BOMAG BW 211 D-4 PD-4 BW 213 D-4 PD-4 Single Drum Roller Service Manual β Complete Workshop PDF
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Complete 1,046-page BOMAG service manual for BW 211 D-4/PD-4 and BW 213 D-4/PD-4 single drum rollers. Covers engine, hydraulics, electrics, drum, axle, air conditioning, wiring diagrams, and full repair procedures.
BOMAG BW 211 D-4 / PD-4 and BW 213 D-4 / PD-4 Service Manual
This BOMAG BW 211 D-4 PD-4 BW 213 D-4 PD-4 Single Drum Roller Service Manual is the complete workshop documentation for the D-4 generation of these machines, published under BOMAG document number 008 911 49. It spans 1,046 pages and is written for trained mechanics carrying out maintenance, repair, diagnosis, and overhaul work on these single drum rollers. Every major system is covered, from the Deutz diesel engine through the hydrostatic travel and vibration circuits, the drum assembly, the oscillating articulated joint, the rear axle, and the complete electrical system including wiring diagrams.
This BOMAG single drum roller service manual gives a technician the full factory repair logic for the BW 211 D-4 and BW 213 D-4 machines. The travel system chapter alone walks through the Sauer 90R075 travel pump, the Poclain MSE 18 2CX drum drive motor, and the Sauer 51D110 axle motor with pressure test points and adjustment values. The vibration section covers the Sauer 42R041 pump and the A10FM 45 motor with flushing valve. The electrical chapters go from basic terminal numbering through CAN-Bus diagnostics, fault codes, and the BEM Evib-meter module. The engine section covers the Deutz TCD 2013 L04 2V in detail, including fuel filter service, coolant temperature switch, valve clearance adjustment, compression testing, and the complete special tool list. Wiring diagrams for the whole machine are included at the back.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the βBOMAG BW 211 D-4 PD-4 BW 213 D-4 PD-4 Single Drum Roller Service Manual β Complete Workshop PDFβ are as follows:
BW 211 D-4 / PD-4p. 1
+BW 213 D-4 / PD-4p. 1
S/N 101 583 09 ….> S/N 101 583 10 ….>p. 1
S/N 101 583 08 ….> S/N 101 583 13 ….>p. 1
+Single drum rollerp. 1
1 Generalp. 7
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
Enginep. 11
Air conditioning systemp. 12
Batteryp. 12
Poisonous substancesp. 13
Special safety regulationsp. 13
+General repair instructionsp. 14
Generalp. 14
Electricsp. 14
Batteryp. 15
Hydraulic systemp. 16
Air conditioning systemp. 17
+Notes on cleanliness for Common Rail enginesp. 18
Fig. 1p. 18
+Fuel hosesp. 20
Fig. 2p. 20
+Gaskets and mating surfacesp. 21
Fig. 3p. 21
Fig. 4p. 21
+Feather keys and keywaysp. 22
Fig. 5p. 22
+Ball and roller bearingsp. 22
Fig. 6p. 22
Fig. 7p. 23
+Screws and nutsp. 23
Fig. 8 Identification of screwsp. 24
Fig. 9 Identification of nutsp. 24
Fig. 10 Identification of nuts in clock systemp. 25
+Tightening torquesp. 26
2 Maintenancep. 31
+2.1 General notes on maintenancep. 32
Notes on the fuel systemp. 32
Notes on the engine performancep. 32
Notes on the hydraulic systemp. 32
Notes on the cooling systemp. 32
2.2 Table of fuels and lubricantsp. 34
2.3 Running-in instructionsp. 35
+2.4 Maintenance chartp. 36
3 Technical datap. 39
Technical datap. 40
Fig. 11p. 40
Fig. 12p. 42
Noise valuep. 46
+Vibration valuep. 46
4 Connection overviewp. 47
Connection overview
+Fig. 1 Travel pumpp. 48
1 Control solenoid, high frequencyp. 49
2 Control solenoid, low frequencyp. 49
3 Multi-function valve 400 bar (boost check and pressure relief valve), travel systemp. 49
4 Connection, charge pressure to brake solenoid valve, travel speed range selection and charge oil supply for vibration pumpp. 49
5 Multi-function valve 400 bar (boost check and pressure relief valve), travel systemp. 49
6 Setscrew, mechanical neutral positionp. 49
7 Connection L, leak oil connection to vibration pumpp. 49
8 Lever, travel controlp. 49
9 Pilot pressure test portp. 49
10 High pressure port B, high pressure reversep. 49
11 Charge pressure relief valve, 26 barp. 49
12 Adjustment screw, low frequencyp. 49
13 Connection L2, leak oil to tankp. 49
14 Pressure test port MB, high frequencyp. 49
15 High pressure test port MA, low frequencyp. 49
16 High pressure port A, low frequencyp. 49
17 High pressure port B, high frequencyp. 49
18 Charge pump, internalp. 49
19 Connection L2, to drum drive motor (flushing)p. 49
20 Adjustment screw, high frequencyp. 49
21 Connection D, charge pressure to filterp. 49
22 Multi function valve 345 bar (boost check and pressure relief valve), vibration drive high frequencyp. 49
23 Connection S, suction line charge pump from hydraulic oil tankp. 49
24 Multi function valve 345 bar (boost check and pressure relief valve), vibration drive low frequencyp. 49
+5.3 Checking / adjusting the neutral positions of the travel pumpp. 58
Fig. 1p. 58
Fig. 2p. 58
Fig. 3p. 58
Fig. 4p. 59
Fig. 5p. 59
Fig. 6p. 59
Fig. 7p. 59
+5.4 Pressure tests in the travel circuitp. 60
Fig. 1p. 60
Fig. 2p. 60
Fig. 3p. 60
Fig. 4p. 61
+5.5 Checking / adjusting the vibrator shaft speedsp. 62
Fig. 1p. 62
Fig. 2p. 62
Fig. 3p. 62
+5.6 Pressure measurements in the vibration circuitp. 63
Fig. 1p. 63
Fig. 2p. 63
+5.7 Check the leakage rate of the vibration motorp. 64
Fig. 1p. 64
Fig. 2p. 64
Fig. 3p. 64
+5.8 Pressure test in steering circuitp. 65
Fig. 1p. 65
Fig. 2p. 65
Fig. 3p. 65
Fig. 4p. 66
+Fig. 5p. 66
6 Flushing and bleedingp. 67
+6.1 Special tools for flushingp. 68
+Fig. 1p. 68
1. Filling and filtering unit with oil bagp. 68
2. Filter elementp. 68
+Fig. 2p. 68
3. Flushing filter (S connection)p. 68
4. Filter element 1mp. 68
5. Flushing hose 20S – 25S (2 pieces)p. 68
6. Screw socket R1β – 25S (2 pieces)p. 68
+Fig. 3p. 68
7. Flushing filter (L connection)p. 68
8. Filter elementp. 68
9. Flushing hose 15L (2 pieces)p. 68
