Operating instructions
Maintenance instructions
Original operating instructions
Catalogue No.
008 043 61
05/2012
BW 213 D-4
S/N 101 5 83 08 19 60>
Single drum roller
Foreword
BOMAG 3BW 213 D-4
Foreword
These BOMAG machines are products from
the wide product range of BOMAG machines
for earth and asphalt construction, refuse
compaction and stabilizing/recycling.
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
guarantee maximum reliability of your machine.
This manual comprises:
l Safety regulations
l Operating instructions
l maintenance instructions
l Trouble shooting
Using these instructions will
l help you to become familiar with the machine.
l avoid malfunctions caused by unprofessional
operation.
Compliance with the maintenance instructions will
l enhance the reliability of the machine on con-
struction sites,
l prolong the lifetime of the machine,
l reduce repair costs and downtimes.
BOMAG will not assume liability for the function of
the machine
l if it is handled in a way not complying with the
usual modes of use,
l if it is used for purposes other than those men-
tioned in these instructions.
No warranty claims can be lodged in case of damage resulting from
l operating errors,
l insufficient maintenance and
l wrong 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 compartment 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 maintenance easier.
In the course of technical development we reserve the right for technical modifications
without prior notification.
These operating and maintenance instructions are
also available in other languages.
Apart from that, 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
Foreword
BOMAG4 BW 213 D-4
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)
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Engine number (Fig. 3)
i
Note
Supplement the above data together with the commissioning 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
Fig. 2
Fig. 3
Table of Contents
BOMAG 5BW 213 D-4
Technical Data 9
Safety regulations 13
Indicators and Controls 23
3.1 General notes 26
3.2 Description of indicators and control elements 26
3.3 Display and control elements
BTM 36
3.4 Description of indicating and control elements
BTM 37
3.5 Line diagram (EVIB) 39
3.6 Description of line diagram (EVIB) 41
3.7 Bar diagram (EVIB) 42
Operation 43
4.1 General 44
4.2 Tests before taking into operation 44
4.3 Electronic immobilizer 45
4.4 Starting the engine 45
4.5 Starting with jump wires 47
4.6 Driving the machine 48
4.7 Stopping the machine, operating the parking brake 49
4.8 Shutting down the engine 50
4.9 Switching the vibration on and off 51
4.10 What to do in events of emergency 52
4.11 Adjusting the steering wheel 53
4.12 Adjusting the seat 54
4.13 Operating the heating/air conditioning system 54
4.14 Operating the hood 55
4.15 BVC/BTM05 settings before start-up 56
4.16 Measuring pass with BTM 59
4.17 Finishing compaction of a track 62
4.18 Printing measuring data after completing compaction 63
4.19 Changing the paper roll in the measuring value printer 64
4.20 Changing the printer ribbon in the measuring value printer 65
4.21 Towing in case of an engine failure 66
4.22 Loading/transport 68
Maintenance 71
5.1 General notes on maintenance 72
5.2 Fuels and lubricants 73
5.3 Table of fuels and lubricants 77
5.4 Running-in instructions 78
5.5 Maintenance table 79
Table of Contents
BOMAG6 BW 213 D-4
5.6 Checking the engine oil level 83
5.7 Checking the fuel level 83
5.8 Check the coolant level 84
5.9 Check the hydraulic oil level 85
5.10 Check the tire pressure 87
5.11 Clean the cooling fins on engine and hydraulic oil cooler 87
5.12 Check the oil level in the drive axle 88
5.13 Check the oil level in the wheel hubs 89
5.14 Check the oil level in the vibration bearings 89
5.15 Check the parking brake 90
5.16 Checking, replacing the refrigerant compressor V-belt 91
5.17 Changing engine oil and oil filter 93
5.18 Check, clean the water separator 94
5.19 Draining the sludge from the fuel tank 95
5.20 Battery service 96
5.21 Service the air conditioning 97
5.22 Cleaning the circulation air filter for the heating 99
5.23 Changing the bypass filter 100
5.24 Checking / replacing the ribbed V-belt 101
5.25 Replace the fuel filter cartridge 102
5.26 Change the fuel pre-filter cartridge 103
5.27 Check the engine mounts 104
5.28 Change the oil in the vibration bearings 104
5.29 Change the oil in thedrive axle 105
5.30 Changing the oil in the wheel hubes 106
5.31 Retighten the fastening of the axle on the frame 107
5.32 Tightening the wheel nuts 108
5.33 Check the ROPS 108
5.34 Check the travel control 109
5.35 Adjust the valve clearance 111
5.36 Changing hydraulic oil and breather filter 112
5.37 Changing the hydraulic oil filter 113
5.38 Changing the coolant 114
5.39 Replacing ribbed V-belt and idler pulley 117
5.40 Replace the injection valves 119
5.41 Replacing the crank case ventilation valve 119
5.42 Air filter maintenance 121
5.43 Adjust the scrapers 123
5.44 Clean the machine 124
5.45 Changing the tires 125
5.46 Change the fresh air filter in the cabin 125
5.47 Fill the provision tank for the windscreen washer system 126
Table of Contents
BOMAG 7BW 213 D-4
5.48 Tightening torques 126
5.49 Engine conservation 127
Trouble shooting 129
6.1 General notes 130
6.2 Reading out faults BVC/BTM05 130
6.3 Engine problems 132
Cab assembly before initial start-up 135
7.1 Preparations 137
7.2 Cabin assembly 138
7.3 Final function tests and checks 144
Disposal 145
8.1 Final shut-down of machine 146
Table of Contents
BOMAG8 BW 213 D-4
BOMAG 9BW 213 D-4
1 Technical Data
Technical Data
BOMAG10 BW 213 D-4
Fig. 4
BW 213 D-4 A B D H H2 K L O1 O2 S W
Dimensions in mm2960 2270 1500 2268 2985 490 5808 70 70 35 2130
*
BW 213 D-4
Weights
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
Max. operating weight kg 14600
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
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
Technical Data
BOMAG 11BW 213 D-4
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 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
Motor l approx. 15,5
Fuel l approx. 340
Hydraulic oil l approx. 160
Coolant l approx. 16
* The right for technical modifications remains reserved
*
BW 213 D-4
Technical Data
BOMAG12 BW 213 D-4
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.
Noise value
sound pressure level at the work place of the operator (with cabin):
L
pA
= 73 dB(A), determined acc. to ISO 11204 and EN 500
Guaranteed sound power level:
L
WA
= 103 dB(A), determined acc. to ISO 3744 and EN 500
Vibration value
Vibration of the entire body (driver’s seat)
The weighted effective acceleration value determined according to ISO 7096 is ≤ 0.5 m/s
2
.
Hand-arm vibration values
The weighted effective acceleration value determined according to ISO 5349 is ≤ 2.5 m/s
2
.
BOMAG 13BW 213 D-4
2 Safety regulations
Safety regulations
BOMAG14 BW 213 D-4
General
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:
l it is used for purposes other than the ones it is
intended for,
l it is operated by untrained personnel,
l it is changed or converted in an unprofessional
way,
l the 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:
l applicable accident prevention instructions,
l generally accepted safety and road traffic reg-
ulations,
l country 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.
Intended use
This machine must only be used for:
l medium to heavy compaction work in earth
construction (road sub-bases)
l probably compaction of bituminous material,
e.g. road surface layers.
Unintended use
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:
l work with vibration on hard concrete, cured bi-
tumen layers or extremely frozen ground
l driving on unstable subbases or too small con-
tact area (danger of tipping over)
l using the machine for towing
l use 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.
Remaining dangers, remaining risks
Despite careful work and compliance with standards and regulations it cannot be ruled out that further dangers may arise when working with and
handling the machine.
Both the machine as well as all other system components comply with the currently valid safety regulations. 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.
Regular safety inspections
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.
Who is allowed to operate the machine?
Only trained, instructed and authorized persons of
at least 18 years of age are permitted to drive and
operate this machine. For operation of the machine the responsibilities must be clearly specified
and complied with.
Safety regulations
BOMAG 15BW 213 D-4
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.
Changes and conversions to the machine
Unauthorized changes to the machine are prohibited for safety reasons.
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.
Damage, deficiencies, misuse of safety
installations
Machines which are not safe to operate or in traffic
must be immediately taken out of service and shall
not be used, until these deficiencies have been
properly rectified.
Safety installations and switches must neither be
removed nor must they be made ineffective.
Notes on safety in the operating and
maintenance instructions:
!
Danger
Paragraphs marked like this highlight possible
dangers for persons.
!
Caution
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.
i
Note
Paragraphs marked like this contain technical information 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 environment.
Loading the machine
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
l they step or stand under loads being lifted
l they remain in the drive range of the machine
during a demonstration 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.
Towing the machine
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.
Checking the Roll Over Protective
Structure (ROPS)
i
Note
On machines with cab the ROPS is an integral part
of the cab.
Safety regulations
BOMAG16 BW 213 D-4
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 tightening 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.
Starting the machine
Before starting
Operation of the machine is only permitted when
sitting in the operator'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:
l there are persons or obstructions beside or
under the machine
l the machine is free of any oily and combustible
material
l all handrails, steps and platforms are free of
grease, oils, fuels, dirt, snow and ice
l the engine compartment hood is closed and
locked
To climb onto the machine use steps and handrails.
Check before starting, whether:
l the machine shows any obvious defects
l all protective devices are properly secured in
their place
l steering, brakes, control elements, lighting
and warning horn are in order
l the seat is correctly adjusted
l the mirrors (if available) are clean and correct-
ly adjusted.
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 immediately.
Starting in closed rooms
Exhaust gases are toxic! Always ensure an adequate supply of fresh air when starting in closed
rooms!
Driving the machine
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 convince yourself that the danger
Safety regulations
BOMAG 17BW 213 D-4
zone is free of persons or obstructions, especially
when driving in reverse.
Give warning signals, if necessary. Stop work immediately if persons 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 emergency stop switch immediately. Do
not use the emergency stop switch as service
brake.
Restart the machine only after the danger that
caused the actuation of the emergency stop switch
has been eliminated.
If the machine has contacted high-voltage power
lines:
l do not leave the operator’s stand,
l warn others from coming close to or touching
the machine,
l if possible drive the machine out of the danger
zone,
l have the power switched off.
Operate the machine only from the operator’s
stand.
Keep the cabin doors closed.
Do not adjust the driver’s seat while driving.
Do not climb onto or off the machine while the machine is driving.
Change the travel direction only at standstill.
Do not use the machine to transport persons.
In case of unusual noises and development of
smoke perform trouble shooting and have the fault
corrected.
Always keep a sufficient distance to excavation
walls and embankments and do not use working
methods that could impair the stability of the machine.
Do not work with vibration on hard concrete, cured
bitumen layers or extremely frozen ground.
Always keep a sufficient distance when passing
through subways, under bridges, tunnels, electric
power lines etc.
Driving on inclinations and slopes
Do not drive on gradients exceeding the maximum
gradability of the machine.
On slopes drive extremely careful and always directly up or down the slope. Change to a lower
gear before starting to drive.
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclinations
and slopes. Higher risk of accident!
Inclination
Fig. 5
The tipping angle was measured in static condition
on level, hard ground with the machine stopped,
no steering and without vibration.
With loose soil, acceleration/deceleration, running
vibration, steering or attached accessoriies the tipping angle may be considerably lower.
Driving across slopes should therefore be strictly
avoided, because of the high risk of tipping over
and the related risk of severe or even fatal accidents.
You should therefore always drive straight up or
down a slope.
Behaviour in traffic
Match the speed to the working conditions. Do not
make extreme steering movements when driving
with high speed, danger of tipping over!
Always give way to loaded transport vehicles.
Switch the lights on if the visibility is poor.
Keep away from edges and embankments.
Safety regulations
BOMAG18 BW 213 D-4
Checking the effect of vibration
When compacting with vibration you must check
the effect on nearby buildings and underground
supply lines (gas, water, sewage, electric power),
if necessary stop compaction work with vibration.
Do not activate the vibration on hard (frozen, concrete) ground. Danger of bearing damage!
Parking the machine
Park the machine on horizontal, level, firm ground.
