BW120AD 4 - Operation Maintenance

Operating instructions
Maintenance instructions
BW 100 AD-4 / BW 120 AD-4

BW 100 AC-4 / BW 120 AC-4
S/N 101 880 00 .... > / S/N 101 880 02 ... .>
S/N 101 880 01 .... > / S/N 101 880 03 ... .>
Tandem Vibratory Roller

Combination Roller
Catalogue number
008 114 81 03/2004
Foreword
BOMAG machines are products from the wide You should only operate the machine after you
F oreword
range of BOMAG compaction equipment. have been instructed and in compliance with these
instructions.
BOMAG’s vast experience in connection with
state-of-the-art production and testing meth- Strictly observe the safety regulations.
ods, such as lifetime tests of all important Please observe also the guidelines of the Civil En-
components and highest quality demands gineering Liability Association ”Safety Rules for
guarantee maximum reliability of your ma- the Operation of Road Rollers and Soil Compac-
chine. tors” and all relevant accident prevention regula-
tions.
This manual comprises:
For your own personal safety you should only
l Safety regulations use original spare parts from BOMAG.
l Operating instructions
In the course of technical development we re-
l Maintenance instructions serve the right for technical modifications
l Trouble shooting without prior notification.
These operating and maintenance instructions are
Using these instructions will also available in other languages.
l help you to become familiar with the machine. Furthermore, the spare parts catalogue is availa-
l avoid malfunctions caused by unprofessional ble from your BOMAG dealer against the serial
operation. number of your machine.
Your BOMAG dealer will also supply you with in-
Compliance with the maintenance instructions will formation about the correct use of our machines in
l enhance the reliability of the machine on con- soil and asphalt construction.
struction sites, The above notes do not constitute an extension of
l prolong the lifetime of the machine, the warranty and liability conditions specified in the
general terms of business of BOMAG.
l reduce repair costs and downtimes.
We wish you successful work with your BOMAG
BOMAG will not assume liability for the function of machine.
the machine BOMAG GmbH
l if it is handled in a way that does not comply Printed in Germany
with the usual modes of use,
Copyright by BOMAG
l if it is used for purposes other than the ones it
is intended for, see safety regulations.
No warranty claims can be lodged in case of dam-

age resulting from
l operating errors,
l insufficient maintenance and
l wrong fuels and lubricants.
Please note!
This manual was written for operators and mainte-
nance personnel on construction sites.
Always keep this manual close at hand, e.g. in the
tool compartment of the machine or in a specially
provided container. These operating and mainte-
nance instructions are part of the machine.
BW 100/120 AD/AC-4 BOMAG 3

Foreword
Please fill in
............................
Machine type (Fig. 1)
............................
Serial-number (Fig. 1 and 2)
............................
Engine type (Fig. 3)
............................
Engine number (Fig. 3)
i Note Fig. 1
Supplement the above data together with the com-
missioning protocol.
During commissioning our organisation will in-
struct you in the operation and maintenance of the
machine.
Please observe strictly the safety regulations and
all notes on risks and dangers!
Fig. 2
Fig. 3
4 BOMAG BW 100/120 AD/AC-4

Table of Contents
Technical Data 7
Safety regulations 13
Indicators and Controls 21
3.1 General notes 24
3.2 Description of indicators and control elements 24
Operation 33
4.2 Inspections before starting operation 34
4.3 Starting the engine 35
4.4 Starting the engine (cold start) 37
4.5 Starting with jump wires 39
4.6 Driving the machine 40
4.7 Stopping the machine / operating the parking brake 41
4.8 Switching the vibration on and off 42
4.9 Switching the gravity sprinkling system on and off 44
4.10 Switching the pressure sprinkling system on and off 44
4.11 Switching the vibration on or off 46
4.12 Shutting the engine down 46
4.13 Shutting down the engine in events of emergency 47
4.14 Adjusting the driver's seat 48
4.15 Towing 49
4.16 Loading and transport 51
Maintenance 55
5.1 General notes on maintenance 56
5.2 Fuels and lubricants 57
5.3 Table of fuels and lubricants 59
5.4 Running-in instructions 60
5.5 Maintenance chart 61
5.6 Check the engine oil level 63
5.7 Check the coolant level 63
5.8 Check the water separator 64
5.9 Check the fuel level 64
5.10 Check the hydraulic oil level 65
5.11 Checking the hydraulic oil filter element 65
5.12 Check the water level 66
5.13 Checking the emulsion level 66
5.14 Checking the tire pressure 67
5.15 Cleaning radiator and hydraulic oil cooler 67
5.16 Checking, tensioning, replacing the V-belt 68
5.17 Checking, adjusting the scrapers 70
5.18 Checking radiator hoses and hose clamps 71

Table of Contents
5.19 Changing the engine oil 72

5.20 Changing the engine oil filter cartridge 73
5.21 Service the battery 74
5.22 Drain the sludge from the fuel tank 75
5.23 Changing the fuel pre-filter 76
5.24 Check, adjust the valve clearance 77
5.25 Changing the fuel filter cartridge, bleeding the fuel system 78
5.26 Check the engine mounts 79
5.27 Change the hydraulic oil 80
5.28 Changing the hydraulic oil filter 82
5.29 Change the coolant 83
5.30 Changing fuel lines 84
5.31 Check the injection valves 85
5.32 Checking the fuel injection pump 85
5.33 Check, clean, change the combustion air filter 86
5.34 Cleaning the water sprinkler system 89
5.35 Draining the water sprinkler system, maintenance in case of frost 91
5.36 Tightening torques for screws with metric unified thread 92
5.37 Engine conservation 92
Trouble shooting 93
6.2 Engine 95

1 Technical Data

Technical Data
Fig. 4
Dimensions in A B D H H2 K L W
mm
BW 100 AD-4 1728 1076 700 1800 2475 255 2475 1000
BW 120 AD-4 1728 1276 700 1800 2475 255 2475 1200
* BW 100 AD-4 BW 120 AD-4
Weights
Basic weight with ROPS kg 2220 2390
Operating weight (CECE) kg 2416 2586
Mean axle load (CECE) kg 1208 1293
Mean static linear load kg/cm 11,8 10,8
(CECE)
Dimensions
Oscillation angle +/-° 12 12
Inner track radius mm 2720 2620

Technical Data
* BW 100 AD-4 BW 120 AD-4

Travel characteristics
Travel speed km/h 0 - 12 0 - 12
Working speed km/h 0-7 0-7
Max. gradability/with vi- % 40/30 40/30
bration (soil dependent)
Drive
Engine manufacturer Kubota Kubota
Type D 1703 MDI D 1703 MDI
Cooling Water Water
Number of cylinders 3 3
Rated power ISO 9249 kW 25,2 25,2
Engine speed 1/2 rpm 2200/2700 2200/2700
Fuel tank capacity (diesel) l 40 40
Electrical equipment V 12 12
Battery V/AH 12/88 12/88
Drive system hydrost. hydrost.
Driven axles front+rear front+rear
Brakes
Service brake hydrost. hydrost.
Parking brake hydro-mechanical hydro-mechanical
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrost. hydrost.
Vibration system
Frequency 1/2 Hz 55/67 55/67
Amplitude mm 0,53 0,51
Vibrating drum front+rear front+rear
Water sprinkler system

Type Gravity feed Gravity feed
** ***
Interval control
Water tank capacity l 220 220
* The right for technical modifications remains reserved
** Optional equipment
*** Optional equipment

Technical Data
Fig. 5
Dimensions in A B C D H H2 K L O S W
mm
BW 100 AC-4 1765 1076 700 1800 2490 210 2475 1000
BW 120 AC-4 1765 1276 700 1800 2490 210 2475 1200
*
BW 100 AC-4 BW 120 AC-4
Weights
Operating weight with kg 2200 2380
ROPS (CECE)
Axle load, drum (CECE) kg 1150 1240
Axle load, wheels (CECE) kg 1050 1140
static linear load (CECE) kg/cm 11,5 10,3
Wheel load (CECE) kg 263 285
Dimensions
Oscillation angle +/-° 12 12
Inner track radius mm 2720 2620

Technical Data
* BW 100 AC-4 BW 120 AC-4

Travel characteristics
Travel speed km/h 0 - 10 0 - 10
Working speed km/h 0-6 0...6
Max. gradability/with vi- % 40/30 40/30
bration (soil dependent)
Drive
Engine manufacturer Kubota Kubota
Type D 1703 MDI D 1703 MDI
Cooling Water Water
Number of cylinders 3 3
Rated power ISO 9249 kW 25,2 25,2
Rated speed rpm 2600 2600,
Fixed engine speed 1 rpm 2200 2200,
Fixed engine speed 2 rpm 2700 2700,
Fuel tank capacity (diesel) l 40 40
Electrical equipment V 12 12
Battery V/AH 12/88 12/88
Driven axles front+rear front+rear
Tires
Number of tires 4 4
Tire size 205/60-15 205/60-15
Brakes
Service brake hydrost. hydrost.
Parking brake hydro-mechanical hydro-mechanical
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrost. hydrost.
Steering/oscillation angle degree 30/12 30/12
Vibration system
Frequency Hz 55/67 55/67
Amplitude mm 0,53 0,50
Vibrating drum front front
Water sprinkler system

Type Pressure Pressure
Interval control Standard Standard
Water tank capacity l 220 220
Emulsion tank capacity l 20 20
* The right for technical modifications remains reserved

Technical Data
The following noise and vibration values according to the EC-directive for machines, edition (98/37/
EEC) and the noise emission regulation 2000/14/EC were measured at nominal engine speed and with
the vibration switched on. The machine was standing on an elastic base.
During operation these values may vary because of the existing operating conditions.
Noise value
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is
sound pressure level at the work place of the operator (with cabin):
BW 100 AD-4
LpA =85,3 dB(A)
BW 100 AC-4
LpA = dB(A)
BW 120 AD-4
LpA =83,6 dB(A)
BW 120 AC-4
LpA = 83,2dB (A)
The nose emission value for the machine according to the noise emission regulation 2000/14/EG is
guaranteed sound capacity level of the machine:
BW 100 AD-4
LWA = 106 dB(A)
BW 100 AC-4
LWA = dB(A)
BW 120 AD-4
LWA = 106 dB(A)
BW 120 AC-4
LWA = 106 dB(A)
These sound values were determined according to ISO 3744 for the sound capacity level (LwA) and ISO
11204 for sound pressure level (LpA) at the place of the operator.
Vibration value
The 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 7096, is <=0,5 m/sec2.
Hand-arm vibration values

Der The weighted effective acceleration value determined according to EN 500/ISO 5349, is <=2,5 m/sec2.

