Fayat BOMAG BW 213 D-4 User manual

BW 213 D-4
Single drum roller
Operating Instruction
Maintenance Instruction
Original Operating Instructions
S/N 101 583 58 1001>
© 08/2014008 043 61

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Table of contents
1Foreword................................................................................................................................................ 7
2 Technical Data..................................................................................................................................... 11
3 Safety regulations............................................................................................................................... 15
3.1 Information and safety stickers/decals on the machine......................................................... 26
4 Indicators and Controls...................................................................................................................... 29
4.1 General notes.............................................................................................................................. 31
4.2 Description of indicators and control elements ...................................................................... 32
4.3 Display and control elements BTM........................................................................................... 45
4.4 Description of indicating and control elements BTM.............................................................. 46
4.5 Line diagram (EVIB)only BTM prof ..................................................................................................... 49
4.6 Description of line diagram (EVIB)only BTM prof ............................................................................. 51
5 Operation............................................................................................................................................. 53
5.1 General......................................................................................................................................... 54
5.2 Tests before taking into operation ........................................................................................... 55
5.3 Electronic immobilizerOptional equipment ........................................................................................ 56
5.4 Starting the engine...................................................................................................................... 57
5.5 Driving the machine ................................................................................................................... 60
5.6 Stopping the machine, operating the parking brake............................................................... 63
5.7 Shutting down the engine.......................................................................................................... 64
5.8 Switching the vibration on and off............................................................................................ 66
5.9 What to do in events of emergency........................................................................................... 68
5.10 Adjusting the steering wheelOptional equipment ............................................................................ 69
5.11 Adjusting the seat..................................................................................................................... 70
5.12 Operating the heating/air conditioning systemOptional equipment .............................................. 71
5.13 Operating the hood................................................................................................................... 73
5.14 BVC/BTM05 settings before start-up ...................................................................................... 74
5.15 Measuring pass with BTMOptional equipment ................................................................................ 78
5.16 Finishing compaction of a track.............................................................................................. 82
5.17 Printing measuring data after completing compactiononly BTM prof ........................................ 83
5.18 Changing the paper roll in the measuring value printeronly BTM prof ...................................... 84
5.19 Changing the printer ribbon in the measuring value printeronly BTM prof ............................... 85
5.20 Towing in case of an engine failure........................................................................................ 86
5.21 Loading/transport..................................................................................................................... 89
6 Maintenance........................................................................................................................................ 93
6.1 General notes on maintenance.................................................................................................. 94
6.2 Fuels and lubricants................................................................................................................... 96
6.2.1 Engine oil................................................................................................................................... 96
6.2.2 Fuel............................................................................................................................................ 98
6.2.3 Coolant....................................................................................................................................... 99
6.2.4 Hydraulic oil.............................................................................................................................. 101
6.2.5 Gear oil..................................................................................................................................... 102
6.2.6 Exciter system.......................................................................................................................... 102
6.3 Table of fuels and lubricants................................................................................................... 103
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6.4 Running-in instructions............................................................................................................ 104
6.4.1 General.................................................................................................................................... 104
6.4.2 After 250 operating hours......................................................................................................... 104
6.4.3 After 500 operating hours......................................................................................................... 104
6.4.4 After 1000 operating hours....................................................................................................... 104
6.5 Maintenance table..................................................................................................................... 105
6.6 Every 10 operating hours......................................................................................................... 107
6.6.1 Checking the engine oil level................................................................................................... 107
6.6.2 Checking the fuel level............................................................................................................. 107
6.6.3 Check the coolant level............................................................................................................ 109
6.6.4 Check the hydraulic oil level .................................................................................................... 109
6.7 Every 250 operating hours....................................................................................................... 111
6.7.1 Check the tire pressure............................................................................................................ 111
6.7.2 Clean the cooling fins on engine and hydraulic oil cooler........................................................ 111
6.7.3 Check the oil level in the drive axle.......................................................................................... 112
6.7.4 Check the oil level in the wheel hubs....................................................................................... 113
6.7.5 Check the oil level in the vibration bearings............................................................................. 114
