Operating Manual

Operating instructions
Maintenance instructions
BW 24/27 RH
S/N 101 538 00 .... S/N 101 538 10 ....
Rubber tire roller
Catalogue number
008 126 31 12/2006
Foreword
BOMAG machines are products from the wide You should only operate the machine after you
F oreword
range of BOMAG compaction equipment. have been instructed and in compliance with these
instructions.
BOMAG’s vast experience in connection with
state-of-the-art production and testing meth- Strictly observe the safety regulations.
ods, such as lifetime tests of all important Please observe also the guidelines of the Civil En-
components and highest quality demands gineering Liability Association ”Safety Rules for
guarantee maximum reliability of your ma- the Operation of Road Rollers and Soil Compac-
chine. tors” and all relevant accident prevention regula-
tions.
This manual comprises:
For your own personal safety you should only
l Safety regulations use original spare parts from BOMAG.
l Operating instructions
In the course of technical development we re-
l Maintenance instructions serve the right for technical modifications
l Trouble shooting without prior notification.
These operating and maintenance instructions are
Using these instructions will also available in other languages.
l help you to become familiar with the machine. Apart from that, the spare parts catalogue is avail-
l avoid malfunctions caused by unprofessional able from your BOMAG dealer against the serial
operation. number of your machine.
Your BOMAG dealer will also supply you with in-
Compliance with the maintenance instructions will formation about the correct use of our machines in
l enhance the reliability of the machine on con- soil and asphalt construction.
struction sites, The above notes do not constitute an extension of
l prolong the lifetime of the machine, the warranty and liability conditions specified in the
general terms of business of BOMAG.
l reduce repair costs and downtimes.
We wish you successful work with your BOMAG
BOMAG will not assume liability for the function of machine.
the machine BOMAG GmbH
l if it is handled in a way not complying with the Printed in Germany
usual modes of use,
Copyright by BOMAG
l if it is used for purposes other than those men-
tioned in these instructions.
No warranty claims can be lodged in case of dam-

age resulting from
l operating errors,
l insufficient maintenance and
l wrong fuels and lubricants.
Please note!
This manual was written for operators and mainte-
nance personnel on construction sites.
Always keep this manual close at hand, e.g. in the
tool compartment of the machine or in a specially
provided container. These operating and mainte-
nance instructions are part of the machine.
BW 24 / 27 RH BOMAG 3
Foreword
Please fill in
............................
Machine type(Fig. 1)
............................
Serial number (Fig. 1)
............................
Engine type(Fig. 2)
............................
Engine number (Fig. 2)
i Note
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. 1
Fig. 2
4 BOMAG BW 24 / 27 RH
Table of Contents
Technical Data 7
Safety regulations 11
Indicators and Controls 19
3.1 General notes 22
3.2 Description of indicators and control elements 22
Operation 33
4.2 Tests before taking into operation 34
4.3 Disarming the anti-theft protection 35
4.4 Starting the engine 36
4.5 Starting with jump wires 39
4.6 Driving the machine / braking 39
4.7 Operating the parking brake 42
4.8 Shutting the engine down, parking the machine 43
4.9 In events of emergency 44
4.10 Operating the pressure sprinkler system 45
4.11 Operating the tire inflation system 45
4.12 Adjusting the driver’s seat 46
4.13 Operating the hood 47
4.14 Ballasting of machine 47
4.15 Towing in case of an engine failure 48
4.16 Transport 49
Maintenance 51
5.1 General notes on maintenance 52
5.2 Fuels and lubricants 53
5.3 Table of fuels and lubricants 57
5.4 Running-in instructions 58
5.5 Maintenance chart 59
5.6 Check the engine oil level 62
5.7 Check, clean the water separator 62
5.8 Check the coolant level 63
5.9 Check the hydraulic oil level 63
5.10 Draining the air pressure vessel 64
5.11 Checking/filling up the water provision in the sprinkler system 64
5.12 Checking/adjusting the scrapers 65
5.13 Check the fuel level 65
5.14 Multi-disc brake, function test 66
5.15 Clean the cooling fins on engine and hydraulic oil cooler 68
5.16 Check the oil level in the drive gear/wheel hub 69
5.17 Changing engine oil and oil filter cartridges 70
5.18 Change the fuel filter cartridge 71
Table of Contents
5.19 Drain the sludge from the fuel tank 72

5.20 Battery maintenance 73
5.21 Change the fuel pre-filter cartridge 74
5.22 Checking, replacing the refrigerant compressor V-belt 76
5.23 Service the air conditioning 77
5.24 Checking hydraulic, pneumatic hoses and electric cables 79
5.25 Check, adjust the valve clearance 80
5.26 Checking / replacing the ribbed V-belt 82
5.27 Check the engine mounts 83
5.28 Tighten the wheel nuts 83
5.29 Checking the Roll Over Protective Structure (ROPS/FOPS) 84
5.30 Changing the air drier for the brake system 84
5.31 Changing the oil in travel gears/wheel hubs 85
5.32 Changing hydraulic oil and breather filter 86
5.33 Changing the hydraulic oil filter 87
5.34 Change the coolant 88
5.35 Checking the supply lines for the compressor 89
5.36 Checking the injection valves 91
5.37 Service the combustion air filter 92
5.38 Servicing the water sprinkling system 95
5.39 Maintenance in case of frost 96
5.40 Filling the windscreen washer system 97
5.41 Changing the fresh air filter in the cabin 97
5.42 Change the tires 98
5.43 Check bolted connections for tight fit 99
5.44 Temporary taking out of service 99
Trouble shooting 101
6.2 Engine 103
Tire compaction values 107
1 Technical Data
Technical Data
Fig. 3
Dimensions in A B H H2 K L W
mm
BW 24 RH 3700 2118 2360 3090 300 4985 2042
BW 27 RH 3700 2118 2360 3090 300 4985 2042
*
BW 24 RH BW 27 RH
Weights
Operating weight (CECE) kg 8400 13200
with ROPS-cabin
Max. operating weight kg 24000 27000
(CECE)
Max. mean wheel load kg 3000 3338
Travel characteristics
Travel speed (1) km/h 0 ... 7 0 ... 7
Travel speed (2) km/h 0 ... 10 0 ... 10
Travel speed (3) km/h 0 ... 20 0 ... 20
Max. gradability % 30 27
Engine
Engine manufacturer Deutz Deutz
Type BF4M 2012 BF4M 2012 C
Cooling Water Water
Number of cylinders 4 4
Rated power ISO 9249 kW 74,9 98
Rated speed rpm 2300 2300
Fuel Diesel Diesel
Electrical equipment V 12 12
Technical Data
* BW 24 RH BW 27 RH
Drive system hydrostatic hydrostatic
Driven axles 1 1
Brakes
Service brake pneum./hydr. pneum./hydr.
Parking brake Spring accum./hydr. re- Spring accum./hydr.
leased released
Steering
Type of steering 2-point pivot steering 2-point pivot steering
Steering operation hydrostatic hydrostatic
Tires
Tire size 11.00-20, 18 PR smooth 11.00-20, 18 PR
smooth
Air pressure min./max. bar 2 ... 8,1 2 ... 8,1
Tank contents
Water Litres 400 400
Fuel Litres 250 250
Engine oil Litres 9,5 9,5
Hydraulic oil Litres 60 60
Coolant Litres approx. 20 approx. 20
* The right for technical modifications remains reserved
Technical Data
The following noise and vibration data acc. to
- EC Machine Regulation edition (98/37/EC) and
- Noise Emission Regulation 2000/14/EC
determined at rated engine speed.
During operation these values may vary because of the existing operating conditions.
Noise value
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is
sound pressure level at the work place of the operator (with cabin):
LpA = 69 dB(A)
The nose emission value for the machine according to the noise emission regulation 2000/14/EC is
guaranteed sound capacity level of the machine:

LWA = 103 dB(A)
These sound values were determined according to ISO 3744 for the sound capacity level (LwA) and ISO
11204 for sound pressure level (LpA) at the place of the operator.
Vibration value
The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are:
Vibration of the entire body (driver’s seat)

The weighted effective acceleration value determined in accordance with ISO 7096 is γ ≤0.5 m/sec2.
Hand-arm vibration values

The weighted effective acceleration value determined in accordance with EN 500/ISO 5349, is γ ≤2.5 m/sec 2.
2 Safety regulations
Safety regulations
General Who is allowed to work with the ma-

chine?
This BOMAG machine is built in accordance
with the latest technical standard and the valid The machine must only be operated by trained
technical rules and regulations. There is, how- and authorized persons which are at least 18
ever, a risk of danger for persons and property years of age. The responsibilities for the operation
if: of the machine must be clearly specified and com-
plied with.
l the machine is used for purposes other than
those it is intended for Persons under the influence of alcohol, medica-
tion or drugs must not operate, service or repair
l the machine is operated by untrained person- the machine.
nel
Maintenance and repair tasks require specific
l the machine is modified or converted in an un- knowledge and must therefore only be carried out
professional way by trained and qualified personnel.
l the applicable safety regulations are not ob-
served. Conversions and alterations to the ma-
Each person involved in operation, mainte- chine
nance and repair of the machine must there- Unauthorized conversions to the machine are pro-
fore read and apply these safety regulations. hibited for safety reasons.
This should be confirmed by obtaining the sig- Original parts and accessories have been special-
natures of the customer, if necessary. ly designed for this machine. We wish to make ex-
Furthermore the following regulations and instruc- pressly clear that we have not tested or authorized
tions are obviously also valid: any original parts or special equipment not sup-
plied by us. The installation and/or use of such
l applicable accident prevention instructions
products can impair the active and/or passive driv-
l generally acknowledged safety and road traffic ing safety. The manufacturer expressly excludes
regulations any liability for damage resulting from the use of
l country specific safety regulations. It is the non-original parts or accessories.
duty of the operator to know and observe
these regulations. This applies also for local Safety notes in the operating and main-
regulations and the regulations for various tenance instructions:
types of manual work. If the recommendations
in this manual differ from the regulations valid
in your country, you must strictly observe the ! Danger
regulations in your country. Sections marked like this point out possible
dangers for persons.
Intended use
This machine must only be used for: Caution
!
l Compaction of bituminous material, e.g. road Sections marked like this point out possible
surface layers, dangers for the machine or for parts of the ma-
chine.
l light compaction work in earth construction
(road sub-bases).
i Note
Unintended use Sections marked like this provide technical infor-
mation concerning the optimal economical use of
However, dangers may arise from this machine if the machine.
it is operated by untrained personnel or if it is sub-
jected of unintended use.
Starting and operation of the machine in explosive
environments is prohibited.
Safety regulations
Environment Checking the Roll Over Protective

