Description
BOMAG BW 211 D-4 / PD-4 & BW 213 D-4 / PD-4 Single Drum Roller Service Manual 008 911 45 – January 2007
This extensive service manual is a workshop reference for BW 211 D-4, BW 211 PD-4, BW 213 D-4 and BW 213 PD-4 single drum rollers. It combines machine-specific repair instructions with technical data, testing and adjustment procedures, hydraulic service information, electrical diagnostics, engine work, component overhaul material and full circuit-diagram sections. The manual is intended to support expert mechanics carrying out efficient repair and maintenance work and explains removal, dismantling, inspection, assembly and adjustment of major components where applicable.
File Details
- Manual type: Service Manual
- Brand: BOMAG
- Models: BW 211 D-4 / PD-4 and BW 213 D-4 / PD-4
- Machine type: Single drum roller
- Language: English
- Pages: 1026
- File format: PDF
- Catalogue number: 008 911 45
- Date: 01/2007
Workshop Repair, Testing and Diagnostic Coverage
The BOMAG BW 211 D-4 / PD-4 & BW 213 D-4 / PD-4 Single Drum Roller Service Manual 008 911 45 – January 2007 goes substantially beyond routine maintenance information. Early sections establish general repair practice, safety requirements and tightening torques, followed by machine technical data and adjustment values. The technical-data material identifies the Deutz BF4M 2012C four-cylinder water-cooled diesel engine, hydraulic drive components, vibration system, steering equipment, rear axle and filling capacities for the covered Series 4 machines.
A dedicated tests and adjustments section provides procedures for checking engine and vibrator shaft speeds, setting the travel-pump neutral position, measuring travel-circuit pressures, measuring vibration-circuit pressures, checking vibration-motor leakage and testing the steering circuit. These procedures identify the appropriate test equipment, connection points, operating conditions and evaluation steps so faults can be narrowed down systematically rather than by replacing components without diagnosis.
Hydraulic work receives particularly detailed treatment. The manual explains flushing and bleeding after component replacement, including travel-circuit arrangements for travel-pump and axle-motor distribution, vibration-drive flushing, travel-circuit bleeding and vibration-circuit bleeding. Connection illustrations, pressure test points and hydraulic schematics are used throughout. The service-training material also explains the closed-circuit travel and vibration systems, variable-displacement pumps and motors, charge-pressure functions, pressure limitation, flushing operation, braking and travel-speed selection.
Engine, Electrical and Electronic Service Information
The engine section covers the Deutz BF4M 2012C installation in considerable depth. Subjects include the lubrication circuit, engine oil and filter service, coolant circuit, thermostat, generator, fuel supply, injection system, injection pump, injection valves, compression checks, valve-clearance adjustment, fuel filtration, heating flange, electric throttle control and engine monitoring. Special tools for the Deutz engine are also identified.
Electrical coverage begins with practical fundamentals for interpreting circuit diagrams and diagnosing electrical systems. The manual explains terminal designations, current and voltage, resistance, series and parallel circuits, Ohm’s law, electrical power, measuring techniques, diodes, relays, fuses, batteries, generators, starters, proximity switches, angle sensors and several types of plug and terminal connections. Separate chapters cover electrical service tools, the seat-contact module and the speedometer module. The service-training material includes BOMAG Evib-meter and MESX information, adjustment and diagnostic functions, component replacement procedures, machine settings, control signals and fault-code related material.
Major Mechanical Systems and Component Overhaul
The later workshop sections contain substantial mechanical repair coverage. Air-conditioning material addresses R134a refrigerant, compressor oil, system operation, components, inspection, belt replacement, evacuation, leak testing, filling and troubleshooting. Cab-window removal and installation has its own procedure and tooling information.
The drum section covers special tools, the drum repair layout, complete drum removal and installation, drum repair, change-over weights, rubber buffers and pretension adjustment. Procedures include work on the travel motor and exciter unit as part of drum repair. The oscillating articulated joint is treated as another major repair assembly, with special tools, repair overview, removal, dismantling and complete assembly procedures.
A large supplier-documentation section follows the machine repair chapters. It contains detailed component information for the Series 90R travel pump, Series 51 travel drive, 42R 041 vibration pump, A10FM vibration motor, MS/MSE 02 ….. 18 drive components and DANA 192 axle. This gives the technician access to both machine-level service procedures and deeper component-level material within the same PDF.
Technical Data, Maintenance and Adjustment Reference
The manual includes dimensional, weight, travel, engine, vibration and capacity data for the covered models. Its technical-data pages identify a 98 kW Deutz BF4M 2012C engine operating at a nominal 2300 1/min, along with travel-pump, travel-motor, vibration-pump, vibration-motor, steering and rear-axle information. Maintenance charts organize service work by intervals including daily checks and 250, 500, 1000, 2000 and 3000 operating-hour schedules, with additional tasks performed as required.
Tightening-torque references include metric unified threads, metric fine threads, fasteners treated with anti-seizure paste, UNC and UNF threads and wheel nuts. Fuel and lubricant sections cover engine oil, diesel fuel, hydraulic oil, vibration-bearing lubrication, axle oil, coolant and air-conditioning service materials. These references are useful during both scheduled maintenance and major repair because settings, fluid requirements and fastening values are available alongside the actual workshop procedures.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “BOMAG BW 211 D-4 / PD-4 & BW 213 D-4 / PD-4 Single Drum Roller Service Manual 008 911 45 – January 2007” are as follows:
BW 211 D-4 / PD-4p. 1
+BW 213 D-4 / PD-4p. 1
S/N 101 582 40 …..> S/N 101 582 41 …..> S/N 101 582 45 …..>p. 1
S/N 101 582 46 ….> S/N 101 582 50 ….>p. 1
+Single drum rollerp. 1
1.1 Introductionp. 8
+Safety regulationsp. 9
Important notesp. 9
Generalp. 9
Precautions and codes of conduct for welding workp. 9
Old oilsp. 10
Hydraulicsp. 10
Fuelsp. 11
Hot fuelsp. 11
Synthetic rubberp. 11
Poisonous substancesp. 11
Air conditioning systemp. 11
Batteryp. 12
Special safety regulationsp. 12
+General repair instructionsp. 14
Generalp. 14
Electricsp. 14
Batteryp. 15
Hydraulic systemp. 16
Air conditioning systemp. 17
+Fuel hosesp. 18
+Gaskets and mating surfacesp. 19
+Feather keys and keywaysp. 20
+Ball and roller bearingsp. 20
+Screws and nutsp. 21
Fig. 7 Identification of screwsp. 22
Fig. 8 Identification of nutsp. 22
Fig. 9 Identification of nuts in clock systemp. 23
+Tightening torquesp. 24
+Technische Daten
2.2 Maintenance chartp. 38
2.3 Table of fuels and lubricantsp. 40
+2.4 Fuels and lubricantsp. 40
+Engine oilp. 40
Fuelsp. 41
Coolant, anti-freeze agentp. 42
Hydraulic oilp. 42
Oil for drive axlep. 42
+Lubrication greasep. 42
3 Connection overviewp. 43
+Fig. 1 Travel pumpp. 44
1 Control solenoid, high frequencyp. 45
2 Control solenoid, low frequencyp. 45
3 Multi-function valve 400 bar (boost check and pressure relief valve), travel systemp. 45
4 Connection, charge pressure to brake solenoid valve, travel speed range selection and charge oil supply for vibration pumpp. 45
5 Multi-function valve 400 bar (boost check and pressure relief valve), travel systemp. 45
6 Setscrew, mechanical neutral positionp. 45
7 Connection L, leak oil connection to vibration pumpp. 45
8 Lever, travel controlp. 45
9 Pilot pressure test portp. 45
10 High pressure port B, high pressure reversep. 45
11 Charge pressure relief valve, 26 barp. 45
12 Adjustment screw, low frequencyp. 45
13 Connection L2, leak oil to tankp. 45
14 Pressure test port MB, high frequencyp. 45
15 High pressure test port MA, low frequencyp. 45
16 High pressure port A, low frequencyp. 45
17 High pressure port B, high frequencyp. 45
18 Charge pump, internalp. 45
19 Connection L2, to drum drive motor (flushing)p. 45
20 Adjustment screw, high frequencyp. 45
21 Connection D, charge pressure to filterp. 45
22 Multi function valve 345 bar (boost check and pressure relief valve), vibration drive high frequencyp. 45
23 Connection S, suction line charge pump from hydraulic oil tankp. 45
24 Multi function valve 345 bar (boost check and pressure relief valve), vibration drive low frequencyp. 45
25 Charge pressure relief valve, vibration pump (blocked)p. 45
26 Connection E, charge oil from travel pumpp. 45
27 Connection L1, leak oil connection to travel pumpp. 45