6.7.6 Check the parking brake.......................................................................................................... 114
6.7.7 Checking, replacing the refrigerant compressor V-beltOptional equipment ...................................... 116
6.8 Every 500 operating hours....................................................................................................... 118
6.8.1 Changing engine oil and oil filter cartridge............................................................................... 118
6.8.2 Check, clean the water separator............................................................................................ 119
6.8.3 Draining the sludge from the fuel tank..................................................................................... 120
6.8.4 Battery service......................................................................................................................... 121
6.8.5 Service the air conditioningOptional equipment ................................................................................ 122
6.8.6 Cleaning the circulation air filter for the heatingOptional equipment ................................................. 126
6.8.7 Changing the bypass filterOptional equipment .................................................................................. 126
6.9 Every 1000 operating hours..................................................................................................... 128
6.9.1 Checking / replacing the ribbed V-belt..................................................................................... 128
6.9.2 Replace the fuel filter cartridge................................................................................................ 129
6.9.3 Change the fuel pre-filter cartridge........................................................................................... 130
6.9.4 Check the engine mounts........................................................................................................ 132
6.9.5 Changing the oil in the vibration bearings................................................................................ 132
6.9.6 Changing the oil in the drive axle............................................................................................. 133
6.9.7 Changing the oil in the wheel hubs.......................................................................................... 134
6.9.8 Retighten the fastening of the axle on the frame..................................................................... 135
6.9.9 Tightening the wheel nuts........................................................................................................ 136
6.9.10 Check the ROPS.................................................................................................................... 136
6.9.11 Check the travel control......................................................................................................... 137
6.10 Every 2000 operating hours................................................................................................... 138
6.10.1 Adjust the valve clearance..................................................................................................... 138
6.10.2 Changing hydraulic oil and breather filter .............................................................................. 139
6.10.3 Changing the hydraulic oil filter ............................................................................................. 140
6.10.4 Changing the coolant............................................................................................................. 141
6.11 Every 3000 operating hours................................................................................................... 144
6.11.1 Replacing ribbed V-belt and idler pulley................................................................................. 144
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6.12 Every 6000 operating hours................................................................................................... 145
6.12.1 Replace the injection valves................................................................................................... 145
6.12.2 Replacing the crank case ventilation valve ........................................................................... 145
6.13 As required.............................................................................................................................. 146
6.13.1 Air filter maintenance............................................................................................................. 146
6.13.2 Retightening the padfoot shell................................................................................................ 149
6.13.3 Adjust the scrapers................................................................................................................ 149
6.13.4 Clean the machine................................................................................................................. 150
6.13.5 Changing the tires.................................................................................................................. 150
6.13.6 Change the fresh air filter in the cabin................................................................................... 151
6.13.7 Fill the provision tank for the windscreen washer systemOptional equipment ................................ 151
6.13.8 Tightening torques................................................................................................................. 151
6.13.9 Engine conservation .............................................................................................................. 152
7 Trouble shooting............................................................................................................................... 153
7.1 Preliminary remarks.................................................................................................................. 154
7.2 Starting the engine with jump leads........................................................................................ 155
7.3 Reading out faults BVC/BTM05............................................................................................... 156
7.4 Engine faults.............................................................................................................................. 158
8 Cab assembly before initial start-up............................................................................................... 161
8.1 Preparations.............................................................................................................................. 163
8.2 Cabin assembly......................................................................................................................... 165
8.3 Final function tests and checks............................................................................................... 173
9 Disposal............................................................................................................................................. 175
9.1 Final shut-down of machine..................................................................................................... 176
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1 Foreword
Foreword
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BOMAG manufactures machine for earth, asphalt and refuse
compaction, stabilizers/recyclers as well as milling machine
and finishers.
BOMAG’s vast experience in connection with state-of-the-art
production and testing methods, such as lifetime tests of all
important components and highest quality demands guar-
antee maximum reliability of your machine.
This manual comprises:
nSafety regulations
nOperating instructions
nmaintenance instructions
nTrouble shooting
Using these instructions will
nhelp you to become familiar with the machine.
navoid malfunctions caused by unprofessional operation.
Compliance with the maintenance instructions will
nenhance the reliability of the machine on construction sites,
nprolong the lifetime of the machine,
nreduce repair costs and downtimes.
BOMAG will not assume liability for the function of the machine
nif it is handled in a way not complying with the usual modes of
use,
nif it is used for purposes other than those mentioned in these
instructions.
