Fayat Group BOMAG BW 27 RH-4i User manual

Service - Manual
Catalogue number.
008 922 89 09/2014
BW 27 RH-4i
S/N 101 538 12 .... S/N 861 538 23 .... / S/N 861 538 24 .... / S/N 861 538 25 ....
Rubber tire roller

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Table of Contents
BOMAG 3008 922 89
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 28
Pneumatic tires rollers 33
2.1 Rubber tire roller 34
Technical data 37
3.1 Technical data 38
Maintenance 43
4.1 General notes on maintenance 44
4.2 Fuels and lubricants 45
4.3 Table of fuels and lubricants 48
4.4 Running-in instructions 49
4.5 Maintenance table 50
Electrics 53
5.1 Overview 54
5.2 Service the battery, check the main battery switch 57
5.3 Main battery switch 58
5.4 Starting with jump wires 59
5.5 Level sensor in diesel tank (R03) 59
5.6 Differential pressure switches hydraulic oil filter, B21and B22 60
5.7 Brake oil temperature switch, B148 60
5.8 Brake pressure switches, B12 and B102 61
5.9 Float switch in water tank, B33 62
5.10 Air filter vacuum switch 63
5.11 Description of indicators and control elements 64
5.12 Fuse assignment 67
5.13 Overview of electric components 71
Electronic modules 87
6.1 Module description A04 89
6.2 Electric module A108 99
Module description A100 103
7.1 Steering column locking module, A100 104
Speedometer Module 107
8.1 Speedometer module 108
Engine electrics 111
9.1 EMR4 system overview 113
9.2 EMR4 system components 117
9.3 Exhaust gas after-treatment 119
9.4 Fuel control unit (FCU) 122
9.5 Injector 123
9.6 Crankshaft speed sensor 124
9.7 Camshaft speed sensor 124
9.8 Rail pressure sensor 125
9.9 EMR coolant temperature sensor 127
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Table of Contents
BOMAG4008 922 89
9.10 Fuel pressure sensor 127
9.11 Charge air temperature - charge air pressure sensor 128
9.12 Oil pressure sensor 128
9.13 Sensor, water in fuel 130
9.14 Fuel pre-heating 131
9.15 Heating flange on engine 131
9.16 Charge control light, operating hour meter 132
9.17 System faults per flashing code 133
List of EMR4 fault codes 137
10.1 List of EMR4 fault codes 139
Engine 243
11.1 Overview 244
11.2 Diesel engine 246
11.3 Engine description TCD 4.1 247
11.4 Lubrication oil circuit TCD 4.1 / 6.1 251
11.5 Coolant circuit TCD 4.1 / 6.1 252
11.6 Common Rail System (CRS) TCD 4.1 / 6.1 254
11.7 Exhaust gas after-treatment 261
11.8 Adjust the valve clearance 264
11.9 Check the engine oil level 265
11.10 Changing engine oil and oil filter cartridge 266
11.11 Check the coolant level 267
11.12 Change the coolant 267
11.13 Check the anti-freeze concentration and the condition of the coolant 269
11.14 Clean the cooling fins on engine and hydraulic oil cooler 270
11.15 Check, clean the water separator 270
11.16 Replacing the fuel filter cartridge 271
11.17 Change the fuel filter, bleed the fuel system 272
11.18 Checking the ribbed V-belt 273
11.19 Replacing ribbed V-belt and idler pulley 274
11.20 Air filter maintenance 274
11.21 Check the engine mounts 276
11.22 Engine problems 277
Hydraulics 281
12.1 Overview 282
12.2 Hydraulic circuit 284
12.3 Travel pumps, A4VG105 DA 286
12.4 Troubleshooting axial piston pumps 295
12.5 External gear pumps 298
12.6 Travel motor, A6VM 107HA2R1 300
12.7 Trouble shooting, variable displacement axial piston motor 303
12.8 Steering valve 305
12.9 Travel circuit 306
12.10 Steering circuit 312
12.11 Cooling and cross-flushing of the brake housing 315
12.12 Edge cutter 317
12.13 Check the hydraulic oil level 319
12.14 Replace hydraulic oil and breather filter. 320
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Table of Contents
BOMAG 5008 922 89
12.15 Replace hydraulic oil filter 321
12.16 Replacing the bypass filter 322
Brake 323
13.1 Overview 324
13.2 Brake system 325
13.3 Stopping the machine, operating the parking brake 332
13.4 Driving the machine / braking the machine 333
13.5 Multi-disc brake, function test 336
13.6 Towing in case of an engine failure 337
Pneumatics 339
14.1 Overview 340
14.2 Pneumatic system 341
14.3 Operating the tire inflation system 349
14.4 Draining the air pressure vessel 350
14.5 Change the air drier for the brake system 351
14.6 Check the supply lines for the compressor 351
Water sprinkling system 353
15.1 Overview 354
15.2 Operating the pressure sprinkler system 355
15.3 Service the water sprinkling system 355
15.4 Maintenance in case of frost 356
Air conditioning system 359
16.1 Overview 360
16.2 Physical basics 362
16.3 Refrigerant R134a 365
16.4 Compressor oil / refrigeration oil 366
16.5 Working principle of the air conditioning system 367
16.6 Monitoring devices 367
16.7 Description of components 368
16.8 Measuring the compressor oil level 374
16.9 Checking the magnetic clutch 374
16.10 Inspection and maintenance work 375
16.11 Servicing the V-belt for the refrigerant compressor 376
16.12 Service the air conditioning 377
16.13 Drying and evacuation 379
16.14 Emptying in case of repair 380
16.15 Leak test 380
16.16 Filling instructions 381
16.17 Trouble shooting in refrigerant circuit, basic principles 383
16.18 Trouble shooting, refrigerant circuit diagram 387
16.19 Trouble shooting procedure 388
16.20 Steam table for R134a 398
Replacing the cab window panes 403