Sections marked like this highlight activities Structure (ROPS/FOPS*)
for the safe and environmental disposal of fu-
els and lubricants as well as replaced parts.
i Note
Observe all environment protection regula- On machines with cab the ROPS/FOPS is an inte-
tions. gral part of the cab.
The frame of the machine must not be warped,
Information and safety stickers/decals bent or cracked in the area of the ROPS fastening.
on the machine
The ROPS must not show any rust, damage, hair-
Keep stickers/decals complete (see spare parts line cracks or open fractures.
catalogue) and fully legible and observe their
The ROPS must not rattle about when driving.
meaning.
This would indicate that it is not properly fastened.
Replace damaged or illegible stickers/decals im- All bolted connections must comply with the spec-
mediately. ifications and should be absolutely tight (observe
the tightening torques). Screw and nuts must not
Loading the machine be damaged, bent or deformed.
Use only strong and stable loading ramps. The With the cab assembled check also the state of the
ramp inclination must be lower than the gradability cabin mounts (rubber elements and screws).
of the machine. No accessories may be welded or bolted on and
Secure the machine against turning over or slip- no additional holes must be drilled without the con-
ping off. sent of the manufacturer, since this will impair the
strength of the unit.
Secure the machine on the transport vehicle
against rolling off, slipping and turning over.
Starting the machine
Persons are highly endangered if
l they step or stand under loads being lifted Before starting
l they remain in the drive range of the machine The machine must only be operated from the driv-
during a demonstration or during loading. er’s seat.
The machine must not swing about when lifted off Use only machines which are serviced at regular
the ground. intervals.
Use only safe lifting gear of sufficient load bearing Become acquainted with the equipment, the con-
capacity. trol elements, the working principle of the machine
and the working area.
Attach the lifting gear only to the specified lifting
points. Wear your personal protective outfit (hard hat,
safety boots, etc.).
Towing the machine Before mounting the machine check whether:
You should generally use a tow bar. l persons or obstructions are beside or under
the machine
Max. towing speed 1 km/h, max. towing distance
500 m. l the machine is free of oily and combustible
material
Before releasing the parking brake secure the ma-
chine against unintended rolling. l all grips, steps and platforms are free of
grease, oils, fuel, dirt, snow and ice
l engine hood is closed and locked
Use steps and grips to mount the machine.
* ROLLOVER PROTECTIVE STRUCTURER/FALLING OB-
JECT PROTECTIVE STRUCTURE
Safety regulations
Before starting the machine check whether: Give warning signals, if necessary. Stop work im-
mediately if persons remain in the danger zone,
l the machine shows any obvious faults
despite the warning.
l all guards and safety elements are in place
Do not step or stand in the steering range of the
l the seat is correctly adjusted front wheels when the engine is running. Danger
l mirrors (if present) are clean and correctly ad- of squashing!
justed. Driving
Do not start the machine with defective gauges, Only attempt to drive when the air pressure in the
control lights or control elements. brake reservoir exceeds 5.7 bar (83 psi) and both
Do not take any loose objects with you or fasten warning light and warning buzzer go out.
them to the machine. Always choose lowest travel speed range when
On machines with roll over protective structure driving downhill, otherwise risk of overheating the
(ROPS/FOPS) you must always wear your seat brakes.
belt! If the engine oil pressure warning light lights up
shut the engine down immediately and check the
Starting
engine oil level.
Start and operate the machine only from the driv-
In events of emergency and in case of danger ac-
er’s seat.
tuate the emergency stop switch immediately. Do
For starting set all control levers to 'neutral posi- not use the emergency stop switch as service
tion'. brake.
Do not use any starting aids like start pilot or ether. Restart the machine only after the danger that
After starting the engine: caused the actuation of the emergency stop switch
has been eliminated.
l check all gauges and displays
If the machine has contacted high-voltage power
l check function of steering, brakes, control ele-
lines:
ments, lighting and warning horn
l do not leave the operator’s stand
Starting with jump wires
l warn others from coming close to or touching
Connect positive with positive and negative with the machine
negative – always connect the ground strap last
and disconnect it first! A wrong connection will l if possible drive the machine out of the danger
cause severe damage in the electric system. zone
Do not start the engine by shorting the electric ter- l have the power switched off
minals on the starter motor, because the machine Operate the machine only from the operator’s
may start to drive immediately. stand.
Starting in closed rooms Keep the cabin doors closed.
Exhaust gases are highly dangerous! Always en- Do not adjust the driver’s seat while driving.
sure an adequate supply of fresh air when starting Do not climb onto or off the machine while the ma-
in closed rooms! chine is driving.
Change the travel direction only at standstill.
Driving the machine
Do not use the machine to transport persons.
Persons in the danger area In case of unusual noises and development of
Before taking up work, also after breaks, you smoke perform trouble shooting and have the fault
should always convince yourself that the danger corrected.
zone is free of persons or obstructions, especially Always keep a sufficient distance to excavation
when driving in reverse. walls and embankments and do not use working
Safety regulations
methods that could impair the stability of the ma- No open fire, do not smoke.
chine. Do not spill any fuel. Catch running out fuel, do not
Always keep a sufficient distance when passing let it seep into the ground.
through subways, under bridges, tunnels, electric Wipe off spilled fuel. Keep fuel free of dirt and wa-
power lines etc. ter.
Driving on inclinations and slopes Leaking fuel tanks can cause explosions. Ensure
Do not drive on gradients exceeding the maximum tight fit of the fuel tank filling cover, replace it if nec-
gradability of the machine. essary.
On slopes drive extremely careful and always di- Fire protection measures
rectly up or down the slope. Change to a lower Make yourself acquainted with the location and the
gear before starting to drive. operation of fire extinguishers. Observe fire warn-
Wet and loose soils considerably reduce the ing and fire fighting installations.
ground adhesion of the machine on inclinations
and slopes. Higher risk of accident! Maintenance work
Behaviour in traffic Comply with the maintenance work described in
Match the speed to the working conditions. the operating and maintenance instructions, in-
cluding the information concerning the replace-
Always give way to loaded transport vehicles. ment of parts.
Switch the lights on if the visibility is poor. Support the engine hood for all maintenance and
Keep away from edges and embankments. repair work in the engine compartment.
Maintenance work must only be performed by
Parking the machine qualified and authorized persons.
Park the machine on horizontal, level, firm ground. For overhead maintenance and assembly work
Before leaving the machine: use the access steps and working platforms pro-
vided or other secure means. Do not use machine
l return the travel lever to neutral position, parts as access steps.
l apply the parking brake, Keep unauthorized persons away from the ma-
l shut down the engine, pull off the ignition key chine.
and the main battery switch Do not perform maintenance work while the ma-
l lock cabin and engine hood, chine is driving or the engine is running.
Park the machine on horizontal, level, firm ground.
l secure the machine against unintended use.
Pull the key out of the ignition switch.
Do not jump off the machine, but use hand grips
and access steps. Working on hydraulic and pneumatic lines
Mark machines, which could be in the way, with a Relieve hydraulic pressures before working on hy-
clearly visible sign. draulic lines. Hydraulic oil escaping under pres-
sure can penetrate the skin and cause severe
Parking on slopes and inclinations
injury. When being injured by hydraulic oil consult
Secure the machine against rolling, place metal a medical doctor immediately, as otherwise this
chocks in front of and behind the wheels. may cause severe infections.
Do not change the setting of pressure relief valves.
Filling the fuel tank
Drain the hydraulic oil at operating temperature –
Do not inhale fuel fumes. danger of scalding!
Refuel only after shutting the engine and the aux- Catch running out hydraulic oil and dispose of en-
iliary heater down. vironmentally.
Do not refuel in closed rooms.
Safety regulations
Do not start the engine after draining the hydraulic Do not leave any tools or other objects, that could
oil. cause damage, in the engine compartment.
Once all work is completed (with the system still Working on electric parts of the machine
depressurized!) check all connections and fittings
for leaks. Before starting to work on electric parts of the ma-
chine disconnect the battery and cover it with insu-
Changing hydraulic hoses lating material.
Hydraulic hoses must be visually inspected at reg- Do not use fuses with higher ampere ratings and
ular intervals. do not repair fuses with a piece of wire. Fire haz-
Hydraulic hoses must be immediately replaced if: ard!
Disconnect the battery before starting welding
l the outer layer is damaged down to the inlay
work on the machine.
(e.g. chafing, cuts, cracks)
l the outer layer is brittle (formation of cracks in Working on the battery
the hose material) When working on the battery do not smoke, do not
l the hose shows deformations in pressurized use open fire!
and depressurized condition, which do not Do not let acid come in contact with hands or
comply with the genuine shape of the hydrau- clothes! When injured by acid flush off with clear
lic hose water and seek medical advice.
l the hose shows deformations in bends, e.g. Metal objects (e.g. tools, rings, watch straps) must
squeezing, buckling, layer separation, forma- not come in contact with the battery poles – dan-
tion of blisters ger of short circuit and burning!
l parts of the hose are leaking. When recharging serviceable batteries remove all
plugs, to avoid the accumulation of explosive gas-
l hoses are not correctly installed.
es.
l the hydraulic hose has separated from the fit-
Observe the applicable instructions when starting
ting
with an auxiliary battery.
l the fitting shows corrosion that impairs both Dispose of old batteries according to regulations.
function and strength.
Switch off the charging current before removing
l hoses are mixed up by mistake. the charging clamps.
l fittings are damaged or deformed, whereby Ensure sufficient ventilation, especially if the bat-
the function and strength of the hose/hose tery is to be charged in a closed room.
connection is impaired.
Working on the fuel system
Only genuine BOMAG replacement hydraulic hos-
es ensure that the correct hose type (pressure Do not inhale any fuel fumes.
range) is used at the right location. Avoid open fire, do not smoke, do not spill any fuel.
Working on the engine Catch running out fuel, do not let it seep into the
ground and dispose off environmentally.
Shut the engine down before opening the engine
hood. Working on the brake system
Drain the engine oil at operating temperature – Have maintenance and repair work on the brake
danger of scalding! system only performed by qualified specialists.
Wipe off spilled oil, catch running out oil and dis-
Working on the transmission
pose of environmentally.
Drain transmission oil at operating temperature –
Store used filters and other oil contaminated ma-
danger of scalding!
terials in a separate, specially marked container
and dispose of environmentally. Wipe off spilled oil, catch running out oil and dis-
pose of environmentally.
Safety regulations
Store used filters and other oil contaminated ma- Test

terials in a separate, specially marked container Depending on the type of application and the op-
and dispose of environmentally. erating conditions vibratory equipment has to be
Working on wheels and tires examined by a specialist whenever required, but
at least once every year.
Explosion-like bursting of tires or parts of tires and
rims can cause most severe or even deadly inju-
ries.
Assembly of tires must only be performed with ap-
propriate experience and tools. If necessary have
tires assembled in a qualified workshop.
Always ensure the correct tire pressure and do not
exceed the specified maximum pressure.
Check tires and wheels every day for specified
pressure, cuts, bulges, damaged rims, missing
wheel studs or nuts. Do not drive with damaged
tires or wheels.
Ant-sticking emulsions for tires must only consist
of water and anti-sticking agent, in a concentration
in accordance with the specifications of the manu-
facturer of the anti-sticking agent. Observe appli-
cable environmental regulations.
Cleaning work
Do not perform cleaning work while the engine is
running.
Do not use gasoline or other easily inflammable
substances for cleaning.
When cleaning with steam cleaning equipment do
not subject electrical parts and insulation material
to the direct jet of water, or cover it beforehand.
l Do not guide the water jet into the exhaust and
into the air filter.
After maintenance work

After all maintenance work is completed reinstall
all guards and safety installations.
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!
Safety regulations
3 Indicators and Controls
Indicators and Controls
Fig. 4
1 Travel lever 14 Warning light, brake temperature

2 Steering wheel 15 Rotary switch for parking brake
3 not used 16 Warning light, brake pressure
4 Tire pressure gauge 17 Push button for warning horn
5 Emergency stop push button 18 Rotary switch for direction indicators left / right
6 Rotary switch for hazard light system 19 Rotary switch for light system (StVZO)
7 Instrument cluster 20 Rotary switch for working lights
8 Speedometer* 21 Throttle pedal
9 not used 22 Ignition switch
10 Push button for heating flange control* 23 Brake pedal
11 Rotary switch for travel ranges 24 Rotary switch for tire inflation
12 Rotary switch, dashboard illumination 25 Rotary switch to relieve tire pressure
13 Rotary switch for pressure sprinkler system 26 Utility socket 12 V
* Optional equipment
3.1 General notes 3.2 Description of indicators

and control elements
Please read this section thoroughly before operat-
ing this machine if you are not yet conversant with
the indicators and control elements. All functions
are described in detail hereunder.
Paragraph 4 Operation contains only concise de-
scriptions of the individual operating steps.
Fig. 5
No. 1 = Travel lever
The travel lever is used to pre-select the travel di-
rection.
Position “N” = Neutral position, engine can
be started.
Position “F” = Forward travel
Position ”R” = Backward travel
No. 2 = Steering wheels
i Note
The two steering wheels are joined by means of a
chain
Fig. 6
l Steer the machine with the steering wheel

