Bomag BW213 DH-3 BW213 PDH-3 BW213 PDBH-3 Single drum roller Operating instructions Manual 00814011

Operating instructions Maintenance instructions

%: '+ %: 3'+ %: 3'%+ S/N 101 580 27 .... S/N 101 580 24 ....

6LQJOH GUXP UROOHU

Catalogue number

)RUHZRUG

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

Only operate the machine after you have been properly instructed and by observing these instructions.

The vast experience of BOMAG as well as most modern production and testing methods, e.g. lifetime tests of all important components and most stringent quaolity demands ensure highest reliability of your machine.

Please observe strictly the safety regulations.

F oreword

Please observe also the guidelines of the civil engineering liability association "Safety Rules for the Operation of Road Rollers and Soil Compactors" and the applicable instructions for the prevention of accidents.

This manual comprises: ●

Safety regulations

●

Operating instructions

●

Maintenance instructions

●

Trouble shooting

For your own safety you should only use genuine BOMAG spare parts.

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

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

Using these instructions will ●

help you become acquainted with the machine.

●

avoid malfunctions caused by unprofessional operation.

You can obtain the spare parts catalogue fromyour BOMAG dealer against the serial number of your machine.

Compliance with the maintenance instructions will ●

increase the reliability of the machine on the construction site,

●

prolong the lifetime of the machine,

●

avoid repair costs and downtime.

You can also obtain information about the correct use of your machine in earth and asphalt construction from your BOMAG dealer.

The information in this manual does not extent or replace the warranty and liability conditions in the general terms of business of BOMAG. We wish you much success with your BOMAG machine.

BOMAG will not assume liability for the correct function of the machine

BOMAG GmbH & Co. OHG Printed in Germany

●

if it is handled in a way which does not comply with the usual mode of operation,

●

if it is used for purposes other than those mentioned in these instructions.

Copyright by BOMAG

No warranty claims can be lodged in case of ●

operating errors,

●

insufficient maintenance and

●

incorrect fuels and lubricants.

Please note!

These instructions were written for the operator and the service man on the construction site.

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

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

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

Serial No. (Fig. 1 and 2) ............................

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

Engine No. (Fig. 3) L

Note

Fig. 1

Fill in the above listed data when receiving the machine.

Upon receipt of the machine our organization will instruct you about correct operation and maintenance.

Please observe strictly all safety regulations and notes on potential dangers!

Fig. 2

Fig. 3

6

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BW 213 DH-3 / PDH-3

Table of Contents

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3.1 General notes

24

3.2 Description of indicators and control elements

24

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4.1 General notes

34

4.2 Tests before starting to operate

34

4.3 Starting the engine

35

4.4 Starting with jump leads

37

4.5 Driving the machine

38

4.6 Emergency exit

40

4.7 Operating the parking brake, stopping the machine

40

4.8 Shutting the engine down

41

4.9 Switching the vibration on and off

42

4.10 Adjusting the steering wheel

43

4.11 Adjusting the seat

44

4.12 Operating the Dozer Blade (BW 213 PDBH-3)

44

4.13 Moving the hood to maintenance position/closing the hood.

45

4.14 Towing the machine in case of an engine failure

46

4.15 Transport

47

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5.1 General notes on maintenance

50

5.2 Fuels and lubricants

51

5.3 Table of fuels and lubricants

54

5.4 Running-in instructions

55

5.5 Maintenance chart

56

5.6 Checking the engine oil level

58

5.7 Checking, cleaning the water separator

58

5.8 Checking the fuel level

59

5.9 Checking the hydraulic oil level

60

5.10 Checking the coolant level

60

5.11 Checking the V-belt

61

5.12 Checking the dust separator on the oil bath air filter

61

5.13 Checking the tire pressure

62

5.14 Adjusting the scrapers

62

5.15 Grease the dozer blade (BW 213 PDBH-3)

63

5.16 Changing engine oil and oil filter cartridge

64

5.17 Cleaning the cooling fins on radiator and hydraulic oil cooler

66

5.18 Checking the oil level in the axle

67

5.19 Checking the oil level in the axle reduction gear

67

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Table of Contents

5.20 Checking the oil level in the planetary drives

68

5.21 Checking the oil level in the vibration bearing housings

68

5.22 Checking the oil level in the axle reduction gear

69

5.23 Servicing the battery

70

5.24 Draining the fuel tank sludge

70

5.25 Changing the fuel filter cartridges

71

5.26 Checking V-belt tension, idler pulley and blower hub

72

5.27 Changing the oil in the drive axle

74

5.28 Changing the oil in the planetary drive

74

5.29 Changing the oil in the axle reduction gear

75

5.30 Changing the oil in the drum drive reduction gear

76

5.31 Changing the the oil for the vibration bearings

77

5.32 Checking the fastening elements on the engine

78

5.33 Tightening the fastening of the axle to the frame

78

5.34 Tightening the wheel nuts

79

5.35 Checking the ROPS

79

5.36 Cleaning the oil bath air filter

80

5.37 Checking, adjusting the valve clearance

81

5.38 Changing the hydraulic oil and the breather filter

83

5.39 Changing the hydraulic oil filter

84

5.40 Changing the coolant

85

5.41 Cleaning, changing the dry air filter cartridge

87

5.42 Adjusting the parking brake

89

5.43 Bleeding the fuel system

90

5.44 Changing the tires

91

5.45 Changing the fresh air filter in the cabin

92

5.46 Tightening torques

92

5.47 Engine conservation 7URXEOH VKRRWLQJ

8

93

6.1 General notes

96

6.2 Engine

97

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1 Technical Data

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Fig. 4

Dim. mm (inch) BW 213 DH-3

A 2868

B 2250

D 1500

H2 2970

H 2268

K 490

L 5610

O1 60

O2 60

S 35

W 2130

BW 213 PDH-3 2868

2250

1480

2970

2268

490

5610

60

60

25

2130

*

Weights Operating weight (CECE) with ROPS and cab Axle load, drum (CECE) Axle load, rear (CECE) Static linear load Travel performance data Travel speed (1) Travel speed (2) Travel speed (3) Max. gradability (depending on soil) Drive Engine manufacturer Type Cooling Number of cylinders Rated power DIN ISO 9249 Rated speed Fuel Electrical equipment

10

BW 213 DH-3

BW 213 PDH-3

kg

12650

13050

kg kg kg/cm

7060 5590 33

7460 5590 -

km/h km/h km/h %

0...3,5 0...6,3 0...12 55

0...3,5 0...6,3 0...12 55

kW

CUMMINS 6BTA5.9 water 6 135

CUMMINS 6BTA5.9 water 6 135

2200 Diesel 12

2200 Diesel 12

rpm V

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Drive system Driven axles

BW 213 DH-3 hydrostatic 2

BW 213 PDH-3 hydrostatic 2

Brakes Service brake Parking brake

hydrostatic hydro-mech.

hydrostatic hydro-mech.

Steering Steering system Steering control

articul. hydrostatic

articul. hydrostatic

Vibration Vibrating drum Drive system Frequency Amplitude

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

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

Hz mm (in)

Tires Tire size Air pressure Filling capacities Engine Fuel Hydraulic oil Coolant *

bar

Goodyear 23.1/18-26TL Goodyear 23.1/18-26TL, AWT, 8PR 10PR Dyna Torque 1,1 1,1

l (USgal) l (USgal) l (USgal) l (USgal)

19 (5.01) 340 (89.82) 60(15.85) 20 (5.28)

19 (5.01) 340 (89.82) 60 (15.85) 20 (5.28)

Technical modifications reserved

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Fig. 5

Dim. mm (inch) A BW 213 PDBH- 2868 3

B 2250

D 1480

H2 2970

H 2268

K 490

L 5610

*

O2 60

S 25

W 2130

BW 213 PDBH-3

Weights Operating weight (CECE) with ROPS and cab Axle load, drum (CECE) Axle load, rear (CECE) Static linear load Travel performance data Travel speed (1) Travel speed (2) Travel speed (3) Max. gradability (depending on soil) Drive Engine manufacturer Type Cooling Number of cylinders Rated power DIN ISO 9249 Rated speed Fuel capacity Electrical equipment

12

O1 60

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kg

12650

kg kg kg/cm

7060 5590 -

km/h km/h km/h %

0...3,5 0...6,3 0...12 55

kW

CUMMINS 6BTA5.9 water 6 135

rpm l V

2200 340 12

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*

Drive system Driven axles

BW 213 PDBH-3 hydrostatic 2

Brakes Service brake Parking brake

hydrostatic hydro-mech.

Steering Steering system Steering control

articul. hydrostatic

Vibration Vibrating drum Drive system Frequency Amplitude

Hz mm

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

bar

Goodyear 23.1/18-26TL, 10PR Dyna Torque 1,1

l (USgal) l (USgal) l (USgal) l (USgal)

19 (5.01) 340 (89.828) 60(15.852) 20 (5.28)

Tires Tire size Air pressure Filling capacities Engine Fuel Hydraulic oil Coolant *

Technical modifications reserved

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The following noise and vibration values according to the EEC machine regulation (edition 91/368/ EEC) have been determined at nominal engine speed and with the vibration running. The machine was standing on an elastic base.