17.1 Assembly of window panes 404
17.2 Special tools, cabin windows 405
17.3 Auxiliary materials 406
17.4 Removing and installing the window pane 408
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Table of Contents
BOMAG6008 922 89
Front axle 413
18.1 Repair overview for front axle 414
18.2 Dismantling the front axle 415
18.3 Assembling the front axle 422
Suppliers documentation 445
19.1 Travel pump 447
19.2 Travel motor 489
19.3 Travel gear 543
19.4 Steering valve 617
Circuit diagrams 651
20.1 Hydraulic diagram 538 110 00 653
20.2 Pneumatic diagram 538 120 00 657
20.3 Wiring diagram 216 661
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BOMAG 7008 922 89
1 General
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1.1 Introduction
BOMAG8008 922 89
1.1 Introduction
This manual addresses the professionally qualified
personnel or the after sales service of BOMAG, and
should be of help and assistance in correct and effi-
cient repair and maintenance work.
This manual describes the disassembly, dismantling,
assembly, installation and repair of components and
assemblies. The repair of components and assem-
blies is only described as this makes sense under due
consideration of working means and spare parts sup-
ply.
Documentation
For the BOMAG machines described in this manual
the following documentation is additionally available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Service information
4 Fundamental electrics
Use only genuine BOMAG spare parts.
Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
This manual is not subject of an updating service; for
this reason we would like to draw your attention to our
additional "Technical Service Bulletins".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this manual must not
be reproduced and distributed, nor must they be used
for the purpose of competition. All rights according to
the copyright law remain expressly reserved.
!Danger
These safety regulations must be read and ap-
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
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Safety regulations
BOMAG 9008 922 89
1.2
1.2 Safety regulations
Important notes
These safety regulations must be read and ap-
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
Repair work shall only performed by appropriately
trained personnel or by the after sales service of
BOMAG.
Workshop equipment and facilities as well as the
use and waste disposal of fuels and lubricants,
cleaning agents and solvent as well as gases and
chemicals are subject to legal regulations, which
are intended to provide a minimum on safety. It is
obviously your own responsibility to know and
adhere to these regulations.
This manual contains headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to inform about and avoid dan-
gers to persons, property and the environment.
i
Note
Paragraphs marked like this contain technical infor-
mation for the optimaleconomical use of the machine.
!
Caution
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.
!Danger
Paragraphs marked like this highlight possible
dangers for persons.
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
lFor repair and maintenance work move the ma-
chine on a firm base and shut it down.
lAlways secure the machine against unintended roll-
ing.
lSecure the engine reliably against unintentional
starting.
lMark a defective machine and a machine under re-
pair by attaching a clearly visible warning label to
the dashboard.
lBlock the articulated joint with the articulation lock.
lUse protective clothes like hard hat, safety boots
and gloves.
lKeep unauthorized persons away from the machine
during repair work.
lTools, lifting gear, lifting tackle, supports and other
auxiliary equipment must be fully functional and in
safe condition.
lUse only safe and approved lifting gear of sufficient
load bearing capacity to remove and install parts or
components from and to the machine.
lDo not use easily inflammable or harmful substanc-
es, such as gasoline or paint thinners for cleaning.
lDo not smoke or use open fire and avoid sparks
when cleaning or repairing a tank.
lWhen performing welding work strictly comply with
the respective welding instructions.
Transport work with cranes and lifting
tackle
i
Note
Cranes must only be operated by instructed persons
who had been trained in handling cranes.
lFollow the operating instructions of the manufactur-
er when working with cranes.
lFollow the operating instructions of the operator
when working with cranes.
lAlways comply with the applicable accident preven-
tion instructions when working with cranes and lift-
ing tackle.
Precautions and codes of conduct for
welding work
Welding work must only be carried out by properly
trained personnel.
!Danger
Electric shock!
Sparks, fire hazard, burning of skin!
Infrared or ultraviolet radiation (arc), flashing of
eyes!
Health hazard caused by welding work on highly
alloyed work pieces, metal coatings, paint coat-
ings, plastic coatings, oil containing dirt deposits,
grease or solvent residues, etc.!
lCheck welding equipment and cables for damage
before use (also the validity of inspection stickers).
lEnsure good conductivity between ground cable
and workpiece, avoid joints and bearings.
