Bomag BW 213 DH-4 PDH-4 BVC with attachment plates Single Drum Roller Operating Instruction Manual

Operating instructions Maintenance instructions

BW 213 DH-4 / PDH-4 BVC with attachment plates S/N 101 583 06 ....

Single drum roller

Catalogue number

008 044 61

05/2007

Foreword

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

F oreword

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

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

Strictly observe the safety regulations.

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

This manual comprises: l

Safety regulations

l

Operating instructions

l

Maintenance instructions

l

Trouble shooting

For your own personal safety you should only use original spare parts from BOMAG. In the course of technical development we reserve the right for technical modifications without prior notification.

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

Using these instructions will l

help you to become familiar with the machine.

l

avoid malfunctions caused by unprofessional operation.

Compliance with the maintenance instructions will l

enhance the reliability of the machine on construction sites,

l

prolong the lifetime of the machine,

l

reduce repair costs and downtimes.

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

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

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

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

BOMAG GmbH

l

if it is handled in a way not complying with the usual modes of use,

l

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

Printed in Germany Copyright by BOMAG

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

operating errors,

l

insufficient maintenance and

l

wrong fuels and lubricants.

Please note!

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

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

BW 213 DH-4/PDH-4 BVC

BOMAG

3

Foreword

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

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

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

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

Engine number (Fig. 3)

i Note

Fig. 1

Supplement the above data together with the commissioning protocol.

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

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

Fig. 2

Fig. 3

4

BOMAG

BW 213 DH-4/PDH-4 BVC

Table of Contents

Technical Data

9

Safety regulations

13

Indicators and Controls

21

3.1 General notes

24

3.2 Description of indicators and control elements

24

3.3 Display and control elements Variocontrol

35

3.4 Description of indicating and control elements Variocontrol

37

3.5 Line diagram Automatic (EVIB)

39

3.6 Description of line diagram Automatic (EVIB)

41

3.7 Line diagram Manual (EVIB)

43

3.8 Description of line diagram Manual (EVIB)

45

3.9 Bar diagram (EVIB)

46

Operation

47 4.1 General notes

48

4.2 Tests before taking into operation

48

4.3 Starting the engine

49

4.4 Starting with jump wires

51

4.5 Driving the machine

52

4.6 Switching the vibration on and off

54

4.7 Operating the parking brake, stopping the machine

56

4.8 Shutting the engine down

56

4.9 Changing the LCD-display

57

4.10 Emergency exit

67

4.11 Adjusting the seat

67

4.12 Operating the hood

68

4.13 Towing in case of an engine failure

69

4.14 Transport

71

4.15 Tests before starting to operate

73

4.16 Mounting the attachment plates

73

4.17 Taking the attachment plates into service

75

4.18 Detaching the attachment plates

77

4.19 Variocontrol, selecting the operating mode

79

4.20 Measuring pass with Variocontrol

81

4.21 Finishing compaction of a track

84

4.22 Printing measuring data after completing compaction

85

4.23 Teaching distance pulses

86

4.24 Amplitude limitation (BVC only)

88

4.25 Changing the paper roll in the measuring value printer

90

4.26 Changing the printer ribbon in the measuring value printer

91

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Table of Contents

Maintenance

6

93 5.1 General notes on maintenance

94

5.2 Fuels and lubricants

95

5.3 Table of fuels and lubricants

99

5.4 Running-in instructions

100

5.5 Maintenance chart

101

5.6 Check the engine oil level

104

5.7 Check, clean the water separator

104

5.8 Check the fuel level

105

5.9 Check the hydraulic oil level

106

5.10 Check the coolant level

106

5.11 Checking the dust separator on the oil bath air filter

107

5.12 Checking the tire pressure

108

5.13 Clean the cooling fins on engine and hydraulic oil cooler

108

5.14 Check the oil level in the drive axle

109

5.15 Checking the oil level in left/right wheel hubs

110

5.16 Check the oil level in the axle reduction gear

110

5.17 Check the oil level in the drum reduction gear

111

5.18 Checking the Vario exciter oil level

112

5.19 Changing engine oil and oil filter cartridges

113

5.20 Change the fuel filter cartridge

114

5.21 Draining the sludge from the fuel tank

115

5.22 Service the battery

116

5.23 Change the fuel pre-filter cartridge

117

5.24 Checking, replacing the refrigerant compressor V-belt

118

5.25 Service the air conditioning

119

5.26 Adjusting the valve clearance

122

5.27 Adjusting the control piston play

124

5.28 Checking / replacing the ribbed V-belt

125

5.29 Check the engine mounts

126

5.30 Change the oil in the drive axle

126

5.31 Changing the oil in the wheel hubs

127

5.32 Changing the oil in the axle reduction gear

128

5.33 Change the oil in the drum reduction gear

129

5.34 Vario exciter oil change

130

5.35 Change the oil in the exciter shaft housing of the attachment plates

131

5.36 Tightening the fastening of the axle to the frame

132

5.37 Tightening the wheel nuts

132

5.38 Check the ROPS

133

5.39 Cleaning the oil bath air filter

133

5.40 Changing hydraulic oil and breather filter

134

5.41 Changing the hydraulic oil filter

135

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Table of Contents

5.42 Changing the steering oil filter

136

5.43 Changing the attachment plate oil filter

137

5.44 Change the coolant

138

5.45 Replacing the crank case ventilation valve

140

5.46 Electronic injector test EMR

141

5.47 Service the combustion air filter

142

5.48 Adjust the scrapers

144

5.49 Adjust the parking brake

145

5.50 Change the tires

146

5.51 Change the fresh air filter in the cabin

147

5.52 Tightening torques

147

5.53 Engine conservation

148

Trouble shooting

149 6.1 General notes

150

6.2 Reading out faults BVC/BTM05

150

6.3 Engine

152

Cab assembly before initial start-up

155

7.1 Preparations

157

7.2 Cabin assembly

158

7.3 Final function tests and checks

164

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Table of Contents

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1 Technical Data

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Technical Data

Fig. 4

Dimensions in mm

A

B

D

H

H2

K

L

O1

O2

S

W

BW 213 DH-4 BVC/P

2960

2250

1500

2268

2972

490

5808

60

60

35

2130

*

Weights Operating weight (CECE) with ROPS and cabin Axle load, drum (CECE) Axle load, wheels (CECE) Static linear load Travel characteristics Speed Max. gradability (depending on soil) Engine Engine manufacturer Type Cooling Number of cylinders Rated power ISO 3046 Rated speed Electrical equipment Drive system Driven axles

10

BW 213 DH-4 BVC/P

kg

15785

kg kg kg/cm

7598 8187 35,7

km/h %

0 ... 13 50

kW rpm V

BOMAG

Deutz TCD 2013 L04 2V Water 4 119 2200 12 hydrostatic 2

BW 213 DH-4/PDH-4 BVC

Technical Data

*

BW 213 DH-4 BVC/P

Brakes Service brake Parking brake

hydrostatic hydr.-mech.

Steering Type of steering Steering operation

articulated hydrostatic

Vibration, drum Drive system Frequency Amplitude

Hz mm

hydrostatic 28 0 ... 2,4

Vibration, attachment plates Drive system Frequency

Hz

hydrostatic 40 ... 55

Tires Tire size Air pressure

bar

23.1/18-26/12PR 1,8

Litres Litres Litres

15 340 60

Filling capacities Engine Fuel Hydraulic oil *

The right for technical modifications remains reserved

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Technical Data

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

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

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

= 76,8 dB(A)

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

= 111 dB(A)

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

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

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

12

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2 Safety regulations

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Safety regulations

General

Unintended use

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

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

l

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

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

l

the machine is operated by untrained personnel

l

the machine is modified or converted in an unprofessional way

l

the applicable safety regulations are not observed.

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

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

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

applicable accident prevention instructions

l

generally acknowledged safety and road traffic regulations

l

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

Intended use This machine must only be used for: l

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

l

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

l

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

l

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

14

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

Who is allowed to work with the machine?

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

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

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

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

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

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

BOMAG

BW 213 DH-4/PDH-4 BVC

Safety regulations

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

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

Towing the machine Since the machine is not fitted with a towing hitch, the machine cannot be towed with a tow bar.

If the machine has to be towed urgently out of the danger zone because of other risks, this must only be done on level ground or uphill using chains and ropes. For this purpose towing ropes of sufficient tensile strength must be fastened on the lifting eyes.

After releasing the brake the machine can only be braked by the towing vehicle.

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

Before releasing the brake block the machine with chocks to prevent unintended rolling.

Checking the Roll Over Protection Structure (ROPS)

Observe all environment protection regulations.

Information and safety stickers/decals on the machine Keep stickers/decals complete (see spare parts catalogue) and fully legible and observe their meaning.

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

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

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

Replace damaged or illegible stickers/decals immediately.

Loading the machine 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.

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.

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

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

Persons are highly endangered if l

they step or stand under loads being lifted

l

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

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

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

Before starting

Use only safe lifting gear of sufficient load bearing capacity.

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

Attach the lifting gear only to the specified lifting points.

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

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Safety regulations

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

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

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

Starting in closed rooms

Check before mounting the machine if:

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

l

there are persons or obstructions beside or under the machine

l

the machine is free of any oily and combustible material

Driving the machine

l

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

l

the engine compartment hood is closed and locked

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

Persons in the endangered area

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.

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

Check before starting, whether: l

the machine shows any obvious defects

l

all protective devices are properly secured in their place

l

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

l

the seat is correctly adjusted

l

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

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

Driving

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

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

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

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

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

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

l

do not leave the operator's stand

Starting

l

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

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

l

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

if possible drive the machine out of the danger zone

l

have the power shut off.

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

Operate the machine only from the operator's seat.

After starting check all gauges.

Keep the cabin doors closed.

Starting with jump leads

Do not adjust the seat while driving.

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

Do not climb onto or off the machine while driving.

16

Change the travel direction only while the machine is standing.

BOMAG

BW 213 DH-4/PDH-4 BVC

Safety regulations

Do not use the machine to transport persons.

l

lock the cabin

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

l

secure the machine against unauthorized use.

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

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.

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

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

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

Filling the fuel tank

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

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

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

Behaviour in traffic

Do not inhale fuel fumes.

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

Do not refuel in closed rooms.

No open fire, do not smoke.

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

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

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

Match the speed of the machine to the working conditions.

Always allow loaded transport vehicles to pass.

Switch the lights on when the visibility is poor.

Fire protection measures

Keep clear of edges and embankments.

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

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

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

Maintenance work Comply with the maintenance work described in the operating and maintenance instructions, including the information concerning the replacement of parts.

Support the engine hood for all maintenance and repair work in the engine compartment.

Parking the machine

Maintenance work must only be performed by qualified and authorized persons.

Park the machine on level and firm ground.

Before leaving the machine:

For overhead maintenance and assembly work use the access steps and working platforms provided or other secure means. Do not use machine parts as access steps.

l

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

l

return the travel lever to neutral position

l

apply the parking brake

Keep unauthorized persons away from the machine.

l

shut the engine down and pull the ignition key out.

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

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17

Safety regulations

Park the machine on horizontal, level, firm ground.

l

the fitting shows corrosion that impairs both function and strength.

l

hoses are mixed up by mistake.

l

fittings are damaged or deformed, whereby the function and strength of the hose/hose connection is impaired.

Pull the key out of the ignition switch.

Secure the articulated joint with the articulation lock.

Work on hydraulic lines Relieve hydraulic pressures before working on hydraulic lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. When being injured by hydraulic oil consult a medical doctor immediately, as otherwise this may cause severe infections.

Do not step in front of or behind the drums/wheels when performing adjustment work in the hydraulic system.

Do not change the setting of pressure relief valves.

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

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

Do not work on the fuel system while the engine is running - danger to life due to high pressures! l

Wait another minute after the engine has stopped.

l

Keep out of the danger zone during the initial test rung.

l

In case of leaks return to the workshop immediately.

l

Make sure that the engine cannot be started unintentionally during service and repair work.

Drain the hydraulic oil at operating temperature – danger of scalding!

Catch running out hydraulic oil and dispose of environmentally.

Always catch and dispose of hydraulic oils separately.

Do not start the engine after draining the hydraulic oil.

Drain the engine oil at operating temperature – danger of scalding!

Once all work is completed (with the system still depressurized!) check all connections and fittings for leaks.

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

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

Hydraulic hoses must be immediately replaced if: l

the outer layer is damaged down to the inlay (e.g. chafing, cuts, cracks)

l

the outer layer is brittle (formation of cracks in the hose material)

l

the hose shows deformations in pressurized and depressurized condition, which do not comply with the genuine shape of the hydraulic hose

l

the hose shows deformations in bends, e.g. squeezing, buckling, layer separation, formation of blisters

l

parts of the hose are leaking.

l

hoses are not correctly installed.

l

the hydraulic hose has separated from the fitting

18

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

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

The settings for idle speed and highest speed must not be changed, since this would affect the exhaust gas values and cause damage to engine and power train.

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

Check and change coolant only when the engine is cold.

Catch coolant and dispose of environmentally.

BOMAG

BW 213 DH-4/PDH-4 BVC

Safety regulations

Working on electric parts of the machine Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material.

Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire. Fire hazard!

wheel studs or nuts. Do not drive with damaged tires or wheels.

Ant-sticking emulsions for tires must only consist of water and anti-sticking agent, in a concentration in accordance with the specifications of the manufacturer of the anti-sticking agent. Observe applicable environmental regulations.

Cleaning work

Disconnect the battery before starting welding work on the machine.

Working on the battery

Do not perform cleaning work while the engine is running.

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

Do not use gasoline or other easily inflammable substances for cleaning.

Do not let acid come in contact with hands or clothes! When injured by acid flush off with clear water and seek medical advice.

When cleaning with steam cleaning equipment do not subject electrical parts and insulation material to the direct jet of water, or cover it beforehand.

Metal objects (e.g. tools, rings, watch straps) must not come in contact with the battery poles – danger of short circuit and burning!

l

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

After maintenance work

When recharging serviceable batteries remove all plugs, to avoid the accumulation of explosive gases.

After all maintenance work is completed reinstall all guards and safety installations.

Observe the applicable instructions when starting with an auxiliary battery.

Repair

Dispose of old batteries according to regulations.

Switch off the charging current before removing the charging clamps.

Repair work must only be performed by qualified and authorized persons. Use our repair instructions for this work.

Ensure sufficient ventilation, especially if the battery is to be charged in a closed room.

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

Working on the fuel system Do not inhale any fuel fumes.

Avoid open fire, do not smoke, do not spill any fuel.

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

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

Assembly of tires must only be performed with appropriate experience and tools. If necessary have tires assembled in a qualified workshop.

Always ensure the correct tire pressure and do not exceed the specified maximum pressure.

Check tires and wheels every day for specified pressure, cuts, bulges, damaged rims, missing

BW 213 DH-4/PDH-4 BVC

Mark a defective machine by attaching a warning tag to the steering wheel.

Do not work on the fuel system while the engine is running - danger to life!

The system is under high pressure! Keep away from leakages in the high pressure system, because fuel squirting out may cause severe injury.

After shutting down the engine wait for another minute, until the pressure has dropped to a permissible level. In case of leakages you should contact the Service Department of the engine manufacturer and refrain from starting the engine.

