Bomag BW 213 D-4 Operating Instructions, Maintenance Instructions Download Page 53

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Maintenance

BOMAG

BW 213 D-4

5.4

Running-in instructions

The following maintenance work must be per-
formed 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

Retighten the V-belt

After 50 operating hours

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

Retighten the bolted connections on the ma-
chine.

Retighten all wheel fastening screws with the
specified tightening torque.

Oil change vibration bearings

Oil change in drive axle

Oil change in wheel hubs

After 500 operating hours

Oil change vibration bearings

Summary of Contents for BW 213 D-4

Page 1: ...Operating instructions Maintenance instructions Catalogue number 008 124 31 06 2004 BW 213 D 4 S N 101 582 50 Single drum roller...

Page 2: ......

Page 3: ...ptional equipment This manual was written for operators and mainte nance personnel on construction sites Always keep this manual close at hand e g in the tool compartment of the machine or in a specia...

Page 4: ...3 Engine number Fig 3 i Note Supplement the above data together with the com missioning protocol During commissioning our organisation will in struct you in the operation and maintenance of the machi...

Page 5: ...45 Maintenance 47 5 1 General notes on maintenance 48 5 2 Fuels and lubricants 49 5 3 Table of fuels and lubricants 52 5 4 Running in instructions 53 5 5 Maintenance chart 54 5 6 Check the engine oil...

Page 6: ...n bearings 78 5 30 Retighten the fastening of the axle on the frame 79 5 31 Tightening the wheel nuts 80 5 32 Check the ROPS 80 5 33 Cleaning the oil bath air filter 81 5 34 Changing hydraulic oil and...

Page 7: ...BOMAG 7 BW 213 D 4 1 Technical Data...

Page 8: ...kg 12525 Axle load drum CECE kg 7000 Rear axle load CECE kg 5525 Static linear load kg cm 32 9 Travel characteristics Travel speed 1 km h 0 5 Travel speed 2 km h 0 6 Travel speed 3 km h 0 7 Travel spe...

Page 9: ...pe of steering articulated Steering operation hydrostatic Vibration Vibrating drum 1 Drive system hydrostatic Frequency Hz 30 36 Amplitude mm 1 8 0 9 Tires Tire size 23 1 18 26 TL 8PR AWT Air pressure...

Page 10: ...bin LpA BW 213 D 4 75 dB A The nose emission value for the machine according to the noise emission regulation 2000 14 EG is guaranteed sound capacity level of the machine LwA BW 213 D 4 105 dB A These...

Page 11: ...BOMAG 11 BW 213 D 4 2 Safety regulations...

Page 12: ...operated with fully functional safety equipment l The machine should be checked by an expert once every year Unintended use Dangers may however arise from the machine if it is used by untrained perso...

Page 13: ...erally use a tow bar Max towing speed 1 km h 1 6 mph max towing distance 500 m 1640 ft Before releasing the multi disc brakes secure the machine properly against unintended rolling Checking the Roll O...

Page 14: ...de quate supply of fresh air when starting in closed rooms Driving the machine Persons in the endangered area If the machine has turned over and the cabin door is jammed use the right hand cabin windo...

Page 15: ...against unauthorized use 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 S...

Page 16: ...rosion of the fitting which impairs the func tion and the strength l Do not mix up hoses by mistake l damage or deformation of the fitting which im pairs the function and strength of the hose hose con...

Page 17: ...ecified pressure cuts bulges damaged wheel rims missing wheel studs and nuts Do not drive with damaged tires or wheels Anti stick emulsions for tires must only be mixed using water and concentrated an...

Page 18: ...Safety regulations BOMAG 18 BW 213 D 4...

Page 19: ...BOMAG 19 BW 213 D 4 3 Indicators and Controls...

Page 20: ...Indicators and Controls BOMAG 20 BW 213 D 4 Fig 5...

Page 21: ...switch vibration high low frequency 8 Rotary switch for speed range selection 9 Emergency stop push button 10 Push button for warning horn 11 Rotary momentary contact switch for engine speed 12 Rotar...

Page 22: ...rning 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 le ver is in braking position The ignition switch...

Page 23: ...ion monitoring sys tem lights when the seat is not occu pied If the machine is travelling the warning buzzer will sound engine is shut down after 4 seconds g red Parking brake with lever shifted to pa...

