Bomag BW 213 DH-4 BVC BW 213 DH-4 BVC plate Variocontrol+ drum roller Service Manual 00891179 PDF

Bomag BW 213 DH-4 BVC BW 213 DH-4 BVC with attachment plate Variocontrol Variocontrol+ Single drum roller Service Manual 00891179 – PDF DOWNLOAD

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Bomag BW 213 DH-4 BVC BW 213 DH-4 BVC with attachment plate Variocontrol Variocontrol+ Single drum roller Service Manual 00891179 – PDF DOWNLOAD

Language : English
Pages : 698
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Bomag BW 213 DH-4 BVC BW 213 DH-4 BVC with attachment plate Variocontrol Variocontrol+ Single drum roller Service Manual 00891179 – PDF DOWNLOAD

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 213 DH-4 BVC BW 213 DH-4 BVC with attachment plate Variocontrol Variocontrol+ Single drum roller Service Manual 00891179 – PDF DOWNLOAD

BW 213 DH-4 BVC 1
BW 213 DH-4 BVC with attachment plate 1
Variocontrol / Variocontrol+ 1
S/N 101 583 16 1
S/N 101 583 06 1
S/N 101 582 12 S/N 101 582 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
Poisonous substances 13
Special safety regulations 13
General repair instructions 14
General 14
Electrics 14
Battery 15
Hydraulic system 16
Air conditioning system 17
Notes on cleanliness for Common Rail engines 18
Fig 1 18
Fuel hoses 20
Fig 2 20
Gaskets and mating surfaces 21
Fig 3 21
Fig 4 21
Feather keys and keyways 22
Fig 5 22
Ball and roller bearings 22
Fig 6 22
Fig 7 23
Screws and nuts 23
Fig 8 Identification of screws 24
Fig 9 Identification of nuts 24
Fig 10 Identification of nuts in clock system 25
Tightening torques 26
2 Maintenance 31
2 1 General notes on maintenance 32
Notes on the fuel system 32
Notes on the performance of the engine 32
Notes on the hydraulic system 32
Notes on the cooling system 32
2 2 Fuels and lubricants 33
Engine oil 33
Fig 11 34
Fuels 34
Coolant, anti-freeze agent 35
Hydraulic oil 35
Oil for drive axle 35
Lubrication grease 35
2 3 Table of fuels and lubricants 36
2 4 Running-in instructions 37
2 5 Maintenance chart 38
3 Technical data 41
Technical data 42
Fig 12 42
Fig 13 44
Fig 14 46
Fig 15 48
Noise value 52
Vibration value 52
4 Connection overview 53
Connection overview 0
Fig 1 54
1 Proportional valve, vibration low frequency 55
2 Proportional valve, vibration high frequency 55
3 Proportional valve, travel drive forward 55
4 Proportional valve, travel drive reverse 55
5 Multi-function valve 400 bar (boost check and pressure relief valve), travel system 55
6 Multi-function valve 400 bar (boost check and pressure relief valve), travel system 55
7 High pressure port B, reverse 55
8 High pressure port A, forward 55
9 Charge pressure relief valve, travel pump 55
10 Charge pressure (connection to travel pump 15) 55
11 Charge oil to filter 55
12 Port L2 (connection to vibration pump 24) 55
13 Pressure test port MA, high pressure forward 55
14 Pressure test port MB, high pressure reverse 55
15 Charge pressure to solenoid valve for brake and speed range selection (charge oil vibration 10) 55
16 Charge pressure test port 55
17 Multi-function valve 400 bar (boost check and pressure relief valve), vibration high frequency 55
18 Multi-function valve 400 bar (boost check and pressure relief valve), vibration low frequency 55
19 Pressure test port, vibration low frequency 55
20 Pressure test port, vibration high frequency 55
21 High pressure port, high frequency 55
22 High pressure port, low frequency 55
23 Charge pressure relief valve vibration pump 55
24 Port L2 (connection to travel pump 12) 55
25 Leak oil port (connection to thermostat housing port A) 55
26 Port S, suction line between hydraulic oil tank and charge pump (charge pump in vibration pump) 55
27 Charge pump (only in vibration pump) 55
28 Pressure test port X1/X2, travel pump, control chamber 55
29 Adjustment screw, mechanical neutral position 55
5 Tests and adjustments 57
5 1 Special tools, tests and adjustments 58
Fig 1 58
Fig 2 58
Fig 3 58
Fig 4 58
Fig 5 59
Fig 6 59
Fig 7 59
Fig 8 59
Fig 9 60
Fig 10 60
Fig 11 60
Fig 12 60
Fig 13 61
Fig 14 61
5 2 Activate service mode 62
Fig 1 62
Fig 2 62
Fig 3 62
Fig 4 63
5 3 Driving against the closed brake 64
Fig 1 64
Fig 2 64
Fig 3 64
Fig 4 65
Fig 5 65
5 4 Turn the steering against an end stop 66
Fig 1 66
Fig 2 66
Fig 3 66
Fig 4 67
Fig 5 67
5 5 Pressure tests in the travel circuit 68
Fig 1 68
Fig 2 68
Fig 3 68
Fig 4 69
5 6 Checking / adjusting the neutral positions of the travel pump 70
Fig 1 70
Fig 2 70
Fig 3 70
Fig 4 71
Fig 5 71
Fig 6 71
5 7 Pressure measurements in the vibration circuit 72
Fig 1 72
Fig 2 72
5 8 Check the leakage rate of the vibration motor 73
Fig 1 73
Fig 2 73
Fig 3 73
5 9 Pressure test in steering circuit 74
Fig 1 74
Fig 2 74
Fig 3 75
Fig 4 75
6 Flushing and bleeding 77
6 1 Special tools for flushing 78
Fig 1 78
1 Filling and filtering unit with oil bag 78
2 Filter element 78
Fig 2 78
3 Flushing filter (S connection) 78
4 Filter element 1m 78
5 Flushing hose 20S – 25S (2 pieces) 78
6 Screw socket R1“ – 25S (2 pieces) 78
Fig 3 78
7 Flushing filter (L connection) 78
8 Filter element 78
9 Flushing hose 15L (2 pieces) 78
10 Screw socket R3/4“ — 15L (2 pieces) 78
Fig 4 78
11 SAE-flange 1“ – 20S 78
12 O-ring 78
Fig 5 79
13 Flanged plate 1“ – 25S 79
14 O-ring 79
Fig 6 79
15 Reducing fitting 18L – 15L 79
Fig 7 79
16 Reducing fitting 25S – 20S 79
Fig 8 79
17 Reducing fitting 20S – 16S 79
Fig 9 80
18 Connecting socket 15L 80
Fig 10 80
19 Connecting socket 18L 80
Fig 11 80
20 Connecting socket 16S 80
Fig 12 80
21 Connecting fitting 20S 80
Fig 13 81
22 Connecting fitting 25S 81
Fig 14 81
23 Angular fitting 18L 81
Fig 15 81
24 Elbow fitting 16L 81
Fig 16 81
25 Elbow 20S 81
Fig 17 82
26 Elbow 25S 82
Fig 18 82
27 Pipe connection 16S – 16S 82
Fig 19 82
28 Connecting hose 15L 82
6 2 Flushing – general 83
Changing a component 83
Chips (abrasion) in the oil 83
Open and clean all components in the oil circuit, replace if necessary 83
Clean all high pressure hoses in the oil circuit, replace if necessary 83
If abrasion is found in the travel circuit you should also flush the vibration circuit 83
If abrasion is found in the vibration circuit you should also flush the travel circuit 83
Before flushing 83
Fig 1 83
Change the hydraulic oil filter element (1) 83
Fig 2 83
Filter the tank content with the filling and filtering unit and pump it into the oil bag 83
Mark all hoses and disconnect them from the hydraulic oil tank 83
Clean the oil tank thoroughly from inside, if necessary remove the complete tank cover 83