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

Noise values The sound level according to enclosure 1, paragraph 1.7.4.f of the EEC-machine regulation is sound pressure level at the operator’s stand (with cabin): LpA = dB(A) soun capacity level: LWA = dB(A) These values were determined according to ISO 3744 for the sound capacity level (LWA) or ISO 6081 for the sound pressure level (LpA) at the operator’s stand.

Vibration values The vibration values according to enclosure 1, paragraph 3.6.3 a of the EC-machine regulation are: Vibration effecting the whole body (operator’s seat) The weighted effective acceleration value according to ISO 2631 part 1 is <= 0,5 m/sec2.

Hand-arm vibration values The weighted effective acceleration value according to ISO 8662 Part 1 is <= 2,5 m/sec2.

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2 Safety regulations

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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.

●

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.

●

the machine is operated by untrained personnel

●

the machine is modified or converted in an unprofessional way

●

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: ●

applicable accident prevention instructions

●

generally acknowledged safety and road traffic regulations

●

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: ●

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

●

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

●

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

●

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

16

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.

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

L

Towing the machine You should generally use a tow bar.

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

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

Note

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

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

Checking the Roll Over Protection Structure (ROPS) L

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 ●

they step or stand under loads being lifted

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

●

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: ●

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there are persons or obstructions beside or under the machine

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●

the machine is free of any oily and combustible material

●

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

●

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: ●

the machine shows any obvious defects

●

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!

●

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

●

the seat is correctly adjusted

●

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!

●

do not leave the operator’s stand

Starting

●

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

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

●

if possible drive the machine out of the danger zone

●

have the power shut off.

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

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

After starting check all gauges.

Operate the machine only from the operator’s seat.

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!

18

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.

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Parking on slopes and gradients

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.

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

Always allow loaded transport vehicles to pass.

Switch the lights on when the visibility is poor.

Keep clear of edges and embankments.

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!

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.

Leaking fuel tanks can cause explosions. Ensure tight fit of the fuel tank lid, replace immediately if required.

Fire protection measures Become familiar with the location of fire extinguishers. Observe all fire alarm and fire fighting possibilities.

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

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

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

●

return the travel lever to neutral position

●

apply the parking brake

●

shut the engine down and pull the ignition key out.

●

lock the cabin

●

secure the machine against unauthorized use.

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Do not refuel in closed rooms.

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

Park the machine on level and firm ground.

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

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

Maintenance

Parking the machine

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

Do not inhale fuel fumes.

Mix diesel fuel and gasoline (no super-grade gasoline) only inside the tank. Fill in the necessary quantity of gasoline first, then add the diesel fuel.

Gasoline - diesel mixes are as inflammable as gasoline!

Match the speed of the machine to the working conditions.

●

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

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.

Keep unauthorized persons away from the machine.

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

Park the machine on horizontal, level and stable ground.

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Pull the key out of the ignition switch.

●

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

●

Do not mix up hoses by mistake.

●

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

Lock the articulated joint with the articulation lock.

Working on hydraulic lines 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.

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

Drain the engine oil at operating temperature danger of scalding!

Drain hydraulic oil at operating temperature - danger of scalding!

Catch running out hydraulic oil and dispose of environmentally.

Always catch and dispose of biological hydraulic oils separately.

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

Do ot use any fuses with higher ampere ratings or repair a fuse with a piece of wire. Fire hazard!

Changing hydraulic hoses All hydraulic hoses must be inspected visually at regular intervals.

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

Hydraulic hoses must be changed immediately if:

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

embrittlement of the outer layer (development of cracks in the hose material) deformation under pressurized and depressurized condition, which are not in accordance with the normal shape of the hydraulic hose deformation in bends, e.g, squeezes, kinks, layer separation, formation of blisters

●

leakages.

●

non-observance of the installation requirements

●

Working on the battery

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

●

separation of the hydraulic hose from the fitting

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

Working on electrical equipment

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

●

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

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

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

●

Working on the engine Shut the engine down before opening the engine compartment hood.

Do not change the setting of high pressure relief valves.

●

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

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.

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

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

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

Dispose of old batteries environmentally.

Switch the charging current off before removing the charge clamps.

20

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

Working on the fuel system

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

Do not inhale fuel fumes.

Test

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

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.

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

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

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 materials to the direct water jet, but cover them beforehand. ●

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

After maintenance work Reinstall all protective devices after completing the maintenance work.

Repair 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.

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3 Indicators and Controls

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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

Nr. 1 =

Fuse box

Fuse box "a" (1), 30A = (F05) socket (2), 30A = (F11) head lights, StVZO (3), 30A = (F13) starting (4), 30A = (F19) working head lights, front, left (5), 30A = (F22) working head lights, rear (6), 30A = (F21) dash board illumination Fuse box "b" (1), 25A = (F40) cabin heater (2), 30A = (F37) sprinkler system, pump (3), 30A = (F07) hazard light (4), 30A = (F09) rear parking light, left (5), 30A = (F10) rear parking light, right (6)

= not used

Fuse box "c" (1), 30A = (F14) engine solenoid (2), 30A = (F26) instruments, travel speed ranges (3), 30A = (F24) monitoring board (4), 30A = (F25) solenoid valve, brake/travel (5), 30A = (F03) vibration (6), 30A = (F23) warning horn

24

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Fuse box "d" (1), 30A = (F51) solenoid valve for speed range selection, anti-spin control (2), 30A = (F18) working head lights, front (3), 10A = (F63) Joystick steering (4), 30A = (F60) speed control (5), 30A = (F06) sprinkler system (6), 30A = (F08) direction indicators Danger Fire hazard!

Fig. 8

Do not use fuses with a higher Ampere rating and do not bridge fuses.

Nr. 3 =

shows the fuel level in the fuel tank.

Fig. 7

Nr. 2 =

Fig. 9

Operating hour meter

Nr. 4 =

counts the operating hours while the engine is running All service work must be carried out according to the reading of the operating hour meter.

Fuel gauge

Rotary switch for hazard light system*

Position "left"

= hazard light switched off, the control lights go out.

Position "right" = hazard light switched on, control light 7 on fault monitoring board lights up.

*

BW 213 DH-3 / PDH-3

%20$ *

Option

25

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Position "turtle" = working speed range on level ground or on inclinations exceeding 15% Position "rabbit, small" = working speed range on level ground and on light inclinations, with high working speed Position "rabbit, big" = transport speed, e.g. when driving to the place of use, vibration not possible Fig. 10

Nr. 5 =

Push button for warning horn

Fig. 13

Nr. 8 =

Tachometer*

shows the travel speed of the machine.

Fig. 11

Nr. 6 =

Rotary switch, vibration

black scale

= km/h

red scale

= M.P.H.

Position "middle" = vibration off Position "left"

= low amplitude, high frequency

Position "right" = high amplitude, low frequency

Fig. 14

Nr. 9 =

Fig. 12

Nr. 7 =

26

Rotary switch, speed ranges

* **

%20$ *

Omega-meter**

Option Option

BW 213 DH-3 / PDH-3

,QGLFDWRUV DQG &RQWUROV

a compaction measuring instrument, which continually shows the load bearing values during the compaction pass.

Omega value increase

= higher load bearing capacity

constant

= end of compaction

1 digit

= 20 Omega values

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.

unlock

= turn the button clockwise and release it.

to drive

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

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

Fig. 15

Nr. 10 = RPM-meter for vibrator shaft* shows the vibrator shaft speed when the vibration is switched on.

Scale value x 100 = revolutions per minute

Fig. 17

Nr. 12 = Rotary switch, lighting (StVZO) ** Position "left"

= light off

Position "middle" = fender lights on, with the ignition switch in position "I" or "P" Position "right" = travel lights on, with ignition switch in position "I".

Fig. 16

Nr. 11 = Emergency stop switch The engine will be shut down and the brake will close.

Danger Danger of accident!

*

Option

BW 213 DH-3 / PDH-3

**

%20$ *

Option

27

,QGLFDWRUV DQG &RQWUROV

Fig. 18

Fig. 20

Nr. 13 = Rotary switch working lights*

Nr. 15 = Fault monitoring board

Position "left"

= light off L

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

L

Note

After switching the ignition on all lamps on the fault monitoring board light up for self-testing.

Note

If the machine is fitted with fender lights, the working head lights can only be switched on together with these fender lights 12 (middle position).

The display will also show functions, which are only preassembled as options but not really installed.

Replace a defective fault monitoring board immediately.

The control and warning lights on the fault monitoring board flash: No. 1

L

= Air filter cartridge dirty. Clean, change the cartridge.

Note

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

No. 2

= engine oil pressure too low, the warning buzzer sound too and the engine shuts down after 10 seconds. Check the engine oil level, if necessary have the engine repaired.

No. 3

= hydraulic oil filter dirty, the warning buzzer will sound and the engine will be shut down after 2 minutes.

Change the filter element, check the hydraulic system if the indicator lights up too early.

No. 4

= battery not being charged, check the V-belt, have the generator repaired if necessary.

No. 5

= brake applied or travel lever in "neutral"-position with the engine running

Fig. 19

Nr. 14 = Rotary switch for direction indicators left / right* Position "middle" = direction indicator off Position "left or right" = front and rear direction indicators on the respective side light up, the control light in the fault monitoring board flashes

*

28

Option

%20$ *

BW 213 DH-3 / PDH-3

,QGLFDWRUV DQG &RQWUROV

No. 6

= direction indicators switched on

No. 7

= hazard light switched on

No. 8

= coolant temperature too high, the warning buzzer sounds too and the engine shuts down after 2 minutes.

