Home

Operating instructions Maintenance instructions

Contents

1. BW 145 D 3 DH 3 PDH 3 Every 1000 operating hours 5 22 Change the oil in the drive axle On other axle versions drain and filler plugs are of slightly different design Perform the oil change ac cordingly Drain oil only at operating temperature Catch old oil and dispose of environmentally e Park the machine on level ground e Clean and unscrew all level inspection and drain plugs Fig 86 e Drain and catch all oil e Clean the drain plug and turn it back in with a new seal ring BOMAG 65 Every 1000 operating hours Fig 87 e Fill in oil through the oil level inspection bores Fig 87 until it has reached the bottom edge of the bore The second level inspection plug as at the back After filling in oil wait until the oil has evenly distrib uted inside the axle For quality and quantity of oil refer to the table of fuels and lubricants e Retighten the filler and level inspection plug 66 BOMAG 5 23 Change the oil in the wheel hubs Drain oil only at operating temperature Change the oil on both sides of the axle Catch old oil and dispose of environmentally f 4 A a 584 031 Fig 88 e Move the drive wheel until the plug Fig 88 is in bottom position e Clean and unscrew the plug e Drain and catch all oil Lf ASS OIL SAE 90 API G Fig 89 e Move the drive wheel until the plug Fig 89 is in
2. BOMAG Operating instructions Maintenance instructions in cord roduct li and safety rea ee BW 145 D 3 DH 3 PDH 3 S N 101 581 21 901 581 47 S N 101 581 22 901 581 48 S N 101 581 23 901 581 49 Single drum roller Catalogue number 008 157 08 01 2004 If the machine is equipped with a battery CALIFORNIA Proposition 65 Warning _ Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling If the machine is equipped with a diesel engine CALIFORNIA Proposition 65 Warning The engine exhaust and some of its constituents are known to the state of California to cause cancer birth defects and other reproductive harm BOMAG machines are products from the wide range of BOMAG compaction equipment BOMAG s vast experience together with the most up to date production and testing meth ods including service life tests of all important components and highest quality demands guarantee maximum reliability of your ma chine These instructions comprise e Safety regulations e Operating instructions e Maintenance instructions e Trouble shooting Using these instructions will e help you to get to know the machine e avoid malfunctions caused by unexpert opera tion Compliance with the maintenance instru
3. Position mid Position right high amplitude low frequency dle direction indicator off Position left or right front and rear direction indica tors on the respective side light up the control light 6 in the fault monitoring board flashes Option Option Option BW 145 D 3 DH 3 PDH 3 BOMAG 23 Indicators and Controls Fig 13 No 8 Rotary switch for speed range selec tion I Position turtle Working speed Position rab bit Transport speed 595 054 Fig 14 No 9 Push button for warning horn STO 595 068 Fig 15 No 10 Emergency stop switch 24 BOMAG The engine will be shut down and the brake will close 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 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 16 No 11 Ignition switch Position P 0 Ignition off key can be pulled out engine off Position I Ignition on
4. cold cleanser let it soak in for a while and spray it off with a strong water jet e Reassemble the cooling air duct cover run the engine warm for a while to avoid corrosion 56 BOMAG 5 12 Cleaning the cooling fins on the hydraulic oil cooler Danger of injury Perform cleaning work only after the engine has cooled down and with the engine stopped Do not damage any cooling fins on the cooler core when cleaning 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 Start to blow out from the exhaust side 0 R d w H WE Fig 65 e Blow the cooler Fig 65 out with compressed air BW 145 D 3 DH 3 PDH 3 Cleaning with cold cleansing agent In case of oily dirt spray the cooler with a cold cleansing agent and let it soak in for about 10 minutes Protect electrical equipment such as genera tor regulator and starter against the direct wa ter jet e Spray the radiator with a suitable cleansing agent e g cold cleanser let it soak in for a while and spray it off with a strong water jet e Run the engine warm for a while to avoid cor rosion BW 145 D 3 DH 3 PDH 3 Every 250 operating hours 5 13 Check the
5. which could be an ob struction by attaching clearly visible signs Parking on gradients or slopes Secure the machine against rolling away place metal chocks in front of and behind the drums BW 145 D 3 DH 3 PDH 3 Safety regulations Filling the fuel tank Do not inhale fuel fumes Refuel only after shutting the engine and the aux iliary heater down Do not refuel in closed rooms No open fire do not smoke Do not spill any fuel Catch running out fuel do not let it seep into the ground Wipe off spilled fuel Keep fuel free of dirt and wa ter Leaking fuel tanks can cause explosions Ensure tight fit of the fuel tank filling cover replace it if nec essary Fire protection measures Make yourself acquainted with the location and the operation of fire extinguishers Observe fire warn ing and fire fighting installations Maintenance work Strictly apply the specified maintenance tasks in cluding the changing of parts Maintenance work must only be carried out by skilled and authorized personnel In case of maintenance and assembly work over head make sure to use the prescribed or other safe access steps ladders and gangways Do not use parts of the machine as access steps Keep unauthorized persons away from the ma chine Do not perform maintenance work while the ma chine is driving or the engine is running Park the machine on ground as level and firm as possible Pull the ignition key ou
6. 3 possible malfunction of important parts In such a case you should perform trouble shoot ing and replace or repair the defective compo nents Nonobservance may lead to total damage of the hydraulic system Do not clean or reuse the filter element e Take the old filter element 3 out and clean the filter bowl and the thread e Reinstall the filter bowl with the new filter ele ment check the condition of the O rings 1 and 2 replace if necessary e After a test run check the filter for leaks BW 145 D 3 DH 3 PDH 3 BOMAG Every 2000 operating hours 73 Every 3000 operating hours 5 32 Checking the injection valves This work must only be performed by authorized service personnel The injection valves must be replaced every 12000 operating hours 74 BOMAG BW 145 D 3 DH 3 PDH 3 5 33 Replacing the toothed belt The toothed belt must only be changed by a specialist workshop or by the After Sales Serv ice of BOMAG Do not retension toothed belts replace them together with the idler pulley Replace a toothed belt at the latest after 5 years even if the number of operating hours has not yet been reached Fig 100 e Have the toothed belt Fig 100 replaced by a specialist workshop BW 145 D 3 DH 3 PDH 3 BOMAG Every 5000 operating hours 75 As required 5 34 Checking cleaning chang ing the combustion air filter Perform cleaning maintenance and repair work only with the engin
7. Check ifthere are persons or obstacles in the dan ger area before starting or resuming work espe cially when driving in reverse If necessary give warning signals Stop work im mediately if persons remain in the danger area despite the warning Do not stand in the machine s articulation area while the engine is running Danger of injury Driving In emergency situations and in case of danger op erate the emergency stop switch immediately Do not use the emergency stop switch as service brake Resume operation only after eliminating the dan ger that has led to the actuation of the emergency stop If the machine comes in contact with high voltage power lines e do not leave the operator s stand e warn others from coming close to the machine or touching it e if possible move the machine out of the danger zone e have the power shut off Operate the machine only from the operator s stand Keep the cabin doors closed Do not adjust the operator s seat while driving Do not climb onto or off the machine while it is driv ing Choose the travel direction only when the machine is standing Do not use the machine to transport persons If you recognize unusual noises and the develop ment of smoke detect the cause and have the fault corrected Always keep a safe distance to excavations and embankments and avoid all activities which could impair the stability of the machine BW 145 D 3 DH 3 PDH 3 Do not wo
8. ISO 6743 3 The viscosity in dex VI should be at least 150 observe informa tion of manufacturer Bio degradable hydraulic oil On request the hydraulic system can also be filled with ester based biodegradable hydraulic oil Pan olin HLP Synth 46 The biologically quickly de gradable hydraulic oil meets all demands of a mineral oil based hydraulic oil according to DIN 51524 BW 145 D 3 DH 3 PDH 3 In hydraulic systems filled with Panolin HLP Synth 46 always use the same oil to top up When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil you should consult the lubrication oil service of the oil manu facturer for details Check the filter more frequently after this change Oil change bio degradable hydraulic oil Perform regular oil analyses for content of wa ter and mineral oil Replace the hydraulic oil filter element every 500 operating hours Oil for drive axle For the drive axle use only multi purpose transmis sion oil of AP 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 BW 145 D 3 DH 3 PDH 3 BOMAG Maintenance 47 Maintenance 5 3 Table of fuels and lubri cants Assembly Fuel or lubricant Quantity approx Summer Winter Attention Observe the level marks En
9. of blisters e leakages e non observance of installation requirements e separation of the hydraulic hose from the crimped fitting e corrosion of the crimped fitting which impairs the function and the strength e do not mix up hoses by mistake e damage or deformation of the fitting which ef fects the function and the strength or impairs the hose hose connection Only the use of genuine BOMAG hoses ensures that the correct type of hose pressure range is used at the right place Working on the engine Shut the engine down before opening the engine compartment hood 16 BOMAG Drain the hydraulic oil at operating temperature danger of scalding Wipe off spilled oil catch running out oil and dis pose of environmentally Store used filters and other oily materials in a spe cially marked refuse container and dispose of en vironmentally Do not leave any tools or other parts which could lead to damage in the engine compartment Working in the electric system Disconnect the battery and cover it with insulating material before starting to work in the electric sys tem Do not use fuses with higher Ampere ratings and do not repair fuses with a piece of wire Fire haz ard Always disconnect the battery before starting to weld on the machine Working on the battery When working on the battery do not smoke do not use open fire Do not let hands or clothes come in contact with acid Treat acid injuries wit
