SM BW 219 DH, PDH-5 BW 226 DH, PDH-5 Ns. 101 586 33 1001 - 00840076

Service Manual
BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 /

BW 226 PDH-5
S/N 101 586 33 1001> / S/N 101 586 37 1001> / S/N 101 586 40 1001> / S/N 101 586 42 1001>
Single drum roller
008 400 76 EN © 12/2015

2
Table of contents
Table of contents
1 General................................................................................................................................................... 9
1.1 Introduction................................................................................................................................. 10
1.2 Concerning your safety.............................................................................................................. 11
1.2.1 General prerequisites................................................................................................................. 11
1.2.2 Definition of responsible persons............................................................................................... 14
1.2.3 Fundamentals for safe operation............................................................................................... 15
1.2.4 Handling fuels and lubricants..................................................................................................... 16
1.2.5 What to do in events of emergency............................................................................................ 21
1.2.6 Park the machine in secured condition...................................................................................... 22
1.2.7 Maintenance and repair............................................................................................................. 23
1.3 Notes on repair............................................................................................................................ 27
1.3.1 General repair instructions......................................................................................................... 27
1.3.2 Tightening torques..................................................................................................................... 37
1.4 Fuels and lubricants................................................................................................................... 44
1.4.1 Engine oil................................................................................................................................... 44
1.4.2 Fuel............................................................................................................................................ 45
1.4.3 AdBlue®/DEF.............................................................................................................................. 46
1.4.4 Coolant....................................................................................................................................... 48
1.4.5 Hydraulic oil................................................................................................................................ 51
1.4.6 Gear oil SAE 75W-90................................................................................................................. 51
1.4.7 Gear oil SAE 80W-140............................................................................................................... 51
1.5 List of fuels and lubricants........................................................................................................ 53
2 Technical data..................................................................................................................................... 55
2.1 Technical data, BW 219 DH-5..................................................................................................... 56
2.1.1 Technical data............................................................................................................................ 56
2.2 Technical data, BW 219 PDH-5.................................................................................................. 59
2.2.1 Technical data............................................................................................................................ 59
2.3 Technical data, BW 226 DH-5..................................................................................................... 62
2.3.1 Technical data............................................................................................................................ 62
2.4 Technical data, BW 226 PDH-5.................................................................................................. 65
2.4.1 Technical data............................................................................................................................ 65
2.5 Additional technical data............................................................................................................ 68
3 Overview of machine.......................................................................................................................... 71
3.1 Electric systems.......................................................................................................................... 75
3.2 Diesel engine............................................................................................................................... 76
3.3 Hydraulic system........................................................................................................................ 79
3.4 Drum............................................................................................................................................. 82
3.5 Stickers and decals..................................................................................................................... 83
4 Electric systems.................................................................................................................................. 87
4.1 Overview of electric system....................................................................................................... 88
4.1.1 CAN BUS overview.................................................................................................................... 93
4.2 Telemecanique switch................................................................................................................ 95
4.3 Deutsch plug, series DT and DTM............................................................................................. 97
4.4 Acceleration transducer........................................................................................................... 101
BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 3

Table of contents
4.5 Servicing the battery, checking the main battery isolation.................................................. 103
4.5.1 Battery service......................................................................................................................... 103
4.5.2 Checking the main battery switch............................................................................................ 103
4.6 Starting the engine with jump leads........................................................................................ 104
4.7 Differential pressure switch for hydraulic oil filter, B21........................................................ 105
4.8 Air filter vacuum switch, B03................................................................................................... 106
4.9 Sensor, water in fuel filter, B124.............................................................................................. 107
4.10 Float switch in coolant compensation tank, B55................................................................. 108
4.11 Level sensor in diesel tank (R03).......................................................................................... 109
4.12 Charge control lamp............................................................................................................... 110
4.13 Central electrics...................................................................................................................... 111
4.14 Power board for SCR-heating................................................................................................ 119
4.15 Fuse assignment..................................................................................................................... 120
4.15.1 Notes on safety...................................................................................................................... 120
4.15.2 Central electrics..................................................................................................................... 120
4.15.3 Main fuses.............................................................................................................................. 121
4.15.4 Exhaust gas after-treatment system...................................................................................... 122
4.15.5 Fuse, cabin............................................................................................................................. 122
4.16 Operator’s platform................................................................................................................. 124
4.16.1 Instrument cluster................................................................................................................... 125
4.16.2 Control panel, cabin............................................................................................................... 129
5 Diesel engine..................................................................................................................................... 131
5.1 Overview.................................................................................................................................... 132
5.2 Lubrication oil circuit TCD 4.1 / 6.1......................................................................................... 139
5.3 Coolant circuit TCD 4.1 / 6.1..................................................................................................... 141
5.4 Common Rail System (CRS).................................................................................................... 143
5.5 Wastegate charge pressure controller.................................................................................... 151
5.6 Exhaust gas recirculation........................................................................................................ 152
5.7 EAT – Exhaust Aftertreatment System................................................................................... 154
5.7.1 Selective Catalytic Reduction, SCR......................................................................................... 157
5.7.2 Description of the SCR system components............................................................................ 159
5.7.3 SCR system warning strategy.................................................................................................. 164
5.8 Regeneration of exhaust gas aftertreatment system............................................................ 167
5.8.1 Preliminary remarks and safety notes...................................................................................... 167
5.8.2 Running regeneration at standstill............................................................................................ 168
5.9 Engine electrics......................................................................................................................... 170
5.9.1 Power board for SCR-heating.................................................................................................. 171
5.9.2 CAN BUS overview.................................................................................................................. 172
5.9.3 EMR4 system overview............................................................................................................ 173
5.9.4 EMR4 system components...................................................................................................... 180
5.10 Inspection and maintenance work........................................................................................ 191
5.10.1 Checking the engine oil level................................................................................................. 191
5.10.2 Change engine oil and oil filter cartridge................................................................................ 191
5.10.3 Checking the coolant level..................................................................................................... 193
5.10.4 Change the coolant................................................................................................................ 194
5.10.5 Checking the anti-freeze concentration and the condition of the coolant............................... 195
4 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

Table of contents
5.10.6 Cleaning the radiator module................................................................................................. 196

5.10.7 Checking the ribbed V-belt..................................................................................................... 197
5.10.8 Replace ribbed V-belt and idler pulley................................................................................... 197
5.10.9 Checking the AdBlue®/DEF level, topping up........................................................................ 198
5.10.10 Renewing the AdBlue®/DEF filter......................................................................................... 200
5.10.11 Replacing the fuel filter, bleeding the fuel system................................................................ 201
5.10.12 Checking, cleaning the water separator............................................................................... 204
5.10.13 Adjusting the valve clearance.............................................................................................. 204
5.10.14 Check the engine mounts.................................................................................................... 206
5.10.15 Air filter maintenance........................................................................................................... 206
6 Hydraulic system.............................................................................................................................. 209
6.1 Overview of hydraulics............................................................................................................. 210
6.2 Open and closed hydraulic circuit.......................................................................................... 213
6.3 Hydraulic units.......................................................................................................................... 215
6.3.1 Travel/vibration pump, H1........................................................................................................ 215
6.3.2 Swash plate principle, pump.................................................................................................... 219
6.3.3 Travel motor, H1...................................................................................................................... 220
6.3.4 Vibration motor A2FM.............................................................................................................. 222
6.3.5 Swash plate principle, motor.................................................................................................... 224
6.3.6 External gear pumps................................................................................................................ 226
6.3.7 Steering valve.......................................................................................................................... 228
6.4 Charge circuit............................................................................................................................ 230
6.5 Travel circuit.............................................................................................................................. 232
6.6 Vibration circuit......................................................................................................................... 240
6.7 Steering circuit.......................................................................................................................... 246
6.8 Inspection and maintenance work.......................................................................................... 250
6.8.1 Checking the hydraulic oil level................................................................................................ 250
6.8.2 Changing the hydraulic oil........................................................................................................ 250
6.8.3 Replacing the hydraulic oil filter............................................................................................... 253
6.9 Flushing and bleeding.............................................................................................................. 255
6.9.1 Flushing - general.................................................................................................................... 255
6.9.2 Drum drive................................................................................................................................ 258
6.9.3 Axle drive................................................................................................................................. 264
6.9.4 Vibration circuit......................................................................................................................... 270
6.9.5 Bleeding the travel circuit......................................................................................................... 275
6.9.6 Bleeding the vibration circuit.................................................................................................... 277
7 Air conditioning................................................................................................................................. 279
7.1 Overview.................................................................................................................................... 280
7.2 Physical principles.................................................................................................................... 281
7.3 Refrigerant R134a..................................................................................................................... 284
7.4 Compressor oil / refrigeration oil............................................................................................ 287
7.5 Working principle of the air conditioning system.................................................................. 290
7.6 Monitoring devices................................................................................................................... 291
7.7 Description of components...................................................................................................... 292
7.8 Compressor............................................................................................................................... 298
7.9 Emptying in case of repair....................................................................................................... 300

Table of contents
7.10 Drying and evacuation............................................................................................................ 301

7.11 Filling instructions.................................................................................................................. 302
7.12 Steam table for R134a............................................................................................................. 307
7.13 Inspection and maintenance work........................................................................................ 311
7.13.1 Checking the compressor oil level / refrigeration oil level...................................................... 311
7.13.2 Servicing the air conditioning system..................................................................................... 311
7.13.3 Cleaning the circulation air filter for the heating..................................................................... 314
7.13.4 Changing the fresh air filter in the cabin................................................................................. 314
7.13.5 Replacing the air conditioning compressor V-belts................................................................ 315
8 Oscillating articulated joint.............................................................................................................. 317
8.1 Overview.................................................................................................................................... 318
8.2 Dismantling the oscillating articulated joint........................................................................... 319
8.3 Assembly of oscillating articulated joint................................................................................ 321
9 Drum................................................................................................................................................... 325
9.1 Assembly of padfoot shell....................................................................................................... 326
9.2 Repair overview for drum......................................................................................................... 328
9.3 Dismantling the drum............................................................................................................... 331
9.4 Dismantling and assembling the change-over weight.......................................................... 346
9.5 Assembling the drum............................................................................................................... 349
9.6 Changing the rubber buffers, adjusting the pretension........................................................ 372
9.7 Inspection and maintenance work.......................................................................................... 377
9.7.1 Retightening the padfoot shell.................................................................................................. 377
9.7.2 Adjust the scrapers.................................................................................................................. 377
9.7.3 Checking the oil level in the exciter housing............................................................................ 378
9.7.4 Change the oil in the exciter housing....................................................................................... 378
9.7.5 Checking the oil level in the drum drive reduction gear........................................................... 380
9.7.6 Change the oil in the drum drive reduction gear...................................................................... 380
10 Drive axle........................................................................................................................................... 383
10.1 Checking the oil level in the drive axle................................................................................. 384
10.2 Change the oil in the drive axle............................................................................................. 385
10.3 Change the oil in the drive axle............................................................................................. 386
10.4 Checking the oil level in the drive axle reduction gear....................................................... 387
10.5 Change the oil in the drum drive reduction gear................................................................. 388
10.6 Checking the oil level in the wheel hubs.............................................................................. 389
10.7 Changing the oil in the wheel hubs....................................................................................... 390
10.8 Checking the tire pressure..................................................................................................... 391
10.9 Tighten the wheel nuts........................................................................................................... 392
10.10 Retightening the fastening of the axle on the frame......................................................... 393
10.11 Adjust the parking brake...................................................................................................... 394
11 Trouble shooting............................................................................................................................... 395
11.1 Preliminary remarks................................................................................................................ 396
11.2 What to do in events of emergency....................................................................................... 397
11.2.1 Actuating the emergency stop switch..................................................................................... 397
11.2.2 Disconnecting the battery....................................................................................................... 397
11.2.3 Towing the machine............................................................................................................... 398

Table of contents
11.2.4 After towing............................................................................................................................ 402

11.3 Troubleshooting, electrical systems..................................................................................... 406
11.3.1 Preliminary remarks............................................................................................................... 406
11.3.2 Starting the engine with jump leads....................................................................................... 407
11.3.3 Servicing the battery, checking the main battery isolation..................................................... 408
11.3.4 Fuse assignment.................................................................................................................... 409
11.3.5 Understanding electric circuit diagrams................................................................................. 412
11.3.6 Metrology............................................................................................................................... 425
11.3.7 ESX, checking the electric power supply............................................................................... 429
11.3.8 Diagnostics concept............................................................................................................... 437
11.4 Trouble shooting, diesel engine............................................................................................ 440
11.4.1 Starting the engine with jump leads....................................................................................... 440
11.4.2 Engine faults.......................................................................................................................... 440
11.4.3 SCR system warning strategy................................................................................................ 444
11.4.4 List of EMR4 fault codes........................................................................................................ 447
11.5 Trouble shooting, hydraulics................................................................................................. 507
11.5.1 Insufficient hydraulic power.................................................................................................... 507
11.5.2 Trouble shooting axial piston pumps...................................................................................... 510
11.5.3 Trouble shooting axial piston motors..................................................................................... 512
11.6 Trouble shooting, air conditioning system.......................................................................... 514
11.6.1 Trouble shooting in refrigerant circuit, basic principles.......................................................... 514
11.6.2 Trouble shooting procedure................................................................................................... 521
11.6.3 Leak test................................................................................................................................. 530
11.6.4 Checking the magnetic clutch ............................................................................................... 531
12 Special tools...................................................................................................................................... 533
12.1 Special tools, electrics........................................................................................................... 534
12.2 Special tools, hydraulic system............................................................................................. 535
12.2.1 Special tools, tests and adjustments...................................................................................... 535
12.2.2 Special tools for flushing........................................................................................................ 537
12.3 Special tools for oscillating articulated joint........................................................................ 542
12.4 Special tools, drum................................................................................................................. 544
12.5 List of special tools................................................................................................................. 546
Appendix............................................................................................................................................ 547
A Supplier documentation................................................................................ 549
A.A Travel pump / vibration pump.................................................................... 549
A.B Vibration motor.......................................................................................... 662
A.C Steering valve........................................................................................... 691
A.D Axle........................................................................................................... 724
A.E Repair instructions, H1 060/080/110......................................................... 810
A.F Service - Manual, H1 060/080/110............................................................ 855
A.G Reduction gear drum, 715C3B................................................................. 900
B Circuit diagrams............................................................................................ 962
B.A Hydraulic diagram, 353............................................................................. 962
B.B Hydraulic diagram, 356............................................................................. 974
B.C Wiring diagram, 327.................................................................................. 986

Table of contents

General
1 General

General – Introduction
1.1 Introduction
General This manual:
n addresses the BOMAG Customer Service and professionally
trained personnel.
n provides support for repair work or maintenance procedures on
the machine.
This manual described the deinstallation, dismantling , assembly,
installation as well as the repair of components and assembly
groups as far as this makes sense with respect to tools and spare
parts supply.
Documentation For the BOMAG machines described in this manual the following
documentation is additionally available:
n Operating and maintenance instructions
n Spare parts catalogue
n Service information (if necessary)
Genuine BOMAG spare parts

Use only genuine BOMAG spare parts.
Spare parts needed for repairs can be taken from the spare parts
catalogue for the machine.
Updating service This manual is not subject of an updating service. For this reason
we would like to draw your attention to the additionally published
service informations.
In case of a new release all necessary changes will be included.
In the course of technical development we reserve the right for
technical modifications without prior notification.
Copyright Information and illustrations in this manual must not be reproduced

and distributed, nor must they be used for the purpose of competi-
tion without the consent of BOMAG. All rights according to the
copyright law remain expressly reserved.

General – Concerning your safety
1.2 Concerning your safety

1.2.1 General prerequisites
1.2.1.1 General
This BOMAG machine has been built in compliance with the latest
technical standard and complies with the applicable regulations
and technical rules.
However, dangers for persons and property may arise from this
machine, if:
n it is used for purposes other than the ones it is intended for,
n it is operated by untrained personnel,
n it is changed or converted in an unprofessional way,
n the safety instructions are not observed.
Each person involved in the operation, maintenance and repair of
the machine must therefore read and comply with these safety reg-
ulations. If necessary, the customer must obtain the relevant signa-
tures as confirmation.
Furthermore, the following obviously also applies:
n applicable accident prevention instructions,
n generally accepted safety and road traffic regulations,
n country specific safety regulations.
It is the duty of the operator to be acquainted with the safety regu-
lations and to apply these accordingly. This also applies for local
regulations amnd regulations concerning different types of handling
activities. Should the recommendations in these instructions be dif-
ferent from the regulations valid in your country, you must comply
with the safety regulations valid in your country.
1.2.1.2 Explanation of warning signs:
DANGER!
Danger to life if failing to comply!
Sections marked accordingly indicate an extremely
dangerous situation that could lead to fatal or severe
injuries, if this warning is disregarded.
WARNING!
Danger to life or danger of severe injuries if failing
to comply!
Sections marked accordingly indicate a dangerous sit-
uation that could lead to fatal or severe injuries, if this
warning is disregarded.

CAUTION!
Danger of injury if failing to comply!
Sections marked accordingly indicate a dangerous sit-
uation that could lead to fatal or severe injuries, if this
warning is disregarded.
NOTICE!
Danger of material damage if failing to comply!
Sections marked accordingly indicate possible dangers
for machines or components.
Sections marked accordingly indicate technical infor-

mation or notes on using the machine or its compo-
nents.
ENVIRONMENT!
Environmental damage if failing to comply!
Paragraphs marked accordingly indicate practices for
safe and environment-friendly disposal of fuels and
lubricants as well as replacement parts.
1.2.1.3 Personal protective equipment

Depending on the work to be carried out, personal protective equipment is required (to be provided
by the operating company):
Working clothes Tight fitting working clothes with low tear resistance, tight
sleeves and without any projecting parts protects against
being caught by moving components.
Safety shoes To protect against heavy falling parts and slipping on

slippery ground.
Protective gloves To protect the hands against excoriation, punctures or

deep injuries, against irritating and caustic substances
as well as against burns.

Safety goggles To protect the eyes against airborne particles and fluid
squirts.
Face protection To protect the face against airborne particles and fluid
squirts.
Hard hat To protect the head against falling parts and to protect
against injuries.
Hearing protection To protect the hearing against too loud noise.
1.2.1.4 Intended use

This machine must only be used for:
n Compaction work in earth construction and road bases.
n Compaction of bituminous material, e.g. road surface layers,
Intended use also includes compliance with the specified oper-
ating, maintenance and repair measures.
1.2.1.5 Unintended use

Dangers may arise from the machine when it is used for purposes
other than the one it is intended for.
Any danger caused by intended use is the sole responsibility of the
customer or driver/operator, the manufacturer cannot be made
liable.
Examples for unintended use are:
n work with vibration on hard concrete, cured bitumen layers or
extremely frozen ground
n driving on unstable subbases or too small contact area (danger
of tipping over)
n Using the machine for towing
n use to pull down walls or demolish buildings
Transporting persons, except the machine driver, is prohibited.

Starting and operation of the machine in explosive environments

and in underground mining is prohibited.
1.2.2 Definition of responsible persons

1.2.2.1 Operating company
The operating company is the natural or juridical person who uses
the machine or in who's name the machine is used.
The operating company must make sure that the machine is only
used for the purpose it is intended for and in strict compliance with
the safety regulations mentioned in these operating and mainte-
nance instructions.
The operating company must determine and assess the danger in
his company. It must then take appropriate action to ensure health
and safety at work for his employees and point out any remaining
dangers.
The operating company must determine whether there are special
operation hazards such as a toxic atmosphere or limiting soil con-
ditions. Such conditions requires special, additional measures to
remove or reduce the hazard.
The operating company must make sure that all users read and
understand the information concerning safety.
The operating company is responsible for the planning and profes-
sional execution of regular safety inspections.
1.2.2.2 Expert / qualified person

An expert / qualified person is a person who, based on his/her pro-
fessional education and experience, has profound knowledge in
the field of construction equipment and the machine in question in
particular.
This person is acquainted with the applicable governmental indus-
trial safety regulations, accident prevention instructions, guidelines
and generally acknowledged technical rules and regulations
(standards, directives, technical rules of other member states of
the European Union or other contractual states concerning the
agreement about the European Economic Area) in as far as is nec-
essary to be able to judge the safe condition of these machines.
1.2.2.3 Driver / operator

This machine must only be operated by trained, instructed persons
entrusted by the operating company aged 18 or more.
Observe your local laws and regulations.
Rights, obligations and rules of conduct for driver or operator:

The driver or operator must:

n be instructed about his rights and obligations,
n wear protective equipment as appropriate for the application,
n have read and understood the operating instructions,
n have made himself familiar with the operation of the machine,
n be physically and psychologically able to drive and operate the
machine.
Persons under the influence of alcohol, medicine or drugs are not
allowed to operate, service or repair the machine.
Maintenance and repair work requires specific knowledge and
must therefore only be performed by trained specialists.
1.2.3 Fundamentals for safe operation

1.2.3.1 Remaining dangers, remaining risks
Despite careful work and compliance with standards and regula-
tions it cannot be ruled out that further dangers may arise when
working with and handling the machine.
Both the machine as well as all other system components comply
with the currently valid safety regulations. Nevertheless, remaining
risks cannot be ruled out completely, even when using the machine
for the purpose it is intended for and following all information given
in the operating instructions.
A remaining risk can also not be excluded beyond the actual
danger zone of the machine. Persons remaining in this area must
pay particular attention to the machine, so that they can react
immediately in case of a possible malfunction, an incident or failure
etc.
All persons remaining ion the area of the machine must be
informed about the dangers that arise from the operation of the
machine.
1.2.3.2 Regular safety inspections

Have the machine inspected by an expert (capable person) as
required for the conditions the machine is working under, but at
least once every year.
1.2.3.3 Modifications and alterations to the machine

Unauthorized changes to the machine are prohibited for safety rea-
sons.
Original parts and accessories have been specially designed for
this machine.
We wish to make explicitly clear that we have not tested or
approved any parts or accessories not supplied by us.

The installation and/or use of such products may have an adverse

effect on the active and/or passive safety.
1.2.3.4 Damage, defects, misuse of safety devices

Machines which are not safe to operate or in traffic must be imme-
diately taken out of service and shall not be used, until these defi-
ciencies have been properly rectified.
Safety installations and switches must neither be removed nor
must they be made ineffective.
1.2.3.5 Roll Over Protective Structure (ROPS)
On machines with cab the ROPS is an integral part of

the cab.
The frame of the machine must not be warped, bent or cracked in

the area of the ROPS fastening.
The ROPS must not show any rust, damage, hairline cracks or
open fractures.
The real machine weight must never exceed the testing weight for
the ROPS.
No accessories may be welded or bolted on and no additional
holes must be drilled without the consent of the manufacturer,
since this will impair the strength of the unit.
The ROPS must therefore also not be straightened or repaired if it
is damaged.
A defect ROPS must generally be replaced with an original spare
part in close coordination with the manufacturer.
1.2.4 Handling fuels and lubricants

1.2.4.1 Preliminary remarks
The operating company must ensure that all professional users
have read and follow the corresponding safety data sheets for the
individual fuels and lubricants.
Safety data sheets provide valuable information about the following
characteristics:
n Name of substance
n Possible dangers
n Composition / information on constituents
n First-Aid measures
n Fire fighting measures
n Measures in case of accidental release
n Handling and storage

n Limitation and monitoring of exposure / personal protective

equipment
n physical and chemical properties
n Stability and reactivity
n Toxicological data
n Environmental data
n Notes on waste disposal
n Information on transport
n Legislation
n other data
1.2.4.2 Safety regulations and environmental protection regulations for handling diesel fuel
WARNING!
Danger of burning by ignited diesel fuel!
– Do not allow diesel fuel to come into contact with
hot components.
– Smoking and open fire is prohibited!
– Wear your personal protective equipment (protec-
tive gloves, protective clothing).
Fig. 1 CAUTION!
Health hazard caused by contact with diesel fuel!
– Do not inhale any fuel fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled diesel fuel!
– Immediately bind spilled diesel fuel with an oil-
binding agent.
ENVIRONMENT!
Diesel fuel is an environmentally hazardous sub-
stance
– Always keep diesel fuel in proper containers.
– Immediately bind spilled diesel fuel with an oil-
binding agent.
– Dispose of diesel fuel and fuel filters according to
regulations.

1.2.4.3 Safety regulations and environmental protection regulations for handling AdBlue®/DEF
CAUTION!
Health hazard caused by ammonia vapours!
– Wear your protective outfit (protective gloves, pro-
tective clothing).
– Do not inhale ammonia vapours.
– Avoid contact and consumption.
AdBlue®/DEF has not been classified as environmen-

Fig. 2 tally harmful.
1.2.4.4 Safety regulations and environmental protection regulations for handling oil
WARNING!
Danger of burning by ignited oil!
– Do not allow oil to come into contact with hot com-
ponents.
Fig. 3 CAUTION!
Health hazard caused by contact with oil!
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
– Immediately bind spilled oil with an oil-binding
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance
– Always keep oil in proper containers.
agent.
– Dispose of oil and oil filter according to regulations.

1.2.4.5 Safety regulations and environmental protection regulations for handling hydraulic oil
WARNING!
Danger of injury caused by escaping pressure
fluid!
– Always depressurize the hydraulic system before
starting work in the hydraulic system.
tive gloves, protective clothing, goggles).
Fig. 4 Should pressure fluid penetrate the skin, immediate

medical help is required.
WARNING!
Danger of burning by ignited hydraulic oil!
– Do not allow hydraulic oil to come into contact with
hot components.
CAUTION!
Health hazard caused by contact with hydraulic oil!
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance
– Always keep oil in proper containers.
agent.
– Dispose of oil and oil filter according to regulations.

1.2.4.6 Safety regulations and environmental protection regulations for handling coolants
WARNING!
Danger of scalding by hot fluid!
– Open the coolant compensation tank only after the
engine has cooled down.
CAUTION!
Fig. 5 Health hazard caused by contact with coolant and
coolant additives!
– Do not inhale any fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled coolant!
– Immediately bind spilled coolant with an oil-binding
agent.
ENVIRONMENT!
Coolant is an environmentally hazardous sub-
stance!
– Always keep coolant and coolant additives in
proper containers.
– Immediately bind spilled coolant with an oil-binding
agent and dispose of it according to regulations.
– Dispose of coolant according to regulations.

1.2.4.7 Safety regulations and environmental protection regulations for handling battery acid
WARNING!
Danger of cauterization with acid!
– Do not allow clothes, skin or eyes to come into
contact with acid.
– Rinse off spilled battery acid immediately with lots
of water.
Fig. 6
Rinse acid off clothes, skin or eyes immediately with
lots of clear water.
Immediately call for medical advice in case of cauteri-
zation.
WARNING!
Danger of injury caused by exploding gas mixture!
– Remove the plugs before starting to recharge the
battery.
– Ensure adequate ventilation.
– Do not lay any tools or other metal objects on the
battery.
– Do not wear jewellery (watch, bracelets, etc.) when
working on the battery.
ENVIRONMENT!
Battery acid is an environmentally hazardous sub-
stance
– Dispose of battery and battery acid according to
regulations.
1.2.5 What to do in events of emergency

1.2.5.1 Actuating the emergency stop switch
In events of emergency and in case of danger actuate the emer-
gency stop switch immediately.
The machine is braked immediately, the engine is shut down.
Restart the machine only after the danger that caused the actua-
tion of the emergency stop switch has been eliminated.

In case of frequent use the wear on the multi-discs brakes will be

very high, you shoudl therefore never use the emergency stop as a
service brake.
1.2.5.2 Disconnect the battery

In events of emergency, e.g. in case of a cable fire, disconnect the
battery from the vehicle network.
Pull out the main battery switch or lift off the battery pole to do so.
1.2.5.3 Towing the machine

Tow the machine only in a case of emergency or to avoid an acci-
dent.
Before releasing the parking brake apply suitable measures to
secure the machine against unintended rolling.
Use a towing vehicle with sufficient traction and braking power for
the unbraked towed load.
If no tow bar is used, towing is only permitted uphill.
Before starting towing operations make sure that the fastening
means are able to withstand the load and are fastened at the
points provided for this purpose.
Before removing the towing facility apply appropriate measures to
secure the machine against unintended rolling.
1.2.6 Park the machine in secured condition.

1. Drive the machine onto level and firm ground.
2. To stop the machine return the travel lever to middle position
and shift it to the right to lock (parking brake position).
ð The parking brake warning lamp lights up.
Fig. 7

NOTICE!
Danger of engine damage!
– Do not shut down the engine all of a sudden from
full load speed, but let it idle for about 2 minutes.
3. Turn the ignition key to position "0" and pull it out.

4. Open and secure the engine hood.
Fig. 8
5. Turn the main battery switch counter-clockwise and pull it

out.
6. Close the engine hood and lock it if necessary.
Fig. 9
1.2.7 Maintenance and repair

n Repairs and welding work must only be carried out by qualified
and specially instructed persons.
n For overhead maintenance and repair work use the access
steps and working platforms provided or other secure means.
n Do not use machine parts as access steps.
n Tools, lifting gear, lifting tackle, supports and other auxiliary
equipment must be fully functional and in safe condition.
n When performing maintenance work on machines used in con-
taminated environments, all applicable national or local safety
regulations must be applied.
n Do not perform maintenance and repair work while the
machine is driving or the engine is running.
n Park the machine on horizontal, level, firm ground.
n Secure the articulated joint with the articulation lock.
n Lower the dozer blade / bucket to the ground.
n Remove the key from the ignition switch.
n Pull the key off the main battery switch.
n Keep unauthorized persons away from the machine.

1.2.7.2 Work on hydraulic lines

Relieve hydraulic pressures before working on hydraulic lines.
Hydraulic oil escaping under pressure can penetrate the skin and
cause severe injury. Immediately call for medical advice when
injured by hydraulic oil.
Do not step in front of or behind the wheels when performing
adjustment work in the hydraulic system.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature – danger of
scalding!
Any hydraulic oil must be caught and disposed of in an environ-
mentally friendly manner.
Always catch and dispose of hydraulic oils separately.
Do not start the engine after draining the hydraulic oil. Once all
work is completed (with the system still depressurized!) check all
connections and fittings for leaks.
Hydraulic hoses must be visually inspected at regular intervals.
Do not mix up hoses by mistake.
Only genuine BOMAG replacement hydraulic hoses ensure that
the correct hose type (pressure range) is used at the right location.
1.2.7.3 Working on the engine

Do not work on the fuel system while the engine is running -
danger to life due to high pressures!
Wait until the engine has stopped, then wait another approx. 15
minutes.
Keep out of the danger zone during the initial test run.
In case of leaks return to the workshop immediately.
Make sure that the engine cannot be accidently started during
service and repair work.
Drain the engine oil at operating temperature – danger of scalding!
Wipe off spilled oil, collect leaking oil and dispose of it in an envi-
ronmentally friendly way.
Store used filters and other oil contaminated materials in a sepa-
rate, specially marked container and dispose of them in an environ-
mentally friendly way.
Do not leave any tools or other objects, that could cause damage,
in the engine compartment.
The settings for idle speed and highest speed must not be
changed, since this would affect the exhaust gas values and cause
damage to engine and power train.
Engine and exhaust system work with high temperatures. Keep
combustible materials away and do not touch any hot surfaces.

Check and change coolant only when the engine is cold. Collect
coolant and dispose of it in an environmentally friendly way.
1.2.7.4 Maintenance work on electric components and battery

Before starting to work on electric parts of the machine disconnect
the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and do not bridge
fuses - fire hazard!
When working on the battery do not smoke, do not use open fire.
Do not let acid come in contact with hands or clothes. When
injured by acid, flush off with clear water and seek medical advice.
Metal objects (e.g. tools, rings, watch straps) must not come in
contact with the battery poles – danger of short circuit and burning!
When recharging non-serviceable batteries remove all plugs, to
avoid the accumulation of explosive gases.
Switch off the charging current before removing the charging
clamps.
Ensure sufficient ventilation, especially if the battery is to be
charged in a closed room.
Dispose of old batteries according to regulations.
1.2.7.5 Working on the air conditioning

Faults on the air conditioning should only be remedied by author-
ized service personnel.
Do not perform welding work in the vicinity of the air conditioning.
Danger of explosion!
Do not clean the condenser in the air conditioning system with a
hot water jet. Danger of explosion!
Do not release refrigerant into the atmosphere, but dispose of envi-
ronmentally.
1.2.7.6 Working on wheels and tires

Explosion-like bursting of tires or parts of tires and rims can cause
most severe or even fatal injuries.
Check tires and wheels every day for cuts, bulges, damaged rims,
missing wheel studs or nuts. Do not drive with damaged tires or
wheels.
Install the tires only if are sufficiently experienced and with the right
tools at hand. If necessary have the tires assembled in a qualified
workshop.
Always ensure the correct tire pressure on one axle and do not
exceed the specified maximum pressure.

When checking the tire pressure you should stand in the travel line
of the wheel. Use an at least 6 m air hose, so that you can keep a
safe distance to the tire.
The tires are filled with a water/anti-freeze mixture. You should
therefore always check the tire pressure with the tire valve in top
position!
Always close the valves with their dust caps.
Always consider the heavy weight of a wheel during disassembly
and assembly. Use a crane or forklift truck equipped with suitable
claws or a belt-type hoisting device.
1.2.7.7 Cleaning work

Do not perform cleaning work while the motor is running.
Allow the engine to coola down before starting cleaning work on
engine and exhaust system.
Do not use gasoline or other easily inflammable substances for
cleaning.
When cleaning with steam cleaning equipment do not subject elec-
trical parts and insulation material to the direct jet of water, or cover
it beforehand.
Do not guide the water jet into the exhaust pipe and into the air
filter.

General – Notes on repair
1.3 Notes on repair

1.3.1 General repair instructions
NOTICE!
Ensure strict cleanliness when performing repair
work!
– No foreign objects should enter into open systems.
– Thoroughly clean the area around the affected
components.
– Dry off wet locations with compressed air.
Before removing or disassembling parts, assembly groups, compo-

nents or hoses mark these parts for easier assembly.
1.3.1.1 Repair notes for electrics

Electrics and welding
NOTICE!
Electrical components may get damaged by
welding work!
– Always remove the main battery switch.
– Disconnect the batteries and connect negative and
positive cables.
– Pull the plugs off the control units.
Always fasten the earth clamp of the welding unit in the immediate
vicinity of the welding location.
When choosing the location for the earth clamp make sure that the
welding current will not pass through joints or bearings.
Battery
Maintenance free batteries also need care. Mainte-
nance free only means that the fluid level does not
need to be checked.
Each battery suffers under self-discharge, which may,
in not checked occasionally, even cause damage to
the battery as a result of exhaustive discharge.
Exhausted batteries (batteries with formation of sul-
phate on the plates) are not covered under warranty!
n When removing a battery always disconnect the minus pole

before the plus pole. When installing the battery connect the
minus pole after the plus pole to avoid short circuits.
n Assemble the battery terminal clamps without force.

n Always keep battery poles and terminal clams clean to avoid

high transition resistances when starting and the related devel-
opment of heat.
n Make sure the battery is properly fastened in the vehicle.
Generator n 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 electronic equip-
ment.
n When removing the battery cable, the B+-nut underneath on
the generator side may also be loosened. This nut must in this
case be retightened.
n When connecting e.g. the battery cable to the terminal of the
generator you must make sure that the polarity is correct (gen-
erator B+ to the + pole of the battery). Mixing up the polarities
by mistake causes short circuit and damage to the rectifier ele-
ments - the generator will be out of function.
n The generator can only be operated with the battery con-
nected. Under special conditions emergency operation without
battery is permitted, the lifetime of the generator is in such
cases especially limited.
n Plus and minus cables must be disconnected during rapid
charging of the battery or electric welding on the vehicle.
n 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. After cleaning the gener-
ator should be operated for about 1 - 2 minutes to remove any
deposits of water from the generator.
Starter n So-called jump starting (using an additional external battery)

without the battery connected is dangerous. When discon-
necting the cables from the poles high inductivities (arcs,
voltage peaks) may occur and destroy the electrical installa-
tion.
n For purposes like e.g. purging the fuel systems, starters may
be operated for maximum 1 minute without interruption. Then
you should wait for at least 30 minutes (cooling down) until
trying again. During the 1 minute starting period this process
should not be interrupted.
n Starter motors must not be cleaned with high pressure steam
cleaning equipment.
n The contacts on starter terminals 30, 45, 50 must be protected
against unintended shorting (jump protection).
n When replacing the starter the ring gear on the engine flywheel
must be checked for damage and its number of teeth - if nec-
essary replace the ring gear.
n Always disconnect the battery before starting assembly work in
the starter area of the engine or on the starter itself.

1.3.1.2 Repair notes for hydraulics

Please note
Cleanliness is of utmost importance. Dirt and other
contaminations must strictly be kept out of the system.
n Connections and screw fittings, filler neck covers and their

immediate surrounding areas must be cleaned before removal.
n Before loosening hoses, pipe lines etc. relieve all pressure
from the system.
n During repair work keep all openings closed with clean plastic
plugs and caps.
n Never run pumps, motors and engine without oil or hydraulic
oil.
n When cleaning hydraulic components take care not to damage
any fine machined surfaces.
n Chemical and rubber dissolving cleansing agents may only be
used to clean metal parts. Do not let such substances come in
contact with rubber parts.
n Rinse of cleaned parts thoroughly, dry them with compressed
air and apply anti-corrosion oil immediately. Do not install parts
that show traces of corrosion.
n Avoid the formation of rust on fine machined parts caused by
hand sweat.
n Use new O-rings or seal rings for reassembly.
n Use only hydraulic oil as sliding agent when reassembling. Do
not use any grease!
n Use only the specified pressure gauges. Risk of damaging the
pressure gauges under too high pressure.
n Check the hydraulic oil level before and after the work.
n Use only clean hydraulic oil in strict compliance with the speci-
fication in the operating and maintenance instructions to fill the
hydraulic system.
n Check the hydraulic system for leaks, if necessary find and rec-
tify the cause.
n Before taking new hydraulic components into operation fill
these with hydraulic oil as specified in the operating and main-
tenance instructions.
n After changing a hydraulic component thoroughly flush, refill
and bleed the complete hydraulic system.
n Perform pressure tests at operating temperature of the
hydraulic oil (approx. 40 °C).
n After the completion of all tests perform a test run and then
check all connections and fittings for leaks with the engine still
stopped and the hydraulic system depressurized.
Before commissioning n Fill the housings of hydraulic pumps and motors with hydraulic
oil. Use only hydraulic oils according to the specification in the
maintenance instructions.
n After changing a component flush the hydraulic system as
described in the flushing instructions.

Taking into operation n Bleed the hydraulic circuits.

n Start up the hydraulic system without load.
n Check the hydraulic oil level in the tank, if necessary top up
with hydraulic oil as specified in the operating and maintenance
instructions or drain oil off into a suitable container.
After taking into operation n Check fittings and flanges for leaks.
n After each repair check all adjustment data, system pressures,
rotational speeds and nominal values in the hydraulic system,
adjust if necessary.
n Do not adjust pressure relief valves and control valves to
values above their specified values.
1.3.1.3 Repair notes for Common Rail engines

Special requirements with respect to cleanliness in the fuel system
do apply for commissioning, maintenance and repair work, particu-
larly for engines with the Common Rail System. Contamination like
dirt, welding residues or similar can lead to the failure of individual
components and adversely affect engine operation.
Spare parts should be left in their original packaging as long as
possible and should only be unpacked just before use.
When parts are unpacked any connections must be closed with
suitable plugs or caps, in order to prevent 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.
Fig. 10
Notes and measures to be applied n The fuel system must be closed. Visual examination for leaks /
before starting work in the fuel damage in the fuel system.
system n Before starting work in the fuel system clean the complete
engine and the engine compartment with the system still
closed.
n The engine should be dry before work is started in the fuel
system.
n Blow drying with compressed air is only permitted while the fuel
system is still closed.

n When using steam cleaning equipment cover control unit,

cable plugs, all other electrical connections and the generator
beforehand and do not expose these items to the direct steam
jet.
n Electrical plug connections must be plugged in during jet
cleaning.
n Remove loose parts (e.g. paint scales that may have come off
during assembly work) with an industrial vacuum cleaner or
any means of extraction.
n Vacuum cleaning equipment must generally be used for
cleaning when the fuel system is open.
n Perform work on the fuel system only in a clean environment
(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.
n Air movements, which could swirl up dust, such as brake
repairs or starting of engines, must be strictly avoided.
n For work, such as the removal and assembly of defective com-
ponents on the Common Rail System, it is highly recom-
mended to cordon off a dedicated area in the workshop. This
area must be spatially separated from other areas (which are
used for general vehicle repairs, like brake repairs)
n No general machine tools should be operated in this room.
n Periodic cleaning of this workshop area is obligatory, draughts,
ventilation system and heating blowers must be minimized.
n Engine compartment area where dirt particles could come
loose, should be covered with new, clean foil.
n Working means and tools must be cleaned before being used
for work. Use only tools without damaged chromium coating, or
tools without chromium coating.
Notes and measures to be applied n Wear clean working clothes.

during work in the fuel system n Use only lint-free cleaning cloths for work in the fuel system.
any means of extraction. Vacuum cleaning equipment must
generally be used for cleaning when the fuel system is open.
n Do not use any previously used cleaning or testing fluids for
cleaning.
n The use of compressed air for cleaning is prohibited when the
fuel system is open.
n Work on disassembled components must only be carried out at
a specially furnished work place.
n When removing or assembling components you should not use
any materials from which particles or fibres could flake off
(cardboard, wood, towels).
n Dismantled parts must only be wiped off with clean, lint-free
cloths if required. No dirt particles must be wiped into the com-
ponents.

n Close openings on components and engine immediately with

suitable plugs/caps.
n Plugs/caps must only be removed just before the installation.
n Keep plugs/caps in their original packaging, where they are
protected against dust and dirt, dispose of after one time use.
n Take new parts out of their original packaging just before
installation.
n Removed components must be stored in new, sealable bags or
– if available – in the packaging material of the new compo-
nents.
n Always use the original packaging material of the new part to
return the disassembled old component.
Notes and measures concerning n For work, such as the removal and assembly of defective com-
the workshop area ponents on the Common Rail System, it is highly recom-
mended to cordon off a dedicated area in the workshop. This
area must be spatially separated from other areas (which are
used for general vehicle repairs, like brake repairs)
n The workshop floor must be sealed or tiled.
n No welding equipment, grinding machines, general machine
tools, brake or power test benches must be operated in this
room.
n Periodic cleaning of this workshop area is obligatory, draughts,
ventilation system and heating blowers must be minimized.
Notes and measures for work place n A special work place must be set up for work on disassembled
and tools in the workshop components.
n Clean disassembly and assembly tools at regular intervals and
keep these in a closed tool cabinet.
any means of extraction.
1.3.1.4 Repair notes for gaskets and mating surfaces

Leaking sealing faces can mostly be traced back to incorrect
assembly of seals and gaskets.
n Before assembling a new seal or gasket make sure that the
sealing surface is free of pitting, flutes, corrosion or other
damage.
n Inappropriately stored or handled seals (e.g. hanging from
hooks or nails) must under no circumstances be used.
n Install seals and gaskets only with sealing compound, grease
or oil, if this is specifically specified in the repair instructions.
n If necessary remove any old sealing compound before assem-
bling. For this purpose do not use any tools that could damage
the sealing surfaces.

n Sealing compound must be applied thin and evenly on the cor-

responding surfaces; take care that the compound does not
enter into oil galleries or blind threaded bores.
n Examine the contact faces for scratches and burrs, remove
these with a fine file or an oilstone; take care that no grinding
dust and dirt enters into tapped bores or enclosed components.
n Blow out lines, ducts and gaps with compressed air, replace
any O-rings and seals that have been dislodged by the com-
pressed air.
Assembly of radial seals

1. Lubricate sealing lips (2) with clean grease; in case of double
seals fill the space between the sealing lips with a generous
amount of grease.
2. Slide the seal over the shaft, with the lip facing towards the
fluid to be sealed.
NOTICE!
Use an assembly sleeve.
If possible, use an assembly sleeve (1) to pro-
tect the lip from being damaged by sharp
Fig. 11 edges, threads or splines. If no assembly
sleeve is available, you should use a plastic tube
or adhesive tape to prevent the sealing lip from
being damaged.
3. Lubricate the outer rim of the seal (3) and press it flat on the
housing seat.
4. Press or knock the seal into the housing, until it is flush with
the housing surface.
NOTICE!
Use an assembly bell.
If possible, use an "assembly bell" (1 ), to make
sure that the seal will not skew. In some cases
it may be advisable to assemble the seal into the
housing first, before sliding it over the shaft.
Under no circumstances should the full weight of
the shaft rest on the seal.
Fig. 12
If you have no proper service tools at hand, use
a suitable 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.

1.3.1.5 Repair notes for ball and roller bearings

n If one bearing of a pair of bearings shows defects, we highly
recommend the replacement of both bearings.
n Remove any lubricant residues from the bearing to be exam-
ined by washing it with a suitable degreasing agent.
n Check balls or rollers, running surfaces, outer faces of outer
races and inner faces of inner races for visible damage. If nec-
essary, replace the bearing.
n Check the bearing for clearance and resistance between the
inner and outer races, replace if necessary.
n Lubricate the bearing with the recommended type of grease
before assembly or reassembly.
n On greased bearings (e.g. wheel bearings) fill the space
between the bearing and the outer seal with the recommended
type of grease before assembling the seal.
n Check shaft and bearing housing for discolouration or other
signs of movement between bearing and seats.
n Make sure that shaft and housing are free of burrs before
Fig. 13 assembling the bearing.
n Always mark the individual parts of separable 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 bearing instead.
NOTICE!
When assembling the ball or roller bearing to the shaft
load must only be applied to the inner race (1).
When fitting the bearing into the housing load must
only be applied to the outer race (2).
Fig. 14
1.3.1.6 Feather keys and keyways

1. Clean the feather key, examine it and only use it again if it
had not been damaged.
2. Deburr and clean the edges of keyways thoroughly before
reassembling the feather key.
Fig. 15
1.3.1.7 Repair notes for cotter pins

Cotter pins

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 illustration, unless
specified differently.
Fig. 16
1.3.1.8 Repair notes for screws and nuts
NOTICE!
Tighten screws and nuts in accordance with the values
in the following tables. Tightening torques deviating
from the ones in the table are specially mentioned in
the repair instructions.
Damaged screws must not be used again.
Recutting threads with thread cutters or taps adversely
affects the strength and leak tightness of the screw
joint. Damaged or corroded thread pitches can cause
incorrect torque value readings.
Self-locking nuts must generally be replaced after dis-
assembly.
The use of screws with too high strength can cause
damage!
n Nuts of a higher strength can generally be used instead of nuts

of a lower strength classification.
n When checking or retightening screw joints to the specified
tightening torque you should first relieve by a quarter turn and
then tighten to the correct torque.
n Before tightening you should slightly oil the thread, in order to
ensure low friction movement. This, however, does not apply
for self-locking nuts.
n Make sure that no oil or grease will enter into blind tapped
bores. The hydraulic power generated when turning in the
screw could cause breakage of the part in question.
1.3.1.9 Strength classes, metric screws and nuts

Strength classes, metric screws The strength classes (from 3.6 to 12.9) are specified for all strength
classes from a nominal diameter of 5mm. The corresponding iden-
tification can be found where allowed for by the shape of the
screw.

Example: A screw is identified with 12.9.

The first number corresponds with 1/100 of the nominal tensile
strength (minimum tensile strength) in N/mm2.
n The nominal tensile strength is 12 X 100 N/mm2 = 1200 N/
mm2.
The second number specifies 10-times the ration between lower
yield point and nominal tensile strength (yield point ratio).
When exceeding the lower yield point, the material will

return to its original shape when being relieved (plastic
deformation).
When exceeding the upper yield point the material will
not restore its original shape after being relieved.
Fig. 17: Identification of screws
n The lower tensile strength is 9/10 X 1200 N/mm2 = 1080 N/
mm2.
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.
Strength classes of metric nuts 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 (1) for screw connections with full load capacity
In a connection with a screw, these nuts (1) must be able to bear
the full pre-load at the yield point.
Nut height above 0.8 d (d = nominal dimension).
Fig. 18: Identification of nuts

Strength class of nut Strength class of associated
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 (2) for screw connections with limited load capacity

The preceding "0" indicates that, due to their low height, nuts 2
Ä Fig. 18 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 (3) for screw connections without specified load capacity
This standard contains strength classes (hardness classes) for
nuts 3 Ä Fig. 18, for which no load values can be specified, e.g.
because of their shape and dimensions, but which can only be
classified by their hardness.
Nut height below 0,5 d (d = nominal dimension).
Identification in clock system

For small nuts Ä Fig. 19 the clock system can be used for identifi-
cation.
n The 12 o'clock position is identified by a dot or the manufactur-
er's symbol.
n The strength class is identified by a dash (b).
Fig. 19: Identification of nuts in clock
system
1.3.1.10 Identification of UNF-threads

Identification of UNF-threads
Studs (1)
At the outmost end a short end of the component is reduced to its
core diameter.
Nuts (2).
An uninterrupted series of stamped in circles parallel to the axis of
the nut on a hexagon area.
Screws (3)
The screw head is marked with a stamped in, round cavity.
Fig. 20
1.3.2 Tightening torques

The values specified in the table apply for screws:
n black oiled
n with surface protection A4C
n with surface protection DACROMET

DACROMET is a surface protection that mainly con-

sists of zinc and aluminium in a chromium oxide
matrix. DACROMETIZATION provides excellent corro-
sion protection for metal surfaces by applying a min-
eral coating with metallic-silver appearance.
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 With-
worth has a flank of only 55°.
Tightening torques for screws with metric unified thread
Tightening torques Nm (Coefficient of friction µ tot. = 0.14)

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
Tightening torques for screws with metric unified fine thread

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 98 137 162
M12 x 1.5 93 127 152
M14 x 1.5 152 216 255


Screw dimension
8.8 10.9 12.9
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 x 2 1147 1578 1920
M30 x 2 1568 2254 2695
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
4² 276 388 464

3/ - 10 UNC
4² 308 432 520

3/ - 16 UNC

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 (Coefficient of friction µ

Thread diameter tot. = 0.14)
10.9
M12 x 1.5 100
M14 x 1.5 150
M18 x 1.5 300 - 350
M20 x 1.5 400 - 500
M22 x 1.5 500 - 600
Tightening torques for screws with UNC thread, UNC Unified Coarse Thread Series, American Unified
Coarse Thread

Screw dimension
8.8 10.9 12.9
4² 11 15 19
1/ - 20
16² 23 32 39
5/ - 18
8² 39 55 66
3/ - 16
16² 62 87 105
7/ - 14
2² 96 135 160
1/ - 13
16² 140 200 235

9/ - 12
8² 195 275 330

5/ - 11
4² 345 485 580

3/ - 10
8² 560 770 940

7/ -9
1² - 8 850 1200 1450
1 1/8² - 7 1200 1700 2000
1 1/4² - 7 1700 2400 2900
1 3/8² - 6 2200 3100 3700
1 1/2² - 6 3000 4200 5100

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

Screw dimension
8.8 10.9 12.9
4² 13 18 22
1/ - 28
16² 25 35 42
5/ - 24
8² 45 63 76
3/ - 24
16² 70 100 120

7/ - 20
2² 110 155 185

1/ - 20
16² 155 220 260

9/ - 18
8² 220 310 370

5/ - 18
4² 385 540 650

3/ - 16
8² 620 870 1050

7/ - 14
1² - 12 930 1300 1600
1 1/8² - 12 1350 1900 2300
1 1/4² - 12 1900 2700 3200
1 3/8² - 12 2600 3700 4400
1 1/2² - 12 3300 4600 5600

Tightening torques for hydraulic fittings with metric thread - series “L” (pressures up to 250 bar)
Thread Spanner width Tightening torque [Nm]

M12 x 1.5 14 15
M14 x 1.5 17 20
M16 x 1.5 19 30
M18 x 1.5 22 35
M22 x 1.5 27 65
M26 x 1.5 32 80
M30 x 2 36 130
M36 x 2 41 160
M45 x 2 50 200
M52 x 2 60 250
Tightening torques for hydraulic fittings with metric thread - series “S” (pressures up to 400 bar)

M14 x 1.5 17 14
M16 x 1.5 19 25
M18 x 1.5 22 27
M20 x 1.5 24 48
M22 x 1.5 27 55
M24 x 1.5 30 65
M30 x 2 36 110
M36 x 2 46 140
M42 x 2 50 180
M52 x 2 60 220
Tightening torques for hydraulic fittings with UNF-thread (Unified Fine Thread)
16² 14 15
7/ - 20
2² 17 20
1/ - 20
16² 19 27
9/ - 18
4² 22 55
3/ - 16
8² 27 80
7/ - 14


1 1/16² - 12 32 110
1 3/16² - 12 36 125
1 5/16² - 12 41 160
1 5/8² - 12 220
1 7/8² - 12 270

General – Fuels and lubricants
1.4 Fuels and lubricants

1.4.1 Engine oil
1.4.1.1 Oil quality
Engine oils for use in DEUTZ engines are classified in DEUTZ
Engine Oil Quality Classes (DQC).
The following engine oil specifications are permitted:
n Low-ash engine oils complying with DQC III-LA or DQC IV-LA.
Avoid mixing of engine oils.
The list of approved engine oils is also available on the

Internet under the following address:
www.deutz.com
de SERVICE \ Maintenance \ Betriebsstoffe \ Öle \
DEUTZ Quality Class \ DQC Freigabeliste
en SERVICE \ Maintenance \ Operating Liquids\ Oils \
DEUTZ Quality Class \ DQC Release List

1.4.1.2 Oil viscosity

Since engine oil changes its viscosity with the temperature, the
ambient temperature at the operating location of the engine is of
utmost importance when choosing the viscosity class (SAE-class).
Only use multi-purpose oils.
The temperature indications of the SAE-class always refer to fresh
oils. In travel operation engine oil ages because of soot and fuel
residues. This adversely affects the properties of the engine oil,
especially under low ambient temperatures.
Optimal operating conditions can be achieved by using the oil vis-
cosity chart as a reference.
Fig. 21: Oil viscosity diagram
1.4.1.3 Oil change intervals

If the oil change intervals are not reached over a period of one
year, the oil change should be performed at least 1 x per year, irre-
spective of the operating hours reached.
The oil change interval must be halved if at least one of the fol-
lowing conditions applies:
n Permanent ambient temperatures below -10 °C (14 °F)
n Lubrication oil temperatures below 60 °C (84 °F).
1.4.2 Fuel
1.4.2.1 Fuel quality
In order to fulfil the regulations of the exhaust gas legislation,
diesel engines equipped with an exhaust gas after-treatment
system, must only be operated with sulphur-free diesel fuel.
The following fuel specifications are permitted:
n EN 590
n ASTM D975 Grade-No. 1-D S15 and 2-D S15

1.4.2.2 Winter fuel

For winter operation use only winter diesel fuel, to avoid clogging
because of paraffin separation.
At very low temperatures disturbing paraffin separation can also be
expected when using winter diesel fuel.
Diesel fuels suitable for temperatures down to -44 °C (-47 °F) are
available for Arctic climates.
NOTICE!
– The admixture of petroleum and the addition of
"flow enhancing additives" (fuel additives) is not
permitted.
1.4.2.3 Storage
Even traces of zinc, lead and copper can cause deposits in the
injection nozzles, especially in modern Common-Rail injection sys-
tems.
Zinc and lead coatings in refuelling systems and fuel lines are not
permitted.
Copper containing materials (copper lines, brass items) should be
avoided, because they can cause catalytic reactions in the fuel with
subsequent depositing in the injection system.
1.4.3 AdBlue®/DEF
1.4.3.1 AdBlue®/DEF quality
AdBlue® is a non-inflammable, non-toxic, colour and odourless as
well as water soluble fluid.
AdBlue® is alternatively also called "Urea" or "DEF" (Diesel
Exhaust Fluid).

NOTICE!
Damage to the exhaust gas after-treatment system!
Filling the AdBlue®/DEF tank with cleaning agent or
other operating media or fuels, mixing in additives or
diluting AdBlue®/DEF will damage the exhaust gas
after-treatment system.
Use only AdBlue®/DEF as per DIN 70070/ISO 22241.
In case of incorrect filling you should contact a quali-
fied expert workshop.
If AdBlue®/DEF comes into contact with spray painted
or aluminium surfaces, you should rinse off the
affected areas immediately with lots of water.
1.4.3.2 Low outside temperatures

AdBlue®/DEF freezes at a temperature of approx. -11 °C (12 °F).
Winter operation is also guaranteed at temperatures below -11 °C
(12 °F).
At low temperatures crystals may form on the wound hose
between engine and exhaust silencer Such crystallization does not
impair the function of the exhaust gas after-treatment. If necessary
just remove the crystals with clear water.
1.4.3.3 Storage
Use only tanks made of the following material to store AdBlue®/
DEF:
n Cr-Ni steels acc. to DIN EN 10 088-1/2/3
n Mo-Cr-Ni steels acc. to DIN EN 10 088-1/2/3
n Polypropylene
n Polyethylene
NOTICE!
Containers made of the following materials are not
suitable for storing AdBlue®/DEF, because compo-
nents of these materials may dissolve and thus
damage the exhaust gas after-treatment system.
– Aluminium
– Copper
– copper containing alloys
– non-alloyed steel
– galvanized steel

The service life of AdBlue®/DEF without any loss of quality is influ-

enced by the storage conditions.
Exposure of stored containers to direct insolation and UV-radiation
must be strictly avoided.
constant storage temperature Minimum shelf life (months)

< 10 °C (50 °F) 36
< 25 °C (77 °F) 18
< 30 °C (86 °F) 12
< 35 °C (95 °F) 6
> 35 °C (95 °F) Check the product before use
AdBlue®/DEF should remain in the tank for max. four months.
1.4.3.4 Cleanliness
NOTICE!
Contaminated AdBlue®/DEF, e.g. caused by other
operating media, cleaning agent or dust will have the
following effects:
– increased emission values
– damage to catalytic converters
– engine damage
– malfunction of the exhaust gas after-treatment
system.
Always ensure strict cleanliness of the AdBlue®/DEF in order to

avoid malfunction of the exhaust gas after-treatment system.
If you pump AdBlue®/DEF out of the tank, e.g. in case of a repair,
do not fill it back into the tank. Otherwise the cleanliness of the fluid
can no longer be guaranteed.
1.4.4 Coolant
1.4.4.1 General
For fluid cooled engines the cooling fluid must be prepared by
admixing a cooling system protection agent to the fresh water and
should be checked within the specified maintenance intervals.
This prevents damage caused by corrosion, cavitation, freezing
and overheating.

1.4.4.2 Water quality

The correct quality of water is highly important when preparing
coolant. Clear and clean water within the boundaries of the fol-
lowing analysis values should generally be used.
Analysis values
pH-value at 20 °C (68 °F) 6.5 - 8.5
Chlorine-ion content max. 100 mg/l
Sulphate ion content max. 100 mg/l
Water hardness (ion content of max. 3.56 mmol/l
calcium and magnesium )
max: 356 mg/l (ppm)
Germ degree: max. 20 °dH
English degree: max: 25 °eH
French degree: max: 35.6 °fH
Bacteria, fungi, yeasts not permitted
Information concerning the water quality can be obtained from the

waterworks.
If the fresh water analysis values are unknown, these must be
determined with the help of a water analysis.
If the values of the analysis deviate, the water must be treated
accordingly:
pH-value too low - Adding of caustic lye of soda or caustic
potash solution.
Water hardness too - Mix with soft, distilled or fully demineral-
high ized water
Chlorides and/or sul- - Mix with distilled or fully demineralized
phates too high water
NOTICE!
– Another analysis must be made after the fresh
water has been prepared.
1.4.4.3 Cooling system protection agent

As a protection against frost, corrosion and boiling point anti-freeze
agents must be used under any climatic conditions.
Coolant is prepared by adding an ethylene-glycol based anti-freeze
agent with corrosion inhibiting properties to the cooling water.
We therefore highly recommend our BOMAG cooling system pro-
tection agent.

If our cooling system protection agent is not available for any

important reasons, you may, in exceptional cases, use products
that have been approved by the engine manufacturer.
The list of approved lubrication oils is also available in the

Internet under the following address:
www.deutz.com
de SERVICE \ Maintenance \ Betriebsstoffe \ Kühlsys-
temschutz
en SERVICE \ Maintenance \ Operating Liquids \
Coolant
Products of the same product group (see Deutz Technical Circular

Cooling System Protection Agents) can be mixed with each other.
The BOMAG cooling system protection agent corresponds with
product group A.
NOTICE!
– Do not mix different coolants and additives of any
other kind.
– Before changing the product you must clean the
entire cooling system.
– Consult our customer service if in doubt.
– The cooling system protection agent must be used
all year round, to provide adequate corrosion pro-
tection.
The mixing ratio must not be below or exceed the following

value:
Cooling system Fresh water Cold protection

protection agent down to
min. 35% 65% -22 °C (-8 °F)
40% 60% -28 °C (-18 °F)
45% 55% -35 °C (-31 °F)
max. 50% 50% -41 °C (-42 °F)
NOTICE!
– A proportion of more than 50% of cooling system
protection agent causes a drop in cooling power.
– The use of corrosion protection oils as cooling
system protection agents is not permitted.

1.4.5 Hydraulic oil

1.4.5.1 Mineral oil based hydraulic oil
The hydraulic system is operated with hydraulic oil HV 46 (ISO)
with a kinematic viscosity of 46 mm2/s at 40 °C (104 °F) and
8 mm2/s at 100 °C (212 °F).
For topping up or for oil changes use only hydraulic oil, type HVLP
according to DIN 51524, part 3, or hydraulic oils type HV according
to ISO 6743/3.
The viscosity index (VI) should be at least 180 (observe informa-
tion of manufacturer).
1.4.5.2 Bio-degradable hydraulic oil

The hydraulic system can also be operated with a synthetic ester
based biodegradable hydraulic oil.
The biologically quickly degradable hydraulic oil Panolin HLP
Synth.46 meets all demands of a mineral oil based hydraulic oil
according to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.46 always use
the same oil to top up.
When changing from mineral oil based hydraulic oil to an ester
based biologically degradable oil, you should consult the lubrica-
tion oil service of the oil manufacturer, or our customer service for
details.
NOTICE!
Risk of damage!
– Check the filter more frequently after this change.
– Perform regular oil analyses for content of water
and mineral oil.
– Replace the hydraulic oil filter element every 500
operating hours.
1.4.6 Gear oil SAE 75W-90

Use a fully synthetic gear oil in accordance with SAE 75W-90,
API GL5 with a kinematic viscosity of at least 16 mm2/s at 100 °C
(212 °F).
1.4.7 Gear oil SAE 80W-140

Use a fully synthetic gear oil in accordance with SAE 80W-140,
API GL5 with a kinematic viscosity of at least 20 mm2/s at 100 °C
(212 °F).

It is a hypoid lubricant of highest quality class for transmissions

under extreme strain.

General – List of fuels and lubricants
1.5 List of fuels and lubricants

Assembly group Fuel or lubricant Spare parts Filling quantity
number
Summer Winter Observe the
level mark!
Engine oil SAE 15W-40 009 920 09 13 l
Specification: Ä Chapter 1.4.1 ‘Engine oil’ 20 l (3.4 gal us)
on page 44
SAE 10W-40
SAE 10W-30
SAE 30 SAE 10W
Fuel Diesel Winter diesel fuel 235 l
Specification: Ä Chapter 1.4.2 ‘Fuel’ (62 gal us)
on page 45
Coolant Mixture of water and anti-freeze agent 009 940 08 26 l
Specification: Ä Chapter 1.4.4 ‘Coolant’ 20 l (6.9 gal us)
on page 48
Hydraulic system Hydraulic oil (ISO), HVLP 46 009 930 09 75 l
Specification: Ä Chapter 1.4.5.1 ‘Mineral oil 20 l (20 gal us)
based hydraulic oil’ on page 51
or ester based biodegradable hydraulic oil
Specification: Ä Chapter 1.4.5.2 ‘Bio-degrad-
able hydraulic oil’ on page 51
Exciter housing Gear oil SAE 75W-90 009 925 05 1 l each
Specification: Ä Chapter 1.4.6 ‘Gear oil SAE 20 l (0.26 gal us)
75W-90’ on page 51
Drum drive reduction Gear oil SAE 80W-140 009 925 07 5l
gear
80W-140’ on page 51
Drive axle Gear oil SAE 80W-140 009 925 07 12.5 l
80W-140’ on page 51
Axle reduction gear Gear oil SAE 80W-140 009 925 07 1.9 l
80W-140’ on page 51
Wheel hubs Gear oil SAE 80W-140 009 925 07 3.7 l each
80W-140’ on page 51
Tires Water + calcium chloride 295 l + 100 kg
(80 gal us +
220 lbs)

General – List of fuels and lubricants
Assembly group Fuel or lubricant Spare parts Filling quantity

number
Summer Winter Observe the
level mark!
or water + magnesium chloride 308 l + 87 kg
(81 gal us +
192 lbs)
Air conditioning Refrigerant R134a 1500 g
(3.3 lbs)

Technical data
2 Technical data

Technical data – Technical data, BW 219 DH-5
2.1 Technical data, BW 219 DH-5

2.1.1 Technical data
Dimensions
Fig. 22
A B D H H2 K L O1/2 S W
3255 2300 1600 2295 3034 495 6502 85 40 2130
(128) (91) (63) (90) (119) (19.5) (256) (3.3) (1.6) (84)
Dimensions in millimetres
(Dimensions in inch)
Weights
Max. operating weight 22250 kg
(49053) (lbs)
Operating weight with ROPS cabin (CECE) 19600 kg
(43211) (lbs)
Axle load, drum (CECE) 12800 kg
(28219) (lbs)
Axle load, wheels (CECE) 6800 kg
(14991) (lbs)
Static linear load 60.1 kg/cm
(337) (pli)

Travel characteristics
Travel speed 0 – 10 km/h
(0 – 6.2) (mph)
Max. gradability without/with vibration (soil dependent) 60/57 %
Drive
Engine manufacturer Deutz
Type TCD 6.1 L6
Cooling Fluid
Number of cylinders 6
Rated power ISO 3046 150 kW
Rated power SAE J 1995 202 hp
Rated speed 2000 min-1
Electric system
Voltage 12 V
Tyres
Tyre size 23.1-26 12PR
Air pressure, nominal value 1.4 bar
(20) (psi)
Brakes
Service brake hydrostatic
Parking brake hydro-mechanical
Steering
Type of steering Oscill.-articul.
Steering angle +/- 35 °
Oscillation angle +/- 12 °
Inner track radius 4117 mm
(162) (in)

Exciter system
Drive system hydrostatic
Frequency (1/2) 26/31 Hz
(1560/1860) (vpm)
Amplitude (1/2) 2.13/1.18 mm
(0.084/0.046) (in)
Centrifugal force (1/2) 310/240 kN
(69691/53954) (lbf)
Filling capacities
Fuel (diesel) 280 l
(74) (gal us)
2.1.1.1 Noise and vibration data

The following noise and vibration data were determined in accord-
ance with the following guidelines under equipment specific condi-
tions and by using harmonized standards:
n EC Machine Directive edition 2006/42/EC
n Noise Emission Directive 2000/14/EC, Noise Protection Direc-
tive 2003/10/EC
n Vibration Protection Directive 2002/44/EC
During operation these values may vary because of the prevailing
operating conditions.
2.1.1.1.1 Noise data

Sound pressure level on the opera- LpA = 75 dB(A), determined acc. to ISO 11204 and EN 500
tor's stand
Guaranteed sound power level LWA = 110 dB(A), determined acc. to ISO 3744 and EN 500
2.1.1.1.2 Vibration data

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

EN 500/ISO 5349 is ≤ 2.5 m/s2.

Technical data – Technical data, BW 219 PDH-5
2.2 Technical data, BW 219 PDH-5

Dimensions
Fig. 23
3255 2300 1500 2295 3034 495 6502 85 35 2130
(128) (91) (59) (90) (119) (19.5) (256) (3.3) (1.4) (84)
Weights
(46628) (lbs)
(44423) (lbs)
(29432) (lbs)
(14991) (lbs)

Travel speed 0 – 10 km/h
(0 – 6.2) (mph)
Drive
Type TCD 6.1 L6
Cooling Fluid
Electric system
Voltage 12 V
Tyres
Air pressure, nominal value 1.4 bar
(20) (psi)
Brakes
Steering
(162) (in)

Exciter system
(1560/1860) (vpm)
Amplitude (1/2) 1.98/1.09 mm
(0.078/0.043) (in)
(70815/55528) (lbf)
Filling capacities
Fuel (diesel) 280 l
(74) (gal us)

tive 2003/10/EC

tor's stand


EN 500/ISO 5349 is ≤ 2.5 m/s2.

2.3 Technical data, BW 226 DH-5

Dimensions
Fig. 24
3355 2500 1600 2339 3078 430 6742 185 40 2130
(132) (98) (63) (92) (121) (16.9) (265) (7.3) (1.6) (84)
Weights
(58879) (lbs)
(55116) (lbs)
(37633) (lbs)
(17483) (lbs)
Static linear load 80.1 kg/cm
(448) (pli)

Travel speed 0 - 10 km/h
(0 - 6.2) (mph)
Drive
Type TCD 6.1 L6
Cooling Fluid
Electric system
Voltage 12 V
Tyres
Air pressure, nominal value 2 bar
(29) (psi)
Brakes
Steering
(168) (in)

Exciter system
(1560/1860) (vpm)
Amplitude (1/2) 2.09/1.14 mm
(0.082/0.045) (in)
(69691/53954) (lbf)
Filling capacities
Fuel (diesel) 280 l
(74) (gal us)

tive 2003/10/EC

tor's stand


EN 500/ISO 5349 is ≤ 2.5 m/s2.

2.4 Technical data, BW 226 PDH-5

Dimensions
Fig. 25
3355 2500 1500 2339 3078 430 6742 185 35 2130
(132) (98) (59) (92) (121) (16.9) (265) (7.3) (1.4) (84)
Weights
(60627) (lbs)
(56769) (lbs)
(39242) (lbs)
(17527) (lbs)

Travel speed 0 - 10 km/h
(0 - 6.2) (mph)
Drive
Type TCD 6.1 L6
Cooling Fluid
Electric system
Voltage 12 V
Tyres
Air pressure, nominal value 2 bar
(29) (psi)
Brakes
Steering
(168) (in)

Exciter system
(1560/1560) (vpm)
Amplitude (1/2) 1.98/1.09 mm
(0.078/0.043) (in)
(70815/55528) (lbf)
Filling capacities
Fuel (diesel) 280 l
(74) (gal us)

tive 2003/10/EC

tor's stand


EN 500/ISO 5349 is ≤ 2.5 m/s2.

Technical data – Additional technical data
2.5 Additional technical data

Additional engine data
Combustion principle 4-cycle diesel engine with charge
air cooling
Combustion method Direct fuel injection
Injection system Common Rail
Exhaust gas recirculation externally cooled
Exhaust gas aftertreatment CSF (Catalyzed Soot Filter)
module + SCR (Selective Cata-
lytic Reduction) module
Low idle speed rpm 800
High idle speed rpm 2300
ECO rpm 1800
Valve clearance intake ° 75° ±15°
Valve clearance exhaust ° 120° ±15°
Travel pumps
Manufacturer Sauer
Type H1 P089 RA (EP)
System Axial piston/swash plate
Max. displacement cm3/rev 89
High pressure limitation bar 450
Charge pressure relief valve for bar 25
high idle speed, travel pump 1
Charge pressure relief valve, against block
travel pump 2
Pressure override bar 400
Reduction gear drum BW 219

Manufacturer Bonfiglioli
Type 711C3
Transmission ratio 93.9
Reduction gear drum BW 226

Manufacturer Bonfiglioli
Type 715C3

Transmission ratio 129.3
Drum drive motor / axle drive

motor
Manufacturer Sauer
Type H1 B110
System Axial piston – bent axle
Max. displacement (stage 1) cm3/rev 110
Min. displacement (stage 2) cm3/rev 50
Perm. leak oil rate l/min 2
Flushing rate l/min 5
Flushing pressure limitation bar 16
Vibration pump
Manufacturer Sauer
Type H1 P0 78 RA (EP)
System Axial piston/swash plate
Max. displacement cm3/rev 78
Starting pressure bar 365 ± 65
Operating pressure (soil bar approx. 100
dependent)
High pressure limitation bar 400
Charge pressure relief valve 34
Pressure override bar 400
Auxiliary pump cm3/rev 17
Vibration motor, BW 219

Manufacturer Bosch-Rexroth
Type A2FM 63 HDD
System Axial piston/bent axle
Displacement cm3/rev 63
Vibration motor, BW 226

Manufacturer Bosch-Rexroth
Type A2FM 80 HDD
System Axial piston/bent axle
Steering/charge pump
System Gear pump
Max. steering pressure bar 175 + 25
Steering valve
Manufacturer Danfoss
Type OSPC 500 ON
System Rotary spool valve
Rear axle
Manufacturer Dana
Type CHC 193/99
Differential No-Spin
Degree of locking % 100
Reduction ratio 93.74

Overview of machine
3 Overview of machine

Overview of machine
Fig. 26
Fig. 27
1 Central electrics
2 Drum
3 Articulated joint
4 Diesel engine

Overview of machine
Simple servicing due to excellent

accessibility
Fig. 28
Smooth drum: BVC, D and DH

machines
Fig. 29
n Compaction of sand, gravel and crushed rock
n Tapered drum edges
n Optimum surface quality

Overview of machine
Padfoot drum: PD and PDH

machines
Fig. 30
n Use on cohesive soils
n Surface enlargement for faster drying
n Flexing and kneading effect
Padfoot shell optional equipment
Fig. 31
For the compaction of cohesive soils; the third of the circumference
shells are placed on the smooth drum and bolted together.
It is recommended to change the drive wheels from

diamond tread to tractor tread.

Overview of machine – Electric systems
3.1 Electric systems
Fig. 32
1 Travel control, A34
2 Inclination sensor, B57
3 Power board
4 Diagnostics interface BOMAG, X34
5 Diagnostics interface Deutz, X32
6 Telematic module, A124
7 Engine control unit, A48
8 Connector strip X100 to X109
9 Measurement technology control, A83

Overview of machine – Diesel engine
3.2 Diesel engine

This single drum roller is powered by a Deutz engine series TCD
6.1. This is a water-cooled 6-cylinder diesel engine with a Common
Rail injection system.
The engine is designed with four-valve technology as well as turbo-
charging with intercooler.
Fig. 33
1 Diesel engine
2 Fuel pre-cleaner with water level sensor (B124)
3 Main fuses
4 Power board for SCR heating
5 AdBlue tank and solenoid valve for tank heating
6 AdBlue pumping module
7 Central electrics, engine control unit (A48)
8 Diagnostics interface, diesel engine (X32)
9 Interface to diesel engine (X41)

Fig. 34
1 Fuel lift pump
2 Fuel pre-filter with water separator, drain valve and optional fuel pre-heating (R79)
3 Water level sensor (B124)
4 Main fuel filter
5 Fuel tank
6 Diesel engine

EAT System – Exhaust Aftertreat- This system is characterized by the following technologies:
ment System
n CSF (Catalyzed Soot Filter) module: Diesel Oxidation Cata-
lyst (DOC) + Diesel Particulate Filter (DPF)
n SCR (Selective Catalytic Reduction) module with ammonia slip
catalyst
Fig. 35: Principle diagram

1 Mixing tube
2 Pressure sensor after SCR- catalyst, B305
3 Nox sensor before SCR-system, B224
4 Dosing module
5 Temperature sensor, B215
6 Nox sensor after SCR-system, B225
7 SCR- catalyst
8 Module bracket
9 CSF (Catalyzed Soot Filter) module
10 Differential pressure sensor after CSF-module
11 Differential pressure sensor before CSF-module, B216

Overview of machine – Hydraulic system
3.3 Hydraulic system
Fig. 36
1 Drum drive motor
2 Steering valve
3 Hydraulic oil tank
4 Steering/charge pump
5 Travel pump for axle drive
6 Travel pump for drum drive
7 Vibration pump
8 Charge oil filter
9 Brake valve, Y04 & travel speed range selection for drum, Y30
10 Rear travel motor, with travel speed range selector Y31
11 Manifold block with thermostat
12 Steering cylinder
13 Vibration motor

Fig. 37
1 Pressure sensor B235, axle MB
2 Pressure sensor B237, drum MB
3 Vibration pump
5 Pressure sensor B236, drum MA
6 Pressure sensor B234, axle MA
8 Steering/ charge pump with installed vibratory plates, BVC or dozer blade as tandem gear pump
MS Pressure test port, charge pressure
ML Pressure test ports for steering
Vibration pump
high amplitude low amplitude

Current on coil C1 C2
Plug Y07 Y08
Pressure on port A B

Travel pump for drum drive
Forward Reverse
Plug Y73 Y72
Travel pump for axle drive
Forward Reverse
Plug Y16 Y17

Overview of machine – Drum
3.4 Drum
Fig. 38
1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel gear
5 Travel motor
6 Drum shell
7 Rubber buffer
8 Rectangular rubber buffers
9 Travel bearings

Overview of machine – Stickers and decals
3.5 Stickers and decals

Keep stickers and decals in good and legible condition and comply
with their meaning.
Replace damaged and illegible stickers or decals immediately.
Fig. 39
1 Warning sticker - Danger of crushing
2 Information sticker - AdBlue®/DEF
3 Information sticker - Lifting point
4 Information sticker - Lashing point
5 Information sticker - Engine oil drain
6 Information sticker - Coolant drain
7 Information sticker - Hydraulic oil drain
8 Prohibition sticker - High pressure cleaning
9 Information sticker - Guaranteed sound capacity level

Fig. 40
1 Information sticker - Low ash engine oil
2 Information sticker - Ultra-low sulphur fuel
3 Information sticker - Diesel
4 Prohibition sticker - High pressure cleaning
5 Operation sticker - Main battery switch
6 Information sticker - Main battery switch plus side
7 Warning sticker - Vehicle voltage 12 V
8 Information sticker - Hydraulic oil

Instruction sticker - Always wear your seat belt
Fig. 41


Electric systems
4 Electric systems

Electric systems – Overview of electric system
4.1 Overview of electric system
Fig. 42
3 Power board

Fig. 43
1 Machine with Telematic
2 GPS satellite
3 Mobile communications network
4 External partner
5 Internet (Cloud)
6 User
7 Telematic server
BOMAG TELEMATIC is a Fleet Management System. BOMAG
TELEMATIC enhances the effective use of machines. The
POWER variant enables continuous recording of the fuel consump-
tion.
With BOMAG TELEMATIC the machine operator can localize his
machines and also detect and save operating states. Actual oper-
ating hours are documented. Maintenance planning and documen-
tation is entirely mapped in BOMAG TELEMATIC.
BOMAG TELEMATIC is able to recognize unauthorized use or
theft. Many insurance companies award this with reduced insur-
ance premiums.
The system consists of a machine integrated hardware and an
internet application. All data are saved in a database. Access is
individual for each user and password protected.

BOMAG TERRAMETER
Fig. 44
The optional TERRAMETER, a development by BOMAG, supports
the driver in a special way. It shows the corresponding compaction
value digitally and in form of a bar graph. Moreover, it also informs
about the end of compaction. This helps to avoid unnecessary
passes , saves time and thus enhances the economy.
Optional modules In addition, the system can also be extended with further modules.
The technical requirements for surface covering compaction con-
trol are achieved with BOMAG COMPACTION METER (BCM) and
GPS, the satellite-assisted location system. This means that all
compaction data of a construction project can be recorded, pro-
cessed, managed, graphically displayed and, if required, printed
out.

Continuous Compaction Control
Fig. 45: BCM05, example single drum roller

1 PC or Laptop
2 Printer
3 Print-outs
4 BCM 05mobile
5 CAN-USB communication
6 Output of measuring data in from of a file on any type of data
storage medium for transfer to third parties (e.g. client, con-
struction supervision, etc.)
The assignment of individual measuring values to the coordinates
is accomplished by manual selection of a track and within the track
by the tachometer signals from the displacement transducer on the
roller.
n Indication of end of compaction
n Office software for analyses
n Interchangeable between machines

Position acquisition for GPS fields
Fig. 46
n To exactly 22 cm
n No local referencing station
The assignment of the individual measuring values to the meas-
uring position is accomplished with the help of an automatic posi-
tion acquisition system.

4.1.1 CAN BUS overview
Fig. 47: CAN-Bus

A15 Monitoring module
A34 Machine control, ESX
A48 Control unit for engine management, MCM

A67 Keyboard anti-theft protection

A83 Measurement control, BVC
A87 USB-CAN interface
A124 Telematic module
A144 Control console cabin
P15 BCM05
S55 Travel lever
X32 Diagnostics interface for engine control unit
X34 Diagnostics interface for ESX machine control
CAN-bus, Controller Area Network created by Bosch at the end of the eighties for automobile applica-
tions.
Development objectives:
Real-time critical, robust and low price communication of control
units, such as transmission and engine control, but also less time
critical applications in the field of convenience electronics, such as
air conditioning.
Why CAN?
n Networking of control units for the realization of complex func-
tions.
n Reduction of the extend of wiring and plug connections.
n Better diagnostic possibilities (central diagnostics socket).
Characteristics of CAN
It is a kind of serial data transmission. The individual bits are trans-
mitted one after the other, only 2 lines are required.
CAN lines are twisted together 30 to 40 times per metre. Electro-
Fig. 48 magnetic interferences therefore always occur simultaneously in
both lines, the software is thus able to filter out interfering signals
more easily.
Wire (+) = cable colour blue
Wire (-) = cable colour yellow
Measuring on the CAN
Signals transmitted through the bus line can generally not be
measured with simple measuring instruments. Testing is therefore
quite complicated for the user. Correct connection of lines can only
be checked by means of a continuity test. BOMAG display mod-
ules are connected to the BUS to give engineers and user the pos-
sibility to detect faults or to receive information from the BUS.

Electric systems – Telemecanique switch
4.2 Telemecanique switch

Dismantling
Fig. 49
1. Lift up the interlock (5).
2. Fold down the switch block (4).
3. Loosen the screw (1).
Fig. 50: Folding down the switch

block
4. Lift up the interlock (2) and pull out the front element (3).
Fig. 51: Pulling out the front element

Electric systems – Telemecanique switch
Assembly
Fig. 52: Assembly

1. Insert the front element (3) into the bore in the control panel.
2. Clip the fastening adapter (6) onto the front element (3).
Watch the marks on front element and fastening

flange.
3. Tighten the screw (1) with a tightening torque of 0.6 Nm.
Fig. 53: Observe the marks.
4. Clip on the switch block (4).
Hook in the switch block at the bottom first.
Fig. 54: Install the switch block

Electric systems – Deutsch plug, series DT and DTM
4.3 Deutsch plug, series DT and DTM

General
NOTICE!
Do not crimp more than one lead per pin or per socket.
Sockets and pins must not be soldered to leads, they
may only be crimped (see special tools for electrics).
When connecting sockets and plugs these must
engage with a noticeable click when both halves inter-
Fig. 55: Crimp connections lock.
The plug connection should not be separable (without
loosening the interlock).
Removing DT contacts
Fig. 56: DT Series

Plug connectors DT and DTM have a wedge to hold the pins and
sockets in their position. This wedge can be removed and
replaced, without having to cut any leads.
Fig. 57
1. Pull the orange wedge out with long nose pliers.
2. Slightly pull the lead and unlock the interlocking hook with a
screw driver.

3. Pull the contact out of the socket.
Use the same method when assembling the

socket.
In this case the interlock disassembly tool serves
as an aid to remove the wedges.
Installing DT contacts
Fig. 58
1. Insert the contacts through the rubber grommet until they
click into place.
2. Insert the orange wedge in direction of arrow.

socket.
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
1. Perform a pull test on each lead, each of the terminals and

connections must withstand a pulling force of 45 N without
any difficulties.

Removing DTM contacts
Fig. 59: DTM Series

Plug connectors DT and DTM have a wedge to hold the pins and
sockets in their position. This wedge can be removed and
replaced, without having to cut any leads.
Fig. 60
1. Pull the orange wedge (interlock) out with long nose pliers.
2. Slightly pull the lead and unlock the interlocking hook with a
screw driver.
3. Pull the contact out of the socket.

socket.
In this case the interlock disassembly tool serves
as an aid to remove the wedges.

Installing DTM contacts
Fig. 61
1. Insert the contacts through the rubber grommet until they
click into place.
2. Insert the orange wedge, until it clicks into place.

socket.
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
1. Perform a pull test on each lead, each of the terminals and

connections must withstand a pulling force of 45 N without
any difficulties.

Electric systems – Acceleration transducer
4.4 Acceleration transducer
Fig. 62
BVC machines and machines with E-VIB meter are equipped with
two piezo-electric acceleration transducers, which are mounted to
the drum.
During operation these transducers transmit the acceleration sig-
nals to the measuring ESX.
The function of the piezo electric acceleration transducer is based
on the self-charging effect of quartz crystals under mechanical load
(pressure, tension, torsion) in vertical direction to the polar axes,
which was discovered in 1880 by J. and P. Curie.
Mode of action
1 Seismic mass (m)Seismic mass

2 Piezo electric material
3 Acceleration (a)
The piezo electric acceleration transducer consists of two basic
components:
n Piezo electric material
n Seismic mass
Fig. 63

Electric systems – Acceleration transducer
Once side of the piezo disc is connected with the so-called seismic
mass, the other one with a rigid carrier. When this combination is
set to oscillate, the seismic (sluggish) mass transfers a force to the
piezo disc. According to Newton's Law the resultant force is the
product of acceleration and mass.
A small wire connects the piezo element with the sensor socket.
The piezo electric effect generates a charge (u) on the electrodes,
which is proportional to the force and thus also to the acceleration
(a).

Electric systems – Servicing the battery, checking the main battery isolation
4.5 Servicing the battery, checking the main battery isolation

4.5.1 Battery service

need to be checked.
Protective equipment: n Working clothes

n Protective gloves
n Safety goggles
1. Park the machine in secured condition Ä Chapter 1.2.6 ‘Park
the machine in secured condition.’ on page 22.
2. Remove the battery and clean the battery compartment.
3. Clean the outside of the battery.
4. Clean battery poles and pole clamps and grease them with
pole grease (Vaseline).
5. Install the battery and check the battery fastening.
6. On serviceable batteries check the acid level, if necessary
top up to the filling mark with distilled water.
Fig. 64
4.5.2 Checking the main battery switch

out.
2. Check by turning the ignition key, whether the battery is dis-
connected from the electric system of the machine.
Fig. 65

Electric systems – Starting the engine with jump leads
4.6 Starting the engine with jump leads
NOTICE!
A wrong connection will cause severe damage in
the electric system.
– Bridge the machine only with a 12 Volt auxiliary
battery.
1. Connect the plus pole of the external battery first with the
plus pole of the vehicle battery using the first jump lead.
2. Then connect the second battery cable first to the minus pole
of the current supplying auxiliary battery and then to engine
or chassis ground, as far away from the battery as possible.
3. Start the engine.
NOTICE!
Danger of damage to the electronic system!
If no powerful consumer is switched on voltage peaks
Fig. 66
may occur when separating the connecting cables
between the batteries, which could damage electrical
components.
4. Once the engine is running switch on a powerful consumer

(working light, etc.).
5. After starting disconnect the negative poles first and the posi-
tive poles after.
6. Switch off the consumer.

Electric systems – Differential pressure switch for hydraulic oil filter, B21
4.7 Differential pressure switch for hydraulic oil filter, B21

The differential pressure switch switches to ground at a pressure
differential of Δp 3.6 bar.
Fig. 67
The switching condition is detected by the ESX-control (A34) and

forwarded to the instrument cluster (A15) via the bus connection.
Fig. 68: ESX control
m Hydraulic oil filter warning light
Fig. 69: Instrument cluster

Electric systems – Air filter vacuum switch, B03
4.8 Air filter vacuum switch, B03

The vacuum switch 1 operates at a vacuum of > 50 mbar.
Fig. 70

d Air filter warning light

Electric systems – Sensor, water in fuel filter, B124
4.9 Sensor, water in fuel filter, B124
Fig. 73

e Warning light water in fuel filter

Electric systems – Float switch in coolant compensation tank, B55
4.10 Float switch in coolant compensation tank, B55
Fig. 76

h Coolant level warning lamp

Electric systems – Level sensor in diesel tank (R03)
4.11 Level sensor in diesel tank (R03)

The sensor inside the tank is equipped with a float, which drops or
rises with the fuel level. Contact springs mounted on the float
thereby slide along two resistor wires arranged parallel to the
movement of the float and generate a resistance value, which is
proportionate to the fluid filling level. The corresponding resistance
value is measured by an electric meter and displayed as fluid level
value.
Fig. 79: R03
Nominal values:
n Tank empty, 64.2 Ω
n Tank full, 0.5 Ω
u Fuel level gauge
If no level switch is connected or the cable is broken, no fuel level

will be displayed
Fig. 80: A15

Electric systems – Charge control lamp
4.12 Charge control lamp
Fig. 81
The switching condition on the generator terminal (D+) is detected

by the ESX-control (A34) and forwarded to the instrument cluster
via the CAN-bus connection.
k Charge control light
The control lamp lights up if a ground signal is applied

to the generator terminal (D+).
The relay K61 on the Powerboard also switches if a
ground signal is applied to the generator terminal (D+).
The LED (D61) on the relay base lights up.

Electric systems – Central electrics
4.13 Central electrics
Fig. 84
3 Power board
Power board for high-current appli-

cations
Fig. 85
Power elements implemented in the board by means of pressing
technology, ensure permanent connections, which meet highest
quality demands throughout the entire life cycle of the product and
thus are a major contribution to product reliability.

A powerful electric press fit is made by pressing a press pin

through the contacted hole in a printed circuit board - within the
course of a cold welding process - whereby a gas tight electrical
connection is achieved.
Advantages
n Particularly quick connection with the wiring loom of the vehicle
n Possibility of combining high-current and signal lines
n Highest possible avoidance of connecting and wiring faults
n Gain in space due to the possibility of compact design (e.g. by
placement from both sides) as well as weight reduction
n 100% electric testing
n Increased reliability and prolonged lifetime of the overall
system
n Clear display of switching states by means of LEDs (simple
diagnostics).

Fig. 86: Plug side

X0A Supply potential 30
X0B Supply GND
X0C Supply potential 30 before battery

Fig. 87: Top side

R10 Dropping resistor for generator excitation

+30 Potential 30, battery
X8B Potential 31, GND
X8A Potential 30
Fuse test Test base for fuses
The LEDs on the relay bases light when Ubat is applied

to the relay coils.
Example: LED D145 on relay K145

K38
K41
K13
K145
K05
K61
K22
K209
K16
K43
K78 K09
K06
A02
K11
K48
S-538-0055
Fig. 88: Installed relays

A01 Flasher encoder
K05 Relay for start current
K06 Relay front working head lights
K09 Relay for air conditioning
K11 Relay for potential 30 to 15
K13 Relay for warning horn
K16 Relay for front working head lights
K22 Relay for engine solenoid
K38 Relay for starter control
K41 Disconnecting relay
K43 Vibration relay for single drum roller
K48 Relay for travel lever 0-position

K61 Relay for charge control

K78 Relay for emulsion pump for BW 11 RH-5
K145 Relay for starter solenoid
FM2 F19
FM1 F22
F243
F39
F157
F23 F268
F68
F11
F13 F84
F09 F67
F10 F07 F146
F124
F40
F103
F91
F08
F05
F244
F29
F24
F169 F122
F148 S-538-0056
Fig. 89: Installed fuses

1 Fuse test cap

Test base to check the conductivity

of plug-in fuses
The printed circuit board is a equipped with a fuse test

socket (Fuse Test). When plugging in an intact fuse,
the LED "DX" lights up.
Fig. 90: Pictogram:

Electric systems – Power board for SCR-heating
4.14 Power board for SCR-heating
Fig. 91
K192 Relay, SCR control
K193 Relay, heating Urea feed module
K194 Relay, heating Urea suction line
K195 Relay, heating Urea throttle line
K196 Relay, heating Urea pressure line

Electric systems – Fuse assignment
4.15 Fuse assignment

4.15.1 Notes on safety
WARNING!
Danger of injury by fire in the machine!
– Do not use fuses with higher ampere ratings and
do not bridge fuses.
4.15.2 Central electrics

Fuse Amperage Designation
F05 20 A 12-V socket
F07 10 A Hazard light
F08 10 A Direction indicators
F09 10 A Parking and tail light, left
F10 10 A Parking and tail light, right
F11 15 A Headlight, front
F13 15 A Starter switch
F19 15 A Working head lights, front
F22 15 A Working head lights, rear
F23 15 A Warning horn
F24 10 A Instrument cluster
F29 15 A Compressor - air suspended seat, seat heating
F39 80 A Main fuse for cabin
F40 25 A Heating, air conditioning, fan
F67 15 A Control (potential 30)
F68 15 A Reserve (potential 30)
F84 10 A Control (contact 54)
F91 5A Sensors
F122 10 A Engine control
F124 25 A Fuel pre-heating
F157 30 A Starter


F169 5A Start current
F243 7.5 A BOMAG TELEMATIC (potential 30)
F244 5A BOMAG TELEMATIC (potential 15)
F268 20 A Fuel pump
FM1 1A Sensors
FM2 1A Sensors
4.15.3 Main fuses

The main fuse box is located in the engine compartment.
Fig. 92

F164 150 A (B+) charge line
F00 125 A Main fuse (potential 30)
Fig. 93

F48 150 A Preheating system

4.15.4 Exhaust gas after-treatment system

The fuse box for the exhaust gas aftertreatment system is located
in the engine compartment under the battery cover.

F238 15 A Exhaust gas recirculation
F250 30 A SCR-control
F251 10 A NOx-Sensors
(NOx: Nitric oxides)
F310 5A Sensor for AdBlue®/DEF quality
F312 20 A Spare
F313 20 A Spare
4.15.5 Fuse, cabin
Fig. 94
Position Fuse Amperage Designation

1 F17 5A Radio
2 F264 10 A BCM
3 F271 10 A BCM net
4 F150 5A GPS
5 F266 10 A Radio/Tachograph
6 F143 20 A Rear windscreen heating
7 F28 15 A Rear windscreen wiper/washer
8 F27 15 A Front windscreen wiper/washer


9 F279 15 A Spare
10 F272 5A Control console cabin

Electric systems – Operator’s platform
4.16 Operator’s platform
Fig. 95
1 [A15] Instrument cluster
2 [S01] Emergency stop switch
3 [S09] Rotary switch for vibration, amplitude pre-selection
4 [S26] Rotary switch for working lights (optional equipment)
5 [S299] Rotary button for regeneration
6 [S127] Rotary switch for engine speed
7 [S37] Rotary switch for direction indicators (optional equipment)
8 [S154] Rotary switch for hazard light system (optional equipment)
9 [S15] Rotary switch for illumination (optional equipment)
10 [S42] Rotary switch for travel speed ranges
11 [S00] Starter switch
12 [S55] Travel lever

4.16.1 Instrument cluster

Overview
Fig. 96
1 Control and warning lamps
2 INFO 3 display field
5 Engine rpm-meter
6 AdBlue®/DEF level gauge
7 Fuel level gauge
8 not used

Control and warning lamps
Designation Note
Warning lamp AdBlue®/DEF Lights up if the AdBlue®/DEF filling level is low, if the AdBlue®/DEF
quality is insufficient or if there is a fault in the exhaust gas after-
treatment system.
Flashes in case of an extremely low AdBlue®/DEF filling level.
Fill up AdBlue®/DEF or have the exhaust gas after-treatment
system checked immediately.
Regeneration warning lamp Flashes when regeneration at standstill is required.
n Carry out regeneration at standstill Ä Chapter 5.8.2 ‘Running
regeneration at standstill’ on page 168.
Lights up during regeneration at standstill.
If regeneration at standstill is not carried out, the crystallization in
the exhaust gas aftertreatment system will increase. The engine
power is reduced.
n Regeneration at standstill must be carried out by authorized
Service Personnel.
Exhaust gas temperature Lights with too high exhaust gas temperature during regeneration
warning lamp at standstill.
Air filter warning lamp Lights up if the air filter is blocked.

Clean or replace the air filter.
Water in fuel warning lamp Lights up when the water content in the fuel pre-cleaner reaches
the sensor contacts, the warning buzzer sounds.
Clean the water separator.
Pre-heating control lamp Lights up during pre-heating.
Coolant temperature Lights up when the engine overheats. The engine power is
warning lamp reduced after a short while.
Run the engine with idle speed or, if necessary, shut it down and
clean the radiator. If necessary, repair the engine.
Coolant level warning lamp Lights up if the coolant level is too low. The engine is shut down
after a short while.
Check coolant level, check cooling system for leaks, repair if nec-
essary.
Engine oil pressure warning Lights up if the engine oil pressure is too low. The engine is shut
lamp down after a short while.
Check the engine oil level; if necessary, repair the engine.
Central warning lamp Flashes in case of system faults, warnings and for information.

Designation Note
Charge control lamp Lights up if the battery is not being charged.
Check the V-belt drive, if necessary repair the generator.
Hydraulic oil temperature Lights up if the hydraulic oil temperature is too high. The engine
warning lamp power is reduced after a short while.
Run the engine with idle speed or shut it down if necessary and
clean the radiator.
Hydraulic oil filter warning Lights up, if the hydraulic oil filter is blocked. Warning buzzer
lamp sounds. The engine is shut down after 2 minutes.
Check the hydraulic system and replace the hydraulic oil filter.
Driver's seat warning lamp Lights up when the driver's seat is not occupied. If the machine is
travelling, the warning buzzer will sound and the machine is decel-
erated after 3 seconds.
To continue driving, occupy the driver's seat and shift the travel
lever again to the desired travel direction through the parking
brake position.
Parking brake warning lamp Lights up when the parking brake is applied.
Indicator control lamp
INFO 1 display field

Each actuation of the button switches between:
n Operating hours
n Coolant temperature
n Battery voltage
n Vibration frequency (optional equipment)
Fig. 97


Each actuation of the button switches between:
n Travel speed
n Evib-value (optional equipment)
n Travel speed and Evib-value (optional equipment)
Fig. 98
Designation Note
Immobilizer control lamp Lights up when the electronic immobilizer is active.
ECOSTOP control lamp Lights up after the engine has been shut down by the ECOSTOP
function.
Floating position control Lights up when the dozer blade is in floating position.
lamp

4.16.2 Control panel, cabin
Fig. 99
Pos. Designation Note

a not used
b not used
c Push button to start measurement only for Terrameter with printer
LED lights: Measurement possible.
LED flashing: Measurement active.
d Push button to stop measurement only for Terrameter with printer
LED lights: EVIB-value has not increased by
more than 10% since the last pass.
e Push button to print measurement report only for Terrameter with printer
LED lights: The measuring report can be
printed out.
f Push button to delete measurement only for Terrameter with printer
g not used
h not used
i Push button for rear windscreen wiper Interval/on/off
j Push button for rear windscreen wiper
k Push button for rear windscreen heating The rear windscreen heating is shut down after
three minutes.
l Push button for rear working lights
m Push button for inside cabin light

Pos. Designation Note

n Push button for front working lights
o Push button for flashing beacon
p Push button for front windscreen washer
q Push button for front windscreen wiper Interval/on/off

Diesel engine
5 Diesel engine

Diesel engine – Overview
5.1 Overview
Fig. 100
1 Diesel engine
3 Main fuses
This single drum roller is powered by a Deutz engine series TCD

6.1. This is a water-cooled 4-cylinder diesel engine with a Common
Rail injection system.
The engine is designed with four-valve technology as well as turbo-
charging with intercooler.

Fig. 101
1 Fuel lift pump
2 Fuel pre-filter with water separator, drain valve and optional fuel pre-heating (R79)
3 Water level sensor (B124)
4 Main fuel filter
5 Fuel tank
6 Diesel engine

ECOMODE
The standard BOMAG ECOMODE ensures a clean environmental
balance. Due to the active engine management power is made
available for the driver when it is needed and is reduced again
when permitted by the application. Intelligent sensors in connection
with an ingenious control immediately detect the actual power
requirement and the engine speed of the engine is automatically
adapted.
A nice side effect – the noise sensation inside the cabin is also
very pleasant.
This means that both the exciter shaft speeds and the travel speed
must permanently be adapted, this is enabled by the EP control on
travel and vibration pumps.
ECOSTOP
With the optional ECOSTOP the engine is shut down automatically
after a defined period in idle speed. This additionally reduces fuel
consumption and wear.
Common Rail diesel injection The engine has a diesel fuel injection system with the Amplified
system Pressure Common Rail System (APCRS), which reduces the fuel
quantity required for combustion to a minimum. The advantage of
this system is the fact that the pressure in rail and high pressure
lines is relatively low. If needed, the fuel pressure is increased by a
pressure booster in a second stage inside the injector. This has
highly positive effect on the loading of materials and the longevity
of components.
Lifting points The engine comes from the factory with lifting points, which
ensure secure and proper handling of the engine during assembly
and disassembly. The lifting points have been sufficiently dimen-
sioned to match engine geometry (centre of gravity) and engine
weight, they should not be altered or modified.

1 adjustable transport beam

2 Transport device, remove before starting operation of engine
Fig. 102
ment System
catalyst


1 Mixing tube
4 Dosing module
7 SCR- catalyst
8 Module bracket

Flywheel side
Fig. 104
1 Coolant pump
2 Fuel lift pump
3 Throttle valve
4 Exhaust turbo charger
5 Exhaust gas recirculation actuator
6 Starter
7 Exhaust gas recirculation cooler
8 Crankshaft speed sensor
9 Belt drive

Flywheel end
Fig. 105
1 Crankcase ventilation
2 Fuel rail
3 Engine transition plug
4 Oil inlet
5 Generator
6 Lubrication oil cooler
7 Oil level control
8 High pressure fuel pump
9 Oil drain
10 Flywheel

Diesel engine – Lubrication oil circuit TCD 4.1 / 6.1
5.2 Lubrication oil circuit TCD 4.1 / 6.1
Fig. 106: Lubrication oil schematic

1 Compressor (optional)
3 Rocker arm
4 Piston cooling nozzle
5 Main lubrication oil gallery
6 By-pass valve
7 By-pass valve
9 Check valve
10 Lubrication oil pump
11 Lubrication oil sump
12 Pressure control valve
13 Lubrication oil filter

Diesel engine – Lubrication oil circuit TCD 4.1 / 6.1
Description - oil circuit Modern diesel engines put high demands on the lubrication oil
system. DEUTZ engines are designed with a pressure lubrication
system. Oil pressure and oil flow quantity secure engine lubrication
and also the cooling of the engine.
The lubrication oil pump draws oil from the oil sump and directs it
through the lubrication cooler and the oil filter to the various lubri-
cation points.
The check valve ensures permanently uniform pressure in the
lubrication oil system.

Diesel engine – Coolant circuit TCD 4.1 / 6.1
5.3 Coolant circuit TCD 4.1 / 6.1
Fig. 107: Coolant circuit

1 Connection possibility for cabin heater
2 Cooler of the exhaust gas recirculation
3 Temperature sensor
4 Thermostat
5 Compensation tank
6 Radiator
7 Coolant pump
9 Coolant flow to engine cooling system
10 Cylinder liner and cylinder head cooling
11 Compressor (optional)
General Depending on the coolant temperature, the coolant will flow in two
circuits.

Diesel engine – Coolant circuit TCD 4.1 / 6.1
The coolant pump (coolant pump, water pump) draws coolant

through the hose lines directly out of the radiator and forces it first
of all through the lubrication oil cooler, which is integrated in the
engine. The coolant then enters into the engine, flows up along the
cylinders into the cylinder head and to the thermostat at the coolant
outlet. Form there the coolant is returned through the corre-
sponding lines to the radiator inlet.
When the engine is cold the coolant is pumped in a short circuit
through the engine, until the response temperature of the thermo-
stat (start of opening) is reached. The coolant pump draws cold
coolant out of the radiator, as required to replenish the hot out
flowing coolant.
Coolant level monitoring The level watchdog based coolant level monitoring in the compen-
sation tank protects the engine against damage caused by a lack
of coolant. Monitoring of the coolant level takes place via the
engine control unit.
Heating system Water-cooled DEUTZ diesel engines utilize the heat contained in
the coolant to heat driver's cab or passenger compartments. For
this purpose the engine coolant is guided directly to the heat
exchanger and the heat is directly dissipated into the environment.

Diesel engine – Common Rail System (CRS)
5.4 Common Rail System (CRS)

Sufficient fuel supply to the high pressure pump at any time is a
prerequisite for perfect starting and performance of the diesel
engine.
The fuel pressure in the low pressure system is permanently moni-
tored by a pressure sensor. In case of pressure deviations, the
engine control unit submits an error message to the operator.
Fig. 108: Injection system

1 Engine control unit
2 Injectors
3 Pressure relief valve
4 Rail
5 High pressure pump (2 pieces)
6 Camshaft
7 FCU (fuel control unit)
8 Fuel filter
9 Return line
10 Tank
11 Fuel pre-filter
12 Fuel pump
13 Rail pressure sensor

The fuel pump draws fuel through the fuel pre-filter from the tank.
The fuel from the fuel pump is directed through the fuel filter to the
fuel control unit (FCU) with a pressure of 6 bar. The FCU meters
the fuel quantity that flows to the high pressure pumps.
The high pressure pumps are driven by the camshaft of the diesel
engine and increase the fuel pressure to 1600 bar. The fuel is then
directed into the Rail.
The Rail contains the pressure relief valve (PRV) and the rail pres-
sure sensor:
n This PRV protects the engine against damage caused by
excessively high fuel pressure. For this reason the PRV has an
opening pressure of 1750-1950 bar. If this PRV opens, fuel will
flow through the return line back into the tank. The PRV is con-
sidered to be worn after it has opened 50 times. The number of
opening events can be read out with the help of Serdia 2010.
n The rail pressure sensor reports the rail pressure to the
engine control unit. From the rail the fuel flows to the injectors.
The injector is equipped with a solenoid, which is controlled by
he engine control unit. The electro-magnet opens the dis-
charge nozzle in the control chamber, which causes the pre-
vailing pressure to collapse. This unbalance of pressures
moves the valve piston and the nozzle needle up and opens
the path for the fuel flow.

Fuel pump
Fig. 109: Fuel pump

1 Roller for pump drive via flat belt
2 Fuel inlet
3 Fuel outlet
The fuel pump is maintenance free. It draws in fuel with a vacuum
of -0.5 bar and generates a pressure of 6 bar.

Fuel pre-cleaner
Fig. 110: Fuel pre-cleaner

1 Bleeding screw
2 Fuel supply by pump
3 Fuel return flow from FCU (Fuel Control Unit)
4 Fuel lift pump
5 Electrical connection for water level sensor
6 Drain plug
7 Filter element
8 Fuel supply from fuel tank
9 Fuel return flow to fuel tank

Fuel control unit (FCU)
Fig. 111: FCU

1 Housing
2 Metering unit with electrical connection
3 Outlet to suction side of fuel pump (not visible)
4 Outlet to high pressure pumps
5 Return flow to tank
6 Inlet from the fuel pump
The FCU consists of housing (1) and metering unit (2).
The FCU has various connections (3), (4), (5) and (6).
The metering unit is a proportional solenoid valve and is controlled
by the control unit by means of PWM (Pulse Width Modulation).
This takes place in dependence on engine load and engine speed.
The metering unit meters the fuel quantity, which then flows
through the high pressure pumps to the Rail, and from there to the
injectors.

High pressure pump
Fig. 112: High pressure pump

1 High pressure port
2 Low pressure connection
3 Fastening flange
4 Roller plunger
The high pressure pumps (2 pieces) are directly driven by the cam-
shaft of the engine. They produce the high pressure to be for-
warded to the Rail. The pump is not self-priming, but is pre-pres-
surized by the fuel pump via the FCU. Due to its design, the high
pressure pump is highly susceptible to dirt particles. Contamination
can cause problems in building up pressure and maintaining the
pressure stability in the Rail.

Rail
Fig. 113: Rail

2 Fuel line connections
3 Tube
4 Bores to fasten the Rail
The Rail generally consists of a pipe (3) with different connections
(2), which has the function of a pressure accumulator. The Rail is
bolted to the engine through the bores (4).
One side contains the pressure relief valve (PRV) (1), which makes
sure that the system pressure will not exceed the defined pressure
of 1600 bar. Should the pressure rise beyond the value of
1750-1950 defin3ed for the PRV. the PRV will open and release
fuel through the return line to the tank.
On the other side you find the rail pressure sensor (5), which sub-
mits a signal directly to the engine control.
The different connections (2) on the none hand serve as an inlet
for the fuel delivered by the high pressure pumps. On the other
hand they are used to connect the lines to the injectors.

Injector
Fig. 114: Injector

1 Electrical connections
2 Flange to fasten the claw clamp
3 Injection nozzle
4 Injector CRIN 2
The injector is equipped with a solenoid, which is controlled by he
engine control unit. This solenoid opens the discharge nozzle in
the control chamber, which causes the valve piston and the nozzle
needle to move up and open the flow path for fuel.

Diesel engine – Wastegate charge pressure controller
5.5 Wastegate charge pressure controller

The Wastegate is a exhaust gas bypass valve and is located on or
in the exhaust gas turbocharger. The Wastegate (exhaust gas
bypass valve) controls the charge air pressure.
The charge air pressure is controlled by a pressure valve triggered
by charge air pressure, in connection with the exhaust gas bypass
valve. Depending on the bypass valve hot exhaust gases flow
along the exhaust gas turbine into the exhaust pipe, whereby their
work energy is not being utilized.
Fig. 115: Exhaust gas turbocharger with Wastegate

1 Control line
2 Pressure control valve
3 Bypass valve closed
The bypass valve is normally closed.

Diesel engine – Exhaust gas recirculation
5.6 Exhaust gas recirculation

Overview
Fig. 116
1 Fresh air intake pipe
2 Exhaust gas recirculation actuator
3 Exhaust gas recirculation cooler
4 Cooling line of the coolant circuit to the EGR cooler
5 Temperature sensor
6 Flap (fresh air inlet)
The exhaust gas recirculation is used to reduce nitrogen oxide
(NOx) emissions. Nitrogen oxides generated in the engine's com-
bustion process must be avoided or at least reduced as early as
possible.
Description Under high combustion temperatures the engine will produce envi-
ronmentally hazardous nitrogen oxides. The higher the combustion
temperature in the cylinder, the higher the proportion of nitrogen
oxide in the exhaust gas.
Feeding in small amounts of exhaust gas reduces the production of
nitrogen oxides. Below the flap (6) and through the fresh air intake
pipe (1) the exhaust gas is returned into the combustion chamber.
The exhaust gas resetter (2) takes over the control of the recircula-
tion. It regulates the exhaust gas quantity to be fed into the com-
bustion process in dependence on the temperature reported by the

Diesel engine – Exhaust gas recirculation
temperature sensor (5). The cooling line (4) supplies the EGR-
cooler (3) to cool the exhaust gas. Temperature peaks and NOx-
emissions are thus reduced. Rapid oxidation of fuel molecules
(which cause the formation of nitrogen oxides) is impeded by the
presence of exhaust gas molecules. This effect is supported by the
higher heat capacity of the main exhaust gas constituents carbon
dioxide and water (in gaseous state).

Diesel engine – EAT – Exhaust Aftertreatment System
5.7 EAT – Exhaust Aftertreatment System
Fig. 117
1 Diesel engine
2 Fuel filter
4 Main fuses and power board for SCR heating
ment System
catalyst


1 Mixing tube
4 Dosing module
7 SCR- catalyst
8 Module bracket

Duty of the diesel oxidation cata-

lyst (DOC)
Fig. 119
The DOC serves the purpose of increasing the temperature before
the diesel particlulate filter (DPF).
Background: With a too low temperature the particles in the
exhaust gas will not burn off. By passing through the DOC the
exhaust gas is heated up to such an extent, that the chemical reac-
tion can take place in the DPF.
The conversion of CO & HC to CO2 & H2O takes place inside the
DOC

Function of the diesel particulate

filter (DPF)
Fig. 120
The diesel particulate filter (DPF) collects and burns the particles
contained in the exhaust gas. These particles are caught by the
diesel particulate filter (DPF) and combusted at high exhaust gas
temperatures.
5.7.1 Selective Catalytic Reduction, SCR
Fig. 121
1 Exhaust gas from engine
2 Hydrolysis section
3 SCR catalyst
4 Exhaust gas after reduction
5 AdBlue®injection CO (NH2)2 + H2O
SCR stands forSelective Catalytic Reduction. This term describes
a technology for the reduction of nitrogen oxides NOx in exhaust
gases from combustion engines.

The chemical reactions in the SCR-catalyst is selective, i.e.

nitrogen oxides (NO, NO2) are preferably reduced, while undesired
side effects (such as the oxidation of sulphur dioxide to sulphur tri-
oxide) is almost completely suppressed.
This reaction requires ammonia (NH3), which is generated by
mixing AdBlue® into the exhaust gas. The products of the reaction
of exhaust gas with ammonia are water (H2O) and nitrogen (N2).
Honeycombs mainly consisting of titanium dioxide (TiO2), wolfram
oxide (WO3) and vanadium pentoxide (V2O2) are used as catalytic
converters.

5.7.2 Description of the SCR system components
Fig. 122: Schematic representation of the SCR-system

1 Diesel engine
2 Heating line via engine cooling circuit
3 Solenoid valve for tank heating, Y292
4 AdBlue tank
5 AdBlue- tank level sensor, B222
6 AdBlue- temperature sensor, B222
7 AdBlue- suction line
8 AdBlue- return line
9 Electric heating, suction line (E105), return line (E106)
10 AdBlue- feed module, pump (M41), solenoid valve (Y291), pressure sensor (B221)
11 Electric heating conveyor module, E107
12 SCR- module

13 SCR- catalyst
14 NOx sensor with control unit, B225
15 End pipe
16 Mixer
17 Metering unit (AdBlue- injector), Y293
18 Cooling line via engine cooling circuit
19 Exhaust pipe
20 Flexible element
22 Exhaust gas temperature before SCR, B223
23 NOx sensor with control unit, B224
24 Electric heating pressure line, E104
25 AdBlue- pressure line
26 Ambient temperature sensor on air filter, B218
Closed loop control The following sensors are used to control and monitor the SCR-
system:
n (14 & 23) NOx sensors (control of the AdBlue- injection quantity
and system monitoring)
n (22) temperature sensor before the metering unit (control of the
AdBlue- injection quantity)
n (5 & 6) AdBlue- tank level and temperature sensor (monitoring
and control of the heat-up strategy)
n (26) ambient temperature sensor (control of the heat-up
strategy)
(3) Solenoid valve for tank heating

In order to prevent freezing up or to ensure operation of the SCR-
system at temperatures below freezing, the tank needs to be
heated. This is accomplished by a heating line inside the tank (2),
which carries engine coolant. The coolant flow through the tank is
controlled via the solenoid valve. This enables a targeted heating
of the tank at low temperatures.
Fig. 123

(4) AdBlue tank

A Dispenser unit
B Heating coil, level sensor
C Plastic tank
D Emergency drain opening (with plastic thread)
E Filler neck
The AdBlue® tank stores the AdBlue provision. In order to ensure
delivery of AdBlue from the tank to the metering unit at any time
and state of operation, the tank needs to be heated at low ambient
temperatures.
Heating of the tank at low ambient temperatures is accomplished
via the engine cooling circuit (2). In order to protect the tank
against excessive heating up, the supply flow is controlled by a
tank heating (3) solenoid valve. For monitoring purposes the tank
is fitted with a temperature sensor (6) and a level sensor (5).
Fig. 124: Schematic representation of

tank with heating coil
Fig. 125: CAN-BUS connection

(10) Feed module

A AdBlue- pressure line
B AdBlue- return line
C AdBlue- suction line
The feed module pumps reduction agent from the tank (4) to the
metering unit (17), from where it is atomized under pressure into
the exhaust gas line. The pressure between feed module and
metering unit is thereby maintained at a constant level of 9 bar.
The change-over valve inside the feed pump makes sure that com-
ponent protection is ensured should the system freeze up. Once
the engine is shut down, both the suction and pressure lines (8 &
9) are pumped empty in order to minimize the AdBlue quantity in
the system. However, this does not generally prevent freezing of
the system, but protects against damage to components. Further-
Fig. 126 more, an electric heater (11) in the feed module prevents freezing
of the feed module. The feed module is controlled by the engine
control unit.
(13) SCR- catalyst The SCR catalyst has a catalytic surface, on which the nitric oxides
(NOx) contained in the exhaust gas are reduced by the ammonia
(NH3). A sufficiently high catalyst temperature of more than 280 °C
is a prerequisite for high NOx conversion rates.
Due to their design, SCR-catalysts have noise reducing properties.
The noise reduction rate is approx. 8-12 dB, depending on the
engine product range.
(16) Mixer The static mixer is installed downstream of the metering unit at an
exactly defined position in the exhaust gas line. The mixer supports
the distribution and treatment of the AdBlue injected into the
exhaust gas line. The AdBlue jet is directed in such a way, that it
hits the mixer, whereby AdBlue drops are atomized and deflected
in direction of the exhaust gas flow.

(17) Metering unit (AdBlue- injector)

A Cooling lines (feed and return flow are freely selectable)
B AdBlue- feed
C Metering valve (connection to control unit)
The sheet metal seal around the injection nozzle must

be replaced during disassembly (disposable seal).
The AdBlue provided by the feed module is injected and atomized

in flow direction via the metering unit (17) installed in the exhaust
line before the SCR- catalyst (13).
The required AdBlue injection quantity is calculated by the engine
control, by means of NOx sensor (22) and temperature sensor (23),
both installed upstream from the metering unit. The metering unit is
protected against overheating by a cooling system (18). Besides
the water cooling, the injector is additionally cooled by the flowing
AdBlue.
NOTICE!
Fig. 127
If no AdBlue is flowing, e.g. if no AdBlue had been
refilled, the AdBlue injector may overheat and suffer
considerable damage (defect).
Another effect of this cooling is the prevention of gas bubble forma-

tion when the AdBlue squirts out of the injection valve. This pre-
vents non-uniform atomizing of the injected AdBlue.

5.7.3 SCR system warning strategy

Overview
Fig. 128
5 Engine rpm-meter
7 Fuel level gauge
8 not used
Designation Note
Warning lamp AdBlue®/DEF Lights up if the AdBlue®/DEF filling level is low, if the AdBlue®/
DEF quality is insufficient or if there is a fault in the exhaust gas

Monitoring the SCR-functionality During operation the SCR-system is monitored by the installed
sensors. This monitoring thereby covers the following areas:
n Tank level monitoring
n Malfunction, defect
n Manipulation (incorrect filling, manipulation of sensors, etc.)
If all warnings concerning filling level, malfunction and

manipulation are ignored, an entry will be made in the
error log and the SCR-system is subsequently shut
down. Apart from this, further coercive measures in the
form of engine power reduction are then applied. The
power reduction takes place to such an extent, that
normal operation of the machine is no longer possible.
Torque limitation / power reduction In case of severe faults or if faults are not properly rectified, the
system will respond with an engine power reduction. Depending on
the type of fault the power will be reduced in one or two stages.
n Power reduction stage 1 = 75% of the torque curve
Warning of a too low tank level

Power reduction stage 1 = 75% of
the torque curve
Once the tank filling level has dropped below 15%, the warning will
be issued.
the torque curve
n If the tank is still not filled up and the filling level drops below
10%, the system will change to the next warning stage.
n Once the tank contents drops below 5%, the next warning
stage is activated. Moreover, a reduction related to the max-
imum power of the engine is activated after a certain count-
down time (Step 1)
n If no filling of the SCR-tank has been recognized, another
power reduction (Step 2) will be activated after a certain count-
down time.
Tank level Warning System reaction Limitation

> 15% None None None
< 15% None None
Level < 15%


< 10% None None
Level < 10%

< 5% Power reduction after Power reduction Step 1
countdown
Power reduction
< 5% Power reduction Step 2 Power reduction Step 2
after countdown
Power reduction
empty Power reduction Step 2 Power reduction Step 2
Power reduction
Test with the Service & Diagnostics With the Service and Diagnostics program SERDIA 2010 it is pos-
Tool SERDIA 2010 sible to test the SCR system.
Fig. 129
The SERDIA 2010 operating instructions contain a

detailed description of the procedure for using this
function.

Diesel engine – Regeneration of exhaust gas aftertreatment system
5.8 Regeneration of exhaust gas aftertreatment system

5.8.1 Preliminary remarks and safety notes
The combustion of diesel fuel produces soot particles, which are fil-
tered out of the exhaust gas in the DPF.
As the load of soot particles in the DPF increases, these deposited
particles must be burned (regeneration).
This regeneration process runs automatically, as soon as an
exhaust gas temperature of approx. 250 °C (480 °F) at the DPF is
reached.
NOTICE!
Low exhaust gas temperatures result in increased
soot loads in the DPF!
– Short engine running times, low engine loads or
excessively long engine idle times should be
avoided.
If the engine control unit detects a high soot load, it will trigger the
regeneration, during which the exhaust gas temperature will be
increased by the engine control unit.
During the regeneration process the exhaust gas reaches very
high temperatures and the exhaust gas quantity increases.
WARNING!
Danger of burning by ignited materials!
– Keep a safe distance to combustible or explosive
materials.
The increased exhaust gas temperature is indicated by the exhaust

gas temperature control lamp.
Fig. 130
If the engine control unit detects a very high soot load, the regener-
ation control lamp will flash.
Regeneration at standstill is activated by the operator.

Ä Chapter 5.8.2 ‘Running regeneration at standstill’
on page 168.
Fig. 131
Regeneration at standstill takes up to 40 minutes.

If regeneration at standstill is not carried out or is interrupted and
the soot load continues to increase, the engine power will be
reduced and the warning buzzer will sound.

If regeneration at standstill is still not carried out after the reduction

of engine power, the soot load will continue to increase. The
engine power is reduced further. The DPF is overloaded.
NOTICE!
DPF overload!
– In this case of a DPF overload, regeneration must
be activated by authorized Service Personnel, or
regeneration of the DPF is no longer possible.
5.8.2 Running regeneration at standstill

If regeneration at standstill needs to be carried out, the regenera-
tion control lamp flashes and the warning buzzer sounds.
1.
WARNING!
Danger of burning by ignited materials!
Fig. 132 – Keep a safe distance to combustible or
explosive materials.
Stop the machine in open terrain.

2. Engage the travel lever to the right (parking brake position).
ð The parking brake warning lamp lights up.
When the travel lever is disengaged out of

parking brake position to the left, regenera-
tion at standstill will be aborted.
3. Turn the rotary switch for engine speed to position "Middle"

(ECO-mode).
Fig. 133

4. Actuate the rotary button for regeneration to the right.

ð As soon as regeneration at standstill starts, the engine
speed will increase.
Regeneration at standstill runs automatically and takes
up to 40 minutes.
Fig. 134
The regeneration control lamp lights up.
Fig. 135
The increased exhaust gas temperature is indicated by

the exhaust gas temperature control lamp.
After the regeneration at standstill has been completed,
the regeneration control lamp goes out.
After the exhaust gas temperature has dropped to its
Fig. 136 normal level, the exhaust gas temperature control lamp
will also go out.

Diesel engine – Engine electrics
5.9 Engine electrics
Fig. 137
1 Diesel engine
3 Main fuses

5.9.1 Power board for SCR-heating
Fig. 138
K192 Relay, SCR control
K193 Relay, heating Urea feed module
K194 Relay, heating Urea suction line
K195 Relay, heating Urea throttle line
K196 Relay, heating Urea pressure line

5.9.2 CAN BUS overview
Fig. 139: CAN-Bus

A15 Monitoring module
A34 Machine control, ESX
A48 Control unit for engine management, MCM

A67 Keyboard anti-theft protection

A83 Measurement control, BVC
A87 USB-CAN interface
A124 Telematic module
A144 Control console cabin
P15 BCM05
S55 Travel lever
X32 Diagnostics interface for engine control unit
X34 Diagnostics interface for ESX machine control
CAN-bus, Controller Area Network created by Bosch at the end of the eighties for automobile applica-
tions.
Development objectives:
Real-time critical, robust and low price communication of control
units, such as transmission and engine control, but also less time
critical applications in the field of convenience electronics, such as
air conditioning.
Why CAN?
n Networking of control units for the realization of complex func-
tions.
n Reduction of the extend of wiring and plug connections.
n Better diagnostic possibilities (central diagnostics socket).
Characteristics of CAN
It is a kind of serial data transmission. The individual bits are trans-
mitted one after the other, only 2 lines are required.
CAN lines are twisted together 30 to 40 times per metre. Electro-
Fig. 140 magnetic interferences therefore always occur simultaneously in
both lines, the software is thus able to filter out interfering signals
more easily.
Wire (+) = cable colour blue
Wire (-) = cable colour yellow
Measuring on the CAN
Signals transmitted through the bus line can generally not be
measured with simple measuring instruments. Testing is therefore
quite complicated for the user. Correct connection of lines can only
be checked by means of a continuity test. BOMAG display mod-
ules are connected to the BUS to give engineers and user the pos-
sibility to detect faults or to receive information from the BUS.
5.9.3 EMR4 system overview

Engine control unit Together with the introduction of the Deutz Tier IV engines the
engine management system EMR4 with the control unit variant
EDC17 CV52, CV54 or CV56 /(depending on required functionali-
ties) has been introduced.
The management system enables precise controlling of fuel injec-
tion in dependence on engine performance parameters and con-
tains further functions required for achieving high system reliability
and the demanded exhaust gas quality.

The EMR 4 system consists of at least the following elements:

n Control unit
n Rotary speed sensors on timing gear cover for crankshaft and
camshaft
n Rail pressure sensor, rail pressure control valves
n Temperature sensor (coolant)
n Combined charge air pressure and temperature sensor
n Oil pressure sensor
n Ambient pressure sensor (integrated in control unit)
n Control lamp for warning, diagnose, fault messaging, etc.
n Diagnostics button
n Engine wiring loom and vehicle wiring loom
n Monitoring of fuel pre-filter (water in fuel)
n Triggering of exhaust gas aftertreatment system
NOTICE!
It is not permitted to interchange control units from one
manufacturing series or against another engine
number. In this case the warranty will become null and
void.
Sensors and actuators must not be connected to
external power sources for the purpose of testing, but
must only be operated on the EMR4. Otherwise com-
ponents may be permanently damaged.
Pulling off the plug connectors of the control unit while
the control unit is working (i.e. with the power supply to
terminal 15switched on) is not permitted. Correct pro-
cedure: Switch off the electric power supply (normally
with the ignition key), wait until the main relay has
switched off (with a delay of up to 15 seconds, listen
for clicking sound), then pull off the plugs from the con-
trol unit.
Replacing the control unit Each control unit is clearly designated to the engine, in accordance
with the respective application. In case of a replacement the con-
trol unit therefore needs to be completed with the engine specific
data set. When ordering a new control unit you must not only
specify the part-number, but also the engine serial number (see
sticker on EMR-control unit).
The Deutz part-number specified on the EMR-control

unit is the part number without software specific for the
engine. The correct part number can be found in the
BOMAG spare parts catalogue.

Replacement of DCR (DEUTZ n On TCD-engines with Common Rail technology the system
Common Rail System) components pressure is so high, that in case of leaks or repair all parts
need to be replaced. When replacing sensors or other electric
components, the new parts must be calibrated with the EMR
control unit. This calibration must be performed with
SerDia2010.
n Any other EMR components (sensors etc.) must under no cir-
cumstances be repaired, but must be replaced if they are
defective.
Main relay The internal main relay serves the purpose of releasing the vehicle
energy supply for the EMR4 system. When shutting down the
engine, the ignition switch isolates the electronic system from ter-
minal 15. The injectors are closed immediately, the Rail pressure is
discharged in an orderly manner and the counter readings are
saved in the non-volatile memory. During this time the system must
not be disconnected from terminal 30 (+Ubatt). Once the time has
expired the main relay switches off and the control unit is no de-
energized..
When terminal 15 is no longer connected to battery (+) (i.e. after
the ignition has been switched off), the main relay is switched off
after approx. 10 seconds.
The main relay thereby disconnects the control unit from terminal
30 battery (+), whereby it becomes de-energized.
EDC17 CV52
Fig. 141
Electronic DCR up to 2000 bar
Designation Technical data

Rated voltage 12 and 24 V DC
Operating voltage 9-32 V, engine start possible to 6 V


Main relay integrated
Plug vehicle side 91 pole
engine side 105 pole
EDC17 CV54 and CV56
Fig. 142
Electronic DCR up to 1600 bar

Rated voltage 12 and 24 V DC
Operating voltage 9-32 V, engine start possible to 6 V
Main relay integrated
Plug vehicle side 94 pole
engine side 60 pole

Fig. 143: System overview

1 Engine side
2 Vehicle side
3 Service
4 Sensors and actuators
5 EMR 4
6 Diagnostics socket, X32 in central electrics
7 CAN-display
8 SerDia2010
Changes to the control units with respect to settings,

parameterization, deleting the fault log and calibration
are level dependent and only possible with
SerDia2010.

A Ubat electric power supply

B Battery minus (-)
F CAN2 low
G CAN1 low
H CAN1 high
K K-Line
M CAN2 high
Fig. 144: Diagnostic interface
CAN-display A CAN-display is available for showing measuring values and fault

messages of the EMR control unit.
BOMAG Part-No.: 057 189 94
The following data can be displayed, as far as these are trans-
mitted by the control unit.
n Engine speed
n Engine torque (current)
n Coolant temperature
n Intake air temperature
n Exhaust gas temperature
n Lubrication oil pressure
n Coolant pressure
n Charge air pressure
n Fuel pressure
n Regeneration status of diesel particulate filter
n Operation monitoring of diesel particulate filter
Fig. 145
n Fault in exhaust gas aftertreatment system
n Battery voltage
n Position of throttle pedal
n Fuel consumption
n Operating hours
Fault messages appear as plain text and audibly, the fault log of
the control unit can be read out.

The display is connected to the diagnostic interface by means of a

special cable.
BOMAG Part-No.: 079 900 19
Fig. 146

5.9.4 EMR4 system components

5.9.4.1 Common Rail and electrics
Fig. 147: Injection system

2 Injectors
4 Rail
5 High pressure pump (2 pieces)
6 Camshaft
7 FCU (fuel control unit)
8 Fuel filter
9 Return line
10 Tank
11 Fuel pre-filter
12 Fuel pump

Fuel control unit (FCU)
Fig. 148: FCU

1 Housing
2 Metering unit with electrical connection
3 Outlet to suction side of fuel pump (not visible)
4 Outlet to high pressure pumps
5 Return flow to tank
6 Inlet from the fuel pump
The FCU consists of housing (1) and metering unit (2).
The FCU has various connections (3), (4), (5) and (6).
The metering unit is a proportional solenoid valve and is controlled
by the control unit by means of PWM (Pulse Width Modulation).
This takes place in dependence on engine load and engine speed.
The metering unit meters the fuel quantity, which then flows
through the high pressure pumps to the Rail, and from there to the
injectors.

Injector
Fig. 149: Injector

1 Electrical connections
2 Flange to fasten the claw clamp
3 Injection nozzle
4 Injector CRIN 2
The injector is equipped with a solenoid, which is controlled by he
engine control unit. This solenoid opens the discharge nozzle in
the control chamber, which causes the valve piston and the nozzle
needle to move up and open the flow path for fuel.

5.9.4.2 Sensors and actuators
Fig. 150: Electronic engine control

1 Fuel pressure sensor (B145)
2 Central plug for engine control unit
3 Coolant temperature sensor (B113)
4 Charge air pressure sensor / charge air temperature sensor (B133)
6 Crankshaft speed sensor (B130)
7 Rail pressure sensor (B93)
8 Lubrication oil level sensor (optional)
9 Oil pressure sensor (B88)
10 Rotary speed sensor for camshaft (B114)
11 Electric energy supply through battery
12 Multi-function display
13 Signal outputs (configurable)
14 Signal inputs
15 Travel pedal, not used

16 Hand throttle, not used

17 Function selector switch, not used
18 Key switch Start/Stop
19 Diagnostics button, not used
20 Fault lamp with flashing code, not used
21 Diagnostics interface/CAN-Bus
(1) Fuel pressure sensor
The low fuel pressure sensor is located after the fuel filter and the
pressure is normally between 5-7 bar.
Fig. 151
(3) Coolant temperature sensor
The coolant temperature has an effect on the calculated injection

quantity and the preheating behaviour of the glow plugs.
Fig. 152
(4) Charge air pressure sensor /

charge air temperature sensor

This sensor unites two functions in one housing. The one function
measures the charge air pressure and adapts the injection quantity
in dependence on the measured pressure. The temperature of the
air flowing past is additionally measured, it is used for limiting the
development of smoke.
With a faulty sensor the engine continues to run with

charge pressure simulation.
With a defective temperature sensor the engine also
carries on running.
Fig. 153
(6) Crankshaft speed sensor
Determination of the top dead center, emergency function in case

of a camshaft sensor failure.
Fig. 154
1. Check the gap dimension with a feeler gauge.

ð Nominal value: 0.17 - 1.45 mm
The feeler gauge must fit with only little

resistance through the gap between toothed
disc and speed sensor.
Fig. 155: Checking the gap dimen-

sion
(7) Rail pressure sensor This sensor serves the purpose of monitoring the injection pres-
sure.

DANGER!
Danger of injury caused by the explosive escape of
diesel fuel
– Wear your personal protective outfit (protective
gloves, protective clothing, goggles).
– Only work on the Common Rail System when it is
completely depressurized.
Disassembling the Rail pressure sensor
1. Unlock and pull out the cable plug.
WARNING!
After shutting down the engine wait 30 seconds, before
starting work in the fuel system.
Fig. 156: Disassembly 2. Unscrew the Rail pressure sensor with a socket spanner.
3. Check thread and sealing edge (arrows) on the Rail pressure

sensor visually.
Fig. 157
Installing the Rail pressure sensor
1.
NOTICE!
Ensure strict cleanliness. Particularly on the
thread and the sealing surface of the rail.
Slightly grease thread and sealing edge on Rail pressure

sensor with assembly grease.
Fig. 158: Assembly

2. Turn in and tighten the Rail pressure sensor (2).
Tightening torque: 40 + 5Nm
3. Plug in the cable plug
(9) Oil pressure sensor This sensor serves the purpose of monitoring the engine oil pres-
sure.
Disassembling the oil pressure sensor
NOTICE!
Ensure absolute cleanliness when working in the lubri-
cation oil system.
Thoroughly clean the area around the affected compo-
nent. Dry off wet locations with compressed air.
Immediately close all connections and openings with
new and clean plugs/caps.
Only remove plugs/caps just before assembling.
1. Unlock and pull out the cable plug.

2. Unscrew oil pressure sensor.
Fig. 159: Disassembling the sensor
Installing the oil pressure sensor

1. Insert the oil pressure sensor with a new seal ring and
tighten.
Tightening torque: 20Nm
Fig. 160: Installing the sensor
(10) Camshaft speed sensor The sensor has the function of determining top dead center, emer-
gency function in case of a crankshaft sensor failure.
Disassembling the speed sensor
1. Unlock and pull out the cable plug (3).

2. Unscrew screw (2).
3. Remove the speed sensor (1).
Fig. 161: Disassembly
4. Clean the sealing surfaces on speed sensor and wheel

housing cover.
5. Install the new O-ring (arrow).
6. Cover the O-ring slightly with oil.
Fig. 162
Installing the speed sensor

1. Insert the speed sensor (1).

2. Tighten the screw (2) with 9 Nm.
3. Plug the cable plugs (3) together.
NOTICE!
Ensure proper routing of cables.
Fig. 163: Assembly
5.9.4.3 Heating flange on engine

Heating flange R19
The heating flange is a component with an electrically operated

heating wire and high energy density used to heat up the intake air
in case of very low ambient temperatures.
The heating power is approx. 2000 Watt.
The heating power improves the cold starting characteristics and
the exhaust emissions (white smoke) of the diesel engine.
A differentiation is made between preheating, to assure the cold
start ability of the engine, and after-heating.
Fig. 164: Heating flange
The heating flange is controlled by the engine control unit via relay
K14.
Fig. 165: K14

5.9.4.4 Fuel pre-heating

Fuel pre-heating (option)
1 Water separator sensor connection (B124)
2 Fuel pre-heating connection (R79) 200 Watt (option)
The preheating system is not monitored by the engine

control unit.
In diesel engines the pre-heating of the fuel prevents malfunctions

caused by the formation of jelly (paraffin separation) in the fuel
under low temperatures.
Operating the ignition switch activates the heater, this should take
place at least 5 minutes before starting the engine.
The generated heat works directly under the filter element and
melts the wax crystals that have formed, so that the fuel can flow
through the filter element without restriction. The 200W heating is
supplied with 12V D.C-current.
Fig. 166
5.9.4.5 Fault display
The detected faults appear in the INFO1 display field

in the instrument cluster.
Fault codes 5000 - 5499 are diesel engine related.
A detailed reading out of fault codes for the diesel
engine is only possible with Deutz-Serdia
A detailed description of how to read out fault codes
can be found in the Service Training Electrics.

Diesel engine – Inspection and maintenance work
5.10 Inspection and maintenance work

5.10.1 Checking the engine oil level
NOTICE!
– If the engine is warm, shut it down and check the
oil level after five minutes. With a cold engine the
oil level can be checked immediately.
– Use only oil of the permitted specification
Ä Chapter 1.4.1 ‘Engine oil’ on page 44.
During the DPF-regeneration process part of the fuel may mix with
the engine oil. This increases the amount of engine oil in the
engine.
NOTICE!
– If the engine oil level is higher than the "MAX"-
mark, the engine oil must be changed immediately.

n Protective gloves
1. Pull the dipstick out, wipe it off with a lint-free, clean cloth and
reinsert it until it bottoms.
2. Pull the dipstick out again.
3. The oil level must always be between the "MIN"- and "MAX"-
marks. If the oil level is too low, top up oil to the "MAX" mark
immediately.
Fig. 167
5.10.2 Change engine oil and oil filter cartridge
During the regeneration at standstill part of the fuel

may mix with the engine oil.
You should therefore run a possibly necessary regen-
eration at standstill before changing the engine oil.
Perform this maintenance work at the latest after one

year.

NOTICE!
– Change the oil only with the engine at operating
temperature.
Ä Chapter 1.4.1 ‘Engine oil’ on page 44.
– Filling quantity: Ä Chapter 1.5 ‘List of fuels and
lubricants’ on page 53

n Protective gloves
WARNING!
Danger of burning on hot components!
2. Unscrew the oil drain plug and catch any oil running out.
3. Turn the drain plug tightly back in.
Fig. 168
4. Thoroughly clean the outside of the oil filter cartridge.

5. Unscrew the filter cartridge using an appropriate filter
wrench.
6. Clean the sealing face on the filter carrier from any dirt.
7. Slightly oil the rubber seal on the new filter cartridge.
8. Spin the new oil filter cartridge on and tighten it hand tight.
Fig. 169

9. Fill in new engine oil.

10. After a short test run check the oil level on the dipstick, if nec-
essary top up to the top dipstick mark.
11. Check oil filter cartridge and drain plug for leaks.
12. Dispose of oil and oil filter cartridge environmentally.
Fig. 170
5.10.3 Checking the coolant level

n Protective gloves
n Safety goggles
NOTICE!
– If, during the daily inspection the coolant level is
found to have dropped, check all lines, hoses and
engine for leaks.
– Do not use radiator sealant to seal leaks.
– Use only coolant of the permitted specification
Ä Chapter 1.4.4 ‘Coolant’ on page 48.
A too low coolant level is indicated by the coolant level warning

lamp.
Fig. 171
1. Check the coolant level in the compensation tank.
WARNING!
Danger of scalding by hot fluid!
– Open the coolant compensation tank only after the
engine has cooled down.
2. To top up, unscrew the filler cap and fill in coolant up to the
Fig. 172 "MAX"-mark.

5.10.4 Change the coolant
Perform this maintenance work at the latest after two

years.
Do not start the engine after draining off the coolant.

In case of lubrication oil entering into the cooling system or a suspi-
cious turbidity caused by corrosion residues or other suspended
matter, the coolant must be drained off and the complete cooling
system needs to be cleaned.
Oil can damage the sealing materials used in the cooling system.
If oil has entered you must add a cleansing agent in order to
remove any residues from the system. Follow the instructions of
the manufacturer! If in doubt consult your Customer Service or the
engine manufacturer.
When changing the coolant without any signs of contamination,
cleaning of the cooling system is not necessary.
NOTICE!
– Use only coolant of the permitted specification
Ä Chapter 1.4.4 ‘Coolant’ on page 48.
– Do not mix different coolants and additives of any
other kind.
lubricants’ on page 53

n Protective gloves
n Safety goggles
2. Allow the engine to cool down.
3. Unscrew the lid from the compensation tank.
Fig. 173

4. Unscrew the plug.

5. Drain off and collect all fluid.
6. Turn the plug tightly back in.
7. Check the condition of the coolant.
8. Thoroughly flush the cooling system if the coolant is contami-
nated by corrosion residues or other suspended matter.
9. Remove the thermostat.
10. Fill in clean water.
Fig. 174 11. Start the engine and run it warm to operating temperature.
12. Allow the engine to cool down to approx. 50 °C (122 °F).
13. Drain all water off.
14. When using a cleansing agent repeat the flushing process
twice with clear water.
15. Reinstall the thermostat.
NOTICE!
The anti-freeze concentration (additive) must be at
least 35 Vol% and maximum 45 Vol%.
16. Fill up coolant.

17. Start the engine and run it warm to operating temperature.
18. Let the engine cool down and check the coolant level again,
top up if necessary.
19. Dispose of the coolant in an environmentally friendly manner.
Fig. 175
5.10.5 Checking the anti-freeze concentration and the condition of the coolant
n Protective gloves
n Safety goggles

3. Unscrew the radiator cap and check the anti-freeze concen-

tration with a conventional tester.
4. Check the condition of the coolant.
5. Thoroughly flush the cooling system if the coolant is contami-
nated by corrosion residues or other suspended matter
Ä Chapter 5.10.4 ‘Change the coolant’ on page 194.
6. Screw the cap back on again.
Fig. 176
5.10.6 Cleaning the radiator module
NOTICE!
Components may get damaged!
– Dirt on fan blades and oil coolers reduce the
cooling effect. Dirt deposits in these areas are sub-
stantially supported by oil and fuel on these sur-
faces. For this reason you should always seal any
oil or fuel leaks in the vicinity of the cooling fan or
the radiator and clean the cooling fins after.
– Do not damage any cooling fins on the cooler core
when cleaning.
Cleaning with compressed air Protective equipment: n Working clothes

n Protective gloves
n Safety goggles
3.
CAUTION!
Danger of eye injuries caused by particles
flying around!
– Wear your personal protective equipment
(safety gloves, protective working clothes,
goggles).
Blow the cooler out with compressed air from the air dis-
charge side.
Fig. 177 4. Blow the cooler out with compressed air from the air supply
side.
Cleaning with cold cleansing agent

The air conditioning condenser is located in front of the
radiator.

WARNING!
Danger of injury caused by exploding component!
– Do not clean the condenser in the air conditioning
system with a hot water jet.
NOTICE!
Electric components can be damaged by water
entering into the system!
– Protect electrical equipment such as generator,
regulator and starter against the direct water jet.
1. Spray engine and cooler with a suitable cleansing agent, e.g.

cold cleansing agent, let it soak in for a while and spray it off
with a strong water jet.
2. Run the engine warm for a while to avoid corrosion.
5.10.7 Checking the ribbed V-belt

n Protective gloves
3. Inspect the entire circumference of the ribbed V-belt visually
for damage and cracks.
4. Replace damaged or cracked ribbed V-belts Ä Chapter
5.10.8 ‘Replace ribbed V-belt and idler pulley’ on page 197.
Fig. 178
5.10.8 Replace ribbed V-belt and idler pulley

n Protective gloves

3. Press the idler pulley (2) in direction of arrow using a socket

wrench, until the locking pin (3) engages in the mounting
bore (1).
ð The ribbed V-belt is now free of tension.
4. Take the ribbed V-belt first off the smallest pulley.
5. Unscrew fastening screw and take off the idler pulley.
6. Attach the new idler pulley and tighten the fastening screw,
tightening torque 80 Nm (59 ft·lbs).
7. Install the new ribbed V-belt.
8. Counter the idler pulley with a socket wrench and remove the
locking pin.
Fig. 179
9. Slowly release the idler pulley in direction of arrow, until the
1 Mounting bore
belt is automatically tensioned.
2 Idler pulley
3 Locking pin 10. Make sure that the belt runs correctly on all pulleys.
5.10.9 Checking the AdBlue®/DEF level, topping up

5.10.9.1 Checking the AdBlue®/DEF level
1. Check the filling level on the AdBlue®/DEF level gauge.
2. Top up if required.
Fig. 180
A filling level, which is too low, is indicated by the AdBlue®/DEF

warning lamp.
If the AdBlue®/DEF level is not topped up in time, the

engine power will be reduced.
Fig. 181

5.10.9.2 Refilling AdBlue®/DEF

n Protective gloves
NOTICE!
Filling the AdBlue®/DEF tank with cleaning agent
or other operating media or fuels, mixing in addi-
tives or diluting AdBlue®/DEF will damage the
exhaust gas after-treatment system.
– Use only AdBlue®/DEF of the permitted specifica-
tion Ä Chapter 1.4.3 ‘AdBlue®/DEF’ on page 46.
– In case of incorrect filling inform our service imme-
diately.
– If AdBlue®/DEF comes into contact with spray
painted or aluminium surfaces while refilling, you
should rinse off the affected areas immediately
with lots of water.
1. Clean the area around the filler opening.

2. Remove the locking cap.
3. Fill in AdBlue®/DEF.
4. Screw the cap back on again.
Fig. 182

5.10.10 Renewing the AdBlue®/DEF filter

years.
NOTICE!
– If AdBlue®/DEF comes into contact with spray
painted or aluminium surfaces while refilling, you
should rinse off the affected areas immediately
with lots of water.
NOTICE!
– Ensure strict cleanliness! Thoroughly clean the
area around the filter housing.
– Take care that no dirt will enter into the filter
housing.

n Protective gloves
n Safety goggles
2. Allow the engine to cool down for at least five minutes.
3. Thoroughly clean the area around the filter housing.
4. Unscrew the filter lid.
Fig. 183

5. Pull out filter carrier (2) together with filter element (1).
6. Attach the new filter element to the filter carrier and reinsert it
into the filter housing.
7. Tighten the filter lid, tightening torque: 23 Nm (17 ft·lbs).
8. Dispose of the filter element in an environmentally friendly
manner.
Fig. 184
5.10.11 Replacing the fuel filter, bleeding the fuel system

NOTICE!
– Ensure strict cleanliness! Thoroughly clean the
area around the fuel filters.
– Air in the fuel system causes irregular running of
the engine, a drop in engine power, stalls the
engine and makes starting impossible.
– After work on the fuel system bleed the system,
perform a test run and check for leaks.
– Additional bleeding of the fuel system by a 5
minute test run in idle speed or low load is manda-
tory.

5.10.11.2 Replacing the fuel filter

year.


n Protective gloves
1. Loosen and unscrew the fuel filter cartridge using an appro-
priate filter wrench.
2. Clean the sealing face on the filter carrier from any dirt.
3. Slightly oil the rubber seal on the new filter cartridge.
4. Turn the new filter cartridge on by hand, until the seal con-
tacts.
5. Tighten the filter cartridge by another half turn.
Fig. 185
5.10.11.3 Replacing the fuel pre-filter

year.

n Protective gloves
1. Pull the plug off the sensor on the water separator.
2. Place a collecting vessel under the drain bore.
3. Unscrew the drain plug (2) and catch running out fuel.
4. Loosen and unscrew the fuel pre-filter (1) using a suitable
filter wrench.
5. Slightly oil the rubber seal on the new fuel pre-filter element.
6. Spin on the new fuel pre-filter.
7. Turn the oil drain plug back in with a new seal ring.
Fig. 186 8. Push the plug on to the sensor on the water separator.
9. Dispose of fuel and filter environmentally.

5.10.11.4 Bleed the fuel system

n Protective gloves
1. Slacken the bleeding screw (1) on the fuel pre-filter for 2 to 3
turns.
2. Unlock the bayonet lock of the manual fuel pump (2) by
pressing it down and turning it anti-clockwise.
3. Operate the hand pump manually, until fuel flows out of the
slackened bleeding screw without air bubbles.
4. Then tighten the bleeding screw while pumping.
5. Lock the bayonet lock of the fuel hand pump by pressing it
down and turning it clockwise.
Fig. 187 6. Start the engine and run it 5 minutes with idle speed.
7. Check the filter cartridges for leaks.

5.10.12 Checking, cleaning the water separator
The service intervals for the water separator depend

on the water content in the fuel and can therefore not
be determined precisely.
After taking the engine into operation you should check
the filter bowl for signs of water and dirt initially every
day, later as required.
If a too high quantity is drained off, the filter needs to
be bled.
Protective equipment: n Protective gloves
1. If the "water in fuel" warning lamp lights up when starting or

during operation, drain the water from the fuel pre-filter
immediately.
Fig. 188
3. Slacken the drain plug for a few turns and catch running out
fluid.
4. Turn the plug tightly back in. Check for leaks, if necessary
use a new seal ring.
ð Once the water separator is empty the warning lamp for
water in fuel must go out.
Fig. 189
5.10.13 Adjusting the valve clearance
NOTICE!
We recommend to have this work carried out by
trained personnel or our after sales service.
– Before checking the valve clearance let the engine
cool down for at least 30 minutes. The engine oil
temperature must be below 80 °C (176 °F).
– After a short test run check the engine for leaks.

Valve clearance adjustment

angle:
Intake valve 75° ±15°
Exhaust valve 120° ±15°
Valve Cylinder
overlapping 1 5 3 6 2 4
adjustment 6 2 4 1 5 3

n Protective gloves
Special tool: n Rotation angle disc
3. Remove the valve cover.
4. Turn the crankshaft with the cranking device until the valves
are overlapping.
5. Loosen counter nut (2).
7. Attach the rotation angle disc (3) and the spanner socket (4)
to the valve clearance adjustment screw (1).
8. Fix the magnet (5) of the rotation angle disc.
9. Turn the rotation angle disc (3) clockwise against the stop
(rocker arm no clearance) and set the scale to zero.
10. Turn the rotation angle disc (3) counter-clockwise, until the
specified angle is reached.
11. Hold the rotation angle disc tight, so that it does not turn, and
tighten counter nut (2), tightening torque: 20 Nm (15 ft·lbf).
12. Repeat this adjustment procedure on all other cylinders, after
cranking the crankshaft accordingly.
13. Install the cylinder head cover again with a new gasket.
ð Tightening torque: 9 Nm (7 ft·lbf)
14. After a short test run check the engine for leaks.
Fig. 190
1 Valve adjustment screw
2 Counter nut
3 Rotation angle disc
4 Socket
5 Magnet

5.10.14 Check the engine mounts

n Protective gloves
3. Check air intake and exhaust manifold fastenings for tight fit.
4. Check sockets and clamps between air filter, exhaust turbo-
charger and charge air line as well as the lubrication air line
for tight fit and leaks.
5. Check fastening screws on oil sump and engine mounts for
tight fit.
6. Check condition and tight fit of engine pillow blocks.
5.10.15 Air filter maintenance
NOTICE!
– Do not start the engine after having removed the
air filter.
– If necessary, the air filter may be cleaned up to six
times. After one year at the latest it must be
replaced together with the safety element.
– Cleaning does not make sense if the air filter ele-
ment is covered with a sooty deposit.
– Do not use gasoline or hot fluids to clean the filter
element.
– After cleaning the air filter must be inspected for
damage using a torch.
– Do not continue to use a damaged air filter ele-
ment. If in doubt use a new air filter.
– If the air filter is damaged, the safety element must
be replaced as well.
– The safety element must not be cleaned.
We generally recommend to renew the air filter. A new

filter element is far less expensive than a possible
engine damage.


n Protective gloves
n Safety goggles
1. Maintenance of the air filter is due when the air filter warning
lamp lights up, but at the latest after one year.
Fig. 191
4. Loosen both locking hooks on the housing cover and take the
cover off.
5. Clean housing cover and dust discharge valve.
Fig. 192
6. Pull out the main filter element with light turning movements.
CAUTION!
Danger of eye injuries caused by particles flying
around!
– Wear your personal protective equipment (safety
gloves, protective working clothes, goggles).
Fig. 193
7. Blow the air filter out with dry compressed air (max. 2.1 bar
(30 psi)) from inside to outside by moving the gun up and
down inside the element, until it if free of dust.
Fig. 194

8. Examine the air filter element with a torch for cracks and
holes in the paper bellows.
9. In case of damage replace the air filter and the safety ele-
ment.
Fig. 195
10. Slide the air filter carefully into the housing.
NOTICE!
– The dust discharge valve must point vertically
downwards.
– Make sure that the cover locks engage correctly.
11. Reassemble the housing cover.

Fig. 196
5.10.15.1 Replace the safety element
NOTICE!
The safety element must not be cleaned and should
not be used again after it has been removed.
The safety element must be replaced:
– if the air filter is damaged.
– at the latest after 1 year.
– if the air filter warning lamp comes on again after
the air filter has been cleaned.
1. Remove the housing cover and pull the air filter off.
2. Pull the safety element out by turning it lightly.
3. Push in a new safety filter element.
4. Insert the air filter and reassemble the housing cover.
Fig. 197

Hydraulic system
6 Hydraulic system

Hydraulic system – Overview of hydraulics
6.1 Overview of hydraulics
Fig. 198
1 Drum drive motor
2 Steering valve
7 Vibration pump
8 Charge oil filter
9 Brake valve, Y04 & travel speed range selection for drum, Y30
10 Rear travel motor, with travel speed range selector Y31
11 Manifold block with thermostat
12 Steering cylinder
13 Vibration motor

Fig. 199
1 Pressure sensor B235, axle MB
2 Pressure sensor B237, drum MB
3 Vibration pump
5 Pressure sensor B236, drum MA
6 Pressure sensor B234, axle MA
Vibration pump

Plug Y07 Y08

Forward Reverse
Plug Y73 Y72
Forward Reverse
Plug Y16 Y17

Hydraulic system – Open and closed hydraulic circuit
6.2 Open and closed hydraulic circuit

Open circuit
Fig. 200: Open circuit

Open in this case means that the suction line of a pump (1) nor-
mally is situated below the fluid level, the surface of which is in
open contact with atmospheric pressure. Reliable equalization of
pressure between the air in the hydraulic oil tank and the ambient
air ensures problem free suction of the pump.
In an open circuit the hydraulic fluid is fed to the consumer (2 or 3)
and also returned to the tank through way valves.

Hydraulic system – Open and closed hydraulic circuit
Closed circuit
Fig. 201: Closed circuit

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

Hydraulic system – Hydraulic units
6.3 Hydraulic units

6.3.1 Travel/vibration pump, H1
6.3.1.1 Variable displacement pumps, H1 P060 / P078 / P089 / P100 RA
Displacement adjustment RA with The variable displacement axial piston pump generates, controls
proportional solenoid and regulates a volumetric pressure fluid flow. It has been
designed for mobile applications, e.g. in construction equipment.
The pump is a variable displacement axial piston pump in swash
plate design for hydrostatic drives in closed circuits. The volumetric
flow is proportional to drive speed and displacement.
Fig. 202: Axial piston pump H1

1 Control unit
2 Servo piston
3 Valve plate
4 Cover plate
5 Auxiliary pump (only with vibration pump)
6 Cylinder block
7 Swash disc
8 Drive shaft
9 Radial seal, drive shaft
10 Slipper pad
11 Piston
12 Feedback lever

NOTICE!
– The aggregate must always be filled with hydraulic
oil and purged before start-up and during opera-
tion.
– This must also be considered for longer periods of
rest, because the aggregate may run empty
through the hydraulic lines.

Fig. 203: Block diagram

1 Control unit
2 Radiator
3 Tank
4 Charge pump
5 Charge oil filter
6 High pressure relief valves
7 Travel or vibration motor
8 Charge valve
9 Control pressure relief valves
10 Servo control
11 Servo adjustment plate
H High pressure
S Servo pressure

N Low pressure
R Return flow
High pressure relief valves with Pressure peaks occurring during very fast swashing processes, as
integrated boost check valves and well as the maximum pressures are safeguarded by superordinate
bypass for towing high pressure relief valves, which open when the adjusted value is
exceeded and relieve oil into the low pressure side.
The boost check valves are integrated in the high pressure relief
valves. These valves open to the low pressure side and let cool
and filtered oil flow from the charge oil circuit into the closed
hydraulic circuit, in order to compensate leaks and flushing quanti-
ties.
Bypass for towing operations:
NOTICE!
Do not back out more than 3 turns!
Observe the tightening torque of 70Nm.
Charge valve The charge pressure valve belongs to the group of safety elements
in a closed hydraulic circuit. This valve limits the pressure in the
charge circuit to the pre-adjusted value.
Control pressure relief valve, pres- If the adjusted pressure is reached, the pressure override will move
sure override the swash plate quickly back towards neutral position, thereby lim-
iting the system pressure. With its possibility to swash the swash
plate inside the pump back within a period of 90 ms, the pressure
override makes sure that the high pressure relief valves will only
respond in exceptional cases. This protects the hydraulic circuit
against overheating and reduces the load on the diesel engine.
RA - control
Fig. 204: RA - control

1 Feedback lever
2 Proportional solenoids

Depending on the pre-selected ampacity “I” on the proportional sol-

enoids, the control cylinder on the pump is supplied with control
pressure through the RA control unit. This way the swash plate and
thus the displacement of the pump can be infinitely varied. Each of
the proportional solenoids is assigned to a certain flow direction.
NOTICE!
The spring reset in the control unit is no safety feature.
Internal contamination – like e.g. contaminated
hydraulic fluid, abrasion or dirt residues from system
components – can cause blockage of the spool valve
in the control unit. The flow volume from the variable
displacement pump will in this case no longer follow
the instructions of the operator.
6.3.2 Swash plate principle, pump
Fig. 205
The swash plate pump is a positive displacement machine with oil
displacing pistons arranged axially to the drive shaft. The pistons
are thereby supported by the swash plate.
Axial piston units based on the swash plate principle with fixed or
variable displacement can be used as hydraulic pumps or hydraulic
motors. In pump mode the mechanical energy is converted to
hydrostatic energy, when used in motor mode the hydrostatic
energy is converted to mechanical energy. When used as a pump,
the flow volume is proportional to the drive speed and the
swashing angle. The available (pump) torque increases with the
pressure drop between high and low pressure side.
Variable displacement pumps and motors can be change their dis-
placement, i.e. the pump delivery rate or motor throughput, by
simply changing the angle of the swash plate.

Description of function
Fig. 206
1 Drive shaft
2 Piston
3 Piston area
4 Piston stroke
5 Slipping disc
6 Adjusting angle
7 Cylinder
8 Through drive
9 Valve plate
10 Top dead centre TDC
11 Bottom dead centre BTC
12 Control slots in suction side of swash plate (for sense of rota-
tion shown)
13 Control slot on pressure side
Driven by the engine, the drive shaft rotates and drives the cylinder
via a splined connection. The cylinder rotates with the drive shaft
and drives the 9 pistons. The pistons rest with their slipper pads on
the sliding face of the swashing cradle and perform an axial move-
ment. The slipper pads are held on the sliding face and are posi-
tively guided by a retaining device. During a complete rotation of
the cylinder block each piston moves through the bottom and top
dead centre back to its initial position. From dead centre to dead
centre is performs a full piston stroke. During this process the flow
volume determined by the stroke is drawn in through the control
slots in the valve plate or pumped out. During the suction stroke
the hydraulic fluid is drawn into the increasing piston chamber, i.e.
it is actually pressed in. On the opposite side the oil is pressed out
of the piston bores into the hydraulic system during the compres-
sion stroke.
6.3.3 Travel motor, H1

6.3.3.1 Swash plate motor (H1) with variable displacement
A plug-in fixed displacement motor converts the hydrostatic volu-
metric flow into mechanical rotary motion. It has mainly been
designed for installation into mechanical gear drives.

Fig. 207
1 Valve plate
2 Bearing plate
3 Synchronizing joint
4 Ring gear for sensor
5 Tapered roller bearing
6 Fastening flange
7 Piston
8 Minimum swashing angle setting
9 Sensor
10 Control piston
11 Flushing pressure relief valve
12 4-way valve
13 Shuttle valve
NOTICE!
tion.

Flushing valve
The flushing valve is used to discharge heat from the
hydraulic circuit.
When the travel circuit is switched on, a pressure difference will be

generated between the two sides (A & B) of the closed circuit. The
higher pressure moves the valve spool of the flushing valve against
the neutral setting spring, so that oil can flow out of the low pres-
sure side.
The flushing valve is fitted with a downstream 16 bar pressure
relief valve. This valve makes sure that only a certain quantity of
hydraulic oil is flushed out. This oil flows back to the hydraulic oil
tank and is immediately replaced by oil from the charge circuit.
Control The motor can be adjusted to two fixed displacements. This is

accomplished by changing the angle between cylinder block and
output shaft.
With a large angle position the motor works with maximum dis-
placement, slow speed and high torque.
When changing the swash plate position to minimal angle the
motor works with minimum displacement, high speed and low
torque.
The displacement is changed by a control piston, which is tightly
connected with the valve segment. The piston rod side (M5) is
thereby permanently pressurized with the actual travel pressure. In
1st gear the piston side (M4) is connected with the tank (solenoid
de-energized). In speed range 2 the solenoids are energized, the
valve switches and the piston side is also pressurized with the cur-
rent travel pressure. Due to the area differential between piston rod
side and piston side and the force resulting from this, the pilot con-
trol moves to Qmin position.
6.3.4 Vibration motor A2FM

6.3.4.1 Axial piston motor A2FE/FM
The plug-in fixed displacement motors A2FE and
A2FM just differ by a different housing.
NOTICE!
tion.

