Service - Manual

BF 800 C
S/N 821 837 17 1001 ....
S/N 821 837 71 1001 ....
S/N 821 837 19 1001 ....
S/N 821 837 66 1001 ....
S/N 861 893 50 1001 ....
S/N 861 893 60 1001 ....

Road Finisher

Catalogue number.
008 917 73 02/2013
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 Table of Contents

General 9
1.1 Introduction 10
1.2 Safety regulations 11
1.3 General repair instructions 15
1.4 Tightening torques 27
Technical data 31
2.1 Technical data 32
Maintenance 39
3.1 General notes on maintenance 40
3.2 Fuels and lubricants 41
3.3 Table of fuels and lubricants 44
3.4 Running-in instructions 45
3.5 Maintenance table 46
E-Plan wiring diagrams 49
4.1 Understanding E-Plan circuit diagrams 50
4.2 Circuit symbols in E-Plan 59
4.3 Identification of switch blocks in the wiring diagram 62
4.4 Designation of components in the wiring diagram 63
4.5 Terminal designations in wiring diagram 64
Engine 67
5.1 Diesel engine 68
5.2 Engine description TCD 2012 69
5.3 Lubrication oil circuit TCD 2012 / 2013 71
5.4 Coolant circuit TCD 2012 / 2013 72
5.5 Fuel system TCD 2012 / 2013 73
5.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 75
5.7 Exhaust gas recirculation TCD 2012 / 2013 79
5.8 Wastegate - charge pressure controller on TCD-engines 80
5.9 Engine problems 82
5.10 Checking the engine oil level 85
5.11 Changing engine oil and oil filter cartridge 85
5.12 Replacing the fuel pre-filter cartridge, bleed the fuel system 86
5.13 Replace the fuel filter 88
5.14 Check, clean the water separator 89
5.15 Check the coolant level 90
5.16 Replace the coolant 90
5.17 Checking the thermostat in disassembled state 91
5.18 Air filter maintenance 92
5.19 Clean the cooling fins on engine and hydraulic oil cooler 94
5.20 Intercooler, drain off oil and condensation water 95
5.21 Adjust the valve clearance 95
5.22 Checking the ribbed V-belt, replacing if necessary 96
5.23 Replace the crank case ventilation valve 97
5.24 Engine conservation 98
5.25 Special tools, Deutz engine (TCD 2012 2V) 99
Engine electrics 115

008 917 73 BOMAG 3

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Table of Contents

6.1 EMR3 system components 116

6.2 Deutz EMR 3 - engine connections 121
6.3 Pin assignment of engine control EDC16 / EMR3 122
6.4 Rotary speed sensor for camshaft 127
6.5 Crankshaft speed sensor 128
6.6 Rail pressure sensor 129
6.7 Fuel pressure sensor 130
6.8 Fuel control unit 132
6.9 Injector 133
6.10 Oil pressure sensor 134
6.11 Sensor for charge air temperature and charge air pressure 136
6.12 EMR coolant temperature sensor 138
6.13 Glow plugs 140
6.14 Sensor, water in fuel 140
6.15 Air filter vacuum switch 141
6.16 Float switch, coolant tank 142
6.17 Charge control light, engine RPM-meter 143
6.18 Diagnose with SERDIA 144
6.19 Diagnose with CAN-bus 147
6.20 Diagnostics interface 148
6.21 EMR3 List of fault codes 150
6.22 Generator 221
6.23 Replacing the voltage regulator 230
6.24 Electric starter 232
Electrics 239
7.1 Service the battery, check the main battery switch 240
7.2 Starting the engine with jump leads 241
7.3 Starting with jump wires 241
7.4 Fuses 242
7.5 Fuse assignment 243
7.6 Component overview - Electrics 246
7.7 Overview of wiring looms 254
7.8 Control elements 267
7.9 View of control panel 268
7.10 Instrument cluster 270
7.11 Data collector 272
7.12 View of external operator stations 276
7.13 View of external operator stations 277
7.14 View of screed control panel 278
7.15 View of electric heating control panel 279
7.16 Functional block diagram overview of functions, complete 280
7.17 Block diagram components on CAN 281
7.18 Block diagram CAN with control elements 282
7.19 Block diagram of travel circuit 283
7.20 Block diagram material feed 284
7.21 Block diagram screed 285
7.22 Block diagram screed heating 286
7.23 Functional block diagram monitoring functions 287

