Page 1 Operating Instruction Maintenance Instruction Original Operating Instructions BW 213 D-5 S/N 101 586 48 1001> Single drum roller 008 202 10 EN © 08/2016...
Page 3: Table Of Contents
Table of contents Table of contents Introduction.................... 9 1.1 Foreword..................10 1.2 Machine type plate and engine type plate......... 13 Technical data..................15 2.1 Noise and vibration data.............. 19 2.1.1 Noise data................... 19 2.1.2 Vibration data................19 Concerning your safety..............21 3.1 General prerequisites..............
Page 4 Table of contents 3.4.6 Safety regulations and environmental protection regulations for handling battery acid..............41 3.5 Load/transport the machine............43 3.6 Start-up procedure............... 45 3.6.1 Prior to starting up............... 45 3.6.2 Starting the engine..............46 3.6.3 Starting the engine with jump leads..........46 3.7 Operating the machine, working operation.......
Page 5 Table of contents 4.2 Cabin..................... 74 4.2.1 Control panel, cabin..............74 4.2.2 Heating / air conditioning ............75 4.2.3 12 V DIN socket................77 4.2.4 Monitor for reversing camera............78 4.2.5 Fire extinguisher................79 4.3 Engine compartment..............80 4.3.1 Main battery switch..............80 4.4 Outside of machine..............
Page 6 Table of contents 6.6 Terrameter................... 107 6.6.1 Terrameter display..............107 6.6.2 Terrameter with printer.............. 108 6.6.3 Line graph (E )................ 112 6.7 Park the machine in secured condition........115 6.8 Operating the heating / air conditioning system..... 116 6.9 ECOSTOP..................117 6.10 Emergency procedures............
Page 7 Table of contents 8.5.3 After 500 operating hours............151 8.5.4 After 1000 operating hours............151 8.6 Maintenance table..............152 8.7 Every 250 operating hours............154 8.7.1 Cleaning the radiator module............ 154 8.7.2 Service the belt drive..............156 8.7.3 Checking the oil level in the drive axle........158 8.7.4 Checking the oil level in the wheel hubs........
Page 8 Table of contents 8.11 As required................196 8.11.1 Air filter maintenance............... 196 8.11.2 Checking, cleaning the water separator........199 8.11.3 Retightening the padfoot shell..........200 8.11.4 Adjust the scrapers..............201 8.11.5 Filling the windscreen washer tank.......... 201 8.11.6 Replacing the paper roll in the printer........201 8.11.7 Replacing the printer ribbon in the printer.......
Page 9: Introduction
Introduction Introduction BW 213 D-5...
Page 10: Foreword
Introduction – Foreword Foreword BOMAG manufactures machines for earth, asphalt and refuse compaction, stabilizers/ recyclers as well as planers and pavers. BOMAG’s vast experience in connection with state-of-the-art production and testing methods, such as lifetime tests of all impor- tant components and highest quality demands guarantee maximum reliability of your machine.
Page 11 Introduction – Foreword You should only operate the machine in compli- ance with these instructions. Strictly observe the safety regulations. If you are not yet acquainted with the controls and indicating elements on this machine, you should thoroughly read the corresponding Ä...
Page 12 Introduction – Foreword The above notes do not constitute an extension of the warranty and liability conditions specified in the general sales and delivery conditions of BOMAG GmbH. We wish you successful work with your BOMAG machine. BW 213 D-5...
Page 13: Machine Type Plate And Engine Type Plate
Introduction – Machine type plate and engine type plate Machine type plate and engine type plate Please enter here: Machine type (1): Serial number (2): Fig. 1: Machine type plate (example) Please enter here: Engine type (1): Engine number (2): Fig.
Page 14 Introduction – Machine type plate and engine type plate BW 213 D-5...
Page 15: Technical Data
Technical data Technical data BW 213 D-5...
Page 16 Technical data Dimensions Fig. 3 2975 2270 1500 2250 2990 5870 2130 (117) (89) (59) (89) (118) (19.3) (231) (2.8) (1.2) (84) Dimensions in millimetres (Dimensions in inch) Weights Max. operating weight 14800 (32628) (lbs) Operating weight with ROPS cabin (CECE) 12510 (27580) (lbs)
Page 17 Technical data Travel characteristics Travel speed (1) 0 – 5 km/h (0 – 3.1) (mph) Travel speed (2) 0 – 6 km/h (0 – 3.7) (mph) Travel speed (3) 0 – 8 km/h (0 – 5.0) (mph) Travel speed (4) 0 –...
Page 18 Technical data Brakes Service brake hydrostatic Parking brake hydro-mechanical Steering Type of steering Oscill.-articul. Steering angle +/- 35 ° Oscillation angle +/- 12 ° Inner track radius 3680 (145) (in) Exciter system Drive system hydrostatic Frequency (1/2) 30/34 (1800/2040) (vpm) Amplitude (1/2) 2.10/1.10 (0.083/0.043)
Page 19: Noise And Vibration Data
Technical data – Noise and vibration data Noise and vibration data The following noise and vibration data were determined in accordance with the following guidelines under equipment specific conditions and by using harmonized standards: EC Machine Directive edition 2006/42/EC Noise Emission Directive 2000/14/EC, Noise Protection Directive 2003/10/EC Vibration Protection Directive 2002/44/EC During operation these values may vary...
Page 20 Technical data – Noise and vibration data BW 213 D-5...
Page 21: Concerning Your Safety
Concerning your safety Concerning your safety BW 213 D-5...
Page 22: General Prerequisites
Concerning your safety – General prerequisites General prerequisites 3.1.1 General This BOMAG machine has been built in compli- ance with the latest technical standard and complies with the applicable regulations and technical rules. However, dangers for persons and property may arise from this machine, if: it is used for purposes other than the ones it is intended for, it is operated by untrained personnel,...
Page 23: Explanation Of Warning Signs
Concerning your safety – General prerequisites 3.1.2 Explanation of warning signs: DANGER! Danger to life if failing to comply! Sections marked accordingly indi- cate an extremely dangerous situa- tion that could lead to fatal or severe injuries, if this warning is dis- regarded.
Page 24: Personal Protective Equipment
Concerning your safety – General prerequisites Sections marked accordingly indi- cate technical information or notes on using the machine or its compo- nents. ENVIRONMENT! Environmental damage if failing to comply! Paragraphs marked accordingly indicate practices for safe and envi- ronment-friendly disposal of fuels and lubricants as well as replace- ment parts.
Page 25: Intended Use
Concerning your safety – General prerequisites Face protection To protect the face against airborne par- ticles and fluid squirts. Hard hat To protect the head against falling parts and to protect against injuries. Hearing protection To protect the hearing against too loud noise.
Page 26 Concerning your safety – General prerequisites Examples for improper use are: work with vibration on hard concrete, cured bitumen layers or extremely frozen ground driving on unstable subbases or too small contact area (danger of tipping over) Using the machine for towing use to pull down walls or demolish buildings transporting persons, except the machine driver, is prohibited.
Page 27: Definition Of Responsible Persons
Concerning your safety – Definition of responsible persons Definition of responsible persons 3.2.1 Operating company The operating company is the natural or jurid- ical person who uses the machine or in who's name the machine is used. The operating company must make sure that the machine is only used for the purpose it is intended for and in strict compliance with the safety regulations mentioned in these operating...
Page 28: Driver / Operator
Concerning your safety – Definition of responsible persons This person is acquainted with the applicable governmental industrial safety regulations, accident prevention instructions, guidelines and generally acknowledged technical rules and regulations (standards, directives, technical rules of other member states of the European Union or other contractual states concerning the agreement about the European Economic Area) in as far as is necessary to be able to...