The A2FE/FM is a plug-in fixed displacement axial piston motor

with a tapered axial piston drive in swash plate design for hydro-
static drives in open and closed hydraulic circuits. Due to this bent
axle design the torque is generated directly on the drive shaft. The
pistons only apply very little transverse forces to the cylinder, which
has a favourable effect on wear, efficiency and starting torque.
Fig. 208
1 Drive shaft
2 Piston
3 Cylinder
4 Valve plate
5 Connecting plate
6 Flushing valve, optional
In fixed displacement motors in bent axle design the pistons (2)
Ä Fig. 208 are arranged in an inclined position to the drive shaft
(1). The pistons perform an axial movement, which is then con-
verted to a rotary movement by the piston joint on the drive shaft
flange. The cylinder (3) is driven by the pistons.
Motor function A fixed displacement plug-in motor converts the hydrostatic energy
into mechanical energy. Pressure fluid is fed through the con-
necting plate (5) and the valve plate (4) into the cylinder bores. The
pistons (2) inside the cylinder bores perform an axial movement,
which is then converted to a rotary movement by the piston joint on
the drive shaft flange (1). The pistons thereby drive the cylinder (3)
and thereby generate the output torque on the drive shaft. The
output torque is generated by the force resulting from pressure and
piston area. The output speed is proportional to the supplied fluid
volume and the displacement. The available motor output torque
increases with the pressure drop between high and low pressure
side.
Flushing valve
The flushing valve is used to discharge heat from the

hydraulic circuit.

Fig. 209: Flushing spool

1 Flushing spool
2 Flushing pressure relief valve
The hydraulic motor is equipped with an integrated flushing valve.
When the hydraulic circuit is switched on, a pressure difference will
be generated between the two sides of the closed circuit. The
sure side.
The flushing valve is fitted with a downstream 16 bar pressure
hydraulic oil is flushed out. The oil flows back to the hydraulic oil
6.3.5 Swash plate principle, motor
Fig. 210
The swash plate pump is a positive displacement machine with oil
displacing pistons arranged axially to the drive shaft. The pistons
are thereby supported by the swash plate.

Axial piston units based on the swash plate principle with fixed or
variable displacement can be used as hydraulic pumps or hydraulic
motors. In pump mode the mechanical energy is converted to
hydrostatic energy, when used in motor mode the hydrostatic
energy is converted to mechanical energy. Variable displacement
motors can change their displacement, i.e. the pump delivery rate
or motor throughput, by simply changing the angle of the swash
plate.
If the unit is used as motor, the output speed is proportional to the
supplied volume of fluid. The available (motor) torque increases
with the pressure drop between high and low pressure side.
Fig. 211
1 Drive shaft
2 Piston
3 Piston area
4 Piston stroke
5 Slipping disc
6 Adjusting angle
7 Cylinder
8 Through drive
9 Valve plate
10 Top dead centre TDC
11 Bottom dead centre BTC
12 Control slots in suction side of swash plate (for sense of rota-
tion shown)
13 Control slot on pressure side
The motor function is a reversal of the pump function. In this case
the hydraulic fluid the hydraulic system directs the oil flow to the
hydraulic motor. The medium flows through control slots in the
valve plate to the cylinder bores. 4 or 5 cylinder bores are opposed
to the kidney shaped control slots in the pressure side. The other
control slot is in this case connected with the rest of the cylinder
bores, which in turn are connected with the return flow side or are
partly covered by the connecting web between the kidney shaped
control slots. By loading the piston it slides down the slanted swash

plate and drives the cylinder that guides it. The cylinder with the 9
pistons rotates with the drive shaft, whereby the piston perform a
stroke-like movement. The hydraulic pressure generates the torque
on the cylinder and thus the rotation of the drive shaft. The sup-
plied fluid quantity determines the output speed.
6.3.6 External gear pumps

External gear pumps mainly consist of the friction bearing mounted
gear pair and the housing with front and rear covers. The drive
shaft, which is sealed with a radial seal, protrudes from the front
cover. The bearing forces are absorbed by friction bearings. These
have been designed for high pressures and have excellent antifric-
tion properties - particularly at low speeds. The gears have 12
teeth each. This keeps flow pulses and noise emissions at a low
level.
Fig. 212: Axial compensation of gear pump
1 Axial seal 5 Cover

2 Outer pressure field 6 Flange
3 Inner pressure field 7 Sealing zone
4 Radial seal 8 Compensation forces
Internal sealing of the pressure chambers is achieved by flow

volume dependent forces. This results in an excellent rate of effi-
ciency. On the rear side the moveable bearing bushings are pres-
surized and thus tightly pressed against the gears. The pressurized
pressure fields are thereby limited by special seals. Sealing around
the circumference of the gears to the housing is assured by small
gaps, which appears between gears and housing in dependence
on the pressure.

Function
Fig. 213
The increasing volume caused by a tooth exiting a tooth gap
results in a vacuum in the suction chamber. The pressure fluid is
transported into the pressure chamber. There the meshing of teeth
and tooth gaps displaces the pressure fluid into the upper supply
line.
Fig. 214
1 Cover 6 Gear (driven)

2 Seals 7 Shaft
3 Housing 8 Flange
4 Gear (driving) 9 Bearing plate
5 Displacement chamber 10 Bearing plate

Multiple gear pumps Gear pumps are most suitable for multiple pump arrangements,
whereby the drive shaft of pump 1 is extended to drive a second or
3. pump. The shafts are connected by drivers in between. The indi-
vidual pump stages are sealed to each other, i.e. the suction ports
are separated from each other.
Fig. 215
6.3.7 Steering valve

The steering unit works hydrostatically, i.e. there is no mechanical
connection between the steering wheel and the wheels to be
steered (articulated joint, drum, etc.). The mechanical link is
replaced by hydraulic piping and hoses between the steering unit
and the steering cylinder(s).
When the steering wheel is operated, the steering unit measures
the exact oil quantity proportional to the rotation of the steering
wheel. This oil quantity is directed to the steering cylinders.
The steering unit mainly comprises of a rotary spool valve and a
rating pump (gear set). The steering column connects the steering
unit to the steering wheel of the vehicle. When operating the
steering wheel the rotary spool valve makes sure that oil from the
steering pump is guided through the gear set to the cylinder ports L
or R, depending on the operating direction of the steering wheel.
The gear set measures the oil flow to the steering cylinder propor-
tionally to the turning angle of the steering wheel.
Fig. 216

1 Check valve 8 Outer spool

2 Shock valve 9 Universal shaft
3 Pressure relief valve 10 Distributor plate
4 Housing with anti-cavitation valves 11 Gear
5 Inner spool 12 Ring gear
6 Neutral setting spring 13 Cover
7 Pin
The steering valve is additionally equipped with a pressure relief

valve, it limits the steering pressure.
Suddenly occurring pressure peaks, which may be caused by e.g.
external influences like driving against a curb stone, are compen-
sated by two shock valves, which are integrated in the steering
valve. Each of these shock valves is fitted with an additional anti-
cavitation valve. These anti-cavitation valves protect the system
against cavitation which could be caused by the reaction of the
shock valves.
A check valve inside the steering unit makes sure that the
hydraulic oil cannot flow to the steering pump if forces are intro-
duced from outside. In such a case the steering cylinders would act
as pumps and press the oil back to the pump.

Hydraulic system – Charge circuit
6.4 Charge circuit
Fig. 217
2 Steering/charge pump + dozer blade (or Vario or attachment plate)
4 Charge circuit filter
5 Vibration pump with integrated charge pump
7 Brake valve
9 Steering valve

Hydraulic system – Charge circuit
B21 Differential pressure switch on charge oil filter

MS Charge circuit test port
The charge circuit provides the oil for the charge system and the
control functions in the closed circuits for travel and vibration drive,
as well as to release the parking brakes.
The steering/charge pump is a gear pump with constant displace-
ment. The gear pump unit is driven by the auxiliary drive of the
diesel engine and draws the hydraulic oil directly out of the oil tank.
Another charge pump is integrated in the vibration pump.
The flows from steering/charge pump and integrated charge pump
(in vibration pump) are joined together before the charge circuit
filter.
The charge circuit is equipped with a 12 µ fine filter with bypass
valve. This valve opens at a pressure differential (pressure differ-
ence between filter inlet and filter outlet) of Δp = 3.5 bar. This pres-
sure differential depends on the filter contamination and the vis-
cosity of the hydraulic oil.
The differential pressure switch (B21) switches when a differen-
tial pressure of Δp 2.5 bar is reached. The fault information will
therefore already be available before the bypass valve opens.

Hydraulic system – Travel circuit
6.5 Travel circuit

Travel system
The rear axles are equipped with a NoSpin differential with auto-
matic locking up to 100 percent. This means propulsion is avail-
able, even if one wheel comes off the ground. The double pump
system optimally converts the engine power to traction. Even gradi-
ents of more than 60 percent are no problem.
Fig. 218
The travel system of the machine consists of two travel circuits.
n Travel circuit for drum drive
n Travel circuit for axle drive
Each travel circuit is a closed hydraulic circuit, it consists mainly of
travel pump and travel motor.
The two travel pumps and the vibration pump are mounted
together to a triple pump unit, which is driven by the flywheel side
of the engine via an elastic coupling.
The travel pump has the function of supplying the travel circuit with
hydraulic oil.
Drive wheels and drum are driven by fast rotating hydraulic motors.
Both travel motors are equipped with flushing valve and speed
range selector valve.
Flushing valves in the drive motors

The flushing valves are used to discharge heat from
the hydraulic circuit.

When the travel circuit is switched on, a pressure difference will be

generated between the two sides (A & B) of the closed circuit. The
sure side.
The flushing valve is fitted with a downstream flushing pressure
hydraulic oil is flushed out. The oil flows back to the hydraulic oil
Return flows All return flows pass through the return flow manifold block with
thermostat. This thermostat guides the oil flow directly back to the
hydraulic oil tank, until the operating temperature is reached. At an
oil temperature of 55 °C the valve starts to switch over and at 70
°C the total amount of oil will flow through the hydraulic oil cooler.
Service brake During operation the closed hydrostatic travel circuit has the func-
tion of a service brake. When the travel lever is returned towards
neutral position, the displacement of the travel motor is adjusted
towards zero accordingly and the machine is hydraulically braked.
Parking brake To avoid creeping movements of the machine, the machine is addi-
tionally equipped with spring accumulator multi-disc parking brakes
in drum drive gear and in the axle. These close in neutral position
of the travel lever and when the engine is stopped.
Drum drive The drum drive motor is a Sauer-Danfoss axial piston motor based
on the swash plate principle with variable displacement, the
hydraulic motor drives the travel gear. The reduction gear reduces
the high output speed to the final rotational speed of the drum.
The travel gearbox is fitted with dip-feed oil lubrication. The equip-
ment includes an integrated, hydraulically released multi-disc
parking brake. The integrated wet, but hydraulically releasable
multi-disc brake serves as parking brake, it is permanently closed
by spring pressure is released by feeding in pressure oil.

Fig. 219
1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel gear
5 Travel motor
6 Drum shell
7 Rubber buffer
9 Travel bearings
Functional principle ECOMODE The standard BOMAG ECOMODE ensures a clean environmental
adapted.
very pleasant.


Travel circuit for drum drive
Fig. 220
2 Radiator


5 Vibration pump
6 Brake valve
7 Travel gear with brake discs
8 Drum drive motor with travel speed range selector
9 Return flow manifold with thermostat
B234 Pressure sensor, axle MA
B235 Pressure sensor, axle MB
B236 Pressure sensor, drum MA
B237 Pressure sensor, drum MB
MA/3 Pressure test port, axle drive MA
MB/3 Pressure test port, axle drive MB
MA/4 Pressure test port, drum drive MA
MB/4 Pressure test port, drum drive MB
Forward Reverse
Plug Y73 Y72

Travel circuit for axle drive
Fig. 221
2 Radiator


5 Vibration pump
6 Brake valve
7 Drive axle with brake
8 Axle drive motor with travel speed range selector
B234 Pressure sensor, axle MA
B235 Pressure sensor, axle MB
B236 Pressure sensor, drum MA
B237 Pressure sensor, drum MB
MA/3 Pressure test port, axle drive MA
MB/3 Pressure test port, axle drive MB
MA/4 Pressure test port, drum drive MA
MB/4 Pressure test port, drum drive MB
Forward Reverse
Plug Y16 Y17

Hydraulic system – Vibration circuit
6.6 Vibration circuit
Fig. 222

2 Radiator
5 Vibration pump
6 Vibration motor
Vibration pump

Plug Y07 Y08
Vibration circuit The vibration circuit is a closed hydraulic circuit, it consists mainly
of vibration pump and vibration motor.
The two travel pumps and the vibration pump are mounted
together to a triple pump unit, which is driven by the flywheel side
of the engine via an elastic coupling. The vibration pump has the
function of supplying the vibration circuit with hydraulic oil.
When changing the swashing angle in the vibration pump through

the neutral position to the opposite side, the flow direction of the oil
and the sense of rotation of the vibration motor will change.
Since the displacement of the vibration pump is different to the two
flow directions, the speeds of the vibration motor are also different.
Fig. 223
The vibration system is designed in such a way, that the high
exciter shaft speed (frequency) is coupled with the low amplitude
and the low exciter shaft speed (frequency) with the high ampli-
tude.

The eccentric weights on the vibrator shaft are fitted with additional
change-over weights. Depending on the sense of rotation of the
exciter shaft these change-over weights add to or subtract from the
basic weights.
n Basic weight plus change-over weight = high amplitude
n Basic weight minus change-over weight = low amplitude
Fig. 224
1 Basic weight
2 Changeover weight
3 Exciter shafts
When switching the vibration on the motor must first start to move
the resting exciter shaft. This resistance causes a hydraulic starting
pressure, which is limited by the pressure override. Once the
exciter shaft has reached its final speed, the pressure will drop to
operating pressure. The value of the operating pressure mainly
depends on the condition of the ground (degree of compaction,
material etc.).
Hard ground High operating pressure

Soft ground Low operating pressure

Fig. 225: low amplitude

Use of low amplitude
n thin layers
n gravels, sands, mixed soils
n gravel and road metal bearing courses
n surface compaction
Fig. 226: high amplitude

Use of high amplitude
n thick layers
n non-cohesive soils and cohesive soils
n gravel and road metal bearing courses
n hydraulically bonded base courses
n frost protection layers
n subsoils
n dam constructions

Fig. 227
1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel gear
5 Travel motor
6 Drum shell
7 Rubber buffer
9 Travel bearings
The vibration motor output shaft is joined with the exciter shaft in
the drum via a Bowex coupling. The rotation of the exciter shaft
with the bolted on eccentric weights causes the vibration of the
elastically suspended drums.
Vibration motor with flushing valve The vibration motor is equipped with an integrated flushing valve.
In the closed hydraulic circuit the flushing and charge pressure
relief valve is used to avoid excessive temperatures and to secure
the minimum charge pressure. The valve is integrated in the con-
necting plate.

A certain amount of pressure fluid, which is determined by the size

of an orifice, is taken out of the corresponding low pressure side
and discharged into the motor housing. This fluid is returned to the
tank, together with the leak oil. The pressure fluid taken out of the
circuit is then replaced by cooled oil from the charge pump.
Return flows All return flows pass through the return flow manifold with tempera-
ture controlled valve (thermostat). This thermostat guides the oil
flow directly back to the hydraulic oil tank, until the operating tem-
perature is reached. At an oil temperature of 55 °C the valve starts
to switch over and at 70 °C the total amount of oil will flow through
the hydraulic oil cooler.
Functional principle ECOMODE The standard BOMAG ECOMODE ensures a clean environmental
adapted.
very pleasant.

Hydraulic system – Steering circuit
6.7 Steering circuit
Fig. 228
3 Charge circuit filter
4 (Optional equipment for cabin) Silencer, it is always subjected to hydraulic oil flow and has the function
of eliminating any vibrations and noises
5 Steering cylinder
6 Steering valve

The steering/charge pump is a gear pump with constant displace-

ment. The gear pump unit is driven by the auxiliary drive of the
diesel engine and draws the hydraulic oil directly out of the oil tank.

Oscillating articulated joint
Fig. 229
1 Drum
2 Front frame
3 Oscillating articulated joint with two steering cylinders
4 Oscillating articulated joint with one steering cylinder
5 Steering cylinder
6 Rear frame
7 Drive axle
8 Single drum roller with one steering cylinder
9 Single drum roller with two steering cylinders
Front and rear frames of the single drum rollers are connected by
an oscillating articulated joint.
The front console of the joint is fastened with screws to the rear
cross-member of the front frame. The rear console is tightly bolted
to the rear frame.

The use of rocker bearings between front and rear frame ensures
that both frames can oscillate to each other for +/- 12°. This ena-
bles good ground contact of drum and wheels, even under severe
soil conditions.
When turning the steering wheel, the steering cylinders will extend
or retract and swivel the front console around the vertical bolt. This
articulates the machine and results in a steering movement.

Hydraulic system – Inspection and maintenance work

6.8.1 Checking the hydraulic oil level
NOTICE!
– Check the hydraulic oil level at room temperature
(approx. 20 °C (68 °F)).
– If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped, check
all lines, hoses and components for leaks.
Ä Chapter 1.4.5 ‘Hydraulic oil’ on page 51.
– In hydraulic systems filled with Panolin HLP Synth.
46 always use the same oil to top up. With other
ester based oils consult the lubrication oil service
of the respective oil manufacturer.
Protective equipment: n Protective gloves

1. Check the oil level in the inspection glass.
ð Normal level: approx. 3 cm (1.2 in) below the upper edge
of the inspection glass.
Minimum level: Middle of inspection glass
2. If necessary fill in hydraulic oil through the filler neck.
Fig. 230
6.8.2 Changing the hydraulic oil

years.
The hydraulic oil must also be changed after major repairs in the
hydraulic system.
Always replace the hydraulic oil filter after each hydraulic oil
change. Change the hydraulic oil filter only after the hydraulic oil
change and after the test run.
Do not start the engine after draining the hydraulic oil.
Do not use any detergents to clean the system.
Use only lint-free cleaning cloths.
When changing from mineral oil based hydraulic oil to an ester
based biologically degradable oil, you should consult the lubrica-
tion oil service of the oil manufacturer, or our customer service for
details.

NOTICE!
Risk of damage!
– Perform the oil change when the hydraulic oil is
warm.
– Use only hydraulic oil of the permitted specification
Ä Chapter 1.4.5 ‘Hydraulic oil’ on page 51.
lubricants’ on page 53.

n Protective gloves
1. Park the machine in secured condition.
2. Clean the area around hydraulic oil tank, filler opening and
filler cap.
3. Remove the cover from the hydraulic oil tank.
Fig. 231
4. Unscrew the plug.

5. Drain off and collect all hydraulic oil.
6. Turn the plug tightly back in.
We recommend to use our filling and filtering unit with

fine filter to fill the system. This ensures finest filtration
of the hydraulic oil, prolongs the lifetime of the
hydraulic oil filter and protects the hydraulic system.
Fig. 232 7. Fill in new hydraulic oil.

8. Check the oil level in the inspection glass.

ð Normal level: approx. 3 cm (1.2 in) below the top edge
of the inspection glass.
Minimum level: Middle of inspection glass
9.
The breather filter for the hydraulic oil tank is
integrated in the filler cap, you must therefore
replace the complete filler cap.
Fig. 233 Close the tank with a new cap.

10. Dispose of oil environmentally.

6.8.3 Replacing the hydraulic oil filter

year.
NOTICE!
– If the filter has to be changed together with the
hydraulic oil, the filter must only be changed after
the oil change and after the test run.
– Do not use the oil in the filter bowl again.
– Apart from the normal oil change intervals, the filter
element must also be changed after major repairs
in the hydraulic system.

n Protective gloves
3. Unscrew filter bowl (4) and take it off with filter element (3).
NOTICE!
Negligence may cause destruction to the entire
hydraulic system.
– Visible dirt may be an early sign for the failure of
system components and indicate the possible
failure of components.
– In this case determine the cause and replace or
repair the defective components, if necessary.
Fig. 234 – Do not clean or reuse the filter element.
4. Take out the old filter element and clean the filter bowl.
5. Clean the thread on the filter bowl.
6. Reassemble the filter bowl with a new filter element and new
O-rings (1, 2).

7. Clean the area around the high pressure filter.

8. Disconnect the high pressure oil lines from the high pressure
filter.
9. Remove the high pressure filter and install the new high pres-
sure filter, pay attention to the flow direction (arrow).
10. After a test run, check for leaks.
11. Dispose of oil and filter in an environmentally-friendly
manner.
Fig. 235

Hydraulic system – Flushing and bleeding
6.9 Flushing and bleeding

6.9.1 Flushing - general
Flushing - general
NOTICE!
Changing a component
– Always flush the complete oil circuit after you have
replaced a component.
– Solid particles in the circuit will very quickly cause
damage to machine components.
Fig. 236
Effect of contamination
n Coarse particles (> 15 µm)
– Sudden failure of components.
n Fine particle contamination (5 – 15 µm)
– Wear of components, internal leaks, inaccurate controlling
behaviour, blockage of valves.
n Extra fine particle contamination (< 2 – 5 µm)
– Silting of oil, accelerated aging of oil, corrosion.

n Water in oil
– Increased wear, accelerated aging of oil.
n Chips (abrasion) in the oil
– Open and clean all components in the oil circuit, replace if
necessary.
– Clean all high pressure hoses in the oil circuit, replace if
necessary.
– If abrasion is found in the travel circuit you should also
flush the vibration circuit.
– If abrasion is found in the vibration circuit you should also
flush the travel circuit.
Before flushing
1. Change the filter element
Fig. 237
2.
NOTICE!
Clean the hydraulic tank
Change the oil in case of excessive contamina-
tion, oil discoloration or if the oil change interval
is almost due.
Filter the tank content with the filling and filtering unit and
pump it into an oil container.
3. Mark all hoses and disconnect them from the hydraulic oil
Fig. 238 tank.
4. Clean the oil tank thoroughly from inside, remove the tank
cover, if necessary.
5. Reconnect all hoses.
6. Fill the hydraulic oil tank again with the filling and filtering
unit.

Bleeding
1. Always bleed closed hydraulic circuits if lines had been
removed or connected.
Fig. 239
Servicing the flushing filter kit

1. Replace the filter element of the flushing filter when the red
control pin of the contamination indicator is pressed out
during the filtering process.
2. Clean hoses and connections and store the flushing kit in a
clean and protected environment.
Fig. 240

6.9.2 Drum drive

Flushing schematic for drum drive
Fig. 241
1 Elbow union (tool)
2 Connecting union (tool)
3 Drum drive motor
4 High pressure hose A <> B
6 High pressure hose B <> A
7 Flushing hose 25S - 20S (tool)

8 Screw socket R1 - 25S (tool)

9 Flushing filter with filter element 1µ (tool)
6.9.2.1 Flushing the drum drive
Observe the chapter "Flushing - General"
Installing the flushing filter

NOTICE!
Before the installation of the filters check hoses and
connections for cleanliness.
The flushing filter must be installed in the low pressure
side in the return flow to the pump, so that only
cleaned oil will enter the travel pump in forward travel.
With the connection shown in the illustration the travel
pump must therefore be actuated to forward direction.
Disconnect the drum drive motor 1. Disconnect the high pressure hose (6) from the drum drive
motor (port A) and connect it with the flushing hose (7,
flushing filter outlet “OUT”).
2. Take the drum drive motor (3) out of the hydraulic circuit by
joining the hoses (4 & 10) together.
Fig. 242

Bleeding the travel circuit

WARNING!
Danger of severe injuries caused by uncontrolled
machine movements
– Operate the travel lever only after the axle drive
has been disabled.
1.
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Fig. 243
Flushing the hoses

1. Keep circulating the complete tank content with the filling and
filtering unit throughout the entire flushing process.
Fig. 244
2. Block drums and wheels with suitable chocks.
Fig. 245

3.
WARNING!
Danger of severe injuries caused by uncon-
trolled machine movements
– Operate the travel lever only after the axle
drive has been disabled.
NOTICE!
Move the travel lever only to travel direction for-
ward, as otherwise the flushing filter will be sub-
jected to oil flow from the wrong direction.
Fig. 246
Start the engine and shift the travel lever to travel direction
forward.
4. Perform the flushing process at various engine speeds for
approx. 10 minutes.
5. Shut down the engine.
Flushing the drum drive motor

1. Reconnect the hoses (4 and 10) to the drum drive motor.
2. Jack up the front of the machine, so that the drum can rotate
freely.
3. Secure the rear wheels with chocks.
4. Pre-select the slow speed range.
Fig. 247
Fig. 248

6.
WARNING!
– Operate the travel lever only after the axle
NOTICE!
Fig. 249
Start the engine, run it with maximum speed and shift the
travel lever to travel direction forward.
7. Run the flushing procedure for approx. 10 minutes. During
this process keep changing the pump flow by shifting the
travel lever several times between full and halve forward
travel.
Removing the flushing filter 1. Disconnect the flushing filter and reconnect the high pressure
hose (4 & 6) to the drum drive motor.

WARNING!
machine movements
– Operate the travel lever only after the axle drive
has been disabled.
1.
Fig. 250

Circulating the tank content

1. After completing the bleeding process circulate the tank con-
tent with the filtering unit for another 15 minutes.
Fig. 251
Function test
1. Check the hydraulic oil level in the tank, fill up if necessary.
2. Check all connections for leaks with the engine running
(visual inspection).
3. Perform a test drive, load the travel system in forward and
reverse, e.g. by driving uphill or starting on a gradient.
4. Check all ports and connections once again for leak tightness
Fig. 252

6.9.3 Axle drive

Flushing diagram for axle drive
Fig. 253
3 Travel motor, axle


6.9.3.1 Flushing the axle drive

NOTICE!
cleaned oil will enter the travel pump in forward travel.
With the connection shown in the illustration the travel
pump must therefore be actuated to forward direction.
Disconnecting the axle motor 1. Disconnect the high pressure hose (6) from the axle drive
motor (port A) and connect it with the flushing hose (7,
flushing filter outlet “OUT”).
2. Take the axle drive motor (3) out of the hydraulic circuit by
Fig. 254


WARNING!
machine movements
– Operate the travel lever only after the drum drive
has been disabled.
1.
Fig. 255
Flushing the hoses

Fig. 256
Fig. 257

3.
WARNING!
– Operate the travel lever only after the drum
NOTICE!
Fig. 258
Start the engine and shift the travel lever to travel direction
forward.
4. Perform the flushing process at various engine speeds for
approx. 10 minutes.
Flushing the axle motor

WARNING!
Danger of accident!
Both wheels must be off the ground. The wheels must
be able to rotate freely.
1. Reconnect the hoses (4 and 10) to the drum drive motor.

2. Jack up the rear of the machine, so that the wheels can
rotate freely.
3. Secure the drum with wheel chocks.
4. Pre-select the slow speed range.
Fig. 259

Fig. 260
6.
WARNING!
– Operate the travel lever only after the drum
NOTICE!
Fig. 261
Start the engine, run it with maximum speed and shift the
travel lever to travel direction forward.
7. Run the flushing procedure for approx. 10 minutes. During
this process keep changing the pump flow by shifting the
travel lever several times between full and halve forward
travel.
Removing the flushing filter 1. Disconnect the flushing filter and reconnect the high pressure
hoses (4 & 6) to the axle drive motor.


WARNING!
machine movements
– Operate the travel lever only after the drum drive
has been disabled.
1.
Fig. 262

Fig. 263
Function test
2. Check all connections for leaks with the engine running
3. Perform a test drive, load the travel system in forward and
reverse, e.g. by driving uphill or starting on a gradient.
Fig. 264

6.9.4 Vibration circuit

Flushing schematic for vibration
drive
Fig. 265
1 Vibration pump


6 Vibration motor
6.9.4.1 Flushing the vibration circuit

NOTICE!
cleaned oil will enter the vibration pump in high fre-
quency.
D-5, DH-5 & PDH-5 machines: For the connection
schematic shown here the vibration must always be fil-
tered with "high frequency / low amplitude".
Disconnect the vibration motor

1. Take the vibration motor (6) out of the hydraulic circuit by
Fig. 266

Bleeding the vibration circuit

1.
Bleeding the vibration circuit, see chapter
"Bleeding the vibration circuit".
Fig. 267
Flushing the hoses

Fig. 268
Fig. 269
3.
NOTICE!
D-5, DH-5 & PDH-5 machines: Use only high
frequency, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
Switch on vibration with high frequency .

4. Start the engine and run it with maximum speed.
5. Flush the circuit for approx. 10 minutes, thereby switch the
Fig. 270 vibration on and off at intervals of approx. 30 seconds.

Flushing the vibration motor 1. Reconnect the hoses (3 and 9) to the vibration motor.
2. Unscrew the fastening screws for the vibration motor and pull
the motor out of the coupling.
Fig. 271
Fig. 272
4.
NOTICE!
D-5, DH-5 & PDH-5 machines: Use only high
frequency, as otherwise the flushing filter will be
Start the engine and run it with maximum speed.

5. Run the flushing procedure for approx. 10 minutes. Switch
the vibration on and off at intervals of approx. 30 seconds.
Fig. 273 6. Shut down the engine.
Remove the flushing filter and rein- 1. Remove the flushing filter, install the vibration motor and
stall the vibration motor reconnect the high pressure hoses (2 & 3).

Bleeding the vibration circuit

1.
Bleeding the vibration circuit, see chapter
"Bleeding the vibration circuit".
Fig. 274

Fig. 275
Function test
2. Test drive.
Fig. 276

6.9.5 Bleeding the travel circuit

1. Install a pressure test hose to the charge pressure test port.
2. Install a pressure test hose each to the high pressure test
ports.
WARNING!
The engine should not start.
3. Actuate the emergency stop switch.
Fig. 277
4. Hold the open ends of the pressure test hoses into a con-
tainer.
5. Operate the starter motor for approx. 30 seconds. Wait one
minute and repeat this procedure, until oil starts to run out
from the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 278
7. Unlock the emergency stop switch.
Fig. 279

8. Connect a 60 bar pressure gauge to the charge pressure test

port and run the engine max. 15 seconds at idle speed.
9. Pause for approx. 30 seconds and keep repeating this proce-
dure, until the gauge shows a constant charge pressure
reading.
Fig. 280
10.
NOTICE!
With the flushing filter installed shift the travel
lever only to travel direction forward, as other-
wise the flushing filter will be subjected to oil flow
from the wrong direction.
WARNING!
Run the engine with idle speed.
Fig. 281
Start the engine.
11. Shift the travel lever approx. 1/3 to forward direction.
12. After approx. 1 to 2 minutes shut down the engine for a
minute.
ð
This waiting time is necessary to allow air
bubbles to escape through the leak oil return
line.
13. After a waiting time of approx. 1 minute keep repeating this

procedure, until the indicated charge pressure drops directly
to zero when shutting down the engine.

6.9.6 Bleeding the vibration circuit

1. Install a pressure test hose to the charge pressure test port.
2. Install a pressure test hose each to the high pressure test
ports.
WARNING!
The engine should not start.
3. Actuate the emergency stop switch.
Fig. 282
4. Hold the open ends of the pressure test hoses into a con-
tainer.
5. Crank the engine approx. 10 seconds with the starter motor.
Wait one minute and keep repeating this procedure, until oil
starts to run out from the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 283
7. Unlock the emergency stop switch.
Fig. 284

8. Connect a 60 bar pressure gauge to the charge pressure test

port and run the engine max. 15 seconds at idle speed.
9. Wait for approx. 30 seconds and repeat the procedure, until
the pressure gauge shows a constant charge pressure.
Fig. 285
10.
NOTICE!
With the flushing filter installed use only high fre-
quency, as otherwise the flushing filter will be
For bleeding switch on vibration with high frequency.

12. After running the engine 1 to 2 minutes pause for approx.
Fig. 286 one minute.
ð
This waiting time is necessary to allow air
bubbles to escape through the leak oil return
line.
13. After a waiting time of approx. 1 minute keep repeating this

procedure, until the indicated charge pressure drops directly
to zero when shutting down the engine.

Air conditioning
7 Air conditioning

Air conditioning – Overview
7.1 Overview
Fig. 287
1 Compressor
2 Condenser
3 Drier / collector
4 HKL-module

Air conditioning – Physical principles
7.2 Physical principles

In order to understand the working principle of an air conditioning
system one must first become familiar with the physical basics of
such a system.
The four well known physical conditions of water apply also for the
refrigerant in the air conditioning system.
1. gaseous (invisible)
2. vaporous
3. liquid
4. solid
If the water in a container is heated up (absorption of heat), the
rising steam is visible. If the steam is heated up further, due to the
absorption of heat, the visible steam will turn into invisible gas. This
process is reversible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into water and finally
into ice.
Fig. 288
A - heat absorption
B- Heat dissipation
Heat always flows from the warmer to the colder matter. Any
matter consists of a mass of moving molecules. The rapidly moving
molecules or a warmer matter dissipate part of their energy to the
slower moving molecules with less heat. The movement of the mol-
ecules in the warmer matter becomes slower and the molecules in
the cooler matter are accelerated. This process continued, until all
molecules in the two matters move with identical speed. The mat-
ters have then reached an identical temperature and the transfer of
heat stops.
Fig. 289
Pressure and boiling point The boiling point is the temperature at which fluid changes to gas-
eous state.
Changing the pressure above a fluid also changes the boiling
point. It is a well known fact, that e.g. the lower the pressure
applied to water, the lower the boiling point.
When looking at water, the following values do apply:
n Atmospheric pressure, boiling point 100°C
n Overpressure 0.4 bar, boiling point 126°C
n Vacuum -0.6 bar, boiling point 71°C
For an optimal exchange of heat, liquid refrigerants must have a
low boiling point, so that they can absorb and dissipate heat
quickly.

Steam pressure curve for refrigerant R134a

The steam pressure curve is a means for explaining the operation
principle of an air conditioning system.
A- liquid
B- gaseous
The diagram shows the evaporation curve of R134a. The diagram
for example shows, that R134a is liquid at 0°C and a pressure of 5
bar, but becomes gaseous at 40°C and 5 bar.
For better understanding one must also be aware of the following:
1. A gas heats up when being compressed (e.g. air pump, turbo
charger, ...).
2. When relieving gas it will cool down (e.g. white frost forms on
the valve when relieving air pressure from a car tire).
Fig. 290: Steam pressure curve 3. Condensing gas dissipates a lot of heat energy.
4. If a fluid evaporates it requires a lot of heat, i.e. the fluid thereby
cools down the surrounding environment (e.g. alcohol on skin)
At absolute pressure 0 bar correspond with an abso-

lute vacuum. The normal ambient pressure (overpres-
sure) corresponds with 1 bar absolute pressure. On
the scales of most pressure gauges 0 bar corresponds
with an absolute pressure of 1 bar (indicated by the
statement -1 bar below the 0).
In the pressure - temperature diagram for the refrigerant the drawn

in closed curve shows the cycle of the refrigerant. This cycle per-
manently continues in direction of the arrow.
The characters A, B, C, D stand for:
A - compression
B- condensation
C- relaxation
D- evaporation.
Fig. 291: Pressure - Temperature

Diagram
Excerpt from the wet steam table

R134aThis table is used for the determination of
evaporation and condensation temperature.
Saturation temperature Overpressure (pressure gauge Absolute pressure (pamb = 1 bar P

reading Pe in bar) in bar)
-20 0,33 1,33
-10 1,01 2,01

Saturation temperature Overpressure (pressure gauge Absolute pressure (pamb = 1 bar P

reading Pe in bar) in bar)
0 1,93 2,93
10 3,15 4,15
20 4,72 5,72

Air conditioning – Refrigerant R134a
7.3 Refrigerant R134a

General
The evaporation and condensation process is the method com-
monly used in mobile air conditioning systems. The system in this
case works with a substance that boils at low temperature, a sub-
stance referred to a refrigerant. The refrigerant used is tetrafluoro-
ethane R134a, which boils at a temperature of -26.5°C and under a
steam pressure of 1 bar.
Although the refrigerant circuit is a hermetically closed loop, the
system loses approx. 100g of refrigerant over the course of 1 year
by diffusion through hoses, pipes and seals, even though the
system is free of leaks. If too much refrigerant is lost the cooling
power of the system will drop.
Physical data of the refrigerant R134a
Chemical formula:
CH2F-CF3 or CF3-CH2F
Chemical designation:
Tetrafluoroethane
Boiling point at 1 bar:

- 26.5 °C
Solidification point:
-101.6 °C
Critical temperature:
100,6 °C
Critical pressure:
40.56 bar (absolute)
Critical point:
Critical point (critical temperature and critical pressure) means that
above this point there is no separating interface between liquid and
gas. Above its critical point any substance is gaseous. At tempera-
tures below the critical point all refrigerant types in pressure con-
tainers have a liquid and a gaseous phase, i.e. a gas cushion is
above the liquid. As long as gas is in the container, besides the
liquid, the pressure depends on the ambient temperature.
Characteristics of the refrigerant R134a:

Refrigerant R134a is currently available under the following trade
marks. H-FKW 134a SUVA 134a KLEA 134a
Colour:

Refrigerant in form of vapour or liquid is colourless as water. The

gas is invisible. Only the bordering layer between gas and liquid is
visible. (Fluid level in rising pipe of filling cylinder or bubbles in
inspection glass). In the inspection glass the liquid refrigerant
R134a may appear coloured (milky). This turbidity results from par-
tially dissolved refrigeration oil and is no indicator for a fault.
Steam pressure:
In an incompletely filled, closed container, vaporous refrigerant will
volatilize from the surface in the same quantity that will turn liquid
in combination with steam particles. This state of equilibrium
occurs under pressure and is frequently referred to as steam pres-
sure. The steam pressure is independent from the temperature.
Physical properties of R134a:

The steam pressure curves of R134a and other refrigerants are
partly very similar, making a clear differentiation solely by pressure
impossible. With R 134a the compressor is lubricated by special
synthetic refrigeration oils, e.g. PAG-oils (polyalkylene glycol oils).
Behaviour with metals:

In pure condition refrigerant R134a is chemically stable and does
not attack iron and aluminium. However, contamination of the
refrigerant, e.g. with chlorine compounds, leads to aggressiveness
against certain metals and plastics. This can cause clogging, leaks
or deposits on the pistons of the compressor.
Critical temperature / critical pressure:

Up to a gas pressure of 39.5 bar overpressure (this corresponds
with a temperature of 101 °C) the refrigerant R134a remains chem-
ically stable, above this temperature the refrigerant decomposes
(see combustibility).
Water content:
In liquid refrigerant water can only be dissolved in very low quanti-
ties. In contrast to this refrigerant steam mixes with water steam at
any ratio. If the dryer in the liquid container has absorbed approx. 8
gr. of water, the refrigerant circuit transports possibly existing water
in form of droplets. This water flows to the nozzle of the expansion
valve and turns to ice. The air conditioning system stops cooling.
Water destroys the air conditioning system, because under high
pressures and temperatures and in connection with other contami-
nants it forms acids.
Inflammability:
Refrigerant is not inflammable. On the contrary, it has fire inhibiting
or fire extinguishing properties. Refrigerant is decomposed by
flames or glowing surfaces. Ultraviolet light also cracks refrigerant
(caused by electric welding). This results in toxic fission products,
these must not be inhaled. However, irritation of the mucous mem-
branes is an early and in-time warning.
Filling factor:

In a container there must be a steam space above the liquid space.

The liquid expands with increasing temperature. The steam filled
space becomes smaller. From a certain time on the container will
be filled with just liquid. After this only a minor temperature
increase is enough to generate very high pressures in the con-
tainer, because the liquid would like to expand, but there is no
more room. The related forces are high enough to cause the con-
tainer to burst. In order to avoid overfilling of a container the pres-
sure gas directive clearly specifies how many kilograms of refrig-
erant may be filled into the container per litre volume. Multiplied
with the internal volume this "filling factor" determines the permis-
sible filling capacity For refrigerants used in motor vehicles it is
1.15 kg/l.
Environmental aspects The contribution of R134a to the greenhouse effect is by factor 10

smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for newly pro-
duced construction equipment were successively converted to
refrigerant R134a. This refrigerant does not contain any chlorine
and is thus harmless for the ozone layer. Until approx. 1992 air
conditioning systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decomposition potential
and also a potential to amplify the greenhouse effect. Conversion
programs for existing old systems with the ozone damaging R12
are in effect. For reasons of protecting the environment refrigerant
must not be discharged into the atmosphere.

Air conditioning – Compressor oil / refrigeration oil
7.4 Compressor oil / refrigeration oil

General
The compressor oil lubricates the movable parts in the com-

pressor, seals e.g. the gap between piston and cylinder inside the
compressor to prevent refrigerant loss and prevents other seals in
the system from drying up.
Part of the compressor oil dissolves in the refrigerant until satura-
tion is reached, so that a gas mixture of refrigerant, water steam,
compressor oil and contrast agent circulates through the system.
Compressor oil (the oil quantity should be 10 % of the refrigerant
weight) mixes with the refrigerant and circulates permanently
through the system.
In connection with R134a- air conditioning systems special syn-
thetic compressor oils, e.g. polyalkylene glycol (PAG) oils, are
used. This is necessary, because e.g. mineral oil does not mix with
R134a. Apart from this, the materials in the R134a air conditioning
system may be attacked when the mixture is flowing through the
refrigerant circuit under high pressure and at high temperatures or
if the lubrication film in the compressor tears off. The use of non-
permitted oils can cause damage to the air conditioning system,
you should therefore only used the approved oils.
Properties of compressor oil / The most important properties are high solvency in connection with
refrigeration oil refrigerants, good lubrication characteristics, that they are free of
acids and their low water content. For this purpose only certain oils
can be used. PAG-oils suitable for use with refrigerant R134a are
highly hygroscopic and will not mix with other oil. As a protection
against the invasion of moisture drums must immediately be closed
again after they had been opened. Compressor oil ages under the
effect of moisture and acids, becomes dark, viscous and aggres-
sive against metals.
Compressor oil level / refrigeration

oil level in the compressor NOTICE!
The refrigeration oil level in the compressor must be
checked after replacing a system component or if a
leak in the system is suspected. Use only refrigeration
oil PAG SP-20 (H14-003-404).
When replacing a heat exchanger, e.g. evaporator or
condenser, any compressor oil / refrigeration oil lost by
exchanging the components, must be replaced with
fresh oil.
The actual quantity depends on the amount of oil that
may have been lost in connection with the possible
replacement of other components.

ENVIRONMENT!
Used compressor oil / refrigeration oil must be dis-
posed of as hazardous waste.
The following table shows how much compressor oil / refrigeration

oil will be lost in connection with various types of work on the air
conditioning system.
Reason of oil loss Amount of oil lost

Loss when emptying approx. 15 gr
Defective A/C hose approx. 30 gr
Hose change approx. 15 gr
Replacement of condenser approx. 30 gr
Replacement of evaporator approx. 30 gr
Replacement of liquid container approx. 30 gr
Replacement of expansion valve approx. 15 gr
NOTICE!
Compressor replacement
New compressors are delivered with an approx. 250
gr.compressor oil filling. To avoid excessive oil in the
A/C-system and thus a poor cooling effect, the oil level
in the A/C-system must be adjusted accordingly.
The quantity depends on the amount of oil that may
have been lost in connection with the possible replace-
ment of other components.
The compressor oil quantity must be 10% of the refrig-
erant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system requires
a compressor oil / refrigerant oil filling of 110 gr.
Procedure
– Drain and measure the compressor oil from the old

compressor.
– Drain the compressor oil from the new compressor
and only fill in the exact quantity that had been
drained out of the old compressor. The com-
pressor oil from the new compressor can be used
for this purpose.

Topping up compressor oil / refrigeration oil is possible

on a pressureless compressor directly into the oil pan,
in a pressureless refrigeration system directly into the
pressure side, but it is also possible to draw it into the
pressure side of the refrigeration system during the
evacuation process.

Air conditioning – Working principle of the air conditioning system
7.5 Working principle of the air conditioning system

All air conditioning systems are based on the same principle. They
extract heat from the surrounding environment. Everybody knows
the effect: if a sweating body is exposed to wind it will cool down,
because heat is extracted. For this purpose a refrigerant circulates
in a closed circuit inside the vehicle. This refrigerant thereby con-
tinuously changes its physical state between liquid and gaseous.
An engine driven compressor (1) draws in gaseous refrigerant from
the evaporator (5) and compresses it. During this process the tem-
perature of the refrigerant increases tremendously.
The refrigerant vapour is then pumped to the condenser (2). This
condenser is arranged directly in front of the vehicle radiator, so
that a sufficient air flow is assured. In the condenser (2) the gas is
cooled down and consequently liquefied.
In the dryer / liquid container (3) the refrigerant is then collected
and freed of moisture and contaminants.
Fig. 292: Principle sketch of an air The expansion valve (4) regulates the flow rate from the dryer /
conditioning system liquid container (3) back to the evaporator (5) and the circuit starts
again.

Air conditioning – Monitoring devices
7.6 Monitoring devices

Pressure switch The pressure switch (8) is used as monitoring feature for too high
and too low pressures. The switching contacts (4 and 5) effect the
magnetic clutch of the compressor via a relay (6).
If the system pressure increases excessively, e.g. because of a
excessively soiled condenser, a failed fan or a defective expansion
valve, the high pressure contact (5) will cut off the electric power
supply to the magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off pressure by the
set differential pressure, the magnetic clutch of the compressor is
switched on again.
The low pressure contact (4) interrupts the electric power supply to
the magnetic clutch when the set pressure is fallen short of (pos-
sible causes: lack of refrigerant, defective expansion valve, too low
heat load, defective evaporator fan, ...). Since the refrigerant
R134a has an evaporation temperature of 0 °C at an overpressure
of 2 bar, the low pressure contact (4) is set to approx. 1.5 bar to
avoid icing. The switch on pressure is 0.5 to 2 bar higher than the
shut-off pressure (depending on system, see description of compo-
nents.)
Thermostat A frost protection thermostat (3) protects the evaporator against

icing. Similar to the pressure switch, the thermostat activates or
deactivates the magnetic clutch for the compressor. Depending on
the design, the feeler of the temperature control is mounted
between the fins of the evaporator or attached to the evaporator
outlet (suction side). With fixed temperature controls the control
switches the compressor off at about 1 °C and back on again at
about 2.5°C to 5.5 °C (depending on system, see description of
components.)
With adjustable temperature regulators the switching point can be
changed so that the compressor is already shut down at higher
temperatures. This enables regulation of the air temperature.
Monitoring chain
1 Switches
2 Fuse
3 Thermostat
4 Low pressure switch contact
5 High pressure switch contact
6 Relays
7 Connection for magnetic clutch
8 Pressure switch
Fig. 293: Monitoring chain

Air conditioning – Description of components
7.7 Description of components

Condenser
The condenser is located in front of the radiator for the machine. It
emits heat energy from the system into the surrounding air and liq-
uefies the gaseous refrigerant.
WARNING!
Fig. 294
The fins must be free of dirt and damage.
NOTICE!
condenser, any compressor oil lost by exchanging the
components, must be replaced with fresh oil.
Dryer / filter / fluid container /

inspection glass
Dryer / filter
The fluid container collects the fluid drops and passes these then
as a constant flow to the expansion valve. Moisture that has
entered during assembly of the refrigerant circuit is absorbed by a
dryer in the fluid container.
At evaporation temperatures below zero the refrigerant will deposit
previously absorbed moisture on the expansion valve, where this
water turns into ice and thus adversely affects the controllability of
the expansion valve. Moreover, moisture in the refrigerant circuit
causes corrosion, forms acids and enters into chemical composi-
tions.
Fig. 295
Inside the refrigerant container the heavy liquid refrigerant collects
in the lower part of the container, flows through a rising pipe to the
outlet marked "A" and thus ensures bubble free operation of the
expansion valve.
Since the absorbing capacity of this filter/dryer is

limited, it must be changed within certain service inter-
vals. We recommend to replace it 1 x per years, before
the start of the season.

NOTICE!
The filter/dryer must generally be replaced whenever
opening the refrigerant circuit, because moisture will
enter in such a case.
This requires emptying the air conditioning system!
Installation position:
The arrow marks on the filter/dryer must point in flow
direction, i.e. towards the expansion valve.
Filter/dryer cannot be treated for further use!
Pressure relief valve

The fluid container is equipped with a safety valve.
Response pressure 32 +/- 4 bar
Tightening torque 10 - 15 Nm
Fig. 296
Inspection glass
During operation the refrigerant must flow through the inspection
glass without air bubbles. In most cases the presence of air bub-
bles is a sign for a too low refrigerant level in the system. Apart
from this, the refrigerant may not sufficiently condense as a result
of a soiled evaporator or a defective condenser fan and the fluid
level in the refrigerant container may drop down to a level, at which
gaseous refrigerant could flow through the rising tube to the
inspection glass. This results in abnormally high temperatures in
and on the fluid lines (between refrigerant container and expansion
valve), as well as very high pressures in the pressure side.
However, incorrect evacuation or filling may also be the reason for
Fig. 297 air entering into the system and since air cannot be condensed,
one will not be able to get rid of these bubbles by topping up refrig-
erant. In this case the air conditioning system needs to be evacu-
ated and refilled.
Air in the system is characterized by high pressures

and temperatures.
On R134a refrigeration systems from KONVEKTA the inspection

glasses are equipped with moisture indicators. In addition to the
float, the dryer/collector/inspection glass combination has an indi-
cator pearl integrated in the inspection glass, which changes its
colour when absorbing moisture.

The refrigerant level should be inside the inspection glass and

should only be checked after approx. 5 minutes continuous opera-
tion, because the refrigerant must first evenly distribute all over the
system.
WARNING!
In case of mechanical damage or corrosion on this
pressure container this collector unit must be replaced,
to avoid bursting and further damage.
Expansion valve
The expansion valve is mounted inside the HKL-module in the

cabin. The expansion valve always allows a small amount of the
high pressure liquefied refrigerant to flow into the evaporator,
which has a much lower pressure. This lower pressure causes
these liquid refrigerant to expand and to evaporate to gaseous
state. The heat required for this evaporation process is taken from
the ambient air through the lamellas and supplied to the refrigerant.
This is the so-called cooling effect.
The thermostatic expansion valve operates with an external pres-
sure compensation. This type of expansion valve works with high
accuracy, because it uses pressure and temperature at the evapo-
rator outlet and adjusts and overheating of approx. 7 K. The
already installed expansion valves and the ones delivered as spare
parts have this overheating value pre-set. In order to prevent a loss
Fig. 298 in performance or compressor damage you should only use orig-
inal expansion valves, because adjusting expansion valves takes a
lot of time and care.
In case of dirt in the refrigerant system you should also

check or clean the screen at the expansion valve inlet.
+

Evaporator
The evaporator is mounted inside the HKL-module in the cabin. It

consists of a heat exchanger (inside air - refrigerant), with refrig-
erant flowing to a pipe system with cooling flanges.
As with the condenser, correct operation of all fans and cleanliness
of the fins must be assured.
Air conditioning systems have a circulation air filter mounted in the
air flow in front of the evaporator, which should be cleaned or
changed by the operator after each third trip, depending on the
amount of dirt.
A condensation water filter is mounted in the air flow after the
evaporator. This filter has the function to collect the water that has
condensed from the air in the evaporator block and to discharge
this water into the water pan With a defective condensation water
Fig. 299 filter condensation water may flow into the inside of the vehicle.
NOTICE!
condenser, any compressor oil lost by exchanging the
components, must be replaced with fresh oil.
Thermostat
Thermostat with fixed setting

The feeler of a defroster thermostat to switch off the magnetic
clutch in case of icing up or to switch the clutch back on after
defrosting, is mounted on the evaporator.
With fixed temperature controls the control switches the com-
pressor off at about +1 °C and back on again at about +2.5°C to
+5.5 °C.
Fig. 300
Adjustable thermostat
With adjustable temperature regulators the switching point can be
changed so that the compressor is already shut down at higher
temperatures. This enables regulation of the air temperature.

The adjusted temperature must be below the actual

temperature inside the cabin, so that the compressor
will be switched on.
Fig. 301: adjustable temperature con-

troller
Pressure switch
After a minimum pressure is reached in the low pressure side or a

maximum pressure in the high pressure side, the pressure switch
will switch of the magnetic clutch of the compressor, thus to avoid
destruction of system components by excessive pressure or
drawing in external gases and foreign matter as a result of too low
pressure.
Working pressure:
Low pressure off: 1,5 ±0,5 bar
Low pressure on: 3.5 bar
Overpressure off: 25,0 ±1,5 bar
Fig. 302
Overpressure on: 18,0 ±1,5 bar
Pipes and hoses
Pipes and hoses in air conditioning systems must meet very high
requirements with respect to resistance against heat and pressure.
The requirements concerning leak tightness and, in case of hoses,
against diffusion, i.e. seepage of refrigerant through the hose
material, are very high. Pipes and hoses to be used must therefore
be specially made for air conditioning purposes. For this reason the
hoses have an inside lining of butyl rubber and an outside coating
of EDPM rubber. Hose sections exposed to heat are provided with
a special heat insulation.
O-rings are made of a special type of chloroprene rubber (neo-
prene). Before assembly of the air conditioning system these O-
rings must be lubricated with compressor oil / refrigeration oil. The
O-rings must always be replaced when assembling A/C-compo-
nents.
Recommended tightening torques for O-ring sealed fittings
Thread Spanner width Torque

5/8“ 17 or 19 13.6 - 20.3 Nm
3/4“ 32.5 - 39.3 Nm

Thread Spanner width Torque

7/8“ 27 35.3 - 42.0 Nm
1 1/16“ 32 40.7 - 47.5 Nm
M30X2 36 105.0 - 115.0 Nm
M36X2 41 165.0 - 175.0 Nm
Bending radii for air conditioning hoses
Hose type Nominal width Bending radius

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

Air conditioning – Compressor
7.8 Compressor
Structure
Fig. 303: Refrigerant compressor
1 Refrigerant compressor 7 Pressure plate

2 Belt pulley 8 Driver disc
3 Melting fuse 9 Swash disc
4 Refrigerant compressor shaft 10 Piston (7 pieces, uniformly distributed over the entire circumference)
5 Ball bearing 11 Slipper pad
6 Magnetic coil 12 Swash plate chamber
A Suction valve B Pressure valve
Magnetic clutch The belt pulley (2) runs on a bearing on the refrigerant compressor
housing. It is driven by the ribbed V-belt and rotates on the ball
bearing (5) around the magnetic coil (6), which is mounted to the
refrigerant compressor housing. The pressure plate (7) is con-
nected to the shaft of the refrigerant compressor (4) by means of a
splined connection. It consists of 2 rings, which are connected by a
resilient plate.
The magnetic coil (6) is energized to start up the refrigerant com-
pressor (1). The magnetic force pulls the outer ring of the pressure
plate (7) against the belt pulley (2) and holds it in position. This
causes a positive connection between pressure plate (7) and belt
pulley (2).
Once the magnetic coil (6) is de-energized, spring force will return
the outer ring of the pressure plate (7) back to its rest position and
the flow of force is interrupted. This ensures switching off of the
refrigerant compressor in case of a mechanical defect.

Air conditioning – Compressor
Delivery process Once the magnetic coupling of the refrigerant compressor (1) has
caused the frictional connection, the shaft of the refrigerant com-
pressor (4) will drive the swash plate (9) via the driver disc (8). The
revolving slanted swash plate (9) causes a stroke movement of the
7 pistons (10), which are evenly distributed along the circumfer-
ence.
The pistons (10) are thereby actuated by slipper pads (11).
During the suction stroke gaseous refrigerant flows through the
suction valve (A) into the corresponding cylinder. When the stroke
of the piston (10) is reversed, it compresses the gaseous refrig-
erant, until the pressure inside the cylinder becomes so high, that
the pressure valve (B) opens and allows the refrigerant to flow
through the compressor outlet and thus into the refrigerant circuit.
The refrigerant compressor (1) has integrated chambers both on
the suction and on the pressure side, which have the function to
dampen resonances, which are generated by suction and com-
pression.
Displacement control The refrigerant compressor (1) is designed in such a way, that
already has sufficient flow rate to keep up the refrigerant circuit,
even at a slow vehicle speed and low engine speed.
Since the flow rate of the refrigerant compressor (1) rises with
increasing engine and travel speed, the flow rate needs to be
reduced or regulated.
This is to avoid that the refrigerant compressor (1) unnecessarily
uses engine power.
The flow rate is controlled by switching the magnetic coupling on
and off.
Safety contgrol of the refrigerant To prevent the ribbed V-belt jumping off in case of a mechanical
compressor (1) defect of the refrigerant compressor (1), the magnetic coupling will
disengage automatically.
In case of a mechanical defect the refrigerant compressor (1) will
be harder to turn or may even block completely. The heat created
on the friction surface of the V-belt (2) blows a meting fuse (3) in
the magnetic coil (6). This interrupts the power supply to the mag-
netic coil (6) and releases the frictional connection.
Service valves The service valves are installed directly on the compressor. These
are used to e.g. evacuate and fill the system.

Air conditioning – Emptying in case of repair
7.9 Emptying in case of repair

For repair work the air conditioning systems must very often be
emptied of all refrigerant.
Especially with expensive refrigerants and larger amounts of oil it
may be necessary to keep the refrigerant for later use.
For later use these refrigerants must be drawn out with suitable
equipment and intermediately stored in collecting containers.
ENVIRONMENT!
Contaminated refrigerant must be disposed of environ-
mentally
Releasing refrigerant into the atmosphere is prohibited
(see restrictive injunction concerning CFC, day of
enforcement 01. 08. 1991, § 8)
WARNING!
For draining refrigeration systems you should not
simply use any delivery containers, but only appro-
priate pressure bottles, which must be specially
marked and should comply with the pressure gas
directive.
When transferring refrigerant you must make sure that
the bottle does not contain more than the permitted
amount of refrigerant in litres and has sufficient gas
space for expansion (filling factor: 0,7).
In order to reduce the evacuation period in case of short repairs,

you may fill the refrigerant circuit with approx. 0.5 bar nitrogen
when opening. This ensures that nitrogen will flow out of the refrig-
erant circuit while it is open and no air or moisture can enter. How-
ever, the necessity for vacuum generation and a dryer change
remains.

Air conditioning – Drying and evacuation
7.10 Drying and evacuation

Evacuation of air conditioning systems using R-type refrigerants
not only has the purpose of emptying the system of all air before
filling in refrigerant, but also to verify the leak tightness over a
longer lifetime in the achieved vacuum. However, the most impor-
tant factor in this work step is the drying of the system.
Any water residues in the refrigerant circuit will combine with the
refrigerant, which will lead to the previously described consequen-
tial damage.
Vacuum pumps with a capacity of more than 100 l/min and a final
pressure of less than 30 micron, i.e. 0.039 mbar should be used to
evacuate the refrigeration system.
The refrigerant compressor is not suitable for the purpose of evac-
uation, because it is not able to achieve a sufficient final vacuum
and, apart from this, may be mechanically damaged because of a
lack of lubrication when running empty during evacuation.
It is common practice to evacuate the refrigeration system to a final
vacuum of 1 Torr, i.e. 1.33 mbar.An exact time for evacuation and
drying cannot be predicted. It can only be determined by means of
a vacuum meter. However, if there is no vacuum meter at hand it is
generally better to evacuate 1 hour longer than 1 hour too less.
Function drying:
Under normal ambient pressure (1.013 mbar) evaporates absolute
at 100° C. If the pressure is reduced, water will already evaporate,
e.g. under a pressure of 10 mbar, at an ambient temperature of
almost 7°C, but the water will not evaporate all at once. Since it is
very difficult to separate the steam from the vacuum in the system,
the evacuation process is supported by the co-called vacuum
breaking (filling the circuit with dried nitrogen). With vacuum
breaking the filled in dried nitrogen absorbs the moisture in the
refrigerant circuit, which can then be easily discharged together
with the nitrogen.

Air conditioning – Filling instructions
7.11 Filling instructions

Filling of refrigerant into the dried, vented and oil filed machines
takes place under various conditions.
In most large series production facilities highly complicated equip-
ment is available for this purpose, whereas individual machines at
the place of installation must be filled directly from the refrigerant
container.
Liquid refrigerant is only used to pre-fill the pressure side of the
evacuated refrigeration system (protective filling).
After switching the refrigeration system on and watching the
inspection glass, gaseous refrigerant can be filled into the system
while the engine is running, if the refrigerant level is found to be too
low (gas bubbles in the inspection glass).
NOTICE!
Liquid refrigerant in the suction side of the compressor
should generally be avoided during filling and opera-
tion of the refrigeration system, since this could
damage the compressor..
When filling the air conditioning system directly from the refrigerant
bottle care must be taken not to overfill the system. As an addi-
tional control and for statistical purposes, e.g. for refilling, it is
important to write down the weight of the filled in refrigerant.
With correct operation of the air conditioning the refrigerant con-
tainer should be about 1/3 filled with liquid refrigerant, the evapo-
rator should be maximally filled at the calculated evaporation tem-
perature, i.e. the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the pressure gauge.
White frost on the suction line is no measure for

assessing the filling.

Fig. 304
Pos Designation Pos Designation

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


10 Filter drier 22 Refrigerant bottle
11 Collecting container 23 Pressure gauge bar
12 Capacitor

Filling instructions
1 Connect the service adapter with the blue hand wheel in the
suction side.
2 Connect the service adapter with the red hand wheel in the
pressure side (the hand wheels on the service adapters must
be fully backed out - left hand stop)
3 Connect the blue suction hose below the blue hand wheel on
the pressure gauge bar to the blue service adapter.
4 Connect the red pressure hose below the red hand wheel on
the pressure gauge bar to the red service adapter.
5 Connect the yellow hose below the yellow hand wheel on the
manometer bar to the 2-stage vacuum pump.
6 Connect the last hose below the black hand wheel on the
nitrogen bottle via the pressure reducing valve.
7 Check on the pressure gauge bar that all hand wheels are
closed.
8 Turn the hand wheels on both service adapter clockwise. This
opens the valves (right hand stop).
9 Open the valve on the nitrogen bottle (only via pressure
reducer); pressure approx. 20 bar.
10 Open the black and red hand wheels on the pressure gauge
bar and fill nitrogen into the system, until a pressure of approx.
3.5 to 5.0 bar is indicated on the suction side.
11 Then open the blue hand wheel and raise the pressure in the
suction side (max. 10 bar). Check for leaks with a leak detec-
tion fluid or soapsuds.
12 If the system is leak tight, release the nitrogen from the system.
For this purpose disconnect the hose from the nitrogen bottle
and open the red, blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand wheels on the
pressure gauge bar. In case of a leak no or only an insufficient
vacuum will be reached. In this case proceed as described
under point 9-12. Once the leak is sealed continue with point
14.
15 Once a sufficient vacuum is reached, both pressure gauges
show -1, close all hand wheels on the pressure gauge bar.
16 Switch off the vacuum pump, watch the pressure gauges to
see whether the vacuum is maintained.
17 Open the valve on the refrigerant bottle and open the black and
red hand wheels on the pressure gauge bar. Fill refrigerant into
the system, until a pressure equilibrium between suction and
pressure side is reached (reading of pressure gauges).
18 Close the red hand wheel.
19 Perform a leak test with the electronic leak detector.
20 Start the engine and switch on the system.
21 Open the blue hand wheel and continue filling in refrigerant
until the inspection glass is free or air bubbles (in fluid con-
tainer/dryer combinations the white pearl should float in the
upper third of the inspection glass). Then close the refrigerant
bottle.
22 Close the blue hand wheel on the pressure gauge bar.
23 Preparing the test run: -Close windows and doors -Fan on full
speed stage -Mount measuring feelers to air discharge and air
intake.
24 Run the system for approx. 20 minutes with medium engine
speed.

25 The temperature difference between air discharge and air

intake should be (depending on type of air condition) 8-10°C.
Ambient temperature in this case approx. 20 °C. (These data
are only reference values, which may be influenced by possible
insolation)
26 Switch off system and engine and check for leaks again.
27 Turn out (left hand stop) and remove the hand wheels on both
service adapters.
28 Fit all valves with dust caps.
29 Perform a leak test.
30 Mark the system with the corresponding type plates and infor-
mation decals, such as type of oil and refrigerant.

Air conditioning – Steam table for R134a
7.12 Steam table for R134a

Tempera- Pressure Density spec. volume spec. enthalpy Evapora-
ture tion heat
of the of the of the of the of the of the
fluid steam fluid steam fluid steam
t p p' p'' v' v'' h' h'' r
°C bar kg/dm3 kg/dm3 dm3/kg dm3/kg kJ/kg kJ/kg kJ/kg
-60 0.16 1.469 0.92 0.681 1082.6 123.17 359.85 236.68
-55 0.22 1.456 1.24 0.687 803.83 129.49 362.99 233.5
-50 0.29 1.443 1.65 0.693 606.45 135.75 366.14 230.39
-45 0.39 1.429 2.15 0.7 464.29 141.98 369.28 227.3
-40 0.51 1.415 2.78 0.707 360.3 148.21 372.41 224.19
-35 0.66 1.401 3.53 0.714 283.08 154.47 375.52 221.05
-30 0.84 1.387 4.45 0.721 224.97 160.78 378.61 217.84
-25 1.06 1.373 5.53 0.728 180.67 167.14 381.68 214.55
-24 1.11 1.37 5.78 0.73 173.12 168.42 382.29 213.88
-23 1.16 1.367 6.03 0.732 165.95 169.7 382.9 213.2
-22 1.22 1.364 6.28 0.733 159.14 170.98 383.51 212.53
-21 1.27 1.361 6.55 0.735 152.66 172.27 384.12 211.85
-20 1.33 1.358 6.83 0.736 146.5 173.56 384.72 211.16
-19 1.39 1.355 7.11 0.738 140.64 174.86 385.33 210.47
-18 1.45 1.352 7.4 0.74 135.06 176.15 385.93 209.78
-17 1.51 1.349 7.71 0.741 129.75 177.45 386.53 209.08
-16 1.57 1.346 8.02 0.743 124.68 178.75 387.13 208.38
-15 1.64 1.343 8.34 0.745 119.86 180.06 387.73 207.67
-14 1.71 1.34 8.68 0.746 115.26 181.37 388.33 206.96
-13 1.78 1.337 9.02 0.748 110.87 182.68 388.93 206.25
-12 1.85 1.334 9.37 0.75 106.68 183.99 389.52 205.53
-11 1.93 1.331 9.74 0.752 102.68 185.31 390.11 204.8
-10 2.01 1.328 10.12 0.753 98.86 186.63 390.71 204.07
-9 2.09 1.324 10.5 0.755 95.21 187.96 391.3 203.34
-8 2.17 1.321 10.9 0.757 91.73 189.28 391.88 202.6
-7 2.26 1.318 11.31 0.759 88.39 190.61 392.47 201.86
-6 2.34 1.315 11.74 0.76 85.21 191.94 393.06 201.11
-5 2.43 1.312 12.17 0.762 82.16 193.28 393.64 200.36
-4 2.53 1.309 12.62 0.764 79.24 194.62 394.22 199.6


ture tion heat
t p p' p'' v' v'' h' h'' r
-3 2.62 1.305 13.08 0.766 76.44 195.96 394.8 198.84
-2 2.72 1.302 13.56 0.768 73.77 197.3 395.38 198.08
-1 2.82 1.299 14.04 0.77 71.2 198.65 395.96 197.31
0 2.93 1.296 14.55 0.772 68.75 200 396.53 196.53
28 7.27 1.196 35.66 0.836 28.04 238.96 411.71 172.75
29 7.48 1.192 36.73 0.839 27.22 240.4 412.21 171.81
30 7.7 1.189 37.83 0.841 26.44 241.83 412.71 170.87
31 7.93 1.185 38.95 0.844 25.67 243.28 413.2 169.92
32 8.16 1.181 40.1 0.847 24.94 244.72 413.69 168.97
33 8.39 1.177 41.28 0.85 24.22 246.17 414.18 168
34 8.63 1.173 42.49 0.853 23.53 247.63 414.66 167.03
35 8.87 1.169 43.74 0.856 22.86 249.08 415.14 166.05
36 9.12 1.164 45.01 0.859 22.22 250.55 415.61 165.07
37 9.37 1.16 46.31 0.862 21.59 252.01 416.08 164.07
38 9.63 1.156 47.65 0.865 20.99 253.48 416.55 163.07
39 9.9 1.152 49.02 0.868 20.4 254.96 417.01 162.05
40 10.17 1.148 50.43 0.871 19.83 256.44 417.47 161.03
41 10.44 1.143 51.87 0.875 19.28 257.92 417.92 160
42 10.72 1.139 53.35 0.878 18.74 259.41 418.37 158.96
43 11.01 1.135 54.87 0.881 18.23 260.9 418.81 157.9
44 11.3 1.13 56.42 0.885 17.72 262.4 419.24 156.84
45 11.6 1.126 58.02 0.888 17.24 263.91 419.68 155.77
46 11.9 1.121 59.65 0.892 16.76 265.42 420.1 154.68
47 12.21 1.117 61.33 0.895 16.3 266.94 420.52 153.58
48 12.53 1.112 63.06 0.899 15.86 268.46 420.93 152.47
49 12.85 1.108 64.82 0.903 15.43 269.99 421.34 151.35
50 13.18 1.103 66.64 0.907 15.01 271.53 421.74 150.21
51 13.51 1.098 68.5 0.91 14.6 273.07 422.14 149.06
52 13.85 1.094 70.41 0.914 14.2 274.62 422.52 147.9
53 14.2 1.089 72.38 0.919 13.82 276.18 422.9 146.72


ture tion heat
t p p' p'' v' v'' h' h'' r
54 14.55 1.084 74.39 0.923 13.44 277.75 423.28 145.53
55 14.91 1.079 76.47 0.927 13.08 279.32 423.64 144.32
56 15.28 1.074 78.59 0.931 12.72 280.91 424 143.09
57 15.66 1.069 80.78 0.936 12.38 282.5 424.35 141.85
58 16.04 1.064 83.03 0.94 12.04 284.1 424.69 140.58
59 16.42 1.059 85.34 0.945 11.72 285.71 425.02 139.3
60 16.82 1.053 87.72 0.949 11.4 287.34 425.34 138
61 17.22 1.048 90.16 0.954 11.09 288.97 425.65 136.68
62 17.63 1.043 92.68 0.959 10.79 290.61 425.95 135.34
63 18.04 1.037 95.27 0.964 10.5 292.26 426.24 133.97
64 18.47 1.032 97.94 0.969 10.21 293.93 426.51 132.58
65 18.9 1.026 100.69 0.975 9.93 295.61 426.78 131.17
66 19.34 1.02 103.53 0.98 9.66 297.3 427.03 129.74
67 19.78 1.014 106.45 0.986 9.39 299 427.27 128.27
68 20.24 1.009 109.46 0.992 9.14 300.72 427.5 126.78
69 20.7 1.003 112.58 0.997 8.88 302.45 427.71 125.26
70 21.17 0.996 115.79 1.004 8.64 304.19 427.9 123.71
71 21.65 0.99 119.11 1.01 8.4 305.95 428.08 122.13
72 22.14 0.984 122.55 1.016 8.16 307.73 428.25 120.52
73 22.63 0.977 126.11 1.023 7.93 309.52 428.39 118.87
74 23.13 0.971 129.79 1.03 7.7 311.33 428.51 117.19
75 23.65 0.964 133.6 1.037 7.48 313.15 428.62 115.46
76 24.17 0.957 137.56 1.045 7.27 315 428.7 113.7
77 24.7 0.95 141.67 1.052 7.06 316.86 428.76 111.9
78 25.23 0.943 145.95 1.06 6.85 318.74 428.79 110.05
79 25.78 0.936 150.4 1.069 6.65 320.64 428.8 108.15
80 26.34 0.928 155.03 1.078 6.45 322.57 428.77 106.21
81 26.9 0.92 159.87 1.087 6.26 324.51 428.72 104.21
82 27.48 0.912 164.92 1.096 6.06 326.48 428.63 102.15
83 28.06 0.904 170.22 1.106 5.87 328.47 428.5 100.04


ture tion heat
t p p' p'' v' v'' h' h'' r
84 28.66 0.895 175.77 1.117 5.69 330.48 428.34 97.86
85 29.26 0.887 181.6 1.128 5.51 332.52 428.12 95.61
86 29.88 0.878 187.75 1.14 5.33 334.58 427.86 93.29
87 30.51 0.868 194.25 1.152 5.15 336.67 427.55 90.88
88 31.14 0.858 201.14 1.165 4.97 338.78 427.17 88.39
89 31.79 0.848 208.48 1.179 4.8 340.92 426.72 85.8
90 32.45 0.837 216.31 1.195 4.62 343.09 426.2 83.1
91 33.12 0.826 224.73 1.211 4.45 345.29 425.58 80.29
92 33.8 0.813 233.84 1.229 4.28 347.53 424.86 77.33
93 34.49 0.801 243.77 1.249 4.1 349.79 424 74.21
94 35.19 0.787 254.71 1.271 3.93 352.08 422.99 70.91
95 35.91 0.771 266.92 1.296 3.75 354.41 421.78 67.37
96 36.64 0.755 280.84 1.325 3.56 356.77 420.3 63.53
97 37.39 0.736 297.17 1.359 3.37 359.17 418.44 59.27
98 38.14 0.714 317.43 1.4 3.15 361.6 415.97 54.37
99 38.92 0.687 346.24 1.455 2.89 364.07 412.16 48.09
100 39.71 0.65 636.32 1.537 1.57 366.58 375.04 8.46
101.06 40.56 0.515 515.3 1.941 1.94 390.05 390.05 0

Air conditioning – Inspection and maintenance work

7.13.1 Checking the compressor oil level / refrigeration oil level
NOTICE!
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only compressor oil / refrig-
eration oil PAG SP-20 (H14-003-404).
1. Run the compressor for 10 minutes at engine idle speed.

2. remove the refrigerant from the air conditioning system.
3. Turn the compressor, as shown in Ä Fig. 305, if necessary
remove V-belt and hoses.
4. Remove the oil plug (the oil level must reach the bottom edge
of the bore, top up or drain off oil if necessary).
5. Turn the oil plug back in (tightening torque 15 to 25 Nm).
6. Refill the air conditioning system.
Fig. 305
7.13.2 Servicing the air conditioning system

7.13.2.1 Cleaning the condenser
n Protective gloves
n Safety goggles
WARNING!
Heat will cause extreme overpressure, which could cause damage

or explosion of the system.
NOTICE!
Electric components can be damaged by water
entering into the system!
– Protect electrical equipment such as generator,
regulator and starter against the direct water jet.


The air conditioning condenser is located in front of the

radiator.
3.
CAUTION!
Danger of eye injuries caused by particles
flying around!
– Wear your personal protective equipment
(safety gloves, protective working clothes,
goggles).
Clean the condenser fins with compressed air or cold water.
Fig. 306
7.13.2.2 Air conditioning function test

2. Switch the fan to the highest stage.
3. Choose the lowest cabin temperature.
4. Switch the air conditioning on.
5. Direct the air flow into the cabin and check, that the flowing
out air is considerably cooler.
ð If the outflowing air is considerably cooler, the air condi-
tioning system is in good working order.
Fig. 307
a Adjust the air distribution
b Regulate the cabin temperature
c Air conditioning on/off
d Fan on/off
7.13.2.3 Checking the condition of the drier/collector unit
Have the drier/collector unit replaced by our customer

service once every year before the operating season.

1. Check the drier/collector unit for mechanical damage or rust.

2. In case of mechanical damage or rust have the drier/collector
unit immediately replaced by our customer service.
4. Switch the air conditioning on.
Fig. 308
5. Check the moisture indication pearl inside the inspection

glass of the drier/collector unit.
orange The degree of moisture in the drying

agent is correct
colourless Moisture level of drying agent too
high
6. If the moisture level of the drying agent is too high, have the
drier/collector unit replaced by our customer service.
Fig. 309
7. Check the white floating ball inside the inspection glass of the
drier/collector unit.
Ball floats right on top The refrigerant level is cor-

rect
Ball floats at bottom The refrigerant level is not
correct
8. If the refrigerant level is too low, have the air conditioning

system inspected by our customer service.
Fig. 310

7.13.3 Cleaning the circulation air filter for the heating

2. Loosen the locks and disassemble the covering.
3. Remove the filter.
4. Clean the filter, replace if necessary.
5. Insert the filter and reassemble the covering.
Fig. 311
7.13.4 Changing the fresh air filter in the cabin

3. Pull the fastening pins out of the left cover and take off the
cover.
Fig. 312
4. Loosen the fastening screw.

5. Remove also the cover from the right hand side and loosen
the fastening screw.
Fig. 313

6. Tilt the console towards the front screen and hold it.
Fig. 314

8. Insert the new filter and fold the console down again.
9. Tighten the left and right fastening screws and reassemble
the covers.
Fig. 315
7.13.5 Replacing the air conditioning compressor V-belts

years.

n Protective gloves
3. Loosen the screws (2, 3, 4) on the air conditioning com-
pressor.
4. Relieve the V-belt with the tensioning screw (1) and take it
off.
5. Install the new V-belt for the air conditioning compressor.
6. Turn the tensioning screw (1) to tighten the V-belt to the
specified value.
7. Tighten screws (2, 3, 4) again.
Fig. 316


Oscillating articulated joint
8 Oscillating articulated joint

Oscillating articulated joint – Overview
8.1 Overview
Fig. 317
1 Oscillating articulated joint
2 Bearing cover
3 Housing
4 Cover
5 Carrier
6 Console

Oscillating articulated joint – Dismantling the oscillating articulated joint
8.2 Dismantling the oscillating articulated joint

1. Unscrew screw (1) and screws (2).
Fig. 318
2. Force the bearing cover (1) off using the thread (2).
3. Disassemble the opposite bearing cover in the same way.
Fig. 319
4. Remove the console (1).
Fig. 320
5. Unscrew screws (1).
Fig. 321

Oscillating articulated joint – Dismantling the oscillating articulated joint
6. Remove the housing (1).
Fig. 322
7. Take off the carrier (1).
Fig. 323

Oscillating articulated joint – Assembly of oscillating articulated joint
8.3 Assembly of oscillating articulated joint

1. Lay the cover (3) on a level base.
2. Apply anti-friction paint to the mating faces of cover and
rocker bearings (2).
3. Knock the rocker bearing into the bore hole.
4. Install the seal ring (1).
Fig. 324
5. Apply anti-friction paint to the mating faces of rocker bearings

(1) and carrier (2).
6. Assemble the rocker bearings.
Fig. 325
7. Place the carrier (1) in mounting position on the cover (2).
Fig. 326

Fig. 327

10. Stand the housing (6) on a level base.

11. Insert shims (5) into the bearing bore as per spare parts cata-
logue.
12. Insert the backing disc (4) into the bearing bore.
13. Insert the Belleville springs (3) into the bearing bore. Ensure
correct alignment!
(2) and housing.
Fig. 328 16. Install the seal ring (1).
17. Position the housing (1) above the carrier (2).
18. Check whether the Belleville sprigs are correctly positioned.
If necessary, reposition the Belleville springs.
19. Lower the housing.
20. Bolt housing and cover together.
Fig. 329

Fig. 330

Fig. 331


(2) and bearing cover (3).
Fig. 332
28. Stand the bearing cover (1) on a level base.

29. Insert shims (2) into the bearing bore as per spare parts cata-
logue.
30. Insert the backing disc (3) into the bearing bore.
31. Insert the Belleville springs (4) into the bearing bore. Ensure
correct alignment!
(5) and bearing housing.
Fig. 333
35. Put the console (1) into place and align it to the carrier (2).
Fig. 334
36. Apply anti-friction paint to the mating faces of console (1) and
bearing cover (3).
37. Turn the guide pins (2) into the threaded bores.
38. Align and assemble the bearing cover.
39. Fasten the bearing cover.
40. Remove the guide pins.
41. Tighten the fastening screws on the bearing cover.
42. Repeat this procedure with two further bearing covers on the
opposite side.
Fig. 335

43. Assemble screws (2).
Fig. 336

Drum
9 Drum

Drum – Assembly of padfoot shell
9.1 Assembly of padfoot shell
Fig. 337
The third of the circumference shells are placed on the smooth
drum and bolted together.
It is recommended to change the drive wheels from

diamond tread to tractor tread.
Fig. 338

Drum – Assembly of padfoot shell
Assembly aid
For assembling the padfoot segments fasten these on
the drum shell with screw clamps.
Tightening torque MA = 578 NM

After a test drive of about 2 minutes with vibration and
after 60 minutes work check the tightening torque.

Drum – Repair overview for drum
9.2 Repair overview for drum
Fig. 339
1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel gear
5 Travel motor
6 Drum shell
7 Rubber buffer
9 Travel bearings

Fig. 340: Repair overview for drum

NOTICE!
Ensure strict cleanliness!
– Thoroughly clean work place and components.
NOTICE!
Notes on repair
– 1
Install the O-ring with some grease.
– 2
Fitting and contact surface of the connection must
be absolutely dry and free of grease, oil, paint and
conserving agent.
– 3
Grease radial seals + running surface on shaft
before assembling.
– 4
Install the dowel pins with the grooves offset by
180° to each other, but in line with the axis of the
shaft.
– 5
The thread must be free of grease, oil, paint and
conserving agents.
– 6
Wet the elastomer part + bore in flanged hub with
spirit (no oil) to ease assembly of the mechanical
seal.
– Clean the sliding surfaces on the seal and
apply a thin film of oil.
– During assembly fill the cavity up to 1/3 with
grease.
– 7
Fill the bearing completely with grease.
– Bearing space to 1/3 filled with grease.
– 8
Ventilation bore in cover pointing down.
– 9
Check the end float of the shaft: Nominal value
0.6 to 1.8 mm.

Drum – Dismantling the drum
9.3 Dismantling the drum

Removing the travel motor
DANGER!
Danger to life caused by suspended loads!
– Do not step or stand under suspended loads.
WARNING!
Danger of crushing caused by heavy components!
– Be extremely cautious when working in the danger
zone
gloves, protective clothing).
1. Attach the lifting tackle to travel drive (3).

2. Unscrew all nuts (1) from the rubber buffers.
3. Take drive disc (2) with travel drive off the rubber buffers and
lay it down.
Fig. 341
4. Unscrew fastening screws (3) and take off gearbox bracket

(4).
5. Unscrew fastening screws (1) and take off drive disc (2).
Fig. 342
Removing the exciter unit (travel

motor side)
DANGER!

WARNING!
zone
1. Unscrew both socket head cap screws from the flange.
Fig. 343
2. Mount bracket (1) for the lifting device to the flange.

3.
NOTICE!
The four short fastening screws (drawn with thin
lines) must remain installed.
Unscrew screws (2) from the flange.
Fig. 344
4. Slide the lifting device over the bracket.

5. Force the exciter unit off with two forcing screws.
Fig. 345

6. Pull the exciter unit out of the drum .

7. Take the coupling element off the coupling half.
Fig. 346
Disassembling the exciter unit

(travel motor side)
1. Unscrew fastening screws (1) for the fan.
2. Loosen the clamping screw (2).
3. Pull the coupling hub off the shaft.
Fig. 347
4. Unscrew all other fastening screws (1) from the flange.

5. Press the flange off the flanged housing with forcing screws
(2).
Fig. 348
6. Lift the flange off the flanged housing.

7. Take the O-ring out of the groove in the flanged housing.
Fig. 349

8. Unclip the circlip from the groove in the flange.
Fig. 350
9. Press the cylinder roller bearing with forcing screws out of

the flange.
Fig. 351
10. Lift the exciter unit out of the flanged housing.
Fig. 352
11. Knock the radial seal out of the flanged housing.
Fig. 353

12. Unclip the circlip from the groove in the flanged housing.
Fig. 354
the flanged housing.
Fig. 355
14. Extract inner ring (1) for the radial seal and inner bearing
races (2).
Fig. 356
15.
If the rings are very tight, heat them up with a
torch.
WARNING!
Danger of burning!
Wear safety gloves.
Fig. 357 Unclip the circlip from the basic weight.

16. To change shaft (1) knock out dowel pins (2 and 3) and press
the shaft out of the basic weight.
Fig. 358

Removing the exciter unit (vibra-

tion motor side)
DANGER!
WARNING!
zone
1.
Perform work steps Ä Fig. 359 or Ä Fig. 360
on both sides of the side plate.
– BW 213
4 rectangular rubber buffers
– BW 216
– BW 219
– BW 226
Fig. 359: The picture shows BW 213 8 rectangular rubber buffers
2. Take up spacer block with rectangular rubber buffers

Ä Fig. 359 or Ä Fig. 360 with lifting gear and unscrew fas-
tening screws (1).
3. Take rectangular rubber buffer (2) with spacer block (3) off
the side plate.
Fig. 360: The picture shows BW 216

4. Unscrew fastening screws (1).

5. Force cover (2) together with the attached vibration motor off
the side plate (4) with forcing screws (3).
Fig. 361
6. To change the vibration motor loosen clamping screw (1) and

pull off coupling half (2).
Fig. 362

8. Take the vibration motor off the cover.
Fig. 363

9. Take off coupling element (1).
Fig. 364
10. Fasten the lifting device.
NOTICE!
The four short fastening screws (2) must remain
screwed in (the two others are not visible).
Fig. 365
12. Press the exciter unit out of the drum with forcing screws.
The second forcing screw is covered by the side

plate.
Fig. 366

13. Pull the exciter unit out of the drum .
Fig. 367
Removing, dismantling the side

plate DANGER!
WARNING!
zone
1. Take off V-ring (1).
Fig. 368
2. Unscrew fastening screws (2) and remove clamping ring (1).
Fig. 369

3. Attach the disassembly device to the side plate and force off
the side plate.
Fig. 370
4. Lift the side plate off the flanged hub.
Fig. 371
5. Knock the self-aligning roller bearing out of the side plate and
take out the spacer ring.
Fig. 372

6. Unclip the circlip from the side plate and knock out the
grooved ball bearing (1).
Fig. 373
7. Take the mechanical seal off the flanged hub.
Fig. 374
Dismantling the exciter unit (vibra-

tion motor side) WARNING!
zone
1. Unscrew the fastening from the coupling hub.

2. Pull the coupling hub off the shaft with a puller.
Fig. 375

3. Loosen the clamping screw (1).

4. Pull coupling hub (2) off the shaft.
Fig. 376
5. Unscrew all other fastening screws (1) and press the flanged
hub off the flanged housing with forcing screws (2).
6. Take off the flanged hub.
7. Take the O-ring out of the groove in the flanged housing.
Fig. 377
8. Unclip the circlip from the groove in the flanged hub.
Fig. 378
9. Knock the cylinder roller bearing out of the flanged hub.
Fig. 379

10. Lift the exciter unit out of the flanged housing.
Fig. 380
11. Knock the radial seal out of the flanged housing.
Fig. 381
12. Unclip the circlip from the groove in the flanged housing.
Fig. 382
Fig. 383

14. Extract inner rings (1) for the radial seals and inner bearing
races (2) from the shafts.
Fig. 384
15.
If the rings are very tight, heat them up with a
torch.
WARNING!
Danger of burning!
Wear protective gloves.
Fig. 385 Unclip the circlip from the basic weight and remove the
cover.
The shafts cannot be pressed out. If damaged

they must be replaced with basic weight and
cover.
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).

Drum – Dismantling and assembling the change-over weight
9.4 Dismantling and assembling the change-over weight

Dismantling the change-over
weight ENVIRONMENT!
Environmental damage!
Catch running out oil and dispose of environmentally.
1. Unscrew all screws.
Fig. 386
2. Force the cover off the basic weight with forcing screws.
Fig. 387
3. Take the change-over weight out of the basic weight.
Fig. 388

4. Pull O-rings (1 and 2) out of the grooves.
Fig. 389
Assembling the change-over

weights NOTICE!
Ensure strict cleanliness.
1. Install new O-rings (1 and 2) with grease.
Fig. 390
2. Insert the change-over weight into the basic weight.
Fig. 391

3. Fill silicon oil 47 V 1000 cst up to the upper edge of the

change-over weight (approx. 2.3 litres) into the basic weight.
Fig. 392
4. Attach the cover, so that the raised areas are in line.

5. Turn in screws with screw retention agent (e.g. Loctite blue
243) and tighten with 120 Nm.
6. Check the end float of the shaft.
ð
There must be play.
Fig. 393

Drum – Assembling the drum
9.5 Assembling the drum

Assembling the exciter unit (vibra-
tion motor side)
WARNING!
zone
WARNING!
Wear your personal protective outfit (protective gloves,
protective clothing).
WARNING!
Danger of body parts freezing due to liquid
nitrogen!
Wear your personal protective outfit (face protection,
protective gloves, protective clothing).
Avoid skin contact.
WARNING!
Danger of body parts freezing on cold surfaces!
NOTICE!
1. Close the bore in the shaft with a screw.

2. Cool the shaft down in liquid nitrogen.
3. Unscrew the screw from the shaft.
4. Slide the cooled down shaft with the bores aligned into the
basic weight until it bottoms.
Fig. 394

5.
NOTICE!
Assemble the dowel pins with the grooves offset
by 180° to each other, but in line with the axis of
the shaft.
Secure shaft (1) with dowel pins (2 and 3).
Fig. 395

cover until it bottoms.
Fig. 396
10.
NOTICE!
the shaft.
Fig. 397
11. Insert the fitting key into the key way in the respective shaft.
Fig. 398

12. Insert the circlip into the groove in the basic weight and on
the cover.
Fig. 399
13. Heat the inner bearing race up to approx. 100° C and press it
onto the basic weight against the shoulder with the larger
outer diameter forward.
Fig. 400
14. Heat the inner ring up to approx. 50° C and slide it onto the
short shaft against the shoulder with the wider chamfer facing
towards the outside.
Fig. 401
onto the cover against the shoulder with the larger outer
diameter forward.
Fig. 402

longer shaft against the shoulder with the wider chamfer
facing towards the outside.
Fig. 403
17. Press cylinder roller bearing (1) with pressing plate (2) into
the flanged housing until it bottoms.
Fig. 404
18. Insert the circlip into the groove in the flanged housing.
Fig. 405
19. Fit the new radial seal with some grease into the groove in
20. Fill approx. 1.2 l of oil SAE 15W-40 into the flanged housing.
Fig. 406

21. Insert the exciter unit with the longer shaft forward into the
flanged housing.
Fig. 407
the flanged hub until it bottoms.
Fig. 408
23. Insert the circlip into the groove in the flanged hub.
Fig. 409
24.
NOTICE!
Fitting and contact surfaces must be absolutely
dry and free of grease, paint and conserving
agents.
Attach the flanged hub to the flanged housing.

25. Unscrew eye bolts (1) and replace them with short screws.
26. Turn short screws (2) into the tapped bores in the flanged
housing (four screws) and tighten them.
Fig. 410

27. Apply some grease to the sealing lip of radial seal (1).
28. Insert the radial seal into the flanged hub with the sealing lip
facing down and press it down against the stop with pressing
bushing (2).
Fig. 411
29. Heat the coupling hub up to approx. 80 °C and slide it onto

the shaft against the stop.
Fig. 412
31. Slide the radial seal with the sealing lip forward over the shaft
and drive it completely into the flanged housing, using a suit-
able tube (2).
Fig. 413
32. Cover the thread of screw (1) with a screw retention agent
(Loctite CVX strong, blue, 582).
33. Slide on the new U-seal ring (2), turn in and tighten the
screws.
Fig. 414

34. Heat coupling hub (1) with marking letter “L“ up to approx.
80° C and slide it over the shaft against the shoulder.
35. Turn in and tighten clamping screw (2).
Fig. 415
Assembling and installing the side

plate WARNING!
zone
1. Fill grooved ball bearing (1) on both sides with grease.

2. Press the grooved ball bearing completely in using pressing
plate (2).
Fig. 416
3. Insert the circlip into the groove in the side plate.
Fig. 417

4. Apply a thick coat of grease to the spacer ring on both sides

and insert it into the side plate.
Fig. 418
5. Fill the self-aligning roller bearing (1) with grease.

6. Press the self-aligning roller bearing completely in using
pressing plate (2).
Fig. 419
7. Clean the sliding surfaces of the mechanical seal and cover

them with oil.
8. Insert the loop-ring into the mechanical seal.
Fig. 420
9.
Wet the elastomer part + bore with spirit (no oil)
to make the assembly easier.
Lay one half of the mechanical seal on the flanged hub with
the sliding surface pointing up.
Fig. 421

10. Lay the second half of the mechanical seal down with the
sliding face pointing down.
11. Fill the cavity of the mechanical seal up to 1/3 with grease.
Fig. 422
12. Bolt the threaded section of the assembly device to the

flanged hub.
Fig. 423
13. Lay the side plate on the flanged hub.
Fig. 424
14. Attach bushing (2) of the assembly device and turn on nut
(1).
Fig. 425

15.
NOTICE!
During assembly make sure that the mechanical
seal slides correctly into the side plate and the
loop rings are not damaged .
Pull the side plate with the assembly device onto the flanged
hub.
16. Remove the assembly device.
Fig. 426
17.
Tighten the fastening screws cross-wise.
Assemble the clamping ring (1) with screws and washers (2).
Fig. 427

Assembling the exciter unit (travel

motor side)
WARNING!
zone
WARNING!
WARNING!
Danger of body parts freezing due to liquid
nitrogen!
Wear your personal protective outfit (face protection,
protective gloves, protective clothing).
Avoid skin contact.
WARNING!
Danger of body parts freezing on cold surfaces!
NOTICE!

basic weight until it bottoms.
Fig. 428

5.
NOTICE!
the shaft.
Fig. 429
6. Insert the circlip into the groove in the basic weight and on
the cover.
Fig. 430

onto the basic weight against the shoulder with the larger
outer diameter forward.
Fig. 431
shaft against the shoulder with the wider chamfer facing
towards the outside.
Fig. 432


onto the cover against the shoulder with the larger outer
diameter forward.
Fig. 433
the flanged housing until it bottoms.
Fig. 434
11. Insert the circlip into the groove in the flanged housing.
Fig. 435
12. Fit the new radial seal with some grease into the groove in
13. Fill approx. 1.2 l of oil SAE-15W/40 into the flanged housing.
Fig. 436

14. Insert the exciter unit into the flanged housing.
Fig. 437
the flange until it bottoms.
Fig. 438
16. Insert the circlip into the groove in the flange.
Fig. 439
17.
NOTICE!
Fitting and contact surfaces must be absolutely
dry and free of grease, paint and conserving
agents.
Lift the flange onto the flanged housing and align it to the
bores.
Fig. 440

18. Turn the screws into the tapped bores of the flanged housing
and tighten them.
Fig. 441
20. Slide the radial seal with the sealing lip forward over the shaft
and drive it completely into the flanged housing, using a suit-
able tube (2).
Fig. 442
21. Cover the thread of screw (1) with a screw retention agent
(e.g. Loctite CVX strong, blue, 582).
22. Slide on the new U-seal ring (2), turn in and tighten the
screws.
Fig. 443
23. Insert the fitting key into the key way of the shaft.
Fig. 444

24. Slide the fan with assembly disc over the shaft.
25. Heat coupling hub (1) with marking letter “R“ up t approx. 80°
C and slide it over the shaft against the shoulder.
26. Turn in and tighten clamping screw (2).
27. Install the fan to the coupling hub.
Fig. 445
Installing the exciter unit (travel

motor side) DANGER!
WARNING!
zone
NOTICE!
Fitting and contact surfaces of the connection between
exciter unit and drum must be absolutely dry and free
of grease, oil, paint and conserving agent.
1. Check coupling elements , replace if necessary.

2. Insert the coupling element into the coupling hub.
Fig. 446

3. Fasten the lifting device to the exciter unit.

4. Insert the vibrator unit into the drum.
Fig. 447
5.
Insert the exciter unit so that oil filler plug 1 is in
line with bore (2) in the drum.
Fig. 448
6.
NOTICE!
The thread must be free of oil, grease and con-
serving agents.
Turn in and tighten screws (2).

7. Remove bracket (1) for the lifting device.
Fig. 449
8. Cover the thread of screws with a screw retention agent (e.g.

Loctite green 270).
9. Slide on the new U-seal ring, turn in and tighten the screws.
Fig. 450

Installing the travel motor

DANGER!
WARNING!
zone
1. Assemble drive disc (2) and gearbox bracket (4) with screws
(3).
Fig. 451
2. Attach drive disc (2) with assembled travel drive (3) to the
rubber buffers. Turn on and tighten the nuts (1).
Fig. 452

Installing the exciter unit (vibration

motor side) DANGER!
WARNING!
zone
NOTICE!
Fitting and contact surfaces of the connection between
exciter unit and drum must be absolutely dry and free
of grease, oil, paint and conserving agent.
1. Fasten the lifting gear to the exciter unit and insert it into the
drum.
Fig. 453
2.
NOTICE!
Ensure correct engagement of coupling and
alignment of shaft .
If the shafts are not correctly in line determine
the cause, if necessary measure the drum.
Fig. 454

3.
NOTICE!
The thread must be free of oil, grease and con-
serving agents.
Turn in and tighten screws (1).

4. Remove the lifting gear.
5. Fit cover (2) to the drum.
Fig. 455
6. Check the end float of the exciter shafts.

ð
Nominal value: 0.6...1.8 mm
Fig. 456
7. Attach disc (1), turn in and tighten the fastening screw (2).
8. Fill the self-aligning roller bearing with grease.
Fig. 457

9.
Check coupling element (1), replace if neces-
sary.
Insert the coupling element into the coupling hub.

10. Assemble V-ring (2).
Fig. 458
11. Install a new O-ring (1) and apply a thin coat of oil.
Fig. 459: Vibration motor
12.
Ventilation bore (3) in cover pointing down.
Mount vibration motor (1) to cover (2).

13. Turn in fastening screws with ball disc and ball socket and
tighten.
Fig. 460

14. Slide on coupling half (2) and secure with clamping screw
(1).
Fig. 461
15. Install a new O-ring (1) and apply a thin coat of oil.
Fig. 462
16. Attach cover (2) with the assembled vibration motor,

assemble screws (1) with washers and tighten.
Fig. 463

17.
Perform work steps Ä Fig. 464 or Ä Fig. 465
on both sides of the side plate.
– BW 213
– BW 216
– BW 219
– BW 226
Fig. 464: The picture shows BW 213 8 rectangular rubber buffers
18. Take rectangular rubber buffers (2) with attached spacer

block (3) with lifting gear mount to the side plate with screws
and washers (1).
Fig. 465: The picture shows BW 216

Drum – Changing the rubber buffers, adjusting the pretension
9.6 Changing the rubber buffers, adjusting the pretension
BW 211/212/213/214 = 4 rectangular rubber buffers

BW 216 = 6 rectangular rubber buffers
BW 219/226 = 8 rectangular rubber buffers
Fig. 466: BW 211/212/213/214 D/PD

1 Weld-on nuts
Fig. 467: BW 211/212 DH/PDH

1 Weld-on nuts

Fig. 468: BW 213 DH/PDH

1 Weld-on nuts
Fig. 469: BW 216 D/PD, BW216/219/226 DH/PDH

1 Weld-on nuts

Relieve the rubber buffers

1. Lift the front frame up by both sides, until rubber buffers and
rectangular buffers are relieved of any load.
2. Loosen all fastening screws.
Fig. 470
3. Turn the screws into the weld-on nuts.
Fig. 471: Picture shows BW216
4. Remove the compensation shims.
Fig. 472
5. Unscrew the screws from the welded nuts.

6.
NOTICE!
Check the rectangular rubber buffers, replace
if necessary
Observe the assembly direction, arrow up.
Fig. 474
Changing the rubber buffers

1. Unscrew nut (1) and remove the washer.
2. Unscrew screws (2).
3. Take off rubber buffer (3).
4. Attach the new rubber buffer to the drive disc and align the
bores to the tapped bores in the drum.
5. Turn in and tighten the fastening screws.
6. Install the washer, turn on and tighten the nut.
Fig. 475
Adjusting the pre-load

1. Measure distance “X” between spacer block and side plate.
2. Calculate the thickness of the compensation plates.
ð Nominal value: Distance "X" + 2 mm
3. Turn in screws into each welded nut and provide sufficient

space to insert the compensation shims.

4. Install the compensation shims.
Fig. 478
5. Unscrew the screws from the welded nuts.
6. Tighten the fastening screws.

7. Lower the front frame again.
Fig. 480

Drum – Inspection and maintenance work

9.7.1 Retightening the padfoot shell
After the installation of the padfoot shell, all fastening screws must
be retightened.
1. Run an approx. two minute test drive with vibration.
3. Retighten all fastening screws.
4. After approx. 60 minutes work retighten all fastening screws
again.
Fig. 481
9.7.2 Adjust the scrapers

1. Check adjustment and condition of front and rear scrapers, if
necessary adjust or replace the scraper rubber.
2. In order to adjust the scrapers, slacken the fastening screws
(1) in the slots and push the scraper towards the drum to
contact.
3. Fasten the fastening screws again.
Fig. 482
1. Check adjustment and condition of scrapers, adjust or

replace the teeth if necessary.
2. To adjust the scrapers slacken the clamping screws and
push the scrapers towards the drum, leaving a gap of about
25 mm.
3. Retighten the clamping screws.
Fig. 483

9.7.3 Checking the oil level in the exciter housing
NOTICE!
– Use only gear oil of the permitted specification
Ä Chapter 1.4.6 ‘Gear oil SAE 75W-90’
on page 51.

n Protective gloves
1. Before checking the oil level, run the machine warm with
vibration for about 1/2 hour.
2. Move the drum, until the oil level inspection plug is in bottom
position.
4. Clean the area around the level inspection plug and unscrew
the plug.
ð The oil level must reach the bottom edge of the level
bore.
Fig. 484
5. Clean the area around the filler plug and unscrew the filler
plug.
6. Fill in oil through the filler bore, until it starts to run out
through the level inspection bore.
8. Retighten the filler and level inspection plugs.

9. Repeat this inspection on the other side.
10. If a loss of oil is found, perform trouble shooting, repair the
drum if necessary.
Fig. 485
9.7.4 Change the oil in the exciter housing
NOTICE!
– Drain gear oil only at operating temperature.
on page 51.


year.

n Protective gloves
1. Before changing the oil level run the machine warm for about
1/2 hour.
2. Move the drum, until the drain plug is in bottom position.
4. Clean the area around the drain plug and unscrew the plug.
5. Drain off and catch old oil.
Fig. 486
7. Clean the area around the oil level inspection plug.

8. Unscrew the oil level inspection plug.
Fig. 487
9. Unscrew the oil filler plug and fill in new oil through the oil
filler bore, until oil starts to drip out through the inspection
bore.
10. Retighten the filler and level inspection plugs.
11. Change the oil on both sides.
Fig. 488

9.7.5 Checking the oil level in the drum drive reduction gear
NOTICE!
on page 51.

n Protective gloves
1. There are 3 inspection plugs arranged around the circumfer-
ence of the reduction gear, always offset to each other by
90°.
Move the machine until one level inspection plug is in hori-
zontal position and one inspection plug points vertically up.
3. Clean the area around the horizontal level inspection plug
and unscrew the plug.
Fig. 489 bore.
4. If necessary clean the area around the upper level inspection
plug and unscrew the plug.
5. Fill in oil through the opening of the upper level inspection
plug, until it starts to run out through the horizontal inspection
plug.
6. Retighten both inspection plugs again.
9.7.6 Change the oil in the drum drive reduction gear
NOTICE!
on page 51.

year.


n Protective gloves
1. There are 3 inspection plugs arranged around the circumfer-
ence of the reduction gear, always offset to each other by
90°.
Move the machine so that one inspection plug is in horizontal
position and the two other plugs are facing vertically upwards
and vertically downwards.
3. Clean the area around the level inspection plugs and
unscrew all plugs.
Fig. 490 4. Drain and catch all oil.
5. Turn the bottom level inspection plug tightly back in.
6. Fill in oil through the opening of the upper level inspection
plug, until it starts to run out through the horizontal inspection
plug.
7. Retighten both inspection plugs again.


Drive axle
10 Drive axle

Drive axle – Checking the oil level in the drive axle
10.1 Checking the oil level in the drive axle
NOTICE!
on page 51.

n Protective gloves
2. Clean the area around the level inspection plug (1) and
unscrew the plug.
bore.
A second inspection plug is located on the

left front side of the drive axle.
3. If necessary clean the area around the filler plug (2) and
unscrew the filler plug.
Fig. 491
5. After filling in oil wait until the oil has evenly distributed inside
the axle.
6. Retighten level inspection and filler plugs.

Drive axle – Change the oil in the drive axle
10.2 Change the oil in the drive axle
NOTICE!
on page 51.

year.

n Protective gloves
3. Drain and catch all oil.
Fig. 492
unscrew the plug.
A second inspection plug is located on the left

front side of the drive axle.
6. Clean the area around the filler plug (2) and unscrew the filler
plug.
Fig. 493
the axle, if necessary fill in some more oil.

Drive axle – Change the oil in the drive axle
10.3 Change the oil in the drive axle
NOTICE!
on page 51.

year.

n Protective gloves
Fig. 494
unscrew the plug.
A second inspection plug is located on the left

front side of the drive axle.
6. Clean the area around the filler plug (2) and unscrew the filler
plug.
Fig. 495
the axle, if necessary fill in some more oil.

Drive axle – Checking the oil level in the drive axle reduction gear
10.4 Checking the oil level in the drive axle reduction gear
NOTICE!
on page 51.

n Protective gloves
the plug.
3. The oil level must reach the bottom edge of the bore, top up
oil if necessary.
4. Turn the level inspection plug tightly back in.
Fig. 496

Drive axle – Change the oil in the drum drive reduction gear
10.5 Change the oil in the drum drive reduction gear
NOTICE!
on page 51.

year.

n Protective gloves
2. Clean the area around drain plug and level inspection plug
and unscrew the plugs.
Fig. 497
the plug.
6. Fill in oil through the inspection bore, until it starts to run out
Fig. 498

Drive axle – Checking the oil level in the wheel hubs
10.6 Checking the oil level in the wheel hubs
NOTICE!
on page 51.

n Protective gloves
1. Move the machine until the oil level inspection plug is in hori-
zontal position.
the plug.
4. The oil level must reach the bottom edge of the bore, top up
oil if necessary.
Fig. 499 6. Change the oil in both wheel hubs.

Drive axle – Changing the oil in the wheel hubs
10.7 Changing the oil in the wheel hubs
NOTICE!
on page 51.

year.

n Protective gloves
1. Move the drum, until the oil level inspection plug is in bottom
position.
the plug.
Fig. 500
5. Move the drive wheel, until the oil level inspection plug is in
horizontal position.
6. Fill in oil through the inspection bore, until it starts to run out
8. Change the oil in both wheel hubs.
Fig. 501

Drive axle – Checking the tire pressure
10.8 Checking the tire pressure
WARNING!
Danger of being injured by bursting tires!
– Wear your personal protective outfit (safety shoes,
gloves, goggles, hard hat).
– When checking the tire pressure stand in the
extension of the tyre tread.
– Use an air hose with a length of min. 6 meters.
– Never exceed the permitted air pressure.
The tire pressure can be adapted to the operating con-

ditions within the specified limits.
A reduced tire pressure improves the traction espe-
cially on sandy soils.
Higher tires pressures improve the driving stability of
the machine.
The total height of the machine can also be influenced
by changing the tire pressure.
Protective equipment: n Safety shoes

n Protective gloves
n Safety goggles
n Hard hat
1. Move the machine until the tire inflation valve (1) is in top
position.
3. Unscrew the valve caps and check the front and rear tire
pressure, correct if necessary.
Ensure equal pressure in all tires.
Tire pressure, nominal value Ä Chapter 2 ‘Tech-

nical data’ on page 55
Fig. 502
4. Screw the valve caps back on again.

Drive axle – Tighten the wheel nuts
10.9 Tighten the wheel nuts

1. Tighten the wheel nuts cross-wise, tightening torque: 550 Nm
(405 ft·lbs).
Fig. 503

Drive axle – Retightening the fastening of the axle on the frame
10.10 Retightening the fastening of the axle on the frame

1. Check all fastening nuts on axle mounting bolts for tight fit.
Fig. 504

Drive axle – Adjust the parking brake
10.11 Adjust the parking brake
NOTICE!
Have adjustment work on the brakes only carried out
by a specialist! Always adjust both sides.
1. Secure the machine with wheel chocks against rolling.

2. Start the diesel engine to relieve the brake.
1. Disengage the travel lever Ä Fig. 505 to the left, but do not
move to position "I" or "II".
The parking brake is released
Fig. 505
1. Unscrew locking plate 2 Ä Fig. 506.

2. Turn the square (1) in anti-clockwise direction against the
stop.
Fig. 506
1. In order to adjust the brake clearance turn the square 1

Ä Fig. 507 three turns back in clockwise direction.
2. Fasten the locking plate again.
3. Pull the plug off the brake solenoid valve and perform the
drive test.
The machine must be braked.
Fig. 507

Trouble shooting
11 Trouble shooting

Trouble shooting – Preliminary remarks
11.1 Preliminary remarks

Malfunctions are frequently caused by incorrect operation of the
machine or insufficient maintenance. Whenever a fault occurs you
should therefore thoroughly read these instruction on correct oper-
ation and maintenance.
If you cannot locate the cause of a fault or rectify it yourself by fol-
lowing the trouble shooting chart, you should contact our customer
service department.

Trouble shooting – What to do in events of emergency
11.2 What to do in events of emergency

11.2.1 Actuating the emergency stop switch
1. In events of emergency and in case of danger actuate the
emergency stop switch immediately.
ð The engine is shut down and the parking brake is closed.
Fig. 508
11.2.2 Disconnecting the battery

1. In events of emergency, e.g. in case of a cable fire, discon-
nect the battery from the vehicle network. For this purpose
turn the main battery switch anti-clockwise and pull it out or
pull the battery terminal off the battery.
Fig. 509

11.2.3 Towing the machine

Tow the machine only in a case of emergency or to avoid an acci-
dent.
Towing distance max. 500 m (1600 ft), towing speed max. 1 km/h
(55 ft/min).
Before towing make sure that:
n the tractor vehicle has sufficient traction and braking power for
the unbraked towed load,
n fastening means are able to withstand the load and are fas-
tened to the points provided for this purpose.
If no tow bar is used, towing is only permitted uphill.
n Protective gloves
WARNING!
Danger of injury caused by uncontrolled machine
movement!
– Always secure the machine against unintended
rolling.
Preparing for towing

1. Fasten the towing device reliably to the towing points.
2. Open and secure the engine hood.
Fig. 510
Access to the travel pumps

4. Loosen both clamps (1, 2) on the exhaust pipe.
Fig. 511

5. Unscrew the screw from the exhaust tube bracket.

6. Take off the exhaust tube with the two seals.
Fig. 512
7. Unscrew four fastening screws (1) from the main fuse box
and lay the main fuse box to the side.
Fig. 513
8. Pull off the plug for the backup alarm system (1).
9. Unscrew three fastening screws (2) for the cover and take off
cover.
Fig. 514
10. Pull off the plug-on connectors and loosen the cable straps
from the wiring loom.
Fig. 515

11. Unscrew the screws (1) from the AdBlue®/DEF dosing unit.
12. Lay the AdBlue®/DEF dosing unit and the wiring loom to the
side.
Fig. 516
13. Loosen the cable (1) from the cross-member.
Fig. 517
14. Unscrew the screws (1) from the engine oil filter bracket.
15. Lay the engine oil filter bracket to the side.
16. Pull the plug off the sensor on the water separator.
17. Unscrew the screws (2) from the engine oil pre-filter bracket.
18. Lay the engine oil pre-filter bracket to the side.
Fig. 518
19. Unscrew the two screws (1) from the left side of the cross-
member.
Fig. 519

20. Unscrew the two outer screws (1) from the right side of the
cross-member.
21. Tilt the cross-member to the right.
Fig. 520
Releasing the parking brake

22. Loosen the high pressure relief valves (1) on both travel
pumps for approx. three turns in counter-clockwise direction
to open a bypass.
Leakage!
– Do not back the valves out for more than
three turns!
Fig. 521
23. Press the emergency operation button completely in.

24. Insert the pump lever extension and operate the pump, until
the brake is released
ð The machine can now be towed.
Fig. 522

11.2.4 After towing
WARNING!
Danger of injury caused by uncontrolled machine
movement!
– Always secure the machine against unintended
rolling.
1. If the engine cannot be started, pull the emergency operation

button completely out after towing.
After starting the engine the emergency opera-

tion button is pushed out by hydraulic pressure.
Fig. 523
2. Retighten the high pressure relief valves (1) on both travel

pumps again, tightening torque: 70 Nm (52 ft·lbs).
3. Return the cross-member to installation position.
Fig. 524
4. Tighten the two outer screws (1) on the right side of the
cross-member.
Fig. 525

5. Tighten the two screws (1) on the left side of the cross-
member.
Fig. 526
6. Move the fuel pre-filter bracket to installation position and

tighten both screws (2).
7. Push the plug on to the sensor on the water separator.
8. Attach the engine oil filter bracket in installation position and
tighten both screws (1).
Fig. 527
9. Fasten the cable (1) on the cross-member.
Fig. 528
11. Position the AdBlue®/DEF dosing unit and tighten the screws
(1).
Fig. 529

12. Position the wiring loom and plug on the plug connectors.
13. Fasten the wiring loom with cable straps.
Fig. 530
14. Install the cover and tighten the screws (2).

15. Plug on the plug (1) for the backup alarm system.
Fig. 531
16. Attach the main fuse box in installation position and tighten
both screws (1).
Fig. 532
17. Return the exhaust tube to installation position.
Fig. 533

18. Mount the two clamps (1, 2) on the exhaust tube with seals
and tighten.
Fig. 534
19. Tighten the screw on the exhaust tube bracket.
Fig. 535

Trouble shooting – Troubleshooting, electrical systems
11.3 Troubleshooting, electrical systems

11.3.1 Preliminary remarks
Malfunctions are frequently caused by incorrect operation of the
machine or insufficient maintenance. Whenever a fault occurs you
should therefore thoroughly read these instruction on correct oper-
ation and maintenance.
If you cannot locate the cause of a fault or rectify it yourself by fol-
lowing the trouble shooting chart, you should contact our customer
service department.
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:
n In approx. 10 % of the examined cases the problems were
caused by control units.
n 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:
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
required 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.
Check for good cable and ground contacts, therefore keep all
mechanical transition points between electric conductors (termi-
nals, plugs) free of oxide and dirt, as far as this is possible.
Always use the machine related wiring diagram for testing. If one
or more faults were detected, these should be corrected immedi-
ately.
Do not disconnect or connect battery or generator while the engine
is running.
Do not operate the main battery switch under load.
Do not use jump leads after the battery has been removed.
Sensors and electric actuators on control units must never be con-
nected individually or between external power sources for the pur-
pose of testing, but only in connection with the control unit in ques-
tion.

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.
Even with an existing polarity reversal protection incorrect polarity
must be strictly avoided. Incorrect polarity can cause damage to
control units!
Plug-in connectors on control units are only dust and water tight if
the mating connector is plugged on! Control units must be pro-
tected against spray water, until the mating connector is finally
plugged on!
Unauthorized opening of control electronics (Microcontroller MC),
modifications or repairs in the wiring can cause severe malfunc-
tions.
Do not use any radio equipment or mobile phones in the vehicle
cab without a proper aerial or in the vicinity of the control elec-
tronics!
11.3.2 Starting the engine with jump leads
NOTICE!
battery.
NOTICE!
Fig. 536
components.

tive poles after.

11.3.3 Servicing the battery, checking the main battery isolation

11.3.3.1 Battery service

need to be checked.

n Protective gloves
n Safety goggles
2. Remove the battery and clean the battery compartment.
3. Clean the outside of the battery.
4. Clean battery poles and pole clamps and grease them with
pole grease (Vaseline).
5. Install the battery and check the battery fastening.
6. On serviceable batteries check the acid level, if necessary
top up to the filling mark with distilled water.
Fig. 537
11.3.3.2 Checking the main battery switch

out.
2. Check by turning the ignition key, whether the battery is dis-
connected from the electric system of the machine.
Fig. 538

11.3.4 Fuse assignment

11.3.4.1 Notes on safety
WARNING!
Danger of injury by fire in the machine!
– Do not use fuses with higher ampere ratings and
do not bridge fuses.
11.3.4.2 Central electrics

F05 20 A 12-V socket
F07 10 A Hazard light
F08 10 A Direction indicators
F09 10 A Parking and tail light, left
F10 10 A Parking and tail light, right
F11 15 A Headlight, front
F13 15 A Starter switch
F19 15 A Working head lights, front
F22 15 A Working head lights, rear
F23 15 A Warning horn
F24 10 A Instrument cluster
F29 15 A Compressor - air suspended seat, seat heating
F39 80 A Main fuse for cabin
F40 25 A Heating, air conditioning, fan
F84 10 A Control (contact 54)
F91 5A Sensors
F124 25 A Fuel pre-heating
F157 30 A Starter


F169 5A Start current
F243 7.5 A BOMAG TELEMATIC (potential 30)
F244 5A BOMAG TELEMATIC (potential 15)
F268 20 A Fuel pump
FM1 1A Sensors
FM2 1A Sensors
11.3.4.3 Main fuses

The main fuse box is located in the engine compartment.
Fig. 539

F164 150 A (B+) charge line
F00 125 A Main fuse (potential 30)
Fig. 540

F48 150 A Preheating system

11.3.4.4 Exhaust gas after-treatment system

The fuse box for the exhaust gas aftertreatment system is located
in the engine compartment under the battery cover.

F238 15 A Exhaust gas recirculation
F250 30 A SCR-control
F251 10 A NOx-Sensors
(NOx: Nitric oxides)
F310 5A Sensor for AdBlue®/DEF quality
F312 20 A Spare
F313 20 A Spare
11.3.4.5 Fuse, cabin
Fig. 541

1 F17 5A Radio
2 F264 10 A BCM
3 F271 10 A BCM net
4 F150 5A GPS
5 F266 10 A Radio/Tachograph
6 F143 20 A Rear windscreen heating
7 F28 15 A Rear windscreen wiper/washer
8 F27 15 A Front windscreen wiper/washer


9 F279 15 A Spare
10 F272 5A Control console cabin
11.3.5 Understanding electric circuit diagrams

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

n Cover sheet, see section "Cover sheet"
n Table of contents, see section "Table of contents"
n Structuring symbol overview, see section "Structuring symbol
overview"
The structuring symbol overview is NOT present in cir-

cuit diagrams, which are sorted by systems and local
identification!
n Sheets with illustration of function, see section"Sheets with

illustration of function"
n List of fuels and lubricants, see "List of fuels and lubricants"
n Terminal strip overview, see section "Terminal strip overview"
n Plug overview, see section "Plug overview"
n Pin overview, see section "Pin overview"

Cover sheet
Fig. 542: Example: Cover sheet

The cover sheet contains general information.

Table of contents
Fig. 543: Example: Table of contents

The table of contents lists the individual functions and informs
about where to find them in the electric circuit diagram (Blatt/
Page).
Overview of structural symbols

The structuring symbol overview is NOT present in cir-
cuit diagrams, which are sorted by systems and local
identification!
The structural identification overview represents the structure of

the machine with respect to equipment, functions and installation
locations.
Structuring symbols are mainly abbreviations for machine parts/
machines, functions and installation locations, which were derived
from designations in English.

Fig. 544: Example: MPH122-2
Fig. 545: Example: MPH122-2

1 Identification of structure, example EBOX

Sheets with representations of n The main reading direction is sheet by sheet, from top to
functions bottom and from left to right.
n All sheets are successively numbered.
n BOMAG used the resolved type of representation. In this case
parts and components with different functions, which belong to
the same components (e.g. relay coil and relay contact), can
be represented on different sheets. Cross-references, which
refer to the sheet and current path, serve as linkage between
these partial components.
Fig. 546: Example: Sheet with functions

1 Relay cross references serve the tracking of signals, which need to be tracked for components with out-
going contacts. A mimic diagram with information about the contact types of a relay and their positions in
the wiring diagram is additionally attached to the bottom of each contactor coil.
2 Structuring symbols
3 Potential cross references serve the purpose of tracking signals, which are transmitted from one repre-
sentation of a function to another. Potential cross-references may additionally have structuring symbols
assigned to them.
4 Mimic diagram of relay
5 Current paths are successively numbered from 0 to 9.
Example: Potential cross-reference (3) → 15_54 ∼ +SEAT/16.1 is
continued to the right to page 16, current path 1. +SEAT is the
structuring symbol.
Example: The relay cross-reference 8-K61/$.2) indicates that the
relay coil on page 4 is found in current path 2.

List of components
Fig. 547: Example: List of components

The list of components, see example , is the first evaluation list that
follows the representation of function. This list contains all compo-
nents used in the wiring diagram, except terminal strips and plugs.
An electric component is a part, assembly or device in an electrical
installation.
n Components are marked with a combination of letters and
numbers. The identification with letters follows the standard
DIN - EN 61346 T1-T2. A component identification (BMK), e.g.:
“S04“ always identifies the same component. In this context the
term "component" is always considered a function specific
assignment and does not represent a parts or article number.
This ensures that the component with the designation "S04"
always refers to the "Brake Switch", irrespective of whether the
abbreviation is used in a wiring diagram for a single drum
roller, a tandem roller, a paver or a milling machine.
n The component identifications are alphabetically sorted in the
list of components. Each component has the corresponding
cross-references assigned, identifying where it can be found in
the wiring diagram, which installation location it is assigned to
and to which part of the system it belongs to. Moreover, the
functions (function text) and the technical characteristics are
also described.

Component identifications are used in both the elec-

trical and the hydraulic documentation and are iden-
tical.
Overview of terminal strips
Fig. 548: Example: Terminal strip overview X1

The overview of terminal strips, see example, contains all terminal
strips used in the circuit diagram. Each terminal strip starts on a
new page and can be localized via the cross-reference in the
wiring diagram.

Overview of plugs
Fig. 549: Example: Plug overview X0

The overview of plugs contains all plugs used in the circuit dia-
gram.
The following information is listed for each plug:
n Contact numbering
n Structuring symbols
n Function text
n Use in wiring diagram.

Overview of pins
Fig. 550: Example: Overview of pins, control A66

The overview of pins informs about the type of inputs and outputs
of the electronic controls (E-BOX) used in the machine, as well as
their signals and potentials.
11.3.5.2 Circuit symbols in E-Plan

Circuit symbol Circuit symbols are standardized representations for electrical
appliances. They serve the purpose of a simplified representation
of complete systems, from which, however, the function can be
clearly identified. This standardization is in compliance with the
globally valid regulations of the IEC (International Electrical Com-
mission). The standardization serves the purpose of global under-
standing and fault free connection of appliances, especially in auto-
mobile repairs. Since the wiring diagram is intended to show only
the most essential aspects, the circuit symbol only shows as much
of the function, as is needed for easy recognition and for the avoid-
ance of mistakes.

Fig. 551: Example: Circuit symbol

1 Current source
2 Conductor
3 Switches
4 Ground
5 Filament lamp
6 Filament lamp with two luminous elements
7 Voltmeter
8 Amperemeter
9 Resistance
10 Fuse
11 Terminal strip
12 Plug
Different symbols are used to simplify the differentiation of terminal
strips 11 Ä Fig. 551 and plugs (12) in a wiring diagram.
Plugs are mainly used to connect two wiring looms or

to connect a wiring loom with a component with cable
connection and mating plug.
Representation of electric devices Electronic devices and components are increasingly used in the
construction equipment industry. Controls with software, control
elements (e.g. joystics and man / machine interfaces, such as e.g.
screens, LC-Displays) are frequently used to represent and control
machine functions. The internal construction of such components
is in most cases protected or just too complex to be illustrated in
the wiring diagram within the context of the actual machine func-
tion. There are two different ways to simplify the representation of
such devices in the diagram.

Black-Box representation
Fig. 552: Example: Central lubrication system

The Black-Box representation shows the device as a Box with the
connections required for the machine function. Connections which
are not needed do not need to be represented.
The Blackbox representation is mainly used if there is no differenti-
ated information (e.g. signals from pins) available from the sub-
supplier.
Identification of externally supplied
documentation
Fig. 553: Example: Identification of externally supplied documenta-

tion
In industrial technology of today it is quite common to integrate
externally supplied electric sub-systems into the projecting of
machines. These systems may be composed of various compo-
nents and wirings. For easier differentiation of BOMAG designation
and manufacturer identification the latter appears under the
BOMAG designation with a text frame and a reduced character
height.

PLC-Box representation (-A66)
Fig. 554: PLC representation

The PLC-Box representation of connecting pins uses a table with
associated connecting plugs, which are used in connection with the
machine functions. The table symbols can be arranged in a line, if
necessary. Connections which are not needed do not need to be
represented. The PLC-Box representation enables the representa-
tion of further reaching functional descriptions to the individual
component connections.
The PLC-Box representation is mainly used for controls with
BOMAG software, or for electronic devices which were specified
accordingly, and where information on the assignment of signals is
available.
Identification of similar, adjacent switching symbols
In wiring diagrams you will frequently find the situation that sym-
bols of the same type appear in a line or are arranged just next to
each other. In such cases it is common practice to reduce the iden-
tification on the subsequent symbol to the criteria, which are dif-
ferent to the previous symbol to the left.
Example: -X0 36 and -X0 37 In the example illustrated here the
component identification "-X0" for the left plug symbol is also valid
for the right plug symbol.

11.3.5.3 Identification of switch blocks

Switches of modular design
Fig. 555
F Direction
n For normally open contacts the contact symbols _3/_4 are
used.
n For normally closed contacts the contact symbols _1/_2 are
used.
In combination with the contact block numbering described above
each individual connection is clearly defined.
Example:
The contact block marked with 4 is called 43/44, if it is a normally
open contact and 41/42, if it is a normally closed contact.
open contact and 21/22 , if it is a normally closed contact.

11.3.6 Metrology
Test lamp
NOTICE!
This type of tester must not be used for testing on
electronic components. The high power consumption
of the test lamp may destroy electronic components in
the control units.
Fig. 556: Test lamp
Diode test lamp

This instrument is used for simple voltage measurements. The test
lamp consists of two test points. The negative measuring cable is
connected to ground and the positive measuring cable to the corre-
sponding measuring location.
If voltage is present, the corresponding light emitting diode will light
up.
Fig. 557: Diode test lamp

Multimeter
This tester is a multimeter and can be used to measure e.g. cur-
rent, voltage and resistance. Furthermore, depending on the
design you must carry out transistor and frequency tests.
In order to avoid damage:
n the range selector switch must be correctly set for the corre-
sponding measurement.
n the test cable must be plugged into the correct socket.
n the voltage type (AC/DC) must be set.
n In case of direct voltage the correct polarity must be assured.
n the measuring range should be chosen higher at the beginning
Fig. 558: Multimeter of the test.
n In order to avoid any influence on the circuitry to be measured,
the internal resistance of the voltage tester should be as high
as possible.
Resistance and continuity measurement with multimeter

The continuity tester of the multimeter can be used to measure
whether there is a connection between 2 measuring points.
Fig. 559
The following information should be observed when measuring

resistance and continuity:
n The component to be measured must not be connected to the
power supply during the measurement.
n At least one side of the component to be measured must be
disconnected from the circuitry, as otherwise the measuring
result may be influenced by parallel components.
n Polarity is of no significance.
Fig. 560
Voltage and voltage drop measurement with multimeter

n Measurement at the voltage source measures the currently

available Voltage.
n The meter is always connected parallel to consumer, compo-
nent or power source.
Fig. 561: Measuring voltage
n A measurement at the consumer measures the voltage drop at

this component.
Fig. 562: Voltage measurement
Current measurement with the multimeter

n The meter is connected in series with the consumer.
n During the measurement the current must be able to flow
through the meter, i.e. the electric circuit must be opened.
Fig. 563: Measuring current

Advice
If the electric circuit is difficult to access and the internal resistance
of the consumer is known, the voltage may also be measured at
the consumer.
The current value can then be calculated with the help of Ohm's
law.
Fig. 564: Current measurement
Clip-on measuring instrument

The clip-on measuring instrument can be used to measure current,
voltage and resistance.
Fig. 565: Clip-on measuring instru-

ment
n For measuring current the individual conductor must be fully

enclosed by the measuring tongs, the actual measurement
takes place without contact.
Fig. 566

Magnet tester
The magnet tester is used to test solenoid valves and magnetic

coils.
The test lamp responds to the magnetic fields of A.C-voltage, D.C.-
voltage and permanent magnets.
n The component to be tested does not need to be removed.
n The magnetic coil can also be tested under a protective cap.
Fig. 567: Magnet tester
Power measurement
The electric power of a module within a circuit can be indirectly
determined (calculated) by separate measuring of current and
voltage.
However, there are also pure power meters with 4 connections
available. The power meter has a electro-dynamic measuring
mechanism. The current circuit must be opened for measuring.
Take care when performing power measurements: Voltage or cur-
rent path may already be overloaded during the measurement,
even though the end stop in the meter has not yet been reached.
Fig. 568
11.3.7 ESX, checking the electric power supply

Power supply All electronic switching and control units require an electric power
supply to be able to work. If the plus or minus supply is faulty, the
control unit will work incorrectly or fail.
The following describes the electric power supply for

the ESX-control.
shows a simplified representation of how the control
unit (ESX, 68 pole) is connected. The complete repre-
sentation can be found in the wiring diagram of the
machine.
The procedure can also be used for other controls. Pin
assignment and voltage supply may be different, but
the procedures for line testing are generally the same.

Fig. 569: Circuitry example

1 Engine block
ESX Control unit
F00 Main fuse
Fx,Fxx Fuses potential 30
Fxxx Fuses potential 15
G Generator
G01 Battery
GND Housing earth
H08 Charge control lamp
S00 Ignition switch
S01 Emergency stop switch
Pin 28 Voltage supply for control
Pin 54 if the signal (12/24 Volt) is applied, the control is
switched on
Pin 55 Ground supply for control
Pin 56 to 60 Voltage supply for outputs
GND Housing earth
Fault in current supply, general Clear interruptions in the plus or minus supply are relatively easy to
detect. However, the plus and minus sides of control units are in
most cases connected to the vehicle mains supply via several
cables, so that several parallel current branches exist. Checking
the power supply is therefore slightly more difficult than expected.
Another point is the fact that every current branch has several plug
connections, which could corrode over the years. Corroded points
are transition resistances and thus cause undesired voltage drops.
In case of undesired voltage drops the control unit is supplied with
a lower voltage. This can lead to faulty reactions or even failure of
the control unit.

Fig. 570: Circuitry example

The arrows point to the contact locations, which may be the cause
if a control unit only receives a reduced supply voltage.
The following faults may occur:
n Line interruption in a plus supply line
n high voltage drop in a plus supply line
n line interruption on the minus side
Measuring principle for line testing When a line conducts an electric current, a voltage drop will occur
in the line (UV).
The size of this voltage drop UV depends on:
n the available amperage (I) and
n the electric resistance (RLine) of the current branch being
checked
In order to have reliable comparison possibilities at hand one
should always work with the same amperage. Identical marginal
conditions are therefore used in all of the following examples:
n 12 Volt – vehicle battery as voltage source or 24 Volt in a 24
Volt vehicle network
n 12 V / 21 W – lamp as load in a 12 Volt vehicle network
n 24 V / 21 W – lamp as load in a 24 Volt vehicle network
Test steps
1. Switch the ignition off
2. Unplug the control unit from wiring loom.
3. 3. If available connect the Pinbox Ä Fig. 571 to the plug of
the wiring loom, do not connect the control unit with the
Pinbox. If no Pinbox is available, provide measuring cables
with appropriate plug-in contacts, e.g. spade-type plugs.

4. 4. Check with multimeter. If a setpoint is not reached, pro-

ceed step by step to identify the weak spot. Repair as neces-
sary. Repeat the measurement.
NOTICE!
The plug must not be pulled off or plugged on while the
ignition is switched on. Switch off the ignition first and
then pull off or plug on the plug.
Only plug the wiring loom onto the control unit, when
the actual value corresponds with the setpoint.
Fig. 571: Pinbox for 68 pole ESX control

General measuring setup to check

a supply line (plus side)
Fig. 572: Measuring arrangement 12 Volt

1 Supply line, plus side
2 Plug contact in wiring loom plug on control or Pinbox
E Lamp, 12V / 21 Watt
P Multimeter
G01 Battery as voltage source, 12V
UV Voltage drop caused by the lamp current
Nominal value
The voltage incident UV should not exceed 0.5 V => UNominal ≤ 0.5
V.

General measuring setup to check

a return line (minus side)
Fig. 573: Measuring arrangement 12 Volt

1 Return line, minus side
2 Plug contact in wiring loom plug on control or Pinbox
E Lamp, 12V / 21 Watt
P Multimeter
G01 Battery as voltage source, 12V
UV Voltage drop caused by the lamp current
Nominal value
The voltage incident UV should not exceed 0.5 V => UNominal ≤ 0.5
V.

Connection example to check the

plus line between battery and plug
pin 28
Fig. 574
X Wiring loom plug disconnected from control unit or Pinbox
P Multimeter
S00 Ignition switched on. Nominal value: E is bright. UV max. 0.5
Volt
S00 Ignition switched off. Nominal value: E is dark. UV = 0.0 Volt
Connection example to check the

minus line between battery and
plug pin 55
Fig. 575
P Multimeter
X Wiring loom plug disconnected from control unit or Pinbox
E Nominal value: E is bright. UV max. 0.5 Volt

Test protocol for ESX
E Lamp 12V / 21W in 12V vehicle network, to load the current

branches
E Lamp 24V / 21W in 24V vehicle network, to load the current
branches.
G01 Battery
P Multimeter, measuring range: DC
Plug pin Note Nominal values

28 Ignition ON
E is bright,
E between plug pin 28 and battery minus
UV max. 0.5 Volt
P between battery plus and plug pin 28
28 Ignition OFF
E is dark,
E between plug pin 28 and battery plus
UV = 0 Volt
P between battery minus and plug pin 28
54 Ignition OFF, emergency stop not operated
E is bright,
UV max. 0.5 Volt
54 Ignition OFF, emergency stop operated
E is dark,
UV = 0 Volt
55 Ignition OFF
E is bright,
UV max. 0.5 Volt
56, 57, 58, 59, 60 Ignition OFF
E is bright,
E between plug pin 56, 57, 58, 59, 60 and battery minus
UV max. 0.5 Volt
P between battery plus and plug pin 56, 57, 58, 59, 60
If one or several setpoint(s) is (are) exceeded, one

must make considerations which are related to the
wiring diagram.
Example 1:
In all supply lines to the pins 56, 57, 58, 59 and 60 the voltage drop
is too high. There are two possible reasons. All contacts are either
corroded, or the supply line between battery and fuse Fxx has poor
contact.
Example 2:
Only one measuring value exceeds the setpoint. In this case the
fault must be located between the last branch and the corre-
sponding plug pin.

11.3.8 Diagnostics concept

Introduction A correct and reliable diagnose is a general prerequisite for the
detection of faults in system. For this to count as a rule several
points must be fulfilled. One of these points is the ability of the
engine to run a systematic trouble shooting procedure. However,
this is only possible when a diagnostics concept is available and in
practice. Trouble shooting can generally be performed in various
ways.
Fault description and questioning After the customer has explained his complaint(s) the engineer has
of the customer to ask further questions to track down the cause of the fault. If the
complaint is additionally related to electric/electronic components,
the visual examination and a possible test drive must be subse-
quently followed by an interrogation of the error log. The further
procedure in this case depends on the outcome of this interroga-
tion.
Fig. 576
(1) Fault memorized in error log
Clear cause? If the fault message leaves no doubt, repair work may be started
immediately.
(2) No fault memorized in the error Even if the fault is in the electric/electronic part of the vehicle, a
log at the time of initial questioning control unit will very often not detect a fault. Right from the start
you should be aware of the fact that a high proportion of faults is
caused by contacts. This even gets worse in case of older and
neglected vehicles.

In order to examine the electric/electronic part of an electronic

system it is recommended to check the incoming sensor informa-
tion and outgoing command values on a control unit. This requires
profound knowledge of system and components.
Consideration, if the error log has n What could be the cause of the complaint?
not recorded a fault n Which measuring possibilities are available?
Localizing faults
Line or component?
Fig. 577
n In most cases the fault message does not clarify whether the
fault is in the sensor or actor, or in one of the connecting lines
(2) between control unit and the mentioned component (1). For
this purpose it makes sense to check the component and the
connecting lines between control unit and component sepa-
rately.
n Checking the voltage supply for the control unit
n Checking the sensor lines
n Checking the actor lines

Sequence after the fault is found
Fig. 578

Trouble shooting – Trouble shooting, diesel engine
11.4 Trouble shooting, diesel engine

11.4.1 Starting the engine with jump leads
NOTICE!
battery.
NOTICE!
Fig. 579
components.

tive poles after.
11.4.2 Engine faults

Fault Possible cause Remedy
Engine does not Fuel tank empty Refuel, bleed the fuel system
start or starts poorly
Temperature below starting limit Check
Cold starting facility Check, replace if necessary
Engine oil with wrong SAE viscosity class Change the engine oil
The fuel quality does not meet the Change the fuel
requirements
Battery defective or not charged Check
Cable to starter loose or oxidized Check cable connection
Starter defective or pinion does not Check starter
engage


Air filter clogged / exhaust turbocharger Check, replace if necessary
defective
Air in the fuel system Bleeding the fuel system
Compression pressure too low Check
Exhaust gas counter pressure too high Check
Injection line leaking Check
High pressure pump defective Check, replace if necessary
Engine does not Engine electronics prevent starting Check fault by fault code, repair as nec-
start and central essary
warning lamp is
flashing
Engine starts, but V-belt/ribbed V-belt (fuel pump in belt Check, whether torn or loose
runs irregularly or drive)
misfires
Cold starting facility Check, replace if necessary
Air in the fuel system Bleeding the fuel system
Fuel pre-cleaner soiled Check, clean the water separator,
replace the fuel pre-cleaner
requirements
Injector defective Replace
Engine wiring loom defective Check, replace if necessary
Speed changes are Engine electronics detected a system Check fault by fault code, repair as nec-
possible and cen- fault and activates a substitute speed essary
tral warning lamp
lights
The engine over- Ventilation line to the coolant compensa- Clean
heats, the coolant tion tank clogged
temperature
warning lamp lights Injector defective Replace
Radiator soiled Clean
Coolant pump defective (V-belt torn or Check, whether torn or loose
loose)
Lack of coolant Check the coolant level, top up if neces-
sary
Resistance in cooling system too high / Check the cooling system
flow quantity too low
Fan defective / V-belt torn or loose Check fan / V-belt, replace if necessary
Intercooler soiled Clean


defective
Throttle valve defective Check, replace if necessary
Coolant temperature sensor Check, replace if necessary
Coolant thermostat defective Check, replace if necessary
Coolant cover defective Check, replace if necessary
Insufficient engine Engine oil level too high Check, drain off if necessary
power
Throttle valve defective Check, replace if necessary
Exhaust gas recirculation, actuator defec- Check, replace if necessary
tive
Fuel intake temperature too high Check the system
requirements
defective
Fan defective / V-belt torn or loose Check fan / V-belt, replace if necessary
Charge air pipe leaking Check
Intercooler soiled Clean
Exhaust gas counter pressure too high Check, clean if necessary
Exhaust turbo charger defective Replace
Insufficient engine Engine electronics reduces the power Check fault by fault code, repair as nec-
power and central essary
warning lamp lights
Engine does not Injection line leaking Check
work with all cylin-
ders Injector defective Check, replace if necessary
Engine wiring loom defective Check, replace if necessary
Engine has too low Engine oil level too low Check, top up or drain off as necessary
or no oil pressure
Engine oil pressure sensor defective Check, replace if necessary
Engine oil control valve jammed Check, clean if necessary
Engine oil suction pipe blocked Check, clean if necessary
Engine has exces- Engine oil level too high Check, drain off if necessary
sive oil consump-
tion Crankcase ventilation Check, replace if necessary


Valve shaft seals defective Check, replace if necessary
Piston rings worn Check, replace if necessary
Exhaust turbo charger defective Check, replace if necessary
Engine oil in the Engine is permanently operated with too Check the load factor
exhaust system low load (< 20-30%)
Blue engine Engine oil level too high Check, drain off if necessary
exhaust smoke
Crankcase ventilation Check, replace if necessary
Piston rings worn Check, replace if necessary
White engine Coolant in exhaust gas Check
exhaust smoke
Condensation water Run the engine warm, to evaporate water
residues
Fault in the SCR- AdBlue®/DEF-tank empty/level indicator Check tank sensor
system (exhaust shows full
gas aftertreatment)
SCR does not work Check plug connections of cables on
pump and injector.
Check plugs and lines on pump, NOx-
sensor and exhaust gas temperature
sensor.
Lines frozen, clean the lines, check
heating
AdBlue®/DEF-Tank frozen, check heating
Frequent regenera- Air filter clogged/exhaust turbocharger Check, replace if necessary
tion at standstill defective
Charge air pipe leaking Check
Differential pressure flow meter defective Replace
NOx ensor defective Replace
Differential pressure sensor on diesel Replace
particulate filter transmits implausible
signal
Differential pressure line blocked Clean

11.4.3 SCR system warning strategy

Overview
Fig. 580
5 Engine rpm-meter
7 Fuel level gauge
8 not used
Designation Note
Warning lamp AdBlue®/DEF Lights up if the AdBlue®/DEF filling level is low, if the AdBlue®/
DEF quality is insufficient or if there is a fault in the exhaust gas

Monitoring the SCR-functionality During operation the SCR-system is monitored by the installed
sensors. This monitoring thereby covers the following areas:
n Tank level monitoring
n Malfunction, defect
n Manipulation (incorrect filling, manipulation of sensors, etc.)
If all warnings concerning filling level, malfunction and

manipulation are ignored, an entry will be made in the
error log and the SCR-system is subsequently shut
down. Apart from this, further coercive measures in the
form of engine power reduction are then applied. The
power reduction takes place to such an extent, that
normal operation of the machine is no longer possible.
Torque limitation / power reduction In case of severe faults or if faults are not properly rectified, the
system will respond with an engine power reduction. Depending on
the type of fault the power will be reduced in one or two stages.
Warning of a too low tank level

the torque curve
Once the tank filling level has dropped below 15%, the warning will
be issued.
the torque curve
n If the tank is still not filled up and the filling level drops below
10%, the system will change to the next warning stage.
n Once the tank contents drops below 5%, the next warning
stage is activated. Moreover, a reduction related to the max-
imum power of the engine is activated after a certain count-
down time (Step 1)
n If no filling of the SCR-tank has been recognized, another
power reduction (Step 2) will be activated after a certain count-
down time.

> 15% None None None
< 15% None None
Level < 15%


< 10% None None
Level < 10%

< 5% Power reduction after Power reduction Step 1
countdown
Power reduction
< 5% Power reduction Step 2 Power reduction Step 2
after countdown
Power reduction
empty Power reduction Step 2 Power reduction Step 2
Power reduction
Test with the Service & Diagnostics With the Service and Diagnostics program SERDIA 2010 it is pos-
Tool SERDIA 2010 sible to test the SCR system.
Fig. 581
The SERDIA 2010 operating instructions contain a

detailed description of the procedure for using this
function.

Revision: 10.02.2015
11.4.4
DTC-List-EMR4
Diagnosis- and Errorcodes
KWP-Code SPN FMI Blink code Fehlerbescheibung Error identification

1 132 11 2-2-6 Luftmengen Sensor Last Korrekturfaktor maximales Drift Air flow sensor load correction factor exceeding the
Limit überschritten; Signal unplausibel maximum drift limit; plausibility error
9 172 2 2-2-6 Ansauglufttemperatursensor unplausibles Signal Air inlet filter temperature, plausibility error
37 523924 3 1-6-7 UB2; Batteriekurzschluss Aktuator Relais 2 UB2; Short circuit to battery error of actuator relay 2
38 523925 3 731 UB3; Batteriekurzschluss Aktuator Relais 3 UB3: Short circuit to battery error of actuator relay 3.
40 523927 3 733 UB5; Batteriekurzschluss Aktuator Relais 5 UB5; Short circuit to battery error of actuator relay 5 (UB6)
SCR-Heater/Rev.Valve
42 523924 4 167 UB2; Kurzschluss gegen Masse Aktuatorrelais 2 UB2; Short circuit to ground actuator relais 2
List of EMR4 fault codes
43 523925 4 731 UB3; Kurzschluss gegen Masse Aktuatorrelais 3 UB3; Short circuit to ground actuator relais 3
44 523926 4 732 UB4; Kurzschluss gegen Masse Aktuatorrelais 4 UB4; Short circuit to ground aktuator relais 4.
45 168 3 318 Sensorwert des Batteriespannungssensors über Grenzwert Sensor error battery voltage; signal range check high.
Sensorfehler Batteriespannung; Signalbereich überschritten
46 168 4 318 Sensorwert des Batteriespannungssensors unter Grenzwert Sensor error battery voltage; signal range check low
47 168 2 318 Batteriespannunug zu hoch; Warnschwelle erreicht High battery voltage; warning threshold exceeded
Batteriespannung Grenzwert überschritten; Warnmeldung
wird generiert
48 168 2 3-1-8 Batteriespannung, unterer Grenzwert unterschritten High battery voltage; shot off threshold exceeded
55 523910 14 6-9-5 Brenner Luftpumpe - genereller Fehler Air pump doesn´t achieve air mass flow setpoint
Luftpumpe erreicht Luftmassen-Sollwertvorgabe nicht Burner Control - burner air pump
56 524013 7 8-5-6 Brenner kontrolle Burner Control; burner Flame;

Brenner startet nicht nach X Versuchen Burner does not start after x trials (burner flame lost
Brennerflamme unbeabsichtigt gelöscht detection)
Burner flame unintentional deleted
BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

Revision 1.0 Page 1 / 59
447
448
DTC-List-EMR4 Revision: 10.02.2015

57 524020 14 8-6-3 Brenner Konrolle: Leistungsreduktion wegen Burner Control: power reduction due to low lambda
Sauerstoffmangel Engine power; Not enough oxygen for regeneration
Leistungsreduzierung Motor; Zu wenig Sauerstoff für

Regeneration
58 523911 0 7-2-3 Brennerdosierventil (DV2); Überstrom am Ende der Burner dosing valve (DV2); overcurrent at the end of the
Einspritzphase injection phase
59 523911 12 7-2-3 Brennerdosierventil (DV2); Leistungsstufe Übertemperatur Burner dosing valve (DV2); powerstage over temperature
60 523911 3 7-2-3 Batteriekurzschluss Leistungsstufe Brennerdosierventil (DV2) Burner dosing valve (DV2); short circuit to battery
62 523911 4 7-2-3 Massekurzschluss einer Leistungsstufe des Burner dosing valve (DV2); short circuit to ground
Brennerdosierventil (DV2); Massekurzschluss
63 523911 11 7-2-3 Brennerdosierventil (DV2); Kurzschluss Leistungsstufe Burner dosing valve (DV2); short circuit high side powerstage
plusseitig
64 523912 2 7-2-2 Kraftstoffdruck; Drucksensor nach Brennerdosierventil (DV2); Burner dosing valve (DV2) downstream pressure sensor;
Drucksignal nicht plausibel plausibility error
66 523912 0 7-2-2 Brenne-Kraftstoffdruck; Druck nach Brennerdosierventil Physical range check high for burner dosing valve (DV2)
(DV2); Druck über Grenzwert downstream pressure; shut off regeneration
Maximalwert überschritten; Abschaltung Regeneration
69 523912 1 7-2-2 Kraftstoffdruck; Drucksensor nach DV2; Druck unter Physical range check low for burner dosing valve (DV2)
Grenzwert downstream pressure; shut off regeneration. When burner
injector is actuated, the measured pressure does not rise
above ca. 1250mbar abs (expected: ca. 2400mbar).
72 523912 3 7-2-2 Sensorfehler Drucksensor nach Brennerdosierventil (DV2); Sensor error burner dosing valve (DV2) downstream
Signalbereich überschritten pressure sensor; signal range check high


73 523912 4 7-2-2 @ Motoren kleiner 4l: @ engines < 4l:
Sammelfehler für Drosselklappe, Wackelkontakt oder Throttle valve error, Open Load or Short cut to Battery,
Kurzschluss nach Masse oder Batterie, blockierte Klappe blocked valve or wrong control signal for valve.
oder falsches Ansteuersignal.
@ Brenner Motoren T4i: @ engines with Burner T4i:
Sensorfehler Drucksensor nach Brennerdosierventil (DV2), Pressure Sensor error after valve (DV2), lower limit reached
unterer Grenzwert unterschritten)
74 523913 3 7-2-1 Diagnoseleitung Glühkerzenkontrolle Spannung zu hoch Sensor error glow plug control diagnostic line voltage; signal
range check high
75 523913 4 7-2-1 Sensorfehler Spannung Diagnoseleitung Sensor error glow plug control diagnostic line voltage; signal
Glühkerzenkontrolle; Signalbereich unterschritten range check low
Diagnoseleitung Glühkerzenkontrolle Spannung zu niedrig
76 523914 5 7-2-1 Glühkerzenkontrolle; Kabelbruch Glow plug control; open load

water pump control (PWM)
77 523914 12 7-2-1 Glühkerzenkontrolle; Leistungsstufe Übertemperatur Glow plug control; powerstage over temperature
78 523914 3 7-2-1 Batteriekurzschluss an der Ansteuerung der Wasserpumpe Glow plug control; short circuit to battery
79 523914 4 7-2-1 Glühkerzenkontrolle; Massekurzschluss Glow plug control; short circuit to ground
82 1235 14 2-7-1 CAN-Bus 2 = CAN_C hat Bus-Fehler {Bei <8L und CV52 CAN-Bus 2 = CAN_C reports Bus-error
handelt es sich um den engine-CAN@250kbaud} (for engines <8L and CV52 it is the engine-CAN@250kbaud)
CAN Bus passiv Fehler; Warnung CAN C - engine CAN CAN Bus error passive; warning CAN C - engine CAN
84 639 14 271 CAN-Bus 0 "BusOff-Status" CAN-Bus 0 "BusOff-Status"

CAN-Bus 0 (CAN_A; Customer-CAN) hat "BusOff"-Message
{I.d.R.: 250kbaud}
85 1231 14 271 CAN-Bus 1 "BusOff-Status" CAN-Bus 1 "BusOff-Status"
86 1235 14 271 CAN-Bus 2 (CAN_C = engine bus) hat "BusOff"-Message CAN-Bus 2 = engine bus "BusOff-Status"

{Bei <8L und CV52 : Engine-CAN; 250kbaud}

449
450

88 102 2 223 Ladeluftdruck Grenzwert überschritten; Warnmeldung wird Charged air pressure above shut off threshold.
generiert
89 102 2 223 Ladedruck zu hoch (Abschaltschwelle überschritten) - Charged air pressure above warning threshold;
Wastegate prüfen
92 110 0 2-2-5 Kühlmitteltemperatur zu hoch, physikalischer oberer Physical Range Check high for Coolant temperature
Grenzwert überschritten
93 110 1 225 Kühlmitteltemperatur zu niedrig, physikalischer unterer Physical Range Check low for Coolant temperature.
Grenzwert unterschritten
96 110 3 225 Sensorfehler Kühlmitteltemperatur, oberer Grenzwert Sensor error coolant temperature; signal range check high
überschritten
97 110 4 225 Sensorfehler Kühlmitteltemperatur, unterer Grenzwert Sensor error coolant temperature; signal range check low
unterschritten
98 110 0 232 Kühlmitteltemperatur zu hoch; Warnschwelle erreicht High coolant temperature; warning threshold exceeded
99 110 0 232 Kühlmitteltemperatur Grenzwert überschritten; Abschaltung Coolant temperature; system reaction initiated
wird generiert
101 111 1 235 Kühlmittelstand zu niedrig Coolant level too low
121 1109 2 341 Motor Abschaltanforderung wurde vom Fahrer ignoriert Engine shut off demand ignored
122 523698 11 591 Abschaltanforderung durch übergeordnete Überwachung Shut off request from supervisory monitoring function
125 523717 12 5-9-5 Timeout der CAN-Sendebotschaft AmbCon; Wetter Timeout Error of CAN-Transmit-Frame AmbCon; Weather
Umgebungsbedingungen environments
126 523603 9 3-3-8 Timeout der CAN-Empfangsbotschaft AMB; Timeout Error of CAN-Receive-Frame AMB; Ambient
Umgebungstemperatur Sensor Temperature Sensor


127 3224 2 5-9-6 DLC Fehler der CAN-Empfangsbotschaft AT1IG1 NOX DLC Error of CAN-Receive-Frame AT1IG1 NOX Sensor
Sensor (SCR-System vor Katalysator; DPF-System nach (SCR-system upstream cat; DPF-system downstream cat);
Katalysator); Botschaftslänge nicht korrekt length of frame incorrect
128 3224 9 5-9-7 Timeout der CAN-Empfangsbotschaft AT1IG1; NOX Sensor Timeout Error of CAN-Receive-Frame AT1IG1; NOX sensor
vor Katalysator upstream
129 3224 2 596 Botschaftlänge des Vor-Kat Nox-Sensors stimmt nicht mit der DLC Error of CAN-Receive-Frame AT1IG1Vol NOX sensor.
Spezifikation überein
DLC Fehler der CAN-Empfangsbotschaft AT1IG1Vol NOX
Sensor (SCR-System vor Katalysator; DPF-System nach
Katalysator); Botschaftslänge nicht korrekt
130 3224 9 597 Timeout der CAN-Empfangsbotschaft AT1IG1Vol; NOX Timeout Error of CAN-Receive-Frame AT1IG1Vol; NOX
Sensor vor Katalysator sensor.
133 523938 9 766 Kalibrierbotschaft 1 vom Vor-Kat Nox-Sensor ist ausgefallen Timeout Error (BAM to packet) for CAN-Receive-Frame
Timeout (BAM to packet) der CAN-Empfangsbotschaft AT1IGCVol1.
AT1IGCVol1 information; Faktoren & Sensorkalibrierung für
NOX Sensor (SCR-System vor Katalysator; DPF-System
nach Katalysator)
134 523939 9 766 Broadcast Announce Message der Kalibrierbotschaft vom Broadcast Announce Message of the calibration message
Vor-Kat Nox-Sensor ist ausgefallen. of the upstream catalytic NOx sensor has failed.
135 523940 9 766 Kalibrierbotschaft 2 vom Vor-Kat Nox-Sensor ist ausgefallen Timeout Error (PCK2PCK) for CAN-Receive-Frame
AT1IGCVol1
137 3234 9 1-1-7 Timeout der CAN-Empfangsbotschaft AT1OG1; NOX Sensor Timeout Error of CAN-Receive-Frame AT1OG1; NOX sensor
(SCR-System nach Katalysator; DPF-System nach (SCR-system downstream cat; DPF-system downstream cat)
Katalysator)
138 3234 2 114 Botschaftlänge des Nach-Kat Nox-Sensors stimmt nicht mit DLC Error of CAN-Receive-Frame AT1O1Vol NOX
der Spezifikation überein
DLC Fehler der CAN-Empfangsbotschaft AT1OG1Vol NOX

Sensor (SCR-System nach Katalysator; DPF-System nach
Katalysator); Botschaftslänge nicht korrekt

451
452

139 3234 9 117 Timeout der CAN-Empfangsbotschaft AT1OG1Vol; NOX Timeout Error of CAN-Receive-Frame AT1OG1Vol.
Sensor (SCR-System nach Katalysator; DPF-System nach
Katalysator)
140 523941 9 767 Ausfall der Nach-Kat Nox-Sensor Botschaft Timeout Error (BAM to packet) for CAN-Receive-Frame
Timeout (BAM to packet) der CAN-Empfangsbotschaft AT1OGCVol2.
AT1OGCVol2 information; Faktoren & Sensorkalibrierung für
NOX Sensor (SCR-System nach Katalysator; DPF-System
nach Katalysator)
141 523942 9 767 Kalibrierbotschaft 1 vom Nach-Kat Nox-Sensor ist Calibration message 1 of the after catalyst NOx sensor has
ausgefallen. failed.
142 523943 9 767 Broadcast Announce Message der Kalibrierbotschaft vom Timeout Error (PCK2PCK) for CAN-Receive-Frame
Nach-Kat Nox-Sensor ist ausgefallen AT1OGCVol2.
Timeout (PCK2PCK) der CAN-Empfangsbotschaft
AT1OGCVol2 information; Faktoren & Sensorkalibrierung für
NOX Sensor (SCR-System nach Katalysator; DPF-System
nach Katalysator)
167 523704 12 6-1-5 Timeout Error of CAN-Transmit-Frame EEC3 Timeout Error of CAN-Transmit-Frame EEC3
168 523935 12 763 Timeout der CAN-Sendebotschaft EEC3VOL1; Motor Timeout Error of CAN-Transmit-Frame EEC3VOL1; Engine
Sendebotschaften send messages
169 523936 12 764 Timeout der CAN-Sendebotschaft EEC3VOL2; Motor Timeout Error of CAN-Transmit-Frame EEC3VOL2; Engine
Sendebotschaften send messages
171 523212 9 3-3-3 Timeout der CAN-Empfangsbotschaft ComEngPrt; Engine Timeout Error of CAN-Receive-Frame ComEngPrt; Engine
Protection Protection
179 523240 9 527 Timeout der CAN-Empfangsbotschaft FunModCtl; Function Timeout CAN-message FunModCtl; Function Mode Control
Mode Control

198 523216 9 3-3-7 Timeout der CAN-Empfangsbotschaft PrHtEnCmd; Timeout Error of CAN-Receive-Frame PrHtEnCmd; pre-heat
Vorheiz-Anforderung, Motor Anforderung command, engine command


202 523793 9 6-7-8 Timeout der CAN-Empfangsbotschaft UAA10; AGS Sensor Timeout Error of CAN-Receive-Frame UAA10; AGS sensor
Service Botschaft service message
203 523794 9 6-7-8 Timeout der CAN-Empfangsbotschaft UAA11; AGS Sensor Timeout Error of CAN-Receive-Frame UAA11; AGS sensor
Daten data
212 523803 9 6-7-8 Timeout der CAN-Empfangsbotschaft RxEngPres; Status Timeout error of CAN Receive Message RxEngPres; Status
Brenner Luftpumpe Burner Air Pump
291 523776 9 119 Timeout der CAN-Empfangsbotschaft TSC1TE - aktiv Timeout Error of CAN-Receive-Frame TSC1TE - active
292 523777 9 119 Passiver Timeout der CAN-Empfangsboschaft TSC1TE; Passive Timeout Error of CAN-Receive-Frame TSC1TE;
Sollwertvorgabe Setpoint
299 523788 12 6-5-5 Timeout der CAN-Sendebotschaft TrbCH; Status Wastegate Timeout Error of CAN-Transmit-Frame TrbCH; Status
Wastegate
305 898 9 118 Timeout der CAN-Empfangsboschaft TSC1TE; Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint
Sollwertvorgabe
306 520 9 1-1-9 Timeout der CAN-Empfangsbotschaft TSC1TR; Timeout Error of CAN-Receive-Frame TSC1TR; control
Sollwertvorgabe signal
313 523858 12 6-7-9 Timeout CAN-Botschaft "UAA11" wurde nicht gesendet Timeout Error of CAN-Transmit-Frame UAA11
No detail informationen!
322 523867 12 6-7-9 Timeout der CAN-Sendebotschaft UAA1 auf CAN 2; Ansteuerung Brenner Luftpumpe;_Timeout Error of
Ansteuerung Brenner Luftpumpe CAN-Transmit-Frame UAA1 on CAN A
360 523982 0 737 Leistungsstufen Diagnose abgeschaltet; Batteriespannung zu Powerstage diagnosis disabled; high battery voltage
hoch
361 523982 1 737 Leistungsstufen Diagnose abgeschaltet; Batteriespannung zu Powerstage diagnosis disabled; low battery voltage
niedrig

362 523090 2 329 Motorbremse Vorauswahlschalter; Plausibilitätsfehler Engine Brake Pre-Selection switch; Plausibility Error
376 630 12 281 Zugriffsfehler EEPROM-Speicher (Löschen) Access error EEPROM memory (delete)

453
454

377 630 12 281 Zugriffsfehler EEPROM-Speicher (Lesen) Access error EEPROM memory (read)
378 630 12 281 Zugriffsfehler EEPROM-Speicher (Schreiben) Access error EEPROM memory (write)
381 411 4 693 AGR Differenzdruck; Minimalwert unterschritten Physical range check low for EGR differential pressure
384 2791 12 4-1-5 Leistungsstufe Aktuator AGR Ventil; Übertemperatur Actuator EGR Valve; powerstage over temperature
387 523612 12 555 Interner Softwarefehler EMR; Injektion abgeschnitten Internal software error ECU; injection cut off
Drehmoment plaus. Fehler / ADC Monitoring Level 2, Notlauf
aktiviert
388 190 0 214 Überdrehzahl Detektion in der Komponente Engine Engine speed above warning threshold
Protection Overspeed detection in component engine protection
389 190 0 214 Motordrehzahl über Warnschwelle (FOC-Level 1) Engine speed above warning threshold (FOC-Level 1)
390 190 11 214 Motordrehzahl über Warnschwelle (FOC-Level 2) Engine speed above warning threshold (FOC-Level 2)
391 190 14 214 Motordrehzahl über Warnschwelle (Schubbetrieb) Engine speed above warning threshold (Overrun Mode)
411 108 11 2-9-2 Umgebungsluftdruck empfangen von einem CAN-Bus ist als DFC for CAN message
defekt gemeldet No detail informationen!
Detailinformationen fehlen!
412 108 3 2-9-2 Sensorfehler Umgebungsluftdruck; Signalbereich Sensor error ambient air pressure; signal range check high
überschritten
413 108 4 2-9-2 Sensorfehler Umgebungsluftdruck; Signalbereich Sensor error ambient air pressure; signal range check low
unterschritten
415 171 0 3-1-2 Umgebungstemperatursensor, Temperatur hat mnaximalen Environment temperature sensor, temperature above upper

physikalischen Grenzwert überschritten physical threshold
416 171 1 3-1-2 Umgebungstemperatursensor, Temperatur hat minimalen Physical Range Check low for Environment Temperature
Grenzwert unterschritten No detail informationen!