Reconnect all hoses 83
Fill the hydraulic oil tank again with the filling and filtering unit 83
Bleeding 83
Fig 3 83
Always bleed closed hydraulic circuits if lines had been removed or connected 83
Servicing the flushing filter kit 84
Fig 4 84
Replace the filter element of the flushing filter when the red control pin of the contamination indicator is pressed out during the filtering process 84
Clean hoses and connections and store the flushing kit in a clean and protected environment 84
Flushing schematic travel circuit (distribution travel pump) 0
1 Elbow union (tool) 86
2 Connecting union (tool) 86
3 Drum drive motor 86
4 Axle motor 86
5 Screw socket R1 – 25S (tool) 86
6 Flushing hose 25S – 20S (tool) 86
7 Flushing hose 25S – 20S (tool) 86
8 Flushing filter with filter element 1m (tool) 86
9 Elbow union (tool) 86
10 Reducing fitting (tool) 86
11 Travel pump 86
12 High pressure hose (B, drum drive motor reverse) 86
13 High pressure hose (A, drum drive motor forward) 86
14 High pressure hose (B, axle motor reverse) 86
15 High pressure hose (A, axle motor forward) 86
16 High pressure hose (B, axle motor reverse) 86
17 High pressure port (B, drum drive motor reverse) 86
18 Flushing hose 25S – 20S (tool) 86
19 Flushing hose 25S – 20S (tool) 86
6 4 Flushing the travel circuit (travel pump distribution) 87
Flushing the drum drive 87
Fig 1 87
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”) 87
2 Connect the flushing hose (6) (flushing filter outlet “OUT”) to the (high pressure port 17) on the travel pump 87
Fig 2 87
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 87
Fig 3 88
Fig 4 88
4 Block drums and wheels with suitable chocks 88
Fig 5 88
Fig 6 88
5 Start the engine and shift the travel lever to travel direction forward 88
6 Perform the flushing process at various engine speeds for approx 10 minutes 88
7 Shut down the engine 88
8 Reconnect the hydraulic hoses (12 and 13) to the drum drive motor 88
Fig 7 89
9 Jack up the front of the machine, so that the drum can rotate freely 89
10 Secure the rear wheels with chocks 89
11 Pre-select the slow speed range 89
Fig 8 89
Fig 9 89
12 Start the engine, run it with maximum speed and shift the travel lever to travel direction forward 89
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 89
14 Shut down the engine 89
15 Remove the flushing filter and reconnect the high pressure lines 89
Flushing the axle drive 90
Fig 10 90
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”) 90
17 Connect the flushing hose (19) (flushing filter outlet “OUT”) to the (high pressure port 16) on the travel pump 90
Fig 11 90
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 90
Fig 12 90
Fig 13 91
19 Block drums and wheels with suitable chocks 91
Fig 14 91
Fig 15 91
20 Start the engine and shift the travel lever to travel direction forward 91
21 Perform the flushing process at various engine speeds for approx 10 minutes 91
22 Shut down the engine 91
23 Reconnect the hydraulic hoses (14 and 15) to the axle drive motor 91
Fig 16 91
24 Jack up the rear of the machine, so that the wheels can rotate freely 91
25 Secure the drum with wheel chocks 91
26 Pre-select the slow speed range 91
Fig 17 92
Fig 18 92
27 Start the engine, run it with maximum speed and shift the travel lever to travel direction forward 92
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 92
29 Shut down the engine 92
30 Remove the flushing filter and reconnect the high pressure lines 92
31 Bleed the travel circuit (see corresponding chapter) 92
32 After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes 92
Fig 19 92
33 Check the hydraulic oil level in the tank, fill up if necessary 92
34 Check all connections for leaks with the engine running (visual inspection) 92
35 Perform a test drive, load the travel system in forward and reverse, e g by driving uphill or starting on a gradient 92
36 Check all ports and connections for leak tightness (visual inspection) 92
Flushing schematic travel circuit (distribution axle motor) 0
1 Elbow union (tool) 97
2 Connecting union (tool) 97
3 Drum drive motor 97
4 Axle motor 97
5 Screw socket R1 – 25S (tool) 97
6 not used 97
7 not used 97
8 Flushing filter with filter element 1m (tool) 97
9 not used 97
10 Reducing fitting (tool) 97
11 Travel pump 97
12 High pressure hose (drum drive motor reverse) 97
13 High pressure hose (drum drive motor forward) 97
14 High pressure hose (B, axle motor reverse) 97
15 High pressure hose (A, axle motor forward) 97
16 High pressure hose (B, axle motor reverse) 97
17 not used 97
18 Flushing hose 25S – 20S (tool) 97
19 Flushing hose 25S – 20S (tool) 97
6 6 Flushing the travel circuit (axle motor distribution) 98
Flushing the drum drive 98
Fig 1 98
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”) 98
2 Connect the flushing hose (18) (flushing filter outlet “OUT”) to the (high pressure port 16) on the travel pump 98
Fig 2 98
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 98
Fig 3 99
Fig 4 99
Fig 5 99
4 Block drums and wheels with suitable chocks 99
Fig 6 99
5 Start the engine and shift the travel lever to travel direction forward 99
6 Perform the flushing process at various engine speeds for approx 10 minutes 99
7 Shut down the engine 99
8 Reconnect the hydraulic hoses (12 and 13) to the drum drive motor 99
Fig 7 100
9 Jack up the front of the machine, so that the drum can rotate freely 100
10 Secure the rear wheels with chocks 100
11 Pre-select the slow speed range 100
Fig 8 100
Fig 9 100
12 Start the engine, run it with maximum speed and shift the travel lever to travel direction forward 100
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 100
14 Shut down the engine 100
Flushing the axle motor 101
Fig 10 101
15 Jack up the rear of the machine, so that the wheels can rotate freely 101
16 Secure the drum with wheel chocks 101
17 Pre-select the slow speed range 101
Fig 11 101
Fig 12 101
18 Start the engine, run it with maximum speed and shift the travel lever to travel direction forward 101
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 101
20 Shut down the engine 101
21 Remove the flushing filter and reconnect the high pressure lines 101
22 Bleed the travel circuit (see corresponding chapter) 101
23 After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes 101
Fig 13 102
24 Check the hydraulic oil level in the tank, fill up if necessary 102
25 Check all connections for leaks with the engine running (visual inspection) 102
26 Perform a test drive, load the travel system in forward and reverse, e g by driving uphill or starting on a gradient 102
