Bomag BW 213 D-4 Single drum roller Operating instructions Manual - PDF DOWNLOAD

Operating instructions Maintenance instructions

BW 213 D-4 S/N 101 582 50 . . . .

Single drum roller

Catalogue number

008 124 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

l

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.

l

avoid malfunctions caused by unprofessional operation.

Compliance with the maintenance instructions will l

enhance the reliability of the machine on construction sites,

l

prolong the lifetime of the machine,

l

reduce repair costs and downtimes.

l

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,

l

insufficient maintenance and

l

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.

BW 213 D-4

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3

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

4

BOMAG

BW 213 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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31

47

5

Table of Contents

Trouble shooting

6

5.21 Change the fuel pre-filter cartridge 5.22 Checking, replacing the refrigerant compressor V-belt 5.23 Service the air conditioning 5.24 Check, adjust the valve clearance 5.25 Checking / replacing the ribbed V-belt 5.26 Check the engine mounts 5.27 Change the oil in the drive axle 5.28 Changing the oil in the wheel hubs 5.29 Change the oil in the vibration bearings 5.30 Retighten the fastening of the axle on the frame 5.31 Tightening the wheel nuts 5.32 Check the ROPS 5.33 Cleaning the oil bath air filter 5.34 Changing hydraulic oil and breather filter 5.35 Changing the hydraulic oil filter 5.36 Changing the coolant 5.37 Checking the injection valves 5.38 Service the combustion air filter 5.39 Adjust the scrapers 5.40 Adjust the parking brake 5.41 Changing the tires 5.42 Change the fresh air filter in the cabin 5.43 Tightening torques 5.44 Engine conservation

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

6.1 General notes 6.2 Engine

96 97

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BW 213 D-4

1 Technical Data

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7

Technical Data

Fig. 4

Dimensions in mm

A

B

D

H

H2

K

L

O1

O2

S

W

BW 213 D-4

2960

2250

1500

2268

2972

490

5808

60

60

35

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 Rated speed Fuel

8

BW 213 D-4

kg

12525

kg kg kg/cm

7000 5525 32,9

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

0 ... 5 0 ... 6 0 ... 7 0 ... 10 43

kW

Deutz BF4M 2012C Water 4 98

rpm

BOMAG

2300 Diesel

BW 213 D-4

Technical Data *

Electrical equipment Drive system Driven axles

V

BW 213 D-4 12 hydrostatic 2

Brakes Service brake Parking brake

hydrostatic hydr.-mech.

Steering Type of steering Steering operation

articulated hydrostatic

Vibration Vibrating drum Drive system Frequency Amplitude

Hz mm

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

Tires Tire size Air pressure

bar

23.1/18-26/TL-8PR-AWT 1,4

Litres Litres Litres Litres

10 340 60 16

Filling capacities Engine Fuel Hydraulic oil Coolant *

The right for technical modifications remains reserved

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9

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

= BW 213 D-4 - 75 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

= BW 213 D-4 - 105 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.

10

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2 Safety regulations

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11

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.

l

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.

l

the machine is operated by untrained personnel

l

the machine is modified or converted in an unprofessional way

l

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

l

generally acknowledged safety and road traffic regulations

l

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)

l

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

l

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

l

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 213 D-4

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

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.).

i Note

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

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

Checking the Roll Over Protection Structure (ROPS)

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

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

BW 213 D-4

BOMAG

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

l

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

l

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!

l

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

l

the seat is correctly adjusted

l

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

l

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 213 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

l

apply the parking brake

l

shut the engine down and pull the ignition key out.

l

lock the cabin

Park the machine on horizontal, level and stable ground.

l

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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15

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.

l

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.

l

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

Catch running out coolant and dispose of environmentally.

l

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

Working on electrical equipment

l

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!

l

leakages.

l

non-observance of the installation requirements

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

l

separation of the hydraulic hose from the fitting

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

l

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 213 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!

l

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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Safety regulations

18

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3 Indicators and Controls

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19

Indicators and Controls

Fig. 5

20

BOMAG

BW 213 D-4

Indicators and Controls 1

Ignition switch

10 Push button for warning horn

2

Instrument cluster

3

Vent for heating and ventilation, driver

11 Rotary momentary contact switch for engine speed

4

Vent for heating and ventilation, footwell

12 Rotary switch for direction indicators left/right*

5

Push button vibration

13 Rotary switch for hazard light system*

6

Travel lever

14 Rotary switch for lighting (StVZO)*

7

Rotary switch vibration, high/low frequency

15 Rotary switch for working head lights*

8

Rotary switch for speed range selection

16 Steering wheel adjustment lever

9

Emergency stop push button

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*

BOMAG

Optional equipment

21

Indicators and Controls 3.1

General notes

3.2

Description of indicators and control elements

Please read this section thoroughly before operating this machine if you are not yet conversant with the indicators and control elements. All functions are described in detail hereunder.

Paragraph 4 Operation contains only concise descriptions of the individual operating steps.

Fig. 6

No. 1 = Ignition switch Position "P"/"0" = ignition off, the key can be pulled out, engine not running.

Position "I"

= ignition on, all control and warning lights on the fault monitoring board light up for a moment. The lighting can be switched on.

i Note The engine can only be started when the travel lever is in braking position.

The ignition switch is provided with a lock against repetitive starting. To repeat the starting procedure you must first turn the ignition switch back to "0"-position.

Position "II"

!

= turn further against spring pressure, the engine starts, return the ignition key to position "I" when the engine starts

Caution

Run the engine warm for a short while before starting to work. Do not let the engine run at idling speed for longer than 10 minutes.

Do not shut the engine down all of a sudden from full speed, but let it idle for a while for temperature equalization.

22

BOMAG

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Indicators and Controls g red

= Parking brake, with lever shifted to parking brake position, with driver’s seat unoccupied.

h green = Direction indicator, flashes when the direction indicator switch is actuated. i yellow = Water separator in fuel pre-cleaner.

Lights when the water proportion in the transparent section of the fuel filter reaches the contacts. j red

= flashes, when the coolant provision (filling level) is too low, the engine is shut down after 2 minutes.

Fig. 7

k yellow = not used

No. 2 = Instrument cluster

l red

= Hazard light, flashes when the hazard light is activated

i Note

m

= Operating hour meter, counts the operating hours while the engine is running. All maintenance work must be performed according to the indicated operating hours.

n

= Fuel tank filling level When falling below the lowest filling level the last green LED will light and the red LED will additionally come on.

When the fuel tank is empty only the red LED will flash.

With the ignition switch in position I all gauges and instruments are switched on for 3 seconds. a red

b red

= flashes if the engine temperature exceeds 135 °C, the warning buzzer sounds, the engine is shut down after 2 minutes.

Switch off vibration, run engine with idle speed or shut down engine if necessary, clean engine oil cooler and radiator, if necessary repair engine. = flashes if engine oil pressure too low, engine is shut down after 10 seconds. Check engine oil level, repair the engine if necessary.

No. 3 = Vents for air conditioning, heating and ventilation, driver No. 4 = Vents for air conditioning, heating and ventilation, footwell*

c yellow = Engine air filter, lights if air filter cartridge is soiled, clean or replace if necessary. d yellow = Charge control light, lights if battery is not being charged.

Check V-belt, if necessary repair the generator. e yellow = lights if the hydraulic oil filter is contaminated, the engine is shut down after 2 minutes.

Check hydraulic system, replace hydraulic oil filter. f yellow = The seat occupation monitoring system lights when the seat is not occupied. If the machine is travelling the warning buzzer will sound, engine is shut down after 4 seconds. *

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Optional equipment

23

Indicators and Controls

Fig. 8

Fig. 10

No. 5 = Push button for vibration

No. 7 = Rotary switch for vibration

l

Select or actuate the frequencies with the vibration selector switch.

Position "Middle" = Vibration off

l

Switch the vibration on or off by pressing the push button.

Position "Right" = low amplitude, high frequency Position "Left" = high amplitude, low frequency

Fig. 9

Fig. 11

No. 6 = Travel lever

No. 8 = Rotary switch for speed range selection

Position "middle" = Braking position service brake Position "middle, right" = Parking brake, to start the engine Position "I"

= Forward travel

Position "II"

= Backwards travel

Position "turtle" = Working speed Position "rabbit"

= Transport speed

i Note If the engine speed drops under load when driving on steep gradients, take the travel lever slightly back towards neutral. This relieves the hydraulic system and reduces the load on the diesel engine.

24

BOMAG

BW 213 D-4

Indicators and Controls

Fig. 12

Fig. 13

No. 9 = Emergency stop switch

No. 10 = Push button for warning horn

The engine will be shut down and the brake will close.

!

Danger

Danger of accident!

Operate only in emergency situations during operation, do not use as a service brake.

The machine should only be started again after the danger, that caused the actuation of the emergency stop switch, has been removed. operate

= push the button completely down, it will automatically lock in end position.

Fig. 14

unlock

= turn the button clockwise and release it.

No. 11 = Rotary momentary contact switch for engine speed

to drive

= move the travel lever first to braking position, then start the engine and choose the travel direction.

Electric engine speed adjustment

For safety reasons the travel system of the machine will only be enabled after the travel lever has been shifted back to braking position.

Position left

= Idle speed position

i Note Normal position for engine start.

Position right

= Full throttle position, operating position for driving and vibration

Caution Always drive and vibrate with max. engine speed! Control the travel speed with the travel lever. !

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25

Indicators and Controls

Fig. 15

Fig. 17

No. 12 = Rotary switch for direction indicators left / right*

No. 14 = Rotary switch for light system (StVZO)***

Position "middle" = Direction indicators disabled

Position "left"

Position "left or right" = Front and rear direction indicators for the corresponding side of the machine light up, the control light in the instrument cluster flashes.

= Light off

Position "middle" = Sidelights on, with ignition switch in position "I" or "P" Position "right" = Travel light on, with ignition switch in position "I".