(Fig. 6).
No. 3 = not used
to drive = return the travel lever first to

“neutral”, then start the engine
and actuate the travel lever
again.
For safety reasons the machine can only start to
drive after returning the travel lever to neutral po-
sition.
Fig. 7
No. 4 = Tire pressure gauge*
Shows the current tire pressure.
Operating pressure approx. 2 ... 8,1 bar (29 - 116
psi)
Fig. 9
No. 6 = Rotary switch for hazard light system
Position "left" = Hazard light switched off, con-
trol lights off.
Position "right" = Hazard light switched on, con-
trol light 1 in instrument cluster
lights up.
Fig. 8
No. 5 = Emergency stop switch
Shuts the engine down and closes the brake.
Danger
!
Danger of accident!
Actuate only in events of emergency during
operation, do not use as service brake.
Restart the machine only after the danger that Fig. 10
caused the actuation of the emergency stop No. 7 = Instrument cluster
switch has been eliminated.
actuate = press the button completely
down, it automatically locks in
i Note
fully pressed position. With the ignition switch in position I all gauges and
instruments are switched on for 3 seconds.
unlock = turn the button clockwise and
let it go. a red = flashes in case of engine overheat-
ing, warning buzzer sounds, clean
engine oil cooler and radiator, if nec- When falling below the lowest filling level the last
essary repair the engine green LED will light and the red LED will addition-
b red = flashes if engine oil pressure is too ally come on.
low, the warning buzzer sounds, the When the fuel tank is empty only the red LED will
engine is shut down after 10 sec- flash.
onds. Check the engine oil level, if
necessary have the engine repaired.
c yellow = Engine air filter, lights if air filter car-
tridge is soiled, clean or replace if
necessary.
d yellow = Charge control light, lights if battery is
not being charged.
Check V-belt, if necessary repair the
generator
e yellow = lights when the hydraulic oil filter is
exhausted, check the hydraulic sys-
tem, replace the hydraulic oil filter
f yellow = not active
Fig. 11
g red = lights when the parking brake is ap-
plied No. 8 = Speedometer*
h green = Direction indicator, flashes when the Shows the travel speed of the machine.
travel direction switch is actuated. black display
i yellow = Water separator in fuel pre-cleaner. scale = km/h
Lights when the amount of water in red display
the transparent section of the fuel fil- scale = M.P.H.
ter reaches the contacts. No. 9 = not used
j red = flashes when the coolant (filling) level
is too low, the warning buzzer
sounds.
k yellow = Pre-heating and after-heating*
l red = Hazard light, flashes when the haz-
ard light is activated
m = Operating hour meter, counts the op-
erating hours while the engine is run-
ning. All maintenance work must be
performed according to the indicated
operating hours.
n = Fuel tank filling level
When falling below the lowest filling
level the last green LED will light and Fig. 12
the red LED will additionally come on. No. 10 = Push button for heating flange**
When the fuel tank is empty only the The heating flange has the function of heating up
red LED will flash. the combustion air under cold ambient tempera-
tures. The high heating up of the combustion air
i Note improves the cold starting characteristics and the
exhaust emissions (white smoke) of the diesel en-
Nine green and one red LED.
gine. The pre-heating time is only started at tem-
* Optional equipment ** Optional equipment
peratures below +5 °C, whereas after-heating is

already activated below 25 °C. This means at tem-
peratures between +5 °C and + 25 °C only after-
heating will take place.
With ignition switched on
press = The heating flange control is
triggered, pre- and after-heat-
ing
If the switch is operated after the engine has been
started, only the after-heating process will take
place.
Fig. 14
No. 12 = Rotary switch, dashboard illumina-
tion
Position "left" = bright light
Position "right" = dimmed light
Fig. 13
No. 11 = Potentiometer for speed limitation
control
Position "left" = slow speed range
Position "Mid-
dle" = medium travel range
Position "right" = fast speed range Fig. 15
No. 13 = Rotary switch for pressure sprinkler
! Danger system
Risk of overheating the brake! Position "Left" = 6 sec. on / 12 sec. off (interval)
emulsion sprinkling
Always select lowest speed range when driv-
Position "0" = Sprinkler system switched off
ing downhill.
Momentary con-
tact switch
! Caution "Right" = 6 sec. emulsion sprinkling on
Pre-select the travel speed ranges at standstill.
i Note
The warning light in the switch flashes if the water
tank is empty.
No. 14 = Warning light, brake temperature
Fig. 16 Fig. 18
Flashes when the brake overheats. No. 16 = Warning light, brake pressure
i Note Danger
!
The warning buzzer sounds too. Lights in case of too low pressure in the brake
accumulator.
!Danger Stop the machine and wait with the engine run-
Stop the machine and run the engine with me- ning, until the warning light goes out or inves-
dium speed until the warning light goes out. tigate the cause of the pressure loss.
Do not drive the machine with a defective
Continue travelling in low travel speed range
brake system!
and with low travel speed.
Fig. 19
Fig. 17
No. 17 = Push button for warning horn
No. 15 = Rotary switch for parking brake
Position "left" = Parking brake applied, control
light in monitoring board lights
up
"Middle" = Parking brake released
Position "right" = to drive against the closed
brake (brake test)
Fig. 20 Fig. 22
No. 18 = Rotary switch for direction indicators No. 20 = Rotary switch for working lights
left / right Position "left" = Light off
Position "mid- Position "right" = Working lights on, with ignition
dle" = Direction indicators disabled switch in position "I".
Position "left or
right" = Front and rear direction indica-
tors for the corresponding side
of the machine light up, the
control light in the instrument
cluster flashes.
Fig. 23
No. 21 = Throttle pedal
Is used to change the engine speed / travel speed
Fig. 21
No. 19 = Rotary switch for light system (StV-
ZO)
Position "left" = Light off
Position "mid-
dle" = Sidelights on, with ignition
switch in position "I" or "P"
Position "right" = Travel light on, with ignition
switch in position "I".
Fig. 24
No. 22 = Ignition switch
Position "P"/"0" = Ignition off, key can be pulled To actuate the service brake (multi-disc brake) on
out, engine off, parking brake the rear axle and the hydrostatic brake (inching)
applied.
Position "I" = Ignition on, parking brake re-
leased (if not activated)
i Note
The engine can only be started when both travel
levers are in “neutral”.
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, Fig. 26
turn the ignition key back to
No. 24 = Rotary switch for tire inflation*
position once the engine has
started Position "left" = Valve closed
Position "right" = Valve open, tire is being filled
i Note
During the starting process all warning and control i Note
lights in the fault monitoring board light up. This is The tire will be filled up to max. 8,1 bar (116 psi).
a self test of the control lights.
! Caution
Run the engine warm for a short while before
starting work. Do not allow the engine to run
longer than 10 minutes with idle speed.
Do not shut the engine down all of the sudden
from full speed, but let it idle for a while for
temperature equalization.
Fig. 27
No. 25 = Rotary switch to release the tire pres-
sure**
Position "left" = Valve closed
Position "right" = Valve open, the tire pressure is
being released
i Note
The tire pressure can be released down to max.
Fig. 25
2.0 bar (29 psi).
No. 23 = Brake pedal
** Optional equipment
F26, 10A = Solenoid valve for speed

range selection
F70, 10A = Direction indicators
F77, 10A = Driving
F120, 15A = Brake light
F09, 10A = Parking and tail light, left hand
side
F10, 10A = Parking and tail light, right
hand side
F11, 10A = Headlights, left
F12, 10A = Headlights, right
Fig. 28
F06, 10A = Water sprinkler system
No. 26 = 2-pole socket
F156, 20A = StVZO
Can only be deenergized via the main battery
F124, 25A = Winter package
switch.
Danger
!
Fire hazard!
Do not use fuses with higher ampere ratings
and do not bridge fuses.
Fig. 29
No. 27 = Fuses in electric installation box
F01, 30A = Main fuse
F05, 15A = Socket
F37, 20A = Sprinkling pump
Fig. 30
F07, 15A = Hazard light
a = toggle switch for flashing beacon
F119, 7,5A = Diesel engine
F14, 10A = Engine solenoid b = toggle switch for front windscreen wiper/
washer
F129, 15A = MD+
up = windscreen wiper moves to
F04, 5A = Instruments
end position and stops.
F149, 5A = Solenoid valve for brake
down = Switches on wiping of front
F22, 15A = Working head lights, rear** windscreen.
F23, 10A = Warning horn Push button = Front windscreen is sprayed
F25, 10A = Solenoid valve brake/travel during wiping.
c = toggle switch for rear windscreen wiper/

washer
up = windscreen wiper moves to
end position and stops.
down = Switches on wiping of rear
windscreen.
Push button = Rear windscreen is sprayed
during wiping.
d = toggle switch for working headlights
e = toggle switch for rear windscreen heating
Fig. 32
d = Fuse box in cabin
! Danger
Fire hazard!
Do not use fuses with higher ampere ratings
and do not bridge fuses.
(1), 15A = (F41) flashing beacon
(2), 15A = (F27) wiper/washer, front
(3), 15A = (F28) wiper/washer, rear
Fig. 31 (4), 25A = (F31) cabin fan
No. 28 = Main battery switch (5), 25A = (F110) working head lights, front/rear
Turn "anti-clock- (6), 5A = (F90) cabin heater
wise" = Battery disconnected
(7), 10A = (F68) potential 30
= protection against unauthor-
(8), 20A = (F40) cabin heater
ized use
= in case of burning of cables
= during welding work on the
machine
Turn "clock-
wise" = operating position, battery
connected
Fig. 33
No. 29 = Control panel for ventilator, air condi-
tioning, heating
e = Rotary switch for cabin ventilator

Position ’’Off“ = cabin ventilator switched off.
Position 1, 2 and i = reading and dashboard light

3 = ventilator stages of different
strengths j = toggle switch for reading and dashboard
light
f = Push button for air conditioning*
k = toggle switch for cabin light
press = air conditioning switched on.
l = cabin light
i Note
The lights above the push buttons light up.
With rotary switch (g) the air conditioning unit can
be regulated within the blue range.
press again = air conditioning switched off.
i Note
The light goes out.
g = Rotary switch for cabin heater (tempera-
ture selector switch)
Position ’’Off“ = cabin heater switched off.
Fig. 35
Position blue
range = temperature selection for air No. 31 = Main fuse for battery
conditioning. 125A = (F00)
Position red
range = Temperature selection for cab-
in heater.
Fig. 36
No. 32 = Anti-theft protection**
prevents unauthorized starting of the engine.
Fig. 34
Keypad = Input of user and service code (main-
No. 30 = Cabin light tenance).
i Note
Enter the user code with the ignition switched
off!
After entering the user code you should start the
engine within 30 seconds.
After entering the service code the anti-theft pro-

tection remains switched off.
red LED
display
flashes
slowly = anti-theft protection active.
LED dis-
play lights
green = every time a digit of the user or serv-
ice code is entered.
i Note
After shutting down the engine it can be restarted
within a period of 12 seconds, in any other case
the user code needs to be entered again.
4 Operation
Operation
4.1 General notes 4.2 Tests before taking into op-

eration
Please read section 3 Indicators and Control Ele-
ments thoroughly before operating the machine if
The following inspections must be carried out be-
you are not yet fully familiar with the indicators and
fore each working day or before a longer working
control elements of the machine.
period.
All indicators and control elements are described
in detail in this chapter.
! Danger
Danger of accident!
Please observe strictly the safety regulations
in chapter 2 of this instruction manual!
l Park the machine on ground as level as possi-
ble.
Check:
l engine, transmission, radiator, fuel system,
steering and brake hydraulics for leaks
l function of steering
l service and parking brakes
l machine for condition, cleanliness, damage
l Presence of the appropriate operating and
maintenance instructions
l check whether the machine has been properly
serviced
i Note
For a description of the following tasks refer to the
chapter "maintenance every 10 operating hours".
l Engine oil level
l Coolant level
Danger
!
Fire hazard!
Do not refuel in closed rooms
l Fuel level
l Water level and function of the tire sprinkler
system
l Water separator in fuel system, drain if neces-
sary
l Air pressure in tires
Operation
After entering the service code (for maintenance

*
4.3 Disarming the anti-theft work) the anti-theft protection remains disarmed.
protection
Before starting the engine the anti-theft protection
must be disarmed by entering a code while the ig-
nition is still off.
! Caution
If the anti-theft protection is disarmed with the
ignition switched on, the diesel engine will run
in limp home program!
Fig. 37
i Note
With the anti-theft protection armed light emitting
diode a (Fig. 37) flashes slowly in red.
l Slowly enter the six-digit user code while the
ignition is switched off.
i Note
With each digit of the code the light emitting diode
lights green.
l Press the confirmation key ’’VAL“.
l The anti-theft protection is now disarmed and
the engine must be started within the next 30
seconds.
i Note
After the engine has been shut down restarting is
possible within 12 seconds. After this the anti-theft
protection will be armed again. The red LED flash-
es at intervals of one second.
Operation
4.4 Starting the engine
! Danger
Danger of accident!
Always wear your seat belt.
Before starting make sure that no persons are
within the danger zone.
Start the engine only from the operator’s seat.
Before starting activate the parking brake and
shift the travel lever to “neutral”-position.
Fig. 39
Do not start the engine by towing the machine.
l Fasten your seat belt (Fig. 39).
If the engine needs to be started with jump
wires, connect terminals (+) with (+) on battery
and (-) with (-) ground on engine block.
When starting with jump wires always connect
the ground cable (negative) first and discon-
nect it last.
Never disconnect a battery cable while the en-
gine is running.
Do not allow the engine to run longer than 10
minutes with idle speed (1500 rpm).
Do not load the engine to its limits before the
operating temperature is reached.
Fig. 40
l Check, whether the emergency stop switch

(Fig. 40) is unlocked, unlock if necessary.
Fig. 38
l Switch the main battery switch (Fig. 38) to po-

sition “On”.
Fig. 41
l Check whether the parking brake is activated,

if necessary activate the parking brake (Fig.
41).
Operation
Caution
!
Perform the starting process for maximum 20

seconds without interruption and pause for a
minute between starting attempts.
If the engine has not started after three at-
tempts perform trouble shooting.
Fig. 42
l Check whether both travel levers (Fig. 42) are

in “neutral”, if necessary set the levers accord-
ingly.
Fig. 45
l Turn the ignition key (Fig. 45) to position "II",

the starter will crank the engine.
l As soon as the engine ignites return the igni-
tion key to position "I".
!Danger
If the pressure in the compressed air accumu-
lator for the brake system drops below 5.7 bar
Fig. 43 (83 psi), the warning buzzer will sound and the
l Turn the ignition key (Fig. 43) to position "I". "brake pressure" warning light will light up. Do
not start to drive before the pressure in the
compressed air accumulator is higher than 5,7
bar and the warning buzzer has stopped.
i Note
During the starting process all control and warning
lights in the fault monitoring board light up and can
therefore be checked.
If the engine does not start after a longer period of
rest it may be necessary to bleed the fuel system.
At temperatures below + 25 °C you should, if nec-
essary, switch on the heating flange control* to re-
duce the development of white smoke.
Fig. 44
Battery control light d (Fig. 44), and engine oil
pressure warning light (b) must light.
Operation
Starting at low temperatures below + 5