No warranty claims can be lodged in case of damage resulting
from
noperating errors,
ninsufficient maintenance and
nwrong fuels and lubricants.
Please note!
This manual was written for operators and maintenance personnel
on construction sites.
Always keep this manual close at hand, e.g. in the tool compart-
ment of the machine or in a specially provided container. These
operating and maintenance instructions are part of the machine.
You should only operate the machine after you have been
instructed and in compliance with these instructions.
Strictly observe the safety regulations.
Please observe also the guidelines of the Civil Engineering Liability
Association ”Safety Rules for the Operation of Road Rollers and
Soil Compactors” and all relevant accident prevention regulations.
For your own personal safety you should only use original
spare parts from BOMAG.
For your machine BOMAG offers service kits to make mainte-
nance easier.
Foreword
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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, the spare parts catalogue is available from your
BOMAG dealer against the serial number of your machine.
Your BOMAG dealer will also supply you with information about the
correct use of our machines in soil and asphalt construction.
The above notes do not constitute an extension of the warranty
and liability conditions specified in the general terms of business of
BOMAG.
We wish you successful work with your BOMAG machine.
BOMAG GmbH
Copyright by BOMAG
Please fill in
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Machine type (Fig. 1)
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Serial-number (Fig. 1 and 2)
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Engine type (Fig. 3)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine number (Fig. 3)
Supplement the above data together with the commis-
sioning protocol.
During commissioning our organisation will instruct you
in the operation and maintenance of the machine.
Please observe strictly the safety regulations and all
notes on risks and dangers!
Fig. 1
Foreword
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Fig. 2
Fig. 3
Foreword
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2 Technical Data
Technical Data
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Fig. 4
BW 213 D-4 A B D H H2 K L O1 O2 S W
Dimensions in mm 2960 2270 1500 2268 2985 490 5808 70 70 35 2130
BW 213 D-4
Weights
Max. operating weight kg 14600
Operating weight (CECE) with ROPS-cabin kg 12525
Axle load, drum (CECE) kg 7225
Rear axle load (CECE) kg 5300
Static linear load kg/cm 33.9
Travel characteristics
Travel speed (1) km/h 0 – 6
Travel speed (2) km/h 0 – 7
Travel speed (3) km/h 0 – 8
Travel speed (4) km/h 0 – 11
Max. gradability without/with vibration (soil dependent) % 45/43
Drive
Engine manufacturer Deutz
Type TCD 2013 L04
Technical Data
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BW 213 D-4
Cooling Water
Number of cylinders 4
Rated power DIN ISO 3046 kW 99
Rated power SAE J 1995 hp 133
Rated speed rpm 2200
Fuel Diesel
Electrical equipment V 12
Drive system hydrostatic
Permissible ambient temperature °C -20 ... +50
Brakes
Service brake hydrostatic
Parking brake hydro-mechanical
Steering
Type of steering Oscill.-articul.
Steering operation hydrostatic
Steering/oscillation angle ± ° 35/12
Inner track radius mm 3494
Vibration
Vibrating drum 1
Drive system hydrostatic
Frequency (1/2) Hz 30/36
Amplitude (1/2) mm 1.90/0.96
Centrifugal force (1/2) kN 275/202
Tires
Tire size 23.1-26/12PR
Air pressure, nominal value bar 1.4
Air pressure, span bar 0.8 - 1.4
Filling capacities
Fuel (diesel) l approx. 340
Technical Data
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Subject to technical alterations.
The following noise and vibration data acc. to
- EC Machine Regulation edition 2006/42/EC
- the noise regulation 2000/14/EG, noise protection guideline
2003/10/EC
- Vibration Protection Regulation 2002/44/EC
were determined during conditions typical for this type of
equipment and by application of harmonized standards.
During operation these values may vary because of the
existing operating conditions.
sound pressure level at the work place of the operator (with
cabin):
LpA = 73 dB(A), determined acc. to ISO 11204 and EN 500
Guaranteed sound power level:
LWA = 103 dB(A), determined acc. to ISO 3744 and EN 500
Vibration of the entire body (driver’s seat)
The weighted effective acceleration value determined according to
ISO 7096 is ≤ 0.5 m/s2.
