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Fayat BOMAG BW 213 D-4, Operating Instructions Manual

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Fayat BOMAG BW 213 D-4 Operating Instructions Manual Download Page 142

WARNING!
Danger of scalding!

Change the coolant only when the engine is cold.

NOTICE!

Do not start the engine after draining off the coolant.

In case of lubrication oil entering into the cooling

system or a suspicious turbidity caused by corrosion

residues or other suspended matter, the coolant must

be drained off and the complete cooling system needs

to be cleaned. Lubrication oil can damage the sealing

materials used in the engine.

When changing the coolant without any signs of con-

tamination, cleaning of the cooling system is not nec-

essary.

For quality and quantity of coolant refer to the "table of

fuels and lubricants".

Do not mix different coolants and additives, see sec-

tion "Fuelds and Lubricants - Coolant".

ENVIRONMENT!

Catch coolant and dispose of environmentally.

Unscrew the lid from the compensation tank.

Fig.  175

Maintenance

 

BW 213 D-4  

 

142

Summary of Contents for BOMAG BW 213 D-4

Page 1: ...BW 213 D 4 Single drum roller Operating Instruction Maintenance Instruction Original Operating Instructions S N 101 583 58 1001 08 2014 008 043 61 ...

Page 2: ...2 ...

Page 3: ...off 66 5 9 What to do in events of emergency 68 5 10 Adjusting the steering wheelOptional equipment 69 5 11 Adjusting the seat 70 5 12 Operating the heating air conditioning systemOptional equipment 71 5 13 Operating the hood 73 5 14 BVC BTM05 settings before start up 74 5 15 Measuring pass with BTMOptional equipment 78 5 16 Finishing compaction of a track 82 5 17 Printing measuring data after com...

Page 4: ...9 6 8 3 Draining the sludge from the fuel tank 120 6 8 4 Battery service 121 6 8 5 Service the air conditioningOptional equipment 122 6 8 6 Cleaning the circulation air filter for the heatingOptional equipment 126 6 8 7 Changing the bypass filterOptional equipment 126 6 9 Every 1000 operating hours 128 6 9 1 Checking replacing the ribbed V belt 128 6 9 2 Replace the fuel filter cartridge 129 6 9 3...

Page 5: ...sh air filter in the cabin 151 6 13 7 Fill the provision tank for the windscreen washer systemOptional equipment 151 6 13 8 Tightening torques 151 6 13 9 Engine conservation 152 7 Trouble shooting 153 7 1 Preliminary remarks 154 7 2 Starting the engine with jump leads 155 7 3 Reading out faults BVC BTM05 156 7 4 Engine faults 158 8 Cab assembly before initial start up 161 8 1 Preparations 163 8 2 ...

Page 6: ...Table of contents BW 213 D 4 6 ...

Page 7: ...1 Foreword Foreword BW 213 D 4 7 ...

Page 8: ...y not complying with the usual modes of use n if it is used for purposes other than those mentioned in these instructions No warranty claims can be lodged in case of damage resulting from n operating errors n insufficient maintenance and n wrong fuels and lubricants Please note This manual was written for operators and maintenance personnel on construction sites Always keep this manual close at ha...

Page 9: ...d 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 We wish you successful work with your BOMAG machine BOMAG GmbH Copyright by BOMAG Please fill in Machine type Fig 1 Serial number Fig 1 and 2 Engine type Fig 3 Engine number Fig 3 Supplement the above data together with the commis sionin...

Page 10: ...Fig 2 Fig 3 Foreword BW 213 D 4 10 ...

Page 11: ...2 Technical Data Technical Data BW 213 D 4 11 ...

Page 12: ...CECE with ROPS cabin kg 12525 Axle load drum CECE kg 7225 Rear axle load CECE kg 5300 Static linear load kg cm 33 9 Travel characteristics Travel speed 1 km h 0 6 Travel speed 2 km h 0 7 Travel speed 3 km h 0 8 Travel speed 4 km h 0 11 Max gradability without with vibration soil dependent 45 43 Drive Engine manufacturer Deutz Type TCD 2013 L04 Technical Data BW 213 D 4 12 ...

Page 13: ... Parking brake hydro mechanical Steering Type of steering Oscill articul Steering operation hydrostatic Steering oscillation angle 35 12 Inner track radius mm 3494 Vibration Vibrating drum 1 Drive system hydrostatic Frequency 1 2 Hz 30 36 Amplitude 1 2 mm 1 90 0 96 Centrifugal force 1 2 kN 275 202 Tires Tire size 23 1 26 12PR Air pressure nominal value bar 1 4 Air pressure span bar 0 8 1 4 Filling...

Page 14: ...these values may vary because of the existing operating conditions sound pressure level at the work place of the operator with cabin LpA 73 dB A determined acc to ISO 11204 and EN 500 Guaranteed sound power level LWA 103 dB A determined acc to ISO 3744 and EN 500 Vibration of the entire body driver s seat The weighted effective acceleration value determined according to ISO 7096 is 0 5 m s2 Hand a...

Page 15: ...3 Safety regulations Safety regulations BW 213 D 4 15 ...

Page 16: ...structions be different from the regulations valid in your country you must comply with the safety regulations valid in your country This machine must only be used for n medium to heavy compaction work in earth construction road sub bases n probably compaction of bituminous material e g road surface layers Dangers may arise from the machine when it is used for purposes other than the one it is int...

Page 17: ...t be clearly specified and complied with Persons under the influence of alcohol medicine or drugs are not allowed to operate service or repair the machine Maintenance and repair work requires specific knowledge and must therefore only be performed by trained specialists Unauthorized changes to the machine are prohibited for safety rea sons Original parts and accessories have been specially designe...

Page 18: ...machine against turning over or slipping off Secure the machine on the transport vehicle against rolling off slipping and turning over Persons are highly endangered if n they step or stand under loads being lifted n they remain in the drive range of the machine during a demon stration or during loading The machine must not swing about when lifted off the ground Use only safe lifting gear of suffic...

Page 19: ...riginal spare part in close coordination with the manufacturer Before starting Operation of the machine is only permitted when sitting in the oper ator s seat Use only machines which have been properly serviced at regular intervals Become acquainted with the equipment the control elements the working mode of the machine and the area you will be working in Use your personal protective outfit hard h...

Page 20: ...r area If a machine has turned over and the cabin door is jammed the right hand cabin window can be used as an escape door Before taking up work also after breaks you should always con vince yourself that the danger zone is free of persons or obstruc tions especially when driving in reverse Give warning signals if necessary Stop work immediately if per sons remain in the danger zone despite the wa...

Page 21: ... of the machine On slopes drive extremely careful and always directly up or down the slope Change to a lower gear before starting to drive Wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes Higher risk of accident Inclination The tipping angle was measured in static condition on level hard ground with the machine stopped no steering and without vi...

