Fayat Group BOMAG BW 213 DH-4 BVC User manual

Service - Manual
Catalogue number.
008 916 77 08/2012
BW 213 DH-4 BVC
BW 213 DH-4 BVC with attachment plate
Variocontrol / Variocontrol+
S/N 101 583 16 1176 > S/N 101 584 12 ....
S/N 101 583 06 1083 >
S/N 101 582 12 1024 > / S/N 101 582 13 1006 >
Single drum roller

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Table of Contents
BOMAG 3008 916 77
General 9
1.1 Introduction 10
1.2 Safety regulations 11
1.3 General repair instructions 16
1.4 Tightening torques 30
BOMAG single drum rollers 35
2.1 BOMAG single drum rollers 36
Technical data 43
3.1 Technical data 44
Maintenance 55
4.1 General notes on maintenance 56
4.2 Fuels and lubricants 57
4.3 Table of fuels and lubricants 60
4.4 Running-in instructions 62
4.5 Maintenance table 63
E-Plan wiring diagrams 67
5.1 Understanding wiring diagrams 68
5.2 Circuit symbols in the circuit diagram 77
5.3 Identification of switch blocks in the wiring diagram 80
5.4 Designation of components in the wiring diagram 81
5.5 Terminal designations in wiring diagram 82
Electrics 85
6.1 Battery ground and analog ground 86
6.2 Current and voltage 86
6.3 Pulse Width Modulation (PWM) 89
6.4 Resistance 91
6.5 Series / parallel connection 93
6.6 Ohm's law 95
6.7 Electrical energy 95
6.8 Formula diagram 96
6.9 Metrology 97
6.10 Diodes, relays, fuses 101
6.11 Telemecanique switch 104
6.12 Plug connectors 106
6.13 Magnetic coil plug 106
6.14 Deutsch plug, series DT and DTM 108
6.15 Inductive proximity switches 113
6.16 Plugs and terminals in spring clamping technology 115
6.17 Batteries 119
6.18 Battery service 122
6.19 Starting with jump wires 123
6.20 Main battery switch 124
6.21 Overview of electric components 125
6.22 Cabin 136
6.23 Fuses 137
6.24 Main battery fuse 138
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Table of Contents
BOMAG4008 916 77
6.25 Electronic control units 139
6.26 Checking the voltage supply for the control unit 141
6.27 Diagnostics concept 149
Electronic modules 153
7.1 Electrics SX 155
7.2 Electrics MESX 257
7.3 Electric module A108 329
Engine electrics 333
8.1 EMR3 system components 334
8.2 Pin assignment of engine control EDC16 / EMR3 339
8.3 Rotary speed sensor for camshaft 344
8.4 Crankshaft speed sensor 345
8.5 Rail pressure sensor 348
8.6 Fuel pressure sensor 350
8.7 Fuel control unit 351
8.8 Injector 353
8.9 Oil pressure sensor 354
8.10 Sensor for charge air temperature and charge air pressure 355
8.11 EMR coolant temperature sensor 357
8.12 Glow plugs 359
8.13 Sensor, water in fuel 360
8.14 Fuel pre-heating 361
8.15 Rotary switch for engine speed 361
8.16 Data collector 362
8.17 Fault display 366
8.18 Diagnose with SERDIA 367
8.19 Diagnose with CAN-bus 370
8.20 Diagnostics interface 371
8.21 EMR3 List of fault codes 374
8.22 Generator 445
8.23 Electric starter 454
BOMAG, Variocontrol 461
9.1 Variocontrol 462
9.2 Control circuit and MESX 468
9.3 Acceleration transducer 469
9.4 Potentiometer on the slewing motor, B62 470
9.5 Display and control elements 
Variocontrol 474
9.6 Description of indicating and control elements 
Variocontrol 475
9.7 BVC/BTM05 settings before start-up 476
9.8 Variocontrol, selecting the operating mode 479
9.9 Measuring pass with Variocontrol 481
9.10 Teaching distance pulses 484
9.11 Amplitude limitation (BVC only) 485
Hydraulics 489
10.1 Hydraulic circuit 490
10.2 Travel and vibration pump, H1 492
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Table of Contents
BOMAG 5008 916 77
10.3 Troubleshooting axial piston pumps 499
10.4 Travel motor 51 C/D 110 502
10.5 Vibration motor A2FM56 504
10.6 Trouble shooting, variable displacement axial piston motor 507
10.7 External gear pumps 509
10.8 Slewing motor 511
10.9 Travel circuit 513
10.10 Stopping the machine, operating the parking brake 522
10.11 Towing in case of an engine failure 522
10.12 Adjust the parking brake 525
10.13 Vibration circuit 526
10.14 Check the hydraulic oil level 535
10.15 Changing hydraulic oil and breather filter 535
10.16 Replace hydraulic oil filter 536
Electric steering 539
11.1 Steering circuit 540
11.2 Electric steering wheel 545
Hydraulic steering (optional) 547
12.1 Steering circuit 548
Tests and adjustments 555
13.1 Special tools, tests and adjustments 556
13.2 Activate service mode 560
13.3 Driving against the closed brake 562
13.4 Turn the steering against an end stop. 564
13.5 Check the leakage rate of the vibration motor 566
13.6 Pressure test in steering circuit 567
Flushing and bleeding 569
14.1 Special tools for flushing 570
14.2 Flushing - general 575
14.3 Flushing schematic travel circuit (distribution travel pump) 577
14.4 Flushing the travel circuit (travel pump distribution) 579
14.5 Flushing schematic travel circuit (distribution axle motor) 585
14.6 Flushing the travel circuit (axle motor distribution) 587
14.7 Flushing schematic for vibration drive 592
14.8 Flushing the vibration circuit 593
14.9 Bleeding the travel circuit 597
14.10 Bleeding the vibration circuit 599
582 502 15 dust protection / 582 502 16 gasket 601
15.1 Assembling the dust protection 602
Engine 607
16.1 Diesel engine 608