10. otherwise the fuel system needs to be bled e Clean the area around the filler opening Fig 60 e Open the fuel tank cover Fig 60 BW 145 D 3 DH 3 PDH 3 BOMAG Every 10 operating hours Contaminated fuel can cause malfunction or even damage of the engine If necessary fill in fuel through a funnel with screen e f necessary top up with fuel diesel or winter diesel For quality of fuel refer to the table of fuels and lubricants 53 Every 10 operating hours 5 9 Checking the hydraulic oil level In hydraulic systems filled with Panolin HLP Synth 46 always use the same oil to top up With other ester based oils consult the lubrica tion oil service of the respective oil manufac turer Fig 61 e Check the hydraulic oil level in the inspection glass Fig 61 Normal level approx 3 cm below the top edge of the inspection glass Minimum level Middle of inspection glass If during the daily inspection of the oil level the hydraulic oil level is found to have dropped check all lines hoses and compo nents for leaks 54 BOMAG l 18 NGS e f necessary fill in hydraulic oil through the filler neck Fig 62 For quality and quantity of oil refer to the table of fuels and lubricants BW 145 D 3 DH 3 PDH 3 5 10 Checking the tire pressure Since the tires are filled with water you should always turn the inflation valve to top position to check the tire pres
11. pull the ignition key out lock the cabin door BW 145 D 3 DH 3 PDH 3 Operation 4 9 Switching the vibration on and off Risk of damage When compacting with vibration you must check the effect of nearby buildings and un derground supply lines gas water sewage electric power if necessary stop compaction with vibration Do not activate the vibration on hard frozen concrete ground Danger of bearing damage When using the machine on asphalt Vibration at standstill causes transverse marks therefore e switch the vibration on only after shifting the travel lever to the desired travel direction e Switch the vibration off before stopping the machine Preselecting the vibration Fig 42 e Preselect amplitude frequency with the rotary switch Fig 42 BOMAG 37 Operation Switching the vibration on 4 10 Adjusting the seat Danger of accident Do not adjust the driver s seat while driving Fig 43 e Set the throttle lever Fig 43 to position II full speed Switch the vibration on only at max engine speed Fig 45 e To adjust the seat in longitudinal direction dis engage lever 1 Fig 45 and push the seat for ward or back e To adjust the inclination of the backrest oper ate lever 2 and tilt the backrest forward or back e To adjust the weight adjust lever 3 accord ingly In its adjustment the lever 3 is locked in upwards direction This lock c
12. stick agent manufacturer Strictly 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 easily inflammable substances for cleaning purposes When using high pressure cleaning equipment do not subject electrical parts and insulating materials to the direct water jet or cover them beforehand e Do not guide the water jet into the exhaust or into the air filter After maintenance work Reinstall all protections and guards once all main tenance work is completed Repair Attach a warning tag to the steering wheel if the machine is defective Repairs must only be performed by qualified per sons who have been instructed for this purpose Use our repair instructions Exhaust gases are highly dangerous Always en sure an adequate supply of fresh air when starting in closed rooms Test Depending on the type of application and the op erating conditions vibratory equipment has to be examined by a specialist whenever required but at least once every year BW 145 D 3 DH 3 PDH 3 BOMAG Safety regulations Safety regulations BOMAG BW 145 D 3 DH 3 PDH 3 BW 145 D 3 DH 3 PDH 3 3 Indicators and Controls BOMAG Indicators and Controls BOMAG BW 145 D 3 DH 3 PDH 3 i NO O R Go DN BW 145 D 3 DH 3 PDH 3 Multi function display Rotary switch for flashing beacon Rotary s
13. the oil sump Fig 76 e Check the oil level again Fig 76 if necessary fill up to the Max mark e Check filter cartridge and drain plug for leaks BOMAG 61 Every 500 operating hours 5 19 Checking the V belt tension tightening Checking the V belt Fig 77 Inspect the entire circumference of the V belt visually for damage and cracks Replace damaged or cracked V belts Check with thumb pressure whether the V belt can be depressed more than 10 15 mm be tween the V belt pulleys Fig 77 retighten the V belt if necessary Retightening the V belt Fig 78 62 Slightly slacken the fastening screw 1 Fig 78 Press the idling pulley 2 in direction I until the correct V belt tension is achieved Tighten the fastening screws 1 BOMAG BW 145 D 3 DH 3 PDH 3 5 20 Checking adjusting the valve clearance Before checking the valve clearance let the en gine cool down for at least 30 minutes The en gine oil temperature must be less than 60 C Valve clearance Intake valve 0 3mm Exhaust valve 0 5mm e Open the engine hood completely and support it safely e Press the engine shut down lever 1 Fig 80 against the stop 2 and fasten it with a wire BW 145 D 3 DH 3 PDH 3 Every 1000 operating hours Fig 81 e Crank the engine with the starter until both valves on cylinder 1 Fig 81 are overlap ping Overlapping means that the exhaust
14. to position l idle speed Run the engine warm for a short while but do not run with idle speed for more than 10 min utes BW 145 D 3 DH 3 PDH 3 Operation 4 4 Starting with jump leads Wrong connection will cause severe damage to the electrical system Fig 34 BOMAG When starting with an external battery connect both plus poles Fig 34 first and both minus poles earth cable after Perform the work steps described in the previ ous paragrapf After starting disconnect the minus poles earth cable first and the plus poles after 33 Operation 4 5 Driving the machine Danger of accident Wet and loose soils considerably reduce the ground adhesion of the machine on inclina tions and slopes Soil conditions and weather influences impair the gradability of the machine Do not drive up and down inclinations exceed ing the maximum gradability of the machine see technical data Do not drive without wearing your seat belt Always give way to loaded transport vehicles Before starting to drive make sure that the drive range is absolutely safe Select the travel speed range only when the machine is standing Fig 35 e Select the desired travel speed range Fig 35 34 BOMAG Fig 36 e Shift the throttle lever to position II Fig 36 full load and lock it Fig 37 e Push the travel lever Fig 37 to the left out of braking position and move it slowly t
15. AG dealer when giving him the serial number of your machine Information about the correct use of our machines in earth work and for asphalt applications can be obtained from your BOMAG dealer The above points do not constitute an extension of the warranty and liability conditions specified in the general terms of business of BOMAG We wish you much success with your BOMAG machines BOMAG GmbH amp Co OHG Printed in Germany Copyright by BOMAG Foreword Please fill in Paz EE WEISER Serial number Fig 1 and 2 meola mu w Engine number Fig 3 SR Supplement the above data together with the com missioning protocol During commissioning our organisation will in struct you in the operation and maintenance of the machine Please observe strictly the safety regulations and all notes on risks and dangers Fig 2 4 BOMAG BW 145 D 3 DH 3 PDH 3 Technical Data Safety regulations Indicators and Controls Operation Maintenance BW 145 D 3 DH 3 PDH 3 3 1 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 4 13 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 5 10 5 11 5 12 5 13 5 14 5 15 5 16 5 17 5 18 5 19 5 20 5 21 5 22 General notes General notes Tests before taking into operation Starting the engine Starting with jump leads Driving the machine Emergency exit Operating the parking brake stopping the machine Shutting the engine down Switching the vibratio
16. For lifting use also the four lifting eyes Fig 55 and appropriate lifting gear Weights See technical data e After transport release the articulation lock again and store it in the receptacle 42 BOMAG BW 145 D 3 DH 3 PDH 3 BW 145 D 3 DH 3 PDH 3 5 Maintenance BOMAG 43 Maintenance 5 1 General notes on mainte nance When performing maintenance work always com ply with the appropriate safety regulations Thorough maintenance of the machine guaran tees far longer safe functioning of the machine and prolongs the lifetime of important components The effort needed for this work is only little com pared with the problems that may arise when not observing this rule The terms right left correspond with travel direc tion forward e Always clean machine and engine thoroughly before starting maintenance work e For maintenance work stand the machine on level ground e Perform maintenance work only with the en gine shut down e Relieve hydraulic pressures before working on hydraulic lines e Before working on electric parts of the ma chine disconnect the battery and cover it with insulation material e When working in the area of the articulated joint attach the articulation lock transport lock During maintenance work catch all oils and fu els and do not let them seep into the ground or into the sewage system Dispose of oils cool ant and fuels environmentally Notes on the fuel s
17. OMAG International Office Addresses Internationale BOMAG Adressen Head Office Hauptsitz BOMAG Hellerwald 56154 Boppard GERMANY Tel 49 6742 100 0 Fax 49 6742 3090 e mail germany bomag com www bomag com BOMAG CANADA INC 1300 Aerowood Drive Mississauga Ontario L4W 1B7 CANADA Tel 1905 6256611 Fax 1905 6254403 e mail canada bomag com BOMAG France S A S BP 34 Z A des Cochets 91223 Bretigny sur Orge cedex FRANCE Tel 33 169883900 Fax 33 160841866 e mail france bomag com BOMAG Italia Srl Zona Industriale Localit Faustinella 25015 Desenzano del Garda BS ITALY Tel 39 030 9127263 Fax 39 030 9127278 e mail italy bomag com BOMAG Representative Office Asia amp Pacific 300 Beach Road The Concourse 32 02 Singapore 199555 SINGAPORE Tel 65 6294 1277 Fax 65 6294 1377 e mail singapore bomag com BOMAG Maschinenhandelsgesellschaft m b H Postfach 73 PorschestraRe 9 1234 Wien Siebenhirten AUSTRIA Tel 43 1 69040 0 Fax 43 1 69040 20 BOMAG Shanghai Compaction Machinery Co Ltd No 1619 Huhang Road Shanghai Comprehensive Industrial Zone Fengxian Shanghai 201400 P R CHINA Tel 86 2167104242 Fax 86 2167104141 BOMAG GREAT BRITAIN LTD Sheldon Way Larkfield Aylesford Kent ME20 6SE GREAT BRITAIN Tel 44 1622 716611 Fax 44 1622 718385 e mail go bomag com BOMAG Japan Co Ltd EKK Bldg 5F 3 2 2 Nihonbashi Kayab
18. S The machine frame must not be distorted bent or cracked in the area of the ROPS structure The ROPS structure must not show any rust dam age hairline cracks or open fractures The ROPS must not rattle about when driving the machine This would mean that the fastening screws are insufficiently fastened All screwed connections must be tight and in accordance with the specifications observe the tightening tor ques Screws and nuts must not be damaged distorted or deformed No additional parts must be welded or bolted on and no holes must be drilled without the permis sion of the dealer since this may impair the strength of the structure Starting the machine Before starting Operation of the machine is only permitted when sitting in the operator s seat Use only machines which have been properly serviced at regular intervals Become acquainted with the equipment the con trol elements the working mode of the machine and the area you will be working in Use your personal protective outfit hard hat safe ty boots etc Check before mounting the machine if e there are persons or obstructions beside or under the machine BOMAG 13 Safety regulations e the machine is free of any oily and combustible material e all handrails steps and platforms are free of grease oils fuels dirt snow and ice e the engine compartment hood is closed and locked To climb onto the machine use steps and hand rai
