Operating instructions Maintenance instructions€¦ · 8 BOMAG BW 145 D-3/DH-3/PDH-3 Fig. 4...

Operating instructions

Maintenance instructions

Catalogue number008 157 08 01/2004

BW 145 D-3 / DH-3 / PDH-3S/N 101 581 21.... 901 581 47 ....S/N 101 581 22.... 901 581 48 ....S/N 101 581 23 .... 901 581 49 ....

Single drum roller

Foreword

BOMAG 3BW 145 D-3/DH-3/PDH-3

F orewordBOMAG machines are products from the widerange of BOMAG compaction equipment.

BOMAG's vast experience, together with themost up-to-date production and testing meth-ods, including service life tests of all importantcomponents and highest quality demands,guarantee maximum reliability of your ma-chine.

These instructions comprise:

l Safety regulations

l Operating instructions

l Maintenance instructions

l Trouble shooting

Using these instructions will

l help you to get to know the machine.

l avoid malfunctions caused by unexpert opera-tion.

Compliance with the maintenance instructions will

l increase the reliability of your machine on thesite,

l increase the service life of the machine,

l reduce repair costs and downtimes.

BOMAG shall not assume liability for safe func-tioning of the machine

l if it is handled in a way which does not complywith the usual modes of use,

l if it is used for purposes other than those men-tioned in the instructions.

No warranty claims can be lodged for damage re-sulting from

l operating errors,

l insufficient maintenance and

l wrong fuels and lubricants.

Please note!

This manual has been written for the operator andthe service personnel at the site.

Keep this manual always close at hand , e.g. in thetool compartment of the machine or in the contain-er provided.

You should only operate the machine if you are ful-ly familiar with the contents of these instructions.

You must also observe all applicable safety regu-lations.

Please observe also the guidelines of the Civil En-gineering Liability Association "Safety Regulationsfor the Operation of Road Rollers and Soil Com-pactors" and the applicable accident prevention in-structions.

For your own safety you should only useBOMAG-spare parts.

We reserve the right for technical modifica-tions without prior notification.

These operating and maintenance instructions arealso available in other languages.

A spare part catalogue can be obtained from yourBOMAG dealer when giving him the serial numberof your machine.

Information about the correct use of our machinesin earth work and for asphalt applications can beobtained from your BOMAG dealer.

The above points do not constitute an extension ofthe warranty and liability conditions specified in thegeneral terms of business of BOMAG.

We wish you much success with your BOMAGmachines.

BOMAG GmbH & Co. OHG

Printed in Germany

Copyright by BOMAG

Foreword

BOMAG4 BW 145 D-3/DH-3/PDH-3

Please fill in

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine type (Fig. 1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial-number (Fig. 1 and 2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine type (Fig. 3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine number (Fig. 3)

i NoteSupplement the above data together with the com-missioning protocol.

During commissioning our organisation will in-struct you in the operation and maintenance of themachine.

Please observe strictly the safety regulations andall notes on risks and dangers!

Fig. 1

Fig. 2

Fig. 3

Table of Contents


Technical Data 7

Safety regulations 11

Indicators and Controls 19

3.1 General notes 22

Operation 29


4.2 Tests before taking into operation 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 seat 38

4.11 Operating the hood 39

4.12 Towing in case of an engine failure 39

4.13 Transport 41

Maintenance 43

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 the fuel filter water separator 52

5.8 Checking the fuel level 53

5.9 Checking the hydraulic oil level 54

5.10 Checking the tire pressure 55

5.11 Cleaning the cooling fins on the radiator 55

5.12 Cleaning the cooling fins on the hydraulic oil cooler 56

5.13 Check the oil level in the drive axle 57

5.14 Checking the oil level in left/right wheel hubs 58

5.15 Checking the oil level in the vibration bearings 58

5.16 Servicing the battery 59

5.17 Draining the sludge from the fuel tank 60

5.18 Change engine oil and oil filter cartridge 60

5.19 Checking the V-belt tension, tightening 62

5.20 Checking, adjusting the valve clearance 63

5.21 Changing the oil in the vibration bearings 64

5.22 Change the oil in the drive axle 65

Table of Contents


5.23 Change the oil in the wheel hubs 66

5.24 Changing the fuel pre-filter 67

5.25 Changing the fuel filter cartridge 68

5.26 Checking the fastenings on the diesel engine 68

5.27 Tightening the fastening of the axle on the frame 69

5.28 Tightening the wheel nuts 69

5.29 Checking the ROPS 70

5.30 Changing hydraulic oil and breather filter 71

5.31 Changing the hydraulic oil filter 72

5.32 Checking the injection valves 74

5.33 Replacing the toothed belt 75

5.34 Checking, cleaning, changing the combustion air filter 76

5.35 Adjusting the parking brake 79

5.36 Changing the tires 80

5.37 Adjusting the scrapers 81

5.38 Changing the fresh air filter in the cabin 82

5.39 Tightening torques 82

5.40 Engine conservation 83

Trouble shooting 85


6.2 Engine 87


1 Technical Data

Technical Data


Fig. 4

Dimensions inmm

A B D H H2 K L O1 O2 S W

BW 145 D-3 2222 1546 1058 1900 2750 313 4194 60 60 22 1426

BW 145 DH-3 2222 1546 1058 1900 2750 313 4194 60 60 22 1426

BW 145 PDH-3 2222 1546 1044 1900 2750 313 4194 60 60 15 1426

* BW 145 D-3 BW 145 DH-3 BW 145 PDH-3

WeightsOperating weight (CECE)with ROPS-cabin

kg 4990 5050 5330

Front axle load (CECE) kg 2620 2680 2960Rear axle load (CECE) kg 2370 2370 2370Static linear load kg/cm 18,4 18,8 -

Travel characteristicsTravel speed (1) km/h 0 ... 6 0 ... 5 0 ... 5Travel speed (2) km/h 0 ... 10 0 ... 10 0 ... 10Max. gradability with vi-bration

% 47 55 55

Technical Data


DriveEngine manufacturer Deutz Deutz DeutzType BF4L 2011 BF4L 2011 BF4L 2011Cooling Air/oil Air/oil Air/oilNumber of cylinders 4 4 4Rated power ISO 3046 kW 56 56 56Rated speed rpm 2650 2650 2650Fuel Diesel Diesel DieselElectrical equipment V 12 12 12Drive system hydrostatic hydrostatic hydrostaticDriven axles 2 2 2

BrakesService brake hydrostatic hydrostatic hydrostaticParking brake hydr.-mech. hydr.-mech. hydr.-mech.

SteeringType of steering articulated articulated articulatedSteering operation hydrostatic hydrostatic hydrostatic

VibrationDrive system hydrostatic hydrostatic hydrostaticFrequency Hz 34 34 34Amplitude mm 1,7/0,85 1,7/0,85 1,4/0,7

TiresTire size 335/80R20MPT81 335/80R20MPT81 340/80R18IT530Air pressure bar 1,8 1,8 1,8

Tank contentsHydraulic oil Litres 44 44 44Fuel Litres 110 110 110Engine oil Litres 10,5 10,5 10,5* The right for technical modifications remains reserved

* BW 145 D-3 BW 145 DH-3 BW 145 PDH-3

Technical Data


The following noise and vibration values according to the EC-directive for machines, edition (91/368/EEC) were measured at nominal engine speed and with the vibration switched on. The machine wasstanding on an elastic base.

During operation these values may vary because of the existing operating conditions.

Noise valueThe sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is

sound pressure level at the work place of the operator (with cabin):

LpA = 78,4 dB(A)

sound capacity level:

LwA = 101,8 dB(A)

These sound values were determined according to ISO 3744 for the sound capacity level (LwA) and ISO 6081for sound pressure level (LpA) at the place of the operator.

Vibration valueThe vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are:

Vibration of the entire boy (driver’s seat)

The weighted effective acceleration value determined according to ISO 2631 part 1, is ≤0,5 m/sec2.

Hand-arm vibration values

The weighted effective acceleration value determined according to ISO 8662 part 1, is ≤2,5 m/sec2.


2 Safety regulations

Safety regulations


General

This BOMAG machine is built in accordancewith the latest technical standard and the validtechnical rules and regulations. There is, how-ever, a risk of danger for persons and propertyif:

l the machine is used for purposes other thanthose it is intended for

l the machine is operated by untrained person-nel

l the machine is modified or converted in an un-professional way

l the applicable safety regulations are not ob-served.

Each person involved in operation, mainte-nance and repair of the machine must there-fore read and apply these safety regulations.This should be confirmed by obtaining the sig-natures of the customer, if necessary.

Furthermore the following regulations and instruc-tions are obviously also valid:

l applicable accident prevention instructions

l generally acknowledged safety and road trafficregulations

l country specific safety regulations. It is theduty of the operator to know and observethese regulations. This applies also for localregulations and the regulations for varioustypes of manual work. If the recommendationsin this manual differ from the regulations validin your country, you must strictly observe theregulations in your country.

