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BW 213 DH-4 BVC
BW 213 DH-4 BVC with attachment plate
Variocontrol / Variocontrol+
S/N 101 583 16 1176 > S/N 101 584 12 ....
S/N 101 583 06 1083 >
S/N 101 582 12 1024 > / S/N 101 582 13 1006 >
Single drum roller
Catalogue number.
08/2012
008 916 77
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Summary of Contents for Fayat Group BOMAG BW 213 DH-4 BVC
- Page 1 Service - Manual BW 213 DH-4 BVC BW 213 DH-4 BVC with attachment plate Variocontrol / Variocontrol+ S/N 101 583 16 1176 > S/N 101 584 12 ..S/N 101 583 06 1083 > S/N 101 582 12 1024 > / S/N 101 582 13 1006 > Single drum roller Catalogue number.
- Page 2 Find manuals at https://best-manuals.com...
- Page 3 Table of Contents General 1.1 Introduction 1.2 Safety regulations 1.3 General repair instructions 1.4 Tightening torques BOMAG single drum rollers 2.1 BOMAG single drum rollers Technical data 3.1 Technical data Maintenance 4.1 General notes on maintenance 4.2 Fuels and lubricants 4.3 Table of fuels and lubricants 4.4 Running-in instructions 4.5 Maintenance table...
- Page 4 Table of Contents 6.25 Electronic control units 6.26 Checking the voltage supply for the control unit 6.27 Diagnostics concept Electronic modules 7.1 Electrics SX 7.2 Electrics MESX 7.3 Electric module A108 Engine electrics 8.1 EMR3 system components 8.2 Pin assignment of engine control EDC16 / EMR3 8.3 Rotary speed sensor for camshaft 8.4 Crankshaft speed sensor 8.5 Rail pressure sensor...
- Page 5 Table of Contents 10.3 Troubleshooting axial piston pumps 10.4 Travel motor 51 C/D 110 10.5 Vibration motor A2FM56 10.6 Trouble shooting, variable displacement axial piston motor 10.7 External gear pumps 10.8 Slewing motor 10.9 Travel circuit 10.10 Stopping the machine, operating the parking brake 10.11 Towing in case of an engine failure 10.12 Adjust the parking brake 10.13 Vibration circuit...
- Page 6 Table of Contents 16.8 Wastegate - charge pressure controller on TCD-engines 16.9 Engine problems 16.10 Check the engine oil level 16.11 Changing engine oil and oil filter cartridges 16.12 Change the fuel pre-filter cartridge 16.13 Replace the fuel filter cartridge 16.14 Check, clean the water separator 16.15 Check the coolant level 16.16 Change the coolant...
- Page 7 Table of Contents Drum 20.1 Repair overview for drum 20.2 Removing and installing the drum 20.3 Dismantling the drum 20.4 Assembling the vibrator unit 20.5 Installing the exciter unit 20.6 Changing the rubber buffers and adjusting the pretension 20.7 Special tools, drum BW 213/226 DH-4 BVC and Variocontrol Articulated joint, electric steering 21.1 Special tools 21.2 Repair overview oscillating articulated joint...
- Page 8 Table of Contents BOMAG 008 916 77 Find manuals at https://best-manuals.com...
- Page 9 1 General 008 916 77 BOMAG Find manuals at https://best-manuals.com...
- Page 10 Introduction 1.1 Introduction This manual addresses the professionally qualified personnel or the after sales service of BOMAG, and should be of help and assistance in correct and effi- cient repair and maintenance work. This manual describes the disassembly, dismantling, assembly, installation and repair of components and assemblies.
- Page 11 Safety regulations Important notes Block the articulated joint with the articulation lock. Safety regulations Use protective clothes like hard hat, safety boots These safety regulations must be read and ap- and gloves. plied by every person involved in the repair /main- tenance of this machine.
- Page 12 Safety regulations Start the extraction fan before starting work and Operation of high-voltage systems guide with the progressing work as required. Always isolate the burner when laying it down (re- Note move possible electrode residues). The rules and statutory regulations valid in the corre- Protect cables from being damaged, use cables sponding do apply in addition to the notes given here.
- Page 13 Safety regulations Fire extinguishers charged with FOAM, CO Environment or POWDER must be available wherever fuel is It is strictly prohibited to drain off oil into the soil, stored, filled in, drained off, or where work on fuel the sewer system or into natural waters. Old oil systems is performed.
- Page 14 Safety regulations Engine air conditioning system. The development of heat may cause the refrigerant to develop toxic and high- ly corrosive breakdown products. Danger Pungent smell! The toxic substances, which are re- Do not work on the fuel system while the engine is sponsible for the pungent smell, must not be in- running.
- Page 15 Safety regulations and repair work and when taking air conditioning Dispose of used filters in accordance with applica- systems into or out of service. ble environmental regulations. When performing repair and maintenance work col- Battery lect oils and fuels in suitable containers and dispose of in compliance with applicable environmental reg- Always wear goggles and protective clothing to ulations.