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 Table of Contents

7.24 Block diagram Emergency Stop functions 288

7.25 Electronic control units 289
7.26 Checking the voltage supply for the control unit 291
7.27 Diagnostics concept 299
Error codes -- general information 303
8.1 Error codes - BF800 -- general information 304
Input codes 307
9.1 Input codes -- Display: Function and operation 308
9.2 Input codes -- automatic calibration of currents in the travel system 309
9.3 Input codes -- manual calibration of currents in the travel system 312
9.4 Input codes -- travel signal by push button for max. screed relief 315
9.5 Input codes -- Changing the type of speed potentiometer 317
9.6 Input codes -- Activating/deactivating the screed heat in low idle speed 318
9.7 Input codes -- activate/deactivate the cleaning function 319
9.8 Input codes -- Saving/loading TCU settings 320
9.9 Input codes -- Teaching L.C.S. Function 321
9.10 Input codes -- changing the tamper start and stop ramps 323
9.11 Input codes -- Changing the currents for the tamper pump 326
9.12 Input codes -- changing the tamper start and stop ramps 329
9.13 Input codes -- Changing the currents for the vibration pump 332
9.14 Input codes -- Saving/loading SCU settings 335
9.15 Input codes -- Restoring factory settings of the SCU 336
9.16 Input codes -- Activate/deactivate hydraulic front gate 337
9.17 Input codes -- Changing the currents in the auger pumps 338
9.18 Input codes -- Change the auger start / stop ramps 341
9.19 Input codes -- Changing the currents in the scraper belt pumps 344
9.20 Input codes -- Enable/disable lifting the auger block together with the screed
347
9.21 Input codes -- Saving/loading MCU settings 348
9.22 Input codes -- Restoring factory settings of the MCU 349
9.23 Input codes -- driving against the closed brake 350
9.24 Input codes -- showing logged errors 351
9.25 Input codes -- showing logged errors with operating hours 352
9.26 Input codes -- deleting the error log 353
Replacement of components 355
10.1 How to proceed when replacing components? 356
Material hopper, description 357
11.1 Material hopper and transport 358
Vibrating screed, description 365
12.1 Screed 366
Basic settings on the screed 371
13.1 Notes on the screed adjustment (type S500 & S600) 372
13.2 Bringing the straight crossfalls to zero position 373
13.3 Aligning basic screed and mobile sections 374
Assembling the screed extensions 377
14.1 Notes on assembling screed extensions 378
14.2 Assembling the screed extensions 381

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Table of Contents

Electric screed heating, repair 393

15.1 Electric screed heating 394
15.2 Electric screed heating - commissioning 399
15.3 Faults in the electric heating 401
Travel drive, description 403
16.1 Travel system 404
Hydraulics 409
17.1 Hydraulic circuit 410
17.2 Component overview -- hydraulics 412
17.3 Description of travel pump 417
17.4 View of the machine 423
17.5 Pumps for: Scraper belt, augers, vibration & tampers 424
17.6 View of the machine 431
17.7 Description of fan pump 433
17.8 View of the machine 437
17.9 Description of charge pumps 438
17.10 Check the hydraulic oil level 440
17.11 Change hydraulic oil and hydraulic oil filter 441
Hydraulics - travel circuit 445
18.1 Description of driving 446
18.2 Description of brake circuit 448
Hydraulics - material transport 451
19.1 Description of scraper belts 452
19.2 Description of augers 453
19.3 Description tamping 454
19.4 Description vibration 455
Hydraulics - Service 457
20.1 Description of fan circuit 458
20.2 Description of Service (a) 459
20.3 Description of Service (b) 460
20.4 Description of Load Control System (LCS) 461
Tests and adjustments 463
21.1 Special tools, tests and adjustments 464
21.2 Checking and adjusting the vibration 468
21.3 Checking/adjusting tamping 475
21.4 Checking/adjusting the scraper belts 486
21.5 Checking/adjusting the augers 493
21.6 Checking & adjusting the service pump/cylinder functions 499
21.7 Checking & adjusting the time for screed levelling 503
21.8 Checking/adjusting the hopper wings 505
21.9 Checking/adjusting the mobile screed 507
Suppliers documentation 509
22.1 Travel pump 511
22.2 Travel motor 549
22.3 Service pump and fan pump 603
22.4 Pump scraper chains, augers, tamper, vibration 633
22.5 Travel gear 691