Clean the radiator.

No. 9

= malfunction of the "ASC"* anti-spincontrol.

L

Note

Further trouble shooting via the flash code on the ASC control unit in the electric installation box.

Fig. 22

Operation of the machine may be continued, but the service departtment of BOMAG should be informed.

No. 10

Nr. 17 = Travel lever

= Coolant too low, the warning buzzer will also sound and the engine will be shut down after 10 seconds.

Position "middle" = brake position for service brake Position "middle, right" = parking brake, to start the engine Position "I"

= forward travel

Position "II"

= reverse travel

L

Note

If the engine speed is forced down when driving up steep inclines, move the travel lever slightly back.

This reduces the load on hydraulic system and diesel engine.

Fig. 21

Nr. 16 = Push button for vibration ●

Pre-select or activate the frequency with the vibration selection switch

●

Press the switch to switch the vibration on and off.

Fig. 23

Nr. 18 = Throttle lever

*

Position "I"

= full load position, operating position for driving and vibration

Position "II"

= idling speed position

Option

BW 213 DH-3 / PDH-3

%20$ *

29

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

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.

Nr. 19 = Locking plate for throttle lever

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

pull

= the throttle lever can be moved to position "II"

release

= the throttle lever locks in position "I".

Fig. 25

Nr. 21 = Shut-off valve for cabin heater* Fig. 24

Nr. 20 = Ignition switch

L

Note

Position "P"/"0" = ignition off, the key can be pulled out, engine not running.

The heat exchanger of the cabin heater receives the heat energy from the engine coolant circuit.

Position "I"

Position "I"

= cabin heater off

Position "II"

= cabin heater full power

L

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

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

Fig. 26

Nr. 22 = Air circulation nozzle for heater** adjust direction = turn outside of nozzle * **

30

%20$ *

Option Option

BW 213 DH-3 / PDH-3

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regulate air flow = adjust and open or close by tilting the flap Nr. 23 = Fuse box, cabin* (1) -

= not used

(2) 7,5A

= cabin light

(3) 7,5A

= windscreen wiper/washer, rear

(4) 7,5A

= windscreen wiper/washer, front

(5) 7,5A

= flashing beacon

(6) 7,5A

= heating blower, radio

Fig. 27

Danger

Nr. 30 = Steering lever*****

Fire hazard!

lever to the left = machine drives to the left

Do not use fuses with a higher Ampere rating and do not bridge fuses.

lever to the right

Nr. 24 = Toggle switch, heating blower

= machine drives to the right

Nr. 25 = Toggle switch, flashing beacon** Nr. 26 = Toggle switch, windscreen wiper/ washer, front*** Nr. 27 = Toggle switch, windscreen wiper/ washer, rear**** Nr. 28 = Cabin light switch on

= turn lamp glass clockwise

switch off

= turn lamp glass counter-clockwise

Nr. 29 = Vent for fresh air intake to operate the slide loosen the adjustment button. slide to the left = air circulation position slide to the right = fresh air position

Fig. 28

Nr. 31 = Main fuse for battery 80A

= (F00)

Switch on the auxiliary hot air blower L

Note

The main fuse is located in the battery compartment.

* Option ** Option *** Option **** Option

BW 213 DH-3 / PDH-3

*****Option

%20$ *

31

,QGLFDWRUV DQG &RQWUROV

Fig. 29

Nr. 32 = Rpm-meter for diesel engine* shows the speed of the diesel engine.

Scale value x 100 = revolutions per minute

Fig. 30

Nr. 33 = Pedal for dozer blade (BW 213 PDBH3)** Position "0"

= stop positoin, dozer blade is standing.

Position "I"

= lifting the dozer blade

Position "II"

= lowering the dozer blade

Position "III"

= Dozer blade, floating position (e.g. to level the ground during reverse travel)

* **

32

Option Option

%20$ *

BW 213 DH-3 / PDH-3

4 Operation

BW 213 DH-3 / PDH-3

%20$ *

33

2SHUDWLRQ

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.

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

4.2

Tests before starting to operate

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

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.

●

Check: ●

Fuel tank and fuel lines for leaks

●

Bolted connections for tight fit

●

Function of the steering

●

Machine for cleanliness, damage

●

Availability of the appropriate operating and maintenance instructions,

●

Check if the machine has been properly serviced.

L

Note

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

●

L

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. ●

Hydraulic oil level, top up if necessary.

●

Coolant level, top up if necessary.

Danger Fire hazard!

Do not refuel in closed rooms

34

●

Fuel level, top up if necessary.

●

Water separator for fuel system, drain if necessary.

%20$ *

BW 213 DH-3 / PDH-3

2SHUDWLRQ

●

Scrapers, adjust if necessary.

●

Tire pressure. Pressure see technical data.

Caution Ensure equal pressure in both tires.

4.3

Starting the engine

Danger Danger of accident!

Always wear your seat belt.

Fig. 31 ●

Wear your seat belt (Fig. 31).

Fig. 32 ●

BW 213 DH-3 / PDH-3

%20$ *

Check, whether the travel lever (Fig. 32) is locked to the right in braking position.

35

2SHUDWLRQ

Fig. 33 ●

Turn the rotary vibration selector switch (Fig. 33) to position "0", vibration off.

Fig. 36

Turn the ignition switch (Fig. 36) to position "I".

●

Fig. 37 Fig. 34 ●

Check, whether the emergency stop switch (Fig. 34) is unlocked.

All control and warning lights (Fig. 37) on the fault monitoring board light for a short moment.

The charge control light (4), the engine oil pressure warning light (2) and the brake warning light (5) light up.

Caution Do not start for longer than 20 seconds at once, but interrupt the starting procedure for one minute.

If the engine has not started after 2 tries, detect the cause.

Fig. 35 ●

36

Shift the throttle lever (Fig. 35) to approx. 1/2 full speed position and hold it.

%20$ *

BW 213 DH-3 / PDH-3

2SHUDWLRQ

4.4

Starting with jump leads

Caution Wrong connection will cause severe damage to the electrical system.

Fig. 38 ●

Turn the ignition switch to position "II", the starter will crank the engine.

●

Once the engine ignites turn the ignition switch back to position "I".

●

Once the engine runs properly, reduce the engine speed.

Fig. 39

Caution

●

When starting with an external battery connect both plus poles (Fig. 39) first and both minus poles (earth cable) after.

●

Perform all steps as described in the previous section.

●

After starting disconnect the minus poles (earth cable) first and the plus poles after.

Run the engine warm for a short while, do not run at idling speed for more than 10 minutes.

BW 213 DH-3 / PDH-3

%20$ *

37

2SHUDWLRQ

4.5

Driving the machine

Danger Danger of accident!

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

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

Do not drive up or down inclinations which exceed the maximum gradability of the machine (see technical data).

Fig. 41

Do not drive without wearing the seat belt.

●

Always allow loaded transport vehicles to pass!

Lifting the dozer blade (BW 213 PDBH-3) (Fig. 41).

Before setting off make sure that the travel area is save to drive.

Caution Always keep the cabin door closed when driving. When articulating the machine while the door is open, heavy oscillation movements of the machine can damage the door.

Fig. 42 ●

Select the desired travel speed range (Fig. 42).

Fig. 40 ●

Close the cabin door (Fig. 40).

Fig. 43

38

●

Shift the throttle lever to full speed position "I" (Fig. 43) and lock it.

%20$ *

BW 213 DH-3 / PDH-3

2SHUDWLRQ

When driving on gradients or to brake the machine move the travel lever slowly back towards "0"-position.

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

Fig. 44

Unlock the travel lever (Fig. 44) by shifting it to the left out of the braking position and move it slowly to the desired travel direction.

●

L

Note

Move the travel lever slowly out of "0"-position forwards or backwards, the machine will drive to the chosen direction at a speed, which is directly related to the distance the travel lever has been moved out of "0"-position.

When returning the travel lever the machine will decelerate and come to a halt when the travel lever is in "0"-position.

Danger

Danger of accident!

To stop on inclinations lock the travel lever in braking position by pushing it to the right.

Important notes on travel operation Caution When reversing the travel direction hold the travel lever for a moment in "0"-position until the machine has come to a halt, then shift the travel lever to the new direction.

Do not operate jerkily!

Do not use the throttle lever to regulate the travel speed! Regulate the travel speed only with the travel lever. During operation the throttle lever should always remain in full speed position.

BW 213 DH-3 / PDH-3

%20$ *

39

2SHUDWLRQ

4.6

Emergency exit

4.7

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.

Operating the parking brake, stopping the machine

Fig. 45

Move the travel lever (Fig. 45) slowly to "neutral"-position and lock it to the right in braking position.

●

The machine will decelerate automatically, the parking brake will close.

L

Note

The parking brake will also close automatically when shutting the engine down.

40

%20$ *

BW 213 DH-3 / PDH-3

2SHUDWLRQ

4.8

Shutting the engine down

Caution Straighten the articulated joint to allow easy access from and to the cabin.

Fig. 48

Pull the locking plate 19 (Fig. 48) up and set the throttle lever (18) to position "II" (idling speed).

●

L Fig. 46 ●

Move the travel lever (Fig. 46) slowly to "neutral"-position and lock it to the right in braking position.

