Fayat Group BOMAG BW 213 D-5 User manual

BW 213 D-5
Single drum roller
Operating Instruction
Maintenance Instruction
Original Operating Instructions
S/N 101 586 71 1117>
© 04/2020008 203 42 EN

terminals, tank trucks and other facilities and equipment.
plants, transport and storage operations such as pipelines, marine
For more information go to www.P65Warnings.ca.gov/petroleum.
These exposures can occur in and around oil fields, refineries, chemical
WARNING: Crude oil, gasoline, diesel fuel and other petroleum
products can expose you to chemicals including toluene and benzene,
which are known to the State of California to cause cancer and birth
defects or other reproductive harm.
WARNING: Breathing diesel engine exhaust exposes you to chemicals
known to the State of California to cause cancer and birth defects or other
reproductive harm.
Always start and operate the engine in a well-ventilated area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
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Table of contents
1 Introduction.......................................................................................... 11
1.1 Foreword....................................................................................... 12
1.2 Machine type plate and engine type plate................................. 14
2 Technical data...................................................................................... 15
2.1 Noise and vibration data.............................................................. 19
2.1.1 Noise data................................................................................... 19
2.1.2 Vibration data.............................................................................. 19
3 Concerning your safety...................................................................... 21
3.1 Basic prerequisites...................................................................... 22
3.1.1 General........................................................................................ 22
3.1.2 Explanation of signal words used:............................................... 23
3.1.3 Personal protective equipment.................................................... 24
3.1.4 Intended use................................................................................ 25
3.1.5 Improper use............................................................................... 25
3.1.6 Estimated service life of the machine.......................................... 26
3.2 Definition of responsible persons.............................................. 27
3.2.1 Operating company..................................................................... 27
3.2.2 Expert / qualified person.............................................................. 27
3.2.3 Driver / operator.......................................................................... 28
3.3 Fundamentals for safe operation................................................ 29
3.3.1 Remaining dangers, remaining risks........................................... 29
3.3.2 Regular safety inspections.......................................................... 29
3.3.3 Modifications and alterations to the machine.............................. 29
3.3.4 Damage, defects, misuse of safety devices................................ 30
3.3.5 Roll Over Protective Structure (ROPS)....................................... 30
3.4 Handling fuels and lubricants..................................................... 32
3.4.1 Preliminary remarks.................................................................... 32
3.4.2 Safety regulations and environmental protection regulations for
handling diesel fuel...................................................................... 33
3.4.3 Safety regulations and environmental protection regulations for
handling oil.................................................................................. 35
3.4.4 Safety regulations and environmental protection regulations for
handling hydraulic oil................................................................... 36
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3.4.5 Safety regulations and environmental protection regulations for
handling coolants........................................................................ 38
3.4.6 Safety regulations and environmental protection regulations for
handling battery acid................................................................... 40
3.5 Load/transport the machine........................................................ 42
3.6 Starting up the machine.............................................................. 44
3.6.1 Prior to commissioning................................................................ 44
3.6.2 Starting the engine...................................................................... 45
3.6.3 Starting the engine with jump leads............................................ 45
3.7 Driving the machine; working operation.................................... 47
3.7.1 Driving the machine..................................................................... 47
3.7.2 Driving up and down slopes........................................................ 48
3.7.3 Cross-slope................................................................................. 48
3.7.4 Working with vibration................................................................. 49
3.7.5 Parking the machine.................................................................... 49
3.8 Refuelling...................................................................................... 50
3.9 Emergency procedures............................................................... 51
3.9.1 Actuating the emergency stop switch.......................................... 51
3.9.2 Disconnecting the battery............................................................ 51
3.9.3 Towing the machine..................................................................... 51
3.10 Maintenance work...................................................................... 53
3.10.1 Preliminary remarks.................................................................. 53
3.10.2 Working on hydraulic lines........................................................ 53
3.10.3 Working on the engine.............................................................. 54
3.10.4 Maintenance work on electric components and battery............ 55
3.10.5 Working on the air conditioning................................................. 55
3.10.6 Working on wheels and tyres.................................................... 55
3.10.7 Cleaning work............................................................................ 56
3.10.8 Measures for longer shut-down periods.................................... 56
3.10.9 After maintenance work............................................................. 57
3.11 Repair.......................................................................................... 58
3.12 Signage....................................................................................... 59
3.13 Danger zones.............................................................................. 67
3.14 Safety components.................................................................... 68
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4 Indicators and control elements........................................................ 71
4.1 Driver’s stand............................................................................... 72
4.1.1 Instrument cluster........................................................................ 72
4.1.2 Operating console....................................................................... 79
4.1.3 Travel lever.................................................................................. 84