Page 22: ... place metal chocks in front of and behind the wheels The wheel chocks must be provided by the operating company Do not inhale any fuel fumes Refuel only with the engine shut down Do not refuel in closed rooms No open fire do not smoke Monitor the entire refuelling process Do not spill any fuel Catch running out fuel do not let it seep into the ground Wipe off spilled fuel Keep dirt and water away...

Page 23: ... Do not change the setting of pressure relief valves Drain the hydraulic oil at operating temperature danger of scalding Any hydraulic oil must be caught and disposed of in an environ mentally friendly manner Always catch and dispose of hydraulic oils separately Do not start the engine after draining the hydraulic oil Once all work is completed with the system still depressurized check all connect...

Page 24: ...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 turbo charger and do not touch any hot surfaces Check and change coolant only when ...

Page 25: ... 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 specifica tions of the manufacturer of the anti sticking agent Observe appli cable environmental regulations Working on the air conditioning Faults on the air conditioning should only be remedied by profes sional personnel ...

Page 26: ... 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 star...

Page 27: ...ion sticker Hood handle 6 Warning sticker Vehicle voltage 12 V 7 Information sticker Lashing point 8 Information sticker Lifting point 9 Information sticker Engine oil drain 10 Prohibition sticker High pressure cleaner 11 Information sticker Hydraulic oil and coolant drains 12 Information sticker Guaranteed sound capacity level Safety regulations BW 213 D 4 27 ...

Page 28: ...Fig 7 1 Instruction sticker Always wear your seat belt 2 Information sticker Emergency exit Safety regulations BW 213 D 4 28 ...

Page 29: ...4 Indicators and Controls Indicators and Controls BW 213 D 4 29 ...

Page 30: ...Fig 8 Indicators and Controls BW 213 D 4 30 ...

Page 31: ...for engine speed 14 Rotary switch direction indicators1 15 Rotary switch for hazard light system1 16 Rotary switch for light system1 17 Rotary switch for working lights1 18 Steering wheel adjustment lever 19 Rotary switch for cabin heater1 1 Optional equipment 4 1 General notes If you are not yet familiar with the control and display elements on this machine you should read this section thoroughly...

Page 32: ...ine can only be started if both travel levers are in neutral The starter switch is designed with a re start lock For a new starting attempt the ignition key must first be turned back to position 0 Position START Turn further against spring pressure the engine starts turn the ignition key back to position I once the engine has started NOTICE Run the engine warm for a short while before starting wor...

Page 33: ...essure warning light Flashes when the engine oil pressure is too low the warning buzzer sounds the engine is shut down after 10 sec onds Check engine oil level repair the engine if necessary e red Coolant level warning light Flashes if the coolant level is too low the warning buzzer sounds the engine is shut down after 10 seconds Check coolant level Check cooling system for leaks repair if necessa...

Page 34: ...tenance work must be performed according to the indi cated operating hours m Fuel level gauge n Rotary switch for cabin fan Position 0 Cabin fan switched off Position 1 2 and 3 Fan stages of different strengths n Rotary switch for air conditioning systemOptional equipment Only switch the air conditioning system on when the rotary switch for the cabin fan in position 1 2 or 3 Position 0 Air conditi...

Page 35: ...ition II Backwards travel If the engine speed drops under load when driving on steep gradients take the travel lever slightly back towards neutral This relieves the hydraulic system and reduces the load on the diesel engine n Rotary switch for vibration amplitude selection Position left low amplitude high frequency Position middle Vibration off Position right high amplitude low frequency Fig 13 Fi...

Page 36: ... accident Use only in events of emergency during operation Do not use as parking brake Restart the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated The machine is braked immediately the engine is shut down actuate press the button completely down it automatically locks in fully pressed position switch off unlock Turn button clockwise Restart ...

Page 37: ...vel lever n Rotary switch for direction indicatorsOptional equipment Position middle Direction indicators disabled Position left or right Front and rear direction indicators on the corresponding side are flashing Indicator control light in instrument cluster flashes n Rotary switch for hazard light system Optional equipment Position left Hazard light system switched off Position right Hazard light...

Page 38: ... off Position right Working lights on with ignition switch in position I n Lever steering wheel adjustmentOptional equipment WARNING Danger of accident Do not adjust the steering wheel while driving pull up adjust height of steering wheel press down adjust inclination of steering wheel n Rotary switch for cabin heater Position 0 Cabin heater switched off Position red range Temperature selection fo...

Page 39: ...l the driver s seat to the desired position Swivelling angle max 20 to either side n 12V socket Permanent current loadable up to 15 A n Fuses in electric junction box WARNING Fire hazard Do not use fuses with higher ampere ratings and do not bridge fuses 15 30A F13 Start switch 16 5A F68 Electronic immobilizer 17 20A F105 Engine speed 18 15A F11 Front head lights 19 15A F07 Hazard light 21 15A F22...

Page 40: ...gine solenoid 28 10A F23 Warning horn 29 10A F25 solenoid valve for driving and braking 30 15A F39 Main fuse for cabin 31 10A F24 Instruments 32 15A F03 Vibration 33 10A F148 Control MESX potential 15 34 10A F84 Control contact 54 35 15A F146 Control MESX potential 30 37 25A F124 Fuel pre heating 80 5A F150 GPS Receiver n Main fuse for battery 125A F00 Fig 29 Fig 30 Indicators and Controls BW 213 ...

Page 41: ...r washer up windscreen wiper moves to end posi tion and stops down Switches on wiping of rear wind screen Push button Rear windscreen is sprayed during wiping d toggle switch for rear windscreen heating WARNING Fire hazard Do not use fuses with higher ampere ratings and do not bridge fuses 1 15A F43 Wiper washer rear 2 15A F44 Wiper washer front 3 10A F130 Night light 4 25A F31 Cabin ventilator 5 ...

Page 42: ...oard electrics protects against unau thorized use when performing welding work on the machine Can be removed Position II Operating position engine can be started NOTICE In events of emergency do not use the main battery switch to shut down the engine This will result in damage to engine and electronic engine control units NOTICE Pull out the main battery switch at the earliest 40 sec onds after th...

Page 43: ...e rotational speed of the diesel engine Scale value x 100 revolutions per minute n Vibration frequency displayOptional equipment Shows the vibration frequency outer scale Frequency in min 1 x 100 inner scale Frequency in Hz n VoltmeterOptional equipment Shows the current on board voltage in Volt Fig 35 Fig 36 Fig 37 Fig 38 Indicators and Controls BW 213 D 4 43 ...

Page 44: ...ontinuous display of the load bearing characteristics MN m2 during the compacting pass EVIB value Increase higher load bearing capacity Constant end of compaction Modular upgrading to BTM plus BTM prof and or BCM 05 possible Fig 39 Indicators and Controls BW 213 D 4 44 ...