10. Screw socket R3/4β — 15L (2 pieces)p. 68
+Fig. 4p. 68
11. SAE-flange 1β – 20Sp. 68
12. O-ringp. 68
+Fig. 5p. 69
13. Flanged plate 1β – 25Sp. 69
14. O-ringp. 69
+Fig. 6p. 69
15. Reducing fitting 18L – 15Lp. 69
+Fig. 7p. 69
16. Reducing fitting 25S – 20Sp. 69
+Fig. 8p. 69
17. Reducing fitting 20S – 16Sp. 69
+Fig. 9p. 70
18. Connecting socket 15Lp. 70
+Fig. 10p. 70
19. Connecting socket 18Lp. 70
+Fig. 11p. 70
20. Connecting socket 16Sp. 70
+Fig. 12p. 70
21. Connecting fitting 20Sp. 70
+Fig. 13p. 71
22. Connecting fitting 25Sp. 71
+Fig. 14p. 71
23. Angular fitting 18Lp. 71
+Fig. 15p. 71
24. Elbow fitting 16Lp. 71
+Fig. 16p. 71
25. Elbow 20Sp. 71
+Fig. 17p. 72
26. Elbow 25Sp. 72
+Fig. 18p. 72
27. Pipe connection 16S – 16Sp. 72
+Fig. 19p. 72
28. Connecting hose 15Lp. 72
+6.2 Flushing – generalp. 73
Changing a componentp. 73
+Chips (abrasion) in the oilp. 73
Open and clean all components in the oil circuit, replace if necessary.p. 73
Clean all high pressure hoses in the oil circuit, replace if necessary.p. 73
If abrasion is found in the travel circuit you should also flush the vibration circuit.p. 73
If abrasion is found in the vibration circuit you should also flush the travel circuit.p. 73
+Before flushingp. 73
+Fig. 1p. 73
Change the hydraulic oil filter element (1).p. 73
+Fig. 2p. 73
Filter the tank content with the filling and filtering unit and pump it into the oil bag.p. 73
Mark all hoses and disconnect them from the hydraulic oil tank.p. 73
Clean the oil tank thoroughly from inside, if necessary remove the complete tank cover.p. 73
Reconnect all hoses.p. 73
Fill the hydraulic oil tank again with the filling and filtering unit.p. 73
+Bleedingp. 73
+Fig. 3p. 73
Always bleed closed hydraulic circuits if lines had been removed or connected.p. 73
+Servicing the flushing filter kitp. 74
+Fig. 4p. 74
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. 74
Clean hoses and connections and store the flushing kit in a clean and protected environment.p. 74
8 Flushing filter with filter element 1m (tool)p. 76
9 Elbow union (tool)p. 76
10 Reducing fitting (tool)p. 76
11 Travel pumpp. 76
12 High pressure hose (B, drum drive motor reverse)p. 76
13 High pressure hose (A, drum drive motor forward)p. 76
14 High pressure hose (B, axle motor reverse)p. 76
15 High pressure hose (A, axle motor forward)p. 76
16 High pressure hose (B, axle motor reverse)p. 76
17 High pressure port (B, drum drive motor reverse)p. 76
18 Flushing hose 25S – 20S (tool)p. 76
19 Flushing hose 25S – 20S (tool)p. 76
+6.4 Flushing the travel circuit (travel pump distribution)p. 77
+Flushing the drum drivep. 77
+Fig. 1p. 77
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. 77
2. Connect the flushing hose (6) (flushing filter outlet "OUT") to the (high pressure port 17) on the travel pump.p. 77
+Fig. 2p. 77
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. 77
Fig. 3p. 78
+Fig. 4p. 78
4. Block drums and wheels with suitable chocks.p. 78
Fig. 5p. 78
+Fig. 6p. 78
5. Start the engine and shift the travel lever to travel direction forward.p. 78
6. Perform the flushing process at various engine speeds for approx. 10 minutes.p. 78
7. Shut down the engine.p. 78
8. Reconnect the hydraulic hoses (12 and 13) to the drum drive motor.p. 78
+Fig. 7p. 79
9. Jack up the front of the machine, so that the drum can rotate freely.p. 79
10. Secure the rear wheels with chocks.p. 79
11. Pre-select the slow speed range.p. 79
Fig. 8p. 79
+Fig. 9p. 79
12. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 79
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. 79
14. Shut down the engine.p. 79
15. Remove the flushing filter and reconnect the high pressure lines.p. 79
+Flushing the axle drivep. 80
+Fig. 10p. 80
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. 80
17. Connect the flushing hose (19) (flushing filter outlet "OUT") to the (high pressure port 16) on the travel pump.p. 80
+Fig. 11p. 80
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. 80
Fig. 12p. 80
+Fig. 13p. 81
19. Block drums and wheels with suitable chocks.p. 81
Fig. 14p. 81
+Fig. 15p. 81
20. Start the engine and shift the travel lever to travel direction forward.p. 81
21. Perform the flushing process at various engine speeds for approx. 10 minutes.p. 81
22. Shut down the engine.p. 81
23. Reconnect the hydraulic hoses (14 and 15) to the axle drive motor.p. 81
+Fig. 16p. 81
24. Jack up the rear of the machine, so that the wheels can rotate freely.p. 81
25. Secure the drum with wheel chocks.p. 81
26. Pre-select the slow speed range.p. 81
Fig. 17p. 82
+Fig. 18p. 82
27. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 82
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. 82
29. Shut down the engine.p. 82
30. Remove the flushing filter and reconnect the high pressure lines.p. 82
31. Bleed the travel circuit (see corresponding chapter).p. 82
32. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.p. 82
+Fig. 19p. 82
33. Check the hydraulic oil level in the tank, fill up if necessary.p. 82
34. Check all connections for leaks with the engine running (visual inspection).p. 82
35. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting on a gradient.p. 82
36. Check all ports and connections for leak tightness (visual inspection).p. 82
8 Flushing filter with filter element 1m (tool)p. 87
9 not usedp. 87
10 Reducing fitting (tool)p. 87
11 Travel pumpp. 87
12 High pressure hose (drum drive motor reverse)p. 87
13 High pressure hose (drum drive motor forward)p. 87
14 High pressure hose (B, axle motor reverse)p. 87
15 High pressure hose (A, axle motor forward)p. 87
16 High pressure hose (B, axle motor reverse)p. 87
17 not usedp. 87
18 Flushing hose 25S – 20S (tool)p. 87
19 Flushing hose 25S – 20S (tool)p. 87
+6.6 Flushing the travel circuit (axle motor distribution)p. 88
+Flushing the drum drivep. 88
+Fig. 1p. 88
