BW202AD-4 Operation

Operating Instruction
Maintenance Instruction
Original Operating Instructions
BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 /

BW 202 AD-4
S/N 961 920 91 1001> / S/N 961 920 87 2581> / S/N 961 920 86 1310> / S/N 961 920 34 1096>
Tandem vibratory roller
008 201 29 EN © 08/2020

WARNING: Breathing diesel engine exhaust exposes you to chemicals
known to the State of California to cause cancer and birth defects or other
reproductive harm.
Always start and operate the engine in a well-ventilated area.

If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
WARNING: Crude oil, gasoline, diesel fuel and other petroleum

products can expose you to chemicals including toluene and benzene,
which are known to the State of California to cause cancer and birth
defects or other reproductive harm.
These exposures can occur in and around oil fields, refineries, chemical
plants, transport and storage operations such as pipelines, marine
terminals, tank trucks and other facilities and equipment.
For more information go to www.P65Warnings.ca.gov/petroleum.
2
Table of contents
Table of contents
1 Introduction........................................................................................................................................... 7
1.1 Foreword........................................................................................................................................ 8
1.2 Machine type plate and engine type plate................................................................................ 10
2 Technical data...................................................................................................................................... 11
2.1 BW 161 AD-4................................................................................................................................ 12
2.1.1 Noise and vibration data............................................................................................................ 14
2.2 BW 202 AD-4................................................................................................................................ 15
2.3 BW 203 AD-4................................................................................................................................ 18
2.4 BW 203 SL-4................................................................................................................................ 21
3 Safety regulations............................................................................................................................... 25
3.1 Signage........................................................................................................................................ 37
4 Indicators and control elements........................................................................................................ 43
4.1 General notes.............................................................................................................................. 45
4.2 Description of indicators and control elements....................................................................... 46
5 Operation............................................................................................................................................. 63
5.1 General......................................................................................................................................... 64
5.2 Tests before taking into operation ........................................................................................... 65
5.3 Adjusting the driver’s seat......................................................................................................... 66
5.4 Starting the engine...................................................................................................................... 67
5.5 Starting with jump wires............................................................................................................. 69
5.6 Driving the machine ................................................................................................................... 71
5.7 Stopping the machine, operating the parking brake............................................................... 74
5.8 Shutting down the engine.......................................................................................................... 75
5.9 Switching the vibration on / off.................................................................................................. 77
5.9.1 Vibration in manual mode.......................................................................................................... 77
5.9.2 Vibration in automatic mode....................................................................................................... 79
5.10 Operating the crabwalk............................................................................................................ 81
5.11 Switching the pressure sprinkling system on and off........................................................... 82
5.12 Sprinkling system for edge cutter on / off.............................................................................. 83
5.13 Actuating the emergency stop switch ................................................................................... 84
5.14 Operating the heating / air conditioning system.................................................................... 85
5.15 Opening or closing the cabin window.................................................................................... 86
5.16 Towing........................................................................................................................................ 87
5.17 Loading/transport..................................................................................................................... 90
6 Maintenance........................................................................................................................................ 95
6.1 General notes on maintenance.................................................................................................. 96
6.2 Fuels and lubricants................................................................................................................... 98
6.2.1 Engine oil................................................................................................................................... 98
6.2.2 Fuel............................................................................................................................................ 99
6.2.3 Coolant..................................................................................................................................... 100
BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4 3

Table of contents
6.2.4 Hydraulic oil.............................................................................................................................. 103

6.2.5 Gear oil SAE 75W-90............................................................................................................... 103
6.2.6 Gear oil SAE 80W-140............................................................................................................. 103
6.2.7 Lubrication grease.................................................................................................................... 104
6.3 List of fuels and lubricants...................................................................................................... 105
6.4 Running-in instructions............................................................................................................ 106
6.4.1 General.................................................................................................................................... 106
6.4.2 After 50 operating hours........................................................................................................... 106
6.4.3 After 250 operating hours......................................................................................................... 106
6.4.4 After 500 operating hours......................................................................................................... 106
6.4.5 After 1000 operating hours....................................................................................................... 106
6.5 Maintenance Table.................................................................................................................... 107
6.6 Every 10 operating hours......................................................................................................... 109
6.6.1 Checking the engine oil level................................................................................................... 109
6.6.2 Checking the fuel level............................................................................................................. 109
6.6.3 Check the hydraulic oil level .................................................................................................... 111
6.6.4 Check the coolant level ........................................................................................................... 112
6.6.5 Check the water level .............................................................................................................. 112
6.7 Every 250 operating hours....................................................................................................... 114
6.7.1 Change the fuel filter cartridge ................................................................................................ 114
6.7.2 Replace the fuel pre-filter cartridge, bleed the fuel system...................................................... 115
6.7.3 Check, clean radiator, fuel cooler, hydraulic oil cooler and intercooler .................................... 116
6.7.4 Check the oil level in vibrator shaft tube................................................................................... 117
6.8 Every 500 operating hours....................................................................................................... 118
6.8.1 Changing engine oil and oil filter cartridge............................................................................... 118
6.8.2 Check the anti-freeze concentration and the condition of the coolant...................................... 119
6.8.3 Service the air conditioningOptional equipment ................................................................................ 120
6.8.4 Cleaning the circulation air filter for the heatingOptional equipment ................................................. 124
6.8.5 Battery service, checking the main battery switch................................................................... 124
6.9 Every 1000 operating hours..................................................................................................... 127
6.9.1 Change the oil in drum drive gear............................................................................................ 127
6.9.2 Checking, tensioning, lubricating the steering chain................................................................ 128
6.9.3 Check the engine mounts........................................................................................................ 129
6.9.4 Servicing the V-belt.................................................................................................................. 129
6.9.5 Replacing the hydraulic oil filter............................................................................................... 134
6.9.6 Change the oil in the exciter shaft tube.................................................................................... 135
6.9.7 Check the ROPS...................................................................................................................... 136
6.9.8 Check the travel control........................................................................................................... 136
6.10 Every 2000 operating hours................................................................................................... 137
6.10.1 Checking, adjusting the valve clearance................................................................................ 137
6.10.2 Changing hydraulic oil and breather filter .............................................................................. 138
6.10.3 Grease the articulated joint.................................................................................................... 141
6.10.4 Changing the coolant............................................................................................................. 141
6.11.1 Change the high current relay of the heating flange.............................................................. 144
4 BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4

Table of contents
6.12.1 Replace the injection valves................................................................................................... 145

6.12.2 Replace crankcase ventilation valve ..................................................................................... 145
6.13 As required.............................................................................................................................. 146
6.13.1 Air filter maintenance............................................................................................................. 146
6.13.2 Check, clean the water separator.......................................................................................... 148
6.13.3 Clean water tank and water filter............................................................................................ 150
6.13.4 Water sprinkler system, maintenance in the event of frost.................................................... 151
6.13.5 Fill the provision tank for the windscreen washer system...................................................... 152
6.13.6 Adjusting the scrapers............................................................................................................ 152
6.13.7 Change the fresh air filter in the cabin................................................................................... 152
6.13.8 Tightening torques................................................................................................................. 153
6.13.9 Engine conservation .............................................................................................................. 153
7 Troubleshooting................................................................................................................................ 155
7.1 General notes............................................................................................................................ 156
7.2 Starting the engine with jump leads........................................................................................ 157
7.3 Engine faults.............................................................................................................................. 158
7.4 Reading out fault codes of the electronic engine control (EMR 3)...................................... 160
8 Disposal............................................................................................................................................. 161
8.1 Final shut-down of machine..................................................................................................... 162

Table of contents

Introduction
1 Introduction

Introduction – Foreword
1.1 Foreword
BOMAG manufactures machines for earth, asphalt and refuse
compaction, stabilizers/recyclers as well as planers and
pavers.
BOMAG’s vast experience in connection with state-of-the-art
production and testing methods, such as lifetime tests of all
important components and highest quality demands guar-
antee maximum reliability of your machine.
These operating and maintenance instructions are part of your
machine.
They provide necessary information to operate your machine
safely and properly.
They also contain information on required operating, maintenance
and repair measures.
Carefully read the operating and maintenance instructions before
taking your machine into operation.
Please observe the safety regulations strictly and follow all instruc-
tions to ensure safe operation.
If you are not yet acquainted with the controls and indicating ele-
ments on this machine, you should thoroughly read the corre-
sponding chapter Ä Chapter 4 ‘Indicators and control elements’
on page 43.
The description of the individual operating steps including the
notes on safety to be followed can be found in chapter “Operation”
Ä Chapter 5 ‘Operation’ on page 63.
Before every start up, carry out all required visual inspections and
function tests.
Ensure the compliance with the specified operating, maintenance
and repair measures to maintain the functional safety of your
machine.
A description of all necessary maintenance work, maintenance
intervals as well as information on fuels and lubricants can be
found in the chapter “Maintenance” Ä Chapter 6 ‘Maintenance’
on page 95.
Do not service or repair your machine by yourself to avoid harming
persons or damaging material or environment.
The machine must only be serviced and repaired by qualified and
authorized personnel.
Contact our Customer Service to carry out the required mainte-
nance work or necessary repairs.
In case of operating errors, inadequate maintenance or the use of
unapproved fuels and lubricants all warranty claims will become
null and void.
For your own personal safety you should only use original parts
from BOMAG.
For your machine we offer service kits to make maintenance
easier.

Introduction – Foreword
In the course of technical development we reserve the right for

technical modifications without prior notification.
These operating and maintenance instructions are also available in
other languages.
Apart from that, you can also order the spare parts catalogue
against the serial number of your machine.
The above notes do not constitute an extension of the warranty
and liability conditions specified in the general sales and delivery
conditions of BOMAG GmbH.
We wish you successful work with your BOMAG machine.

Introduction – Machine type plate and engine type plate
1.2 Machine type plate and engine type plate

Please enter here:
Machine type (1):
Serial number (2):
Fig. 1: Machine type plate (example)
Please enter here:

Engine type (1):
Engine number (2):
Fig. 2: Engine type plate (example)

Technical data
2 Technical data

Technical data – BW 161 AD-4
2.1 BW 161 AD-4
Fig. 3
A B C D H H2 K L O S W
Dimensions in mm 3300 1840 715 1220 2320 3000 350 4610 80 17 1680
Dimensions in inch 129.9 72.4 28.1 48.0 91.3 118.1 13.8 181.5 3.2 0.7 66.1
Weights
Operating weight (CECE) 10050 kg 22156 lbs
Front axle load (CECE) 5050 kg 11133 lbs
Rear axle load (CECE) 5000 kg 11023 lbs
Static linear load front (CECE) 30.1 kg/cm 168.5 pli
Static linear load rear (CECE) 29.8 kg/cm 166.9 pli
Max. operating weight 11500 25353 lbs
Travel characteristics
Travel speed (1) 0 – 6 km/h 0 – 3.7 mph
Max. gradeability without/with vibration (soil 40/35 % 40/35 %
dependent)

Drive
Engine manufacturer Deutz Deutz
Type TCD 2012 L04 2V TCD 2012 L04 2V
Cooling system Water Water
Number of cylinders 4 4
Rated power ISO 14396 100 kW 100 kW
Power SAE J1995 134 hp 134 hp
Rated speed 2300 min-1 2300 rpm
Electrical equipment 12 V 12 V
Brakes
Service brake hydrostatic hydrostatic
Parking brake Spring type accumulator Spring type accumulator
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrostatic hydrostatic
Steering- / oscillation angle +/- 30/6 ° +/- 30/6 °
Inner track radius 4,170 mm 164.2 in
Exciter system
Vibrating drum front + rear front + rear
Drive system hydrostatic hydrostatic
Automatic vibration shut-off Standard Standard
Frequency (1/2) 40/50 Hz 2400/3000 vpm
Amplitude (1/2) 0.94/0.42 mm 0.037/0.017 in
Centrifugal force (1/2) 107/74 kN 24055/16636 lbf
Spraying system
Type of spraying Pressure Pressure
Interval switch Standard Standard
Filling capacities
Fuel (diesel) 200 l 53 gal us
Water 1000 l 264 gal us

2.1.1 Noise and vibration data

The following noise and vibration data were determined in accord-
ance with the following guidelines under equipment specific condi-
tions and by using harmonized standards:
n EU Machine Directive edition 2006/42/EU
n Noise Emission Directive 2000/14/EU, Noise Protection Direc-
tive 2003/10/EU
n Vibration Protection Directive 2002/44/EU
During operation these values may vary because of the prevailing
operating conditions.
2.1.1.1 Noise data

Sound pressure level at the opera- LpA = 84 dB(A), determined acc. to ISO 11201 and EN 500.
tor's stand
WARNING!
Loss of hearing caused by too high noise bur-
dens!
– Wear your personal protective equipment (ear
protection).
Guaranteed sound power level LWA = 108 dB(A), determined acc. to ISO 3744 and EN 500.
2.1.1.2 Vibration data

Vibration of the entire body (driv- The weighted effective acceleration value determined according to
er’s seat) ISO 2631 is ≤ 0.5 m/s2.
Hand-arm vibration The weighted effective acceleration value determined according to

ISO 5349 is ≤ 2.5 m/s2.

2.2 BW 202 AD-4
Fig. 4
Dimensions in mm 3300 2295 715 1220 2320 3000 350 4610 80 19 2135
Weights
Operating weight (CECE) with cabin 11800 kg 26015 lbs
Static linear load front (CECE) 27.6 kg/cm 155 pli
Static linear load rear (CECE) 27.6 kg/cm 155 pli
Max. operating weight 14000 kg 30865 lbs
Max. gradeability without/with vibration (soil dependent) 40/35 % 40/35 %

Drive
Type TCD 2012 L04 2V TCD 2012 L04 2V
Brakes
Parking brake mechanical mechanical
Steering
Inner track radius 4170 mm 164.2 in
Crabwalk, lateral offsetting of drum (right/left) 170 mm 6.7 in
Exciter system
Frequency (1/2) 40/50 Hz 2400/3000 vpm
Amplitude (1/2) 0.81/0.35 mm 0.032/0.014 in
Spraying system
Filling capacities



tive 2003/10/EU
2.2.1.1 Noise data

tor's stand
WARNING!
dens!
protection).


ISO 5349 is ≤ 2.5 m/s2.

2.3 BW 203 AD-4
Fig. 5
Dimensions in mm 3300 2295 715 1236 2320 3000 350 4610 80 27 2135
Weights
Operating weight (CECE) with cabin 13200 kg 29100 lbs
dependent)

Drive
Type TCD 2012 L04 2V TCD 2012 L04 2V
Brakes
Steering
Crabwalk, lateral offsetting of drum (right/left) 170 mm 6.7 in
Exciter system
Frequency (1/2) 40/50 Hz 2400/3000 vpm
Amplitude (1/2) 0.69/0.29 mm 0.027/0.011 in
Spraying system
Filling capacities



tive 2003/10/EU
2.3.1.1 Noise data

tor's stand
WARNING!
dens!
protection).


ISO 5349 is ≤ 2.5 m/s2.

Technical data – BW 203 SL-4
2.4 BW 203 SL-4
Fig. 6
Dimensions in mm 3300 2295 715 1236 2320 3000 350 4610 80 27 2135
Weights
Operating weight (CECE) 13000 kg 28660 lbs
dependent)

Drive
Type TCD 2012 L04 2V TCD 2012 L04 2V
Brakes
Steering
Exciter system
Frequency (1/2) 40/50 Hz 2400/3000 vpm
Amplitude (1/2) 0.69/0.29 mm 0.027/0.011 in
Spraying system
Filling capacities



tive 2003/10/EU
2.4.1.1 Noise data

tor's stand
WARNING!
dens!
protection).


ISO 5349 is ≤ 2.5 m/s2.


