Fayat Group BOMAG BW 226 DH-4 Bedienungsanleitung

Service - Manual

Catalogue number.

008 916 89 06/2012

BW 226 DH-4

BVC

S/N 101 582 86 1109 >

S/N 101 584 08 ....

Single drum roller

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Table of Contents

BOMAG 3008 916 89

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 49

4.1 General notes on maintenance 50

4.2 Fuels and lubricants 51

4.3 Table of fuels and lubricants 54

4.4 Running-in instructions 56

4.5 Maintenance table 57

E-Plan wiring diagrams 61

5.1 Understanding wiring diagrams 62

5.2 Circuit symbols in the circuit diagram 71

5.3 Identification of switch blocks in the wiring diagram 74

5.4 Designation of components in the wiring diagram 75

5.5 Terminal designations in wiring diagram 76

Electrics 79

6.1 Battery ground and analog ground 80

6.2 Current and voltage 80

6.3 Pulse Width Modulation (PWM) 83

6.4 Resistance 85

6.5 Series / parallel connection 87

6.6 Ohm's law 89

6.7 Electrical energy 89

6.8 Formula diagram 90

6.9 Metrology 91

6.10 Diodes, relays, fuses 95

6.11 Telemecanique switch 98

6.12 Plug connectors 100

6.13 Magnetic coil plug 100

6.14 Deutsch plug, series DT and DTM 102

6.15 Inductive proximity switches 107

6.16 Plugs and terminals in spring clamping technology 109

6.17 Batteries 113

6.18 Battery service 116

6.19 Starting with jump wires 117

6.20 Main battery switch 118

6.21 Overview of electric components 119

6.22 Cabin 130

6.23 Fuses 131

6.24 Main battery fuse 132

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Table of Contents

BOMAG4008 916 89

6.25 Electronic control units 133

6.26 Checking the voltage supply for the control unit 135

6.27 Diagnostics concept 143

Electronic modules 147

7.1 Electrics SX 149

7.2 Electrics MESX 245

7.3 Electric module A108 317

Engine electrics 321

8.1 EMR3 system components 322

8.2 Pin assignment of engine control EDC16 / EMR3 327

8.3 Rotary speed sensor for camshaft 332

8.4 Crankshaft speed sensor 333

8.5 Rail pressure sensor 334

8.6 Fuel pressure sensor 336

8.7 Fuel control unit 337

8.8 Injector 339

8.9 Oil pressure sensor 340

8.10 Sensor for charge air temperature and charge air pressure 342

8.11 EMR coolant temperature sensor 344

8.12 Glow plugs 346

8.13 Sensor, water in fuel 346

8.14 Fuel pre-heating 347

8.15 Rotary switch for engine speed 348

8.16 Data collector 348

8.17 Fault display 352

8.18 Diagnose with SERDIA 353

8.19 Diagnose with CAN-bus 356

8.20 Diagnostics interface 357

8.21 EMR3 List of fault codes 360

8.22 Generator 431

8.23 Replacing the voltage regulator 440

8.24 Electric starter 442

BOMAG, Variocontrol 449

9.1 Variocontrol 450

9.2 Control circuit and MESX 456

9.3 Acceleration transducer 457

9.4 Potentiometer on the slewing motor, B62 458

9.5 Display and control elements

Variocontrol 462

9.6 Description of indicating and control elements

Variocontrol 463

9.7 BVC/BTM05 settings before start-up 464

9.8 Variocontrol, selecting the operating mode 467

9.9 Measuring pass with Variocontrol 469

9.10 Teaching distance pulses 472

9.11 Amplitude limitation (BVC only) 473

Hydraulics 477

10.1 Hydraulic circuit 478

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Table of Contents

BOMAG 5008 916 89

10.2 Travel and vibration pump, H1 480

10.3 Troubleshooting axial piston pumps 487

10.4 Travel motor 51 C/D 110 490

10.5 Vibration motor A2FM80 492

10.6 Axial piston swash plate principle / motor 494

10.7 Trouble shooting, variable displacement axial piston motor 496

10.8 External gear pumps 498

10.9 Slewing motor 500

10.10 Travel circuit 502

10.11 Stopping the machine, operating the parking brake 511

10.12 Towing in case of an engine failure 511

10.13 Adjust the parking brake 513

10.14 Vibration circuit 514

10.15 Check the hydraulic oil level 523

10.16 Changing hydraulic oil and breather filter 523

10.17 Replace hydraulic oil filter 524

Electric steering 527

11.1 Steering circuit 528

11.2 Electric steering wheel 536

Hydraulic steering (optional) 537

12.1 Steering circuit 538

Tests and adjustments 545

13.1 Special tools, tests and adjustments 546

13.2 Activate service mode 550

13.3 Driving against the closed brake 552

13.4 Turn the steering against an end stop. 554

13.5 Check the leakage rate of the vibration motor 556

13.6 Pressure test in steering circuit 557

