Bomag BW 211 PD-4 Single Drum Roller Service Repair Manual

Operating instructions Maintenance instructions

BW 211 D-4 / BW 211 PD-4 S/N 101 582 41 . . . .

Single drum roller

Catalogue number

008 119 31

06/2004

Foreword BOMAG machines are products from the wide range of BOMAG compaction equipment.

F oreword

BOMAG’s vast experience in connection with state-of-the-art production and testing methods, such as lifetime tests of all important components and highest quality demands guarantee maximum reliability of your machine.

You should only operate the machine after you have been instructed and in compliance with these instructions.

Strictly observe the safety regulations.

Please observe also the guidelines of the Civil Engineering Liability Association ”Safety Rules for the Operation of Road Rollers and Soil Compactors” and all relevant accident prevention regulations.

This manual comprises: l

Safety regulations

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Operating instructions

l

Maintenance instructions

l

Trouble shooting

For your own personal safety you should only use original spare parts from BOMAG.

Using these instructions will l

help you to become familiar with the machine.

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avoid malfunctions caused by unprofessional operation.

Compliance with the maintenance instructions will l

enhance the reliability of the machine on construction sites,

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prolong the lifetime of the machine,

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reduce repair costs and downtimes.

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In the course of technical development we reserve the right for technical modifications without prior notification.

These operating and maintenance instructions are also available in other languages.

Apart from that, the spare parts catalogue is available from your BOMAG dealer against the serial number of your machine.

Your BOMAG dealer will also supply you with information about the correct use of our machines in soil and asphalt construction.

BOMAG GmbH will not assume liability for the function of the machine l

Always keep this manual close at hand, e.g. in the tool compartment of the machine or in a specially provided container. These operating and maintenance instructions are part of the machine.

if it is handled in a way not complying with the usual modes of use, if it is used for purposes other than those mentioned in these instructions.

The above notes do not constitute an extension of the warranty and liability conditions specified in the general terms of business of BOMAG GmbH. We wish you successful work with your BOMAG machine.

BOMAG GmbH Printed in Germany

No warranty claims can be lodged in case of damage resulting from l

operating errors,

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insufficient maintenance and

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wrong fuels and lubricants.

Copyright by BOMAG

Please note!

With this machine "CE" conformity is only achieved with the corresponding optional equipment.

This manual was written for operators and maintenance personnel on construction sites.

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Foreword Please fill in ............................

Machine type (Fig. 1) ............................

Serial-number (Fig. 1 and 2) ............................

Engine type (Fig. 3) ............................

Engine number (Fig. 3)

i

Note

Fig. 1

Supplement the above data together with the commissioning protocol.

During commissioning our organisation will instruct you in the operation and maintenance of the machine.

Please observe strictly the safety regulations and all notes on risks and dangers!

Fig. 2

Fig. 3

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BW 211 D-4

Table of Contents

Technical Data Safety regulations Indicators and Controls Operation

Maintenance

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7 11 19

3.1 General notes 3.2 Description of indicators and control elements

22 22

4.1 General notes 4.2 Tests before starting to operate 4.3 Starting the engine 4.4 Starting with jump wires 4.5 Driving the machine 4.6 Switching the vibration on and off 4.7 Operating the parking brake, stopping the machine 4.8 Shutting the engine down 4.9 Emergency exit 4.10 Adjusting the steering wheel 4.11 Adjusting the seat 4.12 Operating the hood 4.13 Towing in case of an engine failure 4.14 Transport

32 32 33 35 35 37 38 39 40 40 41 41 43 45

5.1 General notes on maintenance 5.2 Fuels and lubricants 5.3 Table of fuels and lubricants 5.4 Running-in instructions 5.5 Maintenance chart 5.6 Check the engine oil level 5.7 Check, clean the water separator 5.8 Check the fuel level 5.9 Checking the hydraulic oil level 5.10 Check the coolant level 5.11 Checking the dust separator on the oil bath air filter 5.12 Checking the tire pressure 5.13 Clean the cooling fins on engine and hydraulic oil cooler 5.14 Check the oil level in the drive axle 5.15 Checking the oil level in left/right wheel hubs 5.16 Check the oil level in the vibration bearings 5.17 Changing engine oil and oil filter cartridges 5.18 Change the fuel filter cartridge 5.19 Draining the sludge from the fuel tank 5.20 Service the battery

48 49 52 53 54 57 57 58 59 59 60 61 61 62 63 63 64 65 66 67

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47

5

Table of Contents

Trouble shooting

6

5.21 5.22 5.23 5.24 5.25 5.26 5.27 5.28 5.29 5.30 5.31 5.32 5.33 5.34 5.35 5.36 5.37 5.38 5.39 5.40 5.41 5.42 5.43 5.44