Intended useThis machine must only be used for:

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

l medium and heavy compaction tasks in earthwork (road sub-bases)

l This machine must only be operated with fullyfunctional safety equipment.

l The machine should be checked by an expertonce every year.

Unintended useDangers may, however, arise from the machine ifit is used by untrained personnel in an unprofes-sional way or if it is used for purposes other thanthose mentioned in these instructions.

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

Starting and operation of the machine in an explo-sive environment is prohibited.

Who is allowed to work with the ma-chine?The machine must only be operated by trainedand authorized persons which are at least 18years of age. The responsibilities for the operationof the machine must be clearly specified and com-plied with.

Persons under the influence of alcohol, medica-tion or drugs must not operate, service or repairthe machine.

Maintenance and repair tasks require specificknowledge and must therefore only be carried outby trained and qualified personnel.

Conversions and alterations to the ma-chineUnauthorized conversions to the machine are pro-hibited for safety reasons.

Original parts and accessories have been special-ly designed for this machine. We wish to make ex-pressly clear that we have not tested or authorizedany original parts or special equipment not sup-plied by us. The installation and/or use of suchproducts can impair the active and/or passive driv-ing safety. The manufacturer expressly excludesany liability for damage resulting from the use ofnon-original parts or accessories.

Safety notes in the operating and main-tenance instructions:

! Danger

Sections marked like this point out possibledangers for persons.

Safety regulations


! Caution

Sections marked like this point out possibledangers for the machine or for parts of the ma-chine.

i NoteSections marked like this provide technical infor-mation concerning the optimal economical use ofthe machine.

Environment

Sections marked like this highlight activitiesfor the safe and environmental disposal of fu-els and lubricants as well as replaced parts.

Observe all environment protection regula-tions.

Information and safety stickers/decalson the machineKeep stickers/decals complete (see spare partscatalogue) and fully legible and observe theirmeaning.

Replace damaged or illegible stickers/decals im-mediately.

Loading the machineUse only strong and stable loading ramps. Theramp inclination must be lower than the gradabilityof the machine.

Secure the machine against turning over or slip-ping off.

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

Persons are highly endangered if

l they step or stand under loads being lifted

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

The machine must not swing about when lifted offthe ground.

Use only safe lifting gear of sufficient load bearingcapacity.

Attach the lifting gear only to the specified liftingpoints.

Towing the machineSince the machine is not fitted with a towing hitch,the machine cannot be towed with a tow bar.

If the machine has to be towed urgently out of thedanger zone because of other risks, this must onlybe done on level ground or uphill using chains andropes. For this purpose towing ropes of sufficienttensile strength must be fastened on the liftingeyes.

After releasing the brake the machine can only bebraked by the towing vehicle.

Before releasing the brake block the machine withchocks to prevent unintended rolling.

Checking the roll-over protectionstructure (ROPS)The machine frame must not be distorted, bent orcracked in the area of the ROPS structure.

The ROPS structure must not show any rust, dam-age, hairline cracks or open fractures.

The ROPS must not rattle about when driving themachine. This would mean that the fasteningscrews are insufficiently fastened. All screwedconnections must be tight and in accordance withthe specifications (observe the tightening tor-ques). Screws and nuts must not be damaged,distorted or deformed.

No additional parts must be welded or bolted onand no holes must be drilled without the permis-sion of the dealer, since this may impair thestrength of the structure.

Starting the machine

Before starting

Operation of the machine is only permitted whensitting in the operator's seat.

Use only machines which have been properlyserviced at regular intervals.

Become acquainted with the equipment, the con-trol elements, the working mode of the machineand the area you will be working in.

Use your personal protective outfit (hard hat, safe-ty boots etc.).

Check before mounting the machine if:

l there are persons or obstructions beside orunder the machine

Safety regulations


l the machine is free of any oily and combustiblematerial

l all handrails, steps and platforms are free ofgrease, oils, fuels, dirt, snow and ice

l the engine compartment hood is closed andlocked

To climb onto the machine use steps and hand-rails.

Check before starting, whether:

l the machine shows any obvious defects

l all protective devices are properly secured intheir place

l steering, brakes, control elements, lightingand warning horn are in order

l the seat is correctly adjusted

l the mirrors (if available) are clean and correct-ly adjusted.

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

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

On machines with ROPS you should always wearyour seat belt!

Starting

Start and operate the machine only from the oper-ator's seat

For starting set all control levers to "neutral posi-tion".

Do not use any starting aids such as Start Pilot orether.

After starting check all gauges.

Starting with jump leads

Connect plus with plus and minus with minus(ground cable) - always connect the ground cablelast and disconnect it first! Wrong connectionsmay cause severe damage in the electric system.

Never start the engine by bridging the electricalconnections on the starter, because the machinewould probably start to move immediately.

Starting in closed rooms

Exhaust gases are toxic! Always ensure an ade-quate supply of fresh air when starting in closedrooms!

Driving the machine

Persons in the danger area

If the machine should turn over and the cabin dooris closed, the right hand side cabin window can beused as an emergency exit.

Check if there are persons or obstacles in the dan-ger area before starting or resuming work, espe-cially when driving in reverse.

If necessary give warning signals. Stop work im-mediately, if persons remain in the danger areadespite the warning.

Do not stand in the machine's articulation areawhile the engine is running. Danger of injury!

Driving

In emergency situations and in case of danger op-erate the emergency stop switch immediately. Donot use the emergency stop switch as servicebrake.

Resume operation only after eliminating the dan-ger that has led to the actuation of the emergencystop.

If the machine comes in contact with high voltagepower lines:

l do not leave the operator's stand

l warn others from coming close to the machineor touching it

l if possible move the machine out of the dangerzone

l have the power shut off

Operate the machine only from the operator'sstand.

Keep the cabin doors closed.

Do not adjust the operator's seat while driving.

Do not climb onto or off the machine while it is driv-ing.

Choose the travel direction only when the machineis standing.

Do not use the machine to transport persons.

If you recognize unusual noises and the develop-ment of smoke, detect the cause and have thefault corrected.

Always keep a safe distance to excavations andembankments and avoid all activities which couldimpair the stability of the machine.

Safety regulations


Do not work with vibration on hard concrete, curedasphalt or hard frozen ground.

When driving under flyovers, bridges, tunnels,power lines etc. ensure sufficient distance.

Driving on gradients and slopes

Do not drive on gradients which exceed the maxi-mum gradability of the machine.

Always drive extremely carefully on slopes and al-ways directly up or down the slope, never diago-nally. Change to the lower speed range beforeapproaching the inclination.

Wet and loose soils reduce the ground adhesion ofthe machine on gradients and slopes considera-bly. Higher risk of accidents!

Behaviour in traffic

Match your speed to the working conditions.

Always give way to loaded vehicles.

Switch the lights on if the visibility is poor.

Keep away from edges and embankments.

Check the effect of vibration

When compacting with vibration check the effecton nearby buildings and underground supply lines(gas, water, sewage, power lines) and stop vibra-tory compaction if necessary.

Never use the vibration on hard (frozen, concrete)ground. Risk of bearing damage!

Parking the machinePark the machine on level and firm ground.

Before leaving the machine:

l move the travel control lever to neutral position

l apply the parking brake

l shut the engine down and pull the ignition keyout

l lock the cabin door

l secure the cabin against unauthorized use.

Do not jump off the machine, but use access stepsand hand rails.

Mark parked machines, which could be an ob-struction, by attaching clearly visible signs.

Parking on gradients or slopes

Secure the machine against rolling away, placemetal chocks in front of and behind the drums.

Filling the fuel tankDo not inhale fuel fumes.

Refuel only after shutting the engine and the aux-iliary heater down.

Do not refuel in closed rooms.

No open fire, do not smoke.

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

Wipe off spilled fuel. Keep fuel free of dirt and wa-ter.

Leaking fuel tanks can cause explosions. Ensuretight fit of the fuel tank filling cover, replace it if nec-essary.

Fire protection measures

Make yourself acquainted with the location and theoperation of fire extinguishers. Observe fire warn-ing and fire fighting installations.

Maintenance workStrictly apply the specified maintenance tasks, in-cluding the changing of parts.

Maintenance work must only be carried out byskilled and authorized personnel.

In case of maintenance and assembly work over-head make sure to use the prescribed or othersafe access steps, ladders and gangways. Do notuse parts of the machine as access steps.

Keep unauthorized persons away from the ma-chine.

Do not perform maintenance work while the ma-chine is driving or the engine is running.

Park the machine on ground as level and firm aspossible.

Pull the ignition key out.

Secure the articulated joint with the articulationlock.

Working on hydraulic lines

Depressurize hydraulic lines before working onthem. Hydraulic oil escaping under pressure canpenetrate the skin and cause severe injury. Con-sult a doctor if you are injured by pressurized hy-draulic oil as otherwise serious infections mayresult.