Fig. 18

No. 15 = Rotary switch for working lights****

Fig. 16

Position "left"

No. 13 = Rotary switch for hazard light system **

Position "left"

= Hazard light switched off, control lights off.

= Light off

Position "right" = Working lights on, with ignition switch in position "I".

Position "right" = Hazard light switched on, control light 1 in instrument cluster lights up.

* **

26

Optional equipment Optional equipment

*** Optional equipment **** Optional equipment

BOMAG

BW 213 D-4

Indicators and Controls i Note Swivelling angle max. 20° to either side.

Fig. 19

No. 16 = Lever, steering wheel adjustment Fig. 21

Danger Danger of accident! !

No. 18 = 2-pole socket

Do not adjust the steering wheel while driving. pull up

= adjust height of steering wheel

press down

= adjust inclination of steering wheel

Current only with the ignition switch in position "I" or when the engine is running.

Fig. 22

No. 19 = Fuses in electric installation box F03, 15A

= Vibration

F05, 15A

= Socket

F07, 15A

= Hazard light *

F09, 10A

= Parking tail light, left*

F10, 10A

= Parking tail light, right*

F11, 15A

= Head lights, StVZO*

F13, 30A

= Starting

Do not swivel the driver’s seat while driving.

F14, 15A

= Engine solenoid

swivel

F18, 10A

= Working head lights, relay*

F19, 15A

= Working head lights, front, left*

Fig. 20

No. 17 = Lever, swivelling of driver’s seat Danger Danger of accident! !

Always lock the driver’s seat in one of the locking positions while driving.

BW 213 D-4

= Stop the machine and apply the parking brake. Pull the lever up and swivel the driver’s seat to the desired position.

*

BOMAG

Optional equipment

27

Indicators and Controls F22, 15A

= Working head lights, rear*

F23, 10A

= Warning horn

F24, 10A

= Monitoring, gauges

F25, 10A

= Solenoid valve brake/travel

F39, 15A

= Cab*

F70, 15A

= Indicator*

F105, 20A

= Engine speed control

!

d = toggle switch for rear windscreen heating

Danger

Fire hazard!

Do not use fuses with higher ampere ratings and do not bridge fuses.

Fig. 24

No. 20 = Fuse box, cabin

!

Danger

Fire hazard!

Do not use fuses with higher ampere ratings and do not bridge fuses.

(1), 15A = (F43) wiper/washer, rear (2), 15A = (F44) wiper/washer, front (3), 10A = (F130) relay for rear windscreen heating, reading light (4), 25A = (F31) cabin fan

Fig. 23

(5), 10A = (F41) flashing beacon a = toggle switch for flashing beacon b = toggle switch for front windscreen wiper/ washer up

= windscreen wiper moves to end position and stops.

down

= Switches on wiping of front windscreen.

Push button

= Front windscreen is sprayed during wiping.

(6), 15A = (F144) cab socket (7), 15A = (F143) rear windscreen heating (8), 5A

= (F42) potential 30, cab light

c = toggle switch for rear windscreen wiper/ washer up

= windscreen wiper moves to end position and stops.

down

= Switches on wiping of rear windscreen.

Push button

= Rear windscreen is sprayed during wiping.

28

Fig. 25

No. 21 = Control panel for ventilator, air conditioning, heating

BOMAG

BW 213 D-4

Indicators and Controls e = Rotary switch for cabin ventilator

i = reading and dashboard light

Position ’’Off“

j = toggle switch for reading and dashboard light

= cabin ventilator switched off.

Position 1, 2 and 3 = ventilator stages of different strengths

k = toggle switch for cabin light l = cabin light

f = Push button for air conditioning* press

= air conditioning switched on.

i Note The lights above the push buttons light up.

With rotary switch (g) the air conditioning unit can be regulated within the blue range. press again

= air conditioning switched off.

i Note The light goes out. g = Rotary switch for cabin heater (temperature selector switch) Position ’’Off“ Position blue range Position red range

Fig. 27

No. 23 = Main fuse for battery

= cabin heater switched off.

125A

= temperature selection for air conditioning.

= (F00)

i Note

= Temperature selection for cabin heater.

Battery with main fuse is located in the engine compartment

Fig. 28 Fig. 26

No. 22 = Cabin light

No. 24 = EVIBdisplay** is a compaction measuring unit for continuous display of the load bearing characteristics (MN/m2) during the compacting pass.

EVIB value Increase

*

Optional equipment

BW 213 D-4

**

BOMAG

= higher load bearing capacity

Optional equipment

29

Indicators and Controls Constant

30

= end of compaction

BOMAG

BW 213 D-4

4 Operation

BW 213 D-4

BOMAG

31

Operation 4.1

General notes

Please read section 3 Indicators and Control Elements thoroughly before operating the machine if you are not yet fully familiar with the indicators and control elements of the machine.

4.2

Tests before starting to operate

The following tests must be performed before each work day or before a longer work period.

All indicators and control elements are described in detail in this chapter.

!

Danger

Danger of accident!

Please observe strictly the safety regulations in chapter 2 of these operating and maintenance instructions!

Park the machine on level ground.

l

Check: l

Fuel tank and fuel lines for leaks

l

Bolted connections for tight fit

l

Function of the steering

l

Check the machine for cleanliness and damage

l

availability of the appropriate operating and maintenance instructions,

l

check if the machine has been properly serviced.

i Note For a description of the following work refer to the section "maintenance every 10 operating hours" engine oil level

l

i Note Hydraulic systems, which are filled with Panolin HLP Synth. 46, the same oil must be used for filling up. In case of any other ester based oil consult the lubrication service department of the respective oil manufacturer. l

Check the hydraulic oil level, top up if necessary.

l

Check the coolant level, top up if necessary.

!

Danger

Fire hazard!

Do not refuel in closed rooms l

32

BOMAG

Check the fuel level, top up if necessary.

BW 213 D-4

Operation l

Check water separator in the fuel system, drain if necessary.

l

Adjust the scrapers if necessary

l

Tire pressure. Pressure see technical data.

4.3 !

Starting the engine

Danger

Danger of accident!

Caution Ensure equal pressure in both tires. !

Always wear your seat belt.

Fig. 29 l

Check, whether the travel lever (Fig. 29) is engaged to the right in brake position.

Fig. 30 l

BW 213 D-4

BOMAG

Turn the rotary vibration selector switch (Fig. 30) to position "0", vibration off.

33

Operation

Fig. 31 l

Check, whether the emergency stop switch (Fig. 31) is unlocked.

Fig. 34

All control and warning lights (Fig. 34) in the fault monitoring board light up for a moment.

The battery control (d) and brake warning lights (g) light up, the engine oil pressure warning light (b) flashes. !

Caution Perform the starting process for maximum 20 seconds without interruption and pause for a minute between starting attempts.

If the engine has not started after two attempts perform trouble shooting.

Fig. 32 l

Turn rotary switch (Fig. 32) to position "Min" (idle speed).

Fig. 35 l

Turn the ignition key to position "II" (Fig. 35), the starter will crank the engine.

l

As soon as the engine ignites return the ignition key to position "I".

Fig. 33 l

34

Turn the ignition key (Fig. 33) to position "I".

Caution Do not allow the engine to run longer than 10 minutes with idle speed. !

BOMAG

BW 213 D-4

Operation 4.4

Starting with jump wires

4.5 !

Driving the machine

Danger

Danger of accident!

Wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes.

Soil conditions and weather influences impair the gradability of the machine.

Do not drive up and down inclinations exceeding the maximum gradability of the machine (see technical data).

Do not drive without wearing your seat belt.

Fig. 36

Always give way to loaded transport vehicles!

Caution A wrong connection will cause severe damage in the electric system. !

l

Bridge the machine only with a 12 Volt auxiliary battery.

l

When jump starting with an external battery connect both plus poles first.

l

Then connect the ground cable first to the minus pole of the current supplying auxiliary battery and then to engine or chassis ground, as far away from the battery as possible (Fig. 36).

l

Start as described under 'Starting the engine'.

l

Once the engine is running switch on a powerful consumer (working light, etc.). !

Caution

If no powerful consumer is switched on voltage peaks may occur when separating the connecting cables between the batteries, which could damage electrical components. l

After starting disconnect the negative poles (ground cable) first and the positive poles after.

l

Switch off the consumer.

BW 213 D-4

Before starting to drive make sure that the drive range is absolutely safe. !

Caution Always keep the cabin door closed while driving with the machine. With the door opened and the machine fully articulated extreme oscillations of the machine may damage the door.

i Note "Start engine", see previous sections.

The machine is equipped with a seat contact switch (safety feature).

If the travel lever is actuated with the engine running, but the driver's seat is not occupied, the signal horn is triggered and the engine shut down.

If the driver gets up from his seat while driving, the signal horn is activated and the engine shut down after four seconds.

If the driver occupies the seat again within this period of four seconds, the machine will continue travelling.

BOMAG

35

Operation

Fig. 37 l

Close the cabin door (Fig. 37).

Fig. 40 l

Select the desired travel speed range (Fig. 40).

Fig. 38 l

Sit down on the seat (Fig. 38).

Fig. 41 l

Turn the rotary switch (Fig. 41) to "Max" position (full throttle).

Fig. 39 l

Fasten your seat belt (Fig. 39).

Fig. 42 l

36

BOMAG

Push the travel lever (Fig. 42) to the left out of braking position and move it slowly to the desired travel direction.

BW 213 D-4

Operation i Note Shift the travel lever out of "0"-position slowly to forward or reverse, the machine will drive forward or reverse at a speed which corresponds with the displacement of the travel lever.

Returning the travel lever towards neutral will brake the machine and in "0"-position of the travel lever the machine will stop.

Danger Danger of accident! !

When stopping on inclinations and slopes pull the travel lever to the right and lock it in braking position.

4.6

!

Switching the vibration on and off

Danger

Risk of damage!

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

Do not activate the vibration on hard (frozen, concrete) ground. Danger of bearing damage!