Before leaving the machine:
l Straighten the articulated joint to provide easi-
er access to the machine.
l return the control lever to neutral position
l apply the parking brake
l shut the engine down, pull the ignition key off
l close the cabin
l secure the machine against unintended use.
Do not jump off the machine, but use hand grips
and access steps.
Mark machines, which could be in the way, with a
clearly visible sign.
Parking on slopes and inclinations
Secure the machine against rolling, place metal
chocks in front of and behind the wheels. The
wheel chocks must be provided by the operating
company.
Refuelling
Do not inhale any fuel fumes.
Refuel only with the engine shut down.
Do not refuel in closed rooms.
No open fire, do not smoke.
Monitor the entire refuelling process.
Do not spill any fuel. Catch running out fuel, do not
let it seep into the ground.
Wipe off spilled fuel. Keep dirt and water away
from the fuel.
A leaking fuel tank can cause an explosion. Ensure tight fit of the fuel tank cover, if necessary replace immediately.
Fire protection measures
Familiarise yourself with the location and the operation of fire fighting equipment. Observe all fire reporting and fire fighting possibilities.
Maintenance work
Comply with the maintenance work described in
the operating and maintenance instructions, including the information concerning the replacement of parts.
Support the engine hood for all maintenance and
repair work in the engine compartment.
Maintenance work must only be performed by
qualified and authorized persons.
For overhead maintenance and assembly work
use the access steps and working platforms provided or other secure means. Do not use machine
parts as access steps.
Keep unauthorized persons away from the machine.
Do not perform maintenance work while the machine is driving or the engine is running.
Park the machine on horizontal, level, firm ground.
Pull the key out of the ignition switch.
Secure the articulated joint with the articulation
lock.
Work on hydraulic lines
Relieve hydraulic pressures before working on hydraulic lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe
injury. When being injured by hydraulic oil consult
a medical doctor immediately, as otherwise this
may cause severe infections.
Do not step in front of or behind the drums/wheels
when performing adjustment work in the hydraulic
system.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature –
danger of scalding!
Catch running out hydraulic oil and dispose of environmentally.
Always catch and dispose of hydraulic oils separately.
Do not start the engine after draining the hydraulic
oil.
Safety regulations
BOMAG 19BW 213 D-4
Once all work is completed (with the system still
depressurized!) check all connections and fittings
for leaks.
Changing hydraulic hoses
Hydraulic hoses must be visually inspected at regular intervals.
Hydraulic hoses must be immediately replaced if:
l the outer layer is damaged down to the inlay
(e.g. chafing, cuts, cracks)
l the outer layer is brittle (formation of cracks in
the hose material)
l the hose shows deformations in pressurized
and depressurized condition, which do not
comply with the genuine shape of the hydraulic hose
l the hose shows deformations in bends, e.g.
squeezing, buckling, layer separation, formation of blisters
l parts of the hose are leaking.
l hoses are not correctly installed.
l the hydraulic hose has separated from the fit-
ting
l the fitting shows corrosion that impairs both
function and strength.
l hoses are mixed up by mistake.
l fittings are damaged or deformed, whereby
the function and strength of the hose/hose
connection is impaired.
Only genuine BOMAG replacement hydraulic hoses ensure that the correct hose type (pressure
range) is used at the right location.
Working on the engine
Shut the engine down before opening the engine
hood.
Do not work on the fuel system while the engine is
running - danger to life due to high pressures!
l Wait another minute after the engine has
stopped.
l Keep out of the danger zone during the initial
test rung.
l In case of leaks return to the workshop imme-
diately.
l Make sure that the engine cannot be started
unintentionally during service and repair work.
Drain the engine oil at operating temperature –
danger of scalding!
Wipe off spilled oil, catch running out oil and dispose of environmentally.
Store used filters and other oil contaminated materials in a separate, specially marked container
and dispose of environmentally.
Do not leave any tools or other objects, that could
cause damage, in the engine compartment.
The settings for idle speed and highest speed
must not be changed, since this would affect the
exhaust gas values and cause damage to engine
and power train.
Turbo chargers work with high speeds and high
temperatures. Keep hands, tools and materials
away from the intake and outlet openings of the
nturbo charger and do not touch any hot surfaces.
Check and change coolant only when the engine
is cold.
Catch coolant and dispose of environmentally.
Working on electric parts of the machine
Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and
do not repair fuses with a piece of wire. Fire hazard!
Disconnect the battery before starting welding
work on the machine.
Working on the battery
When working on the battery do not smoke, do not
use open fire!
Do not let acid come in contact with hands or
clothes! When injured by acid flush off with clear
water and seek medical advice.
Metal objects (e.g. tools, rings, watch straps) must
not come in contact with the battery poles – danger of short circuit and burning!
When recharging serviceable batteries remove all
plugs, to avoid the accumulation of explosive gases.
Observe the applicable instructions when starting
with an auxiliary battery.
Dispose of old batteries according to regulations.
Switch off the charging current before removing
the charging clamps.
Safety regulations
BOMAG20 BW 213 D-4
Ensure sufficient ventilation, especially if the battery is to be charged in a closed room.
Working on the fuel system
Do not inhale any fuel fumes.
Avoid open fire, do not smoke, do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground and dispose off environmentally.
Working on wheels and tires
Explosion-like bursting of tires or parts of tires and
rims can cause most severe or even deadly injuries.
Assemble the tires only if are sufficiently experienced and with the right tools at hand. If necessary
have the tires assembled in a qualified workshop.
Always ensure the correct tire pressure and do not
exceed the specified maximum pressure.
Check tires and wheels every day for specified
pressure, cuts, bulges, damaged rims, missing
wheel studs or nuts. Do not drive with damaged
tires or wheels.
Ant-sticking emulsions for tires must only consist
of water and anti-sticking agent, in a concentration
in accordance with the specifications of the manufacturer of the anti-sticking agent. Observe applicable environmental regulations.
Working on the air conditioning
Faults on the air conditioning should only be remedied by professional personnel.
According to the regulation for pressure reservoirs
all pressure reservoirs must be repeatedly inspected by a specialist.
In connection with this inspection the drier/collector unit must be visually examined twice every
year. During these inspections special attention
must be paid to corrosion and mechanical damage.
Do not perform welding work in the vicinity of the
air conditioning. Danger of explosion!
Do not clean the condenser in the air conditioning
system with a hot water jet. Danger of explosion!
Do not release refrigerant into the atmosphere, but
dispose of environmentally.
Cleaning work
Do not perform cleaning work while the motor is
running.
Do not use gasoline or other easily inflammable
substances for cleaning.
When cleaning with steam cleaning equipment do
not subject electrical parts and insulation material
to the direct jet of water, or cover it beforehand.
l Do not guide the water jet into the exhaust and
into the air filter.
After maintenance work
After all maintenance work is completed reinstall
all guards and safety installations.
Repair
Mark a defective machine by attaching a warning
tag to the steering wheel.
Repair work must only be performed by qualified
and authorized persons. Use our repair instructions for this work.
Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting
in closed rooms!
Do not work on the fuel system while the engine is
running - danger to life!
The system is under high pressure! Keep away
from leakages in the high pressure system, because fuel squirting out may cause severe injury.
After shutting down the engine wait for another
minute, until the pressure has dropped to a permissible level. In case of leakages you should contact the Service Department of the engine
manufacturer and refrain from starting the engine.
Test
The safety of compaction equipment must be
checked by a specialist as required in dependence
on the application and the operating conditions,
however at least once every year.
Information and safety stickers/decals
on the machine
Keep stickers/decals complete (see spare parts
catalogue) and fully legible and observe their
meaning.
Replace damaged or illegible stickers/decals immediately.
Safety regulations
BOMAG 21BW 213 D-4
Fig. 6
1 Information sticker "Hydraulic oil"
2 Information sticker "Diesel"
3 Operation sticker "Hood handle"
4 Information sticker "Vehicle voltage 12 V"
5 Information sticker "Lifting point"
6 Information sticker "Lashing points"
7 Information sticker "Engine oil drain port"
8 Prohibition sticker "High pressure cleaner"
9 Information sticker "Hydraulic oil and coolant
drains"
10 Information sticker "Guaranteed sound capac-
ity level"
11 Warning sticker "Danger of crushing"
Stickers and decals
Safety regulations
BOMAG22 BW 213 D-4
Fig. 7
Instruction sticker - Always wear your seat belt
Fig. 8
Information sticker "Emergency exit"
Fig. 9
Information sticker - Main battery switch
*
Fig. 10
Information sticker "Bio Hydraulic Oil"
**
Fig. 11
Information sticker "Panolin 46"
***
* Optional equipment
** Optional equipment
*** Optional equipment
BOMAG 23BW 213 D-4
3 Indicators and Controls
Indicators and Controls
BOMAG24 BW 213 D-4
Fig. 12
Indicators and Controls
BOMAG 25BW 213 D-4
1 Start switch
2 Instrument cluster
3 Rotary switch for cabin fan
*
4 Rotary switch for air conditioning system*
5 Vent for heating and ventilation, driver
6 Vent for heating and ventilation, footwell
7 Push button vibration
8 Travel lever
9 Rotary switch for vibration, amplitude selection
10 Rotary switch for travel ranges
11 Emergency stop push button
12 Push button for warning horn
13 Rotary momentary contact switch for engine
speed
14 Rotary switch for direction indicators*
15 Rotary switch for hazard light system*
16 Rotary switch for lighting*
17 Rotary switch for working head lights*
18 Steering wheel adjustment lever
19 Rotary switch for cabin heater*
* Optional equipment
Indicators and Controls
BOMAG26 BW 213 D-4
3.1 General notes
If you are not yet familiar with the control and display elements on this machine you should read
this section thoroughly before starting any operation on the machine. Here all functions are described in detail.
The section "Operation" contains only brief descriptions of the individual control steps.
3.2 Description of indicators
and control elements
Fig. 13
No. 1 = Start switch
Position "P", "0"= Ignition off, key can be pulled
out
Position "I", "II" = Ignition on, all control and
warning lights in the instrument cluster light up for 3 seconds (test function). The oil
pressure warning light flashes,
charge control light and parking brake warning light stay on.
The preheating control light
lights up in case of low temperatures.
i
Note
The engine can only be started if both travel levers
are in “neutral”.
The starter switch is designed with a re-start lock.
For a new starting attempt the ignition key must
first be turned back to position "0".
Position
"START" = Turn further against spring
pressure, the engine starts,
turn the ignition key back to
position "I" once the engine
has started.
!
Caution
Run the engine warm for a short while before
starting work. Do not rev up a cold engine to
high idle speed/full load speed.
Indicators and Controls
BOMAG 27BW 213 D-4
Do not shut down the engine all of a sudden
from full load speed, but let it idle for about 2
minutes.
Fig. 14
No. 2 = Instrument cluster
i
Note
With the ignition switch in position "I" all control
and warning lights are switched on for a moment.
a yellow = Water in fuel warning light
Lights when the water content in the
fuel pre-cleaner reaches the sensor
contacts. Warning buzzer sounds.
The engine is shut down after 2 seconds.
Clean the water separator.
b yellow = Preheating control light
Lights when temperatures are low
(pre-heating for starting)
c yellow = Driver's seat warning light
Lights when the driver's seat is not
occupied. If the machine is travelling
the warning buzzer will sound, engine is shut down after 4 seconds. To
continue travelling occupy the driver's seat and shift the travel lever
through the braking position.
d red = Engine oil pressure warning light
Flashes when the engine oil pressure
is too low, the warning buzzer
sounds, the engine is shut down after
10 seconds.
Check engine oil level, repair the engine if necessary.
e red = Coolant level warning light
Flashes if the coolant level is too low,
the warning buzzer sounds, the engine is shut down after 10 seconds.
Check coolant level. Check cooling
system for leaks, repair if necessary.
f yellow = Charge control light
Lights when the battery is not being
charged.
Check V-belt, if necessary repair the
generator.
g yellow = Air filter warning light
Lights when the combustion air filter
cartridge is contaminated, the warning buzzer sounds.
Clean or replace, as necessary.
h red = Warning light engine overheating
Flashes if the engine overheats, the
warning buzzer sounds, the engine is
shut down after approx. 2 minutes.
Clean engine oil cooler, repair the engine is necessary.
i yellow = Hydraulic oil filter warning light
Lights when the hydraulic oil filter is
contaminated, the warning buzzer
sounds, the engine is shut down after
2 minutes.
