Diagnosing the Sauer-Danfoss hydrostatic drives and screed depth controls takes precise data, which is exactly what fills the 364 pages of this Bomag 815-2 repair manual pdf (OEM ID 0852806) for your self-propelled paver. Factory documentation lays out complete hydraulic schematics for the 800 series alongside dedicated electrical circuit breakdowns. Detailed teardown procedures guide you through servicing the track drive assemblies, Fairfield torque-lock brakes, and conveyor bed removal without damaging components. Routine maintenance charts dictate exactly when to act, instructing you to swap the pressure filter after the first 50 hours before moving to a 200-hour interval, while securing track pad hardware to a strict 68-80 ft-lbs. When you are alone on the mat with a stalled machine and no one to ask, having this bookmarked, text-searchable file ensures you can trace the fault and order the right part number the first time.
What's Inside This Bomag 815-2 Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 13-18 | General Information |
| Specifications | 19-22 | Technical Data, Fluids Specifications |
| Operation | 23-46 | Paver Components, Operating Instructions, Steering and Speed Controls, Conveyor and Auger Drive Controls, Hydraulic Cylinder Controls |
| Maintenance | 47-74 | Maintenance and Service Procedures, Engine Air Filtration, Cooling System |
| Frame, Hopper and Track Assembly | 75-98 | Track Pad Replacement, Conveyor Bed Removal, Track Drive Assembly Repair |
| Engine | 99-108 | Cooling Package Removal and Install, Removing the Engine Assembly |
| Electrical System | 109-169 | Circuit Breakers and Fuses, Basic Electrics Service Training |
| 800 Series Hydraulic Schematic | 170-173 | Hydraulic Schematic, System Pressure, Component List |
| Eaton Char-Lynn 2000 Series Disc Valve Motors | 174-193 | Hydraulic Motor, Disassembly, Reassembly, Special Tools, Product Identification |
| Fairfield Torque-Lock Static Input Brakes | 194-205 | Static Input Brakes, Installation, Maintenance, Spare Parts, Spring Options |
| White Drive Products Hb (300) Series Motors | 206-213 | Service Instructions, Seal Kits, Rotor and Drive Link Replacement, Exploded View |
| Sauer-Danfoss Series 40 M46 Pumps and Motors | 214-255 | Axial Piston Pumps, Troubleshooting, Start-Up Procedures, Technical Specifications, Control Options |
| Sauer-Danfoss Series 45 Frame K and L Open Circuit Axial Piston Pumps | 256-283 | Open Circuit Pumps, Pressure Measurement, Troubleshooting, Adjustments, Minor Repair |
| Sauer-Danfoss Orbital Motors Dh and Ds Series 1 | 284-295 | Orbital Motors, Repair Instructions, Exploded View, Spare Parts List, Special Tools |
| Sauer-Danfoss Series 40 MMF044D and MMV044D Axial Piston Motors | 296-347 | Parts Manual, Fixed Displacement Motor, Variable Displacement Motor, Service Bulletins |
| Screed and Screed Extensions | 348-364 | Screed Extension Guide Tubes and Ram, Screed Depth Control, Foot Screed Factory Null Setup |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Battery | 12 V DC 800 CCA | p. 21 |
| Track pad hardware torque | 68-80 ft-lbs | p. 49 |
| Pressure filter replacement interval | After first 50 hours then every 200 hours | p. 51 |
| Return filter replacement interval | After first 50 hours then every 200 hours | p. 51 |
| Filter element tightening torque | 34 N•m [25 ft-lb] | p. 62 |
| Maximum calcium magnesium hardness | 170 ppm | p. 64 |
| Maximum sulfate content | 100 ppm | p. 64 |
| Battery CCA | 800 CCA | p. 111 |
| Maximum amperage for proximity switches | 300 mA | p. 167 |
| Switching distances for proximity switches | 2 mm or 4 mm | p. 167 |
| Maximum continuous case pressure | 25 PSI (1.7 BAR) | p. 275 |
| Charge pressure | 220 PSI (15.2 BAR) | p. 217 |
Bomag 815-2 Common Problems This Manual Covers
Bomag 815-2 hydraulic pump sluggish response and noticeable vibration at the travel motor
Test charge pressure at the Series 40 M46 pump test port as shown on page 217. Verify pressure does not drop below 220 PSI (15.2 BAR). If pressure is low, inspect the filter element and torque the new filter to 34 N•m [25 ft-lb] following page 62.
Manual Section: Sauer-Danfoss Series 40 M46 Pumps and Motors p. 217Screed extension lays an uneven mat and fails to hold a steady depth control setting
Measure the angle of attack turnbuckle length on the screed assembly. Adjust the turnbuckle to exactly 5.9 inches +/- 1/8 inch as detailed on page 361. Confirm the screed extension angle of attack matches the required 1 degree specification on page 44 before restarting the paving pass.
Manual Section: Screed and Screed Extensions p. 361Engine turns over slowly on cold mornings and screed heater grid fails to ignite
Test the battery cells with a hydrometer. Verify the acid density reads between 1.25-1.28 kg/dm³ at 27 °C for a fully charged state as listed on page 146. If the battery passes, inspect the engine grid heater circuit and replace the 105 Amp fuse on page 117.
Manual Section: Electrical System p. 146Open circuit axial piston pump leaking fluid from the shaft seal during heavy material feed
Install a pressure gauge on the pump case drain line. Run the machine under load and verify maximum continuous case pressure stays below 25 PSI (1.7 BAR) according to page 275. If case pressure runs high, check the return lines for blockages before replacing the blown seal.
Manual Section: Sauer-Danfoss Series 45 Frame K and L Open Circuit Axial Piston Pumps p. 275Frequently Asked Questions
What is the serial number range for the BOMAG 815-2?
The serial number range for the BOMAG 815-2 paver is 911835291027 through 911835291045. p. 1
What is the torque specification for the track pad hardware on the Bomag 815-2?
After the first 50-100 hours, the track pad hardware should be inspected and tightened to a specification of 68-80 ft-lbs (dry/without lubricant). p. 49
What is the valve lash clearance for the intake and exhaust valves on the B3.3 Cummins engine?
The intake valve lash clearance is 0.35 mm (0.014 in) and the exhaust valve lash clearance is 0.50 mm (0.020 in). p. 71
What is the fuel tank capacity for the BOMAG 815-2?
The fuel tank capacity for the BOMAG 815-2 is 25 gallons (95 liters). p. 20
Is this Bomag 815-2 Repair Manual a digital download?
One searchable PDF covering 364 pages, delivered instantly. No disc, no shipping, no waiting on the post.
Does this Bomag 815-2 manual allow printing?
Yes, printing is unrestricted: a single page, a chapter, or the lot, on letter or A4.
Are there wiring harness diagrams in this Bomag 815-2 manual?
Included, and complete: electrical schematics, wire routing, connector pinouts, and circuit descriptions for the Bomag 815-2. See page 111 for an example.
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