.4

Repairing the drum

28. Apply some grease to the sealing lip of radial seal 1 (Fig. 63).

29. Slide the radial seal with the sealing lip forward over the shaft and drive it completely into the flanged housing, using a suitable tube (2).

Fig. 63

30. Cover the thread of screw 1 (Fig. 64) with a screw retention agent (e.g. Loctite green 270).

31. Slide on the new U-seal ring (2), turn in and tighten the screws.

Fig. 64

Danger Danger of burning! !

Wear safety gloves.

32. Heat coupling hub 1 (Fig. 65) with marking letter “L“ up t approx. 80° C and slide it over the shaft against the shoulder.

33. Turn in and tighten clamping screw (2).

Fig. 65

008 912 46

BOMAG

121

5.4

Repairing the drum Assembling and installing the side plate 1. Fill grooved ball bearing 1 (Fig. 66) on both sides with grease.

2. Press the grooved ball bearing completely in using pressing plate (2).

Fig. 66

3. Insert the circlip into the groove in the side plate (Fig. 67).

Fig. 67

4. Apply a thick coat of grease to the spacer ring on both sides and insert it into the side plate (Fig. 68).

Fig. 68

122

BOMAG

008 912 46

5.4

Repairing the drum

5. Fill grooved ball bearing 1 (Fig. 69) on one sides with grease.

6. Insert the grooved ball bearing with the grease side forward and press it completely in with pressing plate (2).

i Note Grease the other side after installing the exciter unit.

Fig. 69

7. Insert the oiled loop-ring into the mechanical seal (Fig. 70).

8. Clean the sliding surface of the mechanical seal and cover it with oil.

Fig. 70

9. Lay one half of the radial seal on the flanged hub with the sliding surface pointing up (Fig. 71).

Fig. 71

10. Lay the second half of the mechanical seal down with the sliding face pointing down (Fig. 72).

Fig. 72

008 912 46

BOMAG

123

5.4

Repairing the drum 11. Bolt the threaded section of the assembly device to the flanged hub (Fig. 73).

Fig. 73

Caution Danger of squashing! !

Do not stand or step under suspended loads.

12. Lay the side plate on the flanged hub (Fig. 74).

Fig. 74

13. Attach bushing 2 (Fig. 75) of the assembly device and turn on nut (1).

Fig. 75

14. Pull the side plate with the assembly device onto the flanged hub.

Caution During assembly make sure that the mechanical seal slides correctly into the side plate and the loop rings are not damaged (Fig. 76). !

Fig. 76

124

BOMAG

008 912 46

5.4

Repairing the drum 15. Remove the assembly device.

16. Insert the circlip into the groove in the flanged hub (Fig. 77).

Fig. 77

Assembling the exciter unit (travel drive side) Danger When working with liquid nitrogen protect your face and wear gloves. !

Do not place any unintended parts into liquid nitrogen.

Observe the safety instructions for the handling of liquid nitrogen.

1. Cool the shaft down in liquid nitrogen.

2. Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig. 78).

Fig. 78

3. Secure shaft 1 (Fig. 79) with dowel pin (2).

Fig. 79

008 912 46

BOMAG

125

5.4

Repairing the drum 4. Insert the circlip into the groove in the basic weight and on the cover (Fig. 80).

Fig. 80 !

Danger

Danger of burning!

Wear safety gloves.

5. Heat the inner bearing race up to approx. 100° C and press it onto the basic weight against the shoulder with the larger outer diameter forward (Fig. 81).

Fig. 81

Danger Danger of burning! !

Wear safety gloves.

6. Apply Loctite 603 to the recess in the shaft or the shoulder of the inner ring (Fig. 82).

7. Heat the inner ring up to approx. 50 °C and slide it onto the shaft against the shoulder with the wider chamfer facing towards the outside .

Fig. 82 !

Danger

Danger of burning!

Wear safety gloves.

8. Heat the inner bearing race up to approx. 100° C and press it onto the cover against the shoulder with the larger outer diameter forward (Fig. 83).

Fig. 83

126

BOMAG

008 912 46

5.4

Repairing the drum

9. Press vibration bearing 1 (Fig. 84) with pressing plate (2) into the flanged housing until it bottoms.

Fig. 84

10. Insert the circlip into the groove in the flanged housing (Fig. 85).

Fig. 85

11. Fit the new radial seal with some grease into the groove in the flanged housing (Fig. 86).

12. Fill approx. 1.2 l Öl SAE-15W/40 into the flanged housing.

approx. 1.8 l BW 219/225 D/DH/PD-3 approx. 1.0 l BW 216 DH/PDH-3

Fig. 86

Caution Danger of squashing! !

Do not stand or work under suspended loads!

13. Insert the exciter unit into the flanged housing (Fig. 87).

Fig. 87

008 912 46

BOMAG

127

5.4

Repairing the drum 14. Press vibration bearing 1 (Fig. 88) with pressing plate (2) into the flanged hub until it bottoms.

Fig. 88

15. Insert the circlip into the groove in the flange (Fig. 89).

Fig. 89

16. Lift the flange onto the flanged housing and align it the bores (Fig. 90).

Fig. 90

17. Turn screws 2 into the tapped bores of the flanged housing and tighten them (Fig. 91).

18. Turn short screws (1) into the forcing bores and tighten them.

Fig. 91

128

BOMAG

008 912 46

5.4

Repairing the drum

19. Apply some grease to the sealing lip of radial seal 1 (Fig. 92).

20. Slide the radial seal with the sealing lip forward over the shaft and drive it completely into the flanged housing, using a suitable tube (2).

Fig. 92

21. Cover the thread of screws 1 (Fig. 93) with a screw retention agent (e.g. Loctite green 270).

22. Slide on the new U-seal ring (2), turn in and tighten the screws.

Fig. 93

23. Insert the fitting key into the keyway of the shaft (Fig. 94).

Fig. 94 !

Danger

Danger of burning!

Wear safety gloves.

24. Slide fan 3 (Fig. 95) with assembly disc on the shaft.

25. Heat coupling hub 1 with marking letter “R“ up t approx. 80° C and slide it over the shaft against the shoulder.

26. Turn in and tighten clamping screw (2).

27. Assemble the fan to the ciupling hub.

Fig. 95

008 912 46

BOMAG

129

5.4

Repairing the drum Assembling the exciter unit (travel motor side) 1. Check coupling elements , replace if necessary.

2. Insert the coupling element into the coupling hub (Fig. 96). !

Caution Fitting and contact surfaces of the connection between exciter unit and drum must be absolutely dry and free of grease, oil, paint and conserving agent.

3. Fasten the lifting device to the exciter unit. !

Fig. 96

Caution

Danger of squashing!

Do not stand or step under suspended loads.

4. Insert the vibrator unit into the drum (Fig. 97).

Fig. 97

i Note Insert the exciter unit so that the oil filler plug (Fig. 98) is in line with the bore in the drum.

Fig. 98

130

BOMAG

008 912 46

5.4

Repairing the drum 5. Turn in and tighten screws 2 (Fig. 99).

6. Remove bracket (1) for the lifting device.

Fig. 99

7. Cover the thread of screws (Fig. 100) with a screw retention agent (e.g. Loctite green 270).

8. Slide on the new U-seal ring, turn in and tighten the screws.

Fig. 100

Assemble the travel drive 1. Assemble drive disc 2 (Fig. 101) and supports (4).

Fig. 101

!

Danger

Danger of squashing!

Do not stand or step under suspended loads.

2. Attach the drive disc (Fig. 102) with the assembled travel drive to the rubber buffers. Turn on and tighten the nut.

Fig. 102

008 912 46

BOMAG

131

5.4

Repairing the drum Installing the exciter unit (vibration motor side) !

Caution

Fitting and contact surfaces of the connection between exciter unit and drum must be absolutely dry and free of grease, oil, paint and conserving agent.

Danger Danger of squashing! !

Do not stand or step under suspended loads.

1. Fasten the lifting gear to the exciter unit and insert it into the drum (Fig. 103).

Fig. 103

Caution Ensure correct engagement of coupling and alignment of shaft (Fig. 104). !

If the shafts are not correctly in line determine the cause, if necessary measure the drum.

Fig. 104

i Note Insert the exciter unit so that oil filler plug 4 (Fig. 105) is in line with bore (3) in the drum.

2. Turn in and tighten fastening screws (1).

3. Remove the lifting gear.

4. Fit cover (2) to the drum.

Fig. 105

132

BOMAG

008 912 46

5.4

Repairing the drum

5. Check the end float of the exciter shafts (Fig. 106).

Nominal value: 0.6...1.8 mm

Fig. 106

6. Attach disc 1 (Fig. 107), turn in and tighten the fastening screws (2).

Fig. 107

7. Lay a new V-ring over the journal of the flanged hub (Fig. 108).

8. Fill the grooved ball bearing with grease.

Fig. 108

9. Check coupling element , replace if necessary.

10. Insert the coupling element into the coupling hub (Fig. 109).

Fig. 109

008 912 46

BOMAG

133

5.4

Repairing the drum !

Caution Fasten the vibration motor to the cover so that hydraulic connections 1 (Fig. 110) and ventilation bore (5) are opposite each other.

11. Turn in fastening screw (2) with ball disc (3) and ball socket (4) and tighten.

Fig. 110

12. Slide on coupling half 2 (Fig. 111) and secure with clamping screw (1).

Fig. 111

13. Attach the cover with the installed vibration motor, turn in and tighten the screws (Fig. 112).

Fig. 112

14. Install rectangular rubber buffers 2 (Fig. 113) with attached spacer block (3) and screws (1) to the side plate.

i Note Assemble both rectangular rubber buffers.

Fig. 113

134

BOMAG

008 912 46

5.4

Repairing the drum

!

Caution Assemble the rectangular buffers (Fig. 114) with the higher side (arrow) towards the outside, to the frame.

Fig. 114

008 912 46

BOMAG

135

5.5

Dismantling, assembling the change-over weights 5.5 Dismantling, assembling the changeover weights Dismantling the change-over weight 1. Unscrew all screws (Fig. 1).

Fig. 1

2. Force the cover off the basic weight with forcing screws (Fig. 2).

Environment Environmental damage!

Catch running out oil and dispose of environmentally.

Fig. 2

3. Take the change-over weight out of the basic weight (Fig. 3).

Fig. 3

136

BOMAG

008 912 46

Dismantling, assembling the change-over weights

5.5

4. Pull O-rings 1 and 2 (Fig. 4) out of the grooves.

Fig. 4

Assembling the change-over weights 1. Install new O-rings 1 and 2 (Fig. 5) with grease.

Fig. 5

2. Insert the change-over weight into the basic weight (Fig. 6).

Fig. 6

3. Fill silicon oil 47 V 1000 cst up to the upper edge of the change-over weight (approx. 2.3 litres) into the basic weight (Fig. 7).

Fig. 7

008 912 46

BOMAG

137

5.5

Dismantling, assembling the change-over weights 4. Attach the cover (Fig. 8), so that the raised areas are in line.

5. Turn in screws with screw retention agent (e.g.

Loctite green 270) and tighten with 120 Nm. 6. Check the end float of the shaft.

i Note There must be play.