When adjusting the hydraulic system do not standbehind the drums/wheels.

Safety regulations


Do not change the setting of high pressure reliefvalves.

Drain the hydraulic oil at operating temperature -danger of scalding!

Catch running out hydraulic oil and dispose of en-vironmentally.

Always collect and dispose of biodegradable hy-draulic oils separately.

Do not start the engine after draining the hydraulicoil.

Check all connections and fittings for leakagesonce all work is completed (with the lines still de-pressurized!).

Changing of hydraulic hoses

Hydraulic hoses must be examined visually at reg-ular intervals.

Hydraulic hoses must be changed immediately incase of:

l damage to the outer surface down to the lining(e.g. chafings, cuts, cracks)

l embrittlement of the outer surface (develop-ment of cracks in the hose material)

l deformation under pressurized and depressu-rized conditions, which are not in accordancewith the natural shape of the hydraulic hose

l deformation in bends such as squeezed spots,extreme bends, layer separation, formation ofblisters

l leakages

l non-observance of installation requirements.

l separation of the hydraulic hose from thecrimped fitting

l corrosion of the crimped fitting, which impairsthe function and the strength

l do not mix up hoses by mistake

l damage or deformation of the fitting which ef-fects the function and the strength or impairsthe hose/hose connection.

Only the use of genuine BOMAG hoses ensuresthat the correct type of hose (pressure range) isused at the right place.

Working on the engine

Shut the engine down before opening the enginecompartment hood.

Drain the hydraulic oil at operating temperature -danger of scalding!

Wipe off spilled oil, catch running out oil and dis-pose of environmentally.

Store used filters and other oily materials in a spe-cially marked refuse container and dispose of en-vironmentally.

Do not leave any tools or other parts, which couldlead to damage, in the engine compartment.

Working in the electric system

Disconnect the battery and cover it with insulatingmaterial before starting to work in the electric sys-tem.

Do not use fuses with higher Ampere ratings anddo not repair fuses with a piece of wire. Fire haz-ard!

Always disconnect the battery before starting toweld on the machine.

Working on the battery

When working on the battery do not smoke, do notuse open fire.

Do not let hands or clothes come in contact withacid. Treat acid injuries with clear water and con-sult a doctor.

Metal objects (e.g. tools, rings, wrist watches)must not touch the battery poles - danger of shortcircuits and fire!

When recharging maintenance free batteries re-move all plugs to avoid the accumulation of highlyexplosive gases.

Observe all relevant instructions when startingwith an auxiliary battery.

Dispose of used batteries environmentally.

Shut the charging current down before discon-necting charging clamps.

Ensure an adequate supply of fresh air, especiallyif the battery is to be charged in a closed room.

Working on the fuel system

Do not inhale fuel fumes.

No open fire, do not smoke, do not spill any fuel.

Catch running out fuel, do not let it seep into theground and dispose of environmentally.

Safety regulations


Working on wheels and tires

Explosion-like bursting of tires and parts of tiresand rims can cause most severe or even fatal inju-ries.

The assembly of tires must only be carried out byexperienced personnel and with the correct equip-ment. If necessary have the tires assembled in aqualified workshop.

Always ensure correct tire pressure and do not ex-ceed the max. permissible pressure.

Examine the tires every day for too low pressure,cuts, bulges, faulty rims, missing wheel studs ornuts. Do not drive with faulty tires or wheels.

Non-stick emulsion must only be mixed of waterand non-stick additives according to the instruc-tions of the non-stick agent manufacturer. Strictlyobserve the regulations for the protection of theenvironment.

Cleaning

Do not clean the machine while the engine is run-ning.

Do not use gasoline or other easily inflammablesubstances for cleaning purposes.

When using high pressure cleaning equipment donot subject electrical parts and insulating materialsto the direct water jet or cover them beforehand.

l Do not guide the water jet into the exhaust orinto the air filter.

After maintenance work

Reinstall all protections and guards once all main-tenance work is completed.

RepairAttach a warning tag to the steering wheel if themachine is defective.

Repairs must only be performed by qualified per-sons who have been instructed for this purpose.Use our repair instructions.

Exhaust gases are highly dangerous! Always en-sure an adequate supply of fresh air when startingin closed rooms!

Test

Depending on the type of application and the op-erating conditions vibratory equipment has to beexamined by a specialist whenever required, butat least once every year.

Safety regulations



3 Indicators and Controls

Indicators and Controls


Fig. 5



1 Multi-function display

2 Rotary switch for flashing beacon*

3 Rotary switch for lighting (StVZO)*

4 Rotary switch for hazard light system*

5 Rotary switch for direction indicators left/right*

6 Rotary switch for working head lights*

7 Rotary switch vibration high/low frequency

8 Rotary switch for speed range selection

9 Push button for warning horn

10 Emergency stop push button

11 Ignition switch (at the side)

12 Push button for vibration

13 Travel lever

14 Throttle lever

15 Locking plate for throttle lever* Optional equipment



3.1 General notes

Please read this section thoroughly before operat-ing this machine if you are not yet conversant withthe indicators and control elements. All functionsare described in detail hereunder.

Paragraph 4 Operation contains only concise de-scriptions of the individual operating steps.

Fig. 6

No. 1 = Multi-function display

i NoteAfter switching the ignition on all lamps light up forapprox. 3 seconds as a self-test.

The control and warning lamps light up whilethe engine is running:

a = Hazard light switched on

b = Direction indicator switched on

c = Engine oil temperature too high,warning buzzer sounds. Clean en-gine and radiator

d = Engine oil pressure too low, warningbuzzer sounds. Check the engine oillevel, if necessary have the enginerepaired.

e = Air filter cartridge soiled. Clean,change the cartridge.

f = The battery is not being charged,check the V-belt, if necessary repairthe generator.

= Light with ignition on and engine off.

g = Hydraulic oil filter soiled, the warningbuzzer sounds. Replace the filter ele-

ment, check the hydraulic system if itcomes on too early.

h = not used

i = Brake closed or travel lever in secondnotched position

j = Fuel level gauge

k = Operating hour meter

Fig. 7

No. 2 = Rotary switch for flashing beacon

Position "left" = Flashing beacon switched off

Position "right" = Flashing beacon switched on

Fig. 8

No. 3 = Rotary switch, lighting (StVZO) *

Position "left" = light off

Position "mid-dle" = fender lights on, with the igni-

tion switch in position "I" or "P"

Position "right" = travel lights on, with ignitionswitch in position "I".

* Option



Fig. 9

No. 4 = Rotary switch for hazard light sys-tem*

Position "left" = hazard light switched off, thecontrol lights go out.

Position "right" = hazard light switched on, con-trol light 7 on fault monitoringboard lights up.

Fig. 10

No. 5 = Rotary switch for direction indicatorsleft / right**

Position "mid-dle" = direction indicator off

Position "left orright" = front and rear direction indica-

tors on the respective side lightup, the control light 6 in thefault monitoring board flashes

Fig. 11

No. 6 = Rotary switch working lights ***

Position "left" = light off

Position "right" = working lights on, with ignitionswitch in position "I".

Fig. 12

No. 7 = Rotary switch, vibration

Position "mid-dle" = vibration off

Position "left" = low amplitude, high frequency

Position "right" = high amplitude, low frequency

* Option** Option *** Option



Fig. 13

No. 8 = Rotary switch for speed range selec-tion

Position "turtle" = Working speed

Position "rab-bit" = Transport speed

Fig. 14

No. 9 = Push button for warning horn

Fig. 15

No. 10 = Emergency stop switch

The engine will be shut down and the brake willclose.

! Danger

Danger of accident!

Operate only in emergency situations duringoperation, do not use as a service brake.

The machine should only be started again afterthe danger, that caused the actuation of theemergency stop switch, has been removed.

operate = push the button completelydown, it will automatically lockin end position.

unlock = turn the button clockwise andrelease it.

to drive = move the travel lever first tobraking position, then start theengine and choose the traveldirection.

For safety reasons the travel system of the ma-chine will only be enabled after the travel lever hasbeen shifted back to braking position.

Fig. 16

No. 11 = Ignition switch

Position "P"/"0" = Ignition off, key can be pulledout, engine off

Position "I" = Ignition on, all control andwarning lights in the multi-function display light up for amoment

i NoteThe engine can only be started if both travel leversare in “neutral”.



The ignition switch is designed with a lock to pre-vent repetitive starting. For a new starting attemptthe ignition key must first be turned back to posi-tion "0".

Position "II" = turn further against springpressure, he engine starts,turn the ignition key back toposition once the engine hasstarted

! Caution

Run the engine warm for a short while beforestarting work. Do not allow the engine to runlonger than 10 minutes with idle speed.

