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Contents
-
Table of Contents
-
Bookmarks
Quick Links
Operating instructions
Maintenance instructions
BW 213 D-4
S/N 101 582 50 . . . .
Single drum roller
Catalogue number
06/2004
008 124 31
Related Manuals for Bomag BW 213 D-4
Summary of Contents for Bomag BW 213 D-4
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Page 1
Operating instructions Maintenance instructions BW 213 D-4 S/N 101 582 50 ..Single drum roller Catalogue number 06/2004 008 124 31… -
Page 3
Your BOMAG dealer will also supply you with in- prolong the lifetime of the machine, formation about the correct use of our machines in reduce repair costs and downtimes. -
Page 4
During commissioning our organisation will in- struct you in the operation and maintenance of the machine. Please observe strictly the safety regulations and all notes on risks and dangers! Fig. 2 Fig. 3 BW 213 D-4 B O M A G… -
Page 5: Table Of Contents
5 . 1 9 D r a i n i n g t h e s l u d g e f r o m t h e f u e l t a n k 5 . 2 0 S e r v i c e t h e b a t t e r y BW 213 D-4 B O M A G…
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Page 6
T r o u b l e s h o o t i n g 6 . 1 G e n e r a l n o t e s 6 . 2 E n g i n e BW 213 D-4 B O M A G… -
Page 7
1 Technical Data BW 213 D-4 B O M A G… -
Page 8: G E N E R A L N O T E
T e c h n i c a l D a t a Fig. 4 Dimensions in 2960 2250 1500 2268 2972 5808 2130 BW 213 D-4 BW 213 D-4 Weights Operating weight (CECE) 12525 with ROPS and cabin Axle load, drum (CECE) 7000 Rear axle load (CECE) 5525…
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Page 9
T e c h n i c a l D a t a BW 213 D-4 Electrical equipment Drive system hydrostatic Driven axles Brakes Service brake hydrostatic Parking brake hydr.-mech. Steering Type of steering articulated Steering operation hydrostatic Vibration Vibrating drum… -
Page 10
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is sound pressure level at the work place of the operator (with cabin): = BW 213 D-4 — 75 dB(A) The nose emission value for the machine according to the noise emission regulation 2000/14/EG is… -
Page 11
2 Safety regulations BW 213 D-4 B O M A G… -
Page 12
General Unintended use Dangers may, however, arise from the machine if This BOMAG machine is built in accordance it is used by untrained personnel in an unprofes- with the latest technical standard and the valid sional way or if it is used for purposes other than technical rules and regulations. -
Page 13
Use your personal protective outfit (hard hat, safe- capacity. ty boots etc.). Attach the lifting gear only to the specified lifting Check before mounting the machine if: points. there are persons or obstructions beside or under the machine BW 213 D-4 B O M A G… -
Page 14
Exhaust gases are toxic! Always ensure an ade- bankments and make sure that you work does not quate supply of fresh air when starting in closed impair the stability of the machine. rooms! BW 213 D-4 B O M A G… -
Page 15
Do not jump off the machine, use access steps Lock the articulated joint with the articulation lock. and hand rails. Always secure parked machines, which could be in the way, with appropriate measures. BW 213 D-4 B O M A G… -
Page 16
In case of being in- Only genuine BOMAG hydraulic hoses ensure jured by hydraulic oil you should immediately seek that the correct type of hose (pressure range) is medical advice, as otherwise this may lead to se- used at the right place. -
Page 17
Do not clean the machine while the engine is run- ning. Do not use gasoline or other combustible sub- stances for cleaning purposes. When using steam cleaning equipment do not subject electrical components and insulating ma- BW 213 D-4 B O M A G… -
Page 18
S a f e t y r e g u l a t i o n s BW 213 D-4 B O M A G… -
Page 19
3 Indicators and Controls BW 213 D-4 B O M A G… -
Page 20
I n d i c a t o r s a n d C o n t r o l s Fig. 5 BW 213 D-4 B O M A G… -
Page 21
14 Rotary switch for lighting (StVZO)* Travel lever 15 Rotary switch for working head lights* Rotary switch vibration, high/low frequency 16 Steering wheel adjustment lever Rotary switch for speed range selection Emergency stop push button Optional equipment BW 213 D-4 B O M A G… -
Page 22
Do not let the engine run at idling speed for longer than 10 minutes. Do not shut the engine down all of a sudden from full speed, but let it idle for a while for temperature equalization. BW 213 D-4 B O M A G… -
Page 23
= The seat occupation monitoring sys- tem lights when the seat is not occu- pied. If the machine is travelling the warning buzzer will sound, engine is shut down after 4 seconds. Optional equipment BW 213 D-4 B O M A G… -
Page 24
If the engine speed drops under load when driving on steep gradients, take the travel lever slightly back towards neutral. This relieves the hydraulic system and reduces the load on the diesel engine. BW 213 D-4 B O M A G… -
Page 25
= Full throttle position, operating been shifted back to braking position. position for driving and vibra- tion Caution Always drive and vibrate with max. engine speed! Control the travel speed with the travel lever. BW 213 D-4 B O M A G… -
Page 26
= Hazard light switched off, con- trol lights off. Position «right» = Hazard light switched on, con- trol light 1 in instrument cluster lights up. Optional equipment *** Optional equipment ** Optional equipment **** Optional equipment BW 213 D-4 B O M A G… -
Page 27