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. 88
2. Connect the flushing hose (18) (flushing filter outlet "OUT") to the (high pressure port 16) on the travel pump.p. 88
+Fig. 2p. 88
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. 88
Fig. 3p. 89
Fig. 4p. 89
+Fig. 5p. 89
4. Block drums and wheels with suitable chocks.p. 89
+Fig. 6p. 89
5. Start the engine and shift the travel lever to travel direction forward.p. 89
6. Perform the flushing process at various engine speeds for approx. 10 minutes.p. 89
7. Shut down the engine.p. 89
8. Reconnect the hydraulic hoses (12 and 13) to the drum drive motor.p. 89
+Fig. 7p. 90
9. Jack up the front of the machine, so that the drum can rotate freely.p. 90
10. Secure the rear wheels with chocks.p. 90
11. Pre-select the slow speed range.p. 90
Fig. 8p. 90
+Fig. 9p. 90
12. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 90
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. 90
14. Shut down the engine.p. 90
+Flushing the axle motorp. 91
+Fig. 10p. 91
15. Jack up the rear of the machine, so that the wheels can rotate freely.p. 91
16. Secure the drum with wheel chocks.p. 91
17. Pre-select the slow speed range.p. 91
Fig. 11p. 91
+Fig. 12p. 91
18. Start the engine, run it with maximum speed and shift the travel lever to travel direction forward.p. 91
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. 91
20. Shut down the engine.p. 91
21. Remove the flushing filter and reconnect the high pressure lines.p. 91
22. Bleed the travel circuit (see corresponding chapter).p. 91
23. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.p. 91
+Fig. 13p. 92
24. Check the hydraulic oil level in the tank, fill up if necessary.p. 92
25. Check all connections for leaks with the engine running (visual inspection).p. 92
26. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting on a gradient.p. 92
27. Check all ports and connections for leak tightness (visual inspection).p. 92
+Flushing schematic for vibration drive
1 Elbow union (tool)p. 93
2 Connecting union (tool)p. 93
3 Vibration motorp. 93
4 Vibration pumpp. 93
5 Screw socket R1 – 25S (tool)p. 93
6 Flushing hose 25S – 20S (tool)p. 93
7 Flushing hose 25S – 20S (tool)p. 93
8 Flushing filter with filter element 1m (tool)p. 93
9 SAE flange (tool)p. 93
10 High pressure hose (B, high frequency)p. 93
11 High pressure hose (A, low frequency)p. 93
+6.8 Flushing the vibration circuitp. 94
+Fig. 1p. 94
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. 94
2. Connect the flushing hose (6) (flushing filter outlet "OUT") to the (high pressure port A) on the vibration pump.p. 94
+Fig. 2p. 94
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. 94
Fig. 3p. 95
+Fig. 4p. 95
4. Block drums and wheels with suitable chocks.p. 95
Fig. 5p. 95
+Fig. 6p. 95
5. Switch on vibration with high frequency.p. 95
6. Start the engine and run it with maximum speed.p. 95
7. Flush the circuit for approx. 10 minutes, thereby switch the vibration on and off at intervals of approx. 30 seconds.p. 95
8. Shut down the engine.p. 95
9. Reconnect the hydraulic hoses (10 and 11) to the vibration motor.p. 95
+Fig. 7p. 96
10. Unscrew the fastening screws for the vibration motor and pull the motor out of the coupling.p. 96
Fig. 8p. 96
+Fig. 9p. 96
11. Start the engine and run it with maximum speed.p. 96
12. Run the flushing procedure for approx. 10 minutes. Switch the vibration on and off at intervals of approx. 30 seconds.p. 96
13. Shut down the engine.p. 96
14. Remove the flushing filter and reinstall the vibration motor.p. 96
15. Bleed the vibration circuit (see corresponding chapter).p. 96
16. After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes.p. 96
+Fig. 10p. 97
17. Check the hydraulic oil level in the tank, fill up if necessary.p. 97
18. Test drive.p. 97
19. Check all ports and connections for leak tightness (visual inspection).p. 97
+6.9 Bleeding the travel circuitp. 98
1. Install a pressure test hose to the charge pressure test port.p. 98
2. Install a pressure test hose each to the high pressure test ports.p. 98
+Fig. 1p. 98
3. Actuate the emergency stop switch.p. 98
+Fig. 2p. 98
4. Hold the open ends of the pressure test hoses (Fig. 2) into a container.p. 98
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. 98
6. Remove the pressure test hoses.p. 98
+Fig. 3p. 98
7. Unlock the emergency stop switchp. 98
+Fig. 4p. 99
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. 99
9. Pause for approx. 30 seconds and keep repeating this procedure, until the gauge shows a constant charge pressure reading.p. 99
+Fig. 5p. 99
10. Start the engine.p. 99
11. Shift the travel lever (Fig. 5) approx. 1/3 to forward direction.p. 99
12. After approx. 1 to 2 minutes shut down the engine for a minute.p. 99
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. 99
+6.10 Bleeding the vibration circuitp. 100
1. Install a pressure test hose to the charge pressure test port.p. 100
2. Install a pressure test hose each to the high pressure test ports.p. 100
+Fig. 1p. 100
3. Actuate the emergency stop switch.p. 100
+Fig. 2p. 100
4. Hold the open ends of the pressure test hoses (Fig. 2) into a container.p. 100
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. 100
6. Remove the pressure test hoses.p. 100
+Fig. 3p. 100
7. Unlock the emergency stop switchp. 100
+Fig. 4p. 101
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. 101
9. Wait for approx. 30 seconds and repeat the procedure, until the pressure gauge shows a constant charge pressure.p. 101
+Fig. 5p. 101
10. For bleeding switch on vibration with high frequency (Fig. 5).p. 101
11. Start the engine.p. 101
12. After running the engine 1 to 2 minutes pause for approx. one minute.p. 101
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. 101
1. Place the drum into the frame and align it parallel to the frame (Fig. 14).p. 458