28 Pressure test port MB, high pressure reversep. 45
29 Charge oil from filterp. 45
30 Pressure test port MA, high pressure forwardp. 45
31 High pressure port A, high pressure forwardp. 45
32 Setscrew, mechanical neutral position, vibrationp. 45
33 Leak oil connection D, leak oil from axle drive motorp. 45
34 Leak oil connection A, leak oil from travel pumpp. 45
35 Leak oil connection G, leak oil from drum drive motorp. 45
36 Leak oil connection F, leak oil from vibration motorp. 45
37 Radiator inletp. 45
4 Tests and adjustmentsp. 47
+4.1 Special tools, tests and adjustmentsp. 48
Fig. 1p. 48
Fig. 2p. 48
Fig. 3p. 48
Fig. 4p. 48
Fig. 5p. 49
Fig. 6p. 49
Fig. 7p. 49
Fig. 8p. 49
Fig. 9p. 50
Fig. 10p. 50
Fig. 11p. 50
Fig. 12p. 50
Fig. 13p. 51
Fig. 14p. 51
+4.2 Checking the rotation speedsp. 52
Fig. 1p. 52
+Check the engine speedp. 52
+Checking the exciter shaft speedp. 53
+4.3 Checking / adjusting the neutral positions of the travel pumpp. 54
Fig. 1p. 54
Fig. 2p. 54
Fig. 3p. 54
Fig. 4p. 55
Fig. 5p. 55
Fig. 6p. 55
Fig. 7p. 55
+4.4 Pressure tests in the travel circuitp. 56
Fig. 1p. 56
Fig. 2p. 56
Fig. 3p. 56
Fig. 4p. 57
+4.5 Checking / adjusting the vibrator shaft speedsp. 58
Fig. 1p. 58
Fig. 2p. 58
Fig. 3p. 58
+4.6 Pressure measurements in the vibration circuitp. 59
+4.7 Check the leakage rate of the vibration motorp. 60
Fig. 1p. 60
Fig. 2p. 60
Fig. 3p. 60
+4.8 Pressure test in steering circuitp. 61
Fig. 1p. 61
Fig. 2p. 61
Fig. 3p. 61
Fig. 4p. 62
+Fig. 5p. 62
5 Flushing and bleedingp. 63
+5.1 Special tools for flushingp. 64
+Fig. 1p. 64
1. Filling and filtering unit with oil bagp. 64
2. Filter elementp. 64
+Fig. 2p. 64
3. Flushing filter (S connection)p. 64
4. Filter element 1mp. 64
5. Flushing hose 20S – 25S (2 pieces)p. 64
6. Screw socket R1“ – 25S (2 pieces)p. 64
+Fig. 3p. 64
7. Flushing filter (L connection)p. 64
8. Filter elementp. 64
9. Flushing hose 15L (2 pieces)p. 64
10. Screw socket R3/4“ — 15L (2 pieces)p. 64
+Fig. 4p. 64
11. SAE-flange 1“ – 20Sp. 64
12. O-ringp. 64
+Fig. 5p. 65
13. Flanged plate 1“ – 25Sp. 65
14. O-ringp. 65
+Fig. 6p. 65
15. Reducing fitting 18L – 15Lp. 65
+Fig. 7p. 65
16. Reducing fitting 25S – 20Sp. 65
+Fig. 8p. 65
17. Reducing fitting 20S – 16Sp. 65
+Fig. 9p. 66
18. Connecting socket 15Lp. 66
+Fig. 10p. 66
19. Connecting socket 18Lp. 66
+Fig. 11p. 66
20. Connecting socket 16Sp. 66
+Fig. 12p. 66
21. Connecting fitting 20Sp. 66
+Fig. 13p. 67
22. Connecting fitting 25Sp. 67
+Fig. 14p. 67
23. Angular fitting 18Lp. 67
+Fig. 15p. 67
24. Elbow fitting 16Lp. 67
+Fig. 16p. 67
+Fig. 17p. 68
+Fig. 18p. 68
27. Pipe connection 16S – 16Sp. 68
+Fig. 19p. 68
28. Connecting hose 15Lp. 68
+5.2 Flushing – generalp. 69
Changing a componentp. 69
+Chips (abrasion) in the oilp. 69
l Open and clean all components in the oil circuit, replace if necessary.p. 69
l Clean all high pressure hoses in the oil circuit, replace if necessary.p. 69
l If abrasion is found in the travel circuit you should also flush the vibration circuit.p. 69
l If abrasion is found in the vibration circuit you should also flush the travel circuit.p. 69
+Before flushingp. 69
+Fig. 1p. 69
l Change the hydraulic oil filter element (1).p. 69
+Fig. 2p. 69
l Filter the tank content with the filling and filtering unit and pump it into the oil bag.p. 69
l Mark all hoses and disconnect them from the hydraulic oil tank.p. 69
l Clean the oil tank thoroughly from inside, if necessary remove the complete tank cover.p. 69
l Reconnect all hoses.p. 69
l Fill the hydraulic oil tank again with the filling and filtering unit.p. 69
+Bleedingp. 69
+Fig. 3p. 69
l Always bleed closed hydraulic circuits if lines had been removed or connected.p. 69
+Servicing the flushing filter kitp. 70
+Fig. 4p. 70
l Replace the filter element of the flushing filter when the red control pin of the contamination indicator is pressed out during the filtering process.p. 70
l Clean hoses and connections and store the flushing kit in a clean and protected environment.p. 70
+Flushing schematic travel circuit (distribution travel pump)
1 Elbow union (tool)p. 72
2 Connecting union (tool)p. 72
3 Drum drive motorp. 72
4 Axle motorp. 72
5 Screw socket R1 – 25S (tool)p. 72
6 Flushing hose 25S – 20S (tool)p. 72
7 Flushing hose 25S – 20S (tool)p. 72
8 Flushing filter with filter element 1m (tool)p. 72
9 Elbow union (tool)p. 72
10 Reducing fitting (tool)p. 72
11 Travel pumpp. 72
12 High pressure hose (B, drum drive motor reverse)p. 72
13 High pressure hose (A, drum drive motor forward)p. 72
14 High pressure hose (B, axle motor reverse)p. 72
15 High pressure hose (A, axle motor forward)p. 72
16 High pressure hose (B, axle motor reverse)p. 72
17 High pressure port (B, drum drive motor reverse)p. 72
18 Flushing hose 25S – 20S (tool)p. 72
19 Flushing hose 25S – 20S (tool)p. 72
+5.4 Flushing the travel circuit (travel pump distribution)p. 73
+Flushing the drum drivep. 73
+Fig. 1p. 73
1. Disconnect the high pressure hose 12 (see chapter "Flushing schematic – travel circuit") from the travel pump (high pressure port 17) and connect it with the flushing hose (7) (flushing filter inlet "IN").p. 73
2. Connect the flushing hose (6) (flushing filter outlet "OUT") to the (high pressure port 17) on the travel pump.p. 73
+Fig. 2p. 73
3. Take the drum drive motor out of the hydraulic circuit by joining the high pressure hoses (12 and 13) on the drum drive motor together.p. 73
Fig. 3p. 74
+Fig. 4p. 74
4. Block drums and wheels with suitable chocks.p. 74
Fig. 5p. 74
+Fig. 6p. 74
5. Start the engine and shift the travel lever to travel direction forward.p. 74
6. Perform the flushing process at various engine speeds for approx. 10 minutes.p. 74
7. Shut down the engine.p. 74
8. Reconnect the hydraulic hoses (12 and 13) to the drum drive motor.p. 74
+Fig. 7p. 75
9. Jack up the front of the machine, so that the drum can rotate freely.p. 75
10. Secure the rear wheels with chocks.p. 75
11. Pre-select the slow speed range.p. 75
Fig. 8p. 75
+Fig. 9p. 75
12. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 75
13. 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.p. 75
14. Shut down the engine.p. 75
15. Remove the flushing filter and reconnect the high pressure lines.p. 75
+Flushing the axle drivep. 76
+Fig. 10p. 76
16. Disconnect the high pressure hose 14 (see chapter "Flushing schematic – travel circuit") from the travel pump (high pressure port 16) and connect it with the flushing hose (18) (flushing filter inlet "IN").p. 76
17. Connect the flushing hose (19) (flushing filter outlet "OUT") to the (high pressure port 16) on the travel pump.p. 76
+Fig. 11p. 76
18. Take the axle drive motor out of the hydraulic circuit by joining the high pressure hoses (14 and 15) on the axle drive motor together.p. 76
Fig. 12p. 76
+Fig. 13p. 77
19. Block drums and wheels with suitable chocks.p. 77
Fig. 14p. 77
+Fig. 15p. 77
20. Start the engine and shift the travel lever to travel direction forward.p. 77
21. Perform the flushing process at various engine speeds for approx. 10 minutes.p. 77
22. Shut down the engine.p. 77
23. Reconnect the hydraulic hoses (14 and 15) to the axle drive motor.p. 77
+Fig. 16p. 77
24. Jack up the rear of the machine, so that the wheels can rotate freely.p. 77
25. Secure the drum with wheel chocks.p. 77
26. Pre-select the slow speed range.p. 77
Fig. 17p. 78
+Fig. 18p. 78
27. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 78
28. 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.p. 78
29. Shut down the engine.p. 78
30. Remove the flushing filter and reconnect the high pressure lines.p. 78
31. Bleed the travel circuit (see corresponding chapter).p. 78
32. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.p. 78
+Fig. 19p. 78
33. Check the hydraulic oil level in the tank, fill up if necessary.p. 78
34. Check all connections for leaks with the engine running (visual inspection).p. 78
35. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting on a gradient.p. 78
36. Check all ports and connections for leak tightness (visual inspection).p. 78
+Flushing schematic travel circuit (distribution axle motor)
1 Elbow union (tool)p. 83
2 Connecting union (tool)p. 83
3 Drum drive motorp. 83
4 Axle motorp. 83
5 Screw socket R1 – 25S (tool)p. 83
6 not usedp. 83
7 not usedp. 83
8 Flushing filter with filter element 1m (tool)p. 83
9 not usedp. 83
10 Reducing fitting (tool)p. 83
11 Travel pumpp. 83
12 High pressure hose (drum drive motor reverse)p. 83
13 High pressure hose (drum drive motor forward)p. 83
14 High pressure hose (B, axle motor reverse)p. 83
15 High pressure hose (A, axle motor forward)p. 83
16 High pressure hose (B, axle motor reverse)p. 83
17 not usedp. 83
18 Flushing hose 25S – 20S (tool)p. 83
19 Flushing hose 25S – 20S (tool)p. 83
+5.6 Flushing the travel circuit (axle motor distribution)p. 84
+Flushing the drum drivep. 84
+Fig. 1p. 84
1. Disconnect the high pressure hose 14 (see chapter "Flushing schematic – travel circuit") from the travel pump (high pressure port 16) and connect it with the flushing hose (19) (flushing filter inlet "IN").p. 84
2. Connect the flushing hose (18) (flushing filter outlet "OUT") to the (high pressure port 16) on the travel pump.p. 84
