Operating and Maintenance Instructions BW 212 D-3 & PD-3 [PDF]

Zitiervorschau

Operating instructions Maintenance instructions

%:'3' S/N 101 580 35 ....

6LQJOHGUXPUROOHU

Catalogue number 



)RUHZRUG

BOMAG - machines are products from the wide product range of BOMAG compaction equipment.

Only operate the machine after you have been properly instructed and by observing these instructions.

The vast experience of BOMAG as well as most modern production and testing methods, e.g. lifetime tests of all important components and most stringent quaolity demands ensure highest reliability of your machine.

Please observe strictly the safety regulations.

F oreword

Please observe also the guidelines of the civil engineering liability association "Safety Rules for the Operation of Road Rollers and Soil Compactors" and the applicable instructions for the prevention of accidents.

This manual comprises: ●

Safety regulations

●

Operating instructions

●

Maintenance instructions

●

Trouble shooting

For your own safety you should only use genuine BOMAG spare parts. In the course of technical development we reserve the right for modifications without prior notification. These operating and maintenance instructions are also available in other languages.

Using these instructions will ●

help you become acquainted with the machine.

●

avoid malfunctions caused by unprofessional operation.

You can obtain the spare parts catalogue fromyour BOMAG dealer against the serial number of your machine.

Compliance with the maintenance instructions will ●

increase the reliability of the machine on the construction site,

●

prolong the lifetime of the machine,

●

avoid repair costs and downtime.

You can also obtain information about the correct use of your machine in earth and asphalt construction from your BOMAG dealer. The information in this manual does not extent or replace the warranty and liability conditions in the general terms of business of BOMAG. We wish you much success with your BOMAG machine.

BOMAG will not assume liability for the correct function of the machine

BOMAG GmbH & Co. OHG Printed in Germany

●

if it is handled in a way which does not comply with the usual mode of operation,

●

if it is used for purposes other than those mentioned in these instructions.

Copyright by BOMAG

No warranty claims can be lodged in case of ●

operating errors,

●

insufficient maintenance and

●

incorrect fuels and lubricants.

Please note! These instructions were written for the operator and the service man on the construction site. Always keep this manual close at hand, e.g. in the tool compartment of the machine or in the container provided for this purpose. These operating and maintenance instructions are part of the machine.

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Please fill in ............................ Machine type (Fig. 1) ............................ Serial No. (Fig. 1 and 2) ............................ Engine type (Fig. 3) ............................ Engine No. (Fig. 3) L

Note

Fig. 1

Fill in the above listed data when receiving the machine. Upon receipt of the machine our organization will instruct you about correct operation and maintenance. Please observe strictly all safety regulations and notes on potential dangers!

Fig. 2

Fig. 3

4

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Table of Contents

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3.1 General notes

20

3.2 Description of indicators and control elements

20

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4.1 General notes

30

4.2 Tests before starting to operate

30

4.3 Starting the engine

31

4.4 Starting with jump leads

33

4.5 Driving the machine

34

4.6 Emergency exit

35

4.7 Operating the parking brake, stopping the machine

36

4.8 Shutting the engine down

36

4.9 Switching the vibration on and off

37

4.10 Adjusting the steering wheel

38

4.11 Adjusting the seat

39

4.12 Moving the hood to maintenance position/closing the hood.

39

4.13 Towing the machine in case of an engine failure

40

4.14 Transport

42

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5.1 General notes on maintenance

44

5.2 Fuels and lubricants

45

5.3 Table of fuels and lubricants

48

5.4 Running-in instructions

49

5.5 Maintenance chart

50

5.6 Checking the engine oil level

52

5.7 Checking, cleaning the water separator

52

5.8 Checking the fuel level

53

5.9 Checking the hydraulic oil level

54

5.10 Checking the coolant level

54

5.11 Checking the dust separator on the oil bath air filter

55

5.12 Checking the tire pressure

56

5.13 Adjusting the scrapers

56

5.14 Checking the condition, tension of the V-belt, changing the V-belt

58

5.15 Cleaning the cooling fins on radiator and hydraulic oil cooler

61

5.16 Checking the oil level in the drive axle

62

5.17 Checking the oil level in the intermediate gear

62

5.18 Checking the oil level in the vibration bearing housings

63

5.19 Changing the engine oil

64

5.20 Changing the engine oil filter cartridge

65

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Table of Contents

5.21 Changing the oil in the drive axle

66

5.22 Changing the oil in the intermediate gear

66

5.23 Draining the fuel tank sludge

67

5.24 Servicing the battery

67

5.25 Checking, adjusting the valve clearance

68

5.26 Changing the fuel filter cartridge

70

5.27 Changing the fuel filter cartridge

71

5.28 Changing the oil for the vibration bearings

72

5.29 Checking the fastening elements on the engine

73

5.30 Checking, changing the fuelreturn lines

73

5.31 Tightening the fastening of the axle to the frame

74

5.32 Tightening the wheel nuts

74

5.33 Checking the ROPS

75

5.34 Cleaning the oil bath air filter

75

5.35 Changing the hydraulic oil and the breather filter

76

5.36 Changing the hydraulic oil filter

77

5.37 Changing the coolant

78

5.38 Cleaning, changing the dry air filter cartridge

81

5.39 Adjusting the parking brake

83

5.40 Changing the tires

84

5.41 Checking the fresh air filter for the cabin

85

5.42 Tightening torques

85

5.43 Engine conservation

86

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6



6.1 General notes

88

6.2 Engine

89

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1 Technical Data

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Fig. 4

Dim. mm (inch) BW 212 D-3

A 2868

B 2250

D 1500

H2 2970

H 2268

K 490

L 5610

O1 60

O2 60

S 35

W 2130

BW 212 PD-3

2868

2250

1480

2970

2268

490

5610

60

60

25

2130

(59.0)

(116.9) (89.5)

(17.7)

(220.9) (2.36)

(2.36)

(1.38) (0.98)

(83.9)

(112.9) (88.6)

*

Weights Operating weight (CECE) with ROPS and cab Axle load, drum (CECE) Axle load, rear (CECE) Static linear load Travel performance data Travel speed (1) Travel speed (2) Max. gradability (depending on soil)

8

BW 212 D-3

BW 212 PD-3

kg (lb)

11100 (24475.5)

11500 (25357.5)

kg (lb) kg (lb) kg/cm (lb)

6600 (14553) 4500 (9922.5) 31 (68.355)

7000 (15435) 4500 -

km/h (mph) km/h (mph) %

0...5,4 (3.355) 0...10 (6.2) 43

0...5,4 0...10 (6.2) 43

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*

Drive Engine manufacturer Type Cooling Number of cylinders Rated power DIN ISO 9249 Rated speed Fuel Electrical equipment Drive system Driven axles

BW 212 D-3

BW 212 PD-3

DEUTZ BF6M 1012E water 6 94 (126)

DEUTZ BF6M 1012E water 6 94

2300 Diesel 12 hydrostatic 2

2300 Diesel 12 hydrostatic 2

hydrostatic hydro-mech.

hydrostatic hydro-mech.

articul. hydrostatic

articul. hydrostatic

1 hydrostatic 30 / 36 1,8 / 0,9(0.0709/0.0354)

1 hydrostatic 30 / 36 1,64 /0,82 (0.0646/ 0.0323)

kW (hp) rpm V

Brakes Service brake Parking brake Steering Steering system Steering control Vibration Vibrating drum Drive system Frequency Amplitude

Tires Tire size Air pressure Filling capacities Engine Fuel Hydraulic oil Coolant *

Hz mm (in)

Goodyear 23.1/18-26TL- Goodyear 23.1/18-26/TL8PR-AWT Dyna Torque 10PR bar 1,0 1,1

l (USgal) l (USgal) l (USgal) l (USgal)

17,5 (4.623) 340 (89.828) 60(15.852) 20 (5.28)

17,5 340 (89.828) 60 (15.852) 20 (5.28)

Technical modifications reserved

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2 Safety regulations

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General

Unintended use

This BOMAG machine is built in accordance with the latest technical standard and the valid technical rules and regulations. There is, however, a risk of danger for persons and property if:

Dangers may, however, arise from the machine if it is used by untrained personnel in an unprofessional way or if it is used for purposes other than those mentioned in these instructions.

●

the machine is used for purposes other than those it is intended for

Starting and operation of the machine in an explosive environment is prohibited.

●

the machine is operated by untrained personnel

●

the machine is modified or converted in an unprofessional way

●

the applicable safety regulations are not observed.

Each person involved in operation, maintenance and repair of the machine must therefore read and apply these safety regulations. This should be confirmed by obtaining the signatures of the customer, if necessary. Furthermore the following regulations and instructions are obviously also valid: ●

applicable accident prevention instructions

●

generally acknowledged safety and road traffic regulations

●

country specific safety regulations. It is the duty of the operator to know and observe these regulations. This applies also for local regulations and the regulations for various types of manual work. If the recommendations in this manual differ from the regulations valid in your country, you must strictly observe the regulations in your country.

Intended use This machine must only be used for: ●

compaction of bituminous materials, e.g. road surface layers. (AC and AD machines only)

●

medium and heavy compaction tasks in earth work (road sub-bases)

●

This machine must only be operated with fully functional safety equipment.

●

The machine should be checked by an expert once every year.

12

Do not work with vibration on hard concrete, on a cured concrete layer or heavily frozen ground.

Who is allowed to work with the machine? The machine must only be operated by trained and authorized persons which are at least 18 years of age. The responsibilities for the operation of the machine must be clearly specified and complied with. Persons under the influence of alcohol, medication or drugs must not operate, service or repair the machine. Maintenance and repair tasks require specific knowledge and must therefore only be carried out by trained and qualified personnel.

Conversions and alterations to the machine Unauthorized conversions to the machine are prohibited for safety reasons. Original parts and accessories have been specially designed for this machine. We wish to make expressly clear that we have not tested or authorized any original parts or special equipment not supplied by us. The installation and/or use of such products can impair the active and/or passive driving safety. The manufacturer expressly excludes any liability for damage resulting from the use of non-original parts or accessories.

Safety notes in the operating and maintenance instructions: 

Danger

Sections marked like this point out possible dangers for persons.

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Caution Sections marked like this point out possible dangers for the machine or for parts of the machine. 

L

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.

Note

Sections marked like this provide technical information concerning the optimal economical use of the machine. Environment Sections marked like this highlight activities for the safe and environmental disposal of fuels and lubricants as well as replaced parts.

Checking the Roll Over Protection Structure (ROPS) L

Note

On machines with cabin the ROPS is an integral part of the cabin. The machine frame must not be distorted, bent or cracked in the area of the ROPS fastening points.

Observe all environment protection regulations.

Information and safety stickers/decals on the machine

The ROPS must not show any signs of corrosion, damage, hairline cracks or open fractures.

Replace damaged or illegible stickers/decals immediately.

The ROPS must not rattle about during driving. This would mean that it is not properly fastened. All bolted connections must be in accordance with the prescribed specifications and correctly tightened (observe the tightening torque values). Screws and nuts must not be damaged, bent or deformed.

