Description
2020 BOMAG BW 213 D-5 Single Drum Roller Operating and Maintenance Manual
The 2020 BOMAG BW 213 D-5 Single Drum Roller Operating and Maintenance Manual brings together the information needed to operate, inspect and maintain the BW 213 D-5 safely and correctly. The document covers the machine from initial checks and control identification through vibration operation, transport, periodic servicing, troubleshooting and machine refitting. It applies to BW 213 D-5 machines identified from S/N 101 586 71 1117> and includes technical information for the Deutz TCD 2012 L04 2V diesel engine fitted to the roller.
File Details
- Manual type: Operating Instruction and Maintenance Instruction / Original Operating Instructions
- Brand and model: BOMAG BW 213 D-5 Single drum roller
- Serial coverage: S/N 101 586 71 1117>
- Language: English
- Page count: 290 pages
- File format: PDF
- Document number: 008 203 42 EN
- Date: 04/2020
Machine Data and Operating Reference
This BOMAG BW 213 D-5 operating and maintenance reference includes detailed machine data alongside the operating procedures. The technical-data section identifies the Deutz TCD 2012 L04 2V four-cylinder fluid-cooled diesel engine with 103 kW rated power to ISO 14396, 140 hp to SAE J1995 and a rated speed of 2400 min-1. It also gives machine dimensions, operating weights and axle loads, travel speeds, gradeability, tyre information, steering geometry, braking systems and exciter characteristics.
Compaction data includes two vibration frequencies of 30/34 Hz, amplitudes of 2.10/1.10 mm and centrifugal forces of 285/196 kN. The manual also explains operation of optional compaction-assistance equipment such as ECONOMIZER and Terrameter. ECONOMIZER displays compaction status and helps identify local weak areas, while the Terrameter section covers EVIB values, measuring passes, comparison of passes and the printer-equipped system for recording and printing measurement results.
Controls, Daily Checks and Machine Operation
The BOMAG BW 213 D-5 manual identifies the instrument cluster, warning and control lights, operating console, travel lever, driver’s seat, cabin controls, heating and air-conditioning controls, auxiliary heating panel, reversing-camera monitor and main battery switch. Procedures explain starting, travelling, applying the parking brake, selecting travel ranges, switching vibration on and off and parking the roller in a secured condition.
Pre-start inspection instructions cover hydraulic and fuel systems, cooling-system condition, bolted connections, engine and exhaust leaks, belt condition, steering, brakes, emergency stop, backup alarm and seat contact switch. Separate procedures show how to check engine oil, fuel, hydraulic oil, coolant, wheels and tyres before operation.
Maintenance, Fluids and Scheduled Service
A substantial portion of the 2020 BOMAG BW 213 D-5 Single Drum Roller Operating and Maintenance Manual is devoted to service work. The maintenance section specifies fuels and lubricants, running-in work and service intervals at 250, 500, 1000, 2000 and 4000 operating hours, plus tasks performed as required.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “2020 BOMAG BW 213 D-5 Single Drum Roller Operating and Maintenance Manual” are as follows:
Table of contentsp. 3
+1 Introductionp. 11
1.1 Forewordp. 12
1.2 Machine type plate and engine type platep. 14
+2 Technical datap. 15
+2.1 Noise and vibration datap. 19
2.1.1 Noise datap. 19
2.1.2 Vibration datap. 19
+3 Concerning your safetyp. 21
+3.1 Basic prerequisitesp. 22
3.1.1 Generalp. 22