Hand-arm vibration values
The weighted effective acceleration value determined according to
ISO 5349 is ≤ 2.5 m/s2.
Noise value
Vibration value
Technical Data
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3 Safety regulations
Safety regulations
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This BOMAG machine has been built in compliance 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:
nit is used for purposes other than the ones it is intended for,
nit is operated by untrained personnel,
nit is changed or converted in an unprofessional way,
nthe safety instructions are not observed.
Each person involved in the operation, maintenance and
repair of the machine must therefore read and comply with
these safety regulations. If necessary, this must be confirmed
by obtaining the signature of the customer.
Furthermore, the following obviously also applies:
napplicable accident prevention instructions,
ngenerally accepted safety and road traffic regulations,
ncountry specific safety regulations. It is the duty of the operator
to be acquainted with these instructions and to apply these
accordingly. This applies also for local regulations concerning
different types of handling work. Should the recommendations
in these instructions be different from the regulations valid in
your country, you must comply with the safety regulations valid
in your country.
This machine must only be used for:
nmedium to heavy compaction work in earth construction (road
sub-bases)
nprobably compaction of bituminous material, e.g. road surface
layers.
Dangers may arise from the machine when it is used for purposes
other than the one it is intended for.
Any danger caused by intended use is the sole responsibility of the
customer or driver/operator, the manufacturer cannot be made
liable.
Examples for unintended use are:
nwork with vibration on hard concrete, cured bitumen layers or
extremely frozen ground
ndriving on unstable subbases or too small contact area (danger
of tipping over)
nusing the machine for towing
nuse to pull down walls or demolish buildings
Transporting persons, except the machine driver, is prohibited.
Starting and operation of the machine in explosive environments
and in underground mining is prohibited.
Despite careful work and compliance with standards and regula-
tions it cannot be ruled out that further dangers may arise when
working with and handling the machine.
General
Intended use
Unintended use
Remaining dangers, remaining
risks
Safety regulations
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Both the machine as well as all other system components comply
with the currently valid safety regulations. Nevertheless, remaining
risks cannot be ruled out completely, even when using the machine
for the purpose it is intended for and following all information given
in the operating instructions.
A remaining risk can also not be excluded beyond the actual
danger zone of the machine. Persons remaining in this area must
pay particular attention to the machine, so that they can react
immediately in case of a possible malfunction, an incident or failure
etc.
All persons remaining ion the area of the machine must be
informed about the dangers that arise from the operation of the
machine.
Have the machine inspected by an expert (capable person) as
required for the conditiosn the machine is working under, but at
least once every year.
Only trained, instructed and authorized persons of at least 18 years
of age are permitted to drive and operate this machine. For opera-
tion of the machine the responsibilities must be clearly specified
and complied with.
Persons under the influence of alcohol, medicine or drugs are not
allowed to operate, service or repair the machine.
Maintenance and repair work requires specific knowledge and
must therefore only be performed by trained specialists.
Unauthorized changes to the machine are prohibited for safety rea-
sons.
Original parts and accessories have been specially designed for
this machine.
We wish to make explicitly clear that we have not tested or
approved any parts or accessories not supplied by us.
The installation and/or use of such products may have an adverse
effect on the active and/or passive safety.
The manufacturer explicitly excludes any liability for damage
caused by the use of non-original parts or accessories.
Machines which are not safe to operate or in traffic must be imme-
diately taken out of service and shall not be used, until these defi-
ciencies have been properly rectified.
Safety installations and switches must neither be removed nor
must they be made ineffective.
Regular safety inspections
Who is allowed to operate the
machine?
Changes and conversions to the
machine
Damage, deficiencies, misuse of
safety installations
Safety regulations
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WARNING!
Paragraphs marked like this highlight possible dangers
for persons.
NOTICE!
Paragraphs marked like this highlight possible dangers
for machines or parts of the machine.
Paragraphs marked like this contain technical informa-
tion for the optimal economical use of the machine.
ENVIRONMENT!
Paragraphs marked like this point out practices for
safe and environmental disposal of fuels and lubricants
as well as replacement parts.
Observe the regulations for the protection of the envi-
ronment.
Use only strong and stable loading ramps. The ramp inclination
must be lower than the gradability of the machine.
Secure the machine against turning over or slipping off.