Test The safety of compaction equipment must be checked by a specialist as required in dependence on the application and the operating conditions, however at least once every year.

BOMAG

19

Safety regulations

20

BOMAG

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3 Indicators and Controls

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BOMAG

21

Indicators and Controls

Fig. 5

22

BOMAG

BW 213 DH-4/PDH-4 BVC

Indicators and Controls

1

Ignition switch

12 Rotary switch vibration extension plates on/off

2

LCD display unit

13 Rotary switch drum vibration on/off

3

Vent for heating and ventilation, driver

14 Travel lever

4

Vent for heating and ventilation, footwell

5

Control panel, travel lever

15 Rotary momentary contact switch for engine speed

6

Display and control unit Variocontrol BOP

7

Rotary switch for speed range selection

16 Rotary momentary contact switch for drum vibration frequency*

8

Emergency stop push button

17 Rotary switch for direction indicators left/right*

9

Push button for warning horn

18 Rotary switch for hazard light system*

10 Rotary switch for extension plates floating position

19 Rotary switch for lighting (StVZO)*

11 Rotary switch for extension plates vibration frequency

21 Steering wheel

20 Rotary switch for working head lights*

*

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Optional equipment

23

Indicators and Controls

3.1

General notes

3.2

Description of indicators and control elements

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

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

Fig. 6

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

Position "I"

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

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

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

Position "II"

!

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

Caution

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

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

24

BOMAG

BW 213 DH-4/PDH-4 BVC

Indicators and Controls

Engine is shut down after 10 seconds. i yellow = lights if the hydraulic oil filter is contaminated, the engine is shut down after 2 minutes.

Check hydraulic system, replace hydraulic oil filter. j yellow = lights when the hydraulic oil temperature is too high k yellow = lights when temperatures are low (pre-heating for starting) l yellow = Charge control light, lights if the battery is not being charged.

Check V-belt, if necessary repair the generator.

Fig. 7

No. 2 = LCD display unit

m red

= Water separator in fuel pre-cleaner.

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

Toggling between the displays is described in the chapter "Operation".

n

= Function display, set brightness of display

a green = flashes when the direction indicator switch is actuated.

o

= Middle display field, can be switched to display of operating hours or mean fuel consumption by actuating the "Info-button 1"

p

= Bottom display field, can be switched to display inclination, vibration frequency, voltage, hydraulic oil pressure, hydraulic oil temperature or ambient temperature by actuating "Info-button 2"

q

= Hydraulic oil temperature gauge

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

b

= Indication of fuel level

c

= Upper display field, shows either the time or the coolant temperature

d

= Indication of travel speed and pre-selected speed limitation (green ring segment)

e red

= flashes if engine oil pressure too low, engine is shut down after 10 seconds. Check engine oil level, repair the engine if necessary.

f red

= flashes if the engine overheats (oil temperature), the warning buzzer sounds, the engine is shut down after 2 minutes.

Switch off vibration, run engine with idle speed or shut down engine if necessary, clean engine oil cooler and radiator, if necessary repair engine.

g yellow = lights if combustion air filter cartridge is soiled, clean or replace if necessary. h red

= flashes when the coolant (filling) level is too low.

BW 213 DH-4/PDH-4 BVC

r yellow = lights in case of problems with the air conditioning s yellow = lights in case of an ASC (Anti Spin Control) failure t red

= The seat occupation monitoring system lights when the seat is not occupied. If the machine is travelling the warning buzzer will sound, engine is shut down after 4 seconds.

u red

= Parking brake, with travel lever disengaged

v red

= Central warning light, lights if a fault code is displayed

w red

= Hazard light, flashes when the hazard light is activated

BOMAG

25

Indicators and Controls

x

= Engine speed display

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

Fig. 9

Changeover of display

i Note Fig. 8

The operation is described in the corresponding chapter

No. 5 = Control panel, travel lever

Info 1 button

(a) Vibration button l

Select the vibration on with the selector switch.

l

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

Changeover possible during travel Info 2 button

(b) Push button "Plates up" Press the push button = Raise the plates (c) Push button "Extend plates" Press the push button = The plates are extended to the right

Navigation in input mode) = Activation of input mode only possible with the brake applied (see chapter operation)

Press the push button = Lower the plates Caution Do not drive backward with the plates lowered to the ground!

= to toggle between display of inclination [%], vibration frequency [Hz], voltage [V], engine oil pressure [bar], hydraulic oil temperature** [°C/ °F], ambient temperature*** [°C/°F] Changeover possible during travel

(d) Push button "Plates down"

!

= to toggle between operating hours and mean consumption.

F2 button

= Change selected field

F3 button

= Select field to change

F4 button

= Select field to change

F5 button

= Change selected field

(e) Push button "Retract plates" Press the push button = The plates are retracted

*

26

Optional equipment

** Optional equipment *** Optional equipment

BOMAG

BW 213 DH-4/PDH-4 BVC

Indicators and Controls

Fig. 10

Fig. 12

No. 6 = Control unit Variocontrol BOP

The adjusted travel range appears in the LCD display unit in form of a green ring segment (Fig. 12).

i Note see section 3.4 „display and control elements Variocontrol“.

Fig. 13

No. 8 = Emergency stop switch Fig. 11

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

No. 7 = Rotary switch for final speed Turn in direction "Turtle" = Reduces the speed Turn in direction "Rabbit" = Increases the speed

! Danger Danger of accident!

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

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

BW 213 DH-4/PDH-4 BVC

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

BOMAG

27

Indicators and Controls

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. 16

No. 11 = Rotary switch for frequency of attachment plate With this switch (potentiometer) the exciter frequency can be infinitely adjusted (see technical data).

Fig. 14

No. 9 = Push button for warning horn

Fig. 15

No. 10 = Rotary switch for attachment plates floating position Position left

= Floating position off

Position right

= Floating position on

Choose the setting in dependence on soil condition and degree of compaction.

Fig. 17

No. 12 = Rotary switch vibration attachment plates on/off Position left

= Vibration off

Position right

= Vibration on

Danger Danger of squashing! !

Maintenance and service work must only be performed with the attachment plates in floating position. For safety reasons the extension plates are then lowered to the ground and the hydraulic lines depressurized.

28

BOMAG

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Indicators and Controls

back towards neutral. This relieves the hydraulic system and reduces the load on the diesel engine.

Fig. 18

No. 13 = Rotary switch for vibration Position "Left" = Vibration off

Fig. 20

Position "Right" = Vibration on

No. 15 = Rotary momentary contact switch for engine speed

i Note

Electric engine speed adjustment

Press additional push button on travel lever to switch on and off.

Position left

= Idle speed position

Position middle = "ECO"-operation.

The engine speed adapts automatically to the power requirements. This enables economical operation.

Position right

= Full throttle position, operating position for driving and vibration

Caution Always drive and vibrate with max. engine speed or in ECO-mode! Control the travel speed with the travel lever. !

Fig. 19

No. 14 = Travel lever Position "middle" = Braking position service brake Position "middle, right" = Parking brake, to start the engine Position "I"

= Forward travel

Position "II"

= Backwards travel

i Note If the engine speed drops under load when driving on steep gradients, take the travel lever slightly

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BOMAG

29

Indicators and Controls

Fig. 21

Fig. 23

No. 16 = Rotary momentary contact switch for vibration frequency*

No. 18 = Rotary switch for hazard light system

Turn "Left"

= Frequency reduction

Position "left"

Turn "Right"

= Frequency increase

***

= Hazard light switched off, control lights off.

Position "right" = Hazard light switched on, control light 7 in the fault monitoring display lights up.

Fig. 22

No. 17 = Rotary switch for direction indicators left / right** Fig. 24

Position "middle" = Direction indicators disabled Position "left or right" = The front and rear direction indicators for the corresponding side of the machine light up, control light 6 in the fault monitoring board flashes

* **

30

Optional equipment Optional equipment

No. 19 = Rotary switch for light system (StVZO)**** Position "left"

= Light off

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

*** Optional equipment **** Optional equipment

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Indicators and Controls

Fig. 25

Fig. 26

No. 20 = Rotary switch for working lights*

No. 22 = Lever, swivelling of driver’s seat

Position "left"

= Light off

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

Danger Danger of accident!

No. 21 = Steering wheel, electrically operated

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

turn

= The machine steers to the corresponding direction

!

Do not swivel the driver’s seat while driving. swivel

i Note The machine is equipped with an armrest contact switch (safety feature).

If the armrest is raised while driving, the warning horn is activated and the machine is decelerated to standstill after four seconds. If the armrest is lowered again within four seconds the machine will continue the travel.

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

i Note Swivelling angle max. 20° to either side.

Lower the armrest before resuming operation, engage the travel lever in "0"-position (brake position), then operate the travel lever again to the desired travel direction.

Fig. 27

No. 23 = 2-pole socket Current only with the ignition switch in position "I" or when the engine is running.

*

Optional equipment

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BOMAG

31

Indicators and Controls

Fig. 28

Fig. 29

No. 24 = Fuses in electric installation box

No. 25 = Toggle switch, cabin

F05, 10A

= Display

a = toggle switch for flashing beacon

F07, 15A

= Hazard light*

F08, 15A

= Indicator*

b = toggle switch for front windscreen wiper/ washer

F09, 10A

= Parking tail light, left*

up

F10, 10A

= Parking tail light, right*

= windscreen wiper moves to end position and stops.

F11, 15A

= Head lights, StVZO*

down

F13, 30A

= Starting

= Switches on wiping of front windscreen.

F18, 10A

= Working head lights, relay*

Push button

F19, 15A

= Working head lights, front*

= Front windscreen is sprayed during wiping.

F22, 15A

= Working head lights, rear*

F23, 15A

= Warning horn

F24, 10A

= Joystick, DASA**, display

F39, 15A

= Socket, cabin*

F67, 15A

= Last ESX***

F84, 10A

= Voltage supply MESX****, ESX via emergency stop

F95, 10A

= EMR*****-control, joystick

F145, 20A

= Attachment plates*

F146, 15A

= Last MESX*

F148, 10A

= Measuring technology*

!

c = toggle switch for rear windscreen wiper/ washer up

= windscreen wiper moves to end position and stops.

down

= Switches on wiping of rear windscreen.

Push button

= Rear windscreen is sprayed during wiping.

Danger

Fire hazard!

Do not use fuses with higher ampere ratings and do not bridge fuses. * Optional equipment ** DASA = Data Collector *** ESX = BDC-remote control **** MESX = BMU-measuring technology control *****EMR = engine control

32

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Indicators and Controls

d = toggle switch for rear windscreen heating

e = Rotary switch for cabin ventilator Position ’’Off“

= cabin ventilator switched off.

Position 1, 2 and 3 = ventilator stages of different strengths f = Push button for air conditioning* press

= air conditioning switched on. (only with fan in stage 1, 2 or 3)

i Note The light above the push button lights up.

Fig. 30

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

No. 26 = Fuse box, cabin

press again

!

= air conditioning switched off.

i Note

Danger

Fire hazard!

The light goes out.

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

g = Rotary switch for cabin heater (temperature selector switch)

(1), 15A = (F43) wiper/washer, rear

Position ’’Off“

(2), 15A = (F44) wiper/washer, front

Position blue range

(3), 10A = (F130) relay for rear windscreen heating, reading light

Position red range

(4), 25A = (F31) cabin fan (5), 10A = (F41) flashing beacon

= cabin heater switched off. = temperature selection for air conditioning. = Temperature selection for cabin heater.

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

= (F42) potential 30, cab light

Fig. 32

No. 28 = Cabin light Fig. 31

No. 27 = Control panel for ventilator, air conditioning, heating

BW 213 DH-4/PDH-4 BVC

*

BOMAG

Optional equipment

33

Indicators and Controls

i = reading and dashboard light j = toggle switch for reading and dashboard light k = toggle switch for cabin light l = cabin light

Fig. 33

No. 29 = Main fuse for battery 125A

= (F00)

i Note The battery with the main fuses is located in the engine compartment.

34

BOMAG

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Indicators and Controls

3.3

Display and control elements Variocontrol

Fig. 34

BW 213 DH-4/PDH-4 BVC

BOMAG

35

Indicators and Controls

1

EVIBdisplay

12 Push button F12 automatic operation

2

Display for jump operation

13 Push button F11 manual operation

3

Push button F5 START

4

Push button F6 STOP

14 Rotary switch for manual setting of amplitude direction

5

Push button F7 PRINT

15 Push button F10 vertical effective direction

6

Push button F8 DELETE

16 Push button F9 horizontal effective direction

7

Vibration frequency display

17 Speed display

8

Rotary switch to set the nominal value (automatic operation)

18 Amplitude display

Push button F14 nominal value increase

20 Fault light

9

10 Push button F13 nominal value decrease

19 Printer for measuring values 21 Amplitude limitation active

11 Rotary switch to select operating mode (automatic/manual)

36

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BW 213 DH-4/PDH-4 BVC

Indicators and Controls

3.4

Caution If the increase of the measuring value is to be calculated on a track press button F8 DELETE only when changing the track. !

Description of indicating and control elements Variocontrol

No. 7 = Frequency display (only BTM 05) No. 1 = EVIB-display Display of the dynamic soil stiffness in MN/m2.

with vibration switched on this instrument shows the frequency (rotating speed) of the exciter shaft.

No. 2 = Display for jump operation yellow symbol red symbol

No. 8 = Rotary switch P3 pre-setting of nominal values

= Drum jumps

For "Automatic" mode In dependence on the stiffness of the soil the effective direction of the amplitude will adjust automatically. The desired maximum dynamic stiffness module EVIB [MN/m2] can be preselected in 6 stages (45, 80, 100, 120,150 and Max.).

= Drum jumps excessively or tumbles

Select a smaller amplitude, if necessary!

No. 3 = Button F5 START press

The selected value is shown on the screen in field "P3"

= Starts recording of measuring values

No. 9 = Button F14 increase of nominal value

Control field "F5" flashes green on the screen.

With each actuation of the button the presetting is raised by one stage.

No. 4 = Button F6 STOP press

= Stops recording of measuring values

The selected value is shown on the screen in field "P3"

The red control field "F6" on the screen lights up.

No. 10 = Button F13 reduction of nominal value

i Note Depending on the measuring result the green control field "F5" may stay on.

No. 5 = Button F 7 measuring value printer

short actuation = Line diagram long actuation ≥5 sec. = Bar chart Control field F7 goes out and the measuring value printer starts to print out measuring data.

i Note After the printing process has finished any amount of diagrams can be printed out by pressing the same button F7 (PRINT). press

= All stored faults are deleted.

The selected value is shown on the screen in field "P3" No. 11 = Rotary switch P2 operating mode

To print out the measuring data saved during the last pass press button F7 PRINT.

No. 6 = Button F8 DELETE

With each actuation of the button the presetting is reduced by one stage.

Position “Auto= The machine automatically matic EVIB” chooses the optimal effective direction of the amplitude in dependence on the stiffness of the ground and the adjusted nominal E VIB-value (switch P3).

Position “EVIBManual” = The effective direction of the amplitude is set in 6 fixed stages (switch P1), when changing the travel direction the vibration will adapt automatically and change to other quadrant.

The selected operating mode is shown on the screen in field "P2".

No. 12 = Button F12 automatic operation

BW 213 DH-4/PDH-4 BVC

BOMAG

37

Indicators and Controls

Pressing this button changes the operating mode to "Automatic".