Fig. 8

138

BOMAG

008 912 46

5.6

Changing the rubber buffers 5.6 Changing the rubber buffers

1. Jack the frame up at the side, until the rubber buffers are unloaded.

2. Unscrw nut 1 (Fig. 1) and remove the washer.

3. Unscrew screws (2).

4. Take off rubber buffer (3).

5. Attach the new rubber buffer to the drive disc and align the bores to the tapped bores in the drum.

6. Turn in and tighten the fastening screws.

7. assemble the washer, turn on and tighten the nut.

8. Lower the side of the frame.

Fig. 1

008 912 46

BOMAG

139

5.6

140

Changing the rubber buffers

BOMAG

008 912 46

6 Drum

008 912 46

BOMAG

141

6.1

Repair overview drum, Vario

6.1 Repair overview drum, Vario

142

BOMAG

008 912 46

6.1

Repair overview drum, Vario Fig. 1

Fig. 2

008 912 46

BOMAG

143

6.1

Repair overview drum, Vario

Caution Repairs should only be performed by the service department of BOMAG! !

144

BOMAG

008 912 46

7 Oscillating articulated joint

008 912 46

BOMAG

145

7.1

Special tools 7.1 Special tools 1. Assembly mandrel for rocker bearings (console of articulated joint).

BOMAG part-no.: 007 211 55

Fig. 1

2. Assembly mandrel for rocker bearings (steering cylinders).

BOMAG part-no.: 007 211 56

Fig. 2

146

BOMAG

008 912 46

7.1

Special tools

008 912 46

BOMAG

147

7.2

Repair overview oscillating articulated joint

Fig. 1

148

BOMAG

008 912 46

7.2

Repair overview oscillating articulated joint 1

Four-point bearing

6

Pivot bearing

2

Console, front

7

Spacer ring

3

Centring disc

8

Washer

4

O-ring

9

Bolt

5

Console, rear

008 912 46

BOMAG

149

7.3

Removing and installing the oscillating articulated joint 7.3 Removing and installing the oscillating articulated joint 1. Jack the back of the frame (Fig. 1) up and secure it with trestles or wooden blocks.

Fig. 1

2. Support the rear frame near the oscillating articulated joint (Fig. 2) safely with trestles or wooden blocks.

Fig. 2

3. Fasten the lifting tackle to the front frame near the oscillating articulated joint (Fig. 3).

Fig. 3

150

BOMAG

008 912 46

Removing and installing the oscillating articulated joint

7.3

4. Unscrew fastening screws 1 (Fig. 4) and take off axle holder (2).

5. Knock out bearing bolt (3).

6. Retract steering cylinder (4).

Fig. 4 !

Danger

Danger of accident!

7. Support the oscillating articulated joint in the middle with a suitable jack or a similar device.

8. Unscrew the fastening screws (Fig. 5) and take off with washers.

Fig. 5

9. Unscrew nuts (Fig. 6) and take off the clamping washers.

10. Pull out the fastening screws.

11. Pull out the oscillating articulated joint.

Fig. 6

Note on assembly 12. Install the oscillating articulated joint so that bores 1 (Fig. 7) for thearticulation lock is on the left hand side.

13. Insert the bolt for the steering cylinder so that groove (2) is in line with tapped bores (3).

Fig. 7

008 912 46

BOMAG

151

7.4

Dismantling the oscillating articulated joint 7.4 Dismantling the oscillating articulated joint 1. Unscrew fastening screws 1 (Fig. 1) and take off axle holder (2). ! Danger Danger of squashing!

2. Take out bolt (3).

Fig. 1

3. Unscrew fastening screws 1 (Fig. 2) and take off axle holder (2).

Fig. 2 !

Danger

Danger of squashing!

4. Turn out bolt 1 (Fig. 3) and separate consoles (2 and 3).

Fig. 3

152

BOMAG

008 912 46

7.4

Dismantling the oscillating articulated joint

5. Take spacer ring 1 (Fig. 4) out of the centring disc.

Fig. 4

6. Unscrew fastening screws 1 (Fig. 5) and take off the centring disc (2).

Fig. 5

7. Take the O-ring out of the rocker bearing (Fig. 6).

Fig. 6

8. Knock both rocker bearings 1 (Fig. 7) out of console (2).

Fig. 7

008 912 46

BOMAG

153

7.4

Dismantling the oscillating articulated joint 9. Knock rocker bearings 1 (Fig. 8) out of the steering cylinder receptacles.

Fig. 8

10. Unscrew fastening screws 1 (Fig. 9) and lift the front console (2) off the four point bearing (3).

11. Check four point bearing for wear , replace if necessary.

Fig. 9

154

BOMAG

008 912 46

7.5

Assembling the oscillating articulated joint

7.5 Assembling the oscillating articulated joint 1. Lay the four point bearing 3 (Fig. 1) on a level surface, insert console (2) and fasten with screws (1) and washers.

Fig. 1

2. Knock rocker bearings 1 (Fig. 2) into the steering cylinder receptacles.

Special tools: Assembly mandrel for rocker bearings (steering cylinders).

Fig. 2

3. Knock rocker bearings 1 (Fig. 3) into console (2).

Special tools: Assembly mandrel for rocker bearings (console of articulated joint).

Fig. 3

008 912 46

BOMAG

155

7.5

Assembling the oscillating articulated joint 4. Grease the new O-rings and insert them into the rocker bearings (Fig. 4).

Fig. 4

5. Fasten centring discs 2 (Fig. 5) with screws (1).

Fig. 5

6. Insert spacer ring 1 (Fig. 6) into one of the centring discs.

Fig. 6

7. Spray bolt 1 (Fig. 7) with Molykote.

Caution Bolt (1) must be knocked in on the side with spacer ring 1 (Fig. 6). !

8. Join both consoles (2 and 3) together and knock in bolt (1).

Fig. 7

156

BOMAG

008 912 46

7.5

Assembling the oscillating articulated joint

9. Assemble disc 2 (Fig. 8) with screws (1) and washers.

Fig. 8

10. Spray bolt 3 (Fig. 9) with Molykote and insert it so that groove (2) is in line with tapped bores (1).

Fig. 9

11. Secure bolt 3 (Fig. 10) with axle holder (2), screws (1) and washers.

Fig. 10

008 912 46

BOMAG

157

7.5

158

Assembling the oscillating articulated joint

BOMAG

008 912 46

8 Suppliers documentation

008 912 46

BOMAG

159

160

BOMAG

008 912 46

8.1

008 912 46

Travel pump series 90R

BOMAG

161

8.1

162

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

163

8.1

164

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

165

8.1

166

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

167

8.1

168

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

169

8.1

170

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

171

8.1

172

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

173

8.1

174

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

175

8.1

176

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

177

8.1

178

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

179

8.1

180

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

181

8.1

182

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

183

8.1

184

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

185

8.1

186

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

187

8.1

188

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

189

8.1

190

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

191

8.1

192

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

193

8.1

194

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

195

8.1

196

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

197

8.1

198

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

199

8.1

200

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

201

8.1

202

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

203

8.1

204

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

205

8.1

206

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

207

8.1

208

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

209

8.1

210

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

211

8.1

212

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

213

8.1

214

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

215

8.1

216

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

217

8.1

218

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

219

8.1

220

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

221

8.1

222

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

223

8.1

224

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

225

8.1

226

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

227

8.1

228

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

229

8.1

230

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

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BOMAG

231

8.1

232

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

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BOMAG

233

8.1

234

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

235

8.1

236

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

237

8.1

238

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

239

8.1

240

Travel pump series 90R

BOMAG

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8.1

Travel pump series 90R

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BOMAG

241

8.1

242

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

243

8.1

244

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

245

8.1

246

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

247

8.1

248

Travel pump series 90R

BOMAG

008 912 46

8.1

Travel pump series 90R

008 912 46

BOMAG

249

8.1

250

Travel pump series 90R

BOMAG

008 912 46

8.2

008 912 46

Vibration pump 42R 041

BOMAG

251

8.2

252

Vibration pump 42R 041

BOMAG

008 912 46

8.2

Vibration pump 42R 041

008 912 46

BOMAG

253

8.2

Vibration pump 42R 041

Series 42

Introduction

1. Introduction 1.1

Using This Manual

The Adjustment and Minor Repair procedures detailed herein may be performed by trained personnel without voiding the unit warranty.

placed. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly. All gasket sealing surfaces must be cleaned prior to installing new gaskets.

Cleanliness is a primary means of assuring satisfactory transmission life. Cleaning parts by using a clean solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign materials and chemicals. When performing service activities, protect all exposed sealing surfaces and open cavities from damage and foreign material.

All exploded view drawings depict the 28cc frame size. For variances in the 41cc frame size, see the outline drawings in section 3. Differences in wrench size and torquing for the two frame sizes are noted in the text. Note that exterior housing screws are mostly Torx-type T30 or T45.

These symbols are used within drawings: Apply petroleum jelly.

Whenever removing a service component, it is recommended that any gaskets and O-rings be re-

1.2

Lubricate with clean hydraulic oil.

Safety Precautions

Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury.

The following general precautions should be taken into consideration whenever servicing a hydrostatic system.

Loss of Hydrostatic Braking Ability

Fluid Under High Pressure

WARNING When Series 42 units are used in vehicular hydrostatic drive systems, the loss of hydrostatic drive line power in any mode of operation (e.g. acceleration, deceleration or “neutral” mode) may cause a loss of hydrostatic braking capacity. A braking system which is independent of the hydrostatic transmission must, therefore, be provided which is adequate to stop and hold the system should the condition develop.

WARNING Use caution when dealing with hydraulic fluid under pressure. Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury. This fluid may also be hot enough to burn. Serious infection or reactions can develop if proper medical treatment is not administered immediately.

Flammable Cleaning Solvents

Disable Work Function

WARNING Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area where a source of ignition may be present.

WARNING Certain service procedures may require the vehicle/machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing them in order to prevent injury to the technician and bystanders.

F000719

254

2

Copyright 1996-1998, Sauer-Sundstrand GmbH & Co. All rights reserved. Contents subject to change. Printed in Germany.