°C
i Note
Only on machines with winter package *
! Danger
Danger of explosion!
Do not use starting aid sprays or other inflam-
mable fluids for starting.
Fig. 47
!Caution
l Operate the push button for the heating flange
If the engine has not started after two attempts
control (Fig. 47).
perform trouble shooting.
The control lamp in the instrument cluster lights
up.
Fig. 46
l Turn the ignition key (Fig. 46) to position "I"

Fig. 48
and wait approx. 5 minutes for pre-heating of
** fuel. l Turn the ignition key (Fig. 48) to position "II",
the starter will crank the engine.
l As soon as the engine ignites return the igni-
tion key to position "I".
! Caution
Run the engine warm for a short while, but do
not run with idle speed for more than 10 min-
utes.
** Optional equipment
Operation
4.5 Starting with jump wires 4.6 Driving the machine / brak-
ing
i Note
The machine can be operated from either of the
two operator’s stands.
Danger
!
Danger of accident!
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclina-
tions and slopes.
Fig. 49
Soil conditions and weather influences impair
the gradability of the machine.
Do not drive up and down inclinations exceed-
!Caution
ing the maximum gradability of the machine
A wrong connection will cause severe damage (see technical data).
in the electric system.
Always select lowest speed range when driv-
l Bridge the machine only with a 12 Volt auxilia- ing downhill. Risk of overheating the brake!
ry battery. Do not drive without wearing your seat belt.
l When jump starting with an external battery Always give way to loaded transport vehicles!
connect both plus poles first.
Before starting to drive make sure that the
l Then connect the ground cable first to the mi- drive range is absolutely safe.
nus pole of the current supplying auxiliary bat-
Switch the lights on if the visibility is poor.
tery and then to engine or chassis ground, as
far away from the battery as possible (Fig. 49). After starting the engine quickly operate the
warning horn and wait for a moment, so that
l Start as described under 'Starting the engine'.
people can leave the danger zone.
l Once the engine is running switch on a power- Only start to drive after the compressed air ac-
ful consumer (working light, etc.). cumulator has been sufficiently filled. The
brake pressure warning light goes out.
! Caution
If no powerful consumer is switched on volt-
age peaks may occur when separating the con-
necting cables between the batteries, which
could damage electrical components.
l After starting disconnect the negative poles
(ground cable) first and the positive poles af-
ter.
l Switch off the consumer.
Operation
Driving the machine
Fig. 53
l Check whether the brake pressure warning

Fig. 50
light has gone out (Fig. 53).
l Pre-select the desired speed range (Fig. 50).
Fig. 54
Fig. 51
l Kick the throttle pedal (Fig. 54) slowly down,
l Pre-select the desired travel direction (Fig. according to the desired travel speed.
51).
Braking the machine (service brake)
Kick down half of
the pedal way = hydrostatic braking (inching
valve)
!Caution
Strictly avoid overreving of the engine.
Danger of engine damage!
i Note
Hydrostatic braking can cause the engine speed to
increase. In this case kick the pedal further daown
Fig. 52
to actuate the multi disc brake.
l Release the parking brake (Fig. 52).
The control light in the instrument cluster goes out.
Operation
longer pedal
stroke = additional dynamic service
brake (multi-disc brake)
i Note
The oil temperature in the service brake (multi-disc
brake) is monitored.
In case of overtemperature the warning light in the
instrument cluster flashes and the warning buzzer
sounds.
Fig. 56
l For steep downhill driving choose lowest

speed range (Fig. 56) in order to avoid over-
heating of the brake.
Fig. 55
l Brake pedal (Fig. 55), kick down as necessary

for the desired braking effect.
! Danger
Danger of accident! Fig. 57
Always brake very gently on slippery roads, Hydrostatic + dynamic permanent braking power
danger of skidding. (Fig. 57).
If the brake oil temperature warning light flash-
es and the warning buzzer sounds stop the i Note
machine immediately, run the engine with me-
The diagram shows the maximum downhill slope
dium speed and wait until the light goes out.
that can be driven in permanent operation, in de-
Then drive on with low speed and in lowest
pendence on machine weight and selected travel
speed range.
speed range.
Example:
Machine weight = 15.000 kg, speed range 3
Solution:
max.
downhill
slope = 12%
Operation
! Danger
4.7 Operating the parking brake
Danger of accident!
The specified values refer to permanent ioper-
ation and are also dependent on ambient tem- ! Caution
perature and degree of soiling of the radiator. Even when leaving the machine just for a short
Steeper downhill slopes can be driven over while you should generally apply the parking
shorter distances (<300m). brake and shut the engine down.
Strictly avoid overreving of the engine. l Stop the machine.
In case of overheating of the brake (indicated
by warning light and warning buzzer) stop im-
mediately and run the engine with medium
speed, until the oil circuit has cooled down.
The diagram solely refers to the permissible
permanent braking power, safe driving on
such slopes requires sufficient grip of the
ground.
Fig. 58
l To operate the parking brake turn the rotary

switch (Fig. 58) counter-clockwise.
The control lamp in the instrument cluster lights
up.
Operation
4.8 Shutting the engine down,

parking the machine
! Danger
Danger of accident!
Park the machine only in places where this is
possible without any danger.
Secure the machine against unauthorized use.
Always remove the ignition key and close the
cabin door.
Fig. 60
Even when leaving the machine just for a short
while you should generally apply the parking l Apply the parking brake (Fig. 60).
brake and shut the engine down. The control lamp in the instrument cluster lights
When parking on inclines block the wheels up.
with suitable wheel chocks. l Switch off all appliances like windscreen wip-
l Stop the machine. ers, ventilator etc.
Caution
!
Do not shut the engine down all of the sudden

from full speed, but let it idle for approx. 3 min-
utes for temperature equalization.
Fig. 59
l Shift the travel lever (Fig. 59) to "Neutral".
Fig. 61
l Turn the ignition key to position “0” or “P” (Fig.

61).
The engine will stop.
l Remove the ignition key and close the switch
with the protective cap.
Operation
4.9 In events of emergency
Fig. 62
l Pull off the hand lever of the main battery

switch (Fig. 62) in the engine compartment
and close the switch with the protective cover. Fig. 63
l Check the condition of the machine, clean and l Press the emergency stop switch (Fig. 63).
repair it as necessary.
Shuts the engine down immediately and closes
l Lock cabine door and engine hood. the brake.
l For restarting turn the emergency stop switch
in direction of arrow to unlock.
l Close the parking brake.
l Shift the travel lever to "Neutral".
i Note
After operating the emergency stop switch the en-
gine cannot be started.
To start the engine both travel levers must be in
“Neutral”-position.
Operation
4.10 Operating the pressure 4.11 Operating the tire inflation**

sprinkler system system
! Caution i Note
Before driving with the wheels on fresh bitumi- Changing of the tire pressure is possible during
nous layers to be compacted, the wheels must operation. For correct tire pressure refer to the ta-
be completely wetted. ble at the ed of this manual.
Spray the rubber tires with a suitable anti-
sticking agent. Caution
!
For normal travel and compaction work in Do not activate both switches (filling / empty-
earth construction lift the scraper brushes* off ing) at the same time
and locke them.
l Check the water level, fill up if necessary. Filling the tires
Fig. 64 Fig. 65
l Turn the rotary switch (Fig. 64) to activate the l Turn the rotary switch (Fig. 65) clockwise.
sprinkler system.
The tires will be inflated, the pressure can be read
on the pressure gauge in the dashboard.
Operation
Relieving the tire pressure

4.12 Adjusting the driver’s seat
Fig. 66
l Turn the rotary switch (Fig. 66) clockwise. Fig. 67
The pressure in the tires will be relieved, the pres- l To adjust the seat in longitudinal direction dis-
sure can be read on the pressure gauge in the engage lever a (Fig. 67).
dashboard.
l To adjust the weight turn lever (b) and read the
weight in sight glass (c).
i Note l Operate lever (d) to adjust the backrest.
A safety device makes sure that the tire pressure
does not fall below 2 bar (29 PSI).
Fig. 68
l To slide the seat pull up lever (Fig. 68) and

slide the seat to the desired position.
! Danger
Danger of accident!
Always engage the seat at the end positions
when adjusting.
Check that the seat is securely engaged.
When releasing the lever the seat is fixed in posi-
tion.
Operation
4.13 Operating the hood 4.14 Ballasting of machine*
! Danger ! Caution
Danger of accident! Drain all water off if there is a risk of frost.
If the hood needs to be opened further for
maintenance or repair work, support it safely.
i Note
Only with optional equipment
Bottom position
If needed, the machine can be filled with approx.
3500 litres of water (3,5 t).
Fig. 69
l Unlock the lock (Fig. 69). Fig. 70

l To open the hood press in the button and turn l Unscrew the filler cap (Fig. 70) and fill in clean
the handle. water.
l Reassemble the filler cap.
Fig. 71
l In order to reduce weight or in case of frost un-

screw the cap (Fig. 71) and let all water run
out.
Operation
4.15 Towing in case of an engine

failure
! Danger
Secure the machine with wheel chocks against
unintentional rolling.
Danger of accident!
When using towing ropes tow the machine
only uphill.
When towing downhill you must use a rigid Fig. 73
towing device.
l Press the emergency operation button (Fig.
The machine cannot be steered. 73) completely down.
l Secure the machine with wheel chocks
against unintentional rolling.
i Note
l Securely attach chains or towing ropes to the Use a suitable pipe.
lifting hooks.
After starting the engine the emergency operation
button returns automatically to initial position.
Caution
!
l Insert the pump lever extension and operate
Towing speed 1 km/h, max. towing distance the pump, until the brake is released.
500 m.
l Open the engine hood. After towing
! Caution
Secure the machine with wheel chocks against
unintentional rolling.
l Retighten the high pressure relief valve car-
tridges (Fig. 72) with 100 Nm.
Fig. 72
l Slacken both high pressure relief valves (Fig.

72) on the travel pump for approx. one turn.
! Caution
Turn only the bigger hexagon (arrow). Do not
turn the pressure adjustment screw, as other-
wise the high pressure relief valves need to be
adjusted!
Operation
4.16 Transport
! Danger
Danger of accident!
Observe the safety regulations and the acci-
dent prevention instructions.
Observe national laws, as well as traffic and
transport regulations.
Use only stable loading ramps of sufficient
load bearing capacity.
Fig. 75
Make sure that persons are not endangered by
the machine tipping or sliding off. l Fasten the lifting gear (Fig. 75) with shackles
at the front and rear lifting points.
Lash the machine down, so that it is secured
against rolling, sliding and turning over.
Do not stand or step under loads being lifted. Caution
!
Keep the ropes sufficiently appart above the

Always use shackles on the lifting points for
cabin (1,95 m), to avoid damage to the cabin.
loading, tying or lifting the machine.
Observe the loading weight (see technical da-
ta).
Observe the loading height, if necessary re-
move cabin or ROPS.
Fig. 76
l Position of centre of gravity (Fig. 76).
Machine X H
Fig. 74
BW 24/27 RH 1955±260 985±390
l Lash the machine to the transport vehicle (Fig.
74) at front (1) and rear (2).
i Note
l Block the wheels with suitable chocks (3). The tolerances account for all possible options,
such as cabin, additional weight etc.
Weights: see technical data.
Operation
5 Maintenance
Maintenance
l Do not draw off fuel from near the bottom of

