Operating Instructions Maintenance Instructions: BW211D-3 / BW211PD-3

Operating Instructions
Maintenance Instructions
BW211D-3 / BW211PD-3
SN: 101580851001 >
Single Drum Vibratory Roller
Catalog Number
00813161 11/08
CALIFORNIA
Proposition 65 Warning
WARNING: Diesel engine exhausts and
some of its constituents are known to the
state of California to cause cancer, birth
defects, and other reproductive harm.
CALIFORNIA
Proposition 65 Warning
WARNING: Battery posts, terminals and
related accessories contain lead and lead
compounds, chemicals known to the state
of California to cause cancer, birth
defects, and other reproductive harm.
Wash hands after handling.
Foreword
These BOMAG - machines are products from Always keep this manual close at hand, e.g. in the
F oreword
the wide product range of BOMAG compaction tool compartment of the machine or in the contain-
equipment. er provided for this purpose. These operating and
maintenance instructions are part of the machine.
The vast experience of BOMAG as well as most
modern production and testing methods, e.g. Only operate the machine after you have been
lifetime tests of all important components and properly instructed and by observing these in-
most stringent quality demands ensure high- structions.
est reliability of your machine. Please observe strictly the safety regulations.
Please observe also the guidelines of the civil en-
This manual comprises:
gineering liability association "Safety Rules for the
l Safety regulations Operation of Road Rollers and Soil Compactors"
l Operating instructions and the applicable instructions for the prevention
of accidents.
l Maintenance instructions
For your own safety you should only use gen-
l Trouble shooting
uine BOMAG spare parts.
Using these instructions will In the course of technical development we re-
l help you become acquainted with the ma- serve the right for modifications without prior
chine. notification.
l avoid malfunctions caused by unprofessional These operating and maintenance instructions are
operation. also available in other languages.
You can obtain the spare parts catalogue from
Compliance with the maintenance instructions will your BOMAG dealer against the serial number of
l increase the reliability of the machine on the your machine.
construction site, You can also obtain information about the correct
l prolong the lifetime of the machine, use of your machine in earth and asphalt construc-
tion from your BOMAG dealer.
l avoid repair costs and downtime.
The information in this manual does not extent or
BOMAG will not assume liability for the correct replace the warranty and liability conditions in the
function of the machine general terms of business of BOMAG.
l if it is handled in a way which does not comply We wish you much success with your BOMAG
with the usual mode of operation, machine.
l if it is used for purposes other than those men- BOMAG GmbH & Co. OHG
tioned in these instructions. Printed in Germany
Copyright by BOMAG
No warranty claims can be lodged in case of
l operating errors,
l insufficient maintenance and
l incorrect fuels and lubricants.
Please note!
CE-conformity of this machine is only

achieved with the respective optional equip-
ment.
These instructions were written for the operator
and the service man on the construction site.
BW 211 D-3/PD-3 BOMAG 3

Foreword
Please fill in
............................
Machine type (Fig. 1)
............................
Serial No. (Fig. 1 and 2)
............................
Engine type (Fig. 3)
............................
Engine No. (Fig. 3)
i Note Fig. 1
Fill in the above listed data when receiving the ma-
chine.
Upon receipt of the machine our organization will
instruct you about correct operation and mainte-
nance.
Please observe strictly all safety regulations and
notes on potential dangers!
Fig. 2
Fig. 3
4 BOMAG BW 211 D-3/PD-3

Table of Contents
Technical Data 7
Safety regulations 11
Indicators and Controls 19
3.1 General notes 20
3.2 Description of indicators and control elements 20
Operation 29
4.2 Tests before starting to operate 30
4.3 Starting the engine 31
4.4 Starting with jump leads 33
4.5 Driving the machine 34
4.6 Emergency exit 35
4.7 Operating the parking brake, stopping the machine 36
4.8 Shutting the engine down 36
4.9 Switching the vibration on and off 37
4.10 Adjusting the seat 38
4.11 Opening the hood 39
4.12 Towing in case of an engine failure 39
4.13 Transport 41
Maintenance 43
5.1 General notes on maintenance 44
5.2 Fuels and lubricants 45
5.3 Table of fuels and lubricants 48
5.4 Running-in instructions 49
5.5 Maintenance chart 50
5.6 Check the engine oil level 52
5.7 Checking, cleaning the water separator 52
5.8 Checking the fuel level 53
5.9 Checking the hydraulic oil level 54
5.10 Checking the coolant level 55
5.11 Checking the dust separator on the oil bath air filter 55
5.12 Checking the tire pressure 56
5.13 Adjusting the scrapers 56
5.14 Clean the cooling fins on engine and hydraulic oil cooler 58
5.15 Checking the oil level in the axle 59
5.16 Checking the oil level in the wheel hubs 59
5.17 Checking the oil level in the vibration bearing housings 60
5.18 Service the air conditioning 60
5.19 Changing engine oil and oil filter cartridges 63
5.20 Draining the fuel tank sludge 64
5.21 Servicing the battery 65

Table of Contents
5.22 Check, adjust the valve clearance 66

5.23 Checking the condition and tension of the fan V-belt, replacing the V-belt 68
5.24 Check condition and tension of refrigerant compressor V-belt, replace the V-
belt 70
5.25 Changing the fuel prefilter element 71
5.26 Check, replace leak fuel return lines 72
5.27 Change the fuel filter cartridge 73
5.28 Replacing the fuel filter for the auxiliary heating 74
5.29 Check the engine mounts 74
5.30 Change the oil in the drive axle 75
5.31 Changing the oil in the wheel hubs 76
5.32 Changing the oil for the vibration bearings 77
5.33 Tightening the fastening of the axle to the frame 78
5.34 Tightening the wheel nuts 78
5.35 Checking the ROPS 79
5.36 Cleaning the oil bath air filter 79
5.37 Changing the hydraulic oil and the breather filter 80
5.38 Changing the hydraulic oil filter 81
5.39 Changing the coolant 82
5.40 Replacing the injection valve 84
5.41 Replacing the coolant pump 84
5.42 Replacing the pressure retaining valve 85
5.43 Replacing the crankcase ventilation valve 85
5.44 Cleaning, changing the dry air filter cartridge 87
5.45 Adjusting the parking brake 89
5.46 Changing the tires 90
5.47 Changing the fresh air filter in the cabin 91
5.48 Tightening torques 91
5.49 Engine conservation 92
Trouble shooting 93
6.2 Engine 95

1 Technical Data

Technical Data
Fig. 4
Dimensions in A B D H2 H K L O1 O2 S W
mm
BW 211 D-3 2868 2250 1500 2970 2268 490 5610 60 60 35 2130
BW 211 PD-3 2868 2250 1480 2970 2268 490 5610 60 60 35 2130
*
BW 211 D-3 BW 211 PD-3
Weights
Operating weight (CECE) kg 10620 11620
with ROPS and cabin
Axle load, drum (CECE) kg 6270 7270
Rear axle load (CECE) kg 4350 4350
Static linear load kg/cm 29,4 29,4
Travel characteristics
Travel speed (1) km/h 0 ... 5 0 ... 5
Travel speed (2) km/h 0 ... 6 0 ... 6
Travel speed (3) km/h 0 ... 9 0 ... 9
Travel speed (4) km/h 0 ... 13,5 0 ... 13,5
Max. gradability (depend- % 47 47
ing on soil)

Technical Data
* BW 211 D-3 BW 211 PD-3

Engine
Engine manufacturer Deutz Deutz
Type BF4M 2012C BF4M 2012C
Cooling Water Water
Number of cylinders 4 4
Rated power DIN ISO kW 98 98
9249
Rated speed 1 rpm 2300 2300
Fuel Diesel Diesel
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 2 2
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydr.-mech. hydr.-mech.
Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic
Vibration
Vibrating drum 1 1
Drive system hydrostatic hydrostatic
Frequency Hz 30/36 30/36
Amplitude mm 1,8/0,9 1,64/0,82
Tires
Tire size Goodyear 23.1/18-26TL- Goodyear 23.1/18-26TL-
8PR-AWT, 8PR-AWT,
Air pressure bar 1,0 1,0
Filling capacities
Engine Litres 10 10
Fuel Litres 250 250
Hydraulic oil Litres 60 60
Coolant Litres 16 16
* The right for technical modifications remains reserved

Technical Data
The following noise and vibration values according to the EC-directive for machines, edition (91/368/
EEC) were measured at nominal engine speed and with the vibration switched on. The machine 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):
LpA = 77 dB(A)
sound capacity level:

LWA = 109 dB(A)
These sound values were determined according to ISO 3744 for the sound capacity level (LWA) and ISO 6081
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 2631 part 1, is <= 0,5 m/sec2.
Hand-arm vibration values

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

2 Safety regulations

Safety regulations
General Unintended use

This BOMAG machine is built in accordance Dangers may, however, arise from the machine if
with the latest technical standard and the valid it is used by untrained personnel in an unprofes-
technical rules and regulations. There is, how- sional way or if it is used for purposes other than
ever, a risk of danger for persons and property those mentioned in these instructions.
if: Do not work with vibration on hard concrete, on a
cured concrete layer or heavily frozen ground.
l the machine is used for purposes other than
those it is intended for Starting and operation of the machine in an explo-
sive environment is prohibited.
l the machine is operated by untrained person-
nel
Who is allowed to work with the ma-
l the machine is modified or converted in an un-
professional way
chine?
The machine must only be operated by trained
l the applicable safety regulations are not ob-
and authorized persons which are at least 18
served.
years of age. The responsibilities for the operation
Each person involved in operation, mainte- of the machine must be clearly specified and com-
nance and repair of the machine must there- plied with.
fore read and apply these safety regulations. Persons under the influence of alcohol, medica-
This should be confirmed by obtaining the sig- tion or drugs must not operate, service or repair
natures of the customer, if necessary. the machine.
Furthermore the following regulations and instruc- Maintenance and repair tasks require specific
tions are obviously also valid: knowledge and must therefore only be carried out
l applicable accident prevention instructions by trained and qualified personnel.
l generally acknowledged safety and road traffic

regulations Conversions and alterations to the ma-
chine
l country specific safety regulations. It is the
duty of the operator to know and observe Unauthorized conversions to the machine are pro-
these regulations. This applies also for local hibited for safety reasons.
regulations and the regulations for various Original parts and accessories have been special-
types of manual work. If the recommendations ly designed for this machine. We wish to make ex-
in this manual differ from the regulations valid pressly clear that we have not tested or authorized
in your country, you must strictly observe the any original parts or special equipment not sup-
regulations in your country. plied by us. The installation and/or use of such
products can impair the active and/or passive driv-
Intended use ing safety. The manufacturer expressly excludes
any liability for damage resulting from the use of
This machine must only be used for:
non-original parts or accessories.
l compaction of bituminous materials, e.g. road
surface layers. (AC and AD machines only) Safety notes in the operating and main-
l medium and heavy compaction tasks in earth tenance instructions:
work (road sub-bases)
l This machine must only be operated with fully Danger
!
functional safety equipment.
Sections marked like this point out possible
l The machine should be checked by an expert dangers for persons.
once every year.