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1.2 Safety regulations
BOMAG10 008 922 89
lStart the extraction fan before starting work and
guide with the progressing work as required.
lAlways isolate the burner when laying it down (re-
move possible electrode residues).
lProtect cables from being damaged, use cables
with insulated couplings.
lEnsure sufficient fire protection, keep a fire extin-
guisher at hand.
lWelding work in areas where there is a risk of fire or
explosion, must only be carried out with welding
permission.
lRemove any combustible materials from the weld-
ing area or cover such items appropriately.
lName a fire watch during and after welding work.
lPlace welding rod holders and inert gas welding
guns only on properly insulated bases.
lPlace the inert gas bottles in a safe place and se-
cure them against falling over.
lUse a protective screen or hand shield with welding
filter, wear welding gloves and clothes.
lSwitch the welding unit off before connecting weld-
ing cables.
lCheck electrode holders and electric cables at reg-
ular intervals.
Behaviour in case of faults
lIn case of faults on the welding unit switch of the
welding unit immediately and have it repaired by ex-
pert personnel.
lIn case of failure of the extraction system switch the
system off and have it repaired by expert personnel.
Maintenance; waste disposal
lReplace damaged insulating jaws and welding rod
holders immediately.
lReplace the welding wire reels only in de-energized
state.
What to do in case of accidents; First Aid
lKeep calm.
lCall first air helpers.
lReport the accident.
lIn case of an electric accident: Interrupt the power
supply and remove the injured person from the
electric circuit. If breathing and heart have stopped
apply reactivation measures and call for an emer-
gency doctor.
Operation of high-voltage systems
i
Note
The rules and statutory regulations valid in the corre-
sponding do apply in addition to the notes given here.
!
Caution
The high-voltage system must only be operated
and serviced by qualified and authorized person-
nel.
Before starting operation the operator must check
the proper condition of the system.
!Danger
Possibility of injury or even death caused by elec-
tric shock:
lif persons come into contact with live parts,
lin case of faulty insulation of live parts,
linadequate, unsuitable insulation,
lif melted parts flake off in case of short circuits.
Old oils
Prolonged and repetitive contact with mineral oils will
remove the natural greases from the skin and causes
dryness, irritation and dermatitis. Moreover, used en-
gine oils contain potentially hazardous contaminants,
which could cause skin cancer. Appropriate skin pro-
tection agents and washing facilities must therefore
be provided.
lWear protective clothes and safety gloves, if possi-
ble.
lIf there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or
full face visor; a facility suitable for rinsing the eyes
should also be available.
lAvoid longer and repetitive contacts with oils. In
case of open incisionsand injuries seek medical ad-
vice immediately.
lApply protective cream before starting work, so that
oil can be easier removed from the skin.
lWash affected skin areas with water and soap (skin
cleansers and nail brushes will help). Lanolin con-
taining agents will replace natural skin oils that were
lost.
lDo not use gasoline, kerosene, diesel, thinner or
solvents to wash the skin.
lDo not put oil soaked cloths into your pockets.
lAvoid clothes getting soiled by oil.
lOveralls must be washed at regular intervals. Dis-
pose of non-washable clothes environmentally.
lIf possible degrease components before handling.
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Safety regulations
BOMAG 11008 922 89
1.2
Environment
It is strictly prohibited to drain off oil into the soil,
the sewer system or into natural waters. Old oil
must be disposed of according to applicable envi-
ronmental regulations. If in doubt you should con-
sult your local authorities.
Hydraulics
lAlways relieve the pressure in the hydraulic system
before disconnecting any lines. Hydraulic oil escap-
ing under pressure can penetrate the skin and
cause severe injury.
lAlways make sure that all screw fittings have been
tightened properly and that hoses and pipes are in
mint condition before pressurizing the system
again.
lHydraulic 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
injured by hydraulic oil escaping under pressure
consult a physician immediately, as otherwise this
may cause severe infections.
lDo not step in front of or behind the drums, wheels
or crawler tracks when performing adjustment work
in the hydraulic system while the engine is running.
Block drums, wheels or crawler tracks with wedges.
Reattach all guards and safety installations after
all work has been completed.
Environment
It is strictly prohibited to drain off oil into the soil,
the sewer system or into natural waters. Oil oil
must be disposed of according to applicable envi-
ronmental regulations. If in doubt you should con-
sult your local authorities.
Fuels
!Danger
Repair work shall only performed by appropriately
trained personnel or by the after sales service of
BOMAG.
Follow the valid accident prevention instructions when
handling fuels.
The following notes refer to general safety precau-
tions for danger free handling of fuel.
Fuel vapours not only are easily inflammable, but also
highly explosive inside closed rooms and toxic; dilu-
tion with air creates an easily inflammable mixture.
The vapours are heavier than air and therefore sink
down to the ground. Inside a workshop they may eas-
ily become distributed by draft. Even the smallest por-
tion of spilled fuel is therefore potentially dangerous.
lFire extinguishers charged with FOAM, CO2GAS
or POWDER must be available wherever fuel is
stored, filled in, drained off, or where work on fuel
systems is performed.
lThe vehicle battery must always be disconnected,
BEFORE work in the fuel system is started. Do not
disconnect the battery while working on the fuel
system. Sparks could cause explosion of the fuel
fumes.
lWherever fuel is stored, filled, drained off or where
work on fuel systems is carried out, all potential ig-
nition sources must be extinguished or removed.