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

Fig. 17

No. 12 = Push button for vibration

l Select or actuate the frequencies with the vi-bration selector switch.

l Switch the vibration on or off by pressing thepush button.

Fig. 18

No. 13 = Travel lever

Position "mid-dle" = Braking position service brake

Position "middle,right" = Parking brake, to start the en-

gine

Position "I" = Forward travel

Position "II" = Backwards travel

i NoteIf the engine speed drops under load when drivingon steep gradients, take the travel lever slightlyback towards neutral. This relieves the hydraulicsystem and the diesel engine.

Fig. 19

No. 14 = Throttle lever

Position "I" = Idle speed position

Position "II" = Full load position, operatingposition for driving and vibra-tion



! Caution

Always drive and vibrate with max. enginespeed! Control the travel speed only with thetravel lever!

No. 15 = Locking plate for throttle lever

pull = The throttle lever can bemoved to position "II"

release = The throttle lever locks in posi-tion "II".

Fig. 20

No. 16 = Fuses in electric installation box

F03, 15A = Vibration

F05, 25A = Socket

F13, 30A = Starting

F19, 15A = Working head lights*

F22, 15A = Working head lights, rear*

F24, 15A = Monitoring, gauges

F25, 15A = Solenoid valve brake/travel

! Danger

Fire hazard!

Do not use fuses with higher ampere ratingsand do not bridge fuses.

Fig. 21

No. 17 = Main fuse for battery

125A = (F00)

i NoteThe main fuse is located in the battery box underthe driver’s seat

Fig. 22

No. 18 = Pedal for dozer blade*

Position "0" = Stop position. Dozer blade atrest

Position "I" = Dozer blade up

Position "II" = Dozer blade down

Position "II" = Float position to level loosesoil when driving in reverse

! Danger

Danger of squashing!

Do not work under the lifted, unsupported doz-er blade, support the blade if necessary.

* Optional equipment



Fig. 23

No. 19 = Fuse box, cabin*

(1) - = not used

(2) 7,5A = Inside light

(3) 7,5A = Windscreen wiper/washer,rear

(4) 7,5A = Windscreen wiper/washer,front

(5) 7,5A = Flashing beacon

(6) 7,5A = Heating blower, radio

! Danger

Fire hazard!

Do not use fuses with higher ampere ratingsand do not bridge fuses.

No. 20 = Toggle switch, heating blower

No. 21 = Toggle switch, flashing beacon**

No. 22 = Toggle switch, windscreen wiper/washer, front***

No. 23 = Toggle switch, windscreen wiper/washer, rear****

No. 24 = Cabin light

switch on = turn lamp glass clockwise

switch off = turn lamp glass counter-clock-wise

No. 25 = 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. 24

No. 26 = Shut-off valve for cabin heater*****

i NoteThe heat exchanger of the cabin heater receivesthe heat energy from the lubrication oil in the en-gine.

Position "I" = Cabin heater switched off

Position "II" = Cabin heater full power

* Optional equipment** Option*** Option**** Option *****Optional equipment


4 Operation

Operation


4.1 General notes

Please read section 3 Indicators and Control Ele-ments thoroughly before operating the machine ifyou are not yet fully familiar with the indicators andcontrol elements of the machine.

All indicators and control elements are describedin detail in this chapter.

4.2 Tests before taking into op-eration

The following inspections must be carried out be-fore each working day or before a longer workingperiod.

! Danger

Danger of accident!

Please observe strictly the safety regulationsin chapter 2 of this instruction manual!

l Park the machine on ground as level as possi-ble.

Check:

l fuel tank and fuel lines for leaks

l screw joints for tight fit

l function of steering

l machine for cleanliness, damage

l presence of the appropriate operating andmaintenance instructions

l check whether the machine has been properlyserviced.

i NoteFor a description of the following tasks refer to thechapter "maintenance every 10 operating hours".

l Engine oil level

i NoteIn hydraulic systems filled with Panolin HLP Synth.46 always use the same oil to top up. With otherester based oils consult the lubrication oil serviceof the respective oil manufacturer.

l Check the hydraulic oil level, top up if neces-sary.

! Danger

Fire hazard!

Do not refuel in closed rooms.

l Check the fuel level, top up if necessary.

l Check water separator in fuel system, drain ifnecessary.

Operation


l Check the scrapers, adjust if necessary

l Check the air pressure in the tires For valuesrefer to the technical data.

! Caution

Ensure equal pressure in both tires.

4.3 Starting the engine

! Danger

Danger of accident!

Always wear your seat belt.

Fig. 25

l Fasten your seat belt (Fig. 25).

Fig. 26

l Check, whether the travel lever (Fig. 26) is en-gaged in brake position.

Operation


Fig. 27

l Turn the rotary vibration selector switch (Fig.27) to position "0", vibration off.

Fig. 28

l Check, whether the emergency stop switch(Fig. 28) is unlocked.

Fig. 29

l Set the throttle lever (Fig. 29) to position "II",full speed.

Fig. 30

l Turn the ignition key (Fig. 30) to position "I".

Fig. 31

All control and warning lights (Fig. 31) in the multi-function display light up for a few seconds as a selftest.

Charge control light (f), engine oil pressure warn-ing light (d) and brake warning light (i) stay on.

! Caution

Perform the starting process for maximum 20seconds without interruption and pause for aminute between starting attempts.

If the engine has not started after two attemptsperform trouble shooting.

Operation


Fig. 32

l Turn the ignition key to position "II", the startercranks the engine.

l As soon as the engine ignites return the igni-tion key to position "I".

Charge control light (f) and engine oil pressurewarning light (d) go out.

Fig. 33

l Once the engine runs correctly reduce the en-gine speed (Fig. 33) to position “I”, idle speed.

! Caution

Run the engine warm for a short while, but donot run with idle speed for more than 10 min-utes.

4.4 Starting with jump leads

! Caution

Wrong connection will cause severe damageto the electrical system.

Fig. 34

l When starting with an external battery connectboth plus poles (Fig. 34) first and both minuspoles (earth cable) after.

l Perform the work steps described in the previ-ous paragrapf.

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

Operation


4.5 Driving the machine

! Danger

Danger of accident!

Wet and loose soils considerably reduce theground adhesion of the machine on inclina-tions and slopes.

Soil conditions and weather influences impairthe gradability of the machine.

Do not drive up and down inclinations exceed-ing the maximum gradability of the machine(see technical data).

Do not drive without wearing your seat belt.

Always give way to loaded transport vehicles!

Before starting to drive make sure that thedrive range is absolutely safe.

! Caution

Select the travel speed range only when themachine is standing.

Fig. 35

l Select the desired travel speed range (Fig.35).

Fig. 36

l Shift the throttle lever to position "II" (Fig. 36)full load and lock it.

Fig. 37

l Push the travel lever (Fig. 37) to the left out ofbraking position and move it slowly to the de-sired travel direction.

The brake warning light (i) goes out.

i NoteShift the travel lever out of "0"-position slowly toforward or reverse, the machine will drive forwardor reverse at a speed which corresponds with thedisplacement of the travel lever.

Returning the travel lever towards neutral willbrake the machine and in "0"-position of the travellever the machine will stop.

! Danger

Danger of accident!

On inclinations and slopes pull the travel leverto the right and lock it in braking position.

Operation


Important notes on travel operation

! Caution

When changing the travel direction hold thetravel lever for a moment in "0"-position, untilthe machine has stopped, before actuating tothe new travel direction.

Do not operate jerkily!

Do not use the throttle lever to control the trav-el speed! Control the travel speed with thetravel lever. During operation the throttle levermust remain in full load position.

When driving up and down inclinations movethe travel lever slowly back towards neutral tobrake the machine.

If the engine speed drops when driving up ex-treme inclinations move the ravel lever slightlyback, if necessary change to the lower speedrange.

Always use the lowest speed range (turtle) todrive up and down inclinations.

4.6 Emergency exit

If the machine should turn over and the cabin dooris closed, the right hand side cabin window can beused as an emergency exit.

Operation


4.7 Operating the parkingbrake, stopping the ma-chine

Fig. 38

l Return the travel lever (Fig. 38) slowly to "neu-tral"-position and engage it to the right parkingbrake position.

The hydrostatic drive brakes the machine auto-matically, the parking brake closes after approx. 2seconds.

i NoteThe parking brake also closes automatically whenshutting the engine down.

4.8 Shutting the engine down

! Caution

Straighten the articulated joint to provide easi-er access to the machine.

Fig. 39

l Return the travel lever (Fig. 39) slowly to "neu-tral"-position and engage it to the right in brak-ing position.

Fig. 40

l Pull the locking plate (Fig. 40) up and set thethrottle lever to position "I" (idle speed).

i NoteDo not shut the engine down all of the sudden fromfull speed, but let it idle for a while for temperatureequalization.