This gauge shows the current vertical amplitude of the machine.

The selected operating mode is shown on the screen in field "P2".

No. 19 = Printer for measuring values To print out the measuring data saved during the last pass press button (7) "PRINT".

No. 13 = Button F11 manual operation

No. 20 = Fault light

Pressing this button changes the operating mode to „Manual“.

Inform the BOMAG After Sales Service if it lights up.

The selected operating mode is shown on the screen in field "P2".

No. 21 = Amplitude limitation active

No. 14 = Rotary switch P1 manual setting of effective direction of amplitude

In automatic operation the amplitude limitation enables a limitation of the effective amplitude.

This switch is used to specify the vertical amplitude in "Manual" mode and is only available in this operating mode.

no symbol displayed = Amplitude limitation inactive Symbol shaded = Amplitude limitation active, but inactive because of the parameter setting (e.g. manual mode)

Position 1 (left) = Horizontal, 0 mm amplitude Position 2

= 0,7 mm amplitude

Position 3

= 1,1 mm amplitude

Position 4

= 1,5 mm amplitude

Position 5

= 1,8 mm amplitude

Position 6 (right)

= Vertical, 2,4 mm amplitude

Symbol bright = Amplitude limitation active

Field P1 on the screen shows graphically with which amplitude the machine is currently working.

i Note In travel lever position "0" the vibrator system remains in position "horizontal" for safety reasons.

On bridges or in sensitive areas it is recommended to use "Manual – Horizontal".

No. 15 = Button F10 vertical effective direction With each actuation of the button the effective direction is changed by one step towards vertical.

The selected value is shown on the screen in field „P1“ No. 16 = Button F9 horizontal effective direction With each actuation of the button the effective direction is changed by one step towards horizontal.

The selected value is shown on the screen in field „P1“ No. 17 = Speed display Shows the travel speed of the machine.

No. 18 = Amplitude display

38

BOMAG

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Indicators and Controls

3.5

Line diagram Automatic (EVIB)

Fig. 35

BW 213 DH-4/PDH-4 BVC

BOMAG

39

Indicators and Controls

1

Pass-No.

11 Mean EVIB-value

2

Travel direction

12 EVIB-change

3

Machine equipment (BTM 05/BTM-E)

13 Medium frequency

4

Software status of the measuring equipment

14 Mean travel speed

5

Machine number

15 Track length

6

Machine type

16 Raster division in longitudinal direction

7

Operating mode

17 Longitudinal raster line

8

Setting of nominal EVIB value

18 Identification of nominal value line

9

Maxiumum EVIB value

19 Measuring value raster line

10 Miniumum E VIB value

40

20 Diagram line

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Indicators and Controls

3.6

Graduation of the measuring track (track length in printout) into fixed sections.

Description of line diagram Automatic (EVIB)

No. 17 = Longitudinal raster line No. 18 = Identification of nominal value line

No. 1 = Pass

Show the setting of nominal value (150).

Total number of measured passes on this track.

No. 19 = Measuring value raster line

No. 2 = Travel direction

No. 20 = Diagram line

No. 3 = Machine equipment

Shows the EVIB-value at any point of the rolled track. The raster line enables the location related assignment of the EVIB-value and the location of a fault (over or under compaction).

No. 4 = Software status of the measuring equipment No. 5 = Machine number No. 6 = Machine type No. 7 = Operating mode Shows the setting of the operating mode (Auto) and the presetting of nominal value (150).

No. 8 = Setting of nominal E VIB value Shows the preset nominal EVIB-value.

No. 9 = Maximum E VIB value No. 10 = Minimum EVIB value No. 11 = Mean EVIB-value shows the mean value of the EVIB-values for the tracks driven between START and STOP. No. 12 = EVIB-change EVIB-change in %. They always relate to the previous pass.

No. 13 = Medium frequency No. 14 = Mean travel speed shows the mean value of speed driven during this pass.

i Note Always shows the same travel speed in order to avoid a falsification of the measuring results.

No. 15 = Track length Measured track length between START and STOP. No. 16 = Raster division in longitudinal direction Is used to pinpoint individual measuring values on the measuring curve.

i Note The raster lines mark measuring track sections of 5 m length.

BW 213 DH-4/PDH-4 BVC

BOMAG

41

Indicators and Controls

42

BOMAG

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Indicators and Controls

3.7

Line diagram Manual (EVIB)

Fig. 36

BW 213 DH-4/PDH-4 BVC

BOMAG

43

Indicators and Controls

1

Pass-No.

12 EVIB-change

2

Travel direction

13 Medium frequency

3

Machine equipment

14 Mean travel speed

4

Software status of the measuring equipment

15 Track length

5

Machine number

16 Raster division in longitudinal direction

6

Machine type

7

Operating mode

17 Marking (thick line) excessive jumping, tumbling of the drum

8

Amplitude

18 Longitudinal raster line

9

Maxiumum EVIB value

19 Measuring value raster line

10 Miniumum E VIB value

20 Diagram line

11 Mean EVIB-value

21 Marking (thin line) jumping of the drum

44

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Indicators and Controls

3.8

i Note

Description of line diagram Manual (EVIB)

The raster lines mark measuring track sections of 5 m length.

No. 1 = Pass

Graduation of the measuring track (track length in printout) into fixed sections.

Total number of measured passes on this track.

No. 17 = Marking of jump information

No. 2 = Travel direction

Indicates excessive jumping/tumbling of the drum on the marked track section (thick line).

No. 3 = Machine equipment No. 4 = Software status of the measuring equipment

i Note

No. 5 = Machine number

Select a smaller amplitude, if necessary!

No. 6 = Machine type

No. 18 = Longitudinal raster line

No. 7 = Operating mode

No. 19 = Measuring value raster line

Shows the setting of the operating mode (Auto) and the presetting of nominal value (150).

No. 20 = Diagram line

Shows the amplitude which was adjusted during the EVIB measuring pass.

Shows the EVIB-value at any point of the rolled track. The raster line enables the location related assignment of the EVIB-value and the location of a fault (over or under compaction).

No. 9 = Maxiumum EVIB value

No. 21 = Marking of jump information

No. 10 = Miniumum E VIB value

Indicates jumping of the drum on the marked track section (thin line).

No. 8 = Amplitude

No. 11 = Mean EVIB-value shows the mean value of the EVIB-values for the tracks driven between START and STOP. No. 12 = EVIB-change EVIB-change in %. They always relate to the previous pass.

No. 13 = Medium frequency No. 14 = Mean travel speed shows the mean value of speed driven during this pass.

i Note Always shows the same travel speed in order to avoid a falsification of the measuring results.

No. 15 = Track length Measured track length between START and STOP. No. 16 = Raster division in longitudinal direction Is used to pinpoint individual measuring values on the measuring curve.

BW 213 DH-4/PDH-4 BVC

BOMAG

45

Indicators and Controls

3.9

Bar diagram* (EVIB)

The bar diagram differs from the line diagram only by the graphic representation of measuring values. In the bar diagram the mean values of 5 m sections are shown as bars. In addition, the EVIB changes of the individual 5 m sections are specified in percent after the second pass in the same travel direction.

*

46

only BTM prof

BOMAG

BW 213 DH-4/PDH-4 BVC

4 Operation

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BOMAG

47

Operation

4.1

General notes

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

4.2

Tests before taking into operation

The following inspections must be carried out before each working day or before a longer working period.

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

Danger

Danger of accident!

Please observe strictly the safety regulations in chapter 2 of this instruction manual!

Park the machine on ground as level as possible.

l

Check: l

fuel tank and fuel lines for leaks

l

screw joints for tight fit

l

function of steering

l

machine for cleanliness, damage

l

presence of the appropriate operating and maintenance instructions,

l

check whether the machine has been properly serviced.

i Note For a description of the following tasks refer to the chapter "maintenance every 10 operating hours".

Engine oil level

l

i Note In hydraulic systems filled with Panolin HLP Synth.

46 always use the same oil to top up. With other ester based oils consult the lubrication oil service of the respective oil manufacturer. l

Check the hydraulic oil level, top up if necessary.

l

Check the coolant level, top up if necessary. !

Danger

Fire hazard!

Do not refuel in closed rooms. l

48

BOMAG

Check the fuel level, top up if necessary.

BW 213 DH-4/PDH-4 BVC

Operation

l

Check water separator in fuel system, drain if necessary.

l

Check the scrapers, adjust if necessary

l

Check the air pressure in the tires For values refer to the technical data.

Caution Ensure equal pressure in both tires. !

4.3 !

Starting the engine

Danger

Danger of accident!

Always wear your seat belt.

If the machine is to be operated with padfoot drum shell the attachment plates must be decoupled!

Danger of damage to the drive axle.

Fig. 37 l

Check, whether the travel lever (Fig. 37) is engaged to the right in brake position.

Fig. 38

BW 213 DH-4/PDH-4 BVC

l

Turn the rotary vibration switch (Fig. 38) to position "0", vibration off.

BOMAG

49

Operation

Fig. 39 l

Check, whether the emergency stop switch (Fig. 39) is unlocked.

Fig. 42

All control and warning lights (Fig. 42) in the fault monitoring board light up for a moment.

The battery control (l) and brake warning lights (u) light up, the engine oil pressure warning light (e) flashes.

Wait until the pre-heating light (k) has gone out.

l

i Note The length of the pre-heating period depends on the engine temperature.

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

Fig. 40 l

Turn rotary switch (Fig. 40) to position "Min" (idle speed).

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

Fig. 41 l

50

Turn the ignition key (Fig. 41) to position "I".

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BW 213 DH-4/PDH-4 BVC

Operation

4.4

Starting with jump wires

Fig. 43 l

Turn the ignition key to position "II" (Fig. 43), the starter cranks the engine.

l

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

Fig. 44

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

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

l

Bridge the machine only with a 12 Volt auxiliary battery.

l

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

l

Then connect the ground cable first to the minus pole of the current supplying auxiliary battery and then to engine or chassis ground, as far away from the battery as possible (Fig. 44).

l

Start as described under 'Starting the engine'.

l

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

Caution

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

BW 213 DH-4/PDH-4 BVC

l

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

l

Switch off the consumer.

BOMAG

51

Operation

4.5 !

Driving the machine

Danger

Danger of accident!

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

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

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

Fig. 45 l

Close the cabin door (Fig. 45).

Do not drive without wearing your seat belt.

Always give way to loaded transport vehicles!

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

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

i Note

Fig. 46

The machine is equipped with an armrest monitoring system and a seat contact switch (safety feature).

l

Sit on the driver's seat (Fig. 46) and fold down the armrest (if applicable).

If the armrest is raised or the driver gets up from his seat while driving, the warning horn is activated and the machine is decelerated to standstill after four seconds. If the armrest is lowered again or the driver sits down again within four seconds the machine will continue the travel.

Lower the armrest or sit down on the seat again before resuming operation, engage the travel lever in "0"-position (brake position), then operate the travel lever again to the desired travel direction.

Fig. 47

52

l

Fasten your seat belt (Fig. 47).

l

"Start engine", see previous sections.

BOMAG

BW 213 DH-4/PDH-4 BVC

Operation

Fig. 48 l

Fig. 50

Select the desired travel speed range (Fig. 48).

Push the travel lever (Fig. 50) to the left out of braking position and move it slowly to the desired travel direction.

l

The adjusted travel range appears in the LCD display unit in form of a green ring segment.

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

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

Fig. 49 l

Turn the rotary switch (Fig. 49) to position "ECO" or "MAX".

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

Important notes on travel operation !

Caution

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

Do not operate jerkily!

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

If the engine speed drops when driving up extreme inclinations move the ravel lever slightly

BW 213 DH-4/PDH-4 BVC

BOMAG

53

Operation

back, if necessary change to the lower speed range.

4.6

!

Switching the vibration on and off

Danger

Risk of damage!

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

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

Fig. 51 l

Pre-select the travel range for max. working speed (Fig. 51).

The adjusted travel range appears in the LCD display unit in form of a green ring segment.

54

BOMAG

BW 213 DH-4/PDH-4 BVC

Operation

Pre-selecting the vibration

Fig. 54 l

Fig. 52 l

Pre-select vibration with rotary switch (Fig. 52).

Press the push button (Fig. 54) in the travel lever while driving, the drum will vibrate.

Switching the vibration off l

Switch the vibration on

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

i Note Vibration is only possible in the range of 0 ... 8 km/ h.

Fig. 53 l

Turn the rotary switch (Fig. 53) to position "ECO" (Automatic) or "MAX" (full throttle).

!

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

BW 213 DH-4/PDH-4 BVC

BOMAG

55

Operation

4.7

Operating the parking brake, stopping the machine

4.8

Shutting the engine down

!

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

Fig. 55

Return the travel lever (Fig. 55) slowly to "neutral"-position and engage it to the right parking brake position.

l

Fig. 56 l

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

Return the travel lever (Fig. 56) slowly to "neutral"-position and engage it to the right in braking position.

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

Fig. 57 l

Turn rotary switch (Fig. 57) to position "ECO" or "MIN" (idle speed).

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

56

BOMAG

BW 213 DH-4/PDH-4 BVC

Operation

4.9

Changing the LCD-display

Switching the middle display over

i Note Switching over possible while machine is operated

Fig. 58

Turn the ignition switch (Fig. 58) to position "0" or "P" and pull the ignition key out.

l

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

Fig. 59

Danger Danger of accident! !

l

Press Info-button 1 (Fig. 59) (back of travel lever).

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

Fig. 60

With each actuation of the button the display changes from operating hours to mean fuel consumption or vice versa (Fig. 60).

Switching the bottom display over

i Note Switching over possible while machine is operated

BW 213 DH-4/PDH-4 BVC

BOMAG

57

Operation

- Setting of time / date - Metric/imperial units - Brightness of display - Input codes for service

Fig. 61

Press Info-button 2 (Fig. 61).

l

Fig. 63 l

Set the travel lever (Fig. 63) to braking position

Fig. 64 l

Fig. 62

With each actuation of the button the values for inclination, vibration frequency, voltage, engine oil pressure, hydraulic oil temperature *and ambient temperature* are successively displayed (Fig. 62).

Press both Info-buttons (Fig. 64) longer than three seconds to access the input mode.

"UHR" or "CLOCK" appears in the display.

Activating input mode and changing display fields (brief instructions)

i Note In input mode the following can be changed: - Display of time/coolant temperature *

58

Optional equipment

BOMAG

BW 213 DH-4/PDH-4 BVC

Operation

Fig. 65 l

Fig. 67

Select the desired field with the selection key F3 (Fig. 65).

l

To change the field press keys F2 or F4 (Fig. 67).

i Note

i Note

With function key F5 you can only jump back within the display, e.g. from minutes to hours. It cannot be used to jump from one field function to the previous one, e.g. from changing the upper display back to the time.

F2 = reduces the value or changes the display F4 = increases the value or changes the display

Fig. 68 l

To quit the input mode press both Info-buttons (Fig. 68) longer than three seconds or press the F3-key as often as required to re-establish normal condition.

BOMAG

59

Fig. 66

Sequence of changeable fields (Fig. 66): Setting of time / date, upper display changing of time / coolant temperature Changing units from metric/imperial Adapting brightness of display, Entering input codes for service

BW 213 DH-4/PDH-4 BVC

Operation

Example of changing "Time/Date"

Fig. 72 l

Fig. 69 l

Press both Info-buttons (Fig. 69) longer than three seconds to access the input mode.