= Stop the machine and apply the parking brake. Pull the le- F19, 15A = Working head lights, front, left* ver up and swivel the driver’s seat to the desired position. Optional equipment BW 213 D-4 B O M A G… -
Page 28
= Switches on wiping of rear windscreen. Push button = Rear windscreen is sprayed Fig. 25 during wiping. No. 21 = Control panel for ventilator, air condi- tioning, heating BW 213 D-4 B O M A G… -
Page 29
No. 22 = Cabin light is a compaction measuring unit for continuous dis- play of the load bearing characteristics (MN/m during the compacting pass. value Increase = higher load bearing capacity Optional equipment ** Optional equipment BW 213 D-4 B O M A G… -
Page 30
I n d i c a t o r s a n d C o n t r o l s Constant = end of compaction BW 213 D-4 B O M A G… -
Page 31
4 Operation BW 213 D-4 B O M A G… -
Page 32
Check the hydraulic oil level, top up if neces- sary. Check the coolant level, top up if necessary. Danger Fire hazard! Do not refuel in closed rooms Check the fuel level, top up if necessary. BW 213 D-4 B O M A G… -
Page 33: Starting The Engine
Fig. 29 Check, whether the travel lever (Fig. 29) is en- gaged to the right in brake position. Fig. 30 Turn the rotary vibration selector switch (Fig. 30) to position «0», vibration off. BW 213 D-4 B O M A G…
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Page 34
As soon as the engine ignites return the igni- tion key to position «I». Fig. 33 Turn the ignition key (Fig. 33) to position «I». Caution Do not allow the engine to run longer than 10 minutes with idle speed. BW 213 D-4 B O M A G… -
Page 35: Starting With Jump Wires
If the driver occupies the seat again within this pe- riod of four seconds, the machine will continue After starting disconnect the negative poles travelling. (ground cable) first and the positive poles af- ter. Switch off the consumer. BW 213 D-4 B O M A G…
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Page 36
Fig. 39 Fasten your seat belt (Fig. 39). Fig. 42 Push the travel lever (Fig. 42) to the left out of braking position and move it slowly to the de- sired travel direction. BW 213 D-4 B O M A G… -
Page 37: Switching The Vibration On And Off
Switch to working speed (Fig. 43) (turtle). treme inclinations move the ravel lever slightly back, if necessary change to the lower speed Pre-selecting the vibration range. Fig. 44 Pre-select amplitude/frequency with the rotary switch (Fig. 44). BW 213 D-4 B O M A G…
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Page 38: Operating The Parking Brake, Stopping The Ma- Chine
Press the push button (Fig. 46) in the travel le- ver while driving, the drum will vibrate. Switching the vibration off Press the push button again and after work switch the rotary vibration switch to position «0». BW 213 D-4 B O M A G…
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Page 39: Shutting The Engine Down
Turn rotary switch (Fig. 49) to position «Min» (idle speed). Note Do not shut the engine down all of the sudden from full speed, but let it idle for a while for temperature equalization. BW 213 D-4 B O M A G…
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Page 40: Emergency Exit
Adjustment of steering wheel inclination, press lever down and adjust the inclination of the steering wheel. Danger Danger of accident! After the adjustment make sure that the steer- ing wheel adjustment is securely locked in place. BW 213 D-4 B O M A G…
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Page 41
To adjust the height of the seat lift the seat up Pull the support (Fig. 55) out of the bracket. (Fig. 53) until it engages at the desired level. When lifting the seat completely it will sink down to lowest position. BW 213 D-4 B O M A G… -
Page 42
(Fig. 58) and push the hood together. Store the hood support. Close the hood, lock it and pull off the key. Fig. 57 Push up the hood and place the support rod into its receptacle. BW 213 D-4 B O M A G… -
Page 43
(2) and turn the screw (4) into the tapped Do not turn the valves out completely. bore (3), until it bottoms. Turn the nut (6) down and tighten it approx. one revolution. The drum must rotate freely. BW 213 D-4 B O M A G… -
Page 44
Fig. 63 Unscrew the brake releasing screws (Fig. 63) for two turns and tighten the counter nuts. Repeat this adjustment procedure on the op- posite wheel side. BW 213 D-4 B O M A G… -
Page 45: R A N S P O R T
Weights: See technical data After transport release the articulation lock again and store it in the receptacle. Fig. 65 Engage the articulation lock and secure it with the spring pin (Fig. 65). BW 213 D-4 B O M A G…
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Page 46
O p e r a t i o n BW 213 D-4 B O M A G… -
Page 47: M A I N T E N A N C
5 Maintenance BW 213 D-4 B O M A G…
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Page 48
Clean machine and engine thoroughly before «thin air» (at high altitudes) and with full power, you starting maintenance work. should consult the after sales service of BOMAG or the service department of the engine manufac- For maintenance work park the machine on turer. -
Page 49: Fuels And Lubricants
In order to keep the occurring wear as low as possible, occassional ex- ceeding of the limits should not happen over a longer period of time. BW 213 D-4 B O M A G…
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Page 50
These intervals apply only when using a diesel fuel. fuel with maximum 0.5 % sulphur by weight European Engine Oil Sequences ** American Petroleum Institute BW 213 D-4 B O M A G… -
Page 51