27 Check all ports and connections for leak tightness (visual inspection) 102
Flushing schematic for vibration drive 0
1 Elbow union (tool) 103
2 Connecting union (tool) 103
3 Vibration motor 103
4 Vibration pump 103
5 Screw socket R1 – 25S (tool) 103
6 Flushing hose 25S – 20S (tool) 103
7 Flushing hose 25S – 20S (tool) 103
8 Flushing filter with filter element 1m (tool) 103
9 SAE flange (tool) 103
10 High pressure hose (B, high frequency) 103
11 High pressure hose (A, low frequency) 103
6 8 Flushing the vibration circuit 104
Fig 1 104
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”) 104
2 Connect the flushing hose (6) (flushing filter outlet “OUT”) to the (high pressure port A) on the vibration pump 104
Fig 2 104
3 Take the vibration motor out of the hydraulic circuit by joining the high pressure hoses (10 and 11) on the vibration motor together 104
Fig 3 105
Fig 4 105
4 Block drums and wheels with suitable chocks 105
5 Switch on vibration with high frequency 105
6 Start the engine and run it with maximum speed 105
7 Flush the circuit for approx 10 minutes, thereby switch the vibration on and off at intervals of approx 30 seconds 105
8 Shut down the engine 105
9 Reconnect the hydraulic hoses (10 and 11) to the vibration motor 105
Fig 7 106
10 Unscrew the fastening screws for the vibration motor and pull the motor out of the coupling 106
Fig 8 106
Fig 9 106
11 Start the engine and run it with maximum speed 106
12 Run the flushing procedure for approx 10 minutes Switch the vibration on and off at intervals of approx 30 seconds 106
13 Shut down the engine 106
14 Remove the flushing filter and reinstall the vibration motor 106
15 Bleed the vibration circuit (see corresponding chapter) 106
16 After completing the bleeding process circulate the tank content with the filtering unit for another 15 minutes 106
Fig 10 107
17 Check the hydraulic oil level in the tank, fill up if necessary 107
18 Test drive 107
19 Check all ports and connections for leak tightness (visual inspection) 107
6 9 Bleeding the travel circuit 108
1 Install a pressure test hose to the charge pressure test port 108
2 Install a pressure test hose each to the high pressure test ports 108
Fig 1 108
3 Actuate the emergency stop switch 108
Fig 2 108
4 Hold the open ends of the pressure test hoses (Fig 2) into a container 108
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 108
6 Remove the pressure test hoses 108
Fig 3 108
7 Unlock the emergency stop switch 108
Fig 4 109
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 109
9 Pause for approx 30 seconds and keep repeating this procedure, until the gauge shows a constant charge pressure reading 109
Fig 5 109
10 Start the engine 109
11 Shift the travel lever (Fig 5) approx 1/3 to forward direction 109
12 After approx 1 to 2 minutes shut down the engine for a minute 109
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 109
6 10 Bleeding the vibration circuit 110
1 Install a pressure test hose to the charge pressure test port 110
2 Install a pressure test hose each to the high pressure test ports 110
Fig 1 110
3 Actuate the emergency stop switch 110
Fig 2 110
4 Hold the open ends of the pressure test hoses (Fig 2) into a container 110
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 110
6 Remove the pressure test hoses 110
Fig 3 110
7 Unlock the emergency stop switch 110
Fig 4 111
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 111
9 Wait for approx 30 seconds and repeat the procedure, until the pressure gauge shows a constant charge pressure 111
Fig 5 111
10 For bleeding switch on vibration with high frequency (Fig 5) 111
11 Start the engine 111
12 After running the engine 1 to 2 minutes pause for approx one minute 111
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 111
7 Fundamental electrics 113
7 1 Understanding circuit diagrams 114
Fig 6 Table of contents 114
Fig 7 Function groups 115
Fig 8 Current paths 116
Fig 9 List of components 116
Fig 10 Graphic symbol 117
Fig 11 Graphic symbol 117
7 2 Terminal designations 118
7 3 Current and voltage 122
General 122
Voltage 122
Fig 1 122
Fig 2 122
Current 123
Fig 3 Circuit 123
Types of current 123
Fig 1 Direct current (D C ) 123
Fig 2 Alternating current (A C ) 123
Fig 3 Pulsating direct current 123
Fig 4 PWM 124
Fig 5 CAN 125
7 4 Resistance 126
Resistance and voltage drop 126
Fig 1 Various size resistors 126
Fig 2 Potentiometer, infinitely adjustable resistor 126
Unnecessary resistances 126
Fig 1 Screw-type terminals 126
Fig 2 Spring clamps 126
Fig 3 127
Fig 4 Balistol oil 127
Fig 5 127
7 5 Series / parallel connection 128
Fig 1 Series connection 128
Fig 2 128
Fig 3 Parallel connection 129
Fig 4 129
7 6 Ohm’s law 130
Fig 1 130
7 7 Electrical energy 130
Fig 1 130
7 8 Formula diagram 131
Fig 1 Formula diagram 131
7 9 Metrology 132
Test lamps 132
Fig 1 Test lamp 132
Fig 2 Diode test lamp 132
Multimeter 132
Fig 1 Multimeter 132
Fig 2 Voltage measurement 133
Fig 3 Current measurement 133
Clip-on measuring instrument 133
Fig 1 Clip-on measuring instrument 133
Magnet tester 134
Fig 1 Magnet tester 134
7 10 Diodes, relays, fuses 134
Diodes 134
Fig 1 134
Fig 2 Marking of the cathode 134
Fig 3 Diode circuitry 135
Fig 4 LED 135
Relays 136
Fig 1 Relays 136
Fig 2 Relay circuitry 136
Fuses 136
Fig 1 136
7 11 Batteries 137
Fig 1 137
Fig 2 137
Fig 3 Reading the acid level 138
Fig 4 Battery and generator tester 138
Fig 5 Charge condition 139
7 12 Three-phase generator 140
General 140
Fig 6 Rotor with claw poles 140
Fig 7 Stator with 3 windings 140
Fig 8 3-phase current 141
Fig 9 Regulator with diode plate and rectifier diodes 142
Checking the generator 142
Fig 10 Connections on the three-phase alternator (exemplary design) 143
Fig 11 Rotor 144
Fig 12 Stator 144
7 13 Electric starter 148
Fig 1 Electric starter 148
Fig 2 Switching position during engagement 149
Fig 3 Switching position during starting 149
7 14 Telemecanique switch 151
Fig 1 Terminal designations 151
Fig 2 Disassembly 152
Fig 3 Folding down the switch block 152
Fig 4 Pulling out the front element 152
Fig 5 Assembly 153
Fig 6 Observe the marks 153
Fig 7 Assemble the switch block 153
7 15 Inductive proximity switches 154
Fig 8 154
Fig 9 PNP circuitry 154
Fig 10 NPN circuitry 154
Fig 11 154
Fig 12 Circuit diagram, making contact 155
7 16 Angle sensor with current output 155
Fig 1 Sensor 155
Fig 2 Connection diagram 156
7 17 Plug connectors 156
7 18 Deutsch plug, series DT and DTM 157
General 157
Fig 3 Crimp connections 157