Press key F3 to select "Minutes" (Fig. 72) and set the displayed minutes with keys F2 or F4 (Fig. 71).

Fig. 73 Fig. 70

"UHR" or "CLOCK" appears in the display and the figures representing the hours are flashing (Fig. 70).

The figures representing minutes flash (Fig. 73) l

Set the minutes with keys F2 or F4 (Fig. 71).

Fig. 74 Fig. 71 l

60

l

Press key F3 to select "Day" (Fig. 74) and set the display keys F2 or F4 (Fig. 71).

BOMAG

BW 213 DH-4/PDH-4 BVC

Set the hours with keys F2 or F4 (Fig. 71).

Operation

the F3-key as often as required to re-establish normal condition.

Switching over the upper display "Time / Coolant Temperature"

Fig. 75 l

Press key F3 to select "Month" (Fig. 75) and set the displayed month with keys F2 or F4 (Fig. 71).

Fig. 78 l

Press both Info-buttons (Fig. 78) longer than three seconds to access the input mode.

"UHR" or "CLOCK" appears in the display.

Fig. 76 l

Press key F3 to select "Year" (Fig. 76) and set the year with keys F2 or F4 (Fig. 71).

Fig. 79 l

Press selection key F3 (Fig. 79) as often as required to quit the setting mode for time/date.

BOMAG

61

Fig. 77 l

To quit the input mode press both Info-buttons (Fig. 77) longer than three seconds or press

BW 213 DH-4/PDH-4 BVC

Operation

Fig. 80

Fig. 83

The display "UHR" or "CLOCK" flashes (Fig. 80).

l

Press selection key F3 (Fig. 83) once to confirm.

Fig. 81 l

Press keys F2 or F4 (Fig. 81).

Fig. 84 l

To quit the input mode press both Info-buttons (Fig. 84) longer than three seconds or press the F3-key as often as required to re-establish normal condition.

BOMAG

BW 213 DH-4/PDH-4 BVC

Fig. 82

The coolant temperature is displayed (Fig. 82).

62

Operation

Changing the display units to "Metric / Imperial"

Fig. 87

The display will show "DEU" or "ENG" (Fig. 87).

Fig. 85 l

Press both Info-buttons (Fig. 85) longer than three seconds to access the input mode.

"UHR" or "CLOCK" appears in the display.

Fig. 88 l

Press selection key F3 (Fig. 88) once to confirm.

Fig. 86 l

Press selection key F3 (Fig. 86) as often as required to reach the "Metric/Imperial" setting mode.

Fig. 89

BW 213 DH-4/PDH-4 BVC

l

To quit the input mode press both Info-buttons (Fig. 89) longer than three seconds or press the F3-key as often as required to re-establish normal condition.

BOMAG

63

Operation

Setting the day/night brightness of the LCD-display

Fig. 92

The symbol "Lamp" and the brightness value (day) in percent flashes (Fig. 92).

Fig. 90 l

Press both Info-buttons (Fig. 90) longer than three seconds to access the input mode.

"UHR" or "CLOCK" appears in the display.

Fig. 93 l

Adjust the value with the keys F2 or F4 (Fig. 93).

Fig. 91 l

Press selection key F3 (Fig. 91) as often as required to reach the "Brightness" setting mode.

Fig. 94 l

64

BOMAG

Switch on the light (Fig. 94).

BW 213 DH-4/PDH-4 BVC

Operation

Fig. 95

Fig. 97

The brightness percentage (night) appears flashing (Fig. 95).

l

Press selection key F3 (Fig. 97) once to confirm.

i Note Standard setting for day = 100 % Standard setting for night = 50 %

Fig. 98 l

To quit the input mode press both Info-buttons (Fig. 98) longer than three seconds or press the F3-key as often as required to re-establish normal condition.

BOMAG

65

Fig. 96 l

Adjust the value with the keys F2 or F4 (Fig. 96).

BW 213 DH-4/PDH-4 BVC

Operation

Entering input codes for service

Fig. 101 Fig. 99 l

The figures to enter the code are displayed (Fig. 101).

Press both Info-buttons (Fig. 99) longer than three seconds to access the input mode.

"UHR" or "CLOCK" appears in the display.

Fig. 102 l

Adjust the value of the first digit with the keys F2 or F4 (Fig. 102).

Fig. 100 l

Press selection key F3 (Fig. 100) as often as required to reach the "Service Codes" setting mode.

Fig. 103 l

66

BOMAG

Select the following code digits with the keys F3 or F5 (Fig. 103) and adjust these with the function keys F2 or F4 (Fig. 102).

BW 213 DH-4/PDH-4 BVC

Operation

4.10 Emergency exit

4.11 Adjusting the seat

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

Fig. 104 l

To adjust the seat in longitudinal direction disengage lever a (Fig. 104).

l

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

l

Operate lever (d) to adjust the backrest.

Fig. 105 l

To adjust the height of the seat lift the seat up (Fig. 105) until it engages at the desired level.

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

BW 213 DH-4/PDH-4 BVC

BOMAG

67

Operation

4.12 Operating the hood !

Danger

Danger of accident!

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

Bottom position Fig. 106 l

To slide the seat pull up lever (Fig. 106) and slide the seat to the desired position.

When releasing the lever the seat is fixed in position.

Fig. 108 l

Unlock the lock (Fig. 108).

l

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

Fig. 107 l

To turn the seat press down lever (Fig. 107) and turn the seat to the desired direction.

When releasing the lever the seat is fixed in position.

Fig. 109 l

Pull the support out of the bracket and support the hood (Fig. 109).

Top position l

68

BOMAG

Push the hood to top position.

BW 213 DH-4/PDH-4 BVC

Operation

4.13 Towing in case of an engine failure !

Danger

Secure the machine with wheel chocks against unintentional rolling.

Danger of accident!

When using towing ropes tow the machine only uphill.

Fig. 110 l

Pull the spring pin (Fig. 110) out of the bracket.

l

Secure the hood i´n the protection tube with spring plug.

When towing downhill you must use a rigid towing device.

The machine cannot be steered. l

Secure the machine with wheel chocks against unintentional rolling.

Fig. 111 l

Attach chains (Fig. 111) or towing ropes to the lifting hooks.

!

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

BW 213 DH-4/PDH-4 BVC

BOMAG

Open the tailgate.

69

Operation

Fig. 112

Fig. 114

Slacken the middle hexagon on both valves (Fig. 112) for approx. 2 to 3 turns.

l

Turn both screws (Fig. 114) for releasing the drum brake evenly in clockwise direction, until the drum can turn freely.

l

Caution Do not turn the valves out completely. !

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

l

Turn the high pressure relief valve cartridges tightly back in.

l

Turn both screws for releasing the drum brake (Fig. 114) anti-clockwise against the stop.

l

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

Fig. 113 l

To release the brake turn counter nuts 1 (Fig. 113) approx. 8 mm back.

l

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

Caution

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

Turn the screws in evenly on both sides. l

l

70

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

Repeat this measure on the opposite wheel side.

Fig. 115 l

Turn the brake releasing screws (Fig. 115) back in again, until they abut against the brake piston.

BOMAG

BW 213 DH-4/PDH-4 BVC

Operation

4.14 Transport !

Danger

Danger of accident!

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

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

Fig. 116 l

Unscrew the brake releasing screws (Fig. 116) for two turns and tighten the counter nuts.

l

Repeat this adjustment procedure on the opposite wheel side.

Do not stand or step under loads being lifted.

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

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

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

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

Fig. 117 l

Pull the spring pin (Fig. 117) out.

l

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

Fig. 118

BW 213 DH-4/PDH-4 BVC

l

Engage the articulation lock and secure it with the spring pin (Fig. 118).

BOMAG

71

Operation

Fig. 119 l

l

Lash the machine on the transport vehicle (Fig. 119), use the four lashing eyes on front and rear frame for this purpose.

Fig. 121 l

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

Position of centre of gravity (Fig. 121).

Machine

L

H

BW 213-4

1470±90

860±70

i Note The tolerances account for all possible options, such as cabin, additional weight etc.

Weights: See technical data. l

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

Fig. 120 l

72

For lifting use also the four lifting eyes (Fig. 120) and appropriate lifting gear.

BOMAG

BW 213 DH-4/PDH-4 BVC

Operation

4.15 Tests before starting to operate

4.16 Mounting the attachment plates

Please observe strictly the safety regulations in chapter 2 of these operating and maintenance instructions and also the safety regulations for the machine these vibratory plates are attached to.

!

Danger

Danger of squashing!

Keep a sufficient safety distance for guiding.

Before each working day: l

Inspect attachment plates and hydraulic hoses for damage, check hydraulic system and vibrator housings for leaks.

!

Caution Rectify faults before starting to operate.

Caution Danger of axle damage! !

Do not attach the plates when working with the padfoot drum shell.

Fig. 122 l

Drive the machine backwards to the plate receptacles (Fig. 122).

Fig. 123

BW 213 DH-4/PDH-4 BVC

l

Lower the retaining bolt into the receptacle guide (Fig. 123) and move it with the pushing cylinder to the left against the stop.

BOMAG

73

Operation

Fig. 124 l

Fig. 126

Flip the lock over and insert the locking bolt (Fig. 124).

!

Caution

Ensure strict cleanliness to keep dirt out of the hydraulic system. l

Insert the quick connect coupling into the connecting block and flip the bow 1 (Fig. 126) over to lock.

The locking button (2) must protrude when locked.

i Note The quick connect coupling can only be plugged in and locked in one position.

Fig. 125 l

Pull the quick connect coupling (Fig. 125) out of the bracket.

l

Check the quick connect coupling for cleanliness, clean thoroughly if necessary.

74

BOMAG

BW 213 DH-4/PDH-4 BVC

Operation

4.17 Taking the attachment plates into service !

Danger

Danger of squashing!

The operator must make sure that no person is in the danger area before he lowers the plates to the ground.

Caution Reversing with the plates lowered will damage the plate suspension! !

Fig. 128 l

Switch to floating position (Fig. 128).

Remember that the plates will swing out when cornering.

Before using the attachment plates perform a trial run to check whether the hydraulic connections are leak tight.

Lower the plates

Fig. 129 l

Pre-select the vibration (Fig. 129).

Fig. 127 l

Operate the push button (Fig. 127), until the attachment plates rest fully on the ground or switch to "floating position".

Switch the vibration on

i Note Vibration can only be switched on when the attachment plates are in floating mode.

BW 213 DH-4/PDH-4 BVC

Fig. 130 l

BOMAG

Adjust the desired vibration frequency (Fig. 130).

75

Operation

Fig. 131

Operate the push button (Fig. 131) in the travel lever, the attachment plates will vibrate.

l

i Note If drum vibration is pre-selected the drum will also vibrate.

Fig. 133 l

Operate the push button (Fig. 133) left or right, until the attachment plates have been extended as desired.

l

Press the right hand button to extend.

l

Press the left hand button to retract.

Extending the attachment plates

Raising the attachment plates (for transport)

Caution Watch out for obstructions when working with extended plates!

Caution Raise the attachment plates completely for transport.

!

!

!

Danger

Danger of squashing!

Do not step or work under the raised plates.

Maintenance and service work must only be performed with the attachment plates in floating position. For safety reasons the extension plates are then lowered to the ground and the hydraulic lines depressurized.

i Note Fig. 132

The attachment plates can only be raised completely in middle position (retracted).

i Note When actuating the cylinder the quick connect coupling must be unlocked. l

76

Pull out the locking bolt in dependence on the desired pushing direction (Fig. 132), flip the cylinder over and lock it again with the bolt.

BOMAG

BW 213 DH-4/PDH-4 BVC

Operation

4.18 Detaching the attachment plates

Fig. 134 l

Press the push button (Fig. 134), until the attachment plates are fully raised.

Fig. 135 l

Switch to floating position (Fig. 135).

Fig. 136

BW 213 DH-4/PDH-4 BVC

l

Press the unlocking button (Fig. 136) and flip the bow over.

l

Pull out the quick connect coupling.

BOMAG

77

Operation

Fig. 137 l

Fig. 139

Plug the quick connect coupling (Fig. 137) into the bracket.

Move the retaining bolt with the pushing cylinder to the right out of the receptacles (Fig. 139).

l

Danger Danger of squashing! !

Do not work under the unsecured frame. l

Lift the frame completely out of the plate receptacle by means of the lift cylinders.

l

Drive the machine forward out of the plate receptacles.

BOMAG

BW 213 DH-4/PDH-4 BVC

Fig. 138 l

Pull out bolt 1 (Fig. 138) and reinsert it in parking position (3).

l

Switch the lock (2) over.

78

Operation

4.19 Variocontrol, selecting the operating mode

Variocontrol automatic operation

i Note The normal mode of operation is Variocontrol in automatic mode. However, based on his experience and with respect to the material to be compacted, the operator can set certain effective amplitudes manually.

In travel lever position "0" the vibrator system remains in position “horizontal” for safety reasons.

Fig. 142 l

Press button F12 or turn rotary button P2 clockwise to set the operating mode to "Auto" (Fig. 142).

The set mode appears in the display as P2. Display field „A“ lights green.

Fig. 140 l

Start the engine and run it with maximum speed or position "ECO" (Fig. 140).

l

Pre-select the slow speed range .

Fig. 143 l

Press button F13 or F14 or turn rotary button P3 to set the required "nominal value" (Fig. 143).

The set nominal value appears in the display as P3.

i Note Fig. 141 l

Enable vibration (Fig. 141).

BW 213 DH-4/PDH-4 BVC

Normal position "Max.". Now the machine works with maximum compaction energy.

On problematic soils, such as sand, it may be necessary to reduce the compaction energy, so that the drum does not dig into the ground.

BOMAG

79

Operation

Also if you want to reduce the depth effect it may be sensible to reduce the compaction energy.

Variocontrol manual setting (Manual)

Fig. 147 Fig. 144 l l

Actuate the travel lever (Fig. 144).

Press button F11 or turn rotary button P2 anticlockwise to set the the operating mode to "Manual" (Fig. 147).

The set mode appears in the display as P2. Display field „M“ lights green.

Fig. 145 l

Switch the vibration on (Fig. 145).

Fig. 148 l

Press button F9 or F10 or turn rotary button P1 to set the required "direction of vibration" (Fig. 148).

The adjusted amplitude direction appears in the display as P1

i Note

Fig. 146

The gauge (Fig. 146) shows the current vertical amplitude to the corresponding travel direction.

80

From position "0" switch slowly up step by step during operation and watch the drum while doing this. When the drum starts to jump turn the rotary switch one step back.

The gauge shows the current vertical amplitude.

BOMAG

BW 213 DH-4/PDH-4 BVC

Operation

On bridges or in sensitive areas it is recommended to use ”Manual – Horizontal”.

4.20 Measuring pass with Variocontrol General notes

i Note The soil measuring values (E VIB) recorded during different passes can only be compared if the recording of measuring values took place in operating mode "Manual" with the same amplitude, frequency and travel speed and on exactly the same track.

Fig. 149 l

Actuate the travel lever (Fig. 149).

A change in travel speed would affect the measuring result, because e.g. with a slow travel speed per pass the energy introduced into the ground is higher and in the comparison of all passes a higher soil measuring value would be displayed.