The hydraulic system is operated with hydraulic oil fuels available on the market, which are caused by HV 46 (ISO) with a kinematic viscosity of the non-existence of a standardization, BOMAG 46 mm /s at 40°C. For topping up or for oil chang- does generally not approve any RME-fuels. -
Page 52: Table Of Fuels And Lubri- Cants
Air conditioning system Refrigerant R134A approx. 1400 g Engine cooling system Cooling system protection agent approx. 16 litres Tires Water approx. 295 litres Calcium chloride (CaCl ) or magnesium chloride approx. 100 kg (MgCl BW 213 D-4 B O M A G…
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Page 53: Running-In Instructions
Retighten all wheel fastening screws with the specified tightening torque. Oil change vibration bearings Oil change in drive axle Oil change in wheel hubs After 500 operating hours Oil change vibration bearings BW 213 D-4 B O M A G…
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Page 54: Maintenance Chart
5.21 Change the fuel pre-filter cartridge 5.22 Check, replace the refrigerant com- pressor V-belt 5.23 Service the air conditioning 5.24 Check, adjust the valve clearance Intake = 0,3 mm Exhaust = 0,5 mm BW 213 D-4 B O M A G…
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Page 55
2 years 5.39 Adjust the scrapers 5.40 Adjust the parking brake 5.41 Change the tires 5.42 Change the fresh air filter in the cabin 5.43 Tightening torques 5.44 Engine conservation BW 213 D-4 B O M A G… -
Page 56
** Oil change intervals after 50 h, after 500 h, after 1000 h, and then every 1000 h. *** Also in case of repair in the hydraulic system. **** Also in case of repair in the hydraulic system. BW 213 D-4 B O M A G… -
Page 57: Check The Engine Oil Level
Slacken the drain plug (Fig. 70) for a few turns of fuels and lubricants. and catch running out fuel / water. Tighten the drain plug again and check for leaks, if necessary replace the seal ring. BW 213 D-4 B O M A G…
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Page 58
Do not drive the fuel tank dry, as otherwise the fuel system needs to be bled. Clean the area around the filler opening. Fig. 72 Open the fuel tank cover (Fig. 72). BW 213 D-4 B O M A G… -
Page 59
If necessary fill in hydraulic oil through the filler neck. For quality and quantity of oil refer to the table of fuels and lubricants. BW 213 D-4 B O M A G… -
Page 60
5.11 Checking the dust separa- tor on the oil bath air filter Fig. 75 If the dust reaches the mark loosen the clamp (Fig. 75), take the cover off and clean the bowl. Option BW 213 D-4 B O M A G… -
Page 61
Ensure even pressure in all tires. Screw the valve caps back on. Fig. 77 Note Start to blow out from the exhaust side. Blow the cooler (Fig. 77) out with compressed air. BW 213 D-4 B O M A G… -
Page 62
The oil level must reach the bottom edge of the level bore. Top up oil, if necessary. For quality of oil refer to the table of fuels and lubricants. Turn the level inspection plug tightly back in. BW 213 D-4 B O M A G… -
Page 63
Screw oil filler (2) and level inspection plug (1) back in tightly. Repeat this inspection on the other side. Caution If a loss of oil is found perform trouble shoot- ing, repair the drum if necessary. BW 213 D-4 B O M A G… -
Page 64
Turn the new filter cartridges (Fig. 83) on by Turn the drain plug tightly back in. hand, until the seal contacts. Tighten the filter cartridges for another half turn. BW 213 D-4 B O M A G… -
Page 65
Clean the sealing face on the filter carrier from sump. any dirt. Check the oil level again, if necessary fill up to the Max.-mark. Fig. 86 Slightly oil the rubber seal (Fig. 86) on the new filter cartridge. BW 213 D-4 B O M A G… -
Page 66
Catch running out fuel, do not let it seep into the ground. Do not inhale any fuel fumes. Fig. 87 Unscrew the cap (Fig. 87) and drain off ap- prox. 5 litres of fuel. Turn the cap tightly back in. BW 213 D-4 B O M A G… -
Page 67
For resting periods of more than one month you should always disconnect the battery. Do not forget to perform regular open-circuit volt- age measurements. Fig. 89 BW 213 D-4 B O M A G… -
Page 68
Therefore bleed the fuel system after changing the fuel prefilter. Fig. 91 Unscrew the water separator from the filter cartridge (Fig. 91). BW 213 D-4 B O M A G… -
Page 69
V-belts. Check with thumb pressure whether the V-belt can be depressed more than 10 to 15 mm (0.4 – 0.6 inches) between the V-belt pulleys, retighten if necessary. Optional equipment BW 213 D-4 B O M A G… -
Page 70
30 minutes. Fig. 96 Unscrew the condenser fastening screws (Fig. 96) and fold the condenser forward. Clean the condenser fins on front and back with compressed air or cold water. Optional equipment BW 213 D-4 B O M A G… -
Page 71
The adjusted temperature must be below the actu- Refrigerant must be filled up, if necessary al temperature inside the cabin, so that the com- check the air conditioning system for leaks. pressor will be switched on. Open the hood. BW 213 D-4 B O M A G… -
Page 72
If the reservoir is not in proper condition it must be replaced for safety reasons, as a precaution to protect op- erators and third parties against any danger BW 213 D-4 B O M A G… -
Page 73
Crankshaft position 2 (Fig. 105) (4 cylinder en- gine) Turn the crankshaft one revolution (360°) fur- ther. Perform the adjustment of the valve by follow- ing the adjustment diagram «crankshaft posi- tion 2», black mark. BW 213 D-4 B O M A G… -
Page 74
Exhaust valve = 0,5 mm The feeler gauge must fit with little resistance. If the gap is too narrow or too wide for the feel- er gauge, the valve must be adjusted. BW 213 D-4 B O M A G… -