+Fig. 2p. 84
3. Take the drum drive motor out of the hydraulic circuit by joining the high pressure hoses (12 and 13) on the drum drive motor together.p. 84
Fig. 3p. 85
Fig. 4p. 85
+Fig. 5p. 85
4. Block drums and wheels with suitable chocks.p. 85
+Fig. 6p. 85
5. Start the engine and shift the travel lever to travel direction forward.p. 85
6. Perform the flushing process at various engine speeds for approx. 10 minutes.p. 85
7. Shut down the engine.p. 85
8. Reconnect the hydraulic hoses (12 and 13) to the drum drive motor.p. 85
+Fig. 7p. 86
9. Jack up the front of the machine, so that the drum can rotate freely.p. 86
10. Secure the rear wheels with chocks.p. 86
11. Pre-select the slow speed range.p. 86
Fig. 8p. 86
+Fig. 9p. 86
12. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 86
13. 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.p. 86
14. Shut down the engine.p. 86
+Flushing the axle motorp. 87
+Fig. 10p. 87
15. Jack up the rear of the machine, so that the wheels can rotate freely.p. 87
16. Secure the drum with wheel chocks.p. 87
17. Pre-select the slow speed range.p. 87
Fig. 11p. 87
+Fig. 12p. 87
18. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 87
19. 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.p. 87
20. Shut down the engine.p. 87
21. Remove the flushing filter and reconnect the high pressure lines.p. 87
22. Bleed the travel circuit (see corresponding chapter).p. 87
23. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.p. 87
+Fig. 13p. 88
24. Check the hydraulic oil level in the tank, fill up if necessary.p. 88
25. Check all connections for leaks with the engine running (visual inspection).p. 88
26. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting on a gradient.p. 88
27. Check all ports and connections for leak tightness (visual inspection).p. 88
+Flushing schematic for vibration drive
1 Elbow union (tool)p. 89
2 Connecting union (tool)p. 89
3 Vibration motorp. 89
4 Vibration pumpp. 89
5 Screw socket R1 – 25S (tool)p. 89
6 Flushing hose 25S – 20S (tool)p. 89
7 Flushing hose 25S – 20S (tool)p. 89
8 Flushing filter with filter element 1m (tool)p. 89
9 SAE flange (tool)p. 89
10 High pressure hose (B, high frequency)p. 89
11 High pressure hose (A, low frequency)p. 89
+5.8 Flushing the vibration circuitp. 90
+Fig. 1p. 90
1. Disconnect the high pressure hose 10 (see chapter "Flushing schematic – vibration circuit") from the vibration pump (4) and connect it with the flushing hose (7) (flushing filter inlet "IN").p. 90
2. Connect the flushing hose (6) (flushing filter outlet "OUT") to the (high pressure port A) on the vibration pump.p. 90
+Fig. 2p. 90
3. Take the vibration motor out of the hydraulic circuit by joining the high pressure hoses (10 and 11) on the vibration motor together.p. 90
Fig. 3p. 91
+Fig. 4p. 91
4. Block drums and wheels with suitable chocks.p. 91
Fig. 5p. 91
+Fig. 6p. 91
5. Switch on vibration with high frequency.p. 91
6. Start the engine and run it with maximum speed.p. 91
7. Flush the circuit for approx. 10 minutes, thereby switch the vibration on and off at intervals of approx. 30 seconds.p. 91
8. Shut down the engine.p. 91
9. Reconnect the hydraulic hoses (10 and 11) to the vibration motor.p. 91
+Fig. 7p. 92
10. Unscrew the fastening screws for the vibration motor and pull the motor out of the coupling.p. 92
Fig. 8p. 92
+Fig. 9p. 92
11. Start the engine and run it with maximum speed.p. 92
12. Run the flushing procedure for approx. 10 minutes. Switch the vibration on and off at intervals of approx. 30 seconds.p. 92
13. Shut down the engine.p. 92
14. Remove the flushing filter and reinstall the vibration motor.p. 92
15. Bleed the vibration circuit (see corresponding chapter).p. 92
16. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.p. 92
+Fig. 10p. 93
17. Check the hydraulic oil level in the tank, fill up if necessary.p. 93
18. Test drive.p. 93
19. Check all ports and connections for leak tightness (visual inspection).p. 93
+5.9 Bleeding the travel circuitp. 94
1. Install a pressure test hose to the charge pressure test port.p. 94
2. Install a pressure test hose each to the high pressure test ports.p. 94
+Fig. 1p. 94
3. Actuate the emergency stop switch.p. 94
+Fig. 2p. 94
4. Hold the open ends of the pressure test hoses (Fig. 2) into a container.p. 94
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.p. 94
6. Remove the pressure test hoses.p. 94
+Fig. 3p. 94
7. Unlock the emergency stop switchp. 94
+Fig. 4p. 95
8. Connect a 60 bar pressure gauge to the charge pressure test port (Fig. 4) and run the engine max. 15 seconds at idle speed.p. 95
9. Pause for approx. 30 seconds and keep repeating this procedure, until the gauge shows a constant charge pressure reading.p. 95
+Fig. 5p. 95
10. Start the engine.p. 95
11. Shift the travel lever (Fig. 5) approx. 1/3 to forward direction.p. 95
12. After approx. 1 to 2 minutes shut down the engine for a minute.p. 95
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.p. 95
+5.10 Bleeding the vibration circuitp. 96
1. Install a pressure test hose to the charge pressure test port.p. 96
2. Install a pressure test hose each to the high pressure test ports.p. 96
+Fig. 1p. 96
3. Actuate the emergency stop switch.p. 96
+Fig. 2p. 96
4. Hold the open ends of the pressure test hoses (Fig. 2) into a container.p. 96
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.p. 96
6. Remove the pressure test hoses.p. 96
+Fig. 3p. 96
7. Unlock the emergency stop switchp. 96
+Fig. 4p. 97
8. Connect a 60 bar pressure gauge to the charge pressure test port (Fig. 4) and run the engine max. 15 seconds at idle speed.p. 97
9. Wait for approx. 30 seconds and repeat the procedure, until the pressure gauge shows a constant charge pressure.p. 97
+Fig. 5p. 97
10. For bleeding switch on vibration with high frequency (Fig. 5).p. 97
11. Start the engine.p. 97
12. After running the engine 1 to 2 minutes pause for approx. one minute.p. 97
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.p. 97
6 Fundamental electricsp. 99
+6.1 Understanding circuit diagramsp. 100
Fig. 6 Table of contentsp. 100
Fig. 7 Function groupsp. 101
Fig. 8 Current pathsp. 102
Fig. 9 List of componentsp. 102
Fig. 10 Graphic symbolp. 103
Fig. 11 Graphic symbolp. 103
6.2 Terminal designationsp. 104
+6.3 Current and voltagep. 108
Generalp. 108
+Voltagep. 108
+Currentp. 109
+Types of currentp. 109
Fig. 1 Direct current (D.C.)p. 109
Fig. 2 Alternating current (A.C.)p. 109
Fig. 3 Pulsating direct currentp. 109
Fig. 4 PWMp. 110
Fig. 5 CANp. 111
+6.4 Resistancep. 112
+Resistance and voltage dropp. 112
Fig. 1 Various size resistorsp. 112
Fig. 2 Potentiometer, infinitely adjustable resistorp. 112
+Unnecessary resistancesp. 112
Fig. 1 Screw-type terminalsp. 112
Fig. 2 Spring clampsp. 112
Fig. 3p. 113
Fig. 4 Balistol oilp. 113
Fig. 5p. 113
+6.5 Series / parallel connectionp. 114
Fig. 1 Series connectionp. 114
Fig. 2p. 114
Fig. 3 Parallel connectionp. 115
Fig. 4p. 115
+6.6 Ohm's lawp. 116
+6.7 Electrical energyp. 116
+6.8 Formula diagramp. 117
Fig. 1 Formula diagramp. 117
+6.9 Metrologyp. 118
+Test lampsp. 118
Fig. 1 Test lampp. 118
Fig. 2 Diode test lampp. 118
+Multimeterp. 118
Fig. 1 Multimeterp. 118
Fig. 2 Voltage measurementp. 119
Fig. 3 Current measurementp. 119
+Clip-on measuring instrumentp. 119
Fig. 1 Clip-on measuring instrumentp. 119
+Magnet testerp. 120
Fig. 1 Magnet testerp. 120
+6.10 Diodes, relays, fusesp. 120
+Diodesp. 120
Fig. 1p. 120
Fig. 2 Marking of the cathodep. 120
Fig. 3 Diode circuitryp. 121
Fig. 4 LEDp. 121
+Relaysp. 122
Fig. 1 Relaysp. 122
Fig. 2 Relay circuitryp. 122
+Fusesp. 122
+6.11 Batteriesp. 123
Fig. 1p. 123
Fig. 2p. 123
Fig. 3 Reading the acid levelp. 124
Fig. 4 Battery and generator testerp. 124
Fig. 5 Charge conditionp. 125
+6.12 Three-phase generatorp. 126
+Generalp. 126
Fig. 6 Rotor with claw polesp. 126
Fig. 7 Stator with 3 windingsp. 127
Fig. 8 3-phase currentp. 127
Fig. 9 Regulator with diode plate and rectifier diodesp. 128
+Checking the generatorp. 129
Fig. 10 Rotorp. 129
Fig. 11 Statorp. 129
Fig. 12p. 130
Fig. 13p. 130
Fig. 14p. 131
Fig. 15p. 131
Fig. 16p. 131
Fig. 17p. 131
+6.13 Electric starterp. 133
Fig. 1 Electric starterp. 133
Fig. 2 Switching position during engagementp. 134
Fig. 3 Switching position during startingp. 134
+6.14 Telemecanique switchp. 136
Fig. 1 Terminal designationsp. 136
Fig. 2 Disassemblyp. 137
Fig. 3 Folding down the switch blockp. 137
Fig. 4 Pulling out the front elementp. 137
Fig. 5 Assemblyp. 138
Fig. 6 Observe the marks.p. 138
Fig. 7 Assemble the switch blockp. 138
+6.15 Inductive proximity switchesp. 139
Fig. 8p. 139
Fig. 9 PNP circuitryp. 139
Fig. 10 NPN circuitryp. 139
Fig. 11p. 139
Fig. 12 Circuit diagram, making contactp. 140
+6.16 Angle sensor with current outputp. 140
Fig. 1 Sensorp. 140
Fig. 2 Connection diagramp. 141
6.17 Plug connectorsp. 141
+6.18 Deutsch plug, series DT and DTMp. 142
+Generalp. 142
Fig. 3 Crimp connectionsp. 142
+DT Seriesp. 142
Fig. 1 DT plug connectionp. 142
Fig. 2 DT Seriesp. 142
Fig. 3 Sectional drawingp. 142
Fig. 4p. 143
Fig. 5p. 144
Fig. 1 DTM plug connectionp. 145