Safety regulations
3 Safety regulations

Safety regulations
General This BOMAG machine has been built in compliance with the
latest technical standard and complies with the applicable
regulations and technical rules. However, dangers for persons
and property may arise from this machine, if:
n it is used for purposes other than the ones it is intended for,
n it is operated by untrained personnel,
n it is changed or converted in an unprofessional way,
n the safety instructions are not observed.
Each person involved in the operation, maintenance and
repair of the machine must therefore read and comply with
these safety regulations. If necessary, this must be confirmed
by obtaining the signature of the customer.
Furthermore, the following obviously also applies:
n applicable accident prevention instructions,
n generally accepted safety and road traffic regulations,
n country specific safety regulations. It is the duty of the operator
to be acquainted with these instructions and to apply these
accordingly. This applies also for local regulations concerning
different types of handling work. Should the recommendations
in these instructions be different from the regulations valid in
your country, you must comply with the safety regulations valid
in your country.
Intended use This machine must only be used for:

n Compaction of bituminous material, e.g. road surface layers,
n medium to heavy compaction work in earth construction or
road sub-bases
Improper use Dangers may arise from the machine when it is used for purposes
other than the one it is intended for.
Any danger caused by improper use is the sole responsibility of the
operating company or driver/operator, the manufacturer cannot be
made liable.
Examples for improper use are:
n work with vibration on hard concrete, cured bitumen layers or
extremely frozen ground
n cleaning the drums while driving or changing nozzles during
travel.
n driving on subsoils with too low load bearing capacity
n driving on slippery subsoils (e.g. ice and snow)
n driving on surfaces of insufficient size (danger of turning over)
n unauthorized use of public roads
n Using the machine for towing
transporting persons, except the machine driver, is prohibited.
starting and operation of the machine in explosive environments
and in underground mining is prohibited.

Safety regulations
Remaining dangers, remaining Despite careful work and compliance with standards and regula-
risks tions it cannot be ruled out that further dangers may arise when
working with and handling the machine.
Both the machine as well as all other system components comply
with the currently valid safety regulations. Nevertheless, remaining
risks cannot be ruled out completely, even when using the machine
for the purpose it is intended for and following all information given
in the operating instructions.
A remaining risk can also not be excluded beyond the actual
danger zone of the machine. Persons remaining in this area must
pay particular attention to the machine, so that they can react
immediately in case of a possible malfunction, an incident or failure
etc.
All persons remaining ion the area of the machine must be
informed about the dangers that arise from the operation of the
machine.
Regular safety inspections Have the machine inspected by an expert (capable person) as
required for the conditiosn the machine is working under, but at
least once every year.
Who is allowed to operate the Only trained, instructed and authorized persons of at least 18 years
machine? of age are permitted to drive and operate this machine. For opera-
tion of the machine the responsibilities must be clearly specified
and complied with.
Persons under the influence of alcohol, medicine or drugs are not
allowed to operate, service or repair the machine.
Maintenance and repair work requires specific knowledge and
must therefore only be performed by trained specialists.
Changes and conversions to the Unauthorized changes to the machine are prohibited for safety rea-
machine sons.
Original parts and accessories have been specially designed for
this machine.
We wish to make explicitly clear that we have not tested or
approved any parts or accessories not supplied by us.
The installation and/or use of such products may have an adverse
effect on the active and/or passive safety.
The manufacturer explicitly excludes any liability for damage
caused by the use of non-original parts or accessories.
Damage, deficiencies, misuse of Machines which are not safe to operate or in traffic must be imme-
safety installations diately taken out of service and shall not be used, until these defi-
ciencies have been properly rectified.
Safety installations and switches must neither be removed nor
must they be made ineffective.

Safety regulations
Notes on safety in the operating

and maintenance instructions WARNING!
Paragraphs marked like this highlight possible dan-
gers for persons.
NOTICE!
Paragraphs marked like this highlight possible dan-
gers for machines or parts of the machine.
Paragraphs marked like this contain technical infor-

mation for the optimal economical use of the
machine.
ENVIRONMENT!
Paragraphs marked like this point out practices for
safe and environmental disposal of fuels and lubri-
cants as well as replacement parts.
Observe the regulations for the protection of the
environment.
Loading/transporting the machine Use only stable loading ramps of sufficient load bearing capacity.
The ramp inclination must be less than the gradability of the
machine.
Loading ramps must be free of grease, oil, snow and ice.
Do not drive with crabwalk onto the transport vehicle. Always
choose the first speed range.
Make sure that persons are not endangered by the machine tipping
or sliding off.
During demonstration and when loading the machine do not
remain in the danger zone of the machine.
Close and lock maintenance doors, cab windows and doors.
Loads must only be attached and hoisted by an expert (capable
person).
Always use suitable lifting tackle on the lifting points to lift or lash
down the machine.
Check all lifting and lashing points for damage before lifting or
lashing down the machine. Do not use damaged or in any other
way impaired lashing points.
Lift the machine only with suitable lifting gear. Use only safe lifting
gear of sufficient load bearing capacity Minimum lifting capacity of
lifting gear: see operating weight in chapter "Technical Data".
Do not lift or lower the machine jerkily.
The tension must always be effective in vertical direction.
The machine must not swing about when being lifted.

Safety regulations
Do not step or stand under suspended loads.

Lash the machine down, so that it is secured against rolling, sliding
and turning over.
After transport release the articulation lock again and store it in the
receptacle.
Towing the machine Apply appropriate measures (e.g. with metal wheel chocks, to be
provided by the operating company) to secure the machine against
rolling away.
Generally use a tow bar (to be provided by the operating com-
pany).
Use a towing vehicle with sufficient traction and braking power for
the unbraked towed load.
The machine cannot be steered.
Do not touch hot engine parts.
Only tow the machine with the parking brake released and the
travel pump short-circuited.
Towing speed 1 km/h, max. towing distance: only out of the imme-
diate danger zone as the travel pump may be destroyed due to
inadmissible heat and insufficient lubrication.
After towing the machine and before disconnecting the tow bar
apply appropriate measures to secure the machine against rolling
(e.g. with metal wheel chocks).
The hydraulic circuit needs to be filled and bled before the machine
can be put back into operation (e.g. following repair).
Checking the Roll Over Protective

Structure (ROPS) On machines with cab the ROPS is an integral part
of the cab.
The frame of the machine must not be warped, bent or cracked in

the area of the ROPS fastening.
The ROPS must not show any rust, damage, hairline cracks or
open fractures.
The actual weight of the machine must not exceed the testing
weight of the ROPS.
The ROPS must not rattle about when driving. This indicates that it
is not properly fastened. All bolted connections must comply with
the specifications and should be absolutely tight (observe the tight-
ening torques). Screw and nuts must not be damaged, bent or
deformed.
With the cab assembled check also the state of the cabin mounts
(rubber elements and screws).
No accessories may be welded or bolted on and no additional
holes must be drilled without the consent of the manufacturer,
since this will impair the strength of the unit.

Safety regulations
The ROPS must therefore also not be straightened or repaired if it

is damaged.
A defect ROPS must generally be replaced with an original spare
part in close coordination with the manufacturer.
Starting the machine Before starting

Use only machines which are serviced at regular intervals.
Become acquainted with the equipment, the control elements, the
working principle of the machine and the working area.
Wear your personal protective outfit (hard hat, safety boots, etc.).
Wear ear defenders.
Before mounting the machine check whether:
n persons or obstructions are beside or under the machine.
n the machine is free of oily and combustible material.
n all grips, steps and platforms are free of grease, oils, fuel, dirt,
snow and ice.
n the maintenance doors is closed and locked.
Use steps and grips to mount the machine.
Before starting the machine check whether:
n the machine shows any obvious faults.
n all guards and safety elements are in place.
n steering, brakes, control elements, light system and warning
horn work correctly.
n the seat is correctly adjusted
n mirrors (if present) are clean and correctly adjusted.
Do not start the machine with defective gauges, control lamps or
control elements.
Do not take any loose objects with you or fasten them to the
machine.
On machines with roll over protection system you must always
wear your seat belt!
Starting
Start and operate the machine only from the driver’s seat.
For starting set all control levers to 'neutral position'.
Do not use any starting aids like start pilot or ether.
After starting check all display instruments.
Starting with jump wires
Connect positive with positive and negative with negative (ground
cable) – always connect the ground strap last and disconnect it
first! A wrong connection will cause severe damage in the electric
system.
Do not start the engine by shorting the electric terminals on the
starter motor, because the machine may start to drive immediately.
Starting in closed rooms

Safety regulations
Exhaust gases pose a danger to life! Always ensure an adequate

supply of fresh air when starting in closed rooms!
Driving the machine Persons in the danger area

Before taking up work, also after breaks, you should always con-
vince yourself that the danger zone is free of persons or obstruc-
tions, especially when driving in reverse.
Give warning signals, if necessary. Stop work immediately if per-
sons remain in the danger zone, despite the warning.
Do not step or stand in the articulation area of the machine when
the engine is running - danger of crushing!
Driving
Do not drive on bases with insufficient load bearing capacity.
Do not drive on ice and snow.
In events of emergency and in case of danger actuate the emer-
gency stop switch immediately. Do not use the emergency stop
switch as service brake.
Restart the machine only after the danger that caused the actua-
tion of the emergency stop switch has been eliminated.
If the machine has contacted high-voltage power lines:
n do not leave the operator’s stand
n warn others from coming close to or touching the machine
n if possible drive the machine out of the danger zone
n have the power switched off
Operate the machine only from the operator’s stand.
Keep the cabin doors closed.
Do not adjust the driver’s seat while driving.
Do not climb onto or off the machine while the machine is driving.
Change the travel direction only at standstill.
Do not use the machine to transport persons.
In case of unusual noises and development of smoke perform
trouble shooting and have the fault corrected.
Always keep a sufficient distance to excavation walls and embank-
ments and do not use working methods that could impair the sta-
bility of the machine.
Do not work with vibration on hard concrete, cured bitumen layers
or extremely frozen ground.
Always keep a sufficient distance when passing through subways,
under bridges, tunnels, electric power lines etc.
Driving on inclinations and slopes
Do not drive on gradients exceeding the maximum gradability of
the machine.
On slopes drive extremely careful and always directly up or down
the slope. Change to a lower gear before starting to drive.

Safety regulations
Wet and loose soils considerably reduce the ground adhesion of

the machine on inclinations and slopes. Higher risk of accident!
Inclination
The tipping angle was measured in static condition on level, hard
ground with the machine stopped, no steering and without vibra-
tion.
The max. permissible inclination of the machine may be limited by
the max. permissible slanted position of the engine.
The specified angle Ä Fig. 7 must not be exceeded.
With loose soil, acceleration/deceleration, running vibration,
steering or attached accessories the tipping angle may be consid-
erably lower.
Driving across slopes should therefore be strictly avoided, because
Fig. 7 of the high risk of tipping over and the related risk of severe or
even fatal accidents.
You should therefore always drive straight up or down a slope.
Behaviour in traffic
Match the speed to the working conditions. Do not make extreme
steering movements when driving with high speed, danger of tip-
ping over!
Always give way to loaded transport vehicles.
Switch the lights on if the visibility is poor.
Keep away from edges and embankments.
Checking the effect of vibration
When compacting with vibration you must check the effect on
nearby buildings and underground supply lines (gas, water,
sewage, electric power), if necessary stop compaction work with
vibration.
Do not activate the vibration on hard (frozen, concrete) ground.
Danger of bearing damage!
Parking the machine Park the machine on horizontal, level, firm ground.
Before leaving the machine:
n return the control lever to neutral position
n apply the parking brake
n shut the engine down, pull the ignition key off
n close the cabin
n secure the machine against unauthorized use.
n pull the key off the main battery switch.
Do not jump off the machine, but use hand grips and access steps.
Mark machines, which could be in the way, with a clearly visible
sign.
Parking on slopes and inclinations
Apply suitable measures to block the machine against rolling away.

Safety regulations
Refuelling Do not inhale any fuel fumes.

Refuel only with the engine shut down.
Always use access steps.
Do not refuel in closed rooms.
No open fire, do not smoke.
Static charges may be generated in the fuel as it passes through
the filling system. A discharge of such charges in the presence of
combustible vapours may cause fire or an explosion.
Ultra-low sulphur diesel fuel poses a higher risk of ignition caused
by static charges than a diesel fuel with a higher sulphur content.
You should therefore always make sure that the filling system is
properly earthed and that there is equipotential bonding to the
machine. If necessary install a connecting cable between filling
system and vehicle ground.
Monitor the entire refuelling process.
Do not spill any fuel. Catch running out fuel, do not let it seep into
the ground.
Wipe off spilled fuel. Keep dirt and water away from the fuel.
A leaking fuel tank can cause an explosion. Ensure tight fit of the
fuel tank cover, if necessary replace immediately.
Fire protection measures
Familiarise yourself with the location and the operation of fire
fighting equipment. Observe all fire reporting and fire fighting possi-
bilities.
Maintenance work Comply with the maintenance work described in the operating and
maintenance instructions, including the information concerning the
replacement of parts.
Maintenance work must only be performed by qualified and author-
ized persons.
For overhead maintenance and assembly work use the access
steps and working platforms provided or other secure means. Do
not use machine parts as access steps.
Keep unauthorized persons away from the machine.
Do not perform maintenance work while the machine is driving or
the engine is running.
Park the machine on horizontal, level, firm ground.
Remove the key from the ignition switch.
pull the key off the main battery switch.
Work on hydraulic lines

Safety regulations
Relieve hydraulic pressures before working on hydraulic lines.

Hydraulic oil escaping under pressure can penetrate the skin and
cause severe injury. When being injured by hydraulic oil consult a
medical doctor immediately, as otherwise this may cause severe
infections.
Do not step in front of or behind the drums/wheels when per-
forming adjustment work in the hydraulic system.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature – danger of
scalding!
Any hydraulic oil must be caught and disposed of in an environ-
mentally friendly manner.
Always catch and dispose of hydraulic oils separately.
Do not start the engine after draining the hydraulic oil.
Once all work is completed (with the system still depressurized!)
check all connections and fittings for leaks.
Changing hydraulic hoses
Hydraulic hoses must not be mixed up by mistake.
Hydraulic hoses must be visually inspected at regular intervals.
Hydraulic hoses must be immediately replaced if:
n the outer layer is damaged down to the inlay (e.g. chafing,
cuts, cracks),
n the outer layer is brittle (formation of cracks in the hose mate-
rial)
n the hose shows deformations in pressurized and depressurized
condition, which do not comply with the genuine shape of the
hydraulic hose
n the hose shows deformations in bends (e.g. squeezing, buck-
ling, layer separation, formation of blisters)
n parts of the hose are leaking.
n hoses are not correctly installed
n the hydraulic hose has separated from the fitting
n the fitting shows corrosion that impairs both function and
strength.
n fittings are damaged or deformed, whereby the function and
strength of the hose - hose connection is impaired.
n expiration of storage time and utilization period
Only genuine BOMAG replacement hydraulic hoses ensure that
the correct hose type (pressure range) is used at the right location.
Working on the engine
Shut the engine down before opening the service doors.
Do not work on the fuel system while the engine is running –
danger to life due to high pressures!
n Wait approx. 5 minutes after the engine has stopped.
n Keep out of the danger zone during the initial test rung.
n In case of leaks return to the workshop immediately.
n Make sure that the engine cannot be started unintentionally
during service and repair work.

Safety regulations
Drain the engine oil at operating temperature – danger of scalding!

Wipe off spilled oil, catch running out oil and dispose of environ-
mentally.
Store used filters and other oil contaminated materials in a sepa-
rate, specially marked container and dispose of environmentally.
Do not leave any tools or other objects, that could cause damage,
in the engine compartment.
Working on the cooling system
Check and change coolant only when the engine is cold.
Wear gloves and goggles.
Catch coolant and dispose of environmentally.
Working on electric parts of the machine
Before starting to work on electric parts of the machine disconnect
the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and do not bridge
fuses - fire hazard!
Working on the battery
When working on the battery do not smoke, do not use open fire!
Do not let acid come in contact with hands or clothes! When
injured by acid flush off with clear water and seek medical advice.
Metal objects (e.g. tools, rings, watch straps) must not come in
contact with the battery poles – danger of short circuit and burning!
When recharging non-serviceable batteries remove all plugs, to
avoid the accumulation of explosive gases.
Observe the applicable instructions when starting with an auxiliary
battery.
Dispose of old batteries according to regulations.
Switch off the charging current before removing the charging
clamps.
Ensure sufficient ventilation, especially if the battery is to be
charged in a closed room.
Working on the fuel system
Do not inhale any fuel fumes.
Avoid open fire, do not smoke, do not spill any fuel.
Catch running out fuel, do not let it seep into the ground and dis-
pose off environmentally.
Working on the air conditioning
Faults on the air conditioning should only be remedied by profes-
sional personnel.
According to the regulation for pressure reservoirs all pressure res-
ervoirs must be repeatedly inspected by a specialist.
In connection with this inspection the drier/collector unit must be
visually examined twice every year. During these inspections spe-
cial attention must be paid to corrosion and mechanical damage.