Check hydraulic system, replace hydraulic oil filter.
j green = Indicator control light
k red = Parking brake warning light
Lights when the parking brake is applied
l = Operating hour meter
Counts the operating hours while the
engine is running.
All maintenance work must be performed according to the indicated operating hours.
m = Fuel level gauge
Indicators and Controls
BOMAG28 BW 213 D-4
Fig. 15
No. 3 = Rotary switch for cabin fan
Position 0 = Cabin fan switched off.
Position 1, 2 and
3 = Fan stages of different
strengths
Fig. 16
No. 4 = Rotary switch for air conditioning
system
*
i
Note
Only switch the air conditioning system on when
the rotary switch for the cabin fan in position 1, 2
or 3.
Position 0 = Air conditioning switched off.
Position min. and
max. = Air conditioning control seg-
ment
No. 5 = Vents for air conditioning, heating
and ventilation, driver
No. 6 = Vents for air conditioning, heating
and ventilation, footwell
**
Fig. 17
No. 7 = Push button vibration
. = Switching the vibration on
press again = Switching the vibration off
Fig. 18
No. 8 = Travel lever
Position "middle" = Braking position service brake
Position "middle,
right" = Parking brake, to start the en-
gine
Position "I" = Forward travel
Position "II" = Backwards travel
* Optional equipment ** Optional equipment
Indicators and Controls
BOMAG 29BW 213 D-4
i
Note
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.
Fig. 19
No. 9 = Rotary switch for vibration, amplitude
selection
Position left = low amplitude, high frequency
Position "middle" = Vibration off
Position right = high amplitude, low frequency
Fig. 20
No. 10 = Rotary switch for speed ranges with-
out ASC
Position "turtle" = Working speed range on level
ground
Position "Drum" = if the drum starts to slip
Position
"Wheels" = if the wheels are slipping
Position "rabbit" = Transport speed range, e.g. to
drive to the work location
Fig. 21
No. 11 = Emergency stop switch
The engine will be shut down and the brake will
close.
!
Danger
Danger of accident!
Operate only in emergency situations during
operation, do not use as a service brake.
The machine should only be started again after
the danger, that caused the actuation of the
emergency stop switch, has been removed.
operate = push the button completely
down, it will automatically lock
in end position.
unlock = turn the button clockwise and
release it.
to drive = move the travel lever first to
braking position, then start the
engine and choose the travel
direction.
For safety reasons the travel system of the machine will only be enabled after the travel lever has
been shifted back to braking position.
Indicators and Controls
BOMAG30 BW 213 D-4
Fig. 22
No. 12 = Push button for warning horn
Fig. 23
No. 13 = Rotary momentary contact switch for
engine speed
Electric engine speed adjustment
Momentary contact position left = Idle speed position
i
Note
Normal position for engine start.
Momentary contact position
right = Full throttle position, operating
position for driving and vibration
!
Caution
Always drive and vibrate with max. engine
speed! Control the travel speed with the travel
lever.
Fig. 24
No. 14 = Rotary switch for direction indica-
tors
*
Position "middle" = Direction indicators disabled
Position "left or
right" = Front and rear direction indica-
tors on the corresponding side
are flashing. Indicator control
light in instrument cluster
flashes.
Fig. 25
No. 15 = Rotary switch for hazard light system
**
Position "left" = Hazard light system switched
off
Position "right" = Hazard light system switched
on. All flashing lamps and the
flashing control light in the instrument cluster are flashing.
* Optional equipment
** Optional equipment
Indicators and Controls
BOMAG 31BW 213 D-4
Fig. 26
No. 16 = Rotary switch for lighting
*
Position Left = Light off
Position "middle" = Sidelights on, with ignition
switch in position "I" or "P"
Position Right = Travel light on with ignition
switch in position "I"
Fig. 27
No. 17 = Rotary switch for working lights
**
Position "left" = Light off
Position "right" = Working lights on, with ignition
switch in position "I".
Fig. 28
No. 18 = Lever, steering wheel adjustment
***
!
Danger
Danger of accident!
Do not adjust the steering wheel while driving.
pull up = adjust height of steering wheel
press down = adjust inclination of steering
wheel
Fig. 29
No. 19 = Rotary switch for cabin heater
Position "0" = Cabin heater switched off
Position red
range = Temperature selection for cab-
in heating
* Optional equipment
** Optional equipment
583149
*** Optional equipment
Indicators and Controls
BOMAG32 BW 213 D-4
Fig. 30
No. 20 = Lever, swivelling of driver’s seat
*
!
Danger
Danger of accident!
Always lock the driver’s seat in one of the locking positions while driving.
Do not swivel the driver’s seat while driving.
turn = Stop the machine and apply
the parking brake. Pull the lever up and swivel the driver’s
seat to the desired position.
i
Note
Swivelling angle max. 20° to either side.
Fig. 31
No. 21 = 2-pole socket
Current only with the ignition switch in position "I"
or when the engine is running.
Fig. 32
No. 22 = Fuses in electric junction box
!
Danger
Fire hazard!
Do not use fuses with higher ampere ratings
and do not bridge fuses.
(15) 30A = (F13) Start switch
(16) 5A = (F68) Electronic immobilizer
(17) 20A = (F105) Engine speed
(18) 15A = (F11) Front head lights
**
(19) 15A = (F07) Hazard light
(21) 15A = (F22) Working headlights, rear
(22) 15A = (F19) Working headlights, rear
(23) 15A = (F09) Parking and tail light, left*
(24) 15A = (F10) Parking and tail light, right*
(25) 15A = (F08) Direction indicators*
(26) 10A = (F18) Pre-fuse for working head
lights
(27) 15A = (F14) Engine solenoid
(28) 10A = (F23) Warning horn
(29) 10A = (F25) solenoid valve for driving and
braking
(30) 15A = (F39) Main fuse for cabin
(31) 10A = (F24) Instruments
(32) 15A = (F03) Vibration
(33) 10A = (F148) Control MESX, potential 15*
(34) 10A = (F84) control, contact 54
(35) 15A = (F146) Control MESX, potential 30*
(37) 25A = (F124) Fuel pre-heating*
* Optional equipment ** Optional equipment
Indicators and Controls
BOMAG 33BW 213 D-4
Fig. 33
(80) 5A = (F150) GPS Receiver*
Fig. 34
No. 23 = Toggle switch, cabin
a = toggle switch for flashing beacon
b = toggle switch for front windscreen wiper/
washer
up = windscreen wiper moves to
end position and stops.
down = Switches on front windscreen
wiping.
Push button = Front windscreen is sprayed
during wiping.
c = toggle switch for rear windscreen wiper/
washer
up = windscreen wiper moves to
end position and stops.
down = Switches on wiping of rear
windscreen.
Push button = Rear windscreen is sprayed
during wiping.
d = toggle switch for rear windscreen heating
Fig. 35
!
Danger
Fire hazard!
Do not use fuses with higher ampere ratings
and do not bridge fuses.
(1) 15A = (F43) Wiper/washer, rear
(2) 15A = (F44) Wiper/washer, front
(3) 10A = (F130) Night light
(4) 25A = (F31) Cabin ventilator
(5) 10A = (F41) Flashing beacon
(6) 15A = (F144) Cab socket
(7) 15A = (F143) Rear windscreen heating
(8) 10A = (F42) Cab lights
Fig. 36
No. 24 = Cabin light
Indicators and Controls
BOMAG34 BW 213 D-4
i = reading and dashboard light
j = toggle switch for reading and dashboard
light
k = toggle switch for cabin light
l = cabin light
Fig. 37
No. 25 = Main fuse for battery
125A = (F00)
Fig. 38
No. 26 = Speedometer
*
Shows the travel speed of the machine.
outer scale = km/h
inner scale = mph
Fig. 39
No. 27 = Tachometer for diesel engine
**
shows the rotational speed of the diesel engine.
Scale value x 100 = revolutions per minute
Fig. 40
No. 28 = Vibration frequency display
***
Shows the vibration frequency.
outer scale = Frequency in min
-1
x 100
inner scale = Frequency in Hz
* Optional equipment
** Optional equipment
*** Optional equipment
Indicators and Controls
BOMAG 35BW 213 D-4
Fig. 41
No. 29 = E
VIB
display
*
is a compaction measuring unit for continuous display of the load bearing characteristics (MN/m
2
)
during the compacting pass.
E
VIB
value
Increase = higher load bearing capacity
Constant = end of compaction
i
Note
Modular upgrading to BTM plus / BTM prof and/or
BCM 05 possible.
* Optional equipment
Indicators and Controls
BOMAG36 BW 213 D-4
3.3 Display and control elements
BTM
*
Fig. 42
1E
VIB
display
2 Display for jump operation
3 Push button F5 START
4 Push button F6 STOP
5 Push button F7 PRINT (only BTM prof)
6 Push button F8 DELETE
7 Vibration frequency display
8 Rotary switch setting of nominal value
9 Push button F14 nominal value increase
10 Push button F13 nominal value decrease
11 not used
12 not used
13 not used
14 not used
15 not used
16 not used
17 Speed display
18 Amplitude display
19 Printer for measuring values (only BTM prof)
20 Fault light
* Optional equipment
Indicators and Controls
BOMAG 37BW 213 D-4
3.4 Description of indicating
and control elements
BTM
i
Note
The BTM plus can be upgraded to BTM prof and/
or BCM 05.
Surface covering dynamic compaction
control (SCCC)
The BOMAG compaction measuring systems
E
VIB
-meter (BEM) and Terrameter BTM plus/prof
are integrated in the work process for continuous
and surface covering evaluation of compaction
and load bearing capacity of soils and non-bonded
bearing courses.
The E
VIB
-value, designated as vibration modulus,
with the unit MN/m
2
is directly linked with the deformation modules EV1 or EV2 known from the
plate load test acc. to DIN 18134.
No. 1 = E
VIB
-display
Display of the dynamic soil stiffness in MN/m
2
.
No. 2 = Display for jump operation
yellow
symbol = Drum jumps
red
symbol = Drum jumps excessively or
tumbles
Select a smaller amplitude, if necessary!
No. 3 = Button F5 START
press = Starts recording of measuring
values
Control field "F5" flashes green on the screen.
No. 4 = Button F6 STOP
press = Stops recording of measuring
values
The green control field "F7" PRINT on the screen
lights up.
i
Note
Depending on the measuring result the green control field "F5" CONTINUE or the red control field
"F6" FINISHED will light up.
No. 5 = Button F 7 Print
*
To print out the measuring data saved during the
last pass press button F7 PRINT.
short actuation = Line diagram
long actuation ≥5
sec. = Bar chart
Control field F7 goes out and the measuring value
printer starts to print out measuring data.
i
Note
After the printing process has finished any amount
of diagrams can be printed out by pressing the
same button F7 (PRINT).
No. 6 = Button F8 DELETE
press = All stored faults are deleted.
!
Caution
If the increase of the measuring value is to be
calculated on a track press button F8 DELETE
only when changing the track.
No. 7 = Frequency display
with vibration switched on this instrument shows
the frequency (rotating speed) of the exciter shaft.
No. 8 = Rotary switch P3 pre-setting of nomi-
nal values
The desired maximum dynamic stiffness modulus
E
VIB
[MN/m2] can be pre-selected in 6 stages (45,
80, 100, 120,150 and Max.).
The selected value is shown on the screen in field
„P3“
No. 9 = Button F14 increase of nominal value
With each actuation of the button the presetting is
raised by one stage.
The selected value is shown on the screen in field
„P3“
No. 10 = Button F13 reduction of nominal val-
ue
With each actuation of the button the presetting is
reduced by one stage.
* only with BTM prof
Indicators and Controls
BOMAG38 BW 213 D-4
The selected value is shown on the screen in field
„P3“
No. 11 = Button F11 is not used
No. 12 = Button F12 is not used
No. 13 = Button F11 is not used
No. 14 = Rotary switch P1 is not used
No. 15 = Button F10 is not used
No. 16 = Button F9 is not used
No. 17 = Travel speed display
Shows the travel speed of the machine.
No. 18 = Amplitude display
This gauge shows the current vertical amplitude of
the machine.
