Bomag BW 213 DH-4 service manual
Models and serial number ranges:
Bomag BW 213 DH-4 BVC S/N 101 583 16 ....
Bomag BW 213 DH-4 BVC with attachment plate S/N 101 583 06 ....
Variocontrol S/N 101 582 12 ....
Variocontrol + S/N 101 582 13 ....

INDEX:
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 26 Maintenance 31
2.1 General notes on maintenance 32
2.2 Fuels and lubricants 33
2.3 Table of fuels and lubricants 36
2.4 Running-in instructions 37
2.5 Maintenance chart 38 Technical data 41
3.1 Technical data 42 Connection overview 53
4.1 Connection overview 54 Tests and adjustments 57
5.1 Special tools, tests and adjustments 58
5.2 Activate service mode 62
5.3 Driving against the closed brake 64
5.4 Turn the steering against an end stop. 66
5.5 Pressure tests in the travel circuit 68
5.6 Checking / adjusting the neutral positions of the travel pump 70
5.7 Pressure measurements in the vibration circuit 72
5.8 Check the leakage rate of the vibration motor 73
5.9 Pressure test in steering circuit 74 Flushing and bleeding 77
6.1 Special tools for flushing 78
6.2 Flushing - general 83
6.3 Flushing schematic travel circuit (distribution travel pump) 85
6.4 Flushing the travel circuit (travel pump distribution) 87
6.5 Flushing schematic travel circuit (distribution axle motor) 93
6.6 Flushing the travel circuit (axle motor distribution) 98
6.7 Flushing schematic for vibration drive 103
6.8 Flushing the vibration circuit 104
6.9 Bleeding the travel circuit 108
6.10 Bleeding the vibration circuit 110 Fundamental electrics 113
7.1 Understanding circuit diagrams 114
7.2 Terminal designations 118
7.3 Current and voltage 122
7.4 Resistance 126
7.5 Series / parallel connection 128
7.6 Ohm's law 130
7.7 Electrical energy 130
7.8 Formula diagram 131
7.9 Metrology 132
Table of Contents
4 BOMAG 008 911 79
7.10 Diodes, relays, fuses 134
7.11Batteries 137
7.12 Three-phase generator 140
7.13 Electric starter 148
7.14 Telemecanique switch 151
7.15 Inductive proximity switches 154
7.16 Angle sensor with current output 155
7.17 Plug connectors 156
7.18 Deutsch plug, series DT and DTM 157
7.19 Plugs and terminals in spring clamping technology 163 Special tools, electrics 167
8.1 Special tools, electrics 168 Machine related electrics 177
9.1 Machine related electrics 179
9.2 Electrics MESX 269 Service Training 331
10.1 Service Training Machine 333
10.2 Service Training BVC 411 Engine 467
11.1 Diesel engine 468
11.2 Engine description TCD 2012 469
11.3 Engine description TCD 2013, 4 and 6 cylinder 471
11.4 Lubrication oil circuit TCD 2012 / 2013 475
11.5 Coolant circuit TCD 2012 / 2013 476
11.6 Fuel system TCD 2012 / 2013 477
11.7 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 481
11.8 Sensors TCD 2012 / 2013 487
11.9 Engine control EDC16 with EMR 3 for TCD 2012 / 2013 502
11.10 Exhaust gas recirculation TCD 2012 / 2013 507
11.11 Fault code monitoring with display TCD 2012 / 2013 508
11.12 Fault code display TCD 2012 / 2013 509
11.13 EMR3 List of fault codes 510
11.14 SerDia Service-Software TCD 2012 / 2013 520
11.15 General trouble shooting chart TCD 2012 / 2013 523
11.16 Valve adjustment TCD 2012 / 2013 525
11.17 Ribbed V-belt - fan drive TCD 2012 / 2013 528
11.18 Special tools, Deutz engine (TCD 2012 2V) 529
11.19 Special tools, Deutz engine (TCD 2013 2V) 544 Air conditioning system 563
12.1 Physical basics 564
12.2 Refrigerant R134a 567
12.3 Compressor oil / refrigeration oil 568
12.4 Working principle of the air conditioning system 569
12.5 Monitoring devices 569
12.6 Description of components 570
12.7 Checking the compressor oil level 576
12.8 Checking the magnetic clutch 577
Table of Contents
008 911 79 BOMAG 5
12.9 Inspection and maintenance work 578
12.10 Checking, replacing the refrigerant compressor V-belt 578
12.11 Service the air conditioning 579
12.12 Drying and evacuation 582
12.13 Emptying in case of repair 582
12.14 Leak test 583
12.15 Filling instructions 584
12.16 Trouble shooting in refrigerant circuit, basic principles 587
12.17 Trouble shooting, refrigerant circuit diagram 591
12.18 Trouble shooting procedure 592
12.19 Steam table for R134a 602
12.20 Heating control / air conditioning control 607 Replacing the cab window panes 613
13.1 Assembly of window panes 614
13.2 Special tools 615
13.3 Auxiliary materials 616
13.4 Removing and installing the window pane 618 Drum 623
14.1 Special tools, drum BW 213/226 DH-4 BVC and Variocontrol 624
14.2 Removing and installing the drum 626
14.3 Changing the rubber buffers and adjusting the pretension 634 Drum 637
15.1 Repair overview for drum 638
15.2 Assembly of tapered roller bearing 644 Articulated joint, electric steering 651
16.1 Special tools 652
16.2 Repair overview oscillating articulated joint 654
16.3 Removing and installing the oscillating articulated joint 658
16.4 Dismantling the oscillating articulated joint 661
16.5 Assembling the oscillating articulated joint 665 Articulated joint, hydraulic steering 675
17.1 Special tools 676
17.2 Repair overview oscillating articulated joint 678
17.3 Removing and installing the oscillating articulated joint 681
17.4 Dismantling the oscillating articulated joint 683
17.5 Assembling the oscillating articulated joint 688 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 Circuit diagrams 1057
19.1 Wiring diagram 1059
19.2 Wiring diagram 1103
19.3 Wiring diagram 1145
Table of Contents
6 BOMAG 008 911 79
19.4 Hydraulic diagram 1187