Change the fuel pre-filter cartridge Checking, replacing the refrigerant compressor V-belt Service the air conditioning Check, adjust the valve clearance Checking / replacing the ribbed V-belt Check the engine mounts Change the oil in the drive axle Changing the oil in the wheel hubs Change the oil in the vibration bearings Retighten the fastening of the axle on the frame Tightening the wheel nuts Check the ROPS Cleaning the oil bath air filter Changing hydraulic oil and breather filter Changing the hydraulic oil filter Changing the coolant Checking the injection valves Service the combustion air filter Adjust the scrapers Adjust the parking brake Changing the tires Change the fresh air filter in the cabin Tightening torques Engine conservation

6.1 General notes 6.2 Engine

68 69 70 73 75 76 76 77 78 79 80 80 81 82 83 84 86 87 90 91 92 93 93 94

95

96 97

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1 Technical Data

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Technical Data

Fig. 4

Dimensions in mm

A

B

D

H

H2

K

L

O1

O2

S

W

BW 211 D-4

2960

2250

1500

2268

2972

490

5808

60

60

25

2130

BW 211 PD-4

2960

2250

1480

2268

2972

490

5808

60

60

25

2130

*

Weights Operating weight (CECE) with ROPS and cabin Axle load, drum (CECE) Rear axle load (CECE) Static linear load Travel characteristics Travel speed (1) Travel speed (2) Travel speed (3) Travel speed (4) Max. gradability (depending on soil) Engine Engine manufacturer Type Cooling Number of cylinders Rated power DIN ISO 3046

8

BW 211 D-4

BW 211 PD-4

kg

10950

11930

kg kg kg/cm

6280 4670 29,5

7260 4670 -

km/h km/h km/h km/h %

0 ... 5 0 ... 6 0 ... 9 0 ... 13,5 47

0 ... 5 0 ... 6 0 ... 9 0 ... 13,5 47

kW

Deutz BF4M 2012C Water 4 98

Deutz BF4M 2012C Water 4 98

BOMAG

BW 211 D-4

Technical Data *

BW 211 D-4 2300 Diesel 12 hydrostatic 2

BW 211 PD-4 2300 Diesel 12 hydrostatic 2

hydrostatic hydr.-mech.

hydrostatic hydr.-mech.

Steering Type of steering Steering operation

articulated hydrostatic

articulated hydrostatic

Vibration Vibrating drum Drive system Frequency Amplitude

Hz mm

1 hydrostatic 30/36 1,8/0,9

1 hydrostatic 30/36 1,64/0,82

Tires Tire size Air pressure

bar

23.1/18-26/TL-8PR AWT 1,1

23.1-26/12TL R1 1,4

Litres Litres Litres Litres

10 340 60 16

10 340 60 16

Rated speed Fuel Electrical equipment Drive system Driven axles

rpm V

Brakes Service brake Parking brake

Filling capacities Engine Fuel Hydraulic oil Coolant *

The right for technical modifications remains reserved

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Technical Data The following noise and vibration data acc. to - EC Machine Regulation edition (98/37/EC) and - Noise Emission Regulation 2000/14/EC were determined at nominal speed of the drive engine and with vibration running. The machine was standing on an elastic base.

During operation these values may vary because of the existing operating conditions.

Noise value The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is sound pressure level at the work place of the operator (with cabin): LpA

= 77.0 dB(A)

The nose emission value for the machine according to the noise emission regulation 2000/14/EG is guaranteed sound capacity level of the machine: LwA

= 109 dB(A)

These sound values were determined according to ISO 3744 for the sound capacity level (LwA) and ISO 11204 for sound pressure level (LpA) at the place of the operator.

Vibration value The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are: Vibration of the entire boy (driver’s seat) The weighted effective acceleration value determined in accordance with ISO 7096 is γ ≤0.5 m/sec2.

Hand-arm vibration values The weighted effective acceleration value determined in accordance with EN 500/ISO 5349 is γ ≤2.5 m/sec2.

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2 Safety regulations

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Safety regulations General

Unintended use

This BOMAG machine is built in accordance with the latest technical standard and the valid technical rules and regulations. There is, however, a risk of danger for persons and property if:

Dangers may, however, arise from the machine if it is used by untrained personnel in an unprofessional way or if it is used for purposes other than those mentioned in these instructions.

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the machine is used for purposes other than those it is intended for

Starting and operation of the machine in an explosive environment is prohibited.

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the machine is operated by untrained personnel

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the machine is modified or converted in an unprofessional way

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the applicable safety regulations are not observed.