Fig. 2 DTM Seriesp. 145
Fig. 3 Sectional drawingp. 145
Fig. 4p. 146
Fig. 5p. 147
+6.19 Plugs and terminals in spring clamping technologyp. 148
+Generalp. 148
Fig. 1p. 148
Fig. 1 That's how it worksp. 149
Fig. 2 Connecting clampp. 149
Fig. 1 That's how it worksp. 150
Fig. 2 Test adapterp. 150
+X-COM plug clampp. 151
Fig. 1 That's how it worksp. 151
Fig. 2 X-COM plug with measuring cablep. 151
Fig. 3 X-COM plug plugged onto the series clampp. 151
7 Special tools, electricsp. 153
+7.1 Special tools, electricsp. 154
Fig. 4p. 154
Fig. 5p. 154
Fig. 6p. 154
Fig. 7p. 154
Fig. 8p. 155
Fig. 9p. 155
Fig. 10p. 155
Fig. 11p. 156
Fig. 12p. 156
Fig. 13p. 156
Fig. 14p. 156
Fig. 15p. 157
Fig. 16p. 157
Fig. 17p. 157
Fig. 18p. 157
Fig. 19p. 158
Fig. 20p. 158
Fig. 21p. 158
Fig. 22p. 158
Fig. 23p. 159
Fig. 24p. 159
Fig. 25p. 159
Fig. 26p. 159
Fig. 27p. 160
Fig. 28p. 160
Fig. 29p. 160
Fig. 30p. 160
Fig. 31p. 161
Fig. 32p. 161
Fig. 33p. 161
Fig. 34p. 161
Fig. 35p. 162
+Fig. 36p. 162
8 Electronic modulesp. 163
+8.1 Seat contact modulep. 165
9 Speedometer Modulep. 173
+9.1 Speedometer modulep. 175
+Fig. 1 Speedometer modulep. 175
10 Service Trainingp. 177
+10.1 Electrics BEM (BOMAG Evib-meter)p. 179
BOMAG Evib-meter (BEM)p. 180
+10.2 Service Trainingp. 237
+11.1 Diesel engine, generalp. 301
Fig. 1 Engine compartmentp. 301
+11.2 Service sidep. 302
Fig. 1 Service sidep. 302
+11.3 Starter sidep. 303
Fig. 1 Starter sidep. 303
+11.4 Lubrication oil circuitp. 304
Fig. 1 Lubrication oil circuitp. 304
+11.5 Oil pressure switch and low oil pressure circuitryp. 306
Fig. 1p. 306
Fig. 2 Oil pressure switchp. 307
+11.6 Check the engine oil levelp. 307
+11.7 Changing engine oil and oil filter cartridgesp. 308
Fig. 4p. 308
Fig. 5p. 308
Fig. 6p. 308
Fig. 7p. 309
+11.8 Coolant circuitp. 310
Fig. 1 Coolant circuitp. 310
Fig. 2 Coolant filling level sensor B55p. 311
Fig. 3 Direct heatingp. 311
+11.9 Coolant temperature switchp. 312
Fig. 1 Coolant temperature switchp. 312
+11.10 Disassembling and assembling the coolant temperature switchp. 313
Fig. 2 Temperature switchp. 313
Fig. 3 Coolant temperature switchp. 313
+11.11 Replacing the thermostatp. 314
Fig. 4p. 314
Fig. 5p. 314
Fig. 6p. 314
+11.12 Checking the thermostat in disassembled statep. 315
Fig. 1p. 315
Fig. 2p. 315
Fig. 3p. 315
+11.13 Check the coolant levelp. 316
+11.14 Change the coolantp. 316
Fig. 5p. 316
Fig. 6p. 316
Fig. 7p. 317
+11.15 Clean the cooling fins on engine and hydraulic oil coolerp. 317
+Cleaning with compressed airp. 317
Cleaning with cold cleansing agentp. 317
+11.16 Three-phase generatorp. 318
+11.17 Fuel supplyp. 320
Fig. 1 Fuel supplyp. 320
Fig. 1p. 322
Fig. 2 Observe the direction of flowp. 322
+11.18 Injection systemp. 323
+Single cylinder plug-in injection pumpsp. 323
Fig. 3 Single cylinder plug-in injection pumpp. 323
Fig. 4 Design of injection valvep. 324
+11.19 Injection pump replacement during servicep. 324
+Disassemblyp. 324
Fig. 1p. 324
Fig. 2p. 324
Fig. 3p. 325
Fig. 4p. 325
Fig. 5p. 325
Fig. 6p. 325
Fig. 7p. 326
Fig. 8 Injection pump code BFM 2012p. 327
Fig. 9 Length of injection pump (A)p. 327
Fig. 10 Injection pump length "A" and Lop. 327
Fig. 11 Table of injection pump codes BFM 2012p. 329
Fig. 12p. 330
Fig. 13p. 330
Fig. 14p. 330
Fig. 15p. 330
Fig. 16p. 330
Fig. 17p. 331
Fig. 18p. 331
Fig. 19p. 331
Fig. 20p. 331
Fig. 21p. 331
Fig. 22p. 332
Fig. 23p. 332
Fig. 24p. 332
Fig. 25p. 332
Fig. 26p. 333
+11.20 Injection valve replacement during servicep. 333
+Removalp. 333
Fig. 1p. 333
Fig. 2p. 334
Fig. 3p. 334
+Installationp. 334
Fig. 1p. 334
Fig. 2p. 334
Fig. 3p. 335
Fig. 4p. 335
Fig. 5p. 335
Fig. 6p. 335
Fig. 7p. 336
+11.21 Checking / repairing injection valvesp. 336
+Check the injection valvesp. 336
Fig. 1p. 336
Fig. 2p. 337
Fig. 3p. 337
+Adjusting tze opening pressure on the injection valvep. 337
Fig. 4p. 337
Fig. 5p. 337
Fig. 6p. 338
Fig. 7p. 338
Fig. 8p. 338
Fig. 9p. 338
Fig. 10p. 338
Fig. 11p. 339
Fig. 12p. 339
Fig. 13p. 339
Fig. 14p. 339
+Leak testp. 340
+Rattle and spray pattern testp. 340
+11.22 Fuel filterp. 341
Fig. 1 Fuel pre-filterp. 341
Functionp. 342
Fuel pre-heating (option)p. 342
Draining off water or fuelp. 342
Performp. 342
+Main fuel filterp. 342
Fig. 2 Main fuel filterp. 342
+11.23 Check, clean the water separatorp. 343
+11.24 Change the fuel pre-filter cartridgep. 343
Fig. 4p. 343
Fig. 5p. 343
Fig. 6p. 344
Fig. 7p. 344
+11.25 Change the fuel filter cartridgep. 344
+11.26 Checking the compressionp. 345
Fig. 1p. 345
Fig. 2p. 345
Fig. 3p. 345
Fig. 4p. 345
+11.27 Check, adjust the valve clearancep. 346
+Valve adjustment schematicp. 346
Fig. 5p. 346
Fig. 6p. 346
Fig. 7p. 346
+Checking the valve clearancep. 346
+Adjusting the valve clearancep. 347
+11.28 Boost fuel solenoid valvep. 348
+11.29 Engine shut-down solenoidp. 349
+11.30 Air filter, differential pressure switchp. 350
+11.31 Service the combustion air filterp. 351
Fig. 2p. 351
Fig. 3p. 352
+Removing the main filter elementp. 352
+Cleaning the main filter elementp. 352
+Cleaning the dust bowlp. 353
Installing the main filter elementp. 353
+Changing the safety filter elementp. 353
+11.32 Heating flange on enginep. 354
Fig. 1 Heating flangep. 354
Fig. 2 Heating flange (R19) with hose socket BF4M 2012 Cp. 354
Fig. 3p. 355
Fig. 4 Coolant temperature sensorp. 355
Fig. 5 Heating flange function diagramp. 356
+11.33 Checking the heating flange controlp. 357
Fig. 1 Monitoring board (A15)p. 357
+11.34 Electric throttle controlp. 358
Fig. 1 Engine solenoidp. 358
Fig. 2 Throttle control switchp. 358
Fig. 3 Electric circuit of solenoidp. 359
Fig. 4p. 359
Fig. 5p. 359
+11.35 Engine monitoringp. 360
Fig. 1p. 360
Fig. 2 Differential pressure switchp. 361
Fig. 3 Sensor water separatorp. 361
Fig. 4 Oil pressure switchp. 361
Fig. 5 Coolant temperature switchp. 362
Fig. 6 Coolant temperature switchp. 362
Fig. 7 Emergency stop switchp. 362
11.36 Enginep. 363
+11.37 Special tools, Deutz engine (BFM 2012)p. 365
12 Air conditioning systemp. 377
+12.1 Physical basicsp. 379
Fig. 1p. 379
Fig. 2p. 379
+Pressure and boiling pointp. 380
Fig. 3 Steam pressure curvep. 380
Fig. 4 Pressure – Temperature Diagramp. 380
+12.2 Refrigerant R134ap. 382
Environmental aspectsp. 383
12.3 Compressor oil / refrigeration oilp. 383
+12.4 Working principle of the air conditioning systemp. 384
Fig. 1 Principle sketch of an air conditioning systemp. 384
+12.5 Monitoring devicesp. 384
Fig. 2 Monitoring chain consisting of:p. 385
+12.6 Description of componentsp. 385
+Compressorp. 385
+Condenserp. 386
+Dryer / filter / fluid container / inspection glassp. 387
Fig. 1p. 387
Fig. 2p. 387
Fig. 3p. 387
+Expansion valvep. 388
+Evaporatorp. 389
+Defroster thermostatp. 389
+Pressure switchp. 390
Pipes and hosesp. 390
+12.7 Checking the compressor oil levelp. 391
+Checking the compressor oil level / refrigeration oil levelp. 391
+12.8 Checking the magnetic clutchp. 392
Fig. 1p. 392
Fig. 2 Measuring the air gapp. 392
+Cross-section of magnetic clutchp. 392
Fig. 3 Cross-section of magnetic clutchp. 392
12.9 Inspection and maintenance workp. 393
+12.10 Checking, replacing the refrigerant compressor V-beltp. 393
+Check the V-beltp. 393
+Tighten the V-belt.p. 393
Changing the V-beltp. 394
+12.11 Service the air conditioningp. 394
+Cleaning the condenserp. 394
+Checking the refrigerant levelp. 394
Fig. 7p. 395
Fig. 8p. 395
Fig. 9p. 395
Fig. 10p. 395
+Checking the moisture level of the drying agentp. 396
+Checking the condition of the drier/collector unitp. 396
12.12 Drying and evacuationp. 397
12.13 Emptying in case of repairp. 397
+12.14 Leak testp. 398
Fig. 1 Electronic leak testerp. 398
Fig. 2 Soap bubble testp. 398
+12.15 Filling instructionsp. 399
Fig. 1p. 400
Filling instructionsp. 401
+12.16 Trouble shooting in refrigerant circuit, basic principlesp. 402
+Basic principlesp. 402
Fig. 2 Pressure gaugep. 402
Fig. 3 Absolute pressure gaugep. 403
Overheatingp. 403
+Supercoolingp. 403
Fig. 1 Refrigerant circuit with t, h- diagramp. 405
+12.17 Trouble shooting, refrigerant circuit diagramp. 406
Fig. 1 Refrigerant circuit diagramp. 406
+12.18 Trouble shooting procedurep. 407
+Procedurep. 407
Fig. 2 Flow diagram with measuring pointsp. 408
Fig. 3p. 411
Fig. 4p. 412
Fig. 5p. 413
Fig. 6p. 414
+12.20 Heating control / air conditioning controlp. 423
13 Replacing the cab window panesp. 429
+Fig. 1p. 430
1 Glass panesp. 430
2 Fastening elementp. 430
3 Fixing washer and spacerp. 430
4 Washerp. 430
5 Hexagon nut, self lockingp. 430
6 Protective capp. 430
13.2 Special toolsp. 431
+Fig. 1p. 431
1. Locking handle for fastening elementp. 431
+Fig. 2p. 431
2. Suction lifterp. 431
13.3 Auxiliary materialsp. 432
+Fig. 1p. 432
+Fig. 2p. 432
4. Window glass bonding agentp. 432
+Fig. 3p. 432
+Fig. 4p. 433
6. Silicone sealantp. 433
13.4 Removing and installing the window panep. 434
+Fig. 1p. 434
1. Pull large glass rests off the bonding strip (Fig. 1).p. 434
+Fig. 2p. 434
2. Clean the sealing surfaces from any adhesive material (Fig. 2).p. 434
3. Use a cutter to remove adhesive residues with glass rests.p. 434
4. Cover places without adhesive residues with an activator.p. 434
+Fig. 3p. 434