Important notes on travel operation Caution When changing the travel direction hold the travel lever for a moment in "0"-position, until the machine has stopped, before actuating to the new travel direction. !

Do not operate jerkily!

When driving up and down inclinations move the travel lever slowly back towards neutral to brake the machine.

If the engine speed drops when driving up extreme inclinations move the ravel lever slightly back, if necessary change to the lower speed range.

Fig. 43 l

Switch to working speed (Fig. 43) (turtle).

Pre-selecting the vibration

Fig. 44

BW 213 D-4

l

Pre-select amplitude/frequency with the rotary switch (Fig. 44).

BOMAG

37

Operation Switch the vibration on

4.7

Operating the parking brake, stopping the machine

Fig. 45

Turn the rotary switch (Fig. 45) to position "Max" (full throttle).

l

Fig. 47

Caution Switch the vibration on only at max. engine speed. !

l

Return the travel lever (Fig. 47) slowly to "neutral"-position and engage it to the right parking brake position.

The machine is automatically braked by the hydrostatic drive and parking brake closes.

i Note The parking brake also closes automatically when shutting the engine down.

Fig. 46 l

Press the push button (Fig. 46) in the travel lever while driving, the drum will vibrate.

Switching the vibration off l

38

Press the push button again and after work switch the rotary vibration switch to position "0".

BOMAG

BW 213 D-4

Operation 4.8

Shutting the engine down

!

Caution Straighten the articulated joint to provide easier access to the machine.

Fig. 50

Turn the ignition switch (Fig. 50) to position "0" or "P" and pull the ignition key out.

l

i Note The parking brake closes automatically when shutting the engine down.

Fig. 48 l

Return the travel lever (Fig. 48) slowly to "neutral"-position and engage it to the right in braking position.

Danger Danger of accident! !

Secure the machine against unauthorized use, pull the ignition key out, lock the cabin door.

Fig. 49 l

Turn rotary switch (Fig. 49) to position "Min" (idle speed).

i Note Do not shut the engine down all of the sudden from full speed, but let it idle for a while for temperature equalization.

BW 213 D-4

BOMAG

39

Operation 4.9

Emergency exit

4.10 Adjusting the steering wheel

If the machine should turn over and the cabin door is closed, the right hand side cabin window can be used as an emergency exit.

Fig. 51 l

Adjustment of steering wheel in height, pull lever (Fig. 51) up and move the steering wheel to the desired height.

l

Adjustment of steering wheel inclination, press lever down and adjust the inclination of the steering wheel.

Danger Danger of accident! !

After the adjustment make sure that the steering wheel adjustment is securely locked in place.

40

BOMAG

BW 213 D-4

Operation 4.11 Adjusting the seat

4.12 Operating the hood !

Danger

Danger of accident!

If the hood needs to be opened further for maintenance or repair work, support it safely.

Opening the hood

Fig. 52 l

To adjust the seat in longitudinal direction disengage lever e (Fig. 52) upwards and push the seat forward or back.

l

To adjust the weight turn lever (d) and read the weight in sight glass (c).

l

To adjust the inclination of the backrest operate lever (a) and tilt the backrest forward or back.

l

Fig. 54

To swivel the seat pull lever (b) up and turn the seat to the desired direction.

l

Unlock the lock (Fig. 54).

l

To open the hood press in the button and turn the handle.

Fig. 53 l

To adjust the height of the seat lift the seat up (Fig. 53) until it engages at the desired level.

Fig. 55 l

Pull the support (Fig. 55) out of the bracket.

When lifting the seat completely it will sink down to lowest position.

BW 213 D-4

BOMAG

41

Operation Closing the hood

Fig. 56 l

Let the spring pin (Fig. 56) click into place.

l

If the hood is to be raised to top position you must also pull out and lock the bottom rod.

Fig. 58 l

Pull down the hood, press in the spring pin (Fig. 58) and push the hood together.

l

Store the hood support.

l

Close the hood, lock it and pull off the key.

Fig. 57 l

42

Push up the hood and place the support rod into its receptacle.

BOMAG

BW 213 D-4

Operation 4.13 Towing in case of an engine failure !

Danger

Secure the machine with wheel chocks against unintentional rolling.

Danger Danger of accident! !

When using towing ropes tow the machine only uphill.

Fig. 60 l

To release the brake turn counter nuts 1 (Fig. 60) approx. 8 mm back.

l

Turn the brake releasing screws (2) completely in against the stop.

When towing downhill you must use a rigid towing device. l

Secure the machine with wheel chocks against unintentional rolling.

l

Attach the towing ropes safely to the front or rear lifting eyes. !

Caution

Towing speed 1 km/h, max. towing distance 500 m.

Caution From this stop turn the screw in for maximum another turn to release the brake! !

Turn the screws in evenly on both sides. l

Turn the screws in alternately for ¼ turn at a time.

l

Repeat this measure on the opposite wheel side.

Open the tailgate.

l

Fig. 59

Slacken the middle hexagon on both valves (Fig. 59) for approx. 2 to 3 turns.

l

Caution Do not turn the valves out completely.

Fig. 61 l

Remove plug 1 (Fig. 61).

l

Place an U-section (5) across the brake housing (2) and turn the screw (4) into the tapped bore (3), until it bottoms.

l

Turn the nut (6) down and tighten it approx. one revolution. The drum must rotate freely.

!

BW 213 D-4

BOMAG

43

Operation After towing

i Note If necessary replace the seal ring under the counter nut if it is leaking.

Caution Before detaching the tow bar block the machine with chocks to prevent unintended rolling.

For this purpose completely unscrew the brake releasing screw, replace the seal ring and lubricate the screw with silicone grease.

l

Turn the high pressure relief valve cartridges tightly back in.

Reinstall the screw with a new seal ring and adjust the protrusion as described above.

l

Turn all brake releasing screws of the axle evenly back out, until they are light moving again.

!

Fig. 62 l

Turn the brake releasing screws (Fig. 62) back in again, until they abut against the brake piston.

Fig. 63 l

Unscrew the brake releasing screws (Fig. 63) for two turns and tighten the counter nuts.

l

Repeat this adjustment procedure on the opposite wheel side.

44

BOMAG

BW 213 D-4

Operation 4.14 Transport !

Danger

Danger of accident!

Use only stable loading ramps of sufficient load bearing capacity. Make sure that persons are not endangered by the machine tipping or sliding off.

Lash the machine down, so that it is secured against rolling, sliding and turning over.

Fig. 66

Do not stand or step under loads being lifted.

Always use shackles on the lifting points for loading, tying or lifting the machine.

l

Lash the machine on the transport vehicle (Fig. 66), use the four lashing eyes on front and rear frame for this purpose.

l

Support the front frame to avoid overstressing of the rubber buffers.

Fig. 64 l

Pull the spring pin (Fig. 64) out.

l

Engage the articulation lock and secure it with the spring pin.

Fig. 67 l

For lifting use also the four lifting eyes (Fig. 67) and appropriate lifting gear.

Weights: See technical data l

After transport release the articulation lock again and store it in the receptacle.

Fig. 65 l

Engage the articulation lock and secure it with the spring pin (Fig. 65).

BW 213 D-4

BOMAG

45

Operation

46

BOMAG

BW 213 D-4

5 Maintenance

BW 213 D-4

BOMAG

47

Maintenance l

Do not let the suction hose disturb the sludge on the bottom of the drum.

l

Do not draw off fuel from near the bottom of the fuel drum.

When servicing the machine pay careful attention to all applicable safety instructions.

l

Thorough maintenance of the machine ensures maximum reliability and prolongs the lifetime of important components. The necessary effort can by no means be compared with the problems and malfunctions that could occur if this is not observed.

Fuel left in the fuel drum is not suitable for the engine and should only be used for cleaning purposes.

Notes on the engine performance

5.1

General notes on maintenance

The terms left/right are always related to travel direction forward.

Combustion air and fuel injection rates of the diesel engine have been carefully adjusted and determine the engine's performance and temperature level as well as the quality of the exhaust gas.

l

Clean machine and engine thoroughly before starting maintenance work.

l

For maintenance work park the machine on level ground.

If your machine has to operate permanently in "thin air" (at high altitudes) and with full power, you should consult the after sales service of BOMAG or the service department of the engine manufacturer.

l

Maintenance work must generally be carried out with the engine shut down.

Notes on the hydraulic system

l

Depressurize hydraulic lines before working on them.

l

Disconnect the battery and cover it with insulation material before starting to work on electrical components.

l

Always attach the articulation lock (transport lock) before starting to work in the articulation area of the machine.

Environment Catch running out oils, coolant and fuel and do not let them seep into the ground or into the sewage system. Dispose of oils, coolant and fuels environmentally.

Notes on the fuel system

During maintenance work in the hydraulic system cleanliness is of utmost importance. Make sure that no dirt or other impurities can enter into the system. Small particles can flute valves, cause pumps to seize and block restrictors and pilot bores, thereby causing costly repairs. l

If during the daily oil level check the oil level is found to have dropped, check all lines, hoses and components for leakages.

l

Seal external leaks immediately. If necessary inform the responsible service department.

l

Do not store drums with hydraulic oil outside, or at least keep them under a cover. During weather changes water may penetrate through the bunghole.

l

Always fill the hydraulic system using the filling and filtering unit (BOMAG part-no.

007 610 01). This unit is equipped with a fine filter, which filters the hydraulic oil and prolongs the lifetime of the system filter.

l

Clean fittings, filler caps and their immediate surrounding area before removing them, so that no dirt can fall in.

l

Do not leave the tank opening unnecessarily open, cover it so that no dirt can fall in.

The lifetime of the diesel engine is decisively depending on the cleanliness of the fuel. l

l

l

48

Keep the engine free of dirt and water as this could damage the injection elements of the engine.

Zinc lined drums are not suitable for storing fuel.

The fuel drum should rest for a longer period of time before drawing off fuel.