Safety regulations
Do not perform welding work in the vicinity of the air conditioning -

danger of explosion.
Do not clean the condenser in the air conditioning system with a
hot water jet - danger of explosion.
Do not release refrigerant into the atmosphere, but dispose of envi-
ronmentally.
Cleaning work
Do not perform cleaning work while the motor is running.
Do not use gasoline or other easily inflammable substances for
cleaning.
When cleaning with steam cleaning equipment do not subject elec-
trical parts and insulation material to the direct jet of water, or cover
it beforehand.
n 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 Mark a defective machine by attaching a warning tag to the

steering wheel.
Always remove the main battery switch before starting welding
work on the machine.
Before pulling the connecting plugs off the control units the ignition
switch must be switched to "0".
For electric welding work the electronic system must be protected
by disconnecting the plug-in connectors from the control units.
Repair work must only be performed by qualified and authorized
persons. Use our repair instructions for this work.
Exhaust gases are highly dangerous! Always ensure an adequate
supply of fresh air when starting in closed rooms!
Do not work on the fuel system while the engine is running -
danger to life!
The system is under high pressure! Keep away from leakages in
the high pressure system, because fuel squirting out may cause
severe injury. After shutting down the engine wait for another
minute, until the pressure has dropped to a permissible level. In
case of leakages you should contact the Service Department of the
engine manufacturer and refrain from starting the engine.
Test
The safety of compaction equipment must be checked by a spe-
cialist as required in dependence on the application and the oper-
ating conditions, however at least once every year.

Safety regulations – Signage
3.1 Signage
Keep stickers and signage in good and legible condition and
comply with their meaning.
Replace damaged and illegible stickers or signage immediately.
Water Diesel Water
Engine Coolant
Spec.: • MB 325.5
• Deutz DQC CC-14
Part No.: 009 940 03 (20 l)
Hydraulic Oil
008 330 17
B-920-0093
Fig. 8

Warning sticker - Follow operating instructions
Fig. 9
Warning sticker - Danger of crushing
Fig. 10
Warning sticker - Close the maintenance door before starting to

drive
B-DEC-0036
Fig. 11
Prohibition sticker - High pressure cleaning
Fig. 12

Instruction sticker - Always wear your seat belt
Fig. 13
Information sticker - Filler opening for water
Water
B-DEC-0218
Fig. 14
Information sticker - Lifting point
Fig. 15
Information sticker - Filler opening for diesel
Diesel
B-DEC-0215
Fig. 16

Information sticker - Lashing point
Fig. 17
Information sticker - Disconnecting the battery
B-DEC-0219
Fig. 18
Information sticker - Guaranteed sound capacity level
Fig. 19
Information sticker - Filler opening for hydraulic oil
Hydraulic Oil
B-DEC-0214
Fig. 20

Information sticker - Coolant

Engine Coolant
Spec.: • MB 325.5
• Deutz DQC CC-14
Part No.: 009 940 03 (20 l)
B-DEC-0221
Fig. 21
Information sticker - Coolant drain
B-DEC-0212
Fig. 22
Information sticker - Hydraulic oil drain
B-DEC-0210
Fig. 23
Information sticker - Engine oil drain
B-DEC-0211
Fig. 24

Machine type plate (example)
Fig. 25

Indicators and control elements
4 Indicators and control elements

Indicators and control elements
Fig. 26
1 Speedometer (optional equipment)
2 Asphalt temperature gauge (optional equipment)
3 Emergency stop switch
4 Instrument cluster
5 Warning light and diagnostics button for engine control unit (EMR)
6 Rotary switch for hazard light system (optional equipment)
7 Starter switch
8 Rotary switch for engine speed
9 Rotary switch for travel ranges
10 Rotary switch for spray pumps
11 Rotary switch for vibration, drum pre-selection
12 Rotary switch for vibration, manual / automatic
13 Rotary switch for vibration, amplitude pre-selection
14 Rotary switch for direction indicators (optional equipment)
15 Rotary switch for lighting (optional equipment)
16 Rotary switch for rear working lights (optional equipment)
17 Lever for moving driver's seat laterally

Indicators and control elements – General notes
18 Push button for lifting edge cutter (optional equipment)

19 Push button for lowering edge cutter (optional equipment)
20 Travel lever, right
21 Push button for manual vibration, right
22 Push button for warning horn
23 Push button for edge cutter spraying system (optional equipment)
24 Interval switch for pressurized spraying system
25 Travel lever, left
26 Push button for manual vibration, left
27 Push button for crabwalk, left (not assigned on BW 203 SL-4)
28 Push button for crabwalk, right (not assigned on BW 203 SL-4)
29 Lever for swivelling the driver’s seat
30 12-V socket
4.1 General notes

If you are not yet familiar with the control and display elements on
this machine you should read this section thoroughly before
starting any operation on the machine. Here all functions are
described in detail.
The section "Operation" contains only brief descriptions of the indi-
vidual control steps.

Indicators and control elements – Description of indicators and control elements
4.2 Description of indicators and control elements

n SpeedometerOptional equipment
Shows the travel speed of the machine.
outer scale km/h

inner scale mph
Fig. 27
n Asphalt temperature displayOptional equipment

Shows the actual asphalt temperature.
black scale in °C
red scale in °F
Fig. 28
n Emergency stop push button
WARNING!
Danger of accident!
Use only in events of emergency during operation.
Do not use as parking brake.
Restart the machine only after the danger that
caused the actuation of the emergency stop switch
has been eliminated.
Fig. 29 The machine is braked immediately, the engine is
shut down.
actuate press the button completely down, it

automatically locks in fully pressed
position.
switch off/unlock Turn button clockwise. Restart the
engine.

n Instrument cluster
With the ignition switch in position "I" all control

and warning lights are switched on for a moment.
a yellow Warning light for seat contact switch

Lights when the engine is running and
the seat is not occupied.
b yellow Warning light water in fuel Lights when
the water content in the fuel pre-
cleaner reaches the sensor contacts.
Warning buzzer sounds. Clean the
Fig. 30 water separator.
c yellow not used
d yellow Warning light water tank filling level
Lights when the water tank is almost
empty. Warning buzzer sounds. Fill
up.
e red Engine oil pressure warning lamp
Flashes if engine oil pressure is low,
warning buzzer sounds, the engine
may be shut down by the engine con-
trol. Check engine oil level, repair the
engine if necessary.
f red Coolant level warning lamp Flashes if
the coolant level is low, warning
buzzer sounds. Check coolant level.
Check cooling system for leaks, repair
if necessary.
g yellow Charge control lamp Lights if the bat-
tery is not being charged. Check the
V-belt, if necessary repair the gener-
ator.
h yellow Air filter warning light Lights when the
combustion air filter is contaminated.
Clean or replace as necessary.
i red Warning light engine overheating
Flashes if the engine overheats,
warning buzzer sounds. The engine
may be shut down by the engine con-
trol. Clean engine oil cooler and radi-
ator, repair the engine is necessary.
j yellow Hydraulic oil filter warning light Lights
when the hydraulic oil filter is contami-
nated. Check hydraulic system,
replace hydraulic oil filter.
k green Indicator control light

l yellow Crabwalk control light Indicates that

the machine is in crabwalk mode.
m red Parking brake warning light Lights
when the parking brake is applied
n Fuel level gauge
o Water tank filling level indicator
p Operating hour meter Counts the
operating hours while the engine is
running. Maintenance work is to be
carried out in accordance with the
indicated operating hours.
n Warning light and diagnostic push button for engine control
The diesel engine with EMR (Electronic Engine

Control) inhibits protective functions for the engine.
Depending on the severity of the detected fault the
engine may continue operation with limitations
(limp home), whereby the warning light will perma-
nently be on.
With flashing warning light the engine is shut down.
If the fault indicators for engine oil pressure,
Fig. 31 engine temperature or coolant level, light up as
well, eliminate the fault.
When the fault is eliminated the control light will go
out.
The diagnostic button provides the possibility to
read out existing faults in form of flashing codes.
With the starting switch in position "I", the warning
light lights for about 2 seconds (function check).
Permanent light A fault message is present, the engine

can be started and the vehicle is still
operable with limitations. Inform the
service department.
the warning light flashes Severe fault, the engine cannot be
after 2 seconds started, inform the service depart-
ment.
goes out after 2 seconds The engine function is free of faults.
does not light Start the engine, press the diagnostic

push button for 3 seconds. Control
light flashes 2x. EMR-control ok.

NOTICE!
In case of a fault make a note of the fault code and
inform the BOMAG customer service or the cus-
tomer service of the engine manufacturer.
See also chapter "Trouble shooting".
n Rotary switch for hazard light system Optional equipment
Position "left" Hazard light system switched off

Position "right" Hazard light system switched on.
Warning lights in switch and indicator
control light in the instrument cluster
start flashing.
Fig. 32
n Start switch
Position "P", "0" Ignition off, key can be pulled out

Position "I", "II" Ignition on, all control and warning
lights in the instrument cluster light up
for 3 seconds (test function). The
engine control warning light lights for
approx. 2 seconds (test function). The
oil pressure warning light flashes,
charge control light and parking brake
Fig. 33
warning light stay on.
The engine can only be started if both travel levers

are in “neutral”.
The starter switch is designed with a re-start lock.
For a new starting attempt the ignition key must
first be turned back to position "0".
Position "START" Turn further against spring pressure,

the engine starts, turn the ignition key
back to position "I" once the engine
has started.

NOTICE!
Run the engine warm for a short while before
starting work. Do not rev up a cold engine to high
idle speed/full load speed.
Do not shut down the engine all of a sudden from
full load speed, but let it idle for about 2 minutes.
n Rotary switch for engine speed

Electric engine speed control
Position left Idle speed position
Normal position for engine start.
Fig. 34
Position right Full load position, operating position

for driving and vibration
NOTICE!
Always drive and vibrate with max. engine speed!
Control the travel speed with the travel lever.
n Rotary switch for travel ranges
Position left I. travel range 0 ... 6 km/h
Position right II. travel range 0 ... 11 km/h
Fig. 35

n Rotary switch for sprinkling pumps
Position left Sprinkling pump I switched on

Position "middle" Sprinkling pumps switched off
Position right Sprinkling pump II switched on
Sprinkling pumps I and II switched on alternately

Fig. 36
n Rotary switch for vibration, drum pre-selection
Vibration change-over is only activated if the vibra-

tion is switched off beforehand.
Position "left" Vibration of front drum

Position "middle" Vibration of front and rear drums
Fig. 37 Position "right" Vibration of rear drum
n Rotary switch for vibration, manual / automatic
Position "Left" Pre-selection vibration in manual mode

Vibration is switched on or off via the
vibration push button in the travel lever.
Position "Right" Pre-selection vibration in automatic
mode
Vibration is automatically switched on or
Fig. 38 off when a certain travel speed is
exceeded or fallen short of.

n Rotary switch for vibration, amplitude selection
Position "left" low amplitude, high frequency

Position "middle" Vibration switched off
Position "right" high amplitude, low frequency
Fig. 39
n Rotary switch for direction indicatorsOptional equipment
Position "middle" Direction indicators disabled.
Position "left or right" Front and rear direction indicators on

the corresponding side are flashing.
Indicator control light in instrument
cluster flashes.
Fig. 40
n Rotary switch for lightingOptional equipment
Position "Left" Light off

Position "Middle" Sidelights on (with starter switch in
position "I" or only with ignition on).
Position "Right" Travel light on (with starter switch in
position "I")
Fig. 41
n Rotary switch for rear working lightsOptional equipment
Position "Left" Rear working lights off

Position "Right" Working light rear on (with starter
switch in position "I")
Fig. 42

n Lever, lateral sliding of driver’s seat
WARNING!
Danger of accident!
Always lock the driver’s seat in one of the locking
positions while driving.
Do not slide the driver’s seat while driving.
Fig. 43 sliding Stop machine, apply parking brake,

pull lever and slide driver’s seat side-
ways to desired position. Let lever
click securely into place.
n Push button to lift the edge cutter
press Edge cutter up

release Edge cutter remains in position reached
last
Optional equipment
Fig. 44
n Push button to lower the edge cutter
WARNING!
Danger of crushing when lowering the edge
cutter!
– Make sure that no persons are in the danger
area.
press Edge cutter down

Fig. 45
release Edge cutter remains in position reached
last
Optional equipment

n Travel lever, right
Position "0" Start forward and backward travel from

position ’’0“.
From forward or backward travel to posi-
tion ’’0“ = service brake
Position "I" Forward travel
Position "II" Backward travel
Fig. 46 Position "III" Parking brake closed
The parking brake warning light in the
instrument cluster lights
The right hand travel lever is mechanically linked

with the left hand travel lever.
n Momentary contact push button for manual vibration, right
press to switch manual vibration on and off.
Fig. 47
n Push button for warning horn
Fig. 48

n Push button, edge cutter sprinkling system
press Sprinkling system for edge cutter on / off
The edge cutter sprinkling system only become

active, when the rotary switch for sprinkling pumps
is in position "Left" or "Right".
Fig. 49
n Interval switch for pressure sprinkler system
Position 12 left permanent sprinkling when pressure

sprinkling is enabled
In travel lever position ’’0“ the sprinkling system is

switched off, except in position 12 (permanent
sprinkling).
Fig. 50
further positions to the various sprinkling intervals

right, between 11 and 1
n Travel lever, left
Position "0" Start forward and backward travel from

position ’’0“.
From forward or backward travel to posi-
tion ’’0“ = service brake
Position "I" Forward travel
Position "II" Backward travel
Fig. 51 Position "III" Parking brake closed
The parking brake warning light in the
instrument cluster lights
The right hand travel lever is mechanically linked

with the left hand travel lever.

n Momentary contact push button for manual vibration, left
press to switch manual vibration on and off.
Fig. 52
n Momentary contact push button for crabwalk, left
press the crabwalk is infinitely adjusted to

left.
The crabwalk control light in the instrument cluster

lights up.
The control light goes out when middle position is
reached.
Fig. 53
release Crabwalk remains in position reached

last.
n Momentary contact push button for crabwalk, right
press the crabwalk is infinitely adjusted to

right.
The crabwalk control light (l) in the instrument

cluster lights up.
The control light goes out when middle position is
reached.
Fig. 54
release Crabwalk remains in position reached

last.

n Lever, swivelling of driver’s seat
WARNING!
Danger of accident!
Always lock the driver’s seat in one of the locking
positions while driving.
Do not swivel the driver’s seat while driving.
Fig. 55 swivel Stop he machine, apply the parking

brake. Pull the lever and swivel the
driver’s seat to the desired position.
Let lever click securely into place.
n 12-V utility socket

Permanent current when main battery switch is switched on.
Fig. 56
n EVIBdisplayOptional equipment
Is a compaction measuring unit for continuous display of the load
bearing characteristics (MN/m2) during the compacting pass.
EVIB value
Increase higher load bearing capacity

Constant end of compaction
Fig. 57

n Main battery switch
Position "0" Disconnects the battery from the on-

board electrics, protects against unau-
thorized use when performing welding
work on the machine. Can be
removed.
Position "I" Operating position, engine can be
started.
Fig. 58
NOTICE!
In events of emergency do not use the main bat-
tery switch to shut down the engine.
This will result in damage to engine and electronic
engine control units.
n Fuses in electric junction box
WARNING!
Fire hazard!
Do not use fuses with higher ampere ratings and
do not bridge fuses.
(2) 30A (F01) Main fuse

(3) 15A (F05) Socket
(4) 10A (F146) BAM, potential 30
(5) 20A (F105/F122) Engine speed
Fig. 59
(6) 25A (F37) Sprinkler pump and emulsion
sprinkling (AC-machine)
(7) 20A (F61) Sprinkler pump
(8) 15A (F07) Hazard light
(9) 7.5A (F119) Engine
(10) 7.5A (F25) solenoid valve for driving and
braking
(11) 10A (F14) Engine solenoid
(12) 15A (F129) MD+
(13) 5A (F04) Gauges
(14) 10A (F23) Warning horn
(15) 10A (F03) Vibration