5. Insert the fastening element with washer into the bore in the glass pane (Fig. 3).p. 434
+Fig. 4p. 435
6. Turn the fixing and spacer washer hand-tight onto the thread of the fastening element (Fig. 4).p. 435
+Fig. 5p. 435
7. Lay an approx. 1 cm high triangular bead of glass pane bonding agent on the inside of the pane, approx. 1.5 cm away from the edge (Fig. 5).p. 435
+Fig. 6p. 435
8. Attach the suction lifter to the outside of the pane (Fig. 6).p. 435
9. Install the window pane so that the fastening elements fit into the bores of the fastening bars.p. 435
10. Press the glass pane against the sealing surface.p. 435
+Fig. 7p. 435
11. Assemble the washer and the self-locking hexagon nut.p. 435
12. Fasten the window pane to the fastening bar using a locking handle and a ring spanner (Fig. 7).p. 435
13. Press the protective cap onto the hexagon nut.p. 435
+Fig. 8p. 436
14. Remove the suction lifter (Fig. 8).p. 436
+Fig. 9p. 436
15. Clean the joining edges on the window pane (Fig. 9).p. 436
16. Mask the upper and lower contact areas to the cabin.p. 436
+Fig. 10p. 436
17. Apply silicone sealant evenly and under pressure first to the inside joint edge (Fig. 10).p. 436
+Fig. 11p. 436
18. Then apply silicone sealant evenly and under pressure to the outside joint edge (Fig. 11).p. 436
+Fig. 12p. 437
19. Then spray the joints from inside and outside with water containing washing up liquid (Fig. 12).p. 437
+Fig. 13p. 437
20. Treat the inside joint (Fig. 13)p. 437
+Fig. 14p. 437
21. and the outside joint (Fig. 14) with a scraper or a spattle.p. 437
14 Drump. 439
+14.1 Special tools, drum, single drum rollersp. 440
+Fig. 1p. 440
1. Disassembly device for side platep. 440
+Fig. 2p. 440
2. Assembly device for side platep. 440
+Fig. 3p. 440
3. Assembly device for coupling hub and flanged hubp. 440
+Fig. 4p. 441
4. Pressing plate for cylinder roller bearingp. 441
+Fig. 5p. 441
5. Pressing plate for travel bearingp. 441
+Fig. 6p. 441
6. Pressing bushing for radial sealp. 441
+Fig. 7p. 441
7. Lifting device for exciter unitp. 441
+Repair overview for drum
1 Drump. 443
2 Cylinder roller bearingp. 443
3 Couplingp. 443
4 Vibration motorp. 443
5 Rear shellp. 443
6 Grooved ball bearingp. 443
7 Spacer blockp. 443
8 Rectangular rubber bufferp. 443
9 Side platep. 443
10 Spacer ringp. 443
11 Grooved ball bearingp. 443
12 Mechanical sealp. 443
13 Flanged hubp. 443
14 Vibrator shaftp. 443
15 Couplingp. 443
16 Vibrator shaftp. 443
17 Change-over weightp. 443
18 Cylinder roller bearingp. 443
19 Basic weightp. 443
20 Flanged housingp. 443
21 Flangep. 443
22 Cylinder roller bearingp. 443
23 Rear shellp. 443
+14.3 Removing and installing the drump. 450
Fig. 1p. 450
Fig. 2p. 450
+Removing the drump. 450
+Fig. 3p. 450
1. Mark the hydraulic hoses (Fig. 3)on the travel motor and disconnect them from the ports.p. 450
2. Close all hydraulic hoses and motor ports with suitable plugs.p. 450
+Fig. 4p. 451
3. Mark the hydraulic hoses on the vibration motor (Fig. 4) and disconnect them from the ports.p. 451
4. Close all hydraulic hoses and motor ports with suitable plugs.p. 451
+Fig. 5p. 451
5. Unscrew bolts 1 (Fig. 5) and nuts and remove the front scraper (2).p. 451
6. Unscrew bolts 3 and nuts and remove the front scraper (4).p. 451
+Fig. 6p. 451
7. Support the front cross-member safely with suitable trestles or wooden blocks (Fig. 6).p. 451
+Fig. 7p. 451
8. Support the rear cross-member safely with suitable trestles or wooden blocks (Fig. 7).p. 451
+Fig. 8p. 452
9. Disassemble bracket 1 (Fig. 8) for the hydraulic hoses.p. 452
+Fig. 9p. 452
10. Fasten the lifting gear to the side plate on the vibration motor side.p. 452
11. Unscrew bolts 1 (Fig. 9) from the spacer blocks on vibration and travel motors.p. 452
+Fig. 10p. 452
12. Force out plug 1 (Fig. 10) and unscrew the bolts (2) from the front and rear cross-members.p. 452
13. Take off the side plate.p. 452
+Fig. 11p. 452
14. Fasten the lifting tackle to the drum and lift the drum carefully sideways out of the front frame (Fig. 11).p. 452
+Fig. 12p. 453
15. Check all rubber buffers (Fig. 12), replace if necessary (see corresponding chapter).p. 453
+Fig. 13p. 453
16. Check rectangular rubber buffers (Fig. 13), replace if necessary.p. 453
+Installing the drump. 453
+Fig. 14p. 453
1. Place the drum into the frame and align it parallel to the frame (Fig. 14).p. 453
+Fig. 15p. 453
2. Attach the side plate, insert the bolts 2 (Fig. 15) into rear and front cross-members and tighten with 463 Nm.p. 453
3. Close the screw holes with plugs (1).p. 453
+Fig. 16p. 454
4. Fasten the spacer blocks on travel and vibration motor sides with bolts 1 (Fig. 16) and nuts to the side plates.p. 454
+Fig. 17p. 454
5. Connect hydraulic hoses to the connections on travel motor and vibration motor according to the marking (Fig. 17).p. 454
+Fig. 18p. 454
6. Fasten bracket 1 (Fig. 18) for the hydraulic hoses.p. 454
+Fig. 19p. 454
7. Assemble the front scraper 2 (Fig. 19), fasten with bolts (1), washers and nuts.p. 454
8. Assemble the rear scraper (4), fasten with bolts (3), washers and nuts.p. 454
9. Observe the adjustment measurement 30-35 mmp. 454
+Fig. 20p. 455
10. Measure distance „X“ between spacer piece 1 (Fig. 20) and side plate.p. 455
11. Calculate the thickness of the compensation plates.p. 455
12. Turn one screw (3) into the welded nut (2) at top and bottom and open a sufficient gap to insert the compensation plates.p. 455
+Fig. 21p. 455
13. Insert the compensation plates 4 (Fig. 21). Insert screws (1), slide on washers (3), turn on and tighten nuts (2).p. 455
14. Unscrew the screws from the welded nuts.p. 455
+14.4 Repairing the drump. 456
+Removing the travel motorp. 456
+Fig. 1p. 456
1. Attach the lifting tackle to the travel motor.p. 456
2. Unscrew all nuts (Fig. 3) from the rubber buffers.p. 456
3. Take the drive disc with the travel motor off the rubber buffers.p. 456
+Fig. 2p. 456
4. Unscrew the nuts, pull out the screws and remove the support legs (Fig. 4).p. 456
+Fig. 3p. 456
5. Attach the lifting tackle to the travel motor (Fig. 3).p. 456
+Fig. 4p. 457
6. Unscrew the bolts (Fig. 4) and separate the travel motor from the drive disc.p. 457
+Disassembling the exciter unit (travel motor side)p. 457
+Fig. 5p. 457
1. Unscrew both socket head cap screws from the flange (Fig. 5).p. 457
+Fig. 6p. 457
2. Mount bracket 1 (Fig. 10) for the lifting device to the flange.p. 457
3. Unscrew screws (2) from the flange.p. 457
+Fig. 7p. 458
4. Slide the lifting device over the bracket.p. 458
5. Force the exciter unit off with two forcing screws (Fig. 7).p. 458
+Fig. 8p. 458
6. Pull the exciter unit out of the drum (Fig. 8).p. 458
7. Take the coupling element off the coupling half.p. 458
+Disassembling the exciter unit (travel motor side)p. 458
+Fig. 9p. 458
1. Unscrew fastening screws 1 (Fig. 9) for the fan.p. 458
2. Loosen clamping screw (2).p. 458
3. Pull the coupling hub off the shaft.p. 458
+Fig. 10p. 459
4. Unscrew all other fastening screws 1 (Fig. 10) from the flange.p. 459
5. Press the flange off the flanged housing with forcing screws (2).p. 459
+Fig. 11p. 459
6. Lift the flange off the flanged housing (Fig. 11).p. 459
7. Take the O-ring out of the groove in the flanged housing.p. 459
+Fig. 12p. 459
8. Unclip the circlip from the groove in the flange (Fig. 12).p. 459
+Fig. 13p. 459
9. Press the cylinder roller bearing with forcing screws out of the flange (Fig. 13).p. 459
+Fig. 14p. 460
10. Take the exciter unit (Fig. 14) out of the flanged housing.p. 460
+Fig. 15p. 460
11. Knock the radial seal (Fig. 15) out of the flanged housing.p. 460
+Fig. 16p. 460
12. Unclip the circlip from the groove in the flanged housing (Fig. 16).p. 460
+Fig. 17p. 460
13. Press the cylinder roller bearing with forcing screws out of the flanged housing (Fig. 17).p. 460
+Fig. 18p. 461
14. Extract inner ring 1 (Fig. 18) for the radial seal and inner bearing races (2).p. 461
+Fig. 19p. 461
15. Unclip the circlip from the basic weight (Fig. 19).p. 461
+Fig. 20p. 461
16. To change shaft 1 (Fig. 20) knock out dowel pins (2 and 3) and press the shaft out of the basic weight.p. 461
+Disassembling the exciter unit (vibration motor side)p. 462
+Fig. 21p. 462
1. Unscrew fastening screw 1 (Fig. 21).p. 462
2. Take rectangular rubber buffer (2) with spacer block (3) off the side plate.p. 462
+Fig. 22p. 462
3. Unscrew fastening screws 1 (Fig. 22).p. 462
4. Force cover (2) together with the attached vibration motor off the side plate with forcing screws.p. 462
+Fig. 23p. 462
5. To change the vibration motor loosen clamping screw 1 (Fig. 23) and pull off coupling half (2).p. 462
+Fig. 24p. 463
6. Unscrew nut 1 (Fig. 24), take off conical socket (2) and conical disc (3).p. 463
7. Take the vibration motor off the cover.p. 463
+Fig. 25p. 463
8. Remove the coupling element (Fig. 25).p. 463
+Fig. 26p. 463
9. Fasten the lifting device.p. 463
10. Unscrew fastening screws 1 (Fig. 26).p. 463
+Fig. 27p. 463
11. Press the exciter unit out of the drum with forcing screws (Fig. 27).p. 463
+Fig. 28p. 464
12. Pull the exciter unit out of the drum (Fig. 28).p. 464
+Removing, dismantling the side platep. 464
+Fig. 29p. 464