Search lights must be fire proof and well protected
against possible contact with running out fuel.
Hot fuels
Please apply the following measures before draining
of fuel to prepare for repair work:
lAllow the fuel to cool down, to prevent any contact
with a hot fluid.
lVent the system, by removing the filler cap in a well
ventilated area. Screw the filler cap back on, until
the tank is finally emptied.
Synthetic rubber
Many O-rings, hoses, etc. are made of synthetic ma-
terial, a so-called fluorocarbon elastomer. Under nor-
mal operating conditions this material is safe and does
not impose any danger to health.
However, if this material becomes damaged by fire or
extreme heat, it may decompose and form highly
caustic hydrofluoric acid, which can cause severe
burns in contact with skin.
lIf the material is in such a state it must only be
touched with special protective gloves. The protec-
tive gloves must be disposed of according to appli-
cable environmental regulations immediately after
use.
lIf the material has contacted the skin despite these
measures, take off the soiled clothes and seek
medical advice immediately. In the meantime cool
and wash the affected area of skin over a sufficient
time with cold water or lime water.
Poisonous substances
Some of the fluids and substances used are toxic and
must under no circumstances be consumed.
Skin contact, especially with open wounds, must be
avoided.
These fluids and substances are, amongst others,
anti-freeze agents, hydraulic oils, fuels, washing addi-
tives, refrigerants, lubricants and various bonding
agents.

1.2 Safety regulations
BOMAG12 008 922 89
Engine
!Danger
Do not work on the fuel system while the engine is
running. (Danger to life!)
Once the engine has stopped wait approx. 5 min-
utes for the system to depressurize. The systems
are under high pressure. (Danger to life!)
Keep out of the danger zone during the initial test
rung. Danger caused by high pressure in case of
leaks. (Danger to life!)
When performing work on the fuel system make
sure that the engine cannot be started uninten-
tionally during repair work. (Danger to life!)
lMaintenance and cleaning work on the engine must
only be performed with the engine stopped and
cooled down. Make sure that the electric system is
switched off and sufficiently secured against being
switched on again (e.g. pull off ignition key, attach a
warning label).
lObserve the accident prevention regulations for
electric systems (e.g. -VDE-0100/-0101/-0104/-
0105 Electric precautions against dangerous con-
tact voltages).
lCover all electric components properly before wet
cleaning.
Air conditioning system
!
Caution
Work on air conditioning systems must only be
carried out by persons who can provide sufficient
evidence of their ability (proof of professionalism)
and only with the appropriate technical equip-
ment.
lAlways wear goggles and protective clothing when
performing maintenance and repair work on air con-
ditioning systems. Refrigerant withdraws heat from
the environment when evaporating, which can
cause injury by freezing when in contact with skin
(boiling point of R134a -26,5 °C at normal pres-
sure).
lPerform maintenance and repair work on air condi-
tioning systems only in well ventilated rooms! Es-
caping refrigerant vapours will mix with the ambient
air and displace the oxygen required for breathing
(danger of suffocating).
lSmoking is prohibited when performing mainte-
nance and repair work on air conditioning systems!
Toxic breakdown products may be generated if re-
frigerant comes into contact with heat.
lRefrigerant should always be extracted and re-
moved by flushing with nitrogen before starting
welding or soldering work near components of the
air conditioning system. The development of heat
may cause the refrigerant to develop toxic and high-
ly corrosive breakdown products.
lPungent smell! The toxic substances, which are re-
sponsible for the pungent smell, must not be in-
haled, since this may cause damage to the
respiratory system, the lung and other organs. Ex-
tract toxic breakdown products with a suitable ex-
traction system (workshop extraction system).
lWhen blowing out components with compressed air
and when flushing with nitrogen the gas mixture es-
caping from the components must be extracted via
suitable extraction facilities (workshop extraction
systems).
Handling pressure vessels
lSince the fluid container is pressurized, the manu-
facture and testing of these pressure vessels is gov-
erned by the pressure vessel directive. The
pressure vessels must be repetitively tested by an
expert as specified in TRB 532 Inspection by Ex-
perts, Repetitive Tests. In this case periodically re-
curring inspections consist of external
examinations, normally on containers in operation.
In combination with the inspection, the refrigerant
collector must be visually examined two times per
year. Special attention must thereby be paid to
signs of corrosion and mechanical damage. If the
container is in no good condition, it should be re-
placed for safety reasons, in order to protect the op-
erator or third parties against the dangers when
handling or operating pressure vessels.
lSecure pressure vessels against tipping over or roll-
ing away.
lDo not throw pressure vessels! Pressure vessels
may thereby be deformed to such an extent, that
they will crack. The sudden evaporationand escape
of refrigerant releases excessive forces. This ap-
plies also when snapping off valves on bottles. Bot-
tles must therefore only be transported with the
safety caps properly installed.
lRefrigerant bottles must never be placed near heat-
ing radiators. Higher temperatures will cause higher
pressures, whereby the permissible pressure of the
vessel may be exceeded.
lDo not heat up refrigerant bottles with an open
flame. Excessive temperatures can damage the
material and cause the decomposition of refriger-
ant.
lDo not overfill refrigerant bottles, since any temper-
ature increase will cause enormous pressures.