BOMAG

BW 213 D-4

Maintenance Notes on the cooling system On water cooled engines the preparation and monitoring of the coolant is of utmost importance, as otherwise engine failures caused by corrosion, caviation and freezing may occur.

5.2

Engine oil Quality

The coolant is a mixture of water and a cooling system protection agent.

The cooling system must be permanently monitored. Apart from the coolant level inspection this includes also the inspection of the concentration of cooling system protection agent.

Lubrication oils are classified according to their performance and quality class. Oils according to other comparable specifications may be used.

Approved engine oils Deutz DQC II ACAE E3/96/E5-02 API CH-4/CG-4 DHD DHD-1

The concentration of the cooling system protection agent can be checked with commercially available test instruments (glycomat). !

Fuels and lubricants

Danger

Health hazard!

The mixing of nitride based cooling system protection agents with amine based agents will cause the generation of highly toxic nitrosamines.

DQC III E4-99 -

The exact assignment of the approved oil qualities and oil change intervals can be taken from the following section "Lubrication oil change intervals".

Consult your local service station if in doubt.

Oil viscosity Multi-purpose oils should be generally used.

Environment Cooling system protection agents must be disposed of environmentally.

Since lubrication oil changes its viscosity with the temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class (SAEclass) .

Optimal operating conditions can be achieved by using the opposite oil viscosity chart (Fig. 68) as a reference.

Occasionally falling short of the temperature limits will impair the cold starting ability, but will not cause any engine damage. In order to keep the occurring wear as low as possible, occassional exceeding of the limits should not happen over a longer period of time.

BW 213 D-4

BOMAG

49

Maintenance and for ambient temperatures higher than -10 °C. When using fuels with a sulphur content of more than 0.5% to 1% or under ambient temperatures below -10 °C the oil change intervals specified in the table must be halved. For fuels with a sulphur content of more than 1% you should consult the responsible service agency.

Fuels Quality You should only use commercially available brand diesel fuel with a sulphur content below 0.5% and ensure strict cleanliness when filling in. A higher sulphur content has a negative effect on the oil change intervals. Use only winter-grade diesel fuel under low ambient temperatures. The fuel level should always be topped up in due time so that the fuel tank is never run dry, as otherwise filter and injection lines need to be bled.

When using fuels with a Cetan number < 49 poor starting and white smoke can be expected, in particular in connection with low ambient temperatures.

Fig. 68

With their better temperature and oxidation stability synthetic lubrication oils offer quite a few benefits.

The following fuel specifications are permitted: DIN/EN 590; DIN 51 601; Nato Codes: F-54, F-75; BS 2869: A1 and A2; ASTM D 975-78: 1-D and 2D.

Oil change intervals

l

DIN/EN 590

l

BS 2869

l

ASTM D 975-78: 1-D and 2-D.

l

Nato Codes: F-54, F-34, F44 und XF63

The longest permissible time a lubrication oil should remain in an engine is 1 year. If the following oil change intervals are not reached over a period of 1 year, the oil change should be performed at least once per year, irrespective of the operating hours reached.

ACEA*

Winter fuel Danger Fire hazard! !

E3-96/E5-02 E4-99

= 500 operating hours

Diesel fuels must never be mixed with gasoline.

API** CG-4/CH-4

= 500 operating hours

Caution These intervals apply only when using a diesel fuel with maximum 0.5 % sulphur by weight !

* **

50

For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel.

European Engine Oil Sequences American Petroleum Institute

BOMAG

BW 213 D-4

Maintenance In most cases a sufficient cold resistance can also be achieved by adding flow enhancing fuel additives. Consult the engine manufacturer.

Operation with rape seed oil methyl ester (RME „Bio Diesel“) Due to the extreme quality differences of RMEWfuels available on the market, which are caused by the non-existence of a standardization, BOMAG does generally not approve any RME-fuels. If this is neglected the warranty will become null and void!

However, if you still intend to operate the machine with RME-fuels you should observe the following information: l

Reduced engine power (approx. 7%), higher fuel consumption.

l

The quality of RME-fuel should be in compliance with DIN draft 51606.

l

Avoid longer periods of standstill (formation of resin, corrosion in injection system)

l

RME-fuel can damage the paint finish of the machine.

l

Fuel dilution of engine oil, therefore shortening of oil change intervals to half.

l

Rubber parts, such as leak fuel return lines, seats will be damaged in the long run and need to be replaced on a regular basis or should be replaced by parts made of fluorinated rubber. However, fluorinated rubber is not resistant against normal diesel fuel.

l

Environment Cooling system protection agents must be disposed of environmentally.

Hydraulic oil The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mm 2/s at 40°C. For topping up or for oil changes use only high-quality hydraulic oil, type HVLP according to DIN 51524, part 3, or hydraulic oils type HV according to ISO 6743/3. The viscosity index (VI) should be at least 150 (observe information of manufacturer).

Bio-degradable hydraulic oil On request the hydraulic system can also be filled with ester based biodegradable hydraulic oil (Panolin HLP Synth. 46). The biologically quickly degradable hydraulic oil meets all demands of a mineral oil based hydraulic oil according to DIN 51524.

In hydraulic systems filled with Panolin HLP Synth.

46 always use the same oil to top up. When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil, you should consult the lubrication oil service of the oil manufacturer for details.

Check the filter more frequently after this change.

Caution Oil change bio-degradable hydraulic oil: !

Perform regular oil analyses for content of water and mineral oil.

If the fuel filter is clogged the filter change intervals must be shortened accordingly.

Coolant, anti-freeze agent

Replace the hydraulic oil filter element every 500 operating hours.

Use only soft tap water (drinking water) to prepare the coolant mix.

Oil for drive axle

As a protection against frost, corrosion and boiling point anti-freeze agents must be used under any climatic conditions.

For the drive axle use only multi-purpose transmission oil of API-class GL5 with viscosity class SAE 90.

The proportion of cooling system protection agent must be between min. 35% and max. 45% to the water.

The additives in this oil ensure low wear lubrication under all operating conditions.

Lubrication grease !

Caution Do not mix different coolants and additives of any other kind.

BW 213 D-4

For lubrication use only EP-high pressure grease, lithium saponified (penetration 2).

BOMAG

51

Maintenance 5.3

Table of fuels and lubricants

Assembly

Fuel or lubricant Summer

Winter

Quantity approx.

Attention Observe the level marks

Engine

Engine oil ACEA: E3-96/E5-02 or

approx. 8.5 litres without oil filter

API: CG-4/CH-4 SAE 10W/40 (-20 °C to +40 °C) SAE 15W/40 (-15 °C to +40 °C) Fuel Diesel Hydraulic system

Winter diesel fuel

Hydraulic oil (ISO), HV46, kinem. viscosity

approx. 150 litres approx. 60 litres

46 mm2/s at 40 °C Vibration bearings

Engine oil SAE 15W/40

approx. 0.8 litres

Drive axle

Gear oil SAE 90, API GL5

approx. 9.5 litres

Wheel hubs

Gear oil SAE 90, API GL5

approx. 1.9 l per side

Air conditioning system

Refrigerant R134A

approx. 1400 g

Engine cooling system

Cooling system protection agent

approx. 16 litres

Water

approx. 295 litres

Calcium chloride (CaCl2) or magnesium chloride (MgCl2)

approx. 100 kg

Tires

52

BOMAG

BW 213 D-4

Maintenance 5.4

Running-in instructions

The following maintenance work must be performed when running in new machines or overhauled engines: !

Caution Up to approx. 250 operating hours check the engine oil level twice every day.

Depending on the load the engine is subjected to, the oil consumption will drop to the normal level after approx. 100 to 250 operating hours.

After a running-in time of 30 minutes l

Retighten the V-belt

After 50 operating hours l

Retighten bolted connections on intake and exhaust tubes, oil sump and engine mounts.

l

Retighten the bolted connections on the machine.

l

Retighten all wheel fastening screws with the specified tightening torque.

l

Oil change vibration bearings

l

Oil change in drive axle

l

Oil change in wheel hubs

After 500 operating hours l

BW 213 D-4

BOMAG

Oil change vibration bearings

53

Dipstick mark

5.7

Check the water separator

X

5.8

Check the fuel level

X

5.9

Check the hydraulic oil level

5.10 Check the coolant level

X

Inspection glass

X

Inspection glass

X

5.11 Check the dust separator

X

5.12 Check the tire pressure

X

5.13 Clean the cooling fins on engine and hydraulic oil cooler

X

5.14 Check the oil level in the drive axle

X

5.15 Check the oil level in the wheel hubs

X

5.16 Check the oil level in the vibration bearings

X

5.17 Change engine oil and oil filter cartridge*

min. 1x per year

X

5.18 Change the fuel filter cartridge

X

5.19 Drain the sludge from the fuel tank

X

5.20 Service the battery

Pole grease

X

5.21 Change the fuel pre-filter cartridge

X

5.22 Check, replace the refrigerant compressor V-belt

X

5.23 Service the air conditioning

X

5.24 Check, adjust the valve clearance

as required

Check the engine oil level

every 3000 operating hours

5.6

every 2000 operating hours

Remark

every 1000 operating hours

Maintenance work

every 500 operating hours

No.

every 10 operating hours, daily

Maintenance chart

Running-in instructions after 50 operating hours

5.5

every 250 operating hours

Maintenance

Intake = 0,3 mm

X

Exhaust = 0,5 mm

54

BOMAG

BW 213 D-4

5.25 Check, replace the ribbed V-belt X

X

5.27 Oil change in drive axle

min. 1x per year

X

X

5.28 Oil change in wheel hubs

min. 1x per year

X

X

5.29 Oil change vibration bearings**

see foot note, min. 1 X x per year

X

5.30 Retighten the fastening of the axle on the frame

as required

X

5.31 Tighten the wheel nuts

X

5.32 Check the ROPS

X X

min. 1x per year

X

5.34 Change hydraulic oil and breather fil- at least every 2 years ter***

X

5.35 Change the hydraulic oil filter****

at least every 2 years

X

5.36 Change the coolant

at least every 2 years

X

5.37 Check the injection valves 5.38 Service the combustion air filter

every 3000 operating hours

X

5.26 Check the engine mounts

5.33 Clean the oil bath air filter

every 2000 operating hours

every 1000 operating hours

every 500 operating hours

Remark

every 250 operating hours

Maintenance work

every 10 operating hours, daily

No.

