Bomag BW 211 D-4 PD-4 BW 213 D-4 PD-4 Single Drum Roller Service Manual – PDF DOWNLOAD

Bomag BW 211 D-4 PD-4 BW 213 D-4 PD-4 Single Drum Roller Service Manual – PDF DOWNLOAD

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Bomag BW 211 D-4 PD-4 BW 213 D-4 PD-4 Single Drum Roller Service Manual – PDF DOWNLOAD

Language : English
Pages : 996
Downloadable : Yes
File Type : PDF
Size: 105 MB

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Bomag BW 211 D-4 PD-4 BW 213 D-4 PD-4 Single Drum Roller Service Manual – PDF DOWNLOAD

S/N 101 583 09 ….> S/N 101 583 10 ….>
S/N 101 583 08 ….> S/N 101 583 13 ….>

1.1Introduction:

• This manual is intended to support expert mechanics in efficient repair and maintenance work. Whoever wants to do repair work himself should have been sufficiently trained and posses profound expert knowledge, he should limit his work only to those parts and components which will not affect the safety of the vehicle or the passengers. It is highly recommended to have repairs to critical systems, such as steering, brakes and travel drive, sole carried out by a BOMAG workshop. Untrained persons should NEVER UNTERTAKE SUCH REPAIR WORK.
• The repair instructions describe the removal or dismantling and assembly of components and assembly groups. The repair of disassembled assembly groups is described as far as this makes sense with respect to available tools and spare parts supply and as far as it can be understood by a skilled mechanic.

Documentation:

For the BOMAG machines described in this training manual the following documentation is additionally available:
1Operating and maintenance instructions
2Spare parts catalogue
3Wiring diagram*
4Hydraulic diagram*
5Service Information

You should only use genuine BOMAG spare parts.

• Spare parts needed for repairs can be taken from the spare parts catalogue for the machine.
• This manual is not subject of any updating service; we would therefore like to draw your
  attention to the additionally published “technical service information”.
• In case of a new release all necessary changes will be included.
• In the course of technical development we reserve the right for technical modifications without prior notification.
• Information and illustrations in this manual must not be reproduced and distributed, nor must they be used for the purpose of competition. All rights according to the copyright law remain expressly reserved.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Bomag BW 211 D-4 PD-4 BW 213 D-4 PD-4 Single Drum Roller Service Manual - PDF DOWNLOAD

BW 211 D-4 / PD-4 1
BW 213 D-4 / PD-4 1
S/N 101 583 09 > S/N 101 583 10 > 1
S/N 101 583 08 > S/N 101 583 13 > 1
Single drum roller 1
1 General 7
1 1 Introduction 8
Safety regulations 9
Important notes 9
General 9
Precautions and codes of conduct for welding work 9
Old oils 10
Hydraulics 10
Fuels 11
Hot fuels 11
Synthetic rubber 11
Poisonous substances 11
Engine 11
Air conditioning system 12
Battery 12
Special safety regulations 13
General repair instructions 14
General 14
Electrics 14
Battery 15
Hydraulic system 16
Air conditioning system 17
Fuel hoses 18
Fig 1 18
Gaskets and mating surfaces 19
Fig 2 19
Fig 3 19
Feather keys and keyways 20
Fig 4 20
Ball and roller bearings 20
Fig 5 20
Fig 6 21
Screws and nuts 21
Fig 7 Identification of screws 22
Fig 8 Identification of nuts 22
Fig 9 Identification of nuts in clock system 23
Tightening torques 24
2 Technical data 29
Technische Daten 0
Fig 10 34
Fig 11 36
2 2 Maintenance chart 38
2 3 Table of fuels and lubricants 40
2 4 Fuels and lubricants 40
Engine oil 40
Fig 12 41
Fuels 41
Coolant, anti-freeze agent 42
Hydraulic oil 42
Oil for drive axle 43
Lubrication grease 43
3 Connection overview 45
Connection overview 0
Fig 1 Travel pump 46
1 Control solenoid, high frequency 47
2 Control solenoid, low frequency 47
3 Multi-function valve 400 bar (boost check and pressure relief valve), travel system 47
4 Connection, charge pressure to brake solenoid valve, travel speed range selection and charge oil supply for vibration pump 47
5 Multi-function valve 400 bar (boost check and pressure relief valve), travel system 47
6 Setscrew, mechanical neutral position 47
7 Connection L, leak oil connection to vibration pump 47
8 Lever, travel control 47
9 Pilot pressure test port 47
10 High pressure port B, high pressure reverse 47
11 Charge pressure relief valve, 26 bar 47
12 Adjustment screw, low frequency 47
13 Connection L2, leak oil to tank 47
14 Pressure test port MB, high frequency 47
15 High pressure test port MA, low frequency 47
16 High pressure port A, low frequency 47
17 High pressure port B, high frequency 47
18 Charge pump, internal 47
19 Connection L2, to drum drive motor (flushing) 47
20 Adjustment screw, high frequency 47
21 Connection D, charge pressure to filter 47
22 Multi function valve 345 bar (boost check and pressure relief valve), vibration drive high frequency 47
23 Connection S, suction line charge pump from hydraulic oil tank 47
24 Multi function valve 345 bar (boost check and pressure relief valve), vibration drive low frequency 47
25 Charge pressure relief valve, vibration pump (blocked) 47
26 Connection E, charge oil from travel pump 47
27 Connection L1, leak oil connection to travel pump 47
28 Pressure test port MB, high pressure reverse 47
29 Charge oil from filter 47
30 Pressure test port MA, high pressure forward 47
31 High pressure port A, high pressure forward 47
32 Setscrew, mechanical neutral position, vibration 47
33 Leak oil connection D, leak oil from axle drive motor 47
34 Leak oil connection A, leak oil from travel pump 47
35 Leak oil connection G, leak oil from drum drive motor 47
36 Leak oil connection F, leak oil from vibration motor 47
37 Radiator inlet 47
4 Tests and adjustments 49
4 1 Special tools, tests and adjustments 50
Fig 1 50
Fig 2 50
Fig 3 50
Fig 4 50
Fig 5 51
Fig 6 51
Fig 7 51
Fig 8 51
Fig 9 52
Fig 10 52
Fig 11 52
Fig 12 52
Fig 13 53
Fig 14 53
4 2 Checking the rotation speeds 54
Fig 1 54
Check the engine speed 54
Fig 2 54
Checking the exciter shaft speed 55
Fig 3 55
4 3 Checking / adjusting the neutral positions of the travel pump 56
Fig 1 56
Fig 2 56
Fig 3 56
Fig 4 57
Fig 5 57
Fig 6 57
Fig 7 57
4 4 Pressure tests in the travel circuit 58
Fig 1 58
Fig 2 58
Fig 3 58
Fig 4 59
4 5 Checking / adjusting the vibrator shaft speeds 60
Fig 1 60
Fig 2 60
Fig 3 60
4 6 Pressure measurements in the vibration circuit 61
Fig 1 61
Fig 2 61
4 7 Check the leakage rate of the vibration motor 62
Fig 1 62
Fig 2 62
Fig 3 62
4 8 Pressure test in steering circuit 63
Fig 1 63
Fig 2 63
Fig 3 63
Fig 4 64
Fig 5 64
5 Flushing and bleeding 65
5 1 Special tools for flushing 66
Fig 1 66
1 Filling and filtering unit with oil bag 66
2 Filter element 66
Fig 2 66
3 Flushing filter (S connection) 66
4 Filter element 1m 66
5 Flushing hose 20S - 25S (2 pieces) 66
6 Screw socket R1“ - 25S (2 pieces) 66
Fig 3 66
7 Flushing filter (L connection) 66
8 Filter element 66
9 Flushing hose 15L (2 pieces) 66
10 Screw socket R3/4“ -- 15L (2 pieces) 66
Fig 4 66
11 SAE-flange 1“ - 20S 66
12 O-ring 66
Fig 5 67
13 Flanged plate 1“ - 25S 67