19. a cho Chuo ku Tokyo 103 0025 JAPAN Tel 813 5645 1610 Fax 813 36648570 e mail japan bomag com BOMAG Americas Inc 2000 Kentville Road Kewanee Illinois 61443 U S A Tel 1 309 8533571 Fax 1 309 8520350 e mail usa bomag com
20. abin 1 not used 2 7 5A Inside light 3 7 5A Windscreen wiper washer rear 4 7 5A Windscreen wiper washer front 5 7 5A Flashing beacon 6 7 5A Heating blower radio Fire hazard Do not use fuses with higher ampere ratings and do not bridge fuses No 20 Toggle switch heating blower No 21 Toggle switch flashing beacon No 22 Toggle switch windscreen wiper washer front No 23 Toggle switch windscreen wiper washer rear No 24 Cabin light switch on turn lamp glass clockwise switch off turn lamp glass counter clock wise No 25 Vent for fresh air intake to operate the slide loosen the adjustment button slide to the left air circulation position slide to the right fresh air position Optional equipment Option 77 Option Option BW 145 D 3 DH 3 PDH 3 Indicators and Controls Switch on the auxiliary hot air blower Fig 24 No 26 Shut off valve for cabin heater kkk The heat exchanger of the cabin heater receives the heat energy from the lubrication oil in the en gine Position I Cabin heater switched off Il Position II Cabin heater full power Optional equipment BOMAG 27 Indicators and Controls 28 BOMAG BW 145 D 3 DH 3 PDH 3 BW 145 D 3 DH 3 PDH 3 4 Operation BOMAG 29 Operation 4 1 General notes Please read section 3 Indicators and Control Ele ments thoroughly before
21. all control and warning lights in the multi function display light up for a moment The engine can only be started if both travel levers are in neutral BW 145 D 3 DH 3 PDH 3 The ignition switch is designed with a lock to pre vent repetitive starting For a new starting attempt the ignition key must first be turned back to posi tion 0 Position II turn further against spring pressure he engine starts turn the ignition key back to position once the engine has started Run the engine warm for a short while before starting work Do not allow the engine to run longer than 10 minutes with idle speed Do not shut the engine down all of the sudden from full speed but let it idle for a while for temperature equalization Fig 17 No 12 Push button for vibration e Select or actuate the frequencies with the vi bration selector switch e Switch the vibration on or off by pressing the push button BW 145 D 3 DH 3 PDH 3 Indicators and Controls Fig 18 No 13 Travel lever Position mid dle Braking position service brake Position middle right Parking brake to start the en gine Position I Forward travel Position II Backwards travel If the engine speed drops under load when driving on steep gradients take the travel lever slightly back towards neutral This relieves the hydraulic system and the diesel engine Q S l ONS 3 582 037 Fig 19 No 14 Th
22. an be released by pressing the lever completely down against the stop Then adjust to the weight of the operator by sliding the e Press the push button Fig 44 in the travel le lever down ver while driving the drum will vibrate Fig 44 Switching the vibration off e Press the push button again and after work switch the rotary vibration switch to position Q 38 BOMAG BW 145 D 3 DH 3 PDH 3 Operation 4 11 Operating the hood 4 12 Towing in case of an engine GER failure Danger of accident If the hood needs to be opened further for Life hazard maintenance or repair work support it safely Since the machine is not fitted with a towing hitch the machine cannot be towed with a tow bar If the machine has to be towed urgently out of the danger zone because of other risks this must only be done on level ground or uphill us ing chains and ropes For this purpose towing ropes of sufficient ten sile strength must be fastened on the lifting eyes After releasing the brake the machine can only be braked by the towing vehicle Before releasing the brake block the machine with chocks to prevent unintended rolling Fig 46 e Unlock the lock 1 Fig 46 e To unlock the hood press the latch 2 down A d2k and pull the handle 3 back e max towing speed must not excee m h development of heat in the drive section of the hydraulic motor The towing distance must not exceed 1 km be cause the hydraul
23. axle on the frame 5 28 Tighten the wheel nuts 5 29 Check the ROPS Intake 0 3 mm exhaust 0 5 mm on cold engine min 1x per year min 1x per year min 1x per year 50 BOMAG BW 145 D 3 DH 3 PDH 3 Maintenance No Designation Note Every 2000 operating hours 5 30 5 31 k Change hydraulic oil and breather filter Change the hydraulic oil filter at least every 2 years at least every 2 years Every 3000 operating hours 5 32 Check the injection valves Every 5000 operating hours 5 33 Replace the toothed belt at least every 5 years As required 5 34 Clean change the combustion air filter min 1x every year safety cartridge at least every 2 years 5 35 Adjust the parking brake 5 36 Change the tires 5 37 _ Adjust the scrapers 5 38 Change the fresh air filter in the cabin 5 39 Tightening torques 5 40 Engine conservation Also in case of repairs in the hydraulic system BW 145 D 3 DH 3 PDH 3 BOMAG 51 Every 10 operating hours 5 6 Checking the engine oil lev el With the machine on level ground shut the engine down and wait for about 15 minutes so that all oil can flow back into the oil sump e Open the engine hood is hua e 582 040 Fig 57 e Pull the dipstick Fig 57 out wipe it off with a lint free clean cloth and reinsert it until it bot toms e Pull the dipstick back out agai
24. ctions will e increase the reliability of your machine on the site e increase the service life of the machine e reduce repair costs and downtimes BOMAG shall not assume liability for safe func tioning of the machine e if itis handled in a way which does not comply with the usual modes of use e ifitis used for purposes other than those men tioned in the instructions No warranty claims can be lodged for damage re sulting from e operating errors e insufficient maintenance and e wrong fuels and lubricants Please note This manual has been written for the operator and the service personnel at the site Keep this manual always close at hand e g inthe tool compartment of the machine or in the contain er provided BW 145 D 3 DH 3 PDH 3 BOMAG Foreword You should only operate the machine if you are ful ly familiar with the contents of these instructions You must also observe all applicable safety regu lations Please observe also the guidelines of the Civil En gineering Liability Association Safety Regulations for the Operation of Road Rollers and Soil Com pactors and the applicable accident prevention in structions For your own safety you should only use BOMAG spare parts We reserve the right for technical modifica tions without prior notification These operating and maintenance instructions are also available in other languages A spare part catalogue can be obtained from your BOM
25. d as an emergency exit BOMAG 35 Operation 4 7 Operating the parking brake stopping the ma chine Fig 38 e Return the travel lever Fig 38 slowly to neu tral position and engage it to the right parking brake position The hydrostatic drive brakes the machine auto matically the parking brake closes after approx 2 seconds The parking brake also closes automatically when shutting the engine down 36 BOMAG 4 8 Shutting the engine down Straighten the articulated joint to provide easi er access to the machine Fig 39 e Return the travel lever Fig 39 slowly to neu tral position and engage it to the right in brak ing position Fig 40 e Pull the locking plate Fig 40 up and set the throttle lever to position I idle speed Do not shut the engine down all of the sudden from full speed but let it idle for a while for temperature equalization BW 145 D 3 DH 3 PDH 3 Fig 41 e Turn the ignition key Fig 41 to position 0 or P and pull the ignition key out After shutting the engine down with the throttle le ver the central warning light lights and the warn ing buzzer sounds until the ignition switch is turned to position 0 The parking brake closes automatically when shutting the engine down Danger of accident On particularly steep inclinations place wheel chocks in front of or behind drum and wheels Secure the machine against unauthorized use
26. e The screw quality is stamped on the screw heads 8 8 8G 10 9 10K 12 9 12K e Axle frame M 24 880Nm e Wheel nuts M 22x1 5 550Nm The values result in a 90 utilization of the screws yielding point at a coefficient of friction of u tot 0 14 The tightening torques are not valid when us ing MOS lubricants Self locking nuts must always be replaced after they have been unscrewed BOMAG BW 145 D 3 DH 3 PDH 3 5 40 Engine conservation If the engine is to be shut down for a longer period of time e g over winter we recommend to apply the following conserving measures to avoid corro sion e Clean the engine including the cooling sys tem With cold cleansing agent and a water jet or even better with a steam cleaner e Run the engine warm and shut it down e Drain off the still hot engine oil and fill in anti corrosion engine oil e Drain off the coolant and fill in system protec tion agent e Drain the fuel from the tank mix it well with 10 anti corrosion oil and fill it back in e Runthe engine for 10 minutes until all lines fil ters pumps and nozzles with this conserving mixture and the new engine oil has been dis tributed to all parts e Now crank the engine several times without ignition to spray the combustion chambers e Take the V belts off and spray the grooves of the V belts with anti corrosion oil Remove the anti corrosion oil before resuming operation e Close in
27. e shut down Do not start the engine after removing the filter ele ment Do not use gasoline or hot fluids to clean the filter element After cleaning the filter element must be in spected for damage using a torch Air filter elements with damaged paper bellows or seal lips must be replaced in any case The main filter element must be replaced after 3 times cleaning but at the latest after one year irrespective of the operating hours Each cleaning interval must be marked with a cross on the cover of the filter element Cleaning does not make sense if the air filter element is covered with a sooty deposit Use a new filter element Incorrectly handled filter elements may be come ineffective because of damage e g cracks and cause engine damage Fig 101 Maintenance of the dry air filter is due when con trol light e Fig 101 in the multi function display lights permanently when the engine is running but at the latest after one year 76 BOMAG Once the air filter service indicator lights up work may be continued until the end of the day Fig 102 e Remove the maintenance cover Fig 102 Fig 103 e Release the locking hook Fig 103 and take the filter hood off e Clean filter hood and dust discharge valve BW 145 D 3 DH 3 PDH 3 723 037 Fig 104 e Carefully loosen the main filter element Fig 104 The main filter element is located directly on the air intake tube