The following description describes an measuring pass in forward. Measuring passes in manual reverse must be performed accordingly.

Measuring values must only be compared for passes performed in the same direction.

Measuring pass

Fig. 150 l

Switch the vibration on (Fig. 150).

Fig. 152 l

Turn the ignition key (Fig. 152) to position "I"

The BTM-E performs a self-test.

Fig. 151

The gauge (Fig. 151) shows the current vertical amplitude to the corresponding travel direction.

BW 213 DH-4/PDH-4 BVC

BOMAG

81

Operation

Fig. 153 l

Control field F5 (Fig. 153) lights green.

Fig. 155

Mark the track to be compacted (Fig. 155).

l

!

Caution

Since the transducer unit is mounted on the left hand side of the drum, it is necessary to arrange the tracks so that track 1 is processed first, followed by further tracks offset to the left.

Fig. 154 l

Turn the ignition key (Fig. 154) to position „II engine start.

i Note Maximum track length 150 m.

Forward: Mark 1

= Start of track

Mark 2

= End of track

i Note The operator may also remember the start and the end of the track by means of distinct points.

82

BOMAG

BW 213 DH-4/PDH-4 BVC

Operation

Fig. 156 l

Fig. 158

Choose the maximum forward speed (Fig. 156).

Shift the travel lever (Fig. 158) fully to position „I“.

l

The adjusted travel speed is indicated by a green ring segment in the tachometer on the LCD display unit.

The machine accelerates up to the preadjusted travel speed. !

Caution

Differences in the travel speeds falsify the measuring result!

Fig. 157 l

In the starting distance set the rotary switch for engine speed (Fig. 157) to "ECO" (Automatic) or "MAX" (full throttle).

Fig. 159 l

Switch the vibration on (Fig. 159).

!

Caution Before reaching mark 1 the nominal exciter shaft speed and the adjusted amplitude must have been reached and a valid Evib-value should be displayed.

BW 213 DH-4/PDH-4 BVC

BOMAG

83

Operation

4.21 Finishing compaction of a track

Fig. 160

When mark 1 is reached, press button F5 “START” (Fig. 160).

l

Control field to the left of F5 lights green.

The EVIB- display shows the present value.

Fig. 162 l

Drive forward and reverse passes on a track until the green control field to the left of F5 (Fig. 162) goes out and the red control field F6 below lights up after pressing the stop button F6.

The compaction process on this track is finished.

Once the travel lever has been returned to neutral position after recording, the printout will immediately start.

i Note Fig. 161

When the end of the track, mark 2, is reached, press the button F6 “STOP” (Fig. 161).

l

Another pass on this track does not make any sense, because an increase in load bearing capacity is hardly possible with this machine. l

If necessary print out the measuring data for this track (see following section).

i Note The first forward pass is finished.

Control field F5 lights green. This means, that the compaction is not yet completed. One or several passes are still required. l

84

Stop the machine.

BOMAG

BW 213 DH-4/PDH-4 BVC

Operation

4.22 Printing measuring data after completing compaction

i Note Measuring data can be printed after completion of any pass.

Always check the paper provision before starting work.

Change the paper roll if a red stripe appears on the paper.

Fig. 163 l

Repeat the complete compaction process on the next track (Fig. 163) to record measuring values.

Fig. 164 l

At the end of the track press push button F7 „PRINT“ (Fig. 164).

short actuation = Line diagram long actuation ≥5 sec. = Bar chart Control field F7 goes out and the measuring value printer starts to print out measuring data.

i Note Once the red control light to the left of field F6 lights up any amount of diagrams can be printed out by pressing the same button F7 (PRINT).

BW 213 DH-4/PDH-4 BVC

BOMAG

85

Operation

4.23 Teaching distance pulses

i Note The distance pulses have already been set by default when setting the correct machine type.

Due to slippage of the drums the recorded distance measurement may differ from the actually driven distance.

An adaptation of the distances pulses in only possible within the range of +/- 10% of the default value.

Fig. 165 l

If no further printouts of this track are needed, press the button F8 “DELETE” (Fig. 165) when the red control lamp F6 “FINISHED” lights up.

l

Compare the actually driven distance with the recorded distance in the printed line diagram*.

l

In case of different distances an adaptation to these distances is required.

l

Engine running.

The red control field F6 “FINISHED” goes out and the green control field F5 “CONTINUE” lights up.

BTM plus/prof is ready to compact the next track.

Fig. 166 l

Press key ’’?“ (menu) (Fig. 166).

i Note The menu appears on the screen.

*

86

BOMAG

Optional equipment

BW 213 DH-4/PDH-4 BVC

Operation

Fig. 167 l

Fig. 169

Press key "F8" (distance pulses) (Fig. 167).

l

i Note The screen page with the pre-set distance pulses appears.

At the end of the 10 m distance press key "F6" (quit teach mode) (Fig. 169).

i Note The screen page to save the distance pulses appears. l

Switch off vibration and stop the machine.

Fig. 168 l

When the machine has stopped press key "F5" (teach mode) (Fig. 168).

Fig. 170 l

i Note

Press key "F14" (safe distance pulses) (Fig. 170).

The screen page with distance pulses appears. l

Switch on vibration and drive the machine 10 m forward.

BW 213 DH-4/PDH-4 BVC

BOMAG

87

Operation

4.24 Amplitude limitation (BVC only)

i Note The amplitude limitation in automatic mode enables a limitation of the effective and measuring depth.

The system offers 5 regulating ranges ( 0 - 0.7 mm; 0 - 1.1 mm; 0 - 1.5 ; 0 - 1.9 mm; 0 - 2.4 mm (max).

Fig. 171

If the screen page states that the distance pulses cannot be saved after pressing the key "F6" (quit teach mode) (Fig. 171), the measurement must be repeated.

l

This is e.g. sensible when a layer on a soft or instable base is to be compacted, and this base itself cannot be compacted or has a extremely high stiffness.

In operating mode "Automatic" with nominal value "MAX" the amplitude limitation is inactive.

i Note The measured distance pulses are not within the range of +/- 10% of the default value.

Saving is not possible. l

Press key "ESC" to return to the working screen.

Fig. 172 l

Turn the ignition key (Fig. 172) to position "I".

i Note The control unit shows the start screen.

88

BOMAG

BW 213 DH-4/PDH-4 BVC

Operation

Fig. 173 l

Fig. 175

When activating the amplitude limitation, the symbol (Fig. 173) will appear on the screen.

l

Set the amplitude limitation with keys F9 or F10, or with rotary button P1 (Fig. 175).

0

= low amplitude

i Note

1

= 0 to 0.7 mm

If no symbol appears, the amplitude limitation may need to be activated (if required).

2

= 0 to 11 mm

3

= 0 to 1.6 mm

4

= 0 to 1.8 mm

6

= 0 to 2.5 mm, max. amplitude, amplitude limitation not active

Activating/deactivating the amplitude limitation

Fig. 174 l

Press button F12 or turn rotary button P2 clockwise to set the operating mode to "Auto" (Fig. 174).

Fig. 176 l

Press key ’’?“ (menu) (Fig. 176).

i Note The menu appears on the screen.

BW 213 DH-4/PDH-4 BVC

BOMAG

89

Operation

4.25 Changing the paper roll in the measuring value printer*

i Note Use a new paper roll if a red stripe appears on the paper.

Fig. 177

Press key "F3" (amplitude limitation) (Fig. 177).

l

i Note The screen page "Amplitude limitation" appears on the screen.

Fig. 179 l

Unscrew the star handles (Fig. 179) and remove the cover.

Fig. 178 l

Press key "F5" to activate/deactivate the limitation (Fig. 178).

0

= Limitation switched off

1

= Limitation switched on

l

Press key "F14" to save the changed setting.

l

Press "ESC" to exit the screen page.

90

Fig. 180 l

Remove shaft 1 (Fig. 180) with the rest of the paper roll (2).

*

only BTM prof

BOMAG

BW 213 DH-4/PDH-4 BVC

Operation

4.26 Changing the printer ribbon in the measuring value printer*

i Note In case of faint or poorly legible diagrams the printer ribbon needs to be replaced.

Fig. 181 l

Insert a new paper roll (Fig. 181).

l

Feed the paper into the guide (1) on the printer.

l

Actuate the toggle switch (2) in direction of arrow, until the paper comes out of the printer.

l

Reassemble the cover.

Fig. 182 l

Unscrew the star handles (Fig. 182) and remove the cover.

Fig. 183

BW 213 DH-4/PDH-4 BVC

l

Lift the tongue at point 1 (Fig. 183) and take the printer ribbon (2) out of the printer.

l

Insert the new printer ribbon into the printer, then press in the tongue (1) on the right.

l

Tension the printer ribbon by turning the rotary button (3) in direction of arrow.

l

Reassemble the cover.

*

only BTM prof

BOMAG

91

Operation

92

BOMAG

BW 213 DH-4/PDH-4 BVC

5 Maintenance

BW 213 DH-4/PDH-4 BVC

BOMAG

93

Maintenance

5.1

General notes on maintenance

When performing maintenance work always comply with the appropriate safety regulations. !

Danger

l

Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.

l

Drums with inside zinc lining are not suitable to store fuel.

l

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

l

Do not let the hose stir up the slurry at the bottom of the drum.

l

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

l

The rest in the drum is not suitable for the engine and should only be used for cleaning purposes.

Danger of squashing!

Maintenance and service work must only be performed with the attachment plates in floating position. For safety reasons the extension plates are then lowered to the ground and the hydraulic lines depressurized.

Thorough maintenance of the machine guarantees far longer safe functioning of the machine and prolongs the lifetime of important components.

The effort needed for this work is only little compared with the problems that may arise when not observing this rule.

Notes on the performance of the engine On diesel engines both combustion air and fuel injection quantities are thoroughly adapted to each other and determine power, temperature level and exhaust gas quality of the engine.

The terms right/left correspond with travel direction forward. l

Always clean machine and engine thoroughly before starting maintenance work.

l

For maintenance work stand the machine on level ground.

l

Perform maintenance work only with the engine shut down.

l

Relieve hydraulic pressures before working on hydraulic lines.

l

Before working on electric parts of the machine disconnect the battery and cover it with insulation material.

l

When working in the area of the articulated joint attach the articulation lock (transport lock).

If your engine has to work permanently in "thin air" (at higher altitudes) and under full load, you should consult the customer service of BOMAG or the customer service of the engine manufacturer.

Notes on the hydraulic system During maintenance work on the hydraulic system cleanliness is of major importance. Make sure that no dirt or other contaminating substances can enter into the system. Small particles can produce flutes in valves, cause pumps to seize, clog nozzles and pilot bores, thereby making expensive repairs inevitable. l

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

l

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

l

Do not store drums with hydraulic oil outdoors, or at least under a cover. Water can be drawn in through the bunghole when the weather changes.

l

Always use the filling and filtering unit (BOMAG part-no. 007 610 01) to fill the hydraulic system. This unit is fitted with a fine fil-

BOMAG

BW 213 DH-4/PDH-4 BVC

Environment During maintenance work catch all oils and fuels and do not let them seep into the ground or into the sewage system. Dispose of oils, coolant and fuels environmentally.

Notes on the fuel system The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel.

94

Maintenance

l

ter to clean the hydraulic oil, thereby prolonging the lifetime of the filter.

5.2

Clean fittings, filler covers and the area around such parts before disassembly to avoid entering of dirt.

Engine oil Quality

Do not leave the tank opening unnecessarily open, but cover it so that nothing can fall in.

l

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

Notes on the cooling system For water-cooled engines the preparation and inspection of the coolant is of greatest importance, as otherwise the engine may be damaged by corrosion, cavitation and freezing.

Approved engine oils Deutz DQC II-05 DQC II-05 ACAE E3/96/E5-02/ E4-99/E6-04 E7-04 API CG-4/CH-4/CI- 4 DHD DHD-1 -

The coolant is prepared by mixing a cooling system protection agent into the coolant.

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

The concentration of cooling system protection agent can be checked by means of commercial testers (glycomat). !

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

Consult your local service station if in doubt.

Oil viscosity Multi-purpose oils should be generally used.

Danger

Health hazard!

The mixing of nitrite based anti-freeze agents with amine based agents results in the formation of health affecting nitrosamines.

Environment Cooling system protection agents must be disposed of environmentally.

BW 213 DH-4/PDH-4 BVC

Fuels and lubricants

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

Optimal operating conditions can be achieved by using the opposite oil viscosity chart (Fig. 184) as a reference.

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

BOMAG

95

Maintenance

Caution These intervals apply only when using a diesel fuel with maximum 0.5 % sulphur by weight and for ambient temperatures higher than -10 °C. !

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

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

Fig. 184

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

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

ACEA* E3-96/E5-02/E704/E4-99/ E6-04 = 500 operating hours

* **

96

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. l

DIN/EN 590

l

BS 2869

l

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

l

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

Winter fuel !

API** CG-4/CH-4/ CI-4

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

Danger

Fire hazard! = 500 operating hours

Association des Constructeurs European d’Automobiles American Petroleum Institute

Diesel fuels must never be mixed with gasoline.

For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. At very low temperatures disturbing paraffin separa-

BOMAG

BW 213 DH-4/PDH-4 BVC

Maintenance

tion can also be expected when using winter diesel fuel.

*1Proportion of carbonate hardness on the total hardness min. 3 dGH

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

Information concerning the water quality can be obtained from the waterworks.

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

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

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

l

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

l

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

l

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

l

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

l

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

l

Coolant, anti-freeze agent The correct quality of water is highly important when preparing coolant. Clear and clean water within the boundaries of the following analysis values should generally be used.

BW 213 DH-4/PDH-4 BVC

min.

6,5 3

max.

8,5 100 100 12

If the values of the analysis deviate, the water must be treated accordingly. l

pH-value too low Adding of caustic lye of soda or caustic potash solution.

l

Total hardness too high: Mixing with dehardenede water.

l

Total hardness or carbonate hardness too low: Mixing with harder water.

l

Chlorides and/or sulphates too high: Mixing with dehardenede water.

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

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

Water quality Analysis values pH-value at 20 °C Chloride ion content [mg/dm3] Sulphate ion content [mg/dm3] Total hardness*1 [°dGH] ]

A test case for checking the water quality can be ordered from the engine manufacturer.

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

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

! Danger Health hazard!

The mixing of nitrite based anti-freeze agents with amine based agents results in the formation of health affecting nitrosamines.

Environment Cooling system protection agents must be disposed of environmentally.

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

BOMAG

97

Maintenance

dex (VI) should be at least 150 (observe information of manufacturer).

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

In hydraulic systems filled with Panolin HLP Synth.

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

Check the filter more frequently after this change.

Caution Oil change bio-degradable hydraulic oil: !

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

Replace the hydraulic oil filter element every 500 operating hours.

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

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

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

98

BOMAG

BW 213 DH-4/PDH-4 BVC

Maintenance

5.3

Table of fuels and lubricants

Assembly

Fuel or lubricant Summer

Winter

Quantity approx.