Operation


Fig. 41

l Turn the ignition key (Fig. 41) to position "0" or"P" and pull the ignition key out.

i NoteAfter shutting the engine down with the throttle le-ver the ”central warning light” lights and the warn-ing buzzer sounds, until the ignition switch isturned to position ”0”. The parking brake closesautomatically when shutting the engine down.

! Danger

Danger of accident!

On particularly steep inclinations place wheelchocks in front of or behind drum and wheels.

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

4.9 Switching the vibration onand off

! Danger

Risk of damage!

When compacting with vibration you mustcheck the effect of nearby buildings and un-derground supply lines (gas, water, sewage,electric power), if necessary stop compactionwith vibration.

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

! Caution

When using the machine on asphalt

Vibration at standstill causes transversemarks, therefore:

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

l Switch the vibration off before stopping themachine.

Preselecting the vibration

Fig. 42

l Preselect amplitude/frequency with the rotaryswitch (Fig. 42).

Operation


Switching the vibration on

Fig. 43

l Set the throttle lever (Fig. 43) to position "II",full speed.

! Caution

Switch the vibration on only at max. enginespeed.

Fig. 44

l Press the push button (Fig. 44) in the travel le-ver while driving, the drum will vibrate.

Switching the vibration offl Press the push button again and after work

switch the rotary vibration switch to position"0".

4.10 Adjusting the seat

! Danger

Danger of accident!

Do not adjust the driver’s seat while driving.

Fig. 45

l To adjust the seat in longitudinal direction dis-engage lever 1 (Fig. 45) and push the seat for-ward or back.

l To adjust the inclination of the backrest oper-ate lever (2) and tilt the backrest forward orback.

l To adjust the weight adjust lever (3) accord-ingly.

i NoteIn its adjustment the lever (3) is locked in upwardsdirection. This lock can be released by pressingthe lever completely down against the stop. Thenadjust to the weight of the operator by sliding thelever down.

Operation


4.11 Operating the hood

! Danger

Danger of accident!

If the hood needs to be opened further formaintenance or repair work, support it safely.

Fig. 46

l Unlock the lock 1 (Fig. 46).

l To unlock the hood press the latch (2) downand pull the handle (3) back.

Fig. 47

l Pull the support (Fig. 47) out of the bracket inthe hood and hook it at the bottom into theframe or at the top into the traverse.

4.12 Towing in case of an enginefailure

! Danger

Life hazard!

Since the machine is not fitted with a towinghitch, the machine cannot be towed with a towbar.

If the machine has to be towed urgently out ofthe danger zone because of other risks, thismust only be done on level ground or uphill us-ing chains and ropes.

For this purpose towing ropes of sufficient ten-sile strength must be fastened on the liftingeyes.

After releasing the brake the machine can onlybe braked by the towing vehicle.

Before releasing the brake block the machinewith chocks to prevent unintended rolling.

! Caution

The max. towing speed must not exceed 2 km/h (development of heat in the drive section ofthe hydraulic motor).

The towing distance must not exceed 1 km, be-cause the hydraulic circuit would run dry with-out the charge circuit in function.

l Secure the machine with wheel chocksagainst unintentional rolling.

l Attach the towing ropes safely to the front orrear lifting eyes.

Operation


Fig. 48

l Slacken the counter nuts on both high pres-sure relief valves (Fig. 48) to create a by-passaround the travel pump.

l Turn the threaded spindle in until it is flush withthe nut.

l Retighten the counter nut.

Fig. 49

l To release the brake turn counter nuts 1 (Fig.49) approx. 8 mm back.

l Turn the brake releasing screws (2) complete-ly in against the stop.

l Repeat this measure on the opposite side.

Fig. 50

l Remove plug 1 (Fig. 50).

l Place an U-section (5) across the brake hous-ing (2) and turn the screw (4) into the tappedbore (3), until it bottoms.

l Turn the nut (6) down and tighten it approx.one revolution. The drum must rotate freely.

After towing

! Caution

Before loosening ropes or chains block themachine with chocks to prevent unintendedrolling.

l Turn the threaded spindle of the high pressurerelief valves completely out again and tightenthe counter nuts.

l Turn all brake releasing screws of the axleevenly back out, until they are light movingagain.

Operation


Fig. 51

l Turn the brake releasing screws (Fig. 51) backin again, until they abut against the brake pis-ton.

Fig. 52

l Unscrew the brake releasing screws (Fig. 52)for two turns and tighten the counter nuts.

l Repeat this adjustment procedure on the op-posite wheel side.

i NoteIf necessary replace the seal ring under the coun-ter nut if it is leaking.

For this purpose completely unscrew the brake re-leasing screw, replace the seal ring and lubricatethe screw with silicone grease.

Reinstall the screw with a new seal ring and adjustthe protrusion as described above.

4.13 Transport

! Danger

Danger of accident!

Use only stable loading ramps of sufficientload bearing capacity. Make sure that personsare not endangered by the machine tipping orsliding off.

Lash the machine down, so that it is securedagainst rolling, sliding and turning over.

Do not stand or step under loads being lifted.Always use shackles on the lifting points forloading, tying or lifting the machine.

Fig. 53

l Attach the articulation lock (Fig. 53).

Operation


Fig. 54

l Lash the machine on the transport vehicle(Fig. 54), use the four lashing eyes on frontand rear frame for this purpose.

l Support the front frame to avoid overstressingof the rubber buffers.

Fig. 55

l For lifting use also the four lifting eyes (Fig. 55)and appropriate lifting gear.

Weights: See technical data

l After transport release the articulation lockagain and store it in the receptacle.


5 Maintenance

Maintenance


5.1 General notes on mainte-nance

When performing maintenance work always com-ply with the appropriate safety regulations.

Thorough maintenance of the machine guaran-tees far longer safe functioning of the machine andprolongs the lifetime of important components.The effort needed for this work is only little com-pared with the problems that may arise when notobserving this rule.

The terms right/left correspond with travel direc-tion forward.

l Always clean machine and engine thoroughlybefore starting maintenance work.

l For maintenance work stand the machine onlevel ground.

l Perform maintenance work only with the en-gine shut down.

l Relieve hydraulic pressures before working onhydraulic lines.

l Before working on electric parts of the ma-chine disconnect the battery and cover it withinsulation material.

l When working in the area of the articulatedjoint attach the articulation lock (transportlock).

Environment

During maintenance work catch all oils and fu-els and do not let them seep into the ground orinto the sewage system. Dispose of oils, cool-ant and fuels environmentally.

Notes on the fuel systemThe lifetime of the diesel engine depends to agreat extent on the cleanliness of the fuel.

l Keep fuel free of contaminants and water,since this will damage the injection elementsof the engine.

l Drums with inside zinc lining are not suitable tostore fuel.

l The fuel drum must rest for a longer period oftime before drawing off fuel.

l Do not let the hose stir up the slurry at the bot-tom of the drum.

l Do not draw off fuel from near the bottom ofthe drum.

l The rest in the drum is not suitable for the en-gine and should only be used for cleaning pur-poses.

Notes on the performance of the en-gineOn diesel engines both combustion air and fuel in-jection quantities are thoroughly adapted to eachother and determine power, temperature level andexhaust gas quality of the engine.

If your engine has to work permanently in "thin air"(at higher altitudes) and under full load, you shouldconsult the customer service of BOMAG or thecustomer service of the engine manufacturer.

Notes on the hydraulic systemDuring maintenance work on the hydraulic systemcleanliness is of major importance. Make sure thatno dirt or other contaminating substances can en-ter into the system. Small particles can produceflutes in valves, cause pumps to seize, clog noz-zles and pilot bores, thereby making expensive re-pairs inevitable.

l If, during the daily inspection of the oil level thehydraulic oil level is found to have dropped,check all lines, hoses and components forleaks.

l Seal external leaks immediately. If necessaryinform the responsible customer service.

l Do not store drums with hydraulic oil outdoors,or at least under a cover. Water can be drawnin through the bunghole when the weatherchanges.

l Always use the filling and filtering unit(BOMAG part-no. 007 610 01) to fill the hy-draulic system. This unit is fitted with a fine fil-ter to clean the hydraulic oil, therebyprolonging the lifetime of the filter.

l Clean fittings, filler covers and the area aroundsuch parts before disassembly to avoid enter-ing of dirt.

l Do not leave the tank opening unnecessarilyopen, but cover it so that nothing can fall in.

Maintenance


5.2 Fuels and lubricants

Engine oil

Quality

Lubrication oils are classified according to theirperformance and quality class. Oils according toother comparable specifications may be used.

The exact assignment of the approved oil qualitiesand oil change intervals can be taken from the fol-lowing section "Lubrication oil change intervals".

Consult your local service station if in doubt.

Oil viscosity

Multi-purpose oils should be generally used.

Since lubrication oil changes its viscosity with thetemperature, the ambient temperature at the oper-ating location of the engine is of utmost impor-tance when choosing the viscosity class (SAE-class) .