BOMAG

008 912 46

8.2

Vibration pump 42R 041

Series 42

Introduction

Contents 1. Introduction ................................................................................................................................ 2 1.1

Using This Manual................................................................................................................................. 2

1.2

Safety Precautions ................................................................................................................................ 2

2. Model Code ................................................................................................................................. 4 3. Component and Port Locations ............................................................................................... 5 3.1

Component Locations ........................................................................................................................... 5

3.2

Ports and Pressure Gauges .................................................................................................................. 6

4. Adjustment and Minor Repair Instructions ............................................................................. 8 4.1

Size and Torque for Plugs and Fittings .................................................................................................. 8

4.2

Pump “Neutral” Adjustment ................................................................................................................... 9

4.3

Control “Neutral” Adjustment for MDC/EDC Controls .......................................................................... 10

4.4

MDC Control Module ............................................................................................................................ 11

4.5

EDC Control Module ........................................................................................................................... 12

4.6

MDC/EDC Control Spool, Control Linkage, and Control Neutral Adjustment Screw ........................... 13

4.7

MDC Neutral Start/Backup Alarm Switch ............................................................................................ 14

4.8

MDC Solenoid Override Valve ............................................................................................................. 16

4.9

FNR, NFPE, and NFPH Controls ........................................................................................................ 17

4.10 System Check Relief Valves (High Pressure Relief, Charge Check, & Bypass Valves) ...................... 18 4.11 Charge Relief Valve............................................................................................................................. 19 4.12 Loop Flushing Valve ............................................................................................................................ 21 4.13 Shaft Seal and Shaft Replacement ..................................................................................................... 22 4.14 Auxiliary Mounting Pads ...................................................................................................................... 24 4.15 Charge Pump ...................................................................................................................................... 25 4.16 Filtration .............................................................................................................................................. 28 4.17 Servo Piston Covers ........................................................................................................................... 29 4.18 Displacement Limiter Adjustment ........................................................................................................ 30

5. Exploded View Parts Drawings............................................................................................... 31 5.1

Shaft Options ...................................................................................................................................... 31

5.2

Filtration, Charge Relief, System Relief, and Loop Flushing ............................................................... 32

5.3

Charge Pump, Auxiliary Pads, and Servo Covers ............................................................................... 33

5.4

Control Options ................................................................................................................................... 34

008 912 46

BOMAG

3255

8.2

256

Vibration pump 42R 041

BOMAG

008 912 46

8.2

Vibration pump 42R 041

Series 42

Component and Port Locations

3. Component and Port Locations 3.1 Component Locations A pump with a manual displacement control (MDC) and no filtration adapter is shown. With non-feedback and automotive controls, the positions of the case drains vary (shown in gray). With a filtration adapter, the porting in the "Filtration Options" area varies (see section 4.16).

Control Neutral Adjustment (MDC/EDC)

Control Module (MDC Shown)

Pump Neutral Adjustment

Servo Piston Covers System Check Relief Valves

Displacement Limiters Charge Pump

Shaft Seal

Filtration Options (No Filtration Adapter Shown Here)

Auxiliary Mounting Pad

Charge Relief Valve

(Loop Flushing Valve) Left Side View (Side "2")

Right Side View (Side "1") P100101 E

Series 42 28cc Variable Pump Control Neutral Adjustment (MDC/EDC)

Control Module (MDC Shown)

Pump Neutral Adjustment

Servo Piston Covers Displacement Limiters

Charge Pump

Auxiliary Mounting Pad

System Check Relief Valves

Shaft Seal

Charge Relief Valve

(Loop Flushing Valve) Left Side View (Side "2")

Filtration Options (No Filtration Adapter Shown Here)

Right Side View (Side "1") P100102 E

Series 42 41cc Variable Pump

008 912 46

BOMAG

5257

8.2

Vibration pump 42R 041

Series 42 3.2

Component and Port Locations

Ports and Pressure Gauges

Proper servicing of pumps and motors requires that pressure be measured and monitored at various points in the hydraulic circuit. The Series 42 pump has several locations at which to take these measure-

ments. The following outlines show the locations of the various gauge ports. The tables show the recommended gauge size and the fitting size for each port.

Refer to this page when installing pressure gauges.

Fitting

Gauge Port Name

Pressure Measured

Recommended Gauge Size

M1 & M2

System Pressure for Ports A and B

600 bar or 10 000 psi

9/16-18 O-Ring Fitting

9/16-18 O-Ring Fitting

M3

Charge Pressure

60 bar or 1000 psi

3/4-16 O-Ring Fitting

3/4-16 O-Ring Fitting

M4 & M5

Servo Pressure

60 bar or 1000 psi

9/16-18 O-Ring Fitting

9/16-18 O-Ring Fitting

L1 & L2

Case Pressure

35 bar or 500 psi

1-1/16-12 O-Ring Fitting

1-5/16-12 O-Ring Fitting

Charge Pump Inlet Vacuum

1 bar, absolute or 30 in Hg Vacuum

1-1/16-12 O-Ring Fitting

1-5/16-12 O-Ring Fitting

S

028

041

T000 025E

System Pressure Gauge Port M2

Servo Pressure Gauge Port M5 Servo Pressure Gauge Port M4

System Pressure Port B

Charge Pressure Gauge Port M3 (Charge Pressure Supply For No Charge Pump Option)

Case Drain Port L2 (Non-Feedback Controls)

System Pressure Port A

Case Drain Port L1 Case Drain Port L1 (Non-Feedback Controls)

Charge Pump Inlet Port S

Case Drain Port L2

System Pressure Gauge Port M1 Left Side View (Side "2")

Right Side View (Side "1") P100103 E

28cc Base Unit with MDC and No Filtration Adapter

258 6

BOMAG

008 912 46

8.2

Vibration pump 42R 041

Series 42

Component and Port Locations

Servo Pressure Gauge Port M5 Servo Pressure Gauge Port M4

System Pressure Gauge Port M2

System Pressure Port B

Charge Pressure Gauge Port M3 (Charge Pressure Supply For No Charge Pump Option)

Case Drain Port L2

System Pressure Port A Charge Pump Inlet Port S

Case Drain Port L1 System Pressure Gauge Port M1 Left Side View (Side "2")

Right Side View (Side "1")

P100104 E

41cc Base Unit with MDC and No Filtration Adapter

To Filter, Port D (Pressure Filtration)

Charge Pressure Gauge Port M3 (Full Flow Pressure Filtration)

From Filter, Port E (Pressure Filtration) Charge Pressure Gauge Port M3 (Partial Flow Pressure Filtration)

Charge Pressure Gauge Port M3 (Suction Filtration) P100105 E

Filtration Adapter (28cc and 41cc Models)

008 912 46

BOMAG

7259

8.2

Vibration pump 42R 041

Series 42

Adjustments and Minor Repairs

4. Adjustment and Minor Repair Instructions 4.1

Size and Torque for Plugs and Fittings

Plug and fitting sizes are given here. Place a fresh O-ring, lightly lubricated with petroleum jelly, whenever a plug is removed. Each should be torqued as indicated. A 28cc unit with manual displacement control (MDC) is shown.

Servo Gage Port M4

11/16 in Hex 27-47 Nm (20-35 ft•lbf)

28cc: 9/16 in Int. Hex 95-135 Nm (70-100 ft•lbf) Case Drain 41cc: 5/8 in Int. Hex Port L1 125-250 Nm (90-190 ft•lbf) Charge Pressure Gage Port M3 (Position Varies, Refer to Filtration Options)

Charge Pump Inlet Port S Torque: 115 Nm (85 ft•lbf)

Case Drain Port L2 Port N (Unused)

11/16 in Hex 27-47 Nm (20-35 ft•lbf) Servo Gage Port M5

System Gage Ports M1 and M2

11/16 in Hex 27-47 Nm (20-35 ft•lbf) 28cc: 9/16 in Int. Hex 95-135 Nm (70-100 ft•lbf) 41cc: 5/8 in Int. Hex 125-250 Nm (90-190 ft•lbf)

System Ports A and B 115 Nm (85 ft•lbf)

11/16 in Hex 27-47 Nm (20-35 ft•lbf) E100001 E

260 8

BOMAG

008 912 46

8.2

Vibration pump 42R 041

Series 42 4.2

Adjustments and Minor Repairs

Pump “Neutral” Adjustment

The pump neutral adjustment sets the position of the servo piston and pump swashplate relative to the controlling mechanism.

WARNING The following procedure requires the vehicle / machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders.

1. Disconnect machine function.

2. Connect a hose between gauge ports M4 and M5 to equalize the pressures on both ends of the pump servo piston.

Pump "Neutral" Adjustment Screw

Pump "Neutral" Adjustment Seal Lock Nut

3. Install pressure gauges in gauge ports M1 and M2 to measure system pressure.

4. Start the prime mover and operate at normal speed.

5. Loosen the pump "neutral" adjustment seal lock nut [28cc 13 mm Hex; 41cc 17 mm Hex]. Turn the pump "neutral" adjustment screw [28cc 5 mm Hex; 41cc 7 mm Hex] until the system pressure gauge readings are equal.

E100002 E

Pump Neutral Adjustment Screw (MDC Control Shown)

6. Turn the adjustment screw clockwise until one of the gauges registers an increase in system pressure. Note the position of the adjustment screw.

Turn the screw counterclockwise until the other gauge registers an increase in system pressure.

Note the position of the adjustment screw.

7. Turn the adjustment screw clockwise to a position halfway between the positions noted above.

The system pressure gauges should indicate equal pressures.

8. While holding the adjustment screw in position, torque the seal lock nut [28cc 20-26 Nm (15-19 ft•lbf); 41cc 28-51 Nm (21-37 ft•lbf)] .

9. Stop the prime mover and remove the hose between gauge ports M4 and M5. Remove the pressure gauges installed in gauge ports M1 and M2. Reinstall the plugs in the gauge ports.

10. Reconnect work function.

IMPORTANT If the pump is equipped with an MDC or EDC, the CONTROL "neutral" adjustment MUST also be performed before putting the pump into service (see next section).

008 912 46

BOMAG

9261

8.2

Vibration pump 42R 041

Series 42 4.3

Adjustments and Minor Repairs

Control “Neutral” Adjustment for MDC/EDC Controls

The control neutral adjustment aligns the pump swashplate and the control spool so that a zero angle control setting provides a zero degree swashplate setting.

This adjustment should be performed whenever any part of the control or swashplate mechanisms is adjusted or removed or after the pump neutral setting (previous section) is adjusted.

MDC / EDC Control "Neutral" Adjustment Screw

WARNING The following procedure requires the vehicle / machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders.

1. Disconnect the work function. Disconnect the external control linkage (for MDC) or control signal input (for EDC) from the pump.

2. Install pressure gauges in gauge ports M4 and M5 to measure pressure on the pump servo piston.

3. Start the prime mover and operate at normal speed.

MDC / EDC Control "Neutral" Adjustment Seal Lock Nut E100003 E

Control Neutral Adjustment Screw (EDC Control Shown)

4. Loosen the CONTROL "neutral" adjustment seal lock nut (see drawing) [17 mm Hex] . Turn the control "neutral" adjustment screw [5 mm Int. Hex] until the servo piston pressure gauge readings are as close to equal as possible.

5. Turn the adjustment screw clockwise until one of the gauges registers an increase in pressure on the servo piston. Note the position of the adjustment screw.

Turn the screw counterclockwise until the other gauge registers an increase in pressure on the servo piston. Note the position of the adjustment screw.

6. Turn the adjustment screw clockwise to a position halfway between the positions noted above.

The servo piston pressure gauges should indicate nearly equal pressures.

7. While holding the adjustment screw in position, torque the seal lock nut [14-24 Nm (10-18 ft•lbf)].

8. Stop the prime mover and remove the pressure gauges installed in gauge ports M4 and M5.

Reinstall the plugs in the gauge ports.

9. Reconnect the external control linkage (for MDC) or control signal input (for EDC) to the pump.

Reconnect the work function.