Page 75
Release the idler pulley against the direction of arrow until the V-belt is tensioned. Measure the V-belt tension, tighten if neces- sary. Note Retighten the new fan V-belt after a running time of 20 minutes. BW 213 D-4 B O M A G… -
Page 76
Fig. 113 Clean and unscrew all level inspection and drain plugs (Fig. 113). Drain and catch all oil. Clean the drain plug and turn it back in with a new seal ring. BW 213 D-4 B O M A G… -
Page 77
Drain and catch all oil. Fig. 116 Move the drive wheel, until the plug (Fig. 116) is in horizontal position on the housing. Fill in oil, until it reaches the bottom edge of the bore. BW 213 D-4 B O M A G… -
Page 78
Move the drum, until the drain plug 1 (Fig. 117) is in bottom position. Unscrew the drain plug, let the oil run out and catch it. Turn the oil drain plug back in tightly after all oil has run out. BW 213 D-4 B O M A G… -
Page 79
Repeat the oil change on the opposite side. Check the oil level once again at operating temperature (after running the machine for about half an hour with vibration). Caution Overfilling causes overheating and destruc- tion of the vibration bearings! BW 213 D-4 B O M A G… -
Page 80
(ROPS) to the operator’s stand for tight fit. Check the rubber buffers of the operator’s plat- form suspension for condition and tight fit. Check the condition and fastening of the seat belts. BW 213 D-4 B O M A G… -
Page 81
Clean the filter mesh by repetitive dipping into diesel fuel. Clean the filter bowl with diesel fuel and fill in engine oil up to the level mark. reinstall the filter bowl. Option BW 213 D-4 B O M A G… -
Page 82
We recommend to use the filling and filtering unit (BOMAG part-no. 079 930 35) with fine filter to fill the hydraulic system. This ensures finest filtration of the hydraulic oil, prolongs the lifetime of the hy- draulic oil filter and protects the hydraulic system. -
Page 83
(5) with the filter element (3) off. Examine the sealing face on the filter element thoroughly for any visible dirt. Caution Visible impurities may be an early indicator for a failure of system components and predict the BW 213 D-4 B O M A G… -
Page 84
Set the cock valve for the cabin heater to posi- tion «warm». Fig. 127 Unscrew the plug, let the coolant run out and catch it. Screw the plug back in once all coolant has run out. BW 213 D-4 B O M A G… -
Page 85
For quality of coolant refer to the chapter 5.2, fuels and lubricants. Start the diesel engine and run it warm to op- erating temperature. Let the engine cool down and check the cool- ant level again, top up if necessary. BW 213 D-4 B O M A G… -
Page 86
E v e r y 3 0 0 0 o p e r a t i n g h o u r s Every 3000 operating hour s 5.37 Checking the injection valves Note This work must only be performed by authorized service personnel. The injection valves must be replaced every 12000 operating hours. BW 213 D-4 B O M A G… -
Page 87
Maintenance of the dry air filter is due when con- trol light “c” (Fig. 129) in the instrument cluster lights permanently when the engine is running, but at the latest after one year. BW 213 D-4 B O M A G… -
Page 88
Especially on the inside of the open end (sealing area). Do not install damaged Fig. 133 filter elements. Pull the main filter element (Fig. 133) carefully If necessary use safety elements. out of the housing. BW 213 D-4 B O M A G… -
Page 89
The safety filter element must be replaced: if the main filter element is defective, after three times cleaning of the main filter ele- ment, at the latest after 2 years, BW 213 D-4 B O M A G… -
Page 90
Retighten the fastening screws. Padfoot drum Check adjustment and condition of front and rear scrapers, if necessary adjust or replace the scraper rubber. BW 213 D-4 B O M A G… -
Page 91
«I» or «II». The parking brake is released Fig. 141 Unscrew locking plate 2 (Fig. 141). Turn the square (1) in anti-clockwise direction against the stop. BW 213 D-4 B O M A G… -
Page 92
The machine must be braked. Fig. 143 Attach the wheel (Fig. 143) and tighten the wheel nuts crosswise with 550 Nm (405 ft. lb.). Check the tire pressure, see technical data. BW 213 D-4 B O M A G… -
Page 93
µ total = 0,14. When using lubricant MOS the specified tighten- ing torques do not apply. Note Self-locking nuts must always be replaced once they have been unscrewed. BW 213 D-4 B O M A G… -
Page 94
5.44 Engine conservation If the engine is to be shut down for a longer period of time (e.g. over winter), please consult the serv- ice department of the engine manufacturer for fur- ther details. BW 213 D-4 B O M A G… -
Page 95
6 Trouble shooting BW 213 D-4 B O M A G… -
Page 96
Danger Danger of injury! Keep away from rotating parts of the engine. BW 213 D-4 B O M A G… -
Page 97
Check the lines for leakages Turbo charger defective Have examined by a specialist Dry air filter dirty clean, replace if necessary Excessive play in the throttle cable Adjust the throttle cable, change it if nec- essary BW 213 D-4 B O M A G… -
Page 98
The generator does not charge the bat- Have examined by a specialis tion, the warning tery, because generator or regulator is de- buzzer sounds fective BW 213 D-4 B O M A G… -
Page 99
T r o u b l e s h o o t i n g BW 213 D-4 B O M A G… -
Page 100
T r o u b l e s h o o t i n g BW 213 D-4 1 0 0 B O M A G…
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Contents
-
Table of Contents
-
Bookmarks
Quick Links
Operating instructions
Maintenance instructions
BW 213 D-4
S/N 101 582 50 . . . .