Safety regulations
! Caution Towing the machine

Sections marked like this point out possible You should generally use a tow bar.
dangers for the machine or for parts of the ma- Max. towing speed 1 km/h (1.6 mph), max. towing
chine. distance 500 m (1640 ft.).
Before releasing the multi-disc brakes secure the
i Note machine properly against unintended rolling.
Sections marked like this provide technical infor-
mation concerning the optimal economical use of Checking the Roll Over Protection
the machine. Structure (ROPS)
Environment i Note
Sections marked like this highlight activities On machines with cabin the ROPS is an integral
for the safe and environmental disposal of fu- part of the cabin.
els and lubricants as well as replaced parts.
The machine frame must not be distorted, bent or
Observe all environment protection regula- cracked in the area of the ROPS fastening points.
tions.
The ROPS must not show any signs of corrosion,
damage, hairline cracks or open fractures.
Information and safety stickers/decals
The ROPS must not rattle about during driving.
on the machine This would mean that it is not properly fastened.
Keep stickers/decals complete (see spare parts All bolted connections must be in accordance with
catalogue) and fully legible and observe their the prescribed specifications and correctly tight-
meaning. ened (observe the tightening torque values).
Replace damaged or illegible stickers/decals im- Screws and nuts must not be damaged, bent or
mediately. deformed.
With the cabin installed check also the condition of
Loading the machine the cabin mounts (rubber elements and screws).
Use only strong and stable loading ramps. The Neither must any additional parts be welded or
ramp inclination must be lower than the gradability bolted on, nor must any holes be drilled without the
of the machine. permission of the manufacturer, since this may im-
pair the strength of the structure.
Secure the machine against turning over or slip-
ping off.
Starting the machine
Secure the machine on the transport vehicle
against rolling off, slipping and turning over. Before starting
Persons are highly endangered if Operation of the machine is only permitted when
l they step or stand under loads being lifted sitting in the operator's seat.
l they remain in the drive range of the machine Use only machines which have been properly
during a demonstration or during loading. serviced at regular intervals.
Become acquainted with the equipment, the con-
The machine must not swing about when lifted off
trol elements, the working mode of the machine
the ground.
and the area you will be working in.
Use only safe lifting gear of sufficient load bearing
Use your personal protective outfit (hard hat, safe-
capacity.
ty boots etc.).
Attach the lifting gear only to the specified lifting
Check before mounting the machine if:
points.
l there are persons or obstructions beside or
under the machine

Safety regulations
l the machine is free of any oily and combustible Driving the machine
material
Persons in the endangered area
l all handrails, steps and platforms are free of
grease, oils, fuels, dirt, snow and ice If the machine has turned over and the cabin door
is jammed, use the right hand cabin window as an
l the engine compartment hood is closed and emergency exit.
locked
Before starting or resuming work and especially
To climb onto the machine use steps and hand- when driving backwards, check that there are no
rails. persons or obstructions in the endangered area.
Check before starting, whether: If necessary give warning signals. Stop work im-
l the machine shows any obvious defects mediately if persons remain in the danger area de-
spite the warning.
l all protective devices are properly secured in
their place Do not step or stand into the articulation area of
the machine while the engine is running. Danger of
l steering, brakes, control elements, lighting squashing!
and warning horn are in order
Driving
l the seat is correctly adjusted
In events of emergency actuate the emergency
l the mirrors (if available) are clean and correct-
stop switch immediately. Do not use the emergen-
ly adjusted.
cy stop push button as service brake.
Do not start the machine if any gauges, control
Restart the machine only after the danger, that has
lights or controls are defective.
caused the actuation of the emergency stop, has
Do not take any loose objects with you or fasten been eliminated.
them to the machine.
If the machine has come in contact with high-volt-
On machines with ROPS you should always wear age power lines:
your seat belt!
l do not leave the operator's stand
Starting l warn others from coming too close to the ma-
Start and operate the machine only from the oper- chine or touching it
ator'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 power shut off.
Do not use any starting aids such as Start Pilot or
Operate the machine only from the operator's
ether.
seat.
After starting check all gauges.
Keep the cabin doors closed.
Starting with jump leads Do not adjust the seat while driving.
Connect plus with plus and minus with minus Do not climb onto or off the machine while driving.
(ground cable) - always connect the ground cable
Change the travel direction only while the machine
last and disconnect it first! Wrong connections
is standing.
may cause severe damage in the electric system.
Do not use the machine to transport persons.
Never start the engine by bridging the electrical
connections on the starter, because the machine Stop the machine if you notice unusual noises or
would probably start to move immediately. the development of smoke. Investigate the cause
and have the fault corrected.
Starting in closed rooms
Keep a sufficient distance to excavations and em-
Exhaust gases are toxic! Always ensure an ade- bankments and make sure that you work does not
quate supply of fresh air when starting in closed impair the stability of the machine.
rooms!

Safety regulations
Do not work with vibration on hard concrete, on a Parking on slopes and gradients
cured concrete layer or heavily frozen ground. Secure the machine against rolling, place metal
When passing under flyovers, bridges, tunnels, chocks in front of and behind the drums.
electric power lines etc. keep a sufficient distance.
Driving on slopes and gradients Filling the fuel tank

Do not drive up and down gradients, which exceed Do not inhale fuel fumes.
the max. gradability of the machine. Refuel only after shutting the engine and the aux-
On lopes always drive directly up or down. Change iliary heater down.
to the lower speed range before approaching the Do not refuel in closed rooms.
slope. No open fire, do not smoke.
Wet and loose soils reduce the ground adhesion of Do not spill any fuel. Catch running out fuel, do not
the machine and inclinations and slopes consider- let it seep into the ground.
ably. Higher risk of accident!
Wipe off spilled fuel. Keep fuel free of dirt and wa-
Behaviour in traffic ter.
Match the speed of the machine to the working Leaking fuel tanks can cause explosions. Ensure
conditions. tight fit of the fuel tank filling cover, replace it if nec-
Always allow loaded transport vehicles to pass. essary.
Switch the lights on when the visibility is poor. Fire protection measures
Keep clear of edges and embankments. Make yourself acquainted with the location and the
operation of fire extinguishers. Observe fire warn-
Check the effect of vibration ing and fire fighting installations.
When compacting with vibration check the effect
of the vibration on nearby buildings and under- Maintenance
ground supply lines (gas, water, sewage, electric
power supply), stop vibratory compaction if neces- Observe the maintenance tasks described in the
sary. operating and maintenance instructions, including
the exchange of parts.
Do not work with vibration on hard (frozen, con-
crete) ground. Risk of bearing damage! For service and repair work in the engine compart-
ment support the engine compartment hood.
Parking the machine Maintenance work must only be carried out by
qualified and authorized personnel.
Park the machine on level and firm ground.
When performing maintenance work above body
Before leaving the machine: height use the access steps on the machine or any
l straighten the articulated joint to allow easy other safe ladders and working platforms. Do not
access to and from the machine. use machine parts as access steps.
l return the travel lever to neutral position Keep unauthorized persons away from the ma-
chine.
l apply the parking brake
Do not perform maintenance work with the ma-
l shut the engine down and pull the ignition key chine driving or the engine running.
out.
Park the machine on horizontal, level and stable
l lock the cabin ground.
l secure the machine against unauthorized use. Pull the key out of the ignition switch.
Do not jump off the machine, use access steps Lock the articulated joint with the articulation lock.
and hand rails.
Always secure parked machines, which could be
in the way, with appropriate measures.

Safety regulations
Working on hydraulic lines l Do not mix up hoses by mistake.

Always relieve the pressure in the hydraulic circuit l damage or deformation of the fitting, which im-
before working on hydraulic lines. Hydraulic oil es- pairs the function and strength of the hose/
caping under pressure may penetrate through the hose connection.
skin and cause severe injury. In case of being in-
Only genuine BOMAG hydraulic hoses ensure
jured by hydraulic oil you should immediately seek
that the correct type of hose (pressure range) is
medical advice, as otherwise this may lead to se-
used at the right place.
rious infections.
When adjusting the hydraulic system do not stand Working on the engine
behind or in front of the drum/wheels. Shut the engine down before opening the engine
Do not change the setting of high pressure relief compartment hood.
valves. Drain the engine oil at operating temperature -
Drain hydraulic oil at operating temperature - dan- danger of scalding!
ger of scalding! Wipe off spilled oil, catch running out oil and dis-
Catch running out hydraulic oil and dispose of en- pose of environmentally.
vironmentally. Store used filters and other oily materials in a sep-
Always catch and dispose of biological hydraulic arate, specially marked container and dispose of
oils separately. environmentally.
Do not start the engine after draining off the hy- Do not leave any tools or other objects, which
draulic oil. could cause damage, in the engine compartment.
Once all work is completed (with the system de- Idle speed and full load speed must not be
pressurized!) check all connections and fittings for changed, since this would have a negative effect
tight and leak-free fit. on the exhaust gas values and cause damage to
engine and drive.
Changing hydraulic hoses
Turbo chargers work with high speeds and high
All hydraulic hoses must be inspected visually at temperatures. Keep hands, tools and materials
regular intervals. away from the intake and outlet openings of the
Hydraulic hoses must be changed immediately if: turbo charger and do not touch any hot surfaces.
l the outer layer is worn down to the metal lining Check and replace the coolant only when the en-
(e.g. chafing, cuts, cracks) gine is cold.
l embrittlement of the outer layer (development Catch running out coolant and dispose of environ-
of cracks in the hose material) mentally.
l deformation under pressurized and depressu- Working on electrical equipment

rized condition, which are not in accordance Before working on electrical equipment disconnect
with the normal shape of the hydraulic hose the battery and cover it with insulating material.
l deformation in bends, e.g, squeezes, kinks, Do not use any fuses with higher ampere ratings
layer separation, formation of blisters or repair a fuse with a piece of wire. Fire hazard!
l leakages. Always disconnect the battery before starting to
l non-observance of the installation require- wled on the machine.
ments Working on the battery
l separation of the hydraulic hose from the fit- When working on the battery do not smoke, do not
ting use open fire.
l corrosion of the fitting, which impairs the func- Do not let acid come in contact with skin and
tion and the strength. clothes. If being injured by acid flush off with clear
water and seek for medical advice.

Safety regulations
Metal objects (e.g. tools, rings, wrist watches) terials to the direct water jet, but cover them be-
must not contact the battery poles - danger of forehand.
short circuit and burns!
l Do not guide the water jet into the exhaust or
When recharging maintenance free batteries re- into the air filter.
move the plugs to avoid the accumulation of explo-
sive gases. After maintenance work
When using an external battery to start the ma- Reinstall all protective devices after completing
chine follow the respective instructions. the maintenance work.
Dispose of old batteries environmentally.
Repair
Switch the charging current off before removing
the charge clamps. Attach a warning tag to the steering wheel if the
machine is defective.
Ensure good ventilation, especially when charging
the battery in a closed room. Repairs must only be performed by qualified per-
sons who have been instructed for this purpose.
Working on the fuel system Use our repair instructions.
Do not inhale fuel fumes. Exhaust gases are highly dangerous! Always en-
No open fire, do not smoke, do not spill any fuel. sure an adequate supply of fresh air when starting
in closed rooms!
Catch running out fuel, do not let it seep into the
ground and dispose of environmentally. Test
Working on wheels and tires Depending on the type of application and the op-
erating conditions vibratory equipment has to be
Explosion like bursting of tires and parts of rims examined by a specialist whenever required, but
and tires can cause severe or even deadly injuries. at least once every year.
Assemble tires only with the appropriate knowl-
edge and tools. If necessary have the tires assem-
bled in a special workshop.
Ensure correct tire pressure and do not exceed the
highest specified pressure.
Check wheels and tires every day for specified
pressure, cuts, bulges, damaged wheel rims,
missing wheel studs and nuts. Do not drive with
damaged tires or wheels.
Anti-stick emulsions for tires must only be mixed
using water and concentrated anti-stick agent ac-
cording to the specifications of the manufacturer of
the anti-stick agent. Observe the regulations for
the protection of the environment.
Cleaning
Do not clean the machine while the engine is run-
ning.
Do not use gasoline or other combustible sub-
stances for cleaning purposes.
When using steam cleaning equipment do not
subject electrical components and insulating ma-