Attention Observe the level marks

Engine

Engine oil ACEA: E3/96/E5-02/ E7-04 or

approx. 15,5 litres incl. oil filter

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

Winter diesel fuel

Hydraulic oil (ISO), HV46, kinem. viscosity

approx. 340 litres approx. 60 litres

46 mm2/s at 40 °C Vario exciter drum

Engine oil SAE 15W/40

approx. 16,5 litres

Exciter housing attachment plates

Engine oil SAE 15W/40

2.7 litres each

Drive axle

Gear oil SAE 90, API GL5

approx. 12,5 litres

Wheel hubs

Gear oil SAE 90, API GL5

approx. 0,7 per side

Axle reduction gear

Gear oil SAE 90, API GL5

approx. 1,9 litres

Drum drive gear

Gear oil SAE 90, API GL5

approx. 3,2 litres

Air conditioning system

Refrigerant R134A

approx. 1400 g

Engine cooling system

Cooling system protection agent

approx. 16 litres

Water

approx. 300 litres

Calcium chloride (CaCl2) or magnesium chloride (MgCl2)

approx. 139 kg

Tires

BW 213 DH-4/PDH-4 BVC

BOMAG

99

Maintenance

5.4

Running-in instructions

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

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

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

After a running-in time of 30 minutes l

Retighten the V-belt

After 250 operating hours l

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

l

Retighten the bolted connections on the machine.

l

Retighten all wheel fastening screws with the specified tightening torque.

l

Oil change diesel engine and engine oil filter

l

1. Oil change in Vario exciter

l

Oil change in drive axle

l

Oil change, axle reduction gear

l

Oil change in wheel hubs

l

1. Oil change in drum drive gear

After 500 operating hours

100

l

2. Oil change in Vario exciter

l

2. Oil change in drum drive gear

BOMAG

BW 213 DH-4/PDH-4 BVC

5.7

Check the water separator

X

5.8

Check the fuel level

X

5.9

Check the hydraulic oil level

5.10 Check the coolant level

X

Inspection glass

X

Inspection glass

X

5.11 Check the dust separator

X

5.12 Check the tire pressure

X

5.13 Clean the cooling fins on engine and hydraulic oil cooler

X

5.14 Check the oil level in the drive axle

X

5.15 Check the oil level in the wheel hubs

X

5.16 Check the oil level in the axle reduction gear

X

5.17 Check the oil level in the drum reduction gear

X

5.18 Checking the Vario exciter oil level

X

5.19 Change engine oil and oil filter car- min. 1x per year tridge*

X

X

5.20 Change the fuel filter cartridge

X

X

5.21 Drain the sludge from the fuel tank 5.22 Battery maintenance

X Pole grease

5.23 Change the fuel pre-filter cartridge

BW 213 DH-4/PDH-4 BVC

as required

Dipstick mark

every 6000 operating hours

Check the engine oil level

every 3000 operating hours

5.6

every 2000 operating hours

Remark

every 1000 operating hours

Maintenance work

every 500 operating hours

No.

every 10 operating hours, daily

Maintenance chart

Running-in instructions after 250 operating hours

5.5

every 250 operating hours

Maintenance

X X

BOMAG

101

5.24 Check, replace the refrigerant compressor V-belt

X

5.25 Service the air conditioning

X

5.26 Check, adjust the valve clearance Intake = 0,4 mm

as required

every 6000 operating hours

every 3000 operating hours

every 2000 operating hours

every 1000 operating hours

every 500 operating hours

Remark

every 250 operating hours

Maintenance work

every 10 operating hours, daily

No.

Running-in instructions after 250 operating hours

Maintenance

X

Exhaust = 0,6 mm 5.27 Adjusting the control piston play

X

5.28 Checking, replacing the V-belt

X

5.29 Check the engine mounts

X

X

5.30 Oil change in drive axle

min. 1x per year

X

X

5.31 Oil change in wheel hubs

min. 1x per year

X

X

5.32 Oil change, axle reduction gear

min. 1x per year

X

X

5.33 Oil change in drum drive reduction min. 1x per year gear**

X

X

see foot note, min. X 1 x per year

X

5.34 Oil change in Vario exciter**

5.35 Oil change exciter shaft housing at- min. 1x per year tachment plates

X

5.36 Retighten the fastening of the axle on the frame

X

5.37 Tighten the wheel nuts

X

5.38 Check the ROPS 5.39 Clean the oil bath air filter

X

X X

min. 1x per year

X

5.40 Change hydraulic oil and breather at least every 2 years filter***

X

5.41 Change the hydraulic oil filter***

X

102

at least every 2 years

BOMAG

BW 213 DH-4/PDH-4 BVC

5.42 Change the steering oil filter***

at least every 2 years

X

5.43 Change the attachment plate oil fil- at least every 2 ter*** years

X

5.44 Change the coolant

X

at least every 2 years

5.45 Replace the crankcase ventilation at least every 2 valve years 5.46 Electronic injector test EMR

as required

every 6000 operating hours

every 3000 operating hours

every 2000 operating hours

every 1000 operating hours

every 500 operating hours

Remark

every 250 operating hours

Maintenance work

every 10 operating hours, daily

No.

Running-in instructions after 250 operating hours

Maintenance

X X

5.47 Cleaning, changing the dry air filter min. 1x per year, cartridge safety cartridge at least every 2 years

X

5.48 Adjusting the scrapers

X

5.49 Adjust the parking brake

X

5.50 Change the tires

X

5.51 Change the fresh air filter in the cabin

X

5.52 Tightening torques

X

5.53 Engine conservation

X

* Oil change intervals depend on quality of oil and fuel (sulphur content) ** Oil change intervals after 250 h, after 500 h, after 1000 h, and then every 1000 h. *** Also in case of repair in the hydraulic system.

BW 213 DH-4/PDH-4 BVC

BOMAG

103

Every 10 operating hours

Every 10 oper ating hours

5.6 !

Check the engine oil level

5.7

Check, clean the water separator

Danger

Danger of injury!

!

Danger

Danger of injury!

Support the engine hood for all maintenance and repair work.

Support the engine hood for all maintenance and repair work.

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

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

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

Environment Catch running out fuel and dispose of environmentally.

Fig. 185 l

Pull the dipstick (Fig. 185) out, wipe it off with a lint-free, clean cloth and reinsert it until it bottoms.

l

Pull the dipstick back out again.

l

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

l

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

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

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

104

Fig. 186 l

Slacken the drain plug (Fig. 186) for a few turns and catch running out fuel / water.

l

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

BOMAG

BW 213 DH-4/PDH-4 BVC

Every 10 operating hours

5.8 !

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

Check the fuel level

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

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.

l

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

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

Fig. 187 l

Check the fuel level on the fuel level gauge "n" (Fig. 187) with the ignition switched on.

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

Clean the area around the filler opening.

Fig. 188 l

Open the fuel tank cover (Fig. 188).

BW 213 DH-4/PDH-4 BVC

BOMAG

105

Every 10 operating hours

5.9

Check the hydraulic oil level

5.10 Check the coolant level

!

Caution In hydraulic systems filled with Panolin HLP Synth. 46 always use the same oil to top up.

With other ester based oils consult the lubrication oil service of the respective oil manufacturer.

!

Danger

Danger of scalding!

Fill up coolant only when the engine is cold.

Fig. 190

Check the coolant level (Fig. 190).

l

Fig. 189 l

Check the hydraulic oil level in the inspection glass (Fig. 189).

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

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

l

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

Minimum level Middle of inspection glass.

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

!

Caution If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components for leaks. l

If necessary fill in hydraulic oil through the filler neck.

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

106

BOMAG

BW 213 DH-4/PDH-4 BVC

Every 10 operating hours

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

Fig. 191 l

If the dust reaches the mark loosen the clamp (Fig. 191), take the cover off and clean the bowl.

*

Option

BW 213 DH-4/PDH-4 BVC

BOMAG

107

Every 250 operating hours

Every 250 operating h ours

5.12 Checking the tire pressure !

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

Always close the valves with the dust cap.

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

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

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

i Note

Fig. 192

Check the tire pressure with a pressure gauge and the tire inflation valve 1 (Fig. 192) in top position.

l

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

Cleaning with compressed air

Nominal value see "technical data".

i Note Ensure even pressure in all tires. l

Screw the valve caps back on.

Fig. 193

i Note Start to blow out from the exhaust side. l

108

BOMAG

Blow the cooler (Fig. 193) out with compressed air.

BW 213 DH-4/PDH-4 BVC

Every 250 operating hours

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

l

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

l

Run the engine warm for a while to avoid corrosion.

5.14 Check the oil level in the drive axle l

Park the machine on level ground.

Fig. 194 l

Unscrew the oil level inspection plug (Fig. 194) and check the oil level.

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

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

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

Top up oil, if necessary.

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

BW 213 DH-4/PDH-4 BVC

BOMAG

Turn the level inspection plug tightly back in.

109

Every 250 operating hours

5.15 Checking the oil level in left/ right wheel hubs

5.16 Check the oil level in the axle reduction gear

Fig. 195

Fig. 196

l

Move the machine until the oil level inspection plug 1 (Fig. 195) is in horizontal position.

l

l

Clean and unscrew the plug.

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

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

Top up oil, if necessary.

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

Screw the plug back in tightly.

l

Repeat this inspection on the other side.

110

Unscrew the filler and oil level inspection plug (Fig. 196) and check the oil level.

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

BOMAG

Retighten the filler and level inspection plug.

BW 213 DH-4/PDH-4 BVC

Every 250 operating hours

5.17 Check the oil level in the drum reduction gear

Caution Investigate the cause for the oil loss, if necessary seal the gearbox

Check

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

!

l

Retighten the filler and level inspection plug.

Fig. 197 l

Unscrew the oil level inspection plug (Fig. 197) and check the oil level.

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

Filling up l

Move the drum until drain and filler plugs are exactly vertically in line.

Fig. 198 l

Unscrew the filler plug at the top (Fig. 198) and fill in oil, until it reaches the bottom edge of the inspection bore.

BW 213 DH-4/PDH-4 BVC

BOMAG

111

Every 250 operating hours

5.18 Checking the Vario exciter oil level

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

Park the machine on level ground.

l

Fig. 199 l

Move the drum, until oil level inspection plug 1 (Fig. 199) on the left hand side of the drum is in bottom position.

l

Unscrew level inspection plug (1).

Some oil should run out of the inspection bore.

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

l

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

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

l

Repeat this inspection on the other side.

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

112

BOMAG

BW 213 DH-4/PDH-4 BVC

Every 500 operating hours

Every 500 oper ating hours

5.19 Changing engine oil and oil filter cartridges !

Caution

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

Refer also to the chapter 5.2, fuels and lubricants.

Drain the engine oil only when the engine is warm.

Fig. 201

Danger Danger of scalding!

l

Thoroughly clean the outside of both filter cartridges (Fig. 201).

l

Unscrew both filter cartridges using an appropriate filter wrench.

!

When draining off hot oil.

By hot oil when unscrewing the engine oil filter.

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

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

l

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

l

Slightly oil the rubber seal on the new filter cartridges.

Fig. 200 l

Unscrew the drain plug (Fig. 200) and catch running out oil.

l

Turn the drain plug tightly back in.

BW 213 DH-4/PDH-4 BVC

Fig. 202 l

Turn the new filter cartridges (Fig. 202) on by hand, until the seal contacts.

l

Tighten the filter cartridges for another half turn.

BOMAG

113

Every 500 operating hours

5.20 Change the fuel filter cartridge !

Danger

Fire hazard!

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

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

Fig. 203

Do not inhale any fuel fumes.

Fill in new engine oil (Fig. 203).

l

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

Tighten the oil filler cap properly.

l

!

Caution

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

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

l

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

l

l

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

Fig. 204 l

Loosen and unscrew the fuel filter cartridge (Fig. 204) using an appropriate filter wrench.

l

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

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

Fig. 205 l

114

BOMAG

Slightly oil the rubber seal (Fig. 205) on the new filter cartridge.

BW 213 DH-4/PDH-4 BVC

Every 500 operating hours

l

Fill the filter cartridge with clean diesel fuel.

l

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

l

Tighten the filter element for another half turn.

l

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

5.21 Draining the sludge from the fuel tank !

Danger

Fire hazard!

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

Do not spill any fuel.

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

Do not inhale any fuel fumes.

Fig. 206

BW 213 DH-4/PDH-4 BVC

l

Unscrew the cap (Fig. 206) and drain off approx. 5 litres of fuel.

l

Turn the cap tightly back in.

BOMAG

115

Every 500 operating hours

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

5.22 Service the battery !

Danger

Danger of cauterisation ! Danger of explosion!

l

Open the engine hood and remove the covering.

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

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

Wear protective clothing!

Do not lay any tools on the battery!

Environment Dispose of the old battery environmentally.

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

Fig. 207 l

Remove the battery (Fig. 207) and clean the battery compartment.

l

Clean the outside of the battery.

l

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

l

Check the fastening of the battery.

l

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

The following therefore applies for the service life: l

l

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

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

Charging voltage recommendation

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

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

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

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

l

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

116

Fig. 208

BOMAG

BW 213 DH-4/PDH-4 BVC

Every 500 operating hours

5.23 Change the fuel pre-filter cartridge !

Danger

Fire hazard!

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

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

Fig. 210

Do not inhale any fuel fumes.

l

Unscrew the water separator from the filter cartridge (Fig. 210).

Fig. 209 l

l

Pull off the cable and unscrew the fuel filter cartridge (Fig. 209) using an appropriate filter wrench.

l

Apply a thin coat of oil to the rubber seal of the water separator 1 (Fig. 211).

l

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

l

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

l

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

l

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

l

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

l

Plug the water sensor cable back on.

l

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

BOMAG

117

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

BW 213 DH-4/PDH-4 BVC

Fig. 211

Every 500 operating hours

i Note

5.24 Checking, replacing the refrigerant compressor V-belt

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

Therefore bleed the fuel system after changing the fuel pre-filter.

!

Danger of injury!

Environment Catch running out fuel and dispose of environmentally.

Fig. 212 l

l

l

118

Slacken the bleeding screw (Fig. 212) on the fuel pre-filter for 2 to 3 turns.

Operate the hand pump manually, until fuel flows out of the slackened bleeding screw (Fig. 212) without air bubbles.

Danger

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

Check the V-belt

Fig. 213 l

Inspect the entire circumference of the V-belt (Fig. 213) visually for damage and cracks. Replace damaged or cracked V-belts.

l

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

BOMAG

BW 213 DH-4/PDH-4 BVC

Then tighten the bleeding screw while pumping.

Every 500 operating hours

Tighten the V-belt.

5.25 Service the air conditioning* Cleaning the condenser !

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

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

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

Fig. 214 l

Slightly slacken fastening screws 1, 2 and 3 (Fig. 214).

l

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

l

Retighten all fastening screws.

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

Danger Danger of accident! !

Changing the V-belt l

Slightly slacken the fastening screws 1, 2 and 3.

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

l

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

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

l

Take the old V-belt off.

l

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

l

Tension the V-belt as previously described.

!

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

Fig. 215

BW 213 DH-4/PDH-4 BVC

l

Unscrew the condenser fastening screws (Fig. 215) and fold the condenser forward.

l

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

*

Optional equipment

BOMAG

119

Every 500 operating hours

Checking the refrigerant level Start the engine.

l

Fig. 218 l

Fig. 216

Check whether the white float (Fig. 218) inside the inspection glass of the drier/collector unit floats right at the top.

Switch the air conditioning (Fig. 216) on.

l

i Note The refrigerant level is correct.