+Fig. 15p. 458
2. Attach the side plate, insert the bolts 2 (Fig. 15) into rear and front cross-members and tighten with 463 Nm.p. 458
3. Close the screw holes with plugs (1).p. 458
+Fig. 16p. 459
4. Fasten the spacer blocks on travel and vibration motor sides with bolts 1 (Fig. 16) and nuts to the side plates.p. 459
+Fig. 17p. 459
5. Connect hydraulic hoses to the connections on travel motor and vibration motor according to the marking (Fig. 17).p. 459
+Fig. 18p. 459
6. Fasten bracket 1 (Fig. 18) for the hydraulic hoses.p. 459
+Fig. 19p. 459
7. Assemble the front scraper 2 (Fig. 19), fasten with bolts (1), washers and nuts.p. 459
8. Assemble the rear scraper (4), fasten with bolts (3), washers and nuts.p. 459
9. Observe the adjustment measurement 30-35 mmp. 459
+Fig. 20p. 460
10. Measure distance βXβ between spacer piece 1 (Fig. 20) and side plate.p. 460
11. Calculate the thickness of the compensation plates.p. 460
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. 460
+Fig. 21p. 460
13. Insert the compensation plates 4 (Fig. 21). Insert screws (1), slide on washers (3), turn on and tighten nuts (2).p. 460
14. Unscrew the screws from the welded nuts.p. 460
+15.4 Repairing the drump. 461
+Removing the travel motorp. 461
+Fig. 1p. 461
1. Attach the lifting tackle to the travel motor.p. 461
2. Unscrew all nuts (Fig. 3) from the rubber buffers.p. 461
3. Take the drive disc with the travel motor off the rubber buffers.p. 461
+Fig. 2p. 461
4. Unscrew the nuts, pull out the screws and remove the support legs (Fig. 4).p. 461
+Fig. 3p. 461
5. Attach the lifting tackle to the travel motor (Fig. 3).p. 461
+Fig. 4p. 462
6. Unscrew the bolts (Fig. 4) and separate the travel motor from the drive disc.p. 462
+Disassembling the exciter unit (travel motor side)p. 462
+Fig. 5p. 462
1. Unscrew both socket head cap screws from the flange (Fig. 5).p. 462
+Fig. 6p. 462
2. Mount bracket 1 (Fig. 10) for the lifting device to the flange.p. 462
3. Unscrew screws (2) from the flange.p. 462
+Fig. 7p. 463
4. Slide the lifting device over the bracket.p. 463
5. Force the exciter unit off with two forcing screws (Fig. 7).p. 463
+Fig. 8p. 463
6. Pull the exciter unit out of the drum (Fig. 8).p. 463
7. Take the coupling element off the coupling half.p. 463
+Disassembling the exciter unit (travel motor side)p. 463
+Fig. 9p. 463
1. Unscrew fastening screws 1 (Fig. 9) for the fan.p. 463
2. Loosen clamping screw (2).p. 463
3. Pull the coupling hub off the shaft.p. 463
+Fig. 10p. 464
4. Unscrew all other fastening screws 1 (Fig. 10) from the flange.p. 464
5. Press the flange off the flanged housing with forcing screws (2).p. 464
+Fig. 11p. 464
6. Lift the flange off the flanged housing (Fig. 11).p. 464
7. Take the O-ring out of the groove in the flanged housing.p. 464
+Fig. 12p. 464
8. Unclip the circlip from the groove in the flange (Fig. 12).p. 464
+Fig. 13p. 464
9. Press the cylinder roller bearing with forcing screws out of the flange (Fig. 13).p. 464
+Fig. 14p. 465
10. Take the exciter unit (Fig. 14) out of the flanged housing.p. 465
+Fig. 15p. 465
11. Knock the radial seal (Fig. 15) out of the flanged housing.p. 465
+Fig. 16p. 465
12. Unclip the circlip from the groove in the flanged housing (Fig. 16).p. 465
+Fig. 17p. 465
13. Press the cylinder roller bearing with forcing screws out of the flanged housing (Fig. 17).p. 465
+Fig. 18p. 466
14. Extract inner ring 1 (Fig. 18) for the radial seal and inner bearing races (2).p. 466
+Fig. 19p. 466
15. Unclip the circlip from the basic weight (Fig. 19).p. 466
+Fig. 20p. 466
16. To change shaft 1 (Fig. 20) knock out dowel pins (2 and 3) and press the shaft out of the basic weight.p. 466
+Disassembling the exciter unit (vibration motor side)p. 467
+Fig. 21p. 467
1. Unscrew fastening screw 1 (Fig. 21).p. 467
2. Take rectangular rubber buffer (2) with spacer block (3) off the side plate.p. 467
+Fig. 22p. 467
3. Unscrew fastening screws 1 (Fig. 22).p. 467
4. Force cover (2) together with the attached vibration motor off the side plate with forcing screws.p. 467
+Fig. 23p. 467
5. To change the vibration motor loosen clamping screw 1 (Fig. 23) and pull off coupling half (2).p. 467
+Fig. 24p. 468
6. Unscrew nut 1 (Fig. 24), take off conical socket (2) and conical disc (3).p. 468
7. Take the vibration motor off the cover.p. 468
+Fig. 25p. 468
8. Remove the coupling element (Fig. 25).p. 468
+Fig. 26p. 468
9. Fasten the lifting device.p. 468
10. Unscrew fastening screws 1 (Fig. 26).p. 468
+Fig. 27p. 468
11. Press the exciter unit out of the drum with forcing screws (Fig. 27).p. 468
+Fig. 28p. 469
12. Pull the exciter unit out of the drum (Fig. 28).p. 469
+Removing, dismantling the side platep. 469
+Fig. 29p. 469
1. Take off V-ring 1 (Fig. 29).p. 469
2. Unclip circlip (2).p. 469
+Fig. 30p. 469
3. Attach the disassembly device to the side plate (Fig. 30) and force off the side plate.p. 469
+Fig. 31p. 469
4. Lift the side plate of the flanged hub (Fig. 31).p. 469
+Fig. 32p. 470
5. Knock the grooved roller bearing out of the side plate (Fig. 32) and take out the spacer ring.p. 470
+Fig. 33p. 470
6. Unclip the circlip from the side plate (Fig. 33).p. 470
+Fig. 34p. 470
7. Take the mechanical seal off the flanged hub (Fig. 34).p. 470
+Dismantling the exciter unit (vibration motor side)p. 471
+Fig. 35p. 471
1. Unscrew the fastening from the coupling hub.p. 471
2. Pull coupling hub (2) off the shaft using a pulling device (Fig. 35).p. 471
+Fig. 36p. 471
3. Loosen hose clamp 1 (Fig. 36).p. 471
4. Pull coupling hub (2) off the shaft.p. 471
+Fig. 37p. 471
5. Unscrew all other fastening screws 1 (Fig. 37) and press the flanged hub off the flanged housing with forcing screws (2).p. 471
6. Take off the flanged hub.p. 471
7. Take the O-ring out of the groove in the flanged housing.p. 471
+Fig. 38p. 472