(16) 15A (F08) Direction indicators and working

head lights
(17) 10A (F101) BAM, potential 15
(17a) 20A (F156) Light system (StVZO)
(18) 10A (F06) Water sprinkling system
(19) 10A (F09) Parking and tail light, left hand
side
(20) 10A (F10) Parking and tail light, right hand
side
(21) 10A (F11) Head lights, left hand side
(22) 10A (F12) head lights, right hand side
n Main fuse for battery

The main fuse for the battery is located inside the battery compart-
ment.
(1), 125A (F00) main fuse for battery
Fig. 60
n Control elements, cabin
Fig. 61
Pos. Designation Note

a Toggle switch for flashing beacon
b Toggle switch windscreen wiper/washer, front Windscreen wiper on/off
hold pressed down: The windscreen is sprayed
while wiping
c Toggle switch windscreen wiper/washer, rear Windscreen wiper on/off
hold pressed down: The windscreen is sprayed
while wiping

Pos. Designation Note

d Fuse box, cabin
e Toggle switch for cabin working lights
f Toggle switch for rear windscreen heating
g Reading and dashboard light
h Toggle switch for inside cabin light
i Toggle switch for reading and dashboard light
j Cabin light
d = Fuse box in cabin
WARNING!
Fire hazard!
(1) 15A (F41) Flashing beacon

Fig. 62 (2) 15A (F27) Wiper/washer, front
(3) 15A (F28) Wiper/washer, rear
(4) 25A (F31) Cabin fan
(5) 25A (F110) Working head lights, front/rear
(6) 5A (F15) Cabin heater
(7) 10A (F68) Potential 30
(8) 20A (F40) Cabin heater
n Rotary switch for cabin heater
Position "0" Cabin heater switched off
Position red range Temperature selection for cabin

heating
Fig. 63

n Rotary switch for cabin fan
Position "0" Cabin fan switched off
Position "1", "2" and "3" Fan stages of different strengths
Fig. 64
n Rotary switch for air conditioning systemOptional equipment
Only switch the air conditioning system on when

the rotary switch for the cabin fan in position 1, 2 or
3.
Position "0" Air conditioning switched off
Fig. 65
Position blue range Air conditioning control segment
n Rotary switch for ROPS working head lightsOptional equipment
Position "left" Light off

Position "right" ROPS working lights on, with ignition
switch in position "I"
Fig. 66
n Fuse box ROPSOptional equipment
WARNING!
Fire hazard!
(1) 25A Working headlights

Fig. 67


Operation
5 Operation

Operation – General
5.1 General
If you are not yet acquainted with the controls and indicating
elements on this machine you should thoroughly read chapter
"Indicators and control elements" before starting work.
All indicators and control elements are described in detail in
this chapter.

Operation – Tests before taking into operation
5.2 Tests before taking into operation

Before the everyday use or before a longer working period the fol-
lowing tests and inspections must be performed.
WARNING!
Danger of accident!
Please observe strictly the safety regulations in the
corresponding section of this instruction manual!
Park the machine on ground as level as possible.
Check:
Fuel tank and fuel lines for condition and leaks
Hydraulic oil tank and lines for condition and leaks
Screw joints for tight fit
Function of steering
Function of emergency stop
Machine for cleanliness, damage
Presence of the appropriate operating and maintenance
instructions
Proper maintenance of the machine
Right and left hand service doors closed and locked
Clean the scrapers, check their condition, replace if neces-
sary
For a description of the following tasks refer to the

chapter "maintenance every 10 operating hours".
Engine oil level, top up if necessary

Fuel level, top up if necessary
Hydraulic oil level, top up if necessary
Coolant level, top up if necessary
Water level, top up if necessary

Operation – Adjusting the driver’s seat
5.3 Adjusting the driver’s seat
WARNING!
Danger of accident!
Do not adjust the driver’s seat while driving.
a Pull the lever and lock the driver's seat

Ä Fig. 68 in one of 9 possible lateral
positions.
b Disengage the lever and adjust the

seat in longitudinal direction.
c Operate the lever and adjust the back

Fig. 68 rest.
d Pull the lever and lock the driver's seat

in one of 9 possible rotary positions.
e Read the adjusted driver’s weight in

the window.
f Adjust the weight of the driver with the

lever.

Operation – Starting the engine
5.4 Starting the engine
WARNING!
dens!
protection).
Prerequisites:
n Main battery switch switched on
n Emergency stop switch unlocked
Fasten your seat belt.
Fig. 69
Adjust the driver’s seat and let it click into place.
Fig. 70
Shift out the travel lever (position "III") (parking brake closed).
Fig. 71

Operation – Starting the engine
Turn the ignition key to position "I".

ð All control and warning lamps in the instrument cluster
light up for a moment.
The warning lamp for the engine control (EMR) lights up
briefly.
Fig. 72
The starter switch is designed with a re-start

lock. The ignition key must first be turned
back to position “0” before a new starting
attempt can be made.
NOTICE!
Components may get damaged!
– Run the starting process for maximum 20
seconds without interruption and pause
Fig. 73 for a minute between starting attempts.
– If the engine has not started after two
attempts, determine the cause.
Turn the ignition key through position "II" to position "III".

ð The starter cranks the engine.
NOTICE!
Danger of engine damage!
– Warm up engine for a short while before
starting work. Do not operate the engine imme-
diately under full load.

Operation – Starting with jump wires
5.5 Starting with jump wires
WARNING!
Wear ear defenders before starting work.
Remove the battery cover Ä Fig. 74.
Fig. 74
NOTICE!
A wrong connection will cause severe damage in
the electric system.
Fig. 75
Only use a 12 Volt battery to bridge the machine.

When jump starting with an external battery connect both
plus poles first.
Then connect the ground cable first to the minus pole of the
current supplying battery and then to engine or chassis
ground, as far away from the battery as possibleÄ Fig. 75.
Start as described under 'Starting the engine'.
Once the engine is running switch on a powerful consumer

(working light, etc.).

Operation – Starting with jump wires
NOTICE!
If no powerful consumer is switched on voltage
peaks may occur when separating the connecting
cables between the batteries, which could damage
electrical components.
After starting disconnect the negative poles (ground cable)

first and the positive poles after.
Switch off the consumer.
Fasten the battery cover again.

Operation – Driving the machine
5.6 Driving the machine
WARNING!
Danger of accident!
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclinations
and slopes.
Soil conditions and weather influences impair the
climbing ability of the machine.
Do not drive up and down inclinations which
exceed the maximum gradability of the machine
(see chapter "technical data").
Driving across slopes should therefore be strictly
avoided, because of the high risk of tipping over
and the related risk of severe or even fatal acci-
dents.
You should therefore always drive straight up or
down a slope.
Always give way to loaded transport vehicles!
Before starting to drive make sure that the drive
range is absolutely safe.
NOTICE!
Pre-select the travel speed range at standstill.
Fig. 76
Pre-select the desired speed range Ä Fig. 76 .
Turn the rotary switch for engine speed Ä Fig. 77 clockwise

to position "MAX".
The engine revs up to maximum speed.
NOTICE!
Always drive and vibrate with max. engine speed!
Control the travel speed with the travel lever.
Fig. 77

Disengage the travel lever Ä Fig. 78 from notched position

"III" towards the inside.
Fig. 78
The parking brake warning light (m) Ä Fig. 79 in the instrument

cluster goes out.
Fig. 79
Move the travel lever form "0"-position slowly to forward or

reverse.
The machine drives forward or backward with a speed that corre-

sponds with the actuation of the travel lever.
Move the travel lever back to "0"-position.
The machine is braked and stops in "0"-position.
WARNING!
Danger of accident!
When stopping on inclinations and slopes engage
the travel lever towards the outside in parking
brake position.

Important notes on travel operation

NOTICE!
When changing the travel direction hold the travel
lever for a moment in "0"-position, until the
machine has stopped, before actuating to the new
travel direction.
Do not operate jerkily! Control the travel speed
with the travel lever.
When driving up and down inclinations move the
travel lever slowly back towards neutral to brake
the machine.
If the engine speed drops under load when driving
on steep gradients, take the travel lever slightly
back towards neutral.
Seat contact switch
WARNING!
Danger of accident!
In positions "I" and "II" the seat contact switch is
active. If the seat is not occupied when the engine
is running the warning horn will sound and the
engine will be shut down after 4 seconds.
The warning lights for seat contact switch (a) and

the parking brake warning light (m) in the instru-
Fig. 80
ment cluster light up.
To continue driving occupy the seat and put on the seat belt
within 4 seconds. Warning lamps and warning buzzer go out.
If the engine stops restarting is required.

Operation – Stopping the machine, operating the parking brake
5.7 Stopping the machine, operating the parking brake

Return the travel lever Ä Fig. 81 slowly to "0"-position and
engage it towards the outside in notched position "III",
parking brake position.
The machine is automatically braked by the hydro-

static drive and the parking brake is applied.
Fig. 81
The parking brake warning light (m) Ä Fig. 82 in the instrument

cluster lights up.
The parking brake also closes automatically when

shutting the engine down.
Fig. 82

Operation – Shutting down the engine
5.8 Shutting down the engine

Shift the travel lever Ä Fig. 83 slowly to neutral position.
The machine is automatically braked hydrostati-

cally.
Fig. 83
Engage the travel lever outward in catch position "III",

parking brake.
The parking brake warning light (m) Ä Fig. 84 on the instrument

cluster lights up.
Fig. 84
Turn the rotary switch for engine speed Ä Fig. 85 anti-clock-

wise to position "MIN" (idle speed).
NOTICE!
Do not shut down the engine all of a sudden from
full load speed, but let it idle for about 2 minutes.
Fig. 85

Operation – Shutting down the engine
Turn the starter switch Ä Fig. 86 to position "0" or "P" and

pull the ignition key out.
The parking brake closes automatically when shut-

ting the engine down.
WARNING!
Fig. 86 Danger of accident!
Secure the machine against unauthorized use, pull
the ignition key out, lock the cabin door.
NOTICE!
Pull out the main battery switch at the earliest 40
seconds after switching off the ignition.
Open the right hand service door.
Switch the main battery switch Ä Fig. 87 to position "0", pull

it out and store it in a safe place.
Fig. 87
Close the right hand service door.

Operation – Switching the vibration on / off
5.9 Switching the vibration on / off
NOTICE!
Possible damage to neighbouring buildings!
– When compacting with vibration you must
always check the effect of the vibration on
nearby buildings and underground supply lines
(gas, water, sewage, electric power).
– If necessary stop compacting with vibration.
NOTICE!
– Do not activate the vibration on hard (frozen,
concrete) ground.
Vibration at standstill causes transverse marks:

n Switch the vibration on only after the machine has reached its
nominal speed.
n Switch the vibration off approx. one machine length before
stopping the machine.
In automatic operation, vibration is automatically activated when a
certain low travel speed is reached. The vibration is automatically
switched off when falling below this certain slow travel speed.
This avoids the formation of transverse marks caused by vibration
with the machine at standstill.
5.9.1 Vibration in manual mode

Turn the rotary switch for travel speed ranges to position
"Left".
Vibration is only possible in the lowest speed

range.
Fig. 88

Preselect the desired amplitude with the rotary switch for

vibration, amplitude pre-selection.
Fig. 89
Use the rotary switch for drum pre-selection to pre-select the

desired drum(s).
Drum pre-selection is only activated, if the

vibration has been switched off beforehand.
Fig. 90
Turn the rotary switch for vibration in manual/auto mode to

position "Left".
Fig. 91
Turn the rotary switch for travel lever button assignment to

position "Right".
Fig. 92

NOTICE!
Vibration at standstill causes transverse
marks!
– Do not switch on vibration with the
machine at standstill.
Shift the travel lever slowly to the desired travel direction.

Press the vibration push button on the travel lever.
ð Vibration is switched on.
Fig. 93
Press the vibration push button on the travel lever once again
to switch off vibration.
ð Vibration is switched off.
5.9.2 Vibration in automatic mode

Turn the rotary switch for travel speed ranges to position
"Left".
Vibration is only possible in the first speed

range.
Fig. 94
Preselect the desired amplitude with the rotary switch for

vibration, amplitude pre-selection.
Fig. 95

Use the rotary switch for drum pre-selection to pre-select the

desired drum(s).
Drum pre-selection is only activated, if the

vibration has been switched off beforehand.
Fig. 96
Turn the rotary switch for vibration in manual/auto mode to

position "Right".
Fig. 97
Shift the travel lever slowly to the desired travel direction.

ð The vibration comes on at a low travel speed.
To switch off vibration return the travel lever towards "Middle"
position.
ð The vibration switches off when falling below the slow
travel speed.
Fig. 98

Operation – Operating the crabwalk
5.10 Operating the crabwalk
WARNING!
Operate the crabwalk only at low travel speed, in
order to stay in track.
The maximum offset to right and left is 170 mm.
Press and hold the left hand push button Ä Fig. 99 on the
left hand travel lever.
The crabwalk is infinitely adjusted to left.

The crabwalk operates immediately, also in stand-
still.
Fig. 99
The crabwalk control light (l) Ä Fig. 100 in the instrument cluster
lights up.
The control light goes out when middle position is reached.
Fig. 100
Press and hold the right hand push button Ä Fig. 101 on the
left hand travel lever.
the crabwalk is infinitely adjusted to right.

The crabwalk operates immediately, also in stand-
still.
Fig. 101

Operation – Switching the pressure sprinkling system on and off
5.11 Switching the pressure sprinkling system on and off

Turn the rotary switch for the sprinkling pumps Ä Fig. 102 to
position "left" (sprinkling pump I) or position "right" (sprinkling
pump II).
The pressure sprinkler system is switched on.
For sprinkling switch alternately between sprinkling

pumps I and II to achieve even straining of the
sprinkling pumps.
Fig. 102
Set the interval switch for pressure sprinkling system

Ä Fig. 103 to the desired sprinkling interval.
Permanent sprinkling, stage 12, is always active in

travel lever position ’’0“, stages 11 to 1 are
switched off after 30 seconds when the travel lever
is in ’’0“-position.
Fig. 103
The level gauge (o) for the water tank in instrument

cluster shows the current filling level.
When the water tank is empty the warning light for
the water tank filling level (d) in the instrument
cluster will light up and the warning buzzer will
sound.
Fig. 104

Operation – Sprinkling system for edge cutter on / off
5.12 Sprinkling system for edge cutter on / off

Turn the rotary sprinkling system switch to left or right.
Fig. 105
Press push button for edge cutter sprinkling system.
The edge cutter is sprinkled in the same

interval as the drums.
Press the push button for the edge cutter sprinkling system
again to switch off.
Fig. 106

Operation – Actuating the emergency stop switch
5.13 Actuating the emergency stop switch
WARNING!
Danger of accident!
In events of emergency and in case of danger
actuate the emergency stop switch immediately.
Start travel operation of the machine only after the
danger that caused the actuation of the emergency
stop switch has been eliminated.
NOTICE!
Do not use as service brake. The deceleration is
extremely high. In case of frequent use the wear
on the multi-discs brakes will be very high.
Press the button of the emergency stop switch Ä Fig. 107

completely down, it automatically locks in fully pressed posi-
tion.
Shuts the engine down and closes the brake.
Fig. 107
Turn the button clockwise to unlock the emergency stop

switch.
Start the engine again, see chapter "Starting the engine".

Operation – Operating the heating / air conditioning system
5.14 Operating the heating / air conditioning system
NOTICE!
The function of the heating / air conditioning
system may be affected!
– Always keep the air inlet slots on the cabin free
of snow, foliage etc.
– Switch the air conditioning on every month for
about ten minutes.
Fig. 108
a Adjust the air distribution
b Regulate the cabin temperature
c Set the fan speed
d Air conditioning on/off
Heating the interior Close all windows completely.

Adjust the desired air distribution.
Switch on the fan.
Regulate the cabin temperature.
Cooling the interior Close all windows completely.