Environment
It is strictly prohibited to release refrigerant into
the atmosphere during operation, maintenance

Safety regulations
BOMAG 13008 922 89
1.2
and repair work and when taking air conditioning
systems into or out of service.
Battery
lAlways wear goggles and protective clothing to
service or clean batteries! Battery acid can cause
severe injury by cauterization when coming in con-
tact with skin.
lWork only well ventilated rooms (formation of oxy-
hydrogen gas).
lDo not lean over the battery while it is under load,
being charged or tested (danger of explosion).
lKeep ignition sources away from the battery. Burn-
ing cigarettes, flames or sparks can cause explo-
sion of the battery
lUse battery chargers etc. only in strict compliance
with the operating instructions.
lAfter an accident with acid flush the skin with a suf-
ficient amount of water and seek medical advice.
lDo not allow children access to batteries.
lWhen mixing battery fluid always pour acid into wa-
ter, never vice-versa.
Special safety regulations
lUse only genuine BOMAG spare parts for repair
and maintenance work. Genuine spare parts and
original accessories were specially developed, test-
ed and approved for the machine.
lThe installation and use of non-genuine spare parts
or non-genuine accessories may therefore have an
adverse effect on the specific characteristics of the
machine and thereby impair the active and/or pas-
sive driving safety. The manufacturer explicitly ex-
cludes any liability for damage caused by the use of
non-original parts or accessories.
lUnauthorized changes to the machine are prohibit-
ed for safety reasons.
lDo not perform any cleaning work while the engine
is running.
lIf tests on the articulated joint need to be performed
with the engine running, do not stand in the articu-
lation area of the machine (danger of crushing!).
lIf tests must be performed with the engine running
do not touch rotating parts of the engine (danger of
injury!).
lAlways ensure an adequate supply of fresh air
when starting in closed rooms. Exhaust gases are
highly dangerous!
lRefuel only with the engineshut down. Ensure strict
cleanliness and do not spill any fuel.
lAlways ensure an adequate supply of fresh air
when refuelling in closed rooms.
lDispose of used filters in accordance with applica-
ble environmental regulations.
lWhen performing repair and maintenance work col-
lect oils and fuels in suitable containers anddispose
of in compliance with applicable environmental reg-
ulations.
lDo not heat up oils higher than 160 °C becausethey
may ignite.
lWipe off spilled or overflown oil using suitable
cleaning means and dispose of in accordance with
applicable environmental regulations.
lDispose of old batteries according to applicable en-
vironmental regulations.
lThere is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature! Allow
engine and hydraulic system to cool down to a suf-
ficient level.
lDo not exceed the max. permissible tire pressure.

1.3 General repair instructions
BOMAG14 008 922 89
1.3 General repair instructions
General
lBefore removing or disassembling parts, assem-
blies, components or hoses mark these parts for
easier assembly.
lBefore assembling and installing parts, assemblies
or components oil or grease all movable parts or
surfaces as required and in compliance with the
compatibility of materials.
Electrics
General
Due to the fast technical development electric and
electronic vehicle systems become more intelligent
and more comprehensive day by day, and can hardly
be dispensed with in hydraulic and mechanical vehicle
systems.
Diagnostics according to plan
Well structured trouble shooting procedures can save
time and money.
Random tests have revealed that purely electronic
components or control units only very rarely are the
actual cause of failures:
lIn approx. 10 % of the examined cases the prob-
lems were caused by control units.
lIn approx. 15 % sensors and actuators were the
cause of the problems.
By far the highest proportion of all faults could be
traced back to wiring and connections (plugs, etc.).
General:
lBefore changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Knowledge in basic electrics is re-
quired for this purpose. If a fault was diagnosed
without having pulled the plug of the control unit or
inspected the wiring, this should be done before
changing any parts.
lCheck for good cable and ground contacts, there-
fore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
lAlways use the machine related wiring diagram for
testing. If one or more faults were detected, these
should be corrected immediately.
lDo not disconnect or connect battery or generator
while the engine is running.
lDo not operate the main battery switch under load.
lDo not use jump leads after thebattery has been re-
moved.
lSensors and electric actuators on control units must
never be connected individually or between exter-
nal power sources for the purpose of testing, but
only in connection with the control unit in question.
lIt is not permitted to pull plugs off while the voltage
supply is switched on (terminal 15 "ON")! Switch the
voltage supply "OFF" first and pull out the plug.
lEven with an existing polarity reversal protection in-
correct polarity must be strictly avoided. Incorrect
polarity can cause damage to control units!

General repair instructions
BOMAG 15008 922 89
1.3
lPlug-in connectors on control units are only dust
and water tight if the mating connector is plugged
on! Control units must be protected against spray
water, until the mating connector is finally plugged
on!
lUnauthorized opening of control electronics (Micro-
controller MC), modifications or repairs in the wiring
can cause severe malfunctions.
lDo not use any radio equipment or mobile phones
in the vehicle cab without a proper aerial or in the vi-
cinity of the control electronics!
Electrics and welding
!