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

5.2 Fuels and lubricants
Prepare and check coolant with highest care,
since otherwise the engine may be damaged by
corrosion, cavitation and freezing. Engine oil
The coolant is prepared by mixing a cooling sys-
tem protection agent (Etylene Glycol / Propylene Quality
Glycol) to the cooling water. Lubrication oils are classified according to their
Mixing with cooling system protection agent is performance and quality class. Oils according to
necessary in all climatic zones. It prevents corro- other comparable specifications may be used.
sion, lowers the freezing point and raises the boil-
Approved engine oils
ing point of the coolant.
ACEA
E3-96/E5-02
API
CG-4/CH-4
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-
ating location of the engine is of utmost impor-
tance when choosing the viscosity class (SAE-
class) .
Maintenance
BW 24 RH / DEUTZ BFM 2012
ACEA*
E3-96/E5-02 = 500 operating hours
API**
CG-4/CH-4 = 500 operating hours
BW 27 RH / DEUTZ BFM 2012C
ACEA
E4-99/E6-04 = 500 operating hours
Caution
!
These intervals apply only when using a diesel

fuel with maximum 0.5 % sulphur by weight
and for ambient temperatures higher than -10
°C.
When using fuels with a sulphur content of
more than 0.5% to 1% or under ambient tem-
peratures 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.
Fig. 77
Coolant, anti-freeze agent
Optimal operating conditions can be achieved by
Use only soft tap water (drinking water) to prepare
using the opposite oil viscosity chart (Fig. 77) as a
the coolant mix.
reference.
As a protection against frost, corrosion and boiling
Occasionally falling short of the temperature limits
point anti-freeze agents must be used under any
will impair the cold starting ability, but will not
climatic conditions.
cause any engine damage. In order to keep the
occurring wear as low as possible, occassional ex- The proportion of cooling system protection agent
ceeding of the limits should not happen over a must be between min. 35% and max. 45% to the
longer period of time. water.
With their better temperature and oxidation stabil-
ity synthetic lubrication oils offer quite a few bene- Caution
!
fits. Do not mix different coolants and additives of
any other kind.
Lubrication oil change intervals
The longest permissible time a lubrication oil
should remain in an engine is 1 year. If the follow- Environment
ing oil change intervals are not reached over a pe- Cooling system protection agents must be dis-
riod of 1 year, the oil change should be performed posed of environmentally.
at least once per year, irrespective of the operating
hours reached.
* European Engine Oil Sequences

** American Petroleum Institute
Maintenance
Fuels However, if you still intend to operate the machine

with RME-fuels you should observe the following
Quality information:
You should only use commercially available brand l Reduced engine power (approx. 7%), higher
diesel fuel with a sulphur content below 0.5% and fuel consumption.
ensure strict cleanliness when filling in. A higher
sulphur content has a negative effect on the oil l The quality of RME-fuel should be in compli-
change intervals. Use only winter-grade diesel fuel ance with DIN draft 51606.
under low ambient temperatures. The fuel level l Avoid longer periods of standstill (formation of
should always be topped up in due time so that the resin, corrosion in injection system)
fuel tank is never run dry, as otherwise filter and in-
l RME-fuel can damage the paint finish of the
jection lines need to be bled.
machine.
When using fuels with a Cetan number < 49 poor
l Fuel dilution of engine oil, therefore shortening
starting and white smoke can be expected, in par-
of oil change intervals to half.
ticular in connection with low ambient tempera-
tures. l Rubber parts, such as leak fuel return lines,
The following fuel specifications are permitted: seats will be damaged in the long run and
DIN/EN 590; DIN 51 601; Nato Codes: F-54, F-75; need to be replaced on a regular basis or
BS 2869: A1 and A2; ASTM D 975-78: 1-D and 2- should be replaced by parts made of fluorinat-
D. ed rubber. However, fluorinated rubber is not
resistant against normal diesel fuel.
l DIN/EN 590
l If the fuel filter is clogged the filter change in-
l BS 2869 tervals must be shortened accordingly.
l ASTM D 975-78: 1-D and 2-D.
l Nato Codes: F-54, F-34, F44 and XF63 Hydraulic oil
The hydraulic system is operated with hydraulic oil
Winter fuel
HV 46 (ISO) with a kinematic viscosity of 46 mm2/
s at 40°C. For topping up or for oil changes use
Danger
! only high-quality hydraulic oil, type HVLP accord-
Fire hazard! ing to DIN 51524, part 3, or hydraulic oils type HV
according to ISO 6743/3. The viscosity index (VI)
Diesel fuels must never be mixed with gaso- should be at least 150 (observe information of
line. manufacturer).
For winter operation use only winter diesel fuel, to
Bio-degradable hydraulic oil
avoid clogging because of paraffin separation. At
very low temperatures disturbing paraffin separa- On request the hydraulic system can also be filled
tion can also be expected when using winter diesel with ester based biodegradable hydraulic oil (Pan-
fuel. olin HLP Synth. 46). The biologically quickly de-
gradable hydraulic oil meets all demands of a
In most cases a sufficient cold resistance can also
mineral oil based hydraulic oil according to DIN
be achieved by adding flow enhancing fuel addi-
51524.
tives. Consult the engine manufacturer.
In hydraulic systems filled with Panolin HLP Synth.
Operation with rape seed oil methyl ester (RME 46 always use the same oil to top up. When
„Bio Diesel“) changing from mineral oil based hydraulic oil to an
Due to the extreme quality differences of RMEW- ester based biologically degradable oil, you should
fuels available on the market, which are caused by consult the lubrication oil service of the oil manu-
the non-existence of a standardization, BOMAG facturer for details.
does generally not approve any RME-fuels. If this Check the filter more frequently after this change.
is neglected the warranty will become null and
void!
Maintenance
! Caution
Oil change bio-degradable hydraulic oil:
Perform regular oil analyses for content of wa-
ter and mineral oil.
Replace the hydraulic oil filter element every
500 operating hours.
Oil for travel gears/wheel hubs

For the drive axle use only multi-purpose transmis-
sion oil of API-class GL4/GL5 with viscosity class
SAE 75W/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).
Maintenance
5.3 Table of fuels and lubri-

cants
Assembly Fuel or lubricant Quantity approx.
Summer Winter Attention

Observe the level marks
Engine BW 24 RH Engine oil ACEA E3-96/E5-02 API: CG-4/CH-4 with oil filter change
Engine oil ACEA E4-99/E6-04 approx. 9,5 litres
SAE 15W/40
(-15 °C to +40 °C)
Fuel
Diesel Winter diesel fuel approx. 250 litres
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity 46 mm2/s at approx. 60 litres
40 °C
Travel gear/wheel hubs Gear oil SAE 75W/90, API GL4/GL5 approx. 7,5 litre per side
Cooling system Coolant approx. 20 litres
Sprinkler system Water approx. 400 litres
Ballast compartment Water approx. 3500 litres
Air conditioning system Refrigerant R134A approx. 1200 g
Lubrication points lithium saponified multi-purpose grease, penetration 2 as required
Maintenance
5.4 Running-in instructions
The following maintenance work must be per-

formed when running in new machines or
overhauled engines:
! Caution
Up to approx. 250 operating hours check the
engine oil level twice every day.
Depending on the load the engine is subjected
to, the oil consumption will drop to the normal
level after approx. 100 to 250 operating hours.
After 50 operating hours

l Retighten the wheel studs

l Change the engine oil
l 1st oil change in drive gear/wheel hubs
l Retighten bolted connections on intake and
exhaust tubes, oil sump and engine mounts.
l Retighten the bolted connections on the ma-
chine.

l 2. oil change in drive gear
Maintenance
5.5 Maintenance chart
every 10 operating hours, daily
every 1000 operating hours


after 250 operating hours
Running-in instructions
No. Maintenance work Remark
as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the coolant level Inspection glass X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Draining the air pressure vessel X
5.11 Checking/filling up the water provi- X
sion in the sprinkler system
5.12 Checking/adjusting the scrapers X
5.13 Check the fuel level X
5.14 Multi-disc brake, function test X
5.15 Clean the cooling fins on engine X
and hydraulic oil cooler
5.16 Check the oil level in the drive X
gear/wheel hub
5.17 Change engine oil and oil filter car- min. 1x per year X X
tridge*
5.18 Change the fuel filter cartridge X
5.19 Drain the sludge from the fuel tank X
5.20 Battery maintenance Pole grease X
5.21 Change the fuel pre-filter cartridge X
5.22 Check, replace the refrigerant X
compressor V-belt
5.23 Service the air conditioning X
Maintenance


as required
5.24 Checking hydraulic, pneumatic min. 1x per year X
hoses and electric cables
5.25 Check, adjust the valve clearance Intake = 0,3 mm X
Exhaust = 0,5
mm
5.26 Check, replace the ribbed V-belt X
5.27 Check the engine mounts X X
5.28 Tighten the wheel nuts X X
5.29 Check the ROPS X
5.30 Brake system air drier min. 1x per year X
5.31 Travel gears/wheel hubs min. 1x per year X X
5.32 Change hydraulic oil and breather at least every 2 X
filter** years
5.33 Change the hydraulic oil filter*** at least every 2 X
years
5.34 Change the coolant at least every 2 X
years
5.35 Checking the supply lines for the X
compressor
5.36 Check the injection valves X
5.37 Service the combustion air filter min. 1x per year, X
safety cartridge
at least every 2
years
5.38 Servicing the water sprinkling sys- X
tem
5.39 Maintenance in case of frost X
Maintenance


as required
5.40 Filling the windscreen washer sys- X
tem
5.41 Change the fresh air filter in the X
cabin
5.42 Change the tires X
5.43 Check bolted connections for tight X
fit
5.44 Temporary taking out of service X
* Oil change intervals depend on quality of oil and fuel (sulphur content)
** Also in case of repair in the hydraulic system.
*** Also in case of repair in the hydraulic system.
Every 10 operating hours
Every 10 oper ating hours
5.6 Check the engine oil level 5.7 Check, clean the water sep-
arator
! Danger
Danger of injury! ! Danger
Support the engine hood for all maintenance Danger of injury!
and repair work.
Support the engine hood for all maintenance
and repair work.
i Note
The machine must be parked horizontally with the i Note
engine shut down.
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.
Environment
Catch running out fuel and dispose of environ-
mentally.
Fig. 78
l Pull the dipstick (Fig. 78) out, wipe it off with a

lint-free, clean cloth and reinsert it until it bot-
toms.
l Pull the dipstick back out again.
l If the oil level is below the "MAX" mark fill in oil.
l If the oil level is above the “MAX” mark, deter-
mine the cause and drain off oil.
Caution
!
Before longer work periods you should always

top the oil up to the "MAX"-mark. Fig. 79
For quality and quantity of oil refer to the table l Slacken the drain plug (Fig. 79) for a few turns
of fuels and lubricants and catch running out fuel / water.
l Tighten the drain plug again and check for
leaks, if necessary replace the seal ring.
5.8 Check the coolant level 5.9 Check the hydraulic oil level
! Danger ! Caution
Danger of scalding! In hydraulic systems filled with Panolin HLP
Synth. 46 always use the same oil to top up.
Do not remove the cap from the compensation
With other ester based oils consult the lubrica-
tank when the engine is still hot.
tion oil service of the respective oil manufac-
turer.
Fig. 80
l Check the coolant level (Fig. 80). Fig. 81
l Check the hydraulic oil level in the inspection

! Caution glass (Fig. 81).
If, during the daily inspection the coolant level Normal level
is found to have dropped, check all lines, hos-
es and engine for leaks. approx. 3 cm below the top edge of the inspection
glass.
Do not use radiator sealant to seal leaks.
Minimum level
Do not fill cold coolants into a hot engine.
Middle of inspection glass.
l To top up unscrew the filler cap and fill in cool-
ant up to the MAX-mark.
! Caution
For quality of coolant refer to the chapter 5.2,
If, during the daily inspection of the oil level
fuels and lubricants.
the hydraulic oil level is found to have
dropped, check all lines, hoses and compo-
nents for leaks.
l If necessary fill in hydraulic oil through the filler
neck.
For quality and quantity of oil refer to the table

of fuels and lubricants.
5.10 Draining the air pressure 5.11 Checking/filling up the wa-

vessel ter provision in the sprinkler
system
i Note
This work can be performed at the end of the work-
ing day when the pressure air vessel is completely
full.
l Shut the engine down and operate the parking
brake.
Fig. 83
l Unscrew the filler cap (Fig. 83) from the water

tank and fill in clean water through the screen
filter.
l Close the tank again.
Fig. 82
!Caution
l Pull the actuator chain (Fig. 82) for the drain In the event of frost observe the notes on
valve for a short moment. "maintenance in case of frost".
Make sure that the ventilation bore in the tank
i Note
cover is free.
During the draining process listen to the sound of
the escaping air.
If the sound changes while draining:
Check whether water or dirt runs out from the
breather valve.
In this case the air drier must be replaced.
5.12 Checking/adjusting the 5.13 Check the fuel level

scrapers
! Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke, do not refuel in closed
rooms, do not inhale any fuel fumes.
Fig. 84
l Check the condition of scrapers (Fig. 84) or

scraper brushes*, if necessary adjust clear-
ance or replace.
Fig. 85
i Note
Clearance tires - scrapers: approx. 10 mm l Check the fuel level on the fuel level gauge "n"
(Fig. 85) with the ignition switched on.
i Note
Do not drive the fuel tank dry, as otherwise the fuel
system needs to be bled.
l Clean the area around the filler opening.
Fig. 86
l Open the fuel tank cover (Fig. 86).
Caution
!
5.14 Multi-disc brake, function
Contaminated fuel can cause malfunction or
even damage of the engine. test
If necessary, fill in fuel through a funnel with
screen.
! Danger
l If necessary top up with fuel (diesel or winter Danger of injury!
diesel).
Make sure that there are no people inside the
For quality of fuel refer to the table of fuels and danger zone of the machine.
lubricants.
The travel range of the machine must be free of
obstructions.
l Start the engine
Fig. 87
l Turn the rotary switch for the parking brake