8. Unclip the circlip from the groove in the flanged hub (Fig. 38).p. 472
+Fig. 39p. 472
9. Knock the cylinder roller bearing out of the flanged hub (Fig. 39).p. 472
+Fig. 40p. 472
10. Lift the exciter unit out of the flanged housing (Fig. 40).p. 472
+Fig. 41p. 472
11. Knock the radial seal (Fig. 41) out of the flanged housing.p. 472
+Fig. 42p. 473
12. Unclip the circlip from the groove in the flanged housing (Fig. 42).p. 473
+Fig. 43p. 473
13. Press the cylinder roller bearing with forcing screws out of the flanged housing (Fig. 43).p. 473
+Fig. 44p. 473
14. Extract inner rings 1 (Fig. 44) for the radial seals and inner bearing races (2) from the shaft.p. 473
+Fig. 45p. 473
15. Unclip the circlip from the basic weight and remove the cover (Fig. 45).p. 473
+Assembling the exciter unit (vibration motor side)p. 474
+Fig. 46p. 474
1. Cool the shaft down in liquid nitrogen.p. 474
2. Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig. 46).p. 474
+Fig. 47p. 474
3. Secure shaft 1 (Fig. 47) with dowel pins (2 and 3).p. 474
+Fig. 48p. 474
4. Cool the shaft down in liquid nitrogen.p. 474
5. Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig. 48).p. 474
+Fig. 49p. 475
6. Secure shaft 2 (Fig. 49) with dowel pins (1 and 3).p. 475
+Fig. 50p. 475
7. Insert the fitting key into the keyway in the respective shaft (Fig. 50).p. 475
+Fig. 51p. 475
8. Insert the circlip into the groove in the basic weight and on the cover (Fig. 51).p. 475
+Fig. 52p. 475
9. Heat the inner bearing race up to approx. 100Λ C and press it onto the basic weight against the shoulder with the larger outer diameter forward (Fig. 52).p. 475
+Fig. 53p. 476
10. Heat the inner ring up to approx. 50Λ C and slide it onto the short shaft against the shoulder with the wider chamfer facing towards the outside (Fig. 53).p. 476
+Fig. 54p. 476
11. Heat the inner bearing race up to approx. 100Λ C and press it onto the cover against the shoulder with the larger outer diameter forward (Fig. 54).p. 476
+Fig. 55p. 476
12. Heat the inner ring up to approx. 50Λ C and slide it onto the longer shaft against the shoulder with the wider chamfer facing towards the outside (Fig. 55).p. 476
+Fig. 56p. 476
13. Press cylinder roller bearing 1 (Fig. 56) with pressing plate (2) into the flanged housing until it bottoms.p. 476
+Fig. 57p. 477
14. Insert the circlip into the groove in the flanged housing (Fig. 57).p. 477
+Fig. 58p. 477
15. Fit the new radial seal with some grease into the groove in the flanged housing (Fig. 58).p. 477
16. Fill approx. 1.2 l oil SAE-15W/40 into the flanged housing.p. 477
+Fig. 59p. 477
17. Insert the exciter unit with the longer shaft forward into the flanged housing (Fig. 59).p. 477
+Fig. 60p. 477
18. Press cylinder roller bearing 1 (Fig. 60) with pressing plate (2) into the flanged hub until it bottoms.p. 477
+Fig. 61p. 478
19. Insert the circlip into the groove in the flanged hub (Fig. 61).p. 478
+Fig. 62p. 478
20. Attach the flanged hub to the flanged housing (Fig. 62).p. 478
21. Unscrew eye bolts (1) and replace them with short screws.p. 478
22. Turn short screws (2) into the tapped bores in the flanged housing (four screws) and tighten them.p. 478
+Fig. 63p. 478
23. Apply some grease to the sealing lip of radial seal 1 (Fig. 63).p. 478
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. 478
+Fig. 64p. 478
25. Heat the coupling hub up to approx. 80 ΛC and slide it onto the shaft against the stop (Fig. 64).p. 478
+Fig. 65p. 479
26. Apply some grease to the sealing lip of radial seal 1 (Fig. 65).p. 479
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. 479
+Fig. 66p. 479
28. Cover the thread of screw 1 (Fig. 66) with a screw retention agent (e.g. Loctite CVX strong, blue, 582).p. 479
29. Slide on the new U-seal ring (2), turn in and tighten the screws.p. 479
+Fig. 67p. 479
30. Heat coupling hub 1 (Fig. 67) with marking letter βLβ up t approx. 80Λ C and slide it over the shaft against the shoulder.p. 479
31. Turn in and tighten clamping screw (2).p. 479
+Assembling and installing the side platep. 480
+Fig. 68p. 480
1. Fill grooved ball bearing 1 (Fig. 68) on both sides with grease.p. 480
2. Press the grooved ball bearing completely in using pressing plate (2).p. 480
+Fig. 69p. 480
3. Insert the circlip into the groove in the side plate (Fig. 69).p. 480
+Fig. 70p. 480
4. Apply a thick coat of grease to the spacer ring on both sides and insert it into the side plate (Fig. 70).p. 480
+Fig. 71p. 481
5. Fill grooved ball bearing 1 (Fig. 71) on one sides with grease.p. 481
6. Insert the grooved ball bearing with the grease side forward and press it completely in with pressing plate (2).p. 481
+Fig. 72p. 481
7. Insert the oiled loop-ring into the mechanical seal (Fig. 72).p. 481
8. Clean the sliding surfaces of the mechanical seal and cover them with oil.p. 481
+Fig. 73p. 481
9. Lay one half of the radial seal on the flanged hub with the sliding surface pointing up (Fig. 73).p. 481
+Fig. 74p. 481
10. Lay the second half of the mechanical seal down with the sliding face pointing down (Fig. 74).p. 481
+Fig. 75p. 482
11. Bolt the threaded section of the assembly device to the flanged hub (Fig. 75).p. 482
+Fig. 76p. 482
12. Lay the side plate on the flanged hub (Fig. 76).p. 482
+Fig. 77p. 482
13. Attach bushing 2 (Fig. 77) of the assembly device and turn on nut (1).p. 482
+Fig. 78p. 482
14. Pull the side plate with the assembly device onto the flanged hub.p. 482
+Fig. 79p. 483
15. Remove the assembly device.p. 483
16. Insert the circlip into the groove in the flanged hub (Fig. 79).p. 483
+Assembling the exciter unit (travel motor side)p. 483
+Fig. 80p. 483
1. Cool the shaft down in liquid nitrogen.p. 483
2. Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig. 80).p. 483
+Fig. 81p. 483
3. Secure shaft 1 (Fig. 81) with dowel pins (2 and 3).p. 483
+Fig. 82p. 484