Loading the machine

With the cabin installed check also the condition of the cabin mounts (rubber elements and screws).

Keep stickers/decals complete (see spare parts catalogue) and fully legible and observe their meaning.

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.

Neither must any additional parts be welded or bolted on, nor must any holes be drilled without the permission of the manufacturer, since this may impair the strength of the structure.

Starting the machine

Secure the machine on the transport vehicle against rolling off, slipping and turning over.

Before starting

Persons are highly endangered if ●

they step or stand under loads being lifted

Operation of the machine is only permitted when sitting in the operator’s seat.

●

they remain in the drive range of the machine during a demonstration or during loading.

Use only machines which have been properly serviced at regular intervals.

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.

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: ●

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there are persons or obstructions beside or under the machine

13

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●

the machine is free of any oily and combustible material

●

all handrails, steps and platforms are free of grease, oils, fuels, dirt, snow and ice

●

Driving the machine Persons in the endangered area If the machine has turned over and the cabin door is jammed, use the right hand cabin window as an emergency exit.

the engine compartment hood is closed and locked

Before starting or resuming work and especially when driving backwards, check that there are no persons or obstructions in the endangered area.

To climb onto the machine use steps and handrails. Check before starting, whether: ●

the machine shows any obvious defects

●

all protective devices are properly secured in their place

If necessary give warning signals. Stop work immediately if persons remain in the danger area despite the warning. Do not step or stand into the articulation area of the machine while the engine is running. Danger of squashing!

●

steering, brakes, control elements, lighting and warning horn are in order

●

the seat is correctly adjusted

●

the mirrors (if available) are clean and correctly adjusted.

Driving

Do not start the machine if any gauges, control lights or controls are defective.

In events of emergency actuate the emergency stop switch immediately. Do not use the emergency stop push button as service brake. Restart the machine only after the danger, that has caused the actuation of the emergency stop, has been eliminated.

Do not take any loose objects with you or fasten them to the machine.

If the machine has come in contact with high-voltage power lines:

On machines with ROPS you should always wear your seat belt!

●

do not leave the operator’s stand

Starting

●

Start and operate the machine only from the operator’s seat

warn others from coming too close to the machine or touching it

●

if possible drive the machine out of the danger zone

●

have the power shut off.

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.

Operate the machine only from the operator’s seat. Keep the cabin doors closed.

Starting with jump leads

Do not adjust the seat while driving.

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.

Do not climb onto or off the machine while driving.

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!

14

Change the travel direction only while the machine is standing. Do not use the machine to transport persons. Stop the machine if you notice unusual noises or the development of smoke. Investigate the cause and have the fault corrected. Keep a sufficient distance to excavations and embankments and make sure that you work does not impair the stability of the machine.

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Parking on slopes and gradients

Do not work with vibration on hard concrete, on a cured concrete layer or heavily frozen ground. When passing under flyovers, bridges, tunnels, electric power lines etc. keep a sufficient distance.

Secure the machine against rolling, place metal chocks in front of and behind the drums.

Filling the fuel tank

Driving on slopes and gradients Do not drive up and down gradients, which exceed the max. gradability of the machine. On lopes always drive directly up or down. Change to the lower speed range before approaching the slope. Wet and loose soils reduce the ground adhesion of the machine and inclinations and slopes considerably. Higher risk of accident! Behaviour in traffic

Do not inhale fuel fumes. Refuel only after shutting the engine and the auxiliary heater down. Do not refuel in closed rooms. No open fire, do not smoke. Do not spill any fuel. Catch running out fuel, do not let it seep into the ground. Wipe off spilled fuel. Keep fuel free of dirt and water.

Always allow loaded transport vehicles to pass.

Leaking fuel tanks can cause explosions. Ensure tight fit of the fuel tank filling cover, replace it if necessary.

Switch the lights on when the visibility is poor.

Fire protection measures

Keep clear of edges and embankments.

Make yourself acquainted with the location and the operation of fire extinguishers. Observe fire warning and fire fighting installations.

Match the speed of the machine to the working conditions.

Check the effect of vibration When compacting with vibration check the effect of the vibration on nearby buildings and underground supply lines (gas, water, sewage, electric power supply), stop vibratory compaction if necessary. Do not work with vibration on hard (frozen, concrete) ground. Risk of bearing damage!

Maintenance Observe the maintenance tasks described in the operating and maintenance instructions, including the exchange of parts. For service and repair work in the engine compartment support the engine compartment hood. Maintenance work must only be carried out by qualified and authorized personnel.

Parking the machine Park the machine on level and firm ground.

When performing maintenance work above body height use the access steps on the machine or any other safe ladders and working platforms. Do not use machine parts as access steps.

Before leaving the machine: ●

straighten the articulated joint to allow easy access to and from the machine.

●

return the travel lever to neutral position

●

apply the parking brake

●

shut the engine down and pull the ignition key out.

●

lock the cabin

Park the machine on horizontal, level and stable ground.

●

secure the machine against unauthorized use.

Pull the key out of the ignition switch.

Do not jump off the machine, use access steps and hand rails.

Keep unauthorized persons away from the machine. Do not perform maintenance work with the machine driving or the engine running.

Lock the articulated joint with the articulation lock.

Always secure parked machines, which could be in the way, with appropriate measures.

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Working on hydraulic lines

●

Do not mix up hoses by mistake.

Always relieve the pressure in the hydraulic circuit before working on hydraulic lines. Hydraulic oil escaping under pressure may penetrate through the skin and cause severe injury. In case of being injured by hydraulic oil you should immediately seek medical advice, as otherwise this may lead to serious infections.

●

damage or deformation of the fitting, which impairs the function and strength of the hose/ hose connection.

When adjusting the hydraulic system do not stand behind or in front of the drum/wheels.

Working on the engine

Only genuine BOMAG hydraulic hoses ensure that the correct type of hose (pressure range) is used at the right place.

Shut the engine down before opening the engine compartment hood.

Do not change the setting of high pressure relief valves. Drain hydraulic oil at operating temperature - danger of scalding! Catch running out hydraulic oil and dispose of environmentally.

Drain the engine oil at operating temperature danger of scalding! Wipe off spilled oil, catch running out oil and dispose of environmentally.

Always catch and dispose of biological hydraulic oils separately.

Store used filters and other oily materials in a separate, specially marked container and dispose of environmentally.

Do not start the engine after draining off the hydraulic oil.

Do not leave any tools or other objects, which could cause damage, in the engine compartment.

Once all work is completed (with the system depressurized!) check all connections and fittings for tight and leak-free fit.

Working on electrical equipment

Changing hydraulic hoses

Do ot use any fuses with higher ampere ratings or repair a fuse with a piece of wire. Fire hazard!

Before working on electrical equipment disconnect the battery and cover it with insulating material.

All hydraulic hoses must be inspected visually at regular intervals.

Always disconnect the battery before starting to weld on the machine.

Hydraulic hoses must be changed immediately if: ●

the outer layer is worn down to the metal lining (e.g. chafing, cuts, cracks)

●

embrittlement of the outer layer (development of cracks in the hose material)

●

deformation under pressurized and depressurized condition, which are not in accordance with the normal shape of the hydraulic hose

●

deformation in bends, e.g, squeezes, kinks, layer separation, formation of blisters

●

leakages.

●

non-observance of the installation requirements

●

separation of the hydraulic hose from the fitting

●

corrosion of the fitting, which impairs the function and the strength.

Working on the battery When working on the battery do not use open fire, do not smoke! Do not let acid come in contact with skin and clothes. If being injured by acid flush off with clear water and seek for medical advice. Metal objects (e.g. tools, rings, wrist watches) must not contact the battery poles - danger of short circuit and burns! When recharging maintenance free batteries remove the plugs to avoid the accumulation of explosive gases. When using an external battery to start the machine follow the respective instructions. Dispose of old batteries environmentally. Switch the charging current off before removing the charge clamps. Ensure good ventilation, especially when charging the battery in a closed room.

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Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting in closed rooms!

Working on the fuel system Do not inhale fuel fumes. No open fire, do not smoke, do not spill any fuel.

Test

Catch running out fuel, do not let it seep into the ground and dispose of environmentally. Working on wheels and tires Explosion like bursting of tires and parts of rims and tires can cause severe or even deadly injuries.

Depending on the type of application and the operating conditions vibratory equipment has to be examined by a specialist whenever required, but at least once every year.

Assemble tires only with the appropriate knowledge and tools. If necessary have the tires assembled in a special workshop. Ensure correct tire pressure and do not exceed the highest specified pressure. Check wheels and tires every day for specified pressure, cuts, bulges, damaged wheel rims, missing wheel studs and nuts. Do not drive with damaged tires or wheels. Anti-stick emulsions for tires must only be mixed using water and concentrated anti-stick agent according to the specifications of the manufacturer of the anti-stick agent. Observe the regulations for the protection of the environment. Cleaning Do not clean the machine while the engine is running. Do not use gasoline or other combustible substances for cleaning purposes. When using steam cleaning equipment do not subject electrical components and insulating materials to the direct water jet, but cover them beforehand. ●

Do not guide the water jet into the exhaust or into the air filter.

After maintenance work Reinstall all protective devices after completing the maintenance work.

Repair Attach a warning tag to the steering wheel if the machine is defective. Repairs must only be performed by qualified persons who have been instructed for this purpose. Use our repair instructions.

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3 Indicators and Controls

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3.1

General notes

3.2

Description of indicators and control elements

Please read this section thoroughly before operating this machine if you are not yet conversant with the indicators and control elements. All functions are described in detail hereunder. Paragraph 4 Operation contains only concise descriptions of the individual operating steps.

Fig. 5

Nr. 1 =

Fuse box

Fuse box "a" (1), 30A = (F05) socket (2), 30A = (F11) head lights, StVZO (3), 30A = (F13) starting (4), 30A = (F19) working head lights, front, left (5), 30A = (F22) working head lights, rear (6), 30A = (F21) dash board light Fuse box "b" (1), 25A = (F40) cabin heater (2), 30A = (F37) water sprinkling system, pump (3), 30A = (F07) hazard light (4), 30A = (F09) parking tail light, left (5), 30A = (F10) parking tail light, right (6)

= not used

Fuse box "c" (1), 30A = (F14) engine solenoid (2), 30A = (F26) controls, speed ranges (3), 30A = (F24) monitoring board (4), 30A = (F25) solenoid valve braking/driving (5), 30A = (F03) vibration (6), 30A = (F23) warning horn

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Fuse box "d" (1), 30A = (F51) solenoid valve, speed range selection, anti spin control (2), 30A = (F18) working head lights, front (3), 10A = (F63) joystick steering (4), 30A = (F60) Speed-Control (5), 30A = (F06) water sprinkling system (6), 30A = (F08) direction indicator Danger Fire hazard! 

Fig. 7

Do not use fuses with a higher Ampere rating and do not bridge fuses.