262 1 0

BOMAG

008 912 46

8.2

Vibration pump 42R 041

008 912 46

BOMAG

263

8.2

Vibration pump 42R 041

Series 42 4.5

Adjustments and Minor Repairs

EDC Control Module

The Electric Displacement Control (EDC) provides a control function through connections to the summing link pin within the pump housing. The following procedure shows how to remove and install the control housings. The next section explains how to remove and install the control spool and linkage.

1. Clean the external surfaces of the pump. If necessary, remove control input signal.

EDC Control Pressure Gauge Port X1

2. Remove the seven (7) control retaining screws [Torx T30] that secure the control to the pump housing. Note the position of the different length screws. Remove the control and control gasket from the pump.

Note: See next section for instructions on removing/installing the control spool and linkage.

EDC Control Pressure Gauge Port X2

3. Clean the sealing surfaces of the control and the pump housing. Place a new gasket in position on the housing.

EDC Module Showing Port Locations

CAUTION The control orifices are part of the control gasket. Refer to the appropriate Service Parts List to determine the correct gasket.

Control Retaining Screws (note different sizes)

4. Hold the summing link pin in position while installing the control. (The spring on the control spool will tend to push the link to an extreme position.)

The link pin MUST engage the hole in the control piston fork.

Note: It may be easiest to lay the servo piston side of the control down first, then watch the link pin engage from the charge pump side of the pump.

5. Install and torque the control screws [15-17 Nm (11-13 ft•lbf)]. Perform Control Neutral Adjustment (Section 4.3).

Control Gasket Hold summing link (and control spool) in position

WARNING Failure to properly engage the link pin with control piston fork will result in incorrect control operation, which may lead to loss of control of the vehicle / machine.

264 1 2

P100106 E

Summing link pin MUST enter the hole in the control piston fork!

E100006 E

EDC Control Module Assembly

BOMAG

008 912 46

8.2

Vibration pump 42R 041

Series 42 4.6

Adjustments and Minor Repairs

MDC/EDC Control Spool, Control Linkage, and Control Neutral Adjustment Screw

The control spool, control linkage, and control neutral adjustment screw can be removed for cleaning and to change the O-rings or the seal lock nut.

Summing Link Linkage Pivot Screw

Removal of Spool, Linkage, and Adjustment Screw 1. Clean the external surfaces of the pump.

Neutral Adjustment Link

2. Remove the MDC or EDC module and the control gasket from the pump housing (see previous two sections).

Feedback Link

Control Neutral Adjust Screw

Opposite Bore Plug Seal Lock Nut Control Spool and Spring Note orientation!

3. Remove the summing link.

4. Remove the control spool bore plug [5/16 in Int. Hex] or screws [Torx T30], cover, and gasket.

Remove the opposite bore plug [5/16 in Int. Hex], and remove the control spool and spring.

Housing without Filtration Adapter

5. Remove the linkage pivot screw [4 mm Int. Hex], feedback link, and neutral adjustment link.

Control Spool Bore Plug

6. Remove the seal lock nut [17 mm Hex] and the control neutral adjustment screw [5 mm Int. Hex].

Installation of Spool, Linkage, and Adjustment Screw 1. Install the control neutral adjustment screw and seal lock nut. Do not tighten the nut.

Housing with Filtration Adapter

Gasket

2. Assemble the "neutral" adjustment link and feedback link, and install as shown. Install and torque the linkage pivot screw [8-15 Nm (6-11 ft•lbf)].

Control Spool Bore Cover

3. Lubricate and install the control spool and spring assembly noting proper orientation.

WARNING The control spool and spring assembly MUST be oriented in the housing as shown for proper control operation.

4. Install and torque the control spool bore plug [4194 Nm (30-70 ft•lbf)]. Or install the control spool cover (with a new gasket) or plug, and torque the screws [15-17 Nm (11-13 ft•lbf)].

5. Install the summing link. Hold the control spool in position while engaging the fork on the summing link with the flats on the spool. If necessary, rotate the spool to engage the summing link.

E100007 E

MDC/EDC Control Spool and Linkage

Feedback link must enter slot in servo piston Pivot screw

Slot in "neutral" adjust link must engage groove in adjusting screw

Fork on summing link must engage flats on control spool E100008 E

Servo Piston Linkage and Control Spool (Internal Parts Shown with Housing Removed)

6. Install a new control gasket. Hold the summing link and control spool in position while reinstalling the MDC or EDC (see section 4.4 or 4.5). Perform Control Neutral Adjustment (section 4.3).

008 912 46

BOMAG

1 3265

8.2

Vibration pump 42R 041

Series 42 4.7

Adjustments and Minor Repairs

MDC Neutral Start/Backup Alarm Switch

The Neutral Start Switch (NSS) prevents the engine and pump from being started when the pump is out of neutral. The NSS should be wired in series with the engine starting circuit. The switch contact is closed at the control handle's neutral position and opens when the control handle is rotated 1.5 to 2° from neutral.

NSS Cover NSS Control Nut NSS Cam

The Backup Alarm Switch (BUA) outputs an electronic signal when the control handle is in a reverse position. This switch is normally wired in series with an audio output. The switch contact is open until the control handle is rotated 2.6 to 3.75° in the reverse direction.

NSS Cavity

NSS with Weatherpack

CAUTION The control handle's neutral position must agree with the pump's neutral position for the NSS/BUA to work effectively (see section 4.3).

NSS with Screw Terminals E100009 E

The Neutral Start / Backup Alarm Switch assembly can be configured for three different settings. i.

NSS Assembly on MDC

A Neutral Start Switch only.

ii. A Neutral Start Switch with Backup Alarm for units where clockwise (CW) handle rotation results in "reverse" motion. iii. A Neutral Start Switch with Backup Alarm for units where counterclockwise (CCW) handle rotation results in "reverse" motion.

The setting must be in accordance with the configuration of the unit. See the model code (section 2) if uncertain of the type of NSS you have.

Alignment of the NSS requires a special alignment tool. Dimensions are given at right.

Control Yolk Cam

NSS only

NSS with BUA (CW = Reverse)

NSS with BUA (CCW = Reverse) P100107 E

Top View of NSS Showing Cam Positions

(continued)

9/16 -18UNF 2A THD .04 x 45 Chamfer

R.125

ø .236–.030 Knurl

35.0 1.250 .306

.354 2.000 Material: .75 DIA x 3 ETD150 (All Dimensions in inches)

P100108 E

Alignment Tool

266 1 4

BOMAG

008 912 46

8.2

Vibration pump 42R 041

008 912 46

BOMAG

267

8.2

Vibration pump 42R 041

Series 42 4.8

Adjustments and Minor Repairs

MDC Solenoid Override Valve

The solenoid override valve is a safety feature that connects both ends of the servo control piston together when the solenoid is de-energized. Thus the pump can be put into stroke only when the solenoid is energized.

Port L4 Port X7

The solenoid override with brake release includes hydraulic control of a safety brake. When de-energized, a spring-applied, hydraulically-released brake is drained through port X7. For conditions where case back-pressure on the spring-applied brake is critical, an external drain to the reservoir can be connected through port L4.

The solenoid override valve can be removed to inspect and remove foreign matter.

Removal 1. Remove retaining nut [9/16 in Hex].

Solenoid Override Valve Assembly

E100010 E

Solenoid Override Valve Assembly

2. Remove solenoid housing.

3. Remove retaining ring at base of solenoid.

Retaining Nut

4. Remove solenoid. This should be connected to internal spool.

Solenoid Housing

Installation 1. Replace O-ring.

Washer Retaining Ring

2. Place spring and plunger inside of solenoid.

Solenoid

3. Attach spool (male notch) to plunger (female notch).

4. Insert solenoid/spool assembly in solenoid override bore.

O-Ring Spring Plunger

5. Snap retaining ring over base of solenoid.

Spool

6. Place washer at base of solenoid.

7. Install housing and retaining nut [2-4 Nm (1.5-3.5 ft•lbf)].

E100011 E

Exploded View of Solenoid Override Assembly

268 1 6

BOMAG

008 912 46

8.2

Vibration pump 42R 041

Series 42 4.9

Adjustments and Minor Repairs

FNR, NFPE, and NFPH Controls

The 3-position FNR control and the electric and hydraulic non-feedback proportional (NFPE and NFPH) controls are non-feedback type controls. The FNR and NFPE controls consist of modules mounted on the pump housing. The hydraulic input for NFPH is received through ports on the top of the pump [9/16–18 SAE O-ring fitting].

NFPH Ports (Ports X1 and X2)

The non-feedback controls are set at the factory. The control modules can be removed to clean the ports and change the O-rings.

The orifice plugs for the FNR and NFPE are located inside the servo piston covers. The orifice plugs for the NFPH are located in the NFPH ports. Orifice plugs may be cleaned or replaced.

E100012 E

Position of NFPH Ports

Note: Future models may contain orifice plate between module and pump housing.

Control Solenoid Control Module

Removal and Installation of FNR and NFPE Modules 1. Clean pump and module housings.

2. Remove four (4) screws retaining module to housing [4 mm Int. Hex], and remove module from pump housing.

Control Ports Locator Pin

3. Remove O-rings from the control ports. Examine ports for cleanliness.

4. Clean sealing surfaces.

5. Replace locator pin.

6. Install new O-rings.

7. Replace screws [4.7-6.1 Nm (3.5-4.5 ft•lbf].

E100013 E

Removal and Installation of FNR and NFPE Control Orifices Note: Future models may contain an orifice plate between module and pump housing. This will take the place of the orifice plugs beneath the servo piston cover.

NFPE Assembly (FNR Similar) Non-Feedback Control Orifice

1. Remove servo piston cover (see section 4.17).

2. Remove orifice plug [1/8 in Int. Hex].

3. Examine orifice and port for cleanliness.

4. Install orifice plug [2.0-3.4 Nm (1.5-2.5 ft•lbf)].

E100014 E

Location of Non-Feedback Control Orifice

008 912 46

BOMAG

1 7269

8.2

Vibration pump 42R 041

Series 42

Adjustments and Minor Repairs

4.10 System Check Relief Valves (High Pressure Relief, Charge Check, & Bypass Valves) The charge check, high pressure relief, and the loop bypass functions are all contained within the system check relief (SCR) valve assembly. This assembly may be removed for cleaning and installation of fresh O-rings. The model code specifies whether high pressure relief valves, combination charge check/ high pressure relief valves, and/or loop bypass valves are present or not.

With Bypass Without Bypass Valve Seat Plug

1. Remove the valve seat plugs [9 mm Int. Hex] or valve seat/bypass plugs [1 in Hex] from the pump housing.

Outer O-Ring Backup Ring

2. Remove the check poppet or relief valve assemblies from the pump housing. The smaller end of each conical spring is crimped to retain it on the check poppet or relief valve. Do not remove.

Inner O-Ring

Valve Seat Retaining Ring Standard Bypass Plunger O-Ring Valve Seat Plug Outer O-Ring Backup Ring Inner O-Ring

3. Inspect the valves and mating seats in the special plugs for damage or foreign material.

CAUTION The relief valves are factory set and should not be tampered with, except for replacing the entire valve.

4. The O-ring on the standard bypass plunger may be replaced by removing the retaining ring and removing the plunger from the special valve seat plug. Remove the O-ring from the plunger and install a new O-ring. Reinstall the plunger and retaining ring.