4. Insert the circlip into the groove in the basic weight and on the cover (Fig. 82).p. 484
+Fig. 83p. 484
5. Heat the inner bearing race up to approx. 100Λ C and press it onto the basic weight against the shoulder with the larger outer diameter forward (Fig. 83).p. 484
+Fig. 84p. 484
6. Heat the inner ring up to approx. 50Λ C and slide it onto the shaft against the shoulder with the wider chamfer facing towards the outside (Fig. 84).p. 484
+Fig. 85p. 484
7. Heat the inner bearing race up to approx. 100Λ C and press it onto the cover against the shoulder with the larger outer diameter forward (Fig. 85).p. 484
+Fig. 86p. 485
8. Press cylinder roller bearing 1 (Fig. 86) with pressing plate (2) into the flanged housing until it bottoms.p. 485
+Fig. 87p. 485
9. Insert the circlip into the groove in the flanged housing (Fig. 87).p. 485
+Fig. 88p. 485
10. Fit the new radial seal with some grease into the groove in the flanged housing (Fig. 88).p. 485
11. Fill approx. 1.2 l oil SAE-15W/40 into the flanged housing.p. 485
+Fig. 89p. 485
12. Insert the exciter unit into the flanged housing (Fig. 89).p. 485
+Fig. 90p. 486
13. Press cylinder roller bearing 1 (Fig. 90) with pressing plate (2) into the flange until it bottoms.p. 486
+Fig. 91p. 486
14. Insert the circlip into the groove in the flange (Fig. 91).p. 486
+Fig. 92p. 486
15. Lift the flange onto the flanged housing and align it the bores (Fig. 92).p. 486
+Fig. 93p. 486
16. Turn the screws into the tapped bores of the flanged housing and tighten them (Fig. 93).p. 486
+Fig. 94p. 487
17. Apply some grease to the sealing lip of radial seal 1 (Fig. 94).p. 487
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. 487
+Fig. 95p. 487
19. Cover the thread of screw 1 (Fig. 95) with a screw retention agent (e.g. Loctite CVX strong, blue, 582).p. 487
20. Slide on the new U-seal ring (2), turn in and tighten the screws.p. 487
+Fig. 96p. 487
21. Insert the fitting key into the keyway of the shaft (Fig. 96).p. 487
+Fig. 97p. 487
22. Slide the fan with assembly disc over the shaft.p. 487
23. Heat coupling hub 1 (Fig. 97) with marking letter βRβ up to approx. 80Λ C and slide it over the shaft against the shoulder.p. 487
24. Turn in and tighten clamping screw (2).p. 487
25. Assemble the fan to the coupling hub.p. 487
+Assembling the exciter unit (travel motor side)p. 488
+Fig. 98p. 488
1. Check coupling elements, replace if necessary.p. 488
2. Insert the coupling element into the coupling hub (Fig. 98).p. 488
3. Fasten the lifting device to the exciter unit.p. 488
+Fig. 99p. 488
4. Insert the vibrator unit into the drum (Fig. 99).p. 488
Fig. 100p. 488
+Fig. 101p. 489
5. Turn in and tighten screws 2 (Fig. 101).p. 489
6. Remove bracket (1) for the lifting device.p. 489
+Fig. 102p. 489
7. Cover the thread of screws (Fig. 102) with a screw retention agent (e.g. Loctite green 270).p. 489
8. Slide on the new U-seal ring, turn in and tighten the screws.p. 489
+Installing the travel motorp. 489
+Fig. 103p. 489
1. Fasten the lifting tackle to the travel motor and attach the motor to the drive disc (Fig. 103).p. 489
+Fig. 104p. 489
2. Turn in and tighten the fastening screws (Fig. 104).p. 489
+Fig. 105p. 490
3. Mount the support leg to the travel motor, insert the screws, turn on and tighten the nuts (Fig. 105).p. 490
+Fig. 106p. 490
4. Attach the drive disc with the assembled travel motor to the rubber buffers. Turn on and tighten the nuts (Fig. 106).p. 490
+Installing the exciter unit (vibration motor side)p. 490
+Fig. 107p. 490
1. Fasten the lifting gear to the exciter unit and insert it into the drum (Fig. 107).p. 490
Fig. 108p. 491
+Fig. 109p. 491
2. Turn in and tighten screws 1 (Fig. 109).p. 491
3. Remove the lifting gear.p. 491
4. Fit cover (2) to the drum.p. 491
+Fig. 110p. 491
5. Check the end float of the exciter shafts (Fig. 110).p. 491
+Fig. 111p. 491
6. Attach disc 1 (Fig. 111), turn in and tighten the fastening screws (2).p. 491
+Fig. 112p. 492
7. Lay a new V-ring over the journal of the flanged hub (Fig. 112).p. 492
8. Fill the grooved ball bearing with grease.p. 492
+Fig. 113p. 492
9. Check coupling element, replace if necessary.p. 492
10. Insert the coupling element into the coupling hub (Fig. 113).p. 492
+Fig. 114p. 492
11. Fasten the vibration motor to the cover so that sockets 1 (Fig. 114) and ventilation bore (2) are opposite each other.p. 492
+Fig. 115p. 492
12. Slide on coupling half 2 (Fig. 115) and secure with clamping screw (1).p. 492
+Fig. 116p. 493
13. Attach the cover with the installed vibration motor, turn in and tighten the screws (Fig. 116).p. 493
+Fig. 117p. 493
14. Install rectangular rubber buffers 2 (Fig. 117) with attached spacer block (3) and screws (1) to the side plate.p. 493
+15.5 Dismantling, assembling the change- over weightsp. 494
+Dismantling the change-over weightp. 494
+Fig. 1p. 494
1. Unscrew all screws (Fig. 3).p. 494
+Fig. 2p. 494
2. Force the cover off the basic weight with forcing screws (Fig. 4).p. 494
+Fig. 3p. 494
3. Take the change-over weight out of the basic weight (Fig. 5).p. 494
+Fig. 4p. 495
4. Pull O-rings 1 and 2 (Fig. 4) out of the grooves.p. 495
+Assembling the change-over weightsp. 496
+Fig. 5p. 496
1. Install new O-rings 1 and 2 (Fig. 5) with grease.p. 496
+Fig. 6p. 496
2. Insert the change-over weight into the basic weight (Fig. 6).p. 496
+Fig. 7p. 496
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. 496
+Fig. 8p. 496
4. Attach the cover (Fig. 13), so that the raised areas are in line.p. 496
5. Turn in screws with screw retention agent (e.g. Loctite blue 243) and tighten with 120 Nm.p. 496
6. Check the end float of the shaft.p. 496
+15.6 Changing the rubber buffers and adjusting the pretensionp. 497
+Fig. 1p. 497
1. Lift the frame up by both sides, until rubber buffers and rectangular buffers are relieved of any load (Fig. 1).p. 497