Page 29: Fundamentals For Safe Operation
Concerning your safety – Fundamentals for safe operation Fundamentals for safe operation 3.3.1 Remaining dangers, remaining risks Despite careful work and compliance with standards and regulations it cannot be ruled out that further dangers may arise when working with and handling the machine. Both the machine as well as all other system components comply with the currently valid safety regulations.
Page 30: Damage, Defects, Misuse Of Safety Devices
Concerning your safety – Fundamentals for safe operation We wish to make explicitly clear that we have not tested or approved any parts or accesso- ries not supplied by us. The installation and/or use of such products may have an adverse effect on the active and/or passive safety.
Page 31 Concerning your safety – Fundamentals for safe operation A defect ROPS must generally be replaced with an original spare part in close coordination with the manufacturer. BW 213 D-5...
Page 32: Handling Fuels And Lubricants
Concerning your safety – Handling fuels and lubricants Handling fuels and lubricants 3.4.1 Preliminary remarks The operating company must ensure that all professional users have read and follow the corresponding safety data sheets for the indi- vidual fuels and lubricants. Safety data sheets provide valuable informa- tion about the following characteristics: Name of substance...
Page 33: Safety Regulations And Environmental Protection Regulations For Handling Diesel Fuel
Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.2 tions for handling diesel fuel WARNING! Danger of burning by ignited diesel fuel! – Do not allow diesel fuel to come into contact with hot compo- nents.
Page 34 Concerning your safety – Handling fuels and lubricants ENVIRONMENT! Diesel fuel is an environmentally hazardous substance – Always keep diesel fuel in proper containers. – Immediately bind spilled diesel fuel with an oil-binding agent. – Dispose of diesel fuel and fuel fil- ters according to regulations.
Page 35: Safety Regulations And Environmental Protection Regulations For Handling Oil
Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.3 tions for handling oil WARNING! Danger of burning by ignited oil! – Do not allow oil to come into con- tact with hot components. – Smoking and open fire is pro- hibited! –...
Page 36 Concerning your safety – Handling fuels and lubricants – Immediately bind spilled oil with an oil-binding agent. – Dispose of oil and oil filter according to regulations. BW 213 D-5...
Page 37: Safety Regulations And Environmental Protection Regulations For Handling Hydraulic Oil
Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.4 tions for handling hydraulic oil WARNING! Danger of injury caused by escaping pressure fluid! – Always depressurize the hydraulic system before starting work in the hydraulic system. –...
Page 38 Concerning your safety – Handling fuels and lubricants CAUTION! Health hazard caused by contact with hydraulic oil! – Wear your personal protective equipment (protective gloves, protective clothing). – Do not inhale any oil vapours. – Avoid contact. CAUTION! Danger of slipping on spilled oil! –...
Page 39: Safety Regulations And Environmental Protection Regulations For Handling Coolants
Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.5 tions for handling coolants WARNING! Danger of scalding by hot fluid! – Open the compensation tank only when the engine is cold. – Wear your personal protective equipment (protective gloves, protective clothing, goggles).
Page 40 Concerning your safety – Handling fuels and lubricants – Immediately bind spilled coolant with an oil-binding agent and dis- pose of it according to regula- tions. – Dispose of coolant according to regulations. BW 213 D-5...
Page 41: Safety Regulations And Environmental Protection Regulations For Handling Battery Acid
Concerning your safety – Handling fuels and lubricants Safety regulations and environmental protection regula- 3.4.6 tions for handling battery acid WARNING! Danger of cauterization with acid! – Wear your personal protective equipment (protective gloves, protective clothing, goggles). – Do not allow clothes, skin or eyes to come into contact with acid.
Page 42 Concerning your safety – Handling fuels and lubricants ENVIRONMENT! Battery acid is an environmen- tally hazardous substance – Dispose of battery and battery acid according to regulations. BW 213 D-5...
Page 43: Load/Transport The Machine
Concerning your safety – Load/transport the machine Load/transport the machine Use only stable loading ramps of sufficient load bearing capacity. Loading ramps and transport vehicle must be free of grease, oil, snow and ice. The ramp inclination must be less than the gradability of the machine.
Page 44 Concerning your safety – Load/transport the machine After the transport loosen the articulation lock again, as otherwise the machine wouild not be steerable. BW 213 D-5...
Page 45: Start-Up Procedure
Concerning your safety – Start-up procedure Start-up procedure 3.6.1 Prior to starting up Use only machines which are serviced at reg- ular intervals. Become acquainted with the equipment, the indicators and control elements, the working principle of the machine and the working area. Use your personal protective equipment (hard hat, safety boots, if necessary also goggles and ear protection).
Page 46: Starting The Engine
Concerning your safety – Start-up procedure 3.6.2 Starting the engine The machine must only be started and oper- ated from the driver’s seat. Before starting and moving the machine make sure that there are no persons inside the danger zone. For starting set all control levers to "neutral position".
Page 47: Operating The Machine, Working Operation
Concerning your safety – Operating the machine, working operation Operating the machine, working operation 3.7.1 Persons in the danger area Before taking up work, also after breaks, you should always convince yourself that the danger zone is free of persons or obstructions, especially when driving in reverse.
Page 48: Driving On Gradients And Slopes
Concerning your safety – Operating the machine, working operation In case of unusual noises and development of smoke perform trouble shooting and have the fault corrected. Match the speed to the working conditions. Do not make extreme steering movements when driving with high speed, danger of tipping over! Always give way to loaded transport vehicles.
Page 49: Cross-Slope
Concerning your safety – Operating the machine, working operation 3.7.4 Cross-slope The tipping angle was measured statically on level, hard ground with the machine stopped and without steering. The max. permissible inclination of the machine may be limited by the max. permis- sible slanted position of the engine.
Page 50 Concerning your safety – Operating the machine, working operation shut down the engine, pull off the ignition key, pull off the main battery switch, secure the machine against unintended use. Do not jump off the machine, but use hand grips and access steps. Mark machines, which could be in the way, with a clearly visible sign.
Page 51: Refuelling
Concerning your safety – Refuelling Refuelling 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. Static charges may be generated in the fuel as it passes through the filling system.
Page 52: What To Do In Events Of Emergency
Concerning your safety – What to do in events of emergency What to do in events of emergency 3.9.1 Actuating the emergency stop switch In events of emergency and in case of danger actuate the emergency stop switch immedi- ately. The machine is braked immediately, the engine is shut down.
Page 53 Concerning your safety – What to do in events of emergency Before starting towing operations make sure that the fastening means are able to withstand the load and are fastened at the points pro- vided for this purpose. Before removing the towing facility apply appropriate measures to secure the machine against unintended rolling.
Page 54: Maintenance Work
Concerning your safety – Maintenance work 3.10 Maintenance work 3.10.1 Preliminary remarks Adhere to the specified operating, maintenance and repair measures. The machine must only be serviced by quali- fied and authorized personnel. Keep unauthorized persons away from the machine. Do not perform maintenance work while the machine is driving or the engine is running.
Page 55: Working On The Engine
Concerning your safety – Maintenance work Do not step in front of or behind the machine when performing adjustment work in the hydraulic system. Do not change the setting of pressure relief valves. Drain the hydraulic oil at operating temperature –...
Page 56: Maintenance Work On Electric Components And Battery
Concerning your safety – Maintenance work Wipe off spilled oil, collect leaking oil and dis- pose of it in an environmentally friendly way. Store used filters and other oil contaminated materials in a separate, specially marked con- tainer and dispose of them environmentally. The settings for idle speed and highest speed must not be changed, since this would affect the exhaust gas values and cause damage to...