Page 45: ...button F8 DELETE 7 Vibration frequency display 8 Rotary switch setting of nominal value 9 Push button F14 nominal value increase 10 Push button F13 nominal value decrease 11 not used 12 not used 13 not used 14 not used 15 not used 16 not used 17 Speed display 18 Amplitude display 19 Printer for measuring values only BTM prof 20 Fault light Indicators and Controls BW 213 D 4 45 ...

Page 46: ...1 or EV2 known from the plate load test acc to DIN 18134 n EVIB Display Display of the dynamic soil stiffness in MN m2 n Display for jump operation yellow Symbol Drum jumps red Symbol Drum jumps excessively or tumbles Select a smaller amplitude if necessary n Button F5 START press Starts recording of measuring values Control field F5 flashes green on the screen n Button F6 STOP press Stops recordi...

Page 47: ...easuring value is to be calcu lated on a track press button F8 DELETE only when changing the track n Frequency display with vibration switched on this instrument shows the frequency rotating speed of the exciter shaft n Rotary switch P3 pre setting of nominal values The desired maximum dynamic stiffness modulus EVIB MN m2 can be pre selected in 6 stages 45 80 100 120 150 and Max The selected value...

Page 48: ...h P1 is not used n Button F10 is not used n Button F9 is not used n Speed display Shows the travel speed of the machine n Amplitude display This gauge shows the current vertical amplitude of the machine n Printer for measuring values To print out the measuring data saved during the last pass press button 7 PRINT n Fault light Inform the BOMAG After Sales Service if it lights up Indicators and Cont...

Page 49: ...4 5 Line diagram EVIB only BTM prof Fig 41 Indicators and Controls BW 213 D 4 49 ...

Page 50: ...ion 16 Marking thick line excessive jumping tumbling of the drum 17 Longitudinal raster line 18 Measuring value raster line 19 Diagram line 20 Marking thin line jumping of the drum 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 ...

Page 51: ...ith on this track n Maxiumum EVIB value n Miniumum EVIB value n Mean EVIB value This gauge shows the vertical amplitude the machine is currently working with on this track n EVIB change EVIB change in This always refers to the previous pass in the same direction of travel n Medium frequency n Mean travel speed shows the mean value of speed driven during this pass Always shows the same travel speed...

Page 52: ...mp information Indicates excessive jumping tumbling of the drum on the marked track section thick line Select a smaller amplitude if necessary n Longitudinal raster line n Measuring value raster line n Diagram line 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 n Ma...

Page 53: ...5 Operation Operation BW 213 D 4 53 ...

Page 54: ...ith the controls and indicating elements on this machine you should thoroughly read chapter Indicators and control elements before starting work All indicators and control elements are described in detail in this chapter Operation BW 213 D 4 54 ...

Page 55: ...r condition and leaks hydraulic oil tank and lines for condition and leaks screw joints for tight fit function of steering function of emergency stop function of brakes machine for cleanliness damage presence of the appropriate operating and maintenance instructions proper maintenance of the machine For a description of the following tasks refer to the chapter maintenance every 10 operating hours ...

Page 56: ...ectronic immobilizer armed the light emit ting diode a Ä Fig 42 flashes slowly Slowly enter the six digit user code When entering the code the light emitting diode 6 lights up with every digit Press the diamond button The electronic immobilizer is now disarmed and the engine can be started within the next 15 minutes Fig 42 Operation BW 213 D 4 56 ...

Page 57: ...he operator is fully acquainted with the function of the different control ele ments on the machine Fasten your seat belt Ä Fig 43 Check whether the travel lever Ä Fig 44 is engaged to the right in brake position Switch the rotary switch for vibration amplitude pre selection Ä Fig 45 to position 0 Fig 43 Fig 44 Fig 45 Operation BW 213 D 4 57 ...

Page 58: ...ld ambient temperatures the preheating control lamp b will also light up Do not start before the preheating control lamp b has gone out NOTICE Run the starting process for maximum 20 seconds without interruption and pause for a minute between starting attempts If the engine has not started after two attempts deter mine the cause The starter switch is designed with a re start lock The ignition key ...

Page 59: ...e ignites return the ignition key to posi tion I The engine oil pressure warning light and the charge control light go out The parking brake warning light stays on NOTICE Run the engine warm for a short while before starting work Do not rev up a cold engine to high idle speed full load speed Fig 49 Operation BW 213 D 4 59 ...

Page 60: ...CE 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 The machine is equipped with a seat contact switch safety feature Only with option SN1 If the driver gets up from his seat while driving the signal horn is activated and the machine is slowed down to standstill after four...

Page 61: ...ove the travel lever slowly to forward or reverse The machine drives forward or backward with a speed that corre sponds with the actuation of the travel lever Return the travel lever to position 0 The machine decelerates to standstill WARNING Danger of accident When stopping on inclinations and slopes pull the travel lever to the right and lock it in braking position Fig 51 Fig 52 Fig 53 Operation...

Page 62: ...tion Do not operate jerkily Control the travel speed with the travel lever When driving up and down inclinations move the travel lever slowly back towards neutral to brake the machine If the engine speed drops under load when driving on steep gradients take the travel lever slightly back towards neutral Important notes on travel operation Operation BW 213 D 4 62 ...

Page 63: ...tion and engage it to the right in braking position The machine is automatically braked by the hydrostatic drive and the parking brake is applied The parking brake warning lamp k Ä Fig 55 lights up The parking brake also closes automatically when shutting the engine down Fig 54 Fig 55 Operation BW 213 D 4 63 ...

Page 64: ... braked by the hydrostatic drive and the parking brake is applied The parking brake warning lamp k Ä Fig 57 lights up The parking brake also closes automatically when shutting the engine down Turn the momentary contact switch for engine speed Ä Fig 58 anti clockwise to position MIN idle speed NOTICE Do not shut down the engine all of a sudden from full load speed but let it idle for about 2 minute...

Page 65: ...r P and pull the ignition key out The parking brake closes automatically when shutting the engine down WARNING Danger of accident Secure the machine against unauthorized use pull the ignition key out lock the cabin door Fig 59 Operation BW 213 D 4 65 ...

Page 66: ... with vibration NOTICE Danger of bearing damage Do not activate the vibration on hard frozen concrete ground Turn the rotary travel speed range switch Ä Fig 60 to posi tion turtle Preselect the desired amplitude with the rotary switch for vibration amplitude preselection Ä Fig 61 NOTICE Switch the vibration on only at max engine speed Fig 60 Pre selecting the vibration Fig 61 Switching the vibrati...

Page 67: ...ctuate the vibration push button Ä Fig 63 in the travel lever while driving Press the vibration push button again After the end of work turn the vibration amplitude prese lecting switch Ä Fig 64 back to position 0 Fig 62 Fig 63 Switching the vibration off Fig 64 Operation BW 213 D 4 67 ...