Check Poppet or High Pressure Relief Valve Conical Spring

5. Install a new outer O-ring, new backup ring, and new inner O-ring on each valve seat plug.

6. Check that the conical springs are properly retained on the check poppets or relief valves.

Install the check poppet or high pressure relief valve assemblies into the pump housing .

CAUTION The conical springs MUST be correctly positioned on the check poppets or relief valves after installation for proper pump operation.

E100015 E

System Check Relief Valve Components

7. Install the valve seat plugs or valve seat/bypass plugs into the pump housing and torque [40-95 Nm (30-70 ft•lbf)].

270 1 8

BOMAG

008 912 46

8.2

Vibration pump 42R 041

Series 42

Adjustments and Minor Repairs

4.11 Charge Relief Valve The charge relief valve may be removed for cleaning and installation of fresh O-rings. The pressure setting may be changed. However, note that the setting will vary for different charge flows which depends on charge pump size and pump speed. The factory setting is set relative to case pressure at 1800 rpm.

The actual charge pressure will vary at different speeds.

Shim Adjustable Style 1. Remove the shim adjustable charge relief valve plug [1 in Hex] from the pump housing. Remove the O-ring from the plug.

Shim Adjustable Charge Relief Valve Plug O-Ring Shims

2. Remove the spring and poppet from the housing.

Spring Poppet

3. Do not alter the shims which may be installed between the spring and valve plug, or interchange parts with another valve. Inspect the poppet and mating seat in the housing for damage or foreign material.

4. If desired, the charge relief valve setting can be changed. An approximate rule of thumb is 4 bar / 1.25 mm (58 psi / 0.050 in). The effective setting will vary.

To confirm the charge relief valve setting, measure charge pressure (port M3) with the pump in stroke. The charge pressure should level off when the relief setting is reached.

5. Install a new O-ring on the valve plug. Reinstall the poppet, spring, and plug (with shims and Oring) into the pump housing [55-135 Nm (40-100 ft•lbf)].

E100016 E

Shim Adjustable Charge Relief Valve Components

Approximate Relief Setting vs Shim Thickness 4 bar / 1.25 mm

(58 psi / 0.050 in) T000 023E

(continued)

008 912 46

BOMAG

1 9271

8.2

Vibration pump 42R 041

Series 42

Adjustments and Minor Repairs

Screw Adjustable Style

Charge Relief Lock Nut

1. Before removing the screw adjustable relief valve plug, mark the plug, lock nut, and housing so as to approximately maintain the original adjustment when assembling, Remove the screw adjustable charge relief valve plug by loosening the lock nut [1-1/16 in Hex] and unscrewing the plug [8 mm Int. Hex]. Remove the O-ring from the plug.

O-Ring Screw Adjustable Charge Relief Valve Plug Spring Poppet

2. Remove the spring and poppet from the housing.

3. Inspect the poppet and mating seat in the housing for damage or foreign material.

4. Install a new O-ring on the valve plug. Reinstall the poppet and spring. Reinstall the plug with its lock nut [47-57 Nm (34-42 ft•lbf)], aligning the marks made at disassembly.

E100017 E

Screw Adjustable Charge Relief Valve Components

5. Check and adjust, if necessary, the charge pressure. For screw adjustable "anti-stall" charge relief valves, an approximate rule of thumb is 2.8 bar / quarter turn (40 psi / quarter turn).

To confirm the charge relief valve setting, measure charge pressure (port M3) with the pump in stroke. The charge pressure should level off when the relief setting is reached.

272 2 0

BOMAG

Approximate Relief Setting vs Screw Revolution 2.8 bar / 1⁄4 turn

(40 psi / 1⁄4 turn) T000 024E

008 912 46

8.2

Vibration pump 42R 041

Series 42

Adjustments and Minor Repairs

4.12 Loop Flushing Valve The loop flushing function consists of the loop flushing shuttle valve and the loop flushing relief valve. The assemblies may be removed for cleaning and installation of new O-rings. The relief valve poppet may be exchanged for one with a different flow rating, but the relief valve shims should not be changed out unless specifically instructed so by Sauer-Sundstrand. The function also can be defeated.

Loop Flushing Relief Plug Loop Flushing Relief Plug (Defeat) O-Ring

O-Ring Shims Spring Poppet

Loop Flushing Valve 1. Remove the loop flushing valve plug from the pump housing [11/16 in Hex]. Remove the O-ring from the plug.

Loop Flushing Plug (Defeat)

2. Remove the loop flushing valve spool assembly from the housing.

O-Ring

3. Inspect the parts for damage or foreign material.

The centering spring must be securely retained to the spool by the washer.

Defeat Spool

Loop Flushing Plug O-Ring Loop Flushing Spool Assembly

4. Install the loop flushing valve spool assembly into its bore. Install a new O-ring on the loop flushing plug and install [27-47 Nm (20-35 ft•lbf)].

Loop Flushing Relief Valve 1. Remove the loop flushing relief valve internal hex plug [5/8 in Hex] from the pump housing. Remove the O-ring from the plug.

2. Remove the spring and poppet from the housing.

3. Do not alter the shims which are installed between the spring and valve plug, or interchange parts with another valve. Inspect the poppet and mating seat in the housing for damage or foreign material. Inspect the orifice in the valve poppet.

4. Install a new O-ring on the valve plug. Reinstall the poppet, spring, shims, and plug (with O-ring) into the pump housing [15-34 Nm (15-25 ft•lbf)].

E100018 E

Loop Flushing Valve and Loop Flushing Defeat Components

Defeating Loop Flushing 1. Remove the loop flushing valve from the pump housing.

2. Install the defeat spool into the spool bore in the housing. Install the plain plug with O-ring into the housing [11/16 in Hex], and torque [27-47 Nm (20-35 ft•lbf)].

3. Remove the charge relief valve (these parts are not necessary).

4. Install the plain hex plug with O-ring into the end cap [5/8 in Hex], and torque [15-34 Nm (15-25 ft•lbf)].

008 912 46

BOMAG

2 1273

8.2

Vibration pump 42R 041

Series 42

Adjustments and Minor Repairs

4.13 Shaft Seal and Shaft Replacement A lip type shaft seal is used in Series 42 pumps. This seal and/or the shaft can be replaced without major disassembly of the unit. Replacement generally requires removal of the pump from the machine.

Retaining Ring Seal Carrier Assembly

1. Position the pump with the shaft facing up.

NOTE: If the unit is positioned horizontally when the shaft is removed, the cylinder block could move out of place, making shaft installation difficult.

2. Remove the retaining ring from the housing.

3. Pull out seal carrier assembly.

4. Remove the O-ring from the seal carrier. To install a new shaft only, proceed to step 8.

5. Place the seal carrier in an arbor press with the shaft bearing side down, and press out the old seal. An appropriately sized pipe spacer or socket wrench can be used as a press tool. Once removed, the seal is not reusable.

6. Inspect the seal carrier and the new seal for damage. Inspect the sealing area on the shaft for rust, wear, or contamination. Polish the sealing area on the shaft if necessary.

7. Press the new seal into the shaft bearing side of the seal carrier. The seal lip must face the outside of the pump. Be careful not to damage the seal.

The outside diameter of the seal may be coated with a sealant (e.g. Loctite High Performance Sealant #59231) prior to installation. This aids in preventing leaks caused by damage to the seal bore in the seal carrier.

E100019 E

Shaft Seal Components

O-Ring

Seal

Sealant may be used on outside diameter

Seal Carrier

Inside Lip (face down)

(continued)

Press Seal to bottom of Seal Carrier E100020 E

Installation of Shaft Seal

274 2 2

BOMAG

008 912 46

8.2

Vibration pump 42R 041

Series 42

Adjustments and Minor Repairs

If the shaft is not being replaced proceed to step 11.

Retaining Ring

8. Remove the shaft and roller bearing assembly from the pump or motor. The bearing assembly can be transferred to the new shaft (steps 9 and 10).

Roller Bearing

9. Remove the retaining ring that secures roller bearing assembly with a snap ring plier. Remove the roller bearing assembly.

10. Place roller bearing assembly on new shaft and secure with the retaining ring.

Key

Shaft OR

Shaft Assembly OR

11. Wrap the spline or key end of shaft with thin plastic to prevent damage to the seal lip during installation. Lubricate the inside diameter of the shaft seal with petroleum jelly.

12. Place the O-ring onto the shaft bearing and lubricate with petroleum jelly.

13. Slide the seal carrier assembly over the shaft and into the housing bore. Press against O-ring. Hold inward pressure against the shaft to compress the cylinder block spring while pressing the seal carrier into place.

14. Install the retaining ring.

E100021 E

Shaft Components

008 912 46

BOMAG

2 3275

8.2

Vibration pump 42R 041

Series 42

Adjustments and Minor Repairs

4.14 Auxiliary Mounting Pads The following procedure can be used to remove and install a new auxiliary mounting pad or to install a fresh O-ring for the current auxiliary mounting pad.

Several auxiliary mounting pads are available.

Auxiliary mounting pads are integrated into the charge pump cover. When nothing is mounted on the pads, a flange cover is attached to protect the mounting flange. This cover is removed when mounting a Charge pump.

Removal of Auxiliary Mounting Pad 1. Remove the auxiliary pump or remove the two screws retaining the flange cover ["A" Pad 9/16 in Hex; "B" Pad 3/4 in Hex]. Remove the O-ring.

Pump Cover

Pad Cover Screws Aux Mount Pad Cover Retaining Screws O-Ring

2. Orient pump so that charge pump cover (auxiliary pad) is facing up.

OR

3. Remove the charge pump cover. The auxiliary pad is integrated into the charge pump cover.

Use a Torx T45 male driver to remove the screws.

Note: If a different auxiliary pad is being installed, then a new drive coupling must be installed. To do this follow the instructions in the section on removing and installing the charge pump (next section).

Note: If the charge pump components come out with the charge pump cover refer to section 4.15 on how to properly reinstall them.

4. Install a new charge pump cover gasket.

OR

Auxiliary Mounting Pad "A" Gasket

Auxiliary Mounting Pad "B" No Charge Pump Defeat

Locating Pin 1 Charge Pump Components

5. Install the charge pump cover (auxiliary pump mounting pad is integrated in cover).

NOTE: The threaded screw holes in the auxiliary pump mounting pad used on very early production pumps with the SAE "A" pad option are drilled through into the area between the gerotor cover and charge pump cover. Any of these holes which are not used to attach the flange cover or auxiliary pump should be plugged with internal hex set screws installed hand tight to prevent the entrance of water or dirt into this area.

Locating Pin 2

E100022 E

Auxiliary Pad Options and Components

6. Attach the auxiliary pump. If no pump is to be attached on an auxiliary mounting pad, the pad should be protected with a flange cover and Oring to prevent leakage.

276 2 4

BOMAG

008 912 46

8.2

Vibration pump 42R 041

Series 42

Adjustments and Minor Repairs

4.15 Charge Pump

(Screw used with "No Pad" and "A Pad" Only) Cover Retaining Screws

1. Remove auxiliary pump, if necessary.

Charge Pump Cover or Auxiliary Pad

Note: For units without integral charge pumps see the last page of this section for additional information.

