Fayat Group BOMAG BW 213 D-5 Instructions for use

BW 213 D-5
Single drum roller
Operating Instruction
Maintenance Instruction
Original Operating Instructions
S/N 101 586 48 1001>
© 08/2016008 202 10 EN

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Table of contents
1Introduction............................................................................................ 9
1.1 Foreword....................................................................................... 10
1.2 Machine type plate and engine type plate................................. 13
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 General prerequisites.................................................................. 22
3.1.1 General........................................................................................ 22
3.1.2 Explanation of warning signs:...................................................... 23
3.1.3 Personal protective equipment.................................................... 24
3.1.4 Intended use................................................................................ 25
3.1.5 Improper use............................................................................... 25
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................................................................... 37
3.4.5 Safety regulations and environmental protection regulations for
handling coolants........................................................................ 39
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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............................... 47
3.7.1 Persons in the danger area......................................................... 47
3.7.2 Driving the machine..................................................................... 47
3.7.3 Driving on gradients and slopes.................................................. 48
3.7.4 Cross-slope................................................................................. 49
3.7.5 Working with vibration................................................................. 49
3.7.6 Parking the machine.................................................................... 49
3.8 Refuelling...................................................................................... 51
3.9 What to do in events of emergency............................................ 52
3.9.1 Actuating the emergency stop switch.......................................... 52
3.9.2 Disconnect the battery................................................................. 52
3.9.3 Towing the machine..................................................................... 52
3.10 Maintenance work...................................................................... 54
3.10.1 Preliminary remarks.................................................................. 54
3.10.2 Work on hydraulic lines............................................................. 54
3.10.3 Working on the engine.............................................................. 55
3.10.4 Maintenance work on electric components and battery............ 56
3.10.5 Working on the air conditioning................................................. 56
3.10.6 Working on wheels and tyres.................................................... 57
3.10.7 Cleaning work............................................................................ 57
3.10.8 After maintenance work............................................................. 58
3.11 Repair.......................................................................................... 59
3.12 Signage....................................................................................... 60
4 Display and control elements............................................................. 63
4.1 Driver's stand................................................................................ 64
4.1.1 Instrument cluster........................................................................ 64
4.1.2 Operating console ...................................................................... 68
4.1.3 Travel lever.................................................................................. 72
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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...................................................................... 81
4.4.1 Reversing camera....................................................................... 81
5 Tests before taking into operation..................................................... 83
5.1 Notes on safety............................................................................. 84
5.2 Visual inspections and function tests........................................ 86
5.3 Checking the engine oil level...................................................... 87
5.4 Checking the fuel level, topping up fuel.................................... 88
5.4.1 Checking the fuel level................................................................ 88
5.4.2 Refuelling.................................................................................... 88
5.5 Checking the hydraulic oil level.................................................. 90
5.6 Checking the coolant level.......................................................... 91
5.7 Checking wheels and tyres......................................................... 93
6 Operation.............................................................................................. 95
6.1 Setting-up the work place............................................................ 96
6.1.1 Adjust the driver’s seat................................................................ 96
6.1.2 Swivelling the driver’s seat.......................................................... 97
6.1.3 Adjust the steering wheel............................................................ 97
6.2 Electronic immobilizer................................................................. 98
6.3 Start the engine............................................................................ 99
6.4 Travel operation.......................................................................... 101
6.4.1 Preliminary remarks and safety notes....................................... 101
6.4.2 Driving the machine................................................................... 101
6.4.3 Applying the parking brake........................................................ 102
6.4.4 Notes on travel operation.......................................................... 103
6.5 Working with vibration............................................................... 104
6.5.1 Preliminary remarks and safety notes....................................... 104
6.5.2 Switching the vibration on and off............................................. 105
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6.6 Terrameter................................................................................... 107
6.6.1 Terrameter display..................................................................... 107
6.6.2 Terrameter with printer.............................................................. 108
6.6.3 Line graph (EVIB)........................................................................ 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............................................................ 119
6.10.1 Actuating the emergency stop switch...................................... 119