Page 68: ... In case of frequent use the wear on the multi dics brakes will be very high Press the button of the emergency stop switch Ä Fig 65 completely down it automatically locks in fully pressed posi tion Shuts the engine down and closes the brake Turn the button clockwise to unlock the emergency stop switch Start the engine again see chapter Starting the engine If a machine has turned over and the cabin...

Page 69: ... up and move the steering wheel to the desired height Adjustment of steering wheel inclination press lever down and adjust the inclination of the steering wheel WARNING Danger of accident After the adjustment make sure that the steering wheel adjustment is securely locked in place Fig 67 Operation BW 213 D 4 69 ...

Page 70: ...n sight glass c To adjust the inclination of the backrest operate lever a and tilt the backrest forward or back To swivel the seat pull lever b up and turn the seat to the desired direction To adjust the height of the seat lift the seat up Ä Fig 69 until it engages at the desired level When lifting the seat completely it will sink down to lowest position Fig 68 Fig 69 Operation BW 213 D 4 70 ...

Page 71: ...th for about 10 minutes Close all windows completely Turn the air nozzles a Ä Fig 70 to direct the air flow down into the footwell In case of cold or damp weather direct the air flow towards the windscreen and door screens Switch on the fan with the rotary switch c Regulate the temperature with the rotary switch b Close all windows completely Direct the air flow towards the body face a Switch on t...

Page 72: ...the air flow towards the wind screen and door screens Switch on the fan with the rotary switch c Regulate the temperature to Max with the rotary switch b Switch the air conditioning d on Reducing the humidity Operation BW 213 D 4 72 ...

Page 73: ...the lock Ä Fig 71 To open the hood press in the button and turn the handle Pull the support out of the bracket and support the hood Ä Fig 72 Push the hood to top position Pull the spring pin Ä Fig 73 out of the bracket Secure the hood i n the protection tube with spring plug Bottom position Fig 71 Fig 72 Top position Fig 73 Operation BW 213 D 4 73 ...

Page 74: ...sition I Ä Fig 74 The control unit shows the start screen Press Ä Fig 75 to change to the menu screen Press F4 Ä Fig 76 to change to the selection screen for Metric or imperial units Switching between metric and imperial units Fig 74 Fig 75 Fig 76 Operation BW 213 D 4 74 ...

Page 75: ...leasing the key F14 the system automatically returns to the start screen and the control triggers a restart Switch the ignition off and on again Ä Fig 79 Both Asphalt Manager control unit and printer have been set to the new units system With a printer connected the language in the printout can be changed Optional equipment Fig 77 Fig 78 Fig 79 Setting the printer language Operation BW 213 D 4 75 ...

Page 76: ...Ä Fig 81 to change to the menu screen Press F6 Ä Fig 82 to change to the Printer language selection screen Press F11 or F12 Ä Fig 83 to choose the desired printer language The screen shows country flags which represent the associated language Fig 80 Fig 81 Fig 82 Fig 83 Operation BW 213 D 4 76 ...

Page 77: ...Press F14 Ä Fig 84 to save the selection The symbol Save lights green for a moment to confirm Press ESC Ä Fig 85 to return to the start screen Fig 84 Fig 85 Operation BW 213 D 4 77 ...

Page 78: ...and travel speed and on exactly the same track Measuring values must only be compared for passes performed in the same direction The following description describes an measuring pass in forward Measuring passes in reverse must be per formed accordingly Turn the ignition key Ä Fig 86 to position I The BTM plus prof performs a self test Control field F5 Ä Fig 87 lights green General notes Measuring ...

Page 79: ...drum it is necessary to arrange the tracks so that track 1 is processed first followed by further tracks offset to the left Maximum track length 150 m Forward Mark 1 Start of track Mark 2 End of track The operator may also remember the start and the end of the track by means of distinct points Pre select working speed Ä Fig 90 Fig 88 Fig 89 Fig 90 Operation BW 213 D 4 79 ...

Page 80: ...the travel speeds falsify the measuring result Switch the vibration on Ä Fig 93 NOTICE Before reaching mark 1 the nominal exciter shaft speed must have been reached and a valid Evib value should be displayed When mark 1 is reached press button F5 START Ä Fig 94 Control field to the left of F5 lights green The EVIB display shows the present value Fig 91 Fig 92 Fig 93 Fig 94 Operation BW 213 D 4 80 ...

Page 81: ...ed press the button F6 STOP Ä Fig 95 Stop the machine 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 Fig 95 Operation BW 213 D 4 81 ...

Page 82: ... Compared with the previous track the increase of the EVIB value in the same travel direction was less than 10 This criterion is also fulfiled if the EVIB decreases Another pass on this track does not make any sense because an increase in load bearing capacity is hardly possible with this machine If necessary print out the measuring data for this track see following section Repeat the complete com...

Page 83: ...uation 5 sec Bar chart Control field F7 goes out and the measuring value printer starts to print out measuring data After the printing process has finished any amount of diagrams can be printed out by pressing the same button F7 PRINT If no further printouts of this track are needed press the button F8 DELETE Ä Fig 99 when the red control lamp F6 FINISHED lights up The red control field F6 FINISHE...

Page 84: ... star handles Ä Fig 100 and remove the cover Remove shaft 1 Ä Fig 101 with the rest of the paper roll 2 Insert a new paper roll Ä Fig 102 Feed the paper into the guide 1 on the printer Actuate the toggle switch 2 in direction of arrow until the paper comes out of the printer Reassemble the cover Fig 100 Fig 101 Fig 102 Operation BW 213 D 4 84 ...

Page 85: ...crew the star handles Ä Fig 103 and remove the cover Lift the tongue at point 1 Ä Fig 104 and take the printer ribbon 2 out of the printer Insert the new printer ribbon into the printer then press in the tongue 1 on the right Tension the printer ribbon by turning the rotary button 3 in direction of arrow Reassemble the cover Fig 103 Fig 104 Operation BW 213 D 4 85 ...

Page 86: ... be steered Use a towing vehicle with sufficient traction and braking power for the unbraked towed load Do not touch hot engine parts NOTICE Tow the machine only after having released the parking brake Towing speed 1 km h max towing distance 500 m Always secure the machine against unintended rolling Fasten the towing device reliably on the towing points Ä Fig 105 Open the engine compartment hood a...

Page 87: ...e wheel side Unscrew plug 1 Ä Fig 108 to release the brake in the drum drive motor Place clamping disc 4 across the brake housing 2 and turn the screw 5 into the tapped bore 3 until it bottoms Turn the nut 6 down and tighten it for approx one turn The drum must rotate freely NOTICE Apply appropriate measures e g with metal wheel chocks to secure the machine against rolling away before disconnectin...