28. er the rear frame and jack the machine up so that the wheel can turn freely e Unscrew the wheel nuts and take the wheel off Fig 113 e Attach the wheel Fig 113 and tighten the wheel nuts crosswise with 550 Nm 405 ft Ib e Check the tire pressure see technical data BW 145 D 3 DH 3 PDH 3 As required EE er towards the drum leaving a gap of approx 5 37 Adjusting the scrapers 25 mm e Retighten the fastening screws smooth drum only Fig 114 e Check the condition and adjustment of the front and rear scrapers adjust or replace the scraper rubber if necessary e To adjust the scrapers 1 Fig 114 loosen the fastening screws 2 in the slots and push the scraper bracket towards the drum until the scraper touches e Retighten the fastening screws padfoot drum only Fig 115 e Check condition and adjustment of scrapers 2 Fig 115 adjust or replace the teeth if neces sary e To adjust the scrapers 2 slacken the fasten ing screws 1 in the slots and move the scrap BW 145 D 3 DH 3 PDH 3 BOMAG 81 As required 5 38 Changing the fresh air filter in the cabin Fig 116 e Remove the filter screen Fig 116 and take the filter out e Insert a new filter and reassemble the filter screen 82 5 39 Tightening torques i Tightening torques ft Ib Bolt dimensions EAA 2 3 4 4 7 7 Fig 117 Strength classes for screws with untreated non lubricated surfac
29. ering operation Vibration Drive system Frequency Amplitude Tires Tire size Air pressure Tank contents Hydraulic oil Fuel Engine oil The right for technical modifications remains reserved BW 145 D 3 DH 3 PDH 3 BW 145 D 3 Deutz BF4L 2011 Air oil A kW 56 rpm 2650 Diesel V 12 hydrostatic 2 hydrostatic hydr mech articulated hydrostatic hydrostatic Hz 34 mm 1 7 0 85 335 80R20MPT81 bar 1 8 Litres 44 Litres 110 Litres 10 5 BOMAG BW 145 DH 3 Deutz BF4L 2011 Air oil 4 56 2650 Diesel 12 hydrostatic 2 hydrostatic hydr mech articulated hydrostatic hydrostatic 34 1 7 0 85 335 80R20MPT81 1 8 44 110 10 5 Technical Data BW 145 PDH 3 Deutz BF4L 2011 Air oil A 56 2650 Diesel 12 hydrostatic 2 hydrostatic hydr mech articulated hydrostatic hydrostatic 34 1 4 0 7 340 80R 1 8IT530 1 8 44 110 10 5 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 Loa 78 4 dB A sound capac
30. g the hydraulic oil filter 72 5 32 Checking the injection valves 74 5 33 Replacing the toothed belt 75 5 34 Checking cleaning changing the combustion air filter 76 5 35 Adjusting the parking brake 79 5 36 Changing the tires 80 5 37 Adjusting the scrapers 81 5 38 Changing the fresh air filter in the cabin 82 5 39 Tightening torques 82 5 40 Engine conservation 83 85 6 1 General notes 86 6 2 Engine 87 BOMAG BW 145 D 3 DH 3 PDH 3 BW 145 D 3 DH 3 PDH 3 1 Technical Data BOMAG Technical Data H2 H Fig 4 Dimensions in A B mm BW 145 D 3 2222 1546 BW 145 DH 3 2222 1546 BW 145 PDH 3 2222 1546 Weights Operating weight CECE with ROPS cabin Front axle load CECE Rear axle load CECE Static linear load Travel characteristics Travel speed 1 Travel speed 2 Max gradability with vi bration 1058 1058 1044 01 H H2 K L Oi 02 1900 2750 313 4194 60 60 1900 2750 313 4194 60 60 1900 2750 313 4194 60 60 BW 145 D 3 BW 145 DH 3 kg 4990 5050 kg 2620 2680 kg 2370 2370 kg cm 18 4 18 8 km h o e 0 5 km h 0 10 0 10 47 55 BOMAG B 02 580 076 S W 22 1426 22 1426 15 1426 BW 145 PDH 3 5330 2960 2370 0 5 0 10 55 BW 145 D 3 DH 3 PDH 3 Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 3046 Rated speed Fuel Electrical equipment Drive system Driven axles Brakes Service brake Parking brake Steering Type of steering Ste
31. gine Engine oil ACEA E3 96 E5 02 or approx 10 5 litres Hydraulic system Vibration bearings Drive axle Planetary drive API CG 4 CH 4 SAE 10W 40 20 C to 40 C Fuel Diesel Winter diesel fuel Hydraulic oil ISO HV46 kinem viscosity 46 mm s at 40 C Engine oil SAE 15W 40 Gear oil SAE 90 API GL5 Gear oil SAE 90 API GL5 approx 110 litres approx 44 litres approx 2 1 litres approx 6 7 litres approx 1 litre per side Tires Water 68 litres Calcium chloride CaCl or magnesium chloride 29 kg MgClo Oil quantity with filter change 48 BOMAG BW 145 D 3 DH 3 PDH 3 BW 145 D 3 DH 3 PDH 3 Maintenance 5 4 Running in instructions The following maintenance work must be per formed when running in new machines or overhauled engines 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 50 operating hours e Retighten bolted connections on intake and exhaust tubes oil sump and engine mounts e Check the engine for leaks e Retighten the bolted connections on the ma chine e Retighten all wheel fastening screws with the specified tightening torque Check the V belt tension tighten if necessary Oil change diesel engine Oil filter cartridge diesel engine Check the valve clearance adjust if necessa
32. h clear water and con sult a doctor Metal objects e g tools rings wrist watches must not touch the battery poles danger of short circuits and fire When recharging maintenance free batteries re move all plugs to avoid the accumulation of highly explosive gases Observe all relevant instructions when starting with an auxiliary battery Dispose of used batteries environmentally Shut the charging current down before discon necting charging clamps Ensure an adequate supply of fresh air especially if the battery is to be charged in a closed room Working on the fuel system Do not inhale fuel fumes No open fire do not smoke do not spill any fuel Catch running out fuel do not let it seep into the ground and dispose of environmentally BW 145 D 3 DH 3 PDH 3 Working on wheels and tires Explosion like bursting of tires and parts of tires and rims can cause most severe or even fatal inju ries The assembly of tires must only be carried out by experienced personnel and with the correct equip ment If necessary have the tires assembled in a qualified workshop Always ensure correct tire pressure and do not ex ceed the max permissible pressure Examine the tires every day for too low pressure cuts bulges faulty rims missing wheel studs or nuts Do not drive with faulty tires or wheels Non stick emulsion must only be mixed of water and non stick additives according to the instruc tions of the non
33. he lubrica tion oil sump Fig 91 e Unscrew the fuel filter cartridge Fig 91 using an appropriate filter wrench e Clean the sealing face on the filter carrier from any dirt e Cover the rubber seal on the new filter car tridge slightly with oil and fill in clean fuel e Turn the new fuel filter cartridge on by hand until the seal contacts e Tighten the fuel filter cartridge for another half turn e After the test drive check the filter cartridge for leaks e Check the condition and tight fit of the engine pillow blocks Fig 93 Bleeding of the fuel system is not necessary 68 BOMAG BW 145 D 3 DH 3 PDH 3 Every 1000 operating hours 5 27 Tightening the fastening of 5 28 Tightening the wheel nuts the axle on the frame Fig 95 Fig 94 e Tighten the wheel nuts Fig 95 in a crosswise e Check all fastening nuts for the axle studs for PELE tight fit Fig 94 Tightening torques 550 Nm 405 ft Ib M22x1 5 BW 145 D 3 DH 3 PDH 3 BOMAG 69 Every 1000 operating hours 5 29 Checking the ROPS With the cabin assembled the ROPS Roll Over Protection Structure is integrated in the cabin Please observe also the respective section in the safety regulations in this manual Fig 96 e Check the cabin especially the ROPS Fig 96 for cracks corrosion damage and missing fastening elements Unusual movements and noises vibrations dur ing operation indicate damage or loose fastening eleme
34. horizontal position on the housing e Fillinoil until it reaches the bottom edge of the bore BW 145 D 3 DH 3 PDH 3 For quality and quantity of oil refer to the table of fuels and lubricants e Turn the plug tightly back in e Change the oil also on the opposite side BW 145 D 3 DH 3 PDH 3 BOMAG Every 1000 operating hours 5 24 Changing the fuel pre filter Fire hazard When working on the fuel system do not use open fire do not smoke and do not spill any fu el Catch running out fuel do not let it seep into the ground Do not inhale any fuel fumes Fig 90 e Remove the hose clamps and pull the fuel pre filter Fig 90 out of the fuel hoses Observe the flow direction of the filter The arrow must point towards the fuel pump e Install the new fuel pre filter 67 Every 1000 operating hours 5 25 Changing the fuel filter car 5 26 Checking the fastenings on tridge the diesel engine Fire hazard When working on the fuel system do not use open fire do not smoke and do not spill any fu el Catch running out fuel do not let it seep into the ground Do not inhale any fuel fumes e Check the fastening of intake and exhaust tubes Fig 92 on the cylinder heads for tight fit Deg NG 0 i E c e 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 e Check fastening and tightness of t
35. ic circuit would run dry with out the charge circuit in function e Secure the machine with wheel chocks against unintentional rolling e Attach the towing ropes safely to the front or rear lifting eyes Fig 47 e Pull the support Fig 47 out of the bracket in the hood and hook it at the bottom into the frame or at the top into the traverse BW 145 D 3 DH 3 PDH 3 BOMAG 39 Operation Fig 48 e Slacken the counter nuts on both high pres sure relief valves Fig 48 to create a by pass around the travel pump e Turn the threaded spindle in until itis flush with the nut e Retighten the counter nut Fig 49 e To release the brake turn counter nuts 1 Fig 49 approx 8 mm back e Turn the brake releasing screws 2 complete ly in against the stop e Repeat this measure on the opposite side 40 BOMAG Fig 50 e Remove plug 1 Fig 50 e Place an U section 5 across the brake hous ing 2 and turn the screw 4 into the tapped bore 3 until it bottoms e Turn the nut 6 down and tighten it approx one revolution The drum must rotate freely After towing Before loosening ropes or chains block the machine with chocks to prevent unintended rolling e Turn the threaded spindle of the high pressure relief valves completely out again and tighten the counter nuts e Turn all brake releasing screws of the axle evenly back out until they are light m
36. in filter ele ment at the latest after 2 years BW 145 D 3 DH 3 PDH 3 if the warning light comes on again after serv icing the main filter cartridge e Remove the housing cover and pull the main filter element off Fig 109 e Pull the safety element Fig 109 out by turn ing it lightly e Push in anew safety filter element e Reassemble main filter element and cover BW 145 D 3 DH 3 PDH 3 As required 5 35 Adjusting the parking brake Have adjustment work on the brake performed by a specialist Always adjust both sides e Secure the machine with chocks against unin tentional rolling e Start the diesel engine to release the brake Fig 110 e Unlock the travel lever Fig 110 by pushing it to the left but do not actuate it to position I or U The parking brake is released Fig 111 e Unscrew the locking plate 2 Fig 111 e Turn the square 1 in anti clockwise direction against the end stop BOMAG 79 As required 3X CI EAM FD 8 a wech E Fig 112 e To adjust the clearance turn the square 1 Fig 112 three revolutions back in clockwise direc tion e Screw the locking plate back on e Pull the plug off the brake valve and try to drive The machine must be braked 80 BOMAG 5 36 Changing the tires Danger of accident Observe all safety notes for the lifting of loads e Place a jack min 5 t bearing capacity und