No. 19 = Printer for measuring values*
To print out the measuring data saved during the
last pass press button (7) "PRINT".
No. 20 = Fault light
Infor the BOMAG After Sales Service if it lights up.
Indicators and Controls
BOMAG 39BW 213 D-4
3.5 Line diagram* (E
VIB
)
Fig. 43
* only BTM prof
Indicators and Controls
BOMAG40 BW 213 D-4
1Pass-No.
2Travel direction
3 Machine equipment (BTM 05/BTM-E)
4 Software status of the measuring equipment
5 Machine number
6 Machine type
7 Amplitude
8Maxiumum E
VIB
value
9 Miniumum E
VIB
value
10 Mean E
VIB
-value
11 E
VIB
-change
12 Medium frequency
13 Mean travel speed
14 Track length
15 Raster division in longitudinal direction
16 Marking (thick line) excessive jumping, tum-
bling of the drum
17 Longitudinal raster line
18 Measuring value raster line
19 Diagram line
20 Marking (thin line) jumping of the drum
Indicators and Controls
BOMAG 41BW 213 D-4
3.6 Description of line diagram *
(E
VIB
)
No. 1 = Pass
Total number of measured passes on this track.
No. 2 = Travel direction
No. 3 = Machine equipment
No. 4 = Software status of the measuring
equipment
No. 5 = Machine number
No. 6 = Machine type
No. 7 = Amplitude
This gauge shows the vertical amplitude the machine has worked with on this track.
No. 8 = Maxiumum E
VIB
value
No. 9 = Miniumum E
VIB
value
No. 10 = Mean E
VIB
-value
This gauge shows the vertical amplitude the machine is currently working with on this track.
No. 11 = E
VIB
-change
E
VIB
-change in %. This always refers to the previ-
ous pass in the same direction of travel.
No. 12 = Medium frequency
No. 13 = Mean travel speed
shows the mean value of speed driven during this
pass.
i
Note
Always shows the same travel speed in order to
avoid a falsification of the measuring results.
No. 14 = Track length
Measured track length between START and
STOP.
No. 15 = Raster division in longitudinal direc-
tion
Is used to pinpoint individual measuring values on
the measuring curve.
i
Note
The raster lines mark measuring track sections of
5 m length.
Graduation of the measuring track (track length in
printout) into fixed sections.
No. 16 = Marking of jump information
Indicates excessive jumping/tumbling of the drum
on the marked track section (thick line).
i
Note
Select a smaller amplitude, if necessary!
No. 17 = Longitudinal raster line
No. 18 = Measuring value raster line
No. 19 = Diagram line
Shows the E
VIB
-value at any point of the rolled
track. The raster line enables the location related
assignment of the E
VIB
-value and the location of a
fault (over or under compaction).
No. 20 = Marking of jump information
Indicates jumping of the drum on the marked track
section (thin line).
* only BTM prof
Indicators and Controls
BOMAG42 BW 213 D-4
3.7 Bar diagram* (E
VIB
)
The bar diagram differs from the line diagram only
by the graphic representation of measuring values. In the bar diagram the mean values of 5 m
sections are shown as bars. In addition, the E
VIB
changes of the individual 5 m sections are specified in percent after the second pass in the same
travel direction.
* only BTM prof
BOMAG 43BW 213 D-4
4Operation
Operation
BOMAG44 BW 213 D-4
4.1 General
If you are not yet acquainted with the controls
and indicating elements on this machine you
should thoroughly read chapter 3 “Indicators
and control elements” before starting work.
All indicators and control elements are described in detail in this chapter.
4.2 Tests before taking into operation
Before the everyday use or before a longer working period the following tests and inspections must
be performed.
!
Danger
Danger of accident!
Please observe strictly the safety regulations
in chapter 2 of this instruction manual!
l Park the machine on ground as level as possi-
ble.
Check:
l fuel tank and fuel lines for leaks
l screw joints for tight fit
l function of steering
l function of emergency stop
l machine for cleanliness, damage
l presence of the appropriate operating and
maintenance instructions
l proper maintenance of the machine
i
Note
For a description of the following tasks refer to the
chapter "maintenance every 10 operating hours".
l Engine oil level, top up if necessary
l Fuel level, top up if necessary.
l Coolant level, top up if necessary
l Hydraulic oil level, top up if necessary.
Operation
BOMAG 45BW 213 D-4
4.3 Electronic immobilizer
*
Before starting the engine the anti-theft protection
must be disarmed by entering a code.
Fig. 44
i
Note
With the electronic immobilizer armed, the light
emitting diode (a) (Fig. 44) flashes slowly.
l Slowly enter the six-digit user code.
i
Note
When entering the code, the light emitting diode
(6) lights up with every digit.
l Press the diamond button.
l The electronic immobilizer is now disarmed
and the engine can be started within the next
15 minutes.
4.4 Starting the engine
! Danger
Danger of accident!
Start the engine only from the operator’s seat.
!
Caution
In this chapter it is assumed that the operator
is fully acquainted with the function of the different control elements on the machine.
Fig. 45
l Fasten your seat belt (Fig. 45).
Fig. 46
l Check, whether the travel lever (Fig. 46) is en-
gaged to the right in brake position.
* Optional equipment
920390
ba
Operation
BOMAG46 BW 213 D-4
Fig. 47
l Switch the rotary switch for vibration amplitude
pre-selection (Fig. 47) to position "0".
Fig. 48
l Check, whether the emergency stop switch
(Fig. 48) is unlocked.
Fig. 49
l Turn the ignition key (Fig. 49) to position "I".
Fig. 50
All control and warning lights (Fig. 50) in the instrument cluster light up for a moment.
The engine oil pressure warning light (d) flashes,
the charge control light (f) and the parking brake
warning light (k) stay on.
Under cold ambient temperatures the preheating
control lamp (b) will also light up. Do not start before the preheating control lamp (b) has gone out.
!
Caution
Run the starting process for maximum 20 seconds without interruption and pause for a
minute between starting attempts.
If the engine has not started after two attempts
perform trouble shooting.
i
Note
The starter switch is designed with a re-start lock.
For a new starting attempt the ignition key must
first be turned back to position "0".
Operation
BOMAG 47BW 213 D-4
Fig. 51
l Turn the ignition key (Fig. 51) through position
"II" to position "III", the starter will crank the engine.
l As soon as the engine ignites return the igni-
tion key to position "I".
The engine oil pressure warning light and the
charge control light go out. The parking brake
warning light stays on.
!
Caution
Run the engine warm for a short while before
starting work. Do not rev up a cold engine to
high idle speed/full load speed.
4.5 Starting with jump wires
Fig. 52
!
Caution
A wrong connection will cause severe damage
in the electric system.
l Bridge the machine only with a 12 Volt auxilia-
ry battery.
l When jump starting with an external battery
connect both plus poles first.
l Then connect the ground cable first to the mi-
nus pole of the current supplying auxiliary battery and then to engine or chassis ground, as
far away from the battery as possible (Fig. 52).
l Start as described under 'Starting the engine'.
l Once the engine is running switch on a power-
ful consumer (working light, etc.).
!
Caution
If no powerful consumer is switched on voltage peaks may occur when separating the connecting cables between the batteries, which
could damage electrical components.
l After starting disconnect the negative poles
(ground cable) first and the positive poles after.
l Switch off the consumer.
Operation
BOMAG48 BW 213 D-4
4.6 Driving the machine
! Danger
Danger of accident!
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclinations and slopes.
Soil conditions and weather influences impair
the gradability of the machine.
Do not drive up and down inclinations exceeding the maximum gradability of the machine
(see technical data).
Do not drive without wearing your seat belt.
Always give way to loaded transport vehicles!
Before starting to drive make sure that the
drive range is absolutely safe.
!
Caution
Always keep the cabin door closed while driving with the machine. With the door opened
and the machine fully articulated extreme oscillations of the machine may damage the
door.
i
Note
The machine is equipped with a seat contact
switch
*
(safety feature).
If the driver gets up from his seat while driving, the
signal horn is activated and the machine is slowed
down to standstill after four seconds. When the
driver sits down again the machine will continue
the travel.
Before resuming operation sit down on the seat,
engage the travel lever in "0"-position (brake position), then operate the travel lever again to the desired travel direction.
Fig. 53
l Close the cabin door (Fig. 53).
Fig. 54
l Select the desired travel speed range (Fig.
54).
Fig. 55
l Turn the rotary momentary contact switch for
engine speed (Fig. 55) clockwise to "MAX".
* Only with option SN1
Operation
BOMAG 49BW 213 D-4
Fig. 56
l Shift the travel lever (Fig. 56) out of braking po-
sition to the left to disengage.
l Move the travel lever slowly to forward or re-
verse.
The machine drives forward or backward with a
speed that corresponds with the actuation of the
travel lever.
l Return the travel lever to position "0".
The machine decelerates to standstill.
! Danger
Danger of accident!
When stopping on inclinations and slopes pull
the travel lever to the right and lock it in braking position.
Important notes on travel operation
!
Caution
When changing the travel direction hold the
travel lever for a moment in "0"-position, until
the machine has stopped, before actuating to
the new travel direction.
Do not operate jerkily! Control the travel speed
with the travel lever.
When driving up and down inclinations move
the travel lever slowly back towards neutral to
brake the machine.
If the engine speed drops under load when
driving on steep gradients, take the travel lever
slightly back towards neutral.
4.7 Stopping the machine, operating the parking brake
Fig. 57
l Return the travel lever (Fig. 57) slowly to "neu-
tral"-position and engage it to the right in braking position.
The machine is automatically braked by the hydrostatic drive and the parking brake is applied.
Fig. 58
The parking brake warning lamp (k) (Fig. 58) lights
up.
i
Note
The parking brake also closes automatically when
shutting the engine down.
Operation
BOMAG50 BW 213 D-4
4.8 Shutting down the engine
!
Caution
Straighten the articulated joint to provide easier access to the machine.
Fig. 59
l Return the travel lever (Fig. 59) slowly to "neu-
tral"-position and engage it to the right in braking position.
The machine is automatically braked by the hydrostatic drive and the parking brake is applied.
Fig. 60
The parking brake warning lamp (k) (Fig. 60) lights
up.
i
Note
The parking brake also closes automatically when
shutting the engine down.
Fig. 61
l Turn the momentary contact switch for engine
speed (Fig. 61) anti-clockwise to position
"MIN" (idle speed).
!
Caution
Do not shut down the engine all of a sudden
from full load speed, but let it idle for about 2
minutes.
Fig. 62
l Turn the starter switch (Fig. 62) to position "0"
or "P" and pull the ignition key out.
i
Note
The parking brake closes automatically when
shutting the engine down.
!
Danger
Danger of accident!
Secure the machine against unauthorized use,
pull the ignition key out, lock the cabin door.
Operation
BOMAG 51BW 213 D-4
4.9 Switching the vibration on
and off
!
Danger
Risk of damage!
When compacting with vibration you must
check the effect of nearby buildings and underground supply lines (gas, water, sewage,
electric power), if necessary stop compaction
with vibration.
!
Caution
Danger of bearing damage!
Do not activate the vibration on hard (frozen,
concrete) ground.
Fig. 63
l Turn the rotary travel speed range switch (Fig.
63) to position "turtle".
Pre-selecting the vibration
Fig. 64
l Preselect the desired amplitude with the rotary
switch for vibration amplitude preselection
(Fig. 64).
Switching the vibration on
!
Caution
Switch the vibration on only at max. engine
speed.
Fig. 65
l Turn the rotary momentary contact switch for
engine speed (Fig. 65) clockwise to "MAX".
Operation
BOMAG52 BW 213 D-4
Fig. 66
l Actuate the vibration push button (Fig. 66) in
the travel lever while driving.
Switching the vibration off
l Press the vibration push button (Fig. 66)
again.
Fig. 67
l After the end of work turn the vibration ampli-
tude preselecting switch (Fig. 67) back to position "0".
4.10 What to do in events of
emergency
Actuating the emergency stop switch
!
Danger
Danger of accident!
In events of emergency and in case of danger
actuate the emergency stop switch immediately.
Start travel operation of the machine only after
the danger that caused the actuation of the
emergency stop switch has been eliminated.
!