Page 57: Working On Wheels And Tyres
Concerning your safety – Maintenance work Do not perform welding work in the vicinity of the air conditioning. Danger of explosion! Do not clean the condenser in the air condi- tioning system with a hot water jet. Danger of explosion! Do not release refrigerant into the atmosphere, but dispose of environmentally.
Page 58: After Maintenance Work
Concerning your safety – Maintenance work Do not use gasoline or other easily inflam- mable substances for cleaning. When cleaning with a high pressure cleaner do not direct the wter jet to electrical insulation material or cover it beforehand. Do not guide the water jet into the exhaust pipe and into the air filter.
Page 59: Repair
Concerning your safety – Repair 3.11 Repair Identify a defect machine with a warning sign. Only operate the machine after it has been repaired. Repairs must only be performed by an expert/ qualified person. When replacing safety relevant components, only original spare parts must be used. BW 213 D-5...
Page 60: Signage
Concerning your safety – Signage 3.12 Signage Keep stickers and decals in good and legible condition and comply with their meaning. Replace damaged and illegible stickers or decals immediately. Fig. 10 1 Warning sticker - Danger of crushing 2 Information sticker - Lifting point 3 Information sticker - Lashing point 4 Information sticker - Engine oil drain 5 Information sticker - Coolant drain...
Page 61 Concerning your safety – Signage Fig. 11 1 Information sticker - Diesel 2 Information sticker - Main battery switch plus side 3 Warning sticker - Vehicle voltage 12 V 4 Operation sticker - Main battery switch 5 Information sticker - Hydraulic oil BW 213 D-5...
Page 62 Concerning your safety – Signage Instruction sticker - Always wear your seat belt Fig. 12 BW 213 D-5...
Page 63: Display And Control Elements
Display and control elements Display and control elements BW 213 D-5...
Page 64: Driver's Stand
Display and control elements – Driver's stand Driver's stand 4.1.1 Instrument cluster Fig. 13 1 Control and warning lamps 2 INFO 3 display field 3 INFO 2 display field 4 INFO 1 display field 5 Engine rpm-meter 6 not used 7 Fuel level gauge 8 not used 9 Button [Reduce frequency]...
Page 65 Display and control elements – Driver's stand Control and warning lamps Designation Note Air filter warning Lights up if the air filter is blocked. lamp Clean or replace the air filter. Water in fuel Lights up when the water content in the fuel warning lamp pre-cleaner reaches the sensor contacts, the warning buzzer sounds.
Page 66 Display and control elements – Driver's stand Designation Note Hydraulic oil temper- Lights up if the hydraulic oil temperature is too ature warning lamp high. The engine power is reduced after a short while. Run the engine with idle speed or shut it down if necessary and clean the radiator.
Page 67 Display and control elements – Driver's stand INFO 2 display field Each actuation of the button switches between: Travel speed -value (optional equipment) Travel speed and E -value (optional equip- ment) Fig. 15 press the left to reduce the vibration fre- button quency press the right...
Page 68: Operating Console
Display and control elements – Driver's stand 4.1.2 Operating console Fig. 17 1 Emergency stop switch 2 Rotary switch for amplitude pre-selection 3 Rotary switch for working lights (optional equipment) 4 Rotary switch for engine speed 5 Rotary switch for direction indicators (optional equipment) 6 Rotary switch for hazard light system (optional equipment) 7 Rotary switch for lighting (optional equipment) 8 Rotary switch for travel ranges...
Page 69 Display and control elements – Driver's stand 4.1.2.1 Emergency stop switch press In events of emergency and in case of danger actuate the emergency stop switch immediately by pressing it fully down. It automatically locks in end position. The machine will be braked immediately.
Page 70 Display and control elements – Driver's stand 4.1.2.3 Rotary switch for working lights Position “Left” Working lights off Position “Right” Working lights on Optional equipment Fig. 20 4.1.2.4 Rotary switch for engine speed Position “Left” Idle speed position (MIN) Position ECO -mode “Middle”...
Page 71 Display and control elements – Driver's stand 4.1.2.6 Rotary switch for hazard light system Position "Left" Hazard light system off Position "Right" Hazard light system on Optional equipment Fig. 23 4.1.2.7 Rotary switch for lighting Position "Left" Light off Position Side light on “Middle”...
Page 72: Travel Lever
Display and control elements – Driver's stand 4.1.2.9 Starter switch Position "P"/"0" Ignition off Ignition key can be removed Position "I"/"II" Ignition on All control and warning lamps light up for a moment (test function). Under low temperatures the Fig. 26 preheating control lamp lights up.
Page 73 Display and control elements – Driver's stand Fig. 28 Pos. Designation Note Warning horn not used Vibration Vibration on/off not used not used Function key [F1] Switch over the INFO 1 display field Function key [F2] Switch over the INFO 2 display field BW 213 D-5...
Page 74: Cabin
Display and control elements – Cabin Cabin 4.2.1 Control panel, cabin Fig. 29 Pos. Designation Note not used not used Push button to start measure- only for Terrameter with printer ment LED lights: Measurement pos- sible. LED flashing: Measurement active. Push button to stop measure- only for Terrameter with printer ment...
Page 75: Heating / Air Conditioning
Display and control elements – Cabin Pos. Designation Note not used not used Push button for rear windscreen Interval/on/off wiper Push button for rear windscreen wiper Push button for rear windscreen The rear windscreen heating is heating shut down after three minutes. Push button for rear working lights Push button for inside cabin light...
Page 76 Display and control elements – Cabin 4.2.2.2 Rotary switch for cabin temperature Position "Top" max. temperature Position min. temperature "Bottom" Fig. 31 4.2.2.3 Rotary switch for blower Position "0" ventilator off Position "1" to Fan stages of different "3" strengths Fig.
Page 77: Din Socket
Display and control elements – Cabin 4.2.3 12 V DIN socket Permanent current, loadable up to 20 A. Fig. 34 BW 213 D-5...
Page 78: Monitor For Reversing Camera
Display and control elements – Cabin 4.2.4 Monitor for reversing camera Fig. 35 Pos. Designation Note Button on/off Push button for camera Within menus to confirm the selec- selection tion. Push button for menu selec- Press briefly (approx. 0.5 s), to tion change to the "DISPLAY MENU".
Page 79: Fire Extinguisher
Display and control elements – Cabin Clean the ventilation slots on the monitor occasionally with a cloth or a brush. 4.2.5 Fire extinguisher Optional equipment NOTICE! Components may get damaged! – When retrofitting a fire extin- guisher, install it only in this posi- Fig.
Page 80: Engine Compartment
Display and control elements – Engine compartment Engine compartment 4.3.1 Main battery switch Position “On” Main battery switch locked Normal position, operation turn counter- Main battery switch can be clockwise pulled off Isolates the batteries from the on-board electrics in case of cable fire and fire in the engine compartment as Fig.
Page 81: Outside Of Machine
Display and control elements – Outside of machine Outside of machine 4.4.1 Reversing camera With the monitor connected it enables the driver to check the working range behind the machine without direct vision. Optional equipment Fig. 38 BW 213 D-5...
Page 82 Display and control elements – Outside of machine BW 213 D-5...
Page 83: Tests Before Taking Into Operation
Tests before taking into operation Tests before taking into operation BW 213 D-5...
Page 84: Notes On Safety
Tests before taking into operation – Notes on safety Notes on safety If the following tests reveal damages or other faults, the machine must not be operated, until these deficiencies have been corrected. Safety installations and switches must neither be removed nor must they be made ineffective. Do not change any fixed settings.