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 Table of Contents

Circuit diagrams 761

23.1 Hydraulic diagram 763
23.2 Electric circuit diagrams 783

008 917 73 BOMAG 7

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Table of Contents

8 BOMAG 008 917 73

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 1 General

008 917 73 BOMAG 9

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1.1 Introduction

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

10 BOMAG 008 917 73

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

l Use protective clothes like hard hat, safety boots

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

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

008 917 73 BOMAG 11

1.2 Safety regulations

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

12 BOMAG 008 917 73

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

008 917 73 BOMAG 13

1.2 Safety regulations

Engine l The installation and use of non-genuine spare parts

or non-genuine accessories may therefore have an
adverse effect on the specific characteristics of the
Danger
!
machine and thereby impair the active and/or pas-
Do not work on the fuel system while the engine is sive driving safety. The manufacturer explicitly ex-
running. (Danger to life!) cludes any liability for damage caused by the use of
non-original parts or accessories.
Once the engine has stopped wait approx. 5 min-
utes for the system to depressurize. The systems l Unauthorized changes to the machine are prohibit-
are under high pressure. (Danger to life!) ed for safety reasons.
Keep out of the danger zone during the initial test l Do not perform any cleaning work while the engine
rung. Danger caused by high pressure in case of is running.
leaks. (Danger to life!) l If tests on the articulated joint need to be performed
When performing work on the fuel system make with the engine running, do not stand in the articu-
sure that the engine cannot be started uninten- lation area of the machine (danger of crushing!).
tionally during repair work. (Danger to life!) l If tests must be performed with the engine running
l Maintenance and cleaning work on the engine must do not touch rotating parts of the engine (danger of
only be performed with the engine stopped and injury!).
cooled down. Make sure that the electric system is l Always ensure an adequate supply of fresh air
switched off and sufficiently secured against being
when starting in closed rooms. Exhaust gases are
switched on again (e.g. pull off ignition key, attach a
highly dangerous!
warning label).
l
Refuel only with the engine shut down. Ensure strict
l Observe the accident prevention regulations for
cleanliness and do not spill any fuel.
electric systems (e.g. -VDE-0100/-0101/-0104/-
0105 Electric precautions against dangerous con- l
Always ensure an adequate supply of fresh air
tact voltages). when refuelling in closed rooms.
l Cover all electric components properly before wet l
Dispose of used filters in accordance with applica-
cleaning. ble environmental regulations.
l
When performing repair and maintenance work col-
Battery lect oils and fuels in suitable containers and dispose
l Always wear goggles and protective clothing to of in compliance with applicable environmental reg-
service or clean batteries! Battery acid can cause ulations.
severe injury by cauterization when coming in con- l
Do not heat up oils higher than 160 °C because they
tact with skin. may ignite.
l Work only well ventilated rooms (formation of oxy- l Wipe off spilled or overflown oil using suitable
hydrogen gas). cleaning means and dispose of in accordance with
l Do not lean over the battery while it is under load, applicable environmental regulations.
being charged or tested (danger of explosion). l Dispose of old batteries according to applicable en-
l Keep ignition sources away from the battery. Burn- vironmental regulations.
ing cigarettes, flames or sparks can cause explo-
sion of the battery
l There is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature! Allow
l Use battery chargers etc. only in strict compliance engine and hydraulic system to cool down to a suf-
with the operating instructions. ficient level.
l After an accident with acid flush the skin with a suf- l Do not exceed the max. permissible tire pressure.
ficient amount of water and seek medical advice.
l Do not allow children access to batteries.
l When mixing battery fluid always pour acid into wa-
ter, never vice-versa.

Special safety regulations

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

14 BOMAG 008 917 73

General repair instructions 1.3
General Electrics
1.3 General repair instructions

l Before removing or disassembling parts, assem- General

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

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

008 917 73 BOMAG 15

1.3 General repair instructions

l Plug-in connectors on control units are only dust Battery

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

16 BOMAG 008 917 73

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

008 917 73 BOMAG 17

1.3 General repair instructions

Hydraulic system l Perform measurements at operating temperature of

the hydraulic oil (approx. 40 ¯C).

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

18 BOMAG 008 917 73

General repair instructions 1.3
Notes on cleanliness for Common Rail l Blow drying with compressed air is only permitted
engines while the fuel system is still closed.