Nr. 3 =

shows the fuel level in the fuel tank.

Fig. 6

Nr. 2 =

Fig. 8

Operating hour meter

Nr. 4 =

counts the operating hours while the engine is running All service work must be carried out according to the reading of the operating hour meter.

Fuel gauge

Rotary switch for hazard light system*

Position "left"

= hazard light switched off, the control lights go out.

Position "right" = hazard light switched on, control light 7 on fault monitoring board lights up.

*

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Option

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Fig. 9

Nr. 5 =

Fig. 11

Push button for warning horn

Nr. 7 =

Rotary switch speed ranges (D and PD machines)

Position "turtle" = working speed Position "rabbit"

= transport speed

Fig. 10

Nr. 6 =

Rotary switch, vibration

Position "middle" = vibration off Position "left"

= low amplitude, high frequency

Position "right" = high amplitude, low frequency

Fig. 12

Nr. 8 =

Tachometer*

shows the travel speed of the machine. black scale

= km/h

red scale

= M.P.H.

*

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Option

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Fig. 13

Nr. 9 =

Fig. 15

Omega-meter*

Nr. 11 = Emergency stop switch

a compaction measuring instrument, which continually shows the load bearing values during the compaction pass.

The engine will be shut down and the brake will close.

Omega value

Danger Danger of accident! 

increase

= higher load bearing capacity

constant

= end of compaction

1 digit

= 20 Omega values

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.

Fig. 14

Nr. 10 = RPM-meter for vibrator shaft** shows the vibrator shaft speed when the vibration is switched on. Scale value x 100 = revolutions per minute

* **

Option Option

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Fig. 16

Fig. 18

Nr. 12 = Rotary switch, lighting (StVZO) *

Nr. 14 = Rotary switch for direction indicators left / right**

Position "left"

= light off

Position "middle" = fender lights on, with the ignition switch in position "I" or "P" Position "right" = travel lights on, with ignition switch in position "I".

Position "middle" = direction indicator off Position "left or right" = front and rear direction indicators on the respective side light up, the control light in the switch flashes

Fig. 17

Nr. 13 = Rotary switch working lights* Position "left"

Fig. 19

= light off

Nr. 15 = Fault monitoring board

Position "right" = working lights on, with ignition switch in position "I". L

L

Note

After switching the ignition on all lamps on the fault monitoring board light up for self-testing.

Note

If the machine is fitted with fender lights, the working head lights can only be switched on together with these fender lights 12 (middle position).

The display will also show functions, which are only preassembled as options but not really installed. Replace a defective fault monitoring board immediately.

*

24

Option

**

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The control and warning lights on the fault monitoring board flash: No. 1

L

= Air filter cartridge dirty. Clean, change the cartridge.

Note

If the air filter service indicator lights up work may still be continued until the end of the day. No. 2

No. 3

= engine oil pressure too low, the warning buzzer sound too and the engine shuts down after 10 seconds. Check the engine oil level, if necessary have the engine repaired. = hydraulic oil filter dirty, the warning buzzer will sound and the engine will be shut down after 2 minutes. Change the filter element, check the hydraulic system if the indicator lights up too early.

No. 4

= battery not being charged, check the V-belt, have the generator repaired if necessary.

No. 5

= brake applied or travel lever in "neutral"-position with the engine running

No. 6

= direction indicators switched on

No. 7

= hazard light switched on

No. 8

= coolant temperature too high, the warning buzzer sounds too and the engine shuts down after 2 minutes. Clean the radiator.

No. 9

= malfunction of the "ASC"* anti-spincontrol.

Fig. 20

Nr. 16 = Push button for vibration ●

Pre-select or activate the frequency with the vibration selection switch

●

Press the switch to switch the vibration on and off.

Fig. 21

Nr. 17 = Travel lever L

Position "middle" = brake position for service brake

Note

Further trouble shooting via the flash code on the ASC control unit in the electric installation box. Operation of the machine may be continued, but the service departtment should be informed.

Position "middle, right" = parking brake, to start the engine

No. 10

Position "I"

= forward travel

Position "II"

= reverse travel

= Coolant too low, the warning buzzer will also sound and the engine will be shut down after 10 seconds.

L

*

Option

BW 212 D-3/PD-3

Note

If the engine speed is forced down when driving up steep inclines, move the travel lever slightly back. This reduces the load on hydraulic system and diesel engine.

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25

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moment. The lighting can be switched on. L

Note

The engine can only be started when the travel lever is in braking position. The ignition switch is provided with a lock against repetitive starting. To repeat the starting procedure you must first turn the ignition switch back to "0"-position. Position "II" Fig. 22

Nr. 18 = Throttle lever Position "I"

= full load position, operating position for driving and vibration

Position "II"

= idling speed position

Caution Always drive and vibrate with max. engine speed! Use the travel lever the regulate the travel speed! 

= turn further against spring pressure, the engine starts, return the ignition key to position "I" when the engine starts

 Caution Run the engine warm for a short while before starting to work. Do not let the engine run at idling speed for longer than 10 minutes.

Do not shut the engine down all of a sudden from full speed, but let it idle for a while for temperature equalization.

Nr. 19 = Locking plate for throttle lever pull

= the throttle lever can be moved to position "II"

release

= the throttle lever locks in position "I".

Fig. 24

Nr. 21 = Shut-off valve for cabin heater* L

Note

Fig. 23

The heat exchanger of the cabin heater receives the heat energy from the engine coolant circuit.

Nr. 20 = Ignition switch

Position "I"

= cabin heater off

Position "P"/"0" = ignition off, the key can be pulled out, engine not running.

Position "II"

= cabin heater full power

Position "I"

26

= ignition on, all control and warning lights on the fault monitoring board light up for a

*

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switch off

= turn lamp glass counter-clockwise

Nr. 29 = Vent for fresh air intake to operate the slide loosen the adjustment button. slide to the left = air circulation position slide to the right = fresh air position Switch on the auxiliary hot air blower

Fig. 25

Nr. 22 = Air circulation nozzle for heater* adjust direction = turn outside of nozzle regulate air flow = adjust and open or close by tilting the flap Nr. 23 = Fuse box, cabin** (1) -

= not used

(2) 7,5A

= cabin light

Fig. 26

(3) 7,5A

= windscreen wiper/washer, rear

Nr. 30 = Steering lever******

(4) 7,5A

= windscreen wiper/washer, front

lever to the left = machine drives to the left

(5) 7,5A

= flashing beacon

(6) 7,5A

= heating blower, radio



lever to the right

= machine drives to the right

Danger

Fire hazard! Do not use fuses with a higher Ampere rating and do not bridge fuses. Nr. 24 = Toggle switch, heating blower Nr. 25 = Toggle switch, flashing beacon*** Nr. 26 = Toggle switch, windscreen wiper/ washer, front**** Nr. 27 = Toggle switch, windscreen wiper/ washer, rear*****

Fig. 27

Nr. 28 = Cabin light

Nr. 31 = Main fuse for battery

switch on

120A

= turn lamp glass clockwise

L * Option ** Option *** Option **** Option *****Option

BW 212 D-3/PD-3

= (F00)

Note

The main fuse is located in the battery compartment under the operator’s seat. ******Option

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Fig. 28

Nr. 32 = Rpm-meter for diesel engine* shows the speed of the diesel engine. Scale value x 100 = revolutions per minute

*

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Option

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4 Operation

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4.1

General notes

Please read section 3 Indicators and Control Elements thoroughly before operating the machine if you are not yet fully familiar with the indicators and control elements of the machine. All indicators and control elements are described in detail in this chapter.

4.2

Tests before starting to operate

The following tests must be performed before each work day or before a longer work period. Danger Danger of accident! 

Please observe strictly the safety regulations in chapter 2 of these operating and maintenance instructions! Park the machine on level ground.

●

Check: ●

Fuel tank and fuel lines for leaks

●

Bolted connections for tight fit

●

Function of the steering

●

Machine for cleanliness, damage

●

Availability of the appropriate operating and maintenance instructions,

●

Check if the machine has been properly serviced. L

Note

For a description of the following work refer to the section "maintenance every 10 operating hours" Engine oil level

●

L

Note

Hydraulic systems, which are filled with Panolin HLP Synth. 46, the same oil must be used for filling up. In case of any other ester based oil consult the lubrication service department of the respective oil manufacturer. ●

Hydraulic oil level, top up if necessary.

●

Coolant level, top up if necessary.

Danger Fire hazard! 

Do not refuel in closed rooms

30

●

Fuel level, top up if necessary.

●

Water separator for fuel system, drain if necessary.

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●

Scrapers, adjust if necessary.

●

Tire pressure. Pressure see technical data.

Caution Ensure equal pressure in both tires. 

4.3

Starting the engine

Danger Danger of accident! 

Always wear your seat belt. L

Note

The diesel engine is fitted with a cold starting devise, which allows starting under low temperatures. The combustion air is warmed up by a glowing spiral in the air intake tube.

Fig. 29 ●

Wear your seat belt (Fig. 29).

Fig. 30 ●

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Check, whether the travel lever (Fig. 30) is locked to the right in braking position.

31

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Fig. 31 ●

Turn the rotary vibration selector switch (Fig. 31) to position "0", vibration off.

Fig. 34

Turn the ignition switch (Fig. 34) to position "I".

●

Fig. 35 Fig. 32 ●

Check, whether the emergency stop switch (Fig. 32) is unlocked.

All control and warning lights (Fig. 35) on the fault monitoring board light for a short moment. The warning lights for battery (4), engine oil pressure (2) and brake (5) light up. Caution Do not start for longer than 20 seconds at once, but interrupt the starting procedure for one minute. 

If the engine has not started after 2 tries, detect the cause.

Fig. 33 ●

32

Shift the throttle lever (Fig. 33) to approx. 1/2 full speed position and hold it.

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4.4

Starting with jump leads

 Caution Wrong connection will cause severe damage to the electrical system.

Fig. 36 ●

Turn the ignition key (Fig. 36) to position "II", the starter will crank the engine.

●

As soon as the engine ignites turn the ignition key back to position "I".

●

Once the engine runs properly, reduce the engine speed. Fig. 37 

Caution

●

When starting with an external battery connect both plus poles (Fig. 37) first and both minus poles (earth cable) after.

●

Perform all steps as described in the previous section.

●

After starting disconnect the minus poles (earth cable) first and the plus poles after.

Run the engine warm for a short while, do not run at idling speed for more than 10 minutes.

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4.5

Driving the machine

Danger Danger of accident! 

Wet and loose soils reduce the ground adhesion of the machine on gradients considerably. Soil conditions and weather influences impair the gradability of the machine. Do not drive up or down inclinations which exceed the maximum gradability of the machine (see technical data).

Fig. 39 ●

Always allow loaded transport vehicles to pass!

Select the desired travel speed range (Fig. 39).

Before setting off make sure that the travel area is save to drive.  Caution Always keep the cabin door closed while driving. If the door is open and the machine is articulated, extreme oscillation between front and rear frama may damage the door.