Each person involved in operation, maintenance and repair of the machine must therefore read and apply these safety regulations.

This should be confirmed by obtaining the signatures of the customer, if necessary.

Furthermore the following regulations and instructions are obviously also valid: l

applicable accident prevention instructions

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generally acknowledged safety and road traffic regulations

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country specific safety regulations. It is the duty of the operator to know and observe these regulations. This applies also for local regulations and the regulations for various types of manual work. If the recommendations in this manual differ from the regulations valid in your country, you must strictly observe the regulations in your country.

Intended use This machine must only be used for: l

compaction of bituminous materials, e.g. road surface layers. (AC and AD machines only)

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medium and heavy compaction tasks in earth work (road sub-bases)

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This machine must only be operated with fully functional safety equipment.

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The machine should be checked by an expert once every year.

12

Do not work with vibration on hard concrete, on a cured concrete layer or heavily frozen ground.

Who is allowed to work with the machine?

The machine must only be operated by trained and authorized persons which are at least 18 years of age. The responsibilities for the operation of the machine must be clearly specified and complied with.

Persons under the influence of alcohol, medication or drugs must not operate, service or repair the machine.

Maintenance and repair tasks require specific knowledge and must therefore only be carried out by trained and qualified personnel.

Conversions and alterations to the machine Unauthorized conversions to the machine are prohibited for safety reasons.

Original parts and accessories have been specially designed for this machine. We wish to make expressly clear that we have not tested or authorized any original parts or special equipment not supplied by us. The installation and/or use of such products can impair the active and/or passive driving safety. The manufacturer expressly excludes any liability for damage resulting from the use of non-original parts or accessories.

Safety notes in the operating and maintenance instructions: Danger Sections marked like this point out possible dangers for persons. !

BOMAG

BW 211 D-4

Safety regulations Caution Sections marked like this point out possible dangers for the machine or for parts of the machine. !

i

Towing the machine You should generally use a tow bar.

Max. towing speed 1 km/h (1.6 mph), max. towing distance 500 m (1640 ft.).

Before releasing the multi-disc brakes secure the machine properly against unintended rolling.

Note

Sections marked like this provide technical information concerning the optimal economical use of the machine.

Environment Sections marked like this highlight activities for the safe and environmental disposal of fuels and lubricants as well as replaced parts.

Checking the Roll Over Protection Structure (ROPS)

i

Note

On machines with cabin the ROPS is an integral part of the cabin.

The machine frame must not be distorted, bent or cracked in the area of the ROPS fastening points.

Observe all environment protection regulations.

Information and safety stickers/decals on the machine

The ROPS must not show any signs of corrosion, damage, hairline cracks or open fractures.

Replace damaged or illegible stickers/decals immediately.

The ROPS must not rattle about during driving.

This would mean that it is not properly fastened.

All bolted connections must be in accordance with the prescribed specifications and correctly tightened (observe the tightening torque values).

Screws and nuts must not be damaged, bent or deformed.

Loading the machine

With the cabin installed check also the condition of the cabin mounts (rubber elements and screws).

Keep stickers/decals complete (see spare parts catalogue) and fully legible and observe their meaning.

Use only strong and stable loading ramps. The ramp inclination must be lower than the gradability of the machine.

Secure the machine against turning over or slipping off.

Neither must any additional parts be welded or bolted on, nor must any holes be drilled without the permission of the manufacturer, since this may impair the strength of the structure.

Starting the machine

Secure the machine on the transport vehicle against rolling off, slipping and turning over.

Before starting

Persons are highly endangered if l

they step or stand under loads being lifted

Operation of the machine is only permitted when sitting in the operator's seat.

l

they remain in the drive range of the machine during a demonstration or during loading.

Use only machines which have been properly serviced at regular intervals.

The machine must not swing about when lifted off the ground.

Use only safe lifting gear of sufficient load bearing capacity.

Attach the lifting gear only to the specified lifting points.

Become acquainted with the equipment, the control elements, the working mode of the machine and the area you will be working in.

Use your personal protective outfit (hard hat, safety boots etc.).

Check before mounting the machine if: l

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there are persons or obstructions beside or under the machine

13

Safety regulations l

the machine is free of any oily and combustible material

l

all handrails, steps and platforms are free of grease, oils, fuels, dirt, snow and ice

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Driving the machine Persons in the endangered area If the machine has turned over and the cabin door is jammed, use the right hand cabin window as an emergency exit.

the engine compartment hood is closed and locked

Before starting or resuming work and especially when driving backwards, check that there are no persons or obstructions in the endangered area.

To climb onto the machine use steps and handrails.

