BOMAG BW211, BW213 D-4, PD-4 single drum roller pdf service manual

Table of Contents for BOMAG-00891145-a07-EN manual

• BW 211 D-4 / PD-4
• BW 213 D-4 / PD-4
  • S/N 101 582 40 .....> S/N 101 582 41 .....> S/N 101 582 45 .....>
  • S/N 101 582 46 ....> S/N 101 582 50 ....>
• Single drum roller
  • 1 General
• 1.1 Introduction
• Safety regulations
  • Important notes
  • General
  • Precautions and codes of conduct for welding work
  • Old oils
  • Hydraulics
  • Fuels
  • Hot fuels
  • Synthetic rubber
  • Poisonous substances
  • Air conditioning system
  • Battery
  • Special safety regulations
• General repair instructions
  • General
  • Electrics
  • Battery
  • Hydraulic system
  • Air conditioning system
  • Fuel hoses
  • Gaskets and mating surfaces
  • Feather keys and keyways
  • Ball and roller bearings
  • Screws and nuts
• Tightening torques
  • 2 Technical data
• Technische Daten
  • Fig. 10
  • Fig. 11
• 2.2 Maintenance chart
• 2.3 Table of fuels and lubricants
• 2.4 Fuels and lubricants
  • Engine oil
  • Fuels
  • Coolant, anti-freeze agent
  • Hydraulic oil
  • Oil for drive axle
  • Lubrication grease
• 4.1 Special tools, tests and adjustments
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
  • Fig. 5
  • Fig. 6
  • Fig. 7
  • Fig. 8
  • Fig. 9
  • Fig. 10
  • Fig. 11
  • Fig. 12
  • Fig. 13
  • Fig. 14
• 4.2 Checking the rotation speeds
  • Fig. 1
  • Check the engine speed
  • Checking the exciter shaft speed
• 4.3 Checking / adjusting the neutral positions of the travel pump
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
  • Fig. 5
  • Fig. 6
  • Fig. 7
• 4.4 Pressure tests in the travel circuit
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
• 4.5 Checking / adjusting the vibrator shaft speeds
  • Fig. 1
  • Fig. 2
  • Fig. 3
• 4.6 Pressure measurements in the vibration circuit
  • Fig. 1
  • Fig. 2
• 4.7 Check the leakage rate of the vibration motor
  • Fig. 1
  • Fig. 2
  • Fig. 3
• 4.8 Pressure test in steering circuit
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
  • Fig. 5
• 5.1 Special tools for flushing
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
  • Fig. 5
  • Fig. 6
  • Fig. 7
  • Fig. 8
  • Fig. 9
  • Fig. 10
  • Fig. 11
  • Fig. 12
  • Fig. 13
  • Fig. 14
  • Fig. 15
  • Fig. 16
  • Fig. 17
  • Fig. 18
  • Fig. 19
• 5.2 Flushing - general
  • Changing a component
  • Chips (abrasion) in the oil
  • Before flushing
  • Bleeding
  • Servicing the flushing filter kit
• Flushing schematic travel circuit (distribution travel pump)
  • 1 Elbow union (tool)
  • 2 Connecting union (tool)
  • 3 Drum drive motor
  • 4 Axle motor
  • 5 Screw socket R1 - 25S (tool)
  • 6 Flushing hose 25S - 20S (tool)
  • 7 Flushing hose 25S - 20S (tool)
  • 8 Flushing filter with filter element 1m (tool)
  • 9 Elbow union (tool)
  • 10 Reducing fitting (tool)
  • 11 Travel pump
  • 12 High pressure hose (B, drum drive motor reverse)
  • 13 High pressure hose (A, drum drive motor forward)
  • 14 High pressure hose (B, axle motor reverse)
  • 15 High pressure hose (A, axle motor forward)
  • 16 High pressure hose (B, axle motor reverse)
  • 17 High pressure port (B, drum drive motor reverse)
  • 18 Flushing hose 25S - 20S (tool)
  • 19 Flushing hose 25S - 20S (tool)
• 5.4 Flushing the travel circuit (travel pump distribution)
  • Flushing the drum drive
  • Flushing the axle drive
• Flushing schematic travel circuit (distribution axle motor)
  • 1 Elbow union (tool)
  • 2 Connecting union (tool)
  • 3 Drum drive motor
  • 4 Axle motor
  • 5 Screw socket R1 - 25S (tool)
  • 6 not used
  • 7 not used
  • 8 Flushing filter with filter element 1m (tool)
  • 9 not used
  • 10 Reducing fitting (tool)
  • 11 Travel pump
  • 12 High pressure hose (drum drive motor reverse)
  • 13 High pressure hose (drum drive motor forward)
  • 14 High pressure hose (B, axle motor reverse)
  • 15 High pressure hose (A, axle motor forward)
  • 16 High pressure hose (B, axle motor reverse)
  • 17 not used
  • 18 Flushing hose 25S - 20S (tool)
  • 19 Flushing hose 25S - 20S (tool)
• 5.6 Flushing the travel circuit (axle motor distribution)
  • Flushing the drum drive
  • Flushing the axle motor
• Flushing schematic for vibration drive
  • 1 Elbow union (tool)
  • 2 Connecting union (tool)
  • 3 Vibration motor
  • 4 Vibration pump
  • 5 Screw socket R1 - 25S (tool)
  • 6 Flushing hose 25S - 20S (tool)
  • 7 Flushing hose 25S - 20S (tool)
  • 8 Flushing filter with filter element 1m (tool)
  • 9 SAE flange (tool)
  • 10 High pressure hose (B, high frequency)
  • 11 High pressure hose (A, low frequency)
• 5.8 Flushing the vibration circuit
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
  • Fig. 5
  • Fig. 6
  • Fig. 7
  • Fig. 8
  • Fig. 9
  • Fig. 10
• 5.9 Bleeding the travel circuit
  • 1. Install a pressure test hose to the charge pressure test port.