Optimal operating conditions can be achieved byusing the opposite oil viscosity chart (Fig. 56) as areference.

Occasionally falling short of the temperature limitswill impair the cold starting ability, but will notcause any engine damage. In order to keep theoccurring wear as low as possible, occassional ex-ceeding of the limits should not happen over alonger period of time.

Fig. 56

With their better temperature and oxidation stabil-ity synthetic lubrication oils offer quite a few bene-fits.

Oil change intervals

The longest permissible time a lubrication oilshould remain in an engine is 1 year. If the follow-ing oil change intervals are not reached over a pe-riod of 1 year, the oil change should be performedat least once per year, irrespective of the operatinghours reached.

ACEA

E3-96/E5-02E4-99 = 500 operating hours

API

CG-4/CH-4 = 500 operating hours

! Caution

These intervals apply only when using a dieselfuel with maximum 0.5 % sulphur by weightand for ambient temperatures higher than-10 °C.

Approved engine oilsDeutz DQC II DQC IIIACAE E3/96/E5-02 E4-99API CH-4/CG-4 -DHD DHD-1 -

Maintenance


When using fuels with a sulphur content ofmore than 0.5% to 1% or under ambient tem-peratures below -10 °C the oil change intervalsspecified in the table must be halved. For fuelswith a sulphur content of more than 1% youshould consult the responsible service agen-cy.

Fuels

Quality

You should only use commercially available branddiesel fuel with a sulphur content below 0.5% andensure strict cleanliness when filling in. A highersulphur content has a negative effect on the oilchange intervals. Use only winter-grade diesel fuelunder low ambient temperatures. The fuel levelshould always be topped up in due time so that thefuel tank is never run dry, as otherwise filter and in-jection lines need to be bled.

When using fuels with a Cetan number < 49 poorstarting and white smoke can be expected, in par-ticular in connection with low ambient tempera-tures.

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 2-D.

l DIN/EN 590

l BS 2869

l ASTM D 975-78: 1-D and 2-D.

l Nato Codes: F-54, F-34, F44 und XF63

Winter fuel

! Danger

Diesel fuels must never be mixed with gaso-line.

For winter operation use only winter diesel fuel, toavoid clogging because of paraffin separation. Atvery low temperatures disturbing paraffin separa-tion can also be expected when using winter dieselfuel.

In most cases a sufficient cold resistance can alsobe achieved by adding flow enhancing fuel addi-tives. Consult the engine manufacturer.

Operation with rape seed oil methyl ester (RME„Bio Diesel“)

Due to the extreme quality differences of RMEW-fuels available on the market, which are caused bythe non-existence of a standardization, BOMAGdoes generally not approve any RME-fuels. If thisis neglected the warranty will become null andvoid!

However, if you still intend to operate the machinewith RME-fuels you should observe the followinginformation:

l Reduced engine power (approx. 7%), higherfuel consumption.

l The quality of RME-fuel should be in compli-ance with DIN draft 51606.

l Avoid longer periods of standstill (formation ofresin, corrosion in injection system)

l RME-fuel can damage the paint finish of themachine.

l Fuel dilution of engine oil, therefore shorteningof oil change intervals to half.

l Rubber parts, such as leak fuel return lines,seats will be damaged in the long run andneed to be replaced on a regular basis orshould be replaced by parts made of fluorinat-ed rubber. However, fluorinated rubber is notresistant against normal diesel fuel.

l If the fuel filter is clogged the filter change in-tervals must be shortened accordingly.

Hydraulic oilThe hydraulic system is operated with hydraulic oilHV 46 (ISO) with a kinematic viscosity of46 mm2/s at 40°C. For topping up or for oil chang-es use only high-quality hydraulic oil, type HVLPaccording to DIN 51524, part 3, or hydraulic oilstype HV according to ISO 6743/3. The viscosity in-dex (VI) should be at least 150 (observe informa-tion of manufacturer).

Bio-degradable hydraulic oil

On request the hydraulic system can also be filledwith ester based biodegradable hydraulic oil (Pan-olin HLP Synth. 46). The biologically quickly de-gradable hydraulic oil meets all demands of amineral oil based hydraulic oil according to DIN51524.

Maintenance


In hydraulic systems filled with Panolin HLP Synth.46 always use the same oil to top up. Whenchanging from mineral oil based hydraulic oil to anester based biologically degradable oil, you shouldconsult the lubrication oil service of the oil manu-facturer for details.

Check the filter more frequently after this change.

! Caution

Oil change bio-degradable hydraulic oil:

Perform regular oil analyses for content of wa-ter and mineral oil.

Replace the hydraulic oil filter element every500 operating hours.

Oil for drive axleFor the drive axle use only multi-purpose transmis-sion oil of API-class GL5 with viscosity class SAE90.

The additives in this oil ensure low wear lubricationunder all operating conditions.

Lubrication greaseFor lubrication use only EP-high pressure grease,lithium saponified (penetration 2).

Maintenance


5.3 Table of fuels and lubri-cants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level marks

Engine Engine oil ACEA: E3-96/E5-02 or approx. 10.5 litres*

API: CG-4/CH-4

SAE 10W/40

(-20 °C to +40 °C)

Fuel

Diesel Winter diesel fuel approx. 110 litres

Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 44 litres

46 mm2/s at 40 °C

Vibration bearings Engine oil SAE 15W/40 approx. 2,1 litres

Drive axle Gear oil SAE 90, API GL5 approx. 6,7 litres

Planetary drive Gear oil SAE 90, API GL5 approx. 1 litre per side

Tires Water 68 litres

Calcium chloride (CaCl2) or magnesium chloride(MgCl2)

29 kg

* Oil quantity with filter change

Maintenance


5.4 Running-in instructions

The following maintenance work must be per-formed when running in new machines oroverhauled engines:

! Caution

Up to approx. 250 operating hours check theengine oil level twice every day.

Depending on the load the engine is subjectedto, the oil consumption will drop to the normallevel after approx. 100 to 250 operating hours.

After 50 operating hours

l Retighten bolted connections on intake andexhaust tubes, oil sump and engine mounts.

l Check the engine for leaks.

l Retighten the bolted connections on the ma-chine.

l Retighten all wheel fastening screws with thespecified tightening torque.

l Check the V-belt tension, tighten if necessary

l Oil change diesel engine

l Oil filter cartridge diesel engine

l Check the valve clearance, adjust if necessary

l Oil change in drive axle

l Oil change in wheel hub of axle

After 500 operating hours

l Oil change vibration bearings

Maintenance


5.5 Maintenance chart

With all maintenance intervals perform alsothe work for shorter preceding service inter-vals.

No. Designation Note

Every 10 operating hours

5.6 Check the engine oil level Dipstick mark5.7 Check the fuel filter water separator5.8 Check the fuel level5.9 Check the hydraulic oil level Inspection glass


5.10 Check the tire pressure see technical data5.11 Cleaning the cooling fins on the radiator5.12 Cleaning the cooling fins on the hydraulic oil cooler5.13 Check the oil level in the drive axle5.14 Check the oil level in the wheel hubs5.15 Check the oil level in the vibration bearings


5.16 Service the battery distilled water, pole grease5.17 Drain the sludge from the fuel tank5.18 Change engine oil and oil filter cartridge min. 1x per year5.19 Checking the V-belt tension, tightening


5.20 Check, adjust the valve clearance Intake = 0.3 mm, exhaust = 0.5 mm, on coldengine

5.21 Change the oil in the vibration bearings min. 1x per year5.22 Change the oil in the drive axle min. 1x per year5.23 Change the oil in the wheel hubs min. 1x per year5.24 Changing the fuel pre-filter5.25 Change the fuel filter cartridge5.26 Check the engine mounts5.27 Check the fastening of the axle on the frame5.28 Tighten the wheel nuts5.29 Check the ROPS

Maintenance


*Also in case of repairs in the hydraulic system.


5.30 Change hydraulic oil and breather filter* at least every 2 years5.31 Change the hydraulic oil filter* at least every 2 years


5.32 Check the injection valves


5.33 Replace the toothed belt at least every 5 years

As required

5.34 Clean, change the combustion air filter min. 1x every year, safety cartridge at leastevery 2 years

5.35 Adjust the parking brake5.36 Change the tires5.37 Adjust the scrapers5.38 Change the fresh air filter in the cabin5.39 Tightening torques5.40 Engine conservation

No. Designation Note




5.6 Checking the engine oil lev-el

i NoteWith the machine on level ground shut the enginedown and wait for about 15 minutes, so that all oilcan flow back into the oil sump.

l Open the engine hood

Fig. 57

l Pull the dipstick (Fig. 57) out, wipe it off with alint-free, clean cloth and reinsert it until it bot-toms.

l Pull the dipstick back out again.

l The oil level must be between both marks"Min" and "Max".

l If the oil level is too low top up oil immediately.

l If the oil level is too high, determine the causeand drain the oil off.