3.1.2 Explanation of signal words used:p. 23
3.1.3 Personal protective equipmentp. 24
3.1.4 Intended usep. 25
3.1.5 Improper usep. 25
3.1.6 Estimated service life of the machinep. 26
+3.2 Definition of responsible personsp. 27
3.2.1 Operating companyp. 27
3.2.2 Expert / qualified personp. 27
3.2.3 Driver / operatorp. 28
+3.3 Fundamentals for safe operationp. 29
3.3.1 Remaining dangers, remaining risksp. 29
3.3.2 Regular safety inspectionsp. 29
3.3.3 Modifications and alterations to the machinep. 29
3.3.4 Damage, defects, misuse of safety devicesp. 30
3.3.5 Roll Over Protective Structure (ROPS)p. 30
+3.4 Handling fuels and lubricantsp. 32
3.4.1 Preliminary remarksp. 32
3.4.2 Safety regulations and environmental protection regulations for handling diesel fuelp. 33
3.4.3 Safety regulations and environmental protection regulations for handling oilp. 35
3.4.4 Safety regulations and environmental protection regulations for handling hydraulic oilp. 36
3.4.5 Safety regulations and environmental protection regulations for handling coolantsp. 38
3.4.6 Safety regulations and environmental protection regulations for handling battery acidp. 40
3.5 Load/transport the machinep. 42
+3.6 Starting up the machinep. 44
3.6.1 Prior to commissioningp. 44
3.6.2 Starting the enginep. 45
3.6.3 Starting the engine with jump leadsp. 45
+3.7 Driving the machine; working operationp. 47
3.7.1 Driving the machinep. 47
3.7.2 Driving up and down slopesp. 48
3.7.3 Cross-slopep. 48
3.7.4 Working with vibrationp. 49
3.7.5 Parking the machinep. 49
3.8 Refuellingp. 50
+3.9 Emergency proceduresp. 51
3.9.1 Actuating the emergency stop switchp. 51
3.9.2 Disconnecting the batteryp. 51
3.9.3 Towing the machinep. 51
+3.10 Maintenance workp. 53
3.10.1 Preliminary remarksp. 53
3.10.2 Working on hydraulic linesp. 53
3.10.3 Working on the enginep. 54
3.10.4 Maintenance work on electric components and batteryp. 55
3.10.5 Working on the air conditioningp. 55
3.10.6 Working on wheels and tyresp. 55
3.10.7 Cleaning workp. 56
3.10.8 Measures for longer shut-down periodsp. 56
3.10.9 After maintenance workp. 57
3.11 Repairp. 58
3.12 Signagep. 59
3.13 Danger zonesp. 67
3.14 Safety componentsp. 68
+4 Indicators and control elementsp. 71
+4.1 Driver’s standp. 72
4.1.1 Instrument clusterp. 72
+4.1.2 Operating consolep. 79
4.1.2.1 Emergency stop switchp. 80
4.1.2.2 Rotary switch for amplitude pre-selectionp. 80
4.1.2.3 Rotary switch for working lightsp. 81
4.1.2.4 Rotary switch for engine speedp. 81
4.1.2.5 Rotary switch for direction indicatorsp. 81
4.1.2.6 Rotary switch for hazard light systemp. 82
4.1.2.7 Rotary switch for lightingp. 82
4.1.2.8 Rotary switch for travel speed rangesp. 82
4.1.2.9 Starter switchp. 83
4.1.2.10 Lever for operating console inclinationp. 84
4.1.3 Travel leverp. 84
+4.1.4 Driver’s seatp. 86
4.1.4.1 Standard driver’s seatp. 86
4.1.4.2 Comfort driver’s seatp. 88
+4.2 Cabinp. 90
4.2.1 Control console cabinp. 90
+4.2.2 Heating / air conditioningp. 91
4.2.2.1 Rotary switch for air distributionp. 91
4.2.2.2 Rotary switch for cabin temperaturep. 92
4.2.2.3 Rotary switch for fanp. 92
4.2.2.4 Rotary switch for air conditioning systemp. 92
4.2.3 12 V DIN socketp. 93
4.2.4 Control panel for auxiliary heatingp. 94
4.2.5 Monitor for reversing camerap. 96
4.2.6 Fire extinguisherp. 97
+4.3 Engine compartmentp. 98
4.3.1 Main battery switchp. 98
+4.4 Outside of machinep. 99
4.4.1 Reversing camerap. 99
+5 Checks prior to start upp. 101
5.1 Notes on safetyp. 102
5.2 Visual inspections and function testsp. 104
5.3 Checking the engine oil levelp. 105
+5.4 Checking the fuel level; topping up fuelp. 106