1. Take off V-ring 1 (Fig. 29).p. 464
2. Unclip circlip (2).p. 464
+Fig. 30p. 464
3. Attach the disassembly device to the side plate (Fig. 30) and force off the side plate.p. 464
+Fig. 31p. 464
4. Lift the side plate of the flanged hub (Fig. 31).p. 464
+Fig. 32p. 465
5. Knock the grooved roller bearing out of the side plate (Fig. 32) and take out the spacer ring.p. 465
+Fig. 33p. 465
6. Unclip the circlip from the side plate (Fig. 33).p. 465
+Fig. 34p. 465
7. Take the mechanical seal off the flanged hub (Fig. 34).p. 465
+Dismantling the exciter unit (vibration motor side)p. 466
+Fig. 35p. 466
1. Unscrew the fastening from the coupling hub.p. 466
2. Pull coupling hub (2) off the shaft using a pulling device (Fig. 35).p. 466
+Fig. 36p. 466
3. Loosen hose clamp 1 (Fig. 36).p. 466
4. Pull coupling hub (2) off the shaft.p. 466
+Fig. 37p. 466
5. Unscrew all other fastening screws 1 (Fig. 37) and press the flanged hub off the flanged housing with forcing screws (2).p. 466
6. Take off the flanged hub.p. 466
7. Take the O-ring out of the groove in the flanged housing.p. 466
+Fig. 38p. 467
8. Unclip the circlip from the groove in the flanged hub (Fig. 38).p. 467
+Fig. 39p. 467
9. Knock the cylinder roller bearing out of the flanged hub (Fig. 39).p. 467
+Fig. 40p. 467
10. Lift the exciter unit out of the flanged housing (Fig. 40).p. 467
+Fig. 41p. 467
11. Knock the radial seal (Fig. 41) out of the flanged housing.p. 467
+Fig. 42p. 468
12. Unclip the circlip from the groove in the flanged housing (Fig. 42).p. 468
+Fig. 43p. 468
13. Press the cylinder roller bearing with forcing screws out of the flanged housing (Fig. 43).p. 468
+Fig. 44p. 468
14. Extract inner rings 1 (Fig. 44) for the radial seals and inner bearing races (2) from the shaft.p. 468
+Fig. 45p. 468
15. Unclip the circlip from the basic weight and remove the cover (Fig. 45).p. 468
+Assembling the exciter unit (vibration motor side)p. 469
+Fig. 46p. 469
1. Cool the shaft down in liquid nitrogen.p. 469
2. Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig. 46).p. 469
+Fig. 47p. 469
3. Secure shaft 1 (Fig. 47) with dowel pins (2 and 3).p. 469
+Fig. 48p. 469
4. Cool the shaft down in liquid nitrogen.p. 469
5. Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig. 48).p. 469
+Fig. 49p. 470
6. Secure shaft 2 (Fig. 49) with dowel pins (1 and 3).p. 470
+Fig. 50p. 470
7. Insert the fitting key into the keyway in the respective shaft (Fig. 50).p. 470
+Fig. 51p. 470
8. Insert the circlip into the groove in the basic weight and on the cover (Fig. 51).p. 470
+Fig. 52p. 470
9. 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. 52).p. 470
+Fig. 53p. 471
10. 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. 53).p. 471
+Fig. 54p. 471
11. Heat the inner bearing race up to approx. 100˚ C and press it onto the cover against the shoulder with the larger outer diameter forward (Fig. 54).p. 471
+Fig. 55p. 471
12. Heat the inner ring up to approx. 50˚ C and slide it onto the longer shaft against the shoulder with the wider chamfer facing towards the outside (Fig. 55).p. 471
+Fig. 56p. 471
13. Press cylinder roller bearing 1 (Fig. 56) with pressing plate (2) into the flanged housing until it bottoms.p. 471
+Fig. 57p. 472
14. Insert the circlip into the groove in the flanged housing (Fig. 57).p. 472
+Fig. 58p. 472
15. Fit the new radial seal with some grease into the groove in the flanged housing (Fig. 58).p. 472
16. Fill approx. 1.2 l oil SAE-15W/40 into the flanged housing.p. 472
+Fig. 59p. 472
17. Insert the exciter unit with the longer shaft forward into the flanged housing (Fig. 59).p. 472
+Fig. 60p. 472
18. Press cylinder roller bearing 1 (Fig. 60) with pressing plate (2) into the flanged hub until it bottoms.p. 472
+Fig. 61p. 473
19. Insert the circlip into the groove in the flanged hub (Fig. 61).p. 473
+Fig. 62p. 473
20. Attach the flanged hub to the flanged housing (Fig. 62).p. 473
21. Unscrew eye bolts (1) and replace them with short screws.p. 473
22. Turn short screws (2) into the tapped bores in the flanged housing (four screws) and tighten them.p. 473
+Fig. 63p. 473
23. Apply some grease to the sealing lip of radial seal 1 (Fig. 63).p. 473
24. 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).p. 473
+Fig. 64p. 473
25. Heat the coupling hub up to approx. 80 ˚C and slide it onto the shaft against the stop (Fig. 64).p. 473
+Fig. 65p. 474
26. Apply some grease to the sealing lip of radial seal 1 (Fig. 65).p. 474
27. Slide the radial seal with the sealing lip forward over the shaft and drive it completely into the flanged housing, using a suitable tube (2).p. 474
+Fig. 66p. 474
28. Cover the thread of screw 1 (Fig. 66) with a screw retention agent (e.g. Loctite CVX strong, blue, 582).p. 474
29. Slide on the new U-seal ring (2), turn in and tighten the screws.p. 474
+Fig. 67p. 474
30. Heat coupling hub 1 (Fig. 67) with marking letter “L“ up t approx. 80˚ C and slide it over the shaft against the shoulder.p. 474
31. Turn in and tighten clamping screw (2).p. 474
+Assembling and installing the side platep. 475
+Fig. 68p. 475
1. Fill grooved ball bearing 1 (Fig. 68) on both sides with grease.p. 475
2. Press the grooved ball bearing completely in using pressing plate (2).p. 475
+Fig. 69p. 475
3. Insert the circlip into the groove in the side plate (Fig. 69).p. 475
+Fig. 70p. 475
4. Apply a thick coat of grease to the spacer ring on both sides and insert it into the side plate (Fig. 70).p. 475
+Fig. 71p. 476
5. Fill grooved ball bearing 1 (Fig. 71) on one sides with grease.p. 476
6. Insert the grooved ball bearing with the grease side forward and press it completely in with pressing plate (2).p. 476
+Fig. 72p. 476
7. Insert the oiled loop-ring into the mechanical seal (Fig. 72).p. 476
8. Clean the sliding surfaces of the mechanical seal and cover them with oil.p. 476
+Fig. 73p. 476
9. Lay one half of the radial seal on the flanged hub with the sliding surface pointing up (Fig. 73).p. 476
+Fig. 74p. 476
10. Lay the second half of the mechanical seal down with the sliding face pointing down (Fig. 74).p. 476
+Fig. 75p. 477
11. Bolt the threaded section of the assembly device to the flanged hub (Fig. 75).p. 477
+Fig. 76p. 477
12. Lay the side plate on the flanged hub (Fig. 76).p. 477
+Fig. 77p. 477
13. Attach bushing 2 (Fig. 77) of the assembly device and turn on nut (1).p. 477
+Fig. 78p. 477
14. Pull the side plate with the assembly device onto the flanged hub.p. 477
+Fig. 79p. 478
15. Remove the assembly device.p. 478
16. Insert the circlip into the groove in the flanged hub (Fig. 79).p. 478
+Assembling the exciter unit (travel motor side)p. 478
+Fig. 80p. 478
1. Cool the shaft down in liquid nitrogen.p. 478
2. Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig. 80).p. 478
+Fig. 81p. 478
3. Secure shaft 1 (Fig. 81) with dowel pins (2 and 3).p. 478
+Fig. 82p. 479
4. Insert the circlip into the groove in the basic weight and on the cover (Fig. 82).p. 479
+Fig. 83p. 479
5. 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. 83).p. 479
+Fig. 84p. 479
6. Heat the inner ring up to approx. 50˚ C and slide it onto the shaft against the shoulder with the wider chamfer facing towards the outside (Fig. 84).p. 479
+Fig. 85p. 479
7. Heat the inner bearing race up to approx. 100˚ C and press it onto the cover against the shoulder with the larger outer diameter forward (Fig. 85).p. 479
+Fig. 86p. 480
8. Press cylinder roller bearing 1 (Fig. 86) with pressing plate (2) into the flanged housing until it bottoms.p. 480
+Fig. 87p. 480
9. Insert the circlip into the groove in the flanged housing (Fig. 87).p. 480
+Fig. 88p. 480
10. Fit the new radial seal with some grease into the groove in the flanged housing (Fig. 88).p. 480
11. Fill approx. 1.2 l oil SAE-15W/40 into the flanged housing.p. 480
+Fig. 89p. 480
12. Insert the exciter unit into the flanged housing (Fig. 89).p. 480
+Fig. 90p. 481
13. Press cylinder roller bearing 1 (Fig. 90) with pressing plate (2) into the flange until it bottoms.p. 481
+Fig. 91p. 481
14. Insert the circlip into the groove in the flange (Fig. 91).p. 481
+Fig. 92p. 481
15. Lift the flange onto the flanged housing and align it the bores (Fig. 92).p. 481
+Fig. 93p. 481
16. Turn the screws into the tapped bores of the flanged housing and tighten them (Fig. 93).p. 481
+Fig. 94p. 482
17. Apply some grease to the sealing lip of radial seal 1 (Fig. 94).p. 482
18. Slide the radial seal with the sealing lip forward over the shaft and drive it completely into the flanged housing, using a suitable tube (2).p. 482
+Fig. 95p. 482
19. Cover the thread of screw 1 (Fig. 95) with a screw retention agent (e.g. Loctite CVX strong, blue, 582).p. 482
20. Slide on the new U-seal ring (2), turn in and tighten the screws.p. 482
+Fig. 96p. 482
21. Insert the fitting key into the keyway of the shaft (Fig. 96).p. 482
+Fig. 97p. 482
22. Slide the fan with assembly disc over the shaft.p. 482
23. Heat coupling hub 1 (Fig. 97) with marking letter “R“ up to approx. 80˚ C and slide it over the shaft against the shoulder.p. 482
24. Turn in and tighten clamping screw (2).p. 482
25. Assemble the fan to the coupling hub.p. 482