Fig. 40 ●

Shift the throttle lever to position "I" (Fig. 40), full load, and lock it.

Fig. 38 ●

Close the cabin door (Fig. 38).

Fig. 41 ●

34

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Unlock the travel lever (Fig. 41) by shifting it to the left out of the braking position and move it slowly to the desired travel direction.

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L

Note

Move the travel lever slowly out of "0"-position forwards or backwards, the machine will drive to the chosen direction at a speed, which is directly related to the distance the travel lever has been moved out of "0"-position.

4.6

Emergency exit

If the machine should turn over and the cabin door is closed, the right hand side cabin window can be used as an emergency exit.

When returning the travel lever the machine will decelerate and come to a halt when the travel lever is in "0"-position. Danger Danger of accident! 

To stop on inclinations lock the travel lever in braking position by pushing it to the right.

Important notes on travel operation Caution When reversing the travel direction hold the travel lever for a moment in "0"-position until the machine has come to a halt, then shift the travel lever to the new direction. 

Do not operate jerkily! Do not use the throttle control lever to regulate the travel speed! Regulate the travel speed only with the travel lever. During operation the throttle lever must always remain in full speed position. When driving on gradients or to brake the machine move the travel lever slowly back towards "0"-position. If the engine speed drops considerably when driving up steep inclinations, move the travel lever slightly back, change to the lower travel speed range if necessary.

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4.7

Operating the parking brake, stopping the machine

4.8

Shutting the engine down

 Caution Straighten the articulated joint to allow easy access from and to the cabin.

Fig. 42

Move the travel lever (Fig. 42) slowly to "neutral"-position and lock it to the right in braking position.

●

Fig. 43

Move the travel lever (Fig. 43) slowly to "neutral"-position and lock it to the right in braking position.

●

The machine will decelerate automatically, the parking brake will close. L

Note

The parking brake will also close automatically when shutting the engine down.

Fig. 44

Pull the locking plate 19 (Fig. 44) up and set the throttle lever (18) to position "II" (idling speed).

●

L

Note

Do not shut the engine suddenly down from full speed, but let it idle for a while for temperature equalization.

36

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4.9

Switching the vibration on and off

Danger Risk of damage! 

When compacting with vibration check the effect of the vibration on buildings in the vicinity and on underground supply lines (gas, water, sewage, electricity), stop compaction work if necessary. Fig. 45

Turn the ignition switch (Fig. 45) to position "0" or "P" and pull the ignition key out. The parking brake closes automatically after shutting the engine down.

●

Danger Danger of accident! 

Do not use the vibration on hard (frozen, concrete) ground. Risk of bearing damage! 

Caution

When using the machine on asphalt (AD-version) Vibration at standstill creates transverse dents in the asphalt, therefore:

Secure the machine properly against unauthorized use, pull the ignition key out, lock the cabin door.

●

only switch the vibration on after shifting the travel lever to the desired direction.

●

Switch the vibration off before stopping the machine.

Selecting the vibration

Fig. 46 ●

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Choose the amplitude/frequency with the rotary switch (Fig. 46).

37

2SHUDWLRQ

Switching the vibration on

4.10 Adjusting the steering wheel*

Fig. 47

Set the throttle lever (Fig. 47) to full speed position "I".

●

Fig. 49

Caution Only switch the vibration on when the engine is running at full speed. 

●

To adjust the height of the steering wheel pull the lever (Fig. 49) up and adjust the steering wheel to the desired height.

●

To adjust the inclination of the steering wheel press the lever down and adjust the inclination of the steering wheel.

Danger Danger of accident! 

After adjusting the steering wheel make sure that it is properly locked.

Fig. 48 ●

Actuate the push button (Fig. 48) in the travel lever during operation, the drum will vibrate.

Switching the vibration off ●

Actuate the push button again and turn the rotary vibration switch back to "0"-position after work.

*

38

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4.11 Adjusting the seat

4.12 Moving the hood to maintenance position/closing the hood. For some service jobs the hood must be opened hydraulically to highest position. For this purpose the machine is equipped with a manually operated pump.

Moving the hood to maintenance position. ●

Open the hood.

The hood will automatically move to middle position.

Fig. 50

●

●

To adjust the seat in longitudinal direction press the lever a (Fig. 50) out.

●

To adjust the weight turn the lever (b) and read the weight in the window (c).

●

Operate the lever (d) to adjust the inclination of the backrest.

Push the hood up against the end stop.

Fig. 51

BW 212 D-3/PD-3

●

Turn the valve lever (Fig. 51) to "open" position.

●

Take the hand lever out of the bracket in the hood and insert it.

●

Pump the hood up to highest position.

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Closing the hood

4.13 Towing the machine in case of an engine failure Danger Secure the machine with chocks against unintentional rolling. 

Fig. 52 ●

Turn the valve lever (Fig. 52) to position "close", insert the hand lever and operate the pump, until the lift cylinder is completely retracted.

Pumping any further is not possible. ●

Remove the hand lever from the pump and lock it in its bracket.

●

Pull the hood down by hand against the stop.

Fig. 54



Danger

Danger of accident! When using ropes you may only pull the machine uphill. Use only a rigid towing bar to tow the machine downhill. ●

Attach the tow bar to the rear towing eye (Fig. 54).

 Caution Towing speed 1 km/h, max. towing distance 500 m.

Fig. 53 ●

●

Open the tail gate.

Push the lever up (Fig. 53) to unlock it and press the hood slightly down at the same time.

The cylinder disengages. ●

40

Now pull the hood totally down and lock it.

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●

Retighten the high pressure relief valves.

●

Place wedges in front of and behind the drum and jack the rear of the machine up until both wheels can rotate freely.

●

Run the diesel engine, but do not apply the parking brake.

Fig. 55

Loosen both high pressure lelief valve cartridges (Fig. 55) on the travel pump for approx. one turn.

●

Caution Do not unscrew the valves completely. 

Fig. 57 ●

Turn the nuts (Fig. 57) in both brake cylinders, until the wheels are blocked.

●

Release the nuts again for two turns and check if the wheels are free again.

●

Insert the springs (1), screw the caps (3) with the seal rings (2) back on and tighten them.

Fig. 56 ●

Unscrew the caps 3 (Fig. 56) from both cylinders, take the springs (1) and seal rings (2) out.

●

Slacken the nuts (4) in both cylinders until the brake springs are relieved.

After towing Caution Before removing the tow bar secure the machine with suitable chocks. 

Adjustment work on the brakes must only be performed by trained specialists. Always adjust both brakes.

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4.14 Transport

 Caution Do not tighten the lashing gear too much, to avoid overstressing of the rubber buffers.

Danger Danger of accident! 

Use only strong and stable loading ramps. Make sure that no persons are endangered if the machine should turn over or slip off. Lash the machine down so that it is properly secured against rolling off, slipping and turning over. Do not step or stand under loads being lifted. Always use shackles on the lashing points to load, lash or lift the machine. Fig. 60 ●

To lift the machine attach the lifting gear to the four lifting eyes (Fig. 60).

Weights: see technical data. ●

After the transport remove the articulation lock and fasten it in its receptacle.

Fig. 58 ●

Attach the articulation lock (Fig. 58).

Fig. 59 ●

42

Lash the machine to the transport vehicle (Fig. 59), attach the lashing gear to the lashing eyes on the front and the rear frame.

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5 Maintenance

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●

Do not let the suction hose disturb the sludge on the bottom of the drum.

●

Do not draw off fuel from near the bottom of the fuel drum.

When servicing the machine pay careful attention to all applicable safety instructions.

●

Thorough maintenance of the machine ensures maximum reliability and prolongs the lifetime of important components. The necessary effort can by no means be compared with the problems and malfunctions that could occur if this is not observed.

Fuel left in the fuel drum is not suitable for the engine and should only be used for cleaning purposes.

Notes on the engine performance

5.1

General notes on maintenance

The terms left/right are always related to travel direction forward.

Combustion air and fuel injection rates of the diesel engine have been carefully adjusted and determine the engine’s performance and temperature level as well as the quality of the exhaust gas.

●

Clean machine and engine thoroughly before starting maintenance work.

●

For maintenance work park the machine on level ground.

If your machine has to operate permanently in "thin air" (at high altitudes) and with full power, you should consult the after sales service of BOMAG or the service department of the engine manufacturer.

●

Maintenance work must generally be carried out with the engine shut down.

Notes on the hydraulic system

●

Depressurize hydraulic lines before working on them.

●

Disconnect the battery and cover it with insulation material before starting to work on electrical components.

●

Always attach the articulation lock (transport lock) before starting to work in the articulation area of the machine.

During maintenance work in the hydraulic system cleanliness is of utmost importance. Make sure that no dirt or other impurities can enter into the system. Small particles can flute valves, cause pumps to seize and block restrictors and pilot bores, thereby causing costly repairs. ●

If during the daily oil level check the oil level is found to have dropped, check all lines, hoses and components for leakages.

●

Seal external leaks immediately. If necessary inform the responsible service department.

●

Do not store drums with hydraulic oil outside, or at least keep them under a cover. During weather changes water may penetrate through the bunghole.

●

Always fill the hydraulic system using the filling and filtering unit (BOMAG part-no. 007 610 01). This unit is equipped with a fine filter, which filters the hydraulic oil and prolongs the lifetime of the system filter.

●

Clean fittings, filler caps and their immediate surrounding area before removing them, so that no dirt can fall in.

●

Do not leave the tank opening unnecessarily open, cover it so that no dirt can fall in.

Environment Catch running out oils, coolant and fuel and do not let them seep into the ground or into the sewage system. Dispose of oils, coolant and fuels environmentally.

Notes on the fuel system The lifetime of the diesel engine is decisively depending on the cleanliness of the fuel. ●

●

●

44

Keep the engine free of dirt and water as this could damage the injection elements of the engine. Zinc lined drums are not suitable for storing fuel. The fuel drum should rest for a longer period of time before drawing off fuel.

%20$ *

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Notes on the cooling system On water cooled engines the preparation and monitoring of the coolant is of utmost importance, as otherwise engine failures caused by corrosion, caviation and freezing may occur.

5.2

Fuels and lubricants

Engine oil To ensure perfect cold starting it is important to choose the viscosity (SAE grade) of the engine oil with respect to the ambient temperature.

The coolant is a mixture of water and a cooling system protection agent. The cooling system must be permanently monitored. Apart from the coolant level inspection this includes also the inspection of the concentration of cooling system protection agent.

The oil change intervals must be halved when working at temperatures below -10°C.

The concentration of the cooling system protection agent can be checked with commercially available test instruments (glycomat). Danger Health hazard! 

The mixing of nitride based cooling system protection agents with amine based agents will cause the generation of highly toxic nitrosamines. Environment Cooling system protection agents must be disposed of environmentally.

Fig. 61

Lubrication oil with a too high viscosity index will cause starting difficulties. The temperature when starting the engine is therefore decisive for selecting the correct viscosity for winter operation.