Page 85 Tests before taking into operation – Notes on safety Ä Chapter Open and secure the engine hood 8.2.1 „Open and secure the engine hood“ on page 136. Close the engine hood again after work is com- pleted. BW 213 D-5...
Page 86: Visual Inspections And Function Tests
Tests before taking into operation – Visual inspections and function tests Visual inspections and function tests 1. Check hydraulic oil tank and lines for con- dition and leaks. 2. Check fuel tank and lines for condition and leaks. 3. Check cooling system for contamination, damage and leakage.
Page 87: Checking The Engine Oil Level
Tests before taking into operation – Checking the engine oil level Checking the engine oil level NOTICE! Danger of engine damage! – If the engine is warm, shut it down and check the oil level after five minutes. With a cold engine the oil level can be checked immediately.
Page 88: Checking The Fuel Level, Topping Up Fuel
Tests before taking into operation – Checking the fuel level, topping up fuel Checking the fuel level, topping up fuel 5.4.1 Checking the fuel level 1. Check the fuel level on the fuel gauge. 2. Refuel if required, shut the engine down to do so.
Page 89 Tests before taking into operation – Checking the fuel level, topping up fuel Protective equip- Working clothes ment: Protective gloves 1. Clean the area around the filler opening. 2. Unscrew the cap and fill in fuel. 3. Close the cap. Fig.
Page 90: Checking The Hydraulic Oil Level
Tests before taking into operation – Checking the hydraulic oil level Checking the hydraulic oil level NOTICE! Components may get damaged! – Check the hydraulic oil level at room temperature (approx. 20 °C (68 °F)). – If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components...
Page 91: Checking The Coolant Level
Tests before taking into operation – Checking the coolant level Checking the coolant level NOTICE! Danger of engine damage! – If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks. –...
Page 92 Tests before taking into operation – Checking the coolant level 3. Unscrew the cap and fill in coolant up to the “MAX” mark. 4. Close the cap. BW 213 D-5...
Page 93: Checking Wheels And Tyres
Tests before taking into operation – Checking wheels and tyres Checking wheels and tyres WARNING! Danger of being injured by bursting tyres! – Wear your personal protective equipment (safety shoes, gloves, goggles, hard hat). – When checking the tyre pressure stand in the extension of the tyre tread.
Page 94 Tests before taking into operation – Checking wheels and tyres Protective equip- Safety shoes ment: Protective gloves Safety goggles Hard hat 1. Move the machine until the tire inflation valve (1) is in top position. 2. Park the machine in secured condition Ä...
Page 95: Operation
Operation Operation BW 213 D-5...
Page 96: Setting-Up The Work Place
Operation – Setting-up the work place Setting-up the work place 1. Park the machine in secured condition Ä Chapter 6.7 „Park the machine in secured condition.“ on page 115. 6.1.1 Adjust the driver’s seat 1. To adjust the inclination of the backrest operate lever (d) and tilt the backrest for- ward or back.
Page 97: Swivelling The Driver's Seat
Operation – Setting-up the work place 6.1.2 Swivelling the driver’s seat 1. Pull the lever and swivel the driver’s seat to the desired position. Optional equipment Fig. 48 6.1.3 Adjust the steering wheel 1. To adjust the inclination kick the pedal down, move the steering wheel to the desired position and release the pedal.
Page 98: Electronic Immobilizer
Operation – Electronic immobilizer Electronic immobilizer Optional equipment Before starting the engine the anti-theft protec- tion* must be disarmed by entering a code. With the electronic immobilizer armed, the light emitting diode (a) flashes slowly. 1. Slowly enter the six-digit user code. ð...
Page 99: Start The Engine
Operation – Start the engine Start the engine Prerequisites: Main battery switch switched on Emergency stop switch unlocked Travel lever in position “Middle right” (parking brake closed) 1. Turn the rotary switch for engine speed to position “Middle” (ECO-mode). Fig. 51 2.
Page 100 Operation – Start the engine The starter switch is designed with a re-start lock. The ignition key must first be turned back to position "0" before a new starting attempt can be made. NOTICE! Components may get damaged! – Run the starting process for max- imum 20 seconds without inter- ruption and pause for a minute between starting attempts.
Page 101: Travel Operation
Operation – Travel operation Travel operation 6.4.1 Preliminary remarks and safety notes DANGER! Danger to life caused by the machine turning over! – Never drive across a slope. – Always drive straight up or down a slope. Do not drive on gradients exceeding the max- Ä...
Page 102: Applying The Parking Brake
Operation – Travel operation 3. Turn the rotary switch for engine speed to position “Middle” (ECO-mode). Fig. 56 4. Disengage the travel lever to the left out of parking brake position and move it slowly to the desired travel direction. ð...
Page 103: Notes On Travel Operation
Operation – Travel operation 6.4.4 Notes on travel operation If the operator leaves his seat while travelling, the driver's seat warning lamp will light up. The machine is automatically decelerated down to standstill and the parking brake is applied after a short delay.
Page 104: Working With Vibration
Operation – Working with vibration Working with vibration 6.5.1 Preliminary remarks and safety notes NOTICE! Possible damage to neigh- bouring buildings! – When compacting with vibration you must always check the effect of the vibration on nearby build- ings and underground supply lines (gas, water, sewage, elec- tric power).
Page 105: Switching The Vibration On And Off
Operation – Working with vibration 6.5.2 Switching the vibration on and off Vibration is automatically switched off in travel range 1 and 5. 1. Turn the rotary switch for travel speed ranges to the desired position. Fig. 60 Pre-selecting the vibra- tion 2.
Page 106 Operation – Working with vibration Changing the frequency 5. If required, change the vibration frequency using both buttons on the instrument cluster. Fig. 63 Switching the vibration 6. Press the push button once again to switch off vibration. ð Vibration is switched off. Fig.
Page 107: Terrameter
Operation – Terrameter Terrameter 6.6.1 Terrameter display With the permanent display of the compaction value (E value) weak spots can be detected during compaction work and unnecessary passes avoided. Optional equipment 1. Press push button INFO 2 on the travel Fig.
Page 108: Terrameter With Printer
Operation – Terrameter 6.6.2 Terrameter with printer Preliminary remarks Optional equipment In case of a Terrameter with printer, the com- paction values (E values) can be saved, compared with each other and printed out. The (E values) recorded during different passes can only be compared, if the recording of measuring values took place with the same amplitude, frequency and travel speed and on...
Page 109 Operation – Terrameter Measuring pass with Ter- rameter 1. Mark the track to be compacted. Fig. 67 2. Select display of E values. ð When working with vibration, the actual value will now be displayed. Fig. 68 BW 213 D-5...
Page 110 Operation – Terrameter 3. Shift the travel lever to the desired travel direction. 4. Press the vibration push button on the travel lever. ð Vibration is switched on. Before reaching mark 1 the nominal exciter shaft speed must have been reached and a valid E value should be displayed.
Page 111 Operation – Terrameter 8. For the second pass press push button “Start measurement” to start the measuring pass when reaching mark 1. ð The measuring pass will be continued. Fig. 72 9. Keep repeating these passes, until there is no considerable increase in the E value.
Page 112: Line Graph (E )
Operation – Terrameter 13. Operate the “Delete measurement” button to delete all saved data. Fig. 76 6.6.3 Line graph (E Fig. 77 Pos. Designation Note Pass Total number of measured passes on this track. Travel direction Software status of the measuring equipment BW 213 D-5...