+Assembling the exciter unit (travel motor side)p. 483
+Fig. 98p. 483
1. Check coupling elements, replace if necessary.p. 483
2. Insert the coupling element into the coupling hub (Fig. 98).p. 483
3. Fasten the lifting device to the exciter unit.p. 483
+Fig. 99p. 483
4. Insert the vibrator unit into the drum (Fig. 99).p. 483
Fig. 100p. 483
+Fig. 101p. 484
5. Turn in and tighten screws 2 (Fig. 101).p. 484
6. Remove bracket (1) for the lifting device.p. 484
+Fig. 102p. 484
7. Cover the thread of screws (Fig. 102) with a screw retention agent (e.g. Loctite green 270).p. 484
8. Slide on the new U-seal ring, turn in and tighten the screws.p. 484
+Installing the travel motorp. 484
+Fig. 103p. 484
1. Fasten the lifting tackle to the travel motor and attach the motor to the drive disc (Fig. 103).p. 484
+Fig. 104p. 484
2. Turn in and tighten the fastening screws (Fig. 104).p. 484
+Fig. 105p. 485
3. Mount the support leg to the travel motor, insert the screws, turn on and tighten the nuts (Fig. 105).p. 485
+Fig. 106p. 485
4. Attach the drive disc with the assembled travel motor to the rubber buffers. Turn on and tighten the nuts (Fig. 106).p. 485
+Installing the exciter unit (vibration motor side)p. 485
+Fig. 107p. 485
1. Fasten the lifting gear to the exciter unit and insert it into the drum (Fig. 107).p. 485
Fig. 108p. 486
+Fig. 109p. 486
2. Turn in and tighten screws 1 (Fig. 109).p. 486
3. Remove the lifting gear.p. 486
4. Fit cover (2) to the drum.p. 486
+Fig. 110p. 486
5. Check the end float of the exciter shafts (Fig. 110).p. 486
+Fig. 111p. 486
6. Attach disc 1 (Fig. 111), turn in and tighten the fastening screws (2).p. 486
+Fig. 112p. 487
7. Lay a new V-ring over the journal of the flanged hub (Fig. 112).p. 487
8. Fill the grooved ball bearing with grease.p. 487
+Fig. 113p. 487
9. Check coupling element, replace if necessary.p. 487
10. Insert the coupling element into the coupling hub (Fig. 113).p. 487
+Fig. 114p. 487
11. Fasten the vibration motor to the cover so that sockets 1 (Fig. 114) and ventilation bore (2) are opposite each other.p. 487
+Fig. 115p. 487
12. Slide on coupling half 2 (Fig. 115) and secure with clamping screw (1).p. 487
+Fig. 116p. 488
13. Attach the cover with the installed vibration motor, turn in and tighten the screws (Fig. 116).p. 488
+Fig. 117p. 488
14. Install rectangular rubber buffers 2 (Fig. 117) with attached spacer block (3) and screws (1) to the side plate.p. 488
+14.5 Dismantling, assembling the change- over weightsp. 489
+Dismantling the change-over weightp. 489
+Fig. 1p. 489
1. Unscrew all screws (Fig. 3).p. 489
+Fig. 2p. 489
2. Force the cover off the basic weight with forcing screws (Fig. 4).p. 489
+Fig. 3p. 489
3. Take the change-over weight out of the basic weight (Fig. 5).p. 489
+Fig. 4p. 490
4. Pull O-rings 1 and 2 (Fig. 4) out of the grooves.p. 490
+Assembling the change-over weightsp. 490
+Fig. 5p. 490
1. Install new O-rings 1 and 2 (Fig. 5) with grease.p. 490
+Fig. 6p. 490
2. Insert the change-over weight into the basic weight (Fig. 6).p. 490
+Fig. 7p. 490
3. Fill silicon oil 47 V 1000 cst up to the upper edge of the change-over weight (approx. 2,5 litres) into the basic weight (Fig. 12).p. 490
+Fig. 8p. 491
4. Attach the cover (Fig. 13), so that the raised areas are in line.p. 491
5. Turn in screws with screw retention agent (e.g. Loctite blue 243) and tighten with 120 Nm.p. 491
6. Check the end float of the shaft.p. 491
+14.6 Changing the rubber buffers and adjusting the pretensionp. 492
+Fig. 1p. 492
1. Lift the frame up by both sides, until rubber buffers and rectangular buffers are relieved of any load (Fig. 1).p. 492
2. Loosen all fastening screws.p. 492
+Fig. 2p. 492
3. Turn one screw each into the welded nuts (Fig. 2) on the spacer blocks.p. 492
+Fig. 3p. 492
4. Remove the compensation shims 1 (Fig. 3).p. 492
+Fig. 4p. 493
5. Unscrew the screws (Fig. 4) from the welded nuts.p. 493
+Fig. 5p. 493
6. Unscrew nut 1 (Fig. 3) and remove the washer.p. 493
7. Unscrew screws (2).p. 493
8. Take off rubber buffer (3).p. 493
9. Attach the new rubber buffer to the drive disc and align the bores to the tapped bores in the drum.p. 493
10. Turn in and tighten the fastening screws.p. 493
11. Assemble the washer, turn on and tighten the nut.p. 493
+Fig. 6p. 493
12. Measure distance „X“ between spacer piece and side plate (Fig. 6).p. 493
13. Calculate the thickness of the compensation plates. Nominal value: Distance „X“ + 2 mmp. 493
+Fig. 7p. 493
14. Turn in screws into each welded nut and provide sufficient space to insert the compensation plates (Fig. 7).p. 493
+Fig. 8p. 494
15. Insert the compensation shims 1 (Fig. 8).p. 494
+Fig. 9p. 494
16. Unscrew the screws (Fig. 9) from the welded nuts.p. 494
+Fig. 10p. 494
17. Tighten the fastening screws (Fig. 10).p. 494
18. Lower the frame again.p. 494
15 Oscillating articulated jointp. 495
+15.1 Special toolsp. 496
+Fig. 1p. 496
1. Pressing mandrel for rocker bearingsp. 496
+Fig. 2p. 496
2. Pressing sleeve for outer race of rocker bearingp. 496
+Fig. 3p. 496
3. Pressing sleeve for inner race of rocker bearingp. 496
+Fig. 4p. 496
+Fig. 5p. 497
+Fig. 6p. 497
6. Disassembly devicep. 497
+Repair overview oscillating articulated joint
1 Housingp. 498
2 Seal ringp. 498
3 Rear shellp. 498
4 Self-aligning bearingp. 498
5 Boltp. 498
6 Shim/supporting discp. 498
7 Belleville springsp. 498
8 Self-aligning bearingp. 498
9 Consolep. 498
10 Belleville springsp. 498
11 Shim/supporting discp. 498
12 Rear shellp. 498
13 Rear shellp. 498
14 Intermediate ringp. 498
15 Self-aligning bearingp. 498
16 Intermediate ringp. 498
17 Self-aligning bearingp. 498
18 Beamp. 498
19 Friction bearingp. 498
20 V-ringp. 498
21 Seal ringp. 498
+15.3 Removing and installing the oscillating articulated jointp. 501
+Fig. 1p. 501
1. Jack up the frame (Fig. 1) at the back and secure it with trestles or wooden blocks.p. 501
+Fig. 2p. 501
2. Support the rear frame near the oscillating articulated joint (Fig. 2) on both sides safely with trestles or wooden blocks.p. 501
+Fig. 3p. 501
3. Fasten the lifting tackle to the front frame near the oscillating articulated joint (Fig. 3).p. 501
+Fig. 4p. 502
4. Unscrew fastening screws 1 (Fig. 4) and take off axle holder (2).p. 502
5. Knock out bearing bolt (3).p. 502
6. Retract steering cylinder (4).p. 502
+Fig. 5p. 502
7. Support the oscillating articulated joint in the middle with a suitable jack or a similar device.p. 502
8. Unscrew fastening screws 1 (Fig. 5) and take off with disc (2).p. 502
+Fig. 6p. 502
9. Unscrew nuts 3 (Fig. 6) and take off the clamping washers (2).p. 502
10. Pull out the fastening screws (1).p. 502
11. Slightly raise the front frame and lower the oscillating articulated joint to the ground.p. 502
12. Pull out the oscillating articulated joint.p. 502
+Fig. 7p. 502
13. Insert the bolt for the steering cylinder so that groove (2) is in line with tapped bores (1).p. 502
+15.4 Dismantling the oscillating articulated jointp. 503
+Fig. 1p. 503
1. Unscrew the nuts from hexagon screw 1 (Fig. 1) and pull out the hexagon screw.p. 503
2. Unscrew the screws (2) for the cover.p. 503
+Fig. 2p. 503
3. Take off the cover with Belleville springs, shim and backing disc (Fig. 2).p. 503
4. Disassemble also the cover from the opposite side.p. 503
+Fig. 3p. 503
5. Drive the console with a plastic hammer to one side against the end stop (Fig. 3).p. 503
+Fig. 4p. 504
6. Force inner race 1 (Fig. 4) of the rocker bearing off the bolt.p. 504
7. Take of supporting disc (2).p. 504
8. Drive the console to the opposite side and remove the rocker bearing in the same way.p. 504
+Fig. 5p. 504
9. Unscrew fastening screws 1 (Fig. 5).p. 504
10. Press bolt (3) out of the console with forcing screws (2).p. 504
+Fig. 6p. 504
11. Lift console 1 (Fig. 6) off housing (2).p. 504
+Fig. 7p. 504
12. Take the seal rings out of the console (Fig. 7).p. 504
+Fig. 8p. 505
13. Remove the cover from the housing.p. 505
14. Take off shims 1 (Fig. 8), backing disc (2) and Belleville springs (3).p. 505
+Fig. 9p. 505
15. Unscrew bolts 1 (Fig. 9) and take off cover (2).p. 505
+Fig. 10p. 505
16. Take the intermediate ring out of the housing (Fig. 10).p. 505
+Fig. 11p. 505
17. Place the plate 1 (Fig. 11) on the beam.p. 505
18. Attach the puller (2) to the housing (3) and separate the carrier from the rocker bearings.p. 505
+Fig. 12p. 506
19. Pull the housing off the beam (Fig. 12).p. 506
+Fig. 13p. 506
20. Drive the outer race of the friction bearing out of the housing (Fig. 13).p. 506
+Fig. 14p. 506
21. Drive the friction bearing out of the housing (Fig. 14).p. 506
+Fig. 15p. 506
22. Take seal ring 1 (Fig. 15) and V-ring (2) off the beam.p. 506
+Fig. 16p. 507
23. Check rocker bearings, if necessary press out of the housing (Fig. 16).p. 507
+15.5 Assembling the oscillating articulated jointp. 508
+Fig. 1p. 508
1. If previously disassembled, press the rocker bearing fully into the housing with a pressing mandrel (Fig. 1).p. 508
+Fig. 2p. 508
2. Slide the new V-ring on the beam against the stop with the lip facing up (Fig. 2).p. 508
+Fig. 3p. 508
3. Lay the seal ring into the beam (Fig. 3).p. 508