DT Series 157
Fig 1 DT plug connection 157
Fig 2 DT Series 157
Fig 3 Sectional drawing 157
Fig 4 158
Fig 5 159
Fig 1 DTM plug connection 160
Fig 2 DTM Series 160
Fig 3 Sectional drawing 160
Fig 4 161
Fig 5 162
7 19 Plugs and terminals in spring clamping technology 163
General 163
Fig 1 163
Fig 2 That’s how it works 163
Fig 3 Connecting clamp 163
Fig 4 That’s how it works 164
Fig 5 Test adapter 164
Fig 6 That’s how it works 165
Fig 7 X-COM plug with measuring cable 165
Fig 8 X-COM plug plugged onto the series clamp 165
8 Special tools, electrics 167
8 1 Special tools, electrics 168
9 Machine related electrics 177
9 1 Machine related electrics 179
9 2 Electrics MESX 269
10 Service Training 331
10 1 Service Training Machine 333
10 2 Service Training BVC 411
11 Engine 467
11 1 Diesel engine 468
Fig 1 Deutz diesel engine TCD 2012 and 2013 468
11 2 Engine description TCD 2012 469
Fig 1 Deutz diesel engine TCD 2012, right hand side 469
Fig 2 Deutz diesel engine TCD 2012, left hand side 470
11 3 Engine description TCD 2013, 4 and 6 cylinder 471
Fig 1 Deutz diesel engine TCD 2013 L04 2V, right hand side 471
Fig 2 Deutz diesel engine TCD 2013 L04 V2, left hand side 472
Fig 3 Deutz diesel engine TCD 2013 L06 2V, right hand side 473
Fig 4 Deutz diesel engine TCD 2013 L06 2V, left hand side 474
11 4 Lubrication oil circuit TCD 2012 / 2013 475
Fig 1 Lubrication oil diagram 475
11 5 Coolant circuit TCD 2012 / 2013 476
Fig 1 Fuel diagram 476
11 6 Fuel system TCD 2012 / 2013 477
Fig 1 Coolant diagram 477
Fig 2 Fuel pre-filter 478
Fig 3 TCD 2013 Fuel system 479
Fig 4 TCD 2012 Fuel system 480
11 7 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 481
Fig 1 TCD 2012 and 2013 481
Fig 2 Schematic of the Deutz Common Rail System “DCR” 482
Fig 3 Fuel Control Unit FCU 483
Fig 4 High pressure pump 483
Fig 5 Injector 484
Fig 6 Excerpt from the wiring diagram 484
Fig 7 TCD 2013 485
Fig 8 Diesel engine TCD 2012 486
11 8 Sensors TCD 2012 / 2013 487
Fig 1 Sensors TCD 2013 487
Fig 2 Sensors TCD 2013 488
Fig 3 Wiring loom TCD 2013 488
Fig 4 Crankshaft speed sensor TCD 2012 490
Fig 5 Crankshaft speed sensor 490
Fig 6 Crankshaft speed sensor TCD 2013 491
Fig 7 Crankshaft speed sensor 491
Fig 8 Camshaft speed sensor TCD 2012/2013 492
Fig 9 Camshaft speed sensor 492
Fig 10 Electric wiring diagram, page 004 493
Fig 11 Speed sensor 493
Fig 12 TCD 2012 494
Fig 13 TCD 2013 494
Fig 14 Charge air pressure and temperature sensor 495
Fig 15 Electric wiring diagram, page 004 495
Fig 16 TCD 2012 496
Fig 17 TCD 2013 496
Fig 18 Electric wiring diagram, page 004 497
Fig 19 Assignment of connections 497
Fig 20 TCD 2013 498
Fig 21 Electric wiring diagram, page 004 498
Fig 22 TCD 2012 499
Fig 23 Electric wiring diagram, page 004 499
Fig 24 TCD 2012 500
Fig 25 TCD 2013 500
Fig 26 Electric wiring diagram, page 004 501
Fig 27 Connecting plug 501
11 9 Engine control EDC16 with EMR 3 for TCD 2012 / 2013 502
Fig 1 EDC 16 – EMR 3 TCD 2012 and 1013 502
Fig 2 EMR 3 – connecting plug TCD 2012 and 2013 503
Fig 3 Connecting plug EMR3 503
Fig 4 Electric wiring diagram, page 004 504
Fig 5 Electric wiring diagram, page 004 505
Fig 6 EMR3-position in the machine under the operator’s stand 506
11 10 Exhaust gas recirculation TCD 2012 / 2013 507
Fig 1 Exhaust/intake valve control TCD 2012 / 2013 507
11 11 Fault code monitoring with display TCD 2012 / 2013 508
Fig 1 Display 508
11 12 Fault code display TCD 2012 / 2013 509
Fig 1 Display 509
11 13 EMR3 List of fault codes 510
11 14 SerDia Service-Software TCD 2012 / 2013 520
Fig 1 Service-Software TCD 2012 / 2013 520
Fig 2 Serdia connection socket electric cabinet 521
Fig 3 Error log 522
11 15 General trouble shooting chart TCD 2012 / 2013 523
11 16 Valve adjustment TCD 2012 / 2013 525
Fig 1 TCD 2012 and 2013 525
Fig 1 TCD 2012 / 2013 Valves 525
Fig 2 TCD 2012 / 2013 Valves 527
11 17 Ribbed V-belt – fan drive TCD 2012 / 2013 528
Fig 1 Ribbed V-belt 528
11 18 Special tools, Deutz engine (TCD 2012 2V) 529
11 19 Special tools, Deutz engine (TCD 2013 2V) 544
12 Air conditioning system 563
12 1 Physical basics 564
Fig 1 564
Fig 2 564
Pressure and boiling point 565
Fig 3 Steam pressure curve 565
Fig 4 Pressure – Temperature Diagram 565
12 2 Refrigerant R134a 567
Environmental aspects 568
12 3 Compressor oil / refrigeration oil 568
12 4 Working principle of the air conditioning system 569
Fig 1 Principle sketch of an air conditioning system 569
12 5 Monitoring devices 569
Fig 2 Monitoring chain consisting of: 570
12 6 Description of components 570
Compressor 570
Fig 1 570
Condenser 571
Fig 1 571
Dryer / filter / fluid container / inspection glass 572
Expansion valve 573
Fig 1 573
Evaporator 574
Fig 1 574
Defroster thermostat 574
Fig 1 574
Pressure switch 575
Fig 1 575
Pipes and hoses 575
12 7 Checking the compressor oil level 576
Checking the compressor oil level / refrigeration oil level 576
Fig 1 576
Fig 2 576
12 8 Checking the magnetic clutch 577
Fig 1 577
Fig 2 Measuring the air gap 577
Cross-section of magnetic clutch 577
Fig 3 Cross-section of magnetic clutch 577
12 9 Inspection and maintenance work 578
12 10 Checking, replacing the refrigerant compressor V-belt 578
Check the V-belt 578
Fig 4 578
Tighten the V-belt 578
Fig 5 578
Changing the V-belt 579
12 11 Service the air conditioning 579
Cleaning the condenser 579
Fig 6 579
Checking the refrigerant level 579
Checking the moisture level of the drying agent 581
Fig 11 581
Checking the condition of the drier/collector unit 581
Fig 12 581
12 12 Drying and evacuation 582
12 13 Emptying in case of repair 582
12 14 Leak test 583
Fig 1 Electronic leak tester 583
Fig 2 Soap bubble test 583
12 15 Filling instructions 584
Fig 1 585
Filling instructions 586
12 16 Trouble shooting in refrigerant circuit, basic principles 587
Basic principles 587
Fig 2 Pressure gauge 587
Fig 3 Absolute pressure gauge 588
Overheating 588
Supercooling 588
Fig 1 Refrigerant circuit with t, h- diagram 590
12 17 Trouble shooting, refrigerant circuit diagram 591
Fig 1 Refrigerant circuit diagram 591
12 18 Trouble shooting procedure 592
Procedure 592
Fig 2 Flow diagram with measuring points 593
Fig 3 596
Fig 4 597
Fig 5 598
Fig 6 599
Steam table for R134a 0
12 20 Heating control / air conditioning control 607
13 Replacing the cab window panes 613
Assembly of window panes 0
Fig 1 614
1 Glass panes 614
2 Fastening element 614
3 Fixing washer and spacer 614
4 Washer 614
5 Hexagon nut, self locking 614
6 Protective cap 614
13 2 Special tools 615
Fig 1 615
1 Locking handle for fastening element 615