(Fig. 87) clockwise and hold it.
Fig. 88
l Move the travel lever forward and kick the

throttle pedal fully down.
l If the machine starts to drive, replace the
brake discs.
! Danger
Take the machine out of service, until the
brake discs have been replaced
Cleaning with cold cleansing agent

Every 250 operating h ours
5.15 Clean the cooling fins on

engine and hydraulic oil ! Caution
cooler Protect electrical equipment such as genera-
tor, regulator and starter against the direct wa-
ter jet.
Danger
!
l Spray the engine with a suitable cleansing
Danger of injury! agent, e.g. cold cleanser, let it soak in for a
Perform cleaning work only after the engine while and spray it off with a strong water jet.
has cooled down and with the engine stopped. l Run the engine warm for a while to avoid cor-
Wear safety goggles. rosion.
Caution
!
Do not damage any cooling fins on the cooler

core when cleaning.
i Note
Dirt on fan blades and oil cooler reduce the cooling
effect. Dirt deposits in these areas are substantial-
ly supported by oil and fuel on these surfaces. For
this reason you should always seal any oil or fuel
leaks in the vicinity of the cooling fan or the oil
cooler and clean the cooling surfaces after.
Cleaning with compressed air
Fig. 89
l Remove the cover plate (Fig. 89).
i Note
Start to blow out from the exhaust side.
l Blow the radiator out with compressed air.
5.16 Check the oil level in the

drive gear/wheel hub
l Park the machine on level ground.
Fig. 90
l Move the machine until the oil level control

plug (Fig. 90) is in horizontal position.
l Clean and unscrew oil level control plug.
The oil level must reach the bottom edge of the
bore.
l Top up oil, if necessary.
For quality of oil refer to the table of fuels and

lubricants.
l Screw the level control plug back in tightly.
l Repeat this inspection on the other side.
Every 500 operating h ours
5.17 Changing engine oil and oil

filter cartridges
! Caution
The oil change at 500 operating hours refers to
the use of oils of oil quality class API CG-4/CH-
4 or ACAE E3-96/E5-02 respectively.
Refer also to the chapter 5.2, fuels and lubri-
cants.
Drain the engine oil only when the engine is
warm. Fig. 92
l Thoroughly clean the outside of both filter car-

tridges (Fig. 92).
Danger
!
Danger of scalding! l Unscrew both filter cartridges using an appro-

priate filter wrench.
When draining off hot oil.
By hot oil when unscrewing the engine oil fil-
ter.
i Note
The filter cartridges are fitted with a valve that pre-
vents engine oil from running out during removal
Environment and installation.
Catch running out oil and dispose of environ- l Clean the sealing face on the filter carrier from
mentally together with the engine oil filter car- any dirt.
tridge.
l Slightly oil the rubber seal on the new filter car-
tridges.
Fig. 91
l Unscrew the drain plug (Fig. 91) and catch Fig. 93

running out oil.
l Turn the new filter cartridges (Fig. 93) on by
l Turn the drain plug tightly back in. hand, until the seal contacts.
l Tighten the filter cartridges for another half
turn.
5.18 Change the fuel filter car-

tridge
! Danger
Fire hazard!
open fire, do not smoke and do not spill any fu-
el.
Catch running out fuel, do not let it seep into
the ground.
Fig. 94
Do not inhale any fuel fumes.
l Fill in new engine oil (Fig. 94).

l Tighten the oil filler cap properly.
! Caution
Before starting crank the engine with the start-
er motor until the oil pressure warning light
goes out.
l After a short test run check the oil level on the
dipstick, if necessary top up to the top dipstick
mark.
Fig. 95
l Check filter cartridge and drain plug for leaks
after a short test run. l Loosen and unscrew the fuel filter cartridge
l Shut the engine down and wait for about 15 (Fig. 95) using an appropriate filter wrench.
minutes, so that all oil can flow back into the oil l Clean the sealing face on the filter carrier from
sump. any dirt.
l Check the oil level again , if necessary fill up to
the Max.-mark.
Fig. 96
l Slightly oil the rubber seal (Fig. 96) on the new

filter cartridge.
l Fill the filter cartridge with clean diesel fuel.

5.19 Drain the sludge from the
l Turn the new filter cartridge on by hand, until
the seal contacts. fuel tank
l Tighten the filter element for another half turn.
l Check the filter cartridge for leaks after a short ! Danger
test run.
Fire hazard!
open fire, do not smoke.
Do not spill any fuel.
Environment
the ground.
Fig. 97
l Unscrew the cap (Fig. 97) and drain off ap-

prox. 5 litres of fuel.
l Turn the cap tightly back in.
!Caution
5.20 Battery maintenance
Exhausted batteries (batteries with formation
of sulphate on the plates are not covered un-
der warranty!
! Danger
Danger of cauterisation ! Danger of explosion! l Open the engine hood and remove the cover-
ing
When working on the battery do not use open
fire, do not smoke!
The battery contains acid. Do not let acid come
in contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
Environment
Dispose of the old battery environmentally.
i Note
Maintenance free batteries also need care. Main-
tenance free only means that the fluid level does Fig. 98
not need to be checked. Each battery suffers un- l Remove the battery (Fig. 98) and clean the
der self-discharge, which may, in not checked oc- battery compartment.
casionally, even cause damage to the battery as a
result of exhaustive discharge. l Clean the outside of the battery.
l Clean battery poles and pole clamps and
The following therefore applies for the service grease them with pole grease (Vaseline).
life:
l Check the fastening of the battery.
l Switch off all consumers (e.g. ignition, light, in-
side light, radio). l On serviceable batteries check the acid level,
if necessary top up to the filling mark with dis-
l Check open-circuit voltage of the battery at
tilled water.
regular intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V = Function "Magic Eye"
50% discharged. green = O.K.
l Recharge the battery immediately after an bright = Charge battery
open-circuit voltage of 12.25 V or less is black = defective, replace battery, do not re-
reached. Do not perform boost charging. charge
The open-circuit voltage of the battery occurs ap-
prox. 10 hours after the last charging process or
one hour after the last discharge.
l After each charging process allow the battery
to rest for one hour before taking it into service.
l For resting periods of more than one month
you should always disconnect the battery. Do
not forget to perform regular open-circuit volt-
age measurements.
Charging voltage recommendation

5.21 Change the fuel pre-filter
cartridge
! Danger
Fire hazard!
open fire, do not smoke and do not spill any fu-
el.
the ground.
Fig. 99
Fig. 100
l Unscrew the fuel filter cartridge (Fig. 100) us-

ing an appropriate filter wrench.
l Clean the sealing face on the filter carrier from
any dirt.
Fig. 101
l Unscrew the water separator from the filter

cartridge (Fig. 101).
Fig. 102 Fig. 103
l Apply a thin coat of oil to the rubber seal of the l Slacken the bleeding screw (Fig. 103) on the
water separator 1 (Fig. 102). fuel pre-filter for 2 to 3 turns.
l Screw the water separator on by hand (2), until l Operate the hand pump manually, until fuel
the seal contacts. flows out of the slackened bleeding screw (Fig.
103) without air bubbles.
l Tighten the water separator for another half
turn (3). l Then tighten the bleeding screw while pump-
ing.
l Fill the filter cartridge with clean diesel fuel (4).
l Apply some oil to the rubber seal of the filter el-
ement (5) and screw it on by hand, until the
seal contacts.
l Tighten the filter element for another half turn
(6).
l Check the filter cartridge for leaks after a short
test run.
i Note
Air in the fuel system causes irregular running of
the engine, a drop in engine power, stalls the en-
gine and makes starting impossible.
Therefore bleed the fuel system after changing the
fuel prefilter.
Tighten the V-belt.

5.22 Checking, replacing the re-
frigerant compressor V-
belt*
Danger
!
Danger of injury!
Work on the V-belt must only be performed
with the engine shut down.
Wear safety goggles.
Check the V-belt

Fig. 105
l Slightly slacken fastening screws 1, 2 and

3 (Fig. 105).
l Press the compressor in direction of arrow, un-
til the correct V-belt tension is reached.
l Retighten all fastening screws.
Changing the V-belt

l Slightly slacken the fastening screws 1, 2 and
3.
l Press the compressor against the direction of
arrow completely against the engine.
Fig. 104
l Take the old V-belt off.
l Inspect the entire circumference of the V-belt
l Fit the new V-belt to the V-belt pulleys.
(Fig. 104) visually for damage and cracks. Re-
place damaged or cracked V-belts. l Tension the V-belt as previously described.
l Check with thumb pressure whether the V-belt
can be depressed more than 10 to 15 mm (0.4 ! Caution
– 0.6 inches) between the V-belt pulleys, Check the V-belt tension after a running time of
retighten if necessary. 30 minutes.
5.23 Service the air conditioning*
Cleaning the condenser
! Caution
A soiled condenser results in a considerable
reduction of air conditioning power.
Under extremely dusty conditions it may be
necessary to clean the condenser several
times per day.
Fig. 107
If, during operation of the air conditioning sys-
tem, the warning buzzer sounds switch the air l Switch the air conditioning (Fig. 107) on.
conditioning off and clean the condenser.
In case of formation of foam have the air con-
ditioning system inspected by the service de-
partment.
Danger
!
Danger of accident!
Do not clean with a hot water jet. Heat will
cause extreme overpressure, which could
cause damage or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.
Fig. 108
l Choose a cooling temperature with the rotary

switch for cabin heater (Fig. 108) in the blue
section.
l Open the air outlet nozzles.
l Check, whether the outflowing air is noticeably
cooler.
i Note
The adjusted temperature must be below the actu-
al temperature inside the cabin, so that the com-
pressor will be switched on.
Fig. 106 l Open the hood.
l Clean the condenser fins with compressed air
or cold water (Fig. 106).
Checking the refrigerant level

l Start the engine.
Checking the moisture level of the dry-

ing agent
Fig. 109
l Check whether the white float (Fig. 109) inside

the inspection glass of the drier/collector unit
floats right at the top. Fig. 111
l Check the moisture indication pearl (Fig. 111)

inside the inspection glass of the drier/collec-
i Note
tor unit.
The refrigerant level is correct.
orange = drying agent o.k.
colorless = moisture level of drying agent too
high.
l Inform the service department. Replace drier/
collector unit, check air conditioning system.
!Caution
Have the drier/collector unit replaced by the
service department every year before the oper-
ating season.
Checking the condition of the drier/col-

Fig. 110 lector unit
l If the white float (Fig. 110) inside the inspec-
tion glass of the drier/collector unit floats at the !Caution
bottom, inform the service department. According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeated-
ly inspected by a specialist. In this sense
i Note
repeated inspections are external examina-
The refrigerant level is not correct.
tions, normally on pressure reservoirs in oper-
l Refrigerant must be filled up, if necessary ation. In connection with this inspection the
check the air conditioning system for leaks. drier/collector unit must be visually examined
twice every year. During these inspections
special attention must be paid to corrosion
and mechanical damage. If the reservoir is not
in proper condition it must be replaced for
safety reasons, as a precaution to protect op-
erators and third parties against any danger
arising from the handling and operation of

pressure reservoirs. 5.24 Checking hydraulic, pneu-
matic hoses and electric ca-
! Danger bles
Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be re-
placed, to avoid bursting and further damage.
Fig. 113
l Check the state of all hydraulic, pneumatic

hoses and electric cables, check fastening and
look for chafing points (Fig. 113).
Fig. 112
l Replace damaged hoses and cables, fasten
l Check the drier/collector unit (Fig. 112) for me-
these properly and avoid chafing.
chanical damage or rust.
Every 1000 operating hour s
5.25 Check, adjust the valve

clearance
! Caution
Before checking the valve clearance let the en-
gine cool down for at least 30 minutes. The en-
gine oil temperature must be less than 80 °C.
After a short test run check the engine for
leaks.
Valve adjustment schematic Fig. 115
Crankshaft position 1 (Fig. 115) (4 cylinder en-

gine)
l Crank the engine with the starter or a spanner
by the V-belt pulley until both valves on cylin-
der 1 are “overlapping”.
Overlapping means: Exhaust valve not yet closed,
intake valve starts to open.
l Perform the adjustment of the valve by follow-
ing the adjustment diagram "crankshaft posi-
tion 1", black mark.
l For control purposes mark the respective rock-
er arm with while chalk once the correspond-
Fig. 114 ing valve is adjusted.
Valve 1 (Fig. 114) white = not adjustable
Valve (2) black = adjustable
Fig. 116
Crankshaft position 2 (Fig. 116) (4 cylinder en-