Single drum roller
Catalogue number
06/2004
008 124 31
Related Manuals for Bomag BW 213 D-4
Summary of Contents for Bomag BW 213 D-4
-
Page 1
Operating instructions Maintenance instructions BW 213 D-4 S/N 101 582 50 ..Single drum roller Catalogue number 06/2004 008 124 31… -
Page 3
Your BOMAG dealer will also supply you with in- prolong the lifetime of the machine, formation about the correct use of our machines in reduce repair costs and downtimes. -
Page 4
During commissioning our organisation will in- struct you in the operation and maintenance of the machine. Please observe strictly the safety regulations and all notes on risks and dangers! Fig. 2 Fig. 3 BW 213 D-4 B O M A G… -
Page 5: Table Of Contents
5 . 1 9 D r a i n i n g t h e s l u d g e f r o m t h e f u e l t a n k 5 . 2 0 S e r v i c e t h e b a t t e r y BW 213 D-4 B O M A G…
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Page 6
T r o u b l e s h o o t i n g 6 . 1 G e n e r a l n o t e s 6 . 2 E n g i n e BW 213 D-4 B O M A G… -
Page 7
1 Technical Data BW 213 D-4 B O M A G… -
Page 8: G E N E R A L N O T E
T e c h n i c a l D a t a Fig. 4 Dimensions in 2960 2250 1500 2268 2972 5808 2130 BW 213 D-4 BW 213 D-4 Weights Operating weight (CECE) 12525 with ROPS and cabin Axle load, drum (CECE) 7000 Rear axle load (CECE) 5525…
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Page 9
T e c h n i c a l D a t a BW 213 D-4 Electrical equipment Drive system hydrostatic Driven axles Brakes Service brake hydrostatic Parking brake hydr.-mech. Steering Type of steering articulated Steering operation hydrostatic Vibration Vibrating drum… -
Page 10
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is sound pressure level at the work place of the operator (with cabin): = BW 213 D-4 — 75 dB(A) The nose emission value for the machine according to the noise emission regulation 2000/14/EG is… -
Page 11
2 Safety regulations BW 213 D-4 B O M A G… -
Page 12
General Unintended use Dangers may, however, arise from the machine if This BOMAG machine is built in accordance it is used by untrained personnel in an unprofes- with the latest technical standard and the valid sional way or if it is used for purposes other than technical rules and regulations. -
Page 13
Use your personal protective outfit (hard hat, safe- capacity. ty boots etc.). Attach the lifting gear only to the specified lifting Check before mounting the machine if: points. there are persons or obstructions beside or under the machine BW 213 D-4 B O M A G… -
Page 14
Exhaust gases are toxic! Always ensure an ade- bankments and make sure that you work does not quate supply of fresh air when starting in closed impair the stability of the machine. rooms! BW 213 D-4 B O M A G… -
Page 15
Do not jump off the machine, use access steps Lock the articulated joint with the articulation lock. and hand rails. Always secure parked machines, which could be in the way, with appropriate measures. BW 213 D-4 B O M A G… -
Page 16
In case of being in- Only genuine BOMAG hydraulic hoses ensure jured by hydraulic oil you should immediately seek that the correct type of hose (pressure range) is medical advice, as otherwise this may lead to se- used at the right place. -
Page 17
Do not clean the machine while the engine is run- ning. Do not use gasoline or other combustible sub- stances for cleaning purposes. When using steam cleaning equipment do not subject electrical components and insulating ma- BW 213 D-4 B O M A G… -
Page 18
S a f e t y r e g u l a t i o n s BW 213 D-4 B O M A G… -
Page 19
3 Indicators and Controls BW 213 D-4 B O M A G… -
Page 20
I n d i c a t o r s a n d C o n t r o l s Fig. 5 BW 213 D-4 B O M A G… -
Page 21
14 Rotary switch for lighting (StVZO)* Travel lever 15 Rotary switch for working head lights* Rotary switch vibration, high/low frequency 16 Steering wheel adjustment lever Rotary switch for speed range selection Emergency stop push button Optional equipment BW 213 D-4 B O M A G… -
Page 22
Do not let the engine run at idling speed for longer than 10 minutes. Do not shut the engine down all of a sudden from full speed, but let it idle for a while for temperature equalization. BW 213 D-4 B O M A G… -
Page 23
= The seat occupation monitoring sys- tem lights when the seat is not occu- pied. If the machine is travelling the warning buzzer will sound, engine is shut down after 4 seconds. Optional equipment BW 213 D-4 B O M A G… -
Page 24
If the engine speed drops under load when driving on steep gradients, take the travel lever slightly back towards neutral. This relieves the hydraulic system and reduces the load on the diesel engine. BW 213 D-4 B O M A G… -
Page 25
= Full throttle position, operating been shifted back to braking position. position for driving and vibra- tion Caution Always drive and vibrate with max. engine speed! Control the travel speed with the travel lever. BW 213 D-4 B O M A G… -
Page 26
= Hazard light switched off, con- trol lights off. Position «right» = Hazard light switched on, con- trol light 1 in instrument cluster lights up. Optional equipment *** Optional equipment ** Optional equipment **** Optional equipment BW 213 D-4 B O M A G… -
Page 27
= Stop the machine and apply the parking brake. Pull the le- F19, 15A = Working head lights, front, left* ver up and swivel the driver’s seat to the desired position. Optional equipment BW 213 D-4 B O M A G… -
Page 28
= Switches on wiping of rear windscreen. Push button = Rear windscreen is sprayed Fig. 25 during wiping. No. 21 = Control panel for ventilator, air condi- tioning, heating BW 213 D-4 B O M A G… -
Page 29
No. 22 = Cabin light is a compaction measuring unit for continuous dis- play of the load bearing characteristics (MN/m during the compacting pass. value Increase = higher load bearing capacity Optional equipment ** Optional equipment BW 213 D-4 B O M A G… -
Page 30
I n d i c a t o r s a n d C o n t r o l s Constant = end of compaction BW 213 D-4 B O M A G… -
Page 31
4 Operation BW 213 D-4 B O M A G… -
Page 32
Check the hydraulic oil level, top up if neces- sary. Check the coolant level, top up if necessary. Danger Fire hazard! Do not refuel in closed rooms Check the fuel level, top up if necessary. BW 213 D-4 B O M A G… -