Page 113 Operation – Terrameter Pos. Designation Note set language Please contact our Customer Service if you want to change the language. Serial number of machine Machine type Amplitude Display of the vertical amplitude the machine has worked with on this track. Maximum E -value Minimum E...
Page 114 Operation – Terrameter Pos. Designation Note Shows the E -value at any point -curve (in MN/m of the rolled track. The raster line enables the loca- tion related assignment of the -value and the location of a fault (excessive or insufficient compaction).
Page 115: Park The Machine In Secured Condition
Operation – Park the machine in secured condition. Park the machine in secured condition. 1. Drive the machine onto level and firm ground. 2. To stop the machine return the travel lever to middle position and shift it to the right to lock (parking brake position).
Page 116: Operating The Heating / Air Conditioning System
Operation – Operating the heating / air conditioning system Operating the heating / air conditioning system NOTICE! The function of the heating / air conditioning system may be affected! – Always keep the air inlet slots on the cabin free of snow, foliage etc.
Page 117: Ecostop
Operation – ECOSTOP ECOSTOP Optional equipment In order to reduce the idle speed times of the machine, the engine is, under certain condi- tions, automatically shut down after an idle time of 10 minutes. The INFO 3 display field shows the control lamp ECOSTOP.
Page 118 Operation – ECOSTOP NOTICE! The battery may partly or fully discharge! After the engine has been shut down, ignition and possibly other consumers (e.g. lighting) may still be switched on. – If necessary switch off con- sumers and ignition. Starting the engine after ECOSTOP 1.
Page 119: Emergency Procedures
Operation – Emergency procedures 6.10 Emergency procedures 6.10.1 Actuating the emergency stop switch 1. In events of emergency and in case of danger actuate the emergency stop switch immediately. ð The engine is shut down and the parking brake is closed. Fig.
Page 120 Operation – Emergency procedures Protective equip- Working clothes ment: Protective gloves WARNING! Danger of injury caused by uncontrolled machine movement! – Always secure the machine against unintended rolling. 1. Fasten the towing device reliably to the towing points. 2. Open and secure the engine hood Ä...
Page 121: After Towing
Operation – Emergency procedures Drive axle 4. To release the brake turn counter nuts (1) approx. 8 mm back. 5. Turn the brake releasing screws (2) com- pletely in against the stop. 6. Turn the screws in alternately for 1/4 turn at a time.
Page 122 Operation – Emergency procedures 1. After towing, park the machine in a safe place and secure it against accidental rolling away. Travel pump 2. Fasten the middle hexagon on both valves again for approx. 2 to 3 turns. Fig. 90 3.
Page 123 Operation – Emergency procedures 7. Unscrew the brake releasing screw out of the brake of the drum drive motor. 8. Turn the plug (1) back in and tighten it. Fig. 93 BW 213 D-5...
Page 124 Operation – Emergency procedures BW 213 D-5...
Page 125: Loading/Transporting The Machine
Loading/transporting the machine Loading/transporting the machine BW 213 D-5...
Page 126: Prepare For Transport
Loading/transporting the machine – Prepare for transport Prepare for transport 1. Close all doors, windows and flaps. 2. Remove all loose objects from the machine or from the operator's stand or fasten them reliably. BW 213 D-5...
Page 127: Loading The Machine
Loading/transporting the machine – Loading the machine Loading the machine Use only stable loading ramps of sufficient load bearing capacity. Loading ramps and transport vehicle must be free of grease, oil, snow and ice. The ramp inclination must be less than the gradability of the machine.
Page 128 Loading/transporting the machine – Loading the machine 1. Turn the rotary switch for travel range selection to position “Ramp”. 2. Drive the machine carefully onto the trans- port vehicle. 3. Mind the centre of gravity. 4. Shut down the engine, pull off the ignition key.
Page 129: Lashing The Machine To The Transport Vehicle
Loading/transporting the machine – Lashing the machine to the transport vehicle Lashing the machine to the transport vehicle Do not use damaged or in any other way impaired lashing points. Always use appropriate lifting and lashing means on the lifting and lashing points. Use lifting and lashing gear only in the pre- scribed direction of load application.
Page 130: Loading By Crane
Loading/transporting the machine – Loading by crane Loading by crane Loads must only be attached and hoisted by an expert / capable person. Do not use damaged or in any other way impaired lashing points. Use only lifting gear and lifting tackle with suffi- cient load bearing capacity for the weight to be loaded.
Page 131 Loading/transporting the machine – Loading by crane DANGER! Danger to life caused by sus- pended loads! – Do not step or stand under sus- pended loads. 6. Lift the machine carefully and lower it again at the intended location. BW 213 D-5...
Page 132: After Transport
Loading/transporting the machine – After transport After transport 1. After transportation loosen the articulation Ä Chapter 8.2.2.2 „Disengaging lock again the articulation lock“ on page 138. BW 213 D-5...
Page 133: Maintenance
Maintenance Maintenance BW 213 D-5...
Page 134: Preliminary Remarks And Safety Notes
Maintenance – Preliminary remarks and safety notes Preliminary remarks and safety notes DANGER! Danger to life caused by an operationally unsafe machine! – The machine must only be serv- iced by qualified and authorized personnel. – Follow the safety regulations for Ä...
Page 135 Maintenance – Preliminary remarks and safety notes 3. Wear your personal protective outfit. 4. Do not touch hot engine parts. 5. Always remove the main battery switch for all maintenance work. 6. Perform maintenance work only with the engine shut down. 7.
Page 136: Preparations / Concluding Work
Maintenance – Preparations / concluding work Preparations / concluding work Certain maintenance tasks require prepara- tions and concluding activities. This includes e.g. opening and closing mainte- nance flaps and maintenance doors as well as securing certain components. After this work close all maintenance flaps and doors again and return all components to their operating condition.
Page 137: Engaging / Releasing The Articulation Lock
Maintenance – Preparations / concluding work Top position 1. Push the hood to top position. 2. Secure the locking bolt with the split pin (1). Fig. 100 8.2.2 Engaging / releasing the articulation lock 8.2.2.1 Engaging the articulation lock WARNING! Danger of crushing by the articu- lating machine! –...
Page 138 Maintenance – Preparations / concluding work 5. Engage the articulation locking bolt and secure it with the spring pin. Fig. 102 8.2.2.2 Disengaging the articulation lock WARNING! Danger of crushing by the articu- lating machine! – Do not step into the articulation area of the machine while the engine is running.
Page 139: Fuels And Lubricants
Maintenance – Fuels and lubricants Fuels and lubricants 8.3.1 Engine oil 8.3.1.1 Oil quality Engine oils for use in DEUTZ engines are clas- sified in DEUTZ Engine Oil Quality Classes (DQC). Tab. 2: The following engine oil specifications are permitted: DEUTZ ACEA DQC II-10 E3-96...
Page 140 Maintenance – Fuels and lubricants 8.3.1.2 Oil viscosity Since engine 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 (SAE-class). Only use multi-purpose oils. The temperature indications of the SAE-class always refer to fresh oils.
Page 141: Fuel
Maintenance – Fuels and lubricants 8.3.2 Fuel 8.3.2.1 Fuel quality You should preferably use commercial diesel fuel with a sulphur content of less than 0.5 %. When using a diesel fuel with a high sulphur content of 0.5 % to 1.0 % the oil change inter- vals must be halved.
Page 142: Coolant
Maintenance – Fuels and lubricants NOTICE! Danger of engine damage! – The admixture of petroleum and the addition of "flow enhancing additives" (fuel additives) is not permitted. 8.3.2.3 Storage Even traces of zinc, lead and copper can cause deposits in the injection nozzles, especially in modern Common-Rail injection systems.