Adjust the desired air distribution.
Switch on the fan.
Switch the air conditioning on.
Regulate the cabin temperature.
Reducing the humidity Direct the air distribution to the windscreen.

Switch the fan to stage “3”.
Set the cabin temperature to “Max”.
Switch the air conditioning on.

Operation – Opening or closing the cabin window
5.15 Opening or closing the cabin window
NOTICE!
Always keep the cabin doors closed while driving.
Always lock the cabin windows in open position or
close them.
Open the locking Ä Fig. 109 of the cabin window.

Swing out and lock the cabin window.
Fig. 109
To close the cabin window press the locking button

Ä Fig. 110, swing the cabin window back and lock it.
Fig. 110

Operation – Towing
5.16 Towing
WARNING!
Danger of accident! Danger of injury!
Apply appropriate measures (e.g. with metal wheel
chocks, to be provided by the operating company)
to secure the machine against rolling away.
Use a towing vehicle with sufficient traction and
braking power for the unbraked towed load.
Use a tow bar (to be provided by the operating
company).
Using the machine as towing vehicle is not per-
mitted.
The machine cannot be steered.
Do not touch hot components.
NOTICE!
Only tow the machine with the parking brake
released and the travel pump short-circuited.
Towing speed 1 km/h, max. towing distance: only
out of the immediate danger zone as the travel
pump may be destroyed due to inadmissible heat
and insufficient lubrication.
The closed hydraulic circuit empties during the
towing process. Therefore, the hydraulic circuit
needs to be filled and bled after towing. To do this,
operate the starter without starting the engine.
Preparing for towing

Shut down the engine.
Fasten the towing hitch at front Ä Fig. 111 or rear with a
tightening torque of 578 Nm (426 ft.lb).
Fig. 111

Unscrew the check nuts (2) Ä Fig. 112 at the high pressure
limiting valves of the travel pump.
Tighten the hexagon socket screws (1) until they touch the
spring cup (increased resistance).
Turn the hexagon socket screws another half turn.
Tighten the counter nuts.
Fig. 112
Press the emergency actuation button Ä Fig. 113 to release

the parking break down as far as it will go.
The pump lever extension bar is stored inside the

service door.
Fig. 113
Release the brake by operating the hand pump Ä Fig. 114.
The machine can then be towed away.
Fig. 114
After towing
WARNING!
Apply appropriate measures to secure the machine
against rolling away (e.g. with metal wheel chocks,
to be provided by the operating company) before
disconnecting the tow bar.

If the engine cannot be started, pull the emergency actuation

button Ä Fig. 115 as far as it will go after towing.
After the engine has started, the emergency actua-

tion button will automatically return to its home
position.
NOTICE!
Fig. 115
The hydraulic circuit needs to be filled and bled
before the machine can be put back into operation
(e.g. following repair).
Unscrew the check nuts (2) Ä Fig. 116 at the high pressure
limiting valves of the travel pump.
Unscrew the hexagon socket screws (1) as far as they will
go.
Tighten the counter nuts.
Fig. 116
Prior to putting into operation, actuate the emergency stop

button Ä Fig. 117, so that the engine will not start.
Fig. 117
Turn the ignition key Ä Fig. 118 to position "START" via

position "II" and hold it in this position for about 20 seconds.
The starter turns the engine and in this way fills and bleeds the
hydraulic circuit.
Fig. 118

Operation – Loading/transport
5.17 Loading/transport
WARNING!
Danger of accident! Life hazard!
Use only stable loading ramps of sufficient load
bearing capacity. The ramp inclination must be less
than the gradability of the machine.
Loading ramps must be free of grease, oil, snow
and ice.
Make sure that persons are not endangered by the
machine tipping or sliding off.
During demonstration and when loading the
machine do not remain in the danger zone of the
machine.
Do not drive with crabwalk onto the transport
vehicle.
Close and lock maintenance doors, cab windows
and doors.
Always use suitable lifting tackle on the lifting
points to lift or lash down the machine.
Check all lifting and lashing points for damage
before lifting or lashing down the machine. Do not
use damaged or in any other way impaired lashing
points.
Lash the machine down, so that it is secured
against rolling, sliding and turning over.
After transport release the articulation lock again
and store it in the receptacle.
Turn the rotary speed range selector switch Ä Fig. 119 to

low speed range.
Make sure that no persons are in the danger area.
Drive the machine carefully on the transport vehicle.
Fig. 119

Remove cotter pin (2) Ä Fig. 120.
Fig. 120
Lift up the articulation lock (1) and turn it to the right, until the
locking pin clicks into place.
Secure the articulation lock (1) with cotter pin (2) Ä Fig. 121.
Fig. 121
Actuate the emergency stop switch Ä Fig. 122.

Close and lock cab windows and doors.
Fig. 122

Lash the machine to the transport vehicle, fasten the lashing

gear Ä Fig. 123 to the lashing points on front and rear sup-
port legs.
Fig. 123
Loading by crane
WARNING!
Only expert personnel (qualified persons) are
allowed to attach lifting tackle to loads and to lift
loads.
Always use suitable lashing gear at the lifting
points for loading or lashing down the machine.
Check all lifting and lashing points for damage
before lifting or lashing down the machine. Do not
use damaged or in any other way impaired lashing
points.
Lift the machine only with suitable lifting gear. Use
only safe lifting gear of sufficient load bearing
capacity Minimum lifting capacity of lifting gear:
see operating weight in chapter "Technical Data".
Do not lift or lower the machine jerkily.
The tension must always be effective in vertical
direction.
The machine must not swing about when being
lifted.
Do not step or stand under suspended loads.
Use appropriate lifting tackle at the four marked lifting eyes

Ä Fig. 124 to lift the machine.
Fig. 124

After transport
WARNING!
After transport release the articulation lock again
and store it in the receptacle.
Disengage the articulation lock and fasten it in the holder.


Maintenance
6 Maintenance

Maintenance – General notes on maintenance
6.1 General notes on maintenance

Always comply with the appropriate safety regulations when per-
forming maintenance work.
Thorough maintenance of the machine guarantees far longer safe
functioning of the machine and prolongs the lifetime of important
components. The effort needed for this work is only little compared
with the problems that may arise when not observing this rule.
The terms right/left correspond with travel direction forward.
Always clean machine and engine thoroughly before starting
maintenance work.
For maintenance work stand the machine on level ground.
Always remove the main battery switch for all maintenance
work.
Perform maintenance work only with the engine shut down.
Relieve hydraulic pressures before working on hydraulic
lines.
Before working on electric parts of the machine disconnect
the battery and cover it with insulation material.
When working in the area of the articulated joint attach the
articulation lock (transport lock).
ENVIRONMENT!
During maintenance work catch all oils and fuels
and do not let them seep into the ground or into
the sewage system. Dispose of oils and fuels envi-
ronmentally.
Keep used filters in a separate waste container
and dispose of environmentally.
Catch biodegradable oils separately.
Notes on the fuel system The lifetime of the diesel engine depends to a great extent on the
cleanliness of the fuel.
Keep fuel free of contaminants and water, since this will
damage the injection elements of the engine.
Drums with inside zinc lining are not suitable to store fuel.
When choosing the storage place for fuel make sure that
spilled fuel will not harm the environment.
Do not let the hose stir up the slurry at the bottom of the
drum.
The fuel drum must rest for a longer period of time before
drawing off fuel.
The rest in the drum is not suitable for the engine and should
only be used for cleaning purposes.

Maintenance – General notes on maintenance
Notes on the performance of the On diesel engines both combustion air and fuel injection quantities
engine are thoroughly adapted to each other and determine power, tem-
perature level and exhaust gas quality of the engine.
If your engine has to work permanently in "thin air" (at higher alti-
tudes) and under full load, you should consult our customer service
or the customer service of the engine manufacturer.
Notes on the cooling system Prepare and check coolant with highest care, since otherwise the
engine may be damaged by corrosion, cavitation and freezing.
Coolant is prepared by adding an ethylene-glycol based anti-freeze
agent with corrosion inhibiting properties to the cooling water.
Mixing with cooling system protection agent is necessary in all cli-
matic zones. It prevents corrosion, lowers the freezing point and
raises the boiling point of the coolant.
Notes on the hydraulic system During maintenance work on the hydraulic system cleanliness is of
major importance. Make sure that no dirt or other contaminating
substances can enter into the system. Small particles can produce
flutes in valves, cause pumps to seize, clog nozzles and pilot
bores, thereby making expensive repairs inevitable.
If, during the daily inspection of the oil level the hydraulic oil
level is found to have dropped, check all lines, hoses and
components for leaks.
Seal external leaks immediately. If necessary inform the
responsible customer service.
Do not store drums with hydraulic oil outdoors, or at least
under a cover. Water can be drawn in through the bunghole
when the weather changes.
We recommend to use our filling and filtering unit with fine
filter to fill the system. This ensures finest filtration of the
hydraulic oil, prolongs the lifetime of the hydraulic oil filter
and protects the hydraulic system.
Clean fittings, filler covers and the area around such parts
before disassembly to avoid entering of dirt.
Do not leave the tank opening unnecessarily open, but cover
it so that nothing can fall in.

Maintenance – Fuels and lubricants
6.2 Fuels and lubricants

6.2.1 Engine oil
6.2.1.1 Oil quality
Engine oils for use in DEUTZ engines are classified in DEUTZ
Engine Oil Quality Classes (DQC).
The following engine oil specifications are permitted:

DEUTZ ACEA API DHD
DQC II-10 E3-96 CH-4 DHD-1
E4-12 CI-4
E5-02 CI-4 Plus
E7-12
DQC III-10 - - -
DQC IV-10 - - -
Avoid mixing of engine oils.
The list of approved engine oils is also available on the

Internet under the following address:
www.deutz.com
de SERVICE \ Maintenance \ Betriebsstoffe \ Öle \
DEUTZ Quality Class \ DQC Freigabeliste
en SERVICE \ Maintenance \ Operating Liquids\ Oils \
DEUTZ Quality Class \ DQC Release List

6.2.1.2 Oil viscosity

Since engine oil changes its viscosity with the temperature, the
ambient temperature at the operating location of the engine is of
utmost importance when choosing the viscosity class (SAE-class).
Only use multi-purpose oils.
The temperature indications of the SAE-class always refer to fresh
oils. In travel operation engine oil ages because of soot and fuel
residues. This adversely affects the properties of the engine oil,
especially under low ambient temperatures.
Optimal operating conditions can be achieved by using the oil vis-
cosity chart as a reference.
Fig. 125: Oil viscosity diagram
6.2.1.3 Oil change intervals

If the oil change intervals are not reached over a period of one
year, the oil change should be performed at least 1 x per year, irre-
spective of the operating hours reached.
The oil change interval must be halved if at least one of the fol-
lowing conditions applies:
n Permanent ambient temperatures below -10 °C (14 °F)
n Engine oil temperatures below 60 °C (84 °F).
n Sulphur content in fuel exceeding 0.5 %
6.2.2 Fuel
6.2.2.1 Fuel quality
You should preferably use commercial diesel fuel with a sulphur
content of less than 0.5 %.
When using a diesel fuel with a high sulphur content of 0.5 % to
1.0 % the oil change intervals must be halved.
Fuels with a sulphur content of more than 1.0 % are not permitted.

In order to fulfil national emission regulations one must strictly use

the legally required fuels (e.g. sulphur content).
The following fuel specifications are recommended:
n EN 590
n ASTM D975 Grade-No. 1-D and 2-D
n JIS K 2204 Grade Fuel 1 and Grade Fuel 2 with lubrication
properties acc. to EN 590
6.2.2.2 Winter fuel

For winter operation use only winter diesel fuel, to avoid clogging
because of paraffin separation.
At very low temperatures disturbing paraffin separation can also be
expected when using winter diesel fuel.
Diesel fuels suitable for temperatures down to -44 °C (-47 °F) are
available for Arctic climates.
NOTICE!
– The admixture of petroleum and the addition of
“flow enhancing additives” (fuel additives) is
not permitted.
6.2.2.3 Storage
Even traces of zinc, lead and copper can cause deposits in the
injection nozzles, especially in modern Common-Rail injection sys-
tems.
Zinc and lead coatings in refuelling systems and fuel lines are not
permitted.
Copper containing materials (copper lines, brass items) should be
avoided, because they can cause catalytic reactions in the fuel with
subsequent depositing in the injection system.
6.2.3 Coolant
6.2.3.1 General
For fluid cooled engines the cooling fluid must be prepared by
admixing a cooling system protection agent to the fresh water and
should be checked within the specified maintenance intervals.
This prevents damage caused by corrosion, cavitation, freezing
and overheating.

6.2.3.2 Water quality

The correct quality of water is highly important when preparing
coolant. Clear and clean water within the boundaries of the fol-
lowing analysis values should generally be used.
Analysis values
pH-value at 20 °C (68 °F) 6.5 - 8.5
Chlorine-ion content max. 100 mg/l
Sulphate ion content max. 100 mg/l
Water hardness (ion content of max. 3.56 mmol/l
calcium and magnesium )
max: 356 mg/l (ppm)
Germ degree: max. 20 °dH
English degree: max: 25 °eH
French degree: max: 35.6 °fH
Bacteria, fungi, yeasts not permitted
Information concerning the water quality can be obtained from the

waterworks.
If the fresh water analysis values are unknown, these must be
determined with the help of a water analysis.
If the values of the analysis deviate, the water must be treated
accordingly:
pH-value too low - Adding of caustic lye of soda or caustic
potash solution.
Water hardness too - Mix with soft, distilled or fully demineral-
high ized water
Chlorides and/or sul- - Mix with distilled or fully demineralized
phates too high water
NOTICE!
– Another analysis must be made after the fresh
water has been prepared.
6.2.3.3 Cooling system protection agent

As a protection against frost, corrosion and boiling, anti-freeze
agents must be used in any climatic conditions.
Coolant is prepared by adding an ethylene-glycol based anti-freeze
agent with corrosion inhibiting properties to the cooling water.
We therefore highly recommend using our BOMAG cooling system
protection agent.

If our cooling system protection agent is not available for any

important reasons, you may, in exceptional cases, use products
that have been approved by the engine manufacturer.
The list of approved lubrication oils is also available on the

internet under the following link:
www.deutz.com
de SERVICE \ Maintenance \ Betriebsstoffe \ Kühlsys-
temschutz
en SERVICE \ Maintenance \ Operating Liquids \
Coolant
Products of the same product group (see Deutz Technical Circular

Cooling System Protection Agents) can be mixed with each other.
The BOMAG cooling system protection agent corresponds with
product group C.
NOTICE!
– Do not mix different coolants and additives of
any other kind.
– Before changing the product you must clean
the entire cooling system.
– Consult our customer service if in doubt.
– The cooling system protection agent must be
used all year round, to provide adequate corro-
sion protection.
The mixing ratio must not be below or exceed the following

value:
Cooling system Fresh water Protection against
protection agent cold down to
min. 35% 65% -22 °C (-8 °F)
40% 60% -28 °C (-18 °F)
45% 55% -35 °C (-31 °F)
max. 50% 50% -41 °C (-42 °F)
NOTICE!
– A proportion of more than 50% of cooling
system protection agent results in reduced
cooling power.
– The use of corrosion protection oils as cooling
system protection agents is not permitted.

6.2.4 Hydraulic oil

6.2.4.1 Mineral oil based hydraulic oil
The hydraulic system is operated with hydraulic oil HV 46 (ISO)
with a kinematic viscosity of 46 mm2/s at 40 °C (104 °F) and
8 mm2/s at 100 °C (212 °F).
When refilling or changing oil, use only hydraulic oil type HVLP
according to DIN 51524, part 3, or hydraulic oil type HV according
to ISO 6743/4.
The viscosity index must be at least 150 (observe information of
manufacturer).
6.2.4.2 Bio-degradable hydraulic oil

The hydraulic system can also be operated with a synthetic ester
based biodegradable hydraulic oil.
The biodegradable hydraulic oil Panolin HLP Synth. 46 or
Plantohyd 46 S meets all the requirements of a mineral oil based
hydraulic oil according to DIN 51524.
In hydraulic systems filled with biodegradable hydraulic oil, always
use the same oil to top up and do not mix oil types.
When changing from mineral oil based hydraulic oil to an ester
based biologically degradable hydraulic oil, you should consult the
lubrication oil service of the oil manufacturer, or our customer
service for details.
NOTICE!
Danger of damage to the hydraulic system!
– After the changeover check the hydraulic oil fil-
ters increasingly for contamination.
– Have regular oil analyses performed regarding
the water content and mineral oil.
– Replace the hydraulic oil filter at the latest after
500 operating hours.
6.2.5 Gear oil SAE 75W-90

Use a fully synthetic gear oil in accordance with SAE 75W-90,
API GL5 with a kinematic viscosity of at least 16 mm2/s at 100 °C
(212 °F).
6.2.6 Gear oil SAE 80W-140

Use a fully synthetic gear oil in accordance with SAE 80W-140,
API GL5 with a kinematic viscosity of at least 20 mm2/s at 100 °C
(212 °F).