Note

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

Fig. 49

Turn the ignition switch (Fig. 49) to position "0" or "P" and pull the ignition key out.

●

Fig. 47 ●

Lifting the dozer blade (BW 213 PDBH-3) (Fig. 47).

L

Note

The parking brake closes automatically after shutting the engine down.

Danger

Danger of accident!

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

BW 213 DH-3 / PDH-3

%20$ *

41

2SHUDWLRQ

4.9

Switching the vibration on and off

Selecting the vibration

Danger Risk of damage!

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

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

Fig. 51

Caution

When using the machine on asphalt (AD-version).

Choose the amplitude/frequency with the rotary switch (Fig. 51).

●

Switching the vibration on

Vibration at standstill creates transverse dents in the asphalt, therefore: ●

only switch the vibration on after shifting the travel lever to the desired direction.

●

Switch the vibration off before stopping the machine.

Fig. 52

Set the throttle lever (Fig. 52) to full speed position "I".

●

Caution Only switch the vibration on when the engine is running at full speed.

Fig. 50 ●

42

Switch to the working speed range (Fig. 50) (turtle or rabbit, small).

%20$ *

BW 213 DH-3 / PDH-3

2SHUDWLRQ

4.10 Adjusting the steering wheel*

Fig. 53 ●

Actuate the push button (Fig. 53) in the travel lever during operation, the drum will vibrate.

Switching the vibration off ●

Fig. 54

Actuate the push button again and turn the rotary vibration switch back to "0"-position after work.

●

To adjust the height of the steering wheel pull the lever (Fig. 54) up and adjust the steering wheel to the desired height.

●

To adjust the inclination of the steering wheel press the lever down and adjust the inclination of the steering wheel.

Danger Danger of accident!

After adjusting the steering wheel make sure that the steering wheel adjustment is securely engaged.

*

BW 213 DH-3 / PDH-3

%20$ *

Option

43

2SHUDWLRQ

4.11 Adjusting the seat

4.12 Operating the Dozer Blade (BW 213 PDBH-3) Danger Do not use the dozer blade to transport persons. Danger to life!

Moving other vehicles with the dozer blade is prohibited!

L

Note

Always lower the dozer blade to the ground before shutting the engine down.

Fig. 55 ●

To adjust the seat in longitudinal direction disengage the lever a (Fig. 55) and slide the seat forward or back.

●

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

●

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

Fig. 57 ●

Position ’I’

= lifting the dozer blade

Position ’0’

= neutral position, the pedals returns automatically to "0"-position

Position ’II’

= lowering the dozer blade

Position ’III’

= float position, for levelling the soil during reverse travel.

Fig. 56 ●

Lift or lower the dozer blade by means of the pedal (Fig. 57).

To adjust the height of the seat lift the seat up (Fig. 56) and engage it in the disired position.

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

44

%20$ *

BW 213 DH-3 / PDH-3

2SHUDWLRQ

Closing the hood

4.13 Moving the hood to maintenance position/closing the hood.

For some service jobs the hood must be opened hydraulically to highest position. For this purpose the machine is equipped with a manually operated pump.

Moving the hood to maintenance position. ●

Open the hood.

The hood will automatically move to middle position. ●

Fig. 59 ●

Push the hood up against the end stop.

Turn the valve lever (Fig. 59) to position "close", insert the hand lever and operate the pump, until the lift cylinder is completely retracted.

Pumping any further is not possible. ●

Remove the hand lever from the pump and lock it in its bracket.

●

Pull the hood down by hand against the stop.

Fig. 58 ●

Turn the valve lever (Fig. 58) to "open" position.

●

Take the hand lever out of the bracket in the hood and insert it.

●

Pump the hood to highest position.

Fig. 60 ●

Push the lever up to unlock it (Fig. 60) and press the hood slightly up at the same time.

The cylinder disengages. ●

BW 213 DH-3 / PDH-3

%20$ *

Now pull the hood totally down and lock it.

45

2SHUDWLRQ

4.14 Towing the machine in case of an engine failure Danger Secure the machine with chocks against unintentional rolling.

Fig. 62

Turn the middle hexagon on both valves (Fig. 62) approx. 2 to 3 turns out.

●

Caution Do not unscrew the valves completely.

Fig. 61

Danger

Danger of accident!

When using ropes you may only pull the machine uphill.

Use only a rigid towing bar to tow the machine downhill.

Attach the tow bar to the rear towing eye (Fig. 61).

●

Fig. 63

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

●

Loosen the counter nut (Fig. 63), turn the threaded spindles (2 pieces opposite each other) on each side of the axle evenly in until the brake is released.

●

Repeat this measure also on the other side.

●

46

Open the tailgate.

%20$ *

BW 213 DH-3 / PDH-3

2SHUDWLRQ

4.15 Transport Danger Danger of accident!

Use only strong and stable loading ramps of sufficient bearing capacity. Make sure that no persons are endangered by the machine turning over or slipping off.

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

Fig. 64

Turn both screws (Fig. 64) in clockwise direction to release the brake for the drum until the drum can turn freely.

●

Do not step or stand under loads being lifted.

Always use shackles on the lashing points to load, lash or lift the machine.

After towing

Caution

Before removing the tow bar secure the machine with suitable chocks. ●

Tighten the high pressure relief valves.

●

Turn the threaded spindles in the axle out again against the stop and tighten the counter nut.

●

Turn both screws of the brake releasing facility on the drum in counter-clockwise irection to the end stop.

Fig. 65 ●

BW 213 DH-3 / PDH-3

%20$ *

Attach the articulation lock (Fig. 65).

47

2SHUDWLRQ

Fig. 66 ●

Lash the machine to the transport vehicle (Fig. 66), attach the lashing gear to the lashing eyes on the front and the rear frame.

●

Support the front frame from underneath to relieve the rubber buffers.

Fig. 67 ●

To lift the machine attach the lifting gear to the four lifting eyes (Fig. 67).

Weights: see technical data ●

48

After the transport remove the articulation lock and fasten it in its receptacle.

%20$ *

BW 213 DH-3 / PDH-3

5 Maintenance

BW 213 DH-3 / PDH-3

%20$ *

49

0DLQWHQDQFH

●

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

●

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.

●

Thorough maintenance of the machine ensures maximum reliability and prolongs the service life of importants components. The work involved is small when compared with the problems which may arise if these instructions are 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. ●

Clean machine and engine thoroughly before starting maintenance work.

●

For maintenance work park the machine on level ground.

●

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

●

Depressurize hydraulic lines before working on them.

●

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

●

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

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.

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.

Notes on the hydraulic system

Environment During maintenance catch all running oil, coolant and fuel and do not let it seep into the ground or into the sewage system. Catch oils, coolant and fuel and dispose of environmentally.

Notes on the fuel system

Cleanliness is of utmost importance when servicing the hydraulic system. Make sure that no dirt or other contaminating substances fall into the system. Small particles can flute valves, cause pumps to seize and block restrictors and pilot bores, thereby causing costly repairs. ●

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

●

Seal external leakages immediately. If necessary inform the responsible service station.

●

Do not store hydraulic oil drums outdoors or at least under a cover. Water may penetrate through the bunghole when the weather changes.

●

Always use the filtering and filling unit (BOMAG part-no. 007 610 01) to fill the hydraulic system. This unit is fitted with a fine filter, which cleans the hydraulic oil and prolongs the service life of the filter.

●

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

●

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

The lifetime of the diesel engine depends decisively on the cleanliness of the fuel. ●

●

●

50

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.

%20$ *

BW 213 DH-3 / PDH-3

0DLQWHQDQFH

Notes on the cooling system On high performance diesel engines the preparation and control of the coolant is of special importance, since the non-observance may cause engine damage as a result of corrosion, cavitation or freezing.

The coolant is prepared by mixing the cooling water with a cooling system protection agent (ethylene glycol / propylene glycol).

Mixing of cooling system protection additives to the cooling water is necessary in all climatic zones. It prevents corrosion, lowers the freezing point and raises the boiling point of the coolant.

5.2

Fuels and lubricants

Engine oil The use of high quality brand HD-oils in connection with the specified filter and oil change intervals prolongs the lifetime of the engine and increases its performance.

Do not use any running-in oil for new or overhauled engines.

Oil viscosity It is recommended by CUMMINS to use preferably oils of the viscosity class SAE 15W-40.

To ensure perfect cold starting it is important to choose the viscosity (SAE grade) of the engine oil with respect to the ambient temperature.

Fig. 68

Although cold starting abilities may be impaired if the temperature occasionally drops below the limit (e.g. use of SAE 15W/40 down to -15°C), this will not cause any damage to the engine.

Having to change the lubrication oil due to changes in temperature can be avoided by using multigrade oils. The oil change intervals given below are also valid for multigrade oils.

Oil quality Lubrication oils are differentiated according to their performance and quality class. The commonly used specifications are those according to API (American Petroleum Institute) and CCMC (Committee of Common Market Automobile Constructors).

BW 213 DH-3 / PDH-3

%20$ *

51

0DLQWHQDQFH

Permitted API-oils API

disturbing separations can also be expected with winter diesel fuel.

= CE/SG

Permitted CCMC-oils

Hydraulic oil

CCMC

The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mm2/s at 40°C (104°F). For topping up or changing the hydraulic oil use only quality hydraulic oil of 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 (refer to the specifications of the manufacturer).