6.10.2 Disconnecting the battery........................................................ 119
6.10.3 Towing the machine................................................................. 119
6.10.4 After towing............................................................................. 121
7 Loading/transporting the machine.................................................. 125
7.1 Prepare for transport................................................................. 126
7.2 Loading the machine................................................................. 127
7.3 Lashing the machine to the transport vehicle......................... 129
7.4 Loading by crane........................................................................ 130
7.5 After transport............................................................................ 132
8 Maintenance....................................................................................... 133
8.1 Preliminary remarks and safety notes..................................... 134
8.2 Preparations / concluding work................................................ 136
8.2.1 Open and secure the engine hood............................................ 136
8.2.2 Engaging / releasing the articulation lock.................................. 137
8.3 Fuels and lubricants.................................................................. 139
8.3.1 Engine oil................................................................................... 139
8.3.2 Fuel........................................................................................... 141
8.3.3 Coolant...................................................................................... 142
8.3.4 Hydraulic oil............................................................................... 146
8.3.5 Gear oil SAE 75W-90................................................................ 147
8.3.6 Gear oil SAE 80W-140.............................................................. 147
8.4 List of fuels and lubricants........................................................ 148
8.5 Running-in instructions............................................................. 150
8.5.1 General...................................................................................... 150
8.5.2 After 250 operating hours.......................................................... 150
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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................................... 159
8.7.5 Checking the oil level in the exciter housing............................. 160
8.7.6 Changing the fresh air filter in the cabin.................................... 162
8.7.7 Check the parking brake........................................................... 163
8.8 Every 500 operating hours........................................................ 164
8.8.1 Change engine oil and oil filter cartridge................................... 164
8.8.2 Replacing the fuel filter, bleeding the fuel system..................... 167
8.8.3 Checking the anti-freeze concentration and the condition of the
coolant....................................................................................... 170
8.8.4 Renewing the AdBlue®/DEF filter.............................................. 171
8.8.5 Check the hydraulic lines.......................................................... 172
8.8.6 Servicing the battery, checking the main battery isolation......... 174
8.8.7 Servicing the air conditioning system........................................ 175
8.9 Every 1000 operating hours...................................................... 179
8.9.1 Replacing the V-belt.................................................................. 179
8.9.2 Check the engine mounts.......................................................... 180
8.9.3 Replacing the hydraulic oil filter................................................. 180
8.9.4 Change the oil in the drive axle................................................. 183
8.9.5 Changing the oil in the wheel hubs........................................... 184
8.9.6 Change the oil in the exciter housing........................................ 185
8.9.7 Retightening the fastening of the axle on the frame.................. 187
8.9.8 Tighten the wheel nuts.............................................................. 187
8.9.9 Checking the ROPS.................................................................. 187
8.9.10 Checking the travel control...................................................... 188
8.9.11 Cleaning the circulation air filter for the heating...................... 189
8.10 Every 2000 operating hours.................................................... 190
8.10.1 Changing the hydraulic oil....................................................... 190
8.10.2 Change the coolant................................................................. 192
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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............................... 202
8.11.8 Drain the fuel tank sludge........................................................ 203
8.11.9 Measures prior to extended shutdown period......................... 203
9 Trouble shooting............................................................................... 207
9.1 Preliminary remarks................................................................... 208
9.2 Starting the engine with jump leads......................................... 209
9.3 Fuse assignment........................................................................ 210
9.3.1 Notes on safety......................................................................... 210
9.3.2 Central electrics......................................................................... 210
9.3.3 Main fuses................................................................................. 211
9.3.4 Fuse, cabin................................................................................ 212
9.4 Engine faults............................................................................... 213
10 Waste disposal................................................................................... 217
10.1 Final shut-down of machine.................................................... 218
11 List of special tools........................................................................... 219
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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.
The machine described in this manual com-
plies with the applicable standards and safety
regulations.
If your machine is used in traffic on public
roads, it must comply with all applicable
national legal regulations. The driving permit
must be acquired from the responsible authori-
ties.
The machine is equipped with latest tech-
nology. Now it's a matter of handling your
machine properly and keeping it in good
working order.
These instructions will provide you with all nec-
essary information. Read and follow these
notes before starting to operate your machine!
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.
This manual was written for operators and
maintenance personnel.
Always keep this manual close at hand, e.g. in
the tool compartment of the machine or in a
specially provided container. These operating
and maintenance instructions are part of the
machine.
Introduction – Foreword
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