14 O-ring 67
Fig 6 67
15 Reducing fitting 18L - 15L 67
Fig 7 67
16 Reducing fitting 25S - 20S 67
Fig 8 67
17 Reducing fitting 20S - 16S 67
Fig 9 68
18 Connecting socket 15L 68
Fig 10 68
19 Connecting socket 18L 68
Fig 11 68
20 Connecting socket 16S 68
Fig 12 68
21 Connecting fitting 20S 68
Fig 13 69
22 Connecting fitting 25S 69
Fig 14 69
23 Angular fitting 18L 69
Fig 15 69
24 Elbow fitting 16L 69
Fig 16 69
25 Elbow 20S 69
Fig 17 70
26 Elbow 25S 70
Fig 18 70
27 Pipe connection 16S - 16S 70
Fig 19 70
28 Connecting hose 15L 70
5 2 Flushing - general 71
Changing a component 71
Chips (abrasion) in the oil 71
l Open and clean all components in the oil circuit, replace if necessary 71
l Clean all high pressure hoses in the oil circuit, replace if necessary 71
l If abrasion is found in the travel circuit you should also flush the vibration circuit 71
l If abrasion is found in the vibration circuit you should also flush the travel circuit 71
Before flushing 71
Fig 1 71
l Change the hydraulic oil filter element (1) 71
Fig 2 71
l Filter the tank content with the filling and filtering unit and pump it into the oil bag 71
l Mark all hoses and disconnect them from the hydraulic oil tank 71
l Clean the oil tank thoroughly from inside, if necessary remove the complete tank cover 71
l Reconnect all hoses 71
l Fill the hydraulic oil tank again with the filling and filtering unit 71
Bleeding 71
Fig 3 71
l Always bleed closed hydraulic circuits if lines had been removed or connected 71
Servicing the flushing filter kit 72
Fig 4 72
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 72
l Clean hoses and connections and store the flushing kit in a clean and protected environment 72
Flushing schematic travel circuit (distribution travel pump) 0
1 Elbow union (tool) 74
2 Connecting union (tool) 74
3 Drum drive motor 74
4 Axle motor 74
5 Screw socket R1 - 25S (tool) 74
6 Flushing hose 25S - 20S (tool) 74
7 Flushing hose 25S - 20S (tool) 74
8 Flushing filter with filter element 1m (tool) 74
9 Elbow union (tool) 74
10 Reducing fitting (tool) 74
11 Travel pump 74
12 High pressure hose (B, drum drive motor reverse) 74
13 High pressure hose (A, drum drive motor forward) 74
14 High pressure hose (B, axle motor reverse) 74
15 High pressure hose (A, axle motor forward) 74
16 High pressure hose (B, axle motor reverse) 74
17 High pressure port (B, drum drive motor reverse) 74
18 Flushing hose 25S - 20S (tool) 74
19 Flushing hose 25S - 20S (tool) 74
5 4 Flushing the travel circuit (travel pump distribution) 75
Flushing the drum drive 75
Fig 1 75
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") 75
2 Connect the flushing hose (6) (flushing filter outlet "OUT") to the (high pressure port 17) on the travel pump 75
Fig 2 75
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 75
Fig 3 76
Fig 4 76
4 Block drums and wheels with suitable chocks 76
Fig 5 76
Fig 6 76
5 Start the engine and shift the travel lever to travel direction forward 76
6 Perform the flushing process at various engine speeds for approx 10 minutes 76
7 Shut down the engine 76
8 Reconnect the hydraulic hoses (12 and 13) to the drum drive motor 76
Fig 7 77
9 Jack up the front of the machine, so that the drum can rotate freely 77
10 Secure the rear wheels with chocks 77
11 Pre-select the slow speed range 77
Fig 8 77
Fig 9 77
12 Start the engine, run it with maximum speed and shift the travel lever to travel direction forward 77
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 77
14 Shut down the engine 77
15 Remove the flushing filter and reconnect the high pressure lines 77
Flushing the axle drive 78
Fig 10 78
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") 78
17 Connect the flushing hose (19) (flushing filter outlet "OUT") to the (high pressure port 16) on the travel pump 78
Fig 11 78
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 78
Fig 12 78
Fig 13 79
19 Block drums and wheels with suitable chocks 79
Fig 14 79
Fig 15 79
20 Start the engine and shift the travel lever to travel direction forward 79
21 Perform the flushing process at various engine speeds for approx 10 minutes 79
22 Shut down the engine 79
23 Reconnect the hydraulic hoses (14 and 15) to the axle drive motor 79
Fig 16 79
24 Jack up the rear of the machine, so that the wheels can rotate freely 79
25 Secure the drum with wheel chocks 79
26 Pre-select the slow speed range 79
Fig 17 80
Fig 18 80
27 Start the engine, run it with maximum speed and shift the travel lever to travel direction forward 80
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 80
29 Shut down the engine 80
30 Remove the flushing filter and reconnect the high pressure lines 80
31 Bleed the travel circuit (see corresponding chapter) 80
32 After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes 80
Fig 19 80
33 Check the hydraulic oil level in the tank, fill up if necessary 80
34 Check all connections for leaks with the engine running (visual inspection) 80
35 Perform a test drive, load the travel system in forward and reverse, e g by driving uphill or starting on a gradient 80
36 Check all ports and connections for leak tightness (visual inspection) 80
Flushing schematic travel circuit (distribution axle motor) 0
1 Elbow union (tool) 85
2 Connecting union (tool) 85
3 Drum drive motor 85
4 Axle motor 85
5 Screw socket R1 - 25S (tool) 85
6 not used 85
7 not used 85
8 Flushing filter with filter element 1m (tool) 85
9 not used 85
10 Reducing fitting (tool) 85
11 Travel pump 85
12 High pressure hose (drum drive motor reverse) 85
13 High pressure hose (drum drive motor forward) 85
14 High pressure hose (B, axle motor reverse) 85
15 High pressure hose (A, axle motor forward) 85
16 High pressure hose (B, axle motor reverse) 85
17 not used 85
18 Flushing hose 25S - 20S (tool) 85
19 Flushing hose 25S - 20S (tool) 85
5 6 Flushing the travel circuit (axle motor distribution) 86
Flushing the drum drive 86
Fig 1 86
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") 86
2 Connect the flushing hose (18) (flushing filter outlet "OUT") to the (high pressure port 16) on the travel pump 86
Fig 2 86
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 86
Fig 3 87
Fig 4 87
Fig 5 87
4 Block drums and wheels with suitable chocks 87
Fig 6 87
5 Start the engine and shift the travel lever to travel direction forward 87
6 Perform the flushing process at various engine speeds for approx 10 minutes 87
7 Shut down the engine 87
8 Reconnect the hydraulic hoses (12 and 13) to the drum drive motor 87
Fig 7 88
9 Jack up the front of the machine, so that the drum can rotate freely 88
10 Secure the rear wheels with chocks 88
11 Pre-select the slow speed range 88
Fig 8 88
Fig 9 88
12 Start the engine, run it with maximum speed and shift the travel lever to travel direction forward 88
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 88
14 Shut down the engine 88
Flushing the axle motor 89
Fig 10 89
15 Jack up the rear of the machine, so that the wheels can rotate freely 89
16 Secure the drum with wheel chocks 89
17 Pre-select the slow speed range 89
Fig 11 89
Fig 12 89