Fig. 217

Choose a cooling temperature with the rotary switch for cabin heater (Fig. 217) in the blue section.

l

l

Open the air outlet nozzles.

l

Check, whether the outflowing air is noticeably cooler.

Fig. 219 l

If the white float (Fig. 219) inside the inspection glass of the drier/collector unit floats at the bottom, inform the service department.

i Note i Note

The refrigerant level is not correct.

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

120

l

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

Open the hood.

BOMAG

BW 213 DH-4/PDH-4 BVC

Every 500 operating hours

Checking the moisture level of the drying agent

arising from the handling and operation of pressure reservoirs. !

Danger

Danger of injury!

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

Fig. 220

Check the moisture indication pearl (Fig. 220) inside the inspection glass of the drier/collector unit.

l

orange

= drying agent o.k.

colorless = moisture level of drying agent too high.

Fig. 221 l

Check the drier/collector unit (Fig. 221) for mechanical damage or rust.

BOMAG

121

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

l

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

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

BW 213 DH-4/PDH-4 BVC

Every 1000 operating hours

Every 1000 operating hour s

5.26 Adjusting the valve clearance !

Caution

We recommend to have this work carried out by trained personnel or our after sales service.

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

Fig. 223

l

Attach the cranking device over the V-belt pulley fastening screws.

l

Remove the valve covers.

l

Crank the engine, until the valves on cylinder 1 overlap.

l

The individual cylinder positions can be taken from the section "valve adjustment schematic".

Adjusting the valve clearance Fig. 224

Fig. 222 l

122

Loosen counter nut 1 (Fig. 222).

l

Attach the rotation angle disc 3 (Fig. 224) and the spanner socket (4) to the valve adjustment screw 2 (Fig. 223).

l

Fix the magnet (5) of the rotation angle disc.

l

Turn the rotation angle disc clockwise against the stop (rocker arm no clearance) and set the scale to zero.

l

Turn the rotation angle disc clockwise, until the specified angle is reached.

Intake valve IN = 90° (0,4 mm) Exhaust valves EX = 150° (0,6 mm) l

Hold the rotation angle disc tight, so that it does not turn, and tighten counter nut 1 (Fig. 222).

l

Repeat this adjustment procedure an all other cylinders, after cranking the crankshaft accordingly.

l

Assemble the cylinder head cover with a new gasket.

BOMAG

BW 213 DH-4/PDH-4 BVC

Every 1000 operating hours

Intake valve clearance adjustment in case of exhaust gas recirculation

Fig. 227 l

Attach the rotation angle disc 3 (Fig. 226) with the special spanner (8) to the valve setscrew 7 (Fig. 227) on the intake valve.

l

Fix the magnet 5 (Fig. 226) of the rotation angle disc.

l

Turn the rotation angle disc 3 (Fig. 226) clockwise against the stop (rocker arm no clearance) and set the scale to zero.

l

Turn the rotation angle disc 3 (Fig. 226) anticlockwise, until the specified angle is reached (90°).

l

Hold the rotation angle disc tight, so that it does not turn, and tighten counter nut 6 (Fig. 225).

l

Repeat the adjustment procedure on each intake valve.

Fig. 225 l

Loosen counter nut 6 (Fig. 225).

Fig. 226

Valve adjustment schematic Firing order 1-3-4-2

l

Valves overlapping adjustment

Cylinder 1 3 4 4 2 1

2 3

Overlapping of valves: Exhaust valve not yet closed, intake valve starts to open.

Caution With the intake valve opened, the exhaust valve will temporarily open for about 2 mm. !

This is no valve overlap condition!

BW 213 DH-4/PDH-4 BVC

BOMAG

123

Every 1000 operating hours

5.27 Adjusting the control piston play !

Caution

This work must be performed after adjusting the valve clearance. l

Crank the engine, until the valves on cylinder 1 overlap.

l

The cylinders to be adjusted can be taken from the section "Adjustment Schematic".

Adjusting the control piston play

Fig. 229 l

Plug rotation angle disc and socket onto the setscrew 2 (Fig. 229).

l

Fix the magnet of the rotation angle disc.

l

Turn the rotation angle disc clockwise against the stop (rocker arm no clearance) and set the scale to zero.

l

Turn the rotation angle disc anti-clockwise, until the specified angle is reached.

l

Hold the rotation angle disc tight, so that it does not turn, and tighten counter nut 1 (Fig. 228).

l

Repeat this adjustmennt procedure on each control piston according to the crankshaft position.

l

Assemble the cylinder head cover with a new gasket.

Fig. 228 l

Loosen counter nut 1 (Fig. 228).

Adjustment schematic Firing order 1-3-4-2

l

Valves overlapping adjustment

Cylinder 1 3 4 4 2 1

2 3

Overlapping of valves: Exhaust valve not yet closed, intake valve starts to open.

Caution With the intake valve opened, the exhaust valve will temporarily open for about 2 mm. !

This is no valve overlap condition!

124

BOMAG

BW 213 DH-4/PDH-4 BVC

Every 1000 operating hours

Changing the ribbed V-belt

5.28 Checking / replacing the ribbed V-belt !

Danger

Danger of injury!

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

Checking the wear limit of the ribbed Vbelt Fig. 231 l

Unscrew the fastening screws (Fig. 231) and slide the fan forward.

Fig. 230 l

Check the distance between the tongue of the moveable tensioner arm and the fixed tensioner housing (Fig. 230).

l

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

Fig. 232 l

Release the idler pulley (Fig. 232) in direction of arrow until the ribbed V-belt is free.

l

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

l

Install the new ribbed V-belt.

l

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

l

Measure the V-belt tension, tighten if necessary.

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

BW 213 DH-4/PDH-4 BVC

BOMAG

125

Every 1000 operating hours

5.29 Check the engine mounts

5.30 Change the oil in the drive axle

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

Caution Drain oil only at operating temperature. !

Environment Catch old oil and dispose of environmentally.

Fig. 233 l

Tighten fastenings of intake and exhaust manifolds (Fig. 233) on the cylinder heads.

l

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

l

Retighten the fastening screws for oil sump and engine mounts.

l

Park the machine on level ground.

Fig. 234

126

l

Clean and unscrew all level inspection and drain plugs (Fig. 234).

l

Drain and catch all oil.

l

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

BOMAG

BW 213 DH-4/PDH-4 BVC

Every 1000 operating hours

5.31 Changing the oil in the wheel hubs !

Caution

Drain oil only at operating temperature.

Change the oil on both sides of the axle.

Environment Catch old oil and dispose of environmentally.

Fig. 235 l

Fill in oil through the oil level inspection bores (Fig. 235), until it has reached the bottom edge of the bore.

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

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

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

Retighten the filler and level inspection plug.

Fig. 236 l

Move the drive wheel, until the plug (Fig. 236) is in bottom position.

l

Clean and unscrew the plug.

l

Drain and catch all oil.

Fig. 237

BW 213 DH-4/PDH-4 BVC

l

Move the drive wheel, until the plug (Fig. 237) is in horizontal position on the housing.

l

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

BOMAG

127

Every 1000 operating hours

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

Turn the plug tightly back in.

5.32 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. 238 l

Unscrew the filler plug (Fig. 238).

l

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

l

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

l

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.

128

l

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

BOMAG

BW 213 DH-4/PDH-4 BVC

Every 1000 operating hours

5.33 Change the oil in the drum reduction gear !

Caution

Drain oil only at operating temperature.

Environment Catch old oil and dispose of environmentally. l

Move the drum until drain and filler plugs are exactly vertically in line.

Fig. 241 l

Fill in oil through the filler bore (Fig. 241), until it reaches the bottom edge of the inspection bore.

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

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

Fig. 239 l

Unscrew the filler plug at the top (Fig. 239).

l

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

l

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

Fig. 240 l

Unscrew the level inspection plug (Fig. 240).

BW 213 DH-4/PDH-4 BVC

BOMAG

129

Every 1000 operating hours

5.34 Vario exciter oil change !

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

Environment Catch running out oil and dispose of environmentally. l

Park the machine on level ground.

Fig. 243

Unscrew oil level inspection plug 1 (Fig. 243) on the drum and fill in oil through the filler opening (2), until it starts to drip out from the level inspection bore.

l

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

Fig. 242 l

Move the drum, until the drain plug 1 (Fig. 242) is in bottom position.

l

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

l

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

130

l

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

l

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

Caution Overfilling causes overheating and destruction of the vibration bearings! !

BOMAG

BW 213 DH-4/PDH-4 BVC

Every 1000 operating hours

5.35 Change the oil in the exciter shaft housing of the attachment plates

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

Screw the filler plug back in with a new seal ring.

Caution Tilt the machine to the side with the oil drain plug and support it safely. !

Environment Catch running out old oil, do not let it seep into the ground.

Fig. 244 l

Unscrew oil drain plugs on both sides (Fig. 244), drain and catch running out old oil.

l

Turn the oil drain plugs back in with a new seal rings.

Fig. 245 l

Stand the plates on level ground and fill in oil (Fig. 245).

BW 213 DH-4/PDH-4 BVC

BOMAG

131

Every 1000 operating hours

5.36 Tightening the fastening of the axle to the frame

5.37 Tightening the wheel nuts

Fig. 247 Fig. 246 l

132

l

Check all fastening nuts for the axle retaining bolts (Fig. 246) for tight fit.

BOMAG

Tighten the wheel nuts (Fig. 247) in a crosstype pattern.

BW 213 DH-4/PDH-4 BVC

Every 1000 operating hours

5.38 Check the ROPS

5.39 Cleaning the oil bath air filter *

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

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

Fig. 249 l

Loosen the quick locks (Fig. 249), take the filter bowl off and empty it.

l

Clean the filter mesh by repetitive dipping into diesel fuel.

l

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

l

reinstall the filter bowl.

*

Option

Fig. 248 l

Inspect the cabin, especially the ROPS (Fig. 248), for cracks, corrosion, damage and missing fastening parts.

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

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

l

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

l

Check the condition and fastening of the seat belts.

BW 213 DH-4/PDH-4 BVC

BOMAG

133

Every 2000 operating hours

Every 2000 operating hour s

5.40 Changing hydraulic oil and breather filter

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

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

Fig. 250

Perform the oil change when the hydraulic oil is warm.

l

Unscrew the plug (Fig. 250) and drain off all hydraulic oil.

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

l

Turn the plug tightly back in.

Do not use any detergents to clean the system.

Do not start the engine after draining the hydraulic oil.

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

Danger

Danger of scalding!

Danger of scalding by hot oil.

Environment Catch running out oil and dispose of environmentally.

Fig. 251 l

Remove the filler cap (Fig. 251).

l

Fill in new hydraulic oil through the screen.

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

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

Check the oil level in the inspection glass.

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

134

BOMAG

BW 213 DH-4/PDH-4 BVC

Every 2000 operating hours

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

5.41 Changing the hydraulic oil filter

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

Close the tank with a new filler cap.

!

Danger

Danger of scalding!

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

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

Do not use the oil in the filter bowl.

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

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

Fig. 252 l

Unscrew the cap nut 4 (Fig. 252) and take the filter bowl (5) with the filter element (3) off.

l

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

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

BW 213 DH-4/PDH-4 BVC

BOMAG

135

Every 2000 operating hours

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

5.42 Changing the steering oil filter

Do not clean or reuse the filter element. l

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

l

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

l

After a test run check the filter for leaks.

!

Danger

Danger of scalding!

Danger of scalding by hot oil when unscrewing the oil filter.

Caution If the filter has to be changed together with the hydraulic oil, the filter must only be changed after the oil change and after the test run. !

Do not use the oil in the filter bowl again.

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

i Note Apart from the normal oil change intervals, the filter element must also be changed after major repairs in the hydraulic system.

Fig. 253 l

Unscrew spigot nut 4 (Fig. 253) and take off filter bowl (5) with filter element (3).

l

Examine the surface of the filter element thoroughly for any visible dirt.

Caution Visible dirt may be an early sign for the failure of system components and indicate the possi!

136

BOMAG

BW 213 DH-4/PDH-4 BVC

Every 2000 operating hours

ble failure of components. In this case determine the cause and replace or repair the defective components, if necessary. Negligence may cause destruction to the entire hydraulic system.

5.43 Changing the attachment plate oil filter

Do not clean or reuse the filter element.

!

l

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

l

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

l

After a short test run check the filter for leaks.

Danger

Danger of scalding!

Danger of scalding by hot oil when unscrewing the oil filter.

Caution If the filter has to be changed together with the hydraulic oil, the filter must only be changed after the oil change and after the test run. !

Do not use the oil in the filter bowl again.

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

i Note Apart from the normal oil change intervals, the filter element must also be changed after major repairs in the hydraulic system.

Fig. 254 l

Unscrew spigot nut 4 (Fig. 254) and take off filter bowl (5) with filter element (3).

l

Examine the surface of the filter element thoroughly for any visible dirt.

Caution Visible dirt may be an early sign for the failure of system components and indicate the possi!

BW 213 DH-4/PDH-4 BVC

BOMAG

137

Every 2000 operating hours

ble failure of components. In this case determine the cause and replace or repair the defective components, if necessary. Negligence may cause destruction to the entire hydraulic system.

5.44 Change the coolant !

Do not clean or reuse the filter element. l

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

l

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

l

After a short test run check the filter for leaks.

Danger

Danger of scalding!

Change the coolant only when the engine is cold.

Environment Catch running out coolant and dispose of environmentally.

Fig. 255 l

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

Fig. 256

138

l

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

l

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

BOMAG

BW 213 DH-4/PDH-4 BVC

Every 2000 operating hours

Fig. 257 l

Unscrew the cap and fill in coolant up to the MAX-mark (Fig. 257).

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

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

l

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

BW 213 DH-4/PDH-4 BVC

BOMAG

139

Every 3000 operating hours

Every 3000 operating hour s

5.45 Replacing the crank case ventilation valve

Fig. 258 l

140

Replace the crank case ventilation valve (Fig. 258).

BOMAG

BW 213 DH-4/PDH-4 BVC

Every 6000 operating hours

Every 6000 operating hours

5.46 Electronic injector test EMR

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

BW 213 DH-4/PDH-4 BVC

BOMAG

141

As required

As requir ed

5.47 Service the combustion air filter !

Removing the main filter element

Caution

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

Fig. 261

Loosen both locking hooks (Fig. 261) on the housing cover and take the cover off.

l

Fig. 259

Maintenance of the dry air filter is due when control light 1 (Fig. 259) in the fault monitoring board lights permanently when the engine is running, but at the latest after 2 years.

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

Fig. 262

Pull out the main filter element (Fig. 262) with light turning movements.

l

Cleaning the main filter element !

Caution

If necessary, the main filter element may be cleaned up to five times. It must be renewed at the latest after a maximum utilization period of two years.

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

Fig. 260 l

142

Open the engine hood (Fig. 260) completely and secure it.

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

BOMAG

BW 213 DH-4/PDH-4 BVC

As required

Incorrectly handled inserts may be ineffective because of damage (e.g. cracks) and cause damage to the engine.

Cleaning the dust bowl

Replace the safety cartridge if the main filter element is defective!

Additional cleaning intervals between two filter services signalized by the fault monitoring board are not necessary.

Fig. 265 l

Pull the internal part (Fig. 265) out and remove the dust from the cover.

l

Reinsert the inner part.