Special requirements with respect to cleanliness in

l When using steam cleaning equipment cover con-
the fuel system do apply for commissioning, mainte- trol unit, cable plugs, all other electrical connections
nance and repair work, particularly for engines with and the generator beforehand and do not expose
the Common Rail System. Contamination like dirt, these items to the direct steam jet.
welding residues or similar can lead to the failure of in- l Electrical plug connections must be plugged in dur-
dividual components and adversely affect engine op- ing jet cleaning.
eration. l Remove 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.
l Vacuum cleaning equipment must generally be
used for cleaning when the fuel system is open.
l Perform 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.
l
Air movements, which could swirl up dust, such as
brake repairs or starting of engines, must be strictly
avoided.
l
For 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).
l
No general machine tools should be operated in this
room.
l
Periodic cleaning of this workshop area is obligato-
Fig. 1 ry, draughts, ventilation system and heating blow-
l
Spare parts should be left in their original packaging ers must be minimized.
as long as possible and should only be unpacked l Engine compartment area where dirt particles could
just before use. come loose, should be covered with new, clean foil.
l
When parts are unpacked any connections must be l Working means and tools must be cleaned before
closed with suitable plugs or caps, in order to pre- being used for work. Use only tools without dam-
vent (Fig. 1) contamination of hose connections. If aged chromium coating, or tools without chromium
e.g. fuel hoses are connected to one side, while the coating.
second side cannot yet be connected, there is a
danger of dirt entering into the system. The free Notes and measures to be applied during work in
connection must in this case also be appropriately the fuel system
closed. l Wear clean working clothes.
Notes and measures to be applied before starting l Use only lint-free cleaning cloths for work in the fuel
work in the fuel system system.
l The fuel system must be closed. Visual examination l Remove loose parts (e.g. paint scales that may
for leaks / damage in the fuel system. have come off during assembly work) with an indus-
trial vacuum cleaner or any means of extraction.
l Before starting work in the fuel system clean the
Vacuum cleaning equipment must generally be
complete engine and the engine compartment with
used for cleaning when the fuel system is open.
the system still closed.
l Working means and tools must be cleaned before
l
The engine should be dry before work is started in
being used for work. Use only tools without dam-
the fuel system.
aged chromium coating, or tools without chromium
coating.

008 917 73 BOMAG 19

1.3 General repair instructions

l Do not use any previously used cleaning or testing l Remove loose parts (e.g. paint scales that may
fluids for cleaning. have come off during assembly work) with an indus-
trial vacuum cleaner or any means of extraction.
l Compressed air should never be used for cleaning
when the fuel system is open. l Working means and tools must be cleaned before
being used for work. Use only tools without dam-
l Work on disassembled components must only be
carried out at a specially furnished work place. aged chromium coating, or tools without chromium
coating.
l When removing or assembling components you
should not use any materials from which particles or
fibres could flake off (cardboard, wood, towels).
l Dismantled parts must only be wiped off with clean,
lint-free cloths if required. No dirt particles must be
wiped into the components.
l Close openings on components and engine imme-
diately with suitable plugs/caps.
l Plugs/caps must only be removed just before the in-
stallation.
l Keep plugs/caps in their original packaging, where
they are protected against dust and dirt, dispose of
after one time use.
l
Take new parts out of their original packaging just
before installation.
l
Removed components must be stored in new, seal-
able bags or – if available – in the packaging mate-
rial of the new components.
l
Always use the original packaging material of the
new part to return the disassembled old component.

Notes and measures concerning the workshop

area
l
For 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).
l The workshop floor must be sealed or tiled.
l No welding equipment, grinding machines, general
machine tools, brake or power test benches must
be operated in this room.
l Periodic 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
l A special work place must be set up for work on dis-
assembled components.
l Clean disassembly and assembly tools at regular
intervals and keep these in a closed tool cabinet.

20 BOMAG 008 917 73

General repair instructions 1.3
Fuel hoses Gaskets and mating surfaces
Leaking sealing faces can mostly be traced back to in-
correct assembly of seals and gaskets.
l Before assembling a new seal or gasket make sure
that the sealing surface is free of pitting, flutes, cor-
rosion or other damage.
l Inappropriately stored or handled seals (e.g. hang-
ing from hooks or nails) must under no circumstanc-
es be used.
l Assemble seals and gaskets only with sealing com-
pound, grease or oil, if this is specifically specified
Fig. 2 in the repair instructions.
l If necessary remove any old sealing compound be-
! Caution fore assembling. For this purpose do not use any
tools that could damage the sealing surfaces.
All fuel hoses have two layers of material, a rein-
forced rubber coating outside and an internal Vi- l Sealing compound must be applied thin and evenly
ton hose. If a fuel hose has come loose one must on the corresponding surfaces; take care that the
make absolutely sure that the internal Viton layer compound does not enter into oil galleries or blind
has not been separated from the reinforced outer threaded bores.
layer. In case of a separation the hose needs to be l
Examine the contact faces for scratches and burrs,
replaced. remove these with a fine file or an oilstone; take
care that no grinding dust and dirt enters into
tapped bores or enclosed components.
l
Blow out lines, ducts and gaps with compressed air,
replace any O-rings and seals that have been dis-
lodged by the compressed air.