Check before starting, whether: l

the machine shows any obvious defects

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all protective devices are properly secured in their place

If necessary give warning signals. Stop work immediately if persons remain in the danger area despite the warning.

Do not step or stand into the articulation area of the machine while the engine is running. Danger of squashing!

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steering, brakes, control elements, lighting and warning horn are in order

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the seat is correctly adjusted

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the mirrors (if available) are clean and correctly adjusted.

Driving

Do not start the machine if any gauges, control lights or controls are defective.

In events of emergency actuate the emergency stop switch immediately. Do not use the emergency stop push button as service brake.

Restart the machine only after the danger, that has caused the actuation of the emergency stop, has been eliminated.

Do not take any loose objects with you or fasten them to the machine.

If the machine has come in contact with high-voltage power lines:

On machines with ROPS you should always wear your seat belt!

l

do not leave the operator's stand

Starting

l

Start and operate the machine only from the operator's seat

warn others from coming too close to the machine or touching it

l

For starting set all control levers to "neutral position".

if possible drive the machine out of the danger zone

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have the power shut off.

Do not use any starting aids such as Start Pilot or ether.

Operate the machine only from the operator's seat.

After starting check all gauges.

Keep the cabin doors closed.

Starting with jump leads

Do not adjust the seat while driving.

Connect plus with plus and minus with minus (ground cable) - always connect the ground cable last and disconnect it first! Wrong connections may cause severe damage in the electric system.

Do not climb onto or off the machine while driving.

Never start the engine by bridging the electrical connections on the starter, because the machine would probably start to move immediately.

Starting in closed rooms Exhaust gases are toxic! Always ensure an adequate supply of fresh air when starting in closed rooms!

14

Change the travel direction only while the machine is standing.

Do not use the machine to transport persons.

Stop the machine if you notice unusual noises or the development of smoke. Investigate the cause and have the fault corrected.

Keep a sufficient distance to excavations and embankments and make sure that you work does not impair the stability of the machine.

BOMAG

BW 211 D-4

Safety regulations Do not work with vibration on hard concrete, on a cured concrete layer or heavily frozen ground.

When passing under flyovers, bridges, tunnels, electric power lines etc. keep a sufficient distance.

Parking on slopes and gradients Secure the machine against rolling, place metal chocks in front of and behind the drums.

Filling the fuel tank

Driving on slopes and gradients Do not drive up and down gradients, which exceed the max. gradability of the machine.

On lopes always drive directly up or down. Change to the lower speed range before approaching the slope.

Wet and loose soils reduce the ground adhesion of the machine and inclinations and slopes considerably. Higher risk of accident!

Behaviour in traffic Match the speed of the machine to the working conditions.

Do not inhale fuel fumes.

Refuel only after shutting the engine and the auxiliary heater down.

Do not refuel in closed rooms.

No open fire, do not smoke.

Do not spill any fuel. Catch running out fuel, do not let it seep into the ground.

Wipe off spilled fuel. Keep fuel free of dirt and water.

Always allow loaded transport vehicles to pass.

Leaking fuel tanks can cause explosions. Ensure tight fit of the fuel tank filling cover, replace it if necessary.

Switch the lights on when the visibility is poor.

Fire protection measures

Keep clear of edges and embankments.

Make yourself acquainted with the location and the operation of fire extinguishers. Observe fire warning and fire fighting installations.

Check the effect of vibration When compacting with vibration check the effect of the vibration on nearby buildings and underground supply lines (gas, water, sewage, electric power supply), stop vibratory compaction if necessary.

Do not work with vibration on hard (frozen, concrete) ground. Risk of bearing damage!

Maintenance Observe the maintenance tasks described in the operating and maintenance instructions, including the exchange of parts.

For service and repair work in the engine compartment support the engine compartment hood.

Maintenance work must only be carried out by qualified and authorized personnel.

Parking the machine Park the machine on level and firm ground.

When performing maintenance work above body height use the access steps on the machine or any other safe ladders and working platforms. Do not use machine parts as access steps.

Before leaving the machine: l

straighten the articulated joint to allow easy access to and from the machine.

l

return the travel lever to neutral position

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apply the parking brake

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shut the engine down and pull the ignition key out.

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lock the cabin

Park the machine on horizontal, level and stable ground.

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secure the machine against unauthorized use.

Pull the key out of the ignition switch.

Do not jump off the machine, use access steps and hand rails.

Keep unauthorized persons away from the machine.

Do not perform maintenance work with the machine driving or the engine running.

Lock the articulated joint with the articulation lock.

Always secure parked machines, which could be in the way, with appropriate measures.

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Safety regulations Working on hydraulic lines

l

Do not mix up hoses by mistake.