18 Start the engine, run it with maximum speed and shift the travel lever to travel direction forward 89
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 89
20 Shut down the engine 89
21 Remove the flushing filter and reconnect the high pressure lines 89
22 Bleed the travel circuit (see corresponding chapter) 89
23 After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes 89
Fig 13 90
24 Check the hydraulic oil level in the tank, fill up if necessary 90
25 Check all connections for leaks with the engine running (visual inspection) 90
26 Perform a test drive, load the travel system in forward and reverse, e g by driving uphill or starting on a gradient 90
27 Check all ports and connections for leak tightness (visual inspection) 90
Flushing schematic for vibration drive 0
1 Elbow union (tool) 91
2 Connecting union (tool) 91
3 Vibration motor 91
4 Vibration pump 91
5 Screw socket R1 - 25S (tool) 91
6 Flushing hose 25S - 20S (tool) 91
7 Flushing hose 25S - 20S (tool) 91
8 Flushing filter with filter element 1m (tool) 91
9 SAE flange (tool) 91
10 High pressure hose (B, high frequency) 91
11 High pressure hose (A, low frequency) 91
5 8 Flushing the vibration circuit 92
Fig 1 92
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") 92
2 Connect the flushing hose (6) (flushing filter outlet "OUT") to the (high pressure port A) on the vibration pump 92
Fig 2 92
3 Take the vibration motor out of the hydraulic circuit by joining the high pressure hoses (10 and 11) on the vibration motor together 92
Fig 3 93
Fig 4 93
4 Block drums and wheels with suitable chocks 93
Fig 5 93
Fig 6 93
5 Switch on vibration with high frequency 93
6 Start the engine and run it with maximum speed 93
7 Flush the circuit for approx 10 minutes, thereby switch the vibration on and off at intervals of approx 30 seconds 93
8 Shut down the engine 93
9 Reconnect the hydraulic hoses (10 and 11) to the vibration motor 93
Fig 7 94
10 Unscrew the fastening screws for the vibration motor and pull the motor out of the coupling 94
Fig 8 94
Fig 9 94
11 Start the engine and run it with maximum speed 94
12 Run the flushing procedure for approx 10 minutes Switch the vibration on and off at intervals of approx 30 seconds 94
13 Shut down the engine 94
14 Remove the flushing filter and reinstall the vibration motor 94
15 Bleed the vibration circuit (see corresponding chapter) 94
16 After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes 94
Fig 10 95
17 Check the hydraulic oil level in the tank, fill up if necessary 95
18 Test drive 95
19 Check all ports and connections for leak tightness (visual inspection) 95
5 9 Bleeding the travel circuit 96
1 Install a pressure test hose to the charge pressure test port 96
2 Install a pressure test hose each to the high pressure test ports 96
Fig 1 96
3 Actuate the emergency stop switch 96
Fig 2 96
4 Hold the open ends of the pressure test hoses (Fig 2) into a container 96
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 96
6 Remove the pressure test hoses 96
Fig 3 96
7 Unlock the emergency stop switch 96
Fig 4 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 97
9 Pause for approx 30 seconds and keep repeating this procedure, until the gauge shows a constant charge pressure reading 97
Fig 5 97
10 Start the engine 97
11 Shift the travel lever (Fig 5) approx 1/3 to forward direction 97
12 After approx 1 to 2 minutes shut down the engine for a minute 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 97
5 10 Bleeding the vibration circuit 98
1 Install a pressure test hose to the charge pressure test port 98
2 Install a pressure test hose each to the high pressure test ports 98
Fig 1 98
3 Actuate the emergency stop switch 98
Fig 2 98
4 Hold the open ends of the pressure test hoses (Fig 2) into a container 98
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 98
6 Remove the pressure test hoses 98
Fig 3 98
7 Unlock the emergency stop switch 98
Fig 4 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 99
9 Wait for approx 30 seconds and repeat the procedure, until the pressure gauge shows a constant charge pressure 99
Fig 5 99
10 For bleeding switch on vibration with high frequency (Fig 5) 99
11 Start the engine 99
12 After running the engine 1 to 2 minutes pause for approx one minute 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 99
6 Fundamental electrics 101
6 1 Understanding circuit diagrams 102
Fig 6 Table of contents 102
Fig 7 Function groups 103
Fig 8 Current paths 104
Fig 9 List of components 104
Fig 10 Graphic symbol 105
Fig 11 Graphic symbol 105
6 2 Terminal designations 106
6 3 Current and voltage 110
General 110
Voltage 110
Fig 1 110
Fig 2 110
Current 111
Fig 3 Circuit 111
Types of current 111
Fig 1 Direct current (D C ) 111
Fig 2 Alternating current (A C ) 111
Fig 3 Pulsating direct current 111
Fig 4 PWM 112
Fig 5 CAN 113
6 4 Resistance 114
Resistance and voltage drop 114
Fig 1 Various size resistors 114
Fig 2 Potentiometer, infinitely adjustable resistor 114
Unnecessary resistances 114
Fig 1 Screw-type terminals 114
Fig 2 Spring clamps 114
Fig 3 115
Fig 4 Balistol oil 115
Fig 5 115
6 5 Series / parallel connection 116
Fig 1 Series connection 116
Fig 2 116
Fig 3 Parallel connection 117
Fig 4 117
6 6 Ohm's law 118
Fig 1 118
6 7 Electrical energy 118
Fig 1 118
6 8 Formula diagram 119
Fig 1 Formula diagram 119
6 9 Metrology 120
Test lamps 120
Fig 1 Test lamp 120
Fig 2 Diode test lamp 120
Multimeter 120
Fig 1 Multimeter 120
Fig 2 Voltage measurement 121
Fig 3 Current measurement 121
Clip-on measuring instrument 121
Fig 1 Clip-on measuring instrument 121
Magnet tester 122
Fig 1 Magnet tester 122
6 10 Diodes, relays, fuses 122
Diodes 122
Fig 1 122
Fig 2 Marking of the cathode 122
Fig 3 Diode circuitry 123
Fig 4 LED 123
Relays 124
Fig 1 Relays 124
Fig 2 Relay circuitry 124
Fuses 124
Fig 1 124
6 11 Batteries 125
Fig 1 125
Fig 2 125
Fig 3 Reading the acid level 126
Fig 4 Battery and generator tester 126
Fig 5 Charge condition 127
6 12 Three-phase generator 128
General 128
Fig 6 Rotor with claw poles 128
Fig 7 Stator with 3 windings 129
Fig 8 3-phase current 129
Fig 9 Regulator with diode plate and rectifier diodes 130
Checking the generator 131
Fig 10 Rotor 131
Fig 11 Stator 131
Fig 12 132
Fig 13 132
Fig 14 133
Fig 15 133
Fig 16 133
Fig 17 133
6 13 Electric starter 135
Fig 1 Electric starter 135
Fig 2 Switching position during engagement 136
Fig 3 Switching position during starting 136
6 14 Telemecanique switch 138
Fig 1 Terminal designations 138
Fig 2 Disassembly 139
Fig 3 Folding down the switch block 139
Fig 4 Pulling out the front element 139
Fig 5 Assembly 140
Fig 6 Observe the marks 140
Fig 7 Assemble the switch block 140
6 15 Inductive proximity switches 141
Fig 8 141
Fig 9 PNP circuitry 141
Fig 10 NPN circuitry 141
Fig 11 141
Fig 12 Circuit diagram, making contact 142
6 16 Angle sensor with current output 142
Fig 1 Sensor 142
Fig 2 Connection diagram 143
6 17 Plug connectors 143
6 18 Deutsch plug, series DT and DTM 144
General 144
Fig 3 Crimp connections 144
DT Series 144
Fig 1 DT plug connection 144
Fig 2 DT Series 144
Fig 3 Sectional drawing 144
Fig 4 145
Fig 5 146
Fig 1 DTM plug connection 147