It is a hypoid lubricant of highest quality class for transmissions

under extreme strain.
6.2.7 Lubrication grease

For lubrication purposes use an EP-high pressure grease, lithium
saponified (penetration 2), acc. to DIN 51502 KP 2G.

Maintenance – List of fuels and lubricants
6.3 List of fuels and lubricants

Assembly group Fuel or lubricant Spare parts Filling quantity
number
Summer Winter Observe the
level mark!
Engine oil SAE 10W-40 009 920 06 10.5 l
Specification: Ä Chapter 6.2.1 ‘Engine oil’ 20 l (2.8 gal us)
on page 98
SAE 15W-40
SAE 5W-40
Fuel Diesel Winter diesel fuel 200 l
Specification: Ä Chapter 6.2.2 ‘Fuel’ (53 gal us)
on page 99
Coolant Mixture of water and anti-freeze agent 009 940 03 16 l
Specification: Ä Chapter 6.2.3 ‘Coolant’ 20 l (4.2 gal us)
on page 100
Hydraulic system Hydraulic oil (ISO), HVLP 46 009 930 09 60 l
Specification: Ä Chapter 6.2.4.1 ‘Mineral oil 20 l (16 gal us)
based hydraulic oil’ on page 103
or ester based biodegradable hydraulic oil
Specification: Ä Chapter 6.2.4.2 ‘Bio-degrad-
able hydraulic oil’ on page 103
Exciter shaft hub tube SAE 75W-90, API GL-5 009 925 05 9.5 l
for drum
Specification: Ä Chapter 6.2.5 ‘Gear oil SAE 20 l (2.5 gal us)
75W-90’ on page 103
Travel gear, drum SAE 80W-140, API GL-5 009 925 07 1.5 l each
Specification: Ä Chapter 6.2.6 ‘Gear oil SAE 20 l (0.4 gal us)
80W-140’ on page 103
Spraying system Water Anti-freeze mixture 1000 l
(264 gal us)
Lock chains High pressure grease (lithium saponified) as required
Oscillating articulated High pressure grease (lithium saponified) as required
joint
Air conditioning Refrigerant R134a 1300 g
(2.9 lbs)

Maintenance – Running-in instructions
6.4 Running-in instructions

6.4.1 General
The following maintenance work must be performed when running
in new machines or overhauled engines.
NOTICE!
– 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.
6.4.2 After 50 operating hours

Check the engine for leaks.
Tighten all bolted connections on air intake, exhaust, oil
sump and engine mounts
Retighten the bolted connections on the machine.

Oil and filter change diesel engine.
Oil change in the exciter shaft tube.
Oil change in travel gear.

Oil and filter change in the diesel engine.
Oil change in the exciter shaft hub tube.
Oil change in the travel gear.

Oil change in the exciter shaft tube.
Oil change in travel gear.

Maintenance – Maintenance Table
6.5 Maintenance Table

No. Maintenance works Page
Every 10 operating hours
6.6.1 Checking the engine oil level 109
6.6.2 Checking the fuel level 109
6.6.3 Check the hydraulic oil level 111
6.6.4 Check the coolant level 112
6.6.5 Check the water level 112
6.7.1 Change the fuel filter cartridge 114
6.7.2 Replace the fuel pre-filter cartridge, bleed the fuel system 115
6.7.3 Check, clean radiator, fuel cooler, hydraulic oil cooler and intercooler 116
6.7.4 Check the oil level in vibrator shaft tube 117
6.8.1 Changing engine oil and oil filter cartridge 118
6.8.2 Check the anti-freeze concentration and the condition of the coolant 119
6.8.3 Service the air conditioningOptional equipment 120
6.8.4 Cleaning the circulation air filter for the heatingOptional equipment 124
6.8.5 Battery service, checking the main battery switch 124
6.9.1 Change the oil in drum drive gear 127
6.9.2 Checking, tensioning, lubricating the steering chain 128
6.9.3 Check the engine mounts 129
6.9.4 Servicing the V-belt 129
6.9.5 Replacing the hydraulic oil filter 134
6.9.6 Change the oil in the exciter shaft tube 135
6.9.7 Check the ROPS 136
6.9.8 Check the travel control 136
6.10.1 Checking, adjusting the valve clearance 137
6.10.2 Changing hydraulic oil and breather filter 138
6.10.3 Grease the articulated joint 141
6.10.4 Changing the coolant 141

Maintenance – Maintenance Table
No. Maintenance works Page

6.11.1 Change the high current relay of the heating flange 144
6.12.1 Replace the injection valves 145
6.12.2 Replace crankcase ventilation valve 145
As required
6.13.1 Air filter maintenance 146
6.13.2 Check, clean the water separator 148
6.13.3 Clean water tank and water filter 150
6.13.4 Water sprinkler system, maintenance in the event of frost 151
6.13.5 Fill the provision tank for the windscreen washer system 152
6.13.6 Adjusting the scrapers 152
6.13.7 Change the fresh air filter in the cabin 152
6.13.8 Tightening torques 153
6.13.9 Engine conservation 153

Maintenance – Every 10 operating hours
6.6 Every 10 operating hours

6.6.1 Checking the engine oil level
NOTICE!
The machine must be in horizontal position.
If the engine is warm, shut it down and check the
oil level after five minutes.
With a cold engine the oil level can be checked
immediately.
For quality of oil refer to the "table of fuels and
lubricants".

Pull the dipstick Ä Fig. 126 out, wipe it off with a lint-free,
clean cloth and reinsert it until it bottoms.
Pull the dipstick back out.
The oil level must always be between the "MIN"- and "MAX"-
marks. If the oil level is too low, top up oil to the "MAX" mark
immediately.
Fig. 126
6.6.2 Checking the fuel level
NOTICE!
Do not drive the fuel tank dry, as otherwise the fuel
system needs to be bled.
Check the fuel level on fuel gauge (n) Ä Fig. 127 in the
instrument cluster.
Fig. 127

Refuelling
WARNING!
Fire hazard!
When working on the fuel system do not use open
fire, do not smoke, do not spill any fuel.
Do not refuel in closed rooms.
WARNING!
Health hazard!
NOTICE!
Monitor the entire refuelling process.
For quality and quantity of fuel refer to the "table of
fuels and lubricants".
ENVIRONMENT!
Catch running out fuel, do not let it seep into the
ground.
Use access steps Ä Fig. 128.
Fig. 128

Clean the area around the filler opening.

Open the fuel tank cover Ä Fig. 129.
NOTICE!
Contaminated fuel can cause malfunction or even
damage of the engine.
If necessary, fill in fuel through a funnel with
screen.
Fig. 129
Top up with fuel (diesel or winter diesel).

Screw the fuel tank cover back on.
6.6.3 Check the hydraulic oil level
NOTICE!
In hydraulic systems filled with Panolin HLP Synth.
46 always use the same oil to top up. With other
ester based oils consult the lubrication oil service
of the respective oil manufacturer.
Check the oil level in the oil level inspection glass

Ä Fig. 130.
At a room temperature of approx. 20 °C the oil

level should reach approx. 2/3 way up the inspec-
tion glass.
Fig. 130
If the oil level is too low top up hydraulic oil immediately.
For quality of oil refer to the table of fuels, lubricants and

filling capacities.
NOTICE!
If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped, check
all lines, hoses and components for leaks.

6.6.4 Check the coolant level
WARNING!
Danger of scalding!
Fill up coolant only when the engine is cold.
A too low coolant level is indicated by the coolant

level warning light (f) in the instrument cluster.
Fig. 131
Check the coolant level Ä Fig. 132 only when the engine is
cold.
NOTICE!
If, during the daily inspection the coolant level is
found to have dropped, check all lines, hoses and
engine for leaks.
Do not use radiator sealant to seal leaks.
Fig. 132
To top up unscrew the filler cap and fill in coolant up to the

MAX-mark.
For quality and quantity of coolant refer to the "table of fuels

and lubricants".
6.6.5 Check the water level
NOTICE!
Risk of damage!
Do not step on the water tank and do not place any
heavy objects on it.

The level gauge (o) for the water tank in instrument

cluster shows the current filling level.
When the water tank is empty the warning light for
the water tank filling level (d) in the instrument
cluster will light up and the warning buzzer will
sound.
Fig. 133
Use access steps Ä Fig. 134.
Fig. 134
Open the caps on both water tanks, top up with water

Ä Fig. 135 and screw the caps back on.
If there is a risk of frost observe the special service

instructions in chapter "water sprinkler system,
maintenance in case of frost".
Make sure that the ventilation bore in the filler cap
is free.
Fig. 135


6.7.1 Change the fuel filter cartridge
WARNING!
Fire hazard!
fire, do not smoke and do not spill any fuel.
WARNING!
Health hazard!
NOTICE!
Ensure strict cleanliness! Thoroughly clean the
area around the fuel filters.
After work on the fuel system bleed the system,
perform a test run and check for leaks.
Additional bleeding of the fuel system by a 5
minute test run in idle speed or low load is manda-
tory.
ENVIRONMENT!
Catch running out oil and dispose of environmen-
tally together with the oil filter cartridge.
Loosen fuel filter Ä Fig. 136 using a suitable filter wrench

and screw it off.
Clean the sealing face on the filter carrier with a lint-free,
clean cloth.
Slightly oil the rubber seal on the new filter cartridge.
NOTICE!
The filter cartridge must not be pre-filled. Danger of
Fig. 136 contamination!
Twist the new filter cartridge on by hand until the seal con-
tacts, then tighten with 10 - 12 Nm.
Bleed the fuel system, see chapter "Changing the fuel pre-
filter cartridge, bleeding the fuel system".
Check for leaks after a short test run.

6.7.2 Replace the fuel pre-filter cartridge, bleed the fuel system
WARNING!
Fire hazard!
fire, do not smoke, do not spill any fuel.
WARNING!
Health hazard!
NOTICE!
Ensure strict cleanliness! Thoroughly clean the
area around the fuel filters.
After work on the fuel system bleed the system,
perform a test run and check for leaks.
Additional bleeding of the fuel system by a 5
minute test run in idle speed or low load is manda-
tory.
ENVIRONMENT!
Any fuel must be caught and disposed of in an
environmentally friendly manner.
Change the fuel pre-filter cartridge

Tighten the cable on the water separator Ä Fig. 137.
(1) Loosen the bleeding screw and drain off fuel from the
bleeding screw.
(2) Loosen and unscrew the fuel pre-filter cartridge using an
appropriate filter wrench.
(3) Unscrew the water separator from the filter cartridge.
(4) Apply a thin coat of oil to the rubber seal of the water sep-
arator.
(5) Turn the water separator on by hand, until the seal con-
Fig. 137 tacts, then tighten hand-tight.
(6) Apply a thin coat of oil to the rubber seal of the filter ele-
ment (5).
(7) Turn the filter cartridge on by hand, until the seal contacts,
then tighten hand-tight.
Plug the water sensor cable back on.

Bleed the fuel system

Air in the fuel system causes irregular running of
the engine, a drop in engine power, stalls the
engine and makes starting impossible.
Therefore bleed the fuel system after changing the
fuel pre-filter or working on the fuel system.
Slacken the bleeding screw (1) Ä Fig. 138 on the fuel pre-
filter for 2 to 3 turns.
Unlock the bayonet lock of the fuel hand pump by pressing it
down and turning it anti-clockwise.
Fig. 138
Operate the fuel hand pump (2) manually, until fuel flows out
of the loosened bleeding screw without air bubbles.
Then tighten the bleeding screw while pumping.
Lock the bayonet lock of the fuel hand pump by pressing it
down and turning it clockwise.
Start the engine and run it 5 minutes with idle speed.
6.7.3 Check, clean radiator, fuel cooler, hydraulic oil cooler and intercooler
Dirty operating conditions, particularly lubrication

oil and fuel deposits on the cooling fins reduce the
cooling effect. You should therefore immediately
seal any oil or fuel leaks near cooling fan, cylinder
or oil cooler and subsequently clean the cooling
fins.
WARNING!
Danger of injury!
Perform cleaning work only with engine stopped
and cooled down!

Unscrew the fastening screws from the radiator covering

plate Ä Fig. 139 and fold the covering plate back.
Fig. 139
Remove dried on dirt from the cooling fins with a suitable

brush.
Blow coolers Ä Fig. 140 out with compressed air. Remove
all dirt that has been blown into the engine compartment.
In case of oily dirt spray the cooler with a cold cleansing
agent and let it soak in for about 10 minutes.
ENVIRONMENT!
Fig. 140 Catch running off fluid and dispose of environmen-
tally.
Clean off with water or steam jet.

Repeat the process if necessary.
6.7.4 Check the oil level in vibrator shaft tube
NOTICE!
Check the oil level in both drums, rear right and
front left.
Move the machine so that the level inspection plug is exactly

behind the bore Ä Fig. 141.
Clean and unscrew oil level inspection plug (1).
The oil level must reach the bottom edge of the bore, top up
oil if necessary.
For quality of oil refer to the table of fuels, lubricants and

filling capacities.
Fig. 141


6.8.1 Changing engine oil and oil filter cartridge
Perform this maintenance work at the latest after

one year.
WARNING!
Danger of scalding!
When draining off hot oil.
By hot oil when unscrewing the engine oil filter.
NOTICE!
Drain the oil only when the engine is warm.
For quality and quantity of oil refer to the ”table of
fuels and lubricants”.
ENVIRONMENT!
tally together with the oil filter cartridge.
Unscrew the oil filler cap .
Unscrew the drain plug Ä Fig. 142, catch running out oil.
Screw the plugs back in.
Fig. 142

Loosen and unscrew the fuel filter cartridge Ä Fig. 143 using
an appropriate filter wrench.
Wipe the sealing face clean.
Cover the rubber seal of the new filter cartridge slightly with
clean oil.
Spin the new fuel filter cartridge on and tighten it hand tight.
Fig. 143
Fill in new engine oil Ä Fig. 144 through the oil filler neck.
Screw the cap back on again.
Fig. 144
After a short test run check the oil level on the dipstick
Ä Fig. 145.
The oil level should reach the MAX-mark, top up oil if neces-
sary.
Check filter cartridge and drain plug for leaks.
Fig. 145
6.8.2 Check the anti-freeze concentration and the condition of the coolant
WARNING!
Danger of scalding!
Check the anti-freeze concentration only when the
engine is cold.

NOTICE!
In order to avoid damage to the engine (e.g. by
corrosion, cavitation and freezing), particular atten-
tion must be paid to the inspection of the coolant.
For quality and quantity of coolant refer to the
"table of fuels and lubricants".
Do not mix different coolants and additives, see
section "Fuels and Lubricants - Coolant".
In case of lubrication oil entering into the cooling
system or a suspicious turbidity caused by corro-
sion residues or other suspended matter, the
coolant must be drained off and the complete
cooling system needs to be cleaned. Lubrication oil
can damage the sealing materials used in the
engine.
ENVIRONMENT!
Collect coolant and dispose of it in an environmen-
tally friendly way.
Unscrew the radiator cap Ä Fig. 146 and check the anti-
freeze concentration with a conventional tester.
NOTICE!
The anti-freeze concentration (additive) must be at
least 35 Vol% and maximum 45 Vol%.
Fig. 146
Check the condition of the coolant.