Page 33: Starting The Engine
Fig. 29 Check, whether the travel lever (Fig. 29) is en- gaged to the right in brake position. Fig. 30 Turn the rotary vibration selector switch (Fig. 30) to position «0», vibration off. BW 213 D-4 B O M A G…
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Page 34
As soon as the engine ignites return the igni- tion key to position «I». Fig. 33 Turn the ignition key (Fig. 33) to position «I». Caution Do not allow the engine to run longer than 10 minutes with idle speed. BW 213 D-4 B O M A G… -
Page 35: Starting With Jump Wires
If the driver occupies the seat again within this pe- riod of four seconds, the machine will continue After starting disconnect the negative poles travelling. (ground cable) first and the positive poles af- ter. Switch off the consumer. BW 213 D-4 B O M A G…
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Page 36
Fig. 39 Fasten your seat belt (Fig. 39). Fig. 42 Push the travel lever (Fig. 42) to the left out of braking position and move it slowly to the de- sired travel direction. BW 213 D-4 B O M A G… -
Page 37: Switching The Vibration On And Off
Switch to working speed (Fig. 43) (turtle). treme inclinations move the ravel lever slightly back, if necessary change to the lower speed Pre-selecting the vibration range. Fig. 44 Pre-select amplitude/frequency with the rotary switch (Fig. 44). BW 213 D-4 B O M A G…
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Page 38: Operating The Parking Brake, Stopping The Ma- Chine
Press the push button (Fig. 46) in the travel le- ver while driving, the drum will vibrate. Switching the vibration off Press the push button again and after work switch the rotary vibration switch to position «0». BW 213 D-4 B O M A G…
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Page 39: Shutting The Engine Down
Turn rotary switch (Fig. 49) to position «Min» (idle speed). Note Do not shut the engine down all of the sudden from full speed, but let it idle for a while for temperature equalization. BW 213 D-4 B O M A G…
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Page 40: Emergency Exit
Adjustment of steering wheel inclination, press lever down and adjust the inclination of the steering wheel. Danger Danger of accident! After the adjustment make sure that the steer- ing wheel adjustment is securely locked in place. BW 213 D-4 B O M A G…
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Page 41
To adjust the height of the seat lift the seat up Pull the support (Fig. 55) out of the bracket. (Fig. 53) until it engages at the desired level. When lifting the seat completely it will sink down to lowest position. BW 213 D-4 B O M A G… -
Page 42
(Fig. 58) and push the hood together. Store the hood support. Close the hood, lock it and pull off the key. Fig. 57 Push up the hood and place the support rod into its receptacle. BW 213 D-4 B O M A G… -
Page 43
(2) and turn the screw (4) into the tapped Do not turn the valves out completely. bore (3), until it bottoms. Turn the nut (6) down and tighten it approx. one revolution. The drum must rotate freely. BW 213 D-4 B O M A G… -
Page 44
Fig. 63 Unscrew the brake releasing screws (Fig. 63) for two turns and tighten the counter nuts. Repeat this adjustment procedure on the op- posite wheel side. BW 213 D-4 B O M A G… -
Page 45: R A N S P O R T
Weights: See technical data After transport release the articulation lock again and store it in the receptacle. Fig. 65 Engage the articulation lock and secure it with the spring pin (Fig. 65). BW 213 D-4 B O M A G…
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Page 46
O p e r a t i o n BW 213 D-4 B O M A G… -
Page 47: M A I N T E N A N C
5 Maintenance BW 213 D-4 B O M A G…
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Page 48
Clean machine and engine thoroughly before «thin air» (at high altitudes) and with full power, you starting maintenance work. should consult the after sales service of BOMAG or the service department of the engine manufac- For maintenance work park the machine on turer. -
Page 49: Fuels And Lubricants
In order to keep the occurring wear as low as possible, occassional ex- ceeding of the limits should not happen over a longer period of time. BW 213 D-4 B O M A G…
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Page 50
These intervals apply only when using a diesel fuel. fuel with maximum 0.5 % sulphur by weight European Engine Oil Sequences ** American Petroleum Institute BW 213 D-4 B O M A G… -
Page 51
The hydraulic system is operated with hydraulic oil fuels available on the market, which are caused by HV 46 (ISO) with a kinematic viscosity of the non-existence of a standardization, BOMAG 46 mm /s at 40°C. For topping up or for oil chang- does generally not approve any RME-fuels. -
Page 52: Table Of Fuels And Lubri- Cants
Air conditioning system Refrigerant R134A approx. 1400 g Engine cooling system Cooling system protection agent approx. 16 litres Tires Water approx. 295 litres Calcium chloride (CaCl ) or magnesium chloride approx. 100 kg (MgCl BW 213 D-4 B O M A G…
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Page 53: Running-In Instructions
Retighten all wheel fastening screws with the specified tightening torque. Oil change vibration bearings Oil change in drive axle Oil change in wheel hubs After 500 operating hours Oil change vibration bearings BW 213 D-4 B O M A G…
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Page 54: Maintenance Chart
5.21 Change the fuel pre-filter cartridge 5.22 Check, replace the refrigerant com- pressor V-belt 5.23 Service the air conditioning 5.24 Check, adjust the valve clearance Intake = 0,3 mm Exhaust = 0,5 mm BW 213 D-4 B O M A G…
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Page 55
2 years 5.39 Adjust the scrapers 5.40 Adjust the parking brake 5.41 Change the tires 5.42 Change the fresh air filter in the cabin 5.43 Tightening torques 5.44 Engine conservation BW 213 D-4 B O M A G… -
Page 56
** Oil change intervals after 50 h, after 500 h, after 1000 h, and then every 1000 h. *** Also in case of repair in the hydraulic system. **** Also in case of repair in the hydraulic system. BW 213 D-4 B O M A G… -
Page 57: Check The Engine Oil Level