37. ing location of the engine is of utmost impor tance when choosing the viscosity class SAE class Optimal operating conditions can be achieved by using the opposite oil viscosity chart Fig 56 as a reference Occasionally falling short of the temperature limits will impair the cold starting ability but will not cause any engine damage In order to keep the occurring wear as low as possible occassional ex ceeding of the limits should not happen over a longer period of time BW 145 D 3 DH 3 PDH 3 Maintenance SAE 20W 50 SAE 15W 40 Dale z l ol lello lol 7 le al lelag Dio lt c lei o Jo less wj Loy Lu Lu REIRE Fig 56 With their better temperature and oxidation stabil ity synthetic lubrication oils offer quite a few bene fits Oil change intervals The longest permissible time a lubrication oil should remain in an engine is 1 year If the follow ing oil change intervals are not reached over a pe riod of 1 year the oil change should be performed atleast once per year irrespective of the operating hours reached ACEA E3 96 E5 02 E4 99 500 operating hours API CG 4 CH 4 500 operating hours These intervals apply only when using a diesel fuel with maximum 0 5 sulphur by weight and for ambient temperatures higher than 10 C BOMAG 45 Maintenance When using fuels with a sulphur content of more than 0 5 to 1 or under ambient tem pe
38. ity level Ka 101 8 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 9 5 m sec Hand arm vibration values The weighted effective acceleration value determined according to ISO 8662 part 1 is 2 5 m sec 10 BOMAG BW 145 D 3 DH 3 PDH 3 BW 145 D 3 DH 3 PDH 3 2 Safety regulations BOMAG Safety regulations General This BOMAG machine is built in accordance with the latest technical standard and the valid technical rules and regulations There is how ever a risk of danger for persons and property if e the machine is used for purposes other than those it is intended for e the machine is operated by untrained person nel e the machine is modified or converted in an un professional way e the applicable safety regulations are not ob served Each person involved in operation mainte nance and repair of the machine must there fore read and apply these safety regulations This should be confirmed by obtaining the sig natures of the customer if necessary Furthermore the following regulations and instruc tions are obviously als
39. ls Check before starting whether e the machine shows any obvious defects e all protective devices are properly secured in their place e steering brakes control elements lighting and warning horn are in order e the seat is correctly adjusted e the mirrors if available are clean and correct ly adjusted Do not start the machine if any gauges control lights or controls are defective Do not take any loose objects with you or fasten them to the machine On machines with ROPS you should always wear your seat belt Starting Start and operate the machine only from the oper ator s seat For starting set all control levers to neutral posi tion Do not use any starting aids such as Start Pilot or ether After starting check all gauges Starting with jump leads Connect plus with plus and minus with minus ground cable always connect the ground cable last and disconnect it first Wrong connections may cause severe damage in the electric system Never start the engine by bridging the electrical connections on the starter because the machine would probably start to move immediately Starting in closed rooms Exhaust gases are toxic Always ensure an ade quate supply of fresh air when starting in closed rooms 14 BOMAG Driving the machine Persons in the danger area If the machine should turn over and the cabin door is closed the right hand side cabin window can be used as an emergency exit
40. lues refer to the technical data Danger of accident Ensure equal pressure in both tires Always wear your seat belt Fig 25 e Fasten your seat belt Fig 25 Fig 26 e Check whether the travel lever Fig 26 is en gaged in brake position BW 145 D 3 DH 3 PDH 3 BOMAG 31 Operation Fig 27 e Turn the rotary vibration selector switch Fig 27 to position O vibration off Spa 595 063 Fig 28 e Check whether the emergency stop switch Fig 28 is unlocked Fig 29 e Set the throttle lever Fig 29 to position II full speed 32 BOMAG Fig 30 e Turn the ignition key Fig 30 to position I Fig 31 All control and warning lights Fig 31 in the multi function display light up for a few seconds as a self test Charge control light f engine oil pressure warn ing light d and brake warning light i stay on 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 BW 145 D 3 DH 3 PDH 3 Fig 32 Turn the ignition key to position II the starter cranks the engine As soon as the engine ignites return the igni tion key to position I Charge control light f and engine oil pressure warning light d go out Fig 33 Once the engine runs correctly reduce the en gine speed Fig 33
41. n e The oil level must be between both marks Min and Max e lf the oil level is too low top up oil immediately e Ifthe oil level is too high determine the cause and drain the oil off Before longer work periods you should always top the oil up to the MAX mark For quality and quantity of oil refer to the table of fuels and lubricants 52 BOMAG 5 7 Checking the fuel filter wa ter separator Danger of injury Support the engine hood for all maintenance and repair work 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 water separator every day for signs of water If a to high quantity is drained off the filter must be refilled with fuel See chapter maintenance as re quired bleeding the fuel system Catch running out fuel and dispose of environ mentally Fig 58 e Slacken the drain plug Fig 58 for a few turns and catch running out fuel water e Tighten the drain plug again and check for leaks if necessary replace the seal ring BW 145 D 3 DH 3 PDH 3 5 8 Checking the fuel level 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 59 e Check the fuel level on the fuel gauge j Fig 59 Do not drive the fuel tank dry as
42. n on and off Adjusting the seat Operating the hood Towing in case of an engine failure Transport General notes on maintenance Fuels and lubricants Table of fuels and lubricants Running in instructions Maintenance chart Checking the engine oil level Checking the fuel filter water separator Checking the fuel level Checking the hydraulic oil level Checking the tire pressure Cleaning the cooling fins on the radiator Cleaning the cooling fins on the hydraulic oil cooler Check the oil level in the drive axle Checking the oil level in left right wheel hubs Checking the oil level in the vibration bearings Servicing the battery Draining the sludge from the fuel tank Change engine oil and oil filter cartridge Checking the V belt tension tightening Checking adjusting the valve clearance Changing the oil in the vibration bearings Change the oil in the drive axle BOMAG Table of Contents 11 19 22 29 30 30 31 33 34 35 36 36 37 38 39 39 41 43 44 45 48 49 50 52 52 53 54 55 55 56 57 58 58 59 60 60 62 63 64 65 Table of Contents Trouble shooting 5 23 Change the oil in the wheel hubs 66 5 24 Changing the fuel pre filter 67 5 25 Changing the fuel filter cartridge 68 5 26 Checking the fastenings on the diesel engine 68 5 27 Tightening the fastening of the axle on the frame 69 5 28 Tightening the wheel nuts 69 5 29 Checking the ROPS 70 5 30 Changing hydraulic oil and breather filter 71 5 31 Changin
43. n the fittings Use winter fuel in the cold season Adjust the valve clearance Have examined by a specialist Check the lines for leakages Have examined by a specialist clean replace if necessary Adjust the throttle cable change it if nec essary BW 145 D 3 DH 3 PDH 3 BOMAG 87 Trouble shooting Faults Possible cause Remedy Excessive ex haust smoke Engine oil level too high Dry air filter dirty Exhaust gas turbo charger defective Poor compression due to burned or bro ken compression rings or incorrect valve clearance Incorrect valve clearance Drain the oil to the upper dipstick mark clean replace if necessary Have examined by a specialist Have compression rings and pistons ex amined by a specialist adjust the valve clearance Adjust the valve clearance Engine over heats shut down immedi ately Cooling fins on radiator extremely soiled the warning light engine oil temperature lights Injection valve defective Engine oil level too low Filling capacity of the injection pump not correctly adjusted Cooling air flow restricted V belt loos or broken Clean the cooling fins Have examined by a specialist Top up engine oil to the upper dipstick mark Have adjusted by a specialist Clean the cooling air duct Tension or replace the V belt Poor engine power Engine oil level too high Dry air filter dirty Exhaust gas turbo charger defective Cha
44. necessary use safety elements BOMAG 77 As required Fig 107 e Insert the main filter element Fig 107 The radial sealing area is located at the inside of the open filter edge This critical sealing area must be under slight tension after the filter has been in stalled In order to achieve a tight seal apply pres sure to the outer edge of the filter and not to the moveable centre e Reinstall the filter hood with the dust discharge valve The dust discharge valve must point vertically downwards Dry cleaning of the main filter element Eye injury Wear protective clothing goggles gloves 78 BOMAG Fig 108 For cleaning purposes fit a tube to the compressed air gun Fig 108 the end of which should be bent for approx 90 The length should reach down to the bottom of the element e Blow the main filter element out with com pressed air max 5 bar from inside to outside by moving the tube up and down inside the el ement until it if free of dust Examine the main filter element with a torch for cracks and holes in the paper bellows Do not continue to use a damaged main filter element If in doubt use a new main filter ele ment Changing the safety filter element The safety filter element must not be cleaned and should not be used again after it has been removed The safety filter element must be replaced if the main filter element is defective after three times cleaning of the ma
45. nts Check the fastening screws for the cabin ROPS to the operator s platform for tight fit e Check the suspension buffers for the opera tor s stand for tight fit e Check the condition and the fastening of the seat belt 70 BOMAG BW 145 D 3 DH 3 PDH 3 5 30 Changing hydraulic oil and breather filter See also chapter 5 1 Notes on the hydraulic sys tem Apart from the normal oil change intervals the hydraulic oil must also be changed after major repairs in the hydraulic system Perform the oil change when the hydraulic oil is warm Clean the area round hydraulic oil tank filler opening and breather filter Do not use any detergents to clean the system Do not start the engine after draining the hy draulic oil Replace the hydraulic oil filter element with every hydraulic oil change Danger of scalding Danger of scalding by hot oil Catch running out oil and dispose of environ mentally Generally replace the hydraulic oil filter element after the test run BW 145 D 3 DH 3 PDH 3 Every 2000 operating hours i 0 a Fig 97 e Unscrew the plug Fig 97 and drain off all hy draulic oil e Check the seal ring replace if necessary and turn the plug tightly back in e Remove the filler cap Fig 98 e Fill in new hydraulic oil through the screen We recommend to use the filling and filtering unit BOMAG part no 079 930 35 with fine filte