Page 88: ...l they abut against the brake piston Unscrew the brake releasing screws Ä Fig 111 for two turns and tighten the counter nuts Repeat this adjustment procedure on the opposite wheel side Unscrew the brake releasing screw from the brake in the drum drive motor screw the plug 1 Ä Fig 112 back in and tighten it Fig 110 Fig 111 Fig 112 Operation BW 213 D 4 88 ...

Page 89: ...age before lifting or lashing down the machine Do not use a dam aged or in any other way impaired lifting and lashing eyes Lift the machine only with suitable lifting gear Use only safe lifting gear of sufficient load bearing capacity Min imum lifting capacity of lifting gear see operating weight in chapter Technical Data The machine must not swing about when being lifted Do not step or stand unde...

Page 90: ... four lashing eyes on front and rear frame for this purpose Support the front frame to avoid overstressing of the rubber buffers WARNING Life hazard Do not step or stand under suspended loads For lifting use the four lifting eyes Ä Fig 116 and appro priate lifting gear Fig 114 Fig 115 Loading by crane Fig 116 Operation BW 213 D 4 90 ...

Page 91: ...ssible options such as cabin additional weight etc WARNING Danger of accident The machine cannot be steered if the articulation lock is applied After the transport loosen the articulation lock Ä Fig 118 again fix it in its receptacle and lock it with the spring plug Fig 117 After transport Fig 118 Operation BW 213 D 4 91 ...

Page 92: ...Operation BW 213 D 4 92 ...

Page 93: ...6 Maintenance Maintenance BW 213 D 4 93 ...

Page 94: ... cover it with insulation material When working in the area of the articulated joint attach the articulation lock transport lock 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 and fuels environmen tally Keep used filters in a separate waste container and dispose of environmentally Catch biodegradable o...

Page 95: ...r 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 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 Seal external leaks immediately If necessary inform the re...

Page 96: ...f the engine Engine oils of the same specification can generally be mixed among each other However mixing of engine oil should be avoided because the poorest characteristics of a mixture will always prevail The use of additives for lubrication oils is not permitted The lubrication oil quality has a considerable influence on the life time performance and thus the economy of the engine The fol lowin...

Page 97: ... cause starting difficulties too low viscosity can jeopardize the lubrication effect and result in a high lubrication oil consumption Optimal operating conditions can be achieved by using the oil vis cosity chart as a reference At ambient temperatures below 40 C 40 F the lubrication oil must be pre heated e g by parking the machine indoors 6 2 1 4 Oil change intervals The longest permissible time ...

Page 98: ...n use only winter diesel fuel to avoid clogging because of paraffin separation At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel Diesel fuels suitable for temperatures down to 44 C 47 F are available for Arctic climates NOTICE Danger of engine damage The admixture of petroleum and the addition of flow enhancing additives fuel additives is no...

Page 99: ...er hardness ion content of calcium and magnesium max 3 56 mmol l max 356 mg l ppm Germ degree max 20 dH English degree max 25 eH French degree max 35 6 fH Bacteria fungi yeasts not permitted Information concerning the water quality can be obtained from the waterworks If the fresh water analysis values are unknown these must be determined with the help of a water analysis If the values of the analy...

Page 100: ...bsstoffe und Additive DeutzQuality Class DQC Freigabeliste en SERVICE Operating Liquids and Additi ves Cooling System Conditioner Products of the same product group see Deutz Technical Circular Cooling System Protection Agents can be mixed with each other The BOMAG cooling system protection agent corresponds with product group A NOTICE Danger of engine damage Do not mix different coolants and addi...

Page 101: ...orma tion of manufacturer 6 2 4 2 Bio degradable hydraulic oil The hydraulic system can also be operated with a synthetic ester based biodegradable hydraulic oil The biologically quickly degradable hydraulic oil Panolin HLP Synth 46 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 W...

Page 102: ... of 20 mm2 s at 100 C 212 F This is a hypoid lubricant of highest quality class for extremely loaded transmissions The additives in this oil ensure low wear lubrication under all oper ating conditions 6 2 6 Exciter system For the exciter unit use a fully synthetic gear oil SAE 75W 90 API GL5 Maintenance BW 213 D 4 102 ...

Page 103: ...tion Ä Chapter 6 2 4 1 Mineral oil based hydraulic oil on page 101 009 930 09 20 l 80 l 21 gal us or ester based biodegradable hydraulic oil Specification Ä Chapter 6 2 4 2 Bio degrad able hydraulic oil on page 101 Vibration bearings SAE 75W 90 API GL 5 Specification Ä Chapter 6 2 6 Exciter system on page 102 009 925 05 20 l 1 0 l each 0 26 gal us Drive axle Gear oil SAE 80W 140 API GL 5 Specifica...

Page 104: ...rating hours 6 4 2 After 250 operating hours Tighten all bolted connections on air intake exhaust oil sump and engine mounts Retighten the bolted connections on the machine Retighten the wheel nuts Oil and filter change diesel engine Oil change in drive axle Oil change in wheel hubs Oil change vibration bearings 6 4 3 After 500 operating hours Oil and filter change diesel engine Oil change vibrati...

Page 105: ... Changing engine oil and oil filter cartridge 118 6 8 2 Check clean the water separator 119 6 8 3 Draining the sludge from the fuel tank 120 6 8 4 Battery service 121 6 8 5 Service the air conditioningOptional equipment 122 6 8 6 Cleaning the circulation air filter for the heatingOptional equipment 126 6 8 7 Changing the bypass filterOptional equipment 126 Every 1000 operating hours 6 9 1 Checking...

Page 106: ...ey 144 Every 6000 operating hours 6 12 1 Replace the injection valves 145 6 12 2 Replacing the crank case ventilation valve 145 As required 6 13 1 Air filter maintenance 146 6 13 2 Retightening the padfoot shell 149 6 13 3 Adjust the scrapers 149 6 13 4 Clean the machine 150 6 13 5 Changing the tires 150 6 13 6 Change the fresh air filter in the cabin 151 6 13 7 Fill the provision tank for the win...

Page 107: ... level can be checked imme diately For quality of oil refer to the table of fuels and lubri cants Pull the dipstick Ä Fig 120 out wipe it off with a lint free clean cloth and reinsert it until it bottoms Pull the dipstick back out The oil level must always be between the MIN and MAX marks If the oil level is too low top up oil to the MAX mark immediately 6 6 2 Checking the fuel level NOTICE Do not...

Page 108: ...fumes NOTICE Monitor the entire refuelling process For quality and quantity of fuel refer to the table of fuels and lubricants ENVIRONMENT Catch running out fuel do not let it seep into the ground Shut down the engine Clean the area around the filler opening Open the fuel tank cover Ä Fig 122 NOTICE Contaminated fuel can cause malfunction or even damage of the engine If necessary fill in fuel thro...