  • 2. Install a pressure test hose each to the high pressure test ports.
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
  • Fig. 5
• 5.10 Bleeding the vibration circuit
  • 1. Install a pressure test hose to the charge pressure test port.
  • 2. Install a pressure test hose each to the high pressure test ports.
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
  • Fig. 5
  • 6.1 Understanding circuit diagrams
  • 6.2 Terminal designations
  • 6.3 Current and voltage
  • 6.4 Resistance
  • 6.5 Series / parallel connection
  • 6.6 Ohm's law
  • 6.7 Electrical energy
  • 6.8 Formula diagram
  • 6.9 Metrology
  • 6.10 Diodes, relays, fuses
  • 6.11 Batteries
  • 6.12 Three-phase generator
  • 6.13 Electric starter
  • 6.14 Telemecanique switch
  • 6.15 Inductive proximity switches
  • 6.16 Angle sensor with current output
  • 6.17 Plug connectors
  • 6.18 Deutsch plug, series DT and DTM
  • 6.19 Plugs and terminals in spring clamping technology
• 7.1 Special tools, electrics
  • Fig. 4
  • Fig. 5
  • Fig. 6
  • Fig. 7
  • Fig. 8
  • Fig. 9
  • Fig. 10
  • Fig. 11
  • Fig. 12
  • Fig. 13
  • Fig. 14
  • Fig. 15
  • Fig. 16
  • Fig. 17
  • Fig. 18
  • Fig. 19
  • Fig. 20
  • Fig. 21
  • Fig. 22
  • Fig. 23
  • Fig. 24
  • Fig. 25
  • Fig. 26
  • Fig. 27
  • Fig. 28
  • Fig. 29
  • Fig. 30
  • Fig. 31
  • Fig. 32
  • Fig. 33
  • Fig. 34
  • Fig. 35
  • Fig. 36
• 8.1 Seat contact module
  • 9 Speedometer Module
• 9.1 Speedometer module
  • Fig. 1 Speedometer module
• 10.1 Electrics BEM (BOMAG Evib-meter)
  • BOMAG Evib-meter (BEM)
• 10.2 Service Training
  • 11 Engine
• 11.1 Diesel engine, general
  • Fig. 1 Engine compartment
• 11.2 Service side
  • Fig. 1 Service side
• 11.3 Starter side
  • Fig. 1 Starter side
• 11.4 Lubrication oil circuit
  • Fig. 1 Lubrication oil circuit
• 11.5 Oil pressure switch and low oil pressure circuitry
  • Fig. 1
  • Fig. 2 Oil pressure switch
• 11.6 Check the engine oil level
  • Fig. 3
• 11.7 Changing engine oil and oil filter cartridges
  • Fig. 4
  • Fig. 5
  • Fig. 6
  • Fig. 7
• 11.8 Coolant circuit
  • Fig. 1 Coolant circuit
  • Fig. 2 Coolant filling level sensor B55
  • Fig. 3 Direct heating
• 11.9 Coolant temperature switch
  • Fig. 1 Coolant temperature switch
• 11.10 Disassembling and assembling the coolant temperature switch
  • Fig. 2 Temperature switch
  • Fig. 3 Coolant temperature switch
• 11.11 Replacing the thermostat
  • Fig. 4
  • Fig. 5
  • Fig. 6
• 11.12 Checking the thermostat in disassembled state
  • Fig. 1
  • Fig. 2
  • Fig. 3
• 11.13 Check the coolant level
  • Fig. 4
• 11.14 Change the coolant
  • Fig. 5
  • Fig. 6
  • Fig. 7
• 11.15 Clean the cooling fins on engine and hydraulic oil cooler
  • Cleaning with compressed air
  • Cleaning with cold cleansing agent
• 11.16 Three-phase generator
  • Fig. 1
• 11.17 Fuel supply
  • Fig. 1 Fuel supply
  • Fig. 1
  • Fig. 2 Observe the direction of flow
• 11.18 Injection system
  • Single cylinder plug-in injection pumps
• 11.19 Injection pump replacement during service