46. o the de sired travel direction The brake warning light i goes out nn Shift the travel lever out of 0 position slowly to forward or reverse the machine will drive forward or reverse at a speed which corresponds with the displacement of the travel lever Returning the travel lever towards neutral will brake the machine and in 0 position of the travel lever the machine will stop Danger of accident On inclinations and slopes pull the travel lever to the right and lock it in braking position BW 145 D 3 DH 3 PDH 3 Important notes on travel operation When changing the travel direction hold the travel lever for a moment in 0 position until the machine has stopped before actuating to the new travel direction Do not operate jerkily Do not use the throttle lever to control the trav el speed Control the travel speed with the travel lever During operation the throttle lever must remain in full load position When driving up and down inclinations move the travel lever slowly back towards neutral to brake the machine If the engine speed drops when driving up ex treme inclinations move the ravel lever slightly back if necessary change to the lower speed range Always use the lowest speed range turtle to drive up and down inclinations BW 145 D 3 DH 3 PDH 3 Operation 4 6 Emergency exit If the machine should turn over and the cabin door is closed the right hand side cabin window can be use
47. o valid e applicable accident prevention instructions e generally acknowledged safety and road traffic regulations e country specific safety regulations It is the duty of the operator to know and observe these regulations This applies also for local regulations and the regulations for various types of manual work If the recommendations in this manual differ from the regulations valid in your country you must strictly observe the regulations in your country Intended use This machine must only be used for e compaction of bituminous materials e g road surface layers AC and AD machines only e medium and heavy compaction tasks in earth work road sub bases e This machine must only be operated with fully functional safety equipment e The machine should be checked by an expert once every year BOMAG Unintended use Dangers may however arise from the machine if it is used by untrained personnel in an unprofes sional way or if it is used for purposes other than those mentioned in these instructions Do not work with vibration on hard concrete ona cured concrete layer or heavily frozen ground Starting and operation of the machine in an explo sive environment is prohibited Who is allowed to work with the ma chine The machine must only be operated by trained and authorized persons which are at least 18 years of age The responsibilities for the operation of the machine must be clearly specified and c
48. oil level in the drive axle e Park the machine on level ground Fig 66 e Unscrew the oil level inspection plug Fig 66 and check the oil level The second level inspection plug as at the back After filling in oil wait until the oil has evenly distrib uted inside the axle The oil level must reach the bottom edge of the level bore e Top up oil if necessary For quality of oil refer to the table of fuels and lubricants e Turn the level inspection plug tightly back in BOMAG 57 Every 250 operating hours 5 14 Checking the oil level in left right wheel hubs A 90 API G 5 15 Checking the oil level in the vibration bearings Fig 67 e Move the machine until the oil level inspection plug 1 Fig 67 is in horizontal position e Clean and unscrew the plug The oil level must reach the bottom edge of the bore e Top up oil if necessary For quality of oil refer to the table of fuels and lubricants e Screw the plug back in tightly e Repeat this inspection on the other side 58 Fig 68 e Drive the machine until the oil level inspection plug 1 Fig 68 is vertically below the hub e Clean and unscrew the oil level inspection plug The oil level must reach the bottom edge of the bore e lfnecessary fill in oil through the filler and drain bore 2 For quality of oil refer to the table of fuels and lubricants BOMAG BW 145 D 3 DH 3 PDH 3 5 16 Servicing the ba
49. om plied with Persons under the influence of alcohol medica tion or drugs must not operate service or repair the machine Maintenance and repair tasks require specific knowledge and must therefore only be carried out by trained and qualified personnel Conversions and alterations to the ma chine Unauthorized conversions to the machine are pro hibited for safety reasons Original parts and accessories have been special ly designed for this machine We wish to make ex pressly clear that we have not tested or authorized any original parts or special equipment not sup plied by us The installation and or use of such products can impair the active and or passive driv ing safety The manufacturer expressly excludes any liability for damage resulting from the use of non original parts or accessories Safety notes in the operating and main tenance instructions Sections marked like this point out possible dangers for persons BW 145 D 3 DH 3 PDH 3 Sections marked like this point out possible dangers for the machine or for parts of the ma chine Sections marked like this provide technical infor mation concerning the optimal economical use of the machine Sections marked like this highlight activities for the safe and environmental disposal of fu els and lubricants as well as replaced parts Observe all environment protection regula tions Information and safety stickers decals on the machine Keep sticke
50. operating the machine if you are not yet fully familiar with the indicators and control elements of the machine All indicators and control elements are described in detail in this chapter 30 BOMAG 4 2 Tests before taking into op eration The following inspections must be carried out be fore each working day or before a longer working period Danger of accident Please observe strictly the safety regulations in chapter 2 of this instruction manual e Park the machine on ground as level as possi ble Check e fuel tank and fuel lines for leaks screw joints for tight fit function of steering machine for cleanliness damage presence of the appropriate operating and maintenance instructions check whether the machine has been properly serviced For a description of the following tasks refer to the chapter maintenance every 10 operating hours e Engine oil level In hydraulic systems filled with Panolin HLP Synth 46 always use the same oil to top up With other ester based oils consult the lubrication oil service of the respective oil manufacturer e Check the hydraulic oil level top up if neces sary Fire hazard Do not refuel in closed rooms e Check the fuel level top up if necessary e Check water separator in fuel system drain if necessary BW 145 D 3 DH 3 PDH 3 Operation e Check the scrapers adjust if necessary 43 Starting the engine e Check the air pressure in the tires For va
51. ound to have dropped check all lines hoses and components for leaks e Seal external leaks immediately If necessary inform the responsible customer service e Donotstore drums with hydraulic oil outdoors or at least under a cover Water can be drawn in through the bunghole when the weather changes e Always use the filling and filtering unit BOMAG part no 007 610 01 to fill the hy draulic system This unit is fitted with a fine fil ter to clean the hydraulic oil thereby prolonging the lifetime of the filter e Clean fittings filler covers and the area around such parts before disassembly to avoid enter ing of dirt e Do not leave the tank opening unnecessarily open but cover it so that nothing can fall in BW 145 D 3 DH 3 PDH 3 5 2 Fuels and lubricants Engine oil Quality Lubrication oils are classified according to their performance and quality class Oils according to other comparable specifications may be used Approved engine oils Deutz DOC H DOC II ACAE E3 96 E5 02 E4 99 API CH 4 CG 4 DHD DHD 1 The exact assignment of the approved oil qualities and oil change intervals can be taken from the fol lowing section Lubrication oil change intervals Consult your local service station if in doubt Oil viscosity Multi purpose oils should be generally used Since lubrication oil changes its viscosity with the temperature the ambient temperature at the oper at
52. oving again BW 145 D 3 DH 3 PDH 3 ae Sh Ae SI SIE EJ E gt A i 6 Fig 51 e Turnthe brake releasing screws Fig 51 back in again until they abut against the brake pis ton Operation 4 13 Transport Danger of accident Use only stable loading ramps of sufficient load bearing capacity Make sure that persons are not endangered by the machine tipping or sliding off Lash the machine down so that it is secured against rolling sliding and turning over Do not stand or step under loads being lifted Always use shackles on the lifting points for loading tying or lifting the machine Fig 52 e Unscrew the brake releasing screws Fig 52 for two turns and tighten the counter nuts e Repeat this adjustment procedure on the op posite wheel side If necessary replace the seal ring under the coun ter nut if it is leaking For this purpose completely unscrew the brake re leasing screw replace the seal ring and lubricate the screw with silicone grease Reinstall the screw with a new seal ring and adjust the protrusion as described above BW 145 D 3 DH 3 PDH 3 BOMAG e Attach the articulation lock Fig 53 41 Operation Fig 54 e Lash the machine on the transport vehicle Fig 54 use the four lashing eyes on front and rear frame for this purpose e Support the front frame to avoid overstressing of the rubber buffers Fig 55 e
53. parts of the engine 86 BOMAG BW 145 D 3 DH 3 PDH 3 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 Temperature below starting limit Fuel filter clogged in winter due to paraf fin separation Fuel lines leaking Battery discharged or not connected Injection valves or injection pump defec tive Fill and bleed the tank Use winter fuel and engine oil acc to the ambient temperature Change the filter use winter fuel Check all line connections for leakages and tighten the fittings Tighten the pole clamps check the cable connections Have examined by a specialist The engine starts poorly and works irregularly with poor power Battery power too low battery clamps loose or oxidized causing the starter to turn too slowly Especially during winter the use of too viscous engine oil Fuel supply restricted in winter fuel sys tem clogged due to paraffin separation Incorrect valve clearance Injection valve defective Injection lines leaking Turbo charger defective Dry air filter dirty Excessive play in the throttle cable Have the battery checked clean the ter minal clamps tighten them and cover them with acid free grease Use engine oil suitable for the ambient temperature Change the fuel filter Check the line con nections for leaks and tighte