417 171 3 312 Sensorfehler SCR-System Umgebungslufttemperatur; Sensor error SCR-System environment temperature;
DPF-System Lufteintrittstemperatur; Signalbereich DPF-System air inlet temperature; signal range check high
überschritten
418 171 4 312 Sensorfehler SCR-System Umgebungslufttemperatur; Sensor error SCR-System environment temperature;
DPF-System Lufteintrittstemperatur; Signalbereich DPF-System air inlet temperature; signal range check low
unterschritten
419 190 8 212 Sensor Nockenwellendrehzahl; Signal gestört Sensor camshaft speed; disturbed signal
420 190 12 212 Sensor Nockenwellendrehzahl; kein Signal Sensor camshaft detection; out of range, signal disrupted; no
signal
421 190 2 213 Offsetfehler zwischen Kurbelwelle und Nockenwelle Offset angle between crank- and camshaft sensor is too
large.
422 190 8 212 Fehlerhaftes Kurbelwellensensorsignal Sensor crankshaft detection; out of range, signal disrupted;
Sensor Kurbelwellendrehzahl; Signal gestört disturbed signal
423 190 12 212 Fehlendes Kurbelwellensensorsignal Speed detection; out of range, signal disrupted
Sensor Kurbelwellendrehzahl; kein Signal Sensor crankshaft speed; no signal
455 975 5 2-3-8 Lüfter Aktuator (PWM Ausgang); Kabelbruch Fan actuator (PWM output); open load
457 975 3 2-3-8 Lüfter Aktuator(PWM Ausgang); Batteriekurzschluss Fan actuator (PWM output); short circuit to battery
458 975 4 2-3-8 Lüfter Aktuator (PWM Ausgang); Massekurzschluss Fan actuator (PWM output); short circuit to ground
459 1639 12 2-3-8 Lüfterdrehzahlsensor; elektrischer Fehler oder Signal gestört Fan speed sensor; electrical error or signal disturbed
460 1639 0 2-3-8 Sensorfehler Lüfterdrehzahl; Signalbereich überschritten Sensor error fan speed; signal range check high
461 1639 1 2-3-8 Sensorfehler Lüfterdrehzahl; Signalbereich unterschritten Sensor error fan speed; signal range check low
462 523602 0 2-3-8 Lüfterdrehzahl zu hoch; Warnschwelle erreicht High fan speed; warning threshold exceeded

463 523602 0 2-3-8 Lüfterdrehzahl zu hoch; Abschaltschwelle erreicht High fan speed; shut off threshold exceeded
464 97 3 228 Sensorfehler Wasser in Kraftstoff; Signalbereich Sensor error water in fuel; signal range check high
überschritten

455
456

465 97 4 228 Sensorfehler Wasser in Kraftstoff; Signalbereich Sensor error water in fuel; signal range check low.
unterschritten
472 94 3 216 Sensorfehler Kraftstoffvordruck; Signalbereich überschritten Sensor error low fuel pressure; signal range check high
473 94 4 216 Sensorfehler Kraftstoffvordrucksensor; Signalbereich Sensor error low fuel pressure; signal range check low
unterschritten
474 94 1 216 Kraftstoffvordruck zu niedrig; Warnschwelle erreicht Low fuel pressure; warning threshold exceeded
475 94 1 2-1-6 Kraftstoffvordruck zu niedrig; Abschaltschwelle erreicht Low fuel pressure; shut off threshold exceeded
486 523618 3 1-3-3 Getriebeöltemperatur; Kurzschluss gegen Batterie oder Gearbox oil temperature; Short circuit to battery or broken
Kabelbruch harness
487 523618 4 1-3-3 Getriebeöltemperatur; Kurzschluss gegen Masse Gearbox oil temperature; Short circuit to ground
488 523619 2 1-3-3 Abgastemperatur vor (SCR-CAT); Maximalwert überschritten Physical range check high for exhaust gas temperature
upstrem (SCR-CAT)
500 523915 0 1-6-5 HCI Dosierventil (DV1); Überstrom am Ende der HCI dosing valve (DV1); overcurrent at the end of the
Einspritzphase injection phase
501 523915 12 1-6-6 HCI Dosierventil (DV1); Leistungsstufe Übertemperature HCI dosing valve (DV1); powerstage over temperature
502 523915 3 1-5-9 Batteriekurzschluss Leistungsstufe HCI Dosierventil (DV1) HCI dosing valve (DV1); short circuit to battery
503 523915 3 1-6-4 Batteriekurzschluss Leistungsstufe plusseitig HCI HCI dosing valve (DV1); short circuit to battery high side
Dosierventil (DV1)
504 523915 4 1-5-9 HCI Dosierventil (DV1); Massekurzschluss HCI dosing valve (DV1); short circuit to ground
505 523915 11 1-6-4 Kurzschluss Leistungsstufe plusseitig Dosierventil (DV1) HCI dosing valve (DV1); short circuit high side powerstage
506 523916 2 7-1-9 Sensor Kraftstoffdruck nach HCI Dosierventil (DV1); Signal Sensor HCI dosing valve (DV1) downstream pressure;
unplausibel plausibility error
508 523916 0 7-1-9 Druck nach HCI Dosierventil (DV1) Maximalwert Physical range check high for HCI dosing valve (DV1)

überschritten; Abschaltung Regeneration downstream pressure; shut off regeneration
511 523916 1 7-1-9 Druck nach HCI Dosierventil (DV1) Minimalwert Physical range check low for HCI dosing valve (DV1)
unterschritten; Abschaltung Regeneration downstream pressure; shut off regeneration


514 523916 3 7-1-9 Sensorfehler Druck nach HCI Dosierventil (DV1); Sensor error HCI dosing valve (DV1) downstream pressure;
Signalbereich überschritten signal range check high
515 523916 4 7-1-9 Sensorfehler Drucksensor nach HCI Dosierventil (DV1), Sensor error HCI dosing valve (DV1) downstream pressure;
unterer Grenzwert unterschritten signal range check low
524 523917 3 7-1-8 Sensorfehler Druck vor DV1 & DV2; Signalbereich Sensor error DV1 & DV2 upstream pressure; signal range
überschritten check high
525 523917 4 7-1-8 Sensorfehler Druck vor DV1 & DV2; Signalbereich Sensor error DV1 & DV2 upstream pressure; signal range
unterschritten check low
534 523918 3 7-1-7 Sensorfehler Temperatur vor DV1 & DV2; Signalbereich Sensor error DV1 & DV2 upstream temperature; signal range
überschritten check high
535 523918 4 7-1-7 Sensorfehler Temperatur vor DV1 & DV2; Signalbereich Sensor error DV1 & DV2 upstream temperature; signal range
unterschritten check low
543 676 11 263 Relais Kaltstarthilfe: Heizflansch defekt (<4L alle Glühstifte Cold start aid relay error.
defekt)
Relais Kaltstarthilfe defekt
544 676 11 263 Relais Kaltstarthilfe Kabelbruch, (,Vorheiz-Sicherung),... Cold start aid relay open load
Relais Kaltstarthilfe Kabelbruch
545 729 5 263 Relais Kaltstarthilfe Kabelbruch Cold start aid relay open load
547 729 12 263 Relais Kaltstarthilfe; Leistungsstufe Übertemperatur Cold start aid relay; over temperature error
549 729 3 263 Vorheizer Ansaugluft; Kurzschluss gegen Batterie Intake Air Heater Device; Short circuit to battery
551 729 4 263 Ansaugluftvorwärmer; Kurzschluss gegen Masse auf CJ945. Air intake heater; Short circuit to ground error for powerstage
on CJ945.
559 523895 13 1-5-8 Fehlender Injektor Korrekturwert (IMA) Injektor 1 (nach Check of missing injector adjustment value programming

Zündfolge) (IMA) injector 1 (in firing order).
560 523896 13 1-5-8 Fehlender Injektor Korrekturwert (IMA) Injektor 2 (nach check of missing injector adjustment value programming

457
458

565 523350 4 151 Injector Zylinder-Bank 1; Kurzschluss Injector cylinder-bank 1; short circuit
566 523352 4 152 Injector Zylinder-Bank 2; Kurzschluss Injector cylinder-bank 2; short circuit
567 523354 12 153 Injektoransteuerung defekt Injector powerstage output defect

568 651 5 154 Injektor 1 (nach Zündfolge); Stromunterbrechung Injector 1 (in firing order); interruption of electric connection
580 651 3 154 Injektor 1 (nach Zündfolge); Kurzschluss Injector 1 (in firing order); short circuit

592 523615 5 135 Zumesseinheit (Kraftstoffsystem); Kabelbruch Metering unit (Fuel-System); open load


593 523615 12 135 Zumesseinheit (Kraftstoffsystem); Leistungsstufe Metering unit (Fuel-System); powerstage over temperature
Übertemperatur
594 523615 3 135 Zumesseinheit (Kraftstoff-System); Batteriekurzschluss Metering unit (Fuel-System); short circuit to battery highside
plusseitig
595 523615 4 135 Zumesseinheit (Kraftstoffsystem); Massekurzschluss Metering unit (Fuel-System); short circuit to ground high side
plusseitig
596 523615 3 135 Zumesseinheit (Kraftstoffsystem); Batteriekurzschluss Metering unit (Fuel-System); short circuit to battery low side
minusseitig
597 523615 4 135 Zumesseinheit (Kraftstoffsystem); Massekurzschluss Metering Unit (Fuel-System); short circuit to ground low side
minusseitig
598 523615 3 1-3-5 Kraftstoffzumesseinheit; Rücklesespannung über Grenzwert; Metering unit, short circuit to battery
Kurzschluss gegen Batterie
599 523615 4 1-3-5 Kraftstoffzumesseinheit; Rücklesespannung unter Grenzwert; Metering unit, short circuit to ground
Kurzschluss gegen Masse
604 1323 12 2-4-1 Zu viele Fehlzündungen in Zylinder 1 (nach Zündfolge) Too many recognized misfires in cylinder 1 (in firing order)
erkannt
erkannt
erkannt
erkannt
erkannt

erkannt
610 1322 12 2-4-1 Zu viele Fehlzündungen in mehreren Zylindern erkannt Too many recognized misfires in more than one cylinder

459
460

612 523612 12 555 Steuergeräte interner Software Fehler Internal ECU monitoring detection reported error
613 523612 12 555 Steuergeräte interner Software Fehler ECU reported internal software error
Internal ECU monitoring detection reported error
615 523612 12 555 Steuergeräte interner Software Fehler ECU reported internal software error.
619 523612 12 555 Einspritzsystem, elektrischer Fehler im Bereich der Injektoren Injection system,electrical error injectors
629 523612 12 555 Plaubilisierungsfehler Fahrpedal Spannung Diagnostic fault check to report the accelerator pedal position
error
630 523612 12 555 Synchronisationsfehler der Motordrehzahl Diagnostic fault check to report the engine speed error
631 523612 12 555 Plausibilisierungsfehler bei der Bestromung der Injektoren Error in the plausibility of the injection energizing time
632 523612 12 555 Plausibilisierungsfehler des Starts der Bestromungswinkel Error in the plausibility of the start of energising angles
633 523612 12 555 Plausibiltätsfehler ZFC Diagnostic fault check to report the error due to non
plausibility in ZFC
634 523612 12 555 Diagnosis fault check to report the demand for normal mode Diagnosis fault check to report the demand for normal mode

due to an error in the PoI2 quantity due to an error in the PoI2 quantity
635 523612 12 555 Diagnosis fault check to report the error to demand for an Diagnosis fault check to report the error to demand for an
ICO due to an error in the PoI2 shut-off ICO due to an error in the PoI2 shut-off


636 523612 12 555 Diagnosis fault check to report the error to demand for an Diagnosis fault check to report the error to demand for an
ICO due to an error in the PoI3 efficiency factor ICO due to an error in the PoI3 efficiency factor
637 523612 12 555 Steuergeräte interner Software Fehler Internal ECU monitoring detection reported error
638 523612 12 555 Überwachung der Einspritzmengenkorrektur Monitoring of Fuel Quantity Correction
639 523612 12 555 Diagnostic fault check to report the plausibility error in rail Diagnostic fault check to report the plausibility error in rail
pressure monitoring pressure monitoring
640 523612 12 555 Diagnostic fault check to report the error due to torque Diagnostic fault check to report the error due to torque
comparison comparison
641 523612 12 555 Diagnosis of curr path limitation forced by ECU monitoring Diagnosis of curr path limitation forced by ECU monitoring
level 2 level 2
642 523612 12 555 Diagnosis of lead path limitation forced by ECU monitoring Diagnosis of lead path limitation forced by ECU monitoring
level 2 level 2
643 523612 12 555 Diagnosis of set path limitation forced by ECU monitoring Diagnosis of set path limitation forced by ECU monitoring
level 2 level 2.
644 523612 3 555 Überwachung; Versorgungsspannung zu hoch Reported Over Voltage of Supply
646 523612 4 555 Überwachung; Versorgungsspannung zu niedrig Reported UnderVoltage of Supply
648 523008 1 4-2-4 Manipulationskontrolle wurde ausgelöst Manipulation control was triggered
649 523008 2 4-2-4 Manipulationskontrolle meldet Timeout Fehler Timeout error in Manipulation control
714 523612 12 555 Diagnostic fault check to report WDA active due to errors in Diagnostic fault check to report WDA active due to errors in
query-/response communication query-/response communication

715 523612 12 555 Diagnostic fault check to report ABE active due to Diagnostic fault check to report ABE active due to
undervoltage detection undervoltage detection

461
462

716 523612 12 555 Diagnostic fault check to report ABE active due to Diagnostic fault check to report ABE active due to
overvoltage detection overvoltage detection
717 523612 12 555 Diagnostic fault check to report WDA/ABE active due to Diagnostic fault check to report WDA/ABE active due to
unknown reason unknown reason
732 100 3 224 Sensorfehler Öldruck; Signalbereich überschritten Sensor error oil pressure; signal range check high
733 100 4 224 Sensorfehler Öldruck, Signalbereich unterschritten Sensor error oil pressure sensor; signal range check low
734 100 0 2-3-1 Öldruck zu hoch; Warnschwelle erreicht. High oil pressure; warning threshold exceeded.
735 100 0 2-3-1 Öldruck zu hoch; Abschaltschwelle erreicht High oil pressure; shut off threshold exceeded
736 100 1 231 Öldruck zu niedrig; Warnschwelle erreicht Low oil pressure; warning threshold exceeded
737 100 1 231 Öldruck zu niedrig; Abschaltschwelle erreicht Low oil pressure; shut off threshold exceeded
743 175 3 1-4-4 Sensorfehler Öltemperatur; Signalbereich überschritten Sensor error oil temperature; signal range check high
744 175 4 1-4-4 Sensorfehler Öltemperatur; Signalbereich unterschritten Sensor error oil temperature; signal range check low
745 175 0 1-4-4 Öltemperatur zu hoch; Warnschwelle erreicht High oil temperature; warning threshold exceeded
746 175 0 1-4-4 Öltemperatur zu hoch; Abschaltschwelle erreicht High oil temperature; shut off threshold exceeded
747 1237 2 145 Überbrückungsschalter; Signal unplausibel Override switch; plausibility error.
750 107 3 1-3-6 Sensorfehler Luftfilter Differenzdruck; Batteriekurzschluss Sensor error airfilter differential pressure; short circuit to
battery
751 107 0 1-3-6 Sensorfehler Luftfilter Differenzdruck; Massekurzschluss Sensor error airfilter differential pressure; short circuit to
ground
752 107 0 136 Luftfilter Differenzdrucksensor; Kurzschluss gegen Masse Air filter differential pressure; short circuit to ground
753 523919 2 6-9-4 DPF Brenner Luftpumpe Drucksensor, Signal unplausibel DPF burner air pump pressure sensor, plausibility error

755 523919 0 6-9-4 DPF Brenner Luftpumpe Drucksensor, Druck über oberer DPF burner air pump pressure sensor, pressure above upper
Abschaltschwelle shutoff threshold


758 523919 1 6-9-4 DPF Brenner Luftpumpe Drucksensor, Druck unter unterer DPF burner air pump pressure sensor, pressure below lower
761 523919 3 6-9-4 DPF Brenner Luftpumpe Drucksensor, Kurzschluss gegen DPF burner air pump pressure sensor, short circuit to battery
Batterie oder Kabelbruch or open load
762 523919 4 6-9-4 DPF Brenner Luftpumpe Drucksensor, Kurzschluss gegen DPF burner air pump pressure sensor, short circuit to ground
Masse
763 523920 2 7-1-6 Abgasdrucksensor vor Brenner, Signal unplausibel Exhaustgaspressure upstream burner, plausibility error
765 523920 0 7-1-6 Abgasdrucksensor vor Brenner, Druck über oberer Exhaustgaspressure upstream burner, pressure above upper
770 523920 3 7-1-6 Abgasdrucksensor vor Brenner, Kurzschluss gegen Batterie Exhaustgaspressure upstream burner, short circuit to battery
oder Kabelbruch or open load
771 523920 4 7-1-6 Abgasdrucksensor vor Brenner, Kurzschluss gegen Masse Exhaustgaspressure upstream burner, short circuit to ground
772 102 2 223 Ladeluftdruck nach Ladeluftkühler, Signal unplausibel Pressure downstream charge air cooler, plausibility error
774 102 1 223 Ladeluftdruck nach Ladeluftkühler, Druck unter unterem Pressure downstream charge air cooler, pressure below
physikalischem Grenzwert lower physical threshold
776 102 3 223 Ladeluftdruck nach Ladeluftkühler, Kurzschluss gegen Pressure downstream charge air cooler, short circuit to
Batterie oder Kabelbruch battery or open load
777 102 4 223 Ladeluftdruck nach Ladeluftkühler, Kurzschluss gegen Masse Pressure downstream charge air cooler, short circuit to
ground
791 411 0 693 Differenzdrucksensorwert AGR Venturiventil über Grenzwert, delta pressure across venturi in EGR line above physical high
zu hoch limit
signal range check low error of pressure control valve
AD-channel


463
464

792 411 1 693 Differenzdruck Venturieinheit (AGR); Maximalwert delta pressure across venturi in EGR line below physical low
überschritten limit
Differenzdrucksensorwert AGR Venturiventil über Grenzwert,
zu niedrig
793 411 11 693 Plausibilitätsprüfung Fehler für AGR-Delta-Drucksensor. Plausibility Check fault for deviation of desired and actual
EGR-mass flow, where the latter is calculated out of
EGR Delta Pressure Sensor.
795 411 3 693 Sensor Differenzdruck Venturieinheit (AGR), CAN Signal Sensor error differential pressure Venturiunit (EGR), signal
ungültig. range check low.
Sensorfehler Differenzdruck Venturieinheit (AGR),
Signalbereich überschritten.
796 411 4 693 Sensorfehler Differenzdruck Venturieinheit (AGR), Sensor error differential pressure Venturiunit (EGR), signal
Signalbereich übererschritten. range check high.
Sensorfehler Differenzdruck Venturieinheit (AGR),
Signalbereich unterschritten.
805 524025 14 8-4-5 Partikelfilter Regeneration. Particulate filter regeneration.

Regeneration nach Zeit X nicht erfolgreich (Der Fehler tritt Regeneration after time X is not successful (The error occurs
auf, wenn die Regeneration mehrmals when the regeneration times
(3x) über die max. erlaubte Regenerationszeit abgebrochen (3x) over the max. has been aborted allowed recovery time).
worden ist).
807 3253 2 692 Differenzdrucksensor DPF, Plausibilisierungsfehler Differential pressure DPF, plausibility error
809 3251 0 692 Differenzdruck DPF Maximalwert überschritten. Differential pressure DPF maximum value is exceeded
Abschaltung Regeneration.
810 3251 0 692 Differenzdrucksensor DPF Differential pressure sensor across DPF exceeds warning
Physikalischer Wert über oberem Grenzwert high limit
812 3251 1 692 Differenzdruck DPF Minimalwert unterschritten. Differential pressure DPF, pressure below lower shutoff

Abschaltung Regeneration. threshold.
813 3251 1 692 Differenzdrucksensor DPF. Differential pressure DPF, pressure below lower warning
Physikalischer Wert unter unterem Grenzwert. threshold.


814 3253 3 692 Sensorfehler Differenzdruck (DPF); Signalbereich Electrical error differential pressure (DPF).
überschritten (signal range check high)
815 3253 4 692 Sensorfehler Differenzdruck (DPF). Electrical error differential pressure (DPF).
Signalbereich überschritten signal range check low.
825 523009 9 253 Druckbegrenzungsventil (DBV) hat seine maximale Anzahl The pressure relief valve (PRV) has reached the number of
an Schaltvorgängen erreicht. allowed activations.
826 523470 2 146 Druckbegrenzungsventil (DBV) ist durch Druckanstieg zum Pressure relief valve is forced to open, perform pressure
Öffnen gezwungen worden. increase.
827 523470 2 146 Druckbegrenzungsventil (DBV) hat wegen Druckstoß Pressure Relief Valve (PRV) forced to open. Performed by
zwangsgeöffnet. pressure increase.
828 523470 12 146 Druckbegrenzungsventil (DBV) geöffnet. Pressure Relief Valve (PRV) forced to open.
Abschaltung Shutoff conditions.
829 523470 12 146 Druckbegrenzungsventil (DBV) geöffnet. Pressure Relief Valve (PRV) forced to open.
Warnung Warning conditions.
830 523470 14 146 Druckbegrenzungsventil (DBV) geöffnet Open Pressure Relief Valve (PRV)
831 523470 11 146 Druckbegrenzungsventil (DBV) ist geöffnet Pressure Relief Valve (PRV) error; Rail pressure out of
tolerance range.
Pressure Relief Valve (PRV) is open.
832 523470 11 146 Raildruck außerhalb Toleranzbereich Rail pressure out of tolerance range.
Das DBV kann in diesem Betriebspunkt nicht von einem The PRV can not be opened at this operating point with a
Druckstoß geöffnet werden pressure shock.
833 523009 10 2-5-3 Druckbegrenzungsventil Rail (PRV) hat seine Maximalzeit im Open time of Pressure Relief Valve (PRV) for wear out
geöffneten Zustand erreicht. monitoring had exceeded

834 523906 5 7-6-1 Elektrische Kraftstoff Vorförderpumpe nicht angeschlossen Electrical fuel pre - supply pump; open load
oder Kabelbruch.

465
466

835 523906 12 7-6-1 Elektrische Kraftstoff Vorförderpumpe Übertemperaturfehler Electrical fuel pre - supply pump.
ECU Treiberstufe. ECU powerstage over temperature.
836 523906 3 7-6-1 Elektrische Kraftstoff - Vorförderpumpe. Electrical fuel pre - supply pump; short circuit to battery
Kurzschluss gegen Batterie.
837 523906 4 7-6-1 Elektrische Kraftstoff - Vorförderpumpe. Electrical fuel pre - supply pump.
Kurzschluss gegen Masse. Short circuit to ground.
839 523450 4 1-4-3 Mehrstufenschalter feste Motordrehzahl; Batteriekurzschluss Multiple Stage Switch constant speed; short circuit to battery
847 1176 0 139 Drucksensor vor Turbine,bei Überprüfung Physikalischer Pressure sensor upstream turbine, Physical Range Check
Messbereich nach oben überschritten . high.
848 1176 1 139 Drucksensor vor Turbine; Maximalwert überschritten Pressure sensor upstream turbine, Physical Range Check
low.
849 1176 3 141 Drucksensor vor Turbine. Bei Signalcheck (SRC) Pressure sensor upstream turbine, signal range check (SRC)
Spannungssignal über oberer Grenze. high.
850 1176 4 141 Drucksensor vor Turbine. Bei Signalcheck (SRC) Pressure sensor upstream turbine, signal range check (SRC)
Spannungssignal unter unterer Grenze. low.
856 523613 0 134 Maximale positive Abweichung Raildruck überschritten. Rail pressure metering unit, Positive governor deviation.
857 523613 0 134 Positive Raildruckabweichung in Zumesseinheit Warngrenze Rail pressure metering unit, Rail pressure disrupted.
überschritten (RailMeUn1) Maximum positive deviation of rail pressure exceeded.
Maximale positive Abweichung Raildruck überschritten

(RailMeUn0)
858 523613 0 134 Leckagedetektion Railsystem (RailMeUn10) Rail pressure metering unit, Rail pressure disrupted.
Maximale positive Raildruckabweichung in Zumesseinheit Maximum positive deviation of rail pressure in metering unit
überschritten (RailMeUn1) exceeded (RailMeUn1).

859 523613 0 134 Negative Raildruckabweichung in Zumesseinheit Rail pressure metering unit, Rail pressure disrupted.
Warngrenze unterschritten (RailMeUn2 Railsystem leakage detected.
Leckage Railsystem (RailMeUn10)


861 523613 1 134 Minimaler Raildruck unterschritten (RailMeUn3) Rail pressure metering unit, Minimum rail pressure exceeded
Negative Raildruckabweichung in Zumesseinheit Stufe 2 (RailMeUn3)
unterschritten (RailMeUn22) Negative deviation of rail pressure second stage
(RailMeUn22)
862 523613 0 134 Maximaler Raildruck überschritten (RailMeUn4) Rail pressure metering unit, Maximum rail pressure
exceeded.
864 523613 2 134 Sollwert Zumesseinheit im Schubbetrieb unplausibel. Rail pressure metering unit, Setpoint of metering unit in
overrun mode not plausible.
876 523470 7 146 Maximaler Raildruck überschritten (DBV). Maximum rail pressure exceeded (PRV).
877 157 3 147 Sensorfehler Raildrucksensor, Sensor error rail pressure.

obere Spannungsgrenze überschritten. Sensor voltage above upper limit.
878 157 4 147 Sensorfehler Raildrucksensor, Sensor error rail pressure.

untere Spannungsgrenze überschritten. Sensor voltage below lower limit.
881 523633 11 1-4-9 Wirkungsgradüberwachung; cat efficiency error Lonterm adaption factor below threshold
882 523633 11 1-4-9 Wirkungsgradüberwachung; cat efficiency error within the Nox conversion rate insufficient (SCR-Cat defect, bad AdBule
range 1 (Nox-Umsatzrate zu gering, SCR-Kat defect, quality)
mangelhafte AdBlue qualität)
Nox Konvertierungsrate ungenügend (SCR-Kat defekt,
mangelhafte AdBlue Qualität)
883 523633 11 1-4-9 Wirkungsgradüberwachung; cat efficiency error within the Nox conversion rate insufficient (SCR-Cat defect, bad AdBule
range 2 (Nox-Umsatzrate zu gering, SCR-Kat defect, quality); temperature range 1
mangelhafte AdBlue qualität)
Nox Konvertierungsrate ungenügend (SCR-Kat defekt,
mangelhafte AdBlue Qualität); Temperaturbereich 1
887 3234 11 1-8-4 Nox-Sensor nach SCR-Kat; NOx Sensor defekt bzw. hängt DFC for plausibility error Min for NOx sensor downstream of
und liefert keine plausibelen Messwerte. SCR Cat.

889 3224 1 1-8-5 Nox-Sensor vor SCR-Kat; NOx Sensor liefert keine DFC for plausibility error Max for NOx sensor upstream of
plausibelen Messwerte. SCR Cat

467
468

892 4345 11 2-3-6 Sensor Druck Rücklaufleitung (SCR); Signal unplausibel Sensor backflow line pressure (SCR); plausibility error
893 4343 11 8-7-1 Druckaufbau durch Förderpumpe fehlerhaft (SCR) SCR Monitoring; Pressure stabilisation error, general
pressure check error (SCR)
894 4374 13 8-7-2 Vorhaltedruck AdBlue Dosierventil schwankt (SCR) Pressure stabilisation error dosing valve (SCR)
897 523632 16 8-7-5 Pumpendruck SCR Dosiereinheit zu hoch. Pump pressure SCR metering unit too high.
898 523632 18 8-7-6 Pumpendruck SCR Dosiereinheit zu niedrig Pump pressure SCR metering unit too low
899 523632 0 8-7-7 Druck Überlastung des SCR-System. Pressure overload of SCR-System.
900 523632 1 8-7-8 Druckaufbau im SCR-System fehlerhaft. Pressure build-up error SCR-System.
903 4365 0 8-8-1 DEF Tank Temperatur zu hoch. DEF tank temperature too high.
905 3241 0 8-8-3 Sensor Abgastemperatur vor SCR Katalysator; Signal Sensor SCR catalyst upstream temperature too high;
unplausibel hoch. plausibility error.
908 3361 7 8-8-6 AdBlue Dosiermodul blockiert (SCR) AdBlue dosing valve blocked (SCR)
914 523720 2 1-4-8 AdBlue Supplymodul Heizertemperatur; Signal unplausibel Urea supply module heater temperature; plausibility error
(Normalbetrieb). (normal condition).
915 523720 2 1-4-8 Sensor Heizertemperatur AdBlue Supplymodul; Signal Sensor urea supply module heater temperature; plausibility
unplausibel (Kaltstart) error (cold start condition)
916 523721 2 6-8-9 Sensor AdBlue Supplymodul Temperatur; Signal unplausibel Sensor urea supply module temperature; plausibility error
(Normalbetrieb) (normal condition)
917 523721 2 6-8-9 Sensor AdBlue Supplymodul Temperatur; Signal unplausibel Sensor urea supply module temperature; plausibility error
(Kaltstart) (cold start condition)

918 523981 11 2-4-3 Heizung AdBlue-Tank ohne Funktion (Aufheizphase). SCR plausibility, OBD and diagnosis; Stuck in range check of
Urea tank temperature sensor
Urea-tank without heating function (heating phase)


919 523330 14 1-3-1 Wegfahrsperrenschlüssel ungültig. Immobilizer status; fuel blocked
Status Wegfahrsperre; Kraftstoffzufuhr gesperrt.
925 523720 8 148 SCR: Dutycycle Temperatur Heizer des Supplymoduls ist Urea supply module heater temperature; duty cycle in failure
ausserhalb der Grenzen range.
AdBlue Supplymodul Heizertemperatur; Duty Cycle fehlerhaft
926 523720 8 148 SCR: Dutycycle Temperatur des Heizers Supplymodul nicht Urea supply module heater temperature; duty cycle in invalid
gültig range.
AdBlue Supplymodul Heizertemperatur; Duty Cycle im
ungültigen Bereich
927 523721 11 689 SCR: Temperaturmessung trotz Anfrage durch ECU nicht Urea supply module temperature measurement not available.
erfolgreich.
AdBlue Supplymodul Temperaturmessung nicht verfügbar.
928 523722 8 691 SCR: Periode des PWM vom Supplymodul ist nicht in den Urea supply module PWM signal; period outside valid range.
Grenzen
AdBlue Supplymodul PWM Signal; Periode außerhalb des
gültigen Bereichs
929 523722 8 691 SCR. Kein gültiges PWM Signal vom Supplymodul Detect faulty PWM signal from Supply Modul.
empfangen.
930 523721 8 689 Kein gültiges PWM Signal vom DEF Supplymodul Urea supply module temperature; duty cycle in failure range.
empfangen.
931 523721 8 689 AdBlue Supplymodul Temperatur; Duty Cycle im ungültigen Urea supply module temperature; duty cycle in invalid range.
Bereich.
932 29 3 1-2-6 Handgasschalter; Batteriekurzschluss Handthrottle idle validation switch; short circuit to battery
935 91 3 2-2-6 Sensorfehler Fahrpedal. Sensor error accelerator pedal.

Signalbereich überschritten. signal range check high.
937 29 4 1-2-6 Handgasschalter; Massekurzschluss Handthrottle idle validation switch; short circuit to ground

469
470

940 91 4 2-2-6 Sensorfehler Fahrpedal. Sensor error accelerator pedal.
Signalbereich unterschritten. Signal is below the range.
942 523921 3 7-1-4 Sensorfehler Brennertemperatur; Signalbereich überschritten Sensor error burner temperature; signal range check high
943 3532 3 1-2-7 Sensorfehler AdBlue Tanklevelsensor; Signalbereich Sensor error urea tank level; signal range check high
überschritten.
Sensorfehler AdBlue Tanklevel; Signalbereich überschritten.
944 523921 4 7-1-4 Sensorfehler Brennkammertemperatur; Signalbereich Sensor error burner temperature; signal range check low
unterschritten
945 3532 4 1-2-7 Sensorfehler AdBlue Tanklevel; Signalbereich unterschritten. Sensor error urea tank level; signal range check low
946 1079 13 282 Ausfall der Sensorversorgungsspannung 1 Failure of sensor supply voltage 1.
956 677 3 512 Starterrelais plusseitig; Batteriekurzschluss Starter relay high side.
Short circuit to battery.
957 677 4 512 Starterrelais plusseitig; Massekurzschluss. Starter relay; short circuit.
958 677 5 512 Starterrelais; Kabelbruch. Starter relay; no load error.
959 677 12 512 Starter Relais; Leistungsstufe Übertemperatur Starter relay: Powerstage over temperature.
960 677 3 512 Starterrelais minusseitig: Batteriekurzschluss Starter relay: short circuit to battery.
961 677 4 512 Starterrelais minusseitig: Massekurzschluss. Starter relay: short circuit to ground.
965 523922 3 7-1-5 Shut Off Valve; Batteriekurzschluß Burner shut of valve; short circuit to battery
969 624 5 5-1-3 Diagnoselampe; Kabelbruch SVS lamp; open load

970 624 12 5-1-3 Diagnoselampe: Leistungsstufe Übertemperatur SVS lamp: powerstage over temperature


971 624 3 5-1-3 Diagnoselampe; Batteriekurzschluß SVS lamp; short circuit to battery
972 624 4 5-1-3 Diagnoselampe; Massekurzschluss SVS lamp; short circuit to ground
973 523612 14 555 Softwarereset CPU SWReset_0 Softwarereset CPU SWReset_0

976 91 11 2-2-6 Plausibilitätfehler zwischen APP1 und APP2 oder APP1 und Plausibility error between APP1 and APP2 or APP1 and idle
Leergasschalter. switch.
978 29 2 1-2-6 Plausibilitätsfehler zwischen Sensor und Leergasschalter bei Plausibility error between sensor and idle switch, Acceleration
Fahrpedalerkennung. Pedal Detection.
Im Falle von Handgas mit Leergasschalter, ist dies die In case of Hand Throttle with Low Idle Switch,
Plausibilitätsprüfung it is the plausibility check between hand throttle and idle
zwischen Handgas und Leergasschalter. switch.
980 523550 12 515 T50 Starterschalter zu lange aktiv. Terminal 50 was operated too long
981 172 3 2-2-6 Sensorfehler Ansauglufttemperatursensor, oberer Grenzwert Air flow temperature sensor; short circuit to battery or open
überschritten. load.
Sensor Luftmengentemperatur; Batteriekurzschluss oder
Kabelbruch
982 172 4 2-2-6 Sensorfehler Ansauglufttemperatursensor, unterer Grenzwert Air flow temperature sensor; short circuit to ground
unterschritten
Sensor Luftmengentemperatur; Massekurzschluss
986 523921 0 7-1-4 Brennertemperatur; Temperatur über oberer Burner temperature, temperature above upper shutoff
Abschaltschwelle threshold
989 523921 1 7-1-4 Brennertemperatur; Temperatur unter unterer Burner temperature, temperature below lower shutoff

Abschaltschwelle threshold

471
472

992 105 1 128 Temperatur nach Ladeluftkühler; Temperatur unter unterer Charged Air cooler down stream temperature.
physikalischer Grenze Temperature below lower physical threshold.
994 105 3 128 Sensorfehler Ladelufttemperatur; Signalbereich überschritten Electrical error charged air temperature.
Signal range check high.(SRC)
995 105 4 128 Sensorfehler Ladelufttemperatur; Signalbereich Electrical error charged air temperature.
unterschritten Signal range check low.
996 105 0 233 Ladelufttemperatur Grenzwert überschritten; Warnmeldung Charged air cooler temperature. System reaction initiated.
wird generiert High charged air cooler temperature. Warning threshold
Ladelufttemperatur zu hoch; Warnschwelle erreicht exceeded.
997 105 0 233 Ladelufttemperatur zu hoch; Abschaltschwelle erreicht Low charged air cooler temperature.
Shut off threshold exceeded.
998 105 11 1-2-8 Diagnostic fault check for charged air cooler downstream Diagnostic fault check for charged air cooler downstream
temperature sensor temperature sensor
Detailinformationen fehlen! No detail informationen!
1007 412 3 682 Sensorfehler Temperatur nach AGR Kühler; Signalbereich Electrical error EGR cooler downstream temperature.
überschritten Signal range check high.
1008 412 4 682 Sensorfehler Temperatur nach AGR Kühler; Signalbereich electrical error EGR cooler downstream temperature.
unterschritten Signal range check low.
1011 523960 0 771 Abgastemperatur nach AGR Kühler; Maximalwert Physical range check high for EGR cooler downstream
überschritten temperature.
1012 523960 1 771 Abgastemperatur nach AGR Kühler; Minimalwert Physical range check low for EGR cooler downstream
unterschritten temperature.
1014 5763 6 594 Aktuatorfehler AGR Ventil (2.9;3.6) Drosselklappe Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve
(4.1;6.1;7.8); Signalbereich überschritten (4.1;6.1;7.8).
Signal range check high.

1015 520521 5 594 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve
(4.1;6.1;7.8); signal range check low.


1016 5763 7 594 Position AGR Ventil (2.9;3.6) Drosselklappe (4.1;6.1;7.8) Actuator position for EGR-Valve (2.9;3.6) or Throttle-Valve
unplausibel (4.1;6.1;7.8) not plausible.
1022 5763 6 5-9-4 Aktuatorfehler AGR Ventil (2.9;3.6) Drosselklappe Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve
(4.1;6.1;7.8), Signalbereich überschritten (4.1;6.1;7.8); signal range check high
1023 5763 5 5-9-4 Aktuatorfehler AGR Ventil (2.9;3.6) Drosselklappe Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve
(4.1;6.1;7.8); Signalbereich unterschritten (4.1;6.1;7.8); signal range check low
1024 5763 3 594 Lagesensorfehler Aktuator AGR Ventil (2.9;3.6) Position sensor error of actuator EGR-Valve (2.9;3.6) or
Drosselklappe (4.1;6.1;7.8), Signalbereich überschritten Throttle-Valve (4.1;6.1;7.8).
Signal range check high.
1025 5763 4 594 Lagesensorfehler Aktuator AGR Ventil (2.9;3.6) Position sensor error actuator EGR-Valve (2.9;3.6) or
Drosselklappe (4.1;6.1;7.8), Signalbereich unterschritten Throttle-Valve (4.1;6.1;7.8).
Signal range check low.
1026 4769 2 684 Abgastemperatur nach DOC; Signal unplausibel Temperature downstream DOC, plausibility error
1029 4766 0 684 Abgastemperatur nach DOC; Temperatur über Temperature downstream DOC, temperature above upper
Abschaltgrenze shutoff threshold
1030 4766 0 684 Abgastemperatur nach DOC; Temperatur über Warngrenze Temperature downstream DOC, temperature above upper
warning threshold
1034 4769 3 684 Sensorfehler Abgastemperatursensor nach (DOC), oberer Sensor error exhaust gas temperature downstream (DOC);
Grenzwert überschritten signal range check high
1035 4769 4 684 Sensorfehler Abgastemperatur nach (DOC); Signalbereich Sensor error exhaust gas temperature downstream (DOC);
unterschritten signal range check low
1036 4768 2 683 Sensor Abgastemperatur vor DOC; Signal unplausibel Temperature upstream DOC, plausibility error
1039 4765 0 683 Abgastemperatur vor (DOC); Maximalwert überschritten Temperature upstream DOC, temperature above upper
shutoff threshold
1040 4765 0 683 Abgastemperatursensor vor DOC über oberen Temperature upstream DOC, temperature above upper

Warngrenzwert warning threshold

473
474

1044 4768 3 683 Abgastemperatursensor vor (DOC) Spannung zu hoch Electrical error exhaust gas temperature upstream (DOC);
Sensorfehler Abgastemperatur vor (DOC); Signalbereich signal range check high
überschritten
1045 4768 4 683 Abgastemperatursensor vor (DOC) Spannung zu niedrig Electrical error exhaust gas temperature upstream (DOC);
Sensorfehler Abgastemperatur vor (DOC); Signalbereich signal range check low
unterschritten
1047 3248 4 6-8-5 Sensorfehler Abgastemperatur nach Partikel Filter; Sensor error particle filter downstream temperature; signal
Signalbereich unterschritten range check low
1067 1180 3 5-5-6 Sensorfehler Abgastemperatursensor, oberer Grenzwert Sensor error exhaust gas temperature upstream turbine;
überschritten signal range check high
Sensorfehler Abgastemperatur vor Turbine; Signalbereich
überschritten
1068 1180 4 5-5-6 Sensorfehler Abgastemperatursensor, unterer Grenzwert Sensor error exhaust gas temperature upstream turbine;
unterschritten signal range check low
Sensorfehler Abgastemperatur vor Turbine; Signalbereich
unterschritten
1069 4360 0 668 Abgastemperatur vor SCR Katalysator; Physikalischer Wert Exhaust temperature upstream SCR-Cat, temperature above
hat obere Grenze überschritten upper physical threshold
1070 4360 1 668 Abgastemperatur vor SCR Katalysator; Minimalwert Sensed exhaust temperature before SCR-Cat is < physical
unterschritten low limit
1072 4361 3 668 SCR: Signalrange Check Kattemperatur Ubatt Sensor error urea catalyst exhaust gas temperature
Sensorfehler Abgastemperatur vor SCR Katalysator; upstream; signal range check high
Signalbereich überschritten
1073 4361 4 668 SCR: Signalrange Check Kattemperatur Masse Sensor error urea catalyst exhaust gas temperature
Sensorfehler Abgastemperatur vor SCR Katalysator; upstream; signal range check low

Signalbereich unterschritten


1074 1761 14 1-2-7 Urea Tanklevelsensor; AdBlue Tanklevel unter Grenzwert Urea tank level; warning threshold exceeded
(Verbleibender Tankfüllstand < 5%)
AdBlue Tanklevel; Warnschwelle erreicht
1075 3361 6 677 SCR: Strom des Dosierventils am Ende einer Einspritzung zu Urea dosing valve; power at the end of injection too high
hoch
AdBlue Dosierventil; Strom am Ende der Einspritzphase zu
hoch
1077 3361 3 677 SCR: Kurzschluß gegen Ubatt an Lowside Schalter des Urea dosing valve; short circuit to battery on low side
Dosierventils
AdBlue Dosieventil; Batteriekurzschluss plusseitig
1078 3361 3 677 AdBlue Dosierventil; Batteriekurzschluss oder Kabelbruch Urea dosing valve; short circuit to battery or open load on
plusseitig high side
1079 3361 4 677 SCR: Kurzschluß gegen Masse oder Openload an lowside Urea dosing valve; short circuit to ground or open load on low
des Dosierventils side
AdBlue Dosierventil; Massekurzschluss oder Kabelbruch
minusseitig
1080 3361 4 677 SCR: Kurzschluß an Highside Schalter vom Dosierventil Urea dosing valve; short circuit on high side
AdBlue Dosierventil; Kurzschluss plusseitig
1081 4345 5 6-7-4 Heizerrelais SCR; Rückleitung; Kabelbruch SCR heater relay urea returnline sekondary side; open load
SCR Heizer Relais AdBlue Rücklaufleitung sekundär Seite;
Kabelbruch
1082 4366 5 7-6-2 Heizerrelais SCR; Hauptrelais; Kabelbruch (sekundär Seite) SCR main relay (secondary side): open load
SCR Hauptrelais (Sekundärseite); Kabelbruch
1083 4343 5 6-7-3 Heizerrelais SCR; AdBlue Druckleitung; Kabelbruch SCR heater relay urea pressureline secondary side; open
SCR Heizer Relais AdBlue Druckleitung sekundär Seite; load

Kabelbruch
1084 4366 5 7-6-2 SCR Hauptrelais (Sekundärseite); Batteriekurzschluss SCR main relay (secondary side); Shortcut to battery

475
476

1085 4366 5 7-6-2 SCR Hauptrelais (Sekundärseite), Heizrelais SCR main relay (secondary side), heat relay (secondary
(Sekundärseite), Heizelemente side), heating elements
oder Heizventil Kurzschluss gegen Masse. or heating valve short to ground.
1086 4341 5 6-7-5 SCR Heizer Relais AdBlue Versorgungsleitung sekundär SCR heater relay urea supplyline secondary side; open load
Seite; Kabelbruch
1087 523719 5 6-7-2 Heizer SCR; Supply Modul; Kabelbruch SCR heater relay urea supply modul secondary side; open
load
1088 4366 5 6-7-1 SCR Tankheizventil sekundär Seite; Kabelbruch SCR Tank heating valve secundary side: open load
1089 4243 11 7-8-3 SCR System Heizerdiagnose meldet Fehler; Abschaltung Heizer SCR; Pressure line heater error and temperature
SCR-System condition to perform an afterrun (Sammelfehler
Heizerdiagnose)
SCR system heater diagnostic reports error; shut off
SCR-system
1090 4345 5 674 SCR: Openload Heizerrelais Rücklaufleitung SCR heater relay urea returnline primary side; open load
SCR Heizer Relais AdBlue Rücklaufleitung primär Seite;
Kabelbruch
1092 4345 3 674 SCR: Kurzschluß Heizerrelais Rücklaufleitung gegen Ubatt SCR heater urea returnline; short circuit to battery
SCR Heizer AdBlue Rücklaufleitung; Batteriekurzschluss
1093 4345 4 674 SCR: Kurzschluß Heizerrelais Rücklaufleitung gegen Masse SCR heater urea returnline; short circuit to ground
SCR Heizer AdBlue Rücklaufleitung; Massekurzschluß
1094 4343 5 673 SCR: Openload Heizerrelais Druckleitung SCR heater relay urea pressureline primary side; open load
SCR Heizer Relais AdBlue Druckleitung primär Seite;
Kabelbruch
1096 4343 3 673 SCR Heizer AdBlue Druckleitung; Batteriekurzschluss SCR heater urea pressureline; short circuit to battery
1097 4343 4 673 SCR Heizer AdBlue Druckleitung; Massekurzschluss SCR heater urea pressureline; short circuit to ground

1098 523718 5 676 SCR: Openload Heizerrelais SCR main relay (primary side); open load
SCR Hauptrelais (Primärseite); Kabelbruch


1099 523718 12 6-7-6 SCR: Die Leistungsstufe des Heizrelays meldet SCR main relay (primary side); powerstage over temperature
Übertemperatur
SCR Hauptrelais (Primärseite); Leistungstufe
Übertemperatur
1100 523718 3 676 SCR Hauptrelais (Primärseite); Batteriekurzschluss SCR main relay (primary side); short circuit to battery
1101 523718 4 676 SCR Hauptrelais (Primärseite); Massekurzschluß SCR main relay (primary side); short circuit to ground
1102 4341 5 675 SCR: Openload Heizerrelais Saugleitung SCR heater relay urea supply line primary side; open load
SCR Heizer Relais AdBlue Versorgungsleitung primär Seite;
Kabelbruch
1104 4341 3 675 SCR: Kurzschluß Heizerrelais Saugleitung gegen Ubatt SCR-heater urea supplyline; short circuit to battery
SCR-Heizer AdBlue Versorgungsleitung; Batteriekurzschluss
1105 4341 4 675 SCR-Heizer AdBlue Versorgungsleitung; Massekurzschluss SCR-heater urea supply line; short circuit to ground
1106 523719 5 672 SCR: Openload Heizerrelais Supplymodul SCR heater relay urea supplymodule primary side; open load
SCR Heizer Relais AdBlue Supply Modul primär Seite;
Kabelbruch
1108 523719 3 672 SCR: Kurzschluß Heizerrelais Supplymodul gegen Ubatt SCR heater urea supplymodule; short circuit to battery
SCR Heizer AdBlue Supply Modul; Batteriekurzschluss
1109 523719 4 672 SCR Heizer AdBlue Supply Modul; Massekurzschluss SCR heater urea supplymodule; short circuit to ground
1110 4366 5 671 SCR: Openload Heizerrelais Tankheizung SCR tank heating valve primary side; open load
SCR Tankheizventil primär Seite; Kabelbruch
1112 4366 3 671 SCR Tankheizventil; Batteriekurzschluss SCR Tank heating valve; short circuit to battery
1113 4366 4 671 SCR Tankheizventil; Massekurzschluss SCR Tank heating valve; short circuit to ground

1114 0 0

477
478

1117 523632 11 666 SCR: Pumpenmotor wird nach Temperaturmessung nicht Pump motor not available for actuation
aktiv
Pump motor not available for actuation
1118 4375 5 666 AdBlue Pumpenmotor; Kabelbruch Urea pump motor; open load
1120 4375 3 666 SCR: Kurzschluß Motor Supplymodul gegen Ubatt Urea pump motor; short circuit to battery
AdBlue Pumpenmotor; Batteriekurzschluss
1121 4375 4 666 SCR: Kurzschluß Motor Supplymodul gegen Masse Urea pump motor; short circuit to ground
AdBlue Pumpenmotor; Massekurzschluss
1122 4334 0 665 SCR: Physikalische Grenze des Pumpendrucks Max Supply module DEF, DEF pressure above upper physical
AdBlue Supplymodul Drucksensor; Signal über oberen threshold
Grenzwert (Defekt am Drucksensor)
1123 4334 1 665 SCR: Physikalische Grenze des Pumpendrucks Min Urea supply module pressure sensor; physical range check
AdBlue Supplymodul Drucksensor; Signal unter unterem low (defect pressure sensor)
Grenwert (Defekt am Drucksensor)
1124 4334 0 6-6-5 Supply Modul Drucksensor SCR; Druckwert über Urea pump pressure sensor; high signal not plusible
vorgegebenen Grenzwert
Sensor AdBlue Pumpendruck; Signal unplausibel hoch
1125 4334 1 6-6-5 Supply Modul Drucksensor SCR; Druckwert unter Urea pump pressure sensor; low signal not plausible
vorgegebenen Grenzwert
Sensor AdBlue Pumpendruck; Signal unplausibel niedrig
1127 523632 3 665 Sensorfehler AdBlue Pumpendruck; Signalbereich Sensor error urea pump pressure; signal range check high
überschritten
1128 523632 4 665 SCR: Kurzschluß Drucksensor gegen Masse Sensor error urea pump pressure; signal range check low

Sensorfehler AdBlue Pumpendruck; Signalbereich
unterschritten


1129 4376 5 667 SCR: Openload Umkehrventil Tankheizung SCR reversal valve; open load
SCR Umkehrventil; Kabelbruch
1131 4376 3 667 SCR: Kurzschluß Umkehrventil Tankheizung gegen Ubatt SCR reversal valve; short circuit to battery
SCR Umkehrventil; Batteriekurzschluss
1132 4376 4 667 SCR: Kurzschluß Umkehrventil Tankheizung gegen Masse SCR reversing valve; short circuit to ground
SCR Umkehrventil; Massekurzschluss
1135 3031 0 669 AdBlue-Tank Temperatur; Maximalwert überschritten DEF tank, DEF temperature above upper physical threshold
1136 3031 1 669 SCR: Überwachung physikalische Grenzen Tanktemperatur DEF tank, DEF temperature below lower physical threshold
low
AdBlue-Tank Temperatur; Minimalwert unterschritten
1137 4365 2 6-6-9 SCR: Überwachung Signalwert wenn Temperatur über CAN Signal error for CAN message
Signal error for CAN message
1138 4365 3 6-6-9 SCR: Signalrange Check Tanktempsensor Sensor error urea tank temperature: short circuit to battery
Sensorfehler AdBlue-Tank Temperatur; Batteriekurzschluss
1139 4365 4 6-6-9 SCR: Signalrange Check Tanktempsensor Sensor error urea tank temperature; short circuit to ground.
Sensorfehler AdBlue-Tank Temperatur; Massekurzschluss
1157 97 12 228 Wasserabscheider Kraftstoffvorfilter; Maximalwert Water in fuel level prefilter; maximum value exceeded
überschritten
1158 523946 0 7-7-2 Nullmengenkalibrierung Injektor 1 (nach Zündfolge); Zerofuel calibration injector 1 (in firing order); maximum value
Maximalwert überschritten exceeded
1159 523947 0 7-7-2 ZFL-Adaption max-Grenze überschitten 1 Zerofuel calibration injector 2 (in firing order); maximum value
Nullmengenkalibrierung Injektor 2 (nach Zündfolge); exceeded
Maximalwert überschritten

479
480

1164 523946 1 7-7-2 ZFL-Adaption Min-Grenze überschitten 0 Zerofuel calibration injector 1 (in firing order); minimum value
Minimalwert unterschritten



1170 523612 12 555 Steuergeräte interner Software Fehler Internal software error ECU
Interner Softwarefehler EMR
1171 175 2 1-4-4 Kundenseitiger Wert für Öltemperatur unplausibel Customer oiltemperature: signal unplausible
Öltemperatur kundenseitig; Signal unplausibel
1173 523973 14 7-7-9 Nox-Sensor vor SCR-Kat bzw. Abgastemperatursensor; SCR Tamper detection; derating timer below limit 1
Timer 1 nach Manipulationserkennung
(SCRChkNOxUsPlausMin oder
SCRPODPlausUCatUsTMax) abgelaufen
SCR Manipulationserkennung; Leistungsreduktions-Timer
Grenzwert 1 unterschritten
1174 523974 14 7-7-9 Nox-Sensor vor SCR-Kat bzw. Abgastemperatursensor; SCR Tamper detection; derating timer below limit 2
Timer 2 nach Manipulationserkennung
(SCRChkNOxUsPlausMin oder
SCRPODPlausUCatUsTMax) abgelaufen
SCR Manipulationserkennung; Leistungsreduktions-Timer
1175 523975 14 1-7-5 Urea quality Sensor; Timer 1 nach erkennung des Fehlers Urea quality; derating timer below limit 1
abgelaufen
Unzureichende AdBlue Qualität; Leistungsreduktions-Timer
1176 523976 14 1-7-5 Urea quality Sensor; Timer 2 nach erkennung des Fehlers Urea qulaity; derating timer below limit 2
abgelaufen
Unzureichende AdBlue Qualität; Leistungsreduktions-Timer
1177 523977 14 7-8-1 Urea Tank Level Sensor; Timer 1 nach erkennung des leeren Urea tank level; derating timer below limit 1
Tanks (UDCRdcAgRmn) abgelaufen
AdBlue Tanklevel; Leistungreduktions-Timer Grenzwert 1

unterschritten

481
482

1178 523978 14 7-8-1 Urea Tank Level Sensor; Timer 2 nach erkennung des leeren Urea tank level; derating timer below limit 2
Tanks (UDCRdcAgRmn) abgelaufen
AdBlue Tanklevel; Leistungreduktions-Timer Grenzwert 2
unterschritten
1180 168 0 318 Sensorwert des Batteriespannungssensors über Grenzwert Physical range check high for battery voltage
Batteriespannung; Maximalwert überschritten
1181 168 1 318 Sensorwert des Batteriespannungssensors unter Grenzwert Physical range check low for battery voltage
Batteriespannung; Minimalwert unterschritten
1183 172 1 226 Temperatur Luft Menge; Minimalwert unterschritten Air inlet filter sensor out of physical range check
1193 1180 0 5-5-6 Temperatursensor vor Turbine; Temperatur über oberen Physical range check high for exhaust gas temperature
physikalischen Grenzwert upstream turbine
Abgastemperatur vor Turbine; Maximalwert überschritten
1194 1180 1 5-5-6 Temperatursensor vor Turbine; Temperatur unter unteren Physical range check low for exhaust gas temperature
physikalischen Grenzwert upstream turbine
Abgastemperatur vor Turbine; Minimalwert unterschritten
1219 524018 14 7-8-6 DPF wurde nicht regeneriert, Leistungsreduktion Phase 1 HMI engine derate service state
(Manuelle Regenerationsanforderung) DPF wasn´t regenerated, power reduction phase 1 (manuell
regeneration request)
1220 524022 14 7-8-6 HMI engine derate stop state HMI engine derate stop state
DPF wasn´t regenerated, power reduction phase 2 (manuell
regeneration request)
1222 190 14 2-1-2 Nockenwellen- und Kurbelwellensensor Signal nicht Camshaft- and Crankshaft speed sensor signal not available
verfügbar auf CAN-Bus on CAN
1223 5763 5 594 H-Brücken Steller; Kabelbruch Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8);
Aktuator AGR Ventil (2.9;3.6) Drosselklappe (4.1;6.1;7.8); open load
Kabelbruch


1224 5763 6 594 H-Brücken Steller; elektrisch überlastet Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); over
Aktuator AGR Ventil (2.9;3.6) Drosselklappe (6.1;7.8); current
elektrisch überlastet
1226 5763 3 594 AGR Ventil (2.9;3.6) Drosselklappe (4.1;6.1;7.8); EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); short
Batteriekurzschluss (A02) circuit to battery
Batteriekurzschluss (A67) circuit to battery
Massekurzschluss (A02) circuit to ground
Massekurzschluss (A67) circuit to ground
1230 5763 6 5-9-4 Aktuator AGR Ventil (2.9;3.6) Drosselklappe (4.1;6.1;7.8); Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve
Überlast durch Kurzschluß (4.1;6.1;7.8); Overload by short-circuit
1231 5763 11 5-9-4 Aktuator AGR Ventil (2.9;3.6) Drosselklappe (4.1;6.1;7.8); Power stage overtemperature due to high current.
Leistungsstufe Übertemperatur durch zu hohen Storm
1232 5763 4 5-9-4 Aktuator AGR Ventil (2.9;3.6) Drosselklappe (4.1;6.1;7.8); Voltage below threshold.
Spannung unter Grenzwert
1239 523984 3 788 UB6; Batteriekurzschluss Aktuator Relais 6 UB6; Short circuit to battery error of actuator relay 5
1241 523986 4 176 Relais SCR-Heizer, Masse-Kurzschluß (Highside Relais SCR-Heater, Short Circuit to Ground (Highside Control
Steuerseite) side)
1242 523987 4 791 UB6; Kurzschluss gegen Masse Aktuatorrelais 6 UB6; Short circuit to ground actuator relay 5
1247 524019 11 8-6-2 Luftpumpe; Luftleitung blockiert Burner Control; Air Line - Blocked us pAir

Air Pump; air lines blocked
1248 523910 9 6-9-5 Luftpumpe; CAN-Kommunikation unterbrochen Burner Control; Air Pump - CAN Lost
Air Pump; CAN communication lost

483
484

1249 523910 7 6-9-5 Burner Control; Air Pump - Elecktronik & Spannung Air pump; CAN communication interrupted no purge function
available
1250 523910 12 6-9-5 Luftpumpe; Interner Fehler Air Pump; internal error
1252 523910 0 6-9-5 Burner Control; Air Pump - falsche Spannung (FMI war früher Air Pump; operating voltage error
auf 0 )
Luftpumpe; Betriebsspannungsfehler
1254 524014 1 8-5-8 Luftdruck Glühkerzenspülleitung; Minimalwert unterschritten Air inlet EPV - pressure too low
Air pressure glow plug flush line; below limit
1255 524013 7 8-5-7 Brennerbetrieb zu oft unterbrochen Burner Control; Flame lost max
Burner operation is interrupted too often
1257 523915 7 8-5-3 HCI Dosierventil (DV1); offen blockiert HCI dosing valve (DV1); blocked open
1258 524016 11 8-5-9 HFM Sensor; elektrischer Fehler Burner Control; HFM - Electrical Fault
HFM sensor; electrical fault
1259 524016 2 8-5-9 Geförderte Luftmenge nicht plausibel zur Pumpendrehzahl Burner Control; HFM - Plausibilitätsfehler 1
Amount of air is not plausible to pump speed
1261 523910 6 6-9-5 Burner Control; Air Pump; Strom über Grenzwert Air Pump; over current
Luftpumpe; elektrisch überlastet
1262 523922 7 8-5-4 Brenner Shut Off Valve; geschlossen blockiert Burner Control; Shut-off Valve - Blocked closed
Burner Shut Off Valve; blocked closed
1263 524021 11 8-6-4 Brenner Kraftstoffleitung nach Shut Off Valve undicht Burner Control; Fuel line ShutOff downstream - broken
Burner fuel line pipe leak behind Shut Off Valve
1264 523922 7 8-5-5 Brenner Shut Off Valve; offen blockiert Burner Shut Off Valve; blocked open
1285 524038 9 8-2-4 Timeout der CAN-Empfangsbotschaft ComMS_Sys1TO Timeout error of CAN-Receive-Frame ComMS_Sys1TO
(Fehlerspeicher Slave); Master Slave interne CAN Botschaft (error memory Slave); Master-Slave internal CAN message



1291 524045 9 8-3-1 Master-Slave CAN; Nachrichtenzähler-Fehler der Master Slave, Error of message counter CAN receive
CAN-Empfangsbotschaft ComMSMoFOvR; message ComMSMoFOvR; ComMSMoFOvR1CNT
ComMSMoFOvR1CNT
1292 524046 9 8-3-2 Master-Slave CAN; Checksummen-Fehler der Master-Slave CAN; Error Checksum of CAN-Receive
CAN-Empfangsbotschaft ComMSMoFOvR Message
1293 524047 9 8-3-3 Master-Slave CAN; Nachrichten-Längen-Fehler der CAN Master-Slave CAN; Error of message length of CAN receive
Empfangsbotschaft ComMSMoFOvR message ComMSMoFOvR;_ComMSMoFOvR1DLC
1294 524048 9 8-3-4 CAN Botschaft ComMSMoFOvR1TO Timeout Fehlerspeicher Timeout error CAN message ComMSMoFOvR1TO error
Slave memory Slave
1299 523788 0 6-5-5 CAN-Sendebotschaft ComTrbChActr Plausibilitäts-Fehler; Wastegate;_ComTrbChActrPlaus

Wastegate
1300 523788 0 6-5-5 Timeout der CAN-Empfangsbotschaft ComTrbChActr; Timeout Error of CAN-Receive-Frame ComTrbChActr;
Wastegate Wastegate
1302 524024 11 8-6-6 Abweichung der Abgastemperatur Sollert zu Istwert nach Deviation of the exhaust gas temperature setpoint to actual
(DOC) zu groß value downstream (DOC) too high
1324 523995 13 7-9-5 Fehlender Injektor Korrekturwert (IMA) Injektor 7 (nach Check of missing injector adjustment value programming
Zündfolge) (IMA) injector 7 (in firing order)

Zündfolge) (IMA) injector 8 (in firing order)

485
486

1326 523997 4 7-9-7 Injektor Zylinder Bank 1 Slave; Kurzschluss Injector cylinder bank 1 slave; short circuit
1327 523998 4 7-9-8 Injektor Zylinder Bank 2 Slave; Kurzschluss Injector cylinder bank 2 slave; short circuit
1328 523999 12 7-9-9 Injektoransteuerung Slave defekt Injector powerstage output Slave defect
1329 524000 5 1-7-7 Injektor 7 (nach Zündfolge); Stromunterbrechung Injector 7 (in firing order); interruption of electric connection
1330 524001 5 1-7-8 Injektor 8 (nach Zündfolge); Stromunterbrechung Injector 8 (in firing order); interruption of electric connection
1333 524000 3 1-7-7 Injektor 7 (nach Zündfolge); Kurzschluss Injector 7 (in firing order); short circuit
1334 524001 3 1-7-8 Injektor 8 (nach Zündfolge); Kurzschluss Injector 8 (in firing order); short circuit
1337 2797 4 565 Injektor Diagnose; Timeout der Massekurzschluss Timeout of Short-Circuit Ground Diagnosis Cyl. Bank
Überwachung Zyl. Bank 0 0;_IVDiaShCirGndToutBnk_0
1338 2798 4 566 Injektor Diagnose; Timeout der Massekurzschluss Timeout of Short-Circuit Ground Diagnosis Cyl. Bank
Überwachung Zyl. Bank 1 1;_IVDiaShCirGndToutBnk_1
1339 2797 4 565 Injektor Diagnose; Test Massekurzschluss Überwachung Zyl. Injector diagnostic; Short circuit to ground cylinder bank 0
Bank 0
1340 2798 4 566 Injektor Diagnose; Test Massekurzschluss Überwachung Zyl. Injector diagnostic; Short circuit to ground cylinder bank 1
Bank 1
1342 524036 12 5-5-5 Injektor Diagnose Slave; Timeout der SPI Kommunikation Injector diagnostics Slave; time out error in the SPI
communication
1345 524069 9 8-9-6 Timeout der CAN-Empfangsbotschaft MSMon_FidFCCTO; Timeout Error of CAN-Receive-Frame MSMon_FidFCCTO;
Master-Slave CAN Kommunikation fehlerhaft Master-Slave CAN communication faulty
1357 524052 11 8-3-6 Sammelfehler im Mastersteuergerät verweist auf Error memory Slave reports FID MSMonFC2 (collective error)

Fehlerspeichereintrag im Salve Steuergerät.
1368 524052 11 8-3-6 Fehlerspeicher Slave meldet FID MSMonFC3 Error memory Slave reports FID MSMonFC3 (collective error)
(Sammelfehler)


1378 523919 2 6-9-4 Luftpresser für die DPF Brennerkomponente; Druck Sensor air pump airpressure; plausibility error
unplausibel
Sensor Luftdruck Luftpumpe; Signal unplausibel
1379 523920 2 7-1-6 Brennerdrucksensor; Druck unplausibel Sensor exhaust gas back pressure burner; plausibility error
Sensor Abgasgegendruck Brenner; Signal unplausibel
1380 3253 2 6-9-2 Partikelfilter Differenzdrucksensor; Druck unplausibel Sensor differential pressure (DPF); plausibility error
Sensor Differenzdruck (DPF); Signal unplausibel
1381 164 2 839 Raildrucksicherheitsfunktion nicht korrekt ausgeführt Rail pressure safety function is not executed correctly
1389 523922 5 7-1-5 Brenner Shut Off Valve; Kabelbruch Burner Shut Off Valve; open load
1390 523922 12 7-1-5 Brenner Shut Off Valve; Übertemperatur Burner Shut Off Valve; powerstage over temperature
1392 523922 4 7-1-5 Brenner Shut Off Valve; Massekurzschluss Burner Shut Off Valve; short circuit to ground
1395 523921 2 7-1-4 Sensor Brennertemperatur; Signal unplausibel Burner temperature sensor; Plausibility Check for burner
temperature sensor
Sensor burner temperature; plausibility error
1398 1136 0 681 ECU Temperatur; Maximalwert überschritten Physical range check high for ECU temperature
1402 4769 2 6-8-4 Temperatursensor nach Oxi-Kat; Temperatur nicht Plausibel Sensor exhaust gas temperature OxiCat downstream
Sensor Abgastemperatur nach OxiCat (Normalbetrieb); (normal operation); plausibility error
Signal unplausibel
1403 4769 2 6-8-4 Temperatursensor nach Oxi-Kat; Temperatur nicht Plausibel Sensor exhaust gas temperature OxiCat downstream
Sensor Abgastemperatur nach OxiCat (Regeneration); Signal (regeneration); plausibility error
unplausibel
1411 1188 11 8-1-4 Wastegate Steller; Interner Fehler Wastegate actuator; internal error

1412 1188 11 8-1-4 Wastegate Steller; EOL Kalibrierung nicht korrekt Wastegate actuator; EOL calibration not performed correctly
durchgeführt

487
488

1413 1188 13 8-1-4 Wastegate Steller Abweichung zu Kalibrierwert zu groß, Wastegate actuator calibration deviation too large,
Neukalibrierung erforderlich recalibration required
1414 1188 2 8-1-4 Wastegate; Statusbotschaft von Steuergerät fehlt Wastegate; status message from ECU missing
1415 1188 7 8-1-4 Wastegate Steller; blockiert Wastegate actuator; blocked
1416 1188 11 8-1-4 Wastegate Steller; Übertemperatur (> 145°C) Wastegate actuator; over temperature (> 145°C)
1417 1188 11 8-1-4 Wastegate Steller; Übertemperatur (> 135°C) Wastegate actuator; over temperature (> 135°C)
1418 1188 11 8-1-4 Wastegate Steller; Betriebsspannungsfehler Wastegate actuator; operating voltage error
1423 5763 0 5-9-4 Warnschwelle für einen internen Aktuator Fehler Warning threshold for an internal actuator error exceeded, <
überschritten, < 4L AGR-Steller und >4L Drosselklappe 4L EGR.actuator und >4L Air Intake Flap
1424 5763 1 5-9-4 Abschaltschwelle für einen internen Aktuator Fehler Shut off threshold for an internal actuator error exceeded, <
überschritten, < 4L AGR-Steller und >4L Drosselklappe 4L EGR.actuator und >4L Air Intake Flap
1425 172 0 226 Umgebungstemperatur über Warnschwelle air temperature within air filter box above maximum physical
value
1426 172 1 2-2-6 Umgebungstemperatur unter Warnschwelle Environment temperature below minimum level
1431 524028 2 8-1-5 CAN Botschaft PROEGRActr unplausibel CAN message PROEGRActr; plausibility error
1432 524029 2 8-1-5 Timeout CAN Empfangsbotschaft ComEGRActr - Timeout Error of CAN-Receive-Frame ComEGRActr -
Abgasrückführsteller exhaust gas recirculation positioner
1434 524050 11 8-3-6 CAN; not used
1435 524051 11 8-3-7 ComRxCustSysReacMin CAN; not used

1436 524034 5 8-1-6 Tellerseparator; Kabelbruch _Disc Separator; open load
1437 524034 12 8-1-6 Tellerseparator; Leistungsstufe Übertemperatur _Disc Separator; powerstage over temperature


1438 524034 3 8-1-6 Tellerseparator; Batteriekurzschluss Separador en disco; cortocircuito en la masa
1439 524034 4 8-1-6 Tellerseparator; Massekurzschluss _Disc separator; short circuit to ground
1440 524030 7 8-1-5 AGR Steller; interner Fehler _EGR actuator; internal error
1441 524031 13 8-1-5 AGR Steller, Kalibrierfehler EGR actuator, calibration error
1442 524032 2 8-1-5 AGR Steller; Statusbotschaft "EGRCust" fehlt _EGR actuator; status message "EGRCust" is missing
1443 524033 7 8-1-5 AGR Steller; wegen Überlastung im Sicherheitsmodus _EGR actuator; due to overload in Save Mode
1455 3711 12 711 SCR Wirkungsgrad Verzögerung Leistungsreduktion 2 Temperature during stand-still main phase too low or too high
abgelaufen
Regenerationstemperatur (PfltRgn LightOff) wird nicht
erreicht; Abbruch der Regeneration
1458 523960 0 7-7-1 EGR Cooler Downstream Temperature Sensor; Temperatur _High exhaust gas temperature EGR cooler downstream;
über Warnschwelle warning threshold exceeded
Abgastemperatur nach AGR Kühler zu hoch; Warnschwelle
erreicht
1481 524025 5 8-4-5 DPF System; Betriebsspannungsfehler _DPF system; operating voltage error
1482 524044 9 1-8-8 CAN-Botschaft ComMS_Sys7 nicht von Slave empfangen CAN message ComMS_Sys7 not received from slave
1484 524068 2 8-9-5 Master ECU und Slave ECU haben sich als identische Typen Master ECU and Slave ECU have been identified as the
identifiziert same types
1485 524052 11 8-3-6 Master ECU und Slave ECU Datenstände oder Software Master ECU and Slave ECU data sets or software are not
nicht identisch identical
1486 523718 5 6-7-6 Heizerendstufe SCR; Hauptrelais Kabelbruch (Fehlerpfad nur SCR mainrelay; open load (only CV56B)

bei CV56b vorhanden)
SCR Hauptrelais; Kabelbruch (nur CV56B)
1488 523718 3 6-7-6 SCR Hauptrelais; Batteriekurzschluss (nur CV56B) SCR mainrelay; short circuit to battery (only CV56B)

489
490

1489 523718 4 6-7-6 SCR Hauptrelais; Massekurzschluss (nur CV56B) SCR mainrelay; short circuit to ground (only CV56B)
1490 4376 5 6-6-7 Supply Modul Umkehrventil SCR; Kabelbruch oder SCR reverting valve; open load
Kurzschluß gegen Batterie
SCR Umkehrventil; Kabelbruch
1491 4376 12 6-6-7 Supply Modul Umkehrventil SCR; Temperatur über SCR reverting valve; over temperature
Grenzwert
SCR Umkehrventil; Übertemperatur
1493 4376 4 6-6-7 Supply Modul Umkehrventil SCR; Kurzschluss gegen Batterie SCR reverting valve; short circuit to ground
SCR Umkehrventil; Massekurzschluss
1505 524057 2 8-4-3 Kraftstoffniederdruck Pumpe; Fehler Druckaufbau Fuel low pressure pump; error pressure build up
1523 2659 2 8-2-2 Abgasrückführung AGS Sensor; Signal unplausibel Exhaust Gas Recirculation AGS Sensor; signal not plausible
1524 2659 0 8-2-2 Abgasrückführung AGS Sensor; Messwert des Exhaust Gas Recirculation AGS Sensor; Sensed exhaust
Abgasmassenstroms über maximaler physikalischer Grenze mass value above maximum physical value
1525 2659 1 8-2-2 Abgasrückführung AGS Sensor; Messwert des Exhaust Gas Recirculation AGS Sensor; Sensed exhaust
Abgasmassenstroms unter minimaler physikalischer Grenze mass value below miniimum physical value
1526 2659 12 8-2-2 Abgasrückführung AGS Sensor; Plausibilitätsfehler, AGS Exhaust Gas Recirculation AGS Sensor; plausibility error,
Sensor hat "Freibrennen" nicht durchgeführt AGS sensor has not passed the burn off process
1527 2659 2 8-2-2 Abgasrückführung AGS Sensor; Temperatur des Exhaust Gas Recirculation AGS Sensor; Temperature of
Abgasmassenstroms unplausbibel EGR mass not plausible
1528 1176 2 1-3-9 Drucksensor vor Turbine; Druck nicht plausibel Pressure sensor upstream turbine, plausibility error
1529 524070 2 8-9-7 NOx-Sensor vor SCR-Cat: ungültige Wert (Upstream NOx-Sensor) Diagnostic Fault Check for invalid
upstream NOx value (Sensor self diagnostic DFC set by

Deutz-SW)
NOx-Sensor before SCR-Cat: Invalid upstream NOx value


1530 524071 2 8-9-8 NOx-Sensor nach SCR-Kat - Lambda Wert ungültig (Downstream NOx-Sensor) Diagnostic Fault Check for invalid
downstream lambda value (Sensor self diagnostic DFC set
by Deutz-SW)
1531 524072 2 8-9-9 NOx-Sensor vor SCR-Cat: ungültige lambda Wert (Upstream NOx-Sensor) Diagnostic Fault Check for invalid
upstream lambda value (Sensor self diagnostic DFC set by
Deutz-SW)
1532 524073 2 2-4-5 NOx-Sensor nach SCR-Kat - NOx Wert ungültig (Downstream NOx-Sensor) Diagnostic Fault Check for invalid
downstream NOx value (Sensor self diagnostic DFC set by
Deutz-SW)
1533 524074 9 246 Kabelbruch Nox-Sensor nach SCR Kat NOx sensor downstream SCR-CAT, sensor internally open
load
1534 524075 11 247 Kurzschluss im Nox-Sensor nach SCR Kat NOx sensor downstream SCR-CAT, sensor internally short
circuit
1535 524076 9 248 Kabelbruch im Nox-Sensor vor SCR Kat NOx sensor upstream SCR-CAT, sensor internally open line
1536 524077 11 249 Kurzschluss Nox-Sensor vor SCR-Kat NOx sensor upstream SCR-CAT, sensor internally short
circuit
1537 524078 9 255 NOx-Sensor nach SCR-Kat, Lambda Wert über oberen NOx sensor downstream SCR-CAT, lambda value above
Grenzwert upper physical threshold
1538 524079 9 256 NOx-Sensor nach SCR-Kat, Lambda Wert unter unterem NOx sensor downstream SCR-CAT, lambda value below
Grenzwert lower physical threshold
1539 524080 9 257 NOx-Sensor vor SCR-Kat, Lambda Wert über oberen NOx sensor upstream SCR-CAT, lambda value above upper
Grenzwert physical threshold
1540 524081 9 258 NOx-Sensor vor SCR-Kat, Lambda Wert unter unterem NOx sensor upstream SCR-CAT, lambda value below lower
1541 524082 9 2-5-9 Nox Sensorwert nach Kat über oberen Grenzwert (Downstream NOx-Sensor) Diagnostic Fault Check for
downstream NOx value over maximum limit (DFC set by

Deutz-SW)

491
492

1542 524083 9 261 NOx-Sensor nach SCR-Kat, NOx Wert unter unterem NOx-Sensor downstream SCR-CAT, NOx value below
Grenzwert minimum value.
1543 524084 9 9-1-1 NOx-Sensor vor SCR-Kat, NOx Wert über oberem Grenzwert NOx-Sensor upstream SCR-CAT, NOx value above
maximum value.
1544 524085 9 912 Nox Sensorwert vor SCR Kat, NOx Wert unter unterem NOx sensor upstream SCR-CAT, NOx value below lower
1545 524149 2 9-6-8 Plausibilitätsfehler zwischen Druck nach Turbine (PTrbnDs) Plausibility error between pressure downstream turbine
und Umgebungsdruck (EnvP) (PTrbnDs) and ambient air pressure (EnvP)
1555 524063 5 869 Heizerrelais für die SCR-Rückflußleistung ist nicht SCR heater return line; open load
angeschlossen
SCR Heizer Rücklauf; Kabelbruch
1556 524063 5 869 Hauptrelais SCR-Heizer, nicht angeschlossen SCR main relay not connected
1557 524063 5 869 Heizerrelais für die SCR-Druckleitung ist nicht angeschlossen SCR heater pressureline; open load
SCR Heizer Druckleitung; Kabelbruch
1558 524063 3 869 Kurzschluß nach Battriespannung des SCR-Heizer SCR heater mainrelay; short circuit to battery
Hauptrelais
SCR Heizer Hauptrelais; Kurzschluss gegen Batterie
1559 524063 4 869 SCR Heizer Hauptrelais Lastseite(K31) über Heizventil (Y31), SCR heater main relay load side (K31) on heating valve
Kurzschluss gegen Masse. (Y31),

Short cut to ground.
1560 524063 5 869 Heizerrelais SCR-Ansaugleitung,nicht angeschlossen SCR relay for suction line not connected
1561 524063 5 869 Heizerrelais für das SCR-Modul ist nicht angeschlossen SCR heater supply module; open load

SCR Heizer Supply Modul; Kabelbruch


1562 524063 5 869 Heizerrelais für den Urea Tank ist nicht angeschlossen SCR heater tank; open load
SCR Heizer Tank; Kabelbruch
1565 524065 0 892 Drucksensor vor SCR Kat; Druck über oberen physikalischen Pressure sensor upstream SCR-CAT, pressure above upper
1566 524065 1 892 Drucksensor vor SCR Kat; Druck unter unteren Pressure sensor upstream SCR-CAT, pressure below lower
physikalischen Grenzwert physical threshold
1569 524065 3 892 Drucksensor vor SCR Kat; Kurzschluss gegen Batterie oder Pressure sensor upstream SCR-CAT; short circuit battery or
Kabelbruch open load
1570 524065 4 892 Drucksensor vor SCR Kat; Kurzschluss gegen Masse Pressure sensor upstream SCR-CAT; short circuit ground
1581 524067 0 894 Temperatur Heizer SCR Pumpenmodul, oberer DEF supply module, heater temperature above upper
physikalischer Grenzwert überschritten physical threshold
1582 524067 1 894 Temperatur Heizer SCR Pumpenmodul, unterer DEF supply module, heater temperature below lower physical
physikalischer Grenzwert unterschritten threshold
1585 524067 0 894 Supplymodul Temperatursensor SCR; Temperatur über DEF supply module, temperature above upper physical
oberen Grenzwert threshold
1586 524067 1 894 Supplymodul Temperatursensor SCR; Temperatur unter DEF supply module, temperature below lower physical
unteren Grenzwert threshold
1593 1761 0 129 Urea Tank Level; maximaler oberer Grenzwert überschritten DEF tank, DEF level above upper physical threshold
1594 1761 1 129 DEF Tank Level; minimaler unterer Grenzwert unterschritten DEF tank, DEF level below lower physical threshold
1597 524149 2 9-6-8 Plausibilitätsfehler zwischen Druck nach Turbine (PTrbnDs) Pressure downstream turbine, plausibility error
und modeliertem Druck aus ASMod Modul

1598 524065 2 892 Drucksensor vor SCR-CAT nicht plausibel. Pressure sensor upstream SCR-CAT, plausibility error

493
494

1616 3699 2 8-1-8 Differenzdruck Sensor DPF und ein weiterer Sensor oder Passive regeneration of DPF; Plausibilitätsfehler
Aktuator CRT System defekt DPF differential pressure sensor and a further sensor or
actuator CRT system defective
1617 3699 2 8-1-8 Temperatur Sensor vor und nach DOC gleichzeitig defekt Passive regeneration of DPF; DOC Fehler
Temperature sensor us. and ds. DOC simultaneously defect
1619 524087 5 8-8-4 AdBlue Fehlerlampe; Kabelbruch Urea Error Lamp; open load
1620 524087 12 8-8-4 AdBlue Fehlerlampe; Temperatur über Grenzwert Urea Error Lamp; temperatur over limit
1621 524087 3 8-8-4 AdBlue Fehlerlampe; Kurzschluss gegen Batterie Urea Error Lamp; short circuit battery
1622 524087 4 8-8-4 AdBlue Fehlerlampe; Kurzschluss gegen Masse Urea Error Lamp; short circuit ground
1630 524132 2 9-5-5 Kraftstoffniederdruck vor Kraftstoffpumpe: Signal unplausibel Fuel low pressure upstream fuel low pressure pump not
plausible
1631 524132 0 9-5-5 Kraftstoffniederdruck vor Kraftstoffpumpe; Druck über oberer Fuel low pressure upstream fuel low pressure pump,
Warnschwelle pressure above maximum warning threshold
1632 524132 0 9-5-5 Kraftstoffniederdruck vor Kraftstoffpumpe; Druck über oberer Fuel low pressure upstream fuel low pressure pump,
Abschaltschwelle pressure above maximum shut off threshold
1633 524132 1 9-5-5 Kraftstoffniederdruck vor Kraftstoffpumpe; Druck unter Fuel low pressure upstream fuel low pressure pump,
unterer Abschaltschwelle pressure below minimum shut off threshold
1634 524132 1 9-5-5 Kraftstoffniederdruck vor Kraftstoffpumpe; Druck unter Fuel low pressure upstream fuel low pressure pump,
unterer Warnschwelle pressure below minimum warning threshold
1635 3699 0 8-1-8 Maximale Stand-still-Dauer erreicht; Ölwechsel-Anforderung Maximum standstill time reached; oil exchange request
ignoriert ignored
1639 524147 13 966 SCR Koordinator; Timer abgelaufen, Initialisierung nicht SCR System,pressure build up not possible
erfolgreich -->Druckleitungen periodisch leeren
Druckaufbau Problem

1646 524063 12 869 DEF Supply Modul, Auftauphase zu lang DEF supply modul, time for defrosting too long


1647 524063 12 8-6-9 DEF Tank, Auftauphase zu lang DEF tank, time for defrosting too long
1654 1761 14 1-3-8 Urea Tank Level unterhalb Level 1 Urea Tank Signal to HMI for indicating the Urea Tank-Level
(Urea tank volume ratio low threshold 1)
1655 1761 14 138 Urea Tank Level unterhalb Level 2 DEF tank, DEF level below first warning threshold
1656 1761 14 138 Urea Tank Level unterhalb Level 3 DEF tank, DEF level below second warning threshold
1658 524096 14 1-9-6 Engine will not be started, because of EPA-Counter Control of the SCR system; If the start stop counter
(EPA-Counter) exceeds the threshold
SCRCtl_ctEngStrtStopThresh_C. This counter will increment
only once in each driving cycle in case of an SCR error. If the
counter reaches the threshold, the DFC will be set to inhibit
the engine start
Engine will not be started, because of EPA-Counter
1659 524114 9 9-3-8 Timeout der CAN-Sendebotschaft A1DOC Timeout error of CAN-Transmit-Frame A1DOC
1660 524115 9 9-3-9 Timeout der CAN-Sendebotschaft AT1S Timeout error of CAN-Transmit-Frame AT1S
1661 524116 9 1-9-4 CAN; Timeout error of transmit frame SCR2 (Sendefehler) Timeout error of CAN-Transmit-Frame SCR2
Timeout der CAN-Sendebotschaft SCR2
1662 524117 9 9-4-1 CAN; Timeout error of transmit frame SCR3 (Sendefehler) Timeout error of CAN-Transmit-Frame SCR3
Timeout der CAN-Sendebotschaft SCR3
1663 524097 9 9-2-1 Timeout der CAN-Sendebotschaft DPFBrnAirPmpCtl Timeout error of CAN-Transmit-Frame DPFBrnAirPmpCtl
1664 524098 9 9-2-2 Timeout der CAN-Sendebotschaft ComDPFBrnPT Timeout error of CAN-Transmit-Frame ComDPFBrnPT
1665 524099 9 9-2-3 Timeout der CAN-Sendebotschaft ComDPFC1 Timeout error of CAN-Transmit-Frame ComDPFC1
1666 524100 9 924 Timeout der CAN-Sendebotschaft ComDPFHisDat Timeout error of CAN-Transmit-Frame ComDPFHisDat.

1667 524101 9 9-2-5 Timeout der CAN-Sendebotschaft ComDPFTstMon Timeout error of CAN-Transmit-Frame ComDPFTstMon
1668 524105 9 9-2-9 Timeout der CAN-Sendebotschaft ComEGRMsFlw Timeout error of CAN-Transmit-Frame ComEGRMsFlw

495
496

1669 524108 9 932 Timeout der CAN-Sendebotschaft ComEGRTVActr Timeout error of CAN-Transmit-Frame ComEGRTVActr.
1670 524110 9 9-3-4 Timeout der CAN-Sendebotschaft ComETVActr
1671 524112 9 9-3-6 Timeout ComIntake Drosselklappe Actr. Timeout ComIntake Throttle Valve Actr.
1672 524118 9 9-4-2 Timeout der CAN-Empfangsbotschaft ComRxCM1 Timeout error of CAN-Receive-Frame ComRxCM1
1673 524119 9 9-4-3 Timeout der CAN-Empfangsbotschaft ComRxCustSCR3 Timeout error of CAN-Receive-Frame ComRxCustSCR3
1674 524102 9 9-2-6 Timeout der CAN-Empfangsbotschaft Timeout error of CAN-Receive-Frame

ComRxDPFBrnAirPmpCtl ComRxDPFBrnAirPmpCtl
1675 524103 9 9-2-7 Timeout der CAN-Empfangsbotschaft ComRxDPFBrnAirPmp Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmp
1676 524104 9 928 Timeout der CAN-Empfangsbotschaft ComRxDPFCtl Timeout error of CAN-Receive-Frame ComRxDPFCtl.
1677 524106 9 1-9-5 Timeout der CAN-Empfangsbotschaft ComRxEGRMsFlw1 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw1
1678 524107 9 9-3-1 Timeout der CAN-Empfangsbotschaft ComRxEGRMsFlw2 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw2
1679 524109 9 933 Timeout der CAN-Empfangsbotschaft ComRxEGRTVActr Timeout error of CAN-Receive-Frame ComRxEGRTVActr
1680 524111 9 9-3-5 Timeout der CAN-Empfangsbotschaft ComRxETVActr Timeout error of CAN-Receive-Frame ComRxETVActr
1681 524113 9 9-3-7 Timeout der CAN-Empfangsbotschaft ComRxITVActr Timeout error of CAN-Receive-Frame ComRxITVActr
1682 524120 9 9-4-4 CAN Timeout Error of receive frame SCRHtDiag Timeout error of CAN-Receive-Frame ComRxSCRHtDiag
(Empfangsfehler)
Timeout der CAN-Empfangsbotschaft ComRxSCRHtDiag
1683 524121 9 9-4-5 Timeout der CAN-Empfangsbotschaft ComRxTrbChActr Timeout error of CAN-Receive-Frame ComRxTrbChActr


1684 524122 9 9-4-6 SCR; Urea Quality; CAN Timeout Error of receive frame Timeout error of CAN-Receive-Frame ComRxUQSens
UQSens (Empfangsfehler)
Timeout der CAN-Empfangsbotschaft ComRxUQSens
1685 524123 9 9-4-7 CAN Timeout error of receive frame SCRHtCtl (Sendefehler) Timeout error of CAN-Receive-Frame ComSCRHtCtl
Timeout der CAN-Empfangsbotschaft ComSCRHtCtl
1686 524124 9 9-4-8 CAN Timeout error of receive frame AT1IMG (Sendefehler) Timeout error of CAN-Receive-Frame ComTxAT1IMG
Timeout der CAN-Empfangsbotschaft ComTxAT1IMG
1687 524125 9 9-4-9 Timeout der CAN-Empfangsbotschaft ComTxTrbChActr Timeout error of CAN-Receive-Frame ComTxTrbChActr
1698 524133 2 9-5-6 HMI-System; wird gesetzt, wenn der Restore button blockiert HMI system; set if restore button blocked
ist
1699 524134 0 957 DPF; Aschebeladung Partikelfilter überschreitet den DPF, ash load exceeds the shutoff threshold
Grenzwert.
1700 524134 0 957 DPF; Aschebeladung Partikelfilter überschreitet die DPF, ash load exceeds the warning threshold
Warnschwelle
1701 524135 0 958 Die Rußbeladung des DPF hat die Abschaltgrenze DPF, soot load exceeds the shutoff threshold
überschritten
1702 524135 14 958 Die Rußbeladung des DPF hat die Grenze DPF, soot load exceeds the service request threshold
Serviceanforderung überschritten
1703 524135 0 958 Die Rußbeladung des DPF hat die Warnschwelle DPF, soot load exceeds the warning threshold
überschritten
1705 524156 9 972 Timeout Fehler für die Radgeschwindigkeits Information Timeout error of CAN-Receive-Frame ComRxEBC2.
1752 2791 7 415 SCR Überwachung, Blockierung AGR Steller erkannt. EGR actuator, actuator blocked

1753 2791 2 415 AGR Steller, CAN Fehler EGR actuator, CAN error

497
498

1754 2791 13 415 AGR Steller, EOL Lernfehler EGR actuator, EOL calibration error
1755 2791 12 415 AGR Steller CAN, interner elektrischer Fehler. EGR Actuator, internal electrical fault
1756 2791 13 415 AGR Steller, Einlernen nicht komplett EGR actuator, learning process aborted
1757 2791 6 415 AGR Steller, Strom über Grenzwert EGR actuator current is above maximum threshold
1758 2791 3 415 AGR Steller CAN, Spannungsversorgung zu hoch EGR actuator supply voltage is above the maximum
threshold
1759 2791 4 415 AGR Steller CAN; Spannungsversorgung zu niedrig EGR actuator supply voltage is below minimum threshold.
1760 2791 13 415 AGR Steller, Lernfehler EGR actuator, learning process out of range
1761 2791 7 415 AGR Steller, Federbruch detektiert EGR actuator, broken spring detected.
1762 2791 16 415 AGR Steller, Temperatur über Grenzwert. EGR actuator, temperature high.
1763 2791 0 415 AGR Steller, Temperatur über kritischem Grenzwert. EGR actuator, temperature critical high
1788 1188 7 8-1-4 Turbolader Wastegate, mechanische Blockierung erkannt. Turbocharger wastegate, mechanical blocking detected.
1789 1188 2 8-1-4 Turbolader Wastegate CAN, CAN Fehler Turbocharger wastegate, CAN Error
1790 1188 13 8-1-4 Turbolader Wastegate CAN, EOL Kalibrierungsfehler. Turbocharger wastegate, EOL calibration error.
1791 1188 12 8-1-4 Turbolader Wastegate, interner elektrischer Fehler. Turbocharger wastegate, internal electrical error.
1792 1188 13 8-1-4 Turbolader Wastegate, Fehler während des Turbocharger wastegate, learning process aborted.
Einlernprozesses.
1793 1188 6 8-1-4 Turbolader Wastegate, Strom über Grenzwert. Turbocharger wastegate, current above maximum threshold.

1794 1188 3 8-1-4 Turbolader Wastegate, Spannungsversorgung zu hoch. Turbocharger wastegate, supply voltage above maximum
threshold.


1795 1188 4 8-1-4 Turbolader Wastegate, Spannungsversorgung zu niedrig. Turbocharger wastegate, supply voltage below minimum
threshold.
1796 1188 13 8-1-4 Turbolader Wastegate, Lernfehler (Bereicherkennung). Turbocharger wastegate, learning process out of range.
1797 1188 7 8-1-4 Turbolader Wastegate, Federbruch detektiert. Turbocharger wastegate, broken spring detected.
1799 1188 0 8-1-4 Turbolader Wastegate, Temperatur über Grenzwert. Turbocharger wastegate, temperature critical high.
1827 524141 7 192 SCR Überwachung; Blockierung an AdBlue Dosierventil DEF dosing valve, dosing valve blocked
erkannt
1857 523612 12 555 Plausibilitätsfehler Freigabe Starter Engine starter, plausibility error of starter release condition
1858 524147 7 966 SCR Überwachung; Umkehrventil blockiert --> AdBlue SCR-System, reverting valve blocked
Pumpendruck steigt während der Systementleerung.
1859 524175 0 993 SCR Überwachung; NOX-Wert nach SCR Kat, oberen SCR-CAT, Nox emissions above maximum threshold
Grenzwert erreicht
1860 524074 2 2-4-6 Unplausibler Wert des Nox-Sensors nach Kat NOx-Sensor after SCR-Cat: Nox-Sensor dew point problem
or plausibility problem
1861 524076 2 2-4-8 Unplausibler Wert des Nox-Sensors vor Kat NOx-Sensor before SCR-Cat: Nox-Sensor dew point
problem or plausibility problem
1863 524177 7 995 SCR Systemdrucküberwachung; Saugleitung Blockierung SCR System, DEF suction line blocked
erkannt
1864 524178 7 996 SCR Systemdrucküberwachung; Systemdruck Fehler SCR System, DEF pressure out of range
1865 4360 2 668 Temperatur vor SCR Kat nicht plausibel Exhaust temperature sensor upstream SCR, plausibility error
1866 4334 2 665 DEF Supply Modul Druck, Signal unplausibel DEF supply module pressure, plausibility error

1867 524067 2 894 Heiztemperatur supply module unplausibel Supply module heater temperature, plausibility error
1868 524067 2 894 Temperatur supply module unplausibel Supply module temperature, plausibility error

499
500

1869 1761 2 129 AdBlue Tankfüllstand; Tanklevelwert nicht plausibel DEF tank level, plausibility error
1874 524152 2 971 Urea Quality Sensor; Timeout CAN-Botschaft Urea Quality Sensor; Timeout CAN message
1875 524153 2 997 SCR Heizer Diagnosenachricht; Timeout CAN-Botschaft Urea tank level & urea tank temperature via CAN bus,
timeout of CAN message
1880 1761 14 138 Urea Tank Level unterhalb Level 4 DEF tank, DEF level below third warning threshold
1881 4768 2 683 Plausibilitätsprüfung Temperatursensoren vor und nach DOC exhaust gas temperature sensors up- and downstream DOC
are physically swapped
1882 524025 14 8-4-5 Zeit des Motors im Modus Stillstandsregeneration größer als The standstill-regeneration mode time exceeds the long-limit.
Grenze Langzeitinterval.
Der Motor war zu lange oder zu oft im Modus Vehicle was too long or too often in standstill mode.
Stillstandsregeneration. Make oil change and reset counter.
Ölwechsel durchführen und Zähler zurücksetzen.
1883 524025 14 8-4-5 Zeit des Motors im Modus Stillstandsregeneration größer als The standstill-regeneration mode time exceeds the
Grenze Kurzzeitinterval short-limit.
Der Motor war zu lange oder zu oft im Modus Vehicle was too long or too often within a short time in
Stillstandsregeneration. standstill mode.
Ölwechsel durchführen und Zähler zurücksetzen. Make oil change and reset counter.
1889 524189 9 2-6-9 Master / Slave Can gestört. Master / Slave Can disturbed.
1891 524190 14 272 Leistungsreduktion Schritt 1 Inducement level 1 activ

1892 524191 14 273 Leistungsreduktion Schritt 2 Inducement level 2 activ
1893 524193 8 275 Zeit des Motors im Modus Stillstandsregeneration größer als The standstill-regeneration mode time exceeds the long limit
Grenze Langzeitinterval. threshold.
Der Motor war zu lange oder zu oft im Modus Vehicle was too long or too often in standstill mode.
Stillstandsregeneration.


1894 524194 8 276 Zeit des Motors im Modus Stillstandsregeneration größer als The standstill-regeneration mode time exceeds the
Grenze Kurzzeitinterval short-limit.
Der Motor war zu lange oder zu oft im Modus Vehicle was too long or too often within a short time in
Stillstandsregeneration. standstill mode.
1895 3519 12 277 DEF Tank Temperatur, Temperatur zu hoch DEF tank temperature, temperature too high
1896 3520 3 278 DEF Qualitätssensor, Kurzschluss gegen Batterie oder DEF quality sensor, short circuit to battery or open load
Kabelbruch
1897 3520 4 278 DEF Qualitätssensor, Kurzschluss gegen Masse DEF quality sensor, short circuit to ground
1898 3519 3 277 DEF Qualitätssensor, Kurzschluss gegen Batterie oder DEF quality sensor, internal temperature sensor short circuit
Kabelbruch des internen Temperatursensors to battery or open load
1899 3519 4 277 DEF Qualitätssensor, Kurzschluss gegen Masse des internen DEF quality sensor, internal temperature sensor short circuit
Temperatursensors to ground
1900 524195 14 279 Aufforderung zur Stillstandsregeneration auf Grund von Standstill request due to crystalisation ignored too long
Kristallisation zu lange ignoriert
1901 524196 13 2-8-3 Variantenumschaltung, Adressenkonflikt Variant handling, address error
1902 524196 2 2-8-3 Variantenumschaltung, Synchronisationsfehler Variant handling, Synchronisation error
1904 3520 2 2-7-8 DEF Qualitätssensor, schlechte DEF Qualität erkannt oder DEF quality seonsor, bad DEF quality detected or no DEF
keine Qualitätsmessung möglich measuring possible.
1905 3520 8 2-7-8 DEF Qualitätssensor, Messbedingungen nicht erfüllt DEF quality seonsor, measurement conditions not fulfilled
1906 524197 7 2-8-4 SCR; Pressure Monitoring; Back flow line; Blockierungs Urea backflow line is blocked
Erkennung

1907 3520 13 278 Urea Quality Überwachung; (Diesel Exhaust Fluid) Urea quality at UQS invalid
ultrasonic/properties sensor; Urea Konzentration/Qualität
ausserhalb der physikalischen Grenzen

501
502

1908 3519 13 277 Urea Quality Überwachung; (Diesel Exhaust Fluid) Temperature at UQS invalid
temperature sensor; Temperatur ausserhalb der
physikalischen Grenzen
1911 3532 3 127 Urea Qualität Sensor; Signalwert größer als max. Grenze Quality at UQS out of max. physical range
1912 3532 4 127 Urea Qualität Sensor; Signalwert kleiner als min. Grenze Quality at UQS out of min. physical range
1914 4365 3 669 DEF Qualitätssensor, Tank Temperatur; Kurzschluss gegen DEF qualitysensor, tank temperatur; Short circuit to battery or
Batterie oder Kabelbruch open load
1915 4365 4 6-6-9 DEF Qualitätssensor, Tank Temperatur; Kurzschluss gegen DEF qualitysensor, tank temperatur; Short circuit to ground
Masse
1917 3936 14 2-8-6 Aufforderung Stillstandsregeneration zu lange ignoriert Standstill request ignored too long.
1918 3936 14 2-8-6 Stillstand Eskalation nach Zeit, Leistungsreduktion Schritt 2 Standstill time based escalation requests Inducement step 2
1921 51 5 5-9-4 Drosselklappe, H-Brückenausgang, Kabelbruch am Intake Throttle Flap, H-Bridge, wiring harness broken at
angeschlossenen Steller connected actuator
1922 51 6 5-9-4 Drosselklappe, H-Brückenausgang, Strom über maximaler Intake Throttle Flap, H-Bridge, current above maximum
oberer Grenze threshold
1924 51 3 5-9-4 Drosselklappe, H-Brückenausgang, Kurzschluss gegen Intake Throttle Flap, H-Bridge, short circuit to battery (A02)
Batterie (A02)
1925 51 3 5-9-4 Drosselklappe, H-Brückenausgang, Kurzschluss gegen Intake Throttle Flap, H-Bridge, short circuit to battery (A67)
Batterie (A67)
1926 51 4 5-9-4 Drosselklappe, H-Brückenausgang, Kurzschluss gegen Intake Throttle Flap, H-Bridge, short circuit to ground (A02)
Masse (A02)

1927 51 4 5-9-4 Drosselklappe, H-Brückenausgang, Kurzschluss gegen Intake Throttle Flap, H-Bridge, short circuit to ground (A67)
Masse (A67)


1931 51 7 5-9-4 Drosselklappe, H-Brückenausgang, Position des Stellers Intake Throttle Flap, H-Bridge, position of actuator not
nicht plausibel (Abweichung vom soll 7%) plausible (deviation from setpoint more than 7%)
1935 51 3 5-9-4 Drosselklappe, H-Brückenausgang, Kurzschluss gegen Intake Throttle Flap, H-Bridge, short circuit to battery oder
Batterie oder Kabelbruch broken wiring harness
1936 51 4 5-9-4 Drosselklappe, H-Brückenausgang, Kurzschluss gegen Intake Throttle Flap, H-Bridge, short circuit to ground
Masse
1939 524198 11 3-1-3 Hardware failure Fehlercode aktiv im Master Steuergerät Inducement HW Failure Master
1940 524199 11 3-1-3 Hardware tampering Fehlercode aktiv im Master Steuergerät Inducement SCR Tamp Master
1941 524200 11 3-1-3 DEF Qualität Fehlercode aktiv im Master Steuergerät Inducement Urea QTY Master
1942 524201 11 3-1-3 DEF Level Fehlercode aktiv im Master Steuergerät Urea Level Error Master
1943 524202 11 3-1-3 SCR Fehlercode aktiv im Master Steuergerät Urea Temp. Error Master
1944 524203 11 3-1-3 M/S Monitoring Fault Coupling: FID6 in the slave not present Urea Level Replace Master
1945 524204 11 3-1-3 M/S Monitoring Fault Coupling: FID7 in the slave not present SCR System Afterrun Master
1946 524205 11 3-1-3 M/S Monitoring Fault Coupling: FID8 in the slave not present Switch Off SCR System Master
1947 524206 11 3-1-3 M/S Monitoring Fault Coupling: FID9 in the slave not present Disable SCR Dosing Master
1948 524207 11 3-1-3 M/S Monitoring Fault Coupling: FID10 in the slave not INH EAT Regeneration Master
present
1949 524208 11 3-1-3 M/S Monitoring Fault Coupling: FID11 in the slave not Power Reduction 1 Master
present

1950 524209 11 3-1-3 M/S Monitoring Fault Coupling: FID12 in the slave not Power Reduction 2 Master
present

503
504

1951 524210 11 3-1-3 M/S Monitoring Fault Coupling: FID13 in the slave not Urea CONC Replace Master
present
1952 524211 11 3-1-3 M/S Monitoring Fault Coupling: FID14 in the slave not Urea Quality Error Master
present
1953 524212 11 3-1-3 M/S Monitoring Fault Coupling: FID15 in the slave not DEF Sensor Diag. Off Master
present
1954 524213 11 3-1-3 M/S Monitoring Fault Coupling: FID16 in the slave not DEF Sens Temp. Replace Master
present
1971 524230 11 3-1-5 Hardware failure Fehlercode aktiv im Slave Steuergerät. Inducement HW Failure Slave
1972 524231 11 3-1-5 Hardware tampering Fehlercode aktiv im Slave Steuergerät Inducement SCR Tamp. Slave
1973 524232 11 3-1-5 DEF Qualität Fehlercode aktiv im Slave Steuergerät Inducement Urea QTY Slave
1974 524233 11 3-1-5 DEF level Fehlercode aktiv im Slave Steuergerät Urea Level Error Slave
1975 524234 11 3-1-5 SCR Fehlercode aktiv im Slave Steuergerät Urea Temp. Error Slave
1976 524235 11 3-1-5 M/S Monitoring Fault Coupling: FID6 in the master not Urea Level Replace Slave
present
1977 524236 11 3-1-5 M/S Monitoring Fault Coupling: FID7 in the master not SCR System Afterrun Slave
present
1978 524237 11 3-1-5 M/S Monitoring Fault Coupling: FID8 in the master not Switch Off SCR System Slave
present
1979 524238 11 3-1-5 M/S Monitoring Fault Coupling: FID9 in the master not Disable SCR Dosing Slave
present

1980 524239 11 3-1-5 M/S Monitoring Fault Coupling: FID10 in the master not INH EAT Regeneration Slave
present


1981 524240 11 3-1-5 M/S Monitoring Fault Coupling: FID11 in the master not Power Reduction 1 Slave
present
1982 524241 11 3-1-5 M/S Monitoring Fault Coupling: FID12 in the master not Power Reduction 2 Slave
present
1983 524242 11 3-1-5 M/S Monitoring Fault Coupling: FID13 in the master not Urea CONC Replace Slave
present
1984 524243 11 3-1-5 M/S Monitoring Fault Coupling: FID14 in the master not Urea Quality Error Slave
present
1985 524244 11 3-1-5 M/S Monitoring Fault Coupling: FID15 in the master not DEF Sensor Diag. Off Slave
present
1986 524245 11 3-1-5 M/S Monitoring Fault Coupling: FID16 in the master not DEF Sens Temp. Replace Slave
present

505

Trouble shooting – Trouble shooting, hydraulics
11.5 Trouble shooting, hydraulics

11.5.1 Insufficient hydraulic power
Trouble shooting charge pressure,
example travel circuit If the charge pressure is not inside the nominal range,
no high pressure can be built up in the system.
Diesel engine running, travel lever

position "0"
Fig. 582: Charge pressure (6S) present

1 Charge pump
2 Variable displacement pump
3 Hydraulic motor
4 Charge pressure relief valve (example 30 bar)
5 Pressure relief valve (example 300 bar)
6 Pressure gauge, (6S) charge pressure, (6H) high pressure
7 Cooler (optional)
8 Filter
9 Connection for pump control

n If the charge pressure in the system drops, there is an internal

leak in the hydraulic circuit.
n But there may also be an internal leak in an external compo-
nent, which is also controlled by charge pressure. For example:
Brake valve, brake piston, etc.
n However, the steering pump could also be defective, because
the steering pump delivers the the oil that is fed into the closed
hydraulic circuit.
Trouble shooting closed travel cir-
cuit, example travel circuit
Fig. 583
10 Pressure resistance plugs
1. Connect pressure gauges (6) for high pressure and charge
pressure.
2. Disconnect hydraulic motor / ´hydraulic motors (3) and close
the ports with pressure resistant plugs (10).
ð The variable displacement pump can now be pressure

tested.

NOTICE!
Do not run the test over a longer period of time
(danger of overheating).
3. Start the engine and accelerate to full speed.

4. Shift the travel lever to forward and reverse.
5. Read the pressure gauges (6).Read the pressure gauge.
ð If the pressure gauges show the correct values, the vari-
able displacement pump is OK. The fault is in the
hydraulic motor /hydraulic motors (3).

11.5.2 Trouble shooting axial piston pumps

The following table should be of help when performing trouble-
shooting. This table is by no means complete. In practice you may
encounter problems that have not been listed here.
Procedure: 1. Always proceed systematically, even under time pressure.
Indiscriminate, ill-considered disassembly and changing of
settings can lead to a situation in which the original cause of
a fault can no longer be detected.
2. Get an overview over the function of the product in connec-
tion with the overall system.
3. Try to clarify whether the product was able to deliver the
required function within the overall system before the fault
occurred.
4. Develop a clear understanding of the troubleshooting
process. If necessary ask the direct operator or machine
driver.
5. Have conditions or area of application of the product been
changed?
6. Were changes (e.g. changeovers) or repairs made to the
overall system (machine/plant, electrics, control) or to the
product? If yes: What kind?
7. Has the product or the machine been operated as intended?
8. How does the fault occur?
Fault description Cause Remedy

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


No or insufficient Faulty mechanical drive (e.g. defective cou- Check and repair the drive.
volumetric flow pling).
Drive speed too low. Consult the service department.
Insufficient suction conditions, e.g. air in the Completely purge the axial piston
suction line, inadequate diameter of the suc- unit, fill the suction line with pres-
tion line, excessive viscosity of the pressure sure fluid.
Pressure fluid not within the optimal viscosity Use appropriate pressure fluid.
range.
External control and setting facilities defective. Check the external control.
Pilot or control pressure too low. Check pilot and control pressure,
consult the service department.
Functional disturbance in the control facility or Consult the service department.
the regulator on the axial piston unit.
Mechanical damage to the axial piston unit. Replace the axial piston unit.
No or insufficient Faulty mechanical drive (e.g. defective cou- Check and repair the drive.
pressure pling).
Poor drive power. Consult the service department.
Pressure fluid not within the optimal viscosity Use appropriate pressure fluid.
range.
External control and setting facilities defective. Check the external control.
Pilot or control pressure too low. Check pilot and control pressure.
Functional disturbance in the control facility or Consult the service department.
the regulator on the axial piston unit.
Wear of the axial piston unit. Replace the axial piston unit.
Mechanical damage to the axial piston unit. Replace the axial piston unit.
Drive unit defective (e.g. hydraulic motor or Check the drive unit, replace if
cylinder). necessary.
Fluctuations in pres- Axial piston unit not or insufficiently purged. Completely purge the axial piston
sure/volumetric flow unit.


Insufficient suction conditions, e.g. air in the Remove foreign bodies from
suction line, inadequate diameter of the suc- inside the suction line.
tion line, excessive viscosity of the pressure
Pressure fluid too hot Excessive input temperature on axial piston Check the system, e.g. malfunc-
unit. tion of the cooler, pressure fluid
level in tank too low.
Malfunction of the pressure control valves (e.g. Consult the service department.
high pressure relief valve, pressure override,
pressure controller).
Malfunction of the flushing valve (not for nom- Consult the service department.
inal size 18).
Wear of the axial piston unit. Replace the axial piston unit.
11.5.3 Trouble shooting axial piston motors

The following table should be of help when performing trouble-
shooting This table is by no means complete.
In practice you may encounter problems that have not been listed
here.
Procedure
1. Always proceed systematically, even under time pressure.
Indiscriminate, ill-considered disassembly and changing of
settings can lead to a situation in which the original cause of
a fault can no longer be detected.
2. Get an overview over the function of the product in connec-
tion with the overall system.
3. Try to clarify whether the product was able to deliver the
required function within the overall system before the fault
occurred.
4. Develop a clear understanding of the troubleshooting
process. If necessary ask the direct operator or machine
driver.
Try to detect changes to the overall system, the product is installed

in:
1. Have conditions or area of application of the product been
changed?
2. Were changes (e.g. changeovers) or repairs made to the
overall system (machine/plant, electrics, control) or to the
product? If yes: What kind?
3. Has the product or the machine been operated as intended?

4. How does the fault occur?

Unusual noises
Inappropriate fastening of the Check the fastening of the axial
axial piston unit piston unit as specified by the
machine or plant manufacturer.
Observe the tightening torques!
Inappropriate fastening of attach- Fasten attachment parts as speci-
ment parts, e.g. coupling and fied by the coupling or fittings
hydraulic lines. manufacturer.
Mechanical damage to the axial Replace the axial piston unit
piston unit.
Fluctuations in pressure/volu- Axial piston unit not or insuffi- Completely purge the axial piston
metric flow ciently purged. unit.
Operation data are not reached. Insufficient flow from hydraulic Check the function of the
pump hydraulic pump
Minimum displacement incorrectly Consult the service department.
set
External control and setting facili- Check the external control.
ties defective.
Control pressure too low Check control pressure, consult
the service department.
Functional disturbance in the con- Consult the service department.
trol facility or the regulator on the
axial piston unit.
Pressure fluid not within the Use appropriate pressure fluid.
optimal viscosity range.
Wear of the axial piston unit Replace the axial piston unit
Mechanical damage to the axial Replace the axial piston unit
piston unit.
Pressure fluid too hot. Excessive input temperature on Check the system, e.g. malfunc-
axial piston unit. tion of the cooler, pressure fluid
level in tank too low.
Malfunction of the pressure con- Consult the service department.
trol valves (e.g. high pressure
relief valve, pressure override,
pressure controller).
Failure of the flushing valve Consult the service department.
Wear of the axial piston unit Replace the axial piston unit

Trouble shooting – Trouble shooting, air conditioning system
11.6 Trouble shooting, air conditioning system

General n Visual inspection of the complete system for damage.
n Check the compressor mounting bracket on the vehicle engine
for tight fit and damage.
n Check the condition, alignment and tightness of the V-belt.
n Check the routing of refrigerant hoses and cables in the area of
the vehicle engine and transmission, as well as on the chassis
for chafing and rectify any detected faults. Ensure sufficient
clearance to hot parts, such as the exhaust; install a protective
shield, if necessary.
n Check the routing of refrigerant hoses and cables in the area of
the vehicle engine and transmission, as well as on the chassis
for chafing and rectify any detected faults. Ensure sufficient
clearance to hot parts, such as the exhaust; install a protective
shield, if necessary.
n Check the routing of hoses and hoses on the attachment box
or in the cabin.
n Check all hose and screw fittings for leaks.
n Check the fastening of the condenser unit.
n Clean the condenser fins, replace the condenser block if dam-
aged fins are found.
n Check the fastening of the evaporator unit.
n Check the function of evaporator and condenser fans.
n Check the electric control panel. If discolorations on conductors
are found, these should be replaced and possibly also the cor-
responding relays.
n Switch on the cooling system and check the refrigerant level.
n Filter/dryer and filter/dryer/fluid container combinations must
always be replaced after opening the refrigerant circuit. If these
are in service for more than 1 year, there is a risk that they may
be clogged by excessive absorption of moisture! The filter/
dryer should be replaced in regular intervals.
n Measure the temperature on the evaporator: Measure the
intake air temperature - Measure the blow out air temperature -
The temperature difference should be at least 8-10 K.
n Measuring the pressure in the refrigerant circuit
11.6.1 Trouble shooting in refrigerant circuit, basic principles

Requirements For trouble shooting two requirements must be fulfilled:
n Expert knowledge
n technical equipment

Technical equipment Pressure gauge and thermometer are the most important auxiliary
means for trouble shooting. The refrigerant states, such as over-
heating and undercooling, provide important information when per-
forming trouble shooting. Even your own senses should not be
underrated in trouble shooting. Bubbles in the inspection glass,
contamination and white frost are visible indicators. If the com-
pressor draws in wet steam, this is visible in the suction line and
may also be audibly perceptible. An overloaded compressor can
even be smelled.
The following tools and auxiliary means should be available for
trouble shooting:
n Service station
n Pressure gauge
n Thermometer
n dry nitrogen
n Refrigerant bottle for new refrigerant
n Container for old oil
n Vacuum pump
n Hoses
n Scales
n Suction station
n Leak detector
The measuring equipment must be checked at regular intervals.
Calibration can only be made by an approved testing authority.
Pressure gauge Most pressure gauges used in practice are (for cost reasons) over-
pressure gauges. These pressure gauges measure the excess
pressure in relation to the ambient pressure (air pressure). In order
to achieve the absolute (actual) pressure the ambient pressure
must be added to the pressure gauge reading. The absolute pres-
sure is needed for the calculation and determination of material
data.
Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = Overpressure (pressure gauge reading)

Example:
A totally empty air conditioning system holds an atmospheric pres-
sure of approx. Pambp = 1 bar.
Filling the system with refrigerant causes an overpressure of Pe = 3
bar.
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
Evacuating the system down to Pe = -0.6 bar, creates a "vacuum"
(negative overpressure).
Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
Fig. 584: Pressure gauge
Pressure gauge with saturation

temperature scale
Temperature scales on the pressure gauges always refer to the
absolute pressures Pabs. Please note that it is not possible to
measure a temperature directly with a pressure gauge. The indi-
cated temperatures are just reference values. Only the saturation
temperature is assigned to the measured pressure.
If the refrigerant is fluid, the temperature is below the saturation
temperature.
If the refrigerant is gaseous, the temperature is above the satura-
tion temperature.
Pressure gauges must indicate 0 bar when not connected to the
system.
Low pressure gauges have a blue, high pressure gauges a red
border.
Fig. 585: Absolute pressure gauge
Thermometer The thermometers used are normally digital thermometers with

surface or attachment sensors. Good heat insulation of the meas-
uring location must be assured, especially in case of big tempera-
ture differences. An economical use of heat-conduction paste is
recommended. If the measuring location is excessively contami-
nated, it needs to be cleaned and possibly treated with a fine
emery cloth. Only the temperature of the sensor is measured.
Temperature differences between the measured and the actual
values of a few degree Kelvin may be caused by missing heat
insulation and by insulating oxide layers on the cable.
Overheating
Due to its design a refrigerant compressor can only deliver gas-

eous or vaporous substances. Fluids are not compressible and
must therefore not enter into the compression chamber of the com-
pressor.

If the suction condition of the compressor is directly on the dew

line, an e.g. incorrect evaporator load can cause "wet suction".
This can lead to two processes, which are destructive for the com-
pressor. The liquid refrigerant washes off the lubricating film
between piston and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in the cylinder
causes a direct energy transfer from piston to cylinder cover during
compression. The valve plate may then be damaged by so-called
fluid strokes.
Apart from protecting the compressor against fluid, overheating
has further advantages. Since the fluid proportions in the drawn in
steam reduces the flow rate of the compressor, it may be
increased by a overheating. Overheating also improves the oil
recirculation.
Common overheating values The optimal overheating value is approx. 5 - 8 Kelvin. With this
overheating the maximum system power is reached. However, the
thermostatic expansion valve is unable to regulate this value
exactly. Depending on design and operating conditions over-
heating fluctuates within a range between 4 and 12 Kelvin. The
influence of the ambient air on the suction line causes an additional
overheating effect.
Overheating is calculated as fol- Δ t o2h = t o2h - t o

lows:
Δ t o2h, overheating at evaporator outlet in K
to2h, temperature at evaporator outlet in °C
to, evaporation temperature in °C
"h" represents "overheated"
Supercooling
It is the function of the expansion valve to reduce the refrigerant to

a lower pressure level (evaporation pressure) after it has been liq-
uefied. For an optimal function of the valve pure fluid must be
applied to its inlet port.
The refrigerant must "squeeze" (literally speaking) through a
throttle gap inside the expansion valve. When comparing a certain
mass of refrigerant in liquid and vaporous condition (under con-
stant pressure), the vaporous refrigerant requires a much higher
volume. That's why the vaporous refrigerant needs a much longer
time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve reduces the
flow rate and results in an undersupply of the evaporator with
refrigerant. Evaporation pressure and evaporator power will drop.
If the refrigeration system is operated with the "expansion valve
inlet" condition directly on the boiling curve, slightest fluctuations in
operating condition may cause a formation of bubbles in front of
the expansion element.

For this reason one shifts the condition "Expansion Valve Inlet"
away from the boiling curve into the fluid area and refers to this
condition as Supercooling. This supercooling ensures a fluid
supply in front of the expansion valve.
Common supercooling values In systems with fluid container the supercooling at the fluid con-
tainer outlet is approx. Zero "0" Kelvin (assumed that the system is
filled with the correct refrigerant quantity). In this case the fluid con-
tainer provides the required fluid supply.
Supercooling is calculated as fol- Δ t c2u = t c - t c2u

lows:
Δ t c2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in °C
tc, evaporation temperature in °C
"u" represents "supercooled"

Fig. 586: Refrigerant circuit with t, h- diagram

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

Fig. 587: Refrigerant circuit diagram

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

11.6.2 Trouble shooting procedure

Knowledge Trouble shooting is not possible with exact knowledge about the
system design, the installed components and their function in the
system trouble shooting is not possible:
Visual inspection With the appropriate experience some faults can be visually
detected or felt. Frequently occurring condenser soiling or forma-
tion of steam bubbles in the inspection glass can be quickly
detected.
In case of unusual formation of hoarfrost on the evaporator the
hoarfrost pattern provides useful information. Hoarfrost only occur-
ring at the inlet side is a clear indication of insufficient refrigerant
feed, which in turn indicates an incorrectly working expansion valve
or a lack of refrigerant.. Complete hoarfrost covering indicates load
problems, i.e. no or insufficient air flow.
Even overheating can sometimes be detected with the naked eye.
At the end of the evaporator there should be an area which is dry
or at least drier at evaporator temperatures above -2 °C.
The fluid line in the refrigeration system is warm. If a local cooling
can be felt or if condensation develops, this is a clear indicator for
an extreme pressure drop in the line. Similar phenomena can be
noticed in case of blocked filters.
Unusually cold pressure lines indicate "wet" intake of the com-
pressor.
The oil level in the compressor sight glass provides information
about the oil quantity and the oil recirculation in the system. How-
ever, the oil level may also be considerably influenced by con-
densing refrigerant. Discoloration informs about the state of the oil.
Water in the system can simply be detected through the inspection
glass with moisture indicator.
The dangerous part of common rules is that they apply

in most, but not in all cases. The refrigerant states in
the individual piping sections or components must
therefore be exactly determined by means of pressure
and temperature measurements.
Test prerequisites n Cooler and condenser are clean, clean if necessary.

n The ribbed belt for compressor and generator is correctly tight-
ened.
n All air ducts, covers and seals are OK and correctly fitted.
Flaps reach their end positions.
n The engine has operating temperature.
n Evaporator and heating (with highest fresh air fan speed) do
not draw leak air.
n The fresh air fan runs when the engine is running and the air
conditioning system is set to max. cooling power.

n Ambient temperature above 15 °C.

n The thermostat is correctly installed and the switching tempera-
tures are correct.
Measuring points and measure-

ments
Fig. 588: Flow diagram with measuring points

n C, condenser measuring points
n E, expansion valve measuring points
n O, evaporator measuring points
n V, compressor measuring points
The flow diagram contains "Minimum Requirements" which must
be fulfilled to be able to check the system or perform trouble
shooting.Temperature and pressure at the evaporator outlet can be
used to derive the overheating of the evaporator. Overheating is a
clear indicator for the evaporator filling level. In case of excessive
overheating the refrigerant quantity fed into the evaporator is too
low, in case of insufficient overheating it is too high. In individual
cases one must then check if this situation is caused by the expan-
sion element or by insufficient filling. A differentiation is only pos-
sible if there is a clear indicator for the refrigerant filling quantity.
Pressure and temperature at the condenser outlet can be used to
derive the supercooling. This can be used to assess the filling
quantity. In systems with fluid container the inspection glass is
most suitable to check the minimum filling quantity. Supercooling is
in this case the between indicator for overfilling.The hot gas tem-
perature can be used to check whether the compressor runs in the
permissible operating range.

Example: Measurement of over- n a) Which measuring equipment is required?

heating n b) Where to measure with which size?
n c) A pressure gauge connected to the evaporator indicates
"Peo2 = 1.7 bar". How high is the evaporator pressure "Po" ?
n d) How high is the evaporator temperature "to" ?
n e) A thermal sensor attached to the evaporator outlet meas-
ures the temperature "to2h = +3 °C". How high is the over-
heating „Δto2h“ ?
n f) Evaluation of the measured overheating.
Solution: n a) Pressure gauge, thermometer, steam table

n b) Evaporation pressure "Peo2" and temperature "to2h" are
measured at the same point on the evaporator outlet.
n c) Po = Peo2 + Pamb, "Evaporation pressure = pressure on evap-
orator + atmospheric pressure" = 1.7 bar + 1 bar = 2.7 bar.
n d) "Pc" = 2,7 bar can then be used to derive an condensing
temperature "to" of -2,2 °C from the steam table for R134a.
n e) Δto2h = to2h - to, „Overheating at evaporator outlet = evapo-
rator outlet temperature - evaporation temperature" = 3 °C -
(-2.2 °C) = 5.2 Kelvin.
n f) The determined overheating is within the usual range of 4 -
12 Kelvin.
Example: Measuring supercooling n a) Which measuring equipment is required?

n b) Where to measure with which size?
n c) A pressure gauge connected to the condenser indicates
"Pec2 = 15 bar". How high is the condensing pressure "Pc" ?
n d) How high is the condensing temperature "tc" ?
n e) A thermal sensor attached to the condenser outlet measures
the temperature "tc2u = 58 °C". How high is the supercooling
"Δtc2u" ?
n f) Evaluation of the measured supercooling.
Solution: n a) Pressure gauge, thermometer, steam table

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

Typical faults and possible causes Most of the faults in the refrigerant side can be assigned with the
help of the checklist. In many cases faults have a quite similar
appearance, but totally different causes. White frost on an evapo-
rator, for instance, may be quite normal. However, in this case the
expansion valve may be defective or there may be oil return prob-
lems.
The following list contains pressure values in a system, that can be
expected at various ambient temperatures (measured at medium
speeds).
Suction pressure (low pressure gauge)
Ambient temperature in °C Excess pressure in bar

25 approx. 2.0
30 approx. 2.5
35 approx. 3
High pressure (high pressure gauge)
Ambient temperature in °C Excess pressure in bar

25 approx. 8.0
35 approx. 13
40 approx. 16
45 approx. 18
Values effecting the operating pres- Since the pressures occurring in a refrigeration system are highly
sures dependent on environmental conditions, it is mandatory to know
these dependencies. The following table contains some of these
dependencies.
Measured variable Suction pressure High pressure

increases drops increases drops
Compressor increases X X
speed
drops X X
Vehicle interior increases X X
temperature
drops X X
Ambient tem- increases X X
perature
drops X X

Measured variable Suction pressure High pressure

Humidity increases X X
drops X X
Suction pressure too low (1), high

pressure too low to normal (2)
Fig. 589
Cause Possible effect Remedy

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

Suction pressure normal (1), high

pressure too high (2)
Fig. 590

Condenser dirty high hot gas temperature, low cooling power clean
Condenser fan failed high hot gas temperature, high pressure shut down repair
overfilled high hot gas temperature, low supercooling, low cooling Correct the filling
power capacity
Leak gas (air) high hot gas temperature, low measured supercooling, renew filling
low cooling power
Restriction between com- high hot gas temperature, low cooling power Check lines and
pressor and condenser valves

Suction pressure too high (1), high

pressure too low to normal (2)
Fig. 591

Compressor defective Cooling power too low Replace the compressor

Suction pressure too high (1), high

pressure too high (2)
Fig. 592

Expansion valve defective overheating too low, wet operation of compressor Replace the valve
Other faults
Symptom Cause Possible effect Remedy

Hot gas temperature Lack of refrigeration oil increased com- Refill refrigeration oil
too high, the hot gas pressor wear
line becomes so hot
that it cannot be
touched long with a
hand
Compressor does not Pressure switch or any other System stopped Check the control units,
start safety feature has triggered, check cause for switching
electrical fault, cylinder filled and rectify
with liquid refrigerant
Compressor switches Switching difference too small, Cycling of com- Check the control units,
continuously triggering of a switching ele- pressor, increased check cause for switching
ment (overpressure switch, low wear, too low and rectify
pressure switch), lack of refrig- cooling power
erant, fan defective, overfilled
Excessive overheating Expansion valve deadjusted or low cooling power, Replace the expansion
screen blocked, lack of refrig- hot gas tempera- valve, clean the screen,
erant tures too high fill in refrigerant, leak test
Hoarfrost on inlet side incorrectly working expansion too low infeed of Check the expansion
of evaporator valve, lack of refrigerant refrigerant into the valve, check the refrig-
evaporator erant filling

Symptom Cause Possible effect Remedy

Evaporator fully cov- Load problem, too low air flow low cooling power of Clean the evaporator,
ered with hoarfrost volume system check the evaporator fan
Fluid line is warm and Pressure drop in fluid line, filter low cooling power Eliminate the pressure
shows condensation dryer clogged drop, replace the filter
dryer
Exceptionally cold pres- "Wet intake" of the compressor low cooling power, Clean the compressor,
sure lines due to insufficient overheating excessive wear of replace if necessary,
of evaporator compressor replace the expansion
valve if necessary
Noise in system
Faults Possible cause Remedy

V-belt loose or excessively worn V-belt slips and generates Retention or renew the V-belt
noise
Magnetic clutch loud Magnetic clutch runs until high Repair or replace the mag-
pressure builds up, then the netic clutch
clutch starts to slip
Refrigerant compressor is loud Mounting bracket is loose, Repair the mounting bracket,
internal parts worn, low oil replace the compressor,
level in compressor renew the refrigeration oil
Fan is loud, fan motor excessively worn Replace the fan motor
Whistling and rattling noise in operation, V-belt pulley and bearing worn Replace the bearing, check
noticeable unevenness when turning by V-belt pulley for wear
hand
Rattling noise or vibration of high pressure System overfilled Draw out refrigerant
line, knocking noise in compressor, ball in
inspection glass floating at the top
Expansion valve loud excessive moisture in system Replace the dryer
Hissing noise in evaporator housing, on refrigerant level in system too Perform a leak test, fill up the
expansion valve, turbidity in inspection low system
glass or ball does not float
Inspection glass

Steam bubbles in inspection No supercooling before expansion valve, Fill up the system, replace the
glass lack of refrigerant in system, pressure loss in filter dryer, perform a leak test
system, supercooling caused by excessively
soiled filter dryer
Discolouration of inspection Lubricant destroyed by excessive operating Replace the refrigeration oil,
glass (black from inside) temperatures examine the temperature
increase


Moisture indicator changes Moisture level of drying agent too high Replace the filter dryer
to pink
Ball floats at bottom lack of refrigerant Fill the system
Monitoring devices

The high pressure contact System pressure exceeded, condenser Clean the condenser, replace
has switched off the mag- excessively soiled, condenser fan defective, the expansion valve, check the
netic clutch expansion valve defective condenser fan
The low pressure contact System pressure fallen short of, refrigerant Clean the evaporator, replace
has switched off the mag- level too low, expansion valve defective, the expansion valve, check the
netic clutch evaporator fan defective, heat load too low, evaporator fan
ambient temperature below 1.5 °C
The thermostat has Ambient temperature below 1°C, expansion Check the thermostat switching
switched off the magnetic valve defective, thermostat defective, air flow point, replace the expansion
clutch volume too low valve, clean the evaporator,
check the evaporator fan
11.6.3 Leak test
NOTICE!
The use of leak detection colouring matter is not per-
mitted, because its chemical composition is unknown
and its effect on compressor oil and rubber elements is
not predictable. The use of leak detection colouring
matter makes any warranty claims null and void.
Before starting the evacuation process, the refrigerant circuit is

filled with nitrogen through a pressure reducer valve (approx. 22
bar). After this all connections in the air conditioning system are
checked with the help of a suitable leak detection spray. A leak is
thereby indicated by means of foam bubbles.
A leak test is required if a pressure drop is noticed.
The leak test must be repeated after filling the air conditioning
system with refrigerant.
Leak test with electronic leak tester

Small leaks with only very low amounts of refrigerant escaping can
be detected, e.g. with an electronic leak tester. Such equipment is
able to detect leaks of less than 5 gr. per year.
The leak tester used must be specially designed for the refrigerant
composition in the air conditioning system. For example, leak
detectors for refrigerant R12 are not suitable for R134a, because
the refrigerant R134a is free of chlorine atoms, meaning that this
leak detector will not respond.
Fig. 593
Leak test with soap bubbles

Points susceptible for leakage are sprayed with a soapy solution.
Bubbles indicate the leak. The detection limit for R 134a is 250 g/
year.
Fig. 594: Soap bubble test
11.6.4 Checking the magnetic clutch

Cross-section of non-operated
magnetic clutch
If the coil (7) is not supplied with operating voltage, there is no con-
tact between the front plate of the clutch (1) and the V-belt pulley
(2). A spring presses the front plate away from the belt pulley. The
V-belt pulley rotates with the bearing (3) in idle speed, the com-
pressor does not work. When the coil is supplied with operating
voltage (12 or 24 V), a magnetic field is generated and pulls the
front plate of the clutch. Both front plate and compressor shaft (8)
are then driven by the V-belt pulley, the compressor works.
In case of excessive flatness faults or deviations the

magnetic clutch needs to be replaced.
Fig. 595

Checking the magnetic clutch

1. Take off the drive V-belt and rotate the V-belt pulley by hand
while the magnetic clutch is disengaged.
2. Measure the air gap on the magnetic clutch between V-belt
pulley (2) and thrust plate (1). The gap should be 0.4 to 0.8
mm.
3. Measure the voltage (nominal value: vehicle voltage)
4. Check the current consumption.
at 12 Volt vehicle voltage approx. 3.5 Amp.

Fig. 596: Measuring the air gap
at 24 Volt vehicle voltage approx. 1.75 Amp.
Overcurrent indicates a short circuit inside the mag-
netic coil.
No current indicates an interrupted electric circuit.

Special tools
12 Special tools

Special tools – Special tools, electrics
12.1 Special tools, electrics
Special tool kit
n Special pliers tool kit consisting of:

n BOMAG part-no.: 079 950 03
n - different tool heads
n - unlocking tools
n - manual
n - operating instructions and plastic box to store the different
Fig. 597: TOO-07995003 contacts
The contacts are not contained in the kit. Depending

on the contact to be crimped, the matching tool head
must be attached to the handle.
Equipment kit for special tool kit (1)
n Equipment kit
Fig. 598
Electric measuring case
n Electric measuring kit consisting of:

n - Prong-type instrument
n - Measuring adapter
n - Measuring cables
n - Screwdriver
Fig. 599 n - Other accessories

Special tools – Special tools, hydraulic system
12.2 Special tools, hydraulic system

12.2.1 Special tools, tests and adjustments
n Hydraulic test case, large
4 X 600 bar pressure gauges

4 X 60 bar pressure gauges
8 pressure test hoses
Fig. 600
n Hydraulic test case, small

2X 60 bar pressure gauge

2X 600 bar pressure gauges
4 pressure test hoses
Fig. 601
n Pressure test hoses

n 1000 mm BOMAG part-no.: 079 930 02
n 2500 mm BOMAG part-no.: 079 930 03
Fig. 602

n Pressure gauge
n 60 bar BOMAG part-no.: 059 721 07
n 600 bar BOMAG part-no.: 059 721 04
Fig. 603
n Adapter for pressure test hose

Fig. 604
n Gear pump testing device

Fig. 605

n Vacuum pump for hydraulic oil tank

n BOMAG part-no.: 007 610 04 (12 Volt)
n BOMAG part-no.: 007 610 24 (24 Volt)
Fig. 606
12.2.2 Special tools for flushing
The following list informs about special tools for

flushing. You should choose the corresponding tool for
the work to be carried out.
n Filling and filtering unit

Fig. 607
n Flushing filter (S connection)

n Filter element 1μ
n Flushing hose 20S - 25S (2 pieces)
n Screw socket R1“ - 25S (2 pieces)
Fig. 608
n Flushing filter (L connection)

n Filter element
n Flushing hose 15L (2 pieces)
n Screw socket R3/4“ -- 15L (2 pieces)
Fig. 609

n SAE-flange 1“ - 20S
n O-ring
n BOMAG part-no. 062 203 30
Fig. 610
n Flanged plate 1“ - 25S

n O-ring
n BOMAG part-no. 062 202 22
Fig. 611
n Reducing fitting 18L - 15L

Fig. 612
n Reducing fitting 25S - 20S

Fig. 613

n Reducing fitting 20S - 16S

Fig. 614
n Connecting socket 15L

Fig. 615
n Connecting socket 18L

Fig. 616
n Connecting socket 16S

Fig. 617

n Connecting fitting 20S

Fig. 618
n Connecting fitting 25S

Fig. 619
n Angular fitting 18L

Fig. 620
n Elbow fitting 16L

Fig. 621

n Elbow 20S
Fig. 622
n Elbow 25S
Fig. 623
n Pipe connection 16S - 16S

Fig. 624
n Connecting hose 15L

Fig. 625

Special tools – Special tools for oscillating articulated joint
12.3 Special tools for oscillating articulated joint

n Pressing device for rocker bearings
Fig. 626
n Pressing bushing for outer rocker bearing race
Fig. 627
n Pressing bushing for inner rocker bearing race
Fig. 628
n Guide pin
Fig. 629

Special tools – Special tools for oscillating articulated joint
n Clamping device
Fig. 630
n Disassembly device
Fig. 631

Special tools – Special tools, drum
12.4 Special tools, drum

n Disassembly device for side plate
Fig. 632
n Assembly device for side plate

Fig. 633
n Assembly device for coupling hub and flanged hub
Fig. 634
n Pressing plate for cylinder roller bearing
Fig. 635

Special tools – Special tools, drum
n Pressing plate for travel bearing
Fig. 636
n Pressing bushing for radial seal
Fig. 637
n Lifting device for exciter unit

Fig. 638

Special tools – List of special tools
12.5 List of special tools

Rotation angle disc
BOMAG 057 250 72
Fig.

Appendix
Appendix

Appendix
A Supplier documentation
A.A Travel pump / vibration pump
A.B Vibration motor
A.C Steering valve
A.D Axle
A.E Repair instructions, H1 060/080/110
A.F Service - Manual, H1 060/080/110
A.G Reduction gear drum, 715C3B
B Circuit diagrams
B.A Hydraulic diagram, 353
B.B Hydraulic diagram, 356
B.C Wiring diagram, 327

Supplier documentation
A Supplier documentation
A.A Travel pump / vibration pump

069/078, 089/100,
115/130, 147/165
H1 Closed Circuit
Axial Piston Pumps
Service Manual
H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Axial Piston Pumps Service Manual
Revisions
History of Revisions Table of Revisions

Date Page Changed Rev.
November 2012 all add 069 frame size AL

June 2011 various add protection bracket for automotive control AK
January 2011 50 Aux. pad alignment pins changed to G450 AJ
August 2010 last new last page AI
March 2010 various Added automotive control AH
October 2009 various various corrections and additions AF
April 2009 various Added 089/100 AE
March 2009 34, 36 text edits AD
December 2008 23, 45 Removed special tool part numbers AC
April 2008 various Added 115/130 AB
Jun 2007 - First edition AA
© 2012 Sauer-Danfoss. All rights reserved.
Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and

other printed material. Sauer -Danfoss reserves the right to alter its products without
prior notice. This also applies to products already ordered, provided that such alterations
can be made without affecting agreed specifications. All trademarks in this material
are properties of their respective owners. Sauer-Danfoss, the Sauer-Danfoss logotype,
the Sauer-Danfoss S-icon, PLUS+1™, What really matters is inside® and Know-How in
Motion™ are trademarks of the Sauer-Danfoss Group.
2 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Contents
Introduction Overview............................................................................................................................................................ 5
Warranty............................................................................................................................................................. 5
General instructions....................................................................................................................................... 5
Safety Precautions.......................................................................................................................................... 6
Unintended Machine Movement......................................................................................................... 6
Flammable Cleaning Solvents............................................................................................................... 6
Fluid Under Pressure................................................................................................................................. 6
Personal Safety........................................................................................................................................... 6
Hazardous Material................................................................................................................................... 6
Symbols Used in Sauer-Danfoss Literature............................................................................................ 7
Design................................................................................................................................................................. 8
The System Circuit.......................................................................................................................................... 9
The Basic Closed Circuit........................................................................................................................... 9
Case Drain and Heat Exchanger........................................................................................................... 9
Operation Pressure Limiter Valves................................................................................................................................11

High Pressure Relief Valve (HPRV) and Charge Check.....................................................................12
Bypass Function.............................................................................................................................................13
Charge Pressure Relief Valve.....................................................................................................................13
Electrical Displacement Control (EDC)..................................................................................................14
EDC Principle.............................................................................................................................................14
EDC Operation .........................................................................................................................................14
Manual OverRide (MOR).............................................................................................................................15
Operating Parameters Overview..........................................................................................................................................................16

Input Speed.....................................................................................................................................................16
System Pressure.............................................................................................................................................16
Charge Pressure.............................................................................................................................................17
Charge Inlet Pressure...................................................................................................................................17
Case Pressure..................................................................................................................................................17
Temperature and Viscosity.........................................................................................................................18
Temperature..............................................................................................................................................18
Viscosity......................................................................................................................................................18
Technical Specifications Overview..........................................................................................................................................................19

General Specifications.................................................................................................................................19
Physical Properties........................................................................................................................................19
Operating Parameters ................................................................................................................................20
Fluid Specifications.......................................................................................................................................20
Fluid and Filter Fluid and Filter Recommendations.........................................................................................................21

Maintenance Hazardous Material.................................................................................................................................21
Pressure Measurements Port Locations and Gauge Installation..................................................................................................22
520L0848 • Rev AL • November 2012 3

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Contents
Specialized Tools Overview..........................................................................................................................................................23

Shaft Seal Installation Tool.........................................................................................................................23
Initial Startup Procedures General . ...........................................................................................................................................................24

Start-Up Procedure.......................................................................................................................................24
Troubleshooting Overview..........................................................................................................................................................26
Safety Precautions........................................................................................................................................26
Electrical Troubleshooting.........................................................................................................................26
System Operating Hot.................................................................................................................................27
Integral Filter Bypass....................................................................................................................................27
Neutral Difficult or Impossible to Find...................................................................................................27
System Will Not Operate in Either Direction........................................................................................28
System Noise or Vibration..........................................................................................................................28
Sluggish System Response........................................................................................................................29
Transmission Operates Normally in One Direction Only................................................................29
Inspections and Pump Adjustment.........................................................................................................................................30

Adjustments Standard Procedures....................................................................................................................................30
Charge Pressure Relief Valve Adjustments...........................................................................................31
Pressure Limiter Adjustment.....................................................................................................................32
Engaging the Bypass Function.................................................................................................................34
Displacement Limiter Adjustment..........................................................................................................35
Control Neutral Adjustment......................................................................................................................36
Mechanical Neutral Adjustment..............................................................................................................38
Pump setup................................................................................................................................................38
Servo Adjustment....................................................................................................................................40
Minor Repair Standard Procedures, Removing the Pump.........................................................................................41

EDC Control.....................................................................................................................................................42
Control Solenoids..........................................................................................................................................43
Automotive Control......................................................................................................................................44
Bearing and Shaft Replacement..............................................................................................................46
Bearing and Shaft Replacement..............................................................................................................47
External Filter Replacement......................................................................................................................48
Filter Bypass Valve and Filter Bypass Switch........................................................................................49
Charge Pump..................................................................................................................................................50
Charge pump removal (removable auxiliary pad/cover)..........................................................50
Charge Pump Removal (integrated auxiliary pad).......................................................................51
High Pressure Relief Valves (HPRV).........................................................................................................53
PressureLimiter Valve Replacement.......................................................................................................55
Torque Chart Fastener Size and Torques..........................................................................................................................56

Plug Size and Torques..................................................................................................................................56
Fasteners and Plugs......................................................................................................................................57

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Introduction
Overview This manual includes information on the installation, maintenance, and minor repair
of H1 pumps. It includes a description of the unit and its individual components,
troubleshooting information, and minor repair procedures.
Performing minor repairs requires the unit to be removed from the vehicle/machine.
Thoroughly clean the unit before beginning maintenance or repair activities. Since dirt
and contamination are the greatest enemies of any type of hydraulic equipment, follow
cleanliness requirements strictly. This is especially important when changing the system
filter and when removing hoses or plumbing.
A worldwide network of Sauer-Danfoss Authorized Service Centers is available for major

repairs. Sauer-Danfoss trains and certifies Authorized Service Centers on a regular basis.
You can locate your nearest Authorized Service Center using the distributor locator at
www.sauer-danfoss.com.
Warranty Performing adjustments and minor repairs according to the procedures in this manual
will not affect your warranty. Major repairs requiring the removal of a unit’s center
section, servo sleeves, or front flange voids the warranty unless a Sauer-Danfoss
Authorized Service Center performs them.
General instructions Follow these general procedures when repairing H1 variable displacement closed circuit
pumps.
w Remove the Unit

Prior to performing repairs, remove the unit from the vehicle/machine. Chock the wheels
on the vehicle or lock the mechanism to inhibit movement. Be aware that hydraulic fluid
may be under high pressure and/or hot. Inspect the outside of the pump and fittings for
damage. Cap hoses after removal to prevent contamination.
e Keep it Clean
Cleanliness is a primary means of assuring satisfactory pump life on either new or
repaired units. Clean the outside of the pump thoroughly before disassembly. Take care
to avoid contamination of the system ports. Cleaning parts by using a clean solvent wash
and air drying is usually adequate.
As with any precision equipment, you must keep all parts free of foreign material and
chemicals. Protect all exposed sealing surfaces and open cavities from damage and
foreign material. If left unattended, cover the pump with a protective layer of plastic.
d Replace all O-rings and Gaskets

We recommend you replace all O-rings and seals during service. Lightly lubricate O-rings
with clean petroleum jelly prior to assembly.
t Secure the Unit

For repair, place the unit in a stable position with the shaft pointing downward. It will be
necessary to secure the pump while removing and torquing fasteners and components.

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Introduction
Safety Precautions Always consider safety precautions before beginning a service procedure. Protect
yourself and others from injury. Take the following general precautions whenever servicing a
hydraulic system.
Unintended Machine Movement

W Warning
Unintended movement of the machine or mechanism may cause injury to the technician
or bystanders. To protect against unintended movement, secure the machine or disable/
disconnect the mechanism while servicing.
Flammable Cleaning Solvents

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

W Warning
Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin
causing serious injury and/or infection. This fluid may also be hot enough to cause burns.
Use caution when dealing with hydraulic fluid under pressure. Relieve pressure in the
system before removing hoses, fittings, gauges, or components. Never use your hand
or any other body part to check for leaks in a pressurized line. Seek medical attention
immediately if you are cut by hydraulic fluid.
Personal Safety
W Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all
times.
Hazardous Material
W Warning
Hydraulic fluid contains hazardous material. Avoid prolonged contact with
hydraulic fluid. Always dispose of used hydraulic fluid according to state, and federal
environmental regulations.

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Introduction
Symbols Used in Sauer-  WARNING may result in injury  Clean area or part
Danfoss Literature
 CAUTION may result in damage to  Be careful not to scratch or damage
product or property
 Note correct orientation
 Non-reusable part, use a new part
 Torque specification
 External hex head
 Pull out with tool – press fit
 Internal hex head
 Cover splines with installation
 Lubricate with hydraulic fluid sleeve
 Inspect for wear or damage  Pressure measurement/gauge

location or specification
The symbols above appear in the illustrations and text of this manual. They are intended
to communicate helpful information at the point where it is most useful to the reader.
In most instances, the appearance of the symbol itself denotes its meaning. The legend
above defines each symbol and explains its purpose.

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Introduction
Design Sauer-Danfoss H1 closed circuit piston pumps convert input torque into hydraulic power.
The input shaft transmits rotational force to the cylinder block. Bearings at the front and
rear of the pump support the shaft. Splines connect the shaft to the cylinder block. A
lip-seal at the front end of the pump prevents leakage where the shaft exits the pump
housing. The spinning cylinder block contains nine reciprocating pistons. Each piston
has a brass slipper connected at one end by a ball joint. The block spring, ball guide, and
slipper retainer hold the slippers to the swashplate. The reciprocating movement of the
pistons occurs as the slippers slide against the inclined swashplate during rotation. Via
the valve plate, one half of the cylinder block is connected to low pressure and the other
half to high pressure. As each piston cycles in and out of its bore, fluid is replenished
by charge flow and displaced to the outlet thereby imparting hydraulic power into the
system. A small amount of fluid is allowed to flow from the cylinder block/valve plate
and slipper/swashplate interfaces for lubrication and cooling. Case drain ports return this
fluid to the reservoir.
The angle of the swashplate controls the volume and direction of fluid displaced into
the system. The servo piston controls the angle of the swashplate. The pump control, by
varying the pressure at the servo piston, controls the piston’s position. An electric signal
to the control coils transmits the command from the operator to the pump. Mechanical
feedback of the swashplate position to the control through the feedback pins allows for
very precise displacement control and increases overall system stability. Non-feedback
control options do not use the mechanical feedback link.
Cross section view

Electric displacement control Servo piston Auxiliary mounting pad “B”
Valve plate
Swashplate feedback pin
Piston
Slipper
Shaf t seal
Shaf t
Swashplate Cylinder block Charge pump P106 045E

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Introduction
The System Circuit The Basic Closed Circuit

Hydraulic lines connect the main ports of the pump to the main ports of the motor. Fluid
flows in either direction from the pump to the motor and back. Either of the hydraulic
lines can be under high pressure. In pumping mode the position of the pump swashplate
determines which line is high pressure as well as the direction of fluid flow.
Case Drain and Heat Exchanger

The pump and motor require case drain lines to remove hot fluid from the system. The
pump and motor drain from the topmost port to ensure the cases remain full of fluid. The
motor case drain can connect to the lower drain port on the pump housing or it can tee
into the case drain line upstream of the heat exchanger. A heat exchanger with bypass
valve cools the case drain fluid before it returns to the reservoir.
System Circuit Diagram
Heat Exchanger
Bypass Valve System Pressure
Reservoir
Displacement Control Servo Pressure
Charge/Low Loop Pressure

Heat Exchanger
Suction/Case Drain/
Charge Pump System Return
Bent Axis Variable

Servo Control Displacement Motor
Cylinder
Charge Filter
Motor Swashplate
Charge Check/
Variable High Pressure Relief Valve
Displacement Output
Pump Shaft
Loop
Flushing
Valve
Charge
Pressure
Pressure
Relief
Limiter
Valve
Valve
To Pump
Case
Input To
Shaft Motor Synchronizing
Case Shaft
Pump Swashplate
Charge Check/High Pressure Relief Valve P104 464E

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Introduction
System Schematic
C2 C1
M3
M5 L2 N
T A
M4 A
n
min.
flow out A disp.
L4 CW T3
T T
L3
M3
B
L2 L1 S B L1 M4
P106 252E
Above schematic shows the function of a hydrostatic transmission using an H1 axial piston variable displacement
pump with electric displacement control (EDC) and a series 51-1 bent axis variable displacement motor with two-
position control (T1).
10 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Operation
Pressure Limiter Valves Pressure limiter valves provide system pressure protection by compensating the pump
swashplate position when the set pressure of the valve is reached. A pressure limiter is a
non-dissipative (non heat generating) pressure regulating system.
Each side of the transmission loop (and each section of the tandem pump) has a
dedicated pressure limiter valve that is set independently. Each system port may have a
different pressure limiter setting.
The pressure limiter setting is the maximum differential pressure between the high
and low loops. When the pressure limiter setting is reached, the valve ports oil to the
lowpressure side of the servo piston. The change in pressure across the servo rapidly
reduces pump displacement. Fluid flow from the valve continues until the resulting drop
in pump displacement causes system pressure to fall below the pressure limiter setting.
An active pressure limiter destrokes the pump to near neutral when the load is in a
stalled condition. The pump swashplate moves in either direction necessary to regulate
the system pressure, including increasing stroke when over-running or over-center.
The pressure limiter is optional on H1 pumps.
069/078/089/100 Single Pumps 115/130/147/165 Single Pumps
520L0848 • Rev AL • November 2012 11

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Operation
High Pressure Relief All H1 pumps have a combination high pressure relief and charge check valve. The high-
Valve (HPRV) pressure relief function is a dissipative (heat generating) pressure control valve for the
and Charge Check purpose of limiting excessive system pressures. The charge check function replenishes
the low-pressure side of the working loop with charge oil. Each side of the transmission
loop has a dedicated non-adjustable, factory-set HPRV valve. When system pressure
exceeds the factory setting of the valve, it passes oil from the high pressure system loop
into the charge gallery and the low pressure system loop via the charge check.
The pump may have different pressure settings at each system port. When an HPRV valve
is used in conjunction with a pressure limiter, the HPRV valve is always factory set above
the setting of the pressure limiter. The system pressure shown in the order code for
pumps with only HPRV is the HPRV setting. The system pressure shown in the order code
for pumps with both pressure limiter and HPRV is the pressure limiter setting.
HPRVs are set at low flow condition. Any application or operating condition which
leads to elevated HPRV flow will cause a pressure rise with flow above the valve setting.
Consult factory for application.
High Pressure Relief and Charge Check Pressures marked on HPRV valve
Valve with Bypass Valve in charging mode Mark Pressure bar [psi]
20 200 [2900]
25 250 [3626]
30 300 [4351]
35 350 [5076]
37 370 [5366]
40 400 [5801]
42 420 [6092]
45 450 [6527]
P003 269 48 480 [6962]
51 510 [7397]
High Pressure Relief and Charge Check

Valve with Bypass Valve in relief mode
P003 268
12 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Operation
Bypass Function The HPRV valve also provides a loop bypass function when each of the two HPRV
hex plugs are mechanically backed out 3 full turns. Engaging the bypass function
hydraulically connects both A & B sides of the working loop to the common charge
gallery. The bypass function allows you to move a machine or load without rotating the
pump shaft or prime mover.
CCaution
The HPRV valves are not tow valves. Damage to the pump and motor can occur when
operating without charge flow. Limit vehicle/machine movement to no more than 20%
of maximum speed and no longer that three minutes. Reseat the HPRV valves after
vehicle/machine movement.
Charge Pressure Relief The charge pressure relief valve maintains charge pressure at a designated level above
Valve case pressure. The charge pressure relief valve is a direct acting poppet valve that opens
and discharges fluid to the pump case when pressure exceeds a designated level. This
level is nominally set with the pump running at 1800 min-1 (rpm). For external charge
flow, the CPRV is set with with a flow of 30 l/min [8 US gal/min]. In forward or reverse,
charge pressure will be slightly lower than in neutral position. The model code of the
pump specifies the charge relief setting.
Typically charge pressure increases from 1.2-1.5 bar per 10 l/min [17.4-21.8 psi per
2.64 US gal/min] case flow.
Charge Pressure Relief Valve
520L0848 • Rev AL • November 2012 13
12 11009999 • Rev A-B • Nov 2006

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Operation
Electrical Displacement EDC Principle

Control (EDC) The Electrical Displacement Control (EDC) consists of proportional solenoids on each
side of a three-position, four-way porting spool. The proportional solenoid applies
a force to the spool, which ports hydraulic fluid to either side of the servo piston.
Differential pressure across the servo piston rotates the swashplate, changing the
pump‘s displacement from full displacement in one direction to full displacement in the
opposite direction.
EDC Operation
H1 EDC’s are current driven controls requiring a Pulse Width Modulated (PWM) signal.
Pulse width modulation allows more precise control of current to the solenoids. The
PWM signal causes the solenoid pin to push against the porting spool, which pressurizes
one end of the servo piston, while draining the other. Pressure differential across the
servo piston moves the swashplate. A swashplate feedback link, opposing control
links, and a linear spring provide swashplate position force feedback to the solenoid.
The control system reaches equilibrium when the position of the swashplate spring
feedback force exactly balances the input command solenoid force from the operator.
As hydraulic pressures in the operating loop change with load, the control assembly and
servo/swashplate system work constantly to maintain the commanded position of the
swashplate.
The EDC incorporates a positive neutral dead-band as a result of the control spool
porting, spring preload from the servo piston assembly, and the linear control spring.
Once the neutral threshold current is reached, the swashplate position becomes
directly proportional to the control current. To minimize the effect of the control neutral
deadband, we recommended the transmission controller or operator input device
incorporate a jump up current.
The neutral position of the control spool does provide a positive preload pressure to
each end of the servo piston assembly.
When the control input signal is either lost or removed, or if there is a loss of charge
pressure, the spring-loaded servo piston automatically returns the pump to neutral
position.
The EDC is a displacement (flow) control. Pump swashplate position is proportional

to the input command and therefore vehicle or load speed (excluding influence of
efficiency), is dependent only on the prime mover speed or motor displacement.
EDC Schematic Diagram
M14
C2 C1
F00B F00A T P
Feedback from
Swash plate P003 478E
14 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Operation
Manual OverRide (MOR) All controls are available with a Manual OverRide (MOR) for temporary actuation of the
control to aid in diagnosis. FNR controls always include MOR functionality.
W Warning
Depressing the plunger causes the pump to go into stroke which will move the machine
or mechanism. Ensure the vehicle or machine is in a safe condition (wheels off the
ground or mechanism disconnected) before attempting to use the MOR feature.
An O-ring seals the MOR plunger. Initial actuation of the function requires additional
force to overcome the O-ring resistance. A threshold force of 45 N is typically required at
first actuation. Additional actuations typically require a threshold force of 12 N to move
the MOR plunger. Force required to keep the pump at full stroke is typically 51 N. Do not
expect proportional control of the pump using the MOR.
Refer to control flow table for the relationship of solenoid to direction of flow.
Control Solenoid
P003 204
EDC Schematic Diagram Showing Manual OverRide
M14
C2 C1
F00B F00A T P
Feedback from
Swash plate P003 205E
520L0848 • Rev AL • November 2012 15

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Operating Parameters
Overview This section defines the operating parameters and limitations for H1 pumps with regard
to input speeds and pressures. For actual parameters, refer to the operating parameters
for each displacement.
Input Speed Minimum speed is the lowest input speed recommended during engine idle condition.
Operating below minimum speed limits the pump’s ability to maintain adequate flow for
lubrication and power transmission.
Rated speed is the highest input speed recommended at full power condition.
Operating at or below this speed generally yields satisfactory product life.
Maximum speed is the highest operating speed permitted. Exceeding maximum speed
reduces product life and can cause loss of hydrostatic power and braking capacity. Never
exceed the maximum speed limit under any operating conditions.
When determining speed limits for a particular application see Sauer-Danfoss

publication BLN-9884 Pressure and speed limits.
WWarning
Unintended vehicle or machine movement hazard
Exceeding maximum speed may cause a loss of hydrostatic drive line power and braking
capacity. You must provide a braking system, redundant to the hydrostatic transmission,
sufficient to stop and hold the vehicle or machine in the event of hydrostatic drive power
loss.
System Pressure System pressure is the differential pressure between system ports A & B. It is the
dominant operating variable affecting hydraulic unit life. High system pressure, which
results from high load, reduces expected life. Hydraulic unit life depends on speed and
normal operating—or weighted average—pressure that you can only determine from a
duty cycle analysis.
Applied pressure is the chosen application pressure in the order code for the pump.
This is the pressure at which the drive line generates maximum pull or torque in the
application.
Rated pressure is the design pressure for the pump. Applications with applied pressures
at or below this pressure should yield satisfactory unit life given proper component
selection.
Maximum pressure (peak) is the highest intermittent pressure allowed under any
circumstances. Applications with applied pressures between rated and maximum require
factory approval with complete application, duty cycle, and life expectancy analysis.
All pressure limits are differential pressures referenced to low loop (charge) pressure.
Subtract low loop pressure from gauge readings to compute the differential.
16 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Charge Pressure An internal charge relief valve regulates charge pressure. The internal charge pump
supplies the control with pressure to operate the swashplate and to maintain a minimum
pressure in the low side of the transmission loop.
Minimum charge pressure is the lowest pressure safe working conditions allow in the
system loop. Minimum control pressure requirements are a function of speed, pressure,
and swashplate angle, and may be higher than the minimum charge pressure shown in
the technical specifications.
Maximum charge pressure is the highest charge pressure the charge relief adjustment
allows, and which provides normal component life. You can use elevated charge pressure
as a secondary means to reduce the swashplate response time.
The charge pressure setting listed in the order code is the set pressure of the charge
relief valve with the pump in neutral, operating at 1800 min-1 (rpm), and with a fluid
viscosity of 32 mm2/sec [150 SUS]. The charge pressure setting is referenced to case
pressure (the differential pressure above case pressure).
Charge Inlet Pressure At normal operating temperature charge inlet pressure must not fall below rated charge
inlet pressure.
Minimum charge inlet pressure is only allowed at cold start conditions. In some
applications, you may need to warm up the fluid (start the prime mover without using
the vehicle/machine functions) before moving the vehicle or operating the machine.
Case Pressure Do not exceed rated case pressure under normal operating conditions. During cold start,
keep case pressure below maximum intermittent case pressure. Size drain plumbing
accordingly.
CCaution
Possible component damage or leakage
Operation with case pressure in excess of stated limits may damage seals, gaskets, and/or
housings, causing external leakage. This condition may also affect performance since
charge and system pressure are referenced to case pressure.
520L0848 • Rev AL • November 2012 17

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Temperature and Temperature

Viscosity High temperature limits apply at the hottest point in the transmission loop, which is
normally the motor case drain. Ensure the system generally runs at or below the rated
temperature. The maximum intermittent temperature is based on material properties:
Never exceed it.
Cold oil will generally not affect the durability of the transmission components, but it
may affect the ability of oil to flow and transmit power: therefore ensure temperatures
remain 16 °C [30 °F] above the pour point of the hydraulic fluid. Minimum temperature
relates to the physical properties of component materials.
Size heat exchangers to keep the fluid within these limits. Sauer-Danfoss recommends
testing to verify that these temperature limits are not exceeded.
Viscosity
For maximum efficiency and bearing life, ensure the fluid viscosity remains in the
recommended range. Minimum viscosity should be encountered only during brief
occasions of maximum ambient temperature and severe duty cycle operation. Maximum
viscosity should be encountered only at cold start.
18 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Technical Specifications
Overview Specifications and operating parameters for pumps are given here for reference.
General Specifications Design Axial piston pump of cradle swashplate design with variable displacement
Direction of rotation Clockwise, counterclockwise
Pipe connections Main pressure ports: SAE straight thread O-ring boss
Remaining ports: SAE straight thread O-ring boss
Recommended installation Pump installation recommended with control position on the top or side.
position Consult Sauer-Danfoss for non conformance to these guidelines.
The housing must always be filled with hydraulic fluid.
Rear case drain recommended
Auxiliary cavity pressure Will be equal to pump case pressure of rear housing.
Please verify mating pump shaft seal capability.
Physical Properties
Frame size
Feature Unit
069 078 089 100 115 130 147 165
Displacement cm3 [in3] 69 [4.21] 78 [4.76] 89 [4.76] 100 [4.76] 115.2 [7.03] 130.0 [7.93] 147 [8.97] 165 [10.07]
Oil volume liter [US gal] 2.0 [0.5] 3.0 [ 0.8]
Mounting flange SAE flange, size C (SAE J 744) mounting pad SAE flange, size D (SAE J 744) mounting pad
SAE A, SAE B, SAE B-B,

Auxiliary mounting SAE A, SAE B, SAE B-B, SAE C
SAE C, SAE D
Splined:
Splined: 27-teeth 16/32,
Shafts
21-teeth 16/32, 23-teeth 16/32, 14-teeth 12/24 13-teeth 8/16
Suction port 1.625-12UN-2B [1 5/8-12UN-2B]

Ø31.5 - 450 bar split flange boss per ISO 6162
Ø25.4 - 450 bar split flange boss per ISO 6162
Main port configuration M12x1.75
M12x1.75
Case drain ports L1, L3 (SAE O-ring boss). 0.875-12UNF-2B [7/8-12UNF-2B] 1.0625-12UNF-2B [1 1/16-12UNF-2B]
Case drain ports L2, L4 (SAE O-ring boss) 1.0625-12UNF-2B [1 1/16-12UNF-2B] 1.3175-12UNF-2B [1 5/16-12UNF-2B]
prefered usage
Other ports SAE O-ring boss. See installation drawings.