Oil viscosity Since the viscosity of the lubrication oil changes with the temperature, the ambient temperature at the engine's operating location determines the viscosity class (SAE-grade) to be chosen (see diagram). Although cold stating abilities may be impaired if the temperature occasionally drops below the limit (e.g. use of SAE 15W/40 down to -15°C), this will not cause any damage to the engine.

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Having to change the lubrication oil due to changes in temperature can be avoided by using multigrade oils. The oil change intervals given below are also valid for multigrade oils.

Regular lubrication oil changes The longest period of time that lubrication oil should remain in the engine is one year. If the oil change intervals specified below are not reached during one year, the lubrication oil must be changed at least once every year, irrespective of the operating hours.

Oil quality Lubrication oils are differentiated according to their performance and quality class. The commonly used specifications are those according to API (American Petroleum Institute) and CCMC (Committee of Common Market Automobile Constructors). Permitted API-oils Turbocharged engines = CD / CF, CE / CF4 Permitted CCMC-oils Turbocharged engines = D4 / D5 (SHPD)

Lubrication oil change intervals Caution These intervals are only valid when using diesel fuel with a sulphur content of max. 0,5 % by weight and at ambient temperatures higher than -10 °C. 

CCMC-D4/ D5 (SHPD) = 500 operating hours API: CD/ SE bzw. CD/SF = 500 operating hours When using fuels with a sulphur content of more than 0,5% to 1% or at ambient temperatures below -10 °C the oil change intervals must be halved. When using fuels with a sulphur content of more than 1% consult your next service station.

46

Fuels Quality Use only commercially available brand diesel fuels with a sulphur content of less than 0,5% and pay attention to cleanliness when filling in fuel. Higher sulphur contents will effect the engine oil change intervals. Use only winter-grade diesel fuel at low ambient temperatures. The fuel level should always be topped up in due time so that the fuel tank will not run dry, as otherwise the filter and the injection lines will have to be bled. The following fuel specifications are permitted: DIN/EN 590; DIN 51 601; Nato Codes: F-54, F-75; BS 2869: A1 and A2; ASTM D 975-78: 1-D and 2D.

Winter fuel During the winter period use only winter-grade diesel fuel to avoid clogging caused by paraffin separation. Disturbing paraffin separation can also be expected under extremely cold condition, even when using winter-grade diesel fuel. In most cases it is also possible to mix in fuel additives to improve the flow properties. Consult the engine manufacturer for details.

Hydraulic oil The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mm2/s at 40 °C (104 °F). For topping up or changing the hydraulic oil use only quality hydraulic oil of 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 (refer to the specifications of the manufacturer).

Biodegradable hydraulic oil On request the hydraulic system can also be filled with ester based biodegradable hydraulic oil (Panolin HLP Synth. 46). This biodegradable hydraulic oil meets the requirements of a mineral oil based hydraulic oil according to DIN 51524. Always use the same oil for topping up if the system is filled with Panolin HLP Synth. 46. When changing from a mineral oil based hydraulic oil to ester based biodegradable hydraulic oil, consult the lubrication oil service department of the respective oil manufacturer.

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Check the filter more frequently after changing to the new oil.

Oil for drive axle For the axle use only multi-purpose gear oil of APIClass GL5 SL of viscosity class SAE 90. The additives in this oil ensure low wear lubrication under all operating conditions.

Lubrication grease Use an EP-high pressure grease, lithium saponified (penetration 2), for lubrication purposes.

Coolant For the coolant mixture use only soft tap water (drinking water) with a hardness of 3 to 12 °dGH. The water must not contain more than 100 mg/dm chlorine and sulphate. The ph-value must be between 6,5 and 8,5. Anti-feeze agents must be used under any climatic conditions as a protection against freezing, corrosion and boiling. The concentration of cooling system protection agent in the water must be between min. 35% and max. 45%. Caution Do not mix different coolants and additives. 

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5.3

Table of fuels and lubricants

Assemblies

Fuels, Lubricants Summer

Winter

Approx. quantity Attention Observe level marks

Engine

Engine oil CCMC-D4/D5 (SHPD) resp. API: CD/CE/CF

without filter change approx. 17,5 litres (4.62 USgal)

SAE 15W/40 (-20 °C to +40 °C) (-4 °F to 104 °F) SAE 30

SAE 10W

(+5 °C to +30 °C)

(-5 °C to -30 °C)

(41 °F to 86 °F)

(23 °F to -22 °F) Fuel

diesel Hydraulic system

winter-diesel fuel

hydraulic oil (ISO), HV46, kinem.viscosity

approx. 340 litres (89.82 USgal) approx. 60 litres (15.8 USgal)

46 mm2/s at 40 °C Vibration bearings

engine oil SAE 15W/40

approx. 0,8 litres per side (0.21 USgal)

Intermediate gear

gear oil SAE 90, API GL5

approx. 0,4 l (0.11 USgal)

Drive axle

gear oil SAE 90, API GL5

approx. 16 litres (5.28 USgal)

cooling system protection agent

approx. 20 litres (5.28 USgal)

Coolant

48

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5.4

Running-in instructions

When taking new machines into operation or when starting up overhauled engines, the following maintenance work must be carried out: 

Caution

Up to approx. 250 operating hours check the engine oil level twice every day. Depending on the engine load the oil consumption will drop to its normal level after approx. 100 to 250 operating hours. After a running time of 30 minutes ●

Tighten the V-belt

After 50 operating hours ●

Change the engine oil filter.

●

Change the engine oil.

●

Check the valve clearance, adjust if necessary.

●

Tighten all screw connections on intake and exhaust manifold, oil sump and engine mounts.

●

Tighten the screw connections on the machine.

●

Tighten the fastening screws for the wheels with the specified torque.

●

Change the oil in the drive axle.

●

Change the oil in the reduction gear for the axle.

After 500 operating hours ●

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Change the oil in the vibration bearing

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5.5

Maintenance chart

During the individual maintenance intervals perform also the work for shorter, preceding intervals. Pos.

Description

Note

Every 10 operating hours 5.6 5.7 5.8 5.9 5.10 5.11

Check the engine oil level Check the water separator Check the fuel level Check the hydraulic oil level Check the coolant level Checking the dust separator of the oil bath air filter

Dipstick mark approx. 340 l Inspection glass

Every 50 operating hours 5.12 5.13

Check the tire pressure Adjust the scrapers

Every 250 operating hours 5.14 5.15 5.16 5.17 5.18

Check the condition, tension of the V-belt, changing the V-belt Clean the cooling fins on radiator and hydraulic oil cooler Check the oil level in the drive axle Check the oil level in the intermediate gear for the axle Check the oil level in the vibration bearings

Every 500 operating hours 5.19 5.20 5.21 5.22 5.23 5.24

50

Change the engine oil* Change the engine oil filter cartridge Change the oil in the drive axle Change the oil in the intermediate gear Draining the fuel tank sludge Servicing the battery

at least 1x per year at least 1x per year at least 1x per year pole grease

%20$ *

BW 212 D-3/PD-3

0DLQWHQDQFH

Pos.

Description

Note

Every 1000 operating hours 5.25

Check, adjust the valve clearance

Inlet = 0,3 mm, Exhaust= 0,5 mm, on cold engine

5.26 5.27 5.28 5.29 5.30 5.31 5.32 5.33 5.34

Change the fuel prefilter cartridge Change the fuel filter cartridge Change the oil in the vibration bearings Check the fastening elements on the engine Check, change the fuelreturn lines Tightening the fastening of the axle to the frame Tighten the wheel nuts Check the ROPS Cleaning the oil bath air filter

min. 1x per year latest after 2 years

Every 2000 operating hours 5.35 5.36 5.37

Change hydraulic oil and breather filter** Change the hydraulic oil filter* Change the coolant

(at least every 2 years) (at least every 2 years) (at least every 2 years)

As required 5.38

Clean, change the dry air filter cartridge

5.39 5.40 5.41 5.42 5.43

Adjust the parking brake Change the tires Change the fresh air filter in the cabin Tightening torques Engine consevation

at least 1x per year, safety cartridge at least every 2 years

*The oil change intervals must be halved when using diesel fuel with a sulphur content of more than 0.5% by weight. **Also after repairs in the hydraulic system.

BW 212 D-3/PD-3

%20$ *

51

(YHU\RSHUDWLQJKRXUV

Every 10 oper ating hours

5.6

L

Checking the engine oil level

5.7

Note

L

Park the machine on level ground, shut the engine down and wait for about 15 minutes to allow the oil to run back into the oil sump.

Checking, cleaning the water separator

Note

The service intervals for the water separator depend on the water contents in the fuel and can therefore not be determined precisely. After taking the engine into operation you should therefore at the beginning check every day if signs of water can be found in the filter bowl. Environment Catch running out fuel and dispose of environmentally.

Fig. 62 ●

Pull the oil dipstick (Fig. 62) out, wipe it clean with a lint-free cloth and reinsert it until it bottoms.

●

Pull the oil dipstick out again.

●

The oil level must be between the two marks "L" and "H".

●

Top up oil immediately if the oil level is too low.

●

If the oil level is too high detect the cause and drain the oil off.

Fig. 63 ●

Loosen the drain screw (Fig. 63) for a few turns and catch running out fuel / water.

●

Tighten the drain screw again and check for leaks, use a new sealing ring if necessary.

 Caution Before a longer work period fill the oil up to the "MAX"-mark.

Top up quantity from the "L" to the "H" mark: approx. 2 litres For quality and quantity of oil refer to the table of fuels and lubricants.

52

%20$ *

BW 212 D-3/PD-3

(YHU\RSHUDWLQJKRXUV

5.8

 Caution Dirty fuel can cause engine failures or even damage to the engine.

Checking the fuel level

If necessary fill in fuel through a screen filter.

Danger Fire hazard! 

●

When working on the fuel system do not use open fire, do not smoke, do not refuel in closed rooms, do not inhale any fuel fumes.

If necessary top up fuel (diesel or winter diesel).

For quality of fuel refer to the table of fuels and lubricants.

Fig. 64

Check the fuel level on the fuel gauge (Fig. 64).

●

L

Note

Never drive the fuel tank empty, because this would required bleeding of the entire fuel system. ●

Clean the area around the filler opening.

Fig. 65 ●

Open the fuel tank cover (Fig. 65).

BW 212 D-3/PD-3

%20$ *

53

(YHU\RSHUDWLQJKRXUV

5.9

Checking the hydraulic oil level

5.10 Checking the coolant level Danger Danger of scalding! 

Caution In mit Panolin HLP Synth. 46, the same oil must be used for filling up. In case of any other ester based oil consult the lubrication service department of the respective oil manufacturer. 

Top up coolant only when the engine is cold.

Fig. 67

Check the coolant level (Fig. 67).

●

Fig. 66 

Check the oil level in the inspection glass (Fig. 66) on the hydraulic oil tank.

●

If during the daily coolant level check the coolant level is found to have dropped, check all lines, hoses and engine for leakages.