Fig 2 DTM Series 147
Fig 3 Sectional drawing 147
Fig 4 148
Fig 5 149
6 19 Plugs and terminals in spring clamping technology 150
General 150
Fig 1 150
Fig 1 That's how it works 151
Fig 2 Connecting clamp 151
Fig 1 That's how it works 152
Fig 2 Test adapter 152
X-COM plug clamp 153
Fig 1 That's how it works 153
Fig 2 X-COM plug with measuring cable 153
Fig 3 X-COM plug plugged onto the series clamp 153
7 Special tools, electrics 155
7 1 Special tools, electrics 156
Fig 4 156
Fig 5 156
Fig 6 156
Fig 7 156
Fig 8 157
Fig 9 157
Fig 10 157
Fig 11 158
Fig 12 158
Fig 13 158
Fig 14 158
Fig 15 159
Fig 16 159
Fig 17 159
Fig 18 159
Fig 19 160
Fig 20 160
Fig 21 160
Fig 22 160
Fig 23 161
Fig 24 161
Fig 25 161
Fig 26 161
Fig 27 162
Fig 28 162
Fig 29 162
Fig 30 162
Fig 31 163
Fig 32 163
Fig 33 163
Fig 34 163
Fig 35 164
Fig 36 164
8 Electronic modules 165
8 1 Seat contact module 167
9 Speedometer Module 175
9 1 Speedometer module 176
Fig 1 Speedometer module 176
10 Service Training 179
10 1 Electrics BEM (BOMAG Evib-meter) 181
BOMAG Evib-meter (BEM) 182
10 2 Service Training 239
11 Engine 301
11 1 Diesel engine 302
Description 302
Fig 1 Engine compartment 302
Fig 2 Numbering of cylinders 302
Fig 3 Operation side 303
Fig 4 Exhaust side 304
Fig 5 Lubrication oil circuit 305
Fig 6 Fuel supply 307
Fig 7 Coolant diagram 308
11 2 Fuel filter and check valve 310
Fuel pre-filter 310
Fig 8 Fuel pre-filter 310
Main fuel filter 311
Fig 9 Main fuel filter 311
Check valve 312
Fig 10 Flow direction 312
Fig 11 Check valve 312
Work in the low pressure system 312
11 3 Check, clean the water separator 313
Fig 12 313
11 4 Change the fuel pre-filter cartridge 313
Fig 13 313
Fig 14 313
Fig 15 314
Fig 16 314
11 5 Change the fuel filter cartridge 314
Fig 17 314
Fig 18 314
11 6 Oil pressure switch and low oil pressure circuitry 315
Fig 1 315
11 7 Changing engine oil and oil filter cartridges 316
Fig 2 316
Fig 3 316
Fig 4 316
Fig 5 317
11 8 Coolant temperature switch 318
Fig 1 Coolant temperature switch 318
11 9 Disassembling and assembling the coolant temperature switch 319
Fig 2 Temperature switch 319
Fig 3 Coolant temperature switch 319
11 10 Removing and installing the thermostat 320
Fig 4 320
Fig 5 320
Fig 6 320
Fig 7 320
Fig 8 321
11 11 Checking the thermostat in disassembled state 321
Fig 1 321
Fig 2 321
Fig 3 322
11 12 Change the coolant 322
Fig 4 322
Fig 5 322
Fig 6 323
11 13 Three-phase generator 324
Fig 1 Generator 324
11 14 Checking / replacing the ribbed V-belt 325
Checking the wear limit of the ribbed V- belt 325
Fig 2 325
Changing the ribbed V-belt 325
Fig 3 325
Fig 4 326
11 15 Boost fuel solenoid valve 327
Fig 5 327
11 16 Engine shut-down solenoid 328
Fig 6 328
11 17 Air filter, differential pressure switch 329
Fig 7 329
11 18 Service the combustion air filter 330
Fig 8 330
Fig 9 330
Removing the main filter element 330
Fig 10 330
Fig 11 330
Cleaning the main filter element 331
Fig 12 331
Fig 13 331
Cleaning the dust bowl 331
Fig 14 331
Installing the main filter element 331
Changing the safety filter element 331
Fig 15 332
11 19 Heating flange on engine 332
Fig 1 Heating flange 332
Fig 2 333
Fig 3 Coolant temperature sensor 333
Fig 4 Heating flange function diagram 334
11 20 Checking the heating flange control 335
Fig 1 Monitoring board (A15) 335
11 21 Electric throttle control 336
Fig 1 Engine solenoid 336
Fig 2 Electric circuit of solenoid 336
Fig 3 337
Fig 4 337
11 22 Crankcase - disassembling and assembling the ventilation valve 337
Fig 1 337
Fig 2 337
Fig 3 338
Fig 4 338
Fig 5 338
11 23 Disassembling and assembling the starter 339
Fig 1 339
Fig 2 339
Fig 3 339
Fig 4 339
11 24 Engine monitoring 340
Fig 1 340
Fig 2 Differential pressure switch 341
Fig 3 Sensor water separator 341
Fig 4 Oil pressure switch 341
Fig 5 Coolant temperature switch 342
Fig 6 Coolant temperature switch 342
Fig 7 Emergency stop switch 342
11 25 Adjusting the valve clearance 343
Adjusting the valve clearance 343
Fig 8 343
Fig 9 343
Fig 10 343
Intake valve clearance adjustment in case of exhaust gas recirculation 344
Fig 11 344
Fig 12 344
Fig 13 344
Valve adjustment schematic 344
11 26 Adjusting the control piston play 345
Adjusting the control piston play 345
Fig 14 345
Fig 15 345
Adjustment schematic 345
11 27 Checking the compression 346
Fig 1 346
Fig 2 346
Fig 3 346
Fig 4 346
Fig 5 347
Fig 6 347
Fig 7 347
Fig 8 347
11 28 Engine 348
11 29 Special tools, Deutz engine (TCD 2013 2V) 350
12 Air conditioning system 369
12 1 Physical basics 370
Fig 1 370
Fig 2 370
Pressure and boiling point 371
Fig 3 Steam pressure curve 371
Fig 4 Pressure - Temperature Diagram 371
12 2 Refrigerant R134a 373
Environmental aspects 374
12 3 Compressor oil / refrigeration oil 374
12 4 Working principle of the air conditioning system 375
Fig 1 Principle sketch of an air conditioning system 375
12 5 Monitoring devices 375
Fig 2 Monitoring chain consisting of: 376
12 6 Description of components 376
Compressor 376
Fig 1 376
Condenser 377
Fig 1 377
Dryer / filter / fluid container / inspection glass 378
Fig 1 378
Fig 2 378
Fig 3 378
Expansion valve 379
Fig 1 379
Evaporator 380
Fig 1 380
Defroster thermostat 380
Fig 1 380
Pressure switch 381
Fig 1 381
Pipes and hoses 381
12 7 Checking the compressor oil level 382
Checking the compressor oil level / refrigeration oil level 382
Fig 1 382
Fig 2 382
12 8 Checking the magnetic clutch 383
Fig 1 383
Fig 2 Measuring the air gap 383
Cross-section of magnetic clutch 383
Fig 3 Cross-section of magnetic clutch 383
12 9 Inspection and maintenance work 384
12 10 Checking, replacing the refrigerant compressor V-belt 384
Check the V-belt 384
Fig 4 384
Tighten the V-belt 384
Fig 5 384
Changing the V-belt 385
12 11 Service the air conditioning 385
Cleaning the condenser 385
Fig 6 385
Checking the refrigerant level 385
Fig 7 386
Fig 8 386
Fig 9 386
Fig 10 386
Checking the moisture level of the drying agent 387
Fig 11 387
Checking the condition of the drier/collector unit 387
Fig 12 387
12 12 Drying and evacuation 388
12 13 Emptying in case of repair 388
12 14 Leak test 389
Fig 1 Electronic leak tester 389
Fig 2 Soap bubble test 389
12 15 Filling instructions 390
Fig 1 391
Filling instructions 392
12 16 Trouble shooting in refrigerant circuit, basic principles 393
Basic principles 393
Fig 2 Pressure gauge 393
Fig 3 Absolute pressure gauge 394
Overheating 394
Supercooling 394
Fig 1 Refrigerant circuit with t, h- diagram 396
12 17 Trouble shooting, refrigerant circuit diagram 397
Fig 1 Refrigerant circuit diagram 397
12 18 Trouble shooting procedure 398
Procedure 398
Fig 2 Flow diagram with measuring points 399
Fig 3 402
Fig 4 403
Fig 5 404
Fig 6 405
Steam table for R134a 0
12 20 Heating control / air conditioning control 413
13 Replacing the cab window panes 419
Assembly of window panes 0
Fig 1 420
1 Glass panes 420
2 Fastening element 420
3 Fixing washer and spacer 420
4 Washer 420
5 Hexagon nut, self locking 420
6 Protective cap 420
13 2 Special tools 421
Fig 1 421
1 Locking handle for fastening element 421
Fig 2 421
2 Suction lifter 421
13 3 Auxiliary materials 422
Fig 1 422
3 Cutter 422
Fig 2 422
4 Window glass bonding agent 422