Page 109: ...leaks Do not use radiator sealant to seal leaks For quality and quantity of coolant refer to the table of fuels and lubricants Check the coolant level Ä Fig 123 To top up unscrew the filler cap and fill in coolant up to the MAX mark 6 6 4 Check the hydraulic oil level NOTICE In hydraulic systems filled with Panolin HLP Synth 46 always use the same oil to top up With other ester based oils consult ...

Page 110: ... Middle of inspection glass NOTICE 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 If necessary fill in hydraulic oil through the filler neck For quality and quantity of oil refer to the table of fuels and lubricants Fig 124 Maintenance BW 213 D 4 110 ...

Page 111: ... pressures improve the driving stability of the machine The total height of the machine can also be influenced by changing the tire pressure With the tire inflation valve check the air pressure on tire inflation valve 1 Ä Fig 125 with a pressure gauge Nominal value see technical data Ensure equal pressure in all rubber tires Screw the valve caps back on again 6 7 2 Clean the cooling fins on engine...

Page 112: ...exhaust side Blow the cooler Ä Fig 126 out with compressed air NOTICE Protect electrical equipment such as generator regu lator and starter against the direct water jet 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 Run the engine warm for a while to avoid corrosion 6 7 3 Check the oil level in the drive axle P...

Page 113: ... of fuels and lubricants Turn the level inspection plug tightly back in 6 7 4 Check the oil level in the wheel hubs NOTICE Check the oil level in both wheel hubs For quality of oil refer to the table of fuels and lubri cants Park the machine so that the plug 1 Ä Fig 128 is in hori zontal position Clean the area around the plug and unscrew the plug Check the oil level The oil level must reach the b...

Page 114: ... of the drum is in bottom position Thoroughly clean the area around the level inspection and filler plug 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 Screw oil filler 2 and level inspection plug 1 back in tightly Repeat...

Page 115: ... first Then shift the travel lever forward NOTICE The machine should not move during this test However if the machine moves the parking brake needs to be adjusted or repaired Adjustments to the parking brake must only be made by authorized service personnel Only operate the machine after the travel control has been repaired Reconnect the plug to the parking brake solenoid valve Ä Fig 130 Close the...

Page 116: ...mm 0 4 0 6 inches between the V belt pulleys retighten if necessary Slightly slacken fastening screws 1 2 and 3 Ä Fig 134 Press the compressor in direction of arrow until the correct V belt tension is reached Retighten all fastening screws Slightly slacken the fastening screws 1 2 and 3 Press the compressor against the direction of arrow com pletely against the engine Take the old V belt off Fit t...

Page 117: ...NOTICE Check the V belt tension after a running time of 30 minutes Maintenance BW 213 D 4 117 ...

Page 118: ...y of oil refer to the table of fuels and lubricants ENVIRONMENT Catch running out oil and dispose of environmentally together with the oil filter cartridge Unscrew the drain plug and catch running out oil Turn the drain plug tightly back in Thoroughly clean the outside of the filter cartridge Unscrew the filter cartridge using an appropriate filter wrench Clean the sealing face on the filter carri...

Page 119: ... Fire hazard When working on the fuel system do not use open fire do not smoke ENVIRONMENT Any fuel must be caught and disposed of in an envi ronmentally friendly manner 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 check the filter bowl initially every day later ...

Page 120: ...se a new seal ring Once the water separator is empty the warning light for water in fuel must go out 6 8 3 Draining the sludge from the fuel tank WARNING 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 Unscrew the cap Ä Fig 141 and drain off approx 5 litres of ...

Page 121: ...age to the battery as a result of exhaustive discharge The following therefore applies for the service life Switch off all consumers e g ignition light inside light radio Check open circuit voltage of the battery at regular intervals At least once per month Reference values 12 6 V fully charged 12 3 V 50 dis charged Recharge the battery immediately after an open circuit voltage of 12 25 V or less ...

Page 122: ...ingOptional equipment WARNING Danger of accident Do not clean with a hot water jet Heat will cause extreme overpressure which could cause damage or explosion of the system Use access steps and grips to mount and dismount the machine NOTICE A soiled condenser results in a considerable reduction of air conditioning power Under extremely dusty conditions it may be necessary to clean the condenser sev...

Page 123: ...rt the engine Turn the rotary switch for the cab ventilator Ä Fig 144 to position 1 Choose a cooling temperature with the rotary switch for the air conditioning system Ä Fig 145 in the blue section Open the air outlet nozzles Check whether the out flowing air is noticeably cooler Fig 143 Checking the refrigerant level Fig 144 Fig 145 Maintenance BW 213 D 4 123 ...

Page 124: ...ector unit floats at the bottom inform the service department The refrigerant level is not correct Refrigerant must be filled up if necessary check the air con ditioning system for leaks Check the moisture indication pearl Ä Fig 148 inside the inspection glass of the drier collector unit orange Drying agent o k colourless moisture level of drying agent too high Inform the service department Replac...

Page 125: ...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 arising from the handling and operation of pressure reservoirs WARNING Danger of injury In case of mechanical damage or corrosion on this dri...

Page 126: ...quipment WARNING Danger of scalding Danger of scalding by hot oil when unscrewing the oil filter NOTICE 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 Replace the filter element at the latest after one year ENVIRONMENT Dispose of the old filter element environmentally Open the engine hood Ä Fig 151 complet...

Page 127: ...Unscrew the fastening screws Ä Fig 152 and take off the cover Replace the filter element attach the cover and fasten it with the screw Fig 152 Maintenance BW 213 D 4 127 ...

Page 128: ...t down Check the distance between the tongue of the moveable ten sioner arm and the fixed tensioner housing Ä Fig 153 If measurement a is smaller than 3 mm replace the ribbed V belt Unscrew the fastening screws Ä Fig 154 and slide the fan forward Checking the wear limit of the ribbed V belt Fig 153 Changing the ribbed V belt Fig 154 Maintenance BW 213 D 4 128 ...

Page 129: ...inutes 6 9 2 Replace the fuel filter cartridge WARNING Danger of fire health hazard When working on the fuel system do not use open fire do not smoke and do not spill any fuel Do not inhale any fuel fumes NOTICE Ensure strict cleanliness Thoroughly clean the area around the fuel filters The filter cartridge must never be filled beforehand After work on the fuel system bleed the system per form a t...

Page 130: ...lement for another half turn 6 9 3 Change the fuel pre filter cartridge WARNING Danger of fire health hazard When working on the fuel system do not use open fire do not smoke and do not spill any fuel Do not inhale any fuel fumes NOTICE Ensure strict cleanliness Thoroughly clean the area around the fuel filters The filter cartridge must never be filled beforehand After work on the fuel system blee...

Page 131: ...er seal of the filter ele ment 5 7 Turn the filter cartridge on by hand until the seal con tacts then tighten hand tight Plug the water sensor cable back on 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 or working on the fuel system Slacken the b...