If the coolant is contaminated by corrosion residues or other
suspended matter, flush the cooling system, see section
"Changing the coolant".
6.8.3 Service the air conditioningOptional equipment
NOTICE!
Under very dusty conditions clean every day in
order to maintain the cooling power of the air con-
ditioning system.

WARNING!
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.
Cleaning the condenser

Unscrew the condenser fastening screws and fold the con-
denser forward.
Fig. 147
Clean the condenser fins on front and back with compressed

air or cold water Ä Fig. 147.
NOTICE!
During cleaning work do not damage the cooling
fins and realign bent fins.
Checking the refrigerant level

Start the engine.
Turn the rotary switch for the cab ventilator Ä Fig. 148 to
position "1".
Fig. 148

Choose a cooling temperature with the rotary switch for the

air conditioning system Ä Fig. 149 in the blue section.
Fig. 149
Open the air outlet nozzles.

Check, whether the out flowing air is noticeably cooler.
The adjusted temperature must be below the

actual temperature inside the cabin, so that the
compressor will be switched on.
Check whether the white float Ä Fig. 150 inside the inspec-
tion glass of the drier/collector unit floats right at the top.
The refrigerant level is correct.
Fig. 150
If the white float Ä Fig. 151 inside the inspection glass of the
drier/collector unit floats at the bottom, inform the service
department.
The refrigerant level is not correct.
Fig. 151
Refrigerant must be filled up, if necessary check the air con-

ditioning system for leaks.

Checking the moisture level of the

drying agent
Check the moisture indication pearl Ä Fig. 152 inside the
inspection glass of the drier/collector unit.
orange Drying agent o.k.

colourless moisture level of drying agent too
high.
Fig. 152
Inform the service department. Replace drier/collector unit,

check air conditioning system.
NOTICE!
Have the drier/collector unit replaced by the
service department every year before the oper-
ating season.
Checking the condition of the drier/

collector unit NOTICE!
According to the regulation for pressure reservoirs
all pressure reservoirs must be repeatedly
inspected by a specialist. In this sense repeated
inspections are external examinations, normally on
pressure reservoirs in operation. In connection with
this inspection the drier/collector unit must be visu-
ally examined twice every year. During these
inspections special attention must be paid to corro-
sion and mechanical damage. If the reservoir is not
in proper condition it must be replaced for safety
reasons, as a precaution to protect operators and
third parties against any danger arising from the
handling and operation of pressure reservoirs.
WARNING!
Danger of injury!
In case of mechanical damage or corrosion on this
drier/collector unit this unit must be replaced, to
avoid bursting and further damage.

Check the drier/collector unit Ä Fig. 153 for mechanical

damage or rust.
Fig. 153
6.8.4 Cleaning the circulation air filter for the heatingOptional equipment
Unscrew screws (1) Ä Fig. 154.
Pull the filter (2) downwards out.
Clean the filter, replace if necessary.
Assemble the filter and tighten the screws.
Fig. 154
6.8.5 Battery service, checking the main battery switch
WARNING!
Danger of cauterisation ! Danger of explosion!
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!
For recharging remove the plugs from the battery
to avoid the accumulation of highly explosive
gases.
ENVIRONMENT!
Dispose of the old battery environmentally.

Maintenance free batteries also need care. Mainte-

nance free only means that the fluid level does not
need to be checked. Each battery suffers under
self-discharge, which may, in not checked occa-
sionally, even cause damage to the battery as a
result of exhaustive discharge.
The following therefore applies for the service life:

Switch off all consumers (e.g. ignition, light, inside light,
radio).
Check open-circuit voltage of the battery at regular intervals.
At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V = 50% dis-

charged.
Recharge the battery immediately after an open-circuit
voltage of 12.25 V or less is reached. Do not perform quick
charging.
The open-circuit voltage of the battery occurs approx. 10 hours

after the last charging process or one hour after the last discharge.
After each charging process allow the battery to rest for one
hour before taking it into service.
For resting periods of more than one month you should
always disconnect the battery. Do not forget to perform reg-
ular open-circuit voltage measurements.
NOTICE!
Exhausted batteries (batteries with formation of
sulphate on the plates) are not covered under war-
ranty!
Disassemble the battery compartment cover Ä Fig. 155.

Clean the battery compartment.
Fig. 155

Clean the outside of the battery Ä Fig. 156.

Clean battery poles and pole clamps and grease them with
pole grease (Vaseline).
Retighten the pole clamps.
Check the fastening of the battery.
On serviceable batteries check the acid level, if necessary
top up to the filling mark with distilled water.
Fig. 156
Checking the main battery switch

Turn the main battery switch Ä Fig. 157 to position "0" and
check by voltage measurement (ignition key test) whether the
batteries are disconnected from the electric system of the
machine.
Fig. 157


6.9.1 Change the oil in drum drive gear
WARNING!
Danger of scalding!
When draining off hot oil.
NOTICE!
Drain oil only at operating temperature.
For quality and quantity of oil refer to the "table of
ENVIRONMENT!
Catch running out old oil and dispose of environ-
mentally.
Clean and unscrew filler and drain plugs Ä Fig. 158.

Drain and catch all oil.
Move the drum by 90° to bring the filler opening in

vertical position!
Fig. 158
Fill in oil through the oil filler opening Ä Fig. 159, until it rea-
ches the bottom edge of the oil level inspection bore.
Fig. 159
Turn the filler and drain plug back in tightly with a new seal
ring.

6.9.2 Checking, tensioning, lubricating the steering chain

Unscrew the dashboard from the drive console and lay down
to the front.
Check
Unscrew the cover plate Ä Fig. 160 from the steering chain
and take it off.
Fig. 160
Check the entire circumference of chain and sprockets

Ä Fig. 161.
Fig. 161
Check the condition of the left hand sliding block Ä Fig. 162,
replace if necessary.
Fig. 162

Check the condition of the right hand sliding block

Ä Fig. 163, replace if necessary.
Fig. 163
Tension
Loosen four fastening screws on the steering column.
Press the steering columns towards the outside and retighten

the fastening screws.
Lubricating
Cover the entire circumference of the chain with grease.
For quality of grease refer to the table of fuels, lubricants and

filling capacities.
6.9.3 Check the engine mounts

Tighten fastenings of intake and exhaust manifolds
Ä Fig. 164 on the cylinder heads.
Check sockets and clamps between air filter, exhaust turbo-
charger and charge air line as well as the lubrication air lines
for tight fit and leaks.
Retighten the fastening screws for oil sump and engine
mounts.
Fig. 164
6.9.4 Servicing the V-belt
Change the V-belt at the latest after two years.

Checking the V-belt for the air con-

ditioning compressor
Inspect the entire circumference of the V-belt Ä Fig. 165 vis-
ually for damage and cracks. Replace damaged or cracked
V-belts.
Check with thumb pressure whether the V-belt can be
depressed more than 10 to 15 mm (0.4 – 0.6 inches)
between the V-belt pulleys, retighten if necessary.
Fig. 165
Tighten the V-belt.

Slightly slacken the fastening screws 1, 2 and 3 Ä Fig. 166.
Press the compressor in direction of arrow, until the correct
V-belt tension is reached.
Retighten all fastening screws.
Fig. 166
Changing the V-belt

Slightly slacken the fastening screws 1, 2 and 3.
Press the compressor against the direction of arrow com-
pletely against the engine.
Take the old V-belt off.
Fit the new V-belt to the V-belt pulleys.
Tension the V-belt as previously described.
NOTICE!
Check the V-belt tension after a running time of 30
minutes.

Checking the generator V-belt

Inspect the entire circumference of the V-belt Ä Fig. 167 vis-
ually for damage and cracks. Replace damaged or cracked
V-belts.
Fig. 167
Press the indicator arm of the tester a Ä Fig. 168 into the
gap of the measuring scale.
Fig. 168
Lay the measuring unit loosely onto the back of the fan V-
belt.
To measure the V-belt tension a free length of at

least 200 mm is required.
Operate measuring unit b Ä Fig. 169 with a finger (I or II or

III), until the pressure spring disengages audibly or notice-
ably.
The indicator arm remains in the measured posi-

tion.
Fig. 169
take the measuring unit carefully off, without moving the indi-
cating arm.

Read the V-belt tension where the upper edge of the indi-
cating arm intersects with the measuring scale Ä Fig. 170.
First installation approx. 450±50 N
Retighten after 15 approx. 300±50 N

minutes
Fig. 170
Tightening the generator V-belt

Slacken the fastening screws 1,2 and 3 Ä Fig. 171 slightly.
Press the generator towards the outside until the correct ten-
sion is achieved. Check with the tester.
Fig. 171
Replacing the generator V-belt

Slightly slacken fastening screws 1,2 and 3.
Press the generator towards the engine.
Take the old V-belt off the V-belt pulley.
Checking the V-belt for coolant

pump and fuel pump
Inspect the entire circumference of the pump V-belt
Ä Fig. 172 visually for damage and cracks. Replace dam-
aged or cracked V-belts.
Fig. 172

Tightening the V-belt for coolant

pump and fuel pump
Slightly slacken fastening screws 1 and 2 Ä Fig. 173 on the
fuel pump.
Fig. 173
Press the fuel pump towards the outside until the correct ten-
sion is achieved. Check with the tester.
First installation 450±50 N
After 15 minutes of oper- 300 ±50N

ation
Replacing the V-belt for coolant

pump and fuel pump
Disassemble the generator and compressor V-belts
Slightly slacken fastening screw 1 and 2.

Press the fuel towards the engine.
Take the old V-belt off the V-belt pulley.
Reassemble and tighten generator and compressor V-belts.

6.9.5 Replacing the hydraulic oil filter

one year.
NOTICE!
– If the filter has to be changed together with the
hydraulic oil, the filter must only be changed
after the oil change and after the test run.
– Do not use the oil in the filter bowl again.
– Apart from the normal oil change intervals, the
filter element must also be changed after major
repairs in the hydraulic system.
If the hydraulic oil filter warning light comes on during start or oper-
ation, replace the hydraulic oil filter immediately.
B-SYM-0017
Fig. 174
Protective equipment: n Working clothes

n Safety shoes
n Protective gloves
Park the machine safely.
Allow the engine to cool down.
Unscrew the filter bowl (3).
1 NOTICE!
Negligence may cause destruction to the entire
hydraulic system!
– Visible dirt may be an early sign for the failure
2 of system components and indicate the pos-
sible failure of components.
3 B-HYD-0013
– In this case determine the cause and replace
or repair the defective components, if neces-
Fig. 175 sary.
– Do not clean or reuse the filter element.
Take the old filter element (1) out and clean the filter bowl.
Clean the thread on the filter bowl.
Reassemble the filter bowl with a new filter element and a
new O-ring (2).
After a test run, check for leaks.
Dispose of the oil and filters in line with environmental regula-
tions.

6.9.6 Change the oil in the exciter shaft tube
NOTICE!
Change the oil in both drums.
For quality and quantity of oil refer to the ”table of
fuels and lubricants”.
ENVIRONMENT!
tally.
Move the drum until drain and filler plugs Ä Fig. 176 are
exactly vertically in line.
Fig. 176
Clean and unscrew drain and filler plugs.
Drain off and catch old oil.
Clean and turn the oil drain plug back in tightly after all oil
has run out.
Clean and unscrew the oil level inspection plug Ä Fig. 177.
Fill in oil through the filler bore, until it starts to run out
through the level inspection bore.
Turn the oil filler and level plug back in with a new seal ring.
Fig. 177

6.9.7 Check the ROPS
On machines with cabin the ROPS (roll over pro-

tection structure) is an integral part of the cabin.
Please observe also the corresponding section in
the safety regulations in this manual.
Inspect the cabin, especially the ROPSÄ Fig. 178, for

cracks, corrosion, damage and missing fastening parts.
Unusual movements and noises (vibrations) during

operation are signs for damage or loosened fas-
tening elements.
Fig. 178
Check the fastening screws for the cabin (ROPS) to the oper-
ator’s stand for tight fit.
Check the rubber buffers of the operator’s platform suspen-
sion for condition and tight fit.
Check the condition and fastening of the seat belts.
6.9.8 Check the travel control

Move the travel lever Ä Fig. 179 forward, backwards and to
braking position. Thereby check for function, light movement,
clearance and damage.
In case of malfunction perform trouble shooting and replace
the corresponding parts.
NOTICE!
Only operate the machine after the travel control
has been repaired.
Fig. 179


6.10.1 Checking, adjusting the valve clearance
NOTICE!
We recommend to have this work carried out by
trained personnel or our after sales service.
– Before checking the valve clearance let the
engine cool down for at least 30 minutes. The
engine oil temperature must be below 80 °C
(176 °F).
Valve clearance adjustment

angle:
Intake valve 75° ± 15°
Exhaust valve 120° ± 15°
Valve Cylinder
overlapping 1 3 4 2
adjustment 4 2 1 3

n Protective gloves
Tool: n Rotation angle disc
Park the machine in secured condition.
Remove the valve cover.
Turn the crankshaft with the cranking device until the valves
are overlapping.

Loosen counter nut (2).
Attach the rotation angle disc (3) and the spanner socket (4)
to the valve adjustment screw (1).
Fix the magnet (5) of the rotation angle disc.
Turn the rotation angle disc (3) clockwise against the stop
(rocker arm no clearance) and set the scale to zero.
Turn the rotation angle disc (3) anticlockwise, until the speci-
fied angle is reached.
Hold the rotation angle disc tight, so that it does not turn, and
tighten the counter nut (2), tightening torque: 20 Nm
(15 ft·lbf).
1
Repeat this adjustment procedure on all other cylinders, after
cranking the crankshaft accordingly.
Install the cylinder head cover again with a new gasket, tight-
B-DEU-0010
ening torque: 13 Nm (10 ft·lbf).
After a short test run, check the engine for leaks.
Fig. 180
1 Valve adjustment screw
2 Counter nut
3 Rotation angle disc
4 Spanner socket
5 Magnet
6.10.2 Changing hydraulic oil and breather filter

two years.
See also the notes on the hydraulic system in the

chapter "General notes on maintenance".
WARNING!
Danger of scalding!
When draining off hot hydraulic oil!

NOTICE!
The hydraulic oil must also be changed after major
repairs in the hydraulic system.
Perform the oil change when the hydraulic oil is
warm.
Replace the hydraulic oil filter elements with every
hydraulic oil change.
Change the filter only after the hydraulic oil change
and after the test run.
Clean the area round hydraulic oil tank, filler
opening and breather filter.
Do not start the engine after draining the hydraulic
oil.
Do not use any detergents to clean the system.
Use only lint-free cleaning cloths.
For quality and quantity of oil refer to the "table of
When changing from mineral oil based hydraulic oil
to an ester based biologically degradable oil, you
should consult the lubrication oil service of the oil
manufacturer for details.
ENVIRONMENT!
Catch running out hydraulic oil and dispose of
environmentally.
Remove the filler cap Ä Fig. 181.
Fig. 181

Unscrew the plug Ä Fig. 182 and drain off all hydraulic oil.
Check the seal ring, replace if necessary and turn the plug
tightly back in.
Fig. 182
Fill in new hydraulic oil through the screen Ä Fig. 183.
We recommend to use our filling and filtering unit

with fine filter to fill the system. This ensures finest
filtration of the hydraulic oil, prolongs the lifetime of
the hydraulic oil filter and protects the hydraulic
system.
Fig. 183
Check the oil level in the inspection glass.
Nominal value:
At a room temperature of approx. 20 °C the oil level should reach
approx. 2/3 way up the inspection glass.
The breather filter for the hydraulic oil tank is inte-

grated in the filler cap, you must therefore replace
the complete filler cap.
Fig. 184
Close the tank with a new filler cap.

6.10.3 Grease the articulated joint

Remove the water tank.
Fig. 185
Clean the grease nipple Ä Fig. 185 and lubricate with

approx. 5 shots of high pressure grease from the grease gun.
For quality of grease refer to the section on "fuels, lubricants

and filling capacities”.
6.10.4 Changing the coolant

two years.
WARNING!
Danger of scalding!
Change the coolant only when the engine is cold.
NOTICE!
Do not start the engine after draining off the
coolant.
In case of lubrication oil entering into the cooling
system or a suspicious turbidity caused by corro-
sion residues or other suspended matter, the
coolant must be drained off and the complete
cooling system needs to be cleaned. Lubrication oil
can damage the sealing materials used in the
engine.
When changing the coolant without any signs of
contamination, cleaning of the cooling system is
not necessary.