Page 24: ...gine 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 back towards neutral This relieve...

Page 25: ...on clockwise and release it to drive move the travel lever first to braking position then start the engine and choose the travel direction For safety reasons the travel system of the ma chine will onl...

Page 26: ...ition left Hazard light switched off con trol lights off Position right Hazard light switched on con trol light 1 in instrument cluster lights up Fig 17 No 14 Rotary switch for light system StV ZO Pos...

Page 27: ...s seat while driving swivel Stop the machine and apply the parking brake Pull the le ver up and swivel the driver s seat to the desired position i Note Swivelling angle max 20 to either side Fig 21 No...

Page 28: ...t windscreen is sprayed during wiping 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 w...

Page 29: ...er tempera ture selector switch Position Off cabin heater switched off Position blue range temperature selection for air conditioning Position red range Temperature selection for cab in heater Fig 26...

Page 30: ...Indicators and Controls BOMAG 30 BW 213 D 4 Constant end of compaction...

Page 31: ...BOMAG 31 BW 213 D 4 4 Operation...

Page 32: ...l Fuel tank and fuel lines for leaks l Bolted connections for tight fit l Function of the steering l Check the machine for cleanliness and dam age l availability of the appropriate operating and main...

Page 33: ...pressure Pressure see technical data Caution Ensure equal pressure in both tires 4 3 Starting the engine Danger Danger of accident Always wear your seat belt Fig 29 l Check whether the travel lever Fi...

Page 34: ...l d and brake warning lights g light up the engine oil pressure warning light b flashes Caution Perform the starting process for maximum 20 seconds without interruption and pause for a minute between...

Page 35: ...nt Wet and loose soils considerably reduce the ground adhesion of the machine on inclina tions and slopes Soil conditions and weather influences impair the gradability of the machine Do not drive up a...

Page 36: ...Fig 38 Fig 39 l Fasten your seat belt Fig 39 Fig 40 l Select the desired travel speed range Fig 40 Fig 41 l Turn the rotary switch Fig 41 to Max posi tion full throttle Fig 42 l Push the travel lever...

Page 37: ...e 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 I...

Page 38: ...ibrate Switching the vibration off l Press the push button again and after work switch the rotary vibration switch to position 0 4 7 Operating the parking brake stopping the ma chine Fig 47 l Return t...

Page 39: ...l Turn rotary switch Fig 49 to position Min idle speed i Note Do not shut the engine down all of the sudden from full speed but let it idle for a while for temperature equalization Fig 50 l Turn the...

Page 40: ...Adjusting the steering wheel Fig 51 l Adjustment of steering wheel in height pull le ver Fig 51 up and move the steering wheel to the desired height l Adjustment of steering wheel inclination press l...

Page 41: ...To swivel the seat pull lever b up and turn the seat to the desired direction Fig 53 l To adjust the height of the seat lift the seat up Fig 53 until it engages at the desired level When lifting the s...

Page 42: ...d to top position you must also pull out and lock the bottom rod Fig 57 l Push up the hood and place the support rod into its receptacle Closing the hood Fig 58 l Pull down the hood press in the sprin...

Page 43: ...e middle hexagon on both valves Fig 59 for approx 2 to 3 turns Caution Do not turn the valves out completely Fig 60 l To release the brake turn counter nuts 1 Fig 60 approx 8 mm back l Turn the brake...

Page 44: ...asing screws Fig 62 back in again until they abut against the brake pis ton Fig 63 l Unscrew the brake releasing screws Fig 63 for two turns and tighten the counter nuts l Repeat this adjustment proce...

Page 45: ...ng or lifting the machine Fig 64 l Pull the spring pin Fig 64 out l Engage the articulation lock and secure it with the spring pin Fig 65 l Engage the articulation lock and secure it with the spring p...

Page 46: ...Operation BOMAG 46 BW 213 D 4...

Page 47: ...BOMAG 47 BW 213 D 4 5 Maintenance...

Page 48: ...dge on the bottom of the drum l Do not draw off fuel from near the bottom of the fuel drum l Fuel left in the fuel drum is not suitable for the engine and should only be used for cleaning purposes Not...

Page 49: ...Engine oil Quality Lubrication oils are classified according to their performance and quality class Oils according to other comparable specifications may be used The exact assignment of the approved...