Secure the machine on the transport vehicle against rolling off,
slipping and turning over.
Persons are highly endangered if
nthey step or stand under loads being lifted
nthey remain in the drive range of the machine during a demon-
stration or during loading.
The machine must not swing about when lifted off the ground.
Use only safe lifting gear of sufficient load bearing capacity.
Attach the lifting gear only to the specified lifting points.
You should generally use a tow bar.
Max. towing speed 1 km/h (1.6 mph), max. towing distance 500 m
(1640 ft.).
Before releasing the multi-disc brakes secure the machine properly
against unintended rolling.
Notes on safety in the operating
and maintenance instructions:
Loading the machine
Towing the machine
Safety regulations
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On machines with cab the ROPS is an integral part of
the cab.
The frame of the machine must not be warped, bent or cracked in
the area of the ROPS fastening.
The ROPS must not show any rust, damage, hairline cracks or
open fractures.
The actual weight of the machine must not exceed the testing
weight of the ROPS.
The ROPS must not rattle about when driving. This indicates that it
is not properly fastened. All bolted connections must comply with
the specifications and should be absolutely tight (observe the tight-
ening torques). Screw and nuts must not be damaged, bent or
deformed.
With the cab assembled check also the state of the cabin mounts
(rubber elements and screws).
No accessories may be welded or bolted on and no additional
holes must be drilled without the consent of the manufacturer,
since this will impair the strength of the unit.
The ROPS must therefore also not be straightened or repaired if it
is damaged.
A defect ROPS must generally be replaced with an original spare
part in close coordination with the manufacturer.
Before starting
Operation of the machine is only permitted when sitting in the oper-
ator's seat.
Use only machines which have been properly serviced at regular
intervals.
Become acquainted with the equipment, the control elements, the
working mode of the machine and the area you will be working in.
Use your personal protective outfit (hard hat, safety boots etc.).
Check before mounting the machine if:
nthere are persons or obstructions beside or under the machine
nthe machine is free of any oily and combustible material
nall handrails, steps and platforms are free of grease, oils, fuels,
dirt, snow and ice
nthe engine compartment hood is closed and locked
To climb onto the machine use steps and handrails.
Check before starting, whether:
nthe machine shows any obvious defects
nall protective devices are properly secured in their place
nsteering, brakes, control elements, lighting and warning horn
are in order
nthe seat is correctly adjusted
nthe mirrors (if available) are clean and correctly adjusted.
Checking the Roll Over Protective
Structure (ROPS)
Starting the machine
Safety regulations
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Do not start the machine if any gauges, control lights or controls
are defective.
Do not take any loose objects with you or fasten them to the
machine.
On machines with ROPS you should always wear your seat belt!
Starting
Start and operate the machine only from the operator's seat
For starting set all control levers to "neutral position".
Do not use any starting aids such as Start Pilot or ether.
After starting check all gauges.
Starting with jump leads
Connect plus with plus and minus with minus (ground cable) -
always connect the ground cable last and disconnect it first! Wrong
connections may cause severe damage in the electric system.
Never start the engine by bridging the electrical connections on the
starter, because the machine would probably start to move imme-
diately.
Starting in closed rooms
Exhaust gases are toxic! Always ensure an adequate supply of
fresh air when starting in closed rooms!
Persons in the danger area
If a machine has turned over and the cabin door is jammed, the
right hand cabin window can be used as an escape door.
Before taking up work, also after breaks, you should always con-
vince yourself that the danger zone is free of persons or obstruc-
tions, especially when driving in reverse.
Give warning signals, if necessary. Stop work immediately if per-
sons remain in the danger zone, despite the warning.
Do not step or stand in the articulation area of the machine when
the engine is running. Danger of squashing!
Driving
Always wear the seat belt when driving.
Do not drive on bases with insufficient load bearing capacity.
Do not drive on ice and snow.
In events of emergency and in case of danger actuate the emer-
gency stop switch immediately. Do not use the emergency stop
switch as service brake.
Restart the machine only after the danger that caused the actua-
tion of the emergency stop switch has been eliminated.
If the machine has contacted high-voltage power lines:
ndo not leave the operator’s stand,
nwarn others from coming close to or touching the machine,
Driving the machine
Safety regulations
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