Caution
Do not use as service brake. The deceleration
is extremely high. In case of frequent use the
wear on the multi-discs brakes will be very
high.
Fig. 68
l Press the button of the emergency stop switch
(Fig. 68) completely down, it automatically
locks in fully pressed position.
i
Note
Shuts the engine down and closes the brake.
l Turn the button clockwise to unlock the emer-
gency stop switch.
l Start the engine again, see chapter "Starting
the engine".
Operation
BOMAG 53BW 213 D-4
Emergency exit
Fig. 69
l If a machine has turned over and the cabin
door is jammed, the right hand cabin window
can be used as an escape door.
4.11 Adjusting the steering
wheel
*
Fig. 70
l Adjustment of steering wheel in height, pull le-
ver (Fig. 70) up and move the steering wheel
to the desired height.
l 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 steering wheel adjustment is securely locked in
place.
* Optional equipment
Operation
BOMAG54 BW 213 D-4
4.12 Adjusting the seat
Fig. 71
l To adjust the seat in longitudinal direction dis-
engage lever e (Fig. 71) upwards and push the
seat forward or back.
l To adjust the weight turn lever (d) and read the
weight in sight glass (c).
l To adjust the inclination of the backrest oper-
ate lever (a) and tilt the backrest forward or
back.
l To swivel the seat pull lever (b) up and turn the
seat to the desired direction.
Fig. 72
l To adjust the height of the seat lift the seat up
(Fig. 72) until it engages at the desired level.
When lifting the seat completely it will sink down to
lowest position.
4.13 Operating the heating/air
conditioning system
*
!
Danger
Danger of suffocation!
Always keep the air inlet slots on the cabin free
of snow, foliage and similar!
i
Note
The heating power depends on the coolant temperature.
The air conditioning system only works when the
engine is running and the fan is switched on.
Operation of the air conditioning system increases
the fuel consumption.
Heating the interior
l Close all windows completely.
Fig. 73
l Turn the air nozzles a (Fig. 73) to direct the air
flow down into the footwell.
l In case of cold or damp weather direct the air
flow towards the windscreen and door
screens.
l Switch on the fan with the rotary switch (c).
l Regulate the temperature with the rotary
switch (b).
* Optional equipment
Operation
BOMAG 55BW 213 D-4
Cooling the interior
l Close all windows completely.
l Direct the air flow towards the body/face (a).
l Switch on the fan (c).
l If necessary switch off the heating (b).
l Switch on the air conditioning system with ro-
tary switch (d) and regulate the temperature.
Reducing the humidity
l In case of damp weather direct the air flow to-
wards the windscreen and door screens.
l Switch on the fan with the rotary switch (c).
l Regulate the temperature to "Max" with the ro-
tary switch (b).
l Switch the air conditioning (d) on.
4.14 Operating the hood
! Danger
Danger of accident!
If the hood needs to be opened further for
maintenance or repair work, support it safely.
Bottom position
Fig. 74
l Unlock the lock (Fig. 74).
l To open the hood press in the button and turn
the handle.
Fig. 75
l Pull the support out of the bracket and support
the hood (Fig. 75).
Top position
l Push the hood to top position.
Operation
BOMAG56 BW 213 D-4
Fig. 76
l Pull the spring pin (Fig. 76) out of the bracket.
l Secure the hood i´n the protection tube with
spring plug.
4.15 BVC/BTM05 settings before
start-up
Changing the units system
i
Note
The Asphalt Manager control unit can be used to
change from metric units (km/h, °C) to imperial
units (mph, °F) in both the display and the printout
*
.
Fig. 77
l Turn the ignition key (Fig. 77) to position "I".
i
Note
The control unit shows the start screen.
Fig. 78
l Press key ’’?“ (menu) (Fig. 78).
* Optional equipment
Operation
BOMAG 57BW 213 D-4
i
Note
The menu appears on the screen.
Fig. 79
l Press key "F4" (Fig. 79).
i
Note
The screen page to select the unit system appears
on the screen.
Fig. 80
l Press key "F5" (Fig. 80) and choose the units
system.
Imperial 0 = metric units
Imperial 1 = imperial units
Fig. 81
l After the desired change press key "F14" (Fig.
81). The "Save" symbol on the screen lights up
green for a moment as confirmation.
i
Note
After releasing key "F14" the system returns automatically to the start screen and restarts.
Fig. 82
l Switch the ignition off and on again (Fig. 82).
i
Note
Both Asphalt Manager control unit and printer
have been set to the new units system.
Setting the printer language
*
i
Note
With a printer* connected the language in the
printout can be changed via the Asphalt Manager
control unit.
* Optional equipment
Operation
BOMAG58 BW 213 D-4
Fig. 83
l Turn the ignition key to position "I" (Fig. 83).
i
Note
The control unit shows the start screen.
Fig. 84
l Press key ’’?“ (menu) (Fig. 84).
i
Note
The menu appears on the screen.
Fig. 85
l Press key "F6" (Fig. 85).
i
Note
The printer language screen page appears.
Fig. 86
l Use keys "F11" or "F12" to choose the desired
printer language (Fig. 86).
i
Note
The screen shows country flags, which represent
the associated language.
Operation
BOMAG 59BW 213 D-4
Fig. 87
l Press key "F14" to save the language setting
(Fig. 87). The "Save" symbol on the screen
lights up green for a moment as confirmation.
Fig. 88
l Press key "ESC" (Fig. 88) to return to the start
screen.
4.16 Measuring pass with BTM
*
General notes
i
Note
The soil measuring values (E
VIB
) recorded during
different passes can only be compared if the recording of measuring values took place in operating mode "Manual" with the same amplitude,
frequency and travel speed and on exactly the
same track.
Measuring values must only be compared for
passes performed in the same direction.
The following description describes an measuring
pass in forward. Measuring passes in reverse
must be performed accordingly.
Measuring pass
Fig. 89
l Turn the ignition key (Fig. 89) to position "I"
The BTM plus/prof performs a self-test.
* Optional equipment
Operation
BOMAG60 BW 213 D-4
Fig. 90
l Control field F5 (Fig. 90) lights green.
Fig. 91
l Turn the ignition key (Fig. 91) to position „II en-
gine start.
Fig. 92
l Mark the track to be compacted (Fig. 92).
!
Caution
Since the transducer unit is mounted on the
left hand side of the drum, it is necessary to arrange the tracks so that track 1 is processed
first, followed by further tracks offset to the
left.
i
Note
Maximum track length 150 m.
Forward:
Mark 1 = Start of track
Mark 2 = End of track
i
Note
The operator may also remember the start and the
end of the track by means of distinct points.
Operation
BOMAG 61BW 213 D-4
Fig. 93
l Pre-select working speed (Fig. 93).
Fig. 94
l Turn the rotary switch (Fig. 94) for engine
speed to position "MAX".
Fig. 95
l Shift the travel lever (Fig. 95) fully to position
„I“.
The machine accelerates up to the preadjusted
travel speed.
!
Caution
Differences in the travel speeds falsify the
measuring result!
Fig. 96
l Switch the vibration on (Fig. 96).
!
Caution
Before reaching mark 1 the nominal exciter
shaft speed must have been reached and a valid E
vib
-value should be displayed.
Fig. 97
l When mark 1 is reached, press button F5
“START” (Fig. 97).
Control field to the left of F5 lights green.
The E
VIB
- display shows the present value.
Operation
BOMAG62 BW 213 D-4
Fig. 98
l When the end of the track, mark 2, is reached,
press the button F6 “STOP” (Fig. 98).
l Stop the machine.
i
Note
The first forward pass is finished.
Control field F5 lights green. This means, that the
compaction is not yet completed. One or several
passes are still required.
4.17 Finishing compaction of a
track
Fig. 99
l Drive forward and reverse passes on a track
until the green control field to the left of F5 (Fig.
99) goes out and the red control field F6 below
lights up after pressing the stop button F6.
The compaction process on this track is finished.
Criterion for a finished track:
Compared with the previous track the increase of
the E
VIB
-value in the same travel direction was
less than 10%. This criterion is also fulfiled if the
E
VIB
decreases.
i
Note
Another pass on this track does not make any
sense, because an increase in load bearing capacity is hardly possible with this machine.
l If necessary print out the measuring data for
this track (see following section).
Operation
BOMAG 63BW 213 D-4
Fig. 100
l Repeat the complete compaction process on
the next track (Fig. 100) to record measuring
values.
4.18 Printing measuring data af-
ter completing compaction
*
i
Note
Measuring data can be printed after completion of
any pass.
Always check the paper provision before starting
work.
Change the paper roll if a red stripe appears on the
paper.
Fig. 101
l At the end of the measurement press push
button F7 "PRINT" (Fig. 101).
short actuation = Line diagram
long actuation ≥5
sec. = Bar chart
Control field F7 goes out and the measuring value
printer starts to print out measuring data.
i
Note
After the printing process has finished any amount
of diagrams can be printed out by pressing the
same button F7 (PRINT).
* only BTM prof
Operation
BOMAG64 BW 213 D-4
Fig. 102
l If no further printouts of this track are needed,
press the button F8 “DELETE” (Fig. 102) when
the red control lamp F6 “FINISHED” lights up.
The red control field F6 “FINISHED” goes out and
the green control field F5 “CONTINUE” lights up.
BTM plus/prof is ready to compact the next track.
4.19 Changing the paper roll in
the measuring value printer
*
i
Note
Use a new paper roll if a red stripe appears on the
paper.
Fig. 103
l Unscrew the star handles (Fig. 103) and re-
move the cover.
Fig. 104
l Remove shaft 1 (Fig. 104) with the rest of the
paper roll (2).
* only BTM prof
Operation
BOMAG 65BW 213 D-4
Fig. 105
l Insert a new paper roll (Fig. 105).
l Feed the paper into the guide (1) on the print-
er.
l Actuate the toggle switch (2) in direction of ar-
row, until the paper comes out of the printer.
l Reassemble the cover.
4.20 Changing the printer ribbon
in the measuring value
printer
*
i
Note
In case of faint or poorly legible diagrams the printer ribbon needs to be replaced.
Fig. 106
l Unscrew the star handles (Fig. 106) and re-
move the cover.
Fig. 107
l Lift the tongue at point 1 (Fig. 107) and take
the printer ribbon (2) out of the printer.
l Insert the new printer ribbon into the printer,
then press in the tongue (1) on the right.
l Tension the printer ribbon by turning the rotary
button (3) in direction of arrow.
l Reassemble the cover.
* only BTM prof
Operation
BOMAG66 BW 213 D-4
4.21 Towing in case of an engine
failure
!
Danger
Secure the machine with wheel chocks against
unintentional rolling.
Danger of accident!
When using towing ropes tow the machine
only uphill.
When towing downhill you must use a rigid
towing device.
The machine cannot be steered.
l Secure the machine with wheel chocks
against unintentional rolling.
Fig. 108
l Attach chains (Fig. 108) or towing ropes to the
lifting hooks.
!
Caution
Towing speed 1 km/h, max. towing distance
500 m.
l Open the tailgate.
Fig. 109
l Slacken the middle hexagon on both valves
(Fig. 109) for approx. 2 to 3 turns.
!
Caution
Do not turn the valves out completely.
Fig. 110
l To release the brake turn counter nuts 1 (Fig.
110) approx. 8 mm back.
l Turn the brake releasing screws (2) complete-
ly in against the stop.
!
Caution
From this stop turn the screw in for maximum
another turn to release the brake!
Turn the screws in evenly on both sides.
l Turn the screws in alternately for turn at a
time.
l Repeat this measure on the opposite wheel
side.
Operation
BOMAG 67BW 213 D-4
Fig. 111
l Unscrew
*
plug 1 (Fig. 111) to release the
brake in the drum drive motor.
l Place clamping disc (4) across the brake
housing (2) and turn the screw (5) into the
tapped bore (3), until it bottoms.
l Turn the nut (6) down and tighten it for approx.
one turn. The drum must rotate freely.
After towing
!
Caution
Before detaching the tow bar block the machine with chocks to prevent unintended rolling.
l Turn the high pressure relief valve cartridges
tightly back in.
l Turn all brake releasing screws of the axle
evenly back out, until they are light moving
again.
Fig. 112
l Turn the brake releasing screws (Fig. 112)
back in again, until they abut against the brake
piston.