Fig 3 422
5 Activator 422
Fig 4 423
6 Silicone sealant 423
13 4 Removing and installing the window pane 424
Fig 1 424
1 Pull large glass rests off the bonding strip (Fig 1) 424
Fig 2 424
2 Clean the sealing surfaces from any adhesive material (Fig 2) 424
3 Use a cutter to remove adhesive residues with glass rests 424
4 Cover places without adhesive residues with an activator 424
Fig 3 424
5 Insert the fastening element with washer into the bore in the glass pane (Fig 3) 424
Fig 4 425
6 Turn the fixing and spacer washer hand-tight onto the thread of the fastening element (Fig 4) 425
Fig 5 425
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) 425
Fig 6 425
8 Attach the suction lifter to the outside of the pane (Fig 6) 425
9 Install the window pane so that the fastening elements fit into the bores of the fastening bars 425
10 Press the glass pane against the sealing surface 425
Fig 7 425
11 Assemble the washer and the self-locking hexagon nut 425
12 Fasten the window pane to the fastening bar using a locking handle and a ring spanner (Fig 7) 425
13 Press the protective cap onto the hexagon nut 425
Fig 8 426
14 Remove the suction lifter (Fig 8) 426
Fig 9 426
15 Clean the joining edges on the window pane (Fig 9) 426
16 Mask the upper and lower contact areas to the cabin 426
Fig 10 426
17 Apply silicone sealant evenly and under pressure first to the inside joint edge (Fig 10) 426
Fig 11 426
18 Then apply silicone sealant evenly and under pressure to the outside joint edge (Fig 11) 426
Fig 12 427
19 Then spray the joints from inside and outside with water containing washing up liquid (Fig 12) 427
Fig 13 427
20 Treat the inside joint (Fig 13) 427
Fig 14 427
21 and the outside joint (Fig 14) with a scraper or a spattle 427
14 Drum 429
14 1 Special tools, drum, single drum rollers 430
Fig 1 430
1 Disassembly device for side plate 430
Fig 2 430
2 Assembly device for side plate 430
Fig 3 430
3 Assembly device for coupling hub and flanged hub 430
Fig 4 431
4 Pressing plate for cylinder roller bearing 431
Fig 5 431
5 Pressing plate for travel bearing 431
Fig 6 431
6 Pressing bushing for radial seal 431
Fig 7 431
7 Lifting device for exciter unit 431
Repair overview for drum 0
1 Drum 433
2 Cylinder roller bearing 433
3 Coupling 433
4 Vibration motor 433
5 Rear shell 433
6 Grooved ball bearing 433
7 Spacer block 433
8 Rectangular rubber buffer 433
9 Side plate 433
10 Spacer ring 433
11 Grooved ball bearing 433
12 Mechanical seal 433
13 Flanged hub 433
14 Vibrator shaft 433
15 Coupling 433
16 Vibrator shaft 433
17 Change-over weight 433
18 Cylinder roller bearing 433
19 Basic weight 433
20 Flanged housing 433
21 Flange 433
22 Cylinder roller bearing 433
23 Rear shell 433
14 3 Removing and installing the drum 440
Fig 1 440
Fig 2 440
Removing the drum 440
Fig 3 440
1 Mark the hydraulic hoses (Fig 3)on the travel motor and disconnect them from the ports 440
2 Close all hydraulic hoses and motor ports with suitable plugs 440
Fig 4 441
3 Mark the hydraulic hoses on the vibration motor (Fig 4) and disconnect them from the ports 441
4 Close all hydraulic hoses and motor ports with suitable plugs 441
Fig 5 441
5 Unscrew bolts 1 (Fig 5) and nuts and remove the front scraper (2) 441
6 Unscrew bolts 3 and nuts and remove the front scraper (4) 441
Fig 6 441
7 Support the front cross-member safely with suitable trestles or wooden blocks (Fig 6) 441
Fig 7 441
8 Support the rear cross-member safely with suitable trestles or wooden blocks (Fig 7) 441
Fig 8 442
9 Disassemble bracket 1 (Fig 8) for the hydraulic hoses 442
Fig 9 442
10 Fasten the lifting gear to the side plate on the vibration motor side 442
11 Unscrew bolts 1 (Fig 9) from the spacer blocks on vibration and travel motors 442
Fig 10 442
12 Force out plug 1 (Fig 10) and unscrew the bolts (2) from the front and rear cross-members 442
13 Take off the side plate 442
Fig 11 442
14 Fasten the lifting tackle to the drum and lift the drum carefully sideways out of the front frame (Fig 11) 442
Fig 12 443
15 Check all rubber buffers (Fig 12), replace if necessary (see corresponding chapter) 443
Fig 13 443
16 Check rectangular rubber buffers (Fig 13), replace if necessary 443
Installing the drum 443
Fig 14 443
1 Place the drum into the frame and align it parallel to the frame (Fig 14) 443
Fig 15 443
2 Attach the side plate, insert the bolts 2 (Fig 15) into rear and front cross-members and tighten with 463 Nm 443
3 Close the screw holes with plugs (1) 443
Fig 16 444
4 Fasten the spacer blocks on travel and vibration motor sides with bolts 1 (Fig 16) and nuts to the side plates 444
Fig 17 444
5 Connect hydraulic hoses to the connections on travel motor and vibration motor according to the marking (Fig 17) 444
Fig 18 444
6 Fasten bracket 1 (Fig 18) for the hydraulic hoses 444
Fig 19 444
7 Assemble the front scraper 2 (Fig 19), fasten with bolts (1), washers and nuts 444
8 Assemble the rear scraper (4), fasten with bolts (3), washers and nuts 444
9 Observe the adjustment measurement 30-35 mm 444
Fig 20 445
10 Measure distance „X“ between spacer piece 1 (Fig 20) and side plate 445
11 Calculate the thickness of the compensation plates 445
12 Turn one screw (3) into the welded nut (2) at top and bottom and open a sufficient gap to insert the compensation plates 445
Fig 21 445
13 Insert the compensation plates 4 (Fig 21) Insert screws (1), slide on washers (3), turn on and tighten nuts (2) 445
14 Unscrew the screws from the welded nuts 445
14 4 Repairing the drum 446
Removing the travel motor 446
Fig 1 446
1 Attach the lifting tackle to the travel motor 446
2 Unscrew all nuts (Fig 3) from the rubber buffers 446
3 Take the drive disc with the travel motor off the rubber buffers 446
Fig 2 446
4 Unscrew the nuts, pull out the screws and remove the support legs (Fig 4) 446
Fig 3 446
5 Attach the lifting tackle to the travel motor (Fig 3) 446
Fig 4 447
6 Unscrew the bolts (Fig 4) and separate the travel motor from the drive disc 447
Disassembling the exciter unit (travel motor side) 447
Fig 5 447
1 Unscrew both socket head cap screws from the flange (Fig 5) 447
Fig 6 447
2 Mount bracket 1 (Fig 10) for the lifting device to the flange 447
3 Unscrew screws (2) from the flange 447
Fig 7 448
4 Slide the lifting device over the bracket 448
5 Force the exciter unit off with two forcing screws (Fig 7) 448
Fig 8 448
6 Pull the exciter unit out of the drum (Fig 8) 448
7 Take the coupling element off the coupling half 448
Disassembling the exciter unit (travel motor side) 448
Fig 9 448
1 Unscrew fastening screws 1 (Fig 9) for the fan 448
2 Loosen clamping screw (2) 448
3 Pull the coupling hub off the shaft 448
Fig 10 449
4 Unscrew all other fastening screws 1 (Fig 10) from the flange 449
5 Press the flange off the flanged housing with forcing screws (2) 449
Fig 11 449
6 Lift the flange off the flanged housing (Fig 11) 449
7 Take the O-ring out of the groove in the flanged housing 449
Fig 12 449
8 Unclip the circlip from the groove in the flange (Fig 12) 449
Fig 13 449
9 Press the cylinder roller bearing with forcing screws out of the flange (Fig 13) 449
Fig 14 450