Slacken the drain plug (Fig. 70) for a few turns of fuels and lubricants. and catch running out fuel / water. Tighten the drain plug again and check for leaks, if necessary replace the seal ring. BW 213 D-4 B O M A G…
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Page 58
Do not drive the fuel tank dry, as otherwise the fuel system needs to be bled. Clean the area around the filler opening. Fig. 72 Open the fuel tank cover (Fig. 72). BW 213 D-4 B O M A G… -
Page 59
If necessary fill in hydraulic oil through the filler neck. For quality and quantity of oil refer to the table of fuels and lubricants. BW 213 D-4 B O M A G… -
Page 60
5.11 Checking the dust separa- tor on the oil bath air filter Fig. 75 If the dust reaches the mark loosen the clamp (Fig. 75), take the cover off and clean the bowl. Option BW 213 D-4 B O M A G… -
Page 61
Ensure even pressure in all tires. Screw the valve caps back on. Fig. 77 Note Start to blow out from the exhaust side. Blow the cooler (Fig. 77) out with compressed air. BW 213 D-4 B O M A G… -
Page 62
The oil level must reach the bottom edge of the level bore. Top up oil, if necessary. For quality of oil refer to the table of fuels and lubricants. Turn the level inspection plug tightly back in. BW 213 D-4 B O M A G… -
Page 63
Screw oil filler (2) and level inspection plug (1) back in tightly. Repeat this inspection on the other side. Caution If a loss of oil is found perform trouble shoot- ing, repair the drum if necessary. BW 213 D-4 B O M A G… -
Page 64
Turn the new filter cartridges (Fig. 83) on by Turn the drain plug tightly back in. hand, until the seal contacts. Tighten the filter cartridges for another half turn. BW 213 D-4 B O M A G… -
Page 65
Clean the sealing face on the filter carrier from sump. any dirt. Check the oil level again, if necessary fill up to the Max.-mark. Fig. 86 Slightly oil the rubber seal (Fig. 86) on the new filter cartridge. BW 213 D-4 B O M A G… -
Page 66
Catch running out fuel, do not let it seep into the ground. Do not inhale any fuel fumes. Fig. 87 Unscrew the cap (Fig. 87) and drain off ap- prox. 5 litres of fuel. Turn the cap tightly back in. BW 213 D-4 B O M A G… -
Page 67
For resting periods of more than one month you should always disconnect the battery. Do not forget to perform regular open-circuit volt- age measurements. Fig. 89 BW 213 D-4 B O M A G… -
Page 68
Therefore bleed the fuel system after changing the fuel prefilter. Fig. 91 Unscrew the water separator from the filter cartridge (Fig. 91). BW 213 D-4 B O M A G… -
Page 69
V-belts. Check with thumb pressure whether the V-belt can be depressed more than 10 to 15 mm (0.4 – 0.6 inches) between the V-belt pulleys, retighten if necessary. Optional equipment BW 213 D-4 B O M A G… -
Page 70
30 minutes. Fig. 96 Unscrew the condenser fastening screws (Fig. 96) and fold the condenser forward. Clean the condenser fins on front and back with compressed air or cold water. Optional equipment BW 213 D-4 B O M A G… -
Page 71
The adjusted temperature must be below the actu- Refrigerant must be filled up, if necessary al temperature inside the cabin, so that the com- check the air conditioning system for leaks. pressor will be switched on. Open the hood. BW 213 D-4 B O M A G… -
Page 72
If the reservoir is not in proper condition it must be replaced for safety reasons, as a precaution to protect op- erators and third parties against any danger BW 213 D-4 B O M A G… -
Page 73
Crankshaft position 2 (Fig. 105) (4 cylinder en- gine) Turn the crankshaft one revolution (360°) fur- ther. Perform the adjustment of the valve by follow- ing the adjustment diagram «crankshaft posi- tion 2», black mark. BW 213 D-4 B O M A G… -
Page 74
Exhaust valve = 0,5 mm The feeler gauge must fit with little resistance. If the gap is too narrow or too wide for the feel- er gauge, the valve must be adjusted. BW 213 D-4 B O M A G… -
Page 75
Release the idler pulley against the direction of arrow until the V-belt is tensioned. Measure the V-belt tension, tighten if neces- sary. Note Retighten the new fan V-belt after a running time of 20 minutes. BW 213 D-4 B O M A G… -
Page 76
Fig. 113 Clean and unscrew all level inspection and drain plugs (Fig. 113). Drain and catch all oil. Clean the drain plug and turn it back in with a new seal ring. BW 213 D-4 B O M A G… -
Page 77
Drain and catch all oil. Fig. 116 Move the drive wheel, until the plug (Fig. 116) is in horizontal position on the housing. Fill in oil, until it reaches the bottom edge of the bore. BW 213 D-4 B O M A G… -
Page 78
Move the drum, until the drain plug 1 (Fig. 117) is in bottom position. Unscrew the drain plug, let the oil run out and catch it. Turn the oil drain plug back in tightly after all oil has run out. BW 213 D-4 B O M A G… -
Page 79
Repeat the oil change on the opposite side. Check the oil level once again at operating temperature (after running the machine for about half an hour with vibration). Caution Overfilling causes overheating and destruc- tion of the vibration bearings! BW 213 D-4 B O M A G… -
Page 80
(ROPS) to the operator’s stand for tight fit. Check the rubber buffers of the operator’s plat- form suspension for condition and tight fit. Check the condition and fastening of the seat belts. BW 213 D-4 B O M A G… -
Page 81
Clean the filter mesh by repetitive dipping into diesel fuel. Clean the filter bowl with diesel fuel and fill in engine oil up to the level mark. reinstall the filter bowl. Option BW 213 D-4 B O M A G… -
Page 82
We recommend to use the filling and filtering unit (BOMAG part-no. 079 930 35) with fine filter to fill the hydraulic system. This ensures finest filtration of the hydraulic oil, prolongs the lifetime of the hy- draulic oil filter and protects the hydraulic system. -
Page 83
(5) with the filter element (3) off. Examine the sealing face on the filter element thoroughly for any visible dirt. Caution Visible impurities may be an early indicator for a failure of system components and predict the BW 213 D-4 B O M A G… -
Page 84