4. Fill the space between V-ring and seal ring with multi-purpose grease.p. 508
+Fig. 4p. 509
5. Press the friction bearing fully into the housing with the chamfered side pointing towards the outside (Fig. 4).p. 509
+Fig. 5p. 509
6. Slide the housing over the beam (Fig. 5).p. 509
+Fig. 6p. 509
7. Press the seal ring carefully towards the inside, until it sits in the recess of the housing (Fig. 6).p. 509
+Fig. 7p. 509
8. Spray the sliding surface of the outer rocker bearing race with sliding agent OKS 571.p. 509
9. Press the outer rocker bearing race 1 (Fig. 7) in until it bottoms with the wider outer rim forward using pressing sleeve (2).p. 509
+Fig. 8p. 510
10. Press inner rocker bearing race 1 (Fig. 8) in until it bottoms, using pressing sleeve (2).p. 510
+Fig. 9p. 510
11. Insert the intermediate ring (Fig. 9).p. 510
+Fig. 10p. 510
12. Press inner rocker bearing race 1 (Fig. 10) in until it bottoms, using pressing sleeve (2).p. 510
+Fig. 11p. 510
13. Press the outer rocker bearing race 1 (Fig. 11) in until it bottoms with the wider outer rim pointing up, using pressing sleeve (2).p. 510
+Fig. 12p. 511
14. Press in intermediate ring 1 (Fig. 12) until it bottoms.p. 511
15. Attach cover (2) with the machined edge forward.p. 511
16. Turn in screws (3) and tighten crosswise.p. 511
+Fig. 13p. 511
17. Determine the shim thickness, for this purpose stand the cross-member on a wooden board with an Æ 18 mm bore.p. 511
18. Slide the rod of the tensioning device in from underneath, attach the plate, screw on the nut and tighten.p. 511
19. Measure the distance from housing edge to intermediate ring (Fig. 13) and write it down, e.g. 4,7 mm.p. 511
20. Remove the tensioning device.p. 511
+Fig. 14p. 512
21. Insert shim 2 (Fig. 14) of appropriate thickness and backing disc (1) into the cover.p. 512
+Fig. 15p. 512
22. Lay the Belleville springs into the cover with the curvature pointing down (Fig. 15).p. 512
+Fig. 16p. 512
23. Assemble cover 2 (Fig. 16) with Belleville springs, shim and backing disc.p. 512
24. Turn in screws (1) and tighten crosswise.p. 512
+Fig. 17p. 512
25. Press the new sealing rings into the respective groove in the console (Fig. 17).p. 512
+Fig. 18p. 513
26. Lift console 1 (Fig. 18) over the housing (2).p. 513
+Fig. 19p. 513
27. Turn four guide pins into the housing bores (Fig. 19).p. 513
+Fig. 20p. 513
28. Slide the bolt over the guide pins (Fig. 20) and drive in until it bottoms.p. 513
Fig. 21p. 513
+Fig. 22p. 514
29. Unscrew the guide pins .p. 514
30. Turn in the screws and tighten with 75 Nm (Fig. 22).p. 514
+Fig. 23p. 514
31. Slide the backing discs over the bolt (Fig. 23).p. 514
+Fig. 24p. 514
32. Drive the inner rocker bearing race on against the end stop with the wider outer rim forward (Fig. 24).p. 514
+Fig. 25p. 514
33. Spray the sliding surface of the outer rocker bearing race with sliding agent OKS 571.p. 514
34. Attach the outer rocker bearing race with the wider outer rim facing towards the outside (Fig. 25) and drive it in until it bottoms.p. 514
+Fig. 26p. 515
35. Attach cover 1 (Fig. 26) to the bottom side of the console.p. 515
36. Turn in and tighten screws (2).p. 515
+Fig. 27p. 515
37. Determine the shim thickness, for this purpose insert rod 1 (Fig. 27) of the tensioning device from underneath. Attach plate (2), screw on nut (3) and tighten.p. 515
+Fig. 28p. 515
38. Measure the distance from outer rocker bearing race to console surface (Fig. 28) and write it down, e.g. 3.4 mm.p. 515
39. Remove the tensioning device.p. 515
+Fig. 29p. 516
40. Insert shims 2 (Fig. 29) of appropriate thickness and backing disc (1) into the cover.p. 516
+Fig. 30p. 516
41. Lay the Belleville springs into the cover with the curvature pointing down (Fig. 30).p. 516
+Fig. 31p. 516
42. Assemble cover 1 (Fig. 31) with Belleville springs, shims and supporting discs.p. 516
43. Turn in screws (2) and tighten crosswise.p. 516
+Fig. 32p. 516
44. Insert hexagon screw 1 (Fig. 32) so that the screw head rests on the upper side of the console.p. 516
+Fig. 33p. 517
45. Assemble the washer, turn on and tighten the nut with 120 Nm (Fig. 33).p. 517
16 Suppliers documentationp. 519
16.1 Travel pump series 90Rp. 521
16.2 Travel drive series 51p. 611
16.3 Vibration pump 42R 041p. 693
16.4 Vibration motor A10FMp. 731
16.5 MS/MSE 02 ….. 18p. 755
+16.6 Axle DANA 192p. 805
17 Circuit diagramsp. 929
17.1 Wiring diagramp. 931
+17.2 Wiring diagramp. 955
Wiring diagram 582 701 97 from serial numberp. 956
17.3 Wiring diagramp. 985
17.4 Hydraulic diagramp. 1021
Chapters Covered
- General: Introduction; Safety regulations; General repair instructions; Tightening torques
- Technical data: Technische Daten; Maintenance chart; Table of fuels and lubricants; Fuels and lubricants
- Connection overview: Connection overview
- Tests and adjustments: Special tools, tests and adjustments; Checking the rotation speeds; Checking / adjusting the neutral positions of the travel pump; Pressure tests in the travel circuit; Checking / adjusting the vibrator shaft speeds; Pressure measurements in the vibration circuit; Check the leakage rate of the vibration motor; Pressure test in steering circuit
- Flushing and bleeding: Special tools for flushing; Flushing – general; Flushing schematic travel circuit (distribution travel pump); Flushing the travel circuit (travel pump distribution); Flushing schematic travel circuit (distribution axle motor); Flushing the travel circuit (axle motor distribution); Flushing schematic for vibration drive; Flushing the vibration circuit; Bleeding the travel circuit; Bleeding the vibration circuit
- Fundamental electrics: Understanding circuit diagrams; Terminal designations; Current and voltage; Resistance; Series / parallel connection; Ohm’s law; Electrical energy; Formula diagram; Metrology; Diodes, relays, fuses; Batteries; Three-phase generator; Electric starter; Telemecanique switch; Inductive proximity switches; Angle sensor with current output; Plug connectors; Deutsch plug, series DT and DTM; Plugs and terminals in spring clamping technology
- Special tools, electrics: Special tools, electrics
- Electronic modules: Seat contact module
- Speedometer Module: Speedometer module
- Service Training: Electrics BEM (BOMAG Evib-meter); Service Training
- Engine: Diesel engine, general; Lubrication oil circuit; Coolant circuit; Fuel supply; Injection system; Injection pump replacement during service; Injection valve replacement during service; Checking / repairing injection valves; Checking the compression; Check, adjust the valve clearance; Electric throttle control; Engine monitoring; Special tools, Deutz engine (BFM 2012)
- Air conditioning system: Refrigerant R134a; Compressor oil / refrigeration oil; Working principle of the air conditioning system; Description of components; Inspection and maintenance work; Service the air conditioning; Drying and evacuation; Leak test; Filling instructions; Trouble shooting procedure; Heating control / air conditioning control
- Replacing the cab window panes: Assembly of window panes; Special tools; Auxiliary materials; Removing and installing the window pane
- Drum: Special tools, drum, single drum rollers; Repair overview for drum; Removing and installing the drum; Repairing the drum; Dismantling, assembling the change-over weights; Changing the rubber buffers and adjusting the pretension
- Oscillating articulated joint: Special tools; Repair overview oscillating articulated joint; Removing and installing the oscillating articulated joint; Dismantling the oscillating articulated joint; Assembling the oscillating articulated joint
- Suppliers documentation: Travel pump series 90R; Travel drive series 51; Vibration pump 42R 041; Vibration motor A10FM; MS/MSE 02 ….. 18; Axle DANA 192
- Circuit diagrams: Wiring diagram; Wiring diagram; Wiring diagram; Hydraulic diagram
Taken as a whole, the manual brings together routine service references, machine-specific diagnostics, hydraulic testing, electrical troubleshooting, engine repair, mechanical disassembly and component-level overhaul documentation. Its final circuit-diagram section also provides wiring information for supply and starting, engine-speed functions, sensors, brake and backup-alarm circuits, speed ranges, seat contact, vibration, cabin equipment and air conditioning, followed by the hydraulic diagram.
Carry Out Repairs With the Correct Service Information
The BOMAG BW 211 D-4 / PD-4 & BW 213 D-4 / PD-4 Single Drum Roller Service Manual 008 911 45 – January 2007 provides the procedures and reference data needed for tasks ranging from pressure testing and hydraulic flushing to engine diagnosis, drum repair, articulated-joint overhaul and electrical fault tracing. Having the specified sequences, adjustment values, diagrams and component information available during the job helps technicians work from documented procedures instead of relying on memory or trial and error. Supplied as an instant PDF download with no shipping required, the manual can be viewed on a phone, tablet or computer and printed when a paper workshop copy is useful.
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