Customer interface threads Metric fastener
520L0848 • Rev AL • November 2012 19

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Technical Specifications
Frame size
Feature Unit
069 078 089 100 115 130 147 165
Minimum 500
Minimum for full
1200
Input speed performance min-1 (rpm)
Rated 3500 3200 3000
Maximum 4000 3400 3100
Rated 450 420 450 400
400 [5800]
[6525] [6090] [6525] [5800]
System pressure Maximum bar [psi] 480 450 480 450
450 [6525]
[6960] [6525] [7000] [6525]
Minimum low loop 10 [150]
Minimum 10 [150] 16 [232]
Charge Pressure bar [psi]
Maximum 35 [508]
Minimum (at corner
17 [ 247]
for EDC and FNR)
Control Pressure Minimum (at corner bar [psi]
20 [290] 17 [247]
for NFPE)
Maximum 40 [580]
Rated bar (absolute) 0.7 [9]
Charge pump inlet
Minimum (cold start) [in Hg vacuum] 0.2 [24]
pressure
Maximum bar [psi] 4.0 [58]
Rated 3.0 [40]
Case pressure bar [psi]
Maximum 5.0 [75]
Fluid Specifications Feature Unit Value

Minimum 7 [49]
mm2/sec
Ratings and data are based Viscosity Recommended Range 12-80 [66-370]
[SUS]
on operation with premium Maximum 1600 [7500]
petroleum-based hydraulic Minimum -40 [-40]
fluids containing oxidation, Temperature Range Rated O
C [OF] 104 [220]
rust, and foam inhibitors. Maximum intermittent 115 [240]
Cleanliness per ISO 4460 22/18/13
Filtration Efficiency (charge pressure filtration) b15-20 = 75 (b10≥10)
(recommended b-ratio
minimum) Efficiency (suction and return line filtration) b35-45 = 75 (b10≥2)
Recommended inlet screen mesh size mm 100 - 125
20 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Fluid and Filter Maintenance
Fluid and Filter To ensure optimum life, perform regular maintenance of the fluid and filter.
Recommendations Contaminated fluid is the main cause of unit failure. Take care to maintain fluid
cleanliness when servicing.
Check the reservoir daily for proper fluid level, the presence of water, and rancid fluid
odor. Fluid contaminated by water may appear cloudy or milky or free water may settle
in the bottom of the reservoir. Rancid odor indicates the fluid has been exposed to
excessive heat. Change the fluid and correct the problem immediately if these conditions
occur.
Inspect vehicle for leaks daily. Change the Fluid and Filter Change Interval
fluid and filter per the vehicle/machine Reservoir type Max oil change interval
manufacturer’s recommendations Sealed 2000 hours
or at intervals shown in the table. We Breather 500 hours
recommend first fluid change at 500 hours.
High temperatures and pressures will result in accelerated fluid aging. More frequent
fluid changes may be required.
Change the fluid more frequently if it becomes contaminated with foreign matter (dirt, water,
grease, etc.) or if the fluid is subjected to temperature levels greater than the recommended
maximum. Dispose of used hydraulic fluid properly. Never reuse hydraulic fluid.
Change filters with the fluid or when the filter indicator shows it’s necessary. Replace all
fluid lost during filter change.
For detailed filtration information, see Sauer-Danfoss publication 520L0463 Fluids

and Filtration. For information on biodegradable fluids see Sauer-Danfoss publication
520L0465 Biodegradable Hydraulic Fluids.
Hazardous Material
W Warning
Hydraulic fluid contains hazardous material. Avoid contact with hydraulic fluid. Always
dispose of used hydraulic fluid according to state and federal environmental regulations.
520L0848 • Rev AL • November 2012 21

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Pressure Measurements
Port Locations and The following table and drawing show the port locations and gauge sizes needed. When
Gauge Installation testing system pressures, calibrate pressure gauges frequently to ensure accuracy. Use
snubbers to protect gauges.
Port Information
Port identifier Port size Wrench size Reading Gauge size, bar [psi] Displacement
L1, L3 7/8-14 UNF 2B 3/8 internal hex Case drain 10 [100] 069/078
L2, L4 1 1/16-12 UNF 2B 9/16 internal hex Case drain 10 [100] 069/078/089/100
L1, L3 1 1/16-12 UNF 2B 9/16 internal hex Case drain 10 [100] 089/100/115/
130/147/165
L2, L4 1 5/16-12 UNF 2B 5/8 internal hex Case drain 10 [100] 115/130/147/165
MA, MB 9/16-18 UNF 1/4 internal hex System pressure 600 [10,000] 115/130/147/165
M3 9/16-18 UNF 2B 1/4 internal hex Charge pressure- after filter 50 [1000] 115/130/147/165
M4, M5 7/16-20 UNF 2B 3/16 internal hex Servo pressure 50 [1000] 115/130/147/165
M6 9/16-18 UNF 2B 1/4 internal hex Charge pressure - pre integrated filter 50 [1000] 115/130/147/165
Port locations Case drain Port L3 Gauge port M5 Servo pressure

7/8-14 UNF (069/078) 7/16-20 UNF
1 1/16-12 UNF
Gage port M4
(089/100/115/130/147/165) Gauge port M3
servo pressure
O-ring boss Charge pressure
7/16-20 UNF
Case drain Port L1 after filter
7/8-14 UNF (069/078/089/100) 9/16-18 UNF
System
1 1/16-12 UNF (147/165)
Port B
O-ring boss
Charge pump inlet S Case drain port L2 Case drain port L2

1 5/8-12 UNF System Port A Case drain Port L4 1 1/16-12 UNF (069/078) 1 1/16-12 UNF (069/078/089/100)
1 1/16-12 UNF (069/078/089/100) 1 5/16-12 UNF (089/100/115/130) 1 5/16-12 UNF (147/165)
1 5/16-12 UNF
G302 (115/130/147/165)
5/16-24 UNF Gauge port MB
air bleed System pressure
9/16-18 UNF
Charge pressure Gauge port MA

D065 O-ring plug Gauge port M6 System pressure
7/16-20 UNF pre integrated filter 9/16-18 UNF
use for air bleed when filling pump 9/16-18 UNF
P106 033E
22 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Specialized Tools
Overview You can perform the service procedures described in this manual using common
mechanic’s hand tools. This section details any specialized tools helpful to service H1
pumps.
Shaft Seal Installation Shaft Seal Installation Tool Drawing

Tool 44.7 mm 89.4 mm
[1.76 in] [3.52 in]
7 mm 68.5 mm
[0.276 in] [2.70 in]
55 mm 51 mm 78 mm
[2.17 in] 50° [2. in] [3.07 in] 80°
120 mm
[4.72 in]
115/130
82 mm
[3.23 in]
147/165
069/078/089/100 7 mm P106 492E
[0.28 in]
520L0848 • Rev AL • November 2012 23

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Initial Startup Procedures
General Follow this procedure when starting-up a new pump installation or when restarting an
installation in which the pump has been removed and re-installed on a machine. Ensure
pump has been thoroughly tested on a test stand before installing on a machine.
WWarning
Prior to installing the pump, inspect for damage that may have occurred during shipping.
Start-Up Procedure 1. Ensure that the machine hydraulic oil and system components (reservoir, hoses,
valves, fittings, and heat exchanger) are clean and free of any foreign material.
2. Install new system filter element(s) if necessary. Check that inlet line fittings are
properly tightened and there are no air leaks.
3. Install the pump. Install a 50 bar [1000 psi] gauge in the charge pressure gauge port M3.
4. Fill the housing by adding filtered oil in the upper case drain port. If the control is
intalled on top, open the construction plug in the top of the control to assist in air
bleed.
5. Fill the reservoir with hydraulic fluid of the recommended type and viscosity. Use a
10-micron filler filter. Fill inlet line from reservoir to pump.
6. Disconnect the pump from all control input signals.
7. Close construction plug removed in Step 4.
CCaution
After start-up the fluid level in the reservoir may drop due to system components filling.
Damage to hydraulic components may occur if the fluid supply runs out. Ensure reservoir
remains full of fluid during start-up.
Air entrapment in oil under high pressure may damage hydraulic components. Check
carefully for inlet line leaks.
Do not run at maximum pressure until system is free of air and fluid has been thoroughly
filtered.
8. Use a common method to disable the engine to prevent it from starting. Crank
the starter for several seconds. Do not to exceed the engine manufacturer’s
recommendation. Wait 30 seconds and then crank the engine a second time as
stated above. This operation helps remove air from the system lines. Refill the
reservoir to recommended full oil level.
24 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Initial Startup Procedures
Startup Procedure 9. When the gauge begins to register charge pressure, enable and start engine. Let the
(continued) engine run for a minimum of 30 seconds at low idle to allow the air to work itself out
of the system. Check for leaks at all line connections and listen for cavitation. Check
for proper fluid level in reservoir.
10. When adequate charge pressure is established (as shown in model code), increase
engine speed to normal operating rpm to further purge residual air from the system.
11. Shut off engine. Connect pump control signal. Start engine, checking to be certain
pump remains in neutral. Run engine at normal operating speed and carefully check
for forward and reverse control operation.
12. Continue to cycle between forward and reverse for at least five minutes to bleed all
air and flush system contaminants out of loop.
Normal charge pressure fluctuation may occur during forward and reverse operation.
13. Check that the reservoir is full. Remove charge pressure gauge. The pump is now
ready for operation.
520L0848 • Rev AL • November 2012 25

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Troubleshooting
Overview This section provides troubleshooting steps to follow if you are having problems with
your machine. Follow the steps as listed until you solve the problem. Some of the
troubleshooting items are system specific. We reference another section in this manual
if more information is available. Always observe the safety precautions listed in the
Introduction section and precautions related to your specific equipment.
Safety Precautions C Caution

High inlet vacuum causes cavitation which can damage internal pump components.
W Warning
causing serious injury and/or infection. Relieve pressure in the system before removing
hoses, fittings, gauges, or components.
W Warning
C Caution
Contamination can damage internal components and void the manufacturer’s warranty.
Take precautions to ensure system cleanliness when removing and reinstalling system
lines
W Warning
dispose of used hydraulic fluid according to state, and federal environmental regulations.
Electrical Troubleshooting
Item Description Action
Control operates pump in Control coil failure Measure resistance at coil pins. Resistance should be
one direction only. 14.20 ohms (24V) or 3.66 ohms (12V) at 20°C [70°F].
Replace coil
No pump function No power to controller Restore power to controller.
Erratic pump function Electrical connection to pump is bad. Disconnect connection, check wires, reconnect wires.
Filter bypass indicator Filter bypass indicator switch may be bad. Check/replace filter switch. Add gauge to filter
switch bypass port to verify proper fluid flow and verify
switch operation by measuring resistance: open
resistance>=510 ohms, closed resistance<=122 ohms
If available, use manual override to check proper pump operation and verify electrical problem.
26 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Troubleshooting
System Operating Hot

Oil level in reservoir. Insufficient hydraulic fluid will not meet Fill reservoir to proper level.
cooling demands of system.
Heat exchanger. Heat exchanger is not sufficiently cooling Check air flow and input air temperature
the system. for heat exchanger. Clean, repair or
replace heat exchanger.
Charge pressure. Low charge pressure will overwork system. Measure charge pressure. Inspect and
adjust or replace charge relief valve. Inspect charge
pump. Repair or replace charge pump.
Charge pump inlet vacuum. High inlet vacuum will overwork system. A dirty filter Check charge inlet vacuum. If high,
will increase the inlet vacuum. Inadequate line size will inspect inlet filter and replace as necessary.
restrict flow. Check for adequate line size, length
or other restrictions.
System relief pressure If the system relief valves are worn, contaminated, or valve Verify settings of pressure limiters and
settings settings are too low, the relief valves will be overworked. high pressure relief valves and adjust or
replace valves as necessary.
System pressure. Frequent or long term operation over system relief Measure system pressure. If pressure
setting will create heat in system. is too high, reduce loads.
Integral Filter Bypass

Filter bypass activated Filter is plugged causing fluid to bypass filter. Replace filter. Check that bypass switch indicates proper
operation after filter is replaced.
Filter bypass indicator Filter bypass indicator switch is indicating wrong bypass Check/replace switch.
switch situation. open>=510 ohms
closed<=122 ohms
Neutral Difficult or Impossible to Find

Input to pump control Input to control module is operating Disconnect input and check to see if pump comes back
improperly. to neutral. If Yes, input fault, replace/repair external
controller. If No, go to next step.
Neutral Neutral set improperly Shunt servo gauge ports (M4 and M5) together with
external hose and see if pump comes back to neutral.
If Yes: Control neutral improperly set. If neutral is
still impossible to set, balance the swashplate (see
Mechanical Neutral Adjustment). If you still cannot set
neutral, replace the control.
520L0848 • Rev AL • November 2012 27

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Troubleshooting
System Will Not Operate

in Either Direction

Oil level in reservoir. Insufficient hydraulic fluid to supply system loop. Fill reservoir to proper level.
Pump control orifices Control orifices are blocked. Clean control orifices.
Pump control screens Control screens are blocked. Replace control screens. Refer to 520L0874 H1
069/078/147/165 Repair instructions for screen locations.
Only a Sauer-Danfoss Authorized Service Center may
remove the unit’s endcap without voiding the warranty.
Bypass function open If bypass function is open, the system loop will be Close bypass valves. Replace high pressure relief valve if
depressurized. defective.
Low charge pressure with Low charge pressure insufficient to recharge system loop. Measure charge pressure with the pump in neutral. If
pump in neutral pressure is low, go to Pump charge relief valve.
Low charge pressure with Low charge pressure resulting from elevated loop Deadhead the pump to isolate it from the motor.
pump in stroke leakage. Insufficient control pressure to hold pump in With pump in partial stroke and engaged for only
stroke. a few seconds, check pump charge pressure. Low
charge pressure indicates a malfunctioning pump.
Continue to next step. Good charge pressure indicates a
malfunctioning motor or other system component. Check
motor charge relief operation (if present).
Pump charge relief valve A pump charge relief valve that is leaky, contaminated, or Adjust or replace pump charge relief valve as necessary.
set too low will depressurize the system.
Charge pump inlet filter A clogged filter will under supply system loop. Inspect filter and replace if necessary.
Charge pump A malfunctioning charge pump will provide insufficient Repair or replace the charge pump.
charge flow.
System pressure Low system pressure does not provide enough power to Measure system pressure. Continue to next step.
move load.
High pressure relief or Defective high pressure relief or pressure limiter valves Repair or replace high pressure relief or pressure limiter
pressure limiter valves cause system pressure to be low. valves.
Input to control Input operating improperly Repair/replace control.
System Noise or
Vibration
Reservoir oil level Low oil level leads to cavitation. Fill reservoir.
Aeration of the oil/pump Air in system decreases efficiency of units and controls. Find location where air is entering into the system and
inlet vacuum Excessive noise, foaming oil, and hot oil all indicate air in repair. Check that inlet line is not restricted and is proper
system. size.
Cold oil If oil is cold, it may be too viscous for proper function and Allow the oil to warm up to its normal operating
pump cavitates. temperature with engine at idle speed.
Pump inlet vacuum High inlet vacuum causes noise/cavitation. Check that inlet line is not restricted and is of proper size.
Check filter and bypass switch.
Shaft couplings A loose shaft coupling will cause excessive noise. Replace loose shaft coupling..
Shaft alignment Misaligned shafts create noise. Align shafts.
Charge/system relief valves Unusual noise may indicate sticking valves and possible Clean/replace valves and test pump.
contamination.
28 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Troubleshooting
Sluggish System
Response
Oil level in reservoir Low oil level causes sluggish response. Fill reservoir.
High pressure relief valves/ Incorrect pressure settings affects system reaction time. Adjust or replace high pressure relief valves.
pressure limiter settings
Low prime mover speed Low engine speed reduces system performance. Adjust engine speed.
Charge pressure Incorrect pressure affects system performance. Measure and adjust charge pressure relief or replace
charge pump.
Air in system Air in system produces sluggish system response. Fill tank to proper level. Cycle system slowly for several
minutes to remove air from system.
Contaminated control Control orifices are plugged. Clean control orifices.
orifices
Contaminated control EDC supply screen is plugged. Replace control screens. Refer to 520L0874 H1
screens 069/078/147/165 Repair instructions for screen locations.
Pump inlet vacuum Inlet vacuum is too high resulting in reduced system Measure charge inlet vacuum. Inspect line for proper
pressure. sizing. Replace filter. Confirm proper bypass operation.
Transmission Operates
Normally in One
Direction Only

Input to pump control. Input to control module is operating improperly. Check control input and repair or replace as necessary.
Control orifices Control orifice(s) are blocked. Clean control orifices.
Control screens Control screen(s) are blocked. Replace control screens. Refer to 520L0874 H1
069/078/147/165 Repair instructions for screen locations.
Exchange system pressure Exchanging the pressure limiter valves will show if the If the problem changes direction, replace the valve that
limiters problem is related to the valve function. does not operate correctly.
Exchange high pressure Exchanging the high pressure relief valves will show if the If the problem changes direction, replace the valve that
relief valves problem is related to the valve function. does not operate correctly.
Servo pressure low or Damaged servo seals may prevent servo piston from Check for torn/missing servo seals. Replace and
decaying stroking the pump. retest. Refer to 520L0874 H1 069/078/147/165 Repair
instructions for seal locations. Only a Sauer-Danfoss
Authorized Service Center may remove the servo piston
without voiding the warranty.
Bypass function open Open bypass will cause one or both directions to be Close bypass function.
inoperative.
520L0848 • Rev AL • November 2012 29

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Adjustments
Pump Adjustment This section offers instruction on inspection and adjustment of pump components.
Read through the entire topic before beginning a service activity. Refer to Pressure
measurements, page 22, for location of gauge ports and suggested gauge size.
Standard Procedures C Caution

Contamination can damage internal components and void your warranty. Take
precautions to ensure system cleanliness when removing and reinstalling system lines
1. With the prime mover off, thoroughly clean the outside of the pump.
2. If removing the pump, tag each hydraulic line. When you disconnect hydraulic lines,
cap them and plug each open port to prevent contamination.
3. Ensure the surrounding area is clean and free of contaminants like dirt and grime.
4. Inspect the system for contamination.
5. Check the hydraulic fluid for signs of contamination: oil discoloration, foam in the oil,
sludge, or metal particles.
6. If there are signs of contamination in the hydraulic fluid, replace all filters and drain
the hydraulic system. Flush the lines and refill the reservoir with the correct filtered
hydraulic fluid.
8. Before re-installing the pump, test for leaks.
30 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Adjustments
Charge Pressure Relief This procedure explains how to check and adjust the charge pressure relief valve.
Valve Adjustments
1. Install a 50 bar [1000 psi] pressure gauge in charge pressure gauge port M3. Install a
10 bar [100 psi] gauge at case drain port L1, L2, L3, or L4. Operate the system with the
pump in neutral (zero displacement) when measuring charge pressure.
2. The table shows the acceptable pump charge pressure range for some nominal
charge relief valve settings (refer to model code located on serial number plate).
These pressures assume 1800 min-1 (rpm) pump speed and a reservoir temperature
of 50°C [120°F], and are referenced to case pressure.
Charge Pressure Adjustment

Case drain port L4 Optional construction port
0 - 10 bar [0 - 100 psi] 0 - 10 bar [0 - 100 psi]
3/8 in (069/078) / 3/16 in
9/16 in (089/100/147/165) 12 N•m [9 lbf•ft]
70 N•m [52 lbf•ft]
Locknut
13 mm
12 N•m
[9 lbf•ft]
Case drain port L2 Charge pressure gauge port M3

Adjustment
0 - 10 bar [0 - 100 psi] screw 0 - 50 bar [0 - 1000 psi]
9/16 (069/078) / 5/8 in (147/165) 5 mm 1/4 in
70 N•m [52 lbf•ft] (078) 24 N•m [18 lbf•ft]
150 N•m [110 lbf•ft] (147/165)
P104 466E
Charge Pressure Ranges

Listed pressures assume a pump speed Model code Actual charge pressure*
of 1800 min¯¹ (rpm). At higher pump 20 20 bar [290 psi ] ± 1.5 bar [21.8 psi]
speeds (with higher charge flows) the 24 24 bar [348 psi] ± 1.5 bar [21.8 psi]
Depending on the pressure charge pressure will rise over the rated 26 26 bar [377 psi] ± 1.5 bar [21.8 psi]
rating, the charge pressure setting. 30 30 bar [435 psi] ± 1.5 bar [21.8 psi]
relief valve may have one or * This is the actual charge pressure port gauge
two springs. 3. Loosen the locknut and turn the reading minus the case pressure port gauge
adjusting screw clockwise to increase reading. Factory set at 1800 min-1 (rpm) with a
reservoir temperature of 50° C [120° F].
the setting; counterclockwise
to decrease it. The table gives
approximate adjustment per turn.
Number of springs Change per turn

1 Spring consult factory
2 Springs 3.9 bar [56.6 psi]
4. While holding the adjusting screw, torque locknut to 12 N•m [9 lbf•ft].
5 When you achieve the desired charge pressure setting, remove the gauges and plug
the ports.
520L0848 • Rev AL • November 2012 31
H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Adjustments
Pressure Limiter Lock motor output shaft to adjust the pressure limiter setting. Lock the vehicle’s brakes
Adjustment or rigidly fix the work function so it cannot rotate.
1. Install 600 bar [10,000 psi] pressure gauges in the high pressure gauge ports (MA
Ensure charge pressure and MB). Install a 50 bar [1000 psi] pressure gauge in the charge pressure gauge port
is properly set before (M3).
checking pressure limiter.
Pressure Limiter Adjustment
System pressure gauge port MB
Pressure limiter
If you change pressure adjusting screw 0 - 600 bar [0 - 10,000 psi]
limiter settings, you must 1/4 in
24 N•m [18 lbf•ft]
also change the HPRV Pressure limiter
valve to maintain proper locknut System pressure gauge port MA
PL function. Refer to (on bottom)
table on next page for 0 - 600 bar [0 - 10,000 psi]
corresponding settings. 1/4 in
24 N•m [18 lbf•ft]
HPRV Charge pressure gauge port M3

0 - 50 bar [0 - 1000 psi]
1/4 in
24 N•m [18 lbf•ft]
Subtract charge pressure P104 465E
from system pressure

115/130/147/165 Fastener Torque 069/078 Pressure limiter Fastener Torque
to get correct system N•m [lbf•ft] N•m [lbf•ft]
L010 Adjusting screw
L028 Adjusting screw
pressure. 5 mm internal hex L010 N/A
8 mm internal hex
L028 N/A
L024 Locking nut
17 mm L024 20 [15] L024 20 [15]
L024 Locking nut
L028 Plug (special) 14 mm
19 mm L028 68 [50] L012 30 [22]
L012 Cartridge
L012 Cartridge 22 mm
22 mm L012 70 [52]
P106 351E
Pressure Limiter Valve Adjustment
Clockwise rotation * Counterclockwise rotation *

Pressure limiter valves Pressure limiter valves
Controls Controls Controls Controls
Port A Port B Port B Port A
Port B Port B
System System
pressure pressure
* *
Port A Port A
System * Counterclockwise rotation as seen System
* Clockwise rotation as seen from
pressure from shaft end of pump pressure
shaft end of pump P106 250E
Endcaps are different for clockwise and counterclockwise rotation.
32 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Adjustments
Pressure Limiter 2. Start the prime mover and operate at normal speed.
Adjustment
(continued) 3. Use a 17mm wrench to loosen the locking nut (L024).
4. Activate the control input until pressure in the high side of the system loop stops
The model code on the rising. This pressure is the PL setting.
serial plate gives the factory
setting of the PL (Pressure 5. Return the pump to neutral and adjust the PL setting using an internal hex wrench.
Limiter). The PL setting Wrench size is in the diagram on the previous page. Turn the adjusting screw
is referenced to charge clockwise to increase the PL setting, counterclockwise to decrease it. The adjustment
pressure. Subtract charge is very sensitive. Change per turn is approximately 150 bar [2176 psi].
pressure from system
pressure gauge readings to Change per turn is 150 bar/rev [2176 psi/rev].
compute the effective PL
setting.
6. Repeat steps four and five until you reach the desired PL setting. After adjustment,
torque the locknut (L024) to 20 N•m [15 lbf•ft]. Do not over torque.
7. Shut down the prime mover. Remove gauges and replace plugs.
Pressure Limiter Settings

Pressure limiter setting HPRV setting Pressure limiter setting HPRV setting
150 200 400
180 230 410 450
200 250 420
230 280 430
250 300 440 480
280 330 450
300 350 460
330 380 470 510
350 400 480
380 420
520L0848 • Rev AL • November 2012 33

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Adjustments
Engaging the Bypass Use this procedure to bypass the pump to allow moving the vehicle/machine short
Function distances when you cannot start the prime mover.
C Caution
It is possible to damage the drive motor(s) by operating in bypass mode without charge
pressure. Move the vehicle/machine at a speed not more than 20% of maximum for a
duration not exceeding 3 minutes.
1. To open the HPRVs (L150), rotate Engaging the Bypass Function

three revolutions counterclockwise.
Do not rotate more than 3 revolutions,
leakage will result.
2. To close the HPRVs, rotate them

clockwise until seated. See table
above for torque values. L150
3. If machine is towable with HPRVs

P106 649E
opened three turns and if wheels
are locked (not towable) with HPRV
valves closed, bypass function is HPRV Wrench Size and Torque Values
working correctly. Displacement Wrench size and torque
069/078 22 mm - 70 N•m [52 lbf-ft]
115/130/147/165 30 mm - 110 N•m [81 lbf-ft]
34 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Adjustments
Displacement Limiter If your pump has displacement limiters, you will find them on either servo cover. You can
Adjustment limit forward and reverse displacement independently.
Displacement limiters are not pre-set by the factory. We install them as far as possible
without contacting the servo piston. Limiting displacement requires clockwise
adjustment of the limiting screw.
1. Loosen the lockingnut. Displacement Limiter Adjustment

C Caution
Before adjusting the 2. Rotate the adjusting screw to
displacement limiter, achieve the desired maximum
mark the position of the displacement. Set the adjusting
servo cylinder. Be sure screw against the servo piston by
the servo cylinder does feel before counting turns. Refer
not turn when setting to the table below for change per
the displacement limiter turn. Clockwise rotation decreases
locknut. displacement, counterclockwise
rotation increases it. Adjustment is
possible from zero to maximum.
3. After establishing the desired Limiting Screw

maximum displacement setting, hold (see table)
the adjusting screw while torquing
the locknut to the value in the table Locknut
below. (see table)
P104 469E
4. Test operation of the vehicle/

machine to verify proper maximum
speed of vehicle/work function.
Displacement Limiter Adjustment Data

Displacement Locknut wrench size and Adjusting screw Approximate displacement change
torque wrench size per revolution of adjusting screw
069 13 mm - 24 N•m [18 lbf-ft] 4 mm 6.0 cm3/turn [0.366 in3/turn]
520L0848 • Rev AL • November 2012 35

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Adjustments
Control Neutral All functions of the Electric Displacement Control (EDC), are preset at the factory. If
Adjustment necessary, adjust the pump to neutral with the pump running on a test stand or on the
vehicle/machine with the prime mover operating. If adjustment fails to give satisfactory
results, you may need to replace the control or coils. See Minor repair for details.
W Warning
1. Install a 50 bar [1000 psi] gauge in each of the two servo gauge ports (M4 and M5).
Disconnect the external control input (electrical connections) from the control. Start
the prime mover and operate at normal speed.
EDC adjustment is very 2. Use a 4mm internal hex wrench to hold the neutral adjusting screw (D015)
sensitive. Be sure to hold stationary while loosening the locknut (D060) with a 13mm wrench.
the hex wrench steady
while loosening the 3. Observe pressure gauges. If necessary, turn adjusting screw (D015) to reduce
locknut. Total adjustment is pressure differential.
less than 120 degrees.
Control Adjustment
Locknut 13 mm Adjusting screw
12 N•m [9 lbf•ft] 4 mm
Servo pressure gauge port M5

Servo pressure gauge port M4
0 - 50 bar [0 - 1000 psi]
0 - 50 bar [0 - 1000 psi]
1/8 in
1/8 in
5 N•m [4 lbf•ft]
P104 970
36 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Adjustments
Control Neutral 4. Rotate the neutral adjusting screw Neutral Adjustment (EDC) (bottom view)
Adjustment (D015) clockwise until the pressure
Solenoid shaft
(continued) increases on the gauge. Note the
Control spool
angular position of the wrench. Then
rotate the neutral adjusting screw
counterclockwise until the pressure
increases by an equal amount on the
other gauge. Again note the angular
position of the wrench.
5. Rotate the neutral adjusting screw

clockwise half the distance between
the wrench positions noted above.
The gauges should read the same
pressure, indicating that the control Adjusting
screw
is in its neutral position. (cam)
Feedback pin
6. Hold the neutral adjusting screw Maximum

stationary and tighten the locknut adjustment
less than 120°
(D060). Torque to 12 N•m [9 lbf•ft]. Do
not over torque the nut.
P106 046E
7. When the neutral position is set, stop

Illustration shows how cam on adjusting pin
the prime mover, remove the gauges, rotates to adjust for neutral position after pump
and install the gauge port plugs. is re-installed.
Reconnect the external control input.
A small pressure differential of 1.5 bar [22 psi] or less is acceptable. Zero differential is
usually not possible.
520L0848 • Rev AL • November 2012 37

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Adjustments
Mechanical Neutral Mechanical neutral is set with the pump running at 1800 min¯¹ (rpm). To set neutral, you
Adjustment must stroke the pump in each direction. You can do this with a small movement of the
eccentric screw on EDC controls, however non-feedback controls (NFPE/FNR) lack this
mechanism. To stroke a pump with non-feedback control, you must provide a 100 Hz
PWM signal to the control solenoids. Refer to the H1 Pumps Technical Information manual
11009999 for signal specifications. If you perform this adjustment with the pump
installed in a vehicle or machine, safely elevate the wheels or disconnect the mechanism
to allow safe operation during adjustment.
This procedure details setting neutral for the pump. Alternate M4/M5 and MA/MB to zero
out forward and reverse directions of the unit Refer to the drawing on the next page to
identify all ports. The control solenoids C1 and C2 are marked on the control.
While performing this adjustment, you will monitor the following pressures.
• Servo pressure at M4 and M5

• System pressure at MA and MB
• Pressure differential between M4 and M5 (optional)
• Pressure differential between A and B (optional)
Refer to Pressure measurement, page 22, and the illustration on the next page for gauge
port locations and information.
Pump setup
1. Attach a 50 bar [1000 psi] gauge to each servo pressure port M4 and M5.
2. Attach a 600 bar [10 000 psi] gauge to each system pressure port (MA and MB).
3. Remove servo cylinder locking screws (E350) and plates (E300) from both sides of
the pump.
4. Disconnect the control solenoids from the vehicle wiring harness.
5. If using a PWM signal to set mechanical neutral, connect the control solenoids C1
and C2 to the signal source. Ensure the source supplies no current to the solenoids
until required in the following procedure.
38 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Adjustments
Mechanical Neutral The figure below shows the locations of sysem and gage ports you use when adjusting
Adjustment the servo neutral postion.
(continued)
System Pressure Gage Port Locations

Servo pressure Servo pressure Solenoid C1
port M4 port M5
System
Port B
System Port A Gauge port MA Gauge port MB Solenoid C2

system pressure system pressure Servo pressure
port M4
P106 489E
520L0848 • Rev AL • November 2012 39

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Adjustments
Mechanical Neutral Servo Adjustment

Adjustment 1. Run prime mover at 1800 min¯¹(rpm).
(continued)
2. If using a PWM signal, ensure the signal is off. Check the servo pressure gauges.
Ensure the differential between M4 and M5 is less than 1.5 bar [22 psi].
3. Using a 3/4 in hex deep socket, unthread both servo cylinders 2-3 turns. This step
ensures the servo cylinders have no contact with the servo piston.
4. Stroke the pump by turning the control eccentric screw (or supplying current to
solenoid C1) until the servo pressure at port M4 is 1 to 2 bar [14– 29 psi] greater than
at port M5 and the system pressure gauges indicate displacement. Pressure should
be greater at port MA for clockwise rotation, or MB for counterclockwise rotation.
This also indicates the servo piston is in contact with the servo cylinder on side M5.
5. Slowly thread the servo cylinder on the M5 side in until the system pressure
differential starts to decrease. Maintain servo pressure differential between 1-2
bar [14-29 psi] during this step. Continue turning the servo cylinder in until the
system pressure differential (between ports MA/MB) is less than 1.5 bar [22 psi]. This
procedure sets the servo and swashplate to mechanical neutral on the M5 side.
6. To complete setting neutral, repeat steps 1-5 but stroke the pump in the opposite
direction by turning the eccentric screw in the opposite direction, or by supplying
current to solenoid C2. Reverse gauge locations (M4 for M5, MB for MA) from those
stated above since the pump is now stroking the other direction.
7. Remove all gauges and replace gauge port plugs. You can find wrench sizes and plug
torques in the Plug Size and Torque Chart.
Servo Adjustment
E300 E350
Servo can Servo can
locking plate locking bolt
P106 490E
40 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Minor Repair
Standard Procedures, Before working on the pump, thoroughly clean the outside. If the pump has an auxiliary
Removing the Pump pump attached, remove both pumps as a single unit. Tag and cap all hydraulic lines as
they are disconnected, and plug all open ports to ensure that dirt and contamination do
not get into the system.
C Caution
Contamination can damage internal components and void the manufacturer’s warranty.
Take precautions to ensure system cleanliness when removing and installing system lines.
Disassembly
1. With the prime mover off, thoroughly clean all dirt and grime from the outside of the
pump.
2. Tag, disconnect, and cap each hydraulic line connected to the pump. As hydraulic
lines are disconnected, plug each open port, to ensure that dirt and contamination
do not get into the pump.
3. Remove the pump and its auxiliary pump (if applicable) as a single unit.
Be careful, do not damage solenoids and electrical connections when using straps or
chains to support the pump.
Inspection
4. Ensure the work surface and surrounding area are clean and free of contaminants
such as dirt and grime.
5. Inspect the system for contamination.
6. Look at the hydraulic fluid for signs of system contamination, oil discoloration, foam
in the oil, sludge, or metal particles.
Reassembly
7. Before replacing the pump, replace all filters and drain the hydraulic system. Flush
the system lines and fill the reservoir with the correct, filtered hydraulic fluid.
8. Fill the pump with clean, filtered hydraulic fluid.
9. Attach the pump to the prime mover. Torque mounting screws according to the
manufacturers recommendation.
10. Replace all hydraulic lines. Ensure the charge inlet line is filled with fluid.
520L0848 • Rev AL • November 2012 41

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Minor Repair
EDC Control Removal

Refer to exploded diagram, next page.
1. Using a 5 mm internal hex wrench, remove the six cap screws (D250).
2. Remove the control module and gasket (D150). Discard the gasket.
3. If necessary, remove orifices (F100) using a 3 mm internal hex wrench. Tag and
number them for reinstallation.
4. If screen (D084) is clogged, use a hook to remove retaining ring (D098) and screen.
Discard screen and replace with new screen.
Inspection
5. Inspect the machined surfaces on the control and top of the pump. If you find any
nicks or scratches, replace the component.
Reassembly
Remove plug on top of
control to ensure the Ensure you install dowel pins (D300) in housing before installing control.
swashplate feedback pin
is properly positioned in 6. Install a new gasket (D150).
the center of the control
module when installing Proper Screen Orientation
control.
D094
D084
D084
Correct screen Incorrect screen

orientation orientation
P106 618E
7. If you removed screen (D084), install a new one. Install with the mesh facing outward
(see drawing). Install retaining ring (D098).
8. If previously removed, install orifices (F100) using a 3 mm internal hex wrench.

Torque to 2.5 N•m [1.8 lbf•ft].
9. Install the control module and six cap screws (D250).
10. Using a 5 mm internal hex wrench, torque the cap screws (D250) to 13.3 N•m [9.8 lbf•ft].
42 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Minor Repair
EDC Control (continued) Control Module and Solenoid Removal/Installation
D050 (3X)
4 mm
5 N•m [4 lbf•ft] D1
D025A D250
5 mm
13.5 N•m
[9.8 lbf•ft]
D025
D025A D050 (3X)
4 mm
D084
5 N•m
Torque sequence D098
[4 lbf•ft]
2 1 D150
6 5 F100 (2X)
3 mm
2.5 N•m
4 3 [1.8 lbf•ft]
D300 (2X)
P106 650E
Control Solenoids Removal

1. Disconnect electrical connection and remove the three cap screws (D050) using a
4 mm internal hex wrench.
2. Remove the solenoid (D025) and O-ring (D025A). Discard the O-ring.
3. If necessary, remove the coil using a 12 point 26 mm socket.
Inspection
4. Inspect the machined surface on the control. If you find any nicks or scratches,
replace the component.
Reassembly
5. Lubricate new O-ring (D025A) using petroleum jelly and install.
6. Install solenoid with three cap screws (D050) using a 4 mm internal hex wrench.
Torque screws to 5 N•m [4 lbf•ft].
7. Install coil using a 12 point 26 mm socket. Torque coil nut to 5 N•m [3.7 lbf•ft].
8. Reconnect electrical connections and test the pump for proper operation.
520L0848 • Rev AL • November 2012 43

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Minor Repair
Automotive Control Removal

1. Drain pump completely before removing control. Disconnect and remove wiring
(D640).
2. Fabricate a special tool to remove two plastic plugs (D610). See drawing below for
tool dimensions. Push down on plug and turn 45 degrees counterclockwise. Discard
plugs.
Wax seals will be destroyed when the plugs are removed. Do not damage the housing in
the plug sealing area.
3. Use a 5 mm internal hex to remove two screws (D674). Remove shield (D672).
4. Use a 5 mm internal hex to remove six screws (D250). Remove control from pump.
5. Remove and discard gasket (D150).
Alignment pins are pressed into control. Do not remove them.

Drill Out Retention Ring
6. If necessary, use a 3 mm internal hex to remove orifices (F00A, F00B) from housing.
Tag each orifice for reinstallation. Each orifice may be a different size.
Screen
7. If it is necessary to remove the screens, drill out screen retention ring (D098) and
Retention remove and discard screen (D084). Note screen orientation for reassembly.
Ring
P108 022E
W Warning
Do not allow metal fragments to fall into control housing. This may cause erratic pump
operation.
Remove Control
Security
13.3 Nm wax seal (2X)
Special Tool [9.8 lbf•ft]
D610 (2X)
Special Plug
D250
tool 5 mm D672
(6X)
45 deg. D674
D084
D640
D098
Ø 9.22 mm
2.5 Nm
[1.8 lbf•ft]
Ø 14 mm
F00A D150
Ø 1.7 mm (x3) 3 mm F00B
P108 021E P107 990E
44 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Minor Repair
Automotive Control Inspection

(continued) Inspect machined surfaces on control and pump housing. Inspect plastic PC board
housing and its sealing areas. If any damage is found, replace damaged components.
Controls are available as a complete unit. Do not disassemble the control.
Assembly
1. If previously removed, install new screen (D084) in original orientation. Press in new
retention ring (D098).
Be sure screen will not move axially in bore after retention ring is installed.
W Warning
Failure to install screen will result in erratic pump operation.
Proper Screen Orientation
D094
D084
D084

P106 618E
2. If previously removed, use a 3 mm internal hex to install orifices (F00A, F00B) in

original orientation. Torque to 2.5 N•m [1.8 lbf•ft][.
If pump has been rebuilt 3. Install new gasket (D150) to bottom of control.
or a new control is being
installed, control software 4. Install control on pump. Use a 5 mm internal hex to install six screws (D250). Torque
must be recalibrated. Refer to 13.3 N•m [9.8 lbf•ft]. Follow torque sequence shown on page 43.
to H1-Automotive Control
User Manual 70012797 for Do not damage the plastic housing in the plug sealing area when installing the screws.
recalibration instructions.
5. Connect wiring (D640).
6. Use the special tool to install new plastic plugs with O-rings (D610). Press plugs in
and turn 45 degrees clockwise.
If control will continue to be under warranty, install new sealing wax of a different color
(original wax is blue). Pumps without sealing wax installed will not be warrantied.
7. Install protection bracket (D672). Install screws (D674). Torque to 5 N•m [3.7 lbf•ft].
520L0848 • Rev AL • November 2012 45

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Minor Repair
Bearing and Shaft The input shaft, seal, and front bearing are serviceable without disassembling the entire
Replacement pump. Orient the pump on the work surface so the shaft is pointing up.
Removal
1. Using a snap-ring pliers, remove the outer snap-ring (J200).
C Caution 2. Puncture the seal (J250) and use a slide-hammer type puller to remove the seal.
Do not damage the Discard the seal. C
housing bore, shaft or
bearing when removing 3. Use a press or gear puller to press down on the shaft. Using a snap-ring pliers,
the seal. remove the inner snap-ring (J200).
4. Remove the shaft (J100) and bearing (J150) from the pump. It may be necessary to
tap the shaft to dislodge it from the internal pump components. After you remove
the shaft, take care not to move or jar the pump. Reassembly can be difficult if the
internal components move while the shaft is out.
5. Remove snap-ring (J300). Press bearing (J150) from shaft.
46 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Minor Repair
Bearing and Shaft Inspection

Replacement 6. Inspect the shaft and bearing for wear, scratching and pits. Rotate the bearing and
feel for roughness. Replace damaged components.
Reassemby
7. Press bearing (J150) on shaft. Install snap-ring (J300).
8. Install the shaft/bearing assembly into the pump. Rotate the shaft to align it with
the block and charge pump splines. Press down on the shaft and replace the inner
snap-ring (J200).
9. Cover end of the shaft with an installation sleeve to protect the seal during
installation. Lubricate the seal. Tap on the seal replacing tool or an appropriate
deep-socket to press in the seal. Remove the protective cover. Refer to Specialized
tools, page 23, for installation sleeve and seal installation tool part numbers and
dimensions.
10. Install the remaining snap-ring.
Shaft Assembly
J300
J150
Protective
cover
J250 J100
J200
P106 038E
J200
Seal
installation
tool
Seal Installation Tool 44.7 mm 89.4 mm

[1.76 in] [3.52 in]
7 mm 68.5 mm
[0.276 in] [2.70 in]
55 mm 51 mm 78 mm
[2.17 in] 50° [2. in] [3.07 in] 80°
120 mm
[4.72 in]
115/130
82 mm
[3.23 in]
147/165
069/078/089/100 7 mm P106 492E
[0.28 in]
520L0848 • Rev AL • November 2012 47

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Minor Repair
External Filter Removal

Replacement 1. With the prime mover off, hold the filter (T150) in place, and remove the plug (T015)
using a 17 mm wrench.
3. Remove and discard the seal (T045) and O-ring (T035).
Inspection
4. Inspect the plug and sealing surfaces in the filter bracket. Replace any damaged
components.
Reassembly
5. Install new seal (T045) and O-ring (T035) on plug.
6. Apply hydraulic fluid to the O-ring and seal for lubrication. Insert the plug into the
bracket.
7. Use a 24 mm wrench to hold the plug in place and install the replacement filter.
Hand tighten filter till it contacts O-ring, then tighten 1/2 turn further.
8. Start the prime mover. Cycle the pump through normal machine operation and
check for leaks.
External Filter Replacement
T035
T045 T150
T015
17mm
P106 035E
48 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Minor Repair
Filter Bypass Valve and Removal Filter Adapter Replacement

Filter Bypass Switch 1. Remove three screws (T250) using a
T025
6mm internal hex wrench. 6 mm
16-20 N•m
2. Remove the filter adapter (T010) and [12 - 15 lbf•ft]
gasket (T350). Discard the gasket. T350
T040
3. Use an 8 mm internal hex wrench to
remove plugs (T025).
T030
4. Remove and discard O-rings (T040).
T020 T010
5. Remove spring (T030), and poppet
(T020). T200
6. If necessary, use a 3 mm internal hex

wrench to remove cap screws (T300)
and bypass switch (T200). T300
3 mm
T250
It is not necessary to remove switch 1.5 N•m
6mm
[1 lbf•ft] 32 N•m
(T200) unless it is being replaced. T040
[24 lbf•ft]
T025
Inspection 6 mm
16-20 N•m P106 138E
7. Inspect poppet (T020) for bending or [12 - 15 lbf•ft]
damage. Replace if necessary.
8. Inspect spring (T030) for cracks or warpage. Replace if necessary.
9. Inspect sealing surface of filter adapter (T010) for scratches or damage. Resurface or
replace scratched or damaged part.
Reassembly
10. Lubricate and replace O-ring (T040) on plug (T025).
11. Install poppet (T020), spring (T030), and plug (T025). Torque to 18 N•m [13 lbf•ft].
12. If replacing bypass switch, install and torque 3 mm cap screws (T300) to 1.4 N•m [1
lbf•ft].
13. Install adapter assembly (T010) using new gasket (T350) to pump. Install cap screws
(T250) using a 6mm internal hex wrench. Torque to 32 N•m [24 lbf•ft].
520L0848 • Rev AL • November 2012 49

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Minor Repair
Charge Pump If the pump has an auxiliary pump attached, remove the auxiliary pump and coupling
before removing the auxiliary pad.
Charge pump removal (removable auxiliary pad/cover)

1. Using a 10 mm internal hex wrench, remove cap screws (K400).
2. Remove charge pump cover or auxiliary pad (K100) and gasket (K150). Discard the
gasket. Alignment pins (G450) may remain in cover or endcap.
3. Remove thrust washer (K500). Note its orientation. Coated side is towards charge
pump coupling (K200).
4. Remove pressure-balance plate (S200) with seal (S300). Note orientation of plate
and seal. Discard seal.
5. Remove charge pump coupling (K200).
6. Remove charge pump gearset (S100) and outer ring (S150).
7. Remove valve plate (S250) with seal (S300). Note orientation of valve plate and seal.
Discard seal (S300).
Charge Pump Removal/Installation
S200
S300
S300
S250
S100
K400
10 mm
92 Nm [68 ft•lb] S150 P106 036E
K200
K500
K150
G450
K400
K100 K100
10 mm
92 Nm [68 ft•lb]
50 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Minor Repair
Charge Pump Charge Pump Removal (integrated auxiliary pad)

(continued) 1. Remove auxilliary pump and O-ring (K250). Discard O-ring.
2. Remove charge pump cover screws (K450) and charge pump cover (K550).
3. Remove thrust washer (K500). Note its orientation. Coated side is towards charge
pump coupling (K200).
4. Remove pressure-balance plate (S200) with seal (S300). Note orientation of valve
plate and seal. Discard seal (S300).
5. Remove charge pump coupling K200).
6. Remove charge pump gearset (S100) and outer ring (S150).
7. Remove valve plate (S250) with seal (S300). Note orientation of valve plate and seal.
Discard seal (S300).
Charge Pump Removal/Installation (integrated auxiliary pad)
S200
S300
K450 S300
6 mm
10 Nm [7 ft•lb] S250
S100
K550
S150
P106 353E
K200
K500
K250
520L0848 • Rev AL • November 2012 51

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Minor Repair
Charge Pump Inspection

(continued) Inspect the components for wear, scratches or pitting. Carefully inspect the valve and
pressure-balance plates. Scratches on these components will cause a loss of charge
pressure. If any component shows signs of wear, scratching, or pitting, replace it.
Reassemby
1. Install new seals (S300) in the valve (S250) and pressure-balance (S200) plates.
2. Install valve plate (S250) in the same orientation as removed.
3. Lubricate and install charge pump gearset (S100) and outer ring (S150).
4. Install charge pump coupling (K200).
5. Install pressure-balance plate (S200) in the same orientation as removed.
6. Install the thrust washer (K500). Coated side goes towards charge pump coupling
(K200).
7. Install a new cover gasket (K150). If removed,install guide pins (K450).
Ensure proper torque on 8. Install the auxiliary pad or charge pump cover and cap screws. Using a 10mm internal
aux pad screws (K400). hex wrench, torque the cap screws (K400) to 92 N•m [68 ft•lb], or using a 6mm internal
If necessary, replace screws. hex wrench (K450), torque to 10 N•m [7 lbf•ft]. Torque in sequence below.
If charge pump replacement is necessary, replace complete charge pump kit.
Cover (K100) Torque Sequence Cover (K550) Torque Sequence
5 4
1 2
5 7
6 3
1 4 P106 659E
3 2
8 6
P106 196E
52 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Minor Repair
High Pressure Relief Removal

Valves (HPRV) 1. Using a hex wrench wrench shown in the table below, remove the HPRVs (L150).
Remove and discard the O-rings (L060) and backup rings (L068).
Inspection
2. Inspect the sealing surfaces in the pump for nicks or scratches. Check the valves for
damage. Replace any damaged components.
Reassemby
3. Lubricate and install new backup rings (L068) and O-rings (L060).
4. Install HPRVs. Torque to the value in the table below.
5. Operate the vehicle/machine through full range of controls to ensure proper

operation. Check for leaks.
HPRVs
L060
L068
L150
P106 039E
see table
HPRV Wrench Size and Torque Values

Displacement Wrench size and torque
069/078/089/100 22 mm - 70 N•m [52 lbf-ft]
115/130/147/165 30 mm - 110 N•m [81 lbf-ft]
520L0848 • Rev AL • November 2012 53

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Minor Repair
Charge Pressure Relief Replace the charge pressure relief valve (V010) as a complete unit. Do not attempt to
Valve repair the internal components of the valve. Torque to 52 N•m [38 lbf•ft]
See Charge Pressure Relief Valve djustment, page 31, for adjustment instructions.
Removal
1. Using a 22 mm wrench, remove the charge pressure relief valve (V010). Discard seal
(V024).
Inspection
2. Inspect the sealing surfaces of the pump for nicks or scratches.
Reassemby
3. Lubricate and install new seal (V024).
4. Install the charge pressure relief valve. Torque to 52 N•m [38 lbf•ft].
5. Operate vehicle/machine through full range of controls to ensure proper operation.
Charge Pressure Relief Valve
V024
V010
22 mm
P106 040E
52 N•m
[38 lbf•ft]
54 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Minor Repair
PressureLimiter Valve Replace the pressure limiter valve as a complete unit. Do not attempt to repair individual
Replacement components. See Pressure Limiter Adjustment, page 32, for adjustment instructions.
Removal
1. Using a 22 mm wrench, remove the pressure limiter valve (L100). Discard O-ring.
Inspection
2. Inspect the sealing surfaces of the pump for nicks or scratches.
Reassemby
3. Install new O-ring. Lubricate 0-ring with petroleum jelly.
4. Replace pressure limiter valve. Torque to 70 N•m [52 lbf•ft].
5. Operate pump at full range of controls to ensure proper machine operation.
Pressure limiter is available as complete unit only. O-ring is available separately.
Pressure Limiter
L300
22 mm
70 N•m [52 lbf•ft]
L400
22 mm O
70 N•m [52 lbf•ft]
L022
E101 336E
520L0848 • Rev AL • November 2012 55

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Torque Chart
Fastener Size and 069/078/115/130/147/165

Torques Item Fastener Wrench size Torque
D015 Neutral adjust screw 4 mm internal hex NA
D050 Coil mounting bolt 4 mm internal hex 8 N•m [6 lbf•ft]
D060 Neutral adjust locking nut 13 mm 10 N•m [7 lbf•ft]
D200 Swash plate feedback pin (not shown) 13 mm deep well socket 25 N•m [18 lbf•ft]
D250 Electric control mounting bolt 5 mm internal hex 13.3 N•m [9.8 lbf•ft]
E350 Servo can locking bolt 10 mm 14 N•m [10 lbf•ft]
T015 Filter mounting bolt 17 mm NA
T025 Filter adapter gage plug 6 mm internal hex 18 N•m [13 lbf•ft]
V010 Charge pressure cartridge 22 mm 52 N•m [38 lbf•ft]
V020 Charge pressure adjusting screw 4 mm internal hex NA
V022 Charge pressure locking nut 13 mm 12 N•m [9 lbf•ft]
069/078/089/100
Item Fastener Wrench size Torque
K400 Rear cover/Aux pad mounting bolt 10 mm internal hex 100 N•m [74 lbf•ft]
K450 Charge Pump Cover Screw 5 mm internal hex 10 N•m [7 lbf•ft]
L010 Pressure limiter adjust screw 8 mm NA
L012 Pressure limiter cartridge 14 mm 30 N•m [22 lbf•ft]
L024 Pressure limiter locking nut 14 mm 20 N•m [15 lbf•ft]
L150 High pressure relief valve 22 mm 70 N•m [52 lbf•ft]
115/130/147/165
L010 Pressure limiter adjust screw 5 mm internal hex NA
L012 Pressure limiter cartridge 22 mm 70 N•m [52 lbf•ft]
L024 Pressure limiter locking nut 17 mm 20 N•m [15 lbf•ft]
L028 Pressure limiter plug (special) 19 mm 68 N•m [50 lbf•ft]
L150 High pressure relief valve 30 mm 110 N•m [81 lbf•ft]
Plug Size and Torques 069/078/115/130/147/165

Item O-ring plug Wrench size Torque
B015 7/16 - 20 3/16 mm internal hex 12 N•m [9 lbf•ft]
B020 (069/078) 7/8 - 14 3/8 internal hex 70 N•m [52 lbf•ft]
B020 (147/165) 1-1/16 - 12 9/16 internal hex 70 N•m [52 lbf•ft]
B035 (069/078) 1 1/16 - 12 9/16 internal hex 70 N•m [52 lbf•ft]
D065 7/16 - 20 3/16 internal hex 12 N•m [9 lbf•ft]
G250 9/16 - 18 1/4 internal hex 24 N•m [18 lbf•ft]
G302 5/16 - 24 UNF 1/8 internal hex 5 N•m [4 lbf•ft]
56 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Torque Chart
Fasteners and Plugs
L150
High pressure
relief valve
V020
Charge pressure
adjusting screw
V022
Charge pressure
locking nut K400
Rear cover / auxiliary pad
mounting bolt
V010
Charge pressure
cartridge
L150
High pressure
relief valve
T015
Filter mounting bolt
P106 066E
520L0848 • Rev AL • November 2012 57

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Torque Chart
Fasteners and Plugs

(continued)
B015 O-ring plug, 7/16 - 20

D015 Neutral adjusting screw L010 Pressure limiter adjusting screw
D060 Neutral adjust locking nut L024 Pressure limiter locking nut
L028 Pressure limiter plug (special)
D050 Coil mounting bolt L012 Pressure limiter cartridge
G302 O-ring plug, 5/16 - 24 UNF

B020 O-ring plug
1-1/16 - 12
G300 O-ring plug, 9/16 - 18
B035 O-ring plug, see table E350

Servo can locking bolt
D250 G250 O-ring plug, 9/16 - 18

Electric control
mounting bolt
G302 O-ring plug

5/16 - 24 UNF
D065 O-ring plug, 7/16 - 20

P106 497E
58 520L0848 • Rev AL • November 2012

H1 069/078, 089/100, 115/130, 147/165 Closed Circuit
Notes
520L0848 • Rev AL • November 2012 59

Products we offer: Sauer-Danfoss is a global manufacturer and supplier of high-
quality hydraulic and electronic components. We specialize in
• Bent Axis Motors providing state-of-the-art technology and solutions that excel in
the harsh operating conditions of the mobile off-highway market.
• Closed Circuit Axial Piston Pumps
Building on our extensive applications expertise, we work closely
and Motors
with our customers to ensure exceptional performance for a broad
• Displays range of off-highway vehicles.
• Electrohydraulic Power Steering
We help OEMs around the world speed up system development,
• Electrohydraulics reduce costs and bring vehicles to market faster.
Sauer-Danfoss – Your Strongest Partner in Mobile Hydraulics.
• Hydraulic Power Steering
• Integrated Systems
• Joysticks and Control Handles
Go to www.sauer-danfoss.com for further product information.
• Microcontrollers and Software
• Open Circuit Axial Piston Pumps
• Orbital Motors Wherever off-highway vehicles are at work, so is Sauer-Danfoss.
• PLUS+1™ GUIDE
We offer expert worldwide support for our customers, ensuring
• Proportional Valves the best possible solutions for outstanding performance. And with
an extensive network of Global Service Partners, we also provide
• Sensors
comprehensive global service for all of our components.
• Steering
• Transit Mixer Drives
Please contact the Sauer-Danfoss representative nearest you.
Local address:
Members of the Sauer-Danfoss Group:
Comatrol
www.comatrol.com
Schwarzmüller-Inverter
www.schwarzmueller-inverter.com
Sauer-Danfoss (US) Company Sauer-Danfoss ApS
2800 East 13th Street DK-6430 Nordborg, Denmark
Ames, IA 50010, USA Phone: +45 7488 4444
Turolla
Phone: +1 515 239 6000 Fax: +45 7488 4400
www.turollaocg.com Fax: +1 515 239 6618
Hydro-Gear Sauer-Danfoss GmbH & Co. OHG Sauer-Danfoss-Daikin LTD.

www.hydro-gear.com Postfach 2460, D-24531 Neumünster Shin-Osaka TERASAKI 3rd Bldg. 6F
Krokamp 35, D-24539 Neumünster, Germany 1-5-28 Nishimiyahara, Yodogawa-ku
Phone: +49 4321 871 0 Osaka 532-0004, Japan
Sauer-Danfoss-Daikin Fax: +49 4321 871 122 Phone: +81 6 6395 6066
Fax: +81 6 6395 8585
www.sauer-danfoss-daikin.com
520L0848 • Rev AL• November 2012 www.sauer-danfoss.com

H1
078/089/100/
115/130/147/165
Closed Circuit
Axial Piston Pumps
Repair Instructions
H1 078/089/100/115/130/147/165 Axial Piston Pumps
Repair Instructions
Revisions

August 2010 38 Update valve plate drawing AL

July 2010 last New back page AK
March 2010 last Fix Osaka Address AJ
October 2009 various various edits and corrections AI
September 2009 16, 24, 38 new valve plate AH
July 2009 11, 43 Added automotive control AG
April 2009 various Added 089/100 AF
December 2008 various remove special tool numbers AE
April 2008 various Added special tools part numbers AC
April 2008 all Added 115/130 AB
Jul 2007 - First edition AA

2 520L0874 • Rev AL • August 2010

Repair Instructions
Contents
Safety Precautions.......................................................................................................................................... 6
Unintended machine movement........................................................................................................ 6
Flammable cleaning solvents................................................................................................................ 6
Fluid under pressure................................................................................................................................. 6
Personal safety............................................................................................................................................ 6
Symbols used in Sauer-Danfoss Literature............................................................................................ 7
Disassembly Shaft Seal Removal......................................................................................................................................... 8

Input Shaft Removal....................................................................................................................................... 8
EDC Control Removal..................................................................................................................................... 9
EDC Control Disassembly...........................................................................................................................10
Automotive Control Removal...................................................................................................................11
Optional Integrated Filter Removal........................................................................................................12
Auxiliary Pad or End Cover Removal......................................................................................................13
Charge Pump Removal................................................................................................................................14
Pressure Limiter Valve Removal...............................................................................................................14
Charge Pressure Relief Valve Removal...................................................................................................15
High Pressure Relief Valve Removal........................................................................................................15
Endcap Removal............................................................................................................................................16
Cylinder Block Kit Removal........................................................................................................................17
Optinal Displacement Limiter...................................................................................................................17
Servo Cylinder Removal..............................................................................................................................18
Servo Piston Removal..................................................................................................................................18
Servo Piston Disassembly..........................................................................................................................19
Swashplate and Cradle Bearings Removal...........................................................................................19
Cylinder Block Kit...........................................................................................................................................20
Inspection Overview..........................................................................................................................................................21
Pistons and Slippers.....................................................................................................................................21
Ball Guide and Slipper Retainer...............................................................................................................21
Block Spring and Washers..........................................................................................................................21
Cylinder Block . ..............................................................................................................................................22
Shaft ..................................................................................................................................................................22
Shaft Bearing...................................................................................................................................................22
Swashplate.......................................................................................................................................................23
Cradle Bearings..............................................................................................................................................23
Valve Plate........................................................................................................................................................24
Endcap..............................................................................................................................................................24
Housing ...........................................................................................................................................................25
Pressure Limiter.............................................................................................................................................25
HPRV Valve.......................................................................................................................................................26
Optional Displacement Limiter................................................................................................................26
Servo Piston Assembly................................................................................................................................27
Control...............................................................................................................................................................27
Optional Integrated Filter...........................................................................................................................28
520L0874 • Rev AL • August 2010 3

Repair Instructions
Contents
Assembly Overview..........................................................................................................................................................29
Cradle Bearings, Swashplate, and Filter Screen Installation ..........................................................29
Servo Piston Assembly................................................................................................................................30
Servo Piston Installation.............................................................................................................................30
Servo Cylinder Installation.........................................................................................................................31
Optinal Displacement Limiter...................................................................................................................32
Install Optional Hold down Clamp..........................................................................................................32
Hold Down Clamp.........................................................................................................................................33
Dimensions......................................................................................................................................................33
Shaft and Seal Installation..........................................................................................................................34
Cylinder Kit Assembly..................................................................................................................................35
Cylinder Kit Installation...............................................................................................................................36
Level Swashplate...........................................................................................................................................36
Endcap Bushing Installation......................................................................................................................37
Valve Plate and Endcap Installation........................................................................................................38
Charge Pump Installation...........................................................................................................................39
Auxiliary Pad or End Cover Installation.................................................................................................39
Charge Pressure Relief Valve Installation..............................................................................................40
Pressure Limiter Valve Installation...........................................................................................................40
HPRV Valve Installation................................................................................................................................41
Optional Displacement Limiter Installation.........................................................................................41
Control Assembly..........................................................................................................................................42
Control Installation.......................................................................................................................................43
Automotive Control Installation..............................................................................................................44
Optional Integrated Filter Installation...................................................................................................45
Startup Procedures Overview..........................................................................................................................................................46

Initial Startup Procedures...........................................................................................................................46
Adjustments....................................................................................................................................................46
Pressure Measurements..............................................................................................................................46
Port Locations Port Locations and Gauge Installation..................................................................................................47
Torque Chart Fastener Size and Torques..........................................................................................................................48

Plug Size and Torques..................................................................................................................................48
Fasteners and Plugs......................................................................................................................................49
4 520L0874 • Rev AL • August 2010

Repair Instructions
Introduction
Overview This manual details major repair procedures for H1 pumps. These include the complete
disassembly, inspection, and reassembly of the unit. Where rework of worn or damaged
components is possible, specifications appear to ensure these parts meet factory
tolerances. Only Sauer-Danfoss Global Service Partners (GSPs) are authorized to perform
major repairs. Sauer-Danfoss trains Global Service Partners and certifies their facilities on
a regular basis.
W Warning
Use of components that do not comply with rework specifications may result in loss of
performance, which may constitute a safety hazard. Do not reuse components that don’t
comply to given specifications: replace with genuine Sauer-Danfoss service parts.
Minor repair procedures, adjustments, and troubleshooting information appear in the H1

078/089/100/115/130/147/165 Closed Circuit Axial Piston Pumps Service Manual, 520L0848.
Minor repairs include service operations you can perform without removing the unit’s
endcap. Removal of the endcap voids your warranty.
pumps.
w Remove the unit

Prior to performing major repairs, remove the unit from the vehicle/machine. Chock
the wheels on the vehicle or lock the mechanism to inhibit movement. Be aware that
hydraulic fluid may be under high pressure and/or hot. Inspect the outside of the
pump and fittings for damage. Cap hoses and plug ports after removal to prevent
contamination.
e Keep it clean
Cleanliness is a primary means of assuring satisfactory pump life, on either new or
repaired units. Clean the outside of the pump thoroughly before disassembly. Take care
to avoid contamination of the system ports. Cleaning parts using a clean solvent wash
As with any precision equipment, keep all parts free of foreign materials and chemicals.
Protect all exposed sealing surfaces and open cavities from damage and foreign material.
If left unattended, cover the pump with a protective layer of plastic.
l Lubricate moving parts

During assembly, coat all moving parts with clean hydraulic fluid. This assures that these
parts are lubricated during start-up.
d Replace all O-rings and gaskets

Sauer-Danfoss recommends you replace all O-rings, seals, and gaskets during repair.
Lightly lubricate all O-rings with clean petroleum jelly prior to assembly. Grease must be
soluable in hydraulic fluid.
t Secure the unit

For major repair, place the unit in a stable position with the shaft pointing downward. It
is necessary to secure the pump while removing and torquing the endcap bolts.
520L0874 • Rev AL • August 2010 5

Repair Instructions
Introduction
Safety Precautions Always consider safety precautions before beginning a service procedure. Protect
yourself and others from injury. Take the following general precautions whenever servicing
a hydraulic system.
Unintended machine movement

W Warning
Flammable cleaning solvents

W Warning
Fluid under pressure

W Warning
Personal safety
W Warning
times.
6 520L0874 • Rev AL • August 2010

Repair Instructions
Introduction
Symbols used in Sauer-  WARNING may result in injury  Clean area or part
Danfoss Literature
 Non-reusable part, use a new part  Be careful not to scratch or damage
 External hex head  Note correct orientation
 Internal hex head  Torque specification
 Lubricate with hydraulic fluid  Pull out with tool – press fit
 Apply grease / petroleum jelly  Cover splines with installation

cylinder
 Inspect for wear or damage
 Mark orientation for reinstallation
520L0874 • Rev AL • August 2010 7

Repair Instructions
Disassembly
Shaft Seal Removal 1. Orient pump with the shaft pointing Remove shaft /seal/bearing
up.
2. Use a snap ring pliers to remove the J200

top snap ring (J200).
J250
3. Puncture the seal (J250) with a
punch or sharp screwdriver.
J200
4. Use a slide-hammer type puller to
remove the seal. Discard the seal, it is
not reusable. J100
Input Shaft Removal 1. Use a press or gear puller to press

down the shaft.
2. Remove the lower snap ring (J200).
3. Pull the shaft (J100) out of pump.

It may be necessary to tap lightly
on the shaft to dislodge it from the
internal pump components. J150
4. Remove snap ring (J300).
5. Press bearing (J150) from shaft. J300
P106 057E
8 520L0874 • Rev AL • August 2010

Repair Instructions
Disassembly
EDC Control Removal 1. Remove control screws (D250) using Remove control
a 5 mm internal hex wrench. Remove
the control from the pump
D250
Some older pumps may have a five bolt 5 mm
control. This control uses a different
gasket and has no control screeen
(D084).
2. Remove and discard the gasket

(D150).
3. Using a 13 mm deep well socket D150

wrench, remove feedback pin (D200)
from top of swashplate.
D084 D200
13 mm
4. Leave dowel pins (D300) in housing. deep well
F00A
socket
5. If necessary, use a 3 mm internal hex 3 mm F00B
D300 (2X)
to remove orifices (F00A, F00B) for Dowel pin
cleaning. Note location of each for
P106 048E
reassembly.
Orifices A and B may be different size.
6. If necessary, remove screen (D084).

Use a hook to remove steel ring
and screen. Note orientation for
installing new screen. Replace screen
if removed.
520L0874 • Rev AL • August 2010 9

Repair Instructions
Disassembly
EDC Control Disassembly It is not necessary to remove solenoids (D025) unless you are replacing them.
1. Use a 4 mm internal hex wrench to remove cap screws (D050).

If you suspect a coil
malfunction, remove the 2. Remove solenoids (D025). Remove and discard O-rings (D025A).
coil. Remove the plastic
nut with a 26 mm 12 point Do not disassemble internal parts of control. Internal parts are not available separately.
socket. Install a new coil. Control is sold as a complete unit only.
Torque nut to 5 N•m
[3.7 lbf•ft].
Disassemble the control

D050 (3X)
4 mm
D025A
D025
D025A
D050 (3X)
4 mm
P106 061E
10 520L0874 • Rev AL • August 2010

Repair Instructions
Disassembly
Automotive Control 1. Drain pump completely before removing control. Disconnect and remove wiring
Removal (D640).
2. Fabricate a special tool to remove two plastic plugs (D610). See drawing below for
tool dimensions. Push down on plug and turn 45 degrees counterclockwise. Discard
plugs.
Wax seals will be destroyed when the plugs are removed. Do not damage the housing in
the plug sealing area.
3. Use a 5 mm internal hex to remove six screws (D250). W Remove control from
pump.
4. Remove and discard gasket (D150).
Alignment pins are pressed into control. Do not remove them.
5. If necessary, use a 3 mm internal hex to remove orifices (F00A, F00B) from housing.
Tag each orifice for reinstallation. Each orifice may be a different size.
Drill Out Retention Ring
6. If it is necessary to remove the screens, drill out screen retention ring (D098) and
remove and discard screen (D084). Note screen orientation for reassembly.
Screen
W Warning
Retention Do not allow metal fragments to fall into control housing. This may cause erratic pump
Ring
operation.
P108 022E
Remove control Security

wax seal (2X)
D610 (2X)
Special Tool D250
5 mm
(6X)
Special Plug D640

tool
D084
45 deg. D098
D150
Ø 9.22 mm
F00A
Ø 14 mm 3 mm F00B
Ø 1.7 mm (x3)
P108 021E
P106 708E
520L0874 • Rev AL • August 2010 11

Repair Instructions
Disassembly
Optional Integrated 1. Use a 24 mm wrench to remove plug (T015). Remove and discard filter (T150).
Filter Removal
2. Remove and discard O-ring (T045) and O-ring (T035).
3. Use an 8 mm internal hex to remove screws (T250).
4. Remove filter adapter T010. Discard gasket (T350).
Remove filter and adapter
24 mm
T015
T350
T045
T035
T010
T250 (3X)
8 mm
T150
P106 136E
5. Use an 8 mm internal hex wrench

to remove plugs (T025). Remove
T025
O-rings (T025A); discard. 8 mm T025A
6. Remove spring (T030), and spool T030

(T020).
T020
7. If necessary, use a 3 mm internal hex
wrench to remove cap screws (T300)
and switch (T200).
T200
It is not necessary to remove switch 3 mm
T300
(T200) unless you are replacing it.
T025
8 mm P106 138E
12 520L0874 • Rev AL • August 2010

Repair Instructions
Disassembly
Auxiliary Pad or End 1. Position pump so end cover (K100) Remove end cover and charge pump
Cover Removal or auxiliary pad is on top. 147/165 shown
2. Remove end cover/auxiliary pad K400

screws (K400) using a 10 mm internal 10 mm
hex wrench.
Alignment pins (K450) are in end cover.

They may dislodge during disassembly.
K100
3. Remove and discard gasket (K150).
K450
K450 K150
4. Remove thrust washer (K500). Note
thrust washer orientation.
5. Remove pressure balance plate K500

(S200) and seal (S300). Note plate
orientation. Discard seal (S300). S300
6. Remove coupling (K200).

S200
078/089/100 Auxiliary pads

K200
S150
S100
B flange S250
A flange
S300
115/130/147/165 Auxiliary pads
B flange A flange C flange
P106 047E
520L0874 • Rev AL • August 2010 13

Repair Instructions
Disassembly
Charge Pump Removal 1. Remove charge pump outer ring (S150), and gearset (S100).
2. Remove valve plate (S250) with seal (S300). Discard seal (S300).
If charge pump requires replacement, replace as a kit. Kit includes (S300), (S250), (S100),
(S150), and (S200).
Pressure Limiter Valve 1. Using a 22 mm wrench, remove pressure limiter cartridges or plugs (L300, L400).
Removal
Pressure limiters (L300, L400) are available as complete units only. O-ring (L022) is
available separately.
2. Remove and discard O-ring (L022).
Right and left pressure settings may be different. Tag each valve for re-assembly.
Remove pressure limiter

L300
L400
22 mm
22 mm
L022
L022
E101 336E
14 520L0874 • Rev AL • August 2010

Repair Instructions
Disassembly
Charge Pressure Relief 1. Using a 22 mm wrench, remove the Remove charge pressure relief valve
Valve Removal charge pressure relief valve (V010).
2. Discard O-ring (V024).
Charge pressure relief valve (V010) is

available as complete unit only. Seal V024
(V024) is available separately.
V030
22 mm P106 159E
High Pressure Relief 1. Using a 30 mm (115/130/147/165) Remove high pressure relief valves
Valve Removal or 22 mm (078/089/100) wrench,
remove the HPRV valves (L100, L200).
Discard O-rings (L060) and seals
(L068). L060
HPRV valves may not have the same

pressure setting. Tag each valve for re- L068
assembly.
L200
L100
Pressure code
42 marked on end
P106 039E
520L0874 • Rev AL • August 2010 15

Repair Instructions
Disassembly
Endcap Removal See table below for endcap screw Remove endcap and components
wrench sizes 147/165 shown
G350 (4X)
1. Remove two endcap screws (G400).
G400 (2X)
2. Remove four endcap screws (G350).
3. Carefully remove the endcap (G100).

C Caution and valveplate (C025). C Valveplate
Note valveplate orientation may be stuck to endcap. Alignment
for proper reassembly. pin (C020) may remain in endcap.
4. Place the endcap and valve plate in

a clean area, protecting them from G100
contamination.
G980
5. Remove and discard gasket (G150). C020 G550
C025
6. If necessary, use a suitable puller to
remove bushing (G550) by pressing
out. Do not remove bushing unless
worn or damaged.
7. Remove locating pins (B010). G150 B060

B040
B010
8. If necessary, remove lubrication B010 (3X)
orifice (G980) using a small P106 058E

screwdriver. Remove bushing to
access orifice.
If necessary, use a hook to remove

retaining rings (B060) and screens
(B040). 078 cm³ pumps have two screens,
089/100/115/130/147/165 cm³ pumps
have three. Screens are not reusable.
Endcap screw wrench sizes - internal hex

Item 078 089/100/115/130 147/165
G400 6mm 8mm 10mm
G350 12mm 14mm 17mm
16 520L0874 • Rev AL • August 2010

Repair Instructions
Disassembly
Cylinder Block Kit 1. Remove cylinder block assembly Remove cylinder block kit
Removal (C010).
C010
C Caution 2. Set cylinder block assembly on a
Do not scratch the running clean dry surface. C
surfaces of the cylinder
block or slippers. Scratches
in these surfaces can lead
to poor performance or P106 056E
pump failure.
Optinal Displacement 1. If so equipped, remove and discard locking nut (E500). Mark position and remove
Limiter displacement limiter screw (E400).
Remove displacement limiter screw
P107 992E
Displacement Limiter wrench sizes

Displacement Locknut wrench size Adjusting screw
wrench size
078/089/100 13 mm 4 mm internal hex
115/130/147/165 22 mm 6 mm internal hex
520L0874 • Rev AL • August 2010 17

Repair Instructions
Disassembly
Servo Cylinder Removal 2. Remove four locking screws (E350) with a 10 mm wrench. Remove locking plates
(E300).
3. Using a 3/4 in. deep socket, unthread the servo cylinders (E150) from each side of
C Caution the pump. Servo piston will be loose after servo cylinders are removed. CDiscard
Do not allow loose servo O-rings (E250).
piston to damage internal
machined surfaces of
pump. Remove servo cylinder
E250
E150
E300
E350
11 mm E101 330E
Servo Piston Removal Tilt swashplate up to disengage servo arm from piston. Remove the servo piston
assembly (E100).
Remove servo piston
E100
E101 430E
18 520L0874 • Rev AL • August 2010

Repair Instructions
Disassembly
Servo Piston Disassembly 1. Remove and discard seals (E025).
2. Remove slider block (E015).
Servo (E100) is available as an assembly only. Seals (E025) and slider block (E015) are
available as repair items.
Remove O-rings, seals, and slider block
E100
E025 (2X)
E015
E025
P101 337E
Swashplate and Cradle 1. Remove swashplate (D070). Note Remove swashplate and cradle bearings
Bearings Removal cradle bearing orientation and
position for reassembly. If reusing
bearings, reinstall in same location
and orientation.
D070
2. Remove cradle bearings (D075).
D075
D075
P106 059E
520L0874 • Rev AL • August 2010 19

Repair Instructions
Disassembly
Cylinder Block Kit Disassemble the cylinder block kit Disassemble the cylinder block kit
1. Pull to remove the slipper retainer
(C20) with the pistons (C10) from the
cylinder kit.
The pistons are not selectively fitted, C10

however units with high hourly usage
may develop wear patterns. Number the
pistons and bores for reassembly if they
are to be reused.
2. Remove ball guide (C15) and spring

washer (C25). Discard spring washer. C20
Block spring removal
Most repairs do not require block spring

C15
removal. Perform this procedure only
if you suspect problems with the block
spring.
C25
3. Using a press, apply pressure on

W Warning the block spring washer (C40) to
Risk of personal injury: compress the block spring (C30).
Compressing the block Compress the spring enough to
C05
spring requires 350 to safely remove the spiral retaining
400 N [80 to 90 lbf ]. Use a ring (C45). While maintaining
press sufficient to maintain pressure, unwind the spiral retaining
this force with reasonable ring. Carefully release the pressure
effort. Ensure the spring is and remove the outer block spring
secure before attempting washer, block spring, and inner
to remove the spiral block spring washer (C35) from the C35
retaining ring. Release the cylinder block. W
pressure slowly after the
retaining ring is removed.
C30
C40
C45
P106 060E
20 520L0874 • Rev AL • August 2010

Repair Instructions
Inspection
Overview After disassembly, wash all parts (including the end-cap and housing) thoroughly with
clean solvent and allow to air dry. Blow out oil passages in the housing and endcap
with compressed air. Conduct inspection in a clean area and keep all parts free from
contamination. Clean and dry parts again after any rework or resurfacing.
Pistons and Slippers Inspect the pistons for damage and Inspect pistons
discoloration. Discolored pistons may
indicate excessive heat; do not reuse. Slipper
Inspect the running surface of the

slippers. Replace any piston assemblies
with scored or excessively rounded
slipper edges. Replace any piston P104 109E
assemblies with worn slippers. Replace
any piston assemblies with excessive
end-play.
Slipperfoot thickness and piston/slipper

endplay are documented in ReWork
specifications maual 520L1033.
Ball Guide and Slipper Ensure the ball guide is free of nicks Inspect guide and retainer
Retainer and scratches, and not scored. Examine
for discoloration that may indicate Slipper
retainer
excessive heat or lack of lubrication.
The slipper retainer should be flat, and
slippers should fit in the retainer with
minimal side play. Discard and replace Ball guide
any damaged parts. Discard and replace Spring washer
spring washer
E101 362E
Block Spring and If cylinder kit was fully disassembled, Inspect block spring and washers
Washers visual inspection of the cylinder block,
spring, and washers should indicate Washer
minimal wear. Replace if cracks or other
damage is present.
Cylinder block spring
Washer
Retaining ring
P101 472
520L0874 • Rev AL • August 2010 21

Repair Instructions
Inspection
Cylinder Block Examine the running face of the cylinder block. The surface should be smooth and free
of nicks and burrs. Remove any burrs. Ensure that no scratches or grooves exist; these
may drastically reduce output flow and life of pump.
Minimum height, maximum bore diameter, total block height and running face flatness
specifications are documented in ReWork specifications manual 520L1033.
Inspect cylinder block

Cylinder
block
check for burrs
P101 067E
Shaft Check to see that the shaft and its splines Inspect shaft
are straight and free of damage or heavy
wear. Inspect the step where the block
splines contact the block spring washer.
Inspect the shaft surface where it meets
the shaft seal. Replace the shaft if a
groove exists at the sealing land. Clean
the sealing area with a nonabrasive
material if necessary. Lubricate the shaft
E101 329E
with hydraulic fluid before reassembly.
Inspect shaft bearing

Shaft Bearing Clean bearing with a solvent and
lubricate with hydraulic fluid. Inspect for
wear, or pitting. Rotate the bearing in
your hand. Replace if it does not rotate E101 343E
smoothly.
22 520L0874 • Rev AL • August 2010

Repair Instructions
Inspection
Swashplate Carefully inspect each machined surface Inspect swashplate

of the swashplate for wear. Ensure all
swashplate surfaces are smooth. Inspect
the swashplate’s slipper running surface
for flatness and brass transfer. Excessive
brass transfer from slippers may
indicate you should replace the pistons
and swashplate. Check the journals
for scratches. Replace swashplate if
necessary.
E101 338E
Cradle Bearings Inspect the cradle bearings for damage or Inspect cradle bearings
excessive wear. Slide the bearings by hand
and feel for roughness. Replace cradle
bearings if scratched, warped, or worn.
Replace cradle bearings as a pair.
E101 339E
520L0874 • Rev AL • August 2010 23

Repair Instructions
Inspection
Valve Plate Inspect the valve plate for scratches and grooves. Check the plate for pitting along the
running face of the valve plate. If pitting from cavitation exists, replace the valve plate.
Check for excess wear on the brass running face. If any discoloration or burn marks are
observed, replace the valve plate.
Run a fingernail or pencil tip across the diameter of the sealing land surface (see
illustration). You should feel no deep or outstanding grooves. These may decrease pump
flow. Lap or replace if grooves or nicks are present. Inspect the mating surfaces of the
endcap and valve plate for any possible contamination; even a few thousandths of an
inch may affect pump operation.
Ensure valve plate appears flat and smooth on both the running face and the bottom
surface. Perform a magnetic particle inspection to detect cracks. Replace if any cracks
exist.
Valve plate thickness, flatness, and parallelism are documented in ReWork specifications
maual 520L1033.
Inspect valve plate timing pin (not shown). Replace if worn or damaged.
Inspect valve plate
Clockwise valveplate Counterclockwise valveplate
P108 061E
Endcap Inspect the endcap. Inspect all machined Inspect endcap

surfaces for scratches or pits. Carefully
check the bearing surface for wear.
Inspect valve seats carefully for wear or
cracks. Replace if damaged.
Endcap flatness specifications are

documented in ReWork specifications
P108 399E
maual 520L1033.
24 520L0874 • Rev AL • August 2010

Repair Instructions
Inspection
Housing Inspect the housing to ensure that it is

clean and free of foreign material. Inspect
the swashplate bearing surfaces, and
endcap and control mating surfaces.
Inspect housing
P108 400E
Pressure Limiter Pressure limiter valves are available as Inspect pressure limiter valve
complete units only. If you suspect valve
malfunction, replace the valve(s) and test
pump operation. Replace O-rings before
reassembly.
E101 435E
520L0874 • Rev AL • August 2010 25

Repair Instructions
Inspection
HPRV Valve HPRV valves are available as complete Inspect HPRV valve
units only. If you suspect valve
malfunction, replace the valve(s) and test
pump operation. Replace O-rings before
reassembly.
Pressures marked on HPRV valve

Code Pressure bar [psi]
15 150[2175]
20 200 [2900]
23 230 [3336]
25 250 [3626]
28 208 [4061]
30 300 [4351] Pressure code
33 330 [4786] 42 marked on end
35 350 [5076]
38 380 [5511] P106 662E
40 400 [5801]
42 420 [6092]
43 430[6237]
44 440[6382]
45 450 [6527]
48 480 [6962]
Optional Displacement Inspect the displacement limiter screw Inspect displacement limiter
Limiter threads. Ensure that the screw is not
bent. Replace the sealnut.
Displacement limiter
screw
Sealnut
E101 345E
Charge Pressure Relief Charge pressure relief valve is available Inspect charge pressure relief valve
Valve as a complete unit only. If you suspect
valve malfunction, replace the valve and
test pump operation. Replace O-rings if
reusing existing valve.
P106 040E
26 520L0874 • Rev AL • August 2010

Repair Instructions
Inspection
Servo Piston Assembly Inspect slider block (E015) for wear or damage. Replace if necessary. Inspect springs for
warping or cracking. Inspect servo piston for wear, cracks, or damage. Replace entire
assembly if servo piston or springs are damaged.
Do not disassemble servo
piston assembly. Seals and
O-rings are available as a Inspect servo assembly
replacement kit.
E100
E025 (2X)
E015
E025
P101 337E
Control Inspect sealing surfaces of control. If you find nicks or scratches that may allow fluid
leakage, replace control. Inspect feedback spring and linkage. Control is available as a
complete unit only. If you suspect control operation problems, replace control with a
new unit and test pump. If necessary, you may remove and clean the control orifices. Use
If you suspect a coil a 3 mm internal hex. wrench Torque to 2.5 N•m [1.8 lbf•ft]. If screen is plugged, remove
malfunction, remove retaining ring and screen and replace with new screen.
the coil by removing the
plastic nut with a 26 mm
12 point socket. Install Inspect control
a new coil. Torque nut
to 5 N•m [3.7 lbf•ft].
O-ring
Solenoid
screen
retaining
ring
orifices
P106 253E
Automotive control
Inspect machined surfaces on control and housing. Inspect plastic PC housing and
sealing areas. If any damage is found, replace damaged component.
520L0874 • Rev AL • August 2010 27

Repair Instructions
Inspection
Optional Integrated Filter Check machined surfaces for nicks and scratches. Check bypass valve poppet, spring, and
seat. Check bypass indicator switch operation. Replace parts as necessary. Replace all
seals and gaskets before reassembly.
Inspect filter adapter and bypass valve
P106 140E
Clean and inspect filter adapter parts.

Check gasket surfaces for nicks and
scratches. Check bypass valve poppet,
spring, and seat. Check bypass indicator
switch operation. Replace parts as
necessary. Replace all seals and gaskets
before reassembly.
P106 142E
28 520L0874 • Rev AL • August 2010

Repair Instructions
Assembly
Overview This section describes assembly procedures for the H1 pump. If special tools are needed
for assembly or adjustment, they appear in this section. After assembly, adjust pump
according to the settings listed on the model code stamped on the serial number plate.
Connect pump to an appropriate test stand. Refer to 520L0848 H1 Closed Circuit Axial
Piston Pumps Service Manual for further instructions and adjustments for the H1 pump.
Cradle Bearings, 1. Position housing as shown in illustration.

Swashplate, and Filter
Screen Installation 2. Coat the cradle bearings (D075) with hydraulic fluid and install them into the pump
housing. Fit retaining pins into holes in housing.
If cradle bearings are reused, reinstall them in their original orientation and position.
3. Swing bearings fully to each side to check for smooth operation.
4. Install swashplate. Ensure retaining pins fit securely in swashplate. Check that
swashplate moves correctly on cradle bearings.
5. Position swashplate in neutral (flat) position.
6. If previously removed, press new filter screens (B040) into the housing. Install screens
and in same orientation as when removed. Press in retaining ring (B060).
Install cradle bearings, swashplate, and screens
D070
D075
D075 B060
B040
(3X)
Correct screen
orientation
Incorrect screen
orientation
E101 346E
520L0874 • Rev AL • August 2010 29

Repair Instructions
Assembly
Servo Piston Assembly 1. Lubricate and install new piston seals and O-rings (E025). Stretch O-rings onto
servo piston, then install piston seals on top of the O-rings. Allow seals to relax after
installation and use a servo cylinder to resize them before further assembly.
2. Lubricate and install slider block (E015).
Assemble servo
Seal
O-ring
E025
E015
E025
E100
P101 337E
Servo Piston Installation Tilt swashplate up and install servo piston assembly (E100). Ensure swashplate pin fits in
servo slider block (E015).
Do not allow loose servo

to damage internal Install servo piston
machined surfaces of
pump.
Do not damage seals when

installing servo cylinders.
E100
E101 331E
30 520L0874 • Rev AL • August 2010

Repair Instructions
Assembly
Servo Cylinder 1. Lubricate new O-rings (E250) and install on each servo cylinder.
Installation
2. While holding the servo piston in place, thread servo cylinders into housing. Thread
cylinders equal distance in each side of pump until each cylinder contacts servo
assembly. Do not compress servo piston springs.
Install servo cylinders
E250
10 mm
14 N•m [10 lbf•ft]
E350
Servo piston
E150
E300 E101 330E
3. Position locking plates (E300) to engage tab into notch on servo cylinder (E150).
Using a 10 mm hex wrench, install screws (E350). Torque to 14 N•m [10 lbf•ft].
After pump assembly is complete, mount pump on test stand. Perform mechanical
neutral adjustment and control neutral adjustment. Refer to H1 Closed Circuit Axial
Piston Pumps 078/089/100/115/130/147/165 Service Manual 520L0848 for adjustment
procedures.
520L0874 • Rev AL • August 2010 31

Repair Instructions
Assembly
Optinal Displacement 1. If so equipped, install displacement limiter screw (E400) a few turns. Install and
Limiter tighten locking nut (E500). Adjust displacement limiter after pump has been set for
mechanical neutral.
Refer to H1 Pumps Service Manual 520L0848 for instructions on setting mechanical

neutral and adjusting the displacement limiter.
Install displacement limiter screw
P107 993E
Displacement Limiter Adjustment Data

078 13 mm - 30 N•m [28 lbf-ft] 4 mm 7.4 cm3 [0.45 in3]
Install Optional Hold Install hold down clamp to hold swashplate in position. Position clamp so no gap occurs
down Clamp between clamp and machined endcap surface of housing.
While it is possible to Install hold down clamp

assemble the pump
without the use of a Hold down clamp
swashplate hold down
clamp, this practice is not No gap
recommended. between clamp
and housing
Applied pressure is
required to seat the
swashplate in the bearings.
Also, if the swashplate is
loose when the pump is
rotated, the swashplate or
housing may be damaged.
E101 402E
32 520L0874 • Rev AL • August 2010

Repair Instructions
Assembly
Hold Down Clamp 147/165 hold down clamp dimensions

Dimensions
Sharp corner
15.3
mm 10 mm 65 mm 40 mm
128.5 mm
8
mm 15°
9.8 mm
8
48 mm
mm
25 mm
16 mm
30
Offset is required to clear speed ring mm P107 877E
078 hold down clamp dimensions

Sharp corner
17.2
mm 10 mm 40 mm
60 mm
100 mm
8
mm
11.7 mm
5
mm 48 mm
23 mm
P107 878E
Offset is required to clear speed ring
115/130 hold down clamp dimensions

Sharp corner
17.2
mm 10 mm 40 mm
65 mm
119.65 mm
9
mm
10.7 mm
5.5
48 mm
mm
23 mm
P107 879E
Offset is required to clear speed ring
520L0874 • Rev AL • August 2010 33

Repair Instructions
Assembly
Shaft and Seal 1. With swashplate hold down clamp in place, orient pump with the front flange as
Installation shown
Holdown clamp holds 2. Lubricate bearing (J150) with clean hydraulic fluid. Press bearing onto shaft. Using a
swashplate in place snap ring pliers, install bearing snap ring (J300).
when housing is rotated.
Swashplate will fall out of 3. Install shaft into housing. CIt may be necessary to tap the shaft to seat the bearing.
place without holdown Using a snap ring pliers, install lower seal snap ring (J200).
clamp.
4. To protect shaft seal during installation, cover end of shaft with protective cover.
C Caution 5. Lubricate the seal (J250) with hydraulic fluid. Using a seal installation tool or
Do not scratch the housing appropriate deep socket, press seal into housing until it bottoms out against the
or shaft during shaft lower snap-ring. Press evenly to avoid binding and damaging the seal. Install the
installation. upper snap ring (J200).
Install shaft /seal/bearing

J300
J150
Protective
cover
J250 J100
Seal J200
installation P106 038E
tool
J200
Seal installation tool

44.7 mm 89.4 mm
[1.76 in] [3.52 in]
7 mm 68.5 mm
[0.276 in] [2.70 in]
55 mm 51 mm 78 mm
[2.17 in] 50° [2. in] [3.07 in] 80°
120 mm
[4.72 in]
115/089/100
82 mm
[3.23 in]
130/147/165
078 7 mm P106 492E
[0.28 in]
34 520L0874 • Rev AL • August 2010

Repair Instructions
Assembly
Cylinder Kit Assembly 1. Coat all parts with clean hydraulic Assemble cylinder kit
fluid prior to reassembly.
W Warning 2. Install the inner block spring washer

Risk of personal injury: (C40), block spring (C30), and outer
Compressing the block washer (C35) into the cylinder C10
spring requires about 350 block. Using a press, compress the
to 400 N [80 to 90 lbf ]. block spring enough to expose the
Use a press sufficient to retaining ring groove. Wind the spiral
maintain this force with retaining ring (C45) into the groove
reasonable effort. Ensure in the cylinder block. W
the spring is secure before
attempting to install 3. Turn the block over and install new C20
the spiral retaining ring. spring washer (C25) and ball guide
Release the pressure slowly (C15). Do not reuse spring washer.
after the retaining ring is
installed. Position sharp edge of spring washer
C15
(C25) against ball guide (C15) to avoid
excessive cylinder block wear.
4. Insert the pistons (C10) into the C25

slipper retainer (C20). Install the
piston/retainer assembly into the
cylinder block. Ensure the concave
surface of the retainer seats on
the ball guide. If you’re reusing the
C05
pistons, install them to the original
block bores. Lubricate the pistons,
slippers, retainer, and ball guide
before assembly. Set the cylinder
block kit aside on a clean surface
until needed.
C40
C30
C35
C45
E101 350E
520L0874 • Rev AL • August 2010 35

Repair Instructions
Assembly
Cylinder Kit Installation 1. Position pump in horizontal position (as shown). Slide the cylinder block kit onto the
shaft.
2. While holding the shaft in place, slightly rotate the cylinder block kit to help start the
shaft splines over the ball guide and align it with the block splines.
Install cylinder block kit
Slightly rotate
cylinder block
E101 351E
Prevent shaft from rotating
Level Swashplate 1. Position pump with shaft pointing down.
2. Ensure swashplate is seated correctly on bearings.
3. Use depth micrometers to measure distance X and Y as shown.
4. Turn servo cylinders in or out until swashplate is level ± 0.025 mm [0.001in].
Measuring block
Y X
Swashplate
P107 876E
After pump is completely assembled, set swashplate neutral on a test stand. Refer to H1
Pumps 078/089/100/115/130/147/165 Service Manual 520L0848 for proper setting neutral
instructions.
36 520L0874 • Rev AL • August 2010

Repair Instructions
Assembly
Endcap Bushing 1. If previously removed, install orifice (G980) and bushing (G550) into endcap.
Installation
2. Lubricate new bushing and use a suitable press to install. Align lubrication hole in
bushing with lubrication orifice in endcap.
Install bushing
(078) 3mm ±0.05mm

[0.12 in ±0.002in] Bushing
installation
(115/130/147/165) tool
4 mm ±0.05mm
[0.18in ±0.002in]
Installation depth
P106 503E
Ensure that bushing is properly installed. Improper installation resulting in improper

depth or misalignment will result in premature bushing and charge pump failure.
520L0874 • Rev AL • August 2010 37

Repair Instructions
Assembly
Valve Plate and Endcap 1. Remove holdown clamp. Install endcap components
Installation 147/165 shown
G350
2. Clean the valve plate (C025) and
endcap surface. Install valve plate
alignment pin (C020).
3. Install end cap alignment pins B010.

G400
4. Apply a liberal amount of assembly

grease to the backside of the valve
plate surface to hold it in place and
position on endcap.
G100
For proper pump operation, it is
extremely important to ensure that there G980
is no contamination between the endcap C020
and valve plate. G550
C025
5. Install new gasket (G150). Do not
reuse. Install an installation cylinder
on the rear shaft splines to protect
bushing during assembly.
Torque sequence
Do not bend or warp the gasket in G150
an attempt to straighten it. This may B010
6 5 damage the embossing under the
B010
rubber coating.
4 2
6. Install endcap with cap screws
(G350) and (G400).
7. Wrench sizes and torques are listed

1 3 in the table below.
P106 193E Use torque sequence shown.
E101 358E
Endcap screw wrench sizes and torques Valveplate orientation
Item 078 089/100/115/130 147/165 Clockwise valveplate Counterclockwise valveplate
G400 6mm 8mm 10mm Notch used for EDC or FNR controls
32 Nm 64 Nm 110 Nm
[24 lbf•ft] [47 lbf•ft] [81 lbf•ft]
G350 12mm 14mm 17mm
170 Nm 300 Nm 400 Nm
[125 lbf•ft] [220 lbf•ft] [295 lbf•ft]
CW CCW
Notch used for NFPE or AC controls P108 060E
38 520L0874 • Rev AL • August 2010

Repair Instructions
Assembly
Charge Pump Installation Charge pump components are available Remove end cover and charge pump
as a complete kit only. Kit includes (S300), 147/165 shown
(S250), (S100), (S150), and (S200).
K400
1. Install new seals (S300) to valve 10 mm
plate and pressure-balance plate. 92 N•m
[68 lbf•ft]
Lubricate valve plate (S250) and
install in same orientation as when it K100
was removed.
K450
2. Lubricate and install outer ring K450 K150
(S150) and charge pump gearset
(S100).
K500
3. Lubricate and install coupling (K200).
4. Lubricate and install pressure- S300

balance plate (S200) in same
orientation as when it was removed.
S200
5. Lubricate and install thrust washer

(K500) in same orientation as
K200
removed.
Bump on thrust washer fits in hole in end

cover. S150
S100
Auxiliary Pad or End 1. Install alignment pins (K450). Install
Cover Installation gasket (K150).
S250
2. Install end cover or auxiliary pad.
Ensure proper torque on Install cap screws (K400) using a 10
aux pad screws (K400). mm internal hex wrench. Torque S300
If necessary, replace screws. to 92 Nm [68 lbf•ft]. Follow torque
sequence below.
If a second pump is used, re-install it on

If pump is equipped with auxiliary pad.
aux pad, install running
cover and O-ring prior to
testing. Torque sequence
5 7
1 4
3 2
P106 116E
8 6
P106 196E
520L0874 • Rev AL • August 2010 39

Repair Instructions
Assembly
Charge Pressure Relief 1. Install new O-ring (V024). Install charge pressure relief valve
Valve Installation
2. Using a 22 mm wrench, install the
charge pressure relief valve (V010).
3. Torque to 52 N•m [38 lbf•ft].

V024
Refer to Sauer-Danfoss
publication 520L0848 H1
078/089/100/115/130/147/165 Service
Manual for instructions on adjusting V010
charge pressure relief. 22 mm
52 N•m P106 115E
[38 lbf•ft]
Pressure Limiter Valve 1. Lubricate and install O-rings (L022). Install pressure limiter
Installation
2. Install pressure limiter valves (L300,
L300
L400). See table below for torques L400
22 mm
22 mm
and wrench sizes.
publication 520L0848 H1 L022
078/089/100/115/130/147/165 Service L022
Manual for instructions on adjusting
pressure limiter.
E101 361E
Model 078 089/100/115

130/147/165
Torque N•m [lbf•ft] 30 [22] 70 [52]
Wrench size 14 mm 22 mm
40 520L0874 • Rev AL • August 2010

Repair Instructions
Assembly
HPRV Valve Installation 1. Install new O-rings (L060, L068) on Install HPRV valve
cartridges (L100, L200).
2. Install and torque HPRV valves per

table below.
L060
Model 078 089/100/115

L068
130/147/165
Torque N•m [lbf•ft] 70 [52] 110 [81]
Wrench size 22 mm 30 mm
L200
L100
P106 114E
Optional Displacement 1. Thread adjusting screw (E400) into Install the displacement limiter
Limiter Installation servo cylinder.
2. Thread locking nut (E500) onto

displacement limiter adjusting screw.
When torquing locking Torque the locknut per the table
nut, be sure servo cylinder below.
does not turn.
publication 520L0848 H1 E400
see table
078/089/100/115/130/147/165 Service
Manual for instructions on adjusting E500
E101 357E
displacement limiter. see table
520L0874 • Rev AL • August 2010 41

Repair Instructions
Assembly
Control Assembly Assemble control

D050 (3X)
4 mm
If you suspect a coil 8 N•m [6 lbf•ft]
malfunction, remove the
coil (D025B) by removing D025B
26 mm
the plastic nut with a 26 5 N•m [3.7 lbf•ft]
mm 12 point socket.
Install a new coil. Torque
D025A
nut to 5 N•m [3.7 lbf•ft].
D025
D025A
D025
D050 (3X)
4 mm
E101 352E
1. Install new O-rings (D025A) on solenoids (D025), and attach solenoids with M6 cap
screws (D050) using 4 mm internal hex wrench. Torque to 8 N•m [6 lbf•ft].
2. Press new retaining ring (D094) and screen (D084) into control assembly. Install as
shown.
Proper screen orientation
D094
D084
D084

P106 618E
42 520L0874 • Rev AL • August 2010

Repair Instructions
Assembly
Control Installation Install the control
D250
5 mm
13.3 N•m
[9.8 lbf•ft]
D150
D200
13 mm Deep well socket
22.5-27.5 N•m
3 mm [16.6-20.3 lbf•ft]
2.5 N•m F00A
[1.8 lbf•ft] F00B
D300
E101 353E
1. Use a 13 mm deep well socket to install feedback pin (D200) in swashplate. Torque to
W Warning 25 N•m [18.5 lbf•ft]. Do not overtorque. W
If feedback pin comes off
during operation, pump 2. If removed, install control orifices (F00A, F00B) into their original positions using a
will loose controllability 3mm internal hex wrench. Torque to 2.5 N•m [2 lbf•ft].
causing a potentially
hazardous situation. Ensure 3. Install dowel pins (D300) to housing.
feedback pin is properly
torqued before further 4. Install new gasket (D150).
assembly.
5. Position control on pump housing.
6. Remove plug on top of control to visually ensure that feedback pin is engaged in
control arms.
Torque sequence 7. Using a 5 mm internal hex wrench, fasten control to pump with cap screws (D250).
Torque screws to 13.3 N•m [9.8 lbf•ft]. Follow torque sequence shown below.
2 1
8. Adjust swashplate neutral, control neutral, and if necessary, displacement limiter
6 5
after assembly is complete. Refer to 520L0848 H1 Closed Circuit Axial Piston Pump
Service Manual for adjustment procedures.
4 3
P106 195E
520L0874 • Rev AL • August 2010 43

Repair Instructions
Assembly
Automotive Control 1. If previously removed, install new screen (D084) in original orientation. Press in new
Installation retention ring (D098). Be sure screen will not move axially in bore after retention ring
is installed. Refer to screen installation diagram on page 43.
W Warning
Failure to install screen will result in erratic pump operation.
2. If previously removed, use a 3 mm internal hex to install orifices (F00A, F00B) in

original orientation. Torque to 2.5 N•m [1.8 lbf•ft].
3. Install new gasket (D150) to bottom of control.
4. Install control on pump. Use a 5 mm internal hex to install six screws (D250). Torque
to 13.3 N•m [9.8 lbf•ft]. Follow torque sequence shown on page 42.
Do not damage the plastic housing when installing the screws.
5. Connect wiring (D640).
If pump has been rebuilt 6. Use a special tool to install new plastic plugs with O-rings (D610). Press in an turn 45
or a new control is being degrees clockwise.
installed, control software
must be recalibrated. Refer If control will continue to be under warranty, install new sealing wax. Pumps without
to H1-Automotive Control sealing wax installed will not be warrantied.
User Manual 70012797 for
recalibration instructions.
Install control
Security
wax seal (2X)
13.3 Nm D610 (2X)

Special plug installation tool [9.8 lbf•ft] D250
5 mm
(6X)
Special Plug
tool D640
D084
45 deg.
D098
D150
Ø 9.22 mm
2.5 Nm F00A
Ø 14 mm
[1.8 lbf•ft] 3 mm F00B
Ø 1.7 mm (x3)
P108 021E
P107 990E
Replacing solenoids
Follow solenoid replacement procedure on page 42.
44 520L0874 • Rev AL • August 2010
Repair Instructions
Assembly
Optional Integrated 1. If replacing switch (T200), use a Assemble filter adapter

Filter Installation 4 mm internal hex wrench to install
cap screws (T300) and switch (T200). T025
Torque to 1.2-1.8 N•m, [0.8-1.3 lbf•ft]. 8 mm
T025A
2. Lubricate and install new O-rings
T030
(T025A) on plugs (T025).
3. Install spring (T030), and spool T020

(T020).
4. Use an 8 mm internal hex wrench T200

to install plugs (T025) and torque to
16-20 N•m, [12-15 lbf•ft].
T025
5. Install new gasket (T350). T300 8 mm
T025A
P106 142E
T015
T350
T045
T035
T010
T250 (3X)
8 mm
T150
P106 140E
6. Use an 8 mm internal hex to install screws (T250). Torque to 29-35 N•m, [21-26 lbf•ft].
7. Lubricate and install new seal (T045) and O-ring (T035).
8. Lubricate filter seal and install new filter (T150). Use a 24 mm wrench to hold plug
(T015) in place and install the replacement filter. Hand tighten filter till it contacts
O-ring, then tighten 1/2 turn further.
520L0874 • Rev AL • August 2010 45

Repair Instructions
Startup procedures
Overview Install pump on test stand. Adjust per Sauer-Danfoss testing specifications TS-392. Refer
to 520L0848 H1 078/089/100/115/130/147/165 Closed Circuit Axial Piston Pumps Service
Manual for startup procedures, adjustments, and pressure measurements for H1 pump.
Initial Startup Procedures Startup procedures include:

• Ensure system components are clean
• Install new filters
• Fill system with fluid
• Disable engine
• Disconnect control
• Crank engine and check for adequate charge pressure
• Check for proper control function
Adjustments Adjustment procedures include:

• Mechanical neutral
• Charge pressure relief adjustment
• Pressure limiter adjustment
• Displacement limiter adjustment
• Electronic displacement control (EDC) adjustment
Pressure Measurements Pressure measurement procedures include:

• Required tools
• Port locations
• Gauge installation
• Leakage test per Sauer-Danfoss test HPP 112
46 520L0874 • Rev AL • August 2010

Repair Instructions
Port locations
Port Locations and The following table and drawing show the port locations and gauge sizes needed. When
Gauge Installation testing system pressures, calibrate pressure gauges frequently to ensure accuracy. Use
snubbers to protect gauges.
Port information
Port identifier Port size Wrench size Reading Gauge size, bar [psi]
L1, L3 (078/089/100) 7/8-14 UNF 2B 3/8 internal hex Case drain 10 [100]
L2, L4 (078/089/100) 1 1/16-12 UNF 2B 9/16 internal hex Case drain 10 [100]
L1, L3 (115/130/147/165) 1 1/16-12 UNF 2B 9/16 internal hex Case drain 10 [100]
L2, L4 (115/130/147/165) 1 5/16-12 UNF 2B 5/8 internal hex Case drain 10 [100]
MA, MB 9/16-18 UNF 1/4 internal hex System pressure 600 [10,000]
M3 9/16-18 UNF 2B 1/4 internal hex Charge pressure- after filter 50 [1000]
M4, M5 7/16-20 UNF 2B 3/16 internal hex Servo pressure 50 [1000]
M6 9/16-18 UNF 2B 1/4 internal hex Charge pressure - pre integrated filter 50 [1000]
Port locations
Gauge port M5 Servo pressure
7/16-20 UNF-2B
Gage port M4 Case drain Port L1 Gauge port M3
servo pressure Port L3 Case drain Charge pressure
7/16-20 UNF 2B after filter
9/16-18 UNF-2B
System
Port B
Charge pump inlet S Case drain port L2

1 5/8-12 UNF 2B System Port A Case drain Port L4 1 5/16-12 UNF-2B
use highest port Gauge port MB
as outlet System pressure
9/16-18 UNF-2B
G300
5/16-24 UNF-2B
air bleed
Charge pressure Gauge port MA

D065 O-ring plug Gauge port M6 System pressure
7/16-20 UNF-2B pre integrated filter 9/16-18 UNF-2B
use for air bleed when filling pump 9/16-18 UNF-2B
P106 033E
520L0874 • Rev AL • August 2010 47

Repair Instructions
Torque chart
Fastener Size and

Torques
D015 Neutral adjust screw 4 mm internal hex NA
D050 Coil mounting bolt 4 mm internal hex 8 N•m [6 lbf•ft]
D060 Neutral adjust locking nut 13 mm 10 N•m [7 lbf•ft]
D200 Swash plate feedback pin (not shown) 13 mm deep well socket 25 N•m [18 lbf•ft]
D250 Electric control mounting bolt 5 mm internal hex 13.3 N•m [9.8 lbf•ft]
E350 Servo can locking bolt 10 mm 14 N•m [10 lbf•ft]
G350 (078) Endcap screw (4) 12 mm internal hex 170N•m [125 lbf•ft]
G400 (078) Endcap screw (2) 6 mm internal hex 32N•m [24 lbf•ft]
G350 (089/100/115/130) Endcap screw (4) 14 mm internal hex 300 N•m [220 lbf•ft]
G400 (089/100/115/130) Endcap screw (2) 8 mm internal hex 64 N•m [47 lbf•ft]
G350 (147/165) Endcap screw (4) 17 mm internal hex 400N•m [295 lbf•ft]
G400 (147/165) Endcap screw (2) 10 mm internal hex 110N•m [81 lbf•ft]
L010 (078) Pressure limiter adjust screw 8 mm NA
L012 (078) Pressure limiter cartridge 14 mm 30 N•m [22 lbf•ft]
L010 (089/100/115/130/147/165) Pressure limiter adjust screw 5 mm internal hex NA
L012 (089/100/115/130/147/165) Pressure limiter cartridge 22 mm 70 N•m [52 lbf•ft]
L024 (078) Pressure limiter locking nut 14 mm 20 N•m [15 lbf•ft]
L150 (078) High pressure relief valve 22 mm 70 N•m [52 lbf•ft]
L024 (089/100/115/130/147/165) Pressure limiter locking nut 17 mm 20 N•m [15 lbf•ft]
L028 (089/100/115/130/147/165) Pressure limiter plug (special) 30 mm 110 N•m [81 lbf•ft]
L150 (089/100/115/130/147/165) High pressure relief valve 19 mm 68 N•m [50 lbf•ft]
T015 Filter mounting bolt 17 mm 21 N•m [16 lbf•ft]
T025 Filter adapter gage plug 6 mm internal hex 18 N•m [13 lbf•ft]
V010 Charge pressure cartridge 22 mm 52 N•m [38 lbf•ft]
V020 Charge pressure adjusting screw 4 mm internal hex NA
V022 Charge pressure locking nut 13 mm 12 N•m [9 lbf•ft]
Plug Size and Torques
Item O-ring plug Wrench size Torque

B015 7/16 - 20 3/16 mm internal hex 12 N•m [9 lbf•ft]
B020 (078/ 089/100/115/130) 7/8 - 14 3/8 internal hex 50N•m [37 lbf•ft]
B020 (147/165) 1-1/16 - 12 9/16 internal hex 70 N•m [52 lbf•ft]
B035 (078/ 089/100/115/130) 1 1/16 - 12 9/16 internal hex 70 N•m [52 lbf•ft]
D065 7/16 - 20 3/16 internal hex 12 N•m [9 lbf•ft]
G302 5/16 - 24 UNF 1/8 internal hex 5 N•m [4 lbf•ft]
48 520L0874 • Rev AL • August 2010

Repair Instructions
Torque chart
Fasteners and Plugs 115/130/147/165 Pressure limiter 078 Pressure limiter

L010 Adjusting screw L028 Adjusting screw
L024 Locking nut
L024 Locking nut
L028 Plug (special)
L012 Cartridge L012 Cartridge
B015 O-ring plug, 7/16 - 20

D015 Neutral adjusting screw
D060 Neutral adjust locking nut
Pressure limiter
D050 Coil mounting bolt G400 Endcap screw

B020 O-ring plug
1-1/16 - 12
G350 Endcap screw
G300 O-ring plug, 9/16 - 18
B030 O-ring plug, 1-5/16 - 12 E350

D250 G250 O-ring plug, 9/16 - 18
Electric control
mounting bolt
G302 O-ring plug

5/16 - 24 UNF
D065 O-ring plug, 7/16 - 20 P106 066E
520L0874 • Rev AL • August 2010 49

Repair Instructions
Torque chart
Fasteners and Plugs

(continued)
B015 O-ring plug, 7/16 - 20

D015 Neutral adjusting screw L010 Pressure limiter adjusting screw
D060 Neutral adjust locking nut L024 Pressure limiter locking nut
L028 Pressure limiter plug (special)
D050 Coil mounting bolt L012 Pressure limiter cartridge

B020 O-ring plug
1-1/16 - 12
G300 O-ring plug, 9/16 - 18
B035 O-ring plug, see table E350

D250 G250 O-ring plug, 9/16 - 18

Electric control
mounting bolt
G302 O-ring plug

5/16 - 24 UNF
D065 O-ring plug, 7/16 - 20

P106 497E
50 520L0874 • Rev AL • August 2010

Repair Instructions
Notes
520L0874 • Rev AL • August 2010 51

Products we offer: Sauer-Danfoss is a global manufacturer and supplier of high-
quality hydraulic and electronic components. We specialize in
• Bent Axis Motors providing state-of-the-art technology and solutions that excel in
the harsh operating conditions of the mobile off-highway market.
• Closed Circuit Axial Piston Pumps
Building on our extensive applications expertise, we work closely
and Motors
with our customers to ensure exceptional performance for a broad
• Displays range of off-highway vehicles.
• Electrohydraulic Power Steering
We help OEMs around the world speed up system development,
• Electrohydraulics reduce costs and bring vehicles to market faster.
Sauer-Danfoss – Your Strongest Partner in Mobile Hydraulics.
• Hydraulic Power Steering
• Integrated Systems
• Joysticks and Control Handles
Go to www.sauer-danfoss.com for further product information.
• Microcontrollers and Software
• Open Circuit Axial Piston Pumps
• Orbital Motors Wherever off-highway vehicles are at work, so is Sauer-Danfoss.
• PLUS+1™ GUIDE
We offer expert worldwide support for our customers, ensuring
• Proportional Valves the best possible solutions for outstanding performance. And with
an extensive network of Global Service Partners, we also provide
• Sensors
comprehensive global service for all of our components.
• Steering
• Transit Mixer Drives
Please contact the Sauer-Danfoss representative nearest you.
Local address:
Members of the Sauer-Danfoss Group:
Comatrol
www.comatrol.com
Schwarzmüller-Inverter
www.schwarzmueller-inverter.com
Ames, IA 50010, USA Phone: +45 7488 4444
Turolla
Phone: +1 515 239 6000 Fax: +45 7488 4400
www.turollaocg.com Fax: +1 515 239 6618
Hydro-Gear Sauer-Danfoss GmbH & Co. OHG Sauer-Danfoss-Daikin LTD.

www.hydro-gear.com Postfach 2460, D-24531 Neumünster Shin-Osaka TERASAKI 3rd Bldg. 6F
Krokamp 35, D-24539 Neumünster, Germany 1-5-28 Nishimiyahara, Yodogawa-ku
Phone: +49 4321 871 0 Osaka 532-0004, Japan
Sauer-Danfoss-Daikin Fax: +49 4321 871 122 Phone: +81 6 6395 6066
Fax: +81 6 6395 8585
www.sauer-danfoss-daikin.com
520L0874 • Rev AL • August 2010

www.sauer-danfoss.com
A.B Vibration motor

Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics
RDE 91 001-03-R/05.03
Konstantmotor A2FM/E ersetzt / replaces 04.00
Fixed Displacement Motor A2FM/E

Baureihe / Series 61
Reparaturanleitung / Repair Instructions

2 Bosch Rexroth AG | Mobile Hydraulics A2F | RDE 91 001-03-R/05.03
Hinweis / Inhalt
Notice / Contents
HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen entsprechen Specifications, descriptions and illustrative material shown here
dem Informationsstand zum Zeitpunkt der Drucklegung dieser in were as accurate as known at the time this publication was
Unterlage. approved for printing.
Änderungen können den Service am Produkt beeinflussen, Ver- BRUENINGHAUS HYDROMATIK reserves the right to dis-
pflichtungen entstehen uns daraus nicht. continue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für deren Re- specifications, materials, or design without notice and without
sultat wir keine Haftung übernehmen können. incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Optional equipment and accessories may add cost to the basic
Fabrik-Nr. bestellt, sind die Basis guter Reparaturen. unit, and some options are available only in combination with
certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf dem
Teststand vorzunehmen. For the available combinations refer to the relevant data sheet for
the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vorkehrungen si-
cherzustellen. Adjustment and tests have to be carried out on the test bench
under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, vermit-
teln wir in unseren Schulungskursen. Protection of personnel and property has to be guar-anteed by
appropriate measures.
Expert knowledge, the precondition of any service work, can be
obtained in our training courses.
INHALT Seite/ CONTENTS

Page
A2F A2F
Schnittbild 3-6 Sectional view

Allgemeine Reparaturhinweise 7 General repair instructions
Dichtsätze und Baugruppen 8-9 Seal kits and sub-assemblies
Triebwelle abdichten 10 Sealing of the drive shaft
Anschlußplatte abdichten 11-14 Sealing of the cover plate
Triebwerk ausbauen 15-16 Removal the rotary group
Überprüfungshinweise 17-18 Inspection guidelines
Triebwerk einbauen 19-21 Installing rotary group
Anziehdrehmomente 22-24 Tightening torques
Sicherheitsbestimmungen 25 Safety regulations
RDE 91 001-03-R/05.03 | A2F Mobile Hydraulics | Bosch Rexroth AG 3
Schnittbild
Sectional view
A2FM Pos.B
Pos.D
Pos.A
Meßpunkte: Measuring points:

Siehe Serviceinfo See service information
Schnittbild
Sectional view
A2FM mit Spülventil /

A2FM with flushing valve
Schnittbild
Sectional view
A2FE
Schnittbild
Sectional view
A2FE
Allgemeine Reparaturhinweise
General repair instructions
Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!
Attention!
Observe the following notices when carrying out
repair work at hydraulic aggregates!
Alle Öffnungen der Hydraulikaggregate

verschließen.
Close all ports of the hydraulic aggregates.
Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.
Replace all seals.

Use only OR IG I NAL B R U E N I NG HAUS
HYDROMATIK spare parts.
Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.
Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.
Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befüllen bzw. entlüften.
Before start-up fill up hydraulic aggregates with

hydraulic oil respectively deaerate.
Dichtsätze und Baugruppen

Seal kits and sub-assemblies
Dichtsatz
Seal kit
Triebwerk, mechanischer Teil /

Rotary group, mechanical part
Triebwerk, mechanischer Teil;

muß abgestimmt werden Pos. "A".
(siehe Serviceinfo)
Rotary group, mechanical part;

has to be adjusted to item "A".
(see service info)
Lagersatz, komplett abgestimmt.

Pos. B (Stützscheibe und Sicherungsring
nicht tauschbar)
zusätzliche Abstimmung Pos. "A".
(siehe Serviceinfo)
Bearing set, matched

Item B (support disc and circlip are
not exchangeable)
Additional adjustment item "A".
(see service info)
Dichtsätze und Baugruppen

Seal kits and sub-assemblies
Triebwerk, hydraulischer Teil /

Rotary group, hydraulic part
Triebwerk, hydraulischer Teil;

Abstimmung hydraulischer Teil Pos. "D".
(siehe Serviceinfo)
Rotary group, hydraulic part;

Adjustment of the hydraulic part Pos. "D".
(see service info)
Triebwerk komplett; - fertig vorabgestimmt -

Abstimmung hydraulischer Teil Pos. "D".
(siehe Serviceinfo)
Complete rotary group, - pre-adjusted -

Adjustment of the hydraulic part Pos. "D".
(see service info)
Spülventil
Flushing valve
Ventil
Valve
Triebwelle abdichten
Sealing of the drive shaft
Bei nicht verzahnten Triebwellen: Paßfeder abneh-

men. Triebwelle abkleben,
For non-splined shafts: remove key.

Protect the drive shaft (e.g. tape).
Sicherungsring ausbauen, Verschlußring abdrücken
Remove circlip, prise off cover.
Sichtkontrolle
Wellendichtring (1), Verschlußring (2),
Triebwelle (3), Gehäuse (4), O-Ring (5).
Visual check
Shaft seal (1), cover (2), drive shaft (3),
housing (4), O-ring (5).
Triebwelle abdichten
Sealing of the drive shaft
Wellendichtring demontieren.
Remove shaft seal.
Neuen Wellendichtring lagerichtig mit

passender Büchse einpressen.
Press in the new shaft seal,ensuring that

it is correctly orientated, using a suitable bush.
Neuen O-Ring einlegen, auf bündiges Anliegen

achten. O-Ring sowie Dicht- und Staublippe des
Wellendichtringes einfetten. (siehe Serviceinfo)
Fit new O-ring, ensure that it is correctly located.

Grease the O-ring as well as the seal and dust lips
of the shaft seal. (see service information)
Sicherungsring einbauen.
Sitzkontrolle des Sicherungsringes in der Nut.
Fit circlip.
Check to ensure that the circlip is correctly located
within the groove.
Anschlußplatte abdichten
Sealing of the cover plate
Lage der Anschlußplatte zum Gehäuse kenn-

zeichnen (Pfeil), Befestigungsschrauben lösen.
Mark the position of the cover plate with regard

to the housing (arrow), loosen the fixing screws.
Anschlußplatte um Verdrillstift schwenken (1)

und abheben (2).
Swing the connection plate about the locating

pin (1) and lift off (2).
Auf Montagestellung des Verdrillstiftes achten

(Pfeile).
Take the assembly position of the locating

pin (arrow) into account.
Pumpe, Drehrichtung rechts.

Saugseite / (Blick auf sphärische Fläche.)
Suction side Druckseite /
Pressure side Pump, clockwise rotation.
(viewed on spherical surface.)
Saugseite /
Druckseite / Pumpe, Drehrichtung links.
Suction side
Pressure side (Blick auf sphärische Fläche.)
Pump, anti-clockwise rotation.

(viewed on spherical surface.)
Motor, beide Drehrichtungen.

(Blick auf sphärische Fläche.)
Motor, bi-directional.
(Viewed on spherical surface.)
Sichtkontrolle
O-Ring (1), Einstich (2), Platte (3).
Visual check
O-ring (1), Groove (2), Plate (3).
Neuen O-Ring einlegen, zuvor leicht einfetten.
Lightly grease and fit O-ring.
Anschlußplatte aufsetzen, auf Kennzeichnung und

Lage des Verdrillstiftes achten.
Place the cover plate onto the housing taking into

account the location mark and position of the
locating pin.
Befestigungsschrauben mit Drehmomenten-

schlüssel anziehen.
Tighten fixing screws using a torque wrench.

Triebwerk ausbauen
Removal the rotary group
Lagersatz / Bearing set
Demontage der Anschlußplatte.

Steuerplatte abheben.
Zylinder am Mittelzapfen mit Schraube befestigen.
Removal of the connection plate.

Lift off the control plate.
Secure the cylinder to the centre pin using a screw.
Gewindestift,Zylinderschraube /
Threaded pin,socket head screw
NG / Size (mm)
10; 12; 16 M3 x 35
23; 28; 32 M5 x 45
45 M5 x 50
56; 63 M5 x 55
80; 90 M5 x 60
107; 125; 131 M6 x 70
160; 180 M6 x 85
Triebwerk ausbauen
Removal the rotary group
Verschlußring, O-Ring und Paßscheibe ausbauen.
Remove the cover, O-ring and shim.
Triebwerk mit Vorrichtung ausbauen.
Withdraw the rotary group using an extractor.
Befestigungsschraube ausbauen.
Zylinder abheben.
Remove the fixing screw.

Lift off the cylinder.
Rückzugplatte demontieren, Schrauben sind

eingeklebt.
Komplettes Triebwerk bei ca. 120o C im Ölbad
erwärmen. Danach Befestigungsschrauben lösen!
Disassemble the retaining plate, screws are locked

with an adhesive.
Heat up the complete rotary group in an oil bath
to approx 120o C, then remove the fixing screws.
Überprüfungshinweise
Inspection guidelines
Triebwelle
4 4 1. kein Passungsrost, nicht ausgeschlagen.
1 2
3 2. keine Einlaufspuren, riefenfrei.
3. Kalotten riefenfrei und keine Pittings.
4. Keine Laufspuren (Lagerdreher)
3
Drive shaft
1. No wear, or fretting
2. No traces of wear, free of scratches.
3. Cups free of wear and no pitting.
4. No traces of wear, (bearing rotation).
1
1. Axiales Kolbenspiel
1. Axial play of piston.
Alt / Old
Kolben
Riefenfrei, keine Pittings.
Piston
Neu / New
Free of scratches, no pitting.
1 2
Mittelzapfen
1. Riefenfrei, ohne Pittings.
2. Riefenfrei.
Center pin
1. Free of scratches, no pittings.
2. Free of scratches.
Rückzugplatte
Riefenfrei, keine Ausbrüche.
Retaining plate
Free of scratches, no wear.
Überprüfungshinweise
Inspection guidelines
Zylinder/Steuerplatte
1. Bohrungen riefenfrei, nicht ausgelaufen.
2. Gleichmäßiges Tragbild, riß- und riefenfrei.
Cylinder / control plate

1. Bores unscratched, and no traces of wear.
2. Even load distribution, free of cracks and
grooves.
Gehäuse
Im Lagerbereich riefenfrei und keine
Einlaufspuren.
Housing
No traces of wear in the bearing area.
Nur kompletten Kolbensatz austauschen.
Only exchange the pistons as a complete set.
Zylinder und Steuerplatte nur gemeinsam

austauschen.
Only replace the cylinder and control plate as a pair.

Triebwerk einbauen
Installing rotary group
Triebwelle mit Lager vormontiert verwenden.
Use a pre-assembled drive shaft with bearings.
S Abstimmung Pos. A / Adjustment item A
A = A* + S
S = Nennmaß - Sicherungsring /Safety ring
A A*
Rückzugplatte mit Kolben und Mittelzapfen

einsetzen.
Schrauben mit Precote-Beschichtung verwenden.
Fit retaining plate complete with pistons and

centre pin.
Uses screws with a Precote coating.
Druckfeder (1) und Abstimmscheibe (2) einbauen.
Fit the compression spring (1) and shim(2).
Zylinder in Neutralposition befestigen.
Fix the cylinder in the neutral position.

Triebwerk einbauen
Triebwerk max. ausschwenken.
Swivel the rotary group to max.
Neuer Radialwellendichtring montiert?
Is the new shaft seal fitted?
Gehäuse auf ca. 80o C erwärmen.
Heat the housing to approx. 80o C.
Heißes Gehäuse bis zum Anschlag aufsetzen.
Push on the hot housing until the stop is reached.
Neue Montagestellung.
New assembly position.

Triebwerk einbauen
Paßscheibe, O-Ring einlegen. Verschlußring

montieren.
O-Ring, Zwischenraum Wellendichtring einfetten
(siehe Serviceinfo).
Fit the shim and O-ring. Then fit the cover.

Grease the O-ring as well as the seal and dust
lipsof the shaft seal.
Triebwerk gegen Verschlußring ziehen.

Kontrolle: Verschlußring spielfrei.
Pull the rotary group against the cover.

Check: to see that the cover is free of play.
Befestigungsschraube ausbauen.
Steuerplatte lagerichtig aufsetzen.
Fertigmontage
Abstimmung Pos. D - siehe Serviceinfo
Remove fixing screw. Fit the control plate into its

correct location.
Final assembly
For adjustment of Pos. D - see service info
Abstimmung Pos. D / Adjustment item D

Pos. D
Anschlüsse mit Staubschutz abdichten.

Korrosionsschutz (innen/außen). Fertig!
Seal connections to protect against dust.

Corrosion proctection (internal/external).
Assembly complete.
Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques
1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)
Die Werte gelten für Schaftschrauben mit metri- The values stated are valid for bolts with metric
schem ISO-Gewinde nach DIN 13 Teil 13, sowie ISO threads to DIN 13 part 13, as well as head
Kopfauflagemaßen nach DIN 912 Zylinder- areas to DIN 912 socked head cap screws, DIN
schrauben, DIN 931 Sechskantschrauben mit 931 hexagon bolt or DIN 933 hexagon bolts with
Schaft bzw. DIN 933 Sechskantschrauben mit threads up to the head.
Gewinde bis Kopf.
Festigkeitsklassen / Tensile strength class

Gewinde / Thread 8.8 10.9 12.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 1,1 1,6 1,9
M4 3,1 4,5 5,3
M5 6,1 8,9 10,4
M6 10,4 15,5 18
M8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).
G
EOLASTIC-
Dichtung / Seal
Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1,5 20 G 3/8 A 35
M14 x 1,5 30 G 1/2 A 60
M16 x 1,5 35 G 3/4 A 90
M18 x 1,5 40 G1 A 140
M20 x 1,5 50 G 1 1/4 A 240
M22 x 1,5 60 G 1 1/2 A 300
M26 x 1,5 70
M27 x 2 90
M30 x 1,5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300

7. Linsenschrauben 7. Oval head screw

mit Innen-TORX, Gewindevorbeschichtung mit "precote" with inner TORX, thread precoated with "precote"
Standard / Standard precote 80 - Rot / Red
precote 86 - Blau / Blue

Variante / Variant
*
Ι 2602493 M5 x 16
Ι 2602395 M6 x 20
siehe Stückliste / as to parts list
* mit Unterkopfbeschichtung - farblos

* with head bottom coating - colorless
Festigkeitsklassen / Tensile strength class

Gewinde / Thread 10.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 2,1
M4 4,7
M5 9,1
M6 15,8
M8 37,7
Sicherheitsbestimmungen
Safety regulations
Allgemein General advice
● Machen Sie sich mit der Ausstattung der Maschine ● Make yourself familiar with the equipment of the
vertraut. machine.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den ● Only operate the machine if your are completely familiar with
Bedien- und Steuerelementen sowie der Arbeitsweise der the operating and control elements as well as the functioning
Maschine vertraut gemacht haben. of the machine.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, ● Use your safety equipment like helmet, safety shoes and
Sicherheitsschuhe und Gehörschutz. hearing protection.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ● Make yourself familiar with your working field.
● Benutzen Sie die Maschine nur für den ihr zugedachten ● Only operate the machine for its intended purpose.
Zweck.
Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.
Hydraulikanlage Hydraulic equipment

1. Hydraulikanlage steht unter hohem Druck! 1. Hydraulic equipment is standing under high pressure.
Unter hohem Druck austretende Hochdruck-Flüssig- High pressure fluids (fuel, hydraulic oil) which escape
keiten (Kraftstoff, Hydrauliköl) können die Haut durch- under high pressure can penetrate the skin and cause
dringen und schwere Verletzungen verursachen. heavy injuries.
Daher sofort einen Arzt aufsuchen, da anderenfalls Therefore immediately consult a doctor as otherwise
schwere Infektionen entstehen können! heavy infections can be caused.
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr 2. When searching leakages use appropriate auxiliary devices
geeignete Hilfsmittel verwenden! because of the danger of accidents.
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt 3. Before working at the hydraulic equipment, lower pressure
drucklos machen und angebaute Geräte absenken! to zero and lower working arms of the rnachine.
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor 4. When working at the hydraulic equipment, absolutely stop
abstellen und Traktor gegen Wegrollen sichern motor and secure tractor against rolling away
(Feststellbremse, Unterlegkeil)! (parking brake, shim)!
5. Beim Anschließen von Hydraulikzylindern und -motoren ist 5. When connecting hydraulic cylinders and motor pay
auf vorgeschriebenen Anschluß der Hydraulikschläuche attention to correct connection of hydraulic flexible hoses.
zu achten! 6. In case of exchanging the ports, the tunctions are vice versa
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen (f. ex. lift-up/lower) - danger of accidents!
(z.B. Heben/Senken) - Unfallgefahr! 7. Check hydraulic flexible hoses regularly and replace them in
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und case of dammage or wear! The new hose pipes must comply
bei Beschädigung und Alterung austauschen! Die with the technical requirements of the machine manufacturer!
Austausch schlauchleitungen müssen den technischen
Anforderungen des Geräteherstellers entsprechen! Orderly disposal or recycling of oil, fuel and
filters!
Öle, Kraftstoffe und Filter ordnungsgemäß
entsorgen!
Bosch Rexroth AG
Mobile Hydraulics
Produktbereich Axialkolbenmaschinen
Werk / Plant Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
info.brm-ak@boschrexroth.de
www.boschrexroth.com/brm
© 2003 by Bosch Rexroth AG, © 2003 by Bosch Rexroth AG,

Mobile Hydraulics, 89275 Elchingen Mobile Hydraulics, 89275 Elchingen
All rights reserved. No part of this Alle Rechte vorbehalten. Kein Teil des
document may be reproduced or Werkes darf in irgendeiner Form ohne
stored, processed, duplicated or vorherige schriftliche Zustimmung der
circulated using electronic systems, in Bosch Rexroth AG reproduziert oder
any form or by any means, without the unter Verwendung elektronischer
prior written authorization of Bosch Systeme gespeichert, verarbeitet,
Rexroth AG. In the event of vervielfältigt oder verbreitet werden.
contravention of the above provisions, Zuwiderhandlungen verpflichten zu
the contravening party is obliged to Schadensersatz.
pay compensation. Die angegebenen Daten dienen allein
The data specified above only serve to der Produktbeschreibung. Eine
describe the product. No statements Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
given information does not release the werden. Die Angaben entbinden den
user from the obligation of own Verwender nicht von eigenen
judgement and verification. It must be Beurteilungen und Prüfungen. Es ist
remembered that our products are zu beachten, dass unsere Produkte
subject to a natural process of wear einem natürlichen Verschleiß- und
and aging. Alterungsprozess unterliegen.
Printed in Germany
RDE 91 001-03-R/05.03
A.C Steering valve

Service
Hydrostatic Steering unit

OSPB, OSPC and OSPF
Service manual
DKMH.PS.210.A1.52 replaces. HN.21.AD.01, HN.21.AD.02, HN.21.AD.03 and HN.21.AD.04
Index Page
Cost-free repairs .........................................................................................................................2
Authorized service-shops............................................................................................................2
Exploded view: OSPB................................................................................................................3

OSPC / OSPF...................................................................................................4
Tools ...........................................................................................................................................5
Dismantling ................................................................................................................................7
Assembling................................................................................................................................16
Max. tightening torque and hydraulic connections ....................................................................29
Hydraulics Organisation ........................................................................................................... 30
05-1999 DKMH.PS.210.A1.52 520L0066 Book 6 partition 3 1

Vederlagsfri reparation Vi gør opmærksom på, at vederlagsfri reparation er som omtalt i Danfoss’ Almindelige Leveringsbetingelser
kun udføres hos Danfoss Nordborg eller hos Danfoss autoriserede service shops.
Cost-free repairs Please note that cost-free repairs as mentioned in Danfoss General Conditions of Sale, are
carried out only at Danfoss Nordborg or at service shops authorized by Danfoss.
Kostenlose Reparatur Beachten Sie bitte, daß die in den "Allgemeinen Lieferbedingungen" von Danfoss erwähnte kostenlose
Reparatur nur bei Danfoss Nordborg oder bei den von Danfoss autorisierten Kundendienstwerkstätten aus-
geführt wird.
Réparation gratuite Nous faisons remarquer que la réparation gratuite mentionnée dans les Conditions générales de Vente de
Danfoss ne devra être effectuée que dans les ateliers Danfoss
à Nordborg ou dans les ateliers de dépannage agréés par Danfoss.
Authorized Service-Shops Australia : Danfoss (Australia) Pty. Ltd., Melbourne

Austria : Hainzl Industriesysteme, GmbH., Linz
Belgium : N.V. Danfoss S.A., Bruxelles
Brazil : Danfoss do Brasil Ind.e Com. Ltda., São Paulo
Canada : Danfoss Mfg. Ltd., Mississauga
Denmark : Danfoss Hydraulik A/S, Ganløse
Finland : OY Danfoss AB, Espoo
France : Danfoss S.a.r.l., Trappes (Paris)
Germany : Danfoss GmbH., Offenbach/Main
Great Britain : Danfoss Limited, Greenford (London)
Iceland : Hedinn Verslun HF, Reykjavik
India : Dantal Hydraulics PVT Ltd., New Delhi
Italy : Danfoss s.r.l. Division Sordella, Torino
Japan : Danfoss K.K., Gotemba
Korea : Unitek Corporation, Seoul
Netherlands : Itho B.V., Schiedam
New Zealand : Danfoss (New Zealand) Limited, Auckland
Norway : Danfoss A/S, Skui
Republic of South Africa : Danfoss (Pty) Ltd., Johannesburg
Singapore : Danfoss Industries Pte. Ltd., Singapore
Spain : Danfoss S.A., San Sebastian de los Reyes, (Madrid)
Sweden : Danfoss AB, Mjölby
Switzerland : Danfoss Werner Kuster AG, Frenkendorf
Turkey : Mert Teknik A.S., Istanbul
U.S.A. : Danfoss Fluid Power Div. Racine, Wisconsin
Service-Shops Australia : Danfoss (Australia) Pty. Ltd., Adelaide

Australia : Danfoss (Australia) Pty. Ltd., Brisbane
Australia : Danfoss (Australia) Pty. Ltd., Perth
Australia : Danfoss (Australia) Pty. Ltd., Sydney
Czech Rep. : Techno Trade, Olomouc
Greece : A. Skoura & Co. E.E., Athens
New Zealand : Danfoss (New Zealand) Limited, Christchurch
Taiwan : Symbridge Machinery Co. Ltd., Taipei
Bemærk: I det følgende er der kun medtaget de punkter hvor der er afvigelser fra HN.21.AD
Note: The following includies only such items that deviate from HN.21.AD
Beachte: Das folgende befaßt sich nur mit solchen Punkten die sich von HN.21.AD unterscheiden.
Important: Seuls les points divergeant du HN 21.AD sont traités dans ce qui suit.
2 DKMH.PS.210.A1.52 520L0066
Exploded view OSPB
1 Dust seal ring 14 Spacer

2 Housing + spool + sleeve 15 O-ring ∅80,5x1,5 mm
3 Ball ∅8,5 mm 16 Distributor plate
4 Thread bushing 17 Gearwheel
5 O-ring with 18 O-ring ∅75,92x1,78 mm
kin-ring or Roto Glyd 19 End cover
7 Bearing assembly 20 Washer ∅8,2x11,9x1,0 mm
10 Ring I/D 39l,6x0,7x4,5 mm 22 Special screw
11 Cross pin ∅6x41 mm 23 Screw
12 Neutral position springs 24 Name label
13 Cardan shaft 26 Spacer
DKMH.PS.210.A1.52 520L0066 3
Exploded view OSPC / OSPF
1 Dust seal ring 16 Distributor plate

2 Housing, spool and sleeve. 17 Gearwheel set
Check valve and the seats for relief and 18 O-ring
shock valves are locktited. 19 End cover
3 Ball ∅8,5 mm 20 Washer
4 Thread bushing 22 Special screw
5 O-ring used with kin-ring (item 6) 23 Screw
6 Kin-ring 24 Name plate
7 Bearing assembly 30 Complete relief valve
10 Ring 31 Spring wire
11 Cross pin 32 Complete shock valve
14 Spacer 33 Ball ∅3/16 in
13 Cardan shaft 38 Spring
12 Set of springs 34 Rolled pin
15 O-ring 36 Bushing
35 Ball
39 Kin ring
40 O-ring
4 DKMH.PS.210.A1.52 520L0066
Tools
Holdeværktøj + styrering
Best.nr.: SJ 150-9000-2.
Best.nr.: SJ 150-9000-16.
Holding tool + guide-ring

Code no.: SJ 150-9000-2.
Best.nr.: SJ 150-9000-16.
Haltewerkzeug + Zentrierring
Artikel-Nr.: SJ 150-9000-2.
Best.nr.: SJ 150-9000-16.
Support de montage + baque de guidage

No de code: SJ 150-9000-2.
Best.nr.: SJ 150-9000-16.
Monteringsværktøj til O-ring/kin-ring / Roto Glyd

Best.nr.: SJ 150-9000-11.
Best.nr.: SJ 150N4014-1.
Assembly tool for o-ring and kin-ring / Roto Glyd

Code no. SJ 150-9000-11.
Best.nr.: SJ 150N4014-1.
Montagewerkzeug für O-Ring/Kin-Ring / Roto Glyd

Artikel-Nr.: SJ 150-9000-11.
Best.nr.: SJ 150N4014-1.
Outil de montage pour joint torique/bague-Kin / Roto Glyd

No. de code: SJ 150-9000-11.
Best.nr.: SJ 150N4014-1.
Monteringsværktøj til læbepakning.

Best.nr.: SJ 150-9000-17.
Assembly tool for lip seal.

Code no. SJ 150-9000-17.
Montagewerkzeug für Lippendichtung.

Artikel-Nr.: SJ 150-9000-17.
Outil de montage pour joint labial.

No. de code: SJ 150-9000-17.
Monteringsværktøj til kardanaksel.

Best.nr.: SJ 150-9000-3.
Assembly tool for cardan shaft.

Code no. SJ 150-9000-3.
Montagewerkzeug für Kardanwelle.

Artikel-Nr.: SJ 150-9000-3.
Outil de montage pour arbre à cardan.

No. de code: SJ 150-9000-3.
DKMH.PS.210.A1.52 520L0066 5
Monteringsværktøj til støvtætningsring.
Best.nr.: SJ 150-9000-22.
Assembly tool for dust seal.

Code no. SJ 150-9000-22.
Montagewerkzeug für Staubdichtungsring.

Artikel-Nr.: SJ 150-9000-22.
Outil de montage pour bague anti-poussière.

No. de code: SJ 150-9000-22.
Momentnøgle 0-7 daNm.

13 mm topnøgle.
6, 8 og 12 mm unbrakoskruer.
12 mm skruetrækker.
2 mm skruetrækker.
13 mm ringnøgle.
6, 8 og 12 mm unbrakonøgler.
Plasthammer.
Pincet.
Værktøjerne nævnt under pkt. F kan ikke købes hos Danfoss.
Torque wrench 0-7 daNm.

13 mm socket spanner.
6, 8 and 12 mm hexagon sockets.
12 mm screwdriver.
2 mm screwdriver.
13 mm ring spanner.
6, 8 and 12 mm hexagon socket spanners.
Plastic hammer.
Tweezers.
The tools named under point F are not available from Danfoss.
Drehmomentschlüssel 0-7 daNm.

13 mm Steckschlüssel.
6, 8 und 12 mm Innensechskantschraube.
12 mm Schraubenzieher.
2 mm Schraubenzieher.
13 mm Ringschlüssel.
6, 8 und 12 mm Innensechskantstiftschlüssel.
Kunststoffhammer.
Pinzette.
Die unter Punkt F genannten Werkzeuge können nicht bei Danfoss bestellt werden.
Clé dynamométrique de 0-7 daNm

Clé à douille de 13 mm.
Vis allen de 6, 8 et 12 mm.
Tournevis pour encoche de 12 mm.
Tournevis pour encoche de 2 mm.
Clé annulaire de 13 mm.
Clé Allen de 6, 8 et 12 mm.
Marteau en matière plastique.
Une paire de brucelles.
Les outils mentionnés dans le text repéré F ne peuvent pas être commandés à Danfoss.
6 DKMH.PS.210.A1.52 520L0066
Dismantling
Demonter ratstammen fra styreenheden og anbring styreenheden i holdeværktøjet.

Skru skruerne i endedækslet ud (seks stk. plus specialskrue).
Dismantle steering column from steering unit and place the steering unit in the holding tool.
Screw out the screws in the end cover (6-off plus one special screw).
Lenksäule von der Lenkeinheit abmontieren und die Lenkeinheit im Haltewerkzeug anbringen.
Schrauben im Enddeckel herausschrauben (sechs Stück und Spezialschraube).
Démonter la colonne de direction du dispositif de direction et placer ensuite celui-ci dans le

support de montage. Dévisser les six vis et la vis spéciale du couvercle extrême.
Fjern endedækslet sideværts.
Remove the end cover, sideways.
Enddeckel seitlich entfernen.
Enlever latéralement le couvercle extrême.
Løft tandhjulssæt med evt. afstandsring af enheden. Tag de to O-ringe ud.
Lift the gearwheel set (with spacer if fitted) off the unit. Take out the two o-rings.
Zahnradsatz mit evtl. Distanzring von der Einheit abheben.

Die beiden O-Ringe herausnehmen.
Enlever le jeu d’engrenages (avec la rondelle d’écartement éventuelle) du dispositif de

direction. Extraire les deux joints toriques.
Demonter kardanakslen.
Remove cardan shaft.
Kardanwelle abmontieren.
Démonter l’arbre à cardan.
DKMH.PS.210.A1.52 520L0066 7
Demonter fordelerpladen.
Remove distributor plate.
Verteilerplatte abmontieren.
Démonter la plaque distributrice.
Skru gevindbøsningen over kontraventilen ud.
Screw out the threaded bush over the check valve.
Gewindebuchse abmontieren.
Dévisser la douille filetée placée au-dessus du clapet anti-retour.
Fjern O-ringen.
Remove o-ring.
O-Ring entfernen.
Enlever le joint torique.
8 DKMH.PS.210.A1.52 520L0066
OSPB; OSPB LS; OSPBX LS:
Ryst kontraventilens kugle (∅8 mm) ud.
OSPC; OSPC LS; OSPC LSR:

Ryst kontraventilens kugle samt efterfyldningsventilernes stifter og kugler ud.
Bemærk: På nogle af stifterne til OSPC findes der to fjedre (Se s. 3 pos. 28).
Se også reservedelsliste for OSPC HN.21.UA.52.
Stifterne skal udskiftes med nye ved genmontering!

Shake out the check valve ball (∅ 8 mm).
OSPC; OSPC LS; OSPC LSR:

Shake out the check valve ball and suction valve pins and balls.
Note: On some pins in the OSPC there are two springs (see page 3, pos. 28). See also
spare parts list for OSPC HN.21.UA.52.
Replace this pins prior to the reassembly!

Kugel des Rückschlagventils (∅ 8 mm) herausschütteln.
OSPC; OSPB LS; OSPC LSR:

Kugel des Rückschlagventils sowie die Stifte und Kugeln des Nachfüllventils herausschütteln.
Beachte: An einigen Stiften für den OSPC befinden sich zwei Federn (siehe S. 3 Pos. 28).
Siehe auch die Ersatzteilliste für OSPC HN.21.UA.52.
Diese Stifte müssen vor erneuter Montage ausgewechselt werden!

Secouer le carter pour en faire sortir la bille (diam. 8 mm) du clapet anti-retour.
OSPC; OSPB LS; OSPC LSR:

Secouer le carter pour en faire sortir la bille du clapet antiretour ainsi que les goupilles et les
billes des clapets d’aspiration.
Attention: Quelques-unes des goupilles de l’OSPC sont montées de deux ressorts (voir à la
page 3, repère 28). Voir aussi la liste des pièces de rechange de l’OSPC,
HN.21.UA.52.
Remplacer les goupilles lors de remontage.
Vær opmærksom på at tap i ydre og indre glider skal holdes vandret. Tappen kan ses gennem
den åbne ende i den indre glider. Tryk indre glider indad. Så følger ydre glider, ring, løbeskiver
og nåleleje med ud af huset.
Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen throu-
gh the open end of the spool. Press the spool inwards and the sleeve, ring, bearing races and
needle bearing will be pushed out of the housing together.
Darauf achten, dass der Stift im äusseren und inneren Schieber waagerecht gehalten wird.
Der Stift ist durch das offene Ende des inneren Schiebers sichtbar. Inneren Schieber nach
innen drücken. So kommen äußerer Schieber, Ring, Laufscheiben und Nadellager mit aus dem
Gehäuse heraus.
Faire attention à tenir horizontalement la goupille traversant le tambour de sélection et le man-

chon d’alimentation. Elle est visible par le bout ouvert du tambour de sélection. En poussant le
tambour de sélection, extraire du carter le manchon d’alimentation, le tambour de sélection, la
bague, les rondelles d’apuui et le roule ment à aiguilles.
DKMH.PS.210.A1.52 520L0066 9
Tag ring, løbeskiver og nålelejer af indre/ydre glider. Den ydre (tynde) løbeskive kan til tider
“klæbe” fast i huset. Kontrollér derfor at den er kommet med ud.
Take ring, bearing races and needle bearing from sleeve and spool. The outer (thin) bearing
race can sometimes “stick” in the housing, therefore check that it has come out.
Ring, Laufscheiben und Nadellager aus dem inneren/äusseren Schieber entfernen. Die äußere
(dünne) Laufscheibe kann manchmal im Gehäuse “festkleben”. Daher kontrollieren, ob sie mit
herausgekommen ist.
Démonter du tambour et du manchon la bague, les rondelles d’appui et les roulements à aiguil-
les. La rondelle extérieure (mince) reste parfois collée au carter. Vérifier donc qu’elle a bien
sorti.
Tryk tappen ud. Brug evt.specialskruen fra endedækslet.

Bemærk næste punkt/afsnit!
Press out the cross pin. Use the special screw from the end cover.
Note next point/paragraph!
Stift herausdrücken. Evt. die Spezialschraube vom Enddeckel verwenden.

Bitte nächsten Punkt/Abschnitt beachten!
Sortir la goupille. Utiliser la vis spéciale du couvercle extrême.

Attetion au point/chapitre suivant!
OSPB CN og OSPC CN
Der er slebet et lille mærke både på indre og ydre glider lige ved siden af en af slidserne til
neutralstillingsfjedrene (se tegningen).
Hvis mærket ikke kan ses, husk da selv at sætte et mærke på begge glidere før neutralstillings-
fjedrene demonteres.
For OSPF skal de to viste mærker stå over for hinanden!
OSPB CN and OSPC CN

A small mark has been made with a pumice stone on both spool and sleeve close to one of the
slots for the neutral position springs (see drawing).
If the mark is not visible, remember to leave a mark of your own on sleeve and spool before the
neutral position springs are dismantled.
For OSPF both marks should be placed opposite each other!
CN
OSPB CN und OSPC CN
Es ist am inneren sowie am äußeren Schieber dicht neben einem der Schlitze für die
Neutral-stellungsfedern eine kleine “Kerbe” geschliffen (siehe die Zeichnung).
Falls diese “Kerbe” nicht zu sehen ist, bitte selbst die beiden Schieber vor Demontage der
Neutralstellungsfedern kennzeichnen.
Für OSPF müssen sich die gezeigten Markierungen gegenüberstehen!
OSPB CN et OSPC CN
On a meulé une petite marque tant sur le tambour de sélection que le manchon d’alimentation
juste à côté l’une des fentes pour les ressorts de centrage (voir le dessin).
Si la marque n’est pas visible, n’oubliez pas vous-même de mettre une marque tant sur le
tambour que le manchon avant le démontage des resorts de centrage.
Les deux repères sur l'OSPF doivent se trouver vis-à-vis l'un de l'autre.
OSPF
10 DKMH.PS.210.A1.52 520L0066
Tryk forsigtigt indre glider ud af ydre glider.
Carefully press the spool out of the sleeve.
Inneren Schieber vorsichtig aus dem äußeren Schieber herausdrücken.
Sortir, en le pressant avec précaution, le tambour de sélection du manchon d’alimentation.
Tryk neutralstillingsfjedrene ud af slidsen indre glider.
Press the neutral position springs out of their slots in the spool.
Neutralstellungsfedern aus dem Schlitz im inneren Schieber herausdrücken.
Presser les ressorts de centrage pour les sortir de la fente du tambour de sélection.
Demonter støvtætningsringen og O-ringen/kin-ringen/Roto Glyd.
Remove dust seal and o-ring/kin-ring/Roto Glyd.
Staubdichtungsring und O-Ring/Kin-Ring/Roto Glyd abmontieren.
Démonter la bague anti-poussière et le joint torique/la bague-Kin/Roto Glyd.
Dismantling the shock valves for OSPC/OSPC LS
Skru propperne til chokventilerne ud med en 6 mm unbrakonøgle.
Remove plugs from shock valves using a 6 mm hexagon socket spanner.
Die Stopfen für die Schockventile mit einem 6 mm Innensechskantstiftschlüssel

herausschrauben.
Dévisser les bouchons des soupapes de sécurité à l’aide d’une clé Allen de 6 mm.
DKMH.PS.210.A1.52 520L0066 11
Fjern tætningsskiverne (to stk.).
Remove seal washers (2-off).
Dichtungsscheiben (zwei Stck.) entfernen.
Enlever les deux rondelles d’étanchéité.
Skru indstillingsskruerne ud med en 6 mm unbrakonøgle.
Unscrew the setting screws using a 6 mm hexagon socket spanner.
Einstellschrauben mit einem 6 mm Innensechskantstiftschlüssel herausschrauben.
Dévisser les vis de réglage à l’aide d’une clé Allen de 6 mm.
Ryst de to fjedre og to ventilkugler ud i hånden. Ventilsæderne kan ikke demonteres da de er

limet fast i huset.
Shake out the two springs and two valve balls into your hand. The valve seats are bonded into
the housing and cannot be removed.
Die beiden Federn und zwei Ventilkugeln in die Hand herausschütteln. Die Ventilsitze lassen
sich nicht abmontieren, da sie im Gehäuse festgeklebt sind.
Secouer le carter pour en faire sortir les deux ressorts et les deux cônes de soupape. Les
sièges des soupapes sont collès au carter et ne s’enlèvent pas.
Chokventilerne er nu adskilt.
The shock valves are now dismantled.
Die Schockventile sind jetzt zerlegt.
Le démontage des soupapes de sécurité effet est alors terminé.
12 DKMH.PS.210.A1.52 520L0066
Dismantling the pressure relief valve for OSPC
Skru proppen ud med en 8 mm unbrakonøgle.

Fjern tætningsskiverne
Screw out the plug using and 8 mm hexagon socket spanner.

Remove seal washers.
Stopfen mit einem 8 mm Innensechskantstiftschlüssel herausschrauben.

Dichtungsscheiben entfernen.
Dévisser le bouchon à l’aide d’une clé Allen de 8 mm.

Enlever les rondelles d’étanchéité.
Skru indstillingsskruen ud med en 8 mm unbrakonøgle.
Unscrew the setting screw using an 8 mm hexagon socket spanner.
Einstellschraube mit einem 8 mm Innensechskantstiftschlüssel herausschrauben.
Dévisser la vis de réglage à l’aide d’une clé Allen de 8 mm.
Ryst fjeder og stempel ud. Ventilsædet kan ikke demonteres da det er limet fast i huset.
Shake out spring and piston. The valve seat is bonded into the housing and cannot be
removed.
Feder und Kolben herausschütteln. Der Ventilsitz lässt sich nicht abmontieren, da er im
Gehäuse festgeklebt ist.
Secouer le carter pour en faire sortir le ressort et le piston. Le siège du limiteur est collé au
carter et ne s’en lève pas.
Overstrømningsventilen er nu adskilt.
The pressure relief valve is now dismantled.
Das Druckbegrenzungsventil ist jetzt demontiert.
Le démontage du limiteur de pression est alors terminé.
DKMH.PS.210.A1.52 520L0066 13
Dismantling the pressure relief valve (cartridge) for OSPC LS/OSPC LSR
Skru overstrømningsventilen ud med en 8 mm unbrakonøgle. Fjern tætningsringen.

Hvis venti-len er defekt skal den skiftes ud (Se OSPC-reservedelslisten HN.21.UA.52).
Screw out the pressure relief valve using and 8 mm hexagon socket spanner. Remove the seal
ring. If the valve is defective it must be replaced (see OSjPC spare parts list, HN.21.UA.52).
Druckbegrenzungsventil mit einem 8 mm Innensechskantstiftschlüssel herausschrauben.

Dichtungsring entfernen. Wenn das Ventil defekt ist, muß es ausgewechselt werden.
(Siehe OSPC-Ersatzteilliste HN.21.UA.52).
Dévisser le limiteur de pression à l’aide d’une clé Allen de 8 mm. Enlever la bague d’étanchéité.
Si le limiteur est défectueux, il faut le remplacer. (Voir la liste des pièces de rechange de
l’OSPC, HN.21.UA.52).
Overstrømningsventilen er nu adskilt.
The pressure relief valve is now dismantled.
Das Druckbegrenzungsventil ist jetzt auseinandergenommen.
Le démontage du limiteur de pression est alors terminé.
OSPB-styreenheden er nu fuldstændig adskilt.
The steering unit OSPB is now completely dismantled.
Die Lenkeinheit OSPB ist jetzt vollständig auseinandergenommen.
Le démontage du dispositif de direction OSPB est alors terminé.
OSPB LS-styreenheden er nu fuldstændig adskilt.
The steering unit OSPB LS is now completely dismantled.
Die Lenkeinheit OSPB LS ist jetzt vollständig auseinandergenommen.
Le démontage du dispositif de direction OSPB LS est alors terminé.
14 DKMH.PS.210.A1.52 520L0066
OSPC-styreenheden er nu fuldstændig adskilt.
Disse stifter skal udskiftes med nye før montering.
The steering unit OSPC is now completely dismantled.

Die Lenkeinheit OSPC ist jetzt vollständig auseinandergenommen.

Le démontage du dispositif de direction OSPC est alors terminé.

Remplacer les goupilles lors de remontage.
OSPC LS-styreenheden er nu fuldstændig adskilt.

Disse stifter skal udskiftes med nye før montering.
The steering unit OSPC LS is now completely dismantled.

Die Lenkeinheit OSPC LS ist jetzt vollständig auseinandergenommen.

Le démontage du dispositif de direction OSPC LS est alors terminé.
Rensning
Rengør alle dele omhyggeligt i Shellsol K eller lign.
Kontrol og udskiftning
Skift alle pakninger og skiver ud. Kontrollér omhyggeligt alle andre dele og skift ud om nødvendigt.
Smøring
Smør alle enkeltdele ind i hydraulikolie før samling.
Cleaning
Clean all parts carefully in Shellsol K or the like.
Inspection and replacement
Replace all seals and washers. Check all parts carefully and make any replacements necessary.
Lubrication
Before assembly, lubricate all parts with hydraulic oil.
Reinigung
Alle Teile sind sorgfältig in Shellsol K oder dgl. zu reinigen.
Kontrolle und Auswechseln
Alle Dichtungen und Scheiben sind auszuwechseln. Alle Teile sind sorgfältig zu kontrollieren und erforderlichenfalls auszu-
wechseln.
Schmierung
Vor der Montage sind alle Einzelteile mit Hydrauliköl einzuschmieren.
Nettoyage
Nettoyer soigneusement toutes les pièces dans du Shellsol K ou un produit analogue.
Vérification et remplacement
Remplacer tous les joints et rondelles. Vérifier soigneusement toutes les pièces et les remplacer s’il y a lieu.
Lubrification
Avant le remontage, enduire toutes les pièces d’huile hydraulique.
DKMH.PS.210.A1.52 520L0066 15
Assembling
Læg de to flade neutralstillingsfjedre i slidsen.

Læg de buede fjedre ind mellem de flade og skub dem på plads.
Place the two flat neutral position springs in the slot.

Place the curved springs between the flat ones and press them into place.
Die beiden flachen Neutralstellungsfedern in den Schlitz einlegen.

Die gebogenen Federn zwischen die flachen Federn legen und sie auf ihren Platz schieben.
Mettre lex deux ressorts à lames planes dans la fente.