Fig 2 615
2 Suction lifter 615
13 3 Auxiliary materials 616
Fig 1 616
3 Cutter 616
Fig 2 616
4 Window glass bonding agent 616
Fig 3 616
5 Activator 616
Fig 4 617
6 Silicone sealant 617
13 4 Removing and installing the window pane 618
Fig 1 618
1 Pull large glass rests off the bonding strip (Fig 1) 618
Fig 2 618
2 Clean the sealing surfaces from any adhesive material (Fig 2) 618
3 Use a cutter to remove adhesive residues with glass rests 618
4 Cover places without adhesive residues with an activator 618
Fig 3 618
5 Insert the fastening element with washer into the bore in the glass pane (Fig 3) 618
Fig 4 619
6 Turn the fixing and spacer washer hand-tight onto the thread of the fastening element (Fig 4) 619
Fig 5 619
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) 619
Fig 6 619
8 Attach the suction lifter to the outside of the pane (Fig 6) 619
9 Install the window pane so that the fastening elements fit into the bores of the fastening bars 619
10 Press the glass pane against the sealing surface 619
Fig 7 619
11 Assemble the washer and the self-locking hexagon nut 619
12 Fasten the window pane to the fastening bar using a locking handle and a ring spanner (Fig 7) 619
13 Press the protective cap onto the hexagon nut 619
Fig 8 620
14 Remove the suction lifter (Fig 8) 620
Fig 9 620
15 Clean the joining edges on the window pane (Fig 9) 620
16 Mask the upper and lower contact areas to the cabin 620
Fig 10 620
17 Apply silicone sealant evenly and under pressure first to the inside joint edge (Fig 10) 620
Fig 11 620
18 Then apply silicone sealant evenly and under pressure to the outside joint edge (Fig 11) 620
Fig 12 621
19 Then spray the joints from inside and outside with water containing washing up liquid (Fig 12) 621
Fig 13 621
20 Treat the inside joint (Fig 13) 621
Fig 14 621
21 and the outside joint (Fig 14) with a scraper or a spattle 621
14 Drum 623
14 1 Special tools, drum BW 213/226 DH-4 BVC and Variocontrol 624
Fig 1 624
1 Mechanical fixation, assembly of gearbox cover with weights pointing downward (vertical amplitude) 624
Fig 2 624
2 Mechanical fixation, adjustment of potentiometer for horizontal amplitude 624
Fig 3 624
3 Auxiliary assembly rings, side plate 624
Fig 4 625
4 Centring sleeve for side plate 10 (Fig 4) and flanged hub (8) 625
Fig 5 625
5 Pressing tool, inner races of tapered roller bearings 625
Fig 6 625
6 Pressing tool, outer races of tapered roller bearings 625
14 2 Removing and installing the drum 626
Fig 1 626
Fig 2 626
Removing the drum 626
Fig 3 626
7 Unscrew the fastening screws and remove the protection hood (Fig 3) 626
Fig 4 627
1 Open the hose brackets (Fig 4) on both sides of the drum 627
Fig 5 627
2 Mark the hydraulic hoses on the vibration motor (Fig 5) and disconnect them from the ports 627
3 Close all hydraulic hoses and vibration motor ports with suitable plugs 627
Fig 6 627
4 Mark the hydraulic hoses on the slewing motor (Fig 6) and disconnect them from the ports 627
5 Close all hydraulic hoses and slewing motor ports with suitable plugs 627
Fig 7 627
6 Mark the hydraulic hoses on the control valve block (Fig 7) and disconnect them from the ports 627
7 Close all hydraulic hoses and control valve ports with suitable plugs 627
8 Pull off both plugs (2) from the solenoid valve 627
9 Disassemble the protection hood (1) for the plug of the wiring loom 627
Fig 8 628
10 Disconnect all plugs (Fig 8) 628
Fig 9 628
11 Mark the hydraulic hoses (Fig 9) on the travel motor and disconnect them from the ports 628
12 Close all hydraulic hoses and travel motor ports with suitable plugs 628
13 Disassemble the guard plates for speed range selection solenoid valve (1) and speed sensor (2) 628
Fig 10 628
14 Disconnect the plug from the speed sensor solenoid valve (Fig 10) 628
15 Close the connections with plugs 628
Fig 11 628
16 Disassemble the front scraper 1 (Fig 11) 628
17 Disassemble the rear scraper (2) 628
Fig 12 629
18 Support the front cross-member safely (Fig 12) 629
Fig 13 629
19 Properly support the rear cross-member on both sides (Fig 13) 629
Fig 14 629
20 Attach the lifting tackle to the side plate (Fig 14) 629
21 Unscrew the front and rear fastening screws from the side plate 629
Fig 15 629
22 Unscrew the fastening screws (Fig 15) from the spacer block on the vibration motor 629
23 Take off the side plate and lay it down 629
Fig 16 630
24 Unscrew the fastening screws on the travel motor side (Fig 16) 630
Fig 17 630
25 Fasten the lifting tackle to the drum and lift the drum carefully sideways out of the front frame (Fig 17) 630
Fig 18 630
26 Examine all rubber buffers on the travel motor side (Fig 18) for wear, replace if necessary 630
27 Check the rectangular rubber buffers on the vibration motor side, replace if necessary 630
Installing the drum 631
Fig 19 631
1 Place the drum into the frame and align it parallel to the frame (Fig 19) 631
Fig 20 631
2 Attach the lifting tackle and assemble the side plate (Fig 20) 631
3 Turn in the front and rear fastening screws and tighten with 463 Nm 631
Fig 21 631
4 Turn in and tighten the fastening screws on the travel motor side (Fig 21) 631
Fig 22 631
5 On the vibration motor side measure the distance „X“ between spacer block 1 (Fig 22) and side plate 631
6 Calculate the thickness of the compensation plates Nominal value: Distance „X“ + 2 mm 631
7 Turn in one screw (3) into each welded nut (2) on the spacer blocks and provide sufficient space to insert the compensation plates 631
Fig 23 632
8 Insert the compensation plates (Fig 23) 632
9 Turn in the fastening screws 632
10 Unscrew the screws from the welded nuts 632
11 Tighten the fastening screws 632
Fig 24 632
12 Connect hydraulic hoses to the travel motor ports according to the marks made during disassembly (Fig 24) 632
13 Connect the plugs (Solenoid valve for travel speed range selection and speed sensor) and reassemble the guard plates (1) and (2) 632
Fig 25 632
14 Connect the hydraulic hoses to the ports on the vibration motor according to the marking (Fig 25) 632
Fig 26 632
15 Connect hydraulic hoses to the slewing motor ports according to the marks made during disassembly (Fig 26) 632
Fig 27 633
16 Connect all cable plugs and reassemble the protection hood 1 (Fig 27) 633
17 Connect the hydraulic hoses to the ports on the control valve block according to the marking 633
18 Plug in both plugs (2) on the solenoid valve 633
Fig 28 633
19 Fasten the brackets (Fig 28) for the hydraulic hoses on both sides 633
Fig 29 633
20 Assemble the front scraper 1 (Fig 29) 633