- Page 16 General repair instructions General Electrics General repair instructions Before removing or disassembling parts, assem- General blies, components or hoses mark these parts for Due to the fast technical development electric and easier assembly. electronic vehicle systems become more intelligent Before assembling and installing parts, assemblies and more comprehensive day by day, and can hardly or components oil or grease all movable parts or be dispensed with in hydraulic and mechanical vehicle...
- Page 17 General repair instructions Battery Plug-in connectors on control units are only dust and water tight if the mating connector is plugged Rules for the handling of batteries on! Control units must be protected against spray water, until the mating connector is finally plugged When removing a battery always disconnect the mi- nus pole before the plus pole.
- Page 18 General repair instructions Generator Starter motor Before removing the generator you must disconnect So-called jump starting (using an additional external the ground cable from the minus pole of the battery battery) without the battery connected is dangerous. while the ignition is switched off. Do not disconnect When disconnecting the cables from the poles high in- the generator while the engine is running, because ductivities (arcs, voltage peaks) may occur and de-...
- Page 19 General repair instructions Hydraulic system Perform measurements at operating temperature of the hydraulic oil (approx. 40 ¯C). After changing a component perform a high and Caution charge pressure test, if necessary check the speed Repair work on hydraulic elements shall only per- of the exciter shaft.
- Page 20 General repair instructions Air conditioning system Damaged or leaking parts of the air conditioning must not be repaired by welding or soldering, but Chemicals/ozone layer regulation must generally be replaced. The chemicals/ozone layer regulation, which became Do not fill up refrigerant, but extract existing refrig- effective on 01.12.2006, supplements the still directly erant and refill the system.
- Page 21 General repair instructions Notes on cleanliness for Common Rail If the air conditioning system had been opened for repair work, a new drier should be installed in the re- engines frigerant circuit. Special requirements with respect to cleanliness in After completion of repair work screw locking caps the fuel system do apply for commissioning, mainte- (with seals) on all valve connections service con- nance and repair work, particularly for TEIRIII engines...
- Page 22 General repair instructions Blow drying with compressed air is only permitted Do not use any previously used cleaning or testing while the fuel system is still closed. fluids for cleaning. When using steam cleaning equipment cover con- Compressed air should never be used for cleaning trol unit, cable plugs, all other electrical connections when the fuel system is open.
- Page 23 General repair instructions Fuel hoses Remove loose parts (e.g. paint scales that may have come off during assembly work) with an indus- trial vacuum cleaner or any means of extraction. Working means and tools must be cleaned before being used for work. Use only tools without dam- aged chromium coating, or tools without chromium coating.
- Page 24 General repair instructions Gaskets and mating surfaces able, you should use a plastic tube or adhesive tape to prevent the sealing lip from being damaged. Leaking sealing faces can mostly be traced back to in- correct assembly of seals and gaskets. Lubricate the outer rim (arrow 3 (Fig.
- Page 25 General repair instructions Feather keys and keyways Ball and roller bearings Caution Caution Feather keys may only be reused if they are free of Ball and roller bearings may only be reused if they damage. are free of damage and do not show any signs of wear.
- Page 26 General repair instructions Screws and nuts Check shaft and bearing housing for discolouration or other signs of movement between ball or roller Tightening torque bearing and seats. Make sure that shaft and housing are free of burrs Caution before assembling the ball or roller bearing. Tighten nuts or screws with the tightening tor- Always mark the individual parts of separable ball or ques specified in the following tables of tighten-...
- Page 27 General repair instructions Strength classes, metric screws Strength classes of metric nuts The strength classes (from 3.6 to 12.9) are specified Nuts are differentiated by three load groups. Each for all strength classes from a nominal diameter of load group has a special designation system for the 5mm.
- Page 28 General repair instructions Identification in clock system Identification of UNF-threads Fig. 10 Identification of nuts in clock system For small nuts (Fig. 10) the clock system can be used for identification. The 12 o'clock position is identified by a dot or the manufacturer's symbol.
- Page 29 General repair instructions Cotter pins Fig. 12 In places where cotter pins are used, these must be reassembled. Cotter pins must generally be renewed after disassembly. Cotter pins must be assembled as shown in the illus- tration, unless specified differently. 008 916 77 BOMAG...
- Page 30 Tightening torques The values specified in the table apply for screws: Tightening torques black oiled with surface protection A4C with surface protection DACROMET Note DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC- ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance.
- Page 31 Tightening torques Tightening torques for screws treated with anti-seizure paste OKS 240 (copper paste) Tightening torques Nm Screw dimension 10.9 12.9 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2 1036 1184 1520 M27 X 2 1263 1536 1136...
- Page 32 Tightening torques The values specified in the table apply for screws: black oiled with surface protection A4C with surface protection DACROMET Note The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks, as the metric ISO-thread, whereas Withworth has a flank of only 55°.
- Page 33 Tightening torques Tightening torques for screws with UNF thread, UNF Unified National Fine Thread Series, American Unified Fine Thread Tightening torques Nm Screw dimension 10.9 12.9 1“ - 12 1300 1600 1 1/8“ - 12 1350 1900 2300 1 1/4“ - 12 1900 2700 3200...