10 Take the exciter unit (Fig 14) out of the flanged housing 450
Fig 15 450
11 Knock the radial seal (Fig 15) out of the flanged housing 450
Fig 16 450
12 Unclip the circlip from the groove in the flanged housing (Fig 16) 450
Fig 17 450
13 Press the cylinder roller bearing with forcing screws out of the flanged housing (Fig 17) 450
Fig 18 451
14 Extract inner ring 1 (Fig 18) for the radial seal and inner bearing races (2) 451
Fig 19 451
15 Unclip the circlip from the basic weight (Fig 19) 451
Fig 20 451
16 To change shaft 1 (Fig 20) knock out dowel pins (2 and 3) and press the shaft out of the basic weight 451
Disassembling the exciter unit (vibration motor side) 452
Fig 21 452
1 Unscrew fastening screw 1 (Fig 21) 452
2 Take rectangular rubber buffer (2) with spacer block (3) off the side plate 452
Fig 22 452
3 Unscrew fastening screws 1 (Fig 22) 452
4 Force cover (2) together with the attached vibration motor off the side plate with forcing screws 452
Fig 23 452
5 To change the vibration motor loosen clamping screw 1 (Fig 23) and pull off coupling half (2) 452
Fig 24 453
6 Unscrew nut 1 (Fig 24), take off conical socket (2) and conical disc (3) 453
7 Take the vibration motor off the cover 453
Fig 25 453
8 Remove the coupling element (Fig 25) 453
Fig 26 453
9 Fasten the lifting device 453
10 Unscrew fastening screws 1 (Fig 26) 453
Fig 27 453
11 Press the exciter unit out of the drum with forcing screws (Fig 27) 453
Fig 28 454
12 Pull the exciter unit out of the drum (Fig 28) 454
Removing, dismantling the side plate 454
Fig 29 454
1 Take off V-ring 1 (Fig 29) 454
2 Unclip circlip (2) 454
Fig 30 454
3 Attach the disassembly device to the side plate (Fig 30) and force off the side plate 454
Fig 31 454
4 Lift the side plate of the flanged hub (Fig 31) 454
Fig 32 455
5 Knock the grooved roller bearing out of the side plate (Fig 32) and take out the spacer ring 455
Fig 33 455
6 Unclip the circlip from the side plate (Fig 33) 455
Fig 34 455
7 Take the mechanical seal off the flanged hub (Fig 34) 455
Dismantling the exciter unit (vibration motor side) 456
Fig 35 456
1 Unscrew the fastening from the coupling hub 456
2 Pull coupling hub (2) off the shaft using a pulling device (Fig 35) 456
Fig 36 456
3 Loosen hose clamp 1 (Fig 36) 456
4 Pull coupling hub (2) off the shaft 456
Fig 37 456
5 Unscrew all other fastening screws 1 (Fig 37) and press the flanged hub off the flanged housing with forcing screws (2) 456
6 Take off the flanged hub 456
7 Take the O-ring out of the groove in the flanged housing 456
Fig 38 457
8 Unclip the circlip from the groove in the flanged hub (Fig 38) 457
Fig 39 457
9 Knock the cylinder roller bearing out of the flanged hub (Fig 39) 457
Fig 40 457
10 Lift the exciter unit out of the flanged housing (Fig 40) 457
Fig 41 457
11 Knock the radial seal (Fig 41) out of the flanged housing 457
Fig 42 458
12 Unclip the circlip from the groove in the flanged housing (Fig 42) 458
Fig 43 458
13 Press the cylinder roller bearing with forcing screws out of the flanged housing (Fig 43) 458
Fig 44 458
14 Extract inner rings 1 (Fig 44) for the radial seals and inner bearing races (2) from the shaft 458
Fig 45 458
15 Unclip the circlip from the basic weight and remove the cover (Fig 45) 458
Assembling the exciter unit (vibration motor side) 459
Fig 46 459
1 Cool the shaft down in liquid nitrogen 459
2 Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig 46) 459
Fig 47 459
3 Secure shaft 1 (Fig 47) with dowel pins (2 and 3) 459
Fig 48 459
4 Cool the shaft down in liquid nitrogen 459
5 Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig 48) 459
Fig 49 460
6 Secure shaft 2 (Fig 49) with dowel pins (1 and 3) 460
Fig 50 460
7 Insert the fitting key into the keyway in the respective shaft (Fig 50) 460
Fig 51 460
8 Insert the circlip into the groove in the basic weight and on the cover (Fig 51) 460
Fig 52 460
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) 460
Fig 53 461
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) 461
Fig 54 461
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) 461
Fig 55 461
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) 461
Fig 56 461
13 Press cylinder roller bearing 1 (Fig 56) with pressing plate (2) into the flanged housing until it bottoms 461
Fig 57 462
14 Insert the circlip into the groove in the flanged housing (Fig 57) 462
Fig 58 462
15 Fit the new radial seal with some grease into the groove in the flanged housing (Fig 58) 462
16 Fill approx 1 2 l oil SAE-15W/40 into the flanged housing 462
Fig 59 462
17 Insert the exciter unit with the longer shaft forward into the flanged housing (Fig 59) 462
Fig 60 462
18 Press cylinder roller bearing 1 (Fig 60) with pressing plate (2) into the flanged hub until it bottoms 462
Fig 61 463
19 Insert the circlip into the groove in the flanged hub (Fig 61) 463
Fig 62 463
20 Attach the flanged hub to the flanged housing (Fig 62) 463
21 Unscrew eye bolts (1) and replace them with short screws 463
22 Turn short screws (2) into the tapped bores in the flanged housing (four screws) and tighten them 463
Fig 63 463
23 Apply some grease to the sealing lip of radial seal 1 (Fig 63) 463
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) 463
Fig 64 463
25 Heat the coupling hub up to approx 80 C and slide it onto the shaft against the stop (Fig 64) 463
Fig 65 464
26 Apply some grease to the sealing lip of radial seal 1 (Fig 65) 464
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) 464
Fig 66 464
28 Cover the thread of screw 1 (Fig 66) with a screw retention agent (e g Loctite CVX strong, blue, 582) 464
29 Slide on the new U-seal ring (2), turn in and tighten the screws 464
Fig 67 464
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 464
31 Turn in and tighten clamping screw (2) 464
Assembling and installing the side plate 465
Fig 68 465
1 Fill grooved ball bearing 1 (Fig 68) on both sides with grease 465
2 Press the grooved ball bearing completely in using pressing plate (2) 465
Fig 69 465
3 Insert the circlip into the groove in the side plate (Fig 69) 465
Fig 70 465
4 Apply a thick coat of grease to the spacer ring on both sides and insert it into the side plate (Fig 70) 465
Fig 71 466
5 Fill grooved ball bearing 1 (Fig 71) on one sides with grease 466
6 Insert the grooved ball bearing with the grease side forward and press it completely in with pressing plate (2) 466
Fig 72 466
7 Insert the oiled loop-ring into the mechanical seal (Fig 72) 466
8 Clean the sliding surfaces of the mechanical seal and cover them with oil 466
Fig 73 466
9 Lay one half of the radial seal on the flanged hub with the sliding surface pointing up (Fig 73) 466
Fig 74 466
10 Lay the second half of the mechanical seal down with the sliding face pointing down (Fig 74) 466
Fig 75 467
11 Bolt the threaded section of the assembly device to the flanged hub (Fig 75) 467
Fig 76 467
12 Lay the side plate on the flanged hub (Fig 76) 467
Fig 77 467
13 Attach bushing 2 (Fig 77) of the assembly device and turn on nut (1) 467
Fig 78 467
14 Pull the side plate with the assembly device onto the flanged hub 467
Fig 79 468
15 Remove the assembly device 468