5.4.1 Checking the fuel levelp. 106
5.4.2 Refuellingp. 106
5.5 Checking the hydraulic oil levelp. 108
5.6 Checking the coolant levelp. 109
5.7 Checking wheels and tyresp. 111
+6 Operationp. 113
6.1 Setting up the workplacep. 114
6.2 Electronic immobilizerp. 115
6.3 Starting the enginep. 116
+6.4 Travel operationp. 118
6.4.1 Preliminary remarks and safety notesp. 118
6.4.2 Driving the machinep. 119
6.4.3 Applying the parking brakep. 120
+6.5 Working with vibrationp. 121
6.5.1 Preliminary remarks and safety notesp. 121
6.5.2 Switching the vibration on and offp. 122
6.6 ECONOMIZERp. 124
+6.7 Terrameterp. 125
6.7.1 Terrameter displayp. 125
6.7.2 Terrameter with printerp. 126
6.7.3 Line graph (EVIB)p. 130
6.8 Parking the machine in secured conditionp. 133
6.9 Operating the heating / air conditioning systemp. 134
+6.10 Operating the auxiliary heatingp. 135
6.10.1 Switching on the operating unitp. 136
6.10.2 Operating surfacep. 136
6.10.3 Heating operationp. 137
6.10.4 Fan operationp. 140
6.10.5 Heating with preselected timesp. 142
6.10.6 Setting the time, week day and time formatp. 144
6.10.7 Switching off the operating unitp. 146
6.11 ECOSTOPp. 147
+6.12 Emergency proceduresp. 149
6.12.1 Actuating the emergency stop switchp. 149
6.12.2 Machine stops in case of faultsp. 150
6.12.3 Disconnecting the batteryp. 151
6.12.4 Emergency exitp. 151
6.12.5 Towing the machinep. 151
6.12.6 After towingp. 154
+7 Loading / transporting the machinep. 157
7.1 Prepare for transportp. 158
7.2 Loading the machinep. 159
7.3 Lashing the machine to the transport vehiclep. 161
7.4 Loading by cranep. 162
7.5 After transportationp. 164
+8 Maintenancep. 165
8.1 Preliminary remarks and safety notesp. 166
+8.2 Preparations/concluding workp. 168
8.2.1 Open and secure the engine hoodp. 168
+8.2.2 Engaging/releasing the articulation lockp. 169
8.2.2.1 Engaging the articulation lockp. 169
8.2.2.2 Disengaging the articulation lockp. 170
+8.3 Fuels and lubricantsp. 171
+8.3.1 Engine oilp. 171
8.3.1.1 Oil qualityp. 171
8.3.1.2 Oil viscosityp. 172
8.3.1.3 Oil change intervalsp. 172
+8.3.2 Fuelp. 173
8.3.2.1 Fuel qualityp. 173
8.3.2.2 Winter fuelp. 173
8.3.2.3 Storagep. 174
+8.3.3 Coolantp. 174
8.3.3.1 Generalp. 174
8.3.3.2 Water qualityp. 175
8.3.3.3 Cooling system protection agentp. 176
+8.3.4 Hydraulic oilp. 178
8.3.4.1 Mineral oil based hydraulic oilp. 178
8.3.4.2 Bio-degradable hydraulic oilp. 178
8.3.5 Gear oil SAE 75W-90p. 179
8.3.6 Gear oil SAE 80W-140p. 179
8.4 List of fuels and lubricantsp. 180
+8.5 Running-in instructionsp. 182
8.5.1 Generalp. 182
8.5.2 After 250 operating hoursp. 182
8.5.3 After 500 operating hoursp. 183
8.5.4 After 1000 operating hoursp. 183
8.6 Maintenance Tablep. 184
+8.7 Every 250 operating hoursp. 186
8.7.1 Checking the rubber-bonded metal rails and rubber buffersp. 186
8.7.2 Cleaning the radiator modulep. 187
+8.7.3 Checking, tensioning the V-belt for the generator systemp. 189
8.7.3.1 Checking the condition of the V-beltp. 189
8.7.3.2 Checking the V-belt tensionp. 189
8.7.3.3 Tightening the V-beltp. 190
8.7.4 Checking the oil level in the drive axlep. 191
8.7.5 Checking the oil level in the wheel hubsp. 192
8.7.6 Checking the oil level in the exciter housingp. 192
8.7.7 Changing the fresh air filter in the cabinp. 194
8.7.8 Check the parking brakep. 195
+8.8 Every 500 operating hoursp. 196
8.8.1 Change engine oil and oil filter cartridgep. 196
+8.8.2 Replacing the fuel filter; bleeding the fuel systemp. 198
8.8.2.1 Preliminary remarksp. 198
8.8.2.2 Replacing the fuel filterp. 199
8.8.2.3 Replacing the fuel pre-filterp. 199