4.1.4 Driver’s seat................................................................................ 86
4.2 Cabin............................................................................................. 90
4.2.1 Control console cabin.................................................................. 90
4.2.2 Heating / air conditioning............................................................. 91
4.2.3 12 V DIN socket.......................................................................... 93
4.2.4 Control panel for auxiliary heating............................................... 94
4.2.5 Monitor for reversing camera...................................................... 96
4.2.6 Fire extinguisher.......................................................................... 97
4.3 Engine compartment.................................................................... 98
4.3.1 Main battery switch...................................................................... 98
4.4 Outside of machine...................................................................... 99
4.4.1 Reversing camera....................................................................... 99
5 Checks prior to start up.................................................................... 101
5.1 Notes on safety........................................................................... 102
5.2 Visual inspections and function tests...................................... 104
5.3 Checking the engine oil level.................................................... 105
5.4 Checking the fuel level; topping up fuel.................................. 106
5.4.1 Checking the fuel level.............................................................. 106
5.4.2 Refuelling.................................................................................. 106
5.5 Checking the hydraulic oil level................................................ 108
5.6 Checking the coolant level........................................................ 109
5.7 Checking wheels and tyres........................................................ 111
6 Operation............................................................................................ 113
6.1 Setting up the workplace........................................................... 114
6.2 Electronic immobilizer............................................................... 115
6.3 Starting the engine..................................................................... 116
6.4 Travel operation.......................................................................... 118
6.4.1 Preliminary remarks and safety notes....................................... 118
6.4.2 Driving the machine................................................................... 119
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6.4.3 Applying the parking brake........................................................ 120
6.5 Working with vibration............................................................... 121
6.5.1 Preliminary remarks and safety notes....................................... 121
6.5.2 Switching the vibration on and off............................................. 122
6.6 ECONOMIZER............................................................................. 124
6.7 Terrameter................................................................................... 125
6.7.1 Terrameter display..................................................................... 125
6.7.2 Terrameter with printer.............................................................. 126
6.7.3 Line graph (EVIB)........................................................................ 130
6.8 Parking the machine in secured condition.............................. 133
6.9 Operating the heating / air conditioning system..................... 134
6.10 Operating the auxiliary heating............................................... 135
6.10.1 Switching on the operating unit............................................... 136
6.10.2 Operating surface.................................................................... 136
6.10.3 Heating operation.................................................................... 137
6.10.4 Fan operation.......................................................................... 140
6.10.5 Heating with preselected times............................................... 142
6.10.6 Setting the time, week day and time format............................ 144
6.10.7 Switching off the operating unit............................................... 146
6.11 ECOSTOP.................................................................................. 147
6.12 Emergency procedures........................................................... 149
6.12.1 Actuating the emergency stop switch...................................... 149
6.12.2 Machine stops in case of faults............................................... 150
6.12.3 Disconnecting the battery........................................................ 151
6.12.4 Emergency exit........................................................................ 151
6.12.5 Towing the machine................................................................. 151
6.12.6 After towing............................................................................. 154
7 Loading / transporting the machine................................................ 157
7.1 Prepare for transport................................................................. 158
7.2 Loading the machine................................................................. 159
7.3 Lashing the machine to the transport vehicle......................... 161
7.4 Loading by crane........................................................................ 162
7.5 After transportation.................................................................... 164
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8 Maintenance....................................................................................... 165
8.1 Preliminary remarks and safety notes..................................... 166
8.2 Preparations/concluding work.................................................. 168
8.2.1 Open and secure the engine hood............................................ 168
8.2.2 Engaging/releasing the articulation lock.................................... 169
8.3 Fuels and lubricants.................................................................. 171
8.3.1 Engine oil................................................................................... 171
8.3.2 Fuel........................................................................................... 173
8.3.3 Coolant...................................................................................... 174
8.3.4 Hydraulic oil............................................................................... 178
8.3.5 Gear oil SAE 75W-90................................................................ 179
8.3.6 Gear oil SAE 80W-140.............................................................. 179
8.4 List of fuels and lubricants........................................................ 180
8.5 Running-in instructions............................................................. 182
8.5.1 General...................................................................................... 182
8.5.2 After 250 operating hours.......................................................... 182
8.5.3 After 500 operating hours.......................................................... 183
8.5.4 After 1000 operating hours........................................................ 183
8.6 Maintenance Table..................................................................... 184
8.7 Every 250 operating hours........................................................ 186