16 Insert the circlip into the groove in the flanged hub (Fig 79) 468
Assembling the exciter unit (travel motor side) 468
Fig 80 468
1 Cool the shaft down in liquid nitrogen 468
2 Slide the cooled down shaft with the bores aligned into the basic weight until it bottoms (Fig 80) 468
Fig 81 468
3 Secure shaft 1 (Fig 81) with dowel pins (2 and 3) 468
Fig 82 469
4 Insert the circlip into the groove in the basic weight and on the cover (Fig 82) 469
Fig 83 469
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) 469
Fig 84 469
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) 469
Fig 85 469
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) 469
Fig 86 470
8 Press cylinder roller bearing 1 (Fig 86) with pressing plate (2) into the flanged housing until it bottoms 470
Fig 87 470
9 Insert the circlip into the groove in the flanged housing (Fig 87) 470
Fig 88 470
10 Fit the new radial seal with some grease into the groove in the flanged housing (Fig 88) 470
11 Fill approx 1 2 l oil SAE-15W/40 into the flanged housing 470
Fig 89 470
12 Insert the exciter unit into the flanged housing (Fig 89) 470
Fig 90 471
13 Press cylinder roller bearing 1 (Fig 90) with pressing plate (2) into the flange until it bottoms 471
Fig 91 471
14 Insert the circlip into the groove in the flange (Fig 91) 471
Fig 92 471
15 Lift the flange onto the flanged housing and align it the bores (Fig 92) 471
Fig 93 471
16 Turn the screws into the tapped bores of the flanged housing and tighten them (Fig 93) 471
Fig 94 472
17 Apply some grease to the sealing lip of radial seal 1 (Fig 94) 472
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) 472
Fig 95 472
19 Cover the thread of screw 1 (Fig 95) with a screw retention agent (e g Loctite CVX strong, blue, 582) 472
20 Slide on the new U-seal ring (2), turn in and tighten the screws 472
Fig 96 472
21 Insert the fitting key into the keyway of the shaft (Fig 96) 472
Fig 97 472
22 Slide the fan with assembly disc over the shaft 472
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 472
24 Turn in and tighten clamping screw (2) 472
25 Assemble the fan to the coupling hub 472
Assembling the exciter unit (travel motor side) 473
Fig 98 473
1 Check coupling elements, replace if necessary 473
2 Insert the coupling element into the coupling hub (Fig 98) 473
3 Fasten the lifting device to the exciter unit 473
Fig 99 473
4 Insert the vibrator unit into the drum (Fig 99) 473
Fig 100 473
Fig 101 474
5 Turn in and tighten screws 2 (Fig 101) 474
6 Remove bracket (1) for the lifting device 474
Fig 102 474
7 Cover the thread of screws (Fig 102) with a screw retention agent (e g Loctite green 270) 474
8 Slide on the new U-seal ring, turn in and tighten the screws 474
Installing the travel motor 474
Fig 103 474
1 Fasten the lifting tackle to the travel motor and attach the motor to the drive disc (Fig 103) 474
Fig 104 474
2 Turn in and tighten the fastening screws (Fig 104) 474
Fig 105 475
3 Mount the support leg to the travel motor, insert the screws, turn on and tighten the nuts (Fig 105) 475
Fig 106 475
4 Attach the drive disc with the assembled travel motor to the rubber buffers Turn on and tighten the nuts (Fig 106) 475
Installing the exciter unit (vibration motor side) 475
Fig 107 475
1 Fasten the lifting gear to the exciter unit and insert it into the drum (Fig 107) 475
Fig 108 476
Fig 109 476
2 Turn in and tighten screws 1 (Fig 109) 476
3 Remove the lifting gear 476
4 Fit cover (2) to the drum 476
Fig 110 476
5 Check the end float of the exciter shafts (Fig 110) 476
Fig 111 476
6 Attach disc 1 (Fig 111), turn in and tighten the fastening screws (2) 476
Fig 112 477
7 Lay a new V-ring over the journal of the flanged hub (Fig 112) 477
8 Fill the grooved ball bearing with grease 477
Fig 113 477
9 Check coupling element, replace if necessary 477
10 Insert the coupling element into the coupling hub (Fig 113) 477
Fig 114 477
11 Fasten the vibration motor to the cover so that sockets 1 (Fig 114) and ventilation bore (2) are opposite each other 477
Fig 115 477
12 Slide on coupling half 2 (Fig 115) and secure with clamping screw (1) 477
Fig 116 478
13 Attach the cover with the installed vibration motor, turn in and tighten the screws (Fig 116) 478
Fig 117 478
14 Install rectangular rubber buffers 2 (Fig 117) with attached spacer block (3) and screws (1) to the side plate 478
14 5 Dismantling, assembling the change- over weights 479
Dismantling the change-over weight 479
Fig 1 479
1 Unscrew all screws (Fig 3) 479
Fig 2 479
2 Force the cover off the basic weight with forcing screws (Fig 4) 479
Fig 3 479
3 Take the change-over weight out of the basic weight (Fig 5) 479
Fig 4 480
4 Pull O-rings 1 and 2 (Fig 4) out of the grooves 480
Assembling the change-over weights 480
Fig 5 480
1 Install new O-rings 1 and 2 (Fig 5) with grease 480
Fig 6 480
2 Insert the change-over weight into the basic weight (Fig 6) 480
Fig 7 480
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) 480
Fig 8 481
4 Attach the cover (Fig 13), so that the raised areas are in line 481
5 Turn in screws with screw retention agent (e g Loctite blue 243) and tighten with 120 Nm 481
6 Check the end float of the shaft 481
14 6 Changing the rubber buffers and adjusting the pretension 482
Fig 1 482
1 Lift the frame up by both sides, until rubber buffers and rectangular buffers are relieved of any load (Fig 1) 482
2 Loosen all fastening screws 482
Fig 2 482
3 Turn one screw each into the welded nuts (Fig 2) on the spacer blocks 482
Fig 3 482
4 Remove the compensation shims 1 (Fig 3) 482
Fig 4 483
5 Unscrew the screws (Fig 4) from the welded nuts 483
Fig 5 483
6 Unscrew nut 1 (Fig 3) and remove the washer 483
7 Unscrew screws (2) 483
8 Take off rubber buffer (3) 483
9 Attach the new rubber buffer to the drive disc and align the bores to the tapped bores in the drum 483
10 Turn in and tighten the fastening screws 483
11 Assemble the washer, turn on and tighten the nut 483
Fig 6 483
12 Measure distance „X“ between spacer piece and side plate (Fig 6) 483
13 Calculate the thickness of the compensation plates Nominal value: Distance „X“ + 2 mm 483
Fig 7 483
14 Turn in screws into each welded nut and provide sufficient space to insert the compensation plates (Fig 7) 483
Fig 8 484
15 Insert the compensation shims 1 (Fig 8) 484
Fig 9 484
16 Unscrew the screws (Fig 9) from the welded nuts 484
Fig 10 484
17 Tighten the fastening screws (Fig 10) 484
18 Lower the frame again 484
15 Oscillating articulated joint 485
15 1 Special tools 486
Fig 1 486
1 Pressing mandrel for rocker bearings 486
Fig 2 486
2 Pressing sleeve for outer race of rocker bearing 486
Fig 3 486
3 Pressing sleeve for inner race of rocker bearing 486
Fig 4 486
4 Guide journal 486
Fig 5 487
5 Clamping device 487
Fig 6 487
6 Disassembly device 487
Repair overview oscillating articulated joint 0
1 Housing 488
2 Seal ring 488
3 Rear shell 488
4 Self-aligning bearing 488
5 Bolt 488
6 Shim/supporting disc 488
7 Belleville springs 488
8 Self-aligning bearing 488
9 Console 488
10 Belleville springs 488
11 Shim/supporting disc 488
12 Rear shell 488
13 Rear shell 488