= D4

If oil of quality class CE/SG is not available, oils of the quality class CC/CD or CD/SF may also be used, if the oil change intervals are halved.

Lubrication oil change intervals The longest period of time that lubrication oil should remain in the engine is 6 months. If the oil change intervals specified below are not reached during 6 months, the lubrication oil must be changed at least once every 6 months, irrespective of the operating hours.

Biodegradable hydraulic oil On request the hydraulic system can also be filled with ester based biodegradable hydraulic oil (Panolin HLP Synth. 46). This biodegradable hydraulic oil meets the requirements of a mineral oil based hydraulic oil according to DIN 51524.

API: CE/ SG = 250 operating hours CCMC/ D4 = 250 operating hours

Always use the same oil for topping up if the system is filled with Panolin HLP Synth. 46. When changing from a mineral oil based hydraulic oil to ester based biodegradable hydraulic oil, consult the lubrication oil service department of the respective oil manufacturer.

API: CC/ CD bzw.

CD/SF = 125 operating hours

Fuels Quality

Check the filter more frequently after changing to the new oil.

Use only commercially available brand diesel fuel with a low sulphur contents.

Oil for drive axle

Ensure strict cleanliness when filling in fuel. Under low ambient temperatures use only winter diesel fuel. Always top the fuel tank up in due time to make sure that the fuel tank does not run dry, as otherwise filter and injection lines must be bled.

For the axle use only multi-purpose gear oil of APIClass GL5 of viscosity class SAE 90.

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.

Lubrication grease

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

Coolant

Winter fuel

Use an EP-high pressure grease, lithium saponified (penetration 2), for lubrication purposes.

Anti-feeze agents must be used under any climatic conditions as a protection against freezing, corrosion and boiling.

Danger

Danger of explosion!

Do not mix diesel fuel with gasoline or alcohol.

During winter use only winter diesel fuel to avoid clogging caused by paraffin separation.

Under extremely low ambient temperatures

52

Caution Do not mix different coolants and additives.

If cooling system protection additives are not available in tropical countries, it is also possi-

%20$ *

BW 213 DH-3 / PDH-3

0DLQWHQDQFH

ble to use a corrosion protection agent (CUMMINS Liquid DCA).

Do not add more than 50% cooling system protection agent, unless a lower anti-freeze protection is required, but an anti-freeze agent proportion of 68% should under no circumstances be exceeded. The anti-freeze protection effect drops at too high concentrations.

Use only soft tap water (drinking water) for the coolant mixture.

The water must not contain more than 300 ppm hardening agents or 100 ppm sulphate or chloride.

The cooling system must be continuously monitored. This applies for the coolant level as well as for the concentration of the cooling system protection agent.

The concentration of cooling system protection agent must be checked with a refractometer (Fleetguard Part No. CC2800). Other measuring instruments are not suitable for high performance diesel engines.

The coolant must be changed every two years.

Environment Cooling system protection agents must be disposed of environmentally.

Specification for cooling system protection agents ASTM4958 (GM6038M) Anti-freeze agent concentrations Ethylene Glycol 40 %

= -23 °C (-10 °F)

50 %

= -34 °C (-34 °F)

60 %

= -54 °C (-65 °F)

68 %

= -71 °C (-90 °F)

Propylene Glycol 40 %

= -21 °C (-6 °F)

50 %

= -33 °C (-27 °F)

60 %

= -49 °C (-56 °F)

68 %

= -63 °C (-82 °F)

BW 213 DH-3 / PDH-3

%20$ *

53

0DLQWHQDQFH

5.3

Table of fuels and lubricants

Assemblies

Fuels, Lubricants Summer

Winter

Approx. quantity Attention Observe level marks

Engine

Engine oil CCMC-D4/D5 (SHPD) or

with filter change

API: CD/CF/CE/CF4

approx. 19 litres

SAE 15W/40 (-20 °C to +40 °C) SAE 30

SAE 10W

(+5 °C to +30 °C)

(-5 °C to -30 °C) fuel

Diesel Hydraulic system

winter diesel fuel*

hydraulic oil (ISO), HV46, kinem. viscosity

approx. 340 litres approx. 60 litres

46 mm2/s bei 40 °C Vibration bearing

Engine oil SAE 15W/40

approx. 0,8 litres per side

Drive axle

gear oil SAE 90, API GL5

approx. 11 litres

Planetary drive

gear oil SAE 90, API GL5

approx. 2,9 litres per side

Reduction gear, axle

gear oil SAE 90, API GL5

approx. 2 litres

Drum drive transmission

gear oil SAE 90, API GL5

approx. 3 litres

Coolant

cooling system protection agent

Tires

water

approx. 300 litres

calcium chloride (CaCl2) or magnesium chloride (MgCl2)

approx. 139 kg

54

%20$ *

16 litres

BW 213 DH-3 / PDH-3

0DLQWHQDQFH

5.4

Running-in instructions

When taking new machines into operation or when starting up overhauled engines, the following maintenance work must be carried out:

Caution

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

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

After 50 operating hours ●

Tighten all screw connections on intake and exhaust manifold, oil sump and engine mounts.

●

Tighten the screw connections on the machine.

●

Tighten the fastening screws for the wheels with the specified torque.

●

Change the oil in the drive axle.

●

Change the oil in the planetary drive.

●

Change the oil in the axle reduction gear

●

Change the oil in the drum drive transmission.

After 500 operating hours ●

Change the oil in the vibration bearing

After 1000 operating hours ●

BW 213 DH-3 / PDH-3

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Check the valve clearance, adjust if necessary.

55

0DLQWHQDQFH

5.5

Maintenance chart

During the individual maintenance intervals perform also the work for shorter, preceding intervals.

Pos.

Description

Note

Every 10 operating hours 5.6 5.7 5.8 5.9 5.10 5.11 5.12

Check the engine oil level Check the water separator Check the fuel level Check the hydraulic oil level Check the coolant level Check the V-belt Checking the dust separator of the oil bath air filter

Dipstick mark

Inspection glass

Every 50 operating hours 5.13 5.14 5.15

Check the tire pressure Adjust the scrapers Grease the dozer blade

BW 213 PDBH-3

Every 250 operating hours 5.16 5.17 5.18 5.19 5.20 5.21 5.22

Change the engine oil and oil filter cartridge min. 1x per year Check, clean the cooling fins on radiator and hydraulic oil cooler Check the oil level in the drive axle Check the oil level in the axle reduction gear Check the oil level in the planetary drive Check the oil level in the vibration bearings Check the oil level in the axle reduction gear

Every 500 operating hours 5.23 5.24 5.25 5.26

56

Battery maintenance Drain the fuel tank sludge Change the fuel filter cartridge Check V-belt tension, idler pulley and blower hub

%20$ *

Pole grease

BW 213 DH-3 / PDH-3

0DLQWHQDQFH

Pos.

Description

Note

Every 1000 operating hours 5.27 5.28 5.29 5.30 5.31 5.32 5.33 5.34 5.35 5.36

Change the oil in the drive axle Change the oil in the planetary drives Change the oil in the axle reduction gear Change the oil in the drum drive reduction gear Change the oil in the vibration bearings Check the fastening elements on the engine Check the fastening of the axle on the frame Tighten the wheel nuts Check the ROPS Cleaning the oil bath air filter

min. 1x per year min. 1x per year at least 1x per year at least 1x per year min. 1x per year

Every 2000 operating hours 5.37

Check, adjust the valve clearance

5.38 5.39 5.40

Change the hydraulic oil and the breather filter* Change the hydraulic oil filter* Change the coolant

Inlet= 0,25 mm (0,010 IN), Exhaust = 0,5 mm (0.020 IN, on cold engine min. every 2 years min. every 2 years min. every 2 years

As required 5.41

Clean, change the dry air filter cartridge,

5.42 5.43 5.44 5.45 5.46 5.47

Adjusting the parking brake Bleed the fuel system Change the tires Changing the fresh air filter in the cabin Tightening torques Engine consevation

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

*Also after repairs in the hydraulic system.

BW 213 DH-3 / PDH-3

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Every 10 oper ating hours

5.6

L

Checking the engine oil level

Note

5.7

Checking, cleaning the water separator

Danger Danger of injury!

Park the machine on level ground, shut the engine down and wait for about 15 minutes to allow the oil to run back into the oil sump.

Always support the engine compartment hood properly when performing service or repair work.

L

Note

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

If a too large quantity is drained off, the filter must be filled again with fuel. See paragraph "Maintenance as Required", bleed the fuel system.

Fig. 69

Environment

●

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

●

Pull the oil dipstick out again.

●

The oil level must be between the two marks "L" and "H".

●

Top up oil immediately if the oil level is too low.

●

If the oil level is too high detect the cause and drain the oil off.

Catch running out fuel and dispose of environmentally.

Caution Before a longer work period fill the oil up to the "MAX"-mark.

Top up quantity from the "L" to the "H" mark:

Fig. 70

approx. 2 litres

●

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

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

●

Tighten the drain screw again and check for leaks, use a new sealing ring if necessary.

58

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5.8

Caution Dirty fuel can cause engine failures or even damage to the engine.

Checking the fuel level

If necessary fill in fuel through a screen filter.

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.

If necessary top up 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 gauge (Fig. 71).

●

L

Note

Never drive the fuel tank empty, because this would required bleeding of the entire fuel system. ●

Clean the area around the filler opening.