Safety regulations

3 Indicators and Controls

Indicators and Controls
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. 5
No. 1 = Fuse box
(1), 30A = (F05) socket
(2), 30A = (F13) starting
(3), 30A = (F24) warning horn, monitoring
(4), 30A = (F25) driving, brake
(5), 30A = (F03) vibration
(6), 30A = (F22) working lights, rear
(7), 30A = (F19) working lights, front
! Danger
Fire hazard!
Do not use fuses with a higher Ampere rating
and do not bridge fuses.
Fig. 6
No. 2 = Fuel gauge

shows the fuel level in the fuel tank.
Fig. 9
No. 5 = Rotary switch, vibration
Fig. 7
Position "mid-
No. 3 = Operating hour meter
dle" = vibration off
counts the operating hours while the engine is run-
Position "left" = low amplitude, high frequency
ning
Position "right" = high amplitude, low frequency
All service work must be carried out according to
the reading of the operating hour meter.
Fig. 10
Fig. 8 No. 6 = Rotary switch, speed ranges

No. 4 = Push button for warning horn Position "turtle" = when working on level ground
Position"drum" = if the drum is spinning
Posi-
tion"wheels" = if the wheels are spinning
Position "rab-
bit" = transport travel range, e.g. to
drive to the job site

operate = push the button completely

down, it will automatically lock
in end position.
unlock = turn the button clockwise and
release it.
to drive = move the travel lever first to
braking position, then start the
engine and choose the travel
direction.
For safety reasons the travel system of the ma-
chine will only be enabled after the travel lever has
been shifted back to braking position.
Fig. 11
No. 7 = Air filter service indicator
With the service indicator the real degree of filter
contamination can even be checked when the en-
gine is stopped.
The filter must be service when the yellow piston
reaches the inscription "Service" in front of the red
background.
After the filter service reset the indicator to "zero"
by pressing the push button.
Fig. 13
No. 9 = Rotary switch working lights *
Position "left" = light off
Position "right" = working lights on, with ignition
switch in position "I".
i Note
If the machine is also equipped with limitation flash
lights, the working head lights can only be
switched on together with the limitation lights 12
Fig. 12 (position middle).
No. 8 = Emergency stop switch
The engine will be shut down and the brake will
close.
!Danger
Danger of accident!
Operate only in emergency situations during
operation, do not use as a service brake.
The machine should only be started again after
the danger, that caused the actuation of the
emergency stop switch, has been removed.
* Option

Fig. 14 Fig. 16
No. 10 = Oil pressure warning light No. 12 = Charge control light
lights = with the ignition switch in posi- lights up = when switching the ignition on
tion "I" (test), engine oil pres- (test), in case of charging
sure too low, the warning faults during operation.
buzzer sounds as well. Check goes out = after starting the engine
the engine oil level, have the
engine repaired if necessary.
! Caution
goes out = after starting the engine
If the control light lights up while the engine is
running, the battery is not being charged. De-
tect the cause and eliminate the fault.
Fig. 15
No. 11 = Coolant temperature warning light
lights up = if the coolant temperature is Fig. 17
too high, the warning buzzer
No. 13 = Service indicator hydraulic oil filter
will sound.
l Check the service indicator at operating tem-
perature and with the engine running.
! Caution
l If necessary press the pin in.
Clean the radiator. Check the coolant level
Pin remains
pressed in = hydraulic oil filter element o.k.
Pin pops out = replace the hydraulic oil filter
element

Fig. 18 Fig. 20
No. 14 = Push button for vibration No. 16 = Ignition switch
l Pre-select or activate the frequency with the Position "P"/"0" = ignition off, the key can be
vibration selection switch pulled out, engine not running.
l Press the switch to switch the vibration on and Position "I" = ignition on, all control and
off. warning lights on the fault
monitoring board light up for a
moment. The lighting can be
switched on.
i Note
The engine can only be started when the travel le-
ver is in braking position.
The ignition switch is provided with a lock against
repetitive starting. To repeat the starting proce-
dure you must first turn the ignition switch back to
"0"-position.
Position "II" = preheating position, for start-
ing at temperatures below
Fig. 19 -10 °C.
No. 15 = Travel lever Position "III" = turn further against spring
Position "mid- pressure, the engine starts, re-
dle" = brake position for service turn the ignition key to position
brake "I" when the engine starts.
Position "middle,
right" = parking brake, to start the en- ! Caution
gine
Run the engine warm for a short while before
Position "I" = forward travel starting to work. Do not let the engine run at
Position "II" = reverse travel idling speed for longer than 10 minutes.
Do not shut the engine down all of a sudden
i Note from full speed, but let it idle for a while for
If the engine speed is forced down when driving up temperature equalization.
steep inclines, move the travel lever slightly back.
This reduces the load on hydraulic system and
diesel engine.

release = the throttle lever locks in posi-

tion "I".
Fig. 21
No. 17 = Main fuse for battery
120A = (F00) Fig. 23
No. 20 = Shut-off valve for cabin heater*
i Note
The main fuse is located in the battery compart- i Note
ment.
The heat exchanger of the cabin heater receives
the heat energy from the engine coolant circuit.
Position "I" = cabin heater off
Position "II" = cabin heater full power
Fig. 22
No. 18 = Throttle lever
Position "I" = full load position, operating po-
sition for driving and vibration
Fig. 24
Position "II" = idling speed position
No. 21 = Fuse box, cabin**
(a) - = not used
! Caution
(b) 7.5A = Inside light
Always drive and vibrate with max. engine
speed! Use the travel lever the regulate the (c) 7.5A = Windscreen wiper/washer,
travel speed! rear
No. 19 = Locking plate for throttle lever (d) 7.5A = Windscreen wiper/washer,
front
pull = the throttle lever can be moved
to position "II" (e) 7.5A = Flashing beacon
* Option
** Optional equipment

(f) 7.5A = Heating blower, radio
! Danger
Fire hazard!
Do not use fuses with higher ampere ratings
and do not bridge fuses.
Fig. 26
No. 23 = Inside light
switch on = turn lamp glass clockwise
switch off = turn lamp glass anti-clockwise
Fig. 25
No. 22 = Switches in cabin*
(a) = Toggle switch windscreen wiper/
washer, rear
= 1. step wiping
= 2. step washing
(b) = Toggle switch. windscreen wiper/
washer, front
= 1. step wiping
= 2. step washing Fig. 27
No. 24 = Fresh air intake slide
(c) = Toggle switch for heating blower
Loosen the adjustment knob to operate the slide.
(d) = Toggle switch for flashing beacon
Slide to the left = Circulation air position
Slide to the
right = Fresh air position
Switch the heating blower on as well
* Optional equipment

maximum fan speed, turn the

slewable air discharge nozzles
to the desired direction. Once
the inside of the cabin has
cooled down adjust fan and
thermostat to the desired tem-
perature.
i Note
If the cabin has extremely heated up set the ther-
mostat to max. cooling, turn the rotary switch for
"Fan" to the highest blowing range, open the cabin
window and close it again after a few minutes.
Fig. 28
Then adjust the air conditioning to the desired tem-
No. 25 = Rotary switch for fan* perature.
Position "0" = Fan off If no cooling can be noticed when the air condition-
Position "1" = minimum fan range ing is running, turn both thermostats and the rotary
Position "2" = medium fan range switch for "Fan" to "0". Perform trouble shooting.
Position "3" = maximum fan range switch off = Turn rotary switch "Fan" and
both thermostats to "0".
i Note
If, during operation of the air conditioning system
the warning buzzer sounds with a continuous tone
switch the air conditioning off and clean the con-
denser.
Fig. 29
No. 26 = Rotary switch, air conditioning ther-
mostat (air blowing temperature)**
Position "0" = Air conditioning switched off
turn clockwise = Air conditioning switched on,
air blowing temperature be-
comes cooler.
Fig. 30
No. 27 = Rotary switch for auxiliary heating***
Caution
!
Position "0" = Off – after switching off auto-
Always keep the cabin door closed when the matic overrunning to assist
air conditioning system is in operation. cooling
switch on = Start the engine, set the ther- blue sector = Ventilation
mostat to max. cooling power,
red sector = Cabin heater switched on,
turn the rotary switch "fan" to
heat regulation of the airflow
* Optional equipment
** Optional equipment *** Optional equipment

by turning in direction of arrow

(stage 1 to 4). The green light
in the rotary switch lights up.
i Note
In case of overheating the green light in the rotary
switch will flash with a uniform pattern. Rectify the
cause and switch the cabin heater back on again.

4 Operation

Operation
4.1 General notes 4.2 Tests before starting to op-

erate
Please read section 3 Indicators and Control Ele-
ments thoroughly before operating the machine if
The following tests must be performed before
you are not yet fully familiar with the indicators and
each work day or before a longer work period.
control elements of the machine.
All indicators and control elements are described
in detail in this chapter. ! Danger
Danger of accident!
Please observe strictly the safety regulations
in chapter 2 of these operating and mainte-
nance instructions!
l Park the machine on level ground.
Check:
l Fuel tank and fuel lines for leaks
l Bolted connections for tight fit
l Function of the steering
l Check the machine for cleanliness and dam-
age
l availability of the appropriate operating and
maintenance instructions,
l check if the machine has been properly serv-
iced.
i Note
For a description of the following work refer to the
section "maintenance every 10 operating hours"
l engine oil level
i Note
Hydraulic systems, which are filled with Panolin
HLP Synth. 46, the same oil must be used for fill-
ing up. In case of any other ester based oil consult
the lubrication service department of the respec-
tive oil manufacturer.
l Check the hydraulic oil level, top up if neces-
sary.
l Check the coolant level, top up if necessary.
! Danger
Fire hazard!
Do not refuel in closed rooms
l Check the fuel level, top up if necessary.

Operation
l Check water separator in the fuel system,

drain if necessary. 4.3 Starting the engine
l Adjust the scrapers if necessary
l Tire pressure. Pressure see technical data. ! Danger
Danger of accident!
! Caution
Always wear your seat belt.
Ensure equal pressure in both tires.
Fig. 31
l Fasten your seat belt (Fig. 31).
Fig. 32
l Check, whether the travel lever (Fig. 32) is en-

gaged in brake position.

Operation
Fig. 33 Fig. 36
l Turn the rotary vibration selector switch (Fig. l Turn the ignition key (Fig. 36) to position "I".
33) to position "0", vibration off. The warning lights for battery and engine oil pres-
sure light up.
Fig. 34
l Check, whether the emergency stop switch Fig. 37

(Fig. 34) is unlocked.
l Wait until the pre-heating light (Fig. 37) has
gone out.
i Note
The length of the pre-heating period depends on
the engine temperature.
! 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. 35
l Set the throttle lever (Fig. 35) to approx. 1/2

throttle and hold it.

Operation
4.4 Starting with jump leads
! Caution
Wrong connection will cause severe damage
to the electrical system.
Fig. 38
l Turn the ignition key to position "II" (Fig. 38).

The starter cranks the engine.
l As soon as the engine ignites return the igni-
tion key to position "I".
Charge control light and engine oil pressure warn-
ing light go out.
Fig. 39
l Once the engine runs correctly you may re-
l When starting with an external battery connect
duce the engine speed „Idle speed“.
both plus poles (Fig. 39) first and both minus
poles (earth cable) after.
!Caution l Perform all steps as described in the previous
Run the engine warm for a short while, but do section.
not run with idle speed for more than 10 min-
l After starting disconnect the minus poles
utes.
(earth cable) first and the plus poles after.

Operation
4.5 Driving the machine
! Danger
Danger of accident!
Wet and loose soils reduce the ground adhe-
sion of the machine on gradients considerably.
Soil conditions and weather influences impair
the gradability of the machine.
Do not drive up or down inclinations which ex-
ceed the maximum gradability of the machine
(see technical data). Fig. 41
Always allow loaded transport vehicles to l Select the desired travel speed range (Fig.
pass! 41).
Before setting off make sure that the travel
area is save to drive.
! Caution
Always keep the cabin door closed while driv-
ing. When the door is open and the full oscilla-
tion angle of the articulated joint is utilized, the
cabin door may be damaged.
Fig. 42
l Set the throttle lever to position "I" (Fig. 42)

(full load) and lock ist.
Fig. 40
l Close the cabin door (Fig. 40).
Fig. 43
l Unlock the travel lever (Fig. 43) by shifting it to

the left out of the braking position and move it
slowly to the desired travel direction.