54. perating hours refers to the use of oils of oil quality class API CG 4 CH 4 or ACAE E3 96 E5 02 respectively See section 5 2 Fuels and Lubricants Drain the engine oil only when the engine is warm Danger of scalding When draining off hot oil By hot oil when unscrewing the engine oil fil ter Catch running out oil and dispose of environ mentally together with the engine oil filter car tridge Fig 72 e Unscrew the drain plug Fig 72 and catch running out oil e Turn the drain plug tightly back in BOMAG BW 145 D 3 DH 3 PDH 3 Fig 73 e Unscrew the filter cartridge Fig 73 using an appropriate filter wrench e Clean the sealing face on the filter carrier from any dirt e Slightly oil the rubber seal on the new filter car tridge e Turn the new filter cartridge on by hand until the seal contacts e Tighten the filter element for another half turn Fig 74 e Fill in new engine oil Fig 74 For quality and quantity of oil refer to the table of fuels and lubricants e Tighten the oil filler cap properly BW 145 D 3 DH 3 PDH 3 Every 500 operating hours Fig 75 e Onmachines with cabin set the lever for oil heat exchanger heating to position Il e Run the engine for approx 3 minutes at idle speed e Shut the engine down and set the lever for oil heat exchanger heating to position I e Wait for about 15 minutes so that all oil can flow back into
55. r to fill the hydraulic system This ensures finest filtration of the hydraulic oil prolongs the lifetime of the hy draulic oil filter and protects the hydraulic system e Check the oil level in the inspection glass Nominal value approx 3 cm below the upper edge of the inspec tion glass BOMAG 71 Every 2000 operating hours For quality and quantity of oil refer to the table of fuels and lubricants The breather filter for the hydraulic oil tank is inte grated in the filler cap you must therefore replace the complete filler cap e Close the tank with a new filler cap 72 BOMAG 5 31 Changing the hydraulic oil gt OD A Danger Danger of scalding There is a danger of scalding by hot oil when unscrewing the filter 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 Catch running out oil dispose of oil and filter element environmentally The filter element must be changed with every hy draulic oil change and after major repairs in the hy draulic system Fig 99 e Unscrew the cap nut 4 Fig 99 and take the filter bowl 5 with the filter element 3 off e Examine the sealing face on the filter element thoroughly for any visible dirt Visible impurities may be an early indicator for a failure of system components and predict the BW 145 D 3 DH 3 PDH
56. ratures below 10 C the oil change intervals specified in the table must be halved For fuels with a sulphur content of more than 1 you should consult the responsible service agen cy Fuels Quality You should only use commercially available brand diesel fuel with a sulphur content below 0 5 and ensure strict cleanliness when filling in A higher sulphur content has a negative effect on the oil change intervals Use only winter grade diesel fuel under low ambient temperatures The fuel level should always be topped up in due time so that the fuel tank is never run dry as otherwise filter and in jection lines need to be bled When using fuels with a Cetan number lt 49 poor starting and white smoke can be expected in par ticular in connection with low ambient tempera tures The following fuel specifications are permitted DIN EN 590 DIN 51 601 Nato Codes F 54 F 75 BS 2869 A1 and A2 ASTM D 975 78 1 D and 2 D e DIN EN 590 e BS 2869 e ASTM D 975 78 1 D and 2 D e Nato Codes F 54 F 34 F44 und XF63 Winter fuel Diesel fuels must never be mixed with gaso line For winter operation use only winter diesel fuel to avoid clogging because of paraffin separation At very low temperatures disturbing paraffin separa tion can also be expected when using winter diesel fuel In most cases a sufficient cold resistance can also be achieved by adding flow enhancing fuel addi tives Consult the engine manufactu
57. rer 46 BOMAG Operation with rape seed oil methyl ester RME Bio Diesel Due to the extreme quality differences of RMEW fuels available on the market which are caused by the non existence of a standardization BOMAG does generally not approve any RME fuels If this is neglected the warranty will become null and void However if you still intend to operate the machine with RME fuels you should observe the following information e Reduced engine power approx 7 higher fuel consumption e The quality of RME fuel should be in compli ance with DIN draft 51606 e Avoid longer periods of standstill formation of resin corrosion in injection system e RME fuel can damage the paint finish of the machine e Fueldilution of engine oil therefore shortening of oil change intervals to half e Rubber parts such as leak fuel return lines seats will be damaged in the long run and need to be replaced on a regular basis or should be replaced by parts made of fluorinat ed rubber However fluorinated rubber is not resistant against normal diesel fuel e Ifthe fuel filter is clogged the filter change in tervals must be shortened accordingly Hydraulic oil The hydraulic system is operated with hydraulic oil HV 46 ISO with a kinematic viscosity of 46 mm s at 40 C For topping up or for oil chang es use only high quality hydraulic oil type HVLP according to DIN 51524 part 3 or hydraulic oils type HV according to
58. rge air hose leaking Incorrect valve clearance Injection valve defective Drain the engine oil down to the upper dip stick mark clean change if necessary Have examined by a specialist Check fastening and connections Adjust the valve clearance Have examined by a specialist Engine oil pres sure too low Engine oil level too low control light en gine oil pressure lights the warning buzzer sounds Leakages in the lubrication system Top up oil 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 trol light lights during opera tion the warning buzzer sounds Generator speed too low The generator does not charge the bat tery because generator or regulator is de fective Check the V belt tension replace the V belt if necessary Have examined by a specialis 88 BOMAG BW 145 D 3 DH 3 PDH 3 BW 145 D 3 DH 3 PDH 3 BOMAG Trouble shooting 89 Trouble shooting 90 BOMAG BW 145 D 3 DH 3 PDH 3 We will help you immediately Operating maintenance repair instructions and spare parts catalogues e e in situ Safe and simple trouble shooting e Secure access to required spare parts Easy to understand from experts for users Contact us or your BOMAG distributor f i i 4 t 3 a a a de a englisch B
59. rk with vibration on hard concrete cured asphalt or hard frozen ground When driving under flyovers bridges tunnels power lines etc ensure sufficient distance Driving on gradients and slopes Do not drive on gradients which exceed the maxi mum gradability of the machine Always drive extremely carefully on slopes and al ways directly up or down the slope never diago nally Change to the lower speed range before approaching the inclination Wet and loose soils reduce the ground adhesion of the machine on gradients and slopes considera bly Higher risk of accidents Behaviour in traffic Match your speed to the working conditions Always give way to loaded vehicles Switch the lights on if the visibility is poor Keep away from edges and embankments Check the effect of vibration When compacting with vibration check the effect on nearby buildings and underground supply lines gas water sewage power lines and stop vibra tory compaction if necessary Never use the vibration on hard frozen concrete ground Risk of bearing damage Parking the machine Park the machine on level and firm ground Before leaving the machine e move the travel control lever to neutral position e apply the parking brake e shut the engine down and pull the ignition key out e lock the cabin door e secure the cabin against unauthorized use Do not jump off the machine but use access steps and hand rails Mark parked machines
60. rottle lever Position I Idle speed position Position II Full load position operating position for driving and vibra tion BOMAG 25 Indicators and Controls Always drive and vibrate with max engine speed Control the travel speed only with the travel lever No 15 Locking plate for throttle lever pull The throttle lever can be moved to position II release The throttle lever locks in posi tion II Z D Cie OC kx CV D CT EK d LB O gt A Fig 20 No 16 Fuses in electric installation box F03 15A Vibration F05 25A Socket F13 30A Starting F19 15A Working head lights F22 15A Working head lights rear F24 15A Monitoring gauges F25 15A Solenoid valve brake travel Fire hazard Do not use fuses with higher ampere ratings and do not bridge fuses 26 BOMAG Fig 21 No 17 Main fuse for battery 125A F00 The main fuse is located in the battery box under the driver s seat No 18 Pedal for dozer blade Position 0 Stop position Dozer blade at rest Position I Dozer blade up Position II Dozer blade down Position II Float position to level loose soil when driving in reverse Danger of squashing Do not work under the lifted unsupported doz er blade support the blade if necessary Optional equipment BW 145 D 3 DH 3 PDH 3 No 19 Fuse box c
61. rs decals complete see spare parts catalogue and fully legible and observe their meaning Replace damaged or illegible stickers decals im mediately Loading the machine Use only strong and stable loading ramps The ramp inclination must be lower than the gradability of the machine Secure the machine against turning over or slip ping off Secure the machine on the transport vehicle against rolling off slipping and turning over Persons are highly endangered if e they step or stand under loads being lifted e they remain in the drive range of the machine during a demonstration or during loading The machine must not swing about when lifted off the ground Use only safe lifting gear of sufficient load bearing capacity Attach the lifting gear only to the specified lifting points BW 145 D 3 DH 3 PDH 3 Safety regulations Towing the machine Since the machine is not fitted with a towing hitch the machine cannot be towed with a tow bar If the machine has to be towed urgently out of the danger zone because of other risks this must only be done on level ground or uphill using chains and ropes For this purpose towing ropes of sufficient tensile strength must be fastened on the lifting eyes After releasing the brake the machine can only be braked by the towing vehicle Before releasing the brake block the machine with chocks to prevent unintended rolling Checking the roll over protection structure ROP
62. ry Oil change in drive axle Oil change in wheel hub of axle After 500 operating hours e Oil change vibration bearings BOMAG 49 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 5 7 Check the fuel filter water separator 5 8 Check the fuel level 5 9 Check the hydraulic oil level Dipstick mark Inspection glass Every 250 operating hours 5 10 Check the tire pressure 5 11 Cleaning the cooling fins on the radiator 5 12 Cleaning the cooling fins on the hydraulic oil cooler 5 13 Check the oil level in the drive axle 5 14 Check the oil level in the wheel hubs 5 15 Check the oil level in the vibration bearings see technical data Every 500 operating hours 5 16 Service the battery 5 17 Drain the sludge from the fuel tank 5 18 Change engine oil and oil filter cartridge 5 19 Checking the V belt tension tightening distilled water pole grease min 1x per year Every 1000 operating hours 5 20 Check adjust the valve clearance 5 21 Change the oil in the vibration bearings 5 22 Change the oil in the drive axle 5 23 Change the oil in the wheel hubs 5 24 Changing the fuel pre filter 5 25 Change the fuel filter cartridge 5 26 Check the engine mounts 5 27 Check the fastening of the