Fig. 72 ●

Open the fuel tank cover (Fig. 72).

BW 213 DH-3 / PDH-3

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59

(YHU\ RSHUDWLQJ KRXUV

5.9

Checking the hydraulic oil level

5.10 Checking the coolant level Danger Danger of scalding!

Caution If the hydraulic system is filled with Panolin HLP Synth. 46 you should always use the same oil to top up. For any other ester based hydraulic oils consult the lubrication service department of the oil manufacturer.

Top up coolant only when the engine is cold.

Fig. 74

Check the coolant level (Fig. 74).

●

Fig. 73

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

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

●

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

Minimum level

Caution

●

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

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

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. ●

If necessary fill in hydraulic oil through the filler neck.

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

60

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BW 213 DH-3 / PDH-3

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5.11 Checking the V-belt

5.12 Checking the dust separator on the oil bath air filter*

Fig. 75 ●

Check the condition of the V-belt (Fig. 75).

Fig. 76

Small cracks in transverse direction are permitted.

●

If the dust reaches the mark loosen the clamp (Fig. 76), take the cover off and clean the bowl.

*

Option

Crack in longitudinal direction are not permitted. ●

Replace the V-belt in case of broken out material, intersecting cracks in longitudinal and transverse direction or fraying.

BW 213 DH-3 / PDH-3

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61

(YHU\ RSHUDWLQJ KRXUV

Every 50 oper ating hours

5.13 Checking the tire pressure

5.14 Adjusting the scrapers

Caution Since the tires are filled with water you should only check the tire pressure with the tire inflation valve in top position.

smooth drum only

Always close the valves with the dust caps.

Fig. 78

Fig. 77

●

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

●

To adjust the scrapers 1 (Fig. 78) loosen the fastening screws (2) in the slots and push the scraper bracket towards the drum until the scraper touches.

●

Retighten the fastening screws.

Check the tire pressure with a pressure gauge and the tire inflation valve 1 (Fig. 77) in top position.

●

Nominal value see technical data.

padfoot drum only L

Note

Ensure even pressure in all tires. ●

Screw the valve caps back on.

Fig. 79

62

●

Check condition and adjustment of scrapers 2 (Fig. 79), adjust or replace the teeth if necessary.

●

To adjust the scrapers (2) slacken the fastening screws (1) in the slots and move the scrap-

%20$ *

BW 213 DH-3 / PDH-3

(YHU\ RSHUDWLQJ KRXUV

er towards the drum, leaving a gap of approx.

25 mm. ●

Retighten the fastening screws.

5.15 Grease the dozer blade (BW 213 PDBH-3)

Fig. 80 ●

Clean the grease nipples (Fig. 80) and grease them with approx. 5 strokes from the grease gun.

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

BW 213 DH-3 / PDH-3

%20$ *

63

(YHU\ RSHUDWLQJ KRXUV

Every 250 operating h ours

5.16 Changing engine oil and oil filter cartridge Caution The oil change at 250 operating hours refers to the use of oils of quality class API CE/SG or CCM D4.

When using oils of quality classes API CC/CD resp. CD/SF the oil change intervals must be halved (see paragraph 5.2, fuels and lubricants).

Fig. 82

Drain the engine oil only when the engine is warm.

●

Unscrew the filter cartridge (Fig. 82) with a suitable filter wrench.

●

Clean the sealing faces on the filter carrier from all dirt.

Danger

Danger of scalding!

When draining hot oil.

By hot oil when unscrewing the engine oil filter.

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

Fig. 83 ●

Fill the filter cartridge (Fig. 83) with clean engine oil.

●

Cover the rubber seal on the new filter cartridge lightly with oil.

Fig. 81 ●

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

●

Screw the drain plug back in.

64

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BW 213 DH-3 / PDH-3

(YHU\ RSHUDWLQJ KRXUV

Fig. 84

Fig. 86

●

Screw the new filter cartridge (Fig. 84) on by hand and tighten it until the seal touches.

●

Tighten the filter cartridge for another half turn.

●

Check the oil level again (Fig. 86), if necessary top up to the Max.-mark.

Fig. 85 ●

Fill in new engine oil (Fig. 85).

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

Screw the lid back on the oil filler neck.

●

Check the oil level on the dipstick after a short test run, top up to the upper dipstick mark if necessary.

●

Perform a short test run and check filter cartridge and drain plug for leaks.

●

Shut the engine down and wait for approx. 15 minutes until all oil has run back into the oil sump.

BW 213 DH-3 / PDH-3

%20$ *

65

(YHU\ RSHUDWLQJ KRXUV

Cleaning with cold cleansing agent

5.17 Cleaning the cooling fins on radiator and hydraulic oil cooler

Caution Protect electrical equipment such as generator, regulator and starter against the direct water jet.

Danger Danger of injury!

●

Spray the engine with a suitable cleansing agent, e.g. cold cleansing agent and wash it off with a strong water jet after a sufficient soaking time.

●

Run the engine warm for a short time to avoid corrosion.

%20$ *

BW 213 DH-3 / PDH-3

Cleaning work should only be carried out with the engine stopped and cooled down.

Caution Take care to avoid deformation of the radiator cooling fins.

L

Note

Dirt deposits on the blower blades and the oil cooler reduce the cooling. Oil and fuel deposits in these areas support the accumulation of dirt on these surfaces. You should therefore eliminate any leakages in this area and clean the cooling surfaces after.

Fig. 87

Open the snap locks 1 (Fig. 87) on the hydraulic oil cooler and tilt the hydraulic oil cooler forward.

●

Cleaning with pressure air L

Note

Start to blow out from the air discharge side. ●

66

Blow the radiator out with pressure air.

(YHU\ RSHUDWLQJ KRXUV

5.18 Checking the oil level in the axle

5.19 Checking the oil level in the axle reduction gear

Fig. 88

Fig. 89

●

Unscrew the level control plug 2 (Fig. 88) and check the oil level.

The oil level must reach the lower edge of the bore. ●

●

Unscrew the filler and level control plug (Fig. 89) and check the oil level.

The oil level must reach the lower edge of the bore, top up oil if necessary.

Top up oil if necessary, unscrew the filler plug (1) to do so.

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

●

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

Screw the filler and control plug in again.

Screw the filler and control plug in again.

BW 213 DH-3 / PDH-3

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67

(YHU\ RSHUDWLQJ KRXUV

5.20 Checking the oil level in the planetary drives

5.21 Checking the oil level in the vibration bearing housings L

Note

Check the oil level only at operating temperature after running the vibration for about 1/2 hour.

Fig. 90 ●

Move the drive wheel until the oil level mark on the plugs (Fig. 90) is in horizontal position.

●

Unscrew the plug.

The oil level must reach the lower edge of the bore. ●

Fig. 91 ●

Move the drum so that the oil level control plug (Fig. 91) on the left hand side is in lowest position.

●

Unscrew the control plug (1).

Top up oil if necessary.

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

Screw the plug back in.

●

Repeat the same procedure on the opposite side.

Some oil should drip out of the level bore ●

If necessary unscrew the oil filler plug (2) and fill in oil through the filler opening (2) until oil starts to drip out of the level bore.

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

68

●

Screw the oil filler (2) and control plug (1) back in.

●

Repeat this procedure on the opposite side.

%20$ *

BW 213 DH-3 / PDH-3

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5.22 Checking the oil level in the axle reduction gear

Fig. 92 ●

Unscrew the level control plug (Fig. 92) and check the oil level.

The oil level must reach the lower edge of the bore, top up oil if necessary.

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

Screw the control plug in again.

BW 213 DH-3 / PDH-3

%20$ *

69

(YHU\ RSHUDWLQJ KRXUV

Every 500 operating h ours

5.23 Servicing the battery Danger Danger of cauticization!

5.24 Draining the fuel tank sludge

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

Do not let skin and clothes come in contact with acid!

Wear your protective outfit!

Do not lay any tools on the battery!

Before recharging the battery remove all plugs to avoid the accumulation of highly explosive gases.

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.

Caution Dispose of used batteries environmentally.

●

Open the flap of the battery compartment on the right hand side.

Fig. 94 ●

Unscrew the drain plug (Fig. 94) from the bottom of the fuel tank and drain off approx. 5 litres of fuel.

●

Screw the drain plug back in with a new sealing ring.

%20$ *

BW 213 DH-3 / PDH-3

Fig. 93 ●

Remove the batteries (Fig. 93) and clean the battery compartment.

●

Clean the batteries from the outside.

●

Clean the battery poles and pole clamps and cover them with acid free grease (vaseline).

●

Check the fastening of the batteries.

70

(YHU\ RSHUDWLQJ KRXUV

5.25 Changing the fuel filter cartridges 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. 96 ●

Fill the new filter cartridges (Fig. 96) with clean fuel according to the table of fuels and lubricants.

●

Cover the seal rings lightly with oil.

Fig. 95 ●

Unscrew both filter cartridges (Fig. 95) with a suitable filter wrench.

●

Clean the sealing faces on the filter carrier from all dirt.

Fig. 97 ●

Screw the filter cartridges on by hand until the seal touches the filter head 1 (Fig. 97).

●

Tighten for a 3/4 turn (2).

L

Note

Small amounts of air, which enter the fuel system when changing the filter, are automatically discharged through the return line.