14 Intermediate ring 488
15 Self-aligning bearing 488
16 Intermediate ring 488
17 Self-aligning bearing 488
18 Beam 488
19 Friction bearing 488
20 V-ring 488
21 Seal ring 488
15 3 Removing and installing the oscillating articulated joint 491
Fig 1 491
1 Jack up the frame (Fig 1) at the back and secure it with trestles or wooden blocks 491
Fig 2 491
2 Support the rear frame near the oscillating articulated joint (Fig 2) on both sides safely with trestles or wooden blocks 491
Fig 3 491
3 Fasten the lifting tackle to the front frame near the oscillating articulated joint (Fig 3) 491
Fig 4 492
4 Unscrew fastening screws 1 (Fig 4) and take off axle holder (2) 492
5 Knock out bearing bolt (3) 492
6 Retract steering cylinder (4) 492
Fig 5 492
7 Support the oscillating articulated joint in the middle with a suitable jack or a similar device 492
8 Unscrew fastening screws 1 (Fig 5) and take off with disc (2) 492
Fig 6 492
9 Unscrew nuts 3 (Fig 6) and take off the clamping washers (2) 492
10 Pull out the fastening screws (1) 492
11 Slightly raise the front frame and lower the oscillating articulated joint to the ground 492
12 Pull out the oscillating articulated joint 492
Fig 7 492
13 Insert the bolt for the steering cylinder so that groove (2) is in line with tapped bores (1) 492
15 4 Dismantling the oscillating articulated joint 493
Fig 1 493
1 Unscrew the nuts from hexagon screw 1 (Fig 1) and pull out the hexagon screw 493
2 Unscrew the screws (2) for the cover 493
Fig 2 493
3 Take off the cover with Belleville springs, shim and backing disc (Fig 2) 493
4 Disassemble also the cover from the opposite side 493
Fig 3 493
5 Drive the console with a plastic hammer to one side against the end stop (Fig 3) 493
Fig 4 494
6 Force inner race 1 (Fig 4) of the rocker bearing off the bolt 494
7 Take of supporting disc (2) 494
8 Drive the console to the opposite side and remove the rocker bearing in the same way 494
Fig 5 494
9 Unscrew fastening screws 1 (Fig 5) 494
10 Press bolt (3) out of the console with forcing screws (2) 494
Fig 6 494
11 Lift console 1 (Fig 6) off housing (2) 494
Fig 7 494
12 Take the seal rings out of the console (Fig 7) 494
Fig 8 495
13 Remove the cover from the housing 495
14 Take off shims 1 (Fig 8), backing disc (2) and Belleville springs (3) 495
Fig 9 495
15 Unscrew bolts 1 (Fig 9) and take off cover (2) 495
Fig 10 495
16 Take the intermediate ring out of the housing (Fig 10) 495
Fig 11 495
17 Place the plate 1 (Fig 11) on the beam 495
18 Attach the puller (2) to the housing (3) and separate the carrier from the rocker bearings 495
Fig 12 496
19 Pull the housing off the beam (Fig 12) 496
Fig 13 496
20 Drive the outer race of the friction bearing out of the housing (Fig 13) 496
Fig 14 496
21 Drive the friction bearing out of the housing (Fig 14) 496
Fig 15 496
22 Take seal ring 1 (Fig 15) and V-ring (2) off the beam 496
Fig 16 497
23 Check rocker bearings, if necessary press out of the housing (Fig 16) 497
15 5 Assembling the oscillating articulated joint 498
Fig 1 498
1 If previously disassembled, press the rocker bearing fully into the housing with a pressing mandrel (Fig 1) 498
Fig 2 498
2 Slide the new V-ring on the beam against the stop with the lip facing up (Fig 2) 498
Fig 3 498
3 Lay the seal ring into the beam (Fig 3) 498
4 Fill the space between V-ring and seal ring with multi-purpose grease 498
Fig 4 499
5 Press the friction bearing fully into the housing with the chamfered side pointing towards the outside (Fig 4) 499
Fig 5 499
6 Slide the housing over the beam (Fig 5) 499
Fig 6 499
7 Press the seal ring carefully towards the inside, until it sits in the recess of the housing (Fig 6) 499
Fig 7 499
8 Spray the sliding surface of the outer rocker bearing race with sliding agent OKS 571 499
9 Press the outer rocker bearing race 1 (Fig 7) in until it bottoms with the wider outer rim forward using pressing sleeve (2) 499
Fig 8 500
10 Press inner rocker bearing race 1 (Fig 8) in until it bottoms, using pressing sleeve (2) 500
Fig 9 500
11 Insert the intermediate ring (Fig 9) 500
Fig 10 500
12 Press inner rocker bearing race 1 (Fig 10) in until it bottoms, using pressing sleeve (2) 500
Fig 11 500
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) 500
Fig 12 501
14 Press in intermediate ring 1 (Fig 12) until it bottoms 501
15 Attach cover (2) with the machined edge forward 501
16 Turn in screws (3) and tighten crosswise 501
Fig 13 501
17 Determine the shim thickness, for this purpose stand the cross-member on a wooden board with an Æ 18 mm bore 501
18 Slide the rod of the tensioning device in from underneath, attach the plate, screw on the nut and tighten 501
19 Measure the distance from housing edge to intermediate ring (Fig 13) and write it down, e g 4,7 mm 501
20 Remove the tensioning device 501
Fig 14 502
21 Insert shim 2 (Fig 14) of appropriate thickness and backing disc (1) into the cover 502
Fig 15 502
22 Lay the Belleville springs into the cover with the curvature pointing down (Fig 15) 502
Fig 16 502
23 Assemble cover 2 (Fig 16) with Belleville springs, shim and backing disc 502
24 Turn in screws (1) and tighten crosswise 502
Fig 17 502
25 Press the new sealing rings into the respective groove in the console (Fig 17) 502
Fig 18 503
26 Lift console 1 (Fig 18) over the housing (2) 503
Fig 19 503
27 Turn four guide pins into the housing bores (Fig 19) 503
Fig 20 503
28 Slide the bolt over the guide pins (Fig 20) and drive in until it bottoms 503
Fig 21 503
Fig 22 504
29 Unscrew the guide pins 504
30 Turn in the screws and tighten with 75 Nm (Fig 22) 504
Fig 23 504
31 Slide the backing discs over the bolt (Fig 23) 504
Fig 24 504
32 Drive the inner rocker bearing race on against the end stop with the wider outer rim forward (Fig 24) 504
Fig 25 504
33 Spray the sliding surface of the outer rocker bearing race with sliding agent OKS 571 504
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 504
Fig 26 505
35 Attach cover 1 (Fig 26) to the bottom side of the console 505
36 Turn in and tighten screws (2) 505
Fig 27 505
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 505
Fig 28 505
38 Measure the distance from outer rocker bearing race to console surface (Fig 28) and write it down, e g 3 4 mm 505
39 Remove the tensioning device 505
Fig 29 506
40 Insert shims 2 (Fig 29) of appropriate thickness and backing disc (1) into the cover 506
Fig 30 506
41 Lay the Belleville springs into the cover with the curvature pointing down (Fig 30) 506
Fig 31 506
42 Assemble cover 1 (Fig 31) with Belleville springs, shims and supporting discs 506
43 Turn in screws (2) and tighten crosswise 506
Fig 32 506
44 Insert hexagon screw 1 (Fig 32) so that the screw head rests on the upper side of the console 506
Fig 33 507
45 Assemble the washer, turn on and tighten the nut with 120 Nm (Fig 33) 507
16 Suppliers documentation 509
16 1 Travel pump series 90R 511
16 2 Travel drive series 51 601
16 3 Vibration pump 42R 041 683
16 4 Vibration motor A10FM 721
16 5 MS/MSE 02 18 745
16 6 Axle DANA 192 795
17 Circuit diagrams 919
17 1 Wiring diagram 921
17 2 Wiring diagram 957
17 3 Hydraulic diagram 991