Fig. 113
l Unscrew the brake releasing screws (Fig. 113)
for two turns and tighten the counter nuts.
l Repeat this adjustment procedure on the op-
posite wheel side.
l Unscrew the brake releasing screw from the
brake* in the drum drive motor, screw the plug
back in and tighten it.
* only with option SN1
Operation
BOMAG68 BW 213 D-4
4.22 Loading/transport
! Danger
Danger of accident! Life hazard!
Use only stable loading ramps of sufficient
load bearing capacity. The ramp inclination
must be less than the gradability of the machine.
Make sure that persons are not endangered by
the machine tipping or sliding off.
During demonstration and when loading the
machine do not remain in the danger zone of
the machine.
Always use shackles on the lifting points for
loading or tying the machine down.
Check all lifting and lashing points for damage
before lifting or lashing down the machine. Do
not use a damaged or in any other way impaired lifting and lashing eyes.
Lift the machine only with suitable lifting gear.
Use only safe lifting gear of sufficient load
bearing capacity Minimum lifting capacity of
lifting gear: see operating weight in chapter
"Technical Data".
The machine must not swing about when being lifted.
Do not step or stand under suspended loads.
Lash the machine down, so that it is secured
against rolling, sliding and turning over.
After transport release the articulation lock
again and store it in the receptacle.
Fig. 114
l Pull the spring pin (Fig. 114) out.
l Lift up the articulation lock and swivel it by
180°.
Fig. 115
l Engage the articulation lock and secure it with
the spring pin (Fig. 115).
Operation
BOMAG 69BW 213 D-4
Fig. 116
l Lash the machine on the transport vehicle
(Fig. 116), use the four lashing eyes on front
and rear frame for this purpose.
l Support the front frame to avoid overstressing
of the rubber buffers.
Loading by crane
!
Danger
Life hazard!
Do not step or stand under suspended loads.
Fig. 117
l For lifting use the four lifting eyes (Fig. 117)
and appropriate lifting gear.
Fig. 118
Position of centre of gravity (Fig. 118):
i
Note
The tolerances account for all possible options,
such as cabin, additional weight etc.
After transport
! Danger
Danger of accident!
The machine cannot be steered if the articulation lock is applied.
Fig. 119
l After the transport loosen the articulation lock
(Fig. 119) again, fix it in its receptacle and lock
it with the spring plug.
Machine L [mm] H [mm]
BW 211 – 214 -4 1150 ± 240 860 ± 60
Operation
BOMAG70 BW 213 D-4
BOMAG 71BW 213 D-4
5 Maintenance
Maintenance
BOMAG72 BW 213 D-4
5.1 General notes on maintenance
When performing maintenance work always comply with the appropriate safety regulations.
Thorough maintenance of the machine guarantees far longer safe functioning of the machine and
prolongs the lifetime of important components.
The effort needed for this work is only little compared with the problems that may arise when not
observing this rule.
The terms right/left correspond with travel direction forward.
l Support the engine hood for all maintenance
and repair work.
l Always clean machine and engine thoroughly
before starting maintenance work.
l For maintenance work stand the machine on
level ground.
l Perform maintenance work only with the motor
switched off.
l Relieve hydraulic pressures before working on
hydraulic lines.
l Before working on electric parts of the ma-
chine disconnect the battery and cover it with
insulation material.
l When working in the area of the articulated
joint attach the articulation lock (transport
lock).
Environment
During maintenance work catch all oils and fuels and do not let them seep into the ground or
into the sewage system. Dispose of oils and fuels environmentally.
Keep used filters in a separate waste container
and dispose of environmentally.
Catch biodegradable oils separately.
Notes on the fuel system
The lifetime of the diesel engine depends to a
great extent on the cleanliness of the fuel.
l Keep fuel free of contaminants and water,
since this will damage the injection elements
of the engine.
l Drums with inside zinc lining are not suitable to
store fuel.
l When choosing the storage place for fuel
make sure that spilled fuel will not harm the environment.
l Do not let the hose stir up the slurry at the bot-
tom of the drum.
l The fuel drum must rest for a longer period of
time before drawing off fuel.
l The rest in the drum is not suitable for the en-
gine and should only be used for cleaning purposes.
Notes on the performance of the engine
On diesel engines both combustion air and fuel injection quantities are thoroughly adapted to each
other and determine power, temperature level and
exhaust gas quality of the engine.
If your engine has to work permanently in "thin air"
(at higher altitudes) and under full load, you should
consult the customer service of BOMAG or the
customer service of the engine manufacturer.
Notes on the cooling system
Prepare and check coolant with highest care,
since otherwise the engine may be damaged by
corrosion, cavitation and freezing.
Coolant is prepared by adding an ethylene-glycol
based anti-freeze agent with corrosion inhibiting
properties to the cooling water.
Mixing with cooling system protection agent is
necessary in all climatic zones. It prevents corrosion, lowers the freezing point and raises the boiling point of the coolant.
Notes on the hydraulic system
During maintenance work on the hydraulic system
cleanliness is of major importance. Make sure that
no dirt or other contaminating substances can enter into the system. Small particles can produce
flutes in valves, cause pumps to seize, clog nozzles and pilot bores, thereby making expensive repairs inevitable.
l If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped,
check all lines, hoses and components for
leaks.
Maintenance
BOMAG 73BW 213 D-4
l Seal external leaks immediately. If necessary
inform the responsible customer service.
l Do not store drums with hydraulic oil outdoors,
or at least under a cover. Water can be drawn
in through the bunghole when the weather
changes.
l We recommend to use the BOMAG filling and
filtering unit with fine filter to fill the system.
This ensures finest filtration of the hydraulic
oil, prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system.
l Clean fittings, filler covers and the area around
such parts before disassembly to avoid entering of dirt.
l Do not leave the tank opening unnecessarily
open, but cover it so that nothing can fall in.
5.2 Fuels and lubricants
Engine oil
Quality
For use in DEUTZ engines the lubrication oils are
classified in DEUTZ Lubrication Oil Quality Classes (DQC).
The list of approved lubrication oils is also available in the Internet under the following address:
Consult your local service station if in doubt.
l Use winter grade engine oil for winter opera-
tion!
Oil viscosity
Since lubrication oil changes its viscosity with the
temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class (SAEclass) .
Approved engine oils
Deutz ACEA
*
* Association des Constructeurs European d’Automobiles
API
**
** American Petroleum Insti tute
DHD
DQC II-05 or
DQC II-10
E3-96,
E5-02,
E7-08,
E4-07,
E6-04,
E9-08
CG-4,
CH-4,
CI-4,
CI-4 Plus,
CJ-4
DHD-1
DQC III-05 or
DQC II-10
-- -
DQC IV-05
or DQC II-10
-- -
www.deutz.com
de >>SERVICE >> Betriebsstoffe und Addi-
tive >> DeutzQualityClass >> DQC-Freigabeliste
en >>SERVICE >> Operating Liquids and Ad-
ditives >> DeutzQualityClass >> DQC Release List
Maintenance
BOMAG74 BW 213 D-4
Too high viscosity can cause starting difficulties,
too low ´viscosity can jeopardize the lubrication effect and result in a high lubrication oil consumption.
Fig. 120
Optimal operating conditions can be achieved by
using the oil viscosity chart (Fig. 120) as a reference.
At ambient temperatures below -40 °C (-58 °F) the
lubrication oil must be pre-heated (e.g. by parking
the machine indoors).
The viscosity is classified acc. to SAE. Multi-purpose oils should generally be used.
Oil change intervals
The longest permissible time a lubrication oil
should remain in an engine is 1 year. If the following oil change intervals are not reached over a period of 1 year, the oil change should be performed
at least once per year, irrespective of the operating
hours reached.
DQC II, DQC III, DQC IV: 500 operating hours
!
Caution
When using fuels with a sulphur content of
more than 0.5% to 1% or under permanent ambient temperatures below -10 °C (14 °F) and
when using biodegradable diesel fuel the oil
change intervals must be halved.
Fuels
You should only use commercially available brand
diesel fuel with a sulphur content of less than 0.5%
and ensure strict cleanliness when filling in. A
higher sulphur content has a negative effect on the
oil change intervals.
The fuel level should always be topped up in due
time so that the fuel tank is never run dry, as otherwise filter and injection lines need to be bled.
Quality
The following fuel specifications are permitted:
l EN 590
l DIN 51628
l ASTM D975 Grade-No. 1-D and 2-D.
l JIS K 2204 Grade Fuel 1 and Grade Fuel 2
with lubrication properties acc. to EN 590
Winter fuel
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation.
Diesel fuels suitable for temperatures down to -44
°C (-47 °F) are available for Arctic climates. At
very low temperatures disturbing paraffin separation can also be expected when using winter diesel
fuel.
The admixture of petroleum and the addition of
"flow enhancing additives" (fuel additives) is not
permitted.
Coolant
For fluid cooled engines the cooling fluid must be
prepared by admixing a cooling system protection
agent to the fresh water and should be checked
within the specified maintenance intervals.
This prevents damage caused by corrosion, cavitation, freezing and overheating.
Maintenance
BOMAG 75BW 213 D-4
Fresh water quality
The correct quality of water is highly important
when preparing coolant. Clear and clean water
within the boundaries of the following analysis values should generally be used.
Information concerning the water quality can be
obtained from the waterworks.
If the fresh water analysis values are unknown,
these must be determined with the help of a water
analysis.
If the values of the analysis deviate, the water
must be treated accordingly.
l pH-value too low
Adding of caustic lye of soda or caustic potash
solution.
l Water hardness too high:
Mix with soft, distilled or fully demineralized
water
l Chlorides and/or sulphates too high:
Mix with distilled or fully demineralized water
l Total hardness or carbonate hardness too low:
Mix with hardened water (harder water is in
most cases available in the form of drinking
water).
!
Caution
Another analysis must be made after the fresh
water has been prepared.
Cooling system protection agent
As a protection against frost, corrosion and boiling
point anti-freeze agents must be used under any
climatic conditions.
Coolant for fluid cooled engines is prepared by
adding an ethylene-glycol based anti-freeze agent
with corrosion inhibiting properties to the cooling
water.
We therefore highly recommend our BOMAG cooling system protection agent.
If our cooling system protection agent is not available for any important reasons, you may, in exceptional cases, use products that have been
approved by the engine manufacturer.
The list of approved cooling system protection
agents is also available in the Internet under the
following address:
Products of the same product group (see Deutz
Technical Circular Cooling System Protection
Agents) can be mixed with each other.
The BOMAG cooling system protection agent corresponds with product group A.
!
Caution
Do not mix different coolants and additives of
any other kind.
Before changing the product you must clean
the entire cooling system.
Consult your local service station if in doubt.
To ensure proper corrosion protection you must
use the cooling system protection agent all year
Fresh water analysis values
pH-value at 20 °C (68 °F) 6.5 - 8.5
Chloride ion content (mg/l) (ppm) max. 100
Sulphate ion content (mg/l)
(ppm)
max. 100
Water hardness (ion content of
calcium and magnesium )
(mmol/l)]
max. 3.56
Conversion to other units:
- German degree (°dH)] max. 20
- English degree (°eH)] max. 25
- French degree (°fH)] max. 36.5
corresponds with the content of
CaCO
3
(mg/l) (ppm)
max. 356
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Flyer Cooling System Conditioner Technical Circular
Maintenance
BOMAG76 BW 213 D-4
around, whereby the following concentration must
not be fallen short of or exceeded.
!
Caution
A proportion of more than 50% of cooling system protection agent causes a drop in cooling
power.
The use of corrosion protection oils as cooling
system protection agents is not permitted.
i
Note
When working at temperature below -41 °C(-42
°F) you should consult our local service representative.
Environment
Coolant must be disposed of environmentally.
Mineral oil based hydraulic oil
The hydraulic system is operated with hydraulic oil
HV 46 (ISO) with a kinematic Viskosität von 46
mm
2
/s bei 40 °C und 8 mm2/s bei 100 °C betrieben. For topping up or for oil changes use only
high-quality hydraulic oil, type HVLP according to
DIN 51524, part 3, or hydraulic oils type HV according to ISO 6743/3. The viscosity index (VI)
should be at least 150 (observe information of
manufacturer).