Insérer entre les resorts à lames planes les ressorts à lames en arc et les pousser en place.
Ret op på fjedersættet.
Line up the spring set.
Federsatz aufrichten.
Aligner le jeu de ressorts.
Før den indre glider ind i den ydre glider. Sørg for at den indre og den ydre glider til OSPB LS,
OSPBX LS, OSPC LS, OSPC LSR og OSPFer placeret korrekt i forhold til hinanden (se side 10).
Guide the spool into the sleeve. Make sure that spool and sleeve for OSPB LS, OSPBX LS,
OSPC LS, OSPC LSR and OSPF are placed correctly in relation to each other (see page 10).
Inneren Schieber in den äußeren Schieber einführen. Darauf achten, daß der innere und der
äußere Schieber für OSPB LS, OSPBX LS, OSPC LS, OSPC LSR ind OSPF im Verhältnis
zueinander richtig angebracht sind (siehe Seite 10).
Placer le tambour de sélection dans le manchon d’alimentation. Veiller à ce que le tambour de

sélection soit placé correctement par rapport au manchon d’alimentation dans les dispositifs de
direction OSPB LS, OSPBX LS, OSPC LS,t OSPC LSR und OSPF (voir à la page 10).
16 DKMH.PS.210.A1.52 520L0066
Saml glidersættet.
Bemærk
OSPB LS, OSPBX LS, OSPC LS, OSPC LSR og OSPF

Ved samling af indre og ydre glider er kun den ene af de to mulige placeringer af fjedrenes slid-
ser rigtig. Der findes tre slidser i indre glider og tre boringer i ydre glider i den ende af gliderne
der er modsat fjederslidserne.
Placer slidser og boringer ud for hinanden så man gennem slidserne i indre glider kan se dele
af boringerne i ydre glider.
OSPB CN og OSPC CN
Saml glidersættet så mærkerne på indre og ydre glider er ud for hinanden (se tegning s. 10).
Assemble spool and sleeve.
Note
OSPB LS, OSPBX LS, OSPC LS, OSPC LSR and OSPF
When assembling spool and sleeve only one of two possible ways of positioning the spring
slots is correct.
There are three slots in the spool and three holes in the sleeve in the end of the spool/sleeve
opposite to the end with spring slots. Place the slots and holes opposite each other so that
parts of the holes in the sleeve are visible through the slots in the spool.
OSPB CN and OSPC CN

Assemble the spool/sleeve and make sure the marks on spool and sleeve are opposite each
other (see drawing page 10).
Innere und äußere Schieber montieren.
Beachte
OSPB LS, OSPBX LS, OSPC LS, OSPC LSR und OSPF
Bei der Montage des inneren und äußeren Schiebers ist nur die eine, der beiden möglichen
Anbringungen der Federschlitze richtig. Es befinden sich drei Schlitze im inneren Schieber und
drei Bohrungen im äußeren
Schieber an dem Ende der Schieber das den Federschlitzen entgegengesetzt ist. Schlitze und
Bohrungen so im Verhältnis zueinander anbringen, daß man durch die Schlitze im inneren
Schieber Teile der Bohrungen im äußeren Schieber sehen kann.
OSPB CN und OSPC CN

Den Schiebersatz so zusammensetzen, dass sich die “Kerben” am inneren und äußeren
Schieber einander gegenüber befinden (siehe Zeichnung Seite 10).
Remonter le manchon d’alimentation et le tambour de sélection.
Attention
OSPB LS, OSPBX LS, OSPC LS, OSPC LSR et OSPF

Pour le remontage du manchon d’alimentation et du tambour de sélection, on ne peut utiliser
qu’un seul des deux emplacements disponibles pour les fentes des ressorts. Il y a trois fentes
dans le tambour de sélection et trois alésages dans le manchon d’alimentation à l’extrémité du
manchon/tambour (côte opposè) des fentes des ressorts. Placer les fentes vis-à-vis des
alésages correspondants de façon qu’une partie des alésages du manchon d’alimentation soit
visible en regardant à travers les fentes du tambour de sélection.
OSPB CN et OSPC CN
Remonter le tambour de sélection et le manchon d’alimentation de façon que les marques du
tambour/du manchon se trouvent vis-à-vis l’une de l’autre. (Voir le dessin a la page 10).
HN.xx.xx.01 17
Klem fjederenderne sammen og tryk neutralstillingsfjedrene på plads i den ydre glider.
Press the springs together and push the neutral position springs into place in the sleeve.
Federenden zusammendrücken und Neutralstellungsfedern im äusseren Schieber auf ihren

Platz drücken.
Comprimer les bouts des ressorts et pousser en place les ressorts de centrage dans le
manchon d’alimentation.
Ret fjedrene op og centrer dem.
Line up the springs and centre them.
Federn aufrichten und zentrieren.
Aligner et centrer les ressorts.
Før ringen ned over den ydre glider.

Bemærk: Ringen skal kunne drejes uhindret af fjedrene.
Guide the ring down over the sleeve.

Note: The ring should be able to move - free of the springs.
Ring über den äußeren Schieber hinunterführen.

Beachte: Der Ring muß sich frei von den Federn drehen können.
Monter la bague sur le manchon d’alimentation.

Attention: La bague doit pouvoir tourner librement des ressorts.
Monter tappen i glidersættet.
Fit the cross pin into the spool/sleeve.
Stift in den Schiebersatz montieren.
Monter la goupille dans le tambour/manchon.
18 DKMH.PS.210.A1.52 520L0066
Monter løbeskiver og nåleleje som vist på tegningen nedenfor.
Fit bearing races and needle bearing as shown on below drawing.
Laufscheibe und Nadellager montieren, wie auf der untenstehenden Zeichnung gezeigt ist.
Monter les rondelles d’appui et le roulement à aiguilles comme indiqué dans le dessin en
dessous.
Assembly pattern for standard bearing
1 Ydre løbeskive
2 Nåleleje
3 Indre løbeskive
4 Indre glider
5 Ydre glider
1 Outer bearing race

2 Needlebearing
3 Inner bearing race
4 Spool
5 Sleeve
1 Äußere Laufscheibe
2 Nadellager
3 Innere Laufscheibe
4 Innerer Schieber
5 Äusserer Schieber
1 Rondelle d’appui extérieure

2 Roulement à aiguilles
3 Rondelle d’appui intérieure
4 Tambour de sélection
5 Manchon d’alimentation
Assembly pattern for double bearing
1 Aksiallejeskive
2 Ydre nåleleje
3 Ydre løbeskive
4 Indre glider
5 Ydre glider
6 Indre nåleleje
7 Indre løbeskive
1 Washer for axial bearing

2 Outer needlebearing
3 Outer bearing race
4 Spool
5 Sleeve
6 Inner needlebearing
7 Inner bearing race
1 Axiallagerscheibe
2 Äußeres Nadellager
3 Äußere Laufscheibe
4 Innerer Schieber
5 Äußerer Schieber
6 Inneres Nadellager
7 Innere Laufscheibe
1 Rondelle de butée
2 Roulement à aiguilles extérieure
3 Rondelle d’appui extèrieure
4 Tambour de sélection
5 Manchon d’alimentation
6 Roulement à aiguilles intérieure
* Den indvendige rejfning på indre løbeskive skal vende mod den indre glider
* The inside chamfer on the inner bearing race must face the inner spool.
* Die innere Abfasung der inneren Laufscheibe muß gegen den inneren Schieber gekehrt sein
* Le chanfrein intérieur de la rondelle d’appui doit être orienté vers le tambour de sélection
DKMH.PS.210.A1.52 520L0066 19
Installation instructions for o-ring/kin-ring / roto Glyd
Læg styreenheden så boringen er vandret. Montageværktøjets ydre del føres ind i boringen til
glidersættet.
Turn the steering unit until the bore is horizontal. Guide the outer part of the assembly tool into
the bore for the spool/sleeve.
Lenkeinheit so umkehren, daß die Bohrung waagerecht ist. Den äußeren Teil des Montage-
werkzeugs in die Bohrung für den Schiebersatz einführen.
Placer le dispositif de direction de sorte que l’alésage soit horizontal. Introduire la partie
extérieure de l’outil de montage dans l’alésage pour le tambour/manchon.
Smør O-ringen og kin-ringen/roto Glyd i hydraulikolie og sæt dem på værktøjet.
Grease o-ring and king-ring/roto Glyd with hydraulic oil and place them on the tool.
O-Ring und Kin-Ring/roto Glyd mit Hydrauliköl schmieren und auf das Werkzeug setzen.
Enduire de l’huile hydraulique le joint torique et la bague-Kin/roto Glyd et les monter sur l’outil.
Hold montageværktøjets ydre del i bund i styreenhedens hus og før den indre del af montage-
værkøjet helt i bund.
Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the
inner part of the tool right to the bottom.
Äußeren Teil des Montagewerkzeugs in den Boden des Gehäuses der Lenkeinheit halten und
den inneren Teil des Montagewerkzeugs ganz in den Boden hineinführen.
Tenir la partie extérieure de l’outil de montage au fond du carter du dispositif de direction et

enfoncer totalement la partie intérieure de l’outil de montage.
Pres og drej O-ring/kin-ring på plads i huset.
Press and turn the o-ring/kin-ring into position in the housing.
O-Ring/Kin-Ring im Gehäuse auf ihren Platz pressen und drehen.
Pousser le joint torique/la bague-Kin dans le carter et les tourner en place.
20 DKMH.PS.210.A1.52 520L0066
Træk indre og ydre del af montageværktøjet ud af styreenhedens boring så styret fra den indre
del sidder tilbage.
Draw the inner and outer parts of the assembly tool out of the steering unit bore, leaving the
guide from the inner part in the bore.
Inneren und äußeren Teil des Montagewerkzeugs aus der Bohrung der Lenkeinheit heraus-
ziehen, so daß die Führung von dem inneren Teil zurückbleibt.
Retirer de l’alèsage du dispositif de direction les parties intérieure et extérieure de l’outil de

montage. Le guide de la partie intérieure de l’outil reste alors dans le carter.
Installation instructions for lip seal
Smør læbepakningen med hydraulikolie og anbring den på montageværktøjet.
Lubricate the lip seal with hydraulic oil and place it on the assembly tool.
Lippendichtung mit Hydrauliköl schmieren und auf dem Montagewerkzeug anbringen.
Enduire de l’huile hydraulique le joint labial et le placer sur l’outil de montage.
Før montageværktøjet helt i bund.
Guide the assembly tool right to the bottom.
Montagewerkzeug bis auf den Boden hineinführen.
Enfoncer totalement l’outil de montage.
Pres og drej læbepakningen på plads i huset.
Press and turn the lip seal into place in the housing.
Lippendichtung im Gehäuse auf ihren Platz pressen und drehen.
Pousser le joint labial dans le carter et le tourner en place.
DKMH.PS.210.A1.52 520L0066 21
Før med lette drejebevægelser indre og ydre glider ind i boringen.
Bemærk: Monter glidersættet sådan at tappen holdes vandret.
With a light turning movement, guide the spool and sleeve into the bore.
Note: Fit the spool set holding the cross pin horizontal.
Inneren und äußeren Schieber mit leichten Drehbewegungen in die Bohrung hineinführen.
Beachten: Schiebersatz so montieren, dass der Stift waagerecht gehalten wird.
Introduire, en les tournant légèrement, le tambour et le manchon dans l’alésage.

Attention: Monter le tambour/manchon de façon que la goupille soit tenue horizontalement.
Glidersættet skubber det tilbageværende styr fra monteringsværktøjet ud. O-ring og kin-ring/
roto Glyd er nu på plads.
The spool set will push out the assembly tool guide. The o-ring and kin-ring/roto Glyd are now
in position.
Die noch im Gehäuse verbliebene Führung vom Montagewerkzeug wird vom Schiebersatz
herausgedrückt. O-Ring und K-Ring/roto Glyd befinden sich jetzt an ihrem Platz.
Le tambour/machon chassent du carter le guide restant de l’outil de montage. Le joint torique/la

bague-Kin/roto Glyd sont alors en place.
Vend styreenheden så boringen igen er lodret. Læg kontraventilens kugle i det hul pilen peger
på.
Turn the stearing unit until the bore is vertical again. Put the check valve ball into the hole indi-
cated by the arrow.
Lenkeinheit wieder umkehren, so daß die Bohrung senkrecht ist. Kugel des Rückschlagventils
in die mit dem Pfeil gekennzeichnete Bohrung einlegen.
Placer le dispositif de direction de sorte que l’alésage soit de nouveau vertical. Placer la bille
du clapet antiretour dans le trou comme l’indique la flèche.
Skru gevindbøsningen let i kontraventilens boring. Toppen af bøsningen skal ligge lige under
husets overflade.
Screw the threaded bush lightly into the check valve bore. The top of the bush must lie just
below the surface of the housing.
Gewindebuchse leicht in die Bohrung des Rückschlagventils einschrauben. Das Oberteil der
Buchse muß gerade unter der Oberfläche des Gehäuses liegen.
Visser légèrement la douille filetée dans l’alèsage du clapet anti-retour. La partie supérieure de
la douille doit se trouver prècisément en-dessous de la surface du carter.
22 DKMH.PS.210.A1.52 520L0066
Anbring en kugle i de to huller pilene peger på.
Place a ball in the two holes indicated by the arrows
Eine Kugel in die beiden mit Pfeil bezeichneten Bohrungen legen.
Placer une bille dans les deux trous comme l’indiquent les flèches.
Anbring en ny stift i de samme to huller.
Place a new pin in the same two holes.
Einen neuen Stift in diesen beiden Bohrungen anbringen.
Placer une nouvelle goupille dans ces mêmes deux trous.
I nogle tilfælde skal der monteres en fjeder (Se s. 4 pos. 38) på stiften inden den placeres i
hullet i huset. (Se OSPC reservedelsliste HN.21.UA.52).
In some cases a spring has to be fitted (see page 4 pos. 38) on the pin before it is placed in the
housing. (See OSPC spare parts list, HN.21.UA.52).
In einigen Fällen muß eine Feder an den Stift montiert werden (siehe Seite 4 Pos. 38), bevor
dieser in der Bohrung im Gehäuse angebracht wird (siehe OSPC Er-satzteilliste HN.21.UA.52).
Dans certains cas, il faut monter un ressort (voir à la page 14) sur la goupille avant de la placer
dans le trou du carter. (Voir la liste des pièces de rechange de l’OSPC, HN.21.UA.52).
Indfedt O-ringen i mineralolie ca. viskositet 500 mm2/s ved 20°C og læg den i noten.
Grease the o-ring with mineral oil approx. viscosity 500 mm2/s at 20°C.
O-Ring mit Mineralöl, Viskosität: 500 mm2/s bei 20°C) einfetten und in die Nut einlegen.
Enduire de l’huile minérale d’une viscosité de 500 mm2/s à 20°C le joint torique et le placer
dans la rainure.
DKMH.PS.210.A1.52 520L0066 23
Anbring fordelerpladen sådan at kanalhullerne passer med hullerne i huset.
Place the distributor plate so that the channel holes match the holes in the housing.
Verteilerplatte so anbringen, dass die Kanalbohrungen und die entsprechenden Bohrungen im

Gehäuse fluchten.
Placer la plaque distributrice de façon que les trous soient vis-à-vis des trous correspondants
du carter.
Før kardanakslen ned i boringen så slidsen er parallel med tilslutningsflangen.
Guide the cardan shaft down into the bore so that the slot is parallel with the connection flange.
Kardanwelle so in die Bohrung einführen, daß der Schlitz parallel zum Anschlußflansch ist.
Descendre l’arbre à cardan dans l’alésage avec sa fente orientée parallèlement à la bride de
raccordement.
Anbring kardanakslen som vist - så den holdes af monteringsgaflen.
Place the cardan shaft as shown - so that it is held in position by the mounting fork.
Kardanwelle wie gezeigt anbringen, so daß sie von der Montagegabel gehalten wird.
Placer l’arbre à cardan comme indiqué; il doit être maintenu par la fourche de montage.
Indfedt de to O-ringe i mineralolie ca. viskositet 500 mm2/s ved 20°C. Læg dem i de to noter på
tandkransen. Monter tandhjul med tandkrans på kardanakslen.
Grease the two o-rings with mineral oil approx. viscosity 500 mm2/s at 20°C and place them in
the two grooves in the gear rim. Fit the gearwheel and rim on the cardan shaft.
Die beiden O-Ringe mit Mineralöl, Viskosität: 500 mm2/s bei 20°C einfetten und in die beiden
Nuten am Zahnkranz einlegen. Zahnrad mit Zahnkranz an die Kardanwelle montieren.
Enduire de l’huile minérale d’une viscosité de 500 mm2/s à 20°C les deux joints torique et les
placer dans les deux rainures de la couronne dentée. Monter la roue dentée avec la couronne
dentée sur l’arbre à cardan.
24 DKMH.PS.210.A1.52 520L0066
Vigtigt: Monter tandhjulet (rotoren) og kardanakslen sådan, at rotorens tandbund placeres i
forhold tilakslens not som vist. Drej tandkransen så de syv gennemgående huller til
skruerne passer med de syv huller i huset.
Important: Fit the gearwheel (rotor) and cardan shaft so that a tooth base in the rotor is
positioned in relation to the shaft slot as shown. Turn the gear rim so that the seven
trough holes match the holes in the housing.
Wichtig: Zahnrad (Rotor) und Kardanwelle so montieren, daß der Zahnfuß des Rotors im
Verhältnis zu der Nut der Welle wie gezeigt, angebracht wird. Zahnkranz so
drehen, daß die sieben durchgehenden Bohrungen für die Schrauben und die
sieben Bohrungen im Gehäuse fluchten.
Important: Monter la roue dentée (le rotor) et l’arbre à cardan de sorte qu’un creux de dent du
rotor ait la position montrée par rapport à la rainure de l’arbre à cardan. Déplacer
ensuite la couronne dentée jusqu’à ce que les sept trous pour les vis se trouvent
en face des sept trous dans le carter.
Monter eventuel afstandsring.
Fit the spacer, if any.
Distanzring montieren (falls vorhanden).
Monter la rondelle d’ècartement éventuelle.
Læg endedækslet på.
Place the end cover in position.
Enddeckel auflegen.
Placer le couvercle extrême.
Forsyn specialskruen med skive og monter den i det viste hul.
Fit the special screw with washer and place it in the hole shown.
Spezialschraube mit Scheibe versehen und in die gezeigte Bohrung montieren.
Munir d’une rondelle la vis spéciale et la monter dans le trou montre.
DKMH.PS.210.A1.52 520L0066 25
Forsyn de seks andre skruer med skiver og monter dem. Krydstilspænd alle syv skruer med et
moment på 3,0 ± 0,6 daNm. OSPB, OSPB LS og OSPBX LS kan nu funktionsafprøves.
Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin
with a torque of 3.0 +/-0.6 daNm. The OSPB, OSPB LS and OSPBX LS can now be function
tested.
Die sechs anderen Schrauben mit Scheiben versehen und montieren. Alle sieben Schrauben
mit einem Moment von 3,0 ± 0,6 daNm überkreuz anziehen. Es kann jetzt eine Funktions-
prüfung an OSPB, OSPB LS und OSPBX LS vorgenommen werden.
Munir les six vis restantes de rondelles et les monter. Serrer par paires opposées les sept vis
au couple de 3,0 ± 0,6 daN.m. On pourra alors procéder à un essai de fonctionnement des dis-
positifs de direction OSPB, OSPB LS et OSPBX LS.
Assembly of the pressure relief valve for OSPC
Monter stemplet.
Fit the piston.
Kolben montieren.
Monter le piston.
Monter fjederen.
Fit the spring.
Feder montieren.
Monter le ressort.
Skru indstillingsskruen i med en 8 mm unbrakonøgle.

Foretag trykindstillingen på et panel eller på køretøjet.
Screw in the setting screw with an 8 mm hexagon socket spanner.

Make the pressure setting on a panel or the vehicle.
Einstellschraube mit einem 8 mm Innensechskantstiftschlüssel montieren.

Die Druckeinstellung an einer Tafel oder an dem Fahrzeug vornehmen.
Envisser la vis de réglage à l’aide d’une clé Allen de 8 mm.

Effectuer le réglage de pression sur un panneau d’essais ou sur le véhicule.
Skru prop med tætningsring i huset med en 8 mm unbrakonøgle.
Tilspændingsmoment 5 ± 1 daNm.
26 DKMH.PS.210.A1.52 520L0066
Screw plug with dust seal into the housing using an 8 mm hexagon socket spanner.
Tightening torque: 5 +/-1 daNm.
Stopfen mit Dichtungsring mit einem 8 mm Innensechskantstiftschlüssel in das Gehäuse

einschrauben.
Anzugsmoment 5 ± 1 daNm.
Visser le bouchon avec joint d’étanchéité dans le carter à l’aide d’une clé Allen de 8 mm.
Couple de serrage: 5 ± 1 daN.m.
Assembly of the shock valves for OSPC/OSPC LS/OSPC LSR
Læg en kugle i de to huller pilene peger på.
Put a ball in the two holes indicated by the arrows.
Eine Kugel in die beiden mit Pfeil bezeichneten Bohrungen legen.
Placer une bille dans les deux trous comme l’indiquent les flèches.
Anbring fjeder og ventilkegle oven på de to kugler.
Bemærk: Den blå fjeder gælder for indstillingsområdet 90-180 bar. Den ubehandlede fjeder
gælder for indstillingsområdet 170-260 bar. (Se OSPC reservedelsliste HN.21.UA.52).
Place springs and valve cones over the two balls.
Note: The blue spring applies to setting range 90-180 bar. The untreated spring applies
to setting range 170-260 bar. (See OSPC spare parts list HN.21.UA.52).
Feder und Ventilkegel oben auf den beiden Kugeln anbringen.
Beachte: Die blaue Feder gilt für den Einstellbereich 90-180 bar. Die unbehandelte Feder gilt
für den Einstellbereich 170-260 bar. (Siehe OSPC-Ersatzteilliste HN.21.UA.52).
Placer le ressort et le cône de soupape au-dessus des deux billes.
Attention: Le ressort bleu s’applique à la plage de réglage de 90 à 180 bar. Le ressort brut
s’applique à la plage de réglage de 170 à 260 bar. (Voir la liste des pièces de
rechange de l’OSPC, HN.21.UA.52).
Skru de to indstillingsskruer i med en 6 mm unbrakonøgle. Foretage trykindstilling på et panel

eller på køretøjet. (Se OSPC reservedelsliste HN.21.UA.52).
Screw in the two setting screws using a 6 mm hexagon socket spanner. Make the pressure
setting on a panel or the vehicle. (See OSPC spare parts list HN.21.UA.52).
Die beiden Einstellschrauben mit einem 6 mm Innensechskantstiftschlüssel einschrauben.

Die Druckeinstellung an einer Tafel oder an dem Fahrzeug vornehmen. (Siehe OSPC-Ersatz-
teilliste HN.21.UA.52).
Envisser les deux vis de réglage à l’aide d’une clé Allen de 6 mm. Effectuer le réglage de pres-
sion sur un panneau d’essais ou sur le véhicule. (Voir la liste des pièces de rechange de
l’OSPC, HN.21.UA.52).
DKMH.PS.210.A1.52 520L0066 27
Skru prop med tætningsring i de to chokventiler og tilspænd med et moment på 3 ± 1 daNm
med en 6 mm unbrakonøgle.
Styreenhed type OSPB, OSPB LS, OSPBX LS, OSPC, OSPC LS eller OSPC LSR er nu samlet.
Screw plug with seal ring into the two shock valves and tighten them with a torque of
3 +1 daNm using a 6 mm hexagon socket spanner.
Steering unit type OSPB, OSPB LS, OSPBX LS, OSPC, OSPC LS or OSPC LSR is now
assembled.
Stopfen mit Dichtungsring in die beiden Schockventile einschrauben und mit einem Moment
von 3 ± 1 daNm mit einem 6 mm Innensechskantstiftschlüssel anziehen.
Die Lenkeinheiten Typ OSPB, OSPB LS, OSPBX LS, OSPC, OSPC LS oder OSPC LSR sind
jetzt montiert.
Visser le bouchon avec joint d’étanchéité dans les deux soupapes de sécurité et serrer d’une
couple de 3 ± 1 daN.m à l’aide d’une clé Allen de 6 mm.
Le remontage du dispositif de direction OSPB, OSPB LS, OSPBX LS, OSPC, OSPC LS ou
OSPC LSR est alors terminè.
Anbring støvtætningsringen i huset. For OSPC, OSPC LS og OSPC LSR anbringes støvtæt-
ningsringen først efter montering af overstrømningsventilen og chokventilerne.
Place the dust seal ring in the housing. With the OSPC, OSPC LS and OSPC LSR the dust
seal ring must be placed only after the pressure relief valve and shock valves have been fitted.
Staubdichtungsring im Gehäuse anbringen. Bei OSPC, OSPC LS und OSPC LSR den Staub-
dichtungsring erst nach der Montage des Druckbegrenzungsventils und der Schockventile
anbringen.
Placer la bague anti-poussière dans le carter. Pour OSPC, OSPC LS et OSPC LSR, ne pas
monter la bague anti-poussière qu’aprés avoir monté le limiteur de pression et les soupapes
de sécurité.
Monter støvtætningsringen i huset med specialværktøjet SJ 150-9000-22 (se s. 5) og en

plasthammer.
Fit the dust seal ring in the housing using special tool SJ 150-9000-22 (see page 5) and a
plastic hammer.
Staubdichtungsring mit Spezialwerkzeug SJ 150-9000-22 (siehe Seite 5) und einem Kunst-

stoffhammer in das Gehäuse montieren.
Monter la bague anti-poussière dans le carter en utilisant l’outil spécial, SJ 150-9000-22

(Voir à la page 5) et un marteau en plastique.
Tryk plastpropper i tilslutningsportene. Brug ikke hammer!
Press the plastic plugs into the connection ports. Do not use a hammer!
Kunstoffstopfen in die Anschlussöffnungen drücken. Keinen Hammer verwenden!
Enfoncer les bouchons en plastique dans les orifices de raccordement. Ne pas utiliser de
marteau!
28 DKMH.PS.210.A1.52 520L0066
Max. tightening torque and hydraulic connections
L: Venstre port / Left port / Linker Anschluß /

Raccordement gauche
R: Højre port / Right port / Rechter Anschluß /
Raccordement droit
T: Tank / Tank / Öltank / Réservoir
P: Pumpe / Pump / Pumpe / Pompe
Max. Tilspændingsmoment daNm

Max. tightening torque daNm (lbf in)
Max. Anzugsmoment daNm
Couple de serrage maxi daN.m
Forskruning Med skærekant Med kobberskive Med aluminiumskive Med O-ring
Screwed connection With cutting edge With copper washer With aluminium washer With O-ring
Verschraubung Mit Dichtkante Mit Kupferscheibe Mit Aluminiumscheibe Mit O-Ring
Raccord Raccord tranchant Avec rondelle en cuivre Avec rondelle en aluminium Avec joint torique
G 1/4 4 (350) 2 (180) 3 (270)
G 3/8 6 (530) 2 (180) 5 (440)
G 1/2 10 (900) 3 (270) 8 (700)
7/16-20 UNF 2 (180)
3/4-16 UNF 6 (530)
M 12 x 1,5 4 (350) 2 (180) 3 (270) 2 (180)
M 18 x 1,5 7 (620) 2 (180) 5 (440) 5 (440)
M 22 x 1,5 10 (900) 3 (270) 8 (700) 7 (620)
DKMH.PS.210.A1.52 520L0066 29
Danfoss Hydraulics Organization
Danfoss is an international concern with factories in 10 countries and subsidiaries in 32 countries.

In addition to the hydraulic components, the Danfoss range of products includes refrigeration controls,
industrial automatics, precision step systems, industrial instrumentations, electrical drives and controls,
controls for heating plant, system controls, components for burners and boilers, compressors
and thermostats for refrigerators and freezers.
Argentina Danfoss S.A. Argentina Cyprus Tektron Ltd. Hungary KITE Nadudvar
San Lorenzo 4310 25, Heroes Street 4181 Nadudvar, Bem. J.U.2.
1605 Vicente Lopez P.O. Box 2123 Tel. : 36 54 48 0401
Buenos Aires Strovolos-Nicosia Telex : 72431
Tel. : 54 1 756 4200 Tel. : 357 2 49 7907 Fax : 36 54 48 0331
Telex : 9900 Booth-AR Telex : 3968 tektron cy
Fax : 54 1 756 4100 Fax : 357 2 31 4844
Iceland HEDINN VERSLUN H/F
Ing. Lahusen S.R.L. Seljaveg 2
Av. Belgrano, 615 - 8° I Czech Republic TECHNO TRADE GmbH P.O. Box 512
1092 - Buenos Aires Slovak Republic Petr Kejdus IS-121 Reykjavik
Tel. : 54 1 342 1083/1835 Tovarni ul. 41 Tel. : 354 562 4260
Fax : 54 1 331 7314 CS 772 00 Olomouc Telex : 2003 Hedinn IS
Tel.: 420 68 52 22 004 Fax : 354 562 4315
Fax: 420 52 32 055 Danfoss authorized service shop
Australia Danfoss (Australia) Pty. Ltd.
Melbourne (Head Office)
1 Ricketts Road Denmark Danfoss A/S India DANTAL HYDRAULICS PVT Ltd.
Private Bag 20, Mt. Waverley DK-6430 Nordborg 805-806 Chiranjeev Tower
Victoria, 3149 International tel.: 45 74 88 2222 Nehru Place
Tel.: 61 3 9543 1033 National tel.: 74 88 2222 New Delhi 110019
Fax: 61 3 9543 4027 Telex : 50599 Tel.: 91 646 01 55 + 642 5036 + 645 3806
Danfoss authorized service shop Fax : 45 74 49 0949 Fax: 91 11 647 6089
45 74 49 1613 (Hydr.) Danfoss authorized service shop
Austria HAINZL INDUSTRIESYSTEME Danfoss Hydraulik A/S

Gesellschaft m.b.H. & Co KG Toppevadvej 44-46, Ganløse Iran Dancool Iran Co. Ltd.
Industriezeile 56 DK-3660 Stenløse Piche Shemiran
P.O. Box 100 Tel. : 45 42 18 4055 Kh. Tonekabon No. 15
A-4040 Linz Telex : 40041 Sondgd dk Teheran 11488
Tel. : 43 732 7892 Fax : 45 42 18 4603 Tel. : 98 21 7532 026
Telex : 22 1522 Danfoss authorized service shop 98 21 7523 835
Fax : 43 732 7892 150 Fax : 98 21 7530 565
Danfoss authorized service shop Telex : 222235 dic IR
Finland OY Danfoss AB
Kivenlahdentie 7
Belgium N.V. Danfoss S.A. SF-02360 Espoo Israel Radion Engineering Company Ltd.
Erasmus Business Park Tel. : 358 9 802 81 11 Ha'sivim St.
Av. Joseph Wybran 45 Fax : Hydraulics dept. 358 9 802 85 61 P.O.B. 7111
B-1070 Bruxelles Danfoss authorized service shop Petah-Tikvah 49250
Tel. : 32 02 525 0711 Tel. : 972 3 922 6688
Telex : 24828 Telex : 3812 93 reco IL
Fax : 32 02 525 0757 France Danfoss S.a.r.l. Fax : 972 3 922 6655
Danfoss authorized service shop Z.A. de Trappes-Elancourt
7, Av. Roger Hennequin
P.O. Box 58 Italy Danfoss s.r.l. Division Sordella
Brazil Danfoss do Brasil F-78193 Trappes-Cedex Strada Carignano 48
Ind. e Com. Ltda. Tel. : 33 1 30 62 5000 I-10024 Moncalieri / Torino
Rua Nelson Francisco 26, Casa Verde Telex : 697 809 F Tel. : 39 11 682 7111
CEP 02712-100 São Paulo Fax : 33 1 30 62 5009 Fax : 39 11 682 7199
Tel.: 55 11 855 5400 Danfoss authorized service shop Danfoss authorized service shop
Fax: 55 11 855 5455
Danfoss authorized service shop
Germany Danfoss Antriebs- und Regeltechnik GmbH Japan Danfoss K.K.
Geschäftsbereich Hydraulik Head Office
Canada Danfoss Fluid Power Carl-Legien-Str. 8 Shinyokohama Mineta Bldg.
7880 Transmere Drive D-63073 Offenbach/Main 3-19, Shinyokohama 2-chome
Mississauga P.O. Box 10 04 53, D-63004 Kohoku-ku
Ontario L5S IL9 Offenbach/Main Yokohama, 222 Japan
Tel. : 1 905 673 0559 Tel. : 49 069 8902 0 Tel. : 81 45 476 5001
Telex : 06 961216 Telex : 4-1 52 876 Fax : 81 45 476 5010
Fax : 1 905 673 5039 Fax : 49 69 8902 319 Danfoss authorized service shop
Danfoss authorized service shop 49 69 8902 316
Danfoss authorized service shop
Korea UNITEK Corporation
Chile TALLERES LUCAS LTDA. Korea World Trade Center
Av. Blanco Encalada 1737 Great Britain Danfoss Limited P.O. Box 181
Santiago Perivale Industrial Park Room 201 Seokyung Bldg.
Tel.: 56 2 672 6223/695 4233 Horsenden Lane South 1000-3 Daichi-Dong, Kang Nam-Ku
Fax: 56 2 698 2515 Greenford, Middx. UB6 7QE Seoul, Korea
Tel. : 44 081 991 7000 Tel. : 82 2 567 0090
Telex : 24223 Fax : 82 2 569 2894
China Danfoss (Tianjin) Ltd. Fax : 44 181 991 7053 Danfoss authorized service shop
Wuging Development Area Road 3 Danfoss authorized service shop
Tianjin 301 700
Peoples Republic of China Malaysia Danfoss Industries Sdn. Bhd.
Tel.: (8622) 2 933 6400-06 Greece A. SKOURA & Co. E.E. No. 14, Jalan 5
Fax: (8622) 2 933 6407 Spirou Patsi 105 Taman Perindustrian Batu Tiga
GR-118 55 Athens 40000 Shah Alam,
Tel. : 30 01 345 3906 Selangor
SYMBRIDGE INTERNATIONAL 30 01 346 3967 Tel. : 60 3 550 1685
Room E 12F Telex : 216713 Deda Gr. Fax : 60 3 550 2805
GaoJia Building No. 1 Fax : 30-1-34 74 106 (Skouras)
Chungfeng Road
Shenzhen 518 005 Mexico Ignacio Gomez, General Manager
P.R. China Hong Kong NICKO INTERNATIONAL Miller Potencia Fluida
Tel.: +86 755 218 6843 RM. 1203, Chevalier Commercial Centre Israel 301 ESQ Damasco
Fax: +86 755 217 0147 8 Wang Hoi Road Col. Ricardo B. Anaya 2A Seccion
Kowloon Bay, Hong Kong Apdo. Postal F-1241
Tel. : 852 2755 2783 San Luis Potosi, S.L.P. Mexico
Colombia Fiza Ltda. Fax : 852 2798 8656 Tel. : 52 48 21 1937
Carrera 40 N° 163-A-55 Fax : 52 48 21 2160
(Toberin)
Santafé de Bogotà
D.C. Colombia S.A.
Tel.: 57 1 677 6346/677 6440
57 1 677 5142
Fax: 57 677 7025
30 DKMH.PS.210.A1.52 520L0066
Danfoss Hydraulics Organization
Jordan Nicola M. Nassar & Sons Poland Danfoss Sp. z o.o. Sweden Danfoss AB
7th Circle - Royal Jordanian City ul. Obozowa 20, 01-161 Warszawa Industrigatan 7
Terminal (I) Bld. Tel. : +48 632 00 75, 632 39 81, S-595 82 Mjølby
P.O. Box 808 632 43 84 Tel. : 0142-88500
Amman 11118, Jordan Fax : +48 632 69 32 Fax : 0142-88509
Tel. : +2 962 65 859 472 E-mail : info@danfoss.com.pl E-mail: danfoss@danfoss-
Fax : +2 962 65 859 473 se.ibmmail.com.
E-mail: nicolaco@go.com.jo Danfoss Sp.z o.o Danfoss authorized service shop
ul. Chrzanowska 5
PL 05-825 Grodzisk Mazowiecki
Korea Unitek Corporation Poland Switzerland Danfoss Werner Kuster AG
Korea World Trade Center Parkstrasse 6
P.O. Box 181 CH-4402 Frenkendorf
Room 201 Seokyung Bldg. Portugal Danfoss (Portugal), Lda. Tel. : +41 061 906 1111
1000-3 Daichi-Dong, Kang Nam-Ku Av.do Forte, 8-1° Fax : +41 061 906 1121
Seoul, Korea P Edificio Pujol E-mail: e-mail@danfoss.ch
Tel. : +82 2 567 0090 P-2795 Carnaxide Danfoss authorized service shop
Fax : +82 2 569 2894 Tel. : +351 1 424 8930
E-mail : unitek@ktnet.co.kr. Fax : +351 1 417 2466
Danfoss authorized service shop Taiwan Symbridge Machinery Co. Ltd.
28 Lane 205, Sec. 3
Republic of Danfoss (Pty) Ltd. Chung Ching North Road
Malaysia Danfoss Industries Sdn. Bhd. South Africa Cambridge Commercial Park P.O. Box 47-132
No: 12B, Jalan Penyelengara U1/77 23 Trinity Close Taipei/Taiwan R.O.C.
Taman Perindustrian Batu Tiga Paulshof Ext. 45 Tel. : +886 2 259 10816 8 (three lines)
40150 Shah Alam, Selangor Johannesburg Fax : +886 2 259 14190
Tel. : +60 3 550 1685 Tel. : +27 11 803 8390 E-mail: symbgtap@ms15.hinet.net
Fax : +60 3 550 2805 Fax : +27 11 803 8244 Service Shops
E-mail : danfoss@po.jaring.my Danfoss authorized service shop
Thailand Danfoss (Thailand) Co., Ltd.

Mexico Danfoss Compressors, S.A. Rumania Michail Petrache 47/11 Soi Mongkol Nives
Mr. Jesus Campos, Hydraulics Department S.C. LYRA PRODIMPEX Ltd. Ngam Wong Warn Road, Ladyao
Carr.a Cd. Miguel Alemàn 162 B-dul Timisoara 41 Jatujak, Bangkok 10900
Apodaca, N.L. C.P. 66600 Bl. P14, Sc. B. Ap. 24 Tel. : +66 2 561 1130
Tel. : +52 8 156 56 14 (or) 15 77309 BUCURESTI Fax : +66 2 561 1446
Fax : +52 8 156 56 25 Tel./fax : 401 413 7627
E-mail: danfossw@infosel.net.mx Mobil : 092 269 844
Internet: http://www.lyra.ro Turkey Mert Teknik Fabr. Malzemeleri
E-mail : lyra@fx.ro Ticaret ve Sanayi A.S.
Netherlands Itho bv Tersane Cad. No. 43
Adm. de Ruyterstraat 2 80000 Karaköy - Istanbul
3115 HB Schiedam Russia Zao Danfoss Tel. : +90 0 212 252 8435
P.O. Box 21 Marksistskaya ul. 34 Fax : +90 0 212 245 6369
3100 AA Schiedam 109147 Moscow E-mail: info@mert.com
Tel. : +31 10 427 8500 Tel.: +7 095 792 5757 Danfoss authorized service shop
Fax : +31 10 427 1534 +7 501 792 5757 (Satellite)
E-mail : “name”@danfoss.nl Fax: +7 095 792 5760
(ex: Jacques.van.der.Windt@danfoss.nl) +7 501 792 5760 (Satellite) U.S.A. Danfoss Fluid Power
E-mail : hyd@danfoss.nl (general group) (Head office)
Danfoss authorized service shop Racine operations
Singapore Danfoss Industries Pte. Ltd. 8635 Washington Avenue
6 Jalan Pesawat Racine, Wisconsin 53406
New Zealand Danfoss (New Zealand) Limited Singapore 619364 Tel. : +1 414 884 7400
15 Byron Street Tel. : +65 261 4088 Fax : +1 414 884 7440
P.O. Box 4435 Fax : +65 261 0488 E-mail: “Name”@danfoss.com
Sydenham, Christchurch Danfoss authorized service shop (Ole Sigvardt: Osigvardt@danfoss.com)
Tel. : +64 03 36 56 123 Danfoss authorized service shop
Fax : +64 03 37 94 365
E-mail : “name”@danfoss.com Slovenia Technical Office Klun
(ex: Broderick@danfoss.com) Ul. Bratov Martinec 16 Danfoss Fluid Power,
Danfoss authorized service shop SI-1000 Ljubljana Easley Operations
Slovenija 1201 Pelzer Highway
Tel. : +386 61 127 3718 P.O. Box 2189
Norway Danfoss A/S Fax : +386 61 127 1624 Easley, South Carolina 29640
Årenga 2 Tel. : +1 864 855 2884
N-1314 Skui Fax : +1 864 855 5885 (general)
Tel. : 47 67 17 7200 Spain Danfoss S.A. +1 864 850 6010
Fax : 47 67 13 6850 Avda. Tenerife No. 22 (executive office)
E-mail : danfoss@online.no Pol. Ind. Norte
Danfoss authorized service shop 28700 San Sebastian de los Reyes (Madrid)
Tel. : +34 91 663 8051
Fax : +34 91 663 7570
Pakistan Khan Brothers E-mail : “NO.”@danfoss.com
Engineers (Luis Baque: SPOO16@danfoss.com)
684, Central Commercil Area Danfoss authorized service shop
Allama Iqbal Road
P.E.C.H.S., Karachi-75400
Tel. : +92 21 452 6002/6003/6004 or
6005
Fax : +92 21 454 5995
DKMH.PS.210.A1.52 520L0066 31
comments
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to
products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed.
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
DK-6430 Nordborg
Denmark
32 DKMH.PS.210.A1.52 520L0066
A.D Axle

1
PRINTED IN ITALY
Copyright By DANA ITALIA S.p.A.
Vietata la riproduzione anche parziale di testo ed illustrazioni
Realizzazione a cura dell'Ufficio Post Vendita della DANA ITALIA S.p.A.
Impaginazione: TEMAS s.r.l. - Gallarate (Va)
Stampa: Agosto 1999 (N.L. 7416)
Data subject to change without notice. We decline all responsability for the use of non-original components, or accessories which have
not been tested and submitted for approval.
Dati soggetti a modifiche senza impegno di preavviso. Si declina ogni responsabilitaÁ per l'utilizzo di componenti non originali o accessori
non collaudati ed approvati.
AÈnderungen ohne vorherige AnkuÈndingung vorbehalten. Es wird jede Verantwortung fuÈr die Verwendung von Nichtoriginalteilen oder
nicht abgenommenem und genehmigtem ZubehoÈr abgelehnt.
Los datos pueden ser modificados sin aviso previo. Se declina toda responsabilidad en el caso de uso de componentes no originales o
bien de accesorios no ensayados y aprobados.
Le constructeur se reÂserve le droit d'apporter des modifications aÁ sa production, sans pour cela eÃtre tenu d'en donner preÂavis. Nous
deÂclinons toute responsabiliteÂ pour l'utilisation de pieÁces non originales ou d'accessoires non testeÂs et homologueÂs.
2
INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX
INTRODUCTION ..........................................................5 DIFFERENTIAL UNIT

GB MAINTENANCE AND LUBRICANTS . Removal and disassembly ....................................................44
. Definition of viewpoints............................................7 . Assembly and installation .....................................................54
. Data plate ..............................................................................7 REDUCTION GEAR AND BEVEL PINION
. Maintenance points ................................................................7 . Disassembly.........................................................................68
. Maintenance intervals.............................................................8 . Installation and adjustment ...................................................74
. Adjustment and checks ..........................................................8
. Conversion tables...................................................................9 SPECIAL TOOLS ......................................................................82
. Tightening torques .................................................................9
. Screw-locking, sealing, and lubricating materials ...................10
NOTES ON SAFETY PRECAUTIONS ........................................13
CHECKING WEAR AND REPLACING THE BRAKING DISKS
. Disassembling the braking units............................................14
. Assembling the braking units ................................................20
. Mechanical and manual release of the axle ...........................28
PLANETARY REDUCTION AND AXLE SHAFT
. Disassembly.........................................................................30
. Assembly .............................................................................38
INTRODUZIONE .......................................................5 GRUPPO DIFFERENZIALE

ITA . Rimozione e smontaggio.......................................................44
MANUTENZIONE E LUBRIFICANTI
. Definizione viste ..................................................7 . Assemblaggio ed installazione ..............................................54
. Targa matricola ......................................................................7 RIDUTTORE E PIGNONE CONICO
. Punti di manutenzione ............................................................7 . Smontaggio..........................................................................68
. Intervalli di manutenzione .......................................................8 . Installazione e registrazione..................................................74
. Registrazione e controlli .........................................................8 ATTREZZI SPECIALI.................................................................82
. Tabelle di conversione............................................................9
. Coppie di serraggio ................................................................9
. Materiali per bloccaggio viti, tenuta e lubrificazione................10
NOTE RIGUARDANTI LA SICUREZZA ......................................13
CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO
. Smontaggio gruppi di frenatura .............................................14
. Assemblaggio dei gruppi di frenatura ....................................20
. Sbloccaggio meccanico manuale dell'assale..........................28
RIDUTTORE EPICICLOIDALE E SEMIASSE
. Smontaggio..........................................................................30
. Assemblaggio ......................................................................38
VORAUSSETZUNG .................................................5 DIFFERENTIAL

D . Abmontieren und zerlegen ....................................................44
WARTUNG UND SCHMIERSTOFFE
. Definition der Ansichten......................................7 . Montieren und installieren.....................................................54
. Kennummernschild.................................................................7 REDUZIERER UND KEGELRAD
. Wartungsstellen .....................................................................7 . Abmontieren ........................................................................68
. Wartungsintervalle..................................................................8 . Installieren und einstellen .....................................................74
. Einstellungen und Kontrollen ..................................................8 SONDERWERZZEUGE ..............................................................82
. Umrechnungstabellen.............................................................9
. Anziehdrehmomente...............................................................9
. Material zur Blockierung von Schrauben und
fuÈr Dichtungen und Schmiermittel .........................................10
BEMERKUNGEN ZUR SICHERHEIT...........................................13
VERSCHLEISS KONTROLLIEREN UND BREMSSCHEIBEN
AUSWECHSELN
. Bremsaggregate abmontieren ...............................................14
. Bremsaggregate montieren ...................................................20
. Achse mechanisch manuell entsichern ..................................28
PLANETENGETRIEBE UND HALBACHSE
. Abmontieren ........................................................................30
. Montieren ............................................................................38
3
INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX
PROLOGO................................................................ 5 GRUPO DIFERENCIAL

ESP MANTENIMIENTO Y LUBRICANTES . Remocion y desmontaje ....................................................... 44
. Definicion vistas................................................... 7 . Montaje e instalacion ........................................................... 54
. Matricula ............................................................................... 7 REDUCTOR Y PINÄON CONICO
. Puntos de manutencion.......................................................... 7 . Remocion ............................................................................ 68
. Intervalos de manutencioÁn...................................................... 8 . Instalacion y ajuste .............................................................. 74
. Ajuste y controles .................................................................. 8 HERRAMIENTAS ESPECIALES................................................. 82
. Tablas de conversion ............................................................. 9
. Pares de torsion .................................................................... 9
. Materiales para el bloqueo, estanqueidad y lubricacion ......... 10
NORMAS CONCERNIENTES A LA SEGURIDAD ....................... 13
CONTROL DEL DESGASTE Y SUSTITUCION DE LOS
DISCOS DEL FRENO
. Montaje de los grupos de frenado......................................... 14
. Desmontaje de los grupos de frenado................................... 20
. Desbloqueo manual de los axal ............................................ 28
REDUCTOR EPICICLOIDAL Y SEMIEJES
. Desmontaje ......................................................................... 30
. Montaje ............................................................................... 38
INTRODUCTION ....................................................... 5 GROUPE DIFFERENTIEL

F ENTRETIEN ET LUBRIFIANTS . Depose et demontage .......................................................... 44
. DeÂfinition vues ..................................................... 7 . Assemblage et installation .................................................... 54
. Plaque d'immatriculation ........................................................ 7 REDUCTEUR ET PIGNON CONIQUE
. Points d'entretien................................................................... 7 . Depose................................................................................ 68
. Intervalle de service ............................................................... 8 . Installation et reglage ........................................................... 74
. Reglages et controles............................................................. 8 OUTILS SPECIAL ..................................................................... 82
. Tableaux de conversion ......................................................... 9
. Couples de serrage................................................................ 9
. MateÂriaux pour le blocage vis, eÂtancheÂiteÂ et lubrification........ 10
NOTES EN MATIERE DE SECURITE......................................... 13
CONTROLE D'USURE ET SUBSTITUTION DES
DISQUES DE FREINAGE
. Desassemblage des groupes de freinage .............................. 14
. Assemblage des groupes de freinage ................................... 20
. Deblocage mecanique manuel de l'essieu............................. 28
REDUCTEUR EPICICLOIDALE ET DU DEMI-ESSIEU
. Demontage.......................................................................... 30
. Assemblage......................................................................... 38
4
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION
The efficiency and continued operation of mechan- martelli in plastica o rame, leve appropriate estrattori e chiavi
GB ical units depend on constant, correct maintenance specifiche, al fine di facilitare il lavoro salvaguardando nel
and also on efficient repair work, should there be a contempo le superfici lavorate e la sicurezza degli operatori.
break-down or malfunction. The instructions contained in this Prima di procedere al disassemblaggio delle parti e scaricare
manual have been based on a complete overhaul of the unit. l'olio, eÁ opportuno eseguire un'accurata pulizia del ponte,
However, it is up to the mechanic to decide whether or not it is asportando incrostazioni ed accumuli di grasso.
necessary to assemble only individual components, when
partial repair work is needed. The manual provides a quick PREMESSA: Tutti gli organi meccanici smontati, devono
and sure guide which, with the use of photographs and essere accuratamente puliti con prodotti appropriati, quindi
diagrams illustrating the various phases of the operations, ripristinati o sostituiti nel caso presentino danni, usura,
allows accurate work to be performed. incrinature, grippaggi, ecc. In particolare, verificare l'integritaÁ
All the information needed for correct disassembly, checks and di tutte quelle parti in movimento (cuscinetti, ingranaggi, coppia
assembly of each individual component is set out below. In conica, alberi) e di tenuta (anelli OR, paraolio), soggette a
order to remove the differential unit from the vehicle, the maggiori sollecitazioni ed usura. EÁ consigliabile, comunque, la
manuals provided by the vehicle manufacturer should be sostituzione degli organi di tenuta ogni qualvolta si proceda alla
consulted. In describing the following operations it is presumed revisione o riparazione dei componenti. Al momento del
that the unit has already been removed from the vehicle.
montaggio, gli anelli di tenuta devono essere lubrificati sui
IMPORTANT: In order to facilitate work and protect both bordi di tenuta. Nel caso della coppia conica, la sostituzione di
working surfaces and operators, it is advisable to use proper uno dei suoi ingranaggi comporta anche la sostituzione
equipment such as: trestles or supporting benches, plastic or dell'altro. In fase di montaggio sono da rispettare scrupolosa-
copper hammers, appropriate levers, pullers and specific mente i giochi, i precarichi e le coppie prescritte.
spanners or wrenches. Á : Il manuale fornisce le validitaÁ dei gruppi sotto forma
VALIDITA
Before going on to disassemble the parts and drain the oil, it is
di matricola. Al fine di una corretta interpretazione, le validitaÁ
best to thoroughly clean the unit, removing any encrusted or
sono indicate come:
accumulated grease.
= fino alla matricola
INTRODUCTORY REMARKS: All the disassembled mechan-
ical units should be thoroughly cleaned with appropriate = dalla matricola
products and restored or replaced if damage, wear, cracking or
seizing have occurred. Se non sono indicate validitaÁ, le operazioni di smontaggio ed
In particular, thoroughly check the condition of all moving parts assemblaggio sono comuni a tutte le versioni.
(bearings, gears, crown wheel and pinion, shafts) and sealing
parts (O-rings, oil shields) which are subject to major stress and MANUTENZIONE E RIPARAZIONE: Al fine di facilitare
wear. In any case, it is advisable to replace the seals every time interventi sui gruppi ponte differenziali e cambi di velocitaÁ la
a component is overhauled or repaired. During assembly, the SPICER CLARK-HURTH, ha ritenuto opportuno compilare
sealing rings must be lubricated on the sealing edge. In the queste istruzioni di manutenzione e riparazione. I disegni delle
case of the crown wheel and pinion, replacement of one attrezzature specifiche eventualmente necessarie per l'esecu-
component requires the replacement of the other one. During zione di interventi di manutenzione e riparazione possono
assembly, the prescribed pre-loading, backlash and torque of essere acquistati direttamente presso il costruttore; i ricambi
parts must be maintained. possono essere ordinati tramite il costruttore della macchina o
direttamente presso la DANA ITALIA S.p.A..
CLASSIFICATION: This manual classifies units according to
part numbers. For a correct interpretation, classification is
indicated as follows:
= up to the part number Die Leistung und Lebensdauer der mechanischen
D Teile haÈngt nicht nur von einer staÈndigen und
= from the part number on richtig durchgefuÈhrten Wartung sondern auch von
einem sofortigen Eingriff im StoÈrungsfall ab. Um dieses
When no classification is given, disassembly and assembly Handbuch zu erstellen sind wir von einer allgemeinen U È ber-
operations are the same for all versions. pruÈfung der Einheit ausgegangen, doch entscheidet der
Mechaniker ob die einzelnen Teile bei Reparaturen montiert
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of werden muÈssen oder nicht. Das Handbuch ist schnell und
all specific tools required for maintenance and repair work can einfach nachzuschlagen und ermoÈglicht es anhand der Abbild-
be found at the end of this manual ; spare parts may be ordered ungen und der Zeichnungen, die die verschiedenen VorgaÈnge
either from the vehicle manufacturer or directly from the darstellen, gezielt einzugreifen. Nachstehend sind alle Infor-
Service Centers or Authorised Distributors of DANA ITALIA mationen und Hinweise aufgefuÈhrt, die zur Zerlegung, PruÈfung
S.p.A.. und Montage der Einzelteile noÈtig sind. Um die Differentia-
lachse des Fahrzeugs abzumontieren, lesen Sie bitte die
Anweisungen in den HandbuÈchern des Fahrzeugherstellers.
Die nachstehenden Beschreibungen gehen davon aus, daû die
Il rendimento e la continuitaÁ degli organi meccanici Fahrzeugachse schon abmontiert worden ist.
ITA dipendono oltre che da una costante e corretta
manutenzione, anche dal tempestivo intervento, WICHTIG: Um die Arbeit zu erleichtern und gleichzeitig die
nell'eventualitaÁ di guasti o anomalie. verarbeiteten FlaÈchen zu schuÈtzen und die Sicherheit der
Nel proporre questo manuale si eÁ considerata l'ipotesi di una Arbeiter zu gewaÈhrleisten, empfehlen wir geeignete Werk-
revisione generale del gruppo ma eÁ il meccanico a valutare la zeuge wie BoÈcke, Tisch, Gummi- oder Kupferhammer, geeig-
necessitaÁ di montare solo i singoli componenti nel caso di nete Abzieher und SchluÈssel zu verwenden.
Bevor mit der Zerlegung der Teile begonnen und das O Èl
riparazione. Il manuale eÁ una guida rapida e sicura che
consente interventi precisi, tramite le fotografie ed i disegni abgelassen wird, muû die Achse sorgfaÈltig gereinigt und
prospettici che illustrano le varie fasi delle operazioni. Di Verkrustungen und Fettablagen abgetragen werden.
seguito sono riportate tutte quelle informazioni ed avvertenze VORAUSSETZUNG: Alle abmontierten mechanischen Teile
necessarie al corretto disassemblaggio, alle relative verifiche muÈssen sorgfaÈltig mit geeigneten Reinigungsmitteln gereinigt
ed all'assemblaggio dei singoli componenti. Per la rimozione oder, wenn beschaÈdigt, verschleiût, gerissen, festgefressen
del ponte differenziale dal veicolo, eÁ necessario consultare i usw. ausgewechselt werden. Insbesondere muû der einwand-
manuali forniti dal costruttore del veicolo. Nel descrivere le freie Zustand aller beweglichen Teile (Lager, ZahnraÈder,
operazioni seguenti, si presuppone che il ponte sia giaÁ stato Kegelradpaare, Wellen) und der Dichtungen (O-Ringe, O È lab-
rimosso dal veicolo. dichtungen), die am meisten beansprucht werden und ver-
schleiûen, kontrolliert werden. Wir empfehlen auf jeden Fall die
IMPORTANTE: In tutte le operazioni, eÁ consigliabile usare Abdichtungselemente immer auszuwechseln, wenn eine U È ber-
attrezzature idonee quali cavalletti o banchi di sostegno, holung oder eine Reparatur der Teile vorgenommen wird. Bei
5
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION
der Montage muÈssen die RaÈnder der Dichtringe geschmiert Si no ha sido indicada validez, las operacioÂn de desmontaje y
werden. Wenn beim Kegelradpaar ein Zahnrad ausgewechselt montaje son comunes a todas las versiones.
werden muû, muû auch das andere Zahnrad ausgewechselt
werden. Bei der Montage muÈssen die vorgeschriebenen HERRAMIENTAS ESPECIFICAS Y RECAMBIOS: Los planos de
Spiele, Vorspannungen und Drehmomente strengstens ein- las herramientas especificas necesarias para la ejecucioÂn de las
gehalten werden. intervenciones de mantenimiento figuran al final del manual; los
recambios se pueden pedir al fabricante de la maÂquina o
È LTIGKEIT: Das Handbuch gibt an zu welchen Kennummern directamente al Service Center o a Distribuidores autorizados de
GU DANA ITALIA S.p.A..
die Einheiten gehoÈren. Der Einfachheit halber sind die
AngehoÈrigkeiten folgendermaûen aufgefuÈhrt:
= bis Kennummer
= ab Kennummer Le rendement et la continuiteÂ des organes meÂca-

F niques deÂpendent, non seulement d'une mainte-
Wenn keine AngehoÈrigkeit angegeben ist, verstehen sich die nance correcte et constante, mais eÂgalement de la
Arbeiten zur Zerlegung und Montage fuÈr alle AusfuÈhrungen rapiditeÂ d'intervention en cas de pannes ou d'anomalies. En
guÈltig. vous proposant ce manuel, on envisage l'hypotheÁse d'une
reÂvision geÂneÂrale du groupe, mais c'est au meÂcanicien
SPEZIFISCHE WERKZEUGE UND ERSATZTEILE: die Zeich- d'eÂvaluer la neÂ cessiteÂ de monter ou non chacun des
nungen der fuÈr Wartungsarbeiten erforderlichen spezifischen composants en cas de reÂparation. Le manuel est un guide
Werkzeuge, sind am Ende des Handbuchs aufgefuÈhrt; Ersatz- rapide et suÃr consentant des interventions preÂcises, au travers
teile koÈnnen beim Fahrzeughersteller oder direkt bei der de photographies et de dessins prospectifs qui illustrent les
Kundendienststelle oder bei einem zugelassenen HaÈndler der diffeÂrentes phases des opeÂrations. Ensuite, sont reporteÂes
DANA ITALIA S.p.A. bezogen werden. toutes les informations et preÂcautions neÂcessaires pour un
deÂmontage correct et les veÂrifications et assemblage de
chaque composant. En ce qui concerne le deÂplacement du
pont d'eÂtai du veÂhicule, il est neÂcessaire consulter les manuels
El rendimiento y la duracioÂn de los oÂrganos mecaÂnicos
fournis par le constructeur du veÂhicule. En deÂcrivant les
ESP depende, ademaÂs que del constante y correcto opeÂrations suivantes, on preÂsume que le pont ait deÂjaÁ eÂteÂ
mantenimiento, tambieÂn de la intervencioÂn inmediata enleveÂ du veÂhicule.
en caso de averõÂas o anomalõÂas.
Al proponer este manual, ha sido considerada la suposicioÂn de una IMPORTANT: Pour faciliter le travail en sauvegardant en
revisioÂn general del grupo, pero es el mecaÂnico quien tiene que meÃme temps les surfaces usineÂes et la seÂcuriteÂ des opeÂra-
valorar la necesidad de montar cada uno de los componentes en teurs, il est preÂconiseÂ d'utiliser des installations approprieÂes
caso de reparacioÂn. El manual es una guõÂa raÂpida y segura que telles que des eÂtais ou banc de support, maillets en plastique
permite intervenciones precisas por medio de fotografõÂas y de ou cuivre, leviers approprieÂs, extracteurs et cleÂs speÂcifiques.
planos que muestran las distintas fases de las operaciones. A
continuacioÂn figuran todas las informaciones y advertencias Avant de proceÂder au deÂmontage des parties et vidanger
necesarias para ejecutar un montaje correcto, para las comproba- l'huile, il vaut mieux nettoyer soigneusement le pont, en
ciones y el montaje de cada uno de los componentes. Para enlevant incrustations et blocs de gras.
remover el puente diferencial del vehõÂculo hay que consultar los
manuales de los fabricantes del vehõÂculo. En la descripcioÂn de las PRELIMINAIRE: Tous les organes meÂcaniques deÂmonteÂs
operaciones siguientes se supone que el puente ya ha sido sacado doivent eÃtre soigneusement nettoyeÂs aÁ l'aide de produits
del vahõÂculo. approprieÂs et reÂpareÂs ou remplaceÂs dans le cas ouÁ ils seraient
abõÃmeÂs, useÂs, feÃleÂs, grippeÂs, etc. VeÂrifier, l'inteÂgriteÂ, en
IMPORTANTE: Para facilitar el trabajo salvaguardando al mismo particulier, de toutes les parties en mouvement (paliers,
tiempo las superficies mecanizadas y la seguridad de los
operadores, se aconseja que se usen equipos y herramientas engrenages, couple conique, arbres) et l'eÂtancheÂiteÂ des
adecuados como caballetes y bancos de soporte, martillos de bagues (bagues OR, parahuile), qui sont sujettes aÁ plus de
plaÂstico o de cobre, palancas adecuadas, extractores y llaves sollicitations et aÁ l'usure. Il est preÂconiseÂ, de toute facËon, de
especõÂficas. substituer les organes d'eÂtancheÂiteÂ, chaque fois que l'on
Antes de desmontar las partes y descargar el aceite, es effectue une reÂvision ou une reÂparation des composants. Au
conveniente que se haga una limpieza minuciosa del puente moment du montage, les bagues d'eÂtancheÂiteÂ doivent eÃtre
sacando las incrustaciones y acumulaciones de grasa. lubrifieÂes sur les bords eÂtanches. Dans le cas du couple
conique, la substitution de l'un de ses engrenages comporte
INTRODUCCION: Todos los oÂrganos mecaÂnicos desmontados eÂgalement la substitution de l'autre. En phase de montage, il
tienen que ser limpiados minuciosamente con productos adecua-
dos y restaurados o sustituidos en el caso de que presenten danÄos, faut respecter scrupuleusement les jeux, les preÂcharges et les
desgaste, rajaduras, agarrotamientos, etc. En particular, compro- couples prescrits.
bar la integridad de todas las partes en movimiento (cojinetes,
engranajes, par coÂnico, ejes) y de estanqueidad (anillos OR, VALIDITE: Le manuel fournit la validiteÂ des groupes sous
detenedor de aceite) sujetas a mayores solicitaciones y desgaste. forme de matricule. Pour une meilleure interpreÂtation, les
Se aconseja, de todas formas, que se sustituyan los oÂrganos de validiteÂs sont indiqueÂes comme:
estanqueidad cada vez que se ejecute la revisioÂn o reparacioÂn de
los componentes. = jusqu'aÁ l'immatriculation
Al volver a montar, los segmentos de compresioÂn tienen que estar
lubricados en los bordes de estanqueidad. En el caso del par = aÁ partir de l'immatriculation et apreÁs
coÂnico, la sustitucioÂn de uno de sus engranajes comporta tambieÂn
la sustitucioÂn del otro. Al montar hay que tener en cuenta Si les validiteÂs ne sont pas indiqueÂes, les opeÂrations de
escrupulosamente los juegos, las precargas y los pares descriptos.
deÂmontage et d'assemblage sont pareilles dans toutes les
VALIDEZ: El manual suministra la validez de los grupos en forma versions.
de matrõÂcula. Para poder tener una interpretacioÂn correcta, la
validez estaÂ indicada: INSTALLATIONS SPECIFIQUES ET PIECES DETACHEES:
Les dessins des installations speÂcifiques neÂcessaires pour
= hasta la matrõÂcula effectuer des interventions d'entretien sont reporteÂes aÁ la fin du
manuel, les pieÁces deÂtacheÂes peuvent eÃtre commandeÂes au
= desde la matrõÂcula en adelante constructeur de la machine ou directement aux Centres de
Services, ou Distributeurs agreÂeÂs de la SocieÂteÂ DANA ITALIA
S.p.A..
6
MAINTENANCE AND LUBRICANT - MANUTENZIONE E LUBRIFICANTI - WARTUNG UND SCHMIERSTOFFE
MANTENIMIENTO Y LUBRICANTES - ENTRETIEN ET LUBRIFIANTS
DEFINITION OF VIEWPOINTS - DEFINIZIONE VISTE - DEFINITION DER ANSICHTEN - DEFINICION VISTAS - DEÂFINITION VUES
LEFT SIDE RIGHT SIDE

LATO SINISTRO LATO DESTRO
LINKE SEITE RECHTE SEITE
LADO IZQUIERDO LADO DERECHO
COTE GAUCHE COTE DROITE
D1240138
DATA PLATE - TARGA MATRICOLA - KENNUMMERNSCHILD - MATRICULA - PLAQUE D'IMMATRICULATION
Type and model unit - modification index
1
Tipo e modello gruppo - indice di modifica
Typ und Modelleles Antriebes - AÈ nderungsverzeichnis
Tipo y modelo grupo - indice de modificacion
Type et modeÂle de ensemble - tableau des modifications
1 2 Serial number
2
Numero di serie
Seriennummer
3 NuÂmero de serie
Numero de serie
MFG. BY CLARK-HURTH COMPONENTS S.P.A. Lubricant
3
38062 Arco (Trento) Lubrificante
Schmieroel
MADE IN ITALY Lubricante
Lubrificant
D1240011
MAINTENANCE POINTS - PUNTI DI MANUTENZIONE - WARTUNGSSTELLEN - PUNTOS DE MANUTENCION - POINTS D'ENTRETIEN
3 1 1 1 3
2 2 2 2
2
1
Oil filling plug - Tappo di carico
EinfuÈllstopfen - Tapon de carga
Bouchon de ravitaillement
2
Oil draining plug - Tappo di scarico
1 3 Ablasstopfen - Tapon de descarga
Bouchon de vidange
2
3
Check level plug - Tappo controllo livello
È lpegelkontrolle -
Stopfen zur O
Tapon de contrl de nivel - Jauge de niveau
D1240139
7
MAINTENANCE INTERVALS - INTERVALLI DI MANUTENZIONE - WARTUNGSINTERVALLE - INTERVALOS DE MANUTENCIOÁN - INTERVALLE DE SERVICE
OPERATION - OPERAZIONE - FREQUENCY - PERIODICITAÁ

LUBRICANTS - LUBRIFICANTI - SCHMIERSTOFFE -
ARBEITSVORGANG - - ZEITABSTAND -
LUBRICANTES - LUBRIFIANTS
OPERACION - OPERATION FRECUENCIA - PERIODICITE
Differential monthly
Differenziale mensile
Im differential monatlich . SAE85W90 (API GL4 - MIL L-2105)
. Check levels: Diferencial cada mes With additives for oil-bath brakes
. Controllo livelli: Differentiel mensuel Con additivi per freni a bagno d'olio
. È lstandkontrolle:
O Mit Zusatzmittel fuÈr Bremsen in OÈ lbad
. Control niveles: Planetary reduction every 200 hours
Con aditivos para frenos de banÄo de aceite
. ControÃle niveaux: Riduzione epicicloidale ogni 200 ore
Avec adjuvants pour freins en bain d'huile
Planetengetrieb alle 200 Std.
ReduccioÂn epicicloidal cada 200 horas . SAE85W90 (API GL5 - MIL 2105-B)
Reduction epicycloidale toutes les 200 heures With additives for oil-bath brakes, for units pre-
Differential every 800 hours ] senting hypoid crown wheel and pinion and /or
Differenziale ogni 800 ore self-locking differential gear
Im differential alle 800 Std. Per esecuzioni con coppia conica ipoide e/o con
Diferencial cada 800 horas differenziale autobloccante, con additivi per freni
Differentiel toutes les 800 heures a bagno d'olio
Bei AusfuÈhrungen mit Kegel- und Telleradpaar
. Oil change: Planetary reduction every 1000 hours ]
und/oder Selbstsperrdifferential, mit Zusatzmit-
. Cambio olio: Riduzione epicicloidale ogni 1000 ore È lbad
È lwechsel: teln fuÈr Bremsen in O
. O Planetengetrieb alle 1000 Std.
Para ejecuciones con par coÂnico hipoide y/o con
. Cambio aceite: ReduccioÂn epicicloidal cada 1000 horas
diferencial autobloqueante con aditivos para fre-
. Vidange huile: Reduction epicycloidale toutes les 1000 heures
nos de banÄo de aceite.
Self-locking differential gear every 700 hours ] r Pour exeÂcutions avec couple conique hypoõÈde et/
Differenziale autobloccante ogni 700 ore ou diffeÂrentiel autobloquant, avec adjuvants pour
Selbstsperrdifferential alle 700 Std. freins en bain d'huile
Diferencial autobloqueante cada 700 horas
Differentiel autobloquant toutes les 700 heures
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de 100 horas
de trabajo - Initialement apreÁs 100 heures de travail
r When it starts sounding noisy - Anche ai primi cenni di rumorositaÁ - Auch falls ungewoÈhnliche GeraÈusche zu bemerken sind - TambieÂn al primer
indicio de ruido - MeÃme aux premiers signaux de bruit
OPERATION - OPERAZIONE - MEMBER - ORGANO - CONDITIONS - CONDIZIONI - FREQUENCY - PERIODICITAÁ - LUBRICANTS - LUBRIFICANTI -
ARBEITSVORGANG - ELEMENT - BEDINGUNG - ZEITABSTAND - SCHMIERSTOFFE -
OPERACION - OPERATION ORGANO - ORGANE CONDICIONES - CONDITIONS FRECUENCIA - PERIODICITE LUBRICANTES - LUBRIFIANTS
Normal work monthly
Lavori normali mensile
Normale Arbeit monatlich
Greasing Articulations Trabajos normales cada mes
Ingrassaggio Snodi TaÃches ordinaires mensuel
Schmieren Gelenk MOLIKOTE
Engrase RoÂtula Awkward work Weekly
Graissage Articulations Lavori gravosi Settimanale
Schwere Arbeit WoÈchentlich
Trabajos pesados Semanal
TaÃches extraordinaires Hebdomadaire
ADJUSTMENT AND CHECKS - REGISTRAZIONE E CONTROLLI - EINSTELLUNGEN UND KONTROLLEN - AJUSTE Y CONTROLES - REGLAGES ET CONTROLES
UNIT - GRUPPO - OPERATION - OPERAZIONE FREQUENCY - PERIODICITAÁ - SERVICE BRAKE CIRCUIT - CIRCUITO COMANDO FRENI -
AGGREGAT - ARBEITSVORGANG - ZEITABSTAND - BREMSKREISLAUF - CIRCUITO MANDOS FRENOS -
GRUPO - GROUPE OPERACION - OPERATION FRECUENCIA - PERIODICITE CIRCUIT DE COMMANDE DES FREINS
Negative brake Adjustment every 1000 hours ]
Freno negativo Registrazione ogni 1000 ore Only for mineral oil use e.g. ATF Dexron II. Make sure
Federspeicherbremse Einstellen alle 1000 Std. that master cylinder seals are suitable for mineral oil.
Freno negativo Ajuste cada 1000 horas Usare esclusivamente olio minerale ATF Dexron II. Ac-
Frein neÂgatif ReÂglage toutes les 1000 hours certarsi che le guarnizioni del cilindro master siano
adatte a questo olio.
Service brake Adjustment every 500 hours È l verwenden, z.B.: ATF Dexron II.
Nur mineralisches O
Freni di servizio Registrazione ogni 500 ore
Achtung: Dichtringe des Hauptbremszylinders muÈs-
Hilfsbremse Einstellen alle 500 Std. È l geeignet sein.
sen fuÈr dieses O
Frenos de ejercicio Ajuste cada 500 horas
Usar exclusivamente aceite mineral ATF Dexron II.
Freins de service ReÂglage toutes les 500 hours
Asegurarse de que las juntas del cilindro principal
Wheel nuts Tightening every 200 hours son adecuadas para este aceite.
Dadi ruota Serraggio - ogni 200 ore Utiliser exclusivement huile mineÂrale ATF Dexron II.
Radmuttern Festziehen alle 200 Std. VeÂrifier que les joints du maõÃtre-cylindre, soien compa-
Tuercas rueda Apriete cada 200 horas tibles avec cette huile.
Ecrous de roue Serrage toutes les 200 hours
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de 100
horas de trabajo - Initialement apreÁs 100 heures de travail
8
CONVERSION TABLES - TABELLE DI CONVERSIONE - UMRECHNUNGSTABELLEN
TABLAS DE CONVERSION - TABLEAUX DE CONVERSION
Units of pressure - UnitaÁ di pressione - Druckeinheiten

Unidad de presioÂn - UniteÂs de pression: 1 Atm%1 bar%105 PA%14.4 PSi
Units of weight - UnitaÁ di peso - Gewichtseinheiten Units of torque - UnitaÁ di coppia - Drehmomenteinheiten
Unidad de peso - UniteÂs de poids Unidad de par - UniteÂs de couple
N daN kN kg lbs Nm daNm kNm kgm lb-in
1N 1 0,1 0,001 0,102 0,225 1Nm 1 0,1 0,001 0,102 8,854
1daN 10 1 0,01 1,02 2,25 1daNm 10 1 0,01 1,02 88,54
1kN 1000 100 1 102 225 1kNm 1000 100 1 102 8854
1kg 9,81 0,981 0,00981 1 2,205 1kgm 9,81 0,981 0,00981 1 86,8
1lb-in 0,1129 0,01129 0,0001129 0,01152 1
TIGHTENING TORQUES - COPPIE DI SERRAGGIO - ANZIEHDREHMOMENTE

PARES DE TORSION - COUPLES DE SERRAGE
Unit - UnitaÁ di misura - Meûeinheiten - Unidad de medida - UniteÂs de mesure: Nm

TYPE OF BOLT - TIPO VITE - GEWINDE - TIPO DE TORNILLO - TYPE DE VIS
SIZE OF BOLT
MISURA VITE
SCHRAUBENMASS 8.8 10.9 12.9
TAMAN Ä O TORNILLO
MESURE VIS Normali Normali Normali Normali Normali Normali
+ Loctite 242 + Loctite 270 + Loctite 242 + Loctite 270 + Loctite 242 + Loctite 270
M6 x 1 9,5-10,5 10,5-11,5 14,3-15,7 15,2-16,8 16,2-17,8 18,1-20,0
COARSE PITCH - PASSO GROSSO - GROûER
SCHRITT - PASO GRUESO - GROS PAS
M8 x 1,25 23,8-26,2 25,6-28,4 34,2-37,8 36,7-40,5 39,0-43,0 43,7-48,3

M10 x 1,5 48-53 52-58 68-75 73-81 80-88 88-97
M12 x 1,75 82-91 90-100 116-128 126-139 139-153 152-168
M14 x 2 129-143 143-158 182-202 200-221 221-244 238-263
M16 x 2 200-221 219-242 283-312 309-341 337-373 371-410
M18 x 2,5 276-305 299-331 390-431 428-473 466-515 509-562
M20 x 2,5 390-431 428-473 553-611 603-667 660-730 722-798
M22 x 2,5 523-578 575-635 746-824 817-903 893-987 974-1076
M24 x 3 675-746 732-809 950-1050 1040-1150 1140-1260 1240-1370
M27 x 3 998-1103 1088-1202 1411-1559 1539-1701 1710-1890 1838-2032
M30 x 3,5 1378-1523 1473-1628 1914-2115 2085-2305 2280-2520 2494-2757
FINE PITCH - PASSO FINE - KLEINER SCHRITT
M8 x 1 25,7-28,3 27,5-30,5 36,2-39,8 40,0-44,0 42,8-47,2 47,5-52,5

M10 x 1,25 49,4-54,6 55,2-61,0 71,5-78,5 78,0-86,0 86,0-94,0 93,0-103,0
M12 x 1,25 90-100 98-109 128-142 139-154 152-168 166-184
M12 x 1,5 86-95 94-104 120-132 133-147 143-158 159-175
PASO FINO - PAS FIN
M14 x 1,5 143-158 157-173 200-222 219-242 238-263 261-289

M16 x 1,5 214-236 233-257 302-334 333-368 361-399 394-436
M18 x 1,5 312-345 342-378 442-489 485-536 527-583 580-641
M20 x 1,5 437-483 475-525 613-677 674-745 736-814 808-893
M22 x 1,5 581-642 637-704 822-908 903-998 998-1103 1078-1191
M24 x 2 741-819 808-893 1045-1155 1140-1260 1235-1365 1363-1507
M27 x 2 1083-1197 1178-1302 1520-1680 1672-1848 1834-2027 2000-2210
M30 x 2 1511-1670 1648-1822 2138-2363 2332-2577 2565-2835 2788-3082
9
SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS - MATERIALI PER BLOCCAGGIO VITI, TENUTA E LUBRIFICAZIONE - MATERIAL ZUR
BLOCKIERUNG VON SCHRAUBEN UND FUÈR DICHTUNGEN UND SCHMIERMITTEL - MATERIALES PARA EL BLOQUEO, ESTANQUEIDAD Y LUBRICACION -
MATEÂRIAUX POUR LE BLOCAGE VIS, EÂTANCHEÂITEÂ ET LUBRIFICATION
1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor.
I materiali per il bloccaggio, tenuta e lubrificazione specifica indicati nel manuale, sono quelli usati in fabbrica.
Die Materialien zur Blockierung von Schrauben, fuÈr Dichtungen und Schmiermittel, die im Handbuch aufgefuÈhrt sind, sind
dieselben die auch vom Hersteller verwendet werden.
Los materiales para el bloqueo, estanqueidad y lubricacioÂn especõÂfica indicados en el manual, son los que se usan en la faÂbrica
Les mateÂriaux de blocage, d'eÂtancheÂiteÂ et de lubrification speÂcifieÂs indiqueÂs dans ce manuel sont ceux employeÂs aÁ l'usine.
2 - The table below gives an account of the typical applications of each single material, in order to facilitate replacement with similar
products marketed by different brand names with different trade marks.
Di questi materiali, vengono riportate le applicazioni tipiche che li distinguono, in modo da poterli sostituire con prodotti similari
commercializzati da altre marche e quindi con altre sigle.
Von diesen Materialien werden die typischen Anwendungen genannt, um sie mit aÈhnlichen Materialien zu ersetzen, die unter
anderen Namen und Kennzeichnungen im Handel erhaÈltlich sind.
De estos materiales damos las aplicaciones tõÂpicas que los distinguen, de manera que se puedan sustituir con productos similares
comercializados por otras marcas y por tanto con otras siglas.
De ces mateÂriaux ne sont reporteÂes que les applications typiques qui les distinguent de telle sorte qu'ils puissent eÃtre substitueÂs
par des produits semblables se trouvant dans le commerce sous d'autres marques et par conseÂquent sous d'autres sigles.
DENOMINATION
DENOMINAZIONE
BEZEICHNUNG APPLICATION - APPLICAZIONE - ANWENDUNG - APLICACION - APPLICATION
DENOMINACION
DENOMINATION
. Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength loc-
king. Before using it, completely remove any lubricant by using the specific activator.
. Prodotto anaerobico adatto a prevenire l'allentamento di viti, dadi e tappi. Usato per la frenatura a media re-
sistenza. Deve essere usato dopo aver asportato ogni traccia di lubrificante con l'attivatore specifico.
. Anaerobes Produkt, um das Lockern von Schrauben, Muttern und Stopfen zu verhindern. FuÈr mittlere Wi-
derstandskraÈfte geeignet. Darf erst aufgetragen werden, wenn die FlaÈchen von Schmiermittel richtig sauber
Loctite 242
sind. Dazu das entsprechende Produkt verwenden.
. Producto anaeroÂbico apto para prevenir el aflojamiento de tornillos, tuerca y tapones. Usado para el frenado
de media resistencia. Tiene que ser usado soÂlo despueÂs de haber quitado todo residuo de lubricante con el
activador especõÂfico.
. Produit anareÂobic servant aÁ preÂvenir le relaÃchement des vis, eÂcrous et bouchons. UtiliseÂ pour le freinage
demi reÂsistant. Il doit eÃtre utiliseÂ apreÁs avoir enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
. The oleocompatible alternative to 242. Does not require the activation of lubricated surfaces.
. Prodotto alternativo al 242 che, essendo oleocompatibile, non richiede l'attivazione di superfici lubrificate.
. Alternatives Produkt zu Loctite 242. Da es oÈlkompatibel ist muÈssen die geschmierten FlaÈchen nicht aktiviert
Loctite 243 werden.
. Producto alternativo al 242 que, siendo oleocompatible, no requiere la activacioÂn de superficies lubricadas.
. Produit en alternance avec le 242 lequel eÂtant oleÂocompatible ne requiert aucune activation des surfaces
lubrifieÂes.
. Anaerobic product for very-high strength locking of screws and nuts. Before using it, completely remove any
lubricant by using the specific activator. To remove parts, it may be necessary to heat them at 80ëC approx.
. Prodotto anaerobico adatto per la frenatura ad altissima resistenza di viti e dadi. Deve essere usato dopo aver
asportato ogni traccia di lubrificante con l'attivatore specifico.
La rimozione delle parti, puoÁ richiedere un riscaldamento a circa 80ëC.
. Anaerobes Produkt fuÈr hohe WiderstandskraÈfte fuÈr Schrauben und Muttern geeignet. Zuerst die FlaÈche sorg-
Loctite 270
faÈltig aktivieren. Um die FlaÈchen zu saÈubern, diese auf ca. 80ëC erwaÈrmen.
. Producto anaeroÂbico apto para el frenado de alta resistencia de tornillos y tuercas. tiene que ser usado de-
spueÂs de haber quitado todo residuo de lubricante con el activador especõÂfico.
La remocioÂn de las partes, puede requerir un calentamiento a unos 80ëC.
. Produit anareÂobic apte au freinage aÁ treÁs haute reÂsistance des vis et des eÂcrous. Il doit eÃtre utiliseÂ apreÁs avoir
enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
. Anaerobic product suitable for high-strength locking and sealing of large threaded parts, bolts and stud bolts,
for pipe sealing and for protecting parts against tampering; suitable for sealing coupling surfaces with a max.
diametrical clearance of 0.25 mm.
. Prodotto anaerobico adatto per la frenatura e sigillatura ad alta resistenza di parti filettate, bulloni e prigionieri
di grandi dimensioni, protezione antimanomissione e sigillatura di tubazioni; puoÁ sigillare accoppiamenti con
gioco diametrale massimo di 0,25 mm.
. Anaerobes Produkt zum Bremsen und Siegeln von groûen Gewinden, Muttern und Stiftschrauben , sehr
Loctite 275 widerstandsfaÈhig, verschleierungsbestaÈndig, und zum Siegeln von Rohrleitungen geeignet; kann Kupplun-
gen mit einer maximalen Lagerluft von 0,25 mm siegeln.
. Producto anaerobico apto para el frenado y selladura a alta resistencia de tornillos, tuercas y prisioneros de
grandes dimensiones, protecion anti manomision y selladura de tubaciones ; puede sellar encolcados con
juego diametral.
. Produit anaeÂrobie adapteÂ au freinage et au scellage aÁ haute reÂsistance des parties fileteÂes, boulons et pri-
sonniers de grandes dimensions, protection anti-alteÂration et scellage de tuyauteries; il peut sceller des ac-
couplements ayant un jeu diameÂtral maximal de 0,25 mm.
10
DENOMINATION
DENOMINAZIONE
DENOMINACION
DENOMINATION
. Anaerobic product for the hermetic sealing of flanged units and screw holes communicating with fluids. Can
seal clearances between flanges up to 0.2 mm.
. Prodotto anaerobico adatto alla tenuta ermetica di fluidi tra assiemi flangiati e di viti a foro comunicante con i
fluidi. PuoÁ sigillare giochi tra le flange fino a 0,2 mm.
. Anaerobes Produkt zur Abdichtung von FluÈssigkeiten an Flanschen und Schrauben mit LoÈcher, die mit FluÈs-
Loctite 510
sigkeiten in Kontakt stehen. Kann ein Spiel zwischen Flanschen bis 0,2 mm abdichten.
. Producto anaeroÂbico apto para le estanqueidad de fluidos entre grupos bridados y de tornillos de orificio co-
municante con los fluidos. Puede sellar juegos entre las bridas hasta 0,2 mm.
. Produit anareÂobic apte aÁ la tenue eÂtanche des fluides entre les pieÁces aÁ brides et des vis aÁ trou en contact
avec les fluides. Il peut sceller un jeu parmi les flasques jusqu'aÁ 0,2 mm.
. Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to M80. Before using
it, remove any lubricant with the specific activator. After polymerisation, disassembly may result rather dif-
ficult, so heating may be necessary for larger diameters.
. Prodotto anaerobico sigillante rapido per la tenuta di filettature di raccordi conici o cilindrici fino a M80.
Deve essere usato dopo aver asportato ogni traccia di lubrificante con l'attivatore specifico.
Dopo la polimerizzazione presenta una moderata difficoltaÁ di smontaggio per cui puoÁ richiedere, per i diametri
maggiori, un riscaldamento.
. Anaerobes Produkt zum schnellen Siegeln und Abdichten von Kegel- oder Zylinderkupplungen bis M80.
Darf erst aufgetragen werden, nachdem mit einem spezifischen Wirkstoff jede Spur von Schmiermittel ab-
getragen worden ist.
Loctite 577
Nach der Polymerisation koÈnnte das Abmontieren etwas schwierig sein weshalb groÈûere Durchmesser
zuerst erhitzt werden muÈssen.
. Producto anaerobico sellante rapido para el estanqueido de tornillos de empalme conico o cilindrico hasta
M80. Debe de ser utilisado despues de haber quitado cada mancha de lubrificante con activador especifico.
Despues de la polimeracion presenta una moderada dificultaÁde desmontaje por lo tanto puede necesitar, para
los diametros majores, un calientamiento.
. Produit anaeÂrobie collage rapide assurant l'eÂtancheÂiteÂ des filetages des raccords coniques ou cylindriques
jusqu'aÁ M80. Il doit eÃtre utiliseÂ apreÁs qu'on ait enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
Une certaine difficulteÂ de deÂmontage se preÂsente apreÁs la polymeÂrisation, on peut donc avoir la neÂcessiteÂ de
devoir chauffer preÂalablement pour de plus amples diameÁtres.
. Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints (hub on shaft). Can glue to-
gether parts with clearance ranging between 0.1 and 0.25 mm.
. Adesivo anaerobico per l'incollaggio rapido ad alta resistenza di giunti cilindrici in metallo (mozzo su albero).
PuoÁ incollare particolari con gioco tra 0,1 e 0, 25 mm.
. Anaerober Klebstoff fuÈr groûe WiderstandskraÈfte fuÈr Zylinderkupplungen aus Metall geeignet (Wellenna-
Loctite 638
ben). Kann Einzelteil mit einem Radialspiel zwischen 0,1 mm und 0,25 mm zusammenkleben.
. Adhesivo anaeroÂbico para el encolado raÂpido de alta resistencia de juntas cilõÂndricas de metal (cubo en el eje).
Puede encolar piezas con juego entre 0,1 mm y 0,25 mm.
. AdheÂsif anaeÂrobic servant aÁ un collage rapide et hautement reÂsistant des joints cylindriques en meÂtal
(moyeu sur l'arbre). Il peut servir aÁ coller des pieÁces avec un jeu allant de 0,1 aÁ 0,25 mm.
. Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints (hub on shaft). Can glue
together parts with radial clearance below 0.1 mm.
. Adesivo anaerobico per l'incollaggio rapido a media resistenza di giunti cilindrici in metallo (mozzo su albero).
PuoÁ incollare particolari con gioco radiale inferiore a 0,1 mm.
. Anaerober Klebstoff fuÈr mittlere WiderstandskraÈfte fuÈr Zylinderkupplungen aus Metall geeignet (Wellenna-
Loctite 648 ben). Kann Einzelteil mit einem Radialspiel von weniger als 0,1 mm zusammenkleben.
. Adhesivo anaeroÂbico para encolado raÂpido de media resistencia juntas cilõÂndricas de metal (cubo en el eje).
Puede encolar piezas con juego radial inferior a 0,1 mm.
. AdheÂsif anaeÂrobic servant aÁ un collage rapide moyennement reÂsistant des joints cylindriques en meÂtal
(moyeu sur l'arbre).
Il peut servir aÁ coller des pieÁces avec un jeu radial infeÂrieur aÁ 0,1 mm.
. Solvent-based sealing compound for elastic seals, drying through evaporation. Used for sealing the outer
diameter of sealing rings for rotating shafts with outer metal reinforcement.
(AREXONS) . Mastice sigillante per guarnizioni elastiche a base di solvente, essicante per evaporazione.
Repositionable jointing
compound for seals Viene utilizzato per la tenuta sul diamentro esterno di anelli di tenuta per alberi rotanti con armatura metallica
Mastice per guarnizioni esterna.
riposizionabile . Klebstoff fuÈr Gummidichtung auf LoÈsemittelbasis, trocknet durch Verdampfung.
Klebstoff fuÈr verstellbare Wird am aÈuûeren Durchmesser von Dichtungsringe bei rotierenden Wellen mit Metallmantel verwendet.
Dichtungen . Pasta para juntas de sellado para juntas elaÂsticas a base de disolvente, deshidratante por evaporacioÂn.
Pasta para juntas Se utiliza para la estanqueidad en el diaÂmetro externo de segmentos de compresioÂn, para ejes giratorios con
reposicionable
armadura metaÂlica exterior.
Mastic pour garnitures aÁ
remettre en place . Mastic adheÂsif aÁ base de solvants pour garnitures eÂlastiques, seÂchant par eÂvaporation.
Il sert garder eÂtanche le diameÁtre exteÂrieur des bagues d'eÂtancheÂiteÂ des arbres rotatifs ayant une arma-
ture meÂtallique externe.
11
DENOMINATION
DENOMINAZIONE
DENOMINACION
DENOMINATION
. Semi-fluid adhesive material used for sealing and filling and to protect components from environmental and
physical elements. Polymerises with non-corrosive dampness.
Silicone . Materiale adesivo semifluido usato per sigillatura, riempimenti e per la protezione di componenti dagli elementi
Silicone ambientali e fisici. Polimerizza con umiditaÁ non corrosiva.
. HalbfluÈssiger Klebstoff zum Befestigen, FuÈllen und zum Schutz von Bestandteilen vor aÈuûeren Einwirkun-
Silikon
gen. Polymerisiert durch nicht korrosive Feuchtigkeit
Silicona . Material adhesivo semifluido usado para el sellado, llenado y para la proteccioÂn de componentes de elemen-
Silicone tos ambientales y fõÂsicos. Polimeriza con humedad no corrosiva.
. Produit adheÂsif semi-fluide utiliseÂ pour le scellage, remplissage et protection des eÂleÂments ambiants et phy-
siques. PolymeÂrise aÁ une humiditeÂ non corrosive.
. Highly adhesive synthetic grease, with silicone compounds added.
Applied to adjustment screws with hole communicating with oil-type fluids.
Used when frequent adjusting is required.
. Grasso sintetico con elevato grado di adesivitaÁ, additivato con composti siliconici.
(TECNO LUPE/101) Applicato su viti di registrazione a foro comunicante con fluidi di tipo oleoso.
Silicone-based grease Usato quando si richiedono frequenti interventi di registrazione.
Grasso al silicone . Synthetisches Fett mit hoher Haftfestigkeit, mit silikonhaltigen Stoffen legiert.
Wird auf Stellschrauben mit Loch, die mit oÈlhaltigen FluÈssigkeiten in Kontakt stehen, angebracht.
Silikonfett Wird verwendet, wenn die Schraub oÈfters eingestellt werden muû.
Grasa a la silicona . Grasa sinteÂtica con elevado grado de adhesioÂn, aditivada con componentes silicoÂnicos.
Graisse au silicone Aplicada en tornillos de ajuste de orificio comunicante con fluidos de tipo oleoso.
Se usa cuando se requieren frecuentes intervenciones de ajuste.
. Graisse syntheÂtique ayant un degreÂ d'adheÂsiviteÂ eÂleveÂ, adjuveÂ de composeÂs au silicone.
AppliqueÂ sur les vis de reÂglage aÁ trou communiquant avec des fluides du type huileux.
UtiliseÂ quand il y a besoin de reÂglages freÂquents.
. Lubricating compound containing molybdenum disulphide, used to lubricate articulation pins and to prevent
sticking and oxidation of parts that are not lubricated on a regular basis.
. Composto lubrificante contenente bisolfuro di molibdeno, usato per la lubrificazione di perni snodo e per pre-
venire incollamenti ed ossidazioni di particolari non lubrificati in modo continuo.
Molikote . Schmierstoff mit MolybidaÈndisulfid; wird zum Schmieren von Gelenkstiften und gegen Ankleben und Oxy-
(DOW CORNING) dation von nicht dauergeschmierten Einzelteilen verwendet.
. Compuesto lubricante que contiene bisulfuro de molibdeno, usado para la lubricacioÂn de roÂtulas y para pre-
venir encoladuras y oxidaciones de piezas no lubricadas de manera continua.
. ComposeÂ lubrifiant contenant du bisulfure de molybdeÁne, utiliseÂ pour lubrifier les axes d'articulation et preÂ-
venir collages et oxydations des pieÁces qui ne sont pas continuellement lubrifieÂes.
. Applied to bearings, sliding parts and used to lubricate seals or parts during assembly
(Lithium-based) Grease . Applicato a cuscinetti, parti scorrevoli e per lubrificare guarnizioni o pezzi in fase di montaggio.
Grasso (al Litio) . Wird auf Lager, Gleitteilen aufgetragen und zum Schmieren von Dichtungen oder von Teilen bei der Mon-
(Lithium) Fett tage verwendet.
Grasa (al Litio) . Aplicada a cojinetes, partes deslizables o para lubricar juntas o piezas en fase de montaje.
Graisse (au Lithium) . AppliqueÂ sur les paliers, parties coulissantes et pour lubrifier les garnitures ou pieÁces pendant la phase de
montage.
12
NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR
SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE
1 - During all operations described in this manual, the LoÈsemittel muÈssen als SondermuÈll und auf jeden Fall laut den
GB axle should be fastened onto a trestle, while the oÈrtlich geltenden Vorschriften entsorgt werden.
other parts mentioned should rest on supporting 9- Zur Reinigung ausschlieûlich schwache LoÈsemittel wie Petroleum,
benches. Terpentin oder wasserhaltige LoÈsemittel verwenden. Auf keinen
2- When removing one of the arms, an anti-tilting safety trestle Fall TrichloraÈthylen, tuolol- oder xylolhlatige LoÈsemittel usw.
should be placed under the other arm. verwenden.
3- When working on an arm that is fitted on the machine, make sure 10 - Um die ArbeitsvorgaÈnge verstaÈndlich abzubilden, werden in
that the supporting trestles are correctly positioned and that the einigen Fotos die Aggregate ohne Einzelteile gezeigt, die sonst
machine is locked lengthways. bei der Arbeit nicht abmontiert werden muÈssen.
4- Do not admit any other person inside the work area; mark off the Nur die beschriebenen Teile abmontieren.
area, hang warning signs and remove the ignition key from the 11 - Unter RECHTS und LINKS versteht man in diesem Handbuch die
machine. Seite einer Person, die zur Achse schaut und zwar dem Antrieb
5- Use only clean, quality tools; discard all worn, damaged, low- entgegengesetzt.
quality or improvised wrenches and tools. Ensure that all 12 - Nach beendeten Arbeiten und um Rostbildungen zu vermeiden,
dynamometric wrenches have been checked and calibrated. die Teile an denen der Lack ggf. beschaÈdigt worden ist,
6- Always wear gloves and non-slip rubber shoes when performing anstreichen.
repair work. 1 - Las operaciones descritas se refieren al eje blo-
7- Should you stain a surface with oil, remove marks straight away. ESP queado en un caballete y a algunas partes apoyadas
8- Dispose of all lubricants, seals, rags and solvents once work has en el banco de trabajo.
been completed. Treat them as special waste and dispose of them 2- Cuando se saca un brazo del eje, colocar debajo del otro un
according to the relative law provisions obtaining in the country caballete de seguridad antivuelco.
where the axles are being overhauled. 3- Si se trabaja con un eje montado en la maÂquina, asegurarse de
9- Make sure that only weak solvents are used for cleaning haber colocado caballetes soporte y de haber inmovilizado
purposes; avoid using turpentine, dilutants and toluol-, xylol- longitudinalmente la maÂquina.
based or similar solvents; use light solvents such as Kerosene, 4- No permitir que personas extranÄas entren en la zona de trabajo;
mineral spirits or water-based, environment friendly solvents. delimitar esta zona, colgar carteles de aviso de hombres
10 - For the sake of clarity, the parts that do not normally need to be trabajando y sacar las llaves de arranque de la maÂquina.
removed have not been reproduced in some of the diagrams. 5- Usar soÂlo y exclusivamente herramientas limpias y de buena
11 - The terms RIGHT and LEFT in this manual refer to the position of cualidad; descartar llaves o herramientas gastadas o danÄadas, de
the operator facing the axle from the side opposite the drive. calidad mediocre o improvisadas. Asegurarse de que las llaves
12 - After repair work has been completed, accurately touch up any dinamomeÂtricas han sido controladas y calibradas.
coated part that may have been damaged. 6- Durante las operaciones de reparacioÂn, llevar siempre guantes y
calzado antideslizamiento.
1 - Le operazioni descritte sono riferite all'assale bloc- 7- Limpiar inmediatamente las zonas que pudieran estar sucias de
ITA cato su cavalletto ed alcuni particolari appoggiati su aceite.
un banco di lavoro.
8- Los lubricantes, las juntas, los trapos para la limpieza y los
2 - Quando si asporta un braccio dell'assale, sistemare sotto l'altro disolventes usados hay que eliminarlos como desechos especia-
braccio un cavalletto di sicurezza antiribaltamento. les y, de todas formas, de acuerdo con las normativas vigentes en
3 - Se si opera su un'assale montato sulla macchina, assicurarsi di el paõÂs en el que se revisan los ejes.
aver sistemato dei cavalletti di sostentamento e di aver immobi- 9- Para limpiar, utilizar soÂlo disolventes deÂbiles excluyendo en
lizzato longitudinalmente la macchina. absoluto tricloroetileno, diluyentes y disolventes a base de toluol,
4 - Non permettere che persone estranee entrino nella zona di lavoro; silol, etc.; usar soÂlo disolventes ligeros como queroseno, aguarraÂs
delimitare questa zona, appendere dei cartelli di avviso di lavori in minerales o disolventes ecoloÂgicos a base de agua.
corso ed asportare le chiavi di avviamento della macchina. 10 - Para que resulte clara la exposicioÂn y la ilustracioÂn, en las figuras
5 - Usare solo ed esclusivamente attrezzi puliti e di buona qualitaÁ; de algunos grupos faltan algunas piezas que por lo general se
scartare chiavi od attrezzi usurati o danneggiati, di bassa qualitaÁ pueden dejar montadas. Sacar soÂlo las partes descritas.
od improvvisati. Assicurarsi che le chiavi dinamometriche siano 11 - Las palabras DERECHA E IZQUIERDA usadas en el manual se
state controllate e tarate. refieren a la persona que mira el eje del lado opuesto a la toma de
6 - Durante le operazioni di riparazione, indossare sempre guanti e movimiento.
scarpe antiscivolo. 12 - Al final de las reparaciones, para evitar oxidaciones, retocar
7 - Pulire immediatamente le zone eventualmente imbrattate d'olio. cuidadosamente las partes pintadas que estuvieran danÄadas.
8 - I lubrificanti, le guarnizioni, gli eventuali stracci di pulizia ed i
solventi usati devono essere smaltiti come rifiuti speciali e 1 - Les opeÂrations deÂcrites se rapportent aÁ l'essieu
comunque secondo le normative vigenti nel Paese ove vengono F bloqueÂ sur chevalet et de quelques pieÁces poseÂes
revisionati gli assali. sur un eÂtabli de travail.
9 - Per la pulizia, usare solo solventi deboli escludendo categorica- 2- Quand on enleÁve un essieu monteÂ sur la machine, ajuster sous
mente trielina, diluenti e solventi a base di toluolo, xilolo, ecc.; l'autre bras un chevalet de seÂcuriteÂ contre tout basculement.
usare solo solventi leggeri quali cherosene, ragie minerali o 3- Si on oeuvre sur un essieu monteÂ sur la machine, s'assurer
solventi ecologici a base d'acqua. d'avoir ameÂnageÂ des chevalets de soutien et d'avoir bloqueÂ la
10 - Per chiarezza di illustrazione ed esposizione, sulle figure di alcuni machine en longueur.
gruppi mancano dei particolari che, normalmente, possono essere 4- Ne jamais permettre aÁ des eÂtrangers de peÂneÂtrer dans la zone de
lasciati montati. Rimuovere solo i particolari descritti. travail; deÂlimiter cette zone, mettre des pancartes de signalisation
11 - I termini DESTRA e SINISTRA usati nel manuale sono riferiti alla de travaux en cours et enlever les cleÂs de contact de la machine.
persona che guarda l'assale dal lato opposto alla presa di moto. 5- N'utiliser que des outils propres et de bonne qualiteÂ; eÂliminer cleÂ
12 - Al termine delle riparazioni, per evitare dannose ossidazioni, ou autres outils useÂs, abõÃmeÂs, de mauvaise qualiteÂ ou improviseÂs.
ritoccare con cura le parti verniciate eventualmente danneggiate. Veiller aÁ ce que les cleÂs dynamomeÂtriques aient eÂteÂ controÃleÂes et
calibreÂes.
1 - Die beschriebenen VorgaÈnge werden an der Achse 6- Pendant les opeÂrations de reÂparation, endosser toujours gants et
D vorgenommen, wenn diese auf einem Bock blockiert chaussures antideÂrapantes.
ist. Zur Bearbeitung der Einzelteile, werden diese 7- Nettoyer tout de suite les eÂventuelles zones souilleÂes d'huile.
auf die Werkbank gelegt. 8- Les lubrifiants, les garnitures, les eÂventuels chiffons servant au
2- Wenn eine Achse abgenommen wird, einen Sicherheitsbock unter nettoyage et les solvants utiliseÂs devront eÃtre reÂcolteÂs et traiteÂs
den zweiten Arm legen. comme rebut speÂcial conformeÂment aux lois en vigueur dans le
3- Werden Arbeiten an der Achse vorgenommen, wenn diese noch pays ouÁ les essieux sont en reÂvision.
an der Maschine montiert ist, BoÈcke zur Halterung unter die 9- Pour le nettoyage, n'utiliser que des solvants aÁ base de toluol,
Achse stellen und die Maschine der LaÈnge nach blockieren. xylol, etc.; n'utiliser que des solvants leÂgers tels que keÂroseÁne,
4- Es duÈrfen sich keine fremde Personen in der NaÈhe der Maschine essences mineÂrales, ou solvants eÂcologiques aÁ base d'eau.
waÈhrend der Arbeiten aufhalten; diesen Bereich absperren und 10 - En ce qui concerne la clarteÂ en matieÁre d'illustration et exposition,
mit Schilder kennzeichnen, die auf die laufenden Arbeiten sur les figures de certains groupes, il y a des pieÁces manquantes
hinweisen. ZuÈndschluÈssel von der Maschine abnehmen. qui normalement peuvent rester monteÂes.
5- Nur saubere Werkzeuge guter QualitaÈt verwenden; alte, beschaÈ- Enlever uniquement les pieÁces deÂcrites.
digte oder improvisierte Hilfsmittel nicht verwenden. Sicher- 11 - Les termes DROITE et GAUCHE utiliseÂs dans ce manuel se
stellen, daû die Dynamometer gepruÈft und geeicht worden sind. rapportent aÁ la personne regardant l'essieu du coÃteÂ opposeÂ aÁ celui
6- Bei Reparaturen, stets Handschuhe und rutschfeste Schuhe tragen. de la prise de mouvement.
7- Mit OÈ l beschmutzte Stellen, sofort reinigen. 12 - A la fin des opeÂrations, afin d'eÂviter un risque d'oxydation
8- Gebrauchte Schmiermittel, Dichtungen, Reinigungslappen und nuisible, retoucher soigneusement les parties vernies eÂventuelle-
ment abõÃmeÂes.
13
CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONT
SIMBOLI KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTR
CONTROÃLE USURE ET SUBST
Disassembly of assembly groups

Smontaggio di sottogruppi
Zerlegen von Baugruppen
Desmontaje de subgrupos
Demontage des sous-groupes
Reassemble to from assembly groups
Montaggio di sottogruppi 1
Zusasmmenbauen von Baugruppen
Ensamblaje de subgrupos
Montage des sous-groupes
Remove obstruction parts
Smontaggio di particolari ingombri
Abbauen-Ausbauen
Desmontaje de componentes abultados
Demontage des pieces encombrante
Reinstall-remount parts which had obstructed disassembly
Montaggio di particolari ingombri
Einbauen-Ausbauen
Montaje de componentes abultados
Montage des pieces encombrante
Attention ! Important notice
Attenzione, indicazione importante
Achtung, wichtiger Hinweis F1241070
¡ Cuidado ! IndicacioÂn importante
Attention, indication importante
Check - adjust e.g. torque, dimensions, pressures, etc.
Controllare - regolare p.e. coppie, misure, pressioni ecc.
GB a
PruÈfen - Einstellen z.B. Momente, Maûe, Drucke u.s.cs.
Controlar y ajustar, por ej. pares, medidas, presiones, etc. CHECKING WEAR
Controler, regler p.e. couples, mesures, pressions ecc. CAUTION! Perform operations on both arms.
T=Special tool P=page Remove the oil-level plug (1).
T=Attrezzature speciali P=Pagina
T=Spezialwerkzeug P=Seite
T=Herramientas especiales P=PaÂgina
T=Outils P=Page
Note direction of installation
Rispettare direzione di montaggio
Einbaurichtung beachten
Respetar la direccioÂn de ensamblaje
Respecter direction de montage
Visual inspection
Esaminare con controllo visuale P
Kontrollieren -PruÈfen
Examinar mediante inspeccioÂn visual
Controler, examiner, controle visuel
Possibly still serviceable, renew if necessary
Eventualmente riutilizzare (sostituire se necessario)
Bedingt weiderverwendbar
Puede volver a utilizarse (reemplazar, si es preciso)
Eventuellement a utiliser a noveau (remplacer si neÂcessaire)
Renew at each reassembly
Sostituire ad ogni montaggio
Beim Zusammenbau immer erneuern
Puede reemplazarse a cada ensamblaje
Remplacer avec chaque montage
Unlock - lock e.g. split pin, locking plate, etc.
Togliere-mettere la sicura F1241072
Entsichern-Sichern
Quitar-colocar el seguro
Enlever-mettre la securite
Lock-adhere (liquid sealant)
bar GB c
Mettere la sicura, incollare (mastice liquido)
Sichern-Kleben (fluÈssige Dichtung) ADJUSTING THE BRAKES
Colocar el seguro, pegar (mastique lõÂquido) Connect an external pump to the union piece "P" of the negative
Mettre la securite, coller (mastic liquide) brake and introduce a pressure of 15 ± 30 bar to eliminate the
Guard against material damage, damage to parts pressure of the Belleville washers (11).
Evitare danni materiali, danni a pezzi
Materialschaden verhuÈten
Evitar danÄar los materials o las piezas
Eviter dommages au materiaux, dommages au pieces
Mark before disassembly, observe marks when reassembly
Marchiare prima dello smontaggio (per il montaggio)
Vor dem Ausbau markieren (fuÈr den Zusammenbau)
Marcar antes de desmontar (para facilitar el ensamblaje)
Marquer avant le demontage (pour le montage)
Filling - topping up - refilling e.g. oil, cooling water, etc.
Caricare - riempire (olio - lubrificante)
EinfuÈllen - AuffuÈllen - NachfuÈllen (OÈ l-Schmiermittel)
Cargar - llenar (aceite lubricante)
Charger - remplir (huile - lubrifiant)
4
Drain off oil, lubricant
Scaricare olio, lubrificante
OÈ l, bzw. Schmiermittel Ablassen
Descargar aceite lubricante
Vidanger, lubrifiant
Tighten
Tendere
Spannen
Tensar
Tendre
Apply pressure into hydraulic circuit
Inserire pressione nel circuito idraulico F1241074
Leitung unter Druck setzen
Introducir presioÂn en el circuito hidraÂulico
Inserer pression dans le circuit hydraulique GB e
To clean
Pulire Turn the brake clearance adjustment pinion (4) clockwise and as
Reinigen
Limpiar far as the limit stop.
Nettoyer Release pressure and disconnect the tubes.
Lubricate - grease NOTE. Remove the lower plug (5) and drain the oil.
Lubrificare - ingrassare
Schmieren - einfetten
Lubrificar - Engrasar
Lubrifier - Graisser
14
CONTROLLO USURA Introdurre l'attrezzo T1 tra i dischi e controllare lo
ITA ATTENZIONE! Eseguire le operazioni per i due ITA spessore "S".
bracci. "S" minimo: 4,5 mm
Asportare il tappo (1) di livello olio.
VERSCHLEISS KONTROLLIEREN Werkzeug T1 zwischen den Scheiben einsetzen und

D D die StaÈrke "S" kontrollieren.
ACHTUNG! Die VorgaÈnge an beiden Armen vorneh-
men. "S" Minimum: 4,5 mm
È leinfuÈllstopfen (1) abnehmen.
O
a b
CONTROL DESGASTE Introducir la herramienta T1 entre los discos y
ESP ESP controlar el espesor "S".
ATENCION! Efectuar las operaciones por los dos
ejes. «S» minimo: 4,5 mm.
Sacar el tapon (1) de nivel aceite.
CONTROLE USURE Introduire l'outil T1 entre les disques et controÃler la

F F cale "S".
ATTENTION! Effectuer les opeÂrations aux deux bras.
Enlever le bouchon (1) du niveau d'huile. "S" minimum: 4,5 mm
REGISTRAZIONE FRENI Asportare la vite (2) e la piastrina di sicurezza (3).

ITA Collegare al raccordo "P" del freno negativo una pompa ITA
esterna ed immettere una pressione di 15v30 bar per
eliminare la pressione delle molle a tazza (11).
BREMSEN EINSTELLEN Schraube (2) und SicherheitsplaÈttchen (3) abnehmen.

D AnschluûstuÈck "P" der Federspeicherbremse an eine D
aÈuûere Pumpe anschlieûen und Druck bei 15v30 bar
einlassen, um Tellerfedern (11) zu entlasten.
c d
REGISTRACION FRENOS Sacar el tornillo (2) y la placa de securidad (3).
ESP Conectar al empalme «P» del freno negativo una ESP
pompa esterna y introducir una presion de 15v30 bar
para eliminar la presion de los muelles a taza (11).
REGLAGE DES FREINS Enlever les vis (2) et la plaquette de seÂcuriteÂ (3).
F Brancher au raccord "P" du frein neÂgatif une pompe F
externe et envoyer une pression de 15v30 bar pour
eÂliminer la pression des ressorts belleville (11).
Ruotare in senso orario il pignone (4) di regolazione SOSTITUZIONE DISCHI FRENO

ITA gioco freni fino a fondo corsa. ITA Imbragare il braccio (6) da asportare e collegarlo ad un
Rilasciare la pressione e scollegare i tubi. mezzo di sollevamento.
NOTA. Rimuovere il tappo inferiore (5) e scaricare l'olio. Allentare ed asportare le viti (7) ed i dadi (8).
Das Kegelrad (4) zur Einstellung des Bremsspiels bis BREMSSCHEIBEN AUSWECHSELN
D zum Endanschlag drehen. D Den abzunehmenden Arm (6) anschlagen und an eine
Druck ablassen und die Leitungen abtrennen. Hebezeug befestigen.
BEMERKUNG. Unteren Stopfen (5) abnehmen und das O È l. Schrauben (7) und Muttern (8) lockern und abschrauben.
e f
Girar en sentido horario el pinon (4) de regulacioÁn SUBSTITUCION DISCOS FRENOS.
ESP juego frenos hasta final carrera. ESP Atar el eje (6) de sacar y conectarlo a un medio de
Dejar la presion y desconectar los tubos. levantamiento.
NOTA. Remover el tapon inferior (5) y descargar el aceite. Aflojar y sacar los tornillos (7) y las tuercas (8).
Tourner le pignon de reÂglage du jeu des freins (4) dans Substitution des disques frein
F le sens des aiguilles d'une montre jusqu'en fin de F Elinguer le bras (6) aÁ enlever et brancher celui-ci aÁ un
course. moyen de relevage.
LibeÂrer la pression et deÂbrancher les tubes. Desserrer et enlever les vis (7), les eÂcrous (8).
REMARQUE: Enlever le bouchon infeÂrieur (5) et vidanger l'huile.
15
CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS
KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
CONTROÃLE USURE ET SUBSTITUTION DES DISQUES FREINS
F1241076 F1241077
GB a GB b
Remove arm (6) together with brakes and axle shafts; lay down the Loosen screws (9) in an alternate manner and remove them.
arm vertically.
11
12
10 10
F1241078 F1241079
GB c GB d
Move the cylinder (10) outwards while supporting the Belleville Remove the cylinder (10) complete with piston (12).
washers (11).
Remove the Belleville washers (11) and note down direction of
assembly.
12
13
12
14
F1241080 F1241081
bar GB e GB f
Slowly introduce low-pressure compressed air through the con- Remove O-rings (13) and (14) from the piston (12).
nection member for the negative brake, in order to extract the NOTE. The O-rings (13) and (14) must be replaced each time the
piston (12). unit is disassembled.
CAUTION! Hold the piston (12) back, as it may be suddenly ejected
and damaged.
16
Rimuovere il braccio (6) completo di freni e semiassi; Allentare in modo alternato le viti (9) ed asportarle.
ITA deporre il braccio in modo verticale. ITA
Den Arm (6) samt Bremsen und Halbachsen ab- Abwechselnd die Schrauben (9) lockern und ab-
D nehmen; den Arm senkrecht ablegen. D schrauben.
a b
Remover el eje (6) completo de frenos y semi-ejes; Aflojar de manera alternada los tornillos (9) y sacarlas.
ESP colocar el eje de manera vertical. ESP
Enlever le bras (6) complet de freins et demi-essieux; Desserrer les vis (9) en alternance, puis les enlever.
F deÂposer le bras en vertical. F
Spostare verso l'esterno il cilindro (10) sostenendo le Rimuovere il cilindro (10) completo di pistone (12).
ITA molle a tazza (11). ITA
Rimuovere le molle (11) ed annotare il senso di
montaggio.
Den Zylinder (10) nach auûen verstellen und dabei die Zylinder (10) samt Kolben (12) abnehmen.
D Tellerfedern (11) stuÈtzen. D
Federn (11) abnehmen und die Montagerichtung
notieren.
c d
Desplazar hacia el esterior el cilindro (10) sosteniendo Remover el cilindro (10) completo de piston (12).
ESP los muelles a taza (11). ESP
Remover los muelles (11) y anotar el sentido de
montaje.
DeÂplacer le cylindre (10) vers l'exteÂrieur en soutenant Enlever le cylindre (10) complet de piston (12).
F le ressort belleville (11). F
Enlever le ressort (11) et prendre note du sens de son
montage.
Immettere lentamente aria compressa a bassa pres- Rimuovere dal pistone (12) gli anelli OR (13) e (14).
ITA sione attraverso l'attacco per il freno negativo per ITA
NOTA. Gli anelli OR (13) e (14) devono essere
estrarre il pistone (12). sostituiti ad ogni smontaggio.
ATTENZIONE! Trattenere il pistone (12) che puoÁ essere espulso
velocemente ed essere danneggiato.
Langsam Druckluft bei Niederdruck durch den An- Kolben (12) und O-Ringe (14) und (14) abnehmen.
D schluû der Federspeicherbremse einlassen, um den D
BEMERKUNG. Die O-Ringe (13) und (14) muÈssen
Kolben (12) heraus zu druÈcken. jedesmal ausgewechselt werden, wenn das Teil zer-
ACHTUNG! Den Kolben (12) halten, da er ploÈtzlich heraus springen legt wird.
e und beschaÈdigt werden koÈnnte. f
Introducir lentamente aire comprimida a baja presioÁn Remover del piston (12) los anillos OR (13) y (14).
ESP atraves el empalme por el freno negativo para sacar el ESP
NOTA. Los anillos OR (13) y (14) deben de ser
piston (12). sobstituidos cada desmontaje.
ATENCION! Tener el piston (12) que puede ser expulso rapida-
mente y estropearse.
Envoyer lentement de l'air comprimeÂ aÁ basse pression Enlever le piston (12), les anneaux O'RING (13) et
F aÁ travers le raccord du frein neÂgatif pour extraire le F (14).
piston (12). REMARQUE. Les anneaux O'RING (13) et (14) sont aÁ
ATTENTION! Tenir le piston (12) qui pourrait eÃtre expulser substituer aÁ chaque deÂmontage.
rapidement et endommager.
17
CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS
KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
CONTROÃLE USURE ET SUBSTITUTION DES DISQUES FREINS
16
15
A
16
F1241082 F1241083
GB a GB b
Remove checking and guiding screws (15) from the pressure plate Remove the pressure plate (16).
(16). CAUTION! Note down the direction of assembly; flow regulator wall
NOTE. Loosen screws (15) in sequence and proportionally. "A" and oil drain holes must face the oil drain plug.
19
17
18
F1241084 F1241085
GB c GB d
Remove springs (17). Remove braking discs (18) and (19), noting down direction of
NOTE. Accurately check the condition of springs. They should not assembly.
be warped. NOTE. If disks are not to be replaced, avoid changing their
Any deformation of the springs requires spring replacement. position.
4 21
20
F1241086 F1241087
GB e GB f
Remove pinion (4) complete with O-ring (20). Unscrew and extract the braking disk clearance adjustment crown
NOTE. The O-ring must be replaced each time the unit is wheel (21).
disassembled.
18
Rimuovere le viti (15) di ritegno e guida dello Rimuovere lo spingidisco (16).
ITA spingidisco (16). ITA
ATTENZIONE! Annotare il senso di montaggio; la
NOTA. Allentare le viti (15) in modo sequenziale ed in parete frangiflusso "A" e gli scarichi olio, devono
uguale misura. essere rivolti verso il tappo di scarico olio.
Befestigungsschrauben (15) und die FuÈhrung der Druckplatte (16) abnehmen.

D Druckplatte (16) abnehmen. D
ACHTUNG! Montagerichtung notieren; der Strahlreg-
BEMERKUNG. Abwechselnd Schrauben (15) im È lablaûoÈffnungen muÈssen in Richtung
ler "A" und die O
gleichen Maû lockern. È lablaûstopfens gerichtet sein.
des O
a b
Remover los tornillos (15) de retencioÁn y guõÁa del Remover el empuja-disco (16).
ESP empuya-disco (16). ESP
ATENCION. Anotar el sentido de montaje; la pared
NOTA. Aflojar los tornillos (15) de manera secuencial rompe-flujo "A" y los descarge aceite, deben de ser
y en la misma mesura. dirijidos hacia el tapon de descarga aceite.
Enlever vis (15) de fixation et guide du plateau de Enlever le plateau de pression (16).
F pression (16). F
ATTENTION! Prendre noter du sens du montage; la
REMARQUE: Desserrer les vis (15) en seÂquence et en paroi brise-jet "A" et les eÂcoulements d'huile sont
eÂgale mesure. tourneÂs vers le bouchon de vidange d'huile.
Rimuovere le molle (17). Rimuovere i dischi di frenatura (18) e (19) annotando

ITA ITA l'ordine di montaggio.
NOTA. Controllare attentamente lo stato delle molle
che non devono essere deformate. NOTA. Se i dischi non devono essere sostituiti, evitare
Ogni deformazione deve portare alla sostituzione. lo scambio di posizione.
Federn (17) abnehmen. Bremsscheiben (18) und (19) abnehmen und Monta-
D D gerichtung notieren.
BEMERKUNG. Die Federn sorgfaÈltig kontrollieren; sie
duÈrfen nicht verformt sein. Sollte dies der Fall sein, BEMERKUNG. Falls die Scheiben ausgewechselt
Federn auswechseln. werden muÈssen, ihre Position nicht verwechseln.
c d
Remover los muelles (17). Remover los discos de frenadura (18) y (19) anotando
ESP ESP el orden de montaje.
NOTA. Controlar atentamente el estado de los
muelles que no deben de ser deformes. NOTA. Si los discos no deben de ser sobstituidos,
A cada deformacioÁn deben de ser cambiados. evitar el cambio de possicioÁn.
Enlever les ressorts (17). Enlever les disques de freinage (18) et (19) et prendre
F F note de l'ordre du montage.
REMARQUE. ControÃler attentivement l'eÂtat des res-
sorts, ils ne doivent pas eÃtre deÂformeÂs. REMARQUE. Si les disques doivent eÃtre substitueÂs,
Toute deÂformation veut dire substitution. eÂviter d'eÂchanger leur position.
Rimuovere il pignone (4) completo di anello OR (20). Svitare ed asportare la corona (21) di regolazione del
ITA ITA gioco dischi di frenatura.
NOTA. L'anello OR deve essere sostituito ad ogni
smontaggio.
Das Kegelrad (4) samt O-Ring (20) entfernen. Den Kranz (21) zur Einstellung des Bremsscheibens-
D D piels abnehmen.
BEMERKUNG. Den O-Ring bei jedem Zerlegen aus-
wechseln.
e f
Remover el pinon (4) completo de anillo OR (20). Destornillar y sacar la corona (21) de regulacioÁn del
ESP ESP juego discos de frenadura.
NOTA. El anillo OR debe de ser sobstituido a cada
desmontaje.
Enlever le pignon (4) complet de l'anneau O'RING DeÂvisser et enlever la couronne (21) de reÂglage du jeu
F (20). F des disques de freinage.
REMARQUE. L'anneau O-Ring est aÁ remplacer aÁ
chaque deÂmontage.
19
ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS - MONTAJE DE LOS
GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS
22
11
13
12
10 14
9
18
18
18
15
21 17
23
16
6 19
19
7
19
4
20
1
3
5 2
24
26 8
25 D1240130
6
21 4
6 20
21
F1241133 F1241134
GB a GB b
Lubricate the threaded portion of the crown wheel (21) and screw it Replace the O-ring (20) of pinion (4).
down into the arm (6) as far as it will go. Lubricate and install the pinion in the slot provided on the arm (6),
inserting the toothing into crown wheel (21).
20
GB
ESP
ITA
Lubrificare la filettatura della corona (21) ed avvitarla a Sostituire l'anello OR (20) del pignone (4).
ITA fondo nel braccio (6). ITA Lubrificare il pignone e montarlo nella sede del braccio
(6) innestando la dentatura nella corona (21).
Das Gewinde des Kranzes (21) schmieren und in den O-Ring (20) des Kegelrads (4) auswechseln. Kegelrad
D Arm (6) festschrauben. D schmieren und in den Sitz des Arms (6) montieren;
dabei die ZaÈhne des Kranzes (21) einrasten.
a b
Lubrificar la rosca de la corona (21) y atornillar a Sobstituir el anillo OR (20) del pinon (4).
ESP hondo en el eje (6). ESP Lubrificar el pinon y montarlo en la sed del eje (6)
introduciendo la dentadura en la corona (21).
Lubrifier le filetage de la couronne (21), puis visser Substituer l'anneau O'RING (20) du pignon (4).
F celle-ci aÁ fond dans le bras (6). F Lubrifier le pignon, puis monter celui-ci dans le
logement du bras (6) en introduisant en meÃme temps
la denture dans la couronne (21).
21
19
18
B
F1241088 F1241089
GB a GB b
Lubricate the first friction disk (19) and install it on the axle shaft .
Lightly lubricate the first steel braking disk (18), then install it on the Complete the assembly, alternating steel disks and friction disks.
arm (6). CAUTION! Oval holes "B" of friction disks must be lined up.
16
17
6 A
F1241084 F1241083
GB c GB d
Position springs (17) in the appropriate slots of the arm (6). Fit the pressure plate (16).
CAUTION! Accurately check orientation: flow regulator "A" and oil
drains must be oriented towards the arm's oil drain plug.
16
15
15
F1241082 F1241090
GB e GB f
Lock the pressure plate into position (16) with screws (15). Lock screws (15) with a dynamometric wrench.
CAUTION! Tighten screws in sequence and a little at a time. Torque wrench setting: 20 ± 30 Nm.
22
Lubrificare leggermente il primo disco di frenatura in Lubrificare il primo disco di attrito (19) e montarlo sul
ITA acciaio (18) e montarlo nel braccio (6). ITA semiasse.
Completare il montaggio alternando dischi di acciaio e
dischi di attrito.
ATTENZIONE! I dischi di attrito devono avere il foro ovale "B"
allineato.
Die erste Bremsscheibe aus Stahl (18) etwas schmie- Die erste Reibscheibe (19) schmieren und auf die
D ren und in den Arm (6) montieren. D Halbachse montieren.
Dann die Stahlscheiben abwechselnd mit den Reibs-
cheiben montieren.
a b ACHTUNG! Die LangloÈcher "B" der Reibscheiben muÈssen ge-
fluchtet sein.
Lubrificar ligermente el primer disco de frenadura en Lubrificar el primer disco de strito (19) y montarlo
ESP acero (18) y montarlo en el eje (6). ESP sobre el semi-eje.
Completar el montaje alternando discos de acero y
discos de atrito.
ATENCION! Los discos de atrito deben tener el agujero oval «B» en
linea.
Lubrifier leÂgeÁrement le premier disque de freinage en Lubrifier le premier disque de friction (19), puis monter
F acier (18), puis monter celui-ci dans le bras (6). F ce dernier sur le demi-essieu.
Achever le montage en alternant les disques en acier
et les disques de friction.
ATTENTION! Les disques de friction doivent avoir le trou ovale "B"
aligneÂ.
Posizionare nelle sedi del braccio (6) le molle (17). Montare lo spingidisco (16).
ITA ITA
ATTENZIONE! Controllare attentamente l'orientamen-
to; il frangiflusso "A" e gli scarichi olio, devono essere
orientati verso il tappo di scarico olio del braccio.
In den Sitz des Arms (6) die Federn (17) einsetzen. Die Druckplatte (16) montieren.
D D
ACHTUNG! SorgfaÈltig die Montagerichtung kontroll-
È lablaûoÈffnungen
ieren; den Stahlregler "A" und die O
muÈssen zum Ablaûstopfen des Arms gerichtet sein.
c d
Colocar en las sedes del eje (6) los muelles (17). Montar el empuja-disco (16).
ESP ESP
ATENCION! Controlar atentamente el orientamiento;
el rompe-flujo "A" y los descarga aceite, deben de ser
orientados hacia el tapon de descarga aceite del eje.
Mettre en place les ressorts (17) dans les logements Monter le plateau de pression (16).
F du bras (6). F
ATTENTION! ControÃler attentivement la direction; la
paroi brise-jet "A" et les eÂcoulements d'huile doivent
eÃtre dirigeÂs vers le bouchon de vidange d'huile du bras.
Fissare la posizione dello spingidisco (16) con le viti Bloccare le viti (15) con chiave dinamometrica.
ITA (15). ITA Coppia di serraggio: 20v30 Nm
ATTENZIONE! Serrare le viti in modo sequenziale ed
in piuÁ tempi.
Die Druckplatte (16) mit den Schrauben (15) be- Schrauben (15) mit dem Dynamometer blockieren.
D festigen. D Anzugsmoment: 20v30 Nm.
ACHTUNG! Die Schrauben der Reihe nach und
schrittweise festziehen.
e f
Fijar la posicioÁn del empuja-disco (16) con los tornillos Bloquear los tornillos (15) con llave dinamometrica.
ESP (15). ESP Par de serraje: 20v30 Nm.
ATENCION! Apretar los tornillos de manera secuen-
cial y en mas tiempos.
Fixer le plateau de pression (16) aÁ sa place avec les Bloquer les vis (15) aÁ l'aide de la cleÂ dynamomeÂtrique.
F vis (15). F Couple de serrage: 20v30 Nm.
ATTENTION! Serrer les vis en plusieurs temps en
ordre seÂquentiel.
23
14 12
12
13 10
10
F1241091 F1241092
GB a GB b
Fit O-rings (13) and (14) onto the piston (12). Using a plastic hammer, ram the piston (12) into the cylinder (10).
Lubricate the piston and the O-rings and install the unit into the NOTE. Lightly hammer all around the edge in an alternate
cylinder (10). sequence.
NOTE. Piston relief «C» must face downwards.
22 11
10
F1241079 F1241078
GB c GB d
Check the condition and the position of the O-ring (22); lubricate Position the Belleville washers (11) and engage the cylinder (10).
the O-ring and position the cylinder on the studs without fastening. NOTE. Check the sense of direction of washers (11) and relative
centring.
10 23
6
9
F1241093 F1241094
GB e GB f
Lock the cylinder (10), tightening the screws (9) with a dynamo- Check integrity and position of the arm's O-ring (23); install the
metric wrench set to a torque of 86 ± 89 Nm. complete arm (6).
NOTE. To assist axle shaft centring, slightly move the wheel hub.
24
Montare sul pistone (12) gli anelli OR (13) e (14). Utilizzando un mazzuolo in materiale plastico, inserire
ITA Lubrificare il pistone e gli anelli OR e montare il ITA a fondo il pistone (12) nel cilindro (10).
gruppo nel cilindro (10). NOTA. Battere leggeri colpi distribuiti in modo
NOTA. Lo scarico "C" del pistone deve essere rivolto verso il alternato su tutta la circonferenza.
basso.
Auf den Kolben (12) die O-Ringe (13) und (14) Mit einem Gummihammer den Kolben (12) in den
D montieren. D Zylinder (10) bis zum Anschlag einschlagen.
Den Kolben und die O-Ringe schmieren und das BEMERKUNG. Den Kolben abwechselnd rund um die
Aggregat in den Zylinder (10) montieren. gesamte Kreislinie leicht schlagen.
a BEMERKUNG. Die AblaûoÈffnung "C" des Kolbens muû nach unten b
gerichtet sein.
Montar sobre el piston (12) los anillos OR (13) y (14). Utilizando un martillo de materia plastica, introducir a
ESP Lubrificar el piston y los anillos OR y montar el grupo ESP fondo el piston (12) en el cilindro (10).
en los cilindros (10). NOTA. Pegar ligeros golpes distribuidos de manera
NOTA. El escargo "C" del piston debe de ser dirijido hacia el bajo. alternada sobre toda la circonferencia.
Monter sur le piston (12), les anneaux O'RING (13) et A l'aide d'un maillet en matieÁre plastique, introduire le
F (14). F piston (12) aÁ fond dans le cylindre (10).
Lubrifier le piston et les anneaux O'RING, puis monter REMARQUE. Donner de leÂgers coups reÂguliers tout
le groupe dans le cylindre (10). autour de la circonfeÂrence.
REMARQUE. L'eÂcoulement "C" du piston doit eÃtre tourneÂ vers le
bas.
Controllare lo stato ed il posizionamento dell'anello Posizionare le molle a tazza (11) e mandare in battuta
ITA OR (22); lubrificare l'anello OR e posizionare il cilindro ITA il cilindro (10).
sui prigionieri senza mandarlo in battuta. NOTA. Controllare il senso di orientamento delle molle
a tazza (11) e la loro centratura.
Den Zustand und die Position des O-Ringes (22) Tellerfedern (11) positionieren und den Zylinder (10)
D kontrollieren; den O-Ring schmieren und den Zylinder D bis zum Anschlag einsetzen.
auf die Stiftschrauben positionieren, ohne ihn bis zum BEMERKUNG. Orientierung der Tellerfedern (11) und
Anschlag ganz einzusetzen. ihre Zentrierung kontrollieren.
c d
Controlar el estado y la colocacioÁn del anillo OR (22); Colocar los muelles a taza (11) y mandar a tope el
ESP lubrificar el anillo OR y colocar el cilindro sobre los ESP cilindro (10).
prigioneros sin llevarlo a tope. NOTA. Controlar el sentido de orientamiento de los
muelles a taza (11) y su centraje.
ControÃler l'eÂtat et la position de l'anneau O'RING (22); Positionner les ressorts belleville (11) et inseÂrer aÁ fond
F lubrifier l'anneau O'RING et positionner le cylindre sur F le cylindre (10).
les prisonniers sans l'envoyer en buteÂe. REMARQUE. ControÃler l'orientation des ressorts
belleville (11) et leur centrage.
Bloccare il cilindro (10) con le viti (9) serrate con chiave Verificare l'integritaÁ ed il posizionamento dell'anello
ITA dinamometrica ad un coppia di 86v89 Nm. ITA OR (23) del braccio; installare il braccio completo (6).
NOTA. Per agevolare la centratura del semiasse,
muovere lentamente il mozzo portaruota.
Den Zylinder (10) mit den Schrauben (9) mit einem Am Arm den Zustand und die Position des O-Ringes
D Dynamometer und einem Anzugsmoment von 86v89 Nm D (23) kontrollieren; den gesamten Arm (6) installieren.
blockieren. BEMERKUNG. Um die Halbachse leichter zentrieren
zu koÈnnen, die Radhalternabe etwas bewegen.
e f
Bloquear el cilindro (10) con los tornillos (9) apretados Averiguar la integridad y la colocacioÁn del anillo OR
ESP con llave dinamometrica a un par de 86v89 Nm. ESP (23) del eje; colocar el eje completo (6).
NOTA. Para facilitar el centraje del semi-eje, mover
lentamente el cubo porta-rueda.
Bloquer le cylindre (10) avec les vis (9), serrer aÁ l'aide VeÂrifier le bon eÂtat et le positionnement de l'anneau
F de la cleÂ dynamomeÂtrique aÁ un couple de 86v89 Nm. F O'RING (23) du bras; installer le bras complet (6).
REMARQUE. Afin de rendre plus aiseÂ le centrage du
demi-essieu, bouger lentement le moyeu porte-roue.
25
T2
6
8
F1241095 F1241096
GB a GB b
Temporarily lock the arm (6) with nuts (8) previously coated with Check the flatness of the arms, using tool T2; then lock the arms
Loctite 242; tighten lightly to make the unit touch the main body. into their final position, using screws (7) adequately coated with
Loctite 242.
Torque wrench setting: 182 ± 202 Nm.
NOTE. Tighten using the criss-cross method.
F1241097 F1241074
bar GB c GB d
Connect an external pump to the union piece "A" of the negative Rotate the adjustment pinion (4) anticlockwise (±) to eliminate all
brake and introduce pressure to 15 ± 30 bar. existing clearance between the braking disks.
Rotate up to a torque of 8 ± 10 Nm.
+ 3
4
-- 2
D1240132
F1241073
GB e GB f
Rotate pinion (4) clockwise (+) to determine the required clearance Install safety plate (3) and lock with screw (2).
of 1 mm. Torque wrench setting: 10 ± 11 Nm.
NOTE. A turn of the adjuster produces a clearance of 0.25 mm
(1mm = 4 turns).
26
Fissare provvisoriamente il braccio (6) con i dadi (8) Controllare la planaritaÁ dei bracci con l'attrezzo T2 e
ITA spalmati con Loctite 242 e serrati leggermente per ITA fissarli definitivamente con le viti (7) spalmate con
frizionare il gruppo sul corpo centrale. Loctite 242.
Coppia di serraggio: 182v202 Nm
NOTA. Serrare con il metodo incrociato.
VoruÈbergehend den Arm (6) mit den mit Loctite 242 Die Ebenheit der Arme mit dem Werkzeug T2 kontroll-
D geschmierten Muttern (8) befestigen und Muttern D ieren und endguÈltig mit den mit Loctite 242 ge-
zuschrauben bis das Aggregat an dem ZentralkoÈrper schmierten Schrauben (7) befestigen.
anliegt. Anzugsmoment: 182v202 Nm
a b BEMERKUNG. Im Kreuz fest drehen.
Fijar provisoriamente el eje (6) con las tuercas (8) Controlar la planaridad de los ejes con la herramienta
ESP pasados con Loctite 242 y apretados ligermente para ESP T2 y fijarlos definitivamente con los tornillos (7) pasar
fricionar el grupo sobre el cuerpo central. con Loctite 242.
Par de serraje: 182v202 Nm
NOTA. Apretar de manera cruzada.
Fixer provisoirement le bras (6) avec les eÂcrous (8) ControÃler la planeÂiteÂ des bras aÁ l'aide de l'outil T2,
F enduits avec du Loctite 242, et serrer ceux-ci pour F puis fixer ceux-ci deÂfinitivement avec les vis (7)
frotter le groupe du corps central. enduites de Loctite 242.
Couple de serrage: 182v202 Nm.
REMARQUE. Serrer avec la meÂthode croiseÂe.
Collegare al raccordo "P" del freno negativo una pompa Ruotare in senso antiorario (±) il pignone di registro (4)
ITA esterna ed immettere una pressione di 15v30 bar. ITA per eliminare totalmente il gioco tra i dischi di frenatura.
Ruotare fino ad ottenere una coppia di 8v10 Nm.
An das AnschluûstuÈck "P" der Federspeicherbremse Gegen den Uhrzeigersinn (±) das Kegelrad (4),
D eine aÈuûere Pumpe schlieûen und Druck bei 15v30 bar D drehen, bis kein Spiel zwischen den Bremsscheiben
einlassen. mehr uÈbrig bleibt. Anzugsmoment: 8v10 Nm.
c d
Conectar al empalme "P" del freno negativo una Girar en sentido anti-horario (±) el pinon de registro (4)
ESP pompa externa y introducir presion de 15v30 bar. ESP para eliminar totalmente el juego entre discos de
frenadura.
Girar hasta obtener un par de 8v10 Nm.
Brancher au raccord "P" du frein neÂgatif une pompe Tourner le pignon de reÂglage (4) dans le sens contraire
F externe et envoyer une pression de 15v30 bar. F aux aiguilles d'une montre(-) le reÂgleur (4) pour faire
disparaõÃtre entieÁrement le jeu existant entre les
disques de freinage.
Tourner jusqu'aÁ obtenir un couple de 8v10 Nm.
Ruotare il pignone (4) in senso orario (+) per Montare la piastrina di sicurezza (3) e bloccarla con la
ITA determinare il gioco prescritto di 1 mm. ITA vite (2).
NOTA. Un giro del registro crea un gioco di 0,25 mm Coppia di serraggio: 10v11 Nm
(1 mm=4 giri).
Das Kegelrad (4) in den Uhrzeigersinn (+) drehen, bis Die Sicherheitsplatte (3) montieren und mit der
D das vorgeschriebene Spiel von 1 mm erreicht ist. D Schraube (2) blockieren.
BEMERKUNG. Eine Umdrehung gleicht einem Spiel Anzugsmoment: 10v11 Nm
von 0,25 mm (1 mm=4 Umdrehungen).
e f
Girar el pinon (4) en sentido horario (+) para Montar la plaqua de seguridad (3) y bloquearla con los
ESP determinar el juego prescrito de 1 mm. ESP tornillos 829.
NOTA. Un giro del registro crea un juego de 0,25 mm Par de serraje: 10v11 Nm
(1mm=4 giros).
Tourner le pignon (4) dans le sens des aiguilles d'une Monter la plaquette de seÂcuriteÂ (3), bloquer celle-ci aÁ
F montre (+) pour deÂfinir le jeu prescrit de 1 mm. F l'aide de la vis (2).
REMARQUE. Un tour de reÂgleur donne un jeu de 0,25 Couple de serrage: 10v11 Nm
mm (1mm=4 tours).
27
MECHANICAL AND MANUAL RELEASE OF THE AXLE - SBLOCCAGGIO MECCANICO MANUALE DELL'ASSALE -
ACHSE MECHANISCH MANUELL ENTSICHERN - DESBLOQUEO MANUAL DE LOS AXAL -
DEBLOCAGE MECANIQUE MANUEL DE L'ESSIEU
11 16
24
25
25
26 24
D1240133
F1241098
GB a GB b
MANUAL EMERGENCY RELEASE Tighten screws (25) so as to fasten them onto the pressure plate
Loosen nuts (24) of screws (25) provided for the mechanical and (16).
manual release of the braking units, then move the nuts backwards
by approx. 8 mm.
25 26
24
25
F1241099 F1241100
GB c GB d
Using a wrench, tighten the screws (25) in an alternate sequence ADJUSTMENT AFTER MANUAL RELEASE
by 1/4 turn at a time so as to compress the Belleville washers (11) Remove screws (25) complete with nuts (24) and seals (26).
and disengage the braking disks. Replace seals (26), apply silicone-based Tecno Lupe /101 grease
IMPORTANT. Tighten max. by one turn. to the screws (25) and install all parts into the arm.
24
34 + 0,5
0
F1241101 F1241102
GB e GB f
Adjust screws (25) to obtain a jut of 34+0.5
0 mm in relation to the arm. Lock into position with nuts (24).
CAUTION! Hold screws (25) into position while locking the nuts
(24); after locking, check the jut of screws (25) once more.
28
SBLOCCAGGIO MANUALE D'EMERGENZA Avvitare le viti (25) fino a mandarle in battuta sullo
ITA Allentare i dadi (24) delle viti (25) per lo sblocco ITA spingidisco (16).
meccanico manuale dei gruppi di frenatura e far
arretrare i dadi di circa 8 mm.
MANUELLE NOT-ENTSICHERUNG Schrauben (25) bis zum Anschlag an die Druckplatte

D Die Muttern (24) der Schrauben (25) zur mechani- D (16) zudrehen.
schen manuellen Entsicherung der Bremsaggregate
lockern und die Muttern um 8 mm zuruÈck drehen.
a b
DESBLOQUEO MANUAL DE EMERGENCIA Atornillar los tornillos (25) hasta llegar al tope sobre el
ESP Aflojar las tuercas (24) de los tornillos (25) para el ESP empuja-disco (16).
desbloqueo mecanico manual de los grupos de
frenadura y hacer pasar las tuercas de 8 mm approx.
DEBLOCAGE MANUEL D'EMERGENCE Visser les vis (25) puis les envoyer en buteÂe sur le
F Desserrer les eÂcrous (24) des vis (25) pour le F plateau de pression (16).
deÂblocage meÂcanique manuel des groupes de frei-
nage en faisant reculer les eÂcrous d'environ 8 mm.
Utilizzando una chiave, avvitare le viti (25) in modo REGOLAZIONE DOPO LO SBLOCCAGGIO MANUALE
ITA alternato di 1/4 di giro alla volta, per comprimere le ITA Rimuovere le viti (25) complete dei dadi (24) e delle
molle a tazza (11) e liberare i dischi di frenatura. guarnizioni (26).
IMPORTANTE. Avvitare per max. un giro. Sostituire le guarnizioni (26), lubrificare le viti (25) con grasso al
silicone Tecno Lupe /101 e montare il tutto nel braccio.
Mit einem SchluÈssel, die Schrauben (25) abwechselnd EINSTELLUNG NACH DER MANUELLEN ENTSICHERUNG
D jeweils um 1/4 Umdrehung zudrehen, um die Tellerfe- D Die Schrauben (25) mit den Muttern (24) und den
dern (11) einzudruÈcken und die Bremsscheiben frei- Dichtungen (26) abnehmen.
zusetzen. Die Dichtungen (26) auswechseln, die Schrauben (25) mit Silikon-
c WICHTIG. Maximal um eine Umdrehung zuschrauben. d fett Tecno Lupe/101 schmieren und das ganze Teil in den Arm
montieren.
Utilizando una llave, atornillar los tornillos (25) de REGULACION DESPUES DEL DESBLOQUEO MANUAL
ESP manera alternada de 1/4 de giro a la vez, para ESP Remover los tornillos (25) completas de guarniciones
comprimir los muelles a taza (11) y librar los discos (26).
de frenadura. Sobstituir las guarniciones (26), lubrificar los tornillos (25) con
IMPORTANTE. Atornillar por max. un giro. grasa al silicone Tecno Lupe/101 y montar todo en el eje.
A l'aide d'une cleÂ, visser les vis (25) alternativement 1/ REGLAGE FAISANT SUITE AU DEBLOCAGE MANUEL
F 4 de tour aÁ la fois, pour contraindre le ressort belleville F Enlever les vis (25) compleÁtes d'eÂcrous (24) et de
(11) et deÂgager les disques de freinage. garnitures (26).
IMPORTANT. Visser pour max. un tour. Substituer les garnitures (26), lubrifier les vis (25) avec de la graisse
au silicone Tecno Lupe/101, monter le tout dans le bras.
Regolare le viti (25) fino ad avere una sporgenza Bloccare la posizione con i dadi (24).
ITA rispetto al braccio di 34+0,5
0 mm
ITA
ATTENZIONE! Mantenere la posizione delle viti (25)
quando si bloccano i dadi (24); dopo il bloccaggio,
ricontrollare la sporgenza delle viti (25).
È berstand zum Arm

Schrauben (25) einstellen, bis der U Die Position mit den Muttern (24) blockieren.
D 34+0.5
0 mm betraÈgt. D
ACHTUNG! Die Position der Schrauben (25) darf sich
beim Festziehen der Muttern (24) nicht aÈndern; nach
der Blockierung den U È berstand der Schrauben (25) nochmals
e f kontrollieren.
Regular los tornillos (25) hasta obtener una parte Bloquear la colocacioÁn con las tuercas (24).
ESP saliente respecto al eje de 34+0,5
0 mm
ESP
ATENCION! Mantener la posicion de los tornillos (25)
cuando se bloquean las tuercas (24); despues del
bloqueo, recontrolar la parte saliente de los tornillos (25).
ReÂgler les vis (25) jusqu'aÁ avoir une saillie de 34+0.5

0 mm Bloquer dans la position aÁ l'aide des eÂcrous (24).
F par rapport au bras. F
ATTENTION! Tenir les vis (25) en place quand on
bloque les eÂcrous (24); apreÁs avoir fixeÂ, controÃler la
saillie des vis (25).
29
DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-
TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU
4
12
9 11
10
3
8 13
14
7
16
15
2
1 D1240131
1
3
2
F1241103 F1241104
GB a GB b
Remove the locking screws (1) of planetary cover (2). Using two screwdrivers or two levers inserted in the slots provided,
pry the planetary cover (2) away from the wheel hub (3).
30
SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE
NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR
GB The axle shafts can only be removed once the 2 - Achse zuerst von der Maschine abmontieren und auf eine
extraction of the planetary cover has been performed. Werkbank legen.
Different procedures need to be followed depending on
the kind of repair work required: Nachstehende Beschreibung bezieht sich auf das Zerlegen an der
Werkbank, doch ist die Vorgehensweise in beiden FaÈllen dieselbe.
1 - Disassembly with axle connected to the machine with machine
resting on safety stands.
2 - Disassembly with the axle disconnected from the machine and
supported by the appropriate equipment (at the bench).
The explanations given herein refer to the removal operation as is La remocioÁn de los semi-ejes puede ser efectuada solo
carried out on the bench, but the stages apply to all versions. ESP despues de la remocioÁn de las tapas lleva-satelites y de
manera deversificada, en funcion del tipo de repara-
cion de efectuar:
1 - Desmontaje con axal montado sobre la maquina colocada sobre
caballetes de seguridad;
2 - Desmontaje con axial desmontado desde la maquina y susten-
tado de apositas herramientas (al banco).
Las explicaciones reportadas se refieren a la remocioÁn efectuada al
La rimozione dei semiassi puoÁ essere eseguita solo banco, ma las fases son comunes.
ITA dopo la rimozione del coperchio portasatelliti ed in
modo diversificato, in funzione del tipo di riparazione
da eseguire:
1 - Smontaggio con assale montato sulla macchina appoggiata su
cavalletti di sicurezza.
2 - Smontaggio con assale smontato dalla macchina e sostenuto da
apposita attrezzatura (al banco).
Le spiegazioni riportate si riferiscono alla rimozione eseguita al Le deÂgagement des demi-essieux ne peut se faire
banco, ma le fasi sono comuni. F qu'apreÁs avoir enleveÂ le couvercle porte-satellites
d'une facËon diversifieÂe, en fonction du type de
reÂparations aÁ effectuer:
1 - DeÂmontage essieu monteÂ sur machine deÂposeÂe sur des baÃtis de
seÂcuriteÂ.
1 - DeÂmontage essieu deÂmonteÂ de la machine et soutenu par un
outil speÂcial (sur banc).
Les explications reporteÂes se reÂfeÁrent au deÂgagement effectueÂ au
Die Halbachse kann erst abmontiert werden, wenn der banc, mais les phases sont communes.
D Deckel des Planetenradhalters abgenommen worden
ist; auûerdem wird sie je nach Reparatur unterschied-
lich abmontiert:
1 - Mit Achse abmontieren, die an der Maschine montiert und durch
SicherheitsbloÈcke gestuÈtzt ist.
Rimuovere le viti (1) di fissaggio del coperchio Utilizzando due cacciaviti o due leve inserite nelle
ITA portasatelliti (2). ITA cave predisposte, staccare il coperchio portasatelliti
(2) dal mozzo portaruota (3).
Schrauben (1) abschrauben, die den Deckel des Zwei Schraubenzieher oder zwei Hebel in die vorge-
D Planetenradhalters (2) befestigen. D sehenen Nuten stecken und den Deckel (2) des
Planetenradhalters von den Radhalternaben (3) ab-
heben.
a b
Remover los tornillos (1) de fisaje de la tapa porta- Utilizando dos destornilladores o dos palancas inser-
ESP satelites (2). ESP tadas en las ranuras predispuestas, destacar la tapa
lleva-satelites (2) del cubo lleva-rueda (3).
Enlever les vis (1) de fixation du couvercle porte- A l'aide de deux tournevis ou de deux leviers dans les
F satellites (2). F creux preÂdisposeÂs, deÂgager le couvercle porte-satel-
lites (2) du moyeu porte-roue (3).
31
2 3
5
F1241105 F1241106
GB a GB b
Rotate the wheel hub (3) until one of the screw holes (1) appears at Only in case of replacement of component parts not requiring
the top. the disassembly of the crown wheel (5).
Apply a "U" piece to the screw hole; connect to a hoist and remove Countermark the position between one of the teeth of the axle shaft
the cover (2). (4) and the crown wheel (5).
F1241107 F1241108
GB c GB d
Remove the axle shaft (4). Loosen the screws (6) and remove them.
NOTE. The removal of the axle shaft allows for the substitution of
the snap ring as described in the following paragraphs.
3 5
7
F1241109 F1241110
GB e GB f
Remove the safety flange (7). Partially tighten five of the ten screws (6) in an alternate and
proportional manner.
Using an extractor and applying a counter pressure to the screws
(6), disengage the crown wheel (5) from the hub (3).
32
Ruotare il mozzo portaruota (3) fino a portare un foro Solo se si devono sostituire dei componenti che
ITA per le viti (1) in posizione alta. ITA non richiedono lo smontaggio della corona (5).
Applicare un grillo ad "U" nel foro vite; collegare un Contrassegnare la posizione tra un dente del semias-
mezzo di sollevamento e rimuovere il coperchio (2). se (4) e la corona (5).
Nur wenn Bestandteile ausgewechselt werden

D Die Radhalternabe (3) drehen bis ein Loch fuÈr die D muÈssen, fuÈr die der Kranz (5) nicht abmontiert
Schrauben (1) in der oberen Position liegt. werden muû.
Einen U-foÈrmigen BuÈgel in das Schraubenloch stecken; ein Die Position zwischen einem Zahn der Halbachse (4) und dem
a Hebezeug anschlieûen und den Deckel (2) abnehmen. b Kranz (5) markieren.
Girar el cubo lleva-rueda (3) hasta hacer un agujero Solo si se deben de sobstituir algunos componentes
ESP para los tornillos (1) en posicioÁn alta. ESP que no comportan el desmontaje de la corona (5).
Aplicar un grillo a "U" en el agujero tornillos; conectar Senalar la colocacioÁn entre un diente del semi-eje (4) y
un medio de levantamiento y remover la tapa (2). la corona (5).
Tourner le moyeu porte-roue (3) jusqu'aÁ aÁ amener un Uniquement si on doit substituer des composants qui
F des trous pour les vis (1) en haut. F ne veulent pas le deÂmontage de la couronne (5).
Appliquer une manille en "U" dans le trou de vis; Marquer la position entre une dent du demi-essieu (4)
appliquer un moyen de relevage et enlever le couvercle (2). et la couronne (5).
Asportare il semiasse (4). Allentare le viti (6) ed asportarle.

ITA ITA
NOTA. L'asportazione del semiasse permette la
sostituzione dell'anello di tenuta come descritto di
seguito.
Die Halbachse (4) abnehmen. Schrauben (6) abschrauben.

D D
BEMERKUNG. Bei abgenommener Halbachse kann
der Dichtring, wie nachstehend beschrieben, ausge-
wechselt werden.
c d
Sacar el semi-eje (4). Aflojar los tornillos (6) y sacarlos.
ESP ESP
NOTA. Sacar el semi-eje permite la sobstitucioÁn del
anillo de tenida como descrito a seguir.
Enlever le demi-essieu (4). Desserrer les vis (6) puis les enlever.
F F
REMARQUE. Le deÂgagement du demi-essieu consent
la substitution de l'anneau d'eÂtancheÂiteÂ comme deÂcrit
par la suite.
Asportare la flangia di sicurezza (7). Avvitare parzialmente, in modo alternato ed in uguale

ITA ITA misura, cinque delle dieci viti (6).
Utilizzando un estrattore e facendo reazione sulle viti
(6) disimpegnare la corona (5) dal mozzo (3).
Sicherheitsflansch (7) abnehmen. Abwechselnd und im gleichen Maû fuÈnf von den zehn
D D Schrauben (6) zuschrauben.
Mit einem Abzieher den Kranz (5) aus der Nabe (3)
ziehen und dabei auf die Schrauben (6) wirken.
e f
Sacar la arandela de seguridad (7). Atornillar parcialmente, de manera alternada y en
ESP ESP igual mesera, cinco de las diez tornillos (6).
Utilizando un extractor y haciendo reacioÁn sobre los
tornillos (6) desempenar la corona (5) del cubo (3).
Enlever la flasque de seÂcuriteÂ (7). Visser partiellement, en alternance et de la meÃme

F F facËon cinq des dix vis (6).
A l'aide d'un extracteur, tout en faisant reÂagir les vis
(6), deÂgager la couronne (5) du moyeu (3).
33
3
F1241111 F1241112
GB a GB b
Remove screws (6) and crown wheel (5). Sling the hub (3) and connect it to a hoist; partially tighten a screw
(6) and with the help of a hammer, shift the hub (3) and the external
bearing (8).
3
9
8
10
3
F1241113 F1241114
GB c GB d
Remove the bearing (8) and the hub (3). Extract the hub (3) complete with snap ring (9) and internal bearing
(10).
14
13
11 12
F1241115 F1241116
GB e GB f
Using an extractor, remove at the same time the snap ring (11) and Remove the safety spring rings (13) of the planetary gears (14).
the centring ring (12).
NOTE. Note down the direction of assembly of snap and centring
rings.
34
Rimuovere le viti (6) e la corona (5). Imbragare il mozzo (3) e collegarlo ad un mezzo di
ITA ITA sollevamento; avvitare parzialmente una vite (6) e, con
un mazzuolo, smuovere il mozzo (3) ed il cuscinetto
esterno (8).
Schrauben (6) und Kranz (5) abnehmen. Nabe (3) anschlagen und an ein Hebezeug befestigen;
D D Schrauben (6) etwas zudrehen und mit einem Ham-
mer die Naben (3) und das aÈuûere Lager (8) bewegen.
a b
Remover los tornillos (6) y la corona (5). Atar el cubo (3) y conectarlo a un medio de
ESP ESP levantamiento; atornillar parcialmente un tornillo (6)
y, con un martillo, mover el cubo (3) y el cojinete
externo (8).
Enlever les vis (6) et la couronne (5). Elinguer le moyeu (3) puis relier celui-ci aÁ un moyen de
F F relevage; visser partiellement une vis (6), puis aÁ l'aide
d'un maillet, bouger le moyeu (3) et le palier externe
(8).
Rimuovere il cuscinetto (8) ed il mozzo (3). Asportare il mozzo (3) completo di anello di tenuta (9) e
ITA ITA cuscinetto interno (10).
Lager (8) und Nabe (3) abnehmen. Nabe (3) samt Dichtring (9) und inneres Lager (10)
D D abnehmen.
c d
Remover el cojinete (8) y el cubo (3). Sacar el cubo (3) completo de anillo de retencioÁn (9) y
ESP ESP cojinete interno (10).
Enlever le palier (8) et le moyeu (3). Enlever le moyeu (3) complet de bague d'eÂtancheÂiteÂ
F F (9) et de palier interne (10).
Utilizzando un estrattore, rimuovere contemporanea- Rimuovere gli anelli elastici (13) di ritegno satelliti (14).
ITA mente l'anello di tenuta (11) e l'anello centratore (12). ITA
NOTA. Annotare il senso di montaggio degli anelli di
tenuta e di centratura.
Mit einem Abzieher gleichzeitig den Dichtring (11) und Kolbenringe (13) und Planetenhalter (14) abnehmen.
D den Zentrierring (12) abnehmen. D
BEMERKUNG. Montagerichtung der Dicht- und Zen-
trierringe notieren.
e f
Utilizando un extractor, remover contemporaneamen- Remover los anillos elasticos (13) de retencioÁn
ESP te el anillo de retencioÁn (11) y el anillo centrador (12). ESP satelites (14).
NOTA. Anotar el sentido de montaje de los anillos de
retencioÁn y de centraje.
A l'aide d'un extracteur enlever en meÃme temps Enlever les anneaux ressorts (13) de fixation des
F l'anneau d'eÂtancheÂiteÂ (11) et l'anneau centreur (12). F satellites (14).
REMARQUE. Prendre note du sens de montage des
anneaux d'eÂtancheÂiteÂ et de centrage.
35
14
15
F1241117 F1241118
GB a GB b
Remove the planetary gears (14). Only if necessary.
NOTE. Note down direction of assembly of planetary gears. Using an extractor, remove the shim washer (15) from the planet
carrier.
9 9
3 10
F1241119 F1241120
GB c GB d
Remove the snap ring (9) from the hub (3). Remove the internal bearing (10).
NOTE. Note down direction of assembly.
CAUTION! The snap ring may not be reused.
10
8
F1241121
GB e GB f
Remove the external thrust blocks of bearings (8) and (10), using a
pin-driver.
NOTE. Hammer in an alternate sequence to prevent crawling and
deformation of the thrust blocks.
36
Asportare gli ingranaggi satelliti (14). Solo se necessario.
ITA ITA Utilizzando un estrattore, rimuovere dal portasatelliti la
NOTA. Annotare il senso di montaggio dei satelliti.
rondella di rasamento (15).
Planetengetriebe (14) abnehmen. Nur wenn notwendig.

D D Mit einem Abzieher vom Planetenradhalter die Zwi-
BEMERKUNG. Montagerichtung notieren.
schenlegscheibe (15) abnehmen.
a b
Sacar los engranajes satelites (14). Solo si necesario.
ESP ESP Utilizando un extractor, remover del lleva-satelites la
NOTA. Anotar el sentido de desmontaje de los
satelites. arandela de rasamiento (15).
Enlever les engrenages satellites (14). Uniquement si besoin.