8.7.1 Checking the rubber-bonded metal rails and rubber buffers..... 186
8.7.2 Cleaning the radiator module.................................................... 187
8.7.3 Checking, tensioning the V-belt for the generator system......... 189
8.7.4 Checking the oil level in the drive axle...................................... 191
8.7.5 Checking the oil level in the wheel hubs................................... 192
8.7.6 Checking the oil level in the exciter housing............................. 192
8.7.7 Changing the fresh air filter in the cabin.................................... 194
8.7.8 Check the parking brake........................................................... 195
8.8 Every 500 operating hours........................................................ 196
8.8.1 Change engine oil and oil filter cartridge................................... 196
8.8.2 Replacing the fuel filter; bleeding the fuel system..................... 198
8.8.3 Checking the anti-freeze concentration and the condition of the
coolant....................................................................................... 201
8.8.4 Checking the hydraulic lines...................................................... 202
8.8.5 Servicing the battery, checking the main battery isolation......... 204
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8.8.6 Servicing the air conditioning system........................................ 205
8.9 Every 1000 operating hours...................................................... 208
8.9.1 Checking the ribbed V-belt........................................................ 208
8.9.2 Replacing the air conditioning compressor V-belts................... 210
8.9.3 Checking the engine mounts..................................................... 211
8.9.4 Replacing the hydraulic oil filter................................................. 211
8.9.5 Change the oil in the drive axle................................................. 214
8.9.6 Changing the oil in the wheel hubs........................................... 215
8.9.7 Change the oil in the exciter housing........................................ 217
8.9.8 Retightening the fastening of the axle on the frame.................. 219
8.9.9 Retightening the wheel nuts...................................................... 219
8.9.10 Checking the ROPS................................................................ 219
8.9.11 Checking the travel lever control............................................. 220
8.9.12 Cleaning the circulation air filter of the heating....................... 221
8.9.13 Servicing the auxiliary heating................................................. 221
8.10 Every 2000 operating hours.................................................... 223
8.10.1 Checking, adjusting the valve clearance................................. 223
8.10.2 Changing the hydraulic oil....................................................... 224
8.10.3 Changing the coolant.............................................................. 227
8.11 Every 4000 operating hours.................................................... 231
8.11.1 Replace ribbed V-belt and idler pulley..................................... 231
8.12 As required............................................................................... 232
8.12.1 Air filter maintenance............................................................... 232
8.12.2 Checking and cleaning the water separator............................ 236
8.12.3 Adjusting the scrapers............................................................. 237
8.12.4 Cleaning the machine.............................................................. 238
8.12.5 Filling the windscreen washer tank......................................... 239
8.12.6 Replacing the paper roll in the printer..................................... 239
8.12.7 Drain the fuel tank sludge........................................................ 240
8.12.8 Measures prior to extended shut-down period........................ 240
9 Setting up / refitting........................................................................... 245
9.1 Attaching the padfoot shells..................................................... 246
9.1.1 Preliminary remarks and safety notes....................................... 246
9.1.2 Preparations.............................................................................. 247
9.1.3 Removing the scrapers............................................................. 248
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9.1.4 Attaching segments................................................................... 251
9.1.5 Attaching the scrapers............................................................... 256
9.1.6 Installing the access steps........................................................ 259
9.2 Removing the padfoot shells.................................................... 261
9.2.1 Preliminary remarks and safety notes....................................... 261
9.2.2 Preparations.............................................................................. 261
9.2.3 Removing the scrapers............................................................. 262
9.2.4 Removing segments.................................................................. 264
9.2.5 Attaching the scrapers............................................................... 267
9.2.6 Removing the access steps...................................................... 269
10 Troubleshooting................................................................................ 271
10.1 Preliminary remarks................................................................. 272
10.2 Starting the engine with jump leads....................................... 273
10.3 Fuse assignment...................................................................... 274
10.3.1 Notes on safety....................................................................... 274
10.3.2 Central electrics....................................................................... 274
10.3.3 Main fuses............................................................................... 275
10.3.4 Control console cabin.............................................................. 276
10.3.5 Auxiliary heating...................................................................... 277
10.4 Fault code display.................................................................... 278
10.5 Engine faults............................................................................. 279
10.6 Fault indicators of auxiliary heating....................................... 283
11 Disposal.............................................................................................. 285
11.1 Final shut-down of machine.................................................... 286
12 List of special tools........................................................................... 287
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1 Introduction
Introduction
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1.1 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.
These operating and maintenance instructions
are part of your machine.
They provide necessary information to operate
your machine safely and properly.
They also contain information on required oper-
ating, maintenance and repair measures.
Carefully read the operating and maintenance
instructions before taking your machine into
operation.
Please observe the safety regulations strictly
and follow all instructions to ensure safe opera-
tion.
If you are not yet acquainted with the controls
and indicating elements on this machine, you
should thoroughly read the corresponding
chapter
Ä Chapter 4 ‘Indicators and control
elements’ on page 71.