8.8.2.4 Bleeding the fuel systemp. 201
8.8.3 Checking the anti-freeze concentration and the condition of the coolantp. 201
8.8.4 Checking the hydraulic linesp. 202
+8.8.5 Servicing the battery, checking the main battery isolationp. 204
8.8.5.1 Battery servicep. 204
8.8.5.2 Checking the main battery shutoffp. 205
+8.8.6 Servicing the air conditioning systemp. 205
8.8.6.1 Cleaning the condenserp. 205
8.8.6.2 Air conditioning function testp. 206
8.8.6.3 Checking the condition of the drier/collector unitp. 206
+8.9 Every 1000 operating hoursp. 208
8.9.1 Checking the ribbed V-beltp. 208
8.9.2 Replacing the air conditioning compressor V-beltsp. 210
8.9.3 Checking the engine mountsp. 211
8.9.4 Replacing the hydraulic oil filterp. 211
8.9.5 Change the oil in the drive axlep. 214
8.9.6 Changing the oil in the wheel hubsp. 215
8.9.7 Change the oil in the exciter housingp. 217
8.9.8 Retightening the fastening of the axle on the framep. 219
8.9.9 Retightening the wheel nutsp. 219
8.9.10 Checking the ROPSp. 219
8.9.11 Checking the travel lever controlp. 220
8.9.12 Cleaning the circulation air filter of the heatingp. 221
+8.9.13 Servicing the auxiliary heatingp. 221
8.9.13.1 Replacing the fuel filter for the auxiliary heatingp. 221
8.9.13.2 Replacing the air filter for the auxiliary heatingp. 222
+8.10 Every 2000 operating hoursp. 223
8.10.1 Checking, adjusting the valve clearancep. 223
8.10.2 Changing the hydraulic oilp. 224
8.10.3 Changing the coolantp. 227
+8.11 Every 4000 operating hoursp. 231
8.11.1 Replace ribbed V-belt and idler pulleyp. 231
+8.12 As requiredp. 232
+8.12.1 Air filter maintenancep. 232
8.12.1.1 Replacing the safety elementp. 235
8.12.2 Checking and cleaning the water separatorp. 236
8.12.3 Adjusting the scrapersp. 237
8.12.4 Cleaning the machinep. 238
8.12.5 Filling the windscreen washer tankp. 239
8.12.6 Replacing the paper roll in the printerp. 239
8.12.7 Drain the fuel tank sludgep. 240
+8.12.8 Measures prior to extended shut-down periodp. 240
8.12.8.1 Measures before shutting downp. 240
8.12.8.2 Battery service during prolonged machine downtimesp. 241
8.12.8.3 Measures before restartingp. 242
+9 Setting up / refittingp. 245
+9.1 Attaching the padfoot shellsp. 246
9.1.1 Preliminary remarks and safety notesp. 246
9.1.2 Preparationsp. 247
9.1.3 Removing the scrapersp. 248
9.1.4 Attaching segmentsp. 251
9.1.5 Attaching the scrapersp. 256
9.1.6 Installing the access stepsp. 259
+9.2 Removing the padfoot shellsp. 261
9.2.1 Preliminary remarks and safety notesp. 261
9.2.2 Preparationsp. 261
9.2.3 Removing the scrapersp. 262
9.2.4 Removing segmentsp. 264
9.2.5 Attaching the scrapersp. 267
9.2.6 Removing the access stepsp. 269
+10 Troubleshootingp. 271
10.1 Preliminary remarksp. 272
10.2 Starting the engine with jump leadsp. 273
+10.3 Fuse assignmentp. 274
10.3.1 Notes on safetyp. 274
10.3.2 Central electricsp. 274
10.3.3 Main fusesp. 275
10.3.4 Control console cabinp. 276
10.3.5 Auxiliary heatingp. 277
10.4 Fault code displayp. 278
10.5 Engine faultsp. 279
10.6 Fault indicators of auxiliary heatingp. 283
+11 Disposalp. 285
11.1 Final shut-down of machinep. 286
12 List of special toolsp. 287
- Engine oil filling quantity: 8.5 l (2.2 gal us)
- Fuel tank: 220 l (58 gal us)
- Coolant: 17 l (4.5 gal us)
- Hydraulic system: 72 l (19 gal us)
- Exciter housing: SAE 75W-90 gear oil, 1.2 l each (0.32 gal us)
- Drive axle: SAE 80W-140 gear oil, 11 l (2.9 gal us)
- Wheel hubs: SAE 80W-140 gear oil, 1.4 l each (0.37 gal us)
- Air-conditioning refrigerant: R134a, 1500 g (3.3 lbs)