F F A l'aide d'un extracteur, enlever du porte-satellite la
REMARQUE. Prendre note du sens de montage.
rondelle de rasage (15).
Rimuovere dal mozzo (3) l'anello di tenuta (9). Rimuovere il cuscinetto interno (10).
ITA ITA
NOTA. Annotare il senso di montaggio.
ATTENZIONE! L'anello di tenuta non puoÁ essere
riutilizzato.
Von der Nabe (3) den Dichtring (9) abnehmen. Das innere Lager (10) abnehmen.
D D
BEMERKUNG. Montagerichtung notieren.
ACHTUNG! Der Dichtring darf nicht wieder verwendet
werden.
c d
Remover del cubo (3) los anillos de retencioÁn (9). Remover el cojinete interior (10).
ESP ESP
NOTA. Anotar el sentido de montaje.
ATENCION! El anillo de retencioÁn no puede ser
reutilizado.
Oter du moyeu (3) l'anneau d'eÂtancheÂiteÂ (9). Enlever le palier interne (10).
F F
REMARQUE. Prendre note du sens de montage.
ATTENTION! L'anneau d'eÂtancheÂiteÂ ne peut pas eÃtre
reÂutiliseÂ.
Rimuovere le ralle esterne dei cuscinetti (8) e (10)

ITA utilizzando un cacciaspine. ITA
NOTA. Battere in modo alternato per evitare impunta-
menti e deformazioni delle ralle.
Die aÈuûeren Scheiben (8) und (10) mit einem DuÈbel

D abnehmen. D
BEMERKUNG. Abwechselnd schlagen, um ein Durch-
schlagen und Verformungen der Scheiben zu vermeiden.
e f
Remover las ranguas externas de los cojinetes (8) y
ESP (10) utilizando un extractor de clavijas. ESP
NOTA. Pegar de manera alternada para evitar
empuntamientos y deformacioÁnes de las ranguas.
Enlever les crapaudines externes des paliers (8) et

F (10) aÁ l'aide d'un chasse-clou. F
REMARQUE. Donner des coups alterneÂs pour eÂviter
talonnages et deÂformations des crapaudines.
37
ASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-
TRIEBE UND HALBACHSE ZUSAMMENBAUEN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR
T3 10 9
3
10
F1241122 F1241123
GB a GB b
Position the wheel hub (3) under a press; lubricate the seat of the Install the bearing (10).
external bearing and, using tool T3, install the thrust block of the Apply an appropriate sealant to the outer surface of the snap ring
bearing (10). (9).
Position the snap ring (9) into the hub (3).
NOTE. Check orientation of the ring.
T4 T3
9 3
8
F1241124 F1241125
GB c GB d
Position tool T4 and press the snap ring (9) down into its seat. Turn the hub (3) upside down, lubricate the seat of the bearing and,
using tool T3, install the thrust block of the bearing (8).
15
2 14
F1241126 F1241117
GB e GB f
Only if shim washer has previously been removed. Fit the planetary gear (14) onto the planetary gear cover (2).
Apply a sealant for removable seals to the outer surface of the shim CAUTION! The jointed portion of the internal ring of the bearings
washer (15) and, using a driver, fit it into the planetary gear cover must face the bottom of the pin.
(2).
38
Posizionare il mozzo ruota (3) sotto una pressa; Installare il cuscinetto (10).
ITA lubrificare la sede del cuscinetto esterno e, utilizzando ITA Spalmare la superficie esterna dell'anello di tenuta (9)
l'attrezzo T3, montare la ralla del cuscinetto (10). con sigillante per guarnizioni.
Posizionare l'anello di tenuta (9) nel mozzo (3).
NOTA. Controllare l'orientamento dell'anello.
Die Radnabe (3) unter eine Presse positionieren; den Lager (10) installieren.
D Sitz des aÈuûeren Lagers schmieren und mit dem D AÈuûere FlaÈche des Dichtringes (9) mit etwas Dicht-
Werkzeug T3 die Scheibe des Lagers (10) montieren. masse schmieren.
Dichtring (9) in die Nabe (3) positionieren.
a b BEMERKUNG. Richtung des Ringes kontrollieren.
Colocar el cubo rueda (3) bajo una prensa; lubrificar la Colocar el cojinete (10).
ESP sed del cojinete externo y, utilizando la herramienta ESP Pasar la superficie externa del anillo de retencioÁn (9)
T3, montar la rangua del cojinete (10). con sigilante para guarniciones.
Colocar el anillo de retencioÁn (9) en el cubo (3).
NOTA. Controlar el orientamiento del anillo.
Positionner le moyeu roue (3) sous la presse; lubrifier Installer le palier (10).
F le logement du palier externe, puis aÁ l'aide de l'outil F Enduire la superficie externe de l'anneau d'eÂtancheÂiteÂ
T3, monter la crapaudine du palier (10). (9) avec de la colle aÁ garnitures.
Positionner l'anneau d'eÂtancheÂiteÂ (9) dans le moyeu (3).
REMARQUE. ControÃler la bonne direction de l'anneau.
Posizionare l'attrezzo T4 e pressare in sede l'anello di Capovolgere il mozzo (3), lubrificare la sede cuscinetto
ITA tenuta (9). ITA e, utilizzando l'attrezzo T3, montare la ralla del
cuscinetto (8).
Das Werkzeug T4 positionieren und den Dichtring (9) Die Nabe (3) wenden, den Lagersitz schmieren und
D in seinen Sitz druÈcken. D mit dem Werkzeug T3 die Nabe des Lagers (8)
montieren.
c d
Colocar la herramienta y apretar en sed el anillo de Volcar el cubo (3), lubrificar la sed cojinete y,
ESP retencioÁn (9). ESP utilizando la herramienta T3, montar la rangua del
cojinete (8).
Placer l'outil T4 et presser dans son logement Faire basculer le moyeu (3), lubrifier le logement du
F l'anneau d'eÂtancheÂiteÂ (9). F palier, puis aÁ l'aide de l'outil T3, monter la crapaudine
dans le palier (8).
Solo se eÁ stata rimossa. Montare sui perni del coperchio portasatelliti (2) gli
ITA Spalmare la superficie esterna della rondella di ITA ingranaggi planetari (14).
rasamento (15) con sigillante per guarnizioni removibili ATTENZIONE! La parte raccordata dell'anello interno
e, utilizzando uno spintore, montarla nel coperchio portasatelliti (2). dei cuscinetti deve essere rivolta verso il fondo del perno.
Nur wenn zuvor abgenommen. Auf die Stifte des Deckels des Planetenradhalters (2)
D AÈuûere FlaÈche der Zwischenlegscheibe (15) mit D die Planetengetriebe (14) montieren.
Dichtmasse fuÈr abnehmbare Dichtungen schmieren ACHTUNG! Das AnschluûstuÈck des inneren Lagerrin-
und mit einem StoÈûel diese Zwischenlegscheibe in den Deckel des ges muû zur unteren Seite des Stiftes gerichtet sein.
e Planetenradhalters (2) montieren. f
Solo si ha sido desplazada. Montar sobre los pernos de la tapa lleva-satelites (2)
ESP Pasar la superficie externa de la arandela de ESP los engranajes planetares (14).
rasamiento (15) con sigilante para guarnicioÁnes ATENCION! La parte empalmada del anillo interno de
removibles y, utilizando un empuje, montarla en la tapa lleva- los cojinetes debe de ser dirijida hacia el fondo de la rotula.
satelites (2).
Uniquement si elle a eÂteÂ enleveÂe. Monter sur les pivots du couvercle porte-satellites (2)
F Enduire la superficie externe de la rondelle de rasage F les engrenages planeÂtaires (14).
(15) avec de la colle pour garnitures amovibles, aÁ ATTENTION! La partie raccordeÂe de l'anneau aÁ
l'aide d'un poussoir monter celle-ci dans le couvercle porte- l'inteÂrieur du palier doit eÃtre tourneÂe vers la partie basse du pivot.
satellites (2).
39
T5
13
14
11 12
F1241127 F1241128
GB a GB b
Lock into position the planetary gears (14) with the snap rings (13). Lubricate and fit the centring ring (12) and snap ring (11) onto tool
T5; install the rings into the arm.
CAUTION! Pay particular attention to the direction of assembly of
the rings.
3
9
3
F1241114 F1241113
GB c GB d
Grease the snap ring (9) and the hub of the arm. Install the external bearing (8).
Install the wheel hub (3). NOTE. Move the bearing to the limit stop by hammering lightly all
around the edge.
7
F1241129 F1241109
GB e GB f
Install the crown wheel (5) and, using a driver with adequate Using Tecno Lupe /101, grease the surface of the safety flange (7)
diameter, fasten it onto the hub of the arm. that touches the crown wheel.
40
Fissare la posizione degli ingranaggi satelliti (14) con Lubrificare e montare sull'attrezzo T5 l'anello centra-
ITA gli anelli elastici (13). ITA tore (12) e l'anello di tenuta (11); montare gli anelli nel
braccio.
ATTENZIONE! Controllare attentamente il senso di montaggio
degli anelli.
Die Position der Planetengetriebe (14) mit den Das Werkzeug T5 schmieren und darauf den Zen-
D Kolbenringen (13) festigen. D trierring (12) und den Dichtring (11) montieren; die
Ringe in den Arm montieren.
ACHTUNG! Montagerichtung der Ringe sorgfaÈltig kontrollieren.
a b
Fijar la posicioÁn de los engranajes satelites (14) con Lubrificar y montar sobre la herramienta T5 el anillo
ESP los anillos elasticos (13). ESP central (12) y el anillo de retencioÁn (11); montar los
anillos en el eje.
ATENCION! Controlar atentamente el sentido de montaje de los
anillos.
Fixer les engrenages porte-satellites (14) aÁ leur place Lubrifier et monter sur l'outil T5 l'anneau centreur (12)
F avec les anneaux ressorts (13). F et l'anneau d'eÂtancheÂiteÂ (11); monter les anneaux
dans le bras.
ATTENTION! ControÃler attentivement le sens du montage des
anneaux.
Lubrificare con grasso l'anello di tenuta (9) ed il mozzo Montare il cuscinetto esterno (8).
ITA del braccio. ITA
NOTA. Mandare a fondo corsa il cuscinetto con
Montare il mozzo portaruota (3). leggeri colpi di mazzuolo distribuiti su tutta la
circonferenza.
Mit Fett den Dichtring (9) und die Armnabe schmieren. AÈuûeres Lager (8) montieren.
D Radhalternabe (3) montieren. D
BEMERKUNG. Das Lager bis zum Anschlag mit
leichten HammerschlaÈgen an der gesamten Kreislinie
einsetzen.
c d
Lubrificar con grasa el anillo de retencioÁn (9) y el cubo Montar el cojinete esterno (8).
ESP del eje. ESP
NOTA. Mandar a tope el cojinete con ligeros colpes de
Montar el cubo lleva-rueda (3). martillo repartidos sobre toda la circonferencia.
Lubrifier avec de la graisse l'anneau d'eÂtancheÂiteÂ (9), Monter le palier externe (8).
F le moyeu du bras. F
REMARQUE. Envoyer en buteÂe le palier avec de
Monter le moyeu porte-roue (3). leÂgers coups de maillet distribueÂs tout autour de la
circonfeÂrence.
Montare la corona (5) e, utilizzando uno spintore di Lubrificare con grasso Tecno Lupe /101 la superficie
ITA diametro adatto, mandarla in battuta sul mozzo del ITA della flangia di sicurezza (7) a contatto con la corona.
braccio.
Den Kranz (5) montieren und mit einem geeigneten Mit Fett Typ Tecno Lupe/ 101 die FlaÈche des Sicher-
D StoÈûel den Kranz bis zum Anschlag an der Armnabe D heitsflanschs (7), der am Kranz anliegt, schmieren.
einsetzen.
e f
Montar la corona (5) y, utilizando un empuje de Lubrificar con grasa Tecno Lupe/101 la superficie de
ESP diametro apto, mandarla a tope sobre el cubo del eje. ESP la brida de seguridad (7) a contacto con la corona.
Monter la couronne (5), puis aÁ l'aide d'un poussoir Lubrifier avec de la graisse Tecno Lupe/ 101 la
F d'un diameÁtre adapteÂ, envoyer celle-ci en buteÂe sur le F superficie de la flasque de seÂcuriteÂ (7) au contact de
moyeu du bras. la couronne.
41
11
4
F1241130 F1241107
GB a GB b
Coat the screws (6) with Loctite 270 and screw them. Lubricate the snap ring (11), the toothed portions and the sealing
Tighten screws (6) in two stages, using the criss-cross method. surface of the axle shaft.
Initial torque wrench setting: 120 Nm Install the axle shaft (4), making sure that it is properly inserted into
Final torque wrench setting: 219 ± 242 Nm braking disks and differential unit.
3 1
2
2
16
F1241131 F1241132
GB c GB d
Fit the planetary gear cover (2) onto the wheel hub (3). Lock the planetary gear cover (2) onto the wheel hub (3) with
CAUTION! 1 - Check the condition and position of the O-ring (16). screws (1).
2 - Line up the locating release points. Screws torque wrench setting: 40 ± 0 Nm.
GB e GB f
42
Spalmare le viti (6) con Loctite 270 ed avvitarle. Lubrificare l'anello di tenuta (11), le dentature e la
ITA Serrare le viti (6) in due tempi e con il metodo del ITA superficie di tenuta del semiasse.
serraggio incrociato. Montare il semiasse (4) assicurandosi che si innesti
Coppia di serraggio iniziale: 120 Nm nei dischi freni e nel differenziale.
Coppia di serraggio finale: 219v242 Nm
Die Schrauben (6) mit Loctite 270 schmieren und Dichtring (11), ZaÈhne und DichtflaÈche der Halbachse
D festschrauben. D schmieren.
Schrauben (6) im Kreuz schrittweise festziehen. Halbachse (4) montieren und darauf achten, daû sie in
Anzugsmoment zuerst: 120Nm die Bremsscheiben und in das Differential einrastet.
a Anzugsmoment am Ende: 219v242 Nm b
Pasar los tornillos (6) con Loctite 270 y atornillarlos. Lubrificar el anillo de retencioÁn (11), las dentaduras y
ESP Apretar los tornillos (6) en doss tiempos con el metodo ESP la superficie del semieje.
de torsion cruzada. Montar el semieje (4) asegurandose que se encaje en
Par de torsion inicial: 120 Nm. los discos y en el diferencial.
Par de torsion final: 219v242 Nm.
Enduire les vis (6) avec du Loctite 270 puis visser. Lubrifier l'anneau d'eÂtancheÂiteÂ (11), les dents, la
F Serrer les vis (6) en deux temps avec la meÂthode du F superficie eÂtanche des demi-essieux.
serrage croiseÂ. Monter le demi-essieu (4) en veillant aÁ ce qu'il
Couple de serrage initial: 120Nm s'enclenche bien dans les disques freins et dans le diffeÂrentiel.
Couple de serrage final: 219v242 Nm.
Montare il coperchio portasatelliti (2) sul mozzo Bloccare il coperchio portasatelliti (2) sul mozzo
ITA portaruota (3). ITA portaruota (3) con le viti (1).
ATTENZIONE! 1 - Controllare lo stato e la posizione Coppia di serraggio viti: 40v50 Nm
della guarnizione OR (16).
2 - Allineare gli scarichi di riferimento.
Den Deckel des Planetenradhalters (2) auf die Nabe Den Deckel des Planetenradhalters (2) an der Rad-
D des Radhalters (3) montieren. D halternabe (3) mit den Schrauben (1) blockieren.
ACHTUNG! 1 - Zustand und Position der O-Ringe (16) Anzugsmoment der Schrauben: 40v50 Nm
kontrollieren.
c 2 - Die Bezugsstellen bzw. AblaûoÈffnung fluchten. d
Montar la tapa lleva-satelites (2) sobre el cubo lleva- Bloquear la tapa lleva-satelietes (2) sobre el cubo
ESP rueda (3). ESP lleva-rueda (3) con los tornillos (1).
ATENCION! 1 - Controlar el estado y la posicioÁn de la Par de torsion tornillos: 40v50 Nm
guarnicioÁn OR (16).
2 - Alinear los descarges de referencia.
Monter le couvercle porte-satellite (2) sur le moyeu Bloquer le couvercle porte-satellite (2) sur le moyeu
F porte-roue (3). F porte-roue (3) aÁ l'aide des vis (1).
ATTENTION! 1 - ControÃler l'eÂtat et la position des Couple de serrage des vis: 40v50 Nm.
garnitures O'Ring (16).
2 - Aligner les points de deÂcharge de reÂfeÂrence.
ITA ITA
D D
e f
ESP ESP
F F
43
REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE -
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL
T6
T7A
F1241141 F1241142
GB a GB b
REMOVAL OF THE DIFFERENTIAL UNIT Apply tool T6 - for crown wheel side centring - with relative distance
Remove the whole arms, the cylinders, and the whole reduction pieces and lock it with two nuts.
unit. Apply centring tool T7A as well.
For details, see «CHECKING WEAR AND REPLACING THE
BRAKING DISKS» and «REMOVAL OF REDUCTION GEAR».
1 T7B
F1241143 F1241144
GB c GB d
Remove the stud screws and remove the intermediate cover (1) on Install centring tool T7B on the opposite side of the crown wheel.
the crown wheel opposite side.
2 T7B
A
4
3
5 6
F1241145 F1241146
GB e GB f
Remove centring tools T6 and T7A from crown wheel side; remove Position a stop block «A» made from tender material (aluminium,
the studs and the intermediate cover (2) on the crown wheel side. etc.) between the main body (3) and the toothed portion of the
crown wheel (4).
With the crown (4) resting on block "A", remove and extract the
screws (5) and the spring washers (6).
44
RIMOZIONE DIFFERENZIALE Applicare l'attrezzo T6 di centraggio dal lato corona
ITA Rimuovere i bracci completi, i cilindri freni ed il ITA con i relativi distanziali e fissarlo con due dadi.
riduttore completo. Applicare anche l'attrezzo T7A di centratura.
Per i dettagli, vedere «CONTROLLO USURA E SOSTITUZIONE
DISCHI FRENO» e «RIMOZIONE RIDUTTORE».
DIFFERENTIAL ABNEHMEN Das Werkzeug T6 zur Zentrierung an der Kranzseite

D Die kompletten Arme, die Bremszylinder und den D mit den entsprechenden DistanzstuÈcken anbringen
kompletten Reduzierer abnehmen. und das Werkzeug mit zwei Muttern befestigen.
Siehe «VERSCHLEISS KONTROLLIEREN UND BREMSSCHEI- Das Werkzeug T7A zur Zentrierung anbringen.
a BEN AUSWECHSELN» und «REDUZIERER ABNEHMEN». b
REMOCION DIFERENCIAL Aplicar la herramienta T6 de centraje del lado corona
ESP Remover los ejes completos, los cilindros frenos y el ESP con los relativos distanciales y fijarla con dos tuercas.
reductor completo. Aplicar tambien la herramienta T7A de centradura.
Para los detalles, vease «CONTROL DESGASTE Y SOBSTITU-
CION DISCOS FRENOS» y «REMOCION REDUCTOR».
DEGAGEMENT DU DIFFERENTIEL Appliquer l'outil T6 de centrage du coÃteÂ couronne

F Enlever les bras entieÁrement, les cylindres freins et le F avec les entretoises correspondantes et fixer l'outil
reÂducteur tout entier. avec deux eÂcrous.
Pour de plus amples deÂtails, voir "CONTROLE DE L'USURE ET Appliquer eÂgalement l'outil de centrage T7A.
SUBSTITUTION DU DISQUE FREIN" et "DEGAGEMENT DU
REDUCTEUR".
Rimuovere le viti prigioniere e rimuovere il coperchio Montare l'attrezzo T7B di centraggio sul lato opposto
ITA intermedio (1) dal lato opposto corona. ITA corona.
Die Stiftschrauben und den Zwischendeckel (1) von Das Werkzeug T7B zur Zentrierung an der dem Kranz
D der dem Kranz entgegengesetzte Seite abnehmen. D entgegengesetzte Seite montieren.
c d
Remover los tornillos prigioneros y remover la tapa Montar la herramienta T7B de centraje sobre el lado
ESP intermedia (1) del lado opuesto corona. ESP opuesto corona.
Enlever les vis prisonnieÁres et enlever le couvercle Monter l'outil de centrage T7B du coÃteÂ opposeÂ aÁ la
F intermeÂdiaire (1) du coÃteÂ opposeÂ aÁ la couronne. F couronne.
Rimuovere gli attrezzi T6 e T7A di centraggio del lato Posizionare tra il corpo centrale (3) e la dentatura della
ITA corona; asportare i prigionieri e rimuovere il coperchio ITA corona (4) un blocchetto "A" di contrasto in materiale
intermedio (2) lato corona. tenero (alluminio ecc.).
Mantenendo in appoggio la corona (4) sul blocchetto "A",
rimuovere ed asportare le viti (5) e le rondelle elastiche (6).
Die Werkzeuge T6 und T7A zur Zentrierung an der Zwischen dem ZentralkoÈrper (3) und den ZaÈhnen des
D Kranzseite entfernen; die Stiftschrauben und den D Kranzes (4) den Block "A" aus weichem Material
Zwischendeckel (2) an der Kranzseite abnehmen. (Aluminium usw.) legen.
Den Kranz (4) am Block "A" anliegen lassen und die Schrauben (5)
e f und die Federscheiben (6) abnehmen.
Remover las herramientas T6 y T7A de centraje del Colocar entre el cuerpo central 83) y la dentadura de
ESP lado corona; sacar los prigioneros y remover la tapa ESP la corona (4) un bloque "A" de contraste de material
intermedia (2) lado corona. tierno (aluminio ect.).
Manteniendo en apoyo la corona (4) sobre el bloque "A", remover y
sacar los tornillos (5) y las arandelas elasticas (6).
Enlever les outils T6 et T7A de centrage du coÃteÂ Placer entre le corps central (3) et la denture de la
F couronne; enlever les prisonniers et deÂplacer le F couronne (4) un petit bloc "A" en mateÂriel leÂger
couvercle intermeÂdiaire (2) du coÃteÂ couronne. (aluminium etc.) de contraste.
En maintenant la couronne (4) sur le petit bloc "A", deÂvisser et
enlever les vis (5), et ensuite les rondelles eÂlastiques (6).
45
7
7
F1241147 F1241148
GB a GB b
Using a driver, push the differential unit (7) or (8) towards the Extract the whole differential unit (7) or (8).
opposite side of the crown so as to disengage it from the crown (4).
T7B 3 3
4
4
F1241223 F1241174
GB c GB d
Remove tool T7B from the crown opposite side. Extract the crown (4).
B
9
9
F1241149 F1241150
GB e GB f
DISASSEMBLY OF THE DIFFERENTIAL UNIT DISASSEMBLY OF THE NO-SPIN DIFFERENTIAL UNIT
Using an extractor, remove bearings (9) from the differential unit. Insert stay "B" provided for holding into position the no-spin unit
(14) and screw tight the wing nut.
46
Utilizzando uno spintore, spingere il differenziale (7) o Estrarre il gruppo differenziale (7) o (8) completo.
ITA (8) verso il lato opposto corona fino a disimpegnarlo ITA
dalla corona (4).
Mit einem StoÈûel das Differential (7) oder (8) in die dem Das komplette Differentialaggregat (7) oder (8) ab-
D Kranz entgegengesetzte Seite druÈcken und aus dem D ziehen.
Kranz (4) freisetzen.
a b
Utilizando un empuje, empujar el diferencial (7) o (8) Sacar el grupo diferencial (7) o (8) completo.
ESP hacia el lado opuesto corona hasta desempenarlo de ESP
la corona (4).
A l'aide d'un poussoir, pousser le diffeÂrentiel (7) ou (8) Extraire le groupe diffeÂrentiel (7) ou (8) tout entier.
F du coÃteÂ opposeÂ aÁ la couronne jusqu'aÁ le deÂgager de la F
couronne (4).
Rimuovere l'attrezzo T7B montato sul lato opposto Estrarre la corona (4).
ITA corona. ITA
Das Werkzeug T7B abnehmen, das an der dem Kranz Kranz (4) abziehen.
D entgegengesetzte Seite montiert ist. D
c d
Remover la herramienta T7B montado sobre el lado Extraer la corona (4).
ESP opuesto corona. ESP
DeÂplacer l'outil T7B monteÂ du coÃteÂ opposeÂ aÁ la Extraire la couronne (4).

F couronne. F
SMONTAGGIO DIFFERENZIALE SMONTAGGIO DIFFERENZIALE NO-SPIN

ITA Utilizzando un estrattore, asportare i cuscinetti (9) dal ITA Inserire il tirante "B" di trattenimento del gruppo no-
gruppo differenziale. spin (14) ed avvitare a fondo il dado ad alette.
DIFFERENTIAL ABMONTIEREN DAS NO-SPIN DIFFERENTIAL ABMONTIEREN

D Mit einem Abzieher die Lager (9) vom Differentialag- D Sie Spannstange "B" einsetzen, um das No-Spin
gregat abnehmen. Aggregat (14) festzuhalten und die FluÈgelmutter fest-
ziehen.
e f
DESMONTAJE DIFERENCIAL DESMONTAJE DIFERENCIAL NO-SPIN
ESP Utilizando un extractor, sacar los cojinetes (9) del ESP Introducir el tirante "B" de detencion del grupo no-spin
grupo diferencial. (14) y atornillar hasta el fondo la tuerca a aletas.
DEMONTAGE DU DIFFERENTIEL DEMONTAGE DU DIFFERENTIEL NO-SPIN

F A l'aide d'un extracteur, enlever les paliers (9) du F Introduire la tringle "B" de retenue du groupe no-spin
groupe diffeÂrentiel. (14), puis visser l'eÂcrou aÁ ailettes aÁ fond.
47
12
10 11
12
F1241151 F1241152
GB a GB b
Remove the screws (10) and the spring washers (11) jointing the Using a plastic hammer, take the half box (12) to pieces.
differential unit half box (12). NOTE. Note down the coupling marks.
13
14
F1241153 F1241154
GB c GB d
Extract the no-spin unit (13). Unscrew the wing nut of stay "B" and take the no-spin unit to
pieces in order to remove the distance piece (14) that prevents the
axial sliding of the axle shafts.
19
16
17
18
20 21
F1241155 F1241156
GB e GB f
DISASSEMBLY OF THE 45% SELF-LOCKING DIFFERENTIAL UNIT Remove the differential cover (18), any shims (19) and the friction
Remove the screws (16) and the spring washers (17) jointing the (20) complete with ring (21).
differential unit. CAUTION! 1 - Do not change the position of the disks forming the
friction.
2 - Check that the overall thickness of friction exceeds 17.3 mm; if
lower, substitute both friction units.
48
Rimuovere le viti (10) e le rondelle elastiche (11) di Utilizzando un mazzuolo in materiale plastico scom-
ITA unione della semiscatola differenziale (12). ITA porre la semiscatola differenziale (12).
NOTA. Annotare la marcatura di accoppiamento.
Schrauben (10) und Federscheiben (11) abnehmen, Mit einem Gummihammer das halbe Differentialge-
D die das halbe DifferentialgehaÈuse (12) zusammen D haÈuse (12) zerlegen.
halten. BEMERKUNG. Die Kupplungsmarkierung notieren.
a b
Remover los tornillos (10) y las arandelas elasticas Utilizando un martillo en material plastico decomponer
ESP (11) de union de la semi-caja diferencial (12). ESP la semicaja diferencial (12).
NOTA. Anotar la marcatura de acoplamiento.
Enlever les vis (10) et les rondelles eÂlastiques (11) A l'aide d'un maillet en matieÁre plastique deÂcomposer
F d'union de la moitieÂ du boõÃtier diffeÂrentiel (12). F la moitieÂ du boõÃtier diffeÂrentiel (12).
REMARQUE. Prendre note de la marque d'accou-
plement.
Estrarre il gruppo no-spin (13). Svitare il dado ad alette del tirante "B" e scomporre il
ITA ITA gruppo no-spin per rimuovere il distanziale (14) contro
lo scorrimento assiale dei semiassi.
Das No-Spin Aggregat (13) abziehen. Die FluÈgelmutter der Spannstange "B" abschrauben
D D und das No-Spin Aggregat zerlegen, um das Differen-
tial (14) an der Achsengleitung der Halbachsen
abnehmen zu koÈnnen.
c d
Sacar el grupo no-spin (13). Destornillar la tuerca a aletas del tirante "B" y
ESP ESP decomponer el grupo no-spin para remover el distan-
cial (14) contra el deslizamiento axial de los semi-ejes.
Extraire le groupe no-spin (13). DeÂvisser l'eÂcrou aÁ ailettes de la tringle "B" et

F F deÂcomposer le groupe no-spin pour enlever le
diffeÂrentiel (14) contre le coulisseau axial des demi-
essieux.
SMONTAGGIO DIFFERENZIALE AUTOBLOCCANTE AL 45% Rimuovere il coperchio differenziale (18), gli eventuali
ITA Rimuovere le viti (16) e le rondelle elastiche (17) di ITA spessori (19) e la frizione (20) completa dell'anello (21).
unione del corpo differenziale. ATTENZIONE! 1 - Non scambiare di posizione i dischi
componenti la frizione.
2 - Controllare che lo spessore totale della frizione sia superiore a
17,3 mm; se eÁ inferiore sostituire ambedue le frizioni.
DAS ZU 45% SELBSTHEMMENDE DIFFERENTIAL ABMONTIEREN Differentialdeckel (18) und evtl. Unterlegscheiben (19)
D Schrauben (16) und Federscheiben (17), die den D und die Kupplung (20) mit dem Ring (21) abnehmen.
DifferentialkoÈrper verbinden, abnehmen. ACHTUNG! 1 - Die Position der Kupplungsscheiben
nicht verwechseln.
e f 2 - Die GesamtstaÈrke der Kupplung muû mehr als 17,3 mm betragen;
sollte dies nicht der Fall sein, beide Kupplungen auswechseln.
DESMONTAJE DIFERENCIAL AUTOBLOQUEO AL 45% Remover la tapa diferencial (18), los eventuales
ESP Remover los tornillos (16) y las arandelas elasticas ESP espesores (19) y la fricion (20) completa del anillo (21).
(17) de union del cuerpo diferencial. ATENCION! 1 - No cambiar de posicion los discos
componentes la fricion.
2 - Controlar que el espesor total de la fricion sea superior a 17,3
mm; si es inferior sobstituir las dos friciones.
DEMONTAGE DU DIFFERENTIEL AUTOBLOQUANT A 45% Enlever le couvercle diffeÂrentiel (18), les eÂventuelles
F Enlever les vis (16), les rondelles eÂlastiques (17) F cales (19) et la friction (20) compleÁte d'anneau (21).
d'union du corps diffeÂrentiel. ATTENTION! 1 - Ne pas changer la position des
disques composant la friction.
2 - ControÃler que la calage total de la friction soit supeÂrieur aÁ
17,3 mm; s'il est infeÂrieur substituer les deux frictions.
49
22
25 23
24
26 24
26
F1241157 F1241158
GB a GB b
Remove the planetary gear (22). Remove the long planetary carrier journal (23) and the two short
Mark the 37 mm value on a pin-driver; using the same pin-driver, journals (24).
insert the spring pins (25) into the journals (23) and (24).
NOTE. The spring pins are centred in journals (23) and (24) when
the countermark is lined up with the edge of the body of the
differential unit (26).
29
28
33
32
F1241159 F1241160
GB c GB d
Extract the cross journal (27), the planet wheels (28) complete with Remove the 2nd friction (20) complete with ring (21). Also remove
shim washers (29) and the second planetary gear (22). any shims (19).
CAUTION! 1 - Do not change the position of the disks forming the
friction.
2 - Check that the overall thickness of friction exceeds 17.3 mm; if
lower, substitute both friction units.
25
23 24
1
9
F1241161 F1241162
GB e GB f
Extract the spring pins (25) from journals (23) and (24). Only if bearings are replaced.
Remove the thrust blocks of bearings (9) from the intermediate
covers (1) and (2).
50
Rimuovere l'ingranaggio planetario (22). Rimuovere il perno porta satelliti lungo (23) ed i due
ITA Segnare su un cacciaspine un contrassegno a 37 mm; ITA perni corti (24).
utilizzando lo stesso cacciaspine, inserire nei perni
(23) e (24) le spine elastiche (25).
NOTA. Le spine elastiche sono centrate nei perni (23) e (24)
quando il contrassegno arriva a filo del corpo differenziale (26).
Das Planetengetriebe (20) abnehmen. An einem DuÈ- Den langen Planetenradhalterstift (23) und die beiden
D bel das Maû von 37 mm markieren; mit diesem DuÈbel D kurzen Planetenradhalterstifte (24) entfernen.
die Federstifte (25) in die Stifte (23) und (24) einsetzen.
BEMERKUNG. Die Federstifte sind in den Stiften (23) und (24)
a zentriert, wenn das markierte Maû auf der HoÈhe des Differential- b
koÈrpers (26) liegt.
Remover el engranaje planetario (22). Senalizar sobre Remover la rotula porta satelites largo (23) y las dos
ESP un extractor de clavijas un contra-segno a 37 mm; ESP rotulas cortas (24).
utilizando el mismo extractor de clavijas, introducir en
los pernos (23) y (24) las clavijas elasticas (25).
NOTA. Las clavijas elasticas son centradas en los pernos (23) y
(24) cuando el contrasegno llega al hilo del cuerpo diferencial (26).
Enlever l'engrenage planeÂtaire (22). Marquer d'une Enlever le pivot porte-satellite long (23) et les deux
F estampille le chasse-clou aÁ 37 mm; a l'aide de ce meÃme F pivots courts (24).
chasse-clou, introduire dans les pivots (23) et (24) les
goupilles eÂlastiques (25).
REMARQUE. Les goupilles eÂlastiques sont centreÂes dans les pivots
(23) et (24) quand l'estampille atteint le bord du corps diffeÂrentiel (26).
Estrarre la crociera (27), i satelliti (28) completi delle Rimuovere la 2ã frizione (20) completa dell'anello (21).
ITA rondelle di rasamento (29) ed il 2ë ingranaggio ITA Rimuovere anche gli eventuali spessori (19).
planetario (22). ATTENZIONE! 1 - Non scambiare di posizione i dischi
componenti la frizione.
2 - Controllare che lo spessore totale della frizione sia superiore a
17,3 mm; se eÁ inferiore sostituire ambedue le frizioni.
Das Kreuz (27), die Planetengetriebe (28) samt Die 2. Kupplung (20) mit Ring (21) abnehmen.
D Zwischenlegscheiben (29) und das 2. Planetengetrie- D Eventuelle Unterlegscheiben (19) auch entfernen.
be (30) abziehen. ACHTUNG! 1 - Die Position der Kupplungsscheiben
nicht verwechseln.
c d 2 - Kontrollieren, ob die GesamtstaÈrke der Kupplung mehr als 17,3 mm
betraÈgt; anderenfalls beide Kupplungen auswechseln.
Sacar la cruceta (27), los satelites (28) completos de Remover la 2ë fricion (30) completa del anillo (21).
ESP las arandelas de rasamiento (29) y el 2ë engranaje ESP Remover tambien los eventuales espesores (19).
planetario (22). ATENCION! 1 - No cambiar de posicion los discos
componentes la fricion.
2 - Controlar que el espesor total de la fricion sea superior a 17,3 mm;
si es inferior sobstituir las dos friciones.
Extraire le croisillon (27), les satellites (28) complet de Enlever la 2ë friction (20) compleÁte d'anneau (21).
F rondelles de rasage (29), puis le 2ë engrenage F Enlever eÂgalement les eÂventuelles cales (19).
planeÂtaire (22). ATTENTION! 1 - Ne pas changer la position des
disques composant la friction.
2 - ControÃler que la calage total de la friction soit supeÂrieur aÁ
17,3 mm; s'il est infeÂrieur substituer les deux frictions.
Estrarre le spine elastiche (25) dai perni (23) e (24). Solo se si sostituiscono i cuscinetti
ITA ITA Rimuovere le ralle dei cuscinetti (9) dai coperchi
intermedi (1) e (2).
Die Federstifte (25) von den Stiften (23) und (24) Nur falls die Lager ausgewechselt werden.
D abziehen. D Die Scheiben von den Lagern (9) der Zwischendeckel
(1) und (2) abnehmen.
e f
Sacar las clavijas elasticas (25) de las rotulas (23) y Solo si se sobstituiyen los cojinetes
ESP (24). ESP Remover las ranguas de los cojinetes (9) de las tapas
intermedias (1) y (2).
Extraire les goupilles eÂlastiques (25) des pivots (23) et Uniquement en cas de substitution des paliers.
F (24). F Enlever les crapaudines des paliers (9) des couvercles
intermeÂdiaires (1) et (2).
51
30
4 33
35 36 3 34
32
7
45 31
1
8
38
44 40
GB a GB b
6 41
39
37
46
43 47
32
42
30
GB
33 34
c GB d
31
D1240134
GB e GB f
52
ITA ITA
18
20 9
29
D 25 22 D
28
a b
24 19 16
ESP 29 ESP 21 17
27
20 29
25
19 24
28
F F
22 29
21 25
23 10
11
ITA 7ITA
26 12
14
9
D D
15
c d 9
9
ESP ESP
13
F F 8
D1240135
ITA ITA
D D
e f
ESP ESP
F F
53
REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE -
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL
12
13
15
14
F1241154 F1241163
GB a GB b
ASSEMBLY OF THE NO-SPIN DIFFERENTIAL UNIT Fit the no-spin unit into the differential unit half box (15).
Assemble the no-spin unit (13), inserting the distance piece (14) Centre the half box (12) and fasten.
and using stay "B". CAUTION! Make sure the connection marks coincide.
10
F1241164 F1241150
GB c GB d
Fit the spring washers (11) onto the screws (10). Remove stay "B".
Coat the screws (10) with Loctite 270 and screw tight to form the
differential box. Tighten screws using the criss-cross method and a
torque of 86 ± 89 Nm.
21
20
21
20 26
17,6
19
F1241224 F1241160
GB e GB f
ASSEMBLY OF THE 45% SELF-LOCKING DIFFERENTIAL UNIT Insert in the body of the differential unit (26) any required shims
Using a depth gauge, check the shim of friction units complete with (19) and the friction (20) complete with ring (21).
rings (21). If thickness is lower than 17.6 mm, add more shims (19). CAUTION! Ring (21) must touch the planetary gear (22).
CAUTION! Shims must be placed right behind the body of the
differential unit (26).
54
ASSEMBLAGGIO DIFFERENZIALE NO-SPIN Montare il gruppo no-spin nella semiscatola differen-
ITA Assemblare il gruppo no-spin (13) inserendo il distan- ITA ziale (15).
ziale (14) ed utilizzando il tirante "B". Centrare la semiscatola (12) e mandarla in battuta.
ATTENZIONE! Controllare che le marcature di accoppiamento
coincidano.
NO-SPIN DIFFERENTIAL ZUSAMMENBAUEN Das No-Spin Aggregat in das halbe Differentialge-

D Das No-Spin (13) Aggregat zusammenbauen; dazu D haÈuse (15) montieren.
das DistanzstuÈck (14) mit der Spannstange "B" Das halbe GehaÈuse (12) zentrieren und bis zum
einsetzen. Anschlag einsetzen.
a b ACHTUNG! Kontrollieren, ob die Kupplungsmarkierungen uÈberein-
stimmen.
MONTAJE DIFERENCIAL NO-SPIN Montar el grupo no-spin en la semi-caja diferencial

ESP Asemblaje el grupo no-spin (13) introduciendo el ESP (15).
diferencial (14) y utilizando el tirante "B". Centrar la semi-caja (12) y mandarla a tope.
ATENCION! Controlar que las marcaduras de acoplamiento
coincidan.
ASSEMBLAGE DU DIFFERENTIEL NO-SPIN Monter le groupe no-spin dans la moitieÂ du boõÃtier

F Assembler le groupe no-spin (13) en introduisant F diffeÂrentiel (15).
l'entretoise (14), puis aÁ l'aide de la tringle "B". Centrer la moitieÂ du boõÃtier (12) et l'envoyer en buteÂe.
ATTENTION! ControÃler que les estampilles d'accouplement
correspondent.
Infilare sulle viti (10) le rondelle elastiche (11). Rimuovere il tirante "B".
ITA Spalmare le viti (10) con Loctite 270 ed avvitarle a ITA
fondo per comporre la scatola differenziale.
Serrare le viti con il metodo incrociato ad una coppia di serraggio di
86v89 Nm.
Federscheiben (11) in die Schrauben (10) einsetzen. Spannstange "B" abnehmen.

D Die Schrauben (10) mit Loctite 270 schmieren und D
festziehen, um das DifferentialgehaÈuse zusammenzu-
bauen.
c Die Schrauben im Kreuz und mit einem Anzugsmoment von 86v89
Nm festziehen.
d
Insertar sobre tornillos (10) las arandelas elasticas Remover el tirante "B".
ESP (11). ESP
Pasar los tornillos (10) con Loctite 270 y atornillar
hasta el fondo para componer la caja diferencial.
Apretar los tornillos con el metodo cruzado y un par de serraje de
86v89 Nm.
Passer sur les vis (10) les rondelles eÂlastiques (11). Enlever la tringle "B".
F Enduire les vis (10) avec du Loctite 270, puis visser F
celles-ci aÁ fond pour recomposer le boõÃtier diffeÂrentiel.
Serrer les vis avec la meÂthode croiseÂe aÁ un couple de serrage de
86v89 Nm.
ASSEMBLAGGIO DIFFERENZIALE AUTOBLOCCANTE AL 45% Inserire nella corpo differenziale (26) gli eventuali
ITA Controllare con un calibro di profonditaÁ lo spessore ITA spessori (19) e la frizione (20) completa dell'anello
delle frizioni complete degli anelli (21). Se lo spessore (21).
eÁ inferiore a 17,6 mm, aggiungere degli spessori (19). ATTENZIONE! L'anello (21) deve rimanere a contatto dell'ingra-
ATTENZIONE! Gli spessori devono essere posizionati a ridosso del naggio planetario (22).
corpo differenziale (26).
ZU 45% SELBSTHEMMENDE DIFFERENTIAL ZUSAMMENBAUEN In den DifferentialkoÈrper (26) eventuelle Unterleg-

D Mit Hilfe einer Tiefenlehre die StaÈrke der Kupplungen D scheiben (19) und die Kupplung (20) samt Ring (21)
mit den Ringen (21) messen. Sollte das Maû weniger einsetzen.
als 17,6 mm betragen, noch Unterlegscheiben (19) hinzufuÈgen. ACHTUNG! Der Ring (21) muû am Planetengetriebe (22) anliegen.
e ACHTUNG! Die Unterlegscheiben muÈssen am DifferentialkoÈrper f
(26) anliegen.
MONTAJE DIFERENCIAL AUTO-BLOQUEO AL 45% Introducir en el cuerpo diferencial (26) los eventuales
ESP Controlar con un calibro de profundidad el espesor de ESP espesores (19) y la fricion (20) completa del anillo (21).
las friciones completas de los anillos (21). Si el ATENCION! El anillo (33) debe quedar a contacto del
espesor es inferior a 17,6 mm, sumar de los espesorees (19). engranaje planetario (22).
ATENCION! Los espesores deben de ser colocados detraÁs del
cuerpo diferencial (26).
ASSEMBLAGE DU DIFFERENTIEL AUTOBLOQUANT A 45% Introduire le corps diffeÂrentiel (26), les eÂventuelles
F ControÃler aÁ l'aide d'un calibre de profondeur l'eÂpais- F cales (19) et la friction (20) compleÁte d'anneau (21.
seur des frictions compleÁtes d'anneaux (21). Si le ATTENTION! L'anneau (21) doit rester au contact de
calage est infeÂrieur aÁ 17,6 mm, ajouter des cales (19). l'engrenage planeÂtaire (22).
ATTENTION! Les cales doivent eÃtre placeÂes aÁ l'abri du corps
diffeÂrentiel (226).
55
27
22 28
26
23
24
F1241165 F1241166
GB a GB b
Install the planetary gear (22) and three of the planet wheels (28), Install the cross journal (27), holding it into position with the long
complete with shim washers (29). journal (23).
Hold the planet wheels (28) and relative washers (29) into position Before inserting journal (23) completely, install the last planet
with pins (24). wheel (28) and the relative washer (29).
19
22
25
20
26 21
26
25,5
F1241167 F1241168
GB c GB d
Countermark a point at 25.5 mm on a pin-driver; using the same Install the second planetary gear (22) and the friction (20) complete
pin-driver, engage the journals (23) and (24) with the spring pins with ring (21) and any shims required (19).
(25). CAUTION! Ring (21) must be installed right behind the planetary
NOTE. When the countermark is lined up with the edge of the body gear (22) and the shims (19) right behind the differential cover (18).
of the differential unit (26), the journals are engaged by half.
16 17
18
26
F1241169 F1241170
GB e GB f
Position the differential cover (18). Fit the spring washers (17) onto the screws (16).
NOTE. Make sure that the assembly marks coincide. Coat the screws (16) with Loctite 270 and screws tight.
Tighten screws using the criss-cross method and a torque of
135 ± 138 Nm.
56
Montare l'ingranaggio planetario (22) e tre degli Montare la crociera (27) e mantenerla in posizione con
ITA ingranaggi satelliti (28) completi di rondelle di rasa- ITA il perno lungo (23).
mento (29). Prima di inserire completamente il perno (23), montare
Mantenere in posizione gli ingranaggi satelliti (28) e le relative l'ultimo satellite (28) e la relativa rondella (29).
rondelle (29) con i perni (24).
Das Planetengetriebe (22) und drei der Planetenge- Das Kreuz (27) montieren und in der Position mit
D triebe (28) samt Zwischenlegscheiben (29) montieren. D einem langen Stift (23) festhalten.
Die Planetengetriebe (28) und die Zwischenlegschei- Bevor der Stift (23) ganz eingesetzt wird, das letzte
ben (29) mit den Stiften (24) in der Position festhalten. Planetengetriebe (28) und die Unterlegscheibe (29) montieren.
a b
Montar el engranaje planetario (22) y tres de los Montar la cruceta (27) y mantenerla en posicion con la
ESP engranajes satelites (28) completos de las arandelas ESP rotula larga (28).
de rasadura (29). Antes de insertar completamente la rotula (23), montar
Mantener en posicion los engranajes satelites (28) y las relativas el ultimo satelite (28) y la relativa arandela (29).
arandelas (29) con las rotulas (24).
Monter l'engrenage planeÂtaire (22) et trois des Monter le croisillon (27) et maintenir celui-ci aÁ sa place
F engrenages satellites (28) complets de rondelles de F aÁ l'aide du pivot long (23).
rasage (29). Avant d'introduire entieÁrement le pivot (23), monter le
Maintenir les engrenages satellites (28) et relatives rondelles (29) aÁ dernier satellite (28) et sa rondelle (29).
leur place avec les pivots (24).
Segnare sul cacciaspine un contrassegno a 25,5 mm; Montare il secondo ingranaggio planetario (22) e la
ITA utilizzando lo stesso cacciaspine impegnare i perni ITA frizione (20) completa dell'anello (21) e degli eventuali
(23) e (24) con le spine elastiche (25). spessori (19).
NOTA. Le spine impegnano metaÁ dei perni quando il contrassegno ATTENZIONE! L'anello (21) deve essere montato a ridosso
arriva a filo del corpo differenziale (26). dell'ingranaggio planetario (22) e gli eventuali spessori (19) a
ridosso del coperchio differenziale (18).
An dem DuÈbel das Maû von 25,5 mm markieren; mit Das zweite Planetengetriebe (22) und die Kupplung
D demselben DuÈbel die Stifte (23) und (24) mit den D (20) mit dem Ring (21) und eventuelle Unterlegschei-
Federstiften (25) einsetzen. ben (19) montieren.
BEMERKUNG. Die Stifte sind durch die Federstifte zur HaÈlfte ACHTUNG! Der Ring (21) muû nach der Montage am Planetenge-
c eingesetzt, wenn die Markierung auf halber HoÈhe des Differential- d triebe (22) und die eventuellen Unterlegscheiben (19) muÈssen am
koÈrpers (26) liegt. Differentialdeckel (18) anliegen.
Senalar sobre el extractor de clavijas un contra-segno Montar el segundo engranaje planetario (22) y la
ESP a 25,5 mm; utilizando el mismo extractor de clavijas ESP fricion (20) completa del anillo (21) y de los eventuales
empegnar las rotulas (23) y (24) con las clavijas espesores (19).
elasticas (25). ATENCION! El anillo (21) debe deser montado detras del
NOTA! Las clavijas empegnan midad de las rotulas cuando el engranaje planetario (22) y los eventuales espesores (19) detras
contra-segno llega al borde del cuerpo diferencial (26). de la tapa diferencial (18).
Marquer d'une estampille le chasse-clou aÁ 25,5 mm; Monter le second engrenage planeÂtaire (22), la friction
F a l'aide de ce meÃme chasse-clou, engager les pivots F (20) compleÁte d'anneau (21) et des eÂventuelles cales
(23) et (24) et les goupilles eÂlastiques (25). (19).
REMARQUE. Les goupilles arrivent aÁ la moitieÂ des pivots quand ATTENTION! L'anneau (21) est aÁ monter aÁ l'abri de l'engrenage
l'estampille atteint le bord du corps diffeÂrentiel (26). planeÂtaire (22) et les eÂventuelles cales (19) aÁ l'abri du couvercle
diffeÂrentiel (18).
Posizionare il coperchio differenziale (18). Infilare sulle viti (16) le rondelle elastiche (17).
ITA ITA Spalmare le viti (16) con Loctite 270 ed avvitarle a
NOTA. Controllare che le marcature di montaggio
coincidano. fondo.
Serrare le viti con il metodo incrociato ad una coppia di serraggio di
135v138 Nm.
Den Differentialdeckel (18) positionieren. Auf die Schrauben (16) die Federscheiben (17)
D D montieren.
BEMERKUNG. Kontrollieren, ob die Montagemarkie-
rungen uÈbereinstimmen. Die Schrauben (16) mit Loctite 270 schmieren und
festziehen. Die Schrauben im Kreuz mit einem Anzugsmoment von
e f 135v138 Nm festziehen.
Colocar la tapa diferencial (18). Introducir sobre los tornillos (16) las arandelas
ESP ESP elasticas (17).
NOTA. Colocar que las marcaduras de montaje
coincidan. Pasar los tornillos (16) con Loctite 270 y atornillarlos a
fondo.
Apretar los tornillos con el metodo cruzado a un par de serraje de
135v138 Nm.
Mettre le couvercle diffeÂrentiel (18) en place. Passer sur les vis (16) les rondelles eÂlastiques (17).
F F Enduire les vis (16) avec du Loctite 270 et visser
REMARQUE. ControÃler que les estampilles de mon-
tage coõÈncident. celles-ci aÁ fond.
Serrer les vis avec la meÂthode croiseÂe aÁ un couple de serrage de
135v138 Nm.
57
9 9 9 9
7
8
8 7
F1241171 F1241172
GB a GB b
INSTALLATION OF THE DIFFERENTIAL UNIT Turn the unit upside down and install the second bearing (9).
Position the differential unit (7) or (8) under a press and, using a CAUTION! Pay particular attention; position a shim with adequate
driver with an adequate diameter, install the first bearing (9). diameter in order to engage the internal ring of bearing (9) without
engaging the cage.
T8
9
F1241173 F1241174
GB c GB d
Only if bearings are replaced Position the crown wheel (4) in the main body (3).
Using tool T8, insert the thrust blocks of the bearings (9) into the
intermediate covers (1) and (2).
T7B 7 8
F1241175 F1241176
GB e GB f
Fit tool T7B on the crown wheel opposite side, holding it in position Install the differential unit (7) or (8), by fitting it into the hole of tool
with two studs and two nuts. T7B.
NOTE. Engage the crown (4) onto tool T7B. Install the crown (4) onto the differential unit (7) or (8), and fasten it
to the flange.
NOTE. Make sure the holes of the flange match those of the crown.
58
INSTALLAZIONE DIFFERENZIALE Capovolgere il gruppo e montare il secondo cuscinetto
ITA Posizionare il differenziale (7) o (8) sotto una pressa ed ITA (9).
utilizzando uno spintore di diametro adatto montare il ATTENZIONE! Prestare molta attenzione e posiziona-
primo cuscinetto (9). re uno spessore di diametro adatto al fine di impegnare l'anello
interno del cuscinetto (9) senza impegnare la gabbia.
DIFFERENTIAL ZUSAMMENBAUEN Das Aggregat wenden und das zweite Lager montie-
D Das Differential (7) oder (8) unter eine Presse legen D ren (9).
und mit einem geeigneten Dynamometer-StoÈûel das ACHTUNG! Den Vorgang mit groûer Sorgfalt durch-
erste Lager (9) montieren. fuÈhren und einen fuÈr die StaÈrke geeigneten Dynamometer
a b verwenden, um den Ring des inneren Lagers (9) einzusetzen,
ohne den KaÈfig einzuklemmen.
INSTALACION DIFERENCIAL Volcar el grupo y montar el segundo cojinete (9).

ESP Colocar el diferencial (7) y (8) bajo una prensa y ESP
ATENCION! Tener mucho cuidado y colocar un
utilizando un empuje de diametro adapto montar el espesor de diametro apto al fin de empegnar el anillo
primer cojinete (9). interno del cojinete (9) si empegnar la jaula.
INSTALLATION DU DIFFERENTIEL Faire basculer le groupe et monter le second palier (9).

F Mettre le diffeÂrentiel (7) ou (8) en place sous la presse, F
ATTENTION! Faire treÁs attention, mettre une cale au
aÁ l'aide d'un poussoir au diameÁtre adeÂquat, monter le diameÁtre adeÂquat afin d'engager l'anneau interne du
premier palier (9). palier (9) sans y engager la cage.
Solo se si sostituiscono i cuscinetti Posizionare la corona (4) dentro il corpo centrale (3).
ITA Utilizzando l'attrezzo T8 inserire le ralle dei cuscinetti ITA
(9) nei coperchi intermedi (1) e (2).
Nur wenn die Lager ausgewechselt werden. Den Kranz (4) in den zentralen KoÈrper (3) einsetzen.
D Mit dem Werkzeug T8 die Scheiben der Lager (9) in D
die Zwischendeckel (1) und (2) einsetzen.
c d
Solo si se sobstituyen los cojinetes Colocar la corona (4) dentro del cuerpo central (3).
ESP Utilizando la herramienta T8 Introducir las ranguas de ESP
los cojinetes (9) en las tapa intermedias (1) y (2).
Uniquement en cas de substitution des paliers Mettre la couronne (4) en place dans le corps central
F A l'aide de l'outil T8, introduire la crapaudine des F (3).
paliers (9) dans les couvercles intermeÂdiaires (1) et (2).
Montare l'attrezzo T7B sul lato opposto corona, Montare il gruppo differenziale (7) o (8) impegnandolo
ITA trattenendolo con due prigionieri e due dadi. ITA nel foro dell'attrezzo T7B.
NOTA. Impegnare la corona (4) sull'attrezzo T7B. Montare la corona (4) sul differenziale (7) o (8)
mandandola in battuta sulla flangia.
NOTA. Far coincidere i fori della flangia con i fori della corona.
Das Werkzeug T7B auf der dem Kranz entgegen- Das Differentialaggregat (7) oder (8) montieren und im
D gesetzten Seite montieren und mit zwei Stiftschrauben D Loch des Werkzeuges T7B einrasten.
und zwei Muttern festhalten. Den Kranz (4) auf das Differential (7) oder (8)
BEMERKUNG. Den Kranz (4) in das Werkzeug T7B einrasten. montieren und bis zum Anschlag am Flansch einsetzen.
e f BEMERKUNG. Die FlanschloÈcher muÈssen mit den KranzloÈchern
uÈbereinstimmen.
Montar la herramienta T7B sobre el lado opuesto Montar el grupo diferencial (7) o (8) empegnandolo en
ESP corona, deteniendo con dos prigionieros y dos ESP el agujero de la herramienta T7B.
tuercas. Montar la corona (4) sobre el diferencial (7) y (8)
NOTA. Empegnar la corona (4) sobre la herramienta T7B. mandandola a tope sobre la brida.
NOTA. Hacer coincidir los agujeros de la brida con los agujeros de
la corona.
Monter l'outil T7B du coÃteÂ opposeÂ aÁ la couronne, en le Monter le groupe diffeÂrentiel (7) ou (8) en l'engageant
F tenant aÁ l'aide de deux prisonniers et de deux eÂcrous. F dans le trou de l'outil T7B.
REMARQUE. Engager la couronne (4) sur l'outil T7B. Monter la couronne (4) sur le diffeÂrentiel (7) ou (8) puis
l'envoyer en buteÂe sur la flasque.
REMARQUE. Faire correspondre les trous de la flasque avec les
trous de la couronne.
59
35
5 A
F1241177 F1241145
GB a GB b
Fit spring washers (6) onto the screws (5). Check the condition and position of the O-ring (30); lubricate the
Coat screws with Loctite 270 and screw them tight into the crown. seal and install the intermediate cover (2) on crown wheel side.
Position the stop block "A"; while holding the crown resting on the
block, tighten the screws (5) to a torque of 135 ± 138 Nm.
CAUTION! Tighten screws using the criss-cross method.
2
T6
31
T7A
F1241178 F1241179
GB c GB d
Lock the intermediate cover (2) with the journals (31) tightened to a Install tool T6 on the journals (31) on the crown wheel side, placing
torque of 129 ± 143 Nm. distance pieces and locking with two nuts. Insert differential
centring and support tool T7A into tool T6.
NOTE. Make sure that the differential unit is tightly engaged in the
intermediate cover (2).
T7B 1
30
F1241180 F1241181
GB e GB f
Remove tool T7B on crown opposite side. Check state and position of O-ring (30); lubricate the seal and fit the
intermediate cover (1) on the crown opposite side.
Lock the intermediate cover (1) with journals (31) tightened to a
torque of 129 ± 143 Nm and remove tools T6 and T7A.
60
Montare sulle viti (5) le rondelle elastiche (6). Controllare lo stato ed il posizionamento dell'anello
ITA Spalmare le viti con Loctite 270 ed avvitarle a fondo ITA OR (30); lubrificare la guarnizione e montare il
nella corona. Posizionare il blocchetto "A" di contra- coperchio intermedio (2) lato corona.
sto; mantenendo in appoggio la corona sul blocchetto, serrare le
viti (5) ad una coppia di 135v138 Nm.
ATTENZIONE! Serrare le viti con il metodo incrociato.
Auf die Schrauben (5) die Federscheiben (6) montieren. Den Zustand und die Position des O-Ringes (30)
D Die Schrauben mit Loctite 270 schmieren und in den D kontrollieren; die Dichtung schmieren und den Zwi-
Kranz schrauben. Den Block "A" positionieren; den schendeckel (2) an der Kranzseite montieren.
Kranz am Block anliegen lassen und die Schrauben (5) mit einem
a Anzugsmoment von 135v138 Nm festziehen. b
ACHTUNG! Die Schrauben im Kreuz festziehen.
Montar sobre los tornillos (5) las arandelas elasticas (6). Controlar el estado y la colocacion del anillo OR (30);
ESP Pasar los tornillos con Loctite 270 y atornillarlos a ESP lubrificar la guarnicion y montar la tapa intermedia (2)
fondo en la corona. Colocar el bloque "A" de contraste; lado corona.
manteniendo en apoyo la corona sobre el bloque, apretar los
tornillos (5) y un par de 135v138 Nm.
ATENCION! Apretar los tornillos con el metodo cruzado.
Monter les vis (5), les rondelles eÂlastiques (6). ControÃler l'eÂtat et le positionnement de l'anneau
F Enduire les vis avec du Loctite 270, puis visser celles- F O'Ring (30); lubrifier la garniture, puis monter le
ci aÁ fond dans la couronne. Mettre le petit bloc "A" de couvercle intermeÂdiaire (2) du coÃteÂ couronne.
contraste; en maintenant la couronne poseÂe sur le petit bloc, serrer
les vis (5) aÁ un couple de 135v138 Nm.
ATTENTION! Serrer les vis avec la meÂthode croiseÂe.
Bloccare il coperchio intermedio (2) con i prigionieri Montare l'attrezzo T6 sui prigionieri (31) lato corona,
ITA (31) serrati ad una coppia di 129v143 Nm. ITA interponendo i relativi distanziali e bloccandolo con
due dadi. Inserire nell'attrezzo T6 l'attrezzo T7A di
centratura e sostegno del differenziale.
NOTA. Assicurarsi che il differenziale sia impegnato a fondo nel
coperchio intermedio (2).
Den Zwischendeckel (2) mit den Stiftschrauben (31) Das Werkzeug T6 an den Stiftschrauben (31) an der
D blockieren und mit einem Anzugsmoment von D Kranzseite montieren und dabei DistanzstuÈcke einsetzen
129v143 Nm festziehen. und mit zwei Muttern befestigen. In das Werkzeug T6 das Werkzeug
T7A zur Zentrierung und Halterung des Differentials einsetzen.
c d BEMERKUNG. Sicherstellen, daû das Differential fest im Zwischen-
deckel (2) sitzt.
Bloquear la tapa intermedia(2) con los prigioneros (31) Montar la herramienta T6 sobre los prigioneros (31)
ESP apretados a un par de 129v143 Nm. ESP lado corona, interponiendo de los distanciales y
bloqueando con dos tuercas. Introducir en la herramienta T6 la
herramienta T7A de centradura y sosten del diferencial.
NOTA. Asegurarse que el diferencial sea empegnado a fondo en la
tapa intermedia (2).
Bloquer le couvercle intermeÂdiaire (2) aÁ l'aide des Monter l'outil T6 sur les prisonniers (31) coÃteÂ cou-
F prisonniers (31) serreÂs aÁ un couple de 129v143 Nm. F ronne, en y intercalant des entretoises, puis bloquer
celui-ci avec deux eÂcrous. Introduire dans l'outil T6,
l'outil T7A de centrage et de support du diffeÂrentiel.
REMARQUE. S'assurer que le diffeÂrentiel soit engageÂ aÁ fond dans
le couvercle intermeÂdiaire (2).
Rimuovere l'attrezzo T7B del lato opposto corona. Controllare lo stato ed il posizionamento dell'anello
ITA ITA OR (30); lubrificare la guarnizione e montare il
coperchio intermedio (1) lato opposto corona.
Fissare il coperchio intermedio (1) con i prigionieri (31) serrati ad
una coppia di 129v143 Nm e rimuovere gli attrezzi T6 e T7A.
Werkzeug T7B an der dem Kranz entgegengesetzten Den Zustand und die Position des O-Ringes (30)
D Seite abnehmen. D kontrollieren; die Dichtung schmieren und den Zwi-
schendeckel (1) an der dem Kranz entgegengesetzten
Seite montieren. Den Zwischendeckel (1) mit den Stiftschrauben
e f (31) und einem Anzugsmoment von 129v143 Nm befestigen und
die Werkzeuge T6 und T7A entfernen.
Remover la herramienta T7B del lado opuesto corona. Controlar el estado y la colocacion del anillo OR (30);
ESP ESP lubrificar la guarnicion y montar la tapa intermedia (1)
lado opuesto corona.
Fijar la tapa intermedia (1) con los prigioneros (31) apretados a un
par de 129v143 Nm y remover las herramientas T6 y T7A.
Enlever l'outil T7B du coÃteÂ opposeÂ aÁ la couronne. ControÃler l'eÂtat et le positionnement de l'anneau
F F O'Ring (30); lubrifier la garniture, puis monter le
couvercle intermeÂdiaire (1) du coÃteÂ opposeÂ aÁ la
couronne.
Fixer le couvercle intermeÂdiaire (1) aÁ l'aide des prisonniers (31)
serreÂs aÁ un couple de 129v143 Nm, enlever les outils T6 et T7A.
61
1 32
32 T9
34
33 F1241182 F1241183
GB a GB b
Remove the screws (33) and remove the safety tabs (34). Using wrench T9, extract the adjustment ring nuts (32) and remove
any residue of thread locking substances.
Screw ring nuts again after applying Loctite 242.
37 3
36
35
F1241184 F1241185
GB c GB d
Remove the spring ring (35) and extract the cap (36) to allow Coat the surface of the main body (3) with Loctite 510 and install
checking of the clearance between pinion and crown to take place. the reduction gear (37) complete with pinion.
NOTE. Make sure that a continuous layer of sealant runs around
the locking holes.
38 32
T9
F1241186 F1241183
GB e GB f
Coat screws (38) with Loctite 242 and screw tight. Tighten screws Screw ring nut (32) on crown wheel side until clearance between
(38), using the criss-cross method and a tightening torque of pinion and crown equals zero, then unscrew by 1/4 turn approx.
129 ± 143 Nm.
62
Asportare le viti (33) e rimuovere le linguette di Utilizzando la chiave T9 rimuovere le ghiere (32) di
ITA sicurezza (34). ITA registrazione ed asportare ogni traccia di frenafiletti.
Riavvitare le ghiere dopo averle spalmate con
Loctite 242.
Die Schraube (33) abschrauben und den Sicherheits- Mit einem SchluÈssel T9, die Nutmuttern (32) zur
D keil (34) abnehmen. D Einstellung entfernen und jede alle uÈberschuÈssigen
Reste der SchraubensicherungsloÈsung sorgfaÈltig ent-
fernen.
a b Nutmuttern mit Loctite 242 schmieren und wieder festschrauben.
Sacar los tornillos (33) y remover les lengues de Utilizando la llave T9, remover las virolas (32) de
ESP seguridad (34). ESP registracion y sacar cada senal de frenaroscas.
Restornillas las virolas despues de haberias pasadas
con Loctite 242.
Enlever le vis (33), puis deÂplacer le languettes de A l'aide de la cleÂ T9, enlever les eÂcrous annulaires (32)
F seÂcuriteÂ (34). F de reÂglage et toute trace de l'agent d'arreÃt de vis.
Enduire les eÂcrous annulaires avec Loctite 242 et
visser.
Asportare l'anello elastico (35) e rimuovere il tappo Spalmare la superficie del corpo centrale (3) con
ITA (36) per poter controllare il gioco tra pignone e corona. ITA Loctite 510 ed installare il riduttore (37) completo di
pignone.
NOTA. Assicurarsi che il sigillante crei un velo continuo attorno ai
fori di fissaggio.
Den Kolbenring (35) abnehmen und den Stopfen (363) Die FlaÈche des ZentralkoÈrpers (3) mit Loctite 510
D entfernen, um das Spiel zwischen Kegelrad und Kranz D schmieren und den Reduzierer (37) samt Kegelrad
kontrollieren zu koÈnnen. installieren.
BEMERKUNG. Sicherstellen, daû die Dichtmasse einen gleich-
c d maÈûigen Film um die BefestigungsloÈcher herum bildet.
Sacar el anillo elastico (35) y remover la tapa (36) para Pasar la superficie del cuerpo central (3) con Loctite
ESP poder controlar el juego entre pignon y corona. ESP 510 y instalar el reductor (37) completo de pignon.
NOTA. Asegurarse que el sigilante cree una pelicula
continua alrededor a los agujeros de fisaje.
Enlever l'anneau eÂlastique (35), enlever le bouchon Enduire la superficie du corps central (3) avec du
F (36) pour controÃler le jeu existant entre pignon et F Loctite 510, installer le reÂducteur (37) complet de
couronne. pignon.
REMARQUE. S'assurer que la couche de colle entoure bien les
trous de fixation.
Spalmare le viti (38) con Loctite 242 e avvitarle a fondo. Avvitare la ghiera (32) lato corona fino ad azzerare i
ITA Serrare le viti (38) con il metodo incrociato ad una ITA giochi tra pignone e corona e poi svitare per circa 1/4
coppia di serraggio di 129v143 Nm. di giro.
Die Schrauben (38) mit Loctite 242 schmieren und Nutmuttern (32) an der Kranzseite zuschrauben bis
D festziehen. Die Schrauben (38) im Kreuz mit einem D zwischen Rad und Kranz kein Spiel mehr uÈbrig bleibt;
Anzugsmoment von 129v143 Nm festziehen. danach um 1/4 Umdrehung aufschrauben.
e f
Pasar los tornillos (38) con Loctite 242 y atornillas a Atornillar las virolas (32) lado corona hasta acerar los
ESP fondo. ESP juegos entre el pinion y corona y despues destornillar
Apretar los tornillos (38) con el metodo cruzado y un por cerca 1/4 de giro.
par de torsion de 129v143 Nm.
Enduire les vis (38) avec du Loctite 242, puis visser Visser l'eÂcrou annulaire (32) du coÃteÂ couronne jusqu'aÁ
F celles-ci aÁ fond. F annuler le jeux entre pignon et couronne, puis
Serrer les vis (38) avec la meÂthode croiseÂe aÁ un couple deÂvisser 1/4 de tour.
de serrage de 129v143 Nm.
63
T3
F1241187 F1241188
GB a GB b
Allow pinion to turn a few times in both directions to allow bearings Introduce a comparator with rotary key "C" through the rear cap
to set. Pre-load the bearings through the ring nut on crown opposite hole (43).
side to increase pinion torque up to a value of 140 ± 210 Ncm Position comparator on the centre of one of the crown teeth (4), pre-
checked by means of a torque meter. set it to 1 mm and reset it to zero.
CAUTION! If bearings are old, check static torque. If new, check Manually move the crown (4) in both directions to check the
continuous torque. existing clearance between pinion and crown.
RATIO - RAPPORTO CLEARANCE - GIOCO - SPIEL

VERHAÈ LTNIS JUEGO - JEU 32
RAPORTE - RAPPORT MIN. MAX.
T9
6v43 0,18 0,23
Difference between MIN and MAX clearance for whole circumference
should not exceed 0.09 mm.
La differenza tra gioco MIN e MAX rilevata sull'intera circonferenza
non deve superare il valore di 0,09 mm.
Der Unterschied zwischen dem MIN e MAX Spiel der gesamten
Kreislinie darf den Wert von 0,09 mm nicht uÈberschreiten.
La diferencia entre el juego Min y Max determinada sobre la entera
circonferencia no debe de superar el valor de 0,09 mm.
La diffeÂrence de jeu entre MIN et MAX releveÂe sur toute la
circonfeÂrence ne doit pas aller au-delaÁ de la valeur de 0,09 mm.
F1241183
GB c GB d
Mark the position of the ring nuts (32) in relation to the intermediate
covers.
Using wrench T9, adjust clearance between pinion and crown by
loosening one ring nut (32) and tightening the opposite proportion-
ally.
Normal clearance: see table.
36
34
33
F1241189 F1241190
GB e GB f
Install safety tabs (41) and lock them with screws (40). Using a driver, fit the cap (36) and position it in its seat with the
Screws tightening torque: 10 ± 11 Nm. snap ring (35).
64
Far compiere al pignone alcuni giri nei due sensi per Posizionare, attraverso il foro per il tappo posteriore
ITA assestare i cuscinetti. Precaricare i cuscinetti tramite la ITA (43), un comparatore a tasto orientabile "C".
ghiera lato opposto corona, per incrementare la coppia di Posizionarlo sul centro di un dente della corona (4),
rotazione pignone fino a 140v210 Ncm controllati con un torsiometro. precaricarlo di circa 1 mm ed azzerarlo.
ATTENZIONE! Con cuscinetti usati, controllare la coppia di spunto; Muovere manualmente nei due sensi la corona (4) per controllare il
con cuscinetti nuovi, controllare la coppia di rotazione continua. gioco esistente tra pignone e corona.
Das Kegelrad um einige Umdrehungen in beide Richtungen Durch das Loch des hinteren Stopfens (43) eine
D drehen, um das Lager in die richtige Position zu bringen. Die D Meûuhr mit schwenkbarer Taste "C" einsetzen.
Lager durch die Nutmutter an der dem Kranz entgegengesetzte Seite Die Meûuhr auf die Mitte eines Zahnes des Kranzes (4)
vorbelasten, um das Gegenmoment des Kegelrads bis auf 140v210 Ncm positionieren und um 1mm vorbelasten; danach zuruÈckstellen.
a zu erhoÈhen. Den Wert mit einem Drehungsmesser kontrollieren.
ACHTUNG! Bei gebrauchten Lagern, das Anlaufdrehmoment kontrollieren; b Von Hand in beide Richtungen den Kranz (4) bewegen, um das
Spiel zwischen Kegelrad und Kranz zu kontrollieren.
bei neuen Lagern, das kontinuierliche Gegenmoment kontrollieren.
Hacer efectuar al pignon algunos giros en los dos sentidos Colocar, atraves el agujero para la tapa posterior (43),
ESP para ordenar los cojinetes. Precargar los cojinetes a ESP un comparador a tecla orientable "C".
traves de las virolas lado opuesto corona, para crecer el par de rotacion Colocarlo sobre el centro de un diente de la corona (4),
pignon hasta 140v210 Ncm controlados con un torsiometro. precargarlo de 1 mm aprox y azerarlo.
ATENCION! Con cojinetes usados, controlar el par de principio; con Mover manualmente en los dos sentidos la corona (4) para
cojinetes nuevos, controlar el par de rotacion continua. controlar el juego esistente entre pignon y corona.
Faire tourner le pignon plusieurs fois dans les deux sens Placer aÁ travers le trou servant au bouchon arrieÁre
F pour ajuster les paliers. PreÂcharger les paliers au moyen de F (43), un comparateur aÁ touche orientable "C".
l'eÂcrou annulaire, du coÃteÂ opposeÂ aÁ la couronne, pour augmenter le couple Positionner celui-ci au centre d'une des dents de la
de rotation du pignon jusqu'aÁ 140v210 Ncm controÃleÂs par un torsiomeÁtre. couronne (4), preÂcharger celui-ci d'environ 1 mm et mettre aÁ zeÂro.
ATTENTION! Avec des paliers usageÂs, controÃler le couple de pointe; avec DeÂplacer manuellement la couronne (4) dans les deux sens pour
des paliers neufs, controÃler le couple de rotation continu. controÃler le jeu existant entre pignon et couronne.
Contrassegnare la posizione delle ghiere (32) rispetto i

ITA ITA coperchi intermedi.
Con la chiave T9, regolare il gioco tra pignone e
corona allentando una ghiera (32) e serrando la ghiera opposta in
egual misura.
Gioco normale: vedere tabella.
Die Position der Nutmuttern (32) im VerhaÈltnis zu den

D D Zwischendeckeln markieren.
Mit dem SchluÈûel T9, das Spiel zwischen Rad und
Kranz einstellen, in dem eine Nutmutter (32) gelockert und die
c d entgegengesetzte festgezogen wird.
Normales Spiel: siehe Tabelle.
Contrasenalr la colocacion de las virolas (32) respecto

ESP ESP a las tapaderas intermedias.
Con la llave T9, regular el juego entre el pignon y la
corona aflojando una virola (32) y apretando la virola opuesta en la
misma mesura.
Juego normal: vease el prospecto.
Marquer la position de l'eÂcrou annulaire (32) par

F F rapport aux couvercles intermeÂdiaires.
A l'aide de la cleÂ T9, reÂgler le jeu entre pignon et
couronne en deÂvissant l'eÂcrou annulaire (32) et en vissant l'eÂcrou
annulaire opposeÂ de la meÃme mesure.
Jeu normal: voir tableau.
Montare le linguette di sicurezza (41) e fissarle con le Con uno spintore, montare il tappo (36) ed assicurarlo
ITA viti (40). ITA in sede con l'anello elastico (35).
Coppia di serraggio viti: 10v11 Nm
Den Sicherheitskeil (41) montieren und mit den Mit einem StoÈûel den Stopfen (36) montieren und in
D Schrauben (40) befestigen. D seinem Sitz mit dem Kolbenring (35) befestigen.
Anzugsmoment der Schrauben: 10v11 Nm
e f
Montar las lenguetas de seguridad (41) y fijarlas con Con un empujador, montar la tapa (36) y asegurarlo en
ESP los tornillos (40). ESP sed con el anillo elastico (36).
Par de serraje tornillos: 10v11 Nm
Monter les languettes de seÂcuriteÂ (41), fixer celles-ci aÁ A l'aide d'un poussoir, monter le bouchon (36), ajuster
F l'aide des vis (40). F celui-ci dans son logement avec l'anneau eÂlastique
Couple de serrage des vis: 10v11 Nm. (35).
65
37
36
40
F1241190 F1241192
GB a GB b
Using a driver and a plastic hammer, install the driving gear (39). Apply Loctite 510 to the surface of the reduction gear body (37) and
install the cover (40).
NOTE. Make sure that a continuous layer of sealant runs around
the locking holes.
41 44
40
46
47
42 43
F1241193 F1241194
GB c GB d
Lock the cover (40), using the snap washers (43) and the screws Install the breath union piece (44) with the relative sealing washers
(42) and (41) adequately tightened to a torque of 82 ± 91 Nm. (45) and plugs (47) and (46); tighten to a torque of 35 ± 50 Nm.
Tighten screws (42) and (41) with a tightening torque of 82 ± 91 Nm.
GB e GB f
Complete assembly of the axle by installing, in the following order,
brake cylinders and complete arms.
For details, see «ASSEMBLING THE BRAKING UNITS».
66
Utilizzando uno spintore ed un mazzuolo in materiale Spalmare la superficie del corpo riduttore (37) con
ITA plastico, montare l'ingranaggio conduttore (39). ITA Loctite 510 ed installare il coperchio (40).
NOTA. Assicurarsi che il sigillante crei un velo
continuo attorno ai fori di fissaggio.
Mit einem StoÈûel und einem Gummihammer das Die FlaÈche des KoÈrpers des Reduzierers (37) mit
D Getriebe (39) montieren. D Loctite 510 schmieren und den Deckel (40) installie-
ren.
BEMERKUNG. Sicherstellen, daû die Dichtmasse einen gleich-
a b maÈûigen Film um die BefestigungsloÈcher herum bildet.
Utilizando un empujador y un martillo en material Pasar la superficie del cuerpo reductor (37) con Loctite
ESP plastico, montar el engranaje conductor (39). ESP 510 y instalar la tapa (40).
NOTA. Asegurarse que el sigilante cree una pelicula
continua alrededor de los agujeros de fisaje.
A l'aide d'un poussoir et d'un maillet en matieÁre Enduire la superficie du corps reÂducteur (37) avec du
F plastique, monter l'engrenage conducteur (39). F Loctite 510, installer le couvercle (40).
REMARQUE. S'assurer que la couche de colle
entoure bien les trous de fixation.
Bloccare il coperchio (40) utilizzando le rondelle Montare il raccordo di sfiato (44) con le relative rosette
ITA elastiche (43) e le viti (42) e (41) serrate con una ITA di tenuta (45) ed i tappi (47) e (46); serrarli con una
coppia di 82v91 Nm. coppia di 35v50 Nm.
Den Deckel (40) mit den Federscheiben (42) und (41) Das abgezogene VerbindungsstuÈck (44) mit den
D und den Schrauben (42) und (41) bei einem Anzu- D Dichtscheiben (45) und den Stopfen (47) und (46)
gsmoment von 82v91 Nm blockieren. montieren; Anzugsmoment 35v50 Nm.
c d
Bloquear la tapa (40) utilizando las arandelas elasti- Montar el recorde de escape (441) con las relativas
ESP cas (43) y los tornillos (42) y (41) apretadas con un par ESP rosas de tenida (45) y las tapas (47) y (46); apretarlos
de 82v91 Nm. con un par de 35v50 Nm.
Bloquer le couvercle (40) aÁ l'aide des rondelles Monter le raccord d'eÂvent (44), les relatives rosettes
F eÂlastiques (43) et des vis (42) et (41) serreÂes aÁ un F d'eÂtancheÂiteÂ (45) et les bouchons (47) et (46), serrer
couple de 82v91 Nm. ceux-ci aÁ un couple de 35v50 Nm.
Completare l'assemblaggio dell'assale installando

ITA nell'ordine i cilindri freni ed i bracci completi. ITA
Per i dettagli, vedere «ASSEMBLAGGIO GRUPPI
FRENO».
Die Achse fertig zusammenbauen und der Reihe nach

D die Bremszylinder und die kompletten Arme installie- D
ren.
Siehe «ZUSAMMENBAU DER BREMSAGGREGATE».
e f
Completar el asemblaje del axial instalando en el
ESP orden los cilindros frenos y los ejes completos. ESP
Para los detalles, vease «ASEMBLAJE GRUPOS
FRENOS».
Achever l'assemblage de l'essieu en y installant dans

F l'ordre les cylindres freins et les bras complets. F
Pour de plus amples deÂtails voir "ASSEMBLAGE DU
GROUPE FREIN".
67
DISASSEMBLY OF REDUCTION GEAR AND BEVEL PINION - SMONTAGGIO RIDUTTORE E PIGNONE CONICO - REDUZIERER UND KEGELRAD
ABMONTIEREN - REMOCION REDUCTOR Y PINÄON CONICO - DEMONTAGE DU REDUCTEUR ET PIGNON CONIQUE
1 7
6 5
F1241141 F1241195
GB a GB b
Remove the whole arms and the differential unit. Loosen and remove screws (1) and (2) and the washers (3) locking
For details, see «CHECKING WEAR AND REPLACING THE the cover (4), the plugs (5) and (6) for oil fill and oil drain, and the
BRAKING DISKS» and «REMOVAL OF DIFFERENTIAL UNIT». bleed union piece (7).
NOTE. Leave two screws (2) in position for safety.
4
13 A
11
4 12
F1241196 F1241197
GB c GB d
Using a plastic hammer, remove the cover (4) and move it away. Place a block of tender material (aluminium, etc.) between the
NOTE. If operations on the differential unit need to be performed, reduction body (11) and the gear (12) of the pinion.
remove the complete reduction gear unit (screws (9) and (10)). Loosen and remove the pinion locking nut (13).
14
12
15
14
F1241198 F1241199
GB e GB f
Remove the gear of the pinion (12) and the driving gear (14) Take the driving gear to pieces (14), extracting the bearing (15).
complete with bearing (15). NOTE. If necessary, use an extractor.
NOTE. To remove the gear (14), use a lever.
68
Rimuovere i bracci completi ed il differenziale. Allentare ed asportare le viti (1) e (2) e le rondelle (3) di
ITA Per i dettagli, vedere «CONTROLLO USURA E ITA ritegno coperchio (4), i tappi (5) e (6) di carico e scarico
SOSTITUZIONE DISCHI FRENO» e «RIMOZIONE olio ed il raccordo di sfiato (7).
GRUPPO DIFFERENZIALE». NOTA. Lasciare in posizione per sicurezza due viti (2) contrappo-
ste.
Die kompletten Arme und das Differential abnehmen. Schrauben (1) und (2) abschrauben und die Unter-
D Siehe «VERSCHLEISS KONTROLLIEREN UND D legscheiben (3) zur Halterung des Deckels (4), die
BREMSSCHEIBEN AUSWECHSELN» und «DIFFE- OÈ leinfuÈll- und Ablaûstopfen (5) und (6) sowie das
RENTIALAGGREGAT ABNEHMEN». EndluÈftungsstuÈck (7) abnehmen.
a b BEMERKUNG. Die entgegengesetzten Schrauben (2) zur Sicher-
heit zuruÈck lassen.
Remover los ejes completos y el duferencial. Aflojar y sacar los tornillos (1) y (2) y las arandelas (3)
ESP Para los detalles, vease «CONTROL DESGASTE Y ESP de retencion tapa (4), los tapones (5) y (6) de carga y
SOBSTITUCION DISCOS FRENOS» y «REMOCION descarga aceite y el recorde de escape (7).
GRUPO DIFERENCIAL». NOTA. Dejar en posicion de seguridad dos tornillos (2) contra-
puestas.
Enlever les bras complets et le diffeÂrentiel. Desserrer et enlever les vis (1) et (2), les rondelles (3)
F Pour de plus amples deÂtails, voir "CONTROLE F de fixation du couvercle (4), les bouchons (5) et (6) de
USURE ET SUBSTITUTION DES DISQUES FREIN" remplissage et vidange d'huile et le raccord d'eÂvent (7).
et "DEPOSE DU GROUPE DIFFERENTIEL". REMARQUE. Pour plus de suÃreteÂ, garder deux vis (2) super-
poseÂes.
Utilizzando un mazzuolo in materiale plastico, rimuo- Sistemare tra il corpo riduttore (11) e l'ingranaggio (12)
ITA vere il coperchio (4) ed asportarlo. ITA del pignone un blocchetto "A" di materiale tenero
NOTA. Se si deve intervenire sul gruppo differenziale, (alluminio, ecc.).
rimuovere il gruppo riduttore completo (viti (9) e (10)). Allentare ed asportare il dado (13) di ritegno pignone.
Mit einem Gummihammer den Deckel (4) ausrasten Zwischen dem ReduziererkoÈrper (11) und dem Getrie-
D und abnehmen. D be (12) des Kegelrads einen Block aus weichen
BEMERKUNG. Soll am Differentialaggregat gearbeitet Material einsetzen (Aluminium usw.)
werden, das komplette Reduzieraggregat abnehmen (Schrauben Mutter (13) zur Halterung des Kegelrads abschrauben.
c (9) und (10)). d
Utilizando un martillo en material plastico, remover la Colocar entre el cuerpo reductor (11) y el engranaje
ESP tapa (4) y sacarla. ESP (12) del pinon un bloquete "A" de material tierno
NOTA. Si se debe intervenir sobre el grupo diferen- (aluminio, ect.).
cial, remover el grupo reductor completo (tornillos (9) y (10)). Aflojar y sacar la tuerca (13) de retencion pinon.
A l'aide d'un maillet en matieÁre plastique, deÂplacer le Ajuster, entre le corps reÂducteur (11) et l'engrenage
F couvercle (4) et puis l'enlever. F (12) du pignon, un petit bloc "A" en mateÂriel leÂger
REMARQUE. S'il faut intervenir sur le groupe diffeÂ- (aluminium etc.).
rentiel, enlever le groupe reÂducteur complet (vis (9) et (10)). Desserrer et enlever l'eÂcrou (13) de fixation pignon.
Rimuovere l'ingranaggio del pignone (12) e l'ingra- Scomporre l'ingranaggio conduttore (14) estraendo il
ITA naggio conduttore (14) completo di cuscinetto (15). ITA cuscinetto (15).
NOTA. Per rimuovere l'ingranaggio (14), utilizzare una NOTA. Se necessario, usare un estrattore.
leva.
Das Getriebe (12) des Kegelrads und das Getriebe Das Getriebe (14) zerlegen; dazu das Lager (15)
D (14) samt Lager (15) entfernen. D abziehen.
BEMERKUNG. Um das Getriebe (14) abnehmen zu BEMERKUNG. Wenn noÈtig, einen Abzieher verwen-
koÈnnen, einen Hebel verwenden. den.
e f
Remover el engranaje del pinon (12) y el engranaje Descomponer el engranaje conductor (14) sacando el
ESP conductor (14) completo de cojinete (15). ESP cojinete (15).
NOTA. Para remover el engranaje (14), utilizar una NOTA. Si necesario, usar un extractor.
palanca.
DeÂplacer l'engrenage du pignon (12) et l'engrenage DeÂcomposer l'engrenage conducteur (14) en deÂga-
F conducteur (14) complet de palier (15). F geant le palier (15).
REMARQUE. Pour deÂplacer l'engrenage (14), utiliser REMARQUE. Si besoin, utiliser un extracteur.
un levier.
69
11
10
F1241200 F1241201
GB a GB b
Loosen all screws (9) and (10) and remove the upper check screws Connect the whole reduction gear body (11) to a hoist and remove
(9) of the reduction gear body. the screws (10) previously left in place for safety.
NOTE. Leave the two lower screws (10) in position for safety. Using a plastic hammer, pull away the whole reduction gear body
(11).
11 16
17
17
19
16 20
17
F1241202 F1241203
GB c GB d
Position the reduction gear body (11) under a press and, using a Remove distance piece (20) and shims (19) from the pinion(16).
driver, extract the pinion (16) complete with internal bearing (17), Position the pinion under a press and remove the internal bearing
shims (19) and distance piece (20). (17).
21
22 17
11 F1241204
GB e GB f
With the help of an extractor, remove the thrust blocks (17) and (21)
of the bearings, and the snap ring (22).
NOTE. Note down direction of assembly of snap ring (22).
70
Allentare tutte le viti (9) e (10) ed asportare le viti (9) Collegare il corpo riduttore completo (11) ad un mezzo
ITA superiori di ritegno del corpo riduttore. ITA di sollevamento ed asportare le viti (10) lasciate in
NOTA. Lasciare in sede le due viti (10) inferiori per sede per sicurezza.
sicurezza. Utilizzando un mazzuolo in materiale plastico, rimuovere il corpo
riduttore (11) completo.
Alle Schrauben (9) und (10) lockern und die oberen Den kompletten ReduziererkoÈrper (11) an ein Hebe-
D Schrauben (9) zur Halterung des ReduziererkoÈrpers D zeug befestigen und die zuvor zur Sicherheit zuruÈck-
abnehmen. gelassenen Schrauben (10) abschrauben.
BEMERKUNG. Die beiden unteren Schrauben (10) zur Sicherheit Mit einem Gummihammer, den kompletten ReduziererkoÈrper (11)
a zuruÈck lassen. b abnehmen.
Aflojar todos los tornillos (9) y (10) y sacar los tornillos Conectar el cuerpo reductor completo (11) a un medio
ESP (9) superiores de retencion del cuerpo reductor. ESP de elevacion y sacar los tornillos (10) dejadas en su
NOTA. Dejar en su lugar los dos tornillos (10) lugar para seguridad.
inferiores para seguridad. Utilizando un martillo en material plastico, remover el cuerpo
reductor (11) completo.
Desserrer toutes les vis (9) et (10), enlever les vis Brancher le corps reÂducteur complet (11) aÁ un moyen
F supeÂrieures (9) de fixation du corps reÂducteur. F de relevage, puis enlever les vis laisseÂe (10) dans leur
REMARQUE. Garder les deux vis infeÂrieures (10) dans sieÁge pour plus de seÂcuriteÂ.
leur sieÁge pour plus de seÂcuriteÂ. A l'aide d'un maillet en matieÁre plastique, enlever le corps
reÂducteur (11) complet.
Posizionare il corpo riduttore (11) sotto una pressa e, Rimuovere dal pignone (16) il distanziale (20) e gli
ITA utilizzando uno spintore, estrarre il pignone (16) ITA spessori (19).
completo di cuscinetto interno (17), spessori (19) ed Posizionare il pignone sotto una pressa e rimuovere il
il distanziale (20). cuscinetto interno (17).
Den ReduziererkoÈrper (11) unter eine Presse legen Vom Kegelrad (16) das DistanzstuÈck (20) und die
D und mit einem StoÈûel das Kegelrad (16) samt dem D Unterlegscheiben (19) abnehmen.
inneren Lager (17), den Unterlegscheiben (19) und Das Kegelrad unter eine Presse legen und das innere
dem DistanzstuÈck (20) abziehen. Lager (17) abnehmen.
c d
Colocar el cuerpo reductor (11) debajo de una prensa Remover del pinon (16) el distancial (20) y los
ESP y, utilizando un empujador (16) completo de cojinete ESP espesores (19).
interno (17), espesores (19) y el distancial (20). Colocar el pinon bajo una prensa y remover el cojinete
interno (17).
Placer le corps reÂducteur (11) sous une presse, aÁ Enlever du pignon (16) l'entretoise (20) et les cales
F l'aide d'un poussoir extraire le pignon (16) complet de F (19).
palier interne (17), cales (19) et entretoise (20). Placer le pignon sous une presse et enlever le palier
interne (17).
Con un estrattore, rimuovere dal corpo riduttore (11) le

ITA ralle dei cuscinetti (17) e (21) e l'anello di tenuta (22). ITA
NOTA. Annotare il senso di montaggio dell'anello di
tenuta (22).
Mit einem Abzieher vom ReduziererkoÈrper (11) die

D Scheiben der Lager (17) und (21) und den Dichtring D
(22) entfernen.
BEMERKUNG. Montagerichtung des Dichtringes (22) notieren.
e f
Con un extractor, remover del cuerpo reductor (11) las
ESP ranguas de los cojinetes (17) y (21) y el anillo de ESP
retencion (22).
NOTA. Anotar el sentido de desmontaje del anillo de retencion
(22).
A l'aide d'un extracteur, enlever le corps reÂducteur

F (11), les crapaudines des paliers (17) et (21) et F
l'anneau d'eÂtancheÂiteÂ (22).
REMARQUE. Prendre note du sens de montage de l'anneau
d'eÂtancheÂiteÂ (22).
71
23
16
17
18
19
20
GB a GB b
7
11
9
8 15
14
4
1
13
22 5
21 12
6
GB c GB d
10 2
3
D1240136
GB e GB f
72
CAUTION! 1 - If disassembly has only been carried ATENCION! 1 - Si el desmontaje ha sido efectuado
GB out to replace the snap ring (22), position the new ring ESP solo para la sobstitucion del anillo de retencion (22),
and reassemble the unit, respecting the tightening proceder al alojamiento del nuevo anillo y remontar el
torques specified in the following section and using the specified grupo respectando los pares de serraje indicadas en el paragrafo
locking and sealing products. siguiente y utilizando los productos de bloqueo y tenida prescritos.
2 - If disassembly is performed to replace either crown wheel and 2 - Si el desmontaje viene efectuado para la sobstitucion del par
pinion, bearings, or planetary gears, take the unit to pieces and find conico, de los cojinetes o de los engranajes satelites, proceder a la
shims and clearances as specified in the sections relative to the descomposicion y a la busqueda de los espesores y de los juegos
removal, disassembly, assembly and installation of the differential como indicados en los paragrafos concernientes la remocion, el
unit and bevel pinion. desmontaje, el asemblaje y la instalacion del diferencial y del pinon
conico.
ATTENZIONE! 1 - Se lo smontaggio eÁ stato eseguito ATTENTION! 1 - Si le deÂmontage n'est effectueÂ que

ITA solo per la sostituzione dell'anello di tenuta (22), F pour substituer l'anneau d'eÂtancheÂiteÂ (22), positionner
procedere al posizionamento del nuovo anello e le nouvel anneau et remonter le groupe en respectant
rimontare il gruppo rispettando le coppie di serraggio indicate nel les couples de serrage indiqueÂs dans le paragraphe suivant aÁ l'aide
paragrafo seguente ed utilizzando i prodotti di bloccaggio e tenuta des produits de blocage et d'eÂtancheÂiteÂ prescrits.
prescritti. 2 - Si le montage est effectueÂ pour substituer le couple conique des
2 - Se lo smontaggio viene eseguito per la sostituzione della coppia paliers et des engrenages satellites, passer aÁ la deÂcomposition et aÁ
conica, dei cuscinetti o degli ingranaggi satelliti, procedere alla la recherche des cales et des jeux comme indiqueÂ dans les
scomposizione ed alla ricerca degli spessori e dei giochi come paragraphes concernant la deÂpose, le deÂmontage, l'assemblage et
indicato nei paragrafi riguardanti la rimozione, lo smontaggio, l'installation du diffeÂrentiel et du pignon conique.
l'assemblaggio e l'installazione del differenziale e del pignone
conico.
ACHTUNG! 1 - Falls das Teil zum Auswechseln des

D Dichtringes (22) zerlegt wurde, den neuen Ring
einsetzen und das Aggregat wieder montieren; dabei
die Anzugsmomente einhalten, die im nachstehenden Kapitel
angegeben sind und die vorgeschriebenen Materialien zur Blok-
kierung und Abdichtung verwenden.
2 - Falls das Zerlegen zum Auswechseln des Kegelradpaars, der
Lager oder der Planetengetriebe vorgenommen wird, den An-
weisungen der Paragraphen zum Zerlegen, Abmontieren und
Zusammenbauen sowie zur Installation des Differentials und des
Kegelrads folgen und die StaÈrken und Spiele einhalten.
73
INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UND
EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE
MEASURE (42.35)
MISURA (42,35)
MAß (42,35) St
MESURA (42,35)
MESURE (42,35) B
MARK
CONTRASSEGNO
C C
B KENNZEICHEN
CONTRASENALACION
11
MARQUAGE
17
F1241205 F1241206
GB a GB b
Mark the thrust block and the internal bearing (17) on a faceplate, Lay two 20 mm gauged blocks "C" on the face of the reduction gear
allow the bearing to set by rotating them in both directions and by body (11). With depth gauge "B" (set to zero at the previous point),
applying a vertical thrust. With a centesimal, digital depth gauge measure space between the "C" blocks and the striking surface of
"B", check overall thickness of bearing (e.g.: 42.35 mm) and set the internal bearing (17). The size obtained (e.g.: 0.81 mm) is the
gauge to zero again. theoretical shim "St" (18) to be inserted under the thrust block of
bearing (17).
DIFFERENTIAL AXIS
ASSE DIFFERENZIALE
DIFFERENTIALACHSE
EJE DEFERENCIAL S
ESSIEU DIFFERENTIEL
Y
X
+ --
DEVIATION "X"
SCOSTAMENTI "X"
ABWEICHUNG "X" S = St + (± X)
DESPLAZAMIENTOS "X"
ECARTS "X"
D1240137
F1241225
GB c GB d
On the bar-hold of pinion (16), check the value "X" (in brackets) To calculate final thickness "S", add the negative value of "X" to
relative to the deviation from the theoretical centre distance. "St" or, alternatively, subtract the positive value of "X".
NOTE. "Y" is the number of pinion/crown coupling. For ex.: Deviation X=(±0.13 mm): S=St+X=0.81+0.13=0.94 mm
Deviation X=(+0.12 mm): S=St ± X=0.81 ± 0.12=0.69 mm
CAUTION! Round off to as close to 0.05 mm as possible.
22
T10
21
22
F1241227 F1241207
GB e GB f
Using a driver, mount the sealing ring (22) in the reduction unit (11). Place the reduction gear body (11) under a press and, using tool
NOTES. 1 - Carefully check the direction of assembly. T10, insert the thrust block of external bearing (21).
2 - Lubricate the outer surface of the sealing ring. CAUTION! Insert the thrust block of the bearing that is not
countermarked.
74
Contrassegnare la ralla ed il cuscinetto (17) interno su Appoggiare sul piano di appoggio del corpo riduttore
ITA un piano di riscontro, assestare il cuscinetto con delle ITA (11) due blocchetti calibrati da 20 mm "C". Con il
rotazioni parziali nei due sensi ed esercitando una calibro di profonditaÁ "B" (azzerato nella fase precedente), rilevare la
spinta verticale. Con un calibro di profonditaÁ digitale centesimale misura tra i blocchetti "C" ed il piano di battuta del cuscinetto
"B", rilevare lo spessore totale del cuscinetto (es 42,35 mm) ed interno (17). La misura risultante (es. 0,81 mm) eÁ lo spessore "St"
azzerare il calibro. (18) teorico da inserire sotto la ralla del cuscinetto (17).
Die Scheibe und das innere Lager (17) an einer Auf eine AuflageflaÈche des ReduziererkoÈrpers (11) zwei
D BezugsflaÈche markieren, das Lager durch hin und her D kalibrierte BloÈcke zu 20 mm "C" legen. Mit einer Tiefen-
Drehen und einem senkrechten Druck richtig ein- lehre "B" (zuvor zuruÈckgestellt) das Maû zwischen den BloÈcken "C" und
setzen. Mit einer digitalen hundertteiligen Tiefenlehre "B" die der AnschlagflaÈche des inneren Lagers (17) messen. Das ermittelte Maû
a GesamtstaÈrke des Lagers messen (z.B. 42,35 mm) und die Lehre
zuruÈckstellen.
b (z.B. 0,81 mm) entspricht der theoretischen Unterlegscheibe "St" (18),
die unter die Scheibe des Lagers (17) gelegt werden muû.
Senalar la rangua t el cojinete (17) interno sobre una Colocar sobre la superficie de apoyo del cuerpo reductor
ESP superficie de rescontre, ordenar el cojinete con unas ESP (11) dos bloques calibrados de 20 mm "C". Con el calibre
rotaciones parciales en los dos sentidos y ejercitando de profundidad "B" (azerando en la fase precediente),
un empuje vertical. Con un calibre de profundidad digital centesimal relevar la mesura entre los bloquetes "C" y la superficie del tope del
"B", relevar el espesor total del cojinete (es.:42,35 mm) y azerar el cojinete interno (17). La mesura resultante (es.: 0,81 mm) es el
calibre. espesor "St" (18) teorico de introducir bajo la rangua del cojinete (17).
Estampiller la crapaudine et le palier (17) interne sur DeÂposer sur un plan d'appui du corps reÂducteur (11),
F un marbre de controÃle, ajuster les paliers par des F deux petits blocs calibreÂs aÁ 20 mm "C". A l'aide du
rotations partielles dans les deux sens tout en calibre de profondeur "B" (mis aÁ zeÂro preÂceÂdemment),
poussant verticalement. A l'aide d'un calibre de profondeur relever la mesure existante entre les petits blocs "C" et le plan de
numeÂrique centeÂsimal "B", relever le calage total des paliers (ex. buteÂe du palier interne (17). La mesure reÂsultante (ex. 0,81 mm) est
42,35 mm), mettre le calibre aÁ zeÂro. le calage "St" (18) aÁ introduire sous la crapaudine du palier (17).
Controllare sul codolo del pignone (16) il valore "X" Per calcolare lo spessore "S" definitivo, aggiungere a
ITA (racchiuso tra parentesi) dello scostamento rispetto ITA "St", il valore "X" negativo oppure sottrarre il valore
l'interasse teorico. "X" positivo.
NOTA. Il numero "Y" eÁ il numero di accoppiamento pignone- Es.: Scostamento X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm
corona. Scostamento X=(+0,12 mm): S=St ± X=0,81 ± 0,12=0,69 mm
ATTENZIONE! Arrotondare al valore piuÁ prossimo dei 0,05 mm.
Den Wert "X" der Gleitung am Kegelradschaft (16) (in Um die endguÈltige StaÈrke "S" auszurechnen, "St" und
D Klammern angegeben) im VerhaÈltnis zum theoreti- D "X" addieren, wenn "X" neÂgatif ist oder "X" von "St"
schen Achsenabstand kontrollieren. abziehen, falls "X" postif ist.
BEMERKUNG. Die Zahl "Y" entspricht dem Kegelrad-Kranz- Beispiel: Abweichung X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm
c Kopplungsgrad. d Abweichung X=(+0,12 mm): S=St ± X ± 0,81 ± 0,12=0,69 mm
ACHTUNG! Auf einen Wert abrunden, der 0,05 mm am naÈchsten liegt.
Controlar sobre al espigon del pinon (16) el valor "X" Para calcolar el espesor "S" definitivo, adicionar a
ESP (serrado entre parantesis) del desplazamiento respec- ESP "St", el valor "X" negativo o detraer el valor "X"
to al intereje teorico. positivo.
NOTA. El numero "Y" y el numero de acoplamiento pinon-corona. Es.: Desplazamiento X=(± 0,13mm): S=St+X=0,81+0,13=0,94 mm
Desplazamiento X=(0,12mm): S=St ± X=0,81 ± 0,12=0.69 mm
ATENCION! Acercar al valor mas cerca de 0,05 mm.
ControÃler sur la queue du pignon (16) la valeur "X" Pour calculer l'eÂpaisseur "S" deÂfinitif, additionner aÁ
F (entre parentheÁses) de l'eÂcart par rapport aÁ l'entraxe F "St" la valeur "X" neÂgative ou soustraire la valeur "X"
theÂorique. positive.
REMARQUE. Le numeÂro "Y" est le numeÂro de l'accouplement Ex. Ecart X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm
pignon-couronne. Ecart X=(+0,12 mm): S=St ± X ± 0,81 ± 0,12=0,69 mm
ATTENTION! Arrondir aÁ la valeur plus proche aÁ 0,05 mm.
Utilizzando uno spintore, montare nel corpo riduttore Sistemare il corpo riduttore (11) sotto una pressa e,
ITA (11) l'anello di tenuta (22). ITA utilizzando l'attrezzo T10 inserire la ralla del cusci-
NOTE. 1 - Controllare attentamente il senso di netto esterno (21).
montaggio. ATTENZIONE! Inserire la ralla del cuscinetto non contrassegnato.
2 - Lubrificare la superficie esterna dell'anello di tenuta.
Mit einem StoÈûel den Dichtring (22) in den Reduzierer- Den ReduziererkoÈrper (11) unter eine Presse legen
D koÈrper (11). D und mit dem Werkzeug T10 die Scheibe des aÈuûeren
BEMERKUNG. 1 - SorgfaÈltig die Montagerichtung des Lagers (21) einsetzen.
Dichtrings kontrollieren. ACHTUNG! Die Scheibe des nicht gekennzeichneten Lagers
e È
2 - Auûere FlaÈche des Dichtrings schmieren. f einsetzen.
Utilizando un espesor, montar en el cuerpo reductor Colocar el cuerpo reductor (11) debajo de una prenso
ESP (11) el anillo de retencion (22). ESP y, utilizando la herramienta T10 insertar la rangua del
NOTA. 1 - Controlar atentamente el sentido de cojinete esterno (21).
montaje. ATENCION! Introducir la rangua del cojinete no segnalado.
2 - Lubrificar la superficie exterior del anillo de retencion.
A l'aide d'un poussoir, monter dans le corps reÂducteur Ajuster le corps reÂducteur (11) sous la presse, aÁ l'aide
F (11) l'anneau d'eÂtancheÂiteÂ (22). F de l'outil T10 introduire la crapaudine du palier
NOTE. 1 - ControÃ ler attentivement le sens de externe (21).
montage. ATTENTION! Introduire la crapaudine du palier non estampilleÂe.
2 - Lubrifier la surface externe de l'anneau d'eÂtancheÂiteÂ.
75
17 T11
18
21
20
17
F1241208 F1241209
GB a GB b
Turn the reduction gear body (11) upside down and insert shim "S"; Fit tool T12 onto tool T11. Then, install bearings (17) and (21) so
then, with tool T10, insert the thrust block of the internal bearing that they are opposed to each other and spaced by the distance
(17). piece (20).
CAUTION! Insert the thrust block of the countermarked bearing. Position the depth comparator in one of the four radial holes; pre-
set the comparator to 3 ± 4 mm, then set it to zero.
T11
21
17
T11
F1241210 F1241211
GB c GB d
Remove the bearings from tool T11 and fit them in the thrust blocks Install tool T11 and tighten it manually to obtain a safe rolling
of the reduction gear body. torque.
CAUTION! Check that the countermarked bearing is fitted in the NOTE. During tightening, perform a few rotations to set the
centring hub of the body of the reduction gear and in the bearings.
countermarked thrust block too.
H + 0,13 ÷ 0,15 = S1
19 S1
F1241212 F1241221
GB e GB f
Introduce the previously reset comparator, in one of the four radial The deviation found is to be added to a fixed value of 0.13(0.15
holes and measure. The deviation from zero indicates the nominal mm. in order to: obtain shim "S1" (to be inserted between internal
value "H" relative to the shims that are to be inserted. bearing (17) and distance piece (20)) and, hence, produce the
specified pre-load of bearings.
CAUTION! Perform accurate measurements - a variation of 0.001 mm
causes a variation in the torque by 20 ± 40 Nm
76
Capovolgere il corpo riduttore (11) ed inserire lo Montare sull'attrezzo T11 l'attrezzo T12. Quindi mon-
ITA spessore "S" e con l'attrezzo T10 la ralla del ITA tare i cuscinetti (17) e (21) contrapposti ed intervallati
cuscinetto interno (17). con il distanziale (20).
ATTENZIONE! Inserire la ralla del cuscinetto contrassegnato. Posizionare un comparatore di profonditaÁ in uno dei quattro fori
radiali; precaricare il comparatore di 3v4 mm ed azzerarlo.
Den RedurziererkoÈrper (11) wenden und die Unter- Auf das Werkzeug T11 das Werkzeug T12 montieren.
D legscheibe "S" einsetzen; mit dem Werkzeug T10 die D Dann die entgegengesetzten Lager (17) und (21)
Scheibe des inneren Lagers (17) einsetzen. montieren und dazwischen das DistanzstuÈck (20)
ACHTUNG! Die Scheibe des gekennzeichneten Lagers einsetzen. legen.
a b Eine Meûuhr in eines der vier RadialloÈcher positionieren; die
Meûuhr auf 3v4 mm vorbelasten und dann zuruÈckstellen.
Volcar el cuerpo reductor (11) y introducir el espesor Montar sobre la herramienta T11 la herramienta T12.
ESP "S" y con la herramienta T10 la rangua del cojinete ESP Entonces colocar los cojinetes (17) y (12) contra-
interno (17). puestos y intervalados con el distancial (20).
ATENCION! Introducir la rangua del cojinete segnalado. Colocar un comparador de profundidad en uno de los cuatro
agujeros radiales, precargar el comparador de 3-4 mm y acerarlo.
Faire basculer le corps reÂducteur (11), introduire la Monter sur l'outil T11, l'outil T12. Ensuite monter les
F cale "S", et aÁ l'aide de l'outil T10 la crapaudine du F paliers (17) et (21) en les superposant et intercalant
palier interne (17). avec l'entretoise (20).
ATTENTION! Introduire la crapaudine du palier estampilleÂ. Placer un comparateur de profondeur dans l'un des quatre trous
radiaux; preÂcharger le comparateur aÁ 3v4 mm, puis le mettre aÁ
zeÂro.
Rimuovere i cuscinetti dall'attrezzo T11 e montarli Montare l'attrezzo T11 e serrarlo manualmente fino ad
ITA nelle ralle del corpo riduttore. ITA avere una sicura coppia di rotolamento.
ATTENZIONE! Controllare che il cuscinetto contras- NOTA. Durante il serraggio, eseguire alcune rotazioni
segnato sia montato nel mozzo di centratura del corpo riduttore e per assestare i cuscinetti.
quindi nella ralla contrassegnata.
Die Lager vom Werkzeug T11 abnehmen und in den Das Werkzeug T11 montieren und von Hand fest-
D Scheiben des ReduziererkoÈrpers montieren. D ziehen bis ein sicheres Gegenmoment erreicht ist.
ACHTUNG! Kontrollieren, ob das markierte Lager in BEMERKUNG. Beim Festziehen einige Umdrehungen
den Zentriernaben des ReduziererkoÈrpers und folglich in der vornehmen, um die Lager richtig in ihren Sitz zu bringen.
c markierten Scheibe montiert ist. d
Remover los cojinetes de la herramienta T11 y Montar la herramienta T11 y apretarla manualmente
ESP montarlos en las ranguas del cuerpo reductor. ESP hasta obtener una segura pareja de rotacion.
ATENCION! Controlar que el cojinete segnalado sea NOTA. Durante la torsion, efectuar algunas rotaciones
colocado en el cubo central del cuerpo reductor y por lo tanto en la para ordenar los cojinetes.
rangua segnalada.
Oter les paliers de l'outil T11, puis monter ces Monter l'outil T11 et serrer celui-ci aÁ la main jusqu'aÁ
F derniers dans les crapaudines du corps reÂducteur. F obtenir un couple de roulement assureÂ.
ATTENTION! ControÃler que le palier estampilleÂ soit REMARQUE. En serrant, effectuer quelques tours de
monteÂ dans le moyeu de centrage du corps reÂducteur, donc, dans rotation pour ajuster les paliers.
la crapaudine estampilleÂe.
Introdurre in uno dei fori radiali il comparatore Lo scostamento rilevato eÁ da sommare ad una misura
ITA azzerato precedentemente ed eseguire la lettura. ITA fissa di 0,13v0,15 mm, per ottenere lo spessore "S1"
Lo scostamento rispetto lo zero, indica il valore (19) da inserire tra cuscinetto interno (17) e distanziale (20) e
nominale "H" degli spessori da inserire. quindi, determinare il precarico stabilito per i cuscinetti.
ATTENZIONE! Curare le misurazioni in quanto la variazione di
0,01 mm fa variare la coppia di rotazione di 20v40 Ncm.
In eines der RadialloÈcher die zuvor zuruÈckgestellte Die ermittelte Abweichung muû mit einem Festmaû von 0,3 (0,15
D Meûuhr einsetzen und das Maû ablesen. D mm zusammengerechnet werden, um die Unterlegscheibe "S1"
Die Abweichung im VerhaÈltnis zur Null, gibt den (19) zu ermitteln, die zwischen dem inneren Lager (17) und das DistanzstuÈck (20)
Nennwert "H" der einzulegenden Unterlegscheiben an. gelegt werden muû und um die Vorbelastung der Lager festlegen zu koÈnnen.
e f ACHTUNG! Die Messungen sehr sorgfaÈltig vornehmen, da ein Unter-
schied von 0,01 mm das Gegenmoment um 20v40 Ncm veraÈndert.
Introducir en uno de los agujeros radiales el compa- El desplazamiento relevado es de sumarse a una
ESP rador acerado precedentemente y efectuar la lectura. ESP mesura fija de 0,13-0,15 mm, para obtener el espesor
El desplazamiento respecto a lo cero, indica el valor "S1" (19) de introducir entre cojinete interno (17) y distancial (20) y
nominal "H" de los espesores de introducir. entonces, determinar el precario establecido para los cojinetes.
ATENCION! Poner atencion a las mesuraciones porque la variacion
de 0,01 mm hace cambiar de ratacion de 20v40Ncm.
Introduire dans l'un des trous radiaux le comparateur L'eÂcart releveÂ est aÁ additionner aÁ la mesure fixe 0,13v0,15 mm
F mis aÁ zeÂro preÂceÂdemment et en faire la lecture. F pour obtenir la cale "S1" (19) aÁ introduire entre le palier interne
L'eÂcart par rapport au zeÂro, indique la valeur nominale (17) et l'entretoise (20) et deÂfinir la preÂcharge eÂtablie pour les paliers.
"H" des cales aÁ introduire. ATTENTION! Effectuer soigneusement les mesurages parce qu'une diffeÂ-
rence de 0,01 mm ameÁne une variation du couple de rotation de 20v40 Ncm.
77
16
16 11
17
F1241213 F1241214
GB a GB b
With the help of the press, install the internal, countermarked Fit the pinion (16), the shims (19), the distance piece (20) and the
bearing (17) onto the pinion (16). external bearing (21) into the body of the reduction gear (11) and
CAUTION! Lubricate pinion with oil. assemble the unit with a press.
CAUTION! Lubricate pinion with oil.
23
11
15
12
13
F1241215 F1241216
GB c GB d
Fit the reduction gear (11) into the main body (23) without Fit the gear (12) of the pinion; coat the nut (13) with Loctite 242 and
differential unit; lock temporarily with the two lower screws (9). hand-screw it.
Fit the bearing (15) of the motion in gear and lock it.
12
11
F1241217
GB e GB f
Between the body of the reduction gear (11) and the gear (12) of the
pinion, place block "A" used for disassembling, and tighten the nut
(13) to a minimum required tightening torque of 500 Nm, using a
box wrench and a dynamometric wrench.
78
Con la pressa, montare il cuscinetto interno e Montare nel corpo riduttore (11) il pignone (16), gli
ITA contrassegnato (17) sul pignone (16). ITA spessori (19), il distanziale (20) ed il cuscinetto esterno
ATTENZIONE! Lubrificare il pignone con olio. (21) ed assemblare il gruppo con la pressa.
ATTENZIONE! Lubrificare il pignone con olio.
Mit einer Presse, das innere und markierte Lager (17) In den ReduziererkoÈrper (11) das Kegelrad (16), die
D auf das Kegelrad (16) montieren. D Unterlegscheiben (19), das DistanzstuÈck (20) und das
ACHTUNG! Rad mit O È l schmieren. aÈuûere Lager (21) montieren und das Aggregat mit der
Presse zusammenbauen.
a b ACHTUNG! Rad mit O È l schmieren.
Con la prensa, montar el cojinete interno y segnalado Montar en el cuerpo reductor (11) el pinon (16) los
ESP (17) sobre el pinon (16). ESP espesores (19), el distancial (20) y el cojinete esterno
ATENCION! Lubrificar el pinon con aceite. (21) y asemblar el grupo con la prensa.
ATENCION! Lubrificar el pinon con aceite.
A l'aide de la presse, monter le palier interne Monter dans le corps reÂducteur (11), le pignon (16), les
F estampilleÂ (17) sur le pignon (16). F cales (19), l'entretoise (20) et le palier externe (21),
ATTENTION! Lubrifier le pignon avec de l'huile. assembler le groupe aÁ l'aide de la presse.
ATTENTION! Lubrifier le pignon avec de l'huile.
Montare il corpo riduttore (11) sul corpo centrale (23) Montare l'ingranaggio (12) del pignone; spalmare il
ITA privo di differenziale e fissarlo provvisoriamente con le ITA dado (13) con Loctite 242 ed avvitarlo manualmente.
due viti inferiori (9).
Montare il cuscinetto (15) dell'ingranaggio di entrata del moto e
mandarlo in battuta.
Den ReduziererkoÈrper (11) auf den zentralen KoÈrper Das Getriebe (12) des Kegelrads montieren; Mutter
D (23) ohne Differential montieren und voruÈbergehend D (13) mit Loctite 242 schmieren und von Hand
mit den zwei unteren Schrauben (9) befestigen. zuschrauben.
Das Lager (15) des Einganggetriebes montieren und bis zum
c Anschlag einsetzen. d
Montar el cuerpo reductor (11) sobre el cuerpo central Asemblar el engranaje (12) del pinon, pasar la tuerca
ESP (23) sin el diferencial y fijarlo provisoriamente con los ESP (13) con Loctite 242 y atornillarla manualmente.
dos tornillos inferiores (9).
Asemblar el cojinete (15) del engranaje de entrada del movimiento
y mandarlo a tope.
Monter le corps reÂducteur (11) sur le corps central (23) Monter l'engrenage (12) du pignon; enduire l'eÂcrou
F sans diffeÂrentiel et fixer provisoirement ce dernier F (13) avec du Loctite 242 et visser celui-ci aÁ la main.
avec les deux vis infeÂrieures (9).
Monter le palier (15) de l'engrenage d'acceÁs au mouvement, puis
l'envoyer en buteÂe.
Sistemare tra il corpo riduttore (11) e l'ingranaggio (12)

ITA del pignone il blocchetto "A" usato per lo smontaggio ITA
e serrare il dado (13) alla coppia minima di 500 Nm,
utilizzando una chiave a bussola ed una chiave dinamometrica.
Zwischen dem ReduziererkoÈrper (11) und dem Getrie-

D be (12) des Kegelrads den Block «A» legen, der zum D
Abmontieren verwendet wurde, und Mutter (13) mit
einem Anzugsmoment von mindestens 500 Nm mit einem
e InbuûschluÈssel und einem Dynamometer festziehen. f
Colocar entre el cuerpo reductor (11) y el engranaje
ESP (12) del pinon el bloquete "A" usado para el ESP
desmontaje y apretar la tierca (13) al valor minimo
de 500 Nm, utilizando una llave a manguito y una llave
dinamometrica.
Placer, entre le corps reÂducteur (11) et l'engrenage

F (12) du pignon, le petit bloc "A" utiliseÂ au deÂmontage, F
serrer l'eÂcrou (13) au couple minimum de 500 Nm aÁ
l'aide d'une cleÂ aÁ pipe et d'une cleÂ dynamomeÂtrique.
79
T13
F1241217
GB a
Allow the pinion to rotate a few times in both directions to enable
bearings to set.
Apply bar-hold T13 onto pinion (16) and, with a torque meter, check
the torque of the pinion.
Torque: 140 ± 150 Ncm.
CAUTION! If torque exceeds the maximum value, then the shim
"S1" (19) placed between bearing (17) and distance piece (20)
needs to be increased.
If torque does not reach the set value, increase the tightening
torque setting of nut (13), in different stages, until the maximum
admitted value of 700 Nm is obtained.
CAUTION! If torque does not reach the minimum value, then the
shim "S1" (19) needs to be reduced.
CAUTION! In order to be able to calculate the increase or reduction
of shim "S1", it is necessary to bear in mind that a 0.01 mm
variation in the size of shim (19) results in the torque of the pinion
(16) varying by 20 ± 40 Ncm.
11
F1241226
GB b
Remove the whole reduction gear body (11) and continue with the
assembly of the differential unit and arms.
For details, see «ASSEMBLY AND INSTALLATION OF THE
DIFFERENTIAL UNIT - ASSEMBLING THE BRAKING UNIT».
80
Far compiere al pignone alcuni giri nei due sensi per Das Kegelrad um einige Umdrehungen in beide
ITA assestare i cuscinetti. D Richtungen drehen, um die Lager richtig einzusetzen.
Applicare sul pignone (16) il codolo T13 e con un Am Kegelrad (16) den Schaft T13 anbringen und mit
torsiometro, controllare la coppia di rotazione del pignone. einem Drehungsmesser das Gegenmoment des Ke-
Coppia di rotazione: 140v150 Ncm gelrads kontrollieren.
ATTENZIONE! Se la coppia supera il valore massimo bisogna Gegenmoment: 140v150 Ncm.
aumentare lo spessore "S1" (19) tra cuscinetto (17) e distanziale ACHTUNG! Falls der Wert den Maximalwert uÈberschreitet, braucht
(20). es eine groÈûere Unterlegscheibe "S1" (19) zwischen Lager (17) und
Se la coppia di rotazione non raggiunge il valore stabilito, DistanzstuÈck (20).
aumentare la coppia di serraggio del dado (13) in piuÁ tempi fino a Falls das Gegenmoment den festgelegten Wert nicht erreicht, das
raggiungere il valore massimo ammesso di 700 Nm. Anzugsmoment der Mutter (13) schrittweise erhoÈhen, bis der
ATTENZIONE! Se la coppia di rotazione non raggiunge il valore maximal zulaÈssige Wert von 700 Nm erreicht worden ist.
minimo, eÁ necessario diminuire lo spessore "S1" (19). ACHTUNG! Falls das Gegenmoment den Mindestwert nicht
ATTENZIONE! Al fine di poter calcolare gli incrementi o la erreicht, muû die Unterlegscheibe "S1" (19) kleiner sein.
diminuzione dello spessore "S1", eÁ necessario considerare che la ACHTUNG! Um das hoÈhere oder niedrigere Maû der Unter-
variazione dello spessore (19) di 0,01 mm, fa variare la coppia di legscheibe "S1" ausrechnen zu koÈnnen, darauf achten, daû ein
rotazione del pignone (16) di 20v40 Ncm. Unterschied von 0,01 mm der Unterlegscheibe (19) das Gegen-
moment des Kegelrads (16) um 20v40 Ncm aÈndert.
a
Hacer efectuar al pinon algunos giros en los dos Faire faire quelques tours au pignon dans les deux
ESP sentidos para ordenar los cojinetes. F sens de manieÁre aÁ ajuster les paliers.
Aplicar sobre el pinon (16) el codolo T13 y con un Appliquer sur le pignon (16), la queue T13, puis aÁ
torsiometro, controlar el par de rotacion del pinon. l'aide d'un torsiomeÁtre, controÃler le couple de rotation du pignon.
Par de rotacion: 140v150 Ncm. Couple de rotation: 140v150 Ncm.
ATENCION! Si el par supera el valor maximo hay que augmentar el ATTENTION! Si le couple de rotation deÂpasse la valeur maximum,
espesor "S1" (19) entre cojinete (17) y distancial (20). augmenter la cale "S1" (19) entre le palier (17) et l'entretoise (20).
Si el par de rotacion no llega al valor establecido, augmentar el par Si le couple de rotation n'atteint pas la valeur eÂtablie, augmenter le
de torsion de la tuerca (13) en mas tiempos hasta llegar al valor couple de serrage de l'eÂcrou (13), en plusieurs temps, jusqu'aÁ
maximo admitido de 700 Nm. atteindre la valeur maximum admise de 700 Nm.
ATENCION! Si el par de rotacion no llega al valor minimo, es ATTENTION! Si le couple de rotation n'atteint pas la valeur
necesario disminuir el espesor "S1" (19). minimum, diminuer la cale "S1" (19).
ATENCION! Al fin de poder calcular los encrementos o la ATTENTION! Pour pouvoir calculer les augmentations et les
disminuciones del espesor "S1", es necesario considerar que la diminutions de la cale "S1", tenir compte que la diffeÂrence de
variacion del espesor (19) de 0,01 mm, hacer cambiar el par de 0,01 de la cale (19) fait varier le couple de rotation du pignon (16) de
rotacion del pinon (16) de 20v40 Ncm. 20v40 Ncm.
Rimuovere il corpo riduttore completo (11) e procedere

ITA con il montaggio del differenziale e dei bracci.
Per i dettagli, vedere «ASSEMBLAGGIO ED INSTAL-
LAZIONE GRUPPO DIFFERENZIALE - ASSEMBLAGGIO GRUP-
PO FRENO».
Den kompletten ReduziererkoÈrper (11) abnehmen und

D das Differential und die Arme montieren.
Siehe «ZUSAMMENBAU UND INSTALLATION DES
DIFFERENTIALAGGREGATS - ZUSAMMENBAU DES BREMSAG-
b GREGATS».
Remover el cuerpo reductor completo (11) y proceder

ESP con el montaje del diferencial y de los ejes.
Para los detalles, vease «ASEMBLAJE Y INSTALA-
CION GRUPO DIFERENCIAL - ASEMBLAJE GRUPO FRENO».
Enlever le corps reÂducteur complet (11) et aller de

F l'avant avec le montage du diffeÂrentiel et des bras.
Pour de plus amples deÂtails, voir "ASSEMBLAGE ET
INSTALLATION DU GROUPE DIFFERENTIEL - ASSEMBLAGE
DU GROUPE FREIN".
81
SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE
HERRAMIENTAS ESPECIALES - OUTILS SPECIAL
4.3 T1 T2
45°
20
25
1
=
32
32
200
=
90
= =
50
160
110
120± 0.1
120± 0.1
32
32
25
1
840
45°
10 4.5 930
2313 D1240046 2305 D1240043
T3 Ø40
T4
Ø40
32
3 x45°
3 x45°
150
150
190
195
0
R1
10
0
R1
8
17 13
40
25
32
45
32
32
3 x45°
32
Ø153
32
125
Ø154
20°
Ø178 Ø178
Ø189
Ø184
Ø200
1502 D1240120 1742 D1240121
T5
295
136 10 150
65 3 x45°
27.5
20
3 x15°
0.05
Ø45 ---- 0.4

0.6
-- 0.3
-- 0.4
Ø46 ---- 0.1

Ø80
Ø61
Ø35
Ø25
Ø63
R1
32 32
0
32
32
107.5 ---- 0.2

0.3
1501 D1240122
82
75 Ø290
T6
5 Ø271
12
Ø20
Ø16
A Sez. B - B
1° 30'
° 2
32 17
°
17
32
7°
° 30' 17° 30' 1
3x15°
B
Ø150 H 7
Ø150 Hn 67
Ø318
B
43.60
° 17
82.13
113.48
17
134.91
°
17
°
Ø22
Ø16
17
21° 30'
Ø26
Ø22
Ø15
53.14
32
32
12 A
90.26
68 12
119.50
80 82
139.29
Sez. A - A n°2 pezzi
1545 D1240124
119.50 T7
190
53.14
Ø20
Ø16
9
Ø25
32 32
20
0 0 2 x30°
R1 R1 32 1° 30'
° 2
17
°
134.91
17
T7B
82.13
7°
17° 30' 7° 30' 1
Ø161.5 ±0.1
Ø264 ---- 0.15

0.25
Ø185 ---- 0.08
0.12
Ø262 ---- 0.25

0.15
Ø250
Ø172
Ø320
43.60
17°
113.49
32
°
17
17°
R5
'
21° 30
15°
15°
Ø16
5 x15° 90.26
16 20 138.29
110
32
Ø290 ±0.15
143
153
70
T7A 30 30
3 x15° 32
PROFILO HURT 45.5 x 40.5
A
Ø24
R5
Ø150 ---- 0.08
0.12
2
Ø140
Ø30
Ø38
0
R1 0
R1
Ø25 Hg 67
Ø24
Ø23,9
40 74
1.2 h 11
200 200
Particolare A 400
1769 D1240125
83
SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE
HERRAMIENTAS ESPECIALES - OUTILS SPECIAL
T8 T9
5 - +0
.5
-0
Ø9
Ø25
13 ± 0..2
-- 0.2
Ø120
+0
3 x45°
Ø102
160
192
Sez. A-A
0
R1
22 10
0.8 600
Ø40
0.8
Es Ch 22
a✽
15 20
30
Ø✽
Ø129
Ø16
] Bearing ref. 32017 DIN720 Acciaio Fe 42
] Ref. cuscinetto 32017 DIN720
] Lager Ref. 32017 DIN720
] Ref. cojinete 32017 DIN720
] ReÂf. palier 32017 DIN720
Acciaio Fe 42
0355 D1240123
Ø85.5
T10
490
Ø40
Ø25
R1
30
0
3 x45°
78
R2
48
40
10
22
150
A A
188
135
Acciaio 18 Ni Cr Mo 5
Cementazione 0.6÷0.8
Temprato HRC 60÷63
0
R1
35.5
32
1.5
40
8
32
30
3
4.5
32
32
20°
Ø23.9 ±-- 00.05
Ø104
Ø25H7
g7
Ø109
Ø30
32
-- 0.1
Ø40.5-- 0.15
Ø80
Ø92
1487/B D1240126 1495 D1240128
84
T11 Ø49.8
T12
Ø41.5
4 x45°
15
93
M14 x1
40 300
Ø110 2323 D1240127
Ø65
T13
M14 x1
Ch
22
Ø20
20
M14 x1
– 0.01
– 0.02
R5
3/4"
4"
61
41
1/
30
25 25
50
Ø20
Ø9
Ø41.2 +-- 0.03
0 14
195
95
25
45
35
Ø11
60
10
Ø80
10
50
25
Ø6.5
Ø35
2312 D1240075 0870 D1240129
85
A.E Repair instructions, H1 060/080/110

H1 060/080/110
Bent Axis
Motors
Repair Instructions
H1 060/080/110 Bent Axis Motors
Repair Instructions
Revisions

February 2010 last Fix Osaka address AF

August 2009 various minor corrections AE
July 2009 9, 10, 36, 37 Coil O-rings are available with the purchase of a new coil AD
April 2009 various add 060 frame size AC
December 2008 various add 080 frame size AB
Nov 2008 - First edition AA

2 11020692 • Rev AF • February 2010
Repair Instructions
Contents
Safety precautions.......................................................................................................................................... 6
Personal safety............................................................................................................................................ 6
Symbols used in Sauer-Danfoss literature.............................................................................................. 7
Disassembly Detach control.................................................................................................................................................. 8

Proportional control................................................................................................................................. 8
Proportional control disassembly............................................................................................................. 9
Two-position control disassembly .........................................................................................................10
Minimum displacement limiter................................................................................................................11
Maximum displacement limiter two-position controls...................................................................11
Speed Sensor..................................................................................................................................................12
Servo piston cover - proportional controls..........................................................................................13
Loop flushing spool and loop flushing charge relief valve............................................................14
Endcap and servo piston - proportional control...............................................................................15
Endcap and servo piston - two position control................................................................................16
Cylinder block and sync Shaft assembly...............................................................................................17
Shaft assembly...............................................................................................................................................18
Inspection Overview..........................................................................................................................................................19
Shaft assembly...............................................................................................................................................19
Pistons and piston rings..............................................................................................................................19
Synchronizing shaft......................................................................................................................................20
Cylinder block . ..............................................................................................................................................20
Bearing plate...................................................................................................................................................20
Valve segment................................................................................................................................................21
Endcap..............................................................................................................................................................21
Housing ...........................................................................................................................................................21
Control shuttle valve....................................................................................................................................21
Optional Minimum displacement limiter.............................................................................................22
Servo piston....................................................................................................................................................22
Control...............................................................................................................................................................22
11020692 • Rev AF • February 2010 3

Repair Instructions
Contents
Assembly Overview..........................................................................................................................................................23
Piston ring assembly....................................................................................................................................23
Install shaft in housing................................................................................................................................24
Synchronizing shaft......................................................................................................................................25
Pistons and cylinder block.........................................................................................................................26
Install bearing plate......................................................................................................................................27
Servo piston and valve segment—proportional control................................................................28
Servo piston and valve segment—two position control................................................................29
Endcap .............................................................................................................................................................30
Loop flushing charge relief valve and spool........................................................................................31
Shaft seal..........................................................................................................................................................32
Servo cover—proportional control........................................................................................................33
Speed sensor...................................................................................................................................................34
Minimum Displacement limiter...............................................................................................................35
Maximum displacement limiter two-position controls...................................................................35
Proportional control.....................................................................................................................................36
Two position control....................................................................................................................................37
Install control.................................................................................................................................................38
Proportional controls.............................................................................................................................38
Two-position controls............................................................................................................................38
Startup procedures Overview..........................................................................................................................................................39

Initial startup procedures...........................................................................................................................39
Adjustments....................................................................................................................................................39
Pressure measurements..............................................................................................................................39
Port locations Port locations and gauge installation....................................................................................................40
Torque chart Fasteners and plugs......................................................................................................................................41

Fastener size and torque chart.................................................................................................................41
Plug size and torque chart.........................................................................................................................41
4 11020692 • Rev AF • February 2010

Repair Instructions
Introduction
Overview This manual details the major repair procedures for H1 motors. These include the
complete disassembly, inspection, and reassembly of the unit. Where rework of worn
or damaged components is possible, specifications appear to ensure these parts meet
factory tolerances. Only Sauer-Danfoss Global Service Partners (GSPs) are authorized to
perform major repairs. Sauer-Danfoss trains Global Service Partners and certifies their
facilities on a regular basis.
W Warning
Use of components that do not comply with rework specifications may result in loss of
performance, which may constitute a safety hazard. Do not reuse components that don’t
comply to given specifications: replace with genuine Sauer-Danfoss service parts.
Minor repair procedures, adjustments, and troubleshooting information appear in the H1

Bent Axis Variable Displacement Motors Service Manual, 11024924. Minor repairs include
service operations you can perform without removing the unit’s endcap. Removal of the
endcap voids your warranty.
Operating parameters and product specifications are given in the H1 Bent Axis Variable
Displacement Motors Technical Information Manual, 11037153.
motors.
w Remove the unit

Prior to performing major repairs, remove the unit from the vehicle/machine. Chock
the wheels on the vehicle or lock the mechanism to inhibit movement. Be aware that
hydraulic fluid may be under high pressure and/or hot. Inspect the outside of the motor
and fittings for damage. Cap hoses after removal to prevent contamination.
e Keep it clean
Cleanliness is a primary means of assuring satisfactory motor life, on either new or
repaired units. Clean the outside of the motor thoroughly before disassembly. Take care
to avoid contamination of the system ports. Cleaning parts by using a clean solvent wash
As with any precision equipment, keep all parts free of foreign materials and chemicals.
Protect all exposed sealing surfaces and open cavities from damage and foreign material.
If left unattended, cover the motor with a protective layer of plastic.
l Lubricate moving parts

During assembly, coat all moving parts with a film of clean hydraulic oil. This assures that
these parts are lubricated during start-up.

Sauer-Danfoss recommends you replace all O-rings, seals, and gaskets during repair.
Lightly lubricate all O-rings with clean petroleum jelly prior to assembly. Grease must be
soluble in hydraulic fluid.
t Secure the unit

For major repair, place the unit in a stable position with the shaft pointing downward. It
will be necessary to secure the motor while removing and torquing the endcap bolts.
11020692 • Rev AF • February 2010 5
Repair Instructions
Introduction
Safety precautions Always consider safety precautions before beginning a service procedure. Protect
yourself and others from injury. Take the following general precautions whenever servicing
a hydraulic system.

W Warning

W Warning

W Warning
Personal safety
W Warning
times.
6 11020692 • Rev AF • February 2010

Repair Instructions
Introduction
Symbols used in  WARNING may result in injury

Sauer-Danfoss  Inspect for wear or damage
literature  CAUTION may result in damage to
product or property  Clean area or part
 Non-reusable part, use a new part  Be careful not to scratch or damage
 Option – either part may exist  Note correct orientation
 External hex wrench head  Mark orientation for reinstallation
 Internal hex wrench head  Torque specification
 Lubricate with hydraulic fluid  Cover splines with installation

sleeve
 Apply grease/petroleum jelly
11020692 • Rev AF • February 2010 7

Repair Instructions
Disassembly
Detach control Proportional control

1. Remove screws (C0110) using a 6 mm internal hex wrench.
Proportional endcap is 2. Remove control housing (C0010). Remove gasket (C0130) and discard.
reversible. Proportional
control may be installed 3. Remove spring guide (F0030). Remove spring (F0040).
on min-angle or max-angle
side of motor. Two position control
1. Remove screws (C0110 and C0120) using a 10 mm internal hex wrench.
2. Remove control housing (C0010). Remove gasket (C0130) and discard.
Remove control
C0120 (2X)
10 mm
C0110 (4X) C0110 (2X)
C0010 6 mm 10 mm
Proportional
control C0010
F0030 2 position
control
F0040
C0130
C0130
Proportional control Two position control

P106 520E
8 11020692 • Rev AF • February 2010

Repair Instructions
Disassembly
Proportional 1. If replacing the coil, remove the plastic cap (B0040). Remove the coil nut (B0027)
control disassembly using a 26mm 12-point socket. Remove the coil and discard the O-rings (B0025,
B0028, B0029).
The coil does not need to 2. Using a 4 mm internal hex wrench, remove three screws (B0050).
be removed unless it is
being replaced 3. Remove solenoid (B0010) and remove and discard O-ring (B0035A).
4. Remove control spool (C0100).
Coil O-rings are not 5. Using a 1/8 in internal hex wrench, remove three plugs (C0060) and remove and
included in the overhaul discard O-rings (C0060A).
seal kit. They are included
with the purchase of a new 6. Use a 3 mm internal hex wrench to remove orifices (E00T2 and E00T3). Tag the
coil. orifices for reassembly.
7. Using a 1/4 inch internal hex wrench, remove plug (C0050). Remove and discard
O-ring (C0050A).
8. Using a 5 mm internal hex wrench, remove shuttle valve assembly (C0025).
Disassemble control - M*B1 or L*B1

B0040
B0027
26mm
B0029
B0028
B0020
B0050
4 mm B0025
(3X)
B0035A B0010
1/8 in
1/4 in C0060
C0050 C0060A
C0050A E00T2
3 mm C0100
C0025
5 mm
B0010
C0060A
C0060 3 mm
1/8 in E00T3
C0060A
C0060
1/8 in
P106 521E
11020692 • Rev AF • February 2010 9

Repair Instructions
Disassembly
Two-position 1. Use a 26 mm 12-point socket to remove the coil nuts (B0026).

control disassembly
2. Remove coils (B0022) and O-rings (B0024) and (B0028). Discard O-rings.
3. Using a 17 mm hex wrench on the flats, remove solenoid assemblies (B0032).

Coil O-rings are not
included in the overhaul 4. Remove and discard O-rings (B0034).
with the purchase of a new 5. Using a 1/8 inch internal hex wrench, remove four plugs (C0060). Remove and
coil. discard O-rings (C0060A).
6. Using a 1/4 inch internal hex wrench, remove two plugs (C0050). Remove and
discard O-rings (C0050A).
7. Using a 17 mm hex wrench, remove pressure compensator adjusting plug (C0090).

Remove and discard O-ring (M223).
8. Remove springs (C0030) and (C0080). Remove spools (C0020) and (C0070).
9. Use a 3 mm internal hex wrench to remove orifices (E00T2) and (E00T3). Tag the
orifices for reassembly.
Disassemble two position control - T*D* or P*D*

B0026
B0028
B0022
B0024
B0032
17 mm
B0026 B0034
B0028 B0024
C0050
B0022 C0050A
1/4 in
B0032
17 mm C0060
1/8 in
B0034 C0060A
C0060 C0060
1/8 in 1/8 in
C0060A C0060A C0070
C0060 C0080
1/8 in M223
E00T3 C0090
3 mm C0020
17 mm
E00T2
3 mm C0030
C0050A
C0050
1/4 in P106 721E
10 11020692 • Rev AF • February 2010

Repair Instructions
Disassembly
Minimum 1. Remove and discard cap (N0120). Remove displacement limiter parts
displacement limiter
2. While holding position of
adjustment screw (N0010) with a 6
mm internal hex wrench, remove
locknut (N0020) using a 19 mm hex
wrench. Discard locknut.
3. Mark the position of adjustment

screw (N0010) for reinstallation.
Remove adjustment screw.
6 mm
N0010
m
N0120
19 mm
N0020
P107 831
Maximum It is not necessary to remove the Remove maximum displacement limiter

displacement limiter maximum displacement limiter unless it parts
two-position is being replaced.
controls P0100
Models with maximum displacement 6 mm
limiter: Remove screw (P0100) and spacer P0200
(P0200).
P107 866E
11020692 • Rev AF • February 2010 11

Repair Instructions
Disassembly
Speed Sensor 1. Using a 5 mm internal hex wrench remove screw (J0020).
2. Remove speed sensor or plug (J0010). Remove and discard O-ring (J0010A).
Speed sensor
J0020 J0020
J0010
J0010 O
J0010A
J0010A
J0010 J0010 J0010A

J0010A
O
J0020
J0020 P107 833
12 11020692 • Rev AF • February 2010

Repair Instructions
Disassembly
Servo piston cover 1. Remove four screws (P0020) using a 10 mm internal hex wrench.
- proportional
controls 2. Remove servo piston cover (P0010) and remove and discard O-ring (P0030).
3. Being careful not to damage inside of endcap, remove screw (P0050). See table for
wrench size.
Servo piston cover
P0050 wrench size

Model wrench size
110 10 mm
060/080 8 mm
P0050
see table
P0030
P0010
P0020
10 mm
(4X) P107 867E
11020692 • Rev AF • February 2010 13

Repair Instructions
Disassembly
Loop flushing spool 1. Using a 24 mm hex wrench, remove two plugs (K0030) and remove and discard
and loop flushing O-rings (K0030A).
charge relief valve
2. Remove springs (K0020).
3. Remove spool (K0010) from endcap.
4. Using a 24 mm wrench remove loop flushing relief valve (L00**).
Loop flushing charge relief valve is available as complete assembly only. If you suspect
valve malfunction, replace with new valve.
Remove loop flushing spool and relief valve
24 mm
K0030
K0020
K0030A
K0010
K0020
K0030
24 mm
K0030A
F0010
L0050
L00**
24 mm
P106 534E
14 11020692 • Rev AF • February 2010

Repair Instructions
Disassembly
Endcap and servo 1. Remove set screw (F0070) using a 5 mm internal hex wrench.
piston - proportional
control 2. Use a magnet to remove pin (F0060). Discard pin.
Proportional endcap is 3. Using expanding pliers, remove servo piston head (P0040). Remove piston seal
reversible. Mark position (P0044) and O-ring (P0043) from piston head. Discard seal and O-ring.
of endcap on housing for
later reassembly. 4. Remove eight screws (F0120) from end cap assembly. See table for wrench size.
5. Remove end cap assembly. Remove and discard gasket (G0070).
6. Using a 4 mm internal hex wrench, remove hold down screw (F0090). Remove valve
segment (QF080).
7. Remove setting lug (F0050) from servo piston (F0020) .

Do not press spindle out of
valve segment. 8. Remove servo piston (F0020) from endcap.
Remove endcap and servo piston F0070

F0060
5 mm
F0020
Rear view of valve segment

proportional controls
Servo m
piston head
G0070
Expanding F0050
pliers
F0120
See table
P106 726E F0090
4 mm
P0040 P0043
QF080 P0044
F0120 wrench size

Model wrench size
110 10 mm P106 522E
060/080 8 mm
11020692 • Rev AF • February 2010 15

Repair Instructions
Disassembly
Endcap and servo 1. Remove eight screws (F0120) from end cap assembly. See table for tool size. Remove
piston - two position end cap assembly.
control
2. Remove and discard gasket (G0070).
3. Using a 4 mm internal hex wrench, remove hold down screw (F0090). Remove valve
segment (QF080).
4. Remove servo piston (F0020) being careful not to damage inside of end cap.
5. Remove and discard seal ring (P0044) and O-ring (P0043).
Remove endcap and servo piston
P0043
P0044
F0020
F0120 wrench size

Model wrench size
110 10 mm
060/080 8 mm Rear view of
valve segment
- two position
control
F0120
See table
F0090
4 mm
QF080 P106 716E
G0070
16 11020692 • Rev AF • February 2010

Repair Instructions
Disassembly
Cylinder block and 1. Remove cylinder block assembly (M0020).

sync Shaft assembly
2. Remove bearing plate (M0030) from cylinder block. Note orientation for reassembly.
C Caution
Take care that the sealing 3. Set cylinder block and components on a clean dry surface. C
surfaces of the cylinder
block do not become 4. Remove synchronizing shaft assembly (M0010) and set on clean dry surface.
contaminated or scratched:
this may lead to poor 5. Remove alignment pins (G0040).
performance or motor
failure.
Remove cylinder block
G0040
M0010 G0040
M0020
M0030
P106 523E
Bronze
surface
11020692 • Rev AF • February 2010 17

Repair Instructions
Disassembly
Shaft assembly 1. Remove retaining ring (G0030).
2. Use seal puller to remove seal (G0020); discard.
3. Using a 1/8 inch internal hex wrench, remove shaft locking screw (G0050). Remove
and discard O-ring (G0050A).
Take care not to damage machined surfaces of housing or shaft assembly.
4. Press shaft assembly (H00**) out of housing by pressing on front face of shaft. C
C Caution
For motors with cartridge Take care not to damage pistons when pressing shaft out of housing.
flange, be sure to remove
speed sensor before 5. If replacing piston rings (H0230), use a small pair of expanding pliers to remove
pressing shaft out of them. Refer to piston ring inspection, page 19.
housing.
Remove shaft assembly
G0030
Shaft, bearings, pistons,
and speed ring form one G0020
complete assembly and
are not serviceable. replace
as a unit if damaged.
G0010
G0050A
G0050
1/8 inch internal hex
P106 525E
G0055A Cartridge model has

G0055 shaft lock screw (G0055)
H00** 3/16 in on top of housing.
H0230
18 11020692 • Rev AF • February 2010

Repair Instructions
Inspection
Overview After disassembly, wash all parts (including the end-cap and housing) thoroughly with
clean solvent and blow out oil passages in the housing and endcap with compressed
air. Allow to air dry. Conduct inspection in a clean area and keep all parts free from
contamination. Clean and dry parts again after any rework or resurfacing.
Shaft assembly Check to see that the shaft and its splines Inspect shaft assembly
are straight and free of damage or heavy
wear. Inspect the shaft journal where it
meets the shaft seal. Replace the shaft
assembly if grooved at the sealing land
surface. Clean the sealing area with a
nonabrasive material if necessary.
Check that the spacer ring between the

bearings is still fixed by bearing preload
and that there is no play between the
bearings. Clean bearings with a solvent Shaft bearings
and lubricate with hydraulic fluid. Inspect
for wear or pitting. If you find excessive
E101 329E
wear, replace the shaft assembly.
Check that there is not excessive axial endplay of the pistons in the piston shoe.
Pistons and piston Inspect sides of piston heads for scuffing Inspect piston heads
rings or marking. If scuffing or marking are
present, replace shaft assembly and Marks or scuffing indicate
unacceptable wear
cylinder block assembly.
Look for
P106 554E
marks or scuffing
If contact (polished) area on ring surface Inspect piston rings

is more than 3/4 of the area, replace
wear area
piston rings. If scuffing or marks are
visible, replace piston rings and inspect
cylinder block bores for scratches or
damage. Marks or scuffing indicate
P107 758E unacceptable wear
11020692 • Rev AF • February 2010 19

Repair Instructions
Inspection
Synchronizing shaft nspect synchronizing shaft, pins, and Inspect synchronizing shaft
rollers. Replace parts as a complete unit
if damaged or worn or if shaft is twisted.
If twisted, closely inspect cylinder block
and pistons for damage. P107 834
Cylinder block Examine the running face of the cylinder

block for scratches, grooves and other Inspect cylinder block
damage. Ensure that no scratches or
grooves exist; these can drastically
reduce output flow, increase internal
leakage, and reduce life of motor. Check
piston bores for scratches, grooves, or Needle
other damage. Replace cylinder block bearing
assembly if damaged.
Inspect needle bearing for scratches,

pitting, and wear. Ensure that bearing P106 627E
moves smoothly. If damaged, replace

cylinder block assembly. Bearing is not
available separately.
Bearing plate Inspect the bearing plate for scratches Inspect bearing plate
and grooves. Check the plate for
evidence of any cavitation along the
running face of the bearing plate. If
pitting from cavitation exists, replace the
bearing plate. Check for excessive wear
on the brass running face. If you observe
any discoloration or burn marks, replace
the bearing plate.
Deep or outstanding grooves in the

sealing lands (see illustration) of the
bearing plate decrease motor efficiency.
Run your fingernail or a pencil tip P106 113E
across the diameter of the sealing land

surface to check for grooves. Lap or replace if detectable grooves or nicks are present.
Inspect the mating surfaces of the valve segment and cylinder block for any possible
contamination; even a few thousandths of a millimeter can affect motor operation.
Appearance should be flat and smooth on both the running face and the bottom
surface. Perform a magnetic particle inspection to detect cracks. Replace bearing plate if
cracked.
20 11020692 • Rev AF • February 2010

Repair Instructions
Inspection
Valve segment Carefully inspect each machined surface Inspect valve segment
of the valve segment and spindle for
wear, scratching, grooves, and other
types of damage. All surfaces should
be smooth. Inspect the bearing plate
running surface for flatness and brass
transfer. Excessive brass transfer indicates
bearing plate needs replacement.
Replace valve segment assembly if
E101 338E
necessary.
Endcap Inspect all machined surfaces of the Inspect endcap

endcap for scratches, smearing or pits.
Carefully check the valve segment
cradle bearing surface for wear. Check
bore of loop flushing relief valve and
loop flushing spool. If damaged, replace
endcap.
E101 342E
Housing Inspect the housing to ensure that it is Inspect housing

clean and free of foreign material. Inspect
the endcap mating surface.
E101 344E
Control shuttle Inspect the shuttle valve for damage or Control shuttle
valve contamination. Check that shuttle ball Shuttle ball
moves freely in the housing
P106 693E
11020692 • Rev AF • February 2010 21

Repair Instructions
Inspection
Optional Minimum Inspect the displacement limiter screw Inspect displacement limiter
displacement limiter threads. Check end of screw for damage.
Ensure that the screw is not bent.
Replace the seal nut.
E101 345E
Servo piston Inspect servo piston for wear, scratches, Inspect servo piston
grooves or damage. Replace if necessary. Proportional
Two-position
P101 337E
Control Inspect control housing, spools, and Inspect control - components

solenoids for wear or damage. Replace
components as necessary. Lubricate all
moving parts during reassembly.
P106 253E
22 11020692 • Rev AF • February 2010

Repair Instructions
Assembly
Overview This section describes assembly procedures for the H1 motor. If special tools are needed
for assembly, they appear in this section. After assembly, adjust motor according to
the settings listed on the model code stamped on the serial number plate. Perform
adjustments with motor on an appropriate test stand. Refer to H1 060/080/110 Bent Axis
Motors Service Manual 11024904, for further instructions and adjustments for the H1
motor.
Piston ring assembly 1. If piston rings (H0230) are being replaced, install and lubricate new rings.
Install piston rings
Piston rings are not symmetrical.