Assembly of radial seals

Fig. 3
l Lubricate the sealing lips (2) (Fig. 3) with clean
grease; in case of double seals fill the space be-
tween the sealing lips with a generous amount of
grease.
l Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.

i Note
If possible, use an assembly sleeve (1 (Fig. 3)), to
protect the lip from being damaged by sharp edg-
es, threads or splines. If no assembly sleeve is avail-

008 917 73 BOMAG 21

1.3 General repair instructions

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

Fig. 4
l
Press or knock the seal into the housing, until it is
flush with the housing surface.

i Note
Fig. 5
If possible, use a "bell" (1 (Fig. 4)), to make sure that
the seal will not skew. In some cases it may be ad-
l Clean and thoroughly examine the feather key.
visable to assemble the seal into the housing first, be- l Deburr and thoroughly clean the edges of the key-
fore sliding it over the shaft. Under no circumstances way with a fine file before reassembling.
should the full weight of the shaft rest on the seal.
If you have no proper service tools at hand, use a suit-
able drift punch with a diameter which is about 0,4 mm
smaller than the outer diameter of the seal. Use VERY
LIGHT blows with the hammer if no press is available.

22 BOMAG 008 917 73

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

Fig. 7

!Caution
When assembling the ball or roller bearing to the
shaft load must only be applied to the inner race 1
(Fig. 7).
When fitting the bearing into the housing load
must only be applied to the outer race (2).

Fig. 6
l
If a ball or roller bearing of a bearing pair shows de-
fects, both ball or roller bearings need to be re-
placed.
l Remove any lubricant residues from the ball or roll-
er bearing to be examined by washing it with gaso-
line or any other appropriate degreasing agent.
Ensure strict cleanliness.
l Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. Replace the ball or roller bearing if
necessary.
l Check the ball or roller bearing for clearance and re-
sistance between the inner and outer races, replace
if necessary.
l Lubricate the ball or roller bearing with the recom-
mended type of grease before assembly or reas-
sembly.
l
On greased bearings (e.g. wheel bearings) fill the
space between ball or roller bearing and outer seal
with the recommended type of grease before as-
sembling the seal.

008 917 73 BOMAG 23

1.3 General repair instructions

Screws and nuts Strength classes, metric screws

The strength classes (from 3.6 to 12.9) are specified
Tightening torque
for all strength classes from a nominal diameter of
5mm. The corresponding identification can be found
!Caution where allowed for by the shape of the screw.
Tighten nuts or screws with the tightening tor-
ques specified in the following tables of tighten-
ing torques. Tightening torques deviating from
the ones in the table are specially mentioned in
the repair instructions.
Damaged screws must under no circumstances
be used any longer. Recutting threads with thread
cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or cor-
roded thread pitches can cause incorrect torque
value readings.
Self-locking nuts must generally be replaced after
disassembly.
The use of screws with too high strength can
cause damage!
l Nut of a higher strength can generally be used in-
stead of nuts of a lower strength classification.
l When checking or retightening screw joints to the
specified tightening torque you should first relieve
Fig. 8 Identification of screws
by a quarter turn and then tighten to the correct
torque. Example: A screw is identified with 12.9.
l Before tightening you should lightly oil the thread, in The first number corresponds with 1/100 of the nomi-
order to ensure low friction movement. The same nal tensile strength (minimum tensile strength) in N/
applies for self-locking nuts. mm2.
l Make sure that no oil or grease will enter into blind l
The nominal tensile strength is 12 X 100 N/mm2 =
tapped bores. The hydraulic power generated when
1200 N/mm2.
turning in the screw could cause breakage of the ef-
fected part. The second number specifies 10-times the ration be-
tween lower yield point and nominal tensile strength
(yield point ratio).

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

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

24 BOMAG 008 917 73

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

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

6, 8, 10, 12)

Fig. 10 Identification of nuts in clock system

For small nuts (Fig. 10) the clock system can be used
for identification.
l The 12 o'clock position is identified by a dot or the
manufacturer's symbol.
Fig. 9 Identification of nuts l
The strength class is identified by a dash (b).
In a connection with a screw, these nuts 1 (Fig. 9)
must be able to bear the full pre-load at the yield point.
Nut height above 0.8 d (d = nominal dimension).