Caution
Before starting welding work you should discon-
nect the negative battery pole or interrupt the
electric circuit with the main battery switch, dis-
connect the generator and pull the plugs off all
control units in order to protect the electrical sys-
tem of the machine.
lDisconnect the minus pole of thebattery or interrupt
the electric circuit with the main battery switch.
lIsolate the generator and all control units from the
electric circuit.
lAlways fasten the earth clamp of the welding unit in
the immediate vicinity of the welding location.
lWhen choosing the location for the earth clamp
make sure that the welding current will not pass
through joints or bearings.
Battery
Rules for the handling of batteries
When removing a battery always disconnect the mi-
nus pole before the plus pole. When installing the bat-
teryconnectthe minus poleafter theplus poleto avoid
short circuits.
Fasten the terminal clamps with a little force as possi-
ble.
Always keep battery poles and terminal clams clean to
avoid high transition resistances when starting and
the related development of heat.
Make sure the battery is properly fastened in the vehi-
cle.

1.3 General repair instructions
BOMAG16 008 922 89
Generator
Before removing the generator you must disconnect
the ground cable from the minus pole of the battery
while the ignition is switched off. Do not disconnect
the generator while the engine is running, because
this may cause extremely high voltage peaks in the
vehicle wiring system ("Load Dump"), which could
possibly damage control units, radios or other elec-
tronic equipment.
When disassembling thebattery cable, the B+-nut un-
derneath on the generator side may also be loosened.
This nut must in this case be retightened.
When connecting e.g. the battery cable to the terminal
of the generator you must make sure that the polarity
is correct (generator B+ to the + pole of the battery).
Mixing up the polarities by mistake causes short cir-
cuit and damage to the rectifier elements - the gener-
ator will be out of function.
The generator can only be operated with the battery
connected. Under special conditions emergency op-
eration without battery is permitted, the lifetime of the
generator is in such cases especially limited.
Plus and minus cables must be disconnected during
rapid charging of the battery or electric welding on the
vehicle.
When cleaning the generator with a steam or water jet
make sure not to direct the steam or water jet directly
on or into the generator openings or ball bearings. Af-
ter cleaning the generator should be operated for
about 1 - 2 minutes to remove any deposits of water
from the generator.
Starter motor
So-called jump starting (using an additional external
battery) without the battery connected is dangerous.
When disconnecting the cables from the poles high in-
ductivities (arcs, voltage peaks) may occur and de-
stroy the electrical installation.
For purposes like e.g. purging the fuel systems, start-
ers may be operated for maximum 1 minute without
interruption. Then you should wait for at least 30 min-
utes (cooling down) until trying again. During the 1
minute starting period this process should not be inter-
rupted.
Starter motors must not be cleaned with high pressure
steam cleaning equipment.
The contacts on starter terminals 30, 45, 50 must be
protected against unintended shorting (jump protec-
tion).
When replacing the starter the ring gear on the engine
flywheel must be checked for damage and its number
of teeth - if necessary replace the ring gear.
Always disconnect the battery before starting assem-
bly work in the starter area of the engine or on the
starter itself.

General repair instructions
BOMAG 17008 922 89
1.3
Hydraulic system
!
Caution
Repair work on hydraulic elements shall only per-
formed by appropriately trained personnel or by
the after sales service of BOMAG.
Please note
i
Note
Cleanliness is of utmost importance. Dirt and other
contaminations must strictly be kept out of the system.
lConnections and screw fittings, filler neck covers
and their immediate surrounding areas must be
cleaned before removal.
lBefore loosening hoses, pipe lines etc. relieve all
pressure from the system.
lDuring repair work keep all openings closed with
clean plastic plugs and caps.
lNever run pumps, motors and engines without oil or
hydraulic oil.
lWhen cleaning hydraulic components take care not
to damage any fine machine surfaces.
lChemical and rubber soluble cleansing agents may
only be used to clean metal parts. Do not let such
substances come in contact with rubber parts.
lRinse of cleaned parts thoroughly, dry them with
compressed air and apply anti-corrosion oil immedi-
ately. Do not install parts that show traces of corro-
sion.
lAvoid the formation of rust on fine machined caused
by hand sweat.
lUse new O-rings or seal rings for reassembly.
lUse only hydraulic oil as sliding agent when reas-
sembling. Do not use any grease!
lUse only the specified pressure gauges. Risk of
damaging thepressure gauges under too high pres-
sure.
lCheck the hydraulic oil level before and after the
work.
lFill in only clean oil as specified in the maintenance
instructions.
lCheck the hydraulic system for leaks, if necessary
find and rectify the cause.
lBefore taking new hydraulic components into oper-
ation fill these with hydraulic oil as specified in the
operating and maintenance instructions.
lAfter changing a hydraulic component thoroughly
flush, refill and bleed the complete hydraulic sys-
tem.
lPerform measurements at operating temperature of
the hydraulic oil (approx. 40 ¯C).
lAfter changing a component perform a high and
charge pressure test, if necessary check the speed
of the exciter shaft.
lThe operating pressure of the exciter shaft to a
great extent depends on the base under the vibrat-
ingdrum. On hardground placethe drums on a suit-
able base and check the drum pressure. Do not
activate the vibration on a hard, concreted base,
danger of bearing damage.
lAfter 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 sys-
tem depressurized.