2. Remove the screws retaining the charge pump cover to the pump housing [Torx T45] (seven (7) screws are used with the "no pad" or SAE "A" auxiliary mounting pad charge pump cover, while six (6) screws are used with the SAE "B" auxiliary mounting pad charge pump cover). Remove the charge pump cover, gasket, and the cover locating pins.

3. Remove the gerotor cover assembly from the charge pump cover or the back of the pump housing. Remove the gerotor cover O-rings. Two (2) O-rings are used on the gerotor cover of all pumps. (An additional O-ring was used on the gerotor cover of very early production pumps with the SAE "A" pad option.)

Gasket O-Rings

Geroter Cover

4. Remove the gerotor assembly from the gerotor cover or pump housing.

5. Remove the gerotor drive pin and drive coupling.

Remove the gerotor cover locating pin from the pump housing.

6. Each part should be inspected separately if they are to be reused. If either of the gerotor assembly parts needs to be replaced, they must both be replaced. Always replace the O-rings and charge pump cover gasket. Inspect the journal bearing in the gerotor cover for excessive wear.

Geroter Assembly Drive Coupling Geroter Cover Locating Pin Charge Pump Cover Locating Pin

Geroter Drive Pin Charge Pump Cover Locating Pin

Charge Pump Components

The charge pump may be disassembled to inspect and clean, or to change the auxiliary shaft drive coupling.

7. Prior to assembly, lubricate the gerotor assembly with clean hydraulic oil.

8. Install the gerotor drive pin into the hole in the drive coupling, and retain with grease or petroleum jelly.

9. Install the drive coupling onto the pump shaft with the smaller outside diameter oriented away from the pump shaft. Different couplings are used with the different auxiliary pad options.

E100023 E

Charge Pump Components

10. Install the gerotor assembly onto the coupling. (continued)

008 912 46

BOMAG

2 5277

8.2

Vibration pump 42R 041

Series 42

Adjustments and Minor Repairs

11. Install the gerotor cover locating pin into the pump housing. Install the gerotor cover assembly over the gerotor. The locating pin must engage the slot in the gerotor cover.

NOTE: The charge pump rotation is determined by the location of the gerotor recess and pressure balance hole in the gerotor cover. Different gerotor covers are used for clockwise and counterclockwise rotation pumps.

12. Install new pressure balance O-rings onto the gerotor cover and retain with petroleum jelly or grease. (An additional O-ring was used on the gerotor cover of very early production pumps with the SAE "A" pad option.)

13. Install the charge pump cover locating pins and a new charge pump cover gasket.

14. Install the charge pump cover. The cover must engage the gerotor cover and the locating pins.

Install the charge pump cover screws and torque evenly [36-43 Nm (26-32 ft•lbf)].

15. If necessary, reinstall auxiliary pump.

CW

CCW P100110 E

Determining Charge Pump Orientation Looking Inside of Gerotor Pump Cover

For units without an integral charge pump see the next section. (continued)

278 2 6

BOMAG

008 912 46

8.2

Vibration pump 42R 041

Series 42

Adjustments and Minor Repairs

Units without Integral Charge Pump Variable Pumps without an integral charge pump do not have a gerotor assembly, gerotor drive pin, or gerotor cover locating pin installed. The charge pump inlet port is plugged with an O-ring plug.

Cover Retaining Screws

For these units that are equipped with housings without filtration adapters, the gerotor cavity outlet is plugged with a special plug installed in a housing passage. The 3/4—16 charge inlet fitting should be torqued to 68 Nm (50 ft•lbf).

For these units that are equipped with housings that include filtration adapters, the gerotor cavity outlet is plugged with an O-ring plug installed in the "To Filter" port of a "Full Filter Flow" (charge relief valve after filter) filter adapter. The 7/8—14 charge inlet fitting should be torqued to 95 Nm (70 ft•lbf).

Gasket

Charge Pump Cover or Auxiliary Pad

(Screw used with "No Pad" and "A Pad" Only)

CAUTION A "Partial Filter Flow" (charge relief valve before filter) adapter must not be used on variable pumps without an integral charge pump. If this design adapter is used, the charge relief valve will be defeated.

Geroter Cover Drive Coupling Charge Pump Cover Locating Pin 2

Geroter Cavity Outlet Plug (Charge Pump Defeat)

Charge Pump Cover Locating Pin 1

"No Charge Pump" Components

O-Rings

Charge Inlet

Charge Pump Inlet Plug

Charge Pump Inlet Plug

Charge Inlet (For Wrench Sizes and Torquing See Filtration Section) E100024 E

No Charge Pump Option Components (Housing with Filtration Adapter)

008 912 46

No Charge Pump Option Components (Housing without Filtration Adapter)

BOMAG

2 7279

8.2

Vibration pump 42R 041

Series 42

Adjustments and Minor Repairs

4.16 Filtration Filtration of foreign matter from the hydraulic fluid is of primary importance. Dirt and foreign fluids within the hydraulic circuit will greatly reduce the life of the hydraulic equipment.

M3 Gauge Port Plug

Filtration Plate Retaining Screws

Filter-Related Pump Hardware Filtration mechanisms for the Series 42 pump may be before (suction filtration) or after (charge pressure filtration) the charge pump. Sauer-Sundstrand provides a filtration adapter to provide for each type of filtration configuration. If filtration is provided for elsewhere in the hydraulic circuit, the pump will not have a filtration adapter.

Partial Flow Pressure Filtration

Full Flow Pressure Filtration

Suction Filtration

Pumps equipped with housings without filtration adapters have an additional construction bore next to the charge relief valve which is unused and plugged [5/8 in Hex, 21-33 Nm (15-25 ft•lbf)]. When these pumps are equipped with suction filtration, the external charge inlet is plugged [5/16 in Int. Hex, 41-94 Nm (30-70 ft•lbf)].

Pumps equipped with housings that include filtration adapters have the appropriate adapter and gasket fastened to the housing with screws [Torx T30, 16 Nm (12 ft•lbf)]. The position of the M3 gauge port [11/ 16 in Hex, 11-13 Nm (8-10 ft•lbf)] will vary depending on filtration type.

Housing with Filtration Adapter

Filter Specifications The selection of a filter depends on a number of factors including the contaminant ingression rate, the generation of contaminants in the system, the required fluid cleanliness, and the desired maintenance interval. A filter capable of controlling the fluid cleanliness to ISO 4406 Class 18/13 or better is recommended and may be located either on the inlet (suction filtration) or discharge (charge pressure filtration) side of the charge pump.

Charge Inlet Plug Construction Bore Plug

E100025 E

Housing without Filtration Adapter (Suction Filtration Only)

Filter capacity depends on desired maintenance levels. As a rough guide, a capacity in grams equal to twice the charge flow in gpm or 1/2 charge flow in l/min has been found to be satisfactory for many closed circuit systems.

Filtration Type Closed Circuit Suction Filtration or Open Circuit Return Line Filtration Systems Sharing a Reservoir with Other Gears, Clutches, or Cylinders Charge Pressure Filtration

Filter efficiency as measured by a "Beta" (β) ratio* should be as in the table at right.

See Sauer-Sundstrand publication BLN-9887 or 697581 and ATI-E 9201 for more information on filtration.

280 2 8

Plug

β-ratio β10 ≥ 2 β10 ≥ 10 β10 ≥ 10

* Filter ßx-ratio is a measure of filter efficiency defined by ISO 4572. It is defined as the ratio of the number of particles greater than a given size (x) upstream of the filter to number of particles greater than the same size downstream of the filter. The ßx-ratio applies to a specific particle size, measured in microns.

BOMAG

008 912 46

8.2

Vibration pump 42R 041

Series 42

Adjustments and Minor Repairs

4.17 Servo Piston Covers The servo piston cover can be removed to change the gasket or to inspect/change the control orifices for NFP or FNR controls (section 4.9).

Pump Neutral Ajustment Seal Lock Nut

1. On the right side (side “1”) of the pump, remove the pump “neutral” adjustment seal lock nut [13 mm Hex]. (Not necessary on side "2") 2. Remove the servo piston cover screws [Torx T30].

Servo Piston Cover Screw

Servo Piston Cover

Servo Piston Cover (Non-Feedback and Automotive controls only)

3. The left side (side "2") servo cover can be removed directly.

Pump "Neutral" Adjustment Screw

On the right side (side “1”) of the pump, the cover should be pushed away from the pump housing.

It is then necessary to turn the “neutral” adjustment screw [5 mm Hex] clockwise (inward) far enough for the servo cover to clear the nearby drain port. Then pull the cover away from the housing and turn the cover counterclockwise to disengage it from the adjustment screw.

Servo Piston Cover – Right Side (Side "1")

4. Remove the gasket.

Note: FNR and NFPE control orifice plugs are located here, see section 4.9 for more information.

5. Install new gasket.

6. On the right side (side "1"), screw the servo piston cover on the neutral adjustment screw. Then, while holding the cover, turn the neutral adjustment screw CCW to engage the cover to the screw threads.

Servo Piston Cover Screws Servo Piston Cover

7. Install servo piston cover screws (15-17 Nm (1113 ft•lbf)].

8. On the right side (side "1"), loosely install neutral adjustment seal lock nut. Perform pump neutral adjustment (section 4.2).

Servo Piston Cover – Left Side (Side "2") E100026 E

Servo Piston Cover Components

WARNING After installing the servo piston cover on right side (side “1”) of the pump, the pump “neutral” adjustment and control neutral adjustment MUST be performed before the vehicle / machine is put back into service.

CAUTION Performance of the above procedure may adjust the position of the displacement limiter somewhat.

008 912 46

BOMAG

2 9281

8.2

Vibration pump 42R 041

Series 42

Adjustments and Minor Repairs

4.18 Displacement Limiter Adjustment Displacement limiters can limit the maximum swashplate position. For Series 42 pumps, displacement limiters are available on one or both sides of the servo piston.

Displacement Limiter Seal Lock Nut

Adjustment of the displacement limiters should be performed on a test stand.

Servo Piston Cover

Displacement Limiter

WARNING Care should be taken in adjusting displacement limiters to avoid undesirable speed conditions. The limiter screw must have full thread engagement in the servo piston cover, and the seal lock nut must be retorqued after every adjustment to prevent unexpected changes in operating conditions and external leakage during unit operation.

Displacement Limiter – Right Side (Side "1") (Exploded View, No Need to Remove Limiter or Nut)

1. Mount pump on test stand.

2. Loosen displacement limiter seal lock nut [13 mm Hex]. Do not remove.

Displacement Limiter Seal Lock Nut

3. Adjust displacement limiter [4 mm Int. Hex].

Tighten the seal lock nut every time the pump is to be tested [20-26 Nm (15-19 ft•lbf)].

One full turn of the displacement limiter adjustment screw will change the displacement of the pump approximately as follows.

28 cc

3.6 cc/rev

0.22 in3/rev

41 cc

5.0 cc/rev

0.31 in3/rev

Displacement Limiter Servo Piston Cover

T000 026E

4. After reaching proper displacement tighten the seal lock nut [20-26 Nm (15-19 ft•lbf)].

If necessary, repeat procedure for displacement limiter on other side.