Strength class of Strength class of associated

nut screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
6 6.8
8 8.8
9 9.8
10 10.8
12 12.8

Nuts for screw joints with limited load factor (04,

05)
The preceding "0" indicates that, due to their low
height, nuts 2 (Fig. 9) in this group are only able to
withstand the force of a screw to a limited extent.
Nut height below 0,8 d (d = nominal dimension).

Nuts for screw joints without specified load factor

(11H, 14H, 17H, 22H)
This standard contains strength classes (hardness
classes) for nuts 3 (Fig. 9), for which no load values
can be specified, e.g. because of their shape and di-
mensions, but which can only be classified by their
hardness.
Nut height below 0,5 d (d = nominal dimension).

008 917 73 BOMAG 25

1.3 General repair instructions

Identification of UNF-threads Cotter pins

Fig. 12
In places where cotter pins are used, these must be
reassembled. Cotter pins must generally be renewed
after disassembly.
Cotter pins must be assembled as shown in the illus-
tration, unless specified differently.
Fig. 11

Screws
The screw head is marked with a stamped in, round
cavity 3 (Fig. 11).

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

Studs and brake rods

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

26 BOMAG 008 917 73

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

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

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

Tightening torques for screws with metric unified thread*

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

Tightening torques for screws with metric unified fine thread*

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

008 917 73 BOMAG 27

1.4 Tightening torques

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

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

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

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

28 BOMAG 008 917 73

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

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

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

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

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

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

008 917 73 BOMAG 29

1.4 Tightening torques

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

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

30 BOMAG 008 917 73

 2 Technical data

008 917 73 BOMAG 31

2.1 Technical data

2.1 Technical data

Fig. 13

Dimensions in A B H H2 K L W
mm
BF 800 C 3360 2550/3000* 3865 3055 190 6800 2500
* with S600 screed

*
BF 800 C -S 500 BF 800 C -S 600

Weights
Operating weight (CECE) kg 20700 21000
Weight of basic screed kg 3900 4200

Screed
Basic mat width mm 2550 3000
Max. mat width without extension mm 5000 6000
Max. mat width with extension mm 9000 10000
Min. mat width with optional re- mm 1800 2300
ducing plates
Max. mat height mm 300 300
Tamper frequency Hz/ min-1 0 ... 29 / 0 ... 1740 0 ... 29 / 0 ... 1740
Vibration frequency Hz/ min-1 20 ... 58 / 1200 ... 3500 20 ... 58 / 1200 ... 3500
Crown adjustment % -2.5/+4.5 -2.5/+4.5
Heating electric electric

Travel characteristics
Working speed m/min 0 - 25 0 - 25
Transport speed km/h 0 - 4.5 0 - 4.5
Max perm. inclination (ramp) ° 15 15
Permissible inclination front/rear/ ° 35/35/14 35/35/14
side

Drive
Engine manufacturer Deutz Deutz
Type TCD 2012 L06 2V TCD 2012 L06 2V
Cooling Water Water
Number of cylinders 6 6
Rated power ISO 3046 kW 136 136
Rated speed rpm 2000 2000

32 BOMAG 008 917 73

Technical data 2.1
*
BF 800 C -S 500 BF 800 C -S 600
Fuel Diesel Diesel
Permissible ambient tempera- °C -20 ... +50 -20 ... +50
ture

Track
Crawler tracks (WxL) mm 300x3360 300x3360

Hopper
Capacity m3 7.2 7.2

Auger
Diameter mm 400 400
Rated speed rpm 95 95

Electric system
Voltage V 24 24
Batteries (2) Ah 2x100 2x100
Generator diesel engine A 55 55
Generator for electric heating KW 40 40

Conveyor system
Conveyor belt width mm 2x400 2x400

Filling capacities
Diesel fuel l 315 315
Coolant l 20 20
Hydraulic oil l 179 179
Engine oil l 20 20
* The right for technical modifications remains reserved

008 917 73 BOMAG 33

2.1 Technical data

Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 950 - 1050
High idle speed rpm 1900 - 2100
Angle de-
Valve clearance intake 75-85
gree
Angle de-
Valve clearance exhaust 120-130
gree