Page 143 Maintenance – Fuels and lubricants 8.3.3.2 Water quality 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. Analysis values pH-value at 20 °C 6.5 - 8.5 (68 °F) Chlorine-ion content...
Page 144 Maintenance – Fuels and lubricants NOTICE! Danger of engine damage! – Another analysis must be made after the fresh water has been prepared. 8.3.3.3 Cooling system protection agent As a protection against frost, corrosion and boiling point anti-freeze agents must be used under any climatic conditions.
Page 145 Maintenance – Fuels and lubricants NOTICE! Danger of engine damage! – Do not mix different coolants and additives of any other kind. – Before changing the product you must clean the entire cooling system. – Consult our customer service if in doubt.
Page 146: Hydraulic Oil
Maintenance – Fuels and lubricants 8.3.4 Hydraulic oil 8.3.4.1 Mineral oil based hydraulic oil The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mm /s at 40 °C (104 °F) and 8 mm /s at 100 °C (212 °F).
Page 147: Gear Oil Sae 75W-90
Maintenance – Fuels and lubricants NOTICE! Risk of damage! – Check the filter more frequently after this change. – Perform regular oil analyses for content of water and mineral oil. – Replace the hydraulic oil filter element every 500 operating hours.
Page 148: List Of Fuels And Lubricants
Maintenance – List of fuels and lubricants List of fuels and lubricants Assembly Fuel or lubricant Spare Filling group parts quantity number Summer Winter Observe the level mark! Engine oil SAE 10W-40 009 920 06 8.0 l Ä Chapter 8.3.1 Specification: 20 l (2.1 gal us)
Page 149 Maintenance – List of fuels and lubricants Assembly Fuel or lubricant Spare Filling group parts quantity number Summer Winter Observe the level mark! Drive axle Gear oil SAE 80W-140 009 925 07 11 l Ä Chapter 8.3.6 Specification: 20 l (2.9 gal us) „Gear oil SAE 80W-140“...
Page 150: Running-In Instructions
Maintenance – Running-in instructions Running-in instructions 8.5.1 General The following maintenance work must be per- formed when running in new machines or over- hauled engines: NOTICE! Danger of engine damage! – Up to approx. 250 operating hours check the engine oil level twice every day.
Page 151: After 500 Operating Hours
Maintenance – Running-in instructions Ä Chapter 8.9.6 7. Exciter unit oil change. „Change the oil in the exciter housing“ on page 185 8.5.3 After 500 operating hours 1. Oil and filter change diesel engine. Ä Chapter 8.8.1 „Change engine oil and oil filter cartridge“...
Page 152: Maintenance Table
Maintenance – Maintenance table Maintenance table Maintenance works Page Every 250 operating hours 8.7.1 Cleaning the radiator module 8.7.2 Service the belt drive 8.7.3 Checking the oil level in the drive axle 8.7.4 Checking the oil level in the wheel hubs 8.7.5 Checking the oil level in the exciter housing 8.7.6...
Page 153 Maintenance – Maintenance table Maintenance works Page 8.9.10 Checking the travel control 8.9.11 Cleaning the circulation air filter for the heating Every 2000 operating hours 8.10.1 Changing the hydraulic oil 8.10.2 Change the coolant As required 8.11.1 Air filter maintenance 8.11.2 Checking, cleaning the water separator 8.11.3...
Page 154: Every 250 Operating Hours
Maintenance – Every 250 operating hours Every 250 operating hours 8.7.1 Cleaning the radiator module NOTICE! Components may get damaged! – Dirt on fan blades and oil coolers reduce the cooling effect. Dirt deposits in these areas are sub- stantially supported by oil and fuel on these surfaces.
Page 155 Maintenance – Every 250 operating hours 4. Blow the cooler out with compressed air from the air supply side. Cleaning with cold The air conditioning condenser is cleansing agent located in front of the radiator. WARNING! Danger of injury caused by exploding component! –...
Page 156: Service The Belt Drive
Maintenance – Every 250 operating hours 8.7.2 Service the belt drive 8.7.2.1 Checking the condition of the V-belt Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.7 „Park the machine in secured condition.“ on page 115. 2.
Page 157 Maintenance – Every 250 operating hours 3. Actuate the push button (b) evenly with a finger under a right angle to the belt, until the pressure spring disengages audibly and noticeably. ð The indicator arm remains in the meas- ured position. 4.
Page 158: Checking The Oil Level In The Drive Axle
Maintenance – Every 250 operating hours 8.7.2.4 Tensioning the generator V-belt Protective equip- Working clothes ment: Protective gloves 1. Slightly loosen the fastening screw on the belt tensioner. 2. Tension the V-belt with the tensioning device, until the correct tension is reached. 3.
Page 159: Checking The Oil Level In The Wheel Hubs
Maintenance – Every 250 operating hours Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.7 „Park the machine in secured condition.“ on page 115. 2. Clean the area around the level inspection plug (1) and unscrew the plug.
Page 160: Checking The Oil Level In The Exciter Housing
Maintenance – Every 250 operating hours Protective equip- Working clothes ment: Protective gloves 1. Move the machine until the oil level inspec- tion plug is in horizontal position. 2. Park the machine in secured condition Ä Chapter 6.7 „Park the machine in secured condition.“...
Page 161 Maintenance – Every 250 operating hours Protective equip- Working clothes ment: Protective gloves 1. Before checking the oil level, run the machine warm with vibration for about 1/2 hour. 2. Move the drum, until the oil level inspection plug is in bottom position. 3.
Page 162: Changing The Fresh Air Filter In The Cabin
Maintenance – Every 250 operating hours 8.7.6 Changing the fresh air filter in the cabin 1. Park the machine in secured condition Ä Chapter 6.7 „Park the machine in secured condition.“ on page 115. 2. Pull the fastening pins out of the left cover and take off the cover.
Page 163: Check The Parking Brake
Maintenance – Every 250 operating hours 6. Take out the filter. 7. Insert the new filter and fold the console down again. 8. Tighten the left and right fastening screws and reassemble the covers. Fig. 121 8.7.7 Check the parking brake This work must only be performed by authorized service personnel.
Page 164: Every 500 Operating Hours
Maintenance – Every 500 operating hours Every 500 operating hours 8.8.1 Change engine oil and oil filter cartridge Protective equip- Working clothes ment: Protective gloves During the regeneration at standstill part of the fuel may mix with the engine oil. You should therefore run a possibly necessary regeneration at standstill before changing the engine oil.
Page 165 Maintenance – Every 500 operating hours NOTICE! Danger of engine damage! – Change the oil only with the engine at operating temperature. – Use only oil of the permitted Ä Chapter 8.3.1 specification „Engine oil“ on page 139. Ä Chapter 8.4 –...
Page 166 Maintenance – Every 500 operating hours 4. Thoroughly clean the outside of the oil filter cartridge. 5. Unscrew the oil filter cartridge using an appropriate filter wrench. 6. Clean the sealing face on the filter carrier from any dirt. 7. Slightly oil the rubber seal on the new oil filter cartridge.
Page 167: Replacing The Fuel Filter, Bleeding The Fuel System
Maintenance – Every 500 operating hours 8.8.2 Replacing the fuel filter, bleeding the fuel system 8.8.2.1 Preliminary remarks NOTICE! Danger of engine damage! – Ensure strict cleanliness! Thor- oughly clean the area around the fuel filters. – Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting...
Page 168 Maintenance – Every 500 operating hours 1. Loosen and unscrew the fuel filter cartridge using an appropriate filter wrench. 2. Pull the plug off the sensor on the water separator. 3. Clean the sealing face on the filter carriers from any dirt. NOTICE! Fig.
