Service Training
Variocontrol Single drum roller - 4 BW 177 / 213 / 226 BVC Teile-Nr. 008 099 94
12/2004
Service Training Table of contents Foreword
A1
Documentation
A2
General
B1
Peculiarities
B3
Electric steering
C1
Steering circuit
C2
Steering pump
C4
Steering wheel
C5
Steering valve
C6
Steering angle sensor
C12
Trouble shooting
C15
Compaction measuring system
D1
BEM
D1
BTM plus
D2
BTM prof.
D3
BVC
D4
BVC - System
E1
Exciter system
E4
Gear pump
E5
Valve block
E7
Swashing motor
E9
Acceleration transducer
E 10
MESX-control
E 11
BOP
E 12
Working principle of the system
Variocontrol Single Drum Rollers Series 4
F1
Service Training Repair and adjustments
G1
Replacement of swashing motor
G2
Replacement of potentiometer
G3
Potentiometer adjustment
G4
Trouble shooting
H1
Electrics
I1
Service Training MESX - Service Training Wiring diagram Hydraulic diagrams
Variocontrol Single Drum Rollers Series 4
Service Training Foreword Reliable construction equipment is of greatest advantage for all parties involved: • for the customer/user it is a basis for an exact calculation of utilization periods and the completion of projects as scheduled. • in the rental business it means that the equipment can be reliably used and planned without having to stock a large number of stand-by machines. • for the manufacturer it means that customers are satisfied, provides him with a good image and gives him a feeling of confidence. It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. This aspect of simple and easy maintenance was one of the key issues when developing and designing the machine: • the location of components in the machine eases maintenance work, • the high quality standard of BOMAG is the basis for the considerable extension of the service and maintenance intervals. • the After Sales Service of BOMAG, including excellent operating and maintenance instruction manuals, high quality training courses and on-site machine demonstrations helps the customer to maintain their machines in good condition over a long period of time. Permanent training of BOMAG’s own service personnel as well as the service personnel of BOMAG Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service. This program of permanent training is only possible with appropriate and up-to-date training material for trainers as well as persons attending the training courses. This training manual has not only been written as a support for the professional work of the trainer, but also for the trainees attending these training courses. The different levels of product training demand, that the training performed by BOMAG, its Profit Centres or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in Boppard. For this reason we invested a lot of time in the preparation of these materials . The structure of this training manual enables us to change or up-date individual chapters in case of alterations to the machine.
Variocontrol Single Drum Rollers Series 4
-A1-
Service Training Documentation These Variocontrol training documents are valid for the following single drum rollers of series 4:
BW 177 DH-4 BVC BW 213 DH-4 BVC BW 213 DH-4 BVC + vibratory plates BW 226 DH-4 BVC
For the BOMAG machines described in this training manual the following documentation is additionally available:
Attention! The currently valid part numbers for the documents can be taken from the Doclist or the Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial number of the machine.
1. Operating and maintenance instructions 2. Spare parts catalogue 3. Wiring diagram * 4. Hydraulic diagram * 5. Repair instructions 6. Service Information * The document versions valid at the date of printing are part of this training manual.
Variocontrol Single Drum Rollers Series 4
-A2-
Service Training General BOMAG VARIOCONTROL (BVC) The increased demands concerning quantity and quality in the application and compaction of soils and rolled asphalt inevitably requires a permanent further development of vibratory rollers. From the contractor's point of view a vibratory roller must fulfil three major requirements: 1. efficient operation 2. fulfilment of a task according to specification 3.flexible in use Due to the inflexible parameterization, standard compaction systems are not able to adapt to the permanently changing construction conditions in an optimal way. However, this problem can be solved by the introduction of intelligent compaction systems. The control values required for an automatic optimization of the compaction parameters are directly gained from the interaction between drum and material to be compacted. BOMAG VARIOCONTROL is a compaction system, which improves the quality and reproducibility of compaction and enhances the efficiency of the roller, independently from the roller operator. BOMAG VARIOCONTROL offers the user the following advantages: 1.Automatic adaptation of the emitted compaction energy to the actual compaction status 2. Better, reproducible results on all materials 3.No jump operation and therefore no particle destruction or loosening of material 4. The resulting direction of force is automatically adapted to the travel direction. This improves the surface quality of the material and the gradability of the roller. 5.Low vibration loads for driver and environment The further development of the VARIOCONTROL system for earthwork was founded on experiences gained with the VARIOMATIC system used for asphalt compaction . The basic difference between VARIOCONTROL and VARIOMATIC is the new exciter system.