Normal level approx. 3 cm below the upper edge of the inspection glass. Minimum level middle of inspection glass. 

Caution

●

To top up unscrew the lid and fill in coolant up to the MAX-mark.

For quality of coolant refer to the table of fuels and lubricants in chapter 5.2.

Caution

If during the daily oil check the oil level is found to have dropped, check all lines, hoses and components for leakages. ●

If necessary fill in hydraulic oil through the filler neck.

For quality and quantity of oil refer to the table of fuels and lubricants.

54

%20$ *

BW 212 D-3/PD-3

(YHU\RSHUDWLQJKRXUV

5.11 Checking the dust separator on the oil bath air filter*

Fig. 68 ●

*

If the dust reaches the mark loosen the clamp (Fig. 68), take the cover off and clean the bowl.

$$sonder%%

BW 212 D-3/PD-3

%20$ *

55

(YHU\RSHUDWLQJKRXUV

Every 50 oper ating hours

5.12 Checking the tire pressure

5.13 Adjusting the scrapers

Caution Always close the valves with the dust caps.

smooth drum only



Fig. 70 Fig. 69

Check the tire pressure with a pressure gauge and the tire inflation valve 1 (Fig. 69) in top position.

●

●

Check the condition and adjustment of the front and rear scrapers, adjust or replace the scraper rubber if necessary.

●

To adjust the scrapers 1 (Fig. 70) loosen the fastening screws (2) in the slots and push the scraper bracket towards the drum until the scraper touches.

●

Retighten the fastening screws.

Nominal value see technical data L

Note

Ensure even pressure in all tires. ●

Screw the valve caps back on.

padfoot drum only

Fig. 71

56

●

Check condition and adjustment of scrapers 2 (Fig. 71), adjust or replace the teeth if necessary.

●

To adjust the scrapers (2) slacken the fastening screws (1) in the slots and move the scrap-

%20$ *

BW 212 D-3/PD-3

(YHU\RSHUDWLQJKRXUV

er towards the drum, leaving a gap of approx. 25 mm. ●

Retighten the fastening screws.

BW 212 D-3/PD-3

%20$ *

57

(YHU\RSHUDWLQJKRXUV

Every 250 operating h ours

5.14 Checking the condition, tension of the V-belt, changing the V-belt

Tightening the generator V-belt

Danger Danger of accident! 

This work must only be performed with the engine shut down!

Checking the V-bel Fig. 73 ●

Slacken the fastening screws 1, 2 and 3 (Fig. 73).

●

Push the generator in direction of arrow until the correct V-belt tension is obtained.

●

Retighten all fastening screws.

Changing the generator V-belt ●

Slacken the fastening screws 1, 2 and 3.

●

Push the generator against the direction of the arrow completely against the engine.

●

Take the old V-belt off.

●

Place the new V-belt on the V-belt pulleys.

●

Tension the V-belt as described before.

Fig. 72 ●

●

Examine the entire circumference of the V-belt (Fig. 72) for damage and cracks. Replace a damaged or cracked V-belt. Check by thumb pressure that the V-belt cannot be depressed for for than 10 - 15 mm between the V-belt pulleys, tighten it if necessary.

 Caution Check the V-belt tension after a running time of 30 minutes.

Tensioning the coolant/fuel pump Vbelt Danger Danger of accident! 

This work must only be performed with the engine shut down.

58

%20$ *

BW 212 D-3/PD-3

(YHU\RSHUDWLQJKRXUV

Fig. 74

Fig. 75

●

Slacken the fastening screws 1 and 2 (Fig. 74).

●

Slacken the fastening screws 1 and 2 (Fig. 75).

●

Push the idler pulley in direction of the arrow until the correct V-belt tension is obtained.

●

Push the idler pulley in direction of the arrow until the correct V-belt tension is obtained.

●

Retighten all fastening screws.

●

Retighten all fastening screws.

Changing the coolant/fuel pump V-belt ●

Take the blower- and generator V-belt off, see suitable section.

●

Slacken the fastening screws 1 and 2.

●

Push the idler pulley against the direction of the arrow completely against the engine.

●

Take the old V-belt off.

●

Place the new V-belt on the V-belt pulleys.

●

Tension the V-belt as described before.

●

Reinstall the blower- and generator V-belt.

Caution Check the V-belt tension after a running time of 30 minutes.

Changing the blower V-belt



Fig. 76 ●

Unscrew the fastening screws (Fig. 76) and push the blower forward.

Tensioning the blower V-belt 

Danger

Danger of accident! This work must only be performed with the engine shut down.

BW 212 D-3/PD-3

%20$ *

59

(YHU\RSHUDWLQJKRXUV

●

Push the compressor in direction of the arrow until the correct V-belt tension is obtained.

●

Retighten all fastening screws.

Changing the V-belt, climatecompressor **

Fig. 77

Slacken the fastening screws 1 and 2 (Fig. 77).

●

Push the idler pulley against the direction of the arrow completely against the engine.

●

●

Take the old V-belt off.

●

Place the new V-belt on the V-belt pulleys.

●

Tension the V-belt as described before.

●

Take the blower- and generator V-belt off, see suitable section.

●

Slacken the fastening screws 1, 2 and 3.

●

Push the compressor against the direction of the arrow completely against the engine.

●

Take the old V-belt off.

●

Place the new V-belt on the V-belt pulleys.

●

Tension the V-belt as described before.

●

Reinstall the blower- and generator V-belt.

Caution Check the V-belt tension after a running time of 30 minutes. 

Caution Check the V-belt tension after a running time of 30 minutes. 

Tensioning the V-belt, climatecompressor *

Fig. 78 ●

*

60

Slacken the fastening screws 1, 2 and 3 (Fig. 78).

Option

**

%20$ *

Option

BW 212 D-3/PD-3

(YHU\RSHUDWLQJKRXUV

5.15 Cleaning the cooling fins on radiator and hydraulic oil cooler Danger Danger of injury! 

Cleaning with cold cleansing agent Caution Protect electrical equipment such as generator, regulator and starter against the direct water jet. 

●

Spray the engine with a suitable cleansing agent, e.g. cold cleansing agent and wash it off with a strong water jet after a sufficient soaking time.

●

Run the engine warm for a short time to avoid corrosion.

Cleaning work should only be carried out with the engine stopped and cooled down. Caution Take care to avoid deformation of the radiator cooling fins. 

L

Note

Dirt on blower blades and oil cooler reduce the cooling effect. Oil and fuel on such surfaces support the accumulation of dirt. You should therefore seal any leaks in the area of the cooling blower or the oil cooler immediately and clean the cooling surfaces after.

Cleaning with pressure air

Fig. 79

L

Note

Start to blow out from the air discharge side. ●

Blow the radiator out with pressure air (Fig. 79).

BW 212 D-3/PD-3

%20$ *

61

(YHU\RSHUDWLQJKRXUV

5.16 Checking the oil level in the drive axle

5.17 Checking the oil level in the intermediate gear

Fig. 80

Fig. 81

●

Unscrew the filler and level plug (Fig. 80) from the axle housing.

●

Unscrew the filler and level plug (Fig. 81) from the intermediate gear.

●

The oil level must reach the bottom edge of the bore.

●

The oil level must reach the bottom edge of the bore.

●

Top up oil if necessary.

●

Top up oil if necessary.

For quality of oil refer to the table of fuels and lubricants. ●

62

Screw the filler and level plug back in.

For quality of oil refer to the table of fuels and lubricants. ●

%20$ *

Screw the filler and level plug back in.

BW 212 D-3/PD-3

(YHU\RSHUDWLQJKRXUV

5.18 Checking the oil level in the vibration bearing housings L

Note

Check the oil level only at operating temperature after running the vibration for about 1/2 hour.

Fig. 82 ●

Move the drum so that the oil level control plug (Fig. 82) on the left hand side is in lowest position.

●

Unscrew the control plug (1).

Some oil should drip out of the level bore ●

If necessary unscrew the oil filler plug (2) and fill in some oil through the filler bore (2), until it starts to run out from the level inspection bore.

For quality of oil refer to the table of fuels and lubricants. ●

Screw the oil filler (2) and control plug (1) back in.

●

Repeat this procedure on the opposite side.

BW 212 D-3/PD-3

%20$ *

63

(YHU\RSHUDWLQJKRXUV

Every 500 operating h ours

5.19 Changing the engine oil  Caution The oil change at 500 operating hours applies when using fuel with a sulphur content of less than 0,5 %.

When using fuel with a sulphur content of more than 0,5 % the oil change intervals must be halved (see section 5.2, fuels and lubricants). Drain the engine oil only when the engine is warm.



Fig. 84 ●

For quality and quantity of oil refer to the table of fuels and lubricants.

Danger

Danger of scalding!

●

Screw the lid back on the oil filler neck.

●

Check the oil level on the dipstick after a short test run, top up to the upper dipstick mark if necessary.

When draining hot oil. Do not let old oil seep into the ground. ●

Fill in new engine oil (Fig. 84).

Unscrew the lid from the oil filler neck on the engine.

Fig. 83 ●

Unscrew the drain plug (Fig. 83) and catch running out oil.

●

Change the engine oil (see following section).

●

Screw the drain plug back in.

64

%20$ *

BW 212 D-3/PD-3

(YHU\RSHUDWLQJKRXUV

5.20 Changing the engine oil filter cartridge Danger Danger of scalding! 

There is a danger of scalding by hot oil when unscrewing the filter. Caution Catch running out oil and dispose of environmentally together with the engine oil filter cartridge. 

Fig. 86 ●

Apply some oil to the rubber seal of the new filter cartridge (Fig. 86).

●

Fill the filter cartridge with clean engine oil.

●

Screw the new filter cartridge on by hand until the seal contacts the filter head.

●

Tighten the filter cartridge for another half turn.

●

After a short test run examine the filter cartridge for tight fit and check the oil level, if necessary top up oil to the MAX-mark.

Fig. 85 ●

Unscrew the filter cartridge 1 (Fig. 85) using a suitable filter wrench.

●

Clean the sealing faces on the filter carrier from all dirt.

BW 212 D-3/PD-3

%20$ *

65

(YHU\RSHUDWLQJKRXUV

5.21 Changing the oil in the drive axle

5.22 Changing the oil in the intermediate gear

Fig. 87

Fig. 88

Caution Drain the oil only at operating temperature. 

●

Clean and unscrew the level plug (Fig. 87).

●

Clean and unscrew the drain plug.

●

Let the oil run out and catch it.

 Caution Do not let old oil seep into the ground.

●

Screw the drain plug tightly back in.

●

Fill in oil through the level control bore until it reaches the bottom edge of the bore.

●

Clean and unscrew the level plug (Fig. 88).

●

Clean and unscrew the drain plug.

●

Let all oil run out and catch it.

Caution Do not let old oil seep into the ground. 

●

Screw the drain plug back in tightly.

●

Fill in oil through the level control bore until it reaches the bottom edge of the bore.

For quality of oil refer to the table of fuels and lubricants. ●

Screw the level plug back in tightly.