Note proper orientation.
H0230
Mark indicates
top of piston ring
P106 526E
11020692 • Rev AF • February 2010 23

Repair Instructions
Assembly
Install shaft in 1. Lubricate bearings and press shaft assembly (H00**) into housing.
housing
2. Lubricate and install new O-ring (G0050A) on shaft locking screw (G0050).
3. Using a 1/8 inch internal hex wrench install shaft locking screw (G0050) and torque
to 8 N•m [6 lbf•ft].
Cartridge model has shaft lock screw (G0055) on top of housing.
Install shaft assembly
P
(H00**)
G0050A
G0050
1/8 inch internal hex
G0010
G0055A Cartridge model has

G0055 shaft lock screw (G0055)
3/16 in on top of housing.
P106 525E
24 11020692 • Rev AF • February 2010

Repair Instructions
Assembly
Synchronizing shaft 1. Position the motor with shaft pointing down.
2. Using petroleum jelly to retain them, install synchronizing shaft rollers (M0013) on
the journals of the synchronizing shaft (M0011). The rollers are symmetrical. You may
install them in either direction on the synchronizing shaft.
3. Position each roller with its outside edge flush to the end of the synchronizing shaft
journal.
4. Install one synchronizing shaft support pin (M0012) into the spring guide of the
motor shaft.
5. Install the synchronizing shaft and rollers into the motor shaft.
You may install either end of the synchronizing shaft into the cylinder block.
6. After installation, tip and rotate the synchronizing shaft in all directions to check for
binding.
Ensure synchronizing shaft rollers move freely in the races of the motor shaft.
Synchronizing shaft
M0012
Install this pin into the
cylinder block M0011
M0013
M0012
P106 544E
11020692 • Rev AF • February 2010 25

Repair Instructions
Assembly
Pistons and cylinder 1. Position the shaft as shown in Shaft alignment - top view
block illustration at right. Position the motor shaft
as shown prior to installing
2. Tip the 3 pistons closest to the the cylinder block
minimum angle stop out, toward the
housing.
3. Tip the 6 remaining pistons forward

toward the lowest part of the end
cap mounting surface.
4. Tip the synchronizing shaft forward

(toward the lowest part of the
endcap mounting surface).
5. Using petroleum jelly to retain it,

install one synchronizing shaft
support pin into the recess in the
P104 103
cylinder block.
(Cylinder block not installed)
6. Position the cylinder block so one of

Refer to page 25 for the synchronizing shaft roller raceways is aligned between the two bottom pistons.
illustration showing
synchronising shaft 7. Install the cylinder block and its support pin on the lower six pistons and
assembly. synchronizing shaft.
The synchronizing shaft rollers enter their races in the cylinder block, while the last two
of the six pistons enter their corresponding bores in the cylinder block.
8. Insert a brass rod through the cylinder block kidneys to guide the pistons into
position.
9. Start with the six (6) pistons closest to the lowest part of the end cap mounting
surface.
The support pin enters its recess in the synchronizing shaft.
10. Lift the cylinder block slightly.
11. Guide the remaining 3 pistons into their bores.
12. After the last piston is in position, check the position of the rollers by trying to turn
the cylinder block. It should not have any free travel. If a roller is not in position,
remove the block and repeat steps 5-12.
13. Maintain an inward force on the cylinder block.
14. Carefully push it toward the highest part of the end cap mounting surface. Tilt the
housing back so the cylinder block remains in place.
15. Hold the cylinder block and turn the shaft in both directions. If you feel any play, one
or more of the rollers are not in place.
26 11020692 • Rev AF • February 2010
Repair Instructions
Assembly
Pistons and cylinder Ensure synchronizing shaft rollers move freely in the races in the motor shaft. If installed
block (continued) correctly there is no free play between cylinder block and shaft.
16. Lubricate the pistons and cylinder block bores liberally with hydraulic fluid.
Hold cylinder block parallel to endcap surface of housing until endcap is installed.
Install bearing plate 1. Install the bearing plate (M0030), with its steel side facing the cylinder block.
2. Lubricate the bronze side of the plate with hydraulic oil.
Install bearing plate
M0030
P106 527E
11020692 • Rev AF • February 2010 27

Repair Instructions
Assembly
Servo piston and

valve segment—
proportional 1. Lubricate and install servo piston (F0020). C
control
2. Lubricate and install setting lug (F0050).
C Caution
Do not allow loose servo 3. Install new pin (F0060). Ensure pin is in groove of setting lug. Using a 5 mm internal
to damage machined hex wrench, install set screw (F0070). Torque to 34 N•m [25 lbf•ft].
surfaces of endcap.
4. Lubricate and install valve segment (QF080). Ensure valve segment spindle properly
sets on setting lug ball. Using a 4 mm internal hex wrench, install hold down screw
(F0090). Torque screw to 8 N•m [6 lbf•ft].
5. Lubricate and install O-ring (P0043) and seal ring (P0044) onto servo piston head
(P0040). Press onto servo piston. Take care not to damage seals.
6. Install screw (P0050). Refer to table for wrench size. Do not torque screw (P0050) until
endcap is installed, see Endcap, page 33).
Install servo piston and valve segment

4 mm
Rear view of
8 Nm [6 lbf•ft]
proportional
F0090 valve segment
do not torque until
valve segment
O-ring is installed
(P0043) (see page 33
Seal ring for torque value)
(P0044)
P0050
Piston head
QF080
P0040
F0050
P0043
P0044
P106 694E
F0020
F0060
F0070
P0050 wrench size
5 mm
Model wrench size 34 N•m
110 10 mm [25 lbf•ft]
060/080 8 mm
P106 725E
28 11020692 • Rev AF • February 2010

Repair Instructions
Assembly
Servo piston and 1. Lubricate and install O-ring (P0043) and seal ring (P0044) onto servo piston.
valve segment—two
position control 2. Lubricate and install servo piston (F0020). CTake care not to damage seals during
installation.
C Caution
Do not allow loose servo 3. Install valve segment (QF080).
to damage machined
surfaces of endcap. Ensure valve segment spindle ball end slides into servo piston hole.
4. Using a 4 mm internal hex wrench, install hold down screw (F0090). Torque screw to
8 N•m [6 lbf•ft].
Install servo piston and valve segment

P0043
P0044
F0020
Rear view of
valve segment
- two position
control
4 mm
F0090
QF080 P106 529E
11020692 • Rev AF • February 2010 29

Repair Instructions
Assembly
Endcap 1. If previously removed, install locator pins (G0040) in housing.
2. Install new gasket (G0070).
3. Install the end cap assembly in position marked during disassembly.
Ensure valve segment spindle engages the bearing in the cylinder block
4. Install screws (F0120).
5. Tighten the screws by hand using sequence shown.
6. When end cap is properly seated, torque screws (F0120) using the sequence shown.
See table for wrench size and torque.
7. Rotate the motor shaft and check for play between the shaft and cylinder block. Any
play indicates that the synchronizing shaft rollers are not installed correctly.
Install Endcap
Endcap torque sequence
5 F0120
8
see table for
wrench size and torque
2 4
3 1
7 6
P106 691E
G0070
G0040
F0120 wrench size and torque

Model Wrench size Torque
110 10 mm 115 N•m [85 lbf•ft] G0040
060 8 mm 66 N•m [49 lbf•ft]
080 8 mm 78 N•m [58 lbf•ft]
P106 528E
30 11020692 • Rev AF • February 2010

Repair Instructions
Assembly
Loop flushing charge 1. Lubricate and install spool (K0010) and springs (K0020) into endcap.
relief valve and
spool 2. Lubricate and install new O-rings (K0030A) on each plug (K0030).
3. Torque both plugs to 67 N•m [49 lbf•ft] using a 24 mm hex wrench.
4. Lubricate and install new O-ring (L0050) onto loop flushing charge relief valve
cartridge (L00**).
5. Using a 24 mm hex wrench, install loop flushing charge relief valve.
6. Torque valve to 67 N•m [39 lb•ft].
Install loop flushing charge relief valve and spool
24 mm
67 N•m [49 lbf•ft]
K0030
K0020
K0030A
K0010
K0020
K0030A
K0030
24 mm
67 N•m [49 lbf•ft]
L0050
L00**
24 mm
67 N•m [49 lbf•ft]
P106 537E
11020692 • Rev AF • February 2010 31

Repair Instructions
Assembly
Shaft seal 1. Lubricate inside diameter of new seal. Cover the shaft splines with shaft cover or
packing tape to avoid damaging the seal during installation.
C If you are not using the
seal installation tool , do 2. Using seal installation tool, press seal into housing bore. C
not press the seal in too far.
Damage to the seal may 3. Using a snap ring pliers, install retaining ring (G0030) into housing bore.
result if the seal rubs on
the shaft assembly when 4 Use seal installation tool to press seal and retaining ring into housing until retaining
the motor is in operation. ring snaps into its groove.
Install shaft seal
G0020
G0030
P106 548E
110 - Seal installation tool dimensions 060/080 - Seal installation tool dimensions
180 mm 150 mm
100 mm [7.09 in] [5.90 in]
100 mm
[3.94 in] [3.94 in]
69 mm 58 mm 56 mm 48 mm 70 mm
82 mm
[2.6 in] [2.3 in] [2.2 in] [1.9 in] [2.76 in]
[3.15 in]
45°
45°
+ 0.10 5 mm
+ 0.10 5 mm 5.4 mm - 0.0 [0.2 in]
5.15 mm - 0.0
[0.2 in] P107 738E [0.21 in + -0.004
0.0 ]
[0.20 in + -0.004
0.0 ]
32 11020692 • Rev AF • February 2010

Repair Instructions
Assembly
Servo cover— 1. Torque servo piston bushing screw (P0050). See table for wrench size and torque.
proportional
control 2. Lubricate and install new O-ring (P0030). Install cover (P0010).
3. Using a 10 mm internal hex wrench, install four screws (P0020). Torque to 115 N•m
[85 lbf•ft].
Install servo bushing cover
(previously installed)
P0050
see table P106 530E
P0030
P0010
P0020
10 mm (4X)
115 N•m [85 lbf•ft]
P0050 wrench size and torque

110 10 mm 115 N•m [85 lbf•ft]
060/080 8 mm 66 N•m [49 lbf•ft]
11020692 • Rev AF • February 2010 33

Repair Instructions
Assembly
Speed sensor 1. Lubricate and install new O-ring (J0010A) on speed sensor or plug (J0010). Install
speed sensor or plug into housing.
2. Using a 5 mm internal hex wrench, torque screw (J0020) to

Install speed sensor
J0020 J0020
J0010
J0010 O
J0010A
J0010A
J0010 J0010 J0010A

J0010A
O
J0020
J0020 P107 833
34 11020692 • Rev AF • February 2010

Repair Instructions
Assembly
Minimum 1. If previously removed, replace Displacement limiter

Displacement limiter displacement limiter screw (N0010)
and locknut (N0020) to original
position.
Refer to H1 060/080/110
Bent Axis Motors Service 2. Hold displacement limiter in place
Manual 11024924 for using a 6 mm internal hex. Install a
displacement limiter new locknut (N0020) using a 19 mm
adjustment procedures. wrench.
3. When motor is properly adjusted

torque locknut to 37 N•m [28 lbf•ft],
and install new cap (N0120).
6 mm
N0010
m
N0120
19 mm
N0020
P107 868E
Maximum Models with maximum displacement Install maximum displacement limiter

displacement limiter limiter: Install spacer (P0200) and screw parts
two-position (P0100). Using a 6 mm internal hex,
controls torque screw to 45 N•m [33 lbf•ft]. P0100
6 mm
P0200
It is not necessary to remove the
maximum displacement limiter unless it
is being replaced.
P107 866E
11020692 • Rev AF • February 2010 35

Repair Instructions
Assembly
Proportional 1. Using a 5 mm internal hex wrench, install shuttle valve assembly (C0025) into side of
control control housing. Torque to 14 N•m [10 lbf•ft].
2. Lubricate and install new O-ring (C0050A) onto plug (C0050). Install plug and torque
Coil O-rings are not to 40 N•m [30 lbf•ft] using a 1/4 in. internal hex wrench.
included in the overhaul
seal kit. They may be 3. Using a 3 mm internal hex wrench, install orifices (E00T2 and E00T3) to both sides of
purchased as a separate kit. housing. Torque to 6 N•m [4 lbf•ft].
4. Lubricate and install new O-rings (C0060A) to all plugs.
5. Using a 1/8 in. internal hex wrench, torque plugs (C0060) to 8 N•m [6 lbf•ft].
6. Lubricate and install valve spool (C0100).
7. Lubricate and install new O-ring (B0035A) and place solenoid (B0010) into place.
8. Using a 4 mm internal hex wrench, install and torque 3 screws (B0050) to

Assemble control
9. If previously removed, install the
B0027
solenoid coil. Replace O-rings (B0025, 26 mm 12-point B0040
B0028, B0029). Install the coil nut 3.5 N•m [2.6 lbf•ft]
(B0027) using a 26mm 12-point
B0029
socket. Torque to 3.5 N•m [2.6 lbf•ft].
Do not overtorque. Install the plastic
cap (B0040). B0028
B0020
B0050 (3x)
4 mm B0025
C0060
B0010
1/8 in B0035A
C0050 C0060A E00T2
1/4 in 3 mm
C0050A
40 N•m 6 N•m
C0025 C0100
[30 lbf•ft] [4 lbf•ft]
5 mm
14 N•m [10 lbf•ft]
B0010
E00T3
3 mm
C0060A
C0060 6 N•m
1/8 in [4 lbf•ft]
8 N•m [6 lbf•ft] C0060A
C0060
P106 521E
1/8 in
36 11020692 • Rev AF • February 2010

Repair Instructions
Assembly
Two position control 1. Lubricate and install new O-rings (B0034) onto solenoids (B0032).
2. Using a 17 mm hex wrench on the flats, install solenoids (B0032) and torque to
Refer to H1 Motors Service 40 N•m [30 lbf•ft] .
Manual 11024924 for
pressure compensator 3. Install coils (B0022) with new O-rings (B0024, B0028).
adjustment procedures.
4. Using a 26 mm 12-point socket, install coil nuts (B0026). Torque to 3.5 N•m [2.6 lbf•ft].
Do not overtorque.
included in the overhaul 5. Lubricate and install four O-rings (C0060A) onto plugs (C0060). Using a 1/8 inch
seal kit. They are included internal hex wrench, install plugs and torque to 8 N•m [6 lbf•ft].
with the purchase of a new
coil. 6. Lubricate and install spools (C0020) and (C0070) and springs (C0080) and (C0030).
7. Lubricate and install O-ring (M223) onto adjusting plug (C0090). Install pressure
compensator adjusting plug. Torque to 25 N•m [18 lbf•ft].
8. Lubricate and install two O-rings (C0050A) onto plugs (C0050). Using a 1/4 inch
internal hex wrench, install plugs and torque to 40 N•m [30 lbf•ft].
9. If previously removed, install orifices (E00T3 and E00T2). Torque to 6 N•m [4 lbf•ft].
Assemble two position control - T*D* or P*D*

B0026
B0028
B0022
B0024
17 mm
B0032 40 N•m [30 lbf•ft]
B0026 B0034
B0028 B0024
B0022 C0050
1/4 in
40 N•m [30 lbf•ft]
B0032
17 mm C0050A
40 N•m [30 lbf•ft] C0060
B0034 1/8 in 8 N•m [6 lbf•ft]
C0060A C0060A
C0060
C0060
1/8 in
8 N•m [6 lbf•ft] 1/8 in 8 N•m [6 lbf•ft]
C0060A C0070
C0060 C0080
1/8 in M223
8 N•m [6 lbf•ft] E00T3
C0020 C0090
3 mm 17 mm
E00T2
6 N•m 3 mm C0030
[4 lbf•ft] 6 N•m 25 N•m
[4 lbf•ft] C0050A [18 lbf•ft]
C0050
1/4 in
40 N•m [30 lbf•ft] P106 721E
11020692 • Rev AF • February 2010 37

Repair Instructions
Assembly
Install control 1. Install new gasket (C0130).
Proportional control only - Install spring (F0040) and spring guide (F0030).
2. Install control housing (C0010).
Proportional controls
3. Using a 6 mm internal hex wrench, install and torque screws (C0110) to 37 N•m
[28 lbf•ft].
Two-position controls
3. Using a 10 mm internal hex wrench, install screws (C0110 and C0120). Torque to
115 N•m [85 lbf•ft].
Install control
C0120 (2X)
10 mm
115 N•m
[85 lbf•ft]
C0110 (4X) C0110 (2X)
C0010 6 mm 10 mm
Proportional
37 N•m [28 lbf•ft] 115 N•m [85 lbf•ft]
control C0010
F0030 2 position
control
F0040
C0130
C0130
Proportional control Two position control P106 532E
38 11020692 • Rev AF • February 2010

Repair Instructions
Startup procedures
Overview Install motor on test stand. Adjust per Sauer-Danfoss testing specifications TS-396. Refer
to H1 Bent Axis Motors Service Manual 11024924 for start-up procedures, adjustments,
and pressure measurements for H1 motor.
Initial startup Startup procedures include:

procedures • Ensure system components are clean
• Install new filters
• Fill system with fluid
• Disable engine
• Disconnect control
• Crank engine and check for adequate charge pressure
• Check for proper control function
Adjustments Adjustment procedures include:

• Displacement limiter adjustment
• Electronic displacement control (EDC) threshold adjustment
• PCOR adjustment
Pressure Pressure measurement procedures include:

measurements • Required tools
• Port locations
• Gauge installation
• Leakage test per Sauer-Danfoss test HPP 112
11020692 • Rev AF • February 2010 39

Repair Instructions
Port locations
Port locations and The following table and drawing show the port locations and gauge sizes needed.
gauge installation
Port Information
060 080 110 Pressure Gauge size,
Port identifier
Port size Wrench size Port size Wrench size Port size Wrench size obtained bar [psi]
L1, L2 7/8-14 UNF 3/8 internal hex 7/8-14 UNF 3/8 internal hex 1 1/16 - 12UN 9/16 internal hex Case drain 10 [100]
MA, MB 7/8-14 UNF 3/8 internal hex 1 1/16 - 12UN 9/16 internal hex 1 1/16 - 12UN 9/16 internal hex System 600 [10,000]
(Radial endcap) pressure
MA, MB 9/16-18 UNF 1/4 internal hex 9/16-18 UNF 1/4 internal hex 9/16-18 UNF 1/4 internal hex System 600 [10,000]
(Axial endcap) pressure
M4 9/16-18 UNF 1/4 internal hex 9/16-18 UNF 1/4 internal hex 9/16-18 UNF 1/4 internal hex Servo pressure 600 [10,000]
rod end
piston end
System Ports
060 080, 110
Port identifier
Split flange boss, thread M12 x 1.75 Split flange boss, thread M10 x 1.5
A 3/4 inch code 62 per ISO 6162, min. thread 18mm [0.71 in] 1 inch code 62 per ISO 6162, min. thread 23mm [0.91 in]
B 3/4 inch code 62 per ISO 6162, min. thread 18mm [0.71 in] 1 inch code 62 per ISO 6162, min. thread 23mm [0.91 in]
Port locations - radial ported endcap shown
M5
(M4 on reverse side)
L1
System Port A
(System Port B
on reverse side)
MA MB
L2
Radial ported endcap
M5
MA
(MB on reverse side)
System System
Port A Port B
L2
Axial ported endcap P106 623E
40 11020692 • Rev AF • February 2010

Repair Instructions
Torque chart
Fasteners and plugs Port/fastener and plug locations and sizes

P0020
L00**
J0020 M5
L2 F0100
G0060
F0120
MB System Port A
F0150
MA
F0150
K0030
F0120
C0060
G0050 B0050
C0110 and C0120 G0060
L1
N0010 N0020
Radial ported endcap P106 622E
Fastener size and Item Fastener Wrench size Torque

torque chart P0020 Servo piston cover screws 10 mm internal hex wrench 115 N•m [85 lbf•ft]
F0120 (110) Endcap screws 10 mm internal hex wrench 115 N•m [85 lbf•ft]
C0110 (proportional) Control assembly screws 6 mm internal hex wrench 37 N•m [28 lbf•ft]
C0110 and C0120 Control assembly screws 10 mm internal hex wrench 115 N•m [85 lbf•ft]
(two position)
B0050 Solenoid screws 4 mm internal hex wrench 6 N•m [4 lbf•ft]
L00** Loop flushing charge relief 24 mm hex 67 Nm [49 lbf•ft]
J0020 Speed sensor screw 5 mm internal hex wrench 8 N•m [6 lbf•ft]
N0010 Displacement limiter screw 6 mm internal hex wrench N/A
N0020 Displacement limiter locknut 19 mm hex 45 N•m [33 lbf•ft]
Plug size and torque Item O-ring plug Wrench size Torque
chart F0100 9/16 - 18UNF 1/4 in. internal hex wrench 40 N•m [30 lbf•ft]
G0050 5/16 - 24UNF (SAE and DIN flange) 1/8 in. internal hex wrench 8 N•m [6 lbf•ft]
G0055 7/16 - 20UNF (Cartridge) 3/16 in. internal hex wrench 8 N•m [6 lbf•ft]
(cartridge model
only) (not shown)
G0060 1-1/16 - 12 3/8 in. internal hex wrench 70 N•m [52 lbf•lb]
L00** M18 - 1.5 24 mm hex wrench 67 N•m [49 lbf•ft]
K0030 M18 - 1.5 24 mm hex wrench 67 N•m [49 lbf•ft]
C0060 5/16 - 24UNF 1/8 internal hex wrench 8 N•m [6 lbf•ft]
F0150 1-1/16 - 12 UN 3/8 internal hex wrench 115 N•m [85 lbf•ft]
Radial endcap
F0160 9/16-18 UNF 1/4 internal hex wrench 40 N•m [30 lbf•ft]
Axial endcap
C0050 (not shown) 9/16-18 UNF 1/4 internal hex wrench 40 N•m [30 lbf•ft]
11020692 • Rev AF • February 2010 41

Repair Instructions
Notes
42 11020692 • Rev AF • February 2010

Repair Instructions
Notes
11020692 • Rev AF • February 2010 43

Our Products Sauer-Danfoss Mobile Power and Control Systems
– Market Leaders Worldwide
Open circuit axial piston pumps
Sauer-Danfoss is a comprehensive supplier providing complete
Gear pumps and motors systems to the global mobile market.
Fan drive systems
Sauer-Danfoss serves markets such as agriculture, construction, road
Closed circuit axial piston pumps building, material handling, municipal, forestry, turf care, and many
and motors others.
Bent axis motors
We offer our customers optimum solutions for their needs and
Hydrostatic transmissions develop new products and systems in close cooperation and
partnership with them.
Transit mixer drives
Hydrostatic transaxles Sauer-Danfoss specializes in integrating a full range of system
components to provide vehicle designers with the most advanced
Electrohydraulics
total system design.
Integrated systems
Sauer-Danfoss provides comprehensive worldwide service for its
Microcontrollers and software
products through an extensive network of Global Service Partners
PLUS+1™ GUIDE strategically located in all parts of the world.
Displays
Joysticks and control handles Local address:
Sensors
Orbital motors
Inverters
Electrohydraulic power steering
Hydraulic power steering
Hydraulic integrated circuits (HIC)
Cartridge valves 2800 East 13th Street DK-6430 Nordborg, Denmark
Ames, IA 50010, USA Phone: +45 7488 4444
Directional spool valves Phone: +1 515 239-6000 Fax: +45 7488 4400
Fax: +1 515 239-6618
Proportional valves Sauer-Danfoss-Daikin LTD
Sauer-Danfoss GmbH & Co. OHG Shin-Osaka TERASAKI 3rd Bldg.6F
Postfach 2460, D-24531 Neumünster 1-5-28 Nishimiyahara, Yodogawa-ku,
Krokamp 35, D-24539 Neumünster, Germany Osaka 532-0004, Japan
Phone: +49 4321 871-0 Phone: +81 6 6395 6066
Fax: +49 4321 871 122 Fax: +81 6 6395 8585
11020692 • Rev AF • February 2010
A.F Service - Manual, H1 060/080/110

H1 060/080/110
Bent Axis
Motors
Service Manual
Service Manual
Revisions
Revision history Table of Revisions

February 2010 last Fix Osaka address AH

August 2009 various Minor corrections AG
July 2009 11, 12, 15, 18 Updates to 060 technical specifications AF
July 2009 35, 36 Coil O-rings are available with the purchase of a new coil AE
April 2009 various added 060 frame size AD
January 2009 33 2 position bolt torques are 115 Nm [85 lbf•ft] AC
December 2008 various added 080 frame size AB
Oct 2008 - First edition AA

2 11024924 • Rev AF • February 2010

Service Manual
Contents
Warranty............................................................................................................................................................. 5
Safety precautions.......................................................................................................................................... 6
Personal safety............................................................................................................................................ 6
Hazardous material................................................................................................................................... 6
Symbols used in Sauer-Danfoss literature.............................................................................................. 7
General information Design................................................................................................................................................................. 8

Overview..........................................................................................................................................................10
System diagram.............................................................................................................................................11
H1P pump and H1 motor with electric proportional control..................................................11
System schematic..........................................................................................................................................12
Operation Shaft rotation direction...............................................................................................................................13

Loop flushing shuttle spool.......................................................................................................................14
Loop flushing relief valve...........................................................................................................................14
Speed sensor...................................................................................................................................................15
Speed sensor connector........................................................................................................................15
Sensor position.........................................................................................................................................15
Target ring..................................................................................................................................................15
Minimum displacement limiter..........................................................................................................15
Operating Overview..........................................................................................................................................................16
parameters Output speed..................................................................................................................................................16
Start speed and low speed stability..................................................................................................16
System pressure.............................................................................................................................................16
Case pressure..................................................................................................................................................17
External shaft seal pressure.......................................................................................................................17
Temperature and viscosity.........................................................................................................................17
Temperature..............................................................................................................................................17
Viscosity......................................................................................................................................................17
Technical Technical specifications..............................................................................................................................18

specifications General specifications............................................................................................................................18
Physical properties..................................................................................................................................18
Operating parameters............................................................................................................................19
Fluid specifications..................................................................................................................................19
Fluid and filter Fluid and filter recommendations...........................................................................................................20

maintenance
11024924 • Rev AF • February 2010 3

Service Manual
Contents
Pressure Port locations and gauge installation....................................................................................................21

measurements
Initial startup Procedure.........................................................................................................................................................22

procedures
Troubleshooting Overview..........................................................................................................................................................24
Electrical troubleshooting..........................................................................................................................24
Sluggish operation.......................................................................................................................................24
System operating hot..................................................................................................................................25
Excessive noise or vibration.......................................................................................................................25
Motor operates normally in one direction only.................................................................................25
Improper output speed..............................................................................................................................26
Low output torque........................................................................................................................................26
Required tools and Required tools................................................................................................................................................27

standard procedures Standard procedures...................................................................................................................................27
Adjustments Displacement limiter....................................................................................................................................28

Adjusting the minimum displacement limiter..............................................................................28
Optional threshold adjustment - proportional controls.................................................................29
Adjusting threshold on test stand.....................................................................................................29
Adjusting threshold on a machine or test stand without flow meter..................................29
Pressure Compensator OverRide (PCOR) adjustment......................................................................30
PCOR adjustment for T1/T2 controls.................................................................................................30
Brake pressure defeat option..............................................................................................................30
PCOR adjustment for P1/P2 controls................................................................................................30
Minor repair Shaft seal..........................................................................................................................................................31

Solenoid replacement.................................................................................................................................32
Control module replacement...................................................................................................................33
Proportional control module....................................................................................................................34
Two-position control module...................................................................................................................36
Maximum displacement limiter - two-position control..................................................................37
Servo piston cover – proportional control...........................................................................................38
Replace speed sensor..................................................................................................................................39
Loop flushing spool......................................................................................................................................40
Loop flushing charge relief valve.............................................................................................................41
Minimum displacement limiter................................................................................................................42
Torque chart Fasteners and plugs......................................................................................................................................43

Fastener size and torque chart.................................................................................................................43
Plug size and torque chart.........................................................................................................................43
4 11024924 • Rev AF • February 2010

Service Manual
Introduction
Overview This manual includes information for the installation, maintenance, and minor repair
of the H1 bent-axis motor. It includes a description of the unit and its individual
components, troubleshooting information, and minor repair procedures.
Performing minor repairs may require removal from the vehicle/machine. Thoroughly
clean the unit before beginning maintenance or repair activities. Since dirt and
contamination are the greatest enemies of any type of hydraulic equipment, follow
cleanliness requirements strictly. This is especially important when changing the system
filter and when removing hoses or plumbing.
A worldwide network of Sauer-Danfoss Global Service Partners is available for major

repair. Sauer-Danfoss trains and certifies Global Service Partners on a regular basis. You
can locate your nearest Global Service Partner using the distributor locator at
www.sauer-danfoss.com. Click on the Sales and Service link.
Warranty Performing installation, maintenance, and minor repairs according to the procedures in
this manual will not affect your warranty. Major repairs requiring the removal of a unit’s
rear cover voids the warranty unless done by a Sauer-Danfoss Global Service Partner.
motors.
w Remove the unit

Chock the wheels on the vehicle or lock the mechanism to inhibit movement. Prior to
performing repairs, remove the unit from the vehicle/machine. Be aware that hydraulic
fluid may be under high pressure and/or hot. Inspect the outside of the motor and
fittings for damage. Cap hoses after removal to prevent contamination.
e Keep it clean
Cleanliness is a primary means of assuring satisfactory motor life, on either new or
repaired units. Clean the outside of the motor thoroughly before disassembly. Take care
to avoid contamination of the system ports. Cleaning parts with a clean solvent wash
Keep all parts free of foreign materials and chemicals. Protect all exposed sealing
surfaces and open cavities from damage and foreign material. If left unattended, cover
the motor with a protective layer of plastic.

Sauer-Danfoss recommends you replace all O-rings and gaskets during repair. Lightly
lubricate O-rings with clean petroleum jelly prior to assembly.
t Secure the unit

For repair, place the unit in a stable position with the shaft pointing downward. Secure
the motor while removing and torquing components and fasteners.
11024924 • Rev AF • February 2010 5

Service Manual
Introduction
Safety precautions Always consider safety precautions before beginning a service procedure. Protect
yourself and others from injury. Take the following general precautions whenever servicing a
hydraulic system.

W Warning

W Warning

W Warning
Personal safety
W Warning
times.
Hazardous material
W Warning
Hydraulic fluid contains hazardous material. Avoid prolonged contact with hydraulic
fluid. Always dispose of used hydraulic fluid according to environmental regulations.
6 11024924 • Rev AF • February 2010

Service Manual
Introduction
Symbols used in  WARNING may result in injury  Internal hex head

Sauer-Danfoss
literature  CAUTION may result in damage to  Lubricate with hydraulic fluid
product or property
 Clean area or part
 Non-reusable part, use a new part
 Mark orientation for reinstallation
 Option – either part may exist
 Torque specification
 External hex head
 Cover splines with installation
sleeve
11024924 • Rev AF • February 2010 7

Service Manual
General information
Design Cross section H1 with electric proportional control
Differential
servo piston
Loop flushing
relief valve
Valve segment
Bearing plate
Tapered
roller bearing
Ramp spring
Loop flushing
shuttle spool
Speed ring (optional )
Minimum displacement limiter
Electric proportional co ntrol

P003 421E
8 11024924 • Rev AF • February 2010

Service Manual
General information
Design Cross section H1 electric two-position control
Electric two- position control
Loop flushing Differential

shuttle spool servo piston
Valve segment
Loop flushing
relief valve Bearing plate
Tapered
roller bearing
Speed ring (optional )

P003 422E
11024924 • Rev AF • February 2010 9

Service Manual
General information
Overview H1 variable displacement motors follow the bent-axis design using spherical pistons.
These motors function primarily with other products in closed-circuit systems to transfer
and control hydraulic power. H1 motors have a large displacement ratio of 5:1 and high
output speed capabilities. Zero-degree capability enables anti-slip and wheel-assist
systems. SAE, cartridge, and DIN flange configurations with radial or axial high pressure
ports and integral loop-flushing are also available.
H1’s complete family of controls and regulators suit a wide range of applications. All
controls use internally-supplied servo pressure. A Pressure Compensator OverRide
(PCOR) feature is available to override the control increasing displacement at a set
pressure threshold. The PCOR is available with a Brake Pressure Defeat (BPD) option to
disable it during dynamic braking. The pressure compensator features a low pressure rise
to ensure optimal power usage throughout the entire displacement range of the motor.
Speed sensor options are available for all frame sizes and flange styles. They can sense
speed, direction, and temperature; all in one compact package.
All H1 electric controls are PLUS+1™ compliant. They are designed specifically to
integrate with Sauer-Danfoss PLUS+1 microcontrollers for easy Plug-and-Perform™
installation.
10 11024924 • Rev AF • February 2010

System diagram
Heat Exchanger
Bypass Valve
Reservoir
Heat Exchanger
Electric
Displacement
Control
Service Manual
Charge Check/ Loop

Servo Cylinder Pressure Limiter High Pressure Flushing Bent Axis Variable
11024924 • Rev AF • February 2010

General information
Valve Relief Valve Valve Displacement Motor
Pump
Swashplate
Output
Shaft
Charge Pressure
Filter
To
Motor
Case
Charge Check/
High Pressure Valve
Relief Valve Segment
H1 pump and H1 motor with electric proportional control
Input Charge
Shaft Pump
Charge
Pressure
Variable Relief
Displacement Valve
Pump Pressure Limiter Valve
Working Loop B Case Working Loop A (Low Pressure) Servo

Suction P003 423E
(High Pressure) Drain and Charge Pressure Pressure
11
Service Manual
General information
System schematic
M14 M6 1 2
R1
R2
C2 C1
M3 L1 L2 MA L2 MA N
A A
F00B F00A
M5
CW
max. min.
L1
M4 B B
S L3 L4 MB M4 M5 MB
max. 3 bar
[43.5 psi]
P003 424E
This schematic shows the function of a hydrostatic transmission using an H1P axial
variable displacement pump with electric proportional displacement control (EDC) and
an H1 bent axis variable displacement motor with electric proportional control (L*) and
integrated loop flushing device.
12 11024924 • Rev AF • February 2010

Service Manual
Operation
Shaft rotation Shaft rotation direction is determined by viewing the shaft end. Rotation direction of the
direction motor is dependent on the control option as the drawing and table below illustrate.
Control Option L
CCW CW
Port B Port A
Control Option M and K
CCW CW
Port A Port B
Control Option E, P, and T
CCW CW
Port A Port B
P003488
Position of control Flow into port Direction of rotation

A CW
Control options L*
B CCW
A CCW
Control options M*, K*, E*, P* and T*
B CW
11024924 • Rev AF • February 2010 13

Service Manual
Operation
Loop flushing An integral loop flushing shuttle spool resolves low loop pressure and connects it to the
shuttle spool loop flushing relief valve. The spool operates on delta pressure in the working loop.
L2
A
System System
loop A loop B
B
to Loop flushing P003 437
relief valve P003 490E
L2
Loop flushing relief An orificed loop flushing relief valve A
valve controls the volume of fluid flushed from
the working loop. Valves are available
with several orifice sizes to meet varying
flow requirements. All valves have a
cracking pressure of 16 bar [232 psi].
P003 491
B
P003 487
Loop flushing relief valve
Loop Flushing Relief Valve Size

05 10 15
Low System Pressure minus Case Pressure
40 [580]
30 [435]
bar [psi]
20 [290]
10 [145]
0 10 20 30 40 50 60 70
[1.3] [5.3] [8.0] [10.6] [13.3] [15.9] [18.6]
Loop Flushing Flow l/min [US gal/min]
P003494E
14 11024924 • Rev AF • February 2010

Service Manual
Operation
Speed sensor An optional speed sensor is available. It is capable of measuring speed, direction of
rotation, and case oil temperature. The temperature sensor can not be used for dynamic
measurement, however, it is excellent for diagnostics. The sensor requires no adjustment.
Speed sensor technical data

Feature Min. Nom. Max. Units
Supply 4.75 5.00 5.25 Vdc
Supply protection - - 30 Vdc
Max. required 25 mA
supply current
Output mode NPN & PNP
Connector Deutsch DTM-Series 6-pin DTM 04 - 6P
4 5 6 Sensor Pinout
1 Signal 2
2 Direction
Connector terminals 3 Signal 1
4 Supply
5 Ground
P107 858E 6 Temperature
3 2 1
IP 67 and IP 69k according

Protection code IP-class
IEC 60529 & DIN 40050
Speed sensor connector

Description Quantity Ordering number
Mating connector Deutsch DTM06-6P 1 11033865
Sensor position
SAE and DIN housing Cartridge housing
P003489
P003450
Minimum Displacement Limiter
Target ring
Target ring - frame size 060 080 110
Number of teeth 71 78 86

H1 motors incorporate mechanical displacement limiters. The minimum displacement of
the motor is adjusted at the factory. A tamper-proof cap is provided.
11024924 • Rev AF • February 2010 15

Service Manual
Operating parameters
Overview This section defines the operating parameters and limitations for H1 motors for output
speeds, fluid pressures, temperature, and viscosity. For actual parameters, refer to
Technical specifications, page 18.
Output speed Start speed and low speed stability

The motor produces maximum starting torque at maximum displacement. It achieves
smooth operation at 15-25 min-1 (rpm) ± 5 %, depending on system pressure, in
applications that require low speed stability. Motor output becomes smoother as speed
increases.
Rated speed is the highest output speed recommended at full power condition.
Operating at or below this speed will yield satisfactory product life.
Maximum speed is the highest operating speed permitted. Exceeding maximum speed
reduces the product life and can cause loss of hydrostatic power and dynamic braking
capacity. Never exceed the maximum speed limit under any operation conditions.
Limit operating between rated speed and maximum speed to short time periods. For
most drive systems, maximum unit speed occurs when the motor is in an overrunning
condition, such as downhill, dynamic braking, or negative power conditions.
For applications outside rated speed limits, please contact your Sauer-Danfoss
representative.
W Warning
Unintended vehicle or machine movement hazard.
Exceeding maximum speed may cause a loss of hydrostatic driveline power and dynamic
braking capacity. You must provide a braking system, redundant to the hydrostatic
transmission, sufficient to stop and hold the vehicle or machine in the event of
hydrostatic drive power loss.
System pressure System pressure is the differential pressure between system ports. It is the dominant
operating variable affecting hydraulic unit life. High system pressure, which results from
high load, reduces expected life. Hydraulic unit life depends on the speed and normal
operating—or weighted average—pressure that can only be determined from a duty
cycle analysis.
Application pressure is the high pressure relief or pressure limiter setting normally
defined within the order code of the pump. This is the applied system pressure at which
the driveline generates the maximum calculated pull or torque in the application.
Maximum working pressure is the highest recommended application pressure.

Maximum working pressure is not intended to be a continuous pressure. Propel systems
with application pressures at, or below, this pressure should yield satisfactory unit life
given proper component sizing.
Maximum pressure is the highest allowable application pressure under any

circumstance. For applications operating above the maximum working pressure, please
contact your Sauer-Danfoss representative.
16 11024924 • Rev AF • February 2010

Service Manual
System pressure All pressure limits are differential pressures referenced to low loop (charge) pressure.
(continued) Subtract low loop pressure from high loop gauge readings to compute the differential.
You must maintain minimum pressure under all operating conditions to avoid
cavitation.
Summing pressure is the sum of both the low and high loop pressures.
Servo pressure is the pressure in the servo system and is supplied from the high side of
the loop to keep the motor at the required displacement.
Under normal operating conditions case pressure must not exceed its rated limit. During
Case pressure cold start, case pressure must remain below maximum intermittent case pressure. Size
drain plumbing accordingly.
CCaution
Possible component damage or leakage.
Operation with case pressure in excess of stated limits may damage seals, gaskets, and/
or housings, causing external leakage. This may also affect performance since charge and
system pressure is referenced to case pressure.
In certain applications, the output shaft seal may be exposed to external pressures. The
External shaft seal shaft seal is designed to withstand an external pressure up to 0.25 bar [3.6 psi] above
pressure the case pressure. The case pressure must also remain within limits to prevent shaft seal
damage.
Temperature
Temperature and The high temperature limits apply at the hottest point in the transmission, which is
viscosity normally the motor case drain. The system should generally be run at or below the
published rated temperature.
The maximum intermittent temperature is based on material properties. Never exceed it.
The minimum temperature relates to the physical properties of component materials.

Cold oil will generally not affect the durability of the transmission components, but
low temperature may affect the ability of oil to flow and transmit power. Therefore,
temperatures should remain 16 °C [30 °F] above the pour point of the hydraulic fluid.
Size heat exchangers too keep the fluid within prescribed limits. Sauer-Danfoss
recommends testing to verify that these temperature limits are not exceeded.
Viscosity
For maximum efficiency and bearing life, ensure that the fluid viscosity remains in the
recommended range.
The motor should encounter minimum viscosity only during brief periods of maximum
ambient temperature and severe duty cycle operation. The motor should encounter
maximum viscosity only at cold start.
11024924 • Rev AF • February 2010 17

Service Manual
Technical specifications
Technical General specifications

specifications Design Axial piston motor with variable displacement bent axis design
Direction of rotation Bi-directional
Pipe connections Main pressure ports: ISO split flange boss
Remaining ports: SAE straight thread O-ring boss
Recommended installation position Discretionary: The housing must always be filled with hydraulic fluid
Physical properties
Feature Unit Frame size
060 080 110
Displacement maximum cm3 [in3] 60 [3.66] 80 [4.88] 110 [6.71]
Displacement minimum cm3 [in3] 12 [0.73] 16 [0.98] 22 [1.34]
Flow at rated speed (theoretical) l/min [US gal/min] 216 [57] 256 [67] 319 [84]
Flow at maximum speed (theoretical) l/min [US gal/min] 270 [71] 328 [86] 407 [107]
Torque at maximum displacements N•m/bar 0.95 [583] 1.28 [784] 1.75 [1064]
(theoretical) [lbf•in/1000 psi]
Theoretical corner power at rated kW [hp] 266 [356] 306 [410] 396 [531]
speed an maximum working
pressure (Dp=450 bar [6527 psi])
Mass moment of inertia of rotating kg•m2 [slug•ft2] 0.0042 [0.0031] 0.0064 [0.0047] 0.0114 [0.0084]
components
Weight dry with electric
proportional control
SAE configuration kg [lb] 29.8 [65.8] 34.9 [76.9] 48.8 [107.8]
DIN configuration kg [lb] 28.3 [62.5] 34.4 [76.0] 45.0 [99.4]
Cartridge configuration kg [lb] 26.9 58.4] 33.0 [72.8] 41.8 [92.3]
Case volume liter [US gal] 0.9 [0.24] 1.0 [0.26] 1.4 [0.37]
Mounting flange
SAE configuration Flange 127-4 (SAE C) Flange 152-4 (SAE D)
DIN configuration Flange 125 B4 HL 4-bolt Flange 140 B4 HL 4-bolt Flange 160 B4 HL 4-bolt
Cartridge configuration pilot dia. 160 mm 2-bolt pilot dia. 190 mm 2-bolt pilot dia. 200 mm 2-bolt
(200 dist.) M16 (224 dist.) M20 (250 dist.) M20
Main port configuration
Radial split flange boss DN19 typ. I 40Mpa series DN25 Typ I 40Mpa Series ISO 6162
ISO 6162
Axial SAE O-ring boss 0.875-14UN-2B 1.0625-12UN-2B [1 1/16 12UN-2B]
(Gauge port) [7/8 14UN- 2B]
Axial split flange boss DN19 typ. I 40Mpa series DN25 Typ I 40Mpa Series ISO 6162
ISO 6162
Gauge port SAE O-ring boss 0.5625-18UNF-2B [9/16-18UNF-2B]
Case drain ports SAE O-ring boss 0.875-14UN-2B [7/8 14UN-2B] 1.0625-12UN-2B
[1 1/16 12UN-2B]
Gauge ports SAE O-ring boss 0.5625-18UNF-2B [9/16-18UNF-2B]
Customer interface threads See installation Metric fastener
drawings in
Technical
Information
Manual
18 11024924 • Rev AF • February 2010

Service Manual
Technical specifications
Technical
specifications
(continued)
Feature Units Frame size
060 080 110
Maximum displacement 32° 3600 3200 2900
Rated Minimum displacement 6° 5900 5100 4800
Output speed zero displacement 0° min-1 (rpm) 6600 5500 5350
Maximum displacement 32° 4500 4100 3700
Maximum Minimum displacement 6° 7000 6350 5950
zero displacement 0° 7600 6750 6500
Max. working pressure 450 [6527]
System pressure Maximum pressure bar [psi] 480 [6960]
Minimum pressure 7.5 [109]
Rated 3 [44]
Case pressure Maximum bar [psi] 5 [73]
Minimum 0.3 [4]
Fluid specifications
Feature Units
Minimum 7 [49]
mm2/sec
Viscosity Recommended range 12-80 [66-370]
[SUS]
Maximum 1600 [7500]
Minimum -40 [-40]
Temperature
Recommended range °C [°F] 104 [220]
Range 1)
Maximum 115 [240]
Cleanliness per ISO 4406 22/18/13
Filtration Efficiency (charge pressure filtration) b15-20=75 (b10≥10)
b-ratio
(recommended minimum) Efficiency (suction and return line filtration) b35-45=75 (b10≥2)
Recommended inlet screen mesh size mm 100-125
1)
At the hottest point, normally case drain port.
11024924 • Rev AF • February 2010 19

Service Manual
Fluid and filter maintenance
Fluid and filter To ensure optimum life, perform regular maintenance of the fluid and filter.
recommendations Contaminated fluid is the main cause of unit failure. Take care to maintain fluid
cleanliness when servicing.
Check the reservoir daily for proper fluid level, the presence of water, and rancid fluid
odor. Fluid contaminated by water may appear cloudy or milky or free water may
settle in the bottom of the reservoir. Rancid odor indicates the fluid has been exposed
to excessive heat. Change the fluid immediately if these conditions occur. Correct the
problem immediately.
Inspect vehicle for leaks daily.

Fluid and filter change interval
Change the fluid and filter per the Reservoir type Max oil change interval
vehicle/machine manufacturer’s Sealed 2000 hours
recommendations or at these intervals. Breather 500 hours
We recommend first fluid change occur
at 500 hours of operation. Change the
fluid more frequently if it becomes contaminated with foreign matter (dirt, water, grease,
etc) or if the fluid is subjected to temperature levels greater than the recommended
maximum.
CCaution
High temperatures and pressures accelerate fluid aging. This may require more frequent
fluid changes.
Change filters when changing fluid or when the filter indicator directs. Replace all fluid
lost during filter change
W Warning
dispose of used hydraulic fluid according to state, and federal environmental regulations.
Never reuse hydraulic fluid.
20 11024924 • Rev AF • February 2010

Service Manual
Pressure measurements
Port locations and The following table and drawing show the port locations and gauge sizes needed.
gauge installation
Port Information
060 080 110 Pressure Gauge size,
Port identifier
Port size Wrench size Port size Wrench size Port size Wrench size obtained bar [psi]
L1, L2 7/8-14 UNF 3/8 internal hex 7/8-14 UNF 3/8 internal hex 1 1/16 - 12UN 9/16 internal hex Case drain 10 [100]
MA, MB 7/8-14 UNF 3/8 internal hex 1 1/16 - 12UN 9/16 internal hex 1 1/16 - 12UN 9/16 internal hex System 600 [10,000]
(Radial endcap) pressure
MA, MB 9/16-18 UNF 1/4 internal hex 9/16-18 UNF 1/4 internal hex 9/16-18 UNF 1/4 internal hex System 600 [10,000]
(Axial endcap) pressure
rod end
piston end
System Ports
060 080, 110
Port identifier
Split flange boss, thread M12 x 1.75 Split flange boss, thread M10 x 1.5
A 3/4 inch code 62 per ISO 6162, min. thread 18mm [0.71 in] 1 inch code 62 per ISO 6162, min. thread 23mm [0.91 in]
B 3/4 inch code 62 per ISO 6162, min. thread 18mm [0.71 in] 1 inch code 62 per ISO 6162, min. thread 23mm [0.91 in]
Port locations - radial ported endcap shown
M5
L1
System Port A
(System Port B
on reverse side)
MA MB
L2
Radial ported endcap
M5
MA
(MB on reverse side)
System System
Port A Port B
L2
Axial ported endcap P106 623E
11024924 • Rev AF • February 2010 21

Service Manual
Initial startup procedures
Procedure Always follow this procedure when starting-up a new H1 installation or when the motor
has been removed.
 Warning 1. Before installing the motor, inspect the units for possible damage incurred during
This service procedure shipping and handling.
may require disabling
the vehicle / machine 2. Make certain all system components (reservoir, hoses, valves, fittings, heat exchanger,
(raising the wheels off the and so forth) are clean before filling with fluid.
ground, disconnecting
work function) while 3. Fill the reservoir with recommended hydraulic fluid. Pass this fluid through a 10
performing, to prevent micron (nominal, no bypass) filter before it enters the reservoir.
injury to the technician
and bystanders. Take 4. Fill the inlet line leading from the reservoir to the pump.
the necessary safety
precautions. 5. Check inlet line for properly tightened fittings. Make sure the inlet line is free of
restrictions and air leaks.
6. Fill the motor and pump housings with clean hydraulic fluid before start up. Fill by
pouring filtered oil into the upper case drain port.
 Caution
Never start the prime mover unless the motor and pump housings are filled completely
with clean hydraulic fluid.
7. For closed loop systems, install a 0-60 bar [0-1000 psi] pressure gauge in the charge
pressure gauge port of the pump to monitor the charge pressure during start-up.
For open circuit systems, use gauges in system ports.
8. Disconnect any external control input signal from the pump control until after initial
start-up. This ensures that the pump remains in its neutral position.
9. Jog (slowly rotate) prime mover until charge pressure starts to rise.
10. Start the prime mover and run at the lowest possible speed until charge pressure
builds. 
 Warning
Do not start the prime If necessary, bleed excess air from the high pressure lines through the high pressure
mover unless the pump is system gauge ports.
in neutral position (swash
plate at 0° angle). Take 11. Once charge pressure is established, increase to normal operating speed. Charge
necessary precautions pressure should be as indicated in the pump model code. If charge pressure is low,
to prevent machine shut down and determine cause.
movement in case pump is
actuated (in stroke) during  Caution
initial start-up. Low charge pressure may affect ability to control the machine.
22 11024924 • Rev AF • February 2010

Service Manual
Initial startup procedures
Procedure (continued) 12. Shut down the prime mover.
13. Connect the external control input signal.
14. Reconnect the machine function if disconnected earlier.
15. Start the prime mover, checking to ensure the pump remains in neutral.
16. Check for forward and reverse machine operation, with the prime mover at
normal operating speed.
Charge pressure may decrease slightly during forward or reverse operation.
17. Continue to cycle slowly between forward and reverse for at least five minutes.
18. Shut down prime mover.
19. Remove gauges. Replace plugs at the gauge ports.
20. Check reservoir level. Add filtered fluid if needed.
The motor/transmission is now ready for operation.
11024924 • Rev AF • February 2010 23

Service Manual
Troubleshooting
Overview This section provides general steps to follow if you observe undesirable system
conditions. Follow the steps until you solve the problem. Some of the items are system
specific. Always observe the safety precautions in the Introduction section, page 6.
W Warning
Electrical troubleshooting
Motor operates at one Control coil failure Measure resistance at coil pins.
displacement only. Proportional controls: Resistance should be 14.20 Ohms (24V) or
3.66 Ohms (12V) at 20°C [70°F].
Two-position controls: Resistance should be 8.4 Ohms (24V) or
34.5 Ohms (12V) at 20°C [70°F].
Replace coil if necessary.
Erratic motor function Electrical connection to motor is intermittent. Disconnect connector, check wires and terminals, reconnect wires.
Check terminals for corrosion and correct position.
Sluggish operation
Check Cause Corrective action
1. Control orifices Blocked or restricted orifice may cause sluggish Remove, inspect and clean all orifices. Ensure the
response. Orifices installed in the wrong appropriate orifices are installed and in the correct
locations may cause PCOR control to be sluggish. location.
2. Threshold setting (proportional Inappropriately high or low threshold setting Check threshold setting. Adjust if necessary.
controls) may shift the motor at the wrong time.
3. Control spool A sticky control may cause sluggish response or Clean and inspect the control spool. Replace if
no response. necessary.
4. Pressure compensator setting Low pressure compensator setting may shift Check pressure compensator setting. Adjust if
motor to maximum displacement at lower necessary.
pressure.
5. Control input signal An improper or erratic input signal to the control Check input signal and correct if necessary.
may cause sluggish response.
6. Internal leakage Excessive leakage will cause lower charge Install loop flushing defeat option and measure
pressure and affect performance. case flow. If case flow is excessive, motor may
require major repair. Contact your Sauer-Danfoss
authorized service center.
24 11024924 • Rev AF • February 2010

Service Manual
Troubleshooting
System operating hot

1. Oil level Insufficient hydraulic fluid may cause Fill reservoir to proper level.
overheating.
2. Heat exchanger Blocked heat exchanger or low air flow may Check temperature upstream and downstream
cause system overheating. of heat exchanger. Clean, repair, or replace heat
exchanger if necessary.
3. Loop flushing flow Restricted orifice in loop flushing cartridge Measure case drain flow. Clean or replace orifice
reduces flow. cartridge.
4. Loop flushing shuttle Loop flushing shuttle may be sticking in one Ensure shuttle moves freely in its bore.
direction.
5. Air in system Entrained air generates heat under pressure Look for foam or bubbles in reservoir. Check for
leaks on inlet side of charge pump.
6. Internal leakage Excessive internal leakage may overheat the Install loop flushing defeat option and monitor
system. case flow. If case flow is excessive, motor may
Excessive noise or vibration

1. Oil level in reservoir Insufficient hydraulic fluid may cause cavitation. Fill reservoir to proper level.
2. Air in system Air bubbles may lead to cavitation. Look for foam or bubbles in reservoir. Check for
leaks on inlet side of charge pump.
3. Shaft coupling Loose shaft coupling may create excess noise. Replace loose shaft coupling. Replace or repair
motor if shaft splines show excessive wear.
4. Shaft alignment Misaligned shafts may create excessive noise and Correct shaft misalignment.
vibration and can damage motor.
Motor operates normally in one direction only

1. Charge pressure If charge pressure is low in one direction, the Measure charge pressure in forward and reverse. If
loop flushing shuttle spool may be sticking to pressure drops significantly lower in one direction,
one side. inspect and repair loop flushing shuttle spool.
2. Pressure compensator control If pressure compensator operates in one Check brake pressure defeat spool. It may be
direction only, the motor may stay at minimum sticking or receiving an improper signal. Repair
displacement in the opposite direction. spool or correct input signal.
11024924 • Rev AF • February 2010 25

Service Manual
Troubleshooting
Improper output speed

1. Oil level in reservoir Insufficient hydraulic fluid may reduce system Fill reservoir to proper level.
efficiency.
2. Threshold setting Improper threshold setting may cause motor to Check threshold setting. Refer to Control Service
have wrong displacement for given signal. Manual for adjustment procedure.
3. Pressure compensator setting Improper pressure compensator setting may Check pressure compensator setting. Adjust if
shift motor displacement at wrong pressure. necessary. Refer to Control Service Manual for
adjustment procedure.
4. PC spool Pressure compensator spool sticking may shift Check pressure compensator spool. Repair or
motor to improper displacement. replace if needed. Refer to Control Service Manual
for adjustment procedure.
5. Control orifices Blocked or restricted orifice may cause motor to Remove, inspect and clean all orifices.
shift improperly.
6. Control spool Sticky proportional control spool may cause Check control spool for proper operation. Repair if
motor to shift improperly. necessary. Refer to control adjustment procedure.
7. Control input signal Improper input signal may cause motor to shift Correct control input signal.
improperly.
8. Internal leakage Excess internal leakage may cause lower Install loop flushing defeat option and measure
charge pressure and affect motor performance case flow. If case flow is excessive, motor may
including output speed. require major repair. Contact your Sauer-Danfoss
Low output torque

1. Pressure compensator setting High pressure compensator setting may cause Check and adjust pressure compensator setting.
improper motor displacement for torque
required.
2. Control orifices Blocked or restricted orifice may cause motor to Remove, inspect and clean all orifices.
shift improperly.
3. Pressure compensator spool Sticking pressure compensator spool may cause Remove and inspect pressure compensating spool.
control to hold motor at minimum displacement. Repair or replace control if necessary.
4. Control spool Sticking control spool may cause motor to shift Remove and inspect control spool. Repair or replace
improperly. control if necessary.
5. Two position solenoid Two position control not shifting motor to Inspect solenoid valve for bent stem or damaged
maximum displacement. coil. Repair or replace if necessary.
6. Control input signal Improper control input signal may cause motor Correct control input signal.
to stay at minimum displacement.
7. Threshold setting Improper threshold setting may cause improper Check and adjust threshold setting.
(proportional control) motor displacement for torque required.
8. Internal leakage Excess internal leakage may cause charge Install loop flushing defeat option and monitor
pressure to decay, reducing output torque. case flow. If case flow is excessive, motor may
26 11024924 • Rev AF • February 2010

Service Manual
Required tools and standard procedures
Required tools The service procedures described in this manual can be performed using common
mechanic’s hand tools. Special tools, if required, are shown. When testing system
pressures, calibrate pressure gauges frequently to ensure accuracy. Use snubbers to
protect gauges.
C Caution
Standard procedures Contamination can damage internal components and void the manufacturer’s warranty.
Take precautions to ensure system cleanliness when removing and reinstalling system
lines
1. With the prime mover off, thoroughly clean all dirt and grime from the outside of the
motor. Ensure the surrounding areas are clean and free of contaminants such as dirt
and grime.
2. If removing the motor, tag each hydraulic line connected to the motor. If you
disconnect hydraulic lines, plug each open port to keep dirt and contamination out
of the motor.
3 Inspect the system for contamination. Look at the hydraulic fluid for signs of system
contamination, such as oil discoloration, foam in the oil, sludge, or small metal
particles.
C Caution
Be careful not to damage 4. Remove the motor as a single unit. C
solenoids and electrical
connections when using 5. Perform motor function test.
straps or chains to remove
motor from machine. 6. Before re-installing the motor on the machine, drain the system, flush all lines,
replace all filters, and fill with new hydraulic fluid.
11024924 • Rev AF • February 2010 27

Service Manual
Adjustments
Minimum Adjusting the minimum displacement limiter

displacement limiter 1. Remove cap (N0120).
Removing cap destroys the caps locking mechanism. Replace with new cap.
2. Using a 6 mm internal hex wrench, hold adjusting screw (N0010) in place.
3. Using a 19 mm hex wrench, loosen seal locknut (N0020).
4. Turn adjusting screw clockwise to increase minimum displacement or

counterclockwise to decrease minimum displacement. Minimum displacement is
inversely related to maximum shaft speed. To increase maximum speed, decrease
minimum displacement. Adjusting displacement limits also affects output torque.
Refer to table for displacement change per turn.
5. When properly adjusted, hold adjusting screw in place and torque seal locknut to
45 N•m [32 lbf•ft].
6. With motor on machine or test stand, verify correct motor function. Refer to Pressure
measurements, page 21, for location of gauge ports and suggested gauge sizes.
7. Install new cap (N0120).
Minimum displacement limiter Displacement change per turn

Model Displacement change
110 3.3 cm3 [0.20 in3]
080 2.7 cm3 [0.17 in3]
060 2.1 cm3 [0.13 in3]
N0010 6 mm
19 mm
45 N•m
[32 lb•ft] N0120
N0020
P106 547E
28 11024924 • Rev AF • February 2010

Service Manual
Adjustments
Optional threshold Adjusting threshold on test stand

adjustment - 1. Connect flow meter to A or B system port. Refer to Port locations and gauge
proportional installation, page 21 for port locations.
controls
2. Connect solenoid to PWM signal generator at 100 Hz.
Threshold is the electric signal when the motor starts to change from maximum to
minimum displacement.
3. Run prime mover at operating speed.

adjusting B0040
Threshold adjustment screw
3 mm
E101 548E
4. Adjust PWM signal to current listed in model code. Note flow reading.
5. If adjustment is necessary, remove cap (B0040). Using a 3mm internal hex wrench,
turn adjusting screw clockwise or counterclockwise until flow starts to change from
maximum. Test your adjustment by lowering the current, then increasing the current
until the displacement starts to change. Readjust the setting if necessary.
6. When threshold is adjusted correctly, stop prime mover, install cap (B0040), and
install motor on vehicle. Run vehicle and test for proper motor operation.
Adjusting threshold on a machine or test stand without flow meter

1. Install 600 bar [10,000 psi] gauges to ports M5 and M4. Connect solenoid to PWM
signal.
W Warning
Unintended movement of 2. Raise wheels off ground, or disconnect the work function. W
the machine or mechanism
may cause injury to the 3. Run prime mover at operating speed. Stroke the pump to get some rotation of
technician or bystanders. motor shaft.
To protect against
unintended movement, 4. Increase signal current until M4 pressure becomes 1/2 of the M5 pressure. Check the
secure the machine signal current at this point.
or disable/disconnect
the mechanism while 5. If adjustment is necessary, remove cap (B0040). Turn the adjusting screw until the
servicing. signal current matches the model code setting.
6. When threshold is adjusted correctly, stop prime mover, install cap. Run vehicle and
test for proper motor operation.
7. Remove from test stand.

11024924 • Rev AF • February 2010 29
Service Manual
Adjustments
Pressure PCOR adjustment for T1/T2 controls

compensator 1. With motor on vehicle, block wheels so vehicle can’t move.
OVERRIDE (PCOR)
adjustment 2. Install 600 bar [10,000 psi] gauges at servo pressure ports M4.
3. With coil de-energised;

W Warning
Unintended movement of 4. Run prime mover at normal operating speed.
the machine or mechanism
may cause injury to the 5. Gradually increase system pressure until pressure at M4 drops.
technician or bystanders.
To protect against The highest system pressure before M4 drops is the PCOR setting.
unintended movement,
secure the machine 6. Use a 3 mm internal hex to hold the PCOR adjusting screw in place. Use a 10 mm
or disable/disconnect wrench to loosen the PCOR locknut.
the mechanism while
servicing.
Locknut 10 mm
Adjusting screw 3 mm
P106 723E
7. Turn the adjusting screw until system pressure is set to the PCOR setting specified
in the model code. Decrease, then increase the system pressure to verify the PCOR
setting. Retorque PCOR locknut.
8. Shut down prime mover. Remove gauges and PWM signal generator. Reconnect
electrical signal to solenoid.
Brake pressure defeat option

No adjustment is available for the brake pressure defeat option. Coil is either energized
or de-energized, if coil is used.
PCOR adjustment for P1/P2 controls

PCOR setting is electrically adjusted using a proportional solenoid.
Nominal settings 240 bar [3500 psi] at 400 mA (12 V), 800 mA (24 V) or per model code.
30 11024924 • Rev AF • February 2010
Service Manual
Minor repair
Shaft seal Removal

1. Using snap ring pliers, remove retaining ring (G0030).
2. Use a slide-hammer style puller to remove seal (G0020). Be careful not to damage the
shaft or seal bore when removing. Discard seal.
Inspection
Inspect retaining ring for wear or damage. Replace if necessary. Inspect shaft for wear or
groove at seal area.
If not using seal installation Assembly

tool: Do not press seal 1. Lubricate inside diameter of new seal. Cover the shaft splines with shaft cover or
beyond snap-ring groove. packing tape to avoid damaging the seal during installation.
Stop pressing just when
you have room to install 2. Using seal installation tool, press seal into housing bore.
the retaining ring into the
bore. Pressing the seal and 3. Using a snap ring pliers, install retaining ring (G0030).
snap-ring together ensures
proper installation depth. 4 Use seal installation tool to press seal and retaining ring into housing until retaining
Using the seal installation ring snaps into its groove.
tool prevents pressing the
seal too deeply. Shaft seal
G0020
G0030
P106 548E
110 - Seal installation tool dimensions 080 - Seal installation tool dimensions
180 mm 150 mm
100 mm [7.09 in] [5.90 in]
100 mm
[3.94 in] [3.94 in]
69 mm 58 mm 56 mm 48 mm 70 mm
82 mm
[2.6 in] [2.3 in] [2.2 in] [1.9 in] [2.76 in]
[3.15 in]
45°
45°
+ 0.10 5 mm
+ 0.10 5 mm 5.4 mm - 0.0 [0.2 in]
5.15 mm - 0.0 + 0.004
[0.2 in] P107 738E [0.21 in - 0.0 ]
[0.20 in + -0.004
0.0 ]
11024924 • Rev AF • February 2010 31

Service Manual
Minor repair
Solenoid Removal
replacement 1. Disconnect electrical connection and remove three cap screws (B0050) using a 4 mm
internal hex wrench.
2. Remove the solenoid (B0010) and O-ring (B0035A). Discard the O-ring.
3. Remove valve spool (C0100).
Inspection
Clean and Inspect valve spool and all machined surfaces for damage or wear. Replace
parts if necessary.
Assembly
1. Lubricate and install valve spool (C0100).
2. Using petroleum jelly, lubricate and install new O-ring (B0035A).
3. Install cap screws (B0050) using a 4 mm internal hex wrench. Torque screws to 6 N•m
[4 lbf•ft].
4. Reconnect electrical connections and test the motor for proper operation.
Replacing solenoid
B0050
B0010 4 mm
6 N•m [ 4 lbf•ft]
B0035A
C0100
P106 724E
32 11024924 • Rev AF • February 2010

Service Manual
Minor repair
Control module Removal

replacement 1. Rremove four cap screws (C0110 and/or C0120). Refer to table for wrench sizes.
2. Remove control (C0010) from motor. Remove and discard gasket (C0130).
3. Proportional control only - using a magnet, remove spring seat (F0030) and spring
(F0040).
Inspection
Clean and inspect the machined surfaces on the control and the endcap. If you find any
nicks or scratches, replace control or endcap. Inspect valve spool, washer, and spring.
Replace if necessary.
Assembly
1. Lubricate and install spring (F0040) and spring seat (F0030) into servo.
2. Install a new gasket (C0130). Position control on motor.
3. Install four cap screws (C0110 and/or C0120). Torque (C0110) to 37 N•m [27 lbf•ft] for
proportional control.
Torque (C0110) and (C0120) to 115 Nm [85 lbf•ft] for 2 position control.
Control module removal/installation
C0120 (2X)
C0110 (4X) 10 mm
6 mm
115 Nm
C0010 37 Nm [85 lbf•ft]
Proportional [27 lbf•ft] C0110 (2X)
control 10 mm
F0030 115 Nm [85 lbf•ft]
C0010
2 position
control
F0040
C0110 and C0120 Wrench Size
Control Screw Internal
Hex C0130
Wrench C0130
Proportional C0110 6 mm
Two-position C0110 10 mm
C0120 10 mm
P106 520E
Proportional control Two position control
11024924 • Rev AF • February 2010 33

Service Manual
Minor repair
Proportional Disassembly
control module 1. Remove the plastic cap (B0040) and O-ring (B0029). Discard the O-ring.
2. Remove the solenoid nut (B0027) using a 26mm 12-point socket. Remove and
Coil O-rings are not discard the O-ring (B0028).
seal kit. They may be 3. Remove the coil (B0020A). Remove and discard the O-ring (B0025).
purchased as a separate kit.
4. Use a 4 mm internal hex wrench to remove screws (B0050). Remove solenoid
(B0010).
5. Remove and discard O-ring (B0035A).
6. Remove spool (C0100).
7. Using a 1/4 in internal hex wrench remove plug (C0050) and discard O-ring (C0050A).
8. Use a 5 mm internal hex to remove shuttle valve (C0025).
9. Using a 1/8 in internal hex wrench, remove 3 plugs (C0060) and discard O-rings
(C0060A).
10. Using a 3 mm internal hex, remove 2 orifices (E00T3 and E00T2).
Inspection
Inspect the machined surfaces on the control and the endcap. If you find any nicks or
scratches, replace the control or endcap assembly. Check that shuttle ball moves freely in
housing (C0025).
Assembly
1. Install orifices (E00T3 and E00T2). Torque to 6 N•m [4 lbf•ft].
2. Lubricate and install new O-rings (C0060A). Using a 1/8 inch internal hex wrench,
install and torque plugs (C0060) to 8 N•m [6 lbf•ft].
3. Lubricate and install spool (C0025) into control block. Using a 5 mm internal hex
wrench, torque to 14 N•m [11 lbf•ft]
4. Install new O-ring (C0050A). Using a 1/4 inch internal hex wrench, install and torque
plug (C0050) to 40 N•m [30 lbf•ft].
5. Lubricate and install spool (C0100).
6. Lubricate and install new O-ring (B035A).
7. Install solenoid (B0010). Using a 4 mm internal hex wrench. Install screws (B0050).
Torque to 6 N•m [4 lbf•ft].
34 11024924 • Rev AF • February 2010

Service Manual
Minor repair
Proportional 8. Lubricate and install new O-ring (B0025) onto solenoid. Install coil (B0020A).
control module Lubricate and install new O-ring (B0028) onto solenoid.
(continued)
9. Install coil nut (B0027) and torque to 3.5 N•m [2.6 lbf•ft] using a 26mm 12-point
socket. Do not overtorque.
Coil O-rings are not 10. Install new O-ring (B0029) and plastic cap (B0040) to solenoid.
coil. Proportional control block assembly
B0027
26 mm B0040
3.5 N•m
[2.6 lbf•ft]
B0029
B0027
B0028
B0020A
B0020
B0050
B0025
4mm
6 N•m
[4 lbf•ft]
8 N•m
B0035A B0010
[6 lbf•ft]
1/8 in
1/4 in C0060 6 N•m [4 lbf•ft]
C0050 C0060A 3 mm
40 N•m C0050A E00T2
[30 lbf•ft] C0100
C0025
5 mm
8 N•m
B0010 3 mm
[6 lbf•ft]
C0060A 6 N•m [4 lbf•ft]
C0060
1/8 in E00T3
8 N•m C0060A
[6 lbf•ft] C0060
P106 521E 1/8 in
8 N•m
[6 lbf•ft]
11024924 • Rev AF • February 2010 35

Service Manual
Minor repair
Two-position Disassembly
control module 1. Use a 26 mm 12-point socket to remove coil nuts (B0026) and O-ring (B0028).
2. Remove coils (B0022) and O-rings (B0024). Discard O-rings.

included in the overhaul 3. Using a 17 mm open-end wrench on the flats provided, remove solenoid assemblies
seal kit. They are included (B0032).
coil. 4. Remove and discard O-rings (B0034).
5. Using a 1/8 inch internal hex wrench, remove four plugs (C0060). Remove and
6. Using a 1/4 inch internal hex wrench, remove two plugs (C0050). Remove and
7. Using a 17 mm hex wrench, remove pressure compensator adjusting plug (C0090).

Remove and discard O-ring (M223).
8. Remove springs (C0030) and (C0080). Remove spools (C0020) and (C0070).
9. If necessary, use a 3 mm internal hex wrench to remove orifices (E00T2) and (E00T3).
Inspection
Clean and inspect the machined surfaces on the control and the endcap. If any nicks or
scratches are found, replace the control/endcap assembly.
Assembly
1. If previously removed, install orifices (E00T3 and E00T2) using a 3mm internal hex
wrench. Torque to 6 N•m [4 lbf•ft].
2. Lubricate and install spools (C0020) and (C0070) and springs (C0080) and (C0030).
3. Lubricate and install O-ring (M223). Install pressure compensator adjusting plug
(C0090). Torque to 40 N•m [30 lbf•ft].
4. Lubricate and install two O-rings (C0050A). Using a 1/4 inch internal hex wrench,
install plugs (C0050). Torque to 25 N•m [19 lbf•ft].
5. Lubricate and install four O-rings (C0060A). Using a 1/8 inch internal hex wrench,
install plugs (C0060). Torque to 8 N•m [6 lbf•ft].
6. Lubricate and install O-rings (B0034).
7. Using a 17 mm open-end wrench on the flats provided, install solenoids (B0032).

Torque to 25 N•m [19 lbf•ft] .
8. Lubricate and install new O-rings (B0024) on solenoids.
9. Install coils (B0022). Lubricate and install new O-rings (B0028).
36 11024924 • Rev AF • February 2010

Service Manual
Minor repair
Two-position 10. Using a 26 mm 12-point socket, install coil nuts (B0026). Torque to 3.5 N•m [2.6 lbf•ft].
control module Do not overtorque.
(Continued)
2 position control assembly

B0028
B0022
B0026
3.5 N•m
[2.6 lbf•ft] B0024
17 mm
B0032 25 N•m [19 lbf•ft]
B0034
B0026 1/4 in
3.5 N•m B0024
40 N•m [30 lbf•ft]
[2.6 lbf•ft] B0028
C0050
B0022
B0032 C0050A
17 mm
25 N•m [19 lbf•ft] C0060 1/8 in 8 N•m [6 lbf•ft]
B0034
C0060A C0060A
C0060
C0060 1/8 in 8 N•m [6 lbf•ft]
1/8 in
8 N•m [6 lbf•ft] C0060A C0070
C0060
1/8 in C0080 M223
8 N•m [6 lbf•ft] E00T3 C0090
C0020
3 mm E00T2 17 mm
6 N•m 3 mm C0030 25 N•m
[4 lbf•ft] 6 N•m [18 lbf•ft]
[4 lbf•ft] C0050A
C0050
1/4 in
40 N•m [30 lbf•ft] P106 721E
Maximum It is not necessary to remove the Maximum displacement limiter parts

displacement limiter maximum displacement limiter unless it
two-position is being replaced.
P0100
controls 6 mm
Disassembly P0200
Models with maximum displacement
limiter: Remove screw (P0100) using a 6
mm internal hex, and spacer (P0200).
Assembly
Install spacer (P0200) and screw (P0100).
Using a 6 mm internal hex, torque screw
to 37 N•m [28 lbf•ft].
P107 866E
11024924 • Rev AF • February 2010 37

Service Manual
Minor repair
Servo piston cover – Removal

proportional 1. Using a 10 mm internal hex wrench, remove four screws (P0020).
control
2. Remove servo piston cover (P0010).
3. Remove and discard O-ring (P0030).
4. Remove screw (P0050). See table for wrench size.
5. Using expanding pliers, remove piston head (P0040). Remove and discard seal ring
(P0044) and O-ring (P0043).
Servo piston cover and bushing
Servo
piston
head
Expanding
P0041
pliers
P0043
P106 726E P0040
P0044
P0050
see table
O-ring P0030
(P0043) Seal ring Piston
(P0044)
P0010
10 mm P106 524E
115 N•m [85 lbf•ft]
P0020
P0050 wrench size and torque

P106 694E 110 10 mm 115 N•m [85 lbf•ft]
060/080 8 mm 66 N•m [49 lbf•ft]
38 11024924 • Rev AF • February 2010

Service Manual
Minor repair
servo piston cover Inspection

(continued) Clean and inspect bushings and machined surfaces for wear or damage. If wear or
damage are found, replace component in question.
Assembly
1. Lubricate and install new O-ring (P0043) and seal ring (P0044) on piston (P0041).
Allow seals time to relax before installing piston.
2. Install piston and install screw (P0050). Torque screw (P0050) per table.
3. Lubricate and install new O-ring (P0030) and install servo piston cover (P0010).
4. Using a 8 mm or 10 mm internal hex install screws (P0020). Torque to 115 N•m [85
lbf•ft].
Replace speed sensor Removal

1. Using a 5 mm internal hex wrench, remove screw (J0020).
2. Remove speed sensor (J0010). Speed sensor

J0020
3. Discard O-ring (J0010A). 5 mm
Assembly J0010
4. Lubricate and install new O-ring
J0010A
(J0010A).
5. Install speed sensor (J0010).
6. Using a 5 mm internal hex wrench,

install screw (J0020). Torque to 8 N•m
[6 lbf•ft].
P107 859E
11024924 • Rev AF • February 2010 39

Service Manual
Minor repair
Loop flushing spool Removal

1. Remove plugs (K0030) using a 24 mm hex wrench.
2. Remove and discard O-rings (K0030A).
3. Use a magnet to remove springs (K0020) and spool (K0010).
Inspection
Clean and inspect spool (K0010). If spool is damaged or worn replace it. Replace springs if
they are cracked or bent.
Reassembly
1. Lubricate and install spool (K0010).
2. Lubricate and install springs (K0020).
3. Lubricate and install new O-rings (K0030A).
4. Using a 24 mm hex wrench, install plugs (K0030). Torque to 52 N•m [39 lbf•ft]
Loop flushing assembly
24 mm
P106 537E
52 N•m [39 lbf•ft]
K0030
K0020
K0030A
24 mm
52 N•m
[39 lbf•ft]
K0030
K0010
K0020
K0030A
40 11024924 • Rev AF • February 2010

Service Manual
Minor repair
Loop flushing charge Removal

relief valve 1. Using a 24 mm hex wrench remove valve (L00**)
Do not disassemble valve. If you suspect malfunction, replace valve.
Assembly
1. Install new O-ring (L0050).
2. Using a 24 mm hex wrench, install valve (L00**). Torque to 52 N•m [39 lbf•ft].
Loop flushing charge relief valve replacement
L0050
L00** P106 538E
24 mm
52 N•m [39 lbf•ft]
11024924 • Rev AF • February 2010 41

Service Manual
Minor repair
Minimum Removal
Displacement limiter 1. Remove cap (N0120).
Removing the cap destroys the caps locking mechanism. Replace with a new cap.
2. While holding the position of the adjustment screw, remove the seal locknut (N0020)
using a 19mm hex wrench. Discard the locknut. After removing the locknut, mark the
position of the limiter screw for reassembly.
3. Using a 6 mm internal hex, remove displacement limiter screw (N0010).
Inspection
Inspect set screw for wear or damage. Replace set screw if necessary.
Assembly
1. Using a 6 mm internal hex wrench, install adjustment screw (N0010) to original
position.
2. Using a 6 mm internal hex wrench, to hold the position of the adjustment screw,
install a new seal locknut (N0020) using a 19mm hex wrench. Torque to 45 N•m [32
lbf•ft].
3. Install new cap (N0120).
Displacement limiter assembly
N0010 6 mm
19 mm
45 N•m
[32 lb•ft] N0120
N0020
P106 547E
42 11024924 • Rev AF • February 2010

Service Manual
Torque chart
Fasteners and plugs Port, plug and fastener locations

P0020
L00** J0020 M4
L2 F0100
G0060
MB System Port A
F0150
MA
F0150
K0030
C0060
G0050 B0050
C0110 and C0120 G0060
L1
N0010 N0020
Radial ported endcap P107 874E
Fastener size and Item Fastener Wrench size Torque

torque chart P0020 Servo piston cover screws 10 mm internal hex 115 N•m [85 lbf•ft]
C0110 (proportional) Control assembly screws 6 mm internal hex 37 N•m [28 lbf•ft]
C0110 & C0120 Control assembly screws 10 mm internal hex 115 N•m [85 lbf•ft]
(two-position)
B0050 Solenoid screws 4 mm internal hex 6 N•m [4 lbf•ft]
L00** Loop flushing charge relief 24 mm 52 N•m [39 lbf•ft]
J0020 Speed sensor screw 5 mm internal hex 8 N•m [6 lbf•ft]
N0010 Displacement limiter screw 6 mm internal hex N/A
N0020 Displacement limiter locknut 19 mm 45 N•m [32 lbf•ft]
Plug size and torque Item O-ring plug Wrench size Torque
chart F0100 9/16 - 18UNF 1/4 internal hex 40 N•m [30 lbf•ft]
G0050 5/16 - 24UNF (SAE and DIN flange) 1/8 internal hex 8 N•m [5 lbf•ft]
G0055 7/16 - 20UNF (Cartridge) 3/16 internal hex 8 N•m [5 lbf•ft]
(cartridge model
only) (not shown)
G0060 (060, 080) 7/8 - 14 3/8 internal hex 70 N•m [52 lbf•lb]
G0060 (110) 1-1/16 - 12 9/16 internal hex 70 N•m [52 lbf•lb]
L00** M18 - 1.5 24 mm hex 67 N•m [49 lbf•ft]
K0030 M18 - 1.5 24 mm hex 67 N•m [49 lbf•ft]
C0060 5/16 - 24UNF 3/8 internal hex 8 N•m [5 lbf•ft]
F0150 (060) 7/8 - 14 9/16 internal hex 95 N•m [70 lbf•ft]
Radial endcap
F0150 (080, 110) 1-1/16 - 12 UN 9/16 internal hex 115 N•m [85 lbf•ft]
Radial endcap
F0160 9/16-18 UNF 1/4 internal hex 40 N•m [30 lbf•ft]
Axial endcap
(not shown)
C0050 (not shown) 9/16-18 UNF 1/4 internal hex 40 N•m [30 lbf•ft]
11024924 • Rev AF • February 2010 43

Our Products Sauer-Danfoss Mobile Power and Control Systems
– Market Leaders Worldwide
Open circuit axial piston pumps
Sauer-Danfoss is a comprehensive supplier providing complete
Gear pumps and motors systems to the global mobile market.
Fan drive systems
Sauer-Danfoss serves markets such as agriculture, construction, road
Closed circuit axial piston pumps building, material handling, municipal, forestry, turf care, and many
and motors others.
Bent axis motors
We offer our customers optimum solutions for their needs and
Hydrostatic transmissions develop new products and systems in close cooperation and
partnership with them.
Transit mixer drives
Hydrostatic transaxles Sauer-Danfoss specializes in integrating a full range of system
components to provide vehicle designers with the most advanced
Electrohydraulics
total system design.
Integrated systems
Sauer-Danfoss provides comprehensive worldwide service for its
Microcontrollers and software
products through an extensive network of Global Service Partners
PLUS+1™ GUIDE strategically located in all parts of the world.
Displays
Joysticks and control handles Local address:
Sensors
Orbital motors
Inverters
Electrohydraulic power steering
Hydraulic power steering
Hydraulic integrated circuits (HIC) Sauer-Danfoss (US) Company Sauer-Danfoss ApS
Cartridge valves Ames, IA 50010, USA Phone: +45 7488 4444
Directional spool valves Phone: +1 515 239-6000 Fax: +45 7488 4400
Fax: +1 515 239-6618
Proportional valves Sauer-Danfoss GmbH & Co. OHG
Sauer-Danfoss-Daikin LTD
Shin-Osaka TERASAKI 3rd Bldg.6F
Postfach 2460, D-24531 Neumünster 1-5-28 Nishimiyahara, Yodogawa-ku,
Krokamp 35, D-24539 Neumünster, Germany Osaka 532-0004, Japan
Phone: +49 4321 871-0 Phone: +81 6 6395 6066
Fax: +49 4321 871 122 Fax: +81 6 6395 8585
11024924 •Rev AH • February 2010
A.G Reduction gear drum, 715C3B

DIVISIONE:
Bonfiglioli Group
Bonfiglioli / Trasmital / Components / Silectron
New Power Solutions
MOTORIDUTTORE PER TRASLAZIONE

DRUM DRIVE
715 C 3 B
CODICE
CODE
Manuale di installazione, uso

e manutenzione
Installation, operation and maintenance

manual
Emissione:
07/2001
Issue:
Aggiornamento - data:
Revision - date: 0.0 - 01/07/2001
Compilatore:
Ufficio tecnico commerciale: Prepared by: ....................................................................
Technical and commercial dept: Approvato da:
Approved by:...................................................................
DIVISIONE:
Bonfiglioli Group
-2-
DIVISIONE:
Bonfiglioli Group
New Power Solutions
INDICE INDEX
1. INFORMAZIONI GENERALI 1. GENERAL INFORMATIONS

1.1. Scopo del manuale ............................................2 1.1. Manual aim ....................................................... 2
1.2. Identificazione del prodotto ................................3 1.2. Product identification......................................... 3
1.3. Modalità di richiesta assistenza .........................3 1.3. Requesting assistance ...................................... 3
1.4. Informazioni sulla sicurezza...............................4 1.4. Informations on safety....................................... 4
1.5. Modalità di consegna .........................................5 1.5. Delivery Methods .............................................. 5
1.6. Modalità di imballaggio ......................................5 1.6. Packaging Methods .......................................... 5
1.7. Sollevamento e movimentazione .......................6 1.7. Lifting and Handling ......................................... 6
1.8. Modalità di magazzinaggio ................................6 1.8. Storage Methods............................................... 6
2. INFORMAZIONI TECNICHE 2. TECHNICAL INFORMATIONS

2.1. Descrizione del prodotto ....................................7 2.1. Product description ........................................... 7
3. INFORMAZIONI SULL’INSTALLAZIONE 3. INSTALLATION INFORMATIONS

3.1. Procedure per l’installazione..............................9 3.1. Installation procedure........................................ 9
3.2. Installazione del motore idraulico.......................9 3.2. Mounting the Product to the Machine ............... 9
3.3. Installazione sulla macchina ............................10 3.3. Connections to the Hydraulic System ............. 10
3.4. Collegamento del freno....................................10 3.4. Filling-up the Gearbox with Lubricating Oil ..... 10
3.5. Riempimento olio lubrificante del riduttore.......11 3.5. Characteristics of the Hydraulic System ......... 11
3.6. Prima messa in esercizio e rodaggio ...............12 3.6. First Start Up and Running in.......................... 12
4. INFORMAZIONI SULLA MANUTENZIONE 4. MAINTENANCE INFORMATIONS

4.1. Manutenzione periodica...................................14 4.1. Periodic Maintenance ..................................... 14
4.2. Sostituzione dell'olio lubrificante ......................15 4.2. Changing the Lubricating oil ........................... 15
4.3. Ricerca guasti ..................................................16 4.3. Troubleshooting .............................................. 16
4.4. Smontaggio del motoriduttore..........................17 4.4. Motorgearbox disassembly ............................. 17
4.5. Fasi di smontaggio...........................................18 4.5. Disassembling Method.................................... 19
4.6. Valutazione dei pezzi da sostituire...................26 4.6. Evaluating that Pieces to Replace .................. 26
4.7. Fasi di rimontaggio...........................................27 4.7. Reassembling Method .................................... 27
4.8. Controllo finale e reinstallazione ......................38 4.8. Final test and reinstallation ............................. 38
4.9. Dismissione e rottamazione del prodotto.........39 4.8. Dismantling and Destroying the Product......... 39
INDICE -1- INDEX

DIVISIONE:
Bonfiglioli Group
New Power Solutions
1. INFORMAZIONI GENERALI 1. GENERAL INFORMATIONS
1.1. Scopo del manuale 1.1. Manual aim
Questo manuale è stato realizzato dal costruttore per This manual has been devised by the manufacturer to
fornire le informazioni necessarie a coloro che sono give necessary information to those authorised to work
autorizzati ad interagire con il prodotto: dai progettisti, on this product for example the design engineers, in-
agli installatori, manutentori e riparatori. stallers, repair and maintenance technicians.
Oltre ad adottare le regole della buona tecnica di co- Besides helping one understand the rules of good
struzione, le informazioni devono essere lette attenta- manufacturing techniques used, the information given
mente ed applicate in modo rigoroso. must be read attentively and strictly put into action.
La non osservanza di dette informazioni può essere Failure to observe this information may lead to health
causa di rischi per la salute e la sicurezza delle perso- and safety risks to persons as well as economic loss.
ne e danni economici.
This information was compiled by the Italian manufac-
Queste informazioni sono state realizzate dal costrut- turer in his original language (Italian) and can be trans-
tore nella propria lingua originale (italiana) e possono lated into other languages to satisfy commercial and/or
essere tradotte in altre lingue per soddisfare le esigen- legal needs.
ze commerciali e/o legislative.
Even though the descriptions may not correspond ex-
Anche se le descrizioni non corrispondono esattamen- actly to the product in possession, this does not have
te al prodotto in Vs possesso, ciò non pregiudica la loro any bearing on their validity.
validità.
INFORMAZIONI GENERALI -2- GENERAL INFORMATIONS

DIVISIONE:
Bonfiglioli Group
New Power Solutions
1.2. Identificazione del prodotto 1.2. Product identification
I dati per l’identificazione del prodotto sono riportati in The data to identify the product are shown on the iden-
una targhetta applicata su di esso. tification plate attached to it.
Informazioni Information
Per la richiesta di informazioni, ricambi, For all enquiries regarding general information on the
assistenza, ect, fornire sempre i dati identificativi. product, spare parts, assistance etc, always give the
identification data stamped on the ID plate.
Nel caso di un motoriduttore vi sono due targhette; una
riporta i dati del riduttore, l’altra quelli del motore idraulico. The gearmotor has two plates, one gives data on the
gearbox and the other data on the hydraulic motor.
Le targhette vanno mantenute integre per tutta la vita
del prodotto. L’illustrazione evidenzia la disposizione The plates must not be removed or damaged during
dei dati. the life of the product. The following illustration shows
how the data is set out.
Identificazione del Costruttore

Manufacturer’s identification
Designazione del prodotto:
composizione alfanumerica che Numero di matricola
consente di identificare il prodotto. Serial number
Product designation:
alphanumeric composition Data di produzione
which allows identification of Date of production
the product.
N. dis. installazione
Installation drawing number
Rapporto di riduzione
Reduction ratio Codice del prodotto
Product code
IDM-1521530010
1.3. Modalità di richiesta assistenza 1.3. Requesting assistance
Per qualsiasi richiesta di assistenza rivolgersi diretta- For all requests for assistance please contact the man-
mente alla rete di vendita del costruttore ufacturers’ sales network, directly.

DIVISIONE:
Bonfiglioli Group
New Power Solutions
1.4. Informazioni sulla sicurezza 1.4. Informations on safety
Leggere attentamente le istruzioni riportate in questo Carefully read the instructions given in this instruction
manuale e eventualmente quelle applicate direttamen- manual as well as the ones attached to the product and
te sul prodotto, in particolare rispettare quelle riguar- make sure to follow the information concerning safety.
danti la sicurezza.
Personnel, which perform any type of work on the
Il personale che effettua qualsiasi tipo di intervento in product during its life span, must possess precise tech-
tutto l’arco di vita del prodotto, deve possedere precise nical qualifications as well as recognised skills and ex-
competenze tecniche, particolari capacità ed espe- perience gained in the specific sector. Failure to do so
rienze acquisite e riconosciute nel settore specifico. La may lead to health and safety risks to persons.
mancanza di questi requisiti può causare danni alla si-
It is recommended that when handling the product at-
curezza e alla salute delle persone.
tention is paid to the information given in this manual
Eseguire la movimentazione del prodotto rispettando and particularly in the sections: “Packaging Methods”
le informazioni riportate in questo manuale nei para- and “Lifting and handling” or simply follow the instruc-
grafi "Modalità di imballaggio" e "Sollevamento e movi- tions given on the packaging (if present).
mentazione" oppure applicate direttamente
Utilise the product only for the use specified by the
sull’imballo (se presenti).
manufacturer. Improper use of the product could lead
Utilizzare il prodotto solo per gli usi previsti dal fabbri- to health and safety risks to persons as well as eco-
cante. L’impiego del prodotto per usi impropri può re- nomic loss and furthermore will invalidate the guaran-
care rischi per la sicurezza e la salute delle persone e tee given by the manufacturer.
danni economici, nonchè il decadere della garanzia da
Keep the product in perfect working order by following
parte del costruttore.
the scheduled maintenance procedure set out by the
Mantenere il prodotto in condizioni di massima effi- manufacturer. Good maintenance will ensure the best
cienza effettuando le operazioni di manutenzione pro- performances, a longer period of operation and a con-
grammata previste dal costruttore. Una buona stant safeguard towards security requirements.
manutenzione consentirà di ottenere le migliori presta-
To undertake maintenance procedures in areas which
zioni, una più lunga durata di esercizio e un manteni-
are hard to reach or otherwise dangerous it is impor-
mento costante dei requisiti di sicurezza.
tant to follow adequate safety conditions for one self
Per eseguire interventi di manutenzione in zone non and for others in compliance with the rules and regula-
facilmente accessibili o pericolose, predisporre ade- tions that govern safety in the workplace.
guate condizioni di sicurezza per sé stessi e per gli altri
When replacing worn parts, use original spare parts.
rispondenti alle leggi vigenti in materia di sicurezza sul
Use oils and greases recommended by the manufac-
lavoro.
turer. Doing this, will ensure that the product works
Sostituire i particolari usurati utilizzando i ricambi origi- properly and that the safety level is “acceptable”.
nali. Usare gli oli e i grassi consigliati dal costruttore.
Tutto questo potrà assicurare la funzionalità del pro-
dotto ed un livello di “sicurezza accettabile”.

DIVISIONE:
Bonfiglioli Group
New Power Solutions
1.5. Modalità di consegna 1.5. Delivery Methods
Tutti i prodotti vengono opportunamente imballati per All the products are appropriately packaged in the fol-
agevolarne la movimentazione, il trasporto e l’imma- lowing conditions to facilitate handling, transport and
gazzinaggio, nelle seguenti condizioni: storage:
– le parti e le superfici di accoppiamento vengono op- – all parts and surfaces to be coupled are appropriate-
portunamente trattate con antiossidanti; ly treated with antioxidants;
– le superfici esterne sono protette con vernice di fon- – external surfaces are protected with antioxidant wa-
do antiossidante all’acqua di color grigio; sopra ver- ter priming paint in a grey colour which can be paint-
niciabile; ed over;
– le parti interne, per garantirne l'integrità, sono pre- – to guarantee their reliability, the internal parts are
ventivamente lubrificate con un velo d'olio usato per properly lubricated with a layer of oil, the same as
il collaudo finale del riduttore e compatibile con gli the one used in the final test of the gearbox and
olii raccomandati (nella tabella a pag. 11). Non vie- compatible with the recommended oils (see Table
ne eseguito il riempimento dell' olio lubrificante (co- concerning oils on page 11). Lubricating oil has not
me segnalato da cartellino). been added (as shown on the card).
IMBALLO SU PALLET CON TERMORETRAIBILE IMBALLO CON CASSA

PACKAGED ON A PALLET WITH PACKAGED IN A CASE
THERMOSHRINKING FILM
Cartellino che informa

“privo di lubrificante”
Card which states: “does not
contain lubricating oil”
IDM-1521500010
1.6. Modalità di imballaggio 1.6. Packaging Methods
Le illustrazioni raffigurano i tipi di imballo più frequenti. The illustrations show the more common types of
Su richiesta possono essere effettuati imballaggi spe- packaging. Upon request, specific packaging can be
cifici per agevolare alcune fasi dell' installazione. organised to help with some of the installation process.
Al ricevimento del prodotto, accertarsi che When the product arrives, ensure that it meets the
corrisponda alle specifiche di acquisto e che non information contained in the purchase agreement
presenti danni o anomalie. Per qualsiasi and that there are no damages or irregularities. If
inconveniente rivolgersi direttamente alla rete di there are any problems contact the manufacturers’
vendita del costruttore. sales network directly.

DIVISIONE:
Bonfiglioli Group
New Power Solutions
1.7. Sollevamento e movimentazione 1.7. Lifting and Handling
Se la movimentazione avviene quando il prodotto è im- If the handling occurs when the product is still pack-
ballato, è sufficiente attenersi alle indicazioni applicate aged, simply follow the instructions given on the pack-
direttamente sull'imballo e/o comunque utilizzando i aging and/or use normal hoisting means.
normali mezzi di sollevamento.
Cautela - Precauzione Caution

Considerando che la massa e la forma del prodotto Considering that the size and form of the product
non ne consentono lo spostamento a mano, in do not allow manual shifting, in particular
particolari movimentazioni (es: installazione), è handlings, (e.g. installation) it is necessary to use
necessario utilizzare accessori che consentono di accessories that guarantee human safety and
garantire la sicurezza delle persone ed evitare which also avoid damages to the product.
danni al prodotto.
1.8. Modalità di magazzinaggio 1.8. Storage Methods
In fase di magazzinaggio del prodotto adottare le pre- In the storage process of the product follow the safety
cauzioni di seguito indicate. measures given below.
1. Evitare ambienti con eccessiva umidità ed esposti 1. Avoid environments with excessive humidity and
ad intemperie ed escludere aree all'aperto. exposed to changing weather conditions and make
sure that open areas are excluded.
2. Evitare il contatto diretto del prodotto con il suolo.
2. Make sure that the product does not lie directly on
3. Disporre il prodotto in modo che abbia una base di
the ground.
appoggio stabile e verificare che non sussistano ri-
schi di spostamenti imprevisti. 3. Make sure that the product is placed on a stable
base thereby avoiding that the product moves
4. Accatastare il prodotto imballato (se consentito) se-
about unexpectedly.
guendo le indicazioni riportate sull'imballo stesso.
4. Stack the packaged product (if allowed) following
Per periodi di magazzinaggio previsti superiori a 6 me-
the indications given on the packaging itself.
si, verificare ed eventualmente eseguire le seguenti
operazioni. For storing periods that go beyond 6 months, check
and consult the following procedures.
5. Per evitare ossidazioni, ricoprire tutte le parti ester-
ne lavorate con grasso. 5. To avoid oxidation, cover all the worked external
parts with grease.
6. Eseguire il riempimento dell'olio lubrificante e
orientare il prodotto in modo che il tappo di sfiato 6. Fill-up the product with lubricating oil and set it in
sia nella posizione più alta. such way that the breather plug is in the uppermost
position.

DIVISIONE:
Bonfiglioli Group
New Power Solutions
2. INFORMAZIONI TECNICHE 2. TECHNICAL INFORMATIONS
2.1. Descrizione del prodotto 2.1. Product description

I motoriduttori TRASMITAL BONFIGLIOLI della serie de- The TRASMITAL BONFIGLIOLI motorgearboxes of
scritta in questo manuale sono stati progettati e costruiti the series described in this manual are designed and
per essere applicati su macchine cingolate per il coman- built for application as track drive for crawled machines
do della traslazione con azionamento in circuito aperto. equipped with open loop hydraulic circuit.
L'unità è composta da un riduttore epicicloidale a cor- The unit includes planetary gearbox, 3 stages, rotating
po rotante a 3 stadi di riduzione. housing type.
Una importante raccomandazione è di progettare “a An important piece of advice given is “to perfectly” de-
regola d’arte” l’impianto idraulico di comando. sign the main hydraulic system.
L’illustrazione mostra le parti e le principali funzioni di The illustrations show the parts and the main functions
un motoriduttore. of the gearmotor.
Gruppo Mozzo freno / Flanged Hub and brake unit
Tappo di carico olio

Oil filling plug
Tappo di livello/scarico olio

Oil level/drain plug
Motore idraulico
Hydraulic motor
Gruppo corpo - riduzioni

Rotary Housing and reduction unit
IDM-1521530020
INFORMAZIONI TECNICHE -7- TECHNICAL INFORMATIONS

DIVISIONE:
Bonfiglioli Group
New Power Solutions
Posizione dei tappi olio sul riduttore/ Oil plugs position on the gearbox
IDM-1521530030
Legenda: Legende:
1 M22x1,5 .................................. Tappo carico olio 1 M22x1,5 ....................................... Oil filling plug
2 M22x1,5 ......................................... Tappo livello 2 M22x1,5 ........................................ Oil level plug
3 M22x1,5 ...................................... Tappo scarico 3 M22x1,5 ....................................... Draining plug
4 R 1/4" G BSP 1/4" 19 TPI ......... Comando freno 4 R 1/4" G BSP 1/4" 19 TPI ................. Brake port
INFORMAZIONI TECNICHE -8- TECHNICAL INFORMATIONS

DIVISIONE:
Bonfiglioli Group
New Power Solutions
3. INFORMAZIONI SULL’INSTALLAZIONE 3. INSTALLATION INFORMATIONS
3.1. Procedure per l’installazione 3.1. Installation procedure
Prima dell’installazione eseguire le seguenti operazioni. Before proceeding with installation, follow the instruc-
tions given below.
1. Pulire accuratamente il prodotto dai residui dell’im-
ballaggio e di protezione. 1. Properly clean the product removing packaging
and all remains of protection padding.
2. Predisporre le parti di accoppiamento facendo rife-
rimento al disegno di installazione. 2. Prepare the parts to be coupled using the installa-
tion drawing as a guide.
Le fasi principali di installazione sono di seguito elen-
cate. Nei paragrafi successivi sono indicate, in detta- The main installation processes are given below. In the
glio, le operazioni da eseguire. following sections, the procedures to follow are given
– Installazione del motore idraulico (paragrafo 3.2.) in detail.
– Installazione del prodotto sulla macchina (paragrafo – Hydraulic motor installation (section 3.2.)
3.3.) – Mounting the product to the machine (section 3.3.)
– Collegamento del freno (paragrafo 3.4.) – Connecting the brake (section 3.4.)
– Riempimento e livello dell'olio lubrificante riduttore – Filling-up the gearmotor with lubricating oil and level
(paragrafo 3.5.). of oil to maintain in the gearbox (Section 3.5.).
3.2. Installazione del motore idraulico 3.2. Hydraulic motor installation

Assicurarsi che le superfici di accoppiamento ed il cen- The mating areas and the pilot diameter of the gearbox
traggio dove va inserito il motore idraulico siano pulite where the motor is to be mounted must be clean and
ed esenti da bave. without burrs.
Prima di montare il motore idraulico, verificare, Before assembling the hydraulic motor, verify by a
con un calibro per interni, il corretto assemblaggio depth slide gauge the correct assembly of the unit
del riduttore controllando la quota assiale indicata checking the axial distance as shown in the
nello schema in basso: scheme below:
Quota assiale = 123,9÷124,7 mm. Axial dimension = 123,9÷124,7 mm.
Montare la guarnizione O-ring (32), fornita con il ridutto- Fit the O-ring (32), supplied with the gearbox, in its seat
re, nella propria sede nel motore idraulico ed assembla- in the hydraulic motor, and assemble it to the gearbox
re quest’ultimo al riduttore facendo attenzione a non being careful not to damage the seal already fitted.
danneggiare la guarnizione precedentemente montata. Lock the screws (38) using the indicated tightening
Serrare le viti (38) alla coppia di serraggio indicata. torque.
INFORMAZIONI SULL’INSTALLAZIONE -9- INSTALLATION INFORMATIONS

DIVISIONE:
Bonfiglioli Group
New Power Solutions
1. Collegare il tubo di comando freno alla porta 4. 1. Connect the brake release pipe to the port 4.
Tubo di comando freno

Brake control tube
IDM-1521530060
3.5. Riempimento olio lubrificante del riduttore 3.5. Filling-up the Gearbox with Lubricating Oil
La lubrificazione è separata fra motore e riduttore. The motor and the gearbox have separate lubrication.
La lubrificazione del riduttore è a sbattimento in bagno d'olio. The gearbox is lubricated by oil splashing.
L'olio consigliato è del tipo per trasmissioni ad ingranaggi, The recommended type of oil is SAE 80W/90 or
con viscosità SAE 80W/90 oppure SAE 85W/140 con ca- SAE 85W/140 with EP features complying with
ratteristiche EP rispondente a: MIL-L-2105 C & API GL 5, MIL-L-2105 C & API GL5, according to Tab.1
secondo le indicazioni di Tabella.
Durante l’esercizio e solo per brevi momenti l’olio During operation the oil temperature must not
può raggiungere, ma non superare, la temperatura exceed 85-90°C intermittent.
di 85-90°C intermittente.
Elenco olii consigliati a Norme SAE 80W/90 e SAE 85W/140 con caratteristiche API GL5
Lubricant oils suggested according SAE 80W/90 and SAE 85W/140 API GL5 grade
Temperatura ambiente
-10°C / +30°C +20°C / +45°C
Ambient temperature
(SAE 80W/90) (SAE 85W/140)
Viscosità olio/ Oil viscosity
Produttori / Manufacturers Tipo olio / Oil Brand
SHELL SPIRAX HD SPIRAX HD
AGIP ROTRA MP ROTRA MP
ARAL GETRIEBEOL HYP GETRIEBEOL HYP
BP-MACH HYPOGEAR EP HYPOGEAR EP
CASTROL HYPOY HYPOY
CHEVRON UNIVERSAL GEAR LUBRICANTE UNIVERSAL GEAR LUBRICANTE
ELF TRANSELFB TRANSELFB
ESSO GEAR OIL GX PONTONIC MP GEAR OIL GX PONTONIC MP
I.P. PONTIAX HD PONTIAX HD
MOBIL MOBILUBE HD MOBILUBE HD
TOTAL TRASMISSION TM TRASMISSION TM
INFORMAZIONI SULL’INSTALLAZIONE - 11 - INSTALLATION INFORMATIONS

DIVISIONE:
Bonfiglioli Group
New Power Solutions
Non mescolare olii di marca o caratteristiche diverse. Do not mix together oils of different brands or
characteristics.
Prima della messa in funzione del motoriduttore, veri-
Before starting up the motorgearbox, check the level of
ficare il livello dell’ olio lubrificante nel riduttore.
lubricating oil in the gearbox.
Questa operazione va eseguita con l'asse del riduttore
Check that the gearbox axis is horizontal. If necessary,
orizzontale. Se necessario effettuare il riempimento o refill with lubricant oil.
il rabbocco. This procedure is undertaken following the indications
Eseguire questa operazione come di seguito indicato. given below.
1. Svitare i tappi (1-2) e riempire dal foro (1) fino a 1. Unscrew the two plugs (1-2) and fill from the hole
che l'olio non fuoriesca dal foro (2). (1) until the oil flows out from the hole (2).
2. Avvitare i tappi (1-2) e mettere in funzione il ridut- 2. Tighten the oil plugs (1-2) and let the gearbox run.
tore; attendere qualche istante, poi verificare nuo- After a few minutes, stop and check the oil level.If
vamente il livello dell'olio. Aggiungerne se necessary, refill.
necessario.
Quantita' olio indicativa = 6 litri ±10% Approximate oil capacity = 6 liters ±10%
IDM-1521530070
3.6. Prima messa in esercizio e rodaggio 3.6. First Start up and Running in
In questa prima fase, si raccomanda di adottare alcune In this first stage it is advised to follow the measures
precauzioni come di seguito indicato. given below.
1. Avviare il motoriduttore dopo aver riempito il corpo 1. Start the gearmotor after having filled the housing of
del motore con olio idraulico fino al foro di drenag- the motor with hydraulic oil up to drain hole. If neces-
gio. Eliminare eventuale aria residua dal circuito sary, add further oil after having bleeded all the air in
idraulico e aggiungere olio se necessario. the hydraulic circuit.
La presenza di aria residua nel circuito idraulico si Air in the hydraulic circuit is shown by foam in the
manifesta con la presenza di schiuma nel serbatoio oil tank and will cause jerking of the motor as well
e causa un funzionamento a strappi del motore ed un as excessive noise coming from the motor and the
eccessiva rumorosità del motore e delle valvole. valves.

DIVISIONE:
Bonfiglioli Group
New Power Solutions
Per lo spurgo dell’aria dal circuito idraulico è consiglia- To bleed the air from the hydraulic circuit, start the motor-
bile avviare il motoriduttore a bassa velocità in entram- gearbox at low speed in both directions of rotation at in-
bi i sensi di rotazione ad intervalli di circa due minuti. tervals of about two minutes
2. Durante il primo avviamento, effettuare un accura- 2. During the first start up, clean the hydraulic circuit
to flussaggio dell’impianto. by flushing and oil filtering.
3. Avviare il motoriduttore a bassa velocità ed incre- 3. Start the gearmotor at a low speed and gradually
mentare gradualmente, dopo avere verificato che increase it after having verified that it is functioning
il funzionamento sia corretto, in assenza di rumore correctly without any noises or vibrations.
e vibrazioni.
Non arrivare alla massima pressione sino a Do not reach maximum pressure unless the entire
quando tutto l’impianto non sia stato filtrato per system has been flushed to clean it from any
l'eliminazione di eventuali particelle di impurità. particles of dirt that may be present.
Durante il rodaggio eseguire le operazioni di seguito During the running-in stage follow the steps given be-
indicate. low.
4. Controllare che il numero dei giri ed il senso di ro- 4. Check the correct revolution and direction of rota-
tazione siano corretti. tion
5. Controllare che il funzionamento sia regolare ed in 5. Make sure that the functioning is regular and with-
assenza di rumore eccessivo e vibrazioni. out any excessive noises and vibrations.
6. Controllare che la temperatura dell’olio non superi 6. Make sure that the oil temperature does not ex-
i 90°. ceed 90°.
7. Controllare che non vi siano altri problemi. 7. Make sure there are no other problems in general.
Al termine di questo primo rodaggio eseguire le opera- After this first running-in, follow the steps given below.
zioni di seguito indicate.
8. Check that there are no oil leakages. If present,
8. Controllare che non vi siano perdite olio. In caso proceed to remove them.
contrario provvedere alla loro eliminazione
9. Check the level of lubricating oil in the gearmotor
9. Controllare il livello dell’olio lubrificante del motori-
10. It could happen that due to the presence of air, dur-
duttore
ing the first start up, the opening action of the brake
10. Durante il primo avviamento, causa l'eventuale could be slowed down. It is advised to repeat the
presenza di aria, l'apertura del freno potrebbe ri- opening and closing function of the brake.
sultare ritardata. Ripetere alcune volte il comando
11. Check that there are no other problems in general.
di apertura e chiusura del freno.
11. Controllare che non vi siano altri problemi.

DIVISIONE:
Bonfiglioli Group
New Power Solutions
4. INFORMAZIONI SULLA MANUTENZIONE 4. MAINTENANCE INFORMATIONS
4.1. Manutenzione periodica 4.1. Periodic Maintenance
Il motoriduttore necessita solamente delle operazioni The gearmotor only requires the scheduled mainte-
di manutenzione programmata prevista dal costruttore nance procedures set out by the manufacturer (see
(vedi tabella). Table below ).
Una buona manutenzione consentirà la continuità di Good maintenance will ensure an on going functioning
funzionamento nel tempo con la massima affidabilità. in time as well as maximum reliability.
Nel caso in cui insorgano anomalie di funzionamento Should irregularities in function arise, it will be neces-
sarà necessario consultare la check-list della ricerca sary to consult the troubleshooting checklist to find the
guasti per trovare una soluzione adeguata. most adequate solution.
In caso contrario potrebbe essere necessario effettua- If unsuccessful, it may be necessary to disassemble a par-
re lo smontaggio parziale o completo del motoriduttore tially or completely the motorgearbox (see section 4.4.)
(vedi paragrafo 4.4.)
Controllo / Inspection Frequenza / Frequency Azione / Action
Serraggio viti Dopo le prime 50 ore Verifica serraggio viti

Tightening screws After the first 50 hours Screws tighening torque check
Livello olio Ogni 100 ore Rabboccare l’olio

Oil level Every 100 hours Refill oil
Primo cambio olio A 150 ore Sostituire olio

1st oil change At 150 hours Oil replacement
Cambi olio successivi Ogni 1000 ore o 1/anno Sostituire olio

Following oil changes Every 1000 hours or 1/year Oil replacement
INFORMAZIONI SULLA MANUTENZIONE - 14 - MAINTENANCE INFORMATIONS

DIVISIONE:
Bonfiglioli Group
New Power Solutions
4.2. Sostituzione dell’olio lubrificante 4.2. Changing the Lubricating oil
1. Posizionare un recipiente sufficientemente capien- 1. Place a large enough container (about 10 litres)
te (circa 10 lt) sotto al tappo di scarico olio. under the oil drain plug.
2. Svitare il tappo (1). 2. Unscrew the plug (1).
3. Svitare il tappo di scarico (3) e lasciare defluire 3. Unscrew the oil drain plug (3) and allow the oil to
l'olio. Per agevolare l'operazione di scarico è bene drain. To facilitate the draining operation, it is bet-
operare con olio caldo. ter to work with hot oil.
4. Attendere qualche minuto affinché tutto l'olio sia 4. Wait a few minutes until all the oil is drained and
uscito, quindi avvitare i tappi (1-3). than proceed to screw on drain plugs (1-3).
5. Effettuare il riempimento dell'olio seguendo le mo- 5. Proceed with the oil fill-up following the procedures
dalità predefinite (vedi paragrafo 3.5.). given (see Section 3.5.).
Cautela - Precauzione Caution

Non disperdere l’ olio nell’ ambiente ma smaltirlo Do not dispose of the oil in the natural
rispettando le leggi vigenti in materia. environment but be careful to eliminate it in
compliance with the relative rules and regulations
that govern locally.
IDM-1521530080

DIVISIONE:
Bonfiglioli Group
New Power Solutions
4.3. Ricerca guasti 4.3. Troubleshooting
La seguente tabella è stata realizzata per una indivi- The following table is a guideline to identify the trou-
duazione dei guasti nei motoriduttori per traslazione bles in the motorgearbox.
completi di motore idraulico.
Anomalie / Anomalies Cause / Causes Rimedi / Remedies

Perdita olio esterna / External oil leakage :
Dalla tenuta frontale a. Tenuta frontale danneggiata a. Sostituzione tenuta frontale
From the lifetime seal Lifetime damaged Replace lifetime seal
Dal coperchio a. Guarnizione O-ring danneggiata a. Sostituzione guarnizioni O-ring

From the end cover O-ring seal damaged Replace O-ring seals
a. Guarnizione tappo danneggiata a. Sostituzione guarnizione tappo

Plug seal damaged Replace plug seal
Dai tappi
From the plugs
b. Tappi o viti allentate b. Serrare tappi/viti
Plugs or screws loose Tighten the plugs/screws
a. Guarnizioni danneggiate a. Sostituzione guarnizioni

O-ring seals damaged Replace O-ring seals
Dal motore idraulico b. Tappi o viti allentate b. Serrare tappi/viti

From hydraulic motor Plugs or screws loose Tighten the plugs/screws
c. Interno motore danneggiato c. Verifica motore idraulico

Internal motor parts damaged Check the hydraulic motor
Eccessiva rumorosità / Too much noise :
Interno al motore idrau- a. Interno motore danneggiato a. Verifica motore idraulico
lico(rumore meccanico) Internal motor parts damaged Check the hydraulic motor
Inside the hydraulic
motor(mechanical noise)
Rumore idraulico (in fase di a. Interno motore danneggiato a. Verifica motore idraulico
rallentamento velocità Internal motor parts damaged Check the hydraulic motor
motore)
Hydraulic noise (during the b. Impianto idraulico malfunzio- b. Verificare che pressione alle boc-
slowing down of the motor nante che motore sia ≥ 3 bar
speed) Hydraulic circuit malfunctioning Verificare l’impianto idraulico
Check the pressure to the motor
ports is ≥ 3 bar
Verify hydraulic circuit
Interno al riduttore(zona a. Danneggiamento interno a. Verificare riduttore

ingranaggi) Internal damage Check the gearbox
Inside the gearmotor(reduc-
tions)

DIVISIONE:
Bonfiglioli Group
New Power Solutions
Anomalie / Anomalies Cause / Causes Rimedi / Remedies

Altro / Other:
a. Verificare livello olio e aggiun-
a) Surriscaldamento a. Livello olio scarso
gerne
Overheating Insufficient oil level
Check the oil level and refill
b) Potenza insufficiente a. Interno motore danneggiato- a. Verifica motore idraulico

Insufficient power Internal motor parts damaged Check the hydraulic motor
a. Motore idraulico bloccato a. Verifica funzionamento motore

Hydraulic motor locked Check hydraulic motor
c) Traslazione cingolo bloccata
b. Componenti meccanici ridut-
Sprocket locked
tore danneggiati b. Sostituzione parti danneggiate
Mechanical components Replace damaged parts
damaged
4.4. Smontaggio del motoriduttore 4.4. Motorgearbox disassembly
Nel caso in cui sia necessario effettuare una revisione In the case that it was necessary to undergo a (partial
(parziale o totale) è necessario smontare il motoridut- or total) revision, it will be necessary to dismount the
tore dalla macchina. Considerando che questo è un in- gearmotor from the machine. As this is known as an
tervento di manutenzione straordinaria, è opportuno out of the ordinary maintenance procedure, it is impor-
che venga realizzato da personale con competenze tant that only personnel with specific skills and experi-
specifiche e capacità acquisite. ence undertake it.
E' altresì importante che tale intervento sia effettuato in It is also important that this procedure is undertaken in
una officina opportunamente attrezzata. Oltre ai nor- a workshop that is adequately tooled. As well as nor-
mali attrezzi, è necessario disporre delle attrezzature mal workshop tools it will be necessary to use special
speciali che possono essere costruite (vedi allegati at- tools that can be made (see special tools attachment)
trezzature speciali) oppure richieste direttamente al or may be requested from the manufacturer.
costruttore.
Attrezzature speciali Special Tools
Attrezzatura per Pushing equipment for
montaggio freno ........................ Codice/: AT715C01 brake assembly ............................ Code/: AT715C01
Attrezzo per montaggio semitenuta Tool for the assembly of the
frontale riduttore ......................... Codice/: AT715C03 half lifetime seal .......................... Code/: AT715C03
Attrezzatura per montaggio Equipment for end
coperchio di chiusura ................. Codice/: AT715C07 cover assembly ...............................Code/: AT715C07
Estrattore a percussione per smontaggio Percussion puller for planet
kit planetario e boccola .............. Codice/: ATZ.05.007 reduction and bush removing........ Code/: ATZ.05.007
Per la realizzazione di queste attrezzature vedi disegni To be able to produce these equipments refer to the
costruttivi in fondo al manuale. production drawings at the end of this manual.

DIVISIONE:
Bonfiglioli Group
New Power Solutions
Nelle pagine seguenti vengono riportate tutte le fasi di In the following pages all the procedures for disassem-
smontaggio e rimontaggio del motoriduttore: rispettar- bling and reassembling the gearmotor are given, it is
le scrupolosamente. important to strictly adhere to them.
Eseguire questi interventi adottando tutte le necessa- Proceed with these operations using all the necessary
rie precauzioni, come ad esempio: safety measures, like for example:
1. chiudere tutti gi attacchi all’impianto oleodinamico sul 1. Plug all the Hydraulic ports on the gearmotor to avoid
motoriduttore per evitare l’introduzione accidentale di the introduction of any foreign particles in the circuit
corpi estranei nel circuito e nel motoriduttore. and the gearmotor.
2. fare attenzione che le superfici di accoppiamento non 2. Making sure that the coupling surfaces are not dam-
vengano danneggiate. aged.
3. eseguire la movimentazione in modo che non crei 3. Following the handling so as to be sure that there are
pericoli per la sicurezza delle persone e garantisca no risks for human safety and to guarantee the relia-
l'integrità del motoriduttore. bility of the gearmotor.
4. predisporre la zona di lavoro al fine di rispettare le leggi 4. Making available a work area that is in line with work
in materia di sicurezza e salute nei posti di lavoro. and health safety in the workplace guidelines.
NOTA: di seguito sono indicate tutte le fasi per eseguire NOTE: Below are all the steps to follow during these oper-
questi interventi. I numeri fra parentesi nel testo, corrispon- ations. Numbers in brackets in the text correspond to the
dono ai riferimenti riportati nel seguente disegno esploso.. references in the exploded view.
37
38
39
40
41
18
23 17
24
25
26
36 1
27 19 2
28 21
29 22
30 3
20
31 6
32 12 5
13 11 4
7
8
9
10
33
35
34
14
15
16
IDM-1521530090

DIVISIONE:
Bonfiglioli Group
New Power Solutions
4.5. Fasi di smontaggio 4.5. Disassembling method

Per le prime verifiche degli ingranaggi e del motore idraulico, è possibile inter- Initial inspection of the gears and of the hydraulic motor, can be made without
venire senza smontare il cingolo e il riduttore dalla macchina. Per dare inizio dismantling the track and the gearbox from the machine. Prior to dismantling
alla fase di smontaggio, fare defluire completamente l'olio lubrificante dal ridut- make sure that the oil is discharged per to instructions specified in section 4.2
tore secondo quanto descritto al paragrafo 4.2 e smontare il motore idraulico. and remove the hydraulic motor.
1. Svitare le 8 viti TCEI M16x35 (35), classe di resi-

stenza 8.8, e sfilare la flangia predisposizione mo-
tore (31) dal mozzo flangiato (17).
1. Unscrew the 8 socket head screws M16x35 (35)

grade 8.8, and remove the motor adaptor flange
(31) from the flanged hub (17).
2. Togliere la guarnizione O-ring (20) dalla propria

sede nella flangia predisposizione motore (31).
2. Remove the O-Ring (20) from its seat in the motor

adaptor flange (31).

sede nel mozzo flangiato (17).
3. Remove the O-Ring (36) from its seat in the flang-

ed hub (17).
4. Fissare l’attrezzatura AT715C01 sul mozzo flan-

giato (17); avvitare la vite filettata (part.C), pre-
mendo la pastiglia (part.B) sul disco spingimolle
(29), allentando così la pressione delle molle (28)
sull' anello elastico (30), favorendone la sua estra-
AT715C01 zione.
4. Assemble the equipment AT715C01 on the flang-

ed hub (17), by screwing the threaded bar (part.C),
push the disc (part.B) on the discs retainer (29),
thus removing the force of the springs (28) on the
circlip (30) and allowing its disassembly.

DIVISIONE:
Bonfiglioli Group
New Power Solutions
5. Con l’ausilio di pinze sfilare l’anello elastico (30)

dalla propria sede nel mozzo flangiato (17).
5. Using pliers remove the circlip (30) from its seat in

the the flanged hub (17).
6. Sfilare il disco spingimolle (29) dal mozzo flangiato

(17).
6. Remove spring retainer disc (29) from the flanged

hub (17).
7. Sfilare le molle (28) dalle proprie sedi nel pistone

freno (27).
7. Remove the springs (28) from their seats in the

brake piston (27).
8. Sfilare il pistone freno (27).
8. Remove the brake piston (27).

DIVISIONE:
Bonfiglioli Group
New Power Solutions
9. Estrarre l’albero freno (19).
9. Remove the brake shaft (19).
10. Sfilare il pacco dei dischi freno (21-22).
10. Remove brake discs pack (21-22).
11. Togliere le guarnizioni O-ring (24-25) e gli anelli

antiestrusione (23-26) dalle proprie sedi situate nel
mozzo flangiato (17).
11. Remove the O-rings (24-25) and the backup rings

(23-26) from their seats in the flanged hub (17).
12. Capovolgere il riduttore, svitare e sfilare i due tappi

M22x1,5 (2) e le relative rondelle (1) dal coperchio
di chiusura (4).
12. Turn the gearbox upside down, unscrew and re-

move the 2 plugs M22x1,5 (2) and the 2 washers
(1) from the end cover (4).

DIVISIONE:
Bonfiglioli Group
New Power Solutions
13. Svitare e sfilare le 16 viti TCEI M14x40 (3), classe

di resistenza 12.9, dal coperchio di chiusura (4).
13. Unscrew and remove the 16 socket head screws

M14X40 (3), grade 12.9, from the cover (4).
14. Sfilare il coperchio di chiusura (4) con l’ausilio

AT715C07 dell’attrezzatura AT715C07.
14. Remove the end cover (4) using the equipment

AT715C07.

sede nel coperchio di chiusura (4).
15. Remove the O-Ring (5) from its seat in the end
cover (4).
16. Avvitare una vite M5x20 nel foro filettato della pa-
stiglia (6), per sfilare la stessa dal coperchio di
chiusura (4).
16. Screw a socket head screw M5x20 in the threaded

hole of the pad (6) in order to remove it from the
end cover (4).

DIVISIONE:
Bonfiglioli Group
New Power Solutions
17. Sfilare il solare di 1° riduzione (7).
17. Remove the 1st stage sun gear (7).
18. Estrarre la 1° riduzione (8).
18. Remove the 1st reduction assembly (8).
19. Remove the 2nd stage sun gear (9).
20. Estrarre la 2° riduzione (10).
20. Remove the 2nd reduction assembly (10).

DIVISIONE:
Bonfiglioli Group
New Power Solutions
21. Remove the 3rdt stage sun gear (14).
22. Svitare le 4 viti TCEI M30x2x150 (11), classe di re-

sistenza 8.8, che fissano la 3° riduzione (12) al
22. Unscrew the 4 socket head screws M30x2x150

(11), grade 8.8, which fix the 3rd reduction assem-
bly (12) to the flanged hub (17).
23. Posizionare il riduttore su 2 distanziali.Servendosi

di una pressa e di un tampone metallico, sfilare il
mozzo flangiato (17) dal corpo riduttore (15), fa-
cendo attenzione all'eventuale caduta delle sfere.
23. Place the gearbox on 2 spacers. By using a press

and a metal stopper, remove the flanged hub (17)
from the gearbox housing (15), paying attention to
the eventual falling down of the main bearing’s
balls.
24. Estrarre la 3° riduzione (12) dal mozzo flangiato

(17).
24. Remove the 3rd reduction assembly (12) from the

flanged hub (17).

DIVISIONE:
Bonfiglioli Group
New Power Solutions
25. Utilizzando l’attrezzatura ATZ.05.007, sfilare le

boccole (13) dal mozzo flangiato (17).
ATZ.05.007
25. Using the equipment ATZ.05.007, remove the

bushes (13) from the flanged hub (17).
26. Servendosi di un estrattore, sfilare l’anello interno

del cuscinetto ed il distanziale rimasti sul mozzo
flangiato (17).
26. By using a puller remove the inner ring of the bear-

ing and the spacer remaining on the flanged hub
(17).
27. Utilizzando l’attrezzatura ATZ.05.007, sfilare i 4

gruppi planetari di 3° riduzione (12).
ATZ.05.007
27. By using a tool at ATZ.05.007 remove the 4 planet
assemblies of the 3rd reduction (12).
28. Vista di un singolo gruppo planetario di 3° riduzio-

ne (12).
28. View of the loose planet assembly of the 3rd reduc-

tion (12).

DIVISIONE:
Bonfiglioli Group
New Power Solutions
4.5. Fasi
Fasi di
di smontaggio
smontaggio 4.5. Disassembling method
Informazioni
Puo’ essere necessario in caso di perdite olio, dover
provvedere al controllo ed alla eventuale sostituzione
della tenuta frontale (16), cioe’ di entrambe le parti
metalliche e delle guarnizioni O-rings.
29. Smontare entrambe le semitenute frontali (16) dal

mozzo flangiato (17) e dal corpo riduttore (15).
Tutti i componenti sono ora a disposizione per le veri-
fiche necessarie.
Information
In case of oil leakages, it might be necessary to check
and eventually replace the lifetime seal (16), wich
means both the metal rings parts and the O-rings.
29. Remove both the half-seals (16) from the flanged

hub (17) and from the gearbox housing (15).
All the components are now ready for required exami-
nation.
4.6. Valutazione dei pezzi da sostituire 4.6. Evaluating that Pieces to Replace
I componenti soggetti ad usura sono i seguenti. The pieces that are subject to general wear and tear
– Ingranaggi. are the following:
– Cuscinetti. – Gears.
– Tutte le guarnizioni. – Bearings.
Sostituire i componenti usurati o guasti rispettando le – All the seals
seguenti indicazioni: Replace the used or irregular parts respecting the fol-
1. Rimuovere accuratamente lo sporco, in particolare lowing steps:
pulire le sedi delle guarnizioni, dei cuscinetti e degli 1. Accurately remove dirt, and in particular properly
anelli di bloccaggio. clean the seals, bearings and locking rings seating.
2. Lubrificare i componenti prima di montarli. 2. Lubricate the parts before connecting them.
3. In caso di ingranaggi danneggiati, esempio un pla- 3. In the case of damaged gears, for example a plan-
netario, non sostituire il singolo ingranaggio ma etary, do not proceed to replace the individual gear
tutta la riduzione. but the entire reduction assembly.
4. Sostituire sempre tutte le guarnizioni interessate 4. When reconnecting a part always replace all the
alla parte da rimontare. seals involved.
5. Sostituire le parti danneggiate con ricambi origina- 5. Replace all the damaged parts with original spare
li e rispettando le indicazioni fornite dal costruttore parts and doing so follow all the steps given by the
nel paragrafo 4.7. manufacturer in Section 4.7.

DIVISIONE:
Bonfiglioli Group
New Power Solutions
4.7.
4.7. Fasi
Fasidi
dirimontaggio
rimontaggio 4.7.
4.7. Reassembling
ReassemblingMethod
Method
IDM-1521530040
Per ottenere una perfetta tenuta del riduttore,è neces- Instructions to properly assemble the lifetime seal.
sario procedere al montaggio degli anelli nel seguente
1. Carefully clean the seats ("A" and "B") using, if
modo:
necessary, metal brushes or solvent (surfaces in
1. Effettuare una accurata pulizia degli alloggiamen- contact with or ("C") must be perfectly clean and
ti (A e B) facendo uso, se necessario, di spazzole dry).
metalliche o solventi (le superfici a contatto con gli
2. Make sure that sealing surfaces "D" of metal
anelli di gomma (C) devono essere perfettamente
rings "E" are free from scratches, dinges or foreign
pulite ed asciutte).
substances; metal ring surfaces must be perfectly
2. Assicurarsi che le superfici di tenuta (D) degli clean and dry.
anelli (E) siano esenti da qualsiasi rigatura, am-
3. Carefully clean the lapped surface "D" of metal
maccatura o corpi estranei e che le superfici (F)
rings "E" and remove dust or fingerprints. Then lu-
degli stessi anelli siano perfettamente pulite ed
brificate them with a thin oil film, taking care not to
asciutte.
oil the other components.
3. Togliere dalle superfici lappate (D) degli anelli
(E) ogni traccia di polvere o impronte digitali e
umettarle poi con un leggero strato di olio, avendo
cura di non ungere le rimanenti parti.

DIVISIONE:
Bonfiglioli Group
New Power Solutions
4.7. Fasi di rimontaggio 4.7. Reassembling Method
1. Montare una semitenuta frontale (16) sull’ attrezzo

AT715C03.
1. Assemble the half seal (16) on the tool AT715C03.
AT715C03
2. Eseguire il montaggio della 1° semi-tenuta frontale

(16) sul corpo riduttore (15).
AT715C03
2. Assemble the 1st half seal (16) in the flanged hub

(15).
3. Montare, sempre con lo stesso attrezzo

AT715C03, la semitenuta frontale (16) sul mozzo
flangiato (17).
AT715C03
3. Assemble, by using the same tool AT715C03, the

half seal (16) on the flanged hub (17).
4. Pulire le parti metalliche della tenuta frontale (16)

da eventuali residui o polvere, e stendere sulla loro
superficie un leggero strato di olio.
4. Clean carefully the metallic faces of the lifetime

seal (16), and Lube them metallic with a thin oil
film.

DIVISIONE:
Bonfiglioli Group
New Power Solutions
5. Montare sul corpo riduttore (17) il giro di sfere infe-

riore (d), sostenendo l’anello interno (c) tramite i di-
stanziali (a-b).
5. Fit the lower ball row (d), into the gearbox housing
(17) holding the inner raceway (c) with spacers (a-b).
IDM-1521530100
6. Sfilare il distanziale (b).

Montare il distanziale (e).
Montare il giro di sfere superiore (f).
Inserire l’anello interno del cuscinetto (g).
g
6. Remove the spacer (b).

f
Insert the spacer (e).
Drop the upper ball row (f).
e Assemble the inner raceway (g).
b a
IDM-1521530110

DIVISIONE:
Bonfiglioli Group
New Power Solutions
7. Posizionare il mozzo flangiato (17) all’interno del

corpo riduttore (15).Servendosi di una pressa e di
un tampone metallico, spingere il mozzo flangiato
(17) in battuta sul corpo riduttore (15) fino ad otte-
nere il completo assemblaggio del gruppo.
7. Place the flanged hub (17) inside the gearbox

housing (15). Using a press and a metallic stopper,
push the flanged hub (17) against the shoulder on
the gearbox housing (15) untill assembling of the
unit is complete.
8. Posizionare le 4 boccole (13) nelle proprie sedi

mozzo flangiato (17). Con la pressa spingere le
boccole (13) in battuta sul mozzo flangiato (17) fino
ad ottenere il completo assemblaggio.
8. Place the 4 bushes (13) into their seats on the

flanged hub (17). Using a press, push the bushes
(13) against the shoulder inside their seats into the
flanged hub (17) until assembling is complete.
9. Posizionare i 4 gruppi planetari di 3° riduzione nel-

le proprie sedi nel mozzo flangiato (17), e con una
pressa spingerli in battuta fino ad ottenere il com-
pleto assemblaggio.
9. Place the 4 planet assemblies of the 3rd reduction

into their seats on the flanged hub (17), and with a
press, push them against the shoulder until as-
sembly is complete.
10. Posizionare il portaplanetari di 3° riduzione sul

10. Place the 3rd reduction planet carrier on the flang-

ed hub (17).

DIVISIONE:
Bonfiglioli Group
New Power Solutions
11. Servendosi di una pressa, spingere il portaplane-

tari di 3° riduzione in battuta sul mozzo flangiato
(17) fino ad ottenere il completo assemblaggio.
11. Using a press, push the 3rd reduction planet carri-

er against the shoulder on the flanged hub (17) un-
til assembling is complete.
12. Applicare LOCTITE tipo 243 sulle 4 viti TCEI

M30x2x150 (11), classe di resistenza 8.8, ed inse-
rirle nei rispettivi fori.
12. Apply LOCTITE type 243 on the 4 socket head

screws M30x2X150 (11), grade 8.8, and insert
them in the thread holes.
13. Serrare le 4 viti TCEI M30x2x150 (11), classe di re-

sistenza 8.8 con una chiave dinamometrica alla
coppia di 1500 Nm.
13. Tighten the 4 socket head screws M30x2x150

(11), grade 8.8, by a torque wrench, at 1500 Nm
torque.
1500 Nm
14. Inserire il solare di 3° riduzione (14).
14. Insert the 3rd stage sun gear (14).

DIVISIONE:
Bonfiglioli Group
New Power Solutions
15. Montare la 2° riduzione (10).
15. Assemble the 2nd reduction assembly (10).
16. Insert the 2nd stage sun gear (9).
17. Montare la 1° riduzione (8).
17. Assemble the 1st reduction assembly (8).
18. Insert the 1st stage sun gear (7).

DIVISIONE:
Bonfiglioli Group
New Power Solutions
19. Montare la guarnizione O-ring (5) nella propria

sede nel coperchio di chiusura (4).
19. Assemble the O-ring (5) into its seat in the cover
(4).
20. Posizionare la pastiglia (6) sul copercio di chiusura

(4) e servendosi di una pressa, spingerla in battuta
fino ad ottenere il completo assemblaggio.
20. Place the pad (6) on the end cover (4) and using a
press, push it against the shoulder untill assem-
bling is complete.
AT715C07 21. Servendosi dell’attrezzatura AT715C07 montare il

coperchio di chiusura (4) sul corpo riduttore (15).
21. Use the equipment AT715C07 to place the end

cover (4) on the gearbox housing (15).
22. Applicare LOCTITE tipo 242 sulle 16 viti M14x40

(3), classe di resistenza 12.9, e serrarle con una
chiave dinamometrica alla coppia di 190 Nm.
22. Apply LOCTITE type 242 on the 16 socket head

screws M14x40 (3),grade 12.9, and tighten them
by a torque wrench at 190 Nm torque.
190 Nm

DIVISIONE:
Bonfiglioli Group
New Power Solutions
23. Inserire le rondelle (1) e serrare i tappi M22x1,5 (2)

con una chiave dinamometrica alla coppia di
60÷70 Nm.
23. Assemble the washers (1) and tighten the plugs

M22x1,5 (2) with a torque wrench at 60÷70 Nm
torque.
60 ÷ 70 Nm
24. Capovolgere il riduttore e montare l'albero freno

(19) all'interno del mozzo flangiato (17).
24. Turn the gearbox upside down and assemble the

brake shaft (19) inside the flanged hub (17).
25. Montare il pacco dei dischi freno secondo il se-

guente ordine: inserire per primo un disco in bron-
zo sinterizzato (21) a dentatura esterna.
25. Assemble the brake discs package according to

the following order:firstly, insert one sintered
bronze disc with external teeth (21).
26. Inserire successivamente un disco in acciaio (22)

a dentatura interna. Ripetere l'operazione sino ad
ottenere una successione di n° 7 dischi in bronzo
sinterizzato e n° 6 in acciaio.
26. Then insert, an internally toothed steel disc (22).

Repeat the operation untill all 7 sintered bronze
discs and 6 steel discs have been assembled.

DIVISIONE:
Bonfiglioli Group
New Power Solutions
27. Applicare nella sedi delle guarnizioni, all’interno

del mozzo flangiato (17) uno film d’olio e montare
gli O-rings (24-25) e gli anelli antiestrusori (23-26).
27. Apply in the seals’ seats, inside the flanged hub (17)
a thin oil film and assemble the O-rings (24-25) and
the back-rings (23-26).
Entrata olio in pressione

Pressurized oil inlet
BA Informazioni
Inserire nelle sedi gli anelli O-ring (A) e gli anelli
AB antiestrusione (B) rispettando le posizioni
reciproche indicate nello schema.
Information
The O-rings (A) and a the backup rings (B) must be
fitted in the seats according the mutual position
as shown in the scheme.
IDM-1521530120
28. Montare il pistone freno (27) all’ interno del mozzo

flangiato (17), facendo attenzione a non danneg-
giare le guarnizioni precedentemente montate.
28. Insert the brake piston (27) inside the flanged hub
(17), being careful not to damage the seals already
fitted
29. Inserire le molle (28) nelle sedi del pistone freno

(27).
29. Insert the springs (28) into the holes in the brake
piston (27).

DIVISIONE:
Bonfiglioli Group
New Power Solutions
30. Inserire il disco spingimolle (29).
30. Insert the spring retainer disc (29).
31. Fissare l’attrezzatura AT715C01 al mozzo flangia-

to (17) e avvitare la vite filettata fino a quando il di-
sco spingimolle (29) non e’ sceso al di sotto della
sede dell’ anello elastico.
AT715C01
31. Assemble the equipment AT715C01 to the flanged

hub (17) and tighten the threaded screw until the
springs retainer disc (29) is below the circlip seat.
32. Con l’aiuto di pinze, montare l’anello elastico (30)

AT715C01 nella propria sede.
32. Using pliers, assemble the circlip (30) into its seat.

sede nel mozzo flangiato (17).
33. Assemble the O-ring (36) into its seat in the flang-
ed hub (17).

DIVISIONE:
Bonfiglioli Group
New Power Solutions

sede nella flangia predisposizione motore (31).
34. Assemble the O-ring (20) into its seat in motor

adaptor flange (31).
35. Posizionare e fissare la flangia predisposizione

motore (31) al mozzo flangiato (17) con 8 viti TCEI
M16x35 (35), classe di resistenza 8.8, serrate con
una chiave dinamometrica alla coppia di 215 Nm.
35. Place and fix the motor adaptor flange (31) to the
flanged hub (17) with 8 screws M16x35 (35) grade
8.8, tightened by a torque wrench at 215 Nm
torque
215 Nm
Informazioni
Prima di montare il motore idraulico, verificare,
con un calibro per interni, il corretto assemblaggio
del riduttore controllando la quota assiale indicata
nel disegno a fianco.
Information
Before assembling the hydraulic motor, verify by a
depth slide gauge the correct assembly of the unit
checking the axial distance as shown in the
scheme.
123,9 ÷ 124,7
IDM-1521530130

DIVISIONE:
Bonfiglioli Group
New Power Solutions
4.8. Controllo
Controllofinale
finaleeereinstallazione
reinstallazione 4.8. Final
Final Test
Test and
and Reinstallation
Reinstallation
Verificare il prodotto reinstallandolo sulla macchina. Check the product by remounting it to the machine.
Verificare la funzionalità della trasmissione eseguendo Check the function of the transmission following all the
tutti i controlli indicati nel paragrafo 3.6. checks shown in section 3.6.
Qualora si sia eseguito un intervento sul freno, è ne- If work on the brake was undertaken, it is important to
cessario controllare che non ci siano perdite d’olio. check that there are no oil leakages.
Procedere come segue: Follow the procedure below:
1. Collegare un manometro (con fondo scala a 300 1. Connect a manometer (with a base scale of 300
bar) come indicato in figura. bars) as shown in the diagram.
2. Collegare il sistema fre- 2. Connect the braking sys-
nante, come indicato tem, as shown in Section
nel paragrafo 3.4. 3.4.
3. Eseguire il riempimento 3. Proceed to fill-up with lu-
dell' olio lubrificante, bricating oil as shown in
come indicato nel para- section 3.5.
grafo 3.5.
4. Command the brake
4. Comandare l’apertura opening with hydraulic
del freno con olio idrau- oil with a pressure of 150
lico alla pressione di bars. Maintain the brake
150 bar. Mantenere la pressure for 3 minutes
pressione nel freno per intercepting the brake
un periodo di 3 minuti control with a valve. Us-
intercettando con una ing the manometer,
valvola il comando fre- check that the pressure
no. Verificare con il ma- remains constant.
nometro che la
pressione rimanga co-
stante.
IDM-1521530140
Se la pressione diminuisce significa che le If the pressure drops it may mean that the brake
guarnizioni del freno non fanno tenuta, in tal caso seals are not tight and consequently they must be
si dovrà procedere alla loro sostituzione, oppure replaced or it may mean that the reassembling was
che il rimontaggio non è stato eseguito in modo not completed properly.
corretto.
5. Al termine delle operazioni rimontare il motore 5. Afer having reassembled the gearbox, fit the hy-
idraulico come indicato nel paragrafo 3.2. draulic motor, as shown in section 3.2.

DIVISIONE:
Bonfiglioli Group
New Power Solutions
4.9. Dismissione e rottamazione del prodotto 4.9. Dismantling and Destroying the Product
La dismissione del motoriduttore va effettuata rispet- When dismantling the gearmotor follow the indications
tando le seguenti indicazioni: given below:
1. Smontare il riduttore dalla sua sede e svuotare 1. Dismount the gearbox from its seating and empty
l’olio lubrificante. the lubricating oil.
2. Smontare completamente il riduttore e rimuovere 2. Completely dismount the gearbox and remove all
l’olio e il grasso dai componenti. oil and grease from its parts.
3. Avviare i materiali pericolosi e/o inquinanti ai ri- 3. Send all dangerous and/or polluted parts to the au-
spettivi centri di smaltimento, come richiesto dalle thorised demolishing centres whilst keeping in line
leggi vigenti in materia. with respective local rules and regulations.

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%21),*/,2/,5,'87725,6S$
DIVISIONE:
%21),*/,2/,5,'87725,6S$ ),/,$/,,7$/,$'20(67,&2)),&(6
6HGH&HQWUDOH+HDG2IILFH
3$50$
Via Giovanni XXIII, 7/A - 40012 Lippo di Calderara di Reno Piazza Badalocchio Sisto Rosa, 9/C
Bologna (ITALY) Tel.0521987275 - Fax 0521987368
TEL. (++039) 0516473111 - FAX (++039)0516473126
%21),*/,2/,5,'87725,6S$ Internet http://www.bonfiglioli.com 725,12
'LYLVLRQH75$60,7$/%21),*/,2/, E-mail: bonfiglioli@bonfiglioli.com Corso Susa, 242 - Palazzo Prisma 88 - 10098 Rivoli
VIA ENRICO MATTEI,12 - Z.I. VILLA SELVA Tel. 0119585116 - Fax 0119587503
%21),*/,2/,5,'87725,6S$
47100 Forli’ (ITALY)
Tel. (++039) 0543789111 'LYLVLRQH%21),*/,2/,&20321(176 '(326,7,,1,7$/,$
Fax (++039) 0543789242 - 0543789245 Via Armaroli, 15 - 40012 Calderara di Reno
672&.+286(6,1,7$/<
E-mail: tramital@bonfiglioli.com Bologna (ITALY)
Tel. (++039) 0516473111 - Fax (++039) 0516473482 $66$*20,/$12
%21),*/,2/,5,'87725,6S$ Via Idiomi ang. Donizetti

'LYLVLRQH6,/(&75216,67(0, Tel. 0248844710 / 024883395 - Fax 0248844750 / 4883874
SS610 Selice, 42/C - 40026 Imola - Bologna (ITALY) 3$'29$
Tel. (++039) 0542640968 - Fax (++039) 0542642154 IX Strada, 1 - Zona Industriale
E-mail: silectron@bonfiglioli.com Tel.0498070911 - Fax 0498074033 / 0498073883
$8675$/,$ )5$1&( ,1',$

BONFIGLIOLI TRANSMISSION Pty Ltd. BONFIGLIOLI TRANSMISSIONS S.A. BONFIGLIOLI TRANSMISSION (Pvt) Ltd - BRS JANUS
48-50 Adderley St. (EAST) - Auburn NSW 2144 14 Rue Eugene Pottier BP 19 34 Tank Blind Road, Nunambakkam – Chennai 600034
Tel. (++61) 2-97488955 - Fax (++61) 2-97488740 Zone Industrielle de Moimont II - 95670 Marly la Ville Tel. (++91) 44 8254719 / 8237228- Fax (++91) 44 8254719
Po Box 6705, Silverwater NSW 2128 AUSTRALIA Tel. (++33) 1-34.47.45.10 - Fax (++33) 1-34.68.88.00 E-mail: bonfig@md3.vsnl.net.in
Tlx 688501 BONFI F - E mail: bonfiglioli@infonie.fr
86$&$1$'$ 63$,1
BNA BONFIGLIOLI NORTH AMERICA INC. *(50$1< TECNOTRANS SABRE S.A.
2-7941 Jane Street - Concord, ONTARIO L4K 4L6 1RWKHUQ*HUPDQ\ Pol. Ind. Zona Franca Sector C, Calle F n°6 08040 Barcelona
Tel. (++1) 905-7384466 - Fax (++1) 905-7389833 BONFIGLIOLI GETRIEBE GmbH Tel. (++34) 93-33.60.261
Internet www.bnagear.com Waldstrasse 23 - 63128 Dietzenbach Fax (++34) 93-33.60.352 o 93-33.60.402
E-mail: carlov@bnagear.com Tel. (++49) 6074-3763.0 - Fax (++49) 6074-3763-50 Internet: http://tecsab.datalab.es
E-mail: joano@datalab.es
(1*/$1' %DGHQ:XUWWHPEHUJ8QG%D\HUQ
BONFIGLIOLI (UK) LIMITED BONFIGLIOLI BWB GmbH 6287+$)5,&$
5 Grosvenor Grange - Woolston - Warrington Werner Von Siemens STR 6/15L - D-86159 Augsburg BONFIGLIOLI POWER TRANSMISSION (PTY) LTD.
Cheshire WA1 4SF Tel. (++49) 821-25746-0 - Fax (++49) 821-25746-20 4 Neutron Street, Linbro Businesspark Sandton
Tel. (++441) 925-852667 - Fax (++441) 925-852668 P.O. Box 650824, 2010 Benmore
*5((&(
E-mail: bonfiglioliuk@btinternet.com Tel. (++27) 11-608-2030 - Fax (++27) 11-608-2631
BONFIGLIOLI HELLAS S.A. E-mail: rohman@bonfiglioli.co.za
Via Laxanagoras, 12 - 54628 Menemeni Thessaloniki
Tel. (++30) 31-754376 / 754377 - Fax (++30) 31-754378 6:('(1
E mail: bonfigr@otenet.gr BONFIGLIOLI SKANDINAVIEN AB
Kontorsgatan - S-234 34 Lomma
Tel. (++46) 40-412545 - Fax (++046) 40-414508
E-mail: info@bonfiglioli.se
http://www.bonfiglioli.com(PDLOtrasmital@bonfiglioli.com

Circuit diagrams
B Circuit diagrams
B.A Hydraulic diagram, 353

F26_FT001
Bomag GmbH
Hellerwald Hydraulikschaltplan
56154 Boppard
Hydraulic schematic
Projektbeschreibung BW 226 DH -5
Project description
Zeichnungsnummer 353
Drawing number
Typ BW 226 DH -5; BW 226 BVC-5; BW 226 PDH-5; BW 226 DI-5; BW 226 RC-5
Type
Maschinenhochnummer 58600040
Machine index 58600041
58600042
58600043
58600044
58600045
58600046
Erstellt am
Created on 17.05.2013
von (Kürzel)
Bearbeitet am 06.11.2015 hagen
Edit date by (short name)

0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Bearb. I. Hagen drawing number
Blatt
Ed. by 27.05.2015 BW 226 DH -5 Deckblatt 353 Page 1
Dokumentart
Gepr Cover sheet document type
Blatt
Appr EPH Page 11
Circuit diagrams
963
964
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Bearbeiter /
Seite / Page Seitenbeschreibung Page description Datum / Date Edited by
X
1 Deckblatt Cover sheet 27.05.2015 hagen X
2 Inhaltsverzeichnis : 1 - Legende.a Table of contents : 1 - Legende.a 06.11.2015 hagen
3 Übersicht DH Übersicht DH 27.05.2015 hagen
4 Fahrkreis DH Fahrkreis DH 30.06.2015 hagen
5 Lenkung / Einspeisung DH Lenkung / Einspeisung DH 30.06.2015 hagen
Circuit diagrams
6 Vibration DH Vibration DH 30.06.2015 hagen

7 Vario Vario 30.06.2015 hagen
8 Rückläufe Return flows 30.06.2015 hagen
9 Logiktabelle Logic table 06.11.2015 hagen
Legende Betriebsmittelliste : 01 - 23 Device tag list : 01 - 23 06.11.2015 hagen
Legende.a Betriebsmittelliste : 30 - 31 Device tag list : 30 - 31 06.11.2015 hagen

0 1 2 3 4 5 6 7 8 9
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Circuit diagrams
965
966
5.5 / A
M14 4.6 / Q M14 A1 A2

01 02
fahren vorwärts fahren rückwärts 6.4 / R
O fahren rückwärts fahren vorwärts 07
to drive forward to drive backward to drive backward to drive forward 37 +/- 2 bar
Y16 Y73 6.4 / F

C1 C2 C1 C2
4.2
Y17 Y72 Q
E MA E MA
M3 L2 M3 L2 Y04
Circuit diagrams
A A P1 P2 T
8.5 / H
Δ 450 bar Δ 450 bar
25 bar (34 bar)
M4 Δ 450 bar M4 Δ 450 bar

31
Option
Option
CW CW
6.4 / J
M5 M5 OUT
B B
3,5 bar
L4 MB L4 MB 1µm nom.
6.2 M
D 2 L/min
IN
B / 8.5 G / 8.6
L2 MA N L2 MA N
09
A A
08 08 10
C6 C6
12 l/min 12 l/min
Max Min Max Min
B B
L1 L1

M4 M5 MB M4 M5 MB
0 1 2 3 4 5 6 7 8 9
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Gepr document type
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12 12
links rechts
L R

11
Δ 175 bar
P T
6.4
N
30
nur bei Maschinen mit Kabine 13
Δp = 3,5 bar
Δp = 2,5 bar
04
4.2 / A
E / 8.7

0 1 2 3 4 5 6 7 8 9
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Ed. by 30.06.2015 BW 226 DH -5 Lenkung / Einspeisung DH 353 Page 5
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Appr EPH Page 11
Circuit diagrams
967
968
4.8
J
4.6 / F K / 8.5
M14
4.2
03 R
große Vibration kleine Vibration
Circuit diagrams
large vibration small vibration

N / 5.4
C1 C2
Y07 Y08
F E MA
M3 L2
A
M1
14
A
(34 bar) Δ 400 bar
M4 Δ 400 bar
14,2 l/min
CW L1
17 cm³ B
M5
M2 L2
B
S L4 MB
4.2 L / 8.6
D
C / 8.7

0 1 2 3 4 5 6 7 8 9
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23
Ø 0,5
vorne P T hinten
A B
22 120 bar (±3 bar)
120 bar (±3 bar)
P5 T
P4 P6 a b
Speicher 1,4 L
20 Accumulator 1,4 L P2
Y140 Y141
Gasdruck 85 bar
Gas pressure 85 bar T2
T1
M
110 bar (±2 bar)
99 bar
P3 T
130 bar (+5 bar)
P1 T1
21
X / 8.4 8.3 / I
P1 P2
05
S1 S2

M / 8.7
0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
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Ed. by 30.06.2015 BW 226 DH -5 Vario 353 Page 7
Dokumentart
Gepr Vario document type
Blatt
Appr EPH Page 11
Circuit diagrams
969
970
Circuit diagrams
K / 6.6
B / 4.1
4.9 / H
L / 6.7
G / 4.5
M / 7.2
X / 7.4
I C H A F G E D E / 5.4
C / 6.4
16
7.7 / I
B
55°C - 70°C

0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
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Ed. by 30.06.2015 BW 226 DH -5 Rückläufe 353 Page 8
Dokumentart
Gepr Return flows document type
Blatt
Appr EPH Page 11
0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 06.11.2015 BW 226 DH -5 Logiktabelle 353 Page 9
Dokumentart
Gepr Logic table document type
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Circuit diagrams
971
972
Betriebsmittelliste Device tag list F03_001
Technische Daten Technische Daten
Betriebsmittelkennzeichen Funktionstext QVW technical data Symbol Betriebsmittelkennzeichen Funktionstext QVW technical data Symbol
Device tag Function text X-Ref Messwert Symbol Device tag Function text X-Ref Messwert Symbol
Metered value Metered value
M14 L R
C1 C2
01 Fahrpumpe vorne 4.0 89 cm³ 11 Lenkventil 5.3 500 cm³

E MA
M3 L2
A
Drive pump forwand steering valve
M4
CW
M5
B
L4 MB P T
M14
Circuit diagrams
C1 C2
02 Fahrpumpe 4.4 89 cm³ 12 Lenkzylinder 5.4 100/50/320 Hub

E MA
M3 L2
A
drive pump Steering cylinder 5.5 100/50/320 Hub
M4
CW
M5
B
L4 MB
M14
C1 C2
F E MA
03 Vibrationspumpe 6.2 78 cm³ M3 L2
A
13 Filter 5.5 12 µm abs.
vibration pump Filter
M4
CW
M5
B
Δp = 3,5 bar
S L4 MB
Δp = 2,5 bar
M1
04 Lenkpumpe 5.4 16 cm³ 14 Vibrationsmotor 6.6 80 cm³ A
Steering pump vibration motor
L1
B
M2 L2
I C H A F G E D
P1 P2
05 Zahnradpumpe 7.2 16/8 cm³ 16 Rücklaufsammler mit Thermoregler 8.6 B
Gear pump Return flows collector with thrmostat 55°C - 70°C
S1 S2
A1 A2 P5 T
P4 P6
07 Bremslöseventil 4.8 37 +/- 2 bar 20 Druckabschaltventil 7.3
brake opening velve Pressure shut-off valve
T1
P1 P2 T P3 T
L2 MA N
A
08 Fahrmotor C6 21 Hochdruckfilter
4.0 110/50 cm³ 7.2 100 µm
drive motor 4.4 110/50 cm³ High pressure filter
Max Min
B
L1
M4 M5 MB
A B
09 Achse 4.3 i= 93,74 22 Ventil 7.6 130 bar

Axis Valve
P2
T2
M
P1 T1
10 Getriebe 4.7 i=129,2 23 Schwenkantrieb 7.6 STF1-00-22

Gearbox Swivel drive

P T
* alle Drücke gemessen bei einer Öltemperatur von ca. 50°C; Verbrennungsmotor im hohen Leerlauf
* all pressure measurement at oil temperature 50 °C; combustion engine at high idle
0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
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Dokumentart
Gepr Device tag list : 01 - 23 document type
Blatt
Appr EPH Page 11
30 Silencer 5.3
Silencer
OUT
31 Nebenstromfilter 4.8 1 µm nom. 3,5 bar
1µm nom.
Partial flow filter
M
2 L/min
IN

0 1 2 3 4 5 6 7 8 9
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Ed. by 06.11.2015 BW 226 DH -5 Betriebsmittelliste : 30 - 31 353 Page Legende.a
Dokumentart
Blatt
Appr EPH Page 11
Circuit diagrams
973
Circuit diagrams
B.B Hydraulic diagram, 356

F26_FT001
Bomag GmbH
Hellerwald Hydraulikschaltplan
56154 Boppard
Hydraulic schematic
Projektbeschreibung BW 219 DH -5
Project description
Zeichnungsnummer 356
Drawing number
Typ BW 219 DH -5; BW 219 BVC-5; BW 226 PDH-5;
Type
Maschinenhochnummer 58600033
Machine index 58600034
58600037
58600038
58600039
Erstellt am
Created on 12.11.2015
von (Kürzel)
Bearbeitet am 12.11.2015 hagen
Edit date by (short name)

0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 12.11.2015 BW 219 DH -5 Deckblatt 356 Page 1
Dokumentart
Gepr Cover sheet document type
Blatt
Appr EPH Page 11
Circuit diagrams
975
976
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Inhaltsverzeichnis / Table of contents Column X: An automatically generated page was edited F06_001
Bearbeiter /
Seite / Page Seitenbeschreibung Page description Datum / Date Edited by
X
1 Deckblatt Cover sheet 12.11.2015 hagen X
2 Inhaltsverzeichnis : 1 - Legende.a Table of contents : 1 - Legende.a 06.11.2015 hagen
3 Übersicht DH Übersicht DH 12.11.2015 hagen
4 Fahrkreis DH Fahrkreis DH 12.11.2015 hagen
5 Lenkung / Einspeisung DH Lenkung / Einspeisung DH 12.11.2015 hagen
Circuit diagrams
6 Vibration DH Vibration DH 12.11.2015 hagen

7 Vario Vario 12.11.2015 hagen
8 Rückläufe Return flows 12.11.2015 hagen
9 Logiktabelle Logic table 12.11.2015 hagen
Legende Betriebsmittelliste : 01 - 23 Device tag list : 01 - 23 06.11.2015 hagen
Legende.a Betriebsmittelliste : 30 - 31 Device tag list : 30 - 31 12.11.2015 hagen

0 1 2 3 4 5 6 7 8 9
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Blatt
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Dokumentart
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Circuit diagrams
977
978
5.5 / A
M14 4.6 / Q M14 A1 A2

01 02
fahren vorwärts fahren rückwärts 6.4 / R
O fahren rückwärts fahren vorwärts 07
to drive forward to drive backward to drive backward to drive forward 37 +/- 2 bar
Y16 Y73 6.4 / F

C1 C2 C1 C2
4.2
Y17 Y72 Q
E MA E MA
M3 L2 M3 L2 Y04
Circuit diagrams
A A P1 P2 T
8.5 / H
25 bar (34 bar)
M4 Δ 450 bar M4 Δ 450 bar

31
Option
Option
CW CW
6.4 / J
M5 M5 OUT
B B
3,5 bar
L4 MB L4 MB 1µm nom.
6.2 M
D 2 L/min
IN
B / 8.5 G / 8.6
L2 MA N L2 MA N
09
A A
08 08 10
C6 C6
12 l/min 12 l/min
Max Min Max Min
B B
L1 L1

M4 M5 MB M4 M5 MB
0 1 2 3 4 5 6 7 8 9
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Gepr document type
Blatt
Appr EPH Page 11
12 12
links rechts
L R

11
Δ 175 bar
P T
6.4
N
30
nur bei Maschinen mit Kabine 13
Δp = 3,5 bar
Δp = 2,5 bar
04
4.2 / A
E / 8.7

0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 12.11.2015 BW 219 DH -5 Lenkung / Einspeisung DH 356 Page 5
Dokumentart
Gepr document type
Blatt
Appr EPH Page 11
Circuit diagrams
979
980
4.8
J
4.6 / F K / 8.5
M14
4.2
03 R
große Vibration kleine Vibration
Circuit diagrams
large vibration small vibration

N / 5.4
C1 C2
Y07 Y08
F E MA
M3 L2
A
M1
14
A
(34 bar) Δ 400 bar
M4 Δ 400 bar
14,2 l/min
CW L1
17 cm³ B
M5
M2 L2
B
S L4 MB
4.2 L / 8.6
D
C / 8.7

0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
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Dokumentart
Gepr document type
Blatt
Appr EPH Page 11
23
Ø 0,5
vorne P T hinten
A B
22 120 bar (±3 bar)
120 bar (±3 bar)
P5 T
P4 P6 a b
Speicher 1,4 L
20 Accumulator 1,4 L P2
Y140 Y141
Gasdruck 85 bar
Gas pressure 85 bar T2
T1
M
110 bar (±2 bar)
99 bar
P3 T
130 bar (+5 bar)
P1 T1
21
X / 8.4 8.3 / I
P1 P2
05
S1 S2

M / 8.7
0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
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Dokumentart
Gepr Vario document type
Blatt
Appr EPH Page 11
Circuit diagrams
981
982
Circuit diagrams
K / 6.6
B / 4.1
4.9 / H
L / 6.7
G / 4.5
M / 7.2
X / 7.4
I C H A F G E D E / 5.4
C / 6.4
16
7.7 / I
B
55°C - 70°C

0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 12.11.2015 BW 219 DH -5 Rückläufe 356 Page 8
Dokumentart
Gepr Return flows document type
Blatt
Appr EPH Page 11
0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 12.11.2015 BW 219 DH -5 Logiktabelle 356 Page 9
Dokumentart
Gepr Logic table document type
Blatt
Appr EPH Page 11
Circuit diagrams
983
984
M14 L R
C1 C2
01 Fahrpumpe vorne 4.0 89 cm³ 11 Lenkventil 5.3 500 cm³

E MA
M3 L2
A
Drive pump forwand steering valve
M4
CW
M5
B
L4 MB P T
M14
Circuit diagrams
C1 C2
02 Fahrpumpe 4.4 89 cm³ 12 Lenkzylinder 5.4 100/50/320 Hub

E MA
M3 L2
A
drive pump Steering cylinder 5.5 100/50/320 Hub
M4
CW
M5
B
L4 MB
M14
C1 C2
F E MA
03 Vibrationspumpe 6.2 78 cm³ M3 L2
A
13 Filter 5.5 12 µm abs.
vibration pump Filter
M4
CW
M5
B
Δp = 3,5 bar
S L4 MB
Δp = 2,5 bar
M1
04 Lenkpumpe 5.4 16 cm³ 14 Vibrationsmotor 6.6 63 cm³ A
Steering pump vibration motor
L1
B
M2 L2
I C H A F G E D
P1 P2
05 Zahnradpumpe 7.2 16/8 cm³ 16 Rücklaufsammler mit Thermoregler 8.6 B
Gear pump Return flows collector with thrmostat 55°C - 70°C
S1 S2
A1 A2 P5 T
P4 P6
07 Bremslöseventil 4.8 37 +/- 2 bar 20 Druckabschaltventil 7.3
brake opening velve Pressure shut-off valve
T1
P1 P2 T P3 T
L2 MA N
A
08 Fahrmotor C6 21 Hochdruckfilter
4.0 110/50 cm³ 7.2 100 µm
drive motor 4.4 110/50 cm³ High pressure filter
Max Min
B
L1
M4 M5 MB
A B
09 Achse 4.3 i= 93,74 22 Ventil 7.6 130 bar

Axis Valve
P2
T2
M
P1 T1
10 Getriebe 4.7 i=93,9 23 Schwenkantrieb 7.6 STF1-00-22

Gearbox Swivel drive

P T
0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 06.11.2015 BW 219 DH -5 Betriebsmittelliste : 01 - 23 356 Page Legende
Dokumentart
Blatt
Appr EPH Page 11
30 Silencer 5.3
Silencer
OUT
31 Nebenstromfilter 4.8 1 µm nom. 3,5 bar
1µm nom.
Partial flow filter
M
2 L/min
IN

0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 12.11.2015 BW 219 DH -5 Betriebsmittelliste : 30 - 31 356 Page Legende.a
Dokumentart
Blatt
Appr EPH Page 11
Circuit diagrams
985
Circuit diagrams
B.C Wiring diagram, 327

Bomag GmbH
Industriegebiet Hellerwald
D-56154 Boppard

0 1 2 3 4 5 6 7 8 9
Function Page from
Created EFS M. Vogt Funktion == Blatt 1 von 86
Erstellt MFS 08.06.2015 BW 213-226 D/DH-5 Cover sheet Higher-level function
=
Anlage 327
Circuit diagrams
Checked K. Brand Mounting location

Deutz TCD 4.1/6.1 Deckblatt Einbauort +
Geprüft 08.06.2015
987
EPE / 000 / 00
988
Table of contents
Inhaltsverzeichnis
Page Higher-level function Function
Blatt Anlage Funktion Description Beschreibung
1 Cover sheet Deckblatt
Circuit diagrams
2 Table of contents Inhaltsverzeichnis

5 Structure identifier overview Strukturkennzeichenübersicht
6 Structure identifier overview Strukturkennzeichenübersicht
7 Layout mounting locations Übersicht Einbauorte
8 Overview CAN Communication Übersicht CAN Kommunkikation
9 =SUPL ==SDR Supply, Starting unit Versorgung, Starten
10 =SUPL ==SDR Fuse protection potential 30 Absicherung Potential 30
11 =SUPL ==SDR Fuse protection potential 15 Absicherung Potential 15
12 =SUPL ==SDR Supply Driving Controller Versorgung Fahrsteuerung
13 =SUPL ==SDR Supply Measurement controller Versorgung Messtechniksteuerung
14 =SUPL ==SDR Supply 8,5V sensors Versorgung 8,5V Sensoren
15 =SUPL ==SDR Supply Monitoring module, Travel lever Versorgung Überwachungsmodul, Fahrhebel
16 =COM ==SDR Communication, Diagnosis Kommunikation, Diagnose
17 =COM ==SDR Communication Kommunikation
18 =COM ==SDR Communication Kommunikation
19 =ENGI ==SDR Pre-heating, Fuel lift pump, Fuel-pre-heating Vorglühen, Kraftstoffförderpumpe, Kraftstoffvorwärmung
20 =ENGI ==SDR Engine speed, Regeneration mode Motordrehzahl, Regenerationsmodus
21 =ENGI ==SDR Engine - Machine-part Motor - Fahrzeugseite
22 =ENGI ==SDR Deutz TCD 3.6, 4.1 u. 6.1 Machine part Deutz TCD 3.6, 4.1 a. 6.1 Fahrzeugseite
23 =ENGI ==SDR Deutz TCD 3.6 Deutz TCD 3.6
24 =ENGI ==SDR Deutz TCD 3.6 Deutz TCD 3.6
25 =ENGI ==SDR Deutz TCD 3.6 - Exhaust aftertreatment Deutz TCD 3.6 - Abgasnachbehandlung
28 =MON ==SDR Monitoring, Failure indicators Überwachung, Störmeldungen
29 =DRIV ==SDR Slope sensor, Speed sensors Neigungssensor, Geschwindigkeitsaufnehmer
30 =DRIV ==SDR Pressure sensors Drucksensoren
31 =DRIV ==SDR Brake, Travel pumps, Speed ranges Bremse, Fahrpumpen, Fahrstufen
32 =DRIV ==SDR Warning horns, Back up alarm, Warnhörner, Rückfahralarm,

33 =DRIV ==SDR Travel lever Fahrhebel
34 =VIB ==SDR Vibration Vibration
35 =VIB ==SDR Variocontrol Variocontrol
36 =VIB ==SDR Dozer blade Planierschild
37 =VIB ==SDR Vibratory plate compactor Anbauplatten
38 =VIB ==SDR Vibratory plate compactor Anbauplatten
39 =MEAS ==SDR Measurement equipment Messtechnik
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Erstellt MFS 08.06.2015 BW 213-226 D/DH-5 Table of contents Higher-level function
=
Anlage 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Inhaltsverzeichnis Einbauort + TOC EPE / 000 / 00
Table of contents
Inhaltsverzeichnis
40 =OPT ==SDR Rops - Lighting, Socket Rops - Beleuchtung, Steckdose
41 =OPT ==SDR StVZO illumination StVZO Beleuchtung
42 =OPT ==SDR Electronical Burglary protection Elektronische Diebstahlsicherung
43 =OPT ==SDR BOMAG Telematics BOMAG Telematik
44 =OPT ==SDR Cabin - Additional heater Kabine - Zusatzheizung
45 =OPT ==SDR Cabin - Heating, Air conditioning, Washer pumps Kabine - Heizung, Klimaanlage, Wascherpumpen
46 =OPT ==SDR Cabin - Supply Kabine - Versorgung
47 =OPT ==SDR Cabin - Fuse protection Kabine - Absicherung
48 =OPT ==SDR Cabin - Lighting Kabine - Beleuchtung
49 =OPT ==SDR Cabin - Cabin equipment Kabine - Kabinenausrüstung
50 =OPT ==SDR Cabin - Cabin equipment Kabine - Kabinenausrüstung
51 =OPT ==SDR Cabin - Radio, Tachograph, Printer measurement Kabine - Radio, Tachograph, Drucker Messtechnik
52 =OPT ==SDR BOMAG Compaction Management BCM, GPS BOMAG Verdichtungsmanagement BCM, GPS
53 =OPT ==SDR Back up monitoring Rückraumüberwachung
54 Device tag list Betriebsmittelliste
62 Plug overview Steckerübersicht

78 Pin overview A15 Pin Übersicht A15
0 1 2 3 4 5 6 7 8 9
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=
Anlage 327
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Inhaltsverzeichnis Einbauort + TOC
989
EPE / 000 / 00
990
Table of contents
Inhaltsverzeichnis
Circuit diagrams

82 Pin overview S55 Pin Übersicht S55
83 Overview Central Electric Übersicht Zentralelektrik
84 Overview plugs X100 - X109 Übersicht Stecker X100 - X109
85 Overview Powerboard Übersicht Powerboard
86 Overview Powerboard Übersicht Powerboard

0 1 2 3 4 5 6 7 8 9
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=
Anlage 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Inhaltsverzeichnis Einbauort + TOC EPE / 000 / 00
Structure identifier overview
Strukturkennzeichenübersicht
Functional assignment
Funktionale Zuordnung
Description Beschreibung
==SDR Basic machine Single drum roller Basismaschine Walzenzug
Higher-level function
Anlage
=COM Communication Kommunikation
=DRIV Drive functions Antriebsfunktionen
=ENGI Engine Motorraum
=MEAS Measurement equipment Messtechnik
=MON Monitoring, Failure indicators Überwachung, Störmeldungen
=OPT Optional functions Optionale Funktionen
=SUPL Supply Versorgung
=VIB Vibration and compaction Vibration und Verdichtung
Mounting location
Einbauort
+ARC Armature carrier Armaturenträger
+BAT Battery-box Batteriekasten
+CAB Cabin Kabine
+DPL Drivers platform Fahrerstand
+DRUM Drum Bandage
+DTLE Device tag list electrical devices Betriebsmittelliste Elektrische Betriebsmittel
+EBOX Central electric Zentralelektrik
+FRFR Front frame Vorderrahmen
+MOT Engine and attachment parts Motor und Anbauteile
+PINO Pin overviews Controller Pin Übersichten Steuerungen
+PLA Vibratory plate compactor Anbauplatten
+PLGO Plug overview Steckerübersicht
+PUMP Pump mounting Pumpenanbau
+REFR Rear frame Hinterrahmen
+ROPS Roll-Over Protection System Überrollschutz System
+SEAT Seat console Sitzkonsole
+SIO Structure identifier overview Strukturkennzeichenübersicht
+TOC Table of contents Inhaltsverzeichnis

+VIEW Overviews general Übersichten allgemein
Kind of Document
Dokumentenart
&DOC1 Leading documentation Einleitende Dokumentation
&DOC2 Reports and drawings Auswertungen und Zeichnungen
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt MFS 08.06.2015 BW 213-226 D/DH-5 Structure identifier overview Higher-level function
=
Anlage 327
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Strukturkennzeichenübersicht Einbauort + SIO
991
EPE / 000 / 00
992
Structure identifier overview
Strukturkennzeichenübersicht
Kind of Document
Dokumentenart
&EFS Circuit diagram Schaltpläne
Circuit diagrams

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt MFS 08.06.2015 BW 213-226 D/DH-5 Structure identifier overview Higher-level function
=
Anlage 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Strukturkennzeichenübersicht Einbauort + SIO EPE / 000 / 00
+FRFR
+DRUM +REFR
+PLA
+CAB
+ROPS
+DPL
+SEAT
+MOT
+ARC +PUMP
+BAT
+EBOX

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt MFS 08.06.2015 BW 213-226 D/DH-5 Layout mounting locations Higher-level function
=
Anlage 327
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Übersicht Einbauorte Einbauort + VIEW
993
EPE / 000 / 00
994
Circuit diagrams
A48 S55
A15 A144 P15
+EBOX +SEAT +ARC +CAB +CAB
CAN 2
CAN 1
A87
+EBOX
A67
+DPL +CAB
CAN 3

A124
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt MFS 08.06.2015 BW 213-226 D/DH-5 Overview CAN Communication Higher-level function
=
Anlage 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Übersicht CAN Kommunkikation Einbauort + VIEW EPE / 000 / 00
F13:2 / 10.0
+REFR X4.A 9
RD
4 mm² F95:2 / 11.0
RD
X0.A 30 +ARC RD
25 mm² 30_PB / 10.0 1,5 mm²
RADSOK® 8mm RD
1,5 mm² S15:11 / =OPT/41.0
RD F48:2
16 mm² Ignition switch
=ENGI/19.3 Startschalter 30
RD at Deutz TCD 3.6
35 mm² bei Deutz TCD 3.6 S00
15/54 58 19 17 50a
1 WH
1,5 mm²
F39
80A
MAXI Fuse
2
Fuse, main cabin WH
MAXI Sicherung
1,5 mm² S15:23 / =OPT/41.0
Hauptsicherung WH WH WH
1,5 mm² 1,5 mm² 1,5 mm²
RD
Kabine
70 mm²
X8.A
=OPT+CAB/46.1
Fuse, engine controller

Sicherung Motorsteuerung
Fuse, main battery
Hauptsicherung Batterie
Fuse, glow plug system
Sicherung Glühanlage
Fuse, B+ charge
Sicherung B+
Ladeleitung
X4.A 13 3 20
2 2 2 2
S00:50a / 11.0
F95 4 F00 3 F48 2 F164 1
30A 1 125A 1 80A 1 125A 1 S00:19 / =ENGI/21.1
1
V01 15_CAB
=OPT+CAB/46.1
S5G-E3 2
+MOT 30
86 1 1
K61
RD
70 mm² K61 R10 /9.6 87 87a
D61
green
/9.7 2 82 Ω 2 Relay, charge control
85 Relais Ladekontrolle
12V/25A
!!! Auch bei ausgeschaltetem Batterietrennschalter unter Spannung

K39:2 / =ENGI/23.8
K39:1 / =ENGI/23.7
D+ / =MON/28.0
(86)
!!! There is still power supply even if the battery disconnector switch is turned off
4 88a 2
S30 K39 X1.A 7 X7.C 5

250A 3 K15 88 1
Disconnect switch, battery (85)
RD Batterietrennschalter
4 mm²
31_AH
=OPT+DPL/44.1
+BAT RD 30 50 B+ D+
70 mm²
86 1 86 1
M01 G02
G K09 K11
D09
D11
green
green
M1 14V / 150A 12V/25A 2 12V/70A 2