Running-in instructions after 50 operating hours

Maintenance

X min. 1x per year, safety cartridge at least every 2 years

X

5.39 Adjust the scrapers

X

5.40 Adjust the parking brake

X

5.41 Change the tires

X

5.42 Change the fresh air filter in the cabin

X

5.43 Tightening torques

X

5.44 Engine conservation

X

BW 213 D-4

BOMAG

55

Maintenance * Oil change intervals depend on quality of oil and fuel (sulphur content) ** Oil change intervals after 50 h, after 500 h, after 1000 h, and then every 1000 h. *** Also in case of repair in the hydraulic system. **** Also in case of repair in the hydraulic system.

56

BOMAG

BW 213 D-4

Every 10 operating hours Every 10 operating hou rs

5.6 !

Check the engine oil level

5.7

Check, clean the water separator

Danger

Danger of injury!

!

Danger

Danger of injury!

Support the engine hood for all maintenance and repair work.

Support the engine hood for all maintenance and repair work.

i Note The machine must be parked horizontally with the engine shut down.

i Note The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should therefore check the water separator every day for signs of water.

If a to high quantity is drained off, the filter must be refilled with fuel. See chapter "maintenance as required", bleeding the fuel system.

Environment Catch running out fuel and dispose of environmentally.

Fig. 69 l

Pull the dipstick (Fig. 69) out, wipe it off with a lint-free, clean cloth and reinsert it until it bottoms.

l

Pull the dipstick back out again.

l

If the oil level is below the "MAX" mark fill in oil.

l

If the oil level is above the “Max” mark determine the cause and drain the oil off.

Caution Before longer work periods you should always top the oil up to the "MAX"-mark. !

For quality and quantity of oil refer to the table of fuels and lubricants.

BW 213 D-4

Fig. 70 l

Slacken the drain plug (Fig. 70) for a few turns and catch running out fuel / water.

l

Tighten the drain plug again and check for leaks, if necessary replace the seal ring.

BOMAG

57

Every 10 operating hours 5.8 !

Check the fuel level

Danger

Fire hazard!

When working on the fuel system do not use open fire, do not smoke, do not refuel in closed rooms, do not inhale any fuel fumes.

Caution Contaminated fuel can cause malfunction or even damage of the engine. !

If necessary, fill in fuel through a funnel with screen. l

If necessary top up with fuel (diesel or winter diesel).

For quality of fuel refer to the table of fuels and lubricants.

Fig. 71

Check the fuel level on the fuel level gauge "n" (Fig. 71) with the ignition switched on.

l

i Note Do not drive the fuel tank dry, as otherwise the fuel system needs to be bled. l

Clean the area around the filler opening.

Fig. 72 l

58

Open the fuel tank cover (Fig. 72).

BOMAG

BW 213 D-4

Every 10 operating hours 5.9

Checking the hydraulic oil level

5.10 Check the coolant level !

!

Danger

Danger of scalding!

Caution

In mit Panolin HLP Synth. 46, the same oil must be used for filling up. In case of any other ester based oil consult the lubrication service department of the respective oil manufacturer.

Fill up coolant only when the engine is cold.

Fig. 74

Check the coolant level (Fig. 74).

l

Fig. 73

Check the oil level in the inspection glass (Fig. 73) on the hydraulic oil tank.

l

Normal level approx. 3 cm below the upper edge of the inspection glass.

Minimum level

Caution If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks. !

l

To top up unscrew the filler cap and fill in coolant up to the MAX-mark.

For quality of coolant refer to the chapter 5.2, fuels and lubricants.

middle of inspection glass.

Caution If during the daily oil check the oil level is found to have dropped, check all lines, hoses and components for leakages. !

l

If necessary fill in hydraulic oil through the filler neck.

For quality and quantity of oil refer to the table of fuels and lubricants.

BW 213 D-4

BOMAG

59

Every 10 operating hours 5.11 Checking the dust separator on the oil bath air filter*

Fig. 75 l

If the dust reaches the mark loosen the clamp (Fig. 75), take the cover off and clean the bowl.

*

Option

60

BOMAG

BW 213 D-4

Every 250 operating hours Every 250 oper ating hours

5.12 Checking the tire pressure !

Caution Since the tires are filled with water, you should always turn the inflation valve to top position to check the tire pressure!

Always close the valves with the dust cap.

5.13 Clean the cooling fins on engine and hydraulic oil cooler Danger Danger of injury! !

Perform cleaning work only after the engine has cooled down and with the engine stopped.

Caution Do not damage any cooling fins on the cooler core when cleaning. !

i Note Dirt on fan blades and oil cooler reduce the cooling effect. Dirt deposits in these areas are substantially supported by oil and fuel on these surfaces. For this reason you should always seal any oil or fuel leaks in the vicinity of the cooling fan or the oil cooler and clean the cooling surfaces after.

Fig. 76 l

Check the tire pressure with a pressure gauge and the tire inflation valve 1 (Fig. 76) in top position.

Cleaning with compressed air

Nominal value see "technical data".

i Note Ensure even pressure in all tires. l

Screw the valve caps back on.

Fig. 77

i Note Start to blow out from the exhaust side.

BW 213 D-4

l

Blow the cooler (Fig. 77) out with compressed air.

BOMAG

61

Every 250 operating hours Cleaning with cold cleansing agent Caution Protect electrical equipment such as generator, regulator and starter against the direct water jet. !

l

Spray the engine with a suitable cleansing agent, e.g. cold cleanser, let it soak in for a while and spray it off with a strong water jet.

l

Run the engine warm for a while to avoid corrosion.

5.14 Check the oil level in the drive axle l

Park the machine on level ground.

Fig. 78 l

Unscrew the oil level inspection plug (Fig. 78) and check the oil level.

i Note The second level inspection plug as at the back.

After filling in oil wait until the oil has evenly distributed inside the axle.

The oil level must reach the bottom edge of the level bore. l

Top up oil, if necessary.

For quality of oil refer to the table of fuels and lubricants. l

62

BOMAG

Turn the level inspection plug tightly back in.

BW 213 D-4

Every 250 operating hours 5.15 Checking the oil level in left/ right wheel hubs

5.16 Check the oil level in the vibration bearings

i Note Check only at operating temperature after running the machine approx. 1/2 hour with vibration.

Park the machine on level ground.

l

Fig. 79 l

Move the machine until the oil level inspection plug 1 (Fig. 79) is in horizontal position.

l

Clean and unscrew the plug.

The oil level must reach the bottom edge of the bore. l

Fig. 80

Top up oil, if necessary.

l

Move the drum, until oil level inspection plug 1 (Fig. 80) on the left hand side of the drum is in bottom position.

l

Unscrew level inspection plug (1).

For quality of oil refer to the table of fuels and lubricants. l

Screw the plug back in tightly.

l

Repeat this inspection on the other side.

Some oil should run out of the inspection bore.

If necessary unscrew oil filler plug (2) and fill in some oil through the oil filler bore (2), until oil starts to drip out through the inspection bore.

l

For quality of oil refer to the table of fuels and lubricants. l

Screw oil filler (2) and level inspection plug (1) back in tightly.

l

Repeat this inspection on the other side.

Caution If a loss of oil is found perform trouble shooting, repair the drum if necessary. !

BW 213 D-4

BOMAG

63

Every 500 operating hours Every 500 operating h ours

5.17 Changing engine oil and oil filter cartridges !

Caution

The oil change at 500 operating hours refers to the use of oils of oil quality class API CG-4/CH4 or ACAE E3-96/E5-02 respectively.

Refer also to the chapter 5.2, fuels and lubricants.

Drain the engine oil only when the engine is warm.

Fig. 82

Danger Danger of scalding!

l

Thoroughly clean the outside of both filter cartridges (Fig. 82).

l

Unscrew both filter cartridges using an appropriate filter wrench.

!

When draining off hot oil.

By hot oil when unscrewing the engine oil filter.

i Note The filter cartridges are fitted with a valve that prevents engine oil from running out during removal and installation.

Environment Catch running out oil and dispose of environmentally together with the engine oil filter cartridge.

l

Clean the sealing face on the filter carrier from any dirt.

l

Slightly oil the rubber seal on the new filter cartridges.

Fig. 81 l

Unscrew the drain plug (Fig. 81) and catch running out oil.

l

Turn the drain plug tightly back in.

64

Fig. 83 l

Turn the new filter cartridges (Fig. 83) on by hand, until the seal contacts.

l

Tighten the filter cartridges for another half turn.

BOMAG

BW 213 D-4

Every 500 operating hours 5.18 Change the fuel filter cartridge !

Danger

Fire hazard!

When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.

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

Fig. 84

Do not inhale any fuel fumes.

Fill in new engine oil (Fig. 84).

l

For quality and quantity of oil refer to the table of fuels and lubricants.

Tighten the oil filler cap properly.

l

!

Caution

Before starting crank the engine with the starter motor until the oil pressure warning light goes out. l

After a short test run check the oil level on the dipstick, if necessary top up to the top dipstick mark.

l

Check filter cartridge and drain plug for leaks after a short test run.

l

l

Fig. 85

Shut the engine down and wait for about 15 minutes, so that all oil can flow back into the oil sump.

l

Loosen and unscrew the fuel filter cartridge (Fig. 85) using an appropriate filter wrench.

l

Clean the sealing face on the filter carrier from any dirt.

Check the oil level again, if necessary fill up to the Max.-mark.

Fig. 86

BW 213 D-4

l

Slightly oil the rubber seal (Fig. 86) on the new filter cartridge.