! Caution

Before longer work periods you should alwaystop the oil up to the "MAX"-mark.

For quality and quantity of oil refer to the tableof fuels and lubricants

5.7 Checking the fuel filter wa-ter separator

! Danger

Danger of injury!

Support the engine hood for all maintenanceand repair work.

i NoteThe service intervals for the water separator de-pend on the water content in the fuel and cantherefore not be determined precisely. After takingthe engine into operation you should thereforecheck the water separator every day for signs ofwater.

If a to high quantity is drained off, the filter must berefilled with fuel. See chapter "maintenance as re-quired", bleeding the fuel system.

Environment

Catch running out fuel and dispose of environ-mentally.

Fig. 58

l Slacken the drain plug (Fig. 58) for a few turnsand catch running out fuel / water.

l Tighten the drain plug again and check forleaks, if necessary replace the seal ring.



5.8 Checking the fuel level

! Danger

Fire hazard!

When working on the fuel system do not useopen fire, do not smoke, do not refuel in closedrooms, do not inhale any fuel fumes.

Fig. 59

l Check the fuel level on the fuel gauge “j” (Fig.59).

i NoteDo not drive the fuel tank dry, as otherwise the fuelsystem needs to be bled.

l Clean the area around the filler opening.

Fig. 60

l Open the fuel tank cover (Fig. 60).

! Caution

Contaminated fuel can cause malfunction oreven damage of the engine.

If necessary, fill in fuel through a funnel withscreen.

l If necessary top up with fuel (diesel or winterdiesel).

For quality of fuel refer to the table of fuels andlubricants.



5.9 Checking the hydraulic oillevel

! Caution

In hydraulic systems filled with Panolin HLPSynth. 46 always use the same oil to top up.With other ester based oils consult the lubrica-tion oil service of the respective oil manufac-turer.

Fig. 61

l Check the hydraulic oil level in the inspectionglass (Fig. 61).

Normal level

approx. 3 cm below the top edge of the inspectionglass.

Minimum level

Middle of inspection glass.

! Caution

If, during the daily inspection of the oil levelthe hydraulic oil level is found to havedropped, check all lines, hoses and compo-nents for leaks.

Fig. 62

l If necessary fill in hydraulic oil through the fillerneck (Fig. 62).

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




5.10 Checking the tire pressure

! Caution

Since the tires are filled with water, you shouldalways turn the inflation valve to top positionto check the tire pressure!

Always close the valves with the dust cap.

Fig. 63

l Check the tire pressure with a pressure gaugeand the tire inflation valve 1 (Fig. 63) in top po-sition.

Nominal value see "technical data".

i NoteEnsure even pressure in all tires.

l Screw the valve caps back on.

5.11 Cleaning the cooling fins onthe radiator

! Danger

Danger of injury!

Perform cleaning work only after the enginehas cooled down and with the engine stopped.

i NoteDirt on fan blades and oil cooler reduce the coolingeffect. Dirt deposits in these areas are substantial-ly supported by oil and fuel on these surfaces. Forthis reason you should always seal any oil or fuelleaks in the vicinity of the cooling fan or the oilcooler and clean the cooling surfaces after.

Cleaning with compressed air

i NoteStart to blow out from the exhaust side.

Fig. 64

l Take the cooling air duct cover off and blowthe radiator (Fig. 64) out, starting from the airdischarge side.

l Remove all dirt that has been blown into the airduct.



Cleaning with cold cleansing agent

! Caution

In case of oily dirt spray the engine with a coldcleansing agent and let it soak in for about 10minutes.

Protect electrical equipment such as genera-tor, regulator and starter against the direct wa-ter jet.

l Spray the engine with a suitable cleansingagent, e.g. cold cleanser, let it soak in for awhile and spray it off with a strong water jet.

l Reassemble the cooling air duct cover, run theengine warm for a while to avoid corrosion.

5.12 Cleaning the cooling fins onthe hydraulic oil cooler

! Danger

Danger of injury!

Perform cleaning work only after the enginehas cooled down and with the engine stopped.

! Caution

Do not damage any cooling fins on the coolercore when cleaning.

i NoteDirt on fan blades and oil cooler reduce the coolingeffect. Dirt deposits in these areas are substantial-ly supported by oil and fuel on these surfaces. Forthis reason you should always seal any oil or fuelleaks in the vicinity of the cooling fan or the oilcooler and clean the cooling surfaces after.

Cleaning with compressed air

i NoteStart to blow out from the exhaust side.

Fig. 65

l Blow the cooler (Fig. 65) out with compressedair.



Cleaning with cold cleansing agent

! Caution

In case of oily dirt spray the cooler with a coldcleansing agent and let it soak in for about 10minutes.

Protect electrical equipment such as genera-tor, regulator and starter against the direct wa-ter jet.

l Spray the radiator with a suitable cleansingagent, e.g. cold cleanser, let it soak in for awhile and spray it off with a strong water jet.

l Run the engine warm for a while to avoid cor-rosion.

5.13 Check the oil level in thedrive axle

l Park the machine on level ground.

Fig. 66

l Unscrew the oil level inspection plug (Fig. 66)and check the oil level.

i NoteThe second level inspection plug as at the back.

After filling in oil wait until the oil has evenly distrib-uted inside the axle.

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

l Top up oil, if necessary.

For quality of oil refer to the table of fuels andlubricants.

l Turn the level inspection plug tightly back in.



5.14 Checking the oil level in left/right wheel hubs

Fig. 67

l Move the machine until the oil level inspectionplug 1 (Fig. 67) is in horizontal position.

l Clean and unscrew the plug.

The oil level must reach the bottom edge of thebore.

l Top up oil, if necessary.


l Screw the plug back in tightly.

l Repeat this inspection on the other side.

5.15 Checking the oil level in thevibration bearings

Fig. 68

l Drive the machine, until the oil level inspectionplug 1 (Fig. 68) is vertically below the hub.

l Clean and unscrew the oil level inspectionplug.

The oil level must reach the bottom edge of thebore.

l If necessary fill in oil through the filler and drainbore (2).





5.16 Servicing the battery

! Danger

Danger of causticization !

When working on the battery do not use openfire, do not smoke!

Do not let acid come in contact with skin orclothes!

Wear protective clothing!

Do not lay any tools on the battery!

For recharging remove the plugs from the bat-tery to avoid the accumulation of highly explo-sive gases.

Environment

Dispose of the old battery environmentally.

Fig. 69

l Unscrew both fastening screws (Fig. 69) fromthe seat console and fold the seat forward.

Fig. 70

l Remove the battery (Fig. 70) and clean thebattery compartment.

l Clean the outside of the battery.

l Clean battery poles and pole clamps andgrease them with pole grease (Vaseline).

l Check the fastening of the battery.

l On serviceable batteries check the acid level,if necessary top up to the filling mark with dis-tilled water.



5.17 Draining the sludge fromthe fuel tank

! Danger

Fire hazard!

When working on the fuel system do not useopen fire, do not smoke!

Do not spill any fuel.

Catch running out fuel, do not let it seep intothe ground.

Do not inhale any fuel fumes.

Fig. 71

l Unscrew the cap (Fig. 71) and drain off ap-prox. 5 litres of fuel.

l Turn the cap tightly back in.

5.18 Change engine oil and oil fil-ter cartridge

! Caution

The oil change at 500 operating hours refers tothe use of oils of oil quality class API CG-4/CH-4 or ACAE E3-96/E5-02 respectively.

See section 5.2 "Fuels and Lubricants".

Drain the engine oil only when the engine iswarm.

! Danger

Danger of scalding!

When draining off hot oil.

By hot oil when unscrewing the engine oil fil-ter.

Environment

Catch running out oil and dispose of environ-mentally together with the engine oil filter car-tridge.

Fig. 72

l Unscrew the drain plug (Fig. 72) and catchrunning out oil.

l Turn the drain plug tightly back in.



Fig. 73

l Unscrew the filter cartridge (Fig. 73) using anappropriate filter wrench.

l Clean the sealing face on the filter carrier fromany dirt.

l Slightly oil the rubber seal on the new filter car-tridge.

l Turn the new filter cartridge on by hand, untilthe seal contacts.

l Tighten the filter element for another half turn.

Fig. 74

l Fill in new engine oil (Fig. 74).


l Tighten the oil filler cap properly.

Fig. 75

l On machines with cabin set the lever for oilheat exchanger heating to position II.

l Run the engine for approx. 3 minutes at idlespeed.

l Shut the engine down and set the lever for oilheat exchanger heating to position I.

l Wait for about 15 minutes, so that all oil canflow back into the oil sump.

Fig. 76

l Check the oil level again (Fig. 76), if necessaryfill up to the Max.-mark.

l Check filter cartridge and drain plug for leaks.