For quality of oil refer to the table of fuels and lubricants. ●

66

Screw the level plug back in tightly.

%20$ *

BW 212 D-3/PD-3

(YHU\RSHUDWLQJKRXUV

5.23 Draining the fuel tank sludge

5.24 Servicing the battery Danger Danger of cauterization! 

Danger Fire hazard! 

When working on the battery do not use open fire, do not smoke!

When working on the fuel system do not use open fire, do not smoke.

Do not let skin and clothes come in contact with acid!

Do not spill any fuel. Catch running out fuel, do not let it seep into the ground.

Wear your protective outfit!

Do not inhale any fuel fumes.

Before recharging the battery remove all plugs to avoid the accumulation of highly explosive gases.

Do not lay any tools on the battery!

 Caution Dispose of used batteries environmentally.

Fig. 89 ●

Unscrew the drain plug 1 (Fig. 89) from the bottom of the fuel tank and drain off approx. 5 litres of fuel.

●

Screw the drain plug back in with a new sealing ring.

BW 212 D-3/PD-3

Fig. 90 ●

Unscrew the fastening screws (Fig. 90) and fold the operator’s seat to the front.

●

Remove the batteries and clean the battery compartment.

●

Clean the batteries from the outside.

●

Clean the battery poles and pole clamps and cover them with acid free grease (vaseline).

●

Check the fastening of the batteries.

%20$ *

67

(YHU\RSHUDWLQJKRXUV

Every 1000 operating hour s

5.25 Checking, adjusting the valve clearance Caution Before checking the valve clearance let the engine cool down for at least 30 minutes. The engine temperature should be lower than 80 °C. 

After a short test run check the engine for leaks. Fig. 92

Valve adjustment diagram

Crankshaft adjustment 1 (Fig. 92) (6 - cylinder engine) ●

Crank the engine with a suitable spanner on the V-belt pulley until the valves on cylinder 1 are "overlapping".

Overlapping means: the outlet valve is not yet completely closed, the inlet valve starts to open. ●

Adjust the valves by following the adjustment schematic for crankshaft adjustment 1, marked black.

●

For control purposes mark the respective rocker lever with chalk.

Fig. 91

Valve 1 (Fig. 91) white = not adjustable Valve (2) black = adjustable

Fig. 93

Crankshaft adjustment 2 (Fig. 93) (6 - cylinder engine)

68

●

Turn the crankshaft one revolution further (360).

●

Adjust the valves by following the adjustment schematic crankshaft adjustment 2, marked black.

%20$ *

BW 212 D-3/PD-3

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Checking the valve clearance ●

Adjusting the valve clearance

Loosen the ventilation valve on the crankcase and swing it to the side.

Fig. 96 ●

Slacken the counter nut. Regulate the adjustment screw with a screwdriver 7 (Fig. 96), so that the feeler gauge (6) fits through the gap with only resistance after tighteneing the counter nut.

●

Check and adjust all adjustable valves.

●

Check the gasket for the cylinder head cover, replace if necessary.

●

Reinstall the cylinder head cover.

●

Swing the ventilation valve back into position and fasten it.

●

Fasten the air filter and ensure correct fit of combustion air hoses and hose clamps.

Fig. 94 ●

Unscrew the fastening screws 1 (Fig. 94) for the air filter bracket.

●

Remove the cylinder head cover (2).

●

Crankshaft adjustment according to "valve adjustment diagram".

Fig. 95 ●

Check the valve clearance 2 (Fig. 95) between the rocker arm (1) and the valve (3) with a feeler gauge.

Inlet valve

= 0,3 mm

Outlet valve

= 0,5 mm

The feeler gauge must fit through the gap with only little resistance. ●

If the gap is too narrow or too wide for the feeler gauge the valve clearance must be adjusted.

BW 212 D-3/PD-3

%20$ *

69

(YHU\RSHUDWLQJKRXUV

5.26 Changing the fuel filter cartridge 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. 97 ●

Unscrew the fuel filter cartridge (Fig. 97) with a suitable filter wrench.

●

Clean the sealing faces on the filter carrier from all dirt.

●

Unscrew the water separator from the filter cartridge.

70

Fig. 98 ●

Cover the rubber seal on the water separator 1 (Fig. 98) slightly with oil.

●

Screw the water separator on by hand (2) until the seal touches.

●

Tighten the water separator for another half turn (3).

●

Fill the new filter cartridge with clean diesel fuel (4).

●

Cover the rubber seal on the filter element (5) slightly with oil and tighten it by hand until the seal touches.

●

Tighten the filter element for another half turn (6).

●

After a short test run check the filter cartridge for tight fit.

%20$ *

BW 212 D-3/PD-3

(YHU\RSHUDWLQJKRXUV

5.27 Changing the fuel filter cartridge Danger Fire hazard!

●

Fill the new filter cartridge with clean diesel fuel.

●

Screw the new filter cartridge on by hand until the seal contacts the filter head.

●

Tighten the filter cartridge for another half turn.

●

After a short test run check the filter cartridge for tight fit.



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. 99 ●

Loosen and unscrew the fuel filter cartridge (Fig. 99) using a suitable filter wrench.

●

Clean the sealing faces on the filter carrier from all dirt.

Fig. 100 ●

Apply some oil to the rubber seal (Fig. 100) of the new filter cartridge.

BW 212 D-3/PD-3

%20$ *

71

(YHU\RSHUDWLQJKRXUV

5.28 Changing the oil for the vibration bearings Caution Change the oil at operating temperature. For this purpose run the machine approx. half an hour with vibration. 

Environment Catch running out oil and dispose of environmentally.

Fig. 102 ●

Unscrew the level plug at the bottom of the drum 1 (Fig. 102) and fill in oil through the filler bore, until it starts to run out through the level bore (2).

For quality and quantity of oil refer to the table of fuels and lubricants. ●

Screw the oil filler (2) and control plug (1) back in.

●

Repeat the oil change on the opposite side.

●

Check the oil level again at operating temperature (after running the vibration for approx. 0.5 hours).

Fig. 101 ●

Move the drum until the drain plug 1 (Fig. 101) is in lowest position.

●

Unscrew the drain plug, drain all oil off and catch it.

●

Once the oil has run out clean the drain plug and screw it tightly back in.

72

 Caution Overfilling causes overheating of the vibration bearings!

%20$ *

BW 212 D-3/PD-3

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5.29 Checking the fastening elements on the engine

5.30 Checking, changing the fuelreturn lines

Fig. 103

Fig. 104

●

Tighten the fastening of intake and exhaust tubes (Fig. 103) on the cylinder heads.

●

Check sockets and clamps between air filter, exhaust gas turbo charger and charge air line as well as lubrication oil lines for tight fit and leaks.

●

●

Remove the cylinder head cover 1 (Fig. 104).

●

Check all rubber hoses of the leakage return line (2), replace them if necessary, but at the latest after 2 years.

●

Check all lines and connections for leaks after a test run.

Tighten the fastening screws for the oil sump and the engine mounts.

BW 212 D-3/PD-3

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73

(YHU\RSHUDWLQJKRXUV

5.31 Tightening the fastening of the axle to the frame

5.32 Tightening the wheel nuts

Fig. 106 Fig. 105 ●

74

Check all fastening nuts for the axle retaining bolts (Fig. 105) for tight fit.

●

Tighten the wheel nuts (Fig. 106) in a crosstype pattern.

Tightening torque: 430 Nm (316 ft-lb)

%20$ *

BW 212 D-3/PD-3

(YHU\RSHUDWLQJKRXUV

5.33 Checking the ROPS L

5.34 Cleaning the oil bath air filter *

Note

With the cabin assembled the ROPS (Roll Over Protection Structure) is integrated in the cabin. Please observe also the respective section in the safety regulations in this manual.

Fig. 108 ●

Loosen the quick locks (Fig. 108), take the filter bowl off and empty it.

●

Clean the filter mesh by repetitive dipping into diesel fuel.

●

Clean the filter bowl with diesel fuel and fill in engine oil up to the level mark.

●

reinstall the filter bowl.

Fig. 107

Check the cabin, especially the ROPS (Fig. 107) for cracks, corrosion, damage and missing fastening elements.

●

L

Note

Unusual movements and noises (vibrations) during operation indicate damage or loose fastening elements. ●

Check the fastening screws for the cabin (ROPS) to the operator’s platform for tight fit.

●

Check the suspension buffers for the operator’s stand for tight fit.

●

Check the condition and the fastening of the seat belt.

*

BW 212 D-3/PD-3

%20$ *

$$sonder%%

75

(YHU\RSHUDWLQJKRXUV

Every 2000 operating hour s

5.35 Changing the hydraulic oil and the breather filter L

Note

See also section 5.1 "Notes on the Hydraulic System". Caution Apart from the normal oil change intervals the hydraulic oil must also be changed after major repairs in the hydraulic system. 

Fig. 109

Change the hydraulic oil only at operating temperature.

●

Unscrew the plug (Fig. 109) and drain the hydraulic oil off.

Clean the area around the hydraulic oil tank, the filler opening and the breather filter.

●

Check the sealing ring (1), replace if necessary and screw the plug tightly back in.

Do not use any detergents to clean the system. Do not start the engine after draining the hydraulic oil. Change the hydraulic oil filter element with every hydraulic oil change. Danger Danger of scalding! 

Danger of scalding by hot oil. Environment Catch running out oil and dispose of environmentally. L

Fig. 110 ●

Take the filler cap (Fig. 110) off.

●

Fill in hydraulic oil through the screen.

Note

The hydraulic oil filter element should only be changed after the test run.

L

Note

We recommend to fill the hydraulic system with the filling and filtering unit (BOMAG part-no. 079 930 35) with fine filter. This filters the hydraulic oil and prolongs the utilization time of the hydraulic oil filter and protects the hydraulic system. ●

Check the oil level in the inspection glass.

Nominal value: approx. 3 cm below the upper edge of the inspection glass For quality and quantity of oil refer to the table of fuels and lubricants.

76

%20$ *

BW 212 D-3/PD-3

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L

Note

The breather filter for the hydraulic tank is located in the filler cap and must therefore be replaced with the filler cap. ●

Close the tank with the new filler cap.

5.36 Changing the hydraulic oil filter Danger Danger of scalding! 

There is a danger of scalding by hot oil when unscrewing the filter. Caution If the filter has to be changed together with the hydraulic oil, the filter should in any case be changed after the oil change and the test run. 

Do not use the oil in the filter bowl. Environment Catch running out oil, dispose of oil and filter element environmentally. L

Note

The filter element must be changed with every hydraulic oil change and after major repairs in the hydraulic system.

Fig. 111 ●

Unscrew the cap nut 4 (Fig. 111) and take the filter bowl (5) with the filter element (3) off.

●

Examine the sealing face on the filter element thoroughly for any visible dirt. 