Bio-degradable hydraulic oil
The hydraulic system can also be operated with a
synthetic ester based biodegradable hydraulic oil.
The biologically quickly degradable hydraulic oil
Panolin HLP Synth.46 meets all demands of a
mineral oil based hydraulic oil according to
DIN 51524.
In hydraulic systems filled with Panolin HLP
Synth.46 always use the same oil to top up.
When changing from mineral oil based hydraulic
oil to an ester based biologically degradable oil,
you should consult the lubrication oil service of the
oil manufacturer for details.
!
Caution
Check the filter more frequently after this
change.
Perform regular oil analyses for content of water and mineral oil.
Replace the hydraulic oil filter element every
500 operating hours.
Gear oil
For the gearboxes use only ,ulti-purpose gear oils
ISO VG 220 of API-GL5-class with a minimum viscosity of 20 mm
2
/s at 100 °C.
This is a hypoid lubricant of highest quality class
for extremely loaded transmissions.
The additives in this oil ensure low wear lubrication
under all operating conditions.
Exciter shaft oil
For the exciter unit in the drum use a fully synthetic
gear oil SAE 75W-90, API GL5.
Lubrication grease
For lubrication purposes use an EP-high pressure
grease, lithium saponified (penetration 2), acc. to
DIN 51502 KP 2G.
Mixing ratio
Cooling sys-
tem protection
agent
Fresh water Cold protec-
tion down to
min. 35% 65% -22 °C (-8 °F)
40% 60% -28 °C (-18 °F)
45% 55% -35 °C (-31 °F)
max. 50% 50% -41 °C (-42 °F)
Maintenance
BOMAG 77BW 213 D-4
5.3 Table of fuels and lubricants
Assembly Fuel or lubricant Quantity
Summer Winter Attention
Observe the level marks
Motor
- Engine oil ACEA: E3-96, E5-02, E7-04, E4-07, E6-04
API: CG-4, CH-4, CI-4, CI-4 Plus, CJ-4
approx. 15.5 litres
SAE 10W-40 (-15 °C to +40 °C)
(BOMAG 009 920 06; 20 l)
SAE 15W-40 (-15 °C to +40 °C)
SAE 5W-40 (-30 °C to +40 °C)
- Fuel Diesel Winter diesel fuel approx. 340 litres
- Coolant Mixture of water and anti-freeze agent
Specification see "Fuels and lubricants - coolant"
approx. 16 litres
Hydraulic system Hydraulic oil (ISO), HLP 46
(BOMAG 009 930 09; 20 l)
or
ester based biodegradable hydraulic oil
approx. 60 litres
Vibration bearings SAE 75W-90, API GL-5
(BOMAG 009 925 05; 20 l)
approx. 1.0 litres
Drive axle SAE 80W-140, API GL-5
(BOMAG 009 925 07; 20 l)
approx. 9.5 litres
Wheel hubs SAE 80W-140, API GL-5
(BOMAG 009 925 07; 20 l)
approx. 1.9 l each
Tires Water approx. 295 litres
Calcium chloride (CaC
2
) or magnesium chloride
(MgCl2
2
)
approx. 100 kg
Air conditioning system Refrigerant R134a approx. 1500 g
Maintenance
BOMAG78 BW 213 D-4
5.4 Running-in instructions
The following maintenance work must be performed when running in new machines or
overhauled engines:
!
Caution
Up to approx. 250 operating hours check the
engine oil level twice every day.
Depending on the load the engine is subjected
to, the oil consumption will drop to the normal
level after approx. 100 to 250 operating hours.
After a running-in time of 30 minutes
l Retighten the V-belt
After 250 operating hours
l Retighten bolted connections on intake and
exhaust tubes, oil sump and engine mounts.
l Retighten the bolted connections on the ma-
chine.
l Retighten all wheel fastening screws with the
specified tightening torque.
l Change engine oil and oil filter
l 1. Oil change vibration bearings
l Oil change in drive axle
l Oil change in wheel hubs
After 500 operating hours
l 2. Oil change vibration bearings
Maintenance
BOMAG 79BW 213 D-4
5.5 Maintenance table
No. Maintenance work Comment
every 10 operating hours, daily
every 250 oper. hours
every 500 oper. hours
every 1000 oper. hours
every 2000 oper. hours
every 3000 oper. hours
every 6000 oper. hours
as required
5.6
Check the engine oil level Dipstick mark X
5.7
Check the fuel level X
5.8
Check the coolant level Inspection glass X
5.9
Check the hydraulic oil level Inspection glass X
5.10
Check the tire pressure X
5.11
Clean the cooling fins on engine and
hydraulic oil cooler
X
5.12
Check the oil level in the drive axle X
5.13
Check the oil level in the wheel hubs X
5.14
Check the oil level in the vibration
bearings
X
5.15
Check the parking brake X
5.16
Check, replace the refrigerant compressor V-belt
X
5.17
Change engine oil and oil filter cartridge
*
see foot note
min. 1x per year
X
5.18
Check, clean the water separator X
5.19
Drain the fuel tank sludge X
5.20
Battery service pole grease X
5.21
Service the air conditioning X
5.22
Clean the circulation air filter for the
heating
X
5.23
Change the bypass filter
**
see foot note
min. 1x per year
X
Maintenance
BOMAG80 BW 213 D-4
5.24
Check / replace the ribbed V-belt X
5.25
Replace the fuel filter cartridge X
5.26
Change the fuel pre-filter cartridge X
5.27
Check the engine mounts X
5.28
Change the oil in the vibration bearings
***
see foot note
min. 1x per year
X
5.29
Change the oil in the drive axle
****
see foot note
min. 1x per year
X
5.30
Change the oil in the wheel hubs**** see foot note
min. 1x per year
X
5.31
Retighten the fastening of the axle
on the frame
X
5.32
Tighten the wheel nuts
*****
see foot note X
5.33
Check the ROPS X
5.34
Check the travel control X
5.35
Check, adjust the valve clearance Intake valve: 90°
+10°
Exhaust: 150°
+10°
X
5.36
Change hydraulic oil and breather fil-
ter**
at least every 2 years X
5.37
Change the hydraulic oil filter** at least every 2 years X
5.38
Change the coolant at least every 2 years X
5.39
Replace ribbed V-belt and idler pul-
ley
at least every 2 years X
5.40
Replace the injection valves only by authorized
service personnel
X
5.41
Replace the crank case ventilation
valve
at least every 2 years X
No. Maintenance work Comment
every 10 operating hours, daily
every 250 oper. hours
every 500 oper. hours
every 1000 oper. hours
every 2000 oper. hours
every 3000 oper. hours
every 6000 oper. hours
as required
Maintenance
BOMAG 81BW 213 D-4
5.42
Air filter maintenance min. 1x per year,
Safety cartridge at
least every 2 years
X
5.43
Adjust the scrapers X
5.44
Clean the machine X
5.45
Change the tires X
5.46
Change the fresh air filter in the cab-
in
X
5.47
Fill the provision tank for the wind-
screen washer system
X
5.48
Tightening torques X
5.49
Engine conservation X
* oil change after 250 and 500 operating hours, then every 500 operating hours
** Also in case of repair in the hydraulic system.
*** Running-in inst ructions: oil change afte r 250, 500 and 1000 operati ng hours, then every 1000 operating hours
**** Running-in instructions: oil change after 250 and 1000 operating hours, then every 1000 operating hours
*****Running-in instructions: oil change after 250 and 1000 operating hours, then every 1000 operating hours
No. Maintenance work Comment
every 10 operating hours, daily
every 250 oper. hours
every 500 oper. hours
every 1000 oper. hours
every 2000 oper. hours
every 3000 oper. hours
every 6000 oper. hours
as required
Maintenance
BOMAG82 BW 213 D-4
Every 10 operating hours
BOMAG 83BW 213 D-4
Every 10 operating hours
5.6 Checking the engine oil level
!
Danger
Danger of injury!
Support the engine hood for all maintenance
and repair work.
!
Caution
The machine must be in horizontal position.
If the engine is warm, shut it down and check
the oil level after five minutes.
With a cold engine the oil level can be checked
immediately.
For quality of oil refer to the "table of fuels and
lubricants".
Fig. 121
l Pull the dipstick (Fig. 121) out, wipe it off with
a lint-free, clean cloth and reinsert it until it bottoms.
l Pull the dipstick back out.
l The oil level must always be between the
"MIN"- and "MAX"-marks. If the oil level is too
low, top up oil to the "MAX" mark immediately.
5.7 Checking the fuel level
!
Caution
Do not drive the fuel tank dry, as otherwise the
fuel system needs to be bled.
Fig. 122
l Check the fuel level on fuel gauge (m) (Fig.
122) in the instrument cluster.
Refuelling
! Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke, do not spill any fuel.
Do not refuel in closed rooms.
Shut down the engine.
!
Danger
Health hazard!
Do not inhale any fuel fumes.
!
Caution
Monitor the entire refuelling process.
For quality and quantity of fuel refer to the "table of fuels and lubricants".
Environment
Catch running out fuel, do not let it seep into
the ground.
Every 10 operating hours
BOMAG84 BW 213 D-4
Fig. 123
l Shut down the engine.
l Clean the area around the filler opening.
l Open the fuel tank cover (Fig. 123).
!
Caution
Contaminated fuel can cause malfunction or
even damage of the engine.
If necessary, fill in fuel through a funnel with
screen.
l Top up with fuel (diesel or winter diesel).
l Screw the fuel tank cover back on.
5.8 Check the coolant level
! Danger
Danger of scalding!
Fill up coolant only when the engine is cold.
!
Caution
If, during the daily inspection the coolant level
is found to have dropped, check all lines, hoses and engine for leaks.
Do not use radiator sealant to seal leaks.
For quality and quantity of coolant refer to the
"table of fuels and lubricants".
Fig. 124
l Check the coolant level (Fig. 124).
l To top up unscrew the filler cap and fill in cool-
ant up to the MAX-mark.
Every 10 operating hours
BOMAG 85BW 213 D-4
5.9 Check the hydraulic oil level
!
Caution
In hydraulic systems filled with Panolin HLP
Synth. 46 always use the same oil to top up.
With other ester based oils consult the lubrication oil service of the respective oil manufacturer.
Fig. 125
l Check the hydraulic oil level in the inspection
glass (Fig. 125).
Normal level
approx. 3 cm below the top edge of the inspection
glass.
Minimum level
Middle of inspection glass.
!
Caution
If, during the daily inspection of the oil level
the hydraulic oil level is found to have
dropped, check all lines, hoses and components for leaks.
l If necessary fill in hydraulic oil through the filler
neck.
For quality and quantity of oil refer to the table
of fuels and lubricants.
Every 10 operating hours
BOMAG86 BW 213 D-4
Every 250 operating hours
BOMAG 87BW 213 D-4
Every 250 operating hours
5.10 Check the tire pressure
!
Caution
Because of the water filling in the tires, you
should always check the tire pressure with the
tire valve in top position!
Always close the valves with their dust caps.
i
Note
Adaptation to operating conditions:
The tire pressure can be adapted to the operating
conditions within the specified limits.
A reduced tire pressure improves the traction especially on sandy soils. Higher tires pressures improve the driving stability of the machine.
The total height of the machine can also be influenced by changing the tire pressure.
Fig. 126
l With the tire inflation valve check the air pres-
sure on tire inflation valve 1 (Fig. 126) with a
pressure gauge.
Nominal value, see "technical data".
i
Note
Ensure equal pressure in all rubber tires!
l Screw the valve caps back on again.
5.11 Clean the cooling fins on
engine and hydraulic oil
cooler
!
Danger
Danger of injury!
Perform cleaning work only after the engine
has cooled down and with the engine stopped.
!
Caution
Do not damage any cooling fins on the cooler
core when cleaning.
i
Note
Dirt on fan blades and oil cooler reduce the cooling
effect. Dirt deposits in these areas are substantially supported by oil and fuel on these surfaces. For
this reason you should always seal any oil or fuel
leaks in the vicinity of the cooling fan or the oil
cooler and clean the cooling surfaces after.
Cleaning with compressed air
Fig. 127
i
Note
Start to blow out from the exhaust side.
l Blow the cooler (Fig. 127) out with com-
pressed air.