  • Disassembly
• 11.20 Injection valve replacement during service
  • Removal
  • Installation
• 11.21 Checking / repairing injection valves
  • Check the injection valves
  • Adjusting tze opening pressure on the injection valve
  • Leak test
  • Rattle and spray pattern test
• 11.22 Fuel filter
  • Fig. 1 Fuel pre-filter
  • Function
  • Fuel pre-heating (option)
  • Draining off water or fuel
  • Perform
  • Main fuel filter
• 11.23 Check, clean the water separator
  • Fig. 3
• 11.24 Change the fuel pre-filter cartridge
  • Fig. 4
  • Fig. 5
  • Fig. 6
  • Fig. 7
• 11.25 Change the fuel filter cartridge
  • Fig. 8
  • Fig. 9
• 11.26 Checking the compression
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
• 11.27 Check, adjust the valve clearance
  • Valve adjustment schematic
  • Checking the valve clearance
  • Adjusting the valve clearance
• 11.28 Boost fuel solenoid valve
  • Fig. 1
• 11.29 Engine shut-down solenoid
  • Fig. 1
• 11.30 Air filter, differential pressure switch
  • Fig. 1
• 11.31 Service the combustion air filter
  • Fig. 2
  • Fig. 3
  • Removing the main filter element
  • Cleaning the main filter element
  • Cleaning the dust bowl
  • Installing the main filter element
  • Changing the safety filter element
• 11.32 Heating flange on engine
  • Fig. 1 Heating flange
  • Fig. 2 Heating flange (R19) with hose socket BF4M 2012 C
  • Fig. 3
  • Fig. 4 Coolant temperature sensor
  • Fig. 5 Heating flange function diagram
• 11.33 Checking the heating flange control
  • Fig. 1 Monitoring board (A15)
• 11.34 Electric throttle control
  • Fig. 1 Engine solenoid
  • Fig. 2 Throttle control switch
  • Fig. 3 Electric circuit of solenoid
  • Fig. 4
  • Fig. 5
• 11.35 Engine monitoring
  • Fig. 1
  • Fig. 2 Differential pressure switch
  • Fig. 3 Sensor water separator
  • Fig. 4 Oil pressure switch
  • Fig. 5 Coolant temperature switch
  • Fig. 6 Coolant temperature switch
  • Fig. 7 Emergency stop switch
• 11.36 Engine
• 11.37 Special tools, Deutz engine (BFM 2012)
  • 12 Air conditioning system
• 12.1 Physical basics
  • Fig. 1
  • Fig. 2
  • Pressure and boiling point
• 12.2 Refrigerant R134a
  • Environmental aspects
• 12.3 Compressor oil / refrigeration oil
• 12.4 Working principle of the air conditioning system
  • Fig. 1 Principle sketch of an air conditioning system
• 12.5 Monitoring devices
  • Fig. 2 Monitoring chain consisting of:
• 12.6 Description of components
  • Compressor
  • Condenser
  • Dryer / filter / fluid container / inspection glass
  • Expansion valve
  • Evaporator
  • Defroster thermostat
  • Pressure switch
  • Pipes and hoses
• 12.7 Checking the compressor oil level
  • Checking the compressor oil level / refrigeration oil level
• 12.8 Checking the magnetic clutch
  • Fig. 1
  • Fig. 2 Measuring the air gap
  • Cross-section of magnetic clutch
• 12.9 Inspection and maintenance work
• 12.10 Checking, replacing the refrigerant compressor V-belt
  • Check the V-belt
  • Tighten the V-belt.