63. sary repair the generator Light with ignition on and engine off g Hydraulic oil filter soiled the warning buzzer sounds Replace the filter ele 22 BOMAG ment check the hydraulic system if it comes on too early h not used i Brake closed or travel lever in second notched position j Fuel level gauge k Operating hour meter Fig 7 No 2 Rotary switch for flashing beacon Position left Flashing beacon switched off Position right ll Flashing beacon switched on Fig 8 No 3 Rotary switch lighting StVZO j Position left light off Position mid dle fender lights on with the igni tion switch in position I or P Position right travel lights on with ignition switch in position I Option BW 145 D 3 DH 3 PDH 3 e A 595 051 Indicators and Controls Fig 9 Fig 11 No 4 Rotary switch for hazard light sys No 6 Rotary switch working lights tem Position left light off Position left hazard light switched off the Position right working lights on with ignition control lights go out switch in position I Position right hazard light switched on con trol light 7 on fault monitoring board lights up Fig 12 No 7 Rotary switch vibration 595 053 AF Position mid Fig 10 i SEE dle vibration off No 5 Rotary switch for direction indicators ELAN EJ f f left right Position left low amplitude high frequency
64. sure Always close the valves with the dust cap e Check the tire pressure with a pressure gauge and the tire inflation valve 1 Fig 63 in top po sition Nominal value see technical data Ensure even pressure in all tires e Screw the valve caps back on BW 145 D 3 DH 3 PDH 3 BOMAG Every 250 operating hours 5 11 Cleaning the cooling fins on the radiator Danger of injury Perform cleaning work only after the engine has cooled down and with the engine stopped 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 Start to blow out from the exhaust side deg Gel by A M J S R Ex NA a 87 Fig 64 e Take the cooling air duct cover off and blow the radiator Fig 64 out starting from the air discharge side e Remove all dirt that has been blown into the air duct 55 Every 250 operating hours Cleaning with cold cleansing agent In case of oily dirt spray the engine with a cold cleansing agent and let it soak in for about 10 minutes Protect electrical equipment such as genera tor regulator and starter against the direct wa ter jet e Spray the engine with a suitable cleansing agent e g
65. t Secure the articulated joint with the articulation lock Working on hydraulic lines Depressurize hydraulic lines before working on them Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury Con sult a doctor if you are injured by pressurized hy draulic oil as otherwise serious infections may result When adjusting the hydraulic system do not stand behind the drums wheels BOMAG 15 Safety regulations Do not change the setting of high pressure relief valves Drain the hydraulic oil at operating temperature danger of scalding Catch running out hydraulic oil and dispose of en vironmentally Always collect and dispose of biodegradable hy draulic oils separately Do not start the engine after draining the hydraulic oil Check all connections and fittings for leakages once all work is completed with the lines still de pressurized Changing of hydraulic hoses Hydraulic hoses must be examined visually at reg ular intervals Hydraulic hoses must be changed immediately in case of e damage to the outer surface down to the lining e g chafings cuts cracks e embrittlement of the outer surface develop ment of cracks in the hose material e deformation under pressurized and depressu rized conditions which are not in accordance with the natural shape of the hydraulic hose e deformation in bends such as squeezed spots extreme bends layer separation formation
66. take and exhaust openings tightly Depending on the weather conditions these con serving measures will provide protection for ap prox 6 to 12 months Before taking the engine back into operation all conserving oil must be drained off and replaced by regular engine oil see chapter Fuels and Lubri cants according to the API MIL classification Anti corrosion oils are those that comply with the specification MIL L 21260 B or TL 9150 037 2 or Nato Code C 640 642 A machine with a conserved engine must be marked by attaching a clearly visible warning tag BW 145 D 3 DH 3 PDH 3 BOMAG As required 83 As required 84 BOMAG BW 145 D 3 DH 3 PDH 3 BW 145 D 3 DH 3 PDH 3 6 Trouble shooting BOMAG 85 Trouble shooting 6 1 General notes The following work must only be carried out by qualified and trained personnel or by the 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 of injury Keep away from rotating
67. thereby providing a seal on the inside of the filter cover Carefully remove the main filter element in order to reduce the released amount of dust To release the seal pull the main filter ele ment carefully up down and sideways or turn it Fig 104 Avoid contact between main filter element and housing RR Tesa Fig 105 e Pull the main filter element Fig 105 carefully out of the housing BW 145 D 3 DH 3 PDH 3 As required Fig 106 e Clean the sealing face on the outlet tube Fig 106 Dust on the outer diameter of the outlet tube can impair effective sealing e Check the old main filter element The old main filter element can be of help to dis cover foreign particles on the sealing face which could lead to leaks A line of dust on the clean air side of the filter may be a sign for such a leak Eliminate this problem before installing a new main filter element e Ifthe main filter element is damaged the safe ty element must be replaced as well e Clean or replace the main filter element We generally recommend to change the filter A new filter element is far less expensive than a pos sible engine damage e Examine the main filter element thoroughly for damage Before installing the new main filter element check it for possible damage from transport cleaning or incorrect handling Especially on the inside of the open end sealing area Do not install damaged filter elements e f
68. ttery Danger of causticization When working on the battery do not use open fire do not smoke Do not let acid come in contact with skin or clothes Wear protective clothing Do not lay any tools on the battery For recharging remove the plugs from the bat tery to avoid the accumulation of highly explo sive gases Dispose of the old battery environmentally 581 041 Fig 69 e Unscrew both fastening screws Fig 69 from the seat console and fold the seat forward BW 145 D 3 DH 3 PDH 3 Every 500 operating hours Fig 70 e Remove the battery Fig 70 and clean the battery compartment e Clean the outside of the battery e Clean battery poles and pole clamps and grease them with pole grease Vaseline e Check the fastening of the battery e Onserviceable batteries check the acid level if necessary top up to the filling mark with dis tilled water BOMAG 59 Every 500 operating hours 5 17 Draining the sludge from the fuel tank Fire hazard When working on the fuel system do not use open fire do not smoke Do not spill any fuel Catch running out fuel do not let it seep into the ground Do not inhale any fuel fumes Fig 71 e Unscrew the cap Fig 71 and drain off ap prox 5 litres of fuel e Turn the cap tightly back in 60 5 18 Change engine oil and oil fil ter cartridge The oil change at 500 o
69. valve is not yet completely closed and the intake valve starts to open The valves marked black Fig 81 can be checked and adjusted Fig 82 e Crank the engine with the starter until both valves on cylinder 4 Fig 82 are overlapping 360 rotation of the crankshaft The valves marked black Fig 82 can be checked and adjusted e Assemble the cylinder head cover with a new gasket BOMAG 63 Every 1000 operating hours Adjusting the valve clearance 5 21 Changing the oil in the vi _ bration bearings Drain oil only at operating temperature e Loosen the counter 2 Fig 83 and regulate the setscrew 1 until the feeler gauge can be inserted and pulled out with little resistance af ter retightening the counter nut After a short test run check the engine for e Move the drum until the drain and filler plug 2 leaks Fig 84 is in bottom position e Clean and unscrew the oil level inspection plug 1 as well as the drain and filler plug Catch running out oil Fig 85 e Once all oil has been drained off move the drum until the oil level inspection plug 1 Fig 85 is positioned vertically under the hub e Fill in oil until it starts to run out through the level inspection bore 64 BOMAG BW 145 D 3 DH 3 PDH 3 For quality and quantity of oil refer to the table of fuels and lubricants e Screw oil level inspection plug 1 and drain and filler plug 2 back in with new seal rings
70. witch for lighting StVZO Rotary switch for hazard light system Rotary switch for direction indicators left right Rotary switch for working head lights Rotary switch vibration high low frequency Optional equipment BOMAG 10 11 12 13 14 15 Indicators and Controls Rotary switch for speed range selection Push button for warning horn Emergency stop push button Ignition switch at the side Push button for vibration Travel lever Throttle lever Locking plate for throttle lever 21 Indicators and Controls 3 1 General notes 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 6 No 1 Multi function display After switching the ignition on all lamps light up for approx 3 seconds as a self test The control and warning lamps light up while the engine is running a Hazard light switched on b Direction indicator switched on c Engine oil temperature too high warning buzzer sounds Clean en gine and radiator d Engine oil pressure too low warning buzzer sounds Check the engine oil level if necessary have the engine repaired e Air filter cartridge soiled Clean change the cartridge f The battery is not being charged check the V belt if neces
71. ystem The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel e Keep fuel free of contaminants and water since this will damage the injection elements of the engine e Drums with inside zinc lining are not suitable to store fuel e The fuel drum must rest for a longer period of time before drawing off fuel 44 BOMAG e Do not let the hose stir up the slurry at the bot tom of the drum e Do not draw off fuel from near the bottom of the drum e The rest in the drum is not suitable for the en gine and should only be used for cleaning pur poses Notes on the performance of the en gine On diesel engines both combustion air and fuel in jection quantities are thoroughly adapted to each other and determine power temperature level and exhaust gas quality of the engine If your engine has to work permanently in thin air at higher altitudes and under full load you should consult the customer service of BOMAG or the customer service of the engine manufacturer Notes on the hydraulic system During maintenance work on the hydraulic system cleanliness is of major importance Make sure that no dirt or other contaminating substances can en ter into the system Small particles can produce flutes in valves cause pumps to seize clog noz zles and pilot bores thereby making expensive re pairs inevitable e If during the daily inspection of the oil level the hydraulic oil level is f

Download Pdf Manuals

Related Search

Related Contents

  normas ocupacionales en el rol - Ministerio de Trabajo, Empleo y  DMR-MC500取扱説明書基本ガイド  取扱説明書 - SANUS  cAchtung - Index of  Targus 400-0088-001A Mouse User Manual  Betriebsanleitung Kurznaht-Automat 2110-5 / 2111-5  

Copyright © All rights reserved. Failed to retrieve file