2 Safety regulations

Safety regulations
General Notes Unintended use

This BOMAG machine has been built in ac- However, dangers may arise from this machine if
cordance with the latest technical standard it is operated by untrained personnel or if it is sub-
and complies with the applicable regulations ject of unintended use.
and technical rules. However, dangers for per- Do not work with vibration on hard concrete, cured
sons and property may arise from this ma- bitumen layers or extremely frozen ground.
chine, if: Starting and operation of the machine in explosive
l it is used for purposes other than the ones it is environments is prohibited.
intended for
l it is operated by untrained personnel Who has permission to operate the ma-
l it is changed or converted in an unprofessional
chine?
way Only trained and instructed persons of at least 18
years of age are permitted to drive and operate
l the safety instructions are not observed
this machine. For operation of the machine the re-
Each person involved in the operation, mainte- sponsibilities must be clearly specified and com-
nance and repair of the machine must there- plied with.
fore read and comply with these safety Persons under the influence of alcohol, medicine
regulations. If necessary, this must be con- or drugs are not allowed to operate, service or re-
firmed by obtaining the signature of the cus- pair the machine.
tomer.
Maintenance and repair work requires specific
Furthermore, the following instructions and regula- knowledge and must therefore only be performed
tions must obviously also be complied with: by trained specialists.
l applicable accident prevention instructions
l generally accepted safety and road traffic reg- Conversions and changes to the ma-
ulations chine
l country specific safety regulations. It is the Unauthorized alterations to the machine are pro-
duty of the operator to be acquainted with hibited for safety reasons.
these instructions and to apply these accord- Original parts and accessories have been special-
ingly. This applies also for local regulations ly designed for this machine. We wish to make ex-
concerning different types of handling work. plicitly clear that we have not tested or approved
Should the recommendations in these instruc- any parts or accessories not supplied by us. The
tions be different from the regulations valid in installation and/or use of such products may have
your country, you must comply with the safety an adverse effect on the active and/or passive
regulations valid in your country. driving safety. The manufacturer explicitly ex-
cludes any liability for damage caused by the use
Intended use of non-original parts or accessories.
This machine must only be used for:
Notes on safety in the operating and
l compaction of bituminous material, e.g. road
maintenance instructions:
surface layers
l light compaction work in earth construction
(road sub-bases) Danger
!
Paragraphs marked like this highlight possible

l You should only operate the unit with fully
dangers for persons.
functional safety equipment.
l Have the machine inspected by an expert
Caution
!
once every year.
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.

Safety regulations
i Note Checking the roll over protection

Paragraphs marked like this contain technical in- structure (ROPS)
formation for the optimal economical use of the The frame of the machine must not be warped,
machine. bent or cracked in the area of the ROPS fastening.
The ROPS must not show any rust, damage, hair-
Environment line cracks or open fractures.
Paragraphs marked like this point out practic- The ROPS must not rattle about when driving.
es for safe and environmental disposal of fuels This would indicate that it is not properly fastened.
and lubricants as well as replacement parts. All bolted connections must comply with the spec-
ifications and should be absolutely tight (observe
Observe environmental regulations.
the tightening torques). Screw and nuts must not
be damaged, bent or deformed.
Information and safety stickers/decals
No accessories may be welded or bolted on and
on the machine no additional holes must be drilled without the con-
Keep safety stickers in good and legible condition sent of the distributor, since this will impair the
(see parts manual) and comply with their meaning. strength of the unit.
Replace damaged and illegible stickers/decals.
Starting the machine
Loading the machine Before starting
Use only strong and stable loading ramps of suffi- The machine must only be operated from the driv-
cient load bearing capacity. The ramp inclination er's seat.
must be less than the gradability of the machine.
Use only machines which are serviced at regular
Secure the machine against tipping or slipping off. intervals.
Secure the machine on the transport vehicle Become acquainted with the equipment, the con-
against rolling, slipping and turning over. trol elements, the working principle of the machine
Persons are highly endangered when and the working area.
l they step or stand under loads being lifted Wear your personal protective outfit (hard hat,
safety boots, etc.).
l they remain in the drive range of the machine
during an instruction and during loading. Before climbing on the machine check whether:
The machine must not swing about when being lift- l persons or obstructions are beside or under
ed. the machine
Use only safe lifting gear of sufficient load bearing l the machine is free of oily and combustible
capacity. material
Fasten the lifting gear only at the specified lifting l all grips, steps and platforms are free of
points. grease, oils, fuel, dirt, snow and ice
l the engine hood is closed and locked
Towing the machine
Use steps and grips to climb onto the machine.
You should generally use a tow bar.
Before starting the machine check whether:
Max. towing speed 1 km/h, max. towing distance
l the machine shows any obvious faults
500 m.
Before releasing the multi-disc brake secure the l all guards and safety elements are in place
machine against unintended rolling. l steering, brakes, control elements, light sys-
tem and warning horn work correctly

Safety regulations
l the seat is correctly adjusted not use the emergency stop switch as service
brake.
l mirrors (if present) are clean and correctly ad-
justed. Restart the machine only after the danger that
caused the actuation of the emergency stop switch
Do not start the machine with defective gauges,
has been eliminated.
control lights or control elements.
If the engine oil pressure control light lights up stop
Do not take any loose objects with you or fasten
the engine immediately.
them to the machine.
If the machine has contacted high-voltage power
On machines with roll over protection system you
lines:
must always wear your seat belt.
l Do not leave the operator's platform
Starting
l Warn others from coming close to or touching
Start and operate the machine only from the driv- the machine
er's seat.
l if possible drive the machine out of the danger
For starting set all control levers to 'neutral posi-
zone
tion'.
l Have the electric power switched off
Do not use any starting aids like start pilot or ether.
Operate the machine only from the operator's
After starting check all gauges and control lights.
stand.
Starting with jump wires Keep the cabin doors closed.
Connect plus with plus and minus with minus Do not adjust the driver's seat while driving.
(ground cable) - always connect the ground strap
Do not climb onto or off the machine while the ma-
last and disconnect it first! A wrong connection will
chine is driving.
cause severe damage in the electric system.
Change the travel direction only at standstill.
Do not start the engine by shorting the electric ter-
minals on the starter motor, because the machine Do not use the machine to transport persons.
may start to drive immediately. In case of unusual noises and development of
smoke perform trouble shooting and have the fault
Starting in closed rooms
corrected.
Exhaust gases are highly dangerous! Always en-
Always keep a sufficient distance to excavation
sure an adequate supply of fresh air when starting
walls and embankments and do not use working
in closed rooms!
methods that could impair the stability of the ma-
chine.
Driving the machine
Do not work with vibration on hard concrete, cured
Persons in the danger area bitumen layers or extremely frozen ground.
Before taking up work, also after breaks, you Always keep a sufficient distance when passing
should always convince yourself that the danger through subways, under bridges, tunnels, electric
zone is free of persons or obstructions, especially power lines etc.
when driving in reverse.
Driving on inclinations and slopes
If necessary give warning signals. Stop work im-
Do not drive on gradients exceeding the maximum
mediately if persons remain in the danger zone,
gradability of the machine.
despite the warning.
On slopes drive extremely carefully and always di-
Do not step or stand in the articulation area of the
rectly up or down the slope. Change to a lower
machine when the engine is running. Danger of
gear before starting to drive.
squashing!
Wet and loose soils considerably reduce the
Driving ground adhesion of the machine on inclinations
In events of emergency and in case of danger ac- and slopes. Higher risk of accident!
tuate the emergency stop switch immediately. Do

Safety regulations
Behaviour in traffic Fire protection measures

Match the speeds to the working conditions. Familiarise yourself with the location and the oper-
Always allow loaded transport vehicles to pass. ation of fire fighting equipment. Observe all fire re-
porting and fire fighting possibilities.
Switch the lights on if the visibility is poor.
Keep away from edges and embankments. Maintenance work
Check the effect of vibration Comply with the maintenance work described in
When compacting with vibration you must always the operating and maintenance instructions, in-
check the effect of the vibration on nearby build- cluding the information concerning the replace-
ings and underground supply lines (gas, water, ment of parts.
sewage, electric power) and stop compaction work Maintenance work must only be performed by
with vibration, if necessary. qualified and authorized persons.
Do not switch the vibration on when working on For overhead maintenance and assembly work
hard (frozen, concrete) ground. Danger of bearing use the access steps and working platforms pro-
damage! vided or other secure means. Do not use machine
parts as access steps.
Parking the machine Keep unauthorized persons away from the ma-
Park the machine on level and firm ground. chine.
Before leaving the machine: Do not perform maintenance work while the ma-
chine is driving or the engine is running.
l return the control lever to neutral position
Park the machine on horizontal, level and firm
l apply the parking brake ground.
l shut the engine down and pull the ignition key Pull the key out of the ignition switch.
out
Secure the articulated joint with the articulation
l secure the machine against unintended use. lock.
Do not jump off the machine, but use access steps Working on hydraulic lines
and grips.
Relieve hydraulic pressures before working on hy-
Mark parked machines, which could be in the way, draulic lines. Hydraulic oil escaping under pres-
with a clearly visible sign. sure can penetrate the skin and cause severe
Parking on slopes and inclinations injury. When being injured by hydraulic oil consult
a medical doctor immediately, as otherwise this
Secure the machine against rolling, place metal may cause severe infections.
chocks in front of and behind the drums.
Do not step in front of or behind the drums/rubber
wheels when performing adjustment work in the
Filling the fuel tank hydraulic system.
Do not inhale any fuel fumes. Do not change the setting of pressure relief valves.
Refuel only with the engine stopped. Drain hydraulic oil at operating temperature - dan-
Do not refuel in closed rooms. ger of scalding!
No open fire, do not smoke. Catch running out hydraulic oil and dispose of en-
vironmentally.
Do not spill any fuel. Catch running out fuel, do not
let it seep into the ground. Always catch and dispose of biodegradable hy-
draulic oils separately.
Wipe off spilled fuel. Keep dirt and water away
from the fuel. Do not start the engine after draining the hydraulic
Leaking fuel tanks can cause explosions. Ensure oil.
tight fit of the fuel tank cover, if necessary replace
immediately.

Safety regulations
Once all work is completed (with the system still Working on electric components
depressurized!) check all connections and fittings Before starting to work on electric parts of the ma-
for leaks. chine disconnect the battery and cover it with insu-
Changing hydraulic hoses lating material.
Hydraulic hoses must be visually inspected at reg- Do not use fuses with higher ampere ratings and
ular intervals. do not repair fuses with a piece of wire. Fire haz-
ard!
Hydraulic hoses must be immediately replaced if:
Before starting welding work on the machine dis-
l the outer layer is damaged down to the inlay connect the battery.
(e.g. chafing, cuts, cracks)
Working on the battery
l the outer layer is brittle (formation of cracks in
the hose material) When working on the battery do not smoke, do not
use open fire.
l the hose shows deformations in pressurized
and depressurized condition, which do not Do not let acid come in contact with hands or
comply with the genuine shape of the hydrau- clothes! When injured by acid flush off with clear
lic hose water and seek medical advice.
l the hose shows deformations in bends, e.g. Metal objects (e.g. tools, rings, watch straps) must
squeezing, buckling, layer separation, forma- not come in contact with the battery poles - danger
tion of blisters of short circuit and burning!
When recharging serviceable batteries remove all
l leakages.
plugs, to avoid the accumulation of explosive gas-
l incorrect installation. es.
l the hydraulic hose has separated from the fit- Observe the applicable instructions when starting
ting with an auxiliary battery.
l mixing up of hoses by mistake. Dispose of old batteries in accordance with valid
regulations.
l the fitting shows corrosion that impairs both
function and strength. Switch off the charging current before removing
the charging clamps.
l fittings are damaged or deformed, whereby
the function and strength of the hose/hose Ensure sufficient ventilation, especially if the bat-
connection is impaired. tery is to be charged in a closed room.
Only genuine BOMAG replacement hydraulic hos- Working on the fuel system
es ensure that the correct hose type (pressure
Do not inhale any fuel fumes.
range) is used at the right location.
No open fire, do not smoke, do not spill any fuel.
Working on the engine
Catch running out fuel, do not let it seep into the
Shut the engine down before opening the engine ground and dispose of environmentally.
hood.
Working on wheels and tires
Drain the engine oil at operating temperature -
danger of scalding! Explosion-like bursting of tires or parts of tires and
rims can cause most severe or even deadly inju-
Wipe off spilled oil, catch running out oil and dis-
ries.
pose of environmentally.
Assembly of tires must only be performed with ap-
Store used filters and other oil contaminated ma-
propriate experience and tools. If necessary have
terials in a separate, specially marked container
tires assembled in a qualified workshop.
and dispose of environmentally.
Always ensure the correct tire pressure and do not
Do not leave any tools or other objects, that could
exceed the specified maximum pressure.
cause damage, in the engine compartment.
Check tires and wheels every day for specified
pressure, cuts, bulges, damaged rims, missing

Safety regulations
wheel studs or nuts. Do not drive with damaged

tires or wheels.
Anti-sticking emulsions for tires must only consist
of water and anti-sticking agent, in a concentration
in accordance with the specifications of the manu-
facturer of the anti-sticking agent. Observe appli-
cable environmental regulations.
Cleaning work
Do not clean the machine while the engine is run-
ning.
Do not use gasoline or other inflammable sub-
stances for cleaning.
When using a steam cleaner for cleaning do not
subject electrical parts and insulation material to
the direct jet or cover these items beforehand.
Do not guide the water jet into the exhaust and into
the air filter.
After maintenance work

After completion of maintenance work reinstall all
guards and safety features.
Repair
Mark a defective machine by attaching a warning
tag to the steering wheel.
Repair work must only be performed by qualified
and authorized persons. Use our repair instruc-
tions for this work.
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!
Test
The safety of compaction equipment must be
checked by a specialist as required in dependence
on the application and the operating conditions,
however at least once every year.

Safety regulations

3 Indicators and Controls

Indicators and Controls
Fig. 6

1 Instrument cluster 11 Interval switch for pressure sprinkler system

2 Rotary switch for lighting (STVZO)* 12 Fuse boxes
3 Rotary switch for working light 13 Ignition switch
4 Rotary switch for flashing beacon* 14 Ball valve, vibration (only AD)
5 Rotary switch for hazard light system* 15 Push button for vibration
6 Rotary switch for vibration pre-selection 16 Travel lever / brake
7 Emergency stop push button 17 Throttle lever
8 Push button for warning horn 18 Rotary switch for edge cutter
9 Rotary switch for direction indicators* 19 Water level gauge
10 Rotary switch for gravity feed sprinkling sys- 20 Foot switch for rubber tire sprinkling system
tem (only AC), foot switch for flow divider (only AD)
* Optional equipment

3.1 General notes 3.2 Description of indicators

and control elements
Please read this section thoroughly before operat-
ing this machine if you are not yet conversant with
the indicators and control elements. All functions
are described in detail hereunder.
Paragraph 4 "Operation" contains only concise de-
scriptions of the individual operating steps.
Fig. 7
No. 1 = Instrument cluster
i Note
With the ignition switch in position I all gauges and
instruments are switched on for 3 seconds.
a red flash-
ing = Overheating of engine, higher than
110°C, warning buzzer sounds.
Switch off vibration, run engine with
idle speed or shut down engine if
necessary, clean engine oil cooler
and radiator, if necessary repair en-
gine.
b red flash-
ing = Engine oil pressure too low, engine is
shut down after 10 seconds. Check
engine oil level, repair the engine if
necessary.
c yellow = not connected.
d yellow = Charge control light, batteries are not
being charged, check V-belt, repair
the generator if necessary
e yellow = not connected.
f yellow = Seat contact monitoring while ma-
chine is travelling, warning buzzer
sounds, engine is shut down after 4
seconds.
g red = Parking brake, with lever shifted to
parking brake position, with driver’s
seat unoccupied.

h green Position "mid-

flashing = Travel direction indicator, with travel dle" = Parking light on
direction lever actuated. Position "right" = Travel light and parking light
i yellow = not connected. on, with ignition switch 28 in
j red flash- position "I".
ing = not connected.
k yellow = Pre-heating* and after-heating
= Between -30°C and +10°C pre-heat-
ing in ignition switch position I and
momentary contact switch for engine
speed in idle speed position. After
light goes out start within 14 seconds.
l red flash-
ing = Hazard light, with hazard light switch
depressed
m = Operating hour meter, counts the op-
erating hours while the engine is run-
ning. All maintenance work must be Fig. 9
performed according to the indicated
No. 3 = Rotary switch for working light
operating hours.
Position "left" = Working light off
n = Fuel tank filling level
Position "right" = Working light on, with ignition
switch 28 in position "I"
i Note
Nine green and one red LED.
When falling below the lowest filling level the last
green LED will light and the red LED will addition-
ally come on.
When the fuel tank is empty only the red LED will
flash.
Fig. 10
No. 4 = Rotary switch for flashing beacon***
Position "left" = Flashing beacon off
Position "right" = Flashing beacon on
Fig. 8
No. 2 = Rotary switch for lighting (STVZO)**
Position "left" = Light off
** Optional equipment *** Optional equipment

Fig. 11 Fig. 13
No. 5 = Rotary switch for hazard light system No. 7 = Emergency stop push button
with control light *
Position "left" = Hazard light system switched
Danger
!
off
Danger of accident!
Position "right" = Hazard light switched on, con-
trol light in instrument cluster Use only in events of emergency during oper-
lights up. ation.
Do not use as parking brake.
Restart the machine only after the danger that
caused the actuation of the emergency stop
switch has been eliminated.
The machine is braked immediately, the engine
is shut down.
actuate = press the button completely
down, it automatically locks in
fully pressed position.
switch off/un-
lock = Turn button clockwise. Re-
start the engine.
Fig. 12
No. 6 = Rotary switch for vibration, manual or
automatic
Position left = Pre-selection for vibration acti-
vation during travel via the vi-
bration push button in the
travel lever.
Position right = Pre-selection for automatic ac-
tivation and deactivation of vi-
bration when exceeding or
falling below a certain slow
travel speed.
Fig. 14
No. 8 = Push button for warning horn

Fig. 15 Fig. 17
No. 9 = Rotary switch for direction indica- No. 11 = Interval switch for pressure sprinkler
tors* system
Position "mid- Position 0 = Interval and pressure sprin-
dle" = Direction indicators off kling system switched off.
Position "left" = Indication left, control light and Position 11 = Permanent sprinkling and
instrument cluster flashes. function test.
Position "right" = Indication right, control light in further posi-
instrument cluster flashes. tions = various sprinkling intervals, ac-
tivation period always 5 sec-
onds.
Fig. 16
No. 10 = Rotary switch for gravity feed sprin-
kling system Fig. 18
Position "left" = Gravity feed sprinkling system No. 12 = Fuses
"OFF"
Position "right" = Gravity feed sprinkling system ! Danger
"ON" Fire hazard!
Do not use fuses with higher ampere ratings
and do not repair fuses with a piece of wire.
Fuse box A
(1) 20A = (F68) potential 30
(2) 30A = (F139) engine solenoid

(3) 10A = (F04) gauges

(4) 10A = (F119) engine
(5) 10A = (F03) vibration
(6) 10A = (F45) edge cutter
(7) 10A = (F23) warning horn
(8) 10A = (F48) pre-heating system
Fuse box B
(1) 15A = (F11) head lights, left *
(2) 15A = (F12) head lights, right*
(3) 15A = (F08) direction indicators* and work-
ing head lights Fig. 20
(4) 15A = (F09) parking and tail light, left* No. 13 = Ignition switch
(5) 15A = (F10) parking and tail light, right* Position "P"/"0" = Ignition off, key can be pulled
out, engine off.
(6) 15A = (F07) hazard light*
Position "I" = Ignition on, control and warn-
(7) = Spare
ing lights in the instrument
(8) = Spare cluster light up. The lighting
system can be switched on.
i Note
The engine can only be started if the travel lever is
in braking position, the seat is occupied and the
emergency stop switch is unlocked.
The ignition switch is designed with a lock to pre-
vent repetitive starting. For a new starting attempt
the ignition key must first be turned back to posi-
tion "0".
Position "II" = Notch for pre-heating, starting
at temperatures below +10 °C,
Fig. 19 hold ignition key in position "II",
until the pre-heating control
Main fuse for battery light in the instrument cluster
80A = F 00 goes out.
Position "III" = turn further against spring
pressure, the engine starts,
turn the ignition key back to
position "I" once the engine
has started.
! Caution
Run the engine warm for a short while before
starting work. Do not allow the engine to run
longer than 10 minutes with idle speed.
Do not shut the engine down all of the sudden
from full speed, but let it idle for a while for
* Optional equipment temperature equalization.

Fig. 21 Fig. 23
No. 14 = Ball valve, vibration (only AD) No. 15 = Push button vibration
Position up- press = to switch the vibration on and
ward = Vibration of both drums off.
Position down-
ward = Vibration of front drum only
Fig. 24
No. 16 = Travel lever / brake
Fig. 22 Position "0" = Neutral position for engine
start, brake closed.
Ball valve for 3-stage vibration*
Position "I" = Forward travel without vibra-
Position up- tion, brake is released.
ward = Vibration of rear drum only
Position "II" = Backward travel without vibra-
Position horizon- tion, brake is released.
tal = Vibration of both drums
Position "III" = max. forward/reverse travel
Position down- with vibration, brake is re-
ward = Vibration of front drum only leased.

Fig. 25 Fig. 27
No. 17 = Throttle lever No. 19 = Water level gauge
Position forward shows the water level inside the water tank.
’’MAX II“ = Full load position 2700 rpm,
operating position for driving
and vibration.
Position forward
’’MAX I“ = Full load position 2200 rpm,
operating position for driving
and vibration.
Position reverse
"MIN" = Idle speed position, engine
start.
Fig. 28
No. 20 = Foot switch for tire sprinkler system
(only AC)
press = Sprinkling on
release = Sprinkling off
Fig. 26
No. 18 = Rotary push button for edge cutter*
Position "mid-
dle" = Edge cutter stops at the pres-
ently reached position
Position "left" = Edged cutter is raised.
Position "right" = Edged cutter is lowered.

Danger
!
Danger of accident!
Always secure with locking screw.
Fig. 29
Foot switch for flow divider* (only AD)

press = flow divider switched on
release = flow divider switched off
Fig. 30
No. 21 = Ball valve, brake releasing device (on-
ly AC-machines)
Position "I" = Brake applied
! Danger
Danger of accident!
Unscrew the locking screw and secure the ma-
chine against rolling away.
i Note
Release brake by turning the steering wheel in
clockwise direction.
Position "II" = Brake released


4 Operation

Operation
4.1 General notes 4.2 Inspections before starting

operation
Please read section 3 Indicators and Control Ele-
ments thoroughly before operating the machine if
you are not yet fully familiar with the indicators and
control elements of the machine. Before the everyday use or before a longer work-
ing period the following tests and inspections must
All indicators and control elements are described
be performed.
in detail in this chapter.
Danger
!
Please observe strictly the safety regulations

in chapter 2 of these operating and mainte-
nance instructions.
l Park the machine on level ground.
Test:
l Check fuel tank and fuel lines for leaks
l Screw connections
l Function of steering
l Function of parking brake
l Machine for damage
i Note
The following inspection work is described in
chapter 'Maintenance every 10 Operating Hours'.
l Engine oil level
l Dry air filter service indicator
l Hydraulic oil level
l Fuel level
l Water level in sprinkler system
l Emulsion level
l Tire pressure

Operation
4.3 Starting the engine Fasten/release your seat belt *.
! Caution
In this chapter it is assumed that the operator
is fully acquainted with the functions of the
various control elements on the machine.
Fig. 33
Fasten
l Press the releasing button 1 (Fig. 33), pull the
seat belt vertically out of the retractor unit and
press the tongue into the buckle on the right
hand side of the driver’s seat.
Fig. 31
l Always start the engine from the driver’s seat Open

with seat contact switch (Fig. 31).
Danger
!
Danger of accident!
Always wear your seat belt.
Fig. 34
l Press the release button on the buckle and

pull the tongue out.
l Press the button 1 (Fig. 34) on the retractor
unit until the seat belt is completely retracted.
Fig. 32
l Fasten your seat belt (Fig. 32).

Operation
Fig. 35 Fig. 38
l Shift the travel lever (Fig. 35) to position '0'. l Turn the ignition key (Fig. 38) to position "I".
The parking brake is closed.
Fig. 39
Fig. 36 l All control and warning lights (Fig. 39) in the in-
l Set the throttle lever (Fig. 36) to position MIN, strument cluster light up for 3 seconds.
idle speed. l Charge control light (d), engine oil pressure
warning light (b) and brake warning light (g)
stay on.
Caution
!
Perform the starting process for maximum 20

seconds without interruption and pause for a
minute between starting attempts.
If the engine has not started after two attempts
perform trouble shooting.
Fig. 37
l Check, whether the emergency stop switch

(Fig. 37) is unlocked.

Operation
4.4 Starting the engine (cold

start)
With cold engine and temperatures below ap-

prox. +10 °C:
i Note
After longer periods of standstill refer to the chap-
ter „Starting the engine (normal starting)“.
l Check whether the fuel tap is in position „ON“.
Fig. 40 l Check, whether the travel lever is in “0”-posi-
l Turn the ignition key (Fig. 40) through position tion.
"II" to position "III" to start the engine. l Check, whether the emergency stop switch is
l As soon as the engine is running turn the igni- unlocked.
tion key back to position "I", charge control
light and oil pressure control light go out.
! Caution
If charge control light and oil pressure warning
light do not go out when the engine is running,
shut the engine down immediately and per-
form trouble shooting.
Run the engine warm for a short while, but do
not run with idle speed for more than 10 min-
utes.
Fig. 41
l Set the throttle lever (Fig. 41) to "MAX I".
Fig. 42
l Turn the ignition key (Fig. 42) through position

"I" to position "II" and hold it in this position for
about 6 seconds.

Operation
Fig. 43 Fig. 45
l The preheating control light k (Fig. 43) in the l Shift the throttle lever (Fig. 45) back to position
instrument cluster lights for approx. 6 seconds. "MIN".
!Caution
Run the engine warm for a short while, but do
not run with idle speed for more than 10 min-
utes.
Fig. 44
l Once the preheating control light has gone out

turn the ignition key to position "III" (Fig. 44),
the starter cranks the engine.
l As soon as the engine ignites return the igni-
tion key to position "I".
l Once the engine runs correctly reduce the en-
gine speed.
i Note
At temperatures below -5 °C preheat for approx.
10 seconds.
!Caution
Do not preheat longer than 20 seconds without
interruption.

Operation
!Caution
4.5 Starting with jump wires
If no powerful consumer is switched on volt-
age peaks may occur when separating the con-
necting cables between the batteries, which
could damage electrical components.
l After starting disconnect the negative poles
(ground cable) first and the positive poles af-
ter.
l Switch off the consumer.
l Close the battery compartment with the cover.
Fig. 46
l Remove the cover from the battery compart-

ment (Fig. 46).
Fig. 47
! Caution
A wrong connection will cause severe damage
in the electric system.
l Only use a 12 Volt battery to bridge the ma-
chine.
l When jump starting with an external battery
connect both plus poles first.
l Then connect the ground cable first to the mi-
nus pole of the current supplying battery and
then to engine or chassis ground, as far away
from the battery as possible (Fig. 47).
l Start as described under 'Starting the engine'.
l Once the engine is running switch on a power-
ful consumer (working light, etc.).

Operation
lights when the

4.6 Driving the machine machine is driv-
ing = when the driver’s seat is unoc-
cupied. The warning buzzer
! Danger sounds. The engine is shut
Danger of accident! down after 3 seconds and the
parking brake closes.
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclina-
tions and slopes.
Soil conditions and weather influences impair
the gradability of the machine.
Do not drive on gradients exceeding the maxi-
mum gradability of the machine.
Before starting to drive make sure that the
drive range is absolutely safe.
Always give way to loaded transport vehicles!
Fig. 49
l Set the throttle lever (Fig. 49) to full load posi-

tion engine ’’Max I“ or ’’MAX II“.
i Note
During operation the throttle lever always remains
locked in one of the two full load positions.
Control the travel speed with the travel lever.
Fig. 48
i Note
Seat contact switch control light in instrument clus-
ter (Fig. 48):
goes out = when the driver’s seat is occu-
pied.
lights up when
the machine is at
rest = when the driver’s seat is unoc-
cupied. Drive operation is not
possible. (The brake is Fig. 50
closed).
! Caution
i Note
Do not operate jerkily!
When moving the travel lever out of braking posi-
tion the engine will be shut down immediately. l Disengage the travel lever (Fig. 50) out of
braking position and move it slowly to the de-
sired travel direction.

Operation
Position "I" = max. forward travel without vi-

bration 4.7 Stopping the machine / op-
Position "II" = max. backward travel without erating the parking brake
vibration
Position "III" = Max. forward/backward travel
with vibration
Fig. 52
l Shift the travel lever (Fig. 52) slowly to "0"-po-

Fig. 51 sition. The machine is automatically braked by
The parking brake warning light in the instrument the hydrostatic drive. The brake closes.
cluster g (Fig. 51) lights up.
Fig. 53
The parking brake warning light in the instrument
cluster g (Fig. 53) lights up.

Operation
Pre-selecting vibration (2 stages only

4.8 Switching the vibration on AD-machines)
and off
! Danger
Risk of damage
When compacting with vibration you must
check the effect of nearby buildings and un-
derground supply lines (gas, water, sewage,
electric power), if necessary stop compaction
with vibration.
Caution
!
Danger of bearing damage!

Fig. 55
Do not activate the vibration on hard (frozen,
concrete) ground.
Caution
!
Destruction of hydraulic components!

i Note
Switch over only with the vibration switched
Switch on the vibration only at full engine speed,
off.
set the throttle lever to full load position.
l Pre-select the desired drum or drums with the
Vibration at standstill causes transverse ruts, ball valve (Fig. 55).
therefore:
Position "top" = Vibration of both drums
l switch the vibration on only after shifting the
travel lever to the desired travel direction. Position "bot-
tom" = Vibration of front drum only
l Switch the vibration off before stopping the
machine.
Pre-selecting the vibration
Fig. 54
l Turn the rotary switch for vibration in manual

or automatic mode (Fig. 54) to manual.

Operation
Pre-selecting vibration (3 stages only Switch the vibration on

AD-machines)*
Fig. 57
Fig. 56 l Set the throttle lever (Fig. 57) to full load posi-
tion, engine Max I or engine Max II.
! Caution
Destruction of hydraulic components!
Switch over only with the vibration switched
off.
l Pre-select the desired drum or drums with the
ball valve (Fig. 56).
Position up-
ward = Vibration of rear drum only
Position horizon-
tal = Vibration of both drums
Position down-
ward = Vibration of front drum only
Fig. 58
l Actuate the vibration push button (Fig. 58) only

after shifting the travel lever to the desired
travel direction.
i Note
When shifting the travel lever through position "III"
to position "I" or "II", the vibration will be automati-
cally switched off.
Switching the vibration off

l Press the vibration push button again.

Operation
4.9 Switching the gravity sprin- 4.10 Switching the pressure

kling system on and off sprinkling system on and
off
Fig. 59
l Turn the rotary switch for gravity feed sprin- Fig. 60

kling system (Fig. 59) to the right, the gravity
l Check whether the water tank is full (Fig. 60).
feed sprinkling system is switched on.
l Turn the rotary switch for gravity feed sprin-
kling system to the left, the gravity feed sprin-
kling system is switched off.
Fig. 61
l Switch the interval switch for pressure sprin-

kling (Fig. 61) to the desired flow interval.
Position "0" = Sprinkling "OFF"
Position 1...10 = Interval sprinkling "ON"
Position 11 = Permanent sprinkling ’’ON“

Operation
Fig. 62 Fig. 64
l To switch the sprinkler system on move the l To switch off the pressure sprinkling system
travel lever out of braking position towards "0"- switch the interval switch for pressure sprin-
position (Fig. 62). kling (Fig. 64) to position ’’0“.
i Note
The sprinkler system will only work when the travel
lever is in direction "0"-position. This is also the
testing position for interval position 11.
Fig. 63
l To switch off the sprinkler system return the

travel lever to the position "brake closed" (Fig.
63).
i Note
The warning light (g) in the instrument cluster must
light up.

Operation
4.11 Switching the vibration on 4.12 Shutting the engine down

or off
! Danger
i Note Danger of accident!
Only AC-machines. On particularly steep inclinations place wheel
chocks in front of or behind the drum.
Fig. 65
l Press the foot switch 23 (Fig. 65). Fig. 66
press = on. l If necessary press push button (Fig. 66) to

switch off vibration.
release = off.
l Shift the travel lever slowly to "0"-position. The
brake closes.
Fig. 67
l The parking brake warning light in the instru-

ment cluster (Fig. 67) lights up.

Operation
4.13 Shutting down the engine in

events of emergency
! Danger
Danger of accident!
In events of emergency and in case of danger
actuate the emergency stop switch immediate-
ly. Do not use the emergency stop switch as
service brake.
Restart the machine only after the danger that
Fig. 68
caused the actuation of the emergency stop
l Set the throttle lever (Fig. 68) to idle speed po- switch has been eliminated.
sition "Engine MIN".
i Note
Do not shut the engine down all of the sudden from
full speed, but let it idle for a while for temperature
equalization.
Fig. 70
l Press the emergency stop switch (Fig. 70).

Shuts the engine down immediately and closes
the brake.
Fig. 69
l Turn the ignition switch (Fig. 69) to position "0"

and pull the ignition key out.
Danger
!
Danger of accident!
Secure the machine against unauthorized use,
pull the ignition key out.
Mark machines, which could be in the way,
with a clearly visible sign.
Fig. 71
l For restarting turn the emergency stop switch

in direction of arrow to unlock (Fig. 71).

Operation
i Note
4.14 Adjusting the driver's seat
After operating the emergency stop switch the en-
gine cannot be started.
To start the engine the travel lever must be in
“Neutral”-position.
Fig. 72
Danger
!
Danger of accident!
Do not adjust the driver's seat while driving.
l Disengage the lever 1 (Fig. 72) and adjust the
seat in longitudinal direction.
l Pull the lever (2) up and adjust the backrest.
l Use lever (3) to adjust to the weight of the op-
erator.
i Note
In this adjustment the lever (3) is locked in up-
wards direction. If a lighter driver's weight is to be
adjusted, the lever must first be pressed down to
the stop in order to release the lock. Then adjust
again in downward direction.

Operation
Releasing the brakes on drum and rub-

4.15 Towing ber wheels (only AC-machines)
! Danger
Danger of accident!
Always secure the machine against unintend-
ed rolling.
Releasing the brake (only AD-ma-

chines)
Fig. 75
l Unscrew the locking bolt (Fig. 75).

l Switch the ball valve over.
Position "II" = Brake released
l Turn the steering wheel slowly approx. two
turns in clockwise direction.
Towing the machine

Fig. 73
l Remove two plugs (Fig. 73).
Fig. 76
Fig. 74 ! Caution
l Press both screws (Fig. 74) in against springs. Generally use the tow bar (Fig. 76), max. tow-
ing speed
l Tighten both screws alternately and in steps
1 km/h, max. towing distance 500 m.
with 35 Nm until they bottom.

Operation
Fig. 77 Fig. 79
l Tow the machine by the front or rear towing l Switch the ball valve back to position "I", turn
eye 1 (Fig. 77). the locking screw back in and counter it with
the hexagon nut (Fig. 79) (only AC-machines).
After towing
Danger
!
The machine must only be started without the

mechanical brake releasing device being acti-
vated.
l Completely release both screws (Fig. 74) to
close the brake.
l Screw both plugs (Fig. 73) back in.
Fig. 78
l Tighten the plugs (Fig. 78) (20 Nm).

Operation
4.16 Loading and transport
! Danger
Life hazard!
Use only stable loading ramps of sufficient
load bearing capacity. Make sure that persons
are not endangered by the machine tipping or
sliding off.
Always use shackles on the lifting points for
loading, tying or lifting the machine.
Lash the machine down, so that it is secured Fig. 81
against rolling, sliding and turning over. l Fold up the covers on front and rear frames.
Do not stand or step under loads being lifted. l Lash the machine to the transport vehicle, use
the lashing eyes (Fig. 81) on front and rear
frame for this purpose.
Fig. 80
l After driving the machine onto the transport

vehicle swing the articulation lock (Fig. 80) out Fig. 82
of its receptacle and fasten it with the bolt to l To lift the machine pull out the lifting eye from
the eye. Secure the bolt with the cotter pin. the bracket and hook it into the lifting gear (Fig.
82).

Operation
Loading weight: See technical data. Foldable ROPS*

After transport Fold down for transport
Fig. 85
Fig. 83
l Slacken the eyebolts (Fig. 85) and adjust the
l Pull the bolt out of the articulation locking bar
clamping plates vertical.
and swing the locking bar back into its recep-
tacle (Fig. 83). l Fold the foldable ROPS back.
Fold up after transport
Fig. 84
l Store the lifting eye in the bracket (Fig. 84). Fig. 86
l Adjust the clamping plates on both sides verti-

cal (Fig. 86).

Operation
Fig. 87
l Fold up the foldable ROPS (Fig. 87).

l Turn the clamping plates to horizontal position
and tighten the eyebolts with a tightening
torque of 75Nm to 200Nm.

Operation

5 Maintenance

Maintenance
l Do not let the hose stir up the slurry at the bot-

5.1 General notes on mainte- tom of the drum.
nance l Do not draw off fuel from near the bottom of
the drum.
l The rest in the drum is not suitable for the en-
When performing maintenance work always com- gine and should only be used for cleaning pur-
ply with the appropriate safety regulations. poses.
Thorough maintenance of the machine guaran-
tees higher functional safety of the unit and pro- Notes on the engine performance
longs the lifetime of important components. The On diesel engines both combustion air quantity
effort needed for this work is only little compared and fuel injection quantity are thoroughly adapted
with the problems that may arise when not observ- to each other and determine power, temperature
ing this rule. level and exhaust gas quality of the engine.
The terms right/left correspond with travel direc- If you engine has to work permanently in "thin air"
tion forward. (at higher altitudes) and under full load, you should
l Always clean machine and engine thoroughly consult the customer service of BOMAG or the
before starting maintenance work. customer service of the engine manufacturer.
l For maintenance work stand the machine on
level ground. Notes on the hydraulic system
l Perform maintenance work generally with the During maintenance work on the hydraulic system
engine stopped. cleanliness is of major importance. Make sure that
no dirt or other contaminating substances can en-
l Relieve hydraulic pressures before working on ter into the system. Small particles can produce
hydraulic lines. flutes in valves, cause pumps to seize, clog noz-
l Before working on electric parts of the ma- zles and pilot bores, thereby making expensive re-
chine disconnect the battery and cover it with pairs inevitable.
insulation material. l If, during the daily inspection of the oil level,
l When working in the area of the articulated the hydraulic oil level is found to have
joint attach the articulation lock (transport dropped, check all lines, hoses and compo-
lock). nents for leaks.
l Seal external leaks immediately. If necessary
Environment inform the responsible customer service.
During maintenance work catch all oils and fu- l Do not store drums with hydraulic oil outdoors,
els and do not let them seep into the ground or or at least under cover. Water can be drawn in
into the sewage system. Dispose of oils and fu- through the bunghole when the weather
els environmentally. changes.
l Always use the filling and filtering unit
Notes on the fuel system (BOMAG part-no. 007 610 01) to fill the hy-
The lifetime of the diesel engine depends to a draulic system. This unit is fitted with a fine fil-
great extent on the cleanliness of the fuel. ter to clean the hydraulic oil, thereby
prolonging the lifetime of the filter.
l Keep fuel free of contaminants and water,
since this will damage the injection elements l Clean fittings, filler covers and the area around
of the engine. such parts before disassembly to avoid enter-
ing of dirt.
l Drums with inside zinc lining are not suitable to
store fuel. l Do not leave the tank opening unnecessarily
open, but cover it so that nothing can fall in.
l The fuel drum must rest for a longer period of
time before drawing off fuel.

Maintenance
at least once per year, irrespective of the operating

5.2 Fuels and lubricants hours reached.
Oil quality
Engine oil
Lubrication oil are classified according to their per-
In order to assure perfect cold starting it is import
formance and quality class. Specifications accord-
to chose the viscosity (SAE-class) of the engine oil
ing to API* are commonly used.
according to the ambient temperature.
Permitted API-oils
CF/CF-4/CG-4
In regions where such qualities are not available
you should consult the engine manufacturer.
Lubrication oil change intervals
!Caution
These intervals apply only when using a diesel
fuel with maximum 0.5 % sulphur by weight
and for ambient temperatures higher than
-10 °C.
Fig. 88 API: CF/CF-4/
Lubrication oil with a too high viscosity index caus- CG-4 = 250 operating hours
es starting difficulties. The temperature when When using fuels with a sulphur content of more
starting the engine is therefore of highest impor- than 0,5% to 1% or under ambient temperatures
tance when choosing the viscosity of engine oil for below -10°C the oil change intervals must be
winter operation. halved.
For fuels with a sulphur content of more than 1%
Oil viscosity you should consult the responsible service agen-
Since lubrication oil changes its viscosity with the cy.
temperature, the ambient temperature at the oper-
ating location of the engine is of utmost impor- Fuels
tance when choosing the viscosity class (SAE-
class) (see diagram). Quality
Occasional falling short of the temperature limit You should only use commercially available brand
(e.g. use of SAE 15W/40 down to -15°C) may ef- diesel fuel with a sulphur content below 0.5% and
fect the cold starting ability of the engine, but will ensure strict cleanliness when filling in. A higher
not cause any engine damage. sulphur content has a negative effect on the oil
Temperature related lubrication oil changes can change intervals. Use only winter-grade diesel fuel
be avoided by using multi-purpose oils. The follow- under low ambient temperatures. The fuel level
ing oil change intervals apply also when using mul- should always be topped up in due time so that the
ti-purpose oils. fuel tank is never run dry, as otherwise filter and in-
jection lines need to be bled.
Regular lubrication oil changes The following fuel specifications are permitted:
DIN/EN 590; DIN 51 601; Nato Codes: F-54, F-75;
The longest permissible time a lubrication oil BS 2869: A1 and A2; ASTM D 975-78: 1-D and
should remain in an engine is 1 year. If the follow- 2-D.
ing oil change intervals are not reached over a pe-
riod of 1 year, the oil change should be performed
* American Petroleum Institute

Maintenance
Winter fuel Caution

!
For winter operation use only winter diesel fuel, to Do not mix different coolants and additives of
avoid clogging because of paraffin separation. At any other kind.
very low temperatures disturbing paraffin separa-
tion can also be expected when using winter diesel Observe the instructions of the manufacturer.
fuel.
In most cases a sufficient cold resistance can also
be achieved by adding flow enhancing fuel addi-
tives. Consult the engine manufacturer.
Hydraulic oil
The hydraulic system is operated with hydraulic oil
HV 46 (ISO) with a kinematic viscosity of
46 mm2/s at 40°C. For topping up or for oil chang-
es use only high-quality hydraulic oil, type HVLP
according to DIN 51524, part 3, or hydraulic oils
type HV according to ISO 6743/3. The viscosity 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 filled
with synthetic ester based biodegradable hydrau-
lic oil (Panolin HLP Synth. 46). The biologically
quickly degradable hydraulic oil meets all de-
mands of a mineral oil based hydraulic oil accord-
ing to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.
46 always use the same oil to top up. When
changing from mineral oil based hydraulic oil to an
ester based biologically degradable oil, you should
consult the lubrication oil service of the oil manu-
facturer for details.
Check the filter more frequently after this change.
Coolant
For the coolant mixture use only clean tap water
(drinking water) and anti-freeze agent acc. to SAE
J1034 or SAE J814c.
As a protection against frost, corrosion and boiling
point anti-freeze agents must be used under any
climatic conditions.
The proportion of cooling system protection agent
must be between min. 35% and max. 50% to the
water.

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 API: CF/CF-4/CG-4 approx. 6.5 litres
up to max. dipstick mark
SAE 10W/40 (-20 °C to +30 °C)
SAE 15W/40
(-10°C to + 40°C)
SAE 30 SAE 10W
(+5 °C to +30 °C) (-5 °C to -30 °C)
SAE 40 SAE 20W/20
(+25°C to +40°C) (+10°C to -10°C)
Fuel
Diesel Winter diesel fuel (down 40 litres

to -12 °C)
Cooling system Coolant
Water + anti-freeze 4l
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 28 litres (tank ca-
pacity)
46 mm2/s at 40 °C
or biodegradable hydraulic oil,
ester based
Sprinkler system Water Anti-freeze mixture as required
Water* 220 litres
Sprinkling of tires Emulsion 20 litres
* Mix water and anti-freeze agent by following the instructions of the manufacturer

Maintenance
5.4 Running-in instructions
i Note
The maintenance plan under the engine hood
helps with the maintenance work!
Maintenance after 50 operating hours
With new or totally overhauled engines you should
generally:
l Change the engine oil.
l Change the engine oil filter.
l Check the engine for leaks
l Tighten the fastening screws on air filter, ex-
haust manifold, and other attachments.
!Caution
Retighten the cylinder head fastening screws
to the engine.
Maintenance after 200 operating hours

l New engines normally have a higher oil con-
sumption. It is recommended to check the oil
level twice every day during the running-in pe-
riod.
l After the running-in period it is quite sufficient
to check the oil level once every day.
l Check and retighten the screws on the ma-
chine.
l Watch out for leaks.

Maintenance
5.5 Maintenance chart
every 10 operating hours, daily
every 1000 operating hours


after 50 operating hours
Running-in instructions
No. Maintenance work Remark
as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the coolant level X
5.8 Check the water separator X
5.9 Check the fuel level X
5.10 Check the hydraulic oil level Dipstick mark X
5.11 Checking the hydraulic oil filter element contamination X
indicator
5.12 Check the water level Display gauge X
5.13 Checking the emulsion level only AC-ma- X
chines
5.14 Check the tire pressure X
5.15 Cleaning radiator and hydraulic oil cool- X
er
5.16 Check, tension, replace the V-belt X
5.17 Checking, adjusting the scrapers X
5.18 Checking radiator hoses and hose X
clamps
5.19 Changing the engine oil at least 1x per X X
year
5.20 Changing the engine oil filter cartridge with each oil X X
change
5.21 Service the battery Pole grease X
5.22 Drain the sludge from the fuel tank X
5.23 Change the fuel pre-filter cartridge X

Maintenance
every 10 operating hours, daily


after 50 operating hours
Running-in instructions
No. Maintenance work Remark
as required
5.24 Check, adjust the valve clearance Intake and ex- X
haust = 0.18 to
0.22 mm
on cold engine
5.25 Change the fuel filter cartridge X
5.26 Check the engine mounts X X
5.27 Change hydraulic oil and breather filter* at least every 2 X
years
5.28 Change the hydraulic oil filter** at least every 2 X
years
5.29 Replace fuel hoses and hose clamps at least every 2 X
years
5.30 Change the coolant at least every 2 X
years
5.31 Check the injection valves X
5.32 Checking the fuel injection pump X
5.33 Cleaning, changing the dry air filter car- min. 1x per year, X
tridge safety cartridge
at least every 2
years
5.34 Cleaning the water sprinkler system X
5.35 Water sprinkler system, maintenance in X
case of frost
5.36 Tightening torques X
5.37 Engine conservation X
* Also in case of repair in the hydraulic system.
** Also in case of repair in the hydraulic system.

Every 10 operating hours
Every 10 operating hou rs
5.6 Check the engine oil level 5.7 Check the coolant level
i Note ! Caution
Park the machine on level ground so that the en- Check and change coolant only when the en-
gine is in horizontal position. gine is cold.
If, during the daily inspection the coolant level
is found to have dropped, check all lines, hos-
es and engine for leaks.
Fig. 89
l Shutting the engine down

l Pull the dipstick (Fig. 89) out, wipe it off with a
lint-free, clean cloth and reinsert it until it bot- Fig. 90
toms. l Check the coolant level in the compensation
l Pull the dipstick back out again. tank (Fig. 90).
l The oil level should reach the upper mark l To top up unscrew the filler cap and fill in cool-
(MAX) on the dipstick. ant up to the MAX-mark.
l If the oil level is too low top up oil immediately. For quality of coolant refer to the chapter 5.2,
fuels and lubricants.
For quality and quantity of oil refer to the ”ta-
ble of fuels, lubricants and filling capacities”.

5.8 Check the water separator 5.9 Check the fuel level
i Note ! Danger
The service intervals for the water separator de- Fire hazard!
pend on the water content in the fuel and can
When working on the fuel system do not use
therefore not be determined precisely. After taking
open fire, do not smoke.
the engine into operation you should therefore
check the water separator every day for signs of Do not refuel in closed rooms.
water.
! Caution
Environment Fill in fuel through the filter screen.
Catch running out fuel and dispose of environ- l Clean the area around the filler opening.
mentally.
Fig. 92
Fig. 91
l Open the fuel filler cap (Fig. 92) and check the
l Slacken the drain plug (Fig. 91) for a few turns fuel level visually.
and catch running out fuel / water.
l If necessary top up with fuel (diesel or winter
l Tighten the drain plug again and check for diesel), see table of fuels and lubricants.
leaks, if necessary replace the seal ring.

5.10 Check the hydraulic oil level 5.11 Checking the hydraulic oil
filter element
! Caution
If, during the daily inspection of the oil level i Note
the hydraulic oil level is found to have If the hydraulic oil is very cold the pin may pop up,
dropped, check all lines, hoses and compo- you should therefore only check the filter and
nents for leaks. press the pin in at operating temperature.
In hydraulic systems filled with Panolin HLP
Synth. 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.
l Clean the area around the filler opening.
l Remove the filler cap.
Fig. 94
l Check the service indicator 1 (Fig. 94) at oper-

ating temperature and with the engine running
at maximum speed.
l If necessary press the pin in.
Pin remains
pressed in = Hydraulic oil filter element o.k.
Fig. 93
Pin pops out = Replace the hydraulic oil filter
l Check the oil level on the dipstick. The oil level element
must be between the "MIN" and "MAX" marks
(Fig. 93).
l If the oil level is too low top up hydraulic oil im-
mediately.
For quality and quantity of oil refer to the ”ta-

ble of fuels and lubricants”.

5.12 Check the water level 5.13 Checking the emulsion level
i Note i Note
If there is a risk of frost observe the special service For mixing ratio of water and emulsion refer to the
instructions under "water sprinkler system, main- specification of the respective manufacturer.
tenance in case of frost".
Make sure that the ventilation bore in the filler cap
is free.
Fig. 97
l Unscrew the cover (Fig. 97) and check the

emulsion level, fill up if necessary.
Fig. 95
l Check the water tank filling level on the water

level gauge (Fig. 95).
Fig. 96
l Open the cap (Fig. 96) and check the water

level.
l If necessary fill in water through the filler
screen and close the cap again.

Every 250 oper ating hours
5.14 Checking the tire pressure 5.15 Cleaning radiator and hy-
draulic oil cooler
i Note
Only AC-machines ! Danger
Danger of injury!
Do not perform cleaning work while the engine
is running.
Cleaning with compressed air
Fig. 98
l Check the tire pressure with a pressure gauge

(Fig. 98).
Nominal value: approx.2.2 bar
i Note Fig. 99
Ensure equal pressure in all rubber tires! l Blow the cooling air passages out with com-
pressed air from the air discharge side (Fig.
99).
Fig. 100
l Blow out the air supply side of the hydraulic oil

cooler (Fig. 100).

Cleaning with cold cleansing agent

5.16 Checking, tensioning, re-
! Caution
placing the V-belt
Protect electrical equipment such as genera-
tor, regulator and starter against the direct wa-
ter jet.
! Danger
Danger of accident!
l Spray engine and cooler with a suitable
cleansing agent, e.g. cold cleanser, let it soak Perform this work only with the engine shut
in for a while and spray it off with a strong wa- down.
ter jet.
l Run the engine warm for a while to avoid cor- Checking the V-belt
rosion.
Fig. 101
l Check the entire circumference of the V-belt

(Fig. 101) for damage and cracks. Replace
damaged or cracked V-belts.
l Check with thumb pressure whether the V-belt
can be depressed more than 7 to 9 mm be-
tween the V-belt pulleys, retighten if neces-
sary.

Tensioning the V-belt Caution

!
Check the V-belt tension again after a running

time of 30 minutes.
Fig. 102
l Slacken the fastening screws 1 and 2 (Fig.

102) slightly.
l Press the generator in direction outward using
a lever, until the correct V-belt tension is
reached.
l Retighten all fastening screws and check the
V-belt tension once again.
Changing the V-belt
Fig. 103
l Slacken the fastening screws 1 and 2 (Fig.

103) slightly.
l Press the generator completely against the
engine.
l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
l Tension the V-belt as previously described.

Wheels on AC-machines
5.17 Checking, adjusting the
scrapers
Drums
i Note
If the scrapers (2 per drum) are worn, they must be
adjusted or replaced.
Fig. 105
l Open the rear flap, check the scrapers, re-

place if necessary (Fig. 105).
l Adjust the scraper with the screws, so that it
has a uniform distance of approx. 2 mm to the
rubber tires.
Fig. 104
l Open the flap, check the scrapers, replace if

ncessary.
l If necessary adjust the scrapers after slacken-
ing the hexagon screws (Fig. 104).

5.18 Checking radiator hoses

and hose clamps
! Danger
Danger of burning!
Perform inspection work only after the engine
has cooled down and with the engine stopped.
! Caution
If a radiator hose is swollen, hardened or
cracked, both hose and hose clamp must be
replaced immediately.
Fig. 106
l Check the conditon and tight fit of all readiator

hoses and hose clamps (Fig. 106).

Every 500 operating h ours
5.19 Changing the engine oil
! Caution
The oil change at 250 operating hours refers to
the use of oils of oil quality class API CF, CF-4
or CG-4 and a fuel sulphur content of less than
0.5%.
When using fuels with a sulphur content high-
er than 0.5% the oil change intervals must be
halved (see section 5.2 fuel and lubricants).
Drain the engine oil only when the engine is Fig. 108
warm.
l Unscrew the left hand drain plug (Fig. 108)
and catch running out oil.
! Danger
l Turn the drain plug tightly back in.
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. 109
l Fill in new engine oil (Fig. 109).
For quality and quantity of oil refer to the table

of fuels and lubricants.
l Tighten the oil filler cap properly.
Fig. 107
l Unscrew the oil filler plug (Fig. 107).

5.20 Changing the engine oil fil-

ter cartridge
! Caution
The oil change at 250 operating hours refers to
the use of oils of oil quality class API CF, CF-4
or CG-4 and a fuel sulphur content of less than
0.5%.
When using fuels with a sulphur content high-
er than 0.5% the oil change intervals must be
Fig. 110 halved (see section 5.2 fuel and lubricants).
l Check the oil level again after a short test run Drain the engine oil only when the engine is
(Fig. 110), if necessary fill up to the Max.- warm.
mark.
Danger
!
Danger of scalding!
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. 111
l Unscrew the filter cartridge 1 (Fig. 111) using

an appropriate filter wrench.
l Clean the sealing face on the filter carrier from
any dirt.

5.21 Service the battery
! Danger
Danger of explosion, causticization!
When working on the battery do not use open
fire, do not smoke!
Do not let acid come in contact with skin or
clothes!
Wear safety goggles!
Fig. 112 Do not lay any tools on the battery!
l Slightly oil the rubber seal on the new filter car- For recharging remove the plugs from the bat-
tridge (Fig. 112). tery to avoid the accumulation of highly explo-
sive gases.
l Turn the new filter cartridge on by hand, until
the seal contacts.
! Caution
l Tighten the filter element for another half turn.
Dispose of the old batteries environmentally.
l Check the filter cartridge for leaks after a short
test run.
Maintenance free batteries:
Fig. 113
l Disassemble the covering flap of the battery

compartment (Fig. 113).

5.22 Drain the sludge from the

fuel tank
! Danger
Fire hazard!
Environment
Fig. 114 Do not spill any fuel.
l Clean battery and battery compartment (Fig. Catch running out fuel, do not let it seep into
114). the ground.
l Clean battery poles and pole clamps and
grease them with pole grease (Vaseline). i Note
l Tighten the terminal clamps. When performing this work the fuel tank shall only
hold max. 5 litres of fuel, pump off if necessary.
l Check the fastening of the battery.
Non-maintenance free batteries:

l Clean battery and battery compartment.
Caution
!
Top up missing fluid with distilled water.

l Unscrew the plugs and check the acid level, if
necessary top up with distilled water.
With control inserts

The acid level must reach the bottom of the control
inserts.
Fig. 115
Without control inserts l Unscrew the plug (Fig. 115) from underneath
The acid level must reach 10 to 15 mm above the the fuel tank and let the fuel run out.
upper edge of the lead plates. l Once all fuel has run out screw the oil drain
plug back in with a new seal ring.
i Note
Measure the acid level with a clean wooden stick.
With transparent battery housing

The acid level must reach the mark on the hous-
ing.
l Clean battery poles and pole clamps and
grease them with pole grease (Vaseline).
l Tighten the terminal clamps.
l Check the fastening of the battery.

5.23 Changing the fuel pre-filter
! Danger
Fire hazard!
Do not spill any fuel.
! Caution
Environmental damage!
Catch running out fuel, do not let it seep into
the ground.
Fig. 116
l Loosen the hose clamps (Fig. 116).

l Pull the fuel filter out of the hoses.
l Install the new fuel filter by observing the flow
direction (arrow).

5.24 Check, adjust the valve

clearance
i Note
Check and adjust only when the engine is cold.
Caution
!
The first cylinder is the one nearest to the cool-

ing fan side.
Fig. 119
Crankshaft position 1 (Fig. 119)

l Crank the engine with the starter or a spanner
by the V-belt pulley until both valves on cylin-
der 1 are “overlapping”.
Overlapping means: Exhaust valve not yet closed,
intake valve starts to open.
l Perform the adjustment of the valve by follow-
ing the adjustment diagram "crankshaft posi-
tion 1", black mark.
l For control purposes mark the respective rock-
Fig. 117 er arm with while chalk once the correspond-
l Remove the valve cover (Fig. 117). ing valve is adjusted.
Valve adjustment schematic
Fig. 120
Crankshaft position 2 (Fig. 120)

Fig. 118 l Turn the crankshaft one revolution (360°) fur-
Valve 1 (Fig. 118) white = not adjustable ther.
Valve (2) black = adjustable l Perform the adjustment of the valve by follow-
ing the adjustment diagram "crankshaft posi-
tion 2", black mark.
I = Intake valve

E = Exhaust valve
5.25 Changing the fuel filter car-
l Check the black valves (Fig. 119) on cylinders
1, 2 and 3, adjust if necessary. tridge, bleeding the fuel
system
Danger
!
Fire hazard!
open fire, do not smoke and do not spill any fu-
el.
Environment
Fig. 121 the ground.
l Check the gap between rocker arm and valve Dispose of used filter cartridges and diesel
with a feeler gauge (Fig. 121). fuel in compliance with local regulations.
Valve clearance:
Intake valve and exhaust valve 0,18 – 0.22 mm.
l If the gap is too wide or too narrow for the feel-
er gauge, the valve clearance must be adjust-
ed.
i Note
Mark checked and adjusted valves with chalk.
l Assemble the cylinder head cover with a new
gasket.
i Note
Fig. 122
After a short test run check the engine for leaks.
l Slacken and unscrew the fuel filter cartridge
(Fig. 122).
l Clean the sealing face on the filter carrier from
any dirt.
l Apply a thin film of fuel to the seals and screw
the filter on hand-tight.
Bleeding of the fuel system
!Caution
Fire hazard!
Do not bleed the engine while it is hot, running
out fuel dripping on the hot exhaust can cause
a fire.

5.26 Check the engine mounts
Fig. 123
l Open the bleeding screw (Fig. 123) on the top

end of the injection pump.
Fig. 125
l Check the fastening of intake and exhaust

tubes (Fig. 125) on the cylinder heads for tight
fit.
l Check sockets and clamps on the air filter for
tight fit and leak tightness.
l Check fastening and tightness of the lubrica-
tion oil sump.
Fig. 124
l Operate the fuel pump (Fig. 124) until fuel runs

out of the bleeding screw without air bubbles.
l Retighten the bleeding screw.
Fig. 126
l Check the condition and tight fit of the engine

pillow blocks (Fig. 126).

Every 2000 operating hour s
5.27 Change the hydraulic oil
! Danger
Danger of scalding!
Danger of scalding by hot oil.
! Caution
Perform the oil change when the hydraulic oil
is warm.
Apart from the normal oil change intervals, the Fig. 127
hydraulic oil must also be changed after major l Remove the cover from the hydraulic oil tank
repairs in the hydraulic system. (Fig. 127).
Do not use any detergents to clean the system.
Do not start the engine after draining the hy-
draulic oil. Do not run the pumps without oil.
Replace the hydraulic oil filter element with
every hydraulic oil change.
When changing from mineral oil based hydrau-
lic oil to an ester based biologically degradable
oil, you should consult the lubrication oil serv-
ice of the oil manufacturer for details.
Environment
Environmental damage!
Catch old oil and dispose of environmentally. Fig. 128
l Unscrew the right hand plug (Fig. 128), drain

off and collect all hydraulic oil.
i Note
Generally replace the hydraulic oil filter element l Turn the plug tightly back in.
after the test run.
l Drive the machine, until the hydraulic oil has i Note
reached operating temperature. We recommend to use the filling and filtering unit
l Shut down the engine. (BOMAG part-no. 079 930 35) with fine filter to fill
the hydraulic system. This ensures finest filtration
of the hydraulic oil, prolongs the lifetime of the hy-
draulic oil filter and protects the hydraulic system.

Fig. 129 Fig. 131
l Fill in new hydraulic oil (Fig. 129). l Close the tank with a new cover (Fig. 131).
l Perform a test run and check the system for
leaks. i Note
For quality and quantity of oil refer to the table The breather filter for the hydraulic oil tank is inte-
of fuels and lubricants. grated in the filler cap, you must therefore replace
the complete filler cap.
Fig. 130
l Check the hydraulic oil level on the dipstick

(Fig. 130).

5.28 Changing the hydraulic oil

filter
! Danger
Danger of scalding!
Danger of scalding by hot oil when unscrewing
the oil filter.
! Caution
If the filter has to be changed together with the Fig. 132
hydraulic oil, the filter must only be changed
after the oil change and after the test run. l Unscrew spigot nut 4 (Fig. 132) and take off fil-
ter bowl (5) with filter element (3).
Do not use the oil in the filter bowl again.
l Examine the surface of the filter element thor-
Visible dirt may be an early sign for the failure oughly for any visible dirt.
of system components and indicate the possi-
ble failure of components. In this case deter- l Take the old filter element (3) out, clean the fil-
mine the cause and replace or repair the ter bowl and thread.
defective components, if necessary. Negli- l Assemble the filter bowl with new filter ele-
gence may cause destruction to the entire hy- ment, check the condition of O-rings (1) and
draulic system. (2), if necessary use new ones.
Do not clean or reuse the filter element. l After a short test run check the filter for leaks.
Apart from the normal oil change intervals, the
filter element must also be changed after major
repairs in the hydraulic system.
Environment
Catch running out oil, dispose of oil and filter
element environmentally.

5.29 Change the coolant
! Danger
Danger of scalding!
Change the coolant only when the engine is
cold.
Do not remove the radiator cap when the en-
gine is still hot.
Always wear gloves when handling anti-freeze
agent.
Fig. 134
l Unscrew the drain plug (Fig. 134).

Caution
!
Always screw the radiator cap tightly back on l Drain the coolant completely off and collect it.
(second detent). l SCrew the drain plug back in.
Always fill the engine cooling system with an
anti-freeze mixture (corrosion protection).
Do not use more than 50% anti-freeze.
Do not mix different types of anti-freeze.
Environment
Catch running out coolant and dispose of envi-
ronmentally.
Fig. 135
l Open the drain cock (Fig. 135).

l Drain the coolant completely off the engine
block and collect it.
l Close the shut-off cock again
l Empty the coolant compensation tank.
l Check the condition of radiator hoses, if nec-
essary replace all radiator hoses.
Fig. 133
l Remove the radiator cap (Fig. 133).

l Disassemble the left hand side plate from the
front frame.

5.30 Changing fuel lines
i Note
For safety reasons this work should be performed
every two years.
Hoses consist of rubber or plastic material and age
over the course of time.
Danger
!
Fire hazard!
Fig. 136
l Fill in coolant until the level reaches the bottom
open fire, do not smoke and do not spill any fu-
edge of the filler socket (Fig. 136).
el.
Environment
the ground.
l Replace all fuel hoses, including their hose
clips.
Fig. 137
l Fill in coolant up to the “MAX” mark (Fig. 137).
For quality of coolant refer to the chapter 5.2,

fuels and lubricants.
l Reattach radiator cap and cap of the compen-
sation tank.
l Start the diesel engine and run it warm to op-
erating temperature.
l Let the engine cool down and check the cool-
ant level again, if necessary top up in the com-
pensation tank.

5.31 Check the injection valves 5.32 Checking the fuel injection
pump
i Note
This work must only be performed by authorized i Note
service personnel.
This work must only be performed by authorized
service personnel.

As required
As requir ed
5.33 Check, clean, change the

combustion air filter
! Caution
Perform cleaning, maintenance and repair
work only with the engine shut down. Do not
start the engine after removing the filter ele-
ment.
Do not use gasoline or hot fluids to clean the
filter element.
After cleaning the filter element must be in- Fig. 138
spected for damage using a torch. Service of the dry air filter is due when the red pis-
Air filter elements with damaged paper bellows ton of the filter service indicator (Fig. 138) reaches
or seal lips must be replaced in any case. into the transparent window, but at the latest after
one year.
The main filter element must be replaced after
3 times cleaning, but at the latest after one
year, irrespective of the operating hours. ! Caution
Each cleaning interval must be marked with a After cleaning the air filter press the reset but-
cross on the cover of the filter element. ton for the red piston on the filter service indi-
cator.
Cleaning does not make sense if the air filter
element is covered with a sooty deposit. Use a
new filter element.
Incorrectly handled filter elements may be-
come ineffective because of damage (e.g.:
cracks) and cause engine damage.
l Open the engine hood.
i Note
Under very dusty conditions you may have to
check the filter service indicator every day.
Fig. 139
l Release the locking hook (Fig. 139) and take

the filter hood off.
l Clean filter hood and dust discharge valve.

As required
Fig. 140 Fig. 142
l Carefully loosen the main filter element (Fig. l Clean the sealing face on the outlet tube (Fig.
140). 142).
The main filter element is located directly on the air Dust on the outer diameter of the outlet tube can
intake tube, thereby providing a seal on the inside impair effective sealing.
of the filter cover. Carefully remove the main filter
l Check the old main filter element.
element, in order to reduce the released amount of
dust. To release the seal pull the main filter ele- The old main filter element can be of help to dis-
ment carefully up, down and sideways or turn it cover foreign particles on the sealing face, which
(Fig. 140). could lead to leaks. A line of dust on the clean air
side of the filter may be a sign for such a leak.
Eliminate this problem before installing a new
Caution
!
main filter element.
Avoid contact between main filter element and
l If the main filter element is damaged, the safe-
housing.
ty element must be replaced as well.
l Clean or replace the main filter element.
i Note
We generally recommend to change the filter. A
new filter element is far less expensive than a pos-
sible engine damage.
l Examine the main filter element thoroughly for
damage.
Before installing the new main filter element check
it for possible damage from transport, cleaning or
incorrect handling. Especially on the inside of the
open end (sealing area). Do not install damaged
Fig. 141
filter elements.
l Pull the main filter element (Fig. 141) carefully
l If necessary use safety elements.
out of the housing.

As required
Fig. 143 Fig. 144
l Insert the main filter element (Fig. 143).

The radial sealing area is located at the inside of i Note
the open filter edge. This critical sealing area must For cleaning purposes fit a tube to the compressed
be under slight tension after the filter has been in- air gun (Fig. 144), the end of which should be bent
stalled. In order to achieve a tight seal apply pres- for approx. 90°.
sure to the outer edge of the filter and not to the The length should reach down to the bottom of the
moveable centre. element.
l Reinstall the filter hood with the dust discharge l Blow the main filter element out with com-
valve. pressed air (max. 5 bar) from inside to outside
by moving the tube up and down inside the el-
Caution
! ement, until it if free of dust.
The dust discharge valve must point vertically l Examine the main filter element with a torch
downwards. for cracks and holes in the paper bellows.
Dry cleaning of the main filter element Caution

!
Do not continue to use a damaged main filter

! Danger element. If in doubt use a new main filter ele-
Eye injury! ment.
Wear protective clothing (goggles, gloves).

Changing the safety filter element
Caution
!
The safety filter element must not be cleaned

and should not be used again after it has been
removed.
The safety filter element must be replaced:
if the main filter element is defective,
after three times cleaning of the main filter ele-
ment,
at the latest after 2 years,

As required
if the red piston of the filter service indicator is

visible again after completion of the service 5.34 Cleaning the water sprinkler
work. system
l Remove the housing cover and pull the main
filter element off.
i Note
If there is a risk of frost observe the special service
instructions under "sprinkler system, maintenance
in case of frost".
Fig. 145
l Pull the safety element (Fig. 145) out by turn-

ing it lightly.
l Push in a new safety filter element.
Fig. 146
l Reassemble main filter element and cover.
l Remove the water tank cover (Fig. 146).
Fig. 147
l Open the covering flap (Fig. 147) on the right

hand side of the rear frame.

As required
l Screw the olastic caps back on again.

l Check the function of the sprinkler tubes, if
necessary clean or replace the nozzles.
Environment
Catch and dispose of old emulsion environ-
mentally.
l Empty the emulsion tank*.
Fig. 148
l Take out the drain hose (Fig. 148).

l Open the drain tap, let all water run out and
close the drain tap again.
Fig. 150
l Loosen the fitting, take the emulsion filter (Fig.

150) out and clean it.
l Flush the emulsion tank thoroughly.
l Reinsert the emulsion filter and tighten the fit-
ting.
Fig. 149
l Unscrew the water hose at the water filter (Fig.

149).
l Unscrew the water filter from the water tank.
l Unscrew the filter element from the cover,
clean it and screw it back onto the cover.
l Flush the water tank out with a strong water
jet.
l Let all water with dirt run out.
l Screw the cover with the filter element back
on.
Fig. 151
l Unscrew the plastic caps from the end of the
sprinkler tube. l Fill the emulsion tank (Fig. 151).
l Fill the water tank with clean water. l Check the function of the sprinkler tubes, if
necessary clean or replace the nozzles.
l Activate the sprinkler system for a short while
so that all lines are flushed out.
* AC-machines

As required
5.35 Draining the water sprinkler

system, maintenance in
case of frost
! Caution
If there is a risk of frost the water sprinkler sys-
tem must be completely emptied or filled with
an anti-freeze mixture.
In this case frost protection measures are of
greatest importance in order to avoid freezing
Fig. 154
of sensitive components like pump, solenoid
valve and water filter. l Take out the drain hose (Fig. 154), open the
drain tap and let all water run out.
Draining the water sprinkler system
Fig. 155
Fig. 152 l Open the hose coupling (Fig. 155) and let the
water run out.
l Remove the water tank cover (Fig. 152).
Filling the sprinkler system with anti-

freeze mixture
l Close drain tap and drain hose.
l Join the hose couplings together.
l Fill the water tank with approx. 5 l of anti-
freeze mixture (water and anti-freeze agent).
l Switch the sprinkler system on, until anti-
freeze mixture comes running out of the sprin-
kler tubes.
Environment
Fig. 153 After the frost period drain off the anti-freeze
l Open the covering flap (Fig. 153) on the right mixture and dispose of environmentally.
hand side of the rear frame.

As required
5.36 Tightening torques for 5.37 Engine conservation

screws with metric unified
If the engine is to be shut down for a longer period
thread of time (e.g. over winter), we recommend to apply
the following conserving measures to avoid corro-
sion:
l Clean the engine, including the cooling sys-
tem: With cold cleansing agent and a water jet
or, even better, with a steam cleaner.
l Run the engine warm and shut it down.
l Drain off the still hot engine oil and fill in anti-
corrosion engine oil.
l Drain off the coolant and fill in system protec-
tion agent.
l Drain the fuel from the tank, mix it well with
Fig. 156 10% anti-corrosion oil and fill it back in.
* Strength classes for screws with untreated, non- l Run the engine for 10 minutes until all lines, fil-
lubricated surface. Screw quality designations are ters, pumps and nozzles with this conserving
stamped on the screw heads. mixture and the new engine oil has been dis-
8.8 = 8G tributed to all parts.
10.9 = 10K l Now crank the engine several times (without
12.9 = 12K ignition) to spray the combustion chambers.
The values result in a 90% utilization of the screw's l Take the V-belts off and spray the grooves of
yield point at a coefficient of friction µ total = 0,14. the V-belts with anti-corrosion oil. Remove the
anti-corrosion oil before resuming operation.
Compliance with the tightening torque is checked
with torque wrenches. l Close intake and exhaust openings tightly.
The specified tightening torques do not apply
when using MoS2 lubricants. i Note
Depending on the weather conditions these con-
i Note serving measures will provide protection for ap-
Self-locking nuts must always be replaced once prox. 6 to 12 months.
they have been unscrewed. Before taking the engine back into operation all
conserving oil must be drained off and replaced by
regular engine oil, see chapter "Fuels and Lubri-
cants" according to the API-(MIL)-classification.
Anti-corrosion oils are those that comply with

the specification MIL-L-21260 B or TL 9150-
037/2 or Nato Code C 640/642.
A machine with a conserved engine must be

marked by attaching a clearly visible warning
tag.

6 Trouble shooting

Trouble shooting
6.1 General notes
The following work must only be carried out by

qualified and trained personnel or by the
BOMAG sales service.
Please observe strictly the safety regulations

in chapter 2 of these operating and mainte-
nance instructions.
Faults occur frequently due to the fact, that the
machine has not been properly operated or serv-
iced. Therefore, whenever a fault occurs, read
through these instructions on correct operation
and maintenance. If you cannot locate the cause
of the fault or eliminate it yourself by following the
trouble shooting charts, you should contact our
customer service departments at our branch office
or dealers.
On the following pages you will find a selection of
fault remedies. It is quite obvious that we were not
able to list all possible causes for faults.

Trouble shooting
6.2 Engine
Faults Possible cause Remedy
The engine Fuel tank empty Fill the tank

does not start
Fuel filter clogged,in winter due to paraffin Change the filter Use winter fuel
separation
Fuel lines leaking Check all line connections for leakages

and tighten the fittings.
Travel lever not in "0"-position Move the travel lever to "0"-position
Battery discharged or not connected Charge the battery, check the terminal
clamps
Operating error see chapter "Starting the engine"
Incorrect valve clearance Adjust the valve clearance
Lack of oil Top up engine oil
Emergency stop switch is engaged. Emergency stop switch is unlocked.
The engine Battery power too low Have the battery inspected
starts poorly and
works irregularly Battery clamps loose or oxidized, causing Clean the terminal clamps, tighten them
with poor power the starter to turn too slowly and cover them with acid free grease
Especially during winter: the use of too Use engine oil suitable for the ambient
viscous engine oil temperature
Insufficient fuel supply, clogging of the Change the fuel filter Check the line con-
fuel system due to paraffin separation in nections for leaks and tighten the fittings.
winter Use winter fuel in the cold season.
Incorrect valve clearance Adjust the valve clearance
Injection valves or injection pump defec- Have examined by a specialist

tive
Air filter cartridge dirty Clean, change if necessary
Excessive play in the throttle cable Adjust the throttle cable, change it if nec-
essary
Engine loses Engine oil level too high Drain the oil to the upper dipstick mark
power and
speed, exces- Poor fuel quality Use specified fuel
sive exhaust Air filter dirty Clean, change if necessary
smoke
Poor compression due to burned or bro- Have compression rings and pistons ex-
ken compression rings or incorrect valve amined by a specialist, adjust the valve
clearance clearance
Injection valve defective Have examined by a specialist

Trouble shooting
Faults Possible cause Remedy
Engine over- Radiator excessively soiled Clean the cooling fins

heats, shut
down immedi- Coolant level to low Top up coolant.Danger! Only when the
ately! engine is cold
Injection valve defective Have examined by a specialist
Engine oil level too low Top up engine oil to the upper dipstick
mark
Filling capacity of the injection pump not Have adjusted by a specialist

correctly adjusted
Lack of cooling air at the cooling air blow- Clean the cooling air duct
er
V-belt loose or broken Tension or replace the V-belt
Air filter cartridge dirty Clean, change if necessary
Engine oil pres- Leakages in the lubrication system, oil Check fittings on oil lines, lubrication oil fil-
sure too low, level too low ter for leaks, tighten the fittings if neces-
shut down im- sary. Top up lubrication oil up to the upper
mediately mark on the dipstick.
Engine oil of wrong SAE-class Change the engine oil.
The charge con- The generator does not charge the bat- Have examined by a specialist
trol light lights tery, because generator or regulator is de-
during operation fective

BW120AD 4 - Operation Maintenance

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Operating instructions

BW 100 AD-4 / BW 120 AD-4

Tandem Vibratory Roller

No warranty claims can be lodged in case of dam-

BW 100/120 AD/AC-4 BOMAG 3

4 BOMAG BW 100/120 AD/AC-4

BW 100/120 AD/AC-4 BOMAG 5

5.19 Changing the engine oil 72

6 BOMAG BW 100/120 AD/AC-4

BW 100/120 AD/AC-4 BOMAG 7

* BW 100 AD-4 BW 120 AD-4

8 BOMAG BW 100/120 AD/AC-4

* BW 100 AD-4 BW 120 AD-4

Water sprinkler system

BW 100/120 AD/AC-4 BOMAG 9

10 BOMAG BW 100/120 AD/AC-4

* BW 100 AC-4 BW 120 AC-4

Water sprinkler system

BW 100/120 AD/AC-4 BOMAG 11

guaranteed sound capacity level of the machine:

Vibration of the entire boy (driver’s seat)

Hand-arm vibration values

12 BOMAG BW 100/120 AD/AC-4

BW 100/120 AD/AC-4 BOMAG 13

General Notes Unintended use

Paragraphs marked like this highlight possible

14 BOMAG BW 100/120 AD/AC-4

i Note Checking the roll over protection

BW 100/120 AD/AC-4 BOMAG 15

16 BOMAG BW 100/120 AD/AC-4

Behaviour in traffic Fire protection measures

BW 100/120 AD/AC-4 BOMAG 17

18 BOMAG BW 100/120 AD/AC-4

wheel studs or nuts. Do not drive with damaged

After maintenance work

BW 100/120 AD/AC-4 BOMAG 19

20 BOMAG BW 100/120 AD/AC-4

BW 100/120 AD/AC-4 BOMAG 21

22 BOMAG BW 100/120 AD/AC-4

1 Instrument cluster 11 Interval switch for pressure sprinkler system

BW 100/120 AD/AC-4 BOMAG 23

3.1 General notes 3.2 Description of indicators

24 BOMAG BW 100/120 AD/AC-4

h green Position "mid-

BW 100/120 AD/AC-4 BOMAG 25

26 BOMAG BW 100/120 AD/AC-4

BW 100/120 AD/AC-4 BOMAG 27

(3) 10A = (F04) gauges

28 BOMAG BW 100/120 AD/AC-4

BW 100/120 AD/AC-4 BOMAG 29

30 BOMAG BW 100/120 AD/AC-4

Foot switch for flow divider* (only AD)

BW 100/120 AD/AC-4 BOMAG 31

32 BOMAG BW 100/120 AD/AC-4

BW 100/120 AD/AC-4 BOMAG 33

4.1 General notes 4.2 Inspections before starting

Please observe strictly the safety regulations

34 BOMAG BW 100/120 AD/AC-4

4.3 Starting the engine Fasten/release your seat belt *.

l Always start the engine from the driver’s seat Open

l Press the release button on the buckle and

l Fasten your seat belt (Fig. 32).

BW 100/120 AD/AC-4 BOMAG 35