Set the cock valve for the cabin heater to posi- tion «warm». Fig. 127 Unscrew the plug, let the coolant run out and catch it. Screw the plug back in once all coolant has run out. BW 213 D-4 B O M A G… -
Page 85
For quality of coolant refer to the chapter 5.2, fuels and lubricants. Start the diesel engine and run it warm to op- erating temperature. Let the engine cool down and check the cool- ant level again, top up if necessary. BW 213 D-4 B O M A G… -
Page 86
E v e r y 3 0 0 0 o p e r a t i n g h o u r s Every 3000 operating hour s 5.37 Checking the injection valves Note This work must only be performed by authorized service personnel. The injection valves must be replaced every 12000 operating hours. BW 213 D-4 B O M A G… -
Page 87
Maintenance of the dry air filter is due when con- trol light “c” (Fig. 129) in the instrument cluster lights permanently when the engine is running, but at the latest after one year. BW 213 D-4 B O M A G… -
Page 88
Especially on the inside of the open end (sealing area). Do not install damaged Fig. 133 filter elements. Pull the main filter element (Fig. 133) carefully If necessary use safety elements. out of the housing. BW 213 D-4 B O M A G… -
Page 89
The safety filter element must be replaced: if the main filter element is defective, after three times cleaning of the main filter ele- ment, at the latest after 2 years, BW 213 D-4 B O M A G… -
Page 90
Retighten the fastening screws. Padfoot drum Check adjustment and condition of front and rear scrapers, if necessary adjust or replace the scraper rubber. BW 213 D-4 B O M A G… -
Page 91
«I» or «II». The parking brake is released Fig. 141 Unscrew locking plate 2 (Fig. 141). Turn the square (1) in anti-clockwise direction against the stop. BW 213 D-4 B O M A G… -
Page 92
The machine must be braked. Fig. 143 Attach the wheel (Fig. 143) and tighten the wheel nuts crosswise with 550 Nm (405 ft. lb.). Check the tire pressure, see technical data. BW 213 D-4 B O M A G… -
Page 93
µ total = 0,14. When using lubricant MOS the specified tighten- ing torques do not apply. Note Self-locking nuts must always be replaced once they have been unscrewed. BW 213 D-4 B O M A G… -
Page 94
5.44 Engine conservation If the engine is to be shut down for a longer period of time (e.g. over winter), please consult the serv- ice department of the engine manufacturer for fur- ther details. BW 213 D-4 B O M A G… -
Page 95
6 Trouble shooting BW 213 D-4 B O M A G… -
Page 96
Danger Danger of injury! Keep away from rotating parts of the engine. BW 213 D-4 B O M A G… -
Page 97
Check the lines for leakages Turbo charger defective Have examined by a specialist Dry air filter dirty clean, replace if necessary Excessive play in the throttle cable Adjust the throttle cable, change it if nec- essary BW 213 D-4 B O M A G… -
Page 98
The generator does not charge the bat- Have examined by a specialis tion, the warning tery, because generator or regulator is de- buzzer sounds fective BW 213 D-4 B O M A G… -
Page 99
T r o u b l e s h o o t i n g BW 213 D-4 B O M A G… -
Page 100
T r o u b l e s h o o t i n g BW 213 D-4 1 0 0 B O M A G…
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16 Июня 2017
В ООО «Ярстройрезерв» для диагностики и ремонта поступили два катка BOMAG из Архангельска. В заказ-наряде заказчик указал, что через час-полтора работы катки теряют тягу до такой степени, что не могут переехать препятствие на дороге.
Гидравлическая схема катка BOMAG BW-100 относительно проста. На нем установлен один реверсивный гидравлический насос переменного объема, имеющий привод от двигателя. На переднем мосту катка установлен один гидромотор, на заднем — два. Они запитаны от основного насоса. Передний и пара задних гидромоторов запитаны параллельно, при этом задние гидромоторы запитаны последовательно. Кроме того, на машине установлен шестеренный гидравлический насос рулевой системы, который также является насосом подпитки основного гидронасоса. Неисправность, проявляющаяся в потере тяги может находиться как в основном гидронасосе, так и в гидромоторах или в гидронасосе подпитки. Сложность диагностики заключается в том, что в замкнутой гидросистеме катка диагностика манометром (по падению давления) лишь может указать на наличие неисправности, однако не позволит локализовать ее. Поэтому было принято решение отсечь гидромоторы хода и вместо них поставить специальный гидротестер, позволяющий не только имитировать работу гидромоторов, но и замерять все необходимые параметры. Кроме того, было принято решение установить дополнительный манометр на линию подпитки. Если главный гидравлический насос выдает необходимые параметры, тогда будет произведена диагностика гидромоторов.
После изготовления необходимой диагностической оснастки, гидротестер был подключен вместо гидромоторов хода, а цифровой манометр установлен на линию подпитки. Изначально прибор показал небольшой поток масла на холостом ходу, что могло возникнуть вследствие неправильной регулировки качели насоса, поскольку на холостом ходу насос должен качать 0, однако это не могло являться причиной описанной неисправности. Манометр, измеряющий давление подпитки, показывал норму. После этого на катке был включен ход вперед. Основной насос запустился и начал выдавать показания 60 литров/минуту. После этого специалисты ООО «Ярстройрезерв» с помощью гидротестера начали имитировать нагрузку на гидромоторы хода, которая обычно возникает, когда каток едет. Как только давление в системе начало возрастать, расход начал снижаться. При давлении в системе 100 бар, давление наполнения сократилось до половины от нормы, а расход упал до 40 литров/минуту. При дальнейшем росте нагрузки до 150 бар, давление наполнения сократилось до четверти от нормы, а расход падает до 25 литров/минуту. При давлении в 180 бар главный насос перестал качать.
Поскольку согласно характеристикам насоса он должен выдавать расход при давлении до 380 бар, а в нашем случае расход прекратился при 180 бар, был сделан вывод о неисправности главного насоса. Дополнительным признаком, свидетельствующем о неисправности насоса, является падение давления наполнения в системе, которое регулируется специальным клапанов в насосе.
Наше отдельное спасибо и особое уважение заказчику за ухоженную и чистую технику, с которой было приятно работать!