21 Assemble the rear scraper (2) 633
Fig 30 633
22 Assemble the protection hood (Fig 30) 633
14 3 Changing the rubber buffers and adjusting the pretension 634
Fig 1 634
1 Lift the frame up by both sides, until rubber buffers and rectangular buffers are relieved of any load (Fig 1) 634
2 Loosen all fastening screws 634
Fig 2 634
3 Turn one screw each into the welded nuts (Fig 2) on the spacer blocks 634
Fig 3 634
4 Remove the compensation shims (Fig 3) 634
Fig 4 635
5 Unscrew the screws (Fig 4) from the welded nuts 635
Fig 5 635
6 Unscrew nut 1 (Fig 3) and remove the washer 635
7 Unscrew screws (2) 635
8 Take off rubber buffer (3) 635
9 Attach the new rubber buffer to the drive disc and align the bores to the tapped bores in the drum 635
10 Turn in and tighten the fastening screws 635
11 Assemble the washer, turn on and tighten the nut 635
Fig 6 635
12 Measure distance „X“ between spacer piece and side plate (Fig 6) 635
13 Calculate the thickness of the compensation plates Nominal value: Distance „X“ + 2 mm 635
Fig 7 635
14 Turn in screws into each welded nut and provide sufficient space to insert the compensation plates (Fig 7) 635
Fig 8 636
15 Assemble the compensation shims (Fig 8) 636
Fig 9 636
16 Unscrew the screws (Fig 9) from the welded nuts 636
Fig 10 636
17 Tighten the fastening screws (Fig 10) 636
18 Lower the frame again 636
15 Drum 637
Repair overview for drum 0
Fig 1 Vario drum 638
1 Eccentric weight 639
2 Swivel motor 639
3 Swashing shaft 639
4 Vibrator shaft 639
5 Eccentric weight 639
6 Rectangular rubber buffer (BW 213, 4 pieces / BW 226, 8 pieces) 639
7 Vibration motor 639
8 Flanged hub 639
9 Mechanical seal 639
10 Side plate 639
11 Drum shell 639
12 Taper roller bearing 639
13 Intermediate rings 639
14 Spacer ring 639
15 Circlip 639
16 Clamping ring 639
Fig 2 640
Fig 3 641
Fig 4 Fixation of vertical amplitude 642
Fig 5 Fixation of vertical amplitude 642
Motor is mounted to gearbox cover in zero position, this applies also for the gear wheel 642
The motor is then swivelled with the gear for 90 (pumping) and assembled in this position 642
Fig 6 Fixation of vertical amplitude 642
Fig 7 Fixation of horizontal amplitude 643
Fig 8 Fixation 643
Fig 9 Fixation 643
Assembly of tapered roller bearing 0
Fig 1 Cross-sectional drawing of right hand drum side 644
1 645
2 Swivel motor 645
3 Swashing shaft 645
4 645
5 645
6 Rectangular rubber buffer (BW 213, 4 pieces / BW 226, 8 pieces) 645
7 Vibration motor 645
8 Flanged hub 645
9 Mechanical seal 645
10 Side plate 645
11 Drum shell 645
12 Taper roller bearing 645
13 Intermediate rings 645
14 Spacer ring 645
15 Circlip 645
16 Clamping ring 645
Fig 2 645
1 Insert half of mechanical seal 9 (Fig 2) into flanged hub (8) 645
Grease the seal ring and fill the space between mechanical seal and flanged hub with grease 645
Fig 3 645
Attach the auxiliary assembly rings to the flanged hub 8 (Fig 3) 645
Fig 4 646
2 Insert half of mechanical seal 9 (Fig 4) into side plate (10) 646
Grease the sealing ring 646
Fig 5 646
Use the centring sleeve to slide the side plate 10 (Fig 5) on the flanged hub (8) 646
Remove the centring sleeve 646
Fig 6 646
Brush some grease on the collar of the side plate (Fig 6) 646
Fig 7 646
Heat the inner ring of the 1st tapered roller bearing up to approx 100C 646
Insert the inner race into the side plate (Fig 7) 646
Press down with a pressing tool 646
Fill the space between inner race and side plate collar with grease 646
Fig 8 647
Cool the outer race of the 1st tapered roller bearing with liquid nitrogen down to approx -30C 647
Assemble the outer race (Fig 8) 647
Press down with a pressing tool 647
Fig 9 647
Insert the two matching intermediate rings of the tapered roller bearing set 13 (Fig 9) 647
Fill the chamber with grease 647
Fig 10 647
Cool the outer race of the 2nd tapered roller bearing with liquid nitrogen down to approx -30C 647
Assemble the outer race (Fig 10) 648
Press down with a pressing tool 648
Fig 11 648
Insert the spacer ring 14 (Fig 11) 648
Fig 12 648
Remove the auxiliary assembly ring (Fig 12) 648
Fig 13 648
Heat the inner ring of the 2nd tapered roller bearing up to approx 100C 648
Insert the inner ring (Fig 13) 648
Press down with a pressing tool 648
Fig 14 648
Install circlip 15 (Fig 14) 648
Fig 15 649
Fasten the clamping ring 16 (Fig 15) with screws 649
16 Articulated joint, electric steering 651
16 1 Special tools 652
Fig 1 652
1 Pressing device for rocker bearings 652
Fig 2 652
2 Pressing sleeve for inner and outer rocker bearing races 652
Fig 3 652
3 Guide pin 652
Fig 4 652
4 Clamping device 652
Repair overview oscillating articulated joint 0
16 3 Removing and installing the oscillating articulated joint 658
Fig 1 658
1 Jack up the frame at the back on both sides and secure it with trestles or wooden blocks (Fig 1) 658
Fig 2 658
2 Support the rear frame near the oscillating articulated joint (Fig 2) on both sides safely with trestles or wooden blocks 658
Fig 3 658
3 Fasten the lifting tackle to the front frame near the oscillating articulated joint (Fig 3) 658
Fig 4 659
4 Unscrew the fastening screws and lift off the angle sensor (Fig 5) 659
Fig 5 659
5 Unscrew fastening screws 1 (Fig 5) and take off axle holder (2) 659
6 Knock out bearing bolt (3) 659
7 Retract steering cylinder (4) 659
Fig 6 659
8 Support the oscillating articulated joint in the middle with a suitable jack or a similar device 659
9 Unscrew fastening screws 1 (Fig 6) and take off with disc (2) 659
Fig 7 659
10 Unscrew nuts 3 (Fig 7) and take off the clamping washers (2) 659
11 Pull out the fastening screws (1) 659
12 Slightly raise the front frame and lower the oscillating articulated joint to the ground 659
13 Pull out the oscillating articulated joint 659
Fig 8 660
14 Insert the bolt for the steering cylinder so that groove 2 (Fig 8) is in line with tapped bores (1) 660
Fig 9 660
15 Align the angle sensor (Fig 9) 660
16 Teach the electric end stops for the steering angle sensor 660
16 4 Dismantling the oscillating articulated joint 661
Fig 1 661
1 Unscrew the nut from the long hexagon screw and pull out the hexagon screw downwards (Fig 1) 661
2 Unscrew the screws for the upper cover 661
3 Take off the upper cover with Belleville springs, shim and backing disc 661
4 Remove the bottom cover 661
Fig 2 661
5 Drive the console with a plastic hammer to one side against the end stop (Fig 3) 661
Fig 3 661
6 Force inner race 1 (Fig 5) of the rocker bearing off the bolt 661
7 Take of supporting disc (2) 661