- Page 34 Tightening torques BOMAG 008 916 77...
- Page 35 2 BOMAG single drum rollers 008 916 77 BOMAG...
- Page 36 BOMAG single drum rollers BOMAG single drum rollers Fig. 1 BOMAG single drum rollers – state-of-the-art compaction technology and highest pro- ductivity. BOMAG single drum rollers set standards in earth compaction. All know-how and experience of the global mar- ket leader when intgo the development of this product range. The result speaks for itself: State-of-the-art com- paction technology with highest productivity, low operating costs and customized solutions for any application.
- Page 37 BOMAG single drum rollers Fig. 2 BOMAG smooth drum for universal applications Even the conventional smooth drum of the D/DH-models is full of very sensible details: The edges are bevelled in order to achieve a smooth surface. The standard polyurethane contact scrapers at front and rear ensure cleanliness.
- Page 38 BOMAG single drum rollers Fig. 4 Rock crusher drum and polygonal drum Crushing and compacting soft to meadium hard rock material is the domain of the . This type of rock crusher drum drum can completely replace mobile breakers up to soil class 6 and thus considerably reduce construction costs. is very flexible in use, because it is suitable for all types of soil and doesn't even require power polygonal drum consuming scrapers.
- Page 39 BOMAG single drum rollers Two travel systems D and DH Fig. 5 DH-drive - up to 63% gradability Here a BW 219 PDH in dam construction Even the D-variant reaches gradability values of up to 53%. With the manual SlipControl the engine power can be specifically converted into traction.
- Page 40 BOMAG single drum rollers The vibration systems. Vibration is the heart of the roller. There are two systems to choose from: Circular exciter and VARIO- CONTROL. Well known and popular: the circular exciter. Single drum rollers with circular exciters offer two amplitudes and are particularly simple to operate. Advantages at a glance: Powerful circular exciter with high compaction power Simple operation with two amplitudes...
- Page 41 BOMAG single drum rollers Outstanding power due to amplitudes of up to 2.85 mm Maximum flexibility Automatic amplitude control Indication of end of compaction Avoidance of jump operation 008 916 77 BOMAG...
- Page 42 BOMAG single drum rollers BOMAG 008 916 77...
- Page 43 3 Technical data 008 916 77 BOMAG...
- Page 44 Technical data Technical data Fig. 8 BW 213 DH-4 BVC/P Dimensions in mm 2960 2270 1500 2268 2985 6626 2130 Dimensions in inch 116.5 89.4 59.1 89.3 117.5 19.3 228.7 83.9 Weights Operating weight (CECE) with ROPS-cabin 15300 kg 33731 lbs Axle load, drum (CECE) 7600 kg 16755 lbs...
- Page 45 Technical data Steering operation hydrostatic hydrostatic Steering angle ± 35° ± 35° Oscillation angle ± 12° ± 12° Inner track radius 3494 mm 191.0 in Vibration Variocontrol Standard Standard Frequency 28 Hz 1680 vpm Amplitude 0 – 2.50 mm 0 – 0.098 in Centrifugal force 365 kN 82055 lbf...
- Page 46 Technical data Fig. 9 Dimensions in mm Dimensions in inches 2960 2270 1500 2268 2985 5808 2130 BW 213 DH-4 BVC 116.5 89.4 59.1 89.3 117.5 19.3 228.7 83.9 BW 213 DH-4 BVC Weights Operating weight (CECE) with ROPS-cabin kg (lbs) 14900 (32849) Axle load, drum (CECE) kg (lbs)
- Page 47 Technical data BW 213 DH-4 BVC Steering/oscillation angle ± ° 35/12 Inner track radius mm (in) 3494 (137.6) Vibration Variocontrol Standard Frequency Hz (vpm) 28 (1680) amplitude mm (in) 0-2.5 (0-0,098) Centrifugal force kN (lbs) 365 (82125) Tires Tire size 23.1-26/12PR Air pressure, nominal value bar (psi)
- Page 48 Technical data Fig. 10 Dimensions in mm 2960 2270 1500 2268 2985 5808 2130 Variocontrol Variocontrol Weights Operating weight (CECE) with ROPS-cabin 14900 Axle load, drum (CECE) 9400 Axle load, wheels (CECE) 5500 Static linear load kg/cm 44.1 Max. operating weight 17200 Travel characteristics Travel speed...
- Page 49 Technical data Variocontrol Vibration Variocontrol Standard Frequency Amplitude 0 – 2.50 Centrifugal force Tires Tire size 23.1-26/12PR Air pressure, nominal value Air pressure, span 0.8 – 1.4 Filling capacities motor 15.5 Fuel Hydraulic oil Coolant The right for technical modifications remains reserved 008 916 77 BOMAG...
- Page 50 Technical data Fig. 11 Dimensions in mm 2960 2270 1500 2268 2972 6626 2130 Variocontrol + Variocontrol + Weights Operating weight (CECE) with ROPS-cabin 15300 Axle load, drum (CECE) 7600 Axle load, wheels (CECE) 7700 Static linear load kg/cm 35.1 Max.
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