The description of the individual operating
steps including the notes on safety to be fol-
lowed can be found in chapter “Operation”
Ä Chapter 6 ‘Operation’ on page 113.
Before every start up, carry out all required
visual inspections and function tests
Ä Chapter
5 ‘Checks prior to start up’ on page 101.
Ensure the compliance with the specified oper-
ating, maintenance and repair measures to
maintain the functional safety of your machine.
Introduction – Foreword
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A description of all necessary maintenance
work, maintenance intervals as well as informa-
tion on fuels and lubricants can be found in the
chapter “Maintenance”
Ä Chapter 8 ‘Mainte-
nance’ on page 165.
Do not service or repair your machine by your-
self to avoid harming persons or damaging
material or environment.
The machine must only be serviced and
repaired by qualified and authorized personnel.
Contact our Customer Service to carry out the
required maintenance work or necessary
repairs.
In case of operating errors, inadequate mainte-
nance or the use of unapproved fuels and lubri-
cants all warranty claims will become null and
void.
For your own personal safety you should only
use original parts from BOMAG.
For your machine we offer service kits to make
maintenance easier.
In the course of technical development we
reserve the right for technical modifications
without prior notification.
These operating and maintenance instructions
are also available in other languages.
Apart from that, you can also order the spare
parts catalogue against the serial number of
your machine.
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.
Introduction – Foreword
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1.2 Machine type plate and engine type plate
Please enter here:
Machine type (1):
Serial number (2):
Please enter here:
Engine type (1):
Engine number (2):
Fig. 1: Machine type plate
(example)
Fig. 2: Engine type plate
(example)
Introduction – Machine type plate and engine type plate
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2 Technical data
Technical data
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Fig. 3
ABDHH2K L O1/2 S W
2975
(117)
2270
(89)
1500
(59)
2250
(89)
2990
(118)
490
(19.3)
5870
(231)
70
(2.8)
30
(1.2)
2130
(84)
Dimensions in millimetres
(Dimensions in inch)
Weights
Max. operating weight 14800
(32628)
kg
(lbs)
Operating weight with ROPS cabin (CECE) 12600
(27778)
kg
(lbs)
Axle load, drum (CECE) 7550
(16645)
kg
(lbs)
Axle load, wheels (CECE) 5050
(11133)
kg
(lbs)
Static linear load 35.4
(198)
kg/cm
(pli)
Dimensions
Technical data
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Travel characteristics
Travel speed (1) 0 – 5
(0 – 3.1)
km/h
(mph)
Travel speed (2) 0 – 6
(0 – 3.7)
km/h
(mph)
Travel speed (3) 0 – 8
(0 – 5.0)
km/h
(mph)
Travel speed (4) 0 – 11
(0 – 6.8)
km/h
(mph)
Max. gradeability without/with vibration (soil
and weather dependent)
45/43 %
Drive
Engine manufacturer Deutz
Type TCD 2012 L04 2V
Cooling system Fluid
Number of cylinders 4
Rated power ISO 14396 103 kW
Power SAE J1995 140 hp
Rated speed 2400 min-1
Fuel Diesel
Electric system
Voltage 12 V
Tyres
Tyre size 23.1-26 12PR
Air pressure, nominal value 1.1
(16)
bar
(psi)
Technical data
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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)
mm
(in)
Exciter system
Drive system hydrostatic
Frequency (1/2) 30/34
(1800/2040)
Hz
(vpm)
Amplitude (1/2) 2.10/1.10
(0.083/0.043)
mm
(in)
Centrifugal force (1/2) 285/196
(64071/44063)
kN
(lbf)
Filling capacities
Fuel (diesel) 220
(58)
l
(gal us)
Technical data
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2.1 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:
nEU Machine Directive edition 2006/42/EU
nNoise Emission Directive 2000/14/EU, Noise
Protection Directive 2003/10/EU
nVibration Protection Directive 2002/44/EU
During operation these values may vary
because of the prevailing operating conditions.
2.1.1 Noise data
LpA = 77 dB(A), determined acc. to ISO 11201
and EN 500.
LWA = 108 dB(A), determined acc. to ISO 3744
and EN 500.
2.1.2 Vibration data
The weighted effective acceleration value
determined according to ISO 2631 is ≤ 0.5
m/s2.
The weighted effective acceleration value
determined according to ISO 5349 is ≤ 2.5
m/s2.
Sound pressure level at
the operator's stand
Guaranteed sound
power level
Vibration of the entire
body (driver’s seat)
Hand-arm vibration
Technical data – Noise and vibration data
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Technical data – Noise and vibration data
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