282 3 0

BOMAG

Displacement Limiter – Left Side (Side "2") (Exploded View, No Need to Remove Limiter or Nut) E100027 E

Displacement Limiters

008 912 46

8.2

Vibration pump 42R 041

Series 42

Exploded View Parts Drawings

5. Exploded View Parts Drawings 5.1

Shaft Options

F096 C020 C017 C018 C015

C005 C002 C003 C001 C015

F001 OR

C001

OR C001

E100028

008 912 46

BOMAG

3 1283

8.2

Vibration pump 42R 041

Series 42 5.2

Exploded View Parts Drawings

Filtration, Charge Relief, System Relief, and Loop Flushing

(F086) (F086A) (F043) (F043A) (F040) (F042)

(F040) (F042)

(F043) (F043A) OR

F043 F043A OR

F040 F042

OR

K001

K001 K005 F091 F091A

K001A K001B F030 K001C F030A

G040 G040A G041

G043 G042

K006 K007

F041 K008 K009 K010

G043 G042 G041 G040A G040 OR 045A G045

K002

J005 J002 J003

F062 F061 F063 F060A F060

(F060A) (F060)

F051

OR

F0511

F0512 F0513 F0514 F0515 F050A F050 OR

(F051) (F050A) (F050)

H005 H002 H003

(F091A)

F093

(F091)

F093A F093 F093A N002A N002

E100029

284 3 2

BOMAG

008 912 46

8.2

Vibration pump 42R 041

Series 42 5.3

Exploded View Parts Drawings

Charge Pump, Auxiliary Pads, and Servo Covers

L010 L010A

F020 F020A

G005

(G075)

G010 G015

G002

G020 (G021) G022

G065

G075

G030 F009

G023

G001

M001 OR (M001)

OR (G001) M005 M010A (M005) (M010A)

G036

M010 OR (G080)

(M010) M020 M025 (G001)

(G036)

G085

G090

(G090) (G036)

(G080) (G085)

E100030

008 912 46

BOMAG

3 3285

8.2

Vibration pump 42R 041

Series 42 5.4

Exploded View Parts Drawings

Control Options D039

D038 D037

D081

D003 D003A (D017)

D080

D082

D019 D016

D002

OR

OR D017

D056 D040 D010 D012

F035

E001

F035A

D070 OR

OR D011 D013 F036

D004

F035 F034

D081

D081 OR

D060

(F010)

F010

D090 D014 D015

D032A E100031

D032

286 3 4

BOMAG

008 912 46

8.2

Vibration pump 42R 041

Series 42

Exploded View Parts Drawings

Notes

008 912 46

BOMAG

3 5287

8.2

288

Vibration pump 42R 041

BOMAG

008 912 46

8.3

008 912 46

Travel drive series 51

BOMAG

289

8.3

290

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

291

8.3

292

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

293

8.3

294

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

295

8.3

296

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

297

8.3

298

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

299

8.3

300

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

301

8.3

302

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

303

8.3

304

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

305

8.3

306

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

307

8.3

308

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

309

8.3

310

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

311

8.3

312

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

313

8.3

314

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

315

8.3

316

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

317

8.3

318

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

319

8.3

320

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

321

8.3

322

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

323

8.3

324

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

325

8.3

326

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

327

8.3

328

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

329

8.3

330

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

331

8.3

332

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

333

8.3

334

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

335

8.3

336

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

337

8.3

338

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

339

8.3

340

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

341

8.3

342

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

343

8.3

344

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

345

8.3

346

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

347

8.3

348

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

349

8.3

350

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

351

8.3

352

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

353

8.3

354

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

355

8.3

356

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

357

8.3

358

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

359

8.3

360

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

361

8.3

362

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

363

8.3

364

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

365

8.3

366

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

367

8.3

368

Travel drive series 51

BOMAG

008 912 46

8.3

Travel drive series 51

008 912 46

BOMAG

369

8.3

370

Travel drive series 51

BOMAG

008 912 46

8.4

008 912 46

Transmission CR

BOMAG

371

8.4

372

Transmission CR

BOMAG

008 912 46

8.4

Transmission CR

008 912 46

BOMAG

373

8.4

374

Transmission CR

BOMAG

008 912 46

8.4

Transmission CR

008 912 46

BOMAG

375

8.4

376

Transmission CR

BOMAG

008 912 46

8.4

Transmission CR

008 912 46

BOMAG

377

8.4

378

Transmission CR

BOMAG

008 912 46

8.4

Transmission CR

008 912 46

BOMAG

379

8.4

380

Transmission CR

BOMAG

008 912 46

8.4

Transmission CR

008 912 46

BOMAG

381

8.4

382

Transmission CR

BOMAG

008 912 46

8.4

Transmission CR

008 912 46

BOMAG

383

8.4

384

Transmission CR

BOMAG

008 912 46

8.4

Transmission CR

008 912 46

BOMAG

385

8.4

386

Transmission CR

BOMAG

008 912 46

8.4

Transmission CR

008 912 46

BOMAG

387

8.4

388

Transmission CR

BOMAG

008 912 46

8.4

Transmission CR

008 912 46

BOMAG

389

8.4

390

Transmission CR

BOMAG

008 912 46

8.4

Transmission CR

008 912 46

BOMAG

391

8.4

392

Transmission CR

BOMAG

008 912 46

8.4

Transmission CR

008 912 46

BOMAG

393

8.4

394

Transmission CR

BOMAG

008 912 46

8.4

Transmission CR

008 912 46

BOMAG

395

8.4

396

Transmission CR

BOMAG

008 912 46

8.5

008 912 46

Brake system, axle

BOMAG

397

8.5

398

Brake system, axle

BOMAG

008 912 46

8.5

Brake system, axle

MOCAT2/310

ANNULAR BRAKING SYSTEM WITH SAFETY BRAKE FOR AXLES CATEGORIES 2 AND 3

SPICER CLARK-HURTH

maintenance and repair INSTRUCTION MANUAL MANUALE D'ISTRUZIONE E RIPARAZIONE WARTUNG UND REPARATURANLEITUNG MANUAL DE MANUTENCION Y REPARACION MANUAL ENTRETIEN ET REPARATION

008 912 46

BOMAG

399

8.5

Brake system, axle

PRINTED IN ITALY Copyright By DANA SPICER CLARK-HURTH Vietata la riproduzione anche parziale di testo ed illustrazioni Realizzazione a cura dell'Ufficio PubblicitaÁ e dell'Ufficio Post Vendita della DANA SPICER CLARK-HURTH Impaginazione: TEMAS s.r.l. - Gallarate (Va) Stampa: Febbraio 1998 (N.L. 7331) Data subject to change without notice. We decline all responsability for the use of non-original components, or accessories which have not been tested and submitted for approval.

Dati soggetti a modifiche senza impegno di preavviso. Si declina ogni responsabilitaÁ per l'utilizzo di componenti non originali o accessori non collaudatied apporvati.

AÈnderungen ohne vorherige AnkuÈndingung vorbehalten. Es wird jede Verantwortung fuÈr die Verwendung von Nichtoriginalteilen oder nicht abgenommenem und genehmigtem ZubehoÈr abgelehnt.

Los datos pueden ser modificados sin aviso previo. Se declina toda responsabilidad en el caso de uso de componentes no originales o bien de accesorios no ensayados y aprobados.

Le constructeur se reÂserve le droit d'apporter des modifications aÁ sa production, sans pour cela eÃtre tenu d'en donner preÂavis. Nous deÂclinons toute responsabilite pour l'utilisation de pieÁces non originales ou d'accessoires non testeÂs et homologueÂs.

400

BOMAG 2

008 912 46

8.5

Brake system, axle

INDEX

GB CATEGORY 2

HOW TO REMOVE THE ANNULAR UNIT AND THE DISK PUSH DEVICE................................................................................................................ 7 HOW TO INSTALL THE ANNULAR PISTON UNIT AND THE DISK PUSH DEVICE ................................................................................................... 9 AXLE MANUAL RELEASE .................................................................................................................................................................................... 12 ADJUSTMENTS AFTER EACH MANUAL RELEASE .............................................................................................................................................. 13

CATEGORY 3

HOW TO REMOVE THE ANNULAR UNIT AND THE DISK PUSH DEVICE.............................................................................................................. 17 HOW TO INSTALL THE ANNULAR PISTON UNIT AND THE DISK PUSH DEVICE ................................................................................................. 19 AXLE MANUAL RELEASE .................................................................................................................................................................................... 22 ADJUSTMENTS AFTER EACH MANUAL RELEASE .............................................................................................................................................. 23

INTRODUCTION

The efficiency and continued operation of mechanical units depend on constant, correct maintenance and also on efficient repair work, should there be a break-down or malfunction. The instructions contained in this manual have been based on a complete overhaul of the unit. However, it is up to the mechanic to decide whether or not it is necessary to assemble only individual components, when partial repair work is needed. The manual provides a quick and sure guide which, with the use of photographs and diagrams illustrating the various phases of the operations, allows accurate work to be performed.

All the information needed for correct disassembly, checks and assembly of each individual component is set out below.

In order to remove the differential unit from the vehicle, the manuals provided by the vehicle manufacturer should be consulted. In describing the following operations it is presumed that the unit has already been removed from the vehicle.

In particular, thoroughly check the condition of all moving parts (bearings, gears, crown wheel and pinion, shafts) and sealing parts (O-rings, oil shields) which are subject to major stress and wear. In any case, it is advisable to replace the seals every time a component is overhauled or repaired.

During assembly, the sealing rings must be lubricated on the sealing edge. In the case of the crown wheel and pinion, replacement of one component requires the replacement of the other one. During assembly, the prescribed pre-loading, backlash and torque of parts must be maintained.

IMPORTANT: In order to facilitate work and protect both working surfaces and operators, it is advisable to use proper equipment such as: trestles or supporting benches, plastic or copper hammers, appropriate levers, extractors and specific spanners or wrenches.

Before going on to disassemble the parts and drain the oil, it is best to thoroughly clean the unit, removing any encrusted or accumulated grease.

When no classification is given, disassembly and assembly operations are the same for all versions.

GB

INTRODUCTORY REMARKS: All the disassembled mechanical units should be thoroughly cleaned with appropriate products and restored or replaced if damage, wear, cracking or seizing have occurred.

008 912 46

BOMAG 3

CLASSIFICATION: This manual classifies units according to part numbers. For a correct interpretation, classification is indicated as follows: = up to the part number = from the part number on

SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of all specific tools required for maintenance and repair work can be found at the end of this manual ; spare parts may be ordered either from the vehicle manufacturer or directly from the Service Centers or Authorised Distributors of SPICER CLARK-HURTH.

401

8.5

402

Brake system, axle

BOMAG

008 912 46

8.5

Brake system, axle

008 912 46

5 BOMAG

403

8.5

404

Brake system, axle

6 BOMAG

008 912 46

8.5

Brake system, axle

HOW TO REMOVE THE ANNULAR UNIT AND THE DISK PUSH DEVICE

1

2 3 F1240218

a

GB

Remove screws (1) and nuts (2) from the side where the operation is being carried out.

NOTE. Leave two opposite screws on for safety.