8 Drive the console to the opposite side and remove the rocker bearing in the same way 661
Fig 4 662
9 Unscrew fastening screws 1 (Fig 6) 662
10 Press bolt (3) out of the console with forcing screws (2) 662
Fig 5 662
11 Lift console 1 (Fig 7) off housing (2) 662
Fig 6 662
12 Take the seal rings out of the console (Fig 8) 662
Fig 7 662
13 Remove the cover from the housing 662
14 Take off shims 1 (Fig 7), backing disc (2) and Belleville springs (3) 662
Fig 8 663
15 Unscrew bolts 1 (Fig 8) and take off cover (2) 663
Fig 9 663
16 Take the intermediate ring out of the housing (Fig 9) 663
Fig 10 663
17 Place the plate 1 (Fig 10) on the beam 663
18 Attach the puller (2) to the housing (3) and separate the carrier from the rocker bearings 663
Fig 11 663
19 Pull the housing off the beam (Fig 11) 663
Fig 12 664
20 Drive the outer race of the friction bearing out of the housing (Fig 12) 664
Fig 13 664
21 Drive the friction bearing out of the housing (Fig 13) 664
Fig 14 664
22 Take seal ring 1 (Fig 14) and V-ring (2) off the beam 664
Fig 15 664
23 Check rocker bearings, if necessary press out of the housing (Fig 15) 664
16 5 Assembling the oscillating articulated joint 665
Fig 1 665
1 If previously disassembled, press the rocker bearing fully into the housing with a pressing mandrel (Fig 1) 665
Fig 2 665
2 Slide the new V-ring on the beam against the stop with the lip facing up (Fig 2) 665
Fig 3 665
3 Lay the seal ring into the beam (Fig 3) 665
4 Fill the space between V-ring and seal ring with multi-purpose grease 665
Fig 4 666
5 Press the friction bearing fully into the housing with the chamfered side pointing towards the outside (Fig 5) 666
Fig 5 666
6 Slide the housing over the beam (Fig 6) 666
Fig 6 666
7 Press the seal ring carefully towards the inside, until it sits in the recess of the housing (Fig 7) 666
Fig 7 666
8 Spray the sliding surface of the outer rocker bearing race with sliding agent OKS 571 666
9 Press the outer rocker bearing race 1 (Fig 8) in until it bottoms with the wider outer rim forward using pressing sleeve (2) 666
Fig 8 667
10 Press inner rocker bearing race 1 (Fig 7) in until it bottoms, using pressing sleeve (2) 667
Fig 9 667
11 Insert the intermediate ring (Fig 8) 667
Fig 10 667
12 Press inner rocker bearing race 1 (Fig 10) in until it bottoms, using pressing sleeve (2) 667
Fig 11 667
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) 667
Fig 12 668
14 Press in intermediate ring 1 (Fig 12) until it bottoms 668
15 Attach cover (2) with the machined edge forward 668
16 Turn in screws (3) and tighten crosswise 668
Fig 13 668
17 Determine the shim thickness, for this purpose stand the cross-member on a wooden board with an Æ 18 mm bore 668
18 Slide the rod of the tensioning device in from underneath, attach the plate, screw on the nut and tighten 668
19 Measure the distance from housing edge to intermediate ring (Fig 13) and write it down, e g 4,7 mm 668
20 Remove the tensioning device 668
Fig 14 669
21 Insert shim 2 (Fig 14) of appropriate thickness and backing disc (1) into the cover 669
Fig 15 669
22 Lay the Belleville springs into the cover with the curvature pointing down (Fig 15) 669
Fig 16 669
23 Assemble cover 2 (Fig 16) with Belleville springs, shim and backing disc 669
24 Turn in screws (1) and tighten crosswise 669
Fig 17 669
25 Press the new sealing rings into the respective groove in the console (Fig 17) 669
Fig 18 670
26 Lift console 1 (Fig 18) over the housing (2) 670
Fig 19 670
27 Turn four guide pins into the housing bores (Fig 19) 670
Fig 20 670
28 Slide the bolt over the guide pins and drive in until it bottoms (Fig 20) 670
Fig 21 670
Fig 22 671
29 Unscrew the guide pins 671
30 Turn in the screws and tighten with 75 Nm (Fig 22) 671
Fig 23 671
31 Cover the rod with LOCTITE blue 243 and insert it into the upper joint bolt (Fig 23) 671
Fig 24 671
32 Slide the backing discs over the bolt (Fig 24) 671
Fig 25 671
33 Drive the inner rocker bearing race on against the end stop with the wider outer rim forward (Fig 25) 671
Fig 26 672
34 Spray the sliding surface of the outer rocker bearing race with sliding agent OKS 571 672
35 Attach the outer rocker bearing race with the wider outer rim facing towards the outside (Fig 26) and drive it in until it bottoms 672
Fig 27 672
36 Attach the lower cover 1 (Fig 27) 672
37 Turn in screws (2) and tighten crosswise 672
Fig 28 672
38 Determine the shim thickness, for this purpose insert rod 1 (Fig 28) of the tensioning device from underneath Attach plate (2), screw on nut (3) and tighten 672
Fig 29 672
39 Measure the distance from outer rocker bearing race to console surface (Fig 29) and write it down, e g 3 2mm 672
40 Remove the tensioning device 672
Fig 30 673
41 Insert shims 2 (Fig 30) of appropriate thickness and backing disc (1) into the upper cover 673
Fig 31 673
42 Lay the Belleville springs into the upper cover with the curvature pointing down (Fig 31) 673
Fig 32 673
43 Assemble the upper cover with Belleville springs, shims and backing disc (Fig 32) 673
44 Turn in the cover fastening screws and tighten crosswise 673
45 Push in the long hexagon screw from underneath, assemble the washer, screw on the nut and tighten with 120 Nm 673
17 Articulated joint, hydraulic steering 675
17 1 Special tools 676
Fig 1 676
1 Pressing mandrel for rocker bearings 676
Fig 2 676
2 Pressing sleeve for outer race of rocker bearing 676
Fig 3 676
3 Pressing sleeve for inner race of rocker bearing 676
Fig 4 676
4 Guide journal 676
Fig 5 677
5 Clamping device 677
Fig 6 677
6 Disassembly device 677
Repair overview oscillating articulated joint 0
Fig 1 678
1 Housing 678
2 Seal ring 678
3 Cover 678
4 Self-aligning bearing 678
5 Bolt 678
6 Shim/supporting disc 678
7 Belleville springs 678
8 Self-aligning bearing 678
9 Console 678
10 Belleville springs 678
11 Shim/supporting disc 678
12 Cover 678
13 Cover 678
14 Intermediate ring 678
15 Self-aligning bearing 678
16 Intermediate ring 678
17 Self-aligning bearing 678
18 Beam 678
19 Friction bearing 678
20 V-ring 678
21 Seal ring 678
Fig 2 679
Fig 3 680
17 3 Removing and installing the oscillating articulated joint 681
Fig 1 681
1 Jack up the frame (Fig 1) at the back and secure it with trestles or wooden blocks 681
Fig 2 681
2 Support the rear frame near the oscillating articulated joint (Fig 2) on both sides safely with trestles or wooden blocks 681
Fig 3 681
3 Fasten the lifting tackle to the front frame near the oscillating articulated joint (Fig 3) 681
Fig 4 682
4 Unscrew fastening screws 1 (Fig 4) and take off axle holder (2) 682