BOMAG

65

Every 500 operating hours l

Fill the filter cartridge with clean diesel fuel.

l

Turn the new filter cartridge on by hand, until the seal contacts.

l

Tighten the filter element for another half turn.

l

Check the filter cartridge for leaks after a short test run.

5.19 Draining the sludge from the fuel tank !

Danger

Fire hazard!

When working on the fuel system do not use open fire, do not smoke!

Do not spill any fuel.

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

Do not inhale any fuel fumes.

Fig. 87

66

l

Unscrew the cap (Fig. 87) and drain off approx. 5 litres of fuel.

l

Turn the cap tightly back in.

BOMAG

BW 213 D-4

Every 500 operating hours Caution Exhausted batteries (batteries with formation of sulphate on thge plates are not covered under warranty!

5.20 Service the battery !

!

Danger

Danger of cauterisation ! Danger of explosion!

l

Open the engine hood and remove the covering.

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

The battery contains acid. Do not let acid come in contact with skin or clothes!

Wear protective clothing!

Do not lay any tools on the battery!

Environment Dispose of the old battery environmentally.

i Note Maintenance free batteries also need care. Maintenance free only means that the fluid level does not need to be checked. Each battery suffers under self-discharge, which may, in not checked occasionally, even cause damage to the battery as a result of exhaustive discharge.

Fig. 88 l

Remove the battery (Fig. 88) and clean the battery compartment.

l

Clean the outside of the battery.

l

Clean battery poles and pole clamps and grease them with pole grease (Vaseline).

l

Check the fastening of the battery.

l

On serviceable batteries check the acid level, if necessary top up to the filling mark with distilled water.

The following therefore applies for the service life: l

l

Switch off all consumers (e.g. ignition, light, inside light, radio).

Check open-circuit voltage of the battery at regular intervals. At least once per month.

Reference values: 12.6 V = fully charged; 12.3 V = 50% discharged. l

Charging voltage recommendation

Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform boost charging.

The open-circuit voltage of the battery occurs approx. 10 hours after the last charging process or one hour after the last discharge. l

After each charging process allow the battery to rest for one hour before taking it into service.

l

For resting periods of more than one month you should always disconnect the battery. Do not forget to perform regular open-circuit voltage measurements.

BW 213 D-4

Fig. 89

BOMAG

67

Every 500 operating hours 5.21 Change the fuel pre-filter cartridge !

Danger

Fire hazard!

When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.

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

Do not inhale any fuel fumes.

Fig. 90 l

Unscrew the fuel filter cartridge (Fig. 90) using an appropriate filter wrench.

l

Clean the sealing face on the filter carrier from any dirt.

Fig. 92 l

Apply a thin coat of oil to the rubber seal of the water separator 1 (Fig. 92).

l

Screw the water separator on by hand (2), until the seal contacts.

l

Tighten the water separator for another half turn (3).

l

Fill the filter cartridge with clean diesel fuel (4).

l

Apply some oil to the rubber seal of the filter element (5) and screw it on by hand, until the seal contacts.

l

Tighten the filter element for another half turn (6).

l

Check the filter cartridge for leaks after a short test run.

i Note Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting impossible.

Therefore bleed the fuel system after changing the fuel prefilter.

Fig. 91 l

68

Unscrew the water separator from the filter cartridge (Fig. 91).

BOMAG

BW 213 D-4

Every 500 operating hours 5.22 Checking, replacing the refrigerant compressor Vbelt* Danger Danger of injury! !

Work on the V-belt must only be performed with the engine shut down.

Check the V-belt

Fig. 93 l

Slacken the bleeding screw (Fig. 93) on the fuel pre-filter for 2 to 3 turns.

l

Operate the hand pump manually, until fuel flows out of the slackened bleeding screw (Fig. 93) without air bubbles.

l

Then tighten the bleeding screw while pumping.

Fig. 94

BW 213 D-4

l

Inspect the entire circumference of the V-belt (Fig. 94) visually for damage and cracks. Replace damaged or cracked V-belts.

l

Check with thumb pressure whether the V-belt can be depressed more than 10 to 15 mm (0.4 – 0.6 inches) between the V-belt pulleys, retighten if necessary.

*

Optional equipment

BOMAG

69

Every 500 operating hours Tighten the V-belt.

5.23 Service the air conditioning* Cleaning the condenser !

Caution A soiled condenser results in a considerable reduction of air conditioning power.

Under extremely dusty conditions it may be necessary to clean the condenser several times per day.

If, during operation of the air conditioning system, the warning buzzer sounds switch the air conditioning off and clean the condenser.

Fig. 95 l

Slightly slacken fastening screws 1, 2 and 3 (Fig. 95).

l

Press the compressor in direction of arrow, until the correct V-belt tension is reached.

l

Retighten all fastening screws.

Changing the V-belt

In case of formation of foam have the air conditioning system inspected by the service department.

Danger Danger of accident! !

l

Slightly slacken the fastening screws 1, 2 and 3.

Do not clean with a hot water jet. Heat will cause extreme overpressure, which could cause damage or explosion of the system.

l

Press the compressor against the direction of arrow completely against the engine.

Use access steps and grips to mount and dismount the machine.

l

Take the old V-belt off.

l

Fit the new V-belt to the V-belt pulleys.

l

Tension the V-belt as previously described.

!

Caution Check the V-belt tension after a running time of 30 minutes.

Fig. 96

70

l

Unscrew the condenser fastening screws (Fig. 96) and fold the condenser forward.

l

Clean the condenser fins on front and back with compressed air or cold water.

*

Optional equipment

BOMAG

BW 213 D-4

Every 500 operating hours Checking the refrigerant level l

Start the engine.

Fig. 99 l

Fig. 97 l

Check whether the white float (Fig. 99) inside the inspection glass of the drier/collector unit floats right at the top.

Switch the air conditioning (Fig. 97) on.

i Note The refrigerant level is correct.

Fig. 98 l

Choose a cooling temperature with the rotary switch for cabin heater (Fig. 98) in the blue section.

Fig. 100 l

l

Open the air outlet nozzles.

l

Check, whether the outflowing air is noticeably cooler.

If the white float (Fig. 100) inside the inspection glass of the drier/collector unit floats at the bottom, inform the service department.

i Note i Note

The refrigerant level is not correct.

The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on. l

l

Refrigerant must be filled up, if necessary check the air conditioning system for leaks.

Open the hood.

BW 213 D-4

BOMAG

71

Every 500 operating hours Checking the moisture level of the drying agent

arising from the handling and operation of pressure reservoirs. !

Danger

Danger of injury!

In case of mechanical damage or corrosion on this drier/collector unit this unit must be replaced, to avoid bursting and further damage.

Fig. 101

Check the moisture indication pearl (Fig. 101) inside the inspection glass of the drier/collector unit.

l

blue

= drying agent o.k.

purple

= moisture level of drying agent too high.

Fig. 102 l

Inform the service department. Replace drier/ collector unit, check air conditioning system.

l

Check the drier/collector unit (Fig. 102) for mechanical damage or rust.

Caution Have the drier/collector unit replaced by the service department every year before the operating season. !

Checking the condition of the drier/collector unit Caution According to the regulation for pressure reservoirs all pressure reservoirs must be repeatedly inspected by a specialist. In this sense repeated inspections are external examinations, normally on pressure reservoirs in operation. In connection with this inspection the drier/collector unit must be visually examined twice every year. During these inspections special attention must be paid to corrosion and mechanical damage. If the reservoir is not in proper condition it must be replaced for safety reasons, as a precaution to protect operators and third parties against any danger !

72

BOMAG

BW 213 D-4

Every 1000 operating hours Every 1000 operating hours

5.24 Check, adjust the valve clearance !

Caution

Before checking the valve clearance let the engine cool down for at least 30 minutes. The engine oil temperature must be less than 80 °C. After a short test run check the engine for leaks.

Valve adjustment schematic

Fig. 104

Crankshaft position 1 (Fig. 104) (4 cylinder engine) l

Crank the engine with the starter or a spanner by the V-belt pulley until both valves on cylinder 1 are “overlapping”.

Overlapping means: Exhaust valve not yet closed, intake valve starts to open. l

Perform the adjustment of the valve by following the adjustment diagram "crankshaft position 1", black mark.

l

For control purposes mark the respective rocker arm with while chalk once the corresponding valve is adjusted.

Fig. 103

Valve 1 (Fig. 103) white = not adjustable Valve (2) black = adjustable

Fig. 105

Crankshaft position 2 (Fig. 105) (4 cylinder engine)

BW 213 D-4

l

Turn the crankshaft one revolution (360°) further.

l

Perform the adjustment of the valve by following the adjustment diagram "crankshaft position 2", black mark.

BOMAG

73

Every 1000 operating hours Check the valve clearance l

Adjusting the valve clearance

Loosen the crankcase ventilation valve and swing it to the side.

Fig. 108 l

Slightly slacken the counter nut. Adjust setscrew 7 (Fig. 108) with a screwdriver, until the feeler gauge (6) can be inserted and pulled out with little resistance after retightening the counter nut.

l

Perform tests and adjustments on all other adjustable valves.

l

Check the gasket of the valve cover, replace it if necessary.

l

Reassemble the cylinder head cover.

l

Swivel the ventilation valve back to correct position and fasten it.

l

Fasten the air filter again and ensure correct fit of combustion air hoses and clamps.

Fig. 106 l

Remove the valve cover (Fig. 106).

l

Crankshaft position as per "valve adjustment schematic".

Fig. 107 l

Check valve clearance 2 (Fig. 107) between rocker arm (1) and valve (3) with a feeler gauge.

Intake valve

= 0,3 mm

Exhaust valve = 0,5 mm The feeler gauge must fit with little resistance. l

74

If the gap is too narrow or too wide for the feeler gauge, the valve must be adjusted.

BOMAG

BW 213 D-4

Every 1000 operating hours Changing the ribbed V-belt

5.25 Checking / replacing the ribbed V-belt !

Danger

Danger of injury!

Work on the V-belt must only be performed with the engine shut down.