Operation
i Note
4.6 Emergency exit
Move the travel lever slowly out of "0"-position for-
wards or backwards, the machine will drive to the
If the machine should turn over and the cabin door
chosen direction at a speed, which is directly relat-
is closed, the right hand side cabin window can be
ed to the distance the travel lever has been moved
used as an emergency exit.
out of "0"-position.
When returning the travel lever the machine will
decelerate and come to a halt when the travel le-
ver is in "0"-position.
! Danger
Danger of accident!
To stop on inclinations lock the travel lever in
braking position by pushing it to the right.
Important notes on travel operation
! Caution
When reversing the travel direction hold the
travel lever for a moment in "0"-position until
the machine has come to a halt, then shift the
travel lever to the new direction.
Do not operate jerkily!
Do not use the throttle control lever to regulate
the travel speed! Regulate the travel speed
only with the travel lever. During operation the
throttle lever must always remain in full speed
position.
When driving on gradients or to brake the ma-
chine move the travel lever slowly back to-
wards "0"-position.
If the engine speed drops considerably when
driving up steep inclinations, move the travel
lever slightly back, change to the lower travel
speed range if necessary.

Operation
4.7 Operating the parking 4.8 Shutting the engine down

brake, stopping the ma-
chine ! Caution
Straighten the articulated joint to allow easy
access from and to the cabin.
Fig. 44
l Move the travel lever (Fig. 44) slowly to "neu-

Fig. 45
tral"-position and lock it to the right in braking
position. l Move the travel lever (Fig. 45) slowly to "neu-
tral"-position and lock it to the right in braking
The machine will decelerate automatically, the
position.
parking brake will close.
i Note
The parking brake will also close automatically
when shutting the engine down.
Fig. 46
l Pull the locking plate 19 (Fig. 46) up and set

the throttle lever (18) to position "II" (idling
speed).
i Note
Do not shut the engine suddenly down from full
speed, but let it idle for a while for temperature
equalization.

Operation
4.9 Switching the vibration on

and off
! Danger
Risk of damage!
When compacting with vibration check the ef-
fect of the vibration on nearby buildings and
underground supply lines (gas, water, sewage,
electric power supply), stop vibratory compac-
tion if necessary.
Fig. 47 Do not use the vibration on hard (frozen, con-
l Turn the ignition switch (Fig. 47) to position "0" crete) ground. Risk of bearing damage!
or "P" and pull the ignition key out.
! Caution
i Note When using the machine on asphalt (AD-ver-
The parking brake closes automatically after shut- sion)
ting the engine down.
Vibration at standstill creates transverse dents
in the asphalt, therefore:
! Danger
l only switch the vibration on after shifting the
Danger of accident! travel lever to the desired direction.
Secure the machine properly against unau- l Switch the vibration off before stopping the
thorized use, pull the ignition key out, lock the machine.
cabin door.
Selecting the vibration
Fig. 48
l Choose the amplitude/frequency with the rota-

ry switch (Fig. 48).

Operation
Switching the vibration on

4.10 Adjusting the seat
! Danger
Danger of accident!
Do not adjust the seat while driving.
Fig. 49
l Set the throttle lever (Fig. 49) to full speed po-

sition "I".
! Caution
Only switch the vibration on when the engine
Fig. 51
is running at full speed.
l To adjust the seat in longitudinal direction dis-
engage the lever 1 (Fig. 51) and slide the seat
forward or back.
l To adjust the weight actuate the lever (3).
l To adjust the inclination of the backrest actu-
ate the lever (2) and tilt the backrest forward or
back.
Fig. 50
l Actuate the push button (Fig. 50) in the travel

lever during operation, the drum will vibrate.
Switching the vibration off

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

Operation
4.11 Opening the hood 4.12 Towing in case of an engine

failure
! Danger
Danger of accident! ! Danger
If the hood has to be opened further for main- Secure the machine with wheel chocks against
tenance or repair work, you must support it unintentional rolling.
safely.
! Danger
Danger of accident!
When using towing ropes tow the machine
only uphill.
When towing downhill you must use a rigid
towing device.
Caution
!
Towing speed 1 km/h, max. towing distance

500 m.
l Open the tailgate.
Fig. 52
l Press the locking bar 1 (Fig. 52) down and pull

the lever (2) back, open the hood.
The hood will automatically move to middle posi-
tion.
Fig. 54
l Slacken both high pressure relief valves (Fig.

54) on the travel pump for approx. one turn.
! Caution
Fig. 53 Do not turn the valves out completely.
l Pull the support out of the bracket in the hood
and hook it into the frame at the bottom or into
the fuel pre-filter at the top (Fig. 53).

Operation
After towing
!Caution
Before detaching the tow bar block the ma-
chine with chocks to prevent unintended roll-
ing.
l Turn the high pressure relief valve cartridges
tightly back in.
l Turn all brake releasing screws of the axle
evenly back out, until they are light moving
again.
Fig. 55
l To release the brake turn counter nut 1 (Fig.

55) approx. 8 mm back.
l Turn the brake releasing screws (2) complete-
ly in against the stop.
! Caution
From this stop turn the screw in for maximum
another turn to release the brake!
Turn the screws in evenly on both sides.
l Turn the screws in alternately for ¼ turn at a
time. Fig. 57
l Repeat this measure on the opposite wheel l Turn the brake releasing screws (Fig. 57) back
side. in again, until they abut against the brake pis-
ton.
Fig. 56
l Remove plug 1 (Fig. 56). Fig. 58
l Place an U-section (5) across the brake hous- l Unscrew the brake releasing screws (Fig. 58)
ing (2) and turn the screw (4) into the tapped for two turns and tighten the counter nuts.
bore (3), until it bottoms. l Repeat this adjustment procedure on the op-
l Turn the nut (6) down and tighten it approx. posite wheel side.
one revolution. The drum must rotate freely.

Operation
i Note
4.13 Transport
If necessary replace the seal ring under the coun-
ter nut if it is leaking.
For this purpose completely unscrew the brake re- ! Danger
leasing screw, replace the seal ring and lubricate Danger of accident!
the screw with silicone grease.
Use only strong and stable loading ramps.
Reinstall the screw with a new seal ring and adjust
Make sure that no persons are endangered if
the protrusion as described above.
the machine should turn over or slip off.
Lash the machine down so that it is properly
secured against rolling off, slipping and turn-
ing over.
Do not step or stand under loads being lifted.
Always use shackles on the lashing points to
load, lash or lift the machine.
Fig. 59
l Attach the articulation lock (Fig. 59).
Fig. 60
l Lash the machine to the transport vehicle, fas-

ten the lashing gear at the four lifting hooks on
front and rear frame (Fig. 60).

Operation
! Caution
Do not overtighten the lashing gear to avoid
excessive strain on the rubber buffers.
Fig. 61
l To lift the machine attach the lifting gear to the

four lifting eyes (Fig. 61).
Weights: see technical data.

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

5 Maintenance

Maintenance
l Do not let the suction hose disturb the sludge

5.1 General notes on mainte- on the bottom of the drum.
nance l Do not draw off fuel from near the bottom of
the fuel drum.
When servicing the machine pay careful attention l Fuel left in the fuel drum is not suitable for the
to all applicable safety instructions. engine and should only be used for cleaning
Thorough maintenance of the machine ensures purposes.
maximum reliability and prolongs the lifetime of im-
portant components. The necessary effort can by Notes on the engine performance
no means be compared with the problems and
malfunctions that could occur if this is not ob- Combustion air and fuel injection rates of the die-
served. sel engine have been carefully adjusted and deter-
mine the engine's performance and temperature
The terms left/right are always related to travel di- level as well as the quality of the exhaust gas.
rection forward.
If your machine has to operate permanently in
l Clean machine and engine thoroughly before "thin air" (at high altitudes) and with full power, you
starting maintenance work. should consult the after sales service of BOMAG
l For maintenance work park the machine on or the service department of the engine manufac-
level ground. turer.
l Maintenance work must generally be carried
out with the engine shut down. Notes on the hydraulic system
l Depressurize hydraulic lines before working During maintenance work in the hydraulic system
on them. cleanliness is of utmost importance. Make sure
that no dirt or other impurities can enter into the
l Disconnect the battery and cover it with insu- system. Small particles can flute valves, cause
lation material before starting to work on elec- pumps to seize and block restrictors and pilot
trical components. bores, thereby causing costly repairs.
l Always attach the articulation lock (transport l If during the daily oil level check the oil level is
lock) before starting to work in the articulation found to have dropped, check all lines, hoses
area of the machine. and components for leakages.
l Seal external leaks immediately. If necessary
Environment inform the responsible service department.
Catch running out oils, coolant and fuel and do l Do not store drums with hydraulic oil outside,
not let them seep into the ground or into the or at least keep them under a cover. During
sewage system. Dispose of oils, coolant and weather changes water may penetrate
fuels environmentally. through the bunghole.
l Always fill the hydraulic system using the filling
Notes on the fuel system and filtering unit (BOMAG part-no.
The lifetime of the diesel engine is decisively de- 007 610 01). This unit is equipped with a fine
pending on the cleanliness of the fuel. filter, which filters the hydraulic oil and pro-
l Keep the engine free of dirt and water as this longs the lifetime of the system filter.
could damage the injection elements of the en- l Clean fittings, filler caps and their immediate
gine. surrounding area before removing them, so
l Zinc lined drums are not suitable for storing fu- that no dirt can fall in.
el. l Do not leave the tank opening unnecessarily
l The fuel drum should rest for a longer period open, cover it so that no dirt can fall in.
of time before drawing off fuel.

Maintenance
Notes on the cooling system

5.2 Fuels and lubricants
On water cooled engines the preparation and
monitoring of the coolant is of utmost importance,
as otherwise engine failures caused by corrosion, Engine oil
caviation and freezing may occur.
In order to assure perfect cold starting it is import
The coolant is a mixture of water and a cooling
to chose the viscosity (SAE-class) of the engine oil
system protection agent.
according to the ambient temperature.
The cooling system must be permanently moni-
For winter operation below -10 °C the oil change
tored. Apart from the coolant level inspection this
intervals must be halved.
includes also the inspection of the concentration of
cooling system protection agent.
The concentration of the cooling system protection
agent can be checked with commercially available
test instruments (glycomat).
! Danger
Health hazard!
The mixing of nitride based cooling system
protection agents with amine based agents will
cause the generation of highly toxic nitro-
samines.
Environment
Cooling system protection agents must be dis-
posed of environmentally.
Fig. 62
Lubrication oil with a too high viscosity index caus-
es starting difficulties. The temperature when
starting the engine is therefore of highest impor-
tance when choosing the viscosity of engine oil for
winter operation.
Oil viscosity
Since lubrication oil changes its viscosity with the
temperature, the ambient temperature at the oper-
ating location of the engine is of utmost impor-
tance when choosing the viscosity class (SAE-
class) (see diagram).
Occasional falling short of the temperature limit
(e.g. use of SAE 15W/40 down to -15 °C) may ef-
fect the cold starting ability of the engine, but will
not cause any engine damage.