HYDRAULIC PUMPS
A1 & A2  Travel pumps
Manufacturer Bosch-Rexroth
Type A4VG
Quantity 2
System Axial piston variable displacement pump
Max. displacement cm3/rev 56
Max. flow capacity l/min 202
Maximum pressure bar 415 - 435
Charge pressure bar 20 - 22

C & E  Pumps auger drive

Manufacturer Bosch-Rexroth
Type A10VG
System Axial piston variable displacement pump
Quantity 2
Displacement cm3/rev 28
Maximum pressure bar 370 - 390
Maximum speed rpm 3900

D & F  Pumps scraper belt drive

Manufacturer Bosch-Rexroth
Type A10VG
System Axial piston variable displacement pump
Quantity 2
Displacement cm3/rev 45
Maximum pressure bar 370 - 390
Maximum speed rpm 3300

G  Pump vibration drive

Manufacturer Bosch-Rexroth
Type A10VG
System Axial piston variable displacement pump
Quantity 2
Displacement cm3/rev 28
Maximum pressure bar 250 - 270
Maximum speed rpm 3900

H  Pump tamper drive

Manufacturer Bosch-Rexroth
Type A10VG
System Axial piston variable displacement pump
Quantity 2
Displacement cm3/rev 28
Maximum pressure bar 250 - 270
Maximum speed rpm 3900

34 BOMAG 008 917 73

Technical data 2.1
I  Service pump
Manufacturer Bosch-Rexroth
Type A10VO
System Gear pump
Quantity 1
Displacement cm3/rev 45
Maximum pressure bar 350
Nominal pressure bar 280
Standby pressure bar 25
Working pressure: bar 180
Maximum speed rpm 3100

J  Charge pump for travel system

Manufacturer Bosch-Rexroth
Type AZPF
System Gear pump
Quantity 1
Displacement cm3/rev 16
Maximum pressure bar 225
Maximum speed rpm 3000

K  Charge pump for auger and scraper

belt pumps left
Manufacturer Bosch-Rexroth
Type AZPF
System Gear pump
Quantity 1
Displacement cm3/rev 16
Maximum pressure bar 280
Maximum speed rpm 3000

L  Charge pump for auger and scraper

belt pumps right
Manufacturer Bosch-Rexroth
Type AZPF
System Gear pump
Quantity 1
Displacement cm3/rev 16
Maximum pressure bar 280
Maximum speed rpm 3000

M  Charge pump for vibration and

tamper pumps
Manufacturer Bosch-Rexroth
Type AZPF
System Gear pump
Quantity 1
Displacement cm3/rev 16
Maximum pressure bar 230
Maximum speed rpm 3000

N  Pump fan drive

Manufacturer Bosch-Rexroth
Type A10VO
System Axial piston variable displacement pump
Quantity 1
Displacement cm3/rev 28
Maximum pressure bar 350

008 917 73 BOMAG 35

2.1 Technical data

Nominal pressure bar 280

Maximum speed rpm 3600

O  Pump asphalt vapour extraction

system drive*
Manufacturer Bosch-Rexroth
Type AZPF
System Gear pump
Quantity 1
Displacement cm3/rev 16
Maximum pressure bar 280
Maximum speed rpm 3000

HYDRAULIC MOTORS
Travel motors
Manufacturer Bosch-Rexroth
Type A6VE
Quantity 2
System Axial piston/bent axle
Nominal pressure bar 400
Top pressure bar 450
Max. displacement. cm3/rev 80
Min. displacement cm3/rev 0

Tamper motors
Manufacturer Haldex
Type WM09
System Gear motor
Displacement cm3/U 16
Maximum pressure bar 300
Nominal pressure bar 276
Rated speed rpm 1900 - 2000

Vibration motors
Manufacturer Haldex
Type WM09
System Gear motor
Displacement cm3/U 8
Maximum pressure bar 300
Nominal pressure bar 276
Rated speed rpm 3350 - 3650
Rotary speed at 1Hz rpm 60
Rotary speed at 60Hz rpm 3600

Auger motors
Manufacturer Poclain
Type MS 08
System Orbital motor
Max. displacement. cm3/rev 857
Rated speed rpm 100 - 108
Quantity 2

Scraper belt motors

Manufacturer Poclain
Type MS 05
System Orbital motor
Max. displacement. cm3/rev 560

36 BOMAG 008 917 73

Technical data 2.1
Motor speed (on drive pinion) rpm 114-117
Speed (on shaft of scraper belt) rpm 61-64
Quantity 2