Checking the wear limit of the ribbed Vbelt Fig. 110 l

Unscrew the fastening screws (Fig. 110) and slide the fan forward.

Fig. 109 l

Check the distance between the tongue of the moveable tensioner arm and the fixed tensioner housing (Fig. 109).

l

If measurement "a" is smaller than 3 mm, replace the ribbed V-belt.

Fig. 111 l

Release the idler pulley (Fig. 111) in direction of arrow until the ribbed V-belt is free.

l

Pull the ribbed V-belt first to the smallest pulley.

l

Install the new ribbed V-belt.

l

Release the idler pulley against the direction of arrow until the V-belt is tensioned.

l

Measure the V-belt tension, tighten if necessary.

i Note Retighten the new fan V-belt after a running time of 20 minutes.

BW 213 D-4

BOMAG

75

Every 1000 operating hours 5.26 Check the engine mounts

5.27 Change the oil in the drive axle

i Note On other axle versions drain and filler plugs are of slightly different design. Perform the oil change accordingly.

Caution Drain oil only at operating temperature. !

Environment Catch old oil and dispose of environmentally.

Fig. 112 l

Tighten fastenings of intake and exhaust manifolds (Fig. 112) on the cylinder heads.

l

Check sockets and clamps between air filter, exhaust turbocharger and charge air line as well as the lubrication air line for tight fit and leaks.

l

Retighten the fastening screws for oil sump and engine mounts.

l

Park the machine on level ground.

Fig. 113

76

l

Clean and unscrew all level inspection and drain plugs (Fig. 113).

l

Drain and catch all oil.

l

Clean the drain plug and turn it back in with a new seal ring.

BOMAG

BW 213 D-4

Every 1000 operating hours 5.28 Changing the oil in the wheel hubs !

Caution

Drain oil only at operating temperature.

Change the oil on both sides of the axle.

Environment Catch old oil and dispose of environmentally.

Fig. 114 l

Fill in oil through the oil level inspection bores (Fig. 114), until it has reached the bottom edge of the bore.

i Note The second level inspection plug as at the back.

After filling in oil wait until the oil has evenly distributed inside the axle.

For quality and quantity of oil refer to the table of fuels and lubricants. l

Retighten the filler and level inspection plug.

Fig. 115 l

Move the drive wheel, until the plug (Fig. 115) is in bottom position.

l

Clean and unscrew the plug.

l

Drain and catch all oil.

Fig. 116

BW 213 D-4

l

Move the drive wheel, until the plug (Fig. 116) is in horizontal position on the housing.

l

Fill in oil, until it reaches the bottom edge of the bore.

BOMAG

77

Every 1000 operating hours For quality and quantity of oil refer to the table of fuels and lubricants. l

Turn the plug tightly back in.

5.29 Change the oil in the vibration bearings !

Caution

Change the oil at operating temperature. For this purpose run the machine approx. half an hour with vibration.

Environment Catch running out oil and dispose of environmentally. l

Park the machine on level ground.

Fig. 117

78

l

Move the drum, until the drain plug 1 (Fig. 117) is in bottom position.

l

Unscrew the drain plug, let the oil run out and catch it.

l

Turn the oil drain plug back in tightly after all oil has run out.

BOMAG

BW 213 D-4

Every 1000 operating hours 5.30 Retighten the fastening of the axle on the frame

Fig. 118 l

Unscrew oil level inspection plug 1 (Fig. 118) on the drum and fill in oil through the filler opening (2), until it starts to drip out from the level inspection bore.

Fig. 119

For quality and quantity of oil refer to the table of fuels and lubricants. l

Screw oil filler (2) and level inspection plug (1) back in tightly.

l

Repeat the oil change on the opposite side.

l

Check the oil level once again at operating temperature (after running the machine for about half an hour with vibration).

l

Check all fastening nuts on axle mounting bolts (Fig. 119) for tight fit.

!

Caution Overfilling causes overheating and destruction of the vibration bearings!

BW 213 D-4

BOMAG

79

Every 1000 operating hours 5.31 Tightening the wheel nuts

5.32 Check the ROPS

i Note On machines with cabin the ROPS (roll over protection structure) is an integral part of the cabin.

Please observe also the corresponding section in the safety regulations in this manual.

Fig. 120 l

Tighten the wheel nuts (Fig. 120) in a crosstype pattern.

Fig. 121 l

Inspect the cabin, especially the ROPS (Fig. 121), for cracks, corrosion, damage and missing fastening parts.

i Note Unusual movements and noises (vibrations) during operation are signs for damage or loosened fastening elements.

80

l

Check the fastening screws for the cabin (ROPS) to the operator’s stand for tight fit.

l

Check the rubber buffers of the operator’s platform suspension for condition and tight fit.

l

Check the condition and fastening of the seat belts.

BOMAG

BW 213 D-4

Every 1000 operating hours 5.33 Cleaning the oil bath air filter *

Fig. 122 l

Loosen the quick locks (Fig. 122), take the filter bowl off and empty it.

l

Clean the filter mesh by repetitive dipping into diesel fuel.

l

Clean the filter bowl with diesel fuel and fill in engine oil up to the level mark.

l

reinstall the filter bowl.

*

Option

BW 213 D-4

BOMAG

81

Every 2000 operating hours Every 2000 operating hour s

5.34 Changing hydraulic oil and breather filter

i Note See also chapter 5.1 "Notes on the hydraulic system".

Caution Apart from the normal oil change intervals, the hydraulic oil must also be changed after major repairs in the hydraulic system. !

Fig. 123

Perform the oil change when the hydraulic oil is warm.

l

Unscrew the plug (Fig. 123) and drain off all hydraulic oil.

Clean the area round hydraulic oil tank, filler opening and breather filter.

l

Check seal ring (1), replace if necessary and turn the plug tightly back in.

Do not use any detergents to clean the system.

Do not start the engine after draining the hydraulic oil.

Replace the hydraulic oil filter element with every hydraulic oil change.

!

Danger

Danger of scalding!

Danger of scalding by hot oil.

Environment Catch running out oil and dispose of environmentally.

Fig. 124 l

Remove the filler cap (Fig. 124).

l

Fill in new hydraulic oil through the screen.

i Note Generally replace the hydraulic oil filter element after the test run.

i Note We recommend to use the filling and filtering unit (BOMAG part-no. 079 930 35) with fine filter to fill the hydraulic system. This ensures finest filtration of the hydraulic oil, prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system. l

Check the oil level in the inspection glass.

Nominal value: approx. 3 cm below the upper edge of the inspection glass

82

BOMAG

BW 213 D-4

Every 2000 operating hours For quality and quantity of oil refer to the table of fuels and lubricants.

5.35 Changing the hydraulic oil filter

i Note The breather filter for the hydraulic oil tank is integrated in the filler cap, you must therefore replace the complete filler cap. l

Close the tank with a new filler cap.

!

Danger

Danger of scalding!

There is a danger of scalding by hot oil when unscrewing the filter.

Caution If the filter has to be changed together with the hydraulic oil, the filter should in any case be changed after the oil change and the test run. !

Do not use the oil in the filter bowl.

Environment Catch running out oil, dispose of oil and filter element environmentally.

i Note The filter element must be changed with every hydraulic oil change and after major repairs in the hydraulic system.

Fig. 125 l

Unscrew the cap nut 4 (Fig. 125) and take the filter bowl (5) with the filter element (3) off.

l

Examine the sealing face on the filter element thoroughly for any visible dirt.

Caution Visible impurities may be an early indicator for a failure of system components and predict the !

BW 213 D-4

BOMAG

83

Every 2000 operating hours possible malfunction of important parts. In such a case you should perform trouble shooting and replace or repair the defective components. Nonobservance may lead to total damage of the hydraulic system.

Do not clean or reuse the filter element. l

Take the old filter element (3) out and clean the filter bowl and the thread.

l

Reinstall the filter bowl with the new filter element, check the condition of the O-rings (1) and (2), replace if necessary.

l

After a test run check the filter for leaks.

5.36 Changing the coolant !

Danger

Danger of scalding!

Change the coolant only when the engine is cold.

Environment Catch running out coolant and dispose of environmentally.

Fig. 126 l

Set the cock valve for the cabin heater to position "warm".

Fig. 127

84

l

Unscrew the plug, let the coolant run out and catch it.

l

Screw the plug back in once all coolant has run out.

BOMAG

BW 213 D-4

Every 2000 operating hours

Fig. 128 l

Unscrew the cap and fill in coolant up to the MAX-mark.

For quality of coolant refer to the chapter 5.2, fuels and lubricants. l

Start the diesel engine and run it warm to operating temperature.

l

Let the engine cool down and check the coolant level again, top up if necessary.

BW 213 D-4

BOMAG

85

Every 3000 operating hours Every 3000 operating hour s

5.37 Checking the injection valves

i Note This work must only be performed by authorized service personnel.

The injection valves must be replaced every 12000 operating hours.

86

BOMAG

BW 213 D-4

As required As r equired

i Note

5.38 Service the combustion air filter !

Once the air filter service indicator lights up, work may be continued until the end of the day.

Caution

Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element.

Do not use gasoline or hot fluids to clean the filter element.

After cleaning the filter element must be inspected for damage using a torch.

Air filter elements with damaged paper bellows or seal lips must be replaced in any case.

The main filter element must be replaced after 3 times cleaning, but at the latest after one year, irrespective of the operating hours.

Fig. 130 l

Open the engine hood (Fig. 130) completely and secure it.

Each cleaning interval must be marked with a cross on the cover of the filter element.

Cleaning does not make sense if the air filter element is covered with a sooty deposit. Use a new filter element.

Incorrectly handled filter elements may become ineffective because of damage (e.g.: cracks) and cause engine damage.

Fig. 131 l

Release the locking hook (Fig. 131) and take the filter hood off.

l

Clean filter hood and dust discharge valve.

Fig. 129

Maintenance of the dry air filter is due when control light “c” (Fig. 129) in the instrument cluster lights permanently when the engine is running, but at the latest after one year.