Page 50: ...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...

Page 51: ...portion 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 Environment Cooling system protection ag...

Page 52: ...r diesel fuel approx 150 litres Hydraulic system Hydraulic oil ISO HV46 kinem viscosity approx 60 litres 46 mm2 s at 40 C Vibration bearings Engine oil SAE 15W 40 approx 0 8 litres Drive axle Gear oil...

Page 53: ...will drop to the normal level after approx 100 to 250 operating hours After a running in time of 30 minutes l Retighten the V belt After 50 operating hours l Retighten bolted connections on intake an...

Page 54: ...evel 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 1...

Page 55: ...every 2 years X 5 35 Change the hydraulic oil filter at least every 2 years X 5 36 Change the coolant at least every 2 years X 5 37 Check the injection valves X 5 38 Service the combustion air filter...

Page 56: ...ange intervals depend on quality of oil and fuel sulphur content Oil change intervals after 50 h after 500 h after 1000 h and then every 1000 h Also in case of repair in the hydraulic system Also in c...

Page 57: ...or quality and quantity of oil refer to the table of fuels and lubricants 5 7 Check clean the water sep arator Danger Danger of injury Support the engine hood for all maintenance and repair work i Not...

Page 58: ...auge n Fig 71 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 72 l Open the fuel tank c...

Page 59: ...Caution If during the daily oil check the oil level is found to have dropped check all lines hoses and components for leakages l If necessary fill in hydraulic oil through the filler neck For quality...

Page 60: ...10 operating hours BOMAG 60 BW 213 D 4 5 11 Checking the dust separa tor on the oil bath air filter Fig 75 l If the dust reaches the mark loosen the clamp Fig 75 take the cover off and clean the bowl...

Page 61: ...n 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 a...

Page 62: ...he engine warm for a while to avoid cor rosion 5 14 Check the oil level in the drive axle l Park the machine on level ground Fig 78 l Unscrew the oil level inspection plug Fig 78 and check the oil lev...

Page 63: ...ating temperature after running the machine approx 1 2 hour with vibration l Park the machine on level ground Fig 80 l Move the drum until oil level inspection plug 1 Fig 80 on the left hand side of t...

Page 64: ...dispose of environ mentally together with the engine oil filter car tridge Fig 81 l Unscrew the drain plug Fig 81 and catch running out oil l Turn the drain plug tightly back in Fig 82 l Thoroughly cl...

Page 65: ...aks after a short test run l Shut the engine down and wait for about 15 minutes so that all oil can flow back into the oil sump l Check the oil level again if necessary fill up to the Max mark 5 18 Ch...

Page 66: ...f turn l Check the filter cartridge for leaks after a short test run 5 19 Draining the sludge from the fuel tank Danger Fire hazard When working on the fuel system do not use open fire do not smoke Do...

Page 67: ...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 b...

Page 68: ...Fig 91 Fig 92 l Apply a thin coat of oil to the rubber seal of the water separator 1 Fig 92 l Screw the water separator on by hand 2 until the seal contacts l Tighten the water separator for another...

Page 69: ...le pump ing 5 22 Checking replacing the re frigerant compressor V belt Danger Danger of injury Work on the V belt must only be performed with the engine shut down Check the V belt Fig 94 l Inspect the...

Page 70: ...he 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...

Page 71: ...ure must be below the actu al temperature inside the cabin so that the com pressor will be switched on l Open the hood Fig 99 l Check whether the white float Fig 99 inside the inspection glass of the...

Page 72: ...irs must be repeated ly inspected by a specialist In this sense repeated inspections are external examina tions normally on pressure reservoirs in oper ation In connection with this inspection the dri...

Page 73: ...inder en gine l Crank the engine with the starter or a spanner by the V belt pulley until both valves on cylin der 1 are overlapping Overlapping means Exhaust valve not yet closed intake valve starts...

Page 74: ...p is too narrow or too wide for the feel er gauge the valve must be adjusted Adjusting the valve clearance Fig 108 l Slightly slacken the counter nut Adjust set screw 7 Fig 108 with a screwdriver unti...

Page 75: ...surement a is smaller than 3 mm re place the ribbed V belt Changing the ribbed V belt Fig 110 l Unscrew the fastening screws Fig 110 and slide the fan forward Fig 111 l Release the idler pulley Fig 11...