Before commissioning
lFill the housings of hydraulic pumps and motors
with hydraulic oil. Use only hydraulic oils according
to the specification in the maintenance instructions.
lAfter changing a component flush the hydraulic sys-
tem as described in the flushing instructions.
Taking into operation
lBleed the hydraulic circuits.
lStart up the hydraulic system without load.
lCheck the hydraulic oil level in the tank, if neces-
sary top up with hydraulic oil as specified in the op-
erating and maintenance instructions or drain oil off
into a suitable container.
After taking into operation
lCheck fittings and flanges for leaks.
lAfter each repair check all adjustment data, system
pressures, rotational speeds and nominal values in
the hydraulic system, adjust if necessary.
lDo not adjust pressure relief valves and control
valves to values above their specified values.

1.3 General repair instructions
BOMAG18 008 922 89
Air conditioning system
Chemicals/ozone layer regulation
The chemicals/ozone layer regulation, which became
effective on 01.12.2006, supplements the still directly
applicable regulation (EG) no. 2037/2000 from
29.06.2000 concerning substances, which cause de-
composition of the ozone layer and at the same time
replaces the previously valid German CFC-halon
0prohibition from 06.05.1991.
Work on air conditioning systems must only be carried
out by persons who:
lhave proven to have sufficient expert knowledge,
lhave the necessary equipment to undertake such
tasks,
lare reliable and
lare not any directives regardingtheiractivities when
carrying out inspection and maintenance work acc.
to § 4 section 2 of the chemical/ozone layer regula-
tion.
The inspection and maintenance tasks, including leak
tests and possible repair activities, must be recorded
in the operating instructions together with information
about the refrigerant quantities used and regained,
whereby the operator is obliged to keep these records
over a period of at least five years.
i
Note
Cleanliness is of utmost importance. Dirt and other
contaminations must strictly be kept out of the system.
lTools used on refrigeration circuits must be of ex-
cellent condition, thus to avoid the damage of any
connections.
lDuring repairs on refrigerant lines and components,
these must be kept closed, as far as this is possible,
to prevent the system from being contaminated by
air, moisture and dirt. The operational safety of the
system can only be assured as long as all compo-
nents in the refrigerant circuit are kept internally
clean and dry.
lConnections, screw fittingsandtheir immediatesur-
rounding areas must be cleaned before removal.
lBefore loosening hoses, pipe lines etc. relieve all
pressure from the system.
lDuring repair work keep all openings closed with
clean plastic plugs and caps.
lAll parts to be reused should be cleaned with a
gasoline free solvent and blow-dried with clean
compressed air or dried with a lint-free cloth.
lBefore opening all components should have
warmed up to ambient temperature, to avoid that
damp air is drawn into the component by the differ-
ence in temperatures.
lDamaged or leaking parts of the air conditioning
must not be repaired by welding or soldering, but
must generally be replaced.
lDo not fill up refrigerant, but extract existing refrig-
erant and refill the system.
lDifferent types of refrigerant must not be mixed.
Only the refrigerant specified for the corresponding
air conditioning system must be used.
lRefrigerant circuits with refrigerant type R134a
must only be operated with the compressor oil / re-
frigeration oil approved for the compressor.
lUsed compressor oil/refrigeration oil must be dis-
posed of in strict compliance with applicable envi-
ronmental regulations.
lDue to its chemical properties compressor oil / re-
frigeration oil must never be disposed of together
with engine or transmission oil.
lCompressor oil / refrigeration oil is highly hydro-
scopic. Oil cans must strictly be kept closed until
use. Oil rests should not be used, if the can had
been opened over a longer period of time.
lAll O-rings/seal rings as well as pipe/ hose fittings
must be oiled with compressor/refrigeration oil bfore
assembly.
lWhen replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil/refrigeration oil
lost by exchanging the components, must be re-
placed with fresh oil.
lA too high compressor oil / refrigeration oil level ad-
versely affects the cooling performance and a too
low oil level has a negative effect on the lifetime of
the compressor.
lUse new O-rings or seal rings for reassembly.
lAlways used 2 spanners to work on pipes/hoses to
avoid damages .
lTighten screw fittings with the specified torque.
lCheck all pipes/hoses, screw fittings or components
for damage, replace if necessary.
lDo not leave the refrigerant circuit unnecessarily
open to the atmosphere.
lIn case of a repair on the refrigeration system you
should first evacuate the air conditioning system for
at least 45 minutes to remove any moisture from the
system, before you start to refill. Moisture bonded in
the compressor oil / refrigeration oil (PAG oil) can
only be removed from the system by changing the
oil.
lCompressor valves must only be opened after the
system has been properly sealed.
lThe use of leak detection spray is not permitted. If
such substances are used the WARRANTY will be-
come null and void.