Every 250 operating hours
BOMAG88 BW 213 D-4
Cleaning with cold cleansing agent
!
Caution
Protect electrical equipment such as generator, regulator and starter against the direct water jet.
l Spray the engine with a suitable cleansing
agent, e.g. cold cleanser, let it soak in for a
while and spray it off with a strong water jet.
l Run the engine warm for a while to avoid cor-
rosion.
5.12 Check the oil level in the
drive axle
l Park the machine on level ground.
Fig. 128
l Unscrew the oil level inspection plug (Fig. 128)
and check the oil level.
i
Note
The second level inspection plug as at the back.
After filling in oil wait until the oil has evenly distributed inside the axle.
The oil level must reach the bottom edge of the
level bore.
l Top up oil, if necessary.
For quality of oil refer to the table of fuels and
lubricants.
l Turn the level inspection plug tightly back in.
Every 250 operating hours
BOMAG 89BW 213 D-4
5.13 Check the oil level in the
wheel hubs
!
Caution
Check the oil level in both wheel hubs.
For quality of oil refer to the "table of fuels and
lubricants".
Fig. 129
l Park the machine so that the plug (1) (Fig.
129) is in horizontal position.
l Clean the area around the plug and unscrew
the plug.
l Check the oil level. The oil level must reach the
bottom edge of the bore, top up oil if necessary.
l Screw the plug back in tightly.
5.14 Check the oil level in the vibration bearings
!
Caution
Check only at operating temperature after running the machine approx. 1/2 hour with vibration.
Danger of bearing damage! Make sure that no
dirt falls into the exciter housing.
If a loss of oil is found perform trouble shooting, repair the drum if necessary.
For quality of oil refer to the "table of fuels and
lubricants".
l Park the machine on level ground.
Fig. 130
l Move the drum, until oil level inspection plug
(1) (Fig. 130) on the left hand side of the drum
is in bottom position.
l Thoroughly clean the area around the level in-
spection and filler plug.
l Unscrew level inspection plug (1).
Some oil should run out of the inspection bore.
l If necessary unscrew oil filler plug (2) and fill in
some oil through the oil filler bore (2), until oil
starts to drip out through the inspection bore.
l Screw oil filler (2) and level inspection plug (1)
back in tightly.
l Repeat this inspection on the other side.
Every 250 operating hours
BOMAG90 BW 213 D-4
5.15 Check the parking brake
! Danger
Life hazard!
Before checking the parking brake make sure
that there are no persons or obstacles in front
or behind the machine.
l Park the machine on level ground.
l Open the engine hood.
Fig. 131
l Pull the plug off the brake solenoid valve(Fig.
131).
l Start the engine.
Fig. 132
l Turn the rotary momentary contact switch for
engine speed (Fig. 132) clockwise to "MAX".
Fig. 133
l Shift the travel lever (Fig. 133) out of braking
position to the left to disengage.
l Pull the travel lever back first.
l Then shift the travel lever forward.
!
Caution
The machine should not move during this test.
However, if the machine moves the parking
brake needs to be adjusted or repaired.
Adjustments to the parking brake must only be
made by authorized service personnel!
Only operate the machine after the travel control has been repaired.
l Reconnect the plug to the parking brake sole-
noid valve (Fig. 131).
l Close the engine hood.
583174
Every 250 operating hours
BOMAG 91BW 213 D-4
5.16 Checking, replacing the refrigerant compressor V-
belt*
!
Danger
Danger of injury!
Work on the V-belt must only be performed
with the engine shut down.
Check the V-belt
Fig. 134
l Inspect the entire circumference of the V-belt
(Fig. 134) visually for damage and cracks. Replace damaged or cracked V-belts.
l 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.
Tighten the V-belt.
Fig. 135
l Slightly slacken fastening screws 1, 2 and 3
(Fig. 135).
l Press the compressor in direction of arrow, un-
til the correct V-belt tension is reached.
l Retighten all fastening screws.
Changing the V-belt
l Slightly slacken the fastening screws 1, 2 and
3.
l Press the compressor against the direction of
arrow completely against the engine.
l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
l Tension the V-belt as previously described.
!
Caution
Check the V-belt tension after a running time of
30 minutes.
* Optional equipment
Every 250 operating hours
BOMAG92 BW 213 D-4
Every 500 operating hours
BOMAG 93BW 213 D-4
Every 500 operating hours
5.17 Changing engine oil and oil
filter
!
Danger
Danger of scalding!
When draining off hot oil.
By hot oil when unscrewing the engine oil filter.
!
Caution
Drain the oil only when the engine is warm.
For quality and quantity of oil refer to the "table
of fuels and lubricants".
Environment
Catch running out oil and dispose of environmentally together with the oil filter cartridge.
Fig. 136
l Unscrew the drain plug (Fig. 136) and catch
running out oil.
l Turn the drain plug tightly back in.
Fig. 137
l Thoroughly clean the outside of the filter car-
tridge (Fig. 137).
l Unscrew the filter cartridge using an appropri-
ate filter wrench.
l Clean the sealing face on the filter carrier from
any dirt.
l Slightly oil the rubber seal on the new filter car-
tridge.
Fig. 138
l Turn the new filter cartridge (Fig. 138) on by
hand, until the seal contacts.
l Tighten the filter element for another half turn.
Every 500 operating hours
BOMAG94 BW 213 D-4
Fig. 139
l Fill in new engine oil (Fig. 139).
l Tighten the oil filler cap properly.
l After a short test run check the oil level on the
dipstick . The oil level should reach the MAXmark, top up oil if necessary.
l Check filter cartridge and drain plug for leaks.
5.18 Check, clean the water separator
!
Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke.
Environment
Any fuel must be caught and disposed of in an
environmentally friendly manner.
i
Note
The service intervals for the water separator depend on the water content in the fuel and can
therefore not be determined precisely. After taking
the engine into operation you should check the filter bowl initially every day, later as required, for
signs of water.
If a too high quantity is drained off, the filter needs
to be bled, see section "Replacing the fuel precleaner cartridge".
Fig. 140
l If the "water in fuel" warning light (a) (Fig. 140)
lights up when starting or during operation,
drain the water from the fuel filter immediately.
Every 500 operating hours
BOMAG 95BW 213 D-4
Fig. 141
l Slacken the drain plug (Fig. 141) for a few
turns and catch running out fuel / water.
l Turn the plug tightly back in. Check for leaks,
if necessary use a new seal ring.
i
Note
Once the water separator is empty the warning
light for water in fuel must go out.
5.19 Draining the sludge from
the fuel tank
!
Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke!
Do not spill any fuel.
Catch running out fuel, do not let it seep into
the ground.
Do not inhale any fuel fumes.
Fig. 142
l Unscrew the cap (Fig. 142) and drain off ap-
prox. 5 litres of fuel.
l Turn the cap tightly back in.
Every 500 operating hours
BOMAG96 BW 213 D-4
5.20 Battery service
! Danger
Danger of cauterisation ! Danger of explosion!
When working on the battery do not use open
fire, do not smoke!
The battery contains acid. Do not let acid come
in contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
For recharging remove the plugs from the battery to avoid the accumulation of highly explosive gases.
Environment
Dispose of the old battery environmentally.
i
Note
Maintenance free batteries also need care. Maintenance free only means that the fluid level does
not need to be checked. Each battery suffers under self-discharge, which may, in not checked occasionally, even cause damage to the battery as a
result of exhaustive discharge.
The following therefore applies for the service
life:
l Switch off all consumers (e.g. ignition, light, in-
side light, radio).
l Check open-circuit voltage of the battery at
regular intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V =
50% discharged.
l Recharge the battery immediately after an
open-circuit voltage of 12.25 V or less is
reached. Do not perform quick charging.
The open-circuit voltage of the battery occurs approx. 10 hours after the last charging process or
one hour after the last discharge.
l After each charging process allow the battery
to rest for one hour before taking it into service.
l For resting periods of more than one month
you should always disconnect the battery. Do
not forget to perform regular open-circuit voltage measurements.
!
Caution
Exhausted batteries (batteries with formation
of sulphate on the plates) are not covered under warranty!
l Open the engine hood and remove the cover-
ing
Fig. 143
l Remove the battery (Fig. 143) and clean the
battery compartment.
l Clean the outside of the battery.
l Clean battery poles and pole clamps and
grease them with pole grease (Vaseline).
l Check the fastening of the battery.
l On serviceable batteries check the acid level,
if necessary top up to the filling mark with distilled water.
Every 500 operating hours
BOMAG 97BW 213 D-4
5.21 Service the air conditioning
*
Clean the condenser
!
Danger
Danger of accident!
Do not clean with a hot water jet. Heat will
cause extreme overpressure, which could
cause damage or explosion of the system.
Use access steps and grips to mount and dismount the machine.
!
Caution
A soiled condenser results in a considerable
reduction of air conditioning power.
Under extremely dusty conditions it may be
necessary to clean the condenser several
times per day.
If, during operation of the air conditioning system, the warning buzzer sounds switch the air
conditioning off and clean the condenser.
In case of formation of foam have the air conditioning system inspected by the service department.
Fig. 144
l Unscrew the condenser fastening screws (Fig.
144) and fold the condenser forward.
l Clean the condenser fins on front and back
with compressed air or cold water .
Checking the refrigerant level
l Start the engine.
Fig. 145
l Turn the rotary switch for the cab ventilator
(Fig. 145) to position "1".
Fig. 146
l Choose a cooling temperature with the rotary
switch for the air conditioning system (Fig.
146) in the blue section.
l Open the air outlet nozzles.
l Check, whether the out flowing air is noticea-
bly cooler.
i
Note
The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.
* Optional equipment
Every 500 operating hours
BOMAG98 BW 213 D-4
Fig. 147
l Check whether the white float (Fig. 147) inside
the inspection glass of the drier/collector unit
floats right at the top.
i
Note
The refrigerant level is correct.
Fig. 148
l If the white float (Fig. 148) inside the inspec-
tion glass of the drier/collector unit floats at the
bottom, inform the service department.
i
Note
The refrigerant level is not correct.
l Refrigerant must be filled up, if necessary
check the air conditioning system for leaks.
Checking the moisture level of the drying agent
Fig. 149
l Check the moisture indication pearl (Fig. 149)
inside the inspection glass of the drier/collector unit.
orange = Drying agent o.k.
colourless = moisture level of drying agent too
high.
l Inform the service department. Replace drier/
collector unit, check air conditioning system.
!
Caution
Have the drier/collector unit replaced by the
service department every year before the operating season.
Checking the condition of the drier/collector unit
!
Caution
According to the regulation for pressure reservoirs all pressure reservoirs must be repeatedly inspected by a specialist. In this sense
repeated inspections are external examinations, normally on pressure reservoirs in operation. In connection with this inspection the
drier/collector unit must be visually examined
twice every year. During these inspections
special attention must be paid to corrosion
and mechanical damage. If the reservoir is not
in proper condition it must be replaced for
safety reasons, as a precaution to protect operators and third parties against any danger
Every 500 operating hours
BOMAG 99BW 213 D-4
arising from the handling and operation of
pressure reservoirs.
!
Danger
Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be replaced, to avoid bursting and further damage.
Fig. 150
l Check the drier/collector unit (Fig. 150) for me-
chanical damage or rust.
5.22 Cleaning the circulation air
filter for the heating
*
Fig. 151
l Unscrew screws (1) (Fig. 151).
l Pull the filter (2) downwards out.
l Clean the filter, replace if necessary.
l Assemble the filter and tighten the screws.
* Optional equipment
Every 500 operating hours
BOMAG100 BW 213 D-4
5.23 Changing the bypass filter
*
!
Danger
Danger of scalding!
Danger of scalding by hot oil when unscrewing
the oil filter.
!
Caution
If the filter has to be changed together with the
hydraulic oil, the filter must only be changed
after the oil change and after the test run.
Replace the filter element at the latest after one
year
Environment
Dispose of the old filter element environmentally.
Fig. 152
l Open the engine hood (Fig. 152) completely
and secure it.
Fig. 153
l Unscrew the fastening screws (Fig. 153) and
take off the cover.
l Replace the filter element, attach the cover
and fasten it with the screw.
* Optional equipment
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