Page 76: ...ghten the fastening screws for oil sump and engine mounts 5 27 Change the oil in the drive axle i Note On other axle versions drain and filler plugs are of slightly different design Perform the oil ch...

Page 77: ...ble of fuels and lubricants l Retighten the filler and level inspection plug 5 28 Changing the oil in the wheel hubs Caution Drain oil only at operating temperature Change the oil on both sides of the...

Page 78: ...hange 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 environ mentally l Park the machine on level...

Page 79: ...fuels and lubricants l Screw oil filler 2 and level inspection plug 1 back in tightly l Repeat the oil change on the opposite side l Check the oil level once again at operating temperature after runn...

Page 80: ...ion in the safety regulations in this manual Fig 121 l Inspect the cabin especially the ROPS Fig 121 for cracks corrosion damage and miss ing fastening parts i Note Unusual movements and noises vibrat...

Page 81: ...air fil ter Fig 122 l Loosen the quick locks Fig 122 take the fil ter 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...

Page 82: ...ange Danger Danger of scalding Danger of scalding by hot oil Environment Catch running out oil and dispose of environ mentally i Note Generally replace the hydraulic oil filter element after the test...

Page 83: ...as 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...

Page 84: ...er bowl and the thread l Reinstall the filter bowl with the new filter ele ment check the condition of the O rings 1 and 2 replace if necessary l After a test run check the filter for leaks 5 36 Chang...

Page 85: ...the cap and fill in coolant up to the MAX mark For quality of coolant refer to the chapter 5 2 fuels and lubricants l Start the diesel engine and run it warm to op erating temperature l Let the engine...

Page 86: ...urs BOMAG 86 BW 213 D 4 Every 3000 operating hours 5 37 Checking the injection valves i Note This work must only be performed by authorized service personnel The injection valves must be replaced ever...

Page 87: ...ours Each cleaning interval must be marked with a cross on the cover of the filter element Cleaning does not make sense if the air filter element is covered with a sooty deposit Use a new filter eleme...

Page 88: ...sealing l Check the old main filter element The old main filter element can be of help to dis cover foreign particles on the sealing face which could lead to leaks A line of dust on the clean air side...

Page 89: ...fit a tube to the compressed air gun Fig 136 the end of which should be bent for approx 90 The length should reach down to the bottom of the element l Blow the main filter element out with com pressed...

Page 90: ...ssemble main filter element and cover 5 39 Adjust the scrapers Smooth drum l Check adjustment and condition of front and rear scrapers if necessary adjust or replace the scraper rubber Fig 138 l In or...

Page 91: ...ping screws 5 40 Adjust the parking brake Caution Have adjustment work on the brakes only car ried out by a specialist Always adjust both sides l Secure the machine with wheel chocks against rolling l...

Page 92: ...rive test The machine must be braked 5 41 Changing the tires Danger Danger of accident Observe all safety notes for the lifting of loads l Place a jack min 5 t bearing capacity under the rear frame an...

Page 93: ...trength classes for screws with untreated non lubricated surface Screw quality designations are stamped on the screw heads 8 8 8G 10 9 10K 12 9 12K l Axle frame M 22x1 5 710 Nm l Wheel nuts M 22x1 5 5...

Page 94: ...d BOMAG 94 BW 213 D 4 5 44 Engine conservation If the engine is to be shut down for a longer period of time e g over winter please consult the serv ice department of the engine manufacturer for fur th...

Page 95: ...BOMAG 95 BW 213 D 4 6 Trouble shooting...

Page 96: ...Faults occur frequently due to the fact that the machine has not been properly operated or serv iced Therefore whenever a fault occurs read through these instructions on correct operation and mainten...

Page 97: ...regularly with poor power Battery power too low battery clamps loose or oxidized causing the starter to turn too slowly Have the battery checked clean the ter minal clamps tighten them and cover them...

Page 98: ...d Clean the cooling air duct V belt loos or broken Tension or replace the V belt Poor engine power Engine oil level too high Drain the engine oil down to the upper dip stick mark Dry air filter dirty...

Page 99: ...Trouble shooting BOMAG 99 BW 213 D 4...

Page 100: ...Trouble shooting BOMAG 100 BW 213 D 4...

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