Maintenance
Temperature related lubrication oil changes can Fuels

be avoided by using multi-purpose oils. The follow-
ing oil change intervals apply also when using mul- Quality
ti-purpose oils. You should only use commercially available brand
diesel fuel with a sulphur content below 0.5% and
Regular lubrication oil changes ensure strict cleanliness when filling in. A higher
sulphur content has a negative effect on the oil
The longest permissible time a lubrication oil
change intervals. Use only winter-grade diesel fuel
should remain in an engine is 1 year. If the follow-
under low ambient temperatures. The fuel level
ing oil change intervals are not reached over a pe-
should always be topped up in due time so that the
riod of 1 year, the oil change should be performed
fuel tank is never run dry, as otherwise filter and in-
at least once per year, irrespective of the operating
jection lines need to be bled.
hours reached.
The following fuel specifications are permitted:
DIN/EN 590; DIN 51 601; Nato Codes: F-54, F-75;
Oil quality
BS 2869: A1 and A2; ASTM D 975-78: 1-D and
Lubrication oil are classified according to their per- 2-D.
formance and quality class. Specifications accord-
ing to API* and ACEA** are commonly used.
Winter fuel
Permitted API-oils For winter operation use only winter diesel fuel, to
Turbo avoid clogging because of paraffin separation. At
charged very low temperatures disturbing paraffin separa-
engines = CG-4 / CH-4 tion can also be expected when using winter diesel
fuel.
Permitted ACEA-oils
In most cases a sufficient cold resistance can also
Turbo be achieved by adding flow enhancing fuel addi-
charged tives. Consult the engine manufacturer.
engines = E3-96 / E4-98
Hydraulic oil
Lubrication oil change intervals
The hydraulic system is operated with hydraulic oil
HV 46 (ISO) with a kinematic viscosity of
! Caution 46 mm2/s at 40°C. For topping up or for oil chang-
These intervals apply only when using a diesel es use only high-quality hydraulic oil, type HVLP
fuel with maximum 0.5 % sulphur by weight according to DIN 51524, part 3, or hydraulic oils
and for ambient temperatures higher than type HV according to ISO 6743/3. The viscosity in-
-10 °C. dex (VI) should be at least 150 (observe informa-
tion of manufacturer).
API: CG-4 / CH-
4 = 500 operating hours
Bio-degradable hydraulic oil
ACEA: E3-96 /
On request the hydraulic system can also be filled
E4-98 = 500 operating hours
with ester based biodegradable hydraulic oil (Pan-
When using fuels with a sulphur content of more olin HLP Synth. 46). The biologically quickly de-
than 0,5% to 1% or under ambient temperatures gradable hydraulic oil meets all demands of a
below -10 °C the oil change intervals must be mineral oil based hydraulic oil according to
halved. DIN 51524.
For fuels with a sulphur content of more than 1% In hydraulic systems filled with Panolin HLP Synth.
you should consult the responsible service agen- 46 always use the same oil to top up. When
cy. changing from mineral oil based hydraulic oil to an
ester based biologically degradable oil, you should
* American Petroleum Institute consult the lubrication oil service of the oil manu-
** European Engine Oil Sequences facturer for details.

Maintenance
Check the filter more frequently after this change.
Oil for drive axle

For the drive axle use only multi-purpose transmis-
sion oil of API-class GL5 with viscosity class
SAE 90.
The additives in this oil ensure low wear lubrication
under all operating conditions.
Lubrication grease
For lubrication use only EP-high pressure grease,
lithium saponified (penetration 2).
Coolant
Use only soft tap water (drinking water) to prepare
the coolant mix.
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. 45% to the
water.
! Caution
Do not mix different coolants and additives of
any other kind.

Maintenance
5.3 Table of fuels and lubri-

cants
Assembly Fuel or lubricant Quantity approx.
Summer Winter Attention

Observe the level marks
Engine Engine oil ACEA-E3-96/E4-98 or without oil filter change
API: CH-4/CG-4 approx. 10 litres
SAE 15W/40
(-20 °C to +40 °C)
SAE 30 SAE 10W
(+5 °C to +30 °C) (-5 °C to -30 °C)
Fuel
Diesel Winter diesel fuel approx. 250 litres
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres
2
46 mm /s at 40 °C
Vibration bearings Engine oil SAE 15W/40 approx. 0,8 litre per side
Drive axle Gear oil SAE 90, API GL5 approx. 12,5 l
Wheel hubs Gear oil SAE 90, API GL5 approx. 1.8 l per side
Engine cooling system Cooling system protection agent approx. 16 litres

Maintenance
5.4 Running-in instructions
The following maintenance work must be per-

formed when running in new machines or
overhauled engines:
Caution
!
Up to approx. 250 operating hours check the

engine oil level twice every day.
Depending on the load the engine is subjected
to, the oil consumption will drop to the normal
level after approx. 100 to 250 operating hours.
After a running-in time of 30 minutes

l Retighten the V-belt
After 50 operating hours

l Change the engine oil filter
l Change the engine oil.
l Check the valve clearance, adjust if necessary
l Retighten bolted connections on intake and
exhaust tubes, oil sump and engine mounts.
l Retighten the bolted connections on the ma-
chine.
l Retighten all wheel fastening screws with the
specified tightening torque.
l Oil change vibration bearings
l Oil change in drive axle
l Oil change in wheel hubs
After 500 operating hours

l Oil change vibration bearings

Maintenance
5.5 Maintenance chart
With all maintenance intervals perform also

the work for shorter preceding service inter-
vals.
No. Designation Note
Every 10 operating hours

5.6 Check the engine oil level Dipstick mark
5.7 Check the water separator
5.8 Check the fuel level
5.9 Check the hydraulic oil level Inspection glass
5.10 Check the coolant level Inspection glass
5.11 Check the dust separator on the oil bath air filter
5.12 Check the tire pressure
5.13 Adjust the scrapers
5.14 Clean the cooling fins on engine and hydraulic oil
cooler
5.15 Check the oil level in the drive axle
5.16 Checking the oil level in the wheel hubs
5.17 Check the oil level in the vibration bearings
5.18 Service the air conditioning
5.19 Change engine oil and oil filter cartridge* min. 1x per year
5.20 Drain the sludge from the fuel tank
5.21 Servicing the battery Pole grease

Maintenance
No. Designation Note

5.22 Check, adjust the valve clearance Intake = 0.3 mm, exhaust = 0.5 mm
5.23 Check condition and tension of cooling fan V-belt, re-
place the V-belt
5.24 Check condition and tension of refrigerant compres-
sor V-belt, replace the V-belt
5.25 Changing the fuel prefilter element
5.26 Replace fuel leak return lines
5.27 Change the fuel filter cartridge
5.28 Replacing the fuel filter for the auxiliary heating
5.29 Check the engine mounts
5.30 Change the oil in the drive axle min. 1x per year
5.31 Changing the oil in the wheel hubs min. 1x per year
5.32 Change the oil in the vibration bearings min. 1x per year
5.33 Check the fastening of the axle on the frame
5.34 Tighten the wheel nuts
5.35 Check the ROPS
5.36 Clean the oil bath air filter
5.37 Change hydraulic oil and breather filter** at least every 2 years
5.38 Change the hydraulic oil filter** at least every 2 years
5.39 Change the coolant at least every 2 years
5.40 Replace the injection valve
5.41 Replace the coolant pump
5.42 Replace the pressure retaining valve
5.43 Replace the crankcase ventilation valve
As required
5.44 Clean, change the dry air filter cartridge min. 1x every year, safety cartridge at least
every 2 years
5.45 Adjust the parking brake
5.46 Change the tires
5.47 Chang the fresh air filter in the cabin
5.48 Tightening torques
5.49 Engine conservation
*When using diesel fuel with a sulphur content of

more than 0,5 % by weight the engine oil change
intervals must be halved.
**Also in case of repairs in the hydraulic system.

Every 10 oper ating hours
5.6 Check the engine oil level 5.7 Checking, cleaning the wa-
ter separator
! Danger
Danger of injury! ! Caution
Support the engine hood for all maintenance When working on the fuel system do not use
and repair work. open fire, do not smoke.
i Note Environment
The machine must be parked horizontally with the Catch running out fuel and dispose of environ-
engine shut down. mentally.
i Note
The service intervals for the water separator de-
pend on the water content in the fuel and can
therefore not be determined precisely. After taking
the engine into operation you should therefore
check the filter bowl initially every day for signs of
water.
Fig. 63
l Pull the dipstick (Fig. 63) out, wipe it off with a

lint-free, clean cloth and reinsert it until it bot-
toms.
l Pull the dipstick back out again.
l If the oil level is below the "MAX" mark fill in oil.
l If the oil level is above the “Max” mark deter-
mine the cause and drain the oil off. Fig. 64
l Place a collecting vessel (Fig. 64) under the

Caution
! drain bore.
Before longer work periods you should always l Open the drain tap.
top the oil up to the "MAX"-mark.
For quality and quantity of oil refer to the table

of fuels and lubricants

5.8 Checking the fuel level
! Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke, do not refuel in closed
rooms, do not inhale any fuel fumes.
Fig. 65
l Drain the fuel off until there is no water left

(Fig. 65).
l Close the drain tap.
Fig. 66
l Check the fuel level on the fuel gauge (Fig.

66).
i Note
Never drive the fuel tank empty, because this
would required bleeding of the entire fuel system.
l Clean the area around the filler opening.
Fig. 67
l Open the fuel tank cover (Fig. 67).

! Caution
5.9 Checking the hydraulic oil
Dirty fuel can cause engine failures or even
damage to the engine. level
If necessary fill in fuel through a screen filter.
l If necessary top up fuel (diesel or winter die- ! Caution
sel). In mit Panolin HLP Synth. 46, the same oil must
For quality of fuel refer to the table of fuels and be used for filling up. In case of any other ester
lubricants. based oil consult the lubrication service de-
partment of the respective oil manufacturer.
Fig. 68
l Check the oil level in the inspection glass (Fig.

68) on the hydraulic oil tank.
Normal level
approx. 3 cm below the upper edge of the inspec-
tion glass.
Minimum level
middle of inspection glass.
! Caution
If during the daily oil check the oil level is
found to have dropped, check all lines, hoses
and components for leakages.
l If necessary fill in hydraulic oil through the filler
neck.

of fuels and lubricants.

5.10 Checking the coolant level 5.11 Checking the dust separa-
tor on the oil bath air filter*
! Danger
Danger of scalding!
Top up coolant only when the engine is cold.
Fig. 70
l If the dust reaches the mark loosen the clamp

(Fig. 70), take the cover off and clean the bowl.
Fig. 69
l Check the coolant level (Fig. 69).
!Caution
If during the daily coolant level check the cool-
ant level is found to have dropped, check all
lines, hoses and engine for leakages.
l To top up unscrew the lid and fill in coolant up
to the MAX-mark.
For quality of coolant refer to the table of fuels

and lubricants in chapter 5.2.
* Option

5.12 Checking the tire pressure 5.13 Adjusting the scrapers
Caution
! smooth drum only
Always close the valves with the dust cap.
Fig. 72
Fig. 71 l Check the condition and adjustment of the

front and rear scrapers, adjust or replace the
l Check the tire pressure with a pressure gauge
scraper rubber if necessary.
and the tire inflation valve 1 (Fig. 71) in top po-
sition. l To adjust the scrapers 1 (Fig. 72) loosen the
fastening screws (2) in the slots and push the
Nominal value see "Technical Data". scraper bracket towards the drum until the
scraper touches.
i Note l Retighten the fastening screws.
Ensure even pressure in all tires.
l Screw the valve caps back on. padfoot drum only
Fig. 73
l Check condition and adjustment of scrapers 2

(Fig. 73), adjust or replace the teeth if neces-
sary.
l To adjust the scrapers (2) slacken the fasten-
ing screws (1) in the slots and move the scrap-

er towards the drum, leaving a gap of approx.

25 mm.
l Retighten the fastening screws.