General repair instructions
BOMAG 19008 922 89
1.3
lIf the air conditioning system had been opened for
repairwork, a newdrier should be installed in the re-
frigerant circuit.
lAfter completion of repair work screw locking caps
(with seals) on all valve connections service con-
nections.
lBefore start up of the air conditioning system after a
new filling: - Turn the compressor approx. 10 revo-
lutions by hand using the clutch or V-belt pulley of
the magnetic clutch. - Start the engine with the com-
pressor/control valve switched off. - Once the idle
speed of the engine has stabilized switch on the
compressor and run it for at least 10 minutes at idle
speed and maximum cooling power.
lNever run the compressor with an insufficient
amount of refrigerant.
Notes on cleanliness for Common Rail
engines
Special requirements with respect to cleanliness in
the fuel system do apply for commissioning, mainte-
nance and repair work, particularly for engines with
the Common Rail System. Contamination like dirt,
welding residues or similar can lead to the failure of in-
dividual components and adversely affect engine op-
eration.
Fig. 1
lSpare parts should be left in their original packaging
as long as possible and should only be unpacked
just before use.
lWhen parts are unpacked any connections must be
closed with suitable plugs or caps, in order to pre-
vent (Fig. 1) contamination of hose connections. If
e.g. fuel hoses are connected to one side, while the
second side cannot yet be connected, there is a
danger of dirt entering into the system. The free
connection must in this case also be appropriately
closed.
Notes and measures to be applied before starting
work in the fuel system
lThe fuel system must be closed. Visualexamination
for leaks / damage in the fuel system.
lBefore starting work in the fuel system clean the
complete engine and the engine compartment with
the system still closed.
lThe engine should be dry before work is started in
the fuel system.

1.3 General repair instructions
BOMAG20 008 922 89
lBlow drying with compressed air is only permitted
while the fuel system is still closed.
lWhen using steam cleaning equipment cover con-
trol unit, cable plugs, all other electrical connections
and the generator beforehand and do not expose
these items to the direct steam jet.
lElectrical plug connections must be plugged in dur-
ing jet cleaning.
lRemove loose parts (e.g. paint scales that may
have come off during assembly work) with an indus-
trial vacuum cleaner or any means of extraction.
lVacuum cleaning equipment must generally be
used for cleaning when the fuel system is open.
lPerform work on the fuel system only in a clean en-
vironment (no dust, no grinding or welding work).
Avoid draughts (dust). The workshop floor must be
cleaned at regular intervals. No brake or power test
stand should be present or operated in the same
room.
lAir movements, which could swirl up dust, such as
brake repairs or starting of engines, must be strictly
avoided.
lFor work, such as disassembly and assembly of de-
fective hydraulic components in the Common Rail
System, it is strongly recommended to set upa sep-
arate workshop area, i.e. an area which is spatially
separated from all other areas (general vehicle re-
pairs, brake repairs).
lNo general machine tools shouldbe operated inthis
room.
lPeriodic cleaning of this workshop area is obligato-
ry, draughts, ventilation system and heating blow-
ers must be minimized.
lEngine compartment area where dirt particles could
come loose, should be covered with new, clean foil.
lWorking means and tools must be cleaned before
being used for work. Use only tools without dam-
aged chromium coating, or tools without chromium
coating.
Notes and measures to be applied during work in
the fuel system
lWear clean working clothes.
lUse only lint-free cleaning cloths for work in the fuel
system.
lRemove loose parts (e.g. paint scales that may
have come off during assembly work) with an indus-
trial vacuum cleaner or any means of extraction.
Vacuum cleaning equipment must generally be
used for cleaning when the fuel system is open.
lWorking means and tools must be cleaned before
being used for work. Use only tools without dam-
aged chromium coating, or tools without chromium
coating.
lDo not use any previously used cleaning or testing
fluids for cleaning.
lCompressed air should never be used for cleaning
when the fuel system is open.
lWork on disassembled components must only be
carried out at a specially furnished work place.
lWhen removing or assembling components you
should not use any materials from which particles or
fibres could flake off (cardboard, wood, towels).
lDismantled parts must only be wiped off with clean,
lint-free cloths if required. No dirt particles must be
wiped into the components.
lClose openings on components and engine imme-
diately with suitable plugs/caps.
lPlugs/caps must only be removed just before the in-
stallation.
lKeep plugs/caps in their original packaging, where
they are protected against dust and dirt, dispose of
after one time use.
lTake new parts out of their original packaging just
before installation.
lRemoved components must be stored in new, seal-
able bags or – if available – in the packaging mate-
rial of the new components.
lAlways use the original packaging material of the
newpart to returnthe disassembledold component.
Notes and measures concerning the workshop
area
lFor work, such as disassembly and assembly of de-
fective hydraulic components in the Common Rail
System, it is strongly recommended to set up a sep-
arate workshop area, i.e. an area which is spatially
separated from all other areas (general vehicle re-
pairs, brake repairs).
lThe workshop floor must be sealed or tiled.
lNo welding equipment, grinding machines, general
machine tools, brake or power test benches must
be operated in this room.
lPeriodic cleaning of this workshop area is obligato-
ry, draughts, ventilation system and heating blow-
ers must be minimized.
Notes and measures for work place and tools in
the workshop
lA special work place must be set up for work on dis-
assembled components.
lClean disassembly and assembly tools at regular
intervals and keep these in a closed tool cabinet.