It meets the demands of many users for an "intelligent" roller with automatic adaptation of compaction.
Variocontrol Single Drum Rollers Series 4
-B1-
Service Training Part of this new further development is the new display and control element Operation Panel) in connection with the MESX.
BOP (Bomag
Besides the display of the entire operation of the measuring technology the BOP also enables a simple self diagnose of the overall system. The operation of the BOP is described in detail in the operating and maintenance instructions. Error and input codes can be found on the electrics page (MESX Service Training).
BOP
-----
Bomag Operation Panel
Variocontrol Single Drum Rollers Series 4
-B2-
Service Training Specialities All BVC single drum rollers of series 4 are equipped with an electric steering system as standard. The hydraulic steering is also available as an option.
Variocontrol Single Drum Rollers Series 4
-B3-
Service Training Electric steering The electric steering consists of an electronically controlled closed control loop and a hydraulic steering circuit. The electronically controlled circuit consists of a small electric steering wheel (in the left hand seat armrest), the ESX-control (located in the electric junction box), which converts the signal from the steering wheel into electric signals for the proportional solenoids of the steering valve and the steering angle sensor (located on the articulated joint), which feeds the steering angle back to the control. The hydraulic steering circuit consists of steering pump, high pressure filter, steering valve and steering cylinders.
Variocontrol Single Drum Rollers Series 4
-C1-
Service Training Pos.
Designation
05 05
one steering cylinder on BW 177 two steering cylinders on BW 213 and 226 Steering valve with 2 proportional solenoids and an integrated accumulator High pressure filter 12µm Steering pump and charge pump additional gear pump 5.5 cm³ on BW 177 BVC additional gear pump 8 cm³ on BW 213 and 226 BVC High pressure line filter for Variocontrol 100 µm Optional emergency steering valve with 2 B/W solenoids
06
07 09 17 17 20 21
Pos. in wiring diagram
Pos. in hydraulic diagram
Measuring values
05 05 Y92 / Y93 Page 006
06
07 09 / MB 17 / MG
200 +/-10 bar 80 bar
17 / MG
120 bar
20 Y112 / Y113 Page 006
21
Emergency steering: The emergency steering valve is only an option and can only be operated via a special input code. The valve is supplied by the additional Variocontrol gear pump.
Variocontrol Single Drum Rollers Series 4
-C4-
Service Training Steering pump with filter
Steering pump
Pressure test port Steering pressure
Filter outlet
High pressure filter Steering circuit 12 Âľm with Pressure differential switc 3,5 bar
Filter inlet
Variocontrol Single Drum Rollers Series 4
-C5-
Service Training Steering wheel The small steering wheel is located in the left hand armrest of the driver's seat
VCC 8,5 V
Pos.
Designation
Electric steering wheel
Variocontrol Single Drum Rollers Series 4
Pos. in wiring diagram
Pos. in hydraulic diagram
Measuring values
A 45 Page 006
-C6-
Service Training Steering valve, electrically proportional The steering valve, together with the optional emergency steering valve, is located behind a protection box on the right hand side of the frame under the operator's stand or the cabin.
to the Steerin cylinder
from the pump
to the charge system
Variocontrol Single Drum Rollers Series 4
-C7-
Service Training Steering valve
5 3 7
6
8
1
Pos.
Designation
1 2 3 4 5 6
Steering valve port P Steering valve port T Steering valve ports A and B Steering valve, pressure relief valve Steering valve, shock valves Steering valve, accumulator
7 8 9
Steering valve, prop. solenoid Steering valve, prop. solenoid Emergency steering valve B/W solenoid Emergency steering valve B/W solenoid
10
Variocontrol Single Drum Rollers Series 4
4 Pos. in wiring diagram
Pos. in hydraulic diagram
06 06 06 06 06 06 Y 93 Y 92 Y 113
Page 006 Page 006 Page 006
Y 112
Page 006
2 Measuring values
175 + 25 bar 230 bar Accumulator pressure 50bar 0,4 - 1,2 A 0,4 - 1,2 A 0/12 V 0/12 V
-C8-
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Service Training Emergency steering valve (option, can only be operated via input code) !!!
9
Variocontrol Single Drum Rollers Series 4
10
-C9-
Service Training BW 177 BVC
2
3
1
Pos.
Designation
Pos. in wiring diagram
Pos. in hydraulic diagram
1 2 3
Steering valve Optional emergency steering valve High pressure line filter 100Âľm in Vario-circuit
Y92 / Y93 Y112 / Y113
06 21 20
Variocontrol Single Drum Rollers Series 4
Measuring values
- C 10 -