85 85
X300:30 / =ENGI/27.0 Starter - Generator B- W
Starter Relay, starter Generator 4
G01 + X7.C
31 Ground Engine Relais Anlasser
12V / 110 Ah
Masse Motor
Battery 31 31
-
Batterie
X300:31 / =ENGI/27.0
BN
X0.B 31
16 mm² Gnd_PB / 10.0
RADSOK® 6mm
BK
70 mm² 31_Eng / =ENGI/19.0 X8.B / =OPT+CAB/46.1

BK
70 mm² 31_EMR / =ENGI/22.0
31 Ground Central Electric
31_DCtrl / 12.0 87 30 87 /11.0
Masse Zentralelektrik 31_MCtrl / 13.0 87a 30 =OPT+CAB/45.1
31 31
Ground Frame Rear
31_RFr / =DRIV/31.0
Masse Hinterrahmen 31_Ar / 15.6
31 31 31 Relay, air conditioning Relay, potential 30 on 15
31_Db / 15.1 Relais Klimaanlage Relais Potential 30 auf 15
0 1 2 3 4 5 6 7 8 9
Function Page from
Created M. Vogt Funktion == SDR Blatt 9 von 86
Erstellt 08.06.2015 BW 213-226 D/DH-5 Supply, Starting unit Higher-level function
=
Anlage SUPL 327
Checked
Circuit diagrams
K. Brand Mounting location

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Versorgung, Starten Einbauort + EBOX
995
EPE / 000 / 00
996
9.6 / 30_PB 30_PB / 11.0
30
K06
=OPT/40.5 87 87a
Relay, headlights rear
Relais Scheinwerfer hinten
1 1 1 1 1 1 1 1 1 1 1 1
F13 F157 F68 F22 F19 F84 F23 F67 F146 F11 F07 F268
15A 30A 15A 15A 15A 10A 15A 15A 15A 15A 10A 20A
Circuit diagrams
2 2 2 2 2 2 2 2 2 2 2 2
Fuse, fuel pump
Fuse, hazard light
Fuse, potential 30
Fuse, signal horns
Fuse, headlight left
Fuse, ignition switch

Sicherung Potential 30
Sicherung Warnblinker
Sicherung Startschalter
Sicherung Signalhörner
Fuse, controller (Pin 54)
Fuse, working lights rear

Sicherung Kraftstoffpumpe
Fuse, solenoid switch starter

Sicherung Scheinwerfer links
Fuse, controller (potential 30)

Fuse, working headlight front left

Sicherung Steuerung (Kontakt 54)
Sicherung Magnetschalter Anlasser

Sicherung Steuerung (Potential 30)
Sicherung Arbeisscheinwerfer hinten

Sicherung Arbeitsscheinwerfer vorne links
F268:2
=ENGI/19.0
X4.A 19
9.9 / F13:2 F07:2

=OPT/41.0
WH
X7.C 1 1,5 mm²
F11:2
11 =OPT/41.0
21 A1
30 +ARC-S01
K145 Switch, emergency off 22 A2 F146:2
12
Schalter NOT AUS 13.0
=ENGI/21.8 87a 87
Relay, solenoid starter
/11.2
Relais Hubmagnet Starter WH F67:2
1,5 mm²
12.0
=DRIV/31.7
30 X4.A 10 F23:2
=DRIV/32.0
K38
=ENGI/21.6 87a 87
Relay, starter control F84:2
1 Relais Anlassteuerung =COM/16.0
Fx
Fuseholder, fuse test S01:12
2
Sicherungshalter Sicherungstest 12.0
X1.A 1 2
F19:2
=OPT/40.0
1 F22:2
=OPT/40.0
Dx
green 2
Indicator light, fuse test F68:2
Meldeleuchte Sicherungstest =OPT+DPL/44.1

9.9 / Gnd_PB Gnd_PB / =COM/16.0
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Fuse protection potential 30 Higher-level function
=
Anlage SUPL 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Absicherung Potential 30 Einbauort + EBOX EPE / 000 / 00
Erstellt
Geprüft
Created
Checked
0
10.9 / 30_PB
9.9 / S00:50a
9.6 / F95:2
M. Vogt
K. Brand
08.06.2015
08.06.2015
Relais Potential 30 auf 15
Relay, potential 30 on 15
/9.8
K11
87
30
15A
F103
X7.C
Fuse, potential 15
1
2
1
Sicherung Potential 15
2
3
/10.4
+ARC-S01
10A
F122
X4.A
X4.A
Fuse, engine controller

2
1
Sicherung Motorsteuerung
1
22
21
WH
WH
12
1,5 mm²
1,5 mm²
Deutz TCD 4.1/6.1

2
BW 213-226 D/DH-5
10A
F148

2
1

10A
F24
Fuse, monitoring module

2
1
Sicherung Überwachungsmodul
3
5A
F91
Fuse, sensors
2
1
Sicherung Sensoren
20A
F05
Fuse, socket
2
1
Sicherung Steckdose
4
10A
F08
Fuse, indicators
2
1
Sicherung Blinker
Absicherung Potential 15
25A
F124
Fuse, fuel-pre-heating
Fuse protection potential 15

2
1
Sicherung Kraftstoffvorheizung
5A
F244
Fuse, Bomag telematics (potential 15)

2
1
Sicherung Bomag Telematik (Potential 15)
6
25A
F40
Fuse, heating unit cabin

2
1
Sicherung Kabinenheizung
15A
F29
Fuse, compressor suspension seat

2
1
Sicherung Kompressor Luftfedersitz
7
5A
F169
Fuse, starting current

2
1
Sicherung Startstrom
Anlage
Function
Funktion
Einbauort
Mounting location
8
Higher-level function
7,5A
F243
X0.C
+
=
==
Fuse, Bomag telematics (potential 30)
2
1
Sicherung Bomag Telematik (Potential 30)

30
SDR
SUPL
EBOX
Blatt
Page
RADSOK® 3,6mm
15.0
12.0
15.0
F24:2
F91:2
F05:2
F08:2
F40:2
F29:2
11
F103:2
F148:2
F124:2
F244:2
F169:2
F243:2
S01:22
=OPT/40.0
=OPT/41.0
=OPT/43.1
=OPT/43.1
=DRIV/29.0
=ENGI/19.0
=ENGI/21.1
X0.C / =ENGI/21.1
9
=OPT+DPL/44.1
=OPT+CAB/45.1
=OPT+CAB/45.1
327
von
from
!!! There is still power supply even if the battery disconnector switch is turned off
86
!!! Auch bei ausgeschaltetem Batterietrennschalter unter Spannung
EPE / 000 / 00
Circuit diagrams
998
10.9 / S01:12 S01:12 / 13.0
11.9 / F148:2 F148:2 / 13.0
10.9 / F67:2
Ground Electronic Ground Electronic Ground Electronic Ground Electronic Ground Electronic
Masse Elektronik Masse Elektronik Masse Elektronik Masse Elektronik Masse Elektronik
-BMESX -BMESX -BMESX -BMESX -BMESX
Circuit diagrams
Driving Controller Driving Controller Driving Controller Driving Controller Driving Controller
A34 A34 A34 A34 A34

GND GND GND GND GND
Driving Controller X35 55 X35 65 X35 66 X35 67 X35 68
Fahrsteuerung
X35 55 X35 65 X35 66 X35 67 X35 68
X5.A 19 18 3
A34
WH
2,5 mm²
X35
Plug, driving controller
Stecker Fahrsteuerung
Splice
Spleiss 38
B57:2 / =DRIV/29.0
Splice
Spleiss 39
X35 28 X35 54 X35 56 X35 57 X35 58 X35 59 X35 60
X35 28 X35 54 X35 56 X35 57 X35 58 X35 59 X35 60

15/54 +UE +UB +UB +UB +UB +UB
A34 A34 A34 A34 A34 A34 A34
Driving Controller Driving Controller Driving Controller Driving Controller Driving Controller Driving Controller Driving Controller
-BMESX -BMESX -BMESX -BMESX -BMESX -BMESX -BMESX
Ignition Power Supply (Electronic) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs)
Zündung Spannungsvers. (Elektronik) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge)
9.4 / 31_DCtrl 31_DCtrl / =DRIV/29.0

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Supply Driving Controller Higher-level function
=
Anlage SUPL 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Versorgung Fahrsteuerung Einbauort + EBOX EPE / 000 / 00
12.9 / F148:2 F148:2 / =COM/16.0
10.9 / F146:2
12.9 / S01:12
Ground Electronic Ground Electronic Ground Electronic Ground Electronic Ground Electronic
Masse Elektronik Masse Elektronik Masse Elektronik Masse Elektronik Masse Elektronik
-BMESX -BMESX -BMESX -BMESX -BMESX
Measurement Controller Measurement Controller Measurement Controller Measurement Controller Measurement Controller
A83 A83 A83 A83 A83

GND GND GND GND GND
Measurement controller X88 55 X88 65 X88 66 X88 67 X88 68
Messtechnik Steuerung
X88 55 X88 65 X88 66 X88 67 X88 68
X5.E 4 13 6
A83
WH
X88
2,5 mm² Plug, measurement controller
Stecker Messtechniksteuerung
Splice
Spleiss 43
X88 28 X88 54 X88 56 X88 57 X88 58 X88 59 X88 60
X88 28 X88 54 X88 56 X88 57 X88 58 X88 59 X88 60

15/54 +UE +UB +UB +UB +UB +UB
A83 A83 A83 A83 A83 A83 A83
Measurement Controller Measurement Controller Measurement Controller Measurement Controller Measurement Controller Measurement Controller Measurement Controller
Ignition Power Supply (Electronic) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs)
Zündung Spannungsvers. (Elektronik) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge)
9.4 / 31_MCtrl 31_MCtrl / =VIB/35.1

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Supply Measurement controller Higher-level function
=
Anlage SUPL 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Versorgung Messtechniksteuerung Einbauort + EBOX
999
EPE / 000 / 00
1000
FM1 / =DRIV/29.0
AGND_DC / =COM/16.0
FM2 / =VIB/35.1
Circuit diagrams
2 2
FM1 FM2
ATO Fuse
ATO Fuse
1A 1A
ATO Sicherung
ATO Sicherung
1 1
Fuse, sensors Fuse, sensors
Sicherung Sensoren Sicherung Sensoren
X5.A 4 13 X5.E 9
AGND / =DRIV/29.0 AGND_MC / =MEAS/39.1

Splice
Spleiss 42
X35 23 X35 1 X88 23 X88 1
X35 23 X35 1 X88 23 X88 1

8,5VEXT AGND 8,5VEXT AGND
A34 A34 A83 A83
Driving Controller Driving Controller Measurement Controller Measurement Controller

-BMESX -BMESX -BMESX -BMESX
8,5V Sensor Power AGND 8,5V Sensor Power AGND
8,5V Sensor Spannung Analogmasse 8,5V Sensor Spannung Analogmasse

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Supply 8,5V sensors Higher-level function
=
Anlage SUPL 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Versorgung 8,5V Sensoren Einbauort + EBOX EPE / 000 / 00
11.9 / S01:22 S01:22 / =ENGI/21.1
11.9 / F24:2
X4.A 18 X4.B 7
+ARC +SEAT
Splice Splice
Spleiss 48 Spleiss 51
15_Db / =ENGI/20.1 15_Ar / =DRIV+SEAT/33.0
A15 S55
Monitoring module Travel lever
Überwachungsmodul Fahrhebel
X33 26
X23 1
X33 26 X23 1
+UB Power supply (8...32V)
A15 S55
Monitoring Module
-BAUSER_1 +Ub
Power supply Power supply
Brückengleichrichter Brückengleichrichter
Ground Ground Ground Ground

Masse Masse Masse Masse
-BAUSER_1 Gnd 0V ADR 1 ADR 2
Monitoring Module
A15 S55
GND Ground Adressing 1 Adressing 2
X33 25 X23 2 X23 9 X23 10
X23 2 X23 9 X23 10
X33 25
Splice
Spleiss 83
31_Db_2 / =MON/28.0
Splice
Spleiss 67
BN
2,5 mm²
9.4 / 31_Db 31_Db / =DRIV/32.0 9.4 / 31_Ar 31_Ar / =DRIV/29.0

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Supply Monitoring module, Travel lever Higher-level function
=
Anlage SUPL 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Versorgung Überwachungsmodul, Fahrhebel Einbauort + EBOX
1001
EPE / 000 / 00
1002
=SUPL/10.9 / F84:2 F84:2 / =OPT/42.1
=SUPL/13.9 / F148:2 F148:2 / 18.0
=SUPL/14.9 / AGND_DC AGND_DC / =DRIV/29.0
CAN1+ / 17.0
CAN1- / 17.0
Circuit diagrams
CAN2+ / 17.0
X7.D 15 13 5
CAN2- / 17.0
M_CAN1+ / 18.0
M_CAN1- / 18.0
X34 Diagnosis interface BOMAG
30 (12V)
15 (12V)
AGND No1
N P R J A B C D E F X34 = Diagnosesteckdose BOMAG
GND
CAN 1 -
CAN 2 -
CAN 3 -
CAN 1 +
CAN 2 +
CAN 3 +
bestückt
Widerstände nicht
Resistors not equiped
X7.D 2 10 R20 7 6 R22 3 11 R24 8

1 2 1 2 1 2
120 Ω 120 Ω 120 Ω
R21 R25
1 2 1 2
120 Ω 120 Ω
X7.C 13 X7.C 14
X5.A 12 15 6 9 X5.E 15 12
X35 27 X35 26 X35 53 X35 33 X88 27 X88 26
X35 27 X35 26 X35 53 X35 33 X88 27 X88 26

CAN1_H CAN1_L CAN2_H CAN2_L CAN1_H CAN1_L
A34 A34 A34 A34 A83 A83
Driving Controller Driving Controller Driving Controller Driving Controller Measurement Controller Measurement Controller
-BMESX -BMESX -BMESX -BMESX -BMESX -BMESX
CAN 1 + CAN 1 - CAN 2 + CAN 2 - CAN 1 + CAN 1 -
CAN 1 + CAN 1 - CAN 2 + CAN 2 - CAN 1 + CAN 1 -

=SUPL/10.2 / Gnd_PB Gnd_PB / 18.0
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Communication, Diagnosis Higher-level function
=
Anlage COM 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Kommunikation, Diagnose Einbauort + EBOX EPE / 000 / 00
16.9 / CAN1+ CAN1+ / 18.0
16.9 / CAN1- CAN1- / 18.0
16.9 / CAN2+ CAN2+ / 18.0
16.9 / CAN2- CAN2- / 18.0
CAN3+ / =OPT+CAB/46.1
CAN3- / =OPT+CAB/46.1
R26
1 2
120 Ω
R27
1 2
120 Ω
X4.A 14 17 X4.B 1 4 X5.E 1 2
+ARC +SEAT
X33 21 X33 22 X88 53 X88 33

X23 6 X23 7
X33 21 X33 22 X23 6 X23 7 X88 53 X88 33
CAN High CAN Low CAN bus high CAN bus low CAN2_H CAN2_L
A15 A15 S55 A83 A83
Monitoring Module Monitoring Module Measurement Controller Measurement Controller

-BAUSER_1 -BAUSER_1 CAN + CAN - -BMESX -BMESX
CAN high CAN low CAN high CAN low CAN 3 + CAN 3 -
CAN + CAN low CAN + CAN low CAN 3 + CAN 3 -

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Communication Higher-level function
=
Anlage COM 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Kommunikation Einbauort + EBOX
1003
EPE / 000 / 00
1004
17.8 / CAN2+ CAN2+ / =ENGI/21.1
17.8 / CAN2- CAN2- / =ENGI/21.1
17.8 / CAN1+ CAN1+ / =OPT/42.1
17.8 / CAN1- CAN1- / =OPT/42.1
16.1 / Gnd_PB Gnd_PB / =ENGI/21.1

Circuit diagrams
16.9 / F148:2 F148:2 / =OPT/42.1
16.9 / M_CAN1+ CAN2+_TM / =OPT/43.1
16.9 / M_CAN1- CAN2-_TM / =OPT/43.1
R28
1 2
120 Ω
Resistors not equiped

Widerstände nicht bestückt
R29
1 2
120 Ω
X7.A 1 2 6 5 3 4 8 7 9 10

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Communication Higher-level function
=
Anlage COM 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Kommunikation Einbauort + EBOX EPE / 000 / 00
=SUPL/11.9 / F124:2
=SUPL/10.9 / F268:2
+MOT
=SUPL/9.6 / F48:2
30
K209
/21.4 87a 87
Relay, fuel pump
Relais Kraftstoffpumpe
X1.A 3 6 X1.A 8 9
K14:2_3.6
23.9
K14:1_3.6
23.8
1 WH WH
4 1,5 mm² 1,5 mm²
K 14
WH
K2 2 3 1,5 mm²
Splice X78
Spleiss 84
WH 1 1
Relay, glow plug system 2,5 mm² X78:1 / 27.0
Relais Vorglühen K14:3_3.6
23.9 WH
2,5 mm²
RD
16 mm²
X67 1
+
1 1 1 1 1
R81 R82 R83 R84 M25 R79

2 2 2 2 I = ca. 10-15A, 200W 2
IE = ca. 20-25A - Fuel-pre-heater
31 31 31 31 Fuel lift pump Kraftstoffvorheizung
Ground Engine Kraftstoffförderpumpe
Masse Motor
X67 2
Glow plugs
Glühstiftkerzen
BN BN
1,5 mm² 2,5 mm²

BN Splice
=SUPL/9.4 / 31_Eng 6 mm² Spleiss 31_Eng / =MON/28.0
74
4 3 /19.4
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Pre-heating, Fuel lift pump, Fuel-pre-heating Higher-level function
=
Anlage ENGI 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Vorglühen, Kraftstoffförderpumpe, Kraftstoffvorwärmung Einbauort + EBOX
1005
EPE / 000 / 00
1006
+ARC
=SUPL/15.2 / 15_Db VIB_TM / =OPT/43.1

Circuit diagrams
13 23 13 23
low
eco
high
1 Stop
0
2 Request
S127 S299 X4.A 16
Switch, engine speed 14 24 Switch, regeneration mode 14 24
Schalter Motordrehzahl Schalter Regenerationsmodus
X33 9 X33 10 X33 11 X33 12 X33 4
X33 9 X33 10 X33 11 X33 12 X33 4

Digital IN3 Digital IN4 Digital IN5 Digital IN6 OUT2
A15 A15 A15 A15 A15
Monitoring Module Monitoring Module Monitoring Module Monitoring Module Monitoring Module
-BAUSER_1 -BAUSER_1 -BAUSER_1 -BAUSER_1 -BAUSER_1
Switch, engine speed Sx. 1 Switch, engine speed Sx. 2 Switch, regeneration Sy. 1 Switch, regeneration Sy. 2 Vibration Telematik
Schalter Motordrehzahl Sx. 1 Schalter Motordrehzahl Sx. 2 Schalter Regeneration Sy. 1 Schalter Regeneration Sy. 2 Vibration Telematics

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Engine speed, Regeneration mode Higher-level function
=
Anlage ENGI 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Motordrehzahl, Regenerationsmodus Einbauort + EBOX EPE / 000 / 00
X1.B:1 / 22.0
X1.B:2 / 22.0
X1.B:14 / 22.4
X1.B:9 / 22.4
X1.B:16 / 22.5
X1.B:12 / 22.5
X1.B:10 / 22.6
X1.B:13 / 22.6
X1.B:15 / 22.2
X1.B:18 / 22.3
X1.B 1 2 3 5 8 6 X1.B 14 9 17 16 X1.B 12 11 10 13 4 15 18 7
85 1
K38
D38
green
87 87a 85 2 86 1 12V/40A 86 2 87 87a 86 1

CN403
D41
green
green
green
D209
D145
K41 87a 87 K05

30 86 1 2 Relay, starter control 30 2
12V/25A K209 85 =DRIV+SEAT/33.8 K145 85
Relais Anlassteuerung
CN413 12V/25A 12V/40A
Relay, separation 30
=SUPL/10.2
K3
Trennrelais
=SUPL/11.8 / X0.C Relay, fuel pump X1.A 4 Relay, starting current Relay, solenoid starter
Relais Kraftstoffpumpe K22 87 87a Relais Startstrom Relais Hubmagnet Starter
87 =DRIV/32.7 87
!!! There is still power supply even if the battery disconnector switch is turned off 87a 30 /19.6 Relay, shut off solenoid engine 30 87a 30 =SUPL/10.2
!!! Auch bei ausgeschaltetem Batterietrennschalter unter Spannung Relais Hubmagnet Abschaltung Motor
=SUPL/9.9 / S00:19
=SUPL/11.9 / F169:2
50a

=SUPL/15.9 / S01:22
=COM/18.8 / CAN2+
=COM/18.8 / CAN2- StU_TM / =OPT/43.1
=COM/18.8 / Gnd_PB Gnd_PB / =DRIV/29.0
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Engine - Machine-part Higher-level function
=
Anlage ENGI 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Motor - Fahrzeugseite Einbauort + EBOX
1007
EPE / 000 / 00
1008
A48
D2
Engine-controller EMR4 (EDC 17-CV52)
Motorsteuergerät EMR4 (EDC 17-CV52)
Circuit diagrams
Plug, engine-controller motor-part Plug, engine-controller machine-part

Stecker Motorsteuergerät Motorseite = X44 D2.1 (A) D2.2 (K) X45 = Stecker Motorsteuergerät Maschinenseite
D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2
1 3 5 26 70 58 91 43 10 50 88 74 23 64 67 18 31 13 85 86 82 83 2 4 6
X45 1 3 5 26 70 58 91 43 10 50 88 74 23 64 67 18 31 13 85 86 82 83 2 4 6
D2.2
WH WH WH BN BN BN
2,5 mm² 2,5 mm² 2,5 mm² X45:13 / 26.0 2,5 mm² 2,5 mm² 2,5 mm²
X45:31 / 26.0
Splice
Spleiss 68
X45:18 / 26.0
WH WH
2,5 mm² 2,5 mm²
K22:87a / 24.0
X108 1 2 X108 3 4 5
Splice
Spleiss 33
+MOT X73 1 2 +MOT

1
1
1 X48 1 2 R30
2
B124 2120 Ω
2 Plug, engine stop
Stecker Motor Stop
B218 R23
120 Ω 1
Sensor, water trap fuel 2

Sensor Wasserabscheider Kraftstoff
Temperature sensor, ambient temperature

Temperatursensor Umgebungstemperatur
Ubat
CAN 2 high
CAN 2 low
CAN 1 high
CAN 1 low
31-GND
A M F H G B
X32

X22
21.2 / X1.B:1
21.2 / X1.B:2
21.5 / X1.B:9
21.7 / X1.B:15
21.7 / X1.B:10
21.7 / X1.B:13
21.8 / X1.B:18
21.4 / X1.B:14
21.5 / X1.B:16
21.6 / X1.B:12
CAN 1 = Diagnosis CAN

CAN 2 = Customer CAN
Diagnosis interface EMR

Diagnoseschnittstelle EMR
BN Splice
=SUPL/9.4 / 31_EMR 6 mm² Spleiss 31_AGR / 24.0
69
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Deutz TCD 3.6, 4.1 u. 6.1 Machine part Higher-level function
=
Anlage ENGI 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Deutz TCD 3.6, 4.1 a. 6.1 Fahrzeugseite Einbauort + EBOX EPE / 000 / 00
A48
D2
Harness EMR - Engine interface

Kabelbaum EMR - Motorschnittstelle

Harness Engine interface - Engine internal Stecker Motorsteuergerät Motorseite = X44 D2.1 (A) D2.2 (K) -X45 = Stecker Motorsteuergerät Maschinenseite
Kabelbaum Motorschnittstelle - Motorintern
D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1
85 64 87 66 44 23 45 24 100 99 75 102 101 46 25 36 78 17 94 95 63 88 58
X44 85 64 87 66 44 23 45 24 100 99 75 102 101 46 25 36 78 17 94 95 63 88 58

D2.1
+MOT
X41 3 4 10
X46 62 35 42 37 38 61 40 41 14 13 9 15 21 1 19 20 31 25 32 3 2 /23.7
X17 X23
X108 7 8 6
2 2 1
2 2 2 2 2
2
B114 B130 Y137 B93
1 1 1 1 B40.1
n B40.2
n Y19 1 B49
Y147 Y166 Y149 Y148 1 1 3
Y15.1 Y15.3 Y15.2 Y15.4
19.4 / K14:1_3.6
19.3 / K14:2_3.6
19.4 / K14:3_3.6
=SUPL/9.5 / K39:1
=SUPL/9.5 / K39:2

Injector A1 Injector A4 Injector A3 Injector A2 EMR Sensor, engine speed 1 EMR Sensor, engine speed 2 EMR Actuator EMR Fuel pressure rail
Injektor A1 Injektor A4 Injektor A3 Injektor A2 EMR Motordrehzahlsensor 1 EMR Motordrehzahlsensor 2 EMR Stellglied EMR Kraftstoffdruck Rail
Camshaft Crankshaft
Nockenwelle Kurbelwelle
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Deutz TCD 3.6 Higher-level function
=
Anlage ENGI 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Deutz TCD 3.6 Einbauort + EBOX
1009
EPE / 000 / 00
1010
A48
D2
Circuit diagrams


Harness Engine interface - Engine internal Stecker Motorsteuergerät Motorseite = X44 D2.1 (A) D2.2 (K) -X45 = Stecker Motorsteuergerät Maschinenseite
D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1
38 07 35 13 74 73 21 11 72 54 67 02 76 55 18 08 51
X44 38 07 35 13 74 73 21 11 72 54 67 02 76 55 18 08 51
D2.1
K22:87a
22.6
31_AGR
22.9
X46 27 24 28 23 22 29 26 17 48 47 51 46 50 7 6
X17
X41 2 1
X23
XB145 XB145 2
+MOT 1
1
1 1
4 2 - + Gnd Sig 5V 2
B133 B145 Y174 5 1 4 2 6 B208
3 3 Y20
B48 B51 B61
3
X46 60 59 49 52 2 4
X40 1 3 2
X17 M
X47
1
1
2 2
B88 XB145 4 B209
Y261 3
1 2 3 4 B113 B6 B64
Y35 2
B43 4

1
ECU
M
EMR Sensor, charging air pressure / -temperature EMR Low pressure Fuel EMR Exhaust gas recirculation EMR Sensor, delta p venturi
EMR Sensor Ladeluftdruck / -temperatur EMR Niederdruck Kraftstoff EMR Abgasrückführung EMR Sensor Delta p Venturi
Air intake throttle EMR Temperature sensor, coolant EMR engine oil pressure EMR Sensor, temperature EGR behind venturi
Drosselklappe Ansaugluft EMR Temperatursensor Kühlmittel EMR Motoröldruck EMR Sensor Temperatur EGR nach Venturi
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Deutz TCD 3.6 Higher-level function
=
Anlage ENGI 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Deutz TCD 3.6 Einbauort + EBOX EPE / 000 / 00
A48
D2
Engine-controller EMR4
(EDC 17-CV52)
Motorsteuergerät EMR4
(EDC 17-CV52)
Plug, Plug, Harness Engine interface - Engine internal 2

1 engine-controller engine-controller Kabelbaum Motorschnittstelle - Motorintern
motor-part machine-part
R32
R31 Stecker Stecker 120 Ω 1
120 Ω 2 Motorsteuergerät Motorsteuergerät
Motorseite = X44 D2.1 (A) D2.2 (K) -X45 = Maschinenseite
Harness EAT-System - Engine internal
D2.1 D2.1 Kabelbaum Abgasnachbehandlung - Motorintern
98 77
X41 12 11 X41 5 6
X23 X44 98 77 X23
D2.1
+MOT
X36 39 38 37 13
X39
31_EAT / 27.0
BN
1,5 mm²
F310:2 / 27.0
WH
1,5 mm² F251:2 / 27.0
1 2
X77
X46 1 2
X42 19 18 21 20
X43
Splice
Splice
86 Spleiss
Spleiss
85
+REFR

+
1 Can L
2
Ub
Ub
Gnd
Gnd
B224 4 3 2 1 B225 4 3 2 1
Can L
Can L
Can H
Can H
Can H
3 B54 B56
grey black
B222 4 grau schwarz
-
B90 ECU ECU
Sensor, urea temperature and level Sensor, NOx befor SCR-Kat Sensor, NOx behind SCR-Kat
Sensor Ureatemperatur und Füllstand Sensor NOx vor SCR-Kat Sensor NOx nach SCR-Kat
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Deutz TCD 3.6 - Exhaust aftertreatment Higher-level function
=
Anlage ENGI 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Deutz TCD 3.6 - Abgasnachbehandlung Einbauort + EBOX
1011
EPE / 000 / 00
1012
A48
D2
Harness Engine interface - Engine internal

Circuit diagrams
Harness EAT-System - Engine internal

Kabelbaum Abgasnachbehandlung - Motorintern
Stecker Motorsteuergerät Motorseite = X44 D2.1 (A) D2.2 (K) -X45 = Stecker Motorsteuergerät Maschinenseite
D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1
15 48 09 27 47 26 20 29 32 70 57 19 82 05 89 59 10 14 92
X44 15 48 09 27 47 26 20 29 32 70 57 19 82 05 89 59 10 14 92
22.6 / X45:18 D2.1
22.6 / X45:31
22.6 / X45:13 X36 18 19 3 5 28 22 14 15 4 33 29 24 30 16 36 35 27 26 25

X39
X41 7 8 9
X23
3 2 1 6 9 14 15 4 5 7
X42
+MOT X43 3 2 1 6 9 14 15 7
X36 10 9 8 +REFR
X39
M41:9 / 27.0
E107:+ / 27.0
E107:- / 27.0
WH WH WH
1,5 mm² 1,5 mm² 1,5 mm²
WH WH
1,5 mm² 1,5 mm² Y292:4 / 27.0
X31 4 3 2 12 11 8 10 9 5 6
3 2 2
2
3 4 -E107
P 3 +
1 2 4
B305 1 B223 1 B214 1 2
B88 B78 B65 P R
2 1 M41 - 1

black Y293 1 Y291 Y292
schwarz B221 5 M10 ???W
Y24 B63 Y30 Y31
Boost module
Fördermodul
EMR Pressure sensor, pressure after DPF EMR Sensor, temperature exhaust gas before oxy Solenoid
cat valve, urea dosing Solenoid valve, urea extraction Heating, supply modul
EMR Drucksensor, Druck nach DPF EMR Temperatursensor Abgas vor Oxy Kat Magnetventil Ureadosierung Magnetventil Urea Absaugung Heizung Versorgungsmodul
Sensor, urea pressure behind pump Urea pump Solenoid valve, urea tank heating
Temperature sensor, exhaust gas before SCR kat Sensor, Ureadruck nach Pumpe Urea Pumpe Magnetventil Ureatank Heizung
Temperatursensor Abgas vor SCR Kat
0 1 2 3 4 5 6 7 8 9
Function Page from
=
Anlage ENGI 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Deutz TCD 3.6 - Abgasnachbehandlung Einbauort + EBOX EPE / 000 / 00
+MOT
A48
D2
26.9 / M41:9
Engine-controller EMR4
(EDC 17-CV52)
19.9 / X78:1 Motorsteuergerät EMR4
(EDC 17-CV52)
26.9 / E107:- Plug,
Plug, engine-controller
engine-controller machine-part
26.9 / E107:+ motor-part
Stecker Stecker
26.9 / Y292:4 Motorsteuergerät Motorsteuergerät
Motorseite = X44 D2.2 (K) X45 = Maschinenseite
D2.1 (A)
25.7 / F310:2
D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1
03 41 04 62 80 37 61
25.7 / F251:2 -E105 -E106 -E104
+ + +
X300:30 X44 03 41 04 62 80 37 61
=SUPL/9.2 R R R
- - - D2.1
X300:31
=SUPL/9.2 BN
10 mm²
X36 34 11 23 31 32 21 20
25.7 / 31_EAT
RD X39
10 mm²
Heating, suction line

Heizung Saugleitung
Heizung Druckleitung
Heating, pressure line
Heizung Rücklaufleitung
Heating, return flow line
-X42 16 17 11 8 10 12 13
X43
+BAT WH WH WH WH WH WH WH
2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm²
X300 31 X300 F312 2 F313 2 X301 12 15 14 4 5 1 7 8 6 3 2 9 10 13 X302 1 2 3 4 5 6 7

30
M6
M5
M5
Stud bolt
Stud bolt
Stud bolt
Gewindebolzen
Gewindebolzen
Gewindebolzen
Amphenol RADSOK® 6mm

Fuse, reserve
Sicherung Reserve
Fuse, SCR control
Sicherung SCR Ansteuerung
Fuse, reserve
Sicherung Reserve
Fuse, NOx sensors
Sicherung NOx Sensoren
Fuse, sensor urea quality
Sicherung Sensor Ureaqualität
Fuse, exhaust gas recirculation
Sicherung Abgasrückführung
Relay, potential 30 on 15
Relay, SCR control
Relais, SCR Ansteuerung
Relay, heating urea feed-in modul
Relais Heizung Urea-Einspeisemodul
Relay, heating urea suction hose
Relais Heizung Urea-Saugleitung
Relay, heating urea restriction hose
Relais Heizung Urea-Drosselleitung
Relay, heating urea pressure hose
Relais Heizung Urea-Druckleitung
2 2 2 2 2 2
Relay, SCR control

Relais, SCR Ansteuerung
Relay, heating urea suction hose
Relais Heizung Urea-Saugleitung
Relay, heating urea restriction hose
Relais Heizung Urea-Drosselleitung
Relay, heating urea pressure hose
Relais Heizung Urea-Druckleitung
Relay, heating urea feed-in modul
Relais Heizung Urea-Einspeisemodul
5A
K227 K192 K193 K194 K195 K196
30A
10A
15A
F312
F250
F313
F251
F310
F238
87 87 87a 87 87a 87 87a 87 87a 12V 86 12V 86 12V 85 12V 85 12V 85 12V 85
max. 20A
max. 20A
1 1 1 1 1 1
K192 K194 K195 K196 K193
K31 30 K28 30 K29 30 K30 30 K27 30 85 K31 85 K27 86 K28 86 K29 86 K30 86

/27.7 /27.8 /27.9 /27.9 /27.8
87
70A
K227 70A
87
87a
87
87a
87
87a
87
87a
87
30 87
30
Relay, potential 30 on 15 /27.1

30
30
30
30
30
/27.6
/27.4 /27.6 /27.5 /27.5 /27.6
0 1 2 3 4 5 6 7 8 9
Function Page from
=
Anlage ENGI 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Deutz TCD 3.6 - Abgasnachbehandlung Einbauort + EBOX
1013
EPE / 000 / 00
1014
+ARC
D+ Alternator Coolant level Water in Fuel Maintenance switch, air cleaner Hydraulic oil filter Warning buzzer, breakdown Fuel level
Circuit diagrams
D+ Generator Kühlmittelfüllstand Wasserabscheider Wartungsschalter Luftfilter Hydraulikölfilter Warnsummer Betriebsstörung Tankfüllstand

-BMESX -BMESX -BMESX -BMESX -BMESX -BAUSER_1 -BAUSER_1
Driving Controller Driving Controller Driving Controller Driving Controller Driving Controller Monitoring Module Monitoring Module
A34 A34 A34 A34 A34 A15 A15

AIN_7 DIN_11 DIN_5 DIN_9 DIN_7 OUT1 Analog IN2
X35 9 X35 39 X35 36 X35 38 X35 37 X33 3 X33 2
X35 9 X35 39 X35 36 X35 38 X35 37 X33 3 X33 2
X4.A 5
X101 1 2 3 X103 11
X5.A 10 X2.A 15
=SUPL/9.6 / D+ D+ / =OPT/43.1
+REFR
X11 1
1
+MOT +REFR
X72 1 X69 2
3 3 (1) 3 (1) + 1 at Prototypes with steel

fuel tank 79,25 Ω
B55 B03 P B21 P H07 R03 bei Prototypen mit
4 4 (2) 4 (2) 70mA - BW 211-216 = 66 Ω 2 Stahltank 79,25 Ω
BW 219-226 = 64,2 Ω
X72 2 X69 3
X11 2
=ENGI/19.8 / 31_Eng 31_Eng / =OPT+CAB/45.1
=SUPL/15.2 / 31_Db_2 31_Db_2 / =DRIV+SEAT/33.0

=DRIV/31.0 / 31_RFr.2
Floating switch, coolant expansion tank Maintenance switch, air cleaner Warning buzzer, breakdown Sender, level gauge
Schwimmerschalter Kühlmittelausgleichsbehälter Wartungsschalter Luftfilter Warnsummer Betriebsstörung Geber Tankanzeige
Differential pressure switch, hydraulic oil filter
Differenzdruckschalter Hydraulikölfilter
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Monitoring, Failure indicators Higher-level function
=
Anlage MON 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Überwachung, Störmeldungen Einbauort + EBOX EPE / 000 / 00
=SUPL/14.9 / FM1
=SUPL/11.9 / F91:2 F91:2 / 30.0
=ENGI/21.8 / Gnd_PB Gnd_PB / 32.0
=SUPL/15.7 / 31_Ar 31_Ar / =VIB/35.1
=SUPL/12.9 / 31_DCtrl 31_DCtrl / 31.0
=SUPL/14.3 / AGND AGND / =VIB/34.1

1 1
=COM/16.9 / AGND_DC V07 V09
Only at DH-Version S1M 2 S1M 2
=SUPL/12.1 / B57:2 Nur bei DH-Version
1 1
Slope sensor, speed range selection
Neigungssensor Stufenumschaltung V08 V010
S1M 2 S1M 2
X2.A 12 14 9 13 X5.A 2 16 1
B57
0,5-4,5V X106:1 / =VIB/34.1
Splice
1 2 3 Spleiss 41
- + S X106:5 / =VIB/34.1
X14 B +REFR X104 1 2 3 4 X105:11 / =VIB/37.1

-
+SEAT BU 5
4+
S06 B60
3 speed +DRUM
Switch, seat contact SW Speed sensor, axle
Sitzkontaktschalter Drehzahlsensor 2
Achsgeschwindigkeit dir Only at DH-Version
X14 A
Nur bei DH-Version
W3 3 4
7x1,0
-
5
+4
B59
speed 3
Speed sensor, drum
2 Drehzahlsensor
dir Bandagengeschwindigkeit
5 6 W3
X4.B 2 X2.A 1 X2.A 4 7x1,0
X5.B 10 X5.B 6 X5.B 5

X7.C 11 X7.C 10
X100 1 X104 5 6
X35 32 X35 15 X35 16 X35 13 X35 12 X35 35 X35 17

X35 32 X35 15 X35 16 X35 13 X35 12 X35 35 X35 17
AIN_8 DIN_8 DIN_10 DIN_4 DIN_2 DIN_3 DIN_12
A34 A34 A34 A34 A34 A34 A34
Slope sensor Seat contact Proximity switch, arm rest right Direction axle Speed axle Speed drum Direction drum
Neigungssensor Sitzkontakt Näherungsinitiator Armlehne rechts Drehrichtung Achse Geschwindigkeit Achse Geschwindigkeit Bandage Drehrichtung Bandage
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Slope sensor, Speed sensors Higher-level function
=
Anlage DRIV 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Neigungssensor, Geschwindigkeitsaufnehmer Einbauort + EBOX
1015
EPE / 000 / 00
1016
29.9 / F91:2 F91:2 / =MEAS/39.1
X2.A 10 at D Version
bei D Version
+REFR-X25 5
Circuit diagrams
+PUMP
Only at DH-Version Y16
Nur bei DH-Version Splice
Spleiss 73
Y07
X55 1 X56 1 X57 1 X58 1
A 1 B 1 C 1 D 1
B234 B235 B236 B237

Pressure sensor, travel
P Pressure sensor, travel
P
pump axle MA 2 pump axle MB 2 pump drum MA 2 pump drum MB 2
Drucksensor Fahrpumpe Drucksensor Fahrpumpe Drucksensor Fahrpumpe Drucksensor Fahrpumpe
Achse MA Achse MB Bandage MA Bandage MB
right - front left - front right - back left - back
Y17
rechts - vorne links - vorne rechts - hinten links - hinten
Y08
X55 2 X56 2 X57 2 X58 2
at DH Version
+REFR-X25 1 2 3 4
bei DH Version
B234
B236 (X55)
(X57)
X103 1 2 3 4
Y16
X35 6 X35 7 X35 29 X35 30 Y73

X35 6 X35 7 X35 29 X35 30
AIN_1 AIN_3 AIN_2 AIN_4
A34 A34 A34 A34 Y07
Driving Controller Driving Controller Driving Controller Driving Controller

Pressure sensor, travel pump axle MA Pressure sensor, travel pump axle MB Pressure sensor, travel pump drum MA Pressure sensor, travel pump drum MB Y17
Drucksensor Fahrpumpe Achse MA Drucksensor Fahrpumpe Achse MB Drucksensor Fahrpumpe Bandage MA Drucksensor Fahrpumpe Bandage MB
B235
(X56)
Y72
B237
(X58)
Y08
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Pressure sensors Higher-level function
=
Anlage DRIV 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Drucksensoren Einbauort + EBOX EPE / 000 / 00
Travel pump axle forward Travel pump axle backward Travel pump drum forward Travel pump drum backward Travel motor axle Valve brake Travel motor drum
Fahrpumpe Achse vorwärts Fahrpumpe Achse rückwärts Fahrpumpe Bandage vorwärts Fahrpumpe Bandage rückwarts Fahrmotor Achse Ventil Bremse Fahrmotor Bandage
A34 A34 A34 A34 A34 A34 A34

PWM_1 PWM_2 PWM_7 PWM_9 DO_2 PWM_5 DO_4
X35 46 X35 47 X35 20 X35 21 X35 2 X35 64 X35 3
X35 46 X35 47 X35 20 X35 21 X35 2 X35 64 X35 3
X5.A 21
K48 30
+SEAT/33.9
Relay, travel lever 0-position
Relais, Fahrhebel 0-Stellung 87 87a
X4.A 21
WH
1,5 mm²
A1
Splice
+ARC-S01 Spleiss 61
=SUPL/10.4 A2
WH
1,5 mm²
X103 5 6 7 8 9 X4.A 7 X103 10 X104 7
X7.C 12 X2.A 7
at DH Version a.
BW 216-219 D
+REFR Splice Splice +DRUM bei DH Version u.
Spleiss 71 Spleiss 70
-X25 7 8 BW 216-219 D
1 W3
X11 3 X11 4
+PUMP 7x1,0
1 1 1 1 1 1 1 1
Y16 Y17 Y72 Y73 Y31 Y04 Y30 Y30
2,41A
Travel pump axle 2 Travel pump axle 2 Travel pump drum 2 Travel pump drum 2 1,05A 2 2 2,41A 2 2
Fahrpumpe Achse C1 Fahrpumpe Achse C2 Fahrpumpe Bandage C2 Fahrpumpe Bandage C1 1,05A
640...1580mA 640...1580mA 640...1580mA 640...1580mA at D Version 2 W3
bei D Version 7x1,0
Splice
Spleiss 75
Only at DH-Version
Nur bei DH-Version
31_RFr.2
=MON/28.0 -X25 6
X11 5 X104 8

BN
1,5 mm²
31_RFr BN Splice 31_RFr
10 mm² Spleiss
=SUPL/9.4 72 32.0
31_DCtrl 31_DCtrl
29.9 =VIB/34.1
Solenoid valve, travel direction forward Solenoid valve, travel direction forward Solenoid valve, speed range selection axle Solenoid valve, brake Solenoid valve, speed range selection drum
Magnetventil Fahrtrichtung vorwärts Magnetventil Fahrtrichtung vorwärts Magnetventil Fahrstufe Achse Magnetventil Bremse Magnetventil Fahrstufe Bandage
Solenoid valve, travel direction backward Solenoid valve, travel direction backward Solenoid valve, speed range selection drum
Magnetventil Fahrtrichtung rückwärts Magnetventil Fahrtrichtung rückwärts Magnetventil Fahrstufe Bandage
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Brake, Travel pumps, Speed ranges Higher-level function
=
Anlage DRIV 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Bremse, Fahrpumpen, Fahrstufen Einbauort + EBOX
1017
EPE / 000 / 00
1018
=SUPL/10.9 / F23:2
Back-up alarm buzzer Warning horn Relay, shut off solenoid engine
Warnsummer Rückwärtsfahrt Signalhorn Relais Hubmagnet Abschaltung Motor
-BMESX -BMESX -BMESX
Circuit diagrams
Driving Controller Driving Controller Driving Controller
A34 A34 A34

DO_5 DO_3 DO_1
X35 61 X35 25 X35 24
X35 61 X35 25 X35 24
30
K13
/32.6 87a 87
Relay, warning horn
Relais Signalhorn
X5.A 5 20 17
X4.A 2
WH Rev
2,5 mm²
=OPT+CAB/46.1
Splice
Spleiss 26 X2.A 2
WH WH
1,5 mm² 1,5 mm²
+REFR
WH WH
1,5 mm² 1,5 mm²
X30 1
1 2 2 1 + 86 1 86 1
B11.1 V02 V03 B11.2 H14 K13 K22
D13
D22
green
green
max. 3,5A 2 SF 64 1 SF 64 1 max. 3,5A 2 300mA - 12V/25A 85 2 12V/25A 85 2
BN BN
1,5 mm² 1,5 mm²
X30 2
BN BN
1,5 mm² 1,5 mm²
=SUPL/15.2 / 31_Db 31_Db / =OPT/40.0
31.9 / 31_RFr 31_RFr / =VIB/34.1

29.9 / Gnd_PB Gnd_PB / +SEAT/33.8
87 87
87a 30 /32.2 87a 30 =ENGI/21.6
Warning horn Warning horn Back-up alarm buzzer Relay, warning horn Relay, shut off solenoid engine
Signalhorn Signalhorn Warnsummer Rückwärtsfahrt Relais Signalhorn Relais Hubmagnet Abschaltung Motor
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Warning horns, Back up alarm, Higher-level function
=
Anlage DRIV 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Warnhörner, Rückfahralarm, Einbauort + EBOX EPE / 000 / 00
+ARC +EBOX
at DH Version at D Version
bei DH Version bei D Version
+ARC
Switch, vibration front Switch, vibration low / high

Schalter Vibration vorne Schalter Vibration klein / gross
13 13 23
low
0
high
S09 S35
14 14 24 BTS brake
BTS Bremse
-BMESX
Switch, speed range selector Driving Controller
S42 Schalter Fahrstufen
Only at BVC Not at BVC A34
1 2 4 6 8 10 12
Nur bei BVC Nicht bei BVC DIN_6
X35 14
12 Steps at DH, 5 Steps at D
12 Stufen bei DH, 5 Stufen bei D 14
X35
1 2 3 6 4 5
Gnd 8-30V 0-20mA 0,5-4,5V AGnd +5V
Relay, travel lever 0-position

X26 3 Relais, Fahrhebel 0-Stellung
X102 6 7 X5.A 14 Relay, starting current
Relais Startstrom 87
31_Db_2 31_Db_2
87 87a 30 +EBOX/31.7
=MON+EBOX/28.8 =OPT+EBOX/41.0
87a 30 =ENGI+EBOX/21.8
S139
Potentiometer, + 14 14
+EBOX X102 1 2 3 4 X102 5 frequency plates S36 S64 X4.B 9
Potentiometer 86 86
- S
Switch, vibration plates 13 Pushbutton, float 13 1 1
Frequenzverstellung position plates
K05 K48
D05
D48
Anbauplatten
green
green
15_Ar 15_Ar Schalter Vibration Taster Schwimmstellung

Anbauplatten Anbauplatten 12V/25A 85 2 12V/25A 85 2
=SUPL+EBOX/15.7 =VIB+EBOX/35.1 Splice
Spleiss 49
X26 1 2 Splice
Spleiss 50
Splice
Spleiss 47
Gnd_PB Gnd_PB
+EBOX/32.9 =VIB+EBOX/34.1
X23 11 X23 8 X23 5 X23 12 X24 4 X24 3 X24 1 X24 2 X23 3

X23 11 X23 8 X23 5 X23 12 X24 4 X24 3 X24 1 X24 2 X23 3
Analog IN 1 Ground / 0V / reference to PIN 5 Output voltage supply "+5V" Analog IN 2 Digital IN 4 Digital IN 3 Digital IN 1 Digital IN 2 BTS signal "Brake catch"
S55
AK Ext 1 AGND 1 Uext 1 AK Ext 2 DK Ext 4 DK Ext 3 DK Ext 1 DK Ext 2 BTS Brake
Switch, speed range selector 2 Ground analog selectors Supply analog selectors Frequency adjustment plates Vibration plates Floating position plates Switch, vibration low/off (on/off) Switch, vibration off/high BTS brake
Schalter Fahrstufen 2 Masse Analoge Wahlschalter Versorgung Analoge Wahlschalter Frequenzverstellung Anbauplatten Vibration Anbauplatten Schwimmstellung Anbauplatten Schalter Vibration klein/aus (an/aus) Schalter Vibration aus/groß BTS Bremse
At dozer blade At vibratory plate

Bei Planierschild Bei Vibrationsplatte

b c b c
e f e f
At vibratory plate or dozer blade

Bei Vibrationsplatte oder Planierschild
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Travel lever Higher-level function
=
Anlage DRIV 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Fahrhebel Einbauort + SEAT
1019
EPE / 000 / 00
1020
=DRIV/29.9 / X106:5
=DRIV/29.9 / X106:1
=DRIV/29.9 / AGND
Speed vibration drum Vibration pump off/high Vibration pump low/off

Circuit diagrams
Drehzahl Vibration Bandage Vibrationspumpe aus/groß Vibrationspumpe klein/aus

Driving Controller Driving Controller Driving Controller
A34 A34 A34

DIN_1 PWM_3 PWM_4
X35 34 X35 48 X35 49
X35 34 X35 48 X35 49
X106 2 1 5 3
X5.B 8 X5.B 1
30
K43
/34.4 87 87a
Relay, vibration
Relais Vibration
X5.B 9 3
not used today
wird zur Zeit nicht genutzt
X103 12 13
86 1 +PUMP 1 1
K43 Y07 Y08
D43
green
12V/25A 2 640...1580mA 2 640...1580mA 2
85
C1 C2
X106 6
=DRIV/31.9 / 31_DCtrl 31_DCtrl / 36.1
=DRIV/32.5 / 31_RFr 31_RFr / =OPT/41.0
=DRIV+SEAT/33.9 / Gnd_PB Gnd_PB / =OPT/40.0

87
87a 30 /34.5
Relay, vibration Solenoid valve, vibration front high Solenoid valve, vibration front low
Relais Vibration Magnetventil Vibration vorne gross Magnetventil Vibration vorne klein
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Vibration Higher-level function
=
Anlage VIB 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Vibration Einbauort + EBOX EPE / 000 / 00
=SUPL/14.9 / FM2
+SEAT X5.E 11
=DRIV/29.9 / 31_Ar 31_Ar

=OPT+CAB/45.1
=DRIV+SEAT/33.2 / 15_Ar X107 7
+DRUM
W1 X86:2 / =MEAS/39.1
12x0,75 9 10 Exciter up Exciter down Exciter priority
Erreger auf Erreger ab Erreger Priorität
Measurement controller Measurement controller Measurement Controller
X86 1
A83 A83 A83

RD
2 (+) + X86 DO(PWM)/2 DO(PWM)/1 DO_5
1 (-) - BK 2 X88 47 X88 46 X88 61
S107 B97
Switch, amplitude adjustment Sensor, adjustable motor X88 47 X88 46 61
3 (S) S
Schalter Amplitudenverstellung Sensor Verstellmotor
WH
12 steps
12 Stufen
4...20mA X86 3
W1
X107 9 10 11
12x0,75 11
X4.B 8
+DRUM
X5.E 14
W2
X107 8
7x1,0 1 3
1 1
X88 32 X88 9 Y140 Y141
400-1200mA 2 400-1200mA 2
X88 32 X88 9 b1 (v.r.) a1 (v.l.)
AIN_8 AI/7
A83 A83 -W2 2 4
7x1,0
Measurement Controller Measurement controller
-BMESX -BMESX Splice
Y140
Spleiss 8 Y141
Switch, amplitude adjustment Position exciter
Schalter Amplitudenverstellung Erregerposition
BN
1,5 mm²
X107 12
BN
=SUPL/13.9 / 31_MCtrl 1,5 mm²

Solenoid valve, exciter up Solenoid valve, exciter down
Magnetventil Erreger auf Magnetventil Erreger ab
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Variocontrol Higher-level function
=
Anlage VIB 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Variocontrol Einbauort + EBOX
1021
EPE / 000 / 00
1022
Dozer blade priority Floating position dozer blade Dozer blade up Dozer blade down Adjustment left plates Adjustment right plates
Planierschild Priorität Schwimmstellung Planierschild Planierschild anheben Planierschild absenken Verschiebung links Platten Verschiebung rechts Platten
-BMESX -BMESX -BMESX -BMESX -BMESX -BMESX
Driving Controller Driving Controller Driving Controller Driving Controller Driving Controller Driving Controller
Circuit diagrams
A34 A34 A34 A34 A34 A34

DO_6 DO_9 PWM_6 PWM_8 DO_10 DO_11
X35 62 X35 11 X35 42 X35 43 X35 50 X35 51
X35 62 X35 11 X35 42 X35 43 X35 50 X35 51
X5.E 10
X105 1 2 3 4 5 6
X105:1 / +REFR/38.0
X5.A 7 X105:2 / +REFR/38.0
X105:3 / +REFR/38.0
Y379
X105:4 / +REFR/38.0
Y378 +DRUM X105:5 / +REFR/38.0
W4
X105:6 / +REFR/38.0
12x0,75 1 3 5 7
Y380
1 1 1 1
Y102 Y378 Y102 Y379 Y380
2 2 2 2
W4
12x0,75 2 4 6 8
Splice
Spleiss 2
BN
1,5 mm²
X105:7 / +REFR/38.0
X105:10 / 37.1
X105:12 / 37.1

X105 7 10 12
BN BN BN
1,5 mm² 1,5 mm² 1,5 mm²
34.8 / 31_DCtrl
Solenoid valve, dozer blade priority Solenoid valve, lift dozer blade
Magnetventil Planierschild Priorität Magnetventil Planierschild heben
Solenoid valve, floating position Solenoid valve, lower dozer blade
Magnetventil Schwimmstellung Magnetventil Planierschild senken
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Dozer blade Higher-level function
=
Anlage VIB 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Planierschild Einbauort + EBOX EPE / 000 / 00
X105 11 Splice
=DRIV/29.9 / X105:11 Spleiss
22
Splice
36.8 / X105:12 Spleiss
23
+REFR
W8 X28 2 1 W7 X29 2 1
BINDER Sensorcable M12 90° BINDER Sensorcable M12 90°
4x0,5 BU (3) BN (1) 4x0,5 BU (3) BN (1)
- (bu) - (bu)
3 3
1 1
B312 + (bn) B313 + (bn)
Sensor, height adjustment plates Sensor, lateral adjustment plates
Sensor Höhenverstellung Platten 4 Sensor Seitenverstellung Platten 4
4...20mA S (bk) 4...20mA S (bk)
W8 BK (4) W7 BK (4)
4x0,5 4x0,5
X28 3 X29 3
X105 13 X105 14
Hour meter plates Plate pump enable Vibration pump plates

Stundenzähler Platten Freigabe Plattenpumpe Vibrationspumpe Platten
-BMESX -BMESX X35 31 -BMESX
X35 8
Driving Controller X35 8 Driving Controller X35 31 Driving Controller
+PLA
View from plate side AIN_5 AIN_6
Ansicht von Plattenseite A34 A34 A34 A34 A34
DO_7 DIN_18 PWM_11
X35 63 Driving Controller X35 10 Driving Controller X35 22
-BMESX -BMESX
X35 63 X35 10 X35 22
Sensor, height adjustment plates Sensor, lateral adjustment plates
Sensor Höhenverstellung Platten Sensor Seitenverstellung Platten
X105 9 X105 15 X105 8
+REFR
X29 4 X29 5
X27
W6
1 3x0,75 BK GY
3
2
-X27 3 X27 +MOT
2
1
1
Plug, quick connect coupling plates W9
X27 = Stecker Schnellverschlußkupplung Platten Y98
3x0,75 BK BN
400-1200mA 2

Solenoid valve, vibration pump plates
W6 Magnetventil Vibrationspumpe Platten
+
P43 3x0,75 BN
Operating hour meter

h plates
Betriebsstundenzähler X29 6
- Platten
BN Splice
36.8 / X105:10 1,5 mm² Spleiss
24
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Vibratory plate compactor Higher-level function
=
Anlage VIB 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Anbauplatten Einbauort + EBOX
1023
EPE / 000 / 00
1024
+EBOX
Floating position plates

Schwimmstellung Anbauplatten
-BMESX
Driving Controller
A34
DO_8
X35 45
Circuit diagrams
X35 45
X105 16
+EBOX/36.8 / X105:2
+EBOX/36.8 / X105:1
+EBOX/36.8 / X105:6
Y145
+EBOX/36.8 / X105:5
Y143
+EBOX/36.8 / X105:4
+EBOX/36.8 / X105:3 Y142
Y122
Y123
1 1 1 1
Y122 Y142 Y145 Y144
b1 a2 a c2
2 2 2 2
1 1 1
Y123 Y143 Y60
a1 b2 c1
2 2 2
Y144
Y60

BN Splice
+EBOX/36.8 / X105:7 2,5 mm² Spleiss
25
Solenoid valve, lift plates Solenoid valve, plate displace left Solenoid valve, plate (priority) Solenoid valve, plate floating position
Magnetventil Platten heben Magnetventil Plattenverschieben links Magnetventil Platten (Priorität) Magnetventil Platten Schwimmstellung
Solenoid valve, let down plates Solenoid valve, plate displace right Solenoid valve, floating position
Magnetventil Platten senken Magnetventil Plattenverschieben rechts Magnetventil Schwimmstellung
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Vibratory plate compactor Higher-level function
=
Anlage VIB 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Anbauplatten Einbauort + REFR EPE / 000 / 00
=SUPL/14.6 / AGND_MC
=DRIV/30.9 / F91:2
X5.E 7
X107 1 2
+DRUM WH WH
1,5 mm² 1,5 mm²
Splice
Spleiss 7
=VIB/35.5 / X86:2
Splice Power supply GPS
Spleiss 6
RxD TxD Spannungsversorgung GPS
W1 -BMESX -BMESX -BMESX
12x0,75 1 2 5 6
Measurement controller Measurement controller Measurement controller
A83 A83 A83

RxD TxD DO(2,5A)/3
X88 4 X88 5 X88 25
X20 1 2 X21 1 2 X88 4 X88 5 X88 25
BK GNYE BK GNYE
+ +
- -
B62 B171
15g 15g
front 20g rear 20g

vorne hinten X5.E 5 3 8
BN BU BN BU
Transducer, acceleration
Transducer, acceleration
Aufnehmer Beschleunigung
Aufnehmer Beschleunigung
X20 4 3 X21 4 3
15_GPS / =OPT+CAB/46.1
W1
TxD / =OPT+CAB/46.1
12x0,75 4 3 8 7
RxD / =OPT+CAB/46.1
X107 3 4 5 6
X88 31 X88 29 X88 7 X88 30
X88 31 X88 29 X88 7 X88 30

AI/6 AI/2 AI/3 AI/4
A83 A83 A83 A83
Measurement controller Measurement controller Measurement controller Measurement controller

Transducer Acceleration front 20g Transducer Acceleration front 15g Transducer Acceleration rear 20g Transducer Acceleration rear 15g
Beschleunigungsaufn. vorne 20g Beschleunigungsaufn. vorne 15g Beschleunigungsaufn. hinten 20g Beschleunigungsaufn. hinten 15g

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Measurement equipment Higher-level function
=
Anlage MEAS 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Messtechnik Einbauort + EBOX
1025
EPE / 000 / 00
1026
=SUPL/10.9 / F22:2 +ARC
S26:13 / 41.0
=SUPL/10.9 / F19:2
=SUPL/11.9 / F05:2
+CAB/46.1
X4.E:9
Circuit diagrams
13
S26
Switch, working lights 14
Schalter Arbeitsbeleuchtung
Access without StvZO
illumination.
At cabin not connected X33 5
Anschluss ohne StvZO
Beleuchtung. Bei Kabine nicht
angeschlossen X33 5
Digital IN1
A15
X4.E 16 18 Monitoring Module

-BAUSER_1
X4.A 15 X7.C 6
Illumination
Beleuchtung
X22
2
X6.B 2 4
1 X22 1
+DPL +ROPS
WH WH
1,5 mm² 1,5 mm²
1 1 1 1
E23 E25 E27 E28
12V 55W 2 12V 55W 2 12V 55W 2 12V 55W 2
+ 86 1
XS K06
green
D118
12V / max. 20A 12V/25A 2

- 85
BN
2,5 mm²
X22 2
Splice
Spleiss 87
BN
2,5 mm²
=DRIV/32.3 / 31_Db 31_Db / 41.0 X4.E 3 6
=VIB/34.8 / Gnd_PB Gnd_PB / 41.0

87
87a 30 =SUPL/10.4
Socket Working headlight, front left Working headlight, rear left Relay, headlights rear
Steckdose Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer hinten links Relais Scheinwerfer hinten
Working headlight, front right Working headlight, rear right
Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer hinten rechts
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Rops - Lighting, Socket Higher-level function
=
Anlage OPT 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Rops - Beleuchtung, Steckdose Einbauort + EBOX EPE / 000 / 00
=SUPL/10.9 / F07:2
=SUPL/11.9 / F08:2
X4.D 6
=SUPL/10.9 / F11:2 +ARC
+ARC
=SUPL/9.9 / S15:23
=SUPL/9.9 / S15:11
30 13 23 13 23
K16 S14 S37
WH Indicators
1,5 mm² /41.3 87a 87 Switch, hazard light 14 24 Switch, indicator 14 24
31 11 23 Relay, headlights front Warnblinkschalter Anzeigen Schalter Blinker
01 2 -BAUSER_1
Relais Scheinwerfer vorne
S15 Monitoring Module
Switch, lighting StVZO 32 12 24
Schalter Beleuchtung StVZO A15
X4.D 5 2 8
Access without StvZO illumination

X4.A
Anschluss ohne StvZO Beleuchtung

11 EN_WL Digital IN2
40.9 / S26:13
WH +CAB/46.1 X33 8
1,5 mm² X1
H06 X33 8 Wb LE RE 30
X2
X4.D 7 A02
10 1 Flasher unit
X4.D Blinkgeber
LA RA 31
1 1
V052 1 X4.A 6
Fuse, parking and tail Fuse, parking and tail
light left F09 light right F10 X4.A
2 1 4
Sicherung Park- und 10A Sicherung Park- und 10A
2 2
Schlussleuchte links Schlussleuchte rechts V06
Meldeleuchte Warnblinker
Indicator light, hazard light
WH
X2.B 2 X4.D 12 X4.D 9 X2.B 3 1,5 mm²
X4.D 3 X2.B 1 X4.D 11 X2.B 4
+REFR X11 6 X11 9

+DPL Splice
Spleiss 4 X11 7 X11 10
Splice
Spleiss 5
X80 3
+DPL X81 3
X79 3 X82 3
X80 1 X81 1
1 1 1 1 86 1 87a 87 5 5 2 2
X79 X82 X79 X82
E13 E12 E14 E15 K16
D16
green
LED 2 5W 2 5W 2 LED 2 12V/25A 85 2 30 1 1 1 1 1 1
E16 E17 E08 E09 E10 E11
/41.4
55W 2 55W 2 21W 2 21W 2 21W 2 21W 2
X80 4 X81 4
X79 6 6 2 2
X82 X80 X81
BN BN
1,5 mm² 1,5 mm²
40.1 / 31_Db 31_Db

+CAB/45.1
31_Db_2
+REFR
+REFR
=DRIV+SEAT/33.2
BN
X11 11 BN Splice
31_RFr 1,5 mm² 1,5 mm² Spleiss

=VIB/34.8 Splice 64
8 BN Spleiss
1,5 mm²
63
40.9 / Gnd_PB Gnd_PB
42.1
Tail light, left Parking light, right Relay, headlights front Headlight, left Indicator, front left Indicator, front right
Schlussleuchte links Parkleuchte rechts Relais Scheinwerfer vorne Scheinwerfer links Blinkleuchte vorne links Blinkleuchte vorne rechts
Parking light, left Tail light, right Headlight, right Indicator, rear left Indicator, rear right
Parkleuchte links Schlussleuchte rechts Scheinwerfer rechts Blinkleuchte hinten links Blinkleuchte hinten rechts
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 StVZO illumination Higher-level function
=
Anlage OPT 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 StVZO Beleuchtung Einbauort + EBOX
1027
EPE / 000 / 00
1028
=COM/18.8 / CAN1+ CAN1+ / +CAB/46.1
=COM/18.8 / CAN1- CAN1- / +CAB/46.1
41.9 / Gnd_PB Gnd_PB / 43.1
=COM/16.9 / F84:2
Circuit diagrams
=COM/18.8 / F148:2
X7.B 3 2 1 4 6
+DPL
A67
Keyboard
Tastatur
X16
1

4
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Electronical Burglary protection Higher-level function
=
Anlage OPT 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Elektronische Diebstahlsicherung Einbauort + EBOX EPE / 000 / 00
A124
Electronic system, BOMAG Telematics
Elektronik BOMAG Telematik
+ARC
A138
Antenna, BOMAG Telematics
Antenne BOMAG Telematik
GPS GSM
GPS GSM
GSM
GPS
CAN_L CAN_H Pot. 30 Pot. 15 IN0 IN1 GND
4 3 12 2 8 11 1
GSM GPS
-XA124 4 3 12 2 8 11 1
X6.D 8
=COM/18.8 / CAN2-_TM
7
=COM/18.8 / CAN2+_TM
4
=SUPL/11.9 / F243:2
1
=SUPL/11.9 / F244:2
2
=MON/28.1 / D+
D+ / +CAB/46.1 5
=ENGI/21.8 / StU_TM

6
=ENGI/20.8 / VIB_TM
3
42.9 / Gnd_PB
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 BOMAG Telematics Higher-level function
=
Anlage OPT 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 BOMAG Telematik Einbauort + EBOX
1029
EPE / 000 / 00
1030
WH
=SUPL+EBOX/11.9 / F103:2 1,5 mm²
WH Splice WH
=SUPL+EBOX/10.9 / F68:2 2,5 mm² Spleiss 1,5 mm²
78
A B
F320 F321
5A 1 5A 2
Fuse, timer additional heater Fuse, timer additional heater
(potential 30) (potential 15)
Sicherung Schaltuhr Sicherung Schaltuhr
Zusatzheizung (Potential 30) Zusatzheizung (Potential 15)
Circuit diagrams
Low Medium High

POWER
niedrig Medium Hoch XS28 11 10 1
Power consumption Pot. 30 Pot. 15 Bel.
Energiebedarf [W] 8 16 30 40
-S28 11 10 1
E30 Timer
Heating unit Schaltuhr
Heizgerät
1
1
4
4
7
7
8
8
6
6
5
5
10
2 6 8 9 12 4
10 S+ Temp DIAG Gnd Gnd Gnd
SetVal Temp
SetVal
XS28 2 6 8 9 12 4
WH
2,5 mm²
X207
1 RD 1 1
1,5 mm²
4 YE 4 4
0,5 mm²
7 GRRD 7 7
0,5 mm²
8 BUYE 8 8
0,5 mm²
6 BNWH 6 6
0,5 mm²
5 GNRD 5 5
1 mm²
10 BN 10 10
1,5 mm²
+MOT X76 1
Y14
Fuel pump, heating unit
Kraftstoffpumpe Heizgerät 2

X76 2
BN
2,5 mm²
BN Splice
=SUPL+EBOX/9.7 / 31_AH 2,5 mm² Spleiss
79
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Cabin - Additional heater Higher-level function
=
Anlage OPT 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Kabine - Zusatzheizung Einbauort + DPL EPE / 000 / 00
+EBOX
=SUPL+EBOX/11.9 / F29:2 WWF / 46.1
=SUPL+EBOX/11.9 / F40:2 WWR / 46.1
X6.C 2 4 X4.B 3 6 X6.B 3 1
WH WH
1,5 mm² 1,5 mm²
30
K09 Splice
Spleiss 9
=SUPL+EBOX/9.7 87 87a
Relay, air conditioning
WH
Relais Klimaanlage 2,5 mm²
+SEAT
+DPL
X1.A 5
A108 1
Heating climatic unit
X10
Heiz-Klima-Einheit Supply
WH X87, X99
1,5 mm² RD
+REFR
X68 1 3 2
sw br BK/GN BK 1
B104 P
LP HP MP Out Gnd
Pressure switch, air conditioning sw/ge br/sw
Druckschalter Klimaanlage WH WH
X10 4 2 1,5 mm² 1,5 mm²
X68 2 4
X87 1 X99 1
WH
1,5 mm²
WH Option
1,5 mm²
3 Option 3
+MOT X12 1 S29 S25
Switch, suspension seat 4 Switch, heating operators seat 4
WH BN Schalter Luftfedersitz Schalter Fahrersitzheizung
1 2 1,5 mm² 2,5 mm²
Y15 V04
3,5A 2 1 + +
1
BN 1 1
1,5 mm² X6.C 1
M10
M R06 M06 M07
12V / < 9A 12V / 6,85A 2 2 3,5A 3,5A
Delivery equipment Sitz
Lieferumfang Sitz
31_Eng BN - -
1,5 mm² 2
=MON+EBOX/28.8
Only at air conditioning 2 2

X87 X99
Nur bei Klimaanlage
BN BN
1,5 mm² 1,5 mm²
=VIB+EBOX/35.2 / 31_Ar

+EBOX/41.3 / 31_Db
Magnetic clutch, air conditioning compressor Compressor, suspension operators seat Motor, windscreen washer front
Magnetkupplung Klimakompressor Kompressor Luftfedersitz Scheibenwaschermotor vorne
Heating, operators seat Motor, windscreen washer rear
Heizung Fahrersitz Scheibenwaschermotor hinten
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Cabin - Heating, Air conditioning, Washer pumps Higher-level function
=
Anlage OPT 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Kabine - Heizung, Klimaanlage, Wascherpumpen Einbauort + CAB
1031
EPE / 000 / 00
1032
+EBOX
X4.E 14
=MEAS+EBOX/39.8 / RxD RxD / 51.6
4
=MEAS+EBOX/39.8 / TxD TxD / 51.6
8
WH
=MEAS+EBOX/39.8 / 15_GPS 1,5 mm² 15_GPS / 52.0
10
Circuit diagrams
=COM+EBOX/17.8 / CAN3+ CAN3+ / 52.0

7
=COM+EBOX/17.8 / CAN3- CAN3- / 52.0
11
=DRIV+EBOX/32.5 / Rev Rev / 53.1
-A178
1 X202 9 Additional working lights left zusätzliche Arbeitsbeleuchtung links
Controller, console terminal cabin 1
+EBOX/42.9 / CAN1+
Controller Bedienkonsole Kabine
2 Illumination drum Bandagenbeleuchtung
2 X202 10
+EBOX/42.9 / CAN1-
3 Start Start
17 X202 6
+EBOX/43.1 / D+ 4 Stop Stop
Print Drucken
DIG In
5
5
X202 4
High active
+EBOX/41.4 / EN_WL 6 Delete Löschen
Reserve Reserve
DIG In
9
7
X202 5
High active
X7.C 7 WH
1,5 mm² 8 Additional working lights right zusätzliche Arbeitsbeleuchtung rechts
9 Windscreen wiper front Scheibenwischer vorne
DIG Out
+EBOX/40.2 / X4.E:9
10 Windscreen wiper rear Scheibenwischer hinten
15 X202 8
WH
=SUPL+EBOX/9.9 / 15_CAB 1,5 mm² 15_PB_CAB / 47.1 11 Windscreen wascher front Scheibenwascher vorne
13 X202 3
45.9 / WWF WWF_PB_CAB / 49.1 12 Rotary beacon Rundumkennleuchte
12 X202 1 13 Working headlights front Arbeitsscheinwerfer vorne
45.9 / WWR WWR_PB_CAB / 49.1
14 Cabin inside light Kabineninnenbeleuchtung
15 Working headlights rear Arbeitsscheinwerfer hinten

X8.A 30 X200 30
RD Rear screen heating Heckscheibenheizung
=SUPL+EBOX/9.6 / X8.A 16 mm² 30_PB_CAB / 47.1 16
RADSOK® 8mm Amphenol RADSOK® 6mm
17 Windscreen wascher rear Scheibenwascher hinten
X8.B 31 BN BN
X201 31
=SUPL+EBOX/9.9 / X8.B 16 mm² 10 mm² GND_PB_CAB / 47.1
RADSOK® 6mm Amphenol RADSOK® 3,6mm
1 8
Optional
Optional
GND_CAB / 48.0
2 7
3 4 5 6
not used

31 31
Ground Cabin wird nicht genutzt
Masse Kabine
9 10
11 12 13 14 15 16 17
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Cabin - Supply Higher-level function
=
Anlage OPT 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Kabine - Versorgung Einbauort + CAB EPE / 000 / 00
46.4 / 30_PB_CAB
46.4 / 15_PB_CAB
1 1 1
30 F17 F264 F271
K32 5A 2 10A 2 10A 2
/47.1 87 87a
Relay, cabin
Relais Kabine
Fuse, radio
Fuse, BCM05
Fuse, BCM-Net
Sicherung Radio
Sicherung BCM05
Sicherung BCM-Net
F271:2 / 52.1
F264:2 / 52.1
F17:2 / 51.1
1 1 1 1 1 1 1
F272 F27 F28 F143 F266 F150 F279
5A 2 15A 2 15A 2 20A 2 10A 2 5A 2 15A 2
Fuse, reserve
terminal cabin
Sicherung Reserve
Fuse, GPS receiver
Sicherung Controller
Bedienkonsole Kabine
Fuse, controller console

Sicherung GPS Receiver
Fuse, radio / tachograph

86
D2.1
K32
Fuse, rear screen heating unit

Sicherung Radio / Tachograph
green
Sicherung Heckscheibenheizung
12V/25A 85 F279:2 / 49.1
Relay, cabin
Relais Kabine
Sicherung Wischer und Wascher vorne

Sicherung Wischer und Wascher hinten
F150:2 / 52.1
Fuse, windscreen wiper and washer rear
Fuse, windscreen wiper and washer front

F266:2 / 51.1
F143:2 / 50.1
F28:2 / 50.1
46.4 / GND_PB_CAB GND_PB_CAB / 48.0

F27:2 / 50.1
87
87a 30 /47.2 F272:2 / 48.0
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Cabin - Fuse protection Higher-level function
=
Anlage OPT 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Kabine - Absicherung Einbauort + CAB
1033
EPE / 000 / 00
1034
A178
/46.5
Controller, console terminal cabin
Circuit diagrams
Ub PWM Out PWM Out Gnd DIG Out DIG Out DIG Out DIG Out DIG Out DIG In DIG Out DIG Out DIG Out DIG Out
Low active
1 1
47.9 / F272:2 E29 E29
Inside light, cabin 2 1 2
Innenleuchte Kabine E72
Illumination, 2
switches
Beleuchtung
Bedienschalter
X206 1 6 2 4 9 X203 2 5 1 4 3 6
+ 1 1 1 1
E32 E27 E28 E23 E25
12V 70W - 12V 55W 2 12V 55W 2 12V 55W 2 12V 55W 2
46.3 / GND_CAB GND_CAB / 50.1

Rotary beacon Working headlight, rear left Working headlight, front left
Rundumkennleuchte Arbeitsscheinwerfer hinten links Arbeitsscheinwerfer vorne links
Working headlight, rear right Working headlight, front right
Arbeitsscheinwerfer hinten rechts Arbeitsscheinwerfer vorne rechts
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Cabin - Lighting Higher-level function
=
Anlage OPT 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Kabine - Beleuchtung Einbauort + CAB EPE / 000 / 00
A178
/46.5
DIG Out DIG Out DIG Out DIG Out DIG Out DIG Out
86 86 86
D2.2 D2.3 D2.4
K141 K20 K21
green green green
12V/25A 85 12V/25A 85 12V/25A 85
Automotive Micro Relay on socket Automotive Micro Relay on socket Automotive Micro Relay on socket
Automotive Mircrorelais auf Sockel Automotive Mircrorelais auf Sockel Automotive Mircrorelais auf Sockel
46.4 / WWF_PB_CAB Relay, heating rear screen Relay, windscreen wiper front Relay, windscreen wiper rear
Relais Heckscheibenheizung Relais Wischer vorne Relais Wischer hinten
46.4 / WWR_PB_CAB
47.9 / F279:2
max. 150 mA
X206 3 7 8

87 87 87
87a 30 /50.7 87a 30 /50.3 87a 30 /50.5
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Cabin - Cabin equipment Higher-level function
=
Anlage OPT 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Kabine - Kabinenausrüstung Einbauort + CAB
1035
EPE / 000 / 00
1036
47.9 / F143:2
47.9 / F28:2
47.9 / F27:2
Circuit diagrams
87a 87 87a 87 30
K20 Relay, windscreen wiper front K21 Relay, windscreen wiper rear K141
/49.5 30 Relais Wischer vorne /49.6 30 Relais Wischer hinten /49.3 87 87a
Relay, heating rear screen
Relais Heckscheibenheizung
X203 7 8 9 10 11 12 13 14
WH WH WH WH WH WH WH WH
1,5 mm² 1,5 mm² 1,5 mm² 1,5 mm² 1,5 mm² 1,5 mm² 1,5 mm² 1,5 mm²
Splice
53b 53 31b 53 Spleiss 77
[gy] [blu] [blu/wht] [blu]
WH
X66 3 2 5 X65 1 4 3 1,5 mm²
4 3
6 5 4
53a 31b 53 53a 31b 53 2 1 1
3 2 1
31 53a
M04 53a 31b 31 M05 [blk] [blk/blu] R80
4,7A [blu/blk] [blu/wht] [blk] 4,7A ca. 11 A
31 31 2
BN
X66 1 X65 2 1,5 mm²
Splice
Spleiss 76
BN BN BN
1,5 mm² 1,5 mm² 2,5 mm²

Motor, windscreen wiper front Motor, windscreen wiper rear Rear window heater
Scheibenwischermotor vorne Scheibenwischermotor hinten Heizung Heckscheibe
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Cabin - Cabin equipment Higher-level function
=
Anlage OPT 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Kabine - Kabinenausrüstung Einbauort + CAB EPE / 000 / 00
47.9 / F266:2
47.9 / F17:2
49.8 / GND_PB_CAB
A178
/46.5
PWM Out PWM Out PWM Out
X205 1 2 3 4 6 5 X202 2
X202:2 / 53.1
Splice
Spleiss 58
Splice
Spleiss 57
46.4 / TxD
Splice
Spleiss 56
46.4 / RxD
A1 Splice
Spleiss 59
P09
A2
A16 A3
3 2 1 3 2 1 2 1
31 15 30 Ctrl Ant
A5 -A12
Radio A8 A7 A4 A5 Ant
XB3 XS5 XS4 Radio
1 A6
2
C3 X94 Ub
1 TxD 2 Gnd 5 4 X83 1 2
3 4 A = white RxD
B = yellow
4 3 B3 P11
C = red
5 2 B7 B8 B5 B6 B3 B4 B1 B2
XB2
XS3 1 B4 rl+ rl- fl+ fl- fr+ fr- rr+ rr-
Printer
Drucker
XS2 Tachograph
Tachograph B51.L B51.R
XS1 123456
+ -
- +
1 2 3 1 2

Speaker radio Speaker radio
Electronic system, tachograph Lautsprecher Radio Lautsprecher Radio
Elektronik Tachograph
Only at VM29-Printer
Nur bei VM29-Drucker
X94 3
AGND
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Cabin - Radio, Tachograph, Printer measurement Higher-level function
=
Anlage OPT 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Kabine - Radio, Tachograph, Drucker Messtechnik Einbauort + CAB
1037
EPE / 000 / 00
1038
47.9 / F271:2
47.9 / F150:2
47.9 / F264:2
Circuit diagrams
X204 1 2 3 4

WH
46.4 / 15_GPS 1,5 mm²
BN BN
1,5 mm² 1,5 mm²
X85 1 X85 2 3
USB-CAN Interface BCM -A93
A87 USB-CAN Schnittstelle BCM GPS receiver
GPS Receiver
X95
X95 X91
X85 4 7 7 1
46.4 / CAN3+ 2
3
X85 5 4
2 2 SH
46.4 / CAN3-
12 6 7 2 11
X211 -X93 C B A -X97
Gnd2 4 A B C D E
RxD2 2
TxD2 3
P15 X96
BCM05 Ub 1 -X210 -X92
Supply
BCM05 Versorgung 1 A
AGnd 1 A
Gnd 2
Splice 2 2 B B
Spleiss 200
X90
Gnd1 5 3 3 C C
GPS receiver
GPS Receiver 2 4 D
RxD1 4 D

TxD1 3 5 5 E E
W10
7x1,0
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 BOMAG Compaction Management BCM, GPS Higher-level function
=
Anlage OPT 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 BOMAG Verdichtungsmanagement BCM, GPS Einbauort + CAB EPE / 000 / 00
51.8 / X202:2
52.7 / GND_CAB
46.4 / Rev
P42
Display, back up monitoring
Monitor Rückraumüberwachung
Pin 5 - Trigger Cam 3

Pin 2 - Gnd
Pin 1 - 12/24V DC
P32 X50 1 RD
Camera, back up monitoring 2 BK

Plug, access display back up monitoring
Kamera Rückraumüberwachung 3 WH X50 = Stecker Anschluß Monitor Rückraumüberwachung
4 BU
5 BN
CA1 CA1
CA2
CA3

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 08.06.2015 BW 213-226 D/DH-5 Back up monitoring Higher-level function
=
Anlage OPT 327
Checked
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Rückraumüberwachung Einbauort + CAB
1039
EPE / 000 / 00
1040
Device tag list
Betriebsmittelliste
Higher-level
Device tag Page Path Mounting location function characteristics
BMK Blatt Pfad Einbauort
Function text Funktionstext Techn.-Kenngrößen
Anlage
A02 41 8 +EBOX Flasher unit Blinkgeber

Circuit diagrams
A12 51 4 +CAB Radio Radio

A15 15 2 +ARC Monitoring module Überwachungsmodul
A16 51 0 +CAB Electronic system, tachograph Elektronik Tachograph
A34 12 3 +EBOX Driving Controller Fahrsteuerung ----> Pin Overview
A48 22 0 +EBOX Engine-controller EMR4 (EDC 17-CV52) Motorsteuergerät EMR4 (EDC 17-CV52)
A67 42 5 +DPL Keyboard Tastatur
A83 13 3 +EBOX Measurement controller Messtechnik Steuerung
A87 52 2 +CAB USB-CAN Interface BCM USB-CAN Schnittstelle BCM
A93 52 7 +CAB GPS receiver GPS Receiver
A108 45 2 +CAB Heating climatic unit Heiz-Klima-Einheit
A124 43 3 +EBOX Electronic system, BOMAG Telematics Elektronik BOMAG Telematik
A138 43 5 +ARC Antenna, BOMAG Telematics Antenne BOMAG Telematik
B03 28 4 +MOT Maintenance switch, air cleaner Wartungsschalter Luftfilter
B11.1 32 1 +REFR Warning horn Signalhorn max. 3,5A
B11.2 32 2 +REFR -"- -"- max. 3,5A
B21 28 5 +REFR Differential pressure switch, hydraulic oil filter Differenzdruckschalter Hydraulikölfilter
B51.L 51 4 +CAB Speaker radio Lautsprecher Radio
B51.R 51 5 +CAB -"- -"-
B55 28 2 +MOT Floating switch, coolant expansion tank Schwimmerschalter Kühlmittelausgleichsbehälter
B57 29 1 +EBOX Slope sensor, speed range selection Neigungssensor Stufenumschaltung 0,5-4,5V
B59 29 7 +DRUM Speed sensor, drum Drehzahlsensor Bandagengeschwindigkeit
B60 29 4 +REFR Speed sensor, axle Drehzahlsensor Achsgeschwindigkeit
B62 39 1 +DRUM Transducer, acceleration Aufnehmer Beschleunigung
B88 24 4 +MOT EMR engine oil pressure EMR Motoröldruck
B93 23 6 +MOT EMR Fuel pressure rail EMR Kraftstoffdruck Rail
B97 35 4 +DRUM Sensor, adjustable motor Sensor Verstellmotor
B104 45 1 +REFR Pressure switch, air conditioning Druckschalter Klimaanlage
B113 24 2 +MOT EMR Temperature sensor, coolant EMR Temperatursensor Kühlmittel
B114 23 4 +MOT EMR Sensor, engine speed 1 EMR Motordrehzahlsensor 1
B124 22 1 +MOT Sensor, water trap fuel Sensor Wasserabscheider Kraftstoff

B130 23 5 +MOT EMR Sensor, engine speed 2 EMR Motordrehzahlsensor 2
B133 24 3 +MOT EMR Sensor, charging air pressure / -temperature EMR Sensor Ladeluftdruck / -temperatur
B145 24 5 +MOT EMR Low pressure Fuel EMR Niederdruck Kraftstoff
B171 39 3 +DRUM Transducer, acceleration Aufnehmer Beschleunigung
B208 24 8 +MOT EMR Sensor, delta p venturi EMR Sensor Delta p Venturi
B209 24 8 +MOT EMR Sensor, temperature EGR behind venturi EMR Sensor Temperatur EGR nach Venturi
0 1 2 3 4 5 6 7 8 9
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Erstellt MFS 08.06.2015 BW 213-226 D/DH-5 Device tag list Higher-level function
=
Anlage 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Betriebsmittelliste Einbauort + DTLE EPE / 000 / 00
Device tag list
Betriebsmittelliste
Higher-level
Anlage
B214 26 3 +MOT EMR Sensor, temperature exhaust gas before oxy cat EMR Temperatursensor Abgas vor Oxy Kat
B218 22 3 +MOT Temperature sensor, ambient temperature Temperatursensor Umgebungstemperatur
B221 26 5 +REFR Sensor, urea pressure behind pump Sensor, Ureadruck nach Pumpe
B222 25 4 +REFR Sensor, urea temperature and level Sensor Ureatemperatur und Füllstand
B223 26 3 +MOT Temperature sensor, exhaust gas before SCR kat Temperatursensor Abgas vor SCR Kat
B224 25 6 +MOT Sensor, NOx befor SCR-Kat Sensor NOx vor SCR-Kat
B225 25 8 +MOT Sensor, NOx behind SCR-Kat Sensor NOx nach SCR-Kat
B234 30 2 +PUMP Pressure sensor, travel pump axle MA Drucksensor Fahrpumpe Achse MA
B235 30 3 +PUMP Pressure sensor, travel pump axle MB Drucksensor Fahrpumpe Achse MB
B236 30 4 +PUMP Pressure sensor, travel pump drum MA Drucksensor Fahrpumpe Bandage MA
B237 30 4 +PUMP Pressure sensor, travel pump drum MB Drucksensor Fahrpumpe Bandage MB
B305 26 1 +MOT EMR Pressure sensor, pressure after DPF EMR Drucksensor, Druck nach DPF
B312 37 5 +REFR Sensor, height adjustment plates Sensor Höhenverstellung Platten 4...20mA
B313 37 6 +REFR Sensor, lateral adjustment plates Sensor Seitenverstellung Platten 4...20mA
D2.1 47 1 +CAB Indicator light, relay K32 Meldeleuchte Relais K32 green
D05 33 9 +EBOX Indicator light, relay K13 Meldeleuchte Relais K13 green

Dx 10 1 +EBOX Indicator light, fuse test Meldeleuchte Sicherungstest green
E08 41 7 +DPL Indicator, front left Blinkleuchte vorne links 21W
E09 41 8 +REFR Indicator, rear left Blinkleuchte hinten links 21W
E10 41 8 +DPL Indicator, front right Blinkleuchte vorne rechts 21W
E11 41 8 +REFR Indicator, rear right Blinkleuchte hinten rechts 21W
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Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Betriebsmittelliste Einbauort + DTLE
1041
EPE / 000 / 00
1042
Device tag list
Betriebsmittelliste
Higher-level
Anlage
E12 41 1 +DPL Parking light, left Parkleuchte links 5W

Circuit diagrams
E13 41 1 +REFR Tail light, left Schlussleuchte links LED

E14 41 2 +DPL Parking light, right Parkleuchte rechts 5W
E15 41 2 +REFR Tail light, right Schlussleuchte rechts LED
E16 41 4 +DPL Headlight, left Scheinwerfer links 55W
E17 41 5 +DPL Headlight, right Scheinwerfer rechts 55W
E23 40 3 +ROPS Working headlight, front left Arbeitsscheinwerfer vorne links 12V 55W
E23 48 8 +CAB -"- -"- 12V 55W
E25 40 3 +ROPS Working headlight, front right Arbeitsscheinwerfer vorne rechts 12V 55W
E25 48 9 +CAB -"- -"- 12V 55W
E27 40 4 +ROPS Working headlight, rear left Arbeitsscheinwerfer hinten links 12V 55W
E27 48 7 +CAB -"- -"- 12V 55W
E28 40 4 +ROPS Working headlight, rear right Arbeitsscheinwerfer hinten rechts 12V 55W
E28 48 8 +CAB -"- -"- 12V 55W
E29 48 1 +CAB Inside light, cabin Innenleuchte Kabine
E30 44 0 +DPL Heating unit Heizgerät
E32 48 6 +CAB Rotary beacon Rundumkennleuchte 12V 70W
E72 48 2 +CAB Illumination, switches Beleuchtung Bedienschalter
E104 27 6 +MOT Heating, pressure line Heizung Druckleitung
E105 27 5 +MOT Heating, suction line Heizung Saugleitung
E106 27 5 +MOT Heating, return flow line Heizung Rücklaufleitung
E107 26 8 +REFR Heating, supply modul Heizung Versorgungsmodul ???W
F00 9 1 +REFR Fuse, main battery Hauptsicherung Batterie 125A
F05 11 4 +EBOX Fuse, socket Sicherung Steckdose 20A
F07 10 8 +EBOX Fuse, hazard light Sicherung Warnblinker 10A
F08 11 4 +EBOX Fuse, indicators Sicherung Blinker 10A
F09 41 1 +EBOX Fuse, parking and tail light left Sicherung Park- und Schlussleuchte links 10A
F10 41 2 +EBOX Fuse, parking and tail light right Sicherung Park- und Schlussleuchte rechts 10A
F11 10 7 +EBOX Fuse, headlight left Sicherung Scheinwerfer links 15A
F13 10 1 +EBOX Fuse, ignition switch Sicherung Startschalter 15A
F17 47 4 +CAB Fuse, radio Sicherung Radio 5A

F19 10 4 +EBOX Fuse, working headlight front left Sicherung Arbeitsscheinwerfer vorne links 15A
F22 10 3 +EBOX Fuse, working lights rear Sicherung Arbeisscheinwerfer hinten 15A
F23 10 5 +EBOX Fuse, signal horns Sicherung Signalhörner 15A
F24 11 3 +EBOX Fuse, monitoring module Sicherung Überwachungsmodul 10A
F27 47 4 +CAB Fuse, windscreen wiper and washer front Sicherung Wischer und Wascher vorne 15A
F28 47 4 +CAB Fuse, windscreen wiper and washer rear Sicherung Wischer und Wascher hinten 15A
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Anlage 327
Device tag list
Betriebsmittelliste
Higher-level
Anlage
F29 11 7 +EBOX Fuse, compressor suspension seat Sicherung Kompressor Luftfedersitz 15A
F39 9 6 +EBOX Fuse, main cabin Hauptsicherung Kabine 80A
F40 11 6 +EBOX Fuse, heating unit cabin Sicherung Kabinenheizung 25A
F48 9 2 +REFR Fuse, glow plug system Sicherung Glühanlage 80A
F67 10 6 +EBOX Fuse, controller (potential 30) Sicherung Steuerung (Potential 30) 15A
F68 10 2 +EBOX Fuse, potential 30 Sicherung Potential 30 15A
F84 10 4 +EBOX Fuse, controller (Pin 54) Sicherung Steuerung (Kontakt 54) 10A
F91 11 3 +EBOX Fuse, sensors Sicherung Sensoren 5A
F95 9 0 +REFR Fuse, engine controller Sicherung Motorsteuerung 30A
F103 11 1 +EBOX Fuse, potential 15 Sicherung Potential 15 15A
F122 11 2 +EBOX Fuse, engine controller Sicherung Motorsteuerung 10A
F124 11 5 +EBOX Fuse, fuel-pre-heating Sicherung Kraftstoffvorheizung 25A
F143 47 5 +CAB Fuse, rear screen heating unit Sicherung Heckscheibenheizung 20A
F150 47 6 +CAB Fuse, GPS receiver Sicherung GPS Receiver 5A
F157 10 2 +EBOX Fuse, solenoid switch starter Sicherung Magnetschalter Anlasser 30A
F164 9 3 +REFR Fuse, B+ charge Sicherung B+ Ladeleitung 125A
F169 11 7 +EBOX Fuse, starting current Sicherung Startstrom 5A
F238 27 3 +BAT Fuse, exhaust gas recirculation Sicherung Abgasrückführung 15A
F243 11 8 +EBOX Fuse, Bomag telematics (potential 30) Sicherung Bomag Telematik (Potential 30) 7,5A
F244 11 6 +EBOX Fuse, Bomag telematics (potential 15) Sicherung Bomag Telematik (Potential 15) 5A
F250 27 2 +BAT Fuse, SCR control Sicherung SCR Ansteuerung 30A
F251 27 2 +BAT Fuse, NOx sensors Sicherung NOx Sensoren 10A
F264 47 4 +CAB Fuse, BCM05 Sicherung BCM05 10A
F266 47 5 +CAB Fuse, radio / tachograph Sicherung Radio / Tachograph 10A
F268 10 8 +EBOX Fuse, fuel pump Sicherung Kraftstoffpumpe 20A
F271 47 5 +CAB Fuse, BCM-Net Sicherung BCM-Net 10A
F272 47 3 +CAB Fuse, controller console terminal cabin Sicherung Controller Bedienkonsole Kabine 5A
F279 47 6 +CAB Fuse, reserve Sicherung Reserve 15A
F310 27 3 +BAT Fuse, sensor urea quality Sicherung Sensor Ureaqualität 5A

F312 27 1 +BAT Fuse, reserve Sicherung Reserve max. 20A
F313 27 2 +BAT -"- -"- max. 20A
F320 44 7 +DPL Fuse, timer additional heater (potential 30) Sicherung Schaltuhr Zusatzheizung (Potential 30) 5A
F321 44 8 +DPL Fuse, timer additional heater (potential 15) Sicherung Schaltuhr Zusatzheizung (Potential 15) 5A
Fx 10 1 +EBOX Fuseholder, fuse test Sicherungshalter Sicherungstest
FM1 14 2 +EBOX Fuse, sensors Sicherung Sensoren 1A
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Anlage 327
Circuit diagrams

1043
EPE / 000 / 00
1044
Device tag list
Betriebsmittelliste
Higher-level
Anlage
FM2 14 5 +EBOX Fuse, sensors Sicherung Sensoren 1A

Circuit diagrams
G01 9 2 +BAT Battery Batterie 12V / 110 Ah

G02 9 5 +MOT Generator Generator 14V / 150A
H06 41 6 +ARC Indicator light, hazard light Meldeleuchte Warnblinker
H07 28 7 +ARC Warning buzzer, breakdown Warnsummer Betriebsstörung 70mA
H14 32 5 +REFR Back-up alarm buzzer Warnsummer Rückwärtsfahrt 300mA
K05 33 8 +EBOX Relay, starting current Relais Startstrom 12V/25A
K06 40 5 +EBOX Relay, headlights rear Relais Scheinwerfer hinten 12V/25A
K09 9 7 +EBOX Relay, air conditioning Relais Klimaanlage 12V/25A
K11 9 8 +EBOX Relay, potential 30 on 15 Relais Potential 30 auf 15 12V/70A
K13 32 6 +EBOX Relay, warning horn Relais Signalhorn 12V/25A
K14.2 19 4 +MOT Relay, glow plug system Relais Vorglühen
K16 41 3 +EBOX Relay, headlights front Relais Scheinwerfer vorne 12V/25A
K20 49 5 +CAB Relay, windscreen wiper front Relais Wischer vorne 12V/25A
K21 49 6 +CAB Relay, windscreen wiper rear Relais Wischer hinten 12V/25A
K22 32 7 +EBOX Relay, shut off solenoid engine Relais Hubmagnet Abschaltung Motor 12V/25A
K32 47 1 +CAB Relay, cabin Relais Kabine 12V/25A
K38 21 6 +EBOX Relay, starter control Relais Anlassteuerung 12V/40A
K39 9 5 +MOT Relay, starter Relais Anlasser
K41 21 3 +EBOX Relay, separation Trennrelais 12V/25A
K43 34 4 +EBOX Relay, vibration Relais Vibration 12V/25A
K48 33 9 +EBOX Relay, travel lever 0-position Relais, Fahrhebel 0-Stellung 12V/25A
K61 9 6 +EBOX Relay, charge control Relais Ladekontrolle 12V/25A
K141 49 3 +CAB Relay, heating rear screen Relais Heckscheibenheizung 12V/25A
K145 21 8 +EBOX Relay, solenoid starter Relais Hubmagnet Starter 12V/40A
K192 27 7 +BAT Relay, SCR control Relais, SCR Ansteuerung 12V
K193 27 8 +BAT Relay, heating urea feed-in modul Relais Heizung Urea-Einspeisemodul 12V
K194 27 8 +BAT Relay, heating urea suction hose Relais Heizung Urea-Saugleitung 12V
K195 27 9 +BAT Relay, heating urea restriction hose Relais Heizung Urea-Drosselleitung 12V
K196 27 9 +BAT Relay, heating urea pressure hose Relais Heizung Urea-Druckleitung 12V
K209 21 4 +EBOX Relay, fuel pump Relais Kraftstoffpumpe 12V/25A

K227 27 6 +BAT Relay, potential 30 on 15 Relais Potential 30 auf 15 12V
M01 9 4 +MOT Starter Starter
M04 50 3 +CAB Motor, windscreen wiper front Scheibenwischermotor vorne 4,7A
M05 50 5 +CAB Motor, windscreen wiper rear Scheibenwischermotor hinten 4,7A
M06 45 8 +DPL Motor, windscreen washer front Scheibenwaschermotor vorne 3,5A
M07 45 9 +DPL Motor, windscreen washer rear Scheibenwaschermotor hinten 3,5A
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Anlage 327
Device tag list
Betriebsmittelliste
Higher-level
Anlage
M10 45 6 +SEAT Compressor, suspension operators seat Kompressor Luftfedersitz 12V / < 9A
M25 19 6 +MOT Fuel lift pump Kraftstoffförderpumpe I = ca. 10-15A,
IE = ca. 20-25A
M41 26 7 +REFR Urea pump Urea Pumpe
P09 51 3 +CAB Tachograph Tachograph
P11 51 6 +CAB Printer Drucker
P15 52 1 +CAB BCM05 BCM05
P32 53 1 +CAB Camera, back up monitoring Kamera Rückraumüberwachung
P42 53 5 +CAB Display, back up monitoring Monitor Rückraumüberwachung
P43 37 4 +PLA Operating hour meter plates Betriebsstundenzähler Platten
R03 28 8 +REFR Sender, level gauge Geber Tankanzeige 66 Ω / 64,2 Ω
R06 45 7 +SEAT Heating, operators seat Heizung Fahrersitz 12V / 6,85A
R10 9 6 +EBOX Parallel resistor Parallelwiderstand 82 Ω
R20 16 3 +EBOX Terminating resistor CAN Abschlußwiderstand CAN 120 Ω
R21 16 3 +EBOX -"- -"- 120 Ω
R22 16 5 +EBOX -"- -"- 120 Ω
R23 22 8 +EBOX -"- -"- 120 Ω
R24 16 7 +EBOX -"- -"- 120 Ω
R25 16 7 +EBOX -"- -"- 120 Ω
R26 17 7 +EBOX -"- -"- 120 Ω
R27 17 7 +EBOX -"- -"- 120 Ω
R28 18 6 +EBOX -"- -"- 120 Ω
R29 18 6 +EBOX -"- -"- 120 Ω
R30 22 9 +EBOX -"- -"- 120 Ω
R31 25 1 +EBOX -"- -"- 120 Ω
R32 25 8 +EBOX -"- -"- 120 Ω
R79 19 8 +MOT Fuel-pre-heater Kraftstoffvorheizung 200W
R80 50 7 +CAB Rear window heater Heizung Heckscheibe ca. 11 A
R81 19 3 +MOT Glow plug 1 Glühstiftkerze 1

S00 9 7 +ARC Ignition switch Startschalter
S01 10 4 +ARC Switch, emergency off Schalter NOT AUS
S06 29 3 +SEAT Switch, seat contact Sitzkontaktschalter
S09 33 5 +SEAT Switch, vibration front Schalter Vibration vorne
S14 41 5 +ARC Switch, hazard light Warnblinkschalter
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Circuit diagrams

1045
EPE / 000 / 00
1046
Device tag list
Betriebsmittelliste
Higher-level
Anlage
S15 41 2 +ARC Switch, lighting StVZO Schalter Beleuchtung StVZO

Circuit diagrams
S25 45 7 +SEAT Switch, heating operators seat Schalter Fahrersitzheizung

S26 40 5 +ARC Switch, working lights Schalter Arbeitsbeleuchtung
S28 44 6 +DPL Timer Schaltuhr
S29 45 6 +SEAT Switch, suspension seat Schalter Luftfedersitz
S30 9 3 +BAT Disconnect switch, battery Batterietrennschalter 250A
S35 33 7 +ARC Switch, vibration low / high Schalter Vibration klein / gross
S36 33 5 +SEAT Switch, vibration plates Schalter Vibration Anbauplatten
S37 41 8 +ARC Switch, indicator Schalter Blinker
S42 33 0 +ARC Switch, speed range selector Schalter Fahrstufen
S55 15 8 +SEAT Travel lever Fahrhebel
S64 33 6 +SEAT Pushbutton, float position plates Taster Schwimmstellung Anbauplatten
S107 35 2 +SEAT Switch, amplitude adjustment Schalter Amplitudenverstellung 4...20mA
S127 20 2 +ARC Switch, engine speed Schalter Motordrehzahl
S139 33 4 +SEAT Potentiometer, frequency plates Potentiometer Frequenzverstellung Anbauplatten
S299 20 4 +ARC Switch, regeneration mode Schalter Regenerationsmodus
V01 9 6 +EBOX Diode Diode S5G-E3
V02 32 1 +REFR -"- -"- SF 64
V03 32 2 +REFR -"- -"- SF 64
V04 45 2 +MOT -"- -"- SF 64
V05 41 7 +ARC -"- -"- SF 64
V06 41 7 +ARC -"- -"- SF 64
V07 29 5 +EBOX -"- -"- S1M
V08 29 5 +EBOX -"- -"- S1M
V09 29 7 +EBOX -"- -"- S1M
V010 29 7 +EBOX -"- -"- S1M
Y04 31 7 +REFR Solenoid valve, brake Magnetventil Bremse 2,41A
Y07 34 5 +PUMP Solenoid valve, vibration front high Magnetventil Vibration vorne gross 640...1580mA
Y08 34 6 +PUMP Solenoid valve, vibration front low Magnetventil Vibration vorne klein 640...1580mA
Y14 44 5 +MOT Fuel pump, heating unit Kraftstoffpumpe Heizgerät
Y15 45 1 +MOT Magnetic clutch, air conditioning compressor Magnetkupplung Klimakompressor 3,5A

Y16 31 1 +PUMP Solenoid valve, travel direction forward Magnetventil Fahrtrichtung vorwärts 640...1580mA
Y17 31 2 +PUMP Solenoid valve, travel direction backward Magnetventil Fahrtrichtung rückwärts 640...1580mA
Y30 31 8 +REFR Solenoid valve, speed range selection drum Magnetventil Fahrstufe Bandage 2,41A
Y30 31 9 +DRUM -"- -"- 1,05A
Y31 31 5 +REFR Solenoid valve, speed range selection axle Magnetventil Fahrstufe Achse 1,05A
Y60 38 5 +REFR Solenoid valve, floating position Magnetventil Schwimmstellung
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Anlage 327
Device tag list
Betriebsmittelliste
Higher-level
Anlage
Y72 31 3 +PUMP Solenoid valve, travel direction forward Magnetventil Fahrtrichtung vorwärts 640...1580mA
Y73 31 4 +PUMP Solenoid valve, travel direction backward Magnetventil Fahrtrichtung rückwärts 640...1580mA
Y98 37 7 +MOT Solenoid valve, vibration pump plates Magnetventil Vibrationspumpe Platten 400-1200mA
Y102 36 4 +DRUM Solenoid valve, floating position Magnetventil Schwimmstellung
Y122 38 1 +REFR Solenoid valve, lift plates Magnetventil Platten heben
Y123 38 2 +REFR Solenoid valve, let down plates Magnetventil Platten senken
Y137 23 5 +MOT EMR Actuator EMR Stellglied
Y140 35 7 +DRUM Solenoid valve, exciter up Magnetventil Erreger auf 400-1200mA
Y141 35 8 +DRUM Solenoid valve, exciter down Magnetventil Erreger ab 400-1200mA
Y142 38 3 +REFR Solenoid valve, plate displace left Magnetventil Plattenverschieben links
Y143 38 3 +REFR Solenoid valve, plate displace right Magnetventil Plattenverschieben rechts
Y144 38 5 +REFR Solenoid valve, plate floating position Magnetventil Platten Schwimmstellung
Y145 38 4 +REFR Solenoid valve, plate (priority) Magnetventil Platten (Priorität)
Y147 23 0 +MOT Injector A1 Injektor A1
Y174 24 6 +MOT EMR Exhaust gas recirculation EMR Abgasrückführung
Y261 24 1 +MOT Air intake throttle Drosselklappe Ansaugluft
Y291 26 6 +REFR Solenoid valve, urea extraction Magnetventil Urea Absaugung
Y292 26 8 +REFR Solenoid valve, urea tank heating Magnetventil Ureatank Heizung
Y293 26 4 +MOT Solenoid valve, urea dosing Magnetventil Ureadosierung
Y378 36 3 +DRUM Solenoid valve, dozer blade priority Magnetventil Planierschild Priorität
Y379 36 5 +DRUM Solenoid valve, lift dozer blade Magnetventil Planierschild heben
Y380 36 6 +DRUM Solenoid valve, lower dozer blade Magnetventil Planierschild senken

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Circuit diagrams

1047
EPE / 000 / 00
1048
Plug overview
Steckerübersicht
Designation Mounting location Function text Designation Mounting location Function text
Bezeichnung Einbauort Funktionstext Bezeichnung Einbauort Funktionstext
Socket Plug, access harness dashboard
XS +DPL Steckdose X4.A +EBOX Stecker Anschluß Kabelbaum Bedienpult
Contact Page Path Type Contact Page Path Type
Circuit diagrams
Kontakt Blatt Pfad Typ Kontakt Blatt Pfad Typ AMP Junior Power Timer 21 pole grey
40 1 6 41 8
Plug, supply potential 30 7 31 7
X0.A +EBOX Stecker Versorgung Potential 30
9 9 7
Contact Page Path Type
Kontakt Blatt Pfad Typ Amphenol RADSOK® 8mm 10 10 4
30 9 4 11 41 3
Plug, supply ground 12 11 2
X0.B +EBOX Stecker Versorgung Masse 13 9 7
Kontakt Blatt Pfad Typ Amphenol RADSOK® 6mm
14 17 2
31 9 6 15 40 5
Plug, supply potential 30 before battery disconnect switch 16 20 5
X0.C +EBOX Stecker Versorgung Potential 30 vor Batterietrennschalter 17 17 3
Contact Page Path Type 18 15 1
Kontakt Blatt Pfad Typ Amphenol RADSOK® 3,6mm
19 10 4
30 11 8 20 9 8
Plug, access harness rear frame
X2.A +EBOX Stecker Anschluß Kabelbaum Hinterrahmen 21 31 7
Contact Page Path Type Plug, access harness console seat
Kontakt Blatt Pfad Typ AMP Junior Power Timer 15 pole green
X4.B +EBOX Stecker Anschluß Kabelbaum Konsole Sitz
1 29 4 Kontakt Blatt Pfad Typ AMP Junior Power Timer 9 pole grey
2 32 5 1 17 4
4 29 5 2 29 3
7 31 7 3 45 7
9 29 5 4 17 5
10 30 2 6 45 7
12 29 4 7 15 6
13 29 5 8 35 2
14 29 5 9 33 8
15 28 8 Plug, access harness StvZO illumination front
Plug, access harness StvZO illumination hinten X4.D +EBOX Stecker Anschluß Kabelbaum StvZO Beleuchtung vorne
X2.B +EBOX Stecker Anschluß Kabelbaum StvZO Beleuchtung rear Contact Page Path Type
Contact Page Path Type Kontakt Blatt Pfad Typ AMP Junior Power Timer 12 pole grey
Kontakt Blatt Pfad Typ AMP Junior Power Timer 6 pole green
1 41 2
1 41 8 2 41 8
2 41 1 3 41 7
3 41 2 5 41 8
4 41 8 6 41 8
Plug, access harness dashboard
X4.A +EBOX Stecker Anschluß Kabelbaum Bedienpult 7 41 4

Kontakt Blatt Pfad Typ AMP Junior Power Timer 21 pole grey 9 41 2
1 11 2 10 41 2
2 32 2 11 41 8
3 9 8 12 41 1
4 41 8
5 28 8
0 1 2 3 4 5 6 7 8 9
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Erstellt MFS 08.06.2015 BW 213-226 D/DH-5 Plug overview Higher-level function
=
Anlage 327
Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Steckerübersicht Einbauort + PLGO EPE / 000 / 00
Plug overview
Steckerübersicht
Plug, access cabin and rops Plug, access harness driving controller 2
X4.E +EBOX Stecker Anschluß Kabine und Rops X5.B +EBOX Stecker Anschluß Kabelbaum Fahrsteuerung 2
Kontakt Blatt Pfad Typ AMP Junior Power Timer 18 pole grey Kontakt Blatt Pfad Typ AMP Junior Power Timer 12 pole brown
1 46 1 1 34 6
2 46 1 3 34 6
3 40 3 5 29 5
4 46 1 6 29 4
5 46 1 8 34 4
6 40 4 9 34 5
7 46 1 10 29 3
8 46 1 Plug, access harness measurement controller
9 46 1
X5.E +EBOX Stecker Anschluß Kabelbaum Messtechnik Steuerung
10 46 1 Kontakt Blatt Pfad Typ AMP Junior Power Timer 15 pole brown
11 46 1 1 17 7
12 46 1 2 17 8
13 46 1 3 39 7
14 46 1 4 13 1
15 46 1 5 39 6
16 40 3 6 13 3
17 46 1 7 39 1
18 40 4 8 39 8
Plug, access harness driving controller 1
X5.A +EBOX Stecker Anschluß Kabelbaum Fahrsteuerung 1
9 14 5
Kontakt Blatt Pfad Typ AMP Junior Power Timer 21 pole brown 11 35 4
1 29 8 12 16 7
2 29 7 13 13 2
3 12 3 14 35 2
4 14 2 15 16 6
5 32 5 Plug, access sockets
6 16 4
X6.B +EBOX Stecker Anschluß Bordsteckdosen
7 36 2 Kontakt Blatt Pfad Typ AMP Junior Power Timer 2 - 4 pole black
9 16 5 1 45 9
10 28 1 2 40 1
12 16 2 3 45 8
13 14 2 4 40 1
14 33 8 Plug, access harness heating-climatic unit
15 16 3 X6.C +EBOX Stecker Anschluß Kabelbaum Heiz-Klimamodul
16 29 7 Kontakt Blatt Pfad Typ AMP Junior Power Timer 2 - 6 pole black

17 32 7 1 45 3
18 12 2 2 45 3
19 12 1 4 45 3
20 32 6 Plug, access telematics
21 31 7 X6.D +EBOX Stecker Anschluß Telematik
Kontakt Blatt Pfad Typ AMP Junior Power Timer 2 - 8 pole black
1 43 2
0 1 2 3 4 5 6 7 8 9
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Anlage 327
Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Steckerübersicht Einbauort + PLGO
1049
EPE / 000 / 00
1050
Plug overview
Steckerübersicht
Plug, access telematics Plug, access diagnosis Interface Bomag
X6.D +EBOX Stecker Anschluß Telematik X7.D +EBOX Stecker Anschluß Diagnosesteckdose Bomag
Circuit diagrams
Kontakt Blatt Pfad Typ AMP Junior Power Timer 2 - 8 pole black Kontakt Blatt Pfad Typ AMP Junior Power Timer 15 pole yellow
2 43 2 15 16 1
3 43 2 Plug, access supply cabin potential 30
4 43 2
X8.A +EBOX Stecker Anschluß Kabine Potential 30
5 43 2 Kontakt Blatt Pfad Typ Amphenol RADSOK® 8mm
6 43 2 30 46 2
7 43 2 Plug, access supply cabin potential 31
8 43 2 X8.B +EBOX Stecker Anschluß Kabine Potential 31
Plug, access keyboard electronical burglary protection Contact Page Path Type
X7.B +EBOX Stecker Anschluß Tastatur elektronische Diebstahlsicherung Kontakt Blatt Pfad Typ Amphenol RADSOK® 6mm
Contact Page Path Type 46 2
Kontakt Blatt Pfad Typ AMP Junior Power Timer 6 pole yellow Plug, heating climatic unit
1 42 3 X10 +CAB Stecker Heiz-Klima-Einheit
2 42 3 Kontakt Blatt Pfad Typ AMP HDSCS 4 pole
3 42 3 1 45 3
4 42 3 2 45 4
6 42 3 4 45 3
Plug, additional options
X7.C +EBOX Plug, connection rear frame - engine module
Stecker Zusatzoptionen X11 +REFR Stecker Verbindung Hinterrahmen - Motormodul
Kontakt Blatt Pfad Typ AMP Junior Power Timer 2 - 14 pole black Contact Page Path Type
Kontakt Blatt Pfad Typ Deutsch DT 12 pole
1 10 2 1 28 8
2 11 1 2 28 8
3 11 1 3 31 6
4 9 6 4 31 7
5 9 6 5 31 6
6 40 6 6 41 1
7 46 1 7 41 8
10 29 6 8 41 1
11 29 5 9 41 2
12 31 6 10 41 8
13 16 2 11 41 1
14 16 3 12
Plug, access diagnosis Interface Bomag
X7.D +EBOX Plug, compressor air conditioning
Stecker Anschluß Diagnosesteckdose Bomag X12 +MOT Stecker Kompressor Klimaanlage
Kontakt Blatt Pfad Typ AMP Junior Power Timer 15 pole yellow Contact Page Path Type
Kontakt Blatt Pfad Typ 4,6RSH2,5
2 16 1 1 45 1
3 16 5 Plug, seat contact switch

5 16 2 X14 +SEAT Stecker Sitzkontaktschalter
6 16 4 Contact Page Path Type
7 16 3
8 16 8 A 29 3
10 16 2 B 29 3
11 16 6 C
13 16 1
0 1 2 3 4 5 6 7 8 9
Function Page from
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Anlage 327
Plug overview
Steckerübersicht
Plug, keyboard electronical burglary protection Plug, IO´s travel lever
X16 +DPL Stecker Tastatur Elektronische Diebstahlsicherung X24 +SEAT Stecker Ein-/Ausgänge Fahrhebel
Kontakt Blatt Pfad Typ Deutsch DT 4 pole Kontakt Blatt Pfad Typ Deutsch DT 8 pole
1 42 5 2 33 8
2 42 5 3 33 6
3 42 5 4 33 5
4 42 5 5
Plug, transducer acceleration front 6
X20 +DRUM Stecker Beschleunigungsaufnehmer vorne
7
Kontakt Blatt Pfad Typ Deutsch DT 4 pole 8
Plug, access double pump
1 39 1 X25 +REFR Stecker Anschluß Doppelpumpe
3 39 2 Kontakt Blatt Pfad Typ Deutsch DTM 8 pole
4 39 1 1 30 2
Plug, transducer acceleration rear 2 30 3
X21 +DRUM Stecker Beschleunigungsaufnehmer hinten
3 30 4
Kontakt Blatt Pfad Typ Deutsch DT 4 pole 4 30 4
1 39 3 5 30 2
2 39 4 6 31 3
3 39 4 7 31 3
4 39 3 8 31 4
Plug, access rotary beacon ROPS Plug, potentiometer frequency plates
X22 +EBOX Stecker Anschluß Rundumkennleuchte ROPS
X26 +SEAT Stecker Potentiometer Frequenzverstellung Anbauplatten
Kontakt Blatt Pfad Typ FASTIN-FASTON TAB housing 2 way Kontakt Blatt Pfad Typ AMP Mateń´loc 3 pole white
1 40 2 1 33 4
2 40 2 2 33 4
Plug, supply travel lever 3 33 4
X23 +SEAT Stecker Vorsorgung Fahrhebel Plug, potentiometer frequency plates
Contact Page Path Type X26 +SEAT Stecker Potentiometer Frequenzverstellung Anbauplatten
Kontakt Blatt Pfad Typ Deutsch DT 12 pole Code A Contact Page Path Type
1 15 6 Kontakt Blatt Pfad Typ AMP Mateń´loc 3 pole
2 15 5 1 33 4
3 33 9 2 33 4
4 3 33 4
Plug, quick connect coupling plates
5 33 3 X27 +PLA Stecker Schnellverschlußkupplung Platten
7 17 5 Kontakt Blatt Pfad Typ
8 33 2 1 37 5
9 15 6 2 37 5

10 15 7 3 37 4
11 33 1 Plug, sensor height adjustment plates
12 33 4
X28 +REFR Stecker Sensor Höhenverstellung Platten
Plug, IO´s travel lever
X24 +SEAT Kontakt Blatt Pfad Typ Deutsch DTM 3 pole
Stecker Ein-/Ausgänge Fahrhebel
1 33 7 3 37 5
0 1 2 3 4 5 6 7 8 9
Function Page from
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Anlage 327
Circuit diagrams

1051
EPE / 000 / 00
1052
Plug overview
Steckerübersicht
Plug, access lifting unit plates Plug, monitoring module
X29 +REFR Stecker Anschluß Hubwerk Platten X33 +ARC Stecker Überwachungsmodul
Circuit diagrams
Kontakt Blatt Pfad Typ Deutsch DTM 6 pole Kontakt Blatt Pfad Typ AMP Superseal 26 pole
1 37 7 1
2 37 6 2 28 8
3 37 6 3 28 7
4 37 4 4 20 5
5 37 6 5 40 7
6 37 6 6
Plug, backup alarm buzzer 7
X30 +REFR Stecker Rückfahrwarnsummer
8 41 7
1 32 5 10 20 2
2 32 5 11 20 3
Plug, backup alarm buzzer 12 20 4
X30 +REFR Stecker Rückfahrwarnsummer 13
14
1 32 5 15
2 32 5 16
Plug, boost module SCR-System 17
X31 +REFR Stecker Fördermodul SCR-System 18
Contact Page Path Type 19
Kontakt Blatt Pfad Typ AMP HDSCS 12 pole grey
20
1 21 17 2
2 26 6 22 17 3
3 26 6 23
4 26 5 24
5 26 8 25 15 1
6 26 8 26 15 1
7 Diagnosis interface BOMAG
8 26 7 X34 +EBOX Diagnosesteckdose BOMAG
Kontakt Blatt Pfad Typ Burndy 19 pole
10 26 7
11 26 6 V
12 26 6 U
Diagnosis interface EMR T
X32 +EBOX Diagnoseschnittstelle EMR S
Contact Page Path Type R 16 1
Kontakt Blatt Pfad Typ ITT Cannon 12pol
P 16 1
A 22 7

N 16 1
B 22 9 M
F 22 8 L
G 22 8 K
H 22 8 J 16 2
M 22 8 H
G
0 1 2 3 4 5 6 7 8 9
Function Page from
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Anlage 327
Plug overview
Steckerübersicht
Diagnosis interface BOMAG Plug, driving controller
X34 +EBOX Diagnosesteckdose BOMAG X35 +EBOX Stecker Fahrsteuerung
Kontakt Blatt Pfad Typ Burndy 19 pole Kontakt Blatt Pfad Typ AMP 68 pole
F 16 8 34 34 3
E 16 6 35 29 6
D 16 5 36 28 3
C 16 4 37 28 5
B 16 3 38 28 4
A 16 2 39 28 2
Plug, driving controller 40
X35 +EBOX Stecker Fahrsteuerung
41
Kontakt Blatt Pfad Typ AMP 68 pole 42 36 5
1 14 2 43 36 6
2 31 5 44
3 31 8 45 38 5
4 46 31 1
5 47 31 2
6 30 2 48 34 4
7 30 3 49 34 5
8 37 5 50 36 7
9 28 1 51 36 8
10 37 6 52
11 36 4 53 16 4
12 29 5 54 12 2
13 29 4 55 12 5
14 33 8 56 12 3
15 29 3 57 12 4
16 29 4 58 12 5
17 29 7 59 12 6
18 60 12 6
19 61 32 5
20 31 3 62 36 3
21 31 4 63 37 4
22 37 7 64 31 7
23 14 2 65 12 6
24 32 7 66 12 7
25 32 6 67 12 8
26 16 3 68 12 9
Plug, access sensors exhaust aftertreatment

27 16 2 X36 +MOT Stecker Anschluß Sensoren Abgasnachbehandlung
29 30 4 Kontakt Blatt Pfad Typ AMP MCP 39 pole (green)
30 30 4 3 26 3
31 37 6 5 26 3
32 29 2 8 26 1
33 16 5 9 26 1
0 1 2 3 4 5 6 7 8 9
Function Page from
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Anlage 327
Circuit diagrams

1053
EPE / 000 / 00
1054
Plug overview
Steckerübersicht
Plug, access sensors exhaust aftertreatment Plug, access external supply engine
X36 +MOT Stecker Anschluß Sensoren Abgasnachbehandlung X41 +EBOX Stecker Anschluß externe Versorgung Motor
Circuit diagrams
Kontakt Blatt Pfad Typ AMP MCP 39 pole (green) Kontakt Blatt Pfad Typ AMP HDSCS 12pole
10 26 1 1 24 1
11 27 7 2 24 1
13 25 6 3 23 8
16 26 6 4 23 9
18 26 3 5 25 8
19 26 3 6 25 8
20 27 9 7 26 1
21 27 9 8 26 1
22 26 4 9 26 1
23 27 8 10 23 9
24 26 6 11 25 1
25 26 8 12 25 1
26 26 8 Plug, access exhaust aftertreatment
27 26 7
X42 +MOT Stecker Anschluss Abgasnachbehandlung
28 26 4 Kontakt Blatt Pfad Typ AMP MCP 2.8 21 pole
29 26 6 1 26 6
30 26 6 2 26 6
31 27 8 3 26 5
32 27 8 4
33 26 5 5
34 27 7 6 26 6
35 26 7 7 26 8
36 26 7 8 27 8
37 25 5 9 26 6
38 25 5 10 27 8
39 25 5 11 27 8
Plug, supply air intake throttle
X40 +MOT Stecker Versorgung Drosselklappe Ansaugluft
12 27 9
Kontakt Blatt Pfad Typ 14 26 7
1 24 0 15 26 7
2 24 0 16 27 7
3 24 0 17 27 7
Plug, supply air intake throttle 18 25 5
X40 +MOT Stecker Versorgung Drosselklappe Ansaugluft
19 25 5

1 24 0 21 25 5
Plug, engine-controller motor-part
1 24 0 X44 +EBOX Stecker Motorsteuergerät Motorseite
2 Contact Page Path Type
3 Kontakt Blatt Pfad Typ Bosch 105 pole
02 24 6
03 27 7
04 27 8
0 1 2 3 4 5 6 7 8 9
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Anlage 327
Plug overview
Steckerübersicht
Plug, engine-controller motor-part Plug, engine-controller motor-part
X44 +EBOX Stecker Motorsteuergerät Motorseite X44 +EBOX Stecker Motorsteuergerät Motorseite
Kontakt Blatt Pfad Typ Bosch 105 pole Kontakt Blatt Pfad Typ Bosch 105 pole
05 26 6 70 26 5
07 24 1 72 24 4
08 24 9 73 24 3
09 26 3 74 24 3
10 26 7 75 23 4
11 24 4 76 24 7
13 24 2 77 25 3
14 26 8 78 23 7
15 26 3 80 27 8
17 23 7 82 26 6
18 24 7 85 23 0
19 26 6 87 23 1
20 26 5 88 23 9
21 24 3 89 26 7
23 23 2 92 26 8
24 23 3 94 23 7
25 23 6 95 23 8
26 26 4 98 25 3
27 26 3 99 23 4
29 26 5 100 23 4
32 26 5 101 23 5
35 24 2 102 23 5
36 23 6 Plug, engine-controller machine-part
37 27 9
X45 +EBOX Stecker Motorsteuergerät Maschinenseite
38 24 1 Kontakt Blatt Pfad Typ AMP 94 pole
41 27 7 1 22 0
44 23 2 2 22 9
45 23 2 3 22 0
46 23 5 4 22 9
47 26 4 5 22 0
48 26 3 6 22 9
51 24 9 10 22 3
54 24 5 13 22 5
55 24 7 18 22 5
57 26 6 23 22 4
58 23 9

26 22 1
59 26 7 31 22 5
61 27 9 43 22 3
62 27 8 50 22 3
63 23 8 58 22 2
64 23 0 64 22 5
66 23 1 67 22 5
67 24 6
0 1 2 3 4 5 6 7 8 9
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Anlage 327
Circuit diagrams

1055
EPE / 000 / 00
1056
Plug overview
Steckerübersicht
Plug, engine-controller machine-part Plug, engine EMR
X45 +EBOX Stecker Motorsteuergerät Maschinenseite X46 +MOT Stecker Motor EMR
Circuit diagrams
Kontakt Blatt Pfad Typ AMP 94 pole Kontakt Blatt Pfad Typ AMP MCP 39 pole
70 22 1 48 24 6
74 22 4 49 24 1
82 22 8 50 24 7
83 22 8 51 24 7
85 22 8 52 24 1
86 22 8 59 24 1
88 22 4 60 24 1
91 22 2 61 23 2
Plug, engine EMR 62 23 0
X46 +MOT Stecker Motor EMR Plug, engine stop
Contact Page Path Type X48 +EBOX Stecker Motor Stop
Kontakt Blatt Pfad Typ AMP MCP 39 pole Contact Page Path Type
2 23 8 1 22 2
3 23 7 2 22 2
6 24 9 Plug, access display back up monitoring
7 24 9
X50 +CAB Stecker Anschluß Monitor Rückraumüberwachung
9 23 4 Kontakt Blatt Pfad Typ Deutsch DT 6 pole
13 23 4 1 53 5
14 23 4 2 53 5
15 23 5 3 53 5
17 24 5 4 53 5
19 23 5 5 53 5
20 23 6 6
21 23 5 Plug, pressure sensor travel pump axle MA
22 24 3 X55 +PUMP Stecker Drucksensor Fahrpumpe Achse MA
23 24 3 Kontakt Blatt Pfad Typ AMP Superseal 3pol
24 24 2 1 30 2
25 23 7 2 30 2
26 24 4 3
27 24 2 Plug, pressure sensor travel pump axle MB
28 24 3 X56 +PUMP Stecker Drucksensor Fahrpumpe Achse MB
Kontakt Blatt Pfad Typ AMP Superseal 3pol
31 23 6
32 23 7 1 30 3
35 23 0 2 30 3
3

37 23 1 Plug, pressure sensor travel pump drum MA
38 23 2 X57 +PUMP Stecker Drucksensor Fahrpumpe Bandage MA
41 23 3 Kontakt Blatt Pfad Typ AMP Superseal 3pol
42 23 1 1 30 4
46 24 7 2 30 4
47 24 6 3
0 1 2 3 4 5 6 7 8 9
Function Page from
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Anlage 327
Plug overview
Steckerübersicht
Plug, pressure sensor travel pump drum MB Plug, floating switch coolant expansion tank
X58 +PUMP Stecker Drucksensor Fahrpumpe Bandage MB X72 +MOT Stecker Schwimmerschalter Kühlmittelausgleichsbehälter
Kontakt Blatt Pfad Typ AMP Superseal 3pol Kontakt Blatt Pfad Typ Deutsch DTM 2 pole
1 30 4 2 28 2
2 30 4 Plug, WaterInFuel Sensor
3
X73 +MOT Stecker Sensor Wasser im Kraftstoff
Plug, windscreen wiper motor rear
X65 +CAB Kontakt Blatt Pfad Typ AMP Junior Power Timer 2 pole
Stecker Scheibenwischermotor hinten
Kontakt Blatt Pfad Typ P4NAT 2 22 1
1 50 5 Plug, access fuel pump additional heater
2 50 5
X76 +MOT Stecker Anschluss Kraftstoffpumpe Zusatzheizung
4 50 5 1 44 5
Plug, windscreen wiper motor front
X66 +CAB Stecker Scheibenwischermotor vorne
2 44 5
Plug, supply NOx sensors DPF
Contact Page Path Type X77 +MOT Stecker Versorgung NOx Sensoren DPF
Kontakt Blatt Pfad Typ P6SNAT
1 50 3 Kontakt Blatt Pfad Typ Bosch Kompakt 1.1a 2 pole black Code 1
2 50 3 1 25 6
3 50 3 2 25 7
4 Plug, access potential 15 Powerboard SCR-System
5 50 3 X78 +MOT Stecker Anschluß Potential 15 Powerboard SCR-System
6 Kontakt Blatt Pfad Typ Deutsch DT 2 pole
Plug, fuel pre heater
X67 +MOT Stecker Kraftstoffvorheizung 1 19 8
Kontakt Blatt Pfad Typ Deutsch DT 2 pole Plug, headlight front left
1 19 8 X79 +DPL Stecker Scheinwerfer vorne links
2 19 8 Kontakt Blatt Pfad Typ Deutsch DT 6 pole
Plug, pressure switch air conditioning
X68 +REFR Stecker Druckschalter Klimaanlage 1
1 45 1 4
2 45 1 5 41 4
3 45 1 6 41 1
4 45 1 Plug, tail light rear left
Plug, sender level gauge X80 +REFR Stecker Rückleuchte links
X69 +REFR Stecker Tauchrohrgeber Contact Page Path Type
Contact Page Path Type Kontakt Blatt Pfad Typ Deutsch DT 4 pole
Kontakt Blatt Pfad Typ AMP Superseal 3pol 1 41 8
1

2 41 8
2 28 8 3 41 1
3 28 8 4 41 1
Plug, floating switch coolant expansion tank Plug, tail light rear right
X72 +MOT Stecker Schwimmerschalter Kühlmittelausgleichsbehälter X81 +REFR Stecker Rückleuchte rechts
Kontakt Blatt Pfad Typ Deutsch DTM 2 pole Kontakt Blatt Pfad Typ Deutsch DT 4 pole
1 28 2 1 41 8
0 1 2 3 4 5 6 7 8 9
Function Page from
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Anlage 327
Circuit diagrams

1057
EPE / 000 / 00
1058
Plug overview
Steckerübersicht
Plug, tail light rear right Plug, measurement controller
X81 +REFR Stecker Rückleuchte rechts X88 +EBOX Stecker Messtechniksteuerung
Circuit diagrams
Kontakt Blatt Pfad Typ Deutsch DT 4 pole Kontakt Blatt Pfad Typ AMP 68 pole
2 41 8 2
3 41 2 3
4 41 2 4 39 6
Plug, headlight front right 5 39 7
X82 +DPL Stecker Scheinwerfer vorne rechts
6
1 8
2 41 8 9 35 4
3 41 2 10
4 11
5 41 5 12
6 41 2 13
Plug, access additional blower 14
X83 +CAB Stecker Anschluß Zusatzlüfter 15
Kontakt Blatt Pfad Typ Deutsch DTM 2 pole
16
1 51 9 17
2 51 9 18
Plug, access BCM-system 19
X85 +CAB Stecker Anschluß BCM-System 20
Kontakt Blatt Pfad Typ
22
1 52 5 23 14 5
2 52 5 24
3 52 6 25 39 8
4 52 1 26 16 7
5 52 1 27 16 6
6 28 13 1
Plug, sensor adjustable motor
X86 +DRUM Stecker Sensor Verstellmotor 29 39 2
Kontakt Blatt Pfad Typ Deutsch DTM 3 pole 31 39 1
1 35 4 32 35 2
2 35 5 33 17 8
3 35 4 34
Plug, suspension seat
X87 +SEAT Stecker Luftfedersitz
35
Kontakt Blatt Pfad Typ P2NAT 37

1 45 6 38
2 45 6 39
Plug, measurement controller 40
X88 +EBOX Stecker Messtechniksteuerung
41
Kontakt Blatt Pfad Typ AMP 68 pole 42
1 14 6 43
44
0 1 2 3 4 5 6 7 8 9
Function Page from
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Anlage 327
Plug overview
Steckerübersicht
Plug, measurement controller Plug, USB BCM Dongle
X88 +EBOX Stecker Messtechniksteuerung X91 +CAB Stecker USB BCM Dongle
Kontakt Blatt Pfad Typ AMP 68 pole Kontakt Blatt Pfad Typ USB
45 4 52 4
46 35 8 SH 52 4
47 35 7 Plug, access GPS-Receiver
48
X92 +CAB Stecker Anschluß GPS-Antenne
49 Kontakt Blatt Pfad Typ Burndy 12 pole
50 M
51 L
52 K
53 17 7 J
54 13 2 H
55 13 5 G
56 13 3 F
57 13 4 E 52 7
58 13 5 D 52 7
59 13 6 C 52 7
60 13 6 B 52 7
61 35 9 A 52 7
62 Plug, supply GPS System
63 X93 +CAB Stecker Spannungsversorgung GPS System
64 Kontakt Blatt Pfad Typ Deutsch DT 3 pole
65 13 6 A 52 6
66 13 7 B 52 6
67 13 8 C 52 6
68 13 9 Plug, printer
Plug, access GPS - BCM X94 +CAB Stecker Drucker
X90 +CAB Stecker Anschluß GPS - BCM Contact Page Path Type
Contact Page Path Type Kontakt Blatt Pfad Typ AMP Mateń´loc 6 pole white
Kontakt Blatt Pfad Typ SUB-D 9 pole
1 51 6
1 2 51 7
2 52 5 3 51 7
3 52 5 4 51 8
4 5 51 7
5 52 5 Plug, CAN BCM Dongle
6 X95 +CAB Stecker CAN BCM Dongle
Kontakt Blatt Pfad Typ SUB-D 9 pole
8
1

9
Plug, USB BCM Dongle 2 52 2
X91 +CAB Stecker USB BCM Dongle 3
Kontakt Blatt Pfad Typ USB
5
1 52 4 6
2 52 4 7 52 2
3 52 4 8
0 1 2 3 4 5 6 7 8 9
Function Page from
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Anlage 327
Circuit diagrams

1059
EPE / 000 / 00
1060
Plug overview
Steckerübersicht
Plug, CAN BCM Dongle Plug, connection Armatures - Console seat
X95 +CAB Stecker CAN BCM Dongle X102 +EBOX Stecker Verbindung Armaturen - Konsole Sitz
Circuit diagrams
Kontakt Blatt Pfad Typ SUB-D 9 pole Kontakt Blatt Pfad Typ AMP Junior Power Timer 15 pole grey
9 1 33 1
Plug, supply BCM 2 33 1
X96 +CAB Stecker Versorgung BCM
3 33 1
1 52 5 5 33 3
2 52 5 6 33 7
Plug, GPS-Receiver StarFire 7 33 7
X97 +CAB Stecker GPS-Antenne StarFire 8
9
1 10
2 52 9 11
3 12
4 13
5 14
6 52 9 15
Plug, connection Driving controller - Rear frame
7 52 9 X103 +EBOX Stecker Verbindung Fahrsteuerung - Hinterrahmen
9 Kontakt Blatt Pfad Typ AMP Junior Power Timer 18 pole green
10 1 30 2
11 52 9 2 30 3
12 52 8 3 30 4
Plug, heating operators seat 4 30 4
X99 +SEAT Stecker Sitzheizung 5 31 1
Kontakt Blatt Pfad Typ P2NAT
6 31 2
1 45 7 7 31 3
2 45 7 8 31 4
Plug, connection Driving controller - Console seat 9 31 5
X100 +EBOX Stecker Verbindung Fahrsteuerung - Konsole Sitz 10 31 8
Kontakt Blatt Pfad Typ AMP Junior Power Timer 6 pole grey
12 34 5
1 29 4 13 34 6
2 14
3 15
4 16
5 17
6

Plug, connection Driving controller - Engine
18
X101 +EBOX Plug, connection Driving controller - Front frame
Stecker Verbindung Fahrsteuerung - Motor X104 +EBOX Stecker Verbindung Fahrsteuerung - Vorderrahmen
Kontakt Blatt Pfad Typ AMP Junior Power Timer 12 pole blue Contact Page Path Type
Kontakt Blatt Pfad Typ AMP Junior Power Timer 9 pole purple
1 28 2 1 29 7
2 28 3 2 29 7
3 28 4 3 29 7
0 1 2 3 4 5 6 7 8 9
Function Page from
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Anlage 327
Plug overview
Steckerübersicht
Plug, connection Driving controller - Front frame Plug, connection Measurement controller - Front frame
X104 +EBOX Stecker Verbindung Fahrsteuerung - Vorderrahmen X107 +EBOX Stecker Verbindung Messrechner - Vorderrahmen
Kontakt Blatt Pfad Typ AMP Junior Power Timer 9 pole purple Kontakt Blatt Pfad Typ AMP Junior Power Timer 12 pole purple
4 29 8 4 39 2
5 29 6 5 39 3
6 29 7 6 39 4
7 31 9 7 35 4
8 31 9 8 35 4
9 9 35 7
Plug, connection Driving controller - Front frame dozer blade 10 35 8
X105 +EBOX Stecker Verbindung Fahrsteuerung - Vorderrahmen Planierschild
11 35 9
Kontakt Blatt Pfad Typ AMP Junior Power Timer 18 pole purple 12 35 7
Plug, connection Engine - Engine Controller
1 36 3 X108 +EBOX Stecker Verbindung Motor - Motorsteuergerät
3 36 5 Kontakt Blatt Pfad Typ AMP Junior Power Timer 15 pole blue
4 36 6 1 22 1
5 36 7 2 22 1
6 36 8 3 22 3
7 36 3 4 22 3
8 37 7 5 22 4
9 37 4 6 23 9
10 36 4 7 23 8
11 37 1 8 23 9
12 36 4 9
13 37 5 10
14 37 6 11
15 37 6 12
16 38 5 13
17 14
18 15
Plug, connection Driving controller - Front frame sensor speed vibration Plug, electronic system BOMAG Telematics
X106 +EBOX Stecker Verbindung Fahrsteuerung - Vorderrahmen Drehzahlaufnehmer Vibration XA124 +EBOX Stecker Elektronik BOMAG Telematik
Kontakt Blatt Pfad Typ AMP Junior Power Timer 6 pole purple Kontakt Blatt Pfad Typ Deutsch DTM 12 pole Code A
1 34 2 1 43 4
2 34 1 2 43 3
3 34 3 3 43 3
4 4 43 3
5 34 2 5

6 34 2 6
Plug, connection Measurement controller - Front frame 7
X107 +EBOX Stecker Verbindung Messrechner - Vorderrahmen
8 43 4
Kontakt Blatt Pfad Typ AMP Junior Power Timer 12 pole purple 9
1 39 1 10
2 39 2 11 43 4
3 39 1 12 43 3
0 1 2 3 4 5 6 7 8 9
Function Page from
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Anlage 327
Circuit diagrams

1061
EPE / 000 / 00
1062
Plug overview
Steckerübersicht
Plug, supply potential 30 Plug, supply BCM System, printer
X200 +CAB Stecker Versorgung Potential 30 X204 +CAB Stecker Versorgung BCM System, Drucker
Circuit diagrams
Kontakt Blatt Pfad Typ Amphenol RADSOK® 6mm Kontakt Blatt Pfad Typ AMP Junior Power Timer 2 - 4 pole black
30 46 3 1 52 5
Plug, supply potential 30 2 52 6
X200 +CAB Stecker Versorgung Potential 30
3 52 6
Plug, access radio and tachograph
30 46 3 X205 +CAB Stecker Anschluß Radio und Tachograph
Plug, supply ground
X201 +CAB Stecker Versorgung Masse
Kontakt Blatt Pfad Typ Amphenol RADSOK® 3,6mm 1 51 0
31 46 3 2 51 1
Plug, supply ground 3 51 1
X201 +CAB Stecker Versorgung Masse 4 51 2
Kontakt Blatt Pfad Typ Amphenol RADSOK® 3,6mm
5 51 2
31 46 3 6 51 2
Plug, access additional headlights, reserve funktions
Plug, signals from/to central electric X206 +CAB
X202 +CAB Stecker Anschluß Zusatzscheinwerfer, Reservefunktionen
Stecker, Signale von/zur Zentralelektrik
Contact Page Path Type Kontakt Blatt Pfad Typ AMP Junior Power Timer 9 pole grey
1 46 3 1 48 3
2 51 8 2 48 4
3 46 3 3 49 7
4 46 3 4 48 5
5 46 3 6 48 4
6 46 3 7 49 7
8 46 3 8 49 7
9 46 3 9 48 5
Plug, heating unit additional heater
10 46 3 X207 +DPL Stecker Heizgerät Zusatzheizung
Plug, access cabin equipment Contact Page Path Type
X203 +CAB Stecker Anschluß Kabinenausrüstung Kontakt Blatt Pfad Typ AMP Junior Power Timer 16 pole
1 44 3
1 48 7 2
2 48 6 3
3 48 8 4 44 3
4 48 8 5 44 3
5 48 7 6 44 3
6 48 9 7 44 3
7 50 3 8 44 3

8 50 3 9
9 50 3 10 44 3
10 50 5 11
11 50 5 12
12 50 5 13
13 50 7 14
14 50 7 15
0 1 2 3 4 5 6 7 8 9
Function Page from
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Anlage 327
Plug overview
Steckerübersicht
Plug, heating unit additional heater Plug, distribution box SCR-heating 2
X207 +DPL Stecker Heizgerät Zusatzheizung X302 +BAT Stecker Verteiler SCR-Heizung 2
Kontakt Blatt Pfad Typ AMP Junior Power Timer 16 pole Kontakt Blatt Pfad Typ AMP Junior Power Timer 9 pole blue
16 1 27 7
Plug, access GPS-Receiver 2 27 7
X210 +CAB Stecker Anschluß GPS-Antenne
3 27 8
Kontakt Blatt Pfad Typ Deutsch DTM 6 pole 4 27 8
1 52 7 5 27 8
2 52 7 6 27 9
3 52 7 7 27 9
4 52 7 8
5 52 7 9
Plug, extension sensor fuel pressure
6 XB145 +MOT Stecker Verlängerung Sensor Kraftstoffdruck
Plug, access temperature sensor asphalt
X211 +CAB Stecker Anschluß Asphalttemperatursensor
Kontakt Blatt Pfad Typ AMP 2,5mm System 4pole
Kontakt Blatt Pfad Typ DTM 4 pole 1 24 4
1 2 24 5
2 52 5 4 24 5
Plug, sensor ambient temperature
3 52 5 XB218 +MOT Stecker Sensor Umgebungstemperatur
Plug, supply distribution box SCR-heating Kontakt Blatt Pfad Typ Bosch Kompakt 1.1a 2 pole black Code 1
X300 +BAT Stecker Versorgung Verteiler SCR-Heizung
1 22 3
Plug, timer additional heater
30 27 1 XS28 +DPL Stecker Schaltuhr Zusatzheizung
Plug, distribution box SCR-heating 1
X301 +BAT Stecker Verteiler SCR-Heizung 1
Kontakt Blatt Pfad Typ AMP Junior Power Timer 12 pole grey
Kontakt Blatt Pfad Typ AMP Junior Power Timer 15 pole blue 1 44 8
1 27 4 2 44 7
2 27 6 3
3 27 5 4 44 8
4 27 3 5
5 27 4 6 44 7
6 27 5 7
7 27 4 8 44 7
8 27 4 9 44 7
9 27 6 10 44 7
10 27 6 11 44 7
11 12 44 7

Plug, fuel pump heating unit
12 27 2 XY14 +MOT Stecker Kraftstoffpumpe Heizgerät
14 Kontakt Blatt Pfad Typ AMP Junior Power Timer 2 pole
15 27 3 1 44 5
2 44 5
0 1 2 3 4 5 6 7 8 9
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1063
EPE / 000 / 00
1064
Pin overview
Pin Übersicht
Monitoring module
A15 Überwachungsmodul
Plug Pin Page Path Description
Signal Signal
Stecker Kontakt Blatt Pfad Beschreibung
Circuit diagrams
X33 2 28 8 Analog IN2 Fuel level Tankfüllstand

X33 3 28 7 OUT1 Warning buzzer, breakdown Warnsummer Betriebsstörung
X33 4 20 5 OUT2 Vibration Telematik Vibration Telematics
X33 5 40 7 Digital IN1 Illumination Beleuchtung
X33 8 41 7 Digital IN2 Indicators Anzeigen
X33 9 20 1 Digital IN3 Switch, engine speed Sx. 1 Schalter Motordrehzahl Sx. 1
X33 10 20 2 Digital IN4 Switch, engine speed Sx. 2 Schalter Motordrehzahl Sx. 2
X33 11 20 3 Digital IN5 Switch, regeneration Sy. 1 Schalter Regeneration Sy. 1
X33 12 20 4 Digital IN6 Switch, regeneration Sy. 2 Schalter Regeneration Sy. 2
X33 21 17 2 CAN High CAN high CAN +
X33 22 17 3 CAN Low CAN low CAN low
X33 25 15 1 GND Ground Masse
X33 26 15 1 +UB Power supply Brückengleichrichter

0 1 2 3 4 5 6 7 8 9
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Pin overview
Pin Übersicht
Driving Controller
A34 Fahrsteuerung
Signal Signal
X35 1 14 2 AGND AGND Analogmasse
X35 2 31 5 DO_2 Travel motor axle Fahrmotor Achse
X35 3 31 8 DO_4 Travel motor drum Fahrmotor Bandage
X35 6 30 2 AIN_1 Pressure sensor, travel pump axle MA Drucksensor Fahrpumpe Achse MA
X35 7 30 3 AIN_3 Pressure sensor, travel pump axle MB Drucksensor Fahrpumpe Achse MB
X35 8 37 5 AIN_5 Sensor, height adjustment plates Sensor Höhenverstellung Platten
X35 9 28 1 AIN_7 D+ Alternator D+ Generator
X35 10 37 6 DIN_18 Plate pump enable Freigabe Plattenpumpe
X35 11 36 4 DO_9 Floating position dozer blade Schwimmstellung Planierschild
X35 12 29 5 DIN_2 Speed axle Geschwindigkeit Achse
X35 13 29 4 DIN_4 Direction axle Drehrichtung Achse
X35 14 33 8 DIN_6 BTS brake BTS Bremse
X35 15 29 3 DIN_8 Seat contact Sitzkontakt
X35 16 29 4 DIN_10 Proximity switch, arm rest right Näherungsinitiator Armlehne rechts
X35 17 29 7 DIN_12 Direction drum Drehrichtung Bandage
X35 20 31 3 PWM_7 Travel pump drum forward Fahrpumpe Bandage vorwärts
X35 21 31 4 PWM_9 Travel pump drum backward Fahrpumpe Bandage rückwarts
X35 22 37 7 PWM_11 Vibration pump plates Vibrationspumpe Platten
X35 23 14 2 8,5VEXT 8,5V Sensor Power 8,5V Sensor Spannung
X35 24 32 7 DO_1 Relay, shut off solenoid engine Relais Hubmagnet Abschaltung Motor
X35 25 32 6 DO_3 Warning horn Signalhorn
X35 26 16 3 CAN1_L CAN 1 - CAN 1 -
X35 27 16 2 CAN1_H CAN 1 + CAN 1 +
X35 28 12 1 15/54 Ignition Zündung
X35 29 30 4 AIN_2 Pressure sensor, travel pump drum MA Drucksensor Fahrpumpe Bandage MA
X35 30 30 4 AIN_4 Pressure sensor, travel pump drum MB Drucksensor Fahrpumpe Bandage MB
X35 31 37 6 AIN_6 Sensor, lateral adjustment plates Sensor Seitenverstellung Platten
X35 32 29 2 AIN_8 Slope sensor Neigungssensor
X35 33 16 5 CAN2_L CAN 2 - CAN 2 -
X35 34 34 3 DIN_1 Speed vibration drum Drehzahl Vibration Bandage

X35 35 29 6 DIN_3 Speed drum Geschwindigkeit Bandage
X35 36 28 3 DIN_5 Water in Fuel Wasserabscheider
X35 37 28 5 DIN_7 Hydraulic oil filter Hydraulikölfilter
X35 38 28 4 DIN_9 Maintenance switch, air cleaner Wartungsschalter Luftfilter
X35 39 28 2 DIN_11 Coolant level Kühlmittelfüllstand
X35 42 36 5 PWM_6 Dozer blade up Planierschild anheben
X35 43 36 6 PWM_8 Dozer blade down Planierschild absenken
0 1 2 3 4 5 6 7 8 9
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1065
EPE / 000 / 00
1066
Pin overview
Pin Übersicht
Driving Controller
A34 Fahrsteuerung
Signal Signal
Circuit diagrams
X35 45 38 5 DO_8 Floating position plates Schwimmstellung Anbauplatten

X35 46 31 1 PWM_1 Travel pump axle forward Fahrpumpe Achse vorwärts
X35 47 31 2 PWM_2 Travel pump axle backward Fahrpumpe Achse rückwärts
X35 48 34 4 PWM_3 Vibration pump off/high Vibrationspumpe aus/groß
X35 49 34 5 PWM_4 Vibration pump low/off Vibrationspumpe klein/aus
X35 50 36 7 DO_10 Adjustment left plates Verschiebung links Platten
X35 51 36 8 DO_11 Adjustment right plates Verschiebung rechts Platten
X35 53 16 4 CAN2_H CAN 2 + CAN 2 +
X35 54 12 2 +UE Power Supply (Electronic) Spannungsvers. (Elektronik)
X35 55 12 5 GND Ground Electronic Masse Elektronik
X35 56 12 3 +UB Power Supply (Outputs) Spannungsvers. (Ausgänge)
X35 57 12 4 +UB -"- -"-
X35 58 12 5 +UB -"- -"-
X35 59 12 6 +UB -"- -"-
X35 60 12 6 +UB -"- -"-
X35 61 32 5 DO_5 Back-up alarm buzzer Warnsummer Rückwärtsfahrt
X35 62 36 3 DO_6 Dozer blade priority Planierschild Priorität
X35 63 37 4 DO_7 Hour meter plates Stundenzähler Platten
X35 64 31 7 PWM_5 Valve brake Ventil Bremse
X35 66 12 7 GND -"- -"-
X35 67 12 8 GND -"- -"-
X35 68 12 9 GND -"- -"-

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Pin overview
Pin Übersicht
Measurement controller
A83 Messtechnik Steuerung
Signal Signal
X88 1 14 6 AGND AGND Analogmasse
X88 4 39 6 RxD RxD RxD
X88 5 39 7 TxD TxD TxD
X88 7 39 3 AI/3 Transducer Acceleration rear 20g Beschleunigungsaufn. hinten 20g
X88 9 35 4 AI/7 Position exciter Erregerposition
X88 23 14 5 8,5VEXT 8,5V Sensor Power 8,5V Sensor Spannung
X88 25 39 8 DO(2,5A)/3 Power supply GPS Spannungsversorgung GPS
X88 26 16 7 CAN1_L CAN 1 - CAN 1 -
X88 27 16 6 CAN1_H CAN 1 + CAN 1 +
X88 28 13 1 15/54 Ignition Zündung
X88 29 39 2 AI/2 Transducer Acceleration front 15g Beschleunigungsaufn. vorne 15g
X88 30 39 4 AI/4 Transducer Acceleration rear 15g Beschleunigungsaufn. hinten 15g
X88 31 39 1 AI/6 Transducer Acceleration front 20g Beschleunigungsaufn. vorne 20g
X88 32 35 2 AIN_8 Switch, amplitude adjustment Schalter Amplitudenverstellung
X88 33 17 8 CAN2_L CAN 3 - CAN 3 -
X88 46 35 8 DO(PWM)/1 Exciter down Erreger ab
X88 47 35 7 DO(PWM)/2 Exciter up Erreger auf
X88 53 17 7 CAN2_H CAN 3 + CAN 3 +
X88 54 13 2 +UE Power Supply (Electronic) Spannungsvers. (Elektronik)
X88 56 13 3 +UB Power Supply (Outputs) Spannungsvers. (Ausgänge)
X88 57 13 4 +UB -"- -"-
X88 58 13 5 +UB -"- -"-
X88 59 13 6 +UB -"- -"-
X88 60 13 6 +UB -"- -"-
X88 61 35 9 DO_5 Exciter priority Erreger Priorität
X88 66 13 7 GND -"- -"-
X88 67 13 8 GND -"- -"-
X88 68 13 9 GND -"- -"-

0 1 2 3 4 5 6 7 8 9
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Circuit diagrams

Geprüft 08.06.2015 Deutz TCD 4.1/6.1 Pin Übersicht A83 Einbauort + PINO
1067
EPE / 000 / 00
1068
Pin overview
Pin Übersicht
Travel lever
S55 Fahrhebel
Signal Signal
Circuit diagrams
X23 1 15 6 Power supply Power supply Brückengleichrichter

(8...32V)
X23 2 15 5 Ground Ground Masse
X23 3 33 9 BTS signal "Brake BTS brake BTS Bremse
catch"
X23.1 4 BTS signal "warning
horn" (prepared)
X23 5 33 3 Output voltage Supply analog selectors Versorgung Analoge Wahlschalter
supply "+5V"
X23 6 17 4 CAN bus high CAN high CAN +
X23 7 17 5 CAN bus low CAN low CAN low
X23 8 33 2 Ground / 0V / Ground analog selectors Masse Analoge Wahlschalter
reference to PIN 5
X23 9 15 6 Adressing 1 Ground Masse
X23 10 15 7 Adressing 2 -"- -"-
X23 11 33 1 Analog IN 1 Switch, speed range selector 2 Schalter Fahrstufen 2
X23 12 33 4 Analog IN 2 Frequency adjustment plates Frequenzverstellung Anbauplatten
X24 1 33 7 Digital IN 1 Switch, vibration low/off (on/off) Schalter Vibration klein/aus (an/aus)
X24 2 33 8 Digital IN 2 Switch, vibration off/high Schalter Vibration aus/groß
X24 3 33 6 Digital IN 3 Floating position plates Schwimmstellung Anbauplatten
X24 4 33 5 Digital IN 4 Vibration plates Vibration Anbauplatten
X23.2 5 Digital IN 5
X23.2 6 Digital IN 6
X23.2 7 Output supply
voltage +Ub
X23.2 8 Output supply
voltage "ground" (0V)

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Circuit diagrams

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1069
EPE / 000 / 00
1070
Top view
Draufsicht
Circuit diagrams

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Circuit diagrams

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1071
EPE / 000 / 00
1072
Circuit diagrams

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Head Office/Hauptsitz
BOMAG
Hellerwald
D-56154 Boppard
Germany
Telefon: +49 6742 100-0
Fax: +49 6742 3090
e-mail: info@bomag.com
BOMAG BOMAG BOMAG

Niederlassung Berlin Niederlassung Boppard Niederlassung Chemnitz
Gewerbestraße 3 Hellerwald Querstraße 6
15366 Hoppegarten 56154 Boppard 09247 Chemnitz
GERMANY GERMANY GERMANY
Tel.: +49 3342 369410 Tel.: +49 6742 100360 Tel.: +49 3722 51590
Fax: +49 3342 369436 Fax: +49 6742 100392 Fax: +49 3722 515951
e-mail: nlberlin@bomag.com e-mail: nlboppard@bomag.com e-mail: nlchemnitz@bomag.com
BOMAG BOMAG BOMAG

Niederlassung Hannover Niederlassung München Niederlassung Stuttgart
Dieselstraße 44 Otto-Hahn-Ring 3 Uferstraße 22
30827 Garbsen-Berenbostel 85301 Schweitenkirchen 73630 Remshalden-Grunbach
GERMANY GERMANY GERMANY
Tel.: +49 5131 70060 Tel.: +49 8444 91840 Tel.: +49 7151 986293
Fax: +49 5131 6766 Fax: +49 8444 918420 Fax: +49 7151 9862959
e-mail: nlhannover@bomag.com e-mail: nlmuenchen@bomag.com e-mail: nlstuttgart@bomag.com
BOMAG Maschinenhandelsgesellschaft m.b.H. BOMAG MARINI EQUIPAMENTOS LTDA BOMAG (CANADA), INC.
Porschestraße 9 Rua Comendador Clemente Cifali, 530 3455 Semenyk Court
1230 Wien Distrito Industrial Ritter Missisauga, Ontario
AUSTRIA Cachoeirinha – RS L5C 4P9
BRAZIL CANADA
ZIP code 94935-225
Tel.: +43 1 69040-0 Tel.: +55 51 2125-6677 Tel.: +1 905 361 9961
Fax: +43 1 69040-20 Fax: +55 51 3470-6220 Fax: +1 905 361 9962
e-mail: austria@bomag.com e-mail: brasil@bomag.com e-mail: canada@bomag.com
BOMAG (China) Construction BOMAG France S.A.S. BOMAG (GREAT BRITAIN), LTD
Machinery Co. , Ltd 2, avenue du Général de Gaulle Sheldon Way, Larkfield
No. 2808, West Huancheng Road, 91170 VIRY-CHATILLON Aylesford
Shanghai Comprehensive Industrial FRANCE Kent ME20 6SE
Zone Fengxian Shanghai 201401 GREAT BRITAIN
CHINA
Tel.: +86 21 3365 5566 Tel.: +33 1 69578600 Tel.: +44 1622 716611
Fax: +86 21 3365 5508 Fax: +33 1 69962660 Fax: +44 1622 710233
e-mail: china@bomag.com e-mail: france@bomag.com e-mail: gb@bomag.com
BOMA Equipment Hong Kong LTD BOMAG Italia Srl. FAYAT BOMAG Polska Sp. z.o.o.
Room 1003, 10/F Charm Centre Via Roma 50 Ul. Szyszkowa 52
700, Castle Peak Road 48011 Alfonsine 02-285 Warzawa
Kowloon, ITALY POLAND
HONG KONG
Tel.: +852 2721 6363 Tel.: +39 0544 864235 Tel.: +48 22 4820400
Fax: +852 2721 3212 Fax: +39 0544 864367 Fax: +48 22 4820401
e-mail: bomahk@bomag.com e-mail: italy@bomag.com e-mail: poland@bomag.com
FAYAT BOMAG Rus OOO BOMAG GmbH, Singapore BOMAG Americas, Inc.
Klyazma block, h 1-g 300, Beach Road 125 Blue Granite Parkway
141400 Khimki, Moscow region The Concourse, ‚ 18-06 Ridgeway SC 29130
RUSSIA Singapore 199555 U.S.A.
SINGAPORE
Tel.: +7 (495) 2879290 Tel.: +65 294 1277 Tel.: +1 803 3370700
Fax: +7 (495) 2879291 Fax: +65 294 1377 Fax: +1 803 3370800
e-mail: russia@bomag.com e-mail: singapore@bomag.com e-mail: usa@bomag.com

SM BW 219 DH, PDH-5 BW 226 DH, PDH-5 Ns. 101 586 33 1001 - 00840076

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SM BW 219 DH, PDH-5 BW 226 DH, PDH-5 Ns. 101 586 33 1001 - 00840076

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Service Manual

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 /

Single drum roller

008 400 76 EN © 12/2015

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 3

4 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

5.10.6 Cleaning the radiator module................................................................................................. 196

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 5

7.10 Drying and evacuation............................................................................................................ 301

6 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

11.2.4 After towing............................................................................................................................ 402

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 7

8 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 9

Genuine BOMAG spare parts

Copyright Information and illustrations in this manual must not be reproduced

10 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

1.2 Concerning your safety

1.2.1.2 Explanation of warning signs:

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 11

Sections marked accordingly indicate technical infor-

1.2.1.3 Personal protective equipment

Safety shoes To protect against heavy falling parts and slipping on

Protective gloves To protect the hands against excoriation, punctures or

12 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

Hearing protection To protect the hearing against too loud noise.

1.2.1.4 Intended use

1.2.1.5 Unintended use

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 13

Starting and operation of the machine in explosive environments

1.2.2 Definition of responsible persons

1.2.2.2 Expert / qualified person

1.2.2.3 Driver / operator

14 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

The driver or operator must:

1.2.3 Fundamentals for safe operation

1.2.3.2 Regular safety inspections

1.2.3.3 Modifications and alterations to the machine

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 15

The installation and/or use of such products may have an adverse

1.2.3.4 Damage, defects, misuse of safety devices

1.2.3.5 Roll Over Protective Structure (ROPS)

On machines with cab the ROPS is an integral part of

The frame of the machine must not be warped, bent or cracked in

1.2.4 Handling fuels and lubricants

16 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

n Limitation and monitoring of exposure / personal protective

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 17

AdBlue®/DEF has not been classified as environmen-

18 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

Fig. 4 Should pressure fluid penetrate the skin, immediate

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 19

20 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

1.2.5 What to do in events of emergency

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 21

In case of frequent use the wear on the multi-discs brakes will be

1.2.5.2 Disconnect the battery

1.2.5.3 Towing the machine

1.2.6 Park the machine in secured condition.

22 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

3. Turn the ignition key to position "0" and pull it out.

5. Turn the main battery switch counter-clockwise and pull it

1.2.7 Maintenance and repair