5.19 Checking the V-belt tension,tightening

Checking the V-belt

Fig. 77

l Inspect the entire circumference of the V-beltvisually for damage and cracks.

l Replace damaged or cracked V-belts.

l Check with thumb pressure whether the V-beltcan be depressed more than 10 ... 15 mm be-tween the V-belt pulleys (Fig. 77), retighten theV-belt if necessary.

Retightening the V-belt

Fig. 78

l Slightly slacken the fastening screw 1 (Fig.78).

l Press the idling pulley (2) in direction "I", untilthe correct V-belt tension is achieved.

l Tighten the fastening screws (1).




5.20 Checking, adjusting thevalve clearance

! Caution

Before checking the valve clearance let the en-gine cool down for at least 30 minutes. The en-gine oil temperature must be less than 60 °C.

Valve clearance

Intake valve = 0.3 mm

Exhaust valve = 0.5 mm

l Open the engine hood completely and supportit safely.

Fig. 79

l Remove the valve cover (Fig. 79).

Fig. 80

l Press the engine shut-down lever 1 (Fig. 80)against the stop (2) and fasten it with a wire.

Fig. 81

l Crank the engine with the starter until bothvalves on cylinder 1 (Fig. 81) are “overlap-ping”.

i NoteOverlapping means that the exhaust valve is notyet completely closed and the intake valve startsto open.

The valves marked black (Fig. 81) can be checkedand adjusted.

Fig. 82

l Crank the engine with the starter until bothvalves on cylinder 4 (Fig. 82) are “overlapping”(360° rotation of the crankshaft).

The valves marked black (Fig. 82) can be checkedand adjusted.

l Assemble the cylinder head cover with a newgasket.



Adjusting the valve clearance

Fig. 83

l Loosen the counter 2 (Fig. 83) and regulatethe setscrew (1), until the feeler gauge can beinserted and pulled out with little resistance af-ter retightening the counter nut.

! Caution

After a short test run check the engine forleaks.

5.21 Changing the oil in the vi-bration bearings

! Caution

Drain oil only at operating temperature.

Fig. 84

l Move the drum, until the drain and filler plug 2(Fig. 84) is in bottom position.

l Clean and unscrew the oil level inspectionplug (1) as well as the drain and filler plug.

Environment

Catch running out oil.

Fig. 85

l Once all oil has been drained off move thedrum, until the oil level inspection plug 1 (Fig.85) is positioned vertically under the hub.

l Fill in oil, until it starts to run out through thelevel inspection bore.




l Screw oil level inspection plug (1) and drainand filler plug (2) back in with new seal rings.

5.22 Change the oil in the driveaxle

i NoteOn other axle versions drain and filler plugs are ofslightly different design. Perform the oil change ac-cordingly.

! Caution


Environment

Catch old oil and dispose of environmentally.

l Park the machine on level ground.

Fig. 86

l Clean and unscrew all level inspection anddrain plugs (Fig. 86).

l Drain and catch all oil.

l Clean the drain plug and turn it back in with anew seal ring.



Fig. 87

l Fill in oil through the oil level inspection bores(Fig. 87), until it has reached the bottom edgeof the bore.

i NoteThe second level inspection plug as at the back.

After filling in oil wait until the oil has evenly distrib-uted inside the axle.


l Retighten the filler and level inspection plug.

5.23 Change the oil in the wheelhubs

! Caution


Change the oil on both sides of the axle.

Environment

Catch old oil and dispose of environmentally.

Fig. 88

l Move the drive wheel, until the plug (Fig. 88) isin bottom position.

l Clean and unscrew the plug.

l Drain and catch all oil.

Fig. 89

l Move the drive wheel, until the plug (Fig. 89) isin horizontal position on the housing.

l Fill in oil, until it reaches the bottom edge of thebore.




l Turn the plug tightly back in.

l Change the oil also on the opposite side.

5.24 Changing the fuel pre-filter

! Danger

Fire hazard!

When working on the fuel system do not useopen fire, do not smoke and do not spill any fu-el.



Fig. 90

l Remove the hose clamps and pull the fuel pre-filter (Fig. 90) out of the fuel hoses.

! Caution

Observe the flow direction of the filter.

The arrow must point towards the fuel pump.

l Install the new fuel pre-filter.



5.25 Changing the fuel filter car-tridge

! Danger

Fire hazard!

When working on the fuel system do not useopen fire, do not smoke and do not spill any fu-el.



Fig. 91

l Unscrew the fuel filter cartridge (Fig. 91) usingan appropriate filter wrench.

l Clean the sealing face on the filter carrier fromany dirt.

l Cover the rubber seal on the new filter car-tridge slightly with oil and fill in clean fuel.

l Turn the new fuel filter cartridge on by hand,until the seal contacts.

l Tighten the fuel filter cartridge for another halfturn.

l After the test drive check the filter cartridge forleaks.

i NoteBleeding of the fuel system is not necessary.

5.26 Checking the fastenings onthe diesel engine

Fig. 92

l Check the fastening of intake and exhausttubes (Fig. 92) on the cylinder heads for tightfit.

l Check sockets and clamps between air filter,exhaust turbocharger and charge air line aswell as the lubrication air line for tight fit andleaks.

l Check fastening and tightness of the lubrica-tion oil sump.

Fig. 93

l Check the condition and tight fit of the enginepillow blocks (Fig. 93).



5.27 Tightening the fastening ofthe axle on the frame

Fig. 94

l Check all fastening nuts for the axle studs fortight fit (Fig. 94).

5.28 Tightening the wheel nuts

Fig. 95

l Tighten the wheel nuts (Fig. 95) in a crosswisepattern.

Tightening torques 550 Nm (405 ft-lb)(M22x1,5)



5.29 Checking the ROPS

i NoteWith the cabin assembled the ROPS (Roll OverProtection Structure) is integrated in the cabin.

Please observe also the respective section in thesafety regulations in this manual.

Fig. 96

l Check the cabin, especially the ROPS (Fig.96) for cracks, corrosion, damage and missingfastening elements.

i NoteUnusual movements and noises (vibrations) dur-ing operation indicate damage or loose fasteningelements.

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

l Check the suspension buffers for the opera-tor's stand for tight fit.

l Check the condition and the fastening of theseat belt.




5.30 Changing hydraulic oil andbreather filter

i NoteSee also chapter 5.1 "Notes on the hydraulic sys-tem".

! Caution

Apart from the normal oil change intervals, thehydraulic oil must also be changed after majorrepairs in the hydraulic system.

Perform the oil change when the hydraulic oilis warm.

Clean the area round hydraulic oil tank, filleropening and breather filter.

Do not use any detergents to clean the system.

Do not start the engine after draining the hy-draulic oil.

Replace the hydraulic oil filter element withevery hydraulic oil change.

! Danger

Danger of scalding!

Danger of scalding by hot oil.

Environment

Catch running out oil and dispose of environ-mentally.

i NoteGenerally replace the hydraulic oil filter elementafter the test run.

Fig. 97

l Unscrew the plug (Fig. 97) and drain off all hy-draulic oil.

l Check the seal ring, replace if necessary andturn the plug tightly back in.

Fig. 98

l Remove the filler cap (Fig. 98).

l Fill in new hydraulic oil through the screen.

i NoteWe recommend to use the filling and filtering unit(BOMAG part-no. 079 930 35) with fine filter to fillthe hydraulic system. This ensures finest filtrationof the hydraulic oil, prolongs the lifetime of the hy-draulic oil filter and protects the hydraulic system.

l Check the oil level in the inspection glass.

Nominal value:

approx. 3 cm below the upper edge of the inspec-tion glass




i NoteThe breather filter for the hydraulic oil tank is inte-grated in the filler cap, you must therefore replacethe complete filler cap.

l Close the tank with a new filler cap.

5.31 Changing the hydraulic oilfilter

! Danger

Danger of scalding!

There is a danger of scalding by hot oil whenunscrewing the filter.

! Caution

If the filter has to be changed together with thehydraulic oil, the filter should in any case bechanged 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 filterelement environmentally.

i NoteThe filter element must be changed with every hy-draulic oil change and after major repairs in the hy-draulic system.

Fig. 99

l Unscrew the cap nut 4 (Fig. 99) and take thefilter bowl (5) with the filter element (3) off.

l Examine the sealing face on the filter elementthoroughly for any visible dirt.

! Caution

Visible impurities may be an early indicator fora failure of system components and predict the



possible malfunction of important parts. Insuch a case you should perform trouble shoot-ing and replace or repair the defective compo-nents. Nonobservance may lead to totaldamage of the hydraulic system.

Do not clean or reuse the filter element.

l Take the old filter ele

Operating instructions Maintenance instructions€¦ · 8 BOMAG BW 145 D-3/DH-3/PDH-3 Fig. 4...

Documents

Transcript of Operating instructions Maintenance instructions€¦ · 8 BOMAG BW 145 D-3/DH-3/PDH-3 Fig. 4...