2. Loosen all fastening screws.p. 497
+Fig. 2p. 497
3. Turn one screw each into the welded nuts (Fig. 2) on the spacer blocks.p. 497
+Fig. 3p. 497
4. Remove the compensation shims 1 (Fig. 3).p. 497
+Fig. 4p. 498
5. Unscrew the screws (Fig. 4) from the welded nuts.p. 498
+Fig. 5p. 498
6. Unscrew nut 1 (Fig. 3) and remove the washer.p. 498
7. Unscrew screws (2).p. 498
8. Take off rubber buffer (3).p. 498
9. Attach the new rubber buffer to the drive disc and align the bores to the tapped bores in the drum.p. 498
10. Turn in and tighten the fastening screws.p. 498
11. Assemble the washer, turn on and tighten the nut.p. 498
+Fig. 6p. 498
12. Measure distance βXβ between spacer piece and side plate (Fig. 6).p. 498
13. Calculate the thickness of the compensation plates. Nominal value: Distance βXβ + 2 mmp. 498
+Fig. 7p. 498
14. Turn in screws into each welded nut and provide sufficient space to insert the compensation plates (Fig. 7).p. 498
+Fig. 8p. 499
15. Insert the compensation shims 1 (Fig. 8).p. 499
+Fig. 9p. 499
16. Unscrew the screws (Fig. 9) from the welded nuts.p. 499
+Fig. 10p. 499
17. Tighten the fastening screws (Fig. 10).p. 499
18. Lower the frame again.p. 499
16 Oscillating articulated jointp. 501
+16.1 Special tools, oscillating articulated joint (BW177 to BW 216)p. 502
+Fig. 1p. 502
1. Pressing device for rocker bearingsp. 502
+Fig. 2p. 502
2. Pressing bushing for outer rocker bearing racep. 502
+Fig. 3p. 502
3. Pressing bushing for inner rocker bearing racep. 502
+Fig. 4p. 503
4. Guide pinp. 503
+Fig. 5p. 503
5. Clamping devicep. 503
+Fig. 6p. 503
6. Disassembly devicep. 503
+Repair overview oscillating articulated joint
1 Housingp. 505
2 Seal ringp. 505
3 Coverp. 505
4 Self-aligning bearingp. 505
5 Boltp. 505
6 Shim/supporting discp. 505
7 Belleville springsp. 505
8 Self-aligning bearingp. 505
9 Consolep. 505
10 Belleville springsp. 505
11 Shim/supporting discp. 505
12 Coverp. 505
13 Coverp. 505
14 Intermediate ringp. 505
15 Self-aligning bearingp. 505
16 Intermediate ringp. 505
17 Self-aligning bearingp. 505
18 Carrierp. 505
19 Friction bearingp. 505
20 V-ringp. 505
21 Seal ringp. 505
+16.3 Removing and installing the oscillating articulated jointp. 508
+Fig. 1p. 508
1. Jack up the frame (Fig. 1) at the back and secure it with trestles or wooden blocks.p. 508
+Fig. 2p. 508
2. Support the rear frame near the oscillating articulated joint (Fig. 2) on both sides safely with trestles or wooden blocks.p. 508
+Fig. 3p. 508
3. Fasten the lifting tackle to the front frame near the oscillating articulated joint (Fig. 3).p. 508
+Fig. 4p. 509
4. Unscrew fastening screws 1 (Fig. 4) and take off axle holder (2).p. 509
5. Knock out bearing bolt (3).p. 509
6. Retract steering cylinder (4).p. 509
+Fig. 5p. 509
7. Support the oscillating articulated joint in the middle with a suitable jack or a similar device.p. 509
8. Unscrew fastening screws 1 (Fig. 5) and take off with disc (2).p. 509
+Fig. 6p. 509
9. Unscrew nuts 3 (Fig. 6) and take off the clamping washers (2).p. 509
10. Pull out the fastening screws (1).p. 509
11. Slightly raise the front frame and lower the oscillating articulated joint to the ground.p. 509
12. Pull out the oscillating articulated joint.p. 509
+Fig. 7p. 509
13. Insert the bolt for the steering cylinder so that groove (2) is in line with tapped bores (1).p. 509
+16.4 Dismantling the oscillating articulated jointp. 510
+Fig. 1p. 510
1. Unscrew the nuts from hexagon screw 1 (Fig. 1) and pull out the hexagon screw.p. 510
2. Unscrew the screws (2) for the cover.p. 510
+Fig. 2p. 510
3. Take off the cover with Belleville springs, shim and backing disc (Fig. 2).p. 510
4. Disassemble also the cover from the opposite side.p. 510
+Fig. 3p. 510
5. Drive the console with a plastic hammer to one side against the end stop (Fig. 3).p. 510
+Fig. 4p. 511
6. Force inner race 1 (Fig. 4) of the rocker bearing off the bolt.p. 511
7. Take of supporting disc (2).p. 511
8. Drive the console to the opposite side and remove the rocker bearing in the same way.p. 511
+Fig. 5p. 511
9. Unscrew fastening screws 1 (Fig. 5).p. 511
10. Press bolt (3) out of the console with forcing screws (2).p. 511
+Fig. 6p. 511
11. Lift console 1 (Fig. 6) off housing (2).p. 511
+Fig. 7p. 511
12. Take the seal rings out of the console (Fig. 7).p. 511
+Fig. 8p. 512
13. Remove the cover from the housing.p. 512
14. Take off shims 1 (Fig. 8), backing disc (2) and Belleville springs (3).p. 512
+Fig. 9p. 512
15. Unscrew bolts 1 (Fig. 9) and take off cover (2).p. 512
+Fig. 10p. 512
16. Take the intermediate ring out of the housing (Fig. 10).p. 512
+Fig. 11p. 512
17. Place the plate 1 (Fig. 11) on the beam.p. 512
18. Attach the puller (2) to the housing (3) and separate the carrier from the rocker bearings.p. 512
+Fig. 12p. 513
19. Pull the housing off the beam (Fig. 12).p. 513
+Fig. 13p. 513
20. Drive the outer race of the friction bearing out of the housing (Fig. 13).p. 513
+Fig. 14p. 513
21. Drive the friction bearing out of the housing (Fig. 14).p. 513
+Fig. 15p. 513
22. Take seal ring 1 (Fig. 15) and V-ring (2) off the beam.p. 513
+Fig. 16p. 514
23. Check rocker bearings, if necessary press out of the housing (Fig. 16).p. 514
+16.5 Assembling the oscillating articulated jointp. 515
+Fig. 1p. 515
1. If previously disassembled, press the rocker bearing fully into the housing with a pressing mandrel (Fig. 1).p. 515
+Fig. 2p. 515
2. Slide the new V-ring on the beam against the stop with the lip facing up (Fig. 2).p. 515
+Fig. 3p. 515
3. Lay the seal ring into the beam (Fig. 3).p. 515
4. Fill the space between V-ring and seal ring with multi-purpose grease.p. 515
+Fig. 4p. 516
5. Press the friction bearing fully into the housing with the chamfered side pointing towards the outside (Fig. 4).p. 516
+Fig. 5p. 516
6. Slide the housing over the beam (Fig. 5).p. 516