F1240219

b

GB

Sling the arm (3), remove the two screws (1) which have been left on for safety and remove the arm.

CAUTION! Unloose screws in an alternate and even way.

4

5

5 4 F1240220

c

GB Remove the two check screws (4) from the cylinder (5).

CAUTION! Unloose screws in an alternate and even way.

F1240221

Extract the entire cylinder unit (5).

7

6 7

8

F1240222

GB

e

Remove the safety spring ring (6) from the Belleville washers (7).

008 912 46

d

GB

BOMAG 7

F1240223

f

GB Remove the Belleville washers (7) from the annular piston (8).

Note down direction for the assembly of the Belleville washers.

405

8.5

Brake system, axle

HOW TO REMOVE THE ANNULAR UNIT AND THE DISK PUSH DEVICE

8 5 10 9 8

F1240224

F1240225

a

GB

Use a plastic mallet to extract the annular piston (8) from the cylinder (5).

b

GB

Remove O-rings (9) and (10) from the piston (8); they have to be replaced each time the unit is disassembled.

12 11 11 12

11 F1240226

F1240227

c

GB

To check or replace the braking disks, remove the check screws (11) and the ways from the disk push device (12).

CAUTION! Unloose screws (11) evenly and in sequence.

GB

d

Remove the disk push device (12).

CAUTION! Note down direction for assembly.

12 11

F1240228

GB

e

GB

f

Check the state of springs (13) and ways of both screws (11) and disk push device (12).

406

BOMAG 8

008 912 46

8.5

Brake system, axle

HOW TO INSTALL THE ANNULAR PISTON UNIT AND THE DISK PUSH DEVICE

A

12 11

12

13 F1240227

F1240226

a

GB

Insert the springs (13) in the slot of the arm and position the disk push device (12) making sure that exhaust "A" is facing downwards.

b

GB

Fasten the disk push device (12) into place by turning the screws (11).

CAUTION! Turn the screws in sequence and at different stages.

8 11

11

10 9

F1240229

c

GB Lock the screws (11) using the dynamometric wrench.

Torque wrench setting : 15 ± 20 Nm.

F1240225

d

GB Fit O-rings (9) and (10) on the piston (8).

8 8

B

5

5 F1240230

GB

e

Lubricate the surfaces of the cylinder (5) and position the annular piston (8).

Adjust hole "B" positioning it on the axis between the two upper holes "C".

008 912 46

BOMAG 9

F1240231

f

GB

Using a push-tool and a plastic mallet, bring the piston (8) to the end of stroke inside the cylinder (5).

407

8.5

Brake system, axle

HOW TO INSTALL THE ANNULAR PISTON UNIT AND THE DISK PUSH DEVICE

C

6

8

7 8

5 F1240222

F1240221

a

GB

Fit the Belleville washers (7) and the safety spring ring (6) on the piston (8).

CAUTION! Check direction for the assembly of the washers.

GB

b

Fit the complete cylinder (5) on the studs.

CAUTION! Make sure that hole "B" of the annular piston (8) centres upper dowel "C".

4 4

4

4

F1240232

c

GB

Lubricate the screws (4) with grease and manually screw them down in the main body.

F1240233

GB

d

Alternately turn the screws (4) and tighten using a dynamometric wrench.

CAUTION! Keep the support planes parallel to each other.

Torque wrench setting : 86 ± 89 Nm

14

5 3 F1240234

GB

e

Fit the O-ring seal (14) on the cylinder (5), positioning it between the arm and the main body.

408

F1240219

GB

f

Lubricate the O-ring (14) and install the arm (3).

BOMAG 10

008 912 46

8.5

Brake system, axle

HOW TO INSTALL THE ANNULAR PISTON UNIT AND THE DISK PUSH DEVICE

2

5

3

3

2 1 1

F1240218

a

GB

Apply Loctite 242 on screws (1) and nuts (2).

Turn screws (1) and nuts (2) until the arm (3) is fastened on the cylinder (5).

Cross tighten in an even way.

F1240235

b

GB

Tighten the check screws (1) and nuts (2) on the arm (3) using a dynamometric wrench.

Cross tighten.

Torque wrench setting: 190 Nm

16

15

+

15

D1240020

F1240236

GB

c

IIntroduce a pressure of 14 ± 30 bar in the braking circuit.

Rotate the adjuster (15) anti-clockwise (±) so as to eliminate any slack between the braking disks.

Rotate up to a torque wrench setting of 8 ± 10 Nm.

GB

008 912 46

e

BOMAG 11

--

d

GB

Rotate the adjuster (15) clockwise (+) so as to obtain the prescribed slack.

NOTE. 1 turn of the adjuster yields a slack of 0.188 mm (0.75 mm slack = 4 turns; 1 mm slack = 5.5 turns).

Fit the safety catch (16).

f

GB

409

8.5

410

Brake system, axle

BOMAG

008 912 46

Brake system, axle

8.5

ADJUSTMENTS AFTER EACH MANUAL RELEASE

19

17

18

19,5 0+1

F1240239

a

GB

Remove the screws (18) complete with nuts (17) and seals (19).

Substitute seals, lubricate screws (18) using silicone-based grease and fit the units inside the arm (3).

F1240240

b

GB Adjust the screws (18) so that they protrude 19.5 arm.

1

mm from the

17 18

F1240237

GB

c

GB

d

GB

f

Lock into position by tightening the nuts (17).

CAUTION! Lock the nuts (17) holding the screws (18) into position.

Check the protrusion of the screws (18) once again.

GB

008 912 46

e

BOMAG 13

411

8.5

412

Brake system, axle

BOMAG 14 14

008 912 46

8.5

Brake system, axle

008 912 46

15 BOMAG

413

8.5

414

Brake system, axle

BOMAG 16

008 912 46

8.5

Brake system, axle

HOW TO REMOVE THE ANNULAR PISTON UNIT AND THE DISK PUSH DEVICE

1

3

2

F1240207

F1240208

a

GB

Remove screws (1) and nuts (2) from the side where the operation is being carried out.

NOTE. Leave two opposite screws on for safety.

b

GB

Sling the arm (3), remove the two screws (1) which have been left on for safety and remove the arm.

CAUTION! Unloose screws in an alternate and even way.

6

5 4

5

F1240209

F1240210

c

GB Remove the two check screws (4) from the cylinder (5).

CAUTION! Unloose screws in an alternate and even way.

d

GB

Extract the cylinder unit (5) and the Belleville washers (6).

Note down the direction for the assembly of the Belleville washers.

5 9

7

F1240212

GB

e

Use a plastic mallet to extract the annular piston (7) from the cylinder (5).

008 912 46

BOMAG 17

8

F1240213

f

GB

Remove O-rings (8) and (9) from the piston (7); they have to be replaced each time the unit is disassembled.

415

8.5

HOW TO REMOVE THE ANNULAR PISTON UNIT AND THE DISK PUSH DEVICE

Brake system, axle

11

10 10

11 F1240211

F1240215

a

GB

To check or replace the braking disks, remove the check screws (10) and the ways from the disk push device (11).

CAUTION! Unloose screws (10) evenly and in sequence.

GB

b

Pull out the disk push device (11).

CAUTION! Note down direction for assembly.

11

10

12

F1240214

GB

c

GB

d

GB

f

Check the state of springs (12), check screws (10) and ways of the disk push device (11).

GB

416

e

BOMAG 18

008 912 46

8.5

Brake system, axle

HOW TO INSTALL THE ANNULAR PISTON UNIT AND THE DISK PUSH DEVICE

A 11

11 10

12

3 F1240190

F1240191

a

GB

Insert the springs (12) in the slot of the arm and position the disk push device (11) making sure that exhausts "A" are facing downwards.

b

GB

Fasten the disk push device (11) into place by turning the screws (10).

CAUTION! Screw down in sequence and at different stages.

9 10

10

8

F1240192

c

GB Lock the screws (10) using the dynamometric wrench.

Torque wrench setting: 50 Nm

F1240213

d

GB Fit O-rings (8) and (9) on the piston (7).

7 B 7

5 F1240193

GB

e

Lubricate the surfaces of the cylinder (5) and position the annular piston (7).

008 912 46

BOMAG 19

F1240194

f

GB

Adjust exhaust "B" of the piston (7) centring it between the two holes of the lower screws.

417

8.5

HOW TO INSTALL THE ANNULAR PISTON UNIT AND THE DISK PUSH DEVICE

Brake system, axle

7

7 5 5 F1240195

F1240196

a

GB

Centre O-rings (8) and (9) in the cylinder (5) by applying manual pressure on the piston (7).

b

GB

Use a plastic mallet to bring the piston (7) to the end of stroke inside the cylinder (5).

6

6

5

5

F1240197

c

GB

Fit the complete cylinder (5) on the studs and insert the Belleville washers (6) in the piston.

CAUTION! Accurately check the orientation of the Belleville washers.

F1240198

d

GB

While holding the Belleville washers (6) centred, push the cylinder (5) until the washers are centred in the slots of both the cylinder and the main body of the axle.

5

4

4

4 F1240199

GB

e

Lubricate the screws (4) in the main body using grease and manually screw down.

418

F1240200

GB

f

Alternately turn the screws (4) and tighten using a dynamometric wrench.

CAUTION! Keep the support planes parallel to each other.

Torque wrench setting : 86 ± 89 Nm

BOMAG 20

008 912 46

8.5

Brake system, axle

HOW TO INSTALL THE ANNULAR PISTON UNIT AND THE DISK PUSH DEVICE

13

3

13

5 F1240201

F1240202

a

GB

Fit the O-ring seal (13) on the cylinder (5), positioning it between the arm and the main body.

b

GB Lubricate the seal (13) and install the arm (3).

1 2

1

2

F1240203

F1240207

GB

c

Tighten screws (1) and nuts (2) so as to fasten the arm (3) on the cylinder (5).

Cross tighten in an even way.

d

GB

Tighten check screws (1) and nuts (2) on the arm (3) by using a dynamometric wrench.

Cross tighten.

Torque wrench setting: 190 Nm

18

+ 17 17

-D1240017

F1240206

GB

e

Introduce a pressure of 14 ± 30 bar in the braking circuit.

Rotate the adjuster (17) anti-clockwise (±) so as to eliminate any slack between the braking disks.

Rotate up to a torque wrench setting of 8 ± 10 Nm.

008 912 46

BOMAG 21

f

GB

Rotate the adjuster (17) clockwise (+) so as to obtain the prescribed slack.

NOTE. 1 turn of the adjuster yields a slack of 0.25 mm (1 mm = 4 turns).

Fit the safety catch (18).

419

8.5

Brake system, axle

AXLE MANUAL RELEASE

6

11

15 14 14

16

D1240019

F1240205

a

GB

Unloose the nuts (15) of the screws (14) for the manual release of the braking units.

Draw the nuts back of about 8 mm.

15

GB

b

Turn the screws (14) until they are fastened on the disk push device (11).

14

F1240216

GB

c

GB

d

GB

f

Using a wrench, alternately turn the screws (14) one fourth turn at a time, so as to compress the Belleville washers (6) and release the braking disks.

GB

420

e

BOMAG 22

008 912 46