BW 213 D-4

BOMAG

87

As required

Fig. 132

Carefully loosen the main filter element (Fig. 132).

l

The main filter element is located directly on the air intake tube, thereby providing a seal on the inside of the filter cover. Carefully remove the main filter element, in order to reduce the released amount of dust. To release the seal pull the main filter element carefully up, down and sideways or turn it (Fig. 132).

Caution Avoid contact between main filter element and housing. !

Fig. 134 l

Clean the sealing face on the outlet tube (Fig. 134).

Dust on the outer diameter of the outlet tube can impair effective sealing. l

Check the old main filter element.

The old main filter element can be of help to discover foreign particles on the sealing face, which could lead to leaks. A line of dust on the clean air side of the filter may be a sign for such a leak.

Eliminate this problem before installing a new main filter element. l

If the main filter element is damaged, the safety element must be replaced as well.

l

Clean or replace the main filter element.

i Note We generally recommend to change the filter. A new filter element is far less expensive than a possible engine damage. l

Fig. 133 l

88

Pull the main filter element (Fig. 133) carefully out of the housing.

Examine the main filter element thoroughly for damage.

Before installing the new main filter element check it for possible damage from transport, cleaning or incorrect handling. Especially on the inside of the open end (sealing area). Do not install damaged filter elements. l

BOMAG

If necessary use safety elements.

BW 213 D-4

As required

Fig. 135

Fig. 136

Insert the main filter element (Fig. 135).

l

The radial sealing area is located at the inside of the open filter edge. This critical sealing area must be under slight tension after the filter has been installed. In order to achieve a tight seal apply pressure to the outer edge of the filter and not to the moveable centre.

i Note For cleaning purposes fit a tube to the compressed air gun (Fig. 136), the end of which should be bent for approx. 90°.

The length should reach down to the bottom of the element.

Reinstall the filter hood with the dust discharge valve.

l

Caution The dust discharge valve must point vertically downwards.

Blow the main filter element out with compressed air (max. 5 bar) from inside to outside by moving the tube up and down inside the element, until it if free of dust.

l

Examine the main filter element with a torch for cracks and holes in the paper bellows.

l

!

Dry cleaning of the main filter element !

Danger

Eye injury!

Wear protective clothing (goggles, gloves).

Caution Do not continue to use a damaged main filter element. If in doubt use a new main filter element. !

Changing the safety filter element Caution The safety filter element must not be cleaned and should not be used again after it has been removed. !

The safety filter element must be replaced: if the main filter element is defective, after three times cleaning of the main filter element, at the latest after 2 years,

BW 213 D-4

BOMAG

89

As required if the warning light comes on again after servicing the main filter cartridge. l

Remove the housing cover and pull the main filter element off.

5.39 Adjust the scrapers Smooth drum l

Check adjustment and condition of front and rear scrapers, if necessary adjust or replace the scraper rubber.

Fig. 137 l

Pull the safety element (Fig. 137) out by turning it lightly.

l

Push in a new safety filter element.

Fig. 138

l

Reassemble main filter element and cover.

l

In order to adjust the scrapers 2 (Fig. 138), slacken the fastening screws (1) in the slots and push the scraper towards the drum to contact.

l

Retighten the fastening screws.

Padfoot drum l

90

BOMAG

Check adjustment and condition of front and rear scrapers, if necessary adjust or replace the scraper rubber.

BW 213 D-4

As required 5.40 Adjust the parking brake !

Caution Have adjustment work on the brakes only carried out by a specialist! Always adjust both sides.

l

Secure the machine with wheel chocks against rolling.

l

Start the diesel engine to relieve the brake.

Fig. 139 l

Check adjustment and condition of scrapers (Fig. 139), adjust or replace the teeth if necessary.

l

To adjust the scrapers slacken the clamping screws and push the scrapers towards the drum, leaving a gap of about 25 mm.

l

Retighten the clamping screws.

Fig. 140 l

Disengage the travel lever (Fig. 140) to the left, but do not move to position "I" or "II".

The parking brake is released

Fig. 141

BW 213 D-4

l

Unscrew locking plate 2 (Fig. 141).

l

Turn the square (1) in anti-clockwise direction against the stop.

BOMAG

91

As required 5.41 Changing the tires !

Danger

Danger of accident!

Observe all safety notes for the lifting of loads. l

Place a jack (min. 5 t bearing capacity) under the rear frame and jack the machine up so that the wheel can turn freely.

l

Unscrew the wheel nuts and take the wheel off.

Fig. 142 l

In order to adjust the brake clearance turn the square 1 (Fig. 142) three turns back in clockwise direction.

l

Fasten the locking plate again.

l

Pull the plug off the brake solenoid valve and perform the drive test.

The machine must be braked.

Fig. 143

92

l

Attach the wheel (Fig. 143) and tighten the wheel nuts crosswise with 550 Nm (405 ft. lb.).

l

Check the tire pressure, see technical data.

BOMAG

BW 213 D-4

As required 5.42 Change the fresh air filter in the cabin

5.43 Tightening torques

Fig. 145

* Strength classes for screws with untreated, nonlubricated surface. Screw quality designations are stamped on the screw heads.

Fig. 144 l

l

8.8 = 8G

Unscrew fastening screws for the ventilation grid (Fig. 144) and remove the filter.

10.9 = 10K

Insert a new filter and reassemble the ventilation grid.

12.9 = 12K l

Axle - frame

M 22x1.5 l

= 710 Nm

Wheel nuts

M 22x1.5

= 550 Nm

The values result in a 90% utilization of the screw yield point at a coefficient of friction µ total = 0,14.

When using lubricant MOS2 the specified tightening torques do not apply.

i Note Self-locking nuts must always be replaced once they have been unscrewed.

BW 213 D-4

BOMAG

93

As required 5.44 Engine conservation If the engine is to be shut down for a longer period of time (e.g. over winter), please consult the service department of the engine manufacturer for further details.

94

BOMAG

BW 213 D-4

6 Trouble shooting

BW 213 D-4

BOMAG

95

Trouble shooting 6.1

General notes

The following work must only be carried out by qualified and trained personnel or by the sales service.

Please observe strictly the safety regulations in chapter 2 of these operating and maintenance instructions.

Faults occur frequently due to the fact, that the machine has not been properly operated or serviced. Therefore, whenever a fault occurs, read through these instructions on correct operation and maintenance. If you cannot locate the cause of the fault or eliminate it yourself by following the trouble shooting charts, you should contact our customer service departments at our branch office or dealers.

Danger Danger of injury! !

Keep away from rotating parts of the engine.

96

BOMAG

BW 213 D-4

Trouble shooting 6.2

Engine

Faults

Possible cause

Remedy

The engine does not start

Starter defective or pinion not engaging

Have examined by a specialist

Fuel tank empty

Fill and bleed the tank

Temperature below starting limit

Use winter fuel and engine oil acc. to the ambient temperature.

Fuel filter clogged, in winter due to paraffin separation.

Change the filter. use winter fuel

Fuel lines leaking

Check all line connections for leakages and tighten the fittings.

Battery discharged or not connected

Tighten the pole clamps, check the cable connections

Injection valves or injection pump defective

Have examined by a specialist

Battery power too low, battery clamps loose or oxidized, causing the starter to turn too slowly

Have the battery checked, clean the terminal clamps, tighten them and cover them with acid free grease

Especially during winter: the use of too viscous engine oil

Use engine oil suitable for the ambient temperature

Fuel supply restricted, in winter fuel system clogged due to paraffin separation

Change the fuel filter. Check the line connections for leaks and tighten the fittings.

Use winter fuel in the cold season.

Incorrect valve clearance

Adjust the valve clearance

Injection valve defective

Have examined by a specialist

Injection lines leaking

Check the lines for leakages

Turbo charger defective

Have examined by a specialist

Dry air filter dirty

clean, replace if necessary

Excessive play in the throttle cable

Adjust the throttle cable, change it if necessary

The engine starts poorly and works irregularly with poor power

BW 213 D-4

BOMAG

97

Trouble shooting Faults

Possible cause

Remedy

Excessive exhaust smoke

Engine oil level too high

Drain the oil to the upper dipstick mark

Dry air filter dirty

clean, replace if necessary

Exhaust gas turbo-charger defective

Have examined by a specialist

Poor compression due to burned or broken compression rings or incorrect valve clearance

Have compression rings and pistons examined by a specialist, adjust the valve clearance

Incorrect valve clearance

Adjust the valve clearance

Cooling fins on radiator extremely soiled (the warning light "engine oil temperature" lights)

Clean the cooling fins

Injection valve defective

Have examined by a specialist

Engine oil level too low

Top up engine oil to the upper dipstick mark

Filling capacity of the injection pump not correctly adjusted

Have adjusted by a specialist

Cooling air flow restricted

Clean the cooling air duct

V-belt loos or broken

Tension or replace the V-belt

Engine oil level too high

Drain the engine oil down to the upper dipstick mark

Dry air filter dirty

clean, change if necessary

Exhaust gas turbo-charger defective

Have examined by a specialist

Charge air hose leaking

Check fastening and connections

Incorrect valve clearance

Adjust the valve clearance

Injection valve defective

Have examined by a specialist

Engine oil level too low (control light "engine oil pressure" lights, the warning buzzer sounds)

Top up oil

Leakages in the lubrication system

Shut the engine down immediately, check fittings on oil lines, lubrication oil filter and oil cooler for leaks, if necessary tighten the fittings.

Generator speed too low

Check the V-belt tension, replace the Vbelt if necessary

The generator does not charge the battery, because generator or regulator is defective

Have examined by a specialis

Engine overheats, shut down immediately!

Poor engine power

Engine oil pressure too low

The charge control light lights during operation, the warning buzzer sounds

98

BOMAG

BW 213 D-4

Trouble shooting

BW 213 D-4

BOMAG

99

Trouble shooting

100

BOMAG

BW 213 D-4