Manual bleeding

BW 213 DH-3 / PDH-3

●

if the filter has not been filled with fuel before removal,

●

if the injection pump has been changed,

●

if injection lines were changed

●

if the fuel tank has been driven empty.

%20$ *

71

(YHU\ RSHUDWLQJ KRXUV

Observe ’Bleeding the fuel system’ in the paragraph "Maintenance as Required".

5.26 Checking V-belt tension, idler pulley and blower hub

Fig. 98 ●

Lift the idler pulley up by means of a socket wrench (Fig. 98) and take the V-belt off.

Fig. 99 ●

Check the condition of the V-belt (Fig. 99).

Small cracks in transverse direction are permitted.

Cracks in longitudinal direction are not permitted.

Replace the V-belt in case of broken out material, intersecting cracks in longitudinal and transverse direction or fraying.

72

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BW 213 DH-3 / PDH-3

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Nominal value: 267 to 578 N (60 to 130 Lbf)

Fig. 100 ●

Check the bearings for idler pulley 1 (Fig. 100) and blower hub (2), replace if necessary.

●

Reinstall the V-belt.

Fig. 101 ●

Check the V-belt tension (Fig. 101).

Fig. 102

We recommend to use the Cummins V-belt tension tester (Fig. 102) Part. No. ST-1293.

BW 213 DH-3 / PDH-3

%20$ *

73

(YHU\ RSHUDWLQJ KRXUV

Every 1000 operating hour s

5.27 Changing the oil in the drive axle L

5.28 Changing the oil in the planetary drive

Note

Caution Drain the oil only at operating temperature.

On other axle versions the drain and filler plugs may be arranged differently. Perform the oil change in a similar way.

Change the oil on both sides of the axle.

Environment Catch the old oil and dispose of environmetally.

Caution Drain the oil only at operating temperature.

Environment Catch the old oil and dispose of environmetally.

Fig. 104

Fig. 103 ●

Clean the filler plug 1 (Fig. 103) and screw it out.

●

Clean the drain plug (2) and screw it out.

●

Clean the control plug (3) and screw it out.

●

Drain the oil off and catch it.

●

Screw the drain plug tighly back in.

●

Fill in oil through the filler bore until it reaches the lower edge of the level bore (3).

●

Move the drive wheel until the plug (Fig. 104) is in lowest position.

●

Clean the plug and screw it out.

●

Drain the oil off and catch it.

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

74

Screw the filler and control plug in again.

%20$ *

BW 213 DH-3 / PDH-3

(YHU\ RSHUDWLQJ KRXUV

5.29 Changing the oil in the axle reduction gear Caution Drain the oil only at operating temperature.

Environment Catch the old oil and dispose of environmetally.

Fig. 105 ●

Move the drive wheel until the plug (Fig. 105) in the housing is in horizontal position.

●

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

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

Screw the plug back in.

Fig. 106 ●

Unscrew the filler plug (Fig. 106).

●

Unscrew the oil drain plug and catch the running out oil.

●

Once the oil has run out clean the drain plug and screw it tightly back in.

●

Fill in oil through the filler and control bore until it reaches the lower edge of the control bore.

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

BW 213 DH-3 / PDH-3

%20$ *

Clean the filler plug and screw it back in tightly with a new sealing ring.

75

(YHU\ RSHUDWLQJ KRXUV

5.30 Changing the oil in the drum drive reduction gear Caution Drain the oil only at operating temperature.

Environment Catch the old oil and dispose of environmentally.

Fig. 108 ●

Unscrew the level control plug (Fig. 108).

●

Fill in oil through the filler bore, until it starts to run out from the level control bore.

Caution After filling wait a few minutes until the oil has been distributed inside the gearbox.

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

Fig. 107 ●

Move the drum (Fig. 107), until the drain plug is in lowest and the filler plug in highest position.

●

Unscrew the filler plug at the top.

●

Unscrew the oil drain plug at the bottom and catch running out oil.

●

Once the oil has run out clean the drain plug and screw it tightly back in.

76

%20$ *

Clean filler and level control plugs and screw them back in tightly with new sealing rings.

BW 213 DH-3 / PDH-3

(YHU\ RSHUDWLQJ KRXUV

5.31 Changing the the oil for the vibration bearings Caution Drain the oil only at operating temperature. for this purpose run the machine for approx.

1/2 hour with vibration.

Environment Catch running out oil and dispose of environmentally.

Fig. 110 ●

Unscrew the level control plug at the bottom 1 (Fig. 110) and fill in oil through the filler opening until it starts to run out through the level control bore (2).

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

Screw the oil filler (2) and control plug (1) back in.

●

Repeat the oil change on the opposite side.

●

Check the oil level again at operating temperature (after running the vibration for approx.

0.5 hours).

Fig. 109 ●

Move the drum until the drain plug 1 (Fig. 109) is in lowest position.

●

Unscrew the drain plug, drain all oil off and catch it.

●

Once the oil has run out clean the drain plug and screw it tightly back in.

BW 213 DH-3 / PDH-3

Caution Overfilling causes overheating of the vibration bearings!

%20$ *

77

(YHU\ RSHUDWLQJ KRXUV

5.32 Checking the fastening elements on the engine

5.33 Tightening the fastening of the axle to the frame

Fig. 111

Fig. 112

●

Check the fastening of air intake and exhaust tube (Fig. 111) on the cylinder heads for tight fit.

●

Check the bellows and clamps between air filter, turbo charger and charge air line as well as the lubrication oil line for tight fit.

●

Check the fastening screws for the oil sump and the engine mounts for tight fit.

78

●

Check all fastening nuts for the axle retaining bolts (Fig. 112) for tight fit.

%20$ *

BW 213 DH-3 / PDH-3

(YHU\ RSHUDWLQJ KRXUV

5.34 Tightening the wheel nuts

5.35 Checking the ROPS L

Note

On machines with a fitted cabin the ROPS (roll over protection structure) is integrated in the cabin.

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

Fig. 113 ●

Tighten the wheel nuts (Fig. 113) in a crosstype pattern.

Tightening torques: 550 Nm (405 ft-lb) (M22x1,5)

Fig. 114

Check the cabin, especially the ROPS (Fig. 114) for cracks, corrosion, damage and missing fastening elements.

●

L

Note

Unusual movements and noises (vibrations) during operation indicate damage or loose fastening elements.

BW 213 DH-3 / PDH-3

●

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

●

Check the suspension buffers for the operator’s stand for tight fit.

●

Check the condition and the fastening of the seat belt.

%20$ *

79

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5.36 Cleaning the oil bath air filter *

Fig. 115 ●

Loosen the quick locks (Fig. 115), take the filter bowl off and empty it.

●

Clean the filter mesh by repetitive dipping into diesel fuel.

●

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

●

reinstall the filter bowl.

*

Option

80

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Every 2000 operating hours

Caution Loosen the pin again after the adjustment.

5.37 Checking, adjusting the valve clearance Caution Let the engine cool down for at least 30 minutes before checking the valve clearance. The engine temperature must be lower than 60 °C.

Perform a short test run and check the engine for leaks. ●

Remove the air filter.

Fig. 118

The locking position (Fig. 118) of the adjustment pin is exactly in accordance with the upper dead center of the first cylinder during the compression stroke.

Fig. 116 ●

Disassemble all cylinder head covers 1 (Fig. 116).

Fig. 119

Caution

Loosen the pin (Fig. 119) again after the adjustment, as otherwise the engine may be damaged.

Fig. 117 ●

Press the adjustment pin (Fig. 117) in and turn the engine crankshaft until the pin clicks into place.

BW 213 DH-3 / PDH-3

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Fig. 120

Fig. 122

(Fig. 120)shows which valves can be adjusted in this position.

●

Fig. 121

Fig. 123

Mark the V-belt pulley (Fig. 122) and turn the engine crankshaft for another turn (360°).

●

Check the clearance between rocker arm and valve (Fig. 121) with a feeler gauge.

●

Check and, if necessary, adjust the valve clearance on all other valves (Fig. 123).

●

If necessary slacken the counter nut and adjust the clearance.

●

Check gaskets and cylinder head covers, replace if necessary.

Nominal value:

●

Reinstall the cylinder head covers.

Inlet valve (I) 0,25 mm (0.010 IN)

●

Turn the ventilation valve back to original position and fasten it.

●

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

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Exhaust valve (E) 0,50 mm (0.020 IN) L

Note

The valve clearance is correct, when the feeler gauge fits through the gap between valve stem and adjustment screw with only little resistance. ●

Tighten the counter nut without turning the adjustment screw.

●

Check the valve clearance again after tightening the counter nut.

82

(YHU\ RSHUDWLQJ KRXUV

5.38 Changing the hydraulic oil and the breather filter L

Note

See also section 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. 124

Change the hydraulic oil only at operating temperature.

●

Unscrew the plug (Fig. 124) and drain the hydraulic oil off.

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

●

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

Do not use any detergents to clean the system.

Do not start the engine after draining the hydraulic oil.

Change 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.

L

Fig. 125 ●

Take the filler cap (Fig. 125) off.

●

Fill in hydraulic oil through the screen.

Note

The hydraulic oil filter element should only be changed after the test run.

L

Note

We recommend to fill the hydraulic system with the filling and filtering unit (BOMAG part-no.

079 930 35) with fine filter. This filters the hydraulic oil and prolongs the utilization time of the hydraulic oil filter and protects the hydraulic system. ●

Check the oil level in the inspection glass.