Fan motor
Manufacturer Haldex
Type WM09
System Gear motor
Max. displacement. cm3/rev 23
Maximum pressure bar 300
Nominal pressure bar 276
Rated speed rpm 1280-1320

GEARBOX
Travel gear
Manufacturer Bonfiglioli
Type 710C3B
System Planetary gear with integrated brake
Reduction ratio 1:105.7
Quantity 2
Maximum torque Nm 36000
Maximum input speed rpm 3500
Brake: Brake torque Nm 250-600
Brake releasing pressure bar 10 - 20

* Option

008 917 73 BOMAG 37

2.1 Technical data

The following noise and vibration data acc. to

- EC Machine Regulation edition 2006/42/EC

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

- Vibration Protection Regulation 2002/44/EC

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

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

Noise value
Sound pressure level on the place of the operator:
LpA = 83 dB(A), determined acc. to ISO 11204 and EN 500

Guaranteed sound power level:

LWA = 107 dB(A), determined acc. to ISO 3744 and EN 500

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

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

Hand-arm vibration values

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

38 BOMAG 008 917 73

 3 Maintenance

008 917 73 BOMAG 39

3.1 General notes on maintenance

3.1 General notes on maintenance Notes on the performance of the engine

On diesel engines both combustion air and fuel injec-
When performing maintenance work always comply
with the appropriate safety regulations. tion quantities are thoroughly adapted to each other
and determine power, temperature level and exhaust
Thorough maintenance of the machine guarantees far gas quality of the engine.
longer safe functioning of the machine and prolongs
If your engine has to work permanently in "thin air" (at
the lifetime of important components. The effort need-
higher altitudes) and under full load, you should con-
ed for this work is only little compared with the prob-
sult the customer service of BOMAG or the customer
lems that may arise when not observing this rule.
service of the engine manufacturer.
The terms right/left correspond with travel direction
forward.
Notes on the cooling system
l Always clean machine and engine thoroughly be-
Prepare and check coolant with highest care, since
fore starting maintenance work.
otherwise the engine may be damaged by corrosion,
l Do not touch hot engine parts. cavitation and freezing.
l For maintenance work stand the machine on level The coolant is prepared by mixing a cooling system
ground. protection agent (ethylene glycol) into the coolant.
l Always remove the main battery switch for all main- Mixing with cooling system protection agent is neces-
tenance work. sary in all climatic zones. It prevents corrosion, lowers
the freezing point and raises the boiling point of the
l Perform maintenance work only with the engine
coolant.
shut down.
l
Relieve hydraulic pressures before working on hy- Notes on the hydraulic system
draulic lines.
During maintenance work on the hydraulic system
l
Before working on electric parts of the machine dis- cleanliness is of major importance. Make sure that no
connect the battery and cover it with insulation ma- dirt or other contaminating substances can enter into
terial. the system. Small particles can produce flutes in
valves, cause pumps to seize, clog nozzles and pilot
Environment bores, thereby making expensive repairs inevitable.
During maintenance work catch all oils and fuels l
If, during the daily inspection of the oil level the hy-
and do not let them seep into the ground or into draulic oil level is found to have dropped, check all
the sewage system. Dispose of oils and fuels en- lines, hoses and components for leaks.
vironmentally. l
Seal external leaks immediately. If necessary in-
Keep used filters in a separate waste container form the responsible customer service.
and dispose of environmentally. l Do not store drums with hydraulic oil outdoors, or at
Catch biodegradable oils separately. least under a cover. Water can be drawn in through
the bunghole when the weather changes.
Notes on the fuel system l We recommend to use our filling and filtering unit
The lifetime of the diesel engine depends to a great with fine filter to fill the system. This ensures finest
extent on the cleanliness of the fuel. filtration of the hydraulic oil, prolongs the lifetime of
the hydraulic oil filter and protects the hydraulic sys-
l Keep fuel free of contaminants and water, since this tem.
will damage the injection elements of the engine.
l Clean fittings, filler covers and the area around such
l Drums with inside zinc lining are not suitable to parts before disassembly to avoid entering of dirt.
store fuel.
l Do not leave the tank opening unnecessarily open,
l When choosing the storage place for fuel make but cover it so that nothing can fall in.
sure that spilled fuel will not harm the environment.
l Do not let the hose stir up the slurry at the bottom of
the drum.
l The fuel drum must rest for a longer period of time
before drawing off fuel.
l The rest in the drum is not suitable for the engine
and should only be used for cleaning purposes.

40 BOMAG 008 917 73

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