16.2 Engine description TCD 2013, 4 and 6 cylinder 609
16.3 Lubrication oil circuit TCD 2012 / 2013 613
16.4 Coolant circuit TCD 2012 / 2013 614
16.5 Fuel system TCD 2012 / 2013 615
16.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 619
16.7 Exhaust gas recirculation TCD 2012 / 2013 625
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Table of Contents
BOMAG6008 916 77
16.8 Wastegate - charge pressure controller on TCD-engines 626
16.9 Engine problems 628
16.10 Check the engine oil level 631
16.11 Changing engine oil and oil filter cartridges 631
16.12 Change the fuel pre-filter cartridge 633
16.13 Replace the fuel filter cartridge 634
16.14 Check, clean the water separator 635
16.15 Check the coolant level 636
16.16 Change the coolant 636
16.17 Combustion air filter service 637
16.18 Check the dust separator 640
16.19 Cleaning the oil bath air filter 640
16.20 Adjusting the valve clearance 641
16.21 Adjusting the control piston play 643
16.22 Checking / replacing the ribbed V-belt 644
16.23 Check the engine mounts 645
16.24 Replacing the crank case ventilation valve 645
16.25 Engine conservation 646
16.26 Special tools, Deutz engine (TCD 2013 2V) 647
Air conditioning system 667
17.1 Physical basics 668
17.2 Refrigerant R134a 671
17.3 Compressor oil / refrigeration oil 672
17.4 Working principle of the air conditioning system 673
17.5 Monitoring devices 673
17.6 Description of components 674
17.7 Measuring the compressor oil level 680
17.8 Checking the magnetic clutch 680
17.9 Inspection and maintenance work 681
17.10 Checking, replacing the refrigerant compressor V-belt 682
17.11 Service the air conditioning 683
17.12 Drying and evacuation 685
17.13 Emptying in case of repair 686
17.14 Leak test 686
17.15 Filling instructions 687
17.16 Trouble shooting in refrigerant circuit, basic principles 690
17.17 Trouble shooting, refrigerant circuit diagram 694
17.18 Trouble shooting procedure 695
17.19 Steam table for R134a 705
Cabin assembly 711
18.1 Preparations 713
18.2 Cabin assembly 714
18.3 Final function tests and checks 719
Replacing the cab window panes 721
19.1 Assembly of window panes 722
19.2 Special tools, cabin windows 723
19.3 Auxiliary materials 724
19.4 Removing and installing the window pane 726
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Table of Contents
BOMAG 7008 916 77
Drum 731
20.1 Repair overview for drum 732
20.2 Removing and installing the drum 742
20.3 Dismantling the drum 750
20.4 Assembling the vibrator unit 754
20.5 Installing the exciter unit 795
20.6 Changing the rubber buffers and adjusting the pretension 802
20.7 Special tools, drum BW 213/226 DH-4 BVC and Variocontrol 805
Articulated joint, electric steering 811
21.1 Special tools 812
21.2 Repair overview oscillating articulated joint 813
21.3 Removing and installing the oscillating articulated joint 817
21.4 Dismantling the oscillating articulated joint 820
21.5 Assembling the oscillating articulated joint 824
Articulated joint, hydraulic steering 833
22.1 Special tools 834
22.2 Repair overview oscillating articulated joint 836
22.3 Removing and installing the oscillating articulated joint 840
22.4 Dismantling the oscillating articulated joint 842
22.5 Assembling the oscillating articulated joint 847
Suppliers documentation 857
23.1 Travel and vibration pump 859
23.2 Vibration motor 973
23.3 Axle drive motor 1003
23.4 Drum reduction gear 1097
23.5 Steering valve 1123
23.6 Axle 1157
Circuit diagrams 1247
24.1 Hydraulikplan 30 1249
24.2 Hydraulikplan 32 1263
24.3 Wiring diagram 12 1275
24.4 Wiring diagram 88 1341
24.5 Wiring diagram 132 1409
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Table of Contents
BOMAG8008 916 77
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BOMAG 9008 916 77
1 General
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1.1 Introduction
BOMAG10 008 916 77
1.1 Introduction
This manual addresses the professionally qualified
personnel or the after sales service of BOMAG, and
should be of help and assistance in correct and effi-
cient repair and maintenance work.
This manual describes the disassembly, dismantling,
assembly, installation and repair of components and
assemblies. The repair of components and assem-
blies is only described as this makes sense under due
consideration of working means and spare parts sup-
ply.
Documentation
For the BOMAG machines described in this manual
the following documentation is additionally available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Service information
Use only genuine BOMAG spare parts.
Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
This manual is not subject of an updating service; for
this reason we would like to draw your attention to our
additional "Technical Service Bulletins".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this manual must not
be reproduced and distributed, nor must they be used
for the purpose of competition. All rights according to
the copyright law remain expressly reserved.
!Danger
These safety regulations must be read and ap-
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
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