NOTICE!
For quality and quantity of coolant refer to the
"table of fuels and lubricants".
Do not mix different coolants and additives, see
section "Fuels and Lubricants - Coolant".
ENVIRONMENT!
Collect coolant and dispose of it in an environmen-
tally friendly way.
Unscrew the cover Ä Fig. 186 from the compensation tank.
Fig. 186
Unscrew the plug, let the coolant run out and catch it
Ä Fig. 187.
Check the condition of the coolant.
NOTICE!
Thoroughly flush the cooling system if the coolant
is contaminated by corrosion residues or other sus-
pended matter.
Fig. 187 If lubrication oil has entered you must add a
cleansing agent in order to remove any residues
from the system. Follow the instructions of the
manufacturer. If in doubt consult your local service
station or the engine manufacturer.
Remove the thermostat.

Fill in clean water.
Start the diesel engine and run it warm to operating tempera-
ture.
Allow the engine to cool down to approx. 50 °C.
Drain all water off.
Repeat the flushing process twice using a cleansing agent
with clear water.
Screw the plug back in once all coolant has run out.

Reinstall the thermostat .
NOTICE!
The anti-freeze concentration (additive) must be at
least 35 Vol% and maximum 45 Vol%.
Fill in coolant Ä Fig. 188 up to the MAX-mark and screw the

filler cap back on.
Start the diesel engine and run it warm to operating tempera-
ture.
Fig. 188
Check the coolant level Ä Fig. 189 again, top up if neces-

sary.
Fig. 189


6.11.1 Change the high current relay of the heating flange
This work must only be performed by authorized service per-
sonnel.


6.12.1 Replace the injection valves
NOTICE!
This work must only be performed by authorized
service personnel.
Injection lines must be renewed after they have
been loosened three times.
6.12.2 Replace crankcase ventilation valve

Replace the ventilation valve Ä Fig. 190.
Fig. 190

Maintenance – As required
6.13 As required
6.13.1 Air filter maintenance
NOTICE!
– Do not start the engine after having removed
the air filter.
– If necessary, the air filter may be cleaned up to
six times. After one year at the latest it must be
replaced together with the safety element.
– Cleaning does not make sense if the air filter
element is covered with a sooty deposit.
– Do not use gasoline or hot fluids to clean the
filter element.
– After cleaning, the air filter must be inspected
for damage using a torch.
– Do not continue to use a damaged air filter ele-
ment. If in doubt use a new air filter.
– If the air filter is damaged, the safety element
must be replaced as well.
– The safety element must not be cleaned.
We generally recommend to renew the air filter. A

new filter element is far less expensive than a pos-
sible engine damage.

n Protective gloves
n Safety goggles
Maintenance of the air filter is due when the air filter warning
light lights up, but at the latest after one year.
Park the machine in secured condition.
Fig. 191
Loosen both locking hooks on the housing cover and take the
cover off.
Clean housing cover and dust discharge valve.
Fig. 192

Pull out the air filter with light turning movements.
CAUTION!
Danger of eye injuries caused by particles
flying around!
– Wear your personal protective equipment
(safety gloves, protective working clothes, gog-
gles).
Fig. 193
Blow the air filter out with dry compressed air (max. 2.1 bar
(30 psi)) from inside to outside by moving the gun up and
down inside the element, until it is free of dust.
Fig. 194
Examine the air filter with a torch for cracks and holes in the
paper bellows.
In case of damage replace the air filter and the safety ele-
ment.
Fig. 195
Slide the air filter carefully into the housing.
NOTICE!
– The dust discharge valve must point vertically
downwards.
– Make sure that the cover locks engage cor-
rectly.
Reassemble the housing cover.

Fig. 196

6.13.1.1 Replacing the safety element
NOTICE!
The safety element must not be cleaned and
should not be used again after it has been
removed.
The safety element must be replaced:
– if the air filter is damaged.
– at the latest after one year.
– if the air filter warning light comes on again
after the air filter has been cleaned.
Remove the housing cover and pull the air filter element off.
Pull the safety element out by turning it lightly.
Push in a new safety element.
Insert the air filter and reassemble the housing cover.
Fig. 197
6.13.2 Check, clean the water separator
WARNING!
Fire hazard!
fire, do not smoke. Do not spill any fuel.
WARNING!
Health hazard!
ENVIRONMENT!
Any fuel must be caught and disposed of in an
environmentally friendly manner.

The service intervals for the water separator

depend on the water content in the fuel and can
therefore not be determined precisely. After taking
the engine into operation you should check the
filter bowl initially every day, later as required, for
signs of water.
If a too high quantity is drained off, the filter needs
to be bled, see section "Replacing the fuel pre-
cleaner cartridge".
If the warning light for water in the fuel (b) Ä Fig. 198 in the
instrument cluster lights up during operation, drain the water
from the prefilter.
Fig. 198
Open the right hand service flap.
Slacken the drain plug Ä Fig. 199 for a few turns and catch
running out fuel / water.
Turn the plug tightly back in. Check for leaks, if necessary
use a new seal ring.
Once the water separator is empty the warning

light for water in fuel must go out.
Fig. 199

6.13.3 Clean water tank and water filter

Unscrew both water tank caps Ä Fig. 200, take out and
clean the filling screens.
Replace damaged filling screens.
Fig. 200
Open the maintenance cover Ä Fig. 201 to gain access to

the water pumps.
Fig. 201
Disconnect the quick lock coupling Ä Fig. 202 on the water

filter.
Unscrew and clean the water filter.
Change a damaged water filter.
Fig. 202
Let all water with dirt run out.

Fill the water tank with clean water.

6.13.4 Water sprinkler system, maintenance in the event of frost
NOTICE!
If there is a risk of frost, the water sprinkler system
must be drained.
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.
Drain the water tank
Disconnect the quick lock couplings Ä Fig. 203 of the water

lines from the water pumps and let all water run out.
Fig. 203
Disconnect the water pipe connection Ä Fig. 204 at the

articulated joint and let all water run out.
Fig. 204
Open all water drain taps Ä Fig. 205 on the sprinkler tubes
and let all water run out.
Unscrew all nozzles.
Fig. 205

6.13.5 Fill the provision tank for the windscreen washer system
Check the fluid level in the tank Ä Fig. 206, top up if neces-
sary.
For winter operation fill in the appropriate amount of ant-
freeze agent; refer to the specifications of the manufacturer
of the ant-freeze agent.
Fig. 206
6.13.6 Adjusting the scrapers

Check the scrapers Ä Fig. 207, two each per drum.
Replace worn scrapers.
Fig. 207
6.13.7 Change the fresh air filter in the cabin

Unscrew fastening screws for the ventilation grid Ä Fig. 208
and remove the filter.
Insert a new filter and reassemble the ventilation grid.
Fig. 208

6.13.8 Tightening torques

* Strength classes for screws with untreated and non-lubricated
surface. The quality designation of the screws is stamped on the
screw heads.
8.8 = 8G
10.9 = 10K
12.9 = 12K
The values result in a 90% utilization of the screws yielding point at
a coefficient of friction of tot. = 0,14. The tightening torques are not
valid when using MOS2 lubricants.
Fig. 209
Self locking nuts must always be replaced by new
ones after they have been unscrewed.
6.13.9 Engine conservation

If the engine is to be shut down for a longer period of time (e.g.
during winter) we recommend the following conservation measures
for the engine to avoid corrosion:
Clean the engine, including the cooling system. With cold
cleansing agent, or, even better, with a steam cleaner.
Run the engine warm and shut it down.
Drain the still warm engine oil and fill in anti-corrosion engine
oil.
Drain the coolant and fill it back in with fresh anti-freeze
agent.
Drain the fuel from the fuel tank, mix it well with 10% anti-cor-
rosion oil and fill it in again.
Run the engine for 10 minutes until all lines, filter, pump and
nozzles are filled with the conserving mixture and the new
engine oil is distributed to all parts.
Crank the engine several times by hand (without ignition) in
order to spray all combustion chamber.
Take the V-belt off and spray the grooves of the V-belt pulleys
with anti-corrosion oil. The anti-corrosion oil must be
removed before taking the machine back into service.
Close the air intake opening on the air filter and the exhaust
opening.

Depending on the weather condition these con-

serving measures will provide protection for
approx. 6 - 12 months.
The conserving oil must be replaced by engine oil
according to the API- (MIL) classification before
taking the machine into operation. Refer to the
section "Fuels and lubricants".
Anti-corrosion oils are those that comply with the specifica-

tion MIL-L-21260 B or TL 9150-037/2 resp. Nato Code C
640/642.
Mark a machine with conserved engine by attaching a clearly
visible warning tag.

Troubleshooting
7 Troubleshooting

Troubleshooting – General notes
7.1 General notes

Please observe strictly the safety regulations in the corre-
sponding section of these operating and maintenance instruc-
tions.
Malfunctions are frequently caused by incorrect operation of the
machine or insufficient maintenance. Whenever a fault occurs you
should therefore thoroughly read these instruction on correct oper-
ation and maintenance.
If you cannot locate the cause of a fault or rectify it yourself by fol-
lowing the trouble shooting chart, you should contact our customer
service department.

Troubleshooting – Starting the engine with jump leads
7.2 Starting the engine with jump leads
NOTICE!
A wrong connection will cause severe damage
in the electric system.
– Bridge the machine only with a 12 Volt auxiliary
battery.
Remove the battery cover.
B-920-0059
Fig. 210
First, connect the plus pole of the external battery to the plus
pole of the vehicle battery using the first jump lead.
Then connect the second battery cable first to the minus pole
of the current supplying external battery and then to engine
or chassis ground, as far away from the battery as possible.
Start the engine:.
12 V NOTICE!
B-ELE-0007 Danger of damage to the electronic system!
If no powerful consuming device is switched on,
Fig. 211
voltage peaks may occur when separating the con-
necting cables between the batteries, which could
damage electrical components.
Once the engine is running, switch on a powerful consuming

device (working light, etc.).
After starting, disconnect the minus poles first and the plus
poles after.
Switch off the consuming device.
Put the battery cover back on.

Troubleshooting – Engine faults
7.3 Engine faults

Fault Possible cause Remedy
Engine does not Fuel tank empty Refuel, bleed the fuel system
start or starts poorly
Temperature below starting limit Check
Engine oil with wrong SAE viscosity class Change the engine oil
The fuel quality does not meet the Change the fuel
requirements
Battery defective or not charged Check
Cable to starter loose or oxidized Check cable connection
Starter defective or pinion does not Check starter
engage
V-belt torn or loose Check, replace if necessary
Air in the fuel system Bleeding the fuel system
Fuel filter soiled Check, clean the water separator /
replace the fuel filter
Incorrect valve clearance Check, adjust if necessary
Injection line leaking Check
Injection valve defective Check, replace if necessary
Engine starts, but V-belt torn or loose Check, replace if necessary
runs irregularly or
misfires Air in the fuel system Bleeding the fuel system
requirements
The engine over- Engine oil with wrong SAE viscosity class Change the engine oil
heats, the coolant
temperature Engine oil filter dirty Replace
warning lamp lights Engine oil level too low or too high Check, top up or drain off as necessary
Charge air pipe leaking Check, replace if necessary
Air filter clogged / exhaust turbocharger Check, replace if necessary
defective
Lack of coolant Check the coolant level, top up if neces-
sary.
Insufficient engine Engine oil level too high Check, drain off if necessary
power

Troubleshooting – Engine faults
Fault Possible cause Remedy

Air in the fuel system Bleeding the fuel system
requirements
Air filter clogged / exhaust turbocharger Check, replace if necessary
defective
Radiator dirty Check, clean if necessary
Engine does not Air in the fuel system Bleeding the fuel system
work with all cylin-
ders Fuel filter soiled Check, clean the water separator /
Engine has too low Engine oil level too low Check, fill up if necessary
or no oil pressure
Engine oil with wrong SAE viscosity class Change the engine oil
Engine has exces- Engine oil level too high Check, drain off if necessary
sive oil consump-
tion Engine oil with wrong SAE viscosity class Change the engine oil
Blue engine Engine oil level too high Check, drain off if necessary
exhaust smoke
White engine Temperature below starting limit Check
exhaust smoke
requirements
Black engine Air filter clogged / exhaust turbocharger Check, replace if necessary
exhaust smoke defective
Radiator dirty Check, clean if necessary

Troubleshooting – Reading out fault codes of the electronic engine control (EMR 3)
7.4 Reading out fault codes of the electronic engine control (EMR 3)
NOTICE!
In case of a fault make a note of the fault code and
inform the BOMAG customer service or the cus-
tomer service of the engine manufacturer.
The diagnostic button provides the possibility to read out existing

faults in form of flashing codes.
Example fault code 211
Press the diagnose button Ä Fig. 212 for approx. 1 to 3 sec-
onds, then release the button.
Fig. 212
After 2 seconds 2 x short flashes of 0,4 seconds of the

first digit for the stored fault
Ä Fig. 213
after another 2 seconds 1 x long flash of 0.8 second of the

second digit for the stored fault code
after another 2 seconds 1 x short flash of 0,4 second of the

Fig. 213 third digit for the stored fault code
Write down the fault code and transmit it to the customer

service department.
After output of fault code 5 seconds pause, the display by

flashing and permanent light.)
If necessary repeat as described above to read out the next

fault code.

Disposal
8 Disposal

Disposal – Final shut-down of machine
8.1 Final shut-down of machine

If the machine can no longer be used and needs to be finally shut
down you must carry out the following work and have the machine
disassembled by an officially recognized specialist workshop.
WARNING!
Danger of cauterisation ! Danger of explosion!
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!
Remove the batteries and dispose of in compliance with legal

regulations.
ENVIRONMENT!
Collect all fuels and lubricants, do not let them
seep into the ground and dispose of in compliance
with legal regulations.
Empty the fuel tank.

Drain the hydraulic oil tank.
Drain coolant from engine and cooling system.
Drain off engine and transmission oil
WARNING!
Danger of explosion!
Parts that previously contained combustible fluids
must not be cut with a cutting torch.

BW202AD-4 Operation

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Operating Instruction

BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 /

Tandem vibratory roller

008 201 29 EN © 08/2020

Always start and operate the engine in a well-ventilated area.

For more information go to www.P65warnings.ca.gov/diesel.

WARNING: Crude oil, gasoline, diesel fuel and other petroleum

For more information go to www.P65Warnings.ca.gov/petroleum.

BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4 3

6.2.4 Hydraulic oil.............................................................................................................................. 103

4 BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4

6.12.1 Replace the injection valves................................................................................................... 145

BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4 5

6 BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4

BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4 7

8 BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4

In the course of technical development we reserve the right for

BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4 9

1.2 Machine type plate and engine type plate

Fig. 1: Machine type plate (example)

Please enter here:

Fig. 2: Engine type plate (example)

10 BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4

BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4 11

2.1 BW 161 AD-4

12 BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4

BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4 13

2.1.1 Noise and vibration data

2.1.1.1 Noise data

2.1.1.2 Vibration data

Hand-arm vibration The weighted effective acceleration value determined according to

14 BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4

2.2 BW 202 AD-4

BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4 15

16 BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4

Fuel (diesel) 200 l 53 gal us

2.2.1 Noise and vibration data

2.2.1.1 Noise data

2.2.1.2 Vibration data

Hand-arm vibration The weighted effective acceleration value determined according to

BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4 17

2.3 BW 203 AD-4

18 BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4

BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4 19

Fuel (diesel) 200 l 53 gal us

2.3.1 Noise and vibration data

2.3.1.1 Noise data

2.3.1.2 Vibration data

Hand-arm vibration The weighted effective acceleration value determined according to

20 BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4

2.4 BW 203 SL-4

BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4 21

22 BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4

Fuel (diesel) 200 l 53 gal us

2.4.1 Noise and vibration data

2.4.1.1 Noise data

2.4.1.2 Vibration data

Hand-arm vibration The weighted effective acceleration value determined according to

BW 203 SL-4 / BW 203 AD-4 / BW 161 AD-4 / BW 202 AD-4 23