Always relieve the pressure in the hydraulic circuit before working on hydraulic lines. Hydraulic oil escaping under pressure may penetrate through the skin and cause severe injury. In case of being injured by hydraulic oil you should immediately seek medical advice, as otherwise this may lead to serious infections.

l

damage or deformation of the fitting, which impairs the function and strength of the hose/ hose connection.

When adjusting the hydraulic system do not stand behind or in front of the drum/wheels.

Working on the engine

Only genuine BOMAG hydraulic hoses ensure that the correct type of hose (pressure range) is used at the right place.

Shut the engine down before opening the engine compartment hood.

Do not change the setting of high pressure relief valves.

Drain hydraulic oil at operating temperature - danger of scalding!

Catch running out hydraulic oil and dispose of environmentally.

Drain the engine oil at operating temperature danger of scalding!

Wipe off spilled oil, catch running out oil and dispose of environmentally.

Always catch and dispose of biological hydraulic oils separately.

Store used filters and other oily materials in a separate, specially marked container and dispose of environmentally.

Do not start the engine after draining off the hydraulic oil.

Do not leave any tools or other objects, which could cause damage, in the engine compartment.

Once all work is completed (with the system depressurized!) check all connections and fittings for tight and leak-free fit.

Idle speed and full load speed must not be changed, since this would have a negative effect on the exhaust gas values and cause damage to engine and drive.

Changing hydraulic hoses

Hydraulic hoses must be changed immediately if:

Turbo chargers work with high speeds and high temperatures. Keep hands, tools and materials away from the intake and outlet openings of the turbo charger and do not touch any hot surfaces.

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the outer layer is worn down to the metal lining (e.g. chafing, cuts, cracks)

Check and replace the coolant only when the engine is cold.

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embrittlement of the outer layer (development of cracks in the hose material)

Catch running out coolant and dispose of environmentally.

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deformation under pressurized and depressurized condition, which are not in accordance with the normal shape of the hydraulic hose

Working on electrical equipment

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deformation in bends, e.g, squeezes, kinks, layer separation, formation of blisters

Do not use any fuses with higher ampere ratings or repair a fuse with a piece of wire. Fire hazard!

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leakages.

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non-observance of the installation requirements

Always disconnect the battery before starting to wled on the machine.

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separation of the hydraulic hose from the fitting

When working on the battery do not smoke, do not use open fire.

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corrosion of the fitting, which impairs the function and the strength.

Do not let acid come in contact with skin and clothes. If being injured by acid flush off with clear water and seek for medical advice.

All hydraulic hoses must be inspected visually at regular intervals.

16

Before working on electrical equipment disconnect the battery and cover it with insulating material.

Working on the battery

BOMAG

BW 211 D-4

Safety regulations terials to the direct water jet, but cover them beforehand.

Metal objects (e.g. tools, rings, wrist watches) must not contact the battery poles - danger of short circuit and burns!

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When recharging maintenance free batteries remove the plugs to avoid the accumulation of explosive gases.

After maintenance work

When using an external battery to start the machine follow the respective instructions.

Reinstall all protective devices after completing the maintenance work.

Dispose of old batteries environmentally.

Do not guide the water jet into the exhaust or into the air filter.

Repair

Switch the charging current off before removing the charge clamps.

Ensure good ventilation, especially when charging the battery in a closed room.

Working on the fuel system Do not inhale fuel fumes.

Attach a warning tag to the steering wheel if the machine is defective.

Repairs must only be performed by qualified persons who have been instructed for this purpose.

Use our repair instructions.

Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting in closed rooms!

No open fire, do not smoke, do not spill any fuel.

Catch running out fuel, do not let it seep into the ground and dispose of environmentally.

Test

Working on wheels and tires Explosion like bursting of tires and parts of rims and tires can cause severe or even deadly injuries.

Depending on the type of application and the operating conditions vibratory equipment has to be examined by a specialist whenever required, but at least once every year.

Assemble tires only with the appropriate knowledge and tools. If necessary have the tires assembled in a special workshop.

Ensure correct tire pressure and do not exceed the highest specified pressure.

Check wheels and tires every day for specified pressure, cuts, bulges, damaged wheel rims, missing wheel studs and nuts. Do not drive with damaged tires or wheels.

Anti-stick emulsions for tires must only be mixed using water and concentrated anti-stick agent according to the specifications of the manufacturer of the anti-stick agent. Observe the regulations for the protection of the environment.

Cleaning Do not clean the machine while the engine is running.

Do not use gasoline or other combustible substances for cleaning purposes.

When using steam cleaning equipment do not subject electrical components and insulating ma-

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