Fayat Group BOMAG BW 213 DH-4 BVC Bedienungsanleitung

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

Find manuals at https://best-manuals.com

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

Find manuals at https://best-manuals.com

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

Find manuals at https://best-manuals.com

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

Find manuals at https://best-manuals.com

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

Find manuals at https://best-manuals.com

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

Find manuals at https://best-manuals.com

Table of Contents

BOMAG8008 916 77

Find manuals at https://best-manuals.com

BOMAG 9008 916 77

1 General

Find manuals at https://best-manuals.com

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

Find manuals at https://best-manuals.com

Dieses Handbuch passt für folgende Modelle

Andere Fayat Group Baumaschinen Handbücher

Fayat Group

Fayat Group DYNAPAC DRP25D Bedienungsanleitung

Fayat Group

Fayat Group BOMAG BW 28 RH Bedienungsanleitung

Fayat Group

Fayat Group DYNAPAC SD1800W Bedienungsanleitung

Fayat Group

Fayat Group BOMAG BW 174 APO-4i Bedienungsanleitung

Fayat Group

Fayat Group BOMAG BW 213 D-5 Bedienungsanleitung

Fayat Group

Fayat Group BOMAG BF 700 C S600 Bedienungsanleitung

Fayat Group

Fayat Group DYNAPAC CA2800 Bedienungsanleitung

Fayat Group

Fayat Group BOMAG BC 463 RB-3 Bedienungsanleitung

Fayat Group

Fayat Group DYNAPAC CA1300 D Bedienungsanleitung

Fayat Group

Fayat Group BOMAG BW 226 BVC-5 Bedienungsanleitung

Fayat Group

Fayat Group Dynapac SD2500C Fehlerbehebungshandbuch

Fayat Group

Fayat Group BOMAG BW 226 DH-4 Bedienungsanleitung

Fayat Group

Fayat Group DYNAPAC CC425 Bedienungsanleitung

Fayat Group

Fayat Group BOMAG BC 473 RB-4 Bedienungsanleitung

Fayat Group

Fayat Group BOMAG BW 226 DH-4i BVC Bedienungsanleitung

Fayat Group

Fayat Group BOMAG BF 700 C-2 Bedienungsanleitung

Fayat Group

Fayat Group DYNAPAC CA4600 Bedienungsanleitung

Fayat Group

Fayat Group BOMAG BW 900-50 Bedienungsanleitung

Fayat Group

Fayat Group BOMAG BW 202 AD-50 Bedienungsanleitung

Fayat Group

Fayat Group Dynapac CA30D Bedienungsanleitung

Fayat Group

Fayat Group BOMAG BF 800-P Series Bedienungsanleitung

Fayat Group

Fayat Group DYNAPAC F80W Produkthandbuch

Fayat Group

Fayat Group BOMAG BW 80/90 AD-5 Bedienungsanleitung

Fayat Group

Fayat Group BOMAG BM 500/15 Bedienungsanleitung

Beliebte Baumaschinen Handbücher anderer Marken

SASFORKS

SASFORKS EXTREME Bedienungsanleitung

Hailo

Hailo H-50 Bedienungsanleitung

Graco

Graco LineLazer ES 1000 Gebrauchs- und Pflegehandbuch

Greenlee

Greenlee 555RSC Bedienungsanleitung

Manitowoc

Manitowoc Grove CD3340B Bedienungsanleitung

Lux Tools

Lux Tools A-FMR-20 Set Bedienungsanleitung

SIP

SIP 03683 Bedienungsanleitung

Volvo

Volvo L30G Bedienungsanleitung

Grizzly

Grizzly G8712 Bedienungsanleitung

Modulift

Modulift CMOD 12 Bedienungsanleitung

Case

Case DV201 Bedienungsanleitung

Sealey

Sealey SC10.V2 Bedienungsanleitung

Wacker Neuson

Wacker Neuson DT05 Bedienungsanleitung

HYVA

HYVA AMCO VEBA 81 Series Bedienungsanleitung

Atlas Copco

Atlas Copco Dynapac V5100TV Bedienungsanleitung

Toro

Toro 323 Bedienungsanleitung

Manitowoc

Manitowoc National Crane 1400A Bedienungsanleitung

SGS

SGS EC1500 Bedienungsanleitung