Page 132: ...er of scalding When draining off hot oil NOTICE Drain oil only at operating temperature For this pur pose run the machine approx half an hour with vibra tion For quality and quantity of oil refer to the table of fuels and lubricants NOTICE Danger of bearing damage Make sure that no dirt falls into the exciter housing Overfilling causes overheating and destruction of the vibration bearings ENVIRONM...

Page 133: ...re Screw oil filler 2 and level inspection plug 1 back in tightly Repeat the oil change on the opposite side Check the oil level once again at operating temperature after running the machine for about half an hour with vibration 6 9 6 Changing the oil in the drive axle WARNING Danger of scalding When draining off hot oil NOTICE Drain oil only at operating temperature For quality and quantity of oi...

Page 134: ...ough the oil level inspection bores until it has reached the bottom edge of the bore The second level inspection plug as at the back After filling in oil wait until the oil has evenly dis tributed inside the axle Retighten the filler and level inspection plug 6 9 7 Changing the oil in the wheel hubs WARNING Danger of scalding when draining off hot gear oil NOTICE Drain oil only at operating temper...

Page 135: ...g Drain and catch all oil Move the drive wheel until the plug is in horizontal position on the housing Fill in oil until it reaches the bottom edge of the bore Turn the plug tightly back in Change the oil also on the opposite side 6 9 8 Retighten the fastening of the axle on the frame Check all fastening nuts on axle mounting bolts Ä Fig 167 for tight fit Fig 165 Fig 166 Fig 167 Maintenance BW 213...

Page 136: ...anual Inspect the cabin especially the ROPS Ä Fig 169 for cracks corrosion damage and missing fastening parts Unusual movements and noises vibrations during operation are signs for damage or loosened fastening elements Check the fastening screws for the cabin ROPS to the oper ator s stand for tight fit Check the rubber buffers of the operator s platform suspen sion for condition and tight fit Chec...

Page 137: ...s and to braking position Thereby check for function light movement clearance and damage In case of malfunction perform trouble shooting and replace the corresponding parts NOTICE Only operate the machine after the travel control has been repaired Fig 170 Maintenance BW 213 D 4 137 ...

Page 138: ...Firing order 1 3 4 2 Overlapping of valves Exhaust valve not yet closed intake valve starts to open Valves Cylinder overlapping 1 3 4 2 adjustment 4 2 1 3 Loosen the counter nut 1 Ä Fig 171 Attach the rotation angle disc 3 and the spanner socket 4 to the valve clearance adjustment screw 2 Fix the magnet 5 of the rotation angle disc Turn the rotation angle disc clockwise against the stop rocker arm...

Page 139: ...n the hydraulic oil is warm Replace the hydraulic oil filter elements with every hydraulic oil change Change the filter only after the hydraulic oil change and after the test run Clean the area round hydraulic oil tank filler opening and breather filter Do not start the engine after draining the hydraulic oil Do not use any detergents to clean the system Use only lint free cleaning cloths For qual...

Page 140: ...ltration of the hydraulic oil prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system Check the oil level in the inspection glass Nominal value approx 3 cm below the upper edge of the inspection glass The breather filter for the hydraulic oil tank is inte grated in the filler cap you must therefore replace the complete filler cap Close the tank with a new cap 6 10 3 Cha...

Page 141: ...ement thoroughly for any visible dirt NOTICE Visible dirt may be an early sign for the failure of system components and indicate the possible failure of components In this case determine the cause and replace or repair the defective components if neces sary Negligence may cause destruction to the entire hydraulic system Do not clean or reuse the filter element Take the old filter element 3 out and...

Page 142: ...mplete cooling system needs to be cleaned Lubrication oil can damage the sealing materials used in the engine When changing the coolant without any signs of con tamination cleaning of the cooling system is not nec essary For quality and quantity of coolant refer to the table of fuels and lubricants Do not mix different coolants and additives see sec tion Fuelds and Lubricants Coolant ENVIRONMENT C...

Page 143: ...move the thermostat Fill in clean water Start the diesel engine and run it warm to operating tempera ture Allow the engine to cool down to approx 50 C Drain all water off When using a cleansing agent repeat the flushing process twice with clear water Screw the plug back in once all coolant has run out Reinstall the thermostat NOTICE The anti freeze concentration additive must be at least 35 Vol an...

Page 144: ...e assembly bore Take the ribbed V belt 2 first off the smallest pulley Unscrew fastening screws 5 and take off idler pulley Install a new idler pulley and tighten the fastening screw with 80 Nm 59 ft lbs Install the new ribbed V belt Counter the idler pulley with a ratchet and remove the locking pin Check whether the ribbed V belt is correctly seated in the guides Install and tighten the compresso...

Page 145: ... This work must only be performed by authorized service personnel Injection lines must be renewed after they have been loosened three times 6 12 2 Replacing the crank case ventilation valve Replace the crank case ventilation valve Ä Fig 179 Fig 179 Maintenance BW 213 D 4 145 ...

Page 146: ...eaning the air filter must be inspected for damage using a torch Do not continue to use a damaged air filter element If in doubt use a new air filter If the air filter is damaged the safety element must be replaced as well The safety element must not be cleaned We generally recommend to renew the air filter A new filter element is far less expensive than a possible engine damage Maintenance of the...

Page 147: ... protective clothing goggles gloves Blow the air filter out with dry compressed air max 5 bar 70 psi from inside to outside by moving the gun up and down inside the element until it if free of dust Examine the air filter element with a torch for cracks and holes in the paper bellows In case of damage replace the air filter and the safety ele ment Fig 182 Fig 183 Fig 184 Fig 185 Maintenance BW 213 ...

Page 148: ...as been removed The safety element must be replaced if the air filter is damaged at the latest after 1 year if the air filter warning lamp comes on again after the air filter has been cleaned Remove the housing cover and pull the main filter element off Pull the safety element Ä Fig 187 out by turning it lightly Push in a new safety filter element Insert the air filter and reassemble the housing c...

Page 149: ...place the scraper rubber In order to adjust the scrapers 2 Ä Fig 189 slacken the fas tening screws 1 in the slots and push the scraper towards the drum to contact Retighten the fastening screws Check adjustment and condition of front and rear scrapers if necessary adjust or replace the scraper rubber Check adjustment and condition of scrapers Ä Fig 190 adjust or replace the teeth if necessary To a...

Page 150: ...roughly cleaned every day Please observe that the correct function of the scrapers is ensured and that no material will build up between rollers and frame 6 13 5 Changing the tires WARNING Danger of accident Observe all safety regulations for the lifting of loads Place a jack min 5 t bearing capacity under the rear frame and jack the machine up so that the wheel can turn freely Unscrew the wheel n...

Page 151: ...fluid level in the tank Ä Fig 194 top up if neces sary For winter operation fill in the appropriate amount of ant freeze agent refer to the specifications of the manufacturer of the ant freeze agent 6 13 8 Tightening torques Strength classes for screws with untreated non lubricated sur face Screw quality designations are stamped on the screw heads 8 8 8G 10 9 10K 12 9 12K Axle frame M 22x1 5 710 N...