+Fig. 6p. 516
7. Press the seal ring carefully towards the inside, until it sits in the recess of the housing (Fig. 6).p. 516
+Fig. 7p. 516
8. Spray the sliding surface of the outer rocker bearing race with sliding agent OKS 571.p. 516
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. 516
+Fig. 8p. 517
10. Press inner rocker bearing race 1 (Fig. 8) in until it bottoms, using pressing sleeve (2).p. 517
+Fig. 9p. 517
11. Insert the intermediate ring (Fig. 9).p. 517
+Fig. 10p. 517
12. Press inner rocker bearing race 1 (Fig. 10) in until it bottoms, using pressing sleeve (2).p. 517
+Fig. 11p. 517
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. 517
+Fig. 12p. 518
14. Press in intermediate ring 1 (Fig. 12) until it bottoms.p. 518
15. Attach cover (2) with the machined edge forward.p. 518
16. Turn in screws (3) and tighten crosswise.p. 518
+Fig. 13p. 518
17. Determine the shim thickness, for this purpose stand the cross-member on a wooden board with an Γ 18 mm bore.p. 518
18. Slide the rod of the tensioning device in from underneath, attach the plate, screw on the nut and tighten.p. 518
19. Measure the distance from housing edge to intermediate ring (Fig. 13) and write it down, e.g. 4,7 mm.p. 518
20. Remove the tensioning device.p. 518
+Fig. 14p. 519
21. Insert shim 2 (Fig. 14) of appropriate thickness and backing disc (1) into the cover.p. 519
+Fig. 15p. 519
22. Lay the Belleville springs into the cover with the curvature pointing down (Fig. 15).p. 519
+Fig. 16p. 519
23. Assemble cover 2 (Fig. 16) with Belleville springs, shim and backing disc.p. 519
24. Turn in screws (1) and tighten crosswise.p. 519
+Fig. 17p. 519
25. Press the new sealing rings into the respective groove in the console (Fig. 17).p. 519
+Fig. 18p. 520
26. Lift console 1 (Fig. 18) over the housing (2).p. 520
+Fig. 19p. 520
27. Turn four guide pins into the housing bores (Fig. 19).p. 520
+Fig. 20p. 520
28. Slide the bolt over the guide pins (Fig. 20) and drive in until it bottoms.p. 520
Fig. 21p. 520
+Fig. 22p. 521
29. Unscrew the guide pins .p. 521
30. Turn in the screws and tighten with 75 Nm (Fig. 22).p. 521
+Fig. 23p. 521
31. Slide the backing discs over the bolt (Fig. 23).p. 521
+Fig. 24p. 521
32. Drive the inner rocker bearing race on against the end stop with the wider outer rim forward (Fig. 24).p. 521
+Fig. 25p. 521
33. Spray the sliding surface of the outer rocker bearing race with sliding agent OKS 571.p. 521
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. 521
+Fig. 26p. 522
35. Attach cover 1 (Fig. 26) to the bottom side of the console.p. 522
36. Turn in and tighten screws (2).p. 522
+Fig. 27p. 522
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. 522
+Fig. 28p. 522
38. Measure the distance from outer rocker bearing race to console surface (Fig. 28) and write it down, e.g. 3.4 mm.p. 522
39. Remove the tensioning device.p. 522
+Fig. 29p. 523
40. Insert shims 2 (Fig. 29) of appropriate thickness and backing disc (1) into the cover.p. 523
+Fig. 30p. 523
41. Lay the Belleville springs into the cover with the curvature pointing down (Fig. 30).p. 523
+Fig. 31p. 523
42. Assemble cover 1 (Fig. 31) with Belleville springs, shims and supporting discs.p. 523
43. Turn in screws (2) and tighten crosswise.p. 523
+Fig. 32p. 523
44. Insert hexagon screw 1 (Fig. 32) so that the screw head rests on the upper side of the console.p. 523
+Fig. 33p. 524
45. Assemble the washer, turn on and tighten the nut with 120 Nm (Fig. 33).p. 524
17 Suppliers documentationp. 525
+17.1 Travel pumpp. 527
Bild 34p. 528
17.2 Vibration pumpp. 617
17.3 Drum drivep. 655
17.4 Vibration motorp. 705
17.5 Axle drive motorp. 729
+17.6 Axlep. 811
+Bild 35p. 812
18 Circuit diagramsp. 933
18.1 Hydraulic diagram 581 202 03p. 935
18.2 Wiring diagram 582 702 09p. 939
18.3 Wiring diagram 582 702 29p. 975
18.4 Wiring diagram 582 702 41p. 1009
What This Manual Enables You To Do
With this BOMAG BW 211 D-4 PD-4 BW 213 D-4 PD-4 service manual PDF you can carry out complete hydraulic pressure tests on the travel and vibration circuits, adjust the neutral positions of the travel pump and vibration pump, check and set the vibrator shaft speeds, measure leakage rates on the vibration motor and drum drive motor, flush and bleed both hydraulic circuits after component replacement, and diagnose electrical faults using the wiring diagrams and fault code tables. The drum repair chapter covers removal of the travel motor, disassembly of the exciter unit on both the travel motor side and the vibration motor side, replacement of the change-over weights, and adjustment of the rubber buffer pretension. The oscillating articulated joint chapter covers dismantling and reassembly including shim thickness determination under axial preload. The engine chapter covers everything from fuel filter and water separator service through valve clearance adjustment, control piston play, compression testing, and the special tools needed for the Deutz TCD 2013 2V.
Correct procedures and tightening torques matter on these machines. The travel pump multi-function valves must be tightened to 89 Nm. The drum side plate bolts go to 463 Nm. The axle brake release screws must be turned uniformly or the brake can be damaged. Having the exact BOMAG figures in front of you avoids guesswork and prevents damage to hydraulic components, bearings, and seals.
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The manual is delivered as an instant PDF download after payment. No shipping, no waiting. You can open it on any device β laptop, tablet, or phone β and print the pages you need for the workshop. The 1,046-page file is organised with a table of contents and clear chapter numbering so you can navigate straight to the system you are working on.
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