Caution

Visible contamination may be an early indicator for the possible failures of system compo-

BW 212 D-3/PD-3

%20$ *

77

(YHU\RSHUDWLQJKRXUV

nents and may indicate a possible malfunction of components. In such a case you should examine the system to detect the cause and replace or repair damaged components. Nonobservance can lead to the destruction of the complete hydraulic system. Do not clean or reuse the filter element. ●

Take the old filter element (3) out and clean the filter bowl and the thread.

●

Reinstall the filter bowl with the new filter element, check the condition of the O-rings (1) and (2), replace if necessary.

●

After a test run check the filter for leaks.

5.37 Changing the coolant Danger Danger of scalding! 

Change the coolant only when the engine is cold. Environment Catch running out coolant and dispose of environmentally.

Fig. 112 ●

Turn the shut-off valve for the cabin heater to "warm" (Fig. 112).

Fig. 113

78

●

Unscrew the plug, let all coolant run out and catch it (Fig. 113).

●

Screw the plug back in after all coolant has run out.

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Fig. 114 ●

Screw the lid off and fill in coolant up to the MAX-mark.

For quality of coolant refer to section 4.2, fuels and lubricants. ●

Start the engine and run it up to operating temperature.

●

Allow the engine to cool down and check the coolant level again, top up if necessary.

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Removing the main filter element

As r equired

5.38 Cleaning, changing the dry air filter cartridge Caution Cleaning, service and repair work must only be performed with the engine shut down. Do not start the engine after removing the filter element. 

Fig. 116

Pull both clamps (Fig. 116) on the housing cover towards the outside and take the cover off.

●

Fig. 115

The air filter needs to be serviced when the control light 1 (Fig. 115) on the fault monitoring board is permanently on while the engine is running, but at the latest after 2 years. L

Note

If the air filter service indicator lights up work may still be continued until the end of the day.

Fig. 117

Pull the main filter element (Fig. 117) off while turning it lightly.

●

Cleaning the main filter element Caution If necessary the main filter element may be cleaned up to five times. It should, however, be replaced after having reached the max. utilization period of two years. 

The number of cleaning processes of the main filter element should be marked with a ball pen or a felt pen on the safety element. In case of a sooty deposit cleaning of the main filter element is useless. Use a new filter cartridge.

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Incorrectly handled filter elements may be ineffective because of faults (e.g. cracks) and cause engine damage.

Cleaning the dust bowl

If the main filter element is defective, you should also change the safety element! Intermediate cleaning procedures between two service intervals indicated by the service indicator are not necessary.

Fig. 119 ●

Pull the inner part (Fig. 119) out and remove all dust from the cover.

●

Reinsert the inner part.

Caution During the assembly of the inner part make sure that the notch in the cover mates with the opening in the inner part. 

Fig. 118

L

Note

To clean the filter fit a tube to the air gun (Fig. 118), the end of which is bent by approx. 90. It must reach down to the bottom of the cartridge. ●

Blow the cartridge out with dry pressure air (max. 5 bar) by moving the tube up and down the inside of the cartridge until all dust has been blown out.

●

Examine the filter cartridge with a torch for any cracks and holes in the paper.

Installing the main filter element Push the main filter element carefully into the housing.

●

Closing the housing cover will automatically position the main filter element correctly.

Changing the safety element 



Caution

Under no circumstances must a damaged main filter element be used again. If in doubt install a new main filter element.

Caution

The safety element must never be cleaned and must never be used again after it has been removed. Open the seal only to replace the safety element. The safety element must be replaced: if the main filter element is defective, after five times cleaning of the filter cartridge, at the latest after 2 years,

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if the warning light still lights after serviving the main filter cartridge.

5.39 Adjusting the parking brake

Take the housing cover off and pull the main filter element off.

●

 Caution Adjustment work on the brake must only be performed by a specialist. Always adjust both brakes.

●

Place wedges in front of the drum and jack the rear of the machine up until the wheels can rotate freely.

Fig. 120 ●

Puncture the seal of the safety element from inside to outside with a suitable tool (Fig. 120) and pull both ears up.

●

Hold the safety element by both ears and pull it out while turning it lightly.

●

Push the new safety element in.

Fig. 121

●

Reinstall the main filter element and the cover.

●

Caution Make sure that the cover clamps are properly engaged. 

Run the diesel engine and pull the travel lever (Fig. 121) to the left out of the detent (parking brake released).

Fig. 122

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Unscrew the caps 3 (Fig. 122) from both cylinders, take off springs (1) and seal rings (2).

●

Turn the nuts (4) in both brake cylinders until the wheels are blocked.

●

Loosen the nuts again for two turns and check if the wheels are free again.

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●

Insert the springs, screw the caps with seal rings on and tighten them.

●

Perform a braking test.

5.40 Changing the tires Danger Danger of accident! 

Observe all safety notes for the lifting of loads. ●

Place a jack (min. 5 t bearing capacity) under the rear frame and jack the machine up so that the wheel can turn freely.

●

Unscrew the wheel nuts and take the wheel off.

Fig. 123

84

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Attach the new wheel (Fig. 123) and tighten the wheel nuts crosswise with a torque of 430 Nm (316 ft. lb.)anziehen.

●

Check the tire pressure, see technical data.

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5.41 Checking the fresh air filter for the cabin

5.42 Tightening torques

Fig. 125

Fig. 124 ●

Unscrew the fastening screws for the filter holders (Fig. 124) and take the filters out.

●

Insert the new filter and reassemble the filter bracket.

* Strength classes for screws with untreated, nonlubricated surface. The designation of the screw quality is stamped on the screw heads. 8.8 = 8G 10.9 = 10K 12.9 = 12K Axle - frame

●

M 24

= 880 Nm

The values result in a 90% utilization of the screws yielding point at a coefficient of friction of tot. = 0,14. The tightening torques are not valid when using MOS2 lubricants. L

Note

Self locking nuts must always be replaced after they have been unscrewed.

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5.43 Engine conservation If the engine is to be shut down for a longer period of time (e.g. over winter), we recommend to apply the following conserving measures to avoid corrosion: ●

Clean the engine, including the cooling system: With cold cleansing agent and a water jet or, even better, with a steam cleaner.

●

Run the engine warm and shut it down.

●

Drain off the still hot engine oil and fill in anticorrosion engine oil.

●

Drain off the coolant and fill in system protection agent.

●

Drain the fuel from the tank, mix it well with 10% anti-corrosion oil and fill it back in.

●

Run the engine for 10 minutes until all lines, filters, pumps and nozzles with this conserving mixture and the new engine oil has been distributed to all parts.

●

Now crank the engine several times (without ignition) to spray the combustion chambers.

●

Take the V-belts off and spray the grooves of the V-belts with anti-corrosion oil. Remove the anti-corrosion oil before resuming operation.

●

Close intake and exhaust openings tightly. L

Note

Depending on the weather conditions these conserving measures will provide protection for approx. 6 to 12 months. Before taking the engine back into operation all conserving oil must be drained off and replaced by regular engine oil, see chapter "Fuels and Lubricants" according to the API-(MIL)-classification. Anti-corrosion oils are those that comply with the specification MIL-L-21260 B or TL 9150037/2 or Nato Code C 640/642. A machine with a conserved engine must be marked by attaching a clearly visible warning tag.

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6 Trouble shooting

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6.1

General notes

The following work must only be carried out by qualified and trained personnel or by the BOMAG sales service. Please observe strictly the safety regulations in chapter 2 of these operating and maintenance instructions. Faults occur frequently due to the fact, that the machine has not been properly operated or serviced. Therefore, whenever a fault occurs, read through these instructions on correct operation and maintenance. If you cannot locate the cause of the fault or eliminate it yourself by following the trouble shooting charts, you should contact our customer service departments at our branch office or dealers.



Danger

Danger of injury! Keep away from rotating parts of the engine. All modules in the electric installation box can be bridged to be able to operate the machine in events of emergency. ●

Inclination module*

●

Vibration module

●

Generator module L

Note

You will find all wiring and hydraulic diagrams at the end of the spare parts catalogue.

*

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6.2

Engine

Faults

Possible cause

Remedy

The engine does not start

Starter defective or pinion not engaging

Have examined by a specialist

Fuel tank empty

Fill and bleed the tank

Temperature below starting limit

Use winter fuel and engine oil acc. to the ambient temperature.

Fuel filter clogged, in winter due to paraffin separation.

Change the filter. use winter fuel

Fuel lines leaking

Check all line connections for leakages and tighten the fittings.

Battery discharged or not connected

Tighten the pole clamps, check the cable connections

Injection valves or injection pump defective

Have examined by a specialist

Battery power too low, battery clamps loose or oxidized, causing the starter to turn too slowly

Have the battery checked, clean the terminal clamps, tighten them and cover them with acid free grease

Especially during winter: the use of too viscous engine oil

Use engine oil suitable for the ambient temperature

Fuel supply restricted, in winter fuel system clogged due to paraffin separation

Change the fuel filter Check the line connections for leaks and tighten the fittings. Use winter fuel in the cold season.

Incorrect valve clearance

Adjust the valve clearance

Injection valve defective

Have examined by a specialist

Injection lines leaking

Check the lines for leakages

Turbo charger defective

Have examined by a specialist

Dry air filter dirty

clean, replace if necessary

Excessive play in the throttle cable

Adjust the throttle cable, change it if necessary

The engine starts poorly and works irregularly with poor power

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Faults

Possible cause

Remedy

Excessive exhaust smoke

Engine oil level too high

Drain the oil to the upper dipstick mark

Dry air filter dirty

Clean, replace if necessary

Exhaust gas turbo-charger defective

Have examined by a specialist

Poor compression due to burned or broken compression rings or incorrect valve clearance

Have compression rings and pistons examined by a specialist, adjust the valve clearance

Incorrect valve clearance

Adjust the valve clearance

Cooling fins on radiator extremely soiled (the warning light "engine oil temperature" lights)

Clean the cooling fins

Injection valve defective

Have examined by a specialist

Engine oil level too lowy

Top up engine oil to the upper dipstick mark

Filling capacity of the injection pump not correctly adjusted

Have adjusted by a specialist

Cooling air flow restricted

Clean the cooling air duct

V-belt loose or broken

Tension or replace the V-belt

Engine oil level too high

Drain the engine oil down to the upper dipstick mark

Dry air filter dirty

Clean, change if necessary

Exhaust gas turbo-charger defective

Have examined by a specialist

Charge air hose leaking

Check fastening and connections

Incorrect valve clearance

Adjust the valve clearance

Injection valve defective

Have examined by a specialist

Engine oil level too low (control light "engine oil pressure" lights, the warning buzzer sounds)

Top up oil

Leakages in the lubrication system

Shut the engine down immediately, check fittings on oil lines, lubrication oil filter and oil cooler for leaks, if necessary tighten the fittings.

Generator speed too low

Check the V-.belt tension, replace the Vbelt if necessary

The generator does not charge the battery, because generator or regulator is defective

Have examined by a specialist

Engine overheats, shut down immediately!

Poor engine power

Engine oil pressure too low

The charge control light lights during operation, the warning buzzer sounds

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