Nominal value: approx. 3 cm below the upper edge of the inspection glass For quality and quantity of oil refer to the table of fuels and lubricants.

BW 213 DH-3 / PDH-3

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L

Note

The breather filter for the hydraulic tank is located in the filler cap and must therefore be replaced with the filler cap. ●

Close the tank with the new filler cap.

5.39 Changing the hydraulic oil filter Danger Danger of scalding!

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

Caution If the hydraulic oil has to be changed at the same time as the filter:

- change the hydraulic oil first, - then perform a test run, - change the filter last.

Do not reuse the filter bowl.

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

L

Note

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

Fig. 126

84

●

Unscrew the cap nut 4 (Fig. 126) and take the filter bowl (5) with the filter element (3) off.

●

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

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Caution Visible contamination may be an early indicator for the fault on a system element or the failure of any components. In such a case detect the cause and replace or repair the respective component. The non-observance can lead to severe damage in the hydraulic system.

Do not clean or reuse the filter element. ●

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

●

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

●

After a test run check the filter for leaks.

5.40 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. 127 ●

Switch the shut-off valve (Fig. 127) for the cabin heater to "warm".

Fig. 128

BW 213 DH-3 / PDH-3

●

Unscrew the drain plug (Fig. 128), drain all coolant off and catch it.

●

Once all coolant has drained off screw the plug back in tightly.

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Fig. 129 ●

To bleed the coolant circuit open the bleeding screw (Fig. 129) while filling.

Fig. 130 ●

Screw the lid off and fill in coolant up to the MAX-mark (Fig. 130).

For quality of coolant refer to the table of fuels and lubricants in chapter 5.2. ●

Start the engine and run it up to operating temperature.

●

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

86

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BW 213 DH-3 / PDH-3

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Removing the main filter element

As r equired

5.41 Cleaning, changing the dry air filter cartridge Caution Cleaning, service and repair work must only be performed with the engine shut down. Do not start the engine after removing the filter element.

Fig. 132

Pull both clamps (Fig. 132) on the housing cover towards the outside and take the cover off.

●

Fig. 131

The air filter needs to be serviced when the control light 1 (Fig. 131) on the fault monitoring board is permanently on while the engine is running, but at the latest after 2 years.

L

Note

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

Fig. 133

Pull the main filter element (Fig. 133) off while turning it lightly.

●

Cleaning the main filter element Caution If necessary the main filter element may be cleaned up to five times. It should, however, be replaced after having reached the max. utilization period of two years.

The number of cleaning processes of the main filter element should be marked with a ball pen or a felt pen on the safety element.

In case of a sooty deposit cleaning of the main filter element is useless. Use a new filter cartridge.

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

Cleaning the dust bowl

If the main filter element is defective, you should also change the safety element!

Intermediate cleaning procedures between two service intervals indicated by the service indicator are not necessary.

Fig. 135 ●

Pull the inner part (Fig. 135) out and remove all dust from the cover.

●

Reinsert the inner part.

Caution During the assembly of the inner part make sure that the notch in the cover mates with the opening in the inner part.

Fig. 134

L

Note

To clean the filter fit a tube to the air gun (Fig. 134), the end of which is bent by approx. 90.

It must reach down to the bottom of the cartridge. ●

Blow the cartridge out with dry pressure air (max. 5 bar) by moving the tube up and down the inside of the cartridge until all dust has been blown out.

●

Examine the filter cartridge with a torch for any cracks and holes in the paper.

Installing the main filter element Push the main filter element carefully into the housing.

●

Closing the housing cover will automatically position the main filter element correctly.

Changing the safety element

Caution

Under no circumstances must a damaged main filter element be used again. If in doubt install a new main filter element.

Caution

The safety element must never be cleaned and must never be used again after it has been removed.

Open the seal only to replace the safety element.

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

88

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if the warning light still lights after serviving the main filter cartridge.

5.42 Adjusting the parking brake

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

●

Caution Have adjustment work on the brake performed by a specialist! Always adjust both sides.

●

Secure the machine with chocks against unintentional rolling.

●

Start the diesel engine to release the brake.

Fig. 136 ●

Puncture the seal of the safety element from inside to outside with a suitable tool (Fig. 136) and pull both ears up.

●

Hold the safety element by both ears and pull it out while turning it lightly.

●

Push the new safety element in.

Fig. 137

●

Reinstall the main filter element and the cover.

●

Caution Make sure that the cover clamps are properly engaged.

Unlock the travel lever (Fig. 137) by pushing it to the left, but do not actuate it to position "I" or "II".

The parking brake is released

Fig. 138

BW 213 DH-3 / PDH-3

●

Unscrew the locking plate 2 (Fig. 138).

●

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

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5.43 Bleeding the fuel system Bleeding the low pressure fuel lines and the fuel filter

Fig. 139 ●

To adjust the clearance turn the square 1 (Fig. 139) three revolutions back in clockwise direction.

●

Screw the locking plate back on.

●

Pull the plug off the brake valve and try to drive.

The machine must be braked.

Fig. 140 ●

Loosen the bleeding screw (Fig. 140).

●

Operate the fuel lift pump until the emergeing fuel is free of air bubbles.

●

Retighten the bleeding screw.

Bleeding the injection pump

Fig. 141 ●

90

%20$ *

Turn the ignition to ’I’ (Fig. 141).

BW 213 DH-3 / PDH-3

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5.44 Changing the tires Danger Danger of accident!

Observe all safety notes for the lifting of loads. ●

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

●

Unscrew the wheel nuts and take the wheel off.

Fig. 142 ●

Loosen the bleeding screw (Fig. 142).

●

Operate the fuel lift pump until the emerging fuel is free of air bubbles.

●

Retighten the bleeding screw.

Bleeding the high pressure fuel lines Danger High pressure can damage the skin. Do not bleed when the engine is hot - fire hazard.

Fig. 144 ●

Attach the new wheel (Fig. 144) and tighten the wheel nuts crosswise with a torque of 430 Nm (316 ft. lb.)anziehen.

●

Check the tire pressure, see technical data.

Fig. 143 ●

Loosen the fuel line slightly on the injection nozzle (Fig. 143).

●

Crank the engine with the starter to force the air out.

●

Start the engine and run it at idling speed.

●

Bleed all lines, one after the other, until the engine runs regularly.

BW 213 DH-3 / PDH-3

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5.45 Changing the fresh air filter in the cabin

5.46 Tightening torques

Fig. 146

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

Fig. 145 ●

Unscrew the fastening screws for the filter brackets (Fig. 145) and take the filter out.

●

Insert a new filter and reinstall the filter brackets.

8.8 = 8G 10.9 = 10K 12.9 = 12K Axle - frame

●

M 24

= 880 Nm

Wheel nuts

●

M 22x1,5

= 550 Nm

The values result in a 90% utilization of the screws yielding point at a coefficient of friction of tot. = 0,14. The tightening torques are not valid when using MOS2 lubricants.

L

Note

Self locking nuts must always be replaced after they have been unscrewed.

92

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5.47 Engine conservation If the engine is to be shut down for a longer period of time (e.g. during winter) we recommend the following conservation measures for the engine to avoid corrosion: ●

Clean the engine including the cooling system: with cold cleansing agent or, even better, with a steam cleaner.

●

Run the engine warm and shut it down.

●

Drain the still warm engine oil and fill in anticorrosion engine oil.

●

Drain the coolant and fill it back in with fresh anti-freeze agent.

●

Drain the fuel from the fuel tank, mix it well with 10% anti-corrosion oil and fil it in again.

●

Run the engine for 10 minutes until all lines, filter, pump and nozzles are filled with the conserving mixture and the new engine oil is distributed to all parts.

●

Crank the engine several times by hand (without ignition) in order to spray all combustion chamber.

●

Take the V-belts off and spray the grooves of the V-belt pulleys with anti-corrosion oil. Clean the anti-corrosion oil off before taking the engine back into service.

●

Close the air intake opening on the air filter and the exhaust opening.

L

Note

Depending on the weather condition these conserving measures will provide protection for approx. 6 - 12 months.

The conserving oil must be replaced by engine oil according to the API- (MIL) classification before taking the machine into operation. Refer to the section "Fuels and lubricants".

Anti-corrosion oils are those that comply with the specification MIL-L-21260 B or TL 9150037/2 resp. Nato Code C 640/642.

Mark a machine with conserved engine by attaching a clearly visible warning tag.

BW 213 DH-3 / PDH-3

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94

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6 Trouble shooting

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7URXEOH VKRRWLQJ

6.1

General notes

The following work must only be carried out by qualified and trained personnel or by the BOMAG 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 cannot eliminate it yourself by following the trouble shooting charts, you should contact our customer service departments at our branch offices or dealers.

Danger

Danger of injury!

Keep away from rotating parts of the engine.

In events of emergencies all modules in the electric installation box can be bridged. ●

Vibration module

●

Generator module L

Note

Wiring diagrams and hydraulic diagrams can be found at the end of the spare parts catalogue.

96

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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 according 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 in 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 during 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 DH-3 / PDH-3

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7URXEOH VKRRWLQJ

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 lowy

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 loose 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 specialist

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

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7URXEOH VKRRWLQJ

BW 213 DH-3 / PDH-3

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99

7URXEOH VKRRWLQJ

100

%20$ *

BW 213 DH-3 / PDH-3