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

l Loosen the crankcase ventilation valve and
swing it to the side.
Fig. 119
l Slightly slacken the counter nut. Adjust set-

Fig. 117 screw 7 (Fig. 119) with a screwdriver, until the
l Remove the valve cover (Fig. 117). feeler gauge (6) can be inserted and pulled out
with little resistance after retightening the
l Crankshaft position as per "valve adjustment counter nut.
schematic".
l Perform tests and adjustments on all other ad-
justable valves.
l Check the gasket of the valve cover, replace it
if necessary.
l Reassemble the cylinder head cover.
l Swivel the ventilation valve back to correct po-
sition and fasten it.
l Fasten the air filter again and ensure correct fit
of combustion air hoses and clamps.
Fig. 118
l Check valve clearance 2 (Fig. 118) between

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

5.26 Checking / replacing the
ribbed V-belt
! Danger
Danger of injury!
Work on the V-belt must only be performed
with the engine shut down.
Checking the wear limit of the ribbed V-

belt
Fig. 121
l Unscrew the fastening screws (Fig. 121) and

slide the fan forward.
Fig. 120
l Check the distance between the tongue of the

moveable tensioner arm and the fixed tension-
er housing (Fig. 120).
l If measurement "a" is smaller than 3 mm, re- Fig. 122
place the ribbed V-belt. l Release the idler pulley (Fig. 122) in direction
of arrow until the ribbed V-belt is free.
l Pull the ribbed V-belt first to the smallest pul-
ley.
l Install the new ribbed V-belt.
l Release the idler pulley against the direction
of arrow until the V-belt is tensioned.
l Measure the V-belt tension, tighten if neces-
sary.
i Note
Retighten the new fan V-belt after a running time
of 20 minutes.
5.27 Check the engine mounts 5.28 Tighten the wheel nuts
Fig. 123 Fig. 124
l Tighten fastenings of intake and exhaust man- l Tighten the wheel nuts (Fig. 124) cross-wise
ifolds (Fig. 123) on the cylinder heads.
l Check sockets and clamps between air filter,
exhaust turbocharger and charge air line as
well as the lubrication air line for tight fit and
leaks.
l Retighten the fastening screws for oil sump
and engine mounts.
5.29 Checking the Roll Over Pro- 5.30 Changing the air drier for
tective Structure (ROPS/ the brake system
FOPS)
Environment
i Note Dispose of the filter environmentally.
On machines with cabin the ROPS/FOPS (roll l Run the engine, until the air pressure vessel
over protection structure) is an integral part of the for the brake is fully filled (shut-off pressure).
cabin.
l Shut down the engine.
Please observe also the corresponding section in
the safety regulations in this manual.
Fig. 126
l Unscrew the filter cartridge (Fig. 126) using an

Fig. 125
appropriate filter wrench.
l Inspect the cabin, especially the ROPS (Fig.
l Clean the sealing face on the filter carrier from
125), for cracks, corrosion, damage and miss-
any dirt.
ing fastening parts.
l Slightly oil the rubber seal on the new filter car-
tridge.
i Note
Unusual movements and noises (vibrations) dur- l Turn the new filter cartridge on by hand, until
ing operation are signs for damage or loosened the seal contacts.
fastening elements. l Tighten the filter element for another half turn.
l Check the fastening screws for the cabin
(ROPS) to the operator’s stand for tight fit.
l Check the rubber buffers of the operator’s plat-
form suspension for condition and tight fit.
l Check the condition and fastening of the seat
belts.
Drain and catch all oil.

l
5.31 Changing the oil in travel
l Screw the drain plug back in and tighten it.
gears/wheel hubs
! Caution
The machine must be in horizontal position.
Drain oil only at operating temperature.
Change the oil on both sides.
Environment
Catch old oil and dispose of environmentally.
Fig. 129
l Fill in oil through the filler opening (Fig. 129),
Fig. 127
l Move the drive wheel, until the oil level control

plug (Fig. 127) is in horizontal position.
l Clean and unscrew oil level control plug.
Fig. 130
l until the oil level reaches the bottom edge of

the level inspection bore (Fig. 130).

l Screw the level inspection and filler plug back
in and tighten correctly.
Fig. 128
l Clean and unscrew filler and drain plug (Fig.

128).
5.32 Changing hydraulic oil and

breather filter
i Note
See also chapter 5.1 "Notes on the hydraulic sys-
tem".
! Caution
Apart from the normal oil change intervals, the
hydraulic oil must also be changed after major
repairs in the hydraulic system. Fig. 131
Perform the oil change when the hydraulic oil l Unscrew the plug (Fig. 131) and drain off all
is warm. hydraulic oil.
Clean the area round hydraulic oil tank, filler l Check seal ring (1), replace if necessary and
opening and breather filter. turn the plug tightly back in.
Do not use any detergents to clean the system.
Do not start the engine after draining the hy-
draulic oil.
Replace the hydraulic oil filter element with
every hydraulic oil change.
! Danger
Danger of scalding!
Danger of scalding by hot oil.
Environment
Catch running out oil and dispose of environ- Fig. 132
mentally. l Remove the filler cap (Fig. 132).
l Fill in new hydraulic oil through the screen.
i Note
Generally replace the hydraulic oil filter element
after the test run.
i Note
We recommend to use the filling and filtering unit
(BOMAG part-no. 079 930 35) with fine filter to fill
the hydraulic system. This ensures finest filtration
of the hydraulic oil, prolongs the lifetime of the hy-
draulic oil filter and protects the hydraulic system.
l Check the oil level in the inspection glass.
Nominal value:
approx. 3 cm below the upper edge of the inspec-
tion glass

of fuels and lubricants. 5.33 Changing the hydraulic oil
filter
i Note
The breather filter for the hydraulic oil tank is inte-
grated in the filler cap, you must therefore replace ! Danger
the complete filler cap. Danger of scalding!
l Close the tank with a new filler cap. There is a danger of scalding by hot oil when
unscrewing the filter.
! Caution
If the filter has to be changed together with the
hydraulic oil, the filter should in any case be
changed after the oil change and the test run.
Do not use the oil in the filter bowl.
Environment
Catch running out oil, dispose of oil and filter
element environmentally.
i Note
The filter element must be changed with every hy-
draulic oil change and after major repairs in the hy-
draulic system.
Fig. 133
l Unscrew the cap nut 4 (Fig. 133) and take the

filter bowl (5) with the filter element (3) off.
l Examine the sealing face on the filter element
thoroughly for any visible dirt.
! Caution
Visible impurities may be an early indicator for
a failure of system components and predict the
possible malfunction of important parts. In

such a case you should perform trouble shoot- 5.34 Change the coolant
ing and replace or repair the defective compo-
nents. Nonobservance may lead to total
damage of the hydraulic system. ! Danger
Do not clean or reuse the filter element. Danger of scalding!
l Take the old filter element (3) out and clean Change the coolant only when the engine is
the filter bowl and the thread. cold.
l Reinstall the filter bowl with the new filter ele-
ment, check the condition of the O-rings (1) Environment
and (2), replace if necessary. Catch running out coolant and dispose of envi-
l After a test run check the filter for leaks. ronmentally.
Fig. 134
l Unscrew the plug (Fig. 134), let the coolant run

out and catch it .
l Screw the plug back in once all coolant has run
out.
Fig. 135
l Unscrew the cap and fill in coolant up to the

MAX-mark (Fig. 135).
For quality of coolant refer to the chapter 5.2,

fuels and lubricants. 5.35 Checking the supply lines
l Start the diesel engine and run it warm to op- for the compressor
erating temperature.
l Let the engine cool down and check the cool- l Shut the engine down and operate the parking
ant level again, top up if necessary. brake.
Fig. 136
l Operate the actuating chain (Fig. 136) of the

drain valve, until the pressure air vessel is
empty.
Fig. 137
l Disassemble the supply lines for the compres-

sor (Fig. 137).
Fig. 138
l Check for deposits inside the pipes and hoses

(Fig. 138).
! Caution
If the value x+x=2 mm is exceeded clean or re-
place the pipe.
Have the compressor repaired.
l Reconnect the pipes.
l Start the engine and fill the pressure air ves-
sel.
l Check the pressure air system for leaks.
5.36 Checking the injection

valves
i Note
This work must only be performed by authorized
service personnel.
The injection valves must be replaced every
12000 operating hours.
As required
As requir ed
5.37 Service the combustion air i Note

Once the air filter service indicator lights up, work
filter may be continued until the end of the day.
l Open the engine hood completely and secure
it.
! Caution
Perform cleaning, maintenance and repair
work only with the engine shut down. Do not
start the engine after removing the filter ele-
ment.
Do not use gasoline or hot fluids to clean the
filter element.
After cleaning the filter element must be in-
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. Fig. 140
Each cleaning interval must be marked with a l Release the locking hook (Fig. 140) and take
cross on the cover of the filter element. the filter hood off.
Cleaning does not make sense if the air filter l Clean filter hood and dust discharge valve.
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. 141
l Carefully loosen the main filter element (Fig.

141).
The main filter element is located directly on the air
intake tube, thereby providing a seal on the inside
Fig. 139
of the filter cover. Carefully remove the main filter
Maintenance of the dry air filter is due when con- element, in order to reduce the released amount of
trol light “c” (Fig. 139) in the instrument cluster dust. To release the seal pull the main filter ele-
lights permanently when the engine is running, but ment carefully up, down and sideways or turn it
at the latest after one year. (Fig. 141) .
As required
Caution
! i Note
Avoid contact between main filter element and We generally recommend to change the filter. A
housing. new filter element is far less expensive than a pos-
sible engine damage.
l Examine the main filter element thoroughly for
damage.
Before installing the new main filter element check
it for possible damage from transport, cleaning or
incorrect handling. Especially on the inside of the
open end (sealing area). Do not install damaged
filter elements.
l If necessary use safety elements.
Fig. 142
l Pull the main filter element (Fig. 142) carefully

out of the housing.
Fig. 144
l Insert the main filter element (Fig. 144).

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
Fig. 143
moveable centre.
l Clean the sealing face on the outlet tube (Fig.
143). l Reinstall the filter hood with the dust discharge
valve.
Dust on the outer diameter of the outlet tube can
impair effective sealing.
! Caution
l Check the old main filter element.
The dust discharge valve must point vertically
The old main filter element can be of help to dis- downwards.
cover foreign particles on the sealing face, which
could lead to leaks. A line of dust on the clean air
Dry cleaning of the main filter element
side of the filter may be a sign for such a leak.
Eliminate this problem before installing a new
main filter element. Danger
!
l If the main filter element is damaged, the safe- Eye injury!

ty element must be replaced as well. Wear protective clothing (goggles, gloves).
l Clean or replace the main filter element.
As required
if the warning light comes on again after serv-

icing the main filter cartridge.
l Remove the housing cover and pull the main
filter element off.
Fig. 145
i Note
For cleaning purposes fit a tube to the compressed
air gun (Fig. 145), the end of which should be bent
Fig. 146
for approx. 90°.
l Pull the safety element (Fig. 146) out by turn-
The length should reach down to the bottom of the
ing it lightly.
element.
l Push in a new safety filter element.
l Blow the main filter element out with com-
pressed air (max. 5 bar) from inside to outside l Reassemble main filter element and cover.
by moving the tube up and down inside the el-
ement, until it if free of dust.
l Examine the main filter element with a torch
for cracks and holes in the paper bellows.
Caution
!
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
Caution
!
The safety filter element must not be cleaned