Caution When assembling the inner part make sure that the notch in the cover engages in the opening of the inner part. !

Fig. 263

Blow the filter cartridge out from inside to outside with dry compressed air (max. 5 bar) (Fig. 263), until all dust has been removed.

l

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

l

When closing the housing cover the main filter element is automatically forced in the correct position.

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

Fig. 264

Break the seal only to replace the safety filter element.

Examine the filter cartridge with a torch for cracks and holes in the paper bellows (Fig. 264).

l

The safety filter element must be replaced: If the main filter element is defective.

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

BW 213 DH-4/PDH-4 BVC

after five service intervals of the filter cartridge, at the latest after 2 years,

BOMAG

143

As required

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

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

l

5.48 Adjust the scrapers Smooth drum l

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

Fig. 266 l

Pull the safety element (Fig. 266) out by slight turning movements.

l

Push in a new safety filter element.

Fig. 267

l

Reassemble main filter element and cover.

l

In order to adjust the scrapers 2 (Fig. 267), slacken the fastening screws (1) in the slots and push the scraper towards the drum to contact.

l

Retighten the fastening screws.

!

Caution

Make sure that the cover locks engage correctly.

Padfoot drum l

144

BOMAG

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

BW 213 DH-4/PDH-4 BVC

As required

5.49 Adjust the parking brake !

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

Secure the machine with wheel chocks against rolling.

l

Start the diesel engine to relieve the brake.

Fig. 268 l

Check adjustment and condition of scrapers (Fig. 268), adjust or replace the teeth if necessary.

l

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

l

Retighten the clamping screws.

Fig. 269 l

Disengage the travel lever (Fig. 269) to the left, but do not move to position "I" or "II".

The parking brake is released

Fig. 270

BW 213 DH-4/PDH-4 BVC

l

Unscrew locking plate 2 (Fig. 270).

l

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

BOMAG

145

As required

5.50 Change the tires !

Danger

Danger of accident!

Observe all safety regulations for the lifting of loads. l

Place a jack (min. 5 t bearing capacity) under the rear frame and jack the machine up until the wheel is off the ground.

l

Unscrew the wheel nuts and take the wheel off.

Fig. 271 l

In order to adjust the brake clearance turn the square 1 (Fig. 271) three turns back in clockwise direction.

l

Fasten the locking plate again.

l

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

The machine must be braked.

Fig. 272

146

l

Attach a new wheel (Fig. 272) and tighten the wheel nuts crosswise with 550 Nm (405 ft. lb. lb.).

l

Check the tire pressure, see technical data.

BOMAG

BW 213 DH-4/PDH-4 BVC

As required

5.51 Change the fresh air filter in the cabin

5.52 Tightening torques

Fig. 274

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

Fig. 273 l

l

8.8 = 8G

Unscrew fastening screws for the ventilation grid (Fig. 273) and remove the filter.

10.9 = 10K

Insert a new filter and reassemble the ventilation grid.

12.9 = 12K l

Axle - frame

M 22x1.5 l

= 710 Nm

Wheel nuts

M 22x1.5

= 550 Nm

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

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

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

BW 213 DH-4/PDH-4 BVC

BOMAG

147

As required

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

148

BOMAG

BW 213 DH-4/PDH-4 BVC

6 Trouble shooting

BW 213 DH-4/PDH-4 BVC

BOMAG

149

Trouble shooting

6.1

General notes

6.2

Reading out faults BVC/ BTM05

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

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

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

Fig. 275 l

Turn the ignition key (Fig. 275) to position "I".

! Danger Danger of injury!

Keep away from rotating parts of the engine.

Fig. 276 l

Press key ’’?“ (menu) (Fig. 276).

i Note The menu appears on the screen.

150

BOMAG

BW 213 DH-4/PDH-4 BVC

Trouble shooting

Fig. 277 l

Press key "F5" (diagnostics) (Fig. 277).

i Note The screen with the currently available fault codes is displayed.

Fig. 278 l

Currently present faults are indicated by a corresponding fault code in the field "Actual Errors".

l

Press key "ESC" (Fig. 278) to leave the screen page with the actual fault codes.

BW 213 DH-4/PDH-4 BVC

BOMAG

151

Trouble shooting

6.3

Engine

Faults

Possible cause

Remedy

The engine does not start

Starter defective or pinion not engaging

Have examined by a specialist

Fuel tank empty

Fill and bleed the tank

Temperature below starting limit

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

Fuel filter clogged, in winter due to paraffin separation.

Change the filter. use winter fuel

Fuel lines leaking

Check all line connections for leakages and tighten the fittings.

Battery discharged or not connected

Tighten the pole clamps, check the cable connections

Injection valves or injection pump defective

Have examined by a specialist

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

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

Especially during winter: the use of too viscous engine oil

Use engine oil suitable for the ambient temperature

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

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

Use winter fuel in the cold season.

Incorrect valve clearance

Adjust the valve clearance

Injection valve defective

Have examined by a specialist

Injection lines leaking

Check the lines for leakages

Turbo charger defective

Have examined by a specialist

Dry air filter dirty

clean, replace if necessary

Excessive play in the throttle cable

Adjust the throttle cable, change it if necessary

The engine starts poorly and works irregularly with poor power

152

BOMAG

BW 213 DH-4/PDH-4 BVC

Trouble shooting

Faults

Possible cause

Remedy

Excessive exhaust smoke

Engine oil level too high

Drain the oil to the upper dipstick mark

Dry air filter dirty

clean, replace if necessary

Exhaust gas turbo-charger defective

Have examined by a specialist

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

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

Incorrect valve clearance

Adjust the valve clearance

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

Clean the cooling fins

Injection valve defective

Have examined by a specialist

Engine oil level too low

Top up engine oil to the upper dipstick mark

Filling capacity of the injection pump not correctly adjusted

Have adjusted by a specialist

Cooling air flow restricted

Clean the cooling air duct

V-belt loos or broken

Tension or replace the V-belt

Engine oil level too high

Drain the engine oil down to the upper dipstick mark

Dry air filter dirty

clean, change if necessary

Exhaust gas turbo-charger defective

Have examined by a specialist

Charge air hose leaking

Check fastening and connections

Incorrect valve clearance

Adjust the valve clearance

Injection valve defective

Have examined by a specialist

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

Top up oil

Leakages in the lubrication system

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

Generator speed too low

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

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

Have examined by a specialis

Engine overheats, shut down immediately!

Poor engine power

Engine oil pressure too low

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

BW 213 DH-4/PDH-4 BVC

BOMAG

153

Trouble shooting

154

BOMAG

BW 213 DH-4/PDH-4 BVC

7 Cab assembly before initial start-up

BW 213 DH-4/PDH-4 BVC

BOMAG

155

Cab assembly before initial start-up

General safety regulations for assembly

The manufacturer explicitly excludes any liability for damage caused by the use of non-original parts or accessories.

When installing the cabin to your BOMAG machine you must strictly comply with the valid accident prevention instructions or the country specific regulations. However, dangers for persons and property may still arise, if:

Notes on safety in the assembly instructions

l

the lifting gear used has a too low bearing capacity

l

damaged or worn lifting tackle is used

l

unqualified personnel is entrusted with the installation

l

!

Danger

Paragraphs marked like this highlight possible dangers for persons.

Caution Paragraphs marked like this highlight possible dangers for machines or parts of the machine. !

the safety instructions are not observed

Each person involved in the installation of the cabin must therefore read and comply with these safety regulations. If necessary, the customer must demand a written confirmation with signature.

Moreover, the following instructions and regulations must obviously also be complied with: l

applicable accident prevention instructions

l

generally accepted safety and road traffic regulations

l

country specific safety regulations. It is the duty of the operator to be acquainted with these instructions and to apply these accordingly. This applies also for local regulations concerning different types of handling work.

Should the recommendations in these instructions be different from the regulations valid in your country, you must comply with the safety regulations valid in your country.

Changes and conversions to the cabin/ machine Unauthorized changes to the cabin are prohibited for safety reasons.

Original parts and accessories have been specially designed for this machine. We wish to make explicitly clear that we have not tested or approved any parts or accessories not supplied by us. The installation and/or use of such products may have an adverse effect on the active and/or passive driving safety.

i Note Paragraphs marked like this contains technical information and hints for optimal assembly.

Environment Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.

Strictly observe the national regulations for the protection of the environment.

Information and safety stickers/decals on the cabin Keep stickers/decals in good and legible condition (see spare parts catalogue) and comply with their meaning.

Replace damaged stickers/decals

Work on heating lines Before starting work on heating pipes relieve any pressure and let them cool down - danger of scalding!

After completing work on the heating system of the machine check all connections and fittings for leaks.

Working on electric parts of the machine Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material.

156

BOMAG

BW 213 DH-4/PDH-4 BVC

Cab assembly before initial start-up

Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire. Fire hazard.

7.1 !

Preparations

Danger

Danger of accident!

For transport purposes the driver's seat must be tied down with cable straps thus to operate the seat contact switch. Before resuming operation of the machine these cable straps must strictly be removed to ensure safe and reliable function of the seat contact switch.

Check the 4 lifting eyes on the cabin roof for tight fit.

Fasten the lifting gear to all four lifting eyes.

Use lifting gear (chains or ropes) of sufficient load bearing capacity. The minimum load bearing capacity of the crane must be 1000 kg.

Do not stand or step under loads being lifted.

Fig. 279

BW 213 DH-4/PDH-4 BVC

l

Make sure that all fastening screws, washers, spacers and nuts to fasten the cabin are available (Fig. 279).

l

Check whether rear rack, foot mat, step plate and fastening kit are available.

BOMAG

157

Cab assembly before initial start-up

7.2 !

Cabin assembly

Danger

Danger of accident!

Use lifting gear (chains or ropes) of sufficient load bearing capacity. The minimum load bearing capacity of the crane must be 1000 kg.

Do not stand or step under loads being lifted.

Clean the operator's stand of dirt, oil and moisture.

l

Fig. 280 l

Fasten the lifting gear to the four lifting eyes 1 (Fig. 280).

l

Loosen possible fastening on the transport pallet.

l

Slowly list the crane with a crane.

Danger Danger of accident! !

Do not stand or step under loads being lifted.

Fig. 281

Stick the supplied sealing tape 1 (Fig. 281) along the edge of the operator's stand.

l

!

Caution

Only unroll and stick the sealing tape on just before mounting the cab to the operator's stand. The sealing tape will swell a few minutes after being unrolled. In this case the cabin can no longer be mounted!

158

BOMAG

BW 213 DH-4/PDH-4 BVC

Cab assembly before initial start-up

Fig. 282

Fig. 284

l

Stick the sealing tape 1 (Fig. 282) all around the operator's stand.

l

Do not run the sealing tape across the front recess in the operator's stand (2), since this is the air inlet for the cabin ventilation.

Slowly lower the cabin vertically to the operator's stand (Fig. 284).

l

Caution The cabin must be lowered vertically onto the operator's stand. !

i Note Mount the cabin immediately after sticking on the sealing tape, because the sealing tape will swell.

Fig. 285

Fig. 283 l

Spray the sealing tape with soapsuds (Fig. 283), to be able to slide the cabin on the operator's stand.

BW 213 DH-4/PDH-4 BVC

!

Caution Take care that none of the hoses and electric cables become squashed (Fig. 285). l

BOMAG

Run cables and hoses from inside the cabin through the operator's stand to the outside.

159

Cab assembly before initial start-up

Fig. 286

Turn both fastening screws (Fig. 286) at the rear of the cabin in hand tight.

l

Fig. 287

Fig. 288 l

Tighten the bottom fastening screw on the access side (Fig. 288) with 578 Nm.

Fig. 289 l

i Note If the bores do not match the cabin can be moved into position by means of a crow bar (Fig. 287).

Loosen both fastening screws (Fig. 289) at the rear of the cabin again.

i Note The cabin will now slide into final assembly position.

160

l

Tighten both fastening screws (Fig. 289) at the rear of the cabin with 578 Nm.

BOMAG

BW 213 DH-4/PDH-4 BVC

Cab assembly before initial start-up

Fig. 290 l

Fig. 293

Tighten the rear lateral fastening screw on the left hand side with 578 Nm (Fig. 290).

Fig. 291 l

Tighten the rear lateral fastening screw on the right hand side with 578 Nm (Fig. 291).

l

Tighten the front lateral fastening screw on the right hand side with 578 Nm (Fig. 294).

Fig. 295

Tighten the rear inside fastening screw on the right hand side with 578 Nm (Fig. 292).

BW 213 DH-4/PDH-4 BVC

Turn nuts with washers onto both studs and tighten with 200 Nm (Fig. 293).

Fig. 294

Fig. 292 l

l

l

Tighten the front lateral fastening screw on the left hand side with 578 Nm (Fig. 295).

BOMAG

161

Cab assembly before initial start-up

Fig. 296 l

Cover all lateral fastening screws with plastic caps (Fig. 296).

Fig. 297 l

Insert the foot mat 1 (Fig. 297).

Fig. 299 l

Insert the dashboard and fasten it with four fastening screws (Fig. 299).

Fig. 300 l

Remove all cable straps from the seat console (Fig. 300) to activate the seat contact switch.

Fig. 298 l

162

Attach the step plate 1 (Fig. 298) and tighten the three fastening screws (2).

Fig. 301 l

Insert the rear rack and knock both plastic fasteners carefully into the bores with a hammer (Fig. 301).

BOMAG

BW 213 DH-4/PDH-4 BVC

Cab assembly before initial start-up

Fig. 302

Fig. 304

l

Connect the feed 1 (Fig. 302) and the return flow (2) for the air conditioning system with quick release couplings.

l

Connect the feed (4) and the return flow (3) of the heating. (Observe the marks on the hoses).

Plug on the hoses for the washing water supply to front and rear windscreens 1 (Fig. 304).

l

i Note Check the function of the washing water system within the scope of the function test.

i Note Run the connecting lines for the heating parallel to each other (do not cross).

i Note Check the function of air conditioning and heating within the scope of the function test.

Observe identical hose diameters when connecting.

Fig. 305 l

Insert the plug 1 (Fig. 305) into the socket (2).

l

Close the bayonet catch by turning the corrugated cap nut in clockwise direction against the stop. !

Danger

Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material.

Fig. 303 l

Plug on both connecting plugs for the washing water pumps (Fig. 303).

BW 213 DH-4/PDH-4 BVC

BOMAG

163

Cab assembly before initial start-up

7.3

!

Final function tests and checks Caution

Make sure that all screws have been tightened with the specified torque.

i Note Fig. 306 l

Connect the plug connection of the air conditioning system (Fig. 306).

After the cabin assembly the following tests must be performed to assure that all cables and lines are correctly connected. l

Insert the ignition key and turn clockwise to position "1".

l

Operate the switches for headlights, direction indicators and interior light to check their function.

l

Operate the switches for front and rear windscreen washer system and check their correct function.

i Note If the function of the windscreen washer system is reversed, the two washing water hoses must be interchanged. l

Start the engine.

l

Switch the air conditioning on by the switch.

After a five minute operation the cabin must become noticeably cooler.

l

Switch the air heater on by the switch. After a five minute operation the cabin must become noticeably warmer.

l

Function of the seat contact switch.

Caution The machine must not be operated if the seat contact switch is not functioning correctly. !

164

BOMAG

BW 213 DH-4/PDH-4 BVC