Service procedures include engine oil and filter replacement, fuel-filter replacement and fuel-system bleeding, cooling-system inspection, hydraulic-line inspection, battery service, air-conditioning maintenance, drive-axle and wheel-hub oil changes, exciter-housing oil changes, hydraulic oil and filter replacement, valve-clearance adjustment, belt inspection and replacement, ROPS inspection, travel-lever checks and auxiliary-heating service. The maintenance table provides a direct schedule for locating work by operating-hour interval.
Chapters Covered
- 1 Introduction
- Foreword
- Machine type plate and engine type plate
- 2 Technical data
- Machine dimensions, weights, drive, tyres, brakes, steering and exciter data
- Noise and vibration data
- 3 Concerning your safety
- Basic prerequisites and responsible persons
- Safe operation, fuels and lubricants, loading, starting, driving and vibration
- Emergency procedures, maintenance, repair, signage, danger zones and safety components
- 4 Indicators and control elements
- Driver’s stand and instrument cluster
- Operating console, travel lever and driver’s seat
- Cabin, heating, air conditioning, auxiliary heating and reversing camera
- Engine compartment and outside-of-machine controls
- 5 Checks prior to start up
- Visual inspections and function tests
- Engine oil, fuel, hydraulic oil and coolant checks
- Wheel and tyre checks
- 6 Operation
- Workplace setup, immobilizer and engine starting
- Travel operation and vibration
- ECONOMIZER and Terrameter
- Parking, heating, air conditioning, auxiliary heating and ECOSTOP
- Emergency procedures and towing
- 7 Loading / transporting the machine
- Transport preparation and loading
- Lashing and crane loading
- Procedures after transportation
- 8 Maintenance
- Preparations, fuels and lubricants and running-in instructions
- Maintenance table and 250/500/1000/2000/4000-hour service
- Air filter, water separator, scrapers, cleaning and extended shut-down work
- 9 Setting up / refitting
- Attaching padfoot shells, scrapers and access steps
- Removing padfoot shells, scrapers, segments and access steps
- 10 Troubleshooting
- Jump starting and fuse assignment
- Fault-code display
- Engine faults and auxiliary-heating fault indicators
- 11 Disposal
- Final shut-down of the machine
- 12 List of special tools
Across these chapters, the document combines operating guidance with maintenance specifications and illustrated procedures. It also covers transport preparation and crane lifting, emergency towing, padfoot shell installation and removal, scraper adjustment, fault-code retrieval and engine troubleshooting, making it useful both during daily operation and scheduled service work.
Operate and Maintain the BW 213 D-5 with the Correct Procedures
The 2020 BOMAG BW 213 D-5 Single Drum Roller Operating and Maintenance Manual supports routine inspections, correct machine operation, vibration and compaction work, scheduled servicing, fluid changes, component checks, troubleshooting and selected setup or refitting jobs using the procedures and specifications provided for this machine. Having the correct BW 213 D-5 maintenance information on hand is particularly valuable when checking service intervals, capacities, operating limits, tightening values and the sequence of illustrated maintenance procedures.
Delivered as an instant PDF download with no physical shipping required. Open the manual on a computer, tablet or phone, keep it available in the workshop or at the job site, and print the pages you need for individual maintenance or operating tasks.
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