Page 169 Maintenance – Every 500 operating hours 8.8.2.3 Bleed the fuel system NOTICE! The high pressure pump may get damaged! – Start the engine only after the bleeding process has been com- pleted. Protective equip- Working clothes ment: Protective gloves 1. Turn the ignition key to position "I". ð...
Page 170: Checking The Anti-Freeze Concentration And The Condition Of The Coolant
Maintenance – Every 500 operating hours 3. Turn the ignition key again to position "I". 4. Repeat the procedure at least 4 times. 5. Start the engine and run it 5 minutes with idle speed. 6. Shut down the engine and check the fuel filters for leak tightness.
Page 171: Renewing The Adblue ® /Def Filter
Maintenance – Every 500 operating hours ® 8.8.4 Renewing the AdBlue /DEF filter Perform this maintenance work at the latest after two years. NOTICE! Components may get damaged! ® – If AdBlue /DEF comes into con- tact with spray painted or alumi- nium surfaces while refilling, you should rinse off the affected areas immediately with lots of...
Page 172: Check The Hydraulic Lines
Maintenance – Every 500 operating hours 3. Thoroughly clean the area around the filter housing. 4. Unscrew the filter lid. Fig. 130 5. Pull out filter carrier (2) together with filter element (1). 6. Attach the new filter element to the filter carrier and reinsert it into the filter housing.
Page 173 Maintenance – Every 500 operating hours 1. Park the machine in secured condition Ä Chapter 6.7 „Park the machine in secured condition.“ on page 115. 2. Check all hydraulic lines. Hydraulic hoses must be immediately replaced if: the outer layer is damaged down to the inlay (e.g.
Page 174: Servicing The Battery, Checking The Main Battery Isolation
Maintenance – Every 500 operating hours 8.8.6 Servicing the battery, checking the main battery isolation 8.8.6.1 Battery service 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-dis- charge, which may, in not checked occasionally, even cause damage to the battery as a result of exhaus-...
Page 175: Servicing The Air Conditioning System
Maintenance – Every 500 operating hours 8.8.6.2 Checking the main battery switch 1. Turn the main battery switch counter-clock- wise and pull it out. 2. Check by turning the ignition key, whether the battery is disconnected from the elec- tric system of the machine. Fig.
Page 176 Maintenance – Every 500 operating hours NOTICE! Electric components can be dam- aged by water entering into the system! – Protect electrical equipment such as generator, regulator and starter against the direct water jet. 1. Park the machine in secured condition Ä...
Page 177 Maintenance – Every 500 operating hours 8.8.7.2 Air conditioning function test 1. Start the engine. 2. Switch the fan to the highest stage. 3. Choose the lowest cabin temperature. 4. Switch the air conditioning on. 5. Direct the air flow into the cabin and check, that the flowing out air is considerably cooler.
Page 178 Maintenance – Every 500 operating hours 5. Check the moisture indication pearl inside the inspection glass of the drier/collector unit. orange The degree of moisture in the drying agent is correct colourless Moisture level of drying agent too high Fig. 137 6.
Page 179: Every 1000 Operating Hours
Maintenance – Every 1000 operating hours Every 1000 operating hours 8.9.1 Replacing the V-belt Protective equip- Working clothes ment: Protective gloves Perform this maintenance work at the latest after two years. 1. Park the machine in secured condition Ä Chapter 6.7 „Park the machine in secured condition.“...
Page 180: Check The Engine Mounts
Maintenance – Every 1000 operating hours 9. Slightly loosen the fastening screws of the generator V-belt tensioning device. 10. Slacken the V-belt by the clamping screw, so that the V-belt can be taken off. 11. Take the V-belt off. 12. Install the new V-belt and tighten it Ä...
Page 181 Maintenance – Every 1000 operating hours NOTICE! Components may get damaged! – 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.
Page 182 Maintenance – Every 1000 operating hours NOTICE! Negligence may cause destruc- tion to the entire hydraulic system. – Visible dirt may be an early sign for the failure of system compo- nents and indicate the possible failure of components. – In this case determine the cause and replace or repair the defec- tive components, if necessary.
Page 183: Change The Oil In The Drive Axle
Maintenance – Every 1000 operating hours 8.9.4 Change the oil in the drive axle NOTICE! Components may get damaged! – Drain gear oil only at operating temperature. – Use only gear oil of the permitted Ä Chapter 8.3.6 specification „Gear oil SAE 80W-140“...
Page 184: Changing The Oil In The Wheel Hubs
Maintenance – Every 1000 operating hours 5. Clean the area around the level inspection plug (1) and unscrew the plug. A second inspection plug is located on the left front side of the drive axle. 6. Clean the area around the filler plug (2) Fig.
Page 185: Change The Oil In The Exciter Housing
Maintenance – Every 1000 operating hours Protective equip- Working clothes ment: Protective gloves 1. Move the drum, until the oil level inspection plug is in bottom position. 2. Park the machine in secured condition Ä Chapter 6.7 „Park the machine in secured condition.“...
Page 186 Maintenance – Every 1000 operating hours Perform this maintenance work at the latest after one year. Protective equip- Working clothes ment: Protective gloves 1. Before changing the oil level run the machine warm for about 1/2 hour. 2. Move the drum, until the drain plug is in bottom position.
Page 187: Retightening The Fastening Of The Axle On The Frame
Maintenance – Every 1000 operating hours 8.9.7 Retightening the fastening of the axle on the frame 1. Check all fastening nuts on axle mounting bolts for tight fit. Fig. 150 8.9.8 Tighten the wheel nuts 1. Tighten the wheel nuts cross-wise, tight- ening torque: 550 Nm (405 ft·lbs).
Page 188: Checking The Travel Control
Maintenance – Every 1000 operating hours 1. Inspect the cabin, especially the ROPS, for cracks, corrosion, damage and missing fastening parts. 2. Check the fastening screws for the cabin (ROPS) to the operator’s stand for tight fit. 3. Check the rubber buffers of the operator’s platform suspension for condition and tight fit.
Page 189: Cleaning The Circulation Air Filter For The Heating
Maintenance – Every 1000 operating hours 8.9.11 Cleaning the circulation air filter for the heating 1. Park the machine in secured condition Ä Chapter 6.7 „Park the machine in secured condition.“ on page 115. 2. Loosen the locks and disassemble the cov- ering.
Page 190: Every 2000 Operating Hours
Maintenance – Every 2000 operating hours 8.10 Every 2000 operating hours 8.10.1 Changing the hydraulic oil Perform this maintenance work at the latest after two years. The hydraulic oil must also be changed after major repairs in the hydraulic system. Always replace the hydraulic oil filter after each hydraulic oil change.
Page 191 Maintenance – Every 2000 operating hours Protective equip- Working clothes ment: Protective gloves 1. Park the machine in secured condition Ä Chapter 6.7 „Park the machine in secured condition.“ on page 115. 2. Clean the area around hydraulic oil tank, filler opening and filler cap.
Page 192: Change The Coolant
Maintenance – Every 2000 operating hours The breather filter for the hydraulic oil tank is integrated in the cap, you must therefore replace the complete cap. Close the tank with a new cap. 10. Dispose of oil in an environmentally friendly way.
Page 193 Maintenance – Every 2000 operating hours NOTICE! Danger of engine damage! – Use only coolant of the permitted Ä Chapter 8.3.3 specification „Coolant“ on page 142. – Do not mix different coolants and additives of any other kind. Ä Chapter 8.4 –...