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

kling system
Fig. 149
l Fill the water tank with clean water (Fig. 149).
Fig. 147
l Unscrew the water tank caps (Fig. 147), take

out and clean the filling screens.
i Note
Replace damaged filling screens.
Fig. 150
l Unscrew the plugs (Fig. 150) from the sprin-

kler tubes.
l Activate the sprinkler system for a short while
so that all lines are flushed out.
l Seal the threads with Teflon tape and screw
the plugs back in.
l Check spray nozzles and filter, clean if neces-
Fig. 148 sary.
l Disconnect the water hose (Fig. 148) on the
water filter.
l Unscrew and clean the water filter.
l Let all water with dirt run out.
l Fill the water tank with clean water.
i Note
Change a damaged water filter.
As required
Ballast tank
5.39 Maintenance in case of frost
! Caution
Water sprinkler system If there is a risk of frost the ballast tank must be
emptied in order to avoid severe deformation
of the vehicle body.
! Caution
If there is a risk of frost the water sprinkler sys-
tem must be emptied or filled with an anti-
freeze mixture.
In this case frost protection measures are of
greatest importance in order to avoid freezing
of sensitive components like pump, solenoid
valve and water filter.
Fig. 152
l Unscrew the cover (Fig. 152) and let all water

run out.
Fig. 151
l Remove the suction hose (Fig. 151) from in

front of the water filter and let the water run
out.
l Reconnect the suction hose.
l Fill the water tank with approx. 25 l of an anti-
freeze mixture (water and anti-freeze agent,
e.g. glysantene).
l Switch the sprinkler system on, until anti-
freeze mixture comes running out of the sprin-
kler tubes.
Environment
After the frost period drain off the anti-freeze
mixture and dispose of environmentally.
As required
5.40 Filling the windscreen 5.41 Changing the fresh air filter
washer system in the cabin
! Caution
In the event of frost the windscreen washer
system must be filled with an anti-freeze mix-
ture.
Fig. 154
l Unscrew the fastening screws for the filter

brackets (Fig. 154) and take the filter out.
l Insert a new filter and reassemble the filter
brackets.
Fig. 153
l Open the cap (Fig. 153) and fill in water with a

windscreen washing agent.
l In case of frost fill in the appropriate quantity of
anti-freeze agent for windscreen washer sys-
tems.
Caution
!
Observe the instructions of the manufacturer.
As required
l Unscrew the wheel nuts and take the wheel

5.42 Change the tires off.
l Attach the new wheel and align the wheel rim
bores to the tapped holes in the wheel hub.
! Danger
l Turn in the wheel studs and tighten these
Danger of squashing!
crosswise with 500 Nm (369 ft. lb.).
Observe all safety regulations for the lifting of l Reconnect the air hose.
loads.
l Secure the machine with wheel chocks
! Danger
against rolling.
Retighten the wheel studs again after 50 oper-
ating hours!
Fig. 155
Lifting points (Fig. 155).
l Lift the rear or the front of the machine, so that
the wheels can turn freely.
l Support the machine safely.
Fig. 156
l Disconnect the air hose (Fig. 156) from the

hub.
l Unscrew the wheel nuts and take the wheel
off.
As required
5.43 Check bolted connections 5.44 Temporary taking out of

for tight fit service
If the machine is to be shut down for a longer peri-
od of time (e.g. over winter), we recommend the
following measures:
l Clean the machine thoroughly.
l If possible park the machine in a well ventilat-
ed hall or weather protected under a roof.
l Inflate the tires to max. pressure.
l Clean the engine, including the cooling sys-
tem. For this purpose use cold cleansing agent
or, even better, a steam cleaner.
Fig. 157
l Run the engine warm and shut it down.
* Strength classes for screws with untreated, non-
lubricated surface. Screw quality designations are l Drain the still warm engine oil and fill in anti-
stamped on the screw heads. corrosion engine oil.
8.8 = 8G l Drain off all coolant and fill in fresh system pro-
tection agent.
10.9 = 10K
l Drain the fuel from the fuel tank, mix it well with
12.9 = 12K
10% anti-corrosion oil and fill it back in.
The values result in a 90% utilization of the screw
yield point at a coefficient of friction μ total = 0,14. l Then run the engine for 10 minutes, so that
When using lubricant MOS2 the specified tighten- lines, filter, pump and nozzles are filled with
ing torques do not apply. the conserving mixture and the new engine oil
is distributed to all parts.
l Crank the engine several times by hand (with-
i Note
out ignition) in order to spray all combustion
Self-locking nuts must always be replaced once chambers.
they have been unscrewed.
l Take the V-belt off and spray the grooves of
Deviating tightening torques are listed in the spare the V-belt pulley with anti-corrosion oil. Re-
parts catalogue. move the anti-corrosion oil before taking the
Check the following points at regular intervals: machine back into service.
l Check state and tight fit of engine mounts. l Close air intake on air filter and exhaust open-
ing tightly.
l Tight fit of connecting bolts between engine
and pumps l Remove the battery and store it in a cool, dry
and frost protected room.
l The fastening of the front axle on the frame.
l Recharge the battery every 3 months.
l The fastening of the steering levers on the
frame.
l Tight fit of wheel nuts 500 Nm (369 ft. lb). i Note
Depending on weather conditions these conserva-
tion measures will protect the machine for approx.
6 to 12 months.
Before taking the machine back into service you
must drain off the conservation oil and replace it
As required
with engine oil, see table of fuels and lubricants,

according to API-(MIL-) classification.
A machine with conserved engine must be
clearly marked by attaching a clear warning
tag.
Anti-corrosion oils are all oils complying with

the specification MIL-L-21260 B or TL 9150-
037/2 or Nato Code C640/642.
l Jack the front and rear of the machine up in or-
der to protect the rubber tires.
l Grease all hinges on doors and flaps.
l Lubricate the machine.
100 BOMAG BW 24 / 27 RH
6 Trouble shooting
BW 24 / 27 RH BOMAG 101
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
Danger of injury!
Keep away from rotating parts of the engine.
102 BOMAG BW 24 / 27 RH
Trouble shooting
6.2 Engine
Faults Possible cause Remedy
The engine Starter defective or pinion not engaging Have examined by a specialist
does not start
Fuel tank empty Fill and bleed the tank
Temperature below starting limit Use winter fuel and engine oil acc. to the
ambient temperature.
Fuel filter clogged, in winter due to paraf- Change the filter. use winter fuel
fin separation.
Fuel lines leaking Check all line connections for leakages

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

tive
The engine Battery power too low, battery clamps Have the battery checked, clean the ter-
starts poorly and loose or oxidized, causing the starter to minal clamps, tighten them and cover
works irregularly turn too slowly them with acid free grease
with poor power
Especially during winter: the use of too Use engine oil suitable for the ambient
viscous engine oil temperature
Fuel supply restricted, in winter fuel sys- Change the fuel filter. Check the line con-
tem clogged due to paraffin separation nections for leaks and tighten the fittings.
Use winter fuel in the cold season.
Incorrect valve clearance Adjust the valve clearance
Injection valve defective Have examined by a specialist
Injection lines leaking Check the lines for leakages
Turbo charger defective Have examined by a specialist
Dry air filter dirty clean, replace if necessary
Excessive play in the throttle cable Adjust the throttle cable, change it if nec-
essary
BW 24 / 27 RH BOMAG 103
Trouble shooting
Faults Possible cause Remedy
Excessive ex- Engine oil level too high Drain the oil to the upper dipstick mark
haust smoke
Dry air filter dirty clean, replace if necessary
Exhaust gas turbo-charger defective Have examined by a specialist
Poor compression due to burned or bro- Have compression rings and pistons ex-
ken compression rings or incorrect valve amined by a specialist, adjust the valve
clearance clearance
Engine over- Cooling fins on radiator extremely soiled Clean the cooling fins
heats, shut (the warning light "engine oil temperature"
down immedi- lights)
ately!
Engine oil level too low Top up engine oil to the upper dipstick
mark
Filling capacity of the injection pump not Have adjusted by a specialist

correctly adjusted
Cooling air flow restricted Clean the cooling air duct
V-belt loos or broken Tension or replace the V-belt
Poor engine Engine oil level too high Drain the engine oil down to the upper dip-
power stick mark
Dry air filter dirty clean, change if necessary
Exhaust gas turbo-charger defective Have examined by a specialist
Charge air hose leaking Check fastening and connections
Engine oil pres- Engine oil level too low (control light "en- Top up oil
sure too low gine oil pressure" lights, the warning
buzzer sounds)
Leakages in the lubrication system Shut the engine down immediately, check
fittings on oil lines, lubrication oil filter and
oil cooler for leaks, if necessary tighten
the fittings.
The charge con- Generator speed too low Check the V-belt tension, replace the V-
trol light lights belt if necessary
during opera-
tion, the warning The generator does not charge the bat- Have examined by a specialis
buzzer sounds tery, because generator or regulator is de-
fective
104 BOMAG BW 24 / 27 RH
Trouble shooting
BW 24 / 27 RH BOMAG 105
Trouble shooting
106 BOMAG BW 24 / 27 RH
7 Tire compaction values
BW 24 / 27 RH BOMAG 107
Tire compaction values
Tables
The following tables show the dependence on
area pressure and area for a given load and the
adjusted air pressure for tire size 11.00-20
18PR Compactor Smooth.
Weight of Wheel Tire pressure bar (psi)

machine kg load kg 3 (44) 4 (58) 5 (73) 6 (87) 7 (102) 8 (116)
(lb) (lb)
10400 1300 3,2 (45) 3,4 (48) 3,6 (52) 3,9 (55) 4,2 (60) 4,5 (64)
(22928) (2866)
12000 1500 3,4 (84) 3,6 (51) 3,8 (55) 4,1 (58 4,3 (62) 4,6 (65)
(26455) (3307)
16000 2000 3,8 (54) 4,0 (57) 4,3 (61) 4,6 (66) 4,7 (67) 5,0 (71)
(35274) (4409)
20000 2500 4,1 (59) 4,4 (62) 4,7 (66) 4,9 (70) 5,1 (72) 5,4 (77)
(44092) (5512)
24000 3000 4,4 (62) 4,7 (66) 5,0 (71) 5,4 (76) 5,6 (79) 5,9 (83)
(52911) (6614)
27000 3750 4,5 (64) 4,8 (69) 5,1 (73) 5,5 (79) 5,8 (82) 6,1 (86)
(59525) (3375)
Table of average area pressure kg/cm2 (lb/in2)
Weight of Wheel Tire pressure bar (psi)

machine kg load kg 3 (44) 4 (58) 5 (73) 6 (87) 7 (102) 8 (116)
(lb) (lb)
10400 1300 409 (63) 385 (60) 358 (55) 335 (52) 310 (48) 292 (45)
(22928) (2866)
12000 1500 442 (69) 416 (64) 390 (60) 365 (57 345 (53) 328 (51)
(26455) (3307)
16000 2000 530 (82) 495 (77) 464 (72) 434 (67) 425 (66) 398 (62)
(35274) (4409)
20000 2500 605 (94) 570 (88) 537 (83) 507 (79) 495 (77) 463 (72)
(44092) (5512)
24000 3000 688 (107) 642 (93) 600 (93) 560 (87) 540 (84) 512 (79)
(52911) (6614)
27000 3750 748 (116) 700 (109) 660 (102) 610 (95) 585 (91) 555 (86)
(59525) (3375)
Table of effective area cm2) (in2)
108 BOMAG BW 24 / 27 RH

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Operating instructions

Rubber tire roller

No warranty claims can be lodged in case of dam-

5.19 Drain the sludge from the fuel tank 72

The following noise and vibration data acc. to

- EC Machine Regulation edition (98/37/EC) and

- Noise Emission Regulation 2000/14/EC

determined at rated engine speed.

guaranteed sound capacity level of the machine:

Vibration of the entire body (driver’s seat)

Hand-arm vibration values

General Who is allowed to work with the ma-

Environment Checking the Roll Over Protective

Towing the machine Before mounting the machine check whether:

Store used filters and other oil contaminated ma- Test

After maintenance work

1 Travel lever 14 Warning light, brake temperature

3.1 General notes 3.2 Description of indicators

l Steer the machine with the steering wheel

to drive = return the travel lever first to

* Optional equipment ** Optional equipment

peratures below +5 °C, whereas after-heating is

F26, 10A = Solenoid valve for speed

c = toggle switch for rear windscreen wiper/

d = toggle switch for working headlights

e = toggle switch for rear windscreen heating

d = Fuse box in cabin

e = Rotary switch for cabin ventilator

Position 1, 2 and i = reading and dashboard light

After entering the service code the anti-theft pro-

4.1 General notes 4.2 Tests before taking into op-

After entering the service code (for maintenance

4.4 Starting the engine

l Check, whether the emergency stop switch

l Switch the main battery switch (Fig. 38) to po-

l Check whether the parking brake is activated,

Perform the starting process for maximum 20

l Check whether both travel levers (Fig. 42) are

l Turn the ignition key (Fig. 45) to position "II",

Starting at low temperatures below + 5

l Turn the ignition key (Fig. 46) to position "I"

Driving the machine

l Check whether the brake pressure warning

l For steep downhill driving choose lowest

l Brake pedal (Fig. 55), kick down as necessary

l To operate the parking brake turn the rotary

4.8 Shutting the engine down,

Do not shut the engine down all of the sudden

l Shift the travel lever (Fig. 59) to "Neutral".

l Turn the ignition key to position “0” or “P” (Fig.

4.9 In events of emergency

l Pull off the hand lever of the main battery

4.10 Operating the pressure 4.11 Operating the tire inflation**

* Optional equipment ** Optional equipment

Relieving the tire pressure

l Turn the rotary switch (Fig. 66) clockwise. Fig. 67

l To slide the seat pull up lever (Fig. 68) and

4.13 Operating the hood 4.14 Ballasting of machine*

l Unlock the lock (Fig. 69). Fig. 70