Flushing and bleeding 559

14.1 Special tools for flushing 560

14.2 Flushing - general 565

14.3 Flushing schematic travel circuit (distribution travel pump) 567

14.4 Flushing the travel circuit (travel pump distribution) 569

14.5 Flushing schematic travel circuit (distribution axle motor) 575

14.6 Flushing the travel circuit (axle motor distribution) 577

14.7 Flushing schematic for vibration drive 582

14.8 Flushing the vibration circuit 583

14.9 Bleeding the travel circuit 587

14.10 Bleeding the vibration circuit 589

582 502 15 dust protection / 582 502 16 gasket 591

15.1 Assembling the dust protection 592

Engine 597

16.1 Diesel engine 598

16.2 Engine description TCD 2012 599

16.3 Lubrication oil circuit TCD 2012 / 2013 601

16.4 Coolant circuit TCD 2012 / 2013 602

16.5 Fuel system TCD 2012 / 2013 603

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Table of Contents

BOMAG6008 916 89

16.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 607

16.7 Exhaust gas recirculation TCD 2012 / 2013 613

16.8 Wastegate - charge pressure controller on TCD-engines 614

16.9 Engine problems 616

16.10 Check the engine oil level 619

16.11 Change engine oil and oil filter cartridge 619

16.12 Change the fuel pre-filter cartridge 620

16.13 Replace the fuel filter cartridge 622

16.14 Check, clean the water separator 623

16.15 Check the coolant level 623

16.16 Change the coolant 624

16.17 Checking the thermostat in disassembled state 625

16.18 Service the combustion air filter 626

16.19 Check the dust separator 628

16.20 Cleaning the oil bath air filter 629

16.21 Adjust the valve clearance 629

16.22 Checking / replacing the ribbed V-belt 630

16.23 Check the engine mounts 631

16.24 Replacing the crank case pressure ventilation valve 632

16.25 Engine conservation 632

16.26 Special tools, Deutz engine (TCD 2012 2V) 633

Air conditioning system 649

17.1 Physical basics 650

17.2 Refrigerant R134a 653

17.3 Compressor oil / refrigeration oil 654

17.4 Working principle of the air conditioning system 655

17.5 Monitoring devices 655

17.6 Description of components 656

17.7 Measuring the compressor oil level 662

17.8 Checking the magnetic clutch 662

17.9 Inspection and maintenance work 663

17.10 Checking, replacing the refrigerant compressor V-belt 664

17.11 Service the air conditioning 665

17.12 Drying and evacuation 667

17.13 Emptying in case of repair 668

17.14 Leak test 668

17.15 Filling instructions 669

17.16 Trouble shooting in refrigerant circuit, basic principles 672

17.17 Trouble shooting, refrigerant circuit diagram 676

17.18 Trouble shooting procedure 677

17.19 Steam table for R134a 687

Cabin assembly 693

18.1 Preparations 695

18.2 Cabin assembly 696

18.3 Final function tests and checks 701

Replacing the cab window panes 703

19.1 Assembly of window panes 704

19.2 Special tools, cabin windows 705

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BOMAG 7008 916 89

19.3 Auxiliary materials 706

19.4 Removing and installing the window pane 708

Drum 713

20.1 Repair overview for drum 714

20.2 Removing and installing the drum 724

20.3 Dismantling the drum 732

20.4 Assembling the vibrator unit 736

20.5 Installing the exciter unit 777

20.6 Changing the rubber buffers and adjusting the pretension 784

20.7 Special tools, drum BW 213/226 DH-4 BVC and Variocontrol 787

Oscillating articulated joint 793

21.1 Special tools 794

21.2 Repair overview oscillating articulated joint 796

21.3 Removing and installing the oscillating articulated joint 800

21.4 Dismantling the oscillating articulated joint 802

21.5 Assembling the oscillating articulated joint 805

Suppliers documentation 809

22.1 Travel and vibration pump 811

22.2 Vibration motor 925

22.3 Axle drive motor 955

22.4 Steering valve 1049

22.5 Axle 1083

Circuit diagrams 1173

23.1 Hydraulic diagram 63 1175

23.2 Wiring diagram 12 1187

23.3 Wiring diagram 88 1253

23.4 Wiring diagram 132 1321

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Table of Contents

BOMAG8008 916 89

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BOMAG 9008 916 89

1 General

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1.1 Introduction

BOMAG10 008 916 89

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

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