Cleaning with cold cleansing agent

Every 250 operating h ours
5.14 Clean the cooling fins on

engine and hydraulic oil ! Caution
cooler Protect electrical equipment such as genera-
tor, regulator and starter against the direct wa-
ter jet.
Danger
!
l Spray the engine with a suitable cleansing
Danger of injury! agent, e.g. cold cleanser, let it soak in for a
Perform cleaning work only after the engine while and spray it off with a strong water jet.
has cooled down and with the engine stopped. l Run the engine warm for a while to avoid cor-
rosion.
! Caution
Do not damage any cooling fins on the cooler
core when cleaning.
i Note
Dirt on fan blades and oil cooler reduce the cooling
effect. Dirt deposits in these areas are substantial-
ly supported by oil and fuel on these surfaces. For
this reason you should always seal any oil or fuel
leaks in the vicinity of the cooling fan or the oil
cooler and clean the cooling surfaces after.
Cleaning with compressed air
Fig. 74
i Note
Start to blow out from the exhaust side.
l Blow the cooler (Fig. 74) out with compressed
air.

5.15 Checking the oil level in the 5.16 Checking the oil level in the
axle wheel hubs
Fig. 75 Fig. 76
l Unscrew the level control plug 2 (Fig. 75) and l Move the drive wheel so that the oil level mark
check the oil level. on the plug (Fig. 76) is in horizontal position.
The oil level must reach the lower edge of the l Unscrew the plugs
bore.
The oil level must reach the bottom edge of the
l Top up oil Fill in oil, unscrew the filler plug (1) level bore.
for this purpose.
l Top up oil, if necessary.
For quality of oil refer to the table of fuels and
lubricants.
lubricants.
l Screw the filler and control plug in again.
l Turn the plug tightly back in.
l Repeat this inspection on the other side.

5.17 Checking the oil level in the 5.18 Service the air conditioning
vibration bearing housings
Cleaning the condenser
i Note
Check the oil level only at operating temperature ! Caution
after running the vibration for about 1/2 hour. A soiled condenser results in a considerable
reduction of air conditioning power.
Under extremely dusty conditions it may be
necessary to clean the condenser several
times per day.
If, during operation of the air conditioning sys-
tem, the warning buzzer sounds switch the air
conditioning off and clean the condenser.
! Danger
Danger of accident!
Do not clean with a hot water jet. Heat will
cause extreme overpressure, which could
Fig. 77 cause damage or explosion of the system.
l Move the drum so that the oil level control plug Use access steps and grips to mount and dis-
(Fig. 77) on the left hand side is in lowest posi- mount the machine.
tion.
l Unscrew the control plug (1). ! Caution
Some oil should drip out of the level bore In case of formation of foam have the air con-
ditioning system inspected by the service de-
l If necessary unscrew the oil filler plug (2) and
partment of BOMAG.
fill in some oil through the filler bore (2), until it
starts to run out from the level inspection bore.

lubricants.
l Screw the oil filler (2) and control plug (1) back
in.
l Repeat this procedure on the opposite side.
Fig. 78
l Clean the condenser fins (Fig. 78) from under-

neath with compressed air or a cold water jet.

Fig. 79 Fig. 81
l Clean the condenser fins (Fig. 79) from above l Turn the rotary switch for the air conditioning
with compressed air or a cold water jet. thermostat (Fig. 81) clockwise. The air flow
cools down.
Checking the refrigerant level
l Start the engine. i Note
The adjusted temperature must be below the actu-
l Switch the air conditioning on. al temperature inside the cabin, so that the com-
pressor will be switched on.
Fig. 80
l Turn the rotary fan switch (Fig. 80) to position Fig. 82

"2", middle fan stage.
l Check whether the white float (Fig. 82) inside
l Open the air outlet openings on both control the inspection glass of the drier/collector unit
units. floats right at the top.
i Note
The refrigerant level is correct.

! Caution
Have the drier/collector unit replaced by the
service department every year before the oper-
ating season.
Checking the condition of the drier/col-

lector unit
!Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeated-
ly inspected by a specialist. In this sense
Fig. 83
repeated inspections are external examina-
l If the white float (Fig. 83) inside the inspection tions, normally on pressure reservoirs in oper-
glass of the drier/collector unit floats at the bot- ation. In connection with this inspection the
tom, inform the service department. drier/collector unit must be visually examined
twice every year. During these inspections
i Note special attention must be paid to corrosion
and mechanical damage. If the reservoir is not
The refrigerant level is not correct.
in proper condition it must be replaced for
l Refrigerant must be filled up, if necessary the safety reasons, as a precaution to protect op-
air conditioning system must be checked for erators and third parties against any danger
leaks. arising from the handling and operation of
pressure reservoirs.
Checking the moisture level of the dry-
ing agent ! Danger
Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be re-
placed, to avoid bursting and further damage.
Fig. 84
l Check the moisture indication pearl (Fig. 84)

inside the inspection glass of the drier/collec-
tor unit.
blue = drying agent o.k. Fig. 85
purple = moisture level of drying agent l Check the drier/collector unit (Fig. 85) for me-
too high. chanical damage or rust.
l Inform the service department. Replace drier/
collector unit, check air conditioning system.

5.19 Changing engine oil and oil

filter cartridges
! Caution
The oil change at 500 operating hours refers to
the use of fuels with a 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 fuels and lubricants).
Drain the engine oil only when the engine is Fig. 87
warm. l Thoroughly clean the outside of both filter car-
tridges (Fig. 87).
! Danger l Unscrew both filter cartridges using an appro-
Danger of scalding! priate filter wrench.
When draining off hot oil.

i Note
The filter cartridges are fitted with a valve that pre-
Environment vents engine oil from running out during removal
Catch running out oil and dispose of environ- and installation.
mentally together with the engine oil filter car-
tridge. l Clean the sealing face on the filter carrier from
any dirt.
l Slightly oil the rubber seal on the new filter car-
tridges.
Fig. 86
l Unscrew the drain plug (Fig. 86) and catch

running out oil.
Fig. 88
l Turn the drain plug tightly back in.
l Turn the new filter cartridges (Fig. 88) on by
hand, until the seal contacts.
l Tighten the filter cartridges for another half
turn.

5.20 Draining the fuel tank

sludge
! Danger
Fire hazard!
open fire, do not smoke.
Do not spill any fuel.
Catch running out fuel, do not let it seep into
Fig. 89
the ground.
l Fill in new engine oil (Fig. 89). Do not inhale any fuel fumes.

l Tighten the oil filler cap properly.
! Caution
Before starting crank the engine with the start-
er motor until the oil pressure warning light
goes out.
l After a short test run check the oil level on the
dipstick, if necessary top up to the top dipstick
mark.
l Check filter cartridge and drain plug for leaks Fig. 90
after a short test run. l Unscrew the drain plug (Fig. 90) from the bot-
l Shut the engine down and wait for about 15 tom of the fuel tank and drain off approx. 5 li-
minutes, so that all oil can flow back into the oil tres of fuel.
sump. l Screw the drain plug back in with a new seal-
l Check the oil level again , if necessary fill up to ing ring.
the Max.-mark.

5.21 Servicing the battery
! Danger
Danger of cauticization!
When working on the battery do not use open
fire, do not smoke!
Do not let skin and clothes come in contact
with acid!
Wear your protective outfit!
Do not lay any tools on the battery!
Before recharging the battery remove all plugs
to avoid the accumulation of highly explosive
gases.
! Caution
Dispose of used batteries environmentally.
l Open the flap of the battery compartment on
the right hand side.
Fig. 91
l Remove the batteries (Fig. 91) and clean the

battery compartment.
l Clean the batteries from the outside.
l Clean the battery poles and pole clamps and
cover them with acid free grease (vaseline).
l Check the fastening of the batteries.

Every 1000 operating hour s
5.22 Check, adjust the valve

clearance
! Caution
Before checking the valve clearance let the en-
gine cool down for at least 30 minutes. The en-
gine oil temperature must be less than 80 °C.
After a short test run check the engine for
leaks.
Valve adjustment schematic Fig. 93
Crankshaft position 1 (Fig. 93) (4 cylinder en-

gine)
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-
er arm with while chalk once the correspond-
Fig. 92 ing valve is adjusted.
Valve 1 (Fig. 92) white = not adjustable
Valve (2) black = adjustable
Fig. 94
Crankshaft position 2 (Fig. 94) (4 cylinder en-

gine)
l Turn the crankshaft one revolution (360°) fur-
ther.
l Perform the adjustment of the valve by follow-
ing the adjustment diagram "crankshaft posi-
tion 2", black mark.

Check the valve clearance Adjusting the valve clearance

l Loosen the crankcase ventilation valve and
swing it to the side.
Fig. 97
l Slightly slacken the counter nut. Adjust set-

Fig. 95 screw 7 (Fig. 97) with a screwdriver, until the
l Remove the valve cover (Fig. 95). feeler gauge (6) can be inserted and pulled out
with little resistance after retightening the
l Crankshaft position as per "valve adjustment counter nut.
schematic".
l Perform tests and adjustments on all other ad-
justable valves.
l Check the gasket of the valve cover, replace it
if necessary.
l Reassemble the cylinder head cover.
l Swivel the ventilation valve back to correct po-
sition and fasten it.
l Fasten the air filter again and ensure correct fit
of combustion air hoses and clamps.
Fig. 96
l Check valve clearance 2 (Fig. 96) between

rocker arm (1) and valve (3) with a feeler
gauge.
Intake valve = 0,3 mm
Exhaust valve = 0,5 mm
The feeler gauge must fit with little resistance.
l If the gap is too narrow or too wide for the feel-
er gauge, the valve must be adjusted.

i Note
5.23 Checking the condition and
To measure the V-belt tension a free length of at
tension of the fan V-belt, re- least 200 mm is required.
placing the V-belt
Danger
!
Danger of injury!
Work on the fan V-belt must only be performed
with the engine shut down.
Checking the fan V-belt
Fig. 100
l Operate measuring unit b (Fig. 100) with a fin-

ger (I or II or II), until the pressure sping disen-
gages audibly or noticeably.
i Note
The indicator arm remains in the measured posi-
tion.
l take the measuring unit carefully off, without
Fig. 98 moving the indicating arm.
l Inspect the entire circumference of the V-belt
(Fig. 98) visually for damage and cracks. Re-
place damaged or cracked V-belts.
Fig. 101
l Read the V-belt tension where the upper edge

of the indicating arm intersects with the meas-
Fig. 99 uring scale (Fig. 101).
l Press the indicator arm of the tester a (Fig. 99) First installation = approx. 900N
into the gap of the measuring scale. at minimum
l Lay the measuring unit loosely onto the back 600N = tension to approx. 900N
of the fan V-belt.

Tensioning the fan V-belt
Fig. 104
l Release the idler pulley (Fig. 104) in direction

Fig. 102
of arrow until the V-belt is free.
l Release the idler pulley (Fig. 102) against the
l Pull the ribbed V-belt first to the smallest pul-
direction of arrow until the V-belt is tensioned.
ley.
l Measure the V-belt tension, tighten if neces-
l Install the new ribbed V-belt.
sary.
l Release the idler pulley against the direction
of arrow until the V-belt is tensioned.
Changing the fan V-belt
l Measure the V-belt tension, tighten if neces-
sary.
i Note
Retighten the new fan V-belt after a running time
of 20 minutes.
Fig. 103
l Unscrew the fastening screws (Fig. 103) and

slide the fan forward.