Page 194 Maintenance – Every 2000 operating hours 10. Fill in clean water. 11. Start the engine and run to operating tem- perature. 12. Allow the engine to cool down to approx. 50 °C (122 °F). 13. Drain all water off. 14. When using a cleansing agent repeat the flushing process twice with clear water.
Page 195 Maintenance – Every 2000 operating hours 18. Set maximum blowing range. Ä Chapter 6.3 „Start the 19. Start the engine engine“ on page 99. 20. Run the machine with idle speed until oper- ating temperature has been reached and the thermostat opens. 21.
Page 196: As Required
Maintenance – As required 8.11 As required 8.11.1 Air filter maintenance NOTICE! Danger of engine damage! – Do not start the engine after having removed the air filter. – If necessary, the air filter may be cleaned up to six times. After one year at the latest it must be replaced together with the safety element.
Page 197 Maintenance – As required Protective equip- Working clothes ment: Protective gloves Safety goggles 1. Maintenance of the air filter is due when the air filter warning lamp lights up, but at the latest after one year. 2. Park the machine in secured condition Ä...
Page 198 Maintenance – As required CAUTION! Danger of eye injuries caused by particles flying around! – Wear your personal protective equipment (safety gloves, protec- tive working clothes, goggles). 7. Blow the air filter out with dry compressed air (max. 2.1 bar (30 psi)) from inside to outside by moving the gun up and down inside the element, until it if free of dust.
Page 199: Checking, Cleaning The Water Separator
Maintenance – As required 8.11.1.1 Replace the safety element NOTICE! Danger of engine damage! The safety element must not be cleaned and should not be used again after it has been removed. The safety element must be replaced: – if the air filter is damaged. –...
Page 200: Retightening The Padfoot Shell
Maintenance – As required Protective equip- Working clothes ment: Protective gloves 1. If the "water in fuel" warning lamp lights up when starting or during operation, drain the water from the fuel pre-filter immediately. 2. Park the machine in secured condition Ä...
Page 201: Adjust The Scrapers
Maintenance – As required 8.11.4 Adjust the scrapers 1. Check adjustment and condition of front and rear scrapers, if necessary adjust or replace the scraper rubber. 2. In order to adjust the scrapers, slacken the fastening screws (1) in the slots and push the scraper towards the drum to contact.
Page 202: Replacing The Printer Ribbon In The Printer
Maintenance – As required 2. Remove shaft (1) with the rest of the paper roll (2). Fig. 175 3. Insert a new paper roll. 4. Feed the paper into the guide (1) on the printer. 5. Actuate the toggle switch (2) in direction of arrow, until the paper comes out of the slot with tear-off edge.
Page 203: Drain The Fuel Tank Sludge
Maintenance – As required 2. Lift the tongue at point (1) and take the printer ribbon (2) out of the printer. 3. Insert the new printer ribbon into the printer, then press in the tongue (1) on the right. 4. Tension the printer ribbon by turning the rotary button (3) in direction of arrow.
Page 204 Maintenance – As required 4. Change engine oil and oil filter if the oil has been changed more than 300 hours ago, or if the oil is older than 12 months. 5. After shutting down store the machine under cover in a dry and well ventilated room.
Page 205 Maintenance – As required Protective equip- Working clothes ment: Protective gloves Safety goggles 1. Switch off all consuming devices (e.g. igni- tion, light). 2. Measure the open-circuit voltage of the battery at regular intervals (at least 1 x per month). ð...
Page 206 Maintenance – As required 5. In case of storage times in excess of four months you should renew the ® AdBlue /DEF filter. 6. Check the coolant level. 7. Check the charge condition of the bat- teries, recharge if necessary. Check the battery fluid level before and after charging.
Page 207: Trouble Shooting
Trouble shooting Trouble shooting BW 213 D-5...
Page 208: Preliminary Remarks
Trouble shooting – Preliminary remarks Preliminary remarks Malfunctions are frequently caused by incorrect operation of the machine or insufficient mainte- nance. Whenever a fault occurs you should therefore thoroughly read these instruction on correct operation and maintenance. If you cannot locate the cause of a fault or rec- tify it yourself by following the trouble shooting chart, you should contact our customer service department.
Page 209: Starting The Engine With Jump Leads
Trouble shooting – Starting the engine with jump leads Starting the engine with jump leads NOTICE! A wrong connection will cause severe damage in the electric system. – Bridge the machine only with a 12 Volt auxiliary battery. 1. Connect the plus pole of the external bat- tery first with the plus pole of the vehicle battery using the first jump lead.
Page 210: Fuse Assignment
Trouble shooting – Fuse assignment Fuse assignment 9.3.1 Notes on safety WARNING! Danger of injury by fire in the machine! – Do not use fuses with higher ampere ratings and do not bridge fuses. 9.3.2 Central electrics Fuse Amperage Designation 20 A 12-V socket 10 A...
Page 211: Main Fuses
Trouble shooting – Fuse assignment Fuse Amperage Designation Sensors F103 15 A Reserve (potential 15) F122 10 A Engine control F124 25 A Fuel pre-heating F146 15 A Control (potential 30) F148 10 A Control (potential 15) F157 30 A Starter F169 Start current...
Page 212: Fuse, Cabin
Trouble shooting – Fuse assignment 9.3.4 Fuse, cabin Fig. 182 Posi- Fuse Amperage Designation tion Radio F264 10 A F271 10 A BCM net F150 F266 10 A Radio/Tachograph F143 20 A Rear windscreen heating 15 A Rear windscreen wiper/washer 15 A Front windscreen wiper/washer F279...
Page 213: Engine Faults
Trouble shooting – Engine faults Engine faults Fault Possible cause Remedy Engine does Fuel tank empty Refuel, bleed the fuel system not start or Temperature below starting Check starts poorly limit Cold starting facility Check, replace if necessary Engine oil with wrong SAE Change the engine oil viscosity class The fuel quality does not...
Page 214 Trouble shooting – Engine faults Fault Possible cause Remedy Air in the fuel system Bleed the fuel system Fuel pre-cleaner soiled Check, clean the water sepa- rator, replace the fuel pre- cleaner The fuel quality does not Change the fuel meet the requirements Injector defective Replace...
Page 215 Trouble shooting – Engine faults Fault Possible cause Remedy Air filter clogged / exhaust Check, replace if necessary turbocharger defective Fan defective / V-belt torn or Check fan / V-belt, replace if loose necessary Exhaust gas counter pres- Check sure too high Insufficient Engine oil level too high Check, top up or drain off as...
Page 216 Trouble shooting – Engine faults Fault Possible cause Remedy Engine has Engine oil level too low Check, top up or drain off as too low or no necessary oil pressure Engine oil with wrong SAE Change the engine oil viscosity class Engine has Engine oil level too high Check, drain off if necessary...
Page 217: Waste Disposal
Waste disposal Waste disposal BW 213 D-5...
Page 218: Final Shut-Down Of Machine
Waste disposal – Final shut-down of machine 10.1 Final shut-down of machine If the machine can no longer be used and needs to be finally shut down you must carry out the following work and have the machine disassembled by an officially recognized spe- cialist workshop.
Page 219: List Of Special Tools
List of special tools List of special tools BW 213 D-5...
Page 220 List of special tools Belt tension tester BOMAG No. 079 947 09 Fig. BW 213 D-5...

Fayat Group Bomag BW 213 D-5 Operating Instruction, Maintenance Instruction

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Fayat Group Bomag BW 213 D-5

Summary of Contents for Fayat Group Bomag BW 213 D-5

Table of Contents