Page 152: ...cified tightening torques do not apply Self locking nuts must always be replaced by new ones after they have been unscrewed 6 13 9 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 Maintenance BW 213 D 4 152 ...

Page 153: ...7 Trouble shooting Trouble shooting BW 213 D 4 153 ...

Page 154: ...aintenance Whenever a fault occurs you should therefore thoroughly read these instruction on correct oper ation and maintenance If you cannot locate the cause of a fault or rectify it yourself by fol lowing the trouble shooting chart you should contact our customer service department Trouble shooting BW 213 D 4 154 ...

Page 155: ...urrent supplying auxiliary battery and then to engine or chassis ground as far away from the battery as possible Start the engine NOTICE Danger of damage to the electronic system If no powerful consumer is switched on voltage peaks may occur when separating the connecting cables between the batteries which could damage electrical components Once the engine is running switch on a powerful consumer ...

Page 156: ...Fig 198 The menu appears on the screen Press key F5 diagnostics Ä Fig 199 The screen with the currently available fault codes is displayed Currently present faults are indicated by a corresponding fault code in the field Actual Errors Fig 197 Fig 198 Fig 199 Fig 200 Trouble shooting BW 213 D 4 156 ...

Page 157: ...Press key ESC Ä Fig 200 to leave the screen page with the actual fault codes Trouble shooting BW 213 D 4 157 ...

Page 158: ...nics prevent starting Check fault by fault code repair as nec essary Engine starts but runs irregularly or misfires V belt ribbed V belt fuel pump in belt drive Check whether torn or loose Incorrect valve clearance Adjustment Injector defective Replace Injection valve defective Check replace if necessary Glow plug defective Replace Air in the fuel system Bleed the fuel system Fuel pre cleaner soil...

Page 159: ...ngine oil with wrong SAE viscosity class Change the engine oil Insufficient engine power Engine oil level too high Check top up or drain off as necessary The fuel quality does not meet the requirements Change the fuel Air filter clogged exhaust turbocharger defective Check replace if necessary Charge air pipe leaking Check Intercooler soiled Clean Injector defective Replace Injection valve defecti...

Page 160: ...e requirements Change the fuel Injection valve defective Check replace if necessary Black engine exhaust smoke Air filter clogged exhaust turbocharger defective Check replace if necessary Charge air pipe leaking Check Injector defective Replace Injection valve defective Check replace if necessary Trouble shooting BW 213 D 4 160 ...

Page 161: ...8 Cab assembly before initial start up Cab assembly before initial start up BW 213 D 4 161 ...

Page 162: ...rdingly This applies also for local regulations con cerning different types of handling work Should the recom mendations in these instructions be different from the regula tions valid in your country you must comply with the safety regulations valid in your country Unauthorized changes to the cabin are prohibited for safety rea sons Original parts and accessories have been specially designed for t...

Page 163: ...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 8 1 Preparations WARNING Danger of accident For transport purposes the driver s seat must be tied down with cable straps thus to operate the seat con tact switch Before resuming operation of the machine these cable straps must strictly be...

Page 164: ... mat step plate and fastening kit are available Fasten the lifting gear to the four lifting eyes 1 Ä Fig 202 Loosen possible fastening on the transport pallet Slowly list the crane with a crane WARNING Danger of accident Do not stand or step under loads being lifted Fig 201 Fig 202 Cab assembly before initial start up BW 213 D 4 164 ...

Page 165: ...unting 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 Stick the sealing tape 1 Ä Fig 204 all around the operator s stand 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 Mount the cabin immediately after sticking on the s...

Page 166: ... s stand NOTICE Take care that none of the hoses and electric cables become squashed Ä Fig 207 Run cables and hoses from inside the cabin through the operator s stand to the outside Turn both fastening screws Ä Fig 208 at the rear of the cabin in handtight Fig 206 Fig 207 Fig 208 Cab assembly before initial start up BW 213 D 4 166 ...

Page 167: ...g screw on the access side Ä Fig 210 with 578 Nm Loosen both fastening screws Ä Fig 211 at the rear of the cabin again The cabin will now slide into final assembly position Tighten both fastening screws Ä Fig 211 at the rear of the cabin with 578 Nm Fig 209 Fig 210 Fig 211 Cab assembly before initial start up BW 213 D 4 167 ...

Page 168: ...eral fastening screw on the right hand side with 578 Nm Ä Fig 213 Tighten the rear inside fastening screw on the right hand side with 578 Nm Ä Fig 214 Turn nuts with washers onto both studs and tighten with 200 Nm Ä Fig 215 Fig 212 Fig 213 Fig 214 Fig 215 Cab assembly before initial start up BW 213 D 4 168 ...

Page 169: ...m Ä Fig 216 Tighten the front lateral fastening screw on the left hand side with 578 Nm Ä Fig 217 Cover all lateral fastening screws with plastic caps Ä Fig 218 Insert the foot mat 1 Ä Fig 219 Fig 216 Fig 217 Fig 218 Fig 219 Cab assembly before initial start up BW 213 D 4 169 ...

Page 170: ...refully into the bores with a hammer Ä Fig 222 Connect the feed 1 Ä Fig 223 and the return flow 2 for the air conditioning system with quick release couplings Connect the feed 4 and the return flow 3 of the heating Observe the marks on the hoses Run the connecting lines for the heating parallel to each other do not cross Fig 220 Fig 221 Fig 222 Fig 223 Cab assembly before initial start up BW 213 D...

Page 171: ...and rear windscreens 1 Ä Fig 225 Check the function of the washing water system within the scope of the function test Insert the plug 1 Ä Fig 226 into the socket 2 Close the bayonet catch by turning the corrugated cap nut in clockwise direction against the stop WARNING Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material Fig 224 Fig ...

Page 172: ...Connect the plug connection of the air conditioning system Ä Fig 227 Fig 227 Cab assembly before initial start up BW 213 D 4 172 ...

Page 173: ...hes for front and rear windscreen washer system and check their correct function If the function of the windscreen washer system is reversed the two washing water hoses must be inter changed Start the engine Switch the air conditioning on by the switch After a five minute operation the cabin must become noticeably cooler Switch the air heater on by the switch After a five minute operation the cabi...

Page 174: ...Cab assembly before initial start up BW 213 D 4 174 ...

Page 175: ...9 Disposal Disposal BW 213 D 4 175 ...

Page 176: ...cid Do not let acid come in con tact with skin or clothes Wear protective clothing Remove the batteries and dispose of in compliance with legal regulations ENVIRONMENT Catch all fuels and lubricants do not let them seep into the ground and dispose of in compliance with legal regulations Empty the fuel tank Drain the hydraulic oil tank Drain coolant from engine and cooling system Drain off engine a...

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