5 Knock out bearing bolt (3) 682
6 Retract steering cylinder (4) 682
Fig 5 682
7 Support the oscillating articulated joint in the middle with a suitable jack or a similar device 682
8 Unscrew fastening screws 1 (Fig 5) and take off with disc (2) 682
Fig 6 682
9 Unscrew nuts 3 (Fig 6) and take off the clamping washers (2) 682
10 Pull out the fastening screws (1) 682
11 Slightly raise the front frame and lower the oscillating articulated joint to the ground 682
12 Pull out the oscillating articulated joint 682
Fig 7 682
13 Insert the bolt for the steering cylinder so that groove (2) is in line with tapped bores (1) 682
17 4 Dismantling the oscillating articulated joint 683
Fig 1 683
1 Unscrew the nuts from hexagon screw 1 (Fig 1) and pull out the hexagon screw 683
2 Unscrew the screws (2) for the cover 683
Fig 2 683
3 Take off the cover with Belleville springs, shim and backing disc (Fig 2) 683
4 Disassemble also the cover from the opposite side 683
Fig 3 683
5 Drive the console with a plastic hammer to one side against the end stop (Fig 3) 683
Fig 4 684
6 Force inner race 1 (Fig 4) of the rocker bearing off the bolt 684
7 Take of supporting disc (2) 684
8 Drive the console to the opposite side and remove the rocker bearing in the same way 684
Fig 5 684
9 Unscrew fastening screws 1 (Fig 5) 684
10 Press bolt (3) out of the console with forcing screws (2) 684
Fig 6 684
11 Lift console 1 (Fig 6) off housing (2) 684
Fig 7 684
12 Take the seal rings out of the console (Fig 7) 684
Fig 8 685
13 Remove the cover from the housing 685
14 Take off shims 1 (Fig 8), backing disc (2) and Belleville springs (3) 685
Fig 9 685
15 Unscrew bolts 1 (Fig 9) and take off cover (2) 685
Fig 10 685
16 Take the intermediate ring out of the housing (Fig 10) 685
Fig 11 685
17 Place the plate 1 (Fig 11) on the beam 685
18 Attach the puller (2) to the housing (3) and separate the carrier from the rocker bearings 685
Fig 12 686
19 Pull the housing off the beam (Fig 12) 686
Fig 13 686
20 Drive the outer race of the friction bearing out of the housing (Fig 13) 686
Fig 14 686
21 Drive the friction bearing out of the housing (Fig 14) 686
Fig 15 686
22 Take seal ring 1 (Fig 15) and V-ring (2) off the beam 686
Fig 16 687
23 Check rocker bearings, if necessary press out of the housing (Fig 16) 687
17 5 Assembling the oscillating articulated joint 688
Fig 1 688
1 If previously disassembled, press the rocker bearing fully into the housing with a pressing mandrel (Fig 1) 688
Fig 2 688
2 Slide the new V-ring on the beam against the stop with the lip facing up (Fig 2) 688
Fig 3 688
3 Lay the seal ring into the beam (Fig 3) 688
4 Fill the space between V-ring and seal ring with multi-purpose grease 688
Fig 4 689
5 Press the friction bearing fully into the housing with the chamfered side pointing towards the outside (Fig 4) 689
Fig 5 689
6 Slide the housing over the beam (Fig 5) 689
Fig 6 689
7 Press the seal ring carefully towards the inside, until it sits in the recess of the housing (Fig 6) 689
Fig 7 689
8 Spray the sliding surface of the outer rocker bearing race with sliding agent OKS 571 689
9 Press the outer rocker bearing race 1 (Fig 7) in until it bottoms with the wider outer rim forward using pressing sleeve (2) 689
Fig 8 690
10 Press inner rocker bearing race 1 (Fig 8) in until it bottoms, using pressing sleeve (2) 690
Fig 9 690
11 Insert the intermediate ring (Fig 9) 690
Fig 10 690
12 Press inner rocker bearing race 1 (Fig 10) in until it bottoms, using pressing sleeve (2) 690
Fig 11 690
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) 690
Fig 12 691
14 Press in intermediate ring 1 (Fig 12) until it bottoms 691
15 Attach cover (2) with the machined edge forward 691
16 Turn in screws (3) and tighten crosswise 691
Fig 13 691
17 Determine the shim thickness, for this purpose stand the cross-member on a wooden board with an Æ 18 mm bore 691
18 Slide the rod of the tensioning device in from underneath, attach the plate, screw on the nut and tighten 691
19 Measure the distance from housing edge to intermediate ring (Fig 13) and write it down, e g 4,7 mm 691
20 Remove the tensioning device 691
Fig 14 692
21 Insert shim 2 (Fig 14) of appropriate thickness and backing disc (1) into the cover 692
Fig 15 692
22 Lay the Belleville springs into the cover with the curvature pointing down (Fig 15) 692
Fig 16 692
23 Assemble cover 2 (Fig 16) with Belleville springs, shim and backing disc 692
24 Turn in screws (1) and tighten crosswise 692
Fig 17 692
25 Press the new sealing rings into the respective groove in the console (Fig 17) 692
Fig 18 693
26 Lift console 1 (Fig 18) over the housing (2) 693
Fig 19 693
27 Turn four guide pins into the housing bores (Fig 19) 693
Fig 20 693
28 Slide the bolt over the guide pins (Fig 20) and drive in until it bottoms 693
Fig 21 693
Fig 22 694
29 Unscrew the guide pins 694
30 Turn in the screws and tighten with 75 Nm (Fig 22) 694
Fig 23 694
31 Slide the backing discs over the bolt (Fig 23) 694
Fig 24 694
32 Drive the inner rocker bearing race on against the end stop with the wider outer rim forward (Fig 24) 694
Fig 25 694
33 Spray the sliding surface of the outer rocker bearing race with sliding agent OKS 571 694
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 694
Fig 26 695
35 Attach cover 1 (Fig 26) to the bottom side of the console 695
36 Turn in and tighten screws (2) 695
Fig 27 695
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 695
Fig 28 695
38 Measure the distance from outer rocker bearing race to console surface (Fig 28) and write it down, e g 3 4 mm 695
39 Remove the tensioning device 695
Fig 29 696
40 Insert shims 2 (Fig 29) of appropriate thickness and backing disc (1) into the cover 696
Fig 30 696
41 Lay the Belleville springs into the cover with the curvature pointing down (Fig 30) 696
Fig 31 696
42 Assemble cover 1 (Fig 31) with Belleville springs, shims and supporting discs 696
43 Turn in screws (2) and tighten crosswise 696
Fig 32 696
44 Insert hexagon screw 1 (Fig 32) so that the screw head rests on the upper side of the console 696
Fig 33 697
45 Assemble the washer, turn on and tighten the nut with 120 Nm (Fig 33) 697
18 Suppliers documentation 699
18 1 Travel pump / vibration pump series 90R 701
18 2 Vibration motor A2FM 791
18 3 Travel drive series 51 821
18 4 Transmission CR 903
18 5 Axle DANA 193 929
18 6 Auxiliary pump for plate, series 1019
19 Circuit diagrams 1057
19 1 Wiring diagram 1059
19 2 Wiring diagram 1103
19 3 Wiring diagram 1145
19 4 Hydraulic diagram 1187