  • Changing the V-belt
• 12.11 Service the air conditioning
  • Cleaning the condenser
  • Checking the refrigerant level
  • Checking the moisture level of the drying agent
  • Checking the condition of the drier/collector unit
• 12.12 Drying and evacuation
• 12.13 Emptying in case of repair
• 12.14 Leak test
  • Fig. 1 Electronic leak tester
  • Fig. 2 Soap bubble test
• 12.15 Filling instructions
  • Fig. 1
  • Filling instructions
• 12.16 Trouble shooting in refrigerant circuit, basic principles
  • Basic principles
  • Overheating
  • Supercooling
• 12.17 Trouble shooting, refrigerant circuit diagram
  • Fig. 1 Refrigerant circuit diagram
• 12.18 Trouble shooting procedure
  • Procedure
• 12.20 Heating control / air conditioning control
  • 13 Replacing the cab window panes
  • Fig. 1
  • Fig. 1
  • Fig. 2
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
  • Fig. 5
  • Fig. 6
  • Fig. 7
  • Fig. 8
  • Fig. 9
  • Fig. 10
  • Fig. 11
  • Fig. 12
  • Fig. 13
  • Fig. 14
• 14.1 Special tools, drum, single drum rollers
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
  • Fig. 5
  • Fig. 6
  • Fig. 7
• Repair overview for drum
  • 1 Drum
  • 2 Cylinder roller bearing
  • 3 Coupling
  • 4 Vibration motor
  • 5 Rear shell
  • 6 Grooved ball bearing
  • 7 Spacer block
  • 8 Rectangular rubber buffer
  • 9 Side plate
  • 10 Spacer ring
  • 11 Grooved ball bearing
  • 12 Mechanical seal
  • 13 Flanged hub
  • 14 Vibrator shaft
  • 15 Coupling
  • 16 Vibrator shaft
  • 17 Change-over weight
  • 18 Cylinder roller bearing
  • 19 Basic weight
  • 20 Flanged housing
  • 21 Flange
  • 22 Cylinder roller bearing
  • 23 Rear shell
• 14.3 Removing and installing the drum
  • Fig. 1
  • Fig. 2
  • Removing the drum
  • Installing the drum
• 14.4 Repairing the drum
  • Removing the travel motor
  • Disassembling the exciter unit (travel motor side)
  • Disassembling the exciter unit (travel motor side)
  • Disassembling the exciter unit (vibration motor side)
  • Removing, dismantling the side plate
  • Dismantling the exciter unit (vibration motor side)
  • Assembling the exciter unit (vibration motor side)
  • Assembling and installing the side plate
  • Assembling the exciter unit (travel motor side)
  • Assembling the exciter unit (travel motor side)
  • Installing the travel motor
  • Installing the exciter unit (vibration motor side)
• 14.5 Dismantling, assembling the change- over weights
  • Dismantling the change-over weight
  • Assembling the change-over weights
• 14.6 Changing the rubber buffers and adjusting the pretension
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
  • Fig. 5
  • Fig. 6
  • Fig. 7
  • Fig. 8
  • Fig. 9
  • Fig. 10
• 15.1 Special tools
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
  • Fig. 5
  • Fig. 6
• Repair overview oscillating articulated joint
  • 1 Housing
  • 2 Seal ring
  • 3 Rear shell
  • 4 Self-aligning bearing
  • 5 Bolt
  • 6 Shim/supporting disc
  • 7 Belleville springs
  • 8 Self-aligning bearing
  • 9 Console
  • 10 Belleville springs
  • 11 Shim/supporting disc
  • 12 Rear shell
  • 13 Rear shell
  • 14 Intermediate ring
  • 15 Self-aligning bearing
  • 16 Intermediate ring
  • 17 Self-aligning bearing
  • 18 Beam
  • 19 Friction bearing
  • 20 V-ring
  • 21 Seal ring
• 15.3 Removing and installing the oscillating articulated joint
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
  • Fig. 5
  • Fig. 6
  • Fig. 7
• 15.4 Dismantling the oscillating articulated joint
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
  • Fig. 5
  • Fig. 6
  • Fig. 7
  • Fig. 8
  • Fig. 9
  • Fig. 10
  • Fig. 11
  • Fig. 12
  • Fig. 13
  • Fig. 14
  • Fig. 15
  • Fig. 16
• 15.5 Assembling the oscillating articulated joint
  • Fig. 1
  • Fig. 2
  • Fig. 3
  • Fig. 4
  • Fig. 5
  • Fig. 6
  • Fig. 7
  • Fig. 8
  • Fig. 9
  • Fig. 10
  • Fig. 11
  • Fig. 12
  • Fig. 13
  • Fig. 14
  • Fig. 15
  • Fig. 16
  • Fig. 17
  • Fig. 18
  • Fig. 19
  • Fig. 20
  • Fig. 21
  • Fig. 22
  • Fig. 23
  • Fig. 24
  • Fig. 25
  • Fig. 26
  • Fig. 27
  • Fig. 28
  • Fig. 29
  • Fig. 30
  • Fig. 31
  • Fig. 32
  • Fig. 33
• 16.1 Travel pump series 90R
• 16.2 Travel drive series 51
• 16.3 Vibration pump 42R 041
• 16.4 Vibration motor A10FM
• 16.5 MS/MSE 02 ..... 18
• 16.6 Axle DANA 192
  • 17 Circuit diagrams
• 17.1 Wiring diagram
• 17.2 Wiring diagram
  • Wiring diagram 582 701 97 from serial number
• 17.3 Wiring diagram
• 17.4 Hydraulic diagram