Tensioning the V-belt

5.24 Check condition and ten-
sion of refrigerant compres-
sor V-belt, replace the V-belt
Danger
!
Danger of injury!
Work on the V-belt must only be performed
with the engine shut down.
Checking the V-belt
Fig. 106
l Slightly slacken the fastening screws 1, 2 and

3 (Fig. 106).
l Press the compressor in direction of arrow, un-
til the correct V-belt tension is reached.
l Retighten all fastening screws.
Changing the V-belt

l Slightly slacken the fastening screws 1, 2 and
3.
Fig. 105 l Press the compressor against the direction of

arrow completely against the engine.
l Inspect the entire circumference of the V-belt
(Fig. 105) visually for damage and cracks. Re- l Take the old V-belt off.
place damaged or cracked V-belts. l Fit the new V-belt to the V-belt pulleys.
l Check with thumb pressure whether the V-belt l Tension the V-belt as previously described.
can be depressed more than 10 to 15 mm (0.4
– 0.6 inches) between the V-belt pulleys,
retighten if necessary. Caution
!
Check the V-belt tension after a running time of

30 minutes.

5.25 Changing the fuel prefilter

element
! Danger
Fire hazard!
No open fire, do not smoke, do not spill any fu-
el.
Do not inhale any fuel fumes.
Environment Fig. 108

Catch running out fuel, do not let it seep into l Place a collecting vessel (Fig. 108) under the
the ground. drain opening.
l Open the drain tap.
l Drain off fuel, water and dirt, then close the
drain cock.
Bleeding the fuel prefilter
i Note
Air in the fuel system causes irregular running of
the engine, a drop in engine power, stalls the en-
gine and makes starting impossible.
Therefore bleed the fuel system after changing the
fuel prefilter.
Fig. 107
l Unscrew the hexagon screws (Fig. 107) from

the filter cover and take the cover off.
l Take the filter element out of the filter housing.
l Insert the new filter element into the filter hous-
ing.
l Check the seal of the filter cover, replace if
necessary.
l Install the filter cover with seal and tighten the
hexagon screws crosswise.
Fig. 109
l Slacken the bleeding screw (Fig. 109) on the

fuel prefilter for 2 to 3 turns.

5.26 Check, replace leak fuel re-

turn lines
Fig. 110
l Operate the hand pump (Fig. 110) manually,

until fuel flows out of the slackened bleeding
screw (Fig. 109) without air bubbles.
l Then tighten the bleeding screw while pump- Fig. 111
ing.
l Remove the valve cover (Fig. 111).
l Check all rubber hoses of the fuel leak line (2),
replace if necessary, but at the latest after 2
years.
l Check all lines and connections for leaks after
test drive.

l Fill the filter cartridge with clean diesel fuel.

5.27 Change the fuel filter car-
l Turn the new filter cartridge on by hand, until
tridge the seal contacts.
l Tighten the filter element for another half turn.
! Danger l Check the filter cartridge for leaks after a short

test run.
Fire hazard!
open fire, do not smoke and do not spill any fu-
el.
the ground.
Fig. 112
l Loosen and unscrew the fuel filter cartridge

(Fig. 112) using an appropriate filter wrench.
l Clean the sealing face on the filter carrier from
any dirt.
Fig. 113
l Slightly oil the rubber seal (Fig. 113) on the

new filter cartridge.

5.28 Replacing the fuel filter for 5.29 Check the engine mounts
the auxiliary heating
! Danger
Fire hazard!
open fire, do not smoke, do not spill any fuel.
! Caution
the ground.
l Open the engine hood. Fig. 115
l Tighten fastenings of intake and exhaust man-

ifolds (Fig. 115) on the cylinder heads.
l Check sockets and clamps between air filter,
exhaust turbocharger and charge air line as
well as the lubrication air line for tight fit and
leaks.
l Retighten the fastening screws for oil sump
and engine mounts.
Fig. 114
l Loosen the hose clamps and pull the hoses off

both connections on the fuel filter (Fig. 114).
l Install the new fuel filter and tighten the hose
clamps.
l After test running the heater check for leaks.

5.30 Change the oil in the drive

axle
i Note
On other axle versions drain and filler plugs are of
slightly different design. Perform the oil change ac-
cordingly.
Caution
!
Drain oil only at operating temperature.

Fig. 117
Environment l Unscrew the oil filler plug (Fig. 117).

Catch old oil and dispose of environmentally. l Fill in oil through the oil filler opening, until it
reaches the bottom edge of the oil level in-
spection bore (Fig. 116).

l Retighten the filler and level inspection plug.
Fig. 116
l Clean and unscrew oil level inspection plug 1

(Fig. 116).
l Clean and unscrew drain plug (2).
l Drain and catch all oil.
l Turn the drain plug tightly back in.


5.31 Changing the oil in the of fuels and lubricants.
wheel hubs l Turn the plug tightly back in.
! Caution
Drain oil only at operating temperature.
Change the oil on both sides of the axle.
Environment
Catch old oil and dispose of environmentally.
Fig. 118
l Move the drive wheel, until the plug (Fig. 118)

is in bottom position.
l Clean and unscrew the plug.
l Drain and catch all oil.
Fig. 119
l Move the drive wheel, until the plug (Fig. 119)

is in horizontal position on the housing.
l Fill in oil, until it reaches the bottom edge of the
bore.

5.32 Changing the oil for the vi-

bration bearings
! Caution
Change the oil at operating temperature. For
this purpose run the machine approx. half an
hour with vibration.
Environment
Catch running out oil and dispose of environ-
mentally. Fig. 121
l Unscrew the level plug 1 (Fig. 121) at the bot-

tom of the drum and fill in oil through the filler
bore (2), until it starts to run out through the
level bore.

l Screw the oil filler (2) and control plug (1) back
in.
l Repeat the oil change on the opposite side.
l Check the oil level again at operating temper-
ature (after running the vibration for approx.
0.5 hours).
Fig. 120
l Move the drum until the drain plug 1 (Fig. 120) Caution
!
is in lowest position. Overfilling causes overheating of the vibration
l Unscrew the drain plug, drain all oil off and bearings!
catch it.
l Once the oil has run out clean the drain plug
and screw it tightly back in.

5.33 Tightening the fastening of 5.34 Tightening the wheel nuts

the axle to the frame
Fig. 123
Fig. 122 l Tighten the wheel nuts (Fig. 123) in a cross-

l Check all fastening nuts for the axle retaining type pattern.
bolts (Fig. 122) for tight fit.

5.35 Checking the ROPS 5.36 Cleaning the oil bath air fil-
ter *
i Note
On machines with a fitted cabin the ROPS (roll
over protection structure) is integrated in the cab-
in.
Please observe also the respective section in the
safety regulations in this manual.
Fig. 125
l Loosen the quick locks (Fig. 125), take the fil-

ter bowl off and empty it.
l Clean the filter mesh by repetitive dipping into
diesel fuel.
Fig. 124 l Clean the filter bowl with diesel fuel and fill in
engine oil up to the level mark.
l Check the cabin, especially the ROPS (Fig.
124) for cracks, corrosion, damage and miss- l reinstall the filter bowl.
ing fastening elements.
i Note
Unusual movements and noises (vibrations) dur-
ing operation indicate damage or loose fastening
elements.
l Check the fastening screws for the cabin
(ROPS) to the operator's platform for tight fit.
l Check the suspension buffers for the opera-
tor's stand for tight fit.
l Check the condition and the fastening of the
seat belt.
* Option

Every 2000 operating hour s
5.37 Changing the hydraulic oil

and the breather filter
i Note
See also section 5.1 "Notes on the Hydraulic Sys-
tem".
! Caution
Apart from the normal oil change intervals the
hydraulic oil must also be changed after major
repairs in the hydraulic system. Fig. 126
Change the hydraulic oil only at operating tem- l Unscrew the plug (Fig. 126) and drain the hy-
perature. draulic oil off.
Clean the area around the hydraulic oil tank, l Check the sealing ring (1), replace if neces-
the filler opening and the breather filter. sary and screw the plug tightly back in.
Do not use any detergents to clean the system.
Do not start the engine after draining the hy-
draulic oil.
Change the hydraulic oil filter element with
every hydraulic oil change.
! Danger
Danger of scalding!
Danger of scalding by hot oil.
Environment
Catch running out oil and dispose of environ- Fig. 127
mentally. l Take the filler cap (Fig. 127) off.
l Fill in hydraulic oil through the screen.
i Note
The hydraulic oil filter element should only be Note
changed after the test run.
i
We recommend to use the filling and filtering unit
(BOMAG part-no. 079 930 35) with fine filter to fill
the hydraulic system. This filters the hydraulic oil,
prolongs the service life of the hydraulic oil filter
and protects the hydraulic system.
l Check the oil level in the inspection glass.
Nominal value:
approx. 3 cm below the upper edge of the inspec-
tion glass


of fuels and lubricants. 5.38 Changing the hydraulic oil
filter
i Note
The breather filter for the hydraulic tank is located
in the filler cap and must therefore be replaced ! Danger
with the filler cap. Danger of scalding!
l Close the tank with the new filler cap. There is a danger of scalding by hot oil when
unscrewing the filter.
! Caution
If the filter has to be changed together with the
hydraulic oil, the filter should in any case be
changed after the oil change and the test run.
Do not use the oil in the filter bowl.
Environment
Catch running out oil, dispose of oil and filter
element environmentally.
i Note
The filter element must be changed with every hy-
draulic oil change and after major repairs in the hy-
draulic system.
Fig. 128
l Unscrew the cap nut 4 (Fig. 128) and take the

filter bowl (5) with the filter element (3) off.
l Examine the sealing face on the filter element
thoroughly for any visible dirt.
! Caution
Visible impurities can be an early indicator for
a premature failure of system components and

a possible malfunction of parts. In such a case

perform trouble shooting and, if necessary, re- 5.39 Changing the coolant
place or repair defective components. Negli-
gance may damage the complete hydraulic
system. ! Danger
Do not clean or reuse the filter element. Danger of scalding!
l Take the old filter element (3) out and clean Change the coolant only when the engine is
the filter bowl and the thread. cold.
l Reinstall the filter bowl with the new filter ele-
ment, check the condition of the O-rings (1) Environment
and (2), replace if necessary. Catch running out coolant and dispose of envi-
l After a test run check the filter for leaks. ronmentally.
Fig. 129
l Switch the shut-off valve for the cabin heater

to "warm".
Fig. 130
l Unscrew the drain plug, drain all coolant off

and catch it.
l Screw the plug back in after all coolant has
been drained off.

Fig. 131
l Screw the lid off and fill in coolant up to the

MAX-mark.
For quality of coolant refer to section 5.2, fuels

and lubricants.
l Start the engine and run it up to operating tem-
perature.
l Allow the engine to cool down and check the
coolant level again, top up if necessary.

Every 12000 o per ating hours
5.40 Replacing the injection 5.41 Replacing the coolant pump

valve
i Note
i Note This work must only be performed by authorized
service personnel.
This work must only be performed by authorized
service personnel.

5.42 Replacing the pressure re- 5.43 Replacing the crankcase

taining valve ventilation valve
i Note i Note
This work must only be performed by authorized This work must only be performed by authorized
service personnel. service personnel.


As required
As r equired
5.44 Cleaning, changing the dry

air filter cartridge
! Caution
Perform cleaning, maintenance and repair
work only with the engine shut down. Do not
start the engine after removing the filter ele-
ment.
Fig. 134
l Unclip three calmps on the housing cover and

take off the cover (Fig. 134).
Fig. 132
Servicing of the dry air filter is necessary when the
yellow piston (Fig. 132) has reached the inscrip-
tion "Service" in front of a red background, but at
the latest after 2 years.
After completion of the filter service reset the indi- Fig. 135
cator back to "Zero" by pressing the button.
l Pull the main filter element (Fig. 135) with light
turning movements.
Removing the main filter element
Cleaning the main filter element
! Caution
If necessary, the main filter element may be
cleaned up to five times. It must be renewed at
the latest after a maximum utilization period of
two years.
The number of cleaning intervals of the main
filter element can be marked on the safety ele-
ment with a ball pen or a felt pen.
Cleaning does not make sense if the main filter
element is covered with a sooty deposit. Use a
Fig. 133 new filter cartridge.
l Remove the maintenance cover (Fig. 133).

As required
Incorrectly handled inserts may be ineffective Cleaning the dust bowl

because of damage (e.g. cracks) and cause
damage to the engine.
Replace the safety cartridge if the main filter el-
ement is defective!
Additional cleaning intervals between two fil-
ter services signalized by the fault monitoring
board are not necessary.
Fig. 137
l Pull the internal part (Fig. 137) out and remove

the dust from the cover.
l Reinsert the inner part.
!Caution
Fig. 136 When assembling the inner part make sure
that the notch in the cover engages in the
Note opening of the inner part.
i
For cleaning purposes fit a tube to the compressed
air gun (Fig. 136), the end of which should be bent Installing the main filter element
for approx. 90°. l Slide the main filter element carefully into the
The length should reach down to the bottom of the housing.
cartridge. When closing the housing cover the main filter el-
l Blow the cartridge out with compressed air ement is automatically forced in the correct posi-
(max. 5 bar) from inside to outside by moving tion.
the tube up and down inside the cartridge, until l Reinstall the service covers.
it if free of dust.
l Examine the filter cartridge with a torch for Changing the safety filter element
cracks and holes in the paper bellows.
Caution
!
Caution
! The safety filter element must not be cleaned
Do not continue to run the machine with a and should not be used again after it has been
damaged main filter element. If in doubt use a removed.
new main filter element.
Break the seal only to replace the safety filter
element.
The safety filter element must be replaced:
if the main filter element is defective,
after five service intervals of the filter car-
tridge,
at the latest after 2 years,

As required
if the warning light comes on again after serv-

icing the main filter cartridge. 5.45 Adjusting the parking brake
l Remove the housing cover and pull the main
filter element off.
! Caution
Have adjustment work on the brake performed
by a specialist! Always adjust both sides.
l Secure the machine with chocks against unin-
tentional rolling.
l Start the diesel engine to release the brake.
Fig. 138
l Perforate the seal of the safety filter element

from inside to outside using a suitable tool
(Fig. 138) and pull both latches up.
l Grip the safety element by both latches and
pull it out with slight turning movements.
Fig. 139
l Push in a new safety filter element.
l Reassemble main filter element and cover. l Unlock the travel lever (Fig. 139) by pushing it
to the left, but do not actuate it to position "I" or
"II".
Caution
!
The parking brake is released
Make sure that the cover locks engage correct-
ly.
Fig. 140
l Unscrew the locking plate 2 (Fig. 140).

l Turn the square (1) in anti-clockwise direction
against the end stop.

As required
5.46 Changing the tires
! Danger
Danger of accident!
Observe all safety notes for the lifting of loads.
l Place a jack (min. 5 t bearing capacity) under
the rear frame and jack the machine up so that
the wheel can turn freely.
l Unscrew the wheel nuts and take the wheel
off.
Fig. 141
l To adjust the clearance turn the square 1 (Fig.

141) three revolutions back in clockwise direc-
tion.
l Screw the locking plate back on.
l Pull the plug off the brake valve and try to
drive.
The machine must be braked.
Fig. 142
l Attach the wheel (Fig. 142) and tighten the

wheel nuts crosswise with 550 Nm (405 ft. lb.).
l Check the tire pressure, see technical data.

As required
5.47 Changing the fresh air filter 5.48 Tightening torques

in the cabin
Fig. 144
* Strength classes for screws with untreated, non-
lubricated surface. The screw quality is stamped
Fig. 143 on the screw heads.
l Unscrew the fastening screws for the filter 8.8 = 8G
bracket (Fig. 143) and take the filter out.
10.9 = 10K
l Insert the new filter and reassemble the filter
12.9 = 12K
bracket.
l Axle - frame
M 24 = 880 Nm
The values result in a 90% utilization of the screws
yielding point at a coefficient of friction of tot. =
0,14. The tightening torques are not valid when us-
ing MOS2 lubricants.
i Note
Self locking nuts must always be replaced after
they have been unscrewed.

As required
5.49 Engine conservation

If the engine is to be shut down for a longer period
of time (e.g. over winter), please consult the serv-
ice department of the engine manufacturer for fur-
ther details.

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.
! Danger
Danger of injury!
Keep away from rotating parts of the engine.

Trouble shooting
6.2 Engine
Faults Possible cause Remedy
The engine Starter defective or pinion not engaging Have examined by a specialist
does not start
Fuel tank empty Fill and bleed the tank
Temperature below starting limit Use winter fuel and engine oil acc. to the
ambient temperature.
Fuel filter clogged, in winter due to paraf- Change the filter. use winter fuel
fin separation.
Fuel lines leaking Check all line connections for leakages

and tighten the fittings.
Battery discharged or not connected Tighten the pole clamps, check the cable
connections
Injection valves or injection pump defec- Have examined by a specialist

tive
The engine Battery power too low, battery clamps Have the battery checked, clean the ter-
starts poorly and loose or oxidized, causing the starter to minal clamps, tighten them and cover
works irregularly turn too slowly them with acid free grease
with poor power
Especially during winter: the use of too Use engine oil suitable for the ambient
viscous engine oil temperature
Fuel supply restricted, in winter fuel sys- Change the fuel filter. Check the line con-
tem clogged due to paraffin separation nections for leaks and tighten the fittings.
Use winter fuel in the cold season.
Incorrect valve clearance Adjust the valve clearance
Injection valve defective Have examined by a specialist
Injection lines leaking Check the lines for leakages
Turbo charger defective Have examined by a specialist
Dry air filter dirty clean, replace if necessary
Excessive play in the throttle cable Adjust the throttle cable, change it if nec-
essary

Trouble shooting
Faults Possible cause Remedy
Excessive ex- Engine oil level too high Drain the oil to the upper dipstick mark
haust smoke
Dry air filter dirty clean, replace if necessary
Exhaust gas turbo-charger defective Have examined by a specialist
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
Engine over- Cooling fins on radiator extremely soiled Clean the cooling fins
heats, shut (the warning light "engine oil temperature"
down immedi- lights)
ately!
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
Cooling air flow restricted Clean the cooling air duct
V-belt loos or broken Tension or replace the V-belt
Poor engine Engine oil level too high Drain the engine oil down to the upper dip-
power stick mark
Dry air filter dirty clean, change if necessary
Exhaust gas turbo-charger defective Have examined by a specialist
Charge air hose leaking Check fastening and connections
Engine oil pres- Engine oil level too low (control light "en- Top up oil
sure too low gine oil pressure" lights, the warning
buzzer sounds)
Leakages in the lubrication system Shut the engine down immediately, check
fittings on oil lines, lubrication oil filter and
oil cooler for leaks, if necessary tighten
the fittings.
The charge con- Generator speed too low Check the V-belt tension, replace the V-
trol light lights belt if necessary
during opera-
tion, the warning The generator does not charge the bat- Have examined by a specialis
buzzer sounds tery, because generator or regulator is de-
fective

Trouble shooting

Optional Pad foot/Smooth Shell Kit Maintenance
Caution Smooth shell kit.
Units equipped with the optional Pad foot

or Smooth shell kit requires maintenance.
Failure to perform required maintenance will
2
result in a shorten equipment life cycle and
the voiding of the warranty.
Units covered under this maintenance infor-

mation are:
Pad foot shell kit: 1
BOMAG BW145D/DH, BW177D/DH,
BW211D, BW213D/DH
HYPAC C820, C830 and C850 series of
single drum rollers.
Smooth shell Kit: Smooth Hardware Torque specifications:

BOMAG BW145PDH, BW177PDH, Items 1 and 2.
BW211PD, BW213PDH BW145PDH, BW177PDH, C822 C832.
HYPAC C822, C832, C842, C852 Grade 10.9 bolt/nut combination 236 ft. lb.
(320 Nm). 30 Bolts.
Caution
BW211PD, BW213PDH, C842, C852. Grade
Maintenance must be performed every 50 10.9 bolt/nut combination 427 ft. lb. (580
hours or weekly which ever comes first. Fail- Nm). 30 Bolts.
ure to comply with the required maintenance
with result in the voiding of the warranty.
Pad foot shell kit.
4
3 C B A
B
1 C
Smooth shell kit torque sequence.

First torque the bolt at the A position, then
the 2 bolts at the B position and then the 2
bolts at the C position on both sides of the
Pad foot Hardware Torque specifications: drum. Repeat the process for the remaining
Items 1 and 2. Grade 10.9 bolt/nut combina- sections. Recheck the torque values.
tion 221 ft. lb. (300 Nm). 2 Bolts.
Items 3 and 4. Grade 8.8 bolt/nut combina-
tion 156 ft. lb. (212 Nm). 18 Bolts.

Addendum
BOMAG Americas, Inc.
2000 Kentville Rd.
Printed in U.S.A. Kewanee, IL 61443

Operating Instructions Maintenance Instructions: BW211D-3 / BW211PD-3

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Operating Instructions Maintenance Instructions: BW211D-3 / BW211PD-3

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Operating Instructions

Single Drum Vibratory Roller

CE-conformity of this machine is only

BW 211 D-3/PD-3 BOMAG 3

4 BOMAG BW 211 D-3/PD-3

BW 211 D-3/PD-3 BOMAG 5

5.22 Check, adjust the valve clearance 66

6 BOMAG BW 211 D-3/PD-3

BW 211 D-3/PD-3 BOMAG 7

8 BOMAG BW 211 D-3/PD-3

* BW 211 D-3 BW 211 PD-3

BW 211 D-3/PD-3 BOMAG 9

sound capacity level:

Vibration of the entire boy (driver’s seat)

Hand-arm vibration values

10 BOMAG BW 211 D-3/PD-3

BW 211 D-3/PD-3 BOMAG 11

General Unintended use

l generally acknowledged safety and road traffic

12 BOMAG BW 211 D-3/PD-3

! Caution Towing the machine

BW 211 D-3/PD-3 BOMAG 13

14 BOMAG BW 211 D-3/PD-3

Driving on slopes and gradients Filling the fuel tank

BW 211 D-3/PD-3 BOMAG 15

Working on hydraulic lines l Do not mix up hoses by mistake.

l deformation under pressurized and depressu- Working on electrical equipment

16 BOMAG BW 211 D-3/PD-3

BW 211 D-3/PD-3 BOMAG 17

18 BOMAG BW 211 D-3/PD-3

BW 211 D-3/PD-3 BOMAG 19

3.1 General notes 3.2 Description of indicators

20 BOMAG BW 211 D-3/PD-3

shows the fuel level in the fuel tank.

Fig. 8 No. 6 = Rotary switch, speed ranges

BW 211 D-3/PD-3 BOMAG 21

operate = push the button completely

22 BOMAG BW 211 D-3/PD-3

BW 211 D-3/PD-3 BOMAG 23

24 BOMAG BW 211 D-3/PD-3

release = the throttle lever locks in posi-

BW 211 D-3/PD-3 BOMAG 25

(f) 7.5A = Heating blower, radio

26 BOMAG BW 211 D-3/PD-3

maximum fan speed, turn the

BW 211 D-3/PD-3 BOMAG 27

by turning in direction of arrow

28 BOMAG BW 211 D-3/PD-3

BW 211 D-3/PD-3 BOMAG 29

4.1 General notes 4.2 Tests before starting to op-

30 BOMAG BW 211 D-3/PD-3

l Check water separator in the fuel system,

l Fasten your seat belt (Fig. 31).

l Check, whether the travel lever (Fig. 32) is en-

BW 211 D-3/PD-3 BOMAG 31

l Check, whether the emergency stop switch Fig. 37

l Set the throttle lever (Fig